Honda WDP20X User's Manual
Contents
1. 10 Spark Arrester Service 70 Spark Plug Service 38 Specifications 61 Starting the Engine 23 stopping the Engine 25 25 Normal 25 Storage Preparation 56 suction Hose Connection 21 T Throttle Lever 11 Transporting Your Pump 27 Troubleshooting Engine Will Not Start 54 Pump Will Not Pump 54 W Warranty Service Information 66 Wiring Diagram 64 72 murs Unleaded gasoline with pump octane rating of 86 Fuel yP or higher page 41 page 41 Capacity Hesistor Spark Plug 0 028 0 031 in 0 70 0 80 mm page 38 Before each Check engine oil level page 35 Maintenance First 20 Change engine oil page 34 pago 34 Grease pump connecting rod bearing page 44 QUICK REFERENCE INFORMATION Capacity 0 66 US galons 2 5 SAE 10W 30 API SH or SJ page 35 Capacity Capacity 046 US quarts 0 6 NGK BPR6ES DENSO W20EPR U Idle speed Idle speed 1 400 2150 rpm page 40 Check fuel level page 33 Check air cleaner 36 Check pump hoses and strainer page 43 Refer to maintenance schedule on page 32 page 32 Flush pump chamber page 43 Il I l i Il gel I III I te te ey j2. 35 S5pecifications 62 Starting 23 Stopping 25 Troubleshooting 54 F Fuel Filter Fuel Line 42 Oxygenated 67 Recommendations 41 Refueling 33 Sediment Cup Cleaning 41 Valve Lever 11 INDEX H Head suction Discharge Total 62 Ignition Switch 12 L Liquid Pumping Fiecommendations 6 M Maintenance Safety 31 Maintenance Schedule 32 O Alert System 12 Oil Engine Change 34 Level Check 35 Recommendations 35 P Pre Operation Checks 13 Publications 68 Pump Clappets 45 Diaphragm 47 Gear 44 Performance 64 Performance Curve 64 Priming 22 Specifications 62 Troubleshooting 54 H Recoil Starter 12 INDEX S Safety Important Safety Information 6 Maintenance 31 Safety Label Locations 8 Safety Message Definitions 2 Serial Numbers
3. Pump hoses and strainer Check lO J Pump connecting red bearing Grease 44 x Check level E loj Pumpdiaphragm _ inspect 47 Nutsandbolls Checktoque _ Every 2 years 2 Replace if necessary x Emission related items Replace the paper element only 1 Service more frequently when used in dusty areas Replace if damaged 2 These items should be serviced by an authorized Honda water pump dealer unless the owner has the proper tools and is mechanically proficient See the Honda WDP20X WDPS30X pump shop manual 3 The spark arrester is an optional part and does not come standard 4 Forprofessional commercial use log hours of operation to determine proper maintenance intervals 32 MAINTENANCE FUEL Fuel tank capacity 0 66 US gal 2 5 2 Refuel in a well ventilated area with the engine stopped If the engine has been running allow it to cool Refer 41 for fuel recommendations and page 67 for information about oxygenated fuels Never refuel the pump inside a building where gasoline fumes may reach flames or sparks Keep gasoline away from appliance pilot lights barbecues electric appliances power tools etc spilled fuel is not only a fire hazard it causes environmental damage Wipe up spills immediately amp WARNING Gasoline is highly flammable a
4. 2 5 the fuel valve ON 3 Is the choke lever in the closed position for cold engine or open position for a warm engine 4 s fuel reaching the carburetor To check place a suitable container under the float bowl and remove the drain screw Turn fuel valve ON Fuel should flow out freely Spark Plug 1 is the ignition switch ON 12 2 Make sure the oil level is correct 35 3 Remove the spark plug and ciean gap or replace as necessary page 38 4 f the engine still will not start take the pump to an authorized Honda servicing dealer PUMP WILL NOT PUMP ls the strainer clogged page 21 Is there a restriction or foreign material in the pump casing Are the suction hose clamps installed securely 15 suction hose connector sealing washer installed Is the suction hose or suction hose nipple face damaged 1s the suction head too high Does the pump require priming page 22 Is debris under clappet valves or are valves damaged page 45 Is the diaphragm torn 10 If the pump still does not pump take the pump to an authorized Honda servicing dealer 54 CO Or Fr C S STORAG This chapter tells you how to protect your pump and ensure that it will start easily when you want to use it again E zh ee nr 56 uu E 56 PUG EI 57 Adding fuel stabilizer to extend fuel storage life 57 Drain
5. 69 Maintenance 69 SPARK ARRESTER SERVICE optional equipment 70 65 ADDITIONAL INFORMATION HONDA PUBLICATIONS These publications will give you additional information about maintaining your pump You may order them from your Honda water pump dealer Shop Manual This manual covers complete maintenance and overhaul procedures It is intended to be used by a skilled technician Parts Catalog This provides a complete pictorial parts listing WARRANTY SERVICE INFORMATION Honda power equipment dealership personnel are trained professionals They should be able to answer any question you may have If you encounter a problem that your dealer does not solve to your satisfaction please discuss it with the dealership s management The Service Manager or General Manager can help Almost all problems are solved in this way if you are dissatisfied with the decision made by the dealership s management contact the Honda Power Equipment Customer Relations Office You can write to American Honda Motor Co Inc Power Equipment Division Customer Relations Office 4475 River Green Parkway Duluth Georgia 30096 2565 Or telephone 770 497 6400 When you write or call please give us this information Model and serial number see page 10 Name of dealer who sold the pump to you Name and address of dealer who services your pump Date of purchase Your name address and telep
6. Equipment iig Owner s Manual Diaphragm Pump WDP20X WDP30X TT manual to your computer dt l Lowe ixl perm TET EI Hr T m LI Ta A gt A eee Cu XU o s LAG dA A L za eee dl e 998 American Honda Motor Co Inc All Rights Reserved amp WARNING A amp A The engine exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm This owner s manual is considered a permanent part of your diaphragm pump It must be available to all operators of the pump and should remain with the pump if resold The information and specifications in this publication were in effect at the time of approval for printing American Honda Motor Co Inc reserves the right to discontinue or change specifications or design at any time without notice and without incurring any obligation whatever No part of this publication may be reproduced without written permission INTRODUCTION Congratulations on your selection of a Honda diaphragm pump We are certain you will be pleased with your purchase of one of the finest pumps on the market We want to help you get the best results from your new pump and to operate it safely This manual contains the information on how to do that please read it carefully As you read this manual you wil
7. position CRANK ARM CONNECTING i HOD 10 Remove bolts and the lower pump case using a 19 mm wrench Remove the connecting rod and diaphragm assembly LOWER CASE BOLT 4 DIAPHRAGM ASSEMBLY WASHER 8 NUT 4 48 MAINTENANCE 10 If the diaphragm is to be T NL reused mark diaphragm and 9 diaphragm locking flanges With a 19 mm wrench DIAPHRAGM remove the four nuts securing the connecting rod to the lower flange Remove the diaphragm For reassembly note shoulder on top of LOWER diaphragm _ FLANGE Heassembly During reassembly note the following WASHER 4 SHOULDER Apply several drops of Hondalock 2 or equivalent thread lock to bolt threads To prevent pump case and or diaphragm damage follow torque sequence shown below Torque Start in one corner increasing the amount or torque 1 8th to 1 4 turn each time around until the specified torque is achieved Pump case bolts 35 ft lb 47 Nem 4 8 kg m Diaphragm flange nuts 35 ft lb 47 Nem 4 8 kg m Connecting rod bolt 40 ft Ib 54 N m 5 5 kg m The pump case and or diaphragm may become damaged if the torque sequence is not followed 49 MAINTENANCE 1 Position diaphragm between connecting rod flange and lower flange then install nuts and washers Note diaphragm shoulder on top See page 49 for tightening torque DIM 4 WASHER 4 DIAPHRAGM DIAPHRAGM SHOULDER x LOWER FLANGE
