OPERATING AND
MAINTENANCE MANUAL
MODEL NO.: FYR PORT
SERIAL NO._______________
Failure to follow the operating, lubrication,
and maintenance requirements set forth in
the operating and instruction manual may
result in serious personal injury and/or damage to equipment.
A Hale pump is a quality product; ruggedly designed, accurately machined, carefully assembled and thoroughly tested. In order to maintain
the high quality of your pump and to keep it in a ready condition, it is important to follow the instructions on care and operation. Proper use and
good preventive maintenance will lengthen the life of your pump.
ALWAYS INCLUDE THE PUMP SERIAL NUMBER IN CORRESPONDENCE
n
HALE PRODUCTS INC.
A Unit of IDEX Corporation
700 Spring Mill Avenue
610/825-6300
www.haleproducts.com
n
Fax: 610/825-6440
Fire Suppression Division
n
Conshohocken, PA 19428
Limited Warranty
EXPRESS WARRANTY: Hale Products Inc. (“Hale”) hereby warrants to the original buyer that products manufactured by it are free of defects in material and workmanship for two (2) years or 2000 hours usage whichever
shall first occur. The “Warranty Period” commences on the date the original buyer takes delivery of the product
from the manufacturer.
LIMITATIONS: HALE’S obligation is expressly conditioned on the Product being:
• Subjected to normal use and service.
• Properly maintained in accordance with HALE’S Instruction Manual as to recommended services and
procedures.
• Not damaged due to abuse, misuse, negligence or accidental causes.
• Not altered, modified, serviced (non-routine) or repaired other than by an Authorized Service Facility.
• Manufactured per design and specifications submitted by the original Buyer.
THE ABOVE EXPRESS LIMITED WARRANTY IS EXCLUSIVE. NO OTHER EXPRESS WARRANTIES ARE
MADE. SPECIFICALLY EXCLUDED ARE ANY IMPLIED WARRANTIES INCLUDING, WITHOUT
LIMITATIONS, THE IMPLIED WARRANTIES OF MERCHANTABILITY OF FITNESS FOR A PARTICULAR
PURPOSE OR USE; QUALITY; COURSE OF DEALING; USAGE OF TRADE; OR PATENT INFRINGEMENT
FOR A PRODUCT MANUFACTURED TO ORIGINAL BUYER’S DESIGN AND SPECIFICATIONS.
EXCLUSIVE REMEDIES: If Buyer promptly notifies HALE upon discovery of any such defect (within the War-
ranty Period), the following terms shall apply:
• Any notice to HALE must be in writing, identifying the Product (or component) claimed defective
and circumstances surrounding its failure.
• HALE reserves the right to physically inspect the Product and require Buyer to return same to
HALE’S plant or other Authorized Service Facility.
• In such event, Buyer must notify HALE for a Returned Goods Authorization number and Buyer
must return the Product F.O.B. within (30) days thereof.
• If determined defective, HALE shall, at its option, repair or replace the Product, or refund the
purchase price (less allowance for depreciation).
• Absent proper notice within the Warranty Period, HALE shall have no further liability or obligation
to Buyer therefore.
THE REMEDIES PROVIDED ARE THE SOLE AND EXCLUSIVE REMEDIES AVAILABLE. IN NO EVENT
SHALL HALE BE LIABLE FOR INCIDENTAL OR CONSEQUENTIAL DAMAGE’ INCLUDING, WITHOUT
LIMITATION, LOSS OF LIFE; PERSONAL INJURY; DAMAGE TO REAL OR PERSONAL PROPERTY DUE TO
WATER OR FIRE; TRADE OR OTHER COMMERCIAL LOSSES ARISING, DIRECTLY OR INDIRECTLY, OUT
OF PRODUCT FAILURE.
Hale Products Inc. • A Unit of IDEX Corporation
700 Spring Mill Avenue • Conshohocken, PA. 19428
Phone: 610-825-6300 • Fax: 610-825-6440
IDEX CORPORATION
www.haleproducts.com
SAFETY PRECAUTIONS
Failure to follow the operating, maintenance and lubrication requirements set forth In this
operating and Instruction manual may result in serious personnel injury and/or damage to
equipment. These WARNING statements indicate potentially hazardous conditions for
operator or equipment.
