Configuration (PUC)Pierce Ultimate Pumpers...© 2014 Pierce Manufacturing Inc. Part No. PM-P-OM420-0914 Configuration (PUC) Pierce Ultimate Operation & Maintenance Manual Pumpers

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

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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

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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

1142

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

1143

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 certain areas, depending on the hydrant system. For additional information, consult your Fire Department standard operating procedures.

3. Maintain 20 in. Hg. Vacuum (Draft Supply)When operating from draft, always maintain 20 in. Hg. of vacuum or less. Intake vacuum of more than 20 in. Hg. can cause pump to cavitate.

4. Avoid Pump CavitationPump Cavitation is happening when:— Discharge pressure changes up and down.— You hear a sound like gravel churning in the pump.— Discharge pressure remains the same when you change engine speed.Reduce discharge flow until cavitation ceases.

Maintain positive intake pressure with soft intake hose.Negative intake pressure will collapse soft intake hose.Attack lines will lose water pressure if hose collapses.Loss of water supply will endanger fire fighters on attack lines.

NEVER cavitate pump.Low intake pressure or high vacuum can cause pump cavitation.Cavitation can:• Cause loss of water pressure.• Damage pump components, requiring expensive repairs.

Avoid water hammer.Water hammer can damage the pump system.


OPERATION

4-12. Refilling the Tank

ALWAYS refill water tank as soon as possible. If the supply source is interrupted, a full tank of water allows you to continue flowing water to the attack lines while an external water source is being restored. 1. Open Tank Fill Valve

OPEN the Tank Fill Valve slowly to ¼ OPEN to divert some supply water into the water tank.2. Watch Intake and Discharge Pressure

Watch the discharge pressure gauges to make sure that you maintain attack hose flow at the desired pressure while you also fill the water tank. If intake or discharge pressure drops below the desired pressure, either CLOSE the Tank Fill Valve to divert less water to the tank OR increase engine speed to maintain pressure.Always keep the water tank full so that a steady discharge flow can be maintained if the intake supply must be shifted.

4-13. Changing from Tank to External Water Supply (without Gated Intake Valve)

If you change from the water tank to an external water source without an Intake Gate Valve, the water flow to the discharge attack lines must be stopped.Pierce recommends that every pumper apparatus have an Intake Gate Valve.Use these procedures if Gate Valve is absent.Make sure fire fighters are withdrawn from attack area, because hoses will lose water.

4-13.1 Stop Flowing Water1. Close Discharge Valves

Water pressure during the transition period can fluctuate. Protect attack line personnel from the hazards of pressure spikes by closing the Discharge Valves. Remember, you are also shutting off water to the attack hoses.

2. Reduce Engine Speed to IDLERunning the pump without water will damage the seals and bearings. Reduce engine speed to IDLE to minimize wear on the pump while the water supply from the tank is stopped.

3. Close Tank-to-Pump ValveCLOSE Tank-to-Pump Valve before the removing the Intake Cap to prevent tank water from flowing out the intake.

4. Connect Intake Hosea. Remove the Intake Cap.b. Connect the Intake Hose.

OPERATION


4-13.2 If you are connecting to a pressurized supply, charge intake line:1. Open Tank Fill Valve or Discharge Valve

OPEN the Tank Fill Valve. Air in the intake hose must be expelled before water can reach the pump. Air will pass through the pump and out the OPEN Tank Fill Valve.- OR -OPEN Discharge Valve and Discharge Drain Valve. Water will flow out the discharge drain valve once the air escapes. Close the drain valve once air has escaped.

2. Charge the Intake LineOPEN the water valve on the hydrant to allow water to flow through the intake hose and into the pump. Before using water from a hydrant, open and vent the hydrant for about 30 seconds to flush out gravel or debris. Always use intake strainers.

3. Close Tank Fill ValveCLOSE the Tank Fill Valve once water tank is full.

4-13.3 Resume Discharge Operation1. Open Discharge Valve

Open the Discharge Valve(s) slowly to resume attack line operations.2. Increase Pressure

Continue to watch the Master Pressure Gauge. Increase speed until you reach the pump discharge pressure you want.

4-14. Engine Status Display

Figure 4-12: Typical Engine Status Displays

1144

The Engine Status Display is either a group of gauges and indicator lights or an electronic display that gives you critical information on engine performance.You must watch this information often during pump operation, and react to any abnormal readings.


OPERATION

Engine information includes:• Engine Speed: shows current engine speed in RPMs.• Engine Oil Pressure Gauge: shows engine oil pressure.• Engine Temperature Gauge: shows oil temperature of the engine.• Electrical System Voltage Meter: measures the voltage level of the vehicle's battery system.• Stop Engine Light

If the Stop Engine light turns ON, the engine's ECU (electronic control unit) has detected a critical error condition. That means engine failure is possible at any moment. Read and study the engine manufacturer's operations manual so you know how to react. Practice your reaction to all different kinds of failure. You need to be prepared in advance so you can react properly in an emergency.Fire apparatus programming does not allow a critical engine failure to automatically stop the engine. The engine will continue to run until it self-destructs or fails.It is your judgment call to balance the risks of damage to the engine with the need for the fire apparatus to remain operational.If possible, replace the apparatus with another apparatus RIGHT AWAY if this light comes on.• Check Engine Light

If the Check Engine light turns ON, the engine's ECU detects a non-critical error condition. Immediately check all gauges at the pump panel and compare with the readings of those in the cab. Compare both readings to normal operating parameters. This will help you make the decision to continue to run the apparatus or replace it with another. If the Check Engine light remains ON, schedule the engine for maintenance.

• Check Transmission MessageA Check Transmission message is displayed if the transmission's control unit detects a non-critical error. If the Check Transmission message remains ON, schedule the transmission for maintenance.

4-15. Ending Water Flow Operation

4-15.1 Shutting Off Water Flow1. Reduce Engine Speed to IDLE2. Close Discharge Valves

Close all discharge and inlet valves slowly to prevent water hammer.

4-15.2 Disengaging the Pump1. Reduce engine speed to IDLE

Adjust the Hand Throttle or Pressure Governor to bring engine to IDLE.

Replace apparatus when STOP ENGINE light is ON.Engine can fail at any time without further warning.Engine failure will stop water flow to attack lines, putting fire-fighting personnel in danger.

