CHERNE AQUA-LOC 278-138 User manual

AQUA-LOC

HYDROSTATIC TEST PUMP
(PISTON STYLE)
OPERATION AND MAINTENANCE MANUAL
PART NUMBER 278-138 (Honda)
______________________________________________________________________________
CHERNE INDUSTRIES INCORPORATED 1-800-THE-PLUG
5700 Lincoln Drive (1-800-843-7584)
® Minneapolis, MN 55436-1695 [phone]

AQUA-LOCHYDROSTATIC TEST PUMP 2
TABLE OF CONTENTS
Caution 3
Features 4
Packed Parts List 5
Complete Parts List 6-12
Pump Set-up & Operation 13-14
Troubleshooting & Maintenance 15-16
Warranty 17

AQUA-LOCHYDROSTATIC TEST PUMP 3
!!CAUTION!!
ENGINE IS SHIPPED WITHOUT OIL!
FILL ENGINE WITH OIL BY REMOVING OIL FILLER
PLUG AND FILL UNTIL OVERFLOWING BEFORE
ATTEMPTING TO START ENGINE!
FAILURE TO FILL ENGINE WITH OIL BEFORE STARTING
ENGINE WILL RESULT IN ENGINE FAILURE AND VOID THE
WARRANTY!!
DO NOT RUN PUMP DRY FOR MORE THAN 30 SECONDS. FAILURE
TO COMPLY COULD RESULT IN PREMATURE PUMP FAILURE AND
VOID THE WARRANTY!!
!!CAUTION!!
TURN FUEL SUPPLY VALVE TO "OFF" POSITION BEFORE
TRANSPORTING UNIT.
VIBRATION DURING TRANSPORT MAY CAUSE FUEL TO
DRAIN INTO ENGINE CYLINDER & CRANKCASE. THIS
MAY DAMAGE ENGINE DUE TO IMPROPER LUBRICATION
OR CAUSE DAMAGE TO ENGINE COMPONENTS DUE TO
AN OVERFILLED CRANKCASE OR ENGINE CYLINDER.

AQUA-LOCHYDROSTATIC TEST PUMP 4
AQUA-LOC FEATURES
* 5.5 HORSE POWER GASOLINE ENGINE (Honda)
* SELF-PRIMING TWIN PISTON PUMP with an output capacity of 10.0 gpm/450 PSI.
Additional pump features include a lightweight gear reduction unit.
•
••
•SILICONE FILLED GAUGE with a stainless steel case.
•
••
•INLINE STRAINER with easy access to filter for cleaning.
* 12' LONG 3/4" ID HIGH PRESSURE OUTPUT HOSE with hydraulic quick-disconnect
and 3/4 NPT swivel adapter fittings.
* THERMAL RELIEF VALVE to automatically protect unit from overheating.
•A WHEEL ASSEMBLY Kit (Optional) with semi-pneumatic tires makes transporting the
unit convenient and simple.
•Manifolds are used to reduce number of fittings and possibility of fluid leakage.
•Clear Recirculation Hose to verify water flow through pump.

AQUA-LOCHYDROSTATIC TEST PUMP 5
UNPACKING THE AQUA-LOC
Included with the unit are O&M manuals from the pump and engine manufacturers as well as a
quart of 30 WT oil.
Please identify and account for each component of your Aqua-Loc after unpacking to make sure
nothing has been damaged or is missing.
1 278-138 1 HYDROSTAIC TEST PUMP
2 039-308 1 OPERATIONS AND MAINTENANCE MANUAL
3 031-198 1 HOSE, DISCHARGE, 12FT
4 091-510 1 OIL, 1 QUART-30WT, BOTTLE WITH CAP
5 N/A 1 HONDA ENGINE MANUAL
6 N/A 1 HYPRO PUMP MANUAL

