Operation & Maintenance Manual HUSKY 12 GPM FOAM SYSTEM Pierce Manufacturing Inc. Part No. PM-F-OM

Transcription

1 HUSKY 12 GPM FOAM SYSTEM Operation & Maintenance Manual 2009 Pierce Manufacturing Inc. Part No. PM-F-OM

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3 TABLE OF CONTENTS FOREWORD 1 PURPOSE OF MANUAL... v 2 SCOPE... v 3 CUSTOMER ASSISTANCE INFORMATION... v SECTION 1. SAFETY 1-1 INTRODUCTION TO THE OWNER OPERATION AND MAINTENANCE OF THIS APPARATUS DESCRIPTION OF DANGER, WARNING, AND CAUTION LIST OF ABBREVIATIONS SECTION 2. GENERAL 2-1 HUSKY 12 SPECIFICATIONS FOAM PROPORTIONER SYSTEM CAPACITY DISCHARGES SYSTEM ELECTRICAL LOAD MAINTENANCE MESSAGE FLUSH SYSTEM FOAM CONCENTRATE COMPATIBILITY DESCRIPTION OF MAJOR COMPONENTS HYDRAULIC DRIVE SYSTEM a HYDRAULIC GEAR PUMP b HYDRAULIC OIL FILTER c HYDRAULIC OIL RESERVOIR d HYDRAULIC OIL COOLER e HYDRAULIC MANIFOLD BLOCK FOAM SUPPLY SYSTEM a FOAM CONCENTRATE TANK b FOAM SUPPLY VALVE c FOAM CONCENTRATE PUMP d FOAM SELECTOR VALVE e PANEL MOUNTED STRAINER / EXTERNAL PICK-UP CONNECTION f PICK-UP HOSE g FOAM CHECK VALVE WATER SUPPLY SYSTEM a MANIFOLD AND MASTER DRAINS b IN-LINE WATER CHECK VALVE c WATER FLOWMETER CONTROL SYSTEM a CONTROLLER MODULE b CONTROL HEAD Pierce Manufacturing Inc. All Rights Reserved. Husky 12 Foam System / i

4 TABLE OF CONTENTS SECTION 3. OPERATION 3-1 FOAM SYSTEM OPERATION CLASS A FOAM - USING ON-BOARD FOAM TANK CLASS A FOAM - DRAFTING CLASS B FOAM - USING ON-BOARD FOAM TANK CLASS B FOAM - DRAFTING FLUSHING SYSTEM GENERAL FLUSHING INFORMATION MANUAL FLUSH MODE FLUSHING AFTER DRAFTING CLASS A FOAM FLUSHING AFTER DRAFTING CLASS B FOAM PRIMING SYSTEM FILLING FOAM TANK(S) CLASS A TANK FILL (OPTIONAL) CLASS B TANK FILL (OPTIONAL) FILL THROUGH FOAM TANK FILL DOME MANUAL MODE FLOWMETER OPERATION SET-UP MODE SECTION 4. MAINTENANCE 4-1 MAINTENANCE INTRODUCTION TESTING AFTER SYSTEM MAINTENANCE SET-UP & CALIBRATION SET-UP MODE ENGLISH/METRIC MODE CALIBRATE FLOWMETER MODE CALIBRATE FOAM PUMP (LVDT) TRANSDUCER CALIBRATE CLASS A FOAM MODE CALIBRATE CLASS B FOAM MODE SET CLASS A CONCENTRATE DEFAULT PERCENTAGE SET CLASS B CONCENTRATE DEFAULT PERCENTAGE SELECT SINGLE OR DUAL FOAM TANK SYSTEM SET DEFAULT FOAM SOURCE TANK FILL ENABLE/DISABLE SET AUTOMATIC FLUSH TIME AUTO START DRAIN MODE RESET MAINTENANCE REMINDERS CHECK CURRENT SOFTWARE REVISION ii / Husky 12 Foam System 2009 Pierce Manufacturing Inc. All Rights Reserved.

5 TABLE OF CONTENTS 4-3 TROUBLESHOOTING PERIODIC OPERATION GENERAL MAINTENANCE PROCEDURES PREVENTIVE MAINTENANCE CHECKS AND SERVICE INTRODUCTION EXPLANATION OF COLUMNS AFTER EVERY USE INSPECTION WEEKLY INSPECTION QUARTERLY INSPECTION ANNUAL INSPECTION RECOMMENDED HYDRAULIC OIL FOR HUSKY 12 PROPORTIONING SYSTEM CHARACTERISTICS RECOMMENDATIONS OIL CHANGE INFORMATION SYSTEM DIAGRAMS INDEX 2009 Pierce Manufacturing Inc. All Rights Reserved. Husky 12 Foam System / iii

6 TABLE OF CONTENTS iv / Husky 12 Foam System 2009 Pierce Manufacturing Inc. All Rights Reserved.

7 FOREWORD 1. Purpose of Manual The information in this manual is for the operation and maintenance of Pierce Husky 12 Proportioning System. It is intended to serve as a guide to assist qualified operators and mechanics in the operation and maintenance of their vehicle. Keep this manual with the vehicle at all times. NOTE: Some of the details of your vehicle s design and construction may be unique to your department alone. For this reason, information contained in this manual may be generic at times. Questions on major inconsistencies between your vehicle s configuration and the information contained in this manual should be directed to your Pierce Dealer or Sales Representative. 2. Scope This supplemental operator s manual provides operating and maintenance instructions for Husky 12 Proportioning Systems on vehicles manufactured by Pierce Manufacturing Inc. This manual provides information under the following headings: Safety. Contains important safety information, requirements before placing a vehicle in service, and information on installing custom equipment and accessories. General. Includes information and instructions on the operation of major systems, controls, and indicators. Operation. Contains procedures on performing common operations. Maintenance. Contains scheduled preventive maintenance checks and inspections. Appendixes. Contains information obtained directly from vendors who supply major components found on this unit. 3. Customer Assistance Information Your satisfaction with your Pierce apparatus is important to your dealer and Pierce Manufacturing Inc. Normally, any question or concern you may have with your apparatus can be handled by your selling or servicing dealer. Your dealer has the facility, trained technicians, special tools, and up-to-date information to promptly address any issue that may arise. Pierce Manufacturing Inc. has empowered dealers to make decisions and repair vehicles, and they are eager to resolve your issues to your complete satisfaction. Should you encounter an issue with your Pierce apparatus that requires service, take the following steps: Step 1.) Contact your authorized Pierce selling or servicing dealer. They will make the necessary arrangements to order the necessary parts and make the required repairs. Step 2.) If they are not able to repair the problem to your satisfaction, discuss your concern with a member of dealer management. Normally, concerns can be quickly resolved at that level. If the matter has already been reviewed with the Sales, Service, or Parts Manager, contact the owner of the dealership or the General Manager. Step 3.) If, after contacting a member of the dealership management, it appears your question or concern cannot be resolved by the dealership without further help, you may contact Pierce Manufacturing Inc. at 888-Y-PIERCE ( ) Pierce Manufacturing Inc. All Rights Reserved. Husky 12 Foam System / v

8 FOREWORD vi / Husky 12 Foam System 2009 Pierce Manufacturing Inc. All Rights Reserved.

9 SECTION 1 SAFETY 1-1. Introduction To the Owner Operation and Maintenance of This Apparatus The information in this manual is for the operation and maintenance of this apparatus. The intent is to instruct operators in the proper operation of this equipment and to warn of improper procedures and potentially dangerous situations. Only personnel who are totally familiar with this manual and have training are qualified to operate this apparatus. It is the responsibility of the department owning this equipment to permit only qualified personnel to operate this apparatus. Qualified drivers of other fire apparatus will require further training for the handling of this unit Description of DANGER, WARNING, and CAUTION THIS SAFETY SYMBOL INDICATES IMPORTANT SAFETY MESSAGES IN THIS MANUAL. WHEN YOU SEE THIS SYMBOL, CAREFULLY READ THE MESSAGE THAT FOLLOWS THIS SYMBOL. BE ALERT TO THE POSSIBILITY OF PERSONAL INJURY OR DEATH. Warning labels located on the vehicle and warning statements contained in this manual all use the same terminology to warn of potential hazards. Each of these potentially harmful conditions is described below: A hazard that will result in death or serious personal injury. A hazard which might result in death or serious personal injury. A hazard which might result in personal injury or damage to property or equipment. The signal words of DANGER, WARNING, and CAUTION have specific meanings to alert you to the relative level or probability of the hazard. Take the safety warnings seriously. If you do not understand them or have questions about them, contact Pierce Manufacturing Inc Pierce Manufacturing Inc. All Rights Reserved. Husky 12 Foam System / 1-1

10 SAFETY 1-2. List of Abbreviations TERM AFFF AR-AFFF FFFP GPM LCD LPM NFPA PSI RPM DEFINITION Aqueous Film Forming Foam Alcohol Resistant Aqueous Film Forming Foam Film Forming Fluoro-Protein Gallons per Minute Liquid Crystal Display Liters per Minute National Fire Protection Association Pounds per Square Inch Revolutions per Minute 1-2 / Husky 12 Foam System 2009 Pierce Manufacturing Inc. All Rights Reserved.

