Duromax XP652WP, XP650WP, XP904WP User Manual

1

Gasoline Water Pump

Owner’s Manual

Max Tool Customer Service

[e-mail] or call 1-800-629-3325 (option 3)
Monday -Thursday 6am to 7pm, Friday - Saturday 6am to 3pm. PST

Product Support

(Product: information, application & warranty questions)

[e-mail] or call 1-800-629-3325 (option 3)
Monday -Thursday 6am to 7pm, Friday - Saturday 6am to 3pm. PST

2

This manual provides information regarding the operation and maintenance of these products. We have
made every effort to ensure the accuracy of the information in this manual. We reserve the right to
change this product at any time without prior notice.
Please keep this manual available to all users during the entire life of the gasoline water pump.

CONTENTS

Ⅰ. General Safeguards …………………………………………… 1
Ⅱ. Location of Component Parts ………………………………… 3
Ⅲ. Operation before Starting Up ………………………………… 4
Ⅳ. Starting of Engine ……………………………………………… 9
Ⅴ. Use in Highland Areas ………………………………………… 1 1
Ⅵ. Operation of Water Pump …………………………………… 12
Ⅶ. Shutting Down the Engine …………………………………… 13
Ⅷ. Maintenance …………………………………………………… 14
Ⅸ. Transportation and Storage …………………………………… 19
Ⅹ. Troubleshooting ………………………………………………… 21
Ⅺ. Specifications …………………………………………………… 23

3

Ⅰ. General Safeguards

Safety Precautions

Before starting the engine, perform inspections according to the
procedures described on pre-operation inspections to avoid
accidents and damage to your machine.

For safety, never attempt using this GEP (gasoline engine
powered) water pump to deliver inflammable or corrosive liquids
(such as gasoline and acids). Likewise, corrosive mediums,
seawater, chemical solvents, alkaline liquids (such as used gasoline,
liquor and honey) should be avoided.

Place the water pump on a solid, level position surface to avoid
tilting or turnover that may give rise to spilling of fuel.

To prevent fire hazards, keep the pump well ventilated during
operation and maintain a distance of at least l meter between the
machine and the wall or other machines. Keep away from
inflammable substances.

Do not allow children and pets to enter the working area as this
may increase the chance of their getting burned by hot surfaces of
the operating parts.

Know how to stop the water pump quickly how to operate the
controls. Do not use the pump against the prescribed operating
rules.

WARNING：

Safety Precautions

The gasoline fuel is highly inflammable and may explode under

certain conditions.

Do the fueling with the engine shut down and in a well-ventilated

Please read this operation manual to have a
thorough understanding of the content there
before use the product. Failure to do so may
lead to personal injury or mechanical damage.

4

environment. No smoking is allowed and no open fire or sparks
allowed to exist in areas where fueling is carried out or the fuel is
stored.

Do not allow the fuel to overflow the fuel tank. Be sure to recap

the tank and tighten it after refueling.

When fueling, take care not to spill the gasoline about as the
gasoline vapor may easily get ignited to cause a fire hazard. Be sure
to remove the spilled gasoline as by wiping before starting the
engine.

Do not run the engine indoors or in a poorly ventilated space as
the exhaust gas produced by the running engine contains toxic
carbon monoxide that may cause the loss of personal
consciousness or even death.

5

Ⅱ. Location of Component Parts

6

Ⅲ. Operation before Starting Up

1. Connecting the water inlet
Connect the water inlet with a commercially available hose,
connector and fastener clip. The inlet hose must be a continuous
non-foldable structure with a length not more than required and
should be placed near to the source of water so as to achieve the
pump should be fitted to the end of the hose with the hose connector
as shown in the figure below.
CAUTION: Before pumping water, attach the filter to the end of the
hose to filter out foreign matters in the water, the presence of which
may cause clogging and damage to the wane wheel.
NOTE: The hose connector and fastener clip should be securely
fastened to prevent air leaks and reduction in suction power. A loose
hose will reduce the pump performance and self-suction capacity.

