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

APPLICATIONS OF THIS FIRE PUMPUSAGE
TOHATSU fire pump “VE1500W” is manufactured for use in firefighting operations.
This 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 these fire pumps 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 pump for applications other than those stated above can result inpersonal 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 this fire pump must read and understandthe following items:

・ Owner’s manual
・ Safety-related instructions on the pump and the other parts such as the battery.
・ The other owner’s manuals, such as battery charger.
The portable 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 theuser.
If a person does not have adequate professional knowledge 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 this 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 this manual in a safe place for future reference.
・ Operators of this fire pump must always refer to all the relevant
manuals in order to avoid errors, personal injuries, andequipment damage when operating the portable fire pump, andto maintain faultless operation.

・ Arrange owner’s manual so that operators can refer to themwhere 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 this fire
pump, be sure to read and understand this 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 firepump.

・ This manual should accompany this fire pump if sold to anotherperson.

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 identification number ismarked on the pump casing.

GENERAL SAFETY INFORMATION
Overview
Before operating the TOHATSU fire pump thoroughly
read this manual. Understanding proper operatingprocedures 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 inthis manual.
Be sure to follow all safety-related instructions,otherwise, personal injury may occur.

Signal words

DANGER ･ Failure to observe will result in severe personal injury or
death.

･ Failure to observe could result in severe personal injury or
death.

CAUTION･ Failure to observe could result in personal injury or property
damage.

・ This instruction provides special information to facilitate the use or maintenanceof the pump or to clarify important points.

・ For attaching position of the warning label, refer to the “CONTENT 3. LABELS”.
・ Warning labels should be read clearly at any time.
If the display of the warning label becomes difficult to b e 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 this 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
illegible or detached, replace it immediately.

Transporting the portable fire pump
CAUTION・ Retractable handle is folding type.
・ Do not put hand or finger between
top of retractablebracket.

handleand・ When transporting the portable fire
pump, assign one person per handle.

・ Also, when you transport the portablefire pump, it should be transported
holding the handle firmly.

・ There is a risk of injury to the leg by fall.
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 plane.
Disposal of packing box
Dispose the packing box by following the environmental laws.
Emissions
Noise emission values
For noise emission values, refer to “CONTENT 17.7
APPENDIX”.
CAUTION・ar proper hearing protection
during operation.

We

Exhaust gas
Exhaust gas emitted from the engine contains carbon monoxide (CO)etc. that may seriously affect human health.
Do not operate the engine in a room, car, warehouse, tunnel, orother closed locations that have poor ventilation.
Mortal danger due to carbon monoxide (CO) poisoning causes.

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

After protective devices have been disassembled aspart of servicing and maintenance work, immediately
install them back to their original locations, making surethat they are in safe and secure condition.

Check the portable fire pump visually and functionallyon a regular basis.
If a failed device or equipment is found, remove it
immediately, and repair or replace it, if necessary. Failure
to do so may cause an accident.
After it has been repaired or replaced, make sure that
it functions correctly.

Protective clothing Protective equipment
During fire extinguishing training or regular firefighting
services, wear normal protective clothing andequipment to protect your body.

・ Fireproof protective clothing・ Fireproof helmet
・ Fireproof protective gloves
・ Fireproof protective boots

Service Maintenance
Servicing and maintenance of this fire pump must be carried out by
o n l y t h e persons who have professional knowledge, who are familiar
with the 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 negative terminal of the battery.
Before starting maintenance work, securely place the portable firepump on the ground.
In the case of just after stopping the engine, do not touch the exhaustpipe, the muffler and the other engine parts until these parts will be coldenough. 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 disconnecting the cable from the battery,disconnect the negative (-) cable first.
When connecting the cable to the battery, be sure toconnect the positive (+) cable first. After that,connect the negative (-) cable.
Do not place any metal on the top of or around thebattery. Doing so may cause 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.
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 location.
Do not smoke around 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.

Disposal
Dispose of disused batteries according to relevant laws
and regulations.

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. Do not smoke while refueling fuel.
Do not refill fuel in an enclosed room. Doing so may cause
an explosion caused by fuel fumes.
If fuel spills, wipe it with a cloth or other material, anddispose of it according to relevant laws andregulations.

Genuine parts
When replacing parts for servicing and maintenance ofthe portable fire pump, use only Tohatsu genuine parts.
If genuine Tohatsu parts and accessories are notused, it may adversely affect the functioning andsafety of the fire pump. Use genuine Tohatsu parts only.
Tohatsu bears no responsibility for any personal
injuries or equipment damage that may result from useof parts or accessories obtained from outside sources.
Environmental protection measures
Dispose of oil, fuel, batteries, etc. 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.

SPECIFICATIONS………………………………..………………………..……………1

2. OPERATION DEVICE.….……….……….….………….….…..….….…..…..…4
3. LABELS…..….……………………….…………..………..............……………….……8
4. OPERATING PRECAUTIONS.….…….………..…....………….….…....….…95. DESCRIPTION OF DEVICES…..……….…………..…...…….…………...…..11
6. PREPARATION FOR OPERATION……..……….…….….…………………18
7. USE OF OPERATION PANEL…..….………….….…...…….…..………..….22
8. STARTING THE ENGINE…..…….…………….……….….……..…….......…25
9. PRIME AND DISCHARGE…….……..…………….……..….….…..………..29
10. STOPPING THE ENGINE...….…..……….….….………...…………………...35
11. MAINTENANCE AFTER OPERATION…..…..…..…….….……...….…..36
12. MAINTENANCE IN COLD CONDITION...……...….……....…....…..…41
13. USE OF ACCESSORY………….……………..…...……….….………….….…..44
14. PERIODICAL INSPECTION……………….……..…..…..….....….….……...46
15. SERVICE AND MAINTENANCE……............................…......…..…….48
16. TROUBLESHOOTING….…………...……………..….………….…..…....….56
17. APPENDIX….………………………….…..………..…...….…………….……....….63
18. TOOL AND STANDARD ACCESSORY……..……..….…….…..………..64

1. SPECIFICATIONS
Model

VE1500W

Description

Portable pump

Max. permissible inclination
angle

During transport : 35° at all sides
In operation : 15° at all sides

Max. operating pressure
P alim

17 barMax. water temperature+60 °C

Temperature range-15 °C to +40 °C ambient temperature

EngineManufacturer

TOHATSU CORPORATION

Model

2WT81AType

2-stroke, water cooled, spark ignition engine

Bore × Stroke

81 mm × 78 mm

Number of Cylinder

2

Piston displacement

804 cm3

Rated power

60 PS (44 kW)

Fuel type

Unleaded petrol RON91

Fuel tank capacity

24 L

Fuel consumption *22 L/hEngine oil tank capacity

1.6 L

Ignition

C.D.I.

Spark plug

NGK BPR7HS-10

Starting system

Electric starter and Manual starter

Lubrication

Auto mixing

Fuel system

Electronic fuel injection

Battery

12 V-16 Ah/5HR , 12 V-18 Ah/10HR

Floodlight bulb

12 V-35 W

Remark: *It is fuel consumption at the time of the standard discharge.