OPERATION


2. Disengage the PumpPress WATER PUMP switch to disengage the water pump.

3. Observe Indicator LightsMake sure that the PUMP ENGAGED light is OFF. If the light is ON, then repeat the procedure.

4-15.3 Disengaging the Pump (Stationary Operation)1. Reduce engine speed to IDLE

Reduce engine speed to IDLE with the throttle control.2. Observe Tachometer

Observe the Tachometer in the cab to confirm that the engine has remained at IDLE speed. If the engine has increased speed, the throttle control on the pump panel might not have been properly reset to IDLE. Exit the cab and return Hand Throttle and/or Pressure Governor to IDLE.

3. Disengage the PumpPress WATER PUMP switch to disengage the water pump.

4. Observe Indicator LightsMake sure that the PUMP ENGAGED light is OFF. If light is ON, repeat the procedure.

4-15.4 Disengaging the Pump (Pump and Roll)1. Stop Apparatus

Bring apparatus to a full stop and reduce engine speed to idle.2. Shift the Transmission into Neutral (N)3. Pull Parking Brake to Apply4. Disengage the Pump

Press WATER PUMP switch to disengage the water pump.5. Observe Indicator Lights

Make sure that the PUMP ENGAGED light is OFF. If light is ON, repeat the procedure.

4-15.5 Securing Pump System

1. Open Drain Valves and Bleed ValvesOpen all pressure release valves to vent any trapped air pressure and water.

2. Open NozzlesRelieve pressure from un-gated inlet hose by OPENING discharge nozzles.

3. Remove HoseRemove all hoses from discharge and intake lines.

4. Replace CapsInstall Caps on Intake and Discharge connections to protect them from contamination.

The pumping system should be drained during cold weather. See “Draining the Pumping System” on page 5-1 for additional information.


OPERATION

5. Flush PumpFlush the pumping system with clean, fresh water if required.

6. Purge PrimerIf equipped with a fluid-lubricated primer pump, operate the primer pump until primer fluid comes out of the primer pump discharge. Check primer fluid tank level, and fill if needed.

4-16. Operating from a Static (Draft) Water Supply

Operating the pump from a draft source is the most demanding type of pump operation. Learn about the complexities and hazards of this operation by studying the IFTSA Pumping Apparatus Driver/Operator Handbook and through formal training.Once the apparatus is prepared for draft operation and the appropriate suction lines are deployed, prime the pump as follows:1. Close Valves

First, close all discharge valves, drain valves, bleed valves, and tank valves or the primer will fail to work.2. Switch Pressure Governor to THROTTLE (RPM) CONTROL Mode

If the apparatus is equipped with a pressure governor, place it in THROTTLE (RPM) CONTROL mode. For governor equipped apparatus, this will hold the prime better than starting out in PRESSURE mode.

3. Increase Engine SpeedIncrease the engine speed to 1000 RPM. This should provide about 50 PSI of water pressure once the prime is established.

4. Open Primer ValvePull to OPEN the Primer Valve and engage the primer motor. Listen to the sound of the primer motor as it pumps air out of the water pump to draw a vacuum. Listen for the tone change as the primer pump begins to expel a mix of air & water, and then begins expelling only water.

5. Observe Pressure GaugeWatch the pressure on the Master Pressure Gauge to make sure that the water has entered the pump and the pressure is beginning to build.

6. Open Discharge ValveOpen the Discharge Valve slowly to begin water flow operation.

7. Switch Pressure Governor to PRESSURE CONTROL ModeFor pressure governor equipped apparatus, switch from THROTTLE (RPM) CONTROL mode back to PRESSURE CONTROL mode.

8. Increase PressureContinue to watch the Master Pressure Gauge. Increase the pressure until you reach the desired discharge pressure.

OPERATION



SECTION 5 MAINTENANCE

5-1. Inspection, Cleaning, and Maintenance

5-1.1 Maintenance ScheduleDevelop a Standard Operating Procedure for the daily, weekly, monthly, and annual inspection and maintenance of this fire apparatus after careful review of all documentation provided. Inspection and maintenance requirements for components such as monitors, foam systems, flow meters, valves, etc., must be established by referencing the service manuals.Follow the pump manufacturer's inspection and maintenance recommendations.Follow the procedures for inspection, cleaning, and maintenance found in the IFSTA Pumping Apparatus Driver/Operator Handbook (latest edition).Follow instructions regarding inspection, cleaning, and maintenance located in the Pierce Custom Chassis Operation & Maintenance Manual (Publication No. PM-C-OM012) or the Pierce Commercial Chassis Supplement (Publication No. PM-C-OM090).

5-2. Draining the Pumping System

NOTE: If it is desired to retain water in the water tank, the Tank to Pump and Tank Fill valves should be left in the closed position.

Every part of the water pump system must be drained if exposed to freezing temperatures. 1. Locate the lowest points on every plumbing line and the drain valve that opens it2. Remove Caps

AFTER opening air bleeder valves, remove all intake and discharge caps.

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

Freezing water can damage pipes, valves, primers, and gauges.If you are moving a truck containing water outside when temperatures will approach freezing (32°F / 0°C), make sure that all fittings, valves, waterlines and caps have been opened or removed.These include, but are not limited to: drain valves, discharge valves, intake valves, etc. Following this recommendation could prevent damage to critical water system components and avoid costly repairs.

MAINTENANCE


3. Open Master Pump Drain

Figure 5-1: Typical Master Pump Drains

1145

The master pump drain (Figure 5-1) will empty both the discharge and inlet manifolds of water when opened. 4. Open Discharge Line Drains

Locate each Discharge Line and open the Drain Valves.5. Open Intake Line Drains

Locate each Intake Line and open the Drain Valves.6. Open Intake Relief Valve Drain—on apparatus equipped with relief valves7. Open Control Valves

Open all Intake and Discharge Valves.8. Purge Primer

Primer should be purged regularly in cold weather to prevent the primer from freezing.9. Allow Water to Drain10. Close all Valves

NOTE: If your apparatus is equipped with a foam system, refer to the applicable foam system manual for draining procedures.

5-3. Flushing the Drain Valves

5-3.1 Forward FlushingDrain Valves are the lowest point in the pump system. Dirt and debris in the water will settle in the drain valve bodies. Flush each drain valve with clean water monthly or after pumping dirty or salty water. Flush drain valves to prevent sediment from accumulating in the valve body and hurting proper operation of the drain valve.1. Fill Water Tank

Begin flushing procedure with a full water tank of clean, fresh water.2. Cap All Intake and Discharge Connections

Cap all connections to hold the clean water from the tank in the pumping system.


MAINTENANCE

3. Open all Intake and Discharge ValvesOpen all control valves to allow fresh water to reach all points in the pumping system.

4. Open the Tank-to-Pump ValveOpen the Tank-to-Pump Valve to flood the pumping system with clean water.

5. Open Drain Valves One at a TimeOpen each Drain Valve. Keep open until a steady stream of water flows from the valve for 20 seconds. If no water or reduced water flows, find out why water fails to drain and make a repair.

