FAST-WAY LIMITED WARRANTY POLICY
Ideal Manufacturing, Inc., hereinafter referred to as “Manufacturer” warrants FAST-WAY
equipment to be free from defect in material and workmanship, under normal use and service,
for a period of one (1) year from the date of original purchase. Manufacturer will, at its
option, replace or repair at factory in Billings, MT, any part or parts which shall appear, to
the satisfaction of the Manufacturer, upon inspection at its factory, to have been defective in
material or workmanship. This warranty does not obligate the Manufacturer to bear any
transportation charges in connection with replacement or repair of defective parts. This
warranty excludes electrical components and damage due to Acts of God, unauthorized
modifications, misuse, abuse or negligence to this product.
In order to proceed with a warranty claim, Ideal Manufacturing must be notified of the
problem. A new part will be shipped out prepaid (Ground UPS). If the customer requests
that the part be expedited that shipping charge will be charged to the owner.
The part that is being warranted must be returned to Ideal Manufacturing postage prepaid.
When the new part is shipped out, it will go out with an invoice and a warranty part return
number. The defective part must be returned to Ideal Manufacturing, Inc freight prepaid, with
the warranty part return number. At that time the invoice will be considered paid in full.
This warranty is exclusive and in lieu of all other obligation, liabilities or warranties. In no
event shall Ideal Manufacturing be liable or responsible for incidental or consequential
damage or for any other direct or indirect damage loss, cost, expense or fee.
This warranty shall not apply to any products or parts that have been altered or repaired
without written consent of Ideal Manufacturing.
Labor to remove and reinstall defective product or parts will be paid from a labor rate and
schedule only. Consult Ideal Manufacturing for that rate and schedule.
For further information on returning your product or questions concerning Ideal
Manufacturing warranty, please contact Ideal Manufacturing.
Ideal Manufacturing Inc., 2011 Harnish Blvd., Billing’s, Montana 59101, 1-800-523-3888 toll free, 1-406-656-4360 phone, 1-406-656-4363 fax
TABLE OF CONTENTS
CS-16 A
AUGER CEMENT SCREW
THIS MANUAL IS FOR AUGERS STARTING WITH
SERIAL NUMBER CS16A0810-107 AND UP
DESCRIPTION
PAGE TO PAGE
WARRANTY POLICY
SAFETY RULES
SET UP PROCIDURE / SPECIAL INSTRUCTIONS
ELECTRICAL DIAGRAMS
LOWER BEARING ASSEMBLY
LOWER BEARING ASSEMBLY DRAWING
DRIVE ASSEMBLY UPPER BEARING MOUNT
DRIVE ASSEMBLY DRAWING
HYDRAULIC CONTROL VALVE ASSEMBLY
HYDRAULIC CONTROL VALVE DRAWING
HYDRAULIC PUMP ASSEMBLY
HYDRAULIC PUMP DRAWING
GAS OR DIESEL DRIVEN HYDRAULICS
GAS OR DIESEL DRIVEN HYDRAULICS DRAWING
FRAME ASSEMBLY
FAME DRAWING
AUGER TUBE AND HOPPER
AUGER TUBE AND HOPPER DRAWING
HAND WINCH MANUAL AND PARTS
HYDRAULIC MOTOR SERVICE INSTRUCTIONS
HYDRAULIC PUMP INSTALLATION INSTRUCTIONS
HYDRAULIC CONTROL VALVE PARTS
HONDA ENGINE MANUAL
1
2 THUR 5
6 THUR 9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24 THUR 27
28 THUR 31
32 THUR 37
38 THUR 65
66 THUR 85
SAFETY RULES
Warning: Maximum Hydraulic PSI Setting is 1800, do not exceed this pressure.
1.
Follow instructions, don't take chances. If you don't know, ask. When setting up, lowering
or putting equipment into traveling position, follow all instructions in operator’s manual.
2.
Correct or report unsafe conditions. If not sure of how to correct a hazard, report it and get
help.
3.
Keep everything clean and orderly. Trips or falls can cause serious injuries.
4.
Use the right tools and equipment for the job. Use them safely. Replace all machine guards
after repairs.
5.
Report all injuries and get first aid or medical treatment promptly.
6.
Use, adjust, and repair equipment only when authorized.
7.
Use prescribed protective equipment. Keep it in good condition. Wear your hardhat, safety
climbing devices or belt. Wear safe clothing to protect you from material being handled, cold
or hot. Wear a dust mask when conditions require them. Use gloves, eye protection/safety
glasses, and earplugs for noise.
8.
Don’t horseplay: avoid distracting others.
9.
When lifting, bend your knees and get help for heavy loads.
10.
Don't repair or adjust equipment while in motion. Shut off power source, gasoline engines or
electric motors.
11.
Comply with safety rules and signs.
12.
Gasoline, L.P. gas fumes are highly explosive.
1
SET UP PROCEDURE CS-16 A
(Refer to Drawings CS-16 A 101 page 4 and CS-16 A 102 page 5)
Step 1
Select a level, and solid site for setting up and operating cement screw.
Step 2
Locate Travel Rod (page 4) – Remove hairpin clip from the hole in the
Travel Rod. Pull Travel Rod out of frame holes. Put Travel Rod in safe
place for future use. Attach Discharge Boot (page 23).
Step 3
Locate Hand Winch (page 4) – Release cable tension from winch and
spool out all cable.
Step 4
Locate Diagonal Braces SSC111 (page 4) – Remove brace pin from
bracket on the auger tube. Use brace SSC111 and swing vertical frame
forward. Two competent people should preform placement of vertical
frame.
Step 5
Locate Diagonal Brace Anchor Point (page 5) – Align diagonal braces
holes with anchor point, and insert brace pins. Secure brace pins with
hairpin clips.
Step 6
Crank hand winch handle in clockwise rotation to raise main tube to
desired position (33 ½º or 45º)
33 ½º Position (Refer to page 5, 33 ½º degree discharge note)
When main tube has been winched to appropriate height above 33 ½º
degree discharge position install auger support bracket, (Part #SSC100).
With auger support bracket placed across vertical frame supports points
lower main tube so that it rests on support bracket while keeping tension
on winch line for additional support.
45º Position (Refer to page 5, 45º degree discharge note)
When main tube has been winched to appropriate height above 45º degree
discharge position install auger support bracket, (Part #SSC100). With
auger support bracket placed across vertical frame supports points lower
main tube so that it rests on support bracket while keeping tension on
winch line for additional support.
Step 7
Check hydraulic oil level in tank. Hydraulic oil should be 6 to 8 inches
below top of tank.
Step 8
Check oil in engine and add fuel Gasoline and Diesel Powered Units Only.
NOTE: Use proper fuel for the engine. Fuel line may have shut off valve
located below fuel tank. Electric powered units are lifetime factory
lubricated.
Step 9
Grease all bearings on conveyor screw.
2
SPECIAL INSTRUCTION
When using machine in 45º position it is recommended to either raise the hopper end
approximately 1” or remove enough ground on the left side of the hopper to let cover
hang free when in open position. Failure to do so may create damage to hinge area of
hopper. Machine is now ready for operation. Electric powered units operate at a fixed
speed. Gasoline powered units speed can be regulated by adjusting governor.
SAFETY FIRST
Keep coupling guard installed during operation and hopper cover closed when not in use.
MOVING & TRAVEL PROCEDURE
Reverse set up procedure starting with Step 6 and working back to Step 1. Check tires
pressure. Inflate to manufacturers specifications. Machine can be towed at highway
speed depending on road conditions.
3
4
3
2
1
D
D
POO887
SSC101
8158
POO863
POO865
POO878
POO885
C
C
POO635
AUGER SUPPORT BRACKET
part # SSC100
CS-16 A
TRAVEL POSITION
4
TRAVEL ROD
9
30516
SSC101
BRACE PIN
VERTICAL FRAME
SSC111
6114
B
B
HAND WINCH
2611
16
15215
16
DRAWN
THenry
CHECKED
QA
A
MFG
IDEAL MFG., INC.
10/30/2009
7/22/2010
TITLE
A
CS-16 A 101 TRAVEL POSITION
APPROVED
SIZE
C
SCALE
4
3
2
DWG NO
REV
CS-16 A 101
SHEET
1
1 OF 1
4
3
2
1
CS-16 A
OPERATION POSITION
D
D
45° OPERATION POSITION SHOWN
33.5° OPERATION POSITION BLUE LINE
DISCHARGE BOOT NOT SHOWN
AUGER SUPPORT BRACKET
HERE FOR 45° DISCHARGE
AUGER SUPPORT BRACKET
HERE FOR 33.5° DISCHARGE
C
C
5
22116
BRACE PIN
9
19732
AT 45°
SSC111
5
POO558
15711
16
AT 33.5°
45.00°
POO865
HAND WINCH
POO635
POO887
33.50°
POO878
B
POO885
3214
ANCHOR POINT
DIAGONAL BRACE
B
POO863
BRACE PIN
16118
5311
16
3
8316
DRAWN
THenry
CHECKED
QA
A
MFG
IDEAL MFG., INC.
10/30/2009
7/22/2010
TITLE
A
CS-16 A OPERATION POSITION
APPROVED
SIZE
C
SCALE
4
3
2
DWG NO
REV
CS-16 A 102
SHEET
1
1 OF 1
CS-16 A
FAST-WAY CEMENT SCREW ELECTRICAL ENCLOSURE 220
VOLT SINGLE PHASE FOR 5 HP
DRAWING #SC-16-E2
REF NO.
1
2
PART NO.
POO558
N/A
3
N/A
4
5
6
POO565
POO606
POO606A
POO606B
POO563
7
DESCRIPTION
Enclosure
Conductor Cord, 220 Volt, 12-3 S.O.
(By Purchaser)
Strain Relief Fitting
(By Purchaser)
Circuit Breaker
Contactor Starter
Overload Relay
Coil
Pushbutton Unit
6
REQ’D NO.
1
1
1
1
1
2
IDEAL MANUFACTURING INC.
CS-16 A
FAST-WAY CEMENT SCREW ELECTRICAL ENCLOSURE
220 VOLT THREE PHASE FOR 5 HP
DRAWING #CS-16 A E3
REF NO.
1
2
PART NO.
POO558
N/A
3
N/A
4
5
6
7
POO559
POO607
POO607A
POO563
DESCRIPTION
Enclosure
Conductor Cord, 220 Volt, 8-4 S.O.
(By Purchaser)
Strain Relief Fitting
(By Purchaser)
Circuit Breaker
Contactor Starter
Overload Relay
Pushbutton Unit
REQ’D NO.
1
1
1
1
2
CS-16 A
FAST-WAY CEMENT SCREW ELECTRICAL ENCLOSURE
440 VOLT THREE PHASE FOR 5 HP
DRAWING #CS-16 A E3
NO.
1
2
PART NO.
POO558
N/A
3
N/A
4
5
6
7
POO560
POO561
POO561C
POO563
DESCRIPTION
Enclosure
Conductor Cord, 440 Volt, 12-4 S.O.
(By Purchaser)
Strain Relief Fitting
(By Purchaser)
Circuit Breaker
Contactor Starter
Overload Relay
Pushbutton Unit
8
REQ’D NO.
1
1
1
1
1
2
IDEAL MANUFACTURING INC.
CS-16 A
LOWER BEARING ASSEMBLY
REFERENCE DRAWING CS-16 A 103
REF NO.
1
2
POO124
PART NO.
N/A
N/A
POO124
4
N/A
DESCRIPTION
½”-13 Nuts
½” Lock washer
1 ½” Bearing
(Lower Conveyor Screw)
½” USS Flat Washer
CSP101
POO125
7
8
CSP102
CSP103
SSC102
SSC103
13
CSP101
POO125
N/A
N/A
CSP102
CSP103
SSC102
SSC103
N/A
Seal Retainer Plate
Seal
⅜” - 16” Nut
⅜” Lock washer
Lower Bearing Holder Plate w/Bolts
Skid Foot
Auger Tube & Hopper Assembly.
