Pressure Washer - DALGETY BAY SAILING CLUB

Issue 2: Aug 2nd 2012
Guidance on Safe Use of Dalgety Bay Sailing Club Pressure Washer
Where any items referred to are mandatory, these are shown in bold type.
The pressure washer is a commercially available petrol driven machine targeted at the
light commercial market. It is more powerful than the average domestic washer and
although the hazards are similar there is increased risk from the higher operating
pressure (186 Bar or 2697 psi). Even though they are moderately safe to handle,
improper use can result in damage to property or even bodily injuries. You should
treat them with the same respect that you would give a chain saw, brush cutter, or any
other dangerous power tool.
These are a few of the safety precautions you need to exercise when operating a
pressure washer. By following these guidelines, you can rest assured that you’ll keep
everything around you safe.
For safety, until you are confident and are familiar with the operations you must
seek assistance from an experienced user.
The Club Management Committee has deemed (July 2012) that the pressure
washer must not be operated by persons under the age of 21
Use of the pressure washer is at your own risk
Safety Labels on the Machine
-1-
Issue 2: Aug 2nd 2012
Guidance
Read:
Appendix 1: Manufacturers Operating and Maintenance Instructions.
Appendix 2: Gasoline Engine Owner’s Manual
Wearing protective gear during the usage or operation of pressure washers is
vital; under no circumstances should you operate the pressure washer without
the proper safety attire. Goggles/safety glasses, ideally good quality waterproof top
and leggings (sailing gear is ideal), gloves, and boots. These items will protect you
from getting hit by minute objects propelled out by the intense pressure or reflected
back from the work surface. Under no circumstances should you use with bare arms,
hands or legs
Inspect all parts of the machine prior to operation. That is, you ought to see if there
are any leaks in the pump, inspect for oil leaks and check oil and fuel levels. The fuel
cap is a bit fiddly and you need to ensure the slots in the tank and filter are aligned
and the fuel cap is engaged before turning.
Inspect the hose for tears and wear. If used frequently, the pressure washer will be
subjected to normal wear and tear. You will be dragging the hose about, and it will be
transporting water that is highly pressurized. This combination can make tears occur.
You must inspect the outlet and inlet ports, like the nozzles, wands, and spray tips to
be certain they are clog free. You must realize that a very high pressure results with
the operation of this machine. So keep in mind that any object that clogs the inlet and
outlet ports may be propelled at extremely high pressure, possibly causing injury
and/or damage.
You also should make sure that you have another person working with you to ensure
the safety of yourself and prevent anyone from straying into the danger area.
Starting the engine
Before starting the engine ensure there is an adequate flow of water from the gun
and follow the procedure outlined in Appendix 1 & 2.


Water flow on
Pressure valve set to minimum
-2-
Issue 2: Aug 2nd 2012





Fuel on
Choke on
Throttle open one third
Cut off switch in run position
Pull cord to start
If the engine fails to start after a couple of pulls you will need to release the pressure
in the lance before continuing.
To switch off:
 Throttle closed
 Turn cut off switch to off.
 Shut off fuel.
Using the washer
Always keep in mind that you should never point the nozzle to anyone, being
particularly aware of ‘kick back’. Always try to start with low pressure and increase it
gradually to get the best result and avoid damage to the surface being cleaned. Also,
make sure that you are using the right spray tip setting for the type of work you are
doing with the pressure washer. The pencil jet setting at full pressure will cut into
many materials. Use the jet at an oblique angle to achieve best results. Using at right
angles to the surface being cleaned will increase the likelihood of debris reflecting
straight back at you.
During use, to avoid overheating of the pump, do not allow the engine to run for
more than 2 minutes with the lance shut off. This will damage the machine and
invalidate warranty.
Finally, prior to its storage, be certain that the equipment is clean and drained down.
Release pressure via the lance before disconnecting hoses. You might want to run
water that is clear through the whole system if cleaning chemicals have been
employed. Prior to storage, allow the engine to cool and then return to storage and
lock up. The washer must be kept frost free to prevent serious damage to the
pump.
These rules keep you safe when you are using a pressure washer. Therefore, if you
remember these things, you will not cause injuries or property damage.
-3-
Appendix 1
PETROL POWER WASHER
MODEL NO: PLS190, PLS260
PART NO: 7330340, 7330350
OPERATION & MAINTENANCE
INSTRUCTIONS
LS1009
2
INTRODUCTION
Thank you for purchasing this CLARKE Petrol Power Washer.
Before attempting to use this product, please read this manual thoroughly and
follow the instructions carefully. In doing so you will ensure the safety of yourself
and that of others around you, and you can look forward to your purchase
giving you long and satisfactory service.
GUARANTEE
This product is guaranteed against faulty manufacture for a period of 12
months from the date of purchase. Please keep your receipt which will be
required as proof of purchase.
This guarantee is invalid if the product is found to have been abused or
tampered with in any way, or not used for the purpose for which it was
intended.
Faulty goods should be returned to their place of purchase, no product can
be returned to us without prior permission.
This guarantee does not effect your statutory rights.
3
TABLE OF CONTENTS
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
GUARANTEE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
TABLE OF CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
GENERAL SAFETY RULES . . . . . . . . . . . . . . . . . . . . . . . . . 5
SAFETY SYMBOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
UNPACKING AND ASSEMBLY . . . . . . . . . . . . . . . . . . . . . 8
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
BEFORE USE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
USING YOUR POWER WASHER . . . . . . . . . . . . . . . . . . . . 12
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
EXPLODED PARTS DIAGRAM . . . . . . . . . . . . . . . . . . . . . . 22
PARTS LIST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
PUMP EXPLODED PARTS DIAGRAM . . . . . . . . . . . . . . . . 23
PUMP PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
PARTS AND SERVICING . . . . . . . . . . . . . . . . . . . . . . . . . . 24
DECLARATION OF CONFORMITY PLS190 . . . . . . . . . . . . 25
DECLARATION OF CONFORMITY PLS260 . . . . . . . . . . . . 26
NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
4
GENERAL SAFETY RULES
WARNING: Water at high pressure can be dangerous and can cause
damage to persons or property if the operator is careless. Never allow
anyone to operate this equipment unless they are thoroughly reliable,
and familiar with the safety precautions.
1. NEVER direct the spray towards any person or animal.
2. NEVER direct the spray towards electrical wiring or equipment.
3. NEVER hold your finger over the high pressure nozzle.
4. NEVER allow children to use this machine.
5. NEVER operate the machine with any of the covers removed.
6. NEVER attempt any repairs to this machine always refer to a qualified
service agent.
7. NEVER supply any liquid other than water to the water inlet.
8. NEVER use the chemical injection facility to introduce solvents, e.g. paint
thinners, petrol, oil etc.
9. ALWAYS release any residual pressure in the system by turning off the water
supply and operating the trigger before disconnecting any hose or
accessory.
10. ALWAYS keep the machine itself dry and well clear of water spray
11. ALWAYS wear protective clothing and safety glasses. Loose particles and
other debris may be propelled at high speed by the water jet.
12. ALWAYS grip the gun firmly before pressing the trigger, expect the gun to
‘kick’ when starting.
13. ALWAYS respect the requirements of the local water company. Power
washers may only be connected to the mains drinking water supply, if a
backflow preventer valve is installed in the supply hose.
14. When not in use, ALWAYS disconnect from the water supply, and ensure the
system is completely drained. Store in a cool dry location.
15. When using the chemical injection facility, use only the chemical cleaning
agents (detergents), that are approved for power washers. CLARKE Traffic
Film Remover or CLARKE Wash and WAX (available from your dealer), is
recommended.
5
SAFETY SYMBOLS
ALWAYS: Read this manual. Understand all warnings and
instructions before operating this equipment.
DANGER: Risk of fire or explosion. Shut off engine before
adding fuel. Keep work area free of combustible materials.
Do not spray flammable liquids.
DANGER: Risk to breathing. Engine exhaust fumes can kill.
For outdoor use only. Work in a well ventilated area.
WARNING: Risk of injection or severe injury. Do not direct
discharge stream at persons or animals. Keep clear of nozzle.
This machine is to be used only by qualified operators.
WARNING: Risk of spray injury. Spray can propel objects.
Always wear ANSI approved Z87.1 Safety Glasses.
WARNING: Risk of chemical burn. Never spray acids, corrosive
or toxic chemicals. Use only cleaners formulated for power
washers.
