recommended practice

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NEW SOUTH WALES FIRE BRIGADESRECOMMENDED PRACTICE

DAVEY PUMPWITH HONDA GX160 ENGINE

VERSION: C1 APPROVED: APRIL 2006 CI: 06750

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© Copyright State Government of NSW (NSWFB) 2006

All rights reserved. The information contained in this Recommended Practice is provided for the use of approved personnel in the performance of their duties. Apart from any use as permitted under the Copyright Act 1968, no part of this Recommended Practice may be reproduced or transmitted in any form or by any means, electronic or mechanical, including photocopying, recording, or any information storage and retrieval system, without permission in writing from the New South Wales Fire Brigades (NSWFB).

Published by:

NSWFB State OperationsAmarina Avenue

Greenacre NSW 2190

Telephone: (02) 9742 7344Facsimile: (02) 9742 7381

Document Control:Version A: February 2004Version B: August 2004 (Include new equipment – suction hose with removable strainer)Version C: June 2005 (Amendment – sediment cup cleaning, p17, and update design)Version: C1 April 2006 (Amend to include unpressurised water source only warning.)

NSWFB Supply Catalogue No:06750

CD electronic master files located at:Equipment Development Unit, Greenacre (filed by CI number)Corporate Head Office (CHO: 04309)

Signed hardcopy and working file located at:Equipment Development Unit, Greenacre (filed by CI number)

Acknowledgements:Firefighter Lindsay SpeldwindeSartech Pty LtdSO Terry MunseyHonda EnginesDavey Products Pty Ltd

Produced by:Specialised State Operations, NSWFB

HAS THIS DOCUMENT BEEN PRINTED OR COPIED?CHECK YOU HAVE THE MOST RECENT VERSION BY COMPARING THE VERSION CONTROL ON THE FOOTER

OR ON THIS INDICIA PAGE WITH THE VERSION THAT CAN BE FOUND ON THE STATION PORTAL ON THE NSW FIRE BRIGADE INTRANET. CONSIDER THE ONLINE DOCUMENT THE MASTER.

This document was produced using Adobe Framemaker™ version 7.1. It is intended for release as an electronic PDF document for online viewing. The online version is formatted for single sided printing. Double-sided print copies are available through the NSWFB Supply Catalog.

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iii Davey Pump

CONTENTS

Using This Document vWarnings, cautions and notes vPDF electronic navigation vDocument control vi

Davey Pump Warnings vii

Part 1 INTRODUCTION 11.1 Manual structure 11.2 General 11.3 Contact 11.4 The Davey pump 2

Part 2 EQUIPMENT FACT SHEET 32.1 Honda engine 32.2 Technical specifications 32.3 Equipment used in conjunction with pump 42.3.1 General 42.3.2 Suction hose 52.3.3 Suction hose with removable strainer 5

Part 3 SAFETY AND PRECAUTIONS 63.1 General 63.2 The Honda engine 63.2.1 Refuelling 63.2.2 Engine oil level 73.2.3 Air cleaner 73.2.4 Best performance 73.3 The Davey pump 73.3.1 Location 73.3.2 Avoiding pump damage 8

Part 4 OPERATING INSTRUCTIONS 94.1 Pre-operation checks 94.1.1 Oil 94.1.2 Air cleaner – dual element type 94.1.3 Fuel 94.1.4 Pump priming 104.2 Operations 104.2.1 Starting the Davey pump 104.2.2 Stopping the Davey pump 12

D.I. Recommended Practice Version: C1 Issued April 2006FILE: W:\NB\RP Bushfire\Davey\Frame\DaveyTOC.fm © Copyright State Govt of NSW (NSWFB) 2006

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Davey Pump iv

Part 5 MAINTENANCE 135.1 Clean up and before transport 135.2 Schedule 135.3 General 145.4 Air cleaner service 145.4.1 General 145.4.2 Foam element 155.4.3 Paper element 155.5 Oil change 165.6 Sediment cup cleaning 175.7 Spark plug service 185.8 Draining fuel 195.9 Storage 205.10 Troubleshooting the Honda engine 215.11 Troubleshooting the Davey pump 22

References 23

Index 24

D.I. Recommended Practice Version: C1 Issued April 2006FILE: W:\NB\RP Bushfire\Davey\Frame\DaveyTOC.fm © Copyright State Govt of NSW (NSWFB) 2006

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v Davey Pump

USING THIS DOCUMENT

Warnings, cautions and notes

Throughout this manual, the reader will find statements titled: WARNING, CAUTION or NOTE. These consist of a short piece of information highlighting a hazard or providing additional clarification, or both. Each of these statements has a particular meaning, as follows:

WARNINGWARNINGA Warning indicates that PERSONAL INJURY MAY RESULT if recommended procedures are not carefully followed, and tells what to do to avoid such injury. Equipment may also be damaged.

