Katsu Power DCA 22 User manual

Owner Manual DCA Water Pumps

6
STORAGE Unscrew the drain plug to allow all the water in the pump to drain out.
Make sure the pump is empty before replacing the drain plug.
Storage
When pump is out of service for long periods, drain it and store in a dry,
and well ventilated room.
Pull engine cord until compressed time so valves are sealed (Never run
pump dry for more than half a minute or mechanical seal may be damaged).
Warning
To avoid a fire, make sure that the engine is cool before transportation or
storage.
Transport the pump with the fuel cock turned off, besides, keep it horizontal
position to prevent spilling.
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The storage place should be dry and free of humidity.
Clean the water pump inside. If the pump is used to pump water with mud,
sand or heavy debris, deposit of that material may remain inside it.
Empty fuel inside the fuel tank.
Set the fuel cock to OFF, unscrew the fuel drain plug of the carburetor
floater room, drain out the fuel in the carburetor. Hold drained gasoline in
a proper container.
Set the fuel cock to ON.
Reinstall the fuel drain plug of the carburetor floater room
Remove the engine oil.
Pull the starter handle towards until resistance is felt, and then continue
pulling until the triangle mark on the starter wheel lines up with the starter
screw hole. In this location, both the air inlet and exhaust valves are
closed.
Triangle mark on the starter wheel lines up with the starter screw hole.
The self-priming DCA Series pumps are designed to operate efficiently for
OWNER MANUAL DCA KAT S U P O W E R WAT E R P U M P S OWNER MANUAL DCA KAT S U P O W E R WAT E R P U M P S
!CAUTION
The engine must be filled with oil before starting, don’t forget to read engine
manual for this procedure.
Do not use pump in explosive atmosphere, Do not pump volatile or flammable
liquids.
Draining: During freezing temperature weather, be sure to drain pump when
it is not in use. Reinstall the fuel drain plug
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Unscrew the drain plug
Close the fuel cock (set to OFF)
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MAINTENANCE years, but like all other machinery, they require regular inspection and
care.
The purpose of regular inspection and maintenance is to prevent
breakdowns and to obtain the longest service life possible.
This pump does not need external lubrication, because the liquid that is
being pumped lubricates the internal parts.
You should periodically inspect the complete installation to find any leaks,
or other problems..
You should clean the whole unit periodically.
If you notice any internal noise, consult immediately with the technical
service.
Protect engine against heat, dirt and moisture. Protect the engine, from the
sun, provide ample cross ventilation. Keep engine vents and surrounding
area clean. Avoid sweeping or stirring up dust near the engine while it is
running. Avoid storing (or spilling) pool chemicals near the engine.
Provide protection from rain, snow, lawn sprinklers etc. Avoid splashing
water near the engine.
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Close the fuel cock (set to OFF).
Running the engine
High suction lifts require high engine speed and low lifts require a lower
engine speed. Therefore, on shallow lifts or when there is little liquid to
pump, save fuel by reducing the engine's speed (See engine manual).
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Close the fuel cock (set to OFF)
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Release the start handle gently instead of suddenly to protect
the starter from being damaged.
!CAUTION
Starting up in high altitude regions
In high altitude places, standard carburetor produces a dense mix of fuel and
air, resulting in decreases in the engine performance and increased fuel
consumption. To keep the engine with high performance, install a carburetor
main spray nozzle and readjust the idle speed screw.
Contact your dealer for replacing the carburetor and to make adjustments in