1

1. SPECIFICATIONS
Model

VE1500W

PrimerType

Rotary-vane vacuum pump (Oil less type)Max. suction height

Approx. 9m

Pump
Type

Single suction, single stage, centrifugal pump

Number of delivery outlet

2

Discharge port coupling

NST thread NH 2-1/2"
JIS fire thread (B-9912) 2-1/2” (65mm)(male)(male)

Suction port coupling

NST thread NH 4”
JIS fire thread (B-9912) 3-1/2” (90mm)(male)(male)

Pump performance(Suction height: 3 m)

2,050 L/min at 6 bar
1,800 L/min at 8 bar
1,500 L/min at 10 bar

Dimensions and weight
Length x Width x Height

748 mm x 732 mm x 827 mm

Mass

104kg (dry)

124kg (ready for operation)

Materials
EngineCrankcase, Cylinder,
Cylinder head

Aluminum alloy

Crankshaft

Chromium-molybdenum steel

Connecting rod

Chromium-molybdenum steel

PistonAluminum alloy

Pump shaft

Chromium-molybdenum steel with metal plating

MufflerSteel and Stainless

Pump
Pump case, Pump cover

Aluminum alloy

Impeller

Aluminum alloy

Shaft sealType

Mechanical seal2

Total delivery pressure P (bar)3

Delivery flow Q (L/min)

6m
geodetic
Suctionheight4.5m
geodetic
Suctionheight3m
geodetic
Suctionheight1m
geodetic
SuctionheightPerformance Curve

7.5m
geodetic
Suctionheight: Guarantee point for PFPN 10 1500(3m geod. Suction height)

1. SPECIFICATIONS(VE1500W)

2. OPERATION DEVICE
⑦

⑦

8

⑧

⑥

⑨
⑥

⑩

⑤
⑤
④

①
②

③

① Suction port
② Inducer③ Impeller④ Starter motor⑤ Crankshaft⑥ Piston⑦ Spark plug
⑧ Cylinder drain valve⑨ Pump drain valve⑩ Muffler drain valve42. OPERATION DEVICE
2
⑥
⑥

⑥
⑤

⑦
④

⑧
①

②

③
③
③
① Air silencer② Fuel tank
③ Muffler④ ECU⑤ Oil tank
⑥ Discharge valve⑦ Fuel feed pump
⑧ Injector52. OPERATION DEVICE
Discharge valve handle(Ball valve type)

Discharge valve handle(Screw down type)

Cowl
Discharge port

Suction port

Fuel tank cap
Fuel level gauge①②③① Cylinder drain valve② Pump drain valve③ Muffler drain valve62. OPERATION DEVICE
Oil tank cap

Priming strainer

Priming lever

Floodlight connector
Fuse

Manual starter handle

Battery charger
socketExhaust pipe

Muffler
Carrying handle (4)Priming outlet④① Hour meter② Battery voltage low warning lamp
③ Overheat warning lamp
④ Engine oil level warning lamp

①

③

②

Main switch
Throttle dial

Pressure gauge for suction

Pressure gauge for discharge

73. LABELS
Instruction

Warning Caution

Warning

Warning8

4. OPERATING PRECAUTIONS
Installing pump
CAUTION

The fire pump must be installed on level ground. Otherwise, anaccident may occur. If the fire pump should be installed on
uneven ground, it must be secured.
When installing the portable pump in a vehicle, place the vehicle
on a level place, and install the pump.
When installing the portable pump in the vehicle, make sure to
apply the brakes of the vehicle in order to stop the wheels.
A serious accident may occur if the vehicle moves.
Do not put your hands or fingers into theretractable part when operating thecarrying handle.
When transporting the portable fire pump,assign one person per handle. Also, when
you transport the portable fire pump, it
should be transported holding the handle
firmly. There is a risk of injury to the leg byfall.
Do not touch the exhaust pipe and the
muffler while the engine is running, or for
more than 10 minutes after the engine has
been stopped.
Confirm the engine temperature is cooled
down enough. These parts are very hot andwill cause severe burns.

9

Carrying handle

4. OPERATING PRECAUTIONSNOTEPlace the pump as near as possible to water source, and watersuction height as low as possible.
When lowering the portable fire pump to the ground, lower it gently
and horizontally.
Max. permissible inclination angle: 15°
In case of the inclined or uneven location, make sure that watersuction hose is lower than suction port of the pump.
In case of the suction hose is put undulated, air can be left easily inthe hose, and possibly causes suction inability when the water
discharge valve is opened. In this case, set the water discharge valve
half-opened, and operate vacuum pump until water is discharged
continuously (for 3 to 5 seconds from beginning of water discharge).
Be sure to install strainer and basket on the end of suction hose. If
the pump may suck sand or mud on the bottom of water source,
place sheet below the basket.
Put the strainer and basket of suction hose into the water more than
30 cm from the surface to prevent suck of air.
Discharge hose should be arranged not to be bent.
When lowering the portable fire pump to the ground, lower it gently
and horizontally.

10

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

Suction port

NST thread NH4”
JIS thread 3-1/2” (90mm)

Putting a finger or a hand into the suction port
while the pump is running without installing thestrainer, it may be seriously damaged by therotating inducer.
CAUTIONInstall the standard strainer to the suction port.
Do not run the pump if the strainer is not installed.
If the pump is operated without the strainer
installed, gravel can enter the pump and thedrainage capacity may be decreased considerably.

Carrying handle
This fire pump is equipped with four carrying handles.
The handles can be manually folded, and opened byrotating them by 90 degrees.

CAUTION

Personal injuries
when opening or
handle.

may occur
closing the

Do not put your hands or fingers intotheretractable
part
when
operating the handle.

11

Carrying handle

5. DESCRIPTION OF DEVICES
Priming lever
Used for suctioning water.
After starting the engine, pull the priming lever tosuction water. After priming has been completed, return
the priming lever to its original position.
Priming lever

Removing cowl
Cowl can be removed by releasing the 4 hooks up.
NOTE

When removing the cowl, do not use
excessive force, because the hook may
be damaged.

Hook

Discharge port
The diameter of the thread for fire pump
NST thread NH2-1/2”

HandleJIS fire thread 2-1/2” (65mm)

Discharge valve
Use discharge valve handle for opening and closing thedischarge valves.

12

Thread5. DESCRIPTION OF DEVICES
Drain valve
Use the drain valves to drain water
NOTE

Close all the valves when operating thisfire pump.
If a valve is opened, water cannot be
suctioned.
ⓐ Cylinder drain valveⓐⓑⓒⓑ Pump drain valveⓒ Muffler drain valve
Battery charger connector
Connect the battery charger plug to the connector.

Battery charger
connector<Specifications of accessory socket>

・ Inner diameter (ID): φ21mm
・ Voltage: DC12V
・ Max. allowable current: 5A
CAUTION

Before charging the battery, turn the main switch OFF.
When starting operation, be sure to remove the battery
charger before turning the main switch ON.
The connector is only for the battery. Do not use the connector
for any other purpose.
Do not connect a cigarette lighter to the connector,
because it is not a heat-resistant object.

Fuel tank

Air vent must be closed any time.
CAUTION

Do not tilt the pump with the air ventopen. Otherwise, the fuel may leak.
If the fuel leaks, wipe it off using acloth or other materials.

NOTE

There is another air vent installed on
the fuel tank.

13

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

Throttle dial

Throttle dial
Use the throttle dial to control discharge pressure.
“ ” indicates the throttle position of engine start andpriming.
Pressure gauge for suction
The pressure gauge for suction indicates suction waterpressure (negative pressure) and the input pressure
supplied from an external water source.

Suction side

Discharge side

Pressure gauge for discharge
The pressure gauge for discharge indicates the actual
operating discharge pressure.
Operation panel
The operation panel is equipped with main switch, allwarning lamps and an hour meter.

