2" Gasoline Powered Clear Water Pump
Item 68375
Using an engine indoors CAN KILL YOU
IN MINUTES.
Engine exhaust contains carbon monoxide.
This is a poison you cannot see or smell.
Only use OUTSIDE
NEVER use inside
and far away from
windows, doors,
and vents.
a home or garage,
EVEN IF doors and
windows are open.
When unpacking, make sure that the product is intact and undamaged.
If any Pump parts are missing or broken, please call 1-800-444-3353 as soon as possible.
If any Engine parts are missing or broken, please call 1-800-520-0882 as soon as possible.
Record Product’s Serial Number Here:
Note: If product has no serial number, record month and year of purchase instead.
Note: Some parts are listed and shown for illustration purposes only, and are not available individually
as replacement parts.
Email our tech support at: [email protected]
Email our Engine support at: [email protected]
©
®
Copyright 2010 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.
Manual Revised 11g
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Save This Manual
Symbol Definitions
Keep this manual for the safety warnings and precautions,
assembly, operating, inspection, maintenance and
cleaning procedures. Write the product’s serial
number in the front 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.
Symbol
Property or Statement
Revolutions Per Minute
RPM
WARNING marking concerning Risk
of Eye Injury. Wear ANSI-approved
safety goggles with side shields.
Read the manual before set-up and/or use.
Safety Warnings
WARNING marking concerning Risk of
Hearing Loss. Wear hearing protection.
In this manual, on the labeling, and all other
information provided with this product:
WARNING marking concerning
Risk of Respiratory Injury. Operate
engine OUTSIDE and far away from
windows, doors, and vents.
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.
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.
DANGER indicates a hazardous situation which, if
not avoided, will result in death or serious injury.
Keep flammable objects away from engine.
WARNING marking concerning
Risk of Explosion.
WARNING indicates a hazardous situation which, if
not avoided, could result in death or serious injury.
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
CAUTION, used with the safety alert symbol,
indicates a hazardous situation which, if not
avoided, could result in minor or moderate injury.
NOTICE is used to address practices
not related to personal injury.
product, but must be supplied by the operator.
SAVE THESE INSTRUCTIONS
CAUTION, without the safety alert symbol, is used
to address practices not related to personal injury.
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.
2. Have multiple ABC class fire extinguishers nearby.
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.
4. Set up and use only on a flat, level,
well-ventilated surface.
Item 68375
For Pump technical questions, please call 1-800-444-3353.
For Engine technical questions, please call 1-800-520-0882.
Page 1
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5. Use only lubricants and fuel recommended in
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.
the Specifications chart of this manual.
6. Wear ANSI-approved safety goggles, heavy-duty
work gloves, and dust mask/respirator during set up.
Engine Precautions
Follow engine precautions and instructions in the included
engine instruction manual.
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.
Operating Precautions
1.
CARbON MONOxIDE HAzARD
Using an engine indoors CAN KILL
YOU IN MINUTES.
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.
Engine exhaust contains carbon
monoxide. This is a poison you cannot
see or smell.
13. Do not overreach. Keep proper footing and
balance at all times. This enables better control
of the equipment in unexpected situations.
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.
NEVER use inside a home or garage, EVEN IF doors
and windows are open.
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. 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.
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.
19. Do not operate the equipment with known
leaks in the engine’s fuel system.
4. Never store fuel or other flammable
materials near the Pump engine.
20. 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.)
5. Industrial applications must follow OSHA requirements.
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.
21. 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.
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.
22. Keep hands and feet away from moving parts.
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.
Do not reach over or across equipment while operating.
For Pump technical questions, please call 1-800-444-3353.
For Engine technical questions, please call 1-800-520-0882.
Item 68375
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23. 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.
5. Maintain labels and nameplates on the equipment.
These carry important information.
If unreadable or missing, contact
Harbor Freight Tools for a replacement.
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.
24. 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.
