Pierce Ultimate Configuration (PUC) Pumpers Operation & Maintenance Manual

Transcription

1 Pierce Ultimate Configuration (PUC) Pumpers Operation & Maintenance Manual 2010 Pierce Manufacturing Inc. Part No. PM-P-OM

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3 TABLE OF CONTENTS SECTION 1. TO THE OWNER 1-1 WHO SHOULD USE, SERVICE AND MAINTAIN THIS VEHICLE WHAT TO DO IF YOU LACK KNOWLEDGE CAUTIONS, WARNINGS AND DANGERS SAFETY WARNING LABELS SAFETY POWER TAKE-OFF (PTO) SAFETY INFORMATION GENERAL SAFETY INFORMATION a TO PREVENT INJURY TO YOURSELF AND/OR DAMAGE TO THE EQUIPMENT b COLD WEATHER OPERATION OF POWERSHIFT POWER TAKE-OFF (PTO) c TO AVOID PERSONAL INJURY OR EQUIPMENT DAMAGE d ROTATING AUXILIARY DRIVESHAFTS e GUARDING AUXILIARY DRIVESHAFTS f USING SET SCREWS RESPONSIBILITY DAILY CHECKS CUSTOM PRODUCTS PROFESSIONAL, TRAINING, AND STANDARDS ORGANIZATIONS SAFETY DEFECT REPORTING KEEPING YOUR KNOWLEDGE REFRESHED AND UP-TO-DATE SECTION 2. BEFORE PLACING IN SERVICE 2-1 CREATE A PUMP CHART CHECK ADJUSTMENT OF INTAKE RELIEF VALVE SECTION 3. GENERAL 3-1 DESCRIPTION OF PIERCE ULTIMATE CONFIGURATION (PUC) PUMP GENERAL OPERATION DEFINITIONS OPERATING THE ENGINE COOLING THE ENGINE SUCTION STRAINERS SUCTION LINE TESTING FOR AIR LEAKS SOURCE OF WATER SUPPLY PUMPING IN COLD WEATHER WHEN FINISHED PUMPING PUMPING SALT WATER Pierce Manufacturing Inc. All Rights Reserved. PUC Pump / i

4 TABLE OF CONTENTS 3-3 TESTING OF EQUIPMENT FOR PRACTICE MEASURING PUMP PERFORMANCE ACCEPTANCE TESTS ENGINES EFFECTS OF ATMOSPHERIC CONDITIONS ON ENGINE AND PUMP PERFORMANCE OPERATING CHARACTERISTICS OF PUMPS SECTION 4. OPERATION 4-1 APPROACHING THE APPARATUS STEPPING AND WALKING SURFACES COMPARTMENT DOORS HOSE BED COVERS FOLDING STEPS OR PLATFORMS HOSE HOSE STORAGE HOSE CHUTES HOSE BEDS HOSE DEPLOYMENT HOSE CONNECTIONS POSITIONING THE APPARATUS FIRE SCENE POSITIONING POSITIONING ON ROADS LIGHTING CHOCK THE WHEELS OPERATION OF PUC FIRE PUMP OPERATION OF PUMP TO ENGAGE THE PUMP STATIONARY OPERATION ENGAGING PUMP WHEN VEHICLE IS DRIVING BASIC PACKAGE (STANDARD) ENGAGING PUMP WHEN VEHICLE IS DRIVING ADVANCED PACKAGE (OPTIONAL) SUPPLY WATER TO PUMP MANUAL PUMP ENGAGEMENT ADJUSTING THE PUMP PRESSURE DETERMINE DISCHARGE PRESSURE ENGINE SPEED AND PUMP PRESSURE CONTROLLING ENGINE SPEED, PUMPING PRESSURE GOVERNOR OPERATION CONTROLLING ENGINE SPEED, NOT PUMPING PRESSURE GOVERNOR OPERATION CONTROLLING ENGINE SPEED WITH MULTIPLE CONTROLS DISCHARGING WATER CONNECTING ATTACK LINE HOSE CHARGING LINE DISCHARGING FOAM CHANGING FROM TANK TO EXTERNAL PRESSURIZED WATER SUPPLY (WITH GATED INTAKE VALVE) CONNECT INTAKE HOSE ii / PUC Pump 2010 Pierce Manufacturing Inc. All Rights Reserved.

5 TABLE OF CONTENTS CHARGE THE INTAKE LINE (PRESSURIZED SUPPLY) SUPPLY THE PUMP PUMP PRIMING PROBLEM SOLUTIONS CONTROL VALVES THAT LEAK MONITORING INTAKE PRESSURE REFILLING THE TANK CHANGING FROM TANK TO EXTERNAL WATER SUPPLY (WITHOUT GATED INTAKE VALVE) STOP FLOWING WATER IF YOU ARE CONNECTING TO A PRESSURIZED SUPPLY, CHARGE INTAKE LINE: RESUME DISCHARGE OPERATION ENGINE STATUS DISPLAY ENDING WATER FLOW OPERATION SHUTTING OFF WATER FLOW DISENGAGING THE PUMP DISENGAGING THE PUMP (STATIONARY OPERATION) DISENGAGING THE PUMP (PUMP AND ROLL) SECURING PUMP SYSTEM OPERATING FROM A STATIC (DRAFT) WATER SUPPLY SECTION 5. MAINTENANCE 5-1 INSPECTION, CLEANING, AND MAINTENANCE MAINTENANCE SCHEDULE DRAINING THE PUMPING SYSTEM FLUSHING THE DRAIN VALVES FORWARD FLUSHING BACK FLUSHING ANNUAL TESTING FLUSHING AND DRAINING THE PUMP PUMP STORAGE PRIMER PUMP LUBRICATION INTAKE & DISCHARGE RELIEF VALVE DRAINS (OPTIONAL) MASTER GAUGE PORTS PUMP TRANSMISSION LUBRICATION MECHANICAL SHAFT SEAL MECHANICAL SEAL BASICS MECHANICAL SEAL OPERATION AND MAINTENANCE Pierce Manufacturing Inc. All Rights Reserved. PUC Pump / iii

6 TABLE OF CONTENTS SECTION 6. REFERENCE TABLES 6-1 CONVERSION FACTORS PUMP TESTS SMOOTH BORE NOZZLE DISCHARGE VARIOUS NOZZLES DISCHARGE NOZZLE PRESSURE VERTICAL AND HORIZONTAL NOZZLE REACH FRICTION LOSS FITTINGS RESISTANCE PSI TO ELEVATION CONVERSION SCREW THREAD iv / PUC Pump 2010 Pierce Manufacturing Inc. All Rights Reserved.

7 SECTION 1 TO THE OWNER 1-1. Who Should Use, Service and Maintain This Vehicle This manual explains the operation of a Pierce fire apparatus equipped with a Pierce Ultimate Configuration (PUC) water pump. The manual reviews basic principles of operation, highlights common safety concerns and procedures, and gives recommendations for using the pump. This manual assumes that you are a pump operator and that: You have already been fully trained and certified to operate a pump. You have had formal education from a technical college or other fire fighter training institution. You understand, are proficient in, and meet all of the requirements set forth in NFPA 1002 Standard on Fire Apparatus Driver/Operator Professional Qualifications (latest edition). You already understand water pump operation. All Pierce vehicles are delivered with a set of manuals for major components that your fire department selected. If you need replacement manuals, or safety warning labels, contact Pierce customer service at 888-Y-PIERCE ( ). BEFORE operating the pumping system, you, the operator, must read, understand, and follow the instructions found in: Pump manufacturer's operator and maintenance manuals. Operator and maintenance manuals for pumping components, such as valves, pressure controllers, flow controls, manual overrides, foam systems, and primer pumps. IFSTA Pumping Apparatus Driver/Operator Handbook (latest edition) What To Do If You Lack Knowledge Pump control systems require you to understand the function of each valve, each switch, each gauge, each Emergency Stop, and each manual override. Before your fire department allows you to operate this pump, you already must be educated, trained, and have passed a test for pump logic and operations. You also must know the principles of operation, so you can change operation when circumstances change. Each valve, switch, or gauge has an important function. If you are uncertain about the function or don't know something, inform your fire department's training officer. You are always welcome to call Pierce Customer Service at 888-Y-PIERCE ( ) with questions. You are the only person who knows what you don't know. You must speak up about the things you don't know, so you can learn about them before someone is injured or killed because of your lack of knowledge. You are responsible for learning how to operate the pumper under all conditions without having to read this manual at a fire or other emergency Pierce Manufacturing Inc. All Rights Reserved. PUC Pump / 1-1

8 TO THE OWNER 1-3. Cautions, Warnings and Dangers Safety Warning Labels Throughout this manual, you will find Caution, Warning and Danger signals. Walk around the apparatus. Find each Safety Warning Label. Read the label. Identify and pay attention to the hazard it describes. Practice all the time to avoid the hazard, so you develop a habit to avoid the hazard: DANGER signals an imminently hazardous situation that, if not avoided, will result in death or serious injury. WARNING signals a potentially hazardous situation that, if not avoided, could result in death or serious injury. CAUTION with the safety triangle signals a potentially hazardous situation that, if not avoided, might result in minor or moderate injury. CAUTION used without the safety triangle symbol signals a potentially hazardous situation that, if not avoided, might result in property damage. 1-2 / PUC Pump 2010 Pierce Manufacturing Inc. All Rights Reserved.

