HUSKY 12 GPM FOAM SYSTEM Operation & Maintenance Manual

TABLE OF CONTENTS

FOREWORD

1PURPOSE OF MANUAL ...... v

2SCOPE ...... v

3CUSTOMER ASSISTANCE INFORMATION ...... v

SECTION 1. SAFETY

1-1 INTRODUCTION ...... 1-1

1-1.1 TO THE OWNER—OPERATION AND MAINTENANCE OF THIS APPARATUS ...... 1-1 1-1.2 DESCRIPTION OF “DANGER,” “WARNING,” AND “CAUTION” ...... 1-1

1-2 LIST OF ABBREVIATIONS ...... 1-2

SECTION 2. GENERAL

2-1 HUSKY 12 SPECIFICATIONS ...... 2-1

2-1.1 FOAM PROPORTIONER ...... 2-1 2-1.2 SYSTEM CAPACITY ...... 2-1 2-1.3 DISCHARGES ...... 2-1 2-1.4 SYSTEM ELECTRICAL LOAD ...... 2-1 2-1.5 MAINTENANCE MESSAGE ...... 2-1 2-1.6 FLUSH SYSTEM ...... 2-2 2-1.7 FOAM CONCENTRATE COMPATIBILITY ...... 2-2

2-2 DESCRIPTION OF MAJOR COMPONENTS ...... 2-2

2-2.1 HYDRAULIC DRIVE SYSTEM ...... 2-2 2-2.1a HYDRAULIC GEAR PUMP ...... 2-3 2-2.1b HYDRAULIC OIL FILTER ...... 2-3 2-2.1c HYDRAULIC OIL RESERVOIR ...... 2-4 2-2.1d HYDRAULIC OIL COOLER ...... 2-4 2-2.1e HYDRAULIC MANIFOLD BLOCK ...... 2-5 2-2.2 FOAM SUPPLY SYSTEM ...... 2-5 2-2.2a FOAM CONCENTRATE TANK ...... 2-5 2-2.2b FOAM SUPPLY VALVE ...... 2-6 2-2.2c FOAM CONCENTRATE PUMP ...... 2-6 2-2.2d FOAM SELECTOR VALVE ...... 2-7 2-2.2e PANEL MOUNTED STRAINER / EXTERNAL PICK-UP CONNECTION ...... 2-8 2-2.2f PICK-UP HOSE ...... 2-9 2-2.2g FOAM CHECK VALVE ...... 2-9 2-2.3 WATER SUPPLY SYSTEM ...... 2-9 2-2.3a MANIFOLD AND MASTER DRAINS ...... 2-10 2-2.3b IN-LINE WATER CHECK VALVE ...... 2-10 2-2.3c WATER FLOWMETER ...... 2-11 2-2.4 CONTROL HEAD & DISPLAY ...... 2-11

SECTION 3. OPERATION

3-1 FOAM SYSTEM OPERATION ...... 3-1

3-1.1 CLASS A FOAM - USING ON-BOARD FOAM TANK ...... 3-1 3-1.2 CLASS A FOAM - DRAFTING ...... 3-2 3-1.3 CLASS B FOAM - USING ON-BOARD FOAM TANK ...... 3-2 3-1.4 CLASS B FOAM - DRAFTING ...... 3-3 3-1.5 CHOOSING A FOAM SOURCE ...... 3-4

3-2 FLUSHING SYSTEM ...... 3-5

3-2.1 GENERAL FLUSHING INFORMATION ...... 3-5 3-2.2 MANUAL FLUSH MODE ...... 3-6

3-3 PRIMING SYSTEM ...... 3-7

3-4 FILLING FOAM TANK ...... 3-8

3-4.1 FILL DOME METHOD ...... 3-8 3-4.2 PICK-UP HOSE METHOD ...... 3-8

3-5 MANUAL MODE (MANUAL WATER FLOW) ...... 3-9

SECTION 4. MAINTENANCE

4-1 MAINTENANCE INTRODUCTION ...... 4-1

4-1.1 TESTING AFTER SYSTEM MAINTENANCE ...... 4-1

4-2 SET-UP & CALIBRATION ...... 4-2

4-2.1 SET-UP MODE ...... 4-2 4-2.2 PARAMETERS ...... 4-2 4-2.3 CALIBRATE FLOWMETER MODE ...... 4-4 4-2.4 CALIBRATE FOAM PUMP (LVDT) TRANSDUCER ...... 4-6 4-2.5 CALIBRATE CLASS A FOAM MODE ...... 4-8 4-2.6 CALIBRATE CLASS B FOAM MODE ...... 4-9 4-2.7 SET CLASS A CONCENTRATE DEFAULT PERCENTAGE ...... 4-10 4-2.8 SET CLASS B CONCENTRATE DEFAULT PERCENTAGE ...... 4-10 4-2.9 SELECT SINGLE OR DUAL FOAM TANK SYSTEM ...... 4-11 4-2.10 SET STARTUP OR DEFAULT FOAM SOURCE ...... 4-12 4-2.11 TANK FILL ENABLE/DISABLE ...... 4-13 4-2.12 SET AUTOMATIC FLUSH TIME ...... 4-13 4-2.13 AUTO START ...... 4-14 4-2.14 DRAIN MODE ...... 4-15 4-2.15 RESET MAINTENANCE REMINDERS ...... 4-17 4-2.16 CHECK CURRENT SOFTWARE REVISION ...... 4-18 4-2.17 DIAGNOSTIC INPUTS ...... 4-19 4-2.18 DIAGNOSTIC OUTPUTS ...... 4-20 4-2.19 PROGRAMMING ...... 4-21

4-3 TROUBLESHOOTING ...... 4-22

4-4 PERIODIC OPERATION ...... 4-34

4-5 GENERAL MAINTENANCE PROCEDURES ...... 4-34

4-6 PREVENTIVE MAINTENANCE CHECKS AND SERVICE ...... 4-35

4-6.1 INTRODUCTION ...... 4-35

4-6.2 EXPLANATION OF COLUMNS ...... 4-35

4-7 AFTER EVERY USE INSPECTION ...... 4-36

4-8 WEEKLY INSPECTION ...... 4-36

4-9 QUARTERLY INSPECTION ...... 4-37

4-10 ANNUAL INSPECTION ...... 4-37

4-11 RECOMMENDED HYDRAULIC OIL FOR HUSKY 12 PROPORTIONING SYSTEM ...... 4-37

4-11.1 CHARACTERISTICS ...... 4-37 4-11.2 RECOMMENDATIONS ...... 4-37 4-11.3 OIL CHANGE INFORMATION ...... 4-38

4-12 SYSTEM DIAGRAMS ...... 4-39

INDEX

1. Purpose of Manual

The information in this manual is for the operation and maintenance of Pierce Husky 12 Proportioning System. It is intended to serve as a guide to assist qualified operators and mechanics in the operation and maintenance of their vehicle. Keep this manual with the vehicle at all times.

NOTE: Some of the details of your vehicle’s design and construction may be unique to your department alone. For this reason, information contained in this manual may be generic at times. Questions on major inconsistencies between your vehicle’s configuration and the information contained in this manual should be directed to your Pierce Dealer or Sales Representative.

2. Scope

This supplemental operator’s manual provides operating and maintenance instructions for Husky 12 Proportioning Systems on vehicles manufactured by Pierce Manufacturing Inc. This manual provides information under the following headings: Safety. Contains important safety information, requirements before placing a vehicle in service, and information on installing custom equipment and accessories. General. Includes information and instructions on the operation of major systems, controls, and indicators. Operation. Contains procedures on performing common operations. Maintenance. Contains scheduled preventive maintenance checks and inspections. Appendixes. Contains information obtained directly from vendors who supply major components found on this unit.

3. Customer Assistance Information

Your satisfaction with your Pierce apparatus is important to your dealer and Pierce Manufacturing Inc. Normally, any question or concern you may have with your apparatus can be handled by your selling or servicing dealer. Your dealer has the facility, trained technicians, special tools, and up-to-date information to promptly address any issue that may arise. Pierce Manufacturing Inc. has empowered dealers to make decisions and repair vehicles, and they are eager to resolve your issues to your complete satisfaction. Should you encounter an issue with your Pierce apparatus that requires service, take the following steps: Step 1.) Contact your authorized Pierce selling or servicing dealer. They will make the necessary arrangements to order the necessary parts and make the required repairs. Step 2.) If they are not able to repair the problem to your satisfaction, discuss your concern with a member of dealer management. Normally, concerns can be quickly resolved at that level. If the matter has already been reviewed with the Sales, Service, or Parts Manager, contact the owner of the dealership or the General Manager. Step 3.) If, after contacting a member of the dealership management, it appears your question or concern cannot be resolved by the dealership without further help, you may contact Pierce Manufacturing Inc. at 888-Y-PIERCE (888- 974-3723).