TAKE NECESSARY STEPS TO PROTECT PERSONNEL AND EQUIPMENT.
1. Carefully read Engine Operating Instructions, before attempting to operate, service, or
disassemble the engine or any of its parts.
2. Warning - Gasoline is a highly combustible fuel.
The Improper use, handling, or storage of gasoline can be dangerous. Prevent
accidents by following these safety rules:
A Use gasoline only as a fuel, never as a cleaning fluid.
B Use only an approved container to hold or store gasoline. Never store gasoline in
familiar containers such as milk containers or soda pop bottles.
C Store gasoline in a cool location, out of the reach of children. Never store
gasoline near heat or an open flame.
D Do not refuel with the engine running. Add fuel to a cool engine only. Spilled fuel
on a hot engine or muffler may cause a fire or an explosion. Fill fuel tank out-ofdoors and wipe up any spills.
E Make sure all fuel lines and connectors are secure.
F Provide a fire extinguisher nearby when working with gasoline. Be sure
extinguisher Is In operating condition; chock the pressure gauge or indicator, Be
familiar with its proper use. Consult local fire department for the correct type of
extinguisher for your application. Extinguishers rated ABC by the NATIONAL FIRE
PROTECTION ASSOCIATION are appropriate for most applications.
G POSITIVELY NO SMOKING!!
3. DO NOT RUN THE ENGINE IN AN ENCLOSED AREA!!
Exhaust fumes contain carbon monoxide that is an odorless poisonous gas. If
equipment is located in an enclosed area with an exhaust line to the outside, regularly
check the exhaust system for leaks. Be sure the area is well ventilated.
4. Do not operate equipment when mentally or physically fatigued.
5. Stay away from moving parts, avoid wearing loose jackets, shirts and ties.
6. Keep the equipment and surrounding area clean. Cluttered areas invite accidents.
Remove all oil deposits from equipment and surrounding area. Accumulations of grease
and oil may present a hazard.
7. All visitors should be kept at a safe distance from work area. Keep children away from
equipment and discharge hose. Do not allow children to hold discharge hose.
8. Be careful not to touch the exterior of a hot engine, especially the muffler and the
surrounding area. The engine is hot enough to be painful or cause injury.
9. Keep power shields and guards in place. Do not make adjustments and repairs while
engine is running, unless specified for in repairs. Use extreme caution around hot
manifolds and moving parts.
10. Prevent accidental starting by always removing spark plug or by disconnecting and
grounding spark plug wire before working on engine or the equipment driven by engine.
11. Maximum speed of the engine is set. Do not tamper with the controls to adjust to run
at higher speeds. Excessive speed increases the hazard of personal injury and reduces
engine life
12. Familiarize yourself with all controls, learn how to stop engine quickly In a
emergency.
13. When shutting off a gasoline engine, be sure It is completely stopped before leaving
the work area.
14. Close fuel tank cap vent when storing or transporting.
15. Do not store vertical with fuel in tank.
16. Open fuel tank cap vent when pumping.
17. Check engine fuel level before Initial start-up each day.
18. Do not run pump more than two minutes without placing in water. After engine has
been started and is operating smoothly, place pump in at least 4 inches (100 mm.) of
water.
19. During freezing weather, drain the pump, throttle actuator tubing, and discharge lines
after each use.
20. Flush pump with fresh, clear water if pump has been used to pump salt water or water
containing sand.
HALE FYR PORT PUMP MODEL:
20FP-C8FR/C8SK OPERATION AND INSTRUCTION MANUAL
ENGINE DRIVEN,
PORTABLE CENTRIFUGAL PUMPING UNIT
INTRODUCTION
PURPOSE:
This operation and instruction manual is published to guide and assist in the
installation, operation, lubrication, maintenance and repair of the Hale FYR PORT
pumping unit.
The installer and operator should understand this manual and the engine
manufacturers operating manual before attempting to install or operate the unit.
