Banjo 222 Series User manual

CAST IRON SELF-PRIMING CENTRIFUGAL PUMPS
INSTRUCTION MANUAL
BANJO CORPORATION | A Unit of IDEX Corporation
150 Banjo Drive, Crawfordsville, IN 47933 U.S.A.
banjocorp.com | Telephone: [phone]
BANJOCORP.COM
2″ 222 SERIES
3″ 333 SERIES
4″ 444 SERIES

CONNECT WITH CONFIDENCE™2
OPERATION WARNING
Do not operate the gas engine (if so equipped)
until you have put oil in the engine. Do not run the
pump dry. Serious damage to the mechanical seal
or complete failure of the mechanical seal can result
from running the pump dry. Always ll the pump with
water or the liquid being pumped before starting the
drive unit.
WARNING! DO NOT USE WITH
FLAMMABLE LIQUIDS.
Do not use ammable liquids. This pump is not
designed or produced to pump ammable liquids of
any kind. Failure to follow this warning can result in
explosion, serious bodily injury or death.
OVERVIEW
Read these instructions and the instructions covering operation of the pump drive unit.
The gas engine (if so equipped) is shipped with no oil. Consult your owners manual for specic oil recommendations, maintenance
procedures, schedules, and troubleshooting. The maximum angle of operation for gas engine drive units is 25° in all directions. For
engine warranty service contact your local engine dealer.
Make certain that all hose and pipe connections are airtight. An air leak in the suction line may prevent priming and will reduce the
performance of the pump.
Do not restrict the pump inlet. High volume pumps such as the Banjo 444 Series pumps should not have the inlet port or line
restricted. If the pump is equipped from the factory with a 4″ inlet ange, the pump should be plumbed with a 4″ inlet line. If the pump
is equipped from the factory with a 3″ inlet ange, the pump should be plumbed with a 3″ inlet line. If the pump is equipped from the
factory with a 2″ inlet ange, the pump should be plumbed with a 2″ inlet line. Failure to follow these instructions can result in pump
cavitation and pump failure.
Always place the pump as close to the liquid to be pumped as possible. Keep the suction line short and with few bends. Keep the
pump and engine on a level foundation. A poor foundation and a heavy suction hose (made heavier when ″primed″ full of liquid) could
result in a pump ″down the hole″. It is not necessary to drain the pump body after use, unless there is a danger of freezing.
There are no points on the pump that need lubrication. The pump seal is cooled and lubricated by the uid being pumped. When
pumping dirty water or liquids containing solids, always use a basket strainer on the end of the suction line.
Engine warranty service available at authorized Honda & Briggs and Stratton Dealers.
*Note: Do NOT operate pump without the supplied EPA approved fuel tank and lines.
WARNINGS
STORAGE WARNING
There are important instructions regarding the
preparation of the engine for long periods
without use (reference the engine owners manual).
Before long periods of storage, the pump should
be ushed with clean water and drained. Leave all
plugs (ll and drain) out of the pump. Always store
the pump in a heated and dry building.

CONNECT WITH CONFIDENCE™3
3″ CAST IRON PUMPS
4″ CAST IRON PUMPS
2″ CAST IRON PUMPS
Port Size
Suction....................................... 2″ NPT
Discharge .................................. 2″ NPT
Port Size
Suction....................................... 3″ NPT
Discharge .................................. 3″ NPT
Port Size
Suction....................................... 4″ NPT
Discharge .................................. 4″ NPT
PERFORMANCE
0
5
10
15
20
25
30
35
40
45
50
205 175 134 97 69 29 0
FLOW (GPM)
0
20
40
60
80
100
120
Pressure (PSI)
Head (FT)
FLOW CHART
FLOW CHART FOR 333PIH13 & 333PBI
FLOW CHART FOR 444PIH24 & 444PBI
FLOW CHART FOR 222PIH5, 222PI6PRO & 222PBI

CONNECT WITH CONFIDENCE™4
222 SERIES 333 & 444 SERIES
DISASSEMBLY INSTRUCTIONS:
Remove the (6) bolts (222: 12715A, 333/444: V20011SS) and lock
washers (222: V10118, 333/444: V20018) that hold the pump body
assembly onto the rear bracket. Remove the body from the remaining
pump assembly.
