DARLEY 2BE6.5H User manual

Prepared by: TED Rev. #: 13
Approved by: MCR 115May2006
© W.S. Darley & Co. 1200569.doc
Operator’s Technical Manual Table of Contents
For Darley
Honda Engine Driven 2BE6.5H Portable Pump
DESCRIPTION FILE PAGE
Introduction to the Darley 2BE6.5H Portable Pump--------------------------------------- 1200569-------- 2
Performance Curves ----------------------------------------------------------------------------- -------------- 3
Operation, & Maintenance--------------------------------------------------------------------- 1200569-------- 4
Quick Start Instructions ------------------------------------------------------------------------- ------------ 4
Starting and Operating the Pump --------------------------------------------------------- ------------ 4
Shutting Down and Stowing the Pump--------------------------------------------------- ------------ 5
Switching Fuel Tanks----------------------------------------------------------------------- ------------ 6
Preparation for Priming ------------------------------------------------------------------------- ------------ 7
Priming and Starting the Pump----------------------------------------------------------------- ------------ 8
Emergency Starting with a Broken Recoil Starter-------------------------------------- ------------ 8
Emergency Shutdown ---------------------------------------------------------------------- ------------ 8
Running and Maintaining the Pump and Engine -------------------------------------------- ------------ 9
To Connect the Fuel Hose ----------------------------------------------------------------- ------------ 9
To Disconnect the Fuel Hose-------------------------------------------------------------- ------------ 9
Preventative Maintenance Quick Reference--------------------------------------------- ------------ 10
Packing the Pump Unit’s Kit Container-------------------------------------------------- ------------ 11
Unpacking the Pump Unit’s Kit Container ---------------------------------------------- ------------ 13
Related Drawings
2BE6.5H Layout (Exploded View)------------------------------------------------------ DBC0502------- 14
2BE6.5H Assembly Cross Section ------------------------------------------------------ DBC0503------- 15
Instructions - Seal Installation, 2BE6.5H----------------------------------------------- 1201004-------- 16
Primer - Hand (Exploded View) -------------------------------------------------------- DGC0214------- 17
Kit - 2.5 Gal. Fuel Tank 2BE6.5H------------------------------------------------------ DGM1108 ------ 18
Fuel Hose Assembly---------------------------------------------------------------------- DGM1109 ------ 19
2BE6.5H Layout (Dimensional) -------------------------------------------------------- DBD0302------- 20
Photos---------------------------------------------------------------------------------------------- ------------ 21
Repair Service Instructions, Type 2BE6.5H Portable Pump------------------------------ 1200569-------- 22
Suggested Tools Supplies and Support Equipment for Performing Repairs & Overhaul------------- 22
Pump Disassembly for Overhaul--------------------------------------------------------------- ------------ 23
Parts Inspection and Measurement ------------------------------------------------------------ ------------ 23
Pump Assembly ---------------------------------------------------------------------------------- ------------ 24
Assembly Tips------------------------------------------------------------------------------- ------------ 24
Assembly------------------------------------------------------------------------------------- ------------ 24
Replacing the Discharge Check Valve-------------------------------------------------------- ------------ 25
Replacing the Primer Cup----------------------------------------------------------------------- ------------ 26
Tool Drawings
Press Arbor for Assembling 1843300 to 2907700--------------------------------------- X4872--------- 27
Bar - Seal Assembly ------------------------------------------------------------------------- X4926--------- 28
Plate - Seal Ring Assembly----------------------------------------------------------------- X4927--------- 29
Spare Parts Kits --------------------------------------------------------------------------------------- ------------ 30
Pump And Accessory Maintenance ---------------------------------------------------------------- ------------ 31
Engine Maintenance---------------------------------------------------------------------------------- ------------ 33
Trouble Shooting-------------------------------------------------------------------------------------- ------------ 34
Model: 2BE6.5H Pump Serial Number:
IF FURTHER INFORMATION IS NEEDED, CALL W.S. DARLEY & CO. IN
CHIPPEWA FALLS, WI. AT 800-634-7812 or 715-726-2650