AQUA-LOCHYDROSTATIC TEST PUMP 6
PARTS LIST
(Honda Engine)
Refer to Drawings on Pages 9-12.
1 039-298 1 ENGINE, HONDA 5.5HP 6:1 GEAR RATIO
2 031-118 1 PUMP, BIG TWIN
3 031-108 1 HOSE, PULSE
4 039-258 1 COUPLING, 1” BORE
5 039-268 1 COUPLING, ¾” BORE
6 039-248 1 URETHANE DISC
7 031-188 1 VALVE, PRESSURE RELIEF, 0-400 PSI
8 031-068 1 COUPLING GUARD
9 031-438 1 STRAINER, ¾”
10 022-778 1 GAUGE, 0-600 PSI
11 031-198 1 HOSE, DISCHARGE, 12FT
12 056-348 1 BASE, PISTON, DIAPHRAGM OR VACUUM PUMP
13 031-598 1 VALVE, THERMAL RELIEF
14 031-208 1 MANIFOLD, PUMP OULET
15 031-218 1 MANIFOLD, COUPLER BLOCK
16 031-228 1 MANIFOLD, PUMP INLET
17 031-238 1 INLET SUPPORT
18 022-828 1 HYDRAULIC QUICK DISCONNECT, ¾”
19 031-248 1 VALVE, BALL, ¾”
20 054-267 1 GARDEN HOSE FITTING
21 030-178 2 HOSE, CLAMP, ¾” – 1 ½”
22 031-258 1 SHOULDER NIPPLE, ¾” STEEL
23 003-344 1 ELBOW, 90 DEGREE, ¼” BRASS
24 021-628 2 ADAPTER, ¾” MPT X HOSE BARB
25 031-268 1 HOSE, CLEAR
26 035-688 1 RUBBER WASHER, ¾”
27 031-278 1 PIPE CAP, ½” BRASS

AQUA-LOCHYDROSTATIC TEST PUMP 7
28 031-138 1 VALVE, DRAIN
29 031-128 1 ELBOW, 90 DEGREE, HYDRAULIC
30 000-507 4 BOLT, 5/16-18 X 1”
31
32 000-450 4 BOLT, 5/16-18 X 1 ½”
33 019-887 2 TACK, METAL, 10105
34 000-930 8 NUT, HEX, 5/16-18, SS, SELF LOCKING
35 000-361 8 BOLT, ¼-20 X ½”
36
37 037-338 6 NUT, HEX, ¼-20, SELF LOCKING
38 031-288 1 SHOULDER NIPPLE, ¾”, BRASS
39 031-298 1 SHOULDER NIPPLE, ½”, BRASS
40 003-565 1 NIPPLE, ¼”, BRASS
41 052-272 3 CLOSE NIPPLE, ¾” STEEL
42 014-796 1.5 FT TUBING, 3/8 INCH POLYETHYLENE
43 008-308 1 PLUG, ¾”, GALVANIZED
44 039-308 1 O&M MANUAL, HYDROSTATIC TESTPUMP
45 002-607 1 TEE, ¼” MPT X 3/8” TUBE, M-RUNNING
46 031-728 1 ELBOW, 90 DEGREE, 1/8” MPT X 3/8” PLOY
47 052-264 1 ELBOW, 90 DEGREE, ¾” GALVANIZED
48 292-656 1 KEY STOCK 3/16” X 1”
49 031-968 1 U-BOLT 2 X ¼-20X 1.13 WIDE
50 026-758 1 CABLE, 1/16 DIA YLW POLY 6.12” L
51 026-768 1 FERRULE, 1/16”, CABLE, NICKEL PLATED
52 031-718 1 TAG, INSTRUCTIONAL, HYDROSTATIC TEST PUMP
53 023-268 .125 LOCTITE-THREAD SEALER, #545, 50ML
54 039-318 1 LABEL, BASE
55 031-748 1 LABEL, INTAKE
56 031-768 1 LABEL 1, INTAKE MANIFOLD

AQUA-LOCHYDROSTATIC TEST PUMP 8
57 031-778 1 LABEL 2, INTAKE MANIFOLD
58 031-788 1 LABEL, OUTPUT MANIFOLD
59 031-808 1 LABEL, COUPLER BLOCK
60 000-027 8 WASHER, ¼” FLAT
61 000-051 4 WASHER, 3/8” FLAT
62 000-043 16 WASHER, 5/16” FLAT
63 091-510 1 Oil, 1 QUART-30WT, BOTTLE WITH CAP
64 N/A 1 HYPRO PUMP MANUAL
65 N/A 1 HONDA ENGINE MANUAL
66 032-218 1 CARTON, HYDROSTATIC TEST PUMP, PISTON STYLE
67 039-328 1 CARTON LABEL, HYDROSTATIC TEST PUMP, PISTON STYLE
68 005-789 1 LABEL, MODEL-SERIAL NUMBER, METAL TAG
70 054-028 2 NIPPLE, CLOSE, ¾” NPT, 1000 PSI MINIMUM
71 054-038 1 ELBOW, 45 DEGREE, ¾” NPT, 3000 PSI
72 054-048 1 CHECK VALVE, ¾ MPT
73 055-568 1 ELBOW, 45 DEGREE STREET, ½ NPT, BRASS

