TOHATSU VF53AS, Owner'S Manual

Page 1: ...TOHATSU PORTABLE FIRE PUMPS OWNER S MANUAL Model VF53AS VF63AS R Original instructions TOHATSU CORPORATION Date of print 2018 02 Date of publication 2018 02 003 12076 0 AH1 ...

Page 2: ...Copyright 2016 Tohatsu Corporation All rights reserved No part of this manual may be reported or transmitted in any from or by any means without the express written permission of Tohatsu Corporation ...

Page 3: ... of the fire pump bears no responsibility for any damages that may result from modification of the fire pump without prior permission from the manufacture improper use of the fire pump or use of the fire pump for applications other than 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 fi...

Page 4: ...essional knowledge which is required for his her assignment he she must undergo relevant training or receive appropriate instructions from an individual who is actually knowledgeable in operation of the fire pump A person who does not have enough knowledge is not permitted to operate the fire pump When using the fire pump conditions under which an explosion may occur are not considered Keep the ma...

Page 5: ...regulations The manual includes descriptions for operation and maintenance Before using the fire pump be sure to read and understand the manual thoroughly Engine operation The manual also includes descriptions for operation and maintenance of the engine The manual is an important item that goes with your portable fire pump The manual should accompany the fire pump if sold to another person NOTE ...

Page 6: ... following boxes This will be useful when you inquire about servicing repairs or genuine parts TOHATSU CORPORATION Address 3 5 4 Azusawa Itabashi ku Tokyo JAPAN FAX 81 3 3966 2951 Phone 81 3 3966 3137 Serial Number Identification Number The pump identification number is marked on the adapter discharge valve ...

Page 7: ...ve could result in severe personal injury or death Failure to observe could result in personal injury or property damage The instruction provides special information to facilitate the use or maintenance of the pump or to clarify important points For attaching position of the warning label refer to the contents 3 LABELS Warning labels should be read clearly at any time If the display of the warning...

Page 8: ...hase a new pump it is placed in a 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 Wear proper hearing protection during operation Exhaust gas Exhaust gas emitted from the engine contains carbon monoxide CO etc that may seriously...

Page 9: ...ts or other reproductive harm These exposures can occur in and around oil fields refineries chemical plants transport and storage operations such as pipelines marine terminals tank trucks and other facilities and equipment For more information go to www P65Warnings ca gov petroleum Safety devices Before operating the portable fire pump be sure to check that all the safety devices have been install...

Page 10: ...aust 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 Safety devices After protection devices such as muffler guard have been disassembled as part of servicing and maintenance work install them back as soon as possible to their original positions and make sure that they are in safe secure condition Check the...

Page 11: ...he negative Do not place any metal on the top of or around the battery Doing so many causes 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 While the engine is running do not touch the high voltage ignition wire attached to spark plug This wire carries very high volt...

Page 12: ... 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 Disposal Dispose the disused batteries according to relevant laws and regulations ...

Page 13: ...njuries 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 fuel only in the specified container When disposing of parts follow the correct disposal procedure Water prohibiting substance...

Page 14: ...rk of the portable fire pump contact our Customer Service Address 3 5 4 Azusawa Itabashiku Tokyo JAPAN FAX 81 3 3966 2951 Phone Service 81 3 3966 3380 Email tohatsu pservice tohatsu co jp Overseas section fire protection sales department 81 3 3966 3137 bousaiex tohatsu co jp ...

Page 15: ...6 8 STARTING THE ENGINE 34 9 PRIME AND DISCHARGE 38 10 STOPPING THE ENGINE 49 11 MAINTENANCE AFTER OPERATION 50 12 MAINTENANCE IN COLD CONDITION 56 13 USE OF ACCESSORY 59 14 PERIODICAL INSPECTION 61 15 SERVICE AND MAINTENANCE 63 16 TROUBLESHOOTING 74 17APPENDIX 80 18 TOOLS AND STANDARD ACCESSORY 81 19 WIRING DIAGRAM 82 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 ...

Page 16: ...5 gal US h Engine oil API SF to SM SAE 10W 30 40 Engine oil tank capacity 1 9 L 0 50 gal US When replacing oil filter 2 0 L 0 53 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 Electronic fuel injection Battery 12 V 16 Ah 5 h Floodli...

Page 17: ...mp performance Suction height 1 m 1 2 m 3 min at 0 6 MPa 87 psi 0 95 m 3 min at 0 8 MPa 116 psi Dimensions and weight Length x Width x Height 670 790 740 mm 26 4 31 1 29 1 in Mass DRY 101kg 223lbs 102 5kg 226 lbs 1 Twin outlet standard Materials Engine Crankcase Cylinder Cylinder head Aluminum alloy Crankshaft Steel Connecting rod Aluminum alloy Piston Aluminum alloy Pump shaft Chromium molybdenum...

