TOHATSU VE1500W Owner's Manual
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TOHATSU VE1500W Owner's Manual

TOHATSU VE1500W Owner's Manual

Portable fire pump
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  • Page 2 Copyright © 2023 Tohatsu Corporation. All rights reserved. No part of this manual may be reproduced or transmitted in any from or by any means without the express written permission of Tohatsu Corporation.
  • Page 3 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.
  • Page 4 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.
  • Page 5 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.
  • Page 6 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.
  • Page 7 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.
  • Page 8 Transporting the portable fire pump ・ Retractable handle is folding type. CAUTION ・ Do not put hand or finger between retractable handle 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.
  • Page 9 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.
  • Page 10 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.
  • Page 11 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.
  • Page 12 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.

  • Page 13: Table Of Contents

    CONTENTS SPECIFICATIONS………………………………..………………………..…………… 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.

  • Page 14: Specifications

    1. SPECIFICATIONS Model VE1500W Description Portable fire pump 1.65 MPa (239.3 psi) Max. operating pressure Usable ambient temperature -20 °C ~ 40 °C (-4 °F ~ 104 °F) Engine Manufacturer TOHATSU CORPORATION Model 2WT81A Type 2-stroke, 2-cylinder, water cooled gasoline engine Bore ×...
  • Page 15 1. SPECIFICATIONS Model VE1500W Primer Type Rotary-vane vacuum pump (Oil less type) Max. suction height Approx. 9 m (29.5 ft) Pump Type Single suction, single stage, high pressure turbine pump Transmission Ratio 1：1 Number of delivery outlet Discharge port coupling NH 2-1/2"...
  • Page 16 1. SPECIFICATIONS Performance curve VE1500W...

  • Page 17: Operation Device

    2. OPERATION DEVICE ⑦ ⑦ ⑧ ⑥ ⑨ ⑥ ⑩ ⑤ ⑤ ④ ① 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...
  • Page 18 2. OPERATION DEVICE ⑥ ⑥ ⑥ ⑤ ⑦ ④ ⑧ ① ② ③ ③ ③ ① Air silencer ② Fuel tank ③ Muffler ④ ECU ⑤ Oil tank ⑥ Discharge valve ⑦ Fuel feed pump ⑧ Injector...
  • Page 19 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...
  • Page 20 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...

  • Page 21: Labels

    3. LABELS Instruction Warning Caution Warning Warning...

  • Page 22: Operating Precautions

    OPERATING PRECAUTIONS Installing pump The fire pump must be installed on level ground. Otherwise, an CAUTION 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.
  • Page 23 OPERATING PRECAUTIONS Place the pump as near as possible to water source, and water NOTE 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.

  • Page 24: Description Of Devices

    5. DESCRIPTION OF DEVICES Suction port Suction port The diameter of the thread for fire pump is ・ JIS 90mm ・ NH 4” 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.
  • Page 25 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. Priming lever Removing cowl Cowl can be removed by releasing the 4 hooks up. Hook When removing the cowl, do not use NOTE...
  • Page 26 5. DESCRIPTION OF DEVICES Drain valve Use the drain valves to drain water Close all the valves when operating this NOTE fire pump. ⓐ If a valve is opened, water cannot be ⓑ suctioned. ⓒ ⓐ Cylinder drain valve ⓑ Pump drain valve ⓒ...
  • Page 27 5. DESCRIPTION OF DEVICES Control panel Throttle dial The control panel is equipped with all the necessary 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.
  • Page 28 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. Use it to check the running time and NOTE maintenance timing.
  • Page 29 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. Warning lamp (Battery) The battery charge warning buzzer NOTE...
  • Page 30 5. DESCRIPTION OF DEVICES Manual starter If the engine will not start with the starter motor, use the manual (recoil) starter. Do not pull the manual starter handle CAUTION when the pump is running. Otherwise, the manual starter may be damaged. Personal injuries may occur.

