Powerhorse M1577149A.3 Owner's Manual

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Powerhorse M1577149A.3 Owner's Manual | Manualzz

Owner’s Manual

WARNING: SPECIAL HAZARDS

 CO Poisoning: Exhaust from engine contains carbon monoxide, a poisonous gas that can cause carbon monoxide poisoning and possible death if inhaled.

 Injection Injury : High-pressure spray can pierce skin and underlying tissues, leading to serious injury and possible amputation. Such an injection injury can result in blood poisoning and/or severe tissue damage.

 Flying Debris : High-pressure spray can cause flying debris and possible surface damage.

 Electric shock : Operating equipment in wet conditions or near water can cause electric shock.

 Chemical Exposure: Cleaning chemical vapors or contact with skin may be hazardous.

 Fire/Explosion: Engine sparking can ignite fuel or other flammable liquids or vapors in the vicinity. Hot exhaust from engine can ignite combustible materials.

 Burns : Pressure Washer pump and engine are hot surfaces that can cause burn injuries.

Detailed safety information about these hazards appears throughout this manual.

Equipment Protection Quick Facts

Inspect Upon Delivery: FIRST! Inspect for missing or damaged components. See “Initial Set-Up/Installation” section for where to report missing or damaged parts.

Add Engine Oil: Engine is shipped without oil . See “Engine Manual” section of this manual for instructions on capacity and viscosity recommendations.

Replace Temporary Pump Oil Plug: Pump is shipped with oil but with temporary shipping plug. Check pump oil level before starting and replace temporary shipping plug with permanent oil fill plug provided within plastic bag containing this Owner’s Manual.

Water Flow Requirements: Make sure your supply water flow rate is 20% higher than the pressure washer's flow rate (see "Operations", section for detail), and that your water is clean and particle free.

Chemical Spraying: Use only approved pressure washer chemicals designed for high-pressure use. Use soap adjustment knob to regulate cleaning power (on select units).

Storage: Do not allow water to freeze in the pump, hose, or spray gun(s). See “Storage” for more information.

Maintenance Schedule: Engine and pump require periodic inspection and servicing to keep pressure washer functioning efficiently. See “ Maintenance Schedule Summary ” for frequency of servicing.

Battery Required: A battery is not included. A battery must be installed before starting the engine or damage to the engine voltage regulator will result. Purchase a standard 12 VDC, 10 Ah battery. Further detail in “Specifications” section.

Any Questions, Comments, Problems, or Parts Orders

Call Powerhorse Product Support 1-866-443-2576

Table of Contents

Equipment Protection Quick Facts ........................................................................................................................................ 1

TABLE OF CONTENTS ................................................................................................................................................ 2

ABOUT YOUR PRESSURE WASHER ......................................................................................................................... 4

SPECIFICATIONS ........................................................................................................................................................ 5

COMPONENT IDENTIFICATION .................................................................................................................................. 6

SAFETY ........................................................................................................................................................................ 7

Hazard Signal Word Definitions ............................................................................................................................................ 7

SAFETY LABELING ..................................................................................................................................................... 8

Safety Decal Locations ......................................................................................................................................................... 8

Safety Decals ........................................................................................................................................................................ 9

INITIAL SET-UP .......................................................................................................................................................... 10

Step 1. Inspect & Unpack ...................................................................................................................................................... 10

Step 2. Assembly ................................................................................................................................................................... 12

Base Assembly ................................................................................................................................................................... 12

Install Battery ( 1577249 Only) ............................................................................................................................................. 14

Step 3. Select Suitable Location ........................................................................................................................................... 15

Moving and Handling .......................................................................................................................................................... 15

Outdoor Use Only ............................................................................................................................................................... 15

Install Spark Arrestor (if Required) ...................................................................................................................................... 16

OPERATION ............................................................................................................................................................... 17

Follow Safety Rules for Operation ....................................................................................................................................... 17

Preparing for Operation ........................................................................................................................................................ 18

Check/Add Oil to Pump ....................................................................................................................................................... 18

Check/Add Engine Oil ......................................................................................................................................................... 19

Inspect Fuel System/Check for Leaks ................................................................................................................................. 20

Connect Hoses, Water Supply, and Spray Nozzle .............................................................................................................. 20

Prime the Water Supply ......................................................................................................................................................... 22

Set Up for Chemical Spray (if desired)................................................................................................................................. 22

Start-Up Procedures .............................................................................................................................................................. 23

Start the Engine to Power the Pump. .................................................................................................................................. 23

Apply Cleaning Chemical (If Desired) ................................................................................................................................. 23

Begin High Pressure Spray ................................................................................................................................................. 24

Shutdown ............................................................................................................................................................................... 25

STORAGE ................................................................................................................................................................... 26

Between-Use Storage ............................................................................................................................................................ 26

Prepare Pressure Washer for Freezing Conditions ............................................................................................................ 26

Prepare Engine for Long Term Storage ............................................................................................................................... 27

Prepare Pressure Washer for Storage ................................................................................................................................. 27

MAINTENANCE & REPAIR ........................................................................................................................................ 28

MAINTENANCE SCHEDULE SUMMARY .................................................................................................................. 28

DETAILED INSTRUCTIONS – MAINTENANCE & REPAIR ...................................................................................... 28

Follow Safety Rules ............................................................................................................................................................ 28

Keep Pressure Washer Clean ............................................................................................................................................. 28

2

Inspect Spray System ......................................................................................................................................................... 29

Do not start pressure washer until all needed repairs have been completed. ..................................................................... 29

Check Tire Pressure ........................................................................................................................................................... 29

Change Pump Oil ................................................................................................................................................................ 30

TROUBLESHOOTING ................................................................................................................................................ 31

PARTS EXPLOSION- MODELS 1577149, 1577249- REV A.3 .................................................................................. 32

PARTS LIST-MODELS 1577149, 1577249- REV A.3 ................................................................................................ 33

PUMP EXPLODED VIEW- REV A.3 ........................................................................................................................... 34

PUMP PARTS LIST- REV A.3 .................................................................................................................................... 35

PUMP KIT PARTS LIST-REV A.3 .............................................................................................................................. 36

ENGINE EXPLODED VIEW (1577149)- REV A.3 ....................................................................................................... 37

ENGINE PARTS LIST (1577149)-REV A.3................................................................................................................. 38

ENGINE KIT PARTS LIST (1577149)-REV A.3 .......................................................................................................... 39

ENGINE EXPLODED VIEW (1577249)-REV A.3 ........................................................................................................ 40

ENGINE PARTS LIST (1577249)-REV A.3................................................................................................................. 41

ENGINE KITS PARTS LISTS (1577249)-REV A.3 ..................................................................................................... 42

ENGINE MANUAL ...................................................................................................................................................... 43

LIMITED WARRANTY ................................................................................................................................................ 51

3

About Your Pressure Washer

Thank you for purchasing a Powerhorse Pressure

Washer! It is designed for long life, dependability, and top performance.

Intended Use.

Produce a high-pressure water spray.

Incorporate cleaning chemicals into a low-pressure water spray.

Note: Do not use for other purposes, as unforeseen hazards or equipment damage may result.

Power Source. The pressure washer is powered by a gasoline engine.

Supplies Required. Normal operation will require you to supply:

 Pressure Washer pump oil

Gasoline

Engine oil

Personal Protection Equipment

See “ Specifications ” section of this manual for more detail.

Site Location. Intended for outdoor use only.

Personal Protection . Wear safety apparel during operation, including safety glasses with side and top protection. Ear protection is also recommended if working near any operating engine. Other safety apparel includes waterproof insulated gloves, and non-slip protective footwear. Cleaning chemicals may require the use of respiration mask; refer to chemical label for further instruction.

Adult control only. Only trained adults should set up and operate the pressure washer. Do not let children operate.

Under The Influence. Never operate, or let anyone else operate, the pressure washer while fatigued or under the influence of alcohol, drugs, or medication.

Keep this manual for reference and review.

ATTENTION: Rental Companies and Private

Owners who loan this equipment to others!

All persons to whom you rent/loan this pressure washer to must have access to and read this manual. Keep this owner’s manual with the pressure washer at all times and advise all persons who will operate the machine to read it. You must also provide personal instruction on how to safely set-up and operate the pressure washer and remain available to answer any questions a renter/borrower might have. Owner’s Manuals are available from Powerhorse at 1-866-443-2576

4

Model #

PSI (bar)

GPM (l/min)

Max Water Temp

Engine

Horsepower

Length

Width

Height

Weight

Pump Oil Capacity

Engine Oil

Pump Oil

(shipped with oil, but refills required)

Battery

Specifications

MODEL

1577149

FLOW OUTPUT

3000 (207)

2.5 (9.4)

140  F (60  C)

ENGINE

Powerhorse

208CC

DIMENSIONS / COMPONENTS

27.5”

23”

1577249

3000 (207)

2.5 (9.4)

140  F (60  C)

Powerhorse w/ Electric Start

208CC

27.5”

23”

38.5”

75lbs

38.5”

80lbs

4 oz. 4 oz.

SUPPLIES REQUIRED (not included)

Refer to the “Engine Manual” section

Refer to the “Engine Manual” section

SAE 30 non-detergent pump oil

(#35605)

N/A

SAE 30 non-detergent pump oil

(#35605)

12 Volt

10 Ah

Max Dimensions:

6-1/8” x 3-1/2 x 4-7/16”

5

12

15

10

14

Component Identification

7

6

5

2

11

9

4

1

8

3

16

13

1.

