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Craftsman 580.768050 User manual

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Operators Manual
ICRRFTSMRN°I
7.8 Horsepower
3000 PSI
2.5 GPM
HIGH PRESSURE WASHER
CLEANING SYSTEM
Model No. 580.768050
HOURS: Mon.- Fr|. 8 a.m. to 5 p.m. (CT)
CAUTION:
Before using this product, read this
manual and follow all its Safety Rules
and Operating Instructions.
Sears, Roebuck and Co., Hoffman Estates, IL 60179
Visit our Craftsman webslte: www.sears.com/craftsman
!
PartNo. B3604 Draft2 (4/5/1999) Printe<:iinthe U.S.A.
•Safety
• Assembly
• Operation
•Maintenance
•Parts
Warranty ................................ 2
Safety Rules ........................... 2-3
Assembly ............................... 4
Operation ............................. 5-9
Maintenance ......................... 10-15
Storage ................................ 16
Troubleshooting ......................... 17
Replacements parts .................... 19-27
Emission Control
Warranty Statement .................... 28-29
How to order parts and
request service .................... Back page
LIMITED ONE YEAR WARRANTY ON CRAFTSMAN CLEANING SYSTEM
For one year from the date of purchase, when this Craftsman Cleaning System is maintained and operated
according to the instructions in the owner's manual, Sears will repair, free of charge, any defect in material and
workmanship.
If this washer is used for commercial purposes, this warranty applies for only 90 days from the date of
purchase. If this cleaning system is used for rental purposes, this warranty applies for only 30 days after date
of purchase.
LIMITED TWO YEAR WARRANTY ON CRAFTSMAN ENGINE
For two years from the date ol purchase, when this Craftsman engine is maintained and operated according to
the instructions on the owner's manual, Sears will repair, free of charge, any defect in matedal and
workmanship.
If the Craftsman engine is used for commercial or rental purposes, this warranty applies for only one year from
the date of purchase.
ThJs warranty does not cover:
• Expendable items such as spark plugs or air filters, which become worn during normal use.
•Repairs necessary because of operator abuse or negligence, including damage resulting from no water
being supplied to pump or failure to maintain the equipment according to the instructions contained in the
owner's manual.
WARRANTY SERVICE IS AVAILABLE BY RETURNING THE HIGH CLEANING SYSTEM TO THE
NEAREST SEARS SERVICE CENTER OR DEALER IN TH E UNITED STATES.
This warranty gives you specific legal dghts and you may dlso have other dghts, which vary from state to state.
Sears, Roebuck and Co., Dept. 817WA, Hoffman Estates, IL 60179
,_ CAUTION: Before using this product, read this
manual and follow all Safety Rules and
Operating Instructions.
,_ DANGER: When transporting, setting up,adjusting or making repairs to your cleaning
system, always disconnect the spark plug wire
and place itwhere it cannot contact the spark
plug to prevent accidental starting.
Engine exhaust gases contain DEADLY carbon
monoxide gas. This dangerous gas, if breathed in
sufficient concentrations, can cause
unconsciousness or even death. Operate this
equipment only in the open air where adequate
ventilation is available.
• Gasoline is highly FLAMMABLE and itsvapors are
EXPLOSIVE. Do not permit smoking, open flames,
sparks or heat in the vicinity while handling
gasoline. Avoid spilling gasoline on ahot engine.
Allow unit to cool for 2 minutes before refueling.
Comply with all laws regulating storage and
handling of gasoline.
• Locate this cleaning system in areas away from
combustible materials, combustible fumes or dust.
•The high pressure equipment is designed to be
used with Sears authorized parts only. If you use
this equipment with parts that do not comply with
minimum specifications, the user assumes all dsks
and liabilities.
•Some chemicals or detergents may be harmful if
inhaled or ingested, causing severe nausea,
fainting or poisoning. The harmful elements may
cause property damage or severe injury.
•Do not allow CHILDREN to operate the cleaning
system at any time.
•Operate engine only at governed speed. Running
the engine at excessive speeds increases the
hazard of personal injury. Do not tamper with parts
which may increase or decrease the governed
speed.
• Do not wear loose clothing,jewelry or anything
that may be caught in the starter or other rotating
parts.
•Before starting the cleaning system in cold
weather, check all parts of the equipment and be
sure ice has not formed there.
•Units with broken or missing parts, or without
protective housing or covers should NEVER be
operated.
•The muffler and air cleaner must be installed and
in good condition before operating the cleaning
system. These components act as spark arrestors
if the engine backfires.
•Check the fuel system for leaks or signs of
deterioration such as chafed or spongy hose,
loose or missing clamps or damaged tank or cap.
