Hale HP Series User Manual
1/8/04
HP SERIES
PORTABLE PUMPS
USER OPERATION AND
MAINTENANCE MANUAL
Pump
Serial
Number
Failure to follow the operating, lubrication, and maintenance
WARNING
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.
HALE PRODUCTS, INC. A Unit of IDEX Corporation 700 Spring Mill Avenue Conshohocken, PA 19428 TEL: 610-825-6300 FAX: 610-825-6440
Class 1 607 NW 27th Avenue Ocala FL 34475 USA Tel: 352-629-5020 800-533-3569 Fax: 352-629-2902 www.class1.com
MANUAL P/N 029-0020-24-0, REV E, © 2004 HALE PRODUCTS, INC., PRINTED IN U.S.A.
requirements set forth in this operating and maintenance manual
may result in serious personal injury and/or damage to equipment.
Hale Products cannot assume responsibility for product failure resulting from improper
maintenance or operation. Hale Products is responsible only to the limits stated in the product
warranty. Product specifications contained in this material are subject to change without notice.
HP SERIES
PORTABLE PUMPS
USER OPERATION AND MAINTENANCE
2
HP SERIES
PORTABLE PUMPS
USER OPERATION AND MAINTENANCE
Table of Contents
1 SAFETY .......................................................................................................5
2 EQUIPMENT DESCRIPTION .......................................................................8
3 OPERA TING CONTROL DESCRIPTION ...................................................14
4 INITIAL CHECKOUT PROCEDURES ......................................................... 18
5 STARTING PROCEDURES ........................................................................24
6 SHUTDOWN AND STORAGE PROCEDURES ......................................... 26
7 MAINTENANCE SCHEDULE .................................................................... 28
8 PUMP MAINTENANCE............................................................................29
9 ENGINE MAINTENANCE.........................................................................32
10 WARRANTY POLICY................................................................................42
11 MOUNTING DIMENSIONS.......................................................................43
12 ELECTRICAL DIAGRAM..........................................................................49
13 PARTS LIST ................................................................................................51
3
HP SERIES
PORTABLE PUMPS
USER OPERATION AND MAINTENANCE
4
HP SERIES
PORTABLE PUMPS
USER OPERATION AND MAINTENANCE
1
THIS SYMBOL MEANS WARNING PERSONAL INJURY MA Y OCCUR UNLESS
INSTRUCTIONS ARE FOLLOWED CAREFULL Y .
1. DO NOT run engine in an enclosed
area. Exhaust gases contain carbon
monoxide, an odorless and deadly
poison.
2. DO NOT check for spark with spark
plug or spark plug wire removed. Use an
approved tester.
3. DO NOT crank engine with spark
plug removed. If engine is flooded,
SAFETY
WARNING
8. DO NOT STORE, SPILL, OR USE
GASOLINE NEAR AN OPEN FLAME, or
devices such as a stove, furnace, or
water heater which utilize a pilot light or
devices which can create a spark.
9. DO NOT refuel indoors where area is
not well ventilated. Outdoor refueling is
preferred.
10. Engine produces excessive noise.
When pump is operating persons in the
place throttle in FAST (
crank until engine starts.
4. DO NOT smoke when filling fuel tank.
5. DO NOT fill fuel tank while engine is
running. Allow engine to cool for two
minutes before refueling.
6. DO NOT operate engine when an
odor of gasoline is present or other
explosive conditions exist
7. DO NOT operate engine if gasoline is
spilled. Move pump away from the spill
and avoid creating any ignition until the
gasoline has evaporated.
) position and
immediate vicinity must wear hearing
protection.
11. DO NOT OPERA TE ENGINE WITHOUT A
MUFFLER. Inspect periodically and
replace if necessary.
12. DO NOT operate engine with an
accumulation of grass, leaves, dirt or
other combustible material in the muffler
area.
13. DO NOT run engine with air cleaner
or air cleaner cover removed.
14. Automatic flow nozzles and tips are
designed to work with a minimum
5
HP SERIES
PORTABLE PUMPS
USER OPERATION AND MAINTENANCE
pressure of 7 BAR (100 PSIG). Under
normal operation conditions these
pumps may not provide the required
pressure to use these nozzles properly.
When selecting a pump and nozzle
combination consideration must also be
given to hose lengths and normal
friction losses.