9 TO THE OWNER 1-4. Safety Open and close valves slowly Be prepared for high nozzle reactions open nozzle slowly Do not exceed system rated pressure, capacity or speed. Observe local regulations on the use of hearing protection. Use only hoses with pressure ratings higher than their intended use. Remove all pressure from hoses before disconnecting. Shutdown and drain completely before attempting maintenance Power Take-Off (PTO) Safety Information The PUC transmission includes a standard SAE 6-bolt PTO opening and drive gear allowing for the adaptation of an auxiliary PTO drive. The following safety instructions are intended for those applications to which an optional PTO has been installed. These instructions are for your safety. Read them carefully until you understand them General Safety Information 1-4.2a To prevent injury to yourself and/or damage to the equipment Read carefully all owner s manuals, service manuals, and/or other instructions. Always follow proper procedures, and use proper tools and safety equipment. Be sure to receive proper training. Never work alone while under a vehicle or while repairing or maintaining equipment. Always use proper components in applications for which they are approved. Be sure to assemble components properly. Never use worn-out or damaged components. Always block any raised or moving device that may injure a person working on or under a vehicle. Never operate the controls of the Power Take-Off (PTO) or other driven equipment from any position that could result in getting caught in the moving machinery Pierce Manufacturing Inc. All Rights Reserved. PUC Pump / 1-3

10 TO THE OWNER 1-4.2b Cold Weather Operation of Powershift Power Take-Off (PTO) During extreme cold weather operation [32 F (0 C) and lower], a disengaged Powershift Power Take- Off (PTO) can momentarily transmit high torque that will cause unexpected output shaft rotation. This is caused by the high viscosity of the transmission oil when it is extremely cold. As slippage occurs between the PTO clutch plates, the oil will rapidly heat up and the viscous drag will quickly decrease. The PTO output shaft rotation could cause unexpected movement of the driven equipment resulting in serious personal injury, death, or equipment damage c To avoid personal injury or equipment damage Driven equipment must have separate controls. The driven equipment must be left in the disengaged position when not in operation. Do not operate the driven equipment until the vehicle is allowed to warm up. 1-4 / PUC Pump 2010 Pierce Manufacturing Inc. All Rights Reserved.

11 TO THE OWNER 1-4.2d Rotating Auxiliary Driveshafts Rotating auxiliary driveshafts are dangerous. They can snag clothes, skin, hair, hands, etc. This can cause serious injury or death. Do not go under the vehicle when the engine is running. Do not work on or near an exposed shaft when the engine is running. Shut off the engine before working on the Power Take-Off (PTO) or driven equipment. Exposed rotating driveshafts must be guarded e Guarding Auxiliary Driveshafts We strongly recommend that a Power Take-Off (PTO) and a directly mounted pump be used to eliminate the auxiliary driveshaft whenever possible. If an auxiliary driveshaft is used and remains exposed after installation, it is the responsibility of the vehicle designer and PTO installer to install a guard f Using Set Screws Auxiliary driveshafts may be installed with either recessed or protruding set screws. If you choose a square head set screw, you should be aware that it will protrude above the hub of the yoke and may be a point where clothes, skin, hair, hands, etc. could be snagged. A socket head set screw, which may not protrude above the hub of the yoke, does not permit the same amount of torquing as does a square head set screw. Also, a square head set screw, if used with a lock wire, will prevent loosening of the screw caused by vibration. Regardless of the choice made with respect to a set screw, an exposed rotating auxiliary driveshaft must be guarded. Operating the Power Take-Off (PTO) with the Vehicle in Motion Some PTOs may be operated when the vehicle is in motion. To do so, the PTO must have been properly selected to operate at highway speeds and correctly matched to the vehicle transmission and the requirements of the driven equipment. If in doubt about the PTO specifications and capabilities, avoid operating the PTO when the vehicle is in motion. Improper applications and/or operation can cause serious personal injury or premature failure of the vehicle, the driven equipment, and/or the PTO. Always remember to disengage the PTO when the driven equipment is not in operation Pierce Manufacturing Inc. All Rights Reserved. PUC Pump / 1-5

12 TO THE OWNER 1-5. Responsibility Study carefully this manual and the manuals for major components such as pump, engine, and other allied equipment. Make sure that all operators and other users also completely understand their contents. The warnings, cautions, and procedures listed in these manuals must be part of the fire department's safety program. As the operator of this vehicle and pumping equipment, you are responsible for: Understanding the function of each component of the pumping system. Understanding how to adjust each control to obtain the results you want. Maintaining control of the pumping system at all times. Remaining proficient in use, so at a fire you can operate and make successful changes in the operation quickly, without having to read the operator's instructions or safety warning labels. Practicing proper manual override and emergency shutdown procedures, so you can respond immediately in an emergency or during the failure of a component. Remember stress is high. Your failure to practice increases the odds you will forget or do it wrong in the heat of the moment Daily Checks At start of shift, follow your department's apparatus check. It is critically important that you turn each control valve, gate, or switch, etc. ON and OFF or OPEN and CLOSED. You want to make sure they work now. You don't want to find out at a fire. ALWAYS check the controls you rarely use. That also reminds you of their location and their function. If you find a control whose function you do not know, then right away find out what it does. Every control serves a purpose. You must know the purpose and how to use the control. Pierce Customer Service is always available to help you and answer your questions. Call 888-Y-PIERCE ( ) Custom Products Your department developed specifications for this fire apparatus. It purchased a Pierce apparatus that is built to meet those specifications. The information in this manual will be generic at times. Due to the highly customized nature of each Pierce fire apparatus, the exact location of each component in the pumper system will vary. This manual describes basic controls. Not every apparatus will have all controls. Some will have extra controls, as determined by each fire department's specification. Pictures describe typical components or devices. Actual parts might vary from those pictured. You must learn the location and function of all controls, switches, gauges, valves, inlets, and discharges. Major inconsistencies between your vehicle and the information contained in this manual should be directed to your Pierce Dealer or Sales Representative. 1-6 / PUC Pump 2010 Pierce Manufacturing Inc. All Rights Reserved.

13 TO THE OWNER 1-8. Professional, Training, and Standards Organizations To keep up-to-date on knowledge and new standards that affect all facets of fire fighting, make sure that you check these organizations' catalogues and websites each month: National Fire Protection Association (for standards and requirements) One Batterymarch Park P.O. Box 9101 Quincy, MA Make sure you read the latest editions. Pierce Manufacturing Inc. Customer Service 2600 American Drive P.O. Box 2017 Appleton, WI, Y-PIERCE ( ) and International Fire Service Training Association (for textbooks and other training material) Fire Protection Publications Oklahoma State University 930 North Willis Stillwater, OK Safety Defect Reporting If you believe your vehicle or any associated component might have a design defect that could result in failure or injury, please report this information immediately to Pierce Manufacturing. Additionally, should any information in this manual prove to be seriously inconsistent with your Pierce fire apparatus also inform Pierce Customer Service. Most service and support issues should be handled by the local Pierce dealer or sales representative. However, to report any design defects or request support directly from Pierce contact: Customer Service Pierce Manufacturing, Inc American Drive, P.O. Box 2017 Appleton, WI, Y-PIERCE ( ) Keeping Your Knowledge Refreshed and Up-to-Date This manual will be revised from time to time. Check the Pierce website, to stay current Pierce Manufacturing Inc. All Rights Reserved. PUC Pump / 1-7

14 TO THE OWNER Also review the latest edition of the IFSTA ( manual Pumping Apparatus Driver/Operator Handbook. Remember, if there's anything you don't understand, call Pierce Customer Service at 888-Y-PIERCE ( ). 1-8 / PUC Pump 2010 Pierce Manufacturing Inc. All Rights Reserved.

15 SECTION 2 BEFORE PLACING IN SERVICE 2-1. Create a Pump Chart Use a Pump Chart to determine the pump discharge pressure that will provide desired nozzle pressure for various hose lay configurations and combinations. The IFSTA Pumping Apparatus Driver/Operator Handbook tells how to develop a pump chart. Develop the chart for all situations. Make sure this chart is always available during pump operation Check Adjustment of Intake Relief Valve Figure 2-1: Typical Intake Relief Valve POM0016 All pumps have a relief valve on the intake side (Figure 2-1). It prevents a pressure spike in intake water from passing to hoses through the discharge side of the pump. The intake relief valve is a pressure regulator. If intake pressure goes over the pressure setting, the valve opens and allows water to flow out the relief outlet. Some departments choose to connect a hose to the relief valve outlet to direct the water discharge away from the apparatus. Pressure surges in this hose can occur without warning. Secure unattended hoses. Water discharged from hose will cause hose to whip violently. Whipping hose can injure or kill. To adjust this valve for desired pressure, the intake pressure to the pump must be higher than the normal static pressure of the municipal water supply. The best method to adjust the valve is to use another pumper to supply water at the desired pressure. 1. Increase inlet pressure until the master inlet pressure gauge reads the relief pressure you want. 2. With a wrench, slowly open the adjusting screw on the valve until water starts to flow from the valve outlet Pierce Manufacturing Inc. All Rights Reserved. PUC Pump / 2-1

16 BEFORE PLACING IN SERVICE 3. Slowly close the adjusting screw until the water stops flowing. Read the valve manufacturer's documentation for complete instructions. 2-2 / PUC Pump 2010 Pierce Manufacturing Inc. All Rights Reserved.

17 SECTION 3 GENERAL 3-1. Description of Pierce Ultimate Configuration (PUC) Pump The PUC pump is a high speed, single stage, UL rated, centrifugal Fire Fighting Pump. Inherent characteristics of the PUC are compactness, lightweight, high efficiency, and a wide range of pumping capabilities. The PUC pump is midship mounted rearward of the chassis engine and powered via the Rear Engine Power Take- Off (REPTO) General Operation Definitions HEAD OF WATER: vertical depth of water measured in feet or in pressure per unit or area. In hydraulics, head always represents pressure and it is expressed interchangeably in feet of water or pounds per square inch and sometimes in inches of depth of mercury. STATIC HEAD: the pressure that is exerted by a stationary column of water of a given height or depth. TOTAL HEAD OR TOTAL DYNAMIC HEAD: the maximum height above the source of supply to which the pump would elevate the water plus all the resistance to flow in the pipe or hose line. DISCHARGE HEAD: the pressure measured at the discharge outlet of a pump. SUCTION HEAD: the positive pressure measured at the suction entrance of a pump (when pumping from an elevated tank or hydrant). VELOCITY HEAD: the equivalent pressure represented by fluid in motion as measured by means of a Pitot gauge. STATIC LIFT: the vertical height of the center of the pump above the source of supply (when pump from draft). TOTAL SUCTION LIFT: the static lift plus the friction in suction line plus entrance losses. NET PUMP PRESSURE: the total dynamic head of the pump. EFFECTIVE NOZZLE PRESSURE: the pump discharge pressure minus hose friction plus or minus the difference in elevation above or below pump. WATER HORSEPOWER: the theoretical power required to deliver a given quantity of water per minute against a given head. BRAKE HORSEPOWER: Actual power as delivered by a motor or engine to a driven machine. PUMP EFFICIENCY: The quotient of the water horsepower divided by brake horsepower required to produce it. WATER HAMMER: a series of shock waves produced in a pipeline or pump by a sudden change in water velocity. A sudden change in flow velocity can result from rapid closure of valves. A pressure wave is set up which travels back and forth in the water column at extremely high speed producing rapid vibrations that may be violent and destructive if the water column is long. The MAXIMUM THEORETICAL LIFT of a pump is 34 feet, which is the pressure of the atmosphere at sea level. The maximum practical total lift at sea level is 20 to 25 feet (depending on the type and condition of the pump) and this decreases with drops in barometric pressure Pierce Manufacturing Inc. All Rights Reserved. PUC Pump / 3-1

