TOHATSU V20D2 Page 78 Owner'S Manual Download

Page: 78 / 90

TROUBLESHOOTING

Trouble

Cause

Batter

y C

har
gin
g failur

tar

ter

do
es

Engi

star
t fai
lu

Engi

stum

e or
st

h id

lin

Idl

ing i
s t

Poor

acc
ele

tio

ngi
ne ov
er

-rev

ine

se
izing

Action

rime
r

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

replace.

Vane, Side plate
Worn or damaged

Replace.

Water stop

valve

Water stop valve
contamination

Clean up.

Water stop valve
diaphragm failure

Replace.

１

２

３

４

５

６

７

８

９

Summary of Contents for V20D2

Page 1: ...TOHATSU PORTABLE FIRE PUMPS OWNER S MANUAL Model V20E S V20D2 S Original instructions TOHATSU CORPORATION Date of print 2016 10 Date of publication 2016 9 003 12061 2...

Page 2: ...ire 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...

Page 3: ...equired 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 do...

Page 4: ...ations This 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 d...

Page 5: ...er in the following boxes This will be useful when you inquire about servicing repairs and genuine parts TOHATSU CORPORATION Address 3 5 4 Azusawa Itabashi ku Tokyo JAPAN FAX 81 3 3966 2951 Phone 81 3...

Page 6: ...bserve could result in severe personal injury or death Failure to observe could result in personal injury or property damage This instruction provides special information to facilitate the use or main...

Page 7: ...d 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...

Page 8: ...f it according to relevant laws and regulations Safety devices Before operating this portable fire pump be sure to check that all the safety devices have been installed in the appropriate positions Be...

Page 9: ...haust 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 muffle...

Page 10: ...the 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...

Page 11: ...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...

Page 12: ...juries 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 envi...

Page 13: ...k of the portable fire pump contact our Customer Service Address 3 5 4 Azusawa Itabashi ku Tokyo Japan Fax 81 3 3966 2951 Phone Service 81 3 3966 3380 Email tohatsu pservice tohatsu co jp Overseas sec...

Page 14: ...ION FOR OPERATION 18 7 ENGINE START 22 8 PRIME AND DISCHARGE 26 9 ENGINE STOP 34 10 MAINTENANCE AFTER OPERATION 35 11 MAINTENANCE IN COLD CONDITION 41 12 USE OF ACCESSORIES 45 13 PERIODICAL INSPECTION...

Page 15: ...f Cylinder 1 Piston displacement 198 ml Authorized output 11 7 PS 8 6kW Fuel type Unleaded petrol RON91 Fuel tank capacity 3 5 L 0 92 gal Fuel consumption 4 9 L h 1 29 gal h Ignition C D I Spark plug...

Page 16: ...SG min at 75 psi 0 40 m3 min at 0 7 MPa 115 USG min at 100 psi Dimensions and weight Length Width Height 560 475 530 mm 22 0 18 7 20 9 in Mass Dry 37 kg 81 6 lbs 43 kg 94 8 lbs Materials Engine Crankc...

Page 17: ...Piston displacement 198 ml Authorized output 11 7 PS 8 6kW Fuel type Unleaded petrol RON91 Fuel tank capacity 3 5 L 0 92 gal Fuel consumption 4 9 L h 1 29 gal h Ignition C D I Spark plug NGK B7HS Sta...

Page 18: ...ight 3 m 9 8 ft 0 65 m3 min at 0 5 MPa 155 USG min at 75 psi 0 40 m3 min at 0 7 MPa 115 USG min at 100 psi Dimensions and weight Length Width Height 555 470 532 mm 21 9 18 5 20 9 in Mass Dry 36 kg 79...

Page 19: ...5 SPECIFICATIONS Performance Curve V20ES 1 10 10 11 11 12 12 13 14 15 16 17 18 13 14 15 16 17 18...

Page 20: ...6 SPECIFICATIONS Performance Curve V20D2S 1 10 10 11 11 12 12 13 14 15 16 17 18 13 14 15 16 17 18...