Auger Flight Assembly.
⅜”–16” x 1 ¼” Hex Head Bolt
10
REQ’D NO.
4
4
1
24 - Seal Spacer
8 - Brg. Spacer
1
1
6
6
1
1
1
1
6
4
3
2
1
CS-16 A
LOWER BEARING ASSEMBLY
D
D
C
C
11
CSP102
SSC102
8
B
B
7
13
SSC103
8
CSP101
7
POO125
POO124
4
2
DRAWN
THenry
1
CHECKED
CSP103
A
4
QA
MFG
IDEAL MFG., INC.
11/4/2009
7/22/2010
TITLE
APPROVED
4
SIZE
C
SCALE
4
A
CS-16 A LOWER BEARING ASSEMBLY
3
2
DWG NO
REV
CS-16 A 103
SHEET
1
1 OF 1
CS-16 A
DRIVE ASSEMBLY
UPPER BEARING MOUNT
REFERENCE DRAWING CS-16 A 104
REF NO.
1
2
3
4
5
6
7
8
9
10
11
POO129A
POO653
POO667
POO869
POO872
POO873
POO874
POO963
POO985
POO1001
POO1008
SSC103
SSC104
SSC105
SSC106
PART NO.
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
POO129A
POO653
POO667
POO869
POO872
POO873
POO874
POO963
900985
POO1001
POO1008
SSC103
SSC104
SSC105
SSC106
DESCRIPTION
5/16-18 X 2 Hex Bolt
3/8-16 X 1 Hex Bolt
3/8 Lock Washer
3/8-16 Hex Nut
3/8-16 X 1 1/4 Hex Bolt
3/8 Flat Washer
1/2 Lock Washer
1/2-13 Hex Nut
1/2-13 X 1 1/2 Hex Bolt
5/16 X 5/16 X 1 1/4 Key
3/8 X 3/8 X 1 3/4 Key
Bearing
Center Light
Tail Light
Pipe Clamp
Coupling Hydraulic Motor
Coupling Auger
Coupling Insert
10-10 Straight JIC ORB
Hydraulic Motor
#10 Hose X 35” MJIC FJIC 90`
Hydraulic Tubing 191”
Auger Flight Assembly
Hydraulic Motor Mount
Upper Bearing Mount With Bolts
Tail Light Bracket
12
REQ’D NO.
4
6
10
10
4
8
6
6
2
1
1
1
1
2
4
1
1
1
2
1
2
2
1
1
1
1
4
3
2
1
CS-16 A
DRIVE AND UPPER BEARING ASSEMBLY
1
POO869
D
SSC106
POO1008
D
POO1001
HOSE B
SSC103
SSC105
POO653
POO1008
POO667
POO1001
HOSE A
POO667
C
C
2
11
POO873
POO874
POO872
3
13
4
5
6
POO129A
7
POO985
8
10
B
B
7
9
SSC104
8
6
POO963
3
4
POO963
POO1001
HOSE A
POO1001
HOSE B
DRAWN
THenry
CHECKED
QA
A
MFG
IDEAL MFG., INC.
11/4/2009
12/3/2010
TITLE
A
CS-16 A DRIVE ASSEMBLY
APPROVED
SIZE
C
SCALE
4
3
2
DWG NO
REV
CS-16 A 104
SHEET
1
1 OF 1
CS-16 A
HYDRAULIC CONTROL VALVE
REFERENCE DRAWING # CS-16 A 105
REF NO.
1
2
3
4
5
6
7
8
POO558
POO865
POO880
POO885
POO887
POO963
POO964
POO1009
POO1010
PART NO.
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
POO558
POO865
POO880
POO885
POO887
POO963
POO964
POO1009
POO1010
DESCRIPTION
1/2 Lock Washer
1/2-13 Hex Nut
1/2 Flat Washer
1/2-13 X 1 3/4 Hex Bolt
1/2-13 Lock Nut
1/2-13 X 1 1/4 Hex Bolt
3/8-16 X 1 1/4 Hex Bolt
3/8 Lock Washer
Electrical Enclosure
Hydraulic Valve
12-10 JIC ORB
Hydraulic Hose Straight JIC 90 JIC
Hydraulic Hose Straight JIC 90 JIC
10-10 JIC ORB
10-8 JIC ORB
#10 Hose X 16” FJIC MJIC
#10 Hose X 18” FJIC MJIC
14
REQ’D NO.
4
4
4
2
2
4
3
3
1
1
1
1
1
1
2
1
1
4
3
2
1
PRESSURE FROM PUMP
POO885
CS-16 A
HYDRAULIC CONTROL VALVE
POO558
POO1010
POO963
POO1009
D
D
RETURN TO TANK
POO964
POO865
POO887
POO880
POO964
C
C
POO1010
POO1009
4
8
15
6
7
2
3
1
5
B
B
DRAWN
THenry
CHECKED
QA
A
MFG
IDEAL MFG., INC.
11/4/2009
12/3/2010
TITLE
A
CS-16 A HYDRAULIC CONTROL VALVE
APPROVED
SIZE
C
SCALE
4
3
2
DWG NO
REV
CS-16 A 105
SHEET
1
1 OF 1
CS-16 A
HYDRAULIC PUMP ASSEMBLY
REFERENCE DRAWING # SC-16 A 106
REF NO.
1
2
3
4
5
6
7
8
9
10
11
POO434
POO635
POO862
POO862A
POO863
POO864
POO866
POO866A
POO867
POO868
POO870
POO875
POO875A
POO876
POO877
POO878
POO878A
POO879
POO885
POO887
POO963
POO964
POO1011
SSC101
SSC107
SSC108
PART NO.
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
POO434
POO635
POO862
POO862A
POO863
POO864
POO866
POO866A
POO867
POO868
POO870
POO875
POO875A
POO876
POO877
POO878
POO878A
POO879
POO885
POO887
POO963
POO964
POO1011
SSC101
SSC107
SSC108
DESCRIPTION
3/8-16 Hex Nut
3/8 Flat Washer
3/8-16 X 1 1/4 Hex Bolt
3/8-16 X 2 3/4 Hex Bolt
3/8-16 X 3 1/4 Hex Bolt
3/8 Lock Washer
5/16-18 Hex Nut
5/16-18 X 1 Hex Bolt
5/16 Lock Washer
1/4 X 1/4 X 1 1/4 Key
1/8 X 1/8 X 3/4 Key
1/2 NPT Plug
5 HP Motor
16-12 Straight JIC ORB Electric
16-10 Straight JIC ORB Gas/Diesel
1” Hyd. Hose Straight JIC 45 JIC
Breather
Filter Housing
Filter
1” Hose Clamp
3/4” Hose Clamp
16-16 Straight JIC NPT
Coupler Electric Motor
Coupler Gas or Diesel
Coupler Hydraulic Pump
Coupler Insert
Hydraulic Pump Electric Motor
Hydraulic Pump Gas / Diesel
12-12 Straight JIC NPT
#10 Hose X 93” FJIC 90` FJIC
#12 Hose X 132” FJIC 90` FJIC
10-10 JIC ORB Electric Motor
10-8 JIC ORB Gas / Diesel
5/8” Hose Clamp
Hydraulic Tank
Pump Guard
Hydraulic Pump Mount
16
REQ’D NO.
14
4
14
10
2
26
2
2
2
1
1
1
1
1
1
1
1
1
1
1
3
1
1
1
1
1
1
1
1
1
1
1
1
2
1
1
1
4
3
2
CS-16 A
HYDRAULIC PUMP ASSEMBLY
1
POO864
SSC-101
D
D
POO868
POO866
POO879
POO868
POO1011
9
POO862
C
SSC107
4
1
6
3
POO878
POO963
ELECTRIC
POO887
7
6
POO876
POO866A
5
11
POO964
GAS/DIESEL
C
8
6
8
RETURN
FROM VALVE
POO434
3
3
POO885
17
PRESSURE
TO VALVE
POO870
3
POO867
SSC108
2
6
1
B
B
POO863
POO877
POO875
10
POO635
1
6
3
DRAWN
THenry
CHECKED
QA
A
MFG
IDEAL MFG., INC.
11/5/2009
12/29/2010
TITLE
A
CS-16 A HYDRAULIC PUMP ASSEMBLY
APPROVED
SIZE
C
SCALE
4
3
2
DWG NO
REV
CS-16 A 106
SHEET
1
1 OF 1
CS-16 A
GAS OR DIESEL DRIVEN HYDRAULICS
REFERENCE DRAWING CS-16 A 107
REF NO.
1
2
3
4
POO268
POO269
POO374
POO374A
POO502
POO507
POO875A
PART NO.
N/A
N/A
N/A
N/A
POO268
POO269
POO374
POO374A
POO502
POO507
POO875A
DESCRIPTION
3/8-16 x 1 3/4 Hex Bolt
3/8 Lock Washer
3/8 flat Washer
3/8-16 Hex Nut
Negative Battery Cable (Ground)
Positive Battery Cable (To Engine)
12 Volt Battery
Battery Box with Tie Down Strap
Diesel Engine
Gas Engine
Coupler Gas or Diesel
18
REQ’D NO.
4
4
2
4
1
1
1
1
1
1
1
4
3
SC-16 A
GAS OR DIESEL DRIVE
2
1
POO374A
D
D
POO268
POSITIVE BATTERY CABLE
TO ENGINE
POO269
POO374
POO374A
BATTERY TIE DOWN STRAP
C
C
POO507
POO502
POO875A
19
16-CS FRAME
B
B
4
2
3
1
DRAWN
THenry
CHECKED
QA
A
MFG
IDEAL MFG., INC.
11/5/2009
7/23/2010
TITLE
A
CS-16 A GAS OR DIESEL DRIVE
APPROVED
SIZE
C
SCALE
4
3
2
DWG NO
REV
CS-16 A 107
SHEET
1
1 OF 1
CS-16 A
FRAME
REFERENCE DRAWING # CS-16 A 108
REF NO.
1
2
3
4
5
6
7
8
9
10
CSP112
POO103
POO110
POO134
POO860
SSC100
SSC109
SSC110L
SSC110R
SSC111
PART NO.
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
CSP112
POO103
POO110
POO134
POO860
SSC100
SSC109
SSC110L
SSC110R
SSC111
DESCRIPTION
5/8-11 X 1 3/4 Heavy Hex Bolt
5/8-11 Heavy Hex Nut
5/8 Flat Washer
5/8 Lock Washer
1/2-13 Hex Nut
1/2 Flat Washer
1/2-13 X 1 1/4 Hex Bolt
1/2 Lock Washer
1/2-13 X 1 3/4 Hex Bolt
1/2-13 Lock Nut
Diagonal Brace Pin
Hand Winch
Shell Block Pulley
Hairpin Clip
Axle Assembly
Auger Support Bracket
CS-16 Frame
Left Fender
Right Fender
Diagonal Brace
20
REQ’D NO.
4
4
4
4
4
8
4
4
2
2
4
1
1
4
1
1
1
1
1
2
4
3
2
1
CS-16 A
FRAME
POO110
D
D
CABLE TO AUGER TUBE
SSC100
CSP112
POO134
CSP112
POO134
SSC111
9
6
DIAGONAL BRACE
C
C
SSC111
10
6
POO134
CSP112
POO134
CSP112
POO103
HAND WINCH
SSC110R
1
3
B
B
8
4
5
POO860
2
7
6
6
7
SSC110L
DRAWN
THenry
A
CHECKED
IDEAL MFG., INC.
11/5/2009
7/23/2010
QA
A
TITLE
CS-16 A FRAME
MFG
APPROVED
SIZE
C
SCALE
4
3
21
2
REV
DWG NO
CS-16 A 108
SHEET
1 OF 1
1
CS-16 A
AUGER TUBE AND HOPPER
REFERENCE DRAWING # CS-16 A 109
REF NO.
1
2
3
4
5
6
7
CSP121
CSP122
POO121
POO122
POO869
POO1008
SSC112
SSC113
PART NO.
