TABLE OF CONTENTS - Découvrez Protect Forest
Contents
1. ENGINE BACKFIRES Possible cause Spark plug fouled or defective Remedy Clean or replace Defective carburetor Replace Improper timing Refer to timing section 2 ENGINE OPERATING ENGINE DOES NOT IDLE PROPERLV Possible cause Carburetor mountings loose Remedv Tighten mountings Too much oil in fuel mixture See Engine Lubrication and Fuel Idle mixture screw misadjusted See Service Manual Spark plug fouled or defective Clean or replace Wrong tvpe spark plug Use plug recommended Main adjustment screw misadjusted See Service Manual Improper timing Refer to timing section ENGINE DOES NOT DEVELOP NORMAL POWER AND OR OVERHEATS Possible cause Carburetor mountings loose Remedv Tighten mountings Wrong gasoline in fuel mixture See Engine Lubrication and Fuel Wrong oil in fuel mixture See Engine Lubrication and Fuel Not enough oil in fuel mixture See Engine Lubrication and Fuel Too much oil in fuel mixture See Engine Lubrication and Fuel Air filter dirty Replace Spark plug fouled or defective Clean or replace Wrong type spark plug Use plug recommended Cooling system dirty See Service Manual Muffler blocked or dirty Replace Main adjustment screw misadjusted See Service Manual Improper timing Refer to timing section ENGINE SOUNDS LIKE A FOUR STROK2. e Insert thrust washer Q e Fit rewind starter parts set ass v B in the rewind starter Note Pay attention to correct positioning The corners of the pivot arm must point toward top left and down right B e Slightly lubricate the serration of the pivot arm e Insert the friction washer so that the serration points towards pivot arm 10 e Fit friction spring and cover washer B www wildfire equipment com 27 4 REGULAR MAINTENANCE 28 Wildfire SERVICING THE REWIND STARTER CONTINUED e Depress cover washer and fit circlip e Pull starter grip B and check whether the pawls are moving outward When releasing the starter grip the starter rope must be rewound to its idle position Note If the pawls do not move outward the rewind starter parts set ass v B has been inserted wrongly In this case disassemble it again and fit the rewind starter parts set ass v correctly e Fit rewind starter ass v with 4 hex Screws M6x20 and lock washers Tightening torque 6 6 Ib ft 9 Nm e Start engine to check function of the rewind starter Ref Part Description Qty R952 Service tool kit l incl all parts listed below 1 R 929 Flywheel holding tool l 2 271 927 Screwdriver l Phillips No 12 3 271 346 Screwdriver standard Il 4 R 928 Cap shaft protector l 5 R930 Puller crankshaft l bearing R 313 6
3. Remove fuel supply line from engine or close fuel supply valve if equipped Remove spark plug With both choke and throttle in fully open position pull starter rope several times until excess fuel is exhausted Before reinstalling spark plug clean and dry electrode and insulator tip COLD WEATHER RECOMMENDED PROCEDURE FOR COLD WEATHER OR PROLONGED STORAGE The following procedure is recommended to ensure proper protection of the engine if the engine is to be left idle for prolonged periods between uses or if there is a possibility that the engine may be stored in an unheated area where freezing temperatures may occur 1 With pump unit running at approximately low RPM approx 3 4 increment V2 throttle remove the quick connect fuel line from the quick connect fitting on the engine Allow engine to run until all fuel has left the carburetor and the engine stops Remove spark plug Rotate crankshaft until piston is at top dead centre u Aa WwW N Pour 30 ml 1 oz of oil into spark plug opening use same oil grade used in fuel mixture 6 Rotate crankshaft 2 or 3 times to assure that cylinder walls are well coated with oil then bring piston to top dead centre 7 Reinstall spark plug It is preferable to keep the pump unit in dry storage above freezing temperature However as this is not always possible some slight rusting may occur which should have no detrimental effect on the life or performance of the unit TROUBLES
4. evenly Reinstall filter and screen into housing and install cover When the filter will not wash clean or is damaged replace it Ref Part Description Qty 1 R I50 Hex lock nut 2 2 R 149 Lockwasher 2 3 R 402 Stud 2 4 R1113 Gasket carburetor l 5 R257 Cylinder l 6 R 270 Cast iron sleeve l 7 R 235 Gasket cylinder flange l 8 R 237 Gasket muffler l 9 R I17 Stud 2 10 R 119 Lockwasher 2 11 R 120 Hex nut 2 12 R 233 Cylinder head 18mm l 13 R 238 Gasket cylinder head l 22 Wildfire Ref Part Description Qty I R414 Mach Screw hex cap 1 2 R 119 Lockwasher l 3 R 413 Cover for spark plug l 4 R 119 Lockwasher l 5 R414 Mach Screw hex cap 1l 6 B 2920 6 Flat slotted bolt 2 7 A 2924 Reset rod l 8 A 2926 Cable l 9 B 6288 Cutout switch assembly 2 includes ref 6 7 8 10 and 14 10 B 2428 6 Hex lock nut 2 11 R408 Mach Screw l 12 12 38 Lockwasher 4 13 R409 Clamp ignition cable 1 14 B 2920 23 Grommet 2 15 TY 1811 Hex nut 3x 16 R 115 Stud 17 R 150 Hex lock nut 2x 18 R 151 Flat washer 19 R402 Stud 20 R 411P Fan cowl with studs painted includes R 115 and R 402 21 R418 Shield fan 4 REGULAR MAINTENANCE SERVICING COOLING SYSTEM Efficient engine cooling is accomplished by a fan attached to the flywheel This fan pulls air through the fan housing screen then forces the air around the cylin der and through the spaces between the cylinder and
5. 2 After starting and warming up engine thoroughly increase to maximum recom YP 9 y life of the cut out switch mended power then lift foot valve out of water supply Engine will speed up then stop suddenly indicating the automatic cutout switch is functioning 16 Make sure pump seal is not leaking 17 Make sure that all necessary tools spares and accessories are with pump unit It is strongly suggested to always have an extra spark plug on hand Should the switch not cutout after l 2 seconds while engine is running at 18 Make sure electronic ignition module is free of debris Verify condition of wiring increased speed close throttle and toggle switch immediately otherwise serious aad E engine damage may result Assuming that cutout is functioning then the speed setting of the switch should be checked to make sure that it is not set too low or too high Use a reliable tachometer to check engine RPM bel Part Description Qty 3 Located in the upper centre of the outer surface of the fan housing is a small R900 Maintenance tool kit incl all parts listed below 1 socket head adjustment screw By using a 1 16 Allen key tool R 909 and l1 Part 117 Grease gun Shown with deterioration turning this screw 1 2 turn clockwise will increase the cutout speed setting 2 271 923 Wrench adjustable 8 203mm i Old style Alum Air vane approximately 150 RPM A 1 2 turn counterclockwise will decrease
6. 343 in crankcase half magneto side 32 Use oil seal pressing tool R 933 to install oil seal R 123 Press bearing R 333 in crankcase half pump side 33 Measure the combined thickness of 2 ball bearings Call this dimension H 34 Subtract H from G and divide by 2 This is J the thickness of shim s to be placed on each side of the crankshaft A B C F G H shim thickness to be placed on each side of crankshaft 2 Note The crankshaft used in the electronic ignition units does not have a lobe ground into the crankshaft end 35 Slide crankshaft in crankcase half pump side Be careful to prevent damage to lip of oil seal 36 Press crankshaft into crankcase half pump side To prevent bending of crank shaft be sure to always use the crankshaft jack tool R 953 fig 1 between the webs of the crankshaft fig 2 37 Install crankcase gasket apply some oil Important Always use a new crankcase gasket 38 Slide the other crankcase half on crankshaft 39 Align dowel tubes and verify that crankshaft jack and connecting rod are in piston axe fig 3 and press crankcase halves together 40 Reassemble crankcase screws and lockwashers Tighten screws uniformly to 11 12 Nm 100 110 inch Ibs torque 41 If piston was removed reinstall it in proper position arrow on top of piston or balancing lumps inside piston head should be on muffler side of engine Replace needle bearing R 324 if necessary 42 Change cylinder head and cylinde
7. B 6571 Noise Reduction Muffler ENGINE 2 Spark plug 41 Nm 360 inch Ibs 30ft Ibs 41 Nm Crankshaft halves run out 0 03 mm 0 0011 With its extra internal baffling and larger size the new B 6571 muffler was e itu dacianed tered MK 3 f O o madek 10 Cylinder head nuts 23 25 Nm 200 220 inch Ibs Crankshaft bearing seat dia ili ET E E A SESAO E A S E E A a Should be retorqued every 100 hours on crankshaft coupling side 20 002 20 011 mm 0 7875 0 7878 of operation Wear limit 20 000 mm 0 7874 l FTA on crankshaft flywheel side 25 002 25 011 mm 0 9843 0 9847 Flywheel hub nut 44 45 Nm 390 400 inch Ibs Wear limit 25 000 mm 0 9843 Collar coupling nut 11 14 Nm 100 120 inch Ibs Gie P d ja both sides 51 95 51 96 mm 2 0453 2 0457 at PTO end should be torqued to Wear iiri 5198 5 99 I 2 0465 2 0489 19 21 Nm 175 185 inch lbs EGR MOSE Connection rod inside dia soli aaa oad Eee a for piston rim bearing 21 997 22 005 mm 0 8660 0 8663 Ring pist e 0 04 0 11 0 0016 0 0043 8 6571 shown installed on MK 3 NR pue rete ai SENET sae Retaining ring screws 6 7 7 3 Nm 60 65 inch Ibs measured on rectangular rings only Shaft nose screw 7 9 8 5 Nm 70 75 inch Ibs Sika 61 mm 2 40 Nut 12 50 28 29 Nm 250 260 inch lbs Suction nozzle screws 7 9 8 5 Nm 70 75 inch Ibs Pump Ref Part Description Qtv D E CA R B O N l S l N G Impeller 12 7 diameter 93 22 mm 0 13 03 670 0 005 oe a ih f i TA ts will f T Impell
