Wildfire MK-3, -B2, -DS Fire pump Service Manual
Below you will find brief information for Fire pump MK-3, Fire pump MK-3-B2, Fire pump MK-3-DS. The MARK-3 unit is a versatile fire pump unit that is suitable for a variety of applications, including forest fire control, rural and municipal fire protection, and any other application where a large volume of water or high pressure is required. The pump end can be interchanged with a B-2 volume pump end, and tandem operations enable the unit to move water over greater distances or higher altitudes. The unit features a one-cylinder, two-cycle, air-cooled engine with a rewind pull-cord starter and an automatic cutout switch. The pump end is an anodized horizontal 4-stage centrifugal precision built pump. The unit is also equipped with an electronic ignition system, which eliminates the need for regular maintenance associated with breaker points. The electronic ignition system allows for a smoother and more responsive engine run.
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TABLE OF CONTENTS
1
GENERAL INFORMATION
SPECIFICATIONS
SERIAL NUMBERS
2
3
5
MAJOR OVERHAUL SERVICE
ENGINE OVERHAUL SERVICE PROCEDURE
DISASSEMBLY PROCEDURE FOR ENGINE
REASSEMBLY SERVICE FOR ENGINE
DISASSEMBLY PROCEDURE FOR PUMP END
ASSEMBLY PROCEDURE FOR PUMP END
31
32
33
34
35
2
ENGINE OPERATING
STARTER
OPERATING INSTRUCTIONS
FLOODING
COLD WEATHER
TROUBLESHOOTING CHART
ELECTRONIC IGNITION
6
6
4
4
7
8
6
MISCELLANEOUS
OPTIONAL NOISE REDUCTION MUFFLER
DECARBONISING
3
PUMP UNIT
PUMP OPERATION AND LUBRICATION
PUMP TEST KIT
PUMP ADJUSTMENTS
UPGRADED CUT- OUT SWITCH
4
REGULAR MAINTENANCE
MAINTENANCE CHECK LIST
UPGRADED SPARK PLUG CAP
SERVICING SPARK PLUG
ELECTRONIC IGNITION UNIT
ELECTRONIC IGNITION MODULE SETTINGS
DECOMPRESSION SWITCH R-233DS
SERVICING CARBURETOR
CARBURETOR TROUBLE CHART
SERVICING AIR FILTER
SERVICING COOLING SYSTEM
SERVICING THE REWIND STARTER
SERVICING MAGNETO
16
17
18
21
13
14
14
15
22
23
24
29
9
10
11
12
7
TECHNICAL SPECIFICATIONS
TORQUE VALUES
CLEARANCE DATA AND LIMITS
8
PARTS INDEX
9
WARRANTY CERTIFICATE
38
38
39
39
40
44 w w w. w i l d f i r e - e q u i p m e n t . c o m
1
1
GENERAL INFORMATION
This handbook includes specifications, performance data, operating instructions, normal servicing information and parts list for the MARK-3 centrifugal fire pump unit.
The MARK-3 unit has been designed to meet all the requirements of advanced techniques in forest fire control, including USDA Forest
Service Specifications No. 5100-
274C. This versatile unit enables the pump to be used for high pressure and volume (B-2 volume Pump End interchangeability). It is also suitable for rural and municipal fire protection, or wherever a large volume of water or high pressure is required.
Tandem operations enable to move water over greater distances or higher altitudes.
SPECIFICATIONS
The MARK-3 Pump end is an anodized horizontal 4-stage centrifugal precision built pump. Both the 2” (51 mm) NPSH male suction connection and 1 1/2”
(38mm) NPSH male discharge connection are made to standard forestry thread specifications.
The MARK-3 Engine is a one-cylinder, two-cycle, air-cooled engine incorporating ball and roller bearings. The unit is also equipped with a rewind pull-cord starter and automatic cutout switch.
WARNING
• The improper use of this pump could result in serious injuries.
Please read the manual before using your MARK-3 pump unit.
•
Always wear eye and ear protection when operating the pump unit.
•
Be careful, never touch the muffler, as it can reach very high temperatures and cause serious burns. Always allow enough time after stopping the unit for the muffler and surrounding parts to cool down.
•
Always use proper fuel mixture to ensure suitable lubrication.
CHARACTERISTICS
58 lbs
16 1/4”
12”
23”
26.3 kg
413 mm
305 mm
584 mm
15 lbs 6,8 kg nee p weerr 10 HP
Approx.
7,4 kW type with integral fuel pump and filter
Champion K7 18 mm
(1 IMP gal, 1.2 US gals) 5 L/hr
150
200
250
300 psi
0
50
75
100
350
380
MAXIMUM PERFORMANCE
1034
1379
1724
2069
2413
2620
Pressure kPa
0
345
517
690 bar
0
3,45
5,17
6,90
10,34
13,79
17,24
20,69
24,13
26,20
65
52
38
25
9
0
US GPM
Discharge Flow
IMP GPM
98 82
89
83
78
74
69
65
54
43
32
21
7
0
L/min
371
337
314
295
246
197
144
95
34
0
1.1
1.2
2
Wi l d f i r e
1.3
MK-3
MK-3-B2
1
GENERAL INFORMATION
MK-3
Maximum Pressure : 380 psi (2620 kPa)
Free flow : 98 US gals/min (370 L /min)
MK-3-B2
Maximum Pressure : 155 psi (1068 kPa)
Free flow : 180 US gals/min (681 L /min)
US gals/min
L /min
50
189
100
379
150
568
200
758
24:1
SERIAL NUMBERS
Pump end serial number is located on the side of the pump (1.1).
Engine end serial number is stamped on a nameplate attached to the crankcase
(1.2).
These serial numbers are the key to various design details pertaining to the original manufacture of each unit. Therefore, it is very important to specify serial numbers whenever ordering parts and tools or when requesting information.
DIRECTIONAL REFERENCES
All references to right side and left side of unit are made as they appear to operator when facing rewind starter, thus the carburetor is on the right side and the muffler is on the left side.
Viewed in this manner (facing the recoil starter), the engine will rotate in a clockwise direction (1.3).
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3
2
ENGINE OPERATING
TIP
If the rewind starter should break while the unit is on the fire line, the complete rewind starter assembly can be easily removed, thereby gaining access to a manual starter pulley which is mounted on the flywheel. Using a rope, wrap around starter pulley and pull. Make sure rope wrapping will ensure clockwise rotation (from starter view).
CAUTION
Not enough emphasis can be placed on the use of correct gasoline and oil mixture. Using less than the recommended portion of oil will cause overheating and possible engine damage. Using more than the recomme nded proportion of oil will cause spark plug fouling, erratic carburetion, excessive exhaust smoke and rapid carbon deposits.
1
1.4
4
Wi l d f i r e
4
3
2
FOR TROUBLE FREE OPERATION
• DO NOT run engine at full speed until thoroughly warmed up.
• DO NOT lift strainer out of the water while pump is operating.
• DO NOT run engine with pump disconnected.
• DO NOT run pump when dry. Priming?
• Check strainer frequently to make sure that it is not clogged with moss, leaves, etc.
• DO NOT use suction hose without foot valve strainer.
• Remove and drain pump after final use.
STARTER
The starter is an automatic rewind type. A proper operating technique will add many hours of life to the starter rope and starter.
Grasp handle firmly and pull slowly until resistance (past compression), then continue to pull with a short, vigorous stroke. Pulling handle sideways causes excessive wear. If kickback occurs, let go of handle immediately.
When engine starts, retain grip on handle and allow rope to rewind slowly.
Note: The rope should be replaced when wear is apparent.
See rewind starter Servicing and Parts, page 24.
OPERATING INSTRUCTIONS
OIL: High quality 2-cycle mixing oil.
FUEL: 87 Octane or higher automotive gasoline.
DO NOT use premium grade gasoline.
Do not use poor quality oil, high detergent oil or oil with solid additives (graphite, moly, T.F.E., etc.).
MIXTURE RATIO
Oil
1 L (0.22 IMP gals, 0.26 US gals)
1 US Quart (0.95 L)
Gasoline
24 L (5.3 IMP gals, 6.3 US gals)
6 US gals (5 IMP gals, 22,75 L)
CONTROLS
There are only 4 controls which are used for normal operation: (1.4)
1
ON/OFF switch
2
Throttle lever
3
Choke lever
4
Reset lever
24:1
1.5
1.6
1.7
1.8
2
B-5980
1
2
ENGINE OPERATING
TO START MARK-3 UNIT
1
Fill fuel supply tank with recommended fuel mixture.
2
Connect fuel supply line to fuel supply tank (1.5).
3
Attach fuel supply line to the adaptor located on right side of engine frame.
Pump fuel to fill supply line (1.6).
DO NOT use suction hose without foot valve strainer. DO NOT allow foot valve strainer to rest on bottom of lake or river bed.
4
Connect foot valve strainer to male end of suction hose, then fill suction hose with water and connect to pump.
1
Use universal hose coupling wrench to tighten coupling firmly (1.8).
5
Connect discharge hose
2
, nozzles, etc., to pump. Use a rope or other means to keep strainer at proper height, approximately 30cm (1 foot) below water surface. If strainer is too close to the water surface, it will draw air and pump may lose prime (1.7).
6
Fill pump with water manually or using a hand primer (B-5980), then replace priming cap and tighten firmly (1.8).
7
Move throttle lever to "Start" and "Warm up" position. Verify that On/Off switch is on "On" position (approx. 3 increments). Verify that the reset cutout switch is not engaged (must be pushed in).
8
Close choke, if engine is cold.
9
Slowly turn engine until resistance (past compression).
10
Give starter rope several quick, steady pulls until engine "coughs".
11
Open choke slightly and pull starter rope until engine runs.
12
Slowly open choke and allow engine to warm up for at least 2 minutes before using full throttle.
The MARK-3 engine was initially run-in at the factory. Full throttle operation can be used provided the engine is given a thorough warm-up period beforehand.
Important: Failure to allow the engine to warm up may lead to piston scoring and possibly more serious damage.
AUTOMATIC CUTOUT SWITCH
The MARK-3 unit is equipped with an automatic cutout switch. This safety device will stop the engine instantly and thereby eliminate overspeeding.
The switch works on cooling fan air pressure. As the engine speed increases, so does the air pressure. At a predetermined speed, there is sufficient air pressure to cause the air vane to move against its contacts, shorting the ignition and thereby stopping the engine.
When the cutout switch automatically stops the engine, this is a warning that there is a problem. Do not reset switch until cause of trouble has been identified and corrected.
TO STOP MARK-3 UNIT:
1
Move throttle lever to "Stop" position.
2
Allow unit to run for approximately 1 minute with throttle in this position.
3
Switch toggle to "Off" position.
4
Remove and drain pump after final use.
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5
2
ENGINE OPERATING
COLD OPERATION
In cold operation it is good practice to put a small quantity of aluminum compatible antifreeze into pump end through priming cap immediately after use to prevent damage from freezing.
FLOODING
Flooding refers to an accumulation of excess fuel in cylinder, mainly due to excessive use of choke.
When the engine is in a flooded condition, an over-rich fuel-air mixture is induced into the cylinder. This mixture does not ignite readily and usually fouls the spark plug.
CLEANING A FLOODED ENGINE
Remove fuel supply line from engine or close fuel supply valve (if equipped).
Remove spark plug. With both choke and throttle in fully open position, pull starter rope several times until excess fuel is exhausted. Before reinstalling spark plug, clean and dry electrode and insulator tip.
COLD WEATHER
RECOMMENDED PROCEDURE FOR COLD WEATHER OR
PROLONGED STORAGE
The following procedure is recommended to ensure proper protection of the engine if the engine is to be left idle for prolonged periods between uses or if there is a possibility that the engine may be stored in an unheated area where freezing temperatures may occur.
1
With pump unit running at approximately low RPM (approx. 3-4 increment)
V2 throttle, remove the quick-connect fuel line from the quick-connect fitting on the engine.
