Manual For The 63405 2 In. Intake/Discharge 212cc Gasoline Engine Water Pump 158 GPM
User Manual: Manual for the 63405 2 in. Intake/Discharge 212cc Gasoline Engine Water Pump - 158 GPM 2 in. 212cc Gasoline Engine Semi-Trash Water Pump - 158 GPM
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Owner’s Manual & Safety Instructions Save This Manual Keep this manual for the safety warnings and precautions, assembly, operating, inspection, maintenance and cleaning procedures. Write the product’s serial number in the back of the manual near the assembly diagram (or month and year of purchase if product has no number). Keep this manual and the receipt in a safe and dry place for future reference. 17d Do not return this pump to the store. Call 1-844-416-9141 Using an engine indoors CAN KILL YOU IN MINUTES. Engine exhaust contains carbon monoxide. This is a poison you cannot see or smell. NEVER use inside a home or garage, EVEN IF doors and windows are open. Only use OUTSIDE and far away from windows, doors, and vents. Visit our website at: http://www.harborfreight.com Email our engine support at: predator@harborfreight.com When unpacking, make sure that the product is intact and undamaged. If any parts are missing or broken, please call 1-888-866-5797 as soon as possible. Copyright© 2016 by Harbor Freight Tools®. All rights reserved. No portion of this manual or any artwork contained herein may be reproduced in any shape or form without the express written consent of Harbor Freight Tools. Diagrams within this manual may not be drawn proportionally. Due to continuing improvements, actual product may differ slightly from the product described herein. Tools required for assembly and service may not be included. Read this material before using this product. Failure to do so can result in serious injury. SAVE THIS MANUAL. Table of Contents Specifications ............................................. 2 Safety ......................................................... 4 Setup .......................................................... 6 Operation ................................................... 10 Maintenance .............................................. 13 Troubleshooting ......................................... 17 Warranties ................................................. 20 Parts Lists and Diagrams .......................... 22 Specifications Pump Suction & Discharge Size 2" NPT Maximum Flow at 0’ 158 GPM Maximum Head Lift at 0 Flow 91 ft. Maximum Intake Lift at 0 26 ft. Mechanical Seal Ceramic Included Accessories Intake Strainer, Hose Clamps, Spark Plug Wrench Engine Displacement 212cc Engine Type Horizontal Single Cylinder 4 stroke OHV EPA phase III compliant Cooling System Forced air cooled Type Fuel Engine Oil 87+ octane stabilizer-treated unleaded gasoline Capacity 0.9 Gallons / 3.6 Liters Type SAE 10W-30 above 32° F 5W30 at 32° F or below Capacity 0.5 Quarts / 0.5 Liters Run Time @ 50% Load with full tank Sound Level at 22 feet Bore x Stroke 70 mm x 55 mm Compression Ratio 8.5:1 Rotation viewed from PTO (power takeoff - the output shaft) Shaft Shaft Spark Plug Valve Clearance No Load Speed 3 hr. 104 dB Counterclockwise 3/4" x 2.41" Keyway 3/16" (4.76 mm) End Tapped 5/16" - 24 UNF Type NGK® BP-6ES NHSP® / Torch® F6TC Gap 0.027" - 0.031" Intake 0.004" - 0.006" Exhaust 0.006" - 0.008" 3,800 ±100 RPM Discharge Head (ft.) PERFORMANCE CURVE Flow (Gallons/minute) Page 2 For technical questions, please call 1-888-866-5797. ITEM 63405 SAFETY WARNING SYMBOLS AND DEFINITIONS This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death. Indicates a hazardous situation which, if not avoided, will result in death or serious injury. SETUP Indicates a hazardous situation which, if not avoided, could result in death or serious injury. Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury. Addresses practices not related to personal injury. Symbol Definitions RPM HP Property or Statement Revolutions Per Minute Horsepower WARNING marking concerning Risk of Eye Injury. Wear ANSI-approved safety goggles with side shields. Read the manual before set-up and/or use. Property or Statement WARNING marking concerning Risk of Respiratory Injury. Operate engine OUTSIDE and far away from windows, doors, and vents. WARNING marking concerning Risk of Fire while handling fuel. Do not smoke while handling fuel. WARNING marking concerning Risk of Fire. Do not refuel while operating. Keep flammable objects away from engine. MAINTENANCE WARNING marking concerning Risk of Hearing Loss. Wear hearing protection. Symbol OPERATION Symbol ITEM 63405 For technical questions, please call 1-888-866-5797. Page 3 Safety Warnings SAFETY WARNING! Read all instructions. Failure to follow all instructions listed below may result in fire, serious injury and/or DEATH. The warnings and precautions discussed in this manual cannot cover all possible conditions and situations that may occur. It must be understood by the operator that common sense and caution are factors which cannot be built into this product, but must be supplied by the operator. SAVE THESE INSTRUCTIONS Set up Precautions 1. Gasoline fuel and fumes are flammable, and potentially explosive. Use proper fuel storage and handling procedures. Do not store fuel or other flammable materials nearby. 4. Set up and use only on a flat, level, well-ventilated surface. 2. Have multiple ABC class fire extinguishers nearby. 6. Wear ANSI-approved safety goggles, heavy-duty work gloves, and dust mask/respirator during set up. SETUP 3. Operation of this equipment may create sparks that can start fires around dry vegetation. A spark arrestor may be required. The operator should contact local fire agencies for laws or regulations relating to fire prevention requirements. 5. Use only lubricants and fuel recommended in the Specifications chart of this manual. Engine Precautions Follow engine precautions and instructions in the included engine instruction manual. Operating Precautions 1. CARBON MONOXIDE HAZARD Using an engine indoors CAN KILL YOU IN MINUTES. Engine exhaust contains carbon monoxide. This is a poison you cannot see or smell. 