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© 2014 Pierce Manufacturing Inc. Part No. PM-P-OM420-0914

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Pierce UltimateConfiguration (PUC)

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© 2014 Pierce Manufacturing Inc. All Rights Reserved. PUC Pumpers / i

TABLE OF CONTENTS

SECTION 1. TO THE OWNER

1-1 WHO SHOULD USE, SERVICE AND MAINTAIN THIS VEHICLE ........................................................................... 1-1

1-2 WHAT TO DO IF YOU LACK KNOWLEDGE ...................................................................................................... 1-1

1-3 CAUTIONS, WARNINGS AND DANGERS .......................................................................................................... 1-2

1-3.1 SAFETY WARNING LABELS ................................................................................................................. 1-2

1-4 SAFETY ........................................................................................................................................................ 1-3

1-4.1 POWER TAKE-OFF (PTO) SAFETY INFORMATION ................................................................................ 1-31-4.2 GENERAL SAFETY INFORMATION ........................................................................................................ 1-3

1-4.2a TO PREVENT INJURY TO YOURSELF AND/OR DAMAGE TO THE EQUIPMENT .............................. 1-31-4.2b COLD WEATHER OPERATION OF POWERSHIFT POWER TAKE-OFF (PTO) ............................. 1-41-4.2c ROTATING AUXILIARY DRIVESHAFTS .................................................................................... 1-4

1-5 RESPONSIBILITY ........................................................................................................................................... 1-4

1-6 DAILY CHECKS ............................................................................................................................................. 1-5

1-7 CUSTOM PRODUCTS ..................................................................................................................................... 1-5

1-8 PROFESSIONAL, TRAINING, AND STANDARDS ORGANIZATIONS ....................................................................... 1-5

1-9 SAFETY DEFECT REPORTING ........................................................................................................................ 1-6

1-10 KEEPING YOUR KNOWLEDGE REFRESHED AND UP-TO-DATE ......................................................................... 1-6

SECTION 2. BEFORE PLACING IN SERVICE

2-1 CREATE A PUMP CHART ............................................................................................................................... 2-1

2-2 CHECK ADJUSTMENT OF INTAKE RELIEF VALVE ............................................................................................ 2-1

SECTION 3. GENERAL

3-1 DESCRIPTION OF PIERCE ULTIMATE CONFIGURATION (PUC) PUMP ................................................................ 3-1

3-2 GENERAL OPERATION .................................................................................................................................. 3-1

3-2.1 DEFINITIONS ...................................................................................................................................... 3-13-2.2 OPERATING THE ENGINE ................................................................................................................... 3-23-2.3 COOLING THE ENGINE ....................................................................................................................... 3-23-2.4 SUCTION STRAINERS ......................................................................................................................... 3-23-2.5 SUCTION LINE ................................................................................................................................... 3-23-2.6 TESTING FOR AIR LEAKS ................................................................................................................... 3-33-2.7 SOURCE OF WATER SUPPLY ............................................................................................................. 3-43-2.8 PUMPING IN COLD WEATHER ............................................................................................................. 3-43-2.9 WHEN FINISHED PUMPING ................................................................................................................. 3-43-2.10 PUMPING SALT WATER ...................................................................................................................... 3-4

3-3 TESTING OF EQUIPMENT FOR PRACTICE ....................................................................................................... 3-4

3-3.1 MEASURING PUMP PERFORMANCE ..................................................................................................... 3-53-3.2 ACCEPTANCE TESTS .......................................................................................................................... 3-53-3.3 ENGINES ........................................................................................................................................... 3-5

TABLE OF CONTENTS

ii / PUC Pumpers © 2014 Pierce Manufacturing Inc. All Rights Reserved.

3-4 EFFECTS OF ATMOSPHERIC CONDITIONS ON ENGINE AND PUMP PERFORMANCE .......................................... 3-6

3-5 OPERATING CHARACTERISTICS OF PUMPS .................................................................................................... 3-6

SECTION 4. OPERATION

4-1 APPROACHING THE APPARATUS .................................................................................................................... 4-1

4-1.1 STEPPING AND WALKING SURFACES ................................................................................................... 4-14-1.2 COMPARTMENT DOORS ...................................................................................................................... 4-24-1.3 HOSE BED COVERS ........................................................................................................................... 4-24-1.4 FOLDING STEPS OR PLATFORMS ........................................................................................................ 4-2

4-2 HOSE ........................................................................................................................................................... 4-3

4-2.1 HOSE STORAGE ................................................................................................................................. 4-34-2.2 HOSE RESTRAINT .............................................................................................................................. 4-34-2.3 HOSE CHUTES ................................................................................................................................... 4-34-2.4 HOSE BEDS ....................................................................................................................................... 4-44-2.5 HOSE DEPLOYMENT ........................................................................................................................... 4-44-2.6 HOSE CONNECTIONS ......................................................................................................................... 4-5

4-3 POSITIONING THE APPARATUS ...................................................................................................................... 4-6

4-3.1 FIRE SCENE POSITIONING .................................................................................................................. 4-64-3.2 POSITIONING ON ROADS .................................................................................................................... 4-64-3.3 LIGHTING ........................................................................................................................................... 4-64-3.4 CHOCK THE WHEELS ......................................................................................................................... 4-6

4-4 OPERATION OF PUC FIRE PUMP ................................................................................................................... 4-7

4-4.1 OPERATION OF PUMP ......................................................................................................................... 4-74-4.2 TO ENGAGE THE PUMP—STATIONARY OPERATION ............................................................................ 4-74-4.3 ENGAGING PUMP WHEN VEHICLE IS DRIVING – BASIC PACKAGE (STANDARD) ...................................... 4-84-4.4 ENGAGING PUMP WHEN VEHICLE IS DRIVING – ADVANCED PACKAGE (OPTIONAL) ................................ 4-94-4.5 SUPPLY WATER TO PUMP ................................................................................................................ 4-10

4-5 MANUAL PUMP ENGAGEMENT ..................................................................................................................... 4-13

4-6 ADJUSTING THE PUMP PRESSURE ............................................................................................................... 4-13

4-6.1 DETERMINE DISCHARGE PRESSURE ................................................................................................. 4-134-6.2 ENGINE SPEED AND PUMP PRESSURE .............................................................................................. 4-144-6.3 CONTROLLING ENGINE SPEED, PUMPING—PRESSURE GOVERNOR OPERATION ................................. 4-144-6.4 CONTROLLING ENGINE SPEED, NOT PUMPING—PRESSURE GOVERNOR OPERATION .......................... 4-144-6.5 CONTROLLING ENGINE SPEED WITH MULTIPLE CONTROLS ................................................................ 4-15

4-7 DISCHARGING WATER ................................................................................................................................. 4-15

4-7.1 CONNECTING ATTACK LINE HOSE ..................................................................................................... 4-154-7.2 CHARGING LINE ............................................................................................................................... 4-17

4-8 DISCHARGING FOAM ................................................................................................................................... 4-18

4-9 CHANGING FROM TANK TO EXTERNAL PRESSURIZED WATER SUPPLY (WITH GATED INTAKE VALVE) ............ 4-18

4-9.1 CONNECT INTAKE HOSE ................................................................................................................... 4-194-9.2 CHARGE THE INTAKE LINE (PRESSURIZED SUPPLY) ........................................................................... 4-204-9.3 SUPPLY THE PUMP .......................................................................................................................... 4-21

© 2014 Pierce Manufacturing Inc. All Rights Reserved. PUC Pumpers / iii

TABLE OF CONTENTS

4-10 PUMP PRIMING PROBLEM SOLUTIONS ........................................................................................................ 4-21

4-10.1 CONTROL VALVES THAT LEAK ......................................................................................................... 4-21

4-11 MONITORING INTAKE PRESSURE ................................................................................................................ 4-21

4-12 REFILLING THE TANK ................................................................................................................................. 4-23

4-13 CHANGING FROM TANK TO EXTERNAL WATER SUPPLY (WITHOUT GATED INTAKE VALVE) ........................... 4-23

4-13.1 STOP FLOWING WATER ................................................................................................................... 4-234-13.2 IF YOU ARE CONNECTING TO A PRESSURIZED SUPPLY, CHARGE INTAKE LINE: ..................................... 4-244-13.3 RESUME DISCHARGE OPERATION .................................................................................................... 4-24

4-14 ENGINE STATUS DISPLAY .......................................................................................................................... 4-24

4-15 ENDING WATER FLOW OPERATION ............................................................................................................ 4-25

