Hitachi L300P Series Welding System User Manual
Contents
1. SPECIFICATIONS Dimensions and Weight Description code WZCA Length x Width x Height 31 5 x 30 5 x 25 7 in with handlebar over engine 800 x 775 x 654 mm Dry weight 163 Ibs 73 9 kg Engine Design and Performance GX120T20a Engine type 4 stroke overhead valve single cylinder Displacement 7 2 cu in 118 cc bore x stroke 2 4 x 1 7 in 60 x 42 mm 0 6 gt 0 6 2 Oil Oil capacity a capacity 0 53 US gal 2 0 Ignition system Transistorized magneto PTO shaft direction Counterclockwise Pump Pump Performance Curve This graph shows the relationship between the pump discharge Pump type ae with spring type capacity and the total dynamic head based on clear water at sea ae rod level As you increase the total head the discharge capacity will Suction Suction port diameter thread type diameter thread type decrease ee port diameter thread 3 in NPT opinas WDP30X Maximum total head total head 50 5005M 15m a a suction head dry 16 E e 4 9 m Maximum suction head after 24 ft 7 3 m priming pump housing Maximum discharge capacity 80 gpm 303 min Self priming time 20 sec at 20 ft 6 1 m 2 in 60 mm Diaphragm Neoprene with nylon cloth Valves Neoprene with cast iron inserts Gear Box Pump operating 73 strokes min frequency Pump stroke 2 77 in 70 4 mm Gear box oil capacity 0 8 qt 0 8 Maintenance Discharge Capacity gpm Unleaded gasoline Wiring Dia2. 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 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 flammable objects 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 SAFETY LABEL LOCATIONS 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 A WARNING Turn engine off and let cool before refueling The engine emits toxic carbon monoxide Do not run in an enclosed area Read owner s manual before operation Thai Honda Mf
3. However if you should require further assistance write or call the Power Equipment Customer Relations Dept of American Honda Motor Co Inc at the address on page 17 Exclusions 1 Any damage or deterioration resulting from the following Neglect of the periodic maintenance as specified in this manual Improper repair or maintenance Operating methods other than those indicated in this manual The use of non genuine Honda parts and accessories other than those approved by Honda other than recommended lubricants and fluids Exposure of the product to soot and smoke chemical agents bird droppings sea water sea breeze salt or other environmental phenomena Collision fuel contamination or deterioration neglect unauthorized alteration misuse incorporation or use of unsuitable attachments or parts Normal wear and tear normal fading of painted or plated surfaces sheet peeling and other natural deterioration 2 Consumable parts Honda does not warrant parts deterioration due to natural wear and tear The parts listed below are not covered by warranty unless they are needed as a part of another warranted repair Spark plug fuel filter air cleaner element clutch disc tire wheel bearing recoil starter rope cable belt cutter blade Lubricant oil and grease 3 Cleaning adjustment and normal periodic maintenance work carburetor cleaning engine oil draining blade sharpening belt and cable adjustments 4 A
4. O RING ON position and check for leaks SEDIMENT CUP Fuel Filter Fuel Line 1 Remove the carburetor Turn the fuel valve to the Disconnect the fuel line Clean the filter with Turn the fuel valve to the OFF position FUEL VALVE ON OFF drain screw and gasket ON position and drain the fuel into a suitable container GASKET DRAIN SCREW 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 6 mm NUT 2 from the fuel filter and unscrew the fuel filter from the tank Inspect the fuel line and replace if cracked or worn FUEL FILTER s T C FUEL LINE nonflammable solvent and carburetor end check that the filter screen is not damaged Replace as necessary Clean the inside of the tank with nonflammable solvent and dry thoroughly Place the O ring on the filter and install the filter in the tank Tighten the filter to the specified torque TORQUE 17 in Ib 2 Nem Install the fuel line on the fuel filter and install the tank on the engine 10 After the tank is installed add fuel and check for leaks REFUELING This engine is certified to operate on unleaded gasoline with a pump octane rating of 86 or higher We recommend refueling after each use to minimize the air present in the fuel tank Refuel in a well ventilated area with the engine stopped If the engi
5. assembly to the side CRANK ARM 7 m 12 x 50 mm _ gt BOLT 4 o 12 mm WASHER 8 DIAPHRAGM ASSEMBLY UPPER PUMP ASSEMBLY 12 mm i LOWER CASE NUT 4 5 Usea17 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 CONNECTING ROD NYLON WASHER j 10 x 20 mm 2 BOLT SN F w CRANK 10 mm LOCK WASHER WASHER ARM 13 6 Ifthe diaphragm is co oe 12mm 4 Install the connecting rod with the hardware shown below and to be reused mark I aT NUT 4 torque the connecting rod bolt to 40 ft lb 54 Nem the diaphragm to CONNECTING allow it to be ROD FLANGE installed in the same 12mm PHE position WASHER 4 WASHER 7 With a19 mm wrench remove the DIAPHRAGM SHOULDER 4 nuts securing the 10mm connecting rod to BOLT the lower flange N Remove the en diaphragm LOWER FLANGE 10 mm LOCK WASHER 8 Inspect the diaphragm for cracks tears or damage and replace it if necessary 5 Pull the starter grip slowly until the diaphragm pulls up against the Pump Diaphragm Reassembly upper case stops During reassembly note the following UPPER CASE STOP 4 UPPER e Apply several drops of Hondalock 2 or equivalent thread lock to the bolt threads e To prevent pump case and or diaphragm damage follow the torque sequence s
6. startup Engine Oil Change Drain the oil while the engine is warm Warm oil drains quickly and completely 1 Remove the filler cap dipstick drain bolt and sealing washer f Drain the oil into a suitable container N Act A OR a CI 72 AT NW FILLER CAP DIPSTICK Wi gt ce S ae SEALING D SN WASHER Erma E DRAIN BOLT 2 Reinstall the drain bolt and sealing washer Tighten the bolt securely Improper disposal of engine oil can be harmful to the environment If you change your own oil please dispose of the used oil properly Put it in a sealed container and take it to a recycling center Do not discard it in a trash bin dump it on the ground or pour it down a drain 3 Fill with the recommended oil to the top of the oil filler neck Quantity 0 6 qt 0 6 I 4 Screw in the filler cap dipstick securely UPPER LIMIT MARK FILLER CAP DIPSTICK TOP OF OIL FILLER NECK Engine Oil Recommendations 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 0 when the average temperature in your area is within the recommended range SW 30 e 10W 30 gt J 20 40 60 80 100 F 20 10 0 10 20 30 40 C The SAE oil viscosity and service category are in the API label on the oil container Honda recommends that you use API service catego
7. 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 American Honda Motor Co Inc Power Equipment Division Customer Relations Office 4900 Marconi Drive Alpharetta GA 30005 8847 Or telephone 770 497 6400 M F 8 30 a m 7 00 p m ET When you write or call please give us this information e Model and serial numbers page 17 e Name of the dealer who sold the lawn mower to you e Name and address of the dealer who services your lawn mower e Date of purchase e Your name address and telephone number e Adetailed description of the problem Honda Publications These publications give you additional information for maintaining and repairing your lawn mower Shop Manual This manual covers complete maintenance and overhaul procedures It is intended to be used by a skilled technician Available through your Honda dealer or through Helm Inc at 888 292 5395 or visit www HondaPowerEquipment com and click on Product Manuals Parts Catalog This manual provides complete illustrated parts