18 GENERAL Operating The Engine After the pump has been primed, the engine speed should be increased gradually; never jerk throttle wide open. Likewise, the engine speed should be decreased gradually when shutting down. Watch the pump pressure gauge and open throttle only enough to give the desired pressure. The pressure may rise high enough to burst the discharge hose, when using small nozzles, if the engine is given full throttle (except pumps equipped with pressure regulators set for desired pressure). Never run engine at high speeds except when pump is primed and ready to discharge water Cooling The Engine NFPA 1901 requires that a supplementary heat exchanger cooling system be provided. This heat exchanger is an integral part of the pump, and the installation of two hoses from the engine cooling system to the pump is all that is required. Valves or other shut offs are integral to the engine. The pump should never be operated under prolonged heavy loads without an adequate supply of cooling water flowing. Coolant temperatures should never be allowed to exceed 225 F while pumping and 180 F is usually taken as a safe operating temperature Suction Strainers A large suction strainer, which will prevent the passage of a body larger than the pump impeller ports, must always be used on the free end of the suction line when pumping from draft. The small hydrant strainer must always be inserted in the suction manifold of pump, when pumping from hydrants and at all other times except when maximum capacity is required from draft. Failure to use a strainer at all times when pumping will cause serious trouble by clogging the pump because, even in water mains, foreign matter is invariably present, and will be drawn into pump by the high velocity of the water entering Suction Line The suction line of a fire pump can be the source of more operating difficulties than all the rest of the pump when working with a suction lift. Faults in the suction line which cause trouble in operation are as follows: 1. AIR LEAKS: A small amount of air, expanding in the vacuum of the suction line, displaces a considerable volume of water which subtracts from the capacity that the pump is able to deliver, makes the priming difficult or causes pump to lose its prime. Therefore, it is absolutely essential to keep the suction line and the suction side of pump casing air tight at all times when drafting water. Air leakage into pump while operating is usually indicated by a rattling sound in pump casing, miniature explosions in stream issuing from the nozzle, or by losing of prime when operating at very low capacities. The usual cause of leaky suction lines is carelessness in handling of suction hose. Bruising of hose threads by bumping against hard surfaces or sand in the coupling often prevents tightening of the joints up against the gaskets. The hose gaskets are often defective and are sometimes lost without being noticed by the operator. 2. INSUFFICIENT SUBMERGENCE: The free end of suction hose must be submerged to a sufficient depth to prevent the entrance of air that may be sucked down from the surface of the water to a considerable depth when operating at large capacities. Entrance of air into suction lines in this manner is indicated by a small whirlpool, or vortex, on the surface of the water over the end of the hose. A minimum submergence of 4 times the hose diameter to the upper holes in suction strainer is recommended where full capacity of pump is required. Where sufficient submergence is not possible, a board or sheet of metal laid over end of suction line will keep air from entering. 3-2 / PUC Pump 2010 Pierce Manufacturing Inc. All Rights Reserved.

19 GENERAL 3. SUCTION LINE ENTRANCE TOO CLOSE TO BOTTOM: If the end of suction line is laid on the bottom of the source of supply, a part of the suction opening will be shut off; and if the bottom is soft the hose will suck itself down into the earth, closing more of the opening and loosening sand and mud to be carried into the pump. The suction entrance should be suspended a foot or more above the bottom, or if this is not possible, it should be laid on a board or piece of sheet metal. A rope tied to the suction strainer is a convenient means of holding it off the bottom. 4. OBSTRUCTION OF SUCTION STRAINER BY FOREIGN MATTER: The high velocity of water entering the suction line will carry loose foreign bodies in against the strainer from a considerable distance. Therefore, all weeds and refuse should be removed from close proximity of the suction entrance. 5. SUCTION LINE TOO SMALL OR TOO LONG: The flow of water into the pump is opposed by the frictional resistance in the suction line. This friction loss must be added to the height of the pump above the water (static lift) to determine the total lift of the pump. When all of the vacuum in the pump (atmospheric pressure) is consumed in raising water through this total life, then the limit of capacity has been reached. This capacity can be increased only by decreasing total lift. If the static lift cannot be reduced, then the friction loss must be reduced by using a shorter or larger suction hose. The rated capacity of the pump is guaranteed for a static lift of 10 feet, with 20 feet of recommended suction hose at sea level. To increase the capacity without reducing the static lift, or to increase lift without sacrificing capacity, requires larger suction hose. An excessively long suction line is a handicap to any pump, for besides reducing capacity through the added friction loss, it retards priming and it produces a detrimental effect known as cavitation. This means a separation of the water column in the pump suction, or void spaces, produced by the inertia of the heavy mass of water in the line resisting sudden change in the velocity when the pump starts to deliver or when discharge valves are opened or closed. This phenomenon reduces capacity further, and usually sets up a vibratory motion and water hammer as the water surges in and out of the void spaces. When operating with a long suction line, the driving engine should be accelerated gradually, the discharge gates opened gradually, and the capacities of the pump should be held down to within the range of smooth performance. 6. AIR TRAP IN SUCTION LINE: If the suction line is laid so that part of it is higher than any other part that is nearer to the pump, as when hose is laid over a high bridge rail, an air trap is formed at the highest part of the hose from which the air cannot be sucked out by the primer. This trapped air is expanded and carried into the pump with the first rush of water causing the pump to immediately lose its prime. If suction line cannot be laid so that it slopes all the way from pump to water, it can still be primed easily by simply allowing the primer to continue to function until all the trapped air in the hose has been carried into the pump and picked up by the primer Testing For Air Leaks Tests for leakage should be made with the suction hose attached and capped, discharge gate open, and all other openings closed tightly. Run electric priming pump with primer shut-off valve open, until maximum vacuum is shown on the gauge. The vacuum should hold for several minutes before satisfactory performance of pump can be expected. If excessive leakage of air occurs, the source of leaks can be located by shutting off primer motor, with vacuum at its highest point, and listening for the hiss of air. In the absence of a vacuum gauge, the vacuum in pump may be judged by closing suction opening with the flat of hand or a rubber pad. Water or air pressure may be applied to pump casing to test for air leakage if more convenient. Do not pressurize with air beyond 10 PSI Pierce Manufacturing Inc. All Rights Reserved. PUC Pump / 3-3

20 GENERAL Source Of Water Supply Water may be drafted from a pond, lake, stream, cistern, stock tank, or well; but whatever the source, the static lift must not exceed 20 feet from the center of the pump to the surface of the water and a lift not exceeding 10 feet is recommended. The source of supply should be reasonably clear and free from foreign matter. It is recommended that all water holes, which may be needed for fire protection, be deepened if necessary and kept free from weeds and refuse. In many fire protection areas, cisterns or reservoirs are built and allowed to fill up with rain water to be used in emergencies Pumping In Cold Weather The first insurance against cold weather trouble is to keep fire apparatus stored in heated quarters. All water must be eliminated from pump casing and primer line between periods of operations. When setting up for pumping, unnecessary delays should be avoided by having thoroughly trained pump operators. Be sure that primer and booster lines are kept closed until ready for use. Having discharge lines ready so that pump may be started as soon as it has become primed. Do not stop flow of water through the pump until ready to drain and return to the station. Engine coolant from the engine circulated through the heater jacket in pump casing helps prevent ordinary freezing troubles When Finished Pumping Drain water out of system by opening all valves, caps and drains, excluding the Tank to Pump Valve and the Tank Fill Valve. Don t forget to close all drain cocks after all water has been drained out. Trouble in priming will follow on the next run if this is forgotten. Shut off cooling line to make pump ready for priming again. Pumps not often used for fire service should be inspected and run periodically to ensure that they will be in readiness for an emergency Pumping Salt Water The pump should be flushed out with fresh water immediately after pumping salt water to prevent excessive rusting. (Except pumps which are built of special material to resist the corrosive action of the brine.) When measuring sea water with a pitot gauge, capacities shown in Table 6-2 should be discounted approximately 1 1/2% to determine the correct capacity. A centrifugal pump will show 2 1/2% higher pressure and require 2 1/2% more power when handling sea water than when handling fresh water if operated at the same speed and capacity Testing Of Equipment For Practice It frequently happens that operators of fire apparatus, who are not thoroughly familiar with its operations, become confused under the stress of emergency and neglect some little detail that may cause trouble or delay in getting the equipment into operation. Therefore, we urge that practice tests be conducted repeatedly until operators are thoroughly trained. More than one person in the department should be a competent operator. Practice should include pumping from low lifts, high lifts with short and long suction lines, with suction line elevated to form an air trap, and from hydrants, at large and small capacities. It is well, also, to note the effects of air leaks in hose, insufficient submergence and restriction of suction line. (Suction line can be restricted by placing a can or other strong closure around the suction strainer). 3-4 / PUC Pump 2010 Pierce Manufacturing Inc. All Rights Reserved.

