Grizzly Pressure Washer H8191 User Manual

MODEL H8191

3600 PSI DIESEL PRESSURE

WASHER

OWNER'S MANUAL

WARNING: NO PORTION OF THIS MANUAL MAY BE REPRODUCED IN ANY SHAPE

OR FORM WITHOUT THE WRITTEN APPROVAL OF GRIZZLY INDUSTRIAL, INC.

#LO9708 PRINTED IN CHINA

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Table of Contents

INTRODUCTION............................................................................................................................... 2

Foreword .................................................................................................................................... 2

Contact Info................................................................................................................................ 2

General Identification ................................................................................................................. 4

SECTION 1: SAFETY....................................................................................................................... 5

Safety Instructions for Machinery............................................................................................... 5

Additional Safety Instructions for Pressure Washers................................................................. 7

SECTION 2: SETUP......................................................................................................................... 8

Unpacking .................................................................................................................................. 8

Inventory..................................................................................................................................... 8

Assembly.................................................................................................................................... 9

SECTION 3: OPERATIONS ........................................................................................................... 10

Connections and Controls........................................................................................................ 10

Break-In.................................................................................................................................... 11

Adjusting Pressure................................................................................................................... 11

Changing Nozzles.................................................................................................................... 11

Applying Chemicals.................................................................................................................. 12

Drawing Water from Standing Water Source........................................................................... 13

Spray Gun Lock ....................................................................................................................... 14

Starting..................................................................................................................................... 14

Shutdown Procedure................................................................................................................ 15

SECTION 4: ACCESSORIES......................................................................................................... 16

SECTION 5: MAINTENANCE ........................................................................................................ 17

Schedule .................................................................................................................................. 17

General Maintenance............................................................................................................... 18

Engine Oil and Filter Service ................................................................................................... 18

Pump Oil Change..................................................................................................................... 19

Air Filter Service....................................................................................................................... 20

Fuel Filter Change.................................................................................................................... 21

Troubleshooting........................................................................................................................ 22

Pump Parts Breakdown ........................................................................................................... 23

Engine Block Parts Breakdown................................................................................................ 25

Engine Cylinder Head Parts Breakdown.................................................................................. 26

Engine Piston and Crank Parts Breakdown............................................................................. 27

Engine Fuel Tank Parts Breakdown ........................................................................................ 28

Engine Lubrication/Speed Parts Breakdown ........................................................................... 29

Engine Recoil Starter Parts Breakdown................................................................................... 30

Engine Air Filter, Muffler, and Fuel Pump Parts Breakdown ................................................... 31

Engine Electric Start Parts Breakdown.................................................................................... 32

Frame and Hardware Parts Breakdown................................................................................... 33

Machine Labels Breakdown..................................................................................................... 34

WARRANTY AND RETURNS........................................................................................................ 37

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INTRODUCTION

Contact Info

Foreword

If you have any comments regarding this manual,

please write to us at the address below:

We are proud to offer the Model H8191 9HP 3600

PSI Diesel Pressure Washer. This machine is part

of a growing Grizzly family of fine power tools.

When used according to the guidelines set forth

in this manual, you can expect years of trouble-

free, enjoyable operation and proof of Grizzly’s

commitment to customer satisfaction.

Grizzly Industrial, Inc.

Technical Documentation Manager

P.O. Box 2069

Bellingham, WA 98227-2069

Email: [email protected]

The specifications, drawings, and photographs

illustrated in this manual represent the Model

H8191 when the manual was prepared.

However, owing to Grizzly’s policy of continuous

improvement, changes may be made at any time

with no obligation on the part of Grizzly.

We stand behind our machines. If you have any

service questions or parts requests, please call or

write us at the location listed below.

Grizzly Industrial, Inc.

1203 Lycoming Mall Circle

Muncy, PA 17756

Phone: (570) 546-9663

Fax: (800) 438-5901

For your convenience, we always keep current

Grizzly manuals available on our website at www.

grizzly.com. Any updates to your machine will

be reflected in these manuals as soon as they

are complete. Visit our site often to check for the

latest updates to this manual!

E-Mail: [email protected]

Web Site: http://www.grizzly.com

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General Identification

Figure 1. General component identification

A. Electric Start Switch

B. Spray Gun Nozzles

C. Spray Gun

G. Pump Output Port

H. Pump Input Port

I. Input Hose

D. High Pressure Hose

E. Fuel Tank

J. Spray Gun Wand

K. Pump

F. Speed Control

L. Engine

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Safety Instructions for Machinery

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Additional Safety Instructions for Pressure

Washers

1. FLUID INJECTION. This machine operates

at fluid pressures and velocities high

enough to penetrate human and animal

flesh. Should such an injury occur, it may

be a surgical emergency. DO NOT treat

fluid injection as a normal cut, instead, see

a physician immediately.

6. CHANGING NOZZLES. Be sure to release

water pressure before changing nozzles, or

performing any service or maintenance, to

reduce the risk of fluid injection injury.

7. APPROVED FLUIDS. Some cleaning

fluids could cause injury to skin, eyes, or

lungs. Use only cleaning fluids approved

for high pressure washers and follow the

manufacturer's recommendations. Never

spray any corrosive chemicals, poisons,

insecticides, or flammable solvents with

this machine.

2. ADEQUATE VENTILATION. During

operation this machine produces carbon

monoxide, which is a poisonous gas. Make

sure the work area is adequately ventilated.

Never operate this machine indoors.

3. COOLING ENGINE. Motor parts get hot

during operation. Allow to cool before

placing hands near motor, adding fuel, or

performing any service or maintenance.

8. HOLDING SPRAY GUN. The reactive

force of the spray will cause the gun to

move, and could cause the operator to

fall or misdirect the spray. Always stand in

a stable position, grip the gun firmly with

both hands, and do not overreach. Use

extreme caution on roofs and ladders and

always wear appropriate harnesses and

safety equipment.

4. FUEL SPILLS. Fuel exposed to hot engine

components may ignite. Thoroughly clean

all fuel spills before starting.

5. ELECTRICAL OVERSPRAY HAZARD.

Spraying water near electrical outlets,

switches, or objects connected to an

electrical circuit, could result in a fatal

electric shock.

