Koshin SEV-50D User manual

22-06 012358201(ENG)
ENGINE DRIVEN PUMP
CONTENTS
INTRODUCTION
NAME OF PARTS................................................ 2
SAFETY PRECAUTIONS.................................... 3
OTHER PRECAUTIONS ..................................... 5
PREPARATION
PREPARATIONS FOR STARTING ..................... 6
HOW TO USE THE PRODUCT
PREPARATIONS FOR PUMP OPERATION ....... 9
STARTING THE ENGINE AND PUMP .............. 10
STOPPING THE ENGINE AND PUMP ............. 13
AFTER USING THE PRODUCT........................ 14
PERIODIC CHECKS AND MAINTENANCE...... 15
LONG-TERM STORAGE .................................. 19
INSPECTION AND MAINTENANCE
TROUBLESHOOTING ...................................... 20
OTHER ITEMS
SPECIFICATIONS............................................. 22
PERFORMANCE CARVE ................................. 23
SPAREPARTS ................................................... 23
Thank you for purchasing this product.
· Read this manual carefully before using the
product.
· Storethemanualonceyouhavenishedread-
ing it.
· Those who do not understand the content of
this operation manual should not operate the
product.
· If you lend this product to another person, ex-
plain how to use the product and instruct them
to read the operation manual carefully.
Please note that the illustrations and content in
thisoperationmanualmaydi󰀨ertotheactual
productduetochangestothespecications.
OPERATION MANUAL
SEV-50D, SEV-80D
Applications
Water transportation
Do not use it for any purpose other than its
intended purpose.

2
NAME OF PARTS
Decompression lever
Primingwaterllercap
Discharge port
Suction port
Mu󰀪er
Water pump
Oil drain plug
Air cleaner
Fuel cock
Speed control
knob
Diesel engine
Oilllercap
/ dipstick
Fuel tank
Fuelllercap
Water drain plug
Recoil starter
handle
Frame

3
SAFETY PRECAUTIONS
Read these safety precautions carefully before using the product. The cautions shown here are
for using the product correctly and to prevent hazards and injury to those using the product and
other people.
■Injuriesandhazardsthatmayoccurifthedisplayedcontentisignoredandtheproduct
isusedincorrectlyarecategorizedas"DANGER","WARNING",and"CAUTION".Allcat-
egoriesareimportantforsafety,soalwaysfollowthem.
■Contentthatyoumustfollowisdescribedincategories.
"PROHIBITED"contentthatyou
mustnotdo.
"EXECUTE"contentthatyoumust
complywith.
■Otherindications: NOTICE …Indicatesthecorrectwaytooperate
theproduct,andnotesoninspectionandmaintenance.
DANGER Content for which it is considered highly likely a person will
die or be seriously injured.
WARNING Content for which it is assumed a person may die or be seri-
ously injured.
CAUTION Content for which it is assumed a person may be moderately
injured and property damage may occur.

4
PREVENTING FIRES
Never add fuel to the fuel tank while the
engine is running. Wipe away all fuel spills
with a clean cloth. Keep gasoline, kerosene,
matches,otherexplosivesandammable
away from the product, since the tempera-
turearoundtheexhaustmu󰀪erisveryhigh
during operation.
·Topreventrehazardsandtoprovide
adequate ventilation, keep the pump at
least 1 m (3 ft) away from the building and
other equipment during operation.
·Operatethepumponaat,level,andrm
surface. If the pump is tilted, fuel spillage
may result.
PREVENTINGEXHAUSTGAS 
INHALATION
· Exhaust gas contains poisonous carbon
monoxide.
· Never use the pump in poorly ventilated
locations such as indoors or inside tun-
nels. If indoor operation is unavoidable,
provide proper ventilation so that people
andlivestockwillnotbea󰀨ected.
PREVENTINGBURNS
·Nevertouchthemu󰀪er,mu󰀪ercoveror
engine body while the engine is running
or hot.
OTHER SAFETY ITEMS
· As this product is heavy, you may be in-
jured if you drop it on your feet or hurt
your back when moving it, so use several
people to move it.
· Know how to stop the pump quickly and
understand how to deal with all of the con-
trols. Never permit anyone to operate the
pump without proper instructions.
· Always wear a helmet and safety shoes
(non-skid soles) and proper clothes.
·Donotoperateunderinuenceofalcohol.
· Keep children and pets away from the
pump when it is in operation.
· Keep away from rotating parts while the
pump is running.
· Work according to rules and regulations
of work area.
SAFETY PRECAUTIONS
WARNING
NOTICE
· Clear water refers to water-supply water,
well-waterwithnoheavylth(suchasslit,
clay, heavy mud).
Also, it is not suitable for seawater.

