Copyright＠2023 Tohatsu Corporation. All rights reserved. No part of this manual may
be reported or transmitted in any from or by any means without the express written
permission of Tohatsu Corporation.

APPLICATIONS OF THIS FIRE PUMPUSAGE
TOHATSU portable fire pump ”VE500AS” is manufactured for use in firefighting
operations.
The portable fire pump is intended only for firefighting activities in collaboration withgeneral public fire extinguishing equipment.
Using it for other applications is regarded as being used for improper purposes.
The manufacturer of the fire pump bears no responsibility for any damages that may
result from modification of the fire pump without prior permission from the manufacture,
improper use of the fire pump, or use of the fire pump for applications other than thosestated above.
Note that use the fire pumps for applications other than those stated above can resultin personal injury or damage to the equipment.
Using the fire pump within the range of intended uses implies that the user should follow
the instructions provided by the manufacturer relevant to operation, servicing andmaintenance.

Intended people
All persons who operate, service or maintain the fire pump must read and understandthe following items:
Owner’s manual
Safety-related instructions on the pump and the other parts such as a battery.
The other owner’s manuals, such as a battery charger.
The portable fire pump should be operated by only persons who received training as
operators of fire engines along with each country’s (region’s) regulations.
The range of personal responsibility and supervision must be strictly defined by the user.
If a person does not have adequate professional knowledge which is required for his/her
assignment, he/she must undergo relevant training or receive appropriate instructions
from an individual who is actually knowledgeable in operation of the fire pump.
A person who does not have enough knowledge is not permitted to operate the firepump.
When using the fire pump, conditions under which an explosion may occur are notconsidered.
CAUTION

Keep the manual in a safe place for further reference.
Operators of the fire pump must always refer to all the relevant
manuals in order to avoid errors, personal injuries and equipment
damage when operating the portable fire pump, and to maintainfaultless operation.
Place owner’s manual so that operators can refer to it where they
operate the fire pump.

INTRODUCTION
Thank you for purchasing the TOHATSU Fire Pump.
This fire pump has passed a range of quality assurance standards.
Owner’s manual
The portable fire pump complies with relevant laws and regulations.
The manual includes a description for operation and maintenance. Before using the fire
pump, be sure to read and understand the manual thoroughly.
Engine operation
This manual also includes a description for operation and maintenance of the engine.
NOTE

The manual is an important item that goes with your portable fire pump.
The manual should accompany the fire pump if sold to the otherperson.

Before using this fire pump, write down the serial number in the following boxes. It will be
useful in the case of asking about servicing, repairs and genuine parts.
Serial Number

The pump serial (identification) number ismarked on the pump case.

GENERAL SAFETY INFORMATION
Overview
Before operating the TOHATSU fire pump thoroughly
read the manual to understand the proper operation
procedures including “DANGER”, ”WARNING”,“CAUTION” and “NOTE”.
These notices are designed to bring attention to very
important information necessary to ensure safe,
trouble free operation.
Warning sign meaningThis sign is used for safety-related instructions in thismanual.
Be sure to follow all safety-related instructions,otherwise personal injury may occur.
Signal words
DANGERWARNINGCAUTION

Failure to observe will result in severe personal injury or death,and possibly property damage.
Failure to observe could result in severe personal injury or death.
Failure to observe could result in personal injury or property
damage.

The instruction provides special information to facilitate the use or maintenance ofthe pump or to clarify important points.
See “Chapter 3. LABELS” for the position of warning and caution labels.
Warning labels should be read clearly at any time.
If the display of the warning label may become difficult to be read, it was almost
come off, you must replace paste immediately.
Safety-related instructions and warning signs
Read and follow the safety-related instructions described in the manual and all warning
signs on the portable fire pump thoroughly.
Always keep the warning signs in a legible condition. If any warning sign becomes illegibleor detached, replace it immediately.

Transporting the portable fire pump
CAUTION

When transporting the portablefire pump, assign one person per
handle.
Also, when you transport theportable fire pump, it should betransported holding the handle
firmly.
There is a risk of injury to the leg byfall.

Durability of protection
When you purchase a new pump, it is placed in packing box and protected.
Storage of pump after transportation
Keep the pump away from high humidity, and place it on a horizontal place.
Disposal of packing box
Dispose the packing box by the following environmental laws.
Emissions
Noise emission
CAUTION

Wear proper hearing protection
during operation.

Exhaust gas
Fatal hazard from carbon monoxide (CO) poisoning
Exhaust gas emitted from the engine contains carbon
monoxide (CO) etc. that may seriously affect humanhealth.
Do not operate the engine in a room, car, warehouse,tunnel or other closed locations that have poor
ventilation.

Safety devices
Before operating the portable fire pump, be sure tocheck that all the safety devices have been installed in
the appropriate positions.
Before removing the safety devices, turn the main
switch off.

After protective parts (such as muffler guard) havebeen disassembled as part of servicing andmaintenance work, install them back as soon as
possible to their original positions, and make sure thatthey are in safe secure condition.

Check the portable fire pump visually and functionallyon a regular basis.
If you find any faulty device or parts, remove it
immediately, and repair or replace it, if necessary.
Remove the cause of failure that may cause an accident.
After repairing or replacing, check that it works
properly.
Protective clothing and Protective equipment
During fire extinguishing training or regular firefighting
services, wear normal protective clothing andequipment to protect your body.
・ Fire protective closing
・ Fireproof helmet
・ Fireproof protective gloves
・ Fireproof protective boots

Service and Maintenance
Servicing and maintenance of the fire pump must be carried out by
only persons who have professional knowledge, who are familiar withthe device, and who understand laws and regulations regarding
safety and accident prevention.
Before starting maintenance work, turn the main switch off to stopthe engine.
Disconnect the cable from the negative (-) terminal of battery.
Before starting maintenance work, securely place the portable firepump on the ground.
Do not touch the high temperature parts such as the muffler, muffler
cover, etc. while running and just after stopping the engine until
these parts will be cold. These parts could be very hot and will cause
severe burns.
Electrical equipment
Only expert electricians or trained staff members
should handle electrical equipment.
When removing the battery cable, always disconnect
the negative (-) cable first.
When connecting the battery cable to the battery, besure to connect the positive (+) cable first, and connect
the negative (-) cable next.
Do not place any metal on the battery. Doing so manycauses a short circuit.
Use a fuse with the same specifications as the original
one when replacing it. Using a fuse that has a greater
capacity than the rated value may damage theequipment.
While the engine is running, do not touch thehigh voltage ignition wire attached to the spark
plug. The wire carries very high voltage which
will cause injury and bodily harm.
Check the electrical equipment of the fire pump on aregular basis.

Battery
Follow any safety-related instructions shown on thebattery.
The battery can generate flammable hydrogen gas that
may cause an explosion.
Do not charge the battery in closed room.
Do not smoke near the battery.
The battery electrolyte is caustic and may cause
personal Injuries.
・ Always wear protective clothing.
・ Always wear protective gloves.
・ Always wear protective glasses.
・ Do not tilt the battery. Doing so may cause thebattery electrolyte to leak out from the vent hole.
Handling of fuelExercise care when handling fuel. Failure to do so may
cause fire.
Do not bring any flames near fuel. Stop the engine
before refueling fuel. Do not smoke while refueling fuel.
Do not refill fuel in an enclosed room to avoid an
explosion by fuel fumes.
If fuel spills, wipe it with a cloth or others, and disposeof it according to relevant laws and regulations.
Disposal
Dispose of disused batteries according to relevant laws
and regulations.

Genuine parts
When replacing parts for servicing and maintenance of
portable fire pumps, be sure to use only Tohatsu
genuine parts.
If genuine Tohatsu parts and accessories are not used,
it may adversely affect the function and safety of thefire pump. Use genuine Tohatsu parts only.
Tohatsu bears no responsibility for any personal injuries
or equipment damage that may result from use of partsor accessories obtained from outside sources.
Environmental protection measures
Dispose the oil, fuel, batteries, etc. should be done
according to relevant environmental laws.
Do not dump waste into the ground, water, or sewerage.
Store the fuel only in the specified container.
When disposing of parts, follow the correct disposal
procedure.

Water-prohibiting substanceDo not discharge water to water-prohibited substance.

Use of water
Do not pump combustible liquids, chemical or caustic
liquids.

CONTENTS
1.

S PE C I F I C A TI ON S ……….……….…………..…….….......….….......…….......1

2.

O PE RA TI ON DE V I CE ……….………………..….….......…….......…….......4

3.

L A B E L S...….….…........….…..………..……………………..…........…..…........…7

4.

O P E R A T I N G P R E C A U T I O N S …………….…….…………………….8

5.

