operation, service, and repair manual for tsurumi ept3
Contents
1. 1 5 Performance Curves Refer to the performance curves for the pumping capacity of NPT3 series trash pumps 100 GROUP T EPT3 80HA PERFORMANCE 5 60 EPT3 100HA MODELS EPT3 50HA a 40 EPT3 80HA EPT3 100HA 20 0 0 100 200 300 400 500 600 QUANTITY g p m Introduction Page 3 Tsurumi s Operation Service and Repair Manual 100 80 INDIVIDUAL 60 MODEL EPT3 50HA PERFORMANCE I a 40 MODEL EPT3 50HA 20 0 100 200 300 400 500 600 QUANTITY 9 a GE g MODEL EPT3 80HA z MODEL 5 EPT3 80HA 100 200 300 400 500 600 QUANTITY g p m INDIVIDUAL 5 l MODEL MODEL EPT3 100HA EPT3 100HA E 100 200 300 400 500 600 QUANTITY g p m Page 4 Introduction Tsurumi s Operation Service and Repair Manual NE Engine Air 1 Filter Discharge Fitting fr Suction Fitting Vibration Isolation Mounts SES p Casing wees 2 SEN BLASS Clamping Knobs PUMP END Tubular Fuel Tank Frame Honda Engine Recoil Starter Engine Controls ENGINE END Figure 1 Key Features of the Trash Pump Introduction Page 5 Tsurumi s2. 6 21 Operating Controls sc eds Eso Ea Ke REC E ex d al a d 6 2 2 Check the Engine Qil Level i2 radon ER Re ER Re Pe ow eRe 6 23 HECK ENGNG Fuel sianida Qux horny acea uox bcd ura dc s bho 8 2 4 Check Fuel Level 86 Oa E UXOR 8 2 5 JPre Start CHECKS 2 dake doa a E RC ECCL ATTE 9 2 6 Starting and Operating the Engine 9 2 7 the Trash PUMP cesta dex eg ES RE ae EY Ex ex 10 2 8 Stopping the Trash Pump 10 DOES Do 10 3 Troubleshooting ea 11 3 14 Troubleshooting Charts yun Rr e dew an caw 11 4 Maintenance 12 4 1 Maintenance Schedule Rt REB 8 9 REOR Rog 12 H2 Changing Engine Oll eye cups ob eds pee 13 4 3 Air Cleaner Service 14 44 Sediment Cup Cleaning ces nronu Errar 14 4 5 Cleaning and Adjusting Spark Plug 14 4 6 Trash Pump Exploded Vie
3. CAUTIONS indicate that there is a possibility of equipment damage if instructions are not followed NOTES are used in procedures to provide additional or supplemental information to make the proce dure easier or more efficient WARNING The trash pump is designed to give safe and dependable service when operated according to the instructions in the technical manual provided with the trash pump Do not operate the trash pump before you have read and understand the instructions and the engine manufacturer s manual Failure to do so could result in personal injury or equip ment damage Introduction Page 1 Tsurumi s Operation Service and Repair Manual 1 3 Safety Precautions WARNING e IN ORDER TO ASSURE SAFE AND EFFICIENT OPERATION OF THE TRASH PUMP OPERA TOR S SHOULD READ AND COMPLY WITH THE FOLLOWING SAFETY PRECAUTIONS Do not operate the trash pump near gasoline or gaseous fuels because of the potential dan ger from explosion or fire Do not fill the fuel tank with fuel while the engine is running Be careful not to spill fuel during refueling If fuel is spilled wipe it off and let it dry before starting the engine Do not smoke or use open flame near the fuel tank Do not place flammable materials near the trash pump Be careful not to place fuel matches gunpowder oily cloths straw trash or any other combustibles near the trash pump Do not operate the trash pump inside a room cave tunnel o
4. Cia a TIRE STEP 1 AXEL AND WHEEL INSTALLATION 1 Elevate pump or generator with a block to allow enough clearance to assemble axle and wheels Place the block between the ground and the bottom of the pump or generator frame 2 Place the axle assembly A beneath the frame B and secure using two short U bolts Ref No 8 and four nuts Ref No 11 on each side of the frame along with axle assembly left Ref No 2 See Fig 3 In total the axle assembly will require both the right Ref No 1 and left Ref No 2 axle assemblies four short U bolts Ref No 8 and eight nuts Ref No 11 to complete the assembly of the axle to the pump or generator frame Note The axle assembly is an adjustable sliding axle system It allows for minimum widths of 13h and maximum widths of 21h Engine driven pumps or generators with frame dimensions smaller or larger than those noted above will not fit properly with this wheel mounting kit Do not use this wheel mounting kit unless pump or genera tor frame dimensions are within the range state above 3 There are eight holes in each axle assembly Ref No 1 and 2 Use the four holes furthest apart as possible for your installation to secure each axle assembly Ref No 1 and 2 to the pump or generator frame The axle assembly Ref No 1 and 2 may be positioned in different locations along the tubular pump or generator frame rails than the position shown below to accommodate as
5. PUMP MOUNTING DETAIL ENGINE 34 MOUNTING DETAIL Page 26 Replacement Parts Tsurumi s Operation Service and Repair Manual Parts Listing Model ETP3 80HA Trash Pump Ref Part Ref Part No Number Description Qty No _ Number Description Qty 1 1200 201 150 Casing STH 80 1 28 203 100 130 Washer Spring 2 2 200201250 Cover Casing 1 M8 SUS Tsurumi Logo 29 1200 500 230 Handle Drain 2 3 1200 210 170 Impeller 1 Cover 4 200210690 Casing Inner 1 30 gr gis 1 5 821 007 Liner 31 19W0 3906000 Plain Washer M6 4 Gy 182008 1 32 200101170 Black 1 Apu UM i 200900520 Mount Anti Vibration 4 NPT 3 34 1001 024 Nut Spring M8 4 8 821 038 Fitting Pipe 1 Mount to Frame 3B NPT NPT 35 203 000 130 Bolt Hex 2 gu x c eddie ae M10 X 40 P 2 Ri Engine to Mount D 36 203 200 070 Spring M10 2 Engine to Mount 12 122 030 13 O Ring P 30 ie 37 203000660 Bolt Hex 2 13 200 500 110 Plug Assembly 1 M10 X 25 P 2 Priming Pump to Mount 14 801 015 Valve Check 1 38 1001 043 Shim Impeller AR 15 1200 800 060 O Ring G 240 1 24 2 x 20 0 x 0 3T 16 1200 800 240 O Ring W1517 46 1 1001 044 Shim Impeller AR 17 203000081 Hex 3 24 2 x 20 0 x 0 6T M10 X 30 17 P 2 1001 045 Shim Impeller AR 18 203 000 600 Bolt Flange 4 24 2 x 20 0 x 1 0T 50 39 13310 2 2