Page 21: ...arburetor Fuse For Model S Socket Vacuum gauge Compound pressure gauge Priming lever Fuel tank cap Fuel gauge Fuel tank Vacuum pump Strainer cap for Vacuum pump Discharge port adaptor opt Suction port...

Page 22: ...LABELS WARNING CAUTION 3 Instruction label Fuel danger label Exhaust gas warning label Muffler caution label Spark plug High voltage caution label 10 10 11 11 12 12 13 14 15 16 17 18 13 14 15 16 17 1...

Page 23: ...undulated air can be left easily in 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 se...

Page 24: ...transport the portable fire pump it should be transported holding the handle firmly Do not touch the exhaust pipe and the muffler while the engine is running or for more than 10 minutes after the engi...

Page 25: ...trainer is not installed if you insert your finger into the suction port you may be seriously injured by the rotating inducer Installed the standard strainer to the suction port Do not run the pump if...

Page 26: ...pump Discharge port The diameter of the thread for fire pump is BSP thread 2 1 2 male for V20E S model JIS B 9912 dimensions of screwed type coupling for fire hose 2 1 2 82 5 5 threads per inch threa...

Page 27: ...l the time except refuel Engine oil tank V20E S Refill appropriate amount of oil to the oil tank Close the oil tank cap all the time except filling The oil tank has an oil level sensor The warning buz...

Page 28: ...n the main switch Stop switch to run or to stop the pump for V20ES and V20D2S Description Function for V20ES V20D2S OFF To stop the pump ON Running position START To start the pump running Push the st...

Page 29: ...in switch ON The socket is for a battery and a floodlight Do not connect a cigarette lighter to the socket because it is not a heat resistant object Fuse box Fuse is in the fuse box Fuse 5A Security f...

Page 30: ...checking the oil level If you pull the dipstick when the pump is running the oil may blow out Manual starter If the engine will not start with the starter motor use the manual starter Personal injuri...

Page 31: ...e this fire pump is operated Connect the floodlight plug to the outlet socket of the pump Fix the projector to the tripod with tightening the adjust screw Secure adequate lighting for the location whe...

Page 32: ...the tank with mixed gasoline Gasoline with two cycle engine oil at a ratio of 30 1 gasoline 30 two cycle engine oil 1 Gasoline 87 octane minimum at pump posted rating Use of low quality fuel results...

Page 33: ...s 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 on...

Page 34: ...higher Always wipe off the spilled oil Governor oil Before using fire pump check governor oil level Pull out governor oil gauge dipstick check the oil level the oil level should be between upper and l...

Page 35: ...ion V20ES V20D2S The battery mounted on the engine can be used immediately after filling cells with electrolyte 1 28 specific gravity at 20 C 68 F Refer to the INSTRUCTIONS on the battery Do not opera...

Page 36: ...ch as indoor in the vehicle warehouse tunnel well in the hold of a ship Do not start engine with discharge valve open Do not pump and discharge liquids other than water e g flammable liquids or chemic...

Page 37: ...thin the range below Low pressure 21 mm 0 8 in High pressure 15 5 mm 0 6 in Over 21 mm 0 8 in nozzle bore can cause pump damages Starting engine Wear proper hearing protection during operation While e...

Page 38: ...eration of the starter motor will run the battery drain Operate the starter motor within maximum 3 seconds If the engine does not start wait for over 5 seconds before operating the starter motor again...

Page 39: ...tarter handle slowly towards you When you feel the ratchet engage pull the handle sharply holding the fire pump in place with your foot 5 After engine starts return the starter handle to the original...

Page 40: ...tion hose Is the suction hose damaged Does the vacuum performance of the priming pump reduced significantly Does the pump case leak vacuum Does a vacuum leak occur when the pump is connected with the...

Page 41: ...ld be run with water discharge for protecting some parts of the pump such as mechanical seal 4 Open the discharge valve Discharge port type V20E S Turn the discharge port lever towards the discharge p...

Page 42: ...more until the water is continuously discharged 5 Adjust the water pressure volume using the throttle dial In the case of using a branch pipe the person holding the branch pipe must be notified of ch...