2. Connecting the water outlet
Connect the water outlet with a commercially available hose, hose
connector and fastener clip. Large diameter hoses are the most
effective while small ones will increase the flow resistance and
reduce the output power of the pump.

7

NOTE:

Be sure to the fastener clip is securely fastened to prevent the
outlet hose from coming off under high water pressure.

3.Checking the oil level

CAUTION:

·The oil is one of the major factors affecting engine performance
and life. Do not use dirty oil or vegetable oil.

·Be sure to check the oil level with the engine shut down and
placed on a level surface.

Please use the SE15-40, 4-stroke engine oil as recommended.
Please use the type of oil with a proper viscosity according to the

local average temperature.

Oil shortage alarm system (OSAS) (installation position)

The OSAS is designed to avoid damage of the engine due to the
shortage of oil in the crankcase. The system will automatically shut
down the engine just before the crankcase oil level drops down to
the minimum line of safety (with the engine switch staying in the ON
position).

If the engine is shut down and cannot be started again, check the
oil level before initiating further troubleshooting procedures.

Remove the oil dipstick and wipe it dry.

Insert the dipstick into the oil filler but not screw it in.

Replenish the crankcase with the recommended type of oil until

8

the oil level comes up to the upper most position of the refilled if the
existing oil level is found too low.

CAUTON:

·Running the engine at a low oil level will cause damage to it.

4. Checking the fuel level
Uncap the fuel tank and check the fuel level. Pouring gasoline if
the fuel level is found too low.
Please use the type of gasoline recommended by the Dealer
(Using the low lead content or lead-free gasoline type is good for
minimizing carbon deposits inside the combustion chamber).
Do not use a mixture of gasoline and oil or dirty gasoline to
prevent dirt, dust or water from entering the fuel tank.
CAUTION:

·The gasoline fuel is highly inflammable and may explode under
certain conditions.

·Do the fueling with the engine shut down and in a well-ventilated
environment. No smoking is allowed and no open fire or sparks
allowed to exist in areas where fueling is carried out or the fuel is
stored.

·Do not allow the fuel to overflow the fuel tank. Be sure to recap
the tank and tighten it after refueling.

9

·When fueling, take care not to spill the gasoline about as the
gasoline vapor may easily get ignited to cause a fire hazard. Be sure
to remove the spilled gasoline as by wiping before starting the
engine.

·Avoid frequent or extensive exposure of the skin to gasoline or
breathing in the gasoline vapor. Keep the gasoline out of the reach of
children.

·Fuel tank capacity: 1.0 gallons (US. 3.6 liters)

5. Checking the air cleaner filter element
Screw the wing nut and remove the washer and cleaner cover.

Check the filter element to see if it is too dirty and clean it if
necessary.

CAUTION:

Do not run the engine without the air cleaner as this may quicken
engine wear if dirt or dust is sucked into the engine through the
carburetor.

10

6. Checking and filling the pump with cooling water

The pump must be filled with water before it is put to operation.
CAU TION:

·Do not attempt running the pump without cooling water or the
pump will get overheated. Extensive running without cooling water
may also damage the air tightness of the pump. If the pump is found
running dry, stop the engine and pouring in water when it cools
down.

1 1

Ⅳ. Starting engine

1. Turn on the fuel tap (by setting it to the ON position).

2. Close the choke.
NOTE:

·The choke is not required when starting the engine warm or the
ambient temperature is rather high, (i.e. keep the choke open when
starting the engine).

3. Set the engine switch to the ON position.

4. Turn the throttle control lever slowly to the left.

12

5. Gently pull up the starter lever until a resistance is felt and then
quickly pull it up.
CAUTION:

·Do not allow the starter lever to retract quickly into the engine. Let
it go back gently to avoid damaging the starter.