21
3 4
Remove the (4) bolts (222: 12715A, 333/444: 18027) and lock
washers (222: 12901, 333/444: V20018) that hold the rear bracket
to the drive unit. With the 4 bolts removed, the rear bracket can be
removed from the drive unit. With the pump completely disas-
sembled, clean all of the reusable parts thoroughly removing any
traces of gasket material with a scraper or wire brush. Remove any
corrosion on the sealing surfaces of the pump components.
5
222 SERIES 333 & 444 SERIES
222 SERIES 333 & 444 SERIES
222 SERIES 333 & 444 SERIES
222 SERIES 333 & 444 SERIES
NOTE:
If bracket shims have been installed from the factory,
the same number of shims will need to be reinstalled
Remove the impeller bolt (222: 12765A, 333/444: 16765) from the
impeller (222: 15772, 333/444: 16772). Remove the impeller bolt
gasket from the impeller.
Remove the cup seal half from the rear bracket. This may be done
by using a round object such as a socket and tapping it with a
hammer as shown in the photo. If necessary, remove the inlet and
outlet anges, the ange gaskets by removal of the ange screws
and lock washers.
65
222, 333 & 444 SERIES
Remove the (3) bolts (222: 12715A, 333/444: V20011SS) and lock
washers (222: V10118, 333/444: V20018) holding the volute to the
rear bracket. Remove the volute (222: 15702, 333/444: 16702) from
the remaining pump assembly. Replace checkvalve if needed.
Screw the supplied (222: 7/16″-14, 333/444: 9/16″-12) hex head cap
screw (16099) into the threaded hole in the impeller. As it tightens,
the impeller will pull off the shaft. Remove the hex head cap screw
once the impeller is removed. If reusing the pump impeller, remove
the primary ring of the seal (222: 12733V, 333/444: 16713) and the
impeller key (222: 12902A, 333/444: 16901).

CONNECT WITH CONFIDENCE™5
ASSEMBLY INSTRUCTIONS:
TOOLS REQUIRED:
222: 5/16″ Box End Wrench, 5/16″, 13/16″ & 5/8″ Socket
333/444: 9/16″ Box End Wrench, 9/16″, 13/16″ & 5/8″ Socket, Ratchet with 3″ Extension, Gasket Scraper or Wire Brush, Locktite 242 and Locktite Gasket Adhesive #2
If shims were installed between the engine and rear bracket from
the factory, install these shims now. Use the same number of shims
as were originally in the pump from the factory. Install the rear
bracket with the handle oriented toward the top of the drive unit.
222: Install 4 bolts, plain washers, and o-rings. Use LOCTITE®
Threadlocker Blue 242®on these bolts due to the heat and vibration
caused by the engine. Tighten to 12 ft-lb.
333/444: Install 4 bolts and lock washers. Use LOCTITE®
Threadlocker Blue 242®on these bolts due to the heat and
vibration caused by the engine. Tighten to 20 ft-lb.
To install the cup half of the seal into the rear bracket, use a tool
such as a 1″ socket (222) or a 1 5/8″ 12-point socket (333 / 444) to
give even pressure on the metal ange of the seal housing during
installation. The seal should be pressed into its bore. Do not strike
the seal with a sharp blow such as from a hammer. Do not
press on the sealing face. Sealing faces are brittle and may
fracture from impact.
222 SERIES 333 & 444 SERIES
222 SERIES 333 & 444 SERIES
Place the seal O-ring behind the lip of the cup half of the seal. The
cup half of the seal should now be installed into the rear bracket.