WARNING: Risk of electrocution. Never direct spray toward
any electrical device or electrical outlet.
WARNING: R i s k o f u n s a f e o p e r a t i o n . K e e p children away
from this equipment. Gun kicks back. Hold with both hands.
WARNING: Risk of hot sur faces. Avoid contact with hot
engine exhaust components. Don't allow hoses to contact
the engine muffler during or after use.
6
OVERVIEW
1
2
8
3
4
7
9
6
NO
DESCRIPTION
5
NO DESCRIPTION
1
Gun/lance
6
Chemical hose
2
Spray wand
7
High pressure hose
3
Engine
8
Foldable handle
4
Adjustable nozzle
9
Pressure regulator
5
Wheels
7
UNPACKING AND ASSEMBLY
Unpack your power washer and check to ensure the following items are
present.
Contact your Clarke dealer immediately if any parts are missing or damaged.
• Hose, Gun/lance, Spray wand, Hook, Nozzle, Detergent hose with
filter, Oil plug, Rubber feet, Fixings pack
ASSEMBLY
CONNECTING THE WHEELS
1. Remove the nut, spring washer
and washer from the axle.
2. Fit the axles into the axle ports as
shown, secure with the nut, spring
washer and washer.
3. Fit the wheels to the axles and
secure with the nut and washer.
NOTE: Do not overtighten the nuts,
the wheels must be able to
rotate freely.
RUBBER FEET
1. Fit the rubber feet to the legs as
shown.
ASSEMBLE THE LANCE
1. Connect the spray wand to the
lance and tighten securely.
8
THE HIGH PRESSURE HOSE
CONNECT THE HOSE TO THE GUN
1. Slide the connector on the hose
backwards.
2. Push the gun into the connector.
3. Release the connector.
NOTE: Make sure the connection is
secure.
CONNECT THE HOSE TO THE POWER WASHER
1. Slide the connector on the power
washer towards the machine.
2. Push the hose into the connector.
3. Release the connector.
NOTE: Make sure the connection is
secure.
CONNECT WATER SOURCE
1. Connect the water supply hose to
the water inlet.
NOTE: Water source must provide
a minimum of 5 gallons per
minute at 20 p.s.i.
NOTE: Make sure the water supply
hose is screwed on tightly.
GUN/HOSE HOOK
1. Fit the hook into the position
shown and secure using the
washers and nuts on the bracket.
9
BEFORE USE
WARNING: TO CARRY OUT THIS CHECK, PLACE THE POWER WASHER ON
LEVEL GROUND WITH THE ENGINE SWITCHED OFF.
WARNING: TAKE CARE NOT TO TOUCH ANY HOT PARTS OF THE POWER
WASHER WHEN CHECKING THE OIL LEVELS.
IMPORTANT: The engine is supplied without any oil in it and must be filled to
the correct level before use, see below.
CHECKING THE PUMP OIL LEVEL
Look at the sight glass on the pump
to check the oil level inside the
pump.
OIL FILLER CAP
If required, remove the oil filler cap
and top up with oil.
SIGHT GLASS
• We recommend the use of
SAE30 oil in this power washer.
DRAIN CAP
CHECKING THE ENGINE OIL LEVEL
1. Turn the oil filler cap/dipstick anticlockwise and remove it from the
oil filler tube, wipe the dipstick
with a clean cloth.
2. Insert the oil filler cap/dipstick
back into the oil filler tube and
then remove it again. Do not
screw it in when doing this.
3. If the oil is low fill the oil reservoir to
the edge of the oil filler hole.
• We recommend the use of
SAE30 oil in this power washer.
4. Replace the oil filler cap.
NOTE: Running the engine with
insufficient oil can cause
engine damage.
10
CHECKING THE FUEL LEVEL
1. To check the fuel level open the fuel tank cap.
2. Just inside the fuel tank is a fuel strainer, check this filter periodically and
remove any contaminants which may have accumulated.
3. Refuel in a well-ventilated area.
Before starting the engine. If the
engine has been running, allow it
to cool. Refuel carefully to avoid
spilling fuel. Do not fill above the
fuel strainer shoulder.
4. After refueling, tighten the fuel
tank cap securely.
5. Replace the fuel filler cap
securely.
RECOMMENDED FUEL
Use unleaded petrol with a pump octane rating of 86 or higher.
WARNING: ALWAYS REFUEL IN A WELL VENTILATED AREA AWAY FROM
ANY HEAT SOURCES.
WARNING: ALLOW THE UNIT TO COOL DOWN BEFORE REFUELLING.
WARNING: DO NOT LEAVE FUEL WITHIN THE REACH OF CHILDREN.
NOTE: Do not overfill the fuel tank.
PRESSURE REGULATOR
When supplied the pressure regulator
may be set to minimum.
Turn the pressure regulator on the
pump fully clockwiseto allow water
pressure to build up when the
pressure washer is running.
If you find the pressure is too high, you
can adjust this later.
11
USING YOUR POWER WASHER
POWER WASHER TERMINOLOGY
PSI: Pounds per square inch, the unit of measurement for water pressure.
GPM: Gallons per minute.
CU: Cleaning units, GPM x PSI.
Bypass mode: In bypass mode, the pump recirculates the water because the
trigger of the spray gun is not being pulled. If unit is left in bypass mode for
more than two minutes, the water temperature will rise to a dangerous level
and could damage internal components of the pump.
NOTE: Any damage to pump due to these causes will not be covered
under warranty.
Thermal Relief Valve: In an effort to prevent extreme damage, pumps are
equipped with a thermal relief valve. This valve will open when the
temperature inside the pump rises too high. This valve will then release a gush
of water in an effort to lower the temperature inside the pump. Immediately
after this occurs, the valve will close.
Chemical Injection System: Mixes cleaners or cleaning solvents with the
pressurised water to improve cleaning effectiveness.
12
STARTING THE POWER WASHER
Prior to starting, refer to your engine manual for proper starting procedures for
your engine type.
1. Make sure the engine has sufficient fuel. See page 11.
2. Check engine oil level. See page 10.
3. Make sure that the filter screen is in water inlet of pump.
• Cone side faces out.
4. Turn water source on.
WARNING: FAILURE TO TURN ON THE WATER COULD CAUSE DAMAGE TO
THE PUMP.
5. Start the engine. See Engine Owners Manual for correct procedure.
NOTE: If the engine does not start after two pulls, pull the trigger on the
gun to relieve the pressure.
6. Pull the trigger on the gun to start water flow.
• Stand on a stable surface and grip gun/spray wand firmly with both
hands.
• Expect the gun to kick when the trigger is pulled.
7. Release trigger to stop water flow.
NOTE: The power washer will automatically go into bypass mode.
WARNING: DO NOT ALLOW UNIT TO OPERATE IN BYPASS MODE FOR
MORE THAN TWO MINUTES AT ANY TIME. OVERHEATING OF PUMP CAN
CAUSE DAMAGE TO PUMP.
13
ADJUSTING THE SPRAY
The nozzle is adjustable to allow you to adjust the spray from a narrow jet of
water to a wide spray.
To adjust the nozzle, proceed as follows.
1. Hold the shaft of the lance in one hand.
2. Twist the nozzle with the other hand.
3. To vary the spray between narrow and wide, turn the nozzle counterclockwise through a half-of-a-turn. The narrow jet should be used to clean
small areas where a small spray is required. The wide beam should be used
for cleaning large areas.
ADJUSTING THE PRESSURE
The pressure setting is preset at the factory. To lower the pressure:
1. Adjust the pressure regulator on
the pump. Turn the pressure
regulator knob counter clockwise
to lower pressure. Once you have
finished using your power washer,
return the pressure regulator to its
original position.
2. Back away from the surface to be
cleaned. The further away you
are the less the pressure will be on
the surface being cleaned.
3. Reduce the speed of the engine (RPM). Slow the engine down and the
water pressure will also go down.
4. Adjust the spray to a wider angle.
14
APPLYING CHEMICALS AND CLEANING SOLVENTS
1. Push the chemical hose onto the
barbed fitting located near high
pressure hose connection of
pump as shown.
2. Place other end of chemical hose
with filter on it into container
holding chemical/cleaning
solution.
• The water/chemical ratio is 7:1,
for every 7 gallons of water
pumped 1 gallon of chemical/ cleaning solution will be used.
