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 portable fire pump “VF21BS” is manufactured for use in firefighting
operations.
The portable fire pump is intended only for the firefighting activities in collaboration
with general 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 damage that may
result from modification of the fire pump without prior permission from the
manufacturer, improper use of the fire pump, or use of the fire pump for
applications other than those stated above.
Note that use of the fire pump for applications other than the stated above canresult in personal injury or damage to the equipment.
Using this fire pump within the range of intended uses implies that the user should
follow the instructions provided by the manufacturer relevant to operation, servicing
and maintenance.

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 the battery.
・ The other owner’s manuals, such as battery charger.
The portable f ire 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 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 this manual in a safe place for future reference.
・ Operators of the 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,and to 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 thisfire pump, be sure to read and understand the manual thoroughly.
Engine operation
This manual also includes a description for operation and maintenance of theengine.
NOTE・ The manual is an important item that goes with your portable firepump.

・ The 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 serial(identification)
number is marked on the pump casing.

GENERAL SAFETY INFORMATION
Overview
Before operating the TOHATSU fire pumpthoroughly read this manual to u nderstand theproper operating procedures including “DANGER”,“WARNING”, “CAUTION” and “NOTE”.
These notices are designed to bring attention tovery important information necessary to ensure
safe, trouble free operation.
Warning sign
Meaning
This sign is used for safety-related instructions inthis manual.
Be sure to follow all safety-related instructions,otherwise personal injury may occur.
Signal words

・ 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 warninglabel becomes difficult to be read or almost come off, you must replace thelabel pasted 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 retractablehandle and bracket.

・ When transporting the portablefire pump, assign one person
per handle.

・ Also, when you transport the portable fire pump, it should betransported 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.
Noise
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 human health.
Do not operate the engine in a room, car, warehouse, tunnel or otherclosed locations that have poor ventilation.

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

After protective devices (such as the muffler guard)
have been disassembled as part of servicing andmaintenance work, immediately install them back totheir original locations, making sure that they are insafe and secure condition.

Check the portable fire pumpfunctionally on a regular basis.

visuallyandIf you find any faulty device or equipment, 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 surethat it functions correctly.
Protective clothing, Protective equipment
During fire extinguishing training or regular
firefighting services, wear normal protective
clothing and equipment 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 arefamiliar 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 becold enough. 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
to connect 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 agreater capacity than the rated value may damage
the equipment.
While the engine is running, do not touch the highvoltage ignition wire attached to the spark plug. The
wire carries very high voltage will cause injury andbody harm.
Check the electrical equipment of the fire pump ona regular 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.

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,and dispose of it according to relevant laws andregulations.

Disposal
Dispose of disused batteries according to relevantlaws 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 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 fromuse of parts or accessories obtained from outside
sources.

Environmental protection measures
Dispose of oil, fuel, batteries, etc. according torelevant 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
substance.

water

to

water-prohibited

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

CONTENTS
1.

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

2. OPERATION DEVICE……………………..……..….……..…….…………...….….….…4
3. LABELS....................….….….……..…......…….…...…..…...……….....…...….….……6
4. OPERATING PRECAUTIONS……………….….….......…..…….….………...…….7
5. DESCRIPTION OF DEVICES……….…………….….……………......……….…….96. PREPARATION FOR OPERATION………………..….……….….……….….….18
7. USE OF OPERATION PANEL……………..……..………..….……....….….……21
8. STARTING THE ENGINE……………….…..............….…….…….…..….…......…26
9. PRIME AND DISCHARGE………………….…….…..…..……..……..…….….…..29
10. STOPPING THE ENGINE……………..……...……….…..……..……….….....…..36
11. MAINTENANCE AFTER OPERATION……………..…...….……..…..……….37
12. MAINTENANCE IN COLD CONDITION………….……….………..……..…42
13. USE OF ACCESSORY…….………………….………….….…….……..…………..…46
14. PERIODICAL INSPECTION…………..……………………..………..…….…….…..48
15. SERVICE AND MAINTENANCE………………………….....…..…..…...……...50
16. TROUBLESHOOTING……………………….……………........………..…..….….….59
17. APPENDIX…………………………………..………..…...……………………….……...….63
18. TOOL AND STANDARD ACCESSORY…………………………….….…….….64

1. SPECIFICATIONS
Model

VF21BS

Description

Portable pumpEngineManufacturer

TOHATSU CORPORATION

Model

2WF55AType

4-stroke, water cooled spark ignition engine

Bore × Stroke

55mm × 44mm (2.17in × 1.73in)

Number of Cylinder

2

Piston displacement

209 cm3

Rated power

7.3 kW

Fuel type

Unleaded petrol RON91

Fuel tank capacity

Approx. 4.0L (1.06 gal(US))

Fuel consumption

Approx. 3.9L/h(1.03 gal/h)Engine oil

API: SH, SJ, SL SAE: 10W-30/40

Engine oil tank capacity

Approx, 1.0L(0.26 gal(US))

Engine lubrication

Trochoid pump

Cooling system

Water cooling

Ignition

Flywheel magneto, C.D. Ignition

Spark plug

NGK DCPR6E

Starting system

Electric starter and Manual starter

Lubrication

Wet sump

Fuel system

Carburetor

Battery

12 V-12 Ah/10 HR

Floodlight bulb *1

12 V-55 W*1 Option1

1. SPECIFICATIONS
Model

VF21BS

PrimerType

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

Approx. 9m (29.5ft)

Pump
Type

Single suction, single stage, centrifugal pump

Number of delivery outlets

1

Discharge port coupling

JIS thread 2-1/2" (65mm), NST thread NH 2-1/2" (male)

Suction port coupling

JIS thread 2-1/2" (65mm), NST thread NH 2-1/2" (male)

Pump performance(Suction height: 3m / 9.8ft)

0.50 m3/min at 0.5 MPa (5.1 kgf/cm2)
150 gal(US)/min at 75 psi
0.29 m3/min at 0.7 MPa (7.1 kgf/cm2)
105 gal(US)/min at 100 psi

Dimensions and weight
Length x Width x Height

480mm × 590mm × 560mm (18.9in × 23.2in × 22.0in)

Mass (Dry)

52kg (114.6lbs)

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/Stainless

Pump
Pump casing, Pump cover

Aluminum alloy

Impeller

Aluminum alloy

Shaft sealType

Mechanical seal2

3

Total delivery pressure P

gal(US) /min

Delivery flow Q

Performance Curvem3 /min

TOHATSU CORPORATION
Suction hose dia.
: 2 1/2”
Suction hose length : 6m
Suction height: 3m

1. SPECIFICATIONS(VF21BS)2. OPERATION DEVICE
Control panel and Battery side

Manual starter handle

Front markControl panel

Carrying handle
Fuel tank cap
Overheat switch

Fuel tankOver heat switch

Primer valve

Battery:
Connecting cables
to the battery
Oil level gauge

4

Engine oil filler cap

2. OPERATION DEVICE

Spark plug cap

Vacuum pump

Vacuum pump strainer cap

Discharge valve handle
Discharge valve
Discharge port
Air valve fordrainage
Suction Port
Drain valve for discharge valve

MufflerDrain valve for
Water pump5

3. LABELS

Instruction label
Warning label
Caution label

Warning label
Caution label
Caution label (muffler)

Caution label (battery)64. OPERATING PRECAUTIONS
Installing pump
CAUTION

The fire pump must be installed on a level ground. Otherwise, anaccident may occur. If the fire pump should be installed on an
uneven ground, it must be secured.