11 SECTION 2 GENERAL 2-1. Husky 12 Specifications Foam Proportioner The foam proportioning system is an on demand, automatic proportioning, single point, direct injection system suitable for all types of Class A & Class B foam concentrates, including the high viscosity (6000 cps), alcohol resistant Class B foams. The operation of the system is based on direct measurement of water flow, and remains consistent within the specified flows and pressures. The system automatically balances and proportions foam solution at rates from 0.1% to 9.9% regardless of variations in water pressure and flow, up to the maximum rated capacity of the foam concentrate pump. The design of the system allows operation from draft, hydrant, or relay operation. This provides a versatile system to meet the demands at a fire scene System Capacity The system has the ability to deliver the following (minimum) foam solution flow rates at accuracies that meet or exceed NFPA requirements at a pump rating of 250 PSI. Table 2-1: Maximum Foam Solution Flow The Class A foam setting is in.1% increments from.1% to 1%. Typical settings are.3% and.5%. *The maximum capacity is limited to the plumbing and water pump capacities Discharges Concentration Percentage Capacity 6% 200 GPM 3% 400 GPM 1% 1,200 GPM.5% 2,400 GPM*.3% 4,000 GPM* The number of discharges capable of dispensing foam varies from truck to truck, depending on customer specifications. Foam discharges can be identified by red/white tags; water only discharges can be identified by silver/black tags System Electrical Load The electrical load for the foam proportioning system is less than five (5) amps at 12VDC Maintenance Message A message is displayed on the control head to notify the operator when system maintenance needs to be performed. The message displays the interval for cleaning the foam strainer & water strainer, and changing the hydraulic oil. These messages will appear after 20 hours of foam system operation, if not reset during normal maintenance Pierce Manufacturing Inc. All Rights Reserved. Husky 12 Foam System / 2-1

12 GENERAL Flush System A flush mode allows the system to flush all foam concentrate with clear water. The flush circuit control logic ensures the foam tank supply valve is closed prior to opening the flush valve. The flush valve is electrically controlled and is operated from the foam system control head. A manual flush drain valve is located under the driver s side running board Foam Concentrate Compatibility The Husky 12 Foam Proportioning System is designed to be compatible with most known Class A and Class B foam concentrates at the date of printing of this manual. The Husky 12 can proportion foam concentrates across a wide range of viscosity, from low viscosities such as Class A or AFFF, through high viscosity AR-AFFF. Table 2-2: Acceptable Foam Concentrate Viscosity Range Acceptable Foam Concentrate Viscosity Range Minimum 3 Centistokes Maximum 6000 Centipoise * * Brookfield #3 30 RPM 2-2. Description of Major Components To understand the relationship of the various components and their functions, refer to Para 4-12., System Diagrams. The following information is intended to identify the various components and describe their function within the system. For specific construction, maintenance, and parts information, please refer to applicable service groups (chapters) in the service manual, drawings included in this manual, and the parts catalog for this unit Hydraulic Drive System The hydraulic drive system that powers the foam pump is automatically activated when the water pump is engaged. A hydraulic oil cooler prevents overheating of the hydraulic oil, which can be detrimental to system components. The oil/water cooler is designed to allow continuous system operation without allowing hydraulic oil temperature to exceed the oil specifications. The system is delivered with ISO 68 hydraulic oil. 2-2 / Husky 12 Foam System 2009 Pierce Manufacturing Inc. All Rights Reserved.

13 GENERAL 2-2.1a Hydraulic Gear Pump Figure 2-1: Hydraulic Gear Pump The larger line is inlet from hydraulic tank; the smaller line is pressure line that drives the foam pump. The pump may be driven directly off Hale pump transmission, the Waterous impeller shaft, or a transmission-driven PTO (Chelsea) controlled by the pump engaged circuit # b Hydraulic Oil Filter Figure 2-2: Hydraulic Oil Filter The Hydraulic Filter is a pressure bypass element-type filter manufactured by Hydac. The filter element is replaceable. The unit is installed inside the pumphouse and is used to filter the pressurized hydraulic loop. The replacement part number for the filter element is Pierce P/N Pierce Manufacturing Inc. All Rights Reserved. Husky 12 Foam System / 2-3

14 GENERAL 2-2.1c Hydraulic Oil Reservoir Figure 2-3: Hydraulic Oil Cooler To Hydraulic Pump Shut-off Valve (in-line position is OPEN) The Hydraulic Reservoir (approximately four gallon capacity) provides a reservoir for the hydraulic drive system. The tank is sufficient size to minimize foaming of the hydraulic fluid and is located to facilitate checking level and adding oil. Refer to Para 4-11., Recommended Hydraulic Oil for Husky 12 Proportioning System, for recommended hydraulic oil for the Husky 12 system d Hydraulic Oil Cooler Figure 2-4: Hydraulic Oil Cooler Hydraulic Oil In/Out Cooling Water In/Out / Husky 12 Foam System 2009 Pierce Manufacturing Inc. All Rights Reserved.

15 GENERAL The Hydraulic Cooler is an oil-to-water type heat exchanger. It takes water directly from the water pump to cool the closed loop hydraulic system. The cooling water is then returned to the water pump suction while the cooled hydraulic oil is returned to the hydraulic tank. The hydraulic cooler allows for continual operation of the Husky 12 hydraulic system e Hydraulic Manifold Block Figure 2-5: Hydraulic Manifold Block Hydraulic Relief Valve Reverse Plug Forward Plug The Hydraulic Manifold Block assembly is a manifold block that controls the direction of the hydraulic oil flow in the system. The manifold block consists of the machined block, a hydraulic compensating valve, an internal hydraulic shuttle valve, a hydraulic relief valve, hydraulic pressure test port and the hydraulic proportional valve Foam Supply System Not shown: P1 pressure test port (on side of hydraulic block) The Foam Supply System stores, pumps and distributes the foam concentrate to the foam/water discharges by use of a foam concentrate tank, foam tank shut-off valve, auxiliary foam inlet, in-line foam strainer, foam pump, check valve and foam injection manifold a Foam Concentrate Tank The Foam Concentrate Tank is designed to provide on-board storage of foam concentrate. Design features shall include: construction compatible with foam concentrates, foam tank drain valve, expansion dome with locking fill hatch and pressure/vacuum vent. The expansion dome allows for changes in foam concentrate volume due to variations in temperature. Foam concentrate level shall be maintained at the one-third full mark in the expansion dome at a minimum to reduce the air to foam concentrate interface. The pressure vacuum vent automatically balances internal foam tank pressure under both suction and filling operations. It is recommended that a cleanable foam concentrate level unit be installed in the storage tank. The control head will display a warning message when the foam tank being used is below one quarter tank Pierce Manufacturing Inc. All Rights Reserved. Husky 12 Foam System / 2-5

16 GENERAL 2-2.2b Foam Supply Valve Figure 2-6: Foam Supply Valve 1006/1007 An electric/air valve is used for the Foam Supply Valve. The foam supply valve shall be controlled at the foam system control head for ease of operation. The supply valve is located to eliminate air pockets in the foam tank supply hose. This foam supply valve opens automatically when the system is turned ON c Foam Concentrate Pump Figure 2-7: Foam Concentrate Pump The Foam Concentrate Pump assembly is a brass/steel constructed, double-acting cylinder pump. The hydraulic end of the pump is painted steel and controls the speed and direction of both cylinders. The hydraulic piston is connected to the foam piston by a single, straight shaft. The foam end of the pump is brass construction and contains 4 cartridge type check valves to prevent foam from flowing the wrong direction in the pump / Husky 12 Foam System 2009 Pierce Manufacturing Inc. All Rights Reserved.

