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Shibaura FK500-A Owner's Manual

Firefighting pump
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OWNER'S MANUAL
FIREFIGHTING PUMP
FK500-A
Please read this operation manual carefully in order to operate the
Shibaura Firefighting Pump in safe and in correct manner. If the pump is
operated incorrectly, any accident may result. If this manual is missing or
damaged, give an order for new one to us or our agent promptly.

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Summary of Contents for Shibaura FK500-A

  • Page 1 FK500-A Please read this operation manual carefully in order to operate the Shibaura Firefighting Pump in safe and in correct manner. If the pump is operated incorrectly, any accident may result. If this manual is missing or damaged, give an order for new one to us or our agent promptly.

  • Page 3: Table Of Contents

    ○ CONTENTS  For safe operation ------------------------------------------- 1 1. Matters to be attended to for safety 1. Warning label locations----------------------------------- 2 2. Caution marks -------------------------------------------- 3 2. Name of components ---------------------------------------- 8 3. Functions of monitor lamps -------------------------------- 10 4. Handling of pump (Before starting operation) -------------------------------- 11 (Operating method) ---------------------------------------- 22 (Discharging with water multiple pumps) ---------------- 29...

  • Page 4: For Safe Operation

    ● For safe operation The operation manual is a part of machine. Keep this manual carefully with the firefighting pump.  In this manual, mark indicates particularly important instructions for safe operation. You should pay attention specifically to those marked descriptions and observe such instructions. If the machine is operated Danger incorrectly, there is high possibility...

  • Page 5: Matters To Be Attended To For Safety

    1. Matters to be attended to for safety 1. Warning label locations Warning labels are attached to the positions of the firefighting pump as shown below. If the labels are peeled off or damaged, please order new ones telling the part No.

  • Page 6: Caution Marks

    1. Matters to be attended to for safety 2. Caution marks (1) General instructions Warning The firefighting pump should be only by such a man among fire officers, firemen, volunteer disaster prevention expedition team members, self-defense firefighting team members or maintenance/inspection service men that has been specifically trained for safe operation.

  • Page 7: Part

    1. Matters to be attended to for safety Warning Use only genuine parts and designated attachments. Do not remodel them. 〈If you do not observe the instruction〉 Accident, injury, or machine failure may result. (2) Cautions before starting operation Warning Install the pump more than 3 m apart from combustibles.
  • Page 8 1. Matters to be attended to for safety Caution Connect the fire hose securely and make sure that it does not fall out. 〈If you do not observe the instruction〉 If the hose falls out while water is being discharged, it may injure people around it.
  • Page 9 1. Matters to be attended to for safety Caution Open or close the water discharge valve always after returning the engine to a low speed. Hold the nozzle at the end positively and wear the back band before discharging the water. 〈If you do not observe the instruction〉...
  • Page 10 1. Matters to be attended to for safety Caution When disconnecting the battery cord, remove the (-) cord first and when connecting, connect the (+) cord first. 〈If you do not observe the instruction〉 Short circuit may occur and cause a fire or burn you. Warning Remove the packing materials from the charger when charging with it.

  • Page 11: Name Of Components

    2. Name of components Operating side Pressure gauge Water discharge valve lever Compound gauge Monitor lamp Tickler Throttle lever Water suction lever Breaker Main switch Cover removable knob Water inlet cap Engine oil tank Carrying handle Recoil starter side Recoil side cover Fastener Recoil starter handle (All two places)
  • Page 12 2. Name of components Pump side Water outlet Front cover Pump side cover Cylinder head drain pipe (small dia.) Vacuum pump exhaust pipe Water shut-off valve drain pipe (large dia.) Pump drain cock Reflux cooling water drain cock Top side Water shut-off valve water drain button (under water discharge valve) Fuel gauge Fuel tank cap...

  • Page 13: Functions Of Monitor Lamps

    3. Functions of monitor lamps The pump is started by setting the main switch to the “Operation” position. When the power switch is turned ON, all of the 3 lamps light up. If any one of the lamps does not light up, the battery voltage is low or circuit has failed. Repair as required in such a case.