2
Allow engine to run until all fuel has left the carburetor and the engine stops.
3
Remove spark plug.
4
Rotate crankshaft until piston is at top dead centre.
5
Pour 30 ml (1 oz) of oil into spark plug opening (use same oil grade used in fuel mixture).
6
Rotate crankshaft 2 or 3 times to assure that cylinder walls are well coated with oil, then bring piston to top dead centre.
7
Reinstall spark plug.
It is preferable to keep the pump unit in dry storage above freezing temperature.
However, as this is not always possible, some slight rusting may occur, which should have no detrimental effect on the life or performance of the unit.
6
Wi l d f i r e
2
ENGINE OPERATING
TROUBLESHOOTING CHART
ENGINE DOES NOT START OR STARTS
MOMENTARILY THEN STOPS
Possible cause
Fuel supply tank empty
Fuel supply valve closed
Air vent on fuel tank closed
Defective fuel supply hose
Dirty fuel strainer screen
Leak in fuel supply system
Carburetor mountings loose
Water or dirt in fuel system
Engine flooded
Too much oil in fuel mixture
Spark plug fouled or defective
No spark
Remedy
Refill fuel tank
Open supply valve
Open air vent or unscrew cap
Replace
Clean or replace
Tighten or replace fittings
Tighten mountings
Drain; flush thoroughly
See "Flooding"
See "Engine Lubrication and Fuel"
Clean or replace
See "Service Manual"
ENGINE DOES NOT IDLE PROPERLY
Possible cause
Carburetor mountings loose
Too much oil in fuel mixture
Idle mixture screw misadjusted
Spark plug fouled or defective
Wrong type spark plug
Main adjustment screw misadjusted
Improper timing
Remedy
Tighten mountings
See "Engine Lubrication and Fuel"
See "Service Manual"
Clean or replace
Use plug recommended
See "Service Manual"
Refer to timing section
ENGINE RUNS IRREGULARLY OR MISSES
Possible cause
Defective fuel supply hose
Dirty fuel strainer screen
Leak in fuel supply system
Carburetor mountings loose
Water or dirt in fuel system
Wrong gasoline in fuel mixture
Too much oil in fuel mixture
Air filter dirty
Idle mixture screw misadjusted
Spark plug fouled or defective
Wrong type spark plug
Improper timing
Remedy
Replace
Clean and replace
Tighten or replace fittings
Tighten mountings
Drain; flush thoroughly
See "Engine Lubrication and Fuel"
See "Engine Lubrication and Fuel"
Clean or replace
See "Service Manual"
Clean or replace
Use plug recommended
Refer to timing section
ENGINE BACKFIRES
Possible cause
Spark plug fouled or defective
Defective carburetor
Improper timing
Remedy
Clean or replace
Replace
Refer to timing section
ENGINE DOES NOT DEVELOP NORMAL
POWER AND/OR OVERHEATS
Possible cause
Carburetor mountings loose
Wrong gasoline in fuel mixture
Wrong oil in fuel mixture
Not enough oil in fuel mixture
Too much oil in fuel mixture
Air filter dirty
Spark plug fouled or defective
Wrong type spark plug
Cooling system dirty
Muffler blocked or dirty
Main adjustment screw misadjusted
Improper timing
Remedy
Tighten mountings
See "Engine Lubrication and Fuel"
See "Engine Lubrication and Fuel"
See "Engine Lubrication and Fuel"
See "Engine Lubrication and Fuel"
Replace
Clean or replace
Use plug recommended
See "Service Manual"
Replace
See "Service Manual"
Refer to timing section
ENGINE SOUNDS LIKE A FOUR STROKE
Possible cause
Too much oil in fuel mixture
Remedy
See "Engine Lubrication and Fuel"
Engine not warmed up properly Allow longer warm up period
Main adjustment screw misadjusted
See "Service Manual"
Air filter dirty
Improper timing
Clean or replace
Refer to timing section
Refer also to section on "Servicing Carburetor" in Service
Manual for additional "Trouble Data" and service information.
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7
2
ENGINE OPERATING
A more efficient and maintenance free electronic ignition system.
The electronic ignition allows for a smoother and more responsive engine run.
ELECTRONIC IGNITION
Since the introduction of the MARK-3 fire pump into the industry, the MARK-3 utilized breaker points in its ignition system, which inherently required maintenance; i.e. the gap adjustment, points cleaned and/or completely changed.
The upgrade to the electronic ignition system will eliminate the need for regular maintenance associated with breaker points. The electronic ignition system uses a magnetic pickup located on the flywheel, which when passing over a certain point on the stator will induce a high voltage, therefore causing the spark plug to fire at the proper moment.
The electronic ignition module is equipped with spark advance, thus allowing for a cleaner burn at a higher RPM. During testing it was found that the engine ran smoother and was much more responsive. When the engine is started cold, it runs rough (as if the timing were off) for about 15-30 seconds, after which the engine runs smooth.
In order to convert a MARK-3 from breaker points to the upgraded electronic ignition system, the following retrofit kit was created: B-7595 MARK-3 Conversion kit, point to CDI.
The ignition cable is larger in diameter than the previous one used on the MARK-3 with breaker points.
The breakdown of the electronic ignition is depicted in the picture to the left. The electronic module is placed in an aluminium box located on the frame below the carburetor shroud.
-
Ref. #
-
1
Description
B-7595
A-7589
R-271
2 R-275
3 R-274
4
5
R-650
R-629
Mark-3 conv. Kit point to CD (Includes all parts with *)
Mounting block/elect. Ignition (not shown)
Electronic ignition *
Ignition cable *
Spark plug connector *
Spark plug
Quantity
1
1
1
1
1
1
3
PUMP UNIT
Ref. Part # Description
_ 212-170P Clamp assembly
(includes all the parts listed below)
Qty
1
1 A-4460 Lever, zinc plated
2 A-4452 Side link for lever
1
1
3 C-4462-5 Cotter pin 3
4 A-4455 Clevis pin for lever side 2
5 B-4461 Clamp - top half
6 B-4457 Clamp- bottom half
1
1
7 A-4454 Clevis pin for eye-bolt side
8 A-4456 Knob for tension adjustment
9 A-4453 Eye-bolt
1
1
1
PUMP OPERATING AND LUBRICATION
1
2
3
4
5
6
3
7
8 9
8
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9
3
PUMP UNIT
COLD OPERATION
In cold operation it is good practice to put a small quantity of aluminum compatible antifreeze into pump end through priming cap immediately after use to prevent damage from freezing.
IMPORTANT
Apply FINGER PRESSURE ONLY to close pump clamp lever. Excessive pressure will damage or break clamp link.
Nozzle
Size
Minimal
Pressure
1/2"
12,7 mm
105 psi
724 kPa
Minimal 100-105 psi
Pressure Range 689-724 kPa
7/16"
11 mm
145 psi
1000 kPa
125-130 psi
862-896 kPa
PUMP LUBRICATION
The pump bearing must be greased every 8 hours of operation.
Use a clean grease gun filled with fresh grease. Remove dirt from grease fitting before applying grease gun. Grease should be pumped slowly into grease zerk while rotating the pump shaft. Continue pumping until fresh grease appears around bearing ring. Wipe off excess grease.
Do not use graphite grease or a pressurized grease gun.
TO REMOVE PUMP FROM ENGINE:
1
Lift pump clamp lever.
2
Release tension adjusting knob at bottom of clamp.
3
Remove clamp.
4
Remove pump from engine.
TO DRAIN PUMP:
It is recommended that the pump be drained after usage. This is a MUST during cold weather, to prevent damage to pump, due to freezing.
1
Remove discharge hose, suction hose and priming cap.
2
Drain pump by tilting pump body several times.
3
Stand pump on suction nozzle end for several minutes to complete drainage.
4
Replace discharge, suction and priming caps.
TO ATTACH PUMP TO ENGINE:
1
Place flexible buffer coupling on engine coupling pins.
2
Align flexible buffer coupling holes to pump end coupling pins and install.
3
Attach pump clamp. Carefully align clamp positioning pins with flange stub.
4
Adjust tension knob located at bottom of clamp to obtain a light pressure on clamp link.
PUMP TEST KIT
TESTING PROCEDURE
The best way to check your pump unit is to make an actual performance test. A test kit consisting of pressure gauge, pressure gauge adaptor, 3 m (10') length of discharge hose, a nozzle and a calibrated set of nozzle tips, is available.
3/8"
9,5 mm
180 psi
1241 kPa
165-170 psi
1138-1172 kPa
5/16"
8 mm
225 psi
1551 kPa
210-215 psi
1448-1482 kPa
1/4"
6 mm
265 psi
1827 kPa
255-260 psi
1758-1793 kPa
1/8"
3 mm
320 psi
2206 kPa
315-320 psi,
2172-2206 kPa
10
Wi l d f i r e
7
8
5
6
9
3
4
1
2
Ref.
Part
# #
_
A-2388
Description
A-2392
Pump test kit (incl. al the parts listed below)
Pressure gauge 0-400 psi (0-2800 kPa), 4 1/2" (114 mm)
F5095E Hose SPEC 187-1 1/2" X 10' w/brass coupling NPSH M/F F5095E00F10RBALFS
A-2389
A-2391
Pump test kit box
Rubber hose assembly (incl. a set of 2 adaptors A-2391B)
A-2391B Adaptor Female NPT-Swivel Female
A-2390A Shut-off valve
A-2390
A-2395
C-1933
Pressure gauge adaptor 1 1/2" (38mm) female NPSH to 1 1/2" (38mm) male NPSH
Brass calibrated nozzle tip set: 1/8", 1/4", 5/16", 3/8", 7/16" (3mm, 6mm, 8mm, 9,5mm, 11mm)
Calibrated nozzle, 1/2" (12,7mm)
3
PUMP UNIT
Qty
1
1
2
1
1
1
1
1
1
IMPORTANT
Carburetor should be properly adjusted before starting performance test. See "Carburetor Adjustment".
In addition the pump unit should be set up as close as possible to water source.
PUMP ADJUSTMENTS
OVERSPEEDING MAY OCCUR IF:
1
Pump not primed properly.
• Suction hose and/or pump body not completely filled with water.
• A bend in the suction hose, located higher than the pump suction inlet, causing an air lock. (The suction hose between the pump and water supply must have a downward slope.)
2
Loose suction hose coupling or priming cap.
3
Foot valve strainer clogged or too close to surface of water.
4
Pump loses prime.
•
Due to lack of water, air lock may form in the suction hose when pump unit works against a high delivery head. If this happens, disconnect the discharge hose from the pump then reprime pump in the normal manner.
•
Pump runs out of water, either because of lack of sufficient water supply or by attempting to pump water from a shallow water source.
w w w. w i l d f i r e - e q u i p m e n t . c o m
11
3
PUMP UNIT
UPGRADED
CUT- OUT SWITCH
MARK-3 UPGRADE OF THE
B-6288 CUT-OUT SWITCH
(The change in material of the air vane from Aluminium to
Stainless Steel)
The aluminium air vane used on the B-6288 cut-out switch has been in service for many years with no complaints.
However, during harsh field testing, it was discovered that the air vane had deteriorated where the reset rod connects into the air vane.
Intense vibrations would cause the reset rod to vibrate with respect to the air vane. This would in turn cause a hammering effect that would slowly enlargen the point of attachment of the reset rod to the air vane.
Therefore, it was decided to upgrade the material of the air vane from aluminium to stainless steel. This would inherently allow the air vane to last longer, thereby extending the life of the cut-out switch.
Shown with deterioration.
Old style Alum. Air vane
New reinforced Stainless Steel Air vane.
Stainless Steel for better durability.
12
Wi l d f i r e
The foot valve must remain at least 30 cm (1 foot) under the water surface while pump is operating.
All suction couplings, including foot valve, must be wrench tightened. Proper fitting gaskets must be used in all coupled joints. Worn or dried out gaskets should be replaced with new gaskets.