17 GENERAL The foam pump also has a pressure relief valve that recirculates the foam from the discharge side to the inlet side in the case of an obstruction or overpressure situation. The foam pump speed and operation are monitored by a foam pump transducer located in the hydraulic end of the pump assembly. The foam concentrate pump is self-priming and has the capability to draw foam concentrate from external supplies such as drums or pails. The foam concentrate pump has a maximum capacity of 12 GPM with all types of foam concentrates with a viscosity at or below 6000 cps including protein, fluoroprotein, AFFF, FFFP, or AR-AFFF d Foam Selector Valve Figure 2-8: Foam Selector Valve Injection Hose Tank Fill Hose* From Foam Pump *A foam selector valve with the tank fill option is shown. On units without the tank fill option, the fill hose will be routed directly to tank. The Foam Selector Valve is a 2-way, quarter-turn ball valve that directs the foam for foam injection (normal operation) or tank filling. A CHECK SELECTOR VALVE message is displayed by the control head in the event that the valve is not in the correct position for the operation selected Pierce Manufacturing Inc. All Rights Reserved. Husky 12 Foam System / 2-7

18 GENERAL 2-2.2e Panel Mounted Strainer / External Pick-Up Connection Figure 2-9: Panel Mounted Strainer / External Pick-Up Connection A bronze body strainer / connector unit is mounted on the pump panel. The external foam pick-up consists of one (1) 1 in. male connection with chrome-plated cap, integrated to a 2 in. strainer clean-out cap. A check valve is installed in the pick-up portion of the clean-out cap. A basket style stainless steel screen is installed in the body of the strainer / connector unit. The strainer is used to prevent any debris from entering the foam system and possibly interfering with the internal foam pump check valves. Removal of the 2 in. clean-out cap is all that is required to gain access to and remove the stainless steel basket screen. The strainer / connector is located ahead of the foam concentrate pump inlet port, to insure that all agent reaching the foam pump has been strained. The external foam pick-up permits the use of a foam agent that is not stored on the vehicle. The external foam pickup also allows continued operation after the on-board foam tank is empty. The external foam pick-up can also be used with training foam or colored water for training purposes. This connection also functions as the Class A tank fill (when equipped with tank fill option) and as the foam tank drain / Husky 12 Foam System 2009 Pierce Manufacturing Inc. All Rights Reserved.

19 GENERAL 2-2.2f Pick-Up Hose Figure 2-10: Pick-up Hose A 1 in. flexible hose, with an end for insertion into foam containers, is provided. The hose has a 1 in. female swivel NST thread swivel connector. (The hose is part of loose equipment.) g Foam Check Valve Figure 2-11: Foam Check Valve The Foam Check Valve located in the foam supply line prevents water from flowing backwards through the foam system and contaminating the foam supply Water Supply System The water supply system supplies water to the foam injection manifold for foam to be added and distributed to the foam/water discharges. This system consists of an in-line water check valve, water flowmeter and flowmeter installation tee. The size of the check valve and the flowmeter installation tee are dependent on the number of foam/ water discharges in the system Pierce Manufacturing Inc. All Rights Reserved. Husky 12 Foam System / 2-9

20 GENERAL 2-2.3a Manifold and Master Drains Figure 2-12: Manifold & Master Drains 1066/1067 The manifold drains are used to bleed off pressure/water anytime the water pump has been pressurized (after the water pump is shut off). If a dry water pump condition is desired, leave manifold drains open until the fire scene is reached. The master pump drain will empty both the discharge and inlet manifolds of water when opened. The water pump drain should be pulled (opened) daily b In-line Water Check Valve Figure 2-13: In-line Water Check Valve The In-line Water Check Valve prevents foam from entering the water pump and the remainder of the water system. It is installed in the water piping, before the foam injection manifold and the water flowmeter / Husky 12 Foam System 2009 Pierce Manufacturing Inc. All Rights Reserved.

21 GENERAL 2-2.3c Water Flowmeter Figure 2-14: Water Flowmeter The Water Flowmeter measures the flow of water supplied to the foam/water discharges before foam is injected. This controls the amount of foam that is injected when the Husky 12 foam system is turned on Control System The control head directs a microprocessor, which receives input from the system s water flowmeter while also monitoring the position of the foam concentrate pump. The microprocessor compares the values of the water flow versus the position/rate of the foam pump, to ensure the proportion rate is accurate a Controller Module Figure 2-15: Controller Module Pierce Manufacturing Inc. All Rights Reserved. Husky 12 Foam System / 2-11

22 GENERAL The foam system is controlled by a foam system controller module that contains the programming to actuate the appropriate valves, direct the hydraulic fluid, and control the injection rate of the foam. All components plug into the Foam Module. The foam module is what actually controls the system. The user interfaces with the controller through the foam system control head. If replaced, the system calibration must be checked b Control Head Figure 2-16: Control Head The Foam System Control Head is the operator interface with the foam system. It is located on the main pump panel. It has six operating buttons: System On/Off, Mode, Display, Enter, Arrow Up, Arrow Down. The display is a 2-line, 32 character, LCD screen. System power is indicated by a red LED; the foam pump operating is indicated by a green LED. Information displayed on the LCD screen includes: mode of operation and various information displays. If the foam system is turned OFF, the display functions as a flowmeter. The percent of injection has presets for class A and class B foam. These presets can be changed at the fire department as desired. The percent of injection can be easily changed at the scene to adjust for changing demands. The modes of operation are: Class A Foam, Class B Foam (optional), Draft Class A, Draft Class B, Prime, Flush, Tank A Fill (optional), Tank B Fill (optional), Manual, and Set-up. Pressing the MODE button on the display head changes from one mode to the next. Detailed instructions on the operation of each mode can be found in Section 3, Operation / Husky 12 Foam System 2009 Pierce Manufacturing Inc. All Rights Reserved.

23 GENERAL Figure 2-17: Control Head Display Modes The information displays are: GPM (used for most operations), Foam Type & Flow Rate, Total Water Flowed, Total Class A usage, and Total Class B usage. Pressing the DISPLAY button on the display head changes from one display view to the next. Figure 2-18: Resetting Control Head Counters to Zero 1030 Display counters and default settings will automatically reset by cycling the batteries after operation. All of the display screens may be zeroed during operation by pushing the ARROW UP/ARROW DOWN buttons at the same time then releasing Pierce Manufacturing Inc. All Rights Reserved. Husky 12 Foam System / 2-13

24 GENERAL 2-14 / Husky 12 Foam System 2009 Pierce Manufacturing Inc. All Rights Reserved.

25 SECTION 3 OPERATION 3-1. Foam System Operation Class A Foam - using on-board Foam Tank Figure 3-1: Control Head in Class A Foam Mode Engage water pump transmission. 2. Recirculate water. 3. Turn the system ON. NOTE: The default foam valve will open automatically (typically Class %). 4. Begin flowing water, foam pump will activate. 5. Use the ARROW UP / ARROW DOWN buttons to change percentage (if needed). 6. When beginning the mop up phase, turn the system OFF; use the foam in the hose for mop up. NOTE: The only flush needed is to run the hose until it is mostly free of bubbles. The foam pump is designed to be flooded with foam 2009 Pierce Manufacturing Inc. All Rights Reserved. Husky 12 Foam System / 3-1

26 OPERATION Class A Foam - Drafting Figure 3-2: Control Head in Class A Drafting Mode 1. Set up for drafting operation by positioning foam and hooking up pick-up hose. 2. Press MODE until the DRAFT CLASS A screen appears, then press ENTER. On-board tank valves will close, causing suction to draw from foam inlet. 3. The default percentage will remain the same as the on-board Class A tank current setting. 4. Use the ARROW UP / ARROW DOWN buttons to change percentage (if needed). 5. See Para 3-2.1, General Flushing Information Class B Foam - using on-board Foam Tank Figure 3-3: Control Head in Class B Foam Mode During the automatic flush, water must be flowing through an open foam discharge OR open manifold drain to give the flush solution somewhere to go. NOTE: This operation is only possible when the Class B foam tank is installed and enabled. 1. Press MODE until the CLASS B FOAM screen appears, then press ENTER. The Class A foam valve will close; an automatic flush will occur prior to the Class B valve opening, provided the water flow meter senses water flow. 2. Use the ARROW UP / ARROW DOWN buttons to change percentage (if needed). 3. See Para 3-2.1, General Flushing Information. 3-2 / Husky 12 Foam System 2009 Pierce Manufacturing Inc. All Rights Reserved.

