Pacific hydrostar 95619 User manual

4HP Gas Pressure Washer
ASSEMBLY AND OPERATING INSTRUCTIONS
95619
Diagrams within this manual may not be drawn proportionally.
Due to continuing improvements, actual product may differ slightly from the product described herein.
Distributed exclusively by Harbor Freight Tools®.
3491 Mission Oaks Blvd., Camarillo, CA 93011
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©2007 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.
For technical questions or replacement parts, please call 1-800-444-3353.

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Specifications
Gas Engine 4HP OHC Mitsubishi Engine, 3600 RPM, Recoil Start, Uses Unleaded Fuel,
20 Oz. Engine Oil Capacity, 6.25 Gal. Fuel Capacity (2.5L).
Environmental Approved by E.P.A. (Environmental Protection Agency)
Pressure Washer 2200 PSI Rated, Cast Iron Cylinder Sleeve, Brass Axial Pump
Pump Dimensions 25-½”L x 19-3/8”W x 33-¾”T
Washer Gun Safety Trigger Activated; for Cold Water use only
Water Output 2.3 Gallons per Minute
High Pressure Hose 27 Foot Long High Pressure Hose
Cart and Wheels Built in Cart with 8”D x 2” Wheels
Features Standard Garden Hose Connector for Water Supply
Thermal Overload Protection and Unloader Valve on Pressure Washer
Save This Manual
You will need the manual for the safety warnings and precautions, assembly
instructions, operating and maintenance procedures, parts list and diagram. Keep
your invoice with this manual. Write the invoice number on the inside of the front
cover. Keep the manual and invoice in a safe and dry place for future reference.
Safety Warnings and Precautions
WARNING: When using tool, basic safety precautions should always be fol-
lowed to reduce the risk of personal injury and damage to equipment. Read
and adhere to all warnings and safety precautions before use.
Read all instructions before using this tool!
1. Carbon Monoxide Hazard. Operate pressure washer in well ventilated
area only. Carbon Monoxide is created when engine is running and is a
DEADLY gas when inhaled. Carbon Monoxide is a colorless, odorless gas.
Early signs of Carbon Monoxide poisoning resemble Flu symptoms such
as headache, dizziness or nausea. If you notice these signs, turn off engine and
immediately move to a well ventilated area.
2. Fire Hazard. Do not ll gas tank when engine is running or hot. Do not
operate engine near spilled gasoline. Clean spilled gasoline before starting
engine. Do not store or handle gasoline near pilot light, electrical equip-
ment or open ame. Do not smoke near gasoline. Gasoline fuel and
fumes are ammable and potentially explosive. Use proper fuel handling proce-
dures. Always have multiple ABC class re extinguishers in the area when handling
fuel.
3. 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.
REV 07c

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4. Burn Hazard. The engine and high pressure pump become hot during
operation. Do not touch the engine or pump until they have cooled down
after use.
Keep work area clean5. . Cluttered areas invite injuries.
Observe work area conditions6. . Do not use machines or power tools in unsafe
locations. Don’t expose to rain. Keep work area well lit.
Keep children away7. . Children must never be allowed in the work area. Do not let
them handle machines, tools, gasoline or oil.
Store idle equipment8. . When not in use, tools must be stored in a dry location to
inhibit rust. Always lock up tools and keep out of reach of children.
Use the right tool for the job9. . Do not attempt to force a small tool or attachment to
do the work of a larger industrial tool. There are certain applications for which this
tool was designed. It will do the job better and more safely at the rate for which it was
intended. Do not modify this tool and do not use this tool for a purpose for which it
was not intended.
Dress properly10. . Do not wear loose clothing or jewelry as they can be caught in
moving parts. Protective, electrically non-conductive clothes and non-skid footwear
are recommended when working. Wear restrictive hair covering to contain long hair.
Use eye and ear protection11. . Always wear ANSI approved impact safety goggles,
heavy rubber boots, work gloves and hearing protection during use. During pressure
washing debris can y back in your face, or into other property, people or animals.
Use extreme caution to prevent unintended spray injury.
Do not overreach12. . Keep proper footing and balance at all times. Do not reach over
or across running machines.
Maintain tools with care13. . Keep tools maintained and clean for better and safer per-
formance. Follow instructions for lubricating and changing accessories. Inspect tool
hoses periodically and, if damaged, have them repaired by an qualied technician.
The handles must be kept clean, dry, and free from oil and grease at all times.
Turn OFF power14. . Turn OFF engine and water supply when not in use.
Remove adjusting keys and wrenches15. . Check that keys and adjusting wrenches
are removed from the tool or machine work surface before turning engine on.
Avoid unintentional starting16. . Be sure the water supply is in the Off position when
not in use. Do not carry the spray handle with your nger on the trigger, whether or
not engine is operating.
Stay alert17. . Watch what you are doing, use common sense. Do not operate any tool
when you are tired.
Take caution as some woods contain preservatives such as copper chromium18.
arsenate (CCA) which can be toxic. When high pressure spraying extra care
should be taken to avoid inhalation and minimize skin contact.