Page 18: ...7 0 5 0 6 0 8 1 1 L min 1 1000 m 3 min 1000 800 600 1200 Delivery flow Q gal US min 150 300 250 200 350 160 140 120 100 80 60 Total delivery pressure P psi １ １ ２ ２ ３ ３ ４ ４ ５ ５ ６ ６ ７ ７ ８ ８ ９ ９ 10 10 11 11 12 12 13 14 15 16 17 18 13 14 15 16 17 18 19 19 ...

Page 19: ...ion knob Control panel Fuel tank Fuel tank cap Carrying handle Floodlight projector and battery charging socket Oil level gauge Engine oil tank cap Bottom cowl Top cowl Vacuum gauge Pressure gauge Main switch Throttle dial １ １ ２ ２ ３ ３ ４ ４ ５ ５ ６ ６ ７ ７ ８ ８ ９ ９ 10 10 11 11 12 12 13 14 15 16 17 18 13 14 15 16 17 18 19 19 ...

Page 20: ...lve Latch for top cowl Discharge valve s drain Cooling water strainer Vacuum pump strainer Muffler Muffler drain valve Air valve for drainage Pump drain valve Suction hose coupling cap １ １ ２ ２ ３ ３ ４ ４ ５ ５ ６ ６ ７ ７ ８ ８ ９ ９ 10 10 11 11 12 12 13 14 15 16 17 18 13 14 15 16 17 18 19 19 ...

Page 21: ...eration part from VF53AS 2 Warning lamp Main Start switch Control panel Stop switch Operation mode switch Priming water mode switch Throttle dial １ １ ２ ２ ３ ３ ４ ４ ５ ５ ６ ６ ７ ７ ８ ８ ９ ９ 10 10 11 11 12 12 13 14 15 16 17 18 13 14 15 16 17 18 19 19 ...

Page 22: ...7 LABEL 3 3 Label Danger Fuel Warning Exhaust gas Instruction label Operation procedure label １ １ ２ ２ ３ ３ ４ ４ ５ ５ ６ ６ ７ ７ ８ ８ ９ ９ 10 10 11 11 12 12 13 14 15 16 17 18 13 14 15 16 17 18 19 19 ...

Page 23: ...n the hose and possibly cause suction inability when the water discharge valve is opened In case of the suction inability due to air remaining in the suction hose set the water discharge valve half opened and operate vacuum pump until water is discharged continuously More operation of vacuum pump for 3 to 5 seconds from beginning of water discharge Be sure to install strainer and basket at the end...

Page 24: ...ransporting 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 on each to avoid falling down the pump When lowering the portable fire pump to the ground lower it gently and horizontally Do not touch the exhaust pipe and the muffler while the engine is running or for more than 10 minutes after the eng...

Page 25: ...fingers into the retractable part when operating the handle To prevent injuries two persons should work together when carrying and placing the pump Opening cowl 1 Lift the latch up on the rear side and remove the cowl 2 Remove the cowl latch from the plate at the front side of the pump 3 Remove the cowl 5 CAUTION Carrying handle Carrying handle Cowl latch Plate １ １ ２ ２ ３ ３ ４ ４ ５ ５ ６ ６ ７ ７ ８ ８ ９ ９ ...

Page 26: ...SP thread 4 100 mm if you insert your finger into the suction port while the pump is running you may be seriously injured by the spinning inducer A strainer must be installed at the suction port Do not run the pump if the strainer is not installed If the pump is running without the strainer gravel may enter the pump and causes significantly reduced water discharge capacity 5 Thread Suction port CA...

Page 27: ...__ Ball cock discharge valve __________ Drain valve Use the drain valves to drain water from the pump Drain valves at the pump case at the muffler from the engine Air intake valve to assist drainage at the ball cock discharge valves Only for ball cock discharge valve type 5 Valve air for drain Valve Muffler Valves Pump case Valve for ball valve Thread Handle Handle １ １ ２ ２ ３ ３ ４ ４ ５ ５ ６ ６ ７ ７ ８ ８ ...

Page 28: ...the fuel tank cap all the time except refuel Engineoil 1 Check the engine oil level before engine start 2 To confirm the engine oil level correctly keep the engine stopped for more than 24 hours After that check the oil level 3 Refill appropriate amount of oil to the oil pan 4 Close the Oil tank cap all the time except filling Fill the 4 stroke engine oil 5 NOTE Priming knob Fuel tank cap Filler c...