5. Industrial applications must follow OSHA requirements. OPERATION 6. Do not leave the equipment unattended when it is running. Turn off the equipment (and remove safety keys, if available) before leaving the work area. 7. Engine can produce high noise levels. Prolonged exposure to noise levels above 85 dBA is hazardous to hearing. Always wear ear protection when operating or working around the gas engine while it is operating. NEVER use inside a home or garage, EVEN IF doors and windows are open. 8. Wear ANSI-approved safety glasses, hearing protection, and NIOSH-approved dust mask/ respirator under a full face shield along with steel-toed work boots during use. MAINTENANCE 9. People with pacemakers should consult their physician(s) before use. Electromagnetic fields in close proximity to a heart pacemaker could cause pacemaker interference or pacemaker failure. Caution is necessary when near the engine’s magneto or recoil starter. Only use OUTSIDE and far away from windows, doors, and vents. 2. Keep children away from the equipment, especially while it is operating. 3. Do not touch Pump engine during use. 4. Never store fuel or other flammable materials near the Pump engine. Page 4 10. Use only accessories that are recommended by Harbor Freight Tools for your model. Accessories that may be suitable for one piece of equipment may become hazardous when used on another piece of equipment. 11. Do not operate in explosive atmospheres, such as in the presence of flammable liquids, gases, or dust. Gasoline-powered engines may ignite the dust or fumes. For technical questions, please call 1-888-866-5797. ITEM 63405 Operating Precautions (cont.) 14. Dress properly. Do not wear loose clothing or jewelry. Keep hair, clothing and gloves away from moving parts. Loose clothes, jewelry or long hair can be caught in moving parts. 15. Parts, especially exhaust system components, get very hot during use. Stay clear of hot parts. 16. Do not cover the engine or equipment during operation. 17. Keep the equipment, engine, and surrounding area clean at all times. 18. Do not smoke, or allow sparks, flames, or other sources of ignition around the equipment, especially when refuelling. 19. Use the equipment, accessories, etc., in accordance with these instructions and in the manner intended for the particular type of equipment, taking into account the working conditions and the work to be performed. Use of the equipment for operations different from those intended could result in a hazardous situation. 21. This product contains or, when used, produces a chemical known to the State of California to cause cancer and birth defects or other reproductive harm. (California Health & Safety Code § 25249.5, et seq.) 22. When spills of fuel or oil occur, they must be cleaned up immediately. Dispose of fluids and cleaning materials as per any local, state, or federal codes and regulations. Store oil rags in a bottom-ventilated, covered, metal container. SAFETY 13. Do not overreach. Keep proper footing and balance at all times. This enables better control of the equipment in unexpected situations. 20. Do not operate the equipment with known leaks in the engine’s fuel system. 23. Keep hands and feet away from moving parts. Do not reach over or across equipment while operating. 24. Before use, check for misalignment or binding of moving parts, breakage of parts, and any other condition that may affect the equipment’s operation. If damaged, have the equipment serviced before using. Many accidents are caused by poorly maintained equipment. 25. Use the correct equipment for the application. Do not modify the equipment and do not use the equipment for a purpose for which it is not intended. SETUP 12. Stay alert, watch what you are doing and use common sense when operating this piece of equipment. Do not use this piece of equipment while tired or under the influence of drugs, alcohol or medication. a. Turn the engine switch to its “OFF” position. b. Allow the engine to completely cool. c. Then, remove the spark plug cap from the spark plug. 2. Keep all safety guards in place and in proper working order. Safety guards include muffler, air cleaner, mechanical guards, and heat shields, among other guards. 6. Have the equipment serviced by a qualified repair person using only identical replacement parts. This will ensure that the safety of the equipment is maintained. Do not attempt any service or maintenance procedures not explained in this manual or any procedures that you are uncertain about your ability to perform safely or correctly. 7. Store equipment out of the reach of children. Refueling: 3. Do not alter or adjust any part of the equipment or its engine that is sealed by the manufacturer or distributor. Only a qualified service technician may adjust parts that may increase or decrease governed engine speed. 1. Do not refill the fuel tank while the engine is running or hot. 4. Wear ANSI-approved safety goggles, heavy-duty work gloves, and dust mask/respirator during service. 3. Do not fill fuel tank to the top. Leave a little room for the fuel to expand as needed. 5. Maintain labels and nameplates on the equipment. These carry important information. If unreadable or missing, contact Harbor Freight Tools for a replacement. 