NOTE

Place 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.
In case of the inclined location or uneven ground, make sure that thewater suction hose is lower than the 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 tip of the hose into the water more than 30cm (11.8in)deep from the surface to prevent air suction.
Discharge hose should be arranged not to be bent.

74. OPERATING PRECAUTIONSCAUTION

When installing the portable pump in a vehicle, place the vehicle
on a level place, and install the pump.
When i ns tall ing the portable pump, i n th e veh i cl e, m akes u r e to ap pl y th e br akes of the v ehi cl e i n or der tos to p th e wh ee ls . A serious accident may occur if the vehicle
moves.
Do not put your hands or fingers in theretractable part when operating thehandle.
When transporting the portablefire pump, assign one person
per handle.
Also, when you
transport the portable fire pump it
should be transported holding thehandle firmly to avoid falling down the
pump.

NOTE

Do not put yourhands or fingers

When lowering the portable fire pump to theground, lower it gently and horizontally.
Do not touch the exhaust pipe and the muffler
while the engine is running, or for more than10
minutes after the engine has been stopped. These
parts are very hot and will cause severe burns.

8

5. DESCRIPTION OF DEVICES
Carrying handle
The fire pump is equipped with for carrying handles.
The handles can be manually folded, and opened byrotating them by 90 degrees.

CAUTION

Personal injuries may occur when
opening or closing the handle.

Caring handle

Do not put your hands or fingers
into the retractable part when
operating the handle.
To prevent injuries, two persons
should work together whencarrying and placing the pump.
Opening cowl
1. When removing or attaching top cowl, turnthrottle lever to “High pressure” side.

theThrottle lever
2. Remove the rear hooks from the holes, and remove
the top cowl while taking care not to give damage
with the recoil starter handle.
NOTE

Top cowl

It is necessary to remove the top
cowl to remove the spark plug.

Hooks

9

5. DESCRIPTION OF DEVICES
Assembling cowl
After putting recoil starter handle through top cowlhole, put front latch into hole of control panel, and then,fit the rear hook into the hole.
NOTE

Pay attention to have the starter
handle for manual starting goes
through the window at the front
upper side of the cowl.

Latch mounting hole
ラッチ取付け穴

Suction port
The diameter of the thread for fire pump・ JIS thread 2-1/2” (65 mm)
・ NST thread NH 2-1/2”

ThreadWhen the pump is run while the strainer is notinstalled, if you insert your finger into thesuction port, you may be seriously injured by
the rotating inducer.

CAUTION

A strainer must be installed at the suction port.
Do not run the pump if the strainer is not installed.
If the pump is run when the strainer is notinstalled, gravel may enter the pump, resulting insignificantly reduced water discharge capacity.

10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”

OPEN
CLOSE

Discharge valve handle

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

Air valve for drainage

Drain valve
Use the drain valves to drain water.
(4-unit, operate at three locations.)
Drain valves:- at the pump case
- at the ball cock discharge valves and the valve for

Pump drain valvesdrain from the engine.

NOTE

Close all the valves when operating
the fire pump.

Drain valve (for ball cock)If a valve is opened, water cannot be
suctioned.

Fuel tank
Refill appropriate amount of gasoline to the fuel tank.
Close the fuel tank cap all the time except refuel.
CAUTION

If the fuel leaks, wipe it off using acloth or other materials.

Fuel tank cap

115. DESCRIPTION OF DEVICES
Engine oil

Oil filler cap

Refill appropriate amount of oil to the oil pan.
Close the oil filler cap all the time except filling.
Recommended engine oil：4-stroke engine oil
API:

SH, SJ, SL

SAE: 10W-30/40
0W-30 is recommended for operation in cold
climates. (10°C or below)

Upper
Lower

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

1. Fuel valve

7. Battery charger and Floodlight projector connector
4. Main switch

3. Engine start knob
2. Fuel drain valve

8. Pressure gauge

9. Vacuum gauge

5. Priming lever

12

6. Throttle lever5. DESCRIPTION OF DEVICES
1. Fuel valve
Turn the fuel valve to control the fuel supply by full open or close completely.
2. Fuel drain valve
Before storing the pump long term, drain the fuel from the carburetor.
3. Engine start knob
Pull the engine start knob.
4. Main switch
Turn the main switch to run or stop the pump for VF21BS.
Description

Function for VF21BSOFF

To Stop the pump

ON

Running position

START

To start the pump running

5. Priming lever
Used for suctioning water.
After starting the engine, pull the priming lever to suction water, after priming has
been completed, return the priming lever to the original position.
6. Throttle lever
Use the throttle lever to control discharge pressure.
It shows the throttle position such as engine start and priming water position.
7. Battery charger connector
When charging the pump battery, connect the charger plug to the connector.
<Specifications of accessory socket>
・ Voltage : DC12V
・ Max, allowable current : 5A
8. Pressure gauge for discharge
The pressure gauge for discharge indicates the actual operating pressure.
9. Pressure gauge for suction
The pressure gauge for suction indicates the input pressure supplied from anexternal water source.

13

5. DESCRIPTION OF DEVICES
Initial charge of battery
The battery can be used immediately after filling cells with electrolyte.
Be sure not to open the battery after filling it with electrolyte.
Refer to the instruction of the battery.
CAUTION

Before charging the battery, turn the main 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 for a battery and a floodlight.
Do not connect a cigarette lighter to the connector, because it
is not a heat resistant object.

Fuse box
Security fuse is installed for electrical circuit in thefuse box.
Fuse is in the yellow color fuse box

Fuse box*Fuse : 7.5A
Manual starter
If the engine does not start with the starter motor,
use the manual starter.

Manual starter handle
CAUTION

Personal injuries may occur.
When you start the engine using the manual starter, pull thestarter handle in a breath when you feel the handle heavier.
Do not pull the manual starter handle when the pump is running.
Otherwise, the manual starter may be damaged.
In case engine will not start due to lack of fuel, squeeze primer
bulb several time, and try starting again.

