⑫ _VE1500-W

OW N ER’S

OWNER’ S MAN UAL

OW N E R’S MAN UAL
M A N UA L

VE1500-W
VE1500W

VE1500-W No.003-12078-1
PORTABLE
FIRE PUMP

PORTABLE
No.003-12078-1

FIRE PUMP
No.003-12078-1

5-4, Azusawa 3-Chome, Itabashi-Ku

Tokyo 174-0051, Japan
Phone : +81-3-3966-3137
Copyright © 2020 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 PUMP
USAGE
TOHATSU fire pump “VE1500W” is manufactured for use in firefighting operations.

This portable fire pump is intended only for 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 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 those stated above.

Note that use the fire pump for applications other than those stated above can result
in personal injury or damage to the equipment.

Using the fire pump within the range of intended uses implies that the user should
follow the instructions provided by the manufacturer relevant to operation, servicing
and maintenance.
Intended people
All persons who operate, service or maintain this fire pump must read and understand
the 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 the
user.
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 fire
pump.
When using the fire pump, conditions under which an explosion may occur are not
considered.

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, and
equipment damage when operating the portable fire pump,
and to maintain faultless operation.
・ Arrange owner’s manual so that operators can refer to them
where they operate the fire pump.
 INTRODUCTION
Thank you for purchasing the TOHATSU Fire Pump.
This fire pump has passed a range of quality assurance standards.

Owner’s manual
The portable fire pump complies with relevant laws and regulations.
The manual includes a description for operation and maintenance. Before using 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 fire
pump.
・ This manual should accompany this fire pump if sold to another
person.
 MANUFACTURER AND AFTER-SALES SERVICE ADDRESS
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 is

marked on the pump casing.
GENERAL SAFETY INFORMATION

Overview
Before operating the TOHATSU fire pump thoroughly
read this manual. Understanding proper operating
procedures including “DANGER”, “WARNING”,
“CAUTION” and “NOTE”.
These notices are designed to bring attention to
very important information necessary to ensure safe,
trouble free operation.

Warning sign meaning

This sign is used for safety-related instructions in
this 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
DANGER 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 maintenance
of 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 retractable handle
and bracket.
・ 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 by all.

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 ・ Wear proper hearing protection
during operation.

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, or
other 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 the
safety devices have been installed in the appropriate positions.
Before removing the safety devices, turn the main switch off.

After protective devices have been disassembled as

part of servicing and maintenance work, immediately
install them back to their original locations, making sure
that they are in safe and secure condition.

Check the portable fire pump visually and functionally

on 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 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 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 stop
the engine.
Disconnect the negative terminal of the battery.
Before starting maintenance work, securely place the portable fire
pump on the ground.
In the case of just after stopping the engine, do not touch the exhaust
pipe, the muffler and the other engine parts until these parts will be
cold 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 the
battery. 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 the
equipment.
Check the electrical equipment of the fire pump on
a regular basis.
Battery
Follow any safety-related instructions shown on the
battery.
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 the
battery electrolyte to leak out from the vent hole.

Handling of fuel
Exercise 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 and
regulations.

Disposal
Dispose of disused batteries according to relevant
laws and regulations.
Genuine parts
When replacing parts for servicing and maintenance of
the portable 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 fire pump. Use genuine Tohatsu parts
only.
Tohatsu bears no responsibility for any personal
injuries or equipment damage 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.
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 substance
Do 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.….…….………..…....………….….…....….…9
5. 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
19. WIRING DIAGRAM……..…….…….…..…….….…….…………….……………65
 1. SPECIFICATIONS

Model VE1500W
Description Portable pump
Max. permissible inclination During transport : 35° at all sides
angle In operation : 15° at all sides
Max. operating pressure
17 bar
P alim
Max. water temperature +60 °C
Temperature range -15 °C to +40 °C ambient temperature
Engine
Manufacturer TOHATSU CORPORATION
Model 2WT81A
Type 2-stroke, water cooled, spark ignition engine
Bore × Stroke 81 mm × 78 mm
Number of Cylinder 2
Piston displacement 804 cm3
Authorized output 60 PS (44 kW)
Fuel type Unleaded petrol RON91
Fuel tank capacity 24 L
Fuel consumption * 22 L/h
Engine 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/5 h , 12 V-18 Ah/10 h
Floodlight bulb 12 V-35 W
Remark: *It is fuel consumption at the time of the standard discharge.