21 GENERAL Do not allow personnel to hold a large nozzle while working at high pressures for serious accidents may result if hose breaks loose. NEVER BREAK OR RESTRICT SUCTION OR ALLOW AIR TO ENTER SUCTION LINE WHILE ENGINE IS OPERATING WITH THROTTLE OPEN. This will release the load and allow engine to run away Measuring Pump Performance Pump performance is measured by the quantity of water it can deliver per minute against a certain pressure called Total Head or Net Pump Pressure, as it is usually termed in fire pump testing. The net pump pressure is the sum of the pump discharge pressure, as shown on the pressure gauge with which the pump is regularly equipped, and the total suction lift converted to equivalent pounds per square inch. If pump is operating from a hydrant, the net pump pressure is the discharge pressure less the incoming pressure from hydrant measured at the suction entrance of pump. Capacity of fire pump is measured in gallons per minute. The usual method of measurement is to determine the pressure of the jet of water leaving a given size of nozzle by means of a Pitot gauge from which the capacity is computed mathematically. A Pitot gauge consists of a small tube adapted to a point directly into the hose nozzle from the center of the issuing stream, the other end of the tube being connected to an accurate pressure gauge. The nozzle jet drives straight into the Pitot tube and converts the velocity of the jet to pressure which is an accurate measure of velocity of the water as it leaves the nozzle. The tip of the Pitot tube should be one-half the diameter of the nozzle away from nozzle tip while taking reading. Table 6-2 gives nozzle capacities for various Pitot gauge readings. If a Pitot gauge is not available, approximate pump capacities can be determined by referencing Table Acceptance Tests Acceptance tests require continuous tests of three hours duration: 2 hours at 100% rated capacity and 150 PSI net pump pressure; one-half hour at 70% capacity and 200 PSI; one-half hour at 50% capacity and 250 PSI; and a spurt test at 100% capacity and 165 PSI. Table 6-1 shows recommended set-ups and gauge readings for rating tests. To adjust nozzle pressure for the correct capacity, while maintaining the correct pump pressure, it is necessary to make simultaneous adjustments of engine throttle and the discharge gate valve, partially closing the latter until just the right discharge resistance is built up Engines An Underwriter fire pump imposes heavy loads on the engine that drives it, often absorbing all of the power the engine is capable of delivering at full throttle. Continuous pumping gives the engine no time to rest. Therefore, a new engine and pump unit must be thoroughly broken-in before it is required to deliver prolonged maximum pump performance. We recommend a minimum break in period of 20 hours at light pumping loads, with occasional spurt tests and interruptions. Temperature and lubrication should be checked during this period Pierce Manufacturing Inc. All Rights Reserved. PUC Pump / 3-5

22 GENERAL Engine manufacturers power ratings usually show maximum performance of a selected, factory adjusted engine, operating without fan, generator, muffler or other accessories, and corrected for ideal conditions, i.e. sea level barometer (29.92 of mercury) 60 F and high humidity. Therefore, the actual power delivered by an average truck mounted engine is considerably lower than the manufacturers rating, and allowances must be made in predicting pump performance Effects Of Atmospheric Conditions On Engine And Pump Performance Each one inch of drop in Barometric pressure or each 1000 feet of elevation of the pumping site reduces engine power approximately 3 1/2% for engines not equipped with a turbo charger. Each 12 rise in temperature above 60 F of carburetor intake air reduces engine power approximately 1%. Lowering of humidity reduces power slightly. Each one inch drop in Barometric pressure or each 1000 feet of elevation reduces the maximum possible static lift of a pump approximately one foot. Temperature of the water supply affects the attainable suction lift of a pump. The effect is slight at low water temperatures but becomes increasingly detrimental as the temperature rises. A 10 rise from 70 F will subtract about 1/2 foot from the maximum attainable suction lift, while an equal rise from 100 F will reduce the lift at least 1 1/2 feet. Temperature is an important consideration when pumping from a test pit where the water is heated by recirculation Operating Characteristics Of Pumps CENTRIFUGAL PUMPS: A centrifugal pump develops pressure by centrifugal force of the liquid rotating in the impeller wheel. The pressure developed depends upon the peripheral speed of the impeller (increasing as the square of the speed) and it remains fairly constant over a wide range of capacities up to the maximum output of the pump, if speed remains constant. If the discharge outlet of a centrifugal pump is entirely shut off, with speed kept constant, there is a small rise in pressure, the water churns in the pump casing and the power drops to a low value. If the discharge is opened wide, with little resistance to flow the pressure drops while the capacity and power both increase to their maximum. A centrifugal pump is an extremely simple mechanism mechanically, but rather complex hydraulically; in that many factors enter into the design of the impeller and water ways which will affect the pump s efficiency. DISPLACEMENT PUMPS: Rotary and piston pumps are termed Positive Displacement pumps because each revolution displaces or discharge (theoretically) an exact amount of liquid, regardless of the resistance. The capacity is, therefore, proportional to the number of revolutions of the pump per minute and independent of the discharge pressure except as it is reduced by slip (leakage past the pistons or rotors). For a given speed the power is directly proportional to the head. If the discharge is completely shut off, the pressure, power, and torque climb indefinitely until the drive power is stalled or breakage occurs. Slip is the greatest factor affecting efficiency of a displacement pump, and this factor is greatly influenced by the condition of and wear on the working parts. 3-6 / PUC Pump 2010 Pierce Manufacturing Inc. All Rights Reserved.

23 SECTION 4 OPERATION 4-1. Approaching the Apparatus Stepping and Walking Surfaces ALWAYS be careful when climbing up or down to avoid a slip and fall, and potential injury to yourself and others. Enter and exit cabs slowly, deliberately, and carefully. NEVER jump to ground. You can injure yourself. ALWAYS maintain three points of contact when climbing up or down. Keep contact with one hand and two feet, or two hands and one foot. Use steps, hand-holds, or sturdy features on the apparatus. ONLY grasp or step on items appropriate for climbing on or firmly attached objects. Keep steps and hand-holds in good repair, and free of grease, mud, dirt, fuel, ice, and snow. Make sure all attaching bolts and hardware are tight, thus eliminating any movement of steps and handholds. NEVER step or climb on any vehicle surface unless it is slip-resistant and hand-holds are provided. Replace slip-resistant material when worn. All surfaces intended for stepping or walking are designed or treated with slip-resistant material your department specified. NEVER step or walk on surfaces not designed for stepping or walking, such as: Chromed surfaces or objects Painted surfaces Hose rollers Compartment doors or hatches Valves Controls Inlet or Outlet Connections 2010 Pierce Manufacturing Inc. All Rights Reserved. PUC Pump / 4-1

24 OPERATION Compartment Doors NEVER step on open compartment doors. They do not support your weight. Falls can cause serious injury or death. Always close swing-up or swing-out compartment doors. People can walk into doors left open at lower levels. Personnel working on top of the apparatus can mistake an open horizontal door for a walking surface Hose Bed Covers CLOSE hose covers after use. Hose bed covers can cause serious injury if blown shut by wind. Keep personnel clear of open hose bed covers during windy conditions. Some apparatus are equipped with aluminum hose bed covers. Always close after use. They protect hose from sun and weather. Hose bed covers are heavy. They might require two or more people to open or close safely Folding Steps or Platforms High voltage electricity can travel down a water stream. NEVER spray through electric wires. High voltage can cause death or serious injury. Keep OFF the ground when operating an aerial device. ALWAYS stand with both feet on the pump operator's platform of an aerial device. High voltage can jump gaps between wires and apparatus. Electrical power will pass through people who stand on the ground and touch the apparatus. Electrical power lines can cause death or serious injury. Before beginning pump operations, make sure that folding steps or platforms are DOWN and firmly engaged in their weight-bearing position. When operating the pump on an aerial apparatus, always stand with both feet on the operator's platform and off the ground. Your body will become an electrical path to ground if you stand with one foot on the platform and one on the ground, or with both feet on the ground and your hands on the apparatus. If the aerial device contacts or comes close to high voltage power lines, electricity can shoot through you. You can die. 4-2 / PUC Pump 2010 Pierce Manufacturing Inc. All Rights Reserved.

25 OPERATION 4-2. Hose Hose Storage The hose is stored in: Body Compartments Bumper Compartments Cross-Lay Trays Speed-Lay Trays Hose Beds Reels Hose Chutes Evaluate each way of storing hose. Determine the most efficient and safest way to pack hose for your fire department's use. Hose restraints (nets, doors, webbing, ropes, etc.) must be used to secure the hoses after repacking. Failure to comply may result in hoses deploying while the vehicle is in motion, causing injury to bystanders and/or damage to equipment. If hose is to be laid from a moving apparatus, first test the packing method under controlled conditions to learn the MPH at which hose will lay out smoothly, without snags or snarls Hose Chutes Some aerial apparatus have a hose chute. The chute guides the hose from the hose bed around the aerial turntable, then out the back of the vehicle. NEVER pack hose in the hose chute, because that can cause snagging and snarling. To avoid creating a jam of tangled hose in the hose chute: Lay couplings so they are pulled out straight, without flipping around. Lay hose so that it never crosses over itself when paying out. Maintain vehicle speed of 5 MPH or less. At 5 MPH, seven feet of hose is pulled out each second. If you travel more than 5 MPH, you are likely to cause a hose jam in the hose chute Hose Beds Pack hose carefully in any hose bed to minimize the risk of hose snags or snarls as it lays out. Hose that snags or snarls during layout from a moving vehicle can fly about, causing serious injury or death to bystanders. Hose beds come in many shapes and sizes. Hose characteristics vary with the size, type, and age of the hose Pierce Manufacturing Inc. All Rights Reserved. PUC Pump / 4-3

26 OPERATION Experiment with different methods of packing a specific hose, bed, and chute combination to determine a packing method that will lay out without snagging or snarling. Make sure you learn the maximum MPH at which hose can be laid out Hose Deployment NEVER ride on rear steps or other areas outside the cab. Limit speed to 5 MPH when laying hose. ALWAYS use a spotter when backing up. Keep the spotter and all other people clear of the vehicle's path. All occupants MUST be seated and belted while vehicle is in motion. Any operation where people are working around a moving vehicle is dangerous. All occupants must be seated and belted while the vehicle is in motion. NEVER ride on rear steps or other areas outside the cab. Flying hose is extremely hazardous. Keep all people clear of hose being laid by a moving vehicle. Flying hose can injure or kill. Fire hose under pressure can burst without warning. NEVER straddle or stand over a charged hose. Always wear complete protective gear, even when testing. Burst hose can injure or kill. When laying hose, an anchorman must protect himself from the dangers of flying hose. It is safest to use rope to tie the hose to the hydrant. In the absence of rope, anchor the hose by wrapping the end half way around the hydrant in a J-pattern only. Never wrap more than half way around the hydrant. Wedge the end fitting against the hydrant with a booted foot. Stand clear of the hose so that you will be away from the hose if it becomes taut and swings out from the hydrant. A snag in the hose bed can pull the hose loose. The metal fitting can swing around and break your leg. Keep people clear of the hose being laid before driving the vehicle. When laying hose, limit vehicle speed to 5 MPH to minimize risk to personnel, equipment, and bystanders. Avoid kinks, crimps, and twists when laying fire hose. 4-4 / PUC Pump 2010 Pierce Manufacturing Inc. All Rights Reserved.