D E S C R I P T I O N O F D E V I C E S …………………….………………….10

6.

P R E P A R A T I O N F O R O P E R A T I O N ……………….……………...18

7.

S T A RTI N G T HE E N GI N E ...……….…………...…..……….………...…..23

8.

P RI ME AN D DI S C H AR GE ..……...……….….………..……...….…...…26

9.

S T O P P I N G T H E E N G I N E ……………………………………………32

10.

M A I N T E N A N C E A F T E R O P E R A T I O N ………………….……..33

11.

M A I N T E N A N C E I N C O L D C O N D I T I O N ….….……...………38

12.

U S E OF AC CE S S O RY…..……......…....….….….…….……..……..…......41

13.

PE RI ODI CA L I N S PE CT I ON ….…….……...………...……………..……43

14.

S E RV I CE AN D MA I N TE N AN CE …..………….…………….…….……46

15.

T R O U B L E S H O OT I N G…...……….……..…..…….……....…....……….….52

16.

A P P E N D I X …………...……...…...…….….…………….……………..…...……….66

17.

T OO L AN D S T AN D A RD A CCE S S O RY …….….….….…….…....67

1. SPECIFICATIONS
ModelDescription
Max. permissible inclinationangle

VE500AS
Portable pump
During transport : 35°at all sides
In operation :15°at all sides

Max. operating pressure Palim

1.1 MPa (11 bar, 160 psi)

Max. water temperature
Temperature range
EngineManufacturer
Model
Type
Bore ×Stroke
Number of Cylinder
Piston displacement
Rated power
Fuel type
Fuel tank capacity
Fuel consumption
Ignition
Spark plug
Starting system
Lubrication
Fuel feed system
Battery
Floodlight bulb

＋60 °C－15 °C ~ ＋40 °C

ambient temperature

TOHATSU CORPORATION
T66D
2-stroke, single cylinder, air cooled gasoline engine
66 mm x 58 mm (2.60 in x 2.28 in)
1
198 cm3
11.7 PS (8.6kW)
Unleaded petrol RON91
5.95 L (1.57 gal(US))
5.4 L/h (1.43 gal(US)/h)
Flywheel magneto (DIGITAL C.D.I. system)NGK BR7HS
Electric starter and Recoil (Manual) starter
Auto mixing
Electronic fuel injection
12V-14Ah/10HR
12V-35W

11. SPECIFICATIONS
Model
VE500AS
PrimerType
Rotary-vane vacuum pump (Oil less type)Max. suction height
Approx. 9 m (29.5 ft)
Pump
Single suction, single stage, high pressure turbine pumpType
Number of delivery outlet 1
JIS thread 2-1/2" (65mm), NST thread NH 2-1/2" (male)
Discharge port coupling
JIS thread 2-1/2" (65mm), NST thread NH 2-1/2" (male)
Suction port coupling
525 L/min at 0.6 MPa (6 bar), 139 gal(US)/min at 87 psi
Pump performance(Suction height: 3 m /9.8 ft) 250 L/min at 0.8 MPa (8 bar), 66 gal(US)/min at 116 psi
Dimensions and weight
Overall Length
575mm x 475mm x 537mm (22.6 x 18.7 x 21.1 in)~with a suction port cap
x Width x Height
49 kg/108 lbs (dry) 55 kg/121 lbs(ready for operation)
Mass
Materials
EngineCrankcase, Cylinder,
Cylinder head
Crankshaft
Connecting rod
PistonPump shaft
Muffler
Pump
Pump casing, Pump cover
Impeller
Shaft seal
Type

Aluminum alloy
Chromium-molybdenum steel
Chromium-molybdenum steel
Aluminum alloy
Chromium-molybdenum steel
Steel
Aluminum alloy
Aluminum alloy
Mechanical seal2

1. SPECIFICATIONS

Total delivery pressure3gal(US)/min

Delivery flow

Performance curve2. OPERATION DEVICE

⑤

⑦
④

②
①

⑥

①
②
③
④
⑤
⑥
⑦

③

Suction port
Impeller
Crankshaft
PistonSpark plug
Drain valve
Discharge valve42. OPERATION DEVICE

⑪
⑩

⑨

⑧

⑧
⑨
⑩
⑪
⑫
⑬
⑭

⑬

Fuel feed pump
Injector
ECU
Fuel tank
Muffler
Oil tank
Starter motor

5

⑭

⑫

2. OPERATION DEVICE

Discharge valve handle
Fuel gauge

Ball cockdischarge valve

Manual (Recoil)starter handle
Fuel valve
Pressure gauge(Compound pressuregauge)

Throttle dial
Main switch
Priming lever

Vacuum gauge(Compound pressuregauge)

Fuel feed pump
Oil tank

Carrying handle (4)Spark plug cap

Fuel tank

Fuel tank cap
Vacuum pump
Strainer cap
for Vacuum
pump

Governor oil
gauge
Battery
Muffler(Inside of muffler cover)Exhaust pipe

Muffler cover

Vacuum pumpdrain pipe

6

Suction port
(Cap: Not included
depending on
specifications.)

3. LABELS
Operating instruction

Warning and Caution7

4. OPERATING PRECAUTIONS
Installing pump
CAUTION

The fire pump must be installed onlevel ground. Otherwise, an accident
may occur.
If the fire pump should be installedon uneven ground, it must be
secured.
When installing the portable pump in
the vehicle, place the vehicle on alevel place, and install the pump.
Do not put your hand or finger inthe retractable part when using thehandle.
When transporting the portable fire
pump, assign one person per handle.
Also, when you transport theportable fire pump, it should betransported holding the handle
firmly.
Do not touch the exhaust pipe andthe muffler while the engine isrunning, or for more than 10 minutes
after the engine has been stopped.
Confirm the engine temperature iscooled down enough. These parts
are very hot and will cause severeburns.

8

Do not put yourhand or finger

4. OPERATING PRECAUTIONSNOTEPlace the pump as near as possible to water source, and water suction
height as low as possible.
When putting the portable fire pump down on the ground, put it gently
and horizontally.
Max. permissible inclination angle: 15°
In case of the inclined location or uneven ground, make sure that thewater suction hose is placed lower than suction port of the pump.
In case of the suction hose is put undulated, air can be left easily in thehose, and possibly cause suction inability when the water discharge
valve is opened.
In case of the suction inability due to air remaining in the suction hose,
set the water discharge valve half-opened, and operate the vacuum
pump until water is discharged continuously. (More operation of
vacuum pump for 3 to 5 seconds from beginning of water discharge.)
Be sure to install strainer and basket at the end of suction hose. If thepump may suck in sand or mud at the water source bottom, place asheet below the basket.
Strainer and basket of suction hose should be placed more than 30 cm
below water surface to prevent suck of air.
Discharge hose should be arranged not to be bent.
When starting / operating the pump, connect the battery. Even if
starting the engine by operating the recoil starter.

9

5. DESCRIPTION OF DEVICES
Suction port
The diameter of the thread for fire pump

Suction port

・ JIS thread 2-1/2” (65 mm)
・ NST thread NH 2-1/2”

WARNING

Putting a finger or a hand into thesuction port while the pump is runningwithout installing the strainer, it may
cause serious damage by the rotating
inducer.

CAUTIONInstall the standard strainer to thesuction port.
Do not run the pump if the strainer is
not installed.
If the pump is operated without thestrainer installed, gravel can enter thepump and the drainage capacity may
be decreased considerably.

Carrying handle
The fire pump is equipped with four carrying handles.
CAUTIONTo prevent injuries, two persons
should work together when carrying
and placing the pump.

10

Carrying handle (4)5. DESCRIPTION OF DEVICES
Discharge port
The diameter of the thread for fire pump・ JIS thread 2-1/2” (65 mm)
・ NST thread NH 2-1/2”
Ball cock discharge valve
ThreadDischarge valve
Use the discharge valve lever handle to open and close thedischarge valve.

Open

Close

Drain valve
Use the drain valves to drain water.

Drain valve
NOTE

Close all the valves when operating thefire pump. If the valve is opened, watercannot be sucked up.

(Ball cock discharge valve)115. DESCRIPTION OF DEVICES
Fuel tank
Refill appropriate amount of gasoline to the fuel tank.
Close the fuel tank cap all the time except refuel.

Fuel tank cap
Fuel tankEngine oil tank
Refill appropriate amount of oil to the oil tank.
Close the oil tank cap all the time except filling.
The oil tank has an oil level sensor.
The warning buzzer sounds, if the engine oil is not enoughfilled.
CAUTION

Running the engine while warningbuzzer sounds could cause the engine
damage such as seized.

NOTE

If the engine oil is not enough, thewarning buzzer sounds.