1
 1. SPECIFICATIONS
Model VE1500W
Primer
Type 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
BSP thread 2-1/2” (65mm) male
Discharge port coupling
JIS fire thread (B-9912) 2-1/2” male
BSP thread 4” (100 mm) male
Suction port coupling
JIS fire thread (B-9912) 3-1/2” (90mm)male
2,050 L/min at 6 bar
Pump performance
1,800 L/min at 8 bar
(Suction height: 3 m)
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
Engine
Crankcase, Cylinder,
Aluminum alloy
Cylinder head
Crankshaft Chromium-molybdenum steel
Connecting rod Chromium-molybdenum steel
Piston Aluminum alloy
Pump shaft Chromium-molybdenum steel with metal plating
Muffler Steel and Stainless
Pump
Pump case, Pump cover Aluminum alloy
Impeller Aluminum alloy
Shaft seal
Type Mechanical seal

2
 Performance Curve

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

(VE1500W)

3
7.5m 1m
geodetic geodetic
Suction 6m
1. SPECIFICATIONS

geodetic Suction
height
Suction height
height

Total delivery pressure P (bar)

4.5m 3m
geodetic geodetic
Suction Suction
height height

Delivery flow Q (L/min)

 2. OPERATION DEVICE
⑦ ⑦

⑧ ⑥
⑨
⑩ ⑥

⑤
⑤

① ④
② ③

① Suction port
② Inducer
③ Impeller
④ Starter motor
⑤ Crankshaft
⑥ Piston
⑦ Spark plug
⑧ Cylinder drain valve
⑨ Pump drain valve
⑩ Muffler drain valve

4
 2. OPERATION DEVICE

⑥ ⑥
⑤
⑦
④
⑧

③
③

① Air silencer
② Fuel tank
③ Muffler
④ ECU
⑤ Oil tank
⑥ Discharge valve
⑦ Fuel feed pump
⑧ Injector

5
 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 gauge

①
②
③

① Cylinder drain valve

② Pump drain valve
③ Muffler drain valve

6
 2. OPERATION DEVICE

Oil tank cap

Priming strainer

Priming lever
Floodlight connector
Fuse
Manual starter handle

Battery charger
Exhaust pipe
socket
Muffler
Carrying handle (4) Priming outlet

④
① Hour meter
② 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

Warning

8
 4. OPERATING PRECAUTIONS
Installing pump

CAUTION The fire pump must be installed on level ground. Otherwise, an

accident 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 the
retractable part when operating the
carrying 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 by
Carrying handle
fall.
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 and
will cause severe burns.

9
 4. OPERATING PRECAUTIONS
NOTE Place the pump as near as possible to water source, and water
suction 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 water
suction hose is lower than suction port of the pump.
In case of the suction hose is put undulated, air can be left easily in
the 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
Suction port
The diameter of the thread for fire pump is
BSP thread 4” (100 mm)
JIS thread 3-1/2” (90 mm)

Putting a finger or a hand into the suction port

while the pump is running without installing the
strainer, it may be seriously damaged by the
rotating inducer.

CAUTION Install 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 the
drainage capacity may be decreased
considerably.

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

Carrying handle
CAUTION Personal injuries may occur
when opening or closing the
handle.
Do not put your hands or fingers
into the retractable part when
operating the handle.

11
 5. DESCRIPTION OF DEVICES
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 its original position.

Removing cowl Priming lever

Cowl can be removed by releasing the 4 hooks up.
Hook
NOTE hen removing the cowl, do not use
excessive force, because the hook
may be damaged.

Discharge port
The diameter of the thread for fire pump is Handle
BSP thread 2-1/2” (65 mm)
JIS fire thread (B-9912) 2-1/2” (65 mm)

Discharge valve
Use discharge valve handle for opening and closing the
Thread
discharge valves.

12
 5. DESCRIPTION OF DEVICES
Drain valve
Use the drain valves to drain water

NOTE Close all the valves when operating this

fire pump.
If a valve is opened, water cannot be ⓐ
suctioned. ⓑ
ⓐ Cylinder drain valve ⓒ

ⓑ Pump drain valve

ⓒ Muffler drain valve

Battery charger
Battery charger socket
socket
Connect the battery charger plug to the socket.
<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.
Socket is only for battery. Do not use socket for other
purpose.
Do not connect a cigarette lighter to the socket,
because it is not a heat-resistant object.