AQUA-LOCHYDROSTATIC TEST PUMP 9

AQUA-LOCHYDROSTATIC TEST PUMP 10

AQUA-LOCHYDROSTATIC TEST PUMP 11

AQUA-LOCHYDROSTATIC TEST PUMP 12

AQUA-LOCHYDROSTATIC TEST PUMP 13
PUMP SET-UP AND OPERATION
Before you begin, make sure the installed line has been adequately flushed and sufficient
backfilling has taken place to prevent pipe movement. Refer to AWWA standard for specific
guidelines on flushing and backfilling.
NOTE: The instructions in this section are also on the yellow tag attached to the pump. Refer to
the appropriate parts lists and drawings on the previous pages for parts identification.
1. Check oil levels in engine and gear reduction unit. See maintenance section of this
manual for proper fluids and fluid levels.
2. Check fuel level in engine. Turn fuel valve to “on” position.
3. Close drain valve.
4. Hook water supply to intake port.
5. Turn on water supply or submerge supply hose in water reservoir.
6. Back off pressure relief valve for easier starting.
7. Open the ¾” ball valve by aligning the handle parallel to the base.
8. Start engine. Cold engine: full choke, throttle to half, pull recoil starter. With engine
running, move choke to half, move throttle to full and choke to run.
Warm engine: half choke, throttle to half, pull recoil starter. With engine running, move
throttle to full and choke to run.
9. Set test pressure. Loosen lock nut on pressure relief valve, turn valve stem until desired
test pressure is reached.Tighten lock nut. Note: turning valve stem clockwise increases
test pressure, turning valve stem counter-clockwise reduces pump pressure.
10. Hook up discharge hose to high-pressure output (3/4” quick disconnect).
11. TESTING PROCEDURE
NOTE: Make sure pipeline has been properly flushed, filled, and purged of all air before
continuing.
A. Allow pump to build required pipeline pressure. Refer to appropriate AWWA standard
pressure requirements for the type of pipe being tested.
B. When required line pressure is reached, shut-off output ball valve to perform pressure
test. Leave ball valve open to perform leakage test. Duration of simultaneous tests is at
least two (2) hours, unless otherwise specified.
NOTE: Pump is equipped with a thermal relief valve that may relieve after extended running
time. Any relieved water will exit under the pump, near the drain valve.
C. If necessary, operate pump to maintain test pressure for the specified time period (2 hours
minimum) while carefully examining all exposed pipe, fittings, valves and hydrants for
leakage.

AQUA-LOCHYDROSTATIC TEST PUMP 14
D. Refer to the appropriate AWWA standard for allowable leakage specifications on the type
of pipe being tested.
12. Shut Down procedures
-Shut off engine.
-Shut off water supply
-Purge the high-pressure output line and hose by opening drain valve to release
pressure. Disconnect discharge hose when pressure gauge reads zero.
-Disconnect water supply.
-With drain valve and ball valve open, start engine and run for 10-15 seconds to
completely drain system.
-If chlorinated water supply was used, flush unit.
-Turn off fuel valve.
-Close drain valve.
WARNING: Unit must be drained to prevent damage from freezing.

AQUA-LOCHYDROSTATIC TEST PUMP 15
TROUBLE SHOOTING GUIDE
PROBLEM POSSIBLE CAUSES SOLUTION
Air bubbles visible in clear
intake hose.
1. Loose crow's foot fitting
connection
2. Intake hose not fully
submerged in water reservoir
1. Connect crow's foot fitting;
use safety clip to ensure proper
fit
2. Check for adequate water
level in reservoir; fully submerge
hose.
Unable to achieve pre-set
output pressure
Air trapped in output
plumbing
1. Run unit for 3 seconds with
drain valve open
2. Open and close drain valve
several times
Engine surges or runs erratic Choke or throttle linkage
spring is disconnected
Connect spring
Engine won't run
Pressure valve indicator
oscillates
Engine's out of gasoline
Water in pulse hose
Pulse hose not elevated
Fill engine with unleaded
gasoline
Bleed pulse hose: Disconnect
output and input water supply,
open ball and drain valves, and
then run engine for 10-15
seconds.
Bleed pulse hose and position
Pulse hose as shown on page 12.

