manual
Contents
1. OIL LEVEL NK SWITCH Ss LOW OIL SENSOR CONTROL BOX 24 Wiring Diagrams Engine Type with Oil Alert and without Electric Starting BLACK o TRANSISTORIZED oa IGNITION UNIT i VF A SO OE SPARK d meari y ENGINE PLUG A FT F f SWITCH Bi Y OIL LEVEL SWITCH LOW OIL SENSOR 25 Optional Parts BATTERY Use a battery rated at 12V 18Ah or more Do not reverse polarity Serious damage to the engine and or battery may occur I IDPE TTT A WARNING A battery can explode if you do not follow the correct procedure seriously injuring anyone nearby Keep all sparks open flames and smoking materials away from the battery Check the electrolyte level to be sure that it is between the marks on the case If the level is below the lower mark remove the caps and add distilled water to bring the electrolyte level to the upper mark The cells should be equally full 26 Emissions Warranty California U S EPA and Pentair Emissions Control Warranty Statement Your Warranty Rights and Obligations The California Air Resources Board U S EPA and Pentair are pleased to explain the emissions control system warranty on your engine equipment In California new small off road engines and large spark ignited engines less than or equal to 1 0 litter must be designed built and equipped to meet the State s stringent anti smog standards Pentair must warrant the emis sion2. e Injury from moving parts Do not run the engine unless instructed to do so e Read the instructions before you begin and make sure you have the tools and skills required to per form the maintenance e To reduce the possibility of fire or explosion be careful when working around gasoline Use only a nonflammable solvent not gasoline to clean parts Keep cigarettes sparks and flames away from all fuel related parts Remember that your servicing dealer knows your engine best and is fully equipped to maintain and repair it To ensure the best quality and reliability use only new genuine parts or their equivalents for repair and replacement Maintenance MAINTENANCE SCHEDULE REGULAR SERVICE PERIOD First Every Every Every Performed at every indicated month or month 3 months 6 months year operating hour interval whichever comes first or or or or ltem 20 hours 50 hours 100 hours 300 hours Engine oil Check level Air cleaner Check Clean Replace Sedimentcup Se Spark plug Check Clean optional parts a a kr i ravo seans eragi EE o ae ee E l O O E Combustion chamber After every 300 Hrs 2 ziatz onek Sarre Replace if necessary 2 eEmission related items t Replace the paper element type only 1 Service more frequently when used in dusty areas 2 These items should be serviced by your servicing dealer unless you have the proper tools and are mechanically proficient REFUELING e Stop the
3. O HYPRO PowerPro Gasoline Engines Form L 1512 5 12 Rev B Operation Repair and Parts Manual PowerPro Model Number 200 and 390 HY200 6 5hp 2541 0045 3 4 keyed shaft 2541 0046 5 8 threaded shaft HY390 13 0 hp 2541 0048 1 keyed shaft 2541 0049 UT keyed shaft w electric start 2541 0050 1 threaded shaft 2541 0051 1 threaded shaft w electric start Note Unit is not shipped with oil Please add oil to engine prior to operating Table of Contents ENGINE SAMEN Vo4neue cca neta eee pad ee een ge eee nh one eee hep eee a teas as 3 COMPONENTS amp CONTROL LOCATIONS A 4 COMMIS e gene e gree reei de oo ete bP de ones nag ene pepe ebb ems SR Pewee rd degree 5 CHECK BEFORE SIE SA IAUN AAA 6 IEA SEAN Sila BANANA T MAINTENANCE Sr GEEAE oe EE ORE Ea EE EE e E E E A Ea d EE 9 STORAGE TRANSPORTATION 2 0 2 0 0000 ce ee 16 TROUBLES HOCOMNG de St E ZE Mee E E eee eee E eu aa eae howe sey Aa Eee E aoe ern he 18 TECHNICAL amp CONSUMER INFORMATION 0 000 0000 cee 19 SPECIFICATIONS a 23 4 44464 aoe Gb Rae heme Se ee dee oe eo REE Reg pote nee Feed es 22 ENGINE REPLACEMENT PARTS A 23 WIRING DIAGRAMS i 524040005 Cb nee ease pean be het eee ees a eae psa PR oh eee eo 24 OPTIONAL PARTS OBATTERY 0 0 00 cc eee 26 EMISSIONS WARRANTY 4 0 050260040504 0 5 BWhea8 PM Oba hehe Oy a ESAS sharara oe 2 READ THIS OWNERS MANUAL CAREFULLY Pay
4. 8 3 11 1 hp 13 3000 9 6 ft Ib 26 5 3000 19 6 ft Ib 0 60 L 0 63 qt 1 1 L 1 2 qt 3 6 L 0 95 gal 6 5 L 1 7 gal lt 395 1400 150 rom lt 10 70db A 80db A 68x54 196 8 5 1 Splash Recoil start Recoil start Electric starting Anti clockwise from PTO side Input valve 0 10 0 15mm Output valve 0 15 0 20mm 0 7 0 8mm Transistorized Magneto Ignition Semi dry Oil bath Foam filter SE 405 376 450 335 443 16 19 31 34 22 Engine Replacement Parts Model HY160 and HY200 HY160 2541 0043 2541 0044 HY 200 2541 0045 2541 0046 Part Number Description Head Gasket HY160 Head Gasket HY200 Exhaust Pipe Gasket Crank Oil Seal 2 Crankcase Cover Gasket Valve Cover Gasket Carb Gaskets 4 23 Model HY270 and HY390 HY 270 2541 0047 HY390 2541 0048 2541 0049 2541 0050 2541 0051 Part Number Description Head Gasket HY270 Head Gasket HY390 Exhaust Pipe Gasket Crank Oil Seal HY270 2 Crank Oil Seal HY390 2 Crank Cover Gasket HY270 Crank Cover Gasket HY390 Valve Cover Gasket Carb Gaskets 5 Wiring Diagrams ENGINE SWITCH BI BLACK BROWN YELLOW R_ RED WHITE GREEN h E STARTER KA MOTOR AN USE ber d BATTERY STARTER CHARGING anes COIL beran FUSE b sm i TRANSISTORIZED Br Ww IGNITION UNIT e EZA Ld a ENGINE SWITCH oe AU g BI CIRCUIT ei SPARK w BREAKER PLUG
5. Never use stale or contaminated gasoline or an oil gasoline mixture Avoid getting dirt or water in the fuel tank Occasionally you may hear a light spark knock or pinging metallic rapping noise while operating under heavy loads This is no cause for concern If spark knock or pinging occurs at a steady engine speed under normal load change brands of gaso line If soark knock or pinging persists see an authorized servicing dealer NOTICE Running the engine with persistent spark knock or pinging can cause engine damage Running the engine with persistent spark knock or pinging is considered misuse and Hypro s Limited Warranty does not cover parts dam aged by misuse ENGINE OIL LEVEL CHECK Check the engine oil level with the engine stopped and in a level position 1 Remove the filler cap dipstick and wipe it clean FILLER CAP DIPSTICK 4 LOWER LIMIT 2 Insert and remove the dipstick without screwing it into the filler neck Check the oil level shown on the dipstick e 3 If the oil level is low fill to the edge of the oil filler hole with the recommended oil 4 Screw in the filler cap dipstick securely NOTICE Running the engine with a low oil level can cause engine damage The Low Oil Sensor applicable engine types will automatically stop the engine before the oil level falls below safe limit However to avoid the incon venience of an unexpected shutdown always check the engine