5
While the engine is still new, applications
of heavy loads may shorten the life of the
engine.Duringtherst20hours,followthe
break-in procedures.
1. Avoidoverloads
During break-in period, avoid applying
heavy loads before the engine is stabi-
lized.
2. Changeengineoilregularly
About one month or 20 hours after initial
starting and every 3 months or 100 hours
thereafter, change the engine oil while the
engine is still warm.
OTHER PRECAUTIONS
NOTICE
· Be sure to drain the oil while the engineis
warm,otherwiseitmaybedi󰀩cultto
drain the oil completely.

6
1. Selectionoffueloil
Use the most suitable diesel fuel oil for
the engine.
2. Keepdustandwateroutofthefuel
Whenllingthefueltankfromdrums,
make sure no dust or water are mixed in
with the fuel since this may lead to serious
fuel injection pump and nozzle problems.
After 3–4 days : Put a
suction piple halfway
into the drum
(Water and dust ac-
cumulate in the lower
portion of the drum)
3. Donotoverll
Overllingisdangerous.Withtheengine
level,donotllthefuelbeynodthetopof
theredcomponentinthefueltanklter.
CAUTION
Onlyusetherecommendeddieselfuel
oil.
Use of non-recommended fuel may cause
clogging in the fuel oil strainer, fuel injection
pump and fuel injection nozzle. This clog-
ging often causes sudden engine stops just
after starting.
ThefuelshouldhaveaCetanevalueof
morethan45inordertopreventdi󰀩cult
starting,misringandwhiteexhaust
smoke.
Dieselfueloilsubstitutesarenotrec-
ommended;theymaybeharmfultofuel
systemcomponents.
Thefuelshouldbefreeofwaterand
dust,becausethesecancausetrouble
inthefuelinjectionpumpandnozzle.
After purchasing
fuel: Allow drum to
stand 3–4 days
PREPARATIONS FOR STARTING
SelectionandHandlingofFuelOil
NOTICE
· Always check the fuel limit position on
the red component inside the fuel tank
lter.
· Check the indication when the product
is level. If the product is on an angle,
you will not get an accurate reading.
Red component
Fuelllercap

7
(°C)
S.A.E.
service
grade
Operating temp
Recommended value
Usable limit
40
-30 -20 -10 0 10 20 30 40
(°F)
30
20
20W
10W
20W 40
10W 30
0 20 6040 80 100
Refuelinawellventilatedareawiththe
enginestopped.Alsocheckthattheen-
ginehassu󰀩cientlycooled.
Donotsmokeorallowamesorsparks
intheareawheretheengineisrefueled
orwherefuelisstored.
Donotoverllthetankandmakesure
thellercapissecurelyclosedafterre-
fueling.
Becarefulnottospillfuelwhenrefue-
ling.Ifanyfuelisspilled,makesurethe
areaisdrybeforestartingtheengine.
Useproperengineoil.
If inferior oil is used, or if the engine oil is not
changed regularly, the risks of piston sei-
zure, piston ring sticking, accelerated wear
of the cylinder liner, bearings and other mov-
ingcomponentsincreasessignicantly.The
pump's life may be seriously shortened. We
recommend CD or Higher oil of API grade
classication.
Always use oil with the right viscosity for the
ambient temperature in which the engine is
being operated. Use the chart below when
choosing the engine oil.
Filltheoiluptothemouthofthellerport
with tne engine placed on the level.
Engine oil capacity 1.1 L
PREPARATIONS FOR STARTING
SelectingandHandlingEngineOil
WARNING
Filluptothetopofthellerport
with the engine on the level
Upper level (H)
Lower level (L)
Beforecheckingtheoillevel,makesure
thepumpissittinglevel.
If it is tilted, you may add either too much or
toolittleoil.Consequently,youmayoverll
and the engine will consume too much oil
and the oil temperature will become dan-
gerously high: or you may not add enough
oil, and the engine could seize up. Faults
caused by engine seizure are not covered
by the warranty.
Whencheckingtheoil,simplydipthe
dipstickintotheoilpan.Donotscrewin
thedipstick.
Besuretochecktheengineonalevel
surfacewiththeenginestopped.
WARNING
CAUTION
Oilllercap
/ dipstick
Oil drain plug