Page 29: ...mode starts The warning lamps turn on and the warning buzzer sounds for a moment while the check mode operates If the lamp and buzzer check mode would show failure refer to Chapter 16 TROUBLESHOOTING to eliminate the cause Remove the cause of failure by following Chapter 16 TROUBLESHOOTING 5 VF53AS Auto priming switch Main switch Warning lamp Throttle dial VF63AS R Throttle dial Main switch Warnin...

Page 30: ...ontinuously when the main switch is at ON position In case of oil pressure switch is defective or the circuit is disconnected the warning lamp blinks slowly when the main switch is turned on In the case of slow blinks or lighting take countermeasures following Chapter 16 TROUBLESHOOTING The lamp turns on and warning buzzer sounds instantaneously when the main switch is turned on is normal The lamp...

Page 31: ...ake countermeasures first following Chapter 16 TROUBLESHOOTING The engine stops automatically when the overheated is detected The lamp turns on and sounds when the main switch is turned on is normal The lamp turning on instantaneously shows the system check operation is done Main switch VF53AS Main switch position and function Description Function OFF To stop the pump running ON Running position S...

Page 32: ...dicates the actual operating water pressure Pressure gauge for suction The pressure gauge for suction indicates the suction side water pressure and the input pressure supplied from an external water source Manual starter In case of the battery is not sufficiently charged to start the engine use the manual starter to start the engine Do not pull the manual starter handle when the pump is running Pe...

Page 33: ... after the main switch turned to STOP position once the alarm lamp will go off reset The alarm buzzer will not sound either Precautions for restarting after the overheat prevention device is actuated Resolve the cause of the abnormally high cooling water temperature and then restart the engine If the cause of the abnormally high cooling water temperature has not been resolved the engine will stop ...

Page 34: ...tery after filling it with electrolyte Maintenance free battery Refer to the INSTRUCTION of the battery Battery charger socket Connect the battery charger plug to the socket to charge the battery of the pump Specifications of accessory socket Voltage DC12V Max allowable current 5A Before charging the battery turn off the main switch When starting operation be sure to remove the battery charger bef...

Page 35: ... use a manual starter Do not pull the manual starter handle when the pump is running Personal injuries may occur Otherwise the manual starter may be damaged When you start the engine using the manual starter engage the starter ratchet by pulling the starter rope slowly toward you Then pull the starter rope fast at once at a breath 5 CAUTION Fuse box Manual starter handle NOTE １ １ ２ ２ ３ ３ ４ ４ ５ ５ ６...

Page 36: ...Loosen the adjust screw and pull up the floodlight projector to adjust its height After the adjustment is completed tighten the adjust screw Secure enough lighting for the location where the fire pump is operated otherwise an accident may occur 5 CAUTION Floodlight connector １ １ ２ ２ ３ ３ ４ ４ ５ ５ ６ ６ ７ ７ ８ ８ ９ ９ 10 10 11 11 12 12 13 14 15 16 17 18 13 14 15 16 17 18 19 19 ...

Page 37: ...er stopping the engine do not touch it while it is hot Refill fuel after the engine has cooled down Close the fuel tank cap tightly Remove the fuel tank cap only in the case of filling fuel to the tank or checking inside of the tank Properly clean out all spilled fuel checking for gasoline vapor before starting engine If petrol or fuel spills wipe it off using a cloth or other materials and dispos...

Page 38: ...he limited warranty Keep fuel tank full with gasoline at all times to ensure readiness Engine oil Before using the pump fill it with the designated amount approximately 1 9L 0 50gal US of 4 stroke engine oil Fill the engine oil until Upper level If the engine oil is not enough filled turning switch ON then the warning buzzer sounds Always wipe off spilled engine oil Check the engine oil level befo...

Page 39: ...our local sales representative 4 stroke engine oil Use engine oil shown below SAE 10W 30 40 of SF SG SH SJ SL and SM series of API classification Engine oil pan capacity 1 9 L 0 50 gal US Drain valves Make sure to close all the drain valves and the air valve 6 NOTE Drain valve For ball cock discharge valve Air valve Close Close Close Open Close １ １ ２ ２ ３ ３ ４ ４ ５ ５ ６ ６ ７ ７ ８ ８ ９ ９ 10 10 11 11 12 12...

Page 40: ...ischarge valve __________ It is possible to lock the direction of the valve by tightening the lock positioning bolt Do not change the direction of the water discharge valves if the lock bolt is tightened 6 NOTE Close Close Lock bolt Close Close １ １ ２ ２ ３ ３ ４ ４ ５ ５ ６ ６ ７ ７ ８ ８ ９ ９ 10 10 11 11 12 12 13 14 15 16 17 18 13 14 15 16 17 18 19 19 ...

