PyroLance B 2000 M-G Technical Manual

Transcription

1 PyroLance B 2000 M-G Technical Manual Unit Serial Number PyroLance 6140 S. Gun Club Road Ste. K6-270 Aurora, Colorado USA

2 Table of Contents Unit Specifications Safety Example of Required Personal Protective Equipment A Quick Look at How the System Works System Component Description Installation Uncrating and Lifting Installation Procedures and Initial Preparation User-Required Installation Material and Labor Option 1: Skid Mount Installation (standard) Option 2: Compartment Mounting Installation General Installation Guide Making Sure Everything is Working Right Operation Instructions Start-up Operation of Power Unit Normal Operation Drafting Operations PyroFoam Direct Injection Foam System Rotary Gear Pumps Foam System Flow Schematic and Major Components Maintenance Engine Maintenance Preventative Maintenance Recommendations Engine Oil, Air Filter, Spark Plug and Filter Replacement Fluid Levels, Spark Plug, Points and Filter Replacement Checking Engine Oil Level Changing Engine Oil Changing Engine Air Filter Changing Engine Fuel Filter Changing Engine Spark Plug

3 Table of Contents 8 Troubleshooting Engine Problems Pump and Plumbing Problems Blitz Nozzle Problems Electrical Problems Anti-Freeze Loading Problems Hose Reel Problems PyroFoam System Problems Specifications Plumbing Schematic Pump Inlet Location Foam Inlet Location Throttle Controller Switch Panel Electrical Schematic APPENDIX: COMPONENT LITERATURE Warranty

4 Unit Specification Name Plate PYROLANCE North America LLC 6140 S. Gun Club Road Ste. K6-270 Aurora, Colorado USA Phone: Web Site: B 1000 M-G B 2000 M-G BB 2000 M-G Nominal Pump Flow 10 GPM (40 L/min) 20 GPM (80 L/min) 20 GPM (80 L/min) Nominal Pump Maximum Pressure 2000 PSI (135 Bar) 2000 PSI (135 Bar) 2000 PSI (135 Bar) Nominal Nozzle Pressure 1500 PSI (100 Bar) 1500 PSI (100 Bar) 1500 PSI (100 Bar) Engine 18 HP 35 HP 35 HP Engine Type BRIGGS & STRATTON BRIGGS & STRATTON BRIGGS & STRATTON Fuel Requirements Unleaded Gasoline Unleaded Gasoline Unleaded Gasoline Fuel Tank Capacity 2.5 Gallons (9 L) 2.5 Gallons (9 L) 2.5 Gallons (9 L) Controls Manual Manual Manual Water Inlet Pressure Limits Atmospheric Atmospheric Atmospheric Nozzle Flow Rate 10 GPM (40 L/min) 20 GPM (80 L/min) 10 GPM (40 L/min) Included Nozzles UDOR UHP Nozzle Standard Standard Standard CAT Twin Strike Optional Optional Optional 200' Hose Length Optional Optional Optional Elkhart UHP Combination Nozzle No Optional No Included Hose Reels Hose Reel Hannay Hannay Hannay Electric Rewind Optional Optional Optional Hose Length 100 ft (30 m) 150 ft (45 m) 2 x 100 ft (2 x 30 m) Optional Hose Length 200 ft (60 m) 200 ft (60 m) 400 ft (120 m) Hose Diameter.750" (19 mm).750" (19 mm).750" (19 mm) Hose Pressure Rating 3,125 PSI (215 Bar) 3,125 PSI (215 Bar) 3,125 PSI (215 Bar) Foam Pump Optional Optional Optional Foam Injection Relative to Pump Discharge Side Discharge Side Discharge Side Drafting Capability Optional Optional Optional Winterization Optional Optional Optional 4

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6 Unit Specifications Scope and General Design Requirements A firefighting system shall be provided for offensively attacking a fire. The high pressure firefighting system shall allow the operator to attack fire from a safe position. The system shall be extremely effective on wildland fire and initial fire attack operations with limited water supplies. Components and Module Design The firefighting system shall consist of: Engine: gasoline driven engine Water pump: high pressure positive displacement piston pump Hose Reel: high pressure hose reel and attack hose Nozzle: manually operated pistol grip high pressure nozzle The system shall be capable of injection of foam liquids on the discharge side of the pump. The major components shall be assembled on a removable assembly with integral engine. The entire system shall be designed to be a quickly installed or removable plug-and-play module. Safety and Standards Compliance The system shall be designed for the safety of the operator and fire fighter in mind with a safety margin of 4:1 built into all components. Performance Capabilities The firefighting system shall be tested and proven to be highly effective in the following scenarios: Wildland, grass, and brush fire applications Automobile and truck fires Limited structural fires Limited industrial fires Shipboard and marine firefighting Military firefighting applications Container fires ENCLOSURE MOUNTING The firefighting system shall be packaged in a selfsupporting baseplate with dimensions of 30 (76 cm) right to left, 24 (61 cm) front to rear (deep), and 32 (81 cm) high. The mounting assembly shall be powder coated and shall be designed to contain the specified major components of the system. ULTRA HIGH PRESSURE FIRE PUMP SPECIFICATIONS The firefighting system shall be equipped with a heavy duty high pressure plunger type positive displacement fire pump. The pump shall be driven as specified under the drive system section of these specifications. The pump shall have the following features: Pump rating: 20 GPM at 2200 PSI (80 L/min at 150 bar) System operational rating: 20 GPM at 1450 PSI (80 L/min at 100 bar) Solid Keyed Shaft Brass Manifold Stainless Steel Check Valve Stainless Steel Plunger Rods Bronze Connecting Rods Tapered Roller Bearings Solid Ceramic Plungers Heavy Duty Flat Base High Pressure Seals Heat Treated Crankshaft ENGINE INSTALLATION The firefighting system shall be powered by a Briggs and Stratton or similar gasoline engine. The engine installation shall be designed with adequate cooling and ventilation air in the mounting area. The engine shall have the following specifications: Model: Vanguard Type: air cooled V-twin horizontal shaft Cylinders: two Horsepower: 35 (gross) RPM: 3,600 Oil filter and cooler Choke control Oil alert system EXHAUST SYSTEM The fire pump engine shall have a muffler, water flip cover, heat guard, and exhaust pipe installed on the engine assembly. The exhaust pipe shall be directed vertically and away from the pump operator panel. 6

