Generac 1538-1 Owner’s Manual

GEN RAC°I

Portable Products

High Pressure Washer Owner's Manual

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Model No. 1538-1 (2,500 PSIHigh PressureWasher) Manual No. 187945 Revision2 (5/16/2001)

Visit our Generac website: www.generac-portables.com

_[iL This isthe safety alert symbol. It is usedto alert you to potential personal injury hazards.

Obey all safety messagesthat follow this symbol to avoid possible injuryor death.

Generac Portable Products 2,500 PSIHigh PressureWasher

EQUIPMENT

DESCRIPTION

CONGRATULATIONS on your purchase of a

GENERAC high pressure washer. It has been designed,
engineered and manufactured to give you the best possible
dependability and performance.

This manual contains information for a high pressure
washer that operates at 2,500 PSIat a flow rate of

3.0gallons per minute. This powerful, high quality
professional system features large 10" wheels, apump

equipped with an automatic cool down system, chemical
injection system, adjustable unloader, nozzle extension with

quick connect nozzles, safety goggles,heavyduty 50' hose,
and more.

Pleaseread and retain this manual.The instructionswill

enable you to assembleyour unit without tools, and
maintain your high pressure washer properly.

Every effort has been madeto ensure that the information

in this manualis both accurate and current. However,
Generac reserves the right to change,alter or otherwise

improve the product and its documentation at any time
without prior notice.

Should you experience any problem you cannot easily

remedy,call the pressure washer helpline at

1-800-270-1408.

SAFETY RULES

_ AUTION! When setting up,transporting,

adjusting or making repairs to your high pressure
washer,alwaysdisconnect the spark plug wire from
the spark plug and place the wire where it cannot
contact spark plug.

_ DANGER! Engineexhaust gasescontain DEADLY

carbon monoxide gas.This dangerousgas,if
breathed in sufficient concentrations, can cause

unconsciousness or even death. Operate this

equipment only in the open air where adequate
ventilation isavailable.

_ WARNING! Gasoline ishighly FLAMMABLE and

itsvapors are EXPLOSIVE.Do Not permit
smoking, open flames, sparks or heat inthe vicinity
while handlinggasoline.Avoid spilling gasolineon a
hot engine.Allow unit to cool for 2 minutes before
refueling. Comply with all laws regulating storage
and handlingof gasoline.

Read this manual carefully and become familiar

with your pressure washer. Know its applications,

its limitations, and any hazards involved.

CUSTOMER

RESPONSIBILITIES

• Readand observe the safety rules.

• Follow regular schedule in maintaining, caring for and
usingyour high pressure washer.

• For off-season storage, review "Preparing the Unit for
Storage" on page 14.

Locate this pressure washer in areas awayfrom

combustible materials, combustible fumes or dust.
The high pressure equipment is designedto be usedwith

Generac authorized parts only. If you use this equipment

with parts that do not comply with minimum
specifications, the user assumesall risks and liabilities.

Some chemicals or detergents may be harmful if inhaled
or ingested,causingsevere nausea,fainting or poisoning.
The harmful elements maycause property damageor
severe injury.

Do Not allow CHILDREN to operate the pressure

washer at any time.

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Generac Portable Products 2,500 PSIHigh PressureWasher

• Operate engine only at governed speed.Runningthe
engine at excessive speeds increasesthe hazard of
personal injury. Do Not tamper with parts which may
increase or decreasethe governed speed.

• Do Not wear loose clothing, jewelry or anything that
may be caught in the starter or other rotating parts.

• Before starting the pressure washer in cold weather,
check all parts of the equipment and be sure ice has not

formed there.

• Never useaspraygunwhichdoesnot haveatrigger lock
or trigger guard in placeandin working order.

• Keep the hose connected to machineor the spraygun
while the system ispressurized. Disconnecting the hose

while the unit ispressurized isdangerous.

• Never operate units with broken or missingparts, or
without protective housing or covers.

• Operate and store this unit on a stable surface.