Page 41: ...ning for refueling Throttle dial Warning for engine trouble Warning for engine overheat Priming water mode switching display Throttle opening indicator Warning lamp Warning lamp Auto priming switch Throttle dial Throttle Suction position Throttle Start Low pressure position Main switch Warning for unable to suction water or start engine １ １ ２ ２ ３ ３ ４ ４ ５ ５ ６ ６ ７ ７ ８ ８ ９ ９ 10 10 11 11 12 12 13 14 1...

Page 42: ...rheat prevention device Warning for unable to suction water or start engine Light on Unable to suck up water Water suction is not complete within 30 seconds in automatic water suction mode Priming water mode switching display Display for chosen water suction mode Light off Auto Slow blinking Manual Throttle opening indicator Shows throttle opening level 9 steps Switch Stop switch Stop engine Power...

Page 43: ...onnection Stop the engine contact the dealer Overheat Light on Overheat prevention device operates Eliminate the cause of cooling water shortage Then after start the engine again Unable to suck up water completely Light on Sucking water is not completed within 30 seconds Refer to Chapter16 TROUBLESHOOTING Eliminate the cause of failure Then after start the engine again Inability of starting Light ...

Page 44: ...g Engine failure warning lamp Light on Throttle opening indicator Blink alternately between odd and even numbered Buzzer Continuous sound Low speed ESG Operate Engine speed is controlled at around 2800r p m Faulty part Electronic throttle Motor malfunction sensor failure disconnection Remedy Stop the engine contact the dealer 7 １ １ ２ ２ ３ ３ ４ ４ ５ ５ ６ ６ ７ ７ ８ ８ ９ ９ 10 10 11 11 12 12 13 14 15 16 17 1...

Page 45: ...usly sound It is normal because these are system check operation when starting the system 1 Light Continuous sound Fuel level in tank is below approximately 1 3 A Slow blinking Continuous sound ON Engine oil pressure drops 2 B Light Continuous sound Stop Engine stops due to insufficient cooling water 3 C Slow blinking Continuous sound Stop Engine stops if it is unable to perform suction water comp...

Page 46: ...ngine starts running Remedy A Replenish fuel B Inspect the amount of engine oil if it is below the designated level replenish oil If the designated oil level is satisfied consult with the sales representative Check the engine oil level before engine start To confirm the engine oil level correctly keep the engine stopped for more than 24 hours After that check the oil level C Correct the cause of c...

Page 47: ...es the setting temperature of approximately 80 C it sounds buzzer alarming and the warning lamp lights In the case of water temperature reaches the setting temperature of approximately 90 C or higher it sounds buzzer alarming the warning lamp lights and automatically stops the engine Status of the alarm after the overheat prevention device actuated 1 If the engine is restarted while the main switc...

Page 48: ...estarted After eliminating the cause of overheating and solving the problem restarting the engine pump up water and discharge water then the cooling water temperature in the engine goes down and then the warning lamp turns off and the warning buzzer stops Do not repeatedly restart the engine without resolving the cause of the abnormally high cooling water temperature Closed Circulating Water Cooli...

Page 49: ...a water pump Do not discharge water to water prohibiting substance Do not run the pump without suction port strainer Do not insert your hand into the suction port If you insert your hand into it you may be seriously injured by the rotating part If gravel enter the pump then the pump could be damaged and the performance would be significantly reduced 1 Place the pump near the water source on a flat...

Page 50: ...ary Make sure that all the discharge valve s is closed Make sure to turn on the Auto priming switch VF53AS In the case of the Auto priming switch is ON position If water supply is not achieved in 30 seconds then the engine will stop VF63AS R In the case of Priming water mode switch status is Auto the switch lights off If water supply is not achieved in 30 seconds then the engine will stop Operate ...

Page 51: ...s are tightly connected and the battery is fully charged Starting engine using the manual starter If electric starter does not work use the manual starter Even an insufficient charge battery install the battery to start the engine and operate the pump VF53AS 1 Turn the throttle dial to the start Low pressure position and turn on the main switch Start the engine by pulling the starter handle forwar...

Page 52: ...on cannot be done within 30 seconds there is the other problem Dry operation This portable pump has an outsource cooling system limit the duration of dry operation so that it is within the following time periods Dry operation Running engine without water Performing dry operation longer than the specified time period may cause damage to the engine or pump Throttle dial at idle position Within 2 min...