7 Unit Specifications GASOLINE FUEL TANK A built in plastic fuel tank shall be installed for the specified gasoline engine. The fuel tank shall have capacity of approximately 2.5 gallons (9 L). A shut/off valve and flexible fuel line shall be furnished. ELECTRIC SUPPLY CABLE AND CONNECTION The 12 volt electrical power supply to the firefighting assembly from the chassis battery location shall use 10' (3 m) flexible stranded copper wiring cables (positive (red) and neutral (black)) properly sized to the anticipated electric load. The installation kit shall be equipped with protective electrical loom, cable clamps, battery terminal connections, and plastic wrap ties for installation in the chassis. An automatic reset circuit breaker shall be supplied for installation at the truck battery location. This power supply cable shall be equipped with a Deutz quick disconnect female and male receptacle plug. A firefighting pump instruction nameplate and necessary warning labels shall be installed on the assembly (English language). A fire pump engine shall be equipped with a Tiny Tach hour meter and tachometer and shall be installed on the control panel. The fire pump engine oil drain shall be equipped with a 12 (30 cm) long wire braided hydraulic type hose, with valve, plug, and identification label. The pump control panel shall be provided with a ON- SCENE 12 volt panel light with switch. PUMP CONTROL PANEL The control panel shall be ergonomically designed and operator friendly. The panel shall be labeled and installed to be easily visible from the operator s position. The following instruments and controls shall be installed: Emergency stop (red) switch Water on-off ball valve control Momentary contact two-position start-stop ignition switch Foam control on/off valve Control panel light and master switch One (1) UHP pressure gauge One (1) primer control valve Foam proportioning valve Tiny Tach tachometer PLUMBING The firefighting system shall be plumbed with high pressure hydraulic type hose, plumbing and fittings. This shall include double wire braided high pressure hoses of various sizes, zinc plated steel hose ends, and plated steel hydraulic fittings. The threads shall be male and female NPT, JIC, SAE O-ring style in various sizes. Rigid plumbing shall be in zinc plated steel piping with pipe fittings of zinc plated steel. BYPASS UNLOADER VALVE The ultra-high pressure plumbing system shall include a bronze adjustable by-pass unloading valve set for the maximum working pressure of the system. The valve shall unload the main pump to the intake side of the pump. PRESSURE SAFETY, EASY START, THERMAL RELIEF VALVE The ultra-high pressure plumbing system shall include the following devices: A) One (1) pressure safety relief valve which shall relieve water pressure to atmosphere; set at a slightly higher pressure than the unloading valve. B) One (1) thermal relief valve which shall open if water temperatures exceed 145 F (62 C) degrees; designed to protect the pump from high temperature conditions and relieve the water to atmosphere. C) One (1) EZ start valve INTAKE FILTER A 1¼" (31 mm) water filter with 32 mesh stainless steel screen shall be installed in the water supply line to the fire pump. The filter shall be easily accessible for cleaning. The water filter shall be rigidly mounted. ELECTRICAL WIRING Necessary low voltage automatic circuit breaker protection shall be provided where required. Wiring shall be stranded copper automotive type, sized for the appropriate electrical load. Exposed wiring shall be protected with convoluted split plastic loom; such looms shall be mechanically secured. Wiring shall be run in protected areas or enclosed in metal panels where subject to mechanical injury. Electrical connections and termination of wiring shall be within weatherproof plastic enclosures with waterproof strain relief's and connectors. 7

8 Unit Specifications WATER TANK SUPPLY LINE A 1¼" (31 mm) water tank to fire pump line shall be installed as follows: A) From the fire pump to the water filter shall be a 1¼ (31 mm) flexible transparent hose. B) 10 feet (3 m) of 1¼ (31 mm) flexible water hose with removable connections and clamping devices. C) One (1) 2.5 (63 mm) liquid filled pressure gauge shall be installed from the discharge side of the ultra high pressure fire pump, with the gauge mounted on the pump panel. THROTTLE CONTROL The engine speed control shall be controlled by a mechanical throttle which shall automatically increase engine RPM speed when actuated and when released shall return the engine speed to idle. ELECTRIC REEL ULTRA-HIGH PRESSURE One (1) electric rewind painted ultra-high pressure steel hose reel shall be installed. The reel shall be plumbed with wire reinforced, high-pressure hose coupled with brass fittings. The reel system shall have a minimum of 4:1 safety ratio and designed for a 2,000 PSI (135 bar) working pressure. The hose reel shall be installed by a qualified OEM installer. The high pressure hose reel shall be supplied by a ¾ (19 mm) hydraulic type wire braided flexible hose line. One (1) chrome plate hose roller assembly shall be supplied for protection of the hose during hose removal and rewind operations. A positive pin type locking device shall be installed on the reel. REEL MOUNTED ULTRA-HIGH PRESSURE HOSE 150' (45 m) length x ¾" (19 mm) hose shall be installed with threaded couplings. The hose shall have a working pressure of 3125 psi (215 bar). NOZZLE -- ULTRA-HIGH PRESSURE One (1) 20 GPM (80 L/min) high pressure pistol grip fog nozzle shall be provided for the high pressure reel. CLASS A -- FOAM EDUCTOR SYSTEM (OPTIONAL) The high pressure reel shall be equipped with a Class A foam eductor system on the discharge side of the high pressure pump. The eductor foam supply line shall be equipped with foam shut off valve. Tachometer/ Hour Meter Pump Pressure Discharge Gauge Engine Oil Level Dipstick Manual Primer Pump Panel Rain Cover C/W Pump Panel Light Foam Proportioner Master Power Switch Emergency Stop Two-Position Momentary Contact Ignition Switch Primer Shut-off Valve 8x4 Aluminum Skid Water Discharge Valve Water/Foam Selector Valve 8

9 1 Safety Before attempting to operate or install the PyroBlitz unit, read all of these safety precautions and follow carefully. An ultra-high pressure fire pump system is inherently powerful and potentially hazardous equipment; however, with the proper care and understanding of the instructions, such firefighting units can be operated effectively and safely. A PyroBlitz firefighting unit must only be operated by qualified personnel who have completely read and understand this PyroBlitz Manual. This manual is intended to reinforce and review safety techniques. It is recommended that qualified users complete extensive firefighting exercises prior to placing a unit in service and practice refresher exercises on an annual basis. It is strongly recommended that this entire instruction manual be reviewed in depth before operating or maintaining this equipment. Service work should only be performed by qualified individuals who have read and completely understand the operations manual. 1. Always wear eye protection 2. Always wear full personal protective equipment (PPE) for operator of nozzle 3. Always inspect hoses and couplings prior to use 4. Keep away from exhaust and hot engine components 5. Follow this Instruction Manual regarding winterization, draining, and protection of the hoses, pump, and entire plumbing system when exposed to temperatures below 32 degrees F / 0 degrees C 6. Check fuel, oil, and lubricant levels prior to operation 7. Do not operate equipment unless operator has read this operation and instruction manual. DANGER: Never direct a water stream towards an electrical power line. 9

10 Safety Example of Required Personal Protective Equipment Helmet and Head Protection Face Shield or Goggles Full Body Structural Clothing Structural Gloves WARNING PyroLance North America is not responsible for damages resulting from a failure to comply with instructions in this manual. Please read carefully before use. Seek immediate medical attention if any unprotected part of the body comes in contact with the high pressure water stream. Serious personal injury can result from an untreated water injection wound. 10

