Pentair Hypro 1542P Series Use and care manual

Series 1542P-55SP, 1542P-65SP, 1542P-550BSP,
1542P-950BSP, 1542P-160HSP, 1542P-200HSP
Gas Engine-Driven, Self-Priming
Polypropylene Centrifugal Pumps
Installation, Operation, Repair and Parts Manual
Description
Form L-1514
Rev. D
Hypro Self-Priming Polypropylene 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.
1542P-55SP
1542P-550BSP
1542P-160HSP
Close-Coupled, Gas Engine-Driven,
Self-Priming Poly Centrifugal Pump
Max Flow Rate: ............................ 150 GPM
Max. Pressure: .................................58 PSI
Max. Total Head .............................134 FT.
Max. Suction Lift: ..............................25 FT.
Ports: ........................................ 2” NPT Inlet
2” NPT Outlet
Engine ............................PowerPro 5.5 H.P.
or Briggs & Stratton 550
or Honda GX160
1542P-65SP
1542P-65SPM
1542P-950BSP
1542P-200HSP
Close-Coupled, Gas Engine-Driven,
Self-Priming Poly Centrifugal Pump
Max Flow Rate: ..............................200 GPM
Max. Pressure: .................................. 58 PSI
Max. Total Head ...............................134 FT.
Max. Suction Lift: ................................25 FT.
Ports: ..........................................2” NPT Inlet
2” NPT Outlet
Engine ............................. PowerPro 6.5 H.P.
or Briggs & Stratton 950
or Honda GX200
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 (120 degrees 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

2
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
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.
Plumbing Installation
IMPORTANT
For best possible performance and continuous,
satisfactory operation, read these instructions before
installing your new pump. Should service be required,
this manual can be a valuable guide. It should be kept
near the installation for ready reference.
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.
Basket Strainer
A basket strainer 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.
INSTALLATION
Location
Place unit as close to water source as possible to minimize
suction lift, obtain the best pumping performance, and
aid in priming. A typical portable installation is shown in
Figure A.
For permanent installation, mount unit on a foundation that
will support the weight of the pump and engine and also
provide stability while the pump is running. For most per-
manent installations, it is advisable to bolt unit directly to
foundation.
NOTE: Settling and/or shifting during operation can cause
piping to place excessive strain on the pump and may
damage pump case. Set pump on hard level surface. Non-
level surfaces may cause the oil sensor in the engine to
shut down the unit.
Suction Connection
Connect either rigid pipe or flexible suction hose to pump
suction as shown in Figure A. If hose is selected, hose
must be rated to hold the suction vacuum and prevent col-
lapse while the pump is running.
Make the suction line a continuous rise from the water
source to the pump. High spots can trap air and also make
priming difficult. Make sure all connections are tight and
free of air leaks.
NOTE: Suction pipe or hose must be at least as large as
the pump suction inlet in order for the pump to operate
properly. If the inlet line is longer than approximately 6 feet,
use the next size larger line.
Minimum depth for the suction inlet is determined by the
diameter of the suction line. See Figure A.
Discharge Connections
Your pump is equipped with a single port discharge. Select
the appropriate size for the application. Install a “T” as
shown to allow easy priming of the pump without discon-
necting the piping, or by using the priming plug on the
housing.
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.

Plumbing Diagram
3
Hazardous Suction
Can trap persons
against suction inlet.
Always use strainer
on suction hose to
prevent entrapment.
FIGURE A

Preparations Before Starting the Engine
1. Fuel: Check fuel level in tank, and do not over fill. 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 after the first 20 hours and
every 100 hours thereafter.
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. 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.
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.
2. Drain all the fuel from the fuel tank, fuel lines, and filter.
3. Store pump in a clean, dry environment.
Operation and Maintenance
4

Repair Instructions
Always flush pump with water or neutralizing agent
before servicing.
PUMP HOUSING DISASSEMBLY
Seal replacement requires that the pump be fully
removed from the engine. Observe carefully the
disassembly process to ensure an easy assembly
process. Replace all worn and eroded parts.
1. Remove spark plug wire from the spark plug for
safety consideration. Remove the 10 bolts and
nuts holding the pump casing to the casing cover
using a 10mm socket and a 10mm open end
wrench. Tap pump casing on the discharge port
with a rubber hammer, if necessary, to break
it loose from the casing cover. Remove o-ring
from casing cover. Inspect parts for wear. (See
Figure 1.
2. Remove diffuser by removing the three screws
with a Phillips screwdriver. Inspect parts for
wear.
(See Figure 2.)
3. Remove impeller bolt with a 13mm wrench.
Pry impeller off engine shaft using two flathead
screwdrivers. Inspect impeller and ceramic for
wear. Ceramic surface must not be scuffed or
cracked. To remove ceramic seal from impeller
bore, use a small blade screwdriver to wedge the
seal out.
(See Figure 3.)
4. To remove mechanical seal from casing cover,
first remove the casing cover from the engine by
removing the four mounting bolts with a 13mm
socket. From the engine side of the casing
cover, press the mechanical seal out using a
1” diameter piece of PVC pipe 4” long. Inspect
parts for wear. (See Figure 4.)
5. Inspect slinger ring on engine shaft for wear.
(See Figure 5.)
Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
5