  • Page 14: Handling Of Pump

    4. Handling of pump (Before starting operation) 1. Unpacking (1) Check the name of the machine shown on the box surface to see whether it is what you ordered. (2) Cut the band bound on the box. (3) Pull up the box; the main unit of the machine and accessories will came out. (4) Check that the following components are included.
  • Page 15 4. Handling of pump (Before starting operation) 3. Removing / installing the cover The cover should be removed when replenishing the coolant or for other maintenance services. During the attachment and detachment of the cover, please not defeat the order and method of attachment and detachment. There is a possibility that the cover is broken.
  • Page 16 4. Handling of pump (Before starting operation) ⑥ Remove the recoil side cover. ⑦ Turn the removable knob counter-clockwise direction on the front bottom right-hand side. Removable knob ⑧ Turn the two removable knobs counter-clockwise direction on rear left upper and lower. Removable knob ⑨...
  • Page 17 4. Handling of pump (Before starting operation) ⑩ Remove the pump side cover. ⑪ Turn the removable knob counter-clockwise direction on front lower left side. Removable knob ⑫ Turn the two removable knobs counter-clockwise direction on rear right upper and lower. Removable knob ⑬...
  • Page 18 4. Handling of pump (Before starting operation) (2) Installing the cover ① Water discharge so that the outlets will be in the same direction as the water intake. It will change the direction of the valve. ② Attach the pump side cover. ③...
  • Page 19 4. Handling of pump (Before starting operation) ⑥ Attach the recoil side cover. ⑦ Attach the hook located inside of the recoil side cover to the pin of the frame. Frame Pump side cover (inside) Hook ⑧ Turn in a clockwise direction while pushing the two removable knobs into the holes of frame on rear left up and down.
  • Page 20 4. Handling of pump (Before starting operation) ⑩ Attach the front cover. ⑪ Place the front cover to the topside of the fuel tank. During this work, please be careful to cover is not touched on the throttle lever of the operation panel. ⑫...

  • Page 21: Part

    4. Handling of pump (Before starting operation) 4. Replenishing the fuel (1) Supply the fuel into the tank (tank capacity 14.5L). The engine of this firefighting pump is fueled independently of the lubricating tank. Supply automobile regular gasoline up to the “F” mark of the fuel gauge. Do not use mixed gasoline and Bio-gasoline.
  • Page 22 4. Handling of pump (Before starting operation) (3) Check the engine coolant level. This firefighting pump is equipped with the radiator type water-cooled engine. ① Put the firefighting pump into a horizontal position when the engine is cold. After removing the cover, open the radiator cap, to see if there is coolant to mouth.
  • Page 23 4. Handling of pump (Before starting operation) Warning ○ Do not install the pump indoors or in the tunnel or the like where is badly ventilated.  If not, you may get poisoned by exhaust gas. (2) Be sure to attach a strainer and a rattan basket to the water inlet of the water suction pipe and position it more than 30 cm below the water level.
  • Page 24 4. Handling of pump (Before starting operation) Warning ○ The firefighting pump should be operated only by such a man among fire officers, firemen, volunteer disaster prevention expedition team members, self-defense firefighting team members or maintenance/inspection service men that has been specifically trained for safe operation. (2) Clothing should be suited to work.

  • Page 25: (Operating Method)

    4. Handling of pump (Operating method) 1. Starting the engine Before starting the engine, close the water discharge valve, pump drain cock and reflux cooling water drain cock. Water discharge valve Pump drain cock Reflux cooling water drain cock (1) Open the fuel cock ①. Pull down the fuel cock lever to Fuel cock ①...
  • Page 26 4. Handling of pump (Operating method) Caution ○ After operating the tickler or discharging the fuel from the carburetor, wipe away the spilt fuel immediately.  If not, the fuel may catch the fire. (3) Position of throttle lever Throttle lever When starting the engine initially while the engine is cold, set the throttle lever ②...
  • Page 27 4. Handling of pump (Operating method) Caution ○ When starting the engine with the rope, be careful not to allow the clothes or gloves to be entangled.  You may get injured. Caution ○ When starting the engine using a rope, do not allow people to be within 2 m around the pump.
  • Page 28 4. Handling of pump (Operating method) ○ Communicate with the person at the snout and discharge water adjusting the pressure with the throttle lever ② depending on the situation of the fire site. ○ Keep the pointer on the pressure gauge and compound gauge in the green range when discharging the water.