IDENTIFICATION:
Whenever a question arises regarding your pumping unit, contact your Hale Dealer for
the latest available information. This dealer will also be able to advise you of the
nearest authorized engine dealer or refer to the supplied list of engine distributors who
can provide service for the engine in your pumping unit. Finally, if additional help is
needed, contact the Service Department of the Hale Fire Pump Company.
Please supply the complete pump model and serial numbers when requesting
information or ordering parts. The pump model and serial numbers are stamped (not
cast) on the Hale nameplate or on top of the pump head. For you convenience, fill in
the information on the hale nameplate below.
Always mention both the model number and serial number of your engine when
ordering engine parts. These numbers are found on the engine identification plate
attached to the engine.
To help you identify the parts used in your FYR PORT, a pump parts catalog is
included toward the back of this manual. To identify the engine parts used in you
pumping unit, refer to the engine manufacturers parts catalog.
DESCRIPTION
GENERAL:
The FYR PORT is a lightweight, portable, centrifugal pump mounted either on
skids or in a wraparound frame. The pumping unit consists of a Hale 20FP single stage
centrifugal pump close coupled to an air cooled, 2 cycle, single cylinder, gasoline
engine. The unit includes an automatic rewind starter, a spark arresting muffler, engine
overspeed control switch, priming pump and priming valve. It is intended for pumping
water from draft, relay, or hydrant. The unit will deliver discharge pressures to 220
PSIG and flows to 75 GPM from draft.
The FYR PORT pumping unit consists of 6 major subassemblies; the engine,
pump, priming system, mounting base, overspeed control switch and wraparound
frame.
ENGINE:
The lightweight engine is a single cylinder, 2 cycle, air-cooled version producing
@ 8 hp (6 Kw) from its 8.2 cu. inch (134 cc) displacement using a gasoline/oil mixture
fuel.
The engine is equipped with water resistant solid state ignition, a pressure
carburetor with built-in fuel pump, and an on/off ignition toggle switch.
The engines interior is protected from impurities by the use of a wire mesh
element air filter, a 75 micron in-line fuel filter, and an integral fuel strainer built into the
fuel pump. PUMP:
The engine crankshaft extension serves as the pump shaft with an enclosed type
bronze impeller mounted directly on the shaft. The shaft is protected against corrosion
by a bronze sleeve, an O-ring, and a mechanical type, self-lubricating and adjusting
seal. The impeller is hydraulically sealed by a replaceable, patented, floating, bronze
clearance ring located in the inlet of the aluminum volute body. . The volute body is
attached to the cast aluminum pump head by four mounting screws.
The pump head, which serves as the mounting bracket for the pump and engine
assembly, is attached to the mounting base with rubber vibration and shock mounts. It
also incorporates a handle for positioning the unit or carrying short distances.
The pump inlet and discharge connections are either 1 1/2" male national fire hose
threads (NST), or 1 1/2" metric threads (ISO 228/1-G 1 1/2 A).
PRIMING SYSTEM:
The priming pump is a hand operated piston pump. Its purpose is to remove air
from the pump allowing atmospheric pressure to push water through the inlet hose into
the pump.
A priming valve is included which controls air flow through the priming line.
MOUNTING BASE:
The mounting base is an intermediate part to which the engine is attached with
three shock-vibration isolation mounts. The base is then attached to the two skids.
The mounting base has the overspeed control switch, priming pump mounting
clamps (skid version) and Hale nameplate attached to it.
OVERSPEED CONTROL:
The overspeed switch control assembly is a safeguard against overspeeding of
the engine. The overspeed switch is attached to the mounting base of pumping unit
below the carburetor. Attached to the front of the overspeed switch is a flexible
transparent hose that is connected to the nozzle plate (riveted to the engine fan
housing). Connected to the back of the overspeed switch are two wires; one goes to
the engines ignition coil, the other goes to ground (engine). The switch senses the air
pressure generated by the engines cooling fan.
When the engine reaches a speed in excess of that which would normally occur,
the fan air pressure generated will be sufficient to cause the switch to close;thereby
grounding the solid state ignition. The engine speed will decrease until the air pressure
reaches a lower trip point, reactivating the ignition system and the engine will
accelerate. The engine will decelerate and accelerate alternately until the operating
conditions are returned to their normal mode.