4-15.1 SHUTTING OFF WATER FLOW .......................................................................................................... 4-254-15.2 DISENGAGING THE PUMP ................................................................................................................. 4-254-15.3 DISENGAGING THE PUMP (STATIONARY OPERATION) ........................................................................ 4-264-15.4 DISENGAGING THE PUMP (PUMP AND ROLL) .................................................................................... 4-264-15.5 SECURING PUMP SYSTEM ............................................................................................................... 4-26

4-16 OPERATING FROM A STATIC (DRAFT) WATER SUPPLY ................................................................................ 4-27

SECTION 5. MAINTENANCE

5-1 INSPECTION, CLEANING, AND MAINTENANCE ................................................................................................ 5-1

5-1.1 MAINTENANCE SCHEDULE ................................................................................................................. 5-1

5-2 DRAINING THE PUMPING SYSTEM ................................................................................................................. 5-1

5-3 FLUSHING THE DRAIN VALVES ..................................................................................................................... 5-2

5-3.1 FORWARD FLUSHING ......................................................................................................................... 5-25-3.2 BACK FLUSHING ................................................................................................................................ 5-3

5-4 FLUSHING AND DRAINING THE PUMP ............................................................................................................ 5-4

5-5 PUMP STORAGE .......................................................................................................................................... 5-4

5-6 PREVENTIVE MAINTENANCE CHECKS & SERVICES ........................................................................................ 5-4

5-7 PRIMER PUMP LUBRICATION ........................................................................................................................ 5-5

5-8 INTAKE & DISCHARGE RELIEF VALVE DRAINS (OPTIONAL) ........................................................................... 5-6

5-9 MASTER GAUGE PORTS ............................................................................................................................... 5-6

5-10 PUMP TRANSMISSION LUBRICATION ............................................................................................................. 5-7

5-11 ANODE RODS (OPTIONAL) ......................................................................................................................... 5-11

5-12 MECHANICAL SHAFT SEAL ......................................................................................................................... 5-12

5-12.1 MECHANICAL SEAL BASICS .............................................................................................................. 5-125-12.2 MECHANICAL SEAL OPERATION AND MAINTENANCE ......................................................................... 5-12

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5-13 ANNUAL TESTING ....................................................................................................................................... 5-13

SECTION 6. REFERENCE TABLES

6-1 CONVERSION FACTORS ................................................................................................................................. 6-1

6-2 PUMP TESTS ................................................................................................................................................ 6-2

6-3 SMOOTH BORE NOZZLE DISCHARGE ............................................................................................................. 6-4

6-4 VARIOUS NOZZLES DISCHARGE ..................................................................................................................... 6-6

6-5 NOZZLE PRESSURE ...................................................................................................................................... 6-7

6-6 VERTICAL AND HORIZONTAL NOZZLE REACH ................................................................................................. 6-8

6-7 FRICTION LOSS ............................................................................................................................................. 6-9

6-8 FITTINGS RESISTANCE ................................................................................................................................ 6-11

6-9 PSI TO ELEVATION CONVERSION ................................................................................................................ 6-11

6-10 SCREW THREAD ......................................................................................................................................... 6-12

© 2014 Pierce Manufacturing Inc. All Rights Reserved. PUC Pumpers / 1-1

SECTION 1 TO THE OWNER

1-1. Who Should Use, Service and Maintain This Vehicle

This manual explains the operation of a Pierce® fire apparatus equipped with a Pierce Ultimate Configuration (PUC) water pump. The manual reviews basic principles of operation, highlights common safety concerns and procedures, and gives recommendations for using the pump. This manual assumes that you are a pump operator and that:• You have already been fully trained and certified to operate a pump.• You have had formal education from a technical college or other fire fighter training institution.• You understand, are proficient in, and meet all of the requirements set forth in NFPA 1002 Standard on Fire

Apparatus Driver/Operator Professional Qualifications (latest edition).• You already understand water pump operation.All Pierce vehicles are delivered with a set of manuals for major components that your fire department selected. If you need replacement manuals, or safety warning labels, contact Pierce customer service at 888-Y-PIERCE (888-974-3723).BEFORE operating the pumping system, you, the operator, must read, understand, and follow the instructions found in:• Pump manufacturer's operator and maintenance manuals.• Operator and maintenance manuals for pumping components, such as valves, pressure controllers, flow

controls, manual overrides, foam systems, and primer pumps.• IFSTA Pumping Apparatus Driver/Operator Handbook (latest edition).

1-2. What To Do If You Lack Knowledge

Pump control systems require you to understand the function of each valve, each switch, each gauge, each Emergency Stop, and each manual override.Before your fire department allows you to operate this pump, you already must be educated, trained, and have passed a test for pump logic and operations.You also must know the principles of operation, so you can change operation when circumstances change.Each valve, switch, or gauge has an important function. If you are uncertain about the function or don't know something, inform your fire department's training officer. You are always welcome to call Pierce Customer Service at 888-Y-PIERCE (888-974-3723) with questions.You are the only person who knows what you don't know. You must speak up about the things you don't know, so you can learn about them before someone is injured or killed because of your lack of knowledge.You are responsible for learning how to operate the pumper under all conditions without having to read this manual at a fire or other emergency.

TO THE OWNER

1-2 / PUC Pumpers © 2014 Pierce Manufacturing Inc. All Rights Reserved.

1-3. Cautions, Warnings and Dangers

1-3.1 Safety Warning LabelsThroughout this manual, you will find Caution, Warning and Danger signals. Walk around the apparatus. Find each Safety Warning Label. Read the label. Identify and pay attention to the hazard it describes. Practice all the time to avoid the hazard, so you develop a habit to avoid the hazard:

DANGER signals an imminently hazardous situation that, if not avoided, will result in death or serious injury.

WARNING signals a potentially hazardous situation that, if not avoided, could result in death or serious injury.

CAUTION with the safety triangle signals a potentially hazardous situation that, if not avoided, might result in minor or moderate injury.

CAUTION used without the safety triangle symbol signals a potentially hazardous situation that, if not avoided, might result in property damage.


TO THE OWNER

1-4. Safety

1-4.1 Power Take-Off (PTO) Safety InformationThe PUC transmission includes a standard SAE 6-bolt PTO opening and drive gear allowing for the adaptation of an auxiliary PTO drive. The following safety instructions are intended for those applications to which an optional PTO has been installed. These instructions are for your safety. Read them carefully until you understand them.

1-4.2 General Safety Information

1-4.2a To prevent injury to yourself and/or damage to the equipment• Read carefully all owner’s manuals, service manuals, and/or other instructions.• Always follow proper procedures, and use proper tools and safety equipment.• Be sure to receive proper training.• Never work alone while under a vehicle or while repairing or maintaining equipment.• Always use proper components in applications for which they are approved.• Be sure to assemble components properly.• Never use worn-out or damaged components.• Always block any raised or moving device that may injure a person working on or under a vehicle.• Never operate the controls of the Power Take-Off (PTO) or other driven equipment from any position that could

result in getting caught in the moving machinery.

Open and close valves slowlyBe prepared for high nozzle reactions – open nozzle slowly

Do not exceed system rated pressure, capacity or speed. Observe local regulations on the use of hearing protection. Use only hoses with pressure ratings higher than their intended use. Remove all pressure from hoses before disconnecting. Shutdown and drain completely before attempting maintenance.

TO THE OWNER


1-4.2b Cold Weather Operation of Powershift Power Take-Off (PTO)

Your PUC pump is equipped with a powershift PTO. During extreme cold weather operation [32° F (0° C) and lower], a disengaged Powershift Power Take-Off (PTO) can momentarily transmit high torque that will cause unexpected output shaft rotation. This is caused by the high viscosity of the transmission oil when it is extremely cold. As slippage occurs between the PTO clutch plates, the oil will rapidly heat up and the viscous drag will quickly decrease.The PTO output shaft rotation could cause unexpected movement of the driven equipment resulting in serious personal injury, death, or equipment damage.Allow engine and transmission to warm up before engaging pump.

1-4.2c Rotating Auxiliary Driveshafts

1-5. Responsibility

Study carefully this manual and the manuals for major components such as pump, engine, and other allied equipment. Make sure that all operators and other users also completely understand their contents.The warnings, cautions, and procedures listed in these manuals must be part of the fire department's safety program.As the operator of this vehicle and pumping equipment, you are responsible for:• Understanding the function of each component of the pumping system.• Understanding how to adjust each control to obtain the results you want.• Maintaining control of the pumping system at all times.

• Spinning shaft hazard.• PTO shaft may rotate unexpectedly in cold weather.• Keep body, hands, hair, and clothes away.• Do not work around shafts with engine on.• Rotating parts will injure or kill.

• Rotating auxiliary driveshafts are dangerous. They can snag clothes, skin, hair, hands, etc. This can cause serious injury or death.