Correct all defects before operating the cleaning
system.
•Do not spray flammable liquids.
•Never allow any part of the body to come in
contact with the fluid stream. DO NOT come in
contact with a fluid stream created by a leak in the
high pressure hose.
•High pressure streams of fluid this equipment
produces can pieme skin and its underlying
tissues, leading to serious injuryand possible
amputation.
•Never aim the gun at people, animals or plants.
•High pressure spray can cause paint chips or
other particles to become airborne and fly at high
speeds.
•Always wear eye protection when you use this
equipment or when you are in the vicinity where
the equipment is in use.
•Operate the pressure at no more than the PSI fluid
pressure rated for your cleaning system.
•Never move the machine by pulling on the high
pressure hose. Use the handle provided on the
top of the unit.
•Always be certain the spray gun, nozzles and
accessories are correctly attached.
•Never use a spray gun which does not have a
trigger lock or tdgger guard in place and in
working order.
•Use a respirator or mask whenever there is a
chance that vapors may be inhaled. Read all
instructions with the mask so you are certain the
mask will provide the necessary protection against
inhaling harmful vapors.
•High pressure spray may damage fragile items
including glass. Do not point spray gun at glass
when in the jet spray mode.
•Keep the hose connected to machine or the spray
gun while the system is pressurized.
Disconnecting the hose while the unit is
pressurized is dangerous.
•Hold the spray gun firmly in your hand before you
start the unit. Failure to do so could result in an
injury from a whipping spray gun. Do not leave the
spray gun unattended while the machine is
running.
•The cleaning area should have adequate slopes
and drainage to reduce the possibilityof a fall due
to slippery surfaces.
•Keep water spray away from electric wiring or fatal
electric shock may result.
•Do not secure tdgger gun in the pull-back (open)
position.
•Do not by-pass any safety device on this machine.
•The muffler and engine heat up dudng operation
and remain hot immediately after shutting it down.
Avoid contact with a hot muffler or engine or you
could be severely burned.
•Operate and store this unit on a stable surface.
•Always store cleaning system with the
Dial-a-Cleaner TM knob in the OFF position.
•High pressure hose can develop leaks from wear,
kinking, abuse, etc. Water spraying from a leak is
capable of injecting material into skin. Inspect
hose each time before using it. Check all hoses for
cuts, leaks, abrasions or bulging of cover, or
damage or movement of couplings. If any of these
conditions exist, replace hose immediately. Never
repair high pressure hose. Replace itwith another
hose that meets minimum pressure rating of your
cleaning system.
I_ OOK FOR THIS SYMBOL TO POINT OUT IMPORTANT SAFETY PRECAUTIONS. IT
MEANS "ATTENTION!!! BECOME ALERTIII YOUR SAFETY IS INVOLVED."
3
CARTON CONTENTS
The following parts are shipped loose with your
cleaning system:
•Main Unit -- cleaning system with wheels,
chemical tanks, guide handle.
•High Pressure Hose (already attached to pump)
•Parts Box (which includes items listed below)
• Spray Gun
•Dual Lance with quick connect nozzle fitting
•Engine Oil
•Three-pack of chemical concentrates
•Four multi-colored nozzles
•Tank Labels
•Manual Bag (which includes the items listed
below)
•Owner's Manual
•Nozzle Cleaner Kit
• _O"-Ring Kit
Become familiar with each piece before assembling
the cleaning system. Check all contents against the
illustration on page 5. It any parts are missing or
damaged, call the Pressure Washer Helpline at
1-800-222-3136.
TO REMOVE CLEANING SYSTEM FROM
CARTON
down flat.
Remove loose parts and parts box included with
your cleaning system.
Slice two corners at guide handle end of carton
from top to bottom so the panel can be folded
Lift the handle to
upright position and
slide the locking
caps into place
•Raise guide handle, secure in place.
•Roll the cleaning system out the open end of the
canon.
•Check carton for additional loose parts.
HOW TO SET UP YOUR CLEANING
SYSTEM
For the most part, your Craftsman High Pressure
Cleaning System has been assembled at the factory.
You must, however, assemble the spray gun, and
attach the high pressure hose to the spray gun.
• Cut the tie wraps on the high pressure hose and
connect high pressure hose to gun. Tighten by
hand.
•Attach dual lance to spray gun.
Place assembled spray gun on holder.
4
KNOW YOUR HIGH CLEANING SYSTEM
Read this owner's manual and safety rules before operating your cleaning system. Compare the
illustrations with your cleaning system to familiarize yourself with the locations of various controls and
adjustments.