12

Oil tank

Oil tank cap

5. DESCRIPTION OF DEVICES
Control panel
The control panel is equipped with all the necessary
operating and control instruments as follows.

Control panel

Throttle dial
Use the throttle dial to control the discharge pressure.
Throttle dial
Fuel valve
Turn the fuel valve to control the fuel supply by full open
or close completely.

Fuel valve
Close

Main switch (Stop switch)

Open

Turn the main switch (Stop switch) to start, run or stopthe engine.
Description

To stop the engine|

Running position○ (Start)

Start

Function○ (Stop)
(Run)

Run

Stop

Main switch

To start the engine

Lift

Priming lever
Use the lever for priming water.
After starting the engine, lift the priming lever to suck up
water. After priming has been completed, return thepriming lever to the original position.

13

Original
position
Priming lever5. DESCRIPTION OF DEVICES
Battery charger connector
Connect the battery charger plug to the connector
when you charge a battery of the pump.

Battery charger
plug connector

Voltage: DC 12V
Max. allowable current: 5A
CAUTION

Before charging the battery, turn themain switch OFF.
When starting the pump operation, be
sure to remove the battery charger
plug from the connector before
turning the main switch ON.
The connector is only for a battery anda floodlight.
Do not connect a cigarette lighter tothe connector, because it is not aheat-resistant specification.

Fuse box
Fuse is in the fuse box* Fuse: 5A and 15A
Security fuse is installed for electrical circuit in thefuse box.
Pressure gauge for discharge
The pressure gauge for discharge indicates the actual
operating pressure.

Fuse box
Pressure gauge(Discharge)

Pressure gauge for suction
The pressure gauge for suction indicates the negative
suction pressure and the input pressure supplied froman external water source.
Pressure gauge(Suction)14

5. DESCRIPTION OF DEVICES
Warning system

Turning the “Main switch” to the “Run ( | ) “ position, the buzzer sounds for a moment.
If the warning buzzer does not stop, check the engine oillevel. If there is no problem with the oil level, refer to
Chapter 15 Troubleshooting to solve the problem.
CAUTION

Even if the low engine oil level warning
Main switch
buzzer sounds, the engine will not stop
immediately. This is to give priority
Engine Oilto the continuation of fire fighting
over protection of the engine.
The engine remains operational for more than 30 minutes evenafter the buzzer sounds.
However, if the engine is operated for longer than this, the engine
will seize up. Refill the oil immediately when the warning buzzer
sounds.

Governor case (Oil)Check the governor oil level with the governor oil level
gauge (dipstick).
The governor oil gauge shows upper and lower level of theoil on the gauge.
If the oil is needed, add 2-stroke engine oil from the oil
gauge port up to the area between Lower and Upper limit
line.

Governor oillevel gauge

Upper
Lower
CAUTIONBe sure to stop the engine before checking
the oil level. If you pull the dipstick when thepump is running, the oil may blow out.
After checking the oil amount, return it to the original position.
(Insert the oil level gauge securely into the hole.)

Mechanical governor
A built-in mechanical governor controls the throttle valve so that the maximum engine
speed does not exceed 6700 r/min.

15

5. DESCRIPTION OF DEVICES
Manual starter
If the engine will not start with the starter motor, use themanual (recoil) starter.
CAUTION

Personal injuries may occur. Do notpull the manual starter handle when Starter handle
the pump is running. Otherwise, themanual starter may be damaged.

NOTE

To start the engine with manual starter,
engage the manual starter ratchet bypulling the starter rope slowly. And thenpull the starter handle quickly with great
force from the position in which feels
harder resistance.

Manual (Recoil) starter

Floodlight (Search light)
Use the floodlight projector to light up the location where
the fire pump is operated.
Connect the floodlight plug to the connector of the pump.
Fix the projector to the tripod with tightening the adjust
screw.
Floodlight projector

PLUG
BULB 12V-35W

ADJUST SCREW

Connector
TRIPOD
CAUTION

Secure adequate lighting for the location where the fire pump is
operated, otherwise an accident may occur.

16

5. DESCRIPTION OF DEVICES
NOTE
Warning system

Alert action check• When the power is turned o n , the warning buzzer will be activatedfor approximately one second.
WarningbuzzerAlert check

One-time
alert

Warnings

Oil level

Continuous

Overheat

Continuous

Prior
warning
overheatEngine o v e r
speed
MAT, MAP, TPS orETS Alert (*1)

Warning control
ESG

Enginestop

Description of faults or notice

RemedyAlert

Normal system test when the main switch isturned on. (*2)
Oil level is below approx. 1/3○

Intermittent(2second interval)○Intermittent

A

Engine has stopped due to insufficientcooling condition.
Warning of engine stoppage due toinsufficient cooling, etc. is warned inadvance.
Engine speed exceeds maximum- allowable
RPM(*3)
MAP, MAP, TPS or ETS failure or open circuit.

(1second interval)

B
B
C
D

*1. Manifold Air Temperature sensor (MAT), Manifold Absolute Pressure sensor (MAP),
Throttle Position Sensor (TPS), and Engine Temperature Sensor (ETS)*2. When the main switch is set to the “Run” position*3. Engine speed is controlled to 7200 rpm
RemedyA. Refill the engine oil.
B. Eliminate the cause of Insufficient cooling air. (Check for damage to the cooling fan
and blockage of the cooling air intake.)
C. Operate the throttle dial to use it outside of the high-speed ESG (over revolution)
operating range.
D. Stop the engine and contact our customer service.
Overheat protection control
Elapsed time after
startupWithin 35 seconds
Over 35 seconds

Overheat protection release temperature
Engine wall
ReleaseControltemperaturetemperature
120℃
100℃
90℃

95℃

Engine stop
control

80℃

Prior warning

Warning buzzer
ContinuousIntermittent(2second interval)

Turning off the main switch during overheat, the warning will be canceled.
• Remove the cause of overheat.
CAUTION• Start the engine after the engine temperature drops and the overheat
prevention control is released.

17

6. PREPARATION FOR OPERATION
Initial charge of battery
The battery can be used immediately after filling cells with electrolyte.
In the case of the battery is maintenance free of electrode (Sealed type battery), do notopen the battery after filling it with electrolyte.
Refer to the instructions of the battery.
CAUTION・ Do not operate the pump while charging the battery.

Fuel
Fuel tank capacity: 5.95L (1.57 gal(US))
Fill the tank with gasoline until the maximum level by checking
the gauge indicator (red).

* Gasoline:87 octane minimum at pump posted rating…91
based on the research octane rating method.

DANGER・ Vaporized fuel may cause ignition or an
explosion.

・ Do not bring any flames near fuel.
・ Smoking, (errant) sparks, static electricity,heat and the other sources of fire can cause
explosion.

・ Stop the engine before refueling or draining
fuel.

・ Do not spill fuel or overfill fuel into the tank.
CAUTION ・ Do not breathe in vapor!
・ Petrol fumes are very toxic.
・ After stopping the engine, do not touch it
while it is hot.

・ Refill fuel after the engine has cooled down.
・ Fuel tank cap should be always tightly closed.
・ Fuel tank cap should be removed only to filltank with fuel.

・ Properly clean up all the fuel spills (checking
for gasoline vapor) before starting engine.

・ If the petrol or the fuel spills, wipe it off using

a cloth or materials, and dispose of themaccording to the relevant laws andregulations.

18

Indicator

6. PREPARATION FOR OPERATIONNOTE

・ Use of low-quality fuel results in a short engine life as well as starting
difficulty and other engine problems.

Fuel containing alcohol, methanol (methyl), or ethanol (ethyl), maycause:- Deterioration of rubber parts and plastic parts.
- Starting, idling and other engine performance problems.

・ Do not use fuel containing over 10% ethanol. Do not use fuelcontaining over 5% methanol.

・ Damages resulting from the use of fuel that contain alcohol are notcovered under the limited warranty.

・ Always fill the fuel tank with gasoline to be ready.

19

6. PREPARATION FOR OPERATION
Engine oil
Refill the 2-stroke engine oil to the oil tank until “UPPERLEVEL”.
CAUTION

Upper level

The warning buzzer sounds if theengine oil is not enough filled.
We recommend the engine oil of ISOL-EGB grade or higher quality.

Lower level

Always wipe off the spilled oil.
Mixing engine oils of different grads
may cause the oil to gel.
Governor oil
Before using the fire pump, check the governor oil level.
1. Place the pump on a level place.
2. Remove the governor oil level gauge (dipstick), and wipe
it with a cloth.
3. Insert the governor oil level gauge into the original
position (port/hole) completely.