WRAPAROUND FRAME:
The wraparound frame protects the pump, engine and fuel system from damage
caused by normal handling. The frame also serves as a convenient means for
transporting the FYR PORT unit over long distances.
PREPARATION
INSPECTION OF NEW UNIT:
When unpacking unit do not discard cushioning materials, carton, or case until
you are certain everything is correct. Inspect carefully; perfect condition of the outside
shipping container does not guarantee undamaged contents. Check for loose,
missing, or damaged parts. Also, check the packing slip for any additional parts.
After inspection proves satisfactory discard all shipping material in a proper
manner.
ATTENTION: The FYR PORT has been shipped with the engine,
carburetor, air filter and fuel systems drained and tagged. Before using, fill
with proper quantities and grades of fuel and oil, refer to Fuel and
Lubricant Specifications, page 9. The idle speed, idle and main fuel
mixture adjustment screws have been factory set. However, the idle and
main fuel mixture adjustment screws may require readjustment, especially
for cold weather or high altitudes (see engine manual for adjustment
procedure).
IDENTIFICATION OF CONTROLS:
(See plate numbers 534B, 1 of 2 and 2 of 2, in Parts section for location of
controls).
EXPLANATION OF CONTROLS:
Air Cleaner: Low restriction cleanable expanded aluminum foil type element.
Carburetor Fuel Strainer: Provides secondary fuel filtering for engine.
Carrying Handle: This is incorporated into the pump head.
Choke: Reduces the amount of air entering the engine to correct the fuel-air ratio for
cold start-up.
Discharge Hose Connection: Located on the air cleaner side of the unit for
connecting a 1 1/2" NST or ISO hose fitting.
Exhaust Muffler: This is a spark arrester type that also reduces the amount of
combustion noise emitted by the engine.
Flexible Transparent Hose: Is connected between the nozzle plate and the overspeed
switch control. This allows for visual inspection of dirt and water which may clog hose
and reduce amount of pressure reaching switch. Check regularly, and be sure hose is
not cracked, crimped, or kinked.
Ignition Toggle Switch: When flipped to the ON position opens circuit to ground
allowing the magneto to develop a spark for the ignition of combustion. Flipped to the
OFF position closes the circuit to ground magneto.
In-Line Fuel Filter: Provides primary fuel filtering for engine. Nozzle Plate: Riveted to
the engine fan housing, directs air pressure to flexible transparent hose and overspeed
control.
Overspeed Control: For description refer to DESCRIPTION - OVERSPEED
CONTROL, page 3.
Starting Handle: Pull to start.
Throttle Lever: Varies the speed of the engine. (Pull up to increase speed). Do not
force the lever against the stops.
Fuel Line Connector (Skid Version): Connect the fuel line from the fuel caddie here.
Priming Valve: For description refer to DESCRIPTION - PRIMING SYSTEM, page 2.
Priming Pump: for description refer to DESCRIPTION - PRIMING SYSTEM-. page 2.
Pump Inlet: Located at the end of the pump, fitted with 1 1/2" NST or ISO male adapter.
TRANSPORTING
WARNING: Before transporting the FYR PORT (Skid unit) the fuel
caddie must be disconnected from the engine, and fuel drained as
instructed under STOPPING PROCEDURE page 7. Also, allow
engine to cool. When carrying the unit in the wraparound frame close
the vent on the fuel tank cap. Carry the unit in an upright position by
using the frame.
The FYR PORT has a handle for moving and positioning the unit. Care should be taken
not to drop or strike the engine or pump as damage may result.
When transporting the unit by motor vehicle, care should be taken to fasten it down
securely. Follow the manufacturers instructions for transporting the fuel caddie.
OPERATION
INSTALLATION:
1. Choose a suitable location, as near to the source of water as is possible, to place the
FYR PORT.
2. Attach hoses. When operating from draft, the inlet hose should slope continuously
downward from the pump to the water.
3. Attach fuel line hose when using the Skid mounted unit. CAUTION: Do not attach
regular pipe threaded (NPSH/NPT) fittings as they could permanently damage the male
threads.