9. SLIPPING HAZARDS. The use of pressure

washers can create puddles and other

slippery surfaces. Use extreme caution on

these surfaces to reduce the risk of a fall.

Like all machinery there is potential danger

when operating this machine. Accidents are

frequently caused by lack of familiarity or

failure to pay attention. Use this machine

with respect and caution to lessen the

possibility of operator injury. If normal safety

precautions are overlooked or ignored,

serious personal injury may occur.

No list of safety guidelines can be complete.

Every shop environment is different. Always

consider safety first, as it applies to your

individual working conditions. Use this and

other machinery with caution and respect.

Failure to do so could result in serious

personal injury, damage to equipment, or

poor work results.

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SECTION 2: SETUP

Inventory

This machine presents

serious injury hazards

to untrained users. Read

through this entire manu-

al to become familiar with

the controls and opera-

tions before starting the

machine!

The following is a description of the main

components shipped with your machine. Lay the

components out to inventory them.

Note: If you can't find an item on this list, check

the mounting location on the machine or examine

the packaging materials carefully. Occasionally

we pre-install certain components for shipping

purposes.

Unpacking

Your machine was carefully packaged for safe

transportation. Remove the packaging materials

from around your machine and inspect it. If

you discover the machine is damaged, please

immediately call Customer Service at (570) 546-

9663 for advice.

Save the containers and all packing materials for

possible inspection by the carrier or its agent.

Otherwise, filing a freight claim can be difficult.

When you are completely satisfied with the condi-

tion of your shipment, inventory the contents.

Figure 2. Model H8191 inventory

H8191 Inventory (Figure 2)

Qty

A. Pressure Washer........................................ 1

B. Spray Gun Wand........................................ 1

C. Spray Gun .................................................. 1

D. Input Hose.................................................. 1

E. High Pressure Hose ................................... 1

F. Accessory Kit ............................................. 1

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Assembly

Refer to Figure 1 on Page 4 for identification of

components in the following steps.

To assemble the H8191:

1. Thread the spray gun wand into the spray

gun and tighten securely.

2. Connect the male end of the high pressure

hose to the pump output port.

Figure 3. Model H8191 accessory inventory.

3. Connect the high pressure hose quick coupler

to the spray gun.

H8191 Accessory Inventory (Figure 3)

Qty

A. Chemical Hose........................................... 1

B. Chemical Filter ........................................... 1

C. O-Ring Seal Kit .......................................... 1

D. Input Hose Filter......................................... 1

E. Hose Adapter Male-to-Male (not shown) .. 1

4. Connect the female end of the input hose

onto the pump input port.

5. Connect the other end of the input hose to

a spigot providing at least 5 GPM, or to the

input hose filter, if drawing from a standing

water source.

Note: Depending on the spigot fitting type, you

may need to use the provided male-to-male

input hose adapter to connect the pressure

washer to this type of water source.

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SECTION 3: OPERATIONS

Connections and Controls

A. Water Pressure Adjustment Knob

E. Fuel Valve

B. Chemical Injection Port

C. Pump Output Port

D. Pump Input Port

F. Speed Control Lever

G. Compression Release Lever

H. Pull-Start Handle

Figure 4. Pump Controls.

Figure 6. Additional motor controls.

Figure 5. Motor controls.

Figure 7. Pull-start handle location.

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Break-In

The first 20 hours of operation is considered the

break-in period. Be sure to follow the maintenance

schedule on Page 16 after 20 hours of use.

NOTICE

Failure to follow the break-in maintenance

schedule can reduce the lifespan of

the machine and negatively impact

performance.

Water Pressure

Adjustment Knob

Figure 8. Water pressure adjustment knob.

•

REDUCE ENGINE SPEED. Slowing the

engine will reduce the pressure created by

the pump.

Adjusting Pressure

NOTICE

DO NOT attempt to increase the maximum

pump pressure by modifying controls or

otherwise altering the machine. A higher

pressure setting than the factory set

maximum pressure may damage the pump

or cause components to fail, resulting in

serious personal injury.

Engine speed should always be set high

enough to handle the load of the pump. If

the engine speed is too low, the motor may

bog or stop when the spray gun trigger is

pulled and the pump is activated. Operating

the engine speed at such a setting can

cause excessive engine wear and premature

engine failure.

The pressure setting on the Model H8191 was

preset at the factory to achieve optimum pressure

for general purpose cleaning.

Changing Nozzles

To adjust the pressure:

•

BACK AWAY FROM THE SURFACE TO BE

CLEANED. Moving further away reduces the

pressure on the workpiece.

The Model H8191 pressure washer is equipped

with five spray nozzles housed in receptacles on

the front panel. Each nozzle is color coded and

delivers a specific spray pattern for a particular

cleaning purpose. The 0°, 15°, 25°, and 40°

nozzles are high pressure nozzles; the chemical

nozzle is a low pressure nozzle.

SELECT A DIFFERENT NOZZLE. Nozzles

with a wider angled spray deliver a less

powerful stream.

ADJUST THE PRESSURE REGULATOR

ON THE PUMP. Turn the water pressure

adjustment knob counterclockwise to lower

the pressure (Figure 8). Once you have

finished using your pressure washer, return

the regulator to its original position by turning

it clockwise.

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To change nozzles:

Nozzles

0° Red Nozzle

This nozzle delivers an extremely powerful pinpoint

stream that covers a very small cleaning area.

1. FOLLOW THE SHUTDOWN PROCEDURE

ON PAGE 15!

2. Pull back the quick connect coupler on the

end of the spray gun wand and remove the

current nozzle.

15° Yellow Nozzle

This nozzle delivers a powerful 15° spray pattern

for intense cleaning of small areas.

3. Select a nozzle, pull back the quick connect

coupler and insert the nozzle, as shown in

Figure 9.

25° Green Nozzle

This nozzle delivers a 25° spray pattern for intense

cleaning of larger areas.

40° White Nozzle

This nozzle delivers a 40° spray pattern and a

less powerful stream of water. It covers a wide

area of cleaning.

Chemical Black Nozzle

This nozzle is used to apply chemicals or cleaning

solutions. It has the least powerful stream.

Applying Chemicals

Figure 9. Inserting a nozzle.

4. Release the quick connect coupler, then twist

and pull the nozzle to make sure it is secure

in the coupler.