6. Close Tank-to-Pump ValveClose the Tank-to-Pump Valve to prevent any more water from entering the pumping system.

7. Open Drain ValvesOpen each Drain Valve again until remaining water is drained from the system.

8. Remove CapsRemove Intake and Discharge Caps.

9. Allow Water to Drain10. Close All Intake and Discharge Valves11. Replace Caps

Replace Intake and Discharge Caps.12. Close Drain Valves13. Refill Water Tank

5-3.2 Back FlushingThe pump should be back flushed with municipal water after salt water or other debris have entered the pump.1. Remove Suction Strainers

Remove the suction strainers so they are not blown out of the pump.2. Open Transfer Valve (if applicable)

Hold the transfer valve clapper, in the second stage volute entrance, open so debris is not trapped behind it.3. Pump Water

Pump fresh, clean water through all of the inlets and outlets, until you see only clear water.4. Open & Close Valves

Open and close all discharge and intake valves to flush them with clean water.5. Activate Primer

In the case of salt water pumping, activate the primer to get clear water through the primer valve and pump.6. Activate Pressure Relief Valve

Activate the pressure relief valve with the pilot valve to flush that system, and move the transfer valve from Volume to Pressure a few times (if the pump is so equipped).

MAINTENANCE


5-4. Flushing and Draining the Pump

Flush the pumping system after pumping dirty, contaminated, or salty water.1. Supply Clean, Fresh Water

Supply clean, fresh water to the pumping system.2. Open Discharge Valves

Open all discharge valves so that clean, fresh water flows through each discharge line and valve for one minute.3. Fill Tank

Fill the water tank with clean, fresh water.4. Flush Drain Valves

Flush all drain valves using the procedure listed under Flushing the Drain Valves.

5-5. Pump Storage

In warm temperatures store pump either entirely full of water or completely empty.Pumps stored partially full of water will rust at the air-to-water interface.In freezing temperatures store pumps dry, without any water in the pump chamber.

5-6. Preventive Maintenance Checks & Services

Refer to Table 5-1 for a schedule of service and lubrication requirements. Perform services at the indicated interval of miles or time, whichever comes first.

Pump body heats to high temperatures during operation.Touching hot areas of pump will burn.Allow pump to cool before servicing.

Store pump completely full of clean water, or completely dry.Do not leave pump partially full of water.Always store pump dry in freezing weather.


MAINTENANCE

Table 5-1: Maintenance Schedule

5-7. Primer Pump Lubrication

Figure 5-2: Primer Pump Lubrication Fluid or Oil Reservoir

POM0031

Some primer pumps require a lubricating fluid or oil. The fluid reservoir (Figure 5-2) is normally located in the pump house behind an access panel or access door.For oil-type priming pumps, the lubricant is expelled with the air as the pump is primed.Use only lubricating fluid that is approved by the manufacturer of the pump and approved for use in the environment.

Description ActionPump Hours Time

Primer Pump Check primer pump lubricating fluid level and fill as necessary. See “Primer Pump Lubrication” on page 5-5.

- Daily

Intake/Discharge Relief Valves

Drained trapped water. See “Intake & Discharge Relief Valve Drains (Optional)” on page 5-6.

- Daily

Pump Transmission Check the oil level. See “Pump Transmission Lubrication” on page 5-7.

25 3-months

Pump Transmission Change the oil and filter. See “Pump Transmission Lubrication” on page 5-7.

100 6-months

Anode Rods Inspect and replace as necessary. See “Anode Rods (Optional)” on page 5-11.

- 6-months

Master Gauges Test and calibrate. See “Master Gauge Ports” on page 5-6.

- Annually

Annual Testing See “Annual Testing” on page 5-13. - Annually

Use environmentally-friendly priming lubricants or use procedures that capture the oil as it is expelled.Expelling standard motor oil used as a lubricating fluid in the primer pump does not meet EPA regulations.

MAINTENANCE


5-8. Intake & Discharge Relief Valve Drains (Optional)

Figure 5-3: Relief Valve Drain

POM0032

Inlet and discharge relief valves can trap water inside the mechanism of the valve.Drain trapped water from the valve daily, and before operating apparatus in freezing temperatures.Frozen water will damage the valve.

5-9. Master Gauge Ports

Vacuum and Pressure Test Ports are provided for use during the annual testing and certification of the pump.

1. Test Master Gauges AnnuallyThe VACUUM test port leads directly to the Master Intake Gauge line.The PRESSURE test port leads directly to the Master Discharge Gauge line.Use certified test gauges to check and calibrate Master Gauges.

Master gauge testing and calibration should only be performed by trained maintenance personnel.NEVER remove plugs in these ports except for test purposes.


MAINTENANCE

5-10. Pump Transmission Lubrication

The Pierce Ultimate Configuration (PUC) pump transmission incorporates an internal lubrication pump providing forced lubrication for power transmission components. The positive lubrication system provides an effective means to filter, cool, and distribute the lubricant in a controlled manner. The pump transmission lubricant is circulated from the gear case reservoir, through a heat exchanger, cooler, filter, and then back into the transmission assembly at the outboard impeller shaft bearing. Internal oil passageways distribute oil to component contact surfaces, minimizing contact wear.In top mount applications, in-line, low pressure non-return valves are installed on transmission lubrication discharge and return ports to prohibit draining of oil from the external lubrication components back to the pump transmission reservoir tank. This ensures that the oil level dipstick will provide accurate and consistent readings.

Only use the recommended PUC lubricant in the PUC transmission. Failure to comply will cause damage to equipment and void the warranty.

MAINTENANCE


Figure 5-4: Pump Transmission Lubrication Circuit - Side Control

1213


MAINTENANCE

Figure 5-5: Pump Transmission Lubrication Circuit- Top Mount

1855834

Maintain gear case oil level to a point between the two grooves on the oil level dipstick. When checking oil level, dipstick must be screwed all the way in and then removed for accurate readings.Check the oil level every 25 hours of pumping operation or every three months. Change the oil and filter every 100 hours or 6 months.

MAINTENANCE


NOTE: • The part number for the replacement spin-on filter element is Pierce PN 1777990.

• Approximate gear case oil reservoir capacity is 4 quarts of lubricant. Oil filter and cooler will require an additional 2 quarts when completely drained.

Service the pump transmission with:• PUC XPL Extreme Performance Lubricant, Pierce PN 1915175 (case containing four 1-gallon containers)• Caterpillar Transmission/Drive Train Oil (TDTO), Caterpillar PN 8T9568 (5-gallon container)• Any equivalent lubricant meeting the specifications in Table 5-2• Do NOT use grease!