SHUTTING DOWN
1. After each use, if you have applied chemicals, place chemical hose into
container of clean water and run clean water through chemical injection
system to flush the system thoroughly.
NOTE: Failure to do so could cause damage to the pump.
2. Turn engine off. See engine owner's manual.
NOTE: NEVER turn the water off with the engine running.
3. Turn water source off.
4. Pull trigger on spray gun to relieve any water pressure.
5. See storage section in this manual for proper storage procedures.
15
MAINTENANCE
CHANGING THE PUMP OIL
CAUTION: PROLONGED EXPOSURE TO USED OIL IS DANGEROUS,
ALWAYS WASH YOUR HANDS THOROUGHLY AFTER HANDLING USED OIL.
1. Unscrew and remove the oil filler
cap.
OIL FILLER CAP
2. Place the oil collection tray (not
supplied) under the drain cap.
CRANKCASE
3. Unscrew the drain cap, and allow
the used oil to drain from the
crankcase into the oil collection
tray.
SIGHT GLASS
DRAIN CAP
NOTE: Drain the oil when the engine
is warm, this will ensure the oil
flows out quicker.
4. Replace the drain plug and its ring seal.
5. With the power washer in a level position, fill to the centre of the
sight glass with the recommended oil.
6. Replace the oil filler cap.
ENVIRONMENTAL PROTECTION
One of the most damaging sources of pollution is oil. Do not throw away used
oil with your domestic rubbish or down drains and sinks. Place it in a leak proof
container and take it to you local waste disposal site.
16
CLEANING THE NOZZLE
If the nozzle becomes clogged with foreign materials such as dirt, excessive
pressure may develop. If the nozzle becomes partially clogged or restricted, the
pump pressure will pulsate, clean the nozzle immediately by follow the below
Instructions:
1. Shut off the power washer and turn off the water supply.
2. Pull trigger on gun handle to relieve any water pressure.
3. Disconnect the spray wand from the gun.
4. Remove any obstructions with the nozzle cleaning tool provided and back
flush with clean water.
5. Direct water supply into spray wand end for 30 seconds to back flush
loosened particles.
6. Reconnect spray wand to gun and turn on water supply.
CLEANING THE WATER INLET FILTER
This screen filter should be checked periodically and cleaned if necessary.
1. Remove filter from the water inlet
of the pump as shown.
2. Clean filter by flushing both sides
with water.
3. Replace the filter into the water
inlet.
• Cone side faces out.
NOTE: Do not operate power
washer without filter properly
installed.
17
STORAGE
ENGINE
See the separate engine manual supplied for information regarding the storage
procedure.
PUMP
1. Drain all water from the high pressure hose, coil it and store it on the gun/
hose holder located on the side of the power washer handle.
2. Drain all water from the spray gun and spray wand by holding the gun/
wand vertically with the nozzle pointing down and pulling the trigger. Store
in the gun/hose holder.
3. Store all other parts so that they are protected from damage.
STORAGE PROCEDURE
For long term storage, the petrol tank should be drained. Ensure that the
engine is cold before draining the tank. Remove the fuel tank cap and use a
pump type syphon to drain the petrol into an appropriate, clean container.
Do not store petrol for long periods of time.
Dispose of excess petrol in an environmentally safe way. Your local recycling
centre can advise you on the best method of disposal. After the petrol tank
has been drained, start the engine and allow it to use any petrol that may
remain in the engine, or fuel pipe. Make sure that the power washer has been
thoroughly cleaned before storing it in a clean dry place.
18
Troubleshooting
If the following does not solve your problem, please contact the CLARKE service
department. See page 24.
PROBLEM
CAUSE
SOLUTION
Engine will not
start (see engine
manual for
further engine
troubleshooting)
No fuel
Add fuel
Low oil
Add oil
Pressure builds up after
two pulls on the recoil
starter or after initial use
Squeeze the gun trigger to relieve the
pressure
Spark plug wire not
attached
Attach the spark plug wire
Engine switch is in the
OFF position
Set the engine switch to the ON position
Choke lever is set to the
choke position when the
engine is warm
Set the choke lever to the NO CHOKE
position
Fuel valve closed
Open the fuel valve
Water supply is not
adequate
Make sure your water supply can deliver 5
gallons per minute at 20psi
Leak in the high pressure
hose fitting
Tighten the fitting, use sealant tape if
required
Nozzle is obstructed
Clear the nozzle
Water filter screen is
clogged
Remove and clean the filter
Defective E-Z start valve
Have it replaced by your dealer
Air in the hose
Turn off the engine
Turn off the water supply,
Disconnect the water source from the
pump inlet and turn on the water source
to expel the air from the hose.
When all the air has been removed, turn
off the water supply and reconnect the
hose.
Turn on the water supply and pull the
trigger to expel any air in the gun/wand
No or low
pressure (initial
use)
19
PROBLEM
CAUSE
SOLUTION
No or low
pressure (initial
use) continued
Choke lever is in the
CHOKE position
Move the choke lever to the NO CHOKE
position
Throttle control lever is
not in the fast position
Move the throttle control lever to the fast
position
High pressure hose is too
long
Make sure the high pressure hose is under
100 feet
Will not draw
chemicals
Chemical filter is blocked Clean the filter
Chemicals being used
are too thick
Dilute the chemicals. The chemicals
should have the consistency of water
Pressure hose is too long.
Use a longer supply hose instead of a
longer high pressure hose
Chemical build up inside
the chemical injector
Have the parts cleaned or replaced by
your dealer
Worn seal or packing
Have it replaced by your dealer
Worn or obstructed
valves
Have it replaced by your dealer
Worn unloader piston
Have it replaced by your dealer
Worn E-Z start valve
Have it replaced by your dealer
Water leaking at
the Gun / spray
wand
connection
Worn or broken O-ring
Check and replace
Loose hose connection
Tighten
Water leaking at
the pump
Loose connections
Tighten
Piston packings worn
Have it replaced by your dealer
Worn or broken O-rings
Have it replaced by your dealer
Pump head or tubes
damaged from freezing
Have it replaced by your dealer. See
“Storage” on page 18.
Oil seals worn
Have it replaced by your dealer
Loose drain plug
Tighten
Worn O-rings
Check and replace
Nozzle obstructed
Clear the nozzle
No or low
pressure (after a
period of normal
use)
Oil leaking at the
pump
Pump pulsates
20
SPECIFICATIONS
Model
PLS190
PLS260
200F(D)
390F(D)
6.5
13
Engine
Engine Model
Power (HP)
Engine type
Petrol (unleaded). OHV Single Cylinder
4 stroke forced air cooling
Starting system
Recoil
Recoil
3.5
6
45oC
45oC
5 gallons per
minute @ 20 psi
5 gallons per
minute @ 20 psi
Working pressure
180 Bar
240 Bar
Max. permissible pressure
186 Bar
250 Bar
12.6
18.2
Guaranteed sound power
level LWA dB
70
80
Length (mm)
710
790
Width (mm)
390
500
Height (mm)
465
600
Weight (kg)
38.5
60.5
Fuel Capacity (L)
Water supply
Max. feed temperature
Min. feed volume
Performance Data
Max. water flow (l/min.)
Dimensions
21
EXPLODED PARTS DIAGRAM
PARTS LIST
NO
DESCRIPTION
1
Filter
2
Chemical Inlet
Hose
QTY
PART NO
QTY
PART NO
1
Model No + 001
NO DESCRIPTION
6
Gun
1
Model No + 006
1m
Model No + 002
7
Wand
1
Model No + 007
3
Pump Fix Bolt
4
Model No + 003
8
Rubber Foot
4
Pump Assy
1
Model No + 004
9
Water Inlet
Hose
5
High-pressure
Hose
10m Model No + 005
10
Wheel
22
2
Model No + 008
3m
Model No + 009
2
Model No + 010
PUMP EXPLODED PARTS DIAGRAM
23
PUMP PARTS LIST
NO
PART NO
NO
11
Oil gauge
DESCRIPTION
Model No + 001
21
Inlet T connector
DESCRIPTION
Model No + 011
12
Drain plug
Model No + 002
22
Inlet connector
Model No + 012
13
Crankcase cover
Model No + 003
23
Water filter
Model No + 013
14
Crankcase
Model No + 004
24
Water injection
tube
Model No + 014
15
Oil seal, crankshaft
Model No + 005
25
Soap suction
nozzle
Model No + 015
16
Ceramic pipe
Model No + 006
26
Manifold head
Model No + 016
17
Plastic cap knob
Model No + 007
27
Valve Plate
Model No + 017
18
Knob
Model No + 008
28
Valve plug
Model No + 018
19
Seat, Valve body
Model No + 009
29
Outlet plug
Model No + 019
20
Outlet connector
Model No + 010
C
Plunger sealing set
F
Inlet assy
D
Unloader valve assy
H
Checking valve assy
E
Pressure regulator, pressure
adjustable
I
Thermal relief valve
DESCRIPTION
PART NO
DESCRIPTION
PARTS AND SERVICING
For Parts & Servicing, please contact your nearest dealer, or
CLARKE International, on one of the following numbers.