• Do not go under the vehicle when the engine is running.• Do not work on or near an exposed shaft when the engine is running.• Shut off the engine before working on the Power Take-Off (PTO) or driven equipment.• Rotating parts will injure or kill.


TO THE OWNER

• Remaining proficient in use, so at a fire you can operate and make successful changes in the operation quickly, without having to read the operator's instructions or safety warning labels.

• Practicing proper manual override and emergency shutdown procedures, so you can respond immediately in an emergency or during the failure of a component. Remember stress is high. Your failure to practice increases the odds you will forget or do it wrong in the heat of the moment.

1-6. Daily Checks

At start of shift, follow your department's apparatus check.It is critically important that you turn each control—valve, gate, or switch, etc.—ON and OFF or OPEN and CLOSED. You want to make sure they work now. You don't want to find out at a fire.ALWAYS check the controls you rarely use. That also reminds you of their location and their function.If you find a control whose function you do not know, then right away find out what it does. Every control serves a purpose. You must know the purpose and how to use the control.Pierce Customer Service is always available to help you and answer your questions. Call 888-Y-PIERCE (888-974-3723).

1-7. Custom Products

Your department developed specifications for this fire apparatus. It purchased a Pierce apparatus that is built to meet those specifications. The information in this manual will be generic at times. Due to the highly customized nature of each Pierce fire apparatus, the exact location of each component in the pumper system will vary. This manual describes basic controls. Not every apparatus will have all controls. Some will have extra controls, as determined by each fire department's specification.Pictures describe typical components or devices. Actual parts might vary from those pictured.You must learn the location and function of all controls, switches, gauges, valves, inlets, and discharges.Major inconsistencies between your vehicle and the information contained in this manual should be directed to your Pierce Dealer or Sales Representative.

1-8. Professional, Training, and Standards Organizations

To keep up-to-date on knowledge and new standards that affect all facets of fire fighting, make sure that you check these organizations' catalogues and websites each month:

National Fire Protection Association (for standards and requirements)One Batterymarch ParkP.O. Box 9101Quincy, MA 02269-9101617-770-3000www.nfpa.orgMake sure you read the latest editions.

TO THE OWNER


Pierce Manufacturing Inc.Customer Service2600 American DriveP.O. Box 2017Appleton, WI, 54913888-Y-PIERCE (888-974-3723)www.piercemfg.com and www.pierceparts.comInternational Fire Service Training Association (for textbooks and other training material)Fire Protection PublicationsOklahoma State University930 North WillisStillwater, OK 74079-8045800-654-4055www.ifsta.org

1-9. Safety Defect Reporting

If you believe your vehicle or any associated component might have a design defect that could result in failure or injury, please report this information immediately to Pierce Manufacturing. Additionally, should any information in this manual prove to be seriously inconsistent with your Pierce fire apparatus also inform Pierce Customer Service.Most service and support issues should be handled by the local Pierce dealer or sales representative. However, to report any design defects or request support directly from Pierce contact:

Customer ServicePierce Manufacturing, Inc.2600 American Drive, P.O. Box 2017Appleton, WI, 54913888-Y-PIERCE (888-974-3723)www.piercemfg.com

1-10. Keeping Your Knowledge Refreshed and Up-to-Date

This manual will be revised from time to time. Check the Pierce website, www.piercemfg.com, to stay current. Also review the latest edition of the IFSTA (www.ifsta.org) manual Pumping Apparatus Driver/Operator Handbook. Remember, if there's anything you don't understand, call Pierce Customer Service at 888-Y-PIERCE (888-974-3723).


SECTION 2 BEFORE PLACING IN SERVICE

2-1. Create a Pump Chart

Use a Pump Chart to determine the pump discharge pressure that will provide desired nozzle pressure for various hose lay configurations and combinations.The IFSTA Pumping Apparatus Driver/Operator Handbook tells how to develop a pump chart. Develop the chart for all situations.Make sure this chart is always available during pump operation.

2-2. Check Adjustment of Intake Relief Valve

Figure 2-1: Typical Intake Relief Valve

POM0016

All pumps have a relief valve on the intake side (Figure 2-1). It prevents a pressure spike in intake water from passing to hoses through the discharge side of the pump.The intake relief valve is a pressure regulator. If intake pressure goes over the pressure setting, the valve opens and allows water to flow out the relief outlet.Some departments choose to connect a hose to the relief valve outlet to direct the water discharge away from the apparatus. Pressure surges in this hose can occur without warning.

To adjust this valve for desired pressure, the intake pressure to the pump must be higher than the normal static pressure of the municipal water supply. The best method to adjust the valve is to use another pumper to supply water at the desired pressure. 1. Increase inlet pressure until the master inlet pressure gauge reads the relief pressure you want.2. With a wrench, slowly open the adjusting screw on the valve until water starts to flow from the valve outlet.

Secure unattended hoses.Water discharged from hose will cause hose to whip violently.Whipping hose can injure or kill.

BEFORE PLACING IN SERVICE


3. Slowly close the adjusting screw until the water stops flowing.Read the valve manufacturer's documentation for complete instructions.


SECTION 3 GENERAL

3-1. Description of Pierce Ultimate Configuration (PUC) Pump

The PUC pump is a high speed, single stage, UL rated, centrifugal Fire Fighting Pump.Inherent characteristics of the PUC are compactness, lightweight, high efficiency, and a wide range of pumping capabilities. The PUC pump is midship mounted rearward of the chassis engine and powered via the Rear Engine Power Take-Off (REPTO).

3-2. General Operation

3-2.1 DefinitionsHEAD OF WATER: vertical depth of water measured in feet or in pressure per unit or area. In hydraulics, head always represents pressure and it is expressed interchangeably in feet of water or pounds per square inch and sometimes in inches of depth of mercury.STATIC HEAD: the pressure that is exerted by a stationary column of water of a given height or depth.TOTAL HEAD OR TOTAL DYNAMIC HEAD: the maximum height above the source of supply to which the pump would elevate the water plus all the resistance to flow in the pipe or hose line.DISCHARGE HEAD: the pressure measured at the discharge outlet of a pump.SUCTION HEAD: the positive pressure measured at the suction entrance of a pump (when pumping from an elevated tank or hydrant).VELOCITY HEAD: the equivalent pressure represented by fluid in motion as measured by means of a Pitot gauge.STATIC LIFT: the vertical height of the center of the pump above the source of supply (when pump from draft).TOTAL SUCTION LIFT: the static lift plus the friction in suction line plus entrance losses.NET PUMP PRESSURE: the total dynamic head of the pump.EFFECTIVE NOZZLE PRESSURE: the pump discharge pressure minus hose friction plus or minus the difference in elevation above or below pump.WATER HORSEPOWER: the theoretical power required to deliver a given quantity of water per minute against a given head.BRAKE HORSEPOWER: Actual power as delivered by a motor or engine to a driven machine.PUMP EFFICIENCY: The quotient of the water horsepower divided by brake horsepower required to produce it.WATER HAMMER: a series of shock waves produced in a pipeline or pump by a sudden change in water velocity. A sudden change in flow velocity can result from rapid closure of valves. A pressure wave is set up which travels back and forth in the water column at extremely high speed producing rapid vibrations that may be violent and destructive if the water column is long.The MAXIMUM THEORETICAL LIFT of a pump is 34 feet, which is the pressure of the atmosphere at sea level. The maximum practical total lift at sea level is 20 to 25 feet (depending on the type and condition of the pump) and this decreases with drops in barometric pressure.

GENERAL


3-2.2 Operating The EngineAfter the pump has been primed, the engine speed should be increased gradually; never jerk throttle wide open. Likewise, the engine speed should be decreased gradually when shutting down.Watch the pump pressure gauge and open throttle only enough to give the desired pressure. The pressure may rise high enough to burst the discharge hose, when using small nozzles, if the engine is given full throttle (except pumps equipped with pressure regulators set for desired pressure).Never run engine at high speeds except when pump is primed and ready to discharge water.

3-2.3 Cooling The EngineNFPA 1901 requires that a supplementary heat exchanger cooling system be provided. This heat exchanger is an integral part of the pump, and the installation of two hoses from the engine cooling system to the pump is all that is required. Valves or other shut offs are integral to the engine.The pump should never be operated under prolonged heavy loads without an adequate supply of cooling water flowing.Coolant temperatures should never be allowed to exceed 225° F while pumping and 180° F is usually taken as a safe operating temperature.