Ⅴ.Use in Highland Areas

Operation in Highland Conditions
In highland areas (with a high ASL elevation), the air-fuel mixture

produced by a standard carburetor will be too thick and result in a
reduced engine performance and soared fuel consumption. For
operation in highland areas, the engine performance may be
increased by using a smaller diameter carburetor nozzle and
readjusting the carburetor idle speed. If the water pump is frequently
used in areas with a ASL elevation of more than 1800 meters (6000
feet), ask the local dealer to replace or readjust the carburetor
beforehand. Even if the engine is fitted with a carburetor nozzle of an
appropriate size, the engine power will still go down by about 3.5%
each time when the ASL elevation goes up by 305 meters (1000
feet). If no replacement or readjustment is ever made of the
carburetor, the highland effect of the engine output power will be
even more obvious.
CAUTION:

13

·Using the water pump in areas where the ASL elevation is lower
than suitable for the carburetor nozzle will lead to a decreased
engine performance and overheating of the engine and even cause
serious damage to the engine due to an extremely thin air-fuel
mixture.

Ⅵ. Operation of the Water Pump

1. Gradually open the choke after the engine warms up.

2. Set the throttle to the predetermined RPM.

Ⅶ. Shutting Down the Engine

1. Set the throttle control lever to the right end.

14

2. Set the engine switch to the OFF position.

3. Turn off the fuel tap (by setting to the OFF position).

NOTE:

·To shut down the engine in an emergency, simply set the engine

switch to the OFF position.

Ⅷ. Maintenance

Periodic inspections and fine-tuning are simply indispensable to
keep the water pump working with high performance and regular
maintenance may also lengthen the pump life. Supplied in the table
on the next page are intervals at which the schedules maintenance
jobs are to be done.

WARNING:

·Before any maintenance attempt, be sure to shut down the
engine. If the maintenance job has to be done with the engine at
work, it should take place in a well-ventilated space as the exhaust
gas contains toxic carbon monoxide that causes the loss of personal
consciousness or even death.

15

CAUTION:

·In cases when the pump is used to suck up seawater, be sure to

flush it with fresh water immediately after use to minimize corrosion
and remove deposits.

·Always use the original parts and relevant tools supplied with the
machine to carry out maintenance. Failure to do this may cause
damage to the pump.

NOTE:

⑴ Inspection and maintenance should take place more frequently
if the pump is used in a dirty environment.
⑵ Leave the following inspection and maintenance jobs to the
authorized dealers unless you, the user, have the relevant tools and
necessary DIY skills. In the latter case, refer to service manual.

Table of Maintenance Schedules

Normal

maintenance

Item period

Each
time

Per
month
or 20
hours

Per

month
or 50
hours

Per
month
or 100
hours

Per
month
or 300
hours

Check engine oil
lever

○

Replace engine oil
lever

○ ○

Air cleaner check

○

Air cleaner for clean

Spark plug

○

○*

Fuel supply

Replace per every two years

Wane wheel

○*

Pump case cover

○*

16

Water inlet

○*

Note: “*” items will be maintained with the help of dealers from

general power machinery Co., Ltd.

1. Replacing the engine oil

Oil drains easily and quickly while the engine is warm.

1. Remove the oil dipstick and drain bolt to let out the oil.

2. Screw the drain bolt back in place and tighten it.

3. Pour in clean oil until the desired level is reached.

Oil sump capacity: 0.6 liters
Clean the hands with soap if stained with the engine oil.
NOTE: Be sure to keep the environment clean when disposing
used engine oil. We suggest you collect the waste oil in a container
to be sent to a waste disposal site or a recycling service center of
spill it in the garbage or on the ground.

2. Maintaining the air cleaner
A dirty air cleaner will let less air into the carburetor. To prevent
carburetor malfunctions, be sure to maintain the air cleaner
periodically. More frequent maintenance of the air cleaner will be
necessary if the pump is working in an extremely dirty environment.
DO not clean the air cleaner with a low ignition point solvent
because it may get enflamed or even explode under certain

17

circumstances.
CAUTION: Do not use the water pump without an air cleaner. The
dirt or dust if sucked into the engine may quicken engine wear.

1) Unscrew the wing nut and remove the air cleaner cover and

filter element.

2) Clean the filter element with a detergent solution inflammable or
with a high ignition point and let it dry thoroughly after cleaning.

3) Immerse the filter element into clean oil and then squeeze out
the excessive amount of oil.

4) Put the filter element as well as the air cleaner back in place.

