Boreal HUMPBACK Series Operation Manual

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WATER TRAILER

HUMPBACK SERIES

WW500E

(HONDA GX120UT3PX2 GASOLINE ENGINE)

(QP2HLF CENTRIFUGAL PUMP)

Revision #1 (09/12/22)

THIS MANUAL MUST ACCOMPANY THE EQUIPMENT AT ALL TIMES.

Read the following instructions carefully before attempting to

assemble, install, operate or service this Water Trailer. Failure

to comply with these instructions could result in personal injury

and/or property damage.

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Page 1 Page 1 of 56 WATER TRAILER HUMPBACK SERIES WW500E (HONDA GX120UT3PX2 GASOLINE ENGINE) (QP2HLF CENTRIFUGAL PUMP) Revision #1 (09/12/22) THIS MANUAL MUST ACCOMPANY THE EQUIPMENT AT ALL TIMES. Read the following instructions carefully before attempting to assemble, install, operate or service this Water Trailer. Failure to comply with these instructions could result in personal injury and/or property damage.
Page 2: Table Of Contents
Page 2 of 56 TABLE OF CONTENTS TABLE OF CONTENTS ............................. 2 SAFETY INFORMATION ..........................3 SPECIFICATIONS ............................7 DIMENSIONS ..............................9 GENERAL INFORMATION ..........................10 COMPONENTS ............................. 12 BASIC ENGINE.............................. 14 INSPECTION ..............................15 OPERATION ..............................16 WINTERIZING PROCEDURE ......................... 21 MAINTENANCE ............................
Page 3: Safety Information
Page 3 of 56 SAFETY INFORMATION Do not operate or service the equipment before reading the entire manual. Safety precautions should be followed at all times when operating this equipment. Failure to read and understand the safety messages and operating instructions could result in injury to yourself and others. SAFETY MESSAGES The four safety messages shown below will inform you about potential hazards that could injure you or others.
Page 4 - Manufacturer does not assume responsibility for any accident due to equipment modifications. Unauthorized equipment modification will void all warranties. - NEVER use accessories or attachments that are not recommended by Boreal Applications Inc. for this equipment. Damage to the equipment and/or injury to user may result.
Page 5 Page 5 of 56 SAFETY INFORMATION PUMP SAFETY - NEVER operate the equipment in an explosive atmosphere or near combustible materials. An explosion or fi re could result causing severe bodily harm or even death. - Accidental starting can cause severe injury or death. ALWAYS place the ON/OFF switch in the OFF position.
Page 6 Page 6 of 56 SAFETY INFORMATION FUEL SAFETY - DO NOT start the engine near spilled fuel or combustible fluids. Fuel is extremely flammable and its vapors can cause an explosion if ignited. - ALWAYS refuel in a well-ventilated area, away from sparks and open flames. - ALWAYS use extreme caution when working with flammable liquids.
Page 7: Specifications
Page 7 of 56 SPECIFICATIONS Table 1. Engine Specifications Model Honda GX120UT3PX2 Type Air-cooled, 4-stroke, Single Cylinder, OHV, Horizontal Shaft Gasoline Engine Bore × Stroke 2.36 in. × 1.65 in. (60 mm × 42 mm) Displacement 7.2 cu-in. (118 cc) Max.
Page 8 Page 8 of 56 SPECIFICATIONS Table 2. Water Trailer Specifications Type Horizontal Leg 16” – Vented Port Fill Port Material Polyethylene Water Tank Capacity 500 Imp gallons (2,273 liters) Weight w/ Empty Water Tank Weight w/ Full Water Tank 2” (51 mm) Centrifugal Type Maximum Flow 158 GPM (600 LPM)
Page 9: Dimensions
Page 9 of 56 DIMENSIONS...
Page 10: General Information
Page 10 of 56 GENERAL INFORMATION APPLICATION Typical applications for the Water Trailers include: dust control, emergency fire fighting response, construction, agricultural support and equipment wash down. The WW500E Series are industrial 500 Imperial gallon Water Trailers. Each water trailer comes with a centrifugal pump, flexible suction/discharge manifold system with simple valve controls, and a rugged polyethylene water tank.
Page 11 Page 11 of 56 GENERAL INFORMATION Elevation Higher elevations will affect the performance of the pump. Due to less atmospheric pressure at higher altitudes, pumps DO NOT have the priming ability that they have at sea level. This is due to the “thinner air”...
Page 12: Components
Page 12 of 56 COMPONENTS...
Page 13 Page 13 of 56 COMPONENTS...
Page 14: Basic Engine