27 OPERATION Class B Foam - Drafting Figure 3-4: Control Head in Class B Drafting Mode 1. Set up for drafting operation by positioning foam and hooking up pick-up hose. 2. Press MODE until the DRAFT CLASS B screen appears, then press ENTER. On-board tank valves will close, causing suction to draw from foam inlet NOTE: An automatic pre-programmed flush of seconds will occur when changing from Class A to Class B foam, once the water flow meter senses water flow. 3. The default percentage will remain the same as the on-board Class B tank current setting. 4. Use the ARROW UP / ARROW DOWN buttons to change percentage (if needed). 5. See Para 3-2.1, General Flushing Information Flushing System General Flushing Information NOTE: For the purposes of this manual, it is assumed that Class A foam is the most commonly used agent and that the system will be stored wet with Class A foam concentrate. If Class A foam is not the primary agent, adjust procedures to accommodate the primary foam concentrate. Typically, no flushing is needed. The Husky 12 foam pump is designed to be flooded with foam. Unless the optional Class B foam tank was used, a different brand of Class A foam was drafted, or Class B foam was drafted, the only system flush that is needed is to turn the system OFF and continue flowing water until the presence of bubbles is minimal. When beginning mop-up operations at the scene, turn the system OFF and use the foam in the hose for mop-up. When equipped with two on-board foam tanks (Class A & Class B), an automatic flush will occur for seconds when switching between the two tanks. A foam discharge or manifold drain must be open during the automatic flush to give the flush solution somewhere to go. This automatic flush time can be adjusted in the set-up mode, refer to Para , Reset Maintenance Reminders for instructions. In addition to the automatic flush, it is recommended to do an additional manual flush to ensure the system is completely free of contaminates Pierce Manufacturing Inc. All Rights Reserved. Husky 12 Foam System / 3-3

28 OPERATION Manual Flush Mode Figure 3-5: Control Head in Flush Mode 1021 NOTE: The Manual Flush Mode is only for use when additional flush time is desired, such as after switching between types and / or brands of foam. 1. Continue flowing water out the discharges that were used. 2. Open both foam pump drains and manifold drain. 3. Press MODE until the FLUSH MODE screen appears, then press ENTER. This enters the flush mode. Water must be flowing through an open foam discharge OR open manifold drain to give the flush solution somewhere to go. 4. Press and hold the ENTER button (a second time). This will run the foam pump at 7 GPM until the button is released. Continue to hold until foam pump drains and manifold drains run clear Flushing After Drafting Class A Foam 1. If the same type and brand of foam as in the on-board tank was used: a. Turn the system OFF and flow water through the discharges that were used until the presence of bubbles is minimal. 2. If a different type or brand of foam as in the on-board tank was used, or if you are uncertain: a. Continue flowing though all foam discharges that were used. b. Disconnect the pick-up hose and reinstall cap. Rinse pick-up hose with clean water when possible. c. Open the foam pump and manifold drains. d. Press the MODE button until CLASS A FOAM appears, then press ENTER. e. Press the MODE button until FLUSH MODE appears, then press ENTER, release, and hold for 1-2 minutes or until foam pump and manifold drains run clear. f. Close foam pump drains continue flowing water though one discharge. g. Press the MODE button until PRIME appears; then press ENTER for 5-10 seconds or when bubbles show up at the manifold drain. h. Turn off the foam system, flow water through the discharge until the presence of bubbles is minimal. It is now primed for the next call. 3-4 / Husky 12 Foam System 2009 Pierce Manufacturing Inc. All Rights Reserved.

29 OPERATION Flushing After Drafting Class B Foam 1. Continue flowing though all foam discharges that were used. 2. Disconnect the pick-up hose and reinstall cap. Rinse pick-up hose with clean water when possible. 3. Open the foam pump and manifold drains. 4. Press the MODE button until CLASS A FOAM appears, then press ENTER. (Automatic flush will occur when changing from B to A). 5. Press the MODE button until FLUSH MODE appears, then press ENTER, release, and hold for 1-2 minutes or until foam pump and manifold drains run clear. 6. Close foam pump drains continue flowing water though one discharge. 7. Press the MODE button until PRIME appears; then press ENTER for 5-10 seconds or when bubbles show up at the manifold drain. 8. Turn off the foam system, flow water through the discharge until the presence of bubbles is minimal. It is now primed for the next call Priming System Figure 3-6: Control Head in Prime Mode The Prime Mode is used to accelerate the foam pump for a short period of time, such as to purge the air out of the on-board tank lines after initial filling or to fill the suction hose while drafting. 1. Select foam source NOTE: Perform Step 2 thru Step 5 if the Husky 12 Foam System is installed on a Pierce Ultimate Configuration (PUC) apparatus, otherwise skip to Step 6. Water must be flowing through an open foam discharge OR open foam pump discharge drain to give the foam solution somewhere to go. 2. Open foam pump discharge drain. 3. Press MODE until the PRIME MODE screen appears, then press ENTER. This enters the prime mode Pierce Manufacturing Inc. All Rights Reserved. Husky 12 Foam System / 3-5

30 OPERATION 4. Press and hold the ENTER button (a second time). This will run the foam pump at 7 GPM until the button is released. 5. Release the button when foam is discharged out of the foam pump discharge drain. Water must be flowing through an open foam discharge OR open manifold drain to give the foam solution somewhere to go. 6. Open manifold drain. 7. Press MODE until the PRIME MODE screen appears, then press ENTER. This enters the prime mode. 8. Press and hold the ENTER button (a second time). This will run the foam pump at 7 GPM until the button is released. 9. Release the button when foam is discharged out of the manifold drain. 10. Allow water/foam solution to run out of manifold drain until it is mostly clear of foam if unit is not immediately going to be used to fight fire. 3-6 / Husky 12 Foam System 2009 Pierce Manufacturing Inc. All Rights Reserved.

31 OPERATION 3-4. Filling Foam Tank(s) Do not mix different types or manufacturer s brands of foam concentrate in the foam cells or piping. Mixing of different foam concentrates (either type or manufacturer) may cause deterioration of the foam concentrate, improper proportioning, and poor performance in a fire situation. Mixing of Class A and Class B foam concentrates may result in a chemical reaction that can create globules, which can clog orifices and cause system failure. NOTE: For the purposes of this manual, it is assumed that Class A foam is the most commonly used agent and that the system will be stored wet with Class A foam concentrate. If Class A foam is not the primary agent, adjust procedures to accommodate the primary foam concentrate Class A Tank Fill (Optional) Figure 3-7: Control Head in Class A Tank Fill Mode 1023/ Engage water pump to activate hydraulics and recirculate water. 2. Turn system ON. 3. Attach pick-up hose to foam pump inlet. Figure 3-8: Selector Valve Foam Inject Position Tank Fill Position 1024/ Pierce Manufacturing Inc. All Rights Reserved. Husky 12 Foam System / 3-7

32 OPERATION 4. Press MODE until the TANK A FILL screen appears. Press ENTER. NOTE: CHECK SELECTOR VALVE will appear on the control head if the selector valve is not in the correct position to fill tank. The float switch in foam tank dome will automatically stop the fill process. 5. Turn the selector valve to the TANK FILL position. NOTE: TANK A FULL will briefly appear on the control head when the fill cycle is complete and then switch to CHECK SELECTOR VALVE. The system will automatically stop the tank fill cycle and return to normal operation. 6. Return selector to the INJECT MODE position Class B Tank Fill (Optional) Figure 3-9: Control Head in Class B Tank Fill Mode Start engine or attach external air supply to chassis. 2. Attach pick-up hose to Foam B refill (this inlet fills Tank B only). 3. Open Foam B Refill valve. NOTE: TANK B FULL will appear on the control head when the fill cycle is complete. The system will automatically stop the tank fill cycle and return to normal operation. 4. Press MODE until the TANK B FILL screen appears. Press ENTER. 3-8 / Husky 12 Foam System 2009 Pierce Manufacturing Inc. All Rights Reserved.