CAUTIONA Caution indicates that EQUIPMENT MAY BE DAMAGED if recommended procedures are not carefully followed, and tells what to do to avoid such damage. Potential for personal injury is not expected.

NOTEA Note provides CLARIFICATION of an operational procedure. Neither personal injury nor equipment damage is involved.

PDF electronic navigation

• The PDF has bookmarks which replicate the contents page. Click on the bookmark to go to that heading.

• The contents page has live links to the referenced pages. Click on the heading to go to that page.

• The index has live links. Click on the page number to go to the original reference.

• To return to either the index or contents page, click on any other bookmark, and then click the index or contents bookmark.

• Within the document you will find cross references. For instance: ‘See Section XX, on page YY’. Click on these to go to the referenced section, table or figure.

D.I. Recommended Practice Version: C1 Issued April 2006FILE: W:\NB\RP Bushfire\Davey\Frame\How to Use.fm © Copyright State Govt of NSW (NSWFB) 2006

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Davey Pump vi

Document control

This Recommended Practice is a NSW Fire Brigades managed document. This document will become uncontrolled if printed or electronically copied in any way, such as distribution by email.

Wherever possible, users should refer to the NSW Fire Brigades Intranet: Station Portal for Recommended Practices.

NOTEIf this document has been printed or copied, always check the validity by confirming the Version control on the footer or on the indicia page with the version that can be found on the Station Portal on the NSW Fire Brigade Intranet.

D.I. Recommended Practice Version: C1 Issued April 2006FILE: W:\NB\RP Bushfire\Davey\Frame\How to Use.fm © Copyright State Govt of NSW (NSWFB) 2006

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vii Davey Pump

D.I. RecommeFILE: W:\NB\RP

Davey Pump Warnings

WARNINGEmergency stop: switch off ignition.

Switch off engine before refuelling. Store fuel and refuel engine away from all sources of ignition.

The Davey pump is not intrinsically safe.

Only use the Davey pump with open relay pumping configurations. Do not connect the Davey pump to high pressure water sources, such as hydrants connected to water mains. These can shatter the impeller housing.

The Davey pump weighs 25 kg. This is a two person lift.

CAUTIONDo not operate the Davey pump dry. The pump is water cooled.

Always start the Davey pump on level ground close to the water source.

nded Practice Version: C1 Issued April 2006 Bushfire\Davey\Frame\Davey Warnings.fm © COPYRIGHT State Govt of NSW (NSWFB) 2006

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Davey Pump viii

D.I. RecommeFILE: W:\NB\RP

This page has been intentionally left blank.

nded Practice Version: C1 Issued April 2006 Bushfire\Davey\Frame\Davey Warnings.fm © COPYRIGHT State Govt of NSW (NSWFB) 2006

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Page 1 Davey Pump

PART 1: INTRODUCTION

1.1 Manual structure

This manual has the following sections:

Part 1: Introduction

Part 2: Equipment Fact Sheet

Part 3: Safety and Precautions

Part 4: Operating Instructions

Part 5: Maintenance

1.2 General

This Manual instructs firefighters and Community Fire Unit volunteers on the use of the Honda GX 140 and GX 160 engine and the Davey ‘Single Impeller Firefighter’ pump.

The Honda engine and the Single Impeller Firefighter pump are coupled together. This configuration is commonly referred to as the Davey pump, and is standard in the NSW Fire Brigades.

Davey pumps are carried on appliances to draft water in open relay pumping configurations from static sources such as static water supply tanks, swimming pools, dams and rivers. Purposes include property protection, firefighting, and salvage operations. Davey pumps are also issued to Community Fire Units (CFUs) for property protection.

The Davey pump is not used with pressurised water sources such as hydrants connected to water mains.

1.3 Contact

Problems related to installation, maintenance and replacement should be directed to the Technical Officer, Rescue Section, Greenacre.