Fuel tank
Air vent must be closed any time.
Do not tilt the pump with the air
CAUTION
vent open. Otherwise, the fuel may
leak.
If the fuel leaks, wipe it off using a
cloth or other materials.
Air vent
NOTE There is another air vent installed on
the fuel tank.

13
 5. DESCRIPTION OF DEVICES
Control panel
The control panel is equipped with all the necessary
Throttle dial
operating and control instruments as follows.

Throttle dial
Use the throttle dial to control discharge pressure.
“ ” indicates the throttle position of engine start and
priming.

Pressure gauge for suction

Suction side
The pressure gauge for suction indicates suction water
pressure (negative pressure) and the input pressure
supplied from an external water source.

Pressure gauge for discharge Discharge side

The pressure gauge for discharge indicates the actual

operating discharge pressure.

Operation panel Operation panel

The operation panel is equipped with main switch, all
warning lamps and an hour meter.

Warning lamp and buzzer

Turning the main switch to “ I ” position, the check mode Main switch
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 the
cause referring to the troubleshooting section.

If they do not, remove the cause by Lamp

CAUTION
following “CHAPTER 16
TROUBLESHOOTING”.

14
 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 and

maintenance 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 the
warning buzzer sounds.

The engine does not stop even if the low engine oil level warning
CAUTION
lamp lights up. This is to give priority to the continuation of fire
fighting 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, the Warning lamp (Overheat)
warning buzzer sounds and the engine stops automatically.

NOTE The engine stops automatically when

the 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 battery charging warning
Battery voltage low warning lamp lights up when the
battery voltage decreases below the limit.
Leaving the battery as it is, the battery will deteriorate,
so please charge the battery as soon as possible.

The battery charge warning buzzer Warning lamp (Battery)

NOTE
does not sound.

Main switch
Main switch has three different functions. Main switch

Symbol 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.

Engine oil tank Oil tank cap

Engine 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.
Dipstick
CAUTION Be sure to stop the engine before
checking the oil level. If you pull the
dipstick when the engine is running,
the oil may blow out.
Governor oil filler port

16
 5. DESCRIPTION OF DEVICES
Manual starter
If the engine will not start with the starter motor, use the
manual (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.

To start the engine with manual starter, Manual (recoil) starter

NOTE
engage the manual starter ratchet by
pulling the starter rope slowly. And then
pull the starter handle quickly with great
force from the position in which feeling
harder resistance.

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
automatically turned 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 the
battery after filling it with electrolyte. Refer to the INSTRUCTIONS of the battery.

Fuel
Fill fuel until the maximum level of the gauge indicator (in
Red).

･ 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 it
is hot.
Refill fuel after the engine has cooled down.
Fuel tank cap should be always tightly closed.
Fuel tank cap should be removed only to fill fuel
to 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 other
materials, and dispose of them according to the
relevant laws and regulations.

18
 6. PREPARATION FOR OPERATION
NOTE 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 that contains more than 10% ethanol or more than
5% methanol.
Damages resulting from the use of fuel that contain alcohol are
not covered 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 vent

open. Otherwise, the fuel may leak.
If the fuel leaks, wipe it off using a Air vent
cloth 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 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 of
engine oil.
2-stroke engine oil
We recommend that usi n g engine oil of ISO FB grade or higher.
Engine oil tank capacity : 1.6L

19
 6. PREPARATION FOR OPERATION
Oil 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
Dipstick
Before using fire pump, check governor oil level with the
oil dipstick. To check oil level, remove the dipstick and
check the oil level. The oil level should be between upper
and 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.

Governor oil filler port

Drain valves
Make sure the 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
Warning lamp (Over heat)
If the temperature of the engine rise approximately 90 ºC
or more, the engine will stop automatically to prevent
overheating.

Warning lamp and sensor Main switch

When you turn the main switch to the “ ” position,
warning lamps light up for a moment to enable lamps to be
checked, 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 the
pump, and returned to the water intake of the pump after cooling the engine and
muffler.