11 2 A Quick Look at How the System Works The system consists of a portable, high-pressure nozzle and a gasoline-powered, high-pressure pumping unit. The unit is typically supplied with a high-pressure attack hose located on a hose reel. The unit is equipped with many features to maintain operator safety while operating with nozzle pressures in the PSI range. Water mist systems operate on the principle of generating very fine droplets of water and delivering them to the fire zone. Water mist is very effective at fire suppression due to its high specific heat and latent heat of vaporization coupled with the increased surface area, allowing faster heat absorption. The majority of the energy absorbed by water in heating occurs during the phase change from liquid to gas. There are a number of complex interactions that occur between water mist and fires, which can lead to extinguishment. The three primary mechanisms of extinguishment are heat extraction, oxygen depletion and radiation blocking, with secondary mechanisms involving air dilution and kinetic effects such as reduced flame velocity. PyroBlitz benefits from more modern delivery systems, both in terms of pump units as well as nozzles. In addition, we can apply the wetting agents far more efficiently and concentrate not only on the fuel phase of the fire, but also the gaseous phase. This all gives a new meaning to the very old phrase where there is smoke, there is fire! Foam Line Water and Foam Tank Water Source Tank-to-Pump Draft Line B2000 Power Unit Hose Reel Pond, Lake, Pool, etc. PyroBlitz Spray Nozzle How the System Works 1. Water is pumped from a water source (tank, pond, lake, river, pool, etc.) 2. Foam is introduced into the water stream (if desired) 3. Water/water-foam mix travels to spray nozzle via the hose reel 4. High-pressure water/water-foam mix extinguishes flames 11

12 3 System Component Description Hannay Electric reel c/w 150" x 3/4" reinforced 3125PSI booster hose B 2000 Pump unit (base unit only without booster tank) UDOR Wand style 20GPM UHP nozzle c/w aerating foam tube (standard) ELKHART 20GPM UHP Booster reel nozzle 12

13 System Component Description The following components are supplied separately from the power unit: 1. One (1) 10 ft (3 m) x 1¼ (32 mm) length of very flexible clear plastic hose with stainless steel clamps shall be provided for connection from the power unit to the fire apparatus water tank. (Cut length as needed.) 2. One (1) 10 ft (3 m) length of #4/0 red and black battery power supply cable, with an Deutz female connection end of the cable. The Deutz male connection is mounted at the top of the power unit. The connections at the battery must be supplied by the installer. 3. One (1) abrasion-resistant plastic conduit protection shall be installed over the battery supply cable. Plastic wire ties are provided for mechanical securement of the cable along the chassis frame area. 4. One (1) high-ampere fuse is provided and must be mounted near the battery location. 5. One (1) Hannay hose reel with roller assembly and bolts for mounting. 6. One (1) 150 ft (45 m) x ¾ (19 mm) length of 3125 PSI (215 Bar) ultra-high pressure booster hose fitted with quick connect high-pressure coupling on the nozzle end. 7. One (1) Blitz nozzle equipped with a quick connection coupling assembly. 8. One (1) 15 ft (5 m) x ¾ (19 mm) length of ultrahigh pressure hose to supply the hose reel from the power unit. This hose will be equipped with female swivel JIC threaded couplings. 9. Tank-to-pump-line installation kit: a) One (1) 1¼ manual valve. 10. One (1) 20 ft (6 m) x 1¼ (32 mm) clear suction hose c/w threaded couplings 13

14 4 Installation Planning Uncrating and Lifting Open the shipping crate with care and inspect the equipment for any damage. If found, immediately contact PyroLance and the shipping company. In the unit, you will find a sealed instruction sheet outlining steps to contact PyroLance. If the unit cannot be installed immediately, leave it in its crate and provide adequate indoor storage to protect the unit against damage. Installation Procedures and Initial Preparation After the unit is uncrated and lifted from its shipping container, immediately ensure the following is performed prior to installation: 1. Fill the engine with the appropriate engine oil. (See link to Engine Manual located in the appendix) Type of oil: SYNTHETIC 5W-30 Quantity of oil: oz. 2. Fill the transfer case of the pump with the appropriate gear oil. (See link to Pump Manual located in Appendix A) Type of gear oil: Udor Lube Premium Pump Oil or SAE30W Non-Detergent Oil Quantity of gear oil: 10 oz. 90 wt. gear lube 3. Fill the pump gear drive with the appropriate gear oil. (See link to Pump Manual located in Appendix A) Type of gear oil: Udor Lube Premium Pump Oil or SAE30W Non-Detergent Oil Quantity of gear oil: 40 oz. User-Required Installation Material and Labor The installation kit is provided with the PyroBlitz power unit to assure the user that few if any additional materials are required. However, due to the hundreds of various types of fire apparatus and body compartments that could be encountered around the world, a user may need to supply additional hose or equipment for a proper installation. The installer should contact PyroLance directly for additional materials or information should problems arise. Installation Requirements from the Apparatus 1. The PyroBlitz unit shall be supplied from the apparatus water tank, with a 1¼ (32 mm) tank to pump supply line (see installation kit). Most fire apparatus have an existing tank-to-pump line to the main fire pump OR a sump in the bottom of the water tank with a threaded 3 (75 mm) NPT plug. The installer needs to connect to one of these locations for water supply. 2. Water tank shall be at least 100 Gallon (480 L) capacity. 3. Battery connections for the electrical supply to the #4/0 electrical cable. 14

15 Installation Option 1: Skid Mount Installation (standard) Pyroblitz power unit can be installed as a skid unit onto a pick-up truck or Rapid Intervention unit. Skid Mounting 1. Provide adequate booster tank with no less than 100 gal capacity. 2. Leave adequate space for air flow and maintenance of unit. 3. Allow adequate open area above unit to allow exhaust gases to escape. 4. If mounted as a skid unit a weather shield can be installed (not provided) with a minimum of 12" clearance above unit to allow for proper ventilation. 5. Ensure that skid unit or pump bay has adequate rigidity to support. Option 2: Compartment Mounting Installation Guidelines The PyroBlitz unit has been designed for installation on either a base-plate type platform or an optional slide-out tray configuration into a fire apparatus compartment. The unit comes complete with a base-plate assembly, specified hoses, and fittings to accommodate installation. If required, PyroLance can also provide the optional slideout tray. Compartment Mounting 1. Compartment provisions and requirements: a) Clearance of the compartment door opening must be a minimum of 40 wide (1016 mm) x 36 (914 mm) high. b) The inside width of the compartment must be a minimum of 48 (1220 mm) wide x 48 (1070 mm) high. c) Adequate door opening and interior compartment clearances for electrical and water lines must be provided. 2. When the unit is to be mounted in a fire apparatus compartment, it must be mounted on the optional slide-out tray. 3. The compartment may be open (with doors) or equipped with hinged or roll-up doors. The unit is NOT designed to be mounted on the floor of an enclosed compartment without using the slide tray. NEVER TRY TO OPERATE THE POWER UNIT WITH THE DOOR(S) CLOSED; the unit must be fully OUT of the compartment on the tray for proper operation. 4. Installation location must be a level surface, able to safely and completely support the unit weight. The compartment floor shall be rated to carry a minimum of 750 lbs (340 kgs) of weight. 5. The slide tray shall be installed on the floor with bolts and nuts as provided with the assembly. An approximate 36 (914 mm) x 24 (610 mm) plate of 12 gauge steel or (4.78 mm) aluminum should be installed under the compartment floor for reinforcement when the slide tray is installed. 6. Orient the unit to allow unrestricted access to the control panel located on the front of the unit (control panel must face outward towards the operator position). 7. Bolt the unit to the PyroBlitz power unit to the slide tray with the bolts provided. Four (4) aligned holes are provided in the slide tray and power unit base plate for this purpose. General Installation Guide (Option 1 or 2) The following installation and mounting procedure is for either a compartment mounting or skid mounting installation. After installation as described above, for either the exterior or compartment location mounting procedures, the following steps should be taken: 1. Determine installation location with respect to load-carrying capacity and compartment requirements (as previously outlined). 2. Install 1¼ (32 mm) tank-to-pump supply hose from apparatus water tank to the power unit. a) In a compartment installation, particular care must be used at the connection point to the power unit, so that sufficient hose is looped in a semi-circle to allow for the extension of the slide tray assembly. b) Install 2-way banjo manual ball valve. c) Connect to the fire apparatus water tank, then to the inlet fitting with a 1¼ (32 mm) inside diameter hose. d) Locate the inlet fitting under the bottom of the tank to ensure a flooded suction line. e) Water quality found in domestic water supplies or fire hydrant water is sufficient 15