Pressure Washer Pump: Inspect for loose/broken parts prior to each use.

2.

Pump Oil Fill: Add pump oil here. Replace shipping plug with vented dipstick.

3.

Pump Oil Drain: Drain pump oil from here.

4.

Pump (Water) Inlet: Attach garden hose here.

5.

Pump (Water) Outlet. Connect high pressure hose here.

9.

Engine: The air-cooled engine powers the pump.

10.

Gun Holder: Store gun here.

11.

Nozzles: Change nozzles for different spray patterns.

12.

Handle: Designed for easy cart movement.

13.

Hose: Attach couplers to gun and water outlet.

14.

Spray Gun: Source of pressurized water, use two hands for safe operation.

6.

Pressure Adjustment (Unloader): Valve that regulates pressure and directs flow into bypass when trigger is closed.

7.

Chemical Injector: Push chemical hose onto injector to route chemical from chemical bucket into pump.

8.

Thermal Protector: Valve that regulates water temp in the pump

15.

16.

Trigger: Pull to allow pressurized water to flow out of spray gun.

Chemical Hose:

See “ Parts Explosion ” for more details

Submerge in cleaning solution.

6

Hazard Signal Word Definitions

DANGER

WARNING

CAUTION

CAUTION

NOTICE

Safety

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 (red) indicates a hazardous situation, which if not avoided, will result in death or serious injury.

WARNING (orange) indicates a hazardous situation, which if not avoided, could result in death or serious injury.

CAUTION (yellow), used with the safety alert symbol, indicates a hazardous situation, which if not avoided, could result in minor or moderate injury.

CAUTION (yellow), without the safety alert symbol, is used to address practices not related to personal injury.

NOTICE is used to address practices not related to personal injury.

7

Safety Labeling

Safety Decal Locations

WARNING:

ALWAYS make sure safety labels are in place and in good condition. If a safety label is missing or not legible, order new labels from Powerhorse Product Support at 1-866-443-2576

4

3

1

Fig0468

4

2

Location

1

2

3

4

On-Product Warning Labels

Part numbers

788935

788936

788937

789002

Description

Fuel Fire Explosion

Burn Hazard

Poisonous Gas

Warnings

8

Safety Decals

To order replacement safety labels, call Powerhorse Product Support at 1-866-443-2576

9

Initial Set-Up

Step 1. Inspect & Unpack

Upon receiving your item check for missing or damaged parts.

See “Component Identification” section of this manual for a diagram of the pressure washer and its components.

For missing or damaged components, contact Product Support at 1-800-270-0810.

If complete, fill out product serial number information. See “Limited Warranty” section of this manual.

Engine/Pump Base Handle

Leg Pressure Hose Lance

Spray Gun Wheel Hardware Bag

Base Tube

Battery Bracket

*

Only on Model# 1577249

10

Hardware Bag

5/16 x 1 1/2" Bolt

Qty-10

Part# 82017

5/16" x 3/4" Bolt

(1577149) Qty-6

(1577249) Qty-2

Part# 82015

Nozzles

Qty-2

Part# 781025

Qty-1

5/16 x 2" Bolt

(1577249) Qty-4

Part# 82018

5/16" x 2" Carriage Bolt

Qty-2

Part# 82233

T-Handle Knobs

Qty-2

Part# 38578

Suction Hose w/ Strainer

5/16” Wing Nut

(1577249) Qty-4

3/4” Lock Washer

Qty-2

Part# 82041

11

5/16" Nut

Qty-18

Part# 82019

Grommet

(1577149) Qty-5

(1577249) Qty-6

Part# 35198

Rubber Foot

Qty-2

Part# 2215

Hook

Qty-1

Part# 38509

3/4” x 4” Bolt

Qty-2

Part# 82230

3/4” Thick Nut

Qty-2

Part# 82040

Breather Plug Tube with Dipstick

Qty-1

Part# 785819

3/4” Thin Nut

Qty-2

Part# 82476

Step 2. Assembly

Note: Remove contents from pallet and assembly can occur at this time

Base Assembly

1.

Bolt pressure washer frame to the engine base using:

 (6) 5/16-18 x 1-1/2” HHSF Flange Bolts (82017)

 (6) 5/16-18 Flange Nut (82019)

Flange

Nut

Frame

Base

Flange

Bolt

FIG

046

85

2.

Attach the leg to the pressure washer base using:

For Model# 1577149

 (4) 5/16-18 x 3/4” HHSF Flange Bolts (82015)

 (4) 5/16-18 Flange Nut (82019)

For Model # 1577249

 (4) 5/16-18 x 2” HHSF Flange Bolts (82018)

 (4) 5/16-18 Flange Nut (82019)

Flange

Nut

FIG0468

6

3.

Bolt the rubber bumpers (feet) to the leg of the pressure washer cart using:

 (2) 5/16-18 x ¾” HHSF Flange Bolts (82015)

 (2) 5/16-18 Flange Nut (82019)

Flange

Bolt Bumper

FIG0

4687

Flange

Nut

Wheel to Base Assembly

4.

Install wheels on the pressure washer base using:

 (2) 3/4 x 4” Bolts (82230)

 (2) 3/4-10 Thin Nut

 (2) 3/4” Thick Nut (82040)

 (2) 3/4” Lock Washers (82041)

Bolt

Wheel

Lock

Washer

Thin Nut

Thick Nut

FIG0

4688

Base

Repeat the process as pictured to install the wheel on opposite side.

Check that wheels turn freely.

After completing this step the pressure washer cart assembly may now be placed right side up, ensuring that the wheels and leg are on a flat surface.

Flange

Bolt

12

Handle to Base Assembly

5.

Bolt the pressure washer handle on to cart assembly using:

 (2) 5/16-18 x 2” Carriage Bolt (82233)

 (2) T-Handle Knobs (38578)

T-Handle

Bolt

FIG0468

9

6.

Install the hose hook and nozzle grommets using:

 (1) Threaded Hose Hook (38509)

 (2) 5/16-18 Flange Nut (82019)

For Model# 1577149

 (5) 7/16 Grommet (35198)

For Model # 1577249

 (6) 7/16 Grommet (35198)

Nozzle (x2)

Nozzle

Grommet

Hose

Hook

Flange Nut

*Grommet

Fig04

690

13

Mounting Engine to Base

7.

Mount engine to cart assembly using:

 (1) Engine & Pump

 (4) /16-18 Flange Nut (82019)

 (4) 5/16-18 X 1 1/2” Flange Bolts (82017)

Insert flange bolt from underneath base of the cart. Tighten flange nuts to the bolts fastening engine to cart.

Engine

Flange Nut

FIG

0469

3

Flange Bolt

Replace Shipping Plug with Dipstick

8.

Remove shipping plug from the pump and replace with the supplied dipstick.

9.

Attach chemical hose to Pump by pushing onto chemical injector barb.

Note: Discard Shipping Plug and O-ring.

Install Battery (

10.

POSITIVE CABLE

1577249 Only)

NEGATIVE CABLE

Route battery cables as shown. Note: Ignition switch and starter removed for clarity.

A.) Install a 12-volt standard lawn and garden battery with a minimum of 10 amp hour rating and max dimensions of 6-1/8” x 3-1/2 x 4-7/16”.

The engine will NOT run unless a battery is installed.

 The battery is to be supplied by the customer.

B.) Following the steps below for connecting and disconnecting the battery:

WARNING: Battery Hazards

Batteries are hazardous because they contain caustic acid, can emit explosive gases, and can cause electric shock. Caution must be exercised when making connections to a battery to avoid shock and contact with the acid, and to prevent any sparking that could lead to an explosion.

ALWAYS follow the general battery safety rules and instructions.

General Battery Safety Rules

 ALWAYS use eye protection and protective

 clothing when handling batteries.

NEVER smoke or work near sparks or other sources of ignition.

NEVER touch both battery terminals at the same time with your hand or any non-insulated tools.

If battery acid contacts skin or clothing, flush immediately with water and neutralize with baking soda.

14

11.

Connecting the Battery

Always connect the cables in the following sequence to avoid possible shock: a.

Connect the red cable to the positive (+) terminal of the battery. b.

Then connect the black cable to the negative (-) terminal of the battery.

Disconnecting the Battery

Always disconnect cables in the following sequence to avoid possible shock. a.

Remove the battery from the battery bracket. b.

First, disconnect the black cable from the

Fig

04

71

9 negative (-) terminal of the battery. c.

Next, disconnect the red cable from the positive (+) terminal of the battery. d.

Reinstall the battery strap.

Bolt (x2)

Black Nut (x2)

*Nuts and bolts not supplied.

Fig04

721

Red

12.

Install battery and battery bracket using:

 (1) Battery, Customer to Purchase Separately

 (1) Battery Bracket (788911)

 (4) 5/16-18 Wing Nuts (777450)

Fig04722

Battery

Battery

Bracket

Wing Nut

WARNING: High Pressure Fluid Injection

Hazard

High-pressure fluid discharge from leaks (even pin-sized) or ruptured components can pierce skin and inject fluid into the body. Injection injury can result in blood poisoning and/or severe tissue damage leading to infection, gangrene, and possibly amputation.

 Never use a finger or skin to check for leaks.