advance. Even with a proper nozzle modification on the engine, the engine
power output will decrease about 3.5% with each 305m over sea level.
Opera t i n g i n s t r u c t i o n s
Start and warm up the engine, and then close the choke gradually.
Set the throttle valve in accordance with specified rational speed.
Stopping
Move throttle handle to the extreme right end.
Set the engine switch to OFF.
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Once a carburetor was changed to used in high altitud places.
Operation at lower altitudes may cause serious engine damage
!CAUTION
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Set the engine switch to OFF
Move the throttle valve to the right
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Before maintenance and service, turn off the engine. If the engine should
run, make sure that the engine is in a well-ventilated area. Exhaust
emissions from the engine contains toxic carbon monoxide (CO2), which
may cause loss of consciousness and even life.
Only use genuine KATSU POWER parts and specified
maintenance tools or the water pump may be damaged.
!CAUTION
17
NOTE
(1) Use in extremely dusty area, the job
should be done more often.
(2) Should be done by your dealer, unless
you are equipped with proper repair tools,
and are proper trained and are qualified
mechanically.
FRECUENCY EACH WHICHEVER COMES FIRST
TIME ITEMS
OIL LEVEL O
OIL CHANGE O
AIR CLEANER CHECK O
CHANGE O(2)
EVERY 100 HOURS RUNNING-LEAN
EVERY TWO YEAR REPLACE O(2)
O(2)
SPARK PLUG
VALVE CLEARANCE ADJUSTMENT
CLEAN COMBUSTION CHAMBER
SPARK ELIMINATOR
FUEL SUPPLY PIPE
IMPELLER CHECK
WATER PUMP TANK COVER
WATER INLET VALVE CHECK O(2)
FIRST MONTH
OR 20 HOURS EVERY 3 MONTH OR 50 HOURS EVERY 6 MONTH
OR 100 HOURS EVERY YEAR
OR 300 HOURS
ENGINE OIL CHECK O
O(1)
O(1)
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Note
Use in extremely dusty area, the job should be done more often.
Should be done by your dealer, unless you are equipped with proper repair
tools, and are proper trained and are qualified.
Engine oil replacement
A warm-up engine can assure quick oil draining.
Remove the dipstick and oil drain plug, and then drain the oil.
Reinstall the dipstick and tighten it.
Fill specified fresh engine oil to oil level mark.
Oil capacity: 0.6 lts
Note
Handle discarded engine oil in accordance with the local environmental
protection rules.
Air Cleaner Maintenance
A filthy air cleaner will decrease airflow quantity through the carburetor.
To avoid carburetor troubles, clean the air cleaner regularly. In extremely
dusty area, the job should be done more often.
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Remove the dipstick
Fill specified engine oil
Air cleaner filter element check
Dismantle the thumbnut, washer and air cleaner cover.
Check the filter element, if too filthy or clogged, clean it.
!CAUTION
Gasoline is extremely inflammable and explosive in certain conditions
Refuel in a well-ventilated area with the engine stopped. Do not allow flames
or sparks in the storage area.
Do not spill fuel out of the fuel tank, after refueling make sure to tighten the
fuel tank cap securely.
If the gasoline was spilled, be sure to wipe it dry before starting the engine.
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Start up
Starting up
Open the fuel cock (set it at ON)
Close the choke.
NOTE
Starting up under high air temperature or in warm engine, do not use the
choke, don't close it before starting up.
Set the engine switch at ON
Move the throttle valve level slowly to the left.
Pull the start handle gently until resistance is felt, and then pull it up
quickly.
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Set the engine
switch at ON
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Move the throttle valve to the left
Pull the start handle
Close the fuel cock (set to ON)
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Check the spark plug just with eyes. If there exists obvious wear sign
around it or gasket is cracked, please replace with a new one. Before
reinstalling a spark plug, clean it first with a wire brush.
Measure spark plug clearance with a feeler gauge and adjust it by bending
