Harbor Freight Tools 68375 User's Manual

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.
NEVER use inside
a home or garage,
EVEN IF doors and
windows are open.
Only use OUTSIDE
and far away from
windows, doors,
and vents.
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.
Visit our website at: http://www.harborfreight.com
Email our tech support at: tech@harborfreight.com
Email our Engine support at: predator@harborfreight.com
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
Specifications
Pump
Suction & Discharge Size
2" NPT
Discharge Capacity
151 GPM
Maximum Discharge Head
97.5 ft.
Maximum Suction Head
26 ft.
Maximum Pressure
42.2 PSI
Mechanical Seal
Ceramic
Included Accessories
Intake Strainer
Hose Clamps
Spark Plug Wrench
Engine
Displacement
212cc
Engine Type
Horizontal Single Cylinder 4 stroke OHV
Cooling System
Fuel
Engine Oil
Forced air cooled
Type
87+ octane unleaded gasoline
Capacity
0.9 Gallons / 3.6 Liters
Type SAE
10W-30 above 32° F
5W30 at 32° F or below
Capacity
0.5 Quarts / 0.5 Liters
Run Time @ 50% Load
with full tank
3 hr.
Sound Level at 22 feet
104 dB
Bore x Stroke
70 mm x 55 mm
Compression Ratio
8.5:1
Rotation viewed from PTO
(power takeoff - the output shaft)
Shaft
Shaft
Spark Plug
Valve Clearance
3/4" x 2.41"
Keyway
3/16" (4.76 mm)
End Tapped
5/16" - 24 UNF
Type
NGK® BP-6ES
NHSP® / Torch® F6TC
Gap
0.7 - 0.8 mm
Intake
Exhaust
0.10 - 0.15 mm
0.15 - 0.20 mm
3,800 ±100 RPM
Discharge Head (ft.)
No Load Speed
Counterclockwise
Flow (Gallons/minute)
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.
RPM
Property or Statement
Revolutions Per Minute
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
In this manual, on the labeling, and all other
information provided with this product:
Symbol
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.
DANGER indicates a hazardous situation which, if
not avoided, will result in death or serious injury.
WARNING indicates a hazardous situation which, if
not avoided, could result in death or serious injury.
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.
WARNING marking concerning Risk of
Hearing Loss. Wear hearing protection.
WARNING marking concerning
Risk of Respiratory Injury. Operate
engine OUTSIDE and far away from
windows, doors, and vents.
WARNING marking concerning
Risk of Fire while handling fuel. Do
not smoke while handling fuel.
WARNING marking concerning Risk of Fire.
Do not refuel while operating.
Keep flammable objects away from engine.
WARNING marking concerning
Risk of Explosion.
WARNING! Read all instructions.
Failure to follow all instructions listed below
may result in fire, serious injury and/or DEATH.
The warnings and precautions discussed in this
manual cannot cover all possible conditions and
situations that may occur. It must be understood
by the operator that common sense and caution
are factors which cannot be built into this
product, but must be supplied by the operator.
SAVE THESE INSTRUCTIONS
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
5. Use only lubricants and fuel recommended in
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.
Operating Precautions
Carbon Monoxide Hazard
Using an engine indoors CAN KILL
YOU IN MINUTES.
Engine exhaust contains carbon
monoxide. This is a poison you cannot
see or smell.
1.
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.
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.
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.
13. Do not overreach. Keep proper footing and
balance at all times. This enables better control
of the equipment in unexpected situations.
NEVER use inside a home or garage, EVEN IF doors
and windows are open.
14. Dress properly. Do not wear loose clothing or
jewelry. Keep hair, clothing and gloves away
from moving parts. Loose clothes, jewelry or
long hair can be caught in moving parts.
15. Parts, especially exhaust system components,
get very hot during use. Stay clear of hot parts.
16. Do not cover the engine or equipment during operation.
17. Keep the equipment, engine, and
surrounding area clean at all times.
Only use OUTSIDE and far away from windows, doors,
and vents.
2. Keep children away from the equipment,
especially while it is operating.
3. Do not touch Pump engine during use.
4. Never store fuel or other flammable
materials near the Pump engine.
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.
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.
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.
Page 2
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.
19. Do not operate the equipment with known
leaks in the engine’s fuel system.
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.)
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.
22. Keep hands and feet away from moving parts.
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
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.
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.
c. Then, remove the spark plug
cap from the spark plug.