SKU 95619 For technical questions please call 1-800-444-3353 Page 4
Check for damaged parts19. . Before using any tool, any part that appears damaged
should be carefully checked to determine that it will operate properly and perform its
intended function. Check for alignment and binding of moving parts; any broken parts
or mounting xtures; and any other condition that may affect proper operation. Any
part that is damaged should be properly repaired or replaced by a qualied techni-
cian. Do not use the tool if any switch does not turn On and Off properly.
Guard against electric shock20. . Prevent water spray into any electrical source such
as a power outlet or extension cord.
Replacement parts and accessories21. . When servicing, use only identical replace-
ment parts. Use of any other parts will void the warranty. Only use accessories in-
tended for use with this tool. Approved accessories are available from Harbor Freight
Tools.
Do not operate tool if under the inuence of alcohol or drugs22. . Read warning
labels on prescriptions to determine if your judgment or reexes are impaired while
taking drugs. If there is any doubt, do not operate the tool.
Maintenance23. . For your safety, service and maintenance should be performed regu-
larly by a qualied technician.
Use only Cold Water and/or pressure washer detergent as the active propellant24.
in this tool. Do not use detergents not designed for pressure washers, caustic mate-
rials, solvents or any ammable materials in this machine. Use of any such material
can cause injury, or damage this tool or personal property.
During use, do not allow the high pressure hose to come in contact with any25.
hot part of the engine or pump. Damage to the hose may occur possibly causing
the hose to burst or leak under high pressure.
In case of emergency during use, immediately release the trigger on the spray26.
handle, then turn the engine off. Do not set the spray handle down without turning
off the engine. Then shut off gas supply to engine. (Refer to engine manufacturer’s
manual for fuel shut off procedures.)
Avoid tipping over the pressure washer.27. Only use on a level solid and stable
surface.
Never leave the engine running for more than 3 minutes without spraying.28. Do not
leave the pressure washer unattended while the engine is running.
Use tools with both hands when required.29. This tool requires the use of two hands to
maintain tool stability and keeps hands away from operating parts of the tool.
People with pacemakers should consult their physician(s) before use.30. Electro-
magnetic elds in close proximity to heart pacemaker could cause pacemaker inter-
ference or pacemaker failure. Caution is necessary when near engine’s magneto or
recoil starter.
Never touch the water jet.31. Never touch the water jet or point it at people or animals.
Injury may result.

SKU 95619 For technical questions please call 1-800-444-3353 Page 5
Clean up fuel spills immediately.32. Dispose of uids and cleaning materials in ac-
cordance with local, state or federal regulations. Store oily rags in a metal container.
Store gasoline in a well ventilated, secure locker.
Do not smoke and do not allow re ame or electrical ignition sources near the 33.
pressure washer or any fuel or ammable materials.
Keep grounded electrically conductive tools and appliances away from any34.
source of ammable materials. Electrical items can cause ignition of ammable
fumes and materials.
Do not rell the fuel tank on the pressure washer while the engine is running or 35.
hot. Do not operate the pressure washer if there are any leaks in the fuel system.
Use only the types and grades of fuel, oil and other lubricants recommended36.
by the engine manufacturer.
WARNING:37. The brass components of this product contain lead, a chemical known to
the State of California to cause birth defects or other reproductive harm. (California
Health and Safety Code § 25249.5, et. seq.)
The warnings, cautions, and instructions discussed in this instruction manual cannot38.
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.

