Hypro L-1512 User manual

PowerPro Gasoline Engines
Operation, Repair, and Parts Manual
Form L-1512
(9-07)
PowerPro Model Number 160, 200, 270 and 390
HY160 (5.5 hp) - 2541-0043 (3/4” keyed shaft)
2541-0044 (5/8” threaded shaft)
HY200 (6.5 hp) - 2541-0045 (3/4” keyed shaft)
2541-0046 (5/8” threaded shaft)
HY270 (9.0 hp) - 2541-0047 (1” keyed shaft)
HY390 (13.0 hp) - 2541-0048 (1” keyed shaft)
2541-0049 (1” 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.

ENGINE SAFETY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
COMPONENTS & CONTROL LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
CHECK BEFORE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
STORAGE/TRANSPORTATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
TECHNICAL & CONSUMER INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
ENGINE REPLACEMENT PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
WIRING DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
OPTIONAL PARTS – BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
READ THIS OWNER’S MANUAL CAREFULLY. Pay special attention to these symbols and any
instructions that follow:
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.
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.
Gives helpful information.
Table of Contents

3
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
•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.
•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.
•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. 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
•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.
•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.
Engine Safety Information

4
Components & Control Locations

5
Fuel Valve Lever
The fuel valve opens and closes the passage
between the fuel tank and the carburetor. The fuel
valve lever must be in the ON position for the
engine to run. When the engine is not in use, leave
the fuel valve lever in the OFF position to prevent
carburetor flooding and to reduce the possibility of
fuel leakage.
Throttle Lever
The throttle lever controls engine speed. Moving
the throttle lever in the directions (shown below)
makes the engine run faster or slower.
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.
Choke Lever
The choke lever opens and closes the choke valve
in the carburetor. The CLOSE position enriches the
fuel mixture for starting a cold engine. The OPEN
position provides the correct fuel mixture for opera-
tion after starting and for restarting a warm engine.
Some engine applications use a remotely-mounted
choke control rather than the engine-mounted
choke lever shown here.
Recoil Starter Grip
Pulling the starter grip operates the recoil starter to
crank the engine.
Controls

6
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.
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
•Look around and underneath the engine for signs
of oil or gasoline leaks.
•Remove any excessive dirt or debris, especially
around the muffler and recoil starter.
•Look for signs of damage.
•Check that all shields and covers are in place,
and all nuts, bolts, and screws are tightened.
Check the Engine
•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.
•Check the air filter. A dirty air filter will restrict air
flow to the carburetor, reducing engine perform-
ance.
•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 procedures that should be followed before
engine startup.
Check Before Operation

7
SAFE OPERATING PRECAUTIONS
Before operating the engine for the first time,
please review the IMPORTANT SAFETY
INFORMATION and the section titled BEFORE
OPERATION.
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.
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.
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.
4. Turn the engine switch to the ON position.
5. Operate the starter.
RECOIL STARTER (all engine types):
Pull the starter grip lightly until you feel resistance,
then pull briskly.
Return the starter 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.
Operation

8
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.
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.
2. Turn the engine switch to the OFF position.
3. Turn the fuel valve lever to the OFF position.
Operation

9
THE IMPORTANCE OF MAINTENANCE
Good maintenance is essential for safe, economi-
cal, and trouble-free operation. It will also help
reduce air pollution.
Improperly maintaining this engine, or failure to
correct a problem before operation, can cause
amalfunction 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 care 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.)
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
•Make sure the engine is off before you begin any
maintenance or repairs. This will eliminate several
potential hazards:
•Carbon monoxide poisoning from engine
exhaust. Be sure there is adequate ventilation
whenever you operate the engine.
•Burns from hot parts. Let the engine and
exhaust system cool before touching.
•Injury from moving parts. Do not run the
engine unless instructed to do so.
•Read the instructions before you begin, and make
sure you have the tools and skills required to per-
form the maintenance.
•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

10
REFUELING
Part Number HP Fuel Tank Capacity
2541-0043 5.5 3.6 L 0.95 Gal
2541-0044
2541-0045 6.5
2541-0046
2541-0047 9 6.0 L 1.6 Gal
2541-0048 13 6.5 L 1.7 Gal
2541-0049
2541-0050
2541-0051
With the engine stopped, remove the fuel tank cap
and check the fuel level. Refill the tank if the fuel
level is low.
Gasoline is highly flammable and explosive.
You can be burned or seriously injured when
handling fuel.
•Stop the engine and keep heat, sparks and
flame away.
•Handle fuel only outdoors.
•Wipe up spills immediately.
Refuel in a well-ventilated area before starting the
engine. If the engine has been running, allow it to
cool. Refuel carefully to avoid spilling fuel. Do not
fill above the fuel strainer shoulder. After refueling,
tighten the fuel tank cap securely.
Never refuel the engine inside a building where
gasoline fumes may reach flames or sparks. Keep
gasoline away from appliance pilot lights, barbe-
cues, electric appliances, power tools, etc.
Maintenance
MAINTENANCE SCHEDULE
REGULAR SERVICE PERIOD First Every Every Every
Performed at every indicated month or Each month 3 months 6 months year
operating hour interval, whichever comes first. use or or or or
Item 20 hours 50 hours 100 hours 300 hours
• Engine oil Check level °
Change ° °
• Air cleaner Check °
Clean °(1)
Replace °†
• Sediment cup Clean °
• Spark plug Check-Clean °
Replace °
Spark arrester Clean
(optional parts) °
• Idle speed Check-Adjust °(2)
• Valve clearance Check-Adjust °(2)
• Fuel tank and strainer Clean °(2)
• Combustion chamber Clean After every 300 Hrs. (2)
• Fuel line Check Every 2 years (Replace if necessary) (2)
•Emission-related items. † 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.