• Check the fuel system for leaks or signs of deterioration,
such as chafed or spongy hose, loose or missingclamps,

or damagedtank or cap. Correct all defects before
operating the pressure washer.

• Do Not spray flammableliquids.

• Do Not secure the spraygun in the open position.

• Use a respirator or maskwhenever there isachance
that vaporsmaybe inhaled.Read all instructionswith
mask so you are certain the mask will provide the
necessary protection againstinhalingharmful vapors.

• Never aim the spraygun at people, animalsor plants.
The high pressure stream of water that this equipment
produces can pierce skin and its underlying tissues,
leading to serious injuryand possible amputation.

• Never allow any part of the body to come in contact
with the fluid stream. Do Not come in contact with a

fluidstream created by a leak in the high pressure hose.

• Always wear eye protection when you usethis
equipment or when you are in the vicinitywhere the
equipment is in use.

• High pressure spraycan causepaint chipsor other
particles to become airborne.

• Do Not operate the pressure washer above the rated
pressure.

• Never move the machine by pulling on the highpressure
hose. Use the handle provided on the unit.

• Always be certain the spraygun, nozzles andaccessories

are correctly attached.

• High pressure spraymay damagefragile items including

glass.Do Not point spraygun at glasswhen in the jet
spray mode.

• Hold the spraygun firmly in your hand before you

squeeze the trigger. Failure to do so could result in an

injuryfrom a whipping spray gun. Do Not leavethe

spray gun unattended while the machine isrunning.

• The cleaningarea should haveadequate slopesand

drainage to reduce the possibility of a fall due to slippery
surfaces.

• Keep water spray awayfrom electric wiring or fatal

electric shock may result.

• Do Not by-pass any safety deviceon this machine.

• The muffler and engineheat up during operation and
remain hot immediatelyafter shutting it down. Avoid

contact with a hot muffler or engine as you could be
severely burned.

• High pressure hose can develop leaksfrom wear, kinking,

abuse, etc. Water sprayingfrom a leak is capable of

injectingmaterial into skin. Inspect hose eachtime before
usingit. Check all hosesfor cuts, leaks,abrasions or
bulgingof cover, or damageor movement of couplings. If

any of these conditions exist, replace hose immediately.

Never repair high pressure hose. Replace it with

another hosethat exceeds maximum pressure rating of
your unit.

• The muffler and air cleaner must be installedandin good

condition before operating the pressure washer.These
components act asspark arresters if the engine backfires.

In the State of California a spark arrester is required by law
(Section 4442 of the California Public Resources Code).

Other states may havesimilar laws. Federal laws applyon
federal lands.

NOTE: If you equip the muffler with a spark arrester, it
must be maintained in effective working order. You can

order a spark arrester through your authorized Honda
service dealer.

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GeneracPortableProducts2,500PSIHighPressureWasher

KNOW YOUR PRESSURE WASHER

Read this owner's manual and safety rules before operating your high pressure washer.

Compare the illustrations with your high pressure washer to familiarize yourself with the locations of various controls and
adjustments. Save this manual for future reference.

Chemical Injection Siphon/Fitter

SprayGun

Gas Tank

Nozzle Extension with

Quick Connect

Pressure

Control Knob

Water Inlet

Pump equipped with

Automatic Cool Down System

Accessory Tray _ Provides convienant storage for
standard and optional accessories, such as brushes, turbo

wands, ect.
Air Filter -- Protects engine by filtering dust and debris out

of intake air.
Automatic Cool Down System -- Cycles w_ter through

pump when water reaches 140°-i45°F. Warm water will

discharge from pump onto ground. This system prevents

internal pump damage.

Chemical Injection Siphon/Filter -- Use to siphon
detergent or other pressure washer chemicals into the low

pressure stream.
Choke Lever -- Prepares a cold engine for starting.

Fuel Valve -- Used to turn fuel on and off to engine.

Gas Tank -- Fill tank with regular unleaded gasoline. Always
leave room for fuel expansion.

