Honda WDP30X Owner's Manual
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 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:
• Safety Labels – on the pump.
• Instructions – how to use this pump correctly and safely.
• Safety Messages – preceded by a safety alert symbol and one
of three signal words: DANGER, WARNING, or CAUTION. These
signal words mean:
DANGER
WARNING
CAUTION
Each message tells you what the hazard is, what can happen, and
what you can do to avoid or reduce injury.
• Damage Prevention Messages – You will also see other
important messages that are preceded by the word NOTICE. This
word means:
NOTICE
Your pump or other property can be damaged
if you don’t follow instructions.
You WILL be KILLED or SERIOUSLY
HURT if you don't follow instructions.
You CAN be KILLED or SERIOUSLY
HURT if you don't follow instructions.
You CAN be HURT if you don't follow
instructions.
OWNER’S MANUAL
WDP30X
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
INTRODUCTION...............................1
SAFETY MESSAGES........................1
PUMP SAFETY .................................2
IMPORTANT SAFETY
INFORMATION.............................2
SAFETY LABEL LOCATIONS......2
SETTING UP YOUR NEW PUMP.....2
CONTROL LOCATIONS ...................3
BEFORE OPERATION......................3
IS YOUR PUMP READY TO GO?3
OPERATION......................................4
PUMP PRECAUTIONS ................4
PUMP PREPARATION.................5
STARTING THE ENGINE.............6
STOPPING THE ENGINE ............6
SERVICING YOUR PUMP................7
MAINTENANCE SAFETY.............7
MAINTENANCE SCHEDULE.......7
ENGINE MAINTENANCE.............8
REFUELING ...............................11
PUMP MAINTENANCE ..............12
TRANSPORTING............................15
STORAGE.......................................15
IPC
TAKING CARE OF UNEXPECTED
PROBLEMS.....................................17
TECHNICAL INFORMATION..........17
SERIAL NUMBER LOCATIONS.17
CARBURETOR
MODIFICATION FOR HIGH
ALTITUDE OPERATION............ 17
EMISSION CONTROL SYSTEM18
AIR INDEX..................................18
SPECIFICATIONS......................18
CONSUMER INFORMATION .........20
REPLACEMENT PARTS,
OPTIONAL EQUIPMENT, AND
SERVICE ITEMS........................ 20
DEALER LOCATOR
INFORMATION...........................20
CUSTOMER SERVICE
INFORMATION...........................20
DISTRIBUTOR'S LIMITED
WARRANTY...............................21
ACCESSORIES,
REPLACEMENT PARTS, AND
APPAREL WARRANTY..............21
EMISSION CONTROL SYSTEM
WARRANTY...............................22
© 1996–2007 American Honda Motor Co., Inc.—All Rights Reserved
31TDP610
00X31-TDP-0610
EM5
K1
IPC
POM52831-C
XXXXX.2007.02
PRINTED IN U.S.A.
1
PUMP SAFETY
WARNING
DO NOT PUMP FLAMMABLE LIQUIDS.
Pump can explode and you can
be seriously hurt or killed.
Follow the Owner’s Manual
instructions carefully.
This chapter explains what you need to know to operate your
diaphragm 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 accidents can be prevented if you follow all instructions in this
manual and on the pump. The most common hazards are discussed
below, along with the best way to protect yourself and others.
Operator Responsibility
It is the operator's responsibility to provide the necessary safeguards
to protect people and property. Know how to stop the pump quickly in
case of emergency. Understand the use of all controls and
connections. For your safety and the safety of others, keep 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.
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.
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.
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).
Please Register Your Diaphragm Pump
If 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 Owner Link ™.
2
CONTROL LOCATIONS BEFORE OPERATION
GEAR BOX OIL FILLER
CAP/DIPSTICK (P. 12)
AIR CUSHION
CHAMBER CAP
(Priming filler
cap) (P. 5)
SPARK
PLUG CAP
(P. 9)
SUCTION
PORT (P. 5)
GEAR BOX DRAIN
BOLT (Remove
connecting rod
cover) (P. 12)
MUFFLER
FUEL CAP
STARTER
GRIP
AIR
CLEANER
(P. 9)
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.