N/A
N/A
N/A
N/A
N/A
N/A
N/A
CSP121
CSP122
POO121
POO122
POO869
POO1008
SSC112
SSC113
DESCRIPTION
1/4-20 Hex Nut
1/4-20 X 5/8 Hex Bolt
1/4 Lock Washer
5/16-18 X 2 Hex Bolt
3/8-16 Hex Nut
3/8-16 X 3/4 Hex Bolt
3/8 Lock Washer
Hopper Grate and Bag Splitter
Hopper Cover with Hinge
Boot Clamp
Discharge Boot
Pipe Clamp
Hydraulic Tube
Auger Tube and Hopper Assembly
Hydraulic Tube
22
REQ’D NO.
8
8
8
4
1
1
1
1
1
1
1
4
2
1
2
4
3
2
1
CS-16 A
AUGER TUBE AND HOPPER
D
D
POO869
4
POO121
CSP122
POO1008
C
C
POO1008
POO122
CSP121
SSC112
23
1
3
2
B
B
5
7
6
DRAWN
THenry
CHECKED
QA
A
MFG
IDEAL MFG., INC.
11/5/2009
7/23/2010
TITLE
A
CS-16 A AUGER TUBE AND HOPPER
APPROVED
SIZE
C
SCALE
4
3
2
DWG NO
REV
CS-16 A 109
SHEET
1
1 OF 1
24
25
26
27
PI255001
Rev. 4.09
whitedriveproducts
SERVICE INSTRUCTIONS FOR THE WR [255 & 256] SERIES MOTORS
For Use With Seal Kit: 255222001
dimensions: mm [in]
IMPORTANT NOTE: The WR(255/256) Series Motors depend on the correct orientation of parts as well as correct internal timing
for proper motor operation. Before disassembling the motor, it is highly recommended that paint or a marker be used to make a
“V” shaped set of lines from the endcover to the housing. This will aid in reassembling the motor components properly. It is also
important that the steps involving internal parts timing be followed carefully to insure proper motor operation.
A) Remove all shaft related components from shaft (15) (i.e. keys, nuts). To aid in reassembly of the motor, make a “V” shaped set of
lines from the endcover (11) to the housing using either paint or a marker. With shaft facing down, secure motor in vise by clamping on to the housing (5).
B) Loosen and remove seven bolts (14) holding motor assembly together. Remove endcover (11). Remove body seal (4) and discard
seal. Remove rotor set assembly (9), & wear plate (8). Remove body seals (4) from rotor assembly (9) and housing (5) and discard seals. Remove drive link pin (10) and drive link (7) from motor and lay aside.
C) Gently tap shaft (15) upward through housing (5) and remove through rear of housing. Remove housing (5) from vise. Collect
thrust bearing and thrust washer from the rear of the housing while turning the housing over. Secure the housing in the vise with
the flange end facing up. Gently pry dust seal (1) from housing using a small screwdriver and a hammer. Gently remove shaft seal
(2) with a small screwdriver and discard it.
At this point, all parts should be cleaned in an oil-based solvent and dried using compressed air (For safety, observe all OSHA
safety guidelines). All new seals should be lightly coated in clean oil prior to installation.
D) Place shaft (15) on a clean flat surface with output end facing up. Place thrust bearing (6) then thrust washer (3) on the shaft. Install shaft seal (2) down onto shaft (15) making sure that lip on seal faces down. (See Figure (1) for shaft component orientation).
NOTE: To turn the WR Series Motors to proper operation, the rotation code of the motor must be known. The rotation code of the
motor is 255 (standard) 256 (reverse timed) – the first 3 digits of the model code. If the rotational code is not known, and if port
‘A’ is pressurized , motors that are to have the shafts turning clockwise (as viewed from the shaft end) should be timed using the
“255” series and motors that are to have the shafts turning counterclockwise (as viewed from shaft end) should be timed using the
“256” series.
E) Turn shaft (15) over so that output end of the shaft faces down. Lower drive link (7) into shaft making sure that the timing mark end
of drive link faces up and that the timing mark on the end of the drive link (7) is aligned to the left of any short, open cutter slot on
shaft (15).
F) Turn housing (5) over so that the pilot of housing faces down and secure housing (5) in vise. Without disturbing the shaft seal (2),
and drive link (7), carefully lower shaft assembly into housing. Apply pressure using an arbor press or a rubber mallet to make
sure that the shaft end is flush or slightly lower than the housing bolt hole surface.
G) Place a body seal (4) in groove in the rear surface of the housing (5). Place wear plate (8) on housing. Make sure that the seven
valving slots on the wear plate line up with the seven bolt holes on the housing (5).
H) Place a body seal (4) in the groove in the face of the rotor assembly (9). With the seal groove surface on the rotor assembly facing
wear plate, lower rotor assembly (9) onto drive link (7) making sure that the timing mark on drive link is aligned with a peak on the
rotor (9) for 256 series, or with a valley on the rotor (9) for 255 series (See Figure (2)). After assembling the rotor assembly on the
drive link rotate the rotor assembly to line up the assembly bolt holes. Insert drive link pin (10) into end of drive link (7) making sure
that concave or the indented end faces up.
I)
Place remaining body seal (4) in groove in endcover (11). Place endcover (11) onto motor making sure that end of drive link pin
(10) is in hole in center of end cover (11). There is no specific orientation to assemble the end cover on the motor.
J)
Install one washer (13) on each bolt (14) from the threaded end side. Insert seven assembly bolts (14) with washers (13) into bolt
holes and pre-torque to 13.6 Nm [10 ft. lb.]. Using a crisscross pattern, final torque bolts to 60 Nm [44 ft. lb.].
K) Remove motor from vise and place on work surface with shaft (15) facing up. Making sure that lip on dust seal (1) faces up, place
dust seal (1) over shaft (15). Using a sleeve and hammer, carefully drive dust seal (1) into place.
White Drive Products, Inc.
•
P.O. Box 1127
•
Hopkinsville, KY 42241
•
Phone: 270.885.1110
•
Fax: 270.886.8462
DUST SEAL
SHAFT SEAL
THRUST BEARING
PEAK ON ROTOR
VALLEY
ON ROTOR
TIMING MARK
ON DRIVE LINK
TIMING MARK
ON DRIVE LINK
HOUSING
THRUST WASHER
255 TIMING
256 TIMING
FIGURE 1
FIGURE 2
14
12
10
9
13
8
11
4
4
4
16
7
1. * 2. * 3. * 4. * 5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
*
3
5
Dust Seal
Shaft Seal
Thrust Washer
Body Seals (3)
Housing
Thrust Bearing
Drive Link
Wear Plate
Rotor Assembly
Drive Link Pin
Endcover
Endcover Plug
Assembly Bolt Washers (7)
Assembly Bolts (7)
Shaft
Shaft Key
Contained in Seal Kit 255222001
15
6
2
1
White Drive Products, Inc.
•
P.O. Box 1127
•
Hopkinsville, KY 42241
•
Phone: 270.885.1110
•
Fax: 270.886.8462
WR (255) SERIES MOTOR
14
12
10
9
13
8
11
4
4
4
16
7
3
5
15
6
2
1
WR (255) SERIES MOTOR COMPONENTS
SEAL KIT 255222001
DESCRIPTION
DUST SEAL
SHAFT SEAL
THRUST WASHER
BODY SEALS (3)
EXP VIEW
ITEM #
1
2
3
4
MISCELLANEOUS KITS
KIT
ITEMS #1-4 INCLUDED
IN SEAL KIT: 255222001
255222001EG - SEAL KIT
INCLUDES ITEM #1-4
SHAFT SEAL IS VITON
DESCRIPTION
THRUST BEARING
WEAR PLATE
ENDCOVER WITH BSP.F DRAIN
ENDCOVER WITH SAE DRAIN
SAE STEEL PLUG
BSP.F STEEL PLUG
BOLT WASHER SET
1000 PSI RELIEF VALVE
2000 PSI RELIEF VALVE
3/4-28 SLOTTED NUT
3/4-28 LOCK NUT
EXPLODED VIEW
ITEM #
6
8
11
11
12
12
13
NOT SHOWN
NOT SHOWN
NOT SHOWN
NOT SHOWN
KIT
255018011
255012001
255016004
255016005
500018186
300018084
255018701
500018228
500018231
200229300
200018077
ROTORS, DRIVE LINKS AND SPACERS, AND BOLTS
WHEN CHANGING MOTOR DISPLACEMENTS, A MATCHING DRIVE LINK KIT,DRIVE LINK PIN KIT, AND BOLT SET KIT MUST ALSO BE ORDERED.
EXPLODED VIEW ITEM #
9
9
7
10
DISPLACEMENT
STANDARD ROTOR KIT
FREETURN ROTOR KIT
DRIVE LINK KIT
DRIVE LINK PIN KIT
040
255027003
--200014002
200224003
060
255037003
--200014002
200224008
070
255047003
--200014001
200224005
090
255057003
--200014001
200224006
100
255997003
--200014001
200224008
115
255077003
--200014003
200224008
130
255087003
--200014003
200224010
160
255107003
--200014003
200224012
200
255127003
--200014003
200224014
240
255147003
--200014003
200224018
320
255207003
--200014003
200224024
400
255247003
--200014003
255018019
14
BOLT SET KIT
255018101
255018102
255018102
255018103
255018103
255018104
255018104
255018105
255018106
255018107
255018108
255018109
HOUSING KITS
(EXPLODED VIEW ITEM #5)
BECAUSE THE HOUSING AND SHAFT ARE MATCH GROUND AS A SET TO EXTREMELY TIGHT TOLERANCES AT THE FACTORY, WHITE DRIVE PRODUCTS DOES NOT
RECOMMEND THAT INDIVIDUAL HOUSINGS OR SHAFTS BE ORDERED TO REPAIR A MOTOR. IT IS RECOMMENDED THAT A MATCHED SET BE ORDERED. TO
ORDER A MATCHED HOUSING/SHAFT KIT, PLEASE CONTACT A WHITE DRIVE PRODUCTS CUSTOMER SERVICE REPRESENTATIVE
DESCRIPTION
HOUSING KIT
DESCRIPTION
HOUSING KIT
255013101
255013127
#A63 - 2-HOLE OFFSET MANIFOLD 1/2" BSP.F (TP)
#A33 - 4-HOLE OFFSET MANIFOLD 1/2” BSP.F
255013102
255013116
#A62 - 2-HOLE MANIFOLD 1/2" BSP.F (TP)
#F33 - 4-HOLE OFFSET MANIFOLD 1/2” BSP.F
255013103
255013117
#A62 - 2-HOLE MANIFOLD 1/2" BSP.F (TP) W/RELIEF
#F38 - 4-HOLE ALIGNED PORTS 1/2” BSP.F
255013105
255013118
#A13 - 2-HOLE OFFSET MANIFOLD 1/2” BSP.F
#F30 - 4-HOLE ALIGNED PORTS 1/2” NPT
255013106
255013119
#A12 - 2-HOLE OFFSET PORTS 1/2” BSP.F
#F37 - 4-HOLE MANIFOLD PORTS
255013107
255013120
#A1D - 2-HOLE OFFSET MANIFOLD 7/8” O-RING
#G37 - 4-HOLE MANIFOLD PORTS METRIC TAP
255013109
255013121
#A11 - 2-HOLE FRONT PORTS 7/8” O-RING
#F39 - 4-HOLE 7/8" O-RING PORTS W/RELIEF
255013110
255013122
#A10 - 2-HOLE FRONT PORTS 7/8” O-RING
#F31 - 4-HOLE ALIGNED PORTS 7/8” O-RING
255013111
255013123
#A17 - 2-HOLE MANIFOLD PORTS 1/2” DRILLED
#F3D - 4-HOLE OFFSET MANIFOLD 7/8” O-RING
255013112
255013126
#AC3 - 4-HOLE OFFSET MANIFOLD 1/2” BSP.F (TP)
#G38 - 4-HOLE ALIGNED 1/2” BSP.F METRIC TAP
255013113
255013124
#A3D - 4-HOLE OFFSET MANIFOLD 7/8” O-RING
#B11 - 2-HOLE ALIGNED PORTS 7/8” O-RING
255013114
255013125
#A31 - 4-HOLE FRONT PORTS 7/8” O-RING
#B18 - 2-HOLE ALIGNED PORTS 1/2” BSP.F
255013115
#A30 - 4-HOLE FRONT PORTS 1/2” NPT
SHAFTS AND RELATED COMPONENTS KITS
HOUSING/SHAFT KITS
SHAFT KITS COME WITH RELATED SHAFT COMPONENTS (i.e. keys, nuts, etc.)