8. clappet valve page 13 TECHNICAL INFORMATION SERIAL NUMBER LOCATIONS i E Moog 3 A T 2 AS A a S Q 7 Wo aa D D ENGINE SERIAL MODEL NAME NUMBER AND FRAME SERIAL NUMBER There are two serial numbers one for the engine and one for the frame Record the engine and frame serial numbers in the space below You will need these serial numbers when ordering parts and when making technical or warranty inquiries Engine serial number Frame serial number Date of purchase 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 Operation at an altitude that differs from that at which this engine was certified for extended periods of time may increase emissions High altitude performance can be improved by specific modifications to the carburetor If you always operate your pump at altitudes above 5 000 feet 1 500 meters have your servicing dealer perform this carburetor modification This engine when operated at high altitude with the carburetor modifications for high altitude use will meet each emission standard throughout its useful life Even with carburetor modification engine horsepower will decrease about 3 5 for each 1 000 foot 300 meter increase in altitude The effect of altitud
9. manual to your computer WARNING The engine exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm CONTENTS PUMP SAFETY ccscecececsesecscscecees 2 TECHNICAL INFORMATION 17 SAFETY LABEL LOCATIONS 2 SERIAL NUMBER LOCATIONS 17 SETTING UP YOUR NEW PUMP 2 CARBURETOR MODIFICATION FOR HIGH NTROL LOCATIONG 2555 OEO ALTITUDE OPERATION 17 iSVOURPUNPREADV TO Goss MISSION CONTROL SYSTEMS OPERATION AIR INDEX 18 a PE D SAFE OPERATING SPECIFICATIONS 18 PRECAUTIONS 4 CONSUMER INFORMATION 20 REPLACEMENT PARTS PUMP PREPARATION S OPTIONAL EQUIPMENT AND E are a a e 20 DEALER LOCATOR SERVICING YOUR PUMP 7 INFORMATION 0 ccccceseeeees 20 MAINTENANCE SAFETY E weave Tera 7 CUSTOMER SERVICE MAINTENANCE SCHEDULE 7 INFORMATION ceeceeseees 20 ENGINE MAINTENANCE 8 DISTRIBUTOR S LIMITED REFUELING noiiire 11 WARRANTY on 21 PUMP MAINTENANCE 12 HONDA PARTS ACCESSORIES TRANSPORTING csessssseeseseesseees 15 AND APPAREL ossessi 21 STORAGE scssssssscsessssssssssnsnsesessees 15 EMISSION CONTROL SYSTEM TANC CARE OF UREXPECIED WARRANTY c ccecescseseseseseeeees 22 PROBLEMS s scscsesessssssseneneees 17 PUMP SAFETY This chapter explains what you need to know to operate your diaphragm
10. 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 Fuel Depending on the region where you operate your equipment fuel formulations may deteriorate and oxidize rapidly Fuel deterioration and oxidation can occur in as little as 30 days and may cause damage to the carburetor and or fuel system Please check with your servicing dealer for local storage recommendations Gasoline will oxidize and deteriorate in storage Deteriorated gasoline will cause hard starting and it leaves gum deposits that can clog the small passages in the fuel system If the gasoline in your engine deteriorates during storage you may need to have the carburetor and other fuel 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 blend 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 war
11. the spark plug 1 Disconnect the spark plug cap and remove any dirt from around the spark plug area 2 Use a 13 16 in 21 mm spark plug wrench to remove the spark plug SPARK PLUG WRENCH 3 Visually inspect the spark plug Discard it if the insulator is cracked chipped or fouled SPARK PLUG CAP 4 Measure the plug gap with a suitable gauge 0 028 0 031 in Correct as necessary 0 70 0 80 mm by carefully bending the side electrode Plug gap 0 028 0 031 in 0 70 0 80 mm SEALING WASHER 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 A 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 Spark Arrester optional equipment Your pump engine is not factory equipped with a spark arrester In some areas it is illegal to operate an engine without a spark arrester Check local laws and regulations An optional USDA approved spark arrester is available from an authorized Honda
12. washer and reinstall the drain bolt 6 Fill the gear box to the upper limit on the oil filler cap dipstick Screw the dipstick in to measure the oil level Recommended oil SAE 80W 90 GL5 Gear oil 7 Dispose of the used oil properly page 8 8 Reinstall the connecting rod cover Avoid getting gear oil on the diaphragm Drain the oil into a drain pan to prevent oil from running down the pump case onto the diaphragm If gear oil comes in contact with the diaphragm the diaphragm will be damaged Pump Gear Box Oil Check With the pump cold and on a level surface remove the oil filler cap dipstick The oil level should be just below the UPPER LIMIT mark on the dipstick Screw the dipstick in to check the oil level Pump Clappet Valves 1 Disconnect the spark plug cap from the spark plug page 3 2 Turn the fuel valve lever to the OFF position page 3 3 Flush the pump chamber page 12 4 Lift the suction side of the pump and allow all the water to drain out the discharge fitting 5 Use a 19 mm wrench and remove the nuts and flat washers from both the suction and discharge ports FLAT NUT 4 WASHER 4 CLAPPET VALVE suction side CLAPPET VALVE discharge side 6 Remove both ports The clappet valves are directional so when removing the valves note the water flow direction 7 Inspect the ports case sealing surfaces and clappets for damage If the clappets are worn torn or damaged replace
13. American Honda to sell those products This warranty applies to the first retail purchaser and each subsequent owner during the applicable warranty time period What American Honda Will Repair or Replace Under Warranty American Honda will repair or replace at its option any part that is proven to be defective in material or workmanship under normal use during the applicable warranty time period Warranty repairs and replacements will be made without charge for parts or labor Anything replaced under warranty becomes the property of American Honda Motor Company Inc All parts replaced under warranty will be considered as part of the original product and any warranty on those parts will expire coincident with the original product warranty To Obtain Warranty Service You must at your expense take the Honda Power Equipment product accessory replacement part apparel or the power equipment on which the accessory or replacement part is installed and proof of purchase to any Honda Power Equipment dealer in the United States Puerto Rico or the U S Virgin Islands who is authorized to sell that product during the dealer s normal business hours To locate a dealer near you go to our web site at http www HondaPowerEquipment com and click on Dealer Locator If you are unable to obtain warranty service or are dissatisfied with the warranty service you receive contact the owner of the dealership involved normally this will resolve the problem
14. GINE OIL FILLER CAP DIPSTICK p 8 IGNITION SWITCH p 6 ENGINE OIL DRAIN BOLT p 8 BEFORE OPERATION Your safety is your responsibility A little time spent in preparation will significantly reduce your risk of injury Read and understand this manual Know what the controls do and how to operate them Familiarize yourself with the pump and its operation before you begin using it Know how to quickly shut off the engine in case of an emergency Be sure of what you are pumping This pump is designed to pump only non potable water muddy water and water containing solids 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 amp 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 pre operation inspection before each operation and correct any problem Before beginning your pre operation checks be sure the pump is on a level surface and the ignition switch is in the OFF position Check the General Condition of the Pump e Look around and underneath the pump for signs of oil or gasoline leaks e Remove any dirt or debris especially around