8. 2 Apply NLGI 2 general purpose grease to connecting rod bearing 3 Rotate crank arm to bottom by pulling the recoil starter Install diaphragm and connecting rod into pump case then install connecting rod with mark made during disassembly facing out 4 Install connecting rod with hardware shown below and torque connecting rod bolt to 40 ft lb 54 N m 5 5 kg m CRANK FIBER ARM WASHER WASHER INS BOLT X D fy 4 x LL ome WASHER 50 MAINTENANCE 5 Pull recoil starter slowly until diaphragm pulls up against upper case stops UPPER UPPER CASE CASE STOP 4 JS i b lt DIAPHRAGM Crank arm should be approximately at the angle shown below CHANK ARM 6 Install lower case making sure the diaphragm is centered and not pinched between the case stops Tighten hardware following torque procedure on page 49 7 If removed install clappet valves Refer 45 8 Install pump handle and springs 9 Check gear box oil level and fill if necessary Refer to page 44 10 Run and test pump for correct operation 51 52 TROUBLESHOOTING This chapter tells you what to check for if you encounter problems with your pump ENGINE WILL NOT START PUGH 54 Shark PUMP WILL NOT PUMP 53 TROUBLESHOOTING ENGINE WILL NOT START Fuel 1 Is there enough fuel in the fuel tank page 33
9. Familiarize yourself with the pump and its operation before you begin pumping Know what to do in case of emergencies Be sure of what you are pumping This pump is designed to pump only non potable water muddy water and water containing solids 14 BEFORE OPERATION IS YOUR PUMP READY TO GO For your safety and to maximize the service life of your equipment it Is very important to take a few moments before you operate the pump to check its condition Be sure to take care of any problem you find or have your servicing dealer correct it before you operate the pump A WARNING Improperly maintaining this pump or failing to correct a problem before operation could cause a malfunction in which you could be seriously injured Always perform a preoperation inspection before each operation and correct any problem Exhaust gas contains poisonous carbon monoxide Avoid inhalation of exhaust gas Never run the engine in a closed garage or confined area To prevent fire hazards keep the pump at least 3 feet 1 meter away from building walls and other equipment during operation Do not place flammable objects close to the engine Before beginning your preoperation checks be sure the pump is ona level surface and the ignition switch is in the OFF position Check the General Condition of the Pump Look around and underneath the pump for signs of oil or gasoline leaks Remove any excessive dirt or debris especially ar
10. OFF position 3 Turn the fuel valve to the OFF position 4 f the pump is not going to be used again for the rest of the day or is going to be stored for a long period of time refer to 55 procedures on properly storing your pump OFF After each use drain the pump chamber and flush with fresh water 25 26 TRANSPORTING This chapter explains how to load and carry your pump safely BEFORE LOADING LOADING AND UNLOADING 27 TRANSPORTING BEFORE LOADING When transporting the pump be sure to keep it upright If the pump is tilted or overturned fuel may spill from the tank which can result in a fire hazard Allow the engine to cool before transporting the pump 1 Turn the ignition switch to the OFF position 2 Turn the fuel valve to the OFF position 3 Drain the pump chamber refer 43 LOADING AND UNLOADING Have two people lift the pump or use a hoist connected to the lifting bracket to load the pump on and off the transport vehicle Position the pump so it is level on the transport vehicle Tie the pump down with rope or straps Keep the tie down rope or straps away from the controls and carburetor 20 MAINTENANCE This chapter explains when and how to perform routine inspection service and adjustments for do it yourself maintenance More difficult maintenance tasks should be done by your dealer Your dealer is best equipped and staffed to provide
11. all clappet valve tabs are positioned correctly 11 Apply several drops of Hondalock 2 or equivalent thread lock to stud threads Handtighten nuts then torque evenly to 20 ft Ib 27 2 8 kg m 12 After tightening nuts insert a screwdriver into each port and check clappet valve operation Clappets should operate freely and should seal when released f a clappet does not operate properly reinstall clappet and recheck 13 Run pump and check for leaks 46 MAINTENANCE Pump Diaphragm Disassembly 1 Disconnect spark plug cap from the spark plug refer to page 38 2 Drain the fuel tank refer to page 42 for fuel tank draining E pos 3 Flush pump chamber refer to page 43 4 Lift suction side of pump and Kas allow all water to drain out discharge fitting 5 Remove hardware securing pump handle and springs FLAT WASHER 4 sasina LOCK WASHER 4 SPRINGS 2 NUT 4 6 Connect a hoist to the lifting bracket or have an assistant help lift pump off handle and onto a workbench Position pump on a workbench as shown 47 MAINTENANCE Hemove connecting rod plastic cover Use a 17 mm wrench and remove the bolt securing the connecting rod to the crank arm Wipe the rod surface clean and use a felt tip marker to mark the outside of the connecting rod for reassembly FIBER es SS BOLT h 9 Pull the recoil starter to rotate the connecting rod to the down
12. ignition switch allows the LABEL OIL ALERT operator to start and stop the engine switch positions OFF To stop the engine ON To start and run the d engine IGNITIO SWITCH Oi Alert System The Oil Alert system is designed to prevent engine damage caused by an insufficient amount of oil in the crankcase Before the oil level in the crankcase can fall below a safe limit the Oil Alert system will automatically shut down the engine the ignition switch will remain in the ON position If the engine stops and will not restart check the engine oil level see page 35 before troubleshooting in other areas Recoil Starter To start the engine pull the recoil starter grip lightly until resistance is felt then pull briskly Do not allow the starter grip to snap back against the engine Return the starter grip gently to prevent damage to the starter RECOIL STARTER GRIP 12 BEFORE OPERATION This chapter tells you how to prepare your pump and yourself before you begin pumping Check the General Condition of the Pump 15 Check the Suction and Discharge Hoses 16 Check the Engine 16 13 BEFORE OPERATION ARE YOU READY TO GET STARTED Your safety is your responsibility A little time spent in preparation will significantly reduce your risk of injury Knowledge Head and understand this manual Know what the controls do and how to operate them
