Idex HALE FYR-PAK Operating instructions

Failure to follow the operating, lubrication,
and maintenance requirements set forth in
the operating and instruction manual may
result in serious personal injury and/or dam-
age to equipment.
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FYR-PFYR-P
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MODEL NO._______________MODEL NO._______________
MODEL NO._______________MODEL NO._______________
MODEL NO._______________
SERIAL NO._______________SERIAL NO._______________
SERIAL NO._______________SERIAL NO._______________
SERIAL NO._______________
A Hale pump is a quality product; ruggedly designed, accurately ma-
chined, carefully assembled and thoroughly tested. In order to maintain
the high quality of your pump and to keep it in a ready condition, it is im-
portant to follow the instructions on care and operation. Proper use and
good preventive maintenance will lengthen the life of your pump.
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Class 1 Inc.  Fire Suppression Division
A Unit of IDEX Corporation
607 NW 27th Ave  Ocala, FL 34475
Phone: [phone]
www.class1.com
Hale Products Inc.  Fire Suppression Division
A Unit of IDEX Corporation
700 Spring Mill Ave.  Conshohocken, PA 19428
Phone: [phone]
www.haleproducts.com

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LIMITED WARRANTY
Hale Products Inc., here in referred to as “Hale,” warrants products of its manufacture to be free
from defects in material and workmanship, under normal use and service, for a period of one year
or 2000 hours of usage, whichever comes first. Products used for rental or contracting purposes
are warranted for a period of six months or 2000 hours of usage, whichever comes first. This
limited warranty is effective only if the equipment or apparatus is used as directed, is not subjected
to misuse, negligence or accident, and is not altered, treated or repaired by someone other than
Hale or its designee. Items not manufactured by Hale shall bear only the limited warranties offered
by their respective manufacturers. The exclusive remedy for breach of this warranty shall be to give
Hale written notice thereof and to request a Returned Goods Authorization. Upon receipt of the
Returned Goods Authorization, the buyer will return the nonconforming material to Hale F.O.B. its
plant within thirty days after the buyer has received the Returned Goods Authorization. Thereupon
Hale at its own election shall repair or replace the same or repay the price thereof. No proximate,
incidental, consequential or other damages shall be recoverable. Hale shall not be liable for
consequential damages or contingent liabilities including; but not limited to, loss of life, personal
injury, loss of crops, loss due to fire or water property damage, and consequential trade or other
commercial loss arising out of the failure of Manufacturer’s product.
HALE MAKES NO WARRANTIES OF FREEDOM FROM PATENT INFRINGEMENT, OF
MERCHANTABILITY OF FITNESS FOR A PARTICULAR PURPOSE OR ARISING FROM A
COURSE OF DEALING OR USAGE OF TRADE OR OTHER LIKE OR DIFFERENT EXPRESS
OR IMPLIED WARRANTIES EXCEPT AS MADE ABOVE.
Hale Products Inc.
A Unit of IDEX Corp.
Conshohocken, PA. 19428
NOTE: The Hale Fyr-pak is equipped with a United States Motor Power Inc., Power Bee Engine.
The engine is warranted by the manufacturer. Information on the engine should be referred to the
manufacturer or an authorized service center.

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WARNING LABEL IDENTIFICATION
The equipment described in this manual contains one or more of the following warning
labels. The following chart identifies the label and provides an explanation of the hazard
associated with the label.
HEARING PROTECTION REQUIRED WHEN OPERATING EQUIPMENT
EYE PROTECTION REQUIRED WHEN OPERATING EQUIPMENT
EQUIPMENT CONTAINS FLAMMABLE FUEL
CORROSIVE HAZARD
ROTATING COMPONENTS
HOT SURFACES
DANGER OF CARBON MONOXIDE POISONING WHEN EQUIPMENT
IS OPERATING
OPERATING EQUIPMENT PRESENTS A DRAW-IN HAZARD
ELECTRICAL SHOCK HAZARD

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SAFETY PRECAUTIONS
Failure to follow the operating, maintenance and lubrication requirements set forth In this operating and Instruction
manual may result in serious personnel injury and/or damage to equipment. These “WARNING” statements
indicate potentially hazardous conditions for operator or equipment.
TAKE NECESSARY STEPS TO PROTECT PERSONNEL AND EQUIPMENT.
