SERVICE MANUAL. For more information contact Customer Service on

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1 SERVICE MANUAL All information, illustrations, directions and specifications included in this publication are based on the latest product information available at the time of approval for printing. KIPOR POWER CO., LTD, reserves the right to make changes without incurring any obligation. No part of this publication may be reproduced without written permission. For more information contact Customer Service on Distributed by PRIMUS AUSTRALIA PTY LTD Bundoora VIC

2 PREFACE Thank you for purchasing a Kipor Diesel Water Pump. This manual covers the operation and maintenance of model KDP20/E, KDP30/E & KDP40/E High Volume Water Transfer Pumps. All information in this publication is based on the latest product information available at the time of approval for printing. We reserve the right to make changes at any time without notice and/or incurring any obligation. No part of this publication may be reproduced without written permission. This manual should be considered a permanent part of the water pump and should remain with it if it is resold. Pay special attention to statements preceded by the following words; Indicates a strong possibility of severe personal injury or death if instructions are not followed. Indicates a possibility of equipment damage or property damage if instructions are not followed. Gives helpful information. If a problem should arise, or if you have any questions about the water pump, consult an authorised dealer. This water pump is designed to give safe and dependable service if operated according to the instructions. Read and understand the Owner's Manual before operating the water pump. WARRANTY & SERVICE Toll Free (for further information see page 19) 1

3 CONTENTS 1. SAFETY INSTRUCTIONS 3 2. IDENTIFICATION OF COMPONENTS 4 3. PRE-OPERATION CHECK 5 4. STARTING THE ENGINE 8 5. STOPPING THE ENGINE MAINTENANCE TRANSPORTING AND STORAGE SAFETY INSTRUCTIONS To ensure safe Operation - This water pump is designed to give safe and dependable service if operated according to instructions. Read and understand the Owner's Manual before operating the water pump. Failure to do so could result in personal injury or equipment damage. The muffler becomes very hot during operation and remains hot for several minutes after stopping the engine. Be careful not to touch the muffler or exhaust system while it is hot. Let the engine cool before storing or transporting the water pump. To prevent burns, pay attention to the warning mark located on the engine muffler. 8. TROUBLESHOOTING SPECIFICATIONS WARRANTY 19 conditions. Never operate the water pump in an enclosed or confined area. Exhaust gas contains poisonous carbon monoxide gas, exposure can cause loss of consciousness and may lead to death. Diesel fuel is extremely flammable and explosive under certain conditions. Stop the engine before refuelling Do not overfill. Keep away from cigarettes, sparks and other flammable materials when refuelling or operating the water pump. Always refuel in a wellventilated location. Wipe up spilled diesel fuel immediately. For safety, never pump flammable or corrosive liquids such as petrol or acid. To avoid pump corrosion never pump sea water, chemical solutions, caustic liquids eg. used oil, wine or milk. Always complete a pre-operation check before you start the engine. You may prevent an accident or equipment damage. Read the Owner s Manual before use and understand the operation of all controls especially how to stop the water pump quickly. Never allow anyone to operate the water pump without proper instruction. To prevent fire hazards and to provide adequate ventilation, keep the water pump at least 1m (3 ft) away from any buildings or other equipment during operation. Do not place flammable objects close to the water pump. Only operate the water pump on a firm level surface. Keep children and pets away from the water pump when it is in operation. 2 3

4 2. IDENTIFICATION OF COMPONENTS 3. PRE-OPERATION CHECK Read all labels, safety instructions and precautions described in this Owner s Manual carefully. These labels warn you of potential hazards that can cause serious injury. If a label comes off or becomes hard to read, contact your authorised dealer for a replacement. Be sure to check the water pump is on a firm level surface with the engine stopped. STEP 1. Check the engine oil level. Using a non-detergent oil or 2-stroke engine oil could shorten the engine's service life. THROTTLE LEVER It is recommended to use SAE 10W-30 Grade engine oil. Can use Part No Jamec Pemsmall engine oil 1L. Only use a high-detergent, premium quality 4-stroke engine oil, certified to meet or exceed U.S. automobile manufacturer's requirements for API Service Classification for diesel engines CC/CD/CE/CF. FRAME SERIAL NUMBER LOCATION The serial number identifies the particular water pump and is important when ordering spare parts for any warranty or service maintenance. The serial number can be found stamped on the engine block below the oil filler dipstick. Oil Filler Dipstick Serial Number To Check Oil Level - Remove the oil filler dipstick, and wipe the dipstick with a clean rag. Insert the oil filler dipstick into the filler hole without rotating it. If the oil level is below or at the lower end of the dipstick, refill with the recommended oil up to the upper level mark. Tighten the oil filler dipstick. Oil Capacity: KDP20/E 0.75L KDP30/E 1.10L KDP40/E 1.62L 4 5