PARTS & SERVICE TEL: 020 8988 7400
PARTS & SERVICE FAX: 020 8558 3622
or e-mail as follows:
PARTS: Parts@clarkeinternational.com
SERVICE: Service@clarkeinternational.com
24
DECLARATION OF CONFORMITY PLS190
DECLARATION OF CONFORMITY
This is an important document and should be retained.
We declare that this product complies with the following directives:
89/336/EE
Electromagnetic Compatibility directive, as amended.
98/37/ EC
Machinery Directive.
2000/14/EC
Noise emissions (amended by 2005/88/EC)
97/68/EC
Emissions (amended by 2004/26/EC
The Following Standards have been applied to the product:
BS EN 55012:2002+A1
BS EN 61000-6-1:2001
BS EN 60335-2-79:2004 +A1
The technical documentation required to demonstrate that the products meet the
requirements of the Low Voltage Equipment directive has been compiled and is available
for inspection by the relevant enforcement authorities.
The CE mark was first applied in: 2007
Product Description:
Petrol Powered Washer
Model number(s):
PLS190
Serial / batch Number:
Current Manufacture.
Date of Issue:
27/03/2009
Signed
A.C. AIKEN
Senior Manager Clarke International.
PLS190-RV2.doc
Page 1 of 1
25
DECLARATION OF CONFORMITY PLS260
DECLARATION OF CONFORMITY
This is an important document and should be retained.
We declare that this product complies with the following directives:
89/336/EE
Electromagnetic Compatibility directive, as amended.
98/37/ EC
Machinery Directive.
2000/14/EC
Noise emissions (amended by 2005/88/EC)
97/68/EC
Emissions (amended by 2004/26/EC
The Following Standards have been applied to the product:
BS EN 55012:2002+A1
BS EN 61000-6-1:2001
BS EN 60335-2-79 :2004 +A1
The technical documentation required to demonstrate that the products meet the
requirements of the Low Voltage Equipment directive has been compiled and is available
for inspection by the relevant enforcement authorities.
The CE mark was first applied in: 2007
Product Description:
Petrol Powered Washer
Model number(s):
PLS260
Serial / batch Number:
Current Manufacture.
Date of Issue:
01/05/2008
Signed
A.C. AIKEN
Senior Manager Clarke International.
PLS260-RV1
Page 1 of 1
26
Appendix 2
Keep this owner's manual handy, so you can refer to it at any time.
This owner's manual is considered a permanent part of the engine and should remain with
the engine if resold.
The information and specifications included in this publication were in effect at the time of
approval for printing.
Only the D Type is equipped for both electric and manual starting.
READ THIS OWNER’S MANUAL CAREFULLY. Pay special attention to these symbols
and any instructions that follow:
Indicates serious injury or death will result if instructions are not
followed.
Indicates a strong possibility that serious injury or death could result if instructions
are not followed.
Indicates a possibility that minor injury or an result if instructions
are not followed.
Indicates that equipment or property damage can result if
instructions are not followed.
NOTE:
Gives helpful information.
If a problem should arise, or if you have any questions about your engine, consult your
engine dealer.
CONTENTS
CONTENTS
1. ENGINE SAFETY........................................................................................2
2. COMPONENTS & CONTROL LOCATIONS……………................................................3
3. CONTROLS...............................................................................................4
4. CHECK BEFORE OPERATION .............................................................................. 6
5. OPERATION............................................................................................ 7
6. MAINTENANCE ……………………….......................................................................11
7. STORAGE/TRANSPORTING ...................................................................................23
8. TROUBLESHOOTING………………………………………………................................26
9.
TECHNICAL & CONSUMER INFORMATION ……..……………………………………27
10. SPECIFICATIONS ...................................................................................33
11. WIRING DIAGRAMS ...............................................................................36
12. OPTIONAL PARTS....................................................................................38
BATTERY.................................................................................................38
ENGINE SAFETY
1. ENGINE SAFETY
IMPORTANT SAFETY INFORMATION
Most accidents with engines can be prevented if you follow all instructions in this manual
and on the engine. Some of the most common hazards are discussed below, along with
the best way to protect yourself and others.
Owner Responsibilities
z
The engines are designed to give safe and dependable service if operated according
to instructions. Read and understand this owner’s manual before operating the engine.
Failure to do so could result in personal injury or equipment damage.
z
Know how to stop the engine quickly, and understand the operation of all controls.
Never permit anyone to operate the engine without proper instructions.
z
Do not allow children to operate the engine. Keep children and pets away from the
area of operation.
Refuel With Care
Gasoline is extremely flammable, and gasoline vapor can explode. Refuel outdoors, in a
well-ventilated area, with the engine stopped. Never smoke near gasoline, and keep other
flames and sparks away. Always store gasoline in an approved container. If any fuel is
spilled, make sure the area is dry before starting the engine.
Hot Exhaust
z
The muffler becomes very hot during operation and remains hot for a while after
stopping the engine. Be careful not to touch the muffler while it is hot. Let the engine
cool before storing it indoors.
z
To prevent fire hazards and to provide adequate ventilation for stationary equipment
applications, keep the engine at least 3 feet (1 meter) away from building walls and
other equipment during operation. Do not place flammable objects close to the engine.
Carbon Monoxide Hazard
Exhaust gas contains poisonous carbon monoxide. Avoid inhalation of exhaust gas. Never
run the engine in a closed garage or confined area.
Other Equipment
Review the instructions provided with the equipment powered by this engine for any
additional safety precautions that should be observed in conjunction with engine startup,
shutdown, operation, or protective apparel that may be needed to operate the equipment.
2
COMPONENTS & CONTROL LOCATIONS
2. COMPONENTS & CONTROL LOCATIONS
THROTTLE LEVER
IGNITION SWITCH
MUFFLER
STARTER GRIP
SPARK PLUG
RECOIL STARTER
AIR CLEANER
CHOKE LEVER
FUEL VALVE LEVER
FUEL FILLER CAP
FUEL TANK
OIL DRAIN PLUG
OIL FILLER CAP/DIPSTICK
3
CONTROLS
3. CONTROLS
Fuel Valve Lever
The fuel valve opens and closes the passage between the fuel tank and the carburetor.
The fuel valve lever must be in the ON position for the engine to run.
When the engine is not in use, leave the fuel valve lever in the OFF position to prevent
carburetor flooding and to reduce the possibility of fuel leakage.
FUEL
VALVE
LEVER
ON
OFF
OFF
Throttle Lever
The throttle lever controls engine THROTTLE LEVER speed.
Moving the throttle lever in the directions shown makes the engine run faster or slower.
THROTTLE
LEVER
SLOW
FAST
Engine Switch
The engine switch enables and disables the ignition system.
The engine switch must be in the ON position for the engine to run.
Turning the engine switch to the OFF position stops the engine.
4
CONTROLS
ALL ENGINE EXCEPT D TYPE
ENGINE SWITCH
OFF
ON
Choke Lever
The choke lever opens and closes the choke valve in the carburetor.
The CLOSE position enriches the fuel mixture for starting a cold engine.
The OPEN position provides the correct fuel mixture for operation after starting, and for
restarting a warm engine.
Some engine applications use a remotely-mounted choke control rather than the
engine-mounted choke lever shown here.
CHOKE LEVER
OPEN
OPEN
CLOSE
Recoil Starter Grip
Pulling the starter grip operates the recoil starter to crank the engine.
STARTER GRIP
5
CHECK BEFORE OPERATION
4. CHECK BEFORE OPERATION
IS YOUR ENGINE READY TO GO?
For your safety, and to maximize the service life of your equipment, it is very important to
take a few moments before you operate the 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.