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.
THROTTLE LEVER
CHOKE LEVER
FUEL VALVE LEVER
(P. 6)
IGNITION SWITCH
(P. 6)
LIFTING
BRACKET
ENGINE OIL DRAIN
BOLT (P. 8)
PUMP GREASE FITTING
ACCESS PLUG (P. 12)
HANDLE RELEASE PIN
HANDLE
DISCHARGE
PORT (P. 5)
ENGINE OIL FILLER
CAP/DIPSTICK (P. 8)
Check the General Condition of the Pump
• Look around and underneath the pump for signs of oil or gasoline
leaks.
• Remove any dirt or debris, especially around the engine, muffler,
and recoil starter.
• Look for signs of damage.
• Check that all nuts, bolts, screws, hose connectors, and clamps are
tightened.
• Keep the connecting rod cover in place while operating the pump.
Check the Suction and Discharge Hoses
• Check the general condition of the hoses. Be sure the hoses are in
serviceable condition before connecting them to the pump.
Remember that the suction hose must be of reinforced construction
to prevent hose collapse.
• Check that the sealing washer in the suction hose connector is in
good condition (page 12).
• Check that the strainer is in good condition and is installed on the
suction hose (page 12).
Check the Engine
• 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.
• Check the air cleaner (page 9).
• Check the fuel level (page 11). Starting with a full tank will help to
eliminate or reduce operating interruptions for refueling.
3
OPERATION
PUMP 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 only non-potable water, muddy
water, and water containing solids. Pumping flammable liquids, such
as gasoline or fuel oils, can result in a fire or 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.
• Attach anchored tie-down straps to the pump frame
• Place blocks in front and behind the wheels
• Try to locate the pump on 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
discharge 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.
NOTICE
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
HOSE
If the discharge hose must run across a roadway, the hose should
cross the roadway perpendicular to traffic flow. Also, heavy boards
should be placed next to the hose so the motor vehicle weight does
not shut off the discharge as vehicles cross over the hose.
BOARDS
DISCHARGE
HOSE
NOTICE
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 noncollapsible. Never use hoses that are smaller than the suction or
discharge fittings size.
This pump requires a 3 inch inside diameter or greater hose. Using
rigid pipes or hoses that are too small will cause severe damage to
the diaphragm pump.
4
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.
NOTICE
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 installed and in good condition. A loosely connected
suction hose will reduce pump performance and self-priming ability.
SEALING
WASHER
DISCHARGE
HOSE
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. Lifting 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
SUCTION HOSE
HOSE
CLAMP
STRAINER
(provided
with the pump)
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).
NOTICE
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.
5
STARTING THE ENGINE
1. Turn the fuel valve to
the ON 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.
3. Turn the ignition
switch to the ON
position.
FUEL VALVE
CLOSED
CHOKE LEVER
IGNITION
SWITCH
ON
7. Set the throttle to the
desired speed to
THROTTLE LEVER
produce the best
pumping conditions.
Pump output can be
controlled by adjusting
the throttle lever to the
desired position.
FULL
At FULL throttle position, the pump will deliver the highest output
volume. Moving the throttle toward the IDLE position will decrease
the output volume of the pump.
STOPPING THE ENGINE
Emergency
To stop the engine in an
emergency, turn the
ignition switch to the OFF
position.
IGNITION
SWITCH
IDLE
OFF
4. Move the throttle
lever slightly to the
left.
5. Pull the starter grip
lightly until resistance
is felt, then pull it
briskly.
NOTICE
Return the starter grip
slowly back to the
engine to prevent
damage to the starter.
THROTTLE LEVER
STARTER GRIP
ON
Normal
1. Move the throttle lever
fully to the right to the
IDLE position.
2. Turn the ignition switch
to the OFF position.
3. Turn the fuel valve to
the OFF position.