TO ORDER INDIVIDUAL KEYS, USE THE KEY KIT NUMBER. TO ORDER NUT
KITS (FOR #13 SHAFT), SEE MISCELLANEOUS KITS LIST ABOVE.
EXPLODED VIEW ITEM #
15
16
DESCRIPTION
SHAFT KIT
KEY KIT
255011004
--#05- 1" WITH .373 PINHOLE
255011005
--#53- 1" WITH .406 PINHOLE
255011001
255018200
#10- 1" STRAIGHT (5/16-18 UN TAP)
255011008
--#02- 6-B SPLINE (5/16-18 UN TAP)
255011011
--#01- 13 TOOTH SPLINE
255011006
255018201
#12- 25MM STRAIGHT
255011013
255018203
#13- 1" TAPERED
255011016
255018205
#B1- 25MM STRAIGHT W/ WOODRUFF KEY
#04- 6-B SPLINE (M8x1.25 TAP)
255011009
--#98- 1" STRAIGHT (3/8-16UNC-2B)
255011017
255018200
255011003
--#66- 1" WITH 8MM PINHOLE
255011014
255018200
#15- 1" STRAIGHT SPEED SENSOR
#16- 25MM STRAIGHT SPEED SENSOR
255011015
255018201
#11- 1" STRAIGHT (M8x1.25 TAP)
255011002
255018200
HOUSING/SHAFT KITS COME WITH ITEMS 5, 15, & 16
White Drive Products, Inc. Phone (270) 885-1110 Fax (270) 886-8462
TO ORDER A MATCHED HOUSING/SHAFT KIT, PLEASE
CONTACT A WHITE DRIVE PRODUCTS CUSTOMER SERVICE
REPRESENTATIVE.
REV. 10.10.08
32
33
34
35
36
37
Prince Manufacturing Corporation
P.O. Box 7000
612 North Derby Lane
North Sioux City, SD 57049-7000
Phone: (605) 235-1220
OEM Sales Fax: (605) 235-1082 Distributor Sales Fax: (605) 217-6300
URL: www.princehyd.com
E-mail: prince@princehyd.com
08/09/29 18:29:52 32Z5K603_001
Thank you for purchasing a Honda engine. We want to help you to
get the best results from your new engine and to operate it safely.
This manual contains information on how to do that; please read it
carefully before operating the engine. If a problem should arise, or
if you have any questions about your engine, consult an
authorized Honda servicing dealer.
ENGLISH
INTRODUCTION
OWNER’S MANUAL
MANUEL DE L’UTILISATEUR
MANUAL DEL PROPIETARIO
All information in this publication is based on the latest product
information available at the time of printing. Honda Motor Co., Ltd.
reserves the right to make changes at any time without notice and
without incurring any obligation. No part of this publication may
be reproduced without written permission.
FRANÇAIS
GX240 · GX270 · GX340 · GX390
This manual should be considered a permanent part of the engine
and should remain with the engine if resold.
United States, Puerto Rico, and U.S. Virgin Islands:
We suggest you read the warranty policy to fully understand its
coverage and your responsibilities of ownership. The warranty
policy is a separate document that should have been given to you
by your dealer.
The engine exhaust from this product
contains chemicals known to the State of
California to cause cancer, birth defects
or other reproductive harm.
SAFETY MESSAGES
Your safety and the safety of others are very important. We have
provided important safety messages in this manual and on the
engine. Please read these messages carefully.
CONTENTS
A safety message alerts you to potential hazards that could hurt
you or others. Each safety message is preceded by a safety alert
symbol
and one of three words, DANGER, WARNING, or
CAUTION.
These signal words mean:
You WILL be KILLED or SERIOUSLY
HURT if you don’t follow instructions.
You CAN be KILLED or SERIOUSLY
HURT if you don’t follow instructions.
You CAN be HURT if you don’t follow
instructions.
Each message tells you what the hazard is, what can happen, and
what you can do to avoid or reduce injury.
DAMAGE PREVENTION MESSAGES
You will also see other important messages that are preceded by
the word NOTICE.
This word means:
Your engine or other property can be damaged if you
don’t follow instructions.
The purpose of these messages is to help prevent damage to your
engine, other property, or the environment.
2008 Honda Motor Co., Ltd. −All Rights Reserved
GX240UT1·GX270UT·GX340UT1·GX390UT1·GX240RT1·GX270RT·GX340RT1·GX390RT1
37Z5K604
00X37-Z5K-6040
ESPAÑOL
Review the instructions provided with the equipment powered by
this engine for any additional information regarding engine
startup, shutdown, operation, adjustments or any special
maintenance instructions.
INTRODUCTION ........................1
SAFETY MESSAGES .................1
SAFETY INFORMATION ...........2
SAFETY LABEL LOCATION ......2
COMPONENT & CONTROL
LOCATION .................................2
FEATURES .................................3
BEFORE OPERATION
CHECKS .....................................3
OPERATION ...............................4
SAFE OPERATING
PRECAUTIONS ......................4
STARTING THE ENGINE .......4
STOPPING THE ENGINE .......5
SETTING ENGINE SPEED......6
SERVICING YOUR ENGINE ......7
THE IMPORTANCE OF
MAINTENANCE .....................7
MAINTENANCE SAFETY.......7
SAFETY PRECAUTIONS ........7
MAINTENANCE
SCHEDULE .............................7
REFUELING ............................8
ENGINE OIL............................8
Recommended Oil .............8
Oil Level Check...................9
Oil Change ..........................9
REDUCTION CASE OIL ..........9
Recommended Oil .............9
Oil Level Check...................9
Oil Change ........................10
AIR CLEANER.......................10
Inspection .........................10
Cleaning ...........................10
ENGLISH
SEDIMENT CUP ...................12
SPARK PLUG .......................12
SPARK ARRESTER ..............13
IDLE SPEED ..........................13
HELPFUL TIPS &
SUGGESTIONS .......................13
STORING YOUR ENGINE ....13
TRANSPORTING .................14
TAKING CARE OF
UNEXPECTED PROBLEMS .....15
FUSE REPLACEMENT .........15
TECHNICAL INFORMATION ...16
Serial Number Location ......16
Battery Connections for
Electric Starter .....................16
Remote Control Linkage......16
Carburetor Modifications for
High Altitude Operation ......17
Emission Control System
Information ..........................17
Air Index ...............................18
Specifications ......................18
Tuneup Specifications.........19
Quick Reference
Information ..........................19
Wiring Diagrams .................19
CONSUMER INFORMATION ..20
Distributor/Dealer Locator
Information ..........................20
Customer Service
Information ..........................20
1
08/09/29 18:30:19 32Z5K603_002
SAFETY INFORMATION
COMPONENT & CONTROL LOCATION
FUEL FILLER CAP
Understand the operation of all controls and learn how to stop
the engine quickly in case of emergency. Make sure the operator
receives adequate instruction before operating the equipment.
Do not allow children to operate the engine. Keep children and
pets away from the area of operation.
Your engine’s exhaust contains poisonous carbon monoxide.
Do not run the engine without adequate ventilation, and never
run the engine indoors.
The engine and exhaust become very hot during operation.
Keep the engine at least 1 meter (3 feet) away from buildings
and other equipment during operation. Keep flammable
materials away, and do not place anything on the engine while it
is running.
FUEL TANK
ELECTRIC STARTER
(applicable types)
OIL DRAIN PLUG
OIL FILLER CAP/DIPSTICK
SAFETY LABEL LOCATION
RECOIL STARTER
MUFFLER
AIR CLEANER
This label warns you of potential hazards that can cause serious
injury. Read it carefully.
If the label comes off or becomes hard to read, contact your Honda
dealer for replacement.
The safety label should be located
either on the fuel tank, fan cover
or packaged loosely with the
engine to be applied by the
manufacture.
SPARK PLUG
STARTER GRIP
ENGINE CONTROL TYPES
CHOKE LEVER
The label is packaged
with the engine.
EXCEPT ELECTRIC
STARTER TYPES
ENGINE SWITCH
See the manufacturer’s
instructions provided
with the equipment.
FUEL
VALVE LEVER
For Canada:
French label is
packaged with
the engine.
CHOKE ROD
(applicable types)
Gasoline is highly flammable and explosive.
Turn engine off and let cool before refueling.
ELECTRIC STARTER TYPES
The engine emits toxic poisonous carbon
monoxide gas. Do not run in an enclosed area.
ENGINE SWITCH
Read Owner’s Manual before operation.
2
ENGLISH
ENGINE SWITCH
08/09/29 18:30:44 32Z5K603_003
FEATURES
BEFORE OPERATION CHECKS
OIL ALERT SYSTEM (applicable types)
IS YOUR ENGINE READY TO GO?
‘‘Oil Alert is a registered trademark in the United States’’
The Oil Alert system is designed to prevent engine damage
caused by an insufficient amount of oil in the crankcase. Before
the oil level in the crankcase can fall below a safe limit, the Oil
Alert system will automatically stop the engine (the engine switch
will remain in the ON position).
For your safety, and to maximize the service life of your
equipment, it is very important to take a few moments before you
operate the engine to check its condition. Be sure to take care of
any problem you find, or have your servicing dealer correct it,
before you operate the engine.
If the engine stops and will not restart, check the engine oil level
(see page 9 ) before troubleshooting in other areas.
Improperly maintaining this engine, or failure to
correct a problem before operation, can cause a
malfunction in which you can be seriously hurt or
killed.
CIRCUIT PROTECTOR (applicable types)
The circuit protector protects the
battery charging circuit. A short
circuit, or a battery connected
with reverse polarity, will trip the
circuit protector.
The green indicator inside the
circuit protector will pop out to
show that the circuit protector has
switched off. If this occurs,
determine the cause of the
problem, and correct it before
resetting the circuit protector.
Always perform a pre-operation inspection before
each operation, and correct any problem.
Before beginning your pre-operation checks, be sure the engine is
level and the engine switch is in the OFF position.
Always check the following items before you start the engine:
Check the General Condition of the Engine
CIRCUIT
PROTECTOR
1. Look around and underneath the engine for signs of oil or
gasoline leaks.
Push the circuit protector button
to reset.
2. Remove any excessive dirt or debris, especially around the
muffler and recoil starter.
ON
3. Look for signs of damage.
OFF
4. Check that all shields and covers are in place, and all nuts, bolts,
and screws are tightened.
Check the Engine
1. Check the fuel level (see page 8 ). Starting with a full tank will
help to eliminate or reduce operating interruptions for refueling.
2. Check the engine oil level (see page 9 ). Running the engine
with a low oil level can cause engine damage.
The Oil Alert system (applicable types) will automatically stop
the engine before the oil level falls below safe limits. However,
to avoid the inconvenience of an unexpected shutdown, always
check the engine oil level before startup.
3. Check the reduction case oil level on applicable types (see page
9 ). Oil is essential to reduction case operation and long life.
4. Check the air filter element (see page 10 ). A dirty air filter
element will restrict air flow to the carburetor, reducing engine
performance.
5. Check the equipment powered by this engine.
Review the instructions provided with the equipment powered
by this engine for any precautions and procedures that should
be followed before engine startup.
ENGLISH
3
08/09/29 18:31:09 32Z5K603_004
OPERATION
To restart a warm engine, leave the choke lever or choke rod in
the OPEN position.
