Koshin KTH - 100X User manual

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PUMPING AND ENERGY SOLUTIONS
PUMP
USER
MANUAL

Petrol engine pump on the frame
Technical specification:
Intended use Drainage water pumping
Make / Type Koshin / KTH –100x
Maximal flow 96 m3 / h, see curve
Maximal head 25 mwc, see curve
Maximal suction lift 8m
Suction connection 4’’
Discharge connection 4’’
Free passage Up to 27mm
Dimensions L x W x H 790mm x 680mm x 580mm
Weight 78kg
Engine Petrol engine
Engine brand / Type Honda / GX340
Engine power / rpm 5,8 kW / 3600 rpm
Fuel tank 6,1 liter
Maximal fuel consumption 3,5 l/h
Maximal working time with full revs 2h
GPS Not equipped

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KTH 50x –80X –100X

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Contents
1 Description....................................................................................................3
2 Construction..............................................................................................4
3 Specification and dimensions.....................................................................5
4 Performance curve.......................................................................................6
5 Safety instruction.........................................................................................7
6 Transportation..............................................................................................9
7 Pipework and installation..........................................................................10
8 Fill the fuel ..................................................................................................11
9 Preparation for starting..............................................................................12
9.1 Filling the pump casing.......................................................................12
9.2 Check fuel in fuel tank.........................................................................12
9.3 Check oil level in engine.....................................................................13
9.4 Checking safety and environmental risks .........................................13
9.5 Checking visual inspection.................................................................14
10 Starting ....................................................................................................15
11 Stopping ..................................................................................................17
12 Draining the pump when there is danger of freezing...........................18
13 Impeller check.........................................................................................19
14 Troubleshooting......................................................................................21

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1 Description
WARNING: This manual is intended to give Important Information that must be followed
during Storage, Transportation, Installation, Operation and Maintenance of the Pump-
Set. We therefore recommend that this manual is read carefully before the Pump-Set is
put into operation. To prevent damage being caused by inappropriate or incorrect use,
or by being used outside the normal operating parameters of the Pump-set, the
Instructions in this manual must be followed. Failure to do so may lead to damage to or
premature failure of the Pump-set and may cause Injury. Any such actions will invalidate
the warranty.

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2 Construction
Main pump elements:
1 –Delivery flange, 2 –Priming plug, 3 –Fuel tank cap, 4 –Muffler, 5 –Suction flange, 6 –
Water drain plug, 7 –Knob, 8 –Oil drain plug, 9 –Impeller removing plug, 10 –Frame

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3 Specification and dimensions
Model
KTH-50X
KTH-80X
KTH-100X
Connection Dia
50mm (2”)
80mm (3’’)
100mm (4’’)
Connection thread
BSP thread
BSP thread
BSP thread
Total head
30m
27m
25m
Delivery volume
700L/min
1340 L/min
1600 L/min
Max. suction head
8m
8m
8m
Engine type
Forced air cooling 4
stroke gasoline
engine
Forced air cooling 4
stroke gasoline
engine
Forced air cooling 4
stroke gasoline engine
Engine model
Honda GX160
Honda GX240
Honda GX340
Exhaust volume
163cc
242cc
337cc
Output rated power
2,9 kW / 3600
4,4kW / 3600rpm
5,8kW / 3600rpm
Output Max. power
3,6 kW / 3600
5,3kW / 3600rpm
5,8kW / 3600rpm
Fuel
Automotive
unleaded gasoline
Automotive unleaded
gasoline
Automotive unleaded
gasoline
Fuel tank capacity
3,6L
5,3L
6,1L
Starting method
Recoil starter
Recoil starter
Recoil starter
Net weight
47kg
58kg
78kg
Dimensions LxHxW (mm)
620x480x480
710x580x530
790x680x580
Solids Handling
20mm
27mm
27mm