2. Do not smoke, or allow sparks, flames, or other sources of ignition around the equipment, especially when refuelling. MAINTENANCE 1. Before service, maintenance, or cleaning: 4. Refuel in a well-ventilated area only. 5. Wipe up any spilled fuel and allow excess to evaporate before starting engine. To prevent FIRE, do not start the engine while the smell of fuel hangs in the air. SAVE THESE INSTRUCTIONS. ITEM 63405 OPERATION Service Precautions For technical questions, please call 1-888-866-5797. Page 5 Set Up Read the ENTIRE IMPORTANT SAFETY INFORMATION section at the beginning of this manual including all text under subheadings therein before set up or use of this product. SAFETY TO PREVENT SERIOUS INJURY: Operate only with proper spark arrestor installed. Operation of this equipment may create sparks that can start fires around dry vegetation. A spark arrestor may be required. The operator should contact local fire agencies for laws or regulations relating to fire prevention requirements. High Altitude Operation Above 3000 feet WARNING! To prevent serious injury from fire: Follow instructions in a well-ventilated area away from ignition sources. If the engine is hot from use, shut the engine off and wait for it to cool before proceeding. Do not smoke. NOTICE Warranty void if necessary adjustments are not made for high altitude use. SETUP At high altitudes, the engine’s carburetor, governor (if so equipped), and any other parts that control the fuel-air ratio will need to be adjusted by a qualified mechanic to allow efficient high-altitude use and to prevent damage to the engine and any other devices used with this product. The fuel system on this engine may be influenced by operation at higher altitudes. Proper operation can be ensured by installing an altitude kit at altitudes higher than 3000 ft. above sea level. At elevations above 8000 ft, the engine may experience decreased performance, even with the proper main jet. Operating this engine without the proper altitude kit installed may increase the engine’s emissions and decrease fuel economy and performance. The kit should be installed by a qualified mechanic. 1. Turn off the engine. 2. Close the fuel valve. 3. Place a bowl under the fuel cup to catch any spilled fuel. CAUTION! Carburetor bowl may have gas in it which will leak upon removing the bolt. 4. Unthread the bolt holding the fuel cup. OPERATION 5. Remove the bolt, Bolt Seal, fuel cup, Fuel Cup Seal and Main Jet from the body of the carburetor assembly. A carburetor screwdriver (not included) is needed to remove and install the Main Jet. Note: The mixing tube is held in place by the Main Jet and might fall out when it is removed. If it falls out, replace it in the same orientation before replacing the Main Jet. 6. Replace the Main Jet with the replacement Main Jet needed for your altitude range (part 1a or 2a). Note: The Fuel Cup Seal and Bolt Seal may be damaged during removal and should be replaced with the new ones from the kit. 7. Replace the Fuel Cup Seal (4a), fuel cup, Bolt Seal (3a), and bolt. Tighten in place. NOTICE: Do not cross thread bolt when tightening. Finger tighten first and then use a wrench to make sure the bolt is properly threaded. Carburetor Assembly Fuel Cup Seal Mixing Tube (might remain inside carburetor) Main Jet MAINTENANCE 8. Wipe up any spilled fuel and allow excess to evaporate before starting engine. To prevent FIRE, do not start the engine while the smell of fuel hangs in the air. Fuel Cup High Altitude Kit Parts List - A Bolt Seal Part 1a 2a 3a 4a Page 6 Description Qty Main Jet 3000-6000 ft. Main Jet 6000-8000 ft. Bolt Seal Fuel Cup Seal 1 1 1 1 For technical questions, please call 1-888-866-5797. Bolt ITEM 63405 Controls SAFETY Fuel Tank Cap Fuel Tank Throttle Choke SETUP Fuel Valve Starter Handle Engine Switch Oil Dipstick Priming Cap Discharge Port Muffler Intake Port OPERATION Air Filter MAINTENANCE Water Drain Plug ITEM 63405 For technical questions, please call 1-888-866-5797. Page 7 Connecting Hoses Note: Hoses not included. SAFETY Note: The Intake Hose (not included) MUST be reinforced with non-collapsible construction. Match hose diameter to port diameters. Do not reduce hose diameter size. 1. Thread intake hose onto Intake Port. NOTICE: Use only a non-collapsible intake hose. Intake Strainer 3. Thread discharge hose onto Discharge Port. Tighten until secure. Intake Hose SETUP 2. Slide the Intake Strainer into the end of the intake hose. Tighten until secure. OPERATION MAINTENANCE Page 8 For technical questions, please call 1-888-866-5797. ITEM 63405 Locate the Water Pump on a flat, level, sturdy surface capable of supporting the weight of the Pump. 1. For best Pump performance, place the Pump near the water level and use hoses that are no longer than necessary. See diagram below. Discharge Head Water Pump Total Head 3. Place Strainer into water to be pumped. NOTICE: Immerse strainer fully in water. Do not operate Pump without Strainer connected to end of suction hose. Keep Strainer out of sand or silt by placing Strainer in a bucket or on stones. NOTICE: Air leaks must not appear in the suction line. If there is an air leak in the suction line, you will not be able to prime the pump. Use a thread sealant to seal air leaks. SAFETY Locating the Water Pump Suction Head As the head (pumping height) increases, pump output decreases. A non-collapsible suction hose must be used. The length, type, and size of the suction and discharge hoses can significantly affect Pump output. Discharge head capability is always greater than suction head capability. This means pumping height for the Intake Hose (suction head) should be shorter than the pumping height for the Discharge Hose. Minimizing suction head (placing the Pump closer to the water level) will also help make it easier to prime the pump (fill it with water). SETUP Strainer 4. Secure the Intake Hose in place to keep it from moving once the Pump is turned on. The Intake Hose should be as short as possible for more efficient operation. 5. Route the discharge hose to the desired discharge location. If necessary, connect additional discharge hoses to direct the discharge to the desired location. Make sure to secure the discharge hose in place to keep it from moving once the Water Pump is turned on. The discharge hose should be kept as short as possible for more efficient operation. MAINTENANCE OPERATION 2. Route the Intake Hose with the Intake Strainer fully immersed in the water supply source. ITEM 63405 For technical questions, please call 1-888-866-5797. Page 9 Operation Read the ENTIRE IMPORTANT SAFETY INFORMATION section at the beginning of this manual including all text under subheadings therein before set up or use of this product. SAFETY Priming Cap Prime the Pump Before starting the engine, fill the Pump with water. To do this: 1. Unthread the Priming Water Filler Cap by turning it counterclockwise. 