CUTOUT SWITCH ADJUSTMENT (STATIC)
The cutout switch must be adjusted when installed in the fan cowl. This is necessary because slight changes in the shape of the mounting plate occur when fastened in position on the fan cowl.
Check that, with the air vane in the approximate centre of its travel, the spring attachment holes "line up" with the pivot to form a straight line (see figure X).
All brackets and pivot should be perpendicular with the face of the plate.
Initial setting: A preliminary setting can be made by placing on the vane an object sufficiently heavy to cause the vane to just leave the stop and start to move towards the contacting position. A 2.5 oz (70 g) weight is used to approximate the setting during assembly. The final calibration must be made with the engine running.
CUTOUT SWITCH ADJUSTMENT (DYNAMIC)
1
Setup pump unit close to water supply. Use a 2 m to 3 m (6' to 10') suction hose with foot valve attached. Connect a short length 2 m to 3 m (6' to 10') of discharge hose to pump outlet. Attach a calibrated nozzle having a 12,7 mm
(1/2") diameter orifice.
2
After starting and warming up engine thoroughly, increase to maximum recommended power, then lift foot valve out of water supply. Engine will speed up then stop suddenly, indicating the automatic cutout switch is functioning.
Should the switch not cutout after 1-2 seconds, while engine is running at increased speed, close throttle and toggle switch immediately, otherwise serious engine damage may result.
Assuming that cutout is functioning, then the speed setting of the switch should be checked to make sure that it is not set too low or too high.
Use a reliable tachometer to check engine RPM.
3
Located in the upper centre of the outer surface of the fan housing, is a small socket head adjustment screw. By using a 1/16" Allen key (tool R-909) and turning this screw 1/2 turn clockwise will increase the cutout speed setting approximately 150 RPM. A 1/2 turn counterclockwise will decrease speed setting approximately 150 RPM. After each adjustment, recheck the actual speed at which cutout switch operates until proper setting is obtained.
If a reliable tachometer is not available, then the cutout switch may be roughly calibrated as follows:
Use a 3 mm (1/8") orifice tip screwed to nozzle. After warming up engine thoroughly, increase to full throttle, then turn adjustment screw slowly counterclockwise until switch cuts out and stops engine. Now turn screw one full turn clockwise and leave it in this position.
The cutout switch will now operate automatically to stop engine should pump run out of water, lose prime, etc. The switch will not interfere with normal operation of the unit and will also allow the use of small nozzle tips as well as complete pump shut-off for short periods of time.
4
3
PUMP UNIT
REGULAR MAINTENANCE
Ref. Part
##
_
R-900
Description Qty
Maintenance tool kit (incl. all parts listed below) 1
1 Part-117 Grease gun 1
2 271-923 Wrench - adjustable 8" (203mm)
3 R-911M Wrench - box & open end 1/2" (13mm)
1
1
4 R-906M Wrench - box & open end 3/8" (10mm)
5 R-910 Wrench - open end 1/2"-9/16" (13-14mm)
6 R-902
7 R-904
Screwdriver 2" (51mm)
Wrench - spark plug
1
1
1
1
8 A-3023 Carburetor adjusting tool
9 R-901 Screwdriver, 4" (102mm) sq. handle
10 R-903
11 R-908
Feeler gauge - spark plug & breaker point
Wrench - open end 5 & 8mm (ignition)
12 R-905 Handle - rod
13 271-488 Bag - tool roll (not shown)
14 271-928 6 mm T-handle Hex 10.5" LG
1
1
1
1
2
1
1
MAINTENANCE CHECK LIST
Regular maintenance is a schedule of continuous systematic maintenance, designed to prevent frequent or major breakdowns before they occur.
Maintenance on a fire pump unit should not be done on the fire line.
Always, check your pump unit immediately after use.
1
Clean unit thoroughly.
2
Clean air filter.
3
Clean fan housing and air intake screen.
4
Make sure cooling passages and cylinder fins are clean.
5
Make sure spark plug is cleaned and has proper gap setting.
6
Check stop switch for proper operation.
7
Check throttle and choke control for proper operation.
8
Make sure carburetor fuel strainer screen is clean.
9
Check fuel line and fittings for signs of wear, etc.
10
Check and grease pump end (as per instructions in previous section)
11
Check starter cable and mechanisms and replace if it shows signs of wear.
12
Check condition of buffer coupling.
13
Operate pump unit and check general performance. Adjust carburetor if necessary (see Service Manual for details)
14
Check carburetor adjustments.
15
Note any performance irregularities or any abnormal mechanical sounds.
16
Make sure pump seal is not leaking.
17
Make sure that all necessary tools, spares and accessories are with pump unit.
It is strongly suggested to always have an extra spark plug on hand.
18
Make sure electronic ignition module is free of debris. Verify condition of wiring and connections.
3
7
1
12
8
2
6
9
4
5
10
11
14 w w w. w i l d f i r e - e q u i p m e n t . c o m
13
4
REGULAR MAINTENANCE
IMPORTANT
Refer also to section on "Servicing
Carburetor" for additional "Trouble
Data" and service information.
SERVICING SPARK PLUG
Operating with a defective or incorrect spark plug will affect the engine's performance; hard starting, fouling, missing, overheating, pre ignition or lack of power. To service and inspect the spark plug, perform the following steps as required:
1
Remove spark plug cover.
2
Disconnect spark plug cable and remove spark plug.
3
Clean spark plug and inspect carefully. If tip of insulator core is rough, cracked, broken or blistered, or if electrodes are burned away to the extent that they are too thin and cannot be satisfactorily adjusted to recommended gap. 0.016" -0.020" (0.41-0.51mm), replace with new plug.
Note: Use R-629 spark plug.
Use only spark plug type specified by engine manufacturer.
4
Reinstall spark plug. Start threads one or two turns with fingers to avoid danger of cross threading. Tighten spark plug to recommended torque of 25 Nm
(18 ft-lbs or 215 inch-lbs).
5
Connect spark plug cable.
6
Install spark plug cover; tighten screws securely.
Caution: Ceramic insulation of spark plug is easily damaged by shock stresses or bending stresses as may be imposed by dropping, striking with hard objects or overtightening. Therefore, if spark plug has been subjected to such accidental abuse, it should be carefully inspected and tested before further use.
UPGRADED
SPARK PLUG CAP
For years the MARK-3 has been using a rubber spark plug connector R-650. The rubber connector has been known to crack where the wire goes into the connector and where the rubber connector goes onto the spark plug.
The rubber connector was replaced with a new robust type of connector used on high performance recreational vehicles. The new connector has the added benefit of being able to shield against signals.
The part number will still remain the R-650.
A new robust type of connector will replace the old spark plug rubber cap.
1
2
3
4
4
REGULAR MAINTENANCE
ELECTRONIC IGNITION UNIT
(Short explanation for retrofit installation of an electronic ignition unit on the
MARK-3 engine which was originally fitted with contact breaker ignition)
PROCEDURE:
• Remove old flywheel and armature plate.
• Fit the new armature plate approximately centrally of the long holes turn it approx. 1 mm anti-clockwise, then tighten the 3 screws.
2
1
, then
• Turn crankshaft until the piston is 3.75 mm before top dead centre, measuring through the spark plug hole with a dial gauge. For the final dynamical ignition timing check make an ink mark on the coupling buffer 12-17
3
as well as on the flange – pump mounting R-136.
4
• Fit electronic box.
5
• Start engine and check ignition timing with a stroboscopic lamp. The 2 marks
3 4
previously made must correspond at 3000 – 4000 r.p.m.
• If the 2 marks do not correspond, remove flywheel and loosen the 3 screws
2
of the armature plate, turn armature plate slightly in the direction needed.
Repeat the procedure until the marks correspond.
• Seal rubber grommet
6
with Silastic.
5
6
14
Wi l d f i r e w w w. w i l d f i r e - e q u i p m e n t . c o m
15
4
REGULAR MAINTENANCE
ELECTRONIC IGNITION MODULE SETTINGS
Table
Resistance value Check
Resistance value Check
System
Ø116mm Flywheel magneto
CDI unit with H.V. coil
Part number
492.19.6009
432.39.9510
FLYWHEEL MAGNETO
+ / -
Green wire
Ground (stator)
Green wire
-
225 ÷ 255
Ω
Ground (stator)
225 ÷ 255
-
Ω
CDI UNIT WITH INTEGRATED IGNITION COIL
+ / testing pin
STOP
VERDE (G)
Ground
H.V. output.
STOP
-
≤ 0.1 Ω
≥ 50 MΩ
≥ 50 MΩ
VERDE
(G)
≤ 0.1 Ω
-
≥ 50 MΩ
≥ 50 MΩ
Ground
(red wire)
≥ 50 MΩ
≥ 50 MΩ
-
4.7 ÷ 5.5 K
Ω
H.V. output
(AT)
≥ 50 MΩ
≥ 50 MΩ
4.7 ÷ 5.5 K
Ω
-
Notes:
• Testing Temperature: 25° C.
• Values (in ohm) detected by Tester Digital BECKMAN RMS 3030.
• The above said values are not always a guarantee of perfect efficiency of the part.
16
Wi l d f i r e
R-233DS
4
REGULAR MAINTENANCE
DECOMPRESSION SWITCH R-233DS
The MARK-3 model MK-3-DS features a decompression switch that significantly facilitates starting the pump.
To convert existing Mark-3’s, simply replace the cylinder head with an R-233DS
(New cylinder head including a decompression switch assembly).
KEY CHARACTERISTICS
•
Decompression switch makes easy pulling / starting of recoil starter on high compression MARK-3
•
Engine fires up much easier
•
No kick back
•
Easily engaged, simply push decompression switch in
•
Automatically disengages / closes when engine starts
PARTS BREAKDOWN
• Decompression Switch: A-7627
• Copper Washer: A-7628
• Cylinder Head: R-233 (machined head not sold separately)
• Head Gasket: R-238 (not shown)
INSTALLATION NOTES
• Torque value for decompression switch: 190-210 in-lbs (21-24 Nm).
• Install cylinder head with decompression switch oriented towards pump end.
A-7627
A-7628
R-233
Exploded view R-233DS w w w. w i l d f i r e - e q u i p m e n t . c o m
17
4
REGULAR MAINTENANCE
SERVICING CARBURETOR
CARBURETOR DESCRIPTION
18
Wi l d f i r e
Ref.#
_
Part#
R-1115
R-1004
R-1036
R-1037
R-1038
R-1101
R-1111
R-1112
R-1110
R-1001
R-1034
R-1046N
R-1047
R-1003
R-1002
R-1005
R-1041
R-1045
R-1113
R-1041
R-1040
R-1026
R-1035
R-1039
R-1019
R-1020
R-1021
R-1022
R-1030
R-1020
R-1021
R-1022
R-1012
R-1013
R-1015
R-1016
R-1014
R-1017
R-1018
R-1050
R-1024
R-1023
R-1029
R-1025N
R-1008
R-1009
R-1010
R-1011
28
29
30
31
24
25
26
27
20
21
22
23
16
17
18
19
12
13
14
15
10
11
8
9
6
7
4
5
1
2
3
44
45
46
_
40
41
42
43
36
37
38
39
32
33
34
35
Description
Carburetor (includes parts listed below except R-1113)
Body
Gasket-carburetor
Mach. screw with lockwasher
Throttle shutter
Inlet control lever pinion screw
Throttle shaft and lever
Throttle shaft return spring
Idle mixture screw
Idle mixture screw spring
Flat washer, brass
Idle mixture screw packing
High speed mixture screw
High speed mixture screw spring
Flat washer, brass
High speed mixture screw packing
Choke shaft and lever
Throttle shaft clip
Lockwasher
Mach. screw
Throttle link lever assembly
Bolt
Flat washer
Hex nut
Body channel welch plug
Nozzle check valve
Inlet needle and seat
Inlet seat gasket
Choke friction spring
Choke friction pin
Choke shutter
Mach. screw with lockwasher
Idle speed screw spring
Idle speed screw
Inlet tension spring
Inlet control lever
Diaphragm gasket
Diaphragm
Diaphragm cover
Fuel pump gasket
Fuel pump diaphragm
Fuel pump body
Fuel strainer screen
Fuel strainer cover gasket
Mach. screw with lockwasher
Fuel strainer cover
Mach. screw
Repair parts kit (includes parts R-1001,
R-1008, R-1009, R-1113, R-1025N, R-1011,
R-1012, R-1016, R-1046N, R-1046N-L)
4
REGULAR MAINTENANCE
The carburetor can be cleaned with a minimum of tools.