6. Remove the foam filter from the paper filter geek 4 Inspect both air filter elements and replace them if they are dam aged Always replace the paper air filter element at the scheduled interval GASKET 5 Clean the air filter elements if they are to be reused Paper air filter element Tap the filter element sev eral times on a hard surface to remove dirt or blow compressed air not exceeding 30 psi 207 kPa through the filter element from the inside Never try to brush off dirt brushing will force dirt into the fibers Foam air filter element Clean in warm soapy water rinse and allow drying thoroughly Or clean in nonflammable solvent and allow drying Dip the filter element in clean engine oil and then squeeze out all excess oil The engine will smoke when started if too much oil is left in the foam 1 Using a moist rag wipe dirt from the inside of the air cleaner base and cover Be careful to prevent dirt from entering the air duct that leads to the car buretor 2 Place the foam air filter element over the paper element and reinstall the assembled air filter Be sure the gasket is in place beneath the air filter Tighten the air filter wing nut securely 3 Install the air cleaner cover and tighten the cover wing nut securely 13 Oil Bath Type 1 Remove the wing nut and remove the air clean er cap and cover 2 Remove the air filter from the cover wash the cover and filter in warm s
7. altitude operation the air fuel mixture will be too lean for low altitude use Operation at alti tudes below 5 000 feet 1 500 meters with a modified carburetor may cause the engine to overheat and result in serious engine damage For use at low altitudes have your servicing dealer return the carburetor to original factory specifications Oxygenated Fuels Some conventional gasolines are being blended with alcohol or an ether compound These gaso lines are collectively referred to as oxygenated fuels To meet clean air standards some areas use oxygenated fuels to help reduce emissions If you use an oxygenated fuel be sure it is unlead ed and meets the minimum octane rating require ment Before using an oxygenated fuel try to confirm the fuel s contents Some areas require this information to be posted on the pump The following are the EPA approved percentages of oxygenates ETHANOL ethyl or grain alcohol 10 by volume You may use gasoline containing up to 10 ethanol by volume Gasoline containing ethanol may be marketed under the name Gasohol MTBE methyl tertiary butyl ether 15 by volume You may use gasoline containing up to 15 MTBE by volume METHANOL methyl or wood alcohol 5 by volume You may use gasoline containing up to 5 methanol by volume as long as it also contains cosolvents and corrosion inhibitors to protect the fuel system Gasoline containing more than 5 methanol by vol
8. engine and keep heat sparks and flame away Part Number OHP Fuel Tank Capacity e Handle fuel only outdoors 2541 0045 6 5 3 6L 0 95 Gal e Wipe up spills immediately 2541 0046 0046 MAXIMUM FUEL LEVEL Ze 0048 1 7 Gal EEE 0049 2541 0050 0050 With the engine stopped remove the fuel tank cap and check the fuel level Refill the tank if the fuel Refuel in a well ventilated area before starting the engine If the engine has been running allow it to BKE cool Refuel carefully to avoid spilling fuel Do not fill above the fuel strainer shoulder After refueling tighten the fuel tank cap securely Gasoline is highly flammable and explosive Never refuel the engine inside a building where You can be burned or seriously injured when gasoline fumes may reach flames or sparks Keep handling fuel gasoline away from appliance pilot lights barbe cues electric appliances power tools etc 10 Maintenance Spilled fuel is not only a fire hazard it causes envi ronmental damage Wipe up spills immediately NOTICE Fuel can damage paint and plastic Be careful not to spill fuel when filling your fuel tank Damage caused by spilled fuel is not covered under warranty FUEL RECOMMENDATIONS Use unleaded gasoline with a pump octane rating of 86 or higher These engines are certified to operate on unleaded gasoline Unleaded gasoline produces fewer engine and spark plug deposits and extends exhaust system life
9. oil level before startup ENGINE OIL CHANGE Drain the used oil while the engine is warm Warm oil drains quickly and completely 1 Place a suitable container below the engine to catch the used oil and then remove the filler cap dipstick and the drain plug 2 Allow the used oil to drain completely and then reinstall the drain plug and tighten it securely Please dispose of used motor oil in a manner that is compatible with the environment We suggest you take used oil in a sealed container to your local recycling center or service station for reclamation Do not throw it in the trash pour it on the ground or down a drain 3 With the engine in a level position fill to the outer edge of the oil filler hole with the recommended oil ENGINE OIL CAPACITIES ES 0045 6 5 0 60 L 0 63 Qt Ea 0046 eee 0048 1 2 Qt ei 0049 2541 0050 0050 Running the engine with a low oil level can cause engine damage The Low Oil Sensor applicable engine types will automatically stop the engine before the oil level falls below the safe limit Maintenance However to avoid the inconvenience of an unex pected shutdown fill to the upper limit and check the oil level regularly 4 Screw in the filler cap dipstick securely N Gz A E j a al j n e r w ZA d be NUK Te FILLER CAP A ys F DIPSTICK goe OIL LEVEL ba DRAIN BOLT SERVICING YOUR ENGINE ENGINE OIL RECOMMENDATIONS Oil is a major factor af
10. wet with fuel Dry and reinstall spark plugs flooded engine Start engine with throttle lever in FAST position Other conditions Fuel filter clogged carburetor Replace or repair faulty malfunction ignition malfunction components as necessary valve stuck etc ENGINE LACKS POWER Possible Cause 1 Check air filter Filter element s clogged Clean or replace filter element s 2 Check fuel Out of fuel Refuel Bad fuel engine stored without Drain fuel tank and carburetor treating or draining gasoline or Refuel with fresh gasoline refueled with bad gasoline 3 Other conditions Fuel filter clogged carburetor Replace or repair faulty malfunction ignition malfunction components as necessary valve stuck etc 18 Technical amp Consumer Information TECHNICAL INFORMATION Serial Number Location ENGINE TYPE 7 SERIAL NUMBER Record the engine serial number in the space below You will need this serial number when order ing parts and when making technical or warranty inquiries Engine serial number Battery Connections for Electric Starter Use a 12 volt battery with an ampere hour rating of at least 18 Ah Be careful not to connect the battery in reverse polarity as this will short circuit the battery charging system Always connect the positive battery cable to the battery terminal before connecting the negative battery cable so your tools cannot cause a short circuit if they touch a groun