 Never operate machine with damaged or missing hoses/parts.

 Never attempt to repair a high-pressure hose or component – Always replace it with a part that is rated at or above the pressure rating of this machine.

15

Step 3. Select Suitable Location

Moving and Handling

Moving your pressure washer around

 Use the handles to manually move the pressure washer.

 Push the pressure washer in front of you has you walk.

 To turn, push down slightly on the handles and pivot the pressure washer on its wheels.

Elevating or lowering your pressure washer

 To reduce risk of injury, it is recommended that two adults lift the pressure washer.

 Only lift the pressure washer by the bumper and handle. Do not use the pump or engine as a lifting point.

WARNING: Lifting hazard

The pressures washer is heavy. It can crush and cause serious injury if it rolls out of control or tips over. Follow the instructions below for safely moving the pressure washer.

Outdoor Use Only

1.

Never run the pressure washer in an enclosed or partially enclosed location such as a building, garage, barn, shed, or house. These spaces can trap poisonous gases. Running a fan or opening windows will not provide adequate ventilation to prevent dangerous CO build-up.

2.

Only use the pressure washer outdoors and far away from open windows, doors, and building or vehicle vents.

3.

Place the pressure washer so that the exhaust fumes will not be directed towards people or building air intakes.

4.

Do not locate and use the pressure washer in the presence of flammable vapors, dust, gases, or other potentially combustible materials.

5.

Ensure that working, battery-operated or battery back-up carbon monoxide alarms are used in any dwelling/structure that is in close proximity to the running pressure washer.

6.

Note that this pressure washer is NOT designed or approved for use in vehicles or marine applications. Never run the pressure washer inside RVs or other vehicles, on boats, or on pick-up truck beds.

Positioning :

1.

The pressure washer should be positioned on a firm, level (less than 3 degree slope), heat-resistant surface with good drainage and a nearby water supply.

2.

The pressure washer should be placed within garden hose distance of a continuous water supply. Ensure that the pressure washer sits level and will not slide or shift during operation. If applicable, block the pressure washer's wheels to prevent movement.

3.

Situate so there is adequate pulling room for starting the engine using the recoil starter.

Attempting to pull at an odd angle could rip off grip cord and/or cause muscular injuries to the operator.

Airflow :

1.

Situate so there is adequate clearance around pressure washer to allow for airflow – at least 7 feet from any non-combustible wall or obstruction.

2.

Do not operate with a tarp, blanket, or cover surrounding the machine.

3.

Do not place any objects against or on top of the unit.

4.

The pressure washer needs adequate, unobstructed flow of air to allow for proper combustion and adequate cooling.

Proper combustion can only be obtained when there is a sufficient supply of oxygen available for the amount of fuel being burned. Cooling ventilation is required to prevent overheating of the pressure washer and possible fire.

Exhaust :

WARNING: Exhaust Modification hazard

Never attempt to attach ductwork to the muffler system to allow for installation inside an enclosure.

This could cause heat build-up and increased exhaust back-pressure, resulting in possible exhaust leakage or damage to the pressure washer.

1.

The exhaust gas from your pressure washer is extremely hot and can cause combustible materials to catch on fire.

2.

Make sure the engine is at least 7 feet from all combustible materials and buildings/structures during operation.

3.

Keep a fire extinguisher rated "ABC" nearby.

Keep it properly charged and be familiar with its use.

4.

Place the unit so that the exhaust fumes will not be directed towards people or building air intakes.

DANGER: Carbon monoxide hazard

Exhaust fumes from the engine contain carbon monoxide (CO), a poisonous gas you cannot see, smell, or taste. The CO generated by the engine can rapidly accumulate, even in areas that appear to be well ventilated, resulting in dangerous and fatal concentrations within minutes. NEVER run pressure washer inside any enclosed or semi-enclosed spaces, including homes, garages, basements, sheds, boxes, pick-up truck beds, RVs, or boats. These spaces can trap poisonous gases, EVEN if you run a fan or open windows. If you start to feel sick, dizzy, or weak while using the pressure washer, shut off the engine and get to fresh air RIGHT AWAY. See a doctor. You may have carbon monoxide poisoning.

Install Spark Arrestor (if Required)

Equip engine with spark arrestor if machine will be used near any ignitable forest, brush, or grassy land. Make sure you comply with applicable local, state, and federal codes.

16

Operation

Follow Safety Rules for Operation

After you have checked and fueled the equipment and positioned it in a suitable worksite, it is time to start your pressure washer. The following are the procedures necessary for safe, successful operation of your pressure washer.

WARNING

Failure to follow safety rules may result in serious injury or death to the operator or bystanders.

Instruct operators . Owner must instruct all operators in safe set-up and operation. Do not allow anyone to operate the pressure washer who has not read the

Owner’s Manual and been instructed on safe use practices.

Safety equipment/controls . Always operate with all safety covers, guards, and barriers in place and in good working order, and all controls properly adjusted for safe operation.

Moving parts . Keep hands, feet, hair and apparel away from moving parts. Air vents may cover moving parts and should be avoided as well. Never remove any guards while the unit is operating.

Ear Protection.

Hearing can be damaged from prolonged, close-range exposure to the type of noise produced by this pressure washer. The use of ear plugs or other hearing protection device is recommended for persons working within 15-20 feet of the running pressure washer for an extended period of time.

Eye Protection. Wear ANSI/OSHA required “Z87.1” safety glasses when operating or servicing the pressure washer.

Pressurized spray from this unit can cause severe injury to the eyes. Small objects can become airborne as the spray contacts them.

NOTE!

Before starting the pressure washer, review the following general safety rules for operation:

Conditions for Use

Know how to stop.

Be thoroughly familiar with proper use of the equipment and all controls and connections.

Know how to stop the pressure washer and depressurize system quickly if needed.

Instruct all operators . The pressure washer's owner must instruct all operators and potential renters in safe set-up and operation. Do not allow anyone to operate the pressure washer who has not read the Owner's

Manual and been instructed on its safe use.

Adult control only.

Only trained adults should set up and operate the pressure washer. Do not let children operate. Pressure washers can generate forces greater than children can control and require judgment beyond what can be expected of children.

Under the influence.

Never operate, or let anyone else operate, the pressure washer while fatigued or under the influence of alcohol, drugs, or medication.

Safety equipment / controls in place.

Do not operate the pressure washer unless all safety covers, guards, and barriers are in place and in good working order, and all controls are properly adjusted for safe operation.

Damaged.

Do not operate the pressure washer with damaged, missing, or broken parts. Never attempt to repair a high pressure hose or component. Always replace it with a part that is rated at or above the pressure rating of the machine.

Modifications.

Do not modify the pressure washer in any way or deactivate any safety device. Do not change or add to fuel tank, fuel lines, or exhaust system.

Modifications can result in hazards related to carbon monoxide poisoning, fuel leaks, fire, explosion or other serious safety hazards, and will also void the warranty.

During Use

Stay alert.

Watch what you are doing at all times.

Clear work area.

Clear the work area of all bystanders.

Keep children and pets away.

Keep spray away from electrical wiring . Spray contact with electrical wiring will likely result in severe electrical shock or electrocution.

Hot exhaust/parts.

Stay clear of engine exhaust.

Never touch hot engine muffler, or other hot surfaces.

All are very hot and will burn you.

Never pull by hose.

Do not move this machine by pulling on the hose. Hose or connections could fail and

17

result in catastrophic high pressure release of fluid as well as hose whipping.

Avoid sharp objects.

Keep hose away from sharp objects. Bursting hoses may cause injury.

No load bearing . Do not use the pump to support other items of equipment that impose unacceptable loads on the pump. Do not attempt to use this machine as a prop.

Lock trigger safety latch when not spraying . Spray gun is equipped with a built-in trigger safety latch to guard against accidental trigger release. Rotate safety latch to the locked position when not spraying.

Leaving unattended . Always turn off the pressure washer and relieve system pressure before leaving the sprayer unattended.

Prompt Emergency Response

Seek medical aid for suspected injection injury . If injured by high-pressure fluid, no matter how small the wound is, see a doctor at once. A typical injection injury may be a small puncture wound that does not look serious. However, severe infection or reaction can result if proper medical treatment is not administered immediately by a doctor who is familiar with injection injuries.

Seek medical aid for suspected carbon monoxide poisoning . The running engine gives off carbon monoxide, a poisonous gas that can kill you. If you start to feel sick, dizzy, or weak while using the pressure washer, shut off the engine and get to fresh air RIGHT

AWAY. See a doctor. You may have carbon monoxide poisoning.

Put on Personal Protective Gear

WARNING: Personal Protective Gear

Use personal protective gear to prevent:

- Eye and skin injection injury from high pressure spray

- Eye injury from flying debris

1.

Wear waterproof gloves, safety glasses with side and top protection, face protection, and protective clothing when operating the machine. If spraying pressure washer specific chemicals, wear a respirator mask to avoid inhalation of vapors if directed on the chemical label.

2.

Wear non-slip, protective footwear. Use of pressure washer can create puddles and slippery surfaces.

Wear footwear capable of maintaining a good grip on wet surfaces.

18

Preparing for Operation

Make sure that any regular maintenance has been performed as prescribed in “Maintenance & Repair” section.

Check/Add Oil to Pump

CAUTION

Never run the pump without sufficient lubrication!

1.

Turn off engine, allow it to cool and disconnect the spark plug wire.

