Kohler TP 4.0 D User manual

TP 4.0 D
Trash Pump Service Manual
KohlerPower.com39 690 01 Rev. -- 1
2 Safety
3 Specifications
5 Troubleshooting
6 Disassembly/Inspection and Service
8 Reassembly
IMPORTANT: Read all safety precautions and instructions carefully before operating equipment. Refer to operating
instruction of equipment that this engine powers.
Ensure engine is stopped and level before performing any maintenance or service.
For all engine related maintenance, disassembly and reassembly, refer to service manual of engine
powering this equipment.

Safety
2 39 690 01 Rev. --KohlerPower.com
SAFETY PRECAUTIONS
WARNING: A hazard that could result in death, serious injury, or substantial property damage.
CAUTION: A hazard that could result in minor personal injury or property damage.
NOTE: is used to notify people of important installation, operation, or maintenance information.
WARNING
Fuel can cause fires and
severe burns.
Do not fill fuel tank while
engine is hot or running.
Fuel is flammable and its vapors
can ignite. Store fuel only in
approved containers, in well
ventilated, unoccupied buildings.
Do not fill fuel tank while engine is
hot or running, since spilled fuel
could ignite if it comes in contact
with hot parts or sparks from
ignition. Do not start engine near
spilled fuel. Never use fuel as a
cleaning agent.
WARNING
High Pressure Fluids can
puncture skin and cause
severe injury or death.
Do not work on fuel
system without proper
training or safety
equipment.
Fluid puncture injuries are highly
toxic and hazardous. If an injury
occurs, seek immediate medical
attention.
WARNING
Rotating Parts can cause
severe injury.
Stay away while pump is
in operation.
Keep hands, feet, hair, and
clothing away from all moving
parts to prevent injury. Never
operate generator with covers,
shrouds, or guards removed.
CAUTION
Electrical Shock can
cause injury.
Do not touch wires while
engine is running.
Never operate pump in rain or
snow.
Never touch pump with wet hands
or electrical shock will occur.
WARNING
Hot Parts can cause
severe burns.
Do not touch engine
while operating or just
after stopping.
Never operate pump with heat
shields or guards removed. Do not
modify pump.
Place pump in a place where
pedestrians or children are not
likely to touch pump.
Be sure to carry pump only by its
carrying handles.
WARNING
Carbon Monoxide. Can cause
severe nausea, fainting or death.
Avoid inhaling exhaust fumes.
Only use product outdoors.
Engine exhaust gases contain poisonous carbon
monoxide.
Carbon monoxide is odorless, colorless, and can
cause death if inhaled.

Specifications
339 690 01 Rev. -- KohlerPower.com
ENGINE IDENTIFICATION NUMBERS
Kohler portable power products identification numbers (model, specification and serial) should be referenced for
efficient repair, ordering correct parts, and engine replacement.
Model. . . . . . . . . . . . . . . . . . . . . TP 4.0
Pump Type
Port Size (Inch)
Specification . . . . . . . . . . . . . . . PA-TP40D-3001
Serial . . . . . . . . . . . . . . . . . . . . . 4323500328
Year Manufactured Code Factory Code
Code Year
43 2013
44 2014
45 2015
GENERAL SPECIFICATIONS3, TP 4.0 D
Overall Dimensions 715 mm (28.2 in.) Length
570 mm (22.4 in.) Width
590 mm (23.2 in.) Height
Suction and Discharge Size 102 mm (4 in.)
Dry Weight 90 kg (198.4 lbs.)
Maximum Flow Rate 1,800 l/min. (476 gal./min.)
Maximum Suction Head 8 m (26.2 ft. )
Maximum Lift Head 17 m (55.7 ft.)
Maximum Debris Size 28 mm (1.1 in.)
3 Values are in Metric units. Values in parentheses are English equivalents.