5 3. PRE-OPERATION CHECK cont. 3. PRE-OPERATION CHECK cont. Running the engine with insufficient oil can cause serious engine damage. NOTE: The Low Oil Alert System will automatically stop the engine before the oil level falls below the safe limit. However, to avoid the inconvenience of an unexpected shutdown, it is still advisable to visually inspect the oil level on a daily and regularly basis. STEP 3. Check the air cleaner. Unscrew the wing nut and remove the air cleaner cover. Remove the air cleaner and inspect both the foam outer air cleaner element (if fitted) and the paper inner air cleaner element. Check to ensure both are clean and in good condition. Clean or replace the element/s if necessary (refer page 13 for air cleaner service maintenance). STEP 2. Check the fuel level. Use ONLY Diesel Fuel Remove fuel tank cap (anti-clockwise). If the fuel level is low, refill the fuel tank. Do not use petrol or add oil to the fuel tank. Do not use dirty or contaminated diesel fuel. Avoid getting dirt, dust or water in the fuel tank. After refuelling, tighten the fuel tank cap securely. Fuel Tank Capacity: KDP20/E 2.5L KDP30/E 3.5L KDP40/E 5.5L Never run the engine without the air cleaner. Rapid engine wear will result from contaminants such as dust and dirt being drawn through the carburettor into the engine. STEP 4. Check connection of the Suction and Discharge hoses Ensure the hose clamp ring, hose coupler are firmly connected to the Suction Hose. Check that the rubber seal is seated corrected onto the suction port. Install the strainer on the other end of the suction hose with a hose band. Tighten securely. RUBBER SEAL Diesel fuel is extremely flammable and is explosive under certain conditions. Refuel in a well-ventilated area with the engine stopped. Do not smoke or allow flames or sparks in the area where the water pump is being refuelled. Do not overfill the fuel tank - there should be no fuel above the upper limit mark. After refuelling, make sure the fuel filler cap is tightened securely. Be careful not to spill fuel when refuelling. Spilled fuel or fuel vapour may ignite. If any fuel is spilled, make sure the area is dry before starting the engine. Avoid repeated or prolonged contact of diesel fuel with skin or breathing of fuel vapour. KEEP OUT OF REACH OF CHILDREN. Always operate the water pump with the strainer installed on the end of the suction hose. The strainer will exclude debris from clogging or damaging the pump impeller. Check that the hose clamp ring of the discharge hose is firmly connected to the discharge port. Check that the rubber seal is seated corrected onto the discharge port. STEP 5. Check and Prime the water pump. The pump chamber must be filled with clean water and primed prior to operating the water pump. Unscrew the water filler cap at the top of the discharge port and fill with clean water. Fuel system damage or engine performance problems resulting from the use of fuels other than diesel fuel, are not covered under the warranty policy. Never attempt to operate the water pump without priming the pump overheating and rapid pump and seal damage will result. 6 7

6 4. STARTING THE ENGINE 4. STARTING THE ENGINE cont. Before starting the engine: Step 1. Turn the fuel tap to ON position. Step 6. Move the throttle lever to the desired engine speed position - tighten knob. Discharge flow is controlled by adjusting the engine speed. Increasing engine speed will increase discharge flow. Slowing the engine speed will decrease discharge flow. Step 2. Move the throttle lever down to start position - tighten knob. Step 3. Pull starter grip until resistance is felt. (Electric start models not required). For safety, never pump flammable or corrosive liquids such as petrol or acid. To avoid pump corrosion never pump sea water, chemical solutions, caustic liquids eg. used oil, wine or milk. Step 4. Push decompression lever down. (Lever will return back automatically after engine started). Step 5. Pull the starter grip firmly. Turn on ignition switch fully (Electric start models). FUEL TAP If the engine stops and will not restart, check the engine oil level and fuel tank level before further troubleshooting. Low Oil Alert System The low oil alert system is designed to prevent engine damage caused by an insufficient amount of oil in the crankcase. Before the oil level in the crankcase falls below a safe limit, the low oil alert system will automatically shut down the engine, even when the engine switch is in the ON position. THROTTLE LEVER STARTER GRIP If the low oil alert system shuts down the engine, check the oil level and add the recommended engine oil. DECOMPRESSION LEVER Do not allow the starter grip to snap back, Return it slowly by hand. 8 9