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4 Performance curve

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5 Safety instruction
This manual contains warning and safety symbols. Do not ignore the instructions. They
are provided for the benefit of your health and safety and to prevent damage to the
environment and the pump unit.
DANGER
When the danger symbol with the text DANGER is shown, it is
accompanied by information that is of great importance for the
safety of everyoneconcerned.
Ignoring the information can result in injury (possibly severe) or even
death.
WARNING
When the warning symbol with the text WARNING is shown, it is
accompanied by information that is of great importance for everyone
concerned with the pump unit. Ignoring the information can result in
injury or damage (possibly severe) to the pump
unit.
The pump unit conforms to the European Machinery Directive. However, this does not
exclude the possibility of accidents if used incorrectly.
Useof the pumpforan application and/or deployment of thepump inanenvironment other
than defined at the time of purchase is strictly prohibited and can result in a hazardous
situation.
This is particularly true for corrosive, toxic or other hazardous liquids. The pump unit may
only be installed, operated and maintained by persons who have received appropriate
training and are aware of the associated dangers.
The installer, operator and maintenance personnel must comply with the local safety
regulations. The company management is responsible for ensuring that all work is
performed by qualified personnel in a safe manner. It is not permitted to make changes
to the pump unit without written permission from Koshin pump.
Ensure that hot/cold and rotating parts of the pump are shielded adequately to prevent
unintentional contact.
It is not permitted to start the pump if such guards are missing or damaged.
The company management must ensure that everyone who works with/on the pump unit
is aware of the type of liquid that is being pumped. These persons must know what
measures are to be taken in the event of leakage.
Dispose of any liquids that have leaked, in a responsible manner. Observe local
regulations.
Never allow the pump unit to run with a blocked discharge line. The heat build-up could
lead to an explosion
WARNING
Only appropriate fire extinguishers (e.g. carbon dioxide) are to be used in case of
fire or any other situation where open flames appear inside or outside the
equipment. It is strictly prohibited to use water to put out the flames

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Danger
Avoid fire when refuel or
maintenance. Highly
inflammable!
Do not use pump on
slope. Fuel spillage at
tank cap or carburetor
may cause fire.
Do not operate Trash
pump inside a room or
under bad ventilation
conditions. Harmful
substances are in
exhaust gas. There is
danger of gas poisoning.
In case of operating
trash pump in a well
or in a hollow, the
person operating the
pump must not enter
the small space as
there is danger of gas
poisoning.
Do not put any obstacle
around engine muffler. It
may cause fire or
breakage.
Do not overhaul or
repair, except by
person who is trained
to do so.
Read carefully and
understand fully before
use.
Keep children away
from pump when in
operation.
Do not touch muffler or
any part of the engine. It
could cause burn.
Do not run pump
without water inside
the pump. This will
cause pump damage.
Use correct type of
suction hose. Water
temperature tolerance: 5
to 45⁰C. may cause
breakage if use outside
the mentioned range.
This pump is not
suitable: Drinking
water, Seawater,
Kerosene, Light oil,
Heavy oil, Gasoline,
Chemical, etc.
Please use suction hose
for suction side. Please
purchase suitable hose
to fit to connection dia
and suitable length.
Please firmly connect
hose with coupling
and hose band when
you connect suction
or delivery hose to
pump.

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6 Transportation
“Transport” refers to the phase when the equipment is transferred from the manufacturing site to
that where it shall be used.
The electrical equipment is supplied mechanically fastened to the structure of its relative machine;
refer to the specific Use and Maintenance Manual for the methods of transport and handling.
Any kind of impact and stress to the components must be avoided when the equipment is
transported and handled. Particular attention must be paid to:
•ensure all covers, plugs, fuel cap, etc are tightened;
•protect the equipment from all kinds of possible impact and stress according to the type of
transport.
WARNING
Equipment before transportation must be switched off and must be cooled
down.