Governor oillevel gauge

4. Pull out the governor oil level gauge (dipstick) again, andcheck the oil level. The oil level should be between Oil line markupper and lower limit line on the gauge.
Upper limit

If the oil level is below the Lower limit, add 2-stroke engine Lower limit
oil from the oil gauge port up to the oil mark line (between
Lower-Upper limit).
CAUTION・ Be sure to stop the engine before
checking the oil level. If you pull thedipstick when the pump is running,
the oil may blow out.

Drain valves
Make sure all the drain valves are closed.
Drain valve

Close

Close

20

Drain valve

6. PREPARATION FOR OPERATION
Discharge valve
Make sure the discharge valve is closed.

Close

Discharge valve
Battery installation
The battery mounted on the engine can be used
immediately after filling cells with electrolyte (1.28 specificgravity at 20°C=68°F).
Refer to the instruction of thebattery.
NOTE

・ Do

not operate the engine notconnecting the battery,the gauge
lamp may burn out.

21

Battery6. PREPARATION FOR OPERATION
Pump installation
WARNING ・ The temperature around the engine will
become high because of the muffler andexhaust gas, install the pump on levelground at least three meters away frominflammable materials including dry grass
and wood.

・ Exhaustgas, which contains carbon
monoxide, is deadly poisonous gas with nocolor and no smell.

・ Do not operate engine in a closed space orin an insufficient ventilation place, such asindoor, in a vehicle, warehouse, tunnel, well,in a hold of ship.

・ Do not start engine with discharge valve
opened.

・ Do not pump and discharge liquids otherthan water (e.g. flammable liquids or
chemicals).

・ This pump is only designed for pumping
water.

・ Do

not discharge waterprohibiting substance.

towater-・ Do not insert your hand into the suction
port to avoid serious injury by the rotating
inducer.

CAUTION・ Do not run the pump without suction portstrainer.

・ If gravels go into the pump, then the pumpcould be damaged and the performance
could be significantly reduced.

22

7. STARTING THE ENGINE
1. Place the pump near the water source on a flat area.
2. Connect the suction hose and delivery hose to the pump securely. Put the end ofsuction hose in water source. The suction hose must have a strainer and a basket atthe end of the hose.
3. When the discharge operation of the pump will be done using a branch pipe withnozzle fitted, recommend nozzle bore are within the range below.
Low pressure 21 mm (0.83 in) ~ High pressure 15.5 mm (0.61 in)
CAUTION ・ Using a nozzle which has larger than 21mm bore
could damage the pump.

Starting the engine
CAUTION ・ Wear proper
operation.

hearing

protection

during・ While the engine is running, do not touch thehigh voltage ignition wire attached to the spark
plug. The wire carries very high voltage which
will cause injury and bodily harm.

・ Do not operate the pump on dry grasses.

The exhaust system will be very hot and could
cause the dry grass burnt and fire. Sweep thearea if necessary.

23

7. STARTING THE ENGINENOTE・ This model is equipped with an injector.

Injector

Fuel valve
1. Turn and open the fuel valve.

Close
Open
Throttle dial

2. Turn the throttle dial to “START･SUCTION (S)” position.
START･SUCTION
3. Turn the main switch to “Run (｜)” position.
Turn the main switch to “Start ( )” position.
Release the main switch immediately after the engine
started.

Run

Stop

Start

Main switch
NOTE

・ Make sure there is enough fuel in the fuel tank and that the fuel cockis opened.

・ Extended operation of the starter motor will run the battery drain.
Operate the starter motor within maximum 3 seconds.

If the engine does not start, wait for over 5 seconds before operating
the starter motor again.

・ Do not operate the starter motor after the engine started (while theengine running).

・ If the starter motor does not work, check that the battery terminals
are tightly connected and the battery is fully charged.

* If the electric starter does not work to start, start the engine with recoil (manual)
starter.

24

7. STARTING THE ENGINE
Starting engine using a manual starter
When you use a manual starter, operate the engine as shown
below.

1. Turn the fuel valve to “OPEN” position to flow thefuel to the carburetor.
2. Turn the throttle dial to “START ･ SUCTION (S)”position.

3. Turn the main switch toFuel valve
Close
Open
Throttle dial

“Run (｜)“ position.
START･SUCTION

4. Engage the starter ratchet by pulling the starter handle
slowly towards you. When you feel the ratchet engage,pull the handle sharply (holding the fire pump in placewith your foot).
5. After the engine started, return the starter handle to theoriginal position slowly so as not to damage the recoil
starter.
CAUTION

NOTE

Stop Run

Main switch

・ Do not pull the manual starter handle
when the pump is running. Otherwise,
the manual starter may be damaged.

・ To start the engine with manual starter,

engage the manual starter ratchet bypulling the starter rope slowly. And thenpull the starter handle quickly with great
force from the position in which feelingharder resistance.

25

Starter handle

8. PRIME AND DISCHARGEWARNING

While the engine is running, do not touch
the rotating parts of the pulley or belt. Thiscan cause personal injuries.
Close the discharge valve before sucking
up water.

NOTE

If the pump cannot suck up water during the operation of the vacuum
pump within 30 seconds, or cannot keep the water in the water path ofthe pump during the water discharge operation, check the following:
The end of the suction pump hose should be completely under thewater surface.
Air should not be sucked through the joint of the suction hose.
The suction hose should not have damage.
The vacuum performance of the vacuum pump should be enough.
The pump case should not leak vacuum.
The vacuum leak should not occur when connecting the suction hosewhich has closed end to the pump. (Confirm no leak in the water line.)* Refer to “Chapter 15 TROUBLESHOOTING”.
Lift

Prime and Discharge
1. After starting the engine, lift the priming lever up to put
tension on the V-belt of vacuum pump to suck up
water.

Priming lever
Return2. Check that the pumped water is discharged
continuously from the vacuum pump drainpipe.
Be sure the pressure gauge shows positive side.
3. Return the priming lever to the original position.
Vacuum pump drainpipe

26

8. PRIME AND DISCHARGE
Limit the vacuum pump operating time within 30 seconds. If thepump cannot suck up water within 30 seconds, it may have problems.
Refer to “Chapter 15 TROUBLESHOOTING” to rectify the problem.
When priming water from a water source that is considerably lower
location than the pump, suction water may not be brought up to thepump.
The engine is cooled by air, but should be operated at a slow speed
when pump is running with no water. The pump may be damaged
when it runs with no water for more than 2 minutes even at a slow
engine speed.
The pump should be run with water discharging for protecting someparts of the pump such as mechanical seal.
4. Open the discharge valve.
Turn the discharge valve handle towards the discharge
port adapter (hose) at a slow speed.
Open
The discharge port can be turned approximately 90°.
Before opening water discharge valve
CAUTIONof the pump, be sure to warn the
person holding the nozzle, and ≒90°
confirm to be ready to discharge
water.
During operation, check the suction
and discharge hoses.
They must be free of kinks, pinches,etc., possibly caused from emergency
Nozzlevehicles rolling over hose.
NOTE

To avoid the air left in the hose, the pump should be located above
the suction hose. If some air left in the hose, the pump may not beable to discharge water by the accumulated air in the hose when you
open the discharge valve. In this case, open the discharge valve andoperate the vacuum pump for 3 to 5 seconds more until the water is
continuously discharge. (To discharge the air in the suction hose.)
5. Adjust the water pressure using the throttle dial turning.
In the case of using a branch pipe, the
CAUTION
person holding the branch pipe must
be notified of changes in water
discharge pressure caused fromengine speed changes or discharge
valve setting changes.
Throttle dial
Discharged water should not bedirected toward people under any
circumstances.
Do not look into the nozzle opening at any time.
Do not put fingers or hands into the discharge nozzle.
NOTE

27

8. PRIME AND DISCHARGE
Performing relayed water supply (When using water from fire hydrant)
1. Decide the pump pressure in consideration of the needed pressure (water
discharge/nozzle pressure), friction loss (hose pressure), and height loss.
Pump pressure = needed pressure + friction loss + height loss
2. Foreign materials such as dirt, gravel, iron rust, etc. may go into a fire hydrant.
Before connecting a hose, open a fire hydrant to discharge water in order toremove foreign materials.
3. When using water from a fire hydrant, use a water relief valve to connect a delivery
hose to the suction port without using the suction hose in principle.
4. Set the discharge valve handle of the pump to the full open position.
5. Gradually open the fire hydrant on-off valve. However, check the water pressure
from fire hydrant with suction pressure gauge of the pump and adjust the openingof fire hydrant on-off valve, if necessary.
CAUTION

If the water pressure from fire hydrant is higher than 0.6 MPa (6bar, 87 psi), do not open the fire hydrant on-off valve more.
* If the water pressure from fire hydrant is higher than therequired discharge pressure, it is not necessary to start theengine.
If the water pressure from fire hydrant has not reach the requiredpressure, then start the engine.