Operation panel

Warning lamp and buzzer
Turning the main switch to “ I ” position, the check mode
starts. The warning lamps light up and the buzzer sounds
for a moment to enable to check those functions.
If the lamp and buzzer check mode shows failure, fix thecause referring to the troubleshooting section.
CAUTION

If they do not, remove the cause byfollowing“CHAPTER
16
TROUBLESHOOTING”.

14

Main switch

Lamp

5. DESCRIPTION OF DEVICES
The monitor indicates the following information:

・ Hour meter
・ Low engine oil level warning
・ Overheat warning
・ Low charged battery warning
Hour meter

Hour meter

Hour meter indicates the accumulated operation time of
the fire pump.
NOTE

Use it to check the running time andmaintenance timing.
Warning lamp (Oil level)

Low engine oil level warning
If the engine oil level decreases below approximately 1/3(0.5 L) of the full oil tank, warning lamp lights up and thewarning buzzer sounds.
CAUTION

The engine does not stop even if the low engine oil level warning
lamp lights up. This is to give priority to the continuation of firefighting over protection of the engine. The engine remains
operational for more than 30 minutes even after the warning lamp
lights up. However, if the engine is operated for longer than this, it
may stuck. Refill the oil immediately.

Overheat warning
If overheat is detected, overheat lamp lights up, thewarning buzzer sounds and the engine stops automatically.
NOTE

The engine stops automatically when theoverheat is detected.

CAUTION

The engine may be damaged.

Warning lamp (Overheat)

Do not restart the engine soon after it has stopped running.

15

5. DESCRIPTION OF DEVICES
Low battery charging warning
Battery voltage low warning lamp lights up when thebattery voltage decreases below the limit.
Leaving the battery as it is, the battery will deteriorate, so
please charge the battery as soon as possible.
NOTE

The battery charge warning buzzer
does not sound.

Warning lamp (Battery)

Main switch
Main switch has three different functions.
SymbolMain switch

Function
The switch is turned OFF.
The switch is turned ON.
The starter motor starts. When you release
the switch, it returns to the “” position.
Oil tank cap

Engine oil tankEngine oil tank cap is located as shown in the picture.

Governor case
The governor oil level can be checked with the dipstick.
Use the engine oil recommended by the engine
manufacturer.
CAUTIONBe sure to stop the engine before
checking the oil level. If you pull thedipstick when the engine is running,
the oil may blow out.

16

Dipstick

Governor oil filler port

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

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

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 feelingharder resistance.

Manual (recoil) starter

Mechanical governor
A built-in mechanical governor controls the throttle valve so that the maximum engine
speed does not exceed 6000 r/min.

Electric Safety Governor (ESG)
Designed as a system to assist the mechanical governor, the electric governor controls
the engine speed by cutting off ignition so that the engine speed does not exceed 6100
r/min.

Battery save control
If the engine is not started within 30 minutes of power ON, the power is automaticallyturned OFF.

Anti-After Burn Control
This substantially reduces the “phenomenon that causes combustion inside the muffler(after burn)” by cutting the fuel injection in advance to purge the residual unburned gas
in the engine when the engine is stopped.

17

6. PREPARATION FOR OPERATION
Initial charge of battery
The battery can be used immediately after filling cells with electrolyte.
If the battery is maintenance free of electrode (Sealed type battery), do not open thebattery after filling it with electrolyte. Refer to the INSTRUCTIONS of the battery.
Fuel
Fill fuel until the maximum level of the gauge indicator (inRed).

・ Fuel tank capacity: 24L
Fuel

DANGER

Vaporized fuel may cause ignition or an explosion.
Do not bring any flames near fuel.
Stop the engine before refilling fuel. Do not spill
fuel.

CAUTION

Do not breathe in petrol vapor!
Petrol fumes are very toxic.
After stopping the engine, do not touch it while itis 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 fill fuelto the tank.
Properly clean up all fuel spills (checking for
gasoline vapor) before starting engine. If petrol or
fuel spills, wipe it off using a cloth or othermaterials, and dispose of them according to therelevant laws and regulations.

18

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 that contains more than 10% ethanol or more than
5% methanol.
Damages resulting from the use of fuel that contain alcohol are notcovered under the limited warranty.
Air vent is installed on the fuel filler cap. Close the cap
tightly after refilling.
Check that the air vent of the cap is closed.
CAUTION

Do not tilt the pump with the air ventopen. Otherwise, the fuel may leak.
If the fuel leaks, wipe it off using acloth or other materials.

NOTE

The air vent is installed on the fuel tank, always close the air vent of
the cap.

Engine oil
Refill the 2-stroke engine oil to the oil tank.
CAUTION

Air vent

If different grades of engine oil are
mixed, the oil may gel, which may
result in oil filters becoming clogged.
Be sure to use the same grade ofengine oil.

2-stroke engine oil
We recommend that usi n g engine oil of ISO-L-EGB grade or higher.
Engine oil tank capacity: 1.6L

19

6. PREPARATION FOR OPERATIONOil level sensor
The lamp on the operation panel will light when the level of engine oil tank has
decreased approximate to 1/3 (0.5 L) of the tank. And also the warning buzzer will sound.
Add 2-stroke engine oil.
Governor oil
Before using fire pump, check governor oil level with theoil dipstick. To check oil level, remove the dipstick andcheck the oil level. The oil level should be between upperand lower limit line on the dipstick. Add 2-stroke engine oil
through the governor oil filler port if the oil level is lower
than the lower limit line.

Dipstick

Governor oil filler port
Drain valves
Make sure all drain valves are closed.

Close

Open

Discharge valves
Make sure the discharge valves are closed.

Close

Overheat protection sensor
This device shuts down the engine automatically when the engine has excessively
overheated caused by lack of cooling water.

20

6. PREPARATION FOR OPERATION
Overheat warning lamp
If the temperature of the engine rises approximately 90ºC or more, the engine will stop automatically to prevent
overheating.

Warning lamp (Overheat)

Main switch

Warning lamp and sensor
When you turn the main switch to the “ ” position,
warning lamps light up for a moment to enable lamps to bechecked, and the buzzer sounds.

Lamp
CAUTION

After the engine has stopped due to overheating, if you restart
the engine immediately, engine may be burnt. Before restarting
the engine, eliminate the cause.
(Refer to “Chapter 16 TROUBLESHOOTING”).
Also check that the warning lamps are all turned off.

Closed Circulating Water Cooling System
In this system, cooling water is taken from the suction water and pressurized by thepump, and returned to the water intake of the pump after cooling the engine andmuffler.

21

7. USE OF OPERATION PANEL
Alert action check (Lamp check)
When the warning lamps are off, there is no trouble on each function. When thewarning lamps are on or blinking, the pump does not work properly.
When the power is turned ON, the warning lamp and buzzer will be
activated for approximately one second, and the alert action check is
automatically performed. After that, the installed computer starts
monitoring.

