Hypro 1542A-SP Series Use and care manual

Series 1542A-SP, 1543A-SP & 1543A-TSP
Gas Engine-Driven, Self-Priming
Centrifugal Pump
General Safety Information
Description
Installation, Operation, Repair and Parts Manual
Form L-1515
(12/07)
Hypro Self-Priming Centrifugal Pumps handle big, high-
capacity, liquid transfer jobs with ease. Use them for
transferring water, liquid fertilizers, and other chemicals
compatible with pump materials. Make short work of other
farm jobs: filling nurse tanks, watering seedbeds, and
transferring liquids. This self-priming model makes it ideal
for de-watering applications.
1542A-SP
Close-Coupled, Gas Engine-Driven
Self-Priming Centrifugal Pump
Max Flow Rate: ............................147 GPM
Max. Pressure: ................................50 PSI
Max. Total Head ..............................115 FT.
Max. Suction Lift: ..............................28 FT.
Ports: ........................................2" BSP Inlet
2" BSP Outlet
Engine ............................PowerPro™5.5 HP
1543A-SP
Close-Coupled, Gas Engine-Driven
Self-Priming Centrifugal Pump
Max Flow Rate: ............................259 GPM
Max. Pressure: ................................43 PSI
Max. Total Head ..............................100 FT.
Max. Suction Lift: ..............................28 FT.
Ports: ........................................3" BSP Inlet
3" BSP Outlet
Engine ............................PowerPro™6.5 HP
1543A-TSP
Close-Coupled, Gas Engine-Driven
Self-Priming Centrifugal Trash Pump
Max Flow Rate: ..........................272 GPM
Max. Pressure: ..............................50 PSI,
Max. Total Head ..............................115 FT.
Max Suction Lift: ..............................28 FT.
Ports:........................................3" BSP Inlet
3" BSP Outlet
Engine............................PowerPro™6.5 HP
Max dia. ........................................1” solids
WARNING: Do not pump flammable or explosive fluids
such as gasoline, fuel oil, kerosene, etc. Do not use in
explosive atmospheres. The pump should be used only
with liquids that are compatible with the pump
component materials. Failure to follow this warning
can result in personal injury and/or property damage
and will void the product warranty.
1. DO NOT EXCEED recommended speed, pressure and
temperature (140˚ F) for pump and equipment being
used.
2. BEFORE SERVICING, drain all liquids from the system
and flush. Remove the spark plug wire from the spark
plug before servicing the pump or engine.
3. Secure the discharge lines before starting the pump.
An unsecured line may whip, causing personal injury
and/or property damage.
4. Check hose for weak or worn condition before each
use. Make certain that all connections are tight and
secure.
5. Periodically inspect the pump and the system
components. Perform routine maintenance as required
(see Maintenance section).
6. Protect pump from freezing conditions by draining
liquid and pumping a permanent-type automobile
antifreeze containing a rust inhibitor through the
system, coating the pump interior. A 50% mixture with
water is recommended.
7. Do not operate a gasoline engine in an enclosed area.
Be sure the area is well ventilated.
WARNING: Gasoline is a highly combustible fuel. The
improper use, handling, or storage of gasoline can be
dangerous. Never touch or fill a hot engine.
8. Use only pipe, hose and fittings rated for the maximum
psi rating of the pump.
9. Do not use these pumps for pumping water or other
liquids for human or animal consumption.

Plumbing Installation
Hazardous Substance Alert
2
Preparations before Starting the Engine
1. Fuel: Check fuel level in tank. Do not over fill tank. Use
fresh, clean automotive fuel. Note: DO NOT FILL
FUEL TANK WHEN ENGINE IS RUNNING.
2. Engine Oil: Before checking or refilling with engine oil,
make sure the engine is stopped and placed on a
stable, level surface. Use oil recommended for ambient
air temperatures that the engine will be running at. See
chart below. Change oil according to manufacturer’s
recommendation. (Once after the first 20 hours and
every 100 hours thereafter.)