16 Installation for normal operation. The PyroBlitz is NOT designed to pump water from an unfiltered water source. 3. Install the 12 volt electrical battery supply connection from the apparatus battery box to the power unit. The Deutz male battery plug is provided on the power unit and the female receptacle shall be installed on the supply cable. Particular attention must be provided during the installation of this cable to avoid higher temperature exhaust and muffler equipment. The cable and abrasion-resistant loom shall be mechanically secured during installation to protect this cable. The fuse protection shall be installed at the battery location. 4. Install the Hannay booster reel as desired. It is recommended the reel be installed within 10 feet (3 m) of the power unit since only 15 ft (4.57 m) of electrical wiring and hose is provided. If over 10 feet from the power unit, the installer must provide additional hose and electrical cable. (Note: these may be ordered on the PyroLance web site if desired.) NOTE: Applicable for electrical hose reel option only. 5. Install ultra-high pressure hose between power unit and hose reel. Pump Inlet Location Pump inlet must be below the tank bottom Water Level 16

17 5 Making Sure Everything is Working Right Preparing the Unit for Operation The following checklist should be completed in advance, so that the unit is always ready for immediate use. This should be completed on a weekly schedule and/or after each use. 1) Check the engine oil. (Download Briggs and Stratton Engine Manual refer to the Appendix.) c. Remove the internal stainless steel strainer assembly (be careful not to damage the fine mesh strainer). Remove Internal Stainless Steel Strainer d. Inspect the strainer and flush any debris with clean water. Pull and Inspect Strainer 2) Check the pump oil. (Download Udor Pump Manual refer to the Appendix.) 3) Check and clean the water inlet strainer. To inspect and clean this strainer, follow this procedure: a. Shut off the 3-way valve (turn to the antifreeze ON position). OPTIONAL: Only if antifreeze option is selected. b. Unscrew the filter bowl (turn counter clockwise) and carefully remove the filter assembly. e. Push strainer back into filter housing. Antifreeze tank-to-pump valve 32 Mesh inline filter 1-1/4 tank-to-pump supply 1-1/2 draft connection 17

18 Making Sure Everything is Working Right Locking Pin Chrome Roller Guides Quick Connect UHP Coupling Hannay Electric 200 3/4 Hose Reel f. Re-install the water filter bowl assembly carefully, threading the unit in a clockwise rotation by hand. Tighten the assembly and check for leaks after the valve is opened. 2) Slide the collar back over the pin. Align slot with pin on female half; slide collar back over pin. g. Open the 3-way anti-freeze/water tank control valve to the water tank ON position. OPTIONAL: Only if antifreeze option is selected. 4) Check the fuel tank and fill if required. 5) Lubricate the couplings on the end of the reel hose and Blitz nozzle connection to the hose. 6) Connect the Blitz nozzles to the hose. 1) On the female half of the coupling, align the slot with the pin. 3) Insert the male coupling half and push together firmly until connected. 4) Release the collar and then rotate the slot away from the pin. 18

19 6 Operation Instructions 20 GPM Water Fog/Foam Combination Nozzle Slide Mechanism Foam Tube Aeration Device Foam Tube Fog/Stream Selector Handle Trigger Safety Mechanism Elkhart Nozzle Tachometer/ Hour Meter Pump Pressure Discharge Gauge Engine Oil Level Dipstick Manual Primer Pump Panel Rain Cover C/W Pump Panel Light Foam Proportioner Master Power Switch Emergency Stop Two-Position Momentary Contact Ignition Switch Primer Shut-off Valve 8x4 Aluminum Skid Water Discharge Valve Water/Foam Selector Valve 19

20 Operation Instructions Engine Oil Dipstick Engine Oil Fill Point Air Filter Element Draft Connection Inline Water Filter Antifreeze Tank to Pump Valve Antifreeze Tank Electric Hose Reel Switch Manual Hand Primer Bypass Relief Valve Udor Pump Dipstick/ Fill Point 2.5 Gallon Fuel Tank 1-1/4 Line Tank to Pump Supply Battery Foam Tank to Pump Valve Hydrant Fill Foam Tank 20

21 Operation Instructions Rain Flap Antifreeze Tank to Pump Valve Tank-to- Pump Valve Hydrant Fill Hose Reel Rewind Switch Foam Tank Bypass Relief Valve Mechanical Throttle Actuator Electrical Junction Box Pressure Safety Relief Valve 10 amp Circuit Breaker Battery Foam Tank to Pump Valve Hose Reel Electrical Junction Box Hydrant Fill Antifreeze Tank 21

22 Operation Instructions Start-Up Operation of Power Unit Before starting the PyroBlitz power unit, review all safety requirements found in Section 1. PyroBlitz units should only be operated by qualified firefighters who have read and understand this instruction and operating manual. The following steps should be taken in start-up operations: 1) Operator #1: Verifies the unit has been properly inspected and is in a total operational state. 2) Operator #1: Verifies the Emergency Stop Button (see photo) is released by twisting clockwise, which is the ON position. 3) Operator #2: Verifies that the Blitz nozzle is properly connected and water trigger control activates the power unit as described above. 4) Operator #2: Should NOT pull the Blitz nozzle water trigger until the hose is unwound to the desired length. Lock hose reel prior to activating throttle to prevent uncoiling of hose on the hose reel drum. The hose will be hard to unroll if pressurized. 5) Operator #1: Warns personnel that the unit will now be started. 6) Operator #1: Starts the engine as if it were a keyed switch in a car by turning the ignition switch (see photo). Water Level Indicator Tank Drain Tank to Pump Valve Antifreeze Valve Inline Filter Engine Choke 22