33 OPERATION Fill through Foam Tank Fill Dome Do not mix different types or manufacturers brands of foam concentrate in the foam cells or piping. Mixing of different foam concentrates (either type or manufacturer) may cause deterioration of the foam concentrate, improper proportioning and poor performance in a fire situation. Mixing of Class A and Class B foam concentrates may result in a chemical reaction that can create globules, which can clog orifices and cause system failure. NOTE: Locate and close all foam tank and manifold drains. They may be found on and behind both the driver and passenger side pump panels. When filling the foam concentrate during a non-fire situation, the following procedure is recommended: 1. The vehicle should be parked on a level surface or with the expansion dome of the tank slightly inclined. 2. If filling from a pressurized source through the expansion dome hatch, the hose should be extended to the bottom of the tank to minimize frothing of the foam concentrate. 3. If foam concentrate must be added by pouring through the expansion dome hatch, it must be done slowly to prevent aeration. If aeration occurs inside the tank, stop pouring until the foam concentrate bubbles dissolve. Take care not to allow dirt or debris to enter the tank. Pour the foam concentrate down the center of the round tube when filling the tank. This tube goes into the tank and allows the foam concentrate to enter under the surface of foam currently in the tank to reduce aeration of the foam per NFPA Manual Mode This mode of operation is the NFPA required manual override. This mode is used to activate the foam pump without the flowmeter operating Pierce Manufacturing Inc. All Rights Reserved. Husky 12 Foam System / 3-9

34 OPERATION In this mode, the foam pump will run regardless of water flow. If discharges are closed, these lines may be charged to over 300 PSI. At least one discharge or manifold drain must be open before entering this mode. Figure 3-10: Control Head in Manual Mode 1. Press MODE until the MANUAL MODE screen appears, then press ENTER. This enters the manual mode. 2. Press and hold the ARROW UP / ARROW DOWN buttons until the estimated flow is reached. 3. Press ENTER; the foam pump will run. 4. Monitor and adjust for estimated water flow rate changes IMPORTANT: The foam flow rate will remain constant, even when actual water flow fluctuates. 5. Turn foam pump OFF to stop foam flow. NOTE: An alternate method would be to set the GPM to a fixed rate and adjust the percentage of foam Flowmeter Operation Figure 3-11: Control Head in Flowmeter Mode / Husky 12 Foam System 2009 Pierce Manufacturing Inc. All Rights Reserved.

35 OPERATION This operation returns the system to (normal) flowmeter control and only appears when in manual mode. 1. Press MODE until the USE FLOWMETER screen appears, then press ENTER. This enters the flowmeter mode Set-up Mode Refer to Para 4-2.1, Set-up Mode for Set-up Mode information Pierce Manufacturing Inc. All Rights Reserved. Husky 12 Foam System / 3-11

36 OPERATION 3-12 / Husky 12 Foam System 2009 Pierce Manufacturing Inc. All Rights Reserved.

37 SECTION 4 MAINTENANCE 4-1. Maintenance Introduction This section of the manual has been prepared to help keep your equipment in good operating condition and ready for its primary mission. The procedures and recommended intervals in this section are based on normal operating conditions and may have to be modified to meet the existing conditions. Some environmental concerns may dictate that inspection and maintenance be performed at more frequent intervals. For various proportioning system components (water pump, discharge devices, valves, actuators, etc.), refer to that particular component s Operation and Maintenance Manual or Service Manual Group (chapter). If, for any reason, the hydraulic reservoir shutoff valve is ever in the closed position, the hydraulic pump should be de-coupled from the water pump or the truck must be taken out of service. Failure to do so will result in severe damage to the hydraulic pump Testing After System Maintenance If during the course of normal system maintenance it becomes necessary to replace, repair, or modify system components, component parts, operating devices or equipment, the system must be tested to ensure proper operation before being placed back into service. The services of a qualified field engineer to inspect the system, run the tests for start-up, and the annual inspection can be provided. Additional details can be obtained by contacting Pierce Manufacturing. During cold weather, the foam system must be blown out after testing with water. Water cannot remain in the foam system after testing. Either fill the foam system with foam concentrate or blow out the foam system with compressed air using the following procedure. Failure to comply may result in the water freezing and damaging foam system components. 1. Draining Foam Pump After Testing a. Open all drains. Remove foam inlet cap. If equipped, turn the selector valve to the middle position (halfway between TANK FILL and INJECT). Cycle foam tank valves as needed until tanks and lines are empty. Reinstall inlet cap. b. After moving truck to its destination, cycle the foam tank valves again to get any residual water out of the lines. 2. Blowing Out After Testing a. After blowing out the main water pump, cycle through and operate the flush mode with air. b. Attach shop air (90 psi or less) directly to the inlet. Run the foam pump through a couple of cycles to get the water out. c. If equipped, run air through the tank fill options. d. After moving truck to its destination, cycle the foam tank valves again to get any residual water out of the lines Pierce Manufacturing Inc. All Rights Reserved. Husky 12 Foam System / 4-1

38 MAINTENANCE 4-2. Set-up & Calibration Set-up and Calibration Modes should only be used by qualified personnel, as any changes made while in the Set-up or Calibration Modes may adversely affect the system performance. Set-up Mode is used to access calibration modes, change default settings and access foam tank drain mode. The functions are shown in this chapter in the order they appear on the control head LCD screen Set-up Mode Figure 4-1: Set-up Screen 3. Press MODE button until display reads: 4. Press ENTER / ARROW UP / ARROW DOWN at the same time to enter the Set Up Mode screens. 5. Press MODE to scroll through the Set Up Mode screens. 6. Follow the prompts on the screen English/Metric Mode Figure 4-2: English/Metric Screen NOTE: The English/Metric screen provides the option of reading the flow in GPM or LPM. 1. Press MODE until the DEFAULT SYSTEM screen appears, then press ENTER 2. Press ARROW UP or ARROW DOWN to toggle between the two options. 3. Press ENTER again to store the new default setting. 4-2 / Husky 12 Foam System 2009 Pierce Manufacturing Inc. All Rights Reserved.

39 MAINTENANCE Calibrate Flowmeter Mode Figure 4-3: Calibrate Flowmeter Screens 1033/1035/1165/1166 NOTE: IMPORTANT: Calibrate Flowmeter Mode is used to calibrate the water flowmeter. Before calibrating, verify the water flow using a pitot tube. If the flow is correct at various flow rates, based on the pitot tube results, no calibration is needed. 1. While in the Set Up Mode screens, press MODE button until display reads CALIBRATE FLOWMETER MODE, then press ENTER. NOTE: If unable to flow the default flow rates, different flow rates may be obtained by pressing ARROW UP or ARROW DOWN in order to achieve different flow rates other than the default settings. The wider the rates are during calibration, the more accurate the flowmeter will be over those flow rates. 2. Attach the appropriate hose(s) and nozzle(s) to one or more foam/water discharge(s) to obtain a known water flow of 50 GPM (low gpm flow meter setting). Open the discharge valve(s). 3. At the CAL FLOWMETER 50 GPM screen, press ENTER. RUNNING CALIBRATION will show on the LCD display until the first calibration set point is complete. 4. CAL FLOWMETER 300 GPM will automatically appear next. 5. Attach the appropriate hose(s) and nozzle(s) to one or more foam/water discharge(s) to obtain a known water flow of 300 GPM (high gpm flow meter setting). Open the discharge valve(s). 6. Press ENTER to begin calibration. RUNNING CALIBRATION will again appear. 7. When calibration is complete, press MODE to exit Set-up Mode. 8. Confirm accuracy by flowing various flow rates Calibrate Foam Pump (LVDT) Transducer Figure 4-4: Foam Pump Transducer Calibration Screen 1037 NOTE: The foam pump transducer must be calibrated before performing any other foam system calibration procedures. 1. While in the Set-up Mode, press MODE button until display reads CALIBRATE FOAM PUMP TRANSDUCER Pierce Manufacturing Inc. All Rights Reserved. Husky 12 Foam System / 4-3