Use only household detergents, cleaners, and

degreasers recommended for use in pressure

washers. NEVER use toxic or corrosive

chemicals, acids, poisons, insecticides, or

flammable solvents such as gasoline or

kerosene with your pressure washer. Failure

to follow this warning could result in machine

failure, significant property damage, severe

personal injury, or death.

Always double-check coupler connections on

all fittings. Improperly connected fittings can

blow apart under pressure, causing severe

personal injury or equipment damage.

NOTICE

Applying chemicals or cleaning solvents

is a low pressure operation. Use only the

chemical nozzle to apply chemicals or

solvents.

Always try a nozzle on a small test area or

piece of test material to determine if it is the

correct nozzle for the task. Some nozzles

provide so much pressure they can destroy

even sturdy materials.

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3. Connect the low pressure chemical nozzle to

the spray gun as described on Page 12.

NOTICE

Chemicals left in the pressure washer can

damage the pump and void the warranty.

Always rinse the unit thoroughly by running

clean water through the chemical hose after

using chemicals or cleaning solvents.

4. After using chemicals or cleaning solutions,

draw clean water through the chemical hose

and pressure washer to rinse the internal

components.

To apply chemicals:

Drawing Water from

Standing Water

Source

1. Push the chemical hose onto the barbed

fitting located near the pump output port, as

shown in Figure 10.

To draw water from a standing source:

1. Attach the supplied input hose filter to the

input hose and place the input hose filter in

the standing water source.

Note: Be sure the water source is free from

debris that could clog the filter and cause a

loss of water flow.

2. Prime the pump by pouring water into the

other end of the input hose (the end without

the filter) while the filter end is submerged in

the water source. Without spilling water out of

the hose, connect the input hose to the input

port on the pump.

Figure 10. Chemical hose attached to barbed

fitting.

2. Push the other end of the chemical hose onto

the chemical hose filter (Figure 11), and fully

submerge in a container holding the chemical

or cleaning solution.

Note: Be sure the water source is large

enough to provide 5 GPM of flow for the

duration of the pressure washer operation.

NOTICE

If the pump is not able to provide pressurized

water when drawing from a standing water

source, shutdown the pressure washer

immediately and re-attempt to prime the

pump. Failure to follow this instruction can

damage the pump and void the warranty.

Figure 11. Chemical hose filter attached.

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Spray Gun Lock

Starting

The spray gun has a lockout lever that can be

engaged to prevent accidental discharge. This

feature is especially useful when climbing up a

ladder or doing any work that might accidentally

discharge the spray gun. To engage the lockout

lever, simply flip it away from the trigger and clip it

into the lockout lever groove in the handle (Figure

12). To release the lever, reverse this procedure

(Figure 13).

Operationofthisequipmenthasthepotential

to propel debris into the air, which can

cause eye injury. Always wear safety glasses

or goggles when operating equipment.

Everyday glasses or reading glasses only

have impact resistant lenses, they are not

safety glasses. Be certain the safety glasses

you wear meet the appropriate standards of

the American National Standards Institute

(ANSI).

To start the pressure washer:

1. Check the engine and pump oil level and fuel

level (refer to the MAINTENANCE section

beginning on Page 17 for locations). Add

engine oil (SAE 10W-30) and fuel (diesel) if

necessary.

2. Securely fasten one end of the provided input

hose to a threaded hose spigot. Securely

fasten the other end of the input hose to the

pump input port.

Figure 12. Spray gun trigger locked.

Note: When drawing water from a standing

source, follow the standing source instructions

on Page 13. When drawing water from a

spigot, you may need to use the provided

male-to-male hose adapter.

3. Makesurethespraygunissecurelyconnected

to the high pressure hose, and that the high

pressure hose is securely connected to the

pump output port.

4. Attach the appropriate nozzle to the quick

coupler at the end of the spray gun wand,

and turn on the water supply at the spigot.

Figure 13. Spray gun trigger unlocked.

NOTICE

Never allow the motor to run without a water

source connected to the pump. Failure

to follow this instruction will damage the

pump and void the warranty.

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5. Switch the motor to the START position by

loosening the speed control lever locking

bolt, moving the mechanism downward, and

retightening the bolt next to the word "START"

(Figure 5, Page 10).

12. Pull the trigger on the spray gun to release

pressurized water and begin spraying.

Note: If the motor does not start after several

pulls of the start rope or brief turns of the

start switch, repeat the starting instructions

from Step 7. If you are still unable to start the

motor, refer to Troubleshooting on Page

22.

6. Open the fuel valve by rotating the lever

clockwise until it is vertical (Figure 14).

Fuel Valve

NOTICE

Never allow the motor to run for more than

five minutes without pulling the trigger

on the spray gun to release water. Failure

to follow this instruction can damage the

pump and void the warranty.

Shutdown Procedure

Figure 14. Fuel valve in open position.

To shut down the pressure washer:

7. Squeeze the spray gun trigger until a steady

1. Release the spray gun trigger and return

the spray gun to the bracket on the washer

handle.

stream of water comes out, then release.

8. Unlock the compression release lever by

pulling the start rope until resistance is felt.

2. Allow the motor to run without pulling the

spray gun trigger for 4 minutes.

9. Push the compression release lever down

until it latches.

3. Switch the motor to the STOP position by

loosening the speed control lever locking

bolt, moving the mechanism upward, and

retightening the bolt next to the word "STOP"

(Figure 5).

10. Pull the start rope handle with forceful, but

even pressure, or turn the electric start switch

to start the motor.

4. Close the fuel valve by rotating the lever

counterclockwise until it is horizontal.

When pull-starting, pull the start rope

slowly until resistance is felt, then pull with

forceful, even pressure. Rapidly jerking the

start rope can cause it to forcefully recoil,

potentially causing hand or arm injury.

5. Shut off the water at the spigot, or remove

the input line from the water if drawing from a

standing source. Purge the pressure from the

system by pulling the spray gun trigger.

11. Allow the motor to run for at least two minutes

to achieve normal operating temperature,

then set the speed control lever to the desired

speed.

NOTICE

To reduce the risk of damaging engine

components, DO NOT stop the engine

abruptly when it is running under load.

NEVER attempt to stop the motor with the

compression release lever.