1-1. Introduction

1-1.1 To the Owner—Operation and Maintenance of This Apparatus The information in this manual is for the operation and maintenance of this apparatus. The intent is to instruct operators in the proper operation of this equipment and to warn of improper procedures and potentially dangerous situations. Only personnel who are totally familiar with this manual and have training are qualified to operate this apparatus. It is the responsibility of the department owning this equipment to permit only qualified personnel to operate this apparatus. Qualified drivers of other fire apparatus will require further training for the handling of this unit.

1-1.2 Description of “DANGER,” “WARNING,” and “CAUTION” THIS SAFETY SYMBOL INDICATES IMPORTANT SAFETY MESSAGES IN THIS MANUAL. WHEN YOU SEE THIS SYMBOL, CAREFULLY READ THE MESSAGE THAT FOLLOWS THIS SYMBOL. BE ALERT TO THE POSSIBILITY OF PERSONAL INJURY OR DEATH. Warning labels located on the vehicle and warning statements contained in this manual all use the same terminology to warn of potential hazards. Each of these potentially harmful conditions is described below:

A hazard that will result in death or serious personal injury.

A hazard which might result in death or serious personal injury.

A hazard which might result in personal injury or damage to property or equipment.

The “signal words” of DANGER, WARNING, and CAUTION have specific meanings to alert you to the relative level or probability of the hazard. Take the safety warnings seriously. If you do not understand them or have questions about them, contact Pierce Manufacturing Inc.

1-2. List of Abbreviations

TERM DEFINITION AFFF Aqueous Film Forming Foam AR-AFFF Alcohol Resistant Aqueous Film Forming Foam FFFP Film Forming Fluoro-Protein GPM Gallons per Minute LCD Liquid Crystal Display LPM Liters per Minute NFPA National Fire Protection Association PSI Pounds per Square Inch RPM Revolutions per Minute

2-1. Husky 12 Specifications

2-1.1 Foam Proportioner The foam proportioning system is an on demand, automatic proportioning, single point, direct injection system suitable for all types of Class A & Class B foam concentrates, including the high viscosity (6000 cps), alcohol resistant Class B foams. The operation of the system is based on direct measurement of water flow, and remains consistent within the specified flows and pressures. The system automatically balances and proportions foam solution at rates from 0.1% to 9.9% regardless of variations in water pressure and flow, up to the maximum rated capacity of the foam concentrate pump. The design of the system allows operation from draft, hydrant, or relay operation. This provides a versatile system to meet the demands at a fire scene.

2-1.2 System Capacity The system has the ability to deliver the following (minimum) foam solution flow rates at accuracies that meet or exceed NFPA requirements at a pump rating of 250 PSI.

Table 2-1: Maximum Foam Solution Flow

Concentration Percentage Capacity 6% 200 GPM 3% 400 GPM 1% 1,200 GPM .5% 2,400 GPM* .3% 4,000 GPM*

The Class A foam setting is in .1% increments from .1% to 1%. Typical settings are .3% and .5%. *The maximum capacity is limited to the plumbing and water pump capacities.

2-1.3 Discharges The number of discharges capable of dispensing foam varies from truck to truck, depending on customer specifications. Foam discharges can be identified by red/white tags; water only discharges can be identified by silver/black tags.

2-1.4 System Electrical Load The electrical load for the foam proportioning system is less than five (5) amps at 12VDC.

2-1.5 Maintenance Message A message is displayed on the control head to notify the operator when system maintenance needs to be performed. The message displays the interval for cleaning the foam strainer & water strainer, and changing the hydraulic oil. These messages will appear after 20 hours of foam system operation if not reset during normal maintenance.

2-1.6 Flush System A flush mode allows the system to flush all foam concentrate with clear water. The flush circuit control logic ensures the foam tank supply valve is closed prior to opening the flush valve. The flush valve is electrically controlled and is operated from the foam system control head. A manual flush drain valve is located under the driver’s side running board.

2-1.7 Foam Concentrate Compatibility The Husky 12 Foam Proportioning System is designed to be compatible with most known Class A and Class B foam concentrates at the date of printing of this manual. The Husky 12 can proportion foam concentrates across a wide range of viscosity, from low viscosities such as Class A or AFFF, through high viscosity AR-AFFF.

Table 2-2: Acceptable Foam Concentrate Viscosity Range

Acceptable Foam Concentrate Viscosity Range Minimum 3 Centistokes Maximum 6000 Centipoise* * Brookfield #3 Spindle @ 30 RPM

2-2. Description of Major Components

To understand the relationship of the various components and their functions, refer to Para 4-12., System Diagrams. The following information is intended to identify the various components and describe their function within the system. For specific construction, maintenance, and parts information, please refer to applicable service groups (chapters) in the service manual, drawings included in this manual, and the parts catalog for this unit.

2-2.1 Hydraulic Drive System The hydraulic drive system that powers the foam pump is automatically activated when the water pump is engaged. A hydraulic oil cooler prevents overheating of the hydraulic oil, which can be detrimental to system components. The oil/water cooler is designed to allow continuous system operation without allowing hydraulic oil temperature to exceed the oil specifications. The system is delivered with ISO 68 hydraulic oil.

2-2.1a Hydraulic Gear Pump

Figure 2-1: Hydraulic Gear Pump

1001 The larger line is inlet from hydraulic tank; the smaller line is pressure line that drives the foam pump. The pump may be driven directly off Hale pump transmission, the Waterous impeller shaft, or a transmission-driven PTO (Chelsea) controlled by the pump engaged circuit #1659.

2-2.1b Hydraulic Oil Filter

Figure 2-2: Hydraulic Oil Filter

1002 The Hydraulic Filter is a pressure bypass element-type filter manufactured by Hydac. The filter element is replaceable. The unit is installed inside the pumphouse and is used to filter the pressurized hydraulic loop. The replacement part number for the filter element is Pierce P/N 1460998.

2-2.1c Hydraulic Oil Reservoir

Figure 2-3: Hydraulic Oil Cooler

Shut-off Valve (in-line position is OPEN) To Hydraulic Pump

1003 The Hydraulic Reservoir (approximately four gallon capacity) provides a reservoir for the hydraulic drive system. The tank is sufficient size to minimize foaming of the hydraulic fluid and is located to facilitate checking level and adding oil. Refer to Para 4-11., Recommended Hydraulic Oil for Husky 12 Proportioning System, for recommended hydraulic oil for the Husky 12 system.

2-2.1d Hydraulic Oil Cooler

Figure 2-4: Hydraulic Oil Cooler

Hydraulic Oil Cooling Water In/Out In/Out

1004

The Hydraulic Cooler is an oil-to-water type heat exchanger. It takes water directly from the water pump to cool the closed loop hydraulic system. The cooling water is then returned to the water pump suction while the cooled hydraulic oil is returned to the hydraulic tank. The hydraulic cooler allows for continual operation of the Husky 12 hydraulic system.

2-2.1e Hydraulic Manifold Block

Figure 2-5: Hydraulic Manifold Block

Hydraulic Relief Valve

Reverse Plug Forward Plug

Not shown: P1 pressure test port (on side of hydraulic block)

1005 The Hydraulic Manifold Block assembly is a manifold block that controls the direction of the hydraulic oil flow in the system. The manifold block consists of the machined block, a hydraulic compensating valve, an internal hydraulic shuttle valve, a hydraulic relief valve, hydraulic pressure test port and the hydraulic proportional valve.

2-2.2 Foam Supply System The Foam Supply System stores, pumps and distributes the foam concentrate to the foam/water discharges by use of a foam concentrate tank, foam tank shut-off valve, auxiliary foam inlet, in-line foam strainer, foam pump, check valve and foam injection manifold.

2-2.2a Foam Concentrate Tank The Foam Concentrate Tank is designed to provide on-board storage of foam concentrate. Design features shall include: construction compatible with foam concentrates, foam tank drain valve, expansion dome with locking fill hatch and pressure/vacuum vent. The expansion dome allows for changes in foam concentrate volume due to variations in temperature. Foam concentrate level shall be maintained at the one-third full mark in the expansion dome at a minimum to reduce the air to foam concentrate interface. The pressure vacuum vent automatically balances internal foam tank pressure under both suction and filling operations. It is recommended that a cleanable foam concentrate level unit be installed in the storage tank. The control head will display a warning message when the foam tank being used is below one quarter tank.

2-2.2b Foam Supply Valve

Figure 2-6: Foam Supply Valve

1006/1007 An electric/air valve is used for the Foam Supply Valve. The foam supply valve shall be controlled at the foam system control head for ease of operation. The supply valve is located to eliminate air pockets in the foam tank supply hose. This foam supply valve opens automatically when the system is turned ON.

2-2.2c Foam Concentrate Pump

Figure 2-7: Foam Concentrate Pump

1008 The Foam Concentrate Pump assembly is a brass/steel constructed, double-acting cylinder pump. The hydraulic end of the pump is painted steel and controls the speed and direction of both cylinders. The hydraulic piston is connected to the foam piston by a single, straight shaft. The foam end of the pump is brass construction and contains 4 cartridge type check valves to prevent foam from flowing the wrong direction in the pump.