13. on the pump Safety Messages preceded by a safety alert symbol AN and one of three words DANGER WARNING or CAUTION These signal words mean DANGER You WILL be KILLED or SERIOUSLY HURT if you don t follow instructions amp WARNING You CAN be KILLED or SERIOUSLY HURT if you don t follow instructions CAUTION You CAN be HURT if you don t follow instructions Safety Headings such as IMPORTANT SAFETY INFORMATION e Safety Section such as PUMP SAFETY e Instructions how to use this pump correctly and safely This entire book is filled with important safety information please read it carefully CONTENTS Turn to the beginning of each chapter for a complete list of subjects Important information about some specific hazards and what you can do to prevent injury Identification of components and information about how the controls work BEFORE OPERATION How to prepare your pump and yourself before yon begin pumping i OPERATION Starting and stopping the engine safe pumping practices and pumping tips TRANSPORTING How to load and carry your pump safely MAINTENANCE When and how to perform routine inspection service and adjustments to keep your pump in good operating condition How to protect your pump from rust and corrosion and ensure that it will start easily when you want to use it again SPECIFICATIONS specifications dimensions capacities and other technical in
14. BPR6ES DENSO W20EPR U Maximum governed speed 3 000 3 150 rpm TUNEUP Spark Plug Gap TM HN Carburetor kile Speed 1 400 17 rpm See page 40 Intake 0 15 0 02 mm Exhaust 0 20 0 02 mm No other adjustments needed See shop manual Valve Clearance cold Other Specifications 63 SPECIFICATIONS PUMP PERFORMANCE CURVE This graph shows the relationship between the pump discharge capacity and the total dynamic head As you increase the total head the discharge capacity will decrease Total Head fft 40 D 10 20 a0 40 650 BD 70 50 Discharge Capacity gpm Based on clear water at sea level WIRING DIAGRAM rese IGNITION IGNITION 5 2 CONTROL SWITCH MODULE HE ADDITIONAL INFORMATION This chapter contains additionai information Honda publications available to you and tells you how to contact us if you have a question or a warranty repair problem HONDA PUBLICATIONS shop 66 Parts Catalog ccc eee ee wees 66 WARRANTY SERVICE INFORMATION OXYGENATED FUELS EMISSION CONTROL SYSTEM INFORMATION 68 Source of Emissions 68 The U S and California Clean Air Acts 68 Tampering and 0 68 Problems that May Affect Emissions 68 Replacement Parts
15. TE ce ILLLLLLLLLLLLILLLLLLLLLLLLLL L Pi tT tT I I j gL TTT TT ETT TPT tT eee eet ye tt ey ee LL Ti TTT yet try yt Pe TSEL amp ere ee et ee fest
16. cess dirt or blow compressed air not exceeding 30 psi 207 kPa through the filter element from the inside out Never try to brush the dirt off brushing will force dirt into the paper fibers Replace the paper element if it is excessively dirty or damaged Foam element cleaning Wash SOLVENT the element in a solution of L household detergent and warm water then rinse thoroughly or wash in nonflammable solvent Allow element to dry thoroughly Soak the element in clean engine oil and squeeze THOROUGHLY 15 out the excess oll Excess oil will restrict air flow through the foam filter element and may transfer to the paper filter element soaking and clogging it ENGINE OIL 5 Wipe dirt from the inside of the air cleaner housing and cover Be careful to prevent dirt from WING NUT entering the air duct that leads to the carburetor AIR CLEANER 6 Install the foam element over COVER the paper element and install the assembled air filter Secure WING NUT the air filter with the inner wing nut Make sure the rubber washer is place under the x filter elements T FOAM FILTER ELEMENT 7 Install the air cleaner cover RUBBER and secure with the outer wing WASHER nut AIR CLEANER HOUSING 37 MAINTENANCE Spark Plug Service Recommended spark plugs NGK BPRGES DENSO W20EPR U NOTICE Spark plugs of the wrong size or incorrect heat range can cause engine damage For good p
17. chamber cap WATER PRIMING FILLER HOLE E wu SUCTION HOSE AIR CUSHION CHAMBER CAP 22 OPERATION STARTING THE ENGINE 1 Turn the fue valve to the ON FUEL VALVE N position ki 2 Move the choke lever to the CHOKE LEVER CLOSED position Do not use the choke if the engine is warm or the ambient temperature is high CLOSED 3 Turn the ignition switch to the ISNITION ON position 4 Move the throttle lever slightly to the left 23 OPERATION 5 Pull the starter grip lightly until resistance is felt then pull it briskly Return the starter grip slowly back to the engine to prevent damage to the starter STARTER GRIP 6 As the engine warms up CHOKE LEVER gradually move the choke lever to the OPEN position 7 Set the throttle at the desired speed to produce the best THROTTLE LEVER pumping conditions The pump output can be controlled by adjusting the throttle lever to the desired position At FULL throttle position the pump will deliver the highest output volume Moving the throttle toward the IDLE position will decrease the output volume of the pump 24 OPERATION STOPPING THE ENGINE Emergency IGNITION NC To stop the engine in an SWITCH L emergency turn the ignition switch to the OFF position Normal 1 Move the throttle lever fully to the right to the IDLE position 2 Turn the ignition switch to the
18. commendations Oil is a major factor affecting performance and service life Use 4 stroke automotive detergent oil SAE 10W 30 is recommended for general use Other viscosities shown in the chart may be used when the average temperature in your area is within the recommended range The SAE oil viscosity and service classification are in the API label on the oil container Honda recommends that you use API SERVICE category SH or SJ oil with the ILSAC starburst certification mark displayed on the container 35 MAINTENANCE Air Cleaner Service A dirty air filter will restrict air flow to the carburetor reducing engine performance If you operate the pump in very dusty areas clean the air filter more often than specified in the MAINTENANCE SCHEDULE Operating the engine without an air filter or with a damaged air filter will allow dirt to enter the engine causing rapid engine wear This type of damage is not covered by the Distributors Limited Warranty 1 Unscrew the outer wing nut and remove the air cleaner cover 2 Remove the inner wing nut and both air filter elements 3 Separate both air filter elements and carefully check them for holes or tears and replace as necessary OUTER WING NUT AIR CLEANER COVER WING NUT PAPEH FILTER ELEMENT FOAM FILTER ELEMENT RUBBER WASHER 36 MAINTENANCE 4 Clean the filters Paper element Tap the element lightly several times on a hard surface to remove ex
19. e engine outdoors and let it warm up to normal operating temperature 2 Move the throttle lever to the slowest position 3 Using a screwdriver turn the throttle stop screw to obtain the standard idle speed Standard Idle Speed 1 400 750 rpm THROTTLE STOP SCREW Carburetor Modification for High Altitude Operation At high altitude the standard carburetor air fuel mixture will be too rich Performance will decrease and fuel consumption will increase A very rich mixture will also foul the spark plug and cause hard starting High altitude performance can be improved by specific modifications to the carburetor If you always operate the pump above 5 000 feet 1 500 meters have an authorized Honda servicing dealer perform this carburetor modification Even with carburetor modification engine horsepower will decrease about 3 5 for each 1 000 foot 300 meter increase in altitude The effect of altitude on horsepower will be greater than this if no carburetor modification is made When the carburetor is modified for high altitude operation the air fuel mixture will be too lean for low altitude use Operation at altitudes below 5 000 feet 1 500 meters with a modified carburetor may cause the engine to overheat and result in serious engine damage For use at low altitudes have an authorized Honda servicing dealer return the carburetor to original factory specifications 40 MAINTENANCE Fuel Recommendations Use u