23 Operation Instructions Normal Operation Normal operation of the PyroBlitz system is defined as: a) Operator #1: Power unit control person. b) Operator #2: Nozzle control person who will control flow of water via the Blitz nozzle water trigger. Normal operation shall be as follows: 1) Normally the Blitz nozzle is pre-connected to the hose on the hose reel. The hose will be spooled off the reel to the required length to reach the operating area by Operator #2. 2) Operator #2 will advance the hose and nozzle to the operating area. 3) Operator #1 will engage the positive latching device on the reel to prevent movement of the reel during operations. 4) Operator #2 will take a firm and stable stance before pulling the water trigger. 5) The duration of water flow into the fire will vary and is determined by many factors such as: a) Type and size of the fire b) Enclosure size. 6) Releasing the water trigger will cause the power unit to go back to idle. Booster Tank Level Indicator Tank Refill Line Engine Choice Lever Fuel Supply On/Off Cock 23

24 Operation Instructions Foam Proportioning Valve Primer Shut-Off Valve Fuel Supply On/Off Cock Udor Pump Oil Sight Level Pump Pulley Guard Udor Pump Oil Sump Drain Plug 24

25 Operation Instructions E-Z Start Discharge Line Foam/Water Divertor Valve Foam Supply Line from Tank Master Electrical Switch Foam Eductor Emergency Stop Switch Ultra High Pressure Supply Line Hose to Hose Reel Water/Tank Fill Divertor Valve Primer On/Off Valve Momentary Contact Ignition Switch 25

26 Operation Instructions Foam Line Water and Foam Tank Water Source Tank-to-Pump Draft Line B2000 Power Unit Hose Reel Pond, Lake, Pool, etc. PyroBlitz Spray Nozzle Drafting Operations The PyroBlitz Ultra High Pressure Fire Suppression unit has been designed for rapid deployment in rural, wildland and municipal environments. It has the capability to draft water from open sources such as ponds, rivers, stream, dams and swimming pools to allow a sustained fire attack with the high pressure hand line as well as the capability to replenish the booster tank while drafting from open water supply. Preparing the Unit Position the unit as close to the open water source as possible, taking into account ground conditions, slopes and current flow direction as well as water condition. Shut down engine. Close tank to pump valve. Remove blank cap from suction inlet port. Position suction hose/strainer to make the connection to the suction inlet port. Ensure that rubber washer in suction hose is present and in good condition. Attach suction hose to suction inlet port and tighten hose until airtight connection is obtained. (A rope can be secured to the suction hose at the strainer and suction connection in order to assist with placement of hose into open water source and/or manipulation of hose during and after operations.) Place the strainer into the open water source with no less than one foot above strainer. Place strainer facing upstream if used in flowing water. Ensure that strainer does not bottom out onto river bed, pond or stream to prevent ingestion of mud and or stones. 26

27 Operation Instructions Start pump. Open primer valve. Use hand primer to exhaust air from suction hose. Observe water rising in suction hose until it reaches pump suction inlet. The pump is capable of drafting water from a maximum of 20 feet deep (optional only with primer fitted). Once pump is primed and lift is observed, close primer valve. Select either tank fill operation or hose reel attack line and commence pumping operation. NOTE: DO NOT RUN THE PUMP WITHOUT WATER FOR LONGER THAN ONE MINUTE. Failure to Obtain/Maintain Lift Failure to obtain or sustain lift can be attributed to the following conditions: Loose or poor suction inlet connection must be airtight Faulty or damaged suction hose washer Blocked strainer Strainer not adequately submersed Faulty primer valve (if fitted) Faulty primer (if fitted) Faulty pump Water level too far below pump suction inlet Pump suction hose not adequately primed NOTE: SUCTION STRAINER MUST BE SUBMERSED AT LEAST ONE FOOT BELOW WATER LEVEL. Initial pumping operations could be accompanied by a certain amount of air in the discharge line. This condition should stabilize within one minute of pumping operations. If air continues to exit during pumping operations, stop the unit as cavitation can damage the pump; ensure proper seal is obtained. 27

28 Operation Instructions PyroFoam Direct Injection Foam System Specifications and Operation Instructions Foam Procedure 1. The Poly-Tank Foam Tank must be completely filled and covered when not in use. 2. At no time should two different types or brands of foam be stored in the same foam tank. 3. Foam concentrates should be tested annually to ensure optimum performance. 4. When changing foam brands, concentrates or performing maintenance, the foam tank and system must be thoroughly flushed to ensure proper operation. Consult foam manufacturer s instructions for proper flush operations. 5. The foam tower has been designed to be removed to help facilitate the cleaning of the foam tank. When re-installing the foam tower, torque the bolts to 20 in-lbs, starting with the four corner bolts. Repeat torque sequence. 6. This equipment complies with all applicable NFPA standards at time of manufacture. Foam System Operation To begin foam operations: 1. Ensure the foam tank(s) contain concentrate. 2. Select the foam tank to be used using the Foam Selector Valve on the pump panel. 3. Select the PyroBlitz on the Hose Selector Valve on the pump panel. 4. Turn On the Foam On/Off Switch on the pump panel. 5. Ensure the PyroLance/PyroBlitz system is running, (see General Operations Section) and begin foaming operations as required. To change foam concentrates (if equipped with a Class A/B foam system): 1. Ensure the PyroLance/PyroBlitz system is running, (see General Operations Section). 2. Keep the Foam On/Off Switch in the On position. 3. Turn Foam Selector Valve to the Flush position. 4. Open the PyroBlitz nozzle and flow water for a minimum of 12 seconds. 5. Select the foam tank to be used using the Foam Selector Valve on the pump panel. 6. Continue foaming operations as required. To end foam operations: 1. Ensure the PyroLance/PyroBlitz system is running, (see General Operations Section). 2. Keep the Foam On/Off Switch in the On position. 3. Turn the Foam Selector Valve to the Flush position. 4. Open the PyroBlitz nozzle and flow water until the discharge is flowing only plain water. 5. If Winterization is required, proceed to Winterization Procedures. 6. Turn the Foam On/Off Switch to Off. Winterization Procedures (added steps): 1. Turn the Foam On/Off Switch to the On position. 2. Turn the Foam Selector Switch to the Flush position. 3. After, Winterization Operations are complete, turn the Foam On/Off Switch to the Off position. Maintenance (added steps): 1. Never mix dissimilar concentrates in the foam tank(s). 2. Always flush the entire system with plain water when changing from one concentrate to another, and at the end of foam operations. 3. Winterize the system whenever the system will be exposed to freezing conditions. 4. Inspect and clean Foam Concentrate Strainers weekly. 28