3-2.4 Suction StrainersA large suction strainer, which will prevent the passage of a body larger than the pump impeller ports, must always be used on the free end of the suction line when pumping from draft.The small hydrant strainer must always be inserted in the suction manifold of pump, when pumping from hydrants and at all other times except when maximum capacity is required from draft.Failure to use a strainer at all times when pumping will cause serious trouble by clogging the pump because, even in water mains, foreign matter is invariably present, and will be drawn into pump by the high velocity of the water entering.

3-2.5 Suction LineThe suction line of a fire pump can be the source of more operating difficulties than all the rest of the pump when working with a suction lift. Faults in the suction line which cause trouble in operation are as follows:1. AIR LEAKS: A small amount of air, expanding in the vacuum of the suction line, displaces a considerable

volume of water which subtracts from the capacity that the pump is able to deliver, makes the priming difficult or causes pump to lose its prime. Therefore, it is absolutely essential to keep the suction line and the suction side of pump casing air tight at all times when drafting water.Air leakage into pump while operating is usually indicated by a rattling sound in pump casing, miniature explosions in stream issuing from the nozzle, or by losing of prime when operating at very low capacities.The usual cause of leaky suction lines is carelessness in handling of suction hose. Bruising of hose threads by bumping against hard surfaces or sand in the coupling often prevents tightening of the joints up against the gaskets. The hose gaskets are often defective and are sometimes lost without being noticed by the operator.

2. INSUFFICIENT SUBMERGENCE: The free end of suction hose must be submerged to a sufficient depth to prevent the entrance of air that may be sucked down from the surface of the water to a considerable depth when operating at large capacities.Entrance of air into suction lines in this manner is indicated by a small whirlpool, or vortex, on the surface of the water over the end of the hose.A minimum submergence of 4 times the hose diameter to the upper holes in suction strainer is recommended where full capacity of pump is required. Where sufficient submergence is not possible, a board or sheet of metal laid over end of suction line will keep air from entering.


GENERAL

3. SUCTION LINE ENTRANCE TOO CLOSE TO BOTTOM: If the end of suction line is laid on the bottom of the source of supply, a part of the suction opening will be shut off; and if the bottom is soft the hose will suck itself down into the earth, closing more of the opening and loosening sand and mud to be carried into the pump.The suction entrance should be suspended a foot or more above the bottom, or if this is not possible, it should be laid on a board or piece of sheet metal. A rope tied to the suction strainer is a convenient means of holding it off the bottom.

4. OBSTRUCTION OF SUCTION STRAINER BY FOREIGN MATTER: The high velocity of water entering the suction line will carry loose foreign bodies in against the strainer from a considerable distance. Therefore, all weeds and refuse should be removed from close proximity of the suction entrance.

5. SUCTION LINE TOO SMALL OR TOO LONG: The flow of water into the pump is opposed by the frictional resistance in the suction line. This friction loss must be added to the height of the pump above the water (static lift) to determine the “total lift” of the pump. When all of the vacuum in the pump (atmospheric pressure) is consumed in raising water through this total life, then the limit of capacity has been reached. This capacity can be increased only by decreasing total lift. If the static lift cannot be reduced, then the friction loss must be reduced by using a shorter or larger suction hose.The rated capacity of the pump is guaranteed for a static lift of 10 feet, with 20 feet of recommended suction hose at sea level. To increase the capacity without reducing the static lift, or to increase lift without sacrificing capacity, requires larger suction hose.An excessively long suction line is a handicap to any pump, for besides reducing capacity through the added friction loss, it retards priming and it produces a detrimental effect known as “cavitation”. This means a separation of the water column in the pump suction, or void spaces, produced by the inertia of the heavy mass of water in the line resisting sudden change in the velocity when the pump starts to deliver or when discharge valves are opened or closed. This phenomenon reduces capacity further, and usually sets up a vibratory motion and “water hammer” as the water surges in and out of the void spaces.When operating with a long suction line, the driving engine should be accelerated gradually, the discharge gates opened gradually, and the capacities of the pump should be held down to within the range of smooth performance.

6. AIR TRAP IN SUCTION LINE: If the suction line is laid so that part of it is higher than any other part that is nearer to the pump, as when hose is laid over a high bridge rail, an air trap is formed at the highest part of the hose from which the air cannot be sucked out by the primer. This trapped air is expanded and carried into the pump with the first rush of water causing the pump to immediately lose its prime.If suction line cannot be laid so that it slopes all the way from pump to water, it can still be primed easily by simply allowing the primer to continue to function until all the trapped air in the hose has been carried into the pump and picked up by the primer.

3-2.6 Testing For Air LeaksTests for leakage should be made with the suction hose attached and capped, discharge gate open, and all other openings closed tightly.Run electric priming pump with primer shut-off valve open, until maximum vacuum is shown on the gauge. The vacuum should hold for several minutes before satisfactory performance of pump can be expected.If excessive leakage of air occurs, the source of leaks can be located by shutting off primer motor, with vacuum at its highest point, and listening for the hiss of air.In the absence of a vacuum gauge, the vacuum in pump may be judged by closing suction opening with the flat of hand or a rubber pad.Water or air pressure may be applied to pump casing to test for air leakage if more convenient. Do not pressurize with air beyond 10 PSI.

GENERAL


3-2.7 Source Of Water SupplyWater may be drafted from a pond, lake, stream, cistern, stock tank, or well; but whatever the source, the static lift must not exceed 20 feet from the center of the pump to the surface of the water and a lift not exceeding 10 feet is recommended. The source of supply should be reasonably clear and free from foreign matter. It is recommended that all water holes, which may be needed for fire protection, be deepened if necessary and kept free from weeds and refuse. In many fire protection areas, cisterns or reservoirs are built and allowed to fill up with rain water to be used in emergencies.

3-2.8 Pumping In Cold WeatherThe first insurance against cold weather trouble is to keep fire apparatus stored in heated quarters. All water must be eliminated from pump casing and primer line between periods of operations.When setting up for pumping, unnecessary delays should be avoided by having thoroughly trained pump operators. Be sure that primer and booster lines are kept closed until ready for use. Having discharge lines ready so that pump may be started as soon as it has become primed. Do not stop flow of water through the pump until ready to drain and return to the station.Engine coolant from the engine circulated through the heater jacket in pump casing helps prevent ordinary freezing troubles.

3-2.9 When Finished PumpingDrain water out of system by opening all valves, caps and drains, excluding the Tank to Pump Valve and the Tank Fill Valve.Don’t forget to close all drain cocks after all water has been drained out. Trouble in priming will follow on the next run if this is forgotten.Shut off cooling line to make pump ready for priming again.Pumps not often used for fire service should be inspected and run periodically to ensure that they will be in readiness for an emergency.

3-2.10 Pumping Salt WaterThe pump should be flushed out with fresh water immediately after pumping salt water to prevent excessive rusting. (Except pumps which are built of special material to resist the corrosive action of the brine.)When measuring sea water with a pitot gauge, capacities shown in Table 6-2 should be discounted approximately 1 1/2% to determine the correct capacity.A centrifugal pump will show 2 1/2% higher pressure and require 2 1/2% more power when handling sea water than when handling fresh water if operated at the same speed and capacity.

3-3. Testing Of Equipment For Practice

It frequently happens that operators of fire apparatus, who are not thoroughly familiar with its operations, become confused under the stress of emergency and neglect some little detail that may cause trouble or delay in getting the equipment into operation. Therefore, we urge that practice tests be conducted repeatedly until operators are thoroughly trained. More than one person in the department should be a competent operator.Practice should include pumping from low lifts, high lifts with short and long suction lines, with suction line elevated to form an air trap, and from hydrants, at large and small capacities.It is well, also, to note the effects of air leaks in hose, insufficient submergence and restriction of suction line. (Suction line can be restricted by placing a can or other strong closure around the suction strainer).


GENERAL

3-3.1 Measuring Pump PerformancePump performance is measured by the quantity of water it can deliver per minute against a certain pressure called “Total Head” or “Net Pump Pressure”, as it is usually termed in fire pump testing.The net pump pressure is the sum of the pump discharge pressure, as shown on the pressure gauge with which the pump is regularly equipped, and the total suction lift converted to equivalent pounds per square inch. If pump is operating from a hydrant, the net pump pressure is the discharge pressure less the incoming pressure from hydrant measured at the suction entrance of pump.Capacity of fire pump is measured in gallons per minute. The usual method of measurement is to determine the pressure of the jet of water leaving a given size of nozzle by means of a Pitot gauge from which the capacity is computed mathematically.A Pitot gauge consists of a small tube adapted to a point directly into the hose nozzle from the center of the issuing stream, the other end of the tube being connected to an accurate pressure gauge.The nozzle jet drives straight into the Pitot tube and converts the velocity of the jet to pressure which is an accurate measure of velocity of the water as it leaves the nozzle. The tip of the Pitot tube should be one-half the diameter of the nozzle away from nozzle tip while taking reading. Table 6-2 gives nozzle capacities for various Pitot gauge readings.If a Pitot gauge is not available, approximate pump capacities can be determined by referencing Table 6-3.