The foam pump also has a pressure relief valve that recirculates the foam from the discharge side to the inlet side in the case of an obstruction or overpressure situation. The foam pump speed and operation are monitored by a foam pump transducer located in the hydraulic end of the pump assembly. The foam concentrate pump is self-priming and has the capability to draw foam concentrate from external supplies such as drums or pails. The foam concentrate pump has a maximum capacity of 12 GPM with all types of foam concentrates with a viscosity at or below 6000 cps including protein, fluoroprotein, AFFF, FFFP, or AR-AFFF.

2-2.2d Foam Selector Valve

Figure 2-8: Foam Selector Valve

Injection Hose

Tank Fill Hose*

*A foam selector valve From Foam Pump with the tank fill option is shown. On units without the tank fill option, the fill hose will be routed directly to tank.

1009 The Foam Selector Valve is a 2-way, quarter-turn ball valve that directs the foam for foam injection (normal operation) or tank filling. A “CHECK SELECTOR VALVE” message is displayed by the control head in the event that the valve is not in the correct position for the operation selected.

2-2.2e Panel Mounted Strainer / External Pick-Up Connection

Figure 2-9: Panel Mounted Strainer / External Pick-Up Connection

1010 A bronze body strainer / connector unit is mounted on the pump panel. The external foam pick-up consists of one (1) 1 in. male connection with chrome-plated cap, integrated to a 2 in. strainer clean-out cap. A check valve is installed in the pick-up portion of the clean-out cap. A basket style stainless steel screen is installed in the body of the strainer / connector unit. The strainer is used to prevent any debris from entering the foam system and possibly interfering with the internal foam pump check valves. Removal of the 2 in. clean-out cap is all that is required to gain access to and remove the stainless steel basket screen. The strainer / connector is located ahead of the foam concentrate pump inlet port, to insure that all agent reaching the foam pump has been strained. The external foam pick-up permits the use of a foam agent that is not stored on the vehicle. The external foam pick- up also allows continued operation after the on-board foam tank is empty. The external foam pick-up can also be used with training foam or colored water for training purposes. This connection also functions as the Class A tank fill (when equipped with tank fill option) and as the foam tank drain.

2-2.2f Pick-Up Hose

Figure 2-10: Pick-up Hose

1012 A 1 in. flexible hose, with an end for insertion into foam containers, is provided. The hose has a 1 in. female swivel NST thread swivel connector. (The hose is part of loose equipment.)

2-2.2g Foam Check Valve

Figure 2-11: Foam Check Valve

1013 The Foam Check Valve located in the foam supply line prevents water from flowing backwards through the foam system and contaminating the foam supply.

2-2.3 Water Supply System The water supply system supplies water to the foam injection manifold for foam to be added and distributed to the foam/water discharges. This system consists of an in-line water check valve, water flowmeter and flowmeter installation tee. The size of the check valve and the flowmeter installation tee are dependent on the number of foam/ water discharges in the system.

2-2.3a Manifold and Master Drains

Figure 2-12: Manifold & Master Drains

1066/1067 The manifold drains are used to bleed off pressure/water anytime the water pump has been pressurized (after the water pump is shut off). If a dry water pump condition is desired, leave manifold drains open until the fire scene is reached. The master pump drain will empty both the discharge and inlet manifolds of water when opened. The water pump drain should be pulled (opened) daily.

2-2.3b In-line Water Check Valve

Figure 2-13: In-line Water Check Valve

1014 The In-line Water Check Valve prevents foam from entering the water pump and the remainder of the water system. It is installed in the water piping, before the foam injection manifold and the water flowmeter.

2-2.3c Water Flowmeter

Figure 2-14: Water Flowmeter

1015 The Water Flowmeter measures the flow of water supplied to the foam/water discharges before foam is injected. This controls the amount of foam that is injected when the Husky 12 foam system is turned on.

2-2.4 Control Head & Display The control head directs a microprocessor, which receives input from the system’s water flowmeter while also monitoring the position of the foam concentrate pump. The microprocessor compares the values of the water flow versus the position/rate of the foam pump, to ensure the proportion rate is accurate. The foam system is controlled by a foam system control head/display module that contains the programming to actuate the appropriate valves, direct the hydraulic fluid, and control the injection rate of the foam. All components plug into this module and are what actually control the system. The user interfaces the foam system through this module. If replaced, the system calibration must be checked.

Figure 2-15: Control Head & Display

OM130_20 It is located on the main pump panel. It has six operating buttons: System On/Off, Page, Foam Prime, Enter, Arrow Up, Arrow Down. The display is a 4.3 diagonally measured color, LCD screen. System power is indicated by a green LED; the foam pump operating is indicated by a green LED. The foam system can be turned on or off from most any screen, you do not have to be at the home screen to turn the system on and off. Information displayed on the LCD screen includes: mode of operation and various setup or information displays. If the foam system is turned OFF, the display functions as a flowmeter. The percent of injection has presets for class A and class B foam. These presets can be changed at the fire department as desired. The percent of injection can be easily changed at the scene to adjust for changing demands. The modes of operation are: Class A Foam, Class B Foam (optional), Draft Class A, Draft Class B, Prime, Flush, Tank A Fill (optional), Tank B Fill (optional), Manual, and Set-up. Pressing the PAGE button on the display allows the user to select the option to from choose a foam class. Detailed instructions on the operation of each mode can be found in Section 3, “Operation”.

Figure 2-16: Control Head & Display - Run Mode

OM130_21

3-1. Foam System Operation

3-1.1 Class A Foam - using on-board Foam Tank

Figure 3-1: Control Head in Class A Foam Mode

OM130_23 1. Engage water pump transmission. 2. Recirculate water. 3. Turn the system ON.

NOTE: • The default foam valve will open automatically (typically Class A, @ 0.3-.5%).

• If water flow drops below 20 GPM, the foam system will go into standby until the water flow is increased to 20 GPM or above. At the toggle point, between 19-20 GPM, the system will want to go on and off standby. Maintaining water flow above 20 GPM will prevent this.

4. Begin flowing water, foam pump will activate. 5. Use the ARROW UP / ARROW DOWN buttons to change percentage (if needed). 6. When beginning the mop up phase, turn the system OFF; use the foam in the hose for mop up.

NOTE: The only flush needed is to run the hose until it is mostly free of bubbles. The foam pump is designed to be flooded with foam.

3-1.2 Class A Foam - Drafting

Figure 3-2: Control Head in Class A Drafting Mode

OM130_24a 1. Set up for drafting operation by positioning foam and hooking up pick-up hose. 2. Press the PAGE button until the DRAFT CLASS A screen appears, then press ENTER. On-board tank valves will close, causing suction to draw from foam inlet. 3. The default percentage will remain the same as the on-board Class A tank current setting. 4. Use the ARROW UP / ARROW DOWN buttons to change percentage (if needed). 5. See Para 3-2.1, General Flushing Information.

3-1.3 Class B Foam - using on-board Foam Tank

Figure 3-3: Control Head in Class B Foam Mode

OM130_24b

During the automatic flush, water must be flowing through an open foam discharge OR open manifold drain to give the flush solution somewhere to go.

NOTE: This operation is only possible when the Class B foam tank is installed and enabled.

1. Press the PAGE button until the CLASS B FOAM screen appears, then press ENTER. The Class A foam valve will close; an automatic flush will occur prior to the Class B valve opening, provided the water flowmeter senses water flow. 2. Use the ARROW UP / ARROW DOWN buttons to change percentage (if needed). 3. See Para 3-2.1, General Flushing Information.

3-1.4 Class B Foam - Drafting

Figure 3-4: Control Head in Class B Drafting Mode

OM130_27 1. Set up for drafting operation by positioning foam and hooking up pick-up hose. 2. Press the PAGE button until the DRAFT CLASS B screen appears, then press ENTER. On-board tank valves will close, causing suction to draw from foam inlet.

NOTE: An automatic pre-programmed flush of 10-15 seconds will occur when changing from Class A to Class B foam, once the water flowmeter senses water flow.

3. The default percentage will remain the same as the on-board Class B tank current setting. 4. Use the ARROW UP / ARROW DOWN buttons to change percentage (if needed). 5. See Para 3-2.1, General Flushing Information.

3-1.5 Choosing a Foam Source

Figure 3-5: Choosing a Foam Source

OM130_22

NOTE: When ever there is a foam class change, the system will automatically flush the pump with water to prevent mixing of foam types.

NOTE: If you highlight an alternate class of foam (Tank 1 Class A to Draft Class B) and press the ENTER button, a new screen will be displayed giving the user a second chance to continue with the new class of foam or revert back to the previous class of foam used.

1. While in the normal run screen, press the PAGE button to go to the MODE SELECT screen. 2. Use the green UP/DOWN arrows to highlight “Change Foam Source” from the menu. 3. Press the ENTER button which will bring you to the SELECT FOAM SOURCE screen.

NOTE: • If you highlight a currently used foam type (Tank 1 Class A to Draft Class A) and press the ENTER button, you will be transferred back to the HOME screen with that source enabled.