PRIME PUMP:
It is recommended that the pump be primed before starting the engine.
a) PRIMING PROCEDURE:
1. The discharge must be closed either with a discharge valve, shut-off nozzle or by
pinching the discharge hose (use a pinch clamp if available).
2. Open priming valve.
3. Operate priming pump until water is discharged from priming pump.
4. Close priming valve.
5. Start engine. See starting procedure.
6. Slowly open discharge valve until a steady stream is discharged.
7. If an unsteady stream is discharged (incomplete prime), open priming valve and
operate hand primer to purge remaining air until a steady stream is discharged.
Then close priming valve and adjust throttle for desired output.
b) ALTERNATE PRIMING METHOD:
If the inlet hose is fitted with a foot valve, the pump may be primed by jabbing the end
of the inlet hose in and out of the water until water expands the discharge hose. The
discharge line must be open when this method is used. Again, be sure the priming
valve is closed before starting engine.
STARTING PROCEDURE
WARNING: DO NOT RUN THE ENGINE IN AN ENCLOSED AREA!!!
Exhaust fumes contain carbon monoxide which is an ordorless and
poisonous gas. Be sure the area is well ventilated.
1. Make sure there is a fresh mixture of gasoline and oil in the tank. Refer to FUEL
SPECIFICATIONS. page 9, for proper amounts and type.
WARNING: Do not change or fill fuel caddies or tank while engine is
running. Fill them out of doors away from any source of ignition.
2. Connect fuel caddie to fuel line connector on engine base (Skid Unit). Open the air
vent on the caddie or tank cap. Squeeze and release the priming bulb until resistance
is felt, indicating the fuel line is full. Further action will pump fuel past the check valve
into the carburetor, flooding it.
3. Close choke.
NOTE: A warm engine requires less choking than a cold engine. 4. Open throttle
slightly (1/4). Closed is down.
5. Move ignition switch to ON position.
6. Place foot on frame or skid to prevent movement.
7. Pull the starting handle slowly to bleed off some compression; then, pull with a quick
short stroke. Repeat as necessary.
8. When engine starts, slowly open choke. 9. Slowly open discharge valve.
10. Set throttle to desired operating point.
NOTE: When operating from draft, especially
speed without a corresponding increase in pump pressure. If the engine speed
increases with no increase in flow or pressure reduce the throttle setting until the
pressure of flow decreases slightly and operate at that point.
STOPPING PROCEDURE
1. Idle engine by pushing throttle lever down.
2. Move ON/OFF switch to off position.
3. Disconnect fuel caddie quick disconnect coupling, close cap and store fuel line (skid
unit). Simply close the fuel tank vent on the frame unit.
4. Restart engine, with water flowing through pump, and allow to idle until it stops from
lack of fuel (skid unit).
5. Allow lines to drain. Disconnect hoses.
CAUTION: Be careful not to touch the, exterior of the engine, especially the
muffler and the surrounding area. The engine is hot enough to cause injury.
on high lifts, do not increase engine
6. Without inlet and discharge caps in place, drain pump by tilting inlet end of pump
downward. Open the priming valve and operate the priming pump until all water is
discharged. When pump is drained, replace caps to prevent damage to threads.
RELAY PROCEDURE
For pumping water over long distances or up high vertical rises, it may be
necessary to use several pumps in series.
When this is done, pressure, (not exceeding 100 PSI), should be maintained at
the inlet of the second and subsequent pumps. PREPARATION FOR STORAGE:
WARNING: Prevent accidental starting by always removing spark
plug or by disconnecting and grounding spark plug wire before
working on engine or pump.
NOTE: Replace the spark plug or wire only after all preparation is completed on
both pump and engine.
1. Fuel System:
If the unit is to be stored for any length of time, drain the fuel system by running
until it stops as instructed in STOPPING PROCEDURE. The wraparound frame unit
can be run until the fuel tank is empty and it stops due to lack of fuel.
2. Engine:
See engine manual for storage instructions.
3. Pump:
a) Follow the procedure under Maintenance-Daily or every 8 Hours, item 2
Pump inlet.
b) Drain water from pump thoroughly. After the flow has ceased, pump should be
turned over a few revolutions so that all water will drain from impeller.
c) While turning the pump over, using the starting handle spray into the pump
inlet and discharge tube with a white lithium or silicone type lubricant.