Service Precautions
1. before service, maintenance, or cleaning:
a. Turn the engine switch to its “OFF” position.
b. Allow the engine to completely cool.
7. Store equipment out of the reach of children.
Refueling:
1. Do not smoke, or allow sparks, flames,
or other sources of ignition around the
equipment, especially when refuelling.
c. Then, remove the spark plug
cap from the spark plug.
2. Do not refill the fuel tank while the
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.
engine is running or hot.
3. Do not fill fuel tank to the top. Leave a little
room for the fuel to expand as needed.
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
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.
technician may adjust parts that may increase
or decrease governed engine speed.
4. Wear ANSI-approved safety goggles, heavy-duty work
gloves, and dust mask/respirator during service.
SAVE THESE
INSTRUCTIONS.
Item 68375
For Pump technical questions, please call 1-800-444-3353.
For Engine technical questions, please call 1-800-520-0882.
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Controls
Fuel Tank Cap
Fuel Tank
Throttle
Choke
Fuel Valve
Engine Switch
Oil Dipstick
Starter Handle
Priming Cap
Air Filter
Muffler
Discharge Port
Intake Port
Water Drain Plug
For Pump technical questions, please call 1-800-444-3353.
For Engine technical questions, please call 1-800-520-0882.
Item 68375
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3. Slide one of the Hose Clamps over the end of the
suction hose (a). Slide the Hose onto the Hose
Coupler (b). Use a screwdriver (not included)
to tighten the Hose Clamp until secure.
Set up
The emission control system for this Pump’s Engine is
warranted for standards set by the U.S. Environmental
Protection Agency. For warranty information, refer to the
last pages of this manual.
CAUTION: Use only a non-collapsible intake hose.
Connecting Hoses
Hose Clamp
Note: Hose coupling components
and hoses not included.
Suction Hose
a
Note: The Suction Hose (not included) MUST be
reinforced with braided material or have non-
collapsible construction. Do not use a hose
with an inside diameter smaller than 2″ (pump’s
intake and discharge port diameters).
CAUTION: Do not over-tighten Hose Clamps as the
clamp may damage the hose or other components.
b
4. Slide a Hose Clamp over the other end of the suction
hose (a). Slide the Intake Strainer into the end of the
suction hose (b). Use a screwdriver to tighten the Hose
Clamp until secure.
1. Slide one of the Hose Coupling Rings over
one of the Hose Couplers (a), then place a
Gasket on the end of the Hose Coupler (b).
Gasket
Hose Coupler
b
Hose Coupling Ring
b
a
a
Intake Strainer
2. Thread the Hose Coupling Ring onto the Intake Port
(a), and turn clockwise until fastened securely (b).
Intake Port
Item 68375
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For Engine technical questions, please call 1-800-520-0882.
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5. For the discharge hose, slide a Hose Coupling Ring
over the remaining Hose Coupler (a) and place a
Gasket onto the end of the Hose Coupler (b).
7. Slide a Hose Clamp over the end of the Discharge
Hose (a). Slide the Discharge Hose onto the Hose
Coupler (b). Use a screwdriver to tighten the Hose
Clamp until secure.
a
b
b
a
6. Thread the Hose Coupling Ring clockwise onto the
Discharge Port until tightened securely.
Discharge Port
For Pump technical questions, please call 1-800-444-3353.
For Engine technical questions, please call 1-800-520-0882.
Item 68375
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Locating the Water Pump
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. This will allow the Pump to produce the
greatest output with the least self-priming time. See
diagram below.
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.
Discharge Head
Total Head
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.
Suction
Head
Water Pump
Operation Concerns
1. Cavitation: This is the sudden formation and collapse
of low-pressure vapor (bubbles) across the vanes of
the impeller.
As the head (pumping height) increases, pump
output decreases. The length, type, and size of the
suction and discharge hoses can also significantly
affect Pump output.
