Harbor Freight Tools 67596 User Manual
6.5 HP PRESSURE WASHER
Model
SET UP, OPERATING, AND SERVICING
INSTRUCTIONS
67596
Using an engine indoors CAN KILL YOU IN
MINUTES.
Engine exhaust contains carbon monoxide.
This is a poison you cannot see or smell.
NEVER use inside
a home or garage,
EVEN IF doors and
windows are open.
Only use OUTSIDE
and far away from
windows, doors, and
vents.
Visit our website at: http://www.harborfreight.com
Read this material before using this product.
Failure to do so can result in serious injury.
SAVE THIS MANUAL.
Copyright© 2009 by Harbor Freight Tools®. All rights reserved. No portion of this manual or any artwork
contained herein may be reproduced in any shape or form without the express written consent of
Harbor Freight Tools. Diagrams within this manual may not be drawn proportionally. Due to continuing
improvements, actual product may differ slightly from the product described herein. Tools required for
assembly and service may not be included.
For technical questions or replacement parts, please call 1-800-444-3353.
CONTENTS
IMPORTANT SAFETY
INFORMATION ............................ 3
SET UP PRECAUTIONS .................... 3
OPERATING PRECAUTIONS ............ 4
SERVICE PRECAUTIONS .................6
BASIC SPECIFICATIONS ............. 8
PARTS LIST & DIAGRAM E -
CRANKSHAFT/PISTON ................ 32
PARTS LIST & DIAGRAM F - GAS
DISTRIBUTION ADJUSTMENT
SYSTEM .........................................33
PARTS LIST & DIAGRAM G -
STARTER SUBASSEMBLY........... 34
PARTS LIST & DIAGRAM H -
DIVERSION ASSEMBLY ............... 35
UNPACKING .................................. 8
SET UP INSTRUCTIONS ............... 8
ASSEMBLY.........................................9
ENGINE DIAGRAM ...................... 11
OPERATING INSTRUCTIONS .... 12
STARTING THE ENGINE ................. 12
EQUIPMENT OPERATION ...............15
TECHNICAL SPECIFICATIONS .. 17
SERVICING .................................. 17
MAINTENANCE PROCEDURES ..... 17
CLEANING, MAINTENANCE, AND
LUBRICATION SCHEDULE .......... 19
STORAGE ........................................20
TROUBLESHOOTING ...................... 21
PARTS LIST & DIAGRAM J -
CARBURETOR ..............................36
PARTS LIST & DIAGRAM K -
FLYWHEEL/COIL ASSEMBLY ......37
PARTS LIST & DIAGRAM M -
CONTROL SYSTEM ......................38
PARTS LIST & DIAGRAM N - AIR
CLEANER ...................................... 39
PARTS LIST & DIAGRAM P -
MUFFLER ...................................... 40
PARTS LIST & DIAGRAM R -
FUEL TANK ...................................41
PARTS LIST & DIAGRAM S -
CARBON CANISTER .................... 42
LIMITED 1 YEAR / 90 DAY
WARRANTY .............................. 43
EMISSION CONTROL SYSTEM
WARRANTY ...................................43
PARTS LISTS AND DIAGRAMS . 25
GENERAL PARTS LIST ................... 25
GENERAL ASSEMBLY DIAGRAM .. 26
PARTS LIST A - PUMP .....................27
ASSEMBLY DIAGRAM A - PUMP ...28
PARTS LIST & DIAGRAM B -
CYLINDER HEAD ..........................29
PARTS LIST & DIAGRAM C -
CRANKCASE ................................30
PARTS LIST & DIAGRAM D -
CRANKCASE COVER ...................31
Page 2 For technical questions, please call 1-800-444-3353. SKU 67596
SAVE THIS MANUAL
Keep t h i s manu a l for the safety
war nings and precautions , assembly,
operating, inspection, maintenance and
cleaning procedures. Write the product’s
serial number in the back of the manual near
the assembly diagram (or month and year of
purchase if product has no number). Keep
this manual and the receipt in a safe and dry
place for future reference.