Table 5-2: Characteristics of PUC XPL Extreme Performance Lubricant

1. Fill reservoir to dipstick level line. 2. Run the engine for a short period to distribute oil. 3. Shut down engine. 4. Recheck fluid level and add additional lubricant if required.

Only use the recommended PUC lubricant in the PUC transmission. Failure to comply will cause damage to equipment and void the warranty.

Do not overfill. Overfilling may cause excessive gear case operating temperatures.

Service driveline universal joint grease fittings at regular chassis service intervals.

Specification SpecificationSAE Viscosity Grade 10W Viscosity:

- cP @ -20°C (ASTM D5293)- cSt @ 40°C (ASTM D445)- cSt @ 100°C (ASTM D445)

313039.16.1

Manufacturer’s Test:- CAT- Allison

TO-4C-4, C-3

Viscosity Index (ASTM D2270) 97

ISO Viscosity Grade 32 Calcium, % wt. .298Gravity, °API (ASTM D287) 27.9 Sulfated Ash, % wt. (ASTM D874) 1.2Appearance (Visual) Clear & Bright Zinc, % wt. (ASTM D1549) .127Flash Point, °C (°F) (ASTM D92) 202 (395) Phosphorous, % wt. (ASTM D1091) .110Pour Point, °C (°F) (ASTM D97) -36 (-33) min. TBN (ASTM D2896) 7.9


MAINTENANCE

Figure 5-6: Oil Level Dipstick and Fill Port and Drain Plug

1132

5-11. Anode Rods (Optional)

Figure 5-7: Anode Rods

1419/1420/1421

Anodes help prevent damage caused by galvanic corrosion within the pump and plumbing. Galvanic corrosion results when different conducting materials are connected and exposed to water. With the use of anodes, galvanic corrosion will attack the less resistant of the two metals (anodes) while protecting the more resistant metal (the pump). Using the proper sacrificial anodes extends the life of your pump by corroding the anode instead of the pump and plumbing.Anodes should be inspected semi-annually and replaced when over 75% of the material has been consumed.

New Rod Used Rod

MAINTENANCE


5-12. Mechanical Shaft Seal

This pump assembly incorporates a high quality mechanical shaft seal separating the pump housing components from atmosphere. The seal size, design type, component materials, and housing configuration have been specifically designed for this pump application and rated operating parameters.

5-12.1 Mechanical Seal BasicsA mechanical seal is a device that houses two highly polished components (known as faces). One face rotates, the other is stationary. A secondary elastomer bellows seals the primary ring to the shaft. An o-ring or cup seal seals the mating ring in the housing. The polished seal faces of the primary and mating rings are pressed together by a spring mechanism to provide adequate force to affect a seal. The force acting between the seal faces increases in direct proportion to product pressure. The elastomer bellows seal utilized in this pump has the following design features:• Mechanical drive of the primary seal ring. The drive band’s notch design eliminates over stressing the elastomer

sealing bellows.• Bellows design provides automatic compensation for shaft end play, run out, and primary ring wear.• Seal face contact pressure is controlled by a single, non-clogging coil spring. This coil spring has been custom

welded per Pierce specifications to eliminate high-speed spring distortion.The seal housing is designed and ported to provide optimal water flow and pressure assuring proper cooling and flushing of the seal components.

Figure 5-8: Mechanical Seal

PT1954

5-12.2 Mechanical Seal Operation and MaintenanceWhen operated within rated operating conditions of this pump, the seal will provide trouble free service for extended periods.

PT1954


MAINTENANCE

Properly selected and applied mechanical shaft seals are leak free and require no adjustment. Should the seal area develop a leak, investigate the cause as soon as possible. Seal failure, leakage, may be the result of: worn seal faces, leaking bellows, or damaged o-rings. These failures may be attributed to bearing failure, impeller blockage, impeller imbalance, seal housing contamination, operating beyond pump design rating, or dry running, Mechanical shaft seal design relies on the sealed media (in this case, water) to cool and lubricate the sealing surfaces. Therefore, extended dry operation may cause overheating and scoring or damage to the sealing surfaces, resulting in excessive leakage or a much shortened seal life.To maximize seal life, minimize operation at pump pressures higher than pump rating. While operating at pressures beyond rating will not immediately damage the seal, it will increase sealing surface wear rate.

5-13. Annual Testing

Test all pumping apparatus annually per the specifications in NFPA 1911, Standard for the Inspection, Maintenance, Testing and Retirement of In-Service Automotive Fire Apparatus (latest edition).These tests are necessary to make sure that the apparatus will continue to perform to specification.These tests help prevent breakdowns.

MAINTENANCE



SECTION 6 REFERENCE TABLES

6-1. Conversion Factors

One pound per square inch = 2.31 feet of water= 2.04 inches of mercury= 27.7 inches of water

One foot of water = 0.43 pounds per square inch

One inch of mercury = 1.13 feet of water= 0.49 pounds per square inch

One cubic foot of water = 62.4 pounds= 7.5 gallons

One gallon of water = 231 cubic inches= 0.13 cubic feet= 8.34 pounds = 3.8 liters

One Imperial Gallon = 1.2 U.S. gallons

Atmospheric Pressure (Sea Level) = 14.8 pounds per square inch= 29.9 inches of mercury= 34 feet of water

REFERENCE TABLES


6-2. Pump Tests

Table 6-1: NFPA 1901 Test

Class ATEST Recom- Min. Min. Min. Net Disch. SuctionNo. GPM mended Nozzle Disch. Pump Lines Hose

Nozzles Press. PSI Press. PSI Press. PSI500 GPM Pump

1 500 1-1/2" 57 143 150 1-50" 20' of 4"2 350 1-1/4" 58 194 2003 250 1" 72 245 2504 500 1-1/2" 57 158 165

750 GPM Pump1 750 1-3/4" or

2, 1-1/4"68 66

142 150 2-50'

2 525 1-1/2" 62 193 200 or 20' of 4-1/2"3 375 1-1/4" 66 244 250 2-100'4 750 1-3/4" or

2, 1-1/4"68 66

157 165 Siamesed

1000 GPM Pump1 1000 1, 2" or

2, 1-1/2"71 57

142 150 2-50'

2 700 1-3/4" or 2, 1-1/4"

60 58

193 200 or 20' of 5"

3 500 1-1/2" 57 244 250 3-100'4 1000 1, 2" or

2, 1-1/2"71 57

157 165 Siamesed

1250 GPM Pump1 1250 2-1/4" or

2, 1-1/2"69 88

143 150 3-50'

2 875 1, 2" or 2, 1-3/8"

55 61

194 200 or

3 625 1-1/2" 88 245 250 3-100' 20' of 6"4 1250 2-1/4" or

2, 1-1/2"69 88

158 165 and 1-50'

Siamesed

Min. discharge pressures listed above are for pumps operating with full 10’ static suction lift. These pressures must be increased by 1 PSI for each 2.3 ft. less than 10’ of lift.