AQUA-LOCHYDROSTATIC TEST PUMP 16
MAINTENANCE
•Flush pump with a 50:50 mixture of water and non-toxic anti-freeze for winter storage or use
in freezing conditions.
•Refer to engine and pump Manufacturer's Operations manuals for specific information on
maintaining and troubleshooting their units.
ENGINE LUBRICATION MAINTENANCE
OIL TYPE CAPACITY/FILL LEVEL
Nondetergent, SAE 30 weight Fill until overflowing
GEAR REDUCTION LUBRICATION MAINTENANCE
OIL TYPE CAPACITY/FILL LEVEL
Nondetergent, SAE 30 weight Fill until overflowing.
PUMP LUBRICATION MAINTENANCE
GREASE TYPE CAPACITY/FILL LEVEL
Moly-Lithium No.2 wheel bearing
grease
N/A
Change engine oil after one month or 20 hours of use, then every 6 months or 100 hours.
Change gear reduction oil after one month or 20 hours of use, then every 6 months or 100 hours.
Lubricate pump a minimum of every 100 hours.
Check engine oil each time engine is run.
Check gear reduction oil each time engine is run.

AQUA-LOCHYDROSTATIC TEST PUMP 17
LIMITED WARRANTY
Manufacturer warrants all products manufactured by it will be free from defects in material and
Workmanship for one (1) year following the date of manufacture. If any of the goods are found to be defective, such
goods will, at manufacturer's option be replaced or repaired at manufacturer's cost. The parties hereto expressly
agree that buyer's sole and exclusive remedy against the manufacturer shall be for the repair or replacement of
defective goods as provided herein. (The sole purpose of the stipulated exclusive remedy shall be to provide the
buyer with free repair and replacement of defective goods in the manner provided herein. The exclusive remedy
shall not be deemed to have failed of its essential purpose so long as the manufacturer is willing and able to repair or
replace defective goods in the prescribed manner.) Goods which may be sold by manufacturer but are not
manufactured by it are not warranted by manufacturer, but are sold only with the warranties, if any, of the original
manufacturers thereof. (This warranty does not cover labor or other costs or expenses to remove or install any
defective, repaired or replaced goods.) Manufacturer's warranty does not apply to any goods which have been
subjected to misuse, mishandling, misapplication, neglect (including but not limited to use of unauthorized parts or
attachments), or adjustment or repair performed by anyone other than manufacturer or one of manufacturer's
authorized agents.
Any claim by buyer with reference to the goods sold hereunder shall be deemed waived by the buyer unless
submitted in writing to manufacturer within the earlier of (1) thirty (30) days following the date buyer discovered or
by reasonable inspection should have discovered, any claimed breach of the foregoing warranty, or (2) thirteen (13)
months following the date of manufacture. Any cause of action for breach of the foregoing warranty shall be brought
within one year from the date the alleged breach was discovered or should have been discovered, whichever comes
first.
LIMITATION OF LIABILITY. Manufacturer's liability (whether under the theories of breach of contract or
warranty, negligence, or strict liability) for its goods shall be limited to repairing or replacing parts found by the
manufacturer to be defective, or at manufacturer's option, to refunding the purchase price of such goods or parts
thereof.
DISCLAIMER OF CONSEQUENTIAL DAMAGES. In no event shall manufacturer be liable for consequential
damages arising out of or in connection with this agreement, including without limitation breach of any obligation
imposed on manufacturer hereunder or in connection herewith. Consequential damages for purposes hereof shall
include, without limitation (including death) to any person, or loss of or damage to property (including without
limitation property handled or processed by the use of goods). Buyer shall indemnify manufacturer against all
liability, cost or expense which may be sustained by manufacturer on account of any such loss, damage or injury.
DEFECTIVE PRODUCTS POLICY. To obtain performance under this warranty, any product suspected of
having a manufacturing defect in materials or workmanship at manufacturers request must be returned to CHERNE
INDUSTRIES INCORPORATED, freight prepaid, for inspection. A returned goods authorization must be obtained
before shipping any product back to CHERNE. Call 1-800-843-7584 and ask for customer service.
CUSTOMER TRANSPORTATION REIMBURSEMENT. Whenever CHERNE repairs or replaces a product at
CHERNE'S expense CHERNE will reimburse the distributor by credit memo, the same surface freight amount it cost
CHERNE to return the warranty items.
The foregoing warranty is in lieu of all other warranties express or implied, including those of merchantability or
fitness for any purpose not expressly set forth herein. No affirmation of manufacturer, by words or action, other than
as set forth in this language shall constitute a warranty.
Form 039-308, REV. E ECN 04-7196
©2004 Cherne Industries Incorporated
All Rights Reserved