20. e will cause pump case and or diaphragm damage To prevent pump damage take the necessary precautions to prevent the discharge hose from getting compressed or collapsed During freezing weather always drain the pump case after use If water is left in the pump case during freezing weather the pump case will break 20 OPERATION PUMP PREPARATION Suction Hose Connection Use a commercially available hose hose connector and hose clamps Hose must be the same size or larger than the suction port To prevent hose from collapsing use a hose that is reinforced with a noncollapsible wall or braided wire construction Keep pump as close as possible to the pumping liquid Avoid hose bends and sharp turns Pump performance is best when the pump is not far above the liquid level and the hose is kept straight Self priming time is also proportional to the suction hose length Using a longer suction hose will increase the self priming time Tighten the hose connector to the suction hose with a hose clamp to prevent air leakage and loss of suction Verify that the connector sealing washer is installed and in good condition A loosely connected suction hose will reduce pump performance and self priming ability DISCHARGE SEALING HOSE WASHER SUCTION HOSE CLAMP COUPLING w The strainer provided with the pump should be attached to the end of the suction hose as shown Always install t
21. echanism to cause the engine to operate outside its design parameters Problems that may Affect Emissions If you are aware of any of the following symptoms have your engine inspected and repaired by your servicing dealer Hard starting or stalling after starting Rough idie e Misfiring or backfiring under load Afterburning backfiring Black exhaust smoke or high fuel consumption 68 ADDITIONAL INFORMATION Replacement Parts The emission control systems on your new Honda engine were designed built and certified to conform with EPA and California emission regulations We recommend the use of genuine Honda parts whenever you have maintenance done These original design replacement parts are manufactured to the same standards as the original parts so you can be confident of their performance The use of replacement parts that are not of the original design and quality may impair the effectiveness of your emission control system A manufacturer of an aftermarket part assumes the responsibility that the part will not adversely affect emission performance The manufacturer or rebuilder of the part must certify that use of the part will not result in a failure of the engine to comply with emission regulations Maintenance Follow the maintenance schedule on page 32 Remember that this schedule is based on the assumption that your machine will be used for its designed purpose Sustained high load or high temperature op
22. en the engine is running Be sure that anyone who operates the pump receives proper instruction Do not let children operate the pump Keep children pets and bystanders away from the area of operation Pump Operation Do not pump drinking water Pumps are designed to only pump non potable water muddy water and water containing solids Pumping flammable liquids such as gasoline or fuel oils can result in a fire or explosion causing serious injury Pumping sea water beverages acids chemical solutions or any other liquid that promotes corrosion can damage the pump Operate pump on a level surface If engine is tilted fuel may spill Refuel With Care Gasoline is extremely flammable and gasoline vapor can explode Refuel outdoors in a well ventilated area with the engine stopped and the pump on a level surface Do not overfill the fuel tank Never smoke near gasoline and keep other flames and sparks away Always store gasoline in an approved container Make sure that any spilled fuel has been wiped up before starting the engine PUMP SAFETY Hot Exhaust The muffler becomes very hot during operation and remains hot for a while after stopping the engine Be careful not to touch the muffler while it is hot Let the engine cool before transporting the pump or storing it indoors To prevent fire hazards keep the pump at least 3 feet 1 meter away from building walls and other equipment during operation Do not place flam
23. ential of this pump you need a complete understanding of its operation and a certain amount of practice with its controls Head this chapter completely before operating the pump Take time to familiarize yourself with the controls and how they operate The small amount of time spent in familiarization will reward you with greater efficiency and reduced risk SAFE OPERATING PRECAUTIONS PUMP PREPARATION Suction Hose Connection 21 Discharge Hose Connection 22 PRIMING ispum wo dex ar d 3 22 STARTING THE ENGINE STOPPING THE ENGINE ME 25 MeWHIEEETLESTUEUEITCCITRERES OLOR EEE ETE OL 25 17 OPERATION SAFE OPERATING PRECAUTIONS To safely realize the full potential of this pump you need a complete understanding of its operation and a certain amount of practice with its controls Before operating the pump for the first time please review the IMPORTANT SAFETY INFORMATION on page and the chapter tilted BEFORE OPERATION For you safety avoid starting or operating the engine in an enclosed area such as a garage Your engine s exhaust contains poisonous carbon monoxide gas which can collect rapidly in an enclosed area and cause illness or death Do not pump drinking water Pump only non potable water muddy water and water containing solids Pumping flammable liquids such as gasoline or fuel oils can result in a fire or explo
24. eration or use in unusually wet or dusty conditions will require more frequent service 69 ADDITIONAL INFORMATION SPARK ARRESTER SERVICE optional equipment The spark arrester must be serviced every 100 hours to keep it functioning as designed 1 Use a soft brush to remove Inspect the spark arrester for Install the spark arrester and Allow the engine to cool the remove the two 8 mm nuts and remove the muffler from the cylinder head Remove the four 5 mm screws from the muffler protector and remove the muffler protector Remove the 4 mm screw from the spark arrester and remove the spark arrester from the muffler MUFFLER SCREW 5 mm 4 PROTECTOR SCREW 4 mm NUTS 8 mm 2 SPARK ARRESTEH MUFFLER carbon deposits from the spark arrester screen Be careful not to damage the spark arrester screen breaks and holes Replace it if necessary the muffler in the reverse order of disassembly SPARK ARRESTEH SCREEN 70 A Air Cleaner Clean 37 Inspect 36 C Carburetor Idle Speed Adjustment 40 High Altitude Operation 40 Choke 11 Component Identification 10 D Description of Controls 11 Discharge Hose Connection 22 E Emission Control System Information 68 Engine Oil Change 34 Oil Level Check
25. erformance the spark plug must be properly gapped and free of deposits Allow the engine to coo before servicing the spark plug Disconnect the spark plug cap SPARK PLUG WRENCH and remove any dirt from around the spark plug area 2 Use a 13 16 in 21 mm spark ON ye Ne d oh plug wrench to remove the F 3 Visually inspect the spark plug Discard it if the insulator is cracked or chipped Clean the spark plug with a wire brush if it 2 spark plug SN a is to be reused SPARK PLUG CAP 4 Measure the plug gap with a suitable gauge 0 028 0 031 in N Correct as necessary by 0 70 0 80 mm carefully bending the side electrode Plug gap 0 028 0 031in SEALING 0 70 0 80 mm ASHER 38 MAINTENANCE 5 Check that the spark plug washer is in good condition and thread the spark plug in by hand to prevent cross threading 6 After the spark plug is seated tighten with a spark plug wrench to compress the washer If installing a new spark plug tighten 1 2 turn after the spark plug seats to compress the washer If reinstalling a used spark plug tighten 1 8 1 4 turn after the spark plug seats to compress the washer loose spark plug can overheat and damage the engine Overtightening the spark plug can damage the threads in the cylinder head 7 Reconnect the spark plug cap 39 MAINTENANCE Carburetor Adjustment 1 Start th
