Black DIC 157 Owner’s Manual GX270・GX390 LPG-Fueled Engine 31ZK6601 00X31-ZK6-6010 EM3 AH 英 N K1:GX390 300.2003.10 Printed in Japan HC 2003 Honda Motor Co., Ltd.
01/11/15 10:56:30 31ZK6600_001 The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects or other reproductive harm. Keep this owner’s manual handy, so you can refer to it at any time. This owner’s manual is considered a permanent part of the engine and should remain with the engine if resold. The information and specifications included in this publication were in effect at the time of approval for printing.
01/11/15 10:56:38 31ZK6600_002 INTRODUCTION Congratulations on your selection of a Honda engine. We are certain you will be pleased with your purchase of one of the finest engines on the market. We want to help you get the best results from your new engine and to operate it safely. This manual contains the information on how to do that; please read it carefully. As you read this manual, you will find information preceded by a symbol.
01/11/15 10:56:50 31ZK6600_003 INTRODUCTION A FEW WORDS ABOUT SAFETY Your safety and the safety of others are very important. And using this engine safely is an important responsibility. To help you make informed decisions about safety, we have provided operating procedures and other information on labels and in this manual. This information alerts you to potential hazards that could hurt you or others.
01/11/15 10:56:54 31ZK6600_004 CONTENTS ENGINE SAFETY ........................................................................................ 5 IMPORTANT SAFETY INFORMATION ................................................. 5 CONTROLS & FEATURES ......................................................................... 7 COMPONENT & CONTROL LOCATIONS ............................................. 7 CONTROLS .............................................................................................
01/11/15 10:56:57 31ZK6600_005 CONTENTS HELPFUL TIPS & SUGGESTIONS .......................................................... 33 STORING YOUR ENGINE .................................................................... 33 Storage Preparation ......................................................................... 33 Storage Precautions ......................................................................... 34 Removal From Storage ....................................................................
01/11/15 10:57:08 31ZK6600_006 ENGINE SAFETY IMPORTANT SAFETY INFORMATION Most accidents with engines can be prevented if you follow all instructions in this manual and on the engine. Some of the most common hazards are discussed below, along with the best way to protect yourself and others. Owner Responsibilities Honda engines are designed to give safe and dependable service if operated according to instructions. Read and understand this owner’s manual before operating the engine.
01/11/15 10:57:13 31ZK6600_007 ENGINE SAFETY Carbon Monoxide Hazard Exhaust gas contains poisonous carbon monoxide. Avoid inhalation of exhaust gas. Never run the engine in a closed garage or confined area. Other Equipment Review the instructions provided with the equipment powered by this engine for any additional safety precautions that should be observed in conjunction with engine startup, shutdown, or operation, or protective apparel that may be needed to operate the equipment.
01/11/15 10:57:19 31ZK6600_008 CONTROLS & FEATURES COMPONENT & CONTROL LOCATIONS MUFFLER AIR CLEANER THROTTLE LEVER SPARK PLUG CHOKE LEVER STARTER GRIP RECOIL STARTER ENGINE SWITCH OIL DRAIN PLUG OIL FILLER CAP 7
01/11/15 10:57:27 31ZK6600_009 CONTROLS & FEATURES CONTROLS Engine Switch The engine switch enables and disables the ignition system. The engine switch must be in the ON position for the engine to run. Turning the engine switch to the OFF position stops the engine.
01/11/15 10:57:34 31ZK6600_010 CONTROLS & FEATURES Choke Lever The choke lever opens and closes the choke valve in the carburetor. The CLOSED position creates a vacuum to help the LPG to flow into the engine during starting. The OPEN position removes the vacuum after the engine has started and can produced its own vacuum. Some engine applications use a remotely-mounted choke control rather than the engine-mounted choke lever shown here.
01/11/15 10:57:42 31ZK6600_011 CONTROLS & FEATURES Throttle Lever The throttle lever controls engine speed. Moving the throttle lever in the directions shown makes the engine run faster or slower. Some engine applications use a remotely-mounted throttle control rather than the engine-mounted throttle lever shown here. THROTTLE LEVER FAST SLOW Recoil Starter Grip Pulling the starter grip operates the recoil starter to crank the engine.