3-3.2 Acceptance TestsAcceptance tests require continuous tests of three hours duration: 2 hours at 100% rated capacity and 150 PSI net pump pressure; one-half hour at 70% capacity and 200 PSI; one-half hour at 50% capacity and 250 PSI; and a spurt test at 100% capacity and 165 PSI.Table 6-1 shows recommended set-ups and gauge readings for rating tests.To adjust nozzle pressure for the correct capacity, while maintaining the correct pump pressure, it is necessary to make simultaneous adjustments of engine throttle and the discharge gate valve, partially closing the latter until just the right discharge resistance is built up.

3-3.3 EnginesAn Underwriter fire pump imposes heavy loads on the engine that drives it, often absorbing all of the power the engine is capable of delivering at full throttle. Continuous pumping gives the engine no time to rest. Therefore, a new engine and pump unit must be thoroughly broken-in before it is required to deliver prolonged maximum pump performance.We recommend a minimum break in period of 20 hours at light pumping loads, with occasional spurt tests and interruptions. Temperature and lubrication should be checked during this period.

Do not allow personnel to hold a large nozzle while working at high pressures for serious accidents may result if hose breaks loose.

NEVER BREAK OR RESTRICT SUCTION OR ALLOW AIR TO ENTER SUCTION LINE WHILE ENGINE IS OPERATING WITH THROTTLE OPEN. This will release the load and allow engine to run away.

GENERAL


Engine manufacturers’ power ratings usually show maximum performance of a selected, factory adjusted engine, operating without fan, generator, muffler or other accessories, and corrected for “ideal” conditions, i.e. sea level barometer (29.92” of mercury) 60° F and high humidity. Therefore, the actual power delivered by an average truck mounted engine is considerably lower than the manufacturers’ rating, and allowances must be made in predicting pump performance.

3-4. Effects Of Atmospheric Conditions On Engine And Pump Performance

Each one inch of drop in Barometric pressure or each 1000 feet of elevation of the pumping site reduces engine power approximately 3 1/2% for engines not equipped with a turbo charger.Each 12° rise in temperature above 60° F of carburetor intake air reduces engine power approximately 1%.Lowering of humidity reduces power slightly.Each one inch drop in Barometric pressure or each 1000 feet of elevation reduces the maximum possible static lift of a pump approximately one foot.Temperature of the water supply affects the attainable suction lift of a pump. The effect is slight at low water temperatures but becomes increasingly detrimental as the temperature rises.A 10° rise from 70° F will subtract about 1/2 foot from the maximum attainable suction lift, while an equal rise from 100° F will reduce the lift at least 1 1/2 feet.Temperature is an important consideration when pumping from a test pit where the water is heated by recirculation.

3-5. Operating Characteristics Of Pumps

CENTRIFUGAL PUMPS: A centrifugal pump develops pressure by centrifugal force of the liquid rotating in the impeller wheel. The pressure developed depends upon the peripheral speed of the impeller (increasing as the square of the speed) and it remains fairly constant over a wide range of capacities up to the maximum output of the pump, if speed remains constant.If the discharge outlet of a centrifugal pump is entirely shut off, with speed kept constant, there is a small rise in pressure, the water churns in the pump casing and the power drops to a low value. If the discharge is opened wide, with little resistance to flow the pressure drops while the capacity and power both increase to their maximum.A centrifugal pump is an extremely simple mechanism mechanically, but rather complex hydraulically; in that many factors enter into the design of the impeller and water ways which will affect the pump’s efficiency.DISPLACEMENT PUMPS: Rotary and piston pumps are termed “Positive Displacement” pumps because each revolution displaces or discharge (theoretically) an exact amount of liquid, regardless of the resistance. The capacity is, therefore, proportional to the number of revolutions of the pump per minute and independent of the discharge pressure except as it is reduced by “slip” (leakage past the pistons or rotors). For a given speed the power is directly proportional to the head. If the discharge is completely shut off, the pressure, power, and torque climb indefinitely until the drive power is stalled or breakage occurs.Slip is the greatest factor affecting efficiency of a displacement pump, and this factor is greatly influenced by the condition of and wear on the working parts.


SECTION 4 OPERATION

4-1. Approaching the Apparatus

4-1.1 Stepping and Walking Surfaces

All surfaces intended for stepping or walking are designed or treated with slip-resistant material your department specified. NEVER step or walk on surfaces not designed for stepping or walking, such as:• Chromed surfaces or objects• Painted surfaces• Hose rollers• Compartment doors or hatches• Valves• Controls• Inlet or Outlet Connections

ALWAYS be careful when climbing up or down to avoid a slip and fall, and potential injury to yourself and others.Enter and exit cabs slowly, deliberately, and carefully.NEVER jump to ground. You can injure yourself.

ALWAYS maintain three points of contact when climbing up or down.Keep contact with one hand and two feet, or two hands and one foot.Use steps, hand-holds, or sturdy features on the apparatus.ONLY grasp or step on items appropriate for climbing on or firmly attached objects.

Keep steps and hand-holds in good repair, and free of grease, mud, dirt, fuel, ice, and snow.Make sure all attaching bolts and hardware are tight, thus eliminating any movement of steps and hand-holds.

NEVER step or climb on any vehicle surface unless it is slip-resistant and hand-holds are provided.Replace slip-resistant material when worn.

OPERATION


4-1.2 Compartment Doors

Always close swing-up or swing-out compartment doors. People can walk into doors left open at lower levels.Personnel working on top of the apparatus can mistake an open horizontal door for a walking surface.

4-1.3 Hose Bed Covers

Some apparatus are equipped with aluminum hose bed covers. Always close after use. They protect hose from sun and weather. Hose bed covers are heavy. They might require two or more people to open or close safely.

4-1.4 Folding Steps or Platforms

Before beginning pump operations, make sure that folding steps or platforms are DOWN and firmly engaged in their weight-bearing position.When operating the pump on an aerial apparatus, always stand with both feet on the operator's platform and off the ground.Your body will become an electrical path to ground if you stand with one foot on the platform and one on the ground, or with both feet on the ground and your hands on the apparatus. If the aerial device contacts or comes close to high voltage power lines, electricity can shoot through you. You can die.

NEVER step on open compartment doors.They do not support your weight.Falls can cause serious injury or death.

CLOSE hose covers after use.Hose bed covers can cause serious injury if blown shut by wind.Keep personnel clear of open hose bed covers during windy conditions.

High voltage electricity can travel down a water stream.NEVER spray through electric wires.High voltage can cause death or serious injury.

Keep OFF the ground when operating an aerial device.ALWAYS stand with both feet on the pump operator's platform of an aerial device.High voltage can jump gaps between wires and apparatus.Electrical power will pass through people who stand on the ground and touch the apparatus.Electrical power lines can cause death or serious injury.


OPERATION

4-2. Hose

4-2.1 Hose StorageThe hose is stored in:• Body Compartments• Bumper Compartments• Cross-Lay Trays• Speed-Lay Trays• Hose Beds• Reels• Hose ChutesEvaluate each way of storing hose. Determine the most efficient and safest way to pack hose for your fire department's use.

4-2.2 Hose Restraint

This vehicle may be provided with a means to store water hose. Anytime hose is stored on this vehicle it must be restrained to ensure that it does not fall out of its storage area while the vehicle is in motion. NFPA standards state that “any hose storage area shall be equipped with a positive means to prevent unintentional deployment of the hose from the top, sides, front, and rear of the hose storage area while the apparatus is underway in normal operations.”Fire departments and manufacturers have developed various methods of preventing inadvertent deployment, including fully enclosed hose bed covers, buckled straps, hook-and-loop straps, fabric covers, webbing mesh, wind deflectors, and other material restraints or combination of restraints.Operational methods vary between fire departments, and methods of restraining the hose may vary as a result. Whether you use the hose restrain feature provided with your apparatus, or develop your own means, it is your responsibility to ensure that whatever method you employ will adequately restrain the hose in those working environment the apparatus will be exposed to. Always restrain the hose properly before placing the vehicle in motion.

4-2.3 Hose ChutesSome aerial apparatus have a hose “chute.” The chute guides the hose from the hose bed around the aerial turntable, then out the back of the vehicle.NEVER pack hose in the hose chute, because that can cause snagging and snarling.