7 5. STOPPING THE ENGINE 6. MAINTENANCE To stop the water pump move the throttle lever to stop position. IN NORMAL USE: Step 1. Move the throttle lever up to the stop position - tighten knob. Turn ignition switch off (Electric start models). Step 2. Turn Fuel Tap to OFF. Periodic inspection and maintenance are essential to keep the water pump in the best operating condition. Inspect and service this water pump as scheduled in the table below. Shut off the engine before performing any maintenance. If the engine must be run, make sure the area is well ventilated. The exhaust gas contains poisonous carbon monoxide. THROTTLE LEVER Use only genuine parts or their equivalent. The use of replacement parts which are not of equivalent quality may damage the water pump. Maintenance Schedule FUEL TAP Make sure that the ignition switch and fuel tap are in the "OFF" position when the water pump is not in use or being transported and/or stored. After use, remove the pump drain plug and drain the pump chamber. Remove the filler cap and flush the pump chamber with fresh, clean water. Drain the water from the pump chamber, then re-install the filler cap and drain plug (refer page 16 Step 2, Clean inside pump). NOTE: (1) Service more frequently when used in dusty areas. (2) Change engine oil every 25 hours when used under heavy load or high ambient temperatures. (3) These items should be serviced by your authorised dealer, unless you have the proper tools and are mechanically proficient. Refer to the workshop manual for service procedures.

8 6.1 CHANGING OIL 6.2 AIR CLEANER SERVICE Drain the oil while the engine is still warm to assure rapid and complete draining. A dirty air cleaner will restrict air flow resulting in hard starting, loss of power and black exhaust smoke. To prevent water pump malfunction, service the air cleaner regularly. Service more frequently when operating the water pump in extremely dusty areas. Make sure the ignition switch and the fuel tap are in the OFF position before draining oil. Step 1. Remove the oil filler dipstick. Step 2. Remove oil drain plug and drain all used dirty oil into a container. Step 3. Refit oil drain plug and tighten securely. Step 4. Refill with the recommended SAE10W/30 Grade Oil and check oil level. API service classification for diesel engines CC/CD/CE/CF. Can use Part No Jamec Pem small engine oil 1L. Step 5. Re-install oil filler dipstick and tighten securely. Engine Oil Capacity: KDP20/E 0.75L KDP30/E 1.1L KDP40/E 1.62L Oil Filler Dipstick Oil Drain Plug Do not use petrol, diesel fuel or low flash point solvents for cleaning. They are flammable and explosive under certain conditions. Never run the water pump without the air cleaner, otherwise rapid engine wear may result. Step 1. Remove the air cleaner cover by loosening the top wing nut. Step 2. Loosen the hex nut that retains the air cleaner element. Step 3. Remove the foam outer air cleaner element and inspect. Inspect the inner paper air cleaner element. Step 4. Wash the foam outer element in a non-flammable or high flash point solvent and dry thoroughly. Step 5. Soak the foam element in clean engine oil and squeeze out excess oil. Step 6. Replace the element/s if torn or damaged and unable to be cleaned properly. Step 7. Refit the foam outer air cleaner element to the paper element and re-install. Tighten hex nut securely. Step 8. Refit the air cleaner cover and tighten wing nut securely. NOTE: Foam outer element not fitted all models Please dispose of used engine oil in a manner that is compatible with the environment. We suggest you take it in a sealed container to your local recycling centre. Do not throw it in the rubbish or pour it on the ground

9 6.3 BATTERY SERVICE 7. TRANSPORTING and STORAGE If the water pump is equipped with a battery for the electric start, recharge the battery once a month to ensure optimum service life of the battery. To prevent any fuel spillage when transporting or during temporary storage, the water pump should be secured upright in its normal operating position. Keep the pump level and ensure the tank cap is tightly secured. Spilled fuel or fuel vapour may ignite. Turn the fuel tap to the OFF position. Before storing the water pump for an extended period: To avoid severe burns or fire hazard, let the engine cool down before transporting or storing indoors. If you must transport the water pump in a vehicle, drain all fuel. Tie down the water pump securely in an upright position while transporting. Diesel fuel is extremely flammable and explosive under certain conditions. Do not smoke or allow flames or sparks in the area. Before storing the water pump for an extended period: Step 1. Ensure that the storage area is level and free of excessive dust and humidity. Step 2. Clean inside pump. Due to sediment collecting and settling inside the pump, prior to shut down, pump clean fresh water through the water pump. After flushing, remove the pump drain plug and drain water from pump housing. Re-install drain plug securely. 1/ Starter cable (+) 4/Battery 12V 2/ Frame 5/Battery Hold down clamp 3/ Battery base bracket 6/Earth cable (-) Mount battery base bracket (3) to frame (2) using bolts & nuts. Fit battery and secure with battery hold down clamp. Tighten nuts securely. Connect cables (1+6) to battery terminals securely