System Rinse, Detergent and
Chemical Rseervolrewith
Internal Filter and Baffle
Spray Gun
Dual Lance with Quick-
Connect Fitting
Gas Tank
Air Filter
High Pressure Hose Primer Bulb
Water Inlet
Dial-A-CleanerTM
Selector Knob
Pressure
CommandTM
Pump
Oil Fill Cap
Air Filter - Dry type filter element limits the amount of
dirt and dust that gets in the engine.
Dial-A-Cleaner TM Selector Knob - Selects any one
of three chemicals or the clean water system rinse,
Dual Lance with Quick-Connect Fitting- The dual
lance attaches to the spray gun and aUowsyou to
switch from low pressure mode, for applying
chemicals, to high pressure mode, for cleaning. The
quick connect fitting lets you quickly exchange the four
provided nozzles to adjust the spray pattern of the
high pressure spray.
Gas Tank - Fill gas tank with regular unleaded
gasoline here.
High Pressure Hose - Connect one end to the spray
gun.
Oil Fill Cap - Fill engine with oil here. See page 8 for
oil recommendations.
Pressure Command TM - Sets output water pressure.
Primer Bulb - Used to start a cold engine.
Pump - Develops high water pressure.
Spray Gun - Controls the application of water onto
cleaning surface with trigger device, includes safety
latch.
System Rinse, Detergent and Chemical Reservoirs
with Internal Filter and Baffle - Used to provide
detergent or other chemicals to the low pressure water
stream.
Water Inlet - Connection for garden hose.
HOW TO USE YOUR CLEANING SYSTEM
Read these instructions and learn how to use your
cleaning system before you attempt to start your
cleaning system. If you have any problems operating
your cleaning system, p_eace cell the pressure washer
helpline at 1-800-222-3136.
How To Use the Nozzles
A DANGER: Never exchange nozzles without
lockingthe safety latch on the trigger.
The quick-connect on the dual lance allows you
switch between four different nozzles. The nozzles
vary the spray pattern of the high pressure stream as
shown below.
White Green
Yellow Red 0o
In order to change the nozzle being used, follow these
instructions:
•Engage the safety latch on the spray gun.
Safety Latch
•Pull back the collar on the quick connect and pull
the current nozzle off. Store the nozzle in the space
provided on the control panel.
Note: For a more gentle dnse, select the 40° or 25 °
degree nozzle. To scour the surface, select the 15° or
0° nozzle.
•Pull back the collar, insert the new nozzle and
release the collar, making sure it becomes flush
with the end of the quick connect. Pull on the
nozzle to make sure it is securely in place.
Note: The chemical nozzle is permanently affixed to
your dual lance and has a spray pattem of 25
degrees. It must be used when applying chemical.
•For most effective cleaning, keep spray nozzle
between 8 to 24 inches away from cleaning
surface.
•Damage to the surface may occur if you get the
spray nozzle too close to it.
Cleaning With The Nozzles and Applying
Chemical
,_ WARNING: You must attach all hoses beforeyou start the engine. Starting the engine without
all the hoses connected and without the water
tumed ON will damage the pump.
II_IPORTANT: Use soaps designed specifically for
pressure washer cleaning systems. Household
detergents could damage the pump.
Up to three (3) different solutions can be carried on the
cleaning system at one time. To apply detergent follow
these steps:
Dilution is necessary when using the supplied
chemical packets. Simply snip one corner of the
plastic pouch, pour the chemical into the tank, then
fill the tank with clean water. Label tanks with the
provided tank labels.
Pour chemical into one of
the tanks labeled A B, C.
6
BEFORE EACH USE
•Check water inlet screen for damage.
• Check high pressure hose for leaks.
• Check chemical tanks and filters for damage.
•Check gun and wand assembly for leaks.
• Purge pump of air and contaminants.
• Check engine oil level.
CLEANING SYSTEM MAINTENANCE
Check and Clean Inlet Screen
Examine garden hose inlet screen. Clean ifit is
clogged or replace if it is torn,
Check High Pressure Hose
High pressure hoses can develop leaks from wear,
kinking, or abuse, inspect hose before each use.
Check for cuts, leaks, abrasions, bulging of cover, or
damage or movement of couplings. If any of these
conditions exist, replace hose immediately.
A ANGER: Never repair ahigh pressure hose.
Replace with hose that meets the minimum
pressure rating of your cleaning system
Check Chemical Reservoirs
Tank covers should snap cleanly onto tank. Ensure
chemical labels correctly identify tank contents.