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 the
warning lamps are on or blinking, the pump does not work properly.

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

Warning system
Warning indicator

Remedy
High Description of
Alert Warning Engine faults or notice
Battery speed
Oil Overheat buzzer operation
charge ESG
warning warning
warning
lamp lamp
lamp
One One time One time Normal system test
One time
Alert check time flash when main switch
flash flash alert ON. (*2)
Oil level is below
Oil level ON ON
approx. 1/3 A
Engine has stopped
Overheat ON ON Stop due to insufficient B
cooling water, etc.
Warning

Warning of engine
Prior stoppage due to
warning
overheat
ON insufficient coolant, C
etc. is sent in
advance.
Battery Battery voltage is
voltage ON low D
Engine speed
Engine over
speed ON exceeds maximum- E
allowable RPM(*3)
MAT or MAP MAT or MAP failure
Alert (*1)
Flashing
or open circuit F
TPS or WTS TPS or WTS failure
Alert (*1)
Flashing
or open circuit 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 rpm

22
 7. USE OF OPERATION PANEL

Engine
Running Restart
status
80°C Light & Buzzer
ON
90°C Engine Engine can start at less than 120°C and
Overheating
STOP keep running for 30 seconds.
70°C Light & Buzzer
OFF
Over Engine
Engine cannot start
120°C STOP

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 of

engine 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 Main switch

23
 7. USE OF OPERATION PANEL
Hour Meter

DANGER Before removing the electrical equipment, turn

the main switch off and remove the battery.
When removing the battery cable from the
battery terminal, always disconnect the negative
(-) cable first.
When connecting battery cables, connect the
positive (+) 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 the
battery. 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 meter
counts if the main switch is set to the “ ” position.

Hour meter Engine oil

Overheat Battery Main switch

24
 8. STARTING THE ENGINE
Pump Installation
Since the temperature around the engine
becomes high because of the muffler and exhaust
gas, 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 a
deadly 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 the
vehicle, warehouse, tunnel, well, in the hold of a
ship.
Do not start engine with discharge valve opened.
Do not pump and discharge liquids other than
water (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 be
seriously 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 and
the 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 a
basket at the tip.
3. When water is discharged through branch pipe and nozzle, following diameter of
nozzles 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 Main switch
the engine after the engine stopped due to lack of gas,
bleed air from the fuel line.

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 and
remove 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 high

voltage 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 if
necessary.

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. Main switch

Release the main switch immediately after the engine
starts.

When the starter motor is operated for a long time continuously, the
NOTE
power of the battery will be exhausted. The maximum time for
starting 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 “ ” mark
position.
3. Engage the manual starter ratchet by
pulling the starter rope slowly. And
then pull the starter handle quickly
with great force from the position in
which 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 to
the 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 water
temperature becomes high.

Discharge water promptly. If the water discharge valve is kept

CAUTION
closed, the water temperature inside the engine rises and the
engine 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,

the pump 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 the
suction 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 the
priming outlet of the vacuum pump and check
pressure 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 the
pump cannot suction water within 30 seconds, it may have been
caused by another problem.
Refer to “Chapter 16 TROUBLE SHOOTING” to rectify the problem

4. Open the discharge valve.

Open
Open

Check that the nozzle is ready to

CAUTION
discharge water before opening the
discharge valve.

NOTE In order to avoid the occurrence of air

pockets, connect the suction hose to Nozzle
the pump so that the pump is on
upward location 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, the
pump may not be able to discharge the
water 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
 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
to remove 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,
check the water pressure from fire hydrant with suction pressure gauge on the
pump and adjust the opening of fire hydrant, if necessary.

In the case of water pressure from fire hydrant is higher than 6

CAUTION
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
discharge pressure, 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.
6. If the water pressure from fire hydrant is insufficient, start the engine and adjust the
pressure 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 stop
the engine, and close the fire hydrant on-off valve.

CAUTION Be 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 is
closed.