14

5. DESCRIPTION OF DEVICES
Warning lamp and buzzer
Turning the main switch to "RUN" position, the lamp and buzzer check mode starts. The
warning lamps light up and the buzzer sound for a moment to enable to check thosefunctions. In the case of manual starting, while pulling the recoil starter the lamps
and buzzer sound for a moment.
Main switch

Over heat warning lamp

CAUTION

Low engine oil pressure warning lamp

If they do not, remove the cause by following the cause byfollowing the “16 TROUBLESHOOTING” section.

The monitor shows the following information:・Overheat warning
・Low engine oil pressure warning
Overheat warning
If overheat is detected, overheat lamp lights up, the warning buzzer sounds and theengine stops automatically.
NOTE

The engine stops automatically when overheat is detected.

CAUTION

The engine may be damaged.
Do not restart the engine soon after it has stopped running.

15

5. DESCRIPTION OF DEVICES
Low engine oil pressure warning
Check engine oil level, and replenish if it is lower than specified level. If the level iswithin specified range, consult the dealer.
CAUTION

The engine does not stop even if the low engine oil pressure
warning lamp lights up. This is to give priority to thecontinuation of fire fighting over protection of the engine.
The engine remains operational for more than 30 minutes evenafter the warning lamp lights up.
However, if the engine is operated for longer than this, it may
seize. Refill oil immediately.

Recommended engine oil：4-stroke engine oil
API:

SH, SJ, SL

SAE: 10W-30/40
0W-30 is recommended for operation in cold
climates. (10°C or below)
For operation in cold weather (10°C below or less), 0W-30 is recommender.
Please refer to the following table to select oil with viscosity suited to outdoor
temperature of the site.
If the oil level is near the lower limit, replenish the oil until the upper level. Do not fill
the oil over the upper limit. (Be sure to check oil level before starting engine.)
CAUTION

If the engine oil is found cloudy or very dirty, consult the dealer.
Do not use engine oil by mixing different brand or grade products.
When refilling engine oil, please be careful not to get dirt andwater into the engine.
If engine oil is spilt, wipe out completely with cloth.

NOTE

For replacement of engine oil, refer to “Chapter 11. MAINTENANCE
AFTER OPERATION “.

165. DESCRIPTION OF DEVICES
Floodlight (Search light) *Option
Use the floodlight projector to light up the location where this 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.

PLUG
BULB 12V-55W
Adjust screw

TripodCAUTION

Secure adequate lighting for the location where the fire pumpworks, otherwise an accident may occur.

17

6. PREPARATION FOR OPERATION
Fuel
Fill the tank with gasoline until the maximum level
which is indicated by the gauge indicator (in red).

Level gauge

・ Fuel tank capacity : 4.0 L (1.06 gal(US))

・ Vaporized fuel may cause ignition or an explosion.
・ Do not bring any flames near fuel.
・ Stop the engine before refueling or draining fuelfrom carburetor.
・ Do not spill fuel or overfill fuel into the tank.
CAUTION ・ Do not breathe in the 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.
・ Close the fuel tank cap tightly.
・ Remove the fuel tank cap and filling fuel into thetank. Do not spill the fuel. If there is spilled fuel,properly clean up all the 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) may
cause:-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.
Engine oil
Before using the pump, fill it with the designatedamount (approximately 1.0L/0.26gal(US)) of engine oil.
Fill the engine oil until “upper” level.

Oil filler cap

CAUTION ・ If the engine oil is not enough filled,
the warning buzzer sounds.

・ Always wipe off spilled engine oil.
NOTE・ If the engine oil is not enough (Lessthan approx. 1/3 of the oil tank), thewarning lamp for oil level lights on,
and the warning buzzer sounds.

・ If oil becomes cloudy white, or it isdirty, please consult with your local
sales representative.

・ For more information about engine

oil change, see the section how tochange the engine oil.

19

Upper
Lower

6. PREPARATION FOR OPERATION
4-stroke engine oil
API:

SH, SJ, SL

SAE: 10W-30/40
Air valve for drainage
Drain valves
Make sure all drain valves are closed.

Pump drain Valves
Drain Valve (Ball cock)

Close

Open

Close

Discharge valve
Close the discharge valve and the drain valve.

Close
NOTE

・ After determining the direction of the discharge valve, tighten thepositioning (lock) bolt, to keep the direction of the valve.

・ Do not change the direction of the water discharge valve when thelock bolt is being fixed (being tightened).

20

7. USE OF OPERATION PANEL

Main switch

Over heatwarning lamp

Low engine oil level
warning lamp

Overheat warning lamp
When the cooling water temperature rises above about 90 ° C, the engine shuts off
automatically to prevent overheating.
Warning lamp and sensor
Turning the main switch to the “RUN” position, warning lamps turn on and the buzzer
sound for a moment. (“Lamp check”)
CAUTION ・ After the engine has stopped due to over- heating, 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 thewarning lamps are turned off.

21

7. USE OF OPERATION PANEL
Warning system
If any abnormality occur in the engine or the pump, an alarm buzzer sounds and thecorresponding warning lamp turns on or flashes, and the engine will stop or the speed
will be controlled which is depending on the status of an abnormal phenomenon.
Alarm Displays, Abnormal Phenomena and Actions

Abnormality

Lamp &
Buzzercheck

Abnormalhydraulicpressure

Engineoverheating

Flashing

Flashing

Speed control
Buzzer

ESG
High
speed

Engineoverheating

Engine
stop

Beep
once

Over
revolution

Lowhydraulicpressure

Low
speed

○

Continuous
soundLight onLight onOverheatsensorswitch
at “OFF○

Continuous
sound

○

Continuous
sound*ESG: Electrical Safety Governor

22

Description
No
abnormality,
Systemoperation
cheek at Main
switch ON(Electric
starter model
only)
6250 r/min incase of Overrevolution.
Controls
engine speed
to less than3000 r/min,in case ofabnormally
low hydraulicpressure.
Activates
engine stop
control incase of engine
overheating.
In the case ofoverheatswitch is OFF,
it notifies withbuzzer sound.

Action(See next Page)

Indication
Lamp

A

B

C

D

7. USE OF OPERATION PANEL
Actions to be taken
A： Turn the throttle lever to low pressure side. Water may not to be kept in thepump.
B： Check the engine oil level, and replenish the oil if it is lower than specified level. If
the level is within the specified range, contact the dealer.
C： After removing the cause of cooling water shortage, set the overheat sensor
switch “OFF” and start engine again.
After checking that the lamp goes out, turn the overheat switch "ON".
D： Keep the overheat sensor switch "ON" side.