Queries regarding the procedures in this document should be directed to Bushfire/Natural Hazards Section, Greenacre.

D.I. Recommended Practice Version: C1 Issued April 2006FILE: W:\NB\RP Bushfire\Davey\Frame\Davey.fm © COPYRIGHT State Govt of NSW (NSWFB) 2006

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Davey Pump Page 2

1.4 The Davey pump

Figure 1 The Davey pump with Honda GX 160 engine

Figure 2 The Davey pump with the Honda GX 140 engine


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Page 3 Davey Pump

PART 2: EQUIPMENT FACT SHEET

2.1 Honda engine

The Honda GX 160 engine is a 4 stroke internal combustion engine. It uses multigrade oil in the sump and unleaded petrol.

The Honda engine is equipped with an Oil Alert System. This prevents engine damage caused by insufficient oil in the crankcase. Before the oil level can fall below a safe limit, or if the engine is positioned on too steep a slope, the Oil Alert System will stop the engine.

2.2 Technical specifications

The technical specifications for the Honda GX 160 engine are:

The technical specifications for the Davey pump are:

Dimension with frame: W 425 mm, L 515 mm, H 370 mm

Dry weight with frame: 25 kg

Engine type: 4 stroke, overhead valve, 1 x cylinder

Engine capacity: 163 cc

Max output: 4 kW at 4000 rpm

Max torque: 10.8 Nm at 2500 rpm

Fuel consumption at 3600 rpm: 1.73 litres per hour

Fuel capacity: 3.6 litres, standard unleaded petrol

Cooling system: Forced air

Ignition system: Transistor magneto

Engine oil capacity: 0.60 litres, SAE 10W-30

PTO shaft rotation: Counter-clockwise

Sound level: 85 dBa at 4 metres at full load and 3600 rpm

Delivery pressure: Up to 650 kPa

Delivery flow, max rpm, at min suction head:

Up to 400 litres per minute

Max total heads: Up to 55 m

Max water temp: 50o C

Min water temp: 1o C

Outlets: 1 x 38 mm, 2 x 25 mm


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Davey Pump Page 4

Hydraulic performance of the Davey pump:

Figure 3 Davey pump hydraulic performance

2.3 Equipment used in conjunction with pump

2.3.1 General

The Davey pump is equipped with:

• 2 x Diffuser nozzles (CFUs), or 1717P Akron branches (NSWFB),• 1 x 1 into 2 breaching, • 38 mm (internal diameter) delivery hose, 30 metre length,• 25 mm (internal diameter) delivery hose, 30 metre length,• 1 x length suction hose with strainer and float.

NOTEFor effective delivery during firefighting operations, no more than 3 lengths of 38 mm or 25 mm hose should be connected to the pump outlet.

60

50

40

30

20

10

400300200100

Total Head, metres

Flow rate, litres per minute

Suction Head Limitation

Total Suction Head 1.5 m 3.0 m 4.5 m 6.0 m

Max output in L per min 330 305 260 210

At max operating speed of 3600 rpm

At extended service speed of 3000 rpm


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Page 5 Davey Pump

2.3.2 Suction hose

The Davey pump is currently equipped with a non-collapsible 38 mm internal diameter suction hose of 3 metres length. This hose is fitted with a fixed suction head and strainer.

Figure 4 Suction hose and float

2.3.3 Suction hose with removable strainer

Due to Planning for Bushfire Protection Legislation, a new suction hose is being issued. This hose connects to water tanks being installed in bushfire prone areas. This hose is 2.4 metres in length and has a removable suction head with a Storz coupling. (Refer to In Orders 2004/18, Procedures: Water tanks in bushfire prone areas.)

Figure 5 Removable strainer

To use the hose with a standing water source, ensure the strainer is fitted.

To use the hose with a water tank:

• check water level in the tank,• remove the suction head,• connect to the tank with the Storz coupling.

Suction head with strainer

Float and chain

38 mm I.D. hose

The new suction hose has a Storz fitting at both ends, and is 2.4 metres in length. It

connects to the strainer head by a

Storz fitting


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Davey Pump Page 6

PART 3: SAFETY AND PRECAUTIONS

3.1 General

This section details safety instructions and precautions for the correct operation of the Davey pump.