40 MAINTENANCE 2. Press ENTER to begin calibration. Figure 4-5: Foam Pump Transducer Voltage Screen 3. While the calibration is running, the display will indicate LVDT voltages at each end of the foam pump stroke. The normal voltage reading is 0.3v - 0.7v (left) and 4.3v - 4.8v (right). 4. When the calibration is complete, the display will again read CALIBRATE FOAM PUMP TRANSDUCER Calibrate Class A Foam Mode Figure 4-6: Calibrate Class A Screen 1152 NOTE: Prior to calibrating, run the system at different rates and verify that it is in need of calibration. The most accurate calibration can be obtained using the actual foam concentrate intended for use at a fire incident. However, if foam is unable to be used, water is an acceptable substitute. Verify that the draft hose is securely installed, the Foam Inlet Valve is OPEN, the Foam Pump is primed, and the foam source is set to DRAFT CLASS A before beginning foam calibration. 1. While in the Set-up Mode, press MODE button until display reads CALIBRATE MODE CLASS A FOAM. 2. Press ENTER to accept. Display should read CALIBRATE FOAM A (or B) 1.00 GPM 3. Press ENTER to begin foam calibration at 1.00 GPM. The foam pump will run for five minutes. 4. Measure actual flow by measuring the foam/water pick-up through draft hose. 5. When green Foam Pump ON light turns off, measure the actual amount of foam concentrate flowed. Calculate the gallons per minute (GPM) used during the five minutes. (Example: 5.5 gallons flowed divided by 5 minutes = 1.1 GPM.) Using the ARROW UP or ARROW DOWN buttons, enter the GPM flowed. (In this example 1.1 ) 6. Press ENTER to accept value. 7. Display should read: CALIBRATE FOAM A 4.00 GPM 8. Press ENTER to begin foam calibration at 4.00 GPM. Foam pump will run for five minutes. 9. Measure actual flow by measuring the foam/water pick-up through draft hose 10. When green Foam Pump On light turns off, measure the actual amount of foam concentrate flowed. Calculate the gallons per minute (GPM) used during the five minutes. (Example: 5.5 gallons flowed divided by 5 minutes = 1.1 GPM.) Using the ARROW UP or ARROW DOWN buttons, enter the GPM flowed. 11. Press ENTER to accept value. 12. Display should read CALIBRATE MODE CLASS A FOAM / Husky 12 Foam System 2009 Pierce Manufacturing Inc. All Rights Reserved.

41 MAINTENANCE 13. Press MODE to exit Set-up Mode Calibrate Class B Foam Mode Figure 4-7: Calibrate Class B Screen NOTE: Prior to calibrating, run the system at different rates and verify that it is in need of calibration. The most accurate calibration can be obtained using the actual foam concentrate intended for use at a fire incident. However, if foam is unable to be used, water is an acceptable substitute. Verify that the draft hose is securely installed, the Foam Inlet Valve is OPEN, the Foam Pump is primed, and the foam source is set to DRAFT CLASS B before beginning foam calibration. 1. While in the Set-up Mode, press MODE button until display reads CALIBRATE MODE CLASS B FOAM. 2. Press ENTER to accept. Display should read CALIBRATE FOAM B 1.00 GPM 3. Press ENTER to begin foam calibration at 1.00 GPM. The foam pump will run for five minutes. 4. Measure actual flow by measuring the foam/water pick-up through draft hose. 5. When green Foam Pump ON light turns off, measure the actual amount of foam concentrate flowed. Calculate the gallons per minute (GPM) used during the five minutes. (Example: 5.5 gallons flowed divided by 5 minutes = 1.1 GPM.) Using the ARROW UP or ARROW DOWN buttons, enter the GPM flowed. (In this example 1.1 ) 6. Press ENTER to accept value. 7. Display should read: CALIBRATE FOAM B 4.00 GPM 8. Press ENTER to begin foam calibration at 4.00 GPM. Foam pump will run for five minutes. 9. Measure actual flow by measuring the foam/water pick-up through draft hose 10. When green Foam Pump On light turns off, measure the actual amount of foam concentrate flowed. Calculate the gallons per minute (GPM) used during the five minutes. (Example: 5.5 gallons flowed divided by 5 minutes = 1.1 GPM.) Using the ARROW UP or ARROW DOWN buttons, enter the GPM flowed. 11. Press ENTER to accept value. 12. Display should read CALIBRATE MODE CLASS B FOAM. 13. Press MODE to exit Set-up Mode Set Class A Concentrate Default Percentage Figure 4-8: Class A Default Screen Pierce Manufacturing Inc. All Rights Reserved. Husky 12 Foam System / 4-5

42 MAINTENANCE NOTE: The default percentage is set at the factory to automatically run at 0.5% for Class A foam. Temporary changes to the foam percentage may be made while running the system by using the ARROW UP or ARROW DOWN buttons. The department may find it beneficial to change the defaults for their particular operating requirements or different types or brands of foam. 1. While in the Set-up Mode, press MODE button until display reads CLASS A DEFAULT, then press ENTER. 2. Press ARROW UP or ARROW DOWN to adjust default to the desired rate. 3. Press ENTER to accept new default rate. 4. Cycle batteries to confirm changes Set Class B Concentrate Default Percentage Figure 4-9: Class B Default Screen 1041 NOTE: The default percentage is set at the factory to automatically run at 3.0% for class B foam. Temporary changes to the foam percentage may be made while running the system by using the ARROW UP or ARROW DOWN buttons. The department may find it beneficial to change the defaults for their particular operating requirements or different types or brands of foam. 1. While in the Set-up Mode, press MODE button until display reads CLASS B DEFAULT, then press ENTER. 2. Press ARROW UP or ARROW DOWN to adjust default to the desired rate. 3. Press ENTER to accept new default rate. 4. Cycle batteries to confirm changes Select Single or Dual Foam Tank System Figure 4-10: Tank Option Screens 1042/1043 NOTE: In the set up mode there is a screen that allows the software to recognize that the truck has been configured with one or two foam tanks. If the single/dual tank selection is not correct, the system may not run as it is searching for the second tank valve that is not installed, or it may not recognize the alternate foam valve is there because it was set for a single tank system. 1. While in the Set-up Mode, press MODE button until the Tank Option screen appears, then press ENTER. 2. Press ARROW UP or ARROW DOWN to toggle between single and dual tank options. 3. Press ENTER to accept the selection. 4-6 / Husky 12 Foam System 2009 Pierce Manufacturing Inc. All Rights Reserved.