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.
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.
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.
2. Do not refill the fuel tank while the
engine is running or hot.
3. Do not alter or adjust any part of the equipment
or its engine that is sealed by the manufacturer
or distributor. Only a qualified service
technician may adjust parts that may increase
or decrease governed engine speed.
4. Refuel in a well-ventilated area only.
4. Wear ANSI-approved safety goggles, heavy-duty work
gloves, and dust mask/respirator during service.
Item 68375
3. Do not fill fuel tank to the top. Leave a little
room for the fuel to expand as needed.
5. Wipe up any spilled fuel and allow excess to evaporate
before starting engine. To prevent fire, do not start
the engine while the smell of fuel hangs in the air.
Save these
instructions.
For Pump technical questions, please call 1-800-444-3353.
For Engine technical questions, please call 1-800-520-0882.
Page 3
Controls
Fuel Tank Cap
Fuel Tank
Throttle
Choke
Fuel Valve
Engine Switch
Starter Handle
Oil Dipstick
Priming Cap
Air Filter
Discharge Port
Muffler
Intake Port
Water Drain Plug
Page 4
For Pump technical questions, please call 1-800-444-3353.
For Engine technical questions, please call 1-800-520-0882.
Item 68375
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.
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.
CAUTION: Use only a non-collapsible intake hose.
Connecting Hoses
Hose Clamp
Note: Hose coupling components
and hoses not included.
Note: The Suction Hose (not included) MUST be
reinforced with braided material or have noncollapsible construction. Do not use a hose
with an inside diameter smaller than 2″ (pump’s
intake and discharge port diameters).
Suction Hose
a
CAUTION: Do not over-tighten Hose Clamps as the
clamp may damage the hose or other components.
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).
Hose Coupler
Gasket
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.
b
Hose Coupling Ring
b
a
a
2. Thread the Hose Coupling Ring onto the Intake Port
(a), and turn clockwise until fastened securely (b).
Intake Strainer
Intake Port
Item 68375
For Pump technical questions, please call 1-800-444-3353.
For Engine technical questions, please call 1-800-520-0882.
Page 5
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).
a
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.
b
b
a
6. Thread the Hose Coupling Ring clockwise onto the
Discharge Port until tightened securely.
Discharge Port
Page 6
For Pump technical questions, please call 1-800-444-3353.
For Engine technical questions, please call 1-800-520-0882.
Item 68375
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.
Discharge Head
Water Pump
Total Head
Suction
Head
Strainer
4. Secure the Intake Hose in place to keep it from moving
once the Pump is turned on. The Intake Hose should
be as short as possible for more efficient operation.
5. Route the discharge hose to the desired discharge
location. If necessary, connect additional discharge
hoses to direct the discharge to the desired location.
Make sure to secure the discharge hose in place
to keep it from moving once the Water Pump is
turned on. The discharge hose should be kept as
short as possible for more efficient operation.
Operation Concerns
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.
Discharge head capability is always greater than
suction head capability. This means pumping height
for the Intake Hose (suction head) should be shorter
than the pumping height for the Discharge Hose.
Minimizing suction head (placing the Pump
closer to the water level) will also help 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. Route the Intake Hose with the Intake Strainer
fully immersed in the water supply source.
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.
Item 68375
1. Cavitation: This is the sudden formation and collapse
of low-pressure vapor (bubbles) across the vanes of
the impeller.
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.
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).
2. Water Hammer Pressure: This is energy sent back to
the Pump due to sudden stoppage of water flowing
from the Pump.
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.
Solution: Use as short a discharge hose as possible
and turn off water pump before closing water flow.
For Pump technical questions, please call 1-800-444-3353.
For Engine technical questions, please call 1-800-520-0882.
Page 7
Checking and Filling Engine Oil
Operation
Read the entire Important Safety
Information section at the beginning
of this manual including all text
under subheadings therein before
set up or use of this product.
Pre-Start Checks
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.
1. Make sure the engine is stopped and is level.
2. Close the Fuel Valve.
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
Before starting the engine, fill the
Pump with water. To do this:
Full level
1. Unthread the Priming Water Filler Cap
by turning it counterclockwise.
2. Fill the unit with clean water up to the top
of the opening. Replace the Priming Water
Filler Cap and tighten securely.
Priming Water
Filler Cap
Full level
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.
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.)
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
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.
