Pentair Hypro 1541A-SP Series Use and care manual

Series 1541A-SP
Gas Engine-Driven, Self-Priming
Centrifugal Pump Form L-1518
Rev. B
HYPRO®
Installation, Operation, Repair and Parts Manual
Description
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.
1541A-SP
Close-Coupled, Gas Engine-Driven
Self-Priming Centrifugal Pump
Max Flow Rate: .............................. 40 GPM
Max. Pressure: .................................28 PSI
Max. Total Head ...............................65 FT.
Max. Suction Lift: ..............................13 FT.
Ports: ........................................ 2” BSP Inlet
2” BSP Outlet
Engine ............................PowerPro™2.5 HP
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.
General Safety Information
California Proposition 65 Warning -- This product and related accessories contain chemicals known to the State of
California to cause cancer, birth defects or other reproductive harm.

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
priming 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.
Hazardous Substance Alert
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 dis-
assembling 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.
Plumbing Installation
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. Note that
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

4
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
a wire 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)
Repair Instructions
Impeller
A
B
Casing
Cover
Volute
(A) – (B) = within 0.024 - 0.036 inches.

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.
Model 1541A-SP
Performance Data is based on testing with water. Performance will vary with fluid density and/or viscosity.
5
Performance Data
Troubleshooting
0 PSI 10 PSI 15 PSI 20 PSI 25 PSI 28 PSI
GPM GPM GPM GPM GPM GPM
40 28 21 14 7 0

6
Model 1541A-SP
Ref. Qty.
No. Req’d. Part No. Description
1 ENGINE PowerPro™ 2.5 hp
1 1 2545-0068 Casing
2 1 2545-0069 Casing Cover
3 1 2545-0070 Impeller
4 1 2545-0071 Inner Casing
5 1 2545-0072 Discharge Port
6 1 2545-0073 Inlet Port
7 1 2120-0074 Mechanical Seal
8 1 2545-0075 O-ring
9 1 2545-0076 O-ring
10 1 2545-0077 Gasket
11 1 2545-0078 Check Valve
12 2 2545-0079 Plug
13 2 2545-0080 O-ring
14 4 2545-0081 Bolt
15 4 2545-0082 Washer
16 4 2545-0083 O-ring
17 12 2545-0084 Bolt
1
917
13 12
11
6
2
4
3
7
8
14
12
13
17
10
5
17
16
15

7
Notes

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 LIMIT-
ED 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 products must be flushed of any chemical (ref. OSHA section 1910.1200 (d) (e) (f) (g) (h)) and hazardous chemicals must be labeled/
tagged before being shipped* to Hypro for service or warranty consideration. Hypro reserves the right to request a Material Safety Data
Sheet from the returnee for any pump/product it deems necessary. Hypro reserves the right to “disposition as scrap” products returned
which contain unknown fluids. Hypro reserves the right to charge the returnee for any and all costs incurred for chemical testing, and proper
disposal of components containing unknown fluids. Hypro requests this in order to protect the environment and personnel from the hazards
of handling unknown fluids.
Be prepared to give Hypro full details of the problem, including the model number, date of purchase, and from whom you purchased your
product. Hypro may request additional information, and may require a sketch to illustrate the problem.
Contact Hypro Service Department at 800-468-3428 to receive a Return Merchandise Authorization number (RMA#).
Returns are to be shipped with the RMA number clearly marked on the outside of the package. Hypro shall not be liable for freight damage
incurred during shipping. Please package all returns carefully. All products returned for warranty work should be sent shipping charges
prepaid to:
HYPRO / PENTAIR
Attention: Service Department
375 Fifth Avenue NW
New Brighton, MN 55112
For technical or application assistance, call the Hypro Technical/Application number: 800-445-8360, or send an email to: technical@
hypropumps.com. To obtain service or warranty assistance, call the Hypro Service and Warranty number: 800-468-3428; or send a fax
to the Hypro Service and Warranty FAX: [phone].
*Carriers, including U.S.P.S., airlines, UPS, ground freight, etc., require specific identification of any hazardous material being shipped. Failure to do so may
result in a substantial fine and/or prison term. Check with your shipping company for specific instructions.
375 Fifth Avenue NW •New Brighton, MN 55112
Phone: [phone] •800-424-9776 •Fax: [phone]
www.hypropumps.com
Hypro (11/12)
Printed in USA
Limited Warranty on Hypro/SHURflo Agricultural Pumps & Accessories