Cause: When the surface pressure on a liquid
becomes low enough, the liquid will begin to boil
(even at room temperature). With centrifugal pumps,
cavitation can occur when the suction vacuum
becomes too great, allowing water vapor or bubbles to
form at the impeller. The rapid pressure increase can
cause impeller damage.
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.
Solution: Minimizing suction head and using
the largest practical suction hose diameter will
reduce the likelihood of cavitation. Do not use
a suction hose with a diameter smaller than
the Pump’s Intake Port (2″ diameter).
Minimizing suction head (placing the Pump
closer to the water level) will also help reduce
self-priming time. This is the time it takes the
Pump to bring the water from the water level
to the Pump during the initial operation.
2. Water Hammer Pressure: This is energy sent back to
the Pump due to sudden stoppage of water flowing
from the Pump.
2. Route the Intake Hose with the Intake Strainer
fully immersed in the water supply source.
Cause: Water hammer pressure is more likely to
occur when using a very long discharge hose. If the
flow of water at the end of the discharge hose is shut
off suddenly, energy is sent back to the pump. This
causes a large pressure spike in the Pump housing,
leading to potential damage to the Pump casing.
3. Place Strainer into water to be pumped. CAUTION:
Strainer must be fully immersed 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: If there is an air leak in the suction
line, you may not be able to prime the pump.
Use of a thread sealant is recommended.
Solution: Use as short a discharge hose as possible
and turn off water pump before closing water flow.
Item 68375
For Pump technical questions, please call 1-800-444-3353.
For Engine technical questions, please call 1-800-520-0882.
Page 7
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Checking and Filling Engine Oil
Operation
CAUTION! 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.
Do not run the engine with low or no engine
oil. Running the engine with no or low engine
oil WILL permanently damage the engine.
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.
1. Make sure the engine is stopped and is level.
2. Close the Fuel Valve.
Pre-Start Checks
Inspect Pump and engine, looking for damaged, loose, and/
or missing parts before set up and starting. If any problems
are found, do not use equipment until fixed properly.
3. Clean the top of the Dipstick and the area around it.
Remove the Dipstick by threading it counterclockwise,
and wipe it off with a clean lint free rag.
Prime the Pump
Full level
Before starting the engine, fill the
Full level
Pump with water. To do this:
1. Unthread the Priming Water Filler Cap
by turning it counterclockwise.
4. 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.
2. Fill the unit with clean water up to the top
of the opening. Replace the Priming Water
Filler Cap and tighten securely.
5. 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 12 in the Service section shows other
viscosities to use in different average temperatures.)
Priming Water
Filler Cap
6. Thread the dipstick back in clockwise.
CAUTION! Do not run the engine with too little
oil. The engine will be permanently damaged.
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.
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.
1. Clean the Fuel Cap and the area around it.
2. Unscrew and remove the Fuel Cap.
3. If needed, fill the Fuel Tank to about 1″
under the fill neck of the Fuel Tank with 87
octane or higher unleaded gasoline.
Note: Do not use gasoline containing more than
10% ethanol (E10). Do not use E85 ethanol.
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.
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.
For Pump technical questions, please call 1-800-444-3353.
For Engine technical questions, please call 1-800-520-0882.
Item 68375
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Starting the Engine
1. To start a cold engine, move the Choke to the CHOKE position.
To restart a warm engine, leave the Choke in the RUN position.
1
2
3
4
5
6
Choke
RUN
2. Open the Fuel Valve.
3. Slide the Throttle to 1/3 away from the SLOW position (the “turtle”).
ON
O
I
ON
OFF
4. Turn the Engine Switch on.
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.
Note: Do not let the Starter Handle snap back against the engine.
Hold it as it recoils so it doesn't hit the engine.
6. Allow the Engine to run
for several seconds. Then, if the Choke lever is in the CHOKE
position, move the Choke Lever very slowly to its RUN position.
NOTE: Moving the Choke Lever too fast could stall the engine.
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.
Choke
RUN
Item 68375
For Pump technical questions, please call 1-800-444-3353.