2.

Twist dipstick cap until the arrow on the cap lines up with the arrow on the breather plug tube. Remove the dipstick from the breather plug tube. Then remove the breather plug tube from the pump.

3.

Wipe the dipstick off with a clean dry cloth.

Insert the dipstick cap 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 above recommended oil as needed.

4.

Thread the pump breather plug tube back into the pump housing.

5.

Align the arrow on the dipstick cap with the arrow on the breather plug tube, insert it, and twist it to secure. Reconnect the spark plug.

6.

If oil level is low, use the following:

Model Oil Type

1577149

1577249

SAE 30 non-detergent pump oil (#35605)

1.

Replace fill cap.

Check/Add Engine Oil

Use the recommended oil type for your engine and expected ambient conditions. (See engine “Engine

Manual” section for oil type and capacity, and more detailed oil check/fill instructions.)

WARNING: Burn Hazard

Never open oil port while engine is running. Hot oil can spray over face and body.

Notes:

 Engine is shipped without oil. You must add oil before first use.

Add Fuel

WARNING: Fuel Fire/Explosion Hazard

Gasoline is highly flammable and explosive. Heat, sparks, and flames can ignite fuel vapors, which can become widespread during fueling. A flash fire and/or explosion could result and cause serious injury or death. Always use extreme care when handling fuels. Carefully follow all instructions to avoid the following conditions which could result in fuel ignition:

 gas vapor collection inside enclosures

 static electric sparks

 sparks from electric wiring, batteries, or running engines

 sources of heat (such as a hot engine exhaust)

 open flames, including pilot lights

Always follow these general safety rules when fueling:

1) Turn pressure washer off and allow to cool for at least two minutes before removing any fuel cap.

Note: A running or still-hot engine is hot enough to ignite fuel.

2) Fill fuel tank OUTDOORS – never indoors. Fuel vapors can ignite if they collect inside and enclosure and explosion can result.

19

3) Stay away from all sources of heat, sparks, and flames. Do not smoke.

4) Never pump fuel directly into the gas tank at a gas station – it could cause a static electric spark. Follow these steps to avoid static electric sparking during fueling:

 Use an approved portable container to transfer fuel to the pressure washer's tank. (A portable container made of metal or conductive plastic is preferred because it dissipates charge to ground more readily.)

 Always place container on the ground to be filled. Never fill the portable gas container while it is sitting inside a vehicle, trailer, trunk, or pick-up truck bed.

 Dissipate static charge from your body before beginning the fueling process by touching a grounded metal object at a safe distance from fuel sources.

 Keep nozzle in contact with container while filling. Do not use a nozzle lock-open device.

5) Clean up fuel spills/splashes immediately.

 If possible, move the pressure washer away from spilled fuel on the ground.

 Wipe up spilled fuel and wait 5 minutes for excess fuel to evaporate before starting engine.

 Fuel soaked rags are flammable and should be disposed of properly.

 If fuel is spilled on your skin or clothes, change clothes and wash skin immediately.

.

Fill Engine Fuel Tank

Check the gasoline tank level. If needed, fill tank with fresh unleaded gasoline from a portable container:

1) Remove engine gas cap.

2) Add gasoline through the fill opening:

 Use only a UL-approved portable gasoline container to transfer the gasoline to engine's tank.

 Do NOT overfill the gasoline tank. Allow at least 1/2" of empty space below the fill neck to allow for fuel expansion.

3) Replace gas cap securely before starting engine.

4) Store extra gasoline in a cool, dry place in a UL approved tightly sealed container.

Inspect Fuel System/Check for Leaks

Inspect the engine fuel system and check for leaks before each use.

Do not start pressure washer until all needed repairs have been completed.

WARNING: Fuel Leak Hazard

Gasoline fuel is highly explosive and fuel leaks can result in fire or explosions. You can be burned and seriously injured if the fuel system is not properly hooked up or there is a fuel leak when you start the engine.

Inspect the entire fuel system. Look for:

 signs of leaks or deterioration chafed or spongy fuel hose 

 loose connections

 loose or missing fuel hose clamps damaged fuel tank or

 defective gasoline shut-off valve

Inspect Spray System

Always inspect spray system for damage and leaks before each use. Do not start pressure washer until all needed repairs have been completed.

WARNING: High Pressure Fluid

Injection Hazard

High-pressure fluid discharge from leaks (even pinsized) or ruptured components can pierce skin and inject fluid into the body. Injection injury can result in blood poisoning and/or severe tissue damage leading to infection, gangrene, and possibly amputation.

 Never use a finger or skin to check for leaks.

 Never operate machine with damaged or missing hoses/parts.

 Never attempt to repair a high-pressure hose or component – Always replace it with a part that is rated at or above the pressure rating of this machine.

Perform Scheduled Maintenance, As needed

Make sure that any other regular maintenance has been performed as prescribed in this manual in the

"Maintenance Schedule Summary" section.

Refer to the “Engine Manual” section for engine maintenance instructions.

20

Connect Hoses, Water Supply, and Spray

Nozzle

Position pressure washer for use

 For detailed instruction on positioning your pressure washer for use, turn to the “Initial Set-Up” section of this manual and reference “Step 3: Select Suitable

Location”.

 Where no flammable vapors, dusts, and gases are present.

 Where there is adequate, unobstructed ventilation

 airflow.

With adequate clearance from combustible materials.

On a firm, level, heat-resistant surface with good drainage and nearby access to a continuous water supply.

Attach Garden Hose to Water Inlet

1

.) Make sure the water supply is clean. Debris can cause excess pump wear and reduce performance.

2.) An insufficient water supply will damage your pump. Make sure the water supply is steady and is

20% over the rated flow of your pump. Use a stopwatch to time how long it takes to fill a 5-gallon bucket with your garden hose. The bucket must fill faster than the times listed in the table below.

Model Time to fill 5 gallon bucket

1577149

1577249

100 seconds

100 seconds

3.) The water supply garden hose must have an inside diameter of at least 5/8”. If the hose is more than

100 ft. long, the diameter must be at least 3/4”.

4.) Never use a reservoir tank as a water source.

Drawing water out of a tank may cause pump cavitation and damage to your pump. This pressure washer is designed for a pressurized water source such as a city water faucet. However, the water source pressure must not exceed 115 psi

(8 bar).

5.) Always use a flexible rubber hose for your water supply. Do not use rigid piping.

Attach High Pressure Hose to Spray Gun and Water Outlet

WARNING: High Pressure

NEVER operate this pump with components (such as hose, connections, and spray gun) rated for lower pressure and/or temperature limits than the machine's maximum rated pressure and temperature, or component could rupture and cause serious personal injury from escaping high pressure fluids.

1) See "Component Identification" section of this manual for location of the pressure washer's water outlet.

2) To attach the pressure hose to the spray gun, spin the pressure hose’s 22mm coupler onto the spray gun’s inlet, hand tight.

Spray Gun

Fig0469

4 22mm Coupler

Pressure Hose

Select Nozzle for Spray Gun

Your pressure washer is equipped with (1) highpressure nozzle and (1) low-pressure nozzle.

Generally, the wider the spray angle of the nozzle, the lower the spray impact produced. Select the appropriate nozzle for the job based on the following table:

Color of Nozzle: Spray

Angle

*Red

*Yellow

0

15

Green

*White

Black-Low pressure

25

40

65

Used For:

Highest Impact

Tough Stains/Stripping

General

Light Cleaning

Chemicals

*Please call Powerhorse Customer Service to order additional nozzles.

NOTE: You must use the low pressure black nozzle for spraying chemicals.

21

Attach Nozzle to Spray Gun

WARNING: Depressurize First

Any time you remove/install/change a nozzle, you must depressurize hose line by squeezing the spray gun trigger while the engine is off. Even if the engine has been off for a long period of time, the hose may remain dangerously pressurized.

Fig04

694

Nozzle

Trigger

1.

Make sure the engine is off and the hose line is depressurized.

2.

To install the nozzle, pull the collar back and twist the nozzle firmly into the coupler on the end of the wand

Lance

Coupler

Nozzle

Collar

3.

Release the collar, making sure it springs back and re-seats to its original (non-retracted) position.

Check the connection by pulling on the nozzle to ensure a tight connection -- if correctly inserted, nozzle will rotate but not pull out.

Prime the Water Supply

Turn on water supply and squeeze the trigger

CAUTION: Water Pressure

Never run the pump without the water supply connected and turned on.

Operating the pressure washer without a sufficient incoming flow of water will damage the pump.

 Turn on the water supply. Make sure the water supply is steady and flowing at a rate 20% over the rated flow of your pump. (Reference the flow rate table under the Connect Hoses, Water Supply, and

Nozzle" section).

 Purge air from the water supply hose by squeezing the trigger until a steady stream of water flows out of

 the nozzle at low pressure. (Air in the hoses can cause damage to the pump, so always make sure all the air is out of the hoses before starting the pressure washer engine.)

Make sure the water supply hose is not kinked. A kinked hose will provide insufficient water supply to the pump and reduce its life. Make sure the hose remains unkinked after moving the pressure washer.

Set Up for Chemical Spray (if desired)

Using the proper cleaning chemical for the application can speed up cleaning jobs tremendously.