3. Maintaining the spark plug
The recommended type of spark plug is NHSP LD P6RTCU.
To ensure normal operation of the engine, the spark plug should
have a correct gap and should remain free of carbon deposits.

1) Remove the plug cap.
The muffler may be very hot if the engine is still running. Take care
not to touch the muffler.

2) Check the spark plug visually. Discard the spark plug if it is

18

obviously worn out or the insulation ring on it is broken or cracked.
Clean the spark plug with a brush when put it back in place.

3) Check the plug gap with a feeler gauge.
Vary the gap by moving the side electrode.
Normal plug gap: 0.70~0.80mm

4) Check the plug O-ring for normal condition. Screw it in with the
plug wrench to protect the plug thread.

NOTE:

·In the case of screwing in a new spark plug, tighten it by an
additional 1/2 screw turn after the plug reaches and pushes on the
O-ring, while in the case of a used spark plug, an additional 1/2~1/4
screw turn is necessary.

CAUTION:

· Make sure the spark plug is properly tightened. Improper

19

tightening may cause the engine to be overheated or damaged.
Never use spark plugs with an incorrect thermal value range.

Ⅸ. Transportation and Storage

CAUTION:

·To avoid causing a fire hazard, let the engine cool down before
transportation or indoor storage of the pump.

·Before transporting the pump, set the fuel tap to the OFF position
and place the pump body in a level position to prevent the fuel from
spilling out. The spilled gasoline or the gasoline vapor may get
ignited.
Note and do the following before storing pump for an extended
period of time:

1) Make sure the storage area is free of moisture or dust.

2) Ch\lean the inside of the pump.
The pump may get clogged if it is used to suck up water containing
such matters as earth, sand or heavy fragments.
Before storing, clean the pump by sucking up clean water or
otherwise the wane wheel may be damaged when the pump is put to
use again. After cleaning, unscrew the water drain plug to drain off
the water from inside the pump casing as much as possible. Then
screw the drain plug back into place.

3) Drain off the fuel.
a. Turn off the fuel tap (OFF position), unscrew the drain screw
from the carburetor float chamber to drain off the fuel from inside the
carburetor and collect the gasoline in a suitable container.
b. Turn on the fuel tap (ON position) and collect the gasoline in a
suitable container.
c. Screw the carburetor fuel drain screw back into place.

20

4) Replace the engine oil.

5) Screw off the spark plug, pour a spoonful of clean oil into the
cylinder, turn the engine alternatively for several times to allow
uniform distribution of oil, and then screw in the spark plug again.

6) Pull up the starter lever until a resistance is felt. Stop pull for a
while and pull it up again until the triangle mark on the starter wheel
gets into collimation with the screw hole in the starter (as shown the
sketch below). In this position, both the inlet valve and outlet valve is
closed to prevent corrosion inside the engine.

7) Cover up the pump to keep out dust.

Ⅹ. Troubleshooting

Engine unable to get started:

1) Is there enough fuel?

2) Is the fuel tap turned on?

21

3) Has the fuel reached the carburetor? Make the check by
unscrewing the oil drain screw from under the carburetor with the
fuel tap turned on.

WARNING:

·Should there be a spill of fuel, be sure to clean it before checking
the spark plug and start the engine or otherwise the spilled fuel or
fuel vapor may get ignited

4) Is the engine switch set to the ON position?

5) Is there enough oil in the crankcase?

6) Is the spark plug generating sparks?
a. Uncap the spark plug, clear off the dirt from around the plug and
remove the spark plug.
b. Fit the spark plug into the plug cap.
c. Turn on the engine with the side electrode and pull up the starter
lever to see if there is sparks generated.
d. Ground the engine with the side electrode and pull up the starter
lever to see if there is sparks generated.
e. Replace the spark plug if no spark is found.
Start the engine as directed in the operation manual if sparks are
generated.

7) If the engine still refuses to get started, send the pump to any of
the authorized dealers.

22

The pump unable to such up water:

1) Is it filled with enough amount of water?

2) Is the filter clogged?

3) Is the hose fastener clip tightened?

4) Is the hose damaged?