  • Page 29: Stopping The Engine

    4. Handling of pump (Operating method) Caution ○ Do not direct the nozzle to other people or do not peep into it.  You may be sent flying by high pressure and injured. Caution ○ Do not touch the ignition plug or high-tension cord during operation. ...
  • Page 30 4. Handling of pump (Operating method) (3) Set the main switch ③ to the “Stop” position. 5. Draining the water After the firefighting pump was operated, much water remains inside. If the water is left in the pump, rust may be generated or the pump may be damaged due to frozen water in the cold season.
  • Page 31 4. Handling of pump (Operating method) 6. Storing the pump The firefighting pump is such a machine that is usually out of operation after being operated for a short time. Therefore, storing it under proper condition is essential in order that the pump operates satisfactorily when required next time or to secure its long life.

  • Page 32: (Discharging With Water Multiple Pumps)

    4. Handling of pump (Discharging with multiple pumps) In the mountains and forests or in urban areas which are inconvenient for water transportation, multiple pumps will be required in order for the water to reach the fire by relaying the pumps. In this case, pumps are separated far from each other and firemen are required judgment based on the existing state and systematic activities based on training.

  • Page 33: (Suction And Discharge Of Water From Fire Hydrant)

    4. Handling of pump (Suction and discharge of water from Fire hydrant) 1. Suction and discharging of water from Fire hydrant (1) Capacity for supply water of the fire hydrant It is necessary to check an enough volume for discharging water from the fire hydrant in advance.
  • Page 34 4. Handling of pump (suction and discharge of water from Fire hydrant) (2) Plural pumps ① Open the water discharge valve for ALL of pumps at first. ② Open the valve of the hydrant before an engine start, check the pressure scale of the original pump.

  • Page 35: (When Overheated)

    4. Handling of pump (When overheated) If the engine is overheated, coolant flows out from the cylinder head drain pipe. Meanwhile a large quantity of steam gushes out of the cylinder head drain pipe. If operation is continued, the safety device is activated and the engine stops. How to cope with (1) When the pump is operated for 15 minutes before sucking in water, steam gushes out of the cylinder head drain pipe.

  • Page 36: (Operation In Cold Districts In Winter)

    4. Handling of pump (Operation in cold districts in winter) 1. Before starting the engine (1) In the cold season, battery capacity is remarkably deteriorated. Charge the battery periodically as far as possible. (2) At the time of shipment from the factory, coolant of freezing temperature adjusted to -30℃...

  • Page 37: Part

    4. Handling of pump (Operation in cold districts in winter) ⑦ Pull the water suction lever again, and stop the engine when the anti-freeze mixture begins to come out of the vacuum pump discharge port. ⑧ Close the reflux cooling water drain cock, open the pump drain cock a little and release the vacuum.

  • Page 38: Periodical Inspections

    5. Periodical inspections 1. Periodical inspection schedule Item Every running Every month Every 6 months Every year Replenishment ● of fuel Replenishment of 2 cycle ● engine oil Replenishment ● of engine coolant Cleaning of dust, ● etc. from outside Battery charging ●...

  • Page 39: Inspection Method

    5. Periodical inspections 2. Inspection method To keep the safety of the firefighting pump and make use of every possible function, periodical inspections are essential. Inspect the firefighting pump correctly and in safe following the procedure below. Caution ○ Start the inspections and services after the engine is stopped and has cooled down sufficiently.
  • Page 40 ○ Entrust a professional industrial waste disposal dealer with disposal of the battery, oil, grease, etc.  If not, fire, burnt or environmental pollution may result. (2) Handling of Shibaura full-automatic charger A) Unpacking Take out the charger from the box.