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
In the case of relay pumping
CAUTION Discharge
operations training in a flat
port adaptor
place, if the number of
extending hose is less than ten,
use the Safety nozzle attached.
Packing

Pumping plate
(Standard accessory)
Part No.151-39045-1

Description of relay pumping operation

Water Water Water

supply supply supply

Fire nozzle

Source pump Relay pump Relay pump Relay pump

Water Suction pressure Suction pressure

source Suction pressure Suction pressure

32
 9. PRIME AND DISCHARGE
Preparation for operation

Never close the discharge valve of source pump and the relay
pump(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 hoses with 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
for next 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
to water or air.
3. When the water is supplied to the pump, check the pressure of the gauge. Start the
engine when it is lower than the decided pressure. If the pressure is higher than the
decided 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
pressure gauge.
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 the
throttle.
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 ENGINE
Do not touch the exhaust pipe and the muffler
CAUTION
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 “ ” position.

NOTE It takes one to three seconds until the

engine stops due to the after burn
control. This is a shut off behavior by an
anti-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) in order 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 pump
has been completely drained.

Open
2. Close all the drain valves and install the suction port cap.

Close
NOTE Prepare a suction cap that is suitable
for the suction coupling.

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 the

priming lever to the original position, and stop the
engine.

5. Check that the vacuum pressure of the pressure gauge

Pressure gauge for suction
for suction shows below -0.8 bar.

6. In order to check that there is no vacuum leak, leave it

for 30 seconds and confirm that the pointer of the
pressure gauge 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 for
suction returns to “0”. Open

8. Close the drain valves.

Close

37
 11. MAINTENANCE AFTER OPERATION
Fuel and Oil Supply
1. Fuel
Fill fuel until the maximum level of the gauge indicator
(in red).
Fuel tank capacity: 24L

Do not tilt the pump with the air

CAUTION
vent open. Otherwise, the fuel
may leak. Gauge indicator
If the fuel leaks, wipe it off using a
cloth or other materials.

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 FB grade

or higher.

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

NOTE Use 2-stroke engine oil of ISO FB grade

or higher.
The oil should be the same oil with the
engine oil.

Governor oil filler port

38
 11. MAINTENANCE AFTER OPERATION
Cleaning strainer for priming water Ring nut
Remove the ring nut and clean the strainer with fresh
water. If the strainer is dirty with dust, etc., vacuum Cup
performance efficiency will be reduced. O-ring

Strainer

NOTE When assembling the strainer, tighten

the ring nut while holding and pushing
slightly 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

CAUTION Use 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 prevention function.
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 socket.

Doing so may melt or burn out the socket due to overheating.

NOTE If the switch is set to the “ ” position, the battery cannot be charged
because the charging circuit is turned OFF.

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

40
 12. MAINTENANCE IN COLD CONDITION
Infuse antifreeze

If the temperature around the pump could be subzero, the pump

CAUTION
inside may freeze up. It may cause not only the damage in the
pump, 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.

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

4. Insert the vinyl pipe in the container filled with anti-

freezing 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 the 1
strainer cup① of the primer, remove the strainer ③ 3
and strainer cup ①.
2. Inject antifreeze (undiluted 50 ml) to strainer guide. 2

3. After injection, assemble the strainer cup ① and

strainer ③, and tighten the ring nut ②.
Antifreeze
50 ml

Strainer guide

42
 12. MAINTENANCE IN COLD CONDITION
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.

When you install a strainer, pay attention to the protrusion of the O-

ring 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.

When charging batteries, be sure to use an

CAUTION
automatic battery charger dedicated to sealed
batteries.
Use an automatic battery charger that matches the
battery specifications. Use of a mismatched
automatic battery charger may cause the battery to
explode.
Keep the battery surface clean.
Battery life is normally 2~3 years even if battery is
used properly. Replace with new battery every 2~3
years checking the deterioration of the charging
performance.
When connecting battery cables, positive (+) lead
shall be connected first.
(When disconnecting battery, remove the negative
(–) lead first.)
Battery electrolyte is a very caustic acid, which will
cause severe burns to your skin and damage to
clothing.
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

When the pump is operated using a discharge nozzle that has a

NOTE
nozzle diameter greater than the maximum nozzle diameter, or
without using a discharge nozzle, be sure to use the pumping plate.
Otherwise the pump may break down due to cavitation or may
overheat due to lack of 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,

Discharge
such as pumping water out of a cellar, pumping plate port adaptor
must be installed to avoid engine overheating caused
by lack of cooling water.
Install the pumping plate between the discharge port
adaptor and the packing as shown in the figure on the Packing
right. With the pumping plate in place, the pump can
be operated without a discharge nozzle, so that Pumping plate
pressure for cooling water in pump is maintained at (Standard accessory)
certain level. Part No.151-39045-1

45
 14. PERIODICAL INSPECTION
Perform periodical inspections and maintenance according to the following
procedures.