2
3
1
222 SERIES 333 & 444 SERIES
222 SERIES 333 & 444 SERIES
4
Install the primary ring seal half into the impeller. The seal half is
pressed into the hub of the impeller by using both thumbs. The
outside diameter of the primary ring may be sparingly coated with
silicone to ease installation. The lapped or polished seal face must
be installed face up.
Be absolutely sure that the primary ring seal half is bottomed
out and installed squarely. If the installation is not square,
seal wobble will occur leading to seal failure. Care must be
used when handling the seal not to scratch or crack the seal
surface. Sealing faces must be kept oil and contaminant free.

CONNECT WITH CONFIDENCE™6
ASSEMBLY INSTRUCTIONS:
222, 333 & 444 SERIES 222, 333 & 444 SERIES
6A: Place the main pump body O-ring on the outside ange of the
rear bracket.
6B: Install the volute onto the rear bracket using 3 bolts and lock
washers. Tighten the bolts to 12 ft-lb (222) or 20 ft-lb (333 / 444).
We strongly recommend using LOCTITE
®
Threadlocker Blue 242
®
on these bolts due to the heat and vibration caused by the engine.
There should be 0.080″ to 0.100″ clearance between the impeller
face and the volute face. If the minimum clearance is not achieved,
a shim will have to be installed between the rear bracket and the
drive unit to achieve the proper clearance. If clearance is greater than
the maximum, a shim will have to be installed in the impeller bore to
achieve the proper clearance.
222, 333 & 444 SERIES 222, 333 & 444 SERIES
5A
5A: The impeller is now ready to be slid onto the drive shaft unit. Be
sure to align the impeller key with the keyway of the drive unit shaft.
5B: Secure the impeller to the drive unit shaft with the impeller
boltgasket or O-ring and the impeller bolt. Tighten the impeller bolt
to 12 ft-lb (222) or 45 ft-lb (333 / 444). The impeller bolt will pull the
impeller into its nal position on the drive unit output shaft.
222, 333 & 444 SERIES 222, 333 & 444 SERIES
7A
7A. Install the volute gasket as shown on the volute. We strongly
recommend a light coating of gasket sealant, such as LOCTITE®
Gasket Sealant #2, be applied between the gasket and the volute.
The gasket sealant will ensure a good seal between the gasket and
the mating cast iron parts. This seal is critical to having the pump
prime well.
7B. Place the main pump body gasket on the outside ange of the
rear bracket. The gasket should be aligned with and placed over the
two dowel pins on the rear bracket. The gasket may be lubricated
with ChapStick®or petroleum jelly. Lubricating the gasket in this
manner will help it not to stick to the cast iron parts it is sealing
against.
7B
6A 6B
O-ring
222, 333 & 444 SERIES
Install the pump body onto the rear bracket aligning the pump body
with the dowel pins on the rear bracket. Secure the pump body to
the rear bracket with six bolts and lock washers. Tighten the bolts to
12 ft-lb (222) or 20 ft-lb (333 / 444).
Pump is ready for operation.
8
5B

CONNECT WITH CONFIDENCE™7
TROUBLESHOOTING GUIDE:
1. GAS ENGINE WILL NOT START.
a. Verify that there is no external damage to the engine.
b. Verify that engine has the manufacturer’s recommended amount and grade of oil in the engine.
c. Verify that the engine gas tank has been lled with a minimum of 87 octane unleaded gasoline. Verify that the
gasoline is fresh and clean.
d. Verify that the spark plug wires are properly connected to the spark plugs.
e. Verify that the battery cables are tight and properly connected to both the battery and engine.
f. Verify that the battery is fully charged and in good condition.
g. Review starting procedures and/or trouble-shooting guide in engine owners manual.
h. Contact the engine manufacturer for warranty assistance and repair information.