Prepared by: TED Rev. #: 13
Approved by: MCR 215May2006
© W.S. Darley & Co. 1200569.doc
Introduction to the
Darley 2BE6.5H
Portable Pump
The Darley 2BE6.5H portable dewatering/fire pump unit is manufactured by W.S. Darley & Company
in Chippewa Falls, WI, U.S.A. It consists of the Darley 2BE pump coupled to a 6.5 horsepower Honda GX-
200 gasoline engine, and is mounted on an aluminum frame for easy transport to the scene of the emergency.
The dewatering kit consists of
•The pump engine unit,
•A 15’ long, 3” diameter suction hose with quick disconnect fitting, and screen,
•A 20’ long, 3” diameter fiber reinforced discharge hose with quick disconnect fitting,
•A removable, 3 gal. portable fuel tank, (four hour capacity)
•A flashlight,
•A laminated instruction card in four languages,
•An operation and maintenance manual, and
•A spare pull rope for starting the engine without the recoil starter.
This equipment is designed to fit in the Coast Guard dewatering pump kit container. The pump/engine
unit weighs less than 60 pounds, and the complete kit, with fuel, weighs less than 120 pounds.
The operation of the Darley 2BE6.5H is simple. The suction and discharge hoses connect to the pump
via quick disconnect camlock style fittings. The different colored fittings used on the suction and discharge
hoses assist in preventing misconnection of the hoses. The four cycle Honda engine runs on regular unleaded
fuel and is easily started. A throttle control allows the operator the ability to adjust the dewatering rate to
meet the needs of the emergency. At full throttle, the pump is capable of delivering over 250 gallons per
minute at a 12’ suction lift. Higher discharge rates will be achieved at lower suction lifts.
The Darley 2BE6.5H utilizes a mechanical pump shaft seal that is a double lip seal. This seal was
chosen because of its performance and ability to survive losses of suction, and still deliver water at rated
capacity even when damaged. While the seal will require replacement after hundreds of hours of operation
(the seal is a normal wear item in pumps), its ability to operate in a damaged condition makes it a better
choice than other mechanical seal designs.
Stainless steel and other marine grade alloys have been used in the construction and assembly of the
Darley 2BE6.5H pump. The pump features an integrated discharge check valve that aids in priming and
operating the unit. If the unit is stopped while dewatering, the pump will remain primed as long as the suction
hose strainer is submerged. The manual, positive-displacement priming pump provides quick and easy
priming in less than a minute at a 12’ suction lift.
The 6.5 horsepower GX-200 Honda engine is commercially available at local engine shops. The
engine incorporates overhead valve technology and reduced maintenance features. A quick disconnect fuel
fitting provides for rapid and easy fuel tank changing without stopping the engine. Testing has proven the
engine to be easy to start and operate, even after extensive environmental exposure. Most of the maintenance
on the engine is condition based instead of time or interval based, which minimizes preventive maintenance.
Notice:
The wire that typically connects the low oil level
float to the engine ignition has been intentionally disabled
to prevent the engine from cutting out or stalling in rough
water.
This wire is to
be removed,
as shown here

Prepared by: TED Rev. #: 13
Approved by: MCR 315May2006
© W.S. Darley & Co. 1200569.doc

Prepared by: TED Rev. #: 13
Approved by: MCR 415May2006
© W.S. Darley & Co. 1200569.doc
Operating and Maintenance Instructions For
Darley
Model 2BE6.5H Portable Pump
Quick Start Instructions
WARNING: DO NOT USE THIS PUMP BELOW
DECKS OR IN CONFINED SPACES
WARNING: THIS PUMP IS NOT TO BE USED TO
PUMP FLAMMABLE LIQUIDS
DANGER: CONTENTS OF THE FUEL CAN ARE FLAMMABLE OR
COMBUSTIBLE VAPORS CAN EXPLODE. HARMFUL IF SWALLOWED.
If swallowed, do not induce vomiting, call physician.
Keep out of reach of children.
Avoid prolonged breathing vapors.
Do not siphon by mouth.
Do not refill or store in vehicle, aircraft or living space.
Store and use in a well-ventilated area.
Vapors can be ignited by a spark or flame source. Keep away from flame, pilot
lights, stoves, heaters, electric motors, and other sources of ignition.
Keep container closed when in use.
Fill without spilling.
Before Initial Use:
- Spray suction and discharge fitting grooves with a dry film silicone lubricant spray.
- Spray the suction and discharge hose fitting cams with a dry film silicone lubricant spray.
Starting and Operating the Pump:
1. Connect the fuel hose from the engine to the fuel tank fitting.
2. Connect the suction hose to the pump and lower the suction hose into the water, ensuring the suction hose
strainer is completely submerged.
3. Connect the discharge hose to the pump and position the hose to discharge overboard. Secure the end of
the hose to prevent it from moving.
4. Turn the engine ignition clockwise to the “ON” position.
5. Open the fuel valve on the engine by pushing it to the right to the “ON” position.
6. Move the choke lever left to the "CHOKE" position.
7. Set the throttle about 1/3 open.
8. Prime the pump by briskly cycling the hand primer handle in and out until water is discharged from the
hand primer cylinder cap (see also the “Priming and Starting the Pump” on page 7).
9. Start the engine using the recoil starter.
10. Shut off the choke.
11. Check the discharge flow. If no flow, operate the hand primer until water is flowing from the
discharge hose.
WARNING: This pump is equipped with a mechanical lip seal. Avoid
running the pump dry or at high speed if there is no discharge
water. If there is no discharge flow after two minutes, shut
down the engine and check for leaks in the suction hose.