NOTE

Set the main switch to the ” “ position, and make sure the warning
lamps light up and the warning buzzer sounds.
Warning system
Warning indicatorOilwarninglamp

Overheatwarning
lamp

Alert check

One
time
flash

Battery
chargewarninglamp

One timeflash

One time
flash

Oil level

ON

WarningbuzzerEngineoperation

One time
alert
ONWarningOverheatON

Prior
warning
overheatON

Battery
voltage

ON

ON

Engine overspeed
MAT or MAP
Alert (*1)
TPS or WTS
Alert (*1)

High
speed
ESG

ON
Flashing
Flashing

Stop

Description of
faults or notice

Normal system testwhen main switch
ON. (*2)
Oil level is below
approx. 1/3
Engine has stopped
due to insufficientcooling water, etc.
Warning of engine
stoppage due toinsufficient coolant,
etc. is sent inadvance.
Battery voltage islowEngine speed
exceeds maximumallowable RPM(*3)
MAT or MAP failure
or open circuit
TPS or WTS failure
or open circuit

Remedy

Alert

A
B
C
D
E
F
F

*1. Manifold Air Temperature sensor (MAT), Manifold Absolute Pressure sensor (MAP),
Throttle Position Sensor (TPS), and Water Temperature Sensor (WTS)*2. Turning the main switch to the “Operation” position*3. Engine speed is controlled to 6000 r/min

22

7. USE OF OPERATION PANEL
Enginestatus
80°C

Running

RestartLight & Buzzer
ON

90°C

EngineSTOP

70°C

Light & Buzzer
OFF

Over
120°C

EngineSTOPEngine can start at less than 120°C andkeep running for 30 seconds.

Overheating

Engine cannot start

Remedy
A: Refill the engine oil.
B: Remove the cause of insufficient cooling water and restart the engine.
C: Remove the cause of insufficient cooling water.
D: Charge the battery.
E: Set the throttle dial to the “ ” mark position.
F: Stop the engine and contact our customer service.
NOTE

System does not detect such overheat as caused by shortage ofengine oil.
Even if the engine oil warning buzzer sounds, the engine will not stop.
The system is designed to make lifesaving the first priority.
Hour meter

Engine oil

Overheat

Battery

23

Main switch

7. USE OF OPERATION PANEL
Hour Meter
DANGER

Before removing the electrical equipment, turnthe main switch off and remove the battery.
When removing the battery cable from thebattery terminal, always disconnect the negative(-) cable first.
When connecting battery cables, connect thepositive (+) lead first.
If the negative (-) lead is connected first,
hydrogen gas generated by the battery may cause
an explosion.
Do not place any metal on the top or around thebattery. Doing so may cause a short circuit.

1. The hour meter starts counting when main switch is set to the “ ” position, even if
the engine has not been started.
2. The hour meter only works during the main switch is on the “ ” position.
3. There is no reset capability.
4. As this fire pump has “Battery save control”, the hour meter keeps counting for
approximately 30 minutes.
5. When the engine stops due to overheating or other reasons, the hour metercounts if the main switch is set to the “ ” position.
Engine oil

Hour meter

Overheat

Battery

24

Main switch

8. STARTING THE ENGINE
Pump Installation
Since the temperature around the engine
becomes high because of the muffler and exhaustgas, install the pump on level ground at least
three meters away from inflammable materials
including dead leaves and wood.
Exhaust gas, which contains carbon monoxide, is adeadly poisonous gas with no color and no smell.
Do not operate engine in a closed space or an
insufficient ventilation place such as indoor, in thevehicle, warehouse, tunnel, well, in the hold of aship.
Do not start engine with discharge valve opened.
Do not pump and discharge liquids other thanwater (e.g. flammable liquids or chemicals).
This pump is only designed to pump up water.
Do not discharge water to water-prohibiting
substance.
Do not run the pump without suction port strainer.
If you insert your hand into the suction port, you may beseriously injured by the rotating inducer.
CAUTION

Do not run the pump without suction port strainer.
If gravel enters the pump, then the pump could be damaged andthe performance would be significantly reduced.

1. Set the pump near water source on flat area.
2. Connect suction hose and delivery hose to the pump securely. Put end of suction
hose in water source. The suction hose must have a strainer, and also must have abasket at the tip.
3. When water is discharged through branch pipe and nozzle, following diameter ofnozzles is recommended.
Largest Nozzle Dia. (mm) *Twin outlet discharging
Single outlet discharging
25
36
Remark: * The largest nozzle dia. at 3 m of suction head.

25

8. STARTING THE ENGINE
Remove air from the fuel line
Before initially fueling this portable pump or restarting
the engine after the engine stopped due to lack of gas,
bleed air from the fuel line.

Main switch

1. Turn the main switch from the “ ” position to the “ ”
position and wait approximately 15 seconds
NOTE

During this period, the electric fuel pump works andremove air from the fuel line.

2. Repeat this operation 2 ~ 3 times, and then start the engine.
CAUTION

Wear proper hearing protection during operation.

While engine is running, never touch the highvoltage ignition wire attached to spark plug. The
wire carries very high voltage which will cause
injury and bodily harm.

Do not operate the pump on dry grass. The
exhaust system will be very hot and could cause
the dry grass burnt and fire. Clear the area ifnecessary.

26

8. STARTING THE ENGINE
Starting engine
1. Check that the air vent of the fuel tank is closed.
Air vent
2. Turn the throttle dial at “ ” mark position.
Throttle dial
3. Turn the main switch to “ ” position.
Release the main switch immediately after the engine
starts.

NOTE

Main switch

When the starter motor is operated for a long time continuously, thepower of the battery will be exhausted. The maximum time forstarting motor operation is 3 seconds at one time. If the engine does
not start up, wait for 5 seconds before operating the starter motor
again.
Do not operate the starter motor after engine started.
If the starter motor does not work, check that the battery terminals
are tightly connected and the battery is fully charged.

Starting engine using a manual starter
If electric starter does not work, use a manual starter as shown in the
picture.
1. Turn the main switch to “ ” position.
2. Turn the throttle dial to “
position.

” mark

3. Engage the manual starter ratchet bypulling the starter rope slowly. And
then pull the starter handle quickly
with great force from the position inwhich feeling harder resistance.

27

8. STARTING THE ENGINE
Dry operation
This portable pump has outsource cooling system, limit the duration of dry operation
so that it is within the following time periods.
Performing dry operation longer than the specified time period may cause damage tothe engine or pump.
In the case of Idling: Within 2 minutes
In the case of running with throttle dial at “ ” mark position: Within 30 seconds
Closed discharge valves operation after priming water
When the pump is operated with the discharge valve closed, the cooling watertemperature becomes high.
CAUTION

Discharge water promptly. If the water discharge valve is kept
closed, the water temperature inside the engine rises and theengine may overheat.

28

9. PRIME AND DISCHARGE
While the engine is running with the cowl removed,
do not touch the rotating parts of the pulley or belt.
This may cause personal injuries.

NOTE

If, when operating the vacuum pump for 30 seconds, thepump does not suck up water, or if the pump cannot
keep the water in it during the water discharge
operation, check the following:
Is the tip of the suction hose completely below the water surface?
Is air sucked through the joint of the suction hose?
Is the suction hose damaged?
Does the vacuum performance of the priming pump reduced
significantly?
Does the pump case leaking vacuum?
Does a vacuum leak occur when the pump is connected with thesuction hose of which the opening is capped?
Refer to “Chapter 16 TROUBLESHOOTING”.

1. After starting the engine, pull down the priming lever.
2. Check that the pumped water is discharged from thepriming outlet of the vacuum pump and checkpressure gauge shows positive side.