Honda®:800-426-7701 | www.honda.com
Briggs and Stratton®:414-259-5262 | www.briggsandstratton.com
2. PUMP WILL NOT PRIME.
a. Verify that the pump is lled with uid prior to start up via the ll hole located on the top of the pump.
b. Verify that the uid is not being lifted more than 15 vertical feet.
c. Verify that there are no kinks in the suction line.
d. Verify that the pump inlet or suction line is not clogged.
e. Verify that the suction line does not have any vacuum leaks at any of the connections.
f. Verify that the pump is operating at a minimum of 3450 RPM for lifting and self-priming applications. Banjo pump will
not prime while operating below 1750 RPM.
g. Verify correct pump rotation if an electric motor or hydraulic motor is being used. A counter clockwise rotation
(right hand rotation) is required from the motor.
h. Verify that the impeller spacing is no more than 0.100″.
3. PUMP LOOSES PRIME DURING OPERATION.
a. See 2B above.
b. See 2C above.
c. Verify that the pump inlet or suction line is not clogged.
d. Verify that the suction line does not have any vacuum leaks at any of the connections.
e. Verify that the pump is operating at a minimum of 3450 RPM for lifting and self-priming applications.
Banjo pump will not prime while operating below 1750 RPM.
4. ENGINE RUNS BUT PUMP DOES NOT TRANSFER LIQUID.
a. Verify that the pump is operating at a minimum of 1750 RPM. Banjo pumps may not operate below this RPM.
b. Verify correct pump rotation if an electric motor or hydraulic motor is being used. A counter clockwise rotation
(right hand rotation) is required from the motor.
c. Verify that the impeller spacing is no more than 0.100″.
d. Verify that the impeller is secured to the engine shaft with a shaft key. This verication can be done by turning the
impeller (via the impeller bolt) on the pump by using a 5/8″ socket attached to a 6″ extension. If the impeller turns
without spinning drive unit impeller, the shaft key is broken or missing. Replace shaft key.
e. Verify that the customer does not have any kinks in the suction or discharge lines.
f. Verify that the pump inlet, outlet, suction line or discharge line is not (partially) blocked.
g. Verify all plumbing system valves are open.
(Continued on next page)

CONNECT WITH CONFIDENCE™8
5. MOTOR RUNS BUT PUMP DOES NOT PERFORM ADEQUATELY.
a. Verify that the pump is operating at a minimum of 1750 RPM. Banjo pumps may not operate below this RPM.
b. Verify correct pump rotation if an electric motor or hydraulic motor is being used. A counter clockwise rotation
(right hand rotation) is required from the motor.
c. Verify that the impeller spacing is no more than 0.100″.
d. Verify that the impeller is secured to the engine shaft with a shaft key. This verication can be done by turning
the impeller (via the impeller bolt) on the pump by using a 5/8″ socket attached to a 6″ extension. If the impeller
turns without spinning drive unit impeller, the shaft key is broken or missing. Replace shaft key.
e. Verify that the customer does not have any kinks in the suction or discharge lines.
f. Verify that the pump inlet, outlet, suction line or discharge line is not (partially) blocked.
g. Verify all plumbing system valves are open.
6. ENGINE BOGS DOWN DURING PUMP OPERATION / ELECTRIC MOTOR TRIPS CIRCUIT BREAKER DURING
START UP OR OPERATION.
a. Verify that the customer does not have any kinks in the suction or discharge lines.
b. Verify that the pump inlet, outlet, suction line or discharge line is not (partially) blocked.
c. Verify that the impeller spacing is no less than .080″. The impeller should not be touching the wear plate/volute.
d. Verify the weight of uid being transferred. Make sure that the drive unit is properly sized for the pump and its
application.
7. GRINDING, TICKING OR WHIRRING SOUND DURING PUMP OPERATION THAT IS UNUSUAL.
a. Verify that the impeller bolt has not loosened, letting the impeller pull itself into the volute. The impeller spacing
should be no less than .080″. The impeller should not be touching the wear plate/volute.
b. Verify that outside diameter is not hitting the pump housing or volute. Slowly rotate the pump several times by hand.
If you can feel the pump dragging on the housing or volute or hear a scraping sound, the impeller may be hitting the pump
body or volute. The impeller can be removed from the pump and led down or trimmed down slightly on a lathe.
c. Remove the pump housing and inspect for internal debris such as rocks, sticks or other foreign material stuck inside
of pump. With the pump housing and volute removed, you can then inspect the impeller face and outside diameter for
signs of contact between the impeller and other pump components.