8. DO NOT use suction hose without foot valve strainer DO NOT allow foot valve strainer to rest on bottom of lake or river bed 4 Connect foot valve strainer to male end of suction hose then fill suction hose with water and connect to pump Use universal hose coupling wrench to tighten coupling firmly 1 8 5 Connect discharge hose CA nozzles etc to pump Use a rope or other means to keep strainer at proper height approximately 30cm 1 foot below water surface If strainer is too close to the water surface it will draw air and pump may lose prime 1 7 6 Fill pump with water manually or using a hand primer B 5980 then replace priming cap and tighten firmly 1 8 7 Move throttle lever to Start and Warm up position Verify that On Off switch is on On position approx 3 increments Verify that the reset cutout switch is not engaged must be pushed in 8 Close choke if engine is cold 9 Slowly turn engine until resistance past compression 10 Give starter rope several quick steady pulls until engine coughs 11 Open choke slightly and pull starter rope until engine runs 12 Slowly open choke and allow engine to warm up for at least 2 minutes before using full throttle The MARK 3 engine was initially run in at the factory Full throttle operation can be used provided the engine is given a thorough warm up period beforehand Important Failure to allow the engine to warm up may lead to piston scoring and possibl
9. High speed mixture screw spring 14 R 1021 Flat washer brass 15 R 1022 High speed mixture screw packing 16 R 1004 Choke shaft and lever 17 R 1036 Throttle shaft clip 18 R 1037 Lockwasher 19 R 1038 Mach screw 20 R 1101 Throttle link lever assembly 21 R 1111 Bolt 22 R 1112 Flat washer 23 R 1110 Hex nut 24 R 1001 Body channel welch plug 25 R 1034 Nozzle check valve 26 R 1046N Inlet needle and seat 27 R 1047 Inlet seat gasket 28 R 1003 Choke friction spring 29 R 1002 Choke friction pin 30 R 1005 Choke shutter 3 R 1041 Mach screw with lockwasher OZ R 1024 Idle speed screw spring 33 R 1023 Idle speed screw 34 R 1029 Inlet tension spring 30 R 1025N Inlet control lever 36 R 1008 Diaphragm gasket 37 R 1009 Diaphragm 38 R 1010 Diaphragm cover 39 R 1011 Fuel pump gasket 40 R 1012 Fuel pump diaphragm 4 R 1013 Fuel pump body 42 R 1015 Fuel strainer screen 43 R 1016 Fuel strainer cover gasket 44 R 1014 Mach screw with lockwasher 45 R 1017 Fuel strainer cover 46 R 1018 Mach screw R 1050 Repair parts kit includes parts R 1001 R 1008 R 1009 R 1113 R 1025N R 1011 R 1012 R 1016 R 1046N R 1046N L 4 REGULAR MAINTENANCE The carburetor can be cleaned with a minimum of tools Before disassembling carburetor it is imperative to flush it clean of dirt by using proper carburetor cleaner 1 Remove strainer cover retaining screw and plastic cover 2 Remove strainer cover gasket and strainer screen 3 Remove screws and fuel pump
10. Hold rope sheave and remove the 2 Allen screws M5x16 B along with lock washers DB and the cover B with plug B Warning Keep rope sheave firmly in hands Risk of injury when rewind spring unwinds e Pass the starter grip B through the window in the starter housing and turn rope sheave approx 4 turns counterclockwise so that the rewind spring unwinds e Remove starter sheave with starter rope and starter grip W e Check bearing bolt for signs of seizure Note If there are slight signs of seizure remove them carefully e Check bearing bore of the rope sheave for signs of seizure Note If there are signs of seizure the rope sheave must be replaced e Apply oil on the rewind spring 26 Wildfire e Apply Molykote G N slide paste on the bearing bolt of the rope sheave 4 REGULAR MAINTENANCE REASSEMBLY OF REWIND STARTER e Wind starter rope fitted with starter grip counter clockwise in the rope sheave e Fit rope sheave on the bearing bolt and engage it by slight turning into the rewind spring O e Hold rope sheave firmly and turn starter housing 4 turns clockwise to preten sion the rewind spring e Fit rope guide B in the recess and pass the starter grip through the window in the starter housing holding the rope sheave firmly e Fit the plug B e Fit the cover B and fix it with 2 Allen screws M5x16 B and lock washers Tightening torque 2 2 3 Ib ft 3 4 Nm
11. body 4 Remove fuel pump diaphragm and gasket 5 Remove main diaphragm cover plate 6 Remove main diaphragm and main diaphragm gasket 7 Remove inlet control lever fulcrum pin lever and tension spring 8 Remove inlet needle 9 With a thin wall 8 mm 5 16 hex socket carefully remove the inlet seat Remove inlet seat gasket When reinstalling seat tighten only to 3 or 4 Nm 25 35 inch Ibs 10 Remove idle and high speed mixture screws 11 When reinstalling O ring type adjusting screws lubricate with SAE 30 oil to prevent seizing Packing spring type adjustments do not require lubrication 12 The ball check type main nozzle can be removed by tap ping it out of the body casting into the venturi with a small punch A replacement ball check nozzle should be pressed into the casting The brass cage should be pressed flush with the metering chamber casting Before reassembling the carburetor in reverse order as out lined above wash all component parts in carburetor cleaner and blow off with compressed air The channels in the metering body should be cleaned by blowing through the idle and main adjusting orifices All fuel passages in the three castings should be cleaned with compressed air Do not clean orifices or passages with wires or drills as this might damage and cause incorrect operation of the carbu retor When reassembling the inlet control lever and spring make sure that the spring rests in the well of the metering
12. body and locates on the dimple of the inlet control lever Do not stretch spring Inlet control lever is properly set when flush with floor of diaphragm chamber Be certain main diaphragm gasket and cover casting are carefully fitted over the three small pins cast in rim at bot tom of metering body Also the fuel pump gasket diaphragm and fuel pump body are placed over similar pins at bottom rim of main diaphragm cover casting Evenly tighten fuel pump body retaining screws to insure complete seal of casting separations at both diaphragms Frequent cleaning or replacement of the fuel strainer screen will aid satisfactory operation of the carburetor www wildfire equipment com 19 20 Wildfire A REGULAR MAINTENANCE SERVICING CARBURETOR CONTINUED CARBURETOR ADJUSTMENT The carburetor is provided with three adjustments namelv high speed main adjustment low speed idle adjustment and idle speed regulating screw 1 Before starting pump unit close both main and idle adjustment screws by turning clockwise until needle just touches seat Note Turn adjustment screws carefully and gently Do not force needle into seat otherwise both needle and seat may be permanently damaged 2 Open main adjustment screw turn by turning counterclockwise 3 Open idle adjustment screw 1 turn by turning counterclockwise 4 Turn idle speed regulating screw until throttle shutter is slightly open 5 Start unit Open choke slowl
13. drive bushing or impellers Do not forget to secure the shaft from rotating 18 Bend lockwasher up onto one flat of the hexagon locknut at a position approx imately 180 from the milled slot in the shaft Old style locknut need to use tool A 1883 to tighten and backing off slightly if necessary until one of lock ing tabs of lockwasher is opposite a milled slot of the locknut then lock by pushing tab into slot 19 If excessive play replace bronze bushing 4 20 Place O ring 10 in groove of suction nozzle 9 then bench press the nozzle into the pump body until it rests on face of first distributor A gap of approxi mately 0 794 mm 1 32 between nozzle flange and end of body is normal 21 Attach nozzle to body by using the 8 screws and lockwashers Tighten screws evenly and firmly 22 Attach shaft nose 5 using lockwasher 4 and screw 3 Tighten screw even ly and firmly 23 Check gasket in the priming cap 13 and replace if damaged 24 Reinstall the suction and discharge thread protectors 25 Reinstall capson suction and discharge inlets Use a clean gun filled with fresh grease Remove dirt from grease fitting before applying grease gun Grease should be pumped slowly into bearing chamber until fresh grease appears around bearing retaining ring Wipe off excess grease A grease relief valve old style only has been provided to prevent pressure buildup on the rotary seal should the fresh grease not be able to flow completely t
14. including a decompression switch assembly KEY CHARACTERISTICS e Decompression switch makes easy pulling starting of recoil starter on high compression MARK 3 e Engine fires up much easier e No kick back e Easily engaged simply push decompression switch in e Automatically disengages closes when engine starts PARTS BREAKDOWN e Decompression Switch A 7627 e Copper Washer A 7628 e Cylinder Head R 233 machined head not sold separately e Head Gasket R 238 not shown INSTALLATION NOTES e Torque value for decompression switch 190 210 in Ibs 21 24 Nm e Install cylinder head with decompression switch oriented towards pump end NOTE Not yet available on MK 3 GSA version R 233 www wildfire equipment com 17 4 REGULAR MAINTENANCE SERVICING CARBURETOR CARBURETOR DESCRIPTION 18 Wildfire Ref Part Description R 1115 Carburetor includes parts listed below except R 1113 l R 1045 Body 2 R 1113 Gasket carburetor 3 R 1041 Mach screw with lockwasher 4 R 1040 Throttle shutter 6 R 1026 Inlet control lever pinion screw 6 R 1035 Throttle shaft and lever 7 R 1039 Throttle shaft return spring 8 R 1019 Idle mixture screw 9 R 1020 Idle mixture screw spring 10 R 1021 Flat washer brass 1 R 1022 Idle mixture screw packing 12 R 1030 High speed mixture screw 13 R 1020
