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DUROMAX XP650WP, Owner'S Manual, Page: 38 / 38

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DUROMAX XP650WP Owner'S Manual Download Page 38

ITEM

PART

QTY

DESCRIPTION

ITEM

PART

QTY

DESCRIPTION

109

DS40-32001

1

ASSEMBLY

, PUMP COVER

123

DS40-32003

1

SUCTION PORT

110

DS40-32015

4

WASHER

124

DS40-32008

2

COUPLING PACKING

111

GB5787-86

4

FLANGE BOLT M8X45

125

DS40-32010

2

HOSE JOINT

112

DS40-32012

1

O-RING, WATER PUMP

126

DS40-32200

2

HOSE COUPLING

113

DS40-30258

1

MECHANICAL SEAL A

127

DS40-32009

1

DISCHARGE GASKET

114

DS40-32038

1

MECHANICAL SEAL B

128

DS40-32004

1

DISCHARGE PORT

115

DS40-32005

1

IMPELLER, WATER PUMP

129

DS40-32016

3

HOSE BAND

116

DS40-32006

1

VOLUTE CASING

130

DS40-32020

1

STRAINER

117

DS40-32011

1

RING, VOLUTE CASING

131

DS40-31100

1

FRAME

118

DS40-32002

1

PUMP CASE HOUS

ING

132

GB6177-86

4

FLANGE NUT M10

119

GB5787-86

12

FLANGE BOLT M10X25

133

GB5789-86

4

FLANGE BOLT M10X35

120

DS40-32050

2

O-RING, PLUG

134

DS40-31203

4

RUBBER PAD, DAMPING

121

DS40-32049

2

PLUG

135

GB5787-86

4

FLANGE BOLT M6X16

122

DS40-32030

1

FLAPPER VALVE GASKET

Summary of Contents for XP650WP

Page 1: ...e maxtool com or call 1 800 629 3325 option 3 Monday Thursday 6am to 7pm Friday Saturday 6am to 3pm PST Product Support Product information application warranty questions support maxtool com or call 1 800 629 3325 option 3 Monday Thursday 6am to 7pm Friday Saturday 6am to 3pm PST ...

Page 2: ...e life of the gasoline water pump CONTENTS ĉ General Safeguards ĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂ 1 Ċ Location of Component Parts ĂĂĂĂĂĂĂĂĂĂĂĂĂ 3 ċ Operation before Starting Up ĂĂĂĂĂĂĂĂĂĂĂĂĂ 4 Č Starting of Engine ĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂ 9 č Use in Highland Areas ĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂ 11 Ď Operation of Water Pump ĂĂĂĂĂĂĂĂĂĂĂĂĂĂ 12 ď Shutting Down the Engine ĂĂĂĂĂĂĂĂĂĂĂĂĂĂ 13 Đ Maintenance ĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂ 14 đ Transpor...

Page 3: ...hazards keep the pump well ventilated during operation and maintain a distance of at least l meter between the machine and the wall or other machines Keep away from inflammable substances Do not allow children and pets to enter the working area as this may increase the chance of their getting burned by hot surfaces of the operating parts Know how to stop the water pump quickly how to operate the c...

Page 4: ...it after refueling When fueling take care not to spill the gasoline about as the gasoline vapor may easily get ignited to cause a fire hazard Be sure to remove the spilled gasoline as by wiping before starting the engine Do not run the engine indoors or in a poorly ventilated space as the exhaust gas produced by the running engine contains toxic carbon monoxide that may cause the loss of personal ...

Page 5: ...5 Ċ Location of Component Parts ...

Page 6: ...fore pumping water attach the filter to the end of the hose to filter out foreign matters in the water the presence of which may cause clogging and damage to the wane wheel NOTE The hose connector and fastener clip should be securely fastened to prevent air leaks and reduction in suction power A loose hose will reduce the pump performance and self suction capacity 2 Connecting the water outlet Con...

Page 7: ...osity according to the local average temperature Oil shortage alarm system OSAS installation position The OSAS is designed to avoid damage of the engine due to the shortage of oil in the crankcase The system will automatically shut down the engine just before the crankcase oil level drops down to the minimum line of safety with the engine switch staying in the ON position If the engine is shut dow...