1 Carefully read “Engine Operating Instructions,” (page 23) before attempting to operate, service, or
disassemble the engine or any of its parts.
2Warning - Gasoline is a highly combustible fuel. The Improper use, handling, or storage of gasoline can
be dangerous. Prevent accidents by following these safety rules:
A Use gasoline only as a fuel, never as a cleaning fluid.
B Use only an approved container to hold or store gasoline. Never store gasoline in familiar
containers such as milk containers or soda pop bottles.
C Store gasoline in a cool location, out of the reach of children. Never store gasoline near heat
or an open flame.
D Do not refuel with the engine running. Add fuel to a cool engine only. Spilled fuel on a hot
engine or muffler may cause a fire or an explosion. Fill fuel tank out-of-doors and wipe up any
spills.
E Make sure all fuel lines and connectors are secure.
F Provide a fire extinguisher nearby when working with gasoline. Be sure extinguisher Is In
operating condition; check the pressure gauge or indicator. Be familiar with its proper use.
Consult local fire department for the correct type of extinguisher for your application.
Extinguishers rated ABC by the NATIONAL FIRE PROTECTION ASSOCIATION are
appropriate for most applications.
G. POSITIVELY NO SMOKING!!
3DO NOT RUN THE ENGINE IN AN ENCLOSED AREA!! Exhaust fumes contain carbon monoxide that is an
odorless poisonous gas. If equipment is located in an enclosed area with an exhaust line to the outside,
regularly check the exhaust system for leaks. Be sure the area is well ventilated.
4 Do not operate equipment when mentally or physically fatigued.
5 Stay away from moving parts, avoid wearing loose jackets, shirts and ties.
6 Keep the equipment and surrounding area clean. Cluttered areas invite accidents. Remove all oil deposits f
from equipment and surrounding area. Accumulations of grease and oil may present a hazard.
7 All visitors should be kept at a safe distance from work area. Keep children away from equipment and
discharge hose. Do not allow children to hold discharge hose.
8 Be careful not to touch the exterior of a hot engine, especially the muffler and the surrounding area. The
engine is hot enough to be painful or cause injury.
9 Keep power shields and guards in place. Do not make adjustments and repairs while engine is running,
unless specified for in repairs. Use extreme caution around hot manifolds and moving parts.
10 Prevent accidental starting by always removing spark plug or by disconnecting and grounding spark plug wire
before working on engine or the equipment driven by engine.
11 Maximum speed of the engine is set. Do not tamper with the controls to adjust to run at higher speeds.
Excessive speed increases the hazard of personal injury and reduces engine life
12 Familiarize yourself with all controls, learn how to stop engine quickly In a emergency.
13 When shutting off a gasoline engine, be sure It is completely stopped before leaving the work area.

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14 For proper handling, storing and transporting fuel, follow fuel tank manufacturer’s instructions sheet and/or
instructions printed on tank
15 If tank is equipped with a closing vented cap, open when pumping
16 Check engine fuel level before Initial start-up each day.
17 Flush pump with fresh, clear water !f pump has been used to pump salt water or water containing sand.
18 During freezing weather, drain the pump, throttle actuator tubing, and discharge lines after each use.
19 The pump must be primed with the hand pump and the priming valve closed before starting engine
20 Do not operate the unit while it is being carried
21 Wear hearing protection when operating the unit.

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OPERATION AND INSTRUCTION MANUAL FOR ENGINE DRIVEN, BACKPACK
CENTRIFUGAL PUMPING UNIT
Introduction
PURPOSE
This operation and instruction manual is published to guide and assist in the installation, operation, lubrication,
maintenance, and repair of the Hale FYR PAK pumping unit. The installer and operator should understand this
manual before attempting to install or operate the unit.
IDENTIFICATION
Whenever a question arises regarding your pumping unit, contact your Hale Dealer for the latest available
information. This dealer will also be able to advise you of the nearest authorized engine dealer or refer to the
supplied list of engine distributors who can provide service for the engine in your pumping unit. Finally, if
additional help is needed, contact the Service Department of Hale Products Inc.
Please supply the complete pump model and serial numbers when requesting information or ordering parts.
The pump model and serial numbers are stamped (not cast) on the Hale nameplate or on top of the pump
head. For your convenience, fill in the information on the Hale nameplate below.