  • Page 31: Preparation For Operation

    6. PREPARATION FOR OPERATION Installing battery Install the battery in the pump. Secure the battery with the battery terminals facing outward. Cover ・ Refer to the contents "13. USE OF CAUTION ACCESSORY Battery". Battery supporter Wing nuts Battery Rubber sheet Initial charge of battery Battery supporter The battery can be used immediately after filling cells with electrolyte.
  • Page 32 6. PREPARATION FOR OPERATION Use of low-quality fuel results in a short engine life as well as starting NOTE difficulty and other engine problems. Fuel containing alcohol, methanol (methyl) or ethanol (ethyl), may cause: ・ Deterioration of rubber parts and plastic parts. ・...
  • Page 33 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 the warning buzzer will sound. Add 2-stroke engine oil. Governor oil Dipstick Before using fire pump, check governor oil level with the oil...
  • Page 34 6. PREPARATION FOR OPERATION Overheat warning lamp Warning lamp (Overheat) If the temperature of the engine rises approximately 90 °C or more, the engine will stop automatically to prevent overheating. Main switch Warning lamp and sensor When you turn the main switch to the “ ” position, warning lamps light up for a moment to enable lamps to be checked, and the buzzer sounds.

  • Page 35: Use Of Operation Panel

    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. When the power is turned ON, the warning lamp and buzzer will be NOTE activated for approximately one second, and the alert action check is automatically performed.
  • Page 36 7. USE OF OPERATION PANEL Engine Running Restart status 80 °C Light & Buzzer 90 °C Engine Engine can start at less than 120 °C and Overheating keep running for 30 seconds. STOP 70 °C Light & Buzzer Over Engine Engine cannot start 120 °C STOP...
  • Page 37 7. USE OF OPERATION PANEL Hour Meter Before removing the electrical equipment, turn DANGER 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.

  • Page 38: Starting The Engine

    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.
  • Page 39 8. STARTING THE ENGINE Remove air from the fuel line Main switch Before initially fueling this portable pump or restarting the engine after the engine stopped due to lack of gas, bleed air from the fuel line. 1. Turn the main switch from the “ ” position to the “ ” position and wait approximately 15 seconds During this period, the electric fuel pump works and NOTE...
  • Page 40 8. STARTING THE ENGINE Starting engine 1. Check that the air vent of the fuel tank is closed. 2. Turn the throttle dial to “ ” mark position. Air vent 3. Turn the main switch to “ ” position. Release the main switch immediately after the engine Throttle dial starts.
  • Page 41 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.

  • Page 42: Prime And Discharge

    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. If, when operating the vacuum pump for 30 seconds, the NOTE pump does not suck up water, or if the pump cannot keep the water in it during the water discharge operation, check the following:...
  • Page 43 9. PRIME AND DISCHARGE Limit the vacuum pump operating time within 30 seconds. If the NOTE 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 Open the discharge valve.
  • Page 44 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.
  • Page 45 9. PRIME AND DISCHARGE Relay pumping operations In the case of relay pumping CAUTION Discharge operation training level port adaptor ground, If the extension hose (inner diameter φ65) is less than 200 m, use the pumping plate (safety nozzle) attached. Packing Pumping plate (Standard accessory)
  • Page 46 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.
  • Page 47 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. ・...

  • Page 48: Stopping The Engine

    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.

  • Page 49: Maintenance After Operation

    11. MAINTENANCE AFTER OPERATION Maintenance after pumping seawater or foul water In case of the pumping seawater or foul water, the pump should be flushed out with fresh water immediately to prevent excessive corrosion. And operate the vacuum pump for 5 seconds at low engine speed (“ ” position) to clean the vacuum pump. Drain water 1.
  • Page 50 11. MAINTENANCE AFTER OPERATION 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.
  • Page 51 11. MAINTENANCE AFTER OPERATION Fuel and Oil Supply 1. Fuel Fill fuel until the maximum level of the gauge indicator (in red). 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.
  • Page 52 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 performance efficiency will be reduced. O-ring Strainer When assembling the strainer, tighten NOTE the ring nut while holding and pushing slightly the strainer cup.
  • Page 53 11. MAINTENANCE AFTER OPERATION Battery charger Use an automatic battery charger. CAUTION Use a maintenance-free (MF) battery. The battery capacity must be 12 V-18 Ah/10HR. Use a battery charger that has an overcharge prevention function. Disconnect the battery charger after charging is completed. 1.