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7 Pipework and installation
Clean pipework thoroughly before connecting it to the pump. Suction pipes must have the same
diameter as the pump’s suction port (for larger diameters, seek Koshin pump advice). Where
possible, avoid curves, elbows or constrictions liable to limit the flow of liquid to the pump.
Install the pump as near to the liquid to be pumped as possible. Where possible, try to reduce the
length of the suction pipe.
Suction pipe connections must be completely airtight: check pipe threads, flange gaskets, quick
couplings etc.
Beware of water hammering
WARNING
Do not allow any vehicle to run over the delivery hose.
Do not close the delivery valve abruptly because water-hammer may occur.
This may result in heavy damage to the pump.

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8 Fill the fuel
WARNING
Perform this operation Engine must be switched off and cooled down. Filling the
Fuel not smoking or be near at open fire.
1. Open the fuel tank cup (1), visually inspect fuel level if necessary, fill it.

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9 Preparation for starting
WARNING
If the pump is not equipped with a vacuum pump, the pump must have to be
filled with the pumped liquid.
DANGER
Before operating the pump, check that all parts of the system have been correctly
installed and that all safety devices are operative.
9.1 Filling the pump casing
Fill the pump casing completely with the liquid to be pumped through the opening on the top of the
casing (1). When the pump is stopped, the casing does not empty and therefore it is not necessary
to refill it.
WARNING
Running without filling water can damage mechanical seal.
9.2 Check fuel in fuel tank
WARNING
Always check fuel level in fuel tank. Don’t start the pump when fuel is running low. In
this case air can get in fuel system.

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WARNING
Filling up the fuel, engine MUST be switched off.
9.3 Check oil level in engine
Before starting engine, please check if engine oil is filled to required level. Without engine oil or
shortage of engine oil can cause troubles for engine.
WARNING
Hot oil and components can cause personal injury. Do not allow hot oil or hot
components to contact the skin.
Note
Perform this maintenance engine must be stopped
1. Remove engine level dipstick (1) level must be above MIN level mark
2. If necessary to fill some oil, fill it through oil dipstick hole(1) .
9.4 Checking safety and environmental risks
THE FOLLOWING ACTIONS ARE STRICTLY FORBIDDEN:
•Using the pumps in a potentially explosive atmosphere.
•Carrying out maintenance with the engine running.
•Climbing on top of the engine-driven pump to perform work of any kind.
•Do not use the engine-driven pump indoors.

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9.5 Checking visual inspection
•Check pump of any leakage
•Check of any cracks
•Check if not missing or damaged parts
•Suction and discharge ports are not damaged
•Ensure not obstacle is at delivery hose side
•etc

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10 Starting
1. Check the pump type (type plate) and the characteristics of the pump unit, such as: rpm,
operating pressure, power consumption, operating temperature, direction of rotation, NPSH,
etc.
2. Check whether the pump unit is placed in accordance with the instructions. Pay particular
attention to the area around the pump unit. Make sure the pump unit can draw adequate fresh
air.
3. Check whether the prescribed safety provisions are in place.
4. Connect the hoses
5. Ensure strainer (suction filter) at the end of suction hose is in water
6. Perform preparation for starting
7. Turn the engine start-Stop switch to position “ON”(1)
8. Push throttle lever to “Turtle” position (2)
9. Open fuel lever (3)
10. If engine is cold, close choke lever (4)
11. Pull starter handle (5).

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12. When motor is started open choke lever (4). Engine pick up nominal speed and start running
smoothly.
WARNING
If vibration occurs during starting, stop the pump immediately and
eliminate the cause before starting again.
WARNING
If the pump vacuum lift is set too high, cavitation in the pump set is
possible and this can be recognized by High levels of vibration, a
crackling noise in the pump, decreased capacity and pressure. If this
condition is allowed to persist for long periods it will cause damage the
pump set. Continued running of the pump set in this condition will
invalidate the warranty
WARNING
Pump not allowed operate without pumping liquid more then 2 minutes. Its can
damage mechanical seal.

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11 Stopping
1. Turn the engine start-Stop switch to position “OFF” (1). Observe whether the system comes
to a gradual, smooth stop.
2. Close Fuel throttle (2).
3. When you suspect that the liquid is beginning to freeze, drain the pump while the medium is
still in the liquid state