Also always mention both the model number and serial number of your engine when ordering engine parts.
These numbers are found on the engine identification plate attached to the engine.
To help identify the pump parts used in your FYR-PAK, a pump parts catalog is included toward the back of this
manual. To identify the engine parts used in your pumping unit refer to the engine manufacturer’s parts cata-
log.
DESCRIPTION
GENERAL
The FYR-PAK is a lightweight portable centrifugal pump mounted on a modern adjustable backpack frame. It
consists of a Hale Type 20FP single stage, centrifugal pump close coupled to an air-cooled, 2-cycle, single
cylinder, engine overspeed control switch, priming pump and priming valve. The unit will deliver discharge
pressures to 220 PSIG and flows to 75 GPM from draft
The FYR PAK pumping unit consists of 6 major subassemblies; the engine, pump, priming system, mounting
base, overspeed control switch and backpack frame.

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ENGINE
The lightweight engine is a single cylinder, two cycle, air-cooled version producing 8 hp (6 kW) from its
8.2 cu. inch (134 cc) displacement using a gasoline/oil fuel mixture. The engine is equipped with water
resistant solid state ignition, a pressure carburetor with built-in fuel pump, and an on/off ignition toggle
switch.
The engine’s interior is protected from impurities by the use of a wire mesh element air filer, a 75 micron
in-line fuel filler, and an integral fuel strainer built into the fuel pump.
PUMP
The engine crankshaft extension serves as the pump shaft with an enclosed type bronze impeller mounted
directly on the shaft. The shaft is protected against corrosion by a bronze sleeve, an “O”-ring, and a mechani-
cal type, self-lubricating and adjusting seal. The impeller is hydraulically sealed by a replaceable, patented
floating, bronze clearance ring located in the suction of the aluminum volute body. The volute body is attached
to the cast aluminum pump head by four mounting screws.
The pump head serves as the mounting bracket for the pump/engine assembly. It is attached to the
mounting base with rubber vibration shock mounts. It also incorporates a handle for positioning the unit
of carrying short distances.
The pump inlet and discharge connections are 1-1/2” male national fire hose threads (NHT/NST
adapters are supplied loose.)
PRIMING SYSTEM
The priming pump is a hand operated piston pump. Its purpose is to remove air from the pump allowing
atmospheric pressure to push water through the inlet hose into the pump. A priming valve is included which
controls air flow through the priming line.
MOUNTING BASE
The mounting base is an intermediate part to which the engine is attached with three shock vibration isolation
mounts. The base is attached to the backpack frame with four vinyl clad tubing clamps. The mounting base
has the overspeed control switch, priming pump mounting clamps and Hale nameplate attached to it.
OVERSPEED CONTROL
The overspeed switch control assembly is an added safeguard against overspeeding of the engine. The
overspeed switch is attached to the mounting base of the pumping unit below the carburetor. Attached to
the front of the overspeed switch is a flexible transparent hose that is connected to the nozzle plate
(riveted to the engine fan housing). Connected to the back of the overspeed switch are two wires one
goes to the engine’s ignition coil, the other goes to ground (engine). The switch senses the air pressure
generated by the engine’s cooling fan. When the engine reaches a speed in excess of that which would
normally occur the fan air pressure generated will be sufficient to cause the switch to close thereby
grounding the solid state ignition. The engine speed will then decrease until the air pressure reaches a
lower trip point, reactivating the ignition system and the engine will accelerate. The engine will decelerate
and accelerate alternately until the operating conditions are returned to their normal mode.
BACKPACK FRAME
The backpack frame serves as a convenient means for transporting the FYR PAK unit over long
distances. The backpack frame is of conventional design incorporating adjustable shoulder straps and
hip belt. The addition of a hip belt allows part of the weight to be carried on the hips.

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PREPARATION
INSPECTION OF NEW UNIT
When unpacking unit do not discard cushioning materials, carton, or case until you are certain everything is
correct. Inspect carefully, perfect condition of the outside shipping container does not guarantee undamaged
contents. Check for loose, missing, or damaged parts. Also, check the packing slip for any additional parts.
After inspection proves satisfactory, discard all shipping material in a proper manner.
ATTENTION: The FYR-PAK has been shipped with the engine, carburetor, air filler, and
fuel systems drained and tagged. Before using, fill with proper quantities and grades of
fuel oil, refer to “Fuel and Lubricant Specifications” .