High Pressure Hose -- Connect one end to the water

pump and the other end to the spray gun.

Accessory Tray

SprayNozzles

High Pressure Hose

SafetyGoggles

Air Filter

Throttle Lever

Choke Lever

FuelValve

Recoil Starter

(on front of engine)

Oil Fill Cap

High Pressure Outlet

with Quick Connect

High Pressure Outlet with Quick Connect -- To

connect high pressure hose.
Nozzle Extension with Quick Connect -- Allows you to

switch between four different spray nozzles.
Oil Fill Cap -- Fill engine with oil here.
Pressure Control Knob -- Varies the pressure of the high

pressure spray.
Pump -- Develops high pressure.

Recoil Starter -- Use for starting the engine manually.
Safety Goggles -- Always use the enclosed goggles or

other eye protection when running your pressure washer.
Spray Gun -- Controls the application of water onto

cleaning surface with trigger device. Includes safety latch.
Spray Nozzles -- Chemical injection (25°), 0°, 15°, 25°, and

40°: for various high pressure cleaning applications.
Throttle Lever_Sets engine in starting mode for recoil

starter and stops a running engine.

Water Inlet -- Connect garden hose here.

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Generac Portable Products 2,500 PSIHigh PressureWasher

IMPORTANT: Readentire owner's manual before you

attempt to assembleor operate your new pressure washer.

REMOVE PRESSURE

WASHER FROM

CARTON

• Removethe parts box packedwith pressurewasher.

• Slicetwo corners at the end of carton from top to
bottom so the panel can be folded down fiat, then

remove all packing material.

• Roll pressure washer out of carton.

Carton Contents

Items in the carton include:

• Main Unit

• Parts Box (which includesthe following):

SafetyGoggles

Handle
PlasticAccessory Tray

Handle FasteningHardware Kit (which includes):

Carriage Bolts (2)

PlasticKnobs (2)

"J" Hook
Chemical Hose Clip

SelfTappingScrews(5)
Nozzle Cleaning Kit
High Pressure Hose

Owner's Manual

EngineManual
EngineWarranty Card

EmissionsControl Warranty Card

Owner's Registration Card
SprayGun with Quick Connect Fitting

Nozzle Extension with Quick Connect Fitting
Bagcontaining5 mult_olored Quick Connect Nozzles

Oit Bottle
O-Ring MaintenanceKit

If any of the above parts are missing or damaged,call the

pressure washer helpline at 1-800-270-1408.

PREPARING PRESSURE

WASHER FOR USE

If you have any problems with the assemblyof your
pressure washer or if parts are missing or damaged,call the
pressure washer helpline at 1-800-270-1408.

To prepare your pressure washer for operation, you
will need to perform these tasks:

• Fitl out and sendin registration card.

• Attach accessorytray to handle, then attach handleto
main unit.

Add oil to engine crankcase.
Add fuel to fuel tank.

Connect high pressure hoseto spraygun and pump.
Connect water supply to pump.

Attach nozzle extension to spray gun.
Select/attach quick connect nozzle to nozzle extension.

Attach Handle and Accessory Tray

NOTE: Alt assemblyoperations given in this section will
be described from the perspective of assemblingthe
pressure washer from the rear.

• Slide the plastic accessory tray onto the handle and align
the holes inthe accessory tray with the holes on the
handle (Figure I).

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GeneracPortableProducts2,500PSIHighPressureWasher

• Secure tray to handlewith selftapping screws usinga
#2 phillips screwdriver. Ensurescrews are tight but not
crushing the plastic accessory tray.

• Placethe handle assemblyonto the handle supports
connected to the main unit. Make sure the holes in the

handle alignwith the holes on the handle supports
(Figure 2).

Atig

Handle

Supports

• Pinchthe chemical hose and slide it into the metal clip as
shown in Figure6.

NOTE: It may be necessaryto move the handle supports

from side to side in order to align the handle so it will slide
over the handle supports.