15. 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 We suggest you read the DISTRIBUTOR S LIMITED WARRANTY page 21 and EMISSION CONTROL SYSTEM WARRANTY page 22 to fully understand coverage and your responsibilities of ownership When your pump needs scheduled maintenance keep in mind that an 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 Keep this owner s manual handy so you can refer to it at any time This owner s manual is considered a permanent part of the pump and should remain with the pump if resold The information and specifications included in this publication were in effect at the time of approval for printing American Honda Motor Co Inc reserves the right however 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 SAFETY MESSAGES Your safety and the safety of others are
16. LIMITATION OF IMPLIED WARRANTIES American Honda Motor Co Inc and Honda Canada disclaim any responsibility for incidental or consequential damages such as loss of time or the use of the power equipment or any commercial loss due to the failure of the equipment and any implied warranties are limited to the duration of this written warranty This warranty is applicable only where the California U S EPA or Environment Canada emission control system warranty regulation is in effect EMISSION CONTROL SYSTEM WARRANTY PARTS SYSTEMS COVERED PARTS BY THIS WARRANTY DESCRIPTION Fuel Metering Carburetor assembly includes starting enrichment system Engine temperature sensor Engine control module Fuel regulator Intake manifold Fuel tank Fuel cap Fuel hoses Vapor hoses Carbon canister Canister mounting brackets Fuel strainer Fuel cock Fuel pump Fuel hose joint Canister purge hose joint Catalyst Exhaust manifold Air filter housing Air filter element Flywheel magneto Ignition pulse generator Crankshaft position sensor Power coil Ignition coil assembly Ignition control module Spark plug cap Spark plug Crankcase breather tube Oil filler cap Tubing fittings seals gaskets and clamps associated with these listed systems Note This list applies to parts supplied by Honda and does not cover parts supplied by the equipment manufacturer Please see the original equipment manufacturer s emissions warranty fo
17. ace the spark plug page 10 Every year or 300 hours Adjust the valve clearance 2 Adjust the idle speed Clean the fuel tank and filter Change the gear box oil page 12 Inspect the pump clappet valve page 13 Inspect the pump diaphragm page 13 Check the torque of nuts and bolts Every 2 years Check the fuel line and replace if necessary 2 1 Service more frequently when used in dusty areas 2 These items should be serviced by an authorized Honda servicing dealer unless you have the proper tools and are mechanically proficient Failure to follow this maintenance schedule could result in non warrantable failures ENGINE MAINTENANCE Engine Oil Level Check Check the engine oil level with the engine stopped and in a level position 1 Remove the filler cap dipstick and wipe it clean LE 2 Insert and remove the dipstick without screwing it into the filler neck Check the oil level shown on the dipstick FILLER CAP DIP STICK UPPER LIMIT LOWER LIMIT 3 If the oil level is low fill to the edge of the oil filler hole with the recommended oil See page 8 4 Screw in the filler cap dipstick securely Running the engine with a low oil level can cause engine damage The Oil Alert system will automatically stop the engine before the oil level falls below the safe limit However to avoid the inconvenience of an unexpected shutdown always check the engine oil level before
18. butor s Limited Warranty whichever is longer This warranty is transferable to each subsequent purchaser for the duration of the warranty period If any emission related part on your engine is defective the part will be repaired or replaced by Honda without charge for diagnosis parts or labor All defective parts replaced under this warranty become the property of Honda A list of warranted parts is in the adjacent column Normal maintenance items such as spark plugs and filters that are on the warranted parts list are warranted up to their required replacement interval only Honda will also replace other engine components damaged by a failure of any warranted part during the warranty period 22 Only Honda approved replacement parts may be used in the performance of any warranty repairs and must be provided without charge to the owner The use of replacement parts not equivalent to the original parts may impair the effectiveness of your engine emission control system If such a replacement part is used in the repair or maintenance of your engine and an authorized Honda dealer determines it is defective or causes a failure of a warranted part your claim for repair of your engine may be denied If the part in question is not related to the reason your engine requires repair your claim will not be denied TO OBTAIN WARRANTY SERVICE You must at your own expense take your Honda Power Equipment engine or the product on which it is i
19. ce of the required maintenance listed in your owner s manual Honda recommends that you retain all receipts covering maintenance on your power equipment engine but Honda cannot deny warranty coverage solely for the lack of receipts or for your failure to ensure the performance of all scheduled maintenance As the power equipment engine owner you should however be aware Honda may deny you warranty coverage if your power equipment engine or a part has failed due to abuse neglect improper maintenance or unapproved modifications You are responsible for presenting your power equipment engine to a Honda Power Equipment dealer as soon as a problem exists The warranty repairs should be completed in a reasonable amount of time not to exceed 30 days If you have any questions regarding your emissions warranty rights and responsibilities you should contact the Honda Office in your region Honda Canada Inc Power Equipment Customer Relations Please visit www honda ca for contact information Telephone 888 946 6329 American Honda Motor Co Inc Power Equipment Customer Relations OF 4900 Marconi Drive Alpharetta Georgia 30005 8847 Telephone 888 888 3139 Email powerequipmentemissions ahm honda com WARRANTY COVERAGE Honda power equipment engines sold in the United States and Canada are covered by this warranty for a period of two years from the date of delivery to the original retail purchaser or the length of the Honda Distri
20. cedures 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 Honda Genuine 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 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 A WARNING Failure to properly follow maintenance instructions and precautions can cause you to be seriously hurt or killed Always follow the procedures and precautions in this owner s manual Safety Precautions e Make sure t
21. charge head greater than 25 feet can damage the pump See the Pump Performance Curve on page 19 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 restricted 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 Flexible hoses must be attached to the pump The suction hose must be non collapsible Never use hoses that are smaller than the suction or discharge fittings This pump requires a 3 inch inside diameter or larger 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 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 a HOSE a ne 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 cro
22. e on horsepower will be greater than this if no carburetor modification is made When the carburetor has been 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 your servicing dealer return the carburetor to original factory specifications 17 EMISSION CONTROL SYSTEM 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 appropriate air fuel ratios and other emissions control systems to reduce the emissions of carbon monoxide oxides of nitrogen and hydrocarbons Additionally Honda fuel systems utilize components and control technologies to reduce evaporative emissions The U S California Clean Air Act and Environment Canada EPA California and Canadian regulations require all manufacturers to furnish written instructions describing the operation and maintenance of emissions control systems The following instructions and procedures must be followed in order to keep the emissions from your Honda engine withi