15. TO PREVENT ACCIDENT AL ST ARTING
when servicing the engine or pump
always disconnect the negative wire
from battery terminal.
CAUTION
1. Engine is shipped without oil in the
5. DO NOT touch hot mufflers,
cylinders, or fins as contact may cause
burns.
6. DO NOT place hands or feet near
moving or rotating parts.
7. DO keep cylinder fins free of debris
as this can affect engine speed.
8. Pull starter cord slowly until
resistance is felt. Then pull cord rapidly
to avoid kickback and prevent hand or
arm injury.
9. The pump and motor assembly are
vibration isolated. When making the
crankcase. Before placing pump into
operation for the first time fill engine to
proper level with SAE 30 Weight
Detergent oil.
2. HP100 gearbox is shipped without oil.
Before placing pump into operation for
the first time fill gearbox to proper level
with SAE 30 Weight Detergent oil.
3. DO NOT tamper with governor
springs, governor links or other parts
which may increase the governed
engine speed.
4. DO NOT tamper with the engine
speed selected by the original
permanent connections to the suction
and discharge fittings DO NOT use hard
piping. A short length of flexible piping is
required to prevent damage to the
pump and engine.
10. Always connect the black wire to
the negative battery terminal last.
11. The pump and motor assembly are
vibration isolated. When making the
permanent connections to the suction
and discharge fittings DO NOT use hard
piping. A short length of flexible piping is
required to prevent damage to the
pump and engine.
equipment manufacturer.
6
12. Do not run pump for more than 45
seconds without suction established.
13. Petroleum solvents, such as
kerosene, are not to be used to clean
cartridge. They may cause
deterioration of the cartridge. DO NOT
OIL CARTRIDGE. DO NOT USE
PRESSURIZED AIR TO CLEAN OR DRY
CARTRIDGE.
14. For proper engine operation, keep
controls and linkages clean and free of
debris.
HP SERIES
PORTABLE PUMPS
USER OPERATION AND MAINTENANCE
15. Periodically clean muffler area to
remove all grass, paper, leaves, dirt or
other combustible debris.
16. Sparking can occur if wire terminal
does not fit firmly on spark plug. Reform
terminal if necessary.
17. Exhaust system components may
smoke during the initial break-in period.
This smoking will stop after the pump is
run several times.
7
HP SERIES
PORTABLE PUMPS
USER OPERATION AND MAINTENANCE
2
The HP Series Portable Pump line
provides emergency services personnel
around the world with portable pumps
to fulfill many types of in-service
applications. The pumps are available
in configurations providing a wide range
of pressures and flows to suit user
requirements in a lightweight portable
unit.
The pumps are available as four
separate models, the Model HP100
Attack Pump, Model HP200
Combination Pump, Model HP300
Supply Pump and Model HP400 Transfer
EQUIPMENT DESCRIPTION
stainless steel clamp. The pump engine
is air cooled and the portable models
are enclosed with high strength
thermoplastic covers that ensure a
clean appearance and quiet operation.
The aluminum parts of the discharge
valves are treated with a hard anodizing
process to increase corrosion resistance
and durability. The molded plastic fuel
tank is an integral part of the pump
base therefore there is only one item to
carry, other than the required suction
and discharge hoses, when the pump is
to be placed into service. An aluminum
skid plate on the bottom of the pump
Pump. The HP100 Attack Pump Is rated
to supply water at flows and pressures
that are suitable for extinguishing fires.
The HP200 Combination Pump is a dual
purpose pump that provides the
capability to attack fires and/or supply
water from an emergency water source.
The HP300 Supply Pump is used to supply
water from an emergency water source.
The HP400 Transfer Pump is a high
volume pump that is suitable for
transferring large volumes of water at
low pressures.
A standard feature of each pump
configuration includes pump ends
made of strong corrosion resistant
assembly provides extra puncture
protection for the fuel tank.
In addition to the standard portable HP
series pumps an "X" model, without the
plastic covers, carrying handles or sub-
frame, is available that can be
permanently mounted to the apparatus
frame.
Also available is the "I" model, which has
no plastic covers or subframe. The
pump and engine are mounted to a
steel skid base which can easily be fitted
to optional carrying handles. The pump
can also be permanently mounted and
comes complete with a remote 3 gal
aluminum alloy held together with a
8
(12 liter) fuel tank.