11. NING Improperly maintaining this engine or failing to correct a problem before operation could cause a malfunction in which you could be seriously injured Always perform a preoperation inspection before each operation and correct any problem Before beginning your preoperation checks be sure the engine is level and the engine switch is in the OFF position Check the General Condition of the Engine e Look around and underneath the engine for signs of oil or gasoline leaks e Remove any excessive dirt or debris especially around the muffler and recoil starter e Look for signs of damage e Check that all shields and covers are in place and all nuts bolts and screws are tightened Check the Engine e Check the engine oil level Running the engine with a low oil level can cause engine damage The Low Oil Sensor applicable engine types will auto matically stop the engine before the oil level falls below safe limits However to avoid the inconven ience of an unexpected shutdown always check the engine oil level before startup e Check the air filter A dirty air filter will restrict air flow to the carburetor reducing engine perform ance e Check the fuel level Starting with a full tank will help to eliminate or reduce operating interruptions for refueling Check the Equipment Powered by this Engine Review the instructions provided with the equip ment powered by this engine for any precautions and pro
12. Never smoke near gasoline and keep other flames and sparks away Always store gasoline in an approved con tainer If any fuel is spilled make sure the area is dry before starting the engine Hot Exhaust e The muffler becomes very hot during operation and remains hot for a while after stopping the engine Be careful not to touch the muffler while it is hot Let the engine cool before storing it indoors e To prevent fire hazards and to provide adequate ventilation for stationary equipment applications keep the engine at least 3 feet 1 meter away from building walls and other equipment during opera tion Do not place flammable objects close to the engine Carbon Monoxide Hazard Exhaust gas contains poisonous carbon monoxide Avoid inhalation of exhaust gas Never run the engine in a closed garage or confined area Other Equipment Review the instructions provided with the equip ment powered by this engine for any additional safety precautions that should be observed in con junction with engine startup shutdown operation or protective apparel that may be needed to oper ate the equipment Components amp Control Locations Throttle Lever Muffler Ignition Switch Spark Plug Recoil Starter Air Cleaner Choke Lever Fuel Valve Lever Oil Drain Plug Oil Filler Cap Dipstick Controls Fuel Valve Lever Choke Lever The fuel valve opens and closes the passage The choke lever opens and closes the c
13. TY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE Hypro s obligation under this warranty is at Hypro s option to either repair or replace free of charge any part or parts of the engine upon return of the entire product to the Hypro factory in accordance with the return procedures set forth below THIS IS THE EXCLUSIVE REMEDY FOR ANY BREACH OF WARRANTY LIMITATIONS AND EXCLUSIONS This Limited Warranty shall not apply to 1 Bent or broken crankshaft or damage caused by vibration related to a bent or broken crankshaft Also damage caused by loose engine mounting bolts or improper or imbalanced accessories 2 Repairs required because of prolonged storage including damage caused by old or contaminated fuel in the fuel tank fuel lines or carburetor sticky valves or corrosion and rust of engine parts 3 Repair required due to overheating Common causes of overheating are clogged or damaged flywheel fan inlet air passages cooling fins or air shrouds 4 Damaged or broken parts caused by low oil levels or dirty or improper grade of motor oil 5 Engine tune ups and normal maintenance services including but not limited to fuel and lubricating oil valve adjustments and normal replacement of service items 6 Dirt or grit related wear caused by improper air cleaner maintenance The damages include but not limited to worn pistons piston rings cylinders valves valve guides carburetors and other internal components 7 Engines that h
14. age Check your engine as described in the section CHECK BEFORE OPERATION If the fuel was drained during storage preparation fill the tank with fresh gasoline If you keep a con tainer of gasoline for refueling be sure that it con tains only fresh gasoline Gasoline oxidizes and deteriorates over time causing hard starting If the cylinders were coated with oil during storage preparation the engine may smoke briefly at start up This is normal TRANSPORTING If the engine has been running allow it to cool for at least 15 minutes before loading the engine pow ered equipment on the transport vehicle A hot engine and exhaust system can burn you and can ignite some materials Keep the engine level when transporting to reduce the possibility of fuel leakage Move the fuel valve lever to the OFF position Troubleshooting ENGINE WILL NOT START Possible Cause Correction 1 Electric starting Battery discharged Recharge battery check battery 2 Check control positions Fuel valve OFF Move lever to ON Choke OPEN Move lever to CLOSE unless engine is warm Engine switch OFF Turn engine switch to ON 3 Check fuel Out of fuel Refuel Bad fuel engine stored without Drain fuel tank and carburetor treating or draining gasoline or Refuel with fresh gasoline refueled with bad gasoline 4 Remove and inspect Spark plugs faulty fouled or Gap or replace spark plugs spark plugs improperly gapped Spark plugs
15. are for your engine the fol lowing pages include a maintenance schedule rou tine inspection procedures and simple mainte nance procedures using basic hand tools Other service tasks that are more difficult or require spe cial tools are best handled by professionals and are normally performed by a technician or other qualified mechanic The maintenance schedule applies to normal oper ating conditions If you operate your engine under unusual conditions such as sustained high load or high temperature operation or use in unusually wet or dusty conditions consult your servicing dealer for recommendations applicable to your individual needs and use MAINTENANCE SAFETY Some of the most important safety precautions are as follows Note We cannot warn you of every conceivable hazard that can arise in performing maintenance Only you can decide whether or not you should perform a given task A WARNING Failure to properly follow maintenance instructions and precautions can cause you to be seriously hurt or killed Always follow the procedures and precautions in the owner s manual Safety Precautions e Make sure the engine is off before you begin any maintenance or repairs This will eliminate several potential hazards e Carbon monoxide poisoning from engine exhaust Be sure there is adequate ventilation whenever you operate the engine e Burns from hot parts Let the engine and exhaust system cool before touching