  • Page 41: Part

    (3) Handling of engine coolant Shibaura FK series firefighting pumps are equipped with an indirectly cooled engine with a water-cooled radiator. It is filled with long-life coolant as the coolant. Handle the coolant in the following procedure.
  • Page 42 5. Periodical inspections B) When replenishing While the engine is cold, open the radiator cap and replenish the coolant into the cylinder head. C) When changing Coolant is deteriorated in one to two years and may corrode the Drain plug cylinder.
  • Page 43 5. Periodical inspections (5) Change of fuel in tank After the fuel is stored for a long time, it may deteriorate and not start the engine smoothly. Sediment may attach to the carburetor and generate rust. When the fuel has decreased down to the middle point of the specified fuel level, replenish the fuel to prevent such troubles.
  • Page 44 5. Periodical inspections (8) Vacuum test Even if the following water discharge test cannot be performed in daily inspections, be sure to carry out the vacuum test. If the vacuum performance is not enough or vacuum leaks, water may not be sucked up when water should be discharged actually or water may fall while being discharged.

  • Page 45: Troubleshooting

    6. Troubleshooting For preventing the fire pump from troubles, routine checkup and maintenance are important. Let us locate any trouble at an early stage and remedy it immediately. For a trouble which is not easy to remove or not mentioned below, contact the sales agent specifying the model and serial number.
  • Page 46 6. Troubleshooting Symptom Cause Remedy No sparks are Ground wire is short-circuited Repair produced short-circuited part Ignition plug is broken or Replace contaminated Ignition plug gap is improper Replace plug or adjust its gap Ignition coil is faulty Replace CDI unit is faulty Ditto Wiring is not connected properly or Review and adjust...
  • Page 47 6. Troubleshooting Symptom Cause Remedy Governor Governor maladjusted Adjust system Governor actuating part worn Replace anomaly Fly weight caulked poorly Correct or replace Governor arm tightened poorly Readjust and retighten Governor spring tension poor Replace Governor lever link hole is worn or Replace or correct there is too much play Cooling...
  • Page 48 6. Troubleshooting Symptom Cause Remedy Vacuum Air is sucked on account of poor Tighten securely leakage (water tightening of suction pipe flow Mechanical seal is faulty Replace discontinues at Oil seal is faulty Replace engine stop) Vacuum pump cock leaks Check and repair Casing rubber packing is faulty Replace...
  • Page 49 6. Troubleshooting 3. Electric Symptom Cause Remedy Starting motor dose Battery capacity is poor Recharge not rotate Magnet switch malfunctions Ditto Main switch is faulty Check or replace wiring Grounding is faulty Correct Fuse is blown Replace Battery is Battery is deteriorated Replace discharged soon Wiring is short-circuited...

  • Page 50: Specifications

    7. Specifications 1. Firefighting pump Model FK500-A Class 701 ㎜×652 ㎜×735 ㎜ Long × wide × high 85 ㎏ Mass Cooing water system Internally circulated cooling water 2. Pump Method High-pressure 1-stage turbine pump (with inducer) Normal 1.29m /min Discharge water volume High pressure 0.88m...
  • Page 51 7. Specifications 4. Engine Method Horizontal 2-cycle 2-cylinder water-cooled radiator Model name L618Z Bore×stroke×number 75 ㎜ × 70 ㎜ × 2 Displacement 618mL Authorized output 33.1 ㎾/5200rpm Cooling system Indirect cooling type (with water-cooled radiator) Lubrication method Separate lubrication Lubricating oil For 2 cycle engine Starting method Starting motor, recoil starter...

  • Page 52: Wiring Diagram

    8. Wiring diagram...
  • Page 56 200812310-0 2016.６ Printed in Japan URL:www.ihi-shibaura.com/english/...

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