26. estricted To avoid pump damage do not restrict shut off or momentarily stop the fluid flow from the discharge hose A rigid pipe should never be used with a diaphragm pump Flexibte hoses must be attached to the pump The suction hose must be noncollapsible Never use hoses that are smaller than the suction or discharge fittings Example 2 inch pump requires a 2 inch inside diameter or greater hose and 3 inch pump requires a 3 inch inside diameter or greater hose Using rigid pipes or hoses that are too small will cause severe damage to the diaphragm pump Due to pump movement during operation connecting a rigid pipe to the pump will cause pump damage Always use flexible suction and discharge hoses to prevent pump damage 19 OPERATION When water being pumped contains solids the solids may get lodged under the clappet valves which will prevent the clappet valves from closing completely To maintain maximum pump performance the discharge hose should angle upward as it exits the pump DISCHARGE HOSE if the discharge hose must run across a roadway the hose should cross the roadway perpendicular to traffic flow Also heavy boards should be placed next to the hose so the motor vehicle weight does not shut off the discharge as vehicles cross over the hose Driving over a discharge hose while the pump is running or even possibly when the pump is stopped will most likely cause pump case failure Collapsing the discharge hos
27. formation ADDITIONAL INFORMATION Additional information Honda publications available to you and how to contact us if you have a question or a warranty repair problem QUICK REFERENCE INFORMATION inside back cover PUMP SAFETY This chapter explains what you need to know to operate your diaphragm pump safely IMPORTANT SAFETY INFORMATION Operator 6 PUMP ODGAUCNs saco sonas sete edie coed howd ds 6 Refuel With 6 Hot Exa ies oan ane h hee eee 7 Carbon Monoxide Hazards 7 SAFETY LABEL LOCATION PUMP SAFETY IMPORTANT SAFETY INFORMATION Honda WDP20X and WDP30X pumps not designed to pump drinking water Pump only non potable water muddy water and water containing solids Other uses can result in injury to the operator or damage to the pump and other property Most accidents can be prevented if you follow all instructions in this manual and on the pump The most common hazards are discussed below along with the best way to protect yourself and others Operator Responsibility It is the operator s responsibility to provide the necessary safeguards to protect people and property Know how to stop the pump quickly in case of emergency Understand the use of all controls and connections For your safety and the safety of others keep ail shields in place wh
28. he strainer on the end of the suction hose before pumping The strainer will prevent debris from entering the pump that can cause clogging diaphragm and or other pump damage 21 OPERATION Discharge Hose Connection Use a commercially available hose hose connector and hose band A short large diameter hose will provide lower fluid friction and improve pump efficiency long or small diameter hose will increase fluid friction and reduces pump output Never use a hose size smaller than the discharge port diameter If a discharge hose is used that has a smaller inside diameter than the port size the pump case may be damaged To avoid pump damage always use the correct size hose Tighten the hose clamp to prevent the hose from disconnecting under high pressure Pump Priming Pump priming is not required if the vertical distance from water to the pump suction head is less than 14 teet on WDP20X or 16 feet for a WDP30X The suction head can be increased to 21 feet for the WDP2OX or 24 feet for the WDP30X by priming the pump To prime the pump remove the air cushion chamber cap Grasp the suction hose next to the suction fitting and lift the hose about 1 foot off the ground Pour about 1 gallon of water into the pump case through the air cushion chamber Lifting the suction hose will help to ensure the water goes into the pump housing and not out the suction hose Lay the hose back on the ground and reinstall the air cushion
29. her service station or switch to another brand of gasoline Fuel system damage or performance problems resulting from the use of an oxygenated fuel containing more than the percentages of oxygenates mentioned above are not covered under warranty 67 ADDITIONAL INFORMATION EMISSION CONTROL SYSTEM INFORMATION Source of Emissions The combustion process produces carbon monoxide oxides of nitrogen and hydrocarbons Control of hydrocarbons and oxides of nitrogen is very important because under certain conditions they react to form photochemical smog when subjected to sunlight Carbon monoxide does not react in the same way but it is toxic Honda utilizes lean carburetor settings and other systems to reduce the emissions of carbon monoxide oxides of nitrogen and hydrocarbons The U S and California Clean Air Acts EPA and California regulations require all manufacturers to furnish wtitten instructions describing the operation and maintenance of emission control systems The following instructions and procedures must be followed in order to keep the emissions from your Honda engine within the emission standards Tampering and Altering Tampering with or altering the emission control system may increase emissions beyond the legal limit Among those acts that constitute tampering are Removal or alteration of any part of the intake fuel or exhaust systems e Altering or defeating the governor linkage or speed adjusting m
30. hese serial numbers when ordering parts and when making technical or warranty inquiries see page 66 Frame serial number WDP20 30 Engine serial number GX120 10 CONTROLS DESCRIPTION OF CONTROLS You will use these controls every time you operate your diaphragm pump Throttle Lever THROTTLE LEVER The throttle lever controls the engine speed Moving the throttle lever fully to the left gives maximum engine speed Moving the throttle lever fully to the right returns the engine to idle speed THROTTLE The pump output can be controlled by adjusting the throttle lever to the desired position At maximum throttle position the pump will deliver the highest output volume Moving the throttle toward the idle position will decrease the output volume of the pump Choke Lever CHOKE LEVER The choke is used to provide an ae enriched mixture when starting a cold engine Move the choke to the CLOSED position when starting a cold engine If the engine is warm leave the choke in the OPEN position CLOSED Fuel Valve Lever FUEL VALVE LEVER The fuel valve lever is used to NM stop flow of fuel from the fuel tank to the carburetor The fuel valve lever must be in the ON position J P to start and operate the engine Y zm Turn the fuel valve lever to the 3 em aga ON Z OFF position when the pump is Vh QE not in use 11 CONTROLS Ignition Switch n OIL ALERT The
31. hone number A detailed description of the pump application and problem 66 ADDITIONAL INFORMATION OXYGENATED FUELS Some conventional gasolines are being blended with alcohol or an ether compound These gasolines are collectively referred to as oxygenated fuels To meet clean air standards some areas of the United States and Canada use oxygenated fuels to help reduce emissions If you use an oxygenated fuel be sure it is unleaded and meets the minimum octane rating requirements Before using an oxygenated fuel try to confirm the fuel s contents some states provinces require this information to be posted on the pump The following are the EPA approved percentages of oxygenates ETHANOL ethyl or grain alcohol 1095 by volume You may use gasoline containing up to 10 ethanol by volume Gasoline containing ethanol may be marketed under the name Gasohofl MTBE methyl tertiary butyl ether 15 by volume You may use gasoline containing up to 1596 MTBE by volume METHANOL methyl or wood alcohol 5 by volume You may use gasoline containing up to 5 methanol by volume as long as it also contains cosolvents and corrosion inhibitors to protect the fuel system Gasoline containing more than 5 methanol by volume may cause starting and or performance problems may also damage metal rubber and plastic parts of your fuel system If you notice any undesirable operating symptoms try anot