• Insert the carriage bolt through the right side hole from
the outside of the unit. Slide the spring clip up the
chemical hoseand slide it onto the carriage bolt. Attach
a plastic knob from the inside of the unit.Tighten by
hand (Figure 3).

• Insert the carriage bolt through the left side hole from
the outside of the unit and attach a plastic knob from the

inside of the unit (viewing unit from the rear). Tighten by
hand (Figure 4).

o

• Insert the "J" hook into the second from the left slot in
the accessorytray (Figure 5).

• Tilt the unit up by the handle and attach the metal clip to
the rib on the center underside of the accessory tray
(Figure 7). Slide the chemical hose through the metal clip
so that it is tight but not kinked.

Add Engine Oil

IMPORTANT: Any attempt to crank or start the engine
before it hasbeen properly servicedwith the
recommendedoil may result in an enginefailure.

• Placepressure washer on a level surface.

• Refer to the engineowners manualto add recommended
oil to engine.

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GeneracPortableProducts2,500PSIHighPressureWasher

NOTE: Check oil often during engine break-in. Refer to

engine owner's manualfor recommendations.

Add Gasoline

_ WARNING! Never fill fuel tank indoors. Never

fill fuel tank when engine is running or hot. Do Not

smoke when filling fuel tank.

_ WARNING! Never fill fuel tank completely full.

Provide spacefor fuel expansion.Wipe awayanyfuel
spillagefrom engine and equipment before starting.

• Use fresh,cleanunleadedautomotivegasolineand store in
approved, clean, covered containers. Use clean fill

funnels. Never use "stale" gasoline left over from last
season or gasolinestored for longperiods.

• Clean area around fuel fill cap, remove cap.

• Slowly addgasoline to fuel tank. Use afunnel to prevent
spillage. Fill tank to "Maximum FuelLevel" (Figure 8).

_ Maximum Fuel Level

==m=q IM =ml Ee_ra

Connect high

pressure hose

here.

Attach the other end of the high pressure hose to the
high pressure outlet on the pump (Figure 10). Pull down
on the collar of the quick connect, slide fitting into the
pump and let go of collar. Pull on hose to be sure of a
tight connection.

Install fuel cap and wipe up any spilled gasoline.

Connect Hose and Water Supply to

Pump

IMPORTANT: Youmust assemblethe nozzle extension

and attach all hoses before you start the engine. Starting
engine without all hoses connected and water supplied will
damagethe pump.

• Uncoil highpressurehose and attach quick connect end of
hose to the baseof the spraygun (Figure 9). Pulldown on

the collar of the quick connect, slide onto the gun andlet
go of collar. Tugon hoseto be sure of a tight connection.

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• Before you connect your garden hose to the water inlet,
inspectthe inlet screen (Figure I I). Clean the screen if it

contains debris, replace it if it isdamaged.DO NOT
RUN THE PRESSUREWASHER IFTHE SCREENIS

DAMAGED. NEVER SIPHON INLETWATER.

• Run water through the garden hose for 30 secondsto
cleanout any debris. Turn off water.

• Connect the garden hoseto the water inlet. Tighten by
hand (Figure II).

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,,n,r,cPort,,,Produc,,,00PSH°hPr,sur,W,h,r

CAUTION! There MUST be at leastten feet of
unrestrictedgarden hose between the pressure washer

inlet and any flow shut off device, such as a 'Y' shut-off

connector or other convenience-type water shut-off valve.

Damage to pressure washer resulting from disregarding this

caution wit{ not be covered by the warrant)'.

• Turn ON the water and squeeze the trigger on the spray

gun to purge the pump system of air and impurities.

_ik AUTION! Before starting the pressure washer,

be sure you are wearing adequate eye protection.

Checklist Before Starting Engine

Reviewthe unit's assemblyto confirm you have performed

all of the following:

• Make sure the handleis in place andsecure.

• Check that oil hasbeen addedto the proper level inthe
engine crankcase.

• Add the proper gasolineto fuel tank.

• Check for properly attached hoseconnections.

• Check to make sure that there are no kinks, cuts, or
damageto the high pressure hose.