Prepared by: TED Rev. #: 13
Approved by: MCR 515May2006
© W.S. Darley & Co. 1200569.doc
12. Once the pump is primed and discharging water, slowly opening the engine throttle, by pushing the
throttle lever to the left until full throttle position, increases the pump’s discharge flow capability.
Shutting Down and Stowing the Pump:
1. Return the throttle to the “IDLE” position.
2. Close the fuel valve by pushing it to the left to the “OFF” position.
3. Shut down the engine by turning the ignition switch counter clockwise to the “OFF” position.
4. Disconnect the suction and discharge hoses.
5. Tip the unit toward the pump’s discharge to drain the water. After all water is drained, return the pump to
its normal upright position.
6. Operate the primer a few times to purge it of water.
7. Flush the pump with fresh water and operate the hand primer.
8. Tip the unit toward the pump’s discharge to drain the water. After all water is drained, return the pump to
its normal upright position.
9. Operate the primer a few times to purge it of water.
10. Check the engine oil and engine fuel levels and add as necessary to prepare the unit for its next use.
11. Flush and drain the hoses; coil for restowing.
12. Spray the interior, exterior, and face of the pump’s discharge, suction inlet and impeller with a
silicone lubricant spray.
13. Allow the entire contents to dry before sealing it into the storage container.
14. Return unit to its ready state for its next usage.
15. Restow the pump unit and hoses in the pump kit container.
WARNING: If any problems with the pump are encountered during or after
operation, do not repack the pump. Notify maintenance
personnel of any problems encountered during or after
operations.
Read and Understand the Honda GX200 Engine’s Owner’s Manual Before Operating This Unit

Prepared by: TED Rev. #: 13
Approved by: MCR 615May2006
© W.S. Darley & Co. 1200569.doc
Switching Fuel Tanks While The Engine Is Running:
DANGER: CONTENTS OF THE FUEL CAN ARE FLAMMABLE OR
COMBUSTIBLE VAPORS CAN EXPLODE. HARMFUL IF SWALLOWED.
If swallowed, do not induce vomiting, call physician.
Keep out of reach of children.
Avoid prolonged breathing vapors.
Do not siphon by mouth.
Do not refill or store in vehicle, aircraft or living space.
Store and use in a well-ventilated area.
Vapors can be ignited by a spark or flame source. Keep away from flame, pilot
lights, stoves, heaters, electric motors, and other sources of ignition.
Keep container closed when in use.
Fill without spilling.
1. Have a fuel can filled with 86 octane or higher gasoline close by, ready to be installed.
WARNING: Keep all fuel cans and gasoline away from the exhaust muffler and the path of the exhaust,
to avoid possible combustion.
2. Disconnect the two fuel tank retaining straps.
3. NOTE: After this step you will have approximately 30 seconds to do steps 4 and 5 before the engine
stops.
Disconnect the fuel line from the spent fuel can by pressing the metal tab on the female quick disconnect
on the fuel can and pull out on the male fitting on the fuel line.
4. Replace the spent fuel can with the full fuel can so that the end of the fuel can with the fuel fitting is
closest to the throttle.
5. Connect the fuel line to the full fuel tank by pushing the male quick disconnect on the fuel line into the
female quick disconnect on the fuel tank.
6. Reconnect the two fuel tank retaining straps.
NOTE: For optimal engine performance and engine life, always use strained or filtered
gasoline with an octane rating of 86 or higher.
NOTE: The fuel tank contains adequate fuel for four hours of run time.