WARNING! To prevent serious
injury from fire:
Fill the fuel tank in a well-ventilated area away
from ignition sources. If the engine is hot from
use, shut the engine off and wait for it to cool
before adding fuel. Do not smoke.
1. Clean the Fuel Cap and the area around it.
2. Unscrew and remove the Fuel Cap.
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.
Page 8
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
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
ChokeRUN
2. Open the Fuel Valve.
2
3. Slide the Throttle to 1/3 away from the SLOW position (the “turtle”).
3
O
ON
4
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.
5
4. Turn the Engine Switch on.
OFF
ON
I
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.
6
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.
Item 68375
For Pump technical questions, please call 1-800-444-3353.
For Engine technical questions, please call 1-800-520-0882.
ChokeRUN
Page 9
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
O
b. Turn the Engine Switch off.
Page 10
b
For Pump technical questions, please call 1-800-444-3353.
For Engine technical questions, please call 1-800-520-0882.
I
Item 68375
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.
Before
Each Use
Procedure
Monthly or
Every 3 mo. or Every 6 mo. or
every 20
50 hr. of use 100 hr. of use
hr. of use
Yearly or
every 300
hr. of use
Every
2 Years
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.
For Engine technical questions, please call 1-800-520-0882.
Page 11
Checking and Filling Fuel
Engine Oil Change
WARNING! To prevent serious
injury from fire:
Fill the fuel tank in a well-ventilated area away
from ignition sources. If the engine is hot from
use, shut the engine off and wait for it to cool
before adding fuel. Do not smoke.
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.
CAUTION! Oil is very hot during operation and can
cause burns. Wait for engine to cool before changing oil.
1. Make sure the engine is stopped and is level.
2. Close the Fuel Valve.
3. Place a drain pan (not included) underneath
the crankcase’s drain plug.
4. Remove the drain plug and, if possible,
tilt the crankcase slightly to help drain
the oil out. Recycle used oil.
5. Replace the drain plug and tighten it.
6. Clean the top of the Dipstick and the area around it.
Remove the Dipstick by threading it counterclockwise,
and wipe it off with a clean lint free rag.
Full level
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
Average outdoor temperature
100°F
8. Thread the dipstick back in clockwise.
CAUTION! Do not run the engine with too little
oil. The engine will be permanently damaged.
Page 12
For Pump technical questions, please call 1-800-444-3353.
For Engine technical questions, please call 1-800-520-0882.
Item 68375
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
Filter Cover
Tab
Filter
1. Disconnect spark plug cap from end of plug.
Clean out debris from around spark plug.
Base Hinge
2. Using a spark plug wrench, remove the spark plug.
2. Cleaning:
• Foam filter element:
Wash the element in warm water and mild
detergent several times. Rinse. Squeeze
out excess water and allow it to dry
completely. Soak the filter in lightweight oil
briefly, then squeeze out the excess oil.
3. Install the new filter or the cleaned filter. Secure the Air Cleaner Cover before use.
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.
Recommended Spark Plug
Brand
NGK®
NHSP® / TORCH®
Part #
BP-6ES
F6TC
NOTICE: Using an incorrect spark
plug may damage the engine.
4. When installing a new spark plug, adjust the
plug’s gap to the specification on the Technical
Specifications chart. Do not pry against the
electrode, the spark plug can be damaged.
5. Install the new spark plug or the cleaned spark plug
into the engine.
Gasket-style: Finger-tighten until the gasket contacts
the cylinder head, then about 1/2-2/3 turn more.
Non-gasket-style: Finger-tighten until the plug
contacts the head, then about 1/16 turn more.
NOTICE: Tighten the spark plug properly.
If loose, the spark plug will cause the engine
to overheat. If overtightened, the threads
in the engine block will be damaged.
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
Storage
3. Lubrication:
When the equipment is to remain idle for longer than
20 days, prepare the engine for storage as follows:
1. CLEANING:
Wait for engine to cool, then clean engine with
dry cloth. NOTICE: Do not clean using water.
The water will gradually enter the engine and cause
rust damage.
Apply a thin coat of rust preventive oil to all metal parts.
2. FUEL:
WARNING! To prevent serious
injury from fire:
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.
a. Place a funnel leading to a proper gasoline
container below the carburetor.
Air Filter
Cover
Muffler
Carburetor
a. Change engine oil.
b. Clean out area around spark plug. Remove
spark plug and pour one tablespoon of engine
oil into cylinder through spark plug hole.