23

7. USE OF OPERATION PANEL
Pump installation
・ Since the temperature around the engine
becomes high because of the muffler andexhaust gas, install the pump on level groundat least three meters away from inflammablematerials including dead leaves and wood.
・ Exhaust gas, which contains carbon monoxide, isa deadly poisonous gas with no color and nosmell.
・ Do not operate engine in a closed space or an
insufficient ventilation place such as indoor, inthe vehicle, warehouse, tunnel, well, in the holdof a ship.
・ Do not start the engine with water discharge
valve open.
・ Do not pump up and discharge liquids otherthan water (e.g. flammable liquids or chemicals).
・ The pump is designed as a water pump only.
・ Do not discharge water to water prohibited
substance.
・ Do not run the pump without suction portstrainer.
・ If you insert your hand into the suction port, you
may be seriously injured by the rotating inducer.

24

7. USE OF OPERATION PANELCAUTION ・ Do not run the pump without suction port strainer. If gravel
enters the pump, then the pump could be damaged and theperformance would be significantly reduced.
1. Place the pump in a horizontal location and close to the water source. Ensuring it
is in a stable position.
2. Connect 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(filter).
Starting engine
CAUTION ・ Wear proper
operation.

hearing

protection

during・ While the engine is running, never touch the highvoltage ignition wire attached to the spark plug.

・ Very high voltage flow on the wire on each, causing
injury and damage to the body.

・ 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.

25

8. STARTING THE ENGINE
Make sure that the discharge valve is closed.

Close

Operate the pump according to the operatingprocedure (along with the order shown on themachine).
If the throttle lever cannot be kept after the engine
is started, adjust the throttle lever as below. (① ~ ④).

Adjustment procedure① Connect the suction hose to the pump.
② Start the engine and suck up water.
③ After sucking water, set the throttle lever to“High pressure” position with the discharge
valve closed.

Throttle leveradjust screw

CAUTION ・ To avoid overheating, do the operation with the water sucked
up condition.
④ Tighten throttle lever adjustment screw until the throttle lever can be kept at"High pressure" position.
CAUTION ・ Do not over tightening throttle lever adjustment screw. The
throttle lever may be broken⑤ After adjusted, return the throttle lever to the "Low pressure" position.
Drain water from the drain cocks.
(Refer to “Chapter 11 MAINTENANCE AFTER OPERATION”)

26

8. STARTING THE ENGINE
1. Turn the fuel valve to the open position, this willallow fuel to flow into the carburetor.
If the fuel line runs short of fuel and cannot be
started, grasp primer valve several times until theprimer valve becomes hard.
2. Turn the main switch to RUN position and pull
the engine start knob.
If continuing to drive for more than 1 minute whilepulling the start knob, the engine may stop due toexcessive fuel supply.
In this case, do not pull the start knob and restart it.
3. Check the throttle dial position.
If the temperature is 0 ° C or less, turn the throttle
lever some times between the high pressure sideand the low pressure side. About twice at 0° C, 5
times at -25° C.
Set the lever at “♦” mark.
If the ambient temperature exceeds 0 ° C, set thethrottle at the low pressure side.

Fuel valve

OPEN
Main switch

Start knob
PULL

START

4. Turn the main switch to the ”START” position.
Release the main switch immediately after theengine started.

NOTE

・ Extended operation of the starter motor will run the battery drain.
Operate the starter motor for maximum 3 seconds.
・ If the engine does not start, then 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.

27

8. STARTING THE ENGINE
Starting engine using the manual starter
If electric starter does not work, use the manual
starter.

Manual starter handle

Start the engine by pulling the handle from theposition where it feels heavy.

NOTE・ In case engine will not start due to lack of fuel, squeeze primer bulb
several times, and try starting again.
・ Keep the operating time of the vacuum pump within 30 seconds.
・ If suction cannot be done within 30 seconds, there is the otherproblem.

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.
・ Throttle lever at idle position: Within 2 minutes
・ Throttle lever at “♦” position: Within 30 seconds
Closed discharge valves operation after priming water
When the pump runs with the discharge valve closed, the cooling water temperature
becomes high.
・ Do not run the engine with opened recoil starter to avoid
serious injury.
CAUTION ・ Run the pump with the closed discharge valve, the pumpwill be overheated.

28

9. PRIME AND DISCHARGE
Prime and discharge

・ While the engine is running with the cowl

removed, do not touch the rotating parts of thepulley or belt.
This may cause personal injuries.

NOTE・ If, when operating the vacuum pump for 30 seconds,
the pump does not suck water or if water drop outof the pump during the water discharge operation,
check the following:・ Is the tip of the suction hose completely below thewater 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 leak 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 the engine starts, pull the priming lever.

Priming lever

2. Check that the pumped water is discharged
continuously from the priming outlet of thevacuum pump.
Be sure the pressure gauge shows positive side.

Priming outlet

29

9. PRIME AND DISCHARGE
3. Return the priming lever to the original position.
NOTE

・ Limit the vacuum pump operating time to within 30 seconds.
・ If the pump can’t suction water within 30 seconds, it may have aproblem. Refer to “Chapter 16 TROUBLESHOOTING” to rectify the
problem.

・ When priming water from a water source that is considerably lower

location than the pump, suction may fail to bring water up to thepump.

・ If the pump runs with no discharge water for more than 2 minutes (Ifit's at low speed), the pump may have damages. The pump should be
run with water discharge for protecting some parts of the pump suchas mechanical seal by cooling water (discharge water).

4. Turn the handle slowly to open the discharge valve

OPEN

as shown in the picture.

CLOSE

The discharge valve handle can be turned
approximately 90 degrees.
Discharge valve handle
CAUTION ・ Before opening water discharge valve of the pump, be sure to
warn the person holding the nozzle, and confirm to be ready todischarge water.

・ During operation, check the suction and discharge hoses.
・ The hoses must be free of kinks, pinches, etc., possibly caused
from emergency vehicles rolling over the 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 the water by the accumulated air in the hose when
you open the discharge valve. In this case, open the discharge valve
and operate the vacuum pump for 3 to 5 seconds more until thewater is continuously discharged.

30

9. PRIME AND DISCHARGE
5 . Adjust the water volume and pressure
turning the throttle lever.

Throttle lever
CAUTION ・ In the case of using a branch pipe, the person holding the branchpipe must be notified of changes in water discharge pressurecaused from engine speed changes or discharge valve settingchanges.

・ Discharged water should not be directed 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.

31

9. PRIME AND DISCHARGE
Relay water supply (when water is supplied from a fire hydrant)

1. Determine the pump pressure in consideration of the water discharge pressure(nozzle pressure), hose pressure loss, and height loss.