This treatment coats the inside of the pump and tends to prevent the clearance
ring and impeller hub from sticking due to corrosion.
d) Spray the threads of the inlet and discharge connections with either a white
lithium or silicone type lubricant.
LUBRICATION AND MAINTENANCE
FUEL AND LUBRICANT SPECIFICATIONS:
GASOLINE: Use clean, fresh, regular grade leaded or low lead type. When regular
or low-lead is unavailable an unleaded type fuel may be used; however, it should be
limited to emergency use only. Oil must be mixed with the gasoline, refer to fuel mixture
below.
OIL: Use a good quality outboard motor oil or equivalent. The oil should meet the Boating
Institute of America (BIA) classification type TC-W. Gasoline must be mixed with the
oil, refer to fuel mixture below.
FUEL MIXTURE:
The engine used in the FYR PORT requires that oil be mixed with the gasoline.
For ease of starting, it is desirable to have a fresh mixture of fuel: therefore, mix only
an amount of fuel you anticipate using in the near future. As a guide, the engine
consumes approximately one gallon (3.8 L.) per hr. at full throttle (depending on load),
less at partial throttle.
To mix fuel, add oil to a small amount of gasoline in the fuel caddie, then add the
rest of the gasoline and shake well. Also, if the fuel caddie has been sitting still for an
extended period, shake container before filling.
The correct ratio of oil to gasoline is one (1) part oil to 24 parts gasoline (1:24).
Table 1 shows various quantities of fuel mixture and the amount of oil and gasoline
required.
APPROXIMATE
QUANTITY OF FUEL OIL GASOLINE
DESIRED
ONE GALLON (PLUS) 5 OZ. 1 GALLON
(3.9 LITERS) (158 ML) (3.8 L.)
THREE GALLONS (PLUS) 16 OZ. 3 GALLONS
(11.8 LITERS) (473 ML) (11.4 L.)
FIVE GALLONS (PLUS) 27 OZ. 5 GALLONS
(19.7 LITERS) (789 ML) (18.9
TABLE 1
SAFETY PRECAUTIONS:
1. DO NOT RUN THE ENGINE IN AN ENCLOSED AREA. Be sure the area is well
ventilated.
2. Stay away from moving parts. Avoid wearing loose jackets, shirts and ties.
3. Keep the equipment and surrounding area clean. Cluttered areas invite accidents.
4. Keep power shields and guards in place. Do not make adjustments and repairs while
the engine is running, unless specified for in repairs.
5. Do not run the pump more than two min. without water in pump.
6. Be careful not to touch the exterior of a hot engine, especially the muffler and the
surrounding area.
7. Prevent accidental starting by always removing spark plug or by disconnecting and
grounding spark plug wire before working on engine or pump.
8. When working on any part of the fuel system be sure the unit is cool. Remove any
sources of heat or flame.
ABSOLUTELY NO SMOKING
Reassembly Note:
Before reassembly begins, visually inspect parts. See that parts are clean; all
sealing surfaces are free of corrosion and nicks. Remove any metal chips from casting
cavities and tapped holes. Also inspect for any damaged or excessively worn parts
which should be replaced.
Refer to Parts Catalog Plate NO. 534B, 1 of 2 of 2, for component parts
location and orientation.
MAINTENANCE SCHEDULE;
Daily or Every 8 hours:
1. Leaks - (gaskets, fuel, seals, washers, and water) Check for any leaks before
operating unit. These leaks must be repaired before operating.
2. Pump Inlet:
a) Remove any debris that might collect in the inlet, impeller eye, or the inlet hose
strainer.
Monthly or Every 25 Hours:
1. Expanded aluminum foil element: Clean as follows.
Note: Service air cleaner more often under dusty conditions.
a) Remove (2) screws and washers so foil element and end plates can be removed.
b) Wash foil element in kerosene or liquid detergent and water.
c) Dry foil element by shaking out excess water. Use compressed air if available.
d) Install foil element, end plates, screws and washers on carburetor.