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).
4. Battery:
Disconnect battery cables (if equipped).
Recharge batteries monthly while in storage.
5. STORAGE AREA:
Cover and store in a dry, level, well-ventilated
area out of reach of children. Storage area should
also be away from ignition sources, such as
water heaters, clothes dryers, and furnaces.
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.
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.
Page 14
For Pump technical questions, please call 1-800-444-3353.
For Engine technical questions, please call 1-800-520-0882.
Item 68375
Pump Troubleshooting
Problem
Pump overheats
Unit stalls
Possible Causes
1. Lubricate using recommended oil or
grease according to directions.
2. Have qualified technician inspect internal
mechanism and replace parts as needed.
1. Low engine speed.
1. Qualified technician should increase
no load speed to 3,800±100 RPM
by adjusting pressure switch.
2. Replace air filter.
3. Check for proper oil level.
2. Severely clogged air filter.
3. Improper lubrication.
Pump does not
pump water
Likely Solutions
1. Incorrect lubrication or not
enough lubrication.
2. Worn parts.
1. Pump is not primed.
2. Intake Strainer clogged.
3. Air leak at intake connector.
4. Hose leaks.
5. Suction hose has collapsing wall.
6. Hose has too small diameter.
7. Pump is too high above water surface.
1. Suction hose collapsed, damaged,
too long or diameter is too small.
2. Air leak at connector.
Low Pump Output
3. Strainer clogged.
4. Discharge hose damaged,
too long or diameter too small.
1. Prime Pump.
2. Clean Intake Strainer or replace if damaged.
3. Replace Coupling Gasket or tighten clamp.
4. Replace hose.
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. Replace or adjust suction hose.
2. Replace Coupling Gasket or tighten Clamp.
3. Clean Strainer.
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
Engine Troubleshooting
Problem
Possible Causes
Engine will not start
Fuel Related:
1. No fuel in tank or fuel valve closed.
2. Choke not in CHOKE position, cold engine.
3. Gasoline with more than 10% ethanol
used. (E15, E20, E85, etc.)
Probable Solutions
9. Clogged Fuel Filter.
Fuel Related:
1. Fill fuel tank and open fuel valve.
2. Move Choke to CHOKE position.
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. Use fresh 87+ octane unleaded gasoline.
Do not use gasoline with more than
10% ethanol (E15, E20, E85, etc.).
5. Pull on Starter Handle to prime.
6. Clean out passageways using fuel additive.
Heavy deposits may require further cleaning.
7. Gently tap side of carburetor float
chamber with screwdriver handle.
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. 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.
4. Spark plug cap broken.
5. Incorrect spark timing or
faulty ignition system.
Ignition (spark) Related:
1. Connect spark plug cap properly.
2. Clean spark plug.
3. Correct spark plug gap.
4. Replace spark plug cap.
5. Have qualified technician diagnose/
repair ignition system.
Compression Related:
1. Cylinder not lubricated. Problem after long
storage periods.
Compression Related:
1. Pour tablespoon of oil into spark
plug hole. Crank engine a few
times and try to start again.
2. Tighten spark plug. If that does not work,
replace spark plug. If problem persists,
may have head gasket problem, see #3.
3. Tighten head. If that does not remedy
problem, replace head gasket.
4. Low quality or deteriorated, old gasoline.
5. Carburetor not primed.
6. Dirty fuel passageways.
7. Carburetor needle stuck. Fuel
can be smelled in the air.
8. Too much fuel in chamber. This can be
caused by the carburetor needle sticking.
2. Loose or broken spark plug. (Hissing
noise will occur when trying to start.)
3. Loose cylinder head or damaged
head gasket. (Hissing noise will
occur when trying to start.)
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.
Page 16
For Pump technical questions, please call 1-800-444-3353.
For Engine technical questions, please call 1-800-520-0882.
Item 68375
Engine Troubleshooting (cont.)
Problem
Engine misfires
Possible Causes
1. Spark plug cap loose.
2. Incorrect spark plug gap or
damaged spark plug.
3. Defective spark plug cap.
4. Old or low quality gasoline.
5. Incorrect compression.
Engine stops
suddenly
1. Low oil shutdown.
2. Fuel tank empty or full of impure or low
quality gasoline.
3. Defective fuel tank cap creating
vacuum, preventing proper fuel flow.