The idle speed, idle and main fuel mixture adjustment screws have been factory set. However, the idle and
main fuel mixture adjustment screws may require readjustment, especially for cold weather or high altitudes
(see “Engine Operating Instructions,” page 30, for adjustment procedure).
IDENTIFICATION OF CONTROLS
(See plate numbers 692B, 1 of 2 and 2 of 2 in parts section for location of controls)
Air Cleaner: Low restriction cleanable expanded aluminum foil type element
Carburetor Fuel Strainer: Provides secondary fuel filtering for engine. Carrying Handle(s): Two are
molded into either side of float.
Carrying Handle: This is incorporated into the pump head
Choke: Reduces the amount of air entering the engine to correct the fuel-air ration for cold start-up.
Discharge Hose Connection: Located on the air cleaner side of the unit for connection a 1-1/2” NST
hose fitting (adapter shipped loose.)
Exhaust muffler: This is a spark arrested type that also reduces the amount of combustion noise
emitted by the engine.
Flexible Transparent Hose: Connected between the nozzle plate and the overspeed switch control.
Allows for visual inspection of dirt and water which may clog hose and reduce amount of pressure
reaching switch. Check regularly, be sure hose is not cracked, crimped, or kinked.
Fuel Line Connector: Connect the fuel line from the fuel caddie here.
Ignition Toggle Switch: When flipped to the “ON” position, opens circuit to ground allowing the
magneto to develop a spark for the ignition of combustion. Flipped to the “OFF” position, closed the
circuit to ground magneto.
In-Line Fuel Filter: Provides primary fuel filtering for engine.
Nozzle Plate: Riveted to the engine fan housing, directs air pressure to flexible, transparent hose and
overspeed control.
Overspeed Control: For description refer to “Description -Overspeed Control”
Priming Valve: For description refer to “Description - Priming System”, Page 2
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Priming Pump: For description refer to “Description - Priming System”, Page 2
Pump Inlet: Located at the end of the pump, fitted with 1-1/2” NST (NHT) male adapter (shipped loose.)
Starting Handle: Pull to start
TRANSPORTING
WARNING
Before transporting the FYR PAK, the fuel caddie MUST be disconnected from the engine and
the fuel drained as instructed under “STOPPING PROCEDURE,” Page 7. Also, allow engine
to cool.
The FYR PAK has a handle for moving and positioning the unit. Care should be taken not to drop or strike the
engine or pump as damage may result.
When transporting the unit by motor vehicle, care should be taken to fasten it down securely. Follow the
manufacturer’s instructions for transporting the fuel caddie.
When carrying the unit as a backpack, the hip belt and shoulder straps should be adjusted to satisfy the
individual.
There are two sets of holes in the frame for adjusting the hip belt.
The top end of the shoulder straps has four positions for attaching to the frame. Position the shoulder straps so
that they are horizontal from the shoulders to the fame by relocating the adjustment spacers.
INSTALLATION
1. Choose a suitable location, as near to the source of water as possible, to place the FYR PAK.
2. Attach hose. When operating from draft, the inlet hose should slope continuously downward from the pump
to the water.
3. Attach fuel line hose.
CAUTION: Do not attach regular pipe threaded (NPSH/NPT) fittings, they will
permanently damage the male fire threads.
PRIME PUMP
It is recommended that the pump be primed before starting the engine.
a) Priming Procedure
1. The discharge must be closed either with a discharge valve, shutoff nozzle or be pinching the
discharge hose (use a pinch clamp if available.)
2. Open priming valve
3. Operate priming valve until water is discharged from priming pump
4. Close priming valve
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5. Start engine. See starting procedures
6. Slowly open discharge valve until a steady stream is discharged
7. If an unsteady stream is discharged (incomplete prime) open priming valve and operate hand
primer to purge remaining air until a steady stream is discharged. Then, close priming valve and
adjust throttle for desired output.
b) Alternate Priming Method:
If the inlet hose is fitted with a foot valve, the pump may be primed by jabbing the end of the inlet hose
in and out of the water until water expands the discharge hose. The discharge line MUST be open
when this method is used. Be sure the priming valve is closed before starting engine.