6. 2 Changing Engine Oil A initial oil change should be performed after the first twenty 20 hours of use Thereafter change oil every 100 hours B Before changing the oil check for a suitable way to dispose of the used oil Do not pour it down sewer drains onto garden soil or into open streams Refer to your local zoning and environmental regulations for disposal and handling requirements C Drain the oil while the engine is still warm to assure rapid and complete draining D Remove the oil filler dipstick cap and drain plug Allow oil to drain from the engine refer to Figure 4 1 OIL FILLER CAP Figure 4 1 Draining Engine Oil E Install the drain plug and tighten it securely F Refill with the recommended oil refer to Figure 2 2 G After filling with oil check the oil level H When oil reaches the upper limit install the oil filler dipstick cap Figure 4 2 NOTE Engine oil capacity 1 1 liters 1 16 U S Quart OIL FILLER CAP DIPSTICK UPPER LIMIT Figure 4 2 Checking Oil Level Maintenance Page 13 Tsurumi s Operation Service and Repair Manual 4 3 Air Cleaner Service WARNING Never use gasoline or low flash point solvents for cleaning the air cleaner element A fire or explosion could result A dirty air cleaner will restrict airflow to the carburetor To prevent degraded engine operation service the air cleaner regularly Service more frequently when operating the engine
7. D Set the ON OFF switch to ON the ON OFF switch is mounted on the recoil shroud E Move the throttle lever slightly to the left Pull the starter grip lightly until resistance is felt then pull briskly NOTE Do not allow the starter grip to snap back against the engine Return it gently to prevent damage to the starter engine warms up gradually move the choke lever to the OPEN position 2 7 Using The Trash Pump A Connect suction and discharge hoses Make sure suction hose is fitted with a strainer B Remove priming plug from top of pump and fill chamber with water C Operate the engine at idle speed for 3 to 5 minutes D After engine warm up move the throttle lever to the operating speed 2 8 Stopping The Trash Pump A Move the throttle lever fully to the right B Set the ON OFF switch to OFF C Turn the fuel valve to the OFF position 2 9 Oil Alert A The oil alert sensor detects the lowering of the oil level in the crankcase and automatical ly stops the engine when the oil level falls below the predetermined level 1 When the engine stops automatically check the oil level Refill engine oil to the upper level and restart the engine 2 Ifthe engine does not start by usual starting procedures check the oil level Page 10 Operating Instructions Tsurumi s Operation Service and Repair Manual TROUBLESHOOTING The troubleshooting tables below can be used as a guide to isol
8. EPT3 100HA Also provided are parts listings that pro vide part number description and quantity The item numbers shown on the illustrations correspond with the item numbers in the facing parts listing 6 2 Ordering Parts Order replacement parts from Tsurumi America Inc 845 North Dillon Drive Wood Dale IL 60191 Tel 1 888 878 7864 Fax 1 630 766 6445 E mail info tsurumiamerica com Replacement Parts Page 23 Tsurumi s Operation Service and Repair Manual Exploded View Model EPT3 50HA Trash Pump PUMP END 4 PUMP CASING PUMP MOUNTING DETAIL ENGINE amp 34 MOUNTING DETAIL Page 24 Replacement Parts Tsurumi s Operation Service and Repair Manual Parts Listing Model ETP3 50HA Trash Pump Ref Part Ref Part No Number Description Qty No _ Number Description Qty 1 200 201 140 Casing STH 50 1 27 203000 650 Bolt Hex Socket 2 2 200 201 240 Cover Casing 1 M8 X 20 SUS Tsurumi Logo 28 203 100 130 Washer Spring 2 3 821 004 Impeller 1 M8 SUS 4 200210810 Casing Inner 1 1200 500 230 Drain 2 3 Liner 1 30 203000530 Bolt Hex 4 6 521 008 Seal Mechanical 1 M6 X 25 SUS 2 In 3 In Sic 31 19 0 3906000 Plain Washer M6 4 a ius valve 1 32 200101160 Black 1 8 521 038A Fitting Pipe 1 33 1200 900 520 Mount Anti Vibration 4 2
9. TIRE SPRING NUT BOLT M8 20 NUT 8 3 Safety Guidelines This manual contains information that is very important to know and understand This information is provided for SAFETY and to PREVENT EQUIPMENT PROBLEMS To help recognize this information observe the following symbols Danger indicates an DANGER imminently hazardous situation which if not avoided will result in death or serious injury Warning indicates a A WARNING potentially hazardous situation which if not avoided COULD result in death or injury Caution indicates a situ CAUTION ation which if not avoid ed MAY result in minor or moderate injury Notice indicates impor A NOTICE tant information that if not followed may cause damage to equipment 1 Read product manual carefully prior to wheel kit assembly to pump generator frame Proper assembly and installation to pump or generator pro vides carefree service 2 Know the typical limitations and poten tial hazards associated with operating and transporting gasoline engine driven pump or generator equipment A DANGER Never run the pumps or generator in an enclosed area Pump or generator should only be operated in well ventilated areas Engines produces exhaust gas containing odorless and poisonous carbon monoxide gas Provide adequate ventilation and pre vent fire hazards by U BOLT HANDLE LEFT WITH GRIP H
