Kodiak PWP2HX User manual

Gasoline Powered Pump
Owner's Manual
Models PWP2HX, PWP3HX,
PWP4HX, PWP2SST, PWP3SST,
PWP2SCH5050
Customer Service Hotline:
1-866-939-6666
visit our website:
www.kodiakpower.ca
Introduction & Overview ....................................... 1
Safety Precautions ............................................ 2
Preparing the Pump ............................................. 3
Operating Instructions ....................................... 4-5
Maintenance.......................................................... 6
Storage, Winterizing & Transport ......................... 7
Troubleshooting .................................................... 8
Parts Breakdown ............................................. 9-14
Warranty Information........................................... 15
IMPORTANT: Do not operate this equipment until you have read and understand all of the
enclosed Owner's Manuals. Carefully read all Warnings, Safety Precautions, Assembly
and Operating Instructions, Maintenance and Storage information.
PWPGAS-MAN
PWP2HX model shown.
May not be exactly as shown.

1
Illustrations are mainly based
on pump model PWP3HX.
May not be exactly as shown.
3
45
6
1
2
7
9
10
11
8
12
13
14
15
16
Overview
Note: Check for visible shipping damage. Shipping damage will cause problems in the
operation of this unit. Contact the Customer Service Hotline immediately at 1-866-939-6666
if there are missing or damaged parts. DO NOT return this product to the store.
We would like to take this opportunity to thank you for choosing Kodiak Power Equipment.
This general-purpose water pump has been designed to provide years of safe and dependable
operation. To obtain the best performance from your unit please read the “Operating Manual”
carefully before using this product.
This manual contains important Safety Precautions, Operating Instructions and
Maintenance Instructions essential to the safe operation of your Kodiak water pump.
Failure abide by these instructions could result in personal injury or equipment damage.
This manual should be considered a permanent part of the pump and should remain with the
pump if it is resold.
Introduction
17
16
15
14
13
12
11
10
9
8
7
6
5
4
3
2
1Recoil starter
Fuel valve
Choke lever
Frame
Fuel tank cap
Priming water cap
Discharge port
Oil filler cap/dipstick
Engine switch
Muffler
Air cleaner
Oil drain plug
Pump drain plug
Suction port
Strainer
Hose couplings
Seals
1" Hose bands (not shown)
Standard Accessories

2
Safety Overview
This unit was designed for specific applications. It
should not be modified or used for any application
other than that for which it was designed.
The Owner's Manual constitutes an essential part
of the water pump and should be kept in a safe
place for future reference. If you sell the water
pump, all manuals should be provided to the new
owner. Read this manual carefully before using
the product – know your equipment.
Save these instructions. The Owner's Manual
should remain with unit at all times.
Important Safety Precautions
6. Do not run the engine in an enclosed area.
Exhaust fumes contain carbon monoxide
which is an odourless, poisonous gas;
exposure can cause loss of consciousness
and may lead to death.
7. If the pump is located in an enclosed area,
use an exhaust line to the outside and
regularly check for exhaust leaks. Be sure
the area is well ventilated.
8. To prevent fire hazards and to provide
adequate ventilation, keep the pump at
least 1 metre (3 feet) away from building
walls and other flammable substances
as well as other equipment during
operation.
9. Do not place flammable objects close to
the pump.
10. For safety, never pump flammable or
corrosive liquids such as gasoline or acid.
11. Wear safety glasses at all times when
working with hazardous chemicals.
12. Check the wind direction before pumping
hazardous chemicals to ensure that spray
or mist does not come into contact with
people or animals.
13. To avoid pump corrosion, never pump sea
water, chemical solutions, or caustic liquids
such as used oil, wine, or milk.
14. Know how to stop the pump quickly, and
understand the operation of all controls.
Never permit anyone to operate the pump
without proper instruction.
15. Keep the work area clean, uncluttered and
properly lighted. Keep visitors at a safe
distance from the work area. Children and
pets must be kept away from the area of
operation due to a possibility of burns from
the hot engine components.
16. Periodically inspect pump and system
components. Perform routine maintenance
as required. (Refer to the Honda Engine
Owner's Manual.)
17. Carefully read the Operating Manual
supplied by the engine manufacturer before
attempting to assemble, operate or service
the engine.
18. Release all pressure and drain all fluids
from the pump before attempting to service
any component.
Safety Precautions
The following safety precautions are essential
for the safe operation of your pump. Make sure
anyone who may be using this gas-powered
pump is familiar with these important safety
safety and equipment precautions.
If safety precautions are overlooked or ignored,
personal injury or property damage may occur.
Always heed these precautions, as they are
essential when using any mechanical equipment.
1. Always make a pre-operation inspection
before you start the engine. You may
prevent a serious accident or equipment
damage.
2. Regularly check engine oil and fuel levels
before start-up. (Please refer to the Honda
Engine Owner's Manual for details.)
3. Secure and inspect all hoses before
start-up, making certain that all connections
are secure. Be sure to provide a means of
pressure relief for the pump if the discharge
line could be shut off or obstructed.
4. If the pump is located in an area subject to
freezing temperatures the pump should
be drained when not in operation.
5. Place the pump on a firm, level surface.
If the pump is tilted or overturned fuel
spillage may result.
IMPORTANT: 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. Allow the
engine to cool before storing the pump
indoors.