Inspection intervals

operation
After each
or 50 hr
0.5 year
100 hr
1 year or
300 hr
3 years or
Description Inspection items Measure

Impurities
● (ie. Water and / Clean out
or waste)
Fuel filter Replace *1
Impurities Check high
(If water has pressure filter, fuel
● accumulated to tank and portable
filter) fuel tank.

● Fuel level Refuel

Preservation
Fuel System ● period 6 month Replace *1
or more
Fuel Degradation
● (ie. Stink or Replace *1
color)
Impurities
● (ie. Water and /or Replace *1
water)
Curling, crack,
Fuel hose ●
leakage Replace *1
High-pressure ●
— Replace *1 *2
fuel filter Replace
Ignition Spark plug ● Fouling, wear, gap Clean or replace
･ Is not locked
･ Proper Replace parts
Cranking ● compression if necessary *1
pressure
Engine
Engine oil ● Oil level Refill the same oil
Oil level with oil
Governor oil ● Refill
dipstick
Starter rope ● Wear, damage Replace *1
Starting ● Voltage measure Charge
System Battery ●
Period of use Replace *1, 2
Replace

46
 14. PERIODICAL INSPECTION
Inspection intervals

After each
or 50 hr
0.5 year
100 hr
1 year or

300 hr
3 years or
operation
Description Inspection items Measure

Wear, crack, belt

V-Belt ● Replace *1
tension

Clogged or broken
Strainer ● Clean or replace
mesh
Priming ･ Is not locked
system ･ Check Replace parts if
●
performance necessary *1
Primer (-0.8 bar)
Check pump unit if
● Air check
necessary

Closed
discharge
Check performance Replace parts if
valves operation ●
Pump unit (10 bar) necessary *1
after priming
water

*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
General
Servicing 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 and
regulations 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 and
maintenance 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 fire
pump. 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 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 with
environmental 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.

Remove the cowl carefully without

CAUTION
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. (2
places)
2. Through the vacuum pump lever, fit the plug to the
hook (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 the
ring nut ② while holding the strainer cup ①. 1
Remove the strainer cup ③ and the strainer ①. 3
2. Wash the strainer ① and the strainer cup ③.
2
3. After washing, assemble the strainer cup ③ and
strainer ①, tighten with the ring nut②.

49
 15. SERVICE AND MAINTENANCE
Engine oil
Check the oil level.

CAUTION Install the filler cap tightly each time

you check the oil level.
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.

NOTE 2-stroke engine oil

We recommend that you use the

engine oil of ISO FB 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. Upper
3. Insert the oil dipstick completely.
4. Pull out the oil dipstick again, and check the
Lower
oil level.

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. Plug cap

2. Use a wire brush or spark plug cleaner, clean the

electrode of the spark plug ②.

3. Check the spark plug for excessive carbon deposit,

electrode ② erosion and check the washer ③
for damage.

4. Measure the spark plug gap ⓐ. If the gap is out of

specification, replace the spark plug with the
specified 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
 15. SERVICE AND MAINTENANCE
Battery

General safety information

Follow the safety instructions on the battery.
When charging batteries, a highly explosive oxyhydrogen
gas mixture is produced.
Never 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 may
be discharged from the air
vents.

Disposal
Disused batteries should be disposed of according to
local laws or regulations.

After each operation using the battery, check the

voltage. 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, be
sure to wear safety glasses and
protective 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 handling
electrical 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) as

that of the installed fuse. Using a fuse that has
excessively high resistance may result in electrical
equipment failures.

Fuse
Security fuses are installed in electrical circuits used in
electrical equipment.
Before replacing the fuse, isolate the cause of the
short 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
Limit continuous operating time of the vacuum pump to 30
CAUTION
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 to
circulate to the engine and cool it.

1. Close (Cap) the suction port and then start the engine.

Close the suction port

2. Pull the priming lever to run the primer (vacuum Priming lever
pump), and check that the pressure gauge for
suction pointer reads approximately -0.8 bar.