Pump pressure = needed pressure + height loss + friction 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 and discharge water in order to remove
foreign materials.

3. When using water from a fire hydrant, set a mediation metal to the suction port ofthe pump. (Between a delivery hose and the pump)

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 on the pump and adjust the openingof fire hydrant on-off valve, if necessary.
CAUTION ・ If the water pressure from a fire hydrant is higher than 0.6MPa,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 the pump.

6. If the water pressure from fire hydrant is insufficient, start the engine and adjust thedischarge water pressure to the required level by operating the throttle lever. Stop
increasing discharge pressure if the suction pressure gauge shows 0.1MPa (15psi) or
below. If it does, stop increasing the pressure and keep the throttle lever as it is.

7. To end discharge water, turn the throttle lever to the low pressure position firstly,
then stop the engine and close the fire hydrant on-off valve.

CAUTION ・ Be 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 to the half-open position, and open all the drain valves todrain the remaining water in the pump as maintenance after operation.

32

9. PRIME AND DISCHARGE
Relay pumping operations
CAUTION

Packing・ In

the case of relay pumping
operations training in a flat place, if
the number of extending hose is lessthan ten, use the safety nozzle
attached.
Pumping plate

Description of relay pumping operation

Water
supplyWater
supplyWater
supplyFire nozzle

Source pumpWatersourceRelay pump

Relay pump

Suction pressure
Suction pressure

Relay pump
Suction pressure

Suction pressure33

9. PRIME AND DISCHARGE
Preparation for operation

・ Do not close the discharge valve of source pump, relay pumps

and fire nozzle. If the discharge valves or nozzle are (is) closed,
there will be a risk of damage to the pumps and hoses withexcessive pressure or water hammer.

1. Decide how many relay pumps are needed in consideration of the 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 valves are open, including the fire nozzle.
4. Decide the discharge pressure of each pump in consideration of needed pressure
for next pump (or fire nozzle) and the height loss and friction loss.

Pump pressure = needed pressure + height loss + friction loss
Start the Source Pump

・ Once the water supply has started, keep supplying water until

finished. If reduce or stop supplying water, overheat or cavitation
may occur in the relay pumps.

1. Start the source pump. Refer to “Chapter 8. STARTING THE ENGINE”.
2. Start supplying water. Refer to “Chapter 9. PRIME AND DISCHARGE”.
Start the Relay Pump

1. Make sure that the discharge valve is opened and wait supplied water.
2. Check that the water was supplied from the source pump. At first, the hose swells
due to air pressure. Step on the hose to judge whether the swelling of the hose isdue to water or air.

3. Confirm that the water is supplied to the pump, read a pressure gauge. Start theengine if the pressure is lower than the required pressure. If the pressure is highenough, no need to start the engine.

34

9. PRIME AND DISCHARGE
4. Adjust the discharge pressure with throttle lever. The suction pressure decreases
with opening up the throttle. Always confirm the pressure with the suction pressuregauge.

5. If the suction pressure drops below 0.1MPa (15 psi), order the operator of the former

pump to increase the water pressure, and adjust the relay pump pressure by thethrottle.

6. If the suction pressure rises, adjust the throttle again.
Start the Attack Pump
It is the same as the relay pump case.
Finish the relay Pumping Operation

1. Do not close the fire nozzle.
2. Stop the attack pump running first.
3. Stop the relay pump running in order from the pump near the nozzle.
4. Finally stop the source pump.
CAUTION ・ Do not touch the exhaust pipe and the muffler
while the engine is running, and also do not touch
if for 10 minutes more after the engine has been
stopped.

・ These parts are very hot and will cause severeburns.

35

10. STOPPING THE ENGINE
Stop the engine
1. Return the throttle lever to “LOW pressure” side.

Throttle lever
2. Close the discharge valves.

Close

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

Main switch

36

11. MAINTENANCE AFTER OPERATION
Maintenance after pumping seawater or foul water
After 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 in order to clean theinside of the vacuum pump.
Drain water(4 drain valves / operate at three locations.)

1. Open the drain valves and check the water in thepump has been completely drained.

Valve for drain
Valves (Pump case)
Open
Close

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

Valve (Ball cock)

Close

Open

Suction performance check1. Open the drain valves and check the water in thepump has been completely drained.

Suction port cap

2. Close all the drain valves and the suction port (witha cap, etc.) .
* Close the suction port not to leak air into the
pump.
NOTE

・ Prepare a suction cap that is suitable for the suction coupling.

37

11. MAINTENANCE AFTER OPERATION
3. Start the engine, and operate the priming lever withthe throttle lever at the suction position to produce a
vacuum.
*Priming (Vacuum) pump operating time: within 30
seconds.

4. After a vacuum is produced, return the priming leverto the original position, and stop the engine.

Start

Priming lever
Stop

5. Check that the vacuum pressure of the pressuregauge for suction is about -0.08 MPa (-12psi).

Priming lever

6. In order to check that there is no vacuum leak, leave
the pump for 30 seconds and confirm that the pointerof the pressure gauge for suction keeps the samepressure indication.

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

Air valve for drainage
OPEN
OPEN

CLOSE
8. Close the drain valves.

CLOSE
Pump drain Valves38

11. MAINTENANCE AFTER OPERATION
Fuel and Oil Supply

Level gauge

Fuel
Fill fuel until the maximum level of the gauge indicator(in red).
Fuel tank capacity: 4.0L (1.06 gal(US))
CAUTION ・ Wipe off fuel using a cloth or theother materials if there is fuel out of
the fuel tank.

Oil filler cap

Engine oil
Fill the engine with 4-stroke engine oil.
API:

SH, SJ, SL

SAE: 10W-30/40
Engine oil tank capacity: 1.0L (0.26 gal(US))
NOTE

・ A new pump is not filled with engine oil.
Before using the pump, fill it with thedesignated amount (approximately 1.0
L/0.26gal(US)) of engine oil.

Upper
Lower

・ How to change the oil is shown below.
1. Set the carrying handles of thesuction water side as shown in the
figure, tilt the pump
2. Put the pan for the waste oil under
the drain hole.
3. Remove the drain bolt to drain out
the oil.
4. Tighten the drain bolt with apredetermined torque.
Be sure to use oil having suitable
viscosityfortheexternal
airtemperature of the area where thepump is used.

* It is possible to check the amount and cleanliness of the engine oil
through the window which is fixed in the oil pan.

39

11. MAINTENANCE AFTER OPERATION
Cleaning strainer for prime
Remove the strainer cap, and remove the strainer.
Clean the strainer with fresh water. If the strainer isdirty with dust, etc., vacuum performance efficiency will
be reduced.

Strainer Cap

Vacuum pumpstrainer case

Charging battery

・ Read the safety instructions carefully and/or warnings before
using or charging the batteries.