10. TsuRUMI PUMP OPERATION SERVICE AND REPAIR MANUAL FOR TSURUMI EPT3 SERIES TRASH PUMPS MODELS EPT3 50HA EPT3 80HA EPT3 100HA LIMITED WARRANTY TSURUMI MANUFACTURING CO LTD TSURUMI warrants to the original end purchaser during the warranty period every new TSURUMI pump or product to be free from defects in material and workmanship under normal use and service when properly installed used and maintained in accor dance with Tsurumi s Operation Service and Repair Manual for a period of two years from the date the unit was first installed or twenty six months from the date of shipment by TSURUMI to wholesaler whichever comes first TSURUMI S sole obligation under this warranty is to repair or replace at TSURUMI S option with new or remanufactured parts any part s that fail or that are found to be defective during the warranty peri od No allowance will be made for shipping charges damages labor or other charges due to failure repair or replacement This warranty does not apply to any TSURUMI product that has been disassembled without prior approval of TSURUMI nor does it apply to any product that has been subjected to misuse neglect alteration misapplication accident or act of God TSURUMI assumes no responsibility for compliance with any regulations codes standards or ordi nances applicable to the installation location operation or maintenance of its products No other
11. in extremely dusty areas NOTE Never run the engine without the air cleaner Rapid engine wear will result from contaminants such as dust and dirt being drawn through the carburetor and into the engine 4 4 Sediment Cup Cleaning WARNING Gasoline is extremely flammable and is explosive under certain conditions Do not smoke or allow open flames or sparks in the area A Turn the fuel valve to OFF refer to Figure 2 1 B Remove the sediment cup and O ring Wash both parts in nonflammable or high flash point solvent C Wipe the sediment cup and O ring dry then reinstall WARNING After installing sediment cup check for leaks and make sure the area is free of resid ual fuel spills or seepage before starting the engine D Set the fuel shutoff valve Figure 2 1 to ON Check for leaks 4 5 Cleaning and Adjusting Spark Plug Recommended spark plugs BPR6ES W20EPR U NIPPONDENSO A To ensure proper engine operation the spark plug must be properly gapped and free of deposits B Remove the spark plug cap C Clean any dirt from around the spark plug base D Use proper size spark plug wrench to remove the spark plug WARNING 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 E Visually inspect the spark plug Discard it if the insulator is cracked or chipped Clean the spark plug
12. warranty expressed or implied is authorized by or applicable to the seller No person agent or dealer is authorized to enlarge upon this warranty TSURUMI expressly disclaims liability for consequential or incidental damages or breach of expressed or implied warranty and any implied warrant of fitness for a particular purpose and merchantability shall be limited to the duration of the expressed warranty Some states do not allow limitations on the duration of an implied warranty so the above limitation or exclusion may not apply to you Some states do not allow the exclusion or limitation of incidental or consequential damages so the above limitation of exclusion may not apply to you This warranty gives you specific legal rights and you may also have other rights which vary from state to state Tsurumi Manufacturing Co Ltd TABLE OF CONTENTS Section Title Page 1 Introduction 1 1 1 Using Your Tsurumi Operation Repair and Service Manual 1 1 2 JPrecautlons 13 tha nian xe pee eae Baked ced ee ees 1 Safety Precautions oH eRe om os eee eae RA S eS 2 1 4 Specifications Key Features 3 15 PenOnnance vt aN EROR c8 Ga redi 3 Operating Instr cllofiS poe ROS o
13. with a wire brush if it is to be reused Page 14 Maintenance F 3 Tsurumi s Operation Service and Repair Manual Measure the plug gap with a feeler gauge Adjust the gap as necessary by bending the side electrode refer to Figure 4 3 The gap should be 0 7 0 8 mm 0 028 0 031 inch as shown 44 0 7 0 8 2 0 028 0 031 in 4 6 Trash Pump Exploded Views A Exploded views of the trash pump components are provided in the MAINTENANCE sec tion for parts identification purposes The item numbers numbers in parentheses correspond with the item numbers in the parts list illustrations located in the REPLACEMENT PARTS section 4 7 Description of the Mechanical Seal A The mechanical seal 6 is a two part seal The seal consists of a fixed element and a rotat ing element The fixed element is installed in the center bore of the pump casing The fixed element is sealed between the seal and the center bore that is provided by a strip of sealant on the outside diameter of the seal The rotating element is installed in the center bore of the impeller The rotating element consists of a silicone carbide mating ring and a close fitting rubber cushion Water is used as an assembly aid when installing the cushion and mating ring 4 8 Replacement of Mechanical Seal WARNING THE SHIPPING WEGHT OF THE MODEL EPT3 SERIES PUMPS RANGES FROM 80 160 POUNDS TO AVOID PERSONAL INJURY USE AN OVERHEA