IMPORTANT SAFETY
INFORMATION
In this manual, on the labeling,
and all other information
provided with this product:
This is the safety alert
symbol. It is used to alert
you to potential personal
injury hazards. Obey all
safety messages that
follow this symbol to avoid
possible injury or death.
DANGER indicates
DANGER
situation which, if not
avoided, will result in death or
serious injury.
WARNING
WARNING
hazardous situation which, if
not avoided, could result in
death or serious injury.
CAUTION, used
CAUTION
alert symbol, indicates a
hazardous situation which, if
not avoided, could result in
minor or moderate injury.
a hazardous
indicates a
with the safety
NOTICE
CAUTION
NOTICE is used to
address practices
not related to personal injury.
CAUTION, without
the safety alert
symbol, is used to address
practices not related to
personal injury.
WARNING! Read all instructions.
Failure to follow all instructions
listed below may result in re,
serious injury and/or DEATH.
The warnings and precautions
discussed in this manual cannot
cover all possible conditions and
situations that may occur. It must
be understood by the operator that
common sense and caution are
factors which cannot be built into
this product, but must be supplied
by the operator.
SAVE THESE INSTRUCTIONS
SET UP PRECAUTIONS
Gasoline fuel and fumes are 1.
ammable, and potentially explosive.
Use proper fuel storage and handling
procedures. Do not store fuel or
other ammable materials nearby.
Have multiple ABC class re 2.
extinguishers nearby.
This equipment has a spark 3.
arresting mufer included. A spark
arresting mufer is required by law
in California, on some US Forest
Service land, and possibly in other
areas or situations.
Set up and use only on a at, level, 4.
well-ventilated surface.
Page 3For technical questions, please call 1-800-444-3353.SKU 67596
The work area should have adequate 5.
drainage to reduce the possibility of a
fall due to slippery surfaces.
Wear ANSI-approved safety goggles, 6.
heavy-duty work gloves, and dust
mask/respirator during set up and
use.
Use only oil and fuel recommended 7.
in the “Specications” section of this
manual.
Only use cold Water or pressure 8.
washer detergent in this tool. Do
not use caustic materials, solvents,
ammable materials, or detergents
not designed for pressure washers.
Use of any such material can cause
injury, or damage this tool or personal
property.
NEVER use inside a home or garage,
EVEN IF doors and windows are
open.
Only use OUTSIDE and far away
from windows, doors, and vents.
Keep children away from the 2.
equipment, especially while it is
operating.
Do not dry run this product. Dry 9.
running will cause serious damage
to the seals. Make sure the water
supply used for the Pressure Washer
is not dirty or sandy.
Prior to starting the Pressure Washer 10.
in cold weather, check all of the
parts of the unit to make sure ice has
not formed. Do not store the unit
anywhere that the temperature will
fall below 32° F (0° C).
OPERATING PRECAUTIONS
1. CARBON MONOXIDE
HAZARD
Using an engine indoors
CAN KILL YOU IN
MINUTES.
Engine exhaust contains carbon
monoxide. This is a poison you
cannot see or smell.
Do not leave the equipment 3.
unattended when it is running. Turn
off the equipment (and remove safety
keys, if available) before leaving the
work area.
Wear ANSI-approved safety goggles 4.
and hearing protection during use.
People with pacemakers should 5.
consult their physician(s) before
use. Electromagnetic elds in close
proximity to a heart pacemaker could
cause pacemaker interference
or pacemaker failure. Caution is
necessary when near the engine’s
magneto or recoil starter.
Use only accessories that are 6.
recommended by Harbor Freight
Tools for your model. Accessories
that may be suitable for one piece of
equipment may become hazardous
when used on another piece of
equipment.
Page 4 For technical questions, please call 1-800-444-3353. SKU 67596
Do not operate in explosive 7.
atmospheres, such as in the
presence of ammable liquids, gases,
or dust. Gasoline-powered engines
may ignite the dust or fumes.
Stay alert, watch what you are 8.
doing and use common sense when
operating a piece of equipment. Do
not use a piece of equipment while
tired or under the inuence of drugs,
alcohol or medication.
Do not overreach. Keep proper 9.
footing and balance at all times.
This enables better control of the
equipment in unexpected situations.
particular type of equipment, taking
into account the working conditions
and the work to be performed. Use
of the equipment for operations
different from those intended could
result in a hazardous situation.