15. one piece bearing heat both crankcase halves on the outside face of the crankcase around the bearing housing portion to a maximum of 100 C 212 F and using a plastic or rubber mallet separate crankcase halves 19 Remove crankshaft with connection rod 20 Press out both oil seals using oil seal pressing tool R 933 21 Remove bearings from crankshaft journals using shaft protector tool R 928 and bearing puller tool R 938 22 Always change oil seals Pistons rings and shims optional sizes Pistons rings and shims optional sizes R 307 Shim 0 008 As req coupling side R 308 Shim 0 012 As req coupling side R 309 Shim 0 016 As req coupling side R 310 Shim 0 020 As req coupling side R 311 Shim 0 031 As req coupling side R 312 Shim 0 040 As req coupling side R 344 Shim 0 004 As req flywheel side R 345 Shim 0 012 As req flywheel side R 346 Shim 0 020 As req flywheel side R 347 Shim 0 039 As req flywheel side R 332 0 Oversized piston includes rings R 331 0 Oversized piston ring 0 078 R 331 0 1 Oversized L type piston ring R 321 Serrated lockwasher 12mm used on old style engine R 307 Shim 0 008 coupling side As req R 308 Shim 0 012 coupling side As req R 309 Shim 0 016 coupling side As req R 310 Shim 0 020 coupling side As req R 311 Shim 0 031 coupling side As req R
16. remains l in the retainer 9 and the starter housing 10 Always wear eye protection 9 R 531 Retainer spring l when removing the rope sheave 10 R 530 Housing starter l 9 Very carefully remove rewind spring Always wear gloves and eye protection includes R 531 when removing the rewind spring 11 12 38 Lockwasher 4 10 Wash all metal parts with proper cleaning solution 12 R 522 Mach screw hex cap 4 13 R 509 Plug rubber l 14 R524 Mach Screw 2 15 R 523 Lockwasher 2 16 R 532 Cover l 17 R 505 Pin starter rope lock l 18 R533 Guide starter rope l 19 R 502 Rope starter l 20 R 544 Buffer rubber l 21 R 501 Handle starter rope l Pawl assembly 5 must be assem bled with the pawl spring stop on the left otherwise the starter will not function 24 Wildfire 4 REGULAR MAINTENANCE REMOVAL OF REWIND STARTER Warning All repairs must to be carried out by qualified professionally trained and authorized staff Only careful assembly and respecting all the instructions of this SERVICE INFORMATION will warrant trouble free operation e Remove 4 hex screws M6x20 with lock washers 6 and detach the rewind starter ass v e Depress the cover washer and remove circlip e Remove cover washer friction spring and friction washer e Remove rewind starter parts set ass v and thrust washer www wildfire equipment com 25 4 REGULAR MAINTENANCE SERVICING THE REWIND STARTER CONTINUED e
17. set 1 A 2688 Thread protector 51 mm 2 34 A 2924 Reset rod 23 A 2926 Cable 23 A 3023 Carburetor adjusting tool 13 A 4005 Mounting pad 37 A 4027 Pin index 22 A 4028 Spring 22 A 4030 Throttle decal english 22 A 4097 Protector shaft 36 A 4329 Pressing sleeve rotary seal assembly 30 30 A 4452 Link for lever side 9 A 4453 Eve bolt 9 A 4454 Clevis pin for eye bolt side 9 A 4455 Clevis pin for lever side 9 A 4456 Knob for tension adjustment 9 A 4460 Lever 9 A 5297 Support tool 34 36 A 5536 Protective cap discharge 34 A 5537 Protective cap suction 34 A 5538 Retainer for priming cap 34 A 6149P Mounting leg 31 37 A 6179 Ring rubber oy B 2428 6 Hex lock nut 23 B 2920 6 Flat slotted bolt 23 B 2920 23 Grommet 23 B 4024 Quadrant for throttle lever 22 B 4036 12 Mach screw hex socket 22 B 4457 Clamp bottom half 9 B 4461 Clamp top half 9 B 5312 4 O ring for drive bushing 35 B 6288 Cutout switch assembly 12 23 C 1933 Calibrated nozzle 12 7 mm 1 2 1 C 4506 3 Bumper rubber 37 C 5200 5 Washer rubber 37 C 5200 6 Flat washer 37 C 5200 7R Spacer rubber sT C 5200 8 Hex bolt 37 C 5200 12 Hex bolt 37 C 5200N Mounting frame assembly 37 C 5201 Frame 37 C 5370 11 Flat washer 31 38 C 6650 14 Hex lock nut 37 C 7010 12 Stop switch assembly 8 C 7010 12C Connector 8 30 D 5269 7 Flat washer 37 FA 552Q Fuel air transport tank 37 MK 138 Gasket 51 mm 2 34 MTR 1000 Hours meter with RPM 22 R 103 Dowel tube 3 R 105
18. set too lean Remedy Enrich idle adjustment Incorrect setting on diaphragm lever Reset Diaphragm cover plate loose Tighten Diaphragm gasket leaking Replace Main fuel orifice plugged Remove diaphragm cover diaphragm diaphragm lever and main adjusting screw Clean out orifice by blowing through main adjustment threaded hole ENGINE WILL NOT IDLE Possible cause Incorrect idle adjustment Remedy Reset to best idle Idle discharge ports or channels clogged Blow out with compressed air or if compressed air is not available clean and flush with gasoline Diaphragm lever set incorrectly Reset diaphragm lever so it is flush with the floor of the diaphragm chamber Throttle shutter cocked in the throttle bore causing fast idle Reset Dirty nozzle check valve Clean and or replace Welch plug covering the idle discharge ports does not seal This causes the engine to idle with idle adjustment shut off Replace welch plug following instructions outlined in service manual ENGINE RUNS OUT LEAN Possible cause Tank vent not working properly Remedy Clean and or replace Leak in fuel system from tank to pump Tighten or replace fittings or lines Ruptured fuel pump diaphragm Replace Main fuel orifice plugged Clean CARBURETOR RUNS RICH WITH MAIN ADJUSTMENT SHUT OFF Possible cause The nozzle channel plug or noz
19. with 1 R665 Mach screw l 2 R661 Lockwasher l 3 R 617 Flat washer l 4 R664 Point amp cable l condenser R 628 5 R612 Mach screw 2 6 R 611 Lockwasher 2 7 R637 Flat washer 2 8 R 661 Coil l 9 R638 Mach screw 3 10 R611 Lockwasher 3 11 R637 Flat washer 3 12 R 662 Condenser l 13 R659 Armature plate l incl R 662 14 R 654 Cap l 15 R 636 Grommet 16 R 630 Cable spark plug l Cable spark plug 17 R 645 Rubber sleeve l 18 R650 Protector spark plug 1 19 R 629 Spark plug 18mm l R 633 T Stop switch kit l incl Ref 20 to 25 20 R 665 Mach screw l 21 R637 Flat washer l 22 R 611 Lockwasher l 23 C 7010 12 Stop switch assembly 1 24 C 7010 12C Stop switch assembly 1 25 R634 Cable stop switch l 30 Wildfire 5 MAJOR OVERHAUL SERVICE SERVICING MAGNETO CONTINUED Before replacing flywheel assembly the ignition timing should be checked See Ignition Timing Ref Part Description ov ENGINE OVERHAUL SERVICE PROCEDURE 1 Replace flywheel assembly make certain that flywheel keyway is aligned prop og erlv with crankshaft kev 1 R146 Mach screw 4 MAJOR OVERHAUL SERVICE PROCEDURE Important Remove all traces of grease oil and dirt from crankshaft taper and a eee To replace or service the following flywheel bore before replacing flywheel assembly 3 R105 Mach Screw 2 4 12 38 oae 5 e Crankshaft connecting rod assembly 2 Replace lockwasher
20. 312 Shim 0 040 coupling side As req R 344 Shim 0 004 flywheel side As req R 345 Shim 0 012 fivwheel side As req R 346 Shim 0 020 flywheel side As req R o4 Shim 0 039 flywheel side As req R 332 0 Oversized piston includes rings R 331 0 Oversized piston ring 0 078 R 33 1 0 1 Oversized L type piston ring R 321 Serrated lockwasher 12mm used on old style engine 5 MAJOR OVERHAUL SERVICE REASSEMBLY SERVICE FOR ENGINE For reassembly 1 piece bearing 23 Place both crankcase halves on a table with inner faces up 24 Using a depth micrometer carefully check the distance from joint face of each crankcase half to lower face of each bearing housing e For pump side crankcase half call this dimension A 5 1 e For magneto side crankcase half call this dimension B 5 2 25 Measure thickness of crankcase gasket R 133 Call this dimension C 26 Subtract dimension B from A Call this dimension D 27 Measure thickness of crankshaft spacer R 334 Call this dimension E 28 Subtract E from D The answer is the thickness of shim s needed to centre the crankshaft 29 Put the spacer and the shims if necessary on crankshaft pump side and measure the total width Call this dimension F 5 3 30 Select acceptable end play see Clearance Data and Limits page 39 and call it G Try G 0 128 mm 0 005 31 Use oil seal pressing tool R 933 to install oil seal R 342 Press bearing R
21. E Possible cause Too much oil in fuel mixture Remedy See Engine Lubrication and Fuel Engine not warmed up properly Allow longer warm up period Main adjustment screw misadjusted See Service Manual Air filter dirty Clean or replace Improper timing Refer to timing section Refer also to section on Servicing Carburetor in Service Manual for additional Trouble Data and service informa tion www wildfire equipment com 7 2 ENGINE OPERATING A more efficient and maintenance free electronic ignition svstem The electronic ignition allows for a smoother and more responsive engine run 8 Wildfire ELECTRONIC IGNITION Since the introduction of the MARK 3 fire pump into the industrv the MARK 3 utilized breaker points in its ignition system which inherently required mainte nance i e the gap adjustment points cleaned and or completely changed The upgrade to the electronic ignition system will eliminate the need for regular maintenance associated with breaker points The electronic ignition system uses a magnetic pickup located on the flywheel which when passing over a certain point on the stator will induce a high voltage therefore causing the spark plug to fire at the proper moment The electronic ignition module is equipped with spark advance thus allowing for a cleaner burn at a higher RPM During testing it was found that the engine ran smoother and was much more resp
22. Gasket carburetor 19 22 R 1114 Quick connect fuel line assy 37 R 1115 Carburetor 45 parts 19 RA 108 Mach screw hex cap 31 38 TY 1811 Hex nut 23 R 532 Cover 24 R 533 Guide starter rope 24 R 544 Buffer rubber 24 R 601 Pulley manual starter rope 29 R 602 Stud 29 R 603 Fan 29 R 611 Lockwasher 30 R 612 Mach screw 30 R 617 Flat washer 30 R 628 Cable condenser 30 R 629 Spark plug 18 mm 8 14 30 R 630 Cable spark plug 30 R 633 T Stop switch kit 30 R 634 Cable stop switch 30 R 636 Grommet 30 R 637 Flat washer 30 R 638 Mach screw 30 R 650 Protector spark plug 8 14 30 R 653 Gasket 29 R 654 Cap 30 R 656 Armature plate complete 30 R 661 Coil 30 R 662 Condenser 30 R 664 Point with cable condenser 30 R 665 Mach screw 30 R 667N E Flywheel magneto assembly 29 R 706 Body quick connect male 37 R 709 Elbow 37 R 712 Handle quick connect female oy R 732 Connector SAE male 37 R 774 Mach screw 22 R 790 Carburetor shroud with decal 22 R 791 Lockwasher 22 29 R 792 Throttle control assemblv 22 R 793 Mach screw hex cap Nvlock 22 R 794 Cover for air filter 22 R 798 Fuel line plastic 37 R 799 Bracket 22 31 R 900 Maintenance tool kit for pump 13 R 901 Screwdriver 102 mm 4 sq handle 13 R 902 Screwdriver 51 mm 2 13 R 903 Feeler gauge spark plug amp breaker point 13 R 904 Wrench spark plug 13 R 905 Handle rod 13 R 906M Wrench box and open end 10 mm 13 R 908 Wrench open end 5 amp 8 mm igni