Page 53: ...ng pump reduced significantly Does the pump case leak vacuum Does the vacuum leak occur when the pump is connected with the suction hose which is capped at the tip of the hose Refer to Chapter 16 TROUBLESHOOTING 1 Once the engine starts turn the throttle dial to the suction position 2 The vacuum pump operates automatically until the suction finished Maximum operating time is for 30 seconds When th...

Page 54: ...e who are on the hose side 5 Open the discharge valve handle slowly to start discharging water Before opening water discharge port or valve of the pump confirm the person holding the nozzle or the branch pipe who have already checked the nozzle is opened and ready to discharge water During operation check the suction and discharge hoses They must be free of kinks pinches etc possibly caused from e...

Page 55: ...hanges in water discharge pressure caused from engine speed changes or discharge water valve opening setting changes Do not direct the nozzle toward people under any circumstances Do not look into the nozzle opening at any time Do not put fingers or a hand into the discharge nozzle 9 Throttle dial Pressure gauge CAUTION １ １ ２ ２ ３ ３ ４ ４ ５ ５ ６ ６ ７ ７ ８ ８ ９ ９ 10 10 11 11 12 12 13 14 15 16 17 18 13 14 ...

Page 56: ...ning in a flat place if the number of extending hose is less than ten use the safety nozzle attached Description of relay pumping operation 9 Packing Pumping plate Discharge port adaptor OPTION CAUTION １ １ ２ ２ ３ ３ ４ ４ ５ ５ ６ ６ ７ ７ ８ ８ ９ ９ 10 10 11 11 12 12 13 14 15 16 17 18 13 14 15 16 17 18 19 19 ...

Page 57: ... is not necessary to run the pump If the water pressure from fire hydrant has not reached the required pressure start to run 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 0 1MPa 15psi or below If it does stop inc...

Page 58: ...d If reducing or stopping to supply water overheat or cavitation may occur in the relay pumps Auto priming 1 Make sure that the discharge valves and the fire nozzle s are all opened 2 Turn the auto switch on VF53AS Turn on the auto priming switch In the case of choosing the manual mode priming water must be done by manual VF63AS R Choose the operating mode of stand alone Press the operation mode s...

Page 59: ...s lower than the decided pressure If the pressure is higher than decided pressure no need to start the engine Adjust the discharge pressure with throttle dial Always check the discharge pressure and suction pressure with the pressure gauges If the suction pressure goes down below 0 1MPa 15psi order the operator of the pre stage pump to increase the discharge water pressure and adjust the relay pum...

Page 60: ... is for stable starting operation by the starter motor and save battery energy If the engine doesn t start in 6 times starting operations then warning lamp starts slow blinking Unable to start engine Air Water decision Even if a large amount of air comes from the source previous pump to the relay pump the pump internal pressure could rise and the relay pump may start In the relay pump of VF63AS R ...

Page 61: ...he nozzle one by one Stop the relay pump which is closest to the nozzle first After that stop the second closest relay pump to the nozzle Then stop the third relay pump in order Finally stop the source pump The signal to stop should be given by the nozzle operator first 3 Drain all the water from the pumps In the case of using water from fire hydrant 1 Decide the pump pressure in consideration of ...

Page 62: ...tart the engine and adjust the pressure to the required pressure by operating the throttle dial Stop increasing discharge pressure if the suction pressure gauge shows 0 1MPa 15 psi or below Keep Operate the throttle dial not to make the suction water side pressure below 0 1MPa 15psi VF53AS VF63AS R Stand alone mode 7 To finish the discharging water turn the throttle dial to the low pressure firstl...

Page 63: ...t off Operation mode switch or Start switch one press Operation mode switch Press for around 2 seconds Stand alone Mode Operation mode switch Blue light Operation mode switch Press for around 2 seconds Stop switch One press Relay mode Operation mode switch Red light Intermittent sound Operation mode switch Press for around 2 seconds Stop switch One press 9 Stop switch Operation mode switch Start s...

Page 64: ...e s In the case of ball valve 3 Turn off the main switch VF53AS Turn off the main switch VF63AS R Press the stop switch until the engine stops 10 VF63AS R Stop switch VF53AS Throttle dial Main switch VF53AS Close Close Close Close Ball valve １ １ ２ ２ ３ ３ ４ ４ ５ ５ ６ ６ ７ ７ ８ ８ ９ ９ 10 10 11 11 12 12 13 14 15 16 17 18 13 14 15 16 17 18 19 19 ...