OPERATION
STARTING PROCEDURE
WARNING: DO NOT RUN THE ENGINE IN AN ENCLOSED AREA! Exhaust
fumes contain carbon monoxide which is an odorless and poisonous gas. Be
sure the area is well ventilated.
1. Make sure there is a FRESH mixture of gasoline and oil in the tank. Refer to “Fuel
Specifications,” for proper amounts and type.
WARNING: Do not change of fill fuel while the engine running. Fill fuel tank
out-of-doors and away from any source of ignition, and wipe up any spills.
2. Connect fuel caddie to fuel line connector on engine base. Open the air vent on the caddie cap. Squeeze
and release the priming bulb until resistance is felt, indicating the fuel line is full. Further action will pump
fuel past the check valve into the carburetor, flooding it.
3. Close Choke
4. Open throttle slightly (1/4). Closed is down
5. Move ignition switch to “ON” position
6. Place foot on frame to prevent movement
7. Pull the starting handle slowly to bleed off some compression, then pull with a quick short stroke. Repeat
as necessary.
8. When engine starts, slowly open choke
9. Slowly open discharge valve
10. Set throttle to desired operating point.
NOTE: When operating from draft, especially on high lifts, do not increase engine speed without a
corresponding increase in pump pressure. If the engine speed increases with no further
increase in flow or pressure, reduce the throttle setting until the pressure or flow decreases
slightly and operate at that point.
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STOPPING PROCEDURE
1. Idle engine by pushing throttle lever down
2. Move ON/OFF switch to OFF position
3. Disconnect fuel caddie quick disconnect coupling, close cap and store fuel line
4. Restart engine with water flowing through pump and allow to idle until it stops from lack of fuel
5. Allow lines to drain. Disconnect hoses
.
CAUTION: Be careful not to touch the exterior of the engine, especially the muffler
and the surrounding area. The engine is hot enough to cause injury.
6. Without inlet and discharge caps in place, drain pump by tilting inlet end of pump downward. When pump
is drained, replace caps to prevent damage to threads.
RELAY PROCEDURE
For pumping water over long distances or up high vertical rises, it may be necessary to use several pumps in
series. When this is done, pressure (not exceeding 100 PSI) should be maintained at the inlet of the second
and subsequent pumps.
PREPARATION FOR STORAGE
WARNING: Prevent accidental starting by always removing spark plug or by
disconnecting and grounding spark plug wire before working on engine or pump.
NOTE: Replace the spark plug or wire only after all preparation is completed on both pump and engine.
1. Fuel System: If the unit is to be stored for any length of time, drain the fuel system by running until it
stops as instructed in “STOPPING PROCEDURE.”
2. Engine: See ENGINE MANUAL for storage instructions
3. Pump:
a. Follow the procedure under “Maintenance - Daily or Every 8 Hours” item 2, “Pump Inlet.”
b. Drain water from pump thoroughly. After the flow has ceased, pump should be turned over a
few revolutions so all water will drain from impeller.
c. While turning the pump over using the starting handle, spray into the pump inlet and dis
charge connections using either a white lithium or silicone type lubricant.
This treatment coats the inside of the pump and tends to prevent the clearance ring and
impeller hub from sticking due to corrosion.
d. Spray the threads of the inlet and discharge connections with either a while lithium or silicone
type lubricant.
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LUBRICATION AND MAINTENANCE
FUEL AND LUBRICANT SPECIFICATIONS:
Gasoline: Use clean, fresh, “regular grade unleaded” or “low lead” type. When “regular” or “low-lead” is
unavailable, an “unleaded” type fuel may be used; however, it should be limited to emergency use only. Oil
must be mixed with the gasoline. Refer to fuel mixture below.
Oil: Use a good quality Outboard motor oil or equivalent. The oil should meet the Boating Institute of America
(BIA) classification type TC-W. Gasoline must be mixed with the oil, refer to the fuel mixture below.
FUEL MIXTURE:
The engine used in the FYR-PAK requires that oil be mixed with the gasoline. For ease of starting, it is desir-
able to have a fresh mixture of fuel; therefore, mix only an amount of fuel you anticipate using in the near
future. As a guide the engine consumes approximately one gallon
(3.8 L) per hour at full throttle (depending on load), less at partial throttle.
To mix fuel, add oil to a small amount of gasoline in a clean container, then add the rest of the gasoline and
shake well.