23. HOOTING CHART ENGINE DOES NOT START OR STARTS MOMENTARILY THEN STOPS Possible cause Fuel supply tank empty Remedy Refill fuel tank Fuel supply valve closed Open supply valve Air vent on fuel tank closed Open air vent or unscrew cap Defective fuel supply hose Replace Dirty fuel strainer screen Clean or replace Leak in fuel supply system Tighten or replace fittings Carburetor mountings loose Tighten mountings Water or dirt in fuel system Drain flush thoroughly Engine flooded See Flooding Too much oil in fuel mixture See Engine Lubrication and Fuel Spark plug fouled or defective Clean or replace No spark See Service Manual ENGINE RUNS IRREGULARLY OR MISSES Possible cause Defective fuel supply hose Remedy Replace Dirty fuel strainer screen Clean and replace Leak in fuel supply system Tighten or replace fittings Carburetor mountings loose Tighten mountings Water or dirt in fuel system Drain flush thoroughly Wrong gasoline in fuel mixture See Engine Lubrication and Fuel Too much oil in fuel mixture See Engine Lubrication and Fuel Air filter dirty Clean or replace Idle mixture screw misadjusted See Service Manual Spark plug fouled or defective Clean or replace Wrong type spark plug Use plug recommended Improper timing Refer to timing section
24. IT COLD OPERATION In cold operation it is good practice to put a small quantity of alu minum compatible antifreeze into pump end through priming cap immediately after use to prevent damage from freezing IMPORTANT Apply FINGER PRESSURE ONLY to close pump clamp lever Excessive pressure will damage or break clamp link PUMP LUBRICATION The pump bearing must be greased every 8 hours of operation Use a clean grease gun filled with fresh grease Remove dirt from grease fitting before applying grease gun Grease should be pumped slowly into grease zerk while rotating the pump shaft Continue pumping until fresh grease appears around bearing ring Wipe off excess grease Do not use graphite grease or a pressurized grease gun TO REMOVE PUMP FROM ENGINE 1 Lift pump clamp lever Release tension adjusting knob at bottom of clamp Remove clamp gt WW NY Remove pump from engine TO DRAIN PUMP It is recommended that the pump be drained after usage This is a MUST during cold weather to prevent damage to pump due to freezing 1 Remove discharge hose suction hose and priming cap Drain pump by tilting pump body several times Stand pump on suction nozzle end for several minutes to complete drainage gt WW NY Replace discharge suction and priming caps TO ATTACH PUMP TO ENGINE 1 Place flexible buffer coupling on engine coupling pins Align flexible buffer coupling holes to pump end coupling pins and in
25. Mach screw 3 R 111 Lockwasher ol R 113 Gasket metal 31 R 115 Stud 23 R 116 Hex lock nut 29 R 117 Stud 22 31 R 119 Lockwasher 22 23 31 38 R 120 Hex nut 22 3 R 123 Oil seal 0 788 31 33 R 130 Stud mounting leg 31 R 132 Mach screw 3 R 133 Gasket for crankcase 31 33 R 136 Flange pump mounting 15 31 R 144 Shield dust 3 R 146 Mach screw 29 31 R 149 Lockwasher 22 R 150 Hex lock nut 8 22 23 38 R 151 Flat washer 23 38 R 152 Crankcase halves set 3 R 206 Flat washer 3 R 229 Muffler 38 R 233 Cylinder head 18 mm l7 22 R 235 Gasket cylinder flange 22 33 R 236 Stud cylinder mounting 31 R 237 Gasket muffler 22 38 R 238 Gasket cylinder head Z 42 33 R 257 Cylinder 22 R 270 Cast iron sleeve 22 R 301 Lockwasher 32 R 302 Hex nut coupling side AL R 303 Hex nut flywheel side 32 R 305 Kev 32 R 306 Shim 0 006 coupling side 32 R 307 Shim 0 008 coupling side 32 99 R 308 Shim 0 012 coupling side 32 9 R 309 Shim 0 016 coupling side 32 33 R 310 Shim 0 020 coupling side 92 9 R 311 Shim 0 031 coupling side 32 33 R 312 Shim 0 040 coupling side 32433 R 315 Collar coupling 32 R 321 Serrated lockwasher old stvle engine 32 39 R 324 Needle bearing 92 33 R 324M Crankshaft conn rod half coupling side 32 R 328 Gudgeon pin 32 R 329 Circlip 92 R 330 Shim beveled 0 040 coupling side 32 R 331 Piston ring 0 078 AL R 33 1 0 Oversized piston ring 0 078 32 33 R 331 0 1 Oversized L type piston
26. R938 Puller crankshaft l bearing R 333 7 R 932 Puller collar coupling 1 8 R 933 Oilseal pressing tool 1 9 R927 Puller magneto l 10 R953 Crankshaft jack l 11 R 954 14 Gauge timing l 12 R926 Socket wrench l 14mm 9 16 13 R909 Key Allen l 2 4 mm 3 32 Ref Part Description Qty 1 R116 Hex lock nut 3 2 R 667N E Flywheel l magneto assembly 3 R 603 Fan l included in R 667N E 4 R 791 Lockwasher 4 5 R 602 Stud 3 6 R 146 Mach screw 4 7 R 653 Gasket l 8 R 601 Pullev l manual starter rope 9 12 38 Lockwasher 3 10 R 116 Hex lock nut 3 New models do not have a dust shield R 647 4 REGULAR MAINTENANCE SERVICING MAGNETO To check if ignition system is functioning remove spark plug and connect another spark plug with gap set to 3 2 mm 0 126 to the ignition cable With this plug resting on top of cylinder head give starter rope a normal pull Spark should easily jump the gap if system is functioning properly If no spark appears If spark is weak Check stop switch and cable for possible short Check magneto air gap Check for shorted condenser Check electronic ignition module Check for open coil Check for broken leads or cables Check electronic ignition module www wildfire equipment com 29 REGULAR MAINTENANCE Ref Part Description Qtv R656 Armature l plate complete incl parts
27. TABLE OF CONTENTS 1 GENERAL INFORMATION SPECIFICATIONS SERIAL NUMBERS 2 ENGINE OPERATING STARTER OPERATING INSTRUCTIONS FLOODING COLD WEATHER TROUBLESHOOTING CHART ELECTRONIC IGNITION 3 PUMP UNIT PUMP OPERATION AND LUBRICATION PUMP TEST KIT PUMP ADJUSTMENTS UPGRADED CUT OUT SWITCH 4 REGULAR MAINTENANCE MAINTENANCE CHECK LIST UPGRADED SPARK PLUG CAP SERVICING SPARK PLUG ELECTRONIC IGNITION UNIT ELECTRONIC IGNITION MODULE SETTINGS DECOMPRESSION SWITCH R 233DS SERVICING CARBURETOR CARBURETOR TROUBLE CHART SERVICING AIR FILTER SERVICING COOLING SYSTEM SERVICING THE REWIND STARTER SERVICING MAGNETO CoO N WO WO A A 10 11 12 13 14 14 15 16 17 18 21 22 23 24 29 D MAJOR OVERHAUL SERVICE ENGINE OVERHAUL SERVICE PROCEDURE DISASSEMBLY PROCEDURE FOR ENGINE REASSEMBLY SERVICE FOR ENGINE DISASSEMBLY PROCEDURE FOR PUMP END ASSEMBLY PROCEDURE FOR PUMP END MISCELLANEOUS OPTIONAL NOISE REDUCTION MUFFLER DECARBONISING TECHNICAL SPECIFICATIONS TORQUE VALUES CLEARANCE DATA AND LIMITS 8 PARTS INDEX 9 WARRANTY CERTIFICATE www wildfire equipment com 1 a1 532 33 55 38 38 39 39 40 44 GENERAL INFORMATION This handbook includes specifica tions performance data operating instructions normal servicing infor mation and parts list for the MARK 3 centrifugal fire pump unit The MARK 3 unit has been designed to meet all the requirements of advanced techniques in fore
28. and flywheel hub nut 5 R152 Crankcase halves set 1 e Crankshaft ball bearings 3 Tighten hub nut to recommended torque This is very important Complete with e Crankcase 2 dowel tubes R 103 Oil A l 4 Attach fan cowl assembly 6 R 120 Hex nut 4 es P follows 5 Attach spark plug cable clamp faa cee l Gal AM 8 R 236 Stud cylinder mounting 4 1 Remove pump end assembly and flexible buffer coupling disc 6 Connect cable to stop switch 9 R133 Gasket for crankcase 1 2 Remove all wiring 10 R342 Oil seal 0 983 l 3 Remove screw lockwasher and clamp which hold spark plug cable to fan cowl 11 R 123 Oil seal 0 788 l 4 Remove bracket R 799 which fastens to side of carburetor shroud to engine 12 R 103 Dowel tube 2 crankcase 13 R117 Stud 3 5 Remove engine from mounting frame 14 R 136 Flange pump mounting 6 Remove muffler 15 RAP Lockwasher 2 7 Remove fan cowl with rewind starter ID eae 2 8 Remove spark plug cover and spark plug ME ar ew 9 Using the flywheel holding tool R 929 to prevent the collar coupling from 18 R 130 Stud mounting leg 4 rotating remove nut and lockwasher from the collar coupling 1 19 A6149P Mounting leg 4 10 Remove collar coupling from engine with collar coupling puller R 932 20 R 113 Gasket metal l w da 11 Remove manual starter rope pulley a l 12 Remove flywheel nut and lockwasher using flywheel holding tool R 929 22 C 5370 11 Flat washer l 13 Remove flywheel magneto fan using magneto puller R 927 and shaft prot
29. ating with a defective or incorrect spark plug will affect the engine s perform ance hard starting fouling missing overheating pre ignition or lack of power To service and inspect the spark plug perform the following steps as required 1 Remove spark plug cover 2 Disconnect spark plug cable and remove spark plug 3 Clean spark plug and inspect carefully If tip of insulator core is rough cracked broken or blistered or if electrodes are burned away to the extent that they are too thin and cannot be satisfactorily adjusted to recommended gap 0 016 0 020 0 41 0 51mm replace with new plug IMPORTANT Note Use R 629 spark plug Use only spark plug type specified by engine manufacturer Refer also to section on Servicing 4 Carburetor for additional Trouble Data and service information Reinstall spark plug Start threads one or two turns with fingers to avoid danger of cross threading Tighten spark plug to recommended torque of 25 Nm 18 ft Ibs or 215 inch Ibs 5 Connect spark plug cable 6 Install spark plug cover tighten screws securely Caution Ceramic insulation of spark plug is easily damaged by shock stresses or bending stresses as may be imposed by dropping striking with hard objects or overtightening Therefore if spark plug has been subjected to such accidental abuse it should be carefully inspected and tested before further use UPGRADED SPARK PLUG CAP For years the MARK 3 has been using a rubbe