3
1. Connect the suction hose.
The strainer that is provided with the pump
should be firmly attached to the end of the
suction hose with a hose band.
Use commercially available hose, connectors
and hose bands. The suction hose must be of
a reinforced, non-collapsible construction.
The suction hose should not be longer than necessary, as pump performance is best
when the pump is not far above the water level. Self-priming time is also proportional
to hose length.
CAUTION: If connecting aluminum fittings to the pump apply at least 8 wraps of Teflon
tape to the threads of both inlet & discharge ports before attaching the fitting. Failure to
do so will cause gauling of the thread and void warranty.
CAUTION: Always install the strainer on the end of the suction hose before pumping.
The strainer will filter debris that can cause clogging or impeller damage.
NOTE: Tighten the hose connector and bands to prevent air leakage and loss of
suction. A loosely connected suction hose will reduce pump performance and
self-priming ability.
2. Connect the discharge hose.
Use a commercially available hose, connectors
and hose bands. A short, large diameter hose
is most efficient. Longer hoses or small diameter
increases fluid friction and reduces pump output.
NOTE: Tighten the hose band securely to prevent
the hose from disconnecting under high pressure.
3. Add fuel as required.
Refer to the Honda engine Owner's Manual for proper fueling instructions.
Refuel in a well-ventilated area with the engine stopped. Do not smoke or allow
flames or sparks in the area where the engine is refueled or where gasoline is stored.
NOTE: Do not add fuel while the engine is running or hot.
Important Safety Precautions – continued
Preparing the pump

FUEL VALVE
LEVER
CHOKE LEVER
OPEN
CLOSED
THROTTLE LEVEL
SLOW
Always make a pre-operation inspection before you start the engine.You may prevent
an accident or equipment damage.
1. Priming the pump.
The pump chamber must be primed
full with water before operating.
Remove priming plug.
Fill with water to prime pump.
Replace priming plug.
CAUTION: Never attempt to operate the pump without priming water or the pump
will overheat. Extended dry operation will destroy the pump seal. If the unit has been
operated dry, stop the engine immediately and allow the pump to cool before adding
priming water.
2. Starting the engine.
Please refer to the Honda Engine Owner’s Manual for any safety precautions that
should be observed in conjunction with engine start-up, shutdown or operation.
2.1 Turn the fuel valve lever
to the ON position
2.2 To start a cold engine,
move the choke lever
to the CLOSED position.
To start a warm engine,
leave the choke lever
in the OPEN position.
2.3 Move the throttle lever away
from the SLOW position,
about 1/3 of the way toward
the FAST position.
4
Operating Instructions

ENGINE SWITCH
STARTER GRIP
THROTTLE LEVEL
SLOW
ENGINE SWITCH
FUEL
VALVE
LEVER
OFF
2.4 Turn the engine switch
to the ON position.
2.5 Pull the starter grip lightly
until resistance is felt, and
then pull it briskly.
Return it gently to prevent
damage to the starter.
2.6 As the engine warms up, gradually open the choke.
2.7 Set the throttle at the desired speed.
3. Stopping the engine
3.1 Move the throttle lever
all the way to the right
(SLOW position)
3.2 Turn the engine switch
to the OFF position.
3.3 Turn the fuel valve to
the OFF position.
To stop the engine in an emergency, turn the engine switch to the OFF position.
5
Operating Instructions - continued