Improperly maintaining this engine,
or failing to correct a problem
before operation, could cause a
malfunction in which you could be
seriously injured.
Always perform a preoperation
inspection before each operation,
and correct any problem.
Before beginning your preoperation checks, be sure the engine is level and the engine
switch is in the OFF position.
Check the General Condition of the Engine
z
z
z
z
Look around and underneath the engine for signs of oil or gasoline leaks.
Remove any excessive dirt or debris, especially around the muffler and recoil starter.
Look for signs of damage.
Check that all shields and covers are in place, and all nuts, bolts, and screws are
tightened.
Check the Engine
Check the engine oil level. Running the engine with a low oil level can cause engine
damage.
The Oil Alert system (applicable engine 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.
Check the air filter. A dirty air filter will restrict air flow to the carburetor, reducing engine
performance.
Check the fuel level. Starting with a full tank will help to eliminate or reduce operating
interruptions for refueling.
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.
6
OPERATION
5. OPERATION
SAFE OPERATING PRECAUTIONS
Before operating the engine for the first time, please review the IMPORTANT SAFETY
INFORMATION and the chapter titled BEFORE OPERATION.
Carbon monoxide gas is toxic.
Breathing it can cause
unconsciousness and even kill you.
Avoid any areas or actions that
expose you to carbon monoxide.
Review the instructions provided with the equipment powered by this engine for any safety
precautions that should be observed in conjunction with engine startup, shutdown, or
operation.
STARTING THE ENGINE
1. Move the fuel valve lever to the ON position.
FUEL VALVE
LEVER
ON
2. To start a cold engine, move the choke lever to the CLOSE position.
To restart a warm engine, leave the choke lever in the OPEN position.
Some engine applications use a remotely-mounted choke control rather than the
engine-mounted choke lever shown here.
7
OPERATION
CHOKE LEVER
OPEN
CLOSE
3. Move the throttle lever away from the SLOW position, about 1/3 of the way toward the
FAST position.
Some engine applications use a remotely-mounted throttle control rather than the
engine-mounted throttle lever shown here.
SLOW
HIGH
THROTTLE LEVER
4. Turn the engine switch to the ON position.
ENGINE SWITCH
OFF
ON
5. Operate the starter.
RECOIL STARTER (all engine types):
Pull the starter grip lightly until you feel resistance, then pull briskly.
8
LOW
OPERATION
Return the starter grip gently.
STARTER GRIP
6. If the choke lever has been moved to the CLOSE position to start the engine, gradually
move it to the OPEN position as the engine warms up.
CHOKE LEVER
OPEN
STOPPING THE ENGINE
To stop the engine in an emergency, simply turn the engine switch to the OFF position.
Under normal conditions, use the following procedure.
1. Move the throttle lever to the SLOW position.
Some engine applications use a remotely-mounted throttle control rather than the
engine-mounted throttle lever shown here.
THROTTLE LEVER
SLOW
9
OPERATION
2. Turn the engine switch to the OFF position.
ENGINE SWITCH
OFF
ON
3. Turn the fuel valve lever to the OFF position.
FUEL VALVE
LEVER
OFF
SETTING ENGINE SPEED
Position the throttle lever for the desired engine speed.
Some engine applications use a remotely-mounted throttle control rather than the
engine-mounted throttle lever shown here.
For engine speed recommendations, refer to the instructions provided with the equipment
powered by this engine.
THROTTLE LEVER
FAST
10
SLOW
MAINTENANCE
6. MAINTENANCE
THE IMPORTANCE OF MAINTENANCE
Good maintenance is essential for safe, economical, and trouble-free operation. It will also help
reduce air pollution.
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.
Always follow the inspection and
maintenance recommendations and
schedules in this owner’s manual.
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 technician or other qualified mechanic.
The maintenance schedule applies to normal operating conditions. If you operate your engine
under unusual conditions, such as sustained high-load or high-temperature operation, or use in
unusually wet or dusty conditions, consult your servicing dealer for recommendations
applicable to your individual needs and use.
MAINTENANCE SAFETY
Some of the most important safety precautions are as follows: 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.
Failure to properly follow
maintenance instructions and
precautions can cause you to be
seriously hurt or killed.
Always follow the procedures and
precautions in the owner’s manual.
Safety Precautions
z
Make sure the engine is off before you begin any maintenance or repairs. This will eliminate
several potential hazards:
11
MAINTENANCE
„
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.
z
Read the instructions before you begin, and make sure you have the tools and skills
required.
z
To reduce the possibility of fire or explosion, be careful when working around gasoline. Use
only a nonflammable solvent, not gasoline, to clean parts. Keep cigarettes, sparks and
flames away from all fuel-related parts.
Remember that your 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, genuine parts or their equivalents for
repair and replacement.
MAINTENANCE SCHEDULE
REGULAR SERVICE PERIOD
Performed at every indicated month or
operating hour interval, whichever comes
first.
ITEM
●
●
Engine oil
Air cleaner
●
Sediment Cup
●
Spark plug
●
●
●
●
●
Spark arrester
(optional parts)
Idle speed
Valve clearance
Fuel tank and strainer
Combustion chamber
Fuel line
Check level
Change
Check
Clean
Replace
Clean
Check-Clean
Replace
Each
use
First
month or
20 Hrs.
Every 3
months or
50 Hrs.
Every 6
months or
100 Hrs.
Every
year or
300 Hrs.
○
○
○
○
○(1)
○☆
○
○
○
Clean
○
Check-Adjust
Check-Adjust
Clean
Clean
Check
○(2)
○(2)
○(2)
After every 300 Hrs. (2)
Every 2 years (Replace if necessary) (2)
Emission-related items.
Replace the paper element type only.
(1)Service more frequently when used in dusty areas.
(2)These items should be serviced by your servicing dealer unless you have the proper tools
z
☆
12
MAINTENANCE
and are mechanically proficient. Refer to manual for service procedures.
REFUELING
Fuel tank capacities
160F(D)/G120F(D): 2.5 L
168F(D)-I / 168F(D)-II / G160F(D) / G200F(D): 3.8 L
170F(D) / 170F(D)-II / G180F(D) / G210F(D): 3.8 L
173F(D) /177F(D) / G240F(D) / G270F(D): 6.0 L
182F(D) / 188F(D) / G340F(D) / G390F(D) /190F(D) / G420F(D): 6.5 L
With the engine stopped, remove the fuel tank cap and check the fuel level. Refill the tank if the
fuel level is low.
Gasoline is highly flammable and
explosive. You can be burned or
seriously injured when handling fuel.
z Stop the engine and keep heat,
sparks, and flame away.
z Handle fuel only outdoors.
z Wipe up spills immediately.
MAXIMUM FUEL LEVEL
Refuel in a well-ventilated area before starting the engine. If the engine has been running, allow
it to cool. Refuel carefully to avoid spilling fuel. Do not fill above the fuel strainer shoulder. After
refueling, tighten the fuel tank cap securely.
Never refuel the engine inside a building where gasoline fumes may reach flames or sparks.
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.
13
MAINTENANCE
Fuel can damage paint and plastic. Be careful not to spill fuel when
filling your fuel tank. Damage caused by spilled fuel is not covered under
warranty.
FUEL RECOMMENDATIONS
Use unleaded gasoline with a pump octane rating of 86 or higher.
These engines are certified to operate on unleaded gasoline. Unleaded gasoline produces
fewer engine and spark plug deposits and extends exhaust system life.
Never use stale or contaminated gasoline or an oil/gasoline mixture. Avoid getting dirt or water
in the fuel tank.
Occasionally you may hear a light ‘‘spark knock’’ or ‘‘pinging’’ (metallic rapping noise) while
operating under heavy loads. This is no cause for concern.
If spark knock or pinging occurs at a steady engine speed, under normal load, change brands of
gasoline. If spark knock or pinging persists, see an authorized servicing dealer.
Running the engine with persistent spark knock or pinging can cause engine damage.
Running the engine with persistent spark knock or pinging is considered misuse, and
the Distributor’s Limited Warranty does not cover parts damaged by misuse.
ENGINE OIL LEVEL CHECK
Check the engine oil level with the engine stopped and in a level position.
1. Remove the filler cap/dipstick and wipe it clean.
FILLER CAP/DIPSTICK
UPPER LIMIT
LOWER LIMIT
14
MAINTENANCE
2. Insert and remove the dipstick without screwing it into the filler neck. Check the oil level
shown on the dipstick.