8. PUMP/ENGINE RUNS TEMPORARILY, THEN STOPS. THE PUMP/ENGINE WILL NOT RESTART.
a. Verify that there is no external damage to the engine.
b. Verify that engine has the manufacturer’s recommended amount and grade of oil in the engine.
c. Verify that the engine gas tank has been lled with a minimum of 87 octane unleaded gasoline. Verify that the
gasoline is fresh and clean.
d. Verify that the spark plug wires are properly connected to the spark plugs.
e. Verify that the impeller bolt has not loosened, letting the impeller pull itself into the volute. The impeller spacing
should be no less than .080″. The impeller should not be touching the wear plate/volute.

CONNECT WITH CONFIDENCE™9
GX630 • GX660 • GX690 Technical Manual
© 2009 American Honda Motor Co., Inc — All Rights Reserved 7
FUEL SYSTEM
This engine is supplied with an incomplete fuel system (no fuel tank, no fuel hose, etc.). As such, the OEM is
responsible for ensuring evaporative emission regulations are met. See page 31 and the Emissions Regulations Guide
for additional information.
Fuel Tank Position
The fuel tank must be installed so that its maximum gasoline level is within 50 cm (19.5 in) above or below the
carburetor gasoline level.
Fuel Line
Use a low permeation fuel line (displaying an Executive Order number) rated for use with gasoline. The fuel line should
have an inside dimension of 5.5 mm (0.22 in). Keep the fuel line as short as possible. Install the fuel line so it will not
rest against any sharp objects or make sharp bends that can restrict the flow of fuel. If the fuel line passes through an
enclosure wall, protect the line with a rubber grommet. Secure the fuel line with the appropriate clamping mechanism.
Route the fuel line away from hot engine and exhaust system components and away from electrical wiring. Secure the
fuel line to prevent sagging and bending.
Fuel Valve
Install the fuel valve so it is easily accessible. Install the fuel valve at the outlet of the fuel tank and use an easily read
label to indicate valve location and operation. If under the fuel tank is not the ideal location, securely install the fuel
valve in-line with the fuel tube in a cool location, so that engine heat cannot cause vapor lock.
Fuel Pump
A fuel pump should be selected that provides an operating pressure of 0.1 kgf/cm2(1.4 psi) and delivers 15 liters/hr
(4.0 US gal/hr). The carburetor inlet float valve has a closing pressure of 0.2 kgf/cm2(2.8 psi). If a secondary fuel pump
is used, its operating pressure must not exceed the standard fuel pump’s operating pressure (to prevent carburetor
flooding).
Fuel Tank Filter Installation
It is recommended that a fuel tank strainer with a mesh rating of #80 be installed at the fuel tank inlet to catch debris
when refueling. It is also recommended that a fuel tank sump be provided at the fuel tank outlet to reduce the chance of
contaminants entering the fuel system.
Fuel-cut Solenoid
The fuel-cut solenoid on the carburetor takes power from the battery and there is continuity in the solenoid when the
engine is running. Removing the battery when the engine is running will cause the engine to stop.
CONTROLS
Engine Switch
Use a three-position engine switch with continuity between its terminals as shown.
Wire Color IGN
(Bl)
GND
(G)
BAT
(W)
LO
(Bl/Y)
ST
(Bl/W)
Switch Position
OFF
ON {{{{
START {{{{{
GX630 • GX660 • GX690 Technical Manual
© 2009 American Honda Motor Co., Inc — All Rights Reserved 7
FUEL SYSTEM
This engine is supplied with an incomplete fuel system (no fuel tank, no fuel hose, etc.). As such, the OEM is
responsible for ensuring evaporative emission regulations are met. See page 31 and the Emissions Regulations Guide
for additional information.