32. ing the Fuel Tank and Carburetor 58 ENGNG ON vvv 58 Air Clana P 59 55 STORAGE STORAGE PREPARATION The following steps will help to keep rust and corrosion from impairing vour pump s function and appearance and will make the engine easier to start when you use the pump again Cleaning Engine Wash the engine by hand and be careful to prevent water from entering the air cleaner or muffler Using a garden hose or pressure washing equipment can force water into the air cleaner Water in the air cleaner will soak the filter and can enter the carburetor or engine causing damage Water contacting a hot engine can cause damage If the engine has been running allow it to cool for at least half an hour before washing Pump 1 Flush the pump chamber see page 43 2 Wash the pump with a garden hose or other low pressure equipment Keep water away from controls and all other places that are difficult to dry as water may promote rust 3 After washing Remove as much standing water as possible with a dry cloth Start the engine outdoors and let it run until it reaches normal operating temperature to evaporate any water remaining on the engine 4 Stop the engine and allow it to cool 5 After the pump is clean and dry touch up any damaged paint and coat other areas that may rust with a light film of oil Lubricate controls with a silicone spray lubricant 96 STORAGE Fuel Gasoline will
33. l find information preceded by a symbol That information is intended to help you avoid damage to your pump other property or the environment We suggest you read the warranty policy to fully understand its coverage and your responsibilities of ownership The warranty policy is a separate document that should have been given to you by your dealer When your pump needs scheduled maintenance keep in mind that your authorized Honda servicing dealer is specially trained in servicing Honda pumps and is supported by the parts and service divisions of American Honda Your Honda dealer is dedicated to your satisfaction and will be pleased to answer your questions and concerns Dest Wishes Power Equipment Division American Honda Motor Co Inc 1998 American Honda Motor Co inc All Rights Reserved INTRODUCTION A FEW WORDS ABOUT SAFETY Your safety and the safety of others are very important And using this pump safely is an important responsibility To help you make informed decisions about safety we have provided operating procedures and other information on labels and in this manual This information alerts you to potential hazards that could hurt you or others Of course it is not practical or possible to warn you about all the hazards associated with operating or maintaining a pump You must use your own good judgment You will find important safety information in a variety of forms including Safety Label
34. mabie cbjects close to the engine Carbon Monoxide Hazards Exhaust gas contains poisonous carbon monoxide Avoid inhalation of exhaust gas Never run the engine in a closed garage or confined area PUMP SAFETY SAFETY LABEL LOCATION The label shown here contains important safety information Please read it carefully This label is considered a permanent part of your pump So if the label comes off or becomes hard to read contact your authorized Honda pump dealer for a replacement amp WARNING DG NOT PUMP FLAMMABLE LIQUIDS Pump can explodes and you can be seriously hurt or killed Follow the Owner s Manual instructions carefully CONTROLS This chapter shows you the locations of controls and other important parts of your pump and tells you how the controls work Ignition Switch 12 Oil Alert 12 giis SLANE rm 12 CONTROLS COMPONENT IDENTIFICATION PUMP GREASE FITTING ACCESS PLUG FRAME SERIAL NUMBER THROTTLE LEVER SUCTION PORT CHOKE LEVER FUEL VALVE LEVER OIL FILLER CAP DIPSTICK STARTER GRIP ENGINE DISCHARGE IGNITION SWITCH SERIAL NUMBER PORT FUEL FILLER CAP LIFTING BRACKET AIR CLEANER AIR CUSHION CHAMBER CAP priming filler cap FRAME STRAINER PES OIL DRAIN PLUG 2 inch WDP2OX 3 inch WDP30X Record the frame and engine serial numbers in the space below You will need t
35. nd deteriorates over time causing hard starting If the cylinder was coated with oil during storage preparation the engine may smoke briefly at startup This is normal 60 SPECIFICATIONS This chapter gives you dimensions capacities and other technical information 61 SPECIFICATIONS DIMENSIONS AND WEIGHT Model _ WDP20X WDP3OX Description code WZBZ 32 5 x 23 4 x 25 0 in Length x Width x Height B26 x 594 x 635 mm Dry Weight 120 Ibs 54 4 kg ENGINE DESIGN AND PERFORMANCE Model X120K 1X2 Engine type 4 stroke overhead valve single cylinder Displacement 7 2 cu in 119 cc bore x stroke 2 4 x 1 7 in 60 x 42 mm jransistorized magneto PUMP Diaphragm with spring type connecting rod Suction port diameter thread type i 50 8 mm NPT 3 in 76 2 mm NPT Discharge port diameter thread type Maximum total head 50 ft 15 m Maximum suction head dry 14 ft 4 3 m 16 ft 4 8 m priming pump housing 60 gpm 227 Neoprene with cast iron inserts GEAR BOX Pump operating frequency 73 strokes min 43 1 Pump stroke 2 56 65 0 mm 2 77 in 70 4 mm Gear box oil capacity Gear box oil type 80W 980 GLS gear oil 62 SPECIFICATIONS MAINTENANCE Fuel Unleaded gasoline with a pump Engine SAE 10W 30 API SH or SJ Gear box oil SAE BOW 90 GL5 gear Spark plug type
36. nd explosive You can be burned or seriously injured when handling fuel e Stop the engine and keep heat sparks and flame away s Handle fuel only outdoors e Wipe up spills immediately 1 Remove the filler cap and check the fuel level 2 Refill the tank if the fuel level is low Do not fill above the shoulder of the fuel filler neck FILLER CAP 3 After refueling make sure the tank filler cap is closed properly and securely 33 MAINTENANCE ENGINE MAINTENANCE Engine Oil Change Drain the oil while the engine is warm Warm oil drains quickly and completely 1 Remove the oil filler cap drain bolt and sealing washer Drain the oil into a suitable container OIL FILLER CAP CONTAINER SEALING WASHER DTA 2 Reinstall the drain bolt and sealing washer Tighten the plug securely Improper disposal of engine oii can be harmful to the environment _ If you change you own oil please dispose of the used oil properly Put itin a sealed container and take it to a recycling center Do not discard it in a trash bin or dump it on the ground 3 Fill with the recommended oil to the top of the oil filler neck see page 35 Engine oil capacity 0 6 US qt 0 6 2 Using nondetergent oil can shorten the engine s service life and using 2 stroke oil can damage the engine 34 MAINTENANCE 4 Screw in the oil filler cap dipstick securely OIL TOP OF OIL FILLEH NECK Engine Oil Re