For Engine technical questions, please call 1-800-520-0882.
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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.
Stopping the Engine
O
1. To stop the engine in an emergency,
turn the Engine Switch off.
I
2. Under normal conditions, use the following procedure:
a. Slide the Throttle to SLOW (the “turtle”).
a
b
O
I
b. Turn the Engine Switch off.
For Pump technical questions, please call 1-800-444-3353.
For Engine technical questions, please call 1-800-520-0882.
Item 68375
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Maintenance and Service
WARNING
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.
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.
Cleaning, Maintenance, and Lubrication Schedule
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.
Monthly or
every 20
hr. of use
Yearly or
every 300
hr. of use
before
Each Use
Every 3 mo. or Every 6 mo. or
50 hr. of use 100 hr. of use
Every
2 Years
Procedure
Brush off outside of engine
Check engine oil level
Check air cleaner
Check deposit cup
Change engine oil
Clean/replace air cleaner
*
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
*Service more frequently when used in dusty areas.
**These items should be serviced by a qualified technician.
Item 68375
For Pump technical questions, please call 1-800-444-3353.
Page 11
For Engine technical questions, please call 1-800-520-0882.
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Checking and Filling Fuel
WARNING! TO PREVENT SERIOUS
Engine Oil Change
CAUTION! Oil is very hot during operation and can
INjURY FROM FIRE:
cause burns. Wait for engine to cool before changing oil.
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. 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.
1. Clean the Fuel Cap and the area around it.
4. Remove the drain plug and, if possible,
tilt the crankcase slightly to help drain
the oil out. Recycle used oil.
2. Unscrew and remove the Fuel Cap.
3. If needed, fill the Fuel Tank to about 1″
under the fill neck of the Fuel Tank with 87
octane or higher unleaded gasoline.
5. Replace the drain plug and tighten it.
6. Clean the top of the Dipstick and the area around it.
Remove the Dipstick by threading it counterclockwise,
and wipe it off with a clean lint free rag.
Note: Do not use gasoline containing more than
10% ethanol (E10). Do not use E85 ethanol.
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.
Full level
4. Then replace the Fuel Cap.
Full level
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
10W-30
5W-30
-20
0
20
40
60
80
100°F
Average outdoor temperature
8. Thread the dipstick back in clockwise.
CAUTION! Do not run the engine with too little
oil. The engine will be permanently damaged.
For Pump technical questions, please call 1-800-444-3353.
For Engine technical questions, please call 1-800-520-0882.
Item 68375
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Air Filter Element Maintenance
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 or replace as described below.
Spark
Plug
Cap
Filter Cover
1. Disconnect spark plug cap from end of plug.
Clean out debris from around spark plug.
Filter
Filter Cover
Tab
2. Using a spark plug wrench, remove the spark plug.
Base Hinge
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.
2. Cleaning:
• Foam filter element:
Recommended Spark Plug
brand
Part #
BP-6ES
F6TC
®
Wash the element in warm water and mild
detergent several times. Rinse. Squeeze
out excess water and allow it to dry
NGK
® /
®
NHSP TORCH
completely. Soak the filter in lightweight oil
briefly, then squeeze out the excess oil.
NOTICE: Using an incorrect spark
plug may damage the engine.
3. Install the new filter or the cleaned filter.
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.
Secure the Air Cleaner Cover before use.
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.
6. Apply dielectric spark plug boot protector
(not included) to the end of the spark plug
and reattach the wire securely.
Item 68375
For Pump technical questions, please call 1-800-444-3353.
For Engine technical questions, please call 1-800-520-0882.
Page 13
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3. LUbRICATION:
Storage
a. Change engine oil.
When the equipment is to remain idle for longer than
20 days, prepare the engine for storage as follows:
b. Clean out area around spark plug. Remove
spark plug and pour one tablespoon of engine
oil into cylinder through spark plug hole.
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.
c. Replace spark plug, but leave spark
plug cap disconnected.