• If you highlight an alternate class of foam (Tank 1 Class A to Draft Class B) and press the ENTER button, a new screen will be displayed, giving the user a second chance to continue with the new class of foam or revert back to the previous class of foam being used.

• Whenever there is a foam class change, the system will automatically flush the pump with water to prevent mixing of foam types in the pump.

4. Use the UP/DOWN arrows to highlight the desired foam source and press ENTER.

3-2. Flushing System

3-2.1 General Flushing Information

NOTE: For the purposes of this manual, it is assumed that Class A foam is the most commonly used agent and that the system will be stored wet with Class A foam concentrate. If Class A foam is not the primary agent, adjust procedures to accommodate the primary foam concentrate.

Typically, no flushing is needed. The Husky 12 foam pump is designed to be flooded with foam. Unless the optional Class B foam tank was used, a different brand of Class A foam was drafted, or Class B foam was drafted, the only system flush that is needed is to turn the system OFF and continue flowing water until the presence of bubbles is minimal. When beginning mop-up operations at the scene, turn the system OFF and use the foam in the hose for mop-up. When equipped with two on-board foam tanks (Class A & Class B), an automatic flush will occur for 10-15 seconds when switching between the two tanks. A foam discharge or manifold drain must be open during the automatic flush to give the flush solution somewhere to go. This automatic flush time can be adjusted in the set-up mode, refer to Para 4-2.12, Set Automatic Flush Time for instructions. In addition to the automatic flush, it is recommended to do an additional manual flush to ensure the system is completely free of contaminates.

3-2.2 Manual Flush Mode

Figure 3-6: Control Head in Flush Mode

OM130_29

NOTE: • The Manual Flush Mode is only for use when additional flush time is desired, such as after switching between types and / or brands of foam.

• Flush mode can be enabled without first turning off the system.

1. From the normal run screen, press PAGE to get to the MODE SELECT screen. 2. Toggle the UP/DOWN buttons to highlight the flush ON/OFF. 3. Press the ENTER button once to enable control of the manual flush and the ON/OFF highlighted area will begin to flash on and off to indicate that you may toggle the UP/DOWN arrows to turn on the manual flush.

You must have the water pump engaged and flowing water for the flush to begin. In the yellow warning bar on the display, a message in red will tell you “water flow is needed”, if you do not have water flow.

4. If water is flowing, the screen will go to the SYSTEM FLUSH TIME screen and count down the preset seconds for the flush. At the end of the flush, you will be returned to the normal run mode screen.

3-3. Priming System

Figure 3-7: Control Head in Prime Mode

om130-20 The Prime Mode is used to accelerate the foam pump for a short period of time, such as to purge the air out of the on-board tank lines after initial filling or to fill the suction hose while drafting. 1. Select foam source.

Water must be flowing through an open foam discharge OR open foam pump discharge drain to give the foam solution somewhere to go.

NOTE: Perform steps (2) thru (4) if the foam system is installed on a Pierce Ultimate Configuration (PUC) apparatus, otherwise skip to step (5).

2. Open foam pump discharge drain. 3. Press FOAM PRIME button to activate. Release FOAM PRIME button when foam is discharged out of the foam pump discharge drain. 4. Close the foam pump discharge drain. 5. Open the manifold drain. 6. Press FOAM PRIME to activate. Release the FOAM PRIME button when foam is discharged out of the manifold drain.

NOTE: Allow water/foam solution to run out of manifold until it is mostly clear of foam, if unit is not immediately going to be used to fight a fire.

7. Close the manifold drain.

3-4. Filling Foam Tank

Do not mix different types or manufacturer’s brands of foam concentrate in the foam cells or piping. Mixing of different foam concentrates (either type or manufacturer) may cause deterioration of the foam concentrate, improper proportioning, and poor performance in a fire situation. Mixing of Class A and Class B foam concentrates may result in a chemical reaction that can create globules, which can clog orifices and cause system failure.

3-4.1 Fill Dome Method

Do not mix different types or manufacturers brands of foam concentrate in the foam cells or piping. Mixing of different foam concentrates (either type or manufacturer) may cause deterioration of the foam concentrate, improper proportioning and poor performance in a fire situation. Mixing of Class A and Class B foam concentrates may result in a chemical reaction that can create globules, which can clog orifices and cause system failure.

NOTE: Locate and close all foam tank and manifold drains. They may be found on and behind both the driver and passenger side pump panels.

When filling the foam concentrate during a non-fire situation, the following procedure is recommended: 1. The vehicle should be parked on a level surface or with the expansion dome of the tank slightly inclined. 2. If filling from a pressurized source through the expansion dome hatch, the hose should be extended to the bottom of the tank to minimize frothing of the foam concentrate. 3. If foam concentrate must be added by pouring through the expansion dome hatch, it must be done slowly to prevent aeration. If aeration occurs inside the tank, stop pouring until the foam concentrate bubbles dissolve. Take care not to allow dirt or debris to enter the tank. Pour the foam concentrate down the center of the round tube when filling the tank. This tube goes into the tank and allows the foam concentrate to enter under the surface of foam currently in the tank to reduce aeration of the foam per NFPA.

3-4.2 Pick-up Hose Method 1. Engage water pump to activate hydraulics and recirculate water. 2. Attach pick-up hose to foam pump inlet. Place pick-up hose in container filled with foam concentrate.

Figure 3-8: Flush/Fill Mode

1462 3. From the normal run screen, press PAGE to get to the MODE SELECT screen. 4. Toggle the UP/DOWN buttons to highlight one of the tanks to be filled with foam concentrate. 5. Press the ENTER button once to enable control of the manual fill. The ON/OFF highlighted area will begin to flash, indicating that you may toggle to UP/DOWN arrows to turn on the manual fill.

NOTE: In the yellow warning bar area on the display, a message in red will advise “Tank Valve Not Closed” if you do not have the foam selector valve in the correct position for filling.

6. The tank will fill until the full level is reached in the tank. 7. Remove pick-up hose from foam pump inlet.

3-5. Manual Mode (Manual Water Flow)

This mode of operation is the NFPA required manual override. This mode is used to activate the foam pump without the flowmeter operating.

In this mode, the foam pump will run regardless of water flow. If discharges are closed, these lines may be charged to over 300 PSI. At least one discharge or manifold drain must be open before entering this mode.

In this mode, there are no interlocks, controls, or specific steps required. Use additional caution when operating in the manual mode. Failure to comply may result in injury or damage to equipment.

Figure 3-9: Control Head in Manual Mode

OM130_33 1. While in the normal run screen, press the PAGE button to go to the MODE SELECT screen. 2. While in the MODE SELECT screen, toggle the UP/DOWN arrows to highlight “Manual Water Flow”. 3. Press the ENTER button, which will bring up a warning screen, giving you a second chance to continue with the manual water flow choice, or revert back to the previous auto water flow mode.An alternate method would be to set the GPM to a fixed rate and adjust the percentage of foam.

4-1. Maintenance Introduction

This section of the manual has been prepared to help keep your equipment in good operating condition and ready for its primary mission. The procedures and recommended intervals in this section are based on normal operating conditions and may have to be modified to meet the existing conditions. Some environmental concerns may dictate that inspection and maintenance be performed at more frequent intervals. For various proportioning system components (water pump, discharge devices, valves, actuators, etc.), refer to that particular component’s Operation and Maintenance Manual or Service Manual Group (chapter).

If, for any reason, the hydraulic reservoir shutoff valve is ever in the closed position, the hydraulic pump should be de-coupled from the water pump or the truck must be taken out of service. Failure to do so will result in severe damage to the hydraulic pump.

4-1.1 Testing After System Maintenance If during the course of normal system maintenance it becomes necessary to replace, repair, or modify system components, component parts, operating devices or equipment, the system must be tested to ensure proper operation before being placed back into service. The services of a qualified field engineer to inspect the system, run the tests for start-up, and the annual inspection can be provided. Additional details can be obtained by contacting Pierce Manufacturing.

During cold weather, the foam system must be blown out after testing with water. Water cannot remain in the foam system after testing. Either fill the foam system with foam concentrate or blow out the foam system with compressed air using the following procedure. Failure to comply may result in the water freezing and damaging foam system components.

1. Draining Foam Pump After Testing a. Open all drains. Remove foam inlet cap. If equipped, turn the selector valve to the middle position (halfway between TANK FILL and INJECT). Cycle foam tank valves as needed until tanks and lines are empty. Reinstall inlet cap. b. After moving truck to its destination, cycle the foam tank valves again to get any residual water out of the lines. 2. Blowing Out After Testing a. After blowing out the main water pump, cycle through and operate the flush mode with air. b. Attach shop air (90 psi or less) directly to the inlet. Run the foam pump through a couple of cycles to get the water out. c. If equipped, run air through the tank fill options. d. After moving truck to its destination, cycle the foam tank valves again to get any residual water out of the lines.