5) Is the suction head too high?

6) If the pump still fails to work, send it to any of the authorized
dealers.

Ⅺ. Specifications

T y p e

XP65 2 W P

XP65 0 W P

XP904WP

Engine type

XP6.5HP

XP6.5HP

XP9.0HP

Max. Power

4.7kw(7HP)

4.7kw(7HP)

6.5kw(9.0HP)

Displacement

208cc

208cc

270cc

Fuel tank capacity

1.0 Gallons

1.0 Gallons

1.7 Gallons

Oil capacity

0.63 US. Qt.

0.63 US. Qt.

1.16 US. Qt.

23

Water i n t a k e pipe dia.

2″

3″

4″

Water output pipe dia.

2″

3″

4″

Revolution

3600rpm

3600rpm

3600rpm

Max. overhead lift

92ft

98ft

98ft

Max. suction lift

26ft

26ft

26ft

Max. flow rate

158 GPM

220 GPM

427 GPM

Size

18.7×15.6×

15.4(in.)

21.3×17.5×

19.3(in.)

25.2×20.7×

22.3(in.)

24

PARTS LIST AND ASSEMBLY (XP652WP/XP650WP)

25

Item

Part

Qty Description

Item Part

Qty

Description

1

GBT5789-86

13

Flange bolt M6×12

45

DJ170F-1 1 1 0 0 -C

1

Crank case assy.

2

DJ168F-11300-B

1

Cover assembly

46

GB276-89-6205

2

3

DJ168F-11011-A

1

cover assembly

47

DJ168F-15100-A

1

Speed Regulating Gear

4

DJ168F-13204-A

1

Lock Nut

48

DJ168F-15100-A

1

centrifugal assy.

5

DJ168F-13203-A

1

Adjusting Nut

49

DJ168F-13100-B

1

Camshaft assy.