16. arrester Check local laws and regulations A spark arrester is available from authorized servicing dealers The spark arrester must be serviced every 100 hours to keep it functioning as designed If the engine has been running the muffler will be very hot Allow the muffler to cool before servicing the spark arrester 1 Remove the three 4 mm screws from the exhaust deflector and remove the deflector 2 Remove the four 5 mm screws from the muffler protector and remove the muffler protector 3 Remove the 4 mm screw from the spark arrester and remove the spark arrester from the muffler 5mm SCREWS MUFFLER PROTECTOR MUFFLER SPARK ARRESTER GASKET 8mm NUTS 15 SCREEN 4 Use a brush to remove carbon deposits from the Spark arrester screen Be careful to avoid damag ing the screen The spark arrester must be free of breaks and holes Replace the spark arrester if it is damaged 5 Install the spark arrester muffler protector and exhaust deflector in reverse order of disassembly Storage Transportation STORING YOUR ENGINE Storage Preparation Proper storage preparation is essential for keeping your engine trouble free and looking good The fol lowing steps will help to keep rust and corrosion from impairing your engine s function and appear ance and will make the engine easier to start after storage Cleaning If the engine has been running allow it to cool for at least half an hour
17. aterial authorization number RMA before sending the product The customer is responsible for all transportation charges related to warranty work If found warrantable returned product s will be sent back to the customer at Hypro s expense Non warrantable items will be evaluated and an estimate of repair will be sent to the customer Please send products back prepaid to HYPRO PENTAIR Attention Service Department 375 Fifth Avenue NW New Brighton Minnesota 55112 Carriers including U S P S airlines UPS ground freight etc require specific identification of any hazardous materials being shipped Failure to do so may result in a substantial fine and or prison term Check with your shipping company for specific instructions gt Pentair FLOW TECHNOLOGIES GROUP 375 Fifth Avenue NW New Brighton MN 55112 Hypro 2012 Phone 651 766 6300 800 424 9776 Fax 800 323 6496 Printed in USA www hypropumps com
18. ave been serviced or repaired with parts or components not manufactured or approved by Hypro 8 Engines that have been serviced by someone other than Hypro or its dealerships 9 Instances when normal use has worn out the component or a engine without any signs of breakage or defects IN NO EVENT SHALL HYPRO BE LIABLE FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES OF ANY KIND WHETHER FOR BREACH OF ANY WARRANTY FOR NEGLIGENCE ON THE BASIS OF STRICT LIABILITY OR OTHERWISE Return Procedures All engines must be flushed of any flammable liquids before being shipped to Hypro for service or warranty consideration For technical or application assistance call the Hypro Technical Application number 1 800 PowerPro 800 769 3777 or send an email to technical hypropumps com To obtain service warranty assistance or a Return Merchandise Authorization number call the Hypro Service and Warranty number 1 800 468 3428 or send a fax to the Hypro Service and Warranty FAX 651 766 6618 Be prepared to give Hypro full details of the problem including the following information 1 Model number date and the company from whom you purchased your PowerPro engine 2 Approximate number of hours on the engine 3 In what application the engine is currently being used 4 Maintenance that has been done on the engine prior to failure Hypro may request additional information to help determine the cause of failure Contact the factory to receive a return m
19. before cleaning Clean all exterior surfaces touch up any damaged paint and coat other areas that may rust with a light film of oil Using a garden hose or pressure washing equipment can force water into the air cleaner or muffler opening Water in the air cleaner will soak the air filter and water that passes through the air filter or muffler can enter the cylinder causing damage Water contacting a hot engine can cause dam age If the engine has been running allow it to cool for at least half an hour before washing Fuel Gasoline will oxidize and deteriorate in storage Old gasoline will cause hard starting and it leaves gum deposits that clog the fuel system If the gasoline in your engine deteriorates during storage you may need to have the carburetor and other fuel system components serviced or replaced The length of time that gasoline can be left in your fuel tank and carburetor without causing functional problems will vary with such factors as gasoline blend your storage temperatures and whether the fuel tank is partially or completely filled The air ina partially filled fuel tank promotes fuel deterioration Very warm storage temperatures accelerate fuel deterioration Fuel deterioration problems may occur within a few months or even less if the gaso line was not fresh when you filled the fuel tank Hypro s Limited Warranty does not cover fuel system damage or engine performance prob lems resulting from negle
20. cedures that should be followed before engine startup Operation SAFE OPERATING PRECAUTIONS Before operating the engine for the first time please review the IMPORTANT SAFETY INFORMATION and the section titled BEFORE OPERATION A WARNING Carbon monoxide gas is toxic Breathing it can cause unconsciousness and even death Avoid any areas or actions that expose you to carbon monoxide Review the instructions provided with the equip ment powered by this engine for any safety precau tions that should be observed in conjunction with engine startup shutdown or operation STARTING THE ENGINE 1 Move the fuel valve lever to the ON position a FUEL VALVE LEVER 2 To start a cold engine move the choke lever to the CLOSE position To restart a warm engine leave the choke lever in the OPEN position Some engine applications use a remotely mounted choke control rather than the engine mounted choke lever shown here CHOKE LEVER 3 Move the throttle lever away from the SLOW position about 1 3 of the way toward the FAST position Some engine applications use a remotely mounted throttle control rather than the engine mounted throttle lever shown here THROTTLE LEVER 4 Turn the engine switch to the ON position ENGINE SWITCH 5 Operate the starter RECOIL STARTER all engine types Pull the starter grip lightly until you feel resistance then pull briskly Return the starte