The dry weight of the Davey pump is 25 kilograms. In accordance with Occupational Health and Safety (OHS) regulations, two people are required to lift or carry this piece of equipment.

WARNINGWARNINGEnsure adequate ventilation, exhaust gases contain carbon monoxide.

The Honda engine is not intrinsically safe.• Do not place flammable objects or substances close to the engine.• Do not use the Davey pump in flammable atmospheres.

CAUTIONLocate the pump on a level surface, otherwise excessive engine wear will result.

3.2 The Honda engine

3.2.1 Refuelling

WARNINGWARNINGUnleaded petrol is extremely flammable and is explosive under certain conditions. Refuel in a well-ventilated area with the engine stopped. Do not smoke or allow flames or sparks in the areas where the engine is refuelled or the petrol is stored.

Do not overfill the fuel tank. There should be no petrol in the filler neck. After refuelling, make sure the tank cap is securely closed. Do not spill petrol. Spilled petrol or petrol vapour may ignite. If any petrol is spilled, make sure the area is dry before starting the engine.

WARNINGWARNINGAvoid repeated or prolonged contact with skin or breathing of petrol vapour. KEEP OUT OF REACH OF CHILDREN.

CAUTIONUse unleaded fuel only.

This is not a 2-stroke engine, do not use an oil/petrol mixture. This will shorten the engine’s service life. Do not use dirty petrol and avoid getting dirt, dust or water in the fuel tank.


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Page 7 Davey Pump

3.2.2 Engine oil level

CAUTIONRunning the engine with insufficient oil can cause serious engine damage. Be sure to check the engine on a level surface with the engine stopped.

Use 4 stroke detergent oil only. SAE 10W-30 is recommended for general, all temperature use.

3.2.3 Air cleaner

CAUTIONNever run the engine without the air cleaner. Rapid engine wear will result.

3.2.4 Best performance

For fire fighting operations use full throttle. For prolonged use over a number of hours, set the throttle at 3/4 throttle or 3000 rpm.

CAUTIONOperating at maximum throttle, or above 3600 rpm, for unbroken periods of several hours will reduce the engine’s working life.

Do not place anything on the engine. Keep the engine at least one metre away from building walls. Heat build up can affect the performance of the engine.

3.3 The Davey pump

3.3.1 Location

The Davey pump should be located as close as possible to the water source. The pump’s efficiency is reduced the higher it is situated above the water surface. The pump will not draw water to a height greater than seven metres above the surface.

Locate the pump in a well-drained position to avoid possible failure and property damage caused by leaking hoses, fittings, pump seals, spilled fuel, etc.

Ensure the strainer is fitted to the end of the suction hose. The strainer should be kept out of mud and sand, etc to avoid particles being drawn into the pump, causing damage by abrasion.

Locate the pump so that the rise of suction hose from the water surface to the pump is even, with no humps or hollows where air can be trapped. Air pockets within the hose can prevent drafting.

Locate the pump on level ground so that it doesn’t fall into the water. Ensure all hose connections are air-tight.


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Davey Pump Page 8

3.3.2 Avoiding pump damage

WARNINGWARNINGOnly use the Davey pump with open relay pumping configurations. Do not connect the Davey pump to high pressure water sources, such as hydrants connected to water mains. These can crack the impeller housing.

After pumping water that contains chemicals or high concentrations of salt, ensure the pump is flushed thoroughly with fresh, clean water.

Don’t pump hydrocarbon based liquids. These will damage the pump.

Do not allow the pump to run dry. Check that there is water flow through the pump at all times. Insufficient flow will damage the pump.

WARNINGWARNINGPump may contain hot water under pressure.


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Page 9 Davey Pump

PART 4: OPERATING INSTRUCTIONS

4.1 Pre-operation checks

4.1.1 Oil

Remove the oil filler cap and dipstick, and clean. See Figure 6.

Insert the dipstick into the oil filler neck, but do not screw it in. Remove and check oil level.

If necessary, fill to the top of the oil filler neck with the recommended oil.

Replace dipstick and oil filler cap.

NOTEUse 4-stroke, or an equivalent high detergent, premium quality motor oil. SAE 10W-30 is recommended for general, all temperature use.

Figure 6 Schematic of engine with filling points

4.1.2 Air cleaner – dual element type

Check the air cleaner elements to be sure they are clean and in good condition.

Clean or replace the elements if necessary. See Part 5.4: Air cleaner service, on page 14.