29 Operation Instructions Rotary Gear Pumps General Description Pump housings and gears are made of top quality bronze, shafts are stainless steel 303. Bearings are made of high performance carbon-graphite material selected for wear resistance and long service life. Gear pumps are positive displacement pumps. Each shaft revolution displaces a definite amount of liquid relatively unaffected by the back pressure in the discharge line. Shaft speed and flow are directly proportional. Drive Arrangement Close coupled pumps are mounted directly to the electric motor by means of a suitable adapter bracket. The pump drive shaft is connected to the motor shaft by a flexible coupling. Liquids and Temperature These pumps are suitable for all liquids that are compatible with bronze. Most common liquids are water, oil, and mild chemicals in the ph-range of 4 to 11. Viscous liquids require reduced shaft speeds of 1150 RPM or lower. Consult factory. Liquids containing solids, abrasives, powders or paint pig- ments are definitely not recommended for gear pumps. If abrasives are unavoidable, use a very low shaft speed. The recommended liquid temperature range is 32 F to 140 F for longest pump life. If more extreme temperature conditions exist, our factory should be consulted. Freezing of water-filled pumps can cause damage and must be avoided. Oils at low temperatures are very viscous requiring a lower speed or extra power. Suction Lift As a general rule, the suction lift should be kept at an absolute minimum by placing the pump as close to the liquid source as possible. A gear pump in new condition can lift 20 feet of water in the suction line. A foot valve (preferably with built-in strainer) is recommended at the beginning of the suction line. For a first start-up, the pump should be primed to avoid dry running. Minimum size of the suction pipe is the size of the pump inlet port. For longer suction lines (over 3 feet), or for viscous liquids, the pipe size should be at least one size or two sizes larger than the pump inlet port. 29 For complete Oberdorfer Pump literature, go to pyrolance.com. Rotation and Relief Valve The relief valve is not intended to be a metering or flow control device. Its main purpose is to function as a discharge pressure relief when the spring tension is exceeded by the discharge pressure. Overheating can occur within 5-10 minutes if the discharge line is completely shut off for extended periods. Unless otherwise specified, the pump motor unit is supplied by the factory for shaft rotation clockwise from shaft end. Reversing the motor rotation will reverse the in and out ports and also requires changing the relief valve location. The relief valve is always on the discharge side in this pump series. The factory pressure setting is 50 PSIG. To increase pressure, turn the relief valve adjusting screw in a clockwise direction. To reverse single phase motors, find instructions on the inside of the junction box cover or on the name plate of the motor. Three phase motors are not wired for any particular rotation. They can be reversed by interchanging any two (2) wires of the three (3) wire leads. Performance Water 70 F PSI GPM HP Req R.P.M. Pump & Motor No. HP Motor Motor Frame Single Phase Three Phase C N990HN26 N990HN /2 145TC N990JT45 N990JT /2 145TC N990JT45 N990JT TC N990JW 45 N990JW TC N990KY45 N990KY TC N990KY45 N990KY95 125* TC N990KY45 N990KY95 150* TC N990KX45 N990KX95 PSI GPM HP Req R.P.M. Pump & Motor No. HP Motor Motor Frame Single Phase Three Phase /4 56C N990HM46 N990HM /4 56C N990HM46 N990HM TC N990JN46 N990JN /2 145TC N990JT46 N990JT TC N990KW46 N990KW TC N990KW46 N990KW96 125* TC N990LY46 N990LY96 150* TC N990LY46 N990LY96 *For pressures over 100 psi, the above selections are suitable for pumping fluids with lubricity (e.q. oils, polymers). Service life will decrease for fluids without lubricity (e.q. water, solvents).

30 Operation Instructions Foam System Flow Schematic and Major Components TO REEL OR NOZZLE WATER SUPPLY EZ START VALVE LOW PRESSURE MANIFOLD THERMAL RELIEF VALVE HAND PRIMER PUMP COLOR FUNCTION BLUE SUCTION MAGENTA FOAM RED PRESSURE GREEN BYPASS PUMP HIGH PRESSURE MANIFOLD PRESSURE RELIEF VALVE FOAM "A" FOAM "B" OBERDORFER FOAM PUMP 30

31 7 Maintenance Engine Maintenance Maintenance on this unit should be restricted to authorized personnel who have read and understand the PyroBlitz Instruction and Operation Manual. Review this manual, especially the safety information section, prior to performing any service on this equipment. If the engine is to be replaced during the life cycle of the power unit, the following information is provided on the Briggs and Stratton engine. Newer versions or alternate engines for replacement purposes must be approved by PyroLance prior to installation. The PyroBlitz B 2000 M-G utilizes the following engine: a. Briggs & Stratton Engine b. Vanguard Series c. Type: Horizontal V-Twin engine d. Gross Horsepower: 35HP at 3600 RPM e. Fuel: 1. Gasoline 2. Type: leaded or non-leaded 3. Octane range: 85 to Fuel tank capacity: 2.5 gallons PLEASE NOTE: When shipped, the PyroBlitz power unit, fire pump, and pump gear box are shipped without fluids. IMMEDIATELY fill the components with lubrication fluids after removing the power unit from the box. The plumbing system is filled with anti-freeze solution; upon start-up operation the anti-freeze solution should be flushed prior to use. Reference Information on Engine and Pump Maintenance The Udor pump and Briggs and Stratton engine instruction, operation, and maintenance manuals in PDF format are located in the Appendix of this manual. Specific information can be found in various sections of the manual for the following: a) Briggs & Stratton engine 1. Oil Types, Manufacturers, and Viscosity Range 2. Engine Oil Fill Location & Procedures 3. Routine Scheduled Maintenance Information 4. Troubleshooting Guide for the Engine WARNING The PyroBlitz power unit emergency shut off control must be in the OFF position prior to performing any service work. For major work, the Deutz electrical plug to the battery system must be unplugged and disconnected entirely. Unauthorized replacement of any part may lead to catastrophic equipment failure and serious personal injury. Use only replacement parts that are supplied by or approved by PyroLance. Use of any other parts may lead to equipment failure and severe personal injury. b) Udor pump 1. Gear Oil Types, Manufacturers, and Viscosity Range 2. Pump and Gear Box Fill Locations and Procedures 3. Routine Scheduled Maintenance Information 4. Troubleshooting Guide for the Pump c) PLEASE NOTE: The user MUST ensure the lubricate levels are correct prior to starting the engine. Dry starting the engine without oil can lead to engine failure and is not covered under the PyroLance warranty or the separate Briggs & Stratton warranty. d) USE OF PDF MANUALS: Please refer to the Briggs & Stratton Engine Manual and the Udor Pump Manual for fluid level information and/or see specific information as follows to verify the correct oil type, quantity, and viscosity prior to start-up operations. 31