3. If the oil level is low, fill to the edge of the oil filler hole with the recommended oil.
4. Screw in the filler cap/dipstick securely.
Running the engine with a low oil level can cause engine damage.
The Oil Alert system (applicable engine types) will automatically stop the engine before the oil
level falls below safe limit. However, to avoid the inconvenience of an unexpected shutdown,
always check the engine oil level before startup.
ENGINE OIL CHANGE
Drain the used oil while the engine is warm. Warm oil drains quickly and completely.
1. Place a suitable container below the engine to catch the used oil, and then remove the filler
cap/dipstick and the drain plug.
2. Allow the used oil to drain completely, and then reinstall the drain plug, 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; pour it on the ground; or down a drain.
3. With the engine in a level position, fill to the outer edge of the oil filler hole with the
recommended oil.
Engine oil capacities:
G120F: 0.63 US qt ( 0. 6 L)
G160/G200F(D), G160/G200F(D)-B, G160/G200F(D)-C: 0.63 US qt ( 0.60 L)
G240/G270/G340/G390/G420F(D), G240/G270F(D)-B: 1.2 US qt ( 1.1 L)
G240/G270 F(D)-C, G340/G390F(D)-D: 1.2 US qt ( 1.1 L)
Running the engine with a low oil level can cause engine damage.
The Oil Alert system (applicable engine 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.
15
MAINTENANCE
4. Screw in the filler cap/dipstick securely.
FILLER CAP/
DIPSTICK
OIL LEVEL
DRAIN BOLT
REDUCTION GEAR OIL (Only on equipped model)
<1/2 reduction with automatic centrifugal clutch>
1. Remove the oil filler cap and wipe the dipstick clean.
2. Insert the dipstick into the filler neck but do not screw it in.
3. If the level is low, fill to the upper level mark with the same oil recommended for the engine.
Oil capacity of G160/G200/G240/G270F(D)-B: 500 cc
DIPSTICK/FILLER CAP
UPPER LEVEL
DRAIN BOLT
SERVICING YOUR ENGINE
ENGINE OIL RECOMMENDATIONS
Oil is a major factor affecting performance and service life. Use 4-stroke automotive detergent
oil.
16
MAINTENANCE
SAE 10W-30 is recommended for general use. Other viscosities shown in the chart may be
used when the average temperature in your area is within the recommended range.
SAE Viscosity Grades
AMBIENT TEMPERATURE
The SAE oil viscosity and service classification are in the API label on the oil container. We
recommend that you use API SERVICE Category SE or SF oil.
AIR FILTER INSPECTION
Remove the air cleaner cover and inspect the filter. Clean or replace dirty filter elements.
Always replace damaged filter elements. If equipped with an oil-bath air cleaner, also check the
oil level.
PAPER
FILTER
ELEMENT
FILTER
FOAM
FILTER
ELEMENT
AIR CLEANER SERVICE
A dirty air filter will restrict air flow to the carburetor, reducing engine performance.
17
MAINTENANCE
If you operate the engine in very dusty areas, clean the air filter more often than specified in the
MAINTENANCE SCHEDULE.
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.
Dual-Filter-Element Types
1. Remove the wing nut from the air cleaner cover, and
remove the air cleaner cover.
AIR
CLEANER
COVER
2. Remove the wing nut from the air filter, and remove
the filter.
PAPER
FILTER
ELEMENT
3. Remove the foam filter from the paper filter.
FOAM
FILTER
ELEMENT
4. Inspect both air filter elements, and replace them if
they are damaged. Always replace the paper air filter
element at the scheduled interval.
GASKET
5. Clean the air filter elements if they are to be reused.
Paper air filter element: Tap the filter element several times on a hard surface to remove dirt,
or blow compressed air [not exceeding 30 psi (207 kPa)] 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 drying thoroughly. Or
clean in nonflammable solvent and allow drying. Dip the filter element in clean engine oil,
and then squeeze out all excess oil. The engine will smoke when started if too much oil is
left in the foam.
6. Wipe dirt from the inside of the air cleaner base and cover, using a moist rag. Be careful to
prevent dirt from entering the air duct that leads to the carburetor.
7. 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.
8. Install the air cleaner cover, and tighten the cover wing nut securely.
18
MAINTENANCE
Oil-Bath Type
1. Remove the wing nut, and remove the air cleaner cap and cover.
2. Remove the air filter from the cover, Wash the cover and filter in warm, soapy water, rinse,
and allow drying thoroughly. Or clean in nonflammable solvent and allow drying.
3. Dip the filter in clean engine oil, and then squeeze out all excess oil. The engine will smoke if
too much oil is left in the foam.
4. Empty the used oil from the air cleaner case, wash out any accumulated dirt with
nonflammable solvent, and dry the case.
5. Fill the air cleaner case to the OIL LEVEL mark with the same oil that is recommended for
the engine. Oil capacity: 2.0 US oz (60 cm3 )
6. Reassemble the air cleaner, and tighten the wing nut securely.
WING
NUT
AIR
CLEANER
COVER
CAP
FILTER
GRID
AIR
CLEANER
CASE
OIL LEVEL
SEDIMENT CUP CLEANING
1. Move the fuel valve to the OFF position, and then remove the fuel sediment cup and O-ring.
Gasoline is highly flammable and explosive.
You can be burned or seriously injured
when handling fuel.
z
z
z
Keep heat, sparks and flame away.
Handle fuel only outdoors.
Wipe up spills immediately.
19
MAINTENANCE
2. Wash the sediment cup and O-ring in nonflammable solvent, and dry them thoroughly.
3. Place the O-ring in the fuel valve, and install the sediment cup. Tighten the sediment cup
securely.
4. Move the fuel valve to the ON position, and check for leaks. Replace the O-ring if there is
any leakage.
O-RING
SEDIMENT CAP
SPARK PLUG SERVICE
Recommended spark plugs: F7RTC or other equivalents.
An incorrect spark plug can cause engine damage.
1. Disconnect the spark plug cap, and remove any dirt from around the spark plug area.
2. Remove the spark plug with a spark plug wrench.
0.028-0.031 in
(0.70-0.80 mm)
SPARK PLUG WRENCH
3. Inspect the spark plug. Replace it if the electrodes are worn, or if the insulator is cracked or
chipped.
20
MAINTENANCE
4. Measure the spark plug electrode gap with a suitable gauge.
The gap should be 0.028 in -0.031 in (0.70 mm - 0.80 mm). Correct the gap, if necessary, by
carefully bending the side electrode.
5. Install the spark plug carefully, by hand, to avoid cross-threading.
6. After the spark plug seats, tighten with a spark plug wrench to compress the water.
If reinstalling the used spark plug ,tighten 1/8 - 1/4 turn after the spark plug seats.
If installing a new spark plug, tighten 1/2 turn after the spark plug seats.
A loose spark plug can overheat and damage the engine.
Over tightening the spark plug can damage the threads in the cylinder head.
7. Attach the spark plug cap.
IDLE SPEED ADJUSTMENT
1. Start the engine outdoors, and allow it to warm up to operating temperature.
2. Move the throttle lever to its slowest position.
3. Turn the throttle stop screw to obtain the standard idle speed.
Standard idle speed: 1,400±150 rpm
THROTTLE STOP SCREW
21
MAINTENANCE
SPARK ARRESTER SERVICE (optional equipment)
Your engine is not factory-equipped with a spark arrester. 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 servicing dealers.
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 very hot. Allow the muffler to cool before
servicing the spark arrester.
1. Remove the three 4 mm screws from the exhaust deflector, and remove the deflector.
2. Remove the four 5 mm screws from the muffler protector and remove the muffler protector.
3. Remove the 4 mm screw from the spark arrester, and remove the spark arrester from the
muffler.
5mm SCREWS
MUFFLER
PROTECTOR
4mm SCREW
MUFFLER
SPARK
ARRESTER
SCREEN
GASKET
8mm NUTS
4. Use a brush to remove carbon deposits from the spark arrester screen. Be careful to avoid
damaging the screen.
The spark arrester must be free of breaks and holes. Replace the spark arrester if it is
damaged.
5. Install the spark arrester, muffler protector, and exhaust deflector in the reverse order of
disassembly.
22
STORAGE/TRANSPORTING
7. STORAGE/ TRANSPORTING
STORING YOUR ENGINE
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 after storage.