Periodic inspection and adjustment of the pump are essential if high level performance is to be
maintained. Regular maintenance will also help to extend service life.
The required maintenance intervals and the kind of maintenance to be performed are described
in the chart below.
WARNING: Shut off the engine before performing any maintenance. If the engine is to be left
running make sure the area is well ventilated. The exhaust contains poisonous carbon mono-
xide gas; exposure can cause loss of consciousness and may lead to death.
¹ Service more frequently when used in dusty areas
² These items should be serviced by an Authorized Service Centre.
* Fuel filter is best kept clean when washed with white kerosene.
Engine Oil Check level ❍
Change ❍ ❍
Air/Fuel Filter* Check ❍
Clean ❍*❍¹
Spark Plug Check/Clean ❍
Valve Clearance Check/Adjust ❍²
Fuel Tank Clean ❍²
and Strainer
Fuel Line Check Every 2 years
Replace if necessary
Impeller Check ❍²
Impeller Clearance Check ❍²
Pump Inlet Check Valve Check ❍²
First Every 3 Every 6 Every
Daily Month Months Months Year
or or or or
20 hrs 50 hrs 100 hrs 300 hrs
Perform each item at every
indicated month or operating hour,
whichever comes first.
IMPORTANT: The engine becomes very hot during operation and remains hot for a while after it
has been turned off. Be careful not to touch the engine while it is hot. Allow the engine to cool before
storing the pump indoors.
On a daily basis be sure to check for any loose nuts, bolts or screws as well as any leaks in fuel or oil.
6
Maintenance

7
Storage & Winterizing
Always store pump in a location where the
temperature will NOT fall below 0˚ C. Store the
pump and accessories in a dry place, protected
from freezing. The pump should NOT be placed
near an open flame i.e. furnace, hot water heater,
etc.
WARNING: The pump is susceptible to
permanent damage if frozen. Damage as a
result of unit freezing is NOT covered by the
warranty.
Transport
1. Avoid severe burns or fire hazards; let the
engine cool before transporting the pump.
2. When transporting the pump, turn the fuel
valve to the OFF position, and keep the pump
level to prevent fuel spillage. Spilled fuel or
fuel vapours may ignite.
1. Be sure the storage area is free of excessive
humidity and dust.
2. Clean the pump interior. Sediment will settle
in the pump if it has been used in muddy
or sandy water, water containing heavy
debris.
3. Pump clean water through the pump before
shutting down or the impeller may be damaged
when restarting. After flushing remove the
pump drain plug. Drain as much water as
possible from the pump housing and reinstall
the plug.
4. If storing the pump for a long period of time
pump clean water through the pump and
allow the engine to run dry of gas/oil
mixture.
CAUTION: Always remove gasoline from the
engine if storing the pump indoors.
Storage, Winterizing & Transport

If you encounter any difficulties not listed above,
please contact the Customer Service hotline.
Customer Service Hotline:
1-866-939-6666
visit our website:
www.kodiakpower.ca
Symptom
Pump will not prime, or
retain prime after operating
Flow rate is low
Pump runs but no fluid
Liquid drips from point where
shaft enters the pump casing
when pump is full of liquid
Pump starts and then
stops pumping
Excessive noise while
pump is in operation
Possible Cause
Air leak in
suction hose
Flapper valve
fouled or defective
Incorrect engine speed
Hoses are fouled
or damaged
Clogged or worn impeller
Discharge hose
restricted or undersized
Faulty suction hose
Pump located too far
from fluid source
Gate valve closed
Clogged strainer
Fouled foot valve
Discharge height
too great
Damaged mechanical
seal
Fouled impeller
Faulty mechanical seal
Leak in suction hose
Leak in foot valve
Engine seizure
Pump is not secured
to a firm foundation
Hoses not supported to
relieve any strain on
pump assembly
Restricted suction hose
Corrective Action
Repair or replace
Clean or replace
Adjust to 3600 rpm
Clean or replace
Clean or replace
Flush out hose
or replace
Replace
Relocate
Open
Clean or replace
Clean or replace
Lower the height
Replace
Clean
Replace
Repair
Repair or replace
Repair
Secure properly
Make necessary
adjustments
Clean or correct
8
Troubleshooting