4-2. Set-up & Calibration

Set-up and Calibration Modes should only be used by qualified personnel, as any changes made while in the Set-up or Calibration Modes may adversely affect the system performance.

Set-up Mode is used to access calibration modes, change default settings and access foam tank drain mode. The functions are shown in this chapter in the order they appear on the control head LCD screen.

4-2.1 Set-up Mode

Figure 4-1: Set-up Screen

OM130_36a

4-2.2 Parameters

Figure 4-2: Parameter Screen

OM130_36b

NOTE: The English/Metric screen provides the option of reading the flow in GPM or LPM.

1. From the normal operation screen (Foam Pump Not Running) press the PAGE button to bring up the MODE SELECT screen. 2. Use the UP/DOWN arrows to select Setup and press and hold the ENTER button for about 5 seconds to bring up the SETUP SELECTION screen. 3. Use the UP/DOWN buttons to highlight the SETUP SELECTION screen. 4. Press and hold the ENTER button. While still holding the ENTER button, press the UP/DOWN buttons simultaneously to bring up the SETUP screen. 5. Use the UP/DOWN buttons to highlight the Parameters and press ENTER to bring up the PARAMETERS screen. 6. On this screen the user will use the UP/DOWN buttons to highlight the selection to be changed. 7. Press the ENTER button to make the selection blink on and off. 8. Use the UP/DOWN buttons to toggle through the list of possible choices. 9. Press the Enter button to lock it in. 10. Do this for each highlighted selection as needed. 11. When complete, press the PAGE button 4 times to get back to the home screen.

4-2.3 Calibrate Flowmeter Mode

Figure 4-3: Calibrate Flowmeter Screens

OM130_37

NOTE: Calibrate Flowmeter Mode is used to calibrate the water flowmeter.

IMPORTANT: Before calibrating, verify the water flow using a pitot tube. If the flow is correct at various flow rates, based on the pitot tube results, no calibration is needed.

1. Press PAGE to go to the MODE SELECT screen. Select SETUP using the UP/DOWN arrows and then press ENTER for approximately 5 seconds until the SETUP SELECTION screen appears. While in SETUP SELECTION screen, press UP/DOWN arrows to highlight Calibration. Press and hold ENTER button, while still pressing ENTER button, press the UP/DOWN buttons simultaneously to enter the CALIBRATION screen. Press the UP/DOWN arrows to highlight the Water Flow selection from the list and then press ENTER to go into the WATER FLOW CALIBRATION screen mode.

NOTE: If unable to flow the default flow rates, different flow rates may be obtained by pressing ARROW UP or ARROW DOWN in order to achieve different flow rates other than the default settings. The wider the rates are during calibration, the more accurate the flowmeter will be over those flow rates.

2. Attach the appropriate hose(s) and nozzle(s) to one or more foam/water discharge(s) to obtain a known water flow of 50 GPM (low gpm flowmeter setting). Open the discharge valve(s). 3. At the CAL FLOWMETER 50 GPM screen, press ENTER. RUNNING CALIBRATION will show on the LCD display until the first calibration set point is complete. 4. CAL FLOWMETER 300 GPM will automatically appear next. 5. Attach the appropriate hose(s) and nozzle(s) to one or more foam/water discharge(s) to obtain a known water flow of 300 GPM (high gpm flowmeter setting). Open the discharge valve(s). 6. Press ENTER to begin calibration. Calibration in Process will appear. 7. When calibration is complete, press PAGE to exit CALIBRATION screen. 8. Confirm accuracy by flowing various flow rates.

4-2.4 Calibrate Foam Pump (LVDT) Transducer

Figure 4-4: Foam Pump Transducer Calibration Screen

1458

NOTE: • The foam pump transducer must be calibrated before performing any other foam system calibration procedures.

• Run LVDT Calibration with foam pump discharge drain open.

1. While in the Set-up Mode, press UP/DOWN arrows until display reads CALIBRATE. 2. Press ENTER, use the UP/DOWN arrows until display reads Foam Pump Sensor, press ENTER to begin calibration.

Figure 4-5: Foam Pump Transducer Voltage Screen

1469 3. While the calibration is running, the display will indicate LVDT voltages at each end of the foam pump stroke. The normal voltage reading is 300mv - 700mv (left) and 4300mv - 4800mv (right). 4. When the calibration is complete, press the PAGE button to Exit.

4-2.5 Calibrate Class A Foam Mode

Figure 4-6: Calibrate Class A or B Foam Screen

1038

NOTE: • Prior to calibrating, run the system at different rates and verify that it is in need of calibration.

• The most accurate calibration can be obtained using the actual foam concentrate intended for use at a fire incident. However, if foam is unable to be used, water is an acceptable substitute.

• Verify that the draft hose is securely installed, the Foam Inlet Valve is OPEN, the Foam Pump is primed, and the foam source is set to DRAFT CLASS A before beginning foam calibration.

1. While in the Set-up Mode, use the UP/DOWN arrows until display reads Calibrate, press the ENTER button.

2. Use the UP/DOWN arrows and go to Class A Calibration. 3. Press ENTER to accept, display should read CALIBRATE FOAM A 1.00 GPM 4. Press ENTER to begin foam calibration at 1.00 GPM. The foam pump will run for five minutes. 5. Measure actual flow by measuring the foam/water pick-up through draft hose. 6. When green Foam Pump ON light turns off, measure the actual amount of foam concentrate flowed. Calculate the gallons per minute (GPM) used during the five minutes. (Example: 5.5 gallons flowed divided by 5 minutes = 1.1 GPM.) Using the ARROW UP or ARROW DOWN buttons, enter the GPM flowed. (In this example “1.1”) 7. Press ENTER to accept value. 8. Display should read: CALIBRATE FOAM A 4.00 GPM 9. Press ENTER to begin foam calibration at 4.00 GPM. Foam pump will run for five minutes. 10. Measure actual flow by measuring the foam/water pick-up through draft hose 11. When green “Foam Pump On” light turns off, measure the actual amount of foam concentrate flowed. Calculate the gallons per minute (GPM) used during the five minutes. (Example: 5.5 gallons flowed divided by 5 minutes = 1.1 GPM.) Using the ARROW UP or ARROW DOWN buttons, enter the GPM flowed. 12. Press ENTER to accept value. 13. Display should read CALIBRATE MODE CLASS A FOAM

4-2.6 Calibrate Class B Foam Mode

NOTE: • Prior to calibrating, run the system at different rates and verify that it is in need of calibration.See Figure 4-6.

• The most accurate calibration can be obtained using the actual foam concentrate intended for use at a fire incident. However, if foam is unable to be used, water is an acceptable substitute.

• Verify that the draft hose is securely installed, the Foam Inlet Valve is OPEN, the Foam Pump is primed, and the foam source is set to DRAFT CLASS B before beginning foam calibration.

1. While in the Set-up Mode, use the UP/DOWN arrows until display reads Calibrate, press the ENTER button. 2. Use the UP/DOWN arrows and go to Class B Calibration 3. Press ENTER to accept. Display should read CALIBRATE FOAM B 1.00 GPM 4. Press ENTER to begin foam calibration at 1.00 GPM. The foam pump will run for five minutes. 5. Measure actual flow by measuring the foam/water pick-up through draft hose. 6. When green Foam Pump ON light turns off, measure the actual amount of foam concentrate flowed. Calculate the gallons per minute (GPM) used during the five minutes. (Example: 5.5 gallons flowed divided by 5 minutes = 1.1 GPM.) Using the ARROW UP or ARROW DOWN buttons, enter the GPM flowed. (In this example “1.1”) 7. Press ENTER to accept value. 8. Display should read: CALIBRATE FOAM B 4.00 GPM 9. Press ENTER to begin foam calibration at 4.00 GPM. Foam pump will run for five minutes. 10. Measure actual flow by measuring the foam/water pick-up through draft hose 11. When green “Foam Pump On” light turns off, measure the actual amount of foam concentrate flowed. Calculate the gallons per minute (GPM) used during the five minutes. (Example: 5.5 gallons flowed divided by 5 minutes = 1.1 GPM.) Using the ARROW UP or ARROW DOWN buttons, enter the GPM flowed. 12. Press ENTER to accept value. 13. Display should read CALIBRATE MODE CLASS B FOAM

4-2.7 Set Class A Concentrate Default Percentage

Figure 4-7: Class A Default Screen

OM130_23

NOTE: The default percentage is set at the factory to automatically run at 0.5% for Class A foam. Temporary changes to the foam percentage may be made while running the system by using the ARROW UP or ARROW DOWN buttons. The department may find it beneficial to change the defaults for their particular operating requirements or different types or brands of foam.

1. While in the Set-up Mode, use the UP/DOWN arrows until display reads Percentage Defaults, then press ENTER. 2. Press ARROW UP or ARROW DOWN to adjust default to the desired rate. 3. Press ENTER to accept new default rate. 4. Cycle batteries to confirm changes.