6

DJ168F-13201-A

1

Arm, valve rocker

50

DJ168F-12100-W

1

Crankshaft Assembly

7

DJ168F-13006-A

1

Rotator, valve

51

DJ170F-12200-B

1

T i e -rod Assembly

8

DJ168F-13202-A

2

Fastening Bolt

52

DJ168F-11002-D

1

Pin, dowel, 7×12

9

DJ168F-13005-A

1

Retainer, EX. Valve spring

53

DJ170F-11003-B

1

Crankcase Gasket

10

DJ168F-13004-A

1

Retainer, IN. Valve spring

54

DJ168F-11007-A

1

Oil Filler Assembly

1 1

DJ168F-13300-A

1

Plate, push rod guide

55

DJ168F-11001-C

1

Crankcase cover

12

DJ168F-13003-A

2

Spring, valve

56

DJ168F-11600-A

1

Dipstick cover

26

13

DJ168F-13010-A

1

Returnrer, Exhaust Valve

57

DJ168F-11014-A

2

Oil seal, 25.14×35×7

14

GBT5787-B8-60

4

Flange bolt M8×60

58

GBT5787-B8-35

6

bolt M8×35

15

DJ168F-18500-B

1

Spark Plug F7TC

59

DJ168F-18100-C

1

Ignition Coil

16

DJ170F-11200-B

1

Head comp, cylinder

60

GBT5787-B6-25

2

bolt M6×25

17

DJ168F-14006-C

1

Outlet Gasket

61

DJ168F-1101 2 -A

1

Air-leading Cover

18

DJ170N-14400-A

1

Muffer Assembly

62

DJ170N-15200-A

1

speed adjuster

19

DJ168F-14002-A

2

Bolt head, M8×35

63

DJ170N-15201-A

1

Speed Regulating Bar

20

GBT6177-N-8

2

Flange nut M8

64

DJ168F-16200-C

1

Flywheel

21

DJ168F-14001-A

2

Bolt Stud, 6×90

65

DJ168F-16002-A

1

Flywheel Fan

22

DJ168F-14003-B

1

Inlet Gasket

66

DJ168F-16000-A

1

Starting Cup

23

DJ168F-14004-A

1

Connecting
Block,Carbretor

67

GBT6177-N-14

1

Flange nut M14

24

DJ168F-14005-A

1

Carbretor Gasket

68

DJ168F-11400-A

1

Wind Shiel Assembly

25

DJ170N-14100-A

1

Carburetor Assembly

69

DJ170N-16121-A

1

Recoil Sarer

27

26

DJ168F-14027-A

1

Air Cleaner Gasket

70

DJ170N-16122-A

1

recoil starter

27

DJ170N-11013-A

1

Tube, Breather

71

GBT5787-B6-8

3

Bolt Flange M6×8

28

DJ170N-11420-A

1

AirCleaner Assembly

72

DJ168F-15001-A

1

Shaft, governor assy.