Do not operate the equipment with 17.
known leaks in the engine’s fuel
system.
This product contains or, when 18.
used, produces a chemical known
to the State of California to cause
cancer and birth defects or other
reproductive harm. (California Health
& Safety Code § 25249.5, et seq.)
Do not carry the spray handle with 10.
your nger on the trigger, whether
engine is operating or not.
Use this equipment with both hands 11.
only. Using equipment with only
one hand can easily result in loss of
control.
Dress properly. Do not wear loose 12.
clothing or jewelry. Keep hair,
clothing and gloves away from
moving parts. Loose clothes, jewelry
or long hair can be caught in moving
parts.
Parts of the Pressure Washer, 13.
especially exhaust system
components, get very hot during use.
Stay clear of hot parts.
Do not cover the engine or equipment 14.
during operation.
Keep the equipment, engine, and 15.
surrounding area clean at all times.
Use the equipment, accessories, etc., 16.
in accordance with these instructions
and in the manner intended for the
WARNING: The brass components 19.
of this product contain lead, a
chemical known to the State of
California to cause birth defects (or
other reproductive harm). (California
Health & Safety code § 25249.5, et
seq.)
When spills of fuel or oil occur, they 20.
must be cleaned up immediately.
Dispose of uids and cleaning
materials as per any local, state,
or federal codes and regulations.
Store oil rags in a bottom-ventilated,
covered, metal container.
Keep hands and feet away from 21.
moving parts. Do not reach over or
across equipment while operating.
Before use, check for misalignment 22.
or binding of moving parts, breakage
of parts, and any other condition
that may affect the equipment’s
operation. If damaged, have the
equipment serviced before use.
Many accidents are caused by poorly
maintained equipment.
Page 5For technical questions, please call 1-800-444-3353.SKU 67596
Use the correct equipment for the 23.
application. Do not modify the
equipment and do not use the
equipment for a purpose for which it
is not intended.
The high pressure water ow can 24.
damage the work surface if not used
properly. Always test the spray in an
open area rst.
When dispensing detergent, apply the 25.
detergent to the cleaning area at low
pressure only. Detergent dispensing
only works when the spray wand is in
the low-pressure position.
26. Injection Hazard. The high
pressure water jet
produced by this tool can
cut skin or cause injury to
hands or eyes. Do not
allow spray to strike you and do not
spray toward people or animals. Do
not spray the tool itself or any
electrical source.
This Pressure Washer is intended for 27.
outdoor residential use only.
In case of an emergency during 28.
use, immediately release the
trigger on the spray handle, turn
the engine off and then shut off
gas supply to the engine. Do not
set the spray handle down without
turning off the engine.
Vibration Hazard:
This tool vibrates during use.
Repeated or long-term exposure to
vibration may cause temporary or
permanent physical injury, particularly
to the hands, arms and shoulders. To
reduce the risk of vibration-related
injury:
Anyone using vibrating tools regularly 1.
or for an extended period should
rst be examined by a doctor and
then have regular medical checkups to ensure medical problems are
not being caused or worsened from
use. Pregnant women or people
who have impaired blood circulation
to the hand, past hand injuries,
nervous system disorders, diabetes,
or Raynaud’s Disease should not
use this tool. If you feel any medical
or physical symptoms related to
vibration (such as tingling, numbness,
and white or blue ngers), seek
medical advice as soon as possible.
Do not smoke during use. Nicotine 2.
reduces the blood supply to the
hands and ngers, increasing the risk
of vibration-related injury.
Wear suitable gloves to reduce the 3.
vibration effects on the user.
Use tools with the lowest vibration 4.
when there is a choice between
different processes.
Include vibration-free periods each 5.
day of work.
Grip tool as lightly as possible (while 6.
still keeping safe control of it). Let
the tool do the work.
To reduce vibration, maintain the tool 7.
as explained in this manual. If any
abnormal vibration occurs, stop use
immediately.
SERVICE PRECAUTIONS
Before service, maintenance, or 1.
cleaning:
Turn the engine switch to its a.
“OFF” position.