6. If the water pressure from fire hydrant is insufficient, start the engine and adjust thepressure to the required pressure level by operating the throttle dial.
Stop increasing discharge pressure if the suction pressure gauge shows 0.1 MPa (1bar, 15 psi) or below. If it does, stop increasing the pressure and keep the throttle
dial as it is.
7. To end discharging water, turn the throttle dial to the low pressure position firstly,
then stop the engine, and close the fire hydrant on-off valve.
CAUTIONBe sure not to close the discharge valve and nozzle of any pumps
until all the pumps stopped and the fire hydrant on-off valve isclosed.

8. Set the discharge valve (Ball cock type) to the half-open position, and open all thedrain valves to drain the remaining water in the pump as maintenance after theoperation.

28

8. PRIME AND DISCHARGE
Relay pumping operation
CAUTION

In the case of relay pumping operations training in a flat place, if
the number of extending hose is less than ten, use the pumping
plate (safety nozzle) attached.
Packing
Pumping plate

Discharge port adaptor
Description of replay pumping operation

Water
supplyWater
supplyWater
supplyFire nozzle

Source pumpWatersourceRelay pump

Suction pressure
Suction pressure

Attack pump

Relay pump

Suction pressure

Suction pressure29

8. PRIME AND DISCHARGE
Preparation for operation
WARNING

Never close the discharge valve of source pump, relay pumps andfire nozzle. If the discharge valves or nozzle are(is) closed, there
will be a risk of damage to the pumps and hoses with excessive
pressure or water hammer.

1. Decide how many relay pumps are needed in the consideration of distance andheight between the water sauce and the fire ground.
2. Place the pumps according to the decision, and connect the hoses.
3. Make sure that the discharge valve(s) and the fire nozzle are all opened.
4. Decide the discharge pressure of each pump in consideration of needed pressure
for next pump (or fire nozzle), the friction loss and height loss.
Pump pressure = needed pressure + friction loss + height loss
Start the source pump
WARNING

Once the water supply has started, keep supplying it until
finishing the discharge operation. If reduce or stop supplying
water, overheat or cavitation may occur in the relay pumps.

1. Start the source pump according to “Chapter 7 STARTING THE ENGINE”.
2. Start supplying water according to “Chapter 8 PRIME AND DISCHARGE”.

30

8. PRIME AND DISCHARGE
Start the Relay pump
1. Make sure that the discharge valve is opened and wait for supplied water.
2. Check that the water is supplied from the source pump. At first, the hose swells due
to air pressure. Step on the hose to confirm whether the swelling of the hose is due
to water or air.
3. Confirm that the water is supplied to the pump checking the pressure gauge.
Start the engine if the pressure is lower than the required pressure.
If the pressure is high enough, no need to start the engine.
4. Adjust the discharge pressure turning the throttle dial. The suction pressure
decreases with opening up the throttle. Always confirm the pressure with thesuction pressure gauge.
5. If the suction pressure drops below 0.1 MPa (1 bar, 15 psi), order the operator of the
pre-stage pump to increase the water pressure, and adjust the relay pump pressure
by the throttle operation.
6. If the suction pressure rises, adjust the pressure with the throttle dial again.
Start the Attack pumpSame as the relay pump.
Finish the relay pumping operation
CAUTION

Do not close the fire nozzle.
Stop the attack pump running first.
Stop the relay pump running from thepump closest the nozzle in order.
Finally, stop the source pump.
Do not touch the muffler while the engine
is running, and also do not touch it for 10
minutes or more after the engine has been
stopped. Confirm the engine temperature
is cooled down enough. The muffler
becomes very hot while the running andwill cause severe burns.

31

9. STOPPING THE ENGINE
1. Turn the throttle dial to “Low／－” position.

Throttle dial

Low

Close

2. Close the discharge valve.

（Ball cock discharge valve -------)
Discharge
valve handle

3. Stop the engine
Turn the main switch to “Stop／○” position.

Stop

Main switch

32

10. MAINTENANCE AFTER OPERATION
Drain Water
1. Open the drain valves and drain out all the water fromthe pump. Do not leave the water in the pump.

Drain valve

2. Close the drain valves for the next operation.
Close

Open

Suction Performance Check
After the drainage of all the water from the pump,
1. Confirm the drain valves are all closed. (The pump caseand discharge valve.)

Drain valve

2. Close the suction port (with a cap, etc.).
* Close the suction port not to leak air into the pump.

Close

3. Turn the throttle dial to ”START” position, and start theengine. Lift the priming lever to decompress the insideof the pump. (within 30 seconds)

Example of using asuction port cap

4. After sufficiently depressurizing the inside of the pump,
return the priming lever to the original position
immediately, and stop the engine.
5. Check the vacuum pressure of the pressure gauge forsuction is approximately -0.08MPa (-0.8 bar,-12 psi).
6. In order to check that there is no vacuum leak, leave it
for 30 seconds and confirm that the pointer of thevacuum pressure gauge keeps the same pressure
indication.

Lift
Priming lever

7. Open the drain valve slowly to expose it to theatmosphere, and check that the pointer of thepressure gauge for suction returns to “0”.

ReturnSTART

8. Close the drain valve again.

Vacuum pressure gauge

3310. MAINTENANCE AFTER OPERATION
Dry operation
In the case of reducing moisture inside the pump so that the inside of the pump does
not corrode, do the “Check Suction Performance” process. It should be carried out for
about 30 seconds. (Don't do it over 30 seconds)
NOTE

Before storing the fire pump, flush with fresh water to purge debris
such as salt water, muddy water, contaminated water, etc. from thepump.
Rubber gaskets, O-rings, seals for thedischarge and suction hose fitting wear:
Worn rubber seals will cause water leaks,
poor vacuum, etc. Frequent inspection ofthese items is mandatory.

Fuel and Oil
1. FuelFill fuel until the maximum level of the fuel tank.

Indicator
E:Empty← →F:Full

The maximum level can be confirmed by the indicator(Red). * Fuel tank capacity: 5.95L (1.57 gal(US))
WARNING

Upper level

Wipe off fuel using a cloth or others if
there is fuel out of the fuel tank.

2. Engine oil
Fill the oil tank with 2-stroke engine oil up to the upper
level.
NOTE
3. Governor oil

Use 2-stroke engine oil of ISO-L-EGB
grade or higher.

Check the oil level using the governor oil level gauge.
(Dipstick)
At least check the oil every six months or every 50 hours
operating time.

Governor oillevel gauge

Refer to "Chapter 6 PREPARATION FOR OPERATION,
Oil line markGovernor oil".
Upper limit
Lower limit

34

10. MAINTENANCE AFTER OPERATION
Cleaning strainer for prime
Remove the strainer cap and clean the strainer with fresh
water.
If the strainer is dirty with dust, etc., vacuum performanceefficiency will be reduced.

Strainer

Strainer cap

Charging the battery
WARNING

Hydrogen gas from the battery is
explosive. Keep battery away fromflame and sparks.
Charge the battery in a well ventilated
area. Do not charge battery inunventilated area.

CAUTION

Read the cautions attached to thebattery carefully before use.

Be sure to charge the battery after each operation.

<Specification of plug socket>
Voltage : DC12V
Max. allowable current : 5A

35

Battery charger
plug connector

10. MAINTENANCE AFTER OPERATION<Battery charger>
Read the instruction manual of the battery charger before use.
*The instruction manual is packed with the charger.
WARNINGCAUTION

Do not connect a cigarette lighter to thebattery charger connector. It may cause melt
or burn out the connector due to overheating.
Use an automatic battery charger
overcharge prevention function.

withSet the battery charger on a suitable non-inflammable stand or
fix on wall, and do not put it directly onto the ground.
Automatic battery charger should be kept in a dry place and awell-ventilated place.
The battery capacity must be 12V-14Ah/10HR.
Disconnect the battery charger after charging is completed.
1. Confirm that there is no dirt, no slack, no backlash of the terminal.
2. Confirm quantity of liquid of the battery.(Shield type battery is excluded)
3. Set the main switch to the “OFF” position.
4. Plug the charging plug to the battery charger connector.
5. Insert the input plug to household power supply.
6. Confirm the battery charging status referring to the battery charger instruction
manual.
7. Disconnect the battery charger when using the pump.
Battery charger
Connector

Input plug

Charging plug36

10. MAINTENANCE AFTER OPERATION<Battery>
WARNING

Hydrogen gas from the battery is explosive. Keep battery awayfrom flame and spark.
Charge the battery in a well ventilated area. Do not charge
battery in unventilated area.

CAUTIONThe battery capacity must be 12V-14Ah/10HR.
Read the instruction (caution) attached to the battery andelectrolyte carefully before use.