4-2.8 Set Class B Concentrate Default Percentage

Figure 4-8: Class B Default Screen

OM130_24b

NOTE: The default percentage is set at the factory to automatically run at 3.0% for class B foam. Temporary changes to the foam percentage may be made while running the system by using the ARROW UP or ARROW DOWN buttons. The department may find it beneficial to change the defaults for their particular operating requirements or different types or brands of foam.

1. While in the Set-up Mode, use the UP/DOWN arrows until display reads Percentage Defaults, then press ENTER. 2. Press ARROW UP or ARROW DOWN to adjust default to the desired rate.

3. Press ENTER to accept new default rate. 4. Cycle batteries to confirm changes.

4-2.9 Select Single or Dual Foam Tank System

Figure 4-9: Tank Option Screens

1460

NOTE: In the set up mode there is a screen that allows the software to recognize that the truck has been configured with one or two foam tanks. If the single/dual tank selection is not correct, the system may not run as it is “searching” for the second tank valve that is not installed, or it may not recognize the alternate foam valve is there because it was set for a single tank system.

1. While in the Set-up Mode, use the UP/DOWN arrows and select Tank Defaults, then press ENTER. 2. Press ARROW UP or ARROW DOWN to toggle between single and dual tank options. 3. Press ENTER to accept the selection.

4-2.10 Set Startup or Default Foam Source

Figure 4-10: Default Foam Source Screens

1460A

NOTE: The default foam source setting is used to determine which tank will open as the default tank, Class A or Class B. On a single tank system it will change the default setting (Class A or Class B). If changing a single tank system from A to B default, the foam valve remains plugged into the Class A harness. If changing the types of foam in the tank, It is imperative to thoroughly flush out and dry the entire system.

1. While in the home screen (normal running mode), press the PAGE button to go to the Mode Select Screen. 2. Arrow down to “Setup”. 3. Press and hold the ENTER button for 5 full seconds to bring up the “Setup Selection” screen. 4. Use the green up/down Arrows to highlight “Setup” from the menu. 5. Press and hold the ENTER button. While holding the enter button, press the UP and DOWN arrows simultaneously. the “SETUP” screen will appear. 6. Arrow down to “Startup Source” and press ENTER. 7. Arrow down to the desired choice. 8. Press the ENTER button, you will be transfered back to the home screen with that source being selected.

4-2.11 Tank Fill Enable/Disable

Figure 4-11: Tank Fill Option Screens

1462

NOTE: The tank fill option must be enabled in order for the option to work. In order for the option to work, the system must have the optional tank fill valve installed for a single tank system, the air diaphragm fill pump for dual tank systems, and shut off floats installed in the tank dome to actuate the automatic shutoff when the tank is full.

NOTE: At any time, the user may press the PAGE button to exit this screen and return to the run mode screen.

1. While in the MODE SELECT screen, use the UP/DWN arrows until the Flush / Fill screen appears, then press ENTER. 2. Press ARROW UP or ARROW DOWN to toggle between DISABLED and ENABLED options. 3. Press ENTER to accept the selection.

4-2.12 Set Automatic Flush Time

Figure 4-12: Flush Time Screen

1470

NOTE: • An automatic flush occurs whenever foam source is switched from a Class A to Class B foam or vice-versa.

• The factory default setting is 10-15 seconds.

1. While in the MODE SELECT screen, use the UP/DOWN arrows until the Flush/Fill screen appears. 2. Press ENTER to accept. 3. Press Arrow Up or Arrow Down arrows and go to Flush timer and press ENTER. 4. Use the UP/DOWN arrows to set the desired flush duration. 5. Press ENTER to accept new default value.

4-2.13 Auto Start

Figure 4-13: Auto Start Screens

1463

NOTE: The auto start option will automatically turn the foam system on the first time the water pump is engaged. The option must have sensors installed in the foam system hydraulics and have additional wiring installed in order to function.

1. While in the Set-up Mode, press ARROW UP or ARROW DOWN until the Parameter screen appears, then press ENTER. 2. Press ARROW UP or ARROW DOWN to select Auto Start, then press ENTER. 3. Press ARROW UP or ARROW DOWN to toggle between ON and OFF options. 4. Press ENTER to accept the selection.

4-2.14 Drain Mode

Figure 4-14: Control Head in Drain Mode

OM130_20

NOTE: The Foam Drain mode is used to drain the foam tanks when needed.

1. Remove the inlet cap, install drain cap, and attach hose. Have container available.

Figure 4-15: Inlet Cap with Check Valve

1069

NOTE: The inlet cap contains a check valve; the drain cap does not have a check valve.

2. While in the Mode Select screen, use ARROW UP or ARROW DOWN until the Flush / Fill screen appears. 3. Press ENTER, use ARROW UP or ARROW DOWN and select which tank to drain. 4. Press ENTER, this will turn the Tank Drain on. 5. Press ENTER again to turn the Drain System off.

4-2.15 Reset Maintenance Reminders

Figure 4-16: Maintenance Reminder Screens

OM130_45

NOTE: • Maintenance messages flash alternately with main operating screen after 20 hours of foam system operation.

• Separate screens allow user to reset the counters for strainer and fluid service reminders.

• If these messages occur in the station, have service performed.

• If these messages occur on the scene, verify the hydraulic oil level, continue operation, and have service performed upon returning to the station.

1. From the normal operation screen (foam pump not running), press the PAGE button to bring up the MODE SELECT screen. 2. Use the UP/DOWN arrows to select “Setup” and press ENTER to bring up the SETUP SELECTION screen. 3. Use the UP/DOWN buttons to highlight the maintenance selection on the screen. 4. Press and hold the ENTER button. While still holding the ENTER button, press the UP/DOWN buttons simultaneously to bring up the MAINTENANCE screen. 5. Use the UP/DOWN buttons to highlight the selection to be cleared (zeroed out). 6. When complete, press PAGE to return to the normal operation screen.

4-2.16 Check Current Software Revision

NOTE: This information is also displayed when the system is first turned ON.

Figure 4-17: Control Head showing Software Revision

OM130_46

4-2.17 Diagnostic Inputs

Figure 4-18: Diagnostic Inputs

OM130_47 1. While in the normal run mode, press the PAGE button to bring up the MODE SELECT screen. 2. Use the UP/DOWN buttons to highlight “Diagnostics” and press ENTER to bring up the DIAGNOSTICS screen. 3. Toggle the UP/DOWN buttons to highlight “Input” and press ENTER to bring up the INPUT information screens. 4. Toggle the UP/DOWN buttons to go to the two screens containing the circuit status of the inputs on the system. 5. Press the PAGE button at any time to go back to the normal run mode screen.

4-2.18 Diagnostic Outputs

Figure 4-19: Diagnostic Outputs

OM130_48 1. While in the normal run mode, press the PAGE button to bring up the MODE SELECT screen. 2. Use the UP/DOWN buttons to highlight “Diagnostics” and press ENTER to bring up the DIAGNOSTICS screen. 3. Toggle the UP/DOWN buttons to highlight “Output” and press ENTER to bring up the OUTPUT information screens. 4. Toggle the UP/DOWN buttons to go to the three screens containing commanded values, actual values, and circuit status of the outputs on the system. 5. Press the PAGE button at any time to go back to the normal run mode screen.

4-2.19 Programming

NOTE: The following procedure is used to update software using the USB.

Figure 4-20: Programming Screens

OM130_49

4-3. Troubleshooting

The following outline represents operational difficulties that may arise during the deployment of the unit. It is not a comprehensive list meant to exhaust every possible malfunction of the equipment. Rather it is a quick checklist to allow operating personnel to ensure that operator error is not preventing the safe deployment of the unit.

Table 4-1: General Troubleshooting

Symptom Possible Cause Corrective Action 1. LCD on control head is blank or Bad control head. • Replace control head. displaying random characters. Wiring issue. • Check the ground circuit, ckt# Red light comes on. 1640, pin 2. • Check the voltage at the battery. • Check the voltage at the control head, ckt# 2878, pin 1. Voltage at the control head should be within .2 volt of the battery voltage. 2. LCD on control head is blank Wiring issue. • Check the ground circuit, ckt# and foam system will not turn 1640, pin 2. on. • Check the voltage at the battery. Bad control head (check for red light • Check the voltage at the control on). head, ckt# 2878, pin 1. Voltage at the control head should be within .2 volt of the battery voltage. Check for bad foam controller • Check the single point ground. (check for flashing green light which If red light is not on, replace indicates a good heart beat). control head. If green light is not flashing, replace foam controller. 3. System does not accurately LVDT or water flowmeter out of • Recalibrate LVDT and water display the amount of foam calibration. flowmeter. used. Incorrect software version. • Contact Pierce for latest software version. 4. System is using excessive LVDT or water flowmeter out of • Recalibrate LVDT and water foam. calibration. flowmeter. Wrong software version. • Contact Pierce for latest software version. Inspect the check valve at the • Foam should not leak past the injection fitting. injection fitting check valve with system OFF. If fitting leaks, replace.