27 OPERATION Hose Connections Hose fittings can fail without warning. Inspect hose fittings for cracks, chips or other damage and replace when worn or damaged. Damaged or worn fittings can burst without warning. Burst fittings can injure or kill. Hose fittings are critical to safe delivery of water to a fire. Treat hose connections with care and inspect regularly Positioning the Apparatus Fire Scene Positioning Operate apparatus away from burning embers that can be sucked into the air intake system. Burning embers in the engine air filter can cause engine fire. Engine fire can cause property damage, serious injury, or death. Heat from a fire can damage electrical systems, rubber seals and gaskets, and plastic components. Always place apparatus upwind from the fire and at a safe distance away from flames. Diesel engines consume as much as 1200 cubic feet of clean air every minute. Hot embers sucked into the air intake can cause the air cleaner element to ignite. Although Pierce Custom Chassis are equipped with ember barriers composed of mesh screens or perforated metal, they are not a foolproof guarantee of protection. Always leave a way out. Always position the apparatus in a location that allows a quick retreat if conditions change. Always park upwind of the fire. Never park the apparatus downwind of the fire. Always avoid electrical lines. Never park under electrical lines Positioning on Roads Position the apparatus so that it protects emergency personnel. Many departments choose to park the apparatus at an angle so that personnel can work behind the vehicle, out of the direct path of oncoming vehicles. Keep emergency response lighting ON to alert traffic Lighting As soon as possible, provide good lighting for people working on and around the apparatus. Use extendable lighting or lighting from another apparatus. Make sure that the pump operator can clearly observe controls, gauges, and hose connections, and can watch the condition of hoses and attack personnel to the greatest extent possible Pierce Manufacturing Inc. All Rights Reserved. PUC Pump / 4-5

28 OPERATION Chock the Wheels ALWAYS place wheel chocks on both front and rear of tire when vehicle is parked. Chock wheels as soon as you exit the cab Operation of PUC Fire Pump Operation of Pump Never run the pump dry except momentarily and at low speeds. Do not use this pump for hose testing. A Rear Engine Power Take-off (REPTO) transmits power to the pump transmission input shaft whenever the chassis engine is operating. The fire pump impeller is engaged or disengaged through a high capacity, multi-plate, electric clutch. This configuration enables the pump transmission to power an auxiliary pump transmission mounted Power Take-off (PTO) independent of pump impeller engagement To Engage the Pump Stationary Operation 1. Pull Parking Brake Auto Neutral feature automatically engages transmission to NEUTRAL. If you fail to apply the parking brake, safety interlocks prevent operation of the hand throttle or pressure governor. NOTE: If the parking brake is released during pump operation, the hand throttle or pressure governor is disconnected AND the engine speed falls to IDLE. Water pressure to the hose will drop. The pump speed will then be controlled only by the driver's throttle pedal. That is the manual override. 2. Observe the OK to Stationary Pump indicator lamp: The OK TO STATIONARY PUMP indicator light should be on when ever the parking brake is applied. 3. Chock the Wheels Block both front and rear of tire using wheel chocks. Engage pump only at engine idle speed. Begin pumping water immediately after engaging pump. Circulate water if hoses are not ready to keep water cool. Running pump dry for more than a few minutes will cause damage. 4. Engage the Pump Confirm engine is at idle rpm. Activate the WATER PUMP switch located on the driver's panel in the cab. 4-6 / PUC Pump 2010 Pierce Manufacturing Inc. All Rights Reserved.

29 OPERATION 5. Observe the Pump Engaged indicator lamp: The WATER PUMP indicator light turn ON when: Pump is engaged, AND Pump is spinning Engaging Pump when Vehicle is Driving Basic Package (Standard) The basic pump and roll mode will use the same operation sequence as stationary pumping mode with a few additional steps. After the vehicle is setup for stationary pumping, the operator will leave the cab and setup the pump panel to discharge at the desired outlet(s). Upon returning to the cab, the operator will disengage the parking brake. An OK to Pump & Roll indicator will illuminate on the cab switch panel. First gear on the transmission gear selector will be selected by the operator for pump and roll operations. The operator will apply the foot throttle and brake pedal as needed. Pump and roll mode will be maintained unless the transmission shifts out of first gear or the Water Pump switch is disengaged. Pump-and-roll operation is dangerous. NEVER ride outside the cab when the vehicle is moving. Keep personnel walking to the side of the vehicle and in sight of driver at all times. Drive slowly. The foot throttle controls both the ground speed and pump pressure. 1. Stop Vehicle 2. Pull Parking Brake Auto Neutral feature automatically engages transmission to NEUTRAL. 3. Engage the Pump Engage pump only at engine idle speed. Begin pumping water immediately after engaging pump. Circulate water if hoses are not ready to keep water cool. Running pump dry for more than a few minutes will cause damage. Figure 4-1: Water Pump & Foam System Control Switches (Basic Package) Pierce Manufacturing Inc. All Rights Reserved. PUC Pump / 4-7

30 OPERATION Confirm engine is at idle rpm. Activate the desired water pump or foam system control switch located on the driver's panel in the cab. Switches are multi-function; see See Table 4-1. Table 4-1: Water Pump & Foam System Control Switches - Modes of Operation *Optional Pressing this Control Switch: Turns these systems ON: Water Pump Water Pump Foam System* Water Pump Foam System CAFS System* Water Pump Foam System CAFS System Pressing this Control Switch: Turns these systems OFF: CAFS System* CAFS System Foam System* CAFS System Foam System Water Pump CAFS System Foam System Water Pump 4. Observe Indicator Light The PUMP ENGAGED indicator lights only when PTO has been engaged and the pump is spinning. 5. Provide Water Supply to Pump Operator must leave the cab and set up Pump at Pump Panel: Open the Tank-to-Pump valve to provide water to the pump. Open the Recirculating Valve (if applicable), or crack open the tank fill valve, to allow water to circulate. 6. Shift Transmission into 1st Gear For pump-and-roll operation the transmission must be in the 1 st Gear (1) position. 7. Release Parking Brake 8. Look at Indicator Light The OK TO PUMP AND ROLL light turns ON when: Parking Brake is released. 9. Use foot throttle and brake pedal as needed Pump will maintain Pump and Roll mode unless transmission shifts out of 1 st gear, OR WATER PUMP control switch is turned OFF Engaging Pump when Vehicle is Driving Advanced Package (Optional) If pump and roll is desired by the operator, the operator will engage the Pump & Roll and Water Pump switches on the cab switch panel. The tank to pump valve and recirculation valve will open automatically with the pump and roll mode so the operator does not have to leave the cab. The foot throttle and brake pedal will be applied by the operator as needed. Pump and roll mode will be maintained unless the pump switch or pump & roll switch is disengaged. 4-8 / PUC Pump 2010 Pierce Manufacturing Inc. All Rights Reserved.

31 OPERATION Pump-and-roll operation is dangerous. NEVER ride outside the cab when the vehicle is moving. Keep personnel walking to the side of the vehicle and in sight of driver at all times. Drive slowly. 1. Press PUMP AND ROLL switch while approaching scene Validate that OK TO PUMP AND ROLL light is ON. The Tank to Pump Valve and Recirculation Valve will automatically open. The engine speed will be limited to approximately 1200 RPM maximum. Engage pump only at engine idle speed. Begin pumping water immediately after engaging pump. Circulate water if hoses are not ready to keep water cool. Running pump dry for more than a few minutes will cause damage. 2. Engage the Pump Confirm engine is at idle rpm. Activate the desired water pump or foam system control switch located on the driver's panel in the cab. Switches are multi-function; see See Table Observe Indicator Light The PUMP ENGAGED indicator lights only when PTO has been engaged and the pump is spinning. 4. Use foot throttle and parking brake as needed Pump will maintain Pump and Roll mode until vehicle is stopped and Parking brake is engaged Supply Water to Pump 1. Open Tank-to-Pump Valve Figure 4-2: Typical Tank-to-Pump Valves Pierce Manufacturing Inc. All Rights Reserved. PUC Pump / 4-9

32 OPERATION The Tank-to-Pump valve (Figure 4-2) controls the flow between the water tank and pump inlet. With this valve OPEN, water from the tank floods the pump intake manifold and slowly primes the pump. 2. Open Primer Valve If the pump is dry, engage primer to expel air in the pump to get prime. Keep pump water cool. ALWAYS circulate fresh water through the pump. Pump can heat trapped water to boiling in seconds. Burst lines can spray personnel with scalding water. Scalding water can injure or kill. 3. Open Tank Fill or Recirculating Valve Figure 4-3: Tank Fill or Recirculating Valve The Tank Fill valve (Figure 4-3) opens the connection from the discharge side of the pump to the water tank. Open Tank Fill Valve to refill the water tank from a water source that is connected to an intake fitting. With the Tank-to-Pump valve and the Tank Fill valve both OPEN, water recirculates from the tank, through the pump, and back to the tank. This cools the pump before you begin flowing water to a discharge line. ALWAYS crack open the Tank Fill Valve when running the pump. If you fail to continuously circulate water through the pump chamber, the water trapped in the pump chamber heats to boiling in seconds. Boiling water and steam can injure people. It also damages pump seals and gaskets. When recirculating water, the water in the tank will eventually become too hot to cool the pump. Exchange tank water with fresh water to keep pump cooled. Keep track of water temperature: a. Touch the outlet pipe to see how warm it is. If it is hot to the touch, it is time to bring fresh, cool water into the water tank or turn OFF pump. b. Watch tank temperature gauge (if your fire department selected this option). When temperature reaches 175 F, then add fresh cool water or turn OFF pump / PUC Pump 2010 Pierce Manufacturing Inc. All Rights Reserved.