8
PREPARATIONS FOR STARTING
ServicingtheAirCleaner
Fastener
Air cleaner
element
Air cleaner
lower body
Max. oil limit
1. Openthefastenersandremovethe
variousparts.
2.Iftheengineoilintheoilbathisdirty,
disposeofitandwashitwithparts
cleaner,kerosene,orgasoline.
3.Fillnewengineoilunderthebore(Max.
oillimit).
Speciedamount 20 mL
4.Retthevariousparts.
Replacetheelementifoutputfallsora
badexhaustcolorisnoticed.
Neveroperatethepumpwithoutanair
cleanerelementandanengineoil.Sand
orforeignmatterispronetogettingin-
sidetheengine,whichmayhastenen-
ginewearandtear.
CAUTION

9
Please install coupling in order of :
1) ->2) ->3).
If you install coupling packing not inabove
order,airleakagemayresult,a󰀨ectingwater
suctione󰀩ciency.
1. Fixthestrainerattheendofthesuc-
tionsidehoseandtightenitwiththe
hoseband.Thenplaceitinthewater.
Make sure suction hose is connected
properly. In case of no self-priming after
llingpumpwithwaterandengineisstart-
ed, check suction hose connection care-
fully again. Most cases of no self-priming
are caused by improper hose connection.
· Use suction hose for suction side.
· Do not change pump diameter by alter-
ing suction hose.
2. Fixthesuctionsidehosetothesuction
portofthepumpandtightenitwitha
band.
3. Fixthedischargeportsidehosetothe
pumpandtightenitwithaband.
4. Fixtheendofthehosetotheplace
wherewaterisrequired.
Ensure no obstacle is at discharge hose
side.
Donotblock,kink,orobstructtheowof
liquid through the discharge hose.
5. Fillthewaterpumpwithwater.(This
wateriscalled"primingwater".)Re-
movetheprimingwaterllercapand
pourthewaterwithabucketorcup.
Fillupuntilwaterisdischargedfrom
thedischargeport.
Aspumpisself-primingtype,fullllwater
fully from priming port into pump casing
before running.
Breakdowns caused by dry running are
not covered by the warranty.
Di󰀨erentaccessoriesaresuitablefordi󰀨erent
models. Please check connection diameter
and install correct parts.
Hose band
Strainer
Discharge hose
2) Hose nipple
PREPARATIONS FOR PUMP OPERATION
1) Coupling
3) Coupling packing
Suction hose
Wooden boards
or blocks
Soft ground
Priming water
llercap
PreparationsforPumpOperation
HowtoInstalltheCoupling
Priming water
NOTICE
· Pump failure will occur if the suction
strainerisnotproperlytted.
The strainer keeps the size of the
suspended solids entering the pump
to the predetermined size the pump has
been designed to handle.
· The strainer should be installed in the
position where water accumulates most
easily. When installing on soft ground,
such as gravel or sand, position wood-
en boards or blocks, etc. below the
strainer to prevent it from sinking into
the ground. Alternatively, suspend the
hose avoiding the bottom.
Coupling set

10
2. Puttheenginespeedcontrolknobon
the"RUN"position."Run"and"High"
arethesameposition.
1. Openthefuelcock.
3. Pullouttherecoilstarterhandletothe
pointwhereyoufeelstrongresistance,
andthenslowlyreturnittotheinitial
position.
If you do not return it slowly, the handle
will move around violently and may hit
other parts damaging them.
4. Pushdownthedecompressionlever.
It will return automatically when the recoil
starter (rope) is pulled.
NOTICE
· Make sure to lower the decompression
lever and then pull the recoil starter
handle. Not doing so may cause engine
failure. Engine faults caused by not
using the decompression lever are not
covered by the warranty.
5. Pullouttherecoilstartinghandle
brisklywithbothhands.
Once the engine starts, slowly return
the handle to its initial position. If you do
not return it slowly, the handle will move
around violently and may hit other parts
damaging them.
NOTICE
· Do not pull the handle after starting the
engine. Doing so may cause engine
failure.
Speed control knob
Rotate
Move
Position
How to use the speed
control knob.
"STOP"
"HIGH","RUN"
STARTING THE ENGINE AND PUMP
Decompression lever
Fuel cock
Recoil starter handle
Recoil starter handle
"LOW "