23. g Co Ltd Made in Thailand CAUTION HOT MUFFLER CAN BURN YOU Stay away if engine has been running Ze g LM ais a oa SE D f J SETTING UP YOUR NEW PUMP Unpacking The handle is installed over the pump for shipment only Remove the handle release pin and reinstall the handlebar facing outward for ease of handling Secure with the handle release pin page 3 The engine is shipped WITHOUT OIL in the engine Refer to page 8 for oil recommendations Please Register Your Diaphragm Pump lf your dealer did not collect registration information from you please take a few minutes and register your purchase with Honda This allows us to contact you with any important updates regarding your pump Please note registration is not required to obtain warranty service You can register by going online to www HondaPowerEquipment com and click on Product Registration CONTROL LOCATIONS GEAR BOX OIL FILLER CAP DIPSTICK p 12 GEAR BOX DRAIN BOLT Remove MUFFLER connecting rod cover p 12 FUEL CAP l AIR CUSHION CHAMBER CAP I Priming filler a p 5 SZ HNES pa mE ATT _ Y PA SF CLEANER Ch Sh Siwy 0 9 To 03 KS SPARK D SUCTION PORT p 5 STARTER GRIP THROTTLE LEVER CHOKE LEVER FUEL VALVE LEVER PUMP GREASE FITTING ACCESS PLUG p 12 LIFTING BRACKET HANDLE HANDLE RELEASE PIN DISCHARGE PORT p 5 EN
24. g the suction hose will help to ensure the water goes into the pump housing and not out the suction hose Pour about 1 gallon of water into the pump case through the air cushion chamber Lay the hose back on the ground and reinstall the air cushion chamber cap WATER AIR CUSHION CHAMBER CAP PRIMING FILLER HOLE SUCTION HOSE FREQUENCY OF USE If your equipment will be used on an infrequent or intermittent basis more than 4 weeks before next use please refer to the Fuel section of the STORAGE chapter page 15 for additional information regarding fuel deterioration STARTING THE ENGINE 5 Pull the starter grip a lightly until resistance 1 Turn the fuel valve to the ON position is felt then pull it briskly Return the starter grip Slowly back to the engine to prevent damage to the starter STARTER GRIP FUEL VALVE 6 As the engine warms up gradually move CHOKE LEVER the choke lever to the OPEN position 2 Move the choke lever to the CLOSED position Do not use the choke if the engine is warm or the ambient temperature is high CHOKE LEVER 7 Set the throttle to the desired speed to produce the best pumping conditions THROTTLE LEVER Pump output can be controlled by adjusting the throttle lever to the desired position 3 Turn the ignition switch to the ON position IGNITION SWITCH At FULL throttle position the pump will deliver the highest output volume Moving the
25. gram Fuel with a pump octane See page 11 rating of 86 or higher SAE 10W 30 eee SAE 80W 90 GL5 ne ENGINE gear oll pag IGNITION SWITCH NGK BPR6ES DENSO W20EPR U speed Tune up 0 028 0 031 in Spark plug gap 0 70 0 80 mm See page 10 Carburetor idle speed 1 400 a rom See page 10 Spark plug type See page 10 Intake See your Valve clearance 0 15 0 02 mm authorized cold Exhaust Honda servicing 0 20 0 02 mm dealer SWITCH Other specifications No other adjustments needed E CR RED 19 CONSUMER INFORMATION REPLACEMENT PARTS OPTIONAL EQUIPMENT AND SERVICE ITEMS Contact an authorized Honda servicing dealer to purchase any of these or other genuine original Honda items for your pump Replacement Parts Spark plug 98079 56876 NGK brand BPR6ES Air filter 17210 ZE0 505 Complete element Optional Equipment arrester hose kit 20 suction hose 50 discharge hose Camlock 124030 1145 CLKT a Steel strainer 3 8 hole Wearplate Q14 0000 065WP Stainless steel wearplate and paper Q14 0000 065P p pap gasket Service Items SAE 10W 30 08207 10W30 Honda ee engine oil recommended oil Fuel 08732 0001 For long term storage stabilizer 20 DEALER LOCATOR INFORMATION To find an Authorized Honda Servicing Dealer anywhere in the United States Visit our website www HondaPowerEquipment com and click on Dealer Locator CUSTOMER SERVICE INFORMATION Honda
26. he 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 emissions regulations Maintenance Follow the MAINTENANCE SCHEDULE on page 7 Remember this schedule is based on the assumption that your machine will be used for its designed purpose Sustained high load or high temperature operation or use in unusually wet or dusty conditions will require more frequent service AIR INDEX An Air Index Information hang tag label is applied to engines certified to an emission durability time period in accordance with the requirements of the California Air Resources Board The bar graph is intended to provide you our customer the ability to compare the emissions performance of available engines The lower the Air Index the less pollution The durability description is intended to provide you with information relating to the engine s emission durability period The descriptive term indicates the useful life period for the engine s emission control system See your EMISSION CONTROL SYSTEM WARRANTY page 22 for additional information Descriptive Term Moderate Applicable to Emission Durability Period 50 hours 0 80 cc inclusive 125 hours greater than 80 cc eee Intermediate 125 hours 0 80 cc inclusive 250 hours greater than 80 cc Extended 300 hours 0 80 cc inclusive 500 hours greater than 80 cc 1000 hours 225 cc and greater
27. he California Air Resources Board and Honda are pleased to explain the emission control system warranty on your Honda Power Equipment engine In California new spark ignited small off road equipment engines must be designed built and equipped to meet the State s stringent anti smog standards OTHER STATES U S TERRITORIES AND CANADA In other areas of the United States and in Canada your engine must be designed built and equipped to meet the U S EPA and Environment Canada emission standards for spark ignited engines at or below 19 kilowatts Specific Honda products that do not meet the California emissions regulations can be identified by a Not for sale in California decal ALL OF THE UNITED STATES AND CANADA Honda must warrant the emission control system on your power equipment engine for the period of time listed below provided there has been no abuse neglect or improper maintenance of your power equipment engine Where a warrantable condition exists Honda will repair your power equipment engine at no cost to you including diagnosis parts and labor Your emission control system may include such parts as the carburetor or fuel injection system the ignition system and catalytic converter Also included may be hoses connectors and other emission related assemblies See adjacent table for additional covered parts OWNER S WARRANTY RESPONSIBILITY As the power equipment engine owner you are responsible for the performan
28. he engine is off before you begin any maintenance or repairs This will eliminate several potential hazards e Carbon monoxide poisoning from engine exhaust Be sure there is adequate ventilation whenever you operate the engine e Burns from hot parts Let the engine and exhaust system cool before touching e Injury from moving parts Do not run the engine unless instructed to do so e Read the instructions before you begin and make sure you have the tools and skills required e To reduce the possibility of fire or explosion be careful when working around gasoline Use only a nonflammable solvent not gasoline to clean parts Keep cigarettes sparks and flames away from all fuel related parts MAINTENANCE SCHEDULE Check the engine oil level page 8 Check the air filter page 9 Check pump hoses and strainer page 12 After each use Flush the pump chamber page 12 Change the engine oil page 8 Grease the pump connecting rod bearing page 12 Before each use First month or 20 hours Clean the air filter page 9 Clean the sediment cup page 11 Grease the pump connecting rod bearing page 12 Check the gear box oil level page 12 Every 3 months or 50 hours Change the engine oil page 8 Inspect adjust the spark plug page 10 Clean check the spark arrester page 10 optional equipment Every 6 months or 100 hours Change the engine oil page 8 Replace the air cleaner paper filter page 9 Repl