Page 8: ...e gasoline type is good for minimizing carbon deposits inside the combustion chamber Do not use a mixture of gasoline and oil or dirty gasoline to prevent dirt dust or water from entering the fuel tank CAUTION gThe gasoline fuel is highly inflammable and may explode under certain conditions gDo the fueling with the engine shut down and in a well ventilated environment No smoking is allowed and no ...

Page 9: ...oline or breathing in the gasoline vapor Keep the gasoline out of the reach of children gFuel tank capacity 1 0 gallons US 3 6 liters 5 Checking the air cleaner filter element Screw the wing nut and remove the washer and cleaner cover Check the filter element to see if it is too dirty and clean it if necessary CAUTION Do not run the engine without the air cleaner as this may quicken engine wear if...

Page 10: ...re it is put to operation CAUTION gDo not attempt running the pump without cooling water or the pump will get overheated Extensive running without cooling water may also damage the air tightness of the pump If the pump is found running dry stop the engine and pouring in water when it cools down ...

Page 11: ...ition 2 Close the choke NOTE gThe choke is not required when starting the engine warm or the ambient temperature is rather high i e keep the choke open when starting the engine 3 Set the engine switch to the ON position 4 Turn the throttle control lever slowly to the left ...

Page 12: ...For operation in highland areas the engine performance may be increased by using a smaller diameter carburetor nozzle and readjusting the carburetor idle speed If the water pump is frequently used in areas with a ASL elevation of more than 1800 meters 6000 feet ask the local dealer to replace or readjust the carburetor beforehand Even if the engine is fitted with a carburetor nozzle of an appropri...

Page 13: ...gine performance and overheating of the engine and even cause serious damage to the engine due to an extremely thin air fuel mixture Ď Operation of the Water Pump 1 Gradually open the choke after the engine warms up 2 Set the throttle to the predetermined RPM ď Shutting Down the Engine 1 Set the throttle control lever to the right end ...

Page 14: ... pump working with high performance and regular maintenance may also lengthen the pump life Supplied in the table on the next page are intervals at which the schedules maintenance jobs are to be done WARNING gBefore any maintenance attempt be sure to shut down the engine If the maintenance job has to be done with the engine at work it should take place in a well ventilated space as the exhaust gas...

Page 15: ...y if the pump is used in a dirty environment ł Leave the following inspection and maintenance jobs to the authorized dealers unless you the user have the relevant tools and necessary DIY skills In the latter case refer to service manual Table of Maintenance Schedules Normal maintenance Item period Each time Per month or 20 hours Per month or 50 hours Per month or 100 hours Per month or 300 hours C...

Page 16: ...TE Be sure to keep the environment clean when disposing used engine oil We suggest you collect the waste oil in a container to be sent to a waste disposal site or a recycling service center of spill it in the garbage or on the ground 2 Maintaining the air cleaner A dirty air cleaner will let less air into the carburetor To prevent carburetor malfunctions be sure to maintain the air cleaner periodi...

Page 17: ...ning 3 Immerse the filter element into clean oil and then squeeze out the excessive amount of oil 4 Put the filter element as well as the air cleaner back in place 3 Maintaining the spark plug The recommended type of spark plug is NHSP LD P6RTCU To ensure normal operation of the engine the spark plug should have a correct gap and should remain free of carbon deposits 1 Remove the plug cap The muff...

Page 18: ...al plug gap 0 70 0 80mm 4 Check the plug O ring for normal condition Screw it in with the plug wrench to protect the plug thread NOTE gIn the case of screwing in a new spark plug tighten it by an additional 1 2 screw turn after the plug reaches and pushes on the O ring while in the case of a used spark plug an additional 1 2 1 4 screw turn is necessary CAUTION g Make sure the spark plug is properl...

Page 19: ...ure or dust 2 Ch lean the inside of the pump The pump may get clogged if it is used to suck up water containing such matters as earth sand or heavy fragments Before storing clean the pump by sucking up clean water or otherwise the wane wheel may be damaged when the pump is put to use again After cleaning unscrew the water drain plug to drain off the water from inside the pump casing as much as pos...