Before disassembling carburetor it is imperative to flush it clean of dirt by using proper carburetor cleaner.
1
Remove strainer cover retaining screw and plastic cover.
2
Remove strainer cover gasket and strainer screen.
3
Remove screws and fuel pump body.
4
Remove fuel pump diaphragm and gasket.
5
Remove main diaphragm cover plate.
6
Remove main diaphragm and main diaphragm gasket.
7
Remove inlet control lever fulcrum pin, lever and tension spring.
8
Remove inlet needle.
9
With a thin wall 8 mm (5/16") hex socket carefully remove the inlet seat. Remove inlet seat gasket. When reinstalling seat, tighten only to 3 or 4 Nm (25-35 inch-lbs).
10
Remove idle and high speed mixture screws.
11
When reinstalling O-ring type adjusting screws, lubricate with SAE-30 oil to prevent seizing. Packing spring type adjustments do not require lubrication.
12
The ball check type main nozzle can be removed by tapping it out of the body casting into the venturi with a small punch. A replacement ball check nozzle should be pressed into the casting. The brass cage should be pressed flush with the metering chamber casting.
Before reassembling the carburetor (in reverse order as outlined above) wash all component parts in carburetor cleaner and blow off with compressed air. The channels in the metering body should be cleaned by blowing through the idle and main adjusting orifices. All fuel passages in the three castings should be cleaned with compressed air.
Do not clean orifices or passages with wires or drills as this might damage and cause incorrect operation of the carburetor.
When reassembling the inlet control lever and spring, make sure that the spring rests in the well of the metering body and locates on the dimple of the inlet control lever.
Do not stretch spring. Inlet control lever is properly set when flush with floor of diaphragm chamber.
Be certain main diaphragm, gasket and cover casting are carefully fitted over the three small pins cast in rim at bottom of metering body. Also the fuel pump gasket, diaphragm and fuel pump body are placed over similar pins at bottom rim of main diaphragm cover casting. Evenly tighten fuel pump body retaining screws to insure complete seal of casting separations at both diaphragms.
Frequent cleaning or replacement of the fuel strainer screen will aid satisfactory operation of the carburetor.
w w w. w i l d f i r e - e q u i p m e n t . c o m
19
4
REGULAR MAINTENANCE
SERVICING CARBURETOR (CONTINUED)
CARBURETOR ADJUSTMENT
The carburetor is provided with three adjustments, namely high speed (main) adjustment; low speed (idle) adjustment; and idle speed regulating screw.
1
Before starting pump unit, close both main and idle adjustment screws, by turning clockwise, until needle just touches seat.
Note: Turn adjustment screws carefully and gently. Do not force needle into seat, otherwise, both needle and seat may be permanently damaged.
2
Open main adjustment screw 1 turn, by turning counterclockwise.
3
Open idle adjustment screw 1 turn, by turning counterclockwise.
4
Turn idle speed regulating screw until throttle shutter is slightly open.
5
Start unit. Open choke slowly, and allow engine to warm up thoroughly, gradually increasing speed to full throttle setting while running with 6 mm (1/4") diameter nozzle tip connected to a 3 m (10') discharge hose.
6
When engine is thoroughly warmed up, close throttle, then adjust idle adjustment screw and idle speed regulating screw, until engine idles smoothly between 2000-2200 RPM.
7
Increase speed gradually to full throttle setting, then turn main adjustment screw until engine gives maximum RPM and pump delivers maximum pressure. Then, turn main adjustment screw 1/4 turn maximum counterclockwise.
This setting will give correct mixture ratio to assure proper engine lubrication.
Do not leave main adjustment screw set too lean, otherwise serious engine damage may occur due to lack of sufficient lubrication.
Note: It will be necessary to readjust the carburator when taking the pump from one altitude and placing in a different altitude. Repeat step 1 to 7.
20
Wi l d f i r e
4
REGULAR MAINTENANCE
CARBURETOR TROUBLE CHART
CARBURETOR FLOODING
Possible cause
Dirt or foreign particles preventing inlet needle from seating.
Diaphragm lever spring not seated on lever dimple.
Diaphragm improperly installed in carburetor.
Improper use of choke
Remedy
Remove, clean and replace.
Remove lever and reinstall.
Replace diaphragm or correct installation.
Proper use of choke at start-up
ENGINE WILL NOT ACCELERATE
Possible cause
Idle adjusting screw set too lean.
Incorrect setting on diaphragm lever.
Diaphragm cover plate loose.
Diaphragm gasket leaking.
Main fuel orifice plugged.
Remedy
Enrich idle adjustment.
Reset.
Tighten.
Replace.
Remove diaphragm cover, diaphragm, diaphragm lever and main adjusting screw. Clean out orifice by blowing through main adjustment threaded hole.
ENGINE WILL NOT IDLE
Possible cause
Incorrect idle adjustment.
Idle discharge ports or channels clogged.
Diaphragm lever set incorrectly.
Throttle shutter cocked in the throttle bore causing fast idle.
Dirty nozzle check valve.
Welch plug covering the idle discharge ports does not seal.
This causes the engine to idle with idle adjustment shut off.
ENGINE RUNS OUT LEAN
Possible cause
Tank vent not working properly.
Leak in fuel system from tank to pump.
Ruptured fuel pump diaphragm.
Main fuel orifice plugged.
Remedy
Reset to best idle.
Blow out with compressed air, or if compressed air is not available, clean and flush with gasoline.
Reset diaphragm lever so it is flush with the floor of the diaphragm chamber.
Reset.
Clean and/or replace.
Replace welch plug, following instructions outlined in service manual.
Remedy
Clean and/or replace.
Tighten or replace fittings or lines.
Replace.
Clean.
CARBURETOR RUNS RICH WITH MAIN ADJUSTMENT SHUT OFF
Possible cause Remedy
The nozzle channel plug, or nozzle check valve cage, is not sealing.
Install new plug or new cage.
w w w. w i l d f i r e - e q u i p m e n t . c o m
21
4
REGULAR MAINTENANCE
Ref. Part
# #
-R-792
1
2
3
4
5
6
R-793
R-791
R-1044
R-794
R-955
R-790
Description Qty
Throttle control assembly (includes all parts with *, 7 items)
1
Mach. screw hex cap, 2
Nylock
Lockwasher
Lock plate
Cover for air filter
Air filter element foam & screen
(option R-795 also available)
Carburetor shroud
(includes decal A-4030)
1
1
1
2
1
7
8
12-79 Lockwasher, star type 2
B-4036-12* Mach. screw hex socket
2
9 R-799
10 12-79*
Bracket
Lockwasher, star type
1
2
11 R-774 Mach. screw
12 R-1102* Link for throttle
13 B-4024* Quadrant for throttle 1 lever
14 R-1107* Throttle lever sub-assembly
1
2
1
15 A-4028* Spring
16 A-4027* Pin - index
-MTR-1000 Hours meter with
RPM (not shown)
1
1
1
SERVICING AIR FILTER
1 2 3
13 14 15 16
12
4 5 5 6 7 8 9 10 11
If not cleaned regularly, the filter element will become clogged and will seriously restrict airflow to the carburetor.
This restriction will cause engine to run irregularly, lose power and four-stroking will develop due to an over-rich mixture entering the carburetor.
Therefore, whenever the filter element becomes dirty, or whenever any of the above conditions occur, remove the filter element and wash it in a appropriate cleaning solution. Apply 2-cycle oil to filter element and squeeze to distribute oil evenly. Reinstall filter and screen into housing and install cover. When the filter will not wash clean or is damaged, replace it.
12 13
Ref. Part
# #
1
2
R-150
R-149
Description
Hex lock nut
Lockwasher
Qty
3 R-402 Stud
4 R-1113 Gasket - carburetor
5
6
R-257
R-270
Cylinder
Cast iron sleeve
7 R-235 Gasket - cylinder flange 1
8 R-237 Gasket - muffler 1
1
1
2
1
2
2
9 R-117 Stud
10 R-119 Lockwasher
11 R-120 Hex nut
12 R-233 Cylinder head - 18mm
13 R-238 Gasket - cylinder head
2
1
2
2
1
8 9 10 11
1 2 3 4 5 6 7
22
Wi l d f i r e
Ref. Part
# #
1
2
R-414
R-119
3 R-413
4 R-119
Description Qty
Mach. Screw hex cap 1
Lockwasher 1
Cover for spark plug
Lockwasher
1
1
5 R-414 Mach. Screw hex cap 1
6 B-2920-6 Flat slotted bolt 2
7 A-2924 Reset rod
8 A-2926 Cable
1
1
9 B-6288 Cutout switch assembly 2
(includes ref. #6, #7, #8, #10 and #14)
10 B-2428-6 Hex lock nut
11 R-408 Mach. Screw
12 12-38
13 R-409
Lockwasher 4
Clamp - ignition cable 1
2
1
14 B-2920-23 Grommet
15 TY-1811 Hex nut
16 R-115
17 R-150
Stud
Hex lock nut
2
3x
3
2x
18 R-151
19 R-402
Flat washer
Stud
20 R-411P Fan cowl with studs, painted (includes
R-115 and R-402)
21 R-418 Shield - fan
1
1
1
1
4
REGULAR MAINTENANCE
SERVICING COOLING SYSTEM
Efficient engine cooling is accomplished by a fan attached to the flywheel. This fan pulls air through the fan housing screen, then forces the air around the cylinder and through the spaces between the cylinder and cylinder head fins.
In time, the cooling air passages will become partially clogged and fins will become coated with dirt, therefore reducing the cooling efficiency.
Therefore, whenever this condition occurs, remove fan housing, then use compressed air or a stiff bristle brush and appropriate cleaning solution to remove all dirt deposits from fins and from inside the fan housing.
16
17 18 19
20 21 w w w. w i l d f i r e - e q u i p m e n t . c o m
23
4
REGULAR MAINTENANCE
Ref. Part Description
# #
_
R-529 Rewind Starter
Qty
1
(includes all parts listed below)
1 R-518 Circlip
2 R-517 Flat Washer
1
1
3 R-516 Spring - friction
4 R-526 Washer - Friction
5 R-528 Pawl assembly
6 R-510 Flat "D" washer
7 R-504 Aluminum sheave starter rope
1
1
1
1
1
8
9
10
R-506
R-531
R-530
Spring - rewind
Retainer - spring
Housing - starter
(includes R-531)
11 12-38 Lockwasher
12 R-522 Mach. screw hex cap
13 R-509 Plug - rubber
14 R-524 Mach. Screw
1
1
1
15
16
17
18
R-523
R-532
R-505
R-533
Lockwasher
Cover
Pin - starter rope lock
Guide - starter rope
19 R-502 Rope - starter
20 R-544 Buffer - rubber
21 R-501 Handle - starter rope
1
1
2
1
1
2
4
4
1
1
1
SERVICING THE REWIND STARTER
Starter proceed as follows:
1. Remove four bolts #12 and four lock washers #11.
2. While holding rope sheave #7 in place to prevent sudden rotation of the sheave, remove handle #21 and rubber buffer #20.
3. Allow sheave to rotate slowly until spring tension is completely relaxed.
4. Remove two screws #14, two lock washers #15, cover #16, lock pin #17 and guide #18.
5. Remove circlip #1 and then remove items #2, 3, 4, 5 and 6 from starter housing.
6. If friction washers #4 and #6 are worn, replace them.
7. If pawls are broken or worn, replace the complete pawl assembly #5.
8. Very carefully remove rope sheave, making sure the rewind spring #8 remains in the retainer #9 and the starter housing #10. Always wear eye protection when removing the rope sheave.