30. cylinder head fins In time the cooling air passages will become partially clogged and fins will become coated with dirt therefore reducing the cooling efficiency Therefore whenever this condition occurs remove fan housing then use com pressed air or a stiff bristle brush and appropriate cleaning solution to remove all dirt deposits from fins and from inside the fan housing www wildfire equipment com 23 REGULAR MAINTENANCE Ref Part Description Qty SERVICING THE REWIND STARTER RSJ Pewni Si itar Starter proceed as follows es f pi ho 1 Remove four bolts 12 and four lock washers 11 1 R518 Circlip l 2 While holding rope sheave 7 in place to prevent sudden rotation of the 2 R 517 Flat Washer sheave remove handle 21 and rubber buffer 20 3 R 516 Spring friction i 3 Allow sheave to rotate slowly until spring tension is completely relaxed Fi 4 Remove two screws 14 two lock washers 15 cover 16 lock pin 17 and 4 R 526 Washer Friction l guide 18 u 5 R528 Pawl assembly 5 Remove circlip 1 and then remove items 2 3 4 5 and 6 from starter 6 R 510 Flat D washer housing 7 R 504 Aluminum sheave 6 If friction washers 4 and 6 are worn replace them starter rope 7 If pawls are broken or worn replace the complete pawl assembly 5 8 R506 Spring rewind 8 Very carefully remove rope sheave making sure the rewind spring 8
31. d in all coupled joints Worn or dried out gaskets should be B 6288 CUT OUT SWITCH replaced with new gaskets MAINTENANCE CHECK LIST The change in material of the Regular maintenance is a schedule of continuous svstematic maintenance air vane from Aluminium to CUTOUT SWITCH ADJUSTMENT STATIC designed to prevent frequent or major breakdowns before thev occur Stainless Steel l Maintenance on a fire pump unit should not be done on the fire line The aluminium air vane used on The cutout switch must be adjusted when installed in the fan cowl This is necessary Always check your pump unit immediately after use the B 6288 cut out switch has been because slight changes in the shape of the mounting plate occur when fastened in in service for many years with no position on the fan cowl 1 Clean unit thoroughly complaints 2 CI ir filter j Check that with the air vane in the approximate centre of its travel the spring 3 a A ee However during harsh field testing attachment holes line up with the pivot to form a straight line see figure X Sen aie and air intake oe it was discovered that the air vane All brackets and pivot should be perpendicular with the face of the plate 4 Make sure cooling passages and cylinder fins are clean had deteriorated where the reset MW 5 Make sure spark plug is cleaned and has proper gap setting PAO N E S A Initial setting A preliminary setting can be made by placing on the vane an Checea horror on PO e E i
32. e object sufficiently heavy to cause the vane to just leave the stop and start to E E E E reset rod to vibrate with respect to move towards the contacting position A 2 5 oz 70 g weight is used to approxi 7 Check throttle and choke control for proper operation iben ant T wod iat mate the setting during assembly The final calibration must be made with the 8 Make sure carburetor fuel strainer screen is clean cause a hammering effect that eget eae 9 Check fuel line and fittings for signs of wear etc would slowly enlargen the point of 10 Check and grease pump end as per instructions in previous section attachment of the reset rod to the CUTOUT SWITCH ADJUSTMENT DYNAMIC 11 Check starter cable and mechanisms and replace if it shows signs of wear air vane 12 Check condition of buffer coupling 1 Setup pump unit close to water supply Use a 2 m to 3 m 6 to 10 suction Therefore it was decided to upgrade hose with foot valve attached Connect a short length 2 m to 3 m 6 to 10 of 13 Operate pump unit and check general performance Adjust carburetor if the material of the air vane from aluminium to stainless steel This would inherently allow the air vane discharge hose to pump outlet Attach a calibrated nozzle having a 12 7 mm necessary see Service Manual for details 1 2 diameter orifice 14 Check carburetor adjustments 15 Note any performance irregularities or any abnormal mechanical sounds to last longer thereby extending the
33. ector 23 R 119 Lockwasher 2 tool R 928 24 R 120 Hex nut 25 RA 108 Mach screw hex cap l 6 eo 6 Gasket R 133 not included www wildfire equipment com 31 MAJOR OVERHAUL SERVICE Ref Part Description Qtv i R 348 Crankshaft conn rod assembly includes parts with and oil seal R 342 l R 328 Gudgeon pin l 2 R329 Circlip l 3 R324 Needle bearing l 4 R 305 Key l 5 R344 Shim 0 004 As req flywheel side 6 R 343 Ball bearing 0 983 ID 1 flywheel side 1 piece bearing 7 R 301 Lockwasher l 8 R 303 Hex nut flywheel side 1 9 R331 1 L type piston ring l 10 R 331 Piston ring 0 078 l 11 R 332 Piston with rings l 12 R 329 Circlip l 13 R 341 Crankshaft l conn rod sub assembly includes half coupling side R 324M and half flywheel side R 341M with req pins 14 R330 Shim bevelled As req 0 040 coupling side 15 R334 Spacer l 16 R306 Shim 0 006 As req coupling side 17 R 333 Ball bearing 0 788 ID 1 coupling side 1 piece bearing 18 R 315 Collar coupling l 19 12 18 Pin 4 20 R 301 Lockwasher l 21 R 302 Hex nut coupling side 1 32 Wildfire DISASSEMBLY PROCEDURE FOR ENGINE 14 Remove armature plate with cables 15 Remove cylinder head and cylinder 16 Remove piston from connecting rod 17 Remove the machine screws which fasten crankcase halves together 18 To separate crankcase halves on engine with
34. er 12 7 width 38 86 mm 0 05 1 530 0 002 1 R237 Gasket muffler 1 er several hours of normal operation carbon deposits will form on piston rar ee crown cylinder head in the cylinder exhaust port and around piston rings and in CLEARANCE DATE AND LIMITS sti Are oi F i eae aa a Flat washer the ring grooves causing erratic and faulty operation The piston skirt may also IN 3 ORIO Hevskmai 1 show sgns of gum and orish depot ROTAX ib 126 deter 12339 mm 12347 my 4584 86 4 R 229 Muffler f ENGINE u i XU EU l To decarbonise the cylinder head cylinder and piston should be removed All car Distributor 12 9 diameter 0123 39 mm 123 47 mm 04 858 4 861 eee bon deposits should be carefully removed particularly from the piston ring Spark plug type Bosch M4AC1 8mm Distributor 12 9 width 34 11 mm 0 05 1 343 0 002 6 R19 Lockwasher l grooves After removing carbon wash all parts in a suitable solvent then dry with Spark plug gap 0 41 0 51 mm 0 016 0 020 Pump inside depth 108 10 mm 0 05 4 256 0 002 7 RA 108 Mach screw hexcap 1 compressed air On reassembly always use new piston rings Bieacerponie cap 0 35 0 45 mm 0 014 0 018 Burp ball bearing housing 51 99 mma 02 mm 2 047 042 Boy pk die After everv 100 hours of operation or more often if a loss of power is indi Ignition timing limits 2 54 4 01 mm 0 100 0 158 BTDC Nozzle bushing 19 037 mm 19 063 mm 0 7495 0 7505 TE cated the engine should be decarbonised I
35. f pump body in vertical position carefully lower distributor 27 until it rests on bottom of body 10 Slide impeller 26 into position aligning with shaft 11 Place O ring 34 in groove of distributor 27 12 Place distributor on open end of body then using bench press and assembly tool A 1884 apply several light downward strokes of press ram until distribu tor drops into body Distributor must then be positioned by hand as before 13 Slide impeller 27 into position aligning with the other impeller 14 Repeat operations 11 and 12 with parts 33 and 25 15 Slide impeller 24 into position aligning with previous impeller 16 Place lockwasher 24 on shaft with locating tab in milled groove www wildfire equipment com 35 5 MAJOR OVERHAUL SERVICE MAINTENANCE TOOLS FOR PUMPS Ref Part Description Qty A 2356 Maintenance tools l for pump includes all parts listed below 1 A 1884 Pressing sleeve l distributor assembly 2 A 4329 Pressing sleeve l rotary seal assembly 3 A 4097 Protector shaft l 4 A 1888 Puller suction nozzle 5 A 1890 Pressing pin l shaft removal 6 A 1886 Pressing pin l distributor removal 8 R 904L Wrench lock nut l 9 A 1887 Guide l shaft aligning body 10 A 5297 Support tool l 36 Wildfire ASSEMBLY PROCEDURE FOR PUMP END CONTINUED 17 Screw locknut 22 onto shaft When tightening the nut do not use excessive force as this may result in failure of the seals
36. g ring for bearingl 32 12 25 Mach screw 6 flat Phillips stainless 33 12 27 O ring 2 34 12 26 O ring l 35 12 17 Coupling buffer l 36 12 2C Shaft riveted assembly 1 22 23 24 25 5 MAJOR OVERHAUL SERVICE ASSEMBLY PROCEDURE FOR PUMP END 1 Slide bearing retaining ring 31 on shaft with plain face toward coupling collar 2 Install drive bushing 29 onto the shaft after the bearing has been pressed on Ensure drive bushing lugs are located in the 2 milled slots at the top of the rotary seal Dial in bearing on shaft within 0 051 mm 0 002 3 Remove the inside O ring from rotary seal 21 Install this O ring over the drive bushing 4 Press rotary seal 21 in pump body using sleeve A 4329 or A 5444 This should be done carefully 5 Carefully pass end of shaft assembly through rotary seal bore Ensure drive bushing lugs are located in 2 milled slots at top of rotary seal then continue pushing shaft until ball bearing rests firmly against shoulder in pump body Use the shaft aligning guide tool A 1887 to ensure that shaft is properly aligned with the pump body centerline 6 Attach retaining ring 31 to pump body using six screws and tighten evenly and firmly 7 Slide impeller 26 onto shaft and engage with drive bushing 29 8 Place O ring 34 in groove of distributor 27 It is important to smear the new O rings with a suitable lubricant used for pump ball bearing This will facilitate the assembly 9 With open end o