4. If the pump is not going
to be used again for the
rest of the day, or is
going to be stored for a
long period of time,
refer to page 16 for
procedures on properly
storing your pump.
5. After each use, drain the pump chamber and flush with fresh water
(page 12).
THROTTLE LEVER
IDLE
FUEL VALVE
OFF
6. As the engine warms
up, gradually move
the choke lever to the
OPEN position.
6
CHOKE LEVER
OPEN
SERVICING YOUR PUMP
Proper maintenance is essential for safe, economical, and
trouble-free operation. It will also help reduce air pollution.
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.
Remember that an authorized Honda servicing dealer knows your
pump best and is fully equipped to maintain and repair it.
To ensure the best quality and reliability, use only new, genuine
Honda parts or their equivalents for repair and replacement.
MAINTENANCE SCHEDULE
Interval Item
Check the engine oil level (page 8)
Before each use
After each use
Check the air filter (page 9)
Check pump hoses and strainer (page 12)
Flush the pump chamber (page 12)
To help you properly care for your pump, the following pages include
a maintenance schedule, routine inspection procedures, and simple
maintenance procedures using basic hand tools. Other service tasks
that are more difficult, or require special tools, are best handled by
professionals and are normally performed by a Honda technician or
other qualified mechanic.
The maintenance schedule applies to normal operating conditions. If
you operate your pump under severe conditions, such as sustained
high-load or high-temperature operation, or use in unusually wet or
dusty conditions, consult your servicing dealer for recommendations
applicable to your individual needs and use.
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.
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.
First month or
20 hours
Every 3 months or
50 hours
Every 6 months or
100 hours
Every year or
300 hours
Every 2 years Check the fuel line and replace if necessary
After every 500
hours
Change the engine oil (page 8)
Grease the pump connecting rod bearing
(page 12)
Clean the air filter
Clean the sediment cup (page 10)
Grease the pump connecting rod bearing
(page 12)
Check the gear box oil level (page 12)
Change the engine oil
Inspect-adjust the spark plug (page 9)
Clean-check the spark arrester (page 10)
(optional equipment)
Change the engine oil
Replace the air cleaner paper filter
Replace the spark plug (page 9)
Adjust the valve clearance
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
Clean the combustion chamber
1
(page 9)
1
1
2
(page 8)
(page 8)
2
2
2
1
(page 9)
2
Safety Precautions
• Make sure the engine is off before you begin any maintenance or
repairs. This will eliminate several potential hazards:
• Carbon monoxide poisoning from engine exhaust.
Be sure there is adequate ventilation whenever you operate
the engine.
• Burns from hot parts.
Let the engine and exhaust system cool before touching.
• Injury from moving parts.
Do not run the engine unless instructed to do so.
• Read the instructions before you begin, and make sure you have
the tools and skills required.
• To reduce the possibility of fire or explosion, be careful when
working around gasoline. Use only a nonflammable solvent, not
gasoline, to clean parts. Keep cigarettes, sparks, and flames away
from all fuel-related parts.
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.
7
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.
FILLER CAP/DIP
STICK
2. Reinstall the drain bolt and sealing washer. Tighten the bolt
securely.
NOTICE
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 t ake 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.
4. Screw in the filler cap/dipstick securely.
UPPER LIMIT
MARK
2. Insert and remove the dipstick without screwing it into the filler
neck. Check the oil level shown on the dipstick.
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.
NOTICE
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
startup.
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.
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.
Drain the oil into a suitable container.
FILLER
CAP/DIPSTICK
SEALING
WASHER
DRAIN
BOLT
8
SAE 10W-30 is recommended for general use. Other viscosities
shown in the chart may be used when the average temperature in
your area is within the recommended range.
The SAE oil viscosity and service category are in the API label on the
oil container. Honda recommends that you use API SERVICE
category SJ or later oil with the ILSAC “starburst” certification mark
displayed on the container.
NOTICE
Using nondetergent oil can shorten the engine's service life, and using
2-stroke oil can damage the engine.
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