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SECTION 4: ACCESSORIES

G9927 and H3143—Wax Buffer

H8118—Spot Sandblaster

Wax the car in a jiffy with this buffer/polisher

system. The pad duplicates hand polishing with

a random orbit rotation. Kit includes a wax

application bonnet and a terrycloth polishing

bonnet. Safe for all types of finishes, gives a

beautiful swirl free result.

This spot sandblaster is the quickest, cleanest

way to remove rust spots, peeling paint, or surface

blemishes without disturbing the surrounding

area. Supplied with 4 nozzles that allow you to

spot blast inside corners, outside corners, edges,

and flat areas for perfect surface prep.

G9927

H3143

Figure 17. Models G9927 and H3143 Wax

Figure 15. Model H8118 Spot Sandblaster.

Buffers.

G7142—Long Rubber Gloves

H3265—24" Blow Gun

Get into hard-to-reach areas with this 24” long

Blow Gun. Includes rubber tip. 1/4” female NPT.

Industrial strength rubber gloves with 11" cuffs

protect from finger tip to elbow. Positive grip on

hands and fingers. Alkali and acid resistant.

H3261—5 pc. Air Blow Kit

This chrome plated, brass body Air Blow Gun

includes five different tips for all normal air

cleaning jobs. 1/4" NPT air inlet.

H3265

Figure 16. Model G7142 Sandblasting Gloves.

H3261

Figure 18. Model H3265 and H3261 air tools.

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SECTION 5: MAINTENANCE

NOTICE

Operating machinery in harsh conditions

mayrequiremorefrequentmaintenance.The

maintenance schedule below is a guideline

for general use. If you operate your machine

in extremely hot, cold, or dusty conditions,

change oils and clean or replace filters with

increased frequency.

Always release water pressure and allow

engine to cool before performing any service

or maintenance. Failure to follow this warning

can result in severe burns or fluid injection

injuries.

Schedule

For optimum performance from your machine,

follow this maintenance schedule and refer to any

specific instructions given in this section.

Interval

Daily

Every 20

hours or 1

month

Every 100

hours or 3

months

Every 500

hours or 6

months

Every 1000

hours or 12

months

Maintenance

Check and tighten

bolts

Check for worn or

damaged wires

Check for oil/fuel

leaks

Check engine oil

Change engine oil

X (First Time

Break In)

Clean engine oil filter

X (First Time

Break In)

Replace engine oil

filter

Check pump oil

Change pump oil

X (First Time

Break In)

Clean outer air filter

Clean filter core

Replace filter core

Clean fuel tank

Clean fuel filter

Replace fuel filter

Figure 19. Maintenance schedule

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General Maintenance

Dipstick/Oil Cap

Before each use, perform the following general

maintenance tasks:

1. Check the engine oil and fuel level

Oil Filter Cap

2. Check the engine for cracked fuel lines,

loose bolts, and any other excessively worn

or damaged parts. Repair or replace worn or

damaged parts as necessary. Tighten any

loose bolts.

Drain Plug

Figure 20. Components for oil and filter service.

3. Check the high pressure hose for leaks.

Replace if necessary.

4. Drain all oil and reinstall the drain plug and

drain plug gasket.

4. Inspect the spray gun and nozzles for clogged

debris or damage. Clean any debris with

a garden hose and replace any damaged

parts.

5. Remove the bolt securing the oil filter cap

(Figure 20).

6. Carefully draw out the oil filter cap and oil

5. Inspect the chemical injection hose and filter

for clogged debris or damage. Clean any

debris with a garden hose and replace any

damaged parts.

filter by hand or with needle nosed pliers.

7. Wipe away any particulate material collected

in the filter screen with a clean, lint-free cloth,

or with a soft bristled brush. Use mineral spir-

its to remove stubborn deposits.

Engine Oil and Filter

Service

8. Reinstall the filter screen and securely fasten

the oil filter cap bolt.

Replace the engine oil and clean the oil filter once

after the first 20 hours, and then regularly after

every 100 hours or 3 months (more frequently in

harsh conditions).

To change the engine oil:

1. FOLLOW SHUTDOWN PROCEDURE AND

ALLOW ENGINE TO COOL!

2. Loosen the dipstick/oil cap.

3. Remove the drain plug and drain plug gasket

on the side of the engine (Figure 20) and

allow oil to drain through the hole in the frame

into a catch basin.

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9. Remove the dipstick/oil cap and fill with

an SAE 10W-30 motor oil rated for diesel

engines. Check the level on the dipstick

frequently until full (Figure 21). Avoid over

filling or seals may be damaged.

Oil Cap

Oil Level Viewport

Drain Plug

Figure 22. Pump oil cap and drain plug.

3. Remove the oil drain plug and drain plug gas-

ket.

4. After all the oil has drained, reinstall and tight-

Figure 21. Correct engine oil level on the

en the oil drain plug with drain plug gasket.

dipstick.

5. Remove the oil cap and fill with SAE 30 oil.

Add oil slowly and check the level frequently.

The pump is full when oil is just past the red

dot, covering the lower ²⁄3 of the viewing port

(Figure 23). Do not overfill.

6. Tighten the dipstick/oil cap.

7. Dispose of the used oil in accordance with

local regulations.

Pump Oil Change

Replace the pump oil once after 20 hours, and

then regularly every 100 hours or 3 months.

To change the pump oil:

1. FOLLOW SHUTDOWN PROCEDURE AND

ALLOW ENGINE TO COOL!

2. Loosen the oil cap (Figure 22).

Figure 23. Correct pump oil level in the viewport.

6. Reinstall the oil cap and tighten securely.

3. Place a container under the oil drain plug

(Figure 22).

7. Dispose of the used oil in accordance with

local regulations.

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4. Remove the outer foam air filter element from

Air Filter Service

the filter core.

5. Clean the outer element thoroughly with min-

Clean the outer air filter element after every 20

hours or 1 month (more frequently in harsh condi-

tions).

eral spirits and allow to dry.

6. Saturate the outer element with fresh motor

oil, then squeeze with a cloth to remove

excess oil.

To clean the outer air filter element:

1. FOLLOW SHUTDOWN PROCEDURE AND

7. Replace the outer air filter element, then

replace the air filter assembly, filter wing nut,

filter cover, and filter cover wing nut.

ALLOW ENGINE TO COOL!

2. Remove the air filter cover by first removing

the air filter cover wing nut.