Table 4-1: General Troubleshooting

Symptom Possible Cause Corrective Action 5. Delay before getting foam from Wrong software version. • Contact Pierce for latest hand line. software version. Needless flushing of system and not • See Chapter 3, Operating recharging. Procedures. System not turned on before • Turn on system at pump panel charging line. as first step in operation. 6. Foam in water tank after using Hand lines not flushed. • Flush hand lines. foam system. Defective flush valve. • Replace flush valve. UPF tank issue. • Fill foam tank; add florescent dye. Let unit sit overnight. Check the water tank to see if the florescent color is present in the water. If so, the foam tank is cracked. Bad manifold check valve. • If foam manifold bleeds down rapidly, replace or disassemble/ clean check valve. It is normal for the manifold to bleed down slowly. Bad foam injection check valve. • Foam should not leak past the injection check valve with system OFF. If fitting leaks, replace. Manifold drain not bled down. • Manifold drain should be used after each use. 7. Foam tank empty after pumping Bad check valve for foam tank fill. • Check selector valve for being operation with foam system in INJECTION mode. turned off. Bad foam injection check valve. • Check injection check valve to see if foam leaks by. Bad tank to pump valve. • Check tank to pump valve. 8. System will not draft foam. • See “Specialized Troubleshooting- System Will Not Pump Foam from Foam Tank” on page 4-24. 9. Tank fill inoperable. Selector valve in wrong mode. • Check tank fill/injection switch at selector valve for being in TANK FILL position. Tank to pump valve did not close. • Check tank to pump valve and the switch on the valve. Float stuck full (false reading). • Check float. Tank fill check valve does not open. • Check to see if check valve is free. 10. Display indicates to check The display is programmed to • Perform maintenance action(s) hydraulic fluid, water strainer, or display maintenance reminders at and reset timer per instructions foam strainer. appropriate intervals. found in “Reset Maintenance Reminders” on page 4-17.

Table 4-1: General Troubleshooting

Symptom Possible Cause Corrective Action 11. Water flow reads 000 when Wiring issue. • Check wiring. Unplug the flowing water. flowmeter and check for a good ground, ckt# 1640. Check for 6-9 volt supply to flowmeter, ckt# 2884. Bad flowmeter • Check flowmeter. Remove flowmeter and check for obstructions or visible damage. Manually spin the paddle wheel and observe the display. Display should indicate flow. 12. Water in hydraulic oil Defective oil cooler. • Check for carry over in oil cooler. If water is found in the oil, change the oil. Pressure washing near filler cap on • Use caution when pressure oil reservoir. washing around oil reservoir. 13. System will not pump foam from • See “Specialized foam tank. Troubleshooting- System Will Not Pump Foam from Foam Tank” on page 4-24.

Table 4-2: Specialized Troubleshooting- System Will Not Pump Foam from Foam Tank

Question Reason for Question Test Procedure A. Is there foam in the foam The foam system will not Visual inspection. tank? operate properly without an adequate supply of concentrate.

Fill tank with foam. See “Filling No Foam Tank” on page 3-8.

Yes

Question Reason for Question Test Procedure B. Does the foam pump engage? To isolate the problem NOTE: You must be flowing water for from between electrical the foam pump to operate. and mechanical failures. Turn the foam percent up and listen for the foam pump to engage.

Go to Step K. No

Yes

Question Reason for Question Test Procedure C. Tank fill option - look to see if If the tank fill valve is Remove the tube from the outlet of the tank fill the selector valve is in the open, all of the foam valve. Operate the foam system. If foam TANK FILL mode. concentrate will circulate concentrate is discharged, the tank fill valve is between the foam pump open. and the foam tank, with little or none being NOTE: In the TANK FILL mode, the injected. tank to pump valve should be closed automatically. If this does not occur, check for a bad switch at the selector valve.

Go to Step J. Yes

Question Reason for Question Test Procedure D. Is the foam injection check Foam concentrate cannot Check by visual inspection, or the foam pump valve stuck in the CLOSED reach the foam injection may make a squealing noise when the pump position? manifold if the check valve goes into the relief mode. is stuck closed.

Replace the foam injection No check valve.

End

Question Reason for Question Test Procedure E. Is the wiring OK? The foam system will not Refer to the wiring diagram for circuit operate properly if the information. wiring is faulty.

Repair wiring. No

Yes

Question Reason for Question Test Procedure F. Is the system voltage OK? Voltage at the control • Check the voltage at the battery. head must be within .2 volt of the battery voltage for the foam system to operate.

1148 • Check the voltage at the control head. Voltage at the control head should be within .2 volt of the battery voltage.

1146

Repair poor connections, No loose pins, etc.

Yes

Question Reason for Question Test Procedure G. Is the ground circuit OK? The foam system must Check ground circuit (ckt# 1640K). Refer to have an adequate ground “System Diagrams” on page 4-39 for additional (continuity) for the system circuit information. to operate.

1149

Repair ground circuit. No

Yes

Question Reason for Question Test Procedure H. Is the flowmeter operating The flowmeter provides If “GPM” appears on the display, the flowmeter correctly? the foam system with is OK. If “GPM” does not appear, replace the information on how much flowmeter. water is being flowed. No signal from the flowmeter will result in the foam system not operating.

Replace flowmeter, see No service group 7950-P-001.

Yes

Question Reason for Question Test Procedure I. Are the system set-up, LVDT The foam system will not See “Set-up & Calibration” on page 4-2: calibration, and defaults set operate if the system has • Check the set-up; correctly? not been set-up and calibrated correctly. • Calibrate the LVDT; • Check all default settings.

Correct set-up, LVDT No calibration & default settings.

Yes

Question Reason for Question Test Procedure J. Is the foam tank valve open? The foam pump will not NOTE: It is possible for the valve to be operate unless the system physically open but a failed receives a signal that the limit switch indicates to the the foam tank valve is system that the valve is not open. open.

• Visually inspect wiring to foam tank valve. • Check continuity, connectors, etc. • Check if foam is present at foam pump drain: a. Open drain on inlet side of foam pump; b. Open foam tank to pump valve; c. Check for foam concentrate. If concentrate is present, foam tank valve is open.

Go to Step Q. No

End

Question Reason for Question Test Procedure K. Does the foam pump engage To check the foam Open the Discharge Foam Pump Drain valve. with the Discharge Foam injection check valve. If Attempt to operate the system. Pump Drain open? the foam pump engages with the valve open, it is likely there is contamination in the injection check valve.

Clean/replace the injection Yes check valve.

Question Reason for Question Test Procedure L. Does the foam pump engage To isolate the flowmeter See “Manual Mode (Manual Water Flow)” on in the manual mode? from the system and page 3-9. eliminate it as a possible cause.

Replace flowmeter, see Yes service group 7950-P-001.

Question Reason for Question Test Procedure M. Is the LVDT working properly? The LVDT informs the 1. Attempt to calibrate the LVDT, refer to TBD. system of what the pump If the LVDT will not calibrate, go to Step 2. is doing. The foam system 2. Remove the cover from the signal will not operate properly if condition box. no signal is received from the LVDT.

1153 3. Check for voltage on Pins 5 & 6 (output & ground). A reading of 0-5 volts should be obtained. It is normal for the voltage to fluctuate as the foam pump cycles.

Replace the LVDT per service No group 7950-P-007.

Yes

Question Reason for Question Test Procedure N. Is the wiring OK? The foam system will not Refer to “System Diagrams” on page 4-39 for operate properly if the additional circuit information. wiring is faulty.

Repair wiring. No

Yes

Question Reason for Question Test Procedure O. Is the system voltage OK? Voltage at the control • Check the voltage at the battery. head must be within .2 volt of the battery voltage for the foam system to operate.

1148 • Check the voltage at the control head, ckt# 2878, pin 1. Voltage at the control head should be within .2 volt of the battery voltage.

1146

Repair wiring. No

Yes

Question Reason for Question Test Procedure P. Is the ground circuit OK? The foam system must Check ground circuit 1640. Refer to “System have an adequate ground Diagrams” on page 4-39 for additional circuit circuit (continuity) for the information. system to operate.

1149

Repair ground circuit. No

Yes

Replace LVDT per service group 7950-P-007.

Question Reason for Question Test Procedure Q. Is the electric tank fill valve If the tank fill valve sticks Inspect the valve for proper operation. Check OK? open, most of the foam the adjustment of the micro switch. Inspect the concentrate will circulate micro switch for moisture. between the foam pump and the foam tank, with little being injected into the water stream.

1025

Replace electronic tank fill No valve and/or micro switch.

End

4-4. Periodic Operation

The foam system should be operated periodically to insure that the foam system is operational, and also to circulate the foam concentrate through the pump. The preferred method is a periodic operation of the system in a normal discharge condition as described in Section 3, “Operation”.

4-5. General Maintenance Procedures

Personal hearing can be PERMANENTLY DAMAGED if exposed to constant high noise levels of 85 db or higher. Wear approved hearing protection devices when working in high-noise-level areas. Hearing loss occurs gradually, but becomes permanent over time.