Fuel Tank Position
The fuel tank must be installed so that its maximum gasoline level is within 50 cm (19.5 in) above or below the
carburetor gasoline level.
Fuel Line
Use a low permeation fuel line (displaying an Executive Order number) rated for use with gasoline. The fuel line should
have an inside dimension of 5.5 mm (0.22 in). Keep the fuel line as short as possible. Install the fuel line so it will not
rest against any sharp objects or make sharp bends that can restrict the flow of fuel. If the fuel line passes through an
enclosure wall, protect the line with a rubber grommet. Secure the fuel line with the appropriate clamping mechanism.
Route the fuel line away from hot engine and exhaust system components and away from electrical wiring. Secure the
fuel line to prevent sagging and bending.
Fuel Valve
Install the fuel valve so it is easily accessible. Install the fuel valve at the outlet of the fuel tank and use an easily read
label to indicate valve location and operation. If under the fuel tank is not the ideal location, securely install the fuel
valve in-line with the fuel tube in a cool location, so that engine heat cannot cause vapor lock.
Fuel Pump
A fuel pump should be selected that provides an operating pressure of 0.1 kgf/cm2(1.4 psi) and delivers 15 liters/hr
(4.0 US gal/hr). The carburetor inlet float valve has a closing pressure of 0.2 kgf/cm2(2.8 psi). If a secondary fuel pump
is used, its operating pressure must not exceed the standard fuel pump’s operating pressure (to prevent carburetor
flooding).
Fuel Tank Filter Installation
It is recommended that a fuel tank strainer with a mesh rating of #80 be installed at the fuel tank inlet to catch debris
when refueling. It is also recommended that a fuel tank sump be provided at the fuel tank outlet to reduce the chance of
contaminants entering the fuel system.
Fuel-cut Solenoid
The fuel-cut solenoid on the carburetor takes power from the battery and there is continuity in the solenoid when the
engine is running. Removing the battery when the engine is running will cause the engine to stop.
CONTROLS
Engine Switch
Use a three-position engine switch with continuity between its terminals as shown.
Wire Color IGN
(Bl)
GND
(G)
BAT
(W)
LO
(Bl/Y)
ST
(Bl/W)
Switch Position
OFF
ON {{{{
START {{{{{

© Copyright 2018 Banjo Corporation. All Rights Reserved.
BJO_MAN_KK-83_222_333_444_PolyPumpManual_Rev0918
BANJO CORPORATION
A Unit of IDEX Corporation
150 Banjo Drive
Crawfordsville, IN 47933 U.S.A.
Telephone: [phone]
Tech Sales: [phone]
Fax: [phone]
banjocorp.com
Please see banjocorp.com for more information
GX630 • GX660 • GX690 Technical Manual
© 2009 American Honda Motor Co., Inc — All Rights Reserved 31
EVAPORATIVE EMISSIONS (CARB TIER 3)
The OEM is responsible for meeting the CARB EVAP emissions regulations for products sold in California. This
regulation concerns evaporative emissions from the fuel system. See the Emission Regulation Guide for additional
details.
Shown below is a simplified overview of required components.
Additional information regarding manufacturers of CARB certified fuel system components can be found at:
http://www.arb.ca.gov/msprog/offroad/sore/sorecomponent/sorecomponent.htm#.
CHARGE TUBE (BREATHER)
The charge tube should be
located as high as possible in
the fuel tank. Fuel should not
flow through the charge tube
during regular use or during
transportation
FUEL FILTER
CARBON CANISTER
Install the carbon canister so
that the intake port will not be
affected by the dynamic
pressure of cooling air.
PURGE TUBE
Maximum length: 80 cm. PURGE JOINT
Connect the purge tube to the joint on
the dirty side of the air cleaner.
Joint outer diameter: 11 mm
FUEL TUBE
Use approved low permeation
fuel tube between the filter
and the fuel tank.
AIR OR EXHAUST GAS
FUEL VAPOR
FUEL VALVE
FUEL CAP (SEALED)
(must be tethered and have positive
feedback mechanism for closure.)