29

GBT6177-N-8

2

Flange nut M8

73

DJ168F-15003-A

1

Pin Lock

30

DJ170F-12301-A

4

Piston Ring A

74

DJ168F-15004-A

1

Speed Regulating Arm

31

DJ170F-12302-A

1

Piston Ring B

75

DJ168F-15005-A

1

Lock Bolt

32

DJ170F-12304-A

1

Side Ring

76

GBT6177-N-6

3

Flange nut M6

33

DJ170F-12303-A

1

W a v e Ring

77

DJ170F-15007-B

1

Back Spring B

34

DJ170F-12304-A

1

Side Ring

78

DJ168F-15006-A

1

Pulling Rod

35

DJ170F-12300-A

1

Scraper Ring Set, Piston

79

DJ170F-15008-A

1

Fine Regulating Spring C

36

DJ168F-12003-A

2

Clip, piston pin

80

DJ1P65F-14008-A

2

Tube clip

37

DJ170F-12002-A

1

Pin, piston

81

DJ170N-14007-A

1

Outlet pipeφ6×φ10×295

38

DJ170F-12001-B

1

Piston

82

DJ168F-18300-A

1

Amplifier

39

DJ168F-13002-A

1

Intake Valve

83

DJ168F-18200-A

1

Oil Sensor Assembly

28

40

DJ168F-13001-A

1

Exhaust Valve

84

GBT5787-B6-16

2

bolt M6×16

41

DJ170F-13008-A

2

Rod, push

85

DJ168F-11004-A

2

Drain Plug Washer

42

DJ170F-13009-A

2

Tappet Litter Valve

86

DJ168F-11005-A

2

Washer, drain lug

43

DJ170F-11010-C

1

Casket, cylinder head

87

DJ170N-14302-A

1

Fuel cock

44

DJ168F-11009-A

2

Set Pin, 10×14

88

DJ170N-14300-A

1

Fuel tank

89

GBT5787-B6-16

3

bolt M6×16

90

GBT93-L W -8

2

spring washer

29

XP652WP

30

Item

Part

Qty

Description

Item

Part

Qty

Description

91

DS20-32001-A

1

Casing

105

DS20-32003-A

1

Suction port

92

GB97.1-W-8

4

Gasket，Φ8x1.6,

106

DS20-32008-A

2

Coupling Packing

93

GB70-B8-60

4

Flange Bolt M8×60

107

DS20-32010-A

2

Hose Joint

94

DS20-32052-A

1

Casing Gasket

108

DS20-32200-A

2

Hose Coupling

95

DS20-32013-A

1

Mechanical seal A

109

DS20-32009-A

1

Discharge gasket

96

DS20-32013-B

1

Mechanical seal B

1 1 0

DS20-32004-A

1

Discharge port

97

DS20-32005-A

1

Impeller

1 1 1

DS20-32016-A

3

Hose Band

98

DS20-32006-A

1

Case Volute

1 1 2

DS20-32020-A

1

Strainer

99

DS20-32011-A

1

O-ring seal

113

XP652WP-31100-A

1

Frame

100

DS20-32002-A

1

Pump case housing

1 1 4

GB6177-N8

4

Flange nut M8

101

GB5787-B8-25

12

Flange Bolt M8×25

115

GB5787-B8-35

4

Flange bolt M8×35

102

DS20-32050-A

2

O-ring, Plug

1 1 6

DS20-31203-A

4

Rubber pad, damping

103

DS20-32049-A

2

Plug

1 1 7

GB5787-86

4

Flange Bolt M6×12

104

DS20-32030-A

1

Flapper valve gasket

31

XP650WP

32

Item

Part

Qty

Description

Item

Part

Qty Description

91

DS30-32001-A

1

Casing

105

DS30-32003-A

1

Suction port

92

GB97.1-W-8

4

GasketΦ8x1.6

106

DS30-32008-A

2

Coupling Packing

93

GB70-B8-60

4

Flange Bolt M8×60

107

DS30-32010-A

2

Hose Joint

94

DS30-32052-A

1

Casing Gasket

108

DS30-32200-A

2

Hose Coupling

95

DS30-32013-A

1

Mechanical seal A

109

DS30-32009-A

1

Discharge gasket

96

DS30-32013-B

1

Mechanical seal B

1 1 0

DS30-32004-A

1

Discharge port

97

DS30-32005-A

1

Impeller

1 1 1

DS30-32016-A

3

Hose Band

98

DS30-32006-A

1

Case Volute

1 1 2

DS30-32020-A

1

Strainer

99

DS30-32011-A

1

O-Ring Seal

113

XP650WP-31100

-A

1

Frame

100

DS30-32002-A

1

Pump case housing

1 1 4

GB6177-N8

4

Flange nut M8

101

GB5787-B8-25

12

Flange Bolt M8×25

115

GB5787-B8-35

4

Flange bolt M8×35

102

DS30-32050-A

2

O-ring, Plug

1 1 6

DS20-31203-A

4

Rubber pad, damping

103

DS30-32049-A

2

Plug

1 1 7

GB5787-B6-12

4

Flange Bolt M6×12

104

DS30-32030-A

1

Flapper valve gasket

33

PARTS LIST AND ASSEMBLY(XP904WP)

34

Item

Part

Qty

Description

Item

Part

Qty

Description

1

16102

1

Starter comp, recoil

21

18105

1

Cord stop switch

2

GB5787-86

3

Flange bolt M6×8

22

15009

Oil seal, 8×14×5

3

18400

1

Engine switch

23

GB/T276-94

2

Radial ball bearing (6202)

4

16103

1

Fan, cover comp

24

15001

1

Shaft, governor arm

5

GB5787-86

12

Flange bolt M6×12

25

15003

1

Pin, lock, 10mm

6

11012

1

Shroud comp

26

15002

1

Washer, 8.2×17×0.8

7

16001

1

Pulley, starter

27

GB6177-86

1

Flange nut M10

8

16002

1

Fan, cooling

28

18201

1

O-ring, 14mm

9

GB6177-86

1

Flange nut M16

29

18200

1

Switch assy. oil level

10

11039

1

Clip. Wire harness

30

12004

1

Weight, balancer

1 1

16200

1

Flywheel comp

31

12100

1

Crankshaft comp

12

11014

2

Oil seal, 35×52×8

32

GB/T 99-88

1

Key

13

1 1 1 0 0

1

Crank case assy.

33

GB/T276-94

2

Radial ball bearing (6207)

14

11004

2

Bolt, drain lug

34

1 1 010

1

Casket, cylinder head

15

18300

1

Amplifier

35

11009

2

Pin, dowel, 12×20

16

11005

2

Washer, drain lug

36

14001

2

Bolt head, 8×111

17

18009

1

Clip, wire

37

14003

1

Packing, insulator

35

18

GB5789-86

2

Flange bolt M6×25

38

14004

1

Insulator, carburetor

19

18100

1

Coil assy. ignition

39

14005

1

Packing, carburetor

20

11017

1

Grommet cord

40

14100

1

Carburetor assy.

41

14113

1

Stay manual choke

63

13001

1

Valve, IN.

42

14207

2

Packing, air cleaner

64

13002

1

Valve, EX.