Entanglement HazardSecure hose and other equipment before placing vehicle in motion.Loose hose may drag behind vehicle and injure or kill.

Hose restraints (nets, doors, webbing, ropes, etc.) must be used to secure the hoses after repacking. Failure to comply may result in hoses deploying while the vehicle is in motion, causing injury to bystanders and/or damage to equipment.

OPERATION


To avoid creating a jam of tangled hose in the hose chute:• Lay couplings so they are pulled out straight, without flipping around.• Lay hose so that it never crosses over itself when paying out.• Maintain vehicle speed of 5 MPH or less. At 5 MPH, seven feet of hose is pulled out each second. If you travel

more than 5 MPH, you are likely to cause a hose jam in the hose chute.

4-2.4 Hose Beds

Hose beds come in many shapes and sizes. Hose characteristics vary with the size, type, and age of the hose.Experiment with different methods of packing a specific hose, bed, and chute combination to determine a packing method that will lay out without snagging or snarling. Make sure you learn the maximum MPH at which hose can be laid out.

4-2.5 Hose Deployment

If hose is to be laid from a moving apparatus, first test the packing method under controlled conditions to learn the MPH at which hose will lay out smoothly, without snags or snarls.Any operation where people are working around a moving vehicle is dangerous. All occupants must be seated and belted while the vehicle is in motion. NEVER ride on rear steps or other areas outside the cab.

Pack hose carefully in any hose bed to minimize the risk of hose snags or snarls as it lays out.Hose that snags or snarls during layout from a moving vehicle can fly about, causing serious injury or death to bystanders.

NEVER ride on rear steps or other areas outside the cab.

Limit speed to 5 MPH when laying hose.

ALWAYS use a spotter when backing up.Keep the spotter and all other people clear of the vehicle's path.

All occupants MUST be seated and belted while vehicle is in motion.


OPERATION

When laying hose, an anchorman must protect himself from the dangers of flying hose. It is safest to use rope to tie the hose to the hydrant. In the absence of rope, anchor the hose by wrapping the end half way around the hydrant in a J-pattern only. Never wrap more than half way around the hydrant. Wedge the end fitting against the hydrant with a booted foot. Stand clear of the hose so that you will be away from the hose if it becomes taut and swings out from the hydrant. A snag in the hose bed can pull the hose loose. The metal fitting can swing around and break your leg.Keep people clear of the hose being laid before driving the vehicle.When laying hose, limit vehicle speed to 5 MPH to minimize risk to personnel, equipment, and bystanders.Avoid kinks, crimps, and twists when laying fire hose.

4-2.6 Hose Connections

Hose fittings are critical to safe delivery of water to a fire. Treat hose connections with care and inspect regularly.

Flying hose is extremely hazardous.Keep all people clear of hose being laid by a moving vehicle.Flying hose can injure or kill.

Fire hose under pressure can burst without warning.NEVER straddle or stand over a charged hose.Always wear complete protective gear, even when testing.Burst hose can injure or kill.

Hose fittings can fail without warning.Inspect hose fittings for cracks, chips or other damage and replace when worn or damaged.Damaged or worn fittings can burst without warning.Burst fittings can injure or kill.

OPERATION


4-3. Positioning the Apparatus

4-3.1 Fire Scene Positioning

Heat from a fire can damage electrical systems, rubber seals and gaskets, and plastic components. Always place apparatus upwind from the fire and at a safe distance away from flames. Diesel engines consume as much as 1200 cubic feet of clean air every minute. Hot embers sucked into the air intake can cause the air cleaner element to ignite. Although Pierce Custom Chassis are equipped with ember barriers composed of mesh screens or perforated metal, they are not a foolproof guarantee of protection.Always leave a way out. Always position the apparatus in a location that allows a quick retreat if conditions change.Always park upwind of the fire. Never park the apparatus downwind of the fire.Always avoid electrical lines. Never park under electrical lines.

4-3.2 Positioning on RoadsPosition the apparatus so that it protects emergency personnel. Many departments choose to park the apparatus at an angle so that personnel can work behind the vehicle, out of the direct path of oncoming vehicles.Keep emergency response lighting ON to alert traffic.

4-3.3 LightingAs soon as possible, provide good lighting for people working on and around the apparatus. Use extendable lighting or lighting from another apparatus.Make sure that the pump operator can clearly observe controls, gauges, and hose connections, and can watch the condition of hoses and attack personnel to the greatest extent possible.

4-3.4 Chock the WheelsALWAYS place wheel chocks on both front and rear of tire when vehicle is parked.Chock wheels as soon as you exit the cab.

Operate apparatus away from burning embers that can be sucked into the air intake system.Burning embers in the engine air filter can cause engine fire.Engine fire can cause property damage, serious injury, or death.


OPERATION

4-4. Operation of PUC Fire Pump

4-4.1 Operation of Pump

A Rear Engine Power Take-off (REPTO) transmits power to the pump transmission input shaft whenever the chassis engine is operating. The fire pump impeller is engaged or disengaged through a high capacity, multi-plate, electric clutch. This configuration enables the pump transmission to power an auxiliary pump transmission mounted Power Take-off (PTO) independent of pump impeller engagement.

4-4.2 To Engage the Pump—Stationary Operation 1. Pull Parking Brake

Auto Neutral feature automatically engages transmission to NEUTRAL. If you fail to apply the parking brake, safety interlocks prevent operation of the hand throttle or pressure governor.

NOTE: If the parking brake is released during pump operation, the hand throttle or pressure governor is disconnected AND the engine speed falls to IDLE. Water pressure to the hose will drop. The pump speed will then be controlled only by the driver's throttle pedal. That is the manual override.

2. Observe the OK to Stationary Pump indicator lamp:The OK TO STATIONARY PUMP indicator light should be on when ever the parking brake is applied.

3. Chock the WheelsBlock both front and rear of tire using wheel chocks.

4. Engage the PumpConfirm engine is at idle rpm. Activate the WATER PUMP switch located on the driver's panel in the cab.

5. Observe the Pump Engaged indicator lamp:The WATER PUMP indicator light turn ON when: — Pump is engaged, AND — Pump is spinning.

Never run the pump dry except momentarily and at low speeds.Do not use this pump for hose testing.

Engage pump only at engine idle speed.Begin pumping water immediately after engaging pump.Circulate water if hoses are not ready to keep water cool.Running pump dry for more than a few minutes will cause damage.

OPERATION


4-4.3 Engaging Pump when Vehicle is Driving – Basic Package (Standard) The basic pump and roll mode will use the same operation sequence as stationary pumping mode with a few additional steps. After the vehicle is setup for stationary pumping, the operator will leave the cab and setup the pump panel to discharge at the desired outlet(s). Upon returning to the cab, the operator will disengage the parking brake. An “OK to Pump & Roll” indicator will illuminate on the cab switch panel. First gear on the transmission gear selector will be selected by the operator for pump and roll operations. The operator will apply the foot throttle and brake pedal as needed. Pump and roll mode will be maintained unless the transmission shifts out of first gear or the “Water Pump” switch is disengaged.

1. Stop Vehicle2. Pull Parking Brake

Auto Neutral feature automatically engages transmission to NEUTRAL.3. Engage the Pump

Figure 4-1: Water Pump & Foam System Control Switches (Basic Package)

1135

Confirm engine is at idle rpm. Activate the desired water pump or foam system control switch located on the driver's panel in the cab. Switches are multi-function; see See Table 4-1.

Pump-and-roll operation is dangerous.NEVER ride outside the cab when the vehicle is moving.Keep personnel walking to the side of the vehicle and in sight of driver at all times.Drive slowly. The foot throttle controls both the ground speed and pump pressure.



OPERATION

Table 4-1: Water Pump & Foam System Control Switches - Modes of Operation

*Optional

4. Observe Indicator LightThe PUMP ENGAGED indicator lights only when PTO has been engaged and the pump is spinning.

5. Provide Water Supply to PumpOperator must leave the cab and set up Pump at Pump Panel: — Open the Tank-to-Pump valve to provide water to the pump.— Open the Recirculating Valve (if applicable), or crack open the tank fill valve, to allow water to circulate.

6. Shift Transmission into 1st GearFor pump-and-roll operation the transmission must be in the 1st Gear (1) position.

7. Release Parking Brake8. Look at Indicator Light

The OK TO PUMP AND ROLL light turns ON when:— Parking Brake is released.

9. Use foot throttle and brake pedal as neededPump will maintain Pump and Roll mode unless transmission shifts out of 1st gear, OR WATER PUMP control switch is turned OFF.