11
6. Untilenginerotationsstabilize,putthe
speedcontrolknobintothe“LOW”
position(warmingup).
NOTICE
· Note that if the knob position goes too
far, the engine will stop.
NOTICE
· If the water pump is operated for a long
time without discharging water, the in-
side of the pump may be damaged.
Breakdowns caused by dry running are
not covered by the warranty.
7. Waitforawhile(for2–3minutes)until
waterisdischarged.Ifnowaterisdis-
charged,performthefollowingactions.
· Remove the cap and add priming water.
·Conrmthatthestraineronthesuction
port side is under the water level.
8. Whenwaterisdischarged,settheen-
ginespeedknobaccordingtothedis-
charging-Volume.
Adjust the engine speed using the engine
speed control knob.
STARTING THE ENGINE AND PUMP
Priming water
Speed control
knob
Priming water
llercap
Iftheenginereverses,engineoilwillnot
besenttoeachpart,whichmaycausea
majorfailureinashortperiodoftime,so
pleasebecareful.
Precautionswhenreversingtheengine
Howtodistinguishenginereversal
(1) The engine oil pressure drops
extremely.
(2) Since the intake side becomes the
exhaust, the engine sound changes,
and the exhaust gas blows out from
the air cleaner.
(3) At the beginning of reversal, the
knocking sound becomes high.
Howtoidentifyandtreatenginereversal
· Iftheenginereverses,theworkequip-
mentreversesandmovesintheop-
positedirection,whichmayleadtoan
unexpectedaccident.
·Iftheenginereverses,exhaustgaswill
blowouttotheintakeside,andtheair
cleanermayburnandcauseare.
CAUTION
Stoptheenginewhenpriming.
If the priming plug is removed during
operation, hot water in the pump may
spray out and cause burns.
CAUTION

12
ChecksduringOperation
· Any abnormal sound or vibration?
· Istheenginemisringorrunningrough?
· What about the color of the exhaust gas?
(Is it black or too white?)
· Is there a fuel leak?
· Has the product moved due to engine
vibrations?
If you notice any of the above, stop the en-
gine and consult with the nearest dealer.
· Temperature: 5 to 45 °C
· Humidity: 85 % or below
· Height: 1000 m or below
NOTICE
· Beware of water hammering
Do not allow any vehicle to run over the
discharge hose. Do not close the discharge
valve abruptly because water-hammer may
occur. This may result in heavy damage to
the pump.
Do not close
discharge
valve abruptly
Collapse of
discharge hose
OperatingCondition
STARTING THE ENGINE AND PUMP
Neverremoveplugsorhosesifthereis
heatorpressureinsidethepump.
If the pump is operated for a long time with
the discharge closed or self-suction defect,
the water in the pump becomes hot and
high-pressure.
If the plug or hose is removed in this con-
dition, hot water may spray out and cause
burns.
Neverrefueltheenginewhileitisrun-
ningorwhenitishoteveniftheengine
isstopped.
WARNING

13
1. Cooling-downbeforestoppingtheen-
gine,turntheenginespeedknobtothe
"SLOW"positionandturntheengine
foraboutthree(3)minutes.
2. Turntheenginespeedcontrolknobto
the"STOP"position.
3. Closefuelcock.
Iftheenginecontinuestoruneven
whenspeedcontrolknobisinthe
"Stop"position,closefuelcockor
loosenthenutonpump'shighpres-
surefuelpipe.
Makesuretoaskyourdealertotight-
enthenutafterthat.Asthispartis
underhighpressure,itisdangerousif
thenutisnottightenedcorrectly.
4. Slowlypullouttherecoilhandleuntil
pressureisfelt(thatis,tothepointin
thecompressionstrokewherethein-
takeandexhaustvalvesareclosed),
andleavethehandleinthisposition.
This prevents rust from forming while the
engine is not in use.
Speed control
knob
Loosen the nut
STOPPING THE ENGINE AND PUMP
Reducetheloadslowlywhenstop-
pingtheengine.Donotstoptheen-
ginesuddenlysincethismaycause
thetemperaturetoriseabnormally.
WARNING
CAUTION
Fuel cock