the side electrode, spark plug clearance should be 0.70~0.80mm.
Check the spark plug gasket, if necessary or replace it with a new one.
Tighten it into the engine with a spark plug wrench to protect thread from
being damaged.
Note
Installing a new spark plug, screw ½ more turns, after that the spark
touches the washer.
!CAUTION
Be sure to tighten the spark plug securely, otherwise it may become very hot
and possibly damage the engine. Never use a spark plug with improper heat
range.
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Unscrew the spark plug
Measure spark plug clearance
0.7-0.8 mm
Dismantle the spark plug cap
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BEFORE STARTING
A suction strainer should be attached to the suction hose or pipe to prevent
large solids to damage the impeller.
Keep the strainer clean, and if possible, lift it away from the sediment.
NOT RECOMMENDED
Do not operate the pump without liquid otherwise serious damage could occur.
Many pump components depend on the liquid for lubrication.
Consult the maintenance section of this manual for lubrication instructions
before operating the pump.
!CAUTION
NOT RECOMMENDED
The quality of the engine oil is one of the key factors in deciding engine
performance and service life. Do not use filthy engine oil or vegetable oil.
Be sure to check engine oil level with the engine stopped and stand vertically
in level ground.
!CAUTION
Use 4-stroke engine oil or equivalent to meet with API requirements,
classification SF, SG.
Oil viscosity varies with average temperature, so select engine oil with
proper viscosity in accordance with your region temperature. 09
SAE
TEMP -20 0 20 40 60 80 100F-20
-30
5W-30
10W-30
30
-20 -10 10 20 300 40 C
0
An strainer should be attached Engine oil level check
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+Engine oil alarm system (installation location)
The engines oil alarm system was designed to avoid engine damage due to
oil low level in the crankcase. Before the engine oil level in the crankcase
drops down below the safety line, the alarm system will stop the engine
automatically (while the engine switch is ON).
If the engine stops and cannot restart, check the engine oil level.
Remove the engine oil dipstick and wipe it clean; insert into engine oil
filler hole without screwing it in, and then take out to check the engine oil
level; if the engine oil level is too low, fill specified engine oil up to the
top of the filler hole.
Engine fuel level check.
Remove the fuel tank cap and check the fuel level. If the fuel level is too
low, refuel it.
Only use specified gasoline or use clean fresh Lead-free gasoline with a
minimun of 77 octane. Leaded gasoline may be used if it is commercially
available and if unleaded 15 unavailable.
Do not use the combination of engine oil and gasoline or filthy gasoline.
Avoid dirt, dust and water into the fuel tank.
Fuel tank capacity: 3.6 lts
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10 Fill the engine check
Engine oil level check
Upper level mark
Warning
Never clean the air cleaner in gasoline or low-flash point solvent, for
gasoline and low-flash point solvent may produce flames and even an
explosion in certain conditions.
Caution
Never operate the water pump without the air cleaner installed. In the case
that dirt and dust is sucked into the engine, the engine will wear out more
quickly.
Unscrew the thumbnut and dismantle the air cleaner cover and filter
element.
Clean the filter element in high flash point solvent or cleansing solvent
thoroughly, and then dry it up.
Soak the filter element in clean engine oil, and then squeeze out excessive
oil.
Reinstall the removed parts well.
Spark plug maintenance
Spark plug recommended: NHSP LD F6RTCU
To keep the engine in good condition, you must keep proper spark plug
clearance and no accumulated carbon.
Dismantle the spark plug cap.
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Dismantle the air cleaner cover
and filter element
OWNER MANUAL DCA KAT S U P O W E R WAT E R P U M P S OWNER MANUAL DCA KAT S U P O W E R WAT E R P U M P S