Air Temperature Single-grade Oil
85° F #40W
60° F #30W
32° F #20W
3. Priming Water: IMPORTANT: PUMP MUST NOT BE
RUN DRY. On self-priming pumps, only the chamber
needs to be filled with liquid. The pump must not run
unless the priming chamber is completely filled with
liquid because there is a danger of damaging the
mechanical seal, which depends on the liquid for its
lubrication.
Self-priming models can be primed by removing the filler
cap, located at the top of the pump where the discharge
line is mounted to the pump, and filling the priming
chamber with liquid. The priming chamber will fill to the
level of the inlet port. After use, the priming chamber
should be flushed and drained to avoid chemical
corrosion and damage from freezing. Drain by removing
the lower drain plug located at the bottom of the casing.
Starting the Pump
IMPORTANT: Before starting engine, be sure the prim-
ing chamber is filled with liquid and the discharge
hose is secure.
1. Turn engine switch located by recoil starter to ON
position.
2. Turn the fuel cock to ON.
3. Push the throttle lever to a slightly open position.
4. Operation of choke lever.
When engine is cold:
In cold weather,start engine with choke in fully
closed position.
In warm weather, start engine with choke in half-
closed position.
When engine is warm:
Start engine with choke in fully open position.
5. Start engine by pulling recoil starter out quickly and
forcefully. Repeat pulling until the engine starts.
Operation of the Pump
1. Idle the engine for 3 to 5 minutes to warm it up.
2. Open the throttle lever to the upper zone after engine
has warmed up.
3. Once the pump has primed, you will note a load on the
engine; adjust rpms to proper speed for your pumping
application.
Please Note: It is illegal to ship or transport any
hazardous chemicals without United States
Environmental Protection Agency Licensing.
1. Always drain and flush pumps before servicing or
disassembling for any reason.
2. Before returning unit for repair, drain out all liquids and
flush unit with neutralizing liquid. Then, drain the pump.
Attach a tag or include a written notice certifying that
this has been done.
3. Never store pumps containing hazardous chemicals.
Preliminary to Mounting
Before setting up the pump for operation, check to see that
the motor and pump turn freely by hand. If it cannot be turned
over by pulling on the recoil starter, open casing to check for
obstructions lodged in pump.
Selecting the Suction Line
To get full capacity of the pump, the suction line should be the
same size as the pump suction port. If suction hose is longer
than approximately 6 feet, use next size larger hose. The
suction line must be free of air leaks. All joints and
connections of the suction line must be tightened securely so
that no additional air may enter the suction side through a
loose connection. Use a good grade of suction hose that will
not collapse.
Basket Strainer
The basket strainer supplied with this pump
is to be used when transferring solutions
that may contain debris and solids which
could become lodged in the pump or
damage the impeller. Because of the high
flow capacity of this pump, unknown debris
could be siphoned off the bottom of the tank. Install the
strainer on the suction side of the pump whenever possible to
avoid pump damage.
Operation and Maintenance

Operation and Maintenance
(Operation and Maintenance Continued)
Always flush pump with water or neutralizing agent
before servicing.
Pump Housing Disassembly
For this pump model, seal replacement requires that the
pump be fully removed from the engine. Observe carefully
the disassembly process, (orientation and order of part
assembly) to ensure an easy assembly process.
1. Pull spark plug wire off spark plug for safety
considerations. Remove the four bolts holding the
casing to the casing cover and frame using a 14mm
socket wrench. Tap pump casing on the discharge port
with a rubber hammer, if necessary, to break it loose
from the casing cover. Check inside pump casing. If
badly eroded or damaged, pump casing should be
replaced. Remove O-rings from casing cover and volute.
2. Remove volute and inspect for wear. Replace if eroded.
3. Remove impeller by turning it counterclockwise using a
socket and impact wrench. If an impact wrench is not
available, it may be necessary to hold the crankshaft
from turning. To keep the crankshaft from turning during
disassembly, remove the three bolts holding the recoil
starter using a 10mm socket wrench. Then, using a
pipe wrench or another tool, hold the starter hub and
spin the impeller off. Look for shims that may be
present between the impeller and shaft. This shim is for
obtaining the proper clearance between the impeller
and volute. Be careful not to damage the starter hub
while gripping it with the wrench.