Page 65: ...conds to drain out all the water 2 Attach the suction port cap 3 Close all the drain valves Prepare a suction cap that is suitable for the suction coupling VF53AS 4 1 Confirm the throttle dial is at Start position and turn on the Auto priming switch 5 1 Start the engine turning the main switch 6 1 Turn the throttle dial to Suction position then the suction will start automatically 7 1 Run the engi...

Page 66: ...onds and confirm that the pointer of the pressure gauge for suction keeps the same pressure indicated 10 Open the drain valves slowly to expose it to the atmosphere and check that the pointer of the pressure gauge for suction returns to 0 11 Close the drain valves again Before storing the fire pump flush with fresh water to purge any debris from the pump Especially after using salt water muddy wat...

Page 67: ...ssification Engine oil level Quantity of oil for full replacement Oil filter replaced Oil filter reused Upper limit 2 0 L 0 53 gal US 1 9 L 0 50gal US Lower limit 1 7 L 0 45gal US 1 6 L 0 42gal US A new pump is not filled with engine oil Before using the pump fill it with the designated amount approximately 1 9L 0 50gal of engine oil For more information about engine oil change see the section on ...

Page 68: ...ner 99 mm long 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 the vacuum leak may occur When assembling the strainer tighten the ring nut while holding and pushing the strainer cup 11 NOTE CAUTION Strainer O ring Ring nut Strainer cup １ １ ２ ２ ３ ３ ４ ４ ５ ５ ６ ６ ７ ７ ８ ８ ９ ９ 10 10 11 11 1...

Page 69: ...rger The battery capacity must be 12V 16 Ah 5h Do not connect a cigarette lighter to the battery charger socket Doing so may melt or burn out the socket due to overheating Hydrogen gas inside the battery may explode if something sparks Keep the battery away from flame and sparks Charge battery in well ventilated area Use an automatic battery charger Use a battery charger that has an overcharge pre...

Page 70: ...lug socket of pump 5 Insert the power plug of the charger to an alternating current power source 6 Confirm the battery charging status Refer to the battery instruction manual 7 Disconnect the battery charger plug from the socket when using or moving the pump If the main switch is on the battery cannot be charged Pull out the battery charger plug from the socket when using or moving the pump 11 NOT...

Page 71: ... the pump drain valves the muffler drain valve and the air valve for drainage and completely drain the water from the pump 2 Close the pump drain valves the muffler drain valve Install the suction port cap Keep the air valve for drainage opened 3 Insert a plastic tube to the air valve which is for assisting water drainage Put the plastic tube into the antifreeze liquid and also put a plastic tube ...

Page 72: ...Release the main switch immediately after the engine starts VF63AS R Press the main switch to run the engine Switch the priming water mode switch to the Automatic 12 Start position Suction position Throttle dial Auto priming switch VF53AS VF63AS R Main switch Priming water mode switch ON START Main switch １ １ ２ ２ ３ ３ ４ ４ ５ ５ ６ ６ ７ ７ ８ ８ ９ ９ 10 10 11 11 12 12 13 14 15 16 17 18 13 14 15 16 17 18 19 ...

Page 73: ...engine Press the main switch to turn off the power 7 Close the air valve which is for assisting water drainage and take the plastic tube off from the air valve Discharge valve Put antifreeze fluid into the seal area of the discharge valve To use a long nozzle container is helpful when pouring antifreeze fluid 12 Discharge valve VF63AS R Suction position OFF Main switch Air valve Close VF53AS Sucti...

Page 74: ...batteries be sure to use an automatic battery charger Use an automatic battery charger that matches a 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 a battery is used properly Replace with new battery every 2 3 years checking the deterioration of the charging performance...

Page 75: ... in between the discharge port adapter and the packing in order to prevent the overheating of the engine and the pump cavitation which may cause damages to the pump Pumping plate is the standard accessory Part No 151 39045 1 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 noz...

Page 76: ...ter strainer After every use Clogging or broken mesh Clean Vacuum pump V belt 100 hr or 1 year Crack wear Replace Cooling water passage 100 hr or 1 year Water temperature clogging water Replace parts if necessary Pump and related components 50 to 100 hr or 1 year Performance check Replace parts if necessary Discharge valve and related components After every 50 to 100 hr or 1 year Vacuum leak handl...

Page 77: ... timing deviation Other rubbers 2 years Functional degradation due to deterioration Starter rope 3 years Breakage due to wear Fuel filter 3 years Unable to start due to clogging with dust or mixing of water Discharge reverse flow check valve rubber 3 years Functional degradation due to wear and deterioration Mechanical seal 3 years Unable to suck water due to wear Vane for oil less vacuum pump 3 y...

