TOHATSU VE 1500, VE 1000 Owner's Manual

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

APPLICATIONS OF THIS FIRE PUMP

USAGE

TOHATSU fire pump “VE1500 / VE1000” are manufactured for use in fire fighting
operations.

These portable fire pumps are intended only for fire fighting activities in
collaboration with general public fire extinguishing equipment.

Using it for other applications is regarded as being used for improper purposes.

The manufacturer of these fire pumps bears no responsibility for any damages that
may result from modification of the fire pump without prior permission from the
manufacture, improper use of the fire pump, or use of the fire pump for applications
other than those stated above.

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

Using these fire pumps within the range of intended uses implies that the user should
follow the instructions provided by the manufacturer relevant to operation, servicing
and maintenance.

CAUTION

Intended people

All persons who operate, service or maintain this fire pump must read and
understand the following items:

• Owner’s manual

• Safety-related instructions on the pump and the other parts such as the battery.

• The other owner’s manuals, such as battery charger.

The portable pump should be operated by only persons who received training as
operators of fire engines along with each country’s (region’s) regulations.
The range of personal responsibility and supervision must be strictly defined by the
user.

If a person does not have adequate professional knowledge required for his/her
assignment, he/she must undergo relevant training or receive appropriate
instructions from an individual who is actually knowledgeable in operation of this fire
pump.

A person who does not have enough knowledge is not permitted to operate this fire
pump.

When using this fire pump, conditions under which an explosion may occur are not
considered.

Keep this manual in a safe place for future reference.

Operators of this fire pump must always refer to all the
relevant manuals in order to avoid errors, personal
injuries, and equipment damage when operating the

portable fire pump, and to maintain faultless operation.

Arrange owner’s manual so that operators can refer to

them where they operate the fire pump.

NOTE

INTRODUCTION

Thank you for purchasing the TOHATSU Fire Pump.
This fire pump has passed a range of quality assurance standards.

Owner’s manual

This portable fire pump complies with relevant laws and regulations.

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 description for operation and maintenance of the
engine.

This manual is an important item that goes with your portable
fire pump.
This manual should accompany this fire pump if sold to another
person.

MANUFACTURER AND AFTER-SALES SERVICE ADDRESS

Before using this fire pump, write down the serial number in the following boxes.
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 : [phone]
Phone : [phone]

Serial Number

The pump identification number is
marked on the pump casing.

DANGER

WARNING

GENERAL SAFETY INFORMATION

Overview

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

Warning sign

Meaning

This sign is used for safety-related instructions in
this manual.
Be sure to follow all safety-related instructions,
otherwise personal injury may occur.

Signal words

Failure to observe will result in severe personal injury or

death.

Failure to observe 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 maintenance

of the pump or to clarify important points.

・For attaching position of the warning label, refer to the “CONTENT 3 LABELS”.

・Warning labels should be read clearly at any time.

If the display of the warning label becomes difficult to be read, it was

almost come off, you must replace paste immediately.

CAUTION

Safety-related instructions and warning signs

Read and follow the safety-related instructions
described in this manual and all warning signs on
the portable fire pump thoroughly.

Always keep the warning signs in a legible
condition. If any warning sign becomes illegible
or detached, replace it immediately.

Transporting the portable fire pump

Retractable handle is

folding type.

Do not put hand or finger
between top of retractable

handle and bracket.

When transporting the portable fire pump,

assign one person per handle.

Also, when you transport the portable fire pump,
it should be transported holding the handle

firmly.
There is a risk of injury to the leg by falling.

Durability of protection

When you purchase a new pump, it is placed in
packing box and protected.

Storage of pump after transportation

Keep the pump away from high humidity, and place
it on a horizontal plane.

Disposal of packing box

Dispose the packing box by following the
environmental laws.

Emissions
Noise emission values

For noise emission values, refer to “CONTENT 17

7

APPENDIX”.

Wear proper hearing protection

during operation.

Exhaust gas

Exhaust gas emitted from the engine contains
carbon monoxide (CO) etc. that may seriously
affect human health.

Do not operate the engine in a room, car,
warehouse, tunnel, or other closed locations that
have poor ventilation.

Mortal danger due to carbon monoxide(CO)
poisoning.

Handling of fuel

Exercise care when handling fuel.
Failure to do so may cause fire.

Do not bring any flames near fuel.
Stop the engine before refueling. Do
not smoke while refueling fuel.

Do not refill fuel in an enclosed room. Doing so may
cause an explosion caused by fuel fumes.

If fuel spills, wipe it with a cloth or other material,
and dispose of it according to relevant laws and
regulations.

CAUTION

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.

Protective clothing

Protective equipment

During fire extinguishing training or normal fire
fighting services, wear normal protective clothing
and equipment to protect your body.

• Fireproof protective clothing

• Fireproof helmet

• Fireproof protective gloves

• Fireproof protective boots

Service Maintenance

Servicing and maintenance of this fire pump must
be carried out by only the persons who have
professional knowledge, who are familiar with the
device, and who understand laws and regulations
regarding safety and accident prevention.

Before starting maintenance work, turn the main
switch off to stop the engine.