HP SERIES
PORTABLE PUMPS
USER OPERATION AND MAINTENANCE
four folding handles. Other than the
Each pump is powered by a reliable
state-of-the-art air cooled, 18 HP, V-twin,
Overhead Valve (OHV) engine. The
engine has electric start with a recoil
backup to ensure starting under all
circumstances. The integral fuel tank
provides 12 liters (3 gallons) of fuel and
will permit the pump to run for 2 hours at
rated performance conditions, but
under many operating conditions longer
run times can be obtained.
Each portable pump is equipped with
stowed position there are two other
positions of the handles to provide for
increased mobility by two people when
moving the pump. When not in use the
handles fold away to provide a sleek
appearance and prevent equipment or
personnel from getting caught on them.
Also when the handles are folded the
pump is more compact and will fit in a
smaller storage compartment.
The discharge valve on the portable
pump version swivels through 175o for
FOLDED FOR STORAGE
EXTENDED TO END
PORTABLE PUMP HANDLE POSITIONS
EXTENDED TO SIDE
9
HP SERIES
PORTABLE PUMPS
USER OPERATION AND MAINTENANCE
ease of discharge hose connection. The
unique valve permits the discharge to
be directed in any direction without
disturbing the position of the pump. The
valve is a self checking type that
automatically closes to form a positive
seal when priming the pump.
Each portable pump is provided with a
marine grade quick connect electrical
socket. This socket is used to power the
optional light mast for night time
operations. The same electrical socket
can also be used to connect a trickle
charger to ensure the battery is charged
and the pump is always in a ready state.
EQUIPMENT SPECIFICA TIONS
ENGINE:
MAKE: BRIGGS AND STRA T TON V ANGUARD™
MODEL: 350447 Series
TYPE: Horizontal Shaft, Air Cooled, V-Twin,
OHV
HORSEPOWER: 18 BHP (13.4 kW) at 4000 RPM
TORQUE: 40.7 N-m (30 ft-lb) Max. at 2600 RPM
BORE x STROKE: 72 x 77 mm (2.83 x 2.75 in)
DISPLACEMENT: 570 cc (34.75 cu in)
OIL CAPACITY: 1.4 liter (3.0 pint)
FUEL TANK: Cross linked Polyethylene
FUEL CAPACITY: 12 liters (3 gallons)
ELECTRICAL: 16 AMP Alternator
EMISSIONS: Meets 1994 California Air
Resources Board (CARB) Standards
The HP series pump line has been
designed to meet stringent
requirements. The curves that follow are
the expected performance that can be
obtained from that specific pump
model. All the tests were conducted at
sea level.
NOTICE
Performance of HP Series pumps
meets or exceeds NFPA1921
requirements. For complete NFPA1921
compliance, the pumping units must be
marked with specific labels. Consult
factory if these labels are required.
The serial number of each pump
assembly is located on a tag attached
to the engine shroud near the recoil
starter pull handle. The following figure
shows the serial number tag.
HALE PRODUCTS, INC
PUMP IDENTIFICATION TAG
10
HP SERIES
PORTABLE PUMPS
USER OPERATION AND MAINTENANCE
20
650
18
600
550
16
500
14
450
12
400
350
10
300
8
250
6
200
150
4
100
2
50
0
0
FEET
BAR
TOTAL HEAD
Hale Fire Pump Company
Hale Products, Inc.
INLET: 2 IN
OUTLET: 1-1/ 2 IN
LIFT: 4 FT
ELEVATION: SEA-LEVEL
CONDITIONS: STP
UNIT MODEL : HP100
ENGINE:
BRIGGS & STRATTON MODEL
VANGUARD 18 OHV
300
280
260
240
220
200
3600 RPM
15 HP
3200 RPM
25 HP
20 HP
180
160
2800 RPM
140
120
2400 RPM
100
80
2000 RPM
60
PERFORMANCE BASED ON
40
95% OF ENGINE
MANUFACTURER'S MAXIMUM
20
BRAKE HORSEPOWER
0
0 50 100 150 200
PSI
5 HP
GPM
0 100 200 300 400 500 600 700
LITERS/MIN
10 HP
FLOW
HP100 SERIES PERFORMANCE CURVE
Conshohocken, Pa. 19428 USA
18 HP @ 4000 RPM
CURVE NO.
1-12-94 JDR
E-1121
180
12
400
160
350
10
140
300
250
200
150
120
8
100
6
4
100
2
50
0
0
FEET
BAR
TOTAL HEAD
4000 RPM
Hale Fire Pump Company
Hale Products, Inc.