Prepared by: TED Rev. #: 13
Approved by: MCR 715May2006
© W.S. Darley & Co. 1200569.doc
Preparation for Priming
•If not already connected, connect the fuel hose from the engine to the fuel tank fitting.
To connect the fuel hose:
-Slide the male fuel fitting on the fuel hose, into the female fuel fitting on the fuel tank. The lock will be
seated in the groove in the fitting on the hose when fully engaged.
•Open the fuel valve by pushing the black fuel valve lever to the right to the “ON” position. The fuel valve
lever is the black lever located lowest on the engine’s carburetor assembly.
•Connect the suction hose to the pump. Latch the couplings by pushing the coupling’s handles towards the
hose until the handles are against the coupling.
•Be certain that the suction hose is absolutely airtight. The pump will not lift water if the suction side of the
pump has the slightest air leak.
•A strainer with openings not larger than 1/4 inch must always be used on the end of the suction hose to
avoid sucking debris into the pump. Debris can clog the impeller and cause the pump to not work.
•Avoid air traps in suction hose if possible.
•If pumping from a shallow water source, stream, or pond, keep the suction intake strainer well above the
bottom to prevent sucking up soil and other foreign matter. If the strainer must lie on the bottom, a metal
plate or pan should be laid under it.
•The suction intake should be several inches below the surface of the water to prevent sucking in air. A hard
flat object laid over the top of strainer like a cover will allow the pump to operate in shallow water.
•Connect the discharge hose to the pump and position the hose to discharge overboard. Secure the end of the
hose to prevent it from moving.
•This unit is designed to achieve optimal performance with 3” suction and discharge hoses, however any size
of suction and discharge hose may be used, depending on the volume of water required.
•Turn the engine ignition switch clockwise to the “ON” position. The engine ignition switch is the red
switch located below the fuel tank bracket on the same side of the engine as the hand primer.
•If the engine is cold, it may be necessary to use the choke to get the engine started. Pushing the choke lever
to the left will “CHOKE” the engine. The choke lever is the gray colored, middle lever on the carburetor
assembly.
•Set the engine throttle lever at about 1/3 open, or in the “START” position by pushing it from the far right
to the left about 3/4 of an inch. The throttle is the largest of the three levers and located highest on the
carburetor assembly.
•Do not start the engine until everything is ready for pumping, with the hose couplings properly latched, the
fuel line connected, fuel valve turned on, ignition switch turned on, and the pump primed.

Prepared by: TED Rev. #: 13
Approved by: MCR 815May2006
© W.S. Darley & Co. 1200569.doc
Priming and Starting The Pump
After the pump is prepared:
1.Prime the pump by briskly cycling the primer in and out. This is done by quickly pulling the hand primer
handle out and pushing it back in many times until water comes out the hand primer cylinder cap. The hand
primer is the tubular device attached to the right side of the fuel tank bracket when looking at the engine
from the recoil end. [Note: The approximate priming time will vary between 10 and 60 seconds depending
upon size and length of suction hose, height above water source, and hand primer cycle rate.]
2.Start the engine by pulling the recoil starter rope fast and hard. It may require more than one pull to start
the engine. If the recoil starter is broken, or breaks before the engine starts, see “Emergency Starting with
a Broken Recoil Starter.”
Note: The ignition and fuel valve must be in the “ON” position.
3.Run engine at about 1/2 open throttle position and shut the choke off by pushing the choke lever all the way
to the right.
4.The pump should now be pumping water; if it is not, cycle hand primer a few more times until discharging
begins.
5.Once the pump is primed and discharging water, slowly open the engine throttle to the “FULL OPEN”
position by pushing the throttle lever to the left. The engine can be run at less than full throttle if desired
for reduced discharge flow rates.
Emergency Starting with a Broken Recoil Starter
1.Once the engine is prepared for starting, remove the three thumbscrews that hold the recoil starter to the
engine.
2.Remove the recoil starter. With the recoil starter removed, the flywheel and starter sheave will be exposed.
3.Place the knot of the spare starter rope in the notch in the flywheel starter sheave.
4.Wrap the spare starter rope clockwise around the flywheel starter sheave.
5.Keeping hands, feet, loose clothing, jewelry, etc. away from exposed flywheel, sheave, and all other
moving parts; pull fast and hard on the spare starter rope to turn the engine flywheel quickly.
NOTE: It may be necessary to repeat this procedure a few times, until the engine starts.
WARNING: With recoil starter removed, the flywheel is exposed.
Extra care must be taken by the operator to avoid
being caught and injured by moving parts!
Emergency Shutdown
In case of an emergency, the spark plug cap incorporates a handle which is to be used to pull the spark plug
cap off the spark plug to shut the unit down.
Other alternative means for shutting down the engine include closing the fuel valve or disconnecting the fuel
line. The engine will shut down in approximately 30 seconds.