NOTE: Do not mix oil and gasoline in the FYR-PAK fuel tank, it will be difficult to get good mixing.
Also if the fuel container has been still for an extended period, shake container before filling fuel tank.
The correct ratio of oil to gasoline is one (1) part oil to 24 parts gasoline (1:24). Table 1 shows various quanti-
ties of fuel mixture and the amount of oil and gasoline required.
Approximate Quantity of
Fuel Desired Oil Gasoline
One Gallon (plus) 5 oz. 1 Gallon
(3.9 Liters) (158 ml.) (3.8 L.)
Three Gallons (plus) 16 oz. 3 Gallons
(11.8 Liters) (473 ml.) (11.4 L.)
Five Gallons (plus) 27 oz. 5 Gallons
(19.7 Liters) (789 ml.) (18.9 L.)
TABLE 1
SAFETY PRECAUTIONS:
1. DO NOT RUN THE ENGINE IN AN ENCLOSED AREA Be sure the area is well ventilated.
2. Stay away from moving parts. Avoid wearing loose jackets, shirts, and lies.
3. Keep the equipment and surrounding area clean. Cluttered areas invite accidents.
4. Keep power shields and guards in place. Do not make adjustments and repairs while the engine is
running, unless specified for in repairs.
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5. Do not run the pump more than two minutes without water in the pump
6. Be careful not to touch the exterior of a hot engine, especially the muffler and the
surrounding area.
7. Prevent accidental starting by always removing spark plug or by disconnecting and
grounding spark plug wire before working on engine or pump.
8. When working on any part of the fuel system be sure the unit is cool. Remove any sources
of heat or flame.
ABSOLUTELY NO SMOKING!
Reassembly Note:
Before reassembly begins, visually inspect parts. See that parts are clean; all sealing surfaces are free of
corrosion and nicks. Remove any metal chips from casting cavities and tapped holes. Also, inspect for any
damaged or excessively worn parts which should be replaced.
Refer to “Parts Catalog” Plate No. 692B, 1 of 2 and 2 of 2 for component parts location and orientation.
MAINTENANCE SCHEDULE
DAILY OR EVERY 8 HOURS:
1. Leaks - (gaskets, fuel, seals, washers, and water): Check for any leaks before operating unit.
These leaks must be repaired before operating.
2. Pump Inlet: Remove any debris that might collect in the inlet, impeller eye, or the inlet hose strainer.
MONTHLY OR EVERY 25 HOURS:
1. Expanded aluminum foil element: clean as follows:
NOTE: Service air cleaner more often under dusty conditions.
a) Remove (2) screws and washers so foil element and end plates can be removed
b) Wash foil element in kerosene or liquid detergent and water
c) Dry foil element by shaking out excess water. Use compressed air if available.
d) Install foil element, end plates, screws and washers on carburetor.
2. Spark Plug: Clean and regap at .030 inch (.8 mm). Spark plug type is champion #RL 86C,
NGK #BR5HS, AC #R46FF Motorcraft #AER6, and FramAutolite #426.
CAUTION: Do not blast clean spark plug. Blasting material could lodge in recesses of plug and
eventually work loose, permanently damaging aluminum bore. Spark plug should be cleaned
by scraping or wire brushing and washing with a commercial solvent.
3. Fuel Filters
General
a. Place the unit in a horizontal position.
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b. Disconnect fuel caddie
c. Place a rag under the carburetor and fuel line to catch any fuel spillage.
d. Refer to filter maintenance below.
e. Wipe up any additional fuel spillage and discard rag in an approved safety container.
In-Line Fuel Filter:
a. Remove the two clamps from both sides of filter and pull hoses using a slight twisting motion.
b. Observe hoses for any signs of cracking or deterioration and replace if necessary.
c. Install a new filter with the word “IN” toward fuel tank. Replace clamps.
Carburetor Fuel Strainer:
a. Remove the screw holding the plastic cover in place (where the fuel line connects to
carburetor). Gently remove the cover, gasket and strainer screen.
b. Clean screen in a nonflammable solvent, blow dry.
c. Replace strainer screen, gasket, cover and screw.