4. Between the impeller and casing cover is the
mechanical seal. On the backside of the impeller is the
seal’s ceramic seat. If either part of the seal is
damaged, with cracked or scuffed surfaces, the seal
will fail to perform satisfactory and will leak. To remove
the seal seat from the impeller, use a small blade
screwdriver and wedge the seal seat out and discard.
To remove the mechanical seal, it is necessary to first
remove the casing cover by removing the four bolts
holding it to the engine, using 13mm socket wrench.
Stopping the Pump
1. Stop pump for a short time:
Run engine throttled all the way down (fully to the right).
Turn engine switch to OFF position.
2. Stopping pump for storage:
Turn fuel cock to OFF position instead of turning the
engine switch off.
Let the engine idle for 2 to 3 minutes until fuel in
carburetor is depleted and engine stops. If a valve is
installed on the discharge hose, you may run pump
with valve closed during this procedure.
Note: Pump must not be run dry. Make sure there is
water in the priming chamber.
Storage
1. Drain pump. Flush Pump after Use.
One of the most common causes for faulty pump
performance is gumming or corrosion inside the pump.
Flush the pump and entire system with a solution that
will chemically neutralize the liquid pumped. Mix
according to the manufacturer’s directions. This will
dissolve most residues remaining in the pump, leaving
the inside of the pump clean and ready for use.
To Prevent Corrosion:
After cleaning the pump as directed above, flush it with
permanent-type automotive antifreeze (Prestone,
Zerex, etc.) containing a rust inhibitor. Use a 50%
solution; half antifreeze and half water, or fill the pump
with FLUID FILM and drain it. A protective coating of
FLUID FILM will remain on the inner pump surfaces.
Save the excess FLUID FILM for the next application.
Plug ports to keep out air during storage. For short
periods of idleness, noncorrosive liquids may be left in
the pump, BUT AIR MUST BE KEPT OUT. Plug the
ports or seal port connections.
2. Drain all the fuel from the fuel tank, fuel lines, and filter.
3. Store pump in a clean, dry environment.
3
Repair Instructions

Repair Instructions
4
Note that these bolts have seal washers on them and
must not be damaged. From the backside of the casing
cover, press the mechanical seal out and discard it.
Clean-up of Pump Housing
If necessary, clean the pump casing, volute, and casing cover
using a solvent to remove debris and corrosion particles. Use
awire brush to further remove buildup of debris if it doesn’t
soak loose.
Seal Replacement and
Pump Housing Assembly
1. Apply a light bead of RTV sealant to the top edge of the
seal cavity on the casing cover.
2. Insert the stationary portion of the new mechanical seal
by carefully pushing only on the outer metal ring as you
press it into the casing cover. Use a tool with 1 1/2" ID,
such as a 1 1/2" PVC pipe, 4" long, that fits over the
carbon face of the seal, but pushes only on the metal ring
to insert the seal. Be careful to avoid scratching the seal’s
carbon surface.
3. Bolt casing cover on engine. Note the arrow and word UP
to indicate orientation of the casing cover. Use bolts with
washers on them. Install o-ring on casing cover; replace
with a new o-ring if necessary.
4. Lubricate the seal cavity of the impeller with WD-40,
LPS, or equivalent, and carefully press the seal’s
mating ceramic ring in place, seating it squarely on the
bottom of the cavity. IMPORTANT: MAKE SURE
BOTH OF THE SEAL’S SURFACES ARE CLEAN
AND LUBRICATED. NEVER RUN THE SEAL
SURFACES DRY.
5. Place the impeller on the shaft and spin it clockwise to
tighten it on the shaft. Secure the impeller using a
socket and wrench (see step 3 in Disassembly
Instructions for socket size).
6. It is now necessary to check the clearance between the
impeller and volute. As shown in the sketch below,
measure the inside depth of the volute case (distance A).
Then measure the distance from the casing cover to the
front edge of the impeller (distance B). The difference
between the two measurements should be between 0.024
and 0.036" or about 1/32" clearance. If the value is out
of range, remove the impeller and adjust by adding or
removing brass shims to achieve the correct amount of
clearance.