Prepared by: TED Rev. #: 13
Approved by: MCR 915May2006
© W.S. Darley & Co. 1200569.doc
Running and Maintaining the Pump and Engine
•Read and understand the Honda GX200 Engine’s Owner’s Manual supplied by Honda.
•The fuel hose from the engine to the fuel tank fitting must be connected.
To connect the fuel hose:
-Slide the male fuel fitting, on the fuel hose, into the female fuel fitting on the fuel tank until the metal lock
is seated in the groove in the fitting on the hose.
To Disconnect the fuel hose:
-Squeeze and hold the metal fitting lock button on the fuel fitting on the fuel tank
-Pull the two halves of the fuel fitting apart.
-Release the metal lock button.
•The fuel valve must be open, or in the “ON” position to run.
•The engine ignition must be in the “ON” position to run.
•Start the engine with the throttle about 1/3 open.
•Never run the pump at high speeds at any time unless it is discharging water.
•Once the pump is discharging water, to increase the flow of water from the discharge, slowly open the
engine throttle, until the throttle is “FULL OPEN”, by pushing the throttle to the left.
•The engine requires the use of unleaded gasoline with an octane rating of 86 or higher.
•Automotive 4 stroke SAE 10W-30 detergent oil is recommended for the engine for general operation. See
the Honda GX200 Engine Owner’s Manual for oil recommendations for adverse operating conditions.
•Check the engine oil level prior to each use. Add oil as necessary.
•Change the engine oil after the first 20 hours; then every 100 hours, or 6 months thereafter.
•Replace the inline fuel filter after the first 20 hours; then every 100 hours, or 6 months thereafter.
•Clean the carburetor sediment cup during every oil change, or more frequently if necessary. The carburetor
sediment cup is the smaller cup, located directly below the fuel valve.
•Check the air filter for cleanliness prior to each use. Clean or replace every 100 hours or as needed.
•Clean and readjust the spark plug every 100 hours.
•Recommended spark plug is an NGK # BPR6ES or equivalent.
•The spark plug electrode gap should be .028-.031 in. (.70-.80mm).
•After each use, return the pump unit to its ready state so that it is prepared for the next emergency.
•Check engine oil level and add as necessary.
•Refill the fuel tank.
•Check the air cleaner for cleanliness and clean or replace if necessary.
•For more in-depth engine operation and maintenance, refer to the Honda GX200 Engine Owner’s Manual
supplied by Honda.
•After each use in salt or brackish water, the pump and primer must be flushed with fresh water.
•After each use, (and after flushing), drain the pump by tipping the unit toward the pump’s discharge. After
all water is drained, return the pump to its normal upright position.
•Flush and drain the hoses, and coil for restowing after each use.
•Spray the pump’s discharge, inlet, and impeller with silicone lubricant spray.
•Spray the fitting cams of the suction and discharge hoses with silicone lubricant spray.
•Allow the entire contents to dry before sealing it into the storage container.
IF FURTHER INFORMATION IS NEEDED, CALL W.S. DARLEY & CO. IN
CHIPPEWA FALLS, WI. AT 800-634-7812 or 715-726-2650