  • Page 54: Maintenance In Cold Condition

    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.
  • Page 55 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. Even if anti-freezing fluid disappears, NOTE continue pulling a priming lever for 30...
  • Page 56 12. MAINTENANCE IN COLD CONDITION When installing the strainer, exercise care so that the O-ring does CAUTION 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- NOTE ring and install it correctly.

  • Page 57: Use Of Accessory

    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.
  • Page 58 13. USE OF ACCESSORY Pumping plate When the pump is operated using a discharge nozzle that has a nozzle NOTE 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.

  • Page 59: Periodical Inspection

    14. PERIODICAL INSPECTION Perform periodical inspections and maintenance according to the following procedures. Inspection intervals Description Inspection items Measure Impurities ● (ie. Water and / Clean out or waste) Replace *1 Fuel filter Impurities Check high (If water has ● pressure filter, fuel accumulated to tank and portable...
  • Page 60 14. PERIODICAL INSPECTION Inspection intervals 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 Replace parts if ･ Check ● performance necessary *1 Primer (-0.8 bar) Check pump unit if...

  • Page 61: Service And Maintenance

    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.
  • Page 62 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.
  • Page 63 15. SERVICE AND MAINTENANCE Engine oil Check the oil level. Install the filler cap tightly each time CAUTION you check the oil level. Filler cap Check the oil level after each operation. 1. Place the pump in a horizontal location. 2.
  • Page 64 15. SERVICE AND MAINTENANCE Spark plug Check the spark plugs Plug cap 1. Remove the plug caps, and remove the spark plugs. Use a wire brush or spark plug cleaner, clean the electrode of the spark plug ②. Check the spark plug for excessive carbon depos it, electrode ②...
  • Page 65 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.
  • Page 66 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.
  • Page 67 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.
  • Page 68 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”.

  • Page 69: Troubleshooting

    16. TROUBLESHOOTING Typical causes of engine troubles are listed in the following tables. Trouble Action Cause ● ● ● ● Refuel. Fuel shortage Deterioration Replace with new ● ● ● ● ● ● of fuel fuel. Fuel tank ● ● ● ●...
  • Page 70 16. TROUBLESHOOTING Trouble 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 ●...
  • Page 71 16. TROUBLESHOOTING Trouble 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 components and ● 5A fuse blown search light connector 5A: Charging connector Check terminals, Starter motor...
  • Page 72 16. TROUBLESHOOTING Trouble Action Cause Piston, piston ● ● ● ● ● ● Correct or replace. ring or cylinder excessively worn. Carbon deposition in the ● ● ● ● Clean out. combustion chamber Suction height Place the pump to too high or nearer and/or lower ●...
  • Page 73 16. TROUBLESHOOTING Trouble Action Cause Tighten securely a Vacuum pipe ● ● clump of vacuum pipe loose or cracking or replace. Strainer cap Tighten securely or ● ● loose replace. or O-ring failure V belt damaged ● ● Replace. or worn Vacuum pump rotor shaft Repair or replace.
  • Page 74 16. TROUBLESHOOTING Trouble 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.
  • Page 75 16. TROUBLESHOOTING Trouble Action Cause Change the nozzle Discharge nozzle for suitable size or ● ● ● too large Incorporate safety nozzle. Spray nozzle ● Clean out. clogged Governor adjustment out of ● ● ● Adjust it securely. specified range Governor link ●...

  • Page 76: Appendix

    17. APPENDIX Tightening torque specifications 0.6~ 1.3~ 2.7~ 4.6~ 11.2~ 22.5~ N·m 15.1 30.6 Standard Bolt 0.06~ 0.13~ 0.27~ 0.47~ 1.14~ 2.30~ kgf·m 0.08 0.18 0.36 0.64 1.54 3.12 8.2~ 20.0~ 40.2~ N·m 10.8 26.5 53.9 Heat Treated Bolt 0.84~ 2.04~ 4.10~ kgf·m...

  • Page 77: Tool And Standard Accessory

    18. TOOL AND STANDARD ACCESSORY Standard accessory Description Remarks Quantity Tool kit ・Tool kit bag ・Plug wrench ・Handle of plug wrench Spark plug BPR7HS-10 Pumping plate Fuse *1 Pipe assy Search light (4P) (Floodlight) Auto battery charger Coupling *2 *1 Spare fuses are attached to fuse box. Whether or not it is included as an accessory depends on the specifications of the pump.

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