14. 20 Pin Special Orientation Make sure tab on check valve is at zero degrees at top Figure 4 7 Replacement of Check Valve Maintenance Page 21 Tsurumi s Operation Service and Repair Manual STORAGE 5 1 Procedures for Storing Pump WARNING To avoid severe burns or fire hazards let the engine cool before transporting it or storing it indoors When transporting the pump turn the fuel shutoff valve to the OFF position and keep the engine level to prevent fuel spillage Fuel vapor or spilled fuel may ignite A following procedures should be followed before storing your pump for periods of 6 months or longer 1 Carefully drain fuel from the fuel tank gasoline left in the fuel tank will eventually dete riorate making engine start difficult 2 Remove the carburetor float chamber and also drain the carburetor 3 Change engine oil 4 Check for loose bolts and screws tighten if necessary 5 Clean pump thoroughly with oiled cloth Spray with preservative if available NEVER USE WATER TO CLEAN PUMP 6 Pull starter handle until resistance is felt leaving handle in that position 7 Store pump in a well ventilated low humidity area Page 22 Storage Tsurumi s Operation Service and Repair Manual REPLACEMENT PARTS 6 1 Introduction This section provides exploded view illustrations that show the replacement parts for Tsurumi Trash Pumps Models EPT3 50HA EPT3 80HA and
15. 630 Crankshaft 1 19 1501 006 oe 4 40 Honda GX240 8 0 HP 1 20 1821 034 crea T 2 AR As Required quantity determined at assembly 24 1821 014 Rivet _12 2 Plug assembly 11 includes O ring 10 22 1821 013 Bolt Cover M16 2 ae Priming plug assembly 13 includes O ring 12 23 1821 016 Holder Casing 2 Th Crankshaft 39 has special metric thread Order Cover Tsurumi replacement crankshaft 39 not Honda 24 821 015 Knob M16 2 Contact Honda distributor for Honda engine parts 25 203 000 630 Bolt Hex Socket 3 26 1203 100 110 Wine pun 3 Items prefixed with a dash are not illustrated M6 SUS 27 203 000 650 Bolt Hex Socket 2 M8 X 20 SUS Replacement Parts Page 27 Tsurumi s Operation Service and Repair Manual Exploded View Model ETP3 100HA Trash Pump PUMP END 4 PUMP CASING 33 ENGIN PUMP MOUNTING DETAIL ENGINE p MOUNTING DETAIL Page 28 Replacement Parts Tsurumi s Operation Service and Repair Manual Exploded View Model EPT3 100HA Trash Pump Ref Ref Part Number Description Qty No Number Description Qty 1 200201160 Casing STH 100 1 28 203100130 Washer Spring 2 2 200201250 Cover Casing 1 M8 SUS Tsurumi Logo 29 200 500 230 Handle Drain 2 3 200210500 Impeller 1 Cover 4 200210510 Casing Inner 1 30 203 000530 Bolt Hex 4 5 11021 007 Li 1 MG X 29 SUS m
16. ANDLE RIGHT WITH GRIP U BOLT FOR HANDLE LONG FOR AXLE ASSY SHORT DANGER Operate the pump generator on a level surface to prevent fuel spills Before installation WARNING ensure that there are no fluids in the pump generator or engine prior to the wheel kit installation Engine oil and gasoline should be properly drained from the engine Ensure that there is no gas in the fuel tank and or carburetor bowl Drain all water from the pump housing Draining all fluids from the engine and pump or generator will eliminate the hazards from fluid spills Keep children and pets away from he installation work site A CAUTION Ensure that the wheel kit contains the appropriate parts See Fig 1 before assembly to pump or generator Assembly of an incomplete wheel may cause damage to the wheel kit the pump and generator This installation is best performed by two people A sturdy and stable block should support the underside of the cart during installation A damaged or incomplete kit may cause injury or property damage PERSONAL SAFETY 1 Wear safety glasses at all times when installing wheel kit to pump or generator 2 Keep work area clean uncluttered and properly lighted replace all unused tools and equipment 3 Keep visitors at a safe distance from the work area 4 Make workshop childproof with padlocks master switches and by removing starter keys TIRE AXLE ASSY
17. B NPT NPT 34 1001 024 Nut Spring M8 4 ems Mount to Frame 10 501 022 O Ring P 24 2 35 203 000 250 Bolt Hex 2 11 501 021 Plug A bl 2 AM RA ug Engine to Mount 12 122 030 13 O Ring P 30 1 36 1001 024 Nut Spring M8 2 13 200 500 110 Plug Assembly 1 Engine to Mount Priming 37 501 041 Bolt Hex 2 14 501 015 Valve Check 1 M8 X 20 P 2 15 1821 017 O Ring G 230 1 Pump to Mount 16 501 002 O Ring W1517 45 1 38 801 037 Shim Impeller AR 17 501 014 Bolt Hex 3 M8 X 25 2 801 038 Shim Impeller AR 18 2203 000 600 Bolt Flange 4 20 0 x 18 0 x 0 6T M8_50 39 13310 ZE1 630 Crankshaft 1 19 1501 006 Washer Aluminum 4 40 Honda GX160 Engine 5 5 HP 1 8 2 x 17 x 3 0 ERE 20 521 034 Pin Snap 10 2 AR is T 21 521 014 Rivet _10 2 as y 11 i s E ee 2 39 hae special met tread Order 23 521 016 2 Tsurumi replacement crankshaft 39 not Honda 24 521 015 Knob M12 2 Contact Honda distributor for Honda engine parts 25 203 000 630 Hex Socket 3 Items prefixed with a dash are not illustrated M6 X 15 SUS 26 203 100 110 Washer Spring 3 M6 SUS Replacement Parts Page 25 Tsurumi s Operation Service and Repair Manual Exploded View Model ETP3 80HA Trash Pump PUMP END A PUMP CASING v ENGINE END