54
 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 leak
again.

Water leak check

1. Connect one end of the suction hose to the suction Close
port, put the other end of the hose in water, and
then close discharge valve handle.

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

3. Operate the throttle dial to raise the pump pressure

almost to 1 M P a ( 10 bar), and then check for
water leaks from each part of the pump and the
cooling 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.

Battery charging failure

Starter motor does not work
Engine start failure
Engine stumble or stall
Rough idling
Idling is too high
Poor acceleration
Engine over-rev.
Engine over heat
Engine seizing
Vacuum pressure defective
Air leaking
Water suction failure

water discharge
Insufficient

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

Caused by suction
Caused by pump unit
Caused by playpipe
Caused by engine unit
Action

Cause
Fuel shortage ● ● ● ● Refuel.
Deterioration Replace with new
● ● ● ● ● ●
of fuel fuel.
Fuel tank air
vent clogging
● ● ● ● ● ● Clean the air vent.
Fuel and lubrication

Fuel filter clogging ● ● ● ● ● ● Clean the filter.

Fuel pump failure ● ● ● ● ● ● Replace.

Injector failure ● ● ● ● ● ● Replace.

Fuel pipe kink or Fix routing of the
● ● ● ● ● ●
snap pipe.
Throttle dial at Set dial to “ ”
other than “ ” ●
position position.

Replace oil filter. (Do

Oil filter clogging ● ● ● ● not fill it up with the
different brand of oil.)

56
 16. TROUBLESHOOTING

Battery charging failure

Starter motor does not work
Engine start failure
Engine stumble or stall
Rough idling
Idling is too high
Poor acceleration
Engine over-rev
Engine over heat
Engine seizing
Vacuum pressure defective
Air leaking
Water suction failure

water discharge
Insufficient

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

Caused by suction
Caused by pump unit
Caused by playpipe
Caused by engine unit
Action

Cause
Spark plug cap
● ● ● ● ● Plug in surely.
comes off
Use of
Replace with specified
unspecified spark ● ● ● ● ● ● ●
spark plug.
plug

Spark plug
Clean or replace with
fouling (No spark ● ● ● ● ●
specified spark plug.
or weak spark)
Electrical

Check wire connection.

ECU and/or Plug in surely.
● ● ● ● ● ● ● ● ●
Sensors failure Replace parts if
necessary.
Battery loose
Clean terminal and/ or
connection,
tighten a terminal screw.
terminal ● ● ●
Replace parts If
corrosion or
necessary.
expired
Check 5A fuse and/ or
Battery
battery charger.
charger ● Replace parts if
defective
necessary.

57
 16. TROUBLESHOOTING

Battery charging failure

Starter motor does not work
Engine start failure
Engine stumble or stall
Rough idling
Idling is too high
Poor acceleration
Engine over-rev
Engine over heat
Engine seizing
Vacuum pressure defective
Air leaking
Water suction failure

water discharge
Insufficient

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

Caused by suction
Caused by pump unit
Caused by playpipe
Caused by engine unit
Action

Cause
Replace with spare
fuse.
When the blowout of
15A fuse blown ● ● the fuse happens
repeatedly, check a
cause.
15A: Battery cable
reverse connection,
operation panel
5A fuse blown components and
Electrical

●
search light connector
5A: Charging connector

Check terminals,
Starter motor cords and screws.
defective ● Replace parts if
necessary.

Check input of starter

solenoid. (Equal to
Operation panel
Operation panel
defective ● ● ●
output.) Replace parts
if necessary.

58
 16. TROUBLESHOOTING

Battery charging failure

Starter motor does not work
Engine start failure
Engine stumble or stall
Rough idling
Idling is too high
Poor acceleration
Engine over-rev
Engine over heat
Engine seizing
Vacuum pressure defective
Air leaking
Water suction failure

water discharge
Insufficient

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

Caused by suction
Caused by pump unit
Caused by playpipe
Caused by engine unit
Action

Cause
Piston, piston
Compression

ring or cylinder ● ● ● ● ● ● Correct or replace.

excessively worn.

Carbon
deposition in the ● ● ● ● Clean out.
combustion
chamber

Suction height Place the pump to

too high or ● nearer and/or lower
length too long position.