4. Faulty magneto.
5. Disconnected or improperly
connected spark plug cap.
Probable Solutions
1. Check wire connections.
2. Re-gap or replace spark plug.
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. Diagnose and repair compression.
(Use Engine will not start:
Compression Related section.)
1. Fill engine oil to proper level. Check
engine oil before EVERY use.
2. Fill fuel tank with fresh 87+ octane
unleaded gasoline.
Do not use gasoline with more than
10% ethanol (E15, E20, E85, etc.).
3. Test/replace fuel tank cap.
4. Have qualified technician service magneto.
5. Secure spark plug cap.
Engine stops when
under heavy load
1. Dirty air filter
2. Engine running cold.
1. Clean or replace element.
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. Do not exceed equipment’s load rating.
3. Have qualified technician diagnose
and service engine.
2. Engine overloaded.
3. Incorrect spark timing, deposit
buildup, worn engine, or other
mechanical problems.
Engine backfires
1. Impure or low quality gasoline.
2. Engine too cold.
3. Intake valve stuck or overheated engine.
4. Incorrect timing.
1. Fill fuel tank with fresh 87+ octane
unleaded gasoline.
Do not use gasoline with more than
10% ethanol (E15, E20, E85, etc.).
2. Use cold weather fuel and oil
additives to prevent backfiring.
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
Parts List (Including Item 68120 212cc engine)
Part
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
Description
Cylinder Head Gasket
Cylinder Head Cover
Subassembly
Cylinder Head
Cover Gasket
Breather Tube
Bolt
Stud
Stud
Stud
Pin
Cylinder Head Bolt
Spark Plug
Cylinder Head
Subassembly
Crankcase
Subassembly
Engine Oil Sensor
Governor Gear Assy.
Governor Arm
Drain Plug Bolt
Washer
Bearing
Oil Seal
Washer
Pin
Bolt
Crankcase Cover
Bearing
Oil Seal
Crankcase Gasket
Pin
Oil Dipstick
Subassembly
Engine Oil Plug
Subassembly
Bolt
Crankshaft Assy.
Piston Pin Clip
Piston
Piston Pin
Connecting Rod
First Ring
Second Ring
Oil Ring Set
Camshaft Assy.
Exhaust Valve
Intake Valve
Valve Spring Seat
Page 18
Qty
1
1
1
1
4
1
1
2
2
4
1
1
1
1
1
1
2
2
1
1
1
1
2
1
1
1
1
2
1
1
6
1
2
1
1
1
1
1
1
1
1
1
1
Part
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
81
82
83
84
85
86
87
88
Description
Retainer Exhaust Valve
Rotator Valve
Seal Guide
Valve Tappet
Valve Lifter
Lifter Stopper Plate
Subassembly
Valve Adjusting Bolt
Valve Rocker
Valve Adjusting Nut
Valve Lock Nut
Valve Spring
Recoil Starter Assy.
Bolt
Shroud
Cylinder Body Shroud
Lower Shield
Oil Protector
Engine Switch
Subassembly
Bolt
Bolt
Collar
Bolt
Bolt
Carburetor Assy.
Air Cleaner Gasket
Carburetor Gasket
Carburetor
Insulator Plate
Carburetor
Insulator Gasket
Nut
Air Cleaner
Exhaust Outlet Gasket
Nut
Muffler Assy.
Fuel Tank
Fuel Filter
Fuel Tank Cover
Fuel Tank Oil Outlet
Subassembly
Collar
Fuel Tube
Bolt
Nut
Flywheel Nut
Starter Pulley
Impeller
Flywheel Subassembly
Qty
1
1
1
2
2
1
2
2
2
2
2
1
3
1
1
1
1
1
2
1
1
1
4
1
1
1
1
1
2
1
1
2
1
1
1
1
1
2
1
1
2
1
1
1
1
Part
89
90
91
92
93
94
95
96
97
98
99
100
101
102
103
104
105
106
107
108
109
110
111
112
113
114
115
116
117
118
119
120
121
122
123
124
125
126
127
128
129
130
131
132
For Pump technical questions, please call 1-800-444-3353.
For Engine technical questions, please call 1-800-520-0882.
Description
Bolt
Ignition Coil
Throttle Control Assy.