REFERENCE TABLES

1500 GPM Pump1 1500 2, 1-3/4” or

3, 1-1/2”6857

142 150 3-50’ 20’ of

2 1050 1, 2” or2, 1-1/2”

7862

194 200 or 6” Min

3 750 1, 1-3/4” or 2, 1-1/4”

6866

245 250 3-100’ and1-50’

or(2) 20’ of

4 1500 2, 1-3/4” or3, 1-1/2”

6857

157 165 Siamesed 6” Max

1750 GPM Pump1 1750 2, 2” or

3, 1-1/2”5576

143 150 4-50’ (2) 20’ of 6”

2 1225 2, 1-5/8” or2, 1-1/2” or

3, 1-1/4”

618479

194 200 or

3 875 1, 2” or2, 1-3/8”

5561

245 250 4-100’

4 1750 2, 2” or 3, 1-1/2”

5576

158 165

2000 GPM Pump1 2000 2, 2” or

4, 1-1/2”7157

147 150 4-50’ (2) 20’ of 6”

2 1400 2, 1-3/4” or3, 1-1/2”

6049

199 200 or

3 1000 1, 2” or2, 1-1/2”

7157

249 250 4-100’

4 2000 2, 2” or4, 1-1/2”

7157

163 165

Min. discharge pressures listed above are for pumps operating with full 10’ static suction lift. These pressures must be increased by 1 PSI for each 2.3 ft. less than 10’ of lift.

REFERENCE TABLES


6-3. Smooth Bore Nozzle Discharge

Table 6-2: Discharge From Smooth Bore Nozzle - Pressures Measured by Pitot Gauge

NozzlePressure 1/4 3/8 1/2 5/8 3/4 7/8 1 1 1/8 1 1/4 1 3/8 1 1/2 1 5/8 1 3/4 2 2 1/4

PSI GALLONS PER MINUTE DELIVERED5 4 9 16 26 37 50 66 84 103 125 149 175 203 266 3376 4 10 18 28 41 55 72 92 113 137 163 192 223 292 3697 4 11 19 30 44 59 78 99 122 148 176 207 241 315 3998 5 11 21 32 47 64 84 106 131 158 188 222 257 336 4279 5 12 22 34 50 67 89 112 139 168 200 235 273 357 45210 6 13 23 36 53 71 93 118 146 177 211 248 288 376 47712 6 15 25 40 58 78 102 130 160 194 231 271 315 412 52214 7 15 27 43 63 84 110 140 173 210 249 293 340 445 56416 7 16 29 46 67 90 118 150 185 224 267 313 364 475 60318 7 17 31 49 71 95 125 159 196 237 283 332 386 504 64020 8 18 33 51 75 101 132 167 206 250 298 350 407 532 67422 8 19 34 54 79 105 139 175 216 263 313 367 427 557 70724 8 20 36 56 82 110 145 183 226 275 327 384 446 582 73926 9 21 37 59 85 115 151 191 235 286 340 400 464 606 76928 9 21 39 61 89 119 157 198 244 297 353 415 481 629 79930 10 22 40 63 92 123 162 205 253 307 365 429 498 651 82632 10 23 41 65 95 127 167 212 261 317 377 443 514 673 85434 11 23 43 67 98 131 172 218 269 327 389 457 530 693 88036 11 24 44 69 100 135 177 224 277 336 400 470 546 713 90538 11 25 45 71 103 138 182 231 285 345 411 483 561 733 93040 11 26 46 73 106 142 187 237 292 354 422 496 575 752 95442 11 26 47 74 109 146 192 243 299 363 432 508 589 770 97844 12 27 49 76 111 149 196 248 306 372 442 520 603 788 100046 12 28 50 78 114 152 200 254 313 380 452 531 617 806 102148 12 28 51 80 116 156 205 259 320 388 462 543 630 824 104350 13 29 52 81 118 159 209 265 326 396 472 554 643 841 106552 13 29 53 83 121 162 213 270 333 404 481 565 656 857 108754 13 30 54 84 123 165 217 275 339 412 490 576 668 873 110856 13 30 56 86 125 168 221 280 345 419 499 586 680 889 112958 13 31 56 87 128 171 225 285 351 426 508 596 692 905 114960 14 31 57 89 130 174 229 290 357 434 517 607 704 920 116862 14 32 58 90 132 177 233 295 363 441 525 617 716 936 118764 14 32 59 92 134 180 237 299 369 448 533 627 727 951 120666 14 33 60 93 136 182 240 304 375 455 542 636 738 965 122468 14 33 60 95 138 185 244 308 381 462 550 646 750 980 124270 15 34 61 96 140 188 247 313 386 469 558 655 761 994 126072 15 34 62 97 142 191 251 318 391 475 566 665 771 1008 127874 15 35 63 99 144 193 254 322 397 482 574 674 782 1023 129676 15 35 64 100 146 196 258 326 402 488 582 683 792 1036 131378 15 36 65 101 148 198 261 330 407 494 589 692 803 1050 1330


REFERENCE TABLES

80 16 36 66 103 150 201 264 335 413 500 596 700 813 1063 134782 16 37 66 104 152 204 268 339 418 507 604 709 823 1076 136484 16 37 67 105 154 206 271 343 423 513 611 718 833 1089 138086 16 37 68 107 155 208 274 347 428 519 618 726 843 1102 139688 16 38 69 108 157 211 277 351 433 525 626 735 853 1115 141290 17 39 70 109 159 213 280 355 438 531 633 743 862 1128 142992 17 39 70 110 161 215 283 359 443 537 640 751 872 1140 144594 17 39 71 111 162 218 286 363 447 543 647 759 881 1152 146096 17 40 72 113 164 220 289 367 452 549 654 767 890 1164 147698 17 40 73 114 166 223 292 370 456 554 660 775 900 1176 1491