7. Place a new o-ring in the groove of the volute’s inlet if
necessary. Place the volute in place with the notch pointing
up so that it mates with the casing cover at the inlet port. It
may be necessary to tip the engine on its side for this
assembly.
8. Carefully set casing over volute and bolt casing onto casing
cover and frame. It may be necessary to tip the engine on
its side for this assembly.
9. Once assembly is complete, pull on engine recoil starter
with engine switch in OFF position to verify that the impeller
rotates smoothly without catching. Connect spark plug
wire. Assembly and inspection is now complete.
(Repair Instructions Continued)
A
B
Casing
Cover
Impeller
Volute
(A) – (B) = within 0.024 - 0.036 inches.

Troubleshooting
Symptom Probable Cause(s) Corrective Action(s)
No discharge Pump not priming Discharge line must be open for priming to
occur. If valve is installed, check that it is open.
Pump not priming Fill priming chamber with water.
Pump not priming Increase engine speed.
Low discharge Air leaks in suction line Check inlet fittings for leaks. Seal leaks.
Undersized or collapsed suction hose Suction inlet hose should be same diameter
as inlet port fitting. Check hose for kinks.
Blocked or clogged inlet Inspect basket strainer and clear any debris
from screen.
Impeller plugged Inspect and clear obstruction.
Fluid leaking from pump Mechanical seal failure Determine fluid is coming from weep holes
between pump and engine. Change out seal.
Crack in pump housing Check casing and casing cover for damage.
Engine doesn’t run Check oil & gas Refer to engine manual for troubleshooting
problem.
5 PSI 10 PSI 15 PSI 20 PSI 25 PSI 30 PSI 35 PSI 40 PSI 45 PSI 50 PSI
GPM GPM GPM GPM GPM GPM GPM GPM GPM GPM
147 144 136.6 124.7 110.2 94.1 78.3 57.1 19.2 0
Model 1542A-SP
5 PSI 10 PSI 15 PSI 20 PSI 25 PSI 30 PSI 35 PSI 40 PSI 45 PSI 50 PSI
GPM GPM GPM GPM GPM GPM GPM GPM GPM GPM
259 251.6 233.7 213.6 190.9 162.2 135.8 99.3 56.1 8.7
5 PSI 10 PSI 15 PSI 20 PSI 25 PSI 30 PSI 35 PSI 40 PSI 45 PSI 50 PSI
GPM GPM GPM GPM GPM GPM GPM GPM GPM GPM
272 269.8 241 207.6 179.3 140.4 98.1 50.7 5.4 0
Model 1543A-SP
Performance Data
Model 1543A-TSP
Performance Data is based on testing with water. Performance will vary with fluid density and/or viscosity.
5

6
Models 1542A-SP & 1543A-SP
Ref. Qty.
No. Req’d. Part No. Description
1ENGINE PowerPro™ 5.5 hp
112545-0085 Casing
2 1 2545-0086 Casing Cover
3 1 2545-0087 Impeller
412545-0088 Inner Casing
5 1 2545-0089 Discharge Port
6 1 2545-0090 Inlet Port
7 1 2120-0050 Mechanical Seal
8 1 2545-0091 O-ring
91 2545-0092 O-ring
10 12545-0093 Gasket
11 1 2545-0094 Check Valve
12 2 2545-0079 Plug
13 2 2545-0080 O-ring
14 4 2545-0095 Bolt
15 42545-0096 Washer
16 12 2545-0097 Bolt
Parts List for Model 1542A-SP
Ref. Qty.
No. Req’d. Part No. Description
1 ENGINE PowerPro™ 6.5 hp
11 2545-0098 Casing
2 1 2545-0099 Casing Cover
3 1 2545-0100 Impeller
4 1 2545-0101 Inner Casing
512545-0102 Discharge Port
612545-0103 Inlet Port
7 1 2120-0051 Mechanical Seal
8 1 2545-0091 O-ring
9 1 2545-0092 O-ring
10 1 2545-0106 Gasket
11 1 2545-0107 Check Valve
12 2 2545-0079 Plug
13 2 2545-0080 O-ring
14 42545-0095 Bolt
15 42545-0096 Washer
16 12 2545-0097 Bolt
Parts List for Model 1543A-SP

Model 1543A-TSP
7
Ref. Qty.