Specifications
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GENERAL TORQUE VALUES
Metric Fastener Torque Recommendations for Standard Applications
Property Class Noncritical
Fasteners
Into Aluminum
Size 4.8 5.8 8.8 10.9 12.9
Tightening Torque: N·m (in. lb.) ± 10%
M4 1.2 (11) 1.7 (15) 2.9 (26) 4.1 (36) 5.0 (44) 2.0 (18)
M5 2.5 (22) 3.2 (28) 5.8 (51) 8.1 (72) 9.7 (86) 4.0 (35)
M6 4.3 (38) 5.7 (50) 9.9 (88) 14.0 (124) 16.5 (146) 6.8 (60)
M8 10.5 (93) 13.6 (120) 24.4 (216) 33.9 (300) 40.7 (360) 17.0 (150)
Tightening Torque: N·m (ft. lb.) ± 10%
M10 21.7 (16) 27.1 (20) 47.5 (35) 66.4 (49) 81.4 (60) 33.9 (25)
M12 36.6 (27) 47.5 (35) 82.7 (61) 116.6 (86) 139.7 (103) 61.0 (45)
M14 58.3 (43) 76.4 (56) 131.5 (97) 184.4 (136) 219.7 (162) 94.9 (70)
Torque Conversions
N·m = in. lb. x 0.113 in. lb. = N·m x 8.85
N·m = ft. lb. x 1.356 ft. lb. = N·m x 0.737
English Fastener Torque Recommendations for Standard Applications
Bolts, Screws, Nuts and Fasteners Assembled Into Cast Iron or Steel Grade 2 or 5 Fasteners
Into Aluminum
Size Grade 2 Grade 5 Grade 8
Tightening Torque: N·m (in. lb.) ± 20%
8-32 2.3 (20) 2.8 (25) — 2.3 (20)
10-24 3.6 (32) 4.5 (40) — 3.6 (32)
10-32 3.6 (32) 4.5 (40) — —
1/4-20 7.9 (70) 13.0 (115) 18.7 (165) 7.9 (70)
1/4-28 9.6 (85) 15.8 (140) 22.6 (200) —
5/16-18 17.0 (150) 28.3 (250) 39.6 (350) 17.0 (150)
5/16-24 18.7 (165) 30.5 (270) — —
3/8-16 29.4 (260) — — —
3/8-24 33.9 (300) — — —
Tightening Torque: N·m (ft. lb.) ± 20%
5/16-24 — — 40.7 (30) —
3/8-16 — 47.5 (35) 67.8 (50) —
3/8-24 — 54.2 (40) 81.4 (60) —
7/16-14 47.5 (35) 74.6 (55) 108.5 (80) —
7/16-20 61.0 (45) 101.7 (75) 142.5 (105) —
1/2-13 67.8 (50) 108.5 (80) 155.9 (115) —
1/2-20 94.9 (70) 142.4 (105) 223.7 (165) —
9/16-12 101.7 (75) 169.5 (125) 237.3 (175) —
9/16-18 135.6 (100) 223.7 (165) 311.9 (230) —
5/8-11 149.5 (110) 244.1 (180) 352.6 (260) —
5/8-18 189.8 (140) 311.9 (230) 447.5 (330) —
3/4-10 199.3 (147) 332.2 (245) 474.6 (350) —
3/4-16 271.2 (200) 440.7 (325) 637.3 (470) —

539 690 01 Rev. -- KohlerPower.com
Troubleshooting
Condition Possible Cause Conclusion
Pump fails to prime. Pump not filled with liquid. Add liquid to pump through priming port.
Air leak at suction line connection. Add sealant to connection.
Worn suction connection gasket. Replace suction gasket.
Leaking suction line. Inspect, repair, or replace suction line.
Engine speed too low. Run engine at maximum speed.
Worn or broken volute or impeller. Replace parts as required.
Leaking/worn mechanical seal. Replace mechanical seal.
Clogged suction strainer/line. Clean strainer and suction line.
Suction lift too great (25 ft. max). Reduce lift.
Suction line too long. Reduce length to under 30 feet.
Pump is air locked. Vent pump discharge through priming port.
Pump primes too slowly. Insufficient priming water. Add more water through pump filler cap.
Mechanical seal chipped or broken. Replace mechanical seal.
Check valve damaged. Replace check valve.
Suction hose damaged or strainer
clogged.
Replace hose.
Air leaks caused by O-ring damage. Clean strainer.
Engine rpm too low. Replace O-rings.
Lift head too high. Check rpm and reset throttle as required.
Insufficient priming water. Lower lift head.
Reduced capacity or
discharge pressure.
Clogged strainer or lines. Clean strainer, suction and discharge
lines.
High friction loss in line. Remove kinks and elbows, reduce length.
Discharge head too high. Lower end of discharge line, remove
nozzles.
Engine speed too low. Increase engine speed.
Drop in engine output. Repair engine.
Clogged impeller. Remove clog.
Worn/damaged impeller or volute. Replace parts as required.
Pump will not work/engine
will not turn over.
Clogged pump. Remove clog between impeller and volute.
Pump parts rusted together. Disassemble pump, free parts.
Damaged impeller or volute. Replace volute or impeller.
Engine seized. Remove pump from engine, check engine
itself.
Pump will not work/engine
runs.
Impeller stripped/key sheared. Disassemble pump, replace parts/engine.
Pump impeller/volute clogged. Clean pump.
Insufficient liquid supply. Increase liquid supply.
TROUBLESHOOTING GUIDE
When troubles occur, be sure to check simple causes which, at first, may seem too obvious to be considered. For
example, a starting problem could be caused by an empty fuel tank.
Some general common causes of pump troubles are listed below. Use these to locate causing factors.