SAFE OPERATING PRECAUTIONS
Some engine applications use a remote-mounted choke control
rather than the engine-mounted choke lever shown here. Refer
to the instructions provided by the equipment manufacturer.
Before operating the engine for the first time, please review the
SAFETY INFORMATION section on page 2 and the BEFORE
OPERATION CHECKS on page 3 .
For your safety, do not operate the engine in an enclosed area
such as a garage. Your engine’s exhaust contains poisonous
carbon monoxide gas that can collect rapidly in an enclosed area
and cause illness or death.
3. Move the throttle lever away from the MIN. position, about 1/3
of the way toward the MAX. position.
Exhaust contains poisonous carbon monoxide gas
that can build up to dangerous levels in closed areas.
Breathing carbon monoxide can cause
unconsciousness or death.
MIN.
MAX.
MIN.
1/3 POSITION
THROTTLE LEVER
Never run the engine in a closed, or even partly
closed area where people may be present.
Review the instructions provided with the equipment powered by
this engine for any safety precautions that should be observed
with engine startup, shutdown or operation.
Some engine applications use a remote-mounted throttle control
rather than the engine-mounted throttle lever shown here. Refer to
the instructions provided by the equipment manufacturer.
4. Turn the engine switch to the ON position.
STARTING THE ENGINE
EXCEPT ELECTRIC
STARTER TYPES
1. Move the fuel valve lever to the ON position.
FUEL VALVE LEVER
ELECTRIC STARTER TYPES
ENGINE SWITCH
ON
ON
ON
ON
OFF
ON
2. To start a cold engine, move the choke lever or choke rod
(applicable types) to the CLOSED position.
ON
CHOKE LEVER
CLOSED
ENGINE SWITCH
OPEN
CLOSED
CHOKE ROD (applicable types)
ON
OPEN
ENGINE SWITCH
CLOSED
4
ENGLISH
08/09/29 18:31:36 32Z5K603_005
5. Operate the starter.
STOPPING THE ENGINE
RECOIL STARTER
Pull the starter grip lightly until you feel resistance, then pull
briskly in the direction of the arrow as shown below. Return the
starter grip gently.
To stop the engine in an emergency, simply turn the engine switch
to the OFF position. Under normal conditions, use the following
procedure. Refer to the instructions provided by the equipment
manufacturer.
1. Move the throttle lever to the MIN. position.
Some engine applications use a remote-mounted throttle
control rather than the engine-mounted throttle lever shown
here.
THROTTLE LEVER
STARTER GRIP
Direction to pull
MIN.
MIN.
Do not allow the starter grip to snap back against the engine.
Return it gently to prevent damage to the starter.
ELECTRIC STARTER (applicable types):
2. Turn the engine switch to the OFF position.
Turn the key to the START position,
and hold it there until the engine starts.
EXCEPT ELECTRIC
STARTER TYPES
If the engine fails to start within 5
seconds, release the key, and wait at
least 10 seconds before operating the
starter again.
ELECTRIC STARTER TYPES
OFF
ENGINE SWITCH
START
OFF
Using the electric starter for more than
5 seconds at a time will overheat the
starter motor and can damage it.
When the engine starts, release the
key, allowing it to return to the ON
position.
OFF
ENGINE SWITCH
(applicable types)
OFF
6. If the choke lever or choke rod (applicable types) has been
moved to the CLOSED position to start the engine, gradually
move it to the OPEN position as the engine warms up.
CHOKE LEVER
ENGINE SWITCH
OPEN
OPEN
OFF
ENGINE SWITCH
CLOSED
CHOKE ROD (applicable types)
3. Turn the fuel valve lever to the OFF position.
OPEN
FUEL VALVE
LEVER
CLOSED
ON
OFF
OFF
ENGLISH
5
08/09/29 18:31:44 32Z5K603_006
SETTING ENGINE SPEED
Position the throttle lever for the desired engine speed.
Some engine applications use a remote-mounted throttle control
rather than the engine-mounted throttle lever shown here. Refer to
the instructions provided by the equipment manufacturer.
For engine speed recommendations, refer to the instructions
provided with the equipment powered by this engine.
THROTTLE LEVER
MAX.
MIN.
MAX.
6
MIN.
ENGLISH
08/09/29 18:32:12 32Z5K603_007
SERVICING YOUR ENGINE
MAINTENANCE SCHEDULE
THE IMPORTANCE OF MAINTENANCE
Good maintenance is essential for safe, economical and troublefree operation. It will also help reduce pollution.
REGULAR SERVICE PERIOD (3)
Each
Use
Perform at every
indicated month or
operating hour interval,
First
Refer
Every 3 Every 6 Every
to
Month Months Months Year
or
or
or
Page
or
20 Hrs 50 Hrs 100 Hrs 300 Hrs
whichever comes first.
ITEM
Improper maintenance, or failure to correct a
problem before operation, can cause a malfunction in
which you can be seriously hurt or killed.
Engine oil
Always follow the inspection and maintenance
recommendations and schedules in this owner’s
manual.
Check level
9
Change
9
Reduction case
Check level
9
oil
Change
10
(applicable types)
Air cleaner
10
Check
Clean
(1)
*(1)
**
Replace
To help you properly care for your engine, the following pages
include a maintenance schedule, routine inspection procedures,
and simple maintenance procedures using basic hand tools. Other
service tasks that are more difficult, or require special tools, are
best handled by professionals and are normally performed by a
Honda technician or other qualified mechanic.
Sediment cup
Clean
12
Spark plug
Check-adjust
12
Replace
Spark arrester
13
Clean
(applicable types)
The maintenance schedule applies to normal operating conditions.
If you operate your engine under severe conditions, such as
sustained high-load or high-temperature operation, or use in
unusually wet or dusty conditions, consult your servicing dealer
for recommendations applicable to your individual needs and use.
Idle speed
Check-adjust
(2)
13
Valve clearance
Check-adjust
(2)
Shop
Combustion
Clean
manual
Fuel tank &
manual
manual
Check
Every 2 years
Shop
(Replace if necessary) (2)
manual
Internal vent carburetor with dual element type only.
Cyclone type every 6 months or 150 hours.
INTERNAL VENT
CARBURETOR TYPE
MAINTENANCE SAFETY
Some of the most important safety precautions follow. However,
we cannot warn you of every conceivable hazard that can arise in
performing maintenance. Only you can decide whether or not you
should perform a given task.
Shop
(2)
Clean
filter
*
Shop
After every 500 Hrs. (2)
chamber
Fuel tube
Maintenance, replacement, or repair of the emission control
devices and systems may be performed by any engine repair
establishment or individual, using parts that are ‘‘certified’’ to
EPA standards.
10 − 11
BREATHER TUBE
STANDARD TYPE
BREATHER TUBE
Failure to properly follow maintenance instructions
and precautions can cause you to be seriously hurt or
killed.
Always follow the procedures and precautions in this
owner’s manual.
TUBE CLIP
SAFETY PRECAUTIONS
Make sure the engine is off before you begin any maintenance
or repairs. This will eliminate several potential hazards:
−Carbon monoxide poisoning from engine exhaust.
Be sure there is adequate ventilation whenever you operate
the engine.
−Burns from hot parts.
Let the engine and exhaust system cool before touching.
−Injury from moving parts.
Do not run the engine unless instructed to do so.
Read the instructions before you begin, and make sure you have
the tools and skills required.
To reduce the possibility of fire or explosion, be careful when
working around gasoline. Use only a non-flammable solvent,
not gasoline, to clean parts. Keep cigarettes, sparks and flames
away from all fuel related parts.
Remember that an authorized Honda servicing dealer knows your
engine best and is fully equipped to maintain and repair it.
To ensure the best quality and reliability, use only new Honda
Genuine parts or their equivalents for repair and replacement.
**
Replace paper element type only.
Cyclone type every 2 years or 600 hours.
(1) Service more frequently when used in dusty areas.
(2) These items should be serviced by your Honda servicing
dealer, unless you have the proper tools and are mechanically
proficient. Refer to the Honda shop manual for service
procedures.
(3) For commercial use, log hours of operation to determine
proper maintenance intervals.
Failure to follow this maintenance schedule could result in nonwarrantable failures.
ENGLISH
7
08/09/29 18:32:34 32Z5K603_008
2. Add fuel to the bottom of the maximum fuel level limit of the
fuel tank. Do not overfill. Wipe up spilled fuel before starting the
engine.
REFUELING
Recommended Fuel
Unleaded gasoline
U.S.
Except U.S.
MAXIMUM
FUEL LEVEL
Pump octane rating 86 or higher
Research octane rating 91 or higher
Pump octane rating 86 or higher
This engine is certified to operate on unleaded gasoline with a
pump octane rating of 86 or higher (a research octane rating of 91
or higher).
Refuel in a well-ventilated area with the engine stopped. If the
engine has been running, allow it to cool first. Never refuel the
engine inside a building where gasoline fumes may reach flames
or sparks.
You may use unleaded gasoline containing no more than 10%
ethanol (E10) or 5% methanol by volume. In addition, methanol
must contain cosolvents and corrosion inhibitors. Use of fuels
with content of ethanol or methanol greater than shown above
may cause starting and/or performance problems. It may also
damage metal, rubber, and plastic parts of the fuel system. Engine
damage or performance problems that result from using a fuel
with percentages of ethanol or methanol greater than shown
above are not covered under warranty.
If your equipment will be used on an infrequent or intermittent
basis, please refer to the fuel section of the HELPFUL TIPS &
SUGGESTIONS chapter (see page 13 ) for additional information
regarding fuel deterioration.
3. Refuel carefully to avoid spilling fuel. Do not fill the fuel tank
completely. It may be necessary to lower the fuel level
depending on operating conditions. After refueling, tighten the
fuel filler cap securely.
Keep gasoline away from appliance pilot lights, barbecues,
electric appliances, power tools, etc.
Spilled fuel is not only a fire hazard, it causes environmental
damage. Wipe up spills immediately.
ENGINE OIL
Oil is a major factor affecting performance and service life. Use
4-stroke automotive detergent oil.
Gasoline is highly flammable and explosive, and you
can be burned or seriously injured when refueling.
Recommended Oil
Stop engine and keep heat, sparks, and flame away.
Refuel only outdoors.
Wipe up spills immediately.
Use 4-stroke motor oil that meets or exceeds the requirements for
API service category SJ or later (or equivalent). Always check the
API service label on the oil container to be sure it includes the
letters SJ or later (or equivalent).
Fuel can damage paint and some types of plastic. Be careful not to
spill fuel when filling your fuel tank. Damage caused by spilled
fuel is not covered under the Distributor’s Limited Warranty.
Never use stale or contaminated gasoline or an oil/gasoline
mixture. Avoid getting dirt or water in the fuel tank.
For refueling, refer to the manufacturer’s instructions provided
with the equipment. See the following for a Honda supplied
standard fuel tank refueling instruction.
AMBIENT TEMPERATURE
1. With the engine stopped and on a level surface, remove the fuel
filler cap and check the fuel level. Refill the tank if the fuel level
is low.
SAE 10W-30 is recommended for general use. Other viscosities
shown in the chart may be used when the average temperature in
your area is within the indicated range.
FUEL FILLER CAP
8
ENGLISH
08/09/29 18:33:04 32Z5K603_009
4. Install the oil filler cap/dipstick and tighten securely.
Oil Level Check
OIL FILLER CAP/
DIPSTICK
Check the engine oil level with the engine stopped and in a level
position.
1. Remove the oil filler cap/dipstick and wipe it clean.
2. Insert the oil filler cap/dipstick into the oil filler neck as shown,
but do not screw it in, then remove it to check the oil level.
WASHER
OIL LEVEL
3. If the oil level is near or below the lower limit mark on the
dipstick, fill with the recommended oil (see page 8 ) to the
upper limit mark (bottom edge of the oil fill hole). Do not overfill.