01/11/15 10:57:47 31ZK6600_012 CONTROLS & FEATURES FEATURES Oil Alert System (applicable engine types) The Oil Alert system is designed to prevent engine damage caused by an insufficient amount of oil in the crankcase. Before the oil level in the crankcase can fall below a safe limit, the Oil Alert system will automatically stop the engine (the ignition switch will remain in the ON position).
01/11/15 10:57:56 31ZK6600_013 BEFORE OPERATION IS YOUR ENGINE READY TO GO? For your safety, and to maximize the service life of your equipment, it is very important to take a few moments before you operate the engine to check its condition. Be sure to take care of any problem you find, or have your servicing dealer correct it, before you operate the engine.
01/11/15 10:58:03 31ZK6600_014 BEFORE OPERATION Check the Engine Check the engine oil level (see page 24). Running the engine with a low oil level can cause engine damage. The Oil Alert system (applicable engine types) will automatically stop the engine before the oil level falls below safe limits. However, to avoid the inconvenience of an unexpected shutdown, always check the engine oil level before startup. Check the air filter (see page 27 ).
01/11/15 10:58:11 31ZK6600_015 OPERATION SAFE OPERATING PRECAUTIONS Before operating the engine for the first time, please review the IMPORTANT SAFETY INFORMATION on page 5 and the chapter titled BEFORE OPERATION. Carbon monoxide gas is toxic. Breathing it can cause unconsciousness and even kill you. Avoid any areas or actions that expose you to carbon monoxide.
01/11/15 10:58:17 31ZK6600_016 OPERATION 2. Move the choke lever to the CLOSED position. Always use the choke when starting the engine. Some engine applications use a remotely-mounted choke control rather than the engine-mounted choke lever shown here. CHOKE LEVER CLOSED 3. Move the throttle lever away from the SLOW position, about 1/3 of the way toward the FAST position. Some engine applications use a remotely-mounted throttle control rather than the engine-mounted throttle lever shown here.
01/11/15 10:58:23 31ZK6600_017 OPERATION 4. Turn the engine switch to the ON position. ENGINE SWITCH ON 5. Operate the starter. Pull the starter grip lightly until you feel resistance, then pull briskly. Return the starter grip gently.
01/11/15 10:58:27 31ZK6600_018 OPERATION 6. Move the choke lever to the OPEN position after the engine has started.
01/11/15 10:58:36 31ZK6600_019 OPERATION STOPPING THE ENGINE To stop the engine in an emergency, simply turn the engine switch to the OFF position. Under normal conditions, use the following procedure. 1. Move the throttle lever to the SLOW position. Some engine applications use a remotely-mounted throttle control rather than the engine-mounted throttle lever shown here. THROTTLE LEVER SLOW 2. Turn the engine switch to the OFF position. ENGINE SWITCH OFF 3.
01/11/15 10:58:42 31ZK6600_020 OPERATION SETTING ENGINE SPEED Position the throttle lever for the desired engine speed. Some engine applications use a remotely-mounted throttle control rather than the engine-mounted throttle lever shown here. For engine speed recommendations, refer to the instructions provided with the equipment powered by this engine.
01/11/15 10:58:49 31ZK6600_021 SERVICING YOUR ENGINE THE IMPORTANCE OF MAINTENANCE Good maintenance is essential for safe, economical, and trouble-free operation. It will also help reduce air pollution. Improperly maintaining this engine, or failure to correct a problem before operation, can cause a malfunction in which you can be seriously hurt or killed. Always follow the inspection and maintenance recommendations and schedules in this owner’s manual.
01/11/15 10:59:01 31ZK6600_022 SERVICING YOUR ENGINE MAINTENANCE SAFETY Some of the most important safety precautions follow. However, we cannot warn you of every conceivable hazard that can arise in performing maintenance. Only you can decide whether or not you should perform a given task. Failure to properly follow maintenance instructions and precautions can cause you to be seriously hurt or killed. Always follow the procedures and precautions in the owner’s manual.