Page 78: ...ems Genuine parts When replacing parts as a part of servicing and maintenance of the fire pump use only Tohatsu genuine parts If genuine Tohatsu parts and accessories are not used it may adversely affect the function and safety of the fire pump Therefore for safety reasons use only Tohatsu genuine parts Tohatsu bears no responsibility for any personal injuries or equipment damages that may result ...

Page 79: ...cowl from the latch at the front side of the pump 3 Remove the cowl Top cowl installation 1 Put the cowl Hook the upper cowl latch plate at the front inside of the cowl to the hook at the front side of the bottom cowl 15 Latch Latch plate Hook Cowl latch １ １ ２ ２ ３ ３ ４ ４ ５ ５ ６ ６ ７ ７ ８ ８ ９ ９ 10 10 11 11 12 12 13 14 15 16 17 18 13 14 15 16 17 18 19 19 ...

Page 80: ... 87mm Remove the cooling water strainer Turn the ring nut while pushing and holding the strainer cup Strainer length 99mm 2 Wash the strainer and the strainer cup on each 3 After the washing assemble the strainer cups and strainers tightening with the ring nuts on each When installing a strainer pay attention to the protrusion of the O ring and install it correctly Otherwise a vacuum leak may occu...

Page 81: ... time whenever you check the oil level Check the oil level before each operation 1 Place the pump in a horizontal location 2 Check the oil level 3 Refill the oil until about Upper level if the oil level is not enough 4 stroke engine oil SAE 10W 30 40 of SF SG SH SJ SL and SM series of API classification Vacuum pump V belt Check the V belt every year or every 100 hours operating time V belt size LA...

Page 82: ...he 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 Sparkplug gap 0 8 0 9 mm Usage limit 1 2 mm Spark plug NGK DCPR6E 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 N m 13 Ib ft 1 8 kgf m 15 Spark plug Washer E...

Page 83: ...otective glasses Do not tip the battery acid would come out through the air vents Disposal 15 Disused batteries should be disposed according to local laws or regulations After each operation of the battery check the voltage Replace the battery if necessary When disconnect a battery disconnect the negative terminal of the battery cable first then disconnect the positive terminal There is a risk of ...

Page 84: ...nal 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 Before replacing the fuse isolate the cause of the short circuit and take an appropriate action After the appropriate action has been taken replace the fuse with...

Page 85: ...water and discharging water to cool down the engine earlier The water discharge operation allows the cooling water go into the engine and circulate in the engine and then the engine will be cooled down 1 Cap the suction port with a suitable suction cap Prepare a suction port cap that is suitable for the suction coupling 2 Confirm the drain valves and air valve are all closed 15 NOTE Suction port c...

Page 86: ...onds before operating the starter motor again 4 Turn the throttle dial to Suction position then the pump will start to suck up water automatically If suction water is not confirmed by the sensor in 30 seconds the engine will stop automatically Refer to Chapter 16 TROBLESHOOTING Then take the appropriate action and check the vacuum leak again 15 Auto priming switch Throttle dial Main switch VF53AS ...

Page 87: ...ose it to the atmosphere and check that the pointer of the suction pressure gauge returns to 0 8 Close the drain valves again Before storing the fire pump flush with fresh water to purge any debris from the pump Especially after using salt water muddy water contaminated water etc Rubber gaskets O rings seals for the discharge and suction hose fitting wear Worn rubber seals will cause water leaks p...

Page 88: ...5 Operate the throttle dial to raise the pump pressure almost to 1MPa 145psi and then check for water leaks from each part of the pump and the cooling water piping If a water leak is found isolate the cause referring to Chapter 16 TROUBLESHOOTING Then take the appropriate action and check the vacuum leak will not happen again 15 Priming knob Manual operation Close Open Open Close Drain valve Close...

Page 89: ...ot work Warning lamp flashing Action Caused by suction Caused by pump unit Caused by playpipe Caused by engine unit Fuel and lubrication Fuel shortage Refuel Deterioration of fuel Replace with new fuel Fuel tank air vent clogging Clean the clogging Fuel filter clogging Clean the clogging Fuel pump failure Replace Injector failure Replace Fuel pipe kink or snap Fix routing of the pipe Throttle dial...

Page 90: ...ump unit Caused by playpipe Caused by engine unit Electrical Spark plug cap comes off Plug in surely Use of unspecified spark plug Replace with specified spark plug Spark plug fouling No spark or weak spark Clean or replace with specified spark plug ECU and or Sensors failure Check wire connection Plug in surely If necessary replace Battery loose connection terminal corrosion or expired Clean term...