43 MAINTENANCE Set Default Foam Source Figure 4-11: Default Foam Source Screens 1044/1045 NOTE: The default foam source setting is used to determine which tank will open as the default tank, Class A or Class B. On a single tank system it will change the default setting (Class A or Class B). If changing a single tank system from A to B default, the foam valve remains plugged into the Class A harness. If changing the types of foam in the tank, It is imperative to thoroughly flush out and dry the entire system. 1. While in the Set-up Mode, press MODE button until the Default Tank screen appears, then press ENTER. 2. Press ARROW UP or ARROW DOWN to toggle between DEFAULT TANK A and DEFAULT TANK B options. 3. Press ENTER to accept the selection Tank Fill Enable/Disable Figure 4-12: Tank Fill Option Screens 1046/1047 NOTE: The tank fill option must be enabled in order for the option to work. In order for the option to work, the system must have the optional tank fill valve installed for a single tank system, the air diaphragm fill pump for dual tank systems, and shut off floats installed in the tank dome to actuate the automatic shutoff when the tank is full. 1. While in the Set-up Mode, press MODE button until the Tank Fill screen appears, then press ENTER. 2. Press ARROW UP or ARROW DOWN to toggle between DISABLED and ENABLED options. 3. Press ENTER to accept the selection Pierce Manufacturing Inc. All Rights Reserved. Husky 12 Foam System / 4-7

44 MAINTENANCE Set Automatic Flush Time Figure 4-13: Flush Time Screen NOTE: An automatic flush occurs whenever foam source is switched from a Class A to Class B foam or vice-versa. The factory default setting is seconds. 1. While in the Set Up Mode screens, press MODE button until the Flush Time screen appears, then press ENTER. 2. Press ENTER to accept. 3. Press Arrow Up or Arrow Down to change the flush time value. 4. Press ENTER to accept new default value Auto Start Figure 4-14: Auto Start Screens /1050 NOTE: The auto start option will automatically turn the foam system on the first time the water pump is engaged. The option must have sensors installed in the foam system hydraulics and have additional wiring installed in order to function. 1. While in the Set-up Mode, press MODE button until the Auto Start screen appears, then press ENTER. 2. Press ARROW UP or ARROW DOWN to toggle between DISABLED and ENABLED options. 3. Press ENTER to accept the selection. 4-8 / Husky 12 Foam System 2009 Pierce Manufacturing Inc. All Rights Reserved.

45 MAINTENANCE Drain Mode Figure 4-15: Control Head in Drain Mode 1051/1052 NOTE: The Foam Drain mode is used to drain the foam tanks when needed. 1. While in the Set-up Mode, press MODE button until the Drain Mode screen appears. 2. Press ENTER - this will close any tank valve that is open. Figure 4-16: Inlet Cap with Check Valve 1069 NOTE: The inlet cap contains a check valve; the drain cap does not have a check valve. 3. Remove the inlet cap, install drain cap, and attach hose - have container available. 4. Select the tank on dual tank systems. 5. PRESS UP TO DRAIN AND DOWN TO STOP message will appear. 6. Pushing ARROW UP will open the drain valve; pushing ARROW DOWN will close the drain valve. Use the buttons as needed when changing containers 7. To exit screen, turn the system OFF Pierce Manufacturing Inc. All Rights Reserved. Husky 12 Foam System / 4-9

46 MAINTENANCE Reset Maintenance Reminders Figure 4-17: Maintenance Reminder Screens NOTE: Maintenance messages flash alternately with main operating screen after 20 hours of foam system operation Separate screens allow user to reset the counters for strainer and fluid service reminders If these messages occur in the station, have service performed. If these messages occur on the scene, verify the hydraulic oil level, continue operation, and have service performed upon returning to the station. 1. While in the Set Up Mode screens, press MODE button until one of the reset screens appears. 2. Press ENTER to reset counter. When counter has been reset, display will read COUNTER RESET Check Current Software Revision Figure 4-18: Control Head showing Software Revision 1057 NOTE: This information is also displayed when the system is first turned ON. While in the Set Up Mode screens, press MODE button until the Software Revision screen appears / Husky 12 Foam System 2009 Pierce Manufacturing Inc. All Rights Reserved.

47 MAINTENANCE 4-3. Troubleshooting The following outline represents operational difficulties that may arise during the deployment of the unit. It is not a comprehensive list meant to exhaust every possible malfunction of the equipment. Rather it is a quick checklist to allow operating personnel to ensure that operator error is not preventing the safe deployment of the unit. Table 4-1: General Troubleshooting Symptom Possible Cause Corrective Action Bad control head. Replace control head. 1. LCD on control head is blank or displaying random characters. Red light comes on. 2. LCD on control head is blank and foam system will not turn on. 3. System does not accurately display the amount of foam used. 4. System is using excessive foam. Wiring issue. Check the ground circuit, ckt# 1640, pin 2. Check the voltage at the battery. Check the voltage at the control head, ckt# 2878, pin 1. Voltage at the control head should be within.2 volt of the battery voltage. Wiring issue. Check the ground circuit, ckt# 1640, pin 2. Check the voltage at the battery. Bad control head (check for red light on). Check for bad foam controller (check for flashing green light which indicates a good heart beat). Check the voltage at the control head, ckt# 2878, pin 1. Voltage at the control head should be within.2 volt of the battery voltage. Check the single point ground. If red light is not on, replace control head. If green light is not flashing, replace foam controller. Recalibrate LVDT and water flow meter. LVDT or water flow meter out of calibration. Incorrect software version. Contact Pierce for latest software version. LVDT or water flow meter out of Recalibrate LVDT and water calibration. flow meter. Wrong software version. Contact Pierce for latest software version. Inspect the check valve at the injection fitting. Foam should not leak past the injection fitting check valve with system OFF. If fitting leaks, replace Pierce Manufacturing Inc. All Rights Reserved. Husky 12 Foam System / 4-11

48 MAINTENANCE Symptom Possible Cause Corrective Action 5. Delay before getting foam from Wrong software version. Contact Pierce for latest hand line. software version. Needless flushing of system and not See Chapter 3, Operating recharging. Procedures. System not turned on before Turn on system at pump panel charging line. as first step in operation. 6. Foam in water tank after using Hand lines not flushed. Flush hand lines. foam system. Defective flush valve. Replace flush valve. UPF tank issue. Fill foam tank; add florescent dye. Let unit sit overnight. Check the water tank to see if the florescent color is present in the water. If so, the foam tank is cracked. Bad manifold check valve. If foam manifold bleeds down rapidly, replace or disassemble/ clean check valve. It is normal for the manifold to bleed down slowly. Bad foam injection check valve. Foam should not leak past the injection check valve with system OFF. If fitting leaks, replace. Manifold drain not bled down. Manifold drain should be used after each use. 7. Foam tank empty after pumping operation with foam system turned off. Bad check valve for foam tank fill. Check selector valve for being in INJECTION mode. Bad foam injection check valve. Check injection check valve to see if foam leaks by. Bad tank to pump valve. Check tank to pump valve. 8. System will not draft foam. See Table TBD, System Will Not Pump Foam from Foam Tank 9. Tank fill inoperable. Selector valve in wrong mode. Check tank fill/injection switch at selector valve for being in TANK FILL position. Tank to pump valve did not close. Check tank to pump valve and the switch on the valve. Float stuck full (false reading). Check float. Tank fill check valve does not open. Check to see if check valve is free. 10. Display indicates to check hydraulic fluid, water strainer, or foam strainer. Table 4-1: General Troubleshooting The display is programmed to display maintenance reminders at appropriate intervals. Perform maintenance action(s) and reset timer per instructions found in para TBD / Husky 12 Foam System 2009 Pierce Manufacturing Inc. All Rights Reserved.

49 MAINTENANCE 11. Water flow reads 000 when flowing water. Wiring issue. Check wiring. Unplug the flow meter and check for a good ground, ckt# Check for 6-9 volt supply to flowmeter, ckt# Bad flow meter Check flow meter. Remove flow meter and check for obstructions or visible damage. Manually spin the paddle wheel and observe the display. Display should indicate flow. Bad control module. Check control module. Does the foam module have heartbeat? No heartbeat indicates faulty module. 12. Water in hydraulic oil Defective oil cooler. Check for carry over in oil cooler. If water is found in the oil, change the oil. Pressure washing near filler cap on Use caution when pressure oil reservoir. washing around oil reservoir. 13. System will not pump foam from foam tank. Table 4-1: General Troubleshooting Symptom Possible Cause Corrective Action See Table TBD, System Will Not Pump Foam from Foam Tank. Table 4-2: Specialized Troubleshooting- System Will Not Pump Foam from Foam Tank Question Reason for Question Test Procedure A. Is there foam in the foam tank? The foam system will not operate properly without an adequate supply of concentrate. Visual inspection. No Fill tank with foam; see Section 2. Yes 2009 Pierce Manufacturing Inc. All Rights Reserved. Husky 12 Foam System / 4-13

50 MAINTENANCE Question Reason for Question Test Procedure B. Is the red light on the control module ON? A red light indicates that the control head is energized. Visual inspection. No Go to Step G. Yes Question Reason for Question Test Procedure C. Is the green light on the control module ON? A green light indicates that the electrical portion of the system is functioning. Visual inspection. No Go to Step K. Yes Question Reason for Question Test Procedure D. Does the foam pump engage? To isolate the problem from between electrical and mechanical failures. NOTE: You must be flowing water for the foam pump to operate. Turn the foam percent up and listen for the foam pump to engage. No Go to Step P. Yes 4-14 / Husky 12 Foam System 2009 Pierce Manufacturing Inc. All Rights Reserved.