Page 6 For technical questions, please call 1-800-444-3353. SKU 67596
Allow the engine to completely b.
cool.
Then, remove the spark plug c.
wire(s) from the spark plug(s).
Keep all safety guards in place and 2.
in proper working order. Safety
guards include mufer, air cleaner,
mechanical guards, and heat shields,
among other guards.
and discharge all pressure before
tightening ttings or having repair
work done by a qualied technician.
When the engine is running, do not 9.
allow the Pressure Washer to remain
idle for more than two minutes. If
allowed to remain idle, the water in
the unit will heat up, possibly causing
damage to the Pressure Washer.
Do not alter or adjust any part of 3.
the equipment or its engine that
is sealed by the manufacturer
or distributor. Only a qualied
service technician may adjust
parts that may increase or
decrease governed engine speed.
Wear ANSI-approved safety goggles, 4.
heavy-duty work gloves, and dust
mask/respirator during use and
service.
Keep the high pressure hose 5.
connected to the pressure washer
and spray Gun while the system
is pressurized. Disconnecting the
pressure hose while the unit is
pressurized is dangerous, and may
cause injury.
Do not allow the high pressure hose 6.
to come in contact with any hot
part of the unit. The hose might be
damaged, possibly causing it to burst
or leak under high pressure.
Maintain labels and nameplates 7.
on the equipment. These carry
important information. If unreadable
or missing, contact Harbor Freight
Tools for a replacement.
If water is leaking out of the Pressure 8.
Washer immediately turn off the
unit. Unplug the Pressure Washer,
Have the equipment serviced by a 10.
qualied repair person using only
identical replacement parts. This
will ensure that the safety of the
equipment is maintained. Do not
attempt any service or maintenance
procedures not explained in this
manual or any procedures that you
are uncertain about your ability to
perform safely or correctly.
Store equipment out of the reach of 11.
children.
Follow scheduled engine and 12.
equipment maintenance.
Refueling:
Do not smoke, or allow sparks, 1.
ames, or other sources of ignition
around the equipment, especially
when refuelling.
Do not rell the fuel tank while the 2.
engine is running or hot.
Do not ll fuel tank to the top. Leave 3.
a little room for the fuel to expand as
needed.
Refuel in a well-ventilated area only.4.
SAVE THESE
INSTRUCTIONS.
Page 7For technical questions, please call 1-800-444-3353.SKU 67596
BASIC SPECIFICATIONS
SET UP INSTRUCTIONS
Fuel
Engine Oil
Pump Oil
Engine Speed 3,600 RPM
Water Flow 3 GPM Maximum
Maximum Pressure 2,500 PSI
Type
Capacity 0.95 Gallons
Type
(SAE)
Capacity 0.63 Quarts
89+ octane unleaded
gasoline
10W-30 above 32° F
5W-30 at 32° F or below
3.75 -oz SAE 10W-30
Non-detergent
Note: Additional specications found
in the TECHNICAL ENGINE
SPECIFICATIONS chart in this
manual.
The emission control system for
this Generator’s Engine is warranted for
standards set by the U.S. Environmental
Protection Agency and by the California Air
Resources Board (also known as CARB).
For warranty information, refer to the last
pages of this manual.
Read the ENTIRE IMPORTANT
SAFETY INFORMATION
section at the beginning of this
manual including all text under
subheadings therein before set
up or use of this product.
Risk of accidental
WARNING
starting; resulting
in serious personal injury.
Turn the Power Switch of the
equipment to its “OFF”
position, wait for the engine to
cool, and unplug the spark
plug wire(s) before
assembling or making any
adjustments to the equipment.
Note: For additional information regarding
the parts listed in the following pages,
refer to the Assembly Diagram near
the end of this manual.
At high altitudes, the engine’s
carburetor, governor (if so equipped), and
any other parts that control the fuel-air
ratio will need to be adjusted by a qualied
mechanic to allow efcient high-altitude
use and to prevent damage to the engine
and any other devices used with this
product.
UNPACKING
When unpacking, make sure that the
item is intact and undamaged. If any parts
are missing or broken, please call Harbor
Freight Tools at 1-800-444-3353 as soon
as possible.