2. Spark Plug: Clean and regap at .030 inch (.8 mm). Spark plug type is Champion
#RL-86C, NGK#BR5HS, AC#R46FF, motorcraft #AER6, and Fram-Autolite #426.
CAUTION: Do not blast clean spark plug. Blasting material could lodge in recesses
of plug and eventually work loose, damaging aluminum bore. Spark plug should be
cleaned by scraping or wire brushing and washing with a commercial solvent.
3. Fuel Filters: General:
a) Place the unit in a horizontal position.
b) Disconnect fuel caddie.
c) Place a rag under the carburetor and fuel line to catch any fuel spillage.
d) Refer to filter maintenance below.
e) Wipe up any additional fuel spillage and discard rag in an approved safety
container.
In-Line Fuel Filter:
a) Remove the two clamps from both sides of filter and pull hoses using a slight
twisting motion.
b) Observe hoses for any signs of cracking or deterioration and replace if necessary.
c) Install a new filter with the word IN toward fuel caddie connection. Replace
clamps.
Carburetor Fuel Strainer:
a) Remove the screw holding the plastic cover in place (where the fuel line connects
to carburetor). Gently remove the cover, gasket, and strainer screen.
b) Clean screen in a nonflammable solvent, blow dry.
c) Replace strainer screen, gasket, cover and screw.
4. Hoses, Fittings, and Tubes: Clean and check all hoses, fittings and tubes for signs
of cracks, kinks, deterioration, etc. They should have uniform bends; If any are
kinked or collapsed they should be replaced. Fittings and clamps should be tight, but
not overtight.
Seasonal or as Required:
1. Engine cooling system: Clean the starter screen, flywheel (fan), and engine
cooling fins. Foreign matter may clog cooling system after prolonged service.
Continued operation with a clogged cooling system causes severe overheating and
possible engine damage.
a) Remove the four screws that fasten the fan housing to the sheet metal cylinder
cover.
b) Remove the flexible transparent hose from nozzle plate and the spark plug wire
from spark plug.
c) Carefully lift the fan housing from engine, push the spark plug and overspeed
switch wires rubber grommet from housing. Reach inside of housing and
disconnect the magneto wire from ignition switch. The fan housing can now be
completely removed and cleaned.
d) Remove the four screws that fasten the sheet metal cylinder cover to engine; be
careful, the lower two holes have small spacers between the cover and engine.
e) To reassemble; reverse above procedure.
2. Pump: Except for draining the casing during freezing weather, the pump requires
only an occasional cleaning.
3. Removal of Pump/Engine Assemble from Mounting Base: a) Place the unit in a
horizontal position.
b) Remove the fuel line from the fuel line connector. Catch any fuel spillage with
a rag. Dispose of the rag in an approved safety container.
c) Disconnect the overspeed switch wire at the connector. Disconnect the short
overspeed switch ground wire by pulling spade connector from the overspeed
switch.
d) Remove the overspeed switch tubing from the overspeed switch.
e) Remove the three locknuts from the vibration isolators that fasten them to the
pump mounting base. The fuel tank must first be lowered on the frame version
by removing the four screws used to retain the straps. This allows access to the
locknut on the large vibration isolator.
f) Remove priming hose from the fitting at the pump.
g) Lift the pump/engine assembly from the mounting base.
4. Assembly of Pump/Engine to Mounting Base:
a) Assembly is the reverse of the removal procedure above
5. Repair or replacement of any Components in Pump: (Replacing Mechanical
Seal)
a) Remove pump/engine assembly from mounting base. Refer to item 3, Removal
of Pump/Engine Assembly
b) Remove the four screws that fasten the volute body to the pump head. Remove
the volute body.
c) Remove the impeller retaining screw and washer.
ATTENTION: The impeller screw is left hand thread.
NOTE: To prevent the engine from rotating, when removing the impeller screw,
place a long 3/8 screw or 3/8 diameter bar through one of the pump head mounting
holes and a flat bar in one of the impeller cavities.
d) Remove impeller by putting hardwood wedges on each side of impeller,
between impeller and pump head. The wedges should bear against impeller disc
directly behind impeller vanes to prevent damaging the impeller; refer to figure 4.