2. Fill the unit with clean water up to the top of the opening. Replace the Priming Water Filler Cap and tighten securely. SETUP IMPORTANT! Always check for water in the Pump Housing before each use. Never attempt to run the Water Pump without the Pump Housing FULL of water. Running the Water Pump without water for an extended period of time will damage the Water Pump and void the Warranty. Checking and Filling Engine Oil NOTICE: Your Warranty is VOID if the engine’s crankcase is not properly filled with oil before each use. Before each use, check the oil level. Engine will not start with low or no engine oil. 3. Make sure the engine is stopped and is level. 4. Close the Fuel Valve. OPERATION 5. Clean the top of the Dipstick and the area around it. Remove the Dipstick by turning it counterclockwise, and wipe it off with a clean, lint free rag. Checking and Filling Fuel WARNING! TO PREVENT SERIOUS INJURY FROM FIRE: Fill the fuel tank in a well-ventilated area away from ignition sources. If the engine is hot from use, shut the engine off and wait for it to cool before adding fuel. Do not smoke. 1. Clean the Fuel Cap and the area around it. 2. Unscrew and remove the Fuel Cap. Note: Do not use gasoline containing more than 10% ethanol (E10). Do not use E85 ethanol. Add fuel stabilizer to the gasoline or the Warranty is VOID. Full level Full level 6. Reinsert the Dipstick without threading it in and remove it to check the oil level. The oil level should be up to the full level as shown above. MAINTENANCE 7. If the oil level is at or below the low mark add the appropriate type of oil until the oil level is at the proper level. SAE 10W-30 oil is recommended for general use. (The SAE Viscosity Grade chart on page 14 in the Maintenance section shows other viscosities to use in different average temperatures.) 8. Thread the dipstick back in clockwise. Note: Do not use gasoline that has been stored in a metal fuel container or a dirty fuel container. It can cause particles to enter the carburetor, affecting engine performance and/or causing damage. 3. If needed, fill the Fuel Tank to about 1 inch under the fill neck of the Fuel Tank with 87 octane or higher unleaded gasoline that has been treated with a fuel stabilizer additive. Follow fuel stabilizer manufacturer’s recommendations for use. 4. Then replace the Fuel Cap. 5. Wipe up any spilled fuel and allow excess to evaporate before starting engine. To prevent FIRE, do not start the engine while the smell of fuel hangs in the air. NOTICE: Do not run the engine with too little oil. Engine will shut off if engine oil level is too low. Page 10 For technical questions, please call 1-888-866-5797. ITEM 63405 Starting the Engine Before Starting the Engine 1. To start a cold engine, move the Choke to the START position. To restart a warm engine, leave the Choke in the RUN position. SAFETY Before starting the engine: a. Inspect the equipment and engine. b. Fill the engine with the proper amount and type of both stabilizer-treated unleaded gasoline and oil. 1 SETUP 2. Open the Fuel Valve. 2 3. Slide the Throttle to 1/3 away from the SLOW position (the “turtle”). ON O 4. Turn the Engine Switch on. OFF ON I 4 OPERATION 3 5. Grip the Starter Handle of the Engine loosely and pull it slowly several times to allow the gasoline to flow into the Engine’s carburetor. Then pull the Starter Handle gently until resistance is felt. Allow Cable to retract fully and then pull it quickly. Repeat until the engine starts. MAINTENANCE Note: If engine does not start, check engine oil level. Engine will not start with low or no engine oil. 5 Note: Do not let the Starter Handle snap back against the engine. Hold it as it recoils so it doesn’t hit the engine. ITEM 63405 For technical questions, please call 1-888-866-5797. Page 11 6. Allow the Engine to run for several seconds. Then, if the Choke lever is in the START position, move the Choke Lever very slowly to its RUN position. NOTE: Moving the Choke Lever too fast could stall the engine. SAFETY IMPORTANT: Allow the engine to run at no load for five minutes with no load after each start-up so that the engine can stabilize. 6 7. Adjust the Throttle as needed. 8. Break-in Period: a. Breaking-in the engine will help to ensure proper equipment and engine operation. b. The operational break-in period will last about 3 hours of use. During this period: • Do not apply a heavy load to the equipment. • Do not operate the engine at its maximum speed. c. The maintenance break-in period will last about 20 hours of use. After this period: • Change the engine oil. Note: Failure to change the oil regularly may damage the engine and void the warranty. Under normal operating conditions subsequent maintenance follows the schedule explained in the MAINTENANCE AND SERVICING section. SETUP Stopping the Engine 1. To stop the engine in an emergency, turn the Engine Switch off. O I 2. Under normal conditions, use the following procedure: a. Slide the Throttle to SLOW (the “turtle”). OPERATION a b. Turn the Engine Switch off. O NOTICE See “Long-Term Storage” on page 16 for complete storage instructions. I b MAINTENANCE Page 12 For technical questions, please call 1-888-866-5797. ITEM 63405 Maintenance and Service TO PREVENT SERIOUS INJURY FROM ACCIDENTAL STARTING: Turn the Power Switch of the equipment to its “OFF” position, wait for the engine to cool, and disconnect the spark plug cap before performing any inspection, maintenance, or cleaning procedures. TO PREVENT SERIOUS INJURY FROM EQUIPMENT FAILURE: Do not use damaged equipment. If abnormal noise, vibration, or excess smoking occurs, have the problem corrected before further use. SAFETY WARNING Follow all service instructions in this manual. The engine may fail critically if not serviced properly. Many maintenance procedures, including any not detailed in this manual, will need to be performed by a qualified technician for safety. If you have any doubts about your ability to safely service the equipment or engine, have a qualified technician service the equipment instead. Note: This maintenance schedule is intended solely as a general guide. If performance decreases or if equipment operates unusually, check systems immediately. The maintenance needs of each piece of equipment will