・ Hydrogen gas form the battery is explosive.
・ Keep battery away from flame and spark.
・ Charge the battery in well ventilated area.
・ Do not charge battery in unventilated area.
CAUTION ・ Read the cautions attached to the battery carefully before use.
Be sure to charge the battery after each operation.

40

11. MAINTENANCE AFTER OPERATION
Battery charger
Read the instruction manual of the battery charger before use.
*The battery charger is packed with the instruction manual.

Use an automatic battery charger.
CAUTION ・ Use a battery charger that has an overcharge prevention function.
・ Read the instruction manual of the battery charger before
charging a battery.

・ Automatic charger should be kept in a dry and well- ventilated
place.

1. Confirm that there is no dirt, no slack, no backlashof the terminal.
2. Confirm the quantity of liquid in the battery.

Main switch(The shield type is excluded)
3. Turn the main switch to the “STOP” 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 thebattery instruction manual.
7. Disconnect the battery charger when using the
pump.
NOTE

・ If the main switch is on, the battery cannot be charged.
・ Pull out the battery charger plug from the socket when you use or
move the pump.

41

12. MAINTENANCE IN COLD CONDITION
Battery・ Hydrogen gas from the battery is explosive.
・ Keep battery away from flame and sparks.
・ Charge the battery in a well ventilated area.
・ Do not charge battery in unventilated area.
CAUTION ・ The battery capacity must be 12V/16Ah.
・ Read the instruction (caution) of the battery carefully beforeuse.
In the case of Opening type battery

・ Battery fluid decreased also in compensation charge state.
・ Inspect the battery liquid level once a month. If battery liquid is “LOW LEVEL”,
supplement steaming water (replenisher) to “UPPER LEVEL”.

・ To know the exact state to charge, measure specific gravity of the battery liquid byan aerometer. The specific gravity of the full charge is 1.28(20ºC conversion).

・ The outer surface of the battery should be kept always clean.
・ The battery life is normally 2 years even if the battery is used properly.
・ Replace with new battery every 2 years checking the deterioration of the charging
performance.

・ When connecting battery wires, attach the positive (+) battery wire first.
(When disconnecting battery, remove the negative (-) wire first.)

・ Hydrogen gas released from the battery can cause damage and severe bums ofthe clothes and skin.

UPPER LEVELLOWER LEVEL
1.20
1.28
1.30

42

12. MAINTENANCE IN COLD CONDITIONIn the case of Maintenance-free battery
CAUTION ・ In the case of a maintenance-free type battery, it is not
required to replenish the distilled water. After starting to use it,
don't open the battery caps later.

・ Replace with new battery every 2 years.
・ Do not replenish distilled water and/or replenisher to a
maintenance-free battery.

Infuse anti-freezing fluid
CAUTION ・ If the temperature around the pump could be subzero, theinside of the pump can be frozen. In this case, the water pumpor the vacuum pump may not be worked. And also the pumpunit including engine and muffler may be damaged or broken.

・ In order to prevent internal corrosion and freeze damage by thewater in the pump, drain all the water from the pump after eachuse.

・ After draining the water, put antifreeze fluid into the pump andvacuum pump.

Air valve for drainage

Pump unit

Open

1. Open the drain valves and the air valve for drain.
Drain all the water from the pump.

Open

Close

2. Close the drain valves.

Close
Drain valve

Open

Air valve for drainage

43

12. MAINTENANCE IN COLD CONDITION
3. Close suction port (with a cap, etc.). (Keep the air
valve for drainage opened)*Close the suction port not to leak air into the pump.

4. Insert the plastic tube (vinyl) to the air valve.

Example of using asuction port cap

Plastic tube

Air valve for drainage
5. Insert the plastic tube in the container filled with
antifreeze fluid.
(180ml/0.04gal - 200ml/0.05 gal(US))

6. Turn the throttle lever at “Low pressure” side.

Throttle lever
7. Turn on the main switch. (Turn the main switch
to ”RUN”) position.

Run

Turn the main switch to ”START” position.
Release the main switch immediately after theengine starts.

Start
Main switch

44

12. MAINTENANCE IN COLD CONDITION
8. After starting the engine, suck antifreeze fluid bypull the priming lever.

NOTE

Priming lever・ Even if all the anti-freezing fluid
sucked up, continue pulling apriming lever for 30 seconds.

9. Turn the main switch to “STOP” position, and close
the air valve for drainage.

STOP
Main switch
Air valve for drainage

Close

Discharge valve
Fill antifreeze fluid the seal area of the discharge valve.
To use a long nozzle containing is helpful whenpouring antifreeze fluid.

45

Discharge valve

13. USE OF ACCESSORY
Battery
Battery performance will degrade if the temperature goes down. Also, if the specificgravity is low, the battery may freeze.
・ Hydrogen gas from the battery is explosive.
・ Keep battery away from flame and sparks.
・ Hydrogen gas emitted from the battery will also
cause severe burns to skin and damage.
・ Charge battery in well ventilated area.
・ Do not charge a battery in unventilated area.
CAUTION ・ Read the instructions attached to the battery
carefully before use.
・ When charging batteries, be sure to use an
automatic battery charger.
・ 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.

46

13. USE OF ACCESSORY
Pumping plate
CAUTION ・ When the fire pump is used for a water lifting device, such as
pumping water out of a cellar. Install the pumping plate* withholes 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.

Packing
Pumping plate

Discharge port adapter(Option)When using the pump without a nozzle, put the pumping plate between the discharge
port adaptor and the packing as shown in the figures above.
NOTE

・ Put the pumping plate as the figure shown above, so that pressure
for cooling water in the pump is maintained at certain level. Then you
can use the pump without a discharge nozzle.

4714. PERIODICAL INSPECTION
Inspection intervals
3 years or
300 hr

1 year or
100 hr

0.5 year or
50 hr

After each
operation

Description

Inspection items

MeasureImpurities (ie. Water
and / or waste)

Clean out.*1

Level

Refuel.

●Preservation period
6 months of more.

Replace.*1●

Degradation(ie. Stink or color)

Replace.*1

Strainer●

Impurities(If water
and/or waste has
accumulated)

Clean out.*1

Fuel
hose

●

Curling, crack,leakage, connection

Replace.*1

Spark
plug

●

Fouling, wear, gap

Clean out or
replace.

Is not locked
Poor compression
pressure

Replace parts if
necessary. *1

Oil level

Refill the sameoil.