100 18 41 73 115 168 225 295 374 461 560 667 783 909 1189 1506105 18 42 75 118 172 230 303 383 473 574 683 803 932 1218 1542110 19 43 77 121 176 236 310 392 484 588 699 822 954 1247 1579115 19 43 79 123 180 241 317 401 495 600 715 840 975 1275 1615120 19 44 80 126 183 246 324 410 505 613 730 858 996 1303 1649125 20 45 82 129 187 251 331 418 516 626 745 876 1016 1329 1683130 20 46 84 131 191 256 337 427 526 638 760 893 1036 1356 1717135 21 47 85 134 195 262 343 435 536 650 775 910 1056 1382 1750140 21 48 87 136 198 266 350 443 546 662 789 927 1076 1407 1780145 21 49 88 139 202 271 356 450 556 674 803 944 1095 1432 1812150 22 50 90 141 205 275 362 458 565 686 817 960 1114 1456 1843

Table 6-2: Discharge From Smooth Bore Nozzle - Pressures Measured by Pitot Gauge (Continued)

REFERENCE TABLES


6-4. Various Nozzles Discharge

This table is offered as an aide in testing pump performance where facilities for accurate measurement of capacity are not available. The capacities given above are conservative, and will not vary more than 5% from actual capacities with any of the standard hose that might be used.

Table 6-3: Approximate Discharge Flow From Different Nozzles At the end of Fifty Feet of Average, 2 1/2”Rubber Lined Fire Hose, for Various Pump Pressures with Discharge Valve Wide Open

PUMPPRESSURE

PSI

SIZE OF NOZZLE – GALLONS PER MINUTE

3/4 7/8 1 1 1/8 1 1/4 1 3/8 1 1/230 90 119 153 187 217 250 282

40 103 137 177 216 253 290 327

50 115 153 198 242 284 325 367

60 126 168 216 265 311 357 402

70 136 182 234 287 337 385 435

80 145 194 250 308 361 414 465

90 154 206 265 325 383 437 492

100 162 217 280 343 405 462 520

110 171 228 295 360 425 485 549

120 179 239 307 377 444 510 572

130 186 249 318 392 462 530 596

140 193 258 330 407 480 549 618

150 200 267 341 421 497 567

175 215 288 374 455 538

200 230 309 395 486

225 243 328 420

250 257 345


REFERENCE TABLES

6-5. Nozzle Pressure

Table 6-4: Pump or Hydrant Pressure required to provide Effective Nozzle Pressure through various Lengths of Rubber Lined Hose

Size of Hose 1 1 1/2 2 2 1/2 3

Size of Nozzle 1/4 3/8 1/2 5/8 5/8 3/4 3/4 7/8 1 1 1/4 1 1/2 1 1/4 1 1/2

Nozzle Press PSI

Length of Hose Feet PUMP OR HYDRANT PRESSURE - PSI

40 100 45 43 48 60 42 50 44 46 51 64 88 51 62

200 49 46 56 79 43 60 47 52 60 86 130 59 78

400 58 51 73 118 46 79 53 62 79 129 212 75 110

600 67 57 89 158 50 99 59 74 97 172 92 143

800 76 62 106 196 53 119 65 85 116 215 108 176

1000 85 68 122 235 56 138 72 96 134 258 124 208

1500 108 72 142 64 187 87 118 181 165

2000 130 96 204 72 226 103 151 227 205

60 100 67 64 72 89 63 73 65 69 75 95 132 76 92

200 74 68 84 117 65 86 70 78 89 126 196 88 115

400 87 76 107 173 69 112 79 94 116 188 111 161

600 101 85 131 231 74 138 88 111 143 250 135 208

800 114 93 153 79 164 98 127 170 158

1000 127 101 178 83 190 107 143 197 182

1500 161 122 237 95 155 130 184 264

2000 195 142 106 153 225

80 100 88 85 96 117 83 99 87 92 99 126 175 101 103

200 97 91 112 154 86 117 93 103 115 167 116 154

400 115 102 143 228 92 154 105 125 148 249 147

600 132 112 174 98 191 117 147 181 178

800 150 123 206 104 228 129 167 214 209

1000 167 134 238 110 141 191 247

1500 211 161 125 171 245

2000 254 188 140 201

100 100 111 107 120 146 104 123 108 115 125 157 126 152

200 122 113 139 192 108 145 116 128 150 209 146 190

400 143 127 177 284 115 190 130 154 200 184

600 165 140 217 123 235 145 180 250 223

800 186 154 256 131 159 206

1000 208 167 138 174 232

1500 262 200 157 211

2000 234 175 253

REFERENCE TABLES


6-6. Vertical and Horizontal Nozzle Reach

Table 6-5: Reach Of Fire Streams

Size ofNozzle 1/4" 3/8" 1/2" 5/8" 3/4" 7/8" 1" 1-1/4" 1-1/2"

NOZZLEPRESSURE EFFECTIVE VERTICAL REACH - Feet

40 30 35 40 50 59 62 64 65 6960 35 40 45 60 74 77 79 84 8780 38 42 48 65 81 85 89 94 96100 40 44 50 68 84 89 94 100 102

NOZZLEPRESSURE MAXIMUM VERTICAL REACH - Feet

40 60 65 70 75 78 79 80 80 8060 70 75 85 95 105 106 108 110 11080 78 83 95 105 117 125 132 140 140100 80 88 100 110 122 135 145 155 155

NOZZLEPRESSURE EFFECTIVE HORIZONTAL REACH - Feet

40 20 25 30 40 44 50 55 62 6660 25 32 37 50 54 61 67 75 8080 28 35 40 57 62 70 76 84 88100 30 37 42 60 66 76 84 93 95

NOZZLEPRESSURE MAXIMUM HORIZONTAL REACH - Feet

40 65 80 90 100 108 120 125 138 14060 80 95 95 120 127 142 156 176 18380 90 105 105 135 143 160 175 201 210100 95 110 110 140 153 180 205 215 223


REFERENCE TABLES

6-7. Friction Loss

Table 6-6: Friction Loss in Fire Hose Loss in PSI per 100 Feet of Hose

SIZE HOSE LINEN HOSE BEST RUBER LINED HOSE

G.P.M. 1 1/2 2 2 1/2 3/4 1 1 1/2 2 2 1/2 3 3 1/2 (2)-2 1/210 1.0 13.5 3.5 0.5 0.115 2.2 29.0 7.2 1.0 0.320 3.6 50.0 12.3 1.7 0.425 5.5 75.0 18.5 2.6 0.630 8.0 1.9 105.0 26.0 3.6 0.940 13.0 3.2 180.0 44.0 6.1 1.550 20.0 4.9 1.6 67.0 9.3 2.360 28.0 7.0 2.2 96.0 13.5 3.370 37.0 9.0 3.1 131.0 17.0 4.380 47.0 11.5 3.8 171.0 23.0 5.690 59.0 14.5 5.0 217.0 29.0 7.0