Suction hose Put the end of suction

end is not in ● ● ● ● hose below 30cm of the
water water surface.
Suction hose Clean out a gasket
Suction

coupling loose and tighten securely.

● ● ● ●
or gasket Replace a gasket if
defective necessary.
Suction hose
strainer
clogged with ● ● Clean out.
dead leaves or
waste etc.
Suction hose
cracking or ● ● ● ● Repair or replace.
lining peeling off

59
 clump of vacuum pipe

Tighten securely or
Tighten securely a

Repair or replace.
Action

or replace.

Clean out.
Replace.

Replace.

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

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

60
●

●
Engine seizing
Engine over heat
Engine over-rev
Poor acceleration
Idling is too high
Rough idling
Engine stumble or stall
Engine start failure
Starter motor does not work
Battery charging failure

worn or damaged

diaphragm failure
loose or cracking

Water stop valve

Water stop valve

or O-ring failure

Vane, Side plate

V belt damaged

contamination
Vacuum pump
Trouble

Vacuum pipe

Strainer cap

rotor shaft
Cause

or worn

seizing
loose
Primer Water stop valve
 16. TROUBLESHOOTING

Battery charging failure

Starter motor does not work
Engine start failure
Engine stumble or stall
Rough idling
Idling is too high
Poor acceleration
Engine over-rev
Engine over heat
Engine seizing
Vacuum pressure defective
Air leaking
Water suction failure

water discharge
Insufficient

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

Caused by suction
Caused by pump unit
Caused by playpipe
Caused by engine unit
Action

Cause
Three drain valves ● ● ● Close securely.
are not closed
Suction port
strainer clogged
● ● Clean out.
with dead leaves
or waste etc.
Discharge valve ● ● Open securely.
imperfect open
Gauge pipe Tighten securely.
connector loose or Replace a gasket if
Pump

● ● ●
gasket defective necessary.
Pump cover bolts ● ● ● ● Tighten securely.
loose

Pump cover O- Clean out or

● ●
ring degradation replace.
Impeller or Guide
vane caught a ● ● Clean or Replace.
stone or damaged
Mechanical seal ● ● Replace.
damaged

61
 Incorporate safety
Change the nozzle
for suitable size or

Adjust it securely.

Attach it securely
Action

Clean out.
nozzle.

Warning lamp flashing

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

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

62
Engine seizing

● ●
Engine over heat
Engine over-rev

● ● ● ●
Poor acceleration
Idling is too high

●
Rough idling
Engine stumble or stall
Engine start failure

●
Starter motor does not work
Battery charging failure

adjustment out of
Discharge nozzle

specified range

disconnected
Governor link
Trouble

Spray nozzle

Governor
Cause

too large

clogged
Nozzles Governor
 17. APPENDIX
Tightening torque specifications

M3 M4 M5 M6 M8 M10
N·m 0.7 1.6 3 6 13 27
Standard Bolt lb·ft 0.5 1.2 2 4 9 20
kgf·m 0.07 0.16 0.3 0.6 1.3 2.7
N·m 9 24 47
Heat Treated Bolt lb·ft - - - 7 17 34
kgf·m 0.9 2.4 4.7

63
 18. TOOL AND STANDARD ACCESSORY
Standard accessory
Description Quantity
Tool kit 1
・Tool kit bag 1
・Plug wrench 1
・Handle of plug wrench 1
Spark plug (BPR7HS-10) 1
Pumping plate 1
Fuse *15A 1
Fuse *5A 1
Vinyl pipe 1
Search Light (4P) (Floodlight) 1

Battery charger 1

* Spare fuses are attached to fuse box.

Spare fuses

Special tool

Description
Puller
Magneto puller assy
Impeller puller
Spring pin tool A
Spring pin tool B
Friction measuring tool

64
19. WIRING DIAGRAM

65
⑫ _VE1500-W

OW N ER’S

OWNER’ S MAN UAL

OW N E R’S MAN UAL
M A N UA L

VE1500W
VE1500-W

VE1500-W No.003-12078-1
PORTABLE
FIRE PUMP

PORTABLE
No.003-12078-1

FIRE PUMP
No.003-12078-1

5-4, Azusawa 3-Chome, Itabashi-Ku

Tokyo 174-0051, Japan
Phone : +81-3-3966-3137