differ depending on factors such as duty cycle, temperature, air quality, fuel quality, and other factors. Note: The following procedures are in addition to the regular checks and maintenance explained as part of the regular operation of the engine and pump. Procedure Before Each Use Monthly or Every 3 mo. or Every 6 mo. or every 20 50 hr. of use 100 hr. of use hr. of use Yearly or every 300 hr. of use SETUP Cleaning, Maintenance, and Lubrication Schedule Every 2 Years Brush off outside of engine Check engine oil level Check air cleaner Check deposit cup Change engine oil Check and clean spark plug 1. Check/adjust idle speed 2. Check/adjust valve clearance 3. Clean fuel tank, filter and carburetor ** 4. Clean carbon build-up from combustion chamber Replace fuel line if necessary ** ** OPERATION * Clean air cleaner MAINTENANCE *Service more frequently when used in dusty areas. **These items should be serviced by a qualified technician. ITEM 63405 For technical questions, please call 1-888-866-5797. Page 13 SAFETY Checking and Filling Fuel Engine Oil Change WARNING! TO PREVENT SERIOUS INJURY FROM FIRE: Fill the fuel tank in a well-ventilated area away from ignition sources. If the engine is hot from use, shut the engine off and wait for it to cool before adding fuel. Do not smoke. CAUTION! Oil is very hot during operation and can cause burns. Wait for engine to cool before changing oil. 1. Clean the Fuel Cap and the area around it. 2. Unscrew and remove the Fuel Cap. Note: Do not use gasoline containing more than 10% ethanol (E10). Do not use E85 ethanol. Add fuel stabilizer to the gasoline or the Warranty is VOID. Note: Do not use gasoline that has been stored in a metal fuel container or a dirty fuel container. It can cause particles to enter the carburetor, affecting engine performance and/or causing damage. SETUP 3. If needed, fill the Fuel Tank to about 1 inch under the fill neck of the Fuel Tank with 87 octane or higher unleaded gasoline that has been treated with a fuel stabilizer additive. Follow fuel stabilizer manufacturer’s recommendations for use. 1. Make sure the engine is stopped and is level. 2. Close the Fuel Valve. 3. Place a drain pan (not included) underneath the crankcase’s drain plug. 4. Remove the drain plug and, if possible, tilt the crankcase slightly to help drain the oil out. Recycle used oil. 5. Replace the drain plug and tighten it. 6. Clean the top of the Dipstick and the area around it. Remove the Dipstick by turning it counterclockwise, and wipe it off with a clean, lint free rag. Full level Full level 4. Then replace the Fuel Cap. 5. Wipe up any spilled fuel and allow excess to evaporate before starting engine. To prevent FIRE, do not start the engine while the smell of fuel hangs in the air. 7. Add the appropriate type of oil until the oil level is at the full level. SAE 10W-30 oil is recommended for general use. The SAE Viscosity Grade chart shows other viscosities to use in different average temperatures. SAE Viscosity Grades 30 OPERATION 10W-30 5W-30 -20 0 20 40 60 80 100°F Average outdoor temperature 8. Thread the dipstick back in clockwise. NOTICE: Do not run the engine with too little oil. Engine will not start with low or no engine oil. MAINTENANCE Page 14 For technical questions, please call 1-888-866-5797. ITEM 63405 Spark Plug Maintenance 1. To remove the air filter cover, push in and lift up on the Filter Cover Tab, pivoting the cover at the Base Hinge. Remove the filter and check for dirt. Clean as described below. Spark Plug Cap SAFETY Air Filter Element Maintenance Filter Cover Filter Cover Tab Filter 1. Disconnect spark plug cap from end of plug. Clean out debris from around spark plug. Base Hinge 2. Using a spark plug wrench, remove the spark plug. • Foam filter element: Wash the element in warm water and mild detergent several times. Rinse. Squeeze out excess water and allow it to dry completely. Soak the filter in lightweight oil briefly, then squeeze out the excess oil. 3. Install the cleaned filter. Secure the Air Cleaner Cover before use. Recommended Spark Plug Brand NGK® NHSP® / TORCH® Part # BP-6ES F6TC NOTICE: Using an incorrect spark plug may damage the engine. 4. When installing a new spark plug, adjust the plug’s gap to the specification on the Technical Specifications chart. Do not pry against the electrode, the spark plug can be damaged. 5. Install the new spark plug or the cleaned spark plug into the engine. Gasket-style: Finger-tighten until the gasket contacts the cylinder head, then about 1/2-2/3 turn more. Non-gasket-style: Finger-tighten until the plug contacts the head, then about 1/16 turn more. NOTICE: Tighten the spark plug properly. If loose, the spark plug will cause the engine to overheat. If overtightened, the threads in the engine block will be damaged. OPERATION 2. Cleaning: SETUP 3. Inspect the spark plug: If the electrode is oily, clean it using a clean, dry rag. If the electrode has deposits on it, polish it using emery paper. If the white insulator is cracked or chipped, the spark plug needs to be replaced. MAINTENANCE 6. Apply dielectric spark plug boot protector (not included) to the end of the spark plug and reattach the wire securely. ITEM 63405 For technical questions, please call 1-888-866-5797. Page 15 After Each Use 1. Remove drain plug from front of Pump. 2. Tilt Pump forward to drain all remaining water from inside. SAFETY Drain Plug Long-Term Storage SETUP When the equipment is to remain idle for longer than 20 days, prepare the engine for storage as follows: c. Replace spark plug, but leave spark plug cap disconnected. 1. CLEANING: Wait for engine to cool, then clean engine with dry cloth. NOTICE: Do not clean using water. The water will gradually enter the engine and cause rust damage. Apply a thin coat of rust preventive oil to all metal parts. d. Pull Starter Handle to distribute oil in cylinder. Stop after one or two revolutions when you feel the piston start the compression stroke (when you start to feel resistance). OPERATION 2. FUEL: To protect the fuel tank during storage, fill the tank with gasoline that has been treated with a fuel stabilizer additive. Follow fuel stabilizer manufacturer’s recommendations for use. Refer to Checking and Filling Fuel on page. WARNING! TO PREVENT SERIOUS INJURY FROM FIRE: Fill tank in a well-ventilated area away from ignition sources. If the engine is hot from use, shut the engine off and wait for it to cool before adding fuel. Do not smoke. 