37. nleaded gasoline with a pump octane rating of 86 or higher This engine is certified to operate on unleaded gasoline Unleaded gasoline produces fewer engine and spark plug deposits and extends exhaust system life Never use stale or contaminated gasoline or oil gasoline mixture Avoid getting dirt or water in the fuel tank Occasionally you may hear light spark knock or pinging metallic rapping noise while operating under heavy loads This is no cause for concern If spark knock or pinging occurs at a steady engine speed under normal load change brands of gasoline If spark knock or pinging persists see an authorized Honda servicing dealer Running the engine with persistent spark knock or pinging can cause engine damage Running the engine with persistent spark knock or pinging ts misuse and the Distributor s Limited Warranty does not cover parts damaged by misuse For oxygenated fuel information refer to page 67 Sediment Cup Cleaning 1 Turn the fuel valve to the OFF FUEL VALVE position 2 Remove the sediment cup and O ring and wash them in nonflammable solvent Dry them thoroughly 3 Install the O ring and sediment cup and tighten securely 4 Turn the fuel valve to the ON position and check for leaks SEDIMENT CUP 41 MAINTENANCE Fuel Filter Fuel Line 1 Turn the fuel valve to the OFF position 2 Remove the carburetor drain screw and gasket 3 Turn the fuel valve to the ON positi
38. ns 2 After adding a fuel stabilizer run the engine outdoors for 10 minutes to be sure that treated gasoline has replaced the untreated gasoline in the carburetor 3 Stop the engine and turn the fuel valve to the OFF position Drain the pump chamber 97 STORAGE Draining the Fuel Tank and Carburetor 1 Remove the carburetor drain screw with a 10 mm wrench or screwdriver and drain the fuet system into an approved gasoline container A WARNING Gasoline is highly flammable and explosive You can be burned or seriously injured when handling fuel Stop the engine and keep heat sparks and flame away e Handle fuel only outdoors e Wipe up spills immediately 2 Turn the fuel valve to the ON position This will allow fuel in the fuel tank to drain through the carburetor bowl FUEL VALVE GASKET DRAIN SCHEW um j m _ e i l 3 Reinstall the drain screw and gasket Engine Oil Change the engine oil see see page 34 see page 34 58 STORAGE Air Cleaner Check the air filter and clean as necessary see page 36 Engine Cylinder 1 Remove the spark plug see Pour a tablespoon HOLE ARROW NOTCH 5 10 cc of clean engine oil into the cylinder Slowly pull the recoil starter rope a few times to distribute the oil in the cylinder Reinstall the spark plug 2 Pull the starter rope slowly until resistance is felt Continue pulling slowly until the arrow notch on the
39. o help you properly care for your pump the following pages include a maintenance schedule routine inspection procedures and simple maintenance procedures using basic hand tools Other service tasks that are more difficult or require special tools are best handled by professionals and are normally performed by a Honda technician or other qualified mechanic The maintenance schedule applies to normal operating conditions If you operate your pump under severe conditions such as sustained high load or high temperature operation or use in unusually wet or dusty conditions consult your servicing dealer for recommendations applicable to your individual needs and use Remember that an authorized Honda servicing dealer knows your pump best and is fully equipped to maintain and repair it To ensure the best quality and reliability use only new genuine Honda parts or their equivalents for repair and replacement Maintenance replacement or repair of the emission control devices and systems may be performed by any engine repair establishment or individual using parts that are certified to EPA standards 30 MAINTENANCE MAINTENANCE SAFETY Some of the most important safety precautions follow However we cannot warn you of every conceivable hazard that can arise in performing maintenance Only you can decide whether or not you should perform a given task Failure to properly follow maintenance instructions and p
40. on and drain the fuel into a suitable container Disconnect the fuel line at the carburetor Remove the two 6 mm nuts and one 6 x 25 mm bolt securing the fuel tank Remove the fuel tank 4 Disconnect the fuel line and unscrew the fuel filter from the tank Inspect the fuel line and replace if cracked or worn 5 Clean the filter with nonflammable solvent and check that the filter screen is not damaged Replace as necessary 6 Clean the inside of the tank with nonflammable solvent and dry thoroughly 7 Place the O ring on the filter and install the filter in the tank Tighten the filter to the specified torque 17 in ib 20 kg cm 2 Nem 8 Install the fuel line on the fuel filter and install the tank on the engine 9 After the tank is installed add fuel and check for leaks 42 Torque GASKE FUEL VALVE DRAIN SCREW O RING FUEL LINE MAINTENANCE PUMP SERVICE Pump Chamber Flushing With the engine stopped the pump case should be flushed after each use to prevent sediment from building up in the case 1 Disconnect the suction and discharge hoses 2 Insert a garden hose into the suction side of the pump Turn on the water and flush sediment out the side SUCTION SIDE z t T Los gt N WP GARDEN HOSE 3 After flushing lift the suction side of the pump and allow water to drain out the discharge side Pump Hoses and Strainer Make sure bo
41. ontact with the diaphragm diaphragm will be damaged DRAIN BOLT Pump Gear Box Oil Check With the pump on a level surface remove the filler bolt The oil level should be just below the filler bolt hole 44 MAINTENANCE Pump Clappet Valves 1 Disconnect spark plug cap from the spark plug refer to page 38 m _ 2 Turn the fuel valve lever to the 8 Lam off positon refer to Z SNL E Ur y kaws ya MJ I 1 3 Flush pump chamber refer to one page 43 4 Lift suction side of pump and allow all water to drain out the discharge fitting 5 Use a 19mm wrench and remove the nuts and flat washers from both the suction and discharge ports Remove both ports 7 The clappet valves are directional so when removing the valves note of the water flow direction CLAPPET VALVE discharge side CLAPPET VALVE suction side FLAT WASHER 4 8 Inspect ports case sealing surfaces and clappets for damage If clappets are worn torn or damaged replace them If the case sealing surface is damaged and cannot be cleaned an optional wear plate is available from your Honda water pump dealer 45 MAINTENANCE 9 install the clappet valves over the studs On the discharge side the flat side of the valve should face the housing On the suction side the flat side of the valve should face the port CLAPPET VALVE TABS 10 Install both ports making sure
42. ound the engine muffler and recoil starter Look for signs of damage Check that all nuts bolts screws hose connectors and clamps are tightened Keep all shields in place while operating the pump 15 BEFORE OPERATION Check the Suction and Discharge Hoses Check the general condition of the hoses Be sure the hoses are in serviceable condition before connecting them to the pump Remember that the suction hose must be of reinforced construction to prevent hose collapse Check that the sealing washer in the suction hose connector ts in Asan creen Check that the hose connectors and clamps are securely installed see pages 21 amp 22 Check that the strainer is in good condition and is installed on the suction hose see page 21 Check the Engine Check the oil level see page 35 To avoid the inconvenience of an unexpected shutdown by the Oil Alert system always check the engine oil level before startup Check the air filter see page 36 A dirty air filter will restrict air flow to the carburetor reducing engine and pump performance Check the fuel level see page 33 Starting with a full tank will help to eliminate or reduce operating interruptions for refueling Remember be sure to correct any problem you find or have your servicing dealer correct it before you operate the pump 16 OPERATION This chapter tells how to operate your pump safely and effectively To safely realize the full pot