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Open the fillings plug, and fill the pump casing. To fill the pump casing it
is necessary to use one to 3 gallons of water (depending on the pump
model).
When there is no plug in the elbow, fill the casing through the discharge
connector. It may be necessary to disconnect the quick connect on the
discharge hose to fill the casing.
Fill the pump with water completely to force all air out.
Slowly rotate the shaft to allow any air trapped in the impeller to escape.
When all air has been forced out of the pump, replace the filling plug. Use
pipe joint compound on plug threads and tighten as necessary to prevent
leakage.
Open the filling plug
Fill the pump with water
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PRIMING
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The pump must be primed before starting. Follow the instructions
given below:
NOT RECOMMENDED
Suction hose sloping downward to pump inlet will trap air which will reduce
performance and may cause pump to lose priming.
An undersized hose will create excess friction losses that may cause
cavitation and pump’s performance reduction.
Excess fittings and bends in the suction line results in trapped air,
bad performance and high friction losses.
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Be sure strainer is not clogged.
There are no clogged or out of adjustment parts or valves. The only
requirement is that the pump casing is full with liquid.
Keep your pump unit clean and properly serviced. Care in this matter will
repay in many years of trouble-free operation.
The suction hose must be kept free of air leaks, particularly when the suction line is
long and the static suction is high. It is advisable to keep the suction hose short,
setting the pump as near as possible to the liquid.
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Examine suction hose or pipe connections. Air leaks in the suction line
and connections to pump are the most frequent causes of priming trouble.
Use a new gasket in the hose coupling. New couplings sometimes require
two gaskets. The Hose lining may also become loose and clog the hose.
Keep the pump as close as possible to the level of the liquid being
pumped. It will give best performance on suction lifts less than 15ft. It is
not guaranteed to handle any lift over 20ft at sea level.
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!CAUTION
The vacuum developed by the pump could damage the flat piece of rubber.
Shut off the pump quickly after the test has been done to prevent
any damage.
Make sure that the pump casing is full
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TROUBLESHOOTING If the pump fails to prime:
If difficulties are experienced, in the majority of casings they can be
traced to well-known causes.
We suggest you check these points first to save needless expense.
Make sure that the pump casing is full of cool liquid.
If difficulty continues, remove suction hose, start engine and hold a flat
and thick piece of rubber, or other suitable material, against the suction
inlet. If the pump develops a strong pull against the material, the problem
Is not in the pump. If there is no pull, the shaft seal may need to be
replaced.
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Remember the pump is self-priming only when the casing pump is filled.
It will prime and reprime itself without refilling. Refilling is necessary
only if the pump has been drained or if the fluid has been lost.
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Priming time : With a suction lift from 5 to 10ft. The pump should
discharge the liquid in less than one minute.A suction lift of 20 ft. (at sea
level) should not require more than 3 minutes for initial prime. If pumping
does not start within this time, shut off engine and check carefully to
analyze the problem. (Refer to "Troubleshooting Section").
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Pump location
Suction and discharge hoses
Install a 90° elbow (supplied) on the pump's discharge and then attach the
quick connectors.
The suction and discharge should have a male adapter to connect the hose.
The fittings should have the same diameter as the suction diameter.
Use Teflon tape to prevent leakage on the joints.
Connect the hose couplings to the suction and discharge fittings.
Be sure to use a strongly reinforced hose on the suction side.
Tighten hose couplings firmly. Hose or pipes should be supported
separately and not carried by the pump.
Place the pump on a firm place to absorb vibration and provide a
permanent and rigid support. This place should allow appropriate
ventilation for the engine.
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PLANNING
THE INSTALLATION
The pump should be located
on a leveled firm foundation,
putting it as near as possible
to the level of the liquid
that is being pumped,
but never higher than 20 feet.
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Don’t forget to read the engine manual, before starting
the unit.
!CAUTION
easier, put oil in the elastic ring of the seal. Do not hit or damage in any
way the ceramic part of the seal. Insert the seal using finger pressure only.
Place the back plate on the engine, checking a close fit between the back
plate and engine flange. Before fixing the parts, be sure that the position of
the back plate is correct with the drain outlet facing down.
Tighten the screw locker washers on, to fix the back plate to the engine
flange. Tighten the screws well and evenly in an "X" sequence.
Place the rotating part of the mechanical seal on the shaft. To make this
operation easier, put oil in the elastic ring of the mechanical seal.
Place the mechanical seal spring on the rotating part.
Fit the impeller on the shaft, with a clockwise rotation be sure that the
impeller is fully screwed.
After cleaning the surfaces thoroughly, place the o-ring in the circular
groove of the back plate.
Place the volute on the back plate.
Place the gasket properly in order to have a perfect fit between the gasket
and volute.
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ASSEMBLY PROCESS Before assembling
(Only for pump ends)
Check that engine flange and shaft measures are in accordance with
diameter and threaded shaft.
All units are partially assembled. In the box there are bags with the
necessary screws and accessories to complete the assembly.
When opening the box be sure that the parts do not show evidence of
damage during transportation.
After unpacking the units, all the parts should be placed on a smooth, dry
and clean surface.
Read carefully all instructions given below before assembling the unit.
All models
Place the engine with the shaft vertically. Clean the matching surfaces, clean
the engine shaft and coat its surface with a small amount of grease.
Place the ceramic part of the mechanical seal on the back plate seal on the
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RECOMMENDED
3
INSTALLATION
The suction hose must be kept free
of air leaks, particularly when
the suction line is long and
the static suction is high.
It is advisable to keep the suction
hose as short as possible,
setting the pump as near
as possible to the liquid.
Use a pipe, or a reinforced hose to make suction connections. Hose must
have sufficient strength to resist collapsing under the atmospheric pressure.
The pump does not need a foot valve. Use a strainer to prevent solids from
being drawn into the pump and clog the pump impeller.
The strainer should be at least 1.5 times the suction diameter away from
the bottom of the container tank of the liquid pumped.
Align properly pipes and fittings.
Independently support pipes and fittings to reduce strain on the pump
casing.
Use Teflon tape on the joints to prevent leakage.
Suction area of the strainer must be at least four times the suction pipe
area.
Suction pipes hoses or fittings should have a diameter equal to the pump
suction diameter.
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Reinforced hose
Strainer
OWNER MANUAL DCA KATSU POWER WATER PUMPS OW N E R M A N U A L DCA KATSU POWER WATER PUMPS