Page 20: ...ter lever until a resistance is felt Stop pull for a while and pull it up again until the triangle mark on the starter wheel gets into collimation with the screw hole in the starter as shown the sketch below In this position both the inlet valve and outlet valve is closed to prevent corrosion inside the engine 7 Cover up the pump to keep out dust Ē Troubleshooting Engine unable to get started 1 Is...

Page 21: ... 6 Is the spark plug generating sparks a Uncap the spark plug clear off the dirt from around the plug and remove the spark plug b Fit the spark plug into the plug cap c Turn on the engine with the side electrode and pull up the starter lever to see if there is sparks generated d Ground the engine with the side electrode and pull up the starter lever to see if there is sparks generated e Replace th...

Page 22: ...d 5 Is the suction head too high 6 If the pump still fails to work send it to any of the authorized dealers ē Specifications Type XP652WP XP650WP XP904WP Engine type XP6 5HP XP6 5HP XP9 0HP Max Power 4 7kw 7HP 4 7kw 7HP 6 5kw 9 0HP Displacement 208cc 208cc 270cc Fuel tank capacity 1 0 Gallons 1 0 Gallons 1 7 Gallons Oil capacity 0 63 US Qt 0 63 US Qt 1 16 US Qt ...

Page 23: ...4ą Water output pipe dia 2ą 3ą 4ą Revolution 3600rpm 3600rpm 3600rpm Max overhead lift 92ft 98ft 98ft Max suction lift 26ft 26ft 26ft Max flow rate 158 GPM 220 GPM 427 GPM Size 18 7h15 6h 15 4 in 21 3h17 5h 19 3 in 25 2h20 7h 22 3 in ...

Page 24: ...24 PARTS LIST AND ASSEMBLY XP652WP XP650WP ...

Page 25: ...usting Nut 49 DJ168F 13100 B 1 Camshaft assy 6 DJ168F 13201 A 1 Arm valve rocker 50 DJ168F 12100 W 1 Crankshaft Assembly 7 DJ168F 13006 A 1 Rotator valve 51 DJ170F 12200 B 1 Tie rod Assembly 8 DJ168F 13202 A 2 Fastening Bolt 52 DJ168F 11002 D 1 Pin dowel 7 12 9 DJ168F 13005 A 1 Retainer EX Valve spring 53 DJ170F 11003 B 1 Crankcase Gasket 10 DJ168F 13004 A 1 Retainer IN Valve spring 54 DJ168F 1100...

Page 26: ...14400 A 1 Muffer Assembly 62 DJ170N 15200 A 1 speed adjuster 19 DJ168F 14002 A 2 Bolt head M8 35 63 DJ170N 15201 A 1 Speed Regulating Bar 20 GBT6177 N 8 2 Flange nut M8 64 DJ168F 16200 C 1 Flywheel 21 DJ168F 14001 A 2 Bolt Stud 6 90 65 DJ168F 16002 A 1 Flywheel Fan 22 DJ168F 14003 B 1 Inlet Gasket 66 DJ168F 16000 A 1 Starting Cup 23 DJ168F 14004 A 1 Connecting Block Carbretor 67 GBT6177 N 14 1 Fla...

Page 27: ...ton Ring B 75 DJ168F 15005 A 1 Lock Bolt 32 DJ170F 12304 A 1 Side Ring 76 GBT6177 N 6 3 Flange nut M6 33 DJ170F 12303 A 1 Wave Ring 77 DJ170F 15007 B 1 Back Spring B 34 DJ170F 12304 A 1 Side Ring 78 DJ168F 15006 A 1 Pulling Rod 35 DJ170F 12300 A 1 Scraper Ring Set Piston 79 DJ170F 15008 A 1 Fine Regulating Spring C 36 DJ168F 12003 A 2 Clip piston pin 80 DJ1P65F 14008 A 2 Tube clip 37 DJ170F 12002 ...

Page 28: ...68F 11004 A 2 Drain Plug Washer 42 DJ170F 13009 A 2 Tappet Litter Valve 86 DJ168F 11005 A 2 Washer drain lug 43 DJ170F 11010 C 1 Casket cylinder head 87 DJ170N 14302 A 1 Fuel cock 44 DJ168F 11009 A 2 Set Pin 10 14 88 DJ170N 14300 A 1 Fuel tank 89 GBT5787 B6 16 3 bolt M6 16 90 GBT93 LW 8 2 spring washer ...