SKU 95619 For technical questions please call 1-800-444-3353 Page 6
Unpacking
When unpacking, check to make sure the parts shown in the photo below and in
the diagrams on pages 13 and 14 are included.
If any parts are missing or broken, please call Harbor Freight Tools at the number
on the cover of this manual.
07d, 08b
Spray Gun
High Pressure Hose
Gas Cap
Fuel Tank
Engine
Spray Nozzle

SKU 95619 For technical questions please call 1-800-444-3353 Page 7
Assembly
NOTE: Please refer to the photo below and the table and diagram on pages 13
and 14 when reading this section and assembling your pressure washer.
1. Attach the Cart Handle (16) to the Cart Frame (5) as shown in the photo
below. Secure in place using the Handle Locking Knobs (23) with Flat
Washers (21) and Spring Washers (22). Tighten Securely.
2. Attach the Wheels (4) to the Cart Frame (5) using the Lock Nuts (2) and Flat
Washers (3). Press Wheel Covers (1) in place to cover axle ends.
3. Connect the High Pressure Hose (38) to the High Pressure Pump (24) by
screwing in place clockwise. Secure tightly.
4. Attach High Pressure Hose (38) to Spray Gun Handle (37) by screwing
clockwise. Tighten securely.
5. Coil the High Pressure Hose (38) and hang it on the Hose Bracket (8). Hang
the Spray Gun on the Gun Bracket (14).
6. Connect a garden hose water supply to the garden hose connector.
07d
Spray Nozzle

SKU 95619 For technical questions please call 1-800-444-3353 Page 8
07d
Using Detergent
CAUTION! To avoid injury, ONLY run pressure washer detergent through the Detergent
Suction Hose (40).
Detergent Suction
Hose (40)
Figure A
1. Press the supplied Detergent Suction Hose (40) onto the tting on top of the pump.
Place the other end of the hose into the detergent container or bottle. See Figure A.
High pressure Low pressure
Figure B
2. Do not dilute the detergent. The detergent sprays out at low pressure only. Slide the
Spray Nozzle out for low pressure. The pressure washer will draw the detergent up
through the Detergent Suction Hose (40) and mix the water and detergent automati-
cally, at about a 6% detergent 94% water ratio.
See Figure B.

SKU 95619 For technical questions please call 1-800-444-3353 Page 9
Important Guidelines for Water Supply
1. Do not leave engine running without spraying water. If engine is left
running for more than three (3) minutes without discharging water, excess
pressure can cause damage to the pump seals and / or high pressure hose.
2. The water supply provided through the garden hose must be at least
3 gallons per minute for this pressure washer to operate at maximum
level. Use only a standard 3/4” diameter garden hose for water supply,
smaller hoses may not provide enough water flow. Test your water supply
before operation by measuring the time required to fill a gallon bucket.
3. Only use clean water supply. Dirty or recycled “grey” water may contain
impurities which can damage the pump or seals. Never use corrosive or
flammable fluids.
Engine Setup
Refer to the engine manufacturer’s manual for complete directions on proper
engine setup, operation and maintenance.
1. Before starting the engine check the engine oil level. Unscrew the Oil Cap,
and read the oil level on the dipstick (which is attached to the underside
of the Oil Cap). If the level is low, fill to the proper level before starting.
Use only clean, high quality engine oil meeting the engine manufacturer’s
specifications.
2. Remove Gas Cap and fill the Fuel Tank with unleaded gasoline. Do not
overfill. Be careful not to spill gasoline. Clean any spills before starting
engine.
Gas Cap
Fuel Tank
Oil Cap
REV 08b
Oil Cap

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Operation
Pick up the Spray Gun (37) and point it in a safe direction. Squeeze the Spray Gun1.
Trigger until all internal air is released, and a steady ow of water comes out. Then
release the Spray Trigger.
2. Turn the Fuel Valve (D) to the open position (see engine photo).
Turn the Speed Control Lever (C) all the way to the left, or fast position (see photo).3.
Move the Choke Lever (B) all the way to the left, or closed position (see photo).4.
Pull the Starting Handle (A) (shown above in photo) lightly until you feel5.
resistance. Then, pull it completely out. The engine should start up. If the en-
gine does not start after a few tries, refer to Engine Manufacturer’s Trouble-
shooting Tips. Slowly release the Starting Handle.
Adjust the Speed Control Lever (C) for the desired speed and subsequent6.
output water pressure. Open the Choke Lever (B) to the right.
Hold the Spray Gun (37) with both hands and begin spraying. Do not allow7.
the engine to run for more than three minutes without spraying.