--In the case of Opening type battery-If battery liquid is “Lower level”, supplement replenisher to “Upper level”.
To know the exact state to charge, measure specific gravity of the battery liquid byan areometer. The specific gravity of the full charge is 1.28 (20°C conversion).
The outer surface of the battery should be kept always clean.
The battery life is normally 2~3 years even if the battery is used properly.
Replace with new battery every 2~3 years checking the deterioration of the charging
performance.
When connecting battery cables, connect the positive (+) battery cable first. (Whendisconnecting battery, remove the negative (-) cable first.)
Hydrogen gas released from the battery can cause damage and severe burns of theclothes and skin.

Upper level
Lower level

1.20
1.28
1.30

-- In the case of Maintenance-free battery-CAUTION

Do not open the caps of the battery.
Replace with new battery every 2~3 years.
Maintenance-free batteries do not need to replenish distilledwater and/or replenisher. Do not replenish distilled water and/or
replenisher.

37

11. MAINTENANCE IN COLD CONDITION
Infuse anti-freezing fluid
CAUTION

If the temperature around the pump could be subzero, the insidewater of the pump may freeze. Then you cannot start the engine,and could have some damages in the pump.
In order to prevent internal corrosion and damage by the water
frozen in the pump, drain all the water from the pump unit. Afterdraining the water, put antifreeze fluid into the water pump andthe vacuum pump.

1. Open the drain valves to drain all the water from thepump.
2. After the drainage of the water, attach the suction
cap. (And close the drain valve ~ Ball cock discharge
valve).

Drain valve
Close

Open

Example of using asuction port cap
Close
Open
3. Close the suction port (with a cap, etc.).
*Close the suction port not to leak air into the pump.
4. Insert the plastic pipe in the container filled with
antifreeze fluid (180~200 mL/0.048~0.053 gal(US)).
Attach the suction port cap to the suction port.

Antifreeze
fluid
Throttle dial

5. Turn the throttle dial to “START・SUCTION” position .
Turn the main switch to “Run” position.
START･SUCTION
Stop

Run

Main switch

38

11. MAINTENANCE IN COLD CONDITION
6. Turn the main switch to “Start” position. Release themain switch immediately after the engine starts.

7. After starting the engine, suck antifreeze fluid byoperating the priming lever (vacuum pump).
NOTE

Run

Start

Main switch
Priming lever

Even if all antifreeze fluid is sucked up,
continue lifting the priming lever for
approximately 30 seconds. (Do notdoing it over 30 seconds.)

Suck
antifreeze
Original
position

Return the priming lever to “Original position”.
Stop

8. Stop the engine.
Turn the main switch to “Stop” position.

Main switch
9. Remove the plastic pipe and close the drain valve.
Drain valve
Close

39

11. MAINTENANCE IN COLD CONDITION
10. Put antifreeze fluid into the seal
area of the discharge valve.
*To use a long nozzle containing is
helpful when pouring antifreeze
fluid, especially in the case of using
a coupling. (Refer to the picture.)
11. Put antifreeze (undiluted 50 ml/(0.013 gal(US)) into the strainer guide.
After putting it, assemble the strainer.
CAUTION

NOTE

When installing the strainer, exercise
care so that the O-ring does not getcaught in, and tighten the cap
securely.
When you install the strainer, pay
attention to the protrusion of the O-ringand install it correctly. Otherwise, thevacuum leak may occur.

O-ringStrainerCap

Strainer guide4012. USE OF ACCESSORY
Battery
Battery performance deteriorates if the temperature falls. Further, battery may freeze
if the specific gravity is low.
Battery specification
Capacity: 12V-14Ah/10HRWARNING

Hydrogen gas from the battery is explosive.
Keep battery away from flame and sparks.

CAUTION

Charge a battery in well ventilated area. Do not
charge a battery in unventilated area.
Read the instructions attached to the battery
carefully before use.
When charging a battery, be sure to use an
automatic battery charger.
Use an automatic battery charger that matches
the battery specifications. Use of a mismatched
automatic battery charger may cause the battery
to explode.
Keep the battery surface clean.
Battery life is normally 2~3 years even if battery isused properly. Replace with new battery every
2~3years checking the deterioration of thecharging performance.
Connecting battery cables, connect the cable tothe positive (+) electrode of battery first.
Removing the battery cable, first remove thecable connected to the negative (-) electrode ofbattery.
Battery electrolyte is very caustic acid, which willcause severe burns to your skin and damage toclothing.

41

12. USE OF ACCESSORY
Pumping plate
CAUTION

When the fire pump is used as a water pump, such as pumping
water out of a cellar, install the pumping plate* which has holes in
between the discharge port adapter and the bracket packing to
avoid the pump cavitation which may cause damages to the pump.

Pumping plate is the standard accessory: Part No. 121-39045-1

Packing
Pumping plate(Standard accessory)

Discharge port adaptor

4213. PERIODICAL INSPECTION
Pay your serious attention to keep the pump in good condition.
1. To store a fire pump properly
Place it in a level place.
Keep it in a dry area. High humidity may cause corrosion in some parts of thepump.
2. Keep the fire pump free of dust.
3. Keep the fuel tank full.
4. Fill the governor case with 2-stroke engine oil to proper level.
5. Run and operate the pump at least once a month.
6. Check the battery condition once a month. Add distilled water if the battery liquid
level is lower than the specific level and charge the battery.
In the case of the battery is maintenance free battery, do not add any water(including distilled water). Just charge the battery.
7. Replace the spark plug* if it is dirty or worn.
* No.: NGK BR7HS Gap 0.6~0.7 mm (0.02~0.03 in)
8. Replace the V-belt of the vacuum pump if the V-belt is cracked or worn.
9. When storing the pump, close the suction port with a cap to avoid foreign objects
entering into the pump.

43

13. PERIODICAL INSPECTION
Perform periodical inspections and maintenance according to the following procedures.

3year or
300hr

1year or
100hr

0.5years or
50hr

Description

After each
operation

Inspection intervals

Fuel
SystemRefuel●Impurities (ie. Water
and/or foreign material)

Replace*1●

Degradation (ie. Stink orcolor)／Preservation
period 6 month or more

Replace*1

Damage, leakage, foreignmaterial stuck

Replace*1

Fuel Tank

Ignition●

Strainer●

Impurities (Water and/or
foreign material)

Clean out*1

Fuel hose●

Curling, crack, leakage,connection

Replace*1

Spark plug●

Fouling, wear,
inappropriate gap

Clean out
or Replace

Locked(Seizing),
poor compression
pressure

Replaceparts ifnecessary*1

Oil level

Refill thesame oil

Cranking
EngineStarting
systemMeasureQuantity of fuel●
Fuel *2

Inspection items

Engine oil●●

Governoroil●

Oil level with oil level
gauge

Refill thesame oilStarter rope●

Wear, damage

Replace*1

Voltage measure

ChargePeriod of use

Replace*1 *3●
Battery●44

13. PERIODICAL INSPECTION

PrimingsystemPump
unit

Discharge
Rubberparts
All parts

3year or
300hr

1year or
100hr●

Clogging or broken
mesh

Clean out or
replace●

Not locked
Check performance(-0.08 MPa,-0.8 bar,
-12 psi)

Replace parts
if necessary*1●

Vane: Water
suction/vacuum
performance

Replace parts
if necessary*1●Side plate: Water
suction/vacuum
performance

Replace parts
if necessary*1

Close the water
discharge valve while
discharging water andcheck the water leakage.

Replace parts
if necessary*1

Water leak

Replace*1●

Vacuum leakage

Replace parts
if necessary*1●

Deterioration, wear

Replace parts
if necessary*1●

Mechanical
seal
Valve

MeasureReplace*1●

Primer(Vacuum
Pump)

Pump
hermetic

Inspection items

Wear, crack,belt-tension

V-BeltStrainer

0.5yearsor 50hr

Description

After each
operation

Inspection intervals●●

Replace parts
if necessary*1*1. Ask our customer service staff to replace the parts.
*2. When the preservation period is 6 months or more, then replace all the fuel. And
check the fuel line including fuel cock regarding with clogging.
*3
WARNING ・Batteries that have been used for more than three years may
explode if charged.
CAUTION ・Finish the performance test within one minute in order to protect
the pump unit. (Vacuum pump: within 30 sec.)
Inspection interval which has been reached earlier in the running time and the periodic
inspection period should be the Inspection timing.

45

14. SERVICE AND MAINTENANCE
GeneralServicing and maintenance of the fire pump must be carried out only by personnel who
have professional related knowledge and who is familiar with the fire pump andregulations regarding safety and accident prevention.
Before starting maintenance work
Stop the engine.
Disconnect the negative terminal of the battery first.
Place the pump on a level location.
Safety devices
CAUTION

In the case of disassembling the safety device or protective
device as a part of maintenance work, assemble the devices back
immediately to the original position after the maintenance, andcheck that the pump operates normally without problems.