9. Very carefully remove rewind spring. Always wear gloves and eye protection when removing the rewind spring.
10. Wash all metal parts with proper cleaning solution.
NOTE
Pawl assembly #5 must be assembled with the pawl-spring-stop on the left, otherwise the starter will not function.
24
Wi l d f i r e
4
REGULAR MAINTENANCE
11
5
5
8
7
5
5
REMOVAL OF REWIND STARTER:
Warning: All repairs must to be carried out by qualified, professionally trained and authorized staff. Only careful assembly and respecting all the instructions of this
SERVICE INFORMATION will warrant trouble free operation.
• Remove 4 hex. screws M6x20 starter ass’y.
7
5
with lock washers (6) and detach the rewind
• Depress the cover washer
8
and remove circlip
9
.
9
10
12
•
Remove cover washer
8
, friction spring
10
and friction washer
11
.
•
Remove rewind starter parts set ass’y
12
and thrust washer.
w w w. w i l d f i r e - e q u i p m e n t . c o m
25
4
REGULAR MAINTENANCE
SERVICING THE REWIND STARTER (CONTINUED)
4
1
13
15
• Hold rope sheave
1
and remove the 2 Allen screws M5x16 lock washers
14
and the cover
15
with plug
16
.
13
along with
Warning: Keep rope sheave spring
4
unwinds!
1
firmly in hands! Risk of injury when rewind
16
1
3
17
•
Pass the starter grip
17
through the window in the starter housing and turn rope sheave
1
approx. 4 turns counterclockwise so that the rewind spring
4
unwinds.
•
Remove starter sheave
1
with starter rope
3
and starter grip
17
.
18
• Check bearing bolt
18
for signs of seizure.
Note: If there are slight signs of seizure remove them carefully.
• Check bearing bore of the rope sheave
1
for signs of seizure.
Note: If there are signs of seizure the rope sheave must be replaced.
•
Apply oil on the rewind spring
4
.
•
Apply Molykote G-N slide paste on the bearing bolt
18
of the rope sheave
1
.
26
Wi l d f i r e
1
13
19
16
15
16
4
REGULAR MAINTENANCE
REASSEMBLY OF REWIND STARTER:
• Wind starter rope
3
fitted with starter grip
17
counter-clockwise in the rope
• Fit rope sheave
1
on the bearing bolt and engage it by slight turning into the rewind spring
4
.
• Hold rope sheave firmly and turn starter housing 4 turns clockwise to pretension the rewind spring.
• Fit rope guide
19
in the recess and pass the starter grip through the window in the starter housing, holding the rope sheave firmly.
• Fit the plug
16
.
• Fit the cover
15
and fix it with 2 Allen screws M5x16
13
and lock washers
16
.
Tightening torque: 2.2 - 3 lb-ft (3 - 4 Nm)
20
21
12
22
• Insert thrust washer
10
.
• Fit rewind starter parts set ass’y
12
in the rewind starter.
Note: Pay attention to correct positioning. The corners of the pivot arm must point toward top / left
21
and down / right
22
.
20
• Slightly lubricate the serration
20
of the pivot arm.
• Insert the friction washer
11
so that the serration points towards pivot arm
20
.
11
11
10
• Fit friction spring
10
and cover washer
8
.
w w w. w i l d f i r e - e q u i p m e n t . c o m
27
4
REGULAR MAINTENANCE
SERVICING THE REWIND STARTER (CONTINUED)
Ref. Part
# #
_
R-952
Description
Service tool kit
Qty
(incl. all parts listed below)
1
1 R-929 Flywheel holding tool
2 271-927 Screwdriver
Phillips No.12
1
1
3 271-346 Screwdriver - standard 1
4 R-928 Cap - shaft protector 1
1 5 R-930 Puller - crankshaft bearing R-313
6 R-938 Puller - crankshaft bearing R-333
1
7 R-932 Puller - collar coupling 1
8 R-933 Oil seal - pressing tool 1
9 R-927 Puller - magneto
10 R-953 Crankshaft jack
1
1
11 R-954-14 Gauge - timing
12 R-926 Socket wrench
14mm (9/16")
13 R-909 Key - Allen
2,4 mm (3/32")
1
1
1
4
REGULAR MAINTENANCE
SERVICING MAGNETO
To check if ignition system is functioning, remove spark plug and connect another spark plug, with gap set to 3,2 mm (0.126"), to the ignition cable. With this plug resting on top of cylinder head, give starter rope a normal pull. Spark should easily jump the gap, if system is functioning properly.
If no spark appears: If spark is weak:
Check stop switch and cable for possible short Check magneto air gap
Check for shorted condenser
Check for open coil
Check electronic ignition module
Check for broken leads or cables
Check electronic ignition module
8
9
• Depress cover washer
8
and fit circlip
9
.
24
• Pull starter grip
17
and check whether the pawls
23 24
are moving outward.
When releasing the starter grip the starter rope must be rewound to its idle position.
Note: If the pawls do not move outward the rewind starter parts set ass’y
12
has been inserted wrongly. In this case disassemble it again and fit the rewind starter parts set ass’y
12
correctly.
23
5
5
28
Wi l d f i r e
7
5
5
• Fit rewind starter ass’y
7
with 4 hex. Screws M6x20
5
and lock washers
6
.
Tightening torque: 6.6 lb-ft (9 Nm)
• Start engine to check function of the rewind starter.
Ref. Part
# #
1 R-116
Description Qty
3 R-603
Hex lock nut
2 R-667N-E* Flywheel magneto assembly
Fan
(included in R-667N-E)
1
3
1
4 R-791
5 R-602
6 R-146
7 R-653
8 R-601
Lockwasher
Stud
Mach. screw
Gasket
Pulley manual starter rope
4
1
4
3
1
9 12-38
10 R-116
Lockwasher
Hex lock nut
3
3
* New models do not have a dust shield
R-647.
w w w. w i l d f i r e - e q u i p m e n t . c o m
29
4
REGULAR MAINTENANCE
Ref. Part
# #
_
R-656
1
2
3
4
5
6
7
8
9
10
11
12
13
R-665*
R-661*
R-617*
R-664*
R-612*
R-611*
R-637*
R-661*
R-638
R-611*
R-637
R-662*
R-659
Description Qty
Armature 1 plate complete
(incl. parts with *)
Mach. screw
Lockwasher
1
1
Flat washer
Point & cable condenser R-628
1
1
Mach. screw
Lockwasher
Flat washer
Coil
Mach. screw
Lockwasher
Flat washer
Condenser
Armature plate
(incl. R-662)
3
1
3
3
1
2
1
2
2
14
15
16
17
18
R-654*
R-636*
R-630*
R-645
R-650
19 R-629
_
R-633-T
Cap
Grommet
Cable-spark plug
Cable- spark plug
1
1
Rubber sleeve 1
Protector - spark plug 1
Spark plug 18mm 1
Stop switch kit
(incl. Ref. #20 to #25)
1
20 R-665
21 R-637
Mach. screw
Flat washer
22 R-611 Lockwasher 1
23 C-7010-12 Stop switch assembly 1
1
1
24 C-7010-12C Stop switch assembly 1
25 R-634* Cable stop switch 1
SERVICING MAGNETO (CONTINUED)
Before replacing flywheel assembly, the ignition timing should be checked.
See "Ignition Timing".
1
Replace flywheel assembly; make certain that flywheel keyway is aligned properly with crankshaft key.
Important: Remove all traces of grease, oil and dirt from crankshaft taper and flywheel bore before replacing flywheel assembly.
2
Replace lockwasher and flywheel hub nut.
3
Tighten hub nut to recommended torque. This is very important.
4
Attach fan cowl assembly.
5
Attach spark plug cable clamp.
6
Connect cable to stop switch.
5
MAJOR OVERHAUL SERVICE
Ref. Part
# #
1 R-146
2 R-144
Description
Mach. screw
Shield - dust
Qty
3 R-105
4 12-38
Mach. Screw
Lockwasher
5 R-152* Crankcase halves set 1
Complete with
2 dowel tubes R-103
2
5
4
1
6 R-120
7 R-206
8 R-236
9 R-133
10 R-342
11 R-123
12 R-103
13 R-117
Hex nut
Flat washer
2
3
1
1
4
4
Stud - cylinder mounting 4
Gasket for crankcase 1
Oil seal 0.983"
Oil seal 0.788"
Dowel tube
Stud
14 R-136
15 R-119
16 R-120
17 R-132
Flange - pump mounting 1
Lockwasher 2
Hex nut
Mach. screw
2
3
18 R-130 Stud - mounting leg
19 A-6149P Mounting leg
20 R-113 Gasket, metal
21 FAST-51 Drain screw
1
1x
4
4
22 C-5370-11 Flat washer
23 R-119 Lockwasher
24 R-120 Hex nut 1
25 RA-108 Mach. screw hex cap 1
1
2
* Gasket R-133 not included.
ENGINE OVERHAUL SERVICE PROCEDURE
MAJOR OVERHAUL SERVICE PROCEDURE
To replace or service the following:
• Crankshaft-connecting rod assembly;
• Crankshaft ball bearings;
• Crankcase;
• Oil seals;
Proceed as follows:
1
Remove pump end assembly and flexible buffer coupling disc.
2
Remove all wiring.
3
Remove screw, lockwasher and clamp, which hold spark plug cable to fan cowl.
4
Remove bracket R-799, which fastens to side of carburetor shroud to engine crankcase.
5
Remove engine from mounting frame.
6
Remove muffler.
7
Remove fan cowl with rewind starter.
8
Remove spark plug cover and spark plug.
9
Using the flywheel holding tool R-929 to prevent the collar coupling from rotating, remove nut and lockwasher from the collar coupling.
10
Remove collar coupling from engine with collar coupling puller R-932.
11
Remove manual starter rope pulley.
12
Remove flywheel nut and lockwasher using flywheel holding tool R-929.
13
Remove flywheel/magneto/fan using magneto puller R-927 and shaft protector tool R-928.
30
Wi l d f i r e w w w. w i l d f i r e - e q u i p m e n t . c o m
31
5
MAJOR OVERHAUL SERVICE
Ref. Part
# #
_
Description Qty
1 R-328
2 R-329
3
4
R-324
R-305
R-348 Crankshaft / conn.rod assembly
(includes parts with * and oil seal R-342)
Gudgeon pin
Circlip
Needle bearing
Key
_
5 R-344* Shim 0.004"
(flywheel side)
As req.
6 R-343* Ball bearing 0.983" ID 1
(flywheel side)
(1piece bearing)
1
1
1
1
7 R-301
8 R-303
Lockwasher 1
Hex nut (flywheel side) 1
9 R-331-1 L-type piston ring
10 R-331 Piston ring 0.078"
1
1
11 R-332
12 R-329
13 R-341* Crankshaft / conn.rod sub-assembly
1
(includes half coupling side
R-324M and half flywheel side R-341M with req. pins)
14 R-330
15
16
R-334
R-306
Shim, bevelled As req.
0.040" (coupling side)
Spacer
Shim 0.006"
(coupling side)
1
As req.
17 R-333
Piston with rings
Circlip
1
1
18
19
R-315
12-18
20 R-301
21 R-302
Ball bearing 0.788" ID 1
(coupling side)
(1 piece bearing)
Collar coupling
Pin
1
4
Lockwasher 1
Hex nut (coupling side) 1
DISASSEMBLY PROCEDURE FOR ENGINE
14
Remove armature plate with cables.
15
Remove cylinder head and cylinder.
16
Remove piston from connecting rod.
17
Remove the machine screws, which fasten crankcase halves together.
18
To separate crankcase halves on engine with one-piece bearing, heat both crankcase halves (on the outside face of the crankcase around the bearing housing portion) to a maximum of 100 °C (212 F) and, using a plastic or rubber mallet, separate crankcase halves.