100 72.0 17.5 5.9 268.0 33.0 8.4120 25.0 8.3 386.0 47.0 11.7140 34.0 11.0 62.0 16.0 5.2 2.0 0.9 1.4160 43.0 14.0 78.0 20.0 6.6 2.6 1.2 1.9180 53.0 17.7 97.0 25.0 8.3 3.2 1.5 2.3200 63.0 21.5 121.0 30.6 10.1 3.9 1.8 2.8220 146.0 12.0 4.6 2.1 3.3240 173.0 14.1 5.4 2.5 3.9260 204.0 16.4 6.3 2.9 4.5280 237.0 18.7 7.2 3.3 5.2300 272.0 21.2 8.2 3.7 5.9320 23.8 9.3 4.2 6.6340 26.9 10.5 4.7 7.4360 30.0 11.5 5.2 8.3380 33.0 12.8 5.8 9.2400 36.2 14.1 6.3 10.1425 40.8 15.7 7.0 11.3450 45.2 17.5 7.9 12.5475 50.0 19.3 8.7 13.8500 55.0 21.2 9.5 15.2525 23.2 10.5 16.6550 25.2 11.4 18.1575 27.5 12.4 19.6600 29.9 13.4 21.2650 34.5 15.5 24.8700 39.5 17.7 28.3750 45.0 20.1 32.2

REFERENCE TABLES


Losses in rough walled, rubber hose may be 50% higher than values given above.

800 50.5 22.7 36.2850 56.5 25.4 40.7900 63.0 28.2 45.2

1000 76.5 34.3 55.0

Table 6-7: Friction Loss in 15-year-old Steel Pipe Loss in PSI per 100 Feet of Pipe

PIPE SIZE 1/8 1/4 3/8 1/2 3/4 1 1 1/4 1 1/2 2 2 1/2 3 4 6 8

G.P.M.1 52.0 12.0 2.8 0.92 45.0 10.0 3.2 4.05 55.0 18.0 4.5 1.4 0.4

10 64.0 16.0 5.0 1.3 0.615 135.0 34.0 11.0 2.7 1.3 0.520 59.0 18.0 4.7 2.2 0.825 89.0 27.0 7.1 3.4 1.230 125.0 39.0 10.0 4.7 1.7 0.635 51.0 13.0 6.3 2.2 0.740 66.0 17.0 8.0 2.9 0.945 82.0 21.0 10.0 3.6 1.250 99.0 26.0 12.0 4.3 1.4 0.660 140.0 38.0 17.0 6.1 2.0 0.870 49.0 23.0 8.0 2.7 1.180 63.0 29.0 10.0 3.4 1.590 78.0 36.0 13.0 4.3 1.8

100 96.0 44.0 15.0 5.1 2.2 0.5125 144.0 66.0 24.0 7.8 3.3 0.8150 93.0 33.0 11.0 4.6 1.1175 125.0 44.0 15.0 6.1 1.5200 56.0 19.0 7.8 1.9250 84.0 28.0 12.0 2.9300 114.0 40.0 16.0 4.0 0.6350 53.0 22.0 5.4 0.8400 68.0 28.0 6.9 1.0450 84.0 35.0 8.6 1.2500 102.0 42.0 10.0 1.4 0.4600 60.0 15.0 2.1 0.6800 25.0 3.5 1

1000 37.0 5.2 1.31500 11.0 2.72000 19.0 4.72500 29.0 7.13000 10

Table 6-6: Friction Loss in Fire Hose Loss in PSI per 100 Feet of Hose (Continued)


REFERENCE TABLES

6-8. Fittings Resistance

6-9. PSI to Elevation Conversion

Table 6-8: Resistance of Fittings Equivalent Lengths of Straight Pipe – Feet

PIPE SIZE 1/2 3/4 1 1 1/4 1 1/2 2 2 1/2 3 4 5 6 8Gate Valve 0.4 0.6 0.8 1.1 1.4 1.8 2.2 2.8 4.1 5.3 6.7 9.4

Global Valve 3.0 4.5 6.0 8.5 10.5 14.0 17.0 22.0 32.0 42.0 53.0 75.0Angle Valve 1.4 2.0 2.7 3.8 4.8 6.3 7.9 10.5 14.5 18.5 23.0 33.0Std. Elbow 1.1 1.5 2.0 2.8 3.5 4.7 5.8 7.5 11.0 14.0 18.0 24.045 Elbow 0.6 0.8 1.0 1.4 1.6 2.1 2.5 3.1 4.2 5.2 6.3 8.5

Long Sweep EI Str Run Tee

0.5 0.8 1.0 1.4 1.7 2.3 2.8 3.7 5.3 7.0 9.0 12.5

Std. Tee Thru Side Outlet

2.1 2.9 3.9 5.5 6.9 9.1 11.6 14.8 21.0 27.0 34.0 49.0

Sudden Enlarge or Contraction

1.8 2.5 3.2 4.2 5.0 6.5 7.5 9.5 13.0 16.0 19.0 25.0

Entrance to Pipe

1.0 1.3 1.6 2.2 2.6 3.3 3.9 4.9 6.5 8.2 10.0 13.0

Table 6-9: To Convert Pounds per Square Inch to Feet Elevation of Water

Feet 5 10 15 20 25 30 35 40 45 50 60 70 80 90

PSI 2.2 4.3 6.5 8.7 11 13 15 17 20 22 26 30 35 39

Feet 100 120 130 140 150 160 170 180 190 200 220 240 260 280

PSI 43 52 56 61 65 69 74 78 82 87 95 104 113 121

Feet 300 320 340 360 380 400 425 450 475 500 525 550 600 700

PSI 130 139 147 156 165 173 184 195 206 217 227 238 260 303

REFERENCE TABLES


6-10. Screw Thread

Table 6-10: American National Fire Hose Connection Screw Thread – NH

Size of Hose 3/4 1 1 1/2 2 1/2 3 3 1/2 4 4 1/2 5 6

Thr’ds per inch 8 8 9 7.5 6 6 4 4 4 4

Thread Designation

0.75-8 NH 1-8 NH 1.5-9 NH 2.5-7.5 NH 3-6 NH 3.5-6 NH 4-4 NH 4.5-4 NH 5-4 NH 6-4 NH

Max. O.D. Male 1.3750 1.3750 1.9900 3.0686 3.6239 4.2439 5.0109 5.7609 6.2600 7.0250