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).
Apply a thin coat of rust preventive oil to all metal parts.
2. FUEL:
WARNING! TO PREVENT SERIOUS
INjURY FROM FIRE:
4. bATTERY:
Disconnect battery cables (if equipped).
Recharge batteries monthly while in storage.
Drain 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 draining fuel. Do not smoke.
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.
a. Place a funnel leading to a proper gasoline
container below the carburetor.
Air Filter
Cover
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.
Muffler
Carburetor
Drain bolt
b. Remove the drain bolt from the bottom of the
carburetor bowl and allow the fuel to drain.
c. Remove the small sediment cup next to the bowl
and allow the fuel to drain from there as well.
d. Open the fuel valve. After all fuel has
drained, reinstall the drain bolt and
sediment cup and tighten securely.
For Pump technical questions, please call 1-800-444-3353.
For Engine technical questions, please call 1-800-520-0882.
Item 68375
Page 14
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Pump Troubleshooting
Problem
Possible Causes
Likely Solutions
1. Incorrect lubrication or not
enough lubrication.
1. Lubricate using recommended oil or
grease according to directions.
Pump overheats
2. Worn parts.
2. Have qualified technician inspect internal
mechanism and replace parts as needed.
1. Low engine speed.
1. Qualified technician should increase
no load speed to 3,800±100 RPM
by adjusting pressure switch.
Unit stalls
2. Severely clogged air filter.
2. Replace air filter.
3. Improper lubrication.
3. Check for proper oil level.
1. Pump is not primed.
1. Prime Pump.
2. Intake Strainer clogged.
3. Air leak at intake connector.
4. Hose leaks.
2. Clean Intake Strainer or replace if damaged.
3. Replace Coupling Gasket or tighten clamp.
4. Replace hose.
Pump does not
pump water
5. Suction hose has collapsing wall.
6. Hose has too small diameter.
7. Pump is too high above water surface.
5. Use hose with non-collapsible wall.
6. Use hose with diameter 2" or greater.
7. Locate Pump at a lower level so it doesn’t
have to work so hard to lift the water.
1. Suction hose collapsed, damaged,
too long or diameter is too small.
1. Replace or adjust suction hose.
2. Air leak at connector.
3. Strainer clogged.
2. Replace Coupling Gasket or tighten Clamp.
3. Clean Strainer.
Low Pump Output
4. Discharge hose damaged,
too long or diameter too small.
4. Replace or adjust Discharge Hose.
Follow all safety precautions whenever diagnosing or servicing the equipment or engine.
Item 68375
For Pump technical questions, please call 1-800-444-3353.
For Engine technical questions, please call 1-800-520-0882.
Page 15
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Engine Troubleshooting
Problem
Possible Causes
Probable Solutions
Engine will not start FUEL RELATED:
1. No fuel in tank or fuel valve closed.
2. Choke not in CHOKE position, cold engine. 2. Move Choke to CHOKE position.
FUEL RELATED:
1. Fill fuel tank and open fuel valve.
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
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 unleaded gasoline.
Do not use gasoline with more than
10% ethanol (E15, E20, E85, etc.).
5. Carburetor not primed.
6. Dirty fuel passageways.
5. Pull on Starter Handle to prime.
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 CHOKE position.
9. Clogged Fuel Filter.
9. Replace Fuel Filter.
IGNITION (SPARK) RELATED:
1. Spark plug cap not connected securely.
2. Spark plug electrode wet or dirty.
3. Incorrect spark plug gap.
IGNITION (SPARK) RELATED:
1. Connect spark plug cap properly.
2. Clean spark plug.
3. Correct spark plug gap.
4. Replace spark plug cap.
4. Spark plug cap broken.
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 1. Pour tablespoon of oil into spark
storage periods.
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 diagnose/
repair ignition system.
Follow all safety precautions whenever diagnosing or servicing the equipment or engine.
For Pump technical questions, please call 1-800-444-3353.