Part Number Description Qty
1 PWP503001 Casing 1
2 PWP501004 Casing Cover 1
3 PWP501009 Impeller 1
4 PWP501011 Inner Casing 1
5 PWP501019A Bend (NPT) 1
6 PWP501013 Valve Case (Al-NPT) 1
7 PWP501010 Mechanical Seal 1
8 PWP501002 Packing (Casing) 1
9 PWP501012 Packing (Inner Casing) 1
10 PWP501020 Packing (Bend) 1
11 PWP501015 Check Valve 1
12 PWP501021 Plug 2
13 PWP501022 Packing (Plug) 2
14 PWP501005 Bolt (M8x48) 4
Part Number Description Qty
15 PWP501007 Washer Spring (M8) 4
16 PWP501008 Plain Washer (8) 4
17 PWP501006 Seal Packing 4
18 PWP501030 Frame 1
19 PWP501003 Bolt (M10x30) w/Spring Washer 4
20 PWP501014 Bolt (M8x25) w/Spring Washer 4
21 PWP501014 Bolt (M8x25) w/Spring Washer 3
22 PWP501023 Bolt (M8x40) w/Spring Washer 4
23 PWP501024 Flange Nut (M8) 4
24 PWP501017 Packing (Coupling) 2
25 PWP501018 Hose Coupling (ABS) 2
26 PWP501016ALUM Hose Coupling (AL-NPT) 2
27 PWP501028 Hose Band 3
28 PWP505029 Strainer 1
9
Parts Breakdown - PWP2HX

Part Number Description Qty
1 PWP802001 Casing 1
2 PWP502004 Casing Cover 1
3 PWP801009 Impeller 1
4 PWP801011 Inner Casing 1
5 PWP801019A Bend (NPT) 1
6 PWP801013 Valve Case (Al-NPT) 1
7 PWP501010 Mechanical Seal 1
8 PWP502002 Packing (Casing) 1
9 PWP801012 Packing (Inner Casing) 1
10 PWP801020 Packing (Bend) 1
11 PWP801015 Check Valve 1
12 PWP501021 Plug 2
13 PWP501022 Packing (Plug) 2
14 PWP501005 Bolt (M8x48) 4
Part Number Description Qty
15 PWP501007 Washer Spring (M8) 4
16 PWP501008 Plain Washer (8) 4
17 PWP501006 Seal Packing 4
18 PWP801030 Frame 1
19 PWP501014 Bolt (M8x25) w/Spring Washer 8
20 PWP801031 Bolt (M8x25) w/Spring Washer 4
21 PWP801014 Bolt (M8x30) w/Spring Washer 3
22 PWP501023 Bolt (M8x40) w/Spring Washer 4
23 PWP501024 Flange Nut (M8) 4
24 PWP801017 Packing (Coupling) 2
25 PWP801018 Hose Coupling (ABS) 2
26 PWP801016ALUM Hose Coupling (AL-NPT) 2
27 PWP801028 Hose Band 3
28 PWP805029 Strainer 1
10
Parts Breakdown - PWP3HX