3. Return the priming lever to the original position.

29

9. PRIME AND DISCHARGE
NOTE

Limit the vacuum pump operating time within 30 seconds. If thepump cannot suction water within 30 seconds, it may have beencaused by another problem.
Refer to “Chapter 16 TROUBLE SHOOTING” to rectify the problem

4. Open the discharge valve.

CAUTION

NOTE

Open

Open

Check that the nozzle is ready todischarge water before opening thedischarge valve.
In order to avoid the occurrence of air
pockets, connect the suction hose to
the pump so that the pump is on upwardlocation of the suction hose.
If there is unevenness on the suction
hose connected to the pump, air will be
trapped in the hose. In this case, thepump may not be able to discharge thewater when you open the discharge valve
by the air in the hose.
In this case, open the discharge valve
and operate the vacuum pump for 3 to
5 seconds until the water is
continuously discharged.

5. Adjust the water volume and pressure using the throttle
dial.

30

Nozzle9. PRIME AND DISCHARGE
Performing relayed water supply (when sucking water from fire hydrant)
1. Determine the pump pressure in consideration of the water discharge pressure(nozzle pressure), hose pressure (friction) loss, and height loss.
Pump pressure = needed pressure + friction loss + height loss
2. Foreign materials such as dirt, gravel, iron rust, etc. may have intruded into a fire
hydrant. Before connecting a hose, open a fire hydrant to discharge water in order toremove foreign materials.
3. When sucking water from a fire hydrant, use a mediation metal 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 for the full open position. However, checkthe water pressure from fire hydrant with suction pressure gauge on the pump andadjust the opening of fire hydrant, if necessary.
In the case of water pressure from fire hydrant is higher than 6 bar,
do not continue to open the fire hydrant on-off valve.
* In case of the water pressure from fire hydrant is higher than the required dischargepressure, it is not necessary to start the pump. If the water pressure from fire hydrant
has not reached the required pump pressure, start the engine.
CAUTION

6. If the water pressure from fire hydrant is insufficient, start the engine and adjust thepressure to the required level by operating the throttle dial.
Stop increasing discharge pressure if the suction pressure gauge shows 1bar 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 firstly, then stopthe engine, and close the fire hydrant on-off valve.
CAUTIONBe sure not to close the discharge valves and nozzle(s) of any
pumps until all the pumps stop and the fire hydrant on-off valve isclosed.

8. Set the discharge valve to the half-open position, and open all the drain valves to drain
the remaining water as maintenance after operation.

31

9. PRIME AND DISCHARGE
Relay pumping operations
CAUTION

In the case of relay pumping
operation training on levelground, If the extension hose(inner diameter φ65) is less than
200 m, use the pumping plate(safety nozzle) attached.

Discharge
port adaptor

Packing
Pumping plate(Standard accessory)

Description of relay pumping operation

Water
supplyWater
supplyWater
supplyFire nozzle

Source pumpWatersourceRelay pump

Relay pump

Suction pressure
Suction pressure

Relay pump
Suction pressure

Suction pressure32

9. PRIME AND DISCHARGE
Preparation for operation
Never close the discharge valve of source pump and the relaypump(s), and the fire nozzle(s). If the discharge valves or nozzle is(are) closed, there will be a risk of damage to the pumps and hoseswith excessive pressure or water hammer.
1. Decide how many relay pumps are needed in consideration of the distance and height
between the water sauce and the fire ground.
2. Place the pumps according to the decision, and then connect the hoses.
3. Make sure that the discharge valves are open, including the fire nozzle.
4. Decide the discharge pressure of each pump in consideration of needed pressure fornext pump (or fire nozzle) and the friction loss and height loss.
Pump pressure = needed pressure + friction loss + height loss
Start the Source Pump
Once the water supply has started, keep supplying it until finished. If reducing or stopping
water supply, overheat or cavitation may occur in the relay pump(s).
1. Start the source pump according to “Chapter 8 ENGINE START”.
2. Start supplying water according to “Chapter 9 PRIME AND DISCHARGE”.
Start the Relay Pump
1. Make sure that the discharge valve is opened and wait for the water supplied.
2. Check that the water was supplied from the source pump. At first, the hose swells due
to air pressure. Step on a hose to judge whether the swelling of the hose is due towater or air.
3. When the water is supplied to the pump, check the pressure of the gauge. Start theengine when it is lower than the decided pressure. If the pressure is higher than thedecided pressure, no need to start the engine.
4. Adjust the discharge pressure with the throttle dial. The suction pressure decreases
with throttle dial up(Increase discharge water). Always check it with a suction pressuregauge.
5. If the suction pressure decreases below 1 bar, order the operator of the pre-stage
pump to increase the water pressure, and adjust the relay pump pressure by thethrottle.
6. When the suction pressure rises, adjust the water pressure by the throttle dial again.

33

9. PRIME AND DISCHARGE
Start the Attack Pump
Same as the relay pump operation.
Finish the relay Pumping Operations

・ Stop the attack pump running first.
・ Stop the relay pump running from the pump closest the nozzle in order.
・ Finally, stop the source pump.

34

10. STOPPING THE ENGINECAUTION

Do not touch the exhaust pipe and the muffler
while the engine is running, or for 10 minutes after
the engine has been stopped. These parts are very
hot and will cause severe burns.

1. Return the throttle dial to “ ” position.

2. Close the discharge valves.
Close

3. Turn the main switch to “
NOTE

” position.

It takes one to three seconds until theengine stops due to the after burncontrol. This is a shut off behavior by ananti-after burn control, not a failure.

35

11. MAINTENANCE AFTER OPERATION
Maintenance after pumping seawater or foul water
In case of the pumping seawater or foul water, the pump should be flushed out with fresh
water immediately to prevent excessive corrosion. And operate the vacuum pump for 5
seconds at low engine speed (“ ” position) to clean the vacuum pump.
Drain water
1. Open the drain valves and check the water in the pump has been completely drained.
2. Close the all drain valves for next operation.

Open

Close

Check Suction Performance
1. Open the drain valves and check the water in the pumphas been completely drained.

Open

2. Close all the drain valves and close the suction port (witha cap, etc.).

Close
NOTE

Close the suction port not to leak air into
the pump.

36

11. MAINTENANCE AFTER OPERATION
3. Start the engine, and turn the throttle dial to the “ ”
position. O perate the priming lever to produce a
vacuum. (Priming water operation must be within 30
seconds)

4. After a vacuum is produced, immediately return thepriming lever to the original position, and stop theengine.

5. Check that the vacuum pressure of the pressure gauge
for suction shows below -0.8 bar.

Pressure gauge for suction

6. To check that there is no vacuum leak, leave it for 30
seconds and confirm that the pointer of the pressuregauge for suction keeps the same pressure indication.

7. Open the drain valves to expose it to the atmosphere,
and check that the pointer of the pressure gauge forsuction returns to “0”.

Open

8. Close the drain valves.
Close

37

11. MAINTENANCE AFTER OPERATION
Fuel and Oil Supply
1. FuelFill fuel until the maximum level of the gauge indicator(in red).
Fuel tank capacity: 24L
CAUTION

Do not tilt the pump with the air ventopen. Otherwise, the fuel may leak.
If the fuel leaks, wipe it off using acloth or other materials.

Gauge indicator

2. Engine oil
Fill the oil tank with engine oil full.
Engine oil tank capacity: 1.6L
NOTE

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

3. Governor oil
Check the oil level using the dipstick.
NOTE

Use 2-stroke engine oil of ISO-L-EGB
grade or higher.
The oil should be the same oil with theengine oil.
Governor oil filler port

38

11. MAINTENANCE AFTER OPERATION
Cleaning strainer for priming water
Remove the ring nut and clean the strainer with fresh water.
If the strainer is dirty with dust, etc., vacuum performanceefficiency will be reduced.