29. he wrong Move the choke lever to the position CHOKE position unless the engine is warm page 6 Throttle lever in the wrong position Out of fuel Refuel page 11 Move the throttle lever slightly to the left page 6 Bad fuel pump stored Drain the fuel tank and carburetor without treating or draining page 16 gasoline or refueled with Refuel with fresh gasoline bad gasoline page 11 Gap or replace the spark plug page 10 Dry and reinstall the spark plug Spark plug faulty fouled or improperly gapped Spark plug wet with fuel flooded engine Fuel filter clogged carburetor malfunction ignition malfunction valves stuck etc Take the pump to an authorized Honda servicing dealer for repair Pump Will Not Pump Strainer clogged Clear strainer page 5 Restriction or foreign Clear restriction page 5 material in pump casing Suction hose clamps loose Tighten hose clamps page 5 Suction hose sealing Install suction hose sealing washer not installed washer page 5 Suction hose or suction Replace damaged parts page 5 hose nipple face damaged Locate pump at appropriate level page 19 Suction head is too high Pump requires priming Prime the pump page 5 Debris under the clappet valve or damaged clappet valve Diaphragm is torn Replace diaphragm page 13 Pump still does not pump Take the pump to an authorized Honda servicing dealer for repair Remove debris or replace
30. hown below DIAPHRAGM The crank arm should be approximately at the angle shown below CRANK TORQUE OY A ARM Start in one corner increasing the amount of torque 1 8 to 1 4 turn each time around until the specified Ar Cy torque is achieved D Diaphragm flange nuts 35 ft lb 47 Nem The pump case and or diaphragm may be damaged if the torque sequence is not followed or the nuts are overtightened 6 Install the upper case assembly making sure the diaphragm is centered and not pinched between the case stops Tighten the 1 Position the diaphragm between the connecting rod flange and the hardware following the torque procedure shown lower flange then install the nuts and washers Note the diaphragm shoulder on top Pump case bolts 35 ft lb 47 Nem 2 Apply NLGI 2 general purpose grease to the connecting rod Connecting rod bolt 40 ft lb 54 Nem bearing page 12 7 Grease the pump connecting rod and install the connecting rod 3 Rotate the crank arm to the bottom by pulling the starter grip cover page 12 Install the diaphragm and connecting rod into the pump case then install the connecting rod with the mark made during disassembly 8 Run and test the pump for correct operation facing out 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 t
31. ify for This Warranty 1 The parts accessories or apparel must be purchased from American Honda or a dealer distributor or distributor s dealer authorized by American Honda to sell those products in the United States Puerto Rico and the U S Virgin Islands Parts and Accessories must be purchased for installation on original Honda equipment or engines to be eligible for warranty coverage Installing parts and accessories on non Honda products or engines voids this warranty 2 You must be the first retail purchaser This warranty is not transferable to subsequent owners Replacement parts Apparel What American Honda Will Repair or Replace Under Warranty American Honda will repair or replace at its option any Honda Power Equipment parts accessories or apparel that are proven to be defective in material or workmanship under normal use during the applicable warranty time period Anything replaced under warranty becomes the property of American Honda Motor Company Inc The warranty on all parts accessories and apparel replaced under warranty will expire coincident with the original warranty on the replaced parts accessories or apparel Parts and accessories installed by a dealer who is authorized by American Honda to sell them will be repaired or replaced under warranty without charge for parts or labor If installed by anyone else parts and accessories will be repaired or replaced under warranty without charge for parts bu
32. in the carburetor and cause premature engine wear These small passages can become blocked causing starting or running problems Always use an air filter soecified for your engine to ensure it seals and performs as designed You will need to clean the filter more frequently if you operate the engine in very dusty conditions 1 Allow the foam filter To clean the paper filter element tap the element lightly several times on a hard surface to remove excess 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 To clean the foam filter SOLVENT element wash the element in a solution of household detergent and warm water then rinse thoroughly or wash in nonflammable solvent SQUEEZE element to dry THOROUGHLY thoroughly Soak the foam filter element in clean engine oil and squeeze out the excess oil Excess oil will restrict air flow through the foam filter element and may transfer to the paper filter element soaking and clogging it Reassemble the air filter as shown Spark Plug Service Recommended Spark Plug NGK BPR6ES Incorrect spark plugs can cause engine damage For good performance the spark plug must be properly gapped and free of deposits Allow the engine to cool before servicing
33. lists and is available through your Honda dealer Accessories Catalog Your authorized Honda power equipment dealer offers a wide selection of accessories to make your pump even more useful Visit www HondaPowerEquipment com and click on Accessories and then Pumps to see the entire catalog of accessories Especially popular accessories include e Suction and discharge hoses e Strainers e Couplers and gaskets Frequently Asked Questions The Honda Power Equipment web site provides additional information for users of Honda equipment Visit www HondaPowerEquipment com and click on FAQs DISTRIBUTOR S LIMITED WARRANTY Honda Power Equipment This warranty is limited to the following Honda Power Equipment products when distributed by American Honda Motor Co Inc Power Equipment Division 4900 Marconi Drive Alpharetta Georgia 30005 8847 The following warranty applies to products purchased at retail or placed in rental service on or after January 1 2010 LENGTH OF WARRANTY from date of original retail purchase PRIVATE COMMERCIAL RENTAL INSTITUTIONAL 1 Private residential Used in maintaining owner s primary and or secondary residence Any other use including but not limited to informal for hire use is considered commercial rental institutional use To Qualify for This Warranty The product must be purchased in the United States Puerto Rico or the U S Virgin Islands from American Honda or a dealer authorized by
34. lly to avoid spilling fuel Do not overfill FUEL CAP After refueling tighten the fuel tank cap securely Move the pump at least 10 feet 3 meters away from the fueling source and site before Starting the engine Fuel can damage paint and plastic Be careful not to spill fuel when filling your fuel tank Damage caused by spilled fuel is not covered by the DISTRIBUTOR S LIMITED WARRANTY page 21 MAX FUEL LEVEL Fuel Storage Container Store your gasoline in a clean plastic sealed container approved for fuel storage Close the vent if equipped when not in use and store the container away from direct sunlight If it will take more than 3 months to use the fuel in the container we suggest adding a fuel stabilizer to the fuel when you fill the container If you have some fuel left in your storage container at the end of the season the Environmental Protection Agency EPA recommends adding the gasoline to your vehicle s gas tank http epa gov reg5oair mobile winter html 11 PUMP MAINTENANCE 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 thoroughly flush sediment out the discharge side SUCTION SIDE DISCHARGE GARDEN HOSE 3 After flushing lift the suction side of the p