• Provide a proper water supplyat an adequate flow.

• Be sure to read "Safety Rules" and "How To Use Your

PressureWasher" before using the pressure washer.

• Make sure unit is in a levelposition.

• Connect the garden hoseto the water inleton the
pressure washer pump. Turn ON the water.

CAUTION! Do Not run the pump without the water
supply connected and turned on. You must follow this

caution or the pump will be damaged.

• Squeeze the trigger on the gun until you have a steady
stream of water. This purges the pump of air and

impurities.

• Attach the nozzle extension to the spray gun (Figure 12).
Tighten by hand.

• Choose the nozzleyou want to use and insert it into the
nozzle extension. See "How to Usethe Nozzles" on

page I0.

• Engagethe safety latch to the spray guntrigger
(Figure 13).

HOW TO USE YOUR

PRESSURE WASH ER

If you have any problems operating your pressure washer,

please call the pressure washer helpline at 1-800-270-1408.

To Start Your Pressure Washer

To start your pressure washer for the first time, follow
these instructions step-by-step. This starting information

also applies if you havelet the pressure washer sit idle for
at least a day.

• Placethe pressure washer in an area close enough to an
outside water source capable of supplying water at a flow

rate greater than 3.3gallons per minute.

• Check that the highpressure hose is connected to the
spray gun and to the pump. See"Preparing Pressure

Washer for Use" for illustrations.

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SafetyLatch

• Rotate the fuel valve leverto the "On" position
(Figure 14).

Off

• Move the throttle lever to the "Fast" position
(Figure 15). Controls are shown in the desired operating

condition.

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Generac Portable Products 2,500 PSIHigh PressureWasher

• Move the choke lever to the "Closed" position
(Figure 16).

Closed

NOTE: For a warm engine, be sure the choke lever is in
the "Open" position.

• Set the engine switch to the "On" position (Figure 17).

NOTE: If the recoil starter is hard to pull, it may be
necessary to squeeze the gun trigger to relieve internal

pump pressure.

How to Stop Your Pressure Washer

• Move the throttle lever to the "Slow" position.

• Wait for the engine to idle down.

• Move the engine switch to the "Off' position.

• Simply shutting off the engine will not release pressure in
the system. Squeeze trigger on the spray gun to

relieve pressure in the hose.

How to Use Accessory Tray

The unit is equipped with an accessory tray with places to
store your nozzle extension and quick connect nozzles, and
slots to hold the cleaning solution bottle and the detergent
siphoning filter. There are also two hooks at the ends of
the handle to hold your spray gun and high pressure hose.

NOTE: The extra holes in the tray are for storing a brush
and a turbo wand. The brush and turbo wand are NOT

included with your pressure washer. You can buy these
items as optional accessories.

• Place the nozzle extension through the hole on the

accessory tray, as shown in Figure 18.

Engine Switch

Grasp starter grip and pull slowly until you feel some
resistance. Then pull cord out with rapid full arm stroke.

Let rope return slowly. Do Not let rope "snap back"
against starter.

• If the choke Jeverhas been moved to the "Closed"
position to start the engine, gradually move it to the

"Open" position as the engine warms up.

• Hang your chemical solution bottle on the "J" hook and
place the detergent siphoning filter in the last slot on the

left (Figure 18).

• Place the spray gun on the hook attached to the
accessory tray on the right side of the unit (Figure 18).

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Generac,° <abe, °d cts25°°,sHi0h' es u eWasher

• Hangthe high pressure hose on the hook attached to
the accessorytray on the left side of the unit as shown
on page4.

How to Use the Nozzles

,_ CAUTION! Never exchangenozzleswithout

locking the safety latch on the trigger.

The quick-connect on the nozzle extension allows you to
switch between five different nozzles.The nozzlesvary the

spray pattern asshown below (Figure 19).

Follow these instructions to change nozzles:

• Engagethe safety latch on the spraygun.

• Putlback the collar on the quick-connect and pull the
current nozzle off. Store the nozzle in the space
provided on the handles storage panel.