21. cted storage prepara tion You can extend fuel storage life by adding a fuel stabilizer that is formulated for that purpose or you can avoid fuel deterioration problems by draining the fuel tank and carburetor Adding a Fuel Stabilizer to Extend Fuel Storage Life When adding a fuel stabilizer fill the fuel tank with fresh gasoline If only partially filled air in the tank will promote fuel deterioration during storage If you keep a container of gasoline for refueling be sure that it contains only fresh gasoline 1 Add fuel stabilizer following the manufacturer s instructions 2 After adding a fuel stabilizer run the engine out doors for 10 minutes to be sure that treated gaso line has replaced the untreated gasoline in the car buretor 3 Stop the engine and move the fuel valve to the OFF position Draining the Fuel Tank and Carburetor 1 Place an approved gasoline container below the carburetor and use a funnel to avoid spilling fuel 2 Remove the carburetor drain bolt and sediment cup and then move the fuel valve lever to the ON position FUEL VALVE LEVER O RING WASHER DRAIN BOLT SEDIMENT CUP 3 After all the fuel has drained into the container reinstall the drain bolt and sediment cup Tighten them securely 16 Storage Transportation Storage Precautions 1 Change the engine oil 2 Remove the spark plugs 3 Pour a tablespoon 5 10 cc of clean engine oil into the cylinde
22. ded part while tightening the positive battery cable end A battery can explode if you do not follow the correct procedure seriously injuring anyone nearby Keep all sparks open flames and smoking materials away from the battery 1 Connect the battery positive cable to the starter solenoid terminal as shown NEGATIVE BATTERY CABLE e STARTER SOLENOID 19 2 Connect the battery negative cable to an engine mounting bolt frame bolt or other good engine ground connection 3 Connect the battery positive cable to the battery positive terminal 4 Connect the battery negative cable to the battery negative terminal 5 Coat the terminals and cable ends with grease Remote Control Linkage The throttle and choke control levers are provided with holes for optional cable attachment The fol lowing illustrations show installation examples for a solid wire cable and for a flexible braided wire cable If using a flexible braided wire cable add a return spring as shown It is necessary to loosen the throttle lever friction nut when operating the throttle with a remotely mounted control Models 2541 0043 thru 2541 0046 REMOTE THROTTLE LINKAGE THROTTLE LEVER zr PIVOT NUT Flexible wire core mounting sA b Gida SCREW die WIRE oS HOLDER OPTIONAL 5 ete THROTTLE mm CIRCLIP aie REMOTE CHOKE LINKAGE Solid wire core mounting Technical amp Consu
23. ecifications No other adjustments needed CONSUMER INFORMATION For technical assistance contact the Hypro Technical Application Department by phone at 1 800 PowerPro 800 769 3777 or by email at technical hypropumps com QUICK REFERENCE INFORMATION Engine Oil Type SAE 10W 30 API SG or SH for general use Capacity 2541 0043 thru 0046 0 6 L 0 63 at 2541 0047 thru 0051 1 1 L 1 2 qt Spark Plug LD F7RTC or NGK BPR6ES cap beno 070 080 mm Idle speed 1400 150 rpm Maintenance Check engine oil Check air filter First 20 hours Change engine oil Subsequent Refer to the maintenance schedule Model Shaft Type Electric Start Low Oil Sensor Type Maximum Power kW 3600rpm Rated Power kKW 3600rpm Max Torque N m rpm Engine Oil Capacity Fuel Tank Capacity Fuel Consumption g kW h Idle Speed Speed Fluctuating Ratio Noise lt BorexStroke mm Displacement CG Compression Ratio Lubricating Mode Starting Mode Rotation Valve Clearance Spark Plug Clearance Igniting Mode Air Cleaner Dimension Length mm Dimension Width mm Dimension High mm Net weight kg Specifications 3 4 5 8 1 I T 1 1 keyed threaded keyed keyed threaded threaded no no no yes no yes 2541 0045 2541 0046 2541 0048 ZO 2541 0050 2541 0051 yes yes yes yes yes yes Single cylinder 4 Stroke Forced Air Cooling OHV 4 85 6 5 hp 9 7 13 0 hp 3 8 5 1 hp
24. fecting performance and service life Use 4 stroke automotive detergent oil SAE 10W 30 is recommended for general use Other viscosities shown in the chart may be used when the average temperature in your area is with in the recommended range SAE Viscosity Grades 30 20 10 0 10 20 30 40 C AMBIENT TEMPERATURE The SAE oil viscosity and service classification are in the API label on the oil container We recom mend that you use API SERVICE Category SG or SH oil AIR FILTER INSPECTION Remove the air cleaner cover and inspect the filter Clean or replace dirty filter elements Always replace damaged filter elements If equipped with an oil bath air cleaner also check the oil level PAPER FILTER ELEMENT FOAM FILTER ELEMENT AIR CLEANER SERVICE A dirty air filter will restrict air flow to the carburetor reducing engine performance If you operate the engine in very dusty areas clean the air filter more often than specified in the MAIN TENANCE SCHEDULE Operating the engine without an air filter or with a damaged air filter will allow dirt to enter the engine causing rapid engine wear This type of damage is not covered by Hypro s Limited Warranty 12 Maintenance Dual Filter Element Types 1 Remove the wing nut e from the air cleaner AIR cover and remove the air 2 cleaner cover PAPER FILTER ELEMENT 2 Remove the wing nut from the air filter and remove the filter 3
25. hoke valve between the fuel tank and the carburetor The fuel in the carburetor The CLOSE position enriches the valve lever must be in the ON position for the fuel mixture for starting a cold engine The OPEN engine to run When the engine is not in use leave position provides the correct fuel mixture for opera the fuel valve lever in the OFF position to prevent tion after starting and for restarting a warm engine carburetor flooding and to reduce the possibility of Some engine applications use a remotely mounted fuel leakage choke control rather than the engine mounted choke lever shown here CHOKE LEVER Recoil Starter Grip Throttle Lever Pulling the starter grip operates the recoil starter to The throttle lever controls engine speed Moving Guede the throttle lever in the directions shown below makes the engine run faster or slower THROTTLE LEVER Engine Switch The engine switch enables and disables the ignition system The engine switch must be in the ON posi tion for the engine to run Turning the engine switch to the OFF position stops the engine ENGINE SWITCH Check Before Operation IS YOUR ENGINE READY TO GO For your safety and to maximize the service life of your equipment it is very important to take a few moments before you operate the engine to check its condition Be sure to take care of any problem you find or have your servicing dealer correct it prior to operating the engine A WAR