4. Hoses, Fittings and Tubes: Clean and check all hoses, fittings and tubes for signs of cracks,
kinks, deterioration, etc. They should have uniform bends; if any are kinked or collapsed they
should be replaced. Fittings and clamps should be tight. but not overtight
SEASONAL OR AS REQUIRED:
1. Engine Cooling System: Clean the starter screen, flywheel (fan), and engine cooling fins.
Foreign matter may clog cooling system after prolonged service. Continued operation with a clogged
cooling system causes severe overheating and possible engine damage.
a. Remove the four screws that fasten the fan housing to the support plate and remove the
two screws that fasten the fan housing to the sheet metal cylinder cover.
b. Remove the flexible transparent hose from nozzle plate and the spark plug wire from
spark plug.
c. Carefully lift the fan housing from engine, push the spark plug and overspeed switch wires rubber
grommet from housing. Reach inside of housing and disconnect the magneto wire from ignition switch.
The fan housing can now be completely removed and cleaned.
d. Remove the four screws that fasten the sheet metal cylinder cover to engine; be careful,
the lower two holes have small spacers between the cover and engine.
e. To reassemble engine; reverse above procedures.
2. Pump: Except for draining the casing during freezing weather, the pump requires only an occasional
cleaning.
3. Removal of Pump/Engine Assembly:
WARNING: When working on any part of the fuel system, be sure the unit is cool. Remove any
sources of heat or flame.
ABSOLUTELY NO SMOKING!
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a. Place the unit in a horizontal position and open fuel tank cap vent.
b. Place a rag under fuel line to catch any fuel spillage. Disconnect the fuel line from
carburetor.
c. Carefully lift the fan housing from engine; push the spark plug and overspeed switch wires,
rubber grommet from housing. Reach inside of housing and disconnect the magneto wire
from ignition switch. The fan housing can now be completely removed and cleaned.
d. Remove the four screws that fasten the sheet metal cylinder cover to the engine. Be
careful. The lower two holes have small spacers between the cover and the engine
f. To reassembly, reverse the above procedure
2. Pump: Except for draining the casing during freezing weather, the pump requires only an occasional
cleaning.
3. Removal of pump/Engine housing from Mounting Base
a) Place the unit in a horizontal position.
b) Remove the fuel line from the fuel line connector. Catch any fuel spillage with a rag. Dispose of the
rag in an approved safety container.
c) Disconnect the overspeed switch wire at the connector. Disconnect the short overspeed switch
ground wire by pulling spade connector from the overspeed switch.
d) Remove the overspeed switch tubing from the overspeed switch.
e) Remove the three locknuts from the vibration isolators that fasten them to the pump mounting base.
f) Lift the pump/engine assembly from the mounting base.
4. Assembly of Pump/Engine to Mounting Base
Assembly is the reverse of the removal procedure above.
5. Repair or Replacement of Any Components in Pump (Replacing mechanical Seal)
a) Remove pump/engine assembly from mounting base. Refer to item 3 “Removal of Pump/Engine
assembly.”
b) Remove the four screws that fasten the volute body to the pump head. Remove the volute body
c) Remove the impeller retaining screw and washer
ATTENTION: The impeller screw is left hand threaded.
NOTE: To prevent the engine from rotating, when removing the impeller screw, place a long 3/8 screw
or 3/8diameter bar through one of the pump head mounting holes and a flat bar in one of the impeller
cavities.
d. Remove impeller by putting hardwood wedges on each side of impeller, between
impeller and pump head. The wedges should bear against impeller disc directly behind
impeller vanes to prevent damaging the impeller; refer to figure 4. Tap end of engine
shaft with a Soft (rawhide, rubber) headed mallet, while maintaining pressure with
wedges until impeller comes off.
DO NOT PUT TOO MUCH PRESSURE ON WEDGES
e. With impeller removed, remove the impeller key.
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Operation and Maintenance Manual
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f. Remove the spring and carbon section (sealing washer) of mechanical seal from engine
crankshaft sleeve. Observe the ceramic seal seat and carbon sealing washer. If they
are scored or lip on the sealing washer is worn or cracked, replace complete assembly.
g. If further disassembly is required beyond mechanical seal replacement, remove the four
5/16-18 x 2-1/2 Lg. screws and 5/16 flat brass washers that fasten pump head to engine.
h. If mechanical seal ceramic seal was not removed previously, remove from head.
i. Pull engine crankshaft projection sleeve from shaft,
j. There is a replaceable clearance or wear ring used in this pump. Inspect impeller hub
and clearance ring bore, replace if any of these surfaces are scored or worn
excessively.