Your pressure washer is equipped with a chemical injection point on the downstream side of the pump for introducing cleaning chemicals into the water stream. A braided chemical hose is provided to connect at this point. Suction pressure at this connection automatically draws the chemical solution in through the hose, mixing in 1 part chemical to 15 parts water. Adequate suction pressure is created only when the low pressure (black) spray nozzle is used.

The introduction of cleaning chemicals via the chemical injection point affords the following advantages:

It protects the pump from damage because no chemical passes through the pump.

CAUTION: Chemicals Containing

Muriatic Acid

Certain chemicals, such as bleach or those containing muriatic acid, will cause pump damage if introduced upstream through the pump's water inlet.

It mixes the cleaning chemical into a low pressure spray. Cleaning chemicals applied under low pressure adhere better to the surface being cleaned, allowing the formula time to react and remove dirt more effectively.

Note: An external chemical injector pump is not recommended for use with this pressure washer, and if used would obviously alter the 15-to-1 dilution ratio.

WARNING: Chemical Spraying

 Never spray acids, corrosives, or abrasive or flammable liquids. Breathing hazards, surface burns/corrosion, or fire/explosion could result.

 Follow the chemical manufacturer's label instructions for proper use and handling of the chemical. Understand all safety hazards and first aid for all chemicals being used.

Always wear protective gloves when handling and cleaning with chemicals, and wear other protective gear as directed by chemical manufacturer. Always dispose of hazardous fluids per local, state, and national guidelines.

Acquire Cleaning Chemical

Use only approved pressure washer chemicals designed for high-pressure use.

CAUTION: Non-approved Chemicals

Non-approved chemicals can damage pressure washer components (seals, wand, hoses, pump, etc.) and be harmful to the environment.

Prepare for Chemical Spray (If Planning to Use)

Prepare the pressure washer for chemical spraying using the following steps:

22

1.

Prepare (dilute) chemical cleaning solution as required for the job.

(Note: the chemical solution will be automatically mixed with the water at a ratio of 15 parts water to

1 part chemical solution.)

2.

Press the braided chemical hose over the chemical injector on the pump.

3.

Submerge the suction strainer connected to the braided chemical hose into a bucket containing the chemical solution.

Start-Up Procedures

Start the Engine to Power the Pump.

1.

Make sure water supply is connected and primed.

CAUTION: Warranty Void

Running the pump dry will cause damage and void the warranty.

2.

To prevent accidental spraying, engage the safety latch on spray gun trigger by rotating it to the locked position.

3.

Follow the instructions in the “Engine Manual” section for starting the engine.

- If the engine doesn't start on the first try, pressure may build up in the pump. Relieve pressure by squeezing the spray gun trigger before attempting to start engine again. This will make starting easier.

DANGER: Engine Exhaust

Do not inhale engine exhaust. It contains dangerous carbon monoxide that can kill you.

Apply Cleaning Chemical (If Desired)

1.

Make sure the chemical injector is properly set up according to the instructions. Reference “Set Up for

Chemical Spray” on the previous page.

2.

Make sure the low pressure BLACK nozzle is attached before beginning to spray chemicals --

Only the low pressure black nozzle will allow chemicals to be drawn through the chemical injector into the water stream.

3.

Apply chemicals by squeezing the spray gun trigger.

The chemical injector will draw the chemical into the water stream.

4.

Apply chemicals evenly to the cleaning surface.

Never use more chemical than is necessary to clean the surface.

5.

Allow the chemicals time to react with the dirt before rinsing.

6.

Prepare to rinse by changing to a high-pressure nozzle. Changing the nozzle from the low-pressure black nozzle to a high-pressure nozzle will stop the flow of chemicals into the water stream.

Instructions for selecting a nozzle can be referenced in the “Connect Hoses, Water Supply, and Spray Nozzle” section, see the subsection

“Select Nozzle for Spray Gun”.

7.

Rinse with high-pressure spray as instructed below.

Pressure Adjustment

Chemical Injector

(Unloader)

Water Outlet

Chemical Hose

Water Inlet

Thermal Protector

23

Begin High Pressure Spray

WARNING: High Pressure Spraying

Safety

 Keep spray away from people.

Never direct discharge stream at or near any person. Do not allow any part of the body to come in contact with the fluid stream. High-pressure spray can cause serious skin, eye, or falling injuries. Injection injury will occur if high-pressure spray pierces the skin, injecting liquid under the skin. Injection injury can result in blood poisoning and/or severe tissue damage leading to infection, gangrene and possibly amputation. Seek medical attention.

 Do not secure trigger open. To reduce risk of injury, do not attempt to secure the spray gun open by blocking or tying the spray gun in the open position.

 Prevent slips / loss of balance . High-pressure spray could cause you to lose balance from kickback forces, and wet surfaces can be slippery .

Keep good footing and balance at all times. Do not overreach.

Do not stand on unstable support when spraying.

If spraying from an elevated surface, use fall protection because spray gun kickback can propel you off the elevated surface. When spraying from a ladder or scaffolding, ensure it is firmly anchored from sway or tip-over.

Be aware of puddles and slippery surfaces.

Ensure there is adequate drainage to prevent pooling of water.

 Prevent surface damage & flying debris –

Surfaces being sprayed must be strong enough to withstand high-pressure spray or damage may result. In addition, high-pressure spray will dislodge unsecured objects as well as surface chips and debris, resulting in hazardous flying objects that can cause personal injury or property damage. Do not spray brittle surfaces or breakable, fragile, or unsecured objects such as: o stucco or laminar flagstone o some painted surfaces o windows or glass doors (because they may break) o light fixtures, flowerbeds, mailboxes o unsecured, lightweight objects

Procedure:

1.

Put on the high-pressure spray nozzle (always relieve system pressure first and follow instructions for attaching a nozzle).

2.

Clear the cleaning area of all persons. Keep children and pets away.

3.

Hold the spray gun firmly with two hands and a sturdy stance -- Gun kicks back when triggered.

4.

Wash from the bottom to the top, using side-toside motions. This washes away heavy dirt and allows the detergent to soak as you work toward the top.

5.

Use the width of the spray pattern to wash a wide path. Overlap spray paths for complete coverage.

6.

The nozzle should be 12" to 24" from the work, closer for tough areas.

7.

Small parts should be washed in a basket so the pressure does not push them away.

Larger, lightweight parts should be clamped down.

8.

The pressure washer is set and locked to the maximum rated pressure when it leaves the factory. To reduce the pressure, turn the unloader knob counterclockwise. To return to maximum pressure turn unloader knob clockwise.

Pressure Adjustment

(Unloader)

WARNING: Warranty Void

Do not attempt to alter the unloader valve's maximum pressure. Excess pressure could cause serious injury from escaping highpressure fluids and/or pump damage. Any alteration other than turning the adjustment knob will void your warranty.

9.

If temporarily interrupting spraying, rotate trigger safety latch downward to the locked position to guard against accidental trigger release.

24

Spray Gun Safety Lock

When not spraying, use the spray gun safety lock to prevent accidental high pressure discharge.

Spray Gun

FIG0

4696

Safety Lock

10.

Always turn off the engine and activate spray gun trigger to relieve system pressure when:

 the sprayer is unattended disconnecting hoses, installing/cleaning nozzles, or servicing the pump.

WARNING: Injury

Always turn off the engine and relieve system pressure when finished spraying or when leaving sprayer unattended. Serious injury could result from unintentional release of highpressure spray.

25

Shutdown

Stop the engine using the following steps:

WARNING: Injury

Never disconnect the high-pressure hose from the pump or spray gun while the system is pressurized. Relieve pressure by squeezing the spray gun trigger after the engine is turned OFF.

1.

Turn engine OFF.

2.

Turn water supply OFF.

3.

Actuate spray gun trigger to relieve system pressure .

4.

Remove garden hose.

5.

Remove pressure hose.

6.

Remove nozzle from spray gun.

7.

Turn gasoline line valve to the OFF position .

8.

If chemicals were used, remove chemical injector tube from the pump.

9.

Cool engine at least five minutes before storing, a hot engine is a fire hazard.

When you are finished using the pressure washer, you must prepare the sprayer for storage and store it in a proper location.

Between-Use Storage

Perform periodic maintenance as directed in this manual to keep the pressure washer in safe working condition.

Choose a storage location that is:

 Clean and dry.

 Away from sources of heat, open flames, sparks, or pilot lights, even if the pressure washer's engine fuel tank is empty. Residual fuel fumes from tank can ignite.

Away from extreme high or low temperatures. Do not store the pressure washer in freezing conditions unless it is prepared as directed below for those conditions.

Note:

 If you will be storing the pressure washer in freezing conditions , follow the instructions for preparing the sprayer for storage in freezing conditions.

 If you will not be using the pressure washer again for 30 days or more , follow the instructions for preparing the engine for long-term storage.

WARNING: Flammable Materials

 Fuel and its vapors can ignite and cause a fire. Select a well-ventilated storage area away from sources of heat, flame, or sparks.

A hot engine can ignite flammable materials. Always let engine cool at least five minutes before storing.

Prepare Pressure Washer for Freezing

Conditions

If you will be storing the pressure washer in freezing temperatures, you must properly prepare the pressure washer to prevent water from freezing in the system.

WARNING: Freezing Conditions

Do not allow water to freeze in the pressure washer, high pressure hose, or spray gun.

Freezing water can cause damage to the equipment and cause the spray gun to fail in the open position. A spray gun that has failed in the open position can whip around and cause personal injury when the pressure washer is started.