19
Remove crankshaft with connection rod.
20
Press out both oil seals using oil seal pressing tool R-933.
21
Remove bearings from crankshaft journals using shaft protector tool R-928 and bearing puller tool R-938.
22
Always change oil seals.
19
Pistons, rings and shims - optional sizes
R-307 Shim 0.008" (coupling side)
R-308
R-309
Shim 0.012" (coupling side)
Shim 0.016" (coupling side)
R-310
R-311
R-312
R-344*
Shim 0.020" (coupling side)
Shim 0.031" (coupling side)
Shim 0.040" (coupling side)
Shim 0.004" (flywheel side)
R-345*
R-346*
R-347*
R-332-0
R-331-0
R-331-0-1
R-321
Shim 0.012" (flywheel side)
Shim 0.020" (flywheel side)
Shim 0.039" (flywheel side)
Oversized piston (includes rings)
Oversized piston ring 0.078"
Oversized L-type piston ring
Serrated lockwasher 12mm (used on old style engine)
20 21
As req.
As req.
As req.
As req.
As req.
As req.
As req.
As req.
As req.
As req.
_
_
_
_
32
Wi l d f i r e
Pistons, rings and shims optional sizes
R-307 Shim 0.008"
(coupling side)
R-308
R-309
R-310
Shim 0.012"
(coupling side)
Shim 0.016"
(coupling side)
Shim 0.020"
(coupling side)
R-311
R-312
Shim 0.031"
(coupling side)
Shim 0.040"
(coupling side)
R-344* Shim 0.004"
(flywheel side)
R-345* Shim 0.012"
(flywheel side)
As req.
As req.
As req.
As req.
As req.
As req.
As req.
As req.
R-346* Shim 0.020"
(flywheel side)
R-347* Shim 0.039"
(flywheel side)
As req.
As req.
R-332-0 Oversized piston
(includes rings)
R-331-0 Oversized piston ring 0.078"
R-331-0-1 Oversized L-type piston ring
R-321 Serrated lockwasher 12mm
(used on old style engine)
_
_
_
5.1 Magneto side
5.2 Pump side
5.3
5
MAJOR OVERHAUL SERVICE
REASSEMBLY SERVICE FOR ENGINE
For reassembly (1 piece bearing)
23
Place both crankcase halves on a table with inner faces up.
24
Using a depth micrometer, carefully check the distance from joint-face of each crankcase half to lower face of each bearing housing.
• For pump side crankcase half, call this dimension (A) (5.1).
•
For magneto side crankcase half, call this dimension (B) (5.2).
25
Measure thickness of crankcase gasket R-133. Call this dimension (C).
26
Subtract dimension (B) from (A). Call this dimension (D).
27
Measure thickness of crankshaft spacer R-334. Call this dimension (E).
28
Subtract (E) from (D). The answer is the thickness of shim(s) needed to centre the crankshaft.
29
Put the spacer and the shims (if necessary) on crankshaft (pump side) and measure the total width. Call this dimension (F) (5.3).
30
Select acceptable end play (see Clearance Data and Limits, page 39) and call it (G). Try (G) = 0.128 mm (0.005").
31
Use oil seal pressing tool R-933 to install oil seal R-342. Press bearing R-343 in crankcase half (magneto side).
32
Use oil seal pressing tool R-933 to install oil seal R-123. Press bearing R-333 in crankcase half (pump side).
33
Measure the combined thickness of 2 ball bearings. Call this dimension (H).
34
Subtract (H) from (G) and divide by 2. This is (J) the thickness of shim(s) to be placed on each side of the crankshaft.
A+B+C-F-G-H = shim thickness to be placed on each side of crankshaft
2
Note: The crankshaft used in the electronic ignition units does not have a lobe ground into the crankshaft end.
35
Slide crankshaft in crankcase half (pump side). Be careful to prevent damage to lip of oil seal.
36
Press crankshaft into crankcase half (pump side). To prevent bending of crankshaft, be sure to always use the crankshaft jack tool R-953 (fig.1) between the webs of the crankshaft (fig.2).
37
Install crankcase gasket (apply some oil). Important: Always use a new crankcase gasket.
38
Slide the other crankcase half on crankshaft.
39
Align dowel tubes and verify that crankshaft jack and connecting rod are in piston axe (fig.3) and press crankcase halves together.
40
Reassemble crankcase screws and lockwashers. Tighten screws uniformly to
11-12 Nm (100-110 inch-lbs) torque.
41
If piston was removed, reinstall it in proper position (arrow on top of piston or balancing lumps inside piston head should be on muffler side of engine).
Replace needle bearing R-324, if necessary.
42
Change cylinder head and cylinder flange gaskets (R-235 and R-238).
Cylinder head gasket must have the large band up.
43
When reassembling cylinder head, be sure the "filled" part inside the head is on the muffler side of the engine (therefore, "scooped-out" part will be on the carburetor side).
Important: Put carburetor side on same side of spark plug cable hole in crankcase.
Tighten cylinder head nuts to recommended torque as 23-25 Nm (200-220 inch-lbs).
Nuts should be retorqued after first 10 hours of operation and every 100 hours after.
44
Reassemble remaining parts in reverse procedure used in disassembly.
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5
MAJOR OVERHAUL SERVICE
Ref. Part
# #
Description Qty
1 A-2688* Thread protector
51mm (2'') (optional item)
(includes MK-138)
1
2 12-42 Mach. screw, nylon insert, 1
Fillister head, stainless
3 12-38 Lockwasher, stainless
4 12-13 Nose for shaft
6 A-5537 Protective cap, suction
7 12-39 Mach. head screw,
Fillester, stainless
8 12-38 Lockwasher, stainless
9 12-12A Suction nozzle
(includes 12-40)
10
11
12-27
12-8
O-ring
Pump body
8
1
12 12-43 Gasket 38 mm (11/2")
13 12-10 Cap for priming port
14 A-5538 Retainer for priming cap 1
15 ADP-A- Thread protector 38 mm 1
Fm15S (11/2") NPSH (optional item)
(includes gasket)
1
1
1
1
1
8
1
1
16 A-5536 Protective cap, discharge 1
17 12-29 Grease fitting 1
18 12-87 Extension for grease fitting 1
19 12-73 Plug, brass 1
20 12-28N Mechanical rotary seal 1
*Available with different threads.
DISASSEMBLY PROCEDURE FOR PUMP END
1
Remove shaft nose #4, by removing screw #2, and lockwasher. These will be visible upon removal of suction protective cap.
2
Remove screws #7, and lockwashers #8.
3
Using tool A-1888, remove suction nozzle #9.
4
Bend lockwasher #23 from locknut #22. Using tool A-1883 or 19 mm (3/4") wrench, remove locknut and lockwasher.
5
Remove screws #32.
6
Using bench-press and tools A-1890 and A-5297, press out shaft assembly.
Insure removal of drive bushing #29 before attempting to continue impeller/ distributor removal.
7
Using bench-press and tools A-1886 and A-5297, remove all internal parts.
(Impellers and distributors #24, 25, 26 and 27). Operation done in jogging strokes of press ram, so that all parts will be removed in a group.
8
If seal #21 is badly worn or damaged, press out complete seal.
Ref. Part
# #
_
_
12-2D
12-2E
Description Qty
_
Shaft sub-assembly
(includes parts with * and **, 8 items)
Shaft sub-assembly
(includes parts with **,
4 items)
_
22 12-50* Locknut, stainless 1
23 12-49* Lockwasher, stainless 1
24 12-11* Impeller
25 12-9 Distributor
1
2
26 12-7*
27 12-6
Impeller
Distributor
28 B-5312-4 O-ring for drive bushing 1
29 12-4AS** Drive bushing
(includes B-5312-4)
1
3
1
30 12-48** Double row ball bearing 1
31 12-3** Retaining ring for bearing1
32 12-25 Mach. screw flat Phillips, stainless
6
33 12-27
34 12-26
O-ring
O-ring
35 12-17 Coupling - buffer 1
36 12-2C** Shaft - riveted assembly 1
2
1
5
MAJOR OVERHAUL SERVICE
ASSEMBLY PROCEDURE FOR PUMP END
1
Slide bearing retaining ring #31 on shaft with plain face toward coupling collar.
2
Install drive bushing #29 onto the shaft after the bearing has been pressed on. Ensure drive-bushing lugs are located in the 2 milled slots at the top of the rotary seal. Dial in bearing on shaft within 0,051 mm (0.002").
3
Remove the inside O-ring from rotary seal #21. Install this O-ring over the drive bushing.
4
Press rotary seal #21 in pump body using sleeve A-4329 or A-5444. This should be done carefully.
5
Carefully pass end of shaft assembly, through rotary seal bore. Ensure drive bushing lugs are located in 2 milled slots at top of rotary seal, then continue pushing shaft until ball bearing rests firmly against shoulder in pump body.
Use the shaft aligning guide tool A-1887 to ensure that shaft is properly aligned with the pump body centerline.
6
Attach retaining ring #31 to pump body using six screws and tighten evenly and firmly.
7
Slide impeller #26 onto shaft, and engage with drive bushing #29.
8
Place O-ring #34 in groove of distributor #27. It is important to smear the new O-rings with a suitable lubricant used for pump ball bearing. This will facilitate the assembly.
9
With open end of pump body in vertical position, carefully lower distributor
#27 until it rests on bottom of body.
10
Slide impeller #26 into position, aligning with shaft.
11
Place O-ring #34 in groove of distributor #27
12
Place distributor on open end of body, then using bench press and assembly tool A-1884, apply several light, downward strokes of press ram until distributor "drops" into body. Distributor must then be positioned by hand as before.
13
Slide impeller #27 into position, aligning with the other impeller.
14
Repeat operations #11 and #12 with parts #33 and #25.
15
Slide impeller #24 into position, aligning with previous impeller.
16
Place lockwasher #24 on shaft with locating tab in milled groove.
34
Wi l d f i r e w w w. w i l d f i r e - e q u i p m e n t . c o m
35
5
MAJOR OVERHAUL SERVICE
MAINTENANCE TOOLS FOR PUMPS
Ref. Part Description
# #
_
A-2356 Maintenance tools for pump (includes all parts listed below)
Qty
1
1 A-1884 Pressing sleeve distributor assembly
2 A-4329 Pressing sleeve rotary seal assembly
3 A-4097 Protector - shaft
1
1
1
4 A-1888 Puller - suction nozzle 1
5 A-1890 Pressing pin shaft removal
1
6 A-1886 Pressing pin distributor removal
1
8 R-904L Wrench - lock nut
9 A-1887 Guide shaft aligning, body
10 A-5297 Support tool
1
1
1
ASSEMBLY PROCEDURE FOR PUMP END (CONTINUED)
17
Screw locknut #22 onto shaft. When tightening the nut, do not use excessive force as this may result in failure of the seals, drive bushing or impellers. Do not forget to secure the shaft from rotating.
18
Bend lockwasher up onto one flat of the hexagon locknut at a position approximately 180° from the milled slot in the shaft. Old style locknut need to use tool A-1883 to tighten and backing-off slightly, if necessary, until one of locking tabs of lockwasher is opposite a milled slot of the locknut then lock by pushing tab into slot.
19
If excessive play, replace bronze bushing #4.
20
Place O-ring #10 in groove of suction nozzle #9, then bench press the nozzle into the pump body until it rests on face of first distributor. A gap of approximately 0,794 mm (1/32") between nozzle flange and end of body, is normal.
21
Attach nozzle to body by using the #8 screws and lockwashers. Tighten screws evenly and firmly.
22
Attach shaft nose #5 using lockwasher #4 and screw #3. Tighten screw evenly and firmly.
23
Check gasket in the priming cap #13 and replace if damaged.
24
Reinstall the suction and discharge thread protectors.
25
Reinstall capson suction and discharge inlets
Use a clean gun filled with fresh grease. Remove dirt from grease fitting before applying grease gun. Grease should be pumped slowly into bearing chamber until fresh grease appears around bearing retaining ring. Wipe off excess grease.
