Star FW0520 User Manual
Operating Instructions & Parts Manual 020598 and 020599
Please read and save these instructions. Read carefully before attempting to assemble, install,
operate or maintain the product described. Protect yourself and others by observing all safety
information. Failure to comply with instructions could result in personal injury and/or property damage! Retain instructions for future reference.
Self-Priming Engine-Driven
Centrifugal Pumps
Description
These centrifugal pumps include a precision mechanical seal with stainless steel
spring, EPDM seals, carbon face and ceramic seat, and a built-in check valve for
better self-priming capabilities (up to 20 ft. suction lift). Clog resistant impeller is
capable of handling solids up to 7/16" diameter. Pumps include molded carrying
handle, rubber foot pads, and two 2" NPT pipe nipples. Handle liquids from 40º to
130º F (4º to 54º C). For use with nonflammable, non-abrasive liquids compatible
with pump component materials.
Applications include pumping clear, clean water, salt water, and some liquid fertilizers and herbicides. An optional Buna N Seal/O-ring/Flapper Kit (see Repair Parts
List) is available for pumping additional liquids. If the liquid is not compatible with
Buna-N (optional) or EPDM (standard) rubber materials, do not use these pumps.
Specifications
Suction inlet . . . . . . . . . . . . . . . . . . 2" †
Discharge outlet . . . . . . . . . . . . . . . 2" †
(†) Standard NPT (female) pipe thread.
Dimensions (overall)
020598 . . . . . . . . 13" H x 15" W x 18" L
020599 . . . . . . . . . 18
Engine
020598 . . . . . . . . . . . . . . . . . 3.5 HP B&S
020599 . . . . . . . . 5.5 HP B&S OHV Intek
Oil type . . . . . . . . . SAE 30W Detergent
Weight
020598 . . . . . . . . . . . . . . . . . . . . 38 lbs.
020599 . . . . . . . . . . . . . . . . . . . . 43 lbs.
Material . . . . Glass-filled p
3
⁄8L x 173⁄8W x 151⁄4H
olypropylene
Safety Guidelines
Failure to follow any
warnings/ cautions
can result in personal injury, pump damage, and/or property damage.
This manual contains information that
is very important to know and under-
3824-254-00 FW0520 0703 Supercedes NEW
stand. This information is provided for
SAFETY and to PREVENT EQUIPMENT
PROBLEMS. To help recognize this
information, observe the following
symbols:
Danger indicates an
imminently hazardous situation which, if not avoided,
WILL result in death or serious injury.
Warning indicates a
potentially hazardous situation which, if not avoided,
COULD result in death or serious injury.
Caution indicates a
potentially hazardous situation which, if not avoided,
MAY result in minor or moderate injury.
NOTE: Indicates important information
that, if not followed, may cause damage to equipment.
Unpacking
After unpacking the unit, inspect carefully for any damage that may have
occurred during transit. Make sure to
tighten fittings, bolts, etc., before putting unit into service.
7/2003
Operating Instructions and Parts Manual
020598 and 020599
Self-Priming Engine-Driven
Centrifugal Pumps
Unpacking (continued)
Do not operate unit
if damaged during
shipping, handling or use. Damage may
cause injury or property damage.
General Safety Information
1. Know the pump application, limita-
tions, and potential hazards. Read all
manuals included with this product
carefully. Be thoroughly familiar with
the pump and the proper use of the
equipment.
Do not use to pump
flammable or explosive fluids such as gasoline, fuel
oil, kerosene, etc. Do not use in
flammable and/or explosive
atmospheres. Pump should only be used
with liquids compatible with pump
component materials. Failure to follow
this warning can result in death, serious
personal injury and/or property damage.
2. Make certain that the power source
(gas engine) conforms to the requirements of your equipment.
3. Provide adequate protection and
guarding around moving parts.
4. Release all pressure within the system
before servicing any component.
5. Drain all liquids from the system
before servicing.
6. Secure the discharge line before
starting the pump. An unsecured discharge line will whip, possibly causing personal injury and/or property
damage.
7. Check hoses for weak or worn condition before each use, making certain
that all connections are secure.
8. Periodically inspect pump and system
components. Perform routine maintenance as required (See
Maintenance section).
9. Provide a means of pressure relief
for pumps whose discharge line can
be shut-off or obstructed.
10. Personal Safety:
a. Wear safety glasses at all times
when working with pumps.
b. Wear a face shield and proper
apparel when pumping hazardous
chemicals.
c. Keep work area clean, uncluttered
and properly lighted; replace all
unused tools and equipment.
d. Keep visitors at a safe distance
from the work area.
e. Make workshop child-proof – with
padlocks, master switches, and by
removing starter keys.
11. Carefully read instruction manuals
supplied by engine manufacturer
before attempting to assemble,
operate, or service the engine or
any part. The WARNING statements
indicate potentially hazardous conditions for operator or equipment.
TAKE NECESSARY STEPS TO PROTECT PERSONNEL AND EQUIPMENT.