Note: To clean the air filter core, DO NOT

use solvent or any other cleaning solution.

Instead, use a soft brush to remove any par-

ticulate build-up.

3. Remove the wing nut and washer holding

the air filter in place, and remove the air filter

assembly (Figure 24).

Figure 24. Removing the air filter.

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Fuel Filter Change

Refer to the part breakdown on Page 27 for identi-

fication of components in the following steps.

Fuel Filter

To change the fuel filter:

1. FOLLOW SHUTDOWN PROCEDURE AND

Fuel Valve

ALLOW ENGINE TO COOL!

1. Drain the fuel tank by removing the fuel tank

drain plug (Figure 25). Use a funnel and cer-

tified fuel container to capture the fuel as it

drains.

Figure 26. Removing the fuel filter.

4. Insert a new filter, making sure the gasket at

the base of the fuel filter and the gasket at the

base of the fuel valve are in place.

Hex Nuts

5. Fasten the fuel valve nuts securely.

6. Fasten the fuel tank drain plug securely.

Note: If you have difficulty removing the fuel

filter, you may find it easier with the fuel tank

removed entirely. To do this, refer to the parts

breakdown on Page 27, remove the upper

and lower fuel lines, and remove the upper

tank bracket. Once the tank is removed, the

fuel filter can be removed and replaced more

easily. Be sure to reattach and securely fas-

ten any fuel lines or brackets you remove.

Fuel Tank Drain Plug

Fuel Valve

Figure 25. Fuel tank drain plug and fuel valve.

2. Remove the two hex nuts shown in Figure

25. These hex nuts hold both the fuel valve

and the fuel filter in place.

3. Remove the fuel tank cap and extract the fuel

filter through the top of the tank as shown in

Figure 26.

-21-

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Troubleshooting

Symptom

Possible Cause

Solution

Engine won't start.

1. No fuel.

1. Add fuel.

2. Cold weather has made fuel and oil overly 2. Move the machine into a warm area and allow the

adhesive.

engine block to warm up before returning to work

area to start.

3. Fuel valve is closed.

3. Open fuel valve.

4. Air filter is clogged.

4. Clean air filter.

5. Water pressure has built up in the pump.

5. Release water pressure by squeezing spray gun trig-

ger.

6. Internal engine components have failed.

6. Refer to engine manual or see a qualified technician

for repair.

Engine starts, but 1. The fuel filter or fuel line is clogged.

1. Clean the fuel filter or clear the fuel lines.

2. Fully open the fuel valve.

3. Replace with a clean, quality diesel fuel.

4. Clean air filter.

runs poorly.

2. The fuel valve is partially closed.

3. Low quality or contaminated fuel.

4. Air filter is dirty.

5. Engine speed is too slow.

5. Increase throttle setting.

6. Internal engine components are worn or 6. Refer to a qualified technician.

have failed.

No, or low, water 1. Low water supply.

pressure. 2. Low pressure nozzle attached.

1. Water supply must flow at least 5 GPM.

2. Attach a higher pressure nozzle.

3. Tighten or replace fitting as necessary.

4. Remove and clean filter.

5. Increase engine speed with throttle lever.

6. Use high pressure hose under 100 ft.

3. Leak at high pressure hose fitting.

4. Input hose filter screen clogged.

5. Engine is not in high throttle position.

6. High pressure hose is too long.

7. Engine or pump components are worn or 7. Refer a qualified technician for repair.

have failed.

Will not draw chemi- 1. Spray gun does not have low pressure 1. Attach low pressure nozzle.

cals.

nozzle attached.

2. Chemical filter clogged.

2. Clean filter.

3. Chemical hose and filter not fully sub- 3. Be sure chemical hose and filter stay fully sub-

merged in chemical.

4. Chemical is too thick.

4. Dilute chemical. Chemicals should be the consis-

tency of water.