Wear, damage

Replace. *1

●
●
Fuel
Fuel
systemIgnition

EngineCranking
Engine oil

Starting
systemStarter
rope

●
●
●

48

14. PERIODICAL INSPECTION
Inspection intervals
3 years or
300 hr

1 year or
100 hrStarting
system

0.5 year or
50 hr

After each
operation

Description●
Battery●
V-Belt●Strainer
Primingsystem

●

Pump
unit

Closeddischarge
valvesoperationafter
priming
water.

Discharge Valve

All parts
*1
*2

●

●

MeasureVoltage measure

Charge.

Period of use

Replace.
*1*2

Wear, crack, belt,tensionReplace.
*1

Clogging or broken
mesh
Is not locked.
Checkperformance(-0.08 MPa/-12psi)●●

PrimerInspection items

Clean or replace.
Replace parts if
necessary.*1

Air check

Check pump unit
if necessary.*1

Check
performance(1 MPa/145psi)

Replace parts if
necessary.*1

Vacuum leakage

Replace parts if
necessary.*1●

Replace parts if
necessary.*1

Ask our customer service staff to replace the parts.

・Batteries that have been used for more than three years may
explode if charged.

4915. SERVICE AND MAINTENANCE
GeneralServicing and maintenance of this fire pump must only be carried out by personnel
who have professional related knowledge and who are familiar with this 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 ground.
Safety devices
CAUTION ・ After safety or protective devices have been disassembled aspart of servicing and maintenance work, install them back totheir original locations as soon as possible, making sure thatthey run 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 firepump. Therefore, for safety reasons, use only Tohatsu
genuine parts. Tohatsu bears no responsibility for any
personal injuries or equipment damages that may result
from use of parts 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.

50

15. SERVICE AND MAINTENANCE
Opening the cowl
・ When removing or attaching top cowl, turn thethrottle lever to “High pressure” side.
*The engine has to be stopped.

Throttle lever・ Remove the rear hook from the hole, and remove the
top cowl while taking care not to give damage withthe recoil starter handle.
NOTE

・ It is necessary to remove top cowl
when removing spark plug.
Hooks
フック

Assembling cowl
After putting recoil starter handle through top cowl hole,
put front latch into hole of control panel, and then, fit
rear hook into hole.

NOTE

・ Pay attention to have the starter
handle for manual starting go throughthe window at the front upper side of
the cowl.

51

Latch mounting hole
ラッチ取付け穴

15. SERVICE AND MAINTENANCE
Vacuum pump strainer
Maintenance
NOTE・ Incorrect installation of the strainer may cause a vacuum leak. Be
sure to install the strainer correctly.

Refer to “Chapter 11 MAINTENANCE AFTER OPERATION”
1. Remove the strainer cap, and remove the strainer.
Strainer cap

2. Wash the strainer with fresh water.
3. After washing, assemble the strainer.
Tighten with the strainer cap.

Vacuum pump strainer
caseEngine oil
Check the oil level
CAUTION ・ Confirm the filler cap closed tightly
each time, whenever you check theoil level.

Oil filler cap

Check the oil level after each operation.
1. Place the pump in a horizontal location.
2. Check the oil level.
3. Refill the oil until the “UPPER” level.
NOTE

Upper

・ 4-stroke engine oil
API:

Lower

SH, SJ, SL

SAE: 10W-30/40

52

15. SERVICE AND MAINTENANCE
Vacuum pump V belt
Check the V belt every year or every 100 hours
operating time.
V belt size: M-23

V-beltSpark plug
Check the spark plugs.
1. Remove the plug cap, and remove the plug.
2. Use a wire brush or spark plug cleaner, clean theelectrode of the spark plug.
3. Check the spark plug for excessive carbon deposits,
electrode erosion and check the washer for damage.

Spark plug cap
4. Measure the spark plug gap. If the gap is out ofspecification, replace the spark plug with thespecified spark plug.
Electrode
ElectrodeIf necessary, adjust the gap to the specification.
・ Spark plug gapⓐ : (0.8 ~ 0.9mm /0.03 ~ 0.04in)・ Spark plug

: DCPR6E (NGK)

5. Assemble the spark plug as far as ⓑ by hand.
Tighten the plug further to the specified
torque using a plug wrench. (Ⓒ)
・tightening torque : 18 Nm[1.8 kgf-m]

53

WasherWasher15. SERVICE AND MAINTENANCE
Battery
General safety information
Follow the safety instructions on the battery.
When charging a battery, a highly
oxyhydrogen gas mixture is produced.

explosive

Do not charge a battery in a poorly ventilated place.
Do not smoke 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 would come out
through the air vents.
Disposal
Disused batteries should be disposed of 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 handing the battery, be sure
to wear safety glasses andprotective gloves.

54

15. 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
handling electrical equipment.
・ Disconnect the negative terminal
disconnect the positive terminal.

first,

and・ When connecting battery cables, connect thepositive terminal first, then after connect thenegative terminal.
・ Use the fuse with the same current rating (ampere) asthat of the installed fuse. Using a fuse that has
excessive high resistance may result in electricalequipment failures.
Fuse・ Security fuses are installed in electrical circuits usedin electrical 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 for emergency.

55

Fuse box

15. SERVICE AND MAINTENANCE
Suction 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 overheat of the engine, then wait until it cools down, ordischarge water to cool down the engine.
* The water discharge operation allows the cooling water to circulate to theengine and cool it.
1. Open the drain valves and check the water in thepump has been completely drained.

Example of using asuction port cap

2. Close all the drain valves and close suction port(with a cap, etc.).
*Close the suction port not to leak air into the
pump.
Start
3. Start the engine, and operate the priming lever(Within 30 seconds). Turn the throttle lever
generating vacuum if needed.

Main switch
Priming lever

4. After the vacuum is generated enough (about -0.08
MPa (-12psi)), immediately return the priming leverto the original position, and stop the engine.

Stop

Priming lever56

15. SERVICE AND MAINTENANCE
5. Check that the vacuum pressure of the pressuregauge for suction is about -0.08 MPa (-12psi).

Priming lever

6. In order to check that there is no vacuum leak, leave
it for 30 seconds and confirm that the pointer of thepressure gauge for suction keeps the same pressure
indication. *１
7. Open the drain valves slowly to expose it to theatmosphere, and check that the pointer of thepressure gauge for suction returns to “0”.

OPEN
CLOSE

OPEN

CLOSE
Pump drain valves

8. Close the drain valves.

*１

Air valve for drainage

Vacuum leak check
If the vacuum leak is found, isolate the cause referring to “Chapter 16
TROUBLESHOOTING”. Then take an appropriate action and check the vacuum leakagain.

57

15. SERVICE AND MAINTENANCE
Water leak check1. Attach the suction hose to the suction port.

Suction hose

2. Place the end of the hose into the water more than
300mm (11.8in) deep from the water surface, andthen close the discharge valve handle.