Page 91: ...used by suction Caused by pump unit Caused by playpipe Caused by engine unit Electrical 15A fuse blown Replace with spare fuse When the blowout of the fuse happens repeatedly check a cause 15A Battery cable reverse connection Operation panel components and search light connector 7 5A charging connector 7 5A fuse blown Starter motor defective Check terminals cords and screws Replace parts if necess...

Page 92: ...gine unit Compression Piston piston ring or cylinder excessively worn Correct or replace Carbon deposition in the combustion chamber Clean out Suction Suction height too high or length too long Place the pump nearer and or lower position Suction hose end is not in water Put the end of suction hose below 30cm from the surface of water Suction hose coupling loose or gasket defective Clean out a gask...

Page 93: ... Warning lamp flashing Action Caused by suction Caused by pump unit Caused by playpipe Caused by engine unit Primer Vacuum pipe loose or cracking Tighten securely a clump of vacuum pipe or replace Strainer cap loose or O ring failure Tighten securely or replace V belt damaged or worn Replace Vacuum pump rotor shaft seizing Repair or replace Vane Side plate worn or damaged Replace Water stop valve ...

Page 94: ...uction port strainer clogged with dead leaf or waste etc Clean out Discharge valve imperfect open Open securely Gauge pipe connector loose or gasket defective Tighten securely Replace a gasket if necessary Pump cover bolts loose Tighten securely Pump cover O ring degradation Clean out or replace Impeller or Guide vane caught a stone or damaged Clean or replace Mechanical seal damaged Replace Nozzl...

Page 95: ...M8 M10 Standard Bolt N m 0 7 1 6 3 6 13 27 lb ft 0 5 1 2 2 4 9 20 kgf m 0 07 0 16 0 3 0 6 1 3 2 7 Heat Treated Bolt N m 9 24 47 lb ft 7 17 34 kgf m 0 9 2 4 4 7 17 １ １ ２ ２ ３ ３ ４ ４ ５ ５ ６ ６ ７ ７ ８ ８ ９ ９ 10 10 11 11 12 12 13 14 15 16 17 18 13 14 15 16 17 18 19 19 ...

Page 96: ... Fuel tank complete 1R3 70172 0 Search light Floodlight 1P3 39020 0 Primer bulb assy 3B7 70200 4 Bracket 1K1 39122 0 Anti freeze kit 1K1 31565 0 Adjusting screw 3B2 63034 0 Tool box 159 39001 1 Tripod 151 39022 0 Ball valve 1K1 02375 0 Special tool 18 Description Parts No Description Parts No Puller 126 39100 0 Piston slider 3AC 72871 0 Puller impeller 151 39101 0 Bevel gear nut socket 346 72232 0...

Page 97: ...ST MODE SWITCH TX RX FLASH MEMORY WRITE CONTROL POWER SOURCE POWER SUPPLY FOR COMMUNICATION WATER PRESSURE SWITCH LED2 ｵｰﾊﾞｰﾋｰﾄ 吸水不能 他 ｲﾝｼﾞｪｸﾀ電源 外部供給 W B PLUG PLUG N C FUEL LEVEL SWITCH AVS 0 5f AVS 0 5f AVS 0 5f AVS 0 5f AVS 0 5f AVS 0 5f AVS 0 5f B2 B3 B4 B5 B6 B8 B9 B10 B11 B12 B13 B14 B15 B16 B17 B7 Sb L B Y R G B L O R B A1 A2 A3 A4 A5 A6 A7 A8 A9 A10 A11 A12 A13 A14 A15 A16 A17 A18 A19 A20 A...

Page 98: ...833 93 6 1 68 7 21 7 5 02 6 7 1 6723 6 1 872 32 5 2 23 5 7 21 7 6 1 21752 3 1 21752 5 6 7 68 7 21 02 6723 78 725 32 5 6833 5 8 17 55837 7 67 02 32 5 6833 UURZ LQGLFDWHV WKH GLUHFWLRQ RI WKH FXUUHQW 29 5 7 68 7 21 7 5 85 27 56 5 9 1 7 5 211 7 1 7 67 02 211 7 1 86 1 3 TEST MODE CONNECTOR 9 219 56 21 81 7 1 3803 32 5 6833 7 5 2 5 9 1 7 5 38 6 5 2 6 1625 32 5 6833 1 3803 2 9 1 3803 2 8 1 3803 2 7 5 2 ...

Page 99: ...TOHATSU CORPORATION Address 3 5 4 Azusawa Itabashi ku Tokyo JAPAN FAX 81 3 3966 2951 Phone 81 3 3966 3137 003 12076 0 AH1 ...