4.1.3 Fuel

Check fuel levels. Refuel if necessary. Use unleaded petrol only. Do not fill tank beyond the level of the bottom of the filler neck.

Oil level

Fuel filler cap

Oil filler capDipstick


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Davey Pump Page 10

4.1.4 Pump priming

Before starting the engine, prime the pump with water.

On top of the pump body is a black plastic plug. See Figure 7. Remove the plug by turning anticlockwise. Fill the pump body with water. Replace the plug and tighten.

A flap valve inside the suction inlet will retain water in the pump.

Figure 7 The Davey pump with priming point, inlet and outlets

4.2 Operations

4.2.1 Starting the Davey pump

Figure 8 The Davey pump with controls

Priming point

25 mm hose outlet

25 mm hose outlet

38 mm hose outlet

38 mm hose inlet – for suction hose

Throttle

Fuel valve

Choke

Ignition switch


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Page 11 Davey Pump

Start the Davey pump as follows:

Locate the pump on a level, well drained area as close to the water source as practical

Attach inlet and outlet hoses. Locate inlet suction hose in the water source. The strainer must be completely submerged

Prime the pump

Move the fuel valve lever to the ON position

When starting a cold engine, move the choke lever as far as possible in the CLOSED direction, indicated by the arrow

When restarting a warm engine, leave the choke lever in the OPEN position

Move the throttle control lever away from the IDLE position, about 1/3 of the way towards the FAST position

Turn the ignition switch to the ON position

Pull the recoil starter until engine compression is felt.Then, give a fast, steady pull. Pull the start handle until the engine starts. Allow the start rope to retract slowly

When the engine starts, open the choke control gradually


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Davey Pump Page 12

Throttle to desired engine speed.

The pump should prime and begin pumping in fifteen seconds. For long or deep suctions, the pump may take up to three minutes to begin pumping water.

NOTEFor effective delivery, use either one 38 mm hose, or two 25 mm hoses connected to the outlet.

4.2.2 Stopping the Davey pump

NOTEIn case of emergency, the engine can be shut down immediately by turning the ignition control switch to the OFF position.

For normal operations, stop the Davey pump in the following manner.

Move the throttle control lever to the IDLE position

Turn the ignition switch to the OFF position

Turn the fuel valve OFF


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Page 13 Davey Pump

PART 5: MAINTENANCE

5.1 Clean up and before transport

Ensure the engine is cold. If required, clean up using a water spray with warm soapy water.

Flush the pump housing, fittings and all hoses – both suction and delivery – with fresh clean water.

Drain any water from the pump.

a) Remove the pump drain plug, which is situated at the base of the housing directly below inlet. Remove priming cap.

b) Allow water to drain from the pump body.c) Replace priming cap. Replace drain plug and seal with plumber’s tape.

WARNINGWARNINGWhen transporting the Davey pump, turn the fuel valve OFF and keep the engine level to prevent fuel spillage. Fuel vapour or spilled fuel may ignite.

5.2 Schedule

Permanent Stations to carry out Station Specific procedures daily.

Retained Stations to carry out Station Specific procedures weekly.

Community Fire Units to carry out Station Specific procedures quarterly.

Every year, or after 300 hours of operation, the Davey pump should be returned to an authorised Honda repairer for further servicing. Particular items to be checked are: valve clearance, idle speed, fuel tank and strainer, and fuel line.

Table 1: Maintenance Schedule

Item Action After Use Station Specific 6 Monthly Paragraph

reference

Engine oilCheck oil level 4.1.1

Replace 5.5

Air filter Check condition Clean or replace as necessary 5.4

Sediment cup Clean 5.6

Spark plugCheck condition Adjust gap and clean Replace if necessary

5.7

Drain Fuel Drain fuel from fuel tank, carburettor and sediment cup CFUs only 5.8


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Davey Pump Page 14

5.3 General

NOTEPeriodic inspection and adjustment of the Honda engine is essential if high performance is to be maintained. The required service intervals and the kind of maintenance to be performed are described in Table 1 above.

Servicing of the Davey pump is to be conducted in accordance with the following procedures:

• Station Commanders are to ensure that station personnel conduct procedure in Part 5.4: Air cleaner service, on page 14.