18. D LIFTING DEVICE OR GAIN THE ASSISTANCE OF ANOTHER PERSON TO LIFT THE PUMP ON AND OFF THE BENCH IT IS RECOMMENDED THAT THE PUMP BE ASSEMBLED AND DISASSEMBLED ON A BENCH OR SIMILAR STRUCTURE WITH THE ENGINE SHROUD FACING DOWN IN ADDI TION WOODEN BLOCKS IN A VARIETY OF LENGTHS AND THICKNESS SHOULD BE AVAILABLE FOR SUPPORT OF THE ENGINE AFTER PUMP REMOVAL NOTE The item numbers in the procedures that follow correspond with the item numbers listed in the REPLACEMENT PARTS section of the manual A Refer to exploded views Figures 4 4 and Views A B and C Maintenance Page 15 Tsurumi s Operation Service and Repair Manual 3 Impeller 4 Inner Casing 1 Casing 15 O Ring 2 Casing Cover 23 Holder 10 11 Plug and O Ring 9 24 16 O Ring Figure 4 4 Exploded View of Internal Components View A Remove casing cover View B If liner is damaged View C Remove 3 screws to gain access to impeller the remove 2 screws and to remove liner Discard rotating member of the separate inner casing from old liner mechanical seal is in the casing cover Replace liner impeller during re assembly Page 16 Maintenance Tsurumi s Operation Service and Repair Manual Loosen two casing holder knobs 24 Pivot the casing holders 23 to the side and away from the casing cover 2 Pull casing cover 2 out
19. Noise or vibration Faulty mounting Pump engine attaching parts loose Tighten as required Damaged vibration isolation mounts Replace mounts Troubleshooting Page 11 Tsurumi s Operation Service and Repair Manual MAINTENANCE 4 1 Maintenance Schedule To maintain the trash pump in peak operating condition observe and implement the maintenance and adjustment schedule in Table 4 1 Inspect and or service the trash pump at the intervals shown in Table 4 1 WARNING e SHUT OFF THE ENGINE BEFORE PERFORMING ANY MAINTENANCE IF OPERATION OF THE ENGINE IS REQUIRED MAKE SURE THE AREA IS WELL VENTILATED THE ENGINE EXHAUST CONTAINS POISONOUS CARBON MONOXIDE GAS CAUTION REFER TO THE HONDA ENGINE OWNER S MANUAL FOR OTHER MAINTENANCE REQUIREMENTS Table 4 1 Maintenance Schedule Frequency Maintenance Action Daily Check oil level Check all components according to the PRE OPERATIONAL CHECKS section 50 Hours Wash cleaner element Check spark plug and clean if necessary 100 Hours Change engine oil 200 Hours Adjust spark plug gap Clean fuel strainer 500 Hours 12 Months Replace spark plug and cleaner element Clean and adjust carburetor valve clearance and valve seat along with cylinder head Replace engine isolation mounts Overhaul engine Change fuel lines Page 12 Maintenance Tsurumi s Operation Service and Repair Manual 4
20. Operation Service and Repair Manual OPERATING INSTRUCTIONS 2 1 Operating Controls A The trash pump operating controls are located on the engine B The controls consist of a throttle lever for speed control choke lever for cold weather starting fuel shutoff lever to prevent fuel spills and a recoil starter to turnover engine by Refer to Figure 2 1 Throttle Lever Choke Lever Fuel Shutoff Valve ON OFF Switch Recoil Starter Hand Grip Located on Recoil Starter Shroud Figure 2 1 Operating Controls 2 2 Check the Engine Oil Level CAUTION ENGINE OIL IS A MAJOR FACTOR AFFECTING PERFORMANCE AND SERVICE LIFE NON DETERGENT OILS AND 2 STROKE OILS ARE NOT RECOMMENDED BECAUSE THEY HAVE INADEQUATE LUBRICATING CHARACTERISTICS CHECK THE OIL LEVEL WITH THE ENGINE A LEVEL SURFACE AND THE ENGINE STOPPED A The trash pump is controlled by the engine operating controls B Use Honda 4 stroke oil or use an equivalent high detergent premium quality motor oil cer tified to meet or exceed U S automobile manufacturer s requirements for Service Classification SG SF Motor oils classified SG SF will show this designation on the con tainer SAE 10W 30 is recommended for general all temperature use C Other viscosity grades shown in Figure 2 2 may be used when the average temperature in your area is within the indicated range Page 6 Operating Instructions Tsurumi s Operation
21. Service and Repair Manual ee an Ee 555 66 et Gee 20 10 10 30 40 temperature 104 F Figure 2 2 Oil Viscosity Grade to Temperature Recommendations D When checking oil observe the following refer to Figure 2 3 Make sure the engine is in a level position 1 Remove the oil filler cap dipstick and wipe it clean 2 Insert the filler cap dipstick into the oil filler neck but do not screw it in 3 Remove the filler cap dipstick and check the oil level 4 the level is low fill to the top of the oil filler neck with the recommended oil 5 Reinstall the oil filler cap dipstick OIL FILLER CAP DIPSTICK UPPER LIMIT Operating Instructions Page 7 Tsurumi s Operation Service and Repair Manual 2 3 Check Engine Fuel WARNING e MAKE SURE YOU REVIEW EACH WARNING IN ORDER TO PREVENT FIRE HAZARD DO NOT REFILL TANK WHILE ENGINE IS RUNNING OR HOT CLOSE FUEL SHUT OFF VALVE BEFORE REFUELING WITH FUEL BE CAREFUL NOT TO GET DUST DIRT WATER OR OTHER FOREIGN OBJECTS INTO FUEL WIPE OFF SPILLED FUEL THOROUGHLY BEFORE STARTING ENGINE KEEP AWAY FROM OPEN FLAMES DO NOT USE SMOKING MATERIALS WHEN FILLING THE FUEL TANK DO NOT REFUEL WHILE SMOKING OR NEAR OPEN FLAME OR OTHER SUCH POTENTIAL FIRE HAZARDS OTHERWISE FIRE ACCIDENT MAY OCCUR AVOID REPEATED OR PROLONGED CONTACT WITH SKIN OR BREATHING OF VAPOR KEEP OUT OF REACH OF CHILDREN 2 4 Check Fuel Level A If fuel leve