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.
z
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.
z
Water contacting a hot engine can cause damage. If the engine has been running,
allow it to cool for at least half an hour before washing.
Fuel
Gasoline will oxidize and deteriorate in storage. Old 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.
The Distributor’s Limited Warranty does not cover fuel system damage or engine
performance problems resulting from neglected storage preparation.
You can extend fuel storage life by adding a fuel stabilizer that is formulated for that
purpose, or you can avoid fuel deterioration problems by draining the fuel tank and
carburetor.
23
STORAGE/TRANSPORTING
ADDING A FUEL STABILIZER TO EXTEND FUEL STORAGE LIFE
When adding a fuel 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. Add fuel stabilizer following the manufacturer’s instructions.
2. After adding a fuel stabilizer, run the engine outdoors for 10 minutes to be sure that
treated gasoline has replaced the untreated gasoline in the carburetor.
3. Stop the engine, and move the fuel valve to the OFF position.
DRAINING THE FUEL TANK AND CARBURETOR
1. Place an approved gasoline container below the carburetor, and use a funnel to avoid
spilling fuel.
2. Remove the carburetor drain bolt and sediment cup, and then move the fuel valve lever
to the ON position.
FUEL VALVE LEVER
O-RING
WASHER
DRAIN BOLT
SEDIMENT CUP
3. After all the fuel has drain into the container, reinstall the drain bolt and sediment cup.
Tighten them securely.
Storage Precautions
1. Change the engine oil.
2. Remove the spark plugs.
24
STORAGE/TRANSPORTING
3. Pour a tablespoon (5-10 cc) of clean engine oil into the cylinder.
4. Pull the starter rope several times to distribute the oil in the cylinder.
5. Reinstall the spark plugs.
6. Pull the starter rope slowly until resistance is felt. This will close the valves so moisture
cannot enter the engine cylinder. Return the starter rope gently.
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 spark-producing electric motor, or where power tools are
operated.
If possible, avoid storage areas with high humidity, because that promotes rust and
corrosion.
Unless all fuel has been drained from the fuel tank, leave the fuel valve lever in the OFF
position to reduce the possibility of fuel leakage.
Position the equipment so the engine is level. Tilting can cause fuel or oil leakage.
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 an electric starter, recharge the battery once a month while
the engine is in storage. This will help to extend the service life of the battery.
Removal from Storage
Check your engine as described in the chapter CHECK BEFORE OPERATION.
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 that it contains only fresh gasoline.
Gasoline oxidizes and deteriorates over time, causing hard starting.
If the cylinders were coated with oil during storage preparation, the engine may smoke
briefly at startup. This is normal.
TRANSPORTING
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.
Keep the engine level when transporting to reduce the possibility of fuel leakage. Move the
fuel valve lever to the OFF position.
25
TROUBLESHOOTING
8. TROUBLESHOOTING
ENGINE
WILL
START
1. Electric starting:
check battery
NOT
2. Check control positions
Possible Cause
Battery discharged.
Recharge battery.
Fuel valve OFF.
Move lever to ON.
Move lever to CLOSE
unless engine is warm.
Turn engine switch to
ON.
Refuel
Choke OPEN.
Engine switch OFF.
3. Check fuel.
Correction
Out of fuel.
Bad fuel; engine stored
Drain fuel tank and
without treating or draining
carburetor. Refuel with
gasoline, or refueled with
fresh gasoline.
bad gasoline.
Spark plugs faulty, fouled, Gap, or replace spark
or improperly gapped.
plugs.
4. Remove and inspect
Dry and reinstall spark
spark plugs.
Spark plugs wet with fuel plugs. Start engine with
(flooded engine).
throttle lever in FAST
position.
5. Take engine to an Fuel
filter
clogged,
Replace or repair faulty
authorized
servicing carburetor
malfunction,
components
as
dealer, or refer to ignition malfunction, valve
necessary.
manual.
stuck, etc.
ENGINE LACKS POWER
Possible Cause
1. Check air filter
Filter element(s) clogged.
Out of fuel.
2. Check fuel.
3.
Take engine to an
authorized
servicing
dealer, or refer to
manual.
Correction
Clean or replace filter
element(s).
Refuel
Bad fuel; engine stored
Drain fuel tank and
without treating or draining
carburetor. Refuel with
gasoline, or refueled with
fresh gasoline.
bad gasoline.
Fuel
filter
clogged,
Replace or repair faulty
carburetor
malfunction,
components
as
ignition malfunction, valve
necessary.
stuck, etc.
26
TECHNICAL & CONSUMER INFORMATION
9. TECHNICAL & CONSUMER INFORMATION
TECHNICAL INFORMATION
Serial Number Location
ENGINE TYPE
SERIAL NUMBER
Record the engine serial number in the space below. You will need this serial number
when ordering parts, and when making technical or warranty inquires.
Engine serial number:
Battery Connections for Electric Starter
Use a 12-volt battery with an ampere-hour rating of at least 18 Ah.
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.
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.
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.
27
TECHNICAL & CONSUMER INFORMATION
NEGATIVE(-)
BATTERY CABLE
STARTER
SOLENOID
POSITIVE(+) BATTERY CABLE
Remote Control Linkage
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
remotely-mounted control.
G120F, G160/G200F(D), G160/G200F(D)-B, G160/G200F(D)-C:
REMOTE THROTTLE LINKAGE
RETURN SPRING
THROTTLE LEVER
PIVOT NUT
Flexible wire core
mounting
4mm SCREW
WIRE
Solid wire core
mounting
WIRE HOLDER
OPTIONAL
THROTTLE
LEVER
5 mm
CIRCLIP
REMOTE CHOKE LINKAGE
WIRE HOLDER
CHOKE LEVER
28
TECHNICAL & CONSUMER INFORMATION
G240/G270/G340/G390/G420F(D), G240/G270F(D)-B, G340/G390F(D)-D:
REMOTE THROTTLE LINKAGE
RETURN SPRING
THROTTLE LEVER
PIVOT NUT
Flexible wire core
mounting
4mm SCREW
WIRE HOLDER
WIRE
OPTIONAL
THROTTLE
LEVER
Solid wire core
mounting
5 mm
CIRCLIP
REMOTE CHOKE LINKAGE
WIRE HOLDER
CHOKE LEVER
Carburetor Modification for High Altitude Operation
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.
High altitude performance can be improved by specific modifications to the carburetor. If
you always operate your engine at altitudes above 5,000 feet (1,500 meters), 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.
29
TECHNICAL & CONSUMER INFORMATION
Even with carburetor modification, engine horsepower will decrease about 3.5% for each
1,000-foot (300-meter) increase in altitude. The effect of altitude on horsepower will be
greater than this if no carburetor modification is made.
When the carburetor has been modified for high altitude operation, the air-fuel mixture will
be too lean for low altitude use. Operation at altitudes below 5,000 feet (1,500meters) with
a modified carburetor may cause the engine to overheat and result in serious engine
damage. For use at low altitudes, have your servicing dealer return the carburetor to
original factory specifications.
Oxygenated Fuels
Some conventional gasolines are being blended with alcohol or an ether compound.
These gasolines are collectively referred to as oxygenated fuels.
To meet clean air standards, some areas use oxygenated fuels to help reduce emissions.
If you use an oxygenated fuel, be sure it is unleaded and meets the minimum octane rating
requirement.
Before using an oxygenated fuel, try to confirm the fuel’s contents. Some areas require
this information to be posted on the pump.
The following are the EPA approved percentages of oxygenates:
ETHANOL ––––––––(ethyl or grain alcohol) 10% by volume
You may use gasoline containing up to 10% ethanol by volume.
Gasoline containing ethanol may be marketed under the name
‘‘Gasohol’’.
MTBE ––––––––––––(methyl tertiary butyl ether) 15% by volume
You may use gasoline containing up to 15% MTBE by volume.
METHANOL ––––––(methyl or wood alcohol) 5% by volume
You may use gasoline containing up to 5% methanol by volume, as
long as it also contains cosolvents and corrosion inhibitors to protect
the fuel system. Gasoline containing more than 5% methanol by
volume may cause starting and/or performance problems. It may
also damage metal, rubber, and plastic parts of your fuel system.
If you notice any undesirable operating symptoms, try another service station, or switch to
another brand of gasoline.
Fuel system damage or performance problems resulting from the use of an oxygenated
fuel containing more than the percentages of oxygenates mentioned above are not
covered under warranty.