26. ly to failures of emissions parts that are not original equipment Pentair parts or to parts that fail due to abuse neglect or improper maintenance as set forth in the Pentair engine warranty policy Pentair is not liable for warranty coverage of failures of emissions parts caused by the use of add on or modified parts Look for Relevant Emissions Durability Period and Air Index Information On Your Small Off Road Engine Emissions Label Engines that are certified to meet the California Air Resources Board CARB small off road Emissions Standard must display information regarding the Emissions Durability Period and the Air Index Pentair makes this information available to the consumer on our emissions labels The engine emissions label will indicate certification information The Emissions Durability Period describes the number of hours of actual running time for which the engine is certified to be emissions compliant assuming proper maintenance in ac cordance with the Operating and Maintenance Instructions The following categories are used Moderate Engine is certified to be emissions compliant for 125 hours of actual engine running time Intermediate Engine is certified to be emissions compliant for 250 hours of actual engine running time Extended Engine is certified to be emissions compliant for 500 hours of actual engine running time For example a typical gas engine powered transfer pump is used 20 25 hours per year Therefore the Emissio
27. mer Information Models 2541 0047 thru 2541 0051 REMOTE THROTTLE LINKAGE RETURN SPRING THROTTLE LEVER err PIVOT NUT Flexible wire core mounting tue Dn SCREW WIRE HOLDER gt OPTION be EZA Gr THROTTLE i z LEVER AA 5 mm Solid wire core CIRCLIP mounting REMOTE CHOKE LINKAGE WIRE HOLDER CHOKE LEVER Carburetor Modification for High Altitude Operation At high altitude the standard carburetor air fuel mixture will be too rich Performance will decrease and fuel consumption will increase A very rich mix ture will also foul the spark plug and cause hard starting Operation at an altitude that differs from that at which this engine was certified for extended periods of time may increase emissions High altitude performance can be improved by spe cific modifications to the carburetor If you always operate your engine at altitudes above 5 000 feet 1 500 meters have your servicing dealer perform this carburetor modification This engine when operated at high altitude with the carburetor modifi cations for high altitude use will meet each emis sion standard throughout its useful life Even with carburetor modification engine horse power will decrease about 3 5 for each 1 000 foot 800 meter increase in altitude The effect of alti tude on horsepower will be greater than this if no carburetor modification is made NOTICE When the carburetor has been modified for high
28. ns Durability Period of an engine with a Moderate rating would equate to 5 6 years Pentair s PowerPro engines are certified to meet the United States Environmental Protection Agency USEPA Phase 3 emissions standards For Phase 3 certified engines the Emissions Compliance Period referred to on the Emissions Compliance label indicates the number of operating hour for which the engine has been shown to meet Federal emissions requirements For engine less than 225 cc displacement Category C 125 hours Category B 250 hours Category A 500 hours For engines of 225 cc or more displacement Category C 250 hours Category B 500 hours Category A 1000 hour Limited Warranty on PowerPro Gasoline Engines Hypro warrants to the original purchaser of its PowerPro gasoline engine to be free from defects in material and workmanship under normal use for the period of one 1 year from the date of purchase This warranty does not cover freight damage normal wear and tear or damage caused by misapplication lack of routine maintenance negligence alterations or repair that affects the performance or reliability of the engine see limitations and exclusions listed below The repair or replacement of any part or parts under this Limited Warranty shall not extend the terms of the warranty beyond the original warrantable period THIS WARRANTY IS EXCLUSIVE HYPRO MAKES NO OTHER WARRANTY EXPRESS OR IMPLIED INCLUDING BUT NOT LIMITED TO ANY WARRAN
29. oapy water rinse and allow drying thoroughly Or clean in nonflammable solvent and allow drying 3 Dip the filter in clean engine oil and then squeeze out all excess oil The engine will smoke if too much oil is left in the foam 4 Empty the used oil from the air cleaner case wash out any accumulated dirt with nonflammable solvent and dry the case 5 Fill the air cleaner case to the OIL LEVEL mark with the same oil that is recommended for the engine Oil capacity 2 0 US oz 60 cm3 6 Reassemble the air cleaner and tighten the wing nut securely OIL LEVEL Maintenance SEDIMENT CUP CLEANING 1 Move the fuel valve to the OFF position and then remove the fuel sediment cup and O ring A WARNING Gasoline is highly flammable and explosive You can be burned or seriously injured when han dling fuel e Keep heat sparks and flame away e Handle fuel only outdoors e Wipe up spills immediately 2 Wash the sediment cup and O ring in nonflam mable solvent and dry them thoroughly 3 Place the O ring in the fuel valve and install the sediment cup Tighten the sediment cup securely 4 Move the fuel valve to the ON position and check for leaks Replace the O ring if there is any leakage KO db Ge E os O RING SEDIMENT CAP SPARK PLUG SERVICE Recommended spark plugs F7RTC or other equiv alents NOTICE An incorrect spark plug can cause engine damage 1 Disconnect
30. r 4 Pull the starter rope several times to distribute the oil in the cylinder 5 Reinstall the spark plugs 6 Pull the starter rope slowly until resistance is felt This will close the valves so moisture cannot enter the engine cylinder Return the starter rope gently If your engine will be stored with gasoline in the fuel tank and carburetor it is important to reduce the hazard of gasoline vapor ignition Select a well ven tilated storage area away from any appliance that operates with a flame such as a furnace water heater or clothes dryer Also avoid any area with a spark producing electric motor or where power tools are operated If possible avoid storage areas with high humidity because that promotes rust and corrosion Unless all fuel has been drained from the fuel tank leave the fuel valve lever in the OFF position to reduce the possibility of fuel leakage Position the equipment so the engine is level Tilting can cause fuel or oil leakage With the engine and exhaust system cool cover the engine to keep out dust A hot engine and exhaust system can ignite or melt some materials Do not use sheet plastic as a dust cover A nonporous cover will trap moisture around the engine promot ing rust and corrosion If equipped with a battery for an electric starter recharge the battery once a month while the engine is in storage This will help to extend the service life of the battery 17 Removal from Stor