Page 43: ...t the opening of fire hydrant on off valve if necessary If the water pressure from fire hydrant is higher than 0 6MPa 87psi do not open the fire hydrant on off valve more If the water pressure from fi...

Page 44: ...ps until all the pumps stopped 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 in the pump as...

Page 45: ...ons In the case of relay pumping operations training in a flat place if the number of extending hose is less than ten use the safety nozzle attached Description of replay pumping operation 8 10 10 11...

Page 46: ...e sure that the discharge valves are opened including the fire nozzle 4 Decide the discharge pressure of each pumps in consideration of needed pressure for next pump or fire nozzle and the height loss...

Page 47: ...e throttle Always confirm the pressure with the suction pressure gauge 5 If the suction pressure drops below 0 1MPa 15psi order the operator of the pre stage pump to increase the water pressure and ad...

Page 48: ...position 2 Close the discharge valve V20E S V20D2 S 3 Stop the engine Electric starter type V20ES V20D2S Turn the main switch to OFF position Manual starter type V20E V20D2 Push the stop switch 9 10 1...

Page 49: ...and lift the priming lever to produce a vacuum within 30 seconds 4 After a vacuum is generated return the priming lever to the original position immediately and stop the engine 5 Check the vacuum pre...

Page 50: ...y 3 5 L 0 92 gal Draining fuel from the carburetor Before storing the pump long term drain the fuel from the carburetor a After stopping the engine close the fuel valve b Pull the knob of the drain va...

Page 51: ...stroke engine oil up to the upper level Use 2 stroke engine oil of ISO FB grade or higher 3 Governor oil Check the oil level using the governor oil level gauge Dipstick Use 2 stroke engine oil of ISO...

Page 52: ...V20ES V20D2S Hydrogen gas from the battery is explosive Keep battery away from flame and sparks Charge the battery in well ventilated area Do not charge battery in unventilated area Read the cautions...

Page 53: ...the battery charger after charging is completed Do not connect a cigarette lighter to the battery charger socket It may cause melt or burn out the socket due to overheating 2 Confirm that there is no...

Page 54: ...he battery liquid by an areometer The specific gravity of the full charge is 1 28 20 C conversion The outer surface of the battery should be kept always clean The battery life is normally 2 years even...

Page 55: ...the water put antifreeze fluid into the pump and vacuum pump 1 Open the drain valves Drain all the water from the pump 2 Close the drain valve s 3 Attach the plastic tube to the pump drain valve and...

Page 56: ...gine suck antifreeze fluid by operating the priming lever Even if antifreeze fluid disappears continue pulling a priming lever for approximately 30 seconds Return the priming lever to the original pos...

Page 57: ...TION 9 Close the drain valve s 10 Fill antifreeze fluid into the seal area of the discharge valve To use a long nozzle containing is helpful when you pour antifreeze fluid 11 10 10 11 11 12 12 13 14 1...

Page 58: ...g and install it correctly Otherwise a vacuum leak may occur 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 not is n...

Page 59: ...to use an automatic battery charger 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 bat...

Page 60: ...t of a cellar Install the pumping plate with holes in between the discharge port adapter and the bracket packing to avoid the pump cavitation which may cause damages to the pump Pumping plate is the s...

Page 61: ...eck the battery condition once a month Add distilled water if the battery liquid level is lower than the specific level And charge the battery If the battery is maintenance free battery do not add any...

Page 62: ...od 6 month or more Replace 1 Degradation ie Stink or color Replace 1 Strainer Impurities If water and or waste has accumulated Clean 1 Fuel hose Curling crack leak age connection Replace 1 Ignition Sp...

Page 63: ...imer Is not locked Check performance 0 08 MPa 12psi Replace parts if necessary 1 Air check Check pump unit if necessary Pump unit Closed discharge valves operation after priming water Check performanc...

Page 64: ...ly without problems Genuine parts When replacing parts as 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...

Page 65: ...her 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 the specification Spark plug gap 0 6...

Page 66: ...ays 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 r...