A grease relief valve (old style only) has been provided to prevent pressure buildup on the rotary seal, should the fresh grease not be able to flow completely through the bearing, due to old grease being hard packed, etc.
6
MISCELLANEOUS
MOUNTING FRAME
Ref. Part Description
# #
_
C-5200N Mounting frame assembly (includes ref. #2 to #14)
Qty
1
1 A-6149P
2 A-4005
Mounting leg
Mounting pad
4
2
3 A-6179 Ring - rubber
4 C-5200-5 Washer - rubber
5 C-4506-3 Bumper - rubber
6 C-5201 Frame
2
1
4
4
7 C-5200-8 Hex bolt
8 D-5269-7 Flat washer
9 C-5200-7R Spacer - rubber
10 C-6650-14 Hex lock nut
11 A-6179 Ring - rubber
12 C-5200-6 Flat washer
13 R-111 Lockwasher
14 C-5200-12 Hex bolt
4
4
4
4
2
2
2
2
MOUNTING FRAME
QUICK-CONNECT FUEL LINE
Ref. Part
# #
_
R-1114
Description
Quick-connect fuel line
(includes parts with *)
1 C-5200-8 Hex bolt
2 D-5269-7* Flat washer
Qty
1
2
2
3 R-798*
4 R-706*
Fuel line - plastic 1
Body quick-connect 1 male
5 R-709* Elbow
6 C-5200-7R* Spacer - rubber
7 C-6650-14* Hex lock nut
8 A-7486
2
Dust cap M. connector 1
1
2
9 R-712
10 R-732
Handle quick connect 1
Connector 1
11 FA-552Q Fuel air transport tank 1
12 FA-451 Fem. quick connect 1
13 12-401B-NS Hose-fuel supply with priming bulb
1
QUICK-CONNECT FUEL LINE
w w w. w i l d f i r e - e q u i p m e n t . c o m
37 36
Wi l d f i r e
6
MISCELLANEOUS
OPTIONAL NOISE REDUCTION MUFFLER
B-6571 Noise Reduction Muffler
With its extra internal baffling, and larger size, the new B-6571 muffler was specifically designed to reduce MK-3 operating noise level by approximately 10%.
B-6571 shown installed on MK-3-NR.
Ref. Part
# #
1
2
3 R-150
4 R-229
5
R-237
R-151
C-5370-11 Flat washer
6 R-119
Description
Gasket - muffler
Flat washer
Hex lock nut
Muffler
Lockwasher
Qty
7 RA-108 Mach. screw hex cap 1
8 PART-205 Spark arrestor 1
1
1
1
1
1
1
PART-205
USFS Approuved
Spark arrestor
8
5 6 7
DECARBONISING
After several hours of normal operation, carbon deposits will form on piston crown, cylinder head, in the cylinder exhaust port and around piston rings and in the ring grooves, causing erratic and faulty operation. The piston skirt may also show signs of gum and varnish deposits.
To decarbonise, the cylinder head, cylinder and piston should be removed. All carbon deposits should be carefully removed, particularly from the piston ring grooves. After removing carbon, wash all parts in a suitable solvent, then dry with compressed air. On reassembly, always use new piston rings.
After every 100 hours of operation, or more often if a loss of power is indicated, the engine should be decarbonised.
To decarbonise the engine, proceed as follows:
1
Remove muffler. If muffler is very dirty internally or appears burned or cracked, it should be replaced with a new muffler.
2
Remove cylinder head and cylinder head gasket.
3
Rotate crankshaft until piston is at bottom dead centre.
4
Using a brass scraper tool, carefully scrape carbon deposit from exhaust port.
During this operation, tilt engine so that deposits will not fall into combustion chamber.
5
Use suitable brass tool to push out any carbon deposit which may have formed in the hole provided in the cylinder liner for bypass.
6
Rotate crankshaft until piston is at top dead centre.
7
Use a stiff (not wire) brush to remove loose, flakey carbon from top of piston.
Do not remove hard deposit of carbon, as this layer forms a natural heat insulator to protect the piston crown.
8
Remove all carbon deposits from cylinder head.
9
Replace cylinder head. Tighten nuts uniformly to recommended torque
23-25 Nm (200-220 inch-lbs) value. Always use a new cylinder head gasket
(cylinder head gasket must have the large band up).
10
Check and replace muffler gasket if worn or damaged. Reinstall muffler.
1 2 3 4
38
Wi l d f i r e
7
TECHNICAL SPECIFICATIONS
TORQUE VALUES
ENGINE
Spark plug
Cylinder head nuts
Flywheel hub nut
Collar coupling nut
Crankcase assy. screws
41 Nm / 360 inch-lbs (30ft-lbs) (41Nm)
23-25 Nm / 200-220 inch-lbs
Should be retorqued every 100 hours of operation.
44-45 Nm / 390-400 inch-lbs
11-14 Nm / 100-120 inch-lbs
Crankshaft with no keyway at PTO end should be torqued to
19-21 Nm / 175-185 inch-lbs.
11-12 Nm / 100-110 inch-lbs
PUMP
Retaining ring screws
Shaft nose screw
Nut #12-50
Suction nozzle screws
6,7-7,3 Nm / 60-65 inch-lbs
7,9-8,5 Nm / 70-75 inch-lbs
28-29 Nm / 250-260 inch-lbs.
7,9-8,5 Nm / 70-75 inch-lbs
CLEARANCE DATE AND LIMITS
ROTAX
ENGINE
Spark plug type
Spark plug gap
Breaker points gap
Ignition timing limits
Ignition timing - nominal
Magneto air gap
Condenser capacity
Bosch M4AC18mm
0,41-0,51 mm / 0.016"-0.020"
0,35-0,45 mm / 0.014"-0.018"
2,54-4,01 mm / 0.100"-0.158" BTDC
2,54mm / 0.100"BTDC
0,25-0,33 mm / 0.010"-0.013"
0,15-0,19 mF
Normal current for testing coil 1,0 amp. nominal / 2,0 amp. max.
Crankshaft end-play 0,025-0,230 mm / 0.001 "-0.009"
Cylinder bore (hone) 62,50-62,51 mm
Cylinder Surface Roughness 1-2 Micron / 39-70 microinches
Piston dia. - nominal
Piston dia. - oversize
Piston / cylinder clearance
Wear limit
61,94 mm/2.4386"
62,44 mm / 2.4583"
0,06-0,08 mm / 0.0024"-0.0032"
0,20 mm / 0.0079"
Cylinder taper
Cylinder out of round max. 0,08 mm / 0.0032" max. 0,05 mm / 0.0020"
Piston ring end gap (new ring) 0,20-0,35 mm / 0.0079"-0.0138"
Wear limit 1,00 mm / 0.03937"
Piston pin hole dia. (in piston) 18,001-18,005 mm / 0.7087"-0.7089"
Piston pin dia.
17,997-18,000 mm / 0.7085"-0.7087"
CLEARANCE DATE AND LIMITS (CONTINUED)
Crankshaft halves run-out 0,03 mm/0.0011"
Crankshaft bearing seat dia.
(on crankshaft coupling side) 20,002-20,011 mm / 0.7875"-0.7878"
Wear limit 20,000 mm / 0.7874"
(on crankshaft flywheel side) 25,002-25,011 mm / 0.9843"-0.9847"
Wear limit 25,000 mm / 0.9843"
Crankcase bearing seats dia.
(both sides)
Wear limit
Connection rod inside dia.
(for piston rim bearing)
51,95-51,96 mm / 2.0453"-2.0457"
51,98-51,99 mm / 2.0465"-2.0469"
21,997-22,005 mm / 0.8660"-0.8663"
Ring / piston groove clearance 0,04-0,11 mm / 0.0016"-0.0043"
Wear limit 0,2 mm / 0.0079"
(measured on rectangular rings only)
Stroke 61 mm / 2.40"
Pump
Impeller #12-7 diameter 93,22 mm ±0,13 / 03.670" ±0.005
Impeller #12-7 width 38,86 mm ±0,05 / 1.530" ±0.002
Impeller #12-11 diameter 93,22 mm ±0,13 / 03.670" ±0.005
Impeller #12-11 width 34,11 mm ±0,05 / 1.343" ±0.002
Distributor #12-6 diameter 123,39 mm-123,47 mm / 04.858"-4.861"
Distributor #12-6 width 31,31 mm ±0.05 / 1.234" ±0.002
Distributor #12-9 diameter 0123,39 mm-123,47 mm/04.858"-4.861"
Distributor #12-9 width 34,11 mm ±0,05 / 1.343" ±0.002
Pump inside depth 108,10 mm ±0,05 / 4.256" ±0.002
Pump ball bearing housing 51,99 mm-52,02 mm / 2.047"-2.048"
Nozzle bushing bearing housing
19,037 mm-19,063 mm/0.7495"-0.7505"
Buffer thickness (#12-17) 8,25 mm-8,89 mm / 0.325"-0.350"
Shaft ball bearing support 25,004 mm-25,011 mm/ 0.9844"-0.9847"
Shaft bushing bearing support 12,687 mm-12,700 mm /0.4995"-0.5000"
Shaft maximum run-out 0,0889 mm / 0.0035" w w w. w i l d f i r e - e q u i p m e n t . c o m
39
8
PARTS INDEX
12-10
12-11
12-12A
12-13
12-17
12-25
12-26
12-27
12-28N
12-29
EW #
12-2C
12-2D
12-2E
12-3
12-4AS
12-6
12-7
12-8
12-9
12-38
12-39
12-40
12-42
12-43
12-48
12-49
12-50
12-73
12-79
T N ME
Shaft - riveted assembly
Shaft sub-assembly of 7 items
Shaft sub-assembly of 4 items
Retaining ring for bearing
Drive bushing (includes B-5312-4)
Distributor
Impeller
Pump body
Distributor
Cap for priming port
Impeller
Suction nozzle (includes 12-40)
Nose for shaft
Coupling - buffer
Mach. screw flat Phillips, stainless
O-ring
O-ring
Mechanical rotary seal
Grease fitting
Lockwasher
Mach. lock screw, Fillester, stainless
Bushing bearing, bronze
Mach. lock screw, Fillester, stainless
Gasket, 38 mm (1 1/2”)
Double row ball bearing
Lockwasher, stainless
Lock nut, stainless
Plug, brass
Lockwasher, star type
12-87 Extension for grease fitting
12-401B-NS Hose-fuel supply with priming bulb
212-170P Clamp assembly
271-346 Screwdriver - standard
271-488
271-923
271-927
A-1883
Bag - tool roll
Wrench - adjustable 203 mm (8")
Screwdriver - Phillips No 1
Wrench - lock nut
35
35
35
34
35
35
35
35
35
15, 35
35
35
34, 35
34
34
34
35
34
34
23, 24, 29, 31, 34
34
34
34
34
35
35
35
34
34
13
13
29
34, 36
34
37
9
29
40
Wi l d f i r e
A-5297
A-5536
A-5537
A-5538
A-6149P
A-6179
B-2428-6
B-2920-6
A-4028
A-4030
A-4097
A-4329
A-4452
A-4453
A-4454
A-4455
A-4456
A-4460
A-2391
A-2391B
A-2392
A-2395
A-2688
A-2924
A-2926
A-3023
A-4005
A-4027
A-1884
A-1886
A-1887
A-1888
A-1890
A-2356
A-2388
A-2389
A-2390
A-2390A
Pressing sleeve - distributor assembly
Pressing pin - distributor removal
Guide - shaft aligning, body
Puller - suction nozzle
Pressing pin - shaft removal
Maintenance tools for pump
Pump test kit
Pump test kit box
Pressure gauge adaptor, 38 mm (1 1/2”)
Shut-off valve
Rubber hose assembly with A-2391B
Adaptor
Pressure gauge, 0-2800 kPa (0-400 psi)
Brass calibrated nozzle tip set
Thread protector 51 mm (2”)
Reset rod
Cable
Carburetor adjusting tool
Mounting pad
Pin - index
Spring
Throttle decal (english)
Protector - shaft
Pressing sleeve - rotary seal assembly
Link for lever side
Eye-bolt
Clevis pin for eye-bolt side
Clevis pin for lever side
Knob for tension adjustment
Lever