Disconnect the negative terminal of the battery.

Before starting maintenance work, securely place
the portable fire pump on the ground.

In the case of just after stopping the engine, do not
touch the exhaust pipe, the muffler and the other
engine parts until these parts will be cold enough.
These parts could be very hot and will cause severe
burns.

Safety devices

After protective devices (such as the muffler guard)
have been disassembled as part of servicing and
maintenance work, immediately install them back to
their original locations, making sure that they are in
safe and secure condition.

Check the portable fire pump visually and
functionally on a regular basis.

If you find any faulty device or equipment, remove
it immediately, and repair or replace it, if necessary.
Failure to do so may cause an accident.
After it has been repaired or replaced, make sure
that it functions correctly.

Electrical equipment

Only expert electricians or trained staff members
should handle electrical equipment.

When removing the battery cable from the electrical
equipment, always disconnect the negative (-) cable
first.

When installing the battery cable, be sure to
connect the positive (+) cable first before
connecting the negative (-).

Do not place any metal on the top of or around the
battery. Doing so may cause a short circuit.

Use a fuse with the same specifications as the
original one when replacing it. Using a fuse that
has a greater capacity than the rated value may
damage the equipment.

Check the electrical equipment of the fire pump on
a regular basis.

Battery

Follow any safety-related instructions shown on the
battery.

The battery can generate flammable hydrogen gas
that may cause an explosion.

Do not charge the battery in closed location.
Do not smoke around the battery.

The battery electrolyte is caustic and may cause
personal injuries.

• Always wear protective clothing.

• Always wear protective gloves.

• Always wear protective glasses.

• Do not tilt the battery.
Doing so may cause the battery electrolyte to leak

out from the vent hole.

Disposal

Dispose of disused batteries according to relevant
laws and regulations.

Genuine parts

When replacing parts for servicing and maintenance
of the portable fire pump, only use Tohatsu genuine
parts.

If genuine Tohatsu parts and accessories are not
used it may adversely affect the functioning and
safety of the fire pump. Use genuine Tohatsu parts
only.

Tohatsu bears no responsibility for any personal
injuries or equipment damage that may result from
use of parts or accessories obtained from outside
sources.

Environmental protection measures

Dispose of oil, fuel, batteries, etc. according to
relevant environmental laws.

Do not dump waste into the ground, water, or
sewerage.

Store fuel only in the specified container.

When disposing of parts, follow the correct disposal
procedure.

Water-prohibiting substance
Do not discharge water to water-prohibited
substance.

Use of water

Do not pump combustible liquids, chemical or
caustic liquids.

Customer Service

If any problems occur during servicing and
maintenance work of the portable fire pump,
contact our Customer Service.

Address : 3-5-4 Azusawa, Itabashi-ku, Tokyo,

JAPAN

FAX : [phone]
Phone : Service [phone]
/ Email [e-mail]

Overseas section fire protection sales
department

[phone]
[e-mail]

EC Declaration of Conformity (DoC)

This product conforms to certain portion of the European Parliament directive.
DoC contains the following information;

• Name and Address of the manufacturer

• Applied community directives

• Reference standard

• Description of the product (Model name and serial number)

• Signature of the responsible person (Name / Title / Date and place of issue)

CONTENTS

1 SPECIFICATIONS……………….……...……………………1
2 OPERATING DEVICE………….………….…..……………5
3 LABELS…….……………………….…...……………………9
4 OPERATING PRECAUTIONS………..……….…...….…10
5 DESCRIPTION OF DEVICES…….………………….….12
6 PREPARATION FOR OPERATION…….…………….…20
7 USE OF OPERATION PANEL………..…………………24

8 STARTING THE ENGINE…..………………….….....…27

9 PRIME AND DISCHARGE…….………….………….…..31
10 STOPPING THE ENGINE..…….……………….……..…..37
11 MAINTENANCE AFTER OPERATION….….……….….38
12 MAINTENANCE IN COLD CONDITIONS….……….…43
13 USE OF ACCESSORIES………….….……………….…46
14 PERIODICAL INSPECTION………..………..…….……..49

15 SERVICE AND MAINTENANCE….....…..…..…..……...51

16 TROUBLESHOOTING………………….……….…...…….61
17 APPENDIX……………..…...…………………….……...….68
18 TOOLS AND STANDARD ACCESSORIES………..….69
19 WIRING DIAGRAM…………….….…….….………..……..70

20 TRANSPORTING DEVICE.…..…...….…..…….….....…..71

1

1 SPECIFICATIONS

Model VE1500 VE1000

Description Portable pump
Applicable standard EN 14466
Type brief designation PFPN 10-1500

PFPN 10-1000

Max. permissible inclination
angle

During transport : 35° at all sides

In operation : 15° at all sides
Max. operating pressure
P alim

17 bar
Max. water temperature +60 °C

Temperature range -15 °C to +40 °C ambient temperature

Engine

Manufacturer TOHATSU CORPORATION
Model 2WT81A
Type 2-stroke, water cooled spark ignition engine
Bore × Stroke 81 mm × 78 mm
Number of Cylinder 2
Piston displacement 804 ml
Authorized output 60 PS (44 kW)
Fuel type Unleaded petrol RON91
Fuel tank capacity 24 L
Fuel consumption * 22 L/h

16 L/h
Engine oil tank capacity 1.6 L
Ignition C.D.I.
Spark plug NGK BPR7HS-10
Starting system Electric starter and Manual starter
Lubrication Auto mixing
Fuel system Electronic fuel injection
Battery 12 V-16 Ah/5 h
Floodlight bulb 12 V-35 W

Remark: *It is fuel consumption at the time of the standard discharge.