37. gnition timing nominal 2 54mm 0 100 BTDC bearing housing z i i Buffer thickness 12 17 8 25 mm 8 89 mm 0 325 0 350 USFS Approuved To decarbonise the engine proceed as follows Magneto air gap 0 23 0 33 mm 0 010 0 013 i i Spark MAN Cond 0 15 0 19 mE Shaft ball bearing support 25 004 mm 25 011 mm 0 9844 0 9847 plus ECE Ea 1 Remove muffler If muffler is very dirty internally or appears burned or cracked pr je Shaft bushina bear 12 687 mm 12 700 mm 0 4995 0 5000 it should be replaced with a new muffler Normal current for testing coil 1 0 amp nominal 2 0 amp max mezz ee fi 2 Remove cylinder head and cylinder head gasket Crankshaft end play 0 025 0 230 mm 0 001 0 009 Shaft maximum run out 0 088 mm 0 0035 3 Rotate crankshaft until piston is at bottom dead centre Cylinder bore hone 62 50 62 51 mm Cylinder Surface Roughness l 2 Micron 39 70 microinches 4 Using a brass scraper tool carefully scrape carbon deposit from exhaust port ET ae wer iston dia nomina 94 mm 2 b well operation tilt engine so that deposits will not fall into combustion ond gi ta 6244 mm 2 4583 iii MA Piston cylinder cl 0 06 0 08 0 0024 0 0032 5 sel ej bia i et out any rae deposit which may have formed fed La 0 20 mm a meu ue B i a ner or ypas Gilindertap r max 0 08 mm 0 0032 otate crankshaft until piston Is at top dead centre ro max 0 05 mm 0 0020 7 as a stiff not vies rh to piu see a from ji l
38. hrough the bearing due to old grease being hard packed etc 10 Ref Part Description Qty 5200N Mounting frame l assembly includes ref 2 to 14 1 A 6149P Mounting leg 4 2 A4005 Mounting pad 2 3 A 6179 Ring rubber 4 4 C 5200 5 Washer rubber 4 5 C 4506 3 Bumper rubber 6 C 5201 Frame l 7 C 5200 8 Hex bolt 2 8 D 5269 7 Flat washer 2 9 C 5200 7R Spacer rubber 2 10 C 6650 14 Hex lock nut 2 11 A 6179 Ring rubber 4 12 C 5200 6 Flat washer 4 13 R IlI Lockwasher 4 14 C 5200 12 Hex bolt A Ref Part Description Qtv RI1114 Quick connect l fuel line includes parts with 1 C 5200 8 Hex bolt 2 2 D 5269 7 Flat washer 2 3 R 798 Fuel line plastic l 4 R 706 Body quick connect 1 male 5 R 709 Elbow l 6 C 5200 7R Spacer rubber 2 7 C 6650 147 Hex lock nut 2 8 A 7486 Dust cap M connector 9 R712 Handle quick connect 1 10 R 732 Connector l 11 FA 552Q Fuel air transport tank 1 12 FA 451 Fem quick connect 13 12 401B NS Hose fuel supply l with priming bulb 6 MISCELLANEOUS MOUNTING FRAME www wildfire equipment com 37 6 MISCELLANEOUS TECHNICAL SPECIFICATIONS OPTIONAL NOISE REDUCTION MUFFLER TORQUE VALUES CLEARANCE DATE AND LIMITS CONTINUED
39. i 315 320 psi Pressure Range 689 724 kPa 862 896 kPa 1138 1172 kPa 1448 1482 kPa 1758 1793 kPa 2172 2206 kPa 10 Wildfire IMPORTANT Carburetor should be properly adjusted before starting performance test See Carburetor Adjustment In addition the pump unit should be set up as close as possible to wqter source PUMP ADJUSTMENTS OVERSPEEDING MAY OCCUR IF Pump not primed properly Suction hose and or pump body not completely filled with water A bend in the suction hose located higher than the pump suction inlet causing an air lock The suction hose between the pump and water supply must have a downward slope Loose suction hose coupling or priming cap Foot valve strainer clogged or too close to surface of water Pump loses prime Due to lack of water air lock may form in the suction hose when pump unit works against a high delivery head If this happens disconnect the discharge hose from the pump then reprime pump in the normal manner Pump runs out of water either because of lack of sufficient water supply or by attempting to pump water from a shallow water source www wildfire equipment com 11 3 PUMP UNIT A REGULAR MAINTENANCE The foot val t in at least l foot th t f hil UPGRADED bel ke remain at least 30 cm 1 foot under the water surface while CUT OUT SWITCH All suction couplings including foot valve must be wrench tightened Proper fitting MARK 3 UPGRADE OF THE gaskets must be use
40. ithout foot valve strainer e Remove and drain pump after final use STARTER The starter is an automatic rewind type A proper operating technique will add many hours of life to the starter rope and starter Grasp handle firmly and pull slowly until resistance past compression then continue to pull with a short vigorous stroke Pulling handle sideways causes excessive wear If kickback occurs let go of handle immediately When engine starts retain grip on handle and allow rope to rewind slowly Note The rope should be replaced when wear is apparent See rewind starter Servicing and Parts page 24 OPERATING INSTRUCTIONS OIL High quality 2 cycle mixing oil FUEL 87 Octane or higher automotive gasoline DO NOT use premium grade gasoline Do not use poor quality oil high detergent oil or oil with solid additives graphite moly T F E etc MIXTURE RATIO Oil Gasoline 1 L 0 22 IMP gals 0 26 US gals 24 L 5 3 IMP gals 6 3 US gals 1 US Quart 0 95 L 6 US gals 5 IMP gals 22 75 L CONTROLS There are only 4 controls which are used for normal operation 1 4 ON OFF switch EA Throttle lever Choke lever O Reset lever 2 ENGINE OPERATING TO START MARK 3 UNIT 1 Fill fuel supply tank with recommended fuel mixture 2 Connect fuel supply line to fuel supply tank 1 5 3 Attach fuel supply line to the adaptor located on right side of engine frame Pump fuel to fill supply line 1 6
41. l side 32 09 R 348 Crankshaft conn rod assembly 92 R 402 Stud 275 29 R 408 Mach screw 23 R 409 Clamp ignition cable 23 R 411P Fan cowl with studs 23 R 413 Cover for spark plug 23 R 414 Mach screw hex cap 23 R 418 Shield fan 23 R 501 Handle starter rope 24 R 502 Rope starter 24 R 504 Aluminium sheave 24 R 505 Pin starter rope lock 24 R 506 Spring rewind 24 R 509 Plug rubber 24 R 510 Flat D washer 24 R 516 Spring friction 24 R 517 Flat washer 24 R 518 Circlip 24 R 522 Mach screw hex cap 24 R 523 Lockwasher 24 R 524 Mach screw 24 R 526 Washer friction 24 R 528 Pawl assembly 24 R 529 Rewind starter 24 R 530 Housing starter 24 R 531 Retainer spring 24 42 Wildfire www wildfire equipment com 43 9 WARRANTY CERTIFICATE Wildfire Group warrants its manufactured products to be free from defect in material and workmanship under normal use and service for a period of one 1 wwvilel i a year or one hundred 100 hours of usage whichever comes first This limited warranty is effective only if the equipment or apparatus is used as directed is not subjected to misuse negligence or accident and is not altered threaded or repaired by anyone other than Wildfire Group Wildfire personnel or one of its authorized representatives Items sold but not manufactured by Wildfire shall bear only the limited warranties offered by their respective manufacturers Any return of defective goods for repair or re
42. n DIRECTIONAL REFERENCES All references to right side and left side of unit are made as they appear to opera tor when facing rewind starter thus the carburetor is on the right side and the muffler is on the left side Viewed in this manner facing the recoil starter the engine will rotate in a clock wise direction 1 3 www wildfire equipment com 3 2 ENGINE OPERATING If the rewind starter should break while the unit is on the fire line the complete rewind starter assembly can be easily removed thereby gaining access to a manual starter pulley which is mounted on the fly wheel Using a rope wrap around starter pulley and pull Make sure rope wrapping will ensure clockwise rotation from starter view CAUTION Not enough emphasis can be placed on the use of correct gasoline and oil mixture Using less than the recommended portion of oil will cause overheating and possible engine damage Using more than the recomme nded proportion of oil will cause spark plug fouling erratic carburetion excessive exhaust smoke and rapid carbon deposits 4 Wildfire FOR TROUBLE FREE OPERATION e DO NOT run engine at full speed until thoroughly warmed up e DO NOT lift strainer out of the water while pump is operating e DO NOT run engine with pump disconnected e DO NOT run pump when dry Priming e Check strainer frequently to make sure that it is not clogged with moss leaves etc e DONOT use suction hose w
43. onsive When the engine is started cold it runs rough as if the timing were off for about 15 30 seconds after which the engine runs smooth In order to convert a MARK 3 from breaker points to the upgraded electronic ignition system the following retrofit kit was created B 7595 MARK 3 Conversion kit point to CDI The ignition cable is larger in diameter than the previous one used on the MARK 3 with breaker points The breakdown of the electronic ignition is depicted in the picture to the left The electronic module is placed in an aluminium box located on the frame below the carburetor shroud Ref Part Description Qty 212 170P Clamp assembly l includes all the parts listed below 1 A4460 Lever zinc plated l 2 A 4452 Side link for lever l 3 C 4462 5 Cotter pin 3 4 A 4455 Clevispinforlever side 2 5 B 4461 Clamp top half l 6 B 4457 Clamp bottom half l 7 A4454 Clevispinfor l eye bolt side 8 A 4456 Knob for tension l adjustment 9 A 4453 Eve bolt l Ref Description Quantity B 7595 Mark 3 conv Kit point to CD Includes all parts with A 7589 Mounting block elect Ignition not shown l l R 271 Electronic ignition l 2 R 275 Protection cap l 9 R 274 Ignition cable l 4 R 650 Spark plug connector l 5 R 629 Spark plug l 3 PUMP UNIT PUMP OPERATING AND LUBRICATION www wildfire equipment com 9 3 PUMP UN
44. piston Piston ring end gap new ring 0 20 0 35 mm 0 0079 0 0138 o not remove har eposit of carbon as this layer forms a natural heat insu Wear limit 1 00 mm 0 03937 lator to protect the piston crown Piston pin hole dia in piston 18 001 18 005 mm 0 7087 0 7089 Piston pin dia 17 997 18 000 mm 0 7085 0 7087 8 Remove all carbon deposits from cylinder head 9 Replace cylinder head Tighten nuts uniformly to recommended torque 23 25 Nm 200 220 inch Ibs value Always use a new cylinder head gasket cylinder head gasket must have the large band up 10 Check and replace muffler gasket if worn or damaged Reinstall muffler 38 Wildfire www wildfire equipment com 39 e PARTS INDEX 8 PARTS INDEX NEW PART NAME PAGE 12 2C Shaft riveted assembly 30 2 2D Shaft sub assembly of 7 items 39 2 2E Shaft sub assembly of 4 items 35 12 3 Retaining ring for bearing 35 12 4AS Drive bushing includes B 5312 4 39 12 6 Distributor 39 12 7 Impeller 35 12 8 Pump bodv 34 12 9 Dis