Support tool
Protective cap, discharge
Protective cap, suction
Retainer for priming cap
Mounting leg
Ring - rubber
Hex lock nut
Flat slotted bolt
34, 36
34
34
34
31, 37
37
23
23
22
22
36
35, 36
9
9
9
9
9
9
34
23
23
13
37
22
11
11
11
11
35, 36
34, 36
35, 36
34, 36
34, 36
36
11
11
11
11
8
PARTS INDEX
B-2920-23 Grommet
B-4024 Quadrant for throttle lever
B-4036-12 Mach. screw hex socket
B-4457 Clamp - bottom half
B-4461
B-5312-4
B-6288
C-1933
Clamp - top half
0-ring for drive bushing
Cutout switch assembly
Calibrated nozzle 12,7 mm (1/2”)
C-4506-3 Bumper - rubber
C-5200-5 Washer - rubber
C-5200-6 Flat washer
C-5200-7R Spacer - rubber
C-5200-8 Hex bolt
C-5200-12 Hex bolt
C-5200N
C-5201
Mounting frame assembly 37
Frame 37
C-5370-11 Flat washer
C-6650-14 Hex lock nut
C-7010-12 Stop switch assembly
31, 38
37
8
37
37
37
37
9
35
12, 23
11
37
37
23
22
22
9
R-117
R-119
R-120
R-123
R-130
R-132
R-133
R-136
D-5269-7 Flat washer
FA-552Q Fuel air transport tank
MK-138 Gasket 51 mm (2")
MTR-1000 Hours meter with RPM
R-103
R-105
R-111
R-113
R-115
R-116
Dowel tube
Lockwasher
Gasket, metal
Stud
Hex lock nut
31
Mach.screw 31
37
31
23
29
37
37
34
22
Stud
Lockwasher
Hex nut
Oil seal 0.788"
Stud - mounting leg
Gasket for crankcase
Flange - pump mounting
22, 31
22, 23, 31, 38
22, 31
31, 33
31
Mach.screw 31
31, 33
15, 31
R-236
R-237
R-238
R-257
R-270
R-301
R-302
R-303
R-305
R-144
R-146
R-149
R-150
R-151
R-152
R-206
R-229
R-233
R-235
Shield - dust 31
Lockwasher
Hex lock nut
Flat washer
Crankcase halves set
22
8, 22, 23, 38
23, 38
31
Flat washer 31
Muffler 38
Cylinder head -18 mm
Gasket - cylinder flange
17, 22
22, 33
Stud - cylinder mounting
Gasket - muffler
Gasket - cylinder head
Cylinder
Cast iron sleeve
Lockwasher
Hex nut (coupling side)
Hex nut (flywheel side)
Key
31
22, 38
17, 22, 33
22
22
32
32
32
32
32
R-307
R-308
R-309
R-310
R-311
R-312
R-315
R-321
R-324
R-324M
Shim 0.008" (coupling side)
Shim 0.012" (coupling side)
Shim 0.016" (coupling side)
Shim 0.020" (coupling side)
Shim 0.031" (coupling side)
Shim 0.040" (coupling side)
Collar coupling
Serrated lockwasher (old style engine)
Needle bearing
Crankshaft / conn rod (half coupling side)
R-328
R-329
R-330
R-331
Gudgeon pin 32
Circlip 32
Shim, beveled 0.040" (coupling side)
Piston ring, 0.078"
32
32
R-331-0 Oversized piston ring 0.078"
R-331-0-1 Oversized L-type piston ring
R-331-1
R-332
L-type piston ring
Piston with rings
32, 33
32, 33
32
32
32, 33
32, 33
32, 33
32, 33
32, 33
32, 33
32
32, 33
32, 33
32 w w w. w i l d f i r e - e q u i p m e n t . c o m
41
8
PARTS INDEX
R-522
R-523
R-524
R-526
R-528
R-529
R-530
R-531
R-501
R-502
R-504
R-505
R-506
R-509
R-510
R-516
R-517
R-518
R-346
R-347
R-348
R-402
R-408
R-409
R-411P
R-413
R-414
R-418
EW #
R-332-0
R-333
R-334
R-341
R-341M
R-342
R-343
R-344
R-345
Handle - starter rope
Rope - starter
Aluminium sheave
Pin - starter rope lock
Spring - rewind
Plug - rubber
Flat "D" washer
Spring - friction
Flat washer
Circlip
Mach. screw hex cap
Lockwasher
Mach. screw
Washer - friction
Pawl assembly
Rewind starter
Housing - starter
Retainer - spring
T N ME
Oversized piston (includes rings)
Ball bearing 0.788" ID
Spacer
Crankshaft / conn. rod sub-assembly
32, 33
29, 32, 33
32, 33
32
Crankshaft / conn. rod (half flywheel side)
Oil seal 0.983"
32
31, 32, 33
Ball bearing 0.983" ID
Shim 0.004" (flywheel side)
Shim 0.012" (flywheel side)
32, 33
32, 33
32, 33
Shim 0.020" (flywheel side)
Shim 0.039" (flywheel side)
Crankshaft / conn. rod assembly
Stud
Mach. screw
Clamp - ignition cable
Fan cowl with studs
Cover for spark plug
Mach. screw hex cap
Shield - fan
32, 33
32, 33
32
22, 23
23
23
23
23
23
23
24
24
24
24
24
24
24
24
24
24
24
24
24
24
24
24
24
24
42
Wi l d f i r e
R-532
R-533
R-544
R-601
R-602
R-603
R-611
R-612
R-617
R-628
R-629
R-630
R-633-T
R-634
R-636
Cover
Guide - starter rope
Buffer - rubber
Pulley - manual starter rope
Stud
Fan
Lockwasher
Mach. screw
Flat washer
Cable condenser
Spark plug 18 mm
Cable - spark plug
Stop switch kit
Cable stop switch
Grommet
R-637
R-638
R-650
R-653
R-654
R-656
R-661
R-662
R-664
R-665
Flat washer
Mach. screw
Protector - spark plug
Gasket
30
30
8, 14, 30
29
Cap
Armature plate complete
30
30
Coil 30
Condenser 30
Point with cable condenser
Mach. screw
30
30
R-667N-E Flywheel/magneto assembly
R-706 Body quick-connect male
R-709
R-712
29
37
Elbow 37
Handle quick connect, female 37
R-732
R-774
R-790
R-791
R-792
R-793
Connector SAE male
Mach. screw
Carburetor shroud with decal
Lockwasher
Throttle control assembly
Mach. screw hex cap, Nylock
37
22
22
22, 29
22
22
R-794
R-798
R-799
Cover for air filter
Fuel line, plastic
22
37
30
8, 14, 30
30
30
30
30
29
30
30
30
24
24
24
29
29
8
PARTS INDEX
R-1004
R-1005
R-1008
R-1009
R-1010
R-1011
R-1012
R-1013
R-1014
R-1015
R-1016
R-932
R-933
R-938
R-952
R-953
R-954-14
R-955
R-1001
R-1002
R-1003
R-909
R-910
R-911M
R-926
R-927
R-928
R-929
R-930
R-900
R-901
R-902
R-903
R-904
R-905
R-906M
R-908
Maintenance tool kit for pump
Screwdriver, 102 mm (4") sq. handle
Screwdriver, 51 mm (2")
Feeler gauge - spark plug & breaker point
Wrench - spark plug
Handle - rod
Wrench - box and open end 10 mm
Wrench - open end 5 & 8 mm (ignition)
Key - Alien 2,4 mm (3/32")
Wrench - open end 1/2” & 9/16”
Wrench - box and open end 13 mm
Socket wrench 14 mm (9/16”)
Puller - magneto
Cap - shaft protector
Flywheel holding tool
Puller - crankshaft bearing R-313
12, 29
13
13
29
29, 31
29, 31, 32
29, 31
29
13
13
13
13
13
13
13
13
Puller - collar coupling
Oil seal - pressing tool
Puller - crankshaft bearing Ft-333
Service toot kit
Crankshaft jack
Gauge - timing
Air filter element - foam & screen
Body channel welch plug
Choke friction pin
Choke friction spring
Choke shaft and lever
Choke shutter
Diaphragm gasket
Diaphragm
Diaphragm cover
Fuel pump gasket
Fuel pump diaphragm
Fuel pump body
Mach. screw with lockwasher
Fuel strainer screen
Fuel strainer cover gasket
Fuel strainer cover
19
19
19
19
19
19
19
19
19
19
19
19
29, 31
29, 32, 33
29, 32
29
29, 33
29
22
19
19
19
Mach. screw
Idle mixture screw
Mixture screw spring
Flat washer, brass
Idle mixture screw packing
Idle speed screw
Idle speed screw spring
Inlet control lever
Inlet control lever pinion screw
Inlet tension spring
High speed mixture screw
Nozzle check valve
Throttle shaft and lever
Throttle shaft clip
Lockwasher
Mach. screw
Throttle shaft return spring
Throttle shutter
Mach. screw with lockwasher
Lock plate
Body
Inlet needle and seat
Inlet seat gasket
Repair parts kit (10 parts)
Throttle link lever assembly
Link for throttle
Throttle lever sub-assembly
Hex nut
Bolt
Flat washer
Gasket - carburetor
Quick connect fuel line assy
Carburetor (45 parts)
Mach. screw hex cap
Hex nut
R-1107
R-1110
R-1111
R-1112
R-1113
R-1114
R-1115
RA-108
TY-1811
R-1039
R-1040
R-1041
R-1044
R-1045
R-1046N
R-1047
R-1050
R-1101
R-1102
R-1026
R-1029
R-1030
R-1034
R-1035
R-1036
R-1037
R-1038
R-1018
R-1019
R-1020
R-1021
R-1022
R-1023
R-1024
R-1025N w w w. w i l d f i r e - e q u i p m e n t . c o m
43
22
19
19
19
19, 22
37
19
31, 38
23
19
19
19
22
19
19
19
22
19
19
19
19
19
19
19
19
19
19
19
19
19
19
19
19
19
19
9
WARRANTY CERTIFICATE
Wildfire Group warrants its manufactured products to be free from defect in material and workmanship, under normal use and service, for a period of one (1) year or one hundred (100) 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, threaded or repaired by anyone other than Wildfire Group, ("Wildfire") personnel or one of its authorized representatives. Items sold but not manufactured by Wildfire shall bear only the limited warranties offered by their respective manufacturers.
Any return of defective goods for repair or replacement must be accompanied by a copy of the warranty registration form with the returned material authorization section properly completed. The authorization number will be given upon request by telephone or mail. An authorized representative may then be designated by
Wildfire to handle the claim on its behalf.
The claimed defective equipment must be delivered; freight prepaid, to Wildfire at its listed address or to the representative, no more than thirty (30) days after the returned good authorization number (RGA) has been processed by Wildfire.
Wildfire will inspect the equipment and reserves the right to refuse responsibility if it is found that the equipment failed for another reason than a defect in material or workmanship.
Wildfire shall not be liable for consequential or indirect 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 or indirect trade or other commercial loss arising out of the failure of manufacturer's product.
Wildfire Group
1100 Norman Street, Suite 200
Lachine, Quebec, Canada
H8S 1A6
Tel.: (514) 637-5572
Fax: (514) 637-3985
44
Wi l d f i r e
Wildfire Fire Equipment Inc. reserves the right to make changes in design, materials and price without notice.

Public link updated
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Key features
- High pressure & volume
- B-2 volume pump end interchangeability
- Tandem operations
- One-cylinder, two-cycle, air-cooled engine
- Rewind pull-cord starter
- Automatic cutout switch
- Anodized horizontal 4-stage centrifugal pump
- Electronic ignition system