02/07/24 11:39:38 31ZK6600_023 SERVICING YOUR ENGINE MAINTENANCE SCHEDULE REGULAR SERVICE PERIOD (3) Each ITEM use Perform at every indicated First or month or operating hour interval, Every Every month 3 months 6 months 20 Hrs. or or Every Refer year to or page 50 Hrs. 100 Hrs. 200 Hrs. whichever comes first.
01/11/15 10:59:22 31ZK6600_024 SERVICING YOUR ENGINE FUEL RECOMMENDATIONS Use LPG with a propane content of 95% or higher. This engine is certified to operate on LPG only. Occasionally you may hear a light ‘‘spark knock’’ or ‘‘pinging’’ (metallic rapping noise) while operating under heavy loads. This is no cause for concern. If spark knock or pinging occurs at a steady engine speed, under normal load, change brands of LPG. If spark knock or pinging persists, see an authorized Honda servicing dealer.
01/11/15 10:59:30 31ZK6600_025 SERVICING YOUR ENGINE ENGINE OIL LEVEL CHECK Check the engine oil level with the engine stopped and in a level position. 1. Remove the filler cap/dipstick and wipe it clean. 2. Insert and remove the dipstick without screwing it into the filler neck. Check the oil level shown on the dipstick. 3. If the oil level is low, fill to the edge of the oil filler hole with the recommended oil (see page 26). 4. Screw in the filler cap/dipstick securely.
02/07/24 11:39:47 31ZK6600_026 SERVICING YOUR ENGINE ENGINE OIL CHANGE Drain the used oil while the engine is warm. Warm oil drains quickly and completely. 1. Place a suitable container below the engine to catch the used oil, then remove the filler cap/dipstick and the drain plug. 2. Allow the used oil to drain completely, then reinstall the drain plug, and tighten it securely. Please dispose of used motor oil in a manner that is compatible with the environment.
01/11/15 10:59:46 31ZK6600_027 SERVICING YOUR ENGINE ENGINE OIL RECOMMENDATIONS Oil is a major factor affecting performance and service life. Use 4-stroke automotive detergent oil that is designed for engines operating on LPG. SAE 30 (API service classification SJ) is recommended for general use.
01/11/15 10:59:52 31ZK6600_028 SERVICING YOUR ENGINE AIR FILTER INSPECTION Remove the air cleaner cover and inspect the filter elements. Clean or replace dirty filter elements. Always replace damaged filter elements. Refer to page 28 for instructions that apply to the air cleaner and filter service.
01/11/15 10:59:58 31ZK6600_029 SERVICING YOUR ENGINE AIR CLEANER SERVICE A dirty air filter will restrict air flow to the carburetor, reducing engine performance. If you operate the engine in very dusty areas, clean the air filter more often than specified in the MAINTENANCE SCHEDULE. Operating the engine without an air filter, or with a damaged air filter, will allow dirt to enter the engine, causing rapid engine wear. This type of damage is not covered by the Distributor’s Limited Warranty. 1.
01/11/15 11:00:03 31ZK6600_030 SERVICING YOUR ENGINE Paper air filter element: Tap the filter element several times on a hard surface to remove dirt, or blow compressed air [not exceeding 30 psi (207 kPa, 2.1 kgf/cm )] through the filter element from the inside. Never try to brush off dirt; brushing will force dirt into the fibers. Foam air filter element: Clean in warm soapy water, rinse, and allow to dry thoroughly. Or clean in nonflammable solvent and allow to dry.
01/11/15 11:00:12 31ZK6600_031 SERVICING YOUR ENGINE SPARK PLUG SERVICE Recommended spark plugs: BPR6ES (NGK) W20EPR-U (DENSO) An incorrect spark plug can cause engine damage. 1. Disconnect the spark plug cap, and remove any dirt from around the spark plug area. 2. Remove the spark plug with a 13/16-inch spark plug wrench. SPARK PLUG WRENCH 3. Inspect the spark plug. Replace it if the electrodes are worn, or if the insulator is cracked or chipped.