45. placement must be accompanied by a copy of the warranty registration form with the returned material authorization section properly completed The authorization number will be given upon request by telephone or mail An authorized representative may then be designated by Wildfire to handle the claim on its behalf The claimed defective equipment must be delivered freight prepaid to Wildfire at its listed address or to the representative no more than thirty 30 days after the returned good authorization number RGA has been processed by Wildfire Wildfire will inspect the equipment and reserves the right to refuse responsibility if it is found that the equipment failed for another reason than a defect in material or workmanship Wildfire shall not be liable for consequential or indirect damages or contingent liabilities including but not limited to loss of life personal injury loss of crops loss due to fire or water property damage and consequential or indirect trade or other commercial loss arising out of the failure of manufacturer s product Wildfire Group 1100 Norman Street Suite 200 Lachine Quebec Canada H8S 1A6 Tel 514 637 5572 Fax 514 637 3985 Wildfire Fire Equipment Inc reserves the right to make changes in design materials and price without notice 44 Wildfire
46. r eye and ear protection when operating the pump unit DANGER DANGER EYE HEARING PROTECTION PROTECTION REQUIRED REQUIRED e Be careful never touch the muffler as it can reach very high temperatures and cause serious burns Always allow enough time after stopping the unit for the muffler and surrounding parts to cool down e Always use proper fuel mixture to ensure suitable lubrication MAXIMUM PERFORMANCE Pressure Discharge Flow psi kPa bar US GPM IMP GPM L min 0 0 0 98 82 371 50 345 3 45 89 7A 337 7D 517 5 17 83 69 314 100 690 6 90 78 65 295 150 1034 10 34 65 54 246 200 1379 13 79 52 43 197 250 1724 17 24 38 32 144 300 2069 20 69 25 21 95 350 2413 24 13 9 7 34 380 2620 26 20 0 0 0 Dg 2 vara H il GENERAL INFORMATION MK 3 Maximum Pressure 380 psi 2620 kPa flow 98 US gals min 370 L min 400 2758 300 2068 MK 3 B2 ssure 155 psi 1068 kPa US gals min 681 L min 200 1379 _ t y G Ay L min 189 379 568 758 me os SERIAL NUMBERS Pump end serial number is located on the side of the pump 1 1 Engine end serial number is stamped on a nameplate attached to the crankcase 1 2 These serial numbers are the key to various design details pertaining to the origi nal manufacture of each unit Therefore it is very important to specify serial numbers whenever ordering parts and tools or when requesting informatio
47. r flange gaskets R 235 and R 238 Cylinder head gasket must have the large band up 43 When reassembling cylinder head be sure the filled part inside the head is on the muffler side of the engine therefore scooped out part will be on the carburetor side Important Put carburetor side on same side of spark plug cable hole in crankcase Tighten cylinder head nuts to recommended torque as 23 25 Nm 200 220 inch lbs Nuts should be retorqued after first 10 hours of operation and every 100 hours after 44 Reassemble remaining parts in reverse procedure used in disassembly www wildfire equipment com 33 MAJOR OVERHAUL SERVICE Ref Part Description Qty DISASSEMBLY PROCEDURE FOR PUMP END ee 1 Remove shaft nose 4 by removing screw 2 and lockwasher These will be A 2688 Thread protector l visible upon removal of suction protective cap 51mm 2 optional item includes M138 2 Remove screws 7 and lockwashers 8 2 12 42 Mach screw nylon insert 1 3 Using tool A 1888 remove suction nozzle 9 Fillister head stainless 4 Bendlockwasher 23 from locknut 22 Using tool A 1883 or 19 mm 3 4 3 12 38 Lockwasher stainless wrench remove locknut and lockwasher 4 12 13 Nose for shaft 5 Remove screws 32 6 353 Protective cap suction 6 Using bench press and tools A 1890 and A 5297 press out shaft assembly 7 12 39 Mach head screw 8 Ins
48. r spark plug connector R 650 The rubber connector has been known to crack where the wire goes into the connector and where the rubber connector goes onto the spark plug The rubber connector was replaced with a new robust type of connector used on high performance recreational vehicles The new connector has the added benefit of being able to shield against signals The part number will still remain the R 650 A new robust type of connector will replace the old spark plug rubber cap 14 Wildfire 4 REGULAR MAINTENANCE ELECTRONIC IGNITION UNIT Short explanation for retrofit installation of an electronic ignition unit on the MARK 3 engine which was originally fitted with contact breaker ignition PROCEDURE e Remove old flywheel and armature plate e Fit the new armature plate approximately centrally of the long holes then turn it approx l mm anti clockwise then tighten the 3 screws e Turn crankshaft until the piston is 3 75 mm before top dead centre measuring through the spark plug hole with a dial gauge For the final dynamical ignition timing check make an ink mark on the coupling buffer 12 17 as well as on the flange pump mounting R 136 e Fit electronic box e Start engine and check ignition timing with a stroboscopic lamp The 2 marks previously made must correspond at 3000 4000 r p m e Ifthe 2 marks do not correspond remove flywheel and loosen the 3 screws of the a
49. ring 32 33 R 331 1 L type piston ring 32 R 332 Piston with rings e2 www wildfire equipment com 41 B PARTS INDEX B PARTS INDEX R 1018 Mach screw 19 R 1019 Idle mixture screw 19 R 1020 Mixture screw spring 19 R 1021 Flat washer brass 19 R 1022 Idle mixture screw packing 19 R 1023 Idle speed screw 19 R 1024 Idle speed screw spring 19 R 1025N Inlet control lever 19 R 1026 Inlet control lever pinion screw 19 R 1029 Inlet tension spring 19 R 1030 High speed mixture screw 19 R 1034 Nozzle check valve 19 R 1035 Throttle shaft and lever 19 R 1036 Throttle shaft clip 19 R 1037 Lockwasher 19 R 1038 Mach screw 19 R 1039 Throttle shaft return spring 19 R 1040 Throttle shutter 19 R 1041 Mach screw with lockwasher 19 R 1044 Lock plate 22 R 1045 Body 19 R 1046N Inlet needle and seat 19 R 1047 Inlet seat gasket 19 R 1050 Repair parts kit 10 parts 19 R 1101 Throttle link lever assembly 19 R 1102 Link for throttle 22 R 1107 Throttle lever sub assembly 22 R 1110 Hex nut 19 R 1111 Bolt 19 R 1112 Flat washer 19 R 1113
50. rmature plate turn armature plate slightly in the direction needed Repeat the procedure until the marks correspond e Seal rubber grommet with Silastic 7 a pee 1 J jo mi fe a i RED ji ki TO GROUND RED TO COIL GREEN ka ff L we ta us rS 4 i AS or a 4 TIN TO STOP 4 CUT OUT ae SWITCHES BLACK ee BIANCO W ECE EES ER a h po ar MUST BE INSERTED BEFORE INSTALLING ELECTRONIC BOX www wildfire equipment com 15 A REGULAR MAINTENANCE 16 Wildfire ELECTRONIC IGNITION MODULE SETTINGS Resistance value Check DI 16mm Flywheel magneto 492 19 6009 Resistance value Check CDI unit with H V coil 432 39 9510 FLYWHEEL MAGNETO Green wire 225 255 Q Ground stator 225 255 Q CDI UNIT WITH INTEGRATED IGNITION COIL STOP 0 1Q gt 50 MQ gt 50 MQ VERDE G 20 10 250 MQ 250 MQ Ground gt 50 MQ gt 50 MQ 4 7 5 5 KQ H V output gt 50 MQ gt 50 MQ 4 7 5 5 KQ Notes e Testing Temperature 25 C e Values in ohm detected by Tester Digital BECKMAN RMS 3030 e The above said values are not always a guarantee of perfect efficiency of the part 4 REGULAR MAINTENANCE DECOMPRESSION SWITCH R 233DS The MARK 3 model MK 3 DS features a decompression switch that significantly facilitates starting the pump To convert existing Mark 3 s simply replace the cylinder head with an R 233DS New cylinder head
51. speed 3 ROIM Wench boxe oparend 1O Smm setting approximately 150 RPM After each adjustment recheck the actual l ane 4 R 906M Wrench box amp open end 3 8 10mm l speed at which cutout switch operates until proper setting is obtained 5 RIO Wrench open end 1 2 9 16 13 14mm l If Mere bla is not available then the cutout switch may be roughly 6 R902 Sa warver Slmm ECP IFGN 7 R904 Wrench spark plug l Use a 3 mm 1 8 orifice tip screwed to nozzle After warming up engine thoroughly 8 A 3023 Carburetor adjusting tool l increase to full throttle then turn adjustment screw slowly counterclockwise until 9 R901 Screwdriver 4 102mm sq handle switch cuts out and stops engine Now turn screw one full turn clockwise and leave it i a 10 R 903 Feeler gauge spark plug amp breaker point l in this position 11 R908 Wrench open end 5 amp 8mm ignition 2 The cutout switch will now operate automatically to stop engine should pump run I R905 Handled l Kiew reinforced Stainless Steel Air vone out of water lose prime etc The switch will not interfere with normal operation of i 971 486 Bag lt teolrell notehown Stainless Steel for better durability the unit and will also allow the use of small nozzle tips as well as complete pump 14 271 928 6mm T handle Hex 10 5 LG l shut off for short periods of time 12 Wildfire www wildfire equipment com 13 4 REGULAR MAINTENANCE SERVICING SPARK PLUG Oper
52. st fire control including USDA Forest Service Specifications No 5100 274C This versatile unit enables the pump to be used for high pressure and volume B 2 volume Pump End interchangeability It is also suitable for rural and municipal fire protec tion or wherever a large volume of water or high pressure is required Tandem operations enable to move water over greater distances or higher altitudes CHARACTERISTICS Complete unit 58 Ibs 26 3 kg Height 16 1 4 413 mm Width 12 305 mm Length 23 584 mm Pump end only 15 Ibs 6 8 kg Max engine power 10 HP Approx 7 4 kW Carburetor Tillotson all position diaphragm type with integral fuel pump and filter Ignition Ducati electronic Spark plug Borsh M4 AC 18 mm or Champion K7 18 mm Consumption approx 1 IMP gal 1 2 US gals 5 L hr 2 Wildfire SPECIFICATIONS The MARK 3 Pump end is an anodized horizontal 4 stage centrifugal precision built pump Both the 2 51 mm NPSH male suction connection and 1 1 2 38mm NPSH male discharge connection are made to standard forestry thread specifications The MARK 3 Engine is a one cylinder two cycle air cooled engine incorporating ball and roller bearings The unit is also equipped with a rewind pull cord starter and automatic cutout switch WARNING e The improper use of this pump could result in serious injuries Please read the manual before using your MARK 3 pump unit e Always wea