INLET: 2-1/2 IN
OUTLET: 2-1/2 IN
LIFT: 4 FT
ELEVATION: SEA-LEVEL
CONDITIONS: STP
Conshohocken, Pa. 19428 USA
UNIT MODEL : HP200
ENGINE:
BRIGGS & STRATTON MODEL
VANGUARD 18 OHV
18 HP @ 4000 RPM
25 HP
80
60
3600 RPM
3200 RPM
2800 RPM
2400 RPM
15 HP
20 HP
10 HP
40
PERFORMANCE BASED ON
95% OF ENGINE
20
MANUFACTURER'S MAXIMUM
BRAKE HORSEPOWER
0
0 50 100 150 200 250
GPM
PSI
0 100 200 300 400 500 600 700 800 900
LITERS/MIN
5 HP
FLOW
HP200 SERIES PERFORMANCE CURVE
1-12-94 JDR
CURVE NO.
E-1122
11
HP SERIES
PORTABLE PUMPS
USER OPERATION AND MAINTENANCE
9
300
8
250
7
6
200
5
150
4
3
100
2
50
1
0
0
FEET
BAR
TOTAL HEAD
Hale Fire Pump Company
Hale Products, Inc.
INLET: 3 IN
OUTLET: 2-1/2 IN
LIFT: 4 FT
ELEVATION: SEA-LEVEL
CONDITIONS: STP
UNIT MODEL : HP300
ENGINE:
BRIGGS & STRATTON MODEL
VANGUARD 18 OHV
140
4000 RPM
120
100
20 HP
3600 RPM
25 HP
15 HP
80
3200 RPM
10 HP
60
2800 RPM
40
2400 RPM
PERFORMANCE BASED ON
20
95% OF ENGINE
MANUFACTURER'S MAXIMUM
BRAKE HORSEPOWER
0
0 100 200 300 400
GPM
PSI
0 200 400 600 800 1,000 1,200 1,400 1,600
LITERS/MIN
5 HP
FLOW
HP300 SERIES PERFORMANCE CURVE
Conshohocken, Pa. 19428 USA
18 HP @ 4000 RPM
CURVE NO.
1-12-94 JDR
E-1123
200
150
100
50
FEET
Hale Fire Pump Company
Hale Products, Inc.
INLET: 4 IN
OUTLET: 3 IN
LIFT: 4 FT
ELEVATION: SEA-LEVEL
CONDITIONS: STP
120
8
7
6
5
4
3
2
1
0
0
BAR
4000 RPM
100
15 HP
3600 RPM
80
3200 RPM
60
2800 RPM
40
2400 RPM
PERFORMANCE BASED ON
20
95% OF ENGINE
MANUFACTURER'S MAXIMUM
BRAKE HORSEPOWER
10 HP
20 HP
25 HP
5 HP
0
0 100 200 300 400 500
GPM
PSI
0 200 400 600 800 1,000 1,200 1,400 1,600 1,800
LITERS/MIN
FLOW
Conshohocken, Pa. 19428 USA
UNIT MODEL : HP400
ENGINE:
BRIGGS & STRATTON MODEL
VANGUARD 18 OHV
18 HP @ 4000 RPM
CURVE NO.
6-21-94 JDRTOTAL HEAD
E-1124
HP400 SERIES PERFORMANCE CURVE
12
HP SERIES
PORTABLE PUMPS
USER OPERATION AND MAINTENANCE
PUMP MODEL 100 200 300 400
TYPE
SUCTION CONNECTION
(Note 1)
HP PORTABLE
HP "X" SERIES
BODY
IMPELLER
MATERIAL
DIAMETER
SHAFT
BEARING
PRIMING
MAXIMUM FLOW AT
RATED PRESSURE
MAXIMUM PRESSURE,
BAR (PSI)
ATTACK COMBINATION SUPPLY TRANSFER
2 inch NPT Female
DISCHARGE CONNECTION (Note 1)
2 in. ISO Female 2-1/2 in. ISO Female 2-1/2 in. ISO Female 2-1/2 in.ISO Female
1-1/2 in. NPT Female
ALUMINUM ALUMINUM ALUMINUM ALUMINUM
SILICON BRONZE SILICON BRONZE SILICON BRONZE SILICON BRONZE
123.83 mm (4.875 in.) 222.25 mm (8.75 in.) 203.20 mm (8.00 in.) 184.15 mm (7.25 in.)