33 OPERATION 4. Open Recirculating Valve (Optional) Figure 4-4: Recirculating Valve A dedicated Recirculating Valve (Figure 4-4) opens a small water flow from the pump to the tank. The flow through this line cools the pump. The recirculating line does not let water flow from the tank to the pump, so it works only if the Tank to Pump valve is OPEN, or if the intake is supplied by a water source. 5. Observe Pump-Overheat Indicator (Optional) Figure 4-5: Pump-Overheat Indicator 1155 Watch the Pump-Overheat indicator (Figure 4-5) during pumping operations to make sure that the pump stays cool. If the Overheat indicator light turns ON, add fresh water, recirculate, discharge water, or shut engine OFF to cool the pump Pierce Manufacturing Inc. All Rights Reserved. PUC Pump / 4-11

34 OPERATION 4-5. Manual Pump Engagement Manual pump engagement is intended for limited use in the event of a failure in the primary control system. If conditions warrant the use of this override, pumping operations may continue, but the truck should be examined by a service technician upon return to the station to identify and repair the cause of the failure. NOTE: If this override is used, make sure it is disengaged once pump operations are complete. If power is lost to the pump shift switch in the cab, the following steps can be used to manually engage the pump. 1. Ensure the parking brake is set and the pump shift in the cab is in the OFF position. 2. Proceed to the pump operator s panel. 3. Open the access panel door located in the lower right of the pump panel. 4. Flip up the switch guard. 5. Turn the switch to the ON position. 6. A yellow indicator light will illuminate if the pump is engaged. Repeat if necessary. 7. Proceed with normal operating functions Adjusting the Pump Pressure Hand Throttle Systems can malfunction. If engine control is lost at pump panel, assign someone to use foot pedal in cab to continue pumping operation. Before controlling the throttle manually, the parking brake must be released and the wheels must be chocked Determine Discharge Pressure Hoses and Nozzles can explode if over-pressurized. NEVER exceed pressure rating of downstream devices. Exploding devices can injure or kill. Keep control of hose under pressure. Hose under pressure wants to fly about. Flying hose can injure or kill / PUC Pump 2010 Pierce Manufacturing Inc. All Rights Reserved.

35 OPERATION Pump pressure is determined by: Engine Speed Pump Size Discharge Restriction (size and length of discharge hose) Intake Restriction (size and length of intake hose) System Restriction (size and shape of valves, fittings, manifolds, etc.) You must determine a pump pressure that will provide the desired nozzle pressure, based on the number and size of attack lines that are deployed. Determine this pressure for all fire-fighting situations you might encounter, and record them on a Pump Chart. Keep the Pump Chart in a location accessible to the pump operator. Refer to the IFSTA Pumping Apparatus Driver/Operator Handbook (latest edition) for procedures on creating a Pump Chart Engine Speed and Pump Pressure The pump pressure is controlled by regulating the engine speed. If the apparatus is equipped with a pressure governor, the governor will regulate the engine speed automatically to maintain the desired pump pressure Controlling Engine Speed, Pumping Pressure Governor Operation If the apparatus is equipped with a pressure governor, the governor will regulate the engine speed automatically to maintain the desired pump pressure. When placed in the PRESSURE CONTROL mode, the system will monitor pressure, increasing or decreasing the engine speed to maintain the set pressure. Apparatus equipped with pressure governors normally do not have pressure relief valves. The pressure governor performs the function of the relief valve. Always pump in pressure control mode. Pumping in throttle (RPM) control mode can cause high pressure and/or pressure spikes. Pressure spikes can injure or kill. NOTE: For additional information concerning the operation of the pressure governor, refer to the PUC Pressure Governor Operator s Guide CD-ROM (PV-P-TM450) and/or the FRC PMA300 Pressure Governor service group (2825-V-007) included in the service manual. 1. Select Pressure Control Mode Place pressure governor in the PRESSURE CONTROL mode. Switching methods will vary depending on the manufacturer of the pressure governor. 2. Adjust Desired Pressure Use the hand wheel throttle control to change the desired pressure setting Controlling Engine Speed, Not Pumping Pressure Governor Operation The THROTTLE (RPM) CONTROL mode allows the operator to increase engine speed when not pumping, to increase alternator output, warm the engine, or other non-pumping operations Pierce Manufacturing Inc. All Rights Reserved. PUC Pump / 4-13

36 OPERATION NOTE: For additional information concerning the operation of the pressure governor, refer to the PUC Pressure Governor Operator s Guide CD-ROM (PV-P-TM450) and/or the FRC PMA300 Pressure Governor service group (2825-V-007) included in the service manual. 1. Select Throttle (RPM) Control Mode 2. Adjust Desired Engine Speed (RPM) Press the red button to cancel the current mode and return the engine speed to idle. The red button also serves as the Emergency Stop. Practice using the Emergency Stop Controlling Engine Speed with Multiple Controls Transferring engine speed control between Hand Throttle and Pressure Governor can cause a jump in engine speed. Engine speed changes can cause discharge water pressure spikes. Spikes in discharge pressure can cause hoses to kick with great force, causing injury. Some apparatus have both a Hand Throttle and a Pressure Governor. The Throttle Selector Switch determines which control is ON. If Hand Throttle is selected, you will control engine speed manually. If Pressure Governor is selected, the Pressure Governor controls engine speed. ALWAYS return the control you are not using to the IDLE position Discharging Water Figure 4-6: Typical Discharge Valves Connecting Attack Line Hose 1. Close Discharge Valve CLOSE Discharge Valve to keep water from flowing once the Discharge Cap is removed / PUC Pump 2010 Pierce Manufacturing Inc. All Rights Reserved.

37 OPERATION ALWAYS OPEN Drain/Bleeder Valve BEFORE removing Inlet or Discharge Cap. Discharge lines can trap pressure if the valve is opened and left closed. Discharge cap under pressure will blow off with explosive force. Exploding Cap will injure or kill. Figure 4-7: Drain/Bleeder Valves 1140/POM Open Drain/Bleeder Valve Pull up or turn Drain/Bleeder Valve counterclockwise to the left to OPEN. Air pressure can be trapped between the Discharge Valve and the Discharge Cap. You must bleed off this pressure BEFORE the cap is removed. Otherwise, any trapped air pressure can blow the cap off with great force and injure someone. 3. Open Discharge Cap Vent if One is Provided Some Discharge Caps have a pressure release vent on the cap. If cap has a vent, OPEN vent before removing cap. 4. Remove Discharge Cap BEFORE removing Discharge Cap, OPEN the Pressure Release Valve or Drain Bleeder Valve to make sure that trapped air pressure escapes. Remove the Discharge Cap after you are certain that pressure has been bled from behind it. You cannot tell by how hard the cap rotates whether pressure exists or not. 5. Connect the Discharge Hose Connect the discharge hose to the discharge connection. 6. Adjust the Discharge Swivel If the discharge connection has a swivel fitting, move the swivel so the hose points AWAY from the pump operator's area. 7. Close the Drain/Bleeder Valve 2010 Pierce Manufacturing Inc. All Rights Reserved. PUC Pump / 4-15

38 OPERATION Charging Line Opening valves rapidly can cause pressure spikes. Open and close valves slowly. Pressure spikes can cause hoses to kick with great force, causing injury. Opening valves rapidly can cause water hammer. Water hammer can damage the pump and other water system components. 1. Slowly Open Discharge Valve Open and close discharge valves slowly. Rapidly opening a valve sends a surge of water through the hose, making it difficult to control. Rapidly closing a valve will cause a pressure spike in other hoses. OPEN Discharge Valve one-half OPEN until attack line is filled with water and air is expelled from hose. Observe personnel on the end of the attack line while the hose is filling. 2. Adjust Discharge Valve AFTER air is expelled from the line and water is flowing steadily from the attack nozzle, adjust the Discharge Valves to send the flow you want to each line. 3. Observe Tank Level Indicator Figure 4-8: Typical Tank Level Indicators Water level in the water tank drops as water flows to the attack lines. Watch the Tank Level Indicator. Plan ahead to add external water before you empty the tank. Learn how to open and close valves using these controls on your pump panel: Lever Controls Pull to open valve Push to close valve Rotate knob clockwise to the right to lock / PUC Pump 2010 Pierce Manufacturing Inc. All Rights Reserved.

39 OPERATION Hand Wheel Controls Rotate counterclockwise to the left to open valve Rotate clockwise to the right to close valve Electronic Controls Follow instructions on controls. Be sure to read the manufacturer s Operators Manual Discharging Foam See Foam System Operator's Manual Changing from Tank to External Pressurized Water Supply (with Gated Intake Valve) Figure 4-9: Typical Gated Intake Valves POM0034, 0035, 0036 Soon after the pump is running and water is being supplied to the discharge lines, you need to establish an external source of water BEFORE the water tank is empty. This supply can come from a hydrant, from another apparatus, or from a draft source, such as a pond, river, or portable tank. A gate intake allows you to maintain water flow at the same pressure at the same time you switch to an external water supply. In the absence of a gate intake valve, clear fire fighters from the attack area before you change to external water supply, because you will lose all water pressure. Most fire departments provide their own gate valves. Pierce recommends use of a gate valve. Before using water from a hydrant, open and vent the hydrant for about 30 seconds to flush out gravel or debris. Always use intake strainers. Gravel can damage the pump and reduce pressure Pierce Manufacturing Inc. All Rights Reserved. PUC Pump / 4-17

40 OPERATION Connect Intake Hose 1. Close Intake Gate Valve Figure 4-10: Intake Gate Valve 1143 Close the gate valve on the intake connection to which the intakes hose will be attached. Always OPEN Drain Valve or Bleed Valve BEFORE removing Intake Cap. Intake Lines can trap pressure. Intake Cap under pressure will blow off with explosive force. Exploding cap will injure or kill. Always bleed air from Intake Line. Air in lines can cause pressure spikes. Air forced from nozzle can increase intensity of fire or cause a pressure surge. Air discharge can injure or kill. 2. Open Air Bleed Valve for Intake BEFORE Cap is Removed Intake connections with a shut-off (or gate) valve can trap pressure if the valve is opened and left closed with the cap in place. ALWAYS OPEN the Intake Air Bleed Valve to let trapped pressure escape BEFORE removing cap. Air Bleed Valves are attached to a tube that is connected to the pipe. Opening the Intake Air Bleed Valve allows air trapped in the Intake Pipe to escape. Rotate the knob one-quarter turn counterclockwise to the left to open the valve. To make sure that all air pressure is removed from the system, keep the Air Bleed Valves OPEN until you start flowing water. Only then may you close it / PUC Pump 2010 Pierce Manufacturing Inc. All Rights Reserved.