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 fuel, neveras 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 reach of children. Never
store gasoline near heat or an
open flame.
d. Add gasoline to a cool engine only.
2
Operating Instructions and Parts Manual
Models 020598 and 020599
General Safety (continued)
Spilled gasoline on a hot engine
may cause fire or an explosion. Fill
gasoline tank out-of-doors and
wipe up any spills.
e. Provide a fire extinguisher nearby
when working with gasoline. Be
sure extinguisher is in operating
condition – check 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.
IMPORTANT: Positively no smoking!
12. DO NOT RUN THE ENGINE IN AN
ENCLOSED AREA!! Exhaust fumes
contain carbon monoxide which is
an odorless and poisonous gas. If
equipment is located in an enclosed
area, use an exhaust line to the outside and regularly check the exhaust
system for leaks. Be sure the area is
well ventilated.
13. Check engine oil and fuel levels
before initial start up each day. Stay
away from moving parts. Avoid
wearing loose jackets, shirts, and
ties. Make sure all nuts and bolts
are secure. Keep power shields and
guards in place. If adjustments must
be made while the unit is running,
use extreme caution around hot
manifolds, moving parts, etc.
14. Do not operate this equipment
when mentally or physically
fatigued.
Be careful not to
touch the exterior of
the engine, especially the muffler and
the surrounding area. The engine is hot
enough to be painful or cause injury!
15. 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.
16. Familiarize yourself with all controls. Learn how to stop an engine
quickly in an emergency.
17. Keep the equipment and surrounding area clean. Remove all oil
deposits from equipment and surrounding area. Accumulations of
grease and oil may present a fire
hazard and can cause engine damage. Cleaning rags and other flammable waste materials must be
stored in approved metal containers.
18. All visitors should be kept at a safe
distance from the working area.
Keep children away from power
equipment. Keep work area clean.
Cluttered areas invite accidents.
19. When shutting off a gasoline
engine, be sure it is completely
stopped before leaving the work
area.
Installation
IMPORTANT: For installations where
property damage might result from an
inoperative or leaking pump due to
power outages, discharge line blockage
or any other reason, a back-up
system(s) and/or warning system(s)
should be used.
1. Locate pump as close to the fluid
source as possible, making the suction line as short and direct as possible.
The unit should be
placed where the
pump/engine is protected from the
weather and extremes of heat, cold and
humidity.
3
Operating Instructions and Parts Manual
020598 and 020599
Self-Priming Engine-Driven
Centrifugal Pumps
Installation (continued)
2. Mount the unit on a solid foundation. On fixed installation, install
both a union and a gate valve (not
furnished) on the discharge side of
the pump for service convenience.
Do not use a globe
or other restricting
type of valve at the discharge, as this
would seriously restrict the capacity of
the pump.
3. Attach suction line piping to the suc-
tion inlet and discharge line piping
to the discharge outlet. The suction
line should be positioned such that
there is a continual upward slope
from the fluid source to the pump.
Avoid using loops or sections of pipe
or fittings which might permit air to
become trapped.
IMPORTANT: If plastic or fabric hose is
used for the suction piping, it should
be of a reinforced type so as not to collapse under suction. The discharge piping should be at least the same size as
the discharge connection. Suction piping should be the same size as the discharge piping or one size larger. Unless
long horizontal runs are involved, discharge piping should not be larger
than suction piping. Avoid using
looped sections of pipe which might
permit air to become entrapped. Assure
air-tight pipe connections with the use
of a pipe joint sealant.
4. A foot-valve may be used on the
suction line to assist in faster pumping. The foot-valve should be
installed when the suction lift is over
10 feet or when the suction line is
over 10 feet long.
5. A suitable suction strainer should be
attached to the suction line so that
large pieces of foreign material are
not drawn into the pump. The maximum opening in the suction strainer
should not be greater than 25% of
the suction inlet size for solid handling pumps and 50% of the suction
inlet size for trash pumps.
Operation
1. Fill the engine crankcase with oil as
specified in the engine manual. If the
engine has no dipstick, then fill the
crankcase with oil until the oil overflows (starts spilling out of the
crankcase). Periodically check oil level
thereafter.
2. Fill the gasoline tank as required.
Refer to engine instruction booklet.
Never add gasoline
to a hot engine!
See General Safety Information for
proper handling of gasoline.
3. Fill the pump with liquid through the
pump discharge or the priming port
supplied with these units. It may be
convenient to screw in a service tee
or a tee with a nipple into the discharge, so that the pump can be
filled (using the upper leg of the tee)
without disconnecting the discharge
hose or pipe. The vertical leg must be
closed with a pipe plug during
pumping. Remember, the pump is
self-priming only when the pump
casing has been filled. The pump
should prime and re-prime without
refilling. Refilling is necessary occasionally if an unusual siphoning has
occurred, if the fluid has been lost by
evaporation, and when the unit is
moved to a new location.
Do not run pump
dry, as permanent
damage to the mechanical seal will
result.
4. Start the engine, following instruc-
tions in the engine manual.
5. With a suction lift of 5 to 10 feet, the
pump should discharge liquid within
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