Page 29: ...29 XP652WP ...

Page 30: ...scharge gasket 96 DS20 32013 B 1 Mechanical seal B 110 DS20 32004 A 1 Discharge port 97 DS20 32005 A 1 Impeller 111 DS20 32016 A 3 Hose Band 98 DS20 32006 A 1 Case Volute 112 DS20 32020 A 1 Strainer 99 DS20 32011 A 1 O ring seal 113 XP652WP 31100 A 1 Frame 100 DS20 32002 A 1 Pump case housing 114 GB6177 N8 4 Flange nut M8 101 GB5787 B8 25 12 Flange Bolt M8 25 115 GB5787 B8 35 4 Flange bolt M8 35 1...

Page 31: ...31 XP650WP ...

Page 32: ...charge gasket 96 DS30 32013 B 1 Mechanical seal B 110 DS30 32004 A 1 Discharge port 97 DS30 32005 A 1 Impeller 111 DS30 32016 A 3 Hose Band 98 DS30 32006 A 1 Case Volute 112 DS30 32020 A 1 Strainer 99 DS30 32011 A 1 O Ring Seal 113 XP650WP 31100 A 1 Frame 100 DS30 32002 A 1 Pump case housing 114 GB6177 N8 4 Flange nut M8 101 GB5787 B8 25 12 Flange Bolt M8 25 115 GB5787 B8 35 4 Flange bolt M8 35 10...

Page 33: ...33 PARTS LIST AND ASSEMBLY XP904WP ...

Page 34: ...8 7 16001 1 Pulley starter 27 GB6177 86 1 Flange nut M10 8 16002 1 Fan cooling 28 18201 1 O ring 14mm 9 GB6177 86 1 Flange nut M16 29 18200 1 Switch assy oil level 10 11039 1 Clip Wire harness 30 12004 1 Weight balancer 11 16200 1 Flywheel comp 31 12100 1 Crankshaft comp 12 11014 2 Oil seal 35 52 8 32 GB T 99 88 1 Key 13 11100 1 Crank case assy 33 GB T276 94 2 Radial ball bearing 6207 14 11004 2 B...

Page 35: ...aner 68 13004 1 Retainer IN Valve spring 47 14212 2 Nut M6 69 13300 1 Plate push rod guide 48 14209 2 Washer drain lug 70 13202 2 Bolt pivot 49 14201 1 Element assy air cleaner 71 13006 1 Rotator valve 50 14203 1 Separator air cleaner 72 13005 1 Retainer EX Valve spring 51 14204 1 Cover comp air cleaner 73 13201 2 Arm valve rocker 52 11015 1 Bolt head cover 74 13203 2 Nut Arm valve rocker 53 11016...

Page 36: ...arm 87 11003 1 Packing case cover 100 15004 1 Arm governor 88 11002 2 Pin dowel 8 12 101 14300 1 Fuel tank 89 11007 1 Cap assy oil filler 102 GB5789 86 2 Flange bolt M8 25 90 15100 1 Governor kit 103 11013 1 Rubber supporter 91 12003 2 Clip piston pin 104 14008 1 Fuel cock 92 12002 1 Pin piston 105 14007 1 Outlet pipeφ4 5 235 93 12300 1 Ping set assy piston 106 14026 1 Joint fuel tank 94 12001 1 P...

Page 37: ...37 ...

Page 38: ...DISCHARGE GASKET 114 DS40 32038 1 MECHANICAL SEAL B 128 DS40 32004 1 DISCHARGE PORT 115 DS40 32005 1 IMPELLER WATER PUMP 129 DS40 32016 3 HOSE BAND 116 DS40 32006 1 VOLUTE CASING 130 DS40 32020 1 STRAINER 117 DS40 32011 1 RING VOLUTE CASING 131 DS40 31100 1 FRAME 118 DS40 32002 1 PUMP CASE HOUSING 132 GB6177 86 4 FLANGE NUT M10 119 GB5787 86 12 FLANGE BOLT M10X25 133 GB5789 86 4 FLANGE BOLT M10X35...

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