SKU 95619 For technical questions please call 1-800-444-3353 Page 11
Operation (Continued)
Turning Off the Pressure Washer
1. Turn the Speed Control Lever (C) to the right, or stop position. The engine will
stop.
2. Turn the Fuel Valve (D) up to the left, or closed position (see photo page 9).
3. Turn off the water supply faucet.
4. Point the nozzle in a safe direction, then press the Spray Gun Trigger Handle
to release water and pressure.
5. Disconnect the water supply hose from the Water Inlet Connector. (See
photo page 9).
Cleaning Recommendations
Clean an inconspicuous test area first to avoid damaging the surface: Always
begin with the fan spray at a distance of about 3-5 feet from the surface
being cleaned to avoid damaging the surface of the object. Make sure
that the test area is clear of people and water prone/delicate objects. If a
pressure washing detergent is to be used, apply the detergent to this area as
well. After cleaning this area, switch off the pressure washer and inspect the
area carefully for any damage or discoloration. If any damage is noted from
the pressure setting, use a lighter setting when cleaning the rest of the area.
If damage or discoloration is noted from the detergent, do not use it when
cleaning.
First, pass over the area with a light cleaning, and then more thoroughly clean
it.
For a vertical or sloped surface:
Wash from the top down.a.
If possible, direct the stream in the same direction as the slope towards a drain-b.
ing area. This will enable better drainage and therefore better cleaning.
For a flat surface:
If a thin layer of water accumulates on the surface, periodically use the stream toa.
direct this water towards the drainage.
After the major cleaning is done, sweep the surface with the stream to helpb.
direct loose debris toward the drainage.

SKU 95619 For technical questions please call 1-800-444-3353 Page 12
Cleaning Suggestions
Hold the Spray Gun (37) at about a 45° angle and steadily sweep the stream
back and forth. Do not point the spray directly at the surface to be cleaned.
If a head-on angle is used, dirt may embedded in the surface being cleaned.
Follow a steady, consistent pace during cleaning; this will help prevent
stripes or discoloration afterwards. If streaking or uneven cleaning is noted at
the end of a project, go over the edges of the streaks with a wide fan pattern
to help blend these lighter areas in.
If several different surfaces are to be cleaned, be careful not to damage
any of the less solid surfaces while trying to clean the harder ones. This is
especially a concern when cleaning tile and grout, bricks and mortar, or
stones and mortar.
If wood is being cleaned, be careful not to damage it. Wood will usually
require resurfacing (sanding) and re-coat with a surface protectant (wood,
stain, varnish) after it has dried again. Try to avoid leaving water on a
wooden surface; doing so can harm the surface.
Maintenance
After each use, wipe down the entire unit with a clean cloth. Do not use solvents.1.
Store the pressure washer in a clean and dry location, away from anything2.
flammable.
If water is leaking from any connections during operation, shut down the3.
Pressure Washer and retighten all connections.
Maintain the engine regularly according to the maintenance instructions pro-4.
vided in the engine’s manual.
Rell the Pump Assembly with 80 ml of SF15W-40 oil whenever it is serviced. 5.
Note: The Pump Assembly comes lled with oil.
The pump oil must be changed after the initial break-in period of 50 hours of
operation and every 100 hours thereafter.
REV 07i

SKU 95619 For technical questions please call 1-800-444-3353 Page 13
PUMP MAINTENANCE CHART*
Maintenance Type Before
Use
After
Use
Hours of operation
After Initial 50
hr. Break-in
Period
Weekly /
10 hr.
100
hr.
150
hr.
200
hr.
Inspect tool for damage X
Wipe off with clean, moist cloth X X X
Clean Filters, Check for Pump Oil
and Water Leaks X X
Pump Oil Change X X
Seal change and regulator/
unloader/relief valve maintenance X
Valve Change X
*Note: This maintenance Chart is intended solely as a general guide. If performance
decreases, check systems immediately. The maintenance needs of each pump will
differ depending on factors such as duty cycle, temperature, cleanness of pumped
liquid, and inlet feed conditions.
Many maintenance procedures will need to be performed by a qualied technician.
Troubleshooting
Symptom Possible Cause Solution
Engine will not
start
Gas tank empty1.
Low oil level2.
Choke is not in correct position3.
Engine throttle set too low4.
Pressure build up in pump5.
Fill gas tank1.
Add oil2.
Close choke3.
Increase throttle setting4.
Squeeze trigger to release pressure5.
Does not
produce high
pressure
Diameter of water supply hose too1.
small
Water supply is restricted2.
Not enough water supply3.
Replace garden hose with a ¾ inch hose1.
Check water supply hose for kinks, leaks,2.
or blockage
Open water faucet all the way3.
Output
pressure varies
Not enough water supply1.
Water inlet screen is clogged2.
Nozzle is clogged3.
Nozzle has mineral build up4.
Check water supply hose for kinks, leaks,1.
or blockage. Open faucet all the way
Remove inlet screen and rinse out2.
Remove nozzle and clean3.
Remove nozzle and clean with vinegar4.
REV 07i