STAINLESS STEEL
BALL N/A N/A N/A
EXHAUST VENTURI EXHAUST VENTURI EXHAUST VENTURI EXHAUST VENTURI
568LPM @ 3.5BAR
150 GPM @ 50 PSI
20 BAR (290 PSI) 11 BAR (165 PSI) 8 BAR (120 PSI) 6 BAR (90 PSI)
3 inch NPT Female
(4 inch Victaulic)
2-1/2 in. NPT Female
(Hale 115 Flange)
ENGINE SHAFT WITH
BRONZE SLEEVE
852LPM @ 3.5BAR
225 GPM @ 50 PSI
3 inch NPT Female
(4 inch Victaulic)
3 in. NPT Female
(Hale 115 Flange)
ENGINE SHAFT WITH
BRONZE SLEEVE
1514LPM @1.4BAR
400 GPM @ 20 PSI
3 inch NPT Female
(4 inch Victaulic)
3 in. NPT Female
(Hale 115 Flange)
ENGINE SHAFT WITH
BRONZE SLEEVE
1893LPM @ 1.4BAR
500 GPM @ 20 PSI
LENGTH
WIDTH
HEIGHT
WEIGHT
LENGTH
Handles Extended
Handles Folded
WIDTH
Handles Extended
Handles Folded
HEIGHT
WEIGHT
"X" SERIES
635 mm (25 in.) 635 mm (25 in.) 635 mm (25 in.) 635 mm (25 in.)
438 mm (17-1/4 in.) 438 mm (17-1/4 in.) 438 mm (17-1/4 in.) 438 mm (17-1/4 in.)
543 mm (21-1/4 in.) 543 mm (21-1/4 in.) 543 mm (21-1/4 in.) 543 mm (21-1/4 in.)
75 kg (165 Lbs) 66 kg (146 Lbs) 67 kg (148 Lbs) 67 kg (148 Lbs)
PORTABLE SERIES
892 mm (35-1/8 in.) 892 mm (35-1/8 in.) 892 mm (35-1/8 in.) 892 mm (35-1/8 in.)
635 mm (25 in.) 635 mm (25 in.) 635 mm (25 in.) 635 mm (25 in.)
698.5 mm (27-1/2 in.) 698.5 mm (27-1/2 in.) 698.5 mm (27-1/2 in.) 698.5 mm (27-1/2 in.)
498.5 mm (19-5/8 in.) 498.5 mm (19-5/8 in.) 498.5 mm (19-5/8 in.) 498.5 mm (19-5/8 in.)
587 mm (23-1/8 in.) 587 mm (23-1/8 in.) 587 mm (23-1/8 in.) 587 mm (23-1/8 in.)
88 Kg (194 Lbs) 80 Kg (176 Lbs) 80 Kg (176 Lbs) 84 Kg (185 Lbs)
Note 1: Standard threads machined into the pump body and valve for the particular model. When ordering
pump specify suction and discharge adapter required for specific needs. With the exception of Storz adapters,
the adapters will be factory installed prior to pump delivery
13
HP SERIES
PORTABLE PUMPS
USER OPERATION AND MAINTENANCE
3
Most of the controls and indicators
necessary for the operation of the pump
are located on the operator panel.
The pump operator should become
thoroughly familiar with the location and
function of all pump controls and
indicators before attempting operation
of the pump.
The "I" version uses engine mounted
controls that are explained in the
enclosed Briggs and Stratton engine
manual.
The controls and indicators along with
their functions are as follows:
OPERATING CONTROL DESCRIPTION
2. MASTER SWITCH: The Master
switch is located below the start
button and is used to close the
electrical circuits on the pump to
enable operation. This is a rocker
type switch which when the (
is depressed energizes the electrical
system to enable pump operation.
When the (—)side is depressed the
electrical system is disconnected and
the pump stops.
3. ST ART BUTTON ( ): The start
button is located to the right of the
❍❍
❍) side
❍❍
1. THROTTLE LEVER: The throttle lever
is located on the left side of the
instrument panel and controls the
speed at which the pump operates
to obtain the required flow. The lever
is a slide type "T"-handle that is
infinitely adjustable from SLOW
( ) to F AST ( ).