NOTE: For a more gentle rinse, select the white 40° or

green 25° nozzle. To scour the surface,select the yellow

15° or red 0° nozzle. To apply chemical, select the black

nozzle.

• Putlback on the collar,insert the new nozzle and release
the collar. Tug on the nozzle to make sure it is securely
in place.

• For most effective cleaning, keepthe spray nozzle
between 8 to 24 inches away from the cleaningsurface. If
you get the spray nozzle too close, you may damagethe

cleaningsurface.

Cleaning and Applying Chemical

CAUTION! You must attach all hoses before you

start the engine. Starting the engine without all the hoses
connected and without the water turned ON witldamage

the pump.

IMPORTANT: Use soaps designed specifically for
pressure washers. Household detergents could damage

the pump.

To apply detergent follow these steps:

• Reviewthe useof the nozzles.

• Prepare the detergent solution as required by the
manufacturer.

• Hangthe detergent solution on the "J" hook attached to

the accessory tray, asshown in Figure20.

• Place the small filter end of the detergent siphoning tube
into the detergent container.

Low Pressure

Black

25°

High Pressure

White Green Yellow Red

40° 25° 15° 0°

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Generac Portable Products 2,500 PSIHigh PressureWasher

CAUTION! Keep the chemical injection tube from

coming in contact with the hot mumer.

• Make sure the blacknozzle is installed.
NOTE: Detergent cannot be applied with the high

pressure nozzles (White, Green, Yellow, or Red).

• Make sure the garden hose is connected to the water
inlet. Check that the high pressure hose is connected to

the spraygun andthe pump and start the engine.

• Apply the detergent to adry surface, starting at lower
portion of area to be washed and work upward, using

long, even, overlapping strokes.

• Allow the detergent to soakin between 3-5 minutes
before washing and rinsing. Reapplyas needed to prevent

surface from drying. Do Not allow the detergent to dry
on (prevents streaking).

IMPORTANT: You must flush the chemical injection

system after each use by placing the filter into a bucket of
clean water, then run the pressure washer in low pressure

for I-2 minutes.

Pressure Washer Rinsing

_ ARNING! Be extremely careful if you must

use the pressure washer from a ladder,scaffolding
or any other relatively unstable location. Hose
water pressure builds asyou climb. When you press
the trigger, the recoil from the initial spray can be
very strong. The high pressure spray could cause
you to falt if you are too close to the cleaning

surface.

After you have applied detergent, scour the surface
and rinse it clean as follows:

• Apply safety latchto spray gun.

• Removethe black chemical nozzlefrom the nozzle

extension.

• Select andinstallthe desired high pressure nozzle

following the instructions "How to Use the Nozzles" on

page 10.

• Keep the spraygun asafedistance from the area you
plan to spray.

• Increaseor decreasespray pressureby turning the
pressure control knob counterclockwise or clockwise
respectively (Figure 21). Use lower pressure to wash
items such a asa car or boat. Use higher pressure to

strip paint and degreasedriveways.

Pressure

Control

Knob

• Apply a high pressure sprayto a smallarea andthen

check the surface for damage.If no damageisfound, you
can assumeit isokay to continue rinsing.

• Start at the top of the areato be rinsed, working down

with same overlapping strokes as you used for cleaning.

Automatic Cool Down System

(Thermal Relief)

Ifyou run the engine on your pressure washer for

3-5 minutes without pressingthe trigger on the spray gun,

circulating water in the pump can reach a temperature

between 140-145°E At this temperature, the system
engagesand cools the pump by discharging the warm
water onto the ground. This system prevents internal
damageto the pump.

SPECIFICATIONS

Rated Pressure ..... 2,500 psi

Flow Rate .......... 3.0 gallons per minute (gpm)

Detergent .......... Use detergent approved for

pressure washers

Water Supply Temp . Not to Exceed IO0°F

Automatic Cool .... Will cycle when water

Down System ....... reaches 140°- 145°F

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