SKU 95619 For technical questions please call 1-800-444-3353 Page 14
NOTE: Some parts are listed and shown for illustration purposes only and are not
available individually as replacement parts.
Assembly Drawing

SKU 95619 For technical questions please call 1-800-444-3353 Page 15
PLEASE READ THE FOLLOWING CAREFULLY
THE MANUFACTURER AND/OR DISTRIBUTOR HAS PROVIDED THE PARTS DIAGRAM IN THIS
MANUAL AS A REFERENCE TOOL ONLY. NEITHER THE MANUFACTURER NOR DISTRIBUTOR
MAKES ANY REPRESENTATION OR WARRANTY OF ANY KIND TO THE BUYER THAT HE OR SHE
IS QUALIFIED TO MAKE ANY REPAIRS TO THE PRODUCT OR THAT HE OR SHE IS QUALIFIED TO
REPLACE ANY PARTS OF THE PRODUCT. IN FACT, THE MANUFACTURER AND/OR DISTRIBUTOR
EXPRESSLY STATES THAT ALL REPAIRS AND PARTS REPLACEMENTS SHOULD BE UNDERTAKEN
BY CERTIFIED AND LICENSED TECHNICIANS AND NOT BY THE BUYER. THE BUYER ASSUMES
ALL RISK AND LIABILITY ARISING OUT OF HIS OR HER REPAIRS TO THE ORIGINAL PRODUCT
OR REPLACEMENT PARTS THERETO, OR ARISING OUT OF HIS OR HER INSTALLATION OF
REPLACEMENT PARTS THERETO.
Parts List
Part Description QTY.
1 Wheel Cover 2
2 Lock Nut 2
3 Flat Washer 2
4 Wheel 2
5 Cart Frame 1
6 Spring Washer 4
7 Screw 4
8 Hose Bracket 1
9 Nut 2
10 Spring Washer 2
11 Flat Washer 2
12 Handle Plate 1
13 Screw 4
14 Gun Bracket 1
15 Screw 2
16 Cart Handle 1
17 Upper Bumper 1
18 Nut 4
19 Spring Washer 4
20 Flat Washer 4
Part Description QTY.
21 Flat Washer 2
22 Spring Washer 2
23 Handle Locking Knob 2
24 High Pressure Pump 1
25 4HP Engine 1
26 Lock Nut 4
27 Motor Mount Plate 1
28 Lower Bumper 1
29 Screw 4
30 Flat Washer 4
31 Lock Nut 2
32 Flat Washer 2
33 Foot Pad 2
34 Flat Washer 2
35 Screw 2
36 Plug 2
37 Spray Gun 1
38 High Pressure Hose 1
39 Pin 1
40 Detergent Suction Hose 1
07d

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LIMITED 1 YEAR WARRANTY
Harbor Freight Tools Co. makes every effort to assure that its products meet high
quality and durability standards, and warrants to the original purchaser that this product is
free from defects in materials and workmanship for the period of one year from the date
of purchase (90 days if used by a professional contractor or if used as rental equipment).
See engine manufacturer’s warranty which covers engine. This warranty does not apply
to damage due directly or indirectly, to misuse, abuse, negligence or accidents, repairs or
alterations outside our facilities, normal wear and tear, or to lack of maintenance. We shall
in no event be liable for death, injuries to persons or property, or for incidental, contingent,
special or consequential damages arising from the use of our product. Some states do
not allow the exclusion or limitation of incidental or consequential damages, so the above
limitation of exclusion may not apply to you. THIS WARRANTY IS EXPRESSLY IN LIEU OF
ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THE WARRANTIES OF
MERCHANTABILITY AND FITNESS.
To take advantage of this warranty, the product or part must be returned to us with
transportation charges prepaid. Proof of purchase date and an explanation of the complaint
must accompany the merchandise. If our inspection veries the defect, we will either repair or
replace the product at our election or we may elect to refund the purchase price if we cannot
readily and quickly provide you with a replacement. We will return repaired products at our
expense, but if we determine there is no defect, or that the defect resulted from causes not
within the scope of our warranty, then you must bear the cost of returning the product.
This warranty gives you specic legal rights and you may also have other rights which
vary from state to state.
3491 Mission Oaks Blvd. • PO Box 6009 • Camarillo, CA 93011 • [phone]