Page 1
SERVICE MANUAL
MODEL # ORDER #
RG-232637 1.107-235.0
9.801-589.0
Page 2
Page 3
Exploded View ......................................................................................... 4
Exploded View Parts List ......................................................................... 5
Legacy Axial Pump ...............................................................................6-7
Troubleshooting ....................................................................................... 8
Preventive Manteinance .......................................................................... 9
Oil Change Record ................................................................................ 10
CONTENTS
3
9.801-589.0 • RG-232637 • Rev. 06/14
Page 4
SERVICE MANUAL
EXPLODED VIEW
PRESSURE WASHER
19
2
15
36
16
17
14
21
35
27
20
30
7
6
29
9
13
25
28
26
31
18
3
1
4
5
4
6
8
22
10
23
9.801-589.0 • RG-232637 • Rev. 06/14
12
11
34
32
33
Page 5
EXPLODED VIEW PARTS LIST
PRESSURE WASHER
ITEM PART NO. DESCRIPTION QTY
1 8.920-004.0 Pump, Legacy Axial
2.6 GPM 3000PSI 1
2 9.194-077.0 Engine Honda GC160 1
3 9.194-881.0 Key SQR 3/16" x 1 47/64" 1
4 9.196-033.0 5/16-24 UNF X 1.75
Socket Head Cap Screw 4
5 9.802-813.0 Washer, 5/16"
Split Ring Lock, Zinc 4
6 9.186-010.0 5/16-18 X 1-1/2
GR 5 HHCS Zinc 4
7 9.802-776.0 Nut, 5/16-18, ESNA 4
8 8.718-980.0 Washer, 5/16" Flat,
SAE (780452) 8
9 9.115-099.0 Powder Coated-P1
Frame Black Wrinkle 1
10 9.802-270.0 Wheel & Tire Assy,
10" Steel Rim W/Tube 2
11 9.182-506.0 Cap Black Plastic, 5/8'' 2
12 9.183-405.0 Rubber Dampener 5/16''-18 2
13 9.196-308.0 5/16-18 X 1/2 Carriage Bolt 2
14 8.753-553.0 Label, Rate Specs, Low 1
15 8.751-096.0 Label, Regulation 4442.6 1
16 9.801-587.0 Rating Plate, RG-232637 1
17 8.750-881.0 Shark, Label Name Plate 1
ITEM PART NO. DESCRIPTION QTY
18 8.783-035.0 Label, Operation
Warnings Trilingual 1
19 9.138-313.0 Caution Engine Oil Tag 1
20 9.138-373.0 Open/Closed
Sticker-(GCV 160) 1
21 9.138-377.0 Quick Start Instruction
Guide Sticker 1
22 5.731-652.0 Filter with weight 1
23 6.388-216.0 Hose DN 5 1
24 9.180-004.0 ▲ Motor Oil, SAE-10W 30, 20 oz.
25 9.140-153.0 Powder Coated Handle 1
26 9.142-015.0 Hanger LT Side 1
27 9.802-786.0 Nut, 5/16, Hex, NC 2
28 9.198-003.0 5/16 Internal
L/W .332 ID X .620 2
29 8.767-003.0 1/4-20 Star Knob 2
30 9.196-307.0 1/4-20 x 1-1/2 GR 2 Hex Bolt 2
31 9.112-012.0 Al Bit 101 Trigger Gun 1
32 9.112-533.0 Lance-AL Quick
Connect-Male 3000 psi 1
33 8.751-356.0 Kit, Nozzle (035) 1
8.712-337.0 ▲Nozzle, 0003, Red 1
8.712-338.0 ▲Nozzle, 0015, Yellow 1
8.712-339.0 ▲Nozzle, 0025, Green 1
8.712-340.0 ▲Nozzle, 0040, White 1
8.712-398.0 ▲Nozzle, Black, Soaper 1
34 8.753-423.0 Hose, HP 5ft, 3600PSI M22 1
35 9.134-022.0 Name plate 1
36 9.196-049.0 Nylon Rivet 1
▲ Not Shown
SERVICE MANUAL
5
9.801-589.0 • RG-232637 • Rev. 06/14
Page 6
8.920-004.0
SERVICE MANUAL
PRESSURE WASHER
PUMP EXPLODED VIEW AND PARTS LIST
*
ITEM PART # DESCRIPTION QTY
1 8.762-010.0 Cylinder Head 1
2 9.175-004.0 Valve Assy Horizontal 3
3 2.884-916.0 Valve Complete (Kit 3) 1
4 5.443-448.0 Nipple Chemestry 1
5 6.362-451.0 O-Ring Seal 8.0 x 1.0 1
6 6.362-175.0 O-Ring Seal, 5.28 x 1.78 1
7 7.401-909.0 Sphere 7 G40 - 1.4401 1
8 5.110-714.0 Sleeve 1
9 5.332-258.0 Helical Spring 1
10 9.139-372.0 Nozzle, INS 020/021 Pump 1
11 9.184-018.0 Outlet-Thermal Valve 1
12 6.362-480.0 O-Ring Seal, 12.42 x 1.78 1
13 7.362-507.0 O-Ring Seal 8 x 2 NBR 90 1
14 6.413-403.0 Thermo Valve Tin Coated 1
ITEM PART # DESCRIPTION QTY
15 5.332-290.0 Helical Spring 1
16 9.175-005.0 Unloader Assembly 1
17 4.132-007.0 Drain Plug Replacement 1
18 5.003-062.0 Plate 1
19 9.177-301.0 Hich Pressure Seal 3
20 9.177-310.0 Back Ring 3
21 6.362-833.0 O-Ring Seal 12.5 x 1.73 3
22 9.155-011.0 Housing Low Pressure Seal 3
23 6.363-058.0 Grooved Ring 3
24 9.134-016.0 Spacer 3
25 6.365-393.0 Oil Sealing 12.20x4/6 3
26 9.133-007.0 Piston Guide 1
27 6.362-390.0 O-Ring Seal 15.6 x 1.8 1
28 9.134-019.0 Male Adapter 1
29 9.181-005.0 Filter Seal 1
30 9.155-013.0 Female House Conn 1
31 8.751-121.0 ◆Gooseneck, Hose Adapter 1
(For pump guard or Filters)
32 9.139-370.0 Spare Part List, Piston 1
33 6.362-471.0 O-Ring Seal 80.0x3.0 NBR70 1
◆Not Included
6