41 OPERATION 3. Remove Intake Cap Figure 4-11: Intake Cap POM0024 Remove the Intake Cap only after you are certain that trapped air pressure has escaped. Make sure to OPEN the Air Bleed Valve or Drain Valve so that trapped air pressure escapes. Point intake hose away from personnel. Hoses and connections under pressure can burst without warning. Burst hose can injure or kill. Inspect hoses and fittings regularly. Replace if worn or damaged. Worn or damaged hoses and fittings can burst. Burst hose or fittings can injure or kill. 4. Connect the Intake Hose Connect the Intake Hose that has been laid from the hydrant to the intake connection. 5. Adjust the Intake Swivel If the intake connection includes a swivel fitting, adjust the swivel so that the hose points AWAY from the pump operator's area Charge the Intake Line (Pressurized Supply) NOTE: Make sure that the pressure control has been set before charging the intake hose. 1. Charge the Intake Line Once the intake hose is properly connected to the intake fitting, open the valve at the hydrant to allow water into the intake hose. Air will escape out the air bleed valve as it is forced from the hose by the incoming water. 2. Close Air Bleed Valve Close the Air Bleed Valve after the air is gone from the intake line Pierce Manufacturing Inc. All Rights Reserved. PUC Pump / 4-19

42 OPERATION Supply the Pump Perform change to external water source properly. Water flow can stop if change is performed incorrectly. Loss of water flow can endanger fire attack crews, resulting in death or injury. 1. Open the Intake Gate Valve OPEN the Intake Gate Valve slowly to change the flow to the external supply. Always open the Intake Gate Valve slowly. Air in the intake line will then enter the pump slowly. Air will be sucked through with a steady flow of water. If a large slug of air enters the pump, the pump can lose prime. Centrifugal pumps cannot pump air. If prime is lost, the attack lines will lose water pressure. 2. Close the Tank-to-Pump Valve Once the Intake Gate Valve is open, the water pressure from a pressurized source keeps water from flowing from the tank. A check valve in the tank-to-pump line keeps the pressurized supply from flowing water back into the tank. A draft source lacks intake pressure. Therefore water can continue to be drawn from the tank. If the tank is run dry, the pump can lose prime. After the Gated Intake Valve is fully open, then slowly CLOSE the Tank-to-Pump Valve to make sure that water is drawn from the external supply only. 3. Close the Tank-Fill and Recirculating Valves As long as the discharge lines are flowing water, the pump will have fresh water to keep it cool. With the Tankto-Pump Valve closed and the Tank-Fill or Recirculating Valves OPEN, the tank will continue to fill until it overflows through the fill hatch. a. CLOSE the Tank-Fill or Recirculating Valves to avoid tank overflow. b. OPEN both valves again when pump cooling is required because discharge lines are CLOSED Pump Priming Problem Solutions Control Valves That Leak 1. Cap Unused Discharge and Intake Pipes Cap all unused discharge and intake pipes to reduce air leakage from a leaky valve Monitoring Intake Pressure The Master Intake Gauge shows the intake manifold pressure. 1. Watch Intake Pressure Look often at the intake pressure on Master Intake Gauge while pumping / PUC Pump 2010 Pierce Manufacturing Inc. All Rights Reserved.

43 OPERATION Maintain positive intake pressure with soft intake hose. Negative intake pressure will collapse soft intake hose. Attack lines will lose water pressure if hose collapses. Loss of water supply will endanger fire fighters on attack lines. NEVER cavitate pump. Low intake pressure or high vacuum can cause pump cavitation. Cavitation can: Cause loss of water pressure. Damage pump components, requiring expensive repairs. Avoid water hammer. Water hammer can damage the pump system. 2. Maintain 20 PSI Intake Pressure (Pressurized Supply) Maintain intake pressure at or above 20 PSI when operating from a pressurized external supply. This provides a safety factor to avoid drawing a vacuum on the intake hose. Changes in supply pressure can cause intake pressure to drop without warning. Drop in pressure below zero (0) PSI can cause water hammer, pump cavitation, or collapse the intake hose AND cause loss of water flow. NOTE: 20 PSI may not be attainable in certain areas, depending on the hydrant system. For additional information, consult your Fire Department standard operating procedures. 3. Maintain 20 in. Hg. Vacuum (Draft Supply) When operating from draft, always maintain 20 in. Hg. of vacuum or less. Intake vacuum of more than 20 in. Hg. can cause pump to cavitate. 4. Avoid Pump Cavitation Pump Cavitation is happening when: Discharge pressure changes up and down. You hear a sound like gravel churning in the pump. Discharge pressure remains the same when you change engine speed. Reduce discharge flow until cavitation ceases Pierce Manufacturing Inc. All Rights Reserved. PUC Pump / 4-21

44 OPERATION Refilling the Tank ALWAYS refill water tank as soon as possible. If the supply source is interrupted, a full tank of water allows you to continue flowing water to the attack lines while an external water source is being restored. 1. Open Tank Fill Valve OPEN the Tank Fill Valve slowly to ¼ OPEN to divert some supply water into the water tank. 2. Watch Intake and Discharge Pressure Watch the discharge pressure gauges to make sure that you maintain attack hose flow at the desired pressure while you also fill the water tank. If intake or discharge pressure drops below the desired pressure, either CLOSE the Tank Fill Valve to divert less water to the tank OR increase engine speed to maintain pressure. Always keep the water tank full so that a steady discharge flow can be maintained if the intake supply must be shifted Changing from Tank to External Water Supply (without Gated Intake Valve) If you change from the water tank to an external water source without an Intake Gate Valve, the water flow to the discharge attack lines must be stopped. Pierce recommends that every pumper apparatus have an Intake Gate Valve. Use these procedures if Gate Valve is absent. Make sure fire fighters are withdrawn from attack area, because hoses will lose water Stop Flowing Water 1. Close Discharge Valves Water pressure during the transition period can fluctuate. Protect attack line personnel from the hazards of pressure spikes by closing the Discharge Valves. Remember, you are also shutting off water to the attack hoses. 2. Reduce Engine Speed to IDLE Running the pump without water will damage the seals and bearings. Reduce engine speed to IDLE to minimize wear on the pump while the water supply from the tank is stopped. 3. Close Tank-to-Pump Valve CLOSE Tank-to-Pump Valve before the removing the Intake Cap to prevent tank water from flowing out the intake. 4. Connect Intake Hose a. Remove the Intake Cap. b. Connect the Intake Hose / PUC Pump 2010 Pierce Manufacturing Inc. All Rights Reserved.

45 OPERATION If you are connecting to a pressurized supply, charge intake line: 1. Open Tank Fill Valve or Discharge Valve OPEN the Tank Fill Valve. Air in the intake hose must be expelled before water can reach the pump. Air will pass through the pump and out the OPEN Tank Fill Valve. - OR - OPEN Discharge Valve and Discharge Drain Valve. Water will flow out the discharge drain valve once the air escapes. Close the drain valve once air has escaped. 2. Charge the Intake Line OPEN the water valve on the hydrant to allow water to flow through the intake hose and into the pump. Before using water from a hydrant, open and vent the hydrant for about 30 seconds to flush out gravel or debris. Always use intake strainers. 3. Close Tank Fill Valve CLOSE the Tank Fill Valve once water tank is full Resume Discharge Operation 1. Open Discharge Valve Open the Discharge Valve(s) slowly to resume attack line operations. 2. Increase Pressure Continue to watch the Master Pressure Gauge. Increase speed until you reach the pump discharge pressure you want Engine Status Display Figure 4-12: Typical Engine Status Displays The Engine Status Display is either a group of gauges and indicator lights or an electronic display that gives you critical information on engine performance. You must watch this information often during pump operation, and react to any abnormal readings Pierce Manufacturing Inc. All Rights Reserved. PUC Pump / 4-23

46 OPERATION Engine information includes: Engine Speed: shows current engine speed in RPMs. Engine Oil Pressure Gauge: shows engine oil pressure. Engine Temperature Gauge: shows oil temperature of the engine. Electrical System Voltage Meter: measures the voltage level of the vehicle's battery system. Stop Engine Light Replace apparatus when STOP ENGINE light is ON. Engine can fail at any time without further warning. Engine failure will stop water flow to attack lines, putting fire-fighting personnel in danger. If the Stop Engine light turns ON, the engine's ECU (electronic control unit) has detected a critical error condition. That means engine failure is possible at any moment. Read and study the engine manufacturer's operations manual so you know how to react. Practice your reaction to all different kinds of failure. You need to be prepared in advance so you can react properly in an emergency. Fire apparatus programming does not allow a critical engine failure to automatically stop the engine. The engine will continue to run until it self-destructs or fails. It is your judgment call to balance the risks of damage to the engine with the need for the fire apparatus to remain operational. If possible, replace the apparatus with another apparatus RIGHT AWAY if this light comes on. Check Engine Light If the Check Engine light turns ON, the engine's ECU detects a non-critical error condition. Immediately check all gauges at the pump panel and compare with the readings of those in the cab. Compare both readings to normal operating parameters. This will help you make the decision to continue to run the apparatus or replace it with another. If the Check Engine light remains ON, schedule the engine for maintenance. Check Transmission Message A Check Transmission message is displayed if the transmission's control unit detects a non-critical error. If the Check Transmission message remains ON, schedule the transmission for maintenance Ending Water Flow Operation Shutting Off Water Flow 1. Reduce Engine Speed to IDLE 2. Close Discharge Valves Close all discharge and inlet valves slowly to prevent water hammer Disengaging the Pump 1. Reduce engine speed to IDLE Adjust Hand Throttle or Pressure Governor to bring engine to IDLE / PUC Pump 2010 Pierce Manufacturing Inc. All Rights Reserved.