31. r grip gently 6 If the choke lever has been moved to the CLOSE position to start the engine gradually move it to the OPEN position as the engine warms up CHOKE LEVER Operation SETTING ENGINE SPEED Position the throttle lever for the desired engine speed Some engine applications use a remotely mounted throttle control rather than the engine mounted throttle lever shown here For engine speed recommendations refer to the instructions provided with the equipment powered by this engine THROTTLE LEVER STOPPING THE ENGINE To stop the engine in an emergency simply turn the engine switch to the OFF position Under normal conditions use the following procedure 1 Move the throttle lever to the SLOW position Some engine applications use a remotely mounted throttle control rather than the engine mounted throttle lever shown here THROTTLE LEVER i i 2 Turn the engine switch to the OFF position ENGINE SWITCH FUEL VALVE LEVER Maintenance THE IMPORTANCE OF MAINTENANCE Good maintenance is essential for safe economi cal and trouble free operation It will also help reduce air pollution A WARNING Improperly maintaining this engine or failure to correct a problem before operation can cause a malfunction in which you can be seriously hurt or killed Always follow the inspection and maintenance recommendations and schedules in this owner s manual To help you properly c
32. s control system on your PowerPro engine equipment for the periods of time listed below provided there has been no abuse neglect or improper maintenance of your engine or equipment Your emissions control system may include parts such as the carburetor of fuel injection system fuel tank ignition system and catalytic converter Also included may be hoses belts connectors sensors and other emissions related assemblies Where a warrant able condition exists Pentair will repair your engine equipment at no cost to you including diagnosis parts and labor California Pentair PowerPro engines available for sale in California can be identified by part number 2541 prefix and engine emissions label These models comply with CARB emission stan dards Other States and U S territories In other areas of the United States Pentair PowerPro engines can be identified by part num ber 2543 prefix and engine emissions label These models comply with U S EPA emission standards and are not available for sale in California Manufacturer s Warranty Coverage Small off road engines and large spark ignited engines less than or equal to 1 0 liter are warrant for two years If any emissions related part on your engine equipment is defective the part will be repaired or replaced by Pentair Owner s Warranty Responsibilities As the engine equipment owner you are responsible for the performance of the required maintenance listed in your owner s man
33. special attention to these symbols and any instructions that follow A DANGER Indicates serious injury or death will result if instructions are not followed Indicates a strong possibility that serious injury or death could result if instructions are not followed A CAUTION Indicates a possibility that minor injury could result if instructions are not followed Indicates that equipment or property damage can result if instructions are not followed NOTE Gives helpful information Engine Safety Information IMPORTANT SAFETY INFORMATION Most accidents with engines can be prevented if you follow all instructions in this manual and on the engine Some of the most common hazards are discussed below along with the best way to protect yourself and others Owner Responsibilities e The engines are designed to give safe and dependable service if operated according to instructions Read and understand this owner s manual before operating the engine Failure to do so could result in personal injury or equipment damage e Know how to stop the engine quickly and under stand the operation of all controls Never permit anyone to operate the engine without proper instructions e Do not allow children to operate the engine Keep children and pets away from the area of operation Refuel with Care Gasoline is extremely flammable and gasoline vapor can explode Refuel outdoors in a well venti lated area with the engine stopped
34. the following symptoms have your engine inspected and repaired by your servicing dealer e Hard starting or stalling after starting e Rough idle e Misfiring or backfiring under load e Afterburning backfiring e Black exhaust smoke or high fuel consumption Replacement Parts The emission control systems on your engine were designed built We recommend the use of genuine parts whenever you have maintenance done These original design replacement parts are manu factured to the same standards as the original parts so you can be confident of their performance The use of replacement parts that are not of the original design and quality may impair the effective ness of your emission control system A manufacturer of an aftermarket part assumes the responsibility that the part will not adversely affect emission performance The manufacturer or rebuilder of the part must certify that use of the part will not result in a failure of the engine to comply with emission regulations 21 Maintenance Follow the maintenance schedule Remember that this schedule is based on the assumption that your machine will be used for its designed purpose Sustained high load or high temperature operation or use in unusually wet or dusty conditions will require more frequent service Engine Tune up ITEM SPECIFICATION Spark plug gap 0 028 0 031 in 0 70 0 80 mm Valve clearance IN 0 15 0 02 mm cold EX 0 20 0 02 mm cold Other sp