Part Number Description Qty
1 PWP1001001 Casing 1
2 PWP1001004 Casing Cover 1
3 PWP1001009 Impeller 1
4 PWP1001011 Inner Casing 1
5 PWP1001019 Bend (AL-NPT) 1
6 PWP1001013 Valve Case (Al-NPT) 1
7 PWP1001010 Mechanical Seal 1
8 PWP1001002 Packing (Casing) 1
9 PWP1001012 Packing (Inner Casing) 1
10 PWP1001020 Packing (Bend) 1
11 PWP1001015 Check Valve 1
12 PWP501021 Plug 2
13 PWP501022 Packing (Plug) 2
14 PWP501005 Bolt (M8x48) 4
15 PWP501007 Washer Spring (M8) 4
16 PWP501008 Plain Washer (8) 4
17 PWP501006 Seal Packing 4
Part Number Description Qty
18 PWP501003 Bolt (M10x30) w/Spring Washer 4
19 PWP501003 Bolt (M10x30) w/Spring Washer 4
20 PWP501003 Bolt (M10x30) w/Spring Washer 4
21 PWP1001030 Frame 1
22 PWP1001031 Base 1
23 PWP1001032 Anti Vibration Rubber 4
24 PWP1001034 Metal 2
25 PWP1001024 Nut (M8) w/Spring Washer 8
26 PWP1001023 Bolt (M10x45) w/Spring Washer 4
27 PWP1001033 Flange Nut (M10) 4
28 PWP1001014 Bolt (M10x20) 4
29 PWP1001033 Flange Nut (M10) 2
30 PWP1001017 Packing (Coupling) 2
31 PWP1001018 Hose Coupling (AL) 2
32 PWP1001016ALUM Hose Coupling (AL-NPT) 2
33 PWP1001028 Hose Band 3
34 PWP1001029 Strainer 1
11
Parts Breakdown - PWP4HX

Part Number Description Qty
1 PWP503001 Casing 1
2 PWP501004 Casing Cover 1
3 PWP571009 Impeller 1
4 PWP571011 Inner Casing 1
5 PWP501019A Bend (NPT) 1
6 PWP501013A Valve Case (Al-NPT) 1
7 PWP521008 Mechanical Seal (SIC) 1
8 PWP501002 Packing (Casing) 1
9 PWP501012 Packing (Inner Casing) 1
10 PWP501020 Packing (Bend) 1
11 PWP501015 Check Valve 1
12 PWP501021 Plug (Priming) 2
13 PWP501022 Packing (Plug) 2
14 PWP501005 Bolt (M8x48)W/S.W. 4
15 PWP501005 Bolt (M8x48)W/S.W. 4
16 PWP501005 Bolt (M8x48)W/S.W. 4
17 PWP501006 Seal Packing 4
Part Number Description Qty
18 PWP571003 Spacial Bolt W/S.W. 4
19 PWP571003 Spacial Bolt W/S.W. 4
20 PWP501014 Bolt (M8x25) W/S.W 4
21 PWP501014 Bolt (M8x25) W/S.W 3
22 PWP501023 Bolt (M8x40) W/S.W. 4
23 PWP501024 Flange Nut (M8) 4
24 PWP571030 Frame 1
25 PWP571021 Hook 1
26 PWP571022 Spanner 1
27 PWP501017 Packing (Coupling) 2
28 PWP501018P Hose Coupling (ABS) 2
29 PWP501016A Hose Coupling Handle (AL-NPT) 2
30 PWP501028 Hose Band 3
31 PWP575029 Strainer 1
32 PWP571027 Capacity Plate 1
33 PWP501026 Caution Plate 1
34 PWP501025 Name Plate 1
12
Parts Breakdown - PWP2SST

Part Number Description Qty
1 PWP803001 Casing 1
2 PWP501004 Casing Cover 1
3 PWP871009 Impeller 1
4 PWP871011 Inner Casing 1
5 PWP801019A Bend (NPT) 1
6 PWP801013A Valve Case (AL-NPT) 1
7 PWP521008 Mechanical Seal (SIC) 1
8 PWP501002 Packing (Casing) 1
9 PWP801012 Packing (Inner Casing) 1
10 PWP801020 Packing (Bend) 1
11 PWP801015 Check Valve 1
12 PWP501021 Priming Plug 2
13 PWP501022 Packing (Plug) 2
14 PWP501055 Bolt (M8x48)W/S.W. 4
15 PWP501005 Bolt (M8x48)W/S.W. 4
16 PWP501005 Bolt (M8x48)W/S.W. 4
17 PWP501006 Seal Packing 4
Part Number Description Qty
18 PWP571003 Spacial Bolt W/S.W. 4
19 PWP571003 Spacial Bolt W/S.W. 4
20 PWP501014 Bolt (M8x25) W/S.W 4
21 PWP801014 Bolt (M8x30) W/S.W 3
22 PWP501023 Bolt (M8x40) W/S.W. 4
23 PWP501024 Flange Nut (M8) 4
24 PWP871030 Frame 1
25 PWP571021 Hook 1
26 PWP571022 Spanner 1
27 PWP801017 Packing (Coupling) 2
28 PWP801018P Hose Coupling (ABS) 2
29 PWP801-016A Hose Coupling Handle (AL-NPT) 2
30 PWP801028 Hose Band 3
31 PWP875029 Strainer 1
32 PWP871027 Capacity Plate 1
33 PWP501020 Caution Plate 1
34 PWP501025 Name Plate 1
13
Parts Breakdown - PWP3SST