Prepared by: TED Rev. #: 13
Approved by: MCR 10 15May2006
© W.S. Darley & Co. 1200569.doc
Pump and Engine Quick Reference Information and Preventative Maintenance Guide
Type Unleaded gasoline with octane rating of 86 or higherFuel
Capacity 3 Gallons (4 hours of run time)
Type SAE 10W-30Engine Oil
Capacity .63 US qt
Idle speed 1400 rpmCarburetor
High speed 3900 rpm +200/-150
Type NGK BPR6ESSpark plug
Gap 0.028-0.031 in (0.70-0.80 mm)
Check engine oil level
Add if necessary
Before each use
Check air filter
Clean if necessary
Flush the pump with fresh water
Flush the primer with fresh water
Drain the pump
Purge the primer
Flush, drain, and coil hoses for restowing
Spray interior, exterior, and face of the pump discharge with
silicone lubricant spray
Spray interior, exterior, and face of the pump inlet & impeller with
silicone lubricant spray
Spray fitting cams of suction and discharge hoses with silicone
lubricant spray.
Check the fuel fitting o’ring, and replace if damaged
Allow entire contents to dry before sealing into storage container.
After each use
Refill fuel tank
Change engine oilFirst 20 hours
Replace the inline fuel filter
Change engine oil
Replace the inline fuel filter
Clean carburetor sediment cup
Clean or replace air cleaner
Clean and readjust sparkplug
Every 100 hours
or every 6 months
Lube primer cup and stem with silicone based or marine grade
grease
Replace paper air filter element
Replace spark plug
Check idle speed and adjust if necessary
Check and adjust valve clearance
Maintenance
Every 300 hours
or every 1 year
Clean fuel tank

Prepared by: TED Rev. #: 13
Approved by: MCR 11 15May2006
© W.S. Darley & Co. 1200569.doc
Packing The Pump Unit
& Accessories Into
The Kit Container
Note: The entire contents of the kit container are to be dry before sealing the kit container.
1. Perform all applicable maintenance to the pump unit.
2. Open two open plastic bags into the kit container – one inside the other.
3. The 20’ discharge hose must be rolled into a coil approximately 8 to 12 inches long when pressed flat. The
coupling will need to be on the outside of the coil.
4. The discharge hose, along with two desiccant bags, are then laid into the kit container, inside the two plastic bags,
so when pressed against the side farthest from you, the bulk of the hose is about half way between the kit container
handles, along the outer edge. The coupling will be laid out to rest directly under the kit container handle to the left.
5. Tie the emergency start rope to the lifting area of the roll base.
6. The pump unit is set into the plastic bags so that the fuel tank is above the bulk of the discharge hose and the
discharge hose coupling is directly under the suction inlet of the pump. The pump unit holds the discharge hose to
the side, but does not rest on it, as shown in the picture above. Secure the inner plastic bag with rubber band, or
light twine. (Note: the plastic bags have been omitted from these pictures for clarity.)
7. The suction strainer on the 15’ suction hose is inserted between the kit container, and the pump unit
discharge, and exhaust shield!
8. Pushing the suction hose down as far as it will go between the kit container and the fuel tank, the suction hose is
coiled around the inside of the kit container, as shown in the photo above. Approximately 2 raps of suction hose
will fit along side the fuel tank, one on top of the other.

Prepared by: TED Rev. #: 13
Approved by: MCR 12 15May2006
© W.S. Darley & Co. 1200569.doc
9. Continue coiling the suction hose as shown above. The coupling will fit into the center of the kit container as
shown.
10. Secure the outer plastic bag with rubber band, or light twine.
11. The flashlight, and laminated instruction card lay on top of the outer plastic bag so that they do not interfere with
the kit container cover, as shown above.
12. Install the kit container cover and locking ring.

Prepared by: TED Rev. #: 13
Approved by: MCR 13 15May2006
© W.S. Darley & Co. 1200569.doc
Unpacking The Pump Unit
& Accessories From
The Kit Container
1. Remove the kit container locking ring and cover.
2. Remove the flashlight, and laminated instruction card from the kit container.
3. Open the outer plastic bag.
4. Grab the suction hose by the coupling, and pull it out until all that is left in the kit container is that which was
inserted under the engine’s exhaust.
5. Lift the pump unit out of the kit container. This will bring the remainder of the suction hose out of the kit container.
6. Open the inner plastic bag.
7. Remove the discharge hose from the plastic bag.