Page 14 of 56 BASIC ENGINE INITIAL SERVICING The engine (Figure 3) must be checked for proper lubrication and filled with fuel prior to operation. Refer engine manufacturer’s manual for instructions and details of operation and servicing. Throttle Lever — Used to adjust engine RPM speed (lever advanced forward SLOW, lever back toward operator FAST).
Page 15: Inspection
Page 15 of 56 INSPECTION ENGINE OIL CHECK 1. To check the engine oil level, place the unit on secure level ground with the engine stopped. 2. Remove the filler dipstick from the engine oil filler hole (Figure 4) and wipe it clean. 3.
Page 16: Operation
Page 16 of 56 OPERATION STARTING THE ENGINE 1. Place the manifold control handle in the vertical position (OFF). See Table 5. 2. Place the engine fuel valve lever (Figure 6) to the ON position. 3. Move the throttle lever (Figure 7) away from the slow position, about 1/3 of the way toward the fast position.
Page 17 Page 17 of 56 OPERATION 5. Place the choke lever (Figure 9) in the OPEN position if starting a warm engine or the temperature is warm. 6. Place the engine ON/OFF switch (Figure 10) in the ON position. 7. Grasp the starter grip (Figure 11) and slowly pull it out. The resistance becomes the hardest at a certain position, corresponding to the compression point.
Page 18 Page 18 of 56 OPERATION 9. Before the water trailer is placed into operation, run the engine for several minutes. 10. Check for fuel leaks and noises that would be associated with a loose component. Check for leaks between pump and engine. If water is leaking between the pump and engine housing, the seal inside the pump may be worn or damaged.
Page 19 Page 19 of 56 OPERATION 2. After the engine cools, turn the engine ON/OFF switch to the OFF position (Figure 14). 3. Place the fuel shut-off lever (Figure 15) in the OFF position. Emergency Shutdown Move the throttle lever quickly to the IDLE position, and place the engine ON/OFF switch in the OFF position.
Page 20 Page 20 of 56 OPERATION FILLING THE WATER TANK (MUNICIPAL FILL) 1. Attach suction hose to Municipal fill port. 2. Attach suction hose to Safe Fill 2” Valve QD port. 3. Make sure there are no bends of sharp kings in the hose between the Municipal fill port and the Safe Fill port.
Page 21: Winterizing Procedure
Page 21 of 56 WINTERIZING PROCEDURE Perform the following procedure to protect water trailer from component damage in freezing temperature environments. 1. Make sure the water tank is completely empty. Use pump to remove any water present in the water tank. 2.
Page 22: Maintenance
Page 22 of 56 MAINTENANCE Use Table 5 as a general maintenance guideline when servicing your engine. For more detailed engine maintenance information, refer to the engine owner’s manual supplied with your engine. Table 5. Engine Maintenance Schedule FIRST EVERY 3 EVERY 6 EVERY 2 EVERY...
Page 23 Page 23 of 56 MAINTENANCE WEEKLY - Remove the fuel filter cap and clean the inside of the fuel tank. - Remove or clean the filter at the bottom of the tank. - Remove and clean the spark plug (Figure 28), then adjust the spark gap to 0.024–0.028 inch (0.6–0.7 mm).
Page 24 Page 24 of 56 MAINTENANCE DO NOT use gasoline as a cleaning solvent to avoid creating the risk of fire or an explosion. STORAGE For storage of the unit for over 30 days, the following is required: - Drain the fuel tank completely. - Run the engine until the fuel in the carburetor is completely consumed.
Page 25 Page 25 of 56 MAINTENANCE The following trailer maintenance guidelines are intended to assist the operator in preventive maintenance. TRAILER BRAKES Properly functioning brake shoes and drums are essential to ensure safety. The brakes should be inspected the first 200 miles of operation. This will allow the brake shoes and drums to seat properly.
Page 26 Page 26 of 56 MAINTENANCE Figure 33 displays the major electric brake components that will require inspection and maintenance. Please inspect these components as required. See Table 8. ELECTRIC BRAKE ACTUATOR The electric brake actuator (Figure 34) is the mechanism that activates the trailer’s brake system.
Page 27 Page 27 of 56 MAINTENANCE Breakaway Switch This switch causes the breakaway battery to operate the electric brakes if the trailer uncouples from the tow vehicle. The pull cable for the pull pin is connected to the tow vehicle, and the switch is connected to the trailer.