OPERATING PANEL
throttle lever and is used to start the
engine. Depressing the button after
the master switch is placed in the on
(—) position will engage the electric
starter on the pump engine. After
the button is released the button will
return to the normal position to
disengage the starter.
4. PRIMING LEVER ( ): The
Priming Lever is a "T" type
handle located to the right of
the start switch and master
switch and is used to engage
the exhaust primer when the
pump is started. Pulling the "T"
handle down will engage the
primer. Due to spring force
14
HP SERIES
PORTABLE PUMPS
USER OPERATION AND MAINTENANCE
the handle must be held in the down
position until the pump is primed.
Once the pump is primed and
pressure is showing on the discharge
pressure gauge the "T" handle is
released and returns to the up
position by spring force for normal
pump operation.
The base "I" version uses a knob
(located above the throttle control)
which is pulled to engage the primer.
5. SUCTION GAUGE: The suction
gauge is located in the center of the
instrument panel and provides the
operator with an indication of the
water pressure on the suction side of
0.2-0.4 kg/cm2 (4-6 PSIG). If the light
should light during normal operation
the operator must shutdown the
engine immediately to avoid engine
damage.
7. CHOKE CONTROL ( ): The choke
control is located below the oil light
and is used to control the air fuel
mixture in the carburetor when
starting the engine. Pulling the choke
control out will engage the choke.
After the pump starts pushing in on
the choke control will gradually
disengage the choke and allow
normal operation.
the pump. The suction gauge is a
compound gauge that reads from -1
to 10 BAR (30 in. Hg vac to 150 PSIG).
6. LOW OIL PRESSURE LIGHT ( ):
The low oil pressure light is located to
the right of the discharge gauge and
is connected to the oil pressure
switch located on the oil filter
adapter. When the master switch is
first energized the low oil pressure
light will light to indicate the pump
power is on. After the pump starts
and oil pressure builds up the light will
go out to indicate there is sufficient
oil pressure in the engine. The engine
is equipped with an oil pressure
switch that activates the low oil
pressure light when pressure drops to
8. DISCHARGE GAUGE: The
discharge gauge is located to the
right of the priming lever and
provides the operator with an
indication of the pump discharge
pressure. The gauge reads from 0 to
28 BAR (0 to 400 PSIG).
9. FUEL PRIMER: The fuel primer is
located on the back side of the
pump engine behind the protective
cover of the HP series pumps. The
fuel system requires priming only
when starting the pump after fuel is
put into the tank initially or if the
pump has run out of fuel. Priming is
accomplished by squeezing the fuel
primer bulb until firm.
15
HP SERIES
PORTABLE PUMPS
USER OPERATION AND MAINTENANCE
FUEL FILTER
FUEL PRIMER BULB
10. RECOIL ST ARTER: The recoil starter
is located on the engine behind the
protective grill. To gain access to the
recoil starter the pump panel below
at the lowest point of the pump
volute. This valve is used to drain all
water from the pump after use and
prior to storage.
12. DISCHARGE V AL VE DRAIN: The
discharge valve drain is a petcock
type valve located below the outlet
of the discharge valve. This valve is
used to relieve the pressure in the
discharge hose before disconnecting
the hose.
13. LIGHT AND CHARGING SOCKET :
An optional marine grade light and
charging socket is located on the top
cover of the HP series portable
the instrument panel must be
opened on the portable models.
11. PUMP DRAIN: The pump drain is a
petcock type valve located below
the suction connection of the pump
PUMP DRAIN PETCOCK
DISCHARGE VALVE
DRAIN PETCOCK
pumps. This socket has a waterproof
plug type cover that is removed to
enable use of the optional light mast
(Hale P/N 200-2100-02-0). The socket
is also used to plug in the optional
trickle charger (Hale P/N 200-0750-01-
0) to maintain the charge on the
pump's 12 volt battery.
14. EXHAUST PRIMER ASSEMBL Y : The
exhaust primer assembly is located
on the outlet of the muffler. Located
on the exhaust primer assembly is a
1/4 turn valve. Under normal
operation conditions, when the
pump is being operated from draft,
the handle on the 1/4 turn valve will
16
be in the open position (in-line with
the tubing). When the pump is being
operated with a positive pressure
source the valve must be closed to
prevent water from being blown out
of the exhaust pipe.