Ensure that the System Rinse tank is filled with clean
water. Ensure that Dial-A-Cleaner TM selector knob
rotates freely between each position. Examine the
tanks and replace if the filter is clogged
Check Gun and Wand
Examine hose connection to gun and make sure it is
secure. Test trigger by pressing it and making sure it
springs back into place when you release it. Put safety
latch in UP position and test trigger. You should not be
able to press trigger. Replace gun immediately ifit
fails any of these tests.
Check In-Une Filter
Refer to the illustration below and service the in-line
filter if it becomes clogged, as follows:
Filter Screen
O-ring
1. Detach gun and lance from high pressure hose.
Detach lance from gun and remove o-ring and
screen from lance. Flush the screen, gun, and
lance with clean water to clear debris.
.
3.
If the screen is damaged, the o-ring kit contains a
replacement in-line filter screen and an o-ring. If
undamaged, reuse screen.
Place the in-line filter screen into the threaded end
of the lance. Direction does not matter. Push the
screen in with the eraser end of a pencil until it
rests flat at the bottom of the opening. Take care to
not bend the screen.
4. Place the o-ring into the recess. Push the o-ring
snugly against the in-line filter screen.
5. Assemble the lance to the spray gun, as described
earlier in this manual.
Purge Pump of Air and Contaminants
To remove the air from the pump, follow these steps:
•Set up the cleaning system as described in the
ASSEMBLY section and connect the water supply.
•Remove the wand extension from the gun.
•Pull the trigger on the gun and hold until a steady
stream of water appears.
To remove the contaminants from the pump, follow
these steps:
•Set up the cieaning system as described in the
ASSEMBLY section, and connect the water supply.
•Remove the nozzle attachment from the gun.
•Start the engine according to instructionsin
OPERATION section.
•Pull the trigger on the gun and hold.
•When the water supply is steady and constant,
engage the safety latch and refasten the nozzle
attachment.
Nozzle Maintenance
If the nozzle becomes restricted or clogged with
for'eign materials, such as dirt, excessive pump
pressure may develop. A partially clogged nozzle can
cause a pulsing condition during use. This generally is
not a pump related problem, but rather a clogged or
partially restricted nozzle.
If the nozzle becomes clogged or partially restricted,
immediately clean the nozzle with the kit included with
your cleaning system by following these instructions:
• Shut off the engine and turn off the water supply.
• Press trigger to relive water pressure.
• Separate the dual lance from the gun.
insert wire into
nozzle and turn
back and forth
to clear
obstruction.
11
Use the wire included in the kit or a small paper
clip to free the foreign materials clogging or
restricting the nozzle.
• 1 rubber washer (p/n B2385) for the inside of the
garden hose connector.
• 1 water inlet screen (p/n B2384) for the garden
hose connector.
Remove additional debris by back flushing water
supply through dual lance. Back flush between 30
to 60 seconds. Back flush both lances by turning
chemical valve handle.
• Ensure the in-line filter is in place, then reconnect
the dual lance to the spray gun.
•Reconnect the water supply, turn on the water,
and start the engine.
•Test the cleaning system by operating with the unit
in high and the low pressure.
O-Ring Maintenance
Through the normal operation of your cleaning
system, the o-rings keep the connections of the hoses
and gun tight and leak-free. They may become worn
or damaged with use. Provided with your cleaning
system is an o-ring Maintenance Kit containing
replacement o-rings, a rubber washer and a garden
hose inlet screen.
Parts in the O-Ring Kit Include:
•1 O-Ring, red, (p/n B2726) for the end of the
spray gun connection between gun and high/low
spray wand.
•2 O-Rings, yellow, (p/n B2264) for the ends of the
high pressure hose.
To remove a worn or damaged o-ring:
•Use a small flathead screwdriver to get
underneath the c-dng and pry it off.
ENGINE MAINTENANCE
Maintenance, replacement or repair of the
emission control devices and svstemg may be
performed by any non-roed engine repair
establishment or individual.
Checldng Oil Level
Oil level should be checked prior to each use or at
least every eight (8) hours of operation. Keep oil level
maintained.
Changing Engine Oil and Oil Rlter
Change oil after first eight (8) hours of operation.
Change oil & oilfilter every fifty (50) hours thereafter.
If you are using your cleaning system under
extremely dirty or dusty conditions, or in extremely hot
weather, change oil more often.
Change oii while engine isstill warm from running, as
follows:
• Clean area around oil drain plug.
•Remove oil drain plug and oil fill plug and drain oil
completely into asuitable container.
Oil Fill Cap
Note: The above two o-rings are close in size.
Please match carefully to assure proper o-ring
usage. Oil Drain Plug
12
•When oil has completely drained, Install oil drain
plug and tighten securely.