22. ate trash pump faults Refer to these tables when the engine fails to start after several attempts If after following these procedures the pump fails to start contact the nearest Tsurumi generator dealer Table 3 1 Troubleshooting Table Fault Probable Cause Remedy Pump does not pump Insufficient priming water Add more water through priming plug Mechanical seal chipped or broken Replace mechanical seal Check valve damaged Replace check valve Suction hose damaged or strainer Replace hose Clean strainer clogged Air leaks caused by O ring Replace O rings damage Discharge flow or pump Air leaks caused by O ring Replace O rings pressure too low damage Suction hose or strainer clogged Replace hose Clean strainer Excessive impeller clearance Disassemble to obtain casing cover and impeller Determine clearance and re shim as required refer to Replacement of Mechanical Seal Engine rpm too low Check rpm and reset throttle as required Lift head too high Lower lift head Pump primes too Insufficient priming water Add more water through priming plug slowly Mechanical seal chipped or broken Replace mechanical seal Check valve damaged Replace check valve Suction hose damaged or strainer Replace hose clogged Clean strainer Air leaks caused by O ring Replace O rings damage Engine rpm too low Check rpm and reset throttle as required Lift head too high Lower lift head
23. d 4 Carefully block and secure the pump or generator and axle assembly so that pump or gen erator will not fall forward during handle assembly Bolt amp Nut TSURUMI AMERICA INC 845 N Dillon Drive Wood Dale IL 60191 tel 1 888 878 7864 fax 1 630 766 6445 2 The handles Ref No 3 and 4 should be installed on the pump or generator and frame assembly See Fig 4 3 Place each handle Ref No 3 and 4 on the bottom tubular support frame as shown Item C in Figure 4 Note Handles should tilt slightly outwards not inwards when assembled to pump or generator frame This allows for easy access and maneuver ability of operator during pump or generator transport 4 Attach each handle Ref No 3 and 4 to the pump or generator frame using two of the longer U bolts Ref No 7 two handles Ref No 6 and two nuts Ref No 11 See Fig 4 and reference items C and D 5 Each handle Ref No 3 and 4 requires two long U bolts Ref No 7 two handle brackets Ref No 6 and four nuts Ref No 11 6 Tighten nuts Ref No 11 to 75 95 in 155 Maintenance 1 Inspect pump or generator frame and wheel kit prior to every use for loose nuts and bolts Tighten as needed 2 Inspect tires for damage and replace as necessary 3 Keep unit clean 4 Wheel bearings sealed bearings No grease or oil is required to lubricate wheeling bearing
24. d controls and read the operating instructions before using the trash pump The Operation Repair and Service Manual also provides instructions to service checkout and repair the trash pump This manual also provides replacement parts information Repair and service information for the Honda engine is provided in the Owner s Manual for Models GX160 GX240 and GX340 A copy of the Owner s Manual has been provided in the trash pump s lit erature package Parts information for the Honda Engine is available in Honda s Parts Catalogs When there are differences between trash pump models separate instructions are provided The sepa rate instructions are provided to make sure the correct procedures are used on the affected trash pumps All information in the Tsurumi manuals is based upon the latest production configuration of the trash pump at the time of approval for printing If you have a problem with your trash pump that cannot be resolved using the Operation Repair and Service Manual or if you have questions about the operation service repair or maintenance of your trash pump contact your local Tsurumi trash pump dealer 1 2 Precautions Pay special attention to precautionary notes preceded by the words WARNING CAUTION and NOTE WARNINGS indicate that there is a strong possibility of personal injury or loss of life if the procedure is not followed or if cleaning lubricating adhesives and other materials are not used properly
25. duty Honda Engine proven reliability quiet operation efficient fuel consumption Oil Level Sensor prevents engine operation when oil level is low New Design Clean Out Cover cover removes quickly for clean out without the need to remove the suction hose New Design larger pump casing for increased durability Mechanical Seal silicon carbide seal element for long life Rubber Vibration Isolation Mounts isolates pump engine vibration from the frame for maximum protection and noise reduction Durable Rolled Steel Frame for strength and durability High Chrome Impeller increase ability to withstand the impact of debris passing through the pump Cast Iron Volute Casing Stainless Steel Wear Plate Galvanized Steel Hose Couplings MODELS EPT3 50HA EPT3 80HA EPT3 100HA Pump Output Gal Min to Total Head See Performance Curve See Performance Curve See Performance Curve Suction Size Inches 2 NPT Male 3 NPT Male 4 Discharge Size Inches 2 3 4 Engine Models Honda GX160K1VED2 GX240K1VED2 GX340K1ED6 Max HP rpm hp rpm 5 5 3600 rpm 8 0 3600 rpm 11 0 3600 rpm z Displacement CC In 163 10 242 15 337 21 2 Fuel Tank Capacity Gals 0 95 1 6 1 7 Noise Level Rated Load dB 64 dB 68 dB 72 dB Starting System Recoil Recoil Recoil m Dimensions L x W x H Inches 23 x18 x17 27 x20 x25 30 x20 x26 2 Shipping Weight Lbs 82 136 160