EXHAUST PRIMER
VALVE ASSEMBLY
HP SERIES
PORTABLE PUMPS
USER OPERATION AND MAINTENANCE
1/4 TURN BALL VALVE
(SHOWN IN NORMAL
OPERATING POSITION)
EXHAUST PRIMER ASSEMBLY
17
HP SERIES
PORTABLE PUMPS
USER OPERATION AND MAINTENANCE
4
Upon receipt of the pump from the
factory remove the pump and all
accessories from the shipping container
and check for damage. Note the serial
number of the pump located on the
engine air shroud near the recoil starter
pull handle. Record this number on the
warranty registration card located at
the back of this manual and return
warranty registration.
PORT ABLE PUMP BATTER Y ACTIV ATION
After unpacking all pump components
open the top cover on the pump and
remove the battery from its holder. The
battery is a dry charged battery and is
shipped dry. Remove the covers from
each cell of the battery and fill each
cell with electrolyte. Replace the covers
on each cell and tighten. Return the
INITIAL CHECKOUT PROCEDURES
battery to its holder and clamp in place.
CAUTION: Always connect
the black wire to the negative
battery terminal last.
Connect the red cable to the positive
(+) terminal and connect the black
cable to the negative (-) terminal.
Make sure that the plastic overflow tube
on the battery is directed down to the
lowest point of the pump.
"X" SERIES PUMP INST ALLATION
1. After unpacking all pump
components remove the mounting bolts
and shock absorbing feet from the four
corners of the pump. Retain these bolts
and feet for securing the pump during
installation.
18
POS BATTERY
TERMINAL
CELL CAPS
NEG BATTERY
TERMINAL
PORTABLE PUMP BATTERY
2. To assist in pump mounting a
mounting dimension drawing is included
at the back of this manual. Mark
location of the mounting holes in
accordance with this drawing.
3. Drill 9.5 mm (3/8 inch) diameter holes
at the four corners of the pump to insert
the bolts to hold the pump in place.
Place pump at proper location on the
apparatus making sure the shock
absorbing feet are under each corner.
HP SERIES
PORTABLE PUMPS
USER OPERATION AND MAINTENANCE
Insert the bolts and secure in place with
lockwashers and nuts provided.
4. When the pump is mounted and if
access is not provided to fill the fuel tank
install optional fill tube and vent
extension as required.
NOTE: The fuel tank on the HP
series pump is already vented,
therefore a vented fuel cap is
not required
5. Locate and install the instrument
panel on the apparatus. A dimensional
drawing is provided of the instrument
panel to locate the mounting holes.
(NOTE: Approximately 2 meters (6 feet)
of wire and control cables is provided
with the pump. When locating the
instrument panel the installer must take
this into account.) Make electrical
connection from the instrument panel to
the pump with the jumper wires
provided.
isolated. When making the
permanent connections to the
suction and discharge fittings
DO NOT use hard piping. A
short length of flexible piping is
required to prevent damage
to the pump and engine.
7. Make piping connections to the
discharge flange as required. When
making the piping connections it may
be necessary to turn the pump volute
for proper alignment. To turn the pump
volute:
a. Loosen and remove the "V"-band
clamp using a 1/2 inch or 13 mm
deep well socket.
b. Remove the volute from the
pump body.
c. Locate and remove the
positioning roll pin from the pump
body.
d. Return the volute to the pump
body and install "V"-band clamp.
e. Turn the volute as necessary when
6. Connect throttle lever and choke
control to the engine. Secure in place
with the clamps provided. After the
connections are made ensure the
controls work smoothly. There may be
excess cable after the connections are
made. Make a loose coil of the cable
and secure in place with wire ties.
CAUTION: The pump and
motor assembly are vibration
V-BAND CLAMP
TIGHTENING NUT
19
HP SERIES
PORTABLE PUMPS
USER OPERATION AND MAINTENANCE
making discharge piping connection.
f. After the discharge connection is
complete tighten the "V"-band
clamp to prevent leakage.
8. Connect the exhaust priming lever
cable to the exhaust primer.
EXHAUST PRIMER
CABLE
CONNECTION
SUCTION GAUGE
TUBING CONNECTION
DISCHARGE GAUGE
TUBING CONNECTION
suction fitting as required. When making
9. Connect tubing for the suction and
discharge gauges. Use the 1/4 inch
diameter tubing provided with the
pump for gauge connections. If a
longer length of tubing is required use 1/
4 inch diameter tubing rated at the
maximum operating pressure of the
pump. Connections to the gauges and
this connection ensure there are a
minimum of restrictions such as elbows
and couplings. Also, to protect the
pump from debris a strainer shall be
installed in the suction connection.