• The Station Commander can permit station personnel to conduct procedures in Part 5.5 to Part 5.9 (Oil Change, Sediment Cup Cleaning, Spark Plug Service, Draining Fuel, and Storage), or can outsource to a local service agent.

• Payment for a local service agent is to be arranged through the zone office. For CFUs, payment should be arranged through the CFU Manager, Bushfire Section, Greenacre.

• The Station Commander / Supervisor is to make an entry in the occurrence book to document the completed Davey pump servicing.

The engine can be serviced by any firefighter having the proper tools and service data, who feels they are mechanically competent.

WARNINGWARNINGShut off the engine and disconnect the spark plug before performing any maintenance.

If the engine has been running, the muffler will be very hot. Be careful not to touch the muffler during maintenance operations.

CAUTIONUse only genuine HONDA parts or their equivalent. The use of replacement parts which are not of equivalent quality may damage the engine.

5.4 Air cleaner service

5.4.1 General

A dirty air cleaner restricts air flow to the carburettor. To prevent carburettor malfunction, service the air cleaner regularly. Service more frequently when operating the engine in dusty areas.

WARNINGWARNINGNever use petrol or low flash point solvents for cleaning the air cleaner element. A fire or explosion could result.

Remove the wing nut and the air cleaner cover. Remove the filter elements and carefully separate them.


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Page 15 Davey Pump

Check both foam and paper elements for holes or tears and replace if damaged.

Figure 9 Air cleaner assembly

5.4.2 Foam element

To clean the foam element:

a) Wash in a solution of household detergent and warm water, then rinse thoroughly.

b) Allow the element to dry thoroughly. c) Soak the element in clean engine oil and squeeze out excess until no more oil

runs between the fingers.

NOTEThe engine will smoke during initial start-up if too much oil is left in the foam element.

5.4.3 Paper element

To clean the paper element:

a) Tap the element lightly several times on a hard surface to remove excess dirt, or blow compressed air through the filter from the inside out.

NOTENever try to brush the dirt off; brushing will force dirt into the fibres.

b) Replace the paper element if it is excessively dirty.c) After cleaning both elements, reassemble.d) Replace air cleaner cover wing nut, and tighten.


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Davey Pump Page 16

5.5 Oil change

Set the pump on a flat surface. Drain the oil while the engine is warm, this will ensure rapid and complete draining.

a) Place a receptacle under the drain plug.b) Remove the oil filler cap and drain plug.c) Drain oil into receptacle by tilting the pump to one side.d) Install the drain plug, and tighten it securely.e) Remove the dipstick. Fill with oil until level with bottom of dipstick hole. SAE

10W-30 is recommended for general, all temperature use. The engine oil capacity is 0.60 litres.

f) Replace both oil filler caps. Check the oil level.

Figure 10 Engine filling points

CAUTIONUsed motor oil can cause cancer or skin infections if left in contact with the skin for prolonged periods. Wear gloves or thoroughly wash hands with soap and water as soon as possible.

NOTEDispose of used motor oil in a manner that is compatible with the environment. The best option is to take it in a sealed container to your local service station for recycling.

Oil level

Oil filler capDipstick

Drain plug


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Page 17 Davey Pump

5.6 Sediment cup cleaning

To clean the sediment cup:

a) Turn the fuel valve to OFF.b) Remove the sediment cup and O-ring.c) Using a clean lint-free cloth, thoroughly wipe out the sediment cup and O-ring.d) Replace the 0-ring in the fuel valve and screw in the sediment cup. Tighten

securely.e) Turn the fuel valve ON and check for leaks. If a leak occurs, replace the O-

ring.

WARNINGWARNINGUnleaded petrol is extremely flammable and is explosive under certain conditions. Do not smoke or allow flames or sparks in the area.

Make sure the area is dry before starting the engine.

Figure 11 Sediment cup assembly

Sediment cup

Carburettor drain screw


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Davey Pump Page 18

5.7 Spark plug service

Recommended spark plug:

• BP6ES, BPR6ES (NGK)• W20EP-U, W20EPR-U (Nippondenso)• Spark plug gap: 0.70 – 0.80 mm (0.028 – 0.031 in)

WARNINGWARNINGNever use a spark plug of incorrect heat range.

To ensure proper engine operation, the spark plug must be properly gapped and free of deposits.

To check the spark plug:

a) Remove the spark plug cap.b) Use the proper size spark plug wrench to remove the spark plug.