3. Start the engine, and pull the priming lever.

4. Operate the throttle lever to raise the pumppressure almost to 1MPa (145psi), and then check forwater leaks from each part of the pump and thecooling water piping.

Priming lever

Priming outlet

If a vacuum leak is found, isolate the cause referring to “Chapter 16
TROUBLESHOOTING”. Then, take the appropriate action and check the water leakagain.

58

16. TROUBLESHOOTING
Typical causes of engine troubles are listed in the following table.

● ● ●Fuel filter
clogging

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

Fuel tank air
vent clogging

Warning lamp flashing●

Caused by Engine unit

● ● ●Caused by Suction●

Caused by Playpipe
Insufficientwater discharge Caused by Pump unit

Fuel and lubrication● ●Deteriorationof fuelWater suction failure

Vacuum pressure defective

Cause
Fuel shortageAir leaking

Engine seizing

Engine overheat

Engine over-revolution

Poor acceleration

Idling revolution is too highRough idlingEngine stumble or stall

Engine start failure

Starter motor doesn't work

Battery charging failure

TroubleAction●Refuel●●Replace with new
fuel.

●

●

●

Clean out
clogging.

● ● ●

●

●

●

Clean out
clogging.

Fuel pump
failure

● ● ●

●

●

●

Replace.

Fuel pipe kinkor snap

● ● ●

●

●

●

Fix pipe kink or
snap.

Spark plug cap
comes off

● ● ●

●

●

Plug in surely.

Use ofunspecified
spark plug

● ● ●

●

●

Replace withspecified spark
plug.

● ● ●

●

●

Clean or replacewith specified
spark plug.

Electrical

Spark plugfouling (Nospark or weak
spark)
Battery loose
connection,
terminal
corrosion or
expiredBattery
charger
defective

7.5A fuse
blown

●

● ●

●

●

●

●

●

59

Clean terminal
and/ or tighten aterminal screw. If
necessary
replace.
Check 7.5A fuse
and/or Battery
charger. Replace
if necessary.
Replace withspare fuse.
When theblowout of thefuse happens
repeatedly, checka cause.

16. TROUBLESHOOTING
Warning lamp flashing
Floodlight, Gauge lamp, Hour meter,
Warning lamp do not work

Starter motor
defective

Caused by Engine unit

Cause

Insufficient Caused by Playpipe
water
Caused by Pump unit
discharge
Caused by Suction

Water suction failure

Air leaking

Vacuum pressure defective

Engine seizing

Engine overheat

Engine over-revolution

Poor acceleration

Idling revolution is too highRough idlingEngine stumble or stall

Engine start failure

Starter motor doesn't work

Battery charging failure

TroubleElectrical

Check theterminals, cords
and screws. If
necessary,
replace part.

●●

Control panel
defective

Compression

Piston, piston
ring orcylinderexcessively
worn.
Carbondeposition in
combustion
chamber●

Action

●

● ●

●

●

●

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

●●

Correct orreplace.

● ●●Clean out.

Suction height
too high or
length too
long●SuctionSuction hose
end is not inwater
Suction hose
coupling loose
or gasket
defective

60

Make it pumplocation tonearer and lower
position.

● ● ● ●

Put the end ofsuction hose
below 30cm of
the water
surface.

● ● ● ●

Clean out agasket andtighten securely.
Replace a gasket
if necessary.

16. TROUBLESHOOTING
Warning lamp flashing

Caused by Engine unit

Caused by Playpipe

Caused by Pump unit

Caused by Suction

Cause

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

Insufficientwaterdischarge

Water suction failure

Air leaking

Vacuum pressure defective

Engine seizing

Engine overheat

Engine over-revolution

Poor acceleration

Idling revolution is too highRough idlingEngine stumble or stall

Engine start failure

Starter motor doesn't work

Battery charging failure

TroubleActionSuctionPrimer
Water stop valve

Suction hosestrainer
clogged withdead leaf or
waste etc.

●●

Clean out.

Suction hose
cracking or
lining peeling
off

● ● ●

●

Repair or replace.

Vacuum pipeloose orcracking●●

Tighten securely aclump of vacuum
pipe or replace.

Strainer cap
loose or Oring failure.

●●

Tighten securelyor replace.

V beltdamaged or
worn.

●

●

Replace.

Vacuum pumprotor shaft
seizing●Vane, sideplate worn or
damaged●Water stop
valve
contamination.

● ● ●Water stop
valve
diaphragm
failure.

● ● ●

61

Repair or replace.

●

Replace.

Clean out.

Replace.

16. TROUBLESHOOTING

Drain valves
are not closed●

Open securely.

●

Pump

Tighten securely.
Replace gasket if
necessary.

●

● ● ●

Tighten securely.

●

Clean out or
replace.

● ●●Clean or replace.

●

Replace.

● ●NozzleDischarge
nozzlediameter too
large

● ●

GovernorSpray nozzle
CloggedGovernoradjustment outof specified
Governor link
disconnected

Clean out.

●

●

● ●

●

●

●

● ● ●

●

●

62

ActionClose securely.

● ● ●Suction portstrainer
clogged withdead leaf or
waste etc.
Discharge
valve
imperfect
open
Gauge pipe
connector
loose orgasketdefective
Pump coverbolts loose
Pump coverO-ringdegradation
Impeller orguide vanecaught a stone
or damaged
Mechanicalseal damaged

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

Cause

Caused by Engine unit
Insufficient Caused by Playpipe
water
Caused by Pump unit
discharge
Caused by Suction

Water suction failure

Air leaking

Vacuum pressure defective

Engine seizing

Engine overheat

Engine over-revolution

Poor acceleration

Idling revolution is too highRough idlingEngine stumble or stall

Engine start failure

Starter motor doesn't work

Battery charging failure

Trouble●●Change a nozzle
for suitable size or
incorporate safety
nozzle.

●Clean out.
●

Readjust it
securely.

●

Attach it securely.

17. APPENDIX
Tightening torque specifications

Standard Bolt

M3

M4

M5

M6

M8

N·m

0.7

1.6

4

6

13

27

lb·ft

0.5

1.2

3

4

9

20

kgf·m

0.07

0.16

0.4

0.6

1.3

2.7

-

-

-

9

24

47

7

17

34

0.9

2.4

4.7

N·m
Heat Treated Bolt

lb·ft
kgf·m

63

M10

18. TOOL AND STANDARD ACCESSORY
Standard accessory
Description

Remarks

QuantityTool kit1• Tool kit bag

1• Plug wrench

1• Handle of plug wrench

1

Spark plug

DCPR6E

Pumping plate
Fuse *

1
1

7.5A

1

Vinyl pipe

1

Auto battery charger

1*A spare fuse is in the fuse box attached to the pump.

64