Bolt
Governor Spring
Governor Rod
Throttle Valve
Returning Spring
Governor Support Bolt
Nut
Governor Support
Subassembly
Hose Clamp
Filter Cover
Filter
Bolt
Washer
Washer
Water Inlet
Gasket Inlet Water
Thread Plug
Screw Plug Washer
Outlet Water
Gasket Outlet
Pump Body
Ring Whorl Case
Sealing
Whorl Case
Bolt
Washer
Water Pump Impeller
Key
Water Pump
Joint Cushion
Impeller Seal Ring
Porcelain Seal
Seal Assy. Mechanism
Water Pump Joint
Washer
Bolt
Water Pump Assy.
Engine Frame Assy.
Bolt
Engine Frame Shock
Absorption Seat
Core Nut
Bolt
Nut
Rubber Jacket
Qty
2
1
1
2
1
1
1
1
1
1
3
1
1
11
7
4
1
1
2
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
4
4
1
1
4
4
4
4
4
1
Item 68375
Item 68375
122
121
120
119
118
117
116
124
99
103
124
124
123
123
123
123
102
103
115
114
108
102 107
104
102
31
For Pump technical questions, please call 1-800-444-3353.
For Engine technical questions, please call 1-800-520-0882.
5
5
5
113
108
107
106
5
99
2 3
112
105
4
10
10
10
103
104
102
104
102
110
104
111
102
109
103
102
31
31
10
11
102
103
30
31
12
8
31
31
8
24
26
6
101
100
99
25
125
27
7
9
9
69
70
71
53
1
40
28
23
42
14
92
68
37 39
38
67
33
15
94
97
34
35
33
17
19
36
75
127
128
129
98
128
127
95
96
93
91
130
129
129
130 128
127
131
44 54 41
23
32
128
127
130
129
47 45
51 43
50 54
52
46
49
53
50
52 51
47 48
48 47
28
29
126
18
16
22
72
72
73
21
13
74
90
18
89
88
17
80
81
20
83
89
76
62
55
62 58
59
64
132
85
86
84
81
87
82
77
84
65
66
79
57
63
60
78
56
56
66
56
66
66
61
Diagram (Including Item 68120 212cc engine)
Page 19
Emission Control System
Warranty
Warranties
Limited 90 Day Warranty
United States Emission Control
Defects Warranty Statement
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.
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 OffRoad 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.
To take advantage of this warranty, the product or part must
be returned to us with transportation charges prepaid. Proof
of purchase date and an explanation of the complaint must
accompany the merchandise. If our inspection verifies the
defect, we will either repair or replace the product at our
election or we may elect to refund the purchase price if we
cannot readily and quickly provide you with a replacement.
We will return repaired products at our expense, but if we
determine there is no defect, or that the defect resulted
from causes not within the scope of our warranty, then you
must bear the cost of returning the product.
This warranty gives you specific legal rights and you may
also have other rights which vary from state to state.
3491 Mission Oaks Blvd. • PO Box
6009 Camarillo, CA 93011
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
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.
• 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.
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.
Page 20
For Pump technical questions, please call 1-800-444-3353.
For Engine technical questions, please call 1-800-520-0882.
Item 68375
Harbor Freight Tools Emission Control
Defects Warranty Provisions
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.
3. Consequential Damages Coverage
5. Service and Maintenance
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.
6. Warranted Parts
1)
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.
2)
4. Coverage Exclusions
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:
a) Use of parts which are not authorized by HFT
b) Improper installation, adjustment or repair of
the engine or of any warranted part unless
performed by an authorized warranty center
c) Failure to follow recommendations on fuel
use contained in the Owner’s Manual
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
3)
4)
5)
Fuel Metering System
i) Carburetor and its internal parts.
ii) Fuel pump (if so equipped).
iii) Cold start enrichment system.
Air Induction System
i) Intake pipe/manifold.
ii) Air cleaner.
Ignition System
i) Spark plug.
ii) Magneto ignition system.
Catalyst System (if so equipped)
i) Exhaust pipe stud.
ii) Muffler.
iii) Catalytic converter (if so equipped).
Miscellaneous Items Used in Above Systems
i) Vacuum, temperature and time
sensitive valves and switches.
ii) Hoses, belts, connectors, and assemblies.
For Pump technical questions, please call 1-800-444-3353.
For Engine technical questions, please call 1-800-520-0882.
Page 21
Notes
3491 Mission Oaks Blvd. • PO Box 6009 • Camarillo, CA 93011
www.harborfreight.com