43

GB6177-86

5

Flange nut M6

65

13008

2

Rod, push

44

14208

1

Case comp, air cleaner

66

13007

1

Seat, valve spring

45

GB5789-86

1

Flange bolt M6×20

67

13003

2

Spring, valve

46

14206

1

Seal, air cleaner

68

13004

1

Retainer, IN. Valve spring

47

14212

2

Nut, M6

69

13300

1

Plate, push rod guide

48

14209

2

Washer, drain lug

70

13202

2

Bolt, pivot

49

14201

1

Element assy. air cleaner

71

13006

1

Rotator, valve

50

14203

1

Separator, air cleaner

72

13005

1

Retainer, EX. Valve spring

51

14204

1

Cover comp, air cleaner

73

13201

2

Arm, valve rocker

52

11015

1

Bolt, head cover

74

13203

2

Nut, Arm, valve rocker

53

11016

1

Washer comp head cover

75

13204

2

Nut, pivot adjusting

54

11300

1

Cover comp, head

76

GB6177-86

6

Flange nut M8

55

11 0 1 1

1

Exhaust piper

77

14006

1

Casket (B) EX. Pipe

56

GB5789-86

4

Flange bolt M10×80

78

14009

1

Pipe comp EX.

57

11013

1

Tube, breather

79

14010

1

Muffler stay

36

58

1 1 2 01

1

Head comp, cylinder

80

14406

1

Arrester, spark

59

14002

2

Bolt head, M8×34

81

14400

1

Muffler

60

18500

1

Plug, spark

82

14417

1

Muffler guard

61

13101

1

Camshaft assy.

83

GB847-85

5

Screw, tapping M5×8

62

13009

2

Lifter, valve

84

GB5789-86

7

Flange bolt M8×35

85

11006

1

Cap, oil hole

98

15008

1

Spring, throttle return

86

11001

1

Crankcase cover

99

15005

1

Bolt, governor arm

87

11003

1

Packing, case cover

100

15004

1

Arm, governor

88

11002

2

Pin, dowel, 8×12

101

14300

1

Fuel tank

89

11007

1

Cap assy. oil filler

102

GB5789-86

2

Flange bolt M8×25

90

15100

1

Governor kit

103

11013

1

Rubber, supporter

91

12003

2

Clip, piston pin

104

14008

1

Fuel cock

92

12002

1

Pin, piston

105

14007

1

Outlet pipeφ4.5×235

93

12300

1

Ping set assy. piston

106

14026

1

Joint, fuel tank

94

12001

1

Piston

107

14311

1

Rubber joint, fuel tank

95

12200

1

Connecting rod assy.

108

14307

1

Fuel filter

96

15200

1

Control assy.

109

14306

1

Fuel filler cap comp

97

15007

1

Spring, governor

37

ITEM PART QTY DESCRIPTION ITEM PART QTY DESCRIPTION

109 DS40-32001 1 ASSEMBLY, PUMP COVER 123 DS40-32003 1 SUCTION PORT
110 DS40-32015 4 WASHER 124 DS40-32008 2 COUPLING PACKING
111 GB5787-86 4 FLANGE BOLT M8X45 125 DS40-32010 2 HOSE JOINT
112 DS40-32012 1 O-RING, WATER PUMP 126 DS40-32200 2 HOSE COUPLING
113 DS40-30258 1 MECHANICAL SEAL A 127 DS40-32009 1 DISCHARGE GASKET
114 DS40-32038 1 MECHANICAL SEAL B 128 DS40-32004 1 DISCHARGE PORT
115 DS40-32005 1 IMPELLER, WATER PUMP 129 DS40-32016 3 HOSE BAND
116 DS40-32006 1 VOLUTE CASING 130 DS40-32020 1 STRAINER
117 DS40-32011 1 RING, VOLUTE CASING 131 DS40-31100 1 FRAME
118 DS40-32002 1 PUMP CASE HOUSING 132 GB6177-86 4 FLANGE NUT M10
119 GB5787-86 12 FLANGE BOLT M10X25 133 GB5789-86 4 FLANGE BOLT M10X35
120 DS40-32050 2 O-RING, PLUG 134 DS40-31203 4 RUBBER PAD, DAMPING
121 DS40-32049 2 PLUG 135 GB5787-86 4 FLANGE BOLT M6X16
122 DS40-32030 1 FLAPPER VALVE GASKET