4. Reinstall the oil filler cap/dipstick.
OIL FILLER CAP/DIPSTICK
OIL DRAIN PLUG
REDUCTION CASE OIL (applicable types)
UPPER LIMIT
Recommended Oil
Use the same oil that is recommended for the engine (see page 8 ).
Oil Level Check
Check the reduction case oil level with the engine stopped and in a
level position.
OIL FILL HOLE
(bottom edge)
1/2 Reduction Case With Centrifugal Clutch
LOWER LIMIT
1. Remove the oil filler cap/dipstick and wipe it clean.
Running the engine with a low oil level can cause engine damage.
This type of damage is not covered by the Distributor’s Limited
Warranty.
The Oil Alert system (applicable types) will automatically stop the
engine before the oil level falls below the safe limit. However, to
avoid the inconvenience of an unexpected shutdown, always
check the engine oil level before startup.
2. Insert and remove the oil filler cap/dipstick without screwing it
into the filler hole. Check the oil level shown on the oil filler cap/
dipstick.
3. If the oil level is low, add the recommended oil to reach the
upper limit mark on the dipstick.
4. Screw in the oil filler cap/dipstick and tighten securely.
Oil Change
OIL FILLER CAP/DIPSTICK
Drain the used oil when the engine is warm. Warm oil drains
quickly and completely.
UPPER LIMIT
1. Place a suitable container below the engine to catch the used oil,
then remove the oil filler cap/dipstick, oil drain plug and washer.
2. Allow the used oil to drain completely, then reinstall the oil drain
plug and new washer, and tighten the oil drain plug securely.
Please dispose of used motor oil in a manner that is compatible
with the environment. We suggest you take used oil in a sealed
container to your local recycling center or service station for
reclamation. Do not throw it in the trash, pour it on the ground,
or pour it down a drain.
LOWER LIMIT
3. With the engine in a level position, fill with the recommended oil
(see page 8 ) to the upper limit mark (bottom edge of the oil fill
hole) on the dipstick.
Running the engine with a low oil level can cause engine
damage. This type of damage is not covered by the Distributor’s
Limited Warranty.
The Oil Alert system (applicable types) will automatically stop
the engine before the oil level falls below the safe limit.
However, to avoid the inconvenience of an unexpected
shutdown, fill to the upper limit, and check the oil level regularly.
ENGLISH
9
08/09/29 18:33:32 32Z5K603_010
Oil Change
AIR CLEANER
Drain the used oil while the engine is warm. Warm oil drains
quickly and completely.
A dirty air cleaner will restrict air flow to the carburetor, reducing
engine performance. If you operate the engine in very dusty areas,
clean the air filter more often than specified in the MAINTENANCE
SCHEDULE (see page 7 ).
1. Place a suitable container below the reduction case to catch the
used oil, then remove the oil filler cap/dipstick, the drain plug
and washer.
Operating the engine without an air filter, or with a damaged air
filter, will allow dirt to enter the engine, causing rapid engine wear.
This type of damage is not covered by the Distributor’s Limited
Warranty.
2. Allow the used oil to drain completely, then reinstall the drain
plug and a new washer, and tighten it securely.
Please dispose of used motor oil in a manner that is compatible
with the environment. We suggest you take used oil in a sealed
container to your local recycling center or service station for
reclamation. Do not throw it in the trash or pour it on the ground
or pour it down a drain.
3. With the engine in a level position, fill with the recommended oil
(see page 8 ) to the upper limit mark on the dipstick. To check the
oil level, insert and remove the dipstick without screwing it into
the filler hole.
Reduction case oil capacity:
0.30 L (0.32 US qt, 0.26 lmp qt)
Inspection
Remove the air cleaner cover and inspect the filter elements.
Clean or replace dirty filter elements. Always replace damaged
filter elements. If equipped with an oil-bath air cleaner, also check
the oil level.
Refer to pages 10 − 11 for instructions that apply to the air cleaner
and filter for your engine type.
Cleaning
Dual-Filter Element Types
Running the engine with a low reduction case oil level can cause
reduction case damage.
4. Screw in the oil filler cap/dipstick and tighten securely.
OIL FILLER CAP/DIPSTICK
1. Remove the wing nut from
the air cleaner cover, and
remove the cover.
2. Remove the wing nut from
the air filter, and remove the
filter.
UPPER LIMIT
3. Remove the foam filter from
the paper filter.
LOWER LIMIT
DRAIN PLUG
4. Inspect both air filter
elements, and replace them if
they are damaged. Always
replace the paper air filter
element at the scheduled
interval (see page 7 ).
STANDARD DUAL-FILTER
ELEMENT TYPE
WING NUT
AIR CLEANER
COVER
WING NUT
PAPER FILTER
ELEMENT
FOAM FILTER
ELEMENT
GASKET
CYCLONE DUAL-FILTER ELEMENT TYPE
PRECLEANER CAP
SPECIAL PAN SCREW (3)
WING NUT
AIR CLEANER COVER
TAB
WING NUT
AIR GUIDE
PAPER FILTER ELEMENT
FOAM FILTER ELEMENT
GROOVE
CYCLONE HOUSING
10
ENGLISH
GASKET
08/09/29 18:34:01 32Z5K603_011
6. Reassemble the air cleaner, and tighten the wing nut securely.
5. Clean the air filter elements if they are to be reused.
SINGLE-FILTER ELEMENT TYPE
OIL-BATH TYPE
Paper air filter element: Tap the filter element several times on a
hard surface to remove dirt, or blow compressed air [not
exceeding 207 kPa (2.1 kgf/cm , 30 psi)] through the filter
element from the inside. Never try to brush off dirt; brushing will
force dirt into the fibers.
Foam air filter element: Clean in warm soapy water, rinse, and
allow to dry thoroughly. Or clean in non-flammable solvent and
allow to dry. Dip the filter element in clean engine oil, then
squeeze out all excess oil. The engine will smoke when started if
too much oil is left in the foam.
WING NUT
AIR
CLEANER
COVER
CAP
WING NUT
AIR
CLEANER
COVER
FOAM
FILTER
ELEMENT
FOAM
FILTER
ELEMENT
GRID
AIR
CLEANER
CASE
STEEL
WOOL
6. CYCLONE TYPE ONLY: Remove the three pan-head screws from
the pre-cleaner cap, then remove the cyclone housing and air
guide. Wash the parts with water, dry them thoroughly, and
reassemble them.
GRID
OIL LEVEL
Be sure to install the air guide as shown in the illustration.
Low Profile Types
1. Unsnap the air cleaner cover clips,
remove the air cleaner cover, and
remove the air filter element.
Install the cyclone housing so the air intake tab fits into the
groove in the pre-cleaner cap.
7. Wipe dirt from the inside of the air cleaner case and cover using
a moist rag. Be careful to prevent dirt from entering the air duct
that leads to the carburetor.
AIR CLEANER COVER
CLIP
8. Place the foam air filter element over the paper element, and
reinstall the assembled air filter. Be sure the gasket is in place
beneath the air filter. Tighten the air filter wing nut securely.
2. Wash the element in a solution of
household detergent and warm
water, then rinse thoroughly, or
wash in non-flammable or high
flash point solvent. Allow the
element to dry thoroughly.
9. Install the air cleaner cover, and tighten the wing nut securely.
3. Soak the air filter element in clean AIR FILTER ELEMENT
CLIP
engine oil and squeeze out the
excess oil. The engine will smoke
during initial startup if too much
oil is left in the element.
Oil Bath & Single-Filter Element Types
1. Remove the wing nut, and remove the air cleaner cap and cover.
2. Remove the air filter element from the cover. Wash the cover
and filter element in warm soapy water, rinse, and allow to dry
thoroughly. Or clean in non-flammable solvent and allow to dry.
4. Reinstall the air filter element and
the cover.
3. Dip the filter element in clean engine oil, then squeeze out all
excess oil. The engine will smoke if too much oil is left in the
foam.
4. OIL BATH TYPE ONLY: Empty the used oil from the air cleaner
case, wash out any accumulated dirt with non-flammable
solvent, and dry the case.
AIR FILTER ELEMENT
5. OIL BATH TYPE ONLY: Fill the air cleaner case to the OIL LEVEL
mark with the same oil that is recommended for the engine (see
page 8 ).
Oil capacities:
GX240/GX270:
GX340/GX390:
60 cm (2.0 US oz , 2.1 Imp oz)
80 cm (2.7 US oz , 2.8 Imp oz)
ENGLISH
11
08/09/29 18:34:28 32Z5K603_012
SEDIMENT CUP
SPARK PLUG
Cleaning
Recommended Spark Plugs: BPR6ES (NGK)
W20EPR-U (DENSO)
The recommended spark plug has the correct heat range for
normal engine operating temperatures.
Gasoline is highly flammable and explosive, and you
can be burned or seriously injured when handling
fuel.
Stop engine and keep heat, sparks, and flame away.
Handle fuel only outdoors.
Wipe up spills immediately.
An incorrect spark plug can cause engine damage.
If the engine has been running, let it cool before servicing the
spark plug.
For good performance, the spark plug must be properly gapped
and free of deposits.
1. Move the fuel valve lever to the OFF position, then remove the
sediment cup and O-ring.
2. Wash the sediment cup in non-flammable solvent, and dry it
thoroughly.
1. Disconnect the spark plug cap,
and remove any dirt from
around the spark plug area.
SPARK PLUG WRENCH
2. Remove the spark plug with a
13/16-inch spark plug wrench.
FUEL VALVE LEVER
O-RING
3. Visually inspect the spark
plug. Replace it if damaged or
badly fouled, if the sealing
SPARK PLUG CAP
washer is in poor condition,
or if the electrode is worn.
OFF
SIDE ELECTRODE
SEDIMENT CUP
3. Place the O-ring in the fuel valve, and install the sediment cup.
Tighten the sediment cup securely.
4. Measure the spark plug
electrode gap with a wiretype feeler gauge. Correct the
gap, if necessary, by carefully
bending the side electrode.
The gap should be:
0.7−0.8 mm (0.028−0.031 in)
0.7−0.8 mm
(0.028−0.031 in)
SEALING
WASHER
5. Install the spark plug carefully,
by hand, to avoid crossthreading.
4. Move the fuel valve lever to the ON position, and check for leaks.
Replace the O-ring if there is any leakage.
6. After the spark plug is seated, tighten with a 13/16-inch spark
plug wrench to compress the sealing washer.
When installing a new spark plug, tighten 1/2 turn after the spark
plug seats to compress the washer.
When reinstalling the original spark plug, tighten 1/8−1/4 turn
after the spark plug seats to compress the washer.
A loose spark plug can overheat and damage the engine.
Overtightening the spark plug can damage the threads in the
cylinder head.
7. Attach the spark plug cap to the spark plug.
12
ENGLISH
08/09/29 18:35:02 32Z5K603_013
SPARK ARRESTER (applicable types)
HELPFUL TIPS & SUGGESTIONS
The spark arrester may be standard or an optional part, depending
on the engine type. In some areas, it is illegal to operate an engine
without a spark arrester. Check local laws and regulations. A spark
arrester is available from authorized Honda servicing dealers.
STORING YOUR ENGINE
The spark arrester must be serviced every 100 hours to keep it
functioning as designed.
If the engine has been running, the muffler will be hot. Allow it to
cool before servicing the spark arrester.
Spark Arrester Removal
1. Remove the two 8 mm nuts and remove the muffler from the
cylinder.
2. Remove the three 4 mm screws from the exhaust deflector, and
remove the deflector.
3. Remove the four 5 mm screws from the muffler protector and
remove the muffler protector.
Storage Preparation
Proper storage preparation is essential for keeping your engine
trouble-free and looking good. The following steps will help to
keep rust and corrosion from impairing your engine’s function and
appearance, and will make the engine easier to start when you use
it again.
Cleaning
If the engine has been running, allow it to cool for at least half an
hour before cleaning. Clean all exterior surfaces, touch up any
damaged paint, and coat other areas that may rust with a light film
of oil.