CAUTIONAvoid contact with the muffler if the engine has been running.

Figure 12 Spark plug, with cap on and cap removed

c) Inspect the spark plug. Discard if there is apparent wear, or if the insulator is cracked or chipped.

d) Clean the elements with a wire brush to remove deposits.e) Measure the plug gap with a feeler gauge. Correct as necessary by bending the

side electrode. See Figure 13.

Figure 13 Spark plug gap

Muffler Air cleanerSpark plug cap

Spark plug

Air cleanerMuffler

Feeler gauge

Spark plug gap 0.70 mm to 0.8 mm


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Page 19 Davey Pump

f) Check that the spark plug washer is in good condition. Thread the spark plug in by hand to prevent cross-threading.

g) After the spark plug is seated, tighten with a spark plug wrench to compress the washer.

NOTEWhen installing a new spark plug, tighten 1/2 turn after the spark plug seats to compress the washer. When reinstalling a used spark plug, tighten 1/8 – 1/4 turn after the spark plug seats to compress the washer.

CAUTIONThe spark plug must be securely tightened. An improperly tightened spark plug can become very hot and may damage the engine.

5.8 Draining fuel

To drain the fuel:

a) Turn the fuel valve off.b) Remove and empty the sediment cup.c) Turn the fuel valve to the ON position and drain the petrol from the fuel tank

into a suitable container. The fuel drains from the sediment cup attachment. See Figure 14.

Figure 14 Draining the fuel tank

d) Replace the sediment cup and tighten securely.e) Drain the carburettor by loosening the drain screw. Drain the petrol into a

suitable container. The drain screw is located under the fuel valve switch.

WARNINGWARNINGUnleaded petrol is extremely flammable and is explosive under certain conditions. Do not smoke or allow flames or sparks in the area.

Sediment cup and o-ring

Drain fuel into a suitable container

Carburettor drain screw


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Davey Pump Page 20

5.9 Storage

Carry out the following procedure before storing the unit for an extended period:

a) Drain the pump of water.b) Drain the fuel.c) Drain and fill the sump with fresh oil.d) Remove the spark plug and pour about 20 ml of clean engine oil into the

cylinder.e) Crank the engine several revolutions to distribute the oil, then reinstall the

spark plug.f) Pull the starter rope slowly until resistance is felt AND the notch on the starter

pulley aligns with the hole on the recoil starter. See Figure 15 below. At this point, the intake and exhaust valves are closed. This will help to protect the engine from internal corrosion.

Figure 15 Starter pulley and hole on recoil starter

NOTEThe Honda GX 160 is a 4-stroke engine. The pulley will revolve twice for each engine cycle. One revolution will have valves closed, and you will feel resistance to turning the engine. The next revolution will have exhaust and inlet valves open, and you will not feel resistance.

After long periods of storage, ensure the engine and pump are free to rotate. With engine switch off, pull the recoil starter cord.

Hole on recoil starter

Notch on starter pulley

Adjust by pulling starter cord


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Page 21 Davey Pump

5.10 Troubleshooting the Honda engine

If the engine still does not start contact the Technical Officer, Rescue Section, Greenacre on (02) 9742 7155, or take it to an authorized Honda service centre.

Table 2: Honda engine troubleshooting

Symptom Possible Cause Remedy

Engine will not start

Incorrect control positions

Verify fuel valve lever and ignition switch are both in the ON position.

If engine is warm, move the choke lever to the OPEN positionIf the engine is cold, move the choke lever to the CLOSED position

Fuel level low Check fuel level, if necessary refuel

Contaminated fuel If fuel is contaminated, the fuel tank and carburettor will have to be drained. See Part 5.8

Spark plug faulty, fouled or improperly gapped

Replace, clean or correct gap in spark plug as detailed in Part 5.7

Flooded engine (spark plug is wet with fuel)

Dry and reinstall spark plug. Start engine with the throttle control lever in the FAST position.

Fuel filter clogged, carburettor or ignition malfunction, valves stuck

Return to Rescue Section, Greenacre for service by authorised Honda mechanic.