-22-

H8191 3600 PSI Diesel Pressure Washer

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Pump Parts Breakdown

-23-

H8191 3600 PSI Diesel Pressure Washer

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Pump Parts List

REF PART #

DESCRIPTION

REF PART #

DESCRIPTION

PSB20M

CAP SCREW M5-.8 X 14

OIL GAUGE

43 PH81910043

44 PH81910044

45 PH81910045

46 PH81910046

47 PH81910047

48 PH81910048

49 PH81910049

50 PH81910050

51 PH81910051

52 PH81910052

53 PH81910053

54 PH81910054

55 PH81910055

56 PH81910056

57 PH81910057

58 PH81910058

59 PH81910059

60 PH81910060

61 PH81910061

62 PH81910062

63 PH81910063

64 PH81910064

65 PH81910065

66 PH81910066

67 PH81910067

68 PH81910068

69 PH81910069

70 PH81910070

71 PH81910071

72 PH81910072

73 PH81910073

74 PH81910074

75 PH81910075

76 PH81910076

77 PH81910077

78 PH81910078

79 PH81910079

79-1 PLW03M

VALVE JACKET WATER RETURN

VALVE JACKET OUTER GASKET

WATER RETURN VALVE CORE

WATER RETURN VALVE SEAT

VALVE SEAT GASKET

PH81910002

PH81910003

PH81910004

PH81910005

PH81910006

PH81910007

PH81910008

PH81910009

OIL GAUGE CASKET

DRAINPLUG GASKET

DRAINPLUG

CRANK CASE COVER

CRANK CASE COVER GASKET

OIL INLET PLUG

OUTLET T CONNECTOR GASKET

WATER OUTLET T CONNECTOR

FIX BLOT GASKET

OIL INLET PLUG GASKET

CRANK CASE

FIX BLOT OUTLET T CONNECTOR

FIX BLOT INLET T CONNECTOR

INLET T CONNECTOR GASGET SMALL

WATER INLET T CONNECTOR

TWO T CONNECTOR GASKET

INLET T CONNECTOR GASGET

WATER INLET CONNECTOR GASGET

WATER INLET CONNECTOR

3/8" QD BODY

10 PH81910010

11 PSB74M

CAP SCREW M6-1 X 18

CRANK SHAFT COVER

BEARING COVER GASKET

BEARING CLIP

12 PH81910012

13 PH81910013

14 PH81910014

15 PH81910015

16 PH81910016

17 PH81910017

18 PH81910018

19 PH81910019

20 PH81910020

21 PH81910021

22 PH81910022

23 PH81910023

24 PH81910024

25 PH81910025

26 PH81910026

27 PH81910027

28 PH81910028

29 PH81910029

30 PH81910030

31 PH81910031

32 PH81910032

33 PH81910033

34 PSB31M

BALL BEARING

CRANKSHAFT

NEEDLE ROLLER BEARING

BEARING COVER GASKET

FLANGE

DETERGENT INJECTOR

INJECTOR SPRING

FLANGE OIL SEAL

INJECTOR BALL

CAP SCREW M8-1.25 X 24

CONNECTING ROD

INJECTION NOZZLE GASKET

INJECTION NOZZLE

PLUNGER PIN

WATER SHOOTING NOZZLE

WATER OUTLET JOINT

PLUNGER ROD

PLUNGER ROD GASKET

WATER CHECKING FLAKE

CERAMIC PLUNGER

WATER OUTLET JOINT GASKET

WATER OUTLET CONE VALVE SPRING

WATER OUTLET CONE VALVE

WATER OUTLET CONE VALVE GASKET

CYLINDER

LOCATING RING

LOCATING RING GASKET

LOCATING RING WATER SEAL

U-PACKING SEAL

CHECK VALVE GASKET

WASHER CHECK VALVE

U-PACKING SEAL SEAT

PRESSURE ADJUSTING HANDLE COVER

CAP SCREW M8-1.25 X 25

HEX NUT M8-1.25

CHECK VALVE STOPPER

SPRING CHECK VALVE

CHECK VALVE BOX

35 PN03M

COMPACTION GASKET

36 PH81910036

37 PH81910037

38 PH81910038

39 PH81910039

40 PH81910040

41 PH81910041

42 PH81910042

PRESSURE ADJUSTING HANDLE

PRESSURE ADJUSTING SEAT

UPPER SPRING WASHER

PRESSURE ADJUSTING SPRING

LOWER SPRING WASHER

WATER RETURN VALVE ROD

VALVE JACKET INNER GASKET

CHECK VALVE COMPACTION CAP

CAP SCREW M6-1 X 53

LOCK WASHER 6MM

80 PSB31M

CAP SCREW M8-1.25 X 25

LOCK WASHER 8MM

81 PLW04M

82 PW01M

FLAT WASHER 8MM

-24-

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Engine Block Parts Breakdown

REF PART #

PH81910103

DESCRIPTION

REF PART #

DESCRIPTION

SEALING PLATE GASKET

SEALING PLATE

103

104

105

106

107

108

109

110

111

112

113

114

115

116

117

118

119

CYLINDER HEAD NUTS (LONG)

CYLINDER HEAD NUTS (SHORT)

CYLINDER HEAD NUT GASKET

CYLINDER HEAD GASKET

OVAL RING GASKET 5.1 X 2.6

CYLINDER HEAD BOLTS LONG

CYLINDER HEAD BOLTS SHORT

ENGINE BLOCK

120

121

122

123

124

125

126

127

128

129

130

131

132

133

135

138

PH81910120

PH81910104

PH81910105

PH81910106

PH81910107

PH81910108

PH81910109

PH81910110

PH81910111

PH81910112

PH81910113

PH81910114

PH81910115

PH81910116

PH81910117

PH81910118

PN01M

PH81910121

PH81910122

PH81910123

PH81910124

PH81910125

PH81910126

PH81910127

PH81910128

PH81910129

PH81910130

PH81910131

PH81910132

PH81910133

PH81910135

PH81910138

THRUST PIECE

FLANGE FACE WITH BOLTS

NEEDLE BEARING

BALL BEARING

CRANKCASE COVER GASKET

BEARING 207

REAR OIL SEAL 35 X 50 X 8

OIL DRAIN PLUG

RETAINING PIN 8 X 12

FUEL PIPE

OIL DRAIN PLUG GASKET

O-RING FOR OIL DIPSTICK

FUEL PUMP STUD

CRANKCASE COVER

INNER HEXAGON PLUG G1/8

FLANGE BOLT M8-1.25 X 33.5

FRONT OIL SEAL 35 X 50 X 10

MAIN BUSHING

FUEL PUMP LONG STUD

FUEL INJECTOR GASKET

OIL DIPSTICK

ALUMINUM PLUG DIAMETER 8 X 8

HEX NUT M6-1

-25-

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Engine Cylinder Head Parts Breakdown

REF PART #

DESCRIPTION

REF PART #

DESCRIPTION

201

202

203

204

205

206

207

208

209

PH81910201

FLANGE BOLT M6-1 X 70

OIL HOLE PLUG

215

216

217

218

219

220

221

222

223

224

225

226

227

228

PH81910215

VALVE GUIDE OIL SEAL

VALVE SPRING WASHER

PIN 4 X 8

PH81910202

PH81910203

PH81910204

PH81910205

PH81910206

PH81910207

PH81910208

PH81910209

PH81910216

PH81910217

PH81910218

PH81910219

PH81910220

PH81910221

PH81910222

PN01M

DECOMPRESSION SHAFT

O-RING 10 X 1.9

DOUBLE ENDED STUD

CYLINDER HEAD

TORSION SPRING

RETAINING PIN 3 X 16

CYLINDER HEAD COVER

CYLINDER HEAD COVER GASKET

ROCKER ARM

DOUBLE ENDED BOLT

INTAKE VALVE

EXHAUST VALVE

HEX NUT M6-1

209-1 PH81910209-1 VALVE ADJUSTING SCREW

PH81910224

PH81910225

PH81910226

PH81910227

PH81910228

FUEL INJECTOR PRESSURE PLATE

FUEL INJECTOR GASKET

FUEL INJECTOR BOLT (LONG)

BREATHER ASSEMBLY

O-RING 12 X 1.9

210

211

212

213

214

PH81910210

PH81910211

PH81910212

PH81910213

PH81910214

ROCKER SHAFT FASTENING BOLT

ADJUSTING VALVE SPACER

VALVE CLIP

VALVE SPRING SEAT

VALVE SPRING

-26-

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Engine Piston and Crank Parts Breakdown