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10
14
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RIGHT VIEW LEFT VIEW
Frame
Fuel tank
Air filter Muffler
Oil plug
Filling plug
Drain plug
Dipstick
OHV Engine
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OWNER MANUAL DCA KATSU POWER WATER PUMPS OW N E R M A N U A L DCA KATSU POWER WATER PUMPS

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Place the casing on the back plate.
Tighten the casing with the washers and screws provided. Tighten the
screws well and evenly in an "X" sequence.
Place the drain plug.
Place the Suction Connection along with the gasket and screws, on the
suction port.
Tighten Suction Connection well to prevent leakage or lose priming.
Connect the 90°-elbow along with the gasket on the discharge connection.
Place the filling plug.
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UNPACKING THE EQUIPMENT
Check the contents of each box
for missing items and for damage
that may have occurred during shipment.
Report any loss and damage at once.
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OWNER MANUAL DCA KATSU POWER WATER PUMPS OW N E R M A N U A L DCA KATSU POWER WATER PUMPS

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PARTS LIST
27
TIME
KATSU POWER ENGINE 168F
KATSUPOWER ENGINE 168F-2
KATSUPOWER ENGINE 177F
PUMP DCA
DCA 22/168F
TIME
No.
*1
*1
*1
2
DCA 33/168F-2 DCA 44/177F
1
-
-
1
-
1
-
1
-
-
1
1
SPARE PARTS QUANTITY
DESCRIPCION
BACK PLATE
IMPELLER
VOLUTE
TIME
No.
3
MECHANICAL SEAL5 GASKET (O-RING)
4
6
7
QUANTITY
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
CASING9
VOLUTE GASKET8 1 1 1
DISCHARGE CONNECTION10 TUBULAR FRAME11 1 1 1
1
1
1
1
1
1
DRAIN PLUG
SUCTION CONNECTION
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13
FILLING PLUG12
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OWNER MANUAL DCA KATSU POWER WATER PUMPS OW N E R M A N U A L DCA KATSU POWER WATER PUMPS

TABLE OF CONTENTS
3
5
6
7
9
11
16
21
23
27
UNPACKING THE EQUIPMENT
PLANNING THE INSTALLATION
INSTALLATION
PRIMING
BEFORE STARTING
START UP
MAINTENANCE
TROUBLESHOOTING
ASSEMBLY PROCESS
PARTS LIST
PAGE
OWNER MANUAL DCA KATSU POWER WATER PUMPS OW N E R M A N U A L DCA KATSU POWER WATER PUMPS

OWNER MANUAL DCA KATSU POWER WATER PUMPS

This manual gives you operation and maintenance
instructions of your new Katsu Power gasoline pump.
Before starting the engine read carefully, and follow
the instructions to get the best engine-pump performance
and longest life. If you have any question please contact
the nearest dealer.
This manual is for models:
DCA 22/168F
DCA 33/168F-2
DCA 44/177F
INTRODUCTION
OWNER MANUAL DCA KATSU POWER WATER PUMPS