Page 8 For technical questions, please call 1-800-444-3353. SKU 67596
Assembly
This equipment has a spark 1.
arresting mufer included. A spark
arresting mufer is required by law
in California, on some US Forest
Service land, and possibly in other
areas or situations.
Dipstick (60A)
Aluminum Pump
Breather Plug
(59A)
Brass Pump
Plug (14A)
Detergent Inlet
Connection (26A)
Hose
Connection
Pressure Regulator
Knob (44A)
Water Inlet
Connection
Figure 2
4. Attach the Hose (18) to the Hose
Connection on the unit. (See Figure
2.)
Pull the Collar at the end of the hose 5.
back and attach the Gun (19) to the
hose.
Figure 1
2. Replace the Brass Pump Plug (14A)
with the aluminum Pump Breather
Plug (59A) and Dipstick (60A) before
rst use. The Pump Breather Plug
must be used whenever the pressure
washer is used. The Brass Pump
Plug (without the breather hole)
should be used for transporting only.
Attach the Handle (14) onto the 3.
Frame (17) with the Handle Bolts (15)
and Nuts (16).
Screw the Wand (20) onto the Gun 6.
and secure with the grommet.
Choose the right Nozzle (5) for the 7.
job. Pull back the quick connect
collar and push the Nozzle onto the
end of the Wand. Make sure the
quick connect collar locks the Nozzle
in place.
Black• Nozzle -
Low Pressure
This Nozzle is used with pressure
washer detergent.
White• Nozzle -
Wide Spray
This Nozzle can be used to clean
very large areas.
Green• Nozzle -
Medium Spray
This Nozzle can be used to clean
larger areas.
Page 9For technical questions, please call 1-800-444-3353.SKU 67596
Yellow• Nozzle -
Narrow Spray
This Nozzle is used to clean small
areas.
Red• Nozzle -
Pencil Spray
This Nozzle should only be used
on hard surfaces such as concrete
or metal. This Nozzle can damage
wood.
Connect the water supply to the 8.
Water Inlet Connection. The water
source must be able to provide a
minimum of ve gallons of clean, cold
water per minute at 20 PSI. Only use
a 5/8” inner diameter (or larger) hose
that is rated to meet this capacity.
If using detergent:
Read detergent directions. Connect 9.
one end of the Detergent Inlet Hose
(8) to the Detergent Inlet Connection,
and the other end into the container
holding the detergent. Only use
detergents specied for use with
Pressure Washers. The Pressure
Washer will draw one gallon of
detergent for every seven gallons
of water. Only use the Black (low
pressure) Nozzle when spraying
detergents.
Page 10 For technical questions, please call 1-800-444-3353. SKU 67596
ENGINE DIAGRAM
Page 11For technical questions, please call 1-800-444-3353.SKU 67596
OPERATING INSTRUCTIONS
Read the ENTIRE IMPORTANT
SAFETY INFORMATION
section at the beginning of this
manual including all text under
subheadings therein before set
up or use of this product.
Starting the Engine
Inspect engine and equipment
looking for damaged, loose,
and missing parts before
set up and starting. If any
problems are found, do not use
equipment until xed properly.
Checking Engine Oil Level
the upper limit (H) mark on the dip-
stick (bottom edge of the oil ll hole).
Low oil level can trigger the low oil
sensor to shutdown the engine and
prevent restart (See Figure 3 for correct oil level).
If the oil level is low, add the 4.
appropriate type of oil until the oil
level is at the bottom lip of the oil ll
hole.
Oil type:
32° F or above = SAE 10W-30
Below 32° F = SAE 5W-30.
Replace the Oil Filler Cap.5.
CAUTION! Do not run the engine with too
little or too much oil. The engine will
be permanently damaged.
CAUTION! Your Warranty is VOID if the
engine’s crankcase is not properly
lled with oil before each use. Before
each use, check the oil level. Do not
run the engine with low or no engine
oil. Running the engine with no or
low engine oil WILL permanently
damage the engine.
Turn off engine and allow it to cool.1.
Clean the Oil Filler Cap and the area 2.
around it. Remove the Oil Filler Cap.