Page 28 Page 28 of 56 MAINTENANCE ADJUSTABLE CHANNEL Your trailer may be equipped with an adjustable channel (Figure 35) that allows the coupler to be raised or lowered to a desired height. Periodically check the channel bolts for damage or loosening. When replacing channel mounting hardware (nuts, bolts and washers), NEVER substitute substandard hardware.
Page 29 Page 29 of 56 MAINTENANCE If the trailer has not been used for an extended amount of time, have the bearings inspected and packed more frequently, at least every six months and prior to use. Follow the steps below to disassemble the wheel hub and service the wheel bearings. See Figure 36. - After removing the dust cap, cotter pin, spindle nut and spindle washer, remove the hub to inspect the bearings for wear and damage.
Page 30 Page 30 of 56 MAINTENANCE Improper weld repair will lead to early failure of the trailer structure and can cause serious injury or death. DO NOT repair cracked or broken welds unless you have a certified welder perform the repair. If not, have the welds repaired by your dealer. If the trailer is involved in an accident, have it inspected immediately by qualified personnel.
Page 31: Trailer Safety Guidelines
Page 31 of 56 TRAILER SAFETY GUIDELINES The following guidelines are intended to assist the operator in the operation and handling of a trailer. Safety precautions should be followed at all times when operating a trailer. Failure to read, understand and follow the safety guidelines could result in injury to yourself and others. Loss of control of the trailer or tow vehicle can result in death or serious injury.
Page 32 Page 32 of 56 TRAILER SAFETY GUIDELINES Make regular stops, about once each hour. Confirm that: • Coupler is secure to the hitch and is locked. • Electrical connectors are secure. • There is appropriate slack in the safety chains. •...
Page 33 Page 33 of 56 TRAILER SAFETY GUIDELINES Proper selection and condition of the coupler and hitch are essential to safely towing your trailer. A loss of coupling may result in death or serious injury. • Be sure the hitch load rating is equal to or greater than the load rating of the coupler. •...
Page 34 Page 34 of 56 TRAILER SAFETY GUIDELINES Improper electrical connection between the tow vehicle and the trailer will result in inoperable lights and can lead to collision. Before each tow, check that the tail lights, brake lights and turn signals work. TRAILER TOWING TIPS Driving a vehicle with a trailer in tow is vastly different from driving the same vehicle without a trailer in tow.
Page 35 Page 35 of 56 TRAILER SAFETY GUIDELINES If you are towing a bumper hitch rig, be careful not to allow the trailer to turn too much because it will hit the rear of the tow vehicle. To straighten the rig, either pull forward or turn the steering wheel in the opposite direction.
Page 36 Page 36 of 56 TRAILER SAFETY GUIDELINES TOW VEHICLE The towing hitch attached to your tow vehicle must have a capacity equal to or greater than the load rating of the trailer you intend to tow. The hitch capacity must also be matched to the tow vehicle capacity.
Page 37 Page 37 of 56 TRAILER SAFETY GUIDELINES TRAILER LIGHTING AND BRAKING CONNECTOR A device that connects electrical power from the tow vehicle to the trailer. Electricity is used to turn on brake lights, running lights, and turn signals as required. In addition, if your trailer has a separate braking system, the electrical connector will also supply power to the brakes from the tow vehicle.
Page 38 Page 38 of 56 TRAILER SAFETY GUIDELINES The coupler handle lever must be able to rotate freely and automatically snap into the latched position. Oil the pivot points, sliding surfaces, and spring ends with SAE 30W motor oil. Keep the ball socket and latch mechanism clean. Dirt or contamination can prevent proper operation of the latching mechanism.
Page 39 Page 39 of 56 TRAILER SAFETY GUIDELINES - Be sure the coupler is secured tightly to the tongue of the trailer. All coupler fasteners must be visibly solid against the trailer frame. - The bottom surface of the coupler must be above the top of the hitch ball. Use the tongue jackstand to support the trailer tongue.
Page 40 Page 40 of 56 TRAILER SAFETY GUIDELINES If the coupler cannot be secured to the hitch ball, do not tow the trailer. Call your dealer for assistance. Lower the trailer so that its entire tongue weight is held by the hitch and continue retracting the jack to its fully retracted position.