Using a garden hose or pressure washing equipment can force
water into the air cleaner or muffler opening. Water in the air
cleaner will soak the air filter, and water that passes through the
air filter or muffler can enter the cylinder, causing damage.
Fuel
4. Remove the 4 mm screw from the spark arrester, and remove
the spark arrester from the muffler.
5 mm SCREWS
MUFFLER
PROTECTOR
EXHAUST
DEFLECTOR
4 mm SCREW
4 mm
SCREWS
SPARK
ARRESTER
SPARK ARRESTER
8 mm NUTS
MUFFLER
Spark Arrester Cleaning & Inspection
1. Use a brush to remove carbon
deposits from the spark arrester
screen. Be careful not to damage
the screen. Replace the spark
arrester if it has breaks or holes.
SCREEN
2. Install the spark arrester, muffler protector, exhaust deflector
and muffler in the reverse order of disassembly.
Depending on the region where you operate your equipment, fuel
formulations may deteriorate and oxidize rapidly. Fuel
deterioration and oxidation can occur in as little as 30 days and
may cause damage to the carburetor and/or fuel system. Please
check with your servicing dealer for local storage
recommendations.
Gasoline will oxidize and deteriorate in storage. Deteriorated
gasoline will cause hard starting, and it leaves gum deposits that
clog the fuel system. If the gasoline in your engine deteriorates
during storage, you may need to have the carburetor and other
fuel system components serviced or replaced.
The length of time that gasoline can be left in your fuel tank and
carburetor without causing functional problems will vary with
such factors as gasoline blend, your storage temperatures, and
whether the fuel tank is partially or completely filled. The air in a
partially filled fuel tank promotes fuel deterioration. Very warm
storage temperatures accelerate fuel deterioration. Fuel
deterioration problems may occur within a few months, or even
less if the gasoline was not fresh when you filled the fuel tank.
Fuel system damage or engine performance problems resulting
from neglected storage preparation are not covered under the
Distributor’s Limited Warranty.
You can extend fuel storage life by adding a gasoline stabilizer
that is formulated for that purpose, or you can avoid fuel
deterioration problems by draining the fuel tank and carburetor.
IDLE SPEED
Adding a Gasoline Stabilizer to Extend Fuel Storage Life
Adjustment
When adding a gasoline stabilizer, fill the fuel tank with fresh
gasoline. If only partially filled, air in the tank will promote fuel
deterioration during storage. If you keep a container of gasoline
for refueling, be sure that it contains only fresh gasoline.
1. Start the engine outdoors, and
allow it to warm up to operating
temperature.
1. Add gasoline stabilizer following the manufacturer’s instructions.
2. Move the throttle lever to its
minimum position.
2. After adding a gasoline stabilizer, run the engine outdoors for 10
minutes to be sure that treated gasoline has replaced the
untreated gasoline in the carburetor.
3. Turn the throttle stop screw to
obtain the standard idle speed.
THROTTLE STOP SCREW
Standard idle speed: 1,400 ±150 rpm
3. Stop the engine.
ENGLISH
13
08/09/29 18:35:31 32Z5K603_014
Draining the Fuel Tank and Carburetor
Storage Precautions
If your engine will be stored with gasoline in the fuel tank and
carburetor, it is important to reduce the hazard of gasoline vapor
ignition. Select a well-ventilated storage area away from any
appliance that operates with a flame, such as a furnace, water
heater, or clothes dryer. Also avoid any area with a sparkproducing electric motor, or where power tools are operated.
Gasoline is highly flammable and explosive, and you
can be burned or seriously injured when handling
fuel.
Stop engine and keep heat, sparks, and flame away.
Handle fuel only outdoors.
Wipe up spills immediately.
If possible, avoid storage areas with high humidity, because that
promotes rust and corrosion.
Keep the engine level in storage. Tilting can cause fuel or oil
leakage.
1. Move the fuel valve lever to the OFF positions.
2. Place an approved gasoline container below the carburetor, and
use a funnel to avoid spilling fuel.
3. Remove the carburetor drain bolt and gasket. Remove the
sediment cup and O-ring, then move the fuel valve lever to the
ON position.
With the engine and exhaust system cool, cover the engine to
keep out dust. A hot engine and exhaust system can ignite or melt
some materials. Do not use sheet plastic as a dust cover.
A nonporous cover will trap moisture around the engine,
promoting rust and corrosion.
If equipped with a battery for electric starter types, recharge the
battery once a month while the engine is in storage.
This will help to extend the service life of the battery.
FUEL VALVE LEVER
Removal from Storage
Check your engine as described in the BEFORE OPERATION
CHECKS section of this manual (see page 3 ).
O-RING
ON
GASKET
DRAIN BOLT
SEDIMENT CUP
4. After all the fuel has drained into the container, reinstall the
drain bolt, gasket, sediment cup and O-ring. Tighten the drain
bolt and sediment cup securely.
If the fuel was drained during storage preparation, fill the tank with
fresh gasoline. If you keep a container of gasoline for refueling, be
sure it contains only fresh gasoline. Gasoline oxidizes and
deteriorates over time, causing hard starting.
If the cylinder was coated with oil during storage preparation, the
engine will smoke briefly at startup. This is normal.
TRANSPORTING
Engine Oil
If the engine has been running, allow it to cool for at least 15
minutes before loading the engine-powered equipment on the
transport vehicle. A hot engine and exhaust system can burn you
and can ignite some materials.
1. Change the engine oil (see page 9 ).
2. Remove the spark plug (see page 12 ).
3. Pour a teaspoon 5−10 cm (5−10 cc) of clean engine oil into the
cylinder.
Keep the engine level when transporting to reduce the possibility
of fuel leakage. Turn the fuel valve to the OFF position (see
page 5 ).
4. Pull the starter grip several times to distribute the oil in the
cylinder.
5. Reinstall the spark plug.
6. Pull the starter grip slowly until resistance is felt and the notch
on the starter pulley aligns with the hole at the top of the recoil
starter cover. This will close the valves so moisture cannot enter
the engine cylinder. Return the starter grip gently.
Align notch on pulley
with hole at top of cover.
14
ENGLISH
08/09/29 18:35:51 32Z5K603_015
TAKING CARE OF UNEXPECTED PROBLEMS
ENGINE WILL
NOT START
1. Electric
starting
(applicable
types):
Check battery
and fuse.
2. Check control
positions.
Possible Cause
4. Check fuel.
5. Remove and
inspect spark
plug.
Recharge battery.
Fuse burnt out.
Replace fuse.
(p. 15).
1. Remove the 6 × 12 mm screw from the rear cover of the engine
switch box.
Fuel valve OFF.
Move lever to ON
position.
Move lever to
CLOSED position
unless the engine
is warm.
Turn engine switch
to ON position.
Fill with the
recommended oil
to the proper level
(p. 9).
Refuel (p. 8).
Drain fuel tank and
carburetor (p. 14).
Refuel with fresh
gasoline (p. 8).
2. Remove the fuse cover, then pull out and inspect the fuse.
Engine switch
OFF.
Engine oil level
low (Oil Alert
models).
Out of fuel.
Bad fuel; engine
stored without
treating or
draining
gasoline, or
refueled with
bad gasoline.
Spark plug faulty,
fouled, or
improperly
gapped.
Spark plug wet
with fuel
(flooded engine).
Dry and reinstall
spark plug. Start
engine with
throttle lever in
MAX. position.
Replace or repair
faulty components
as necessary.
ENGINE LACKS
POWER
1. Check air filter.
Possible Cause
Correction
Filter element(s)
restricted.
Clean or replace
filter element(s)
(p. 10−11).
Drain fuel tank and
carburetor (p. 14).
Refuel with fresh
gasoline (p. 8).
3. Take engine to
an authorized
Honda
servicing
dealer, or refer
to shop
manual.
Never use a fuse with a rating greater than the one originally
equipped with the engine. Serious damage to the electrical
system or a fire could result.
3. Reinstall the rear cover. Install the 6 × 12 mm screw and tighten
it securely.
FUSE
COVER
ENGINE SWITCH
REAR COVER
6 × 12 mm
SPECIAL SCREW
FUSE
Fuel filter
restricted,
carburetor
malfunction,
ignition
malfunction,
valves stuck, etc.
Bad fuel; engine
stored without
treating or
draining
gasoline, or
refueled with
bad gasoline.
Fuel filter
restricted,
carburetor
malfunction,
ignition
malfunction,
valves stuck, etc.
If the fuse is burnt out, discard the burnt-out fuse. Install a new
fuse with the same rating as the one that was removed, and
reinstall the cover.
If you have questions regarding the rating of the original fuse,
contact your servicing Honda engine dealer.
Gap or replace
spark plug (p. 12).
6. Take engine to
an authorized
Honda
servicing
dealer, or refer
to shop
manual.
2. Check fuel.
The electric starter relay circuit and battery charging circuit are
protected by a fuse. If the fuse burns out, the electric starter will
not operate. The engine can be started manually if the fuse burns
out, but running the engine will not charge the battery.
Battery
discharged.
Choke open.
3. Check engine
oil level.
Correction
FUSE REPLACEMENT (applicable types)
Frequent fuse failure usually indicates a short circuit or an
overload in the electrical system. If the fuse burns out frequently,
take the engine to a servicing Honda dealer for repair.
Replace or repair
faulty components
as necessary.
ENGLISH
15
08/09/29 18:36:23 32Z5K603_016
TECHNICAL INFORMATION
Remote Control Linkage
Serial Number Location
Record the engine serial
number in the space below. You
will need this information when
ordering parts and when
making technical or warranty
inquiries.
The throttle and choke control levers are provided with holes for
optional cable attachment. The following illustrations show
installation examples for a solid wire cable and for a flexible,
braided wire cable. If using a flexible, braided wire cable, add a
return spring as shown.
It is necessary to loosen the throttle lever friction nut when
operating the throttle with a remote-mounted control.
SERIAL NUMBER &
ENGINE TYPE LOCATION
REMOTE THROTTLE LINKAGE
ELECTRIC STARTER
(applicable types)
RETURN SPRING
Engine serial number: __ __ __ __ − __ __ __ __ __ __ __
THROTTLE LEVER
FRICTION NUT
Engine type: ___ ___ ___ ___
Date Purchased: ______ / ______ / ______
Flexible wire core
mounting
Battery Connections for Electric Starter (applicable types)
4 mm SCREW
Recommended Battery
GX240
12 V − 14 Ah ∼ 12 V − 30 Ah
GX270
12 V − 18 Ah ∼ 12 V − 30 Ah
GX340
GX390
WIRE
5 mm
CIRCLIP
Be careful not to connect the battery in reverse polarity, as this will
short circuit the battery charging system. Always connect the
positive (+) battery cable to the battery terminal before
connecting the negative (−) battery cable, so your tools cannot
cause a short circuit if they touch a grounded part while tightening
the positive (+) battery cable end.
WIRE HOLDER
THROTTLE
LEVER
Solid wire core
mounting
REMOTE CHOKE LINKAGE
A battery can explode if you do not follow the correct
procedure, seriously injuring anyone nearby.
Keep all sparks, open flames, and smoking materials
away from the battery.
WARNING: Battery posts, terminals, and related accessories
contain lead and lead compounds. Wash hands after handling.
WIRE HOLDER
1. Connect the battery positive (+) cable to the starter solenoid
terminal as shown.
2. Connect the battery negative (−) cable to an engine mounting
bolt, frame bolt, or other good engine ground connection.
3. Connect the battery positive (+) cable to the battery positive (+)
terminal as shown.
4. Connect the battery negative (−) cable to the battery negative
(−) terminal as shown.
5. Coat the terminals and cable ends with grease.
NEGATIVE (−)
BATTERY CABLE
STARTER
SOLENOID
POSITIVE (+) BATTERY CABLE
16
ENGLISH
CHOKE LEVER
OPTIONAL
08/09/29 18:36:45 32Z5K603_017
Carburetor Modifications for High Altitude Operation
Emission Control System Information
At high altitude, the standard carburetor air-fuel mixture will be
too rich. Performance will decrease, and fuel consumption will
increase. A very rich mixture will also foul the spark plug and
cause hard starting. Operation at an altitude that differs from that
at which this engine was certified, for extended periods of time,
may increase emissions.