35. the spark plug cap and remove any dirt from around the spark plug area 2 Remove the spark plug with a spark plug wrench SPARK PLUG WRENCH 0 028 0 031 in 3 Inspect the spark plug Replace it if the elec trodes are worn or if the insulator is cracked or chipped 4 Measure the spark plug electrode gap with a suitable gauge The gap should be 0 028 0 031 in 0 70 0 80 mm Correct the gap if necessary by carefully bending the side electrode 5 By hand install the spark plug carefully to avoid cross threading 6 After the spark plug seats tighten with a spark plug wrench to compress the washer If reinstalling the used spark plug tighten 1 8 1 4 turn after the spark plug seats If installing a new spark plug tighten 1 2 turn after the spark plug seats NOTICE A loose spark plug can overheat and damage the engine Over tightening the spark plug can damage the threads in the cylinder head 7 Attach the spark plug cap IDLE SPEED ADJUSTMENT 1 Start the engine outdoors and allow it to warm up to operating temperature 2 Move the throttle lever to its slowest position 3 Turn the throttle stop screw to obtain the stan dard idle speed Standard idle speed 1 400 150 rom THROTTLE STOP SCREW 14 Maintenance SPARK ARRESTER SERVICE optional equipment Your engine is not factory equipped with a spark arrester In some areas it is illegal to operate an engine without a spark
36. ual Pentair recommends that you retain all receipts covering maintenance on you engine equipment but Pentair cannot deny warrant solely for the lack of receipts or your failure to ensure the performance of all scheduled maintenance As the engine equipment owner you should however be aware that Pentair may deny you war ranty coverage if your engine equipment or a part has failed due to abuse neglect improper maintenance or unapproved modifications You are responsible for presenting you engine equipment to a Pentair distribution center servicing dealer or other equivalent entity as appli cable as soon as a problem exists The warranty repairs should be completed in a reasonable amount of time not to exceed 30 days If you have any questions regarding your warranty rights and responsibilities you should contact Pentair at 800 PowerPro 800 769 3777 or hypro service pentair com Pentair Emissions Control Warranty Provisions The following are specific provisions relative to your Emissions Control Warranty Coverage It is in addition to the Pentair engine warranty for non regulated engines found in the Operator s Manual 1 Warranted Emissions Parts Coverage under this warranty extends only to the parts listed below the emissions control systems parts to the extent these parts where present on the engine purchased a Fuel Metering System e Cold start enrichment system soft choke e Carburetor and internal parts e Fuel pump e Fuel line f
37. uel line fittings clamps e Fuel tank cap and tether e Carbon canister b Air Induction System e Air cleaner e Intake manifold e Purchase and vent line c Ignition System e Spark plug s e Magneto ignition system d Catalyst System e Catalytic converter e Exhaust manifold e Air injection system or pulse valve e Miscellaneous Items Used in Above Systems e Vacuum temperature position time sensitive valves and switches e Connectors and assemblies 27 2 Length of Coverage For a period of two years from date of original purchase Pentair warrants to the original purchaser and each subsequent purchaser that the engine is designed built and equipped so as to conform with all applicable regulations adopted by the Air Resources Board that it is free from defects in material and workmanship that could cause the failure of a warranted part and that it is identical in all material respects to the engine described in the manufacturer s application for certification The Warranty period begins on the date the engine is originally purchased The warranty on emissions related parts is as follows e Any warranted part that is scheduled for replacement as required maintenance in the owner s manual supplied is warranted for the warranty period stated above If any such part fails during the period of warranty coverage the part will be repaired or replaced by Pentair at no charge to the owner Any such part repaired or replaced under the warrant
38. ume may cause starting and or performance problems It may also damage metal rubber and plastic parts of your fuel system If you notice any undesirable operating symptoms try another service station or switch to another brand of gasoline Fuel system damage or performance problems resulting from the use of an oxygenated fuel con taining more than the percentages of oxygenates mentioned above are not covered under warranty 20 Technical amp Consumer Information EMISSION CONTROL SYSTEM INFORMATION Source of Emissions The combustion process produces carbon monox ide oxides of nitrogen and hydrocarbons Control of hydrocarbons and oxides of nitrogen is very important because under certain conditions they react to form photochemical smog when subjected to sunlight Carbon monoxide does not react in the same way but it is toxic This utilizes lean carburetor settings and other sys tems to reduce the emissions of carbon monoxide oxides of nitrogen and hydrocarbons Tampering and Altering Tampering with or altering the emission control sys tem may increase emissions beyond the legal limit Among those acts that constitute tampering are e Removal or alteration of any part of the intake fuel or exhaust systems e Altering or defeating the governor linkage or speed adjusting mechanism to cause the engine to operate outside its design parameters Problems that may Affect Emissions If you are aware of any of
39. y will be war ranted for the remaining warranty period e Any warranted part that is scheduled only for regular inspection in the owner s manual supplied is warranted for the warranty period stated above Any such part repaired or replaced under warranty will be warranted for the remaining warranty period e Any warranted part that is scheduled for replacement as required maintenance in the owner s manual supplied is warranted for the period of time prior to the first scheduled replacement point for that part If the part fails prior to the first scheduled replacement the part will be repaired or replaced by Pentair at no charge to the owner Any such part repaired or replaced under warranty will be warranted for the remainder of the period prior to the first scheduled replacement point for the part e Add on or modified parts that are not exempted by the Air Resources Board may not be used The use of any non exempted add on or modified parts by the owner will be grounds for disallowing a warranty claim The manufacturer will not be liable to warrant failures of war ranted parts caused by the use of a non exempted add on or modified part 3 Consequential Coverage Coverage shall extend to the failure of any engine components caused by the failure of any warranted emissions parts 4 Claims and Coverage Exclusions Warranty claims shall be filed according to the provisions of the Pentair engine warranty policy Warranty coverage does not app
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