51 MAINTENANCE Question Reason for Question Test Procedure E. Tank fill option - look to see if the selector valve is in the TANK FILL mode. If the tank fill valve is open, all of the foam concentrate will circulate between the foam pump and the foam tank, with little or none being injected. Remove the tube from the outlet of the tank fill valve. Operate the foam system. If foam concentrate is discharged, the tank fill valve is open. NOTE: In the TANK FILL mode, the tank to pump valve should be closed automatically. If this does not occur, check for a bad switch at the selector valve. Yes Go to Step T. No Question Reason for Question Test Procedure F. Is the foam injection check valve stuck in the CLOSED position? Foam concentrate cannot reach the foam injection manifold if the check valve is stuck closed. Check by visual inspection, or the foam pump may make a squealing noise when the pump goes into the relief mode. No Replace the foam injection check valve. End Question Reason for Question Test Procedure G. Is the wiring OK? The foam system will not operate properly if the wiring is faulty. Refer to the wiring diagram for circuit information. No Repair wiring. Yes 2009 Pierce Manufacturing Inc. All Rights Reserved. Husky 12 Foam System / 4-15

52 MAINTENANCE Question Reason for Question Test Procedure H. Is the system voltage OK? Voltage at the control Check the voltage at the battery. head must be within.2 volt of the battery voltage for the foam system to operate. Check the voltage at the control head. Voltage at the control head should be within.2 volt of the battery voltage No Repair poor connections, loose pins, etc. Yes 4-16 / Husky 12 Foam System 2009 Pierce Manufacturing Inc. All Rights Reserved.

53 MAINTENANCE Question Reason for Question Test Procedure I. Is the ground circuit OK? The foam system must have an adequate ground (continuity) for the system to operate. Check ground circuit (ckt# 1640K). Refer to System Diagrams on page 4-30 for additional circuit information No Repair ground circuit. Yes Question Reason for Question Test Procedure J. Does the control module have a heartbeat? A flashing red LED (heartbeat) indicates that the control module is communicating with the control head. Visual inspection No Replace control module, see service group 7950-P-005. Yes Replace control head Pierce Manufacturing Inc. All Rights Reserved. Husky 12 Foam System / 4-17

54 MAINTENANCE Question Reason for Question Test Procedure K. Are there any error messages on the display? Messages on the display will indicate if there is a low foam level or if the system is being operated beyond its capacity. Visual inspection. Yes Correct problem(s) indicated by the display message. No Question Reason for Question Test Procedure L. Does the control module have a heartbeat? A flashing red LED (heartbeat) indicates that the control module is communicating with the control head. Visual inspection No Replace control module, see service group 7950-P-005. Yes 4-18 / Husky 12 Foam System 2009 Pierce Manufacturing Inc. All Rights Reserved.

55 MAINTENANCE Question Reason for Question Test Procedure M. Is the flow meter operating correctly? The flow meter provides the foam system with information on how much water is being flowed. No signal from the flow meter will result in the foam system not operating. If GPM appears on the display, the flow meter is OK. If GPM does not appear, replace the flow meter. No Replace flow meter, see service group 7950-P-001. Yes Question Reason for Question Test Procedure N. Are the system set-up, LVDT The foam system will not See Set-up & Calibration on page 4-2: calibration, and defaults set operate if the system has Check the set-up; correctly? not been set-up and calibrated correctly. Calibrate the LVDT; Check all default settings. No Correct set-up, LVDT calibration & default settings. Yes 2009 Pierce Manufacturing Inc. All Rights Reserved. Husky 12 Foam System / 4-19

56 MAINTENANCE Question Reason for Question Test Procedure O. Is the foam tank valve open? The foam pump will not operate unless the system receives a signal that the the foam tank valve is open. NOTE: It is possible for the valve to be physically open but a failed limit switch indicates to the system that the valve is not open. Visually inspect wiring to foam tank valve. Check continuity, connectors, etc. Check if foam is present at foam pump drain: a. Open drain on inlet side of foam pump; b. Open foam tank to pump valve; c. Check for foam concentrate. If concentrate is present, foam tank valve is open. No Check & repair wiring to valve. Repl valve and/or limit switch. End Question Reason for Question Test Procedure P. Does the foam pump engage with the Discharge Foam Pump Drain open? To check the foam injection check valve. If the foam pump engages with the valve open, it is likely there is contamination in the injection check valve. Open the Discharge Foam Pump Drain valve. Attempt to operate the system. Yes Clean/replace the injection check valve. No 4-20 / Husky 12 Foam System 2009 Pierce Manufacturing Inc. All Rights Reserved.

57 MAINTENANCE Question Reason for Question Test Procedure Q. Does the foam pump engage in the manual mode? To isolate the flow meter from the system and eliminate it as a possible cause. See Manual Mode on page 3-9. Yes Replace flow meter, see service group 7950-P-001. No Question Reason for Question Test Procedure R. Is the LVDT working properly? The LVDT informs the system of what the pump is doing. The foam system will not operate properly if no signal is received from the LVDT. 1. Attempt to calibrate the LVDT, refer to Calibrate Foam Pump (LVDT) Transducer on page 4-3. If the LVDT will not calibrate, go to Step Remove the cover from the signal condition box Check for voltage on Pins 5 & 6 (output & ground). A reading of 0-5 volts should be obtained. It is normal for the voltage to fluctuate as the foam pump cycles. No Replace the LVDT per service group 7950-P-007. Yes 2009 Pierce Manufacturing Inc. All Rights Reserved. Husky 12 Foam System / 4-21

58 MAINTENANCE Question Reason for Question Test Procedure S. Is the wiring OK? The foam system will not operate properly if the wiring is faulty. Refer to System Diagrams on page 4-30 for additional circuit information. No Repair wiring. Yes 4-22 / Husky 12 Foam System 2009 Pierce Manufacturing Inc. All Rights Reserved.

59 MAINTENANCE Question Reason for Question Test Procedure T. Is the system voltage OK? Voltage at the control Check the voltage at the battery. head must be within.2 volt of the battery voltage for the foam system to operate Check the voltage at the control head, ckt# 2878, pin 1. Voltage at the control head should be within.2 volt of the battery voltage No Repair wiring. Yes 2009 Pierce Manufacturing Inc. All Rights Reserved. Husky 12 Foam System / 4-23

60 MAINTENANCE Question Reason for Question Test Procedure U. Is the ground circuit OK? The foam system must have an adequate ground circuit (continuity) for the system to operate. Check ground circuit Refer to System Diagrams on page 4-30 for additional circuit information No Repair ground circuit. Yes Replace LVDT per service group 7950-P / Husky 12 Foam System 2009 Pierce Manufacturing Inc. All Rights Reserved.

61 MAINTENANCE Question Reason for Question Test Procedure V. Is the electric tank fill valve OK? If the tank fill valve sticks open, most of the foam concentrate will circulate between the foam pump and the foam tank, with little being injected into the water stream. Inspect the valve for proper operation. Check the adjustment of the micro switch. Inspect the micro switch for moisture No Replace electronic tank fill valve. End 4-4. Periodic Operation The foam system should be operated periodically to insure that the foam system is operational, and also to circulate the foam concentrate through the pump. The preferred method is a periodic operation of the system in a normal discharge condition as described in Section 3, Operation General Maintenance Procedures Personal hearing can be PERMANENTLY DAMAGED if exposed to constant high noise levels of 85 db or higher. Wear approved hearing protection devices when working in high-noise-level areas. Hearing loss occurs gradually, but becomes permanent over time. Cleanliness Dirt, grease, oil, and debris may cover up a serious problem. Use an approved dry cleaning solvent to clean all metal surfaces Pierce Manufacturing Inc. All Rights Reserved. Husky 12 Foam System / 4-25