3. LUBRICATION: a. Change engine oil. b. Clean out area around spark plug. Remove spark plug and pour one tablespoon of engine oil into cylinder through spark plug hole. 4. BATTERY: Disconnect battery cables (if equipped). Recharge batteries monthly while in storage. 5. STORAGE AREA: Cover and store in a dry, level, well-ventilated area out of reach of children. Storage area should also be away from ignition sources, such as water heaters, clothes dryers, and furnaces. NOTICE: For every 3 months of an extended storage period, the pump must be connected to a water supply, primed, started, and allowed to run for 15 – 20 minutes or the Warranty is VOID. 6. AFTER STORAGE: Before starting the engine after storage, keep in mind that untreated gasoline will deteriorate quickly. Drain the fuel tank and change to fresh fuel if untreated gasoline has been sitting for a month, if treated gasoline has been sitting beyond the fuel stabilizer’s recommended time period, or if the engine does not start properly. MAINTENANCE Page 16 For technical questions, please call 1-888-866-5797. ITEM 63405 Pump Troubleshooting 1. Incorrect lubrication or not enough lubrication. 2. Worn parts. 1. Lubricate using recommended oil or grease according to directions. 2. Have qualified technician inspect internal mechanism and replace parts as needed. 1. Low engine speed. 2. Severely clogged air filter. 3. Improper lubrication. 1. Qualified technician should increase no load speed to 3,800±100 RPM by adjusting pressure switch. 2. Clean air filter. 3. Check for proper oil level. 1. 2. 3. 4. 5. 6. 7. 1. 2. 3. 4. 5. 6. 7. Unit stalls Pump does not pump water Likely Solutions Pump is not primed. Intake Strainer clogged. Air leak at intake connector. Hose leaks. Suction hose has collapsing wall. Hose has too small diameter. Pump is too high above water surface. 1. Suction hose collapsed, damaged, too long or diameter is too small. 2. Air leak at connector. Low Pump Output 3. Strainer clogged. 4. Discharge hose damaged, too long or diameter too small. Prime Pump. Clean Intake Strainer or replace if damaged. Replace Coupling Gasket or tighten clamp. Replace hose. Use hose with non-collapsible wall. Use hose with diameter 2" or greater. Locate Pump at a lower level so it doesn’t have to work so hard to lift the water. 1. Replace or adjust suction hose. SAFETY Pump overheats Possible Causes SETUP Problem 2. Replace Coupling Gasket or tighten Clamp. 3. Clean Strainer. 4. Replace or adjust Discharge Hose. MAINTENANCE OPERATION Follow all safety precautions whenever diagnosing or servicing the equipment or engine. ITEM 63405 For technical questions, please call 1-888-866-5797. Page 17 Engine Troubleshooting Problem Possible Causes Engine will not start FUEL RELATED: Probable Solutions FUEL RELATED: SAFETY SETUP OPERATION MAINTENANCE 1. No fuel in tank or fuel valve closed. 1. Fill fuel tank with fresh 87+ octane stabilizertreated unleaded gasoline and open fuel valve. Do not use gasoline with more than 10% ethanol (E15, E20, E85, etc.). 2. Choke not in START position, cold engine. 2. Move Choke to START position. 3. Gasoline with more than 10% ethanol used. (E15, E20, E85, etc.) 3. Clean out ethanol rich gasoline from fuel system. Replace components damaged by ethanol. Use fresh 87+ octane stabilizertreated unleaded gasoline only. Do not use gasoline with more than 10% ethanol (E15, E20, E85, etc.). 4. Low quality or deteriorated, old gasoline. 4. Use fresh 87+ octane stabilizer-treated unleaded gasoline. Do not use gasoline with more than 10% ethanol (E15, E20, E85, etc.). 5. Carburetor not primed. 5. Pull on Starter Handle to prime. 6. Dirty fuel passageways. 6. Clean out passageways using fuel additive. Heavy deposits may require further cleaning. 7. Carburetor needle stuck. Fuel can be smelled in the air. 7. Gently tap side of carburetor float chamber with screwdriver handle. 8. Too much fuel in chamber. This can be caused by the carburetor needle sticking. 8. Turn Choke to RUN position. Remove spark plug and pull the start handle several times to air out the chamber. Reinstall spark plug and set Choke to START position. 9. Clogged Fuel Filter. 9. Replace Fuel Filter. IGNITION (SPARK) RELATED: IGNITION (SPARK) RELATED: 1. Spark plug cap not connected securely. 1. Connect spark plug cap properly. 2. Spark plug electrode wet or dirty. 2. Clean spark plug. 3. Incorrect spark plug gap. 3. Correct spark plug gap. 4. Spark plug cap broken. 4. Replace spark plug cap. 5. Incorrect spark timing or faulty ignition system. 5. Have qualified technician diagnose/ repair ignition system. COMPRESSION RELATED: COMPRESSION RELATED: 1. Cylinder not lubricated. Problem after long storage periods. 1. Pour tablespoon of oil into spark plug hole. Crank engine a few times and try to start again. 2. Loose or broken spark plug. (Hissing noise will occur when trying to start.) 2. Tighten spark plug. If that does not work, replace spark plug. If problem persists, may have head gasket problem, see #3. 3. Loose cylinder head or damaged head gasket. (Hissing noise will occur when trying to start.) 3. Tighten head. If that does not remedy problem, replace head gasket. 4. Engine valves or tappets mis-adjusted or stuck. 4. Have qualified technician adjust/ repair valves and tappets. ENGINE OIL RELATED: ENGINE OIL RELATED: 1. Low engine oil. 1. Fill engine oil to proper level. Check engine oil before EVERY use. 2. Engine mounted on slope, triggering low oil shutdown. 2. Operate engine on level surface. Check engine oil level. Follow all safety precautions whenever diagnosing or servicing the equipment or engine. Page 18 For technical questions, please call 1-888-866-5797. ITEM 63405 Engine Troubleshooting (cont.) 1. Spark plug cap loose. 1. Check cap and wire connections. 