For Engine technical questions, please call 1-800-520-0882.
Item 68375
Page 16
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Engine Troubleshooting (cont.)
Problem
Possible Causes
Probable Solutions
Engine misfires
1. Spark plug cap loose.
1. Check wire connections.
2. Incorrect spark plug gap or
damaged spark plug.
2. Re-gap or replace spark plug.
3. Defective spark plug cap.
4. Old or low quality gasoline.
3. Replace spark plug cap.
4. Use only fresh 87+ octane unleaded gasoline.
Do not use gasoline with more than
10% ethanol (E15, E20, E85, etc.).
5. Incorrect compression.
1. Low oil shutdown.
5. Diagnose and repair compression.
(Use Engine will not start:
COMPRESSION RELATED section.)
Engine stops
suddenly
1. Fill engine oil to proper level. Check
engine oil before EVERY use.
2. Fuel tank empty or full of impure or low
quality gasoline.
2. Fill fuel tank with fresh 87+ octane
unleaded gasoline.
Do not use gasoline with more than
10% ethanol (E15, E20, E85, etc.).
3. Defective fuel tank cap creating
3. Test/replace fuel tank cap.
vacuum, preventing proper fuel flow.
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 1. Dirty air filter
1. Clean or replace element.
under heavy load
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
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.
Engine backfires
1. Impure or low quality gasoline.
1. Fill fuel tank with fresh 87+ octane
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.
4. Incorrect timing.
3. Have qualified technician diagnose
and service engine.
4. Check engine timing.
Follow all safety precautions whenever diagnosing or servicing the equipment or engine.
Item 68375
For Pump technical questions, please call 1-800-444-3353.
For Engine technical questions, please call 1-800-520-0882.
Page 17
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Parts List (Including Item 68120 212cc engine)