4-4.4 Engaging Pump when Vehicle is Driving – Advanced Package (Optional)If pump and roll is desired by the operator, the operator will engage the “Pump & Roll” and “Water Pump” switches on the cab switch panel. The tank to pump valve and recirculation valve will open automatically with the pump and roll mode so the operator does not have to leave the cab. The foot throttle and brake pedal will be applied by the operator as needed. Pump and roll mode will be maintained unless the pump switch or pump & roll switch is disengaged.

Pressing this Control Switch: Turns these systems ON:

Water Pump Water PumpFoam System* Water Pump Foam SystemCAFS System* Water Pump Foam System CAFS System

Pressing this Control Switch: Turns these systems OFF:

CAFS System* CAFS SystemFoam System* CAFS System Foam SystemWater Pump CAFS System Foam System Water Pump

OPERATION


1. Press PUMP AND ROLL switch while approaching sceneValidate that OK TO PUMP AND ROLL light is ON. The Tank to Pump Valve and Recirculation Valve will automatically open. The engine speed will be limited to approximately 1200 RPM maximum.

2. Engage the PumpConfirm engine is at idle rpm. Activate the desired water pump or foam system control switch located on the driver's panel in the cab. Switches are multi-function; see See Table 4-1.

3. Observe Indicator LightThe PUMP ENGAGED indicator lights only when PTO has been engaged and the pump is spinning.

4. Use foot throttle and parking brake as neededPump will maintain Pump and Roll mode until vehicle is stopped and Parking brake is engaged.

4-4.5 Supply Water to Pump1. Open Tank-to-Pump Valve

Figure 4-2: Typical Tank-to-Pump Valves

1136

Pump-and-roll operation is dangerous.NEVER ride outside the cab when the vehicle is moving.Keep personnel walking to the side of the vehicle and in sight of driver at all times.Drive slowly.



OPERATION

The Tank-to-Pump valve (Figure 4-2) controls the flow between the water tank and pump inlet. With this valve OPEN, water from the tank floods the pump intake manifold and slowly primes the pump.

2. Open Primer ValveIf the pump is dry, engage primer to expel air in the pump to get prime.

3. Open Tank Fill or Recirculating Valve

Figure 4-3: Tank Fill or Recirculating Valve

1137

The Tank Fill valve (Figure 4-3) opens the connection from the discharge side of the pump to the water tank. Open Tank Fill Valve to refill the water tank from a water source that is connected to an intake fitting.With the Tank-to-Pump valve and the Tank Fill valve both OPEN, water recirculates from the tank, through the pump, and back to the tank. This cools the pump before you begin flowing water to a discharge line.ALWAYS crack open the Tank Fill Valve when running the pump. If you fail to continuously circulate water through the pump chamber, the water trapped in the pump chamber heats to boiling in seconds. Boiling water and steam can injure people. It also damages pump seals and gaskets.When recirculating water, the water in the tank will eventually become too hot to cool the pump. Exchange tank water with fresh water to keep pump cooled. Keep track of water temperature:a. Touch the outlet pipe to see how warm it is. If it is hot to the touch, it is time to bring fresh, cool water into

the water tank or turn OFF pump.b. Watch tank temperature gauge (if your fire department selected this option). When temperature reaches

175° F, then add fresh cool water or turn OFF pump.

Keep pump water cool.ALWAYS circulate fresh water through the pump.Pump can heat trapped water to boiling in seconds.Burst lines can spray personnel with scalding water.Scalding water can injure or kill.

OPERATION


4. Open Recirculating Valve (Optional)

Figure 4-4: Recirculating Valve

1155

A dedicated Recirculating Valve (Figure 4-4) opens a small water flow from the pump to the tank. The flow through this line cools the pump. The recirculating line does not let water flow from the tank to the pump, so it works only if the Tank to Pump valve is OPEN, or if the intake is supplied by a water source.

5. Observe Pump-Overheat Indicator (Optional)

Figure 4-5: Pump-Overheat Indicator

1138

Watch the Pump-Overheat indicator (Figure 4-5) during pumping operations to make sure that the pump stays cool. If the Overheat indicator light turns ON, add fresh water, recirculate, discharge water, or shut engine OFF to cool the pump.


OPERATION

4-5. Manual Pump Engagement

NOTE: If this override is used, make sure it is disengaged once pump operations are complete.

If power is lost to the pump shift switch in the cab, the following steps can be used to manually engage the pump.1. Ensure the parking brake is set and the pump shift in the cab is in the OFF position.2. Proceed to the pump operator’s panel.3. Open the access panel door located in the lower right of the pump panel.4. Flip up the switch guard.5. Turn the switch to the ON position.6. A yellow indicator light will illuminate if the pump is engaged. Repeat if necessary.7. Proceed with normal operating functions.

4-6. Adjusting the Pump Pressure

4-6.1 Determine Discharge Pressure

Manual pump engagement is intended for limited use in the event of a failure in the primary control system. If conditions warrant the use of this override, pumping operations may continue, but the truck should be examined by a service technician upon return to the station to identify and repair the cause of the failure.

Hand Throttle Systems can malfunction.If engine control is lost at pump panel, assign someone to use foot pedal in cab to continue pumping operation. Before controlling the throttle manually, the parking brake must be released and the wheels must be chocked.

Hoses and Nozzles can explode if over-pressurized. NEVER exceed pressure rating of downstream devices.Exploding devices can injure or kill.

Keep control of hose under pressure.Hose under pressure wants to fly about.Flying hose can injure or kill.

OPERATION


Pump pressure is determined by: • Engine Speed• Pump Size• Discharge Restriction (size and length of discharge hose)• Intake Restriction (size and length of intake hose)• System Restriction (size and shape of valves, fittings, manifolds, etc.)You must determine a pump pressure that will provide the desired nozzle pressure, based on the number and size of attack lines that are deployed. Determine this pressure for all fire-fighting situations you might encounter, and record them on a Pump Chart. Keep the Pump Chart in a location accessible to the pump operator. Refer to the IFSTA Pumping Apparatus Driver/Operator Handbook (latest edition) for procedures on creating a Pump Chart.

4-6.2 Engine Speed and Pump PressureThe pump pressure is controlled by regulating the engine speed. If the apparatus is equipped with a pressure governor, the governor will regulate the engine speed automatically to maintain the desired pump pressure.

4-6.3 Controlling Engine Speed, Pumping—Pressure Governor OperationIf the apparatus is equipped with a pressure governor, the governor will regulate the engine speed automatically to maintain the desired pump pressure. When placed in the PRESSURE CONTROL mode, the system will monitor pressure, increasing or decreasing the engine speed to maintain the set pressure.

NOTE: For additional information concerning the operation of the pressure governor, refer to the Pierce Pressure Governor Interactive Manual (2012V1) on CD-ROM and the FRC PMA300 Pressure Governor service group (2825-V-007) included in the service manual.

1. Select Pressure Control ModePlace pressure governor in the PRESSURE CONTROL mode. Switching methods will vary depending on the manufacturer of the pressure governor.

2. Adjust Desired PressureUse the hand wheel throttle control to change the desired pressure setting.

4-6.4 Controlling Engine Speed, Not Pumping—Pressure Governor OperationThe THROTTLE (RPM) CONTROL mode allows the operator to increase engine speed when not pumping, to increase alternator output, warm the engine, or other non-pumping operations.

Apparatus equipped with pressure governors normally do not have pressure relief valves. The pressure governor performs the function of the relief valve. Always pump in pressure control mode.Pumping in throttle (RPM) control mode can cause high pressure and/or pressure spikes. Pressure spikes can injure or kill.


OPERATION

NOTE: For additional information concerning the operation of the pressure governor, refer to the PUC Pressure Governor Operator’s Guide CD-ROM (PV-P-TM450) and/or the FRC PMA300 Pressure Governor service group (2825-V-007) included in the service manual.

1. Select Throttle (RPM) Control Mode2. Adjust Desired Engine Speed (RPM)

Press the red button to cancel the current mode and return the engine speed to idle.The red button also serves as the Emergency Stop. Practice using the Emergency Stop.

4-6.5 Controlling Engine Speed with Multiple Controls

Some apparatus have both a Hand Throttle and a Pressure Governor. The Throttle Selector Switch determines which control is ON.If Hand Throttle is selected, you will control engine speed manually.If Pressure Governor is selected, the Pressure Governor controls engine speed.ALWAYS return the control you are not using to the IDLE position.

4-7. Discharging Water

Figure 4-6: Typical Discharge Valves

1139

4-7.1 Connecting Attack Line Hose 1. Close Discharge Valve

CLOSE Discharge Valve to keep water from flowing once the Discharge Cap is removed.