Page 67: ...nect the negative terminal Use the fuse with the same current rating ampere as that of the installed fuse Using a fuse that has excessive high resistance may result in electrical equipment failures Fu...

Page 68: ...iming lever to run the primer and check that the pressure gauge for suction points approximately 0 08MPa 12psi Return the priming lever to the original position Vacuum leak check After completing the...

Page 69: ...he priming lever to run the vacuum pump 3 Operate the throttle dial to raise the pump pressure almost to 1MPa 145 psi and then check for water leaks from each part of the pump and the cooling water pi...

Page 70: ...e seizing Action Fuel and Lubrication Low fuel Refuel Deterioration of fuel Replace with new fuel Fuel filter clogging Clean the clogging Fuel pipe kink or snap Fix routing of pipe Carburetor Clean or...

Page 71: ...cation Low fuel Refuel Deterioration of fuel Replace with new fuel Fuel filter clogging Clean the clogging Fuel pipe kink or snap Fix routing of pipe Carburetor Clean or replace with new Carburetor Th...

Page 72: ...rk 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 Battery loose...

Page 73: ...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 Battery loo...

Page 74: ...n 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 5A Charging connector...

Page 75: ...lown 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 5A Charging connec...

Page 76: ...ustion chamber Clean out Suction Suction height too high or length too long Make it pump location to nearer and or lower position Suction hose end is not in water Put the end of suction hose below 300...

Page 77: ...ombustion chamber Clean out Suction Suction height too high or length too long Make it pump location to nearer and or lower position Suction hose end is not in water Put the end of suction hose below...

Page 78: ...n 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 ro...

Page 79: ...ine 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...

Page 80: ...Close securely Suction 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...

Page 81: ...sed Close securely Suction 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 Repl...

Page 82: ...celeration Engine over rev Engine overheat Engine seizing Action Nozzle Discharge nozzle too large Change the nozzle for suitable size or incorporate safety nozzle Spray nozzle clogged Clean out Gover...

Page 83: ...uction Caused by Pump unit Caused by Playpipe Caused by Engine unit Nozzle Discharge nozzle too large Change the nozzle for suitable size or incorporate safety nozzle Spray nozzle clogged Clean out Go...

Page 84: ...cations M3 M4 M5 M6 M8 M10 Standard Bolt N m 0 7 1 6 4 6 13 27 lb ft 0 5 1 2 3 4 9 20 kgf m 0 07 0 16 0 4 0 6 1 3 2 7 Heat Treated Bolt N m 9 24 47 lb ft 7 17 34 kgf m 0 9 2 4 4 7 16 10 10 11 11 12 12...

Page 85: ...antity Owner s manual 1 Tool bag 1 Tools Crown spanner 21mm 0 8 in 1 Tools Handle for spanner 1 Spark plug NGK B7HS 1 Pilot bulb 12V 3 4W 1 Pumping plate 1 1 Battery charger 12V 1 1 Fuse 5A 1 2 Fuel m...

Page 86: ...d White B W Black White B Y Black Yellow G W Green White Spark plug Control panel Oil level sensor Ignition coil Control panel Ground cord Pilot lamp cord Lamp Lamp Controller buzzer Flood light optio...

Page 87: ...W Red White B W Black White B Y Black Yellow G W Green White Plug Battery Starter motor Spark plug Ignition coil Oil level sensor CDI unit Flood light option Main Switch PTC heater Buzzer Controller...

Page 88: ...nk R Red W White Y Yellow Ignition coil lamp lamp Control panel CD unit Magneto Flood light Projector Option Plug Option Stop switch PTC heater Rectifier Socket WIRING DIAGRAM WIRING DIAGRAM for V20D2...

Page 89: ...Green P Pink R Red W White Y Yellow Plug Option Flood light Projector Option Battery Spark plug Starter motor Ignition coil Main switch Socket Fuse Starter solenoid CD Unit Magneto Rectifier Control...

Page 90: ...TOHATSU CORPORATION Address 3 5 4 Azusawa Itabashi ku Tokyo JAPAN FAX 81 3 3966 2951 Phone 81 3 3966 3137 003 12061 2 1610 300...

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