Reassembly Note:
Before Reassembly visually inspect parts. See that parts are clean and all sealing surfaces are free of corro-
sion and nicks. Remove any metal chips from casting cavities and tapped holes. Also inspect for any damaged
or excessively worn parts which should be replaced.
a. Coat the engine crankshaft with a thin layer of gasket sealer, such as, Loctite Gasket
Eliminator 504
b. Lubricate the groove in the pump shaft sleeve (048-0770-00) using a multipurpose
grease and install “O”-ring (040-0180-00) in groove. Slide this assembly on engine
crankshaft.
C. Position pump head on engine and align holes. If original screws are in good condition,
reuse, but apply a thread locking adhesive, such as Locktite Threadlocker 242 or equal to
Pump Head
Impeller Disc
Impeller Cavity
Wedge
Impeller
Vane
Bent or Cracked
Impeller Disc
CORRECT INCORRECT
Wedge

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Operation and Maintenance Manual
18
threads. If original screws were damaged, or corroded, replace with four new 5/16-18 x 2-1/
2 Ig, plated nylok screws P/N: 018-1424-07. When installing screws use a new 5/16 flat
brass washer (097-0810-00) under the head of each screw.
Note: Hale has available small tubes of Loctite Threadlocker 242 adhesive (0.5 cc). Hale
P/N: 029-0010-01.
d. Coat rubber cup of mechanical seal ceramic seat with oil and press into pump head with
ceramic surface toward you.
e. Coat rubber on inside of mechanical seat carbon sealing washer With oil and using a
turning motion, push onto shaft sleeve until carbon lip comes into contact with ceramic surface.
CAUTION: Keep the ceramic seal seat and carbon sealing washer surfaces clean. Be careful
not to crack or chip ceramic surface or carbon wearing lip.
g. Line up keyway of impeller with keyway of shaft. Push impeller on shaft. Insert impeller key
(017-0060-01) until flush with face of impeller
f. Line up keyway of impeller with keyway of shaft; push impeller on shaft. Insert impeller key
(017-0060-01) until flush with face of impeller.
g. Coat end of shaft and impeller with a thin layer of gasket sealer.
h. Coat threads of a new impeller screw (018-9350-00) with a thread locking adhesive
(Loctite 242 or equal).
i. Mount impeller washer (097-0381-00) and impeller screw. Torque impeller screw to 10 ft/lbs
ATTENTION: The impeller screw is left hand thread.
If impeller clearance ring requires replacement proceed with the following steps.
However, if impeller clearance ring is in good condition proceed to step m.
j. With the clearance ring removed from volute body, inspect clearance ring pins
(064-0310-12). If these are damaged replace.
k. Apply a thin coat of oil to groove of impeller clearance ring (321-0121-00) and install O-ring
(040-2320-00) into groove. Coat the outside of clearance ring and O-ring with oil.
l. Aligning the holes in impeller clearance ring with pins in volute body, press clearance ring
into volute body.
m. Coat the inside of clearance ring bore and outside of impeller hub with oil.
n. install o-ring (040-1590-00) on pump head pilot and coat 0-ring and pump head pilot
diameter with either oil or a multipurpose grease.
o. Mount volute body with clearance ring to pump head aligning holes and bolt volute body to
pump head using four 3/8-16x 7/8 Ig. stainless screws (018-1607-12) and four 3/8 plated lock
washers (097-0140-01).
p. Install the pump/engine assembly to mounting base. Refer to item 4, “Assembly of Pump/
Engine to Mounting Base”
!
!
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Operation and Maintenance Manual
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FYR PAK (545-2140-00-0) HOSE ADAPTER(S) INSTALLATION
A Install adapter part no. 0070470-00 into INlet side of the Fyr Pak
volute body. Apply a small amount of loctite teflon pipe sealant
(Part no. 029-0210-00-0) to the 2” N.P.T. end of the adapter before
installation. Tighten until snug.
B Repeat step A for dishcarge side with adapter part no.
007-0480-00. Apply loctite teflon piupe sealant to the 1-1/2” N.P.T.
side before installation. Tighten until snug.

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Operation and Maintenance Manual
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