Transferring engine speed control between Hand Throttle and Pressure Governor can cause a jump in engine speed.Engine speed changes can cause discharge water pressure spikes.Spikes in discharge pressure can cause hoses to kick with great force, causing injury.

OPERATION


Figure 4-7: Drain/Bleeder Valves

1140/POM0021

2. Open Drain/Bleeder ValvePull up or turn Drain/Bleeder Valve counterclockwise to the left to OPEN.Air pressure can be trapped between the Discharge Valve and the Discharge Cap. You must bleed off this pressure BEFORE the cap is removed. Otherwise, any trapped air pressure can blow the cap off with great force and injure someone.

3. Open Discharge Cap Vent if One is ProvidedSome Discharge Caps have a pressure release vent on the cap. If cap has a vent, OPEN vent before removing cap.

4. Remove Discharge Cap BEFORE removing Discharge Cap, OPEN the Pressure Release Valve or Drain Bleeder Valve to make sure that trapped air pressure escapes.Remove the Discharge Cap after you are certain that pressure has been bled from behind it. You cannot tell by how hard the cap rotates whether pressure exists or not.

5. Connect the Discharge HoseConnect the discharge hose to the discharge connection.

6. Adjust the Discharge SwivelIf the discharge connection has a swivel fitting, move the swivel so the hose points AWAY from the pump operator's area.

7. Close the Drain/Bleeder Valve

ALWAYS OPEN Drain/Bleeder Valve BEFORE removing Inlet or Discharge Cap.Discharge lines can trap pressure if the valve is opened and left closed.Discharge cap under pressure will blow off with explosive force.Exploding Cap will injure or kill.


OPERATION

4-7.2 Charging Line

1. Slowly Open Discharge ValveOpen and close discharge valves slowly. Rapidly opening a valve sends a surge of water through the hose, making it difficult to control. Rapidly closing a valve will cause a pressure spike in other hoses.OPEN Discharge Valve one-half OPEN until attack line is filled with water and air is expelled from hose.Observe personnel on the end of the attack line while the hose is filling.

2. Adjust Discharge ValveAFTER air is expelled from the line and water is flowing steadily from the attack nozzle, adjust the Discharge Valves to send the flow you want to each line.

3. Observe Tank Level Indicator

Figure 4-8: Typical Tank Level Indicators

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Water level in the water tank drops as water flows to the attack lines. Watch the Tank Level Indicator. Plan ahead to add external water before you empty the tank.Learn how to open and close valves using these controls on your pump panel:Lever Controls— Pull to open valve— Push to close valve— Rotate knob clockwise to the right to lock

Opening valves rapidly can cause pressure spikes.Open and close valves slowly.Pressure spikes can cause hoses to kick with great force, causing injury.

Opening valves rapidly can cause water hammer.Water hammer can damage the pump and other water system components.

OPERATION


Hand Wheel Controls— Rotate counterclockwise to the left to open valve— Rotate clockwise to the right to close valveElectronic Controls— Follow instructions on controls. Be sure to read the manufacturer’s Operators Manual.

4-8. Discharging Foam

See Foam System Operator's Manual.

4-9. Changing from Tank to External Pressurized Water Supply (with Gated Intake Valve)

Figure 4-9: Typical Gated Intake Valves

POM0034, 0035, 0036

Soon after the pump is running and water is being supplied to the discharge lines, you need to establish an external source of water BEFORE the water tank is empty. This supply can come from a hydrant, from another apparatus, or from a draft source, such as a pond, river, or portable tank. A gate intake allows you to maintain water flow at the same pressure at the same time you switch to an external water supply.In the absence of a gate intake valve, clear fire fighters from the attack area before you change to external water supply, because you will lose all water pressure.Most fire departments provide their own gate valves. Pierce recommends use of a gate valve.Before using water from a hydrant, open and vent the hydrant for about 30 seconds to flush out gravel or debris. Always use intake strainers. Gravel can damage the pump and reduce pressure.


OPERATION

4-9.1 Connect Intake Hose1. Close Intake Gate Valve

Figure 4-10: Intake Gate Valve

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Close the gate valve on the intake connection to which the intakes hose will be attached.

2. Open Air Bleed Valve for Intake BEFORE Cap is RemovedIntake connections with a shut-off (or gate) valve can trap pressure if the valve is opened and left closed with the cap in place. ALWAYS OPEN the Intake Air Bleed Valve to let trapped pressure escape BEFORE removing cap.Air Bleed Valves are attached to a tube that is connected to the pipe.Opening the Intake Air Bleed Valve allows air trapped in the Intake Pipe to escape.Rotate the knob one-quarter turn counterclockwise to the left to open the valve.To make sure that all air pressure is removed from the system, keep the Air Bleed Valves OPEN until you start flowing water. Only then may you close it.

Always OPEN Drain Valve or Bleed Valve BEFORE removing Intake Cap.Intake Lines can trap pressure.Intake Cap under pressure will blow off with explosive force.Exploding cap will injure or kill.

Always bleed air from Intake Line.Air in lines can cause pressure spikes.Air forced from nozzle can increase intensity of fire or cause a pressure surge. Air discharge can injure or kill.

OPERATION


3. Remove Intake Cap

Figure 4-11: Intake Cap

POM0024

Remove the Intake Cap only after you are certain that trapped air pressure has escaped. Make sure to OPEN the Air Bleed Valve or Drain Valve so that trapped air pressure escapes.

4. Connect the Intake HoseConnect the Intake Hose that has been laid from the hydrant to the intake connection.

5. Adjust the Intake SwivelIf the intake connection includes a swivel fitting, adjust the swivel so that the hose points AWAY from the pump operator's area.

4-9.2 Charge the Intake Line (Pressurized Supply)

NOTE: Make sure that the pressure control has been set before charging the intake hose.

1. Charge the Intake LineOnce the intake hose is properly connected to the intake fitting, open the valve at the hydrant to allow water into the intake hose. Air will escape out the air bleed valve as it is forced from the hose by the incoming water.

2. Close Air Bleed ValveClose the Air Bleed Valve after the air is gone from the intake line.

Point intake hose away from personnel.Hoses and connections under pressure can burst without warning.Burst hose can injure or kill.

Inspect hoses and fittings regularly.Replace if worn or damaged.Worn or damaged hoses and fittings can burst. Burst hose or fittings can injure or kill.


OPERATION

4-9.3 Supply the Pump

1. Open the Intake Gate ValveOPEN the Intake Gate Valve slowly to change the flow to the external supply.Always open the Intake Gate Valve slowly. Air in the intake line will then enter the pump slowly. Air will be sucked through with a steady flow of water. If a large slug of air enters the pump, the pump can lose prime. Centrifugal pumps cannot pump air. If prime is lost, the attack lines will lose water pressure.

2. Close the Tank-to-Pump ValveOnce the Intake Gate Valve is open, the water pressure from a pressurized source keeps water from flowing from the tank. A check valve in the tank-to-pump line keeps the pressurized supply from flowing water back into the tank.A draft source lacks intake pressure. Therefore water can continue to be drawn from the tank. If the tank is run dry, the pump can lose prime.After the Gated Intake Valve is fully open, then slowly CLOSE the Tank-to-Pump Valve to make sure that water is drawn from the external supply only.

3. Close the Tank-Fill and Recirculating ValvesAs long as the discharge lines are flowing water, the pump will have fresh water to keep it cool. With the Tank-to-Pump Valve closed and the Tank-Fill or Recirculating Valves OPEN, the tank will continue to fill until it overflows through the fill hatch. a. CLOSE the Tank-Fill or Recirculating Valves to avoid tank overflow. b. OPEN both valves again when pump cooling is required because discharge lines are CLOSED.

4-10. Pump Priming Problem Solutions

4-10.1 Control Valves That Leak1. Cap Unused Discharge and Intake Pipes

Cap all unused discharge and intake pipes to reduce air leakage from a leaky valve.

4-11. Monitoring Intake Pressure

The Master Intake Gauge shows the intake manifold pressure.1. Watch Intake Pressure

Look often at the intake pressure on Master Intake Gauge while pumping.

Perform change to external water source properly.Water flow can stop if change is performed incorrectly.Loss of water flow can endanger fire attack crews, resulting in death or injury.

OPERATION


2. Maintain 20 PSI Intake Pressure (Pressurized Supply)Maintain intake pressure at or above 20 PSI when operating from a pressurized external supply.This provides a safety factor to avoid drawing a vacuum on the intake hose.Changes in supply pressure can cause intake pressure to drop without warning. Drop in pressure below zero (0) PSI can cause water hammer, pump cavitation, or collapse the intake hose AND cause loss of water flow.

NOTE: 20 PSI may not be attainable in cer

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