35. m storage temperatures accelerate fuel deterioration Fuel problems may occur within a month of inactivity or even less if the gasoline was not fresh when you filled the fuel tank If you keep a container of gasoline for refueling be sure that it contains only fresh gasoline If it will take more than 3 months to use the fuel in your storage container we suggest adding a fuel stabilizer to the fuel when you fill the container 15 Fuel system damage or engine performance problems resulting from neglected storage preparation are not covered under the Distributor s Limited Warranty Short Term Storage 30 90 days If your equipment will not be used for 30 to 90 days we recommend the following to prevent fuel related problems 1 Add fuel stabilizer following the manufacturer s instructions When adding a fuel stabilizer fill the fuel tank with fresh gasoline If only partially filled air in the tank will promote fuel deterioration during storage Note All stabilizers have a shelf life and their performance will deteriorate over time Fuel stabilizers will not reconstitute stale fuel 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 Turn the fuel valve to the OFF position 4 Continue to run the engine until it stops from the lack of fuel in the carburetor fuel bowl Running time should be less tha
36. n 3 minutes Long Term or Seasonal Storage greater than 90 days 1 Remove the carburetor drain screw with a 10 mm wrench or screwdriver and drain the fuel into an approved gasoline container A WARNING Gasoline is highly flammable and explosive You can be burned or seriously injured when handling fuel e 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 SCREW 3 Reinstall the drain screw and gasket Engine Oil 1 Change the engine oil page 8 2 Check the air filter and clean as necessary page 9 3 Remove the spark plug page 10 4 Pour a tablespoon 5 10 cc of clean engine oil into the cylinder 5 Slowly pull the starter grip a few times to distribute the oil in the cylinder 6 Reinstall the spark plug 7 Pull the starter grip slowly until resistance is felt Continue pulling slowly until the arrow notch on the starter pulley aligns with the hole on the recoil starter Return the starter grip gently This will close the valves so moisture cannot enter the engine cylinder 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 awa
37. n the emissions standards Tampering and Altering Tampering is a violation of Federal and California law Tampering with or altering the emissions control system may increase emissions beyond the legal limit Among those acts that constitute tampering are e Removal or alteration of any part of the intake fuel or exhaust systems e Altering or defeating the speed adjusting mechanism 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 e Hard starting or stalling after starting e Rough idle e Misfiring or backfiring under load e Afterburning backfiring e Black exhaust smoke or high fuel consumption Replacement Parts The emissions control systems on your new Honda engine were designed built and certified to conform with EPA California and Canadian emissions 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 emissions control system A manufacturer of an aftermarket part assumes the responsibility that the part will not adversely affect emissions performance T
38. ne has been running allow it to cool first Never refuel the engine inside a building where gasoline fumes may reach flames or sparks You may use regular unleaded gasoline containing no more than 10 ethanol E10 or 5 methanol by volume In addition methanol must contain cosolvents and corrosion inhibitors Use of fuels with content of ethanol or methanol greater than shown above may cause starting and or performance problems It may also damage metal rubber and plastic parts of the fuel system In addition ethanol is hygroscopic which means it attracts and retains water in the fuel system Engine damage or performance problems that result from using a fuel with percentages of ethanol or methanol greater than shown above are not covered by warranty If your equipment will be used on an infrequent or intermittent basis more than 4 weeks before next use refer to the Fuel section of the STORAGE chapter page 15 for additional information regarding fuel deterioration A WARNING Gasoline is highly flammable and explosive You can be burned or seriously injured when handling fuel e Stop the engine and keep heat sparks and flame away e Handle fuel only outdoors e Wipe up spills immediately Never use stale or contaminated gasoline or an oil gasoline mixture Avoid getting dirt or water in the fuel tank To refuel remove the fuel tank cap and fill the tank with gasoline to the shoulder of the filler neck Refuel carefu
39. nly 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 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 and wheels as necessary e Attach anchored tie down straps to the pump frame e Place blocks in front and behind the wheels Try to locate the pump on a level surface 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 dis
40. nstalled along with your sales registration card or other proof of original purchase date to any Honda Power Equipment dealer who is authorized by Honda to sell and service that Honda product during his normal business hours Claims for repair or adjustment found to be caused solely by defects in material or workmanship will not be denied because the engine was not properly maintained and used If you are unable to obtain emission warranty service or are dissatisfied with the warranty service you received contact the owner of the dealership involved Normally this should resolve your problem However if you require further assistance contact the Honda office in your region Refer to adjacent column for contact information EXCLUSIONS Failures other than those resulting from defects in material or workmanship are not covered by this warranty This warranty does not extend to emission control systems or parts that are affected or damaged by owner abuse neglect improper maintenance misuse misfueling improper storage collision the incorporation of or use of unsuitable attachments or the unauthorized alteration of any part This warranty does not cover replacement of expendable maintenance items made in connection with required maintenance service after the item s first scheduled replacement as listed in the maintenance section of the product Owner s Manual such as spark plugs and filters DISCLAIMER OF CONSEQUENTIAL DAMAGE AND
41. ny product that has ever been declared a total loss or sold for salvage by a financial institution or insurer 5 Auger and paddle assemblies of snowthrowers tiller tines of roto tillers mower blades and mower deck housings are specifically not warranted against impact damage including but not limited to abrasive damage Disclaimer of Consequential Damage and Limitation of Implied Warranties American Honda disclaims any responsibility for loss of time or use of the product transportation commercial loss or any other incidental or consequential damage Any implied warranties are limited to the duration of this written limited warranty Some states do not allow limitations on how long an implied warranty lasts and or do not allow the exclusion or limitation of incidental or consequential damages so the above exclusions and limitations 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 PRODUCTS COVERED BY THIS WARRANTY RESIDENTIAL Diaphragm pump Honda Parts Accessories and Apparel This warranty is limited to Honda Power Equipment parts accessories and apparel when distributed by American Honda Motor Co Inc 4900 Marconi Drive Alpharetta Georgia 30005 8847 LENGTH OF WARRANTY from date of original retail purchase PRIVATE COMMERCIAL RESIDENTIAL RENTAL INSTITUTIONAL PRODUCTS COVERED BY THIS WARRANTY Accessories To Qual