2

Materials

Engine

Crankcase, Cylinder,
Cylinder head

Aluminum alloy

Crankshaft Chromium-molybdenum steel
Connecting rod Chromium-molybdenum steel
Piston Aluminum alloy
Pump shaft Chromium-molybdenum steel with metal plating
Muffler Steel and Stainless

Pump

Pump case, Pump cover

Aluminum alloy

Impeller

Aluminum alloy
Shaft seal
Type

Mechanical seal

1 SPECIFICATIONS

Model VE1500 VE1000

Primer

Type Rotary-vane vacuum pump (Oil less type)
Max. suction height Approx. 9m

Pump

Type Single suction, single stage, centrifugal pump
Number of delivery outlet 2
Discharge port coupling BSP thread 2-1/2” (65mm) male
Suction port coupling BSP thread 4” (100 mm) male

Pump performance
(Suction height: 3 m)

2,050 L/min at 6 bar 1,900 L/min at 6 bar

1,800 L/min at 8 bar 1,650 L/min at 8 bar

1,500 L/min at 10 bar 1,300 L/min at 10 bar
Dimensions and weight
Length x Width x Height 748 mm x 732 mm x 827 mm
Mass 107kg (dry) 127 kg (ready for operation)
Center of gravity 387 mm

3

Performance Curve (VE1500)

1 SPECIFICATIONS

4

Performance Curve (VE1000)

1 SPECIFICATIONS

5

2 OPERATION DEVICE

8

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

①

② ③ ④ ⑤ ⑥ ⑥ ⑤

⑦⑦

⑧

⑨ ⑩

6

2 OPERATION DEVICE

2

① Air silencer
② Fuel tank
③ Muffler
④ ECU
⑤ Oil tank
⑥ Discharge valve

⑦

Fuel feed pump

⑧

Injector

①

② ③ ④ ⑤ ⑥ ⑥ ⑦ ⑧

7

2 OPERATION DEVICE

① Cylinder drain valve
② Pump drain valve
③ Muffler drain valve

Discharge valve

handle

Oil tank cap

Floodlight

Cowl

Cowl mounting
bolt

Fuel tank cap

Fuel level gauge

Discharge port

Suction port

Muffler guard

①

② ③

8

2 OPERATION DEVICE

① Hour meter
② Battery voltage low warning lamp
③ Overheat warning lamp
④ Engine oil level warning lamp

①

② ③ ④

Main switch

Throttle dial

Pressure gauge for suction

Pressure gauge for discharge

Battery

charger

socket

Priming lever

Priming strainer

Floodlight

connector Fuse

Manual starter

handle

Carrying handle

Muffler

Exhaust pipe

Priming outlet

Thermo valve outlet

9

3 LABELS

Instruction

Warning
Caution

Warning

Warning

Warning

CE label

10

4 OPERATING PRECAUTIONS

Installing pump

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

an accident may occur.

If the fre pump should be installed on uneven ground, it must
be secured. 4

• Place the pump as near as possible to water source, and water
suction height as low as possible.

• When lowering the portable fire pump to the ground, lower it
gently and horizontally.

Max. permissible inclination angle: 15°

• In case of the inclined or uneven location, make sure that water
suction hose is lower than suction port of the pump.

• In case of the suction hose is put undulated, air can be left
easily in the hose, and possibly causes suction inability when
the water discharge valve is opened. In this case, set the water
discharge valve half-opened, and operate vacuum pump until
water is discharged continuously (for 3 to 5 seconds from
beginning of water discharge).

• Be sure to install strainer and basket on the end of suction hose.
If the pump may suck sand or mud on the bottom of water
source, place sheet below the basket .

• Put the strainer and basket of suction hose into the water more
than 30 cm from the surface to prevent suck of air.

• Discharge hose should be arranged not to be bent.

1
2
3
4
5
6
7

CAUTION

NOTE

11

4 OPERATING PRECAUTIONS

When installing the portable pump in the vehicle, to equip
with the pump in the vehicle placed on a level place.
When installing the portable pump in the vehicle, make sure
to apply the brakes of the vehicle in order to stop the wheels.

A serious accident may occur if the vehicle moves.

Carrying handle is folding type.
Do not put your hands or fingers into the retractable part
when operating the handle.

When transporting the portable fire pump, assign one person
per handle. Also, when you transport the portable fire pump,
it should be transported holding the handle firmly.

There is a risk of injury to the leg by fall.

When lowering the portable fire pump to the ground, lower it
gently and horizontally.

CAUTION

NOTE