Emission Control System Information
30
TECHNICAL & CONSUMER INFORMATION
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.
This utilizes lean carburetor settings and other systems to reduce the emissions of carbon
monoxide, oxides of nitrogen and hydrocarbons.
Tampering and Altering
Tampering with or altering the emission control system may increase emissions beyond
the legal limit. Among those acts that constitute tampering are:
z
z
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.
z
z
z
z
z
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 engine were designed, built. We recommend the
use of 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. Remember that this schedule is based on the
assumption that your machine will be used for its designed purpose. Sustained high-load
31
TECHNICAL & CONSUMER INFORMATION
or high-temperature operation, or use in unusually wet or dusty conditions, will require
more frequent service.
Engine Tune-up
ITEM
SPECIFICATION
Spark plug gap
0.028-0.031 in
(0.70 mm -0.80 mm)
Valve clearance
IN: 0.15 mm±0.02 mm (cold)
EX: 0.20 mm±0.02 mm (cold)
Other specifications
No other adjustments needed
CONSUMER INFORMATION
Publications
These publications will give you additional information for maintaining and repairing your
engine. You may order them from your engine dealer.
Parts Catalog
This manual provides complete, illustrated parts lists.
QUICK REFERENCE INFORMATION
Type
Engine Oil
Spark Plug
Carburetor
Maintenance
Capacity
Type
Gap
Idle speed
Each use
First 20 hours
Subsequent
SAE 10W-30,API SE or SF, for general use
G120F: 0.6 L G160/G200F(D):0.6 L
G240/G270F(D):1.1L
G340/G390/G420F(D):1.1 L
F7RTC or other equivalents.
0.028-0.031 in (0.70 mm-0.80 mm)
1400 rpm±150 rpm
Check engine oil. Check air filter.
Change engine oil.
Refer to the maintenance
32
TECHNICAL & CONSUMER INFORMATION
10. Specifications
Model
Type
Rated
power(kW/3600rpm)
Max. torque(N·m/rpm)
G120F
G160F(D)
G200F(D)
G160F(D)-B
G200F(D)-B
G160F(D)-C
G200F(D)-C
Single cylinder, 4-Stroke, Forced Air Cooling, OHV
2.5
3.1
3.8
3.1
3.8
3.1
3.8
7.5
3000
10.5
3000
13
3000
20
1500
22
1500
20
1500
24
1500
Fuel
consumption(g/kW·h)
≤395
1400±150
Idle speed
SpeedFluctuating Ratio
≤10%
Transmission Mode
-
-
-
Reduction Ratio
-
-
-
Clutch Mode
Chain mode
2:1
Noise(≤)
70db(A)
Bore×Stroke(mm)
60×42
68×45
68×54
68×45
68×54
68×45
68×54
Displacement(cc)
118
163
196
163
196
163
196
Compression Ratio
8.5:1
Splash
Recoil start( Recoil start / Electric starting)
Anti-clockwise(from P.T.O. side)
input valve:0.10 mm ~0.15mm, output valve:0.15 mm ~0.20mm
0.7 mm ~0.8mm
Transistorized magneto Ignition
Semi-dry, Oil bath, Foam filter
Lubricating mode
Starting Mode
Rotation
Valve Clearance
Spark plug clearance
Igniting Mode
Air cleaner
Dimension(Length)
(mm)
Dimension(Width)
(mm)
Dimension(High)
(mm)
Net weight(kg)
305
312
312
391
391
342
342
341
362
376
362
376
362
376
318
335
335
335
335
335
335
13
15(18)
16(19)
19(22)
20(23)
15.5(18.5)
16.5(19.5)
33
TECHNICAL & CONSUMER INFORMATION
Model
G180F(D)
G210F(D)
G240F(D) G270F(D)
G240F(D)-B
G240F(D)-C
G270F(D)-C
Single cylinder, 4-Stroke, Forced Air Cooling, OHV
Type
Rated
power(kW/3600rpm)
Max.
torque(N·m/rpm)
3.2
4.0
5.1
5.8
5.1
5.8
5.1
5.8
11
3000
13
3000
16.5
3000
19
3000
32
1500
37
1500
32
1500
37
1500
Fuelconsumption(
g/kW·h)
≤395
1440±150
Idle speed
Speed
Ratio
G270F(D)-B
Fluctuating
≤10%
Transmission Mode
-
-
Reduction Ratio
-
-
Noise(≤)
Clutch Mode
Chain Mode
2:1
70 db(A)
80 db(A)
Bore×Stroke(mm)
70×46
70×55
73×58
77×58
73×58
77×58
73×58
77×58
Displacement(cc)
177
212
242
270
242
270
242
270
Compression
Ratio
8.5:1
8.2:1
Splash
Lubricating mode
Recoil start( Recoil start / Electric starting)
Starting Mode
Anti-clockwise(from P.T.O. side)
Rotation
Valve Clearance
Spark
clearance
input valve:0.10 mm ~0.15mm,
plug
0.7 mm ~0.8mm
Transistorized magneto Ignition
Igniting Mode
Semi-dry, Oil bath, Foam filter
Air cleaner
Dimension(L×W×
H) (mm)
Net weight(kg)
output valve:0.15 mm ~0.20mm
342×376×335
16(19)
17(20)
380×430×410
25(28)
26(29)
34
440×430×410
29(32)
30(33)
405×430×410
28(31)
29(32)
TECHNICAL & CONSUMER INFORMATION
Model
G340F(D)
Type
Rated
power(kW/3600rpm)
Max. torque(N·m/rpm)
G390F(D)
G340F(D)-D
G390F(D)-D
G420F(D)
Single cylinder, 4-Stroke, Forced Air Cooling, OHV
7
8.3
7
8.3
8.5
23.5
3000
26.5
3000
45
1500
50
1500
28
3000
Fuel
consumption(g/kW·h)
≤395
1440±150
Idle speed
Speed Fluctuating Ratio
≤10%
Transmission Mode
-
-
Gear transmission
Reduction Ratio
-
-
2:1
Noise(≤)
80 db(A)
Bore×Stroke(mm)
82×64
88×64
82×64
88×64
90×66
Displacement(cc)
337
389
337
389
420
Compression Ratio
8:1
Lubricating mode
Splash
Starting Mode
Recoil start( Recoil start / Electric starting)
Rotation
Valve Clearance
Anti-clockwise(from P.T.O. side)
input valve:0.10 mm ~0.15mm, output valve:0.15 mm ~0.20mm
Spark plug clearance
0.7 mm ~0.8mm
Igniting Mode
Air cleaner
Dimension(L×W×H)
(mm)
Net weight (kg)
8.3:1
Transistorized magneto Ignition
Semi-dry, Oil bath, Foam filter
405×450×443
440×450×443
405×452×443
31(34)
33(36)
32(35)
35
WIRING DIAGRAMS
11. Wiring Diagrams
ENGINE SWITCH
IG
E
OFF
O
O
ON
START
ST
BAT
O
O
Bl
Y
W
BLACK
YELLOW
WHITE
Br
R
G
BROWN
RED
GREEN
STARTER
MOTOR
BATTERY
STARTER
SOLENOID
CHARGING
COIL
Bl/W
RECTIFIER
W
FUSE
Br
W
TRANSISTORIZED
IGNITION UNIT
Bl
Br
ENGINE SWITCH
W
Bl
CIRCUIT
BREAKER
Bl
SPARK
PLUG
W
W
Y
Y
OIL LEVEL
SWITCH
Bl
OIL ALERT UNIT
CONTROL BOX
36
WIRING DIAGRAMS
Engine Type with Oil Alert and Without Electric Starting
Bl
Y
G
BLACK
YELLOW
GREEN
TRANSISTORIZED
IGNITION UNIT
ENGINE
SWITCH
SPARK
PLUG
Bl
Y
OIL LEVEL
SWITCH
Bl
Y
OIL ALERT UNIT
37
Y
OPTIONAL PARTS
12. OPTIONAL PARTS
BATTERY
Use a battery rated at 12V, 18Ah or more.
UPPER LEVEL
Do not reverse polarity. Serious damage
to the engine and/or battery may occur.
LOWER LEVEL
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.
Check the electrolyte level to be sure that it is between the marks on the case. If the level
is below the lower mark, remove the caps and add distilled water to bring the electrolyte
level to the upper mark. The cells should be equally full.
38