42. o cool before transporting the pump 1 Turn the ignition switch to the OFF position IGNITION SWITCH 2 Turn the fuel valve to the OFF position FUEL 3 Drain the pump chamber page 12 LOADING AND UNLOADING Roll the pump on a ramp 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 attached to the frame and place blocks in front and behind the wheels to prevent rolling Keep the tie down rope or straps away from the controls and carburetor STORAGE STORAGE PREPARATION The following steps will help to keep rust and corrosion from impairing your pump s function and appearance and will make the engine easier to start when you use the pump again Cleaning the Engine Wash the engine by hand and be careful to prevent water from entering the air cleaner or muffler e 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 e 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 Cleaning the Pump 1 Flush the pump chamber page 12 2 Wash the pump with a garden hose or other low pressure equipment Keep water away from controls and all other places
43. pump safely IMPORTANT SAFETY INFORMATION The Honda WDP30X pump is 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 injuries or property damage 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 the connecting rod cover in place when 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 the pump on a level surface If the engine is tilted fuel may spill
44. r non Honda parts Covered up to the first required replacement only See the MAINTENANCE SCHEDULE on page 7 Evaporative Exhaust Air Induction Ignition Crankcase Emission Control Miscellaneous Parts NOTES HONDA The Power of Dreams
45. ry SJ or later oil Using nondetergent oil can shorten the engine s service life and using 2 stroke oil can damage the engine Air Filter Inspection 1 Unscrew the outer wing nut and remove the air cleaner cover p OUTER WING NUT AIR CLEANER COVER WING NUT PAPER FILTER ELEMENT p f l A T FOAM FILTER P EN ELEMENT K lt gt V N Dn RUBBER 2 Y WASHER Se a RSs D Remove the inner wing nut and both air filter elements Separate both air filter elements and carefully check them for holes or tears Replace the filter elements if they are damaged If the air filter elements are dirty clean them as described below Wipe dirt from the inside of the air cleaner housing and cover Be careful to prevent dirt from entering the air duct that leads to the carburetor Install the foam element over the paper element and install the assembled air filter Secure the air filter with the inner wing nut Make sure the rubber washer is in place under the filter elements Install the air cleaner cover and secure with the outer wing nut 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 DISTRIBUTOR S LIMITED WARRANTY Air Filter Cleaning A properly maintained air filter will help prevent dirt from entering your engine Dirt entering the carburetor can be drawn into small passages
46. servicing dealer See page 20 for part numbers The spark arrester must be serviced every 100 hours to keep it functioning as designed 1 Allow the engine to cool then remove the two 8 mm nuts and remove the muffler from the cylinder head 2 Remove the four 5 mm screws from the muffler protector and remove the muffler protector 3 Remove the 4 mm screw from the spark arrester and remove the spark arrester from the muffler MUFFLER PROTECTOR 5 mm SCREW 4 4mm SCREW SPARK ARRESTER MUFFLER 4 Use a stiff brush to remove carbon deposits from the spark arrester screen Be careful not to damage the spark arrester screen 5 Inspect the spark arrester for breaks and holes Replace it if necessary 6 Install the spark arrester and the muffler in the reverse order of disassembly SPARK ARRESTER SCREEN Carburetor Adjustment 1 Start the engine outdoors and let it warm up to normal operating temperature 2 Move the throttle lever to the idle position page 6 3 Using a screwdriver turn the throttle stop screw to obtain the standard idle speed Standard Idle Speed 200 150 THROTTLE STOP SCREW 1 400 rpm Sediment Cup Cleaning 1 Remove the sediment Install the O ring and Turn the fuel valve to the Turn the fuel valve to the OFF position cup and O ring and wash them in nonflammable solvent Dry them thoroughly sediment cup and tighten securely
47. ss over the hose OO ee N BOARDS has re ESV RO DISCHARGE 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 hose 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 PUMP PREPARATION Optional hose kits designed specifically for this pump are available from your Honda dealer See page 20 Suction Hose Connection If using a commercially available hose ensure it is the same size or larger than the suction port diameter 3 inches To prevent the hose from collapsing use a hose that is reinforced with a non collapsible wall or braided wire construction Keep the 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 ins
48. t any labor charges will be the responsibility of the purchaser Apparel will be repaired or replaced under warranty without any charge To Obtain Warranty Service You must at your expense take the Honda Power Equipment part accessory or apparel or the Honda Power Equipment on which the accessory or part is installed and proof of purchase to any Honda Power Equipment dealer distributor or distributor s dealer in the United States Puerto Rico or the U S Virgin Islands who is authorized to sell that product during the dealer s normal business hours To locate a dealer near you go to our web site at http www HondaPowerEquipment com and click on Dealer Locator If you are unable to obtain warranty service or are dissatisfied with the warranty service you receive contact the owner of the dealership involved normally this will resolve the problem However if you should require further assistance write or call the Power Equipment Customer Relations Department of American Honda Motor Co Inc Refer to adjacent column for contact information Exclusions This warranty does not extend to parts accessories or apparel affected or damaged by collision normal wear use in an application for which the product was not designed or any other misuse neglect incorporation or use of unsuitable attachments or parts unauthorized alteration improper installation or any causes other than defects in material or workmanship of the product Ins
49. talled and in good condition A loosely connected suction hose will reduce pump performance and self priming ability SEALING WASHER DISCHARGE HOSE SUCTION HOSE HOSE CLAMP STRAINER ONTA provided with the pump ACY COUPLING The strainer provided with the pump should be attached to the end of the suction hose as shown Always install the 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 Discharge Hose Connection If using a commercially available hose a short large diameter hose will provide lower fluid friction and improve pump output A long or small diameter hose will increase fluid friction and reduce pump output Never use a hose size smaller than the discharge port diameter 3 inches 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 16 feet The suction head can be increased to 24 feet if the pump is primed 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 Liftin