2. Incorrect spark plug gap or damaged spark plug. 2. Re-gap or replace spark plug. 3. Defective spark plug cap. 3. Replace spark plug cap. 4. Old or low quality gasoline. 4. Use only fresh 87+ octane stabilizer-treated unleaded gasoline. Do not use gasoline with more than 10% ethanol (E15, E20, E85, etc.). 5. Incorrect compression. 5. Diagnose and repair compression. (Use Engine will not start: COMPRESSION RELATED section.) 1. Fuel tank empty or full of impure or low quality gasoline. 1. Fill fuel tank with fresh 87+ octane stabilizertreated unleaded gasoline. Do not use gasoline with more than 10% ethanol (E15, E20, E85, etc.). 2. Low oil shutdown. 2. Fill engine oil to proper level. Check engine oil before EVERY use. 3. Defective fuel tank cap creating vacuum, preventing proper fuel flow. 3. Test/replace fuel tank cap. 4. Faulty magneto. 4. Have qualified technician service magneto. 5. Disconnected or improperly connected spark plug cap. 5. Secure spark plug cap. Engine stops when under heavy load 1. Dirty air filter 1. Clean element. 2. Engine running cold. 2. Allow engine to warm up prior to operating equipment. Engine knocks 1. Old or low quality gasoline. 1. Fill fuel tank with fresh 87+ octane stabilizertreated unleaded gasoline. Do not use gasoline with more than 10% ethanol (E15, E20, E85, etc.). 2. Engine overloaded. 2. Do not exceed equipment’s load rating. 3. Incorrect spark timing, deposit buildup, worn engine, or other mechanical problems. 3. Have qualified technician diagnose and service engine. 1. Impure or low quality gasoline. 1. Fill fuel tank with fresh 87+ octane stabilizertreated unleaded gasoline. Do not use gasoline with more than 10% ethanol (E15, E20, E85, etc.). 2. Engine too cold. 2. Use cold weather fuel and oil additives to prevent backfiring. 3. Intake valve stuck or overheated engine. 3. Have qualified technician diagnose and service engine. 4. Incorrect timing. 4. Check engine timing. Engine stops suddenly Engine backfires After sudden impact, engine will run, but equipment will not operate Shaft key or other shear pin broken by impact to disconnect engine and limit damage. Have qualified technician check and replace broken shaft key or other shear pins. For technical questions, please call 1-888-866-5797. MAINTENANCE Follow all safety precautions whenever diagnosing or servicing the equipment or engine. ITEM 63405 SAFETY Probable Solutions SETUP Engine misfires Possible Causes OPERATION Problem Page 19 Warranties Limited 90 Day Warranty (Retail) SAFETY Harbor Freight Tools Co. makes every effort to assure that its products meet high quality and durability standards, and warrants to the original purchaser that this product is free from defects in materials and workmanship for the period of 90 days from the date of purchase. This warranty does not apply to damage due directly or indirectly, to misuse, abuse, negligence or accidents, repairs or alterations outside our facilities, criminal activity, improper installation, normal wear and tear, or to lack of maintenance. We shall in no event be liable for death, injuries to persons or property, or for incidental, contingent, special or consequential damages arising from the use of our product. Some states do not allow the exclusion or limitation of incidental or consequential damages, so the above limitation of exclusion may not apply to you. THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THE WARRANTIES OF MERCHANTABILITY AND FITNESS, EXCEPT FOR THE EMISSIONS CONTROL SYSTEM WARRANTY BELOW. SETUP To take advantage of this warranty, the product or part must be returned to us with transportation charges prepaid. Proof of purchase date and an explanation of the complaint must accompany the merchandise. If our inspection verifies the defect, we will either repair or replace the product at our election or we may elect to refund the purchase price if we cannot readily and quickly provide you with a replacement. We will return repaired products at our expense, but if we determine there is no defect, or that the defect resulted from causes not within the scope of our warranty, then you must bear the cost of returning the product. This warranty gives you specific legal rights and you may also have other rights which vary from state to state. Emissions Control System Warranty Harbor Freight Tools (HFT) is pleased to explain the emissions control system warranty on your Small Off-Road Engine produced after January 1, 2015 (engine), in addition to the Retail Warranty above. HFT warrants that the emissions control system on your engine is designed, built, and equipped so that it conforms to the United States Environmental Protections Agency’s (EPA) emissions requirements in effect at the time of manufacture. HFT also warrants that the emissions control system on your engine will be free from defects in material and workmanship for two (2) years, provided there has been no improper maintenance, misuse, or abuse of your engine. Your emissions control system may include parts such as the carburetor or fuel-injection system, and the ignition system. Also included may be hoses, belts, connectors and other emissions-related assemblies. OPERATION WHAT WE WILL DO Where a warrantable condition exists, HFT will repair or replace, at our option, any emissions-related part on your engine if it becomes defective, malfunctions, or otherwise fails to conform with this warranty under normal use and service during the two (2) year term of this warranty at no cost to you, including diagnosis, parts and labor. This warranty applies to the original purchaser and any subsequent owner within the two year warranty period. MAINTENANCE Page 20 For technical questions, please call 1-888-866-5797. ITEM 63405 WHAT IS COVERED? 1. Fuel Metering System a. Carburetor and its internal parts. b. Fuel pump (if so equipped). c. Cold start enrichment system. 4. Catalyst System (if so equipped) a. Exhaust pipe stud. b. Muffler. c. Catalytic converter (if so equipped). 2. Air Induction System a. Intake pipe/manifold. b. Air cleaner. 5. Miscellaneous Items Used in Above Systems a. Vacuum, temperature and time sensitive valves and switches. b. Hoses, belts, connectors, and assemblies. 