Introduction 1 Introduction 1.1 Document description This manual gives a full description of how to do maintenance and repair on the product. It also gives safety instructions that the personnel must obey. 1.2 Target group This manual is for personnel with a general knowledge of how to do repair and do servicing.
Safety 2 Safety 2.1 Safety definitions 2.4 Symbols on the product Warnings, cautions and notes are used to point out spe- cially important parts of the manual. Warning: Careless or incorrect use can result in injury or death to the operator WARNING: Used if there is a risk of injury or others or death for the operator or bystanders...
Prepare and do servicing on the product 3 Prepare and do servicing on the product 3.1 Assembly performance. • Check the fuel level. Starting with a full tank will help 3.2 Function test to eliminate or reduce operating interruptions for refueling.
Prepare and do servicing on the product Figure 3 Driving over a discharge hose while the pump is run- ning, or even possibly when the pump is stopped, may cause pump case failure. To start the engine 1. Fill the product with fuel and engine oil. 2.
Prepare and do servicing on the product 3.2.3 To stop the product 1. Unfasten the knob. This makes the knob return to the “STOP”position and the engine shuts down. Figure 8 2. Turn the fuel valve to the “CLOSED” position. Figure 10 Add the fuel in a well-ventilated area before starting the engine.
Prepare and do servicing on the product 3.2.5 To examine the oil level 3.2.6 To examine the engine oil filter Examine the level of the engine oil when the engine is 1. Remove the oil filter retaining bolt. stopped and in a level position. 2.
Prepare and do servicing on the product 3.3 Service schedule Daily Every 50 hours Every 200 hours Every 400 hours Examine engine oil level Change engine oil X¤ Examine air cleaner Replace air cleaner X¹ Check for oil leakage Replace engine oil filter X¤...
Repair instructions 5 Repair instructions 5.1 Introduction WARNING: Make sure the engine is off before you begin any repairs. This will eliminate several potential hazards: - Carbon monoxide poisoning from Engine exhaust. - Burns from hot parts. - Injury from moving parts. 5.2 Product overview for repair instruction 1.
Repair instructions 5.3 Air filter housing (O). 11. Remove the gasket (P) from the pipe intake (Q). 5.3.1 To disassemble the Air filter 12. Remove the gasket (R). Note: Operating the engine without an air filter, or with a damaged air filter, will allow dirt to enter the engine, causing rapid engine wear 5.3.2 To clean and examine the Air filter A dirty air filter will restrict air flow to the carburetor,...
Repair instructions 5.4 Muffler 5.4.1 To disassemble the Muffler Figure 1 1. Remove the screws (A), nuts (B) and washers (C) and (D). 2. Remove the muffler. Figure 2 5.4.2 To clean and examine the Muffler Clean any carbon deposits from the muffler. 5.4.3 To assemble the Muffler Assemble the muffler in the opposite sequence.
Repair instructions 5.5 Fuel tank 4. Remove the nuts (D) on the fuel shut off valve. 5. Remove and discard the O-ring (E). 5.5.1 To disassemble the Fuel tank 6. Pull the outlet fuel filter (F) and gasket (H) out of the fuel tank.
Repair instructions 5.6 Starter 5.6.1 To disassemble the Starter Figure 1 Figure 2 1. Remove the M6 bolts (A) from the starter case (B) and remove the starter assembly. 2. Remove the M8 nut (C) and the washer (D). 3. Remove the friction reel (E). 4.
Repair instructions 5.7 Engine oil 5.7.2 Engine oil recommendation 5.7.1 To change the oil Select the appropriate engine oil viscosity based on the Drain the used oil while the engine is warm. Warm oil ambient temperature and use the SAE, Service Grade drains quickly and completely.
Repair instructions 2. Remove the M10 bolts (A) and the washers (B). 5.8 Water pump 3. Remove the inlet (C) and the valve sleeve (D). 5.8.1 To disassemble the Water pump 4. Remove the M10 bolts (E) and the washers (F). 5.
Repair instructions The suction hose (G) should be no longer than neces- sary. Pump performance is best when the pump is near the water level and the hoses are short. Use a hose clamp (C) to securely fasten the hose con- nector to the suction hose (G) in order to prevent air leakage and loss of suction.
Repair instructions 5.9 Fuel Injection Pump 5.9.1 To disassemble the fuel injection pump. 1. Clean the areas adjacent to the fuel injection pump (A) and fuel injector (B). 2. Close the fuel valve (C). 3. Remove the high-pressure fuel injection line (D). 4.
Repair instructions 5.10 Valve Clearance 5.10.2 Adjustment 1. Put the feeler gauge (D) between the rocker arm (E) 5.10.1 To examine and adjust the valve and the valve cap (F). clearance. 2. Loosen the adjusting screw locknut (G). 1. Remove the head cover bolts (A). 3.
Troubleshooting 6 Troubleshooting Trouble Possible cause Solution Engine lacks power Dirty air filter Replace the air filter Engine will not start No fuel in engine Fill fuel tank or turn on fuel supply STOP/Run lever in STOP position Move the lever to RUN position Engine runs well at no load but Engine speed is too slow Adjust STOP/RUN to suit load...