50. talling Parts and Accessories on non Honda products or engines voids this warranty Disclaimer of Consequential Damage and Limitation of Implied Warranties American Honda disclaims any responsibility for loss of time or use of the product or the power equipment on which the product is installed transportation commercial loss or any other incidental or consequential damage Any implied warranties are limited to the duration of this written warranty Some states do not allow limitations on how long an implied warranty lasts and or do not allow the exclusion or limitation of incidental or consequential damages so the above exclusions and limitations 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 PWL50623 Q 2011 08 21 EMISSION CONTROL SYSTEM WARRANTY Your new Honda Power Equipment engine complies with the U S EPA Environment Canada and State of California emission regulations models certified for sale in California only American Honda Motor Co Inc provides the emission warranty coverage for engines in the United States and its territories Honda Canada Inc provides the emission warranty for engines in the 13 provinces and territories of Canada In the remainder of this Emission Control System Warranty American Honda Motor Company Inc and Honda Canada Inc will be referred to as Honda YOUR WARRANTY RIGHTS AND OBLIGATIONS CALIFORNIA T
51. the engine muffler and recoil starter e Look for signs of damage e Check that all nuts bolts screws hose connectors and clamps are tightened e Keep the connecting rod cover in place while operating the pump Check the Suction and Discharge Hoses e 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 e Check that the sealing washer in the suction hose connector is in good condition page 12 e Check that the strainer is in good condition and is installed on the suction hose page 12 Check the Engine e Check the oil level page 8 To avoid the inconvenience of an unexpected shutdown by the Oil Alert system always check the engine oil level before startup e Check the air cleaner page 9 e Check the fuel level page 11 Starting with a full tank will help to eliminate or reduce operating interruptions for refueling OPERATION SAFE OPERATING PRECAUTIONS Before operating the pump for the first time please review IMPORTANT SAFETY INFORMATION page 2 and BEFORE OPERATION page 3 For your 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 o
52. them If the case sealing surface is damaged and cannot be cleaned an optional wear plate and gasket is available from your Honda water pump dealer page 20 8 Install the clappet valves over the studs On the discharge side install the flat side of the valve facing the pump housing On the suction side install the flat side of the valve facing the port DISCHARGE PORT SUCTION CLAPPET VALVE PORT flat side facing the pump housing flat side facing the port df we NS CLAPPET VALVE a CLAPPET 9 Install both ports making sure all clappet valve tabs are positioned correctly 10 Apply several drops of Hondalock 2 or equivalent thread lock to the stud threads Hand tighten the nuts then torque evenly TORQUE 20 ft lb 27 Nem 11 After tightening the nuts insert a screwdriver into each port and check clappet valve operation Clappets should operate freely and should seal when released If a clappet does not operate properly reinstall the clappet and recheck 12 Run the pump and check for leaks Pump Diaphragm Disassembly 1 Disconnect the spark plug cap from the spark plug page 3 2 Drain the fuel tank page 16 Flush the pump chamber page 12 3 Remove the plastic connecting rod cover page 12 Pull the starter grip to rotate the connecting rod to the down position 4 Remove the 4 nuts washers bolts and the upper pump assembly using a 19 mm wrench Place the upper pump and engine
53. throttle toward the IDLE position will decrease the output volume of the pump STOPPING THE ENGINE Emergency IGNITION ae To stop the engine inan SWITCH v gt emergency turn the ignition switch to the OFF position 4 Move the throttle control lever slightly to the left Normal 1 Move the throttle lever fully to the right to the IDLE position THROTTLE LEVER 2 Turn the ignition switch i to the OFF position 3 Turn the fuel valve to the OFF position Ea VN EZ 4 After each use drain me ae ee Lo the pump chamber and o w flush with fresh water page 12 5 If your equipment will not be used for 3 to 4 weeks we recommend running the engine s carburetor out of fuel You can do this by leaving the fuel valve OFF restarting the engine and running it out of fuel See STORAGE PREPARATION on page 15 for periods of inactivity that exceed 4 weeks SERVICING YOUR PUMP Proper maintenance is essential for safe economical and trouble free operation It will also help reduce air 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 recommendations and schedules in this owner s manual To help you properly care for your pump the following pages include a maintenance schedule routine inspection procedures and simple maintenance pro
54. ump and allow water to drain out the discharge side Pump Hoses and Strainer 1 Check both hoses to make STRAINER sure they are not torn or cracked It is especially important that there are no tears in the suction hose Tears or air leaks on the SEALING suction side will prevent the WASHER pump from priming properly 2 Inspect the suction hose sealing washer to make sure it is in good condition SUCTION 3 Inspect the strainer to be HOSE sure it is not plugged or damaged Grease the Pump Connecting Rod 1 Remove the plastic access plug PLASTIC ACCESS 2 Disconnect the spark ach plug cap page 10 and pull the starter grip until the grease fitting is visible in the access opening 3 Wipe the grease fitting clean to prevent dirt from getting into the bearing Using a manual grease gun pump one or two strokes of NLGI 2 general purpose grease into the bearing 4 Reinstall the access plug securely Pump Gear Box Oil Change 1 Run the engine for 10 minutes to warm up the gear box oil Warm oil drains quickly and completely 2 Shut off the engine 3 Remove the two 8 x 15 mm bolts and washers from the connecting rod cover and remove the cover OIL FILLER CAP CONNECTING FAN DIPSTICK ROD COVER ENN L_ a 8mm WASHER 2 8x15mm a BOLT 2 UPPER LIMIT amp LOWER LIMIT Pe RIER WASHER F a DRAINNBOLT 5 Replace the drain bolt
55. very important We have provided important safety messages in this manual and on the pump This information alerts you to potential hazards that could hurt you or others Please read these messages carefully Of course it is not practical or possible to warn you about all the hazards associated with operating or maintaining a diaphragm pump You must use your own good judgment You will find important safety information in a variety of forms e Safety Labels on the pump e Instructions how to use this pump correctly and safely e Safety Messages preceded by a safety alert symbol and one of three signal words DANGER WARNING or CAUTION These signal words mean You WILL be KILLED or SERIOUSLY A DANGER HURT if you don t follow instructions You CAN be KILLED or SERIOUSLY amp WARNING HURT if you don t follow instructions You CAN be HURT if you don t follow CAUTION instructions Each message tells you what the hazard is what can happen and what you can do to avoid or reduce injury e Damage Prevention Messages You will also see other important messages that are preceded by the word NOTICE This word means Your pump or other property can be damaged if you don t follow instructions 1996 2011 American Honda Motor Co Inc All Rights Reserved POM31TDP614 31TDP614 00X31 TDP 6140 AHM 300 2011 11 PRINTED IN U S A HON DA OWNER S MANUAL WDP30X GaN 4 Click here to save this
56. y 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 HOLE ARROW NOTCH STARTER GRIP 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 BEFORE OPERATION page 3 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 and 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 TAKING CARE OF UNEXPECTED PROBLEMS Engine Will Not Start Ignition switch OFF Turn the ignition switch ON page 6 Fuel valve OFF Turn the fuel valve ON page 6 Choke lever in t
Download Pdf Manuals
Related Search