Source of Emissions
The combustion process produces carbon monoxide, oxides of
nitrogen, and hydrocarbons. Control of hydrocarbons and oxides
of nitrogen is very important because, under certain conditions,
they react to form photochemical smog when subjected to
sunlight. Carbon monoxide does not react in the same way, but it
is toxic.
High altitude performance can be improved by specific
modifications to the carburetor. If you always operate your engine
at altitudes above 1,500 meters (5,000 feet), have your servicing
dealer perform this carburetor modification. This engine, when
operated at high altitude with the carburetor modifications for
high altitude use, will meet each emission standard throughout its
useful life.
Even with carburetor modification, engine horsepower will
decrease about 3.5% for each 300-meter (1,000-foot) increase in
altitude. The effect of altitude on horsepower will be greater than
this if no carburetor modification is made.
Honda utilizes appropriate air/fuel ratios and other emissions
control systems to reduce the emissions of carbon monoxide,
oxides of nitrogen, and hydrocarbons.
Additionally, Honda fuel systems utilize components and control
technologies to reduce evaporative emissions.
The U.S., California Clean Air Acts and Environment Canada
EPA, California and Canadian regulations require all
manufacturers to furnish written instructions describing the
operation and maintenance of emission control systems.
The following instructions and procedures must be followed in
order to keep the emissions from your Honda engine within the
When the carburetor has been modified for high altitude operation, emission standards.
the air-fuel mixture will be too lean for low altitude use. Operation
Tampering and Altering
at altitudes below 1,500 meters (5,000 feet) with a modified
carburetor may cause the engine to overheat and result in serious Tampering with or altering the emission control system may
increase emissions beyond the legal limit. Among those acts that
engine damage. For use at low altitudes, have your servicing
constitute tampering are:
dealer return the carburetor to original factory specifications.
Removal or alteration of any part of the intake, fuel, or exhaust
systems.
Altering or defeating the governor linkage or speed-adjusting
mechanism to cause the engine to operate outside its design
parameters.
Problems That May Affect Emissions
If you are aware of any of the following symptoms, have your
engine inspected and repaired by your servicing dealer.
Hard starting or stalling after starting.
Rough idle.
Misfiring or backfiring under load.
Afterburning (backfiring).
Black exhaust smoke or high fuel consumption.
Replacement Parts
The emission control systems on your Honda engine were
designed, built, and certified to conform with EPA, California
(models certified for sale in California), and Canadian emission
regulations. We recommend the use of Honda Genuine parts
whenever you have maintenance done. These original-design
replacement parts are manufactured to the same standards as the
original parts, so you can be confident of their performance. The
use of replacement parts that are not of the original design and
quality may impair the effectiveness of your emission control
system.
A manufacturer of an aftermarket part assumes the responsibility
that the part will not adversely affect emission performance. The
manufacturer or rebuilder of the part must certify that use of the
part will not result in a failure of the engine to comply with
emission regulations.
Maintenance
Follow the maintenance schedule on page 7 . Remember that this
schedule is based on the assumption that your machine will be
used for its designed purpose. Sustained high-load or hightemperature operation, or use in unusually wet or dusty conditions,
will require more frequent service.
ENGLISH
17
08/09/29 18:37:13 32Z5K603_018
Air Index
(Models certified for sale in California)
Specifications
An Air Index Information label is applied to engines certified to an
emission durability time period in accordance with the
requirements of the California Air Resources Board.
The bar graph is intended to provide you, our customer, the ability
to compare the emissions performance of available engines. The
lower the Air Index, the less pollution.
The durability description is intended to provide you with
information relating to the engine’s emission durability period.
The descriptive term indicates the useful life period for the engine’s
emission control system. See your Emission Control System
Warranty for additional information.
Descriptive Term Applicable to Emissions Durability Period
Moderate
50 hours (0−80 cc, inclusive)
125 hours (greater than 80 cc)
Intermediate
125 hours (0−80 cc, inclusive)
250 hours (greater than 80 cc)
300 hours (0−80 cc, inclusive)
Extended
500 hours (greater than 80 cc)
1,000 hours (225 cc and greater)
GX240/GX270 (PTO shaft type S, with fuel tank)
Length × Width ×
355 × 430 × 422 mm
Height
(14.0 × 16.9 × 16.6 in)
Dry mass [weight]
25.0 kg (55.1 lbs)
4-stroke, overhead valve, single cylinder
Engine type
242 cm (14.8 cu-in)
Displacement
GX240
[Bore × Stroke]
[73.0 × 58.0 mm (2.9 × 2.3 in)]
270 cm (16.5 cu-in)
GX270
[77.0 × 58.0 mm (3.0 × 2.3 in)]
GX240 5.3 kW (7.2 PS, 7.1 bhp) at 3,600 rpm
Net power
6.0 kW (8.2 PS, 8.0 bhp) at 3,600 rpm
(in accordance
with SAE J1349*)
Max. Net torque
(in accordance
with SAE J1349*)
GX270
GX240
GX270
Engine oil capacity
Fuel tank capacity
Cooling system
Ignition system
PTO shaft rotation
15.3 N·m (1.56 kgf·m, 11.3 lbf·ft)
at 2,500 rpm
17.7 N·m (1.80 kgf·m, 13.1 lbf·ft)
at 2,500 rpm
1.1 L (1.2 US qt, 1.0 lmp qt)
5.3 L (1.40 US gal, 1.17 lmp gal)
Forced air
Transistor magneto
Counterclockwise
GX340/GX390 (PTO shaft type S, with fuel tank)
Length × Width ×
380 × 450 × 447 mm
Height
(15.0 × 17.7 × 17.6 in)
Dry mass [weight]
31.5 kg (69.4 lbs)
4-stroke, overhead valve, single cylinder
Engine type
Displacement
337 cm (20.6 cu-in)
GX340
[Bore × Stroke]
[82.0 × 64.0 mm (3.2 × 2.5 in)]
389 cm (23.7 cu-in)
GX390
[88.0 × 64.0 mm (3.5 × 2.5 in)]
GX340 7.1 kW (9.7 PS, 9.5 bhp) at 3,600 rpm
Net power
8.2 kW (11.1 PS, 11.0 bhp) at 3,600 rpm
(in accordance
with SAE J1349*)
Max. Net torque
(in accordance
with SAE J1349*)
GX390
GX340
GX390
Engine oil capacity
Fuel tank capacity
Cooling system
Ignition system
PTO shaft rotation
22.1 N·m (2.25 kgf·m, 16.3 lbf·ft)
at 2,500 rpm
25.1 N·m (2.56 kgf·m, 18.5 lbf·ft)
at 2,500 rpm
1.1 L (1.2 US qt, 1.0 lmp qt)
6.1 L (1.61 US gal, 1.34 lmp gal)
Forced air
Transistor magneto
Counterclockwise
*The power rating of the engine indicated in this document is the
net power output tested on a production engine for the engine
model and measured in accordance with SAE J1349 at 3,600
rpm (Net Power) and at 2,500 rpm (Max. Net Torque). Mass
production engines may vary from this value.
Actual power output for the engine installed in the final machine
will vary depending on numerous factors, including the
operating speed of the engine in application, environmental
conditions, maintenance, and other variables.
18
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08/09/29 18:37:37 32Z5K603_019
Tuneup Specifications GX240/GX270/GX340/GX390
ITEM
SPECIFICATION
MAINTENANCE
0.7−0.8 mm
Refer to page: 12
Spark plug gap
(0.028−0.031 in)
Refer to page: 13
1,400 ± 150 rpm
Idle speed
See your
IN: 0.15 ± 0.02 mm
Valve clearance
authorized
EX: 0.20 ± 0.02 mm
(cold)
Honda dealer
No other adjustments needed.
Other
specifications
Wiring Diagrams
With Oil Alert and Electric Starter
Quick Reference Information
Fuel
Engine oil
Reduction
case oil
Spark plug
Maintenance
Unleaded gasoline (Refer to page 8)
U.S.
Pump octane rating 86 or higher
Except Research octane rating 91 or higher
U.S.
Pump octane rating 86 or higher
SAE 10W-30, API SJ or later, for general use.
Refer to page 8.
Same oil as engine oil, see above (applicable
types).
BPR6ES (NGK)
W20EPR-U (DENSO)
Before each use:
Check engine oil level. Refer to page 9.
Check reduction case oil (applicable types).
Refer to page 9.
Check air filter. Refer to page 10.
First 20 hours:
Change engine oil. Refer to page 9.
Change reduction case oil (applicable types).
Refer to page 10.
Subsequent:
Refer to the maintenance schedule on page 7.
With Oil Alert and Without Electric Starter
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
CONTROL BOX
RECTIFIER
FUSE
CIRCUIT PROTECTOR
ENGINE SWITCH
OIL ALERT UNIT
Type with Oil Alert unit
OIL LEVEL SWITCH
Bl
Y
Bu
G
R
W
ENGLISH
Black
Yellow
Blue
Green
Red
White
Br
O
Lb
Lg
P
Gr
(9)
(10)
(11)
(12)
(13)
(14)
(15)
CHARGING COIL
IGNITION COIL
SPARK PLUG
STARTER MOTOR
STARTER SOLENOID
BATTERY (12 V)
Type without Oil Alert unit
Brown
Orange
Light blue
Light green
Pink
Gray
19
08/09/29 18:38:09 32Z5K603_020
CONSUMER INFORMATION
Canada:
Honda Canada, Inc.
715 Milner Avenue
Toronto, ON
M1B 2K8
DISTRIBUTOR/DEALER LOCATOR INFORMATION
United States, Puerto Rico, and U.S. Virgin Islands:
Call (800) 426-7701
or visit our website: www.honda-engines.com
Telephone: (888) 9HONDA9
(888) 946-6329
(416) 299-3400
Facsimile: (877) 939-0909
(416) 287-4776
Canada:
Call (888) 9HONDA9
or visit our website: www.honda.ca
For European Area:
Visit our website: http://www.honda-engines-eu.com
Local Toronto dialing area
Toll free
Local Toronto dialing area
Australia:
Honda Australia Motorcycle and Power Equipment Pty. Ltd.
1954−1956 Hume Highway Campbellfield Victoria 3061
Telephone: (03) 9270 1111
Facsimile: (03) 9270 1133
CUSTOMER SERVICE INFORMATION
Servicing dealership personnel are trained professionals. They
should be able to answer any question you may have. If you
encounter a problem that your dealer does not solve to your
satisfaction, please discuss it with the dealership’s management.
The Service Manager, General Manager, or Owner can help.
Almost all problems are solved in this way.
For European Area:
Honda Europe NV.
European Engine Center
http://www.honda-engines-eu.com
All Other Areas:
Please contact the Honda distributor in your area for assistance.
United States, Puerto Rico, and U.S. Virgin Islands:
If you are dissatisfied with the decision made by the dealership’s
management, contact the Honda Regional Engine Distributor for
your area.
If you are still dissatisfied after speaking with the Regional Engine
Distributor, you may contact the Honda Office as shown.
All Other Areas:
If you are dissatisfied with the decision made by the dealership’s
management, contact the Honda Office as shown.
《Honda’s Office》
When you write or call, please provide this information:
Equipment manufacturer’s name and model number that the
engine is mounted on
Engine model, serial number, and type (see page 16 )
Name of dealer who sold the engine to you
Name, address, and contact person of the dealer who services
your engine
Date of purchase
Your name, address and telephone number
A detailed description of the problem
United States, Puerto Rico, and U.S. Virgin Islands:
American Honda Motor Co., Inc.
Power Equipment Division
Customer Relations Office
4900 Marconi Drive
Alpharetta, GA 30005-8847
Or telephone: (770) 497-6400, 8:30 am - 7:00 pm ET
20
Toll free
ENGLISH