Page 41 Page 41 of 56 TRAILER SAFETY GUIDELINES Breakaway Cable Surge Brake System The breakaway brake system includes a brake cable connected to the tow vehicle on one end and to the emergency brake lever located on the hydraulic actuator on the other end. •...
Page 42 Page 42 of 56 TRAILER SAFETY GUIDELINES Improper electrical connection between the tow vehicle and the trailer will result in inoperable lights and electric brakes, and can lead to collision. Before each tow: • Check that the taillights, brake lights and turn signals work. •...
Page 43 Page 43 of 56 TRAILER SAFETY GUIDELINES The load rating of the coupler and the necessary pintle hitch size are listed on the trailer tongue. You must provide a pintle hitch and pintle coupler for your tow vehicle, where the load rating of the pintle hitch and pintle coupler is equal to or greater than that of your trailer.
Page 44 Page 44 of 56 TRAILER SAFETY GUIDELINES - Rock the pintle eye coupler to make sure it is secured tightly to the hitch. - Wipe the inside and outside of the pintle coupler. Clean and inspect it visually for cracks and deformations.
Page 45 Page 45 of 56 TRAILER SAFETY GUIDELINES TIRE SAFETY Unsafe Tires, Lug Nuts or Wheels Trailer tires and wheels are more likely to fail than car tires and wheels because they carry a heavier load. Therefore, it is essential to inspect the trailer tires before each tow. If a tire has a bald spot, bulge, cuts, is showing any cords, or is cracked, replace the tire before towing.
Page 46 Page 46 of 56 TRAILER SAFETY GUIDELINES Improper lug nut torque can cause a wheel parting from the trailer, leading to death or serious injury. Be sure lug nuts are tight before each tow. Improper tire pressure can result in a blowout and loss of control, which can lead to death or serious injury.
Page 47 Page 47 of 56 TRAILER SAFETY GUIDELINES Step 1. Locate the statement, “The weight of cargo should never exceed XXX kg or XXX lbs.,” on your vehicle’s Tire and Loading Information placard (Figure I). This value equals the available amount of equipment load capacity. Step 2.
Page 48 Page 48 of 56 TRAILER SAFETY GUIDELINES TIRE FUNDAMENTALS Federal law requires tire manufacturers to place standardized information on the sidewall of all tires (Figure J). This information identifies and describes the fundamental characteristics of the tire and also provides a tire identification number for safety standard certification and in case of a recall.
Page 49 Page 49 of 56 TRAILER SAFETY GUIDELINES Table A. Speed Rating Letter Rating Speed Rating 99 mph 106 mph 112 mph 118 mph 124 mph 130 mph 149 mph 168mph 186 mph U.S. DOT Tire Identification Number: This begins with the letters “DOT” and indicates that the tire meets all federal standards.
Page 50 Page 50 of 56 TRAILER SAFETY GUIDELINES Refer to Figure K for additional tire information for light trucks. Tires for light trucks have other markings besides those found on the sidewalls of passenger tires. LT: The “LT” indicates the tire is for light trucks or trailers. ST: An “ST”...
Page 51 Page 51 of 56 TRAILER SAFETY GUIDELINES Tire Repair The proper repair of a punctured tire requires a plug for the hole and a patch for the area inside the tire that surrounds the puncture hole. Punctures through the tread can be repaired if they are not too large, but punctures to the sidewall should not be repaired.
Page 52 Page 52 of 56 TRAILER SAFETY GUIDELINES Lug Nut Torque Requirements It is extremely important to apply and maintain proper wheel mounting torque on the trailer. Be sure to use only the fasteners matched to the cone angle of the wheel. Proper procedure for attachment of the wheels is as follows: 1.
Page 53 Page 53 of 56 TRAILER SAFETY GUIDELINES Lights and Signals Before each tow, check the trailer taillights, stoplights, turn signals and any clearance lights for proper operation. Replace any broken or burned-out lamps as necessary. Check the wire harness for cuts, fraying or other damage.
Page 54: Troubleshooting
Page 54 of 56 TROUBLESHOOTING...
Page 55 Page 55 of 56 TROUBLESHOOTING...
Page 56 Page 56 of 56 Boreal Applications Inc. 1-800-667-5636 2048 – 529 Gateway Road NE Airdrie, AB Canada T4B 0J6 info@borealapps.ca This manual MUST accompany the equipment at all times. This manual is considered a permanent part of the equipment and should remain with the unit if resold.

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