Storage

1.

Drain the water from the high pressure hose and spray gun by depressing the trigger on the spray gun until all water drains out.

2.

Disconnect the plumbing that connects to the pump outlet.

3.

Obtain the materials you will need:

 12" piece of garden hose or equivalent

 funnel

 approximately 6 oz. of RV antifreeze.

4.

Attach the 12" garden hose piece with the funnel to the pump inlet.

5.

Pour RV antifreeze into the funnel, then pull the recoil a few times until antifreeze comes out of the pump outlet.

Water Inlet

Funnel

Hose

RV Antifreeze

26

Prepare Engine for Long Term Storage

First prepare the engine for long term storage if you will not be using the pressure washer for more than

30 days.

Fuel can become stale when stored over 30 days. Stale fuel causes acid and gum deposits to form in the fuel system which can cause malfunction of the engine.

1.

Prepare fuel system for storage:

 Drain all gasoline from the tank and carburetor. This is most easily accomplished by running the pressure washer with the high pressure hose until the engine stops from lack of fuel.

OR

 Add fuel stabilizer to the gasoline (following manufacturer's instructions)

Fuel stabilizer steps: a.

Ensure gas tank is full. b.

Add fuel stabilizer to fuel tank. c.

Run pressure washer with high pressure hose at least 5 minutes after adding stabilizer to allow it to enter the fuel system. d.

Shut off engine

2.

Lubricate cylinder and piston: a.

Disconnect spark plug wire and remove spark plug b.

Add one teaspoon oil through spark plug hole c.

Place rag over spark plug hole and slowly pull the recoil a few times to lubricate the combustion chamber.

Replace spark plug, but do not reconnect the spark plug wire.

27

Prepare Pressure Washer for Storage

Prepare the pressure washer for storage.

1.

Make sure the engine start switch is OFF.

2.

Disconnect the engine spark plug wire if you haven't already done so.

3.

Disconnect the high-pressure hose, garden hose, and spray gun.

Move Pressure Washer to Storage Location

Let engine cool for 5 minutes before moving the pressure washer to its storage location.

Maintenance & Repair

WARNING: Maintenance Hazards

ALWAYS shut off water supply, bleed water pressure, turn off engine and disconnect the spark plug wire before cleaning, adjusting, or servicing the pressure washer. After servicing, make sure all guards and cover shields are replaced before using.

Maintenance Schedule Summary

Item

Remove dust/debris accumulation

Inspect fuel system

Frequency

Inspect spray system

Clean inlet filter

Check tire pressure

As needed

Each use

Each use

Each use

Each use

Perform engine maintenance

Change pump oil

As specified in the “Engine Manual” section

 After first 50 hours of use

 Every 3 months or 500 hours of use after that

See detailed instructions for each maintenance item below.

(Note: For end-of-the-season storage instructions, see the "Storage" section of this manual.)

See detailed instructions for each maintenance item below.

Detailed Instructions – Maintenance & Repair

No modifications.

Never modify or alter the pressure washer in any way. Modifications can create serious safety hazards and will also void the warranty.

Follow Safety Rules

Read and follow these safety rules whenever you will be servicing the pressure washer:

 Turn off / relieve pressure first.

Always turn off pressure washer and relieve system pressure before inspection or maintenance. Remove spark plug or spark plug wire to prevent accidental starting.

 Fuel valve off.

Turn fuel shut-off valve to OFF position before transporting or servicing the pressure washer.

 Replace guards.

Make sure all guards and cover shields are replaced after servicing the pressure washer.

 Major repair.

Major service, including the installation or replacement of parts, should be performed only by a qualified service technician. Obtain factory approved

 parts from Powerhorse Product Support at 1-800-270-

0810.

Replacement parts . If a part needs replacement, only use factory approved repair parts. Replacement parts that do not meet specifications may result in a safety hazard or poor operation of the pressure washer and will void the warranty.

Keep Pressure Washer Clean

If dust or debris accumulates on the pressure washer, clean the pressure washer with a damp cloth or soft bristle brush. Do not allow air intakes to become blocked.

CAUITION

Do not spray pressure washer with a garden hose or pressure washer. Water may enter the pressure washer and cause damage.

28

Exposed wire mesh due to wear

Inspect Spray System

Inspect spray system for damage and leaks before each use.

Do not start pressure washer until all needed repairs have been completed.

WARNING: High Pressure Fluid

Injection Hazard

High pressure fluid discharge from leaks (even pin-sized) or ruptured components can pierce skin and inject fluid into the body. Injection injury can result in blood poisoning and/or severe tissue damage leading to infection, gangrene, and possibly amputation.

Never use a finger or skin to check for leaks.

Never operate machine with damaged or missing hoses/parts.

 Never attempt to repair a high-pressure hose or component – Always replace it with a part that is rated at or above the pressure rating of this machine.

1) Check hoses, fittings, wand, trigger gun and connections for signs of wear, cracks, looseness, or leaks. Replace as required.

2) Check and clean the nozzle orifice.

Water dripping or spraying, or localized moisture

Bad

Bad

Good

Bad

Bad

29

Inspect Fuel System

Inspect the engine fuel system and check for leaks before each use.

Do not start pressure washer until all needed repairs have been completed.

WARNING: Filter Disposal

Gasoline fuel is highly explosive and fuel leaks can result in fire or explosions. You can be burned and seriously injured if the fuel system is not properly hooked up or there is a fuel leak when you start the engine.

Inspect the entire fuel system. Look for:

 signs of leaks or deterioration,

 chafed or spongy fuel hose, loose connections, loose or missing fuel hose clamps, damaged fuel tank, or defective gasoline shut-off valve.

Check Tire Pressure

Check and refill tire pressure before each use .

1) Remove air cap on tire.

2) Check tire pressure.

3) If needed, fill tire to 30 psi (2.07 bar). Do not overinflate.

Replace air cap.

Perform Engine Maintenance

-As specified in the “Engine Manual” section.

Engine maintenance items include:

1.

Changing oil and oil filter

2.

Air filter check/replacement

3.

Spark plug cleaning and replacement

4.

Fuel filter check/replacement

Inspecting and cleaning muffler (and spark arrestor if equipped)

.

*Drain plug not visible in picture.

Change Pump Oil

Change the pump oil after the first 50 hours of use, and then after every 3 months or 500 hours of use after that.

1.

Remove drain plug from pump.

2.

Drain pump oil into suitable container and dispose of responsibly.

3.

Reinstall oil drain plug.

4.

Make sure unit is sitting level.

5.

Reference the “Specifications” section of this manual to determine the oil type and quantity needed for your pump model.

6.

Replace oil fill cap.

Breather Plug Tube with Dipstick

Oil Drain Plug

NOTE TO COMMERCIAL USERS:

All mechanical equipment, no matter how well designed, will need maintenance and repairs. A Powerhorse pressure washer is no exception. At times, a

Powerhorse pressure washer may become inoperable because repairs are required. Powerhorse Product

Support will assist in these repairs as needed, but if an inoperable pressure washer creates a major expense to your business, then we strongly recommend the following:

 Have a staff person become familiar with the mechanical operation of the pressure washer and capable of making minor repairs and performing all preventative maintenance procedures.

 Keep a stock of recommended service parts for maintenance and minor repairs.

IMPORTANT: Replacement Parts

If a part needs replacement, only use parts that meet the manufacturer's part number specifications.

Replacement parts that do not meet specifications may result in a safety hazard or poor operation of the pressure washer.

Contact Powerhorse Product Support at

1-866-443-2576 for any questions, problems, or parts orders.

30

Troubleshooting

This section provides a list of the more frequently encountered pressure washer malfunctions, their causes and corrective actions. Some corrective actions can be performed by the operator or maintenance personnel, and others may require assistance of a qualified electrician or Service Center.