14
AFTER USING THE PRODUCT
Water drain plug
1. Drainwaterafteruse
· After use, remove the drain plug at the
bottom and pour water from the suction
/ discharge ports so that the remaining
sand is forced out of the pump.
NOTICE
· Water inside may freeze at below
0 °C in winter and may damage pump.
Frosen cracks of pump are not covered
by the warranty.
2. Fillthefueluptoredcomponentofthe
fueltanklter.
3. Conrmthattheboltsandnutsare
tightenedproperly,andifnot,tighten
them.
4. Wipeawayanydustanddirtonthe
outsideoftheenginewithaclean
cloth.

15
PERIODICCHECKSANDMAINTENANCE
To keep the engine in good condition and
durable for a long time, periodic checks and
maintenance are very important.
The chart below indicates what checks to
make and when to make them.
Themark(●)indicatesthatspecialtoolsand
skills are required. Consult with the dealer.
Maintenanceschedule
○:Check◊:Replenishment■:Cleaning□:Changing
●:Contactyourauthorizeddealerforthesemaintenanceservices.
Check item Daily
20 hours or 1
month after initial
operation
100 Hours or
Every 3 months
500 Hours or
Every 6 months
1000 Hours or
Every year
Tightening nut and bolt ○
Engine oil ○◊ □ □
Oillter ■ ■ □
Oil leakage ○
Airlter ■
50 hours or every
month □
Fuel tank ■
Every month
Fuellter ■ □
Nozzle ● ○■
Injection pump ● ○
Pipeline of fuel ○
(Change if
necessary)
Valve clearance ●○
1st time ○
Shuto󰀨theenginebeforeperforming
anymaintenance.Iftheenginemustbe
run,makesuretheareaiswellventilat-
ed.Theexhaustcontainspoisonouscar-
bonmonoxidegas.
Afterthepumphasbeenusedcleanthe
pumpimmediatelywithaclothtopre-
ventcorrosionortoremovesediment.
Alwaysusethespeciedparts.Theuse
ofreplacementpartswhicharenotof
equivalentqualitymaydamagetheprod-
uct.
NOTICE
· Service more frequently when using the
pump in dusty areas.
· These items should be serviced by an au-
thorized dealer, unless you have the proper
toolsandaremechanicallyprocient.
WARNING
CAUTION

16
Removetheoilllercapanddrainplugand
drain the old oil while the engine is still warm.
The plug is located on the bottom of cylinder
block.
Tightenthedrainplugandrellwiththe
recommended oil. (See the section under
"Preparations for starting".)
Loosenthexingboltandthenpullouttheoil
lter.
Cleaning time Every 6 months or 500 hours
Change air cleaner element 500 hours or every 6 months
(or earlier if dirty)
Clean air cleaner lower body every month or 50 hours
(or earlier if dirty)
PERIODIC CHECKS AND MAINTENANCE
HowToChangetheEngineOil
CleaningOilFilter
Oilller
Clean/changetheAirCleanerparts
Seethesectionforchangingtheairclean-
erelementunder"Preparationsforstart-
ing".
Oilllercap
/ dipstick
Oil drain plug
Fastener
Air cleaner
element
Air cleaner
lower body
Max. oil limit