26. er 31 19 0 3906000 Plain Washer M6 4 6 821 008 1 32 200 101 180 Frame Black 1 7 1001 013 Case Check Valve 1 33 200 900 520 Mount Anti Vibration 4 NPT 4 34 1001 024 Nut Spring M8 4 8 1021 038A Fitting Pipe 1 Mount to Frame 4B NPT NPT 35 203 000 130 Bolt Hex 2 pet EI 2 M10 X 40 P 2 Bi Engine to Mount 19 1501 022 O Ring 5 36 1203200070 Nut Spring M10 2 11 1501 021 Plug Assembly 2 Engine to Mount 12 1122 030 13 O Ring P 30 Tr 37 203 000 660 8 Hex 2 13 200 500 110 Plug Assembly 1 M10 X 25 P 2 Priming Pump to Mount 14 1001 015 Valve Check 1 38 1001 040 Shim Impeller AR 15 821 017 O Ring G 240 1 22 2 x 0 3T 16 200 800240 8 W1517 46 1 1001 041 Shim Impeller AR 17 203 000 081 Bolt Hex 3 22 2 x 0 6T M10 X 30 17 2 1001 042 Shim Impeller AR 18 1021 026A Bolt Flange 4 22 2 x 1 0T UNC3 8 45 1001 043 Shim Impeller AR 19 1203 100 190 Washer Aluminum 4 222x23T 10 2 20 3 0 39 13310 2 3 630 Crankshaft 1 20 5821 034 Pin Snap 12 2 40 Honda GX340 Engine 11 0 HP 1 SE 821 011 Rivet _12 As Required quantity determined at assembly 22 821 013 Bolt Cover M16 2 Plug assembly 11 includes O ring 10 23 821 016 2 ae Priming plug assembly 13 includes O ring 12 24 1821 015 Knob M16 2 25 203000380 Bolt Hex Socket 3 siege qoa M5 X 4 SUS Co
27. ickness OD x ID Part Number EPT3 50HA 0 3 mm 0 012 Inch 20 x 18 mm 801 037 0 6 mm 0 024 Inch 0 787 x 0 709 inch 801 038 EPT3 80HA 0 3 mm 0 012 Inch 24 2 x 20 0 mm 1001 043 0 6 mm 0 024 Inch 0 952 x 0 787 inch 1001 044 1 0 mm 0 039 Inch 1001 045 EPT3 100HA 0 3 mm 0 012 Inch 22 2 mm 0 874 inch 1001 040 0 6 mm 0 024 Inch 1001 041 1 6 mm 0 063 Inch 1001 042 0 3 mm 0 091 Inch 1001 043 Noted shim is a disk and does not have an inside diameter OD Outside Diameter ID Inside Diameter l oo gt H 4 9 Replacement of Check Valve A Remove three bolts 17 check valve 14 and suction case 7 B Discard damaged check valve 14 C Align bolt holes in replacement check valve 14 and suction case 7 D Attach suction case 7 to pump casing 1 Figure 4 6 Shim Dimensions Overall uninstalled height of mechanical seal Diameter of pump casing center bore slip fit Inside diameter of mechanical seal Tool length Depth of pump casing center bore to face of installed seal multiplied by 2 Figure 4 7 Mechanical Seal Installation Tool Page 20 Maintenance Tsurumi s Operation Service and Repair Manual 13 Priming Plug and 12 O Ring 14 Check Valve 1 Casing 7 Case 21 Rivet d 17 Bolt 11 Plug 10 O Ring 23 Holder 24 Knob
28. l is low refill with unleaded automotive gasoline B Fuel tank capacities are provided below 50 0 95 gal 80 1 60 gal ie aa eae eae 1 70 gal Page 8 Operating Instructions Tsurumi s Operation Service and Repair Manual 2 5 Pre Start Checks WARNING SURE YOU REVIEW EACH WARNING IN ORDER PREVENT FIRE HAZARD KEEP AREA CLEAR OF FLAMMABLES OTHER HAZARDOUS MATERIALS A Check the following items before starting the engine 1 2 3 4 Fuel leakage from fuel hose sediment cup etc Bolts and nuts for looseness Components for damage or breakage Check trash pump surroundings Keep trash pump at least three 3 feet one 1 meter away from buildings or other structures Only operate trash pump in a dry well ventilated area Keep exhaust pipe clear of foreign objects Keep trash pump away from open flame Keep trash pump on a stable and level surface Do not block trash pump air vents with paper or other material 2 6 Starting and Operating the Engine A gt Refer to the Honda engine owner s manual B Put the fuel valve the ON position C Move the choke lever to the closed position Operating Instructions Page 9 Tsurumi s Operation Service and Repair Manual NOTE The choke may not be needed if the engine is warm or the air temperature is high
29. ness of shaft mounted shims l Measure and record dimensions A and B Subtract dimension B from dimension A The resultant dimension is the shim thickness required to provide the required clearance between the rotating and fixed seal elements J Select the combination of shims 41 that will provide clearance of 0 020 inch to 0 040 inch 0 508 mm to 1 016 mm K the liner 5 was damaged remove two screws 25 and separate casing cover 2 from inner casing 4 L Remove three screws from liner 5 and inner casing 4 Separate liner 5 from inner casing 4 M Secure liner 5 to inner casing 4 using three screws 25 IMPELLER IMPELLER O RINGS MATING RING FRONT COVER CUSHION View D Use water as a View E Install seal in lubricant on mating ring pump casing refer to and cushion Put side of Figure 4 5 with seal mating ring with white driving tool driver mark facing downward Replace O Rings if damaged Page 18 Maintenance Tsurumi s Operation Service and Repair Manual 1 CASING 4 VOLUTE CASING 5 WEAR PLATE 3 IMPELLER 41 IMPELLER SHIM 6 3 MECHANICAL SEAL FIXED ELEMENT 1 CASING 3 IMPELLER 6 2 MATING RING ROTATIN 6 1 RUBBER CUSHION REMOVED VIEW Figure 4 5 Shimming Of Mechanical Seal Maintenance Page 19 Tsurumi s Operation Service and Repair Manual Model Number Shim Th
30. ntact Honda distributor for Honda engine parts 26 203 100 100 Washer Spring 3 Items prefixed with a dash are not illustrated M5 SUS 27 203 000 670 Hex Socket 2 8 X 20 SUS Replacement Parts Page 29 2 TsuRUMI PUMP WHEEL KIT PGWK 200 FITS TSURUMI PUMPS amp GENERATORS Installation Instructions Product Features W DESIGNED FOR LIFELONG DURABILITY STATE OF THE ART ADJUSTABLE SLIDING AXLE SYSTEM W FITS MOST GENERATOR SIZES AND PUMPS E HIGHEST QUALITY METAL TUBING W ALL BRACKETS ARE PRECISION FIT E WIDE ANGLE HANDLE BARS FOR EASY PORTABILITY W EASY COMFORTABLE GRIP W DOUBLE BALL BEARINGS ON EACH AIRLESS TIRE E MPOSSIBLE TO PUNCTURE SMOOTH SLEEK DESIGN Upon receiving the wheel kit it should be inspected for damage or parts shortages See Fig 1 If damage has occurred file a claim immediately with the carrier that delivered the wheel kit If the manual is removed from the packaging do not lose or misplace Wheel Kit Parts Include 2 Description 1 AXLE ASSY RIGHT 1 AXLE ASSY LEFT 1 HANDLE RIGHT WITH GRIP 1 HANDLE LEFT WITH GRIP 2 TIRE 4 U BOLT FOR AXLE ASSY SHORT 4 4 2 2 U BOLT FOR HANDLE LONG HANDLE BRACKET PLAIN WASHER FOR TIRE COTTER PIN FOR