9.801-589.0 • RG-232637 • Rev. 06/14
Page 7
PUMP EXPLODED VIEW PARTS LIST (CONT)
8.920-004.0 Housing View
PRESSURE WASHER
SERVICE MANUAL
ITEM PART # DESCRIPTION QTY
1 9.166-016.0 Grooved Ball Bearing 1
2 9.135-018.0 Swash Plate Hor. 1
3 9.165-356.0 Ball Bearing No 6207 1
4 9.177-314.0 Radial Seal 35 x 52 x 7 1
5 9.135-016.0 Oil Housing 1
7
9.801-589.0 • RG-232637 • Rev. 06/14
Page 8
TROUBLESHOOTING
PROBLEM POSSIBLE CAUSE SOLUTION
ENGINE OPERATES
FOR 15 MINUTES
THEN STOPS
ENGINE LACKS
POWER
ENGINE FALTERS
WATER DRIPPING
FROM UNDER PUMP
OIL DRIPPING
WATER LEAKING
FROM PUMP
PRESSURE WASHER Troubleshooting Guide
PROTECTOR
NO DETERGENT
Not enough gas or engine oil Fill tank with gas. Check oil level.
Vapor lock developed by heat of day Keep gas tank full to avoid vapor locking.
Obstruction in fuel fi lter Clean or replace fuel fi lter.
Dirty air fi lter Replace air fi lter.
Choke is opened too soon Move choke to halfway position until engine
runs smoothly.
Piston packing worn Call local distributor.
O-Ring plunger retainer worn Call local distributor.
Cracked piston Call local distributor.
Oil seal worn or damaged Call local distributor.
Spray gun closed with machine
running 5 minutes or longer
Excess water supply pressure Place a pressure regulator at end of 50'
Detergent suction tube not properly
connected to machine
Detergent is too thick Dilute detergent. For best results, use
Detergent fi lter valve is at lowest
setting
Open spray gun or turn off machine.
garden hose.
Check connection.
manufacturers detergent.
Set detergent fi lter valve to a higher setting.
GARDEN HOSE
CONNECTION
LEAKS
SPRAY WAND
LEAKS
PUMP IS NOISY
Filter on detergent suction tube is
clogged
Damaged or clogged detergent suction tube
A high pressure nozzle is attached. Replace with black detergent nozzle.
Discharge nozzle is obstructed Blow out or remove debris with fi ne needle.
Loose fi ttings Tighten fi ttings.
Missing/worn rubber washer Insert new washer.
Spray wand not properly attached Slide the spray wand into the gun. Turn the
Broken o-ring Call local distributor and order an o-ring.
Pump is sucking air Check that hoses and fi ttings are air tight.
Run warm water through fi lter to remove
debris.
Remove obstruction or replace detergent
suction tube.
wand collar clockwise onto the spray gun
threads until tight.
Turn off machine and purge pump by
squeezing trigger gun until a steady fl ow of
water emerges through nozzle.
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9.801-589.0 • RG-232637 • Rev. 06/14
Page 9
PREVENTATIVE MAINTENANCE
This pressure washer was produced with the best available materials and quality craftsmanship. However, you
as the owner have certain responsibilities for the correct care of the equipment. Attention to regular preventative maintenance procedures will assist in preserving the performance of your equipment. Contact your dealer
for maintenance. Regular preventative maintenance will add many hours to the life of your pressure washer.
Perform maintenance more often under severe conditions. Check pump oil and engine oil level before fi rst use
of your new pressure washer.
MAINTENANCE SCHEDULE
Inspect Daily
Engine Oil
Air Cleaner/Filter
Engine Fuel Filter 500 hours or 6 months
Spark Plug Maintenance 300 hours or annually
Clean Fuel Tank(s) Annually
Replace Fuel Lines Annually
Replace High Pressure Nozzle Every 6 months
Replace Quick Connects/O-Rings Annually/As needed
Clean Water Screen/Filter Weekly
Replace HP Hose Annually (if there are any signs of wear)
Change First month or 20 hours.
Every 100 hours or every 6 months after fi rst month
Filter Every 50 hours
Inspect Every 50 hours
Clean Monthly
PRESSURE WASHER Troubleshooting Guide
9
9.801-589.0 • RG-232637 • Rev. 06/14
Page 10
OIL CHANGE RECORD
Check pump oil and engine oil level before fi rst use of your new pressure washer.
Date Oil Changed
SERVICE MANUAL
Month/Day/Year
PRESSURE WASHER
Estimated Operating
Hours Since Last
Oil Change
Date Oil Changed
Month/Day/Year
Estimated Operating
Hours Since Last
Oil Change
10
9.801-589.0 • RG-232637 • Rev. 06/14
Page 11
Page 12
Form #9.801-589.0 • RG-232637 • Revised 06/14
Printed in U.S.A. or Mexico
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