47 OPERATION 2. Disengage the Pump Press WATER PUMP switch to disengage the water pump. 3. Observe Indicator Lights Make sure that the PUMP ENGAGED light is OFF. If the light is ON, then repeat the procedure Disengaging the Pump (Stationary Operation) 1. Reduce engine speed to IDLE Reduce engine speed to IDLE with the throttle control. 2. Observe Tachometer Observe the Tachometer in the cab to confirm that the engine has remained at IDLE speed. If the engine has increased speed, the throttle control on the pump panel might not have been properly reset to IDLE. Exit the cab and return Hand Throttle and/or Pressure Governor to IDLE. 3. Disengage the Pump Press WATER PUMP switch to disengage the water pump. 4. Observe Indicator Lights Make sure that the PUMP ENGAGED light is OFF. If light is ON, repeat the procedure Disengaging the Pump (Pump and Roll) 1. Stop Apparatus Bring apparatus to a full stop and reduce engine speed to idle. 2. Shift the Transmission into Neutral (N) 3. Pull Parking Brake to Apply 4. Disengage the Pump Press WATER PUMP switch to disengage the water pump. 5. Observe Indicator Lights Make sure that the PUMP ENGAGED light is OFF. If light is ON, repeat the procedure Securing Pump System The pumping system should be drained during cold weather. See Draining the Pumping System on page 5-1 for additional information. 1. Open Drain Valves and Bleed Valves Open all pressure release valves to vent any trapped air pressure and water. 2. Open Nozzles Relieve pressure from un-gated inlet hose by OPENING discharge nozzles. 3. Remove Hose Remove all hoses from discharge and intake lines. 4. Replace Caps Install Caps on Intake and Discharge connections to protect them from contamination Pierce Manufacturing Inc. All Rights Reserved. PUC Pump / 4-25

48 OPERATION 5. Flush Pump Flush the pumping system with clean, fresh water if required. 6. Purge Primer If equipped with a fluid-lubricated primer pump, operate the primer pump until primer fluid comes out of the primer pump discharge. Check primer fluid tank level, and fill if needed Operating from a Static (Draft) Water Supply Operating the pump from a draft source is the most demanding type of pump operation. Learn about the complexities and hazards of this operation by studying the IFTSA Pumping Apparatus Driver/Operator Handbook and through formal training. Once the apparatus is prepared for draft operation and the appropriate suction lines are deployed, prime the pump as follows: 1. Close Valves First, close all discharge valves, drain valves, bleed valves, and tank valves or the primer will fail to work. 2. Switch Pressure Governor to THROTTLE (RPM) CONTROL Mode If the apparatus is equipped with a pressure governor, place it in THROTTLE (RPM) CONTROL mode. For governor equipped apparatus, this will hold the prime better than starting out in PRESSURE mode. 3. Increase Engine Speed Increase the engine speed to 1000 RPM. This should provide about 50 PSI of water pressure once the prime is established. 4. Open Primer Valve Pull to OPEN the Primer Valve and engage the primer motor. Listen to the sound of the primer motor as it pumps air out of the water pump to draw a vacuum. Listen for the tone change as the primer pump begins to expel a mix of air & water, and then begins expelling only water. 5. Observe Pressure Gauge Watch the pressure on the Master Pressure Gauge to make sure that the water has entered the pump and the pressure is beginning to build. 6. Open Discharge Valve Open the Discharge Valve slowly to begin water flow operation. 7. Switch Pressure Governor to PRESSURE CONTROL Mode For pressure governor equipped apparatus, switch from THROTTLE (RPM) CONTROL mode back to PRESSURE CONTROL mode. 8. Increase Pressure Continue to watch the Master Pressure Gauge. Increase the pressure until you reach the desired discharge pressure / PUC Pump 2010 Pierce Manufacturing Inc. All Rights Reserved.

49 SECTION 5 MAINTENANCE 5-1. Inspection, Cleaning, and Maintenance Never run the pump dry except momentarily and at low speeds. Do not use this pump for hose testing Maintenance Schedule Develop a Standard Operating Procedure for the daily, weekly, monthly, and annual inspection and maintenance of this fire apparatus after careful review of all documentation provided. Inspection and maintenance requirements for components such as monitors, foam systems, flow meters, valves, etc., must be established by referencing the service manuals. Follow the pump manufacturer's inspection and maintenance recommendations. Follow the procedures for inspection, cleaning, and maintenance found in the IFSTA Pumping Apparatus Driver/ Operator Handbook (latest edition). Follow instructions regarding inspection, cleaning, and maintenance located in the Pierce Custom Chassis Operation & Maintenance Manual (Publication No. PM-C-OM012) or the Pierce Commercial Chassis Supplement (Publication No. PM-C-OM090) Draining the Pumping System Freezing water can damage pipes, valves, primers, and gauges. If you are moving a truck containing water outside when temperatures will approach freezing (32 F / 0 C), make sure that all fittings, valves, waterlines and caps have been opened or removed. These include, but are not limited to: drain valves, discharge valves, intake valves, etc. Following this recommendation could prevent damage to critical water system components and avoid costly repairs. NOTE: If it is desired to retain water in the water tank, the Tank to Pump and Tank Fill valves should be left in the closed position. Every part of the water pump system must be drained if exposed to freezing temperatures. 1. Locate the lowest points on every plumbing line and the drain valve that opens it 2. Remove Caps AFTER opening air bleeder valves, remove all intake and discharge caps Pierce Manufacturing Inc. All Rights Reserved. PUC Pump / 5-1

50 MAINTENANCE 3. Open Master Pump Drain Figure 5-1: Typical Master Pump Drains The master pump drain (Figure 5-1) will empty both the discharge and inlet manifolds of water when opened. 4. Open Discharge Line Drains Locate each Discharge Line and open the Drain Valves. 5. Open Intake Line Drains Locate each Intake Line and open the Drain Valves. 6. Open Intake Relief Valve Drain on apparatus equipped with relief valves 7. Open Control Valves Open all Intake and Discharge Valves. 8. Purge Primer Primer should be purged regularly in cold weather to prevent the primer from freezing. 9. Allow Water to Drain 10. Close all Valves 1145 NOTE: If your apparatus is equipped with a foam system, refer to the applicable foam system manual for draining procedures Flushing the Drain Valves Forward Flushing Drain Valves are the lowest point in the pump system. Dirt and debris in the water will settle in the drain valve bodies. Flush each drain valve with clean water monthly or after pumping dirty or salty water. Flush drain valves to prevent sediment from accumulating in the valve body and hurting proper operation of the drain valve. 1. Fill Water Tank Begin flushing procedure with a full water tank of clean, fresh water. 2. Cap All Intake and Discharge Connections Cap all connections to hold the clean water from the tank in the pumping system. 5-2 / PUC Pump 2010 Pierce Manufacturing Inc. All Rights Reserved.

51 MAINTENANCE 3. Open all Intake and Discharge Valves Open all control valves to allow fresh water to reach all points in the pumping system. 4. Open the Tank-to-Pump Valve Open the Tank-to-Pump Valve to flood the pumping system with clean water. 5. Open Drain Valves One at a Time Open each Drain Valve. Keep open until a steady stream of water flows from the valve for 20 seconds. If no water or reduced water flows, find out why water fails to drain and make a repair. 6. Close Tank-to-Pump Valve Close the Tank-to-Pump Valve to prevent any more water from entering the pumping system. 7. Open Drain Valves Open each Drain Valve again until remaining water is drained from the system. 8. Remove Caps Remove Intake and Discharge Caps. 9. Allow Water to Drain 10. Close All Intake and Discharge Valves 11. Replace Caps Replace Intake and Discharge Caps. 12. Close Drain Valves 13. Refill Water Tank Back Flushing The pump should be back flushed with municipal water after salt water or other debris have entered the pump. 1. Remove Suction Strainers Remove the suction strainers so they are not blown out of the pump. 2. Open Transfer Valve (if applicable) Hold the transfer valve clapper, in the second stage volute entrance, open so debris is not trapped behind it. 3. Pump Water Pump fresh, clean water through all of the inlets and outlets, until you see only clear water. 4. Open & Close Valves Open and close all discharge and intake valves to flush them with clean water. 5. Activate Primer In the case of salt water pumping, activate the primer to get clear water through the primer valve and pump. 6. Activate Pressure Relief Valve Activate the pressure relief valve with the pilot valve to flush that system, and move the transfer valve from Volume to Pressure a few times (if the pump is so equipped) Annual Testing Test all pumping apparatus annually per the specifications in NFPA 1911, Standard for the Inspection, Maintenance, Testing and Retirement of In-Service Automotive Fire Apparatus (latest edition) Pierce Manufacturing Inc. All Rights Reserved. PUC Pump / 5-3

52 MAINTENANCE These tests are necessary to make sure that the apparatus will continue to perform to specification. These tests help prevent breakdowns Flushing and Draining the Pump Pump body heats to high temperatures during operation. Touching hot areas of pump will burn. Allow pump to cool before servicing. Flush the pumping system after pumping dirty, contaminated, or salty water. 1. Supply Clean, Fresh Water Supply clean, fresh water to the pumping system. 2. Open Discharge Valves Open all discharge valves so that clean, fresh water flows through each discharge line and valve for one minute. 3. Fill Tank Fill the water tank with clean, fresh water. 4. Flush Drain Valves Flush all drain valves using the procedure listed under Flushing the Drain Valves Pump Storage Store pump completely full of clean water, or completely dry. Do not leave pump partially full of water. Always store pump dry in freezing weather. In warm temperatures store pump either entirely full of water or completely empty. Pumps stored partially full of water will rust at the air-to-water interface. In freezing temperatures store pumps dry, without any water in the pump chamber. 5-4 / PUC Pump 2010 Pierce Manufacturing Inc. All Rights Reserved.

53 MAINTENANCE 5-7. Primer Pump Lubrication Use environmentally-friendly priming lubricants or use procedures that capture the oil as it is expelled. Expelling standard motor oil used as a lubricating fluid in the primer pump does not meet EPA regulations. Figure 5-2: Primer Pump Lubrication Fluid or Oil Reservoir POM0031 Some primer pumps require a lubricating fluid or oil. The fluid reservoir (Figure 5-2) is normally located in the pump house behind an access panel or access door. For oil-type priming pumps, the lubricant is expelled with the air as the pump is primed. Use only lubricating fluid that is approved by the manufacturer of the pump and approved for use in the environment Intake & Discharge Relief Valve Drains (Optional) Figure 5-3: Relief Valve Drain POM Pierce Manufacturing Inc. All Rights Reserved. PUC Pump / 5-5