CAUTION: Always connect
the black wire to the negative
battery terminal last.
11. Connect the pump electrical system
to a 12 volt battery to provide power to
start the pump. Always connect the
positive battery cable first.
NOTE: The pump may be
connected to the apparatus
battery or a separate battery
may be used.
pump are compression type. Make sure
the gauge lines are connected to the
proper connection on the pump body.
10. Make piping connection to the
20
INITIAL OPERA TION CHECKOUT
After activating the battery on the
portable pump, or installing the "X" series
pump, prior to placing the pump into
operation the following items must be
checked.
WARNING: DO NOT smoke
when filling fuel tank.
HP SERIES
PORTABLE PUMPS
USER OPERATION AND MAINTENANCE
WARNING: DO NOT fill fuel
tank while engine is running.
Allow engine to cool for two
minutes before refueling.
WARNING: DO NOT operate
engine when an odor of
gasoline is present or other
explosive conditions exist
WARNING: DO NOT STORE,
SPILL, OR USE GASOLINE NEAR
AN OPEN FLAME, or devices
such as a stove, furnace, or
water heater which utilize a
pilot light or devices which
can create a spark.
WARNING: DO NOT refuel
indoors where area is not well
ventilated. Outdoor refueling
is preferred.
1. CHECK FUEL LEVEL: Remove fuel filler
cap to check fuel level. Fill tank as
FUEL FILLER CAP
gasoline. The engine will
operate satisfactorily on any
gasoline intended for
automotive use. A minimum
of 85 octane is
recommended. DO NOT MIX
OIL WITH GASOLINE. Leaded
gasoline may be used if leadfree is not available.
NOTE: The use of gasoline
which contains alcohol, such
as gasohol is not
recommended. If gasoline
with alcohol must be used, it
MUST NOT contain more than
10 percent Methanol and
MUST be removed from the
engine during storage.
necessary and replace cap. DO NOT fill
the fuel tank to the point of overflowing.
The tank is designed to provide sufficient
expansion space when the tank is full.
When refilling the fuel tank ensure the
pump is level to prevent overfilling or
fuel being spilled on the ground.
FUEL RECOMMENDA TIONS: Use
clean, fresh, lead-free
2. PRIME FUEL SYSTEM: When initially
placing the pump into operation gain
access to the fuel primer bulb, located
behind the pump cover on the portable
pump, and squeeze until firm. Replace
cover after fuel system is primed.
CAUTION: The pump is
shipped without oil in the
21
HP SERIES
PORTABLE PUMPS
USER OPERATION AND MAINTENANCE
engine crankcase. Before
placing pump into operation
for the first time fill engine
crankcase to proper level with
SAE 30 Weight Detergent oil.
3. FILL ENGINE WITH OIL: When received
the engine crankcase doesnot contain
oil. Remove oil dipstick or cap on valve
cover and fill with 3.5 pints of SAE 30 Oil.
Check oil level by removing the oil
dipstick and wiping oil from dipstick with
clean cloth. Screw dipstick firmly into
place until cap bottoms on tube.
Remove to check oil level. If necessary
add additional oil to bring oil up to the
proper level. Dipstick assembly must be
firmly assembled into tube when engine
is operating .
pump into operation for the
first time fill gearbox to proper
level with SAE 30 Weight
Detergent oil.
4. FILL HP100 GEAR BOX WITH OIL: The
HP100 is shipped without oil in the gear
box. Add oil to proper level in
accordance with procedures listed in
section 8. Replace oil level plug.
5. CONNECT SUCTION HOSE: Ensure the
hose connections are tightened with a
spanner and a strainer is placed at the
end of the hose to prevent debris from
entering the pump and causing
irreparable damage. Place end of
suction hose in water source. Make sure
the end of the suction hose does not
CAUTION: The HP100 is
shipped without oil in the
gearbox. Before placing
OIL FILL CAP
become submerged in the mud or silt on
the bottom. Also make sure the suction
hose has no bends or loops that are
higher than the suction connection of
the pump that would trap air and
prevent priming of the pump.
OIL FILL FITTING
OIL LEVEL PLUG
OIL DIPSTICK
OIL DRAIN PLUG
22
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