Ring nut
Cup
O-ringStrainer

NOTE

When assembling the strainer, tighten
the ring nut while holding and pushingslightly the strainer cup.

Charging battery
NOTE

Removed the cowl when replacing battery.
Refer to “Chapter 15 SERVICE AND MAINTENANCE”.

Make sure to charge the battery after each operation.

39

11. MAINTENANCE AFTER OPERATION
Battery charger
CAUTIONUse an automatic battery charger.
Use a maintenance-free (MF) battery.
The battery capacity must be 12V-16Ah/5h (12V-18Ah/10h).
Use a battery charger that has an overcharge preventionfunction.
Disconnect the battery charger after charging is completed.

1. When charging the battery, set the main switch to the “ ” position.
Do not connect a cigarette lighter to the battery charger connector.
Doing so may melt or burn out the connector due to overheating.
NOTE

If the main switch is set to the “ ” position, the battery cannot becharged because the charging circuit is turned OFF.

2. When the main switch is set to the “ ” position, check that the Low Battery warning
lamp goes out after alert action check.

40

12. MAINTENANCE IN COLD CONDITION
Infuse antifreeze
CAUTION

If the temperature around the pump could be subzero, the pumpinside may freeze up. It may cause not only the damage in thepump, but also the inability to start the engine.

For pump unit
1. Open the drain valvesⓐ,ⓑ,ⓒ.
Drain all the water from the pump.
ⓐ Cylinder drain valveⓐⓑⓒⓑ Pump drain valveⓒ Muffler drain valveⓓ Discharge valve(Ball valve type)＊Turn the handles to the middle.

2. Close the drain valves ⓐ,ⓒ,ⓓ and the discharge valve
handles. Close the suction port (with a cap, etc.).
*Close the suction port not to leak air into the pump.

3. Attach the vinyl pipe (standard accessory) to the drain
valveⓑ.

4. Insert the vinyl pipe in the container filled with antifreezing fluid (180 ~ 200 mL).

5. Turn the throttle dial to “ ” mark position.

41

ⓓ

ⓐ
ⓑ
ⓒ

12. MAINTENANCE IN COLD CONDITION
6. Turn the main switch to “ ” position.

Main switch

Release the main switch immediately after the engine
starts.

7. After starting the engine, pull down the priming lever.
8. Make sure the pressure gauge shows positive side.
NOTE

Even if anti-freezing fluid disappears,
continue pulling a priming lever for 30
seconds.
By this operation, anti-freezing fluid
reaches every part of the pump.

9. Return the priming to original position.

10. Stop the engine and close the drain valves.

For primer
1. Turn the ring nut ② while holding and pressing thestrainer cup① of the primer, remove the strainer ③
and strainer cup ①.
2. Inject antifreeze (undiluted 50 ml) to strainer guide.

3

1
2

3. After injection, assemble the strainer cup ① andstrainer ③, and tighten the ring nut ②.
Antifreeze
50 ml
Strainer guide4212. MAINTENANCE IN COLD CONDITIONCAUTION

When installing the strainer, exercise care so that the O-ring does
not get caught in, and tighten the ring nut securely. If the ring nut
is not tightened completely, a vacuum leak may occur.

NOTE

When you install a strainer, pay attention to the protrusion of the Oring and install it correctly. Otherwise, a vacuum leak may occur.
When installing a strainer, tighten the ring nut while pressing the cup
with your palm.

Discharge valve
Fill the inside of the discharge valve with antifreeze using a long nozzle containing
antifreeze liquid.

43

13. USE OF ACCESSORY
Battery
Battery performance deteriorates if the temperature goes down. Further, battery
may freeze if the specific gravity is low.
CAUTION

When charging batteries, be sure to use an
automatic battery charger dedicated to sealed
batteries.
Use an automatic battery charger that matches thebattery 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 2~3
years checking the deterioration of the charging
performance.
When connecting battery cables, positive (+) leadshall be connected first.
(When disconnecting battery, remove the negative(–) lead first.)
Battery electrolyte is a very caustic acid, which willcause severe burns to your skin and damage toclothing.
Hydrogen gases emitted from the battery will also
cause severe burns to skin and damage to clothing.
Read instructions attached to the battery carefully
before use.

44

13. USE OF ACCESSORY
Pumping plate
NOTE

When the pump is operated using a discharge nozzle that has a nozzle
diameter greater than the maximum nozzle diameter, or without using
a discharge nozzle, be sure to use the pumping plate. Otherwise thepump may break down due to cavitation or may overheat due to lackof cooling water.
Largest Nozzle Dia. (mm) *Twin outlet discharging

Single outlet discharging

25

36

Remark: * The largest nozzle dia. at 3 m of suction head.
When the fire pump is used for water pumping device,
such as pumping water out of a cellar, pumping plate
must be installed to avoid engine overheating causedby lack of cooling water.
Install the pumping plate between the discharge port
adaptor and the packing as shown in the figure on theright. With the pumping plate in place, the pump can be
operated without a discharge nozzle, so that pressure
for cooling water in pump is maintained at certain level.

45

Discharge
port adaptor

Packing
Pumping plate(Standard accessory)14. PERIODICAL INSPECTION
Perform periodical inspections and maintenance according to the following
procedures.
Inspection intervals
3 years or

300 hr
1 year or
100 hr

0.5 yearor 50 hrAfter each
operation

Description●

Impurities(ie. Water and /or waste)●

Impurities(If water has
accumulated tofilter)Fuel filter

Fuel level

●

Fuel

●
●

Fuel hose●

High-pressure
fuel filter

Ignition●●

Cranking
EngineStarting
SystemEngine oil—

Replace

Spark plug

MeasureClean out
Replace *1

Check highpressure filter, fueltank and portable
fuel tank.

RefuelPreservation
period 6 month Replace *1
or moreDegradation(ie. Stink orReplace *1
color)
Impurities(ie. Water and /or Replace *1
water)
Curling, crack,
Replace *1leakage●

Fuel System

Inspection items●●

Replace *1 *2

Fouling, wear, gap Clean or replace･ Is not locked･ ProperReplace parts
compression
if necessary *1
pressure
Oil level

Refill the same oil

Governor oil●

Oil level with oil
dipstick

RefillStarter rope●

Wear, damage

Replace *1

Voltage measure Charge●
Battery●
Replace46

Period of use

Replace *1, 2

14. PERIODICAL INSPECTION
Inspection intervals●

Clogged or broken
mesh

Clean or replace●･ Is not locked･ Check
performance(-0.8 bar)●

Air checkPriming

PrimerPump unit

Closeddischarge
valves operation
after priming
water

MeasureReplace *1●

systemInspection items

Wear, crack, belttension

V-BeltStrainer

3 years or
300 hr

1 year or
100 hr

0.5 yearor 50 hrAfter each
operation

Description

Replace parts if
necessary *1
Check pump unit ifnecessary

Check performance Replace parts if(10 bar)necessary *1●*1. Ask our customer service staff to replace the parts*2.

･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.

47

15. SERVICE AND MAINTENANCE
GeneralServicing and maintenance of the fire pump must only be carried out by personnel who
have professional related knowledge and who are 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.
Place the pump on a level location.
Safety Devices
CAUTION

In the case of safety or protective devices have been
disassembled as such part of servicing and maintenance work,
immediately install them back to the original position after the
maintenance. Make sure that it works without problems.