53. stall Attach pump clamp Carefully align clamp positioning pins with flange stub gt WW NY Adjust tension knob located at bottom of clamp to obtain a light pressure on clamp link PUMP TEST KIT TESTING PROCEDURE The best way to check your pump unit is to make an actual performance test A test kit consisting of pressure gauge pressure gauge adaptor 3 m 10 length of discharge hose a nozzle and a calibrated set of nozzle tips is available PUMP UNIT a hati Description Qtv A 2388 Pump test kit incl al the parts listed below A 2392 Pressure gauge 0 400 psi 0 2800 kPa 4 1 2 114 mm F5095E Hose SPEC 187 1 1 2 X 10 w brass coupling NPSH M F F5095E00F TORBALFS A 2389 Pump test kit box A 2391 Rubber hose assembly incl a set of 2 adaptors A 2391B A 2391B Adaptor Female NPT Swivel Female A 2390A Shut off valve A 2390 Pressure gauge adaptor 1 2 38mm female NPSH to 1 1 2 38mm male NPSH A 2395 Brass calibrated nozzle tip set 1 8 1 4 5 16 3 8 7 16 3mm 6mm 8mm 9 5mm 11mm SO ON OW Or BR WN C 1933 Calibrated nozzle 1 2 12 7mm J SS N es eS I WO Nozzle 1 2 7 16 3 8 5 16 1 4 1 8 Size 12 7 mm 11 mm 9 5 mm 8 mm 6 mm 3 mm Minimal 105 psi 145 psi 180 psi 225 psi 265 psi 320 psi Pressure 724 kPa 1000 kPa 1241 kPa 1551 kPa 1827 kPa 2206 kPa Minimal 100 105 psi 125 130 psi 165 170 psi 210 215 psi 255 260 ps
54. tion 13 R 909 Key Alien 2 4 mm 3 32 12 29 R 910 Wrench open end 1 2 amp 9 16 I3 R 911M Wrench box and open end 13 mm 13 R 926 Socket wrench 14 mm 9 16 29 R 927 Puller magneto 29 81 R 928 Cap shaft protector 27 2192 R 929 Flywheel holding tool 29 31 R 930 Puller crankshaft bearing R 313 29 R 932 Puller collar coupling 29 31 R 933 Oil seal pressing tool 29 32 33 R 938 Puller crankshaft bearing Ft 333 29732 R 952 Service toot kit 29 R 953 Crankshaft jack 29 33 R 954 14 Gauge timing 29 R 955 Air filter element foam amp screen 22 R 1001 Body channel welch plug 19 R 1002 Choke friction pin 19 R 1003 Choke friction spring 19 R 1004 Choke shaft and lever 19 R 1005 Choke shutter 19 R 1008 Diaphragm gasket 19 R 1009 Diaphragm 19 R 1010 Diaphragm cover 19 R 1011 Fuel pump gasket 19 R 1012 Fuel pump diaphragm 19 R 1013 Fuel pump bodv 19 R 1014 Mach screw with lockwasher 19 R 1015 Fuel strainer screen 19 R 1016 Fuel strainer cover gasket 19 R 1017 Fuel strainer cover 19 NEW PART NAME PAGE R 332 0 Oversized piston includes rings 32 33 R 333 Ball bearing 0 788 ID 29 32 33 R 334 Spacer 32 39 R 341 Crankshaft conn rod sub assembly 32 R 341M Crankshaft conn rod half flywheel side 32 R 342 Oil seal 0 983 3323 R 343 Ball bearing 0 983 ID 32 33 R 344 Shim 0 004 flywheel side 3233 R 345 Shim 0 012 flywheel side 32 33 R 346 Shim 0 020 flywheel side 32 33 R 347 Shim 0 039 flywhee
55. tributor 39 12 10 Cap for priming port 34 12 11 Impeller 39 12 12A Suction nozzle includes 12 40 34 12 13 Nose for shaft 34 12 17 Coupling buffer 35 12 25 Mach screw flat Phillips stainless 35 12 26 O ring 35 12 27 O ring 35 12 28N Mechanical rotary seal 34 12 29 Grease fitting 34 12 38 Lockwasher 34 12 39 Mach lock screw Fillester stainless 34 12 40 Bushing bearing bronze 34 12 42 Mach lock screw Fillester stainless 34 12 43 Gasket 38 mm 1 1 2 34 12 48 Double row ball bearing 35 12 49 Lockwasher stainless 35 12 50 Lock nut stainless 35 12 73 Plug brass 34 12 79 Lockwasher star type 34 12 87 Extension for grease fitting 34 12 401B NS Hose fuel supply with priming bulb 37 212 170P Clamp assembly 9 271 346 Screwdriver standard 29 271 488 Bag tool roll 13 271 923 Wrench adjustable 203 mm 8 13 271 927 Screwdriver Phillips No 1 29 A 1883 Wrench lock nut 34 36 40 Wildfire A 1884 Pressing sleeve distributor assembly 35 36 A 1886 Pressing pin distributor removal 34 36 A 1887 Guide shaft aligning body 30 36 A 1888 Puller suction nozzle 34 36 A 1890 Pressing pin shaft removal 34 36 A 2356 Maintenance tools for pump 36 A 2388 Pump test kit 1 A 2389 Pump test kit box 1 A 2390 Pressure gauge adaptor 38 mm 1 1 2 1 A 2390A Shut off valve 1 A 2391 Rubber hose assembly with A 239 1B 1 A 2391B Adaptor 1 A 2392 Pressure gauge 0 2800 kPa 0 400 psi 1 A 2395 Brass calibrated nozzle tip
56. ure removal of drive bushing 29 before attempting to continue impeller Fillester stainless distributor removal 8 12 38 Lockwasher stainless 8 7 Using bench press and tools A 1886 and A 5297 remove all internal parts 9 12 12A Suction nozzle l Impellers and distributors 24 25 26 and 27 Operation done in jogging includes 12 40 strokes of press ram so that all parts will be removed in a group 10 12 27 O ring l 8 If seal 21 is badly worn or damaged press out complete seal 11 12 8 Pump body l 12 12 43 Gasket 38 mm 11 2 l 13 12 10 Cap for priming port l 14 A 5538 Retainer for priming cap 1 15 ADP A Thread protector 38 mm Fm15S_ 11 2 NPSH optional item 1718 19 20 includes gasket 16 A 5536 Protective cap discharge 1 17 12 29 Grease fitting l 18 12 87 Extension for grease fitting 1 19 12 73 Plug brass l 20 12 28N Mechanical rotary seal Available with different threads 34 Wildfire Ref Part Description Qty 12 2D Shaft sub assembly includes parts with and 8 items 12 2E Shaft sub assembly includes parts with 4 items 22 12 50 Locknut stainless l 23 12 49 Lockwasher stainless l 24 12 11 Impeller l 25 12 9 Distributor 2 26 12 7 Impeller 3 27 12 6 Distributor l 28 B 5312 4 O ring for drive bushing 1 29 12 4AS Drive bushing l includes B 5312 4 30 12 48 Double row ball bearing 1 31 12 3 Retainin
57. v and allow engine to warm up thoroughiv gradu ally increasing speed to full throttle setting while running with 6 mm 1 4 diameter nozzle tip connected to a 3 m 10 discharge hose 6 When engine is thoroughly warmed up close throttle then adjust idle adjust ment screw and idle speed regulating screw until engine idles smoothly between 2000 2200 RPM 7 Increase speed gradually to full throttle setting then turn main adjustment screw until engine gives maximum RPM and pump delivers maximum pres sure Then turn main adjustment screw 1 4 turn maximum counterclockwise This setting will give correct mixture ratio to assure proper engine lubrication Do not leave main adjustment screw set too lean otherwise serious engine dam age may occur due to lack of sufficient lubrication Note It will be necessary to readjust the carburator when taking the pump from one altitude and placing in a different altitude Repeat step to 7 CARBURETOR TROUBLE CHART CARBURETOR FLOODING Possible cause Dirt or foreign particles preventing inlet needle from seating 4 REGULAR MAINTENANCE Remedy Remove clean and replace Diaphragm lever spring not seated on lever dimple Remove lever and reinstall Diaphragm improperly installed in carburetor Replace diaphragm or correct installation Improper use of choke Proper use of choke at start up ENGINE WILL NOT ACCELERATE Possible cause Idle adjusting screw
58. y more serious damage AUTOMATIC CUTOUT SWITCH The MARK 3 unit is equipped with an automatic cutout switch This safety device will stop the engine instantly and thereby eliminate overspeeding The switch works on cooling fan air pressure As the engine speed increases so does the air pressure At a predetermined speed there is sufficient air pressure to cause the air vane to move against its contacts shorting the ignition and thereby stopping the engine When the cutout switch automatically stops the engine this is a warning that there is a problem Do not reset switch until cause of trouble has been identified and corrected TO STOP MARK 3 UNIT 1 Move throttle lever to Stop position 2 Allow unit to run for approximately 1 minute with throttle in this position 3 Switch toggle to Off position 4 Remove and drain pump after final use www wildfire equipment com 5 2 ENGINE OPERATING COLD OPERATION In cold operation it is good practice to put a small quantity of alu minum compatible antifreeze into pump end through priming cap immediately after use to prevent damage from freezing 6 Wildfire FLOODING Flooding refers to an accumulation of excess fuel in cylinder mainly due to exces sive use of choke When the engine is in a flooded condition an over rich fuel air mixture is induced into the cylinder This mixture does not ignite readily and usually fouls the spark plug CLEANING A FLOODED ENGINE
59. zle check valve cage is not sealing Remedy Install new plug or new cage www wildfire equipment com 21 4 REGULAR MAINTENANCE ie ae Description oy SERVICING AIR FILTER R792 Throttle control l assembly includes all parts with 7 items 1 1 R793 Mach screw hex cap 2 Nylock 2 R 791 Lockwasher 2 3 R1044 Lock plate l 4 R 794 Cover for air filter l 5 R955 Air filter element l foam amp screen option R 795 also available 6 R 790 Carburetor shroud l includes decal A 4030 7 12 79 Lockwasher star tvpe 2 8 B 4036 12 Mach screw hex 2 socket 9 R799 Bracket l 10 12 79 Lockwasher star type 2 IT R774 Mach screw 2 12 R 1102 Link for throttle l 13 B 4024 Quadrant for throttle 1 lever If not cleaned regularly the filter element will become clogged and will seriously I Rii Throttle lever restrict airflow to the carburetor sub assembly a 15 A 4028 Spring This restriction will cause engine to run irregularly lose power and four stroking will develop due to an over rich mixture entering the carburetor 16 A4027 Pin index l MTR 1000 Hours meter with Therefore whenever the filter element becomes dirtv or whenever anv of the RPM not shown above conditions occur remove the filter element and wash it in a appropriate cleaning solution Apply 2 cycle oil to filter element and squeeze to distribute oil
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