Part Number Description Qty
1 PWP502001 Casing 1
2 PWP511004 Casing Cover 1
3 PWP511009 Impeller 1
4 PWP511011 Inner Casing 1
5 PWP501019A Bend (AL-NPT) 1
6 PWP501013A Valve Case (AL-NPT) 1
7 PWP501010 Mechanical Seal 1
8 PWP502002 Packing (Casing) 1
9 PWP501012 Packing (Inner Casing) 1
10 PWP501020 Packing (Bend) 1
11 PWP501015 Check Valve 1
12 PWP501021 Plug 2
13 PWP501022 Packing (Plug) 2
14 PWP501005 Bolt (M8x48) 4
15 PWP501007 Washer Spring (M8) 4
16 PWP501008 Washer (8) 4
Part Number Description Qty
17 PWP501006 Seal Packing 4
18 PWP501014 Bolt (M8x25) W/S.W. 8
19 PWP501014 Bolt (M8x25) W/S.W. 4
20 PWP501014 Bolt (M8x25) W/S.W 3
21 PWP501023 Bolt (M8x40) W/S.W 4
22 PWP501024 Flange Nut (M8) 4
23 PWP511030 Frame 1
24 PWP501017 Packing (Coupling) 2
25 PWP501018P Hose Coupling (ABS) 2
26 PWP501016A Hose Coupling Handle (AL-NPT) 2
27 PWP501028 Hose Band 3
28 PWP505029 Strainer 1
29 PWP511027 Capacity Plate 1
30 PWP501026 Caution Plate 1
31 PWP501025 Name Plate 1
14
Parts Breakdown - PWP2SCH5050

Customer Service Hotline:
1-866-939-6666
visit our website:
www.kodiakpower.ca
PWP2HXJB
Pump Warranty
This product is warranted to be free from defects in materials and workmanship under normal use
and service, for a period of one year from the date of purchase, when operated and maintained in
accordance with the Maintenance and Operating Instructions supplied with the unit. Warranty period
commences on date of purchase. This warranty is extended only to the original purchaser.
The warranty herein is expressly conditioned upon the customer's compliance with all precautions
and instructions contained in the Owner's Manual.
If the machine is still under warranty, the customer has a valid receipt, and the machine meets the
warranty criteria, then the repair will be made at no charge to the customer. Units and parts should
be returned at the customer's expense to the nearest Authorized Service Centre. Include original
purchase receipt with any claim, making sure to keep a copy for your files. Be sure to pack the unit
in a strong carton and pad tightly to avoid damage. Damage in transit is NOT covered by warranty.
Warranty is void if any devices or accessories other than those distributed or recommended by
Kodiak are attached to or connected with the equipment in such a manner that the original factory
construction is altered.
Warranty is void if repairs are attempted by anyone other than an Authorized Service Centre. In the
event that a difficulty develops with the product, you should contact the nearest Authorized Service
Centre. Only these locations are authorized to make repairs to the product or affect replacement of
defective parts, which will be done at no charge within a reasonable time after receipt of the product.
This warranty shall not apply to any problem which is due to misuse, neglect, accident, abuse,
improper handling, freezing, normal wear and tear, use of improper detergents/chemicals, or
non-compliance with precautions and instructions contained in the Owner's Manual. This warranty
is non-transferable.
The liability of John Brooks Company Limited is limited to repair of the product and/or replacement of
parts, and is given to the purchaser in lieu of all other remedies including incidental and consequential
charges. There are no expressed warranties other than those specified herein.
Engine Warranty
The engine is warranted for a period of two years by the Honda Motor Company Limited.
In the unlikely event that you have a problem with the engine you must contact an authorized Honda
Service Centre. Please call the Honda toll-free hotline at 1-888-946-6329 to locate the Service Centre
nearest you.
15
Warranty