Part
Description
Cylinder Head Gasket
Cylinder Head Cover
Subassembly
Cylinder Head
Cover Gasket
Breather Tube
Bolt
Stud
Stud
Stud
Pin
qty
Part
Description
qty
Part
Description
qty
2
1
1
2
1
1
1
1
2
1
1
44 Retainer Exhaust Valve
45 Rotator Valve
46 Seal Guide
47 Valve Tappet
48 Valve Lifter
49 Lifter Stopper Plate
Subassembly
1
1
1
2
2
1
89 Bolt
90 Ignition Coil
91 Throttle Control Assy.
92 Bolt
93 Governor Spring
94 Governor Rod
95 Throttle Valve
Returning Spring
96 Governor Support Bolt
97 Nut
98 Governor Support
Subassembly
99 Hose Clamp
100 Filter Cover
101 Filter
3
1
4
5
6
7
8
9
1
4
1
1
2
2
4
1
1
50 Valve Adjusting Bolt
51 Valve Rocker
52 Valve Adjusting Nut
53 Valve Lock Nut
54 Valve Spring
55 Recoil Starter Assy.
56 Bolt
2
2
2
2
2
1
3
1
1
1
1
1
1
1
1
10 Cylinder Head Bolt
11 Spark Plug
12 Cylinder Head
Subassembly
13 Crankcase
Subassembly
14 Engine Oil Sensor
15 Governor Gear Assy.
16 Governor Arm
17 Drain Plug Bolt
18 Washer
19 Bearing
20 Oil Seal
21 Washer
22 Pin
23 Bolt
24 Crankcase Cover
25 Bearing
26 Oil Seal
27 Crankcase Gasket
28 Pin
3
1
1
11
7
4
1
1
2
2
1
1
1
1
57 Shroud
58 Cylinder Body Shroud
59 Lower Shield
60 Oil Protector
61 Engine Switch
Subassembly
62 Bolt
63 Bolt
64 Collar
65 Bolt
102 Bolt
103 Washer
104 Washer
1
1
1
1
2
2
1
1
1
1
2
1
1
1
1
2
1
105 Water Inlet
106 Gasket Inlet Water
107 Thread Plug
108 Screw Plug Washer
109 Outlet Water
110 Gasket Outlet
111 Pump Body
112 Ring Whorl Case
Sealing
113 Whorl Case
114 Bolt
115 Washer
116 Water Pump Impeller
117 Key
118 Water Pump
Joint Cushion
2
1
1
1
4
1
1
1
1
66 Bolt
67 Carburetor Assy.
68 Air Cleaner Gasket
69 Carburetor Gasket
70 Carburetor
Insulator Plate
71 Carburetor
Insulator Gasket
72 Nut
73 Air Cleaner
74 Exhaust Outlet Gasket
75 Nut
76 Muffler Assy.
77 Fuel Tank
1
1
1
1
1
1
1
29 Oil Dipstick
Subassembly
30 Engine Oil Plug
Subassembly
2
1
1
2
1
1
1
1
1
119 Impeller Seal Ring
120 Porcelain Seal
121 Seal Assy. Mechanism
122 Water Pump Joint
123 Washer
1
1
1
1
4
4
1
1
4
4
1
31 Bolt
6
1
2
1
1
1
1
1
1
1
1
1
1
32 Crankshaft Assy.
33 Piston Pin Clip
34 Piston
35 Piston Pin
36 Connecting Rod
37 First Ring
38 Second Ring
39 Oil Ring Set
40 Camshaft Assy.
41 Exhaust Valve
42 Intake Valve
43 Valve Spring Seat
78 Fuel Filter
79 Fuel Tank Cover
80 Fuel Tank Oil Outlet
Subassembly
81 Collar
82 Fuel Tube
83 Bolt
84 Nut
85 Flywheel Nut
86 Starter Pulley
87 Impeller
124 Bolt
125 Water Pump Assy.
126 Engine Frame Assy.
127 Bolt
128 Engine Frame Shock
Absorption Seat
129 Core Nut
130 Bolt
131 Nut
132 Rubber Jacket
2
1
1
2
1
1
1
1
4
4
4
1
88 Flywheel Subassembly
For Pump technical questions, please call 1-800-444-3353.
For Engine technical questions, please call 1-800-520-0882.
Item 68375
Page 18
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Diagram (Including Item 68120 212cc engine)
Item 68375
For Pump technical questions, please call 1-800-444-3353.
Page 19
For Engine technical questions, please call 1-800-520-0882.
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Emission Control System
Warranty
Warranties
United States Emission Control
Defects Warranty Statement
Limited 90 Day Warranty
The United States Environmental Protection Agency (herein EPA)
and Harbor Freight Tools (herein HFT) are pleased to explain the
emission control system warranty on your 1997 and later Small Off-
Road Engine (herein engine). Within the United States, new off-road,
spark-ignition engines certified for model year 1997 and later, must be
designed, built and equipped to meet the stringent anti-smog standards
set forth by the EPA. HFT must warrant the emission control system
on your engine for the periods of time described below, provided there
has been no abuse, neglect or improper maintenance of your engine.
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.
Your emission 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 emission-related assemblies.
Where a warrantable condition exists, HFT will repair your
engine at no cost to you including diagnosis, parts and labor.
Manufacturer’s Warranty Coverage
The 1997 and later engines are warranted for two
(2) years. If any emission-related part on your engine is
defective, the part will be repaired or replaced by HFT.
Harbor Freight Tools Emission Control
Defects Warranty Coverage
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.
Engines are warranted for a period of two (2) years relative
to emission control parts defects, subject to the provisions
set forth below. If any emission related part on your engine is
defective, the part will be repaired or replaced by HFT.
Owner’s Warranty Responsibilities
• As the engine owner, you are responsible for the performance
of the required maintenance listed in your Owner’s Manual.
HFT recommends that you retain all receipts covering
maintenance on your engine, but HFT cannot deny warranty
solely for the lack of receipts or for your failure to ensure
the performance of all scheduled maintenance.