32 Maintenance Check engine oil and add if low 1 Check pump oil and add if low 2 Replace engine oil and oil filter 1 Replace engine fuel filter 1 Replace engine air filter 1 Check water strainer Inspect hose for wear or damage 3 Replace hoses Preventive Maintenance Recommendations After Monthly Every 3 Every 6 Every 3 Every Use Months or Months or Years or 100 Hours* 200 Hours* 1,500 Hours* X X * Whichever comes first 1 See engine manufacturer s literature found in the Appendix for additional recommendations. 2 See pump manufacturer s literature found in the Appendix for additional recommendations. 3 If any damage to the hose is found, replace immediately. X X X X X X Engine Oil, Air Filter, Spark Plug and Filter Replacement The Briggs & Stratton engine oil needs to be checked and/or changed regularly. Use the following guide as a template: a. 5 hours of initial operation change engine oil and filter. b. 8 hours of operation/daily check engine oil level. c. 100 hours of operation or annually: Change engine oil and filter. Change engine air filter. Change engine spark plug. Clean engine of foreign debris. d. 250 hours of operation or annually: Check engine valve clearance (it may be necessary to have this service preformed at an Authorized Briggs & Stratton service center). e. 400 hours of operation or annually: Change air filter. Change fuel filter. Fluid Levels, Spark Plug, Points and Filter Replacement The first level of normal maintenance includes the following: a. Engine Oil: Manufacturers: All high quality detergent oils are acceptable if classified for service SF, SG, SH, SJ or higher Type Oil: Synthetic 5W-30 Viscosity Range: 5W-30 Quantity (including the filter): oz. b. Oil Filter: Manufacturers: Briggs & Stratton Model: Briggs & Stratton Part No c. Fuel Filter: Manufacturers: Briggs & Stratton Model: Briggs & Stratton Part No d. Air Filter: Manufacturers: Briggs & Stratton Low Profile Model: Briggs & Stratton Part No e. Spark Plug: Manufacturers: Long Life Platinum Model: Briggs & Stratton Part No f. Spark Plug Gap: Manufacturers: Long Life Platinum Model: Briggs & Stratton Part No Spark Plug Gap Setting: in. (.076 mm) 32

33 Maintenance Checking Engine Oil Level Prior to checking oil, be sure the engine is located on a level and horizontal surface. Safely clean the oil fill area and remove any debris. The user should follow the indicated steps in checking the engine oil on a Briggs & Stratton engine: Step 1: Remove the dipstick from the engine and wipe the dipstick with a clean dry cloth. Step 2: Re-insert the dipstick into the engine from which it was removed. Step 3: Remove the dipstick from the engine again and verify that the oil level is correct. The oil level should be near or at the top of the indicator marks located on the dipstick. Step 4: If the oil level is found to be low: a) Remove the oil fill cap and safely add the correct viscosity to the engine; based on how low the oil level is found in Step 3. b) To verify the correct viscosity oil, refer to the Briggs & Stratton Manual. c) After adding the correct amount of oil, wait approximately 60 seconds for the oil to move through the engine. Step 5: Wipe the dipstick with a clean dry cloth and safely re-insert the dipstick fully into the engine. Step 6: Safely remove the dipstick from the engine and verify the oil level. Again, the oil level should be near or at the top of the oil of the indicator marks found on the dipstick. Step 7: If the oil level is still found to be low, repeat Steps 4, 5 and 6 until the oil level is correct. Step 8: Replace the oil fill cap that was removed in Step 4. Changing Engine Oil Prior to changing oil, be sure the engine is located on a level and horizontal surface. Safely clean the oil fill area and remove any debris. The user should follow the indicated steps in changing the engine oil on a Briggs & Stratton engine: Step 1: Safely remove drain plug from engine turning a counter clockwise direction and capture the used oil as it drains from the engine. Dispose of the used waste oil in an environmentally safe way. Step 2: Wipe the drain plug with a clean dry rag and re-install into the engine, turning in a clockwise direction until it is hand tight. Use an appropriate size wrench to torque the drain plug to its recommended specifications. See Briggs & Stratton Manual for correct torque specifications. Step 3: Safely remove the engine oil filter, turning it in a counter clockwise direction. Capture any residual oil and dispose of it in environmentally safe way. Step 4: Prepare to re-install a new oil filter. Lubricate the oil filter gasket with a thin layer of fresh, clean oil. Install oil filter onto engine, turning in a clockwise direction until the oil filter gasket comes in contact with the base of the engine. Hand tighten the oil filter an additional ½ to ¾ turn until the filter is seated properly to the engine oil filter adapter. Step 5: Prior to filling the engine with oil, please check earlier in this section for oil quantity and type. The oil should be suitable for your temperatures and altitudes. Changing Engine Air Filter To change the air filter in the Briggs & Stratton engine, the following steps must preformed: Step 1: Remove air cleaner latches and safely remove air filter from the air filter assembly housing. Step 2: Dispose of air cleaner in an environmentally safe way. Step 3: Re-install new air cleaner into air filter assembly housing and re-latch retainer latches. 33

34 Maintenance Changing Engine Fuel Filter To change the fuel filter in the Briggs & Stratton engine, the following steps must be performed: Step 1: Close fuel shut-off valve. Failure to do so could cause an explosion leading to injury or death. Step 2: Using pliers, gently squeeze the fuel filter retaining clamp tabs and remove the fuel filter from the fuel lines. A twisting motion may be needed to remove the filter. Step 3: Safely dispose of the fuel filter in an environmentally safe way. Step 4: Re-install a new Briggs & Stratton or approved fuel filter and re-install fuel retaining clamps to fuel filter and fuel lines. Step 5: Turn on the fuel valve. Changing Engine Spark Plugs To replace the spark plugs in the Briggs & Stratton engine, the following steps must be preformed: Step 1: Remove spark plug caps from spark plugs. Then using a proper-sized socket wrench, safely remove spark plugs from engine, turning in a counter clockwise motion. Step 2: Dispose of used spark plugs in an environmentally safe way. Step 3: Replace spark plugs with new Briggs & Stratton or approved replacement spark plugs. Re-install into engine, turning in a clockwise direction until seated properly. (Refer to Briggs & Stratton Manual for proper torque settings.) Step 4: Replace spark plug wire caps. Gasoline Engine Service Manual The gasoline engine requires routine maintenance similar to a car engine. Oil must be checked and changed regularly. Oil, air and fuel filters must be checked and changed regularly. For detailed information on these routine maintenance requirements as well as other service recommendations, please see the Briggs and Stratton Manual referenced in the Appendix. Pump Service Manual The Udor high-pressure water pump requires minimal maintenance. The pump and gear box gear oil should be checked on a regular basis. For detailed information on these routine maintenance requirements as well as other service recommendations, please see the Udor Pump Manual referenced in the Appendix. Additional Maintenance Procedures IF EQUIPPED WITH PYROFOAM SYSTEM 1. Never mix dissimilar concentrates in the foam tank(s). 2. Always flush the entire system with plain water when changing from one concentrate to another, and at the end of foam operations. 3. Winterize the system whenever the system will be exposed to freezing conditions. Inspect and clean Foam Concentrate Strainers weekly. 34