Genuine parts
When replacing parts as part of servicing andmaintenance of the fire pump, use only Tohatsu genuine
parts.
If genuine Tohatsu parts and accessories are not used, it
may adversely affect the function and safety of the fire
pump.
Therefore, for safety reason, use only Tohatsu genuine
parts.
Tohatsu bears no responsibility for any personal injuries
or equipment damage that may result from the use ofparts or accessories obtained from outside sources.
Environmental protection measures
Dispose of oil, fuel, batteries, etc. according to relevant
environmental laws in the region.
Do not dump to nature or sewerage.
Waste
When discarding parts, go waste in accordance withenvironmental laws in the region procedure.

46

14. SERVICE AND MAINTENANCE
Spark plug
1. Remove the plug cap, and remove the spark plug.

Spark plug

Electrode

2. Use a wire brush or spark plug cleaner to clean theelectrode of the spark plug.
3. Check the spark plug for excessive carbon deposits,
electrode erosion and check the washer for damage.

Washer

4. Measure the spark plug gap. If the gap is out ofspecification, replace the spark plug with the specified
spark plug.
If necessary, adjust the gap to the specification.
Spark plug gap ⓐ : 0.6-0.7 mm (0.02~0.03 in)Spark plugⓐ

: NGK BR7HS

5. After assembling the spark plug, tighten it as far as ⓑ
by hand. And tighten it further using a plug wrench withthe specified torque.Ⓒ･ Tightening torque : 24.5~29.4 NmⓑⒸ

47

14. SERVICE AND MAINTENANCE
Battery
General safety information
Follow the safety instructions of the battery.
When charging a battery, highly explosive oxyhydrogen gas
mixture is produced.
Do not charge a battery in a poorly ventilated place.
Do not smoke near the battery.
DANGER

Danger of injury due
substances of battery

tocaustic

Always wear protective clothing.
Always wear protective gloves.
Always wear protective glasses.
Do not tip the battery, acid may comeout of the air vents.
Disposal
Dispose of disused battery should be done according tolocal laws or regulations.

After each operation of the battery, check the voltage.
Replace the battery if necessary.
Disconnect the negative terminal of the battery cable
first, and disconnect the positive terminal.

CAUTION

There is a risk of injury.
When handling the battery, be sure towear safety glasses and protective
gloves.

48

14. SERVICE AND MAINTENANCE
Electric equipment
Only expert electricians or trained staff members should
handle the electrical equipment.
Be sure to disconnect the battery cables before handlingelectrical equipment.
Disconnect the negative terminal first, and disconnect thepositive terminal next.
When connecting the battery cables, connect the positive
terminal first, connect the negative terminal next.

Fuse
Security fuse is installed in electrical circuit used for electrical equipment.
Before replacing the fuse, isolate the cause of the short circuit, and take theappropriate action.
After the appropriate action has been taken, replace the fuse with a new one.
Use the fuse with the same rated current (ampere) as the attached fuse. Using a higher
resistance fuse, there is a possibility that the electrical equipment will not prevent the
failure.
Prepare the spare fuse at all times in case of an emergency.

49

14. SERVICE AND MAINTENANCE
Suction performance check
CAUTION

Limit continuous operating time of the vacuum pump to 30
seconds or less. Operating the vacuum pump for more than 30
seconds continuously may cause the overheat damage to someparts.

1. Close the drain valves and the suction port (with a cap,etc.).
*Close the suction port not to leak air into the pump.

Example of using asuction port cap

Close
Drain valve
2. Turn the throttle dial to “START･SUCTION (S)”position.
Start the engine. Lift the priming lever to run thevacuum pump, and check that the pressure gauge forsuction indicates approximately -0.08 MPa (-0.8 bar,12 psi). Return the priming lever to the original position.

Lift

ReturnSTART
SUCTION

Priming
lever

Throttle
dial

Vacuum leak check
After completing the suction performance check, leave it for 30 seconds and confirm
that the pointer of the suction pressure gauge keeps the same pressure indication.
If the vacuum leak is found, isolate the cause by referring to “Chapter 15
TROUBLESHOOTING”. Then, take the appropriate action and check the vacuum leakagain.

50

14. SERVICE AND MAINTENANCE
Water leak check1. Connect one end of the suction hose to the pumpsuction port. Put the other end of the hose in water.
Close the discharge valve and all the drain valves.

Suction hose

Suction port
2. Start the engine, and lift the priming lever to run thevacuum pump.

Lift

ReturnSTART
SUCTION

Priming
lever
3. Operate the throttle dial to raise the pump pressure
almost to 1 MPa (10 bar, 145 psi), and then check forwater leaks from each part of the pump.

Throttle
dial
Throttle
dial

If the water leak is found, isolate the cause by referring to “Chapter 15
TROUBLESHOOTING”. Then, take the appropriate action and check the water leakagain.

51

15. TROUBLE SHOOTING
Typical causes of engine troubles are listed in the following tables.
Engine seizing

Engine overheat

Engine over-rev.

Poor acceleration

Idling rev. is too highRough idlingEngine stumble or stall

Engine start failure

Starter motor does not work

Battery charging failure

TroubleActionCause

Fuel and Lubrication

Fuel shortage● ●●Refuel.

Deterioration of fuel

● ● ●

●

Replace with new
fuel.

Fuel tank cap breather
hole clogging

● ● ●

●

Clean out clogging.

Fuel filter clogging

● ● ●

●

Clean out clogging.

Fuel pipe kink or snap

● ● ●

●

Fix routing of pipe.

Fuel pump failure

● ● ●

●

Replace.

Injector failure

● ● ●

●

Replace.

Throttle dial at otherthan “Start” position●

Oil filter clogging

Turn dial to “Start”
position.
●

52●

Replace oil filter.
(Do not fill it up with●the different brandof oil)15. TROUBLE SHOOTING

Caused by engine unit

Caused by playpipe

Caused by pump unit

Caused by suction hose

Floodlight, Gauge lamp, do not work

Insufficientwaterdischarge

Water suction failure

Air leaking

Vacuum pressure defective

TroubleActionCause
Fuel shortage●

Refuel.

Deterioration of fuel●Replace with new fuel.

Fuel tank cap breather
hole clogging

Clean out clogging.

Fuel and Lubrication

Fuel filter clogging●

Clean out clogging.

Fuel pipe kink or snap●

Fix routing of pipe.

Fuel pump failure●

Replace.

Injector failure●

Replace.

Throttle dial at otherthan “Start” position

Turn dial to “Start”
position.

Oil filter clogging

Replace oil filter.
(Do not fill it up with thedifferent brand of oil)53

15. TROUBLE SHOOTINGEngine seizing

Engine overheat

Engine over-rev.

Poor acceleration

Idling rev. is too highRough idlingEngine stumble or stall

Engine start failure

Starter motor does not work

Battery charging failure

TroubleActionCause
Spark plug cap comes
off

● ● ●

●

Use of unspecified
spark plug

● ● ●

●

Spark plug fouling (Nospark or weak spark)

● ● ●

●

Electrical

ECU and/or Sensor
failureBattery loose
connection,
disconnection ofcable or terminal
corrosion
Battery charger
defective

Plug in surely.
● ●● ● ● ● ● ● ●Replace withspecified spark plug.
Clean or replacewith specified spark
plug.
Check wire
connection, plug insurely.
Replace parts if
necessary.

● ●Clean terminal
and/or tighten
terminal screw.
Replace ifnecessary.

●

Check 5A fuse
and/or Battery
charger. Replace ifnecessary.

5415. TROUBLE SHOOTING

Caused by engine unit

Caused by playpipe

Caused by pump unit

Caused by suction hose

Floodlight, Gauge lamp, do not work

Insufficientwaterdischarge

Water suction failure

Air leaking

Vacuum pressure defective

TroubleAction

Cause

Electrical

Spark plug cap comes
off●

Plug in surely.

Use of unspecified
spark plug●

Replace with specified
spark plug.

Spark plug fouling (Nospark or weak spark)●

Clean or replace withspecified spark plug.

ECU and/or Sensor
failure●Check wire connection,plug in surely.
Replace parts if necessary.

Battery loose
connection,
disconnection ofcable or terminal
corrosion●

Clean terminal and/or
tighten terminal screw.
Replace if necessary.
Check 5A fuse and/orBattery charger. Replace ifnecessary.

Battery charger
defective55

15. TROUBLE SHOOTINGEngine seizing

Engine overheat

Engine over-rev.