Causes

Low Oil Shutdown

Cold Engine

No Fuel

ENGINE WILL NOT START

Solutions

Fill engine with the adequate amount of oil

Choke engine to start

Add gas to fuel tank - Make sure fuel shutoff valve is open

Place ON/OFF switch in the ON position

Attach spark plug wire to spark plug

Engine not turned ON

Spark plug wire not attached

Causes

Insufficient water supply

Plugged inlet screen

Need to use high pressure nozzle

Plugged nozzle

Worn nozzle

Leak in high pressure line

LOW/SURGING PRESSURE

Solutions

Increase water flow - Check for kinked or pinched hose

Pull out and clean screen carefully

Change to the green nozzle

Remove nozzle, check for blockage

Replace nozzle

Causes

Need to use different nozzle

Back pressure from extra-long hose

Leak in clear chemical hose

Chemical strainer not submerged

Fix leaks

NO CHEMICAL INJECTION

Solutions

Change to the black nozzle

Try shorter high pressure hose

Replace hose. Use hose clamps if necessary

Make sure strainer is completely submerged in solution

31

Parts Explosion- Models 1577149, 1577249- Rev A.3

32

FIG0

4697

Ref#

1

2

3

6

7

4

5

8

13

14

15

16

9

10

11

12

17

18

19

Parts List-Models 1577149, 1577249- Rev A.3

Part#

2215

Description

Rubber Feet

12278 Wheels

35198 Rubber Grommet

38578 T-Handle Knob

779166 18.5” Lance

38509 Threaded Gun Hook

780828 Spray Gun, 3000 PSI, 22mm Coupler

789703 Powerhorse 208cc Engine, Recoil

788704 Powerhorse 208cc Engine, Electric Start

789459 Pump, 2.5 GPM, 3000PSI, Easy Start

788421 Base

788529 Leg

788568 Base Tube

788569 Handle

788911 Battery Bracket

788800 Billboard Decal

780841 High Pressure Hose, ¼” x 25”,22mm Coupler

777165 Chemical Hose (Sold by Foot)

221222 Chemical Strainer

781025 Nozzle 2 Pack (3.0 orifice)

1

1

1

1

1

1

1

1

1

1

6

2

Qty

2

2

5

1

1

1

3 ft

1

1

Model

All

All

1577149

1577249

All

All

All

All

1577149

1577249

All

All

All

All

All

1577249

All

All

All

All

All

33

Pump Exploded View- Rev A.3

34

Pump Parts List- Rev A.3

Item Description

1 Socket head screw

2 Pump basal flange

3 O-ring 80X2.4

4 Radial shaft seal FB36-50-7

5 Angular contact bearing

6 Wearable sheath

7 Wobble plate

8 Front bearing (51307B)

9 Spring disk

10 Plunger

11 Plunger spring

12 Crankcase

13 O-ring 14.2X1.9

14 Outlet plug

15 Oil seal

16 O-ring 15X2.2

17 Spacer

18 O-ring 21.8X1.9

19 Water seal

20 Compaction washer

21 Inlet plug

22 Washer

23 O-ring 9.8X1.9

24 Valve

25 Hose barb

26 O-ring Ø3.68X1.78

27 Steel ball

28 Small cone spring

29 O-ring 5.3X2.65

30 Outlet cone valve

31 Cone valve spring

Part #

781361

Kit #1

Kit #1

Kit #1

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

781373

Kit #5

Kit #2

Kit #2

Kit #2

Kit #2

Kit #2

Kit #2

N/A

N/A

781383 or Kit #3

781384 or Kit #3

Kit #4

Kit #4

Kit #4 or Kit #10

Kit #4

Kit #4

Kit #4

Kit #4

Qty Item Description

1 32 O-ring 14.2X1.9

1 33 Hose barb seat

1 34 Outlet nut M22×1.5-14

1 35 Back up ring 9X6.2X1.2

1 36 O-ring 6 X1.78

1 37 Back water valve core

1 38 Pump head

1 39 Inlet water seal

1 40 Inlet water body

1 41 Thermal relief valve

1 42 Inlet swivel nut

1 43 Clip ring

2 44 Water filter

4 45 Socket head screw M8X50

3 46 Adjusting screw

3 47 Adjusting screw plug

3 48 O-ring 15X2.5

3 49 Back up ring 8.4X5.3X1.2

3 50 O-ring 5.2X1.9

3 51 Spring holder

3 52 Big pressure spring

3 53 Small pressure spring

9 54 Ball holder

Part #

Kit #4 or Kit #5

Kit #4

Kit #4

Kit #5

Kit #5 or Kit #10

Kit #5

N/A

Kit #6

Kit #6

781401

Kit #7

Kit #7

Kit #7

N/A

Kit #8

Kit #8

Kit #8

Kit #8

Kit #8

Kit #8

Kit #8

Kit #8

Kit #8

Kit #8

6 55 Steel ball 8.7

1 56 Back water valve port

1 57 O-ring 9.25X1.78

58 Breather Plug Tube

2

59 Dipstick

1 60 Siphon hose with filter

1 61 Easy start

1 62 Spring

1 63 Drain plug

Kit #8

Kit #8

Kit #9

789237

Kit # 10

789480

Qty

7

1

1

1

2

1

4

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

35

Pump Kit Parts List-Rev A.3

Kit #

1

2

3

4

5

6

7

8

9

10

Description

Flange w/ Seal Kit

Seal Kit

Valve Kit

Outlet Kit w/ Injector

Valve Cap Kit

Inlet Flange Kit

Inlet Kit

Unloader Kit

Breather Plug with

Dipstick Kit

Easy Start Kit

Item # Items Included

2

3

Pump basal flange

O-ring 80X2.4

4 Radial shaft seal FB36-50-7

15 Oil seal

16 O-ring 15X2.2

17 Spacer

18 O-ring 21.8X1.9

19 Water seal

20 Compaction washer

23 O-ring 9.8X1.9

24 Valve

25 Hose barb

26 O-ring Ø3.68X1.78

27 Steel ball

28 Small cone spring

29 O-ring 5.3X2.65

30 Outlet cone valve

31 Cone valve spring

32 O-ring 14.2X1.9

33 Hose barb seat

34 Outlet nut M22×1.5-14

14 Outlet plug

32 O-ring 14.2X1.9

35 Back up ring 9X6.2X1.2

36 O-ring 6X1.78

37 Back water valve core

39 Inlet water seal

40 Inlet water body

42 Inlet swivel nut

43 Clip ring

44 Water filter

46 Adjusting screw

47 Adjusting screw plug

48 O-ring 15X2.5

49 Back up ring 8.4X5.3X1.2

50 O-ring 5.2X1.9

51 Spring holder

52 Big pressure spring

53 Small pressure spring

54 Ball holder

55 Steel ball 8.7

56 Back water valve port

57 O-ring 9.25X1.78

58 Breather Plug Tube

59 Dipstick

27 Steel ball

36 O-ring 6X1.78

61 Easy start

62 Spring

36

Qty

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

Kit Part #

782837

Kit Qty

Needed

1

782843

781122

782838

782839

782840

782841

782842

785819

789479

3

6

1

4

1

1

1

1

1

Engine Exploded View (1577149)- Rev A.3

37

Engine Parts List (1577149)-Rev A.3

24

25

26

27

20

21

22

23

28

29

15

16

17

18

19

11

12

13

14

Ref#

5

6

7

8

1

2

3

4

9

10

44

45

46

47

40

41

42

43

48

49

34

35

36

37

30

31

32

33

38

39

50

Part # Description

N/A

N/A

N/A

N/A

Crankshaft

Ball bearing

Oil Seal

Governor Assembly

N/A

N/A

Shaft, Governor Arm

Washer, Governor arm shaft

N/A Pin, Lock

Bolt, Drain Plug

Kit # 11

Washer, Drain Plug

788901 Switch Assembly, Oil Level

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

Kit # 5 Bolt

N/A Dowel Pin, Case Cover

N/A

N/A

Dowel Pin, Case Cover

Piston

N/A

N/A

N/A

N/A

N/A

Scraper Ring Set ,Piston

Rod Assembly., Connecting

Pin, Piston

Clip, Piston

Cover Assembly, Crankcase

Oil Plug

Cylinder head

Valve, In

Valve Exhaust

Returner, Intake Valve

Spring, Valve

Seat, Valve Spring, In

Seat, Valve Spring, Ex

Plate, Push Rod Guide

Rocker Assembly

N/A Rotator

Kit # 7 Bolt, Stud

Kit # 6 Bolt, Stud

Kit # 7 Carburetor

Kit # 5 Fuel line

Kit # 5 Clip, Fuel line

N/A

N/A

Governor arm

Bolt, Governor Arm

Kit # 2 Nut

N/A Crankshaft Assembly

N/A

N/A

N/A

N/A

Lifter, Valve

Packing, Case Cover

Camshaft Assembly

Pin, Dowel

N/A

N/A

Bolt

Gasket, Cylinder Head

N/A Bolt

783127 Spark Plug

N/A

N/A

Rod, Push

Shroud

Kit # 1, Kit

# 8

&

Kit # 10

Bolt

1

2

1

1

1

1

1

1

1

2

1

1

1

2

1

5

1

1

1

Qty

1

1

1

2

1

2

2

1

2

1

6

1

4

1

2

1

1

2

2

1

1

2

1

1

1

2

2

1

3

1

13

83

84

85

86

87

88

89

90

79

80

81

82

75

76

77

78

71

72

73

74

65

66

67

68

61

62

63

64

69

70

Ref#

55

56

57

58

51

52

53

54

59

60

82.1

Part #

Kit # 8

N/A

N/A

N/A

Kit # 1

Kit # 9

N/A

Kit # 9

Kit # 7

N/A

N/A

Kit # 1

N/A

N/A

Kit # 2

N/A

N/A

Kit # 10

Kit # 6

Kit # 5

&

Kit # 6

Kit # 6

783136

Kit # 5

Kit # 4

&

Kit # 5

789697

&

Kit # 5

Kit # 5

Kit # 4

&

Kit # 5

Kit # 5

Kit # 3

Description

Packing, Head Cover

Cover Comp, Cylinder Head

Wind Shield Comp.