Oil Alert activated Confirm pump is located on level groundCheck oil level

Engine lacks power

Air cleaner elements clogged Clean or replace air cleaner elements as detailed in Part 5.4

Contaminated fuel If fuel is contaminated, the fuel tank and carburettor need to be drained. See Part 5.8

Fuel filter clogged, carburettor or ignition malfunction, valves stuck

Return to Rescue Section for service by authorised Honda mechanic

Engine stopsOut of fuel Refuel

Oil alert system activated Confirm pump is located on level groundCheck oil level


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Davey Pump Page 22

5.11 Troubleshooting the Davey pump

In all cases, if the unit doesn’t draw water, switch off the engine.

If the pump still does not draw water, withdraw from service. Contact the Technical Officer, Rescue Section, Greenacre.

CAUTIONDo not operate the Davey pump dry. The pump mechanism is water cooled.

Table 3: Davey pump troubleshooting

Symptom Possible Cause Remedy

Unit doesn’t draw water

Air leak in suction hose or fittings

Confirm all connections are tight

Confirm hose rises evenly from the water source, with no air pockets

Blocked suction hose Clear blockage. Ensure strainer is not embedded in mud

Pump flap valve not seated properly.

Remove suction hose. Confirm valve will retain water in the pumpPrime pump and re-fit suction hose. Try again

Pump not primed Prime the pump and start again


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Davey Pump Page 23

D.I. Recommended Practice Version: C1 Issued April 2006FILE: W:\NB\RP Bushfire\Davey\Frame\Appendix.fm © COPYRIGHT State Govt of NSW (NSWFB) 2006

REFERENCES

Honda Motor Co., 2003, Honda Engines Owner’s Manual GX120, GX160, GX200, Honda document number 31ZH7631 00X31-ZH7-6310, Honda, Japan.

Honda Motor Co., 1994, Honda GX120, GX160, GX200 Owner’s Manual, Honda document number 32ZH7620 00X32-ZH7-6200, Honda, Japan.

NSW Fire Brigades, 2004, In Orders 2004/18, Procedures: Water tanks in bushfire prone areas, NSWFB, Sydney.

NSW Fire Brigades, 2006, Safety Bulletin 2006/08: Aussie and Davey brand portable pumps, NSWFB, Sydney.

Portable Self Priming Pumps, Installation and Operating Instructions 2000, Davey document number P/N 48066-4, Davey Products Pty Ltd, Scoresby.

Single Impeller Firefighter 1999, Davey document number D840-1/SK/0901/GPW, Davey Products Pty Ltd, Scoresby.

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Davey Pump Page 24

D.I. Recommended Practice Version: C1 Issued April 2006FILE: W:\NB\RP Bushfire\Davey\Frame\DaveyIX.fm © COPYRIGHT State Govt of NSW (NSWFB) 2006

INDEX

Aair cleaner 14, 21

foam element 15paper element 15

Akron branches 4Aussie pump, purpose 1

Bbookmarks v

Cchecking oil 9choke 10

off, or open 11operating, or closed 11

Community Fire Units 1, 13contaminated fuel 21

DDavey Pump

hydraulic performance 4purpose 1technical specs 3

delivery head 4delivery hose 4diffuser nozzles 4dipstick 9, 16draining fuel 19draining oil 16

Eeffective delivery 4, 12emergency stop 12

Fflap valve 10, 22flooded engine 21flow rate 4flushing pump 13fuel filter 21fuel valve 10

off 12on 11

HHonda engine

emergency stop 12starting 11, 21stop 12technical specs 3

Iignition switch 10, 12

emergency stop 12starting 11

Intranet vi

Llinks vlocal service agent 14location

Davey pump 7strainer 7suction hose 7

Mmaintenance

annual 13Community Fire Units 13Permanent Stations 13Retained Stations 13Station Commander responsibilities 14

manual handling 6

Ooccurrence book 14OHS safe lift 6oil alert system 3, 21oil drain plug, location 16oil filler cap, location 16

Ppetrol vapour 6Planning for Bushfire Protection Legislation 5prolonged use of pump 7pump, priming 10, 22

Qqueries on maintenance and procedures 1

Rrecoil starter 11, 20

Sspark plug 20

changing 18disconnect before maintenance 14gap 18specifications 18

Station Portal visuction head 4, 5suction hose 5, 7, 22

float and chain 5strainer 5, 7

suction hose, new 5suction inlet 10

Tthrottle 10, 11, 12

Uunleaded petrol 6, 9used motor oil 16

Wwater tanks, bushfire prone areas 5

recommended practice - davey pump

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