Ref. NFPA 1963

Underwriters Nozzle Tip Thread: 2.1875 O.D. - 12 threads per inch

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

INDEX

A

Acceptance Tests ...................................... 3-5Adjusting the Pump Pressure ..................... 4-13Annual Testing ........................................ 5-13Anode Rods ........................................... 5-11Approaching the Apparatus .......................... 4-1

B

Back Flushing ........................................... 5-3

C

Cautions .................................................. 1-2Changing from Tank to External Pressurized

Water Supply (with Gated Intake Valve) ................................ 4-18

Changing from Tank to External Water Supply (without Gated Intake Valve) ........... 4-23

Charge the Intake Line (Pressurized Supply) ....................................... 4-20

Charging Line ......................................... 4-17Check Adjustment of Intake Relief Valve ........ 2-1Chock the Wheels ...................................... 4-6Compartment Doors ................................... 4-2Connect Intake Hose ................................ 4-19Connecting Attack Line Hose ..................... 4-15Control Valves That Leak .......................... 4-21Controlling Engine Speed with Multiple

Controls ...................................... 4-15Controlling Engine Speed, Not Pumping - Pressure

Governor Operation ....................... 4-14Controlling Engine Speed, Pumping - Pressure

Governor Operation ....................... 4-14Conversion Factors .................................... 6-1Cooling the Engine ..................................... 3-2Create a Pump Chart .................................. 2-1Custom Products ....................................... 1-5

D

Daily Checks ............................................ 1-5Dangers ................................................... 1-2Definitions ................................................ 3-1

Determine Discharge Pressure ................... 4-13Discharge Relief Valve Drain (Optional) ......... 5-6Discharging Foam .................................... 4-18Discharging Water .................................... 4-15Disengaging the Pump (Driveline

Driven Pump) ............................... 4-25Disengaging the Pump (Pump and Roll) ........ 4-26Disengaging the Pump (Stationary Operation) 4-26Draining the Pumping System ...................... 5-1Driveline Driven Pump ................................ 4-7

E

Effects of Atmospheric Conditions on Engine and Pump Performance ......................... 3-6

Ending Water Flow Operation ..................... 4-25Engaging Pump when Vehicle is Driving – Advanced

Package (Optional) ......................... 4-9Engaging Pump when Vehicle is Driving – Basic

Package (Standard) ........................ 4-8Engine Speed and Pump Pressure .............. 4-14Engine Status Display ............................... 4-24Engines ................................................... 3-5

F

Fire Scene Positioning ............................... 4-6Fittings Resistance ................................... 6-11Flushing and Draining the Pump ................... 5-4Flushing the Drain Valves ........................... 5-2Folding Steps or Platforms .......................... 4-2Forward Flushing ...................................... 5-2Friction Loss ............................................ 6-9

G

General Operation ..................................... 3-1General Safety Information .......................... 1-3

H

Hose ...................................................... 4-3Hose Bed Covers ...................................... 4-2Hose Beds ............................................... 4-4

INDEX

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

Hose Chutes ............................................ 4-3Hose Connections ..................................... 4-5Hose Deployment ...................................... 4-4Hose Restraint .......................................... 4-3Hose Storage ........................................... 4-3

I

Inspection, Cleaning, and Maintenance .......... 5-1Intake Relief Valve Drain (Optional) ............... 5-6

K

Keeping Your Knowledge Refreshed and Up-to-Date .................................... 1-6

L

Lighting ................................................... 4-6

M

Maintenance Schedule ............................... 5-1Manual Pump Engagement ....................... 4-13Master Gauge Ports ................................... 5-6Measuring Pump Performance ..................... 3-5Mechanical Seal ...................................... 5-12Mechanical Seal Basics ............................ 5-12Mechanical Seal Operation and Maintenance 5-12Mechanical Shaft Seal .............................. 5-12Monitoring Intake Pressure ........................ 4-21

N

Nozzle Pressure ........................................ 6-7

O

Oil Level Dipstick and Fill Port and Drain Plug 5-11Operating Characteristics of Pumps .............. 3-6Operating from a Static (Draft) Water Supply . 4-27Operating the Engine ................................. 3-2Operation of Pump ..................................... 4-7Operation PUC Fire Pump ........................... 4-7

P

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

Positioning on Roads .................................. 4-6Positioning the Apparatus ............................ 4-6Power Take-Off (PTO) Safety Information ....... 1-3Powershift PTO, Cold Weather Operation ....... 1-4Preventive Maintenance Checks & Services .... 5-4Primer Pump Lubrication ............................. 5-5Professional, Training, and Standards

Organizations ................................. 1-5PSI to Elevation Conversion ....................... 6-11Pump Priming Problem Solutions ................ 4-21Pump Storage ........................................... 5-4Pump Tests .............................................. 6-2Pump Transmission Lubrication ...... 5-7, 5-8, 5-9Pumping in Cold Weather ............................ 3-4Pumping Salt Water ................................... 3-4

R

Refilling the Tank ..................................... 4-23Responsibility ............................................ 1-3Resume Discharge Operation ..................... 4-24Rotating Auxiliary Driveshafts ....................... 1-4

S

Safety ...................................................... 1-3Safety Defect Reporting .............................. 1-6Safety Warning Labels ................................ 1-2Screw Thread ......................................... 6-12Securing Pump System ............................. 4-26Shutting Off Water Flow ............................ 4-25Smooth Bore Nozzle Discharge .................... 6-4Source of Water Supply .............................. 3-4Stepping and Walking Surfaces .................... 4-1Stop Flowing Water .................................. 4-23Suction Line .............................................. 3-2Suction Strainers ....................................... 3-2Supply the Pump ..................................... 4-21Supply Water to Pump .............................. 4-10

T

Testing for Air Leaks ................................... 3-3

INDEX

© 2014 Pierce Manufacturing Inc. All Rights Reserved. PUC Pumpers / Index-3

Testing of Equipment for Practice .................. 3-4To Engage the Pump—Stationary Operation ... 4-7To prevent injury to yourself and/or damage to the

equipment ..................................... 1-3

V

Various Nozzles Discharge .......................... 6-6Vertical and Horizontal Nozzle Reach ............ 6-8

W

Warnings ................................................. 1-2What To Do If You Lack Knowledge .............. 1-1When Finished Pumping ............................. 3-4Who Should Use, Service and Maintain

This Vehicle ................................... 1-1

INDEX

Index-4 / PUC Pumpers © 2014 Pierce Manufacturing Inc. All Rights Reserved.

Documents

Configuration (PUC)Pierce Ultimate Pumpers...© 2014 Pierce Manufacturing Inc. Part No. PM-P-OM420-0914 Configuration (PUC) Pierce Ultimate Operation & Maintenance Manual Pumpers