Bolt

Flywheel Assembly

Fan, Recoil starter

Pulley, Starter

Nut

Ignition Coil Assembly

Clip

Bolt

Packing, Intake

Insulator, Carburetor

Packing, Carburetor

Spacer, Carburetor

Rod, Governor

Spring, Throttle Return

Recoil Starter Assembly

Switch Assembly

Shroud Assembly, Upper

Speed Regulating Handle

Air Cleaner Assembly

Tube, Breather

Clip

Spring, Governor

Oil Alert

Packing, Exhaust

Muffler

Nut

Spring Washer

Cap Assembly

Fuel tank Assembly

Fuel Filter

Fuel Cock

Spring Washer

Fuel tank cap comp

Tank Vent Fitting

Non-Return Valve Sealing Ring

Connecting pipe

Clip, Fuel line

Clip, Fuel line

2

2

1

1

1

1

1

1

1

1

1

1

1

1

1

1

2

1

1

1

1

1

Qty

1

1

1

1

1

1

1

1

1

2

1

1

1

1

1

1

1

1

3

38

Engine Kit Parts List (1577149)-Rev A.3

Kit Ref #

7

8

5

6

3

4

1

2

9

10

11

Kit Part # Description

786734

789690

789691

789262

789692

789693

789694

789695

789696

787154

783126

Recoil & Fan Kit

Air Filter Kit

Fuel Cap Kit

Fuel Cap Kit

Tank Kit

Muffler Kit

Carburetor Kit

Valve Cover Kit

Ignition Coil Kit

Ducar Amplifier Kit

Drain Bolt Kit

39

Qty

1

1

1

1

1

1

1

1

1

1

2

Engine Exploded View (1577249)-Rev A.3

40

Engine Parts List (1577249)-Rev A.3

26

27

28

29

22

23

24

25

30

31

18

19

20

21

14

15

16

17

Ref#

1

2

3

8

9

10

11

4

5

6

7

12

13

46

47

48

49

42

43

44

45

36

37

38

39

32

33

34

35

40

41

50

Part # Description

N/A Crankshaft

N/A

N/A

Ball bearing

Oil Seal

N/A

N/A

N/A

N/A

Governor Assembly

Shaft, Governor Arm

Washer, Governor arm shaft

Pin, Lock

Kit # 11

Bolt, Drain Plug

Washer, Drain Plug

788901 Switch Assembly, Oil Level

Kit # 5 Bolt

N/A

N/A

Dowel Pin, Case Cover

Dowel Pin, Case Cover

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

Piston

Scraper Ring Set ,Piston

Rod Assembly., Connecting

Pin, Piston

Clip, Piston

Cover Assembly, Crankcase

Oil Plug

Cylinder head

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

Valve, In

Valve Exhaust

Returner, Intake Valve

Spring, Valve

Seat, Valve Spring, In

Seat, Valve Spring, Ex

Plate, Push Rod Guide

Rocker Assembly

N/A Rotator

Kit # 7 Bolt, Stud

Kit # 6 Bolt, Stud

Kit # 7 Carburetor

Kit # 5 Fuel line

Kit # 5 Clip, Fuel line

N/A

N/A

Governor arm

Bolt, Governor Arm

Kit # 2 Nut

N/A Crankshaft Assembly

N/A

N/A

Lifter, Valve

Packing, Case Cover

N/A

N/A

N/A

N/A

Camshaft Assembly

Pin, Dowel

Bolt

Gasket, Cylinder Head

N/A Bolt

783127 Spark Plug

N/A

N/A

Rod, Push

Shroud

Kit # 1

Kit # 8

Kit # 10

Kit # 12

Bolt

1

1

1

2

1

1

1

2

1

2

2

1

1

1

1

1

1

1

2

2

1

5

1

1

1

1

1

1

Qty

1

2

2

4

1

2

1

1

2

6

1

1

1

3

1

2

1

1

2

2

1

13

Kit # 7

N/A

N/A

Kit # 1

N/A

N/A

Kit # 2

N/A

N/A

Kit # 10

Kit # 6

Kit # 5

Kit # 6

Kit # 6

783136

Kit # 5

Kit # 4

Kit # 5

789697

Kit # 5

Kit # 5

Kit # 4

Kit # 5

Kit # 5

78

79

80

81

70

71

72

73

66

67

68

69

74

75

62

63

64

65

76

77

Ref#

51

52

53

54

55

56

57

58

59

60

61

82

82.1

83

84

91

92

93

94

95

96

N/A

85

86

87

88

89

90

Part #

Kit # 8

N/A

N/A

N/A

Kit # 1

Kit # 9

N/A

Kit # 9

Kit # 14

Kit # 3

Kit # 12

Kit # 13

Kit # 14

789702

4

2

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

Qty

1

1

1

1

1

2

2

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

3

Description

Packing, Head Cover

Cover Comp, Cylinder Head

Wind Shield Comp.

Bolt

Flywheel Assembly

Fan, Recoil starter

Pulley, Starter

Nut

Ignition Coil Assembly

Clip

Bolt

Packing, Intake

Insulator, Carburetor

Packing, Carburetor

Spacer, Carburetor

Rod, Governor

Spring, Throttle Return

Recoil Starter Assembly

Shroud Assembly, Upper

Speed Regulating Handle

Air Cleaner Assembly

Tube, Breather

Clip

Spring, Governor

Oil Alert

Packing, Exhaust

Muffler

Nut

Spring Washer

Cap Assembly

Fuel tank Assembly

Fuel Filter

Fuel Cock

Spring Washer

Fuel tank cap comp

Tank Vent Fitting

Non-Return Valve Sealing Ring

Connecting pipe

Clip, Fuel line

Clip, Fuel line

Starter Control Box Assembly

Positive Battery Cable

Negative Battery Cable

Pressure B lock

Charging Coil

Bolt

Starter Motor Assembly

Replacement Key

41

Engine Kits Parts Lists (1577249)-Rev A.3

Kit Ref #

8

9

10

5

6

7

3

4

1

2

11

12

13

14

Kit Part #

789698

789690

789691

789262

789692

789693

789694

789695

789696

787154

783126

789699

789700

789701

Description

Recoil & Fan Kit

Air Filter Kit

Vent Hose Kit

Fuel Cap Kit

Tank Kit

Muffler Kit

Carburetor Kit

Valve Cover Kit

Ignition Coil Kit

Ducar Amplifier Kit

Drain Bolt Kit

Starter Control Box Kit (with key)

Battery Cable Kit

Starter Motor Kit

42

Qty

1

1

1

1

1

1

1

1

1

1

2

1

1

1

CAUTION

Engine Manual

43

44

45

46

47

48

49

50

Limited Warranty

Dear Valued Customer:

The Powerhorse Product you just purchased is built with the finest material and craftsmanship. Use this product properly and enjoy the benefits from its high performance. By purchasing a Powerhorse product, you show a desire for quality and durability. Like all mechanical equipment this unit requires a due amount of care. Treat this unit like the high quality piece of machinery it is. Neglect and improper handling may impair its performance. Please thoroughly read the instructions and understand the operation before using your product. Always contact Powerhorse Product Support at 1-866-443-2576 prior to having any service or warranty work performed, as some services performed by parties other than Powerhorse approved service centers may void this warranty. This warranty is in lieu of any other warranty expressed or implied and Powerhorse assumes no other responsibility or liability outside that expressed within this warranty.

Limited Warranty

Powerhorse shall warranty any piece of equipment manufactured, or parts of equipment manufactured, to be free from defects in material or workmanship for a period of:

Powerhorse Warranty

Item # Consumer Warranty Period

1577149

1577249

2 years from date of purchase by user

Commercial Warranty Period

90 days from date of purchase by user

“Consumer use” means personal residential household use by a consumer. “Commercial use” means all other uses, including use for commercial, income producing or rental purposes or when purchased by a business.

This warranty applies to the original purchaser of the equipment (verification of purchase, in the form of a receipt, is the responsibility of the buyer), is nontransferable, and covers parts and labor. Parts will be replaced or repaired at no charge, except when the equipment has failed due to lack of proper maintenance. If a part is no longer available, the part may be replaced with a similar part of equal function. Any misuse, abuse, alteration or improper installation or operations will void warranty. Determining whether a part is to be replaced or repaired is the sole decision of Powerhorse. Powerhorse will not provide for replacement of complete products due to defective parts. Any costs incurred due to replacement or repair of items outside of a Powerhorse approved facility is the responsibility of the buyer and not covered under warranty. Transportation costs to and from service center is the responsibility of the customer.

In addition to the normal warranty, Powerhorse shall warrant any normal wear item from defects in material or workmanship for a period of 90 days from the date of purchase by user . Normal wear items include, but are not limited to, nozzles, quick connect fittings, valves, seals, hoses, springs, O-rings, unloader valves and filter elements.

This warranty specifically excludes the following; failure of parts due to damage caused by accident, fire, flood, windstorm, acts of God, applications not approved by Powerhorse in writing, corrosion caused by chemicals, use of replacement parts which do not conform to manufacturer’s specifications, damage related to rodent and/or insect infestation and damage caused by vandalism. Additional exclusions: loss of running time, inconvenience, loss of income, or loss of use, including any implied warranty of merchantability of fitness for a specific use. Also, Outdoor Power Equipment needs periodic parts and service to perform well, and this warranty does not cover instances when normal use has exhausted the life of a component or the engine.

This warranty does not cover any personal injury or damage to surrounding property caused by failure of any part. Repair or replacement of parts does not extend the warranty period.

The engine warranty is covered under the same terms and conditions as outlined above. Normal engine maintenance such as spark plugs, air filters, adjustments, fuel system cleaning and obstruction due to build up is not covered by this Powerhorse warranty.

Please fill in the following information and have it on hand when you call in on a warranty claim.

Customer Number: ______________________________________________________________

Date of Purchase: _______________________________________________________________

Powerhorse Serial Number: _______________________________________________________

Item Number: __________________________________________________________________

51

Assembled by

Northern Tool & Equipment Company, Inc.

Burnsville, MN 55306

NorthernTool.com

52

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