35 8 Troubleshooting Engine Problems 1. ENGINE DOESN T START UP. a) Check if the Emergency Stop control is released. b) Check the fuses located at the main power unit electrical box. c) Check if the Deutz connector to the battery terminals are securely connected and power is being supplied to the power unit from the vehicle s battery system. d) Check the fuel level in the fuel tank. e) Check the fuses located at the main power unit electrical box. 2. THE ENGINE DOESN T SPEED UP WHEN PULLING THE WATER TRIGGER. a) Check that pump is primed. b) Check that throttle actuator is flooded and sensing flow condition. c) Check throttle cable for proper setting. Pump and Plumbing Problems 1. PUMP IS UNDER PRESSURE AND WILL NOT ALLOW ENGINE TO TURN. a) Check that the bypass/relief valve is not stuck in the closed position. b) Check that vehicle batteries are in a fully charged condition. c) Check the battery supply cable from the vehicle batteries to the power unit. 2. PUMP IS CAVITATING OR WATER IS SURGING. a) Check water tank level. b) Check that tank to pump valve is in fully open position. c) Check that bypass/relief valve is not stuck. d) Check that pump water is not overheating by observing thermal relief valve discharge port. 3. BYPASS/RELIEF VALVE CONTINUOUSLY CYCLING. a) Check for water leaks in plumbing system. b) Check for blocked water filter strainer. c) Check pump-to-tank valve is fully open. Blitz Nozzle Problems 1. WATER DOES NOT EXIT THE BLITZ NOZZLE UNDER LOAD a) Check if the tank-to-pump valve is open. b) Prime the system. c) Check the water level in the tank. d) Check for leakages in plumbing system. e) Check if the water filter element remove and clean. f) Check to see if the Blitz nozzle orifice is blocked. g) Check diverter valve setting. h) Check that pump is primed properly. Electrical Problems 1. POWER UNIT IS NOT RESPONDING TO BLITZ INPUTS. a) Check that Emergency Stop control is released and power is ON. b) Check that fuses work in main power unit electrical box. c) Check that pump is primed properly. Anti-Freeze Loading Problems 1. ANTI-FREEZE SYSTEM DOES NOT LOAD OR WORK PROPERLY. a) Check tank-to-pump valve and ensure it is in the anti-freeze position. b) Check anti-freeze container for contents. c) Check that UHP pump is primed. Hose Reel Problems 1. THE REEL DOES NOT REWIND. a) Check if battery is connected. b) Check if the fuse reel electrical box is operational. c) Check wiring connections in power unit electrical box and reel electrical box for loose connections. d) Check the reel rewind button on the front panel for proper operation. 35

36 Troubleshooting PyroFoam System Problems 1. Foam does not exit the nozzle a) Ensure that foam selector valve is in either class A or B mode. b) Ensure those foam tank to pump valves are open. c) Ensure that foam pump master switch is activated. d) Ensure that foam proportioner is adequately set. e) Ensure that there is foam in tanks. 2. Foam pump master switch is on but foam pump is not working a) Ensure that foam tank level switch is not activated by ensuring that adequate foam in tanks and that the red low foam warning lights are not illuminated. b) Ensure that micro switch located at throttle controller is operating properly. 3. Foam pump does not switch off when engine goes to idle a) Faulty micro switch at throttle controller. Isolate pump using foam pump master switch and replace micro switch as soon as possible. 4. Foam pump cavitates a) Adjust foam proportioning system to lower level until cavitation stops. b) Check viscosity of foam concentrate. 5. Foam quality poor a) Adjust foam proportioner until proper foam quality is achieved. b) Ensure that correct type of foam compound is in relevant tanks. 6. Winterization a) Ensure that foam tank to pump valves are closed. b) Flush foam system completely. c) Select either class A or B system and run foam pump for no longer than 15 seconds dry. 36

37 9 Specifications Pump Pressure Gauge LED Light Stick 18HP Engine Main Power Switch Emergency Stop Switch Hand Primer Valve Foam Eductor Tachometer/ Hour Meter Foam/Water Selector Reel Supply/ Tank Fill Ignition Switch 37

38 Specifications Plumbing Schematic Color Key Column Column 2 Blue Suction Red Pressure Green Bypass Thermal Relief Valve Low Pressure Manifold High Pressure Manifold Pump Foam Eductor Hand Primer Pump Hand Primer Valve Unloader/Bypass Valve Diverter Valve Water/Foam Diverter Valve Tank Fill/System Supply Pump Pressure Gauge Water Supply "In" Pressure Relief Valve EZ Start Valve To Tank Fill To Reel Or Nozzle 38

39 Specifications Pump Inlet Location Front View A Rear View Pump Inlet Location Pump Inlet Location with Fitting 1-1/4" O-ring Boss with 1-1/4" Barb Fitting 39

40 Specifications Foam Inlet Location Front View A Rear View Foam Inlet Location Foam Inlet Location 1/4" Barb Fitting 40

41 Specifications Throttle Controller Cat Pumps Model 8100 System Saver Throttle Controller Specifications Max. System Pressure 4000 PSI 275 BAR Actuation Pressure 250 PSI 18 BAR Max. Temperature 160 F 71 C Fitting Size 3/8" NPTM 10 mm Cable Length 48" 1219 mm Weight 22 oz kg Dimensions 5.25 x 1.75" 133 x 45 mm Installation The Throttle Controller will function in any position, however, a minimum number of bends should be in the throttle cable to insure smooth consistent operation. If multiple discharge ports are available, install directly into the discharge manifold port. If not, tee into the discharge line between the unloader valve and the pump. Operation When the shut-off gun is closed (trigger released) the unloader will go into by-pass and drop the system pressure to 250 PSI or less. This change in pressure moves the piston in the throttle controller, reducing the tension on the throttle cable to permit the engine to idle. NOTE: The Throttle Controller cannot be used with a pressure regulator as a regulator maintains system pressure and will not give the required low pressure drop to activate the piston in the Controller. Setting and Adjustment Connect the Throttle Controller cable by turning the threaded cable end into the cable retainer. Thread hand tight until Locking Nut and Housing are flush with the cable retainer. Then secure locking nut with wrench. Torque to 100 in/lbs. Slide cable wire through the hole in the L connecting rod. Apply a small amount of Loctite 242 to the I.D. of the socket head screw. Only partially thread onto L connecting rod until remaining connection is made. Slide Z end of cable through the housing clamp. Then insert Z end into cable insert on the engine throttle rack. Only partially tighten screw on housing clamp now to allow later fine tuning of the throttle cable. With the engine in idle position, tighten the socket head screw on the L connecting rod. Torque to 8-10 in/lbs. Start the engine and make the necessary pressure adjustment to your unit to obtain full operating pressure at rated RPM. Check this pressure with the trigger gun open. Leave gun open and adjust the engine to full RPM by sliding the cable housing back and forth to obtain a minimum of 5/1000ths of a gap at the stop on the engine throttle rack. When the engine gap is reached tighten screw on cable housing clamp. Torque to 10 in/lbs. Caution: The engine throttle should not be allowed to hammer against the throttle rack stop. Be certain to leave a small air gap between the throttle and the stop to prevent stress on the cable, the throttle stop and the L connecting rod (see Tech Bulletin 061). Troubleshooting Water leaking around L connecting port: O-ring worn. Replace as needed. Engine does not drop to idle Regulator incorrectly installed or pressure lock-up unloader incorrectly installed. Use only Unloader with low pressure of less than 250 PSI in by-pass. Plugged orifice in throttle controller. Clean as needed. Cable broken or restricted with severe bends. Engine does not return to full system RPM Cable broken or restricted with severe bends. Cable extremely dirty. Lubricate and resume operation. 41