TP 4.0 D Components
EL
M
B
I
H
CN
AE
D
F
G
J
K
AInspection Flap BInlet Flange CCheck Valve DPump Case
ERubber Seal FImpeller GGasket HRotating Seal
IMechanical Seal JBack Plate KOutlet Flange LPump Filler Cap
MO-ring NPump Drain Plug
Disassembly/Inspection and Service
6 39 690 01 Rev. --KohlerPower.com

Remove Outlet Flange
1. Remove outlet flange screws and remove outlet
flange.
Inspection
Inspect gasket for cracks, tears or improper fit. Replace
if necessary.
Remove Inlet Flange and Check Valve
NOTE: Check valve position is important. Observe
which way check valve faces inlet flange for
reassembly.
1. Remove inlet flange screws and remove inlet flange.
Inspection
Inspect check valve for tears, cracks, or twists. Replace
if necessary.
Remove Pump Case
NOTE: Pump case is heavy; be prepared to handle the
weight to maneuver for inspection and service.
1. Drain any water from pump case by loosening drain
plug.
2. Remove screws that hold pump case to back plate.
3. Remove pump case.
Inspection
Inspect pump case for cracks or bent castings.
Remove Impeller
NOTE: Impeller is heavy.
1. Using a rubber mallet hit impeller to loosen.
2. Turn impeller counter-clockwise by hand until free
from crankshaft. Be prepared to catch impeller when
free from crankshaft.
3. Inspect impeller for cracks and bent blades.
Inspection
1. Measure distance between shaft shoulder and
rotating seal on shaft. Clearance is 19.1/19.5 mm
(0.7520/0.7677 in.).
2. Thread impeller back on shaft and measure distance
from back plate to outer surface of impeller.
Clearance is 86.0/86.4 mm (3.3858/3.4016 in.).
Remove Mechanical Seal
NOTE: Drops of dish washing soap on shaft will help
remove mechanical seal. This prevents sealing
lip from possibly tearing when removing.
1. Using two screwdrivers, remove mechanical seal by
prying side to side until it is free. It may be
necessary to remove pump case to remove
mechanical seal.
2. Pull seal off crankshaft and inspect for cracks, burn
marks and overall condition. Replace if necessary.
Remove Back Plate
1. Remove screws securing back plate to engine.
These are special screws with special washers.
Make sure to replace with same part numbers if
needed.
Inspection
Inspect back plate for cracks or bent. Replace if
necessary.
Disassembly/Inspection and Service
739 690 01 Rev. -- KohlerPower.com

8
Reassembly
39 690 01 Rev. --KohlerPower.com
TP 4.0 D Components
EL
M
B
I
H
CN
AE
D
F
G
J
K
AInspection Flap BInlet Flange CCheck Valve DPump Case
ERubber Seal FImpeller GGasket HRotating Seal
IMechanical Seal JBack Plate KOutlet Flange LPump Filler Cap
MO-ring NPump Drain Plug

9
Reassembly
39 690 01 Rev. -- KohlerPower.com
Install Back Plate
1. Apply Loctite® 587™ Ultra Blue or equivalent to
screws.
2. Replace back plate and hold in position.
3. Secure with screws and washers.
4. Torque back plate screws to 17.6-20.3 N·m
(13-15 ft. lbs.).
Install Mechanical Seal
NOTE: Drops of liquid detergent on shaft will help install
mechanical seal.
1. Using thumbs, push mechanical seal into place.
Install Impeller
1. Install rotating seal onto shaft and press against
back plate.
2. Turn impeller on by hand in a clockwise position until
tight.
3. Hit 1 blade in a clockwise position to tighten impeller
until resistance is observed.
Install Pump Case
1. Place a new gasket on back plate.
2. Install pump case to back plate and loosely tighten
screws making sure gasket is seated correctly.
3. Torque screws to 36.6 N·m (27 ft. lb.).
Install Inlet Flange and Check Valve
1. Apply Loctite® 587™ Ultra Blue or equivalent to inlet
flange screws.
2. Install inlet flange and check valve to pump case
with screws and washers. Torque screws to
4.1-5.4 N·m (36-48 in. lbs.).
Install Outlet Flange
1. Apply Loctite® 5770™ High Temperature Thread
Sealant or equivalent to screws.
2. Install outlet flange and rubber gasket with screws
and washers.
3. Torque screws to 4.1-5.4 N·m (36-48 in. lbs.).
Testing Pump
1. Before running check oil and pull engine over with
retractable starter to make sure nothing is binding in
pump.
2. Fill with prime water, start engine. After warm up run
engine at full throttle and check vacuum with
vacuum tester to make sure no leaks have
developed. A vacuum of 20 to 25 lbs at sea level
should be read. This reading should be obtained
within 5 seconds.

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1139 690 01 Rev. -- KohlerPower.com

© 2013 by Kohler Co. All rights reserved.
12 KohlerPower.com 39 690 01 Rev. --