17
1.Removethefuelcap.
2.Removethedrainplug(1)ofthefuel
tankanddischargethefuel.
3.Removetheclampandremovethefuel
hose(2).
4.Loosenandremovethetwofuellter
nuts(3).
5.Pulloutthefuellter(4)fromthebot-
tomofthetank.
6.Fitanewlter.
· Always be environmentally responsible.
· Follow the guidelines of the EPA or oth-
er governmental agencies for the proper
disposal of hazardous materials such as
engine oil, diesel fuel and engine coolant.
Consult the local authorities or reclamation
facility.
7.Fitthefuelhosetothetankwitha
clamp.
8.Fillthefueltankwithfuelandcheckfor
leaks.
Repair or replace parts as necessary.
PERIODIC CHECKS AND MAINTENANCE
DraintheFueITankandReplaceFuelFilter
Alwayswipeupallspillsimmediately.
Dieselfuelisammableandexplosiveun-
der certain conditions. Store any containers
containing fuel in a well-ventilated area,
away from any combustibles or sources of
ignition. Wipe up all spills immediately and
never use a shop rag to catch spilled fuel.
DANGER
NOTICE
Remove debris from impeller.
(Do not remove the impeller unless replacing
parts.)
CleaningtheInsideofthePumpCasing
(1)
Loosen Fuel Screw,
drain out Fuel
(2)Takeo󰀨HighPressure
Fuel Pump
(4) Pull out Filter
(3)
Loosen Nut
and Take it out
Clean Every 6 months or 500 hours
Change Every year or 1000 hours
Pump casing
Volute casing
Impeller
Washer
Left handed screw

18
Check suction hose. In case of no suction or
small discharge, the cause is usually due to
air leakage at suction side. In such case:
1. Removesuctionhose.
2. Startenginewithwaterinsidethe
pump.
3. Pressthepalmofyourhandtocover
thesuctionholeandwait30seconds.
If you feel suction on your palm, the pump
isworkingnebuthoseconnectionneeds
correction.
PERIODIC CHECKS AND MAINTENANCE
Recoil starter handle
Checkhoseatsuctionside
Test for suction
4.Pleasecheckifrubber/gasketpacking
isinstalledandifthereisanyholeand
crackinsuctionhose.
Hole and crack
in hose
OK
Suction hose
(not discharge
hose)
Flat / crushed
hose
Conrminstallingpacking!
NGNG
Aleakbetweenthepumpcasingandthe
engineisusuallyduetoadamagedme-
chanicalseal.Refertoadealer.
Leakbetweenthepumpcasingandthe
engine

19
When storing the pump for long periods,
make the following preparations.
1. Fillthepumpwithcleanwaterandrun
theengineforabout2minutesatlow
speed.
2. Stoptheengineandclosethefuel
cock.Draintheengineoilwhiletheen-
gineisstillwarmandllwithnewoil.
3. Pushthedecompressionleverdown
(non-compressionposition)andholdit
whileyoupulltherecoilstarter2or3
times.(Donotstarttheengine.)
4. Pullthedecompressionleverup.Pull
therecoilstarterslowly.Stopwhenit
feelstight.(Thisclosestheintakeand
exhaustvalvesincompressionposi-
tionandpreventfromrusting).
5. Wipetheoilanddirtfromtheengine
andstoreinadriedplace.
6. Removethedrainplugonpumpand
drainwaterfrompumpfully.
7. Alwayskeeptheoutsideofthewater
pumpclean.
· Temperature: -20 to 60 °C
· Humidity: 85 % or below
· Location: Outdoors
LONG-TERM STORAGE
StorageCondition
Decompression lever
Water drain plug
Recoil starter handle
Oilllercap
/ dipstick
Oil drain plug

20
SYMPTOM POSSIBLE CAUSE(S) CORRECTIVE ACTION
Cannot pull or hard to pull
recoil starter handle
Old fuel Replace fuel. If there is no improvement,
repair engine
Rusting inside engine Repair
Burn out of engine Repair
Blocked impeller Dismantle & clean the impeller
Debris at impeller Dismantle & clean the impeller
The decompression lever has not been lowered Push down the decompression lever.
Low discharge volume
Air leakage from suction side Check hose at suction side
Low output from engine Check and repair engine
Damage of mechanical seal Replace mechanical seal (Repair)
The total head (particularly the suction head) is
too high Reducethetotalheadwithinthespecication.
Thin or too long or kinks of hose Thicken or shorten or straight.
Water leaking from discharge hose or pipe Check and stop leakage of water
Debris at impeller Dismantle & clean the impeller
Worn or broken impeller Replace the impeller (Repair)
Suspended solid percentage is too high Checkthespecicationsandreducetheratio
Pump does not prime wa-
ter
Air leaking in from suction side Check hose and connections at suction side
Insu󰀩cientprimingwaterinsidepumpcasing Fill pump with water for priming
Drain plug is not tightened Tightendrainplugrmly.
TROUBLESHOOTING