• As the engine owner, you should, however, be aware that HFT may
deny you warranty coverage if your engine or a part has failed due to
abuse, neglect, improper maintenance, or unapproved modifications.
This warranty gives you specific legal rights and you may
also have other rights which vary from state to state.
• You are responsible for shipping your engine to a HFT warranty
station as soon as a problem exists. Contact the HFT Customer
Service department at the number below to make shipping
arrangements. The warranty repairs should be completed
in a reasonable amount of time, not to exceed 30 days.
3491 Mission Oaks Blvd. • PO Box
6009 Camarillo, CA 93011
If you have any questions regarding your warranty rights
and responsibilities, you should contact the Harbor Freight
Tools Customer Service Department at 1-800-520-0882.
For Pump technical questions, please call 1-800-444-3353.
For Engine technical questions, please call 1-800-520-0882.
Item 68375
Page 20
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5. Service and Maintenance
Harbor Freight Tools Emission Control
Defects Warranty Provisions
Component parts which are not scheduled for replacement as
required maintenance or are scheduled only for regular inspection
to the effect of “repair or replace as necessary” are warranted for
the warranty period. Any warranted part which is scheduled for
replacement as required maintenance is warranted for the period
of time up to the first scheduled replacement point for that part.
Any replacement part, provided it is equivalent in durability and
performance, may be used in performance of maintenance or repairs.
The owner is responsible for commissioning a qualified technician/
mechanic to perform all required maintenance, as outlined in the
Inspection, Cleaning, and Maintenance section in this manual.
1. Length of Coverage
HFT warrants to a first retail purchaser and each subsequent
purchaser that the engine is free from defects in materials and
workmanship that cause the failure of warranted parts for a period of
two (2) years after the date of delivery to the first retail purchaser.
2. No Charge Repair or Replacement
Repair or replacement of any warranted part will be performed at
no charge to the owner if the work is performed through a warranty
station authorized by HFT. For emissions warranty service, contact
the HFT Customer Service Department at 1-800-520-0882.
6. Warranted Parts
1) Fuel Metering System
3. Consequential Damages Coverage
i)
Carburetor and its internal parts.
Coverage under this warranty shall also extend to the failure
of any engine components caused by the failure of any
warranted part while it is still covered under this warranty.
ii) Fuel pump (if so equipped).
iii) Cold start enrichment system.
2) Air Induction System
4. Coverage Exclusions
i)
Intake pipe/manifold.
Warranty claims shall be filed in accordance with the provisions
of the HFT warranty policy explained in the box at the top of the
previous page. HFT shall not be liable for any loss of use of
the engine, for any alternative usage, for any damage to goods,
loss of time, or inconvenience. Warranty coverage shall also be
excluded for any part which fails, malfunctions, or is damaged
due to failure to follow the maintenance and operating instructions
set forth in the Owner’s Manual including, but not limited to:
ii) Air cleaner.
3) Ignition System
i)
Spark plug.
ii) Magneto ignition system.
4) Catalyst System (if so equipped)
i)
Exhaust pipe stud.
a) Use of parts which are not authorized by HFT
ii) Muffler.
b) Improper installation, adjustment or repair of
the engine or of any warranted part unless
performed by an authorized warranty center
iii) Catalytic converter (if so equipped).
5) Miscellaneous Items Used in Above Systems
i)
Vacuum, temperature and time
sensitive valves and switches.
c) Failure to follow recommendations on fuel
use contained in the Owner’s Manual
ii) Hoses, belts, connectors, and assemblies.
d) Improper or inadequate maintenance of any warranted parts
e) Repairs performed outside of the authorized
warranty service dealers
f)
Alterations by changing, adding to or
removing parts from the engine.
Item 68375
For Pump technical questions, please call 1-800-444-3353.
Page 21
For Engine technical questions, please call 1-800-520-0882.
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Notes
3491 Mission Oaks Blvd. • PO Box 6009 • Camarillo, CA 93011
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