REF PART #

DESCRIPTION

REF PART #

DESCRIPTION

301

302

303

304

305

306

307

308

309

310

311

312

313

PH81910301

PISTON RINGS

314

315

316

317

319

320

321

322

323

324

325

326

327

PH81910314

KEY 6 X 63

PH81910302

PH81910303

PH81910304

PH81910305

PH81910306

PH81910307

PH81910308

PH81910309

PH81910310

PH81910311

PH81910312

PH81910313

PISTON PIN RETAINER CLIP 23MM

PISTON

PH81910315

PH81910316

PH81910317

PH81910319

PH81910320

PH81910321

PH81910322

PH81910323

PH81910324

PH81910325

PH81910326

PH81910327

CRANKSHAFT

PLUG 6 X 8

WRIST PIN

BALANCING SHAFT DRIVING GEAR

FLYWHEEL NUT GASKET

FLYWHEEL NUT

CONNECTING ROD ASSEMBLY

CONNECTING ROD BEARING

BEARING

FLYWHEEL WITH RING GEAR

FUEL PUMP ROD SLEEVE

PUSH ROD

BALANCING SHAFT

KEY 5 X 7

BALANCING SHAFT TIMING GEAR

FLANGE BOLT

TAPPET

KEY 5 X 14

CRANKSHAFT TIMING GEAR

KEY 5 X 12

CAMSHAFT

CAMSHAFT TIMING GEAR

313-1 PH81910313-1 KEY 5 X 14

-27-

H8191 3600 PSI Diesel Pressure Washer

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Engine Fuel Tank Parts Breakdown

REF PART #

DESCRIPTION

REF PART #

DESCRIPTION

401

402

403

404

405

406

407

408

409

412

413

414

415

PH81910401

FLANGE BOLT M8-1.25 X 45

UPPER BRACKET FASTENER

FLAT WASHER 8MM

UPPER TANK BRACKET

INJECTOR

416

417

418

419

420

421

422

423

424

425

426

427

428

PH81910416

HEX NUT M6-1

PH81910402

PW01M

PW03M

FLAT WASHER 6MM

FUEL TANK PETCOCK ASSEMBLY

FLAT WASHER

PH81910418

PH81910419

PH81910420

PH81910421

PH81910422

PH81910423

PH81910424

PH81910425

PH81910426

PH81910427

PH81910428

PH81910404

PH81910405

PH81910406

PH81910407

PH81910408

PH81910409

PH81910412

PH81910413

PH81910414

PH81910415

FUEL PIPE CLAMP

HOSE CLAMP

FUEL HOSE

FUEL FILTER GASKET

FUEL FILTER ASSEMBLY

FUEL INJECTION PUMP

HIGH PRESSURE FUEL PIPE

FUEL CUP FILTER

RUBBER FUEL TANK MOUNT

FUEL TANK

FUEL DRAIN GASKET

FUEL DRAIN PLUG

LOWER TANK BRACKET

FLANGE BOLT M6-1 X 14

FUEL CAP ASSEMBLY

FUEL INJECTOR CAP

-28-

H8191 3600 PSI Diesel Pressure Washer

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Engine Lubrication/Speed Parts Breakdown

��

REF PART #

DESCRIPTION

REF PART #

DESCRIPTION

506

507

508

509

510

511

512

513

514

515

516

517

518

PFB01M

FLANGE BOLT M6-1 X 12

OIL PUMP COVER

O-RING 34.5 X 1.8

OIP PUMP ASSEMBLY

PIN 3 X 6

519

520

521

522

523

524

525

526

527

528

529

530

531

PH81910519

LEVER SHAFT GASKET

BEARING

PH81910507

PH81910508

PH81910509

PH81910510

PH81910511

PH81910512

PH81910513

PH81910514

PH81910515

PH81910516

PH81910517

PH81910518

PH81910520

PH81910521

PH81910522

PH81910523

PH81910524

PH81910525

PH81910526

PH81910527

PH81910528

PH81910529

PH81910530

PH81910531

FORK LEVER ASSEMBLY

WASHER

FUEL CONTROLLER PARTS

HANDLE BRACKET ASSEMBLY

SPEED CONTROL LEVER

FLANGE BOLT M6-1 X 14

FLANGE BOLT M6-1 X 18

LEAD SEAL

FLANGE BOLT M9 X 14

OIL FILTER CLEANING ELEMENT

SEALING RING 20 X 2.65

OIL GUIDE

OIL PUMP DRIVING GEAR

FLY BLOCK PIN

RETURN SPRING 2

FLY BLOCK

RETURN SPRING 1

GOVERNER FORK TAPPET

SPEED CONTROL SPRING

-29-

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Engine Recoil Starter Parts Breakdown

REF PART #

DESCRIPTION

REF PART #

DESCRIPTION

601

602

603

604

605

606

607

608

609

610

611

612

613

614

PH81910601

RECOIL CASE ASSEMBLY

FLANGE BOLT M6-1 X 8

RECOIL STARTER ROPE

RECOIL STARTER HANDLE

FLAT TORSIONAL SPRING

RECOIL REEL

615

616

617

618

619

620

621

622

623

624

625

626

627

PFB01M

FLANGE BOLT M6-1 X 12

STARTER

PH81910602

PH81910603

PH81910604

PH81910605

PH81910606

PH81910607

PH81910608

PH81910609

PH81910610

PH81910611

PH81910612

PH81910613

PN01M

PH81910616

PH81910617

PH81910618

PW03M

RECOIL STARTER COVER

FLANGE BOLT M6-1 X 22

FLAT WASHER 6MM

COLLAR

PH81910620

PH81910621

PH81910622

PH81910623

PH81910624

PH81910625

PH81910626

PH81910627

STARTING CLAW

SHOCK ABSORBER

SHOCK PADS

HELICAL SPRING

TORSIONAL SPRING

STARTING CLAW PLATE

FRICTION PLATE

SHOCK ISOLATOR

COLLAR

PAD

FRICTION PLATE GASKET

SPRING WASHER

WIND LEADING PLATE

FLANGE BOLT M6-1 X 22

HEX NUT M6-1

-30-

H8191 3600 PSI Diesel Pressure Washer

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Engine Air Filter, Muffler, and Fuel Pump