3. Ignition System a. Spark plug. b. Magneto ignition system. SAFETY The following parts are examples of components of the emissions control system and are covered by this two (2) year warranty. For a full list of emissions control components covered by this warranty, please see 40 CFR §1068, Appendix I. This warranty does not cover normal maintenance services or replacement of maintenance items such as filters, oils, or spark plugs. In order to obtain warranty repair or replacement, you may either (a) contact HFT product support at 1-888-866-5797 or productsupport@harborfreight.com; or (b) bring the to your nearest Harbor Freight Tools retail store. When going to the retail store or contacting product support, you must indicate the specific emissions control part or defect that you are claiming and the date this was originally purchased. The nearest Harbor Freight Tools retail store can be found on the internet at http://www.harborfreight.com. PLEASE READ THE FOLLOWING CAREFULLY MAINTENANCE THE MANUFACTURER AND/OR DISTRIBUTOR HAS PROVIDED THE PARTS LIST AND ASSEMBLY DIAGRAM IN THIS MANUAL AS A REFERENCE TOOL ONLY. NEITHER THE MANUFACTURER OR DISTRIBUTOR MAKES ANY REPRESENTATION OR WARRANTY OF ANY KIND TO THE BUYER THAT HE OR SHE IS QUALIFIED TO MAKE ANY REPAIRS TO THE PRODUCT, OR THAT HE OR SHE IS QUALIFIED TO REPLACE ANY PARTS OF THE PRODUCT. IN FACT, THE MANUFACTURER AND/OR DISTRIBUTOR EXPRESSLY STATES THAT ALL REPAIRS AND PARTS REPLACEMENTS SHOULD BE UNDERTAKEN BY CERTIFIED AND LICENSED TECHNICIANS, AND NOT BY THE BUYER. THE BUYER ASSUMES ALL RISK AND LIABILITY ARISING OUT OF HIS OR HER REPAIRS TO THE ORIGINAL PRODUCT OR REPLACEMENT PARTS THERETO, OR ARISING OUT OF HIS OR HER INSTALLATION OF REPLACEMENT PARTS THERETO. OPERATION As the engine owner, you are responsible for the performance of the required maintenance listed in your Owner’s Manual. HFT may deny you warranty coverage if your engine or a part has failed due to abuse (including failure to follow the fuel use instructions contained in this manual), neglect, improper maintenance, or unapproved modifications. SETUP WHAT YOU MUST DO TO OBTAIN WARRANTY SERVICE ITEM 63405 For technical questions, please call 1-888-866-5797. Page 21 Parts Lists and Diagrams Parts List SAFETY Part SETUP OPERATION MAINTENANCE 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 Page 22 Description Gasket, Cylinder Head Cover Subassembly, Cylinder Head Gasket, Cylinder Head Cover Tube, Breather Bolt Stud Stud Stud Pin Bolt, Cylinder Head Plug, Spark Head Subassembly, Cylinder Crankcase Subassembly. Sensor, Engine Oil Gear Assy, Governor Arm, Governor Bolt, Drain Plug Washer Bearing Seal, Oil Washer Pin Bolt Cover, Crankcase Bearing Seal, Oil Gasket, Crankcase Pin Dipstick Subassembly, Oil Plug Subassembly, Engine Oil Bolt Crankshaft Assy. Clip, Piston Pin Piston Pin, Piston Rod, Connecting Ring, The First Ring, The Second Ring Set, Oil Camshaft Assy. Valve, Exhaust Valve, Intake Seat, Valve Spring Retainer, Exhaust Valve Rotator, Valve Guide, Seal Tappet, Valve Lifter, Valve Plate Subassembly, Lifter Stopper Bolt, Valve Adjusting Rocker, Valve Nut, Valve Adjusting Nut, Valve Lock Spring, Valve Starter Assy, Recoil Bolt Shroud Shroud, Cylinder Body Shield,Lower Protector, Oil Switch Subassembly, Stop Engine Bolt Bolt Collar Bolt Bolt Carburetor Assy. Gasket, Air Cleaner Qty 1 1 1 1 4 1 1 2 2 4 1 1 1 1 1 1 2 2 1 1 1 1 2 1 1 1 1 2 1 1 6 1 2 1 1 1 1 1 1 1 1 1 1 1 1 1 2 2 1 2 2 2 2 2 1 3 1 1 1 1 1 2 1 1 1 4 1 1 Part 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 101 102 103 104 105 106 107 108 109 110 111 112 113 114 115 116 117 118 119 120 121 122 123 124 125 126 127 128 129 130 131 132 133 134 135 Description Gasket, Carburetor Plate, Carburetor Insulator Gasket, Carburetor Insulator Nut Cleaner, Air Gasket, Exhaust Outlet Nut Muffler Assy Tank, Fuel Strainer, Fuel Cover, Fuel Tank Outlet Subassembly, Fuel Tank Oil Clamp Tube, Fuel Bolt Nut Nut, Flywheel Pulley,Starter Impeller Flywheel Subassembly Bolt Coil, Ignition Control Assy, Throttle Bolt Spring, Governor Rod, Governor Spring, Throttle Valve Returning Bolt, Governor Support Nut Support Subassembly, Governor Hoop Assy, Hose Screen Connector Intake Screen Bolt Washer Washer Inlet, Water Gasket, Inlet Water Plug, Thread Washer, Screw Plug Outlet, Water Gasket, Outlet Pump Body Ring, Whorl Case Sealing Case, Whorl Bolt Washer Impeller, Water Pump Key Cushion, Water Pump Joint Ring, Impeller Seal Seal,Porcelain Seal Assy, Mechanism Joint, Water Pump Washer Bolt Pump Assy, Water Frame Assy, Engine Bolt Seat, Engine Frame Shock Absorption Core Nut Bolt Nut Jacket, Rubber Valve, One Way Clamp Hose, Fuel Steam Rubber For technical questions, please call 1-888-866-5797. Qty 1 1 1 2 1 1 2 1 1 1 1 1 3 1 1 2 1 1 1 1 2 1 1 2 1 1 1 1 1 1 3 1 1 11 7 4 1 1 2 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 4 4 1 1 4 4 4 4 4 1 1 1 1 ITEM 63405 102 103 103 107 108 102 99 10 102 103 109 110 31 31 102 31 31 31 7 1 9 25 103 102 102 102 24 26 31 102 102 103 103 104 104 30 102 8 99 102 105 104 104 103 107 106 111 108 11 8 6 9 29 28 125 48 47 28 32 23 23 92 92 14 42 54 46 49 44 54 41 43 50 50 45 51 51 40 47 53 52 52 70 71 53 48 27 SETUP SAFETY 123 124 124 124 113 112 2 3 10 10 10 12 37 38 91 97 34 95 96 94 93 33 15 39 67 98 36 75 19 17 35 33 75 22 16 18 21 73 74 13 76 90 89 83 89 88 20 18 OPERATION 123 123 123 124 115 5 4 69 72 72 17 80 81 84 82 77 81 64 84 59 85 134 86 81 132 87 62 62 58 135 65 66 126 79 78 133 63 60 57 129 66 131 131 131 131 129 130 128 127 55 66 61 128 127 130 66 Note: Some parts are listed and shown for illustration purposes only, and are not available individually as replacement parts. 68 129 130 127 128 MAINTENANCE 121 120 119 117 116 114 Assembly Diagram 122 118 99 100 101 5 5 5 Record Product’s Serial Number Here: Note: If product has no serial number, record month and year of purchase instead. 129 128 56 127 56 56 Page 23 For technical questions, please call 1-888-866-5797. ITEM 63405 3491 Mission Oaks Blvd. • PO Box 6009 • Camarillo, CA 93011 • 1-888-866-5797
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