Genuine parts
When replacing parts as part of servicing andmaintenance of this fire pump, use only Tohatsu genuine
parts.
If genuine Tohatsu parts and accessories are not used, it
may adversely affect the functioning and safety of the firepump. Therefore, for safety reasons, use only Tohatsu
genuine parts.
Tohatsu bears no responsibility for any personal injuries
or equipment damage that may result from use of parts oraccessories 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 natureor sewerage.
Waste
When discarding parts, go waste in accordance withenvironmental laws in the region procedure.

48

15. SERVICE AND MAINTENANCE
Removal and installation of cowl
Top cowl removal
1. Pull the cowl hook (front side 2 pieces), lift cowl
slowly.
CAUTION

Remove the cowl carefully without
coming in contact with the priming
lever and discharge valve.

2. Pull the cowl hook (total 4 hooks), remove the cowl
completely.
Top cowl installation
Assemble in reverse order of removal.
1. Fit the hooks to the plug holes on the front side. (2places)2. Through the vacuum pump lever, fit the plug to thehook (hole) on the front side. (2 places)
3. Put the plugs in completely while holding the cowl
top.
Vacuum pump strainer
Maintenance
NOTE

Incorrect installation of the strainer may
cause a vacuum leak. Be sure to install
the strainer correctly.

Wash the strainer ① with fresh water after each use.
1. On the occasion of washing the strainer, turn thering nut ② while holding the strainer cup ①.
Remove the strainer cup ③ and the strainer ①.
2. Wash the strainer ① and the strainer cup ③.
3. After washing, assemble the strainer cup ③ andstrainer ①, tighten with the ring nut②.

49

3

1
2

15. SERVICE AND MAINTENANCE
Engine oil
Check the oil level.
Install the filler cap tightly each time
you check the oil level.

CAUTION

Filler cap

Check the oil level after each operation.
1. Place the pump in a horizontal location.
2. Open the oil tank cap and check the oil level.
3. Refill the oil until the lip of the oil tank.
2-stroke engine oil

NOTE

We recommend that you use theengine oil of ISO-L-EGB grade or
higher.
Governor oil
Check every three months or every 50 hours operating time.
1. Place the pump on a level location.
2. Remove the oil dipstick, wipe it with a cloth.
3. Insert the oil dipstick completely.
4. Pull out the oil dipstick again, and check theoil level.

Upper
Lower
Governor oil filler port

Vacuum pump V belt
Check the V-belt.
Check the V-belt every year or every 100 hours operating.
V- belt size··············A-29

50

15. SERVICE AND MAINTENANCE
Spark plug
Check the spark plugs
1. Remove the plug caps, and remove the spark plugs.

2. Use a wire brush or spark plug cleaner, clean theelectrode of the spark plug ②.
3. Check the spark plug for excessive carbon deposit,
electrode ② erosion and check the washer ③for damage.
4. Measure the spark plug gap ⓐ. If the gap is out ofspecification, replace the spark plug with thespecified spark plug.
If necessary, adjust the gap to specification.
Spark plug gap ⓐ : 0.9–1.0 mm
Usage limit: 1.2 mm

Spark plug : NGK BP7HS-10
5. After assembling the spark plug, as far as by handⓑ , using a plug wrench further tightening,tighten to the specified torque ⓒ.
Tightening torque : 27 N·m (20 Ib·ft) [2.7 kgf·m]

51

Plug cap

15. SERVICE AND MAINTENANCE
Battery
General safety information
Follow the safety instructions on the battery.
When charging batteries, a highly explosive oxyhydrogengas mixture is produced.
Never charge a battery in a poorly ventilated place. Do notsmoke near the battery.
Danger of injury due to caustic
substances of battery.

Always wear protective
clothing.
Always wear protective gloves.
Always wear protective glasses.
Do not tip the battery, acid may
be discharged from the air
vents.
Disposal
Disused batteries should be disposed of according tolocal laws or regulations.

After each operation using the battery, check thevoltage. Replace the battery if necessary.
1. Remove the muffler guard.
2. Disconnect the negative terminal of the battery
cable first, disconnect the positive terminal next.
CAUTION

There is a risk of injury.
When handling the battery, besure to wear safety glasses andprotective gloves.

52

15. SERVICE AND MAINTENANCE
Electric equipment
Only expert electricians or trained staff members
should handle electrical equipment.
Be sure to disconnect battery cables before handlingelectrical equipment. Disconnect the negative terminal
first, and then disconnect the positive terminal.
When connecting battery cables, connect the positive
terminal first, and connect the negative terminal.
Use the fuse with the same current rating (ampere) asthat of the installed fuse. Using a fuse that has
excessively high resistance may result in electricalequipment failures.
Fuse
Security fuses are installed in electrical circuits used inelectrical equipment.
Before replacing the fuse, isolate the cause of theshort circuit, and take the appropriate action.
After the appropriate action has been taken, replace
the fuse with a new one.
Prepare the spare fuse at all times in case of
emergency.

53

15. SERVICE AND MAINTENANCE
Vacuum performance check
CAUTION

Limit continuous operating time of the vacuum pump to 30
seconds or less.
Operating the pump for 30 seconds or more continuously
may cause the engine to overheat. If the engine overheats, wait
until it cools down, or perform the water discharge operation.
The water discharge operation allows the cooling water tocirculate to the engine and cool it.

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

Close the suction port.

2. Pull the priming lever to run the primer (vacuumpump), and check that the pressure gauge forsuction pointer reads approximately -0.8 bar.

54

Priming lever15. SERVICE AND MAINTENANCE
Vacuum leak check
After completing the vacuum performance check, monitor the suction pressure
indicated with the suction gauge for approximately 30 seconds to check for vacuum
leaks. If the vacuum leak is found, isolate the cause by referring to the “Chapter 16
TROUBLESHOOTING”. Then, take the appropriate action and check the vacuum leakagain.
Water leak check1. Connect one end of the suction hose to the suction
port, put the other end of the hose in water, andthen close discharge valve handle.

2. Start the engine, and pull priming lever to run thevacuum pump.

Close

Priming lever

3. Operate the throttle dial to raise the pump pressure
almost to 1 M P a ( 10 bar), and then check forwater leaks from each part of the pump and thecooling water piping.
If the leak is found, isolate the cause by referring to “Chapter 16 TROUBLESHOOTING”.
Then, take the appropriate action and check the vacuum leak again.

55

16. TROUBLESHOOTING
Typical causes of engine troubles are listed in the following tables.
Warning lamp flashing

Cause

Floodlight, Gauge lamp, Hour meter, Warning lamp do
not work

Caused by engine unit
Caused by playpipe
Insufficientwater discharge
Caused by pump unit
Caused by suction
Water suction failure
Air leaking
Vacuum pressure defective
Engine seizing
Engine over heat
Engine over-rev.
Poor acceleration
Idling is too highRough idlingEngine stumble or stall
Engine start failure
Starter motor does not work
Battery charging failure

TroubleAction●Refuel.

●●Replace with new
fuel.

●

●

●

Clean the air vent.

● ● ●

●

●

●

Clean the filter.

Fuel pump failure

● ● ●

●

●

●

Replace.

Injector failure

● ● ●

●

●

●

Replace.

Fuel pipe kink or
snap

● ● ●

●

●

●

Fix routing of thepipe.

Throttle dial atother than “ ”
position●

Fuel shortage

Fuel and lubrication

● ●

●

● ● ●

●

● ● ●

Fuel filter clogging

Deteriorationof fuelFuel tank air
vent clogging

Oil filter clogging

Set dial to “ ”
position.