Parts Breakdown

REF PART #

DESCRIPTION

REF PART #

DESCRIPTION

701

702

703

704

705

PH81910701

INTAKE PIPE GASKET

INTAKE PIPE

721

722

723

724

725

731

732

733

734

PH81910721

AIR FILTER SHOCK ABSORBER

COLLAR

PH81910702

PH81910703

PH81910704

PH81910705

PH81910722

PH81910723

PH81910724

PWN02M

AIR CLEANER GASKET

EXHAUST MANIFOLD STUD

FLANGE BOLT M6-1 X 22

AIR FILTER SHOCK ABSORBER

COLLAR

WING NUT M8-1.25

DELIVERY HOLDER

DELIVERY SPRING

DELIVERY GASKET

DELIVERY VALVE

706A PH81910706A AIR FILTER TOP ASSEMBLY

PH81910731

PH81910732

PH81910733

PH81910734

706

707

708

709

710

711

712

713

714

715

716

717

718

719

720

PH81910706

PH81910707

PH81910708

PH81910709

PH81910710

PW01M

AIR FILTER ASSEMBLY

HEX NUT M6-1

AIR FILTER ELEMENT

MUFFLER GASKET

736A PH81910736A FUEL PUMP ASSEMBLY

MUFFLER ASSEMBLY

FLAT WASHER 8MM

736

737

738

739

740

741

742

743

744

746

PH81910736

PH81910737

PH81910738

PH81910739

PH81910740

PH81910741

PH81910742

PH81910743

PH81910744

PN01M

PLUNGER ASSEMBLY

ADJUSTING GASKET

PUMP BODY CONNECTING PLATE

CIRCLIP

PLW04M

LOCK WASHER 8MM

PH81910713

PH81910714

PH81910715

PH81910716

PH81910717

PH81910718

PH81910719

PH81910720

HEX NUT M6-1

FLANGE BOLT M8-1.25 X 14

MUFFLER SCREAN COVER

FLANGE BOLT M6-1 X 14

MUFFLER TAIL PIPE

CONTROL LEVER ASSEMBLY

SPRING SEAT

SLEEVE PIN

FUEL INJECTION PUMP

FUEL INJECTION PUMP SPRING

HEX NUT M6-1

INNER SHOCK SEALING RING

AIR FILTER BOTTOM ASSEMBLY

OUTER SHOCK SEALING RING

-31-

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Engine Electric Start Parts Breakdown

REF PART #

DESCRIPTION

REF PART #

DESCRIPTION

801

802

803

804

805

806

807

PH81910801

BATTERY

808

809

810

811

812

813

814

PH81910808

WIRING HARNESS

FUSE

PH81910802

PN06M

CAP SCREW M5-0.8 X 13

HEX NUT M5-.8

PH81910809

PH81910810

PB14M

STARTER MOTOR

HEX BOLT M10-1.5 X 35

LOCK WASHER 10MM

FLAT WASHER 10MM

BATTERY CABLE

PH81910804

PFB01M

ALTERNATOR ASSEMBLY

FLANGE BOLT M6-1 X 12

VOLTAGE REGULATOR

KEY AND SWITCH ASSEMBLY

PLW06M

PH81910806

PH81910807

PW04M

PH81910814

-32-

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Frame and Hardware Parts Breakdown

REF PART #

DESCRIPTION

REF PART #

DESCRIPTION

901

902

903

904

905

906

907

908

909

910

PH81910901

SPRAY GUN BRACKET

FLAT WASHER 8MM

HEX NUT M8-1.25

911

912

913

914

915

916

917

918

919

PH81910911

15 DEGREE NOZZLE

25 DEGREE NOZZLE

40 DEGREE NOZZLE

CHEMICAL NOZZLE

AXLE

PW01M

PH81910912

PH81910913

PH81910914

PH81910915

PH81910916

PLN09M

PN03M

PH81910904

PH81910905

PH81910906

PH81910907

PH81910908

PH81910909

PH81910910

FRAME ASSEMBLY

HIGH PRESSURE HOSE ASSEMBLY

IN-FEED HOSE ASSEMBLY

IN-FEED FILTER

WHEEL ASSEMBLY

LOCK NUT M12-1.75

O-RING KIT

CHEMICAL HOSE

PH81910918

PH81910919

CHEMICAL FILTER

SPRAY GUN AND WAND ASSEMBLY

0 DEGREE NOZZLE

-33-

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Machine Labels Breakdown

��

REF PART #

DESCRIPTION

REF PART #

DESCRIPTION

1001 PH81911001 MACHINE ID LABEL

1004 PH81911004 HOT SURFACES WARNING LABEL

1005 PH81911005 CARBON MONOXIDE WARNING LABEL

1002 PH81911002 NOZZLE COLOR CHART LABEL

1003 PH81911003 FLAMABLE WARNING LABEL

Safety labels warn about machine hazards and ways to prevent injury. The owner of this machine

MUST maintain the original location and readability of the labels on the machine. If any label is

removed or becomes unreadable, REPLACE that label before using the machine again. Contact

Grizzly at (800) 523-4777 or www.grizzly.com to order new labels.

-34-

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WARRANTY AND RETURNS

Grizzly Industrial, Inc. warrants every product it sells for a period of 1 year to the original purchaser from

the date of purchase. This warranty does not apply to defects due directly or indirectly to misuse, abuse,

negligence, accidents, repairs or alterations or lack of maintenance. This is Grizzly’s sole written warranty

and any and all warranties that may be implied by law, including any merchantability or fitness, for any par-

ticular purpose, are hereby limited to the duration of this written warranty. We do not warrant or represent

that the merchandise complies with the provisions of any law or acts unless the manufacturer so warrants.

In no event shall Grizzly’s liability under this warranty exceed the purchase price paid for the product and

any legal actions brought against Grizzly shall be tried in the State of Washington, County of Whatcom.

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 products.

To take advantage of this warranty, contact us by mail or phone and give us all the details. We will then

issue you a “Return Number,’’ which must be clearly posted on the outside as well as the inside of the

carton. We will not accept any item back without this number. Proof of purchase must accompany the

merchandise.

The manufacturers reserve the right to change specifications at any time because they constantly strive to

achieve better quality equipment. We make every effort to ensure that our products meet high quality and

durability standards and we hope you never need to use this warranty.

Please feel free to write or call us if you have any questions about the machine or the manual.

Thank you again for your business and continued support. We hope to serve you again soon.

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