Poor acceleration

Idling rev. is too highRough idlingEngine stumble or stall

Engine start failure

Starter motor does not work

Battery charging failure

TroubleActionCause

15A fuse blown

5A fuse blown
Electrical

Starter motor
defective

Operation panel
defective

Replace with spare
fuse.
When the blowoutof the fuse happens
repeatedly, find out
the cause.
15A: Battery cablereverse connection,
operation panel
components,
sensor, ECU
5A: Charging
connector.
Floodlight.

●

●

●

Check terminals,
cords and screws.
Replace parts if
necessary.

● ●Check input ofstarter solenoid.
(Equal to operation
panel output.)
Replace parts if
necessary.
Replace parts.

Blown light (bulb)

5615. TROUBLE SHOOTING

Caused by engine unit

Caused by playpipe

Caused by pump unit

Caused by suction hose

Floodlight, Gauge lamp, do not work

Insufficientwaterdischarge

Water suction failure

Air leaking

Vacuum pressure defective

TroubleActionCause

Replace with spare fuse.
When the blowout of thefuse happens repeatedly,
find out the cause.
15A: Battery cable reverse
connection, operation
panel components, sensor,
ECU● 5A: Charging connector.
Floodlight.

15A fuse blown

5A fuse blown
Electrical

Check terminals, cords andscrews.
Replace parts if necessary.

Starter motor
defective

Operation panel
defective

Check input of startersolenoid.
● (Equal to operation panel
output.)Replace parts if necessary.

Blown light (bulb)●

57

Replace parts.

15. TROUBLE SHOOTINGEngine seizing

Engine overheat

Engine over-rev.

Poor acceleration

Idling rev. is too highRough idlingEngine stumble or stall

Engine start failure

Starter motor does not work

Battery charging failure

TroubleActionCause
Compression

Piston, piston ring or
cylinder excessively
worn.

● ● ●

Carbon deposition in
the combustion
chamber

●

●

●

● ●

Correct or replace.
Clean out.

SuctionSuction height toohigh or length too long

Place pump nearwater source andlower position.

Suction hose end is
not in water.

Put the tip of hose
into water morethan 30cm deep
from surface ofwater.

Suction hose couplingloose or gasket
defective

Clean out the gasket
and tighten securely.
Replace the gasket if
necessary.

Suction hose strainer
clogged with deadleaves or waste etc.

Clean out.

Suction hose cracking
or lining peeling off.

Repair or replace.

5815. TROUBLE SHOOTING

Caused by engine unit

Caused by playpipe

Caused by pump unit

Caused by suction hose

Floodlight, Gauge lamp, do not work

Insufficientwaterdischarge

Water suction failure

Air leaking

Vacuum pressure defective

TroubleActionCause
Compression

Piston, piston ring or
cylinder excessively
worn.

●

Correct or replace.

Carbon deposition in
the combustion
chamber●

Clean out.

Suction height toohigh or length too long

Place pump near water
source and lower position.

●● ● ● ●

Put the tip of hose into
water more than 30cm
deep from surface of water.

Suction hose couplingloose or gasket
defective● ● ● ●

Clean out the gasket andtighten securely.
Replace the gasket if
necessary.

Suction hose strainer
clogged with deadleaves or waste etc.

● ●Suction hose cracking
or lining peeling off.

● ● ● ●

Suction hose end is
not in water.
SuctionClean out.
Repair or replace.

5915. TROUBLE SHOOTINGEngine seizing

Engine overheat

Engine over-rev.

Poor acceleration

Idling rev. is too highRough idlingEngine stumble or stall

Engine start failure

Starter motor does not work

Battery charging failure

TroubleActionCause

Primer
Water stop valve

Vacuum pipe loose or
cracking

Tighten securely aclump of vacuum
pipe or replace.

Strainer cap loose or
O-ring failure

Tighten securely or
replace.

V-belt damaged or
worn

Replace.

Vacuum pump rotor
shaft seizing

Repair or replace.

Vane, Side plate
worn or damaged

Replace.

Water stop valve
contamination

Clean out.

Water stop valve
diaphragm failure

Replace.

60

15. TROUBLE SHOOTING

Caused by engine unit

Caused by playpipe

Caused by pump unit

Caused by suction hose

Floodlight, Gauge lamp, do not work

Insufficientwaterdischarge

Water suction failure

Air leaking

Vacuum pressure defective

TroubleActionCause

Primer
Water stop valve

Vacuum pipe loose or
cracking●●

Tighten securely clump of
vacuum pipe or replace.

Strainer cap loose or
O-ring failure●●

Tighten securely or replace.

V-belt damaged or
worn

●

●

Replace.

Vacuum pump rotor
shaft seizing●●

Repair or replace.

Vane, side plate
worn or damaged●●

Replace.

Water stop valve
contamination● ● ●Clean out.

Water stop valve
diaphragm failure● ● ●Replace.

6115. TROUBLE SHOOTINGEngine seizing

Engine overheat

Engine over-rev.

Poor acceleration

Idling rev. is too highRough idlingEngine stumble or stall

Engine start failure

Starter motor does not work

Battery charging failure

TroubleActionCause
Drain valve(s) is not
closedClose securely.

Suction port strainer
clogged with deadleaves or waste etc.

Clean out.

Discharge valve
imperfect open

● ●Open securely.

Pump

Gauge pipe connectorloose or gasket
defective

Tighten securely.
Replace gasket if
necessary.

Pump cover bolts
loose

Tighten securely.

Pump cover O-ringdegradation

Clean out or
replace.

Impeller or guide vanecaught a stone ordamaged

Clean out or
replace.

Mechanical seal
damagedReplace.

6215. TROUBLE SHOOTING

Caused by engine unit

Caused by playpipe

Caused by pump unit

Caused by suction hose

Floodlight, Gauge lamp, do not work

Insufficientwaterdischarge

Water suction failure

Air leaking

Vacuum pressure defective

TroubleActionCause
Drain valve(s) is not
closedSuction port strainer
clogged with deadleaves or waste etc.

Clean out.

● ●Discharge valve
insufficiently open

●

Pump

Gauge pipe connectorloose or gasket
defective● ● ● ●

Pump cover bolts
loose

● ● ●

Pump cover O-ringdegradation● ●Impeller or guide vanecaught a stone ordamagedMechanical seal
damagedClose securely.

● ● ●Open sufficiently.
Tighten securely.
Replace gasket if necessary.

●

Tighten securely.
Clean out or replace.

●

Clean out or replace.
Replace.

● ●63

15. TROUBLE SHOOTINGEngine seizing

Engine overheat

Engine over-rev.

Poor acceleration

Idling rev. is too highRough idlingEngine stumble or stall

Engine start failure

Starter motor does not work

Battery charging failure

TroubleActionCause

NozzleToo large discharge
nozzle diameter● ●Spray nozzle clogged

Clean out.

Governor

Governor adjustment
out of specified range
Governor link
disconnected

Change nozzle forsuitable size or
incorporate safety
nozzle.

●Adjust it securely.

● ● ● ●

Attach it securely.

●
●

64

15. TROUBLE SHOOTING

Caused by engine unit

Caused by playpipe

Caused by pump unit

Caused by suction hose

Floodlight, Gauge lamp, do not work

Insufficientwaterdischarge

Water suction failure

Air leaking

Vacuum pressure defective

TroubleActionCause

NozzleToo large discharge
nozzle diameter●

Change nozzle for suitablesize or incorporate safety
nozzle.

Spray nozzle clogged●

Clean out.

Governor

Governor adjustment
out of specified range
Governor link
disconnected

●

●

65

●

Adjust it securely.

●

Attach it securely.

16. APPENDIX

Tightening torque specifications

M3

M4

M5

M6

M8

M10

N･m

0.6~
0.8

1.3~
1.8

2.7~
3.5

4.6~
6.3

11.2~
15.1

22.5~
30.6

kgf･m

0.06~
0.08

0.13~
0.18

0.27~
0.36

0.47~
0.64

1.14~
1.54

2.30~
3.12

8.2~
10.8

20.0~
26.5

40.2~
53.9

0.84~
1.10

2.04~
2.70

4.10~
5.50

Standard Bolt

N･mHeat Treated Bolt

-

-

kgf･m

66

-

17. TOOL AND STANDARD ACCESSORY
Description

Remarks

QuantityTool kit

1・ Tool kit bag
・ Plug wrench
・ Handle of plug wrench

1

Spark plug

1
1
NGK BR7HS

Pumping plate
Fuse *1

1
1

5A

1

15A

1

Pipe assy

1

Search light (Floodlight)

1

Auto battery charger

1

Coupling *2

1*1 Spare fuses are in the fuse box attached to the pump.

*2 Whether or not it is included as an accessory depends on the specifications of thepump.

67