Figure 3
Checking Pump Oil Level
The Oil pump is lled with 3.75 -oz 1.
of SAE 10W-30 NON DETERGENT
oil at the factory. Under normal conditions there is no reason to add any oil
or change the oil.
Turn off engine, allow it to cool and 2.
disconnect the spark plug wire.
Twist the Dipstick on the Pump 3.
Breather Plug until the arrow on it
lines up with the arrow on the Plug
and remove the Dipstick.
Remove the Pump Breather Plug 4.
from the Pump.
3. Remove dipstick and wipe away the
oil with dry cloth. Reinsert the dip-
stick into the oil ller neck, but do not
screw in, then remove it to check the
oil level. The oil level should reach
Page 12 For technical questions, please call 1-800-444-3353. SKU 67596
Figure 4
Fill with oil
to here
TOO LOW
TOO HIGH
Clear oil
ll hole
Align the arrow on the Dipstick with 8.
the arrow on the Plug, insert it, and
twist it to secure.
Reconnect the spark plug wire.9.
Checking Fuel Level
WARNING! To prevent re,
shut the engine off and wait
for it to cool before adding
fuel. Do not smoke.
5. Look into the hole in the pump housing. If a metal wheel can be seen
extending into the hole, SLOWLY pull
the starter rope until the hole appears
clear, as shown above.
Figure 5
Clean the Fuel Filler Cap and the 1.
area around it.
To check the fuel level, unscrew and 2.
remove the Fuel Filler Cap.
Mix fuel stabilizer (not included) 3.
with 89 octane (or better) unleaded
gasoline according to fuel stabilizer
directions.
Fill the Fuel Tank to about 1 inch 4.
under the lip of the gasoline tank
with the stabilized unleaded gasoline
mixture.
Then replace the Fuel Filler Cap.5.
6. Wipe the Dipstick off with a clean,
dry cloth. Insert the Dipstick into the
pump housing and remove it. The oil
level should be at least to the lower
(L) notch on the dipstick, but not
above the upper (H) notch. Add SAE
10W-30 NON-DETERGENT oil as
needed.
Thread the Pump Breather Plug back 7.
into the pump.
Page 13For technical questions, please call 1-800-444-3353.SKU 67596
Start Procedure
Before starting the engine:
Follow the Set Up a.
Instructions to prepare the
equipment.
Inspect the equipment and b.
engine. Make sure the pump
has the Pump Breather Plug
installed.
Replace the non-vented c.
brass oil plug with the
aluminum Pump Breather
Plug.
Fill the engine with the d.
proper amount and type of
both fuel and oil.
Read the Equipment e.
Operation section that
follows.
Point Nozzle in safe direction and 1.
squeeze trigger to release all pressure from the pump.
Turn the fuel valve lever to its 2.
“OPEN” position.
Turn the ignition switch to its ON or 3.
RUN position.
Then, turn the engine choke lever 4.
to its “CHOKE” position for cold
start. Set the choke lever in the “1/2
CHOKE” position when starting a
warm engine.
After the engine starts and warms 7.
up, slowly move the choke lever to its
“RUN” position.
IMPORTANT: Allow the engine to 8.
run at no load (low pressure) for ve
minutes after each start-up so that
the engine can stabilize.
Move the throttle up to operating 9.
speed. Operating speed is maximum
speed (fast or rabbit), except during
operational break-in period.
Break-in Period
Breaking-in the engine will help to 1.
ensure proper equipment and engine
operation.
The operational break-in period will 2.
last about 3 hours of use. During this
period:
Do not apply a heavy load to the •
equipment.
Do not operate the engine at its •
maximum speed.
The maintenance break-in period will 3.
last about 20 hours of use. After this
period:
Change the engine oil.•
Under normal operating conditions
subsequent maintenance follows the
schedule in the MAINTENANCE AND
SERVICING section.
Close the throttle.5.
Grasp the starter handle, and pull 6.
slowly until resistance is felt. While
holding the handle, allow the starter
rope to rewind slowly. Then, pull the
starter handle with a rapid, full arm
stroke. Once again while holding
the handle, allow the rope to rewind
slowly. Repeat as necessary, until
the engine starts.
Page 14 For technical questions, please call 1-800-444-3353. SKU 67596
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