No. Req’d. Part No. Description
1 ENGINE PowerPro™ 6.5 hp
1 1 2545-0111 Casing Cover
2 4 2545-0112 O-ring
31 2120-0052 Mechanical Seal
442545-0113 Bolt
5 1 2545-0114 Impeller
6 1 2545-0115 O-ring
712545-0116 Inner Casing
8 1 2545-0117 O-ring
912545-0118 Check Valve
10 1 2545-0119 Casing
11 2 2545-0080 O-ring
12 2 2545-0079 Plug
13 62545-0120 O-ring
14 6 2545-0121 T-bolt
1
2
3
4
5
6
7
8
9
12
11
12
10
11
13
14

Limited Warranty on Hypro Pumps and Other Hypro Products
Hypro ("Hypro") warrants to the original purchaser of its products (the "Purchaser") that such products will be free from defects in material
and workmanship under normal use for the period of one (1) year for all products except: oil crankcase plunger pumps will be free from
defects in material and workmanship under normal use for the period of five (5) years, and accessories will be free from defects in material
and workmanship under normal use for the period of ninety (90) days. In addition, Hypro warrants to the
purchaser all forged brass pump manifolds will be free from defects in material and workmanship under normal use and from damage
resulting from environmental conditions for the life of the pump.
"Normal use" does not include use in excess of recommended maximum speeds, pressures, vacuums and temperatures, or use requiring
handling of fluids not compatible with component materials, as noted in Hypro product catalogs, technical literature, and instructions. This
warranty does not cover freight damage, freezing damage, normal wear and tear, or damage caused by misapplication, fault, negligence,
alterations, or repair that affects the performance or reliability of the product.
THIS WARRANTY IS EXCLUSIVE. HYPRO MAKES NO OTHER WARRANTY, EXPRESS OR IMPLIED, INCLUDING BUT NOT LIMITED
TO ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE.
Hypro’s obligation under this warranty is, at Hypro’s option, to either repair or replace the product 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.
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 pumps or products must be flushed of any chemical (ref. OSHA Section 0910.1200 (d)(e)(f)(g)(h) and hazardous chemicals must
be labeled before being shipped* to Hypro for service or warranty consideration. Hypro reserves the right to request a Material Safety
Data sheet from the Purchaser for any pump or product Hypro deems necessary. Hypro reserves the right to "disposition as scrap" pumps
or products returned which contain unknown substances, or to charge for any and all costs incurred for chemical testing and proper disposal
of components containing unknown substances. Hypro requests this in order to protect the environment and personnel from the hazards of
handling unknown substances.
For technical or application assistance, call the Hypro Technical/Application number: 1-800-445-8360. To obtain service or
warranty assistance, call the Hypro Service and Warranty number: 1-800-468-3428; or call the Hypro Service and Warranty
FAX: [phone].
Be prepared to give Hypro full details of the problem, including the following information:
1. Model number and the date and from whom you purchased your pump.
2. A brief description of the pump problem, including the following:
•Liquid pumped. State the pH and any non-soluble •Drive type (gas engine/electric motor; direct/belt drive;
materials, and give the generic or trade name. tractor PTO) and rpm of pump.
•T
emperature of the liquid and ambient environment.•Viscosity (of oil, or other than water weight liquid).
•Suction lift or vacuum (measured at the pump). •Elevation from the pump to the discharge point.
•Discharge pressure. •Size and material of suction and discharge line.
•Size, type, and mesh of the suction strainer.•Type of spray gun, orifice size, unloader/relief valve.
Hypro may request additional information, and may require a sketch to illustrate the problem.
Contact the factory to receive a return material authorization before sending the product. All pumps returned for warranty work should be
sent shipping charges prepaid to:
Hypro
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.
Printed in the USA
2007 Hypro