43. oxidize and deteriorate in storage Old gasoline will cause hard starting and it leaves gum deposits that clog the fuel system If the gasoline in your pump s engine deteriorates during storage you may need to have the carburetor and other fue system components serviced or replaced The length of time that gasoline can be left in your fuel tank and carburetor without causing functional problems will vary with such factors as gasoline biend your storage temperatures and whether the fuel tank is partially or completely filled The air in a partially filled fuel tank promotes fuel deterioration Very warm storage temperatures accelerate fuel deterioration Fuel deterioration problems may occur within a few months or even less if the gasoline was not fresh when you filled the fuel tank The Distributor s Limited Warranty does not cover fuel system damage or engine performance problems resulting from neglected storage preparation You can extend fuel storage life by adding a fuel stabilizer that is formulated for that purpose or you can avoid fuel deterioration problems by draining the fuel tank and carburetor Adding fuel stabilizer to extend fuel storage life Fill the fuel tank with fresh gasoline If only partially filled air in the tank will promote fuel deterioration during storage If you keep a container of gasoline for refueling be sure that it contains only fresh gasoline 1 Add fuel stabilizer following manufacturer instructio
44. recautions can cause you to be seriously hurt or killed Always follow the procedures and precautions in this owner s manual Safety Precautions Make sure the engine is off before you begin any maintenance or repairs This will eliminate several potential hazards Carbon monoxide poisoning from engine exhaust Be sure there is adequate ventilation whenever you operate the engine Burns from hot parts Let the engine and exhaust system cool before touching Injury from moving parts Do not run the engine unless instructed to do so Read the instructions before you begin and make sure you have the tools and skills required To reduce the possibility of fire or explosion be careful when working around gasoline Use only a nonffammable solvent not gasoline to clean parts Keep cigarettes sparks and flames away irom all fuel related parts 31 MAINTENANCE MAINTENANCE SCHEDULE qi REGULAR SERVICE PERIOD 4 g P 22 5 EE S2 g Perform at every o o 9o w ro o t gt O ITEM indicated month or U Es se eg operating hour interval JEE mi Dej zo 8 whichever comes first gjeo 309l 20 G m lt Check level Spark plug Spark arrester aptionat equipment Idle speed Adj a Valve clearance Check Adjust fs Fuel tank and fiter Clean Pump chamber Flush fo
45. sion causing serious injury Pumping sea water beverages acids chemical solutions or any other liquid that promotes corrosion can damage the pump 18 OPERATION Due to the pump diaphragm reciprocating motion pump assembly and hoses will move up and down and side to side during pumping This may cause the pump to walk or move around while pumping Depending on the surface conditions pump hose length and other factors it may be necessary to anchor the pump to limit pump movement During operation observe pump movement and anchor the pump frame as necessary To anchor the pump attach anchored tie down straps to the pump lift handles While pumping the suction hose may move out of the pumping source and the discharge hose may move away from the pumping destination It may also be necessary to anchor hose ends to prevent hose movement If there is no one to monitor the pump during operation it is advisable to anchor the pump to prevent unexpected movement Pump total dynamic discharge head is 50 feet Total dynamic discharge head includes static discharge head discharge vertical height and head loss due to friction Head loss makes it impractical for the static discharge head to exceed 25 feet Pumping to a static discharge head greater than 25 feet can damage pump This diaphragm pump should never be run with the discharge output shut off or restricted Pump case failure may result if the discharge output is shut off or r
46. starter pulley aligns with the hole on the recoil starter Heturn the starter grip gently This will close the valves so moisture can not enter the engine cylinder 99 STORAGE PLACING IN STORAGE If your pump will be stored with gasoline in the fuel tank and carburetor it is important to reduce the hazard of gasoline vapor ignition Select a well ventilated storage area away from any appliance that operates with a flame such as a furnace water heater or clothes dryer Also avoid any area with a spark producing electric motor or where power tools are operated If possible avoid storage areas with high humidity because that promotes rust and corrosion Unless all fuel has been drained from the fuel tank leave the fuel valve in the OFF position to reduce the possibility of fuel leakage Place the pump on a level surface Tilting can cause fuel or oil leakage With the engine and exhaust system cool cover the pump to keep out dust A hot engine and exhaust system can ignite or melt some materials Do not use sheet plastic as a dust cover A nonporous cover will trap moisture around the pump promoting rust and corrosion REMOVAL FROM STORAGE Check your pump as described in the BEFORE OPERATION chapter of this manual If the fuel was drained during storage preparation fill the tank with fresh gasoline if you keep a container of gasoline for refueling be sure that it contains only fresh gasoline Gasoline oxidizes a
47. th hoses are not STRAINER torn or cracked It is especially important that there are no tears in the suction hose Tears or air leaks on the suction side will SEALING prevent the pump from priming WASHER properly Inspect the suction hose sealing washer to make sure it is in good condition Also inspect the strainer to be 5 HOSE sure it is not plugged or damaged 43 MAINTENANCE Grease Pump Connecting Rod 1 Remove plastic access plug m 2 Disconnect spark plug cap and pull recoil starter until grease fitting is below access opening 3 Wipe grease fitting clean to prevent dirt from getting into bearing Using a manual grease gun pump one or two Te Lay strokes of NLGI 2 general purpose grease into bearing 4 Reinstall access plug securely Pump Gear Box Oil Change 1 Run engine for 10 minutes to FILLER warm up gear box oil Warm oil BOLT GASKET FILLER BOLT drains quickly and completely 2 Shut off engine remove the drain bolt and drain the gear oil from the gear box 3 Replace drain bolt washer and reinstall the drain bolt Fill gear box to bottom of the filler bolt Dispose of used oil property di see page 34 d Gear box oil Capacity 0 8 qt 0 8 2 Type SAE 80W 90 GL5 gear DRAIN oil BOLT GASKET Avoid getting gear oil on diaphragm Drain oil into a drain pan to prevent oil from running down pump case onto diaphragm If gear oil comes in c
48. the level of service and safety you and your pump deserve Engine Oil Change ie i indi 34 Engine Oil 35 Air Cleaner Service 36 Spark Plug Service 38 Carburetor 40 Carburetor Modification for High Altitude Operation 40 Fuel 41 Sediment Cup 0 41 Fuel Filter Fuel 42 PUMP SERVICE Pump Chamber Flushing 43 Pump Hoses and 43 Grease Pump Connecting Rod 44 Pump Gear Box Oil Change 44 Pump Gear Box Oil 44 Pump Clappet Valves 45 Pump 47 Dia Ol P D 47 Jo Oil P 49 29 MAINTENANCE THE IMPORTANCE OF MAINTENANCE Good maintenance is essential for safe economical and trouble free operation It will also help reduce pollution A WARNING Improper maintenance or failure to correct a problem before operation can cause a malfunction in which you can be seriously hurt or killed Always follow the inspection and maintenance recommendattons and schedules in this owner s manual T
Download Pdf Manuals
Related Search