01/11/15 11:00:20 31ZK6600_032 SERVICING YOUR ENGINE 6. After the spark plug seats, tighten with a 13/16-inch spark plug wrench to compress the washer. If reinstalling the used spark plug, tighten 1/8−1/4 turn after the spark plug seats. If installing a new spark plug, tighten 1/2 turn after the spark plug seats. A loose spark plug can overheat and damage the engine. Overtightening the spark plug can damage the threads in the cylinder head. 7. Attach the spark plug cap. IDLE SPEED ADJUSTMENT 1.
01/11/15 11:00:33 31ZK6600_033 SERVICING YOUR ENGINE SPARK ARRESTER SERVICE (optional equipment) Your engine is not factory-equipped with a spark arrester. In some areas, it is illegal to operate an engine without a spark arrester. Check local laws and regulations. A spark arrester is available from authorized Honda servicing dealers. The spark arrester must be serviced every 100 hours to keep it functioning as designed. If the engine has been running, the muffler will be very hot.
01/11/15 11:00:40 31ZK6600_034 HELPFUL TIPS & SUGGESTIONS STORING YOUR ENGINE Storage Preparation Proper storage preparation is essential for keeping your engine troublefree and looking good. The following steps will help to keep rust and corrosion from impairing your engine’s function and appearance, and will make the engine easier to start when you use it again. Cleaning If the engine has been running, allow it to cool for at least half an hour before cleaning.
01/11/15 11:00:50 31ZK6600_035 HELPFUL TIPS & SUGGESTIONS Engine Oil 1. Change the engine oil (see page 25). Engine Cylinder 1. Remove the spark plug (see page 30). 2. Pour a tablespoon (5−10 cc) of clean engine oil into the cylinder. 3. Pull the starter rope several times to disribute the oil in the cylinder. 4. Reinstall the spark plug. 5. Pull the starter rope slowly until resistance is felt and the notch on the starter pulley aligns with the hole at the top of the recoil starter cover.
01/11/15 11:00:56 31ZK6600_036 HELPFUL TIPS & SUGGESTIONS Position the equipment so the engine is level. Tilting can cause oil leakage. With the engine and exhaust system cool, cover the engine to keep out dust. A hot engine and exhaust system can ignite or melt some materials. Do not use sheet plastic as a dust cover. A nonporous cover will trap moisture around the engine, promoting rust and corrosion. Removal From Storage Check your engine as described in the BEFORE OPERATION chapter of this manual.
01/11/15 11:01:01 31ZK6600_037 HELPFUL TIPS & SUGGESTIONS TRANSPORTING If the engine has been running, allow it to cool for at least 15 minutes before loading the engine-powered equipment on the transport vehicle. A hot engine and exhaust system can burn you and can ignite some materials. Keep the engine level when transporting to reduce the possibility of fuel leakage. Turn the fuel valve OFF at the source.
01/11/15 11:01:13 31ZK6600_038 TAKING CARE OF UNEXPECTED PROBLEMS ENGINE WILL NOT START 1. Check control positions. 2. Check fuel. 3. Remove and inspect spark plug. 4. Take engine to an authorized Honda servicing dealer, or refer to shop manual. ENGINE LACKS POWER 1. Check air filter. 2. Take engine to an authorized Honda servicing dealer, or refer to shop manual. Possible Cause Fuel valve OFF. Choke OPEN. Engine switch OFF. Out of fuel. Spark plug faulty, fouled, or improperly gapped.
01/11/15 11:01:20 31ZK6600_039 TECHNICAL & CONSUMER INFORMATION TECHNICAL INFORMATION Serial Number Location SERIAL NUMBER & ENGINE TYPE Record the engine serial number in the space below. You will need this serial number when ordering parts, and when making technical or warranty inquires (see page 47 ).
01/11/15 11:01:29 31ZK6600_040 TECHNICAL & CONSUMER INFORMATION Remote Control Linkage The throttle and choke control levers are provided with holes for optional cable attachment. The following illustrations show installation examples for a solid wire cable and for a flexible, braided wire cable. If using a flexible, braided wire cable, add a return spring as shown. It is necessary to loosen the throttle lever friction nut when operating the throttle with a remotely-mounted control.