10 7. TRANSPORTING and STORAGE cont. 8. TROUBLESHOOTING When the engine will not start: Step 3. Drain the fuel Drain all diesel fuel from the fuel tank into an approved fuel container using a funnel to avoid spilling. a). With the fuel tap in the OFF position, remove the fuel tank drain plug and drain all the fuel into a suitable container. b). Re-install the drain plug. Tighten securely. Is there fuel in the tank? YES NO Refill the fuel tank? Is the fuel tap on? NO Turn the fuel tap on YES Is there enough oil in the engine? NO Add the recommended oil FUEL TAP DRAIN PLUG YES Is fuel injector blocked YES Clean or replace fuel injector NO Take the water pump to an authorised dealer Step 4. Change the engine oil use recommended SAE10W-30 grade oil. Step 5. Pull the starter grip until resistance is felt. This will close the engine valves so moisture cannot enter the engine cylinder. Leave decompression lever in normal running position. WARNING - Be sure there is no spilled fuel around engine. Spilled fuel may ignite NO If the engine still does not start, take the water pump to an authorised dealer. Cover the water pump to keep out dust and dirt. If the water pump is fitted with a battery for the electric start, recharge the battery once a month to ensure optimum service life of the battery. 16 When the Pump will not Pump Water: Step 1. Is the pump fully primed? check water level in pump chamber. Fill with clean fresh water. Step 2. Is the Suction Hose strainer clogged? Step 3. Are the hose bands installed securely? Step 4. Is there any damage or twisted hose? Step 5. Is the suction head too high? If the water pump still does not operate, take the water pump to an authorised dealer. 17

11 9. SPECIFICATIONS 10. WARRANTY Terms & Conditions Model High Volume Water Transfer KDP20/KDP20E High Volume Water Transfer KDP30/KDP30E High Volume Water Transfer KDP40/KDP40E Suction port (mm) dia 50mm (2 ) 75mm (3 ) 100mm (4 ) Discharge port (mm) dia 50mm (2 ) 75mm (3 ) 75mm (4 ) Rated flow (max) 600L/min 900L/min 1250L/min Total Head (max) 26m 25m 31m Suction head (max) 8m 8m 8m Self-priming time at 4am 80sec 120sec 180sec Dry weight (kg) 35kg 52kg 69kg Overall dimension (mm) 525 x 410 x 515mm 510 x 445 x 550mm 650 x 480 x 600mm Starting system Recoil starter E: Electric start Recoil starter E: Electric start Recoil starter E: Electric start Engine Model KM170 KM178 KM186 Engine type Single cylinder, 4 stroke, vertical, direct injection diesel Single cylinder, 4 stroke, vertical, direct injection diesel Single cylinder, 4 stroke, vertical, direct injection diesel Displacement (cc) 211cc 296cc 406cc Bore x Stroke (mm) 70 x 55mm 78 x 62mm 86 x 70mm Rated power 4.2hp 6.0hp 9.0hp Cooling system Forced air-cooled Forced air-cooled Forced air-cooled Noise level - db(a)7m Fuel tank (Lt) 2.5L 3.5L 5.5L Fuel Diesel fuel Diesel fuel Diesel fuel Lube oil (Lt) 0.75L 1.1L 1.62L The water pump as standard original equipment is covered by this warranty from the date of original retail purchase for a period of 2 years for residential use and 1 year for commercial applications. Water Pumps used in rental fleets or as demonstration models will be considered commercial usage. The warranty coverage is continual from the original date of purchase, and does not restart upon the replacement of any part or complete unit. Individual parts replaced at any point during the warranty period are only eligible for warranty coverage for the balance of the original warranty period. Eligibility: To be eligible for warranty service, the product must be purchased in Australia from an authorised Kipor dealer. This warranty applies to the original retail purchaser only, and is not transferable. The original Proof of Purchase is required. To obtain warranty service: Contact any authorised dealer or Primus Australia Pty Ltd Bundoora Victoria 3083: Phone Fax enquires@primusaustralia.com.au Website: Please Note: To perform any warranty service or assessment, the authorised dealer will require the original Proof of Purchase and a record of the water pump s serial number. Exclusions: This warranty does not extend to parts affected or damaged by accident and/or collision, normal wear, fuel contamination, use in an application for which the product was not designed or any other misuse, neglect, incorporation or use of unsuitable attachments or parts, unauthorised alteration, or any causes other than defects in material or workmanship of the product. This warranty does not extend to normal maintenance items such as spark plugs and filters. Irrespective of whether warranty is approved or rejected, the following costs are not covered under this warranty policy: Fares, charter fares, car hire, freight, tolls, hire or loan equipment, loss of earnings or stock and medications

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