31. of pump casing 1 When you first attempt to remove the casing cover 2 you may feel resistance caused by O ring drag C D NOTE Position the frame 32 so the pump is facing up with the engine shroud facing down Using a hard plastic hammer rap on the hex of the impeller to loosen the impeller 3 Then remove the impeller by turning counterclockwise The hex is cast into the impeller and is not a separate removable part E E Remove two nuts 34 securing pump anti vibration mounts to the pump casing Remove four bolts and washers 18 and 19 securing the pump casing 1 to the engine Remove fixed element of the old seal using a driver similar to the driver in Figure 4 6 The tool should be sized to have a slip fit with the bore the sealant used on the mechanical seal has a strong bond in the casing bore it will take considerable driving force to remove the seal use of an arbor press is recommended Clean bore in pump casing to remove all traces of sealant residue 1 Pump Casing 6 Mechanical Seal 41 Shim 18 Flange Bolt 34 Spring Nut 37 38 Screw 19 AL Washer Figure 4 5 Replacing Rotating Seal Member Maintenance Page 17 Tsurumi s Operation Service and Repair Manual NOTE Refer to View D for an illustration depicting the mating ring Lubricate mating ring and cushion with water Make the measurements that need to be taken for calculating the thick
32. r other insufficiently ventilated area Always operate the trash pump in a well ventilated area The engine may become overheat ed and the poisonous carbon monoxide gas contained in the exhaust gases will endanger human lives Keep the trash pump at least 1 meter 3 feet away from any structure or building during use When a trash pump is located close to a building or nearby equipment heat and exhaust from the engine will cause the surrounding temperature to rise This will degrade the engines cooling effi ciency causing overheating Do not enclose the trash pump nor cover it with a box The trash pump has a built in forced air cooling system and may become overheated if it is enclosed Operate the trash pump on a level surface It is not necessary to prepare a special foundation for the trash pump However the trash pump will vibrate on an irregular surface Therefore choose a level place without surface irregularities Shutoff the trash pump when moving the trash pump to another work site It the trash pump is tilted or moved during operation fuel may spill and or the trash pump may tip over causing a haz ardous situation Proper lubrication cannot be expected if the trash pump is operated on a steep incline or slope In such a case the piston may seize it may seize even if the oil is above the upper level Page 2 Introduction Tsurumi s Operation Service and Repair Manual 1 4 Specifications Key Features Heavy
33. sembly to different pump or generator frames 4 Tighten Nuts Ref No 11 to 75 95 in Ibs 5 Once axle assembly Ref No 1 and 2 is in place secure width adjustment by tightening bolt Ref No 12 and nut Ref No 13 6 Install each tire Ref No 5 to the axle Ref No 1 and 2 The inside of the tire Ref No 5 is the side of the wheel that has the four nuts Install each tire Ref No 5 so that the side of the wheel that has the nuts is facing the pump or gen erator frame See Figure 3 7 After the tires Ref No 5 are placed on the axle Ref No 1 and 2 place one plain washer Ref No 9 over the axle Ref No 1 and 2 on each side of the axle Ref No 1 and 2 A total of two washers Ref No 9 are required one on each side of the axle Ref No 1 and 2 After the washers Ref No 9 are installed over the ends of the axle Ref No 1 and 2 insert the hairpin sprint pins Ref No 10 into the holes on each side of the axle Ref No 1 and 2 One hair pin style cotter pin is required one each side of the axle Ref No 1 and 2 for a total of two pins Ref No 10 Pins must be installed properly See Figure 3 as improperly installed pins may cause washer and tires to come off dur ing pump or generator transport STEP 2 INSTALL HANDLES 1 The pump or generator and frame with the axle and wheels installed will need to be tilted forward slightly to assemble the handles Ref No 3 an
34. ws 15 4 7 Description of Mechanical Seal 0 15 4 8 Replacement of Mechanical 596 15 4 9 Replacing or Check Valve uice uos beet enn eee Ru es eke a aae 20 5 Storage Instrucuofs cc Kis cee Saw ee oS REI ERE ERK 22 5 1 Procedures Tor Storing PUMP o ss sce sess dew an dew cowed ona F288 OR bees 22 6 Replacement Parts 23 6 1 Introduction ik koe be Paw ees 0 EERO RSE ER Ke Pa ewes 23 62 Ordening Pans ob ese sie eee te 23 Appendix A Wheel Kit Model PGWK 200 2 0 2 2 2 0 ee 1 Tsurumi s Operation Service and Repair Manual INTRODUCTION 1 1 Using Your Tsurumi Operation Repair and Service Manual We thank you for purchasing a Tsurumi trash pump We are sure that the trash pump you have select ed will meet your portable pumping needs This manual applies to the Tsurumi trash pumps listed below Specifications for the trash pumps are provided in the SPECIFICATIONS section Key features of the trash pump are shown in the DESCRIPTION section EPT3 50HA EPT3 80HA EPT3 100HA This manual provides instructions for operation service and repair of your trash pump We strongly recommend that those who operate the trash pump become familiar with the trash pump s features an
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