Tap end of engine shaft with a soft (rawhide, rubber) headed mallet, while
maintaining pressure with wedges until impeller comes off.
DO NOT PUT TOO MUCH PRESSURE ON WEDGES
Pump Head
Impeller Disc
Impeller Cavity
Wedge
CORRECT
Bent or Cracked
Impeller Disc
Impeller
Vane
INCORRECT
Wedge
(Incorrect)
Figure 4
e) With impeller removed, remove the impeller key.
f) Remove the spring and carbon section (sealing washer) of mechanical seal
from engine crankshaft sleeve. Observe the ceramic seal seat and carbon
sealing washer. If they are scored or lip on the sealing washer is worn or
cracked, replace complete assembly.
g) If further disassembly is required beyond mechanical seal replacement, remove
the four 5/16-18 X 2 1/2 lg. screws and 5/16 flat brass washers that fasten pump
head to engine.
h) If mechanical seal ceramic seat was not removed previously, remove from head.
i) Pull engine crankshaft protection sleeve from shaft.
j) There is a replaceable clearance or wear ring used in this pump. Inspect impeller
hub and clearance ring bore, replace if any of these surfaces are scored or worn
excessively.
Assembly of Pump to Engine:
a) Coat the engine crankshaft with a thin layer of gasket sealer; such as, Loctite
Gasket Eliminator 504.
b) Lubricate the groove in the pump shaft sleeve (048-077000) using a
multipurpose grease and install O ring (0400180-00) in groove. Slide this
assembly on engine crankshaft.
c) Position pump head on engine and align holes. If original screws are in good
condition, reuse, but apply a thread locking adhesive; such as, Loctite
Threadlocker 242 or equal to threads. If original screws were damaged or
corroded replace with four new 5/16-18 X 2 1/2 lg. plated nylok screws
P.N 018-1424-07. When installing screws use a new 5/16 flat brass washer
(097-0810-00) under the head of each screw.
NOTE: Hale has available small tubes of Loctite threadlocker adhesive (0.5cc),
Hale P/N 029-0010-01 d) Coat rubber cup of mechanical seal ceramic seal with
oil and press into pump head with ceramic surface toward you.
e) Coat rubber on inside of mechanical seal carbon sealing washer with oil and
using a turning motion, push onto shaft sleeve until carbon lip comes into contact
with ceramic surface.
CAUTION: Keep the ceramic seal seat and carbon sealing washer
surfaces clean. Be careful not to crack or chip ceramic surface or carbon
wearing lip.
f) Line up keyway of impeller with keyway of shaft, push impeller on shaft. Insert
impeller key (017-0060-01) until flush with face of impeller.
g) Coat end of shaft and impeller with thin layer of gasket sealer.
h) Coat the threads of a new impeller screw (018-9350-00) with a thread locking
adhesive (Loctite 242 or equal).
i) Mount impeller washer (097-0381-00) and impeller screw, torque impeller screw
to loft./lbs.
ATTENTION: The impeller screw is left hand thread.
If impeller clearance ring requires replacement, proceed with the following steps.
However, if impeller clearance ring is in good condition proceed to step M.
j) With clearance ring removed from volute body inspect clearance ring pins
(064-0310-02), if these are damaged, replace.
k) Apply a thin coat of oil to groove of impeller clearance ring (321-0121-00) and
install O-ring (040-2320-00) into groove. Coat the outside of clearance ring and
O ring with oil.
l) Align the holes in impeller clearance ring with pins in volute body and press
clearance ring into volute body.
m) Coat the inside of clearance ring bore and outside of impeller hub with oil.
n) Install O-ring (040-1590-00) on pump head pilot and coat O-ring and pump
head pilot diameter with either oil or a multipurpose grease.
o) Mount volute body with clearance ring to pump head. Align holes and bolt volute
body to pump head using four 3/8-16 X 7/8 lg. stainless steel screws
(018-1607-12) and four 3/8 cad plated lock washers (097-0140-01).
p) Install the pump/engine assembly to mounting base. Refer to item 4, Assembly
of pump/engine to mounting base.
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