•Place a suitable container beneath the oil filter and
turn filter counterclockwise to remove. Discard
according to local regulations.
•Coat gasket of new filter with engine oil. turn filter
clockwise until gasket contacts tightly with filter
adapter. Then tighten an additional 3/4 tum.
•Fill oil sump with recommended oil. (See "Before
Starting the Engine" on page 8 for oil
recommendations)
•Install the oil fill plug and tighten securely.
• Wipe up any spilled oil.
Service Air Cleaner
Your engine will not run properly and may be
damaged ifyou run it using adirty air cleaner. Clean
or replace the air cleaner paper filter once every 50
hours of operation or once a year, whichever comes
first. Clean or replace more often if operating under
dusty or dirty conditions. Clean foam pre--filter every
25 hours of operation or sooner under dusty
conditions.
To clean or replace the air cleaner components:
•Loosen the two screws on the air cleaner cover.
Remove the air cleaner cover.
Foam
Pro-Filter May
Stick to Cover
Remove the paper air filter and the foam pre-filter
from the air cleaner cover.
Foam
Pre-FIIter
To clean or replace foam pre-filter:
1. Wash pre-filter in soapy water.
2. Squeeze pre-filter dry in clean cloth. Do not twist.
If the pre-filter is still dirty after washing and drying
it, replace it with a new one.
Note: If you need to order a new air filter, please call
1-800-366-PART.
3. Apply enough engine oilto saturate the pre-filter.
4. Wrap the pre-filter in a clean dry cloth and
squeeze out the excess oil. Do not twist. Set the
pre-filter aside.
To clean or replace paper air filter:
1. Clean paper filter by tapping it gently on a solid
surface. If the filter istoo dirty, replace it with a new
one. Dispose of the old filter properly.
2. Clean air cleaner cover.
3. Insert pre-filter intothe cover, then the paper air
filter.
4. Reinstall the air cleaner cover and tighten the two
(2) screws.
Clean Spark Arrestor Screen
The engine exhaust muffler has a spark arrestor
screen. Inspect and clean the screen every 100 hours
of operation or once each year, whichever comes first.
Note: If you use your cleaning system on any forest-
covered, brush-covered or grass-covered unimproved
land, it must have a spark arrestor. The spark arrestor
must be maintained in good condition by the
owner/operator.
Clean and inspect the spark arrestor as follows:
Inspect the screen and replace it if it is tom, perforated
or otherwise damaged. Do not use a defective
screen. If the screen is not damaged, clean it with a
chemical solvent.
If the spark arrestor is damaged, replace it as follows:
•Remove the four (4) screws that connect the heat
shield to the muffler.
Paper
Filter
13
Spirk
ArrHtor
Scrlen
S30413
® @
Remove four (4) screws that attach the spark
arrestor screen.
Replace damaged screen with new screen
(pin 83083).
Reattach the spark arrestor screen and the heat
shield.
Carburetor
If you think your carburetor needs adjusting, see your
nearest Sears Service Center. Engine performance
may be affected at altitudes above 5000 feet. For
operation at higher elevations, contact your nearest
Sears Service Center.
Adjusting Valve Clearance
After the first fifty (50) hours of operation, you should
adjust the valve clearance in the engine.
Important" If you feel uncomfortable about doing this
procedure or you don't have the proper tools, please
take your cleaning system in to the nearest service
center to have the valve clearance adjusted. This is a
ve_ impo_ant step to insure the longest life for your
engine.
To adjust valve clearance:
•Make sure the engine is at room temperature.
•Make sure that the spark plug wire is removed from
the spark plug and out of the way.
•Remove the breather tube from the valve cover.
•Remove the'four screws attaching the valve cover
with a #2 or 3 phillips screwdriver.
Clean /Replace Spark Plug
Replace the spark plug yearly or every 100 hours of
operation, whichever comes first.
A CAUTION: Disconnect spark plug wire from
spark plug and keep wire away from spark plug.
Clean area around spark plug.
Remove spark plug form the cylinder head.
Replace spark plug if the electrodes are pitted,
burned or porcelain is cracked. For replacement
use Champion RC12YC or equivalent.
Check electrode gap with wire feeler gauge and set
gap to 0.76mm (.030 inches), if necessary.
O
Valve Cover Breather Tube
Make sure the piston is at Top Dead Center (TDC)
of its compression stroke (both valves closed). To
get the piston at top dead center, pull on the recoil
handle slowly watching the piston trough the spark
plug hole. As you pull on the recoil handle the
Install a correctly gapped spark plug into the
cylinder head, tighten securely.
piston should move up and down. The piston is put
Top Dead Center when it is up as high as it can go.
14