02/07/24 11:39:55 31ZK6600_041 TECHNICAL & CONSUMER INFORMATION Carburetor Modification for High Altitude Operation The GX270 and GX390 LPG-fueled engine do not require any modifications for high-altitude operation. However, performance will decrease at high altitudes. Fuel Regulator Information This engine is certified to comply with U.S. EPA and California ARB emission regulations using the Impco Beam regulator specified in the installation instructions (see below).
01/11/15 11:01:44 31ZK6600_042 TECHNICAL & CONSUMER INFORMATION Emission Control System Information Source of Emissions The combustion process produces carbon monoxide, oxides of nitrogen, and hydrocarbons. Control of hydrocarbons and oxides of nitrogen is very important because, under certain conditions, they react to form photochemical smog when subjected to sunlight. Carbon monoxide does not react in the same way, but it is toxic.
01/11/15 11:01:55 31ZK6600_043 TECHNICAL & CONSUMER INFORMATION Problems That May Affect Emissions If you are aware of any of the following symptoms, have your engine inspected and repaired by your servicing dealer. Hard starting or stalling after starting. Rough idle. Misfiring or backfiring under load. Afterburning (backfiring). Black exhaust smoke or high fuel consumption.
01/11/15 11:02:09 31ZK6600_044 TECHNICAL & CONSUMER INFORMATION Air Index An Air Index Information hang tag/label is applied to engines certified to an emission durability time period in accordance with the requirements of the California Air Resources Board. The bar graph is intended to provide you, our customer, the ability to compare the emissions performance of available engines. The lower the Air Index, the less pollution.
01/11/15 11:02:24 31ZK6600_045 TECHNICAL & CONSUMER INFORMATION Specifications GX270 Length × Width × Height Dry weight Engine type Displacement [Bore × Stroke] Max. output Max. torque Fuel consumption Cooling system Ignition system PTO shaft rotation 15.7 × 16.9 × 16.0 in (400 × 430 × 407 mm) 50.7 lbs (23.0 kg) 4-stroke, overhead valve, single cylinder 16.5 cu-in (270 cm ) [ 3.0 × 2.3 in (77 × 58 mm) ] 8.9 bhp (6.6 kW, 9.0 PS) at 3,600 rpm 14.1 lbf·ft (19.1 N·m, 1.95 kgf·m) at 2,500 rpm 0.
01/11/15 11:02:30 31ZK6600_046 TECHNICAL & CONSUMER INFORMATION Wiring Diagram Engine Types With Oil Alert 45
01/11/15 11:02:37 31ZK6600_047 TECHNICAL & CONSUMER INFORMATION CONSUMER INFORMATION Honda Publications These publications will give you additional information for maintaining and repairing your engine. You may order them from your Honda engine dealer. Shop Manual This manual covers complete maintenance and overhaul procedures. It is intended to be used by a skilled technician. Parts Catalog This manual provides complete, illustrated parts lists.
01/11/15 11:02:48 31ZK6600_048 TECHNICAL & CONSUMER INFORMATION Warranty Service Information Servicing dealership personnel are trained professionals. They should be able to answer any question you may have. If you encounter a problem that your dealer does not solve to your satisfaction, please discuss it with the dealership’s management. The Service Manager or General Manager can help. Almost all problems are solved in this way.
01/11/15 11:02:50 31ZK6600_049 MEMO 48
02/07/24 11:40:03 31ZK6600_050 QUICK REFERENCE INFORMATION Fuel Type Engine Oil Type Spark Plug Capacity Type Gap Carburetor Maintenance Idle speed Before each use First 20 hours Subsequent LPG with a propane content of 95 % or higher (page 23) SAE 30, API SJ, for general use (page 26) 1.16 US qt (1.10 ) NGK: BPR6ES , DENSO: W20EPR-U 0.028−0.031 in (0.70−0.80 mm) (page 30) 200 1,400 ＋ −150 rpm (page 31) Check engine oil level. Check air filter. Change engine oil.
Black DIC 157 Owner’s Manual GX270・GX390 LPG-Fueled Engine 31ZK6601 00X31-ZK6-6010 EM3 AH 英 N K1:GX390 300.2003.10 Printed in Japan HC 2003 Honda Motor Co., Ltd.