●

●

●

56

●

Replace oil filter. (Donot fill it up with thedifferent brand of oil.)16. TROUBLESHOOTING

Cause

Electrical

Spark plug cap
comes off

● ● ●

●

Use ofunspecified spark
plug

● ● ●

●

Spark plugfouling (No spark
or weak spark)

● ● ●

●

ECU and/or
Sensors failure● ● ● ● ● ● ●Battery loose
connection,
terminal
corrosion or
expiredBattery
charger
defective● ●Warning lamp flashing
Floodlight, Gauge lamp, Hour meter, Warning lamp do
not work

Caused by engine unit
Insufficient
Caused by playpipe
water discharge
Caused by pump unit
Caused by suction
Water suction failure
Air leaking
Vacuum pressure defective
Engine seizing
Engine over heat
Engine over-rev
Poor acceleration
Idling is too highRough idlingEngine stumble or stall
Engine start failure
Starter motor does not work
Battery charging failure

Trouble●Plug in surely.

●

Replace with specified
spark plug.

●

Clean or replace withspecified spark plug.

●● ●Action●●Check wire connection.
Plug in surely.
Replace parts if
necessary.
Clean terminal and/ ortighten a terminal screw.
Replace parts If
necessary.
Check 5A fuse and/ or
battery charger.
Replace parts if
necessary.

●57

16. TROUBLESHOOTING

15A fuse blown

Electrical

5A fuse blown●●

Warning lamp flashing

Cause

Floodlight, Gauge lamp, Hour meter, Warning lamp do
not work

Caused by engine unit
Insufficient
Caused by playpipe
water discharge
Caused by pump unit
Caused by suction
Water suction failure
Air leaking
Vacuum pressure defective
Engine seizing
Engine over heat
Engine over-rev
Poor acceleration
Idling is too highRough idlingEngine stumble or stall
Engine start failure
Starter motor does not work
Battery charging failure

TroubleActionReplace with spare
fuse.
When the blowout of
the fuse happens
repeatedly, check acause.
15A: Battery cablereverse connection,
operation panel
components andsearch light connector●

5A: Charging connector
Starter motor
defective

Operation panel
defective

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

●

● ●

●

58

Check input of startersolenoid. (Equal toOperation panel
output.) Replace parts
if necessary.

16. TROUBLESHOOTING

Compression

Piston, piston
ring or cylinder
excessively worn.

● ● ●Carbondeposition in the
combustion
chamber●●

Warning lamp flashing

Cause

Floodlight, Gauge lamp, Hour meter, Warning lamp do
not work

Caused by engine unit
Insufficient
Caused by playpipe
water discharge
Caused by pump unit
Caused by suction
Water suction failure
Air leaking
Vacuum pressure defective
Engine seizing
Engine over heat
Engine over-rev
Poor acceleration
Idling is too highRough idlingEngine stumble or stall
Engine start failure
Starter motor does not work
Battery charging failure

TroubleAction●●Correct or replace.

● ●●Clean out.

Suction height
too high or
length too long●

Place the pump tonearer and/or lower
position.

SuctionSuction hose
end is not inwater● ● ● ●

Put the end of suction
hose below 30cm of thewater surface.

Suction hose
coupling loose
or gasket
defective● ● ● ●

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

Suction hosestrainer
clogged withdead leaves orwaste etc.

● ●Suction hose
cracking or
lining peeling off● ● ● ●

59

Clean out.

Repair or replace.

16. TROUBLESHOOTING

Cause

60

Warning lamp flashing
Floodlight, Gauge lamp, Hour meter, Warning lamp do
not work●

Tighten securely aclump of vacuum pipeor replace.
Strainer cap
loose
or O-ring failure●●

Tighten securely or
replace.
V belt damaged
or worn●●

Replace.

Vacuum pumprotor shaft
seizing●Vane, Side plate
worn or damaged●

Water stop valve
contamination● ● ●Clean out.

Water stop valve
diaphragm failure● ● ●Replace.

Water stop valve●

PrimerVacuum pipeloose or cracking

Replace.
●

ActionCaused by engine unit
Insufficient
Caused by playpipe
water discharge
Caused by pump unit
Caused by suction
Water suction failure
Air leaking
Vacuum pressure defective
Engine seizing
Engine over heat
Engine over-rev
Poor acceleration
Idling is too highRough idlingEngine stumble or stall
Engine start failure
Starter motor does not work
Battery charging failure

TroubleRepair or replace.

16. TROUBLESHOOTING

Three drain valves
are not closed

Discharge valve
imperfect open

●

●

Pump

● ●

Pump cover bolts
loose

● ● ●

Pump cover Oring degradation● ●Impeller or Guide
vane caught astone or damaged

Clean out.

● ●Gauge pipe
connector loose or
gasket defective

●

● ●

61

Open securely.
Tighten securely.
Replace a gasket if
necessary.

●●

Tighten securely.
Clean out or
replace.

●

Mechanical seal
damagedActionClose securely.

● ● ●Suction portstrainer cloggedwith dead leaves
or waste etc.

Warning lamp flashing

Cause

Floodlight, Gauge lamp, Hour meter, Warning lamp do
not work

Caused by engine unit
Caused by playpipe
Insufficientwater discharge
Caused by pump unit
Caused by suction
Water suction failure
Air leaking
Vacuum pressure defective
Engine seizing
Engine over heat
Engine over-rev
Poor acceleration
Idling is too highRough idlingEngine stumble or stall
Engine start failure
Starter motor does not work
Battery charging failure

TroubleClean or Replace.
Replace.

16. TROUBLESHOOTING

Warning lamp flashing

Cause

Floodlight, Gauge lamp, Hour meter, Warning lamp do
not work●

Clean out.

Nozzles●

Attach it securely●● ● ● ●●

Governor

Governor link
disconnected

62

Adjust it securely.

●

●
●
●

Governoradjustment out ofspecified range

Change the nozzle
for suitable size or
Incorporate safety
nozzle.
Spray nozzle
clogged●● ●Discharge nozzle
too large

ActionCaused by engine unit
Caused by playpipe
Insufficientwater discharge
Caused by pump unit
Caused by suction
Water suction failure
Air leaking
Vacuum pressure defective
Engine seizing
Engine over heat
Engine over-rev
Poor acceleration
Idling is too highRough idlingEngine stumble or stall
Engine start failure
Starter motor does not work
Battery charging failure

Trouble17. APPENDIX
Tightening torque specifications
M3

M4

M5

M6

M8

M10

0.6~ 1.3~ 2.7~ 4.6~ 11.2~ 22.5~
0.8
1.8
3.5
6.3
15.1 30.6
Standard Bolt
0.06~ 0.13~ 0.27~ 0.47~ 1.14~ 2.30~
kgf·m
0.08 0.18 0.36 0.64 1.54 3.12
8.2~ 20.0~ 40.2~
N·m
10.8 26.5 53.9
Heat Treated Bolt
0.84~ 2.04~ 4.10~
kgf·m
1.10 2.70 5.50
N·m63

18. TOOL AND STANDARD ACCESSORY
Standard accessory
Description

Remarks

QuantityTool kit

1・Tool kit bag

1・Plug wrench

1・Handle of plug wrench

1

Spark plug

BPR7HS-10

Pumping plate
Fuse *1

1
2

15A

1

5A

1

Pipe assy

1

Search light (4P) (Floodlight)

1

Auto battery charger

1

Coupling *2

2*1 Spare fuses are attached to fuse box.

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

64