Cleanliness Dirt, grease, oil, and debris may cover up a serious problem. Use an approved dry cleaning solvent to clean all metal surfaces.

Common Hardware Check bolts, nuts, and screws for obvious looseness, or missing, bent, or broken conditions. Look for rust around bolt heads. Tighten any obvious loose parts. Weldments Inspect for rust or gaps where parts are welded together. Broken parts should be repaired or replaced. Electrical Wiring and Connectors Look for cracked or broken insulation, bare wires, and loose or broken connectors. Tighten loose connectors and make sure wires are in good shape. Repair all bad wiring and connectors. Lines and Fittings Look for wear, damage, and leaks. Make sure clamps and fittings are tight. Wet spots can indicate a leak, and a stain around a fitting or connector can also indicate a leak. If a leak originates from a loose fitting or connector, tighten it. Replace any leaking line or fitting. Hydraulic Tank The fluid return line, located at the top of the tank, should be cracked open when performing service on the hydraulic system to prevent siphoning of oil that is in the tank.

4-6. Preventive Maintenance Checks and Service

4-6.1 Introduction These checks and services have been provided to help you keep your equipment in good operating condition and in service. The preventive maintenance section is intended to formally maintain and document the device on a regular schedule. This schedule is intended as a minimum and is greatly dependent on operating conditions. Heavy use and extreme environmental conditions such as heat, cold, sand, or salt spray will demand increased inspection and maintenance. This preventive maintenance section is not intended to replace or negate any routine pre-operation safety inspections. The operator must be aware of the condition of the equipment before operating. A pre-operational visual safety inspection should always be performed. During the warranty period and thereafter, inspections and maintenance schedules must be performed according to the specified Pierce Manufacturing Inc. standards. Failure to comply with these requirements will be considered grounds or conditions that may void the warranty on individual components, assemblies, or the entire device.

4-6.2 Explanation of Columns

Item No. Numbers in this column are to be used as a source of the item number for the “Item No.” column on the Equipment Inspection and Maintenance Worksheet. Item to Check/Service This column tells you the item to be checked or serviced. Procedure This column tells you how to perform the required check or service.

4-7. After Every Use Inspection

NOTE: After every use of the system, the following components and systems should be inspected and repaired/replaced as necessary:

Table 4-3: After Every Use Inspection

Item No. Item to Check/Service Procedure Check the oil level in the hydraulic reservoir.

Site Glass 3/4 full is sufficient

1 Hydraulic Oil Level

2 Foam Tank Level Check foam concentrate level in the foam tank and fill as necessary. 3 Hydraulic System Check hydraulic tubing/hoses for leaks, loose fittings, damage, etc. 4 Foam System Plumbing Check foam system plumbing for leaks, loose fittings, damage, etc. 5 Manifold Drains Open manifold drain.

4-8. Weekly Inspection

NOTE: After every week of service, perform the following maintenance procedure:

Table 4-4: Weekly Inspection

Item No. Item to Check/Service Procedure Remove clean-out cap and remove basket. Inspect for foreign debris. If any are found, clean the basket with water and reinstall.

1 Water Strainer Water Strainer

1029

4-9. Quarterly Inspection

NOTE: After every three months of service (quarterly), perform the following maintenance procedure:

Table 4-5: Quarterly Inspection

Item No. Item to Check/Service Procedure Remove clean-out cap and remove basket. Inspect for foreign debris. If any are found, clean the basket with water and reinstall.

1 Foam Strainer Foam Strainer

1073

4-10. Annual Inspection

NOTE: Annually, perform the Quarterly inspection, then the following maintenance procedure:

Table 4-6: Annual Inspection

Item No. Item to Check/Service Procedure Obtain an oil sample and compare to previous results. If the current sample matches 1 Hydraulic Oil Sample previous test results, the oil does not have to be changed. Replace oil and filter if test results indicate oil degradation.

4-11. Recommended Hydraulic Oil for Husky 12 Proportioning System

4-11.1 Characteristics The system is delivered, charged with ISO 68 hydraulic oil. It is recommended that same or similar oil be used to maintain optimum efficiency and component life. If the vehicle has been subjected to extreme cold temperatures for extended periods of time, engaging the water pump will allow the hydraulic oil to warm up before initiating operation of the Husky 12 system.

4-11.2 Recommendations U.S. Oil Multi-Vis 68R, Mobil DTE16M ISO 68 or equivalent.

The hydraulic fluid used for cold weather application may not function properly at higher temperatures, and must be changed to an appropriate recommended type for proper operation of unit.

4-11.3 Oil Change Information We recommend taking an initial sample of hydraulic oil and having it analyzed to serve as a baseline for future oil analysis results. Annually, obtain an oil sample and compare to previous results. If the current sample matches previous test results, the oil does not have to be changed. Replace oil and filter if test results indicate oil degradation.

4-12. System Diagrams

Figure 4-21: Husky 12 Hydraulic Schematic

1563671

Figure 4-22: Husky 12 Wiring Harness

64-5033-H004

Figure 4-23: Husky 12 Wiring Harness

64-5033-H004

Figure 4-24: Husky 12 Foam System Schematic

1563917

A E

Acceptable Foam Concentrate English/Metric Mode ...... 4-2 Viscosity Range ...... 2-2 Explanation of Columns ...... 4-35 After Every Use Inspection ...... 4-36 External Pick-Up Connection ...... 2-8 Annual Inspection ...... 4-37 Auto Start ...... 4-14 F

B Filling Foam Tank ...... 3-8 Fill Dome Method ...... 3-8 Blowing Out After Testing ...... 4-1 Pick-up Hose Method ...... 3-8 Flush System ...... 2-2 Flushing System ...... 3-5 C Foam Check Valve ...... 2-9 Calibrate Class A Foam Mode ...... 4-8 Foam Concentrate Compatibility ...... 2-2 Calibrate Class B Foam Mode ...... 4-9 Foam Concentrate Pump ...... 2-6 Calibrate Flowmeter Mode ...... 4-4 Foam Concentrate Tank ...... 2-5 Calibrate Foam Pump (LVDT) Transducer ...... 4-6 Foam Proportioner ...... 2-1 Calibration ...... 4-2 Foam Selector Valve ...... 2-7 Characteristics, Hydraulic Oil ...... 4-37 Foam Supply System ...... 2-5 Check Current Software Revision ...... 4-18 Foam Supply Valve ...... 2-6 Choosing a Foam Source ...... 3-4 Foam System Operation ...... 3-1 Class A Foam - Drafting ...... 3-2 Foam System Schematic ...... 4-42 Class A Foam - using on-board Foam Tank .... 3-1 Class B Foam - Drafting ...... 3-3 G Class B Foam - using on-board Foam Tank .... 3-2 Control Head & Display ...... 2-11 General Flushing Information ...... 3-5 Customer Assistance Information ...... v General Maintenance Procedures ...... 4-34

D H

Description of “DANGER,” “WARNING,” and Husky 12 Specifications ...... 2-1 “CAUTION” ...... 1-1 Hydraulic Drive System ...... 2-2 Description of Major Components ...... 2-2 Hydraulic Gear Pump ...... 2-3 Diagnostic Inputs ...... 4-19 Hydraulic Manifold Block ...... 2-5 Diagnostic Outputs ...... 4-20 Hydraulic Oil Cooler ...... 2-4 Discharges ...... 2-1 Hydraulic Oil Filter ...... 2-3 Drain Mode ...... 4-15 Hydraulic Oil Reservoir ...... 2-4 Draining Foam Pump After Testing ...... 4-1 Hydraulic Schematic ...... 4-39 Hydraulic Tank ...... 4-35

I S

In-line Water Check Valve ...... 2-10 Scope ...... v Introduction ...... 1-1 Select Single or Dual Foam Tank System ..... 4-11 Introduction, Preventive Maintenance Checks and Set Automatic Flush Time ...... 4-13 Service ...... 4-35 Set Class A Concentrate Default Percentage . 4-10 Set Class B Concentrate Default Percentage . 4-10 L Set Startup or Default Foam Source ...... 4-12 Set-up Mode ...... 4-2 List of Abbreviations ...... 1-2 System Capacity ...... 2-1 System Diagrams ...... 4-39 M System Electrical Load ...... 2-1

Maintenance Introduction ...... 4-1 T Maintenance Message ...... 2-1 Manifold Drains ...... 2-10 Tank Fill Enable/Disable ...... 4-13 Manual Flush Mode ...... 3-6 Testing After System Maintenance ...... 4-1 Manual Mode (Manual Water Flow) ...... 3-9 To the Owner—Operation and Maintenance of This Master Drain ...... 2-10 Apparatus ...... 1-1 Maximum Foam Solution Flow ...... 2-1 Troubleshooting ...... 4-22 Troubleshooting, General ...... 4-22 O Troubleshooting, Specialized ...... 4-24

Oil Change Information ...... 4-38 W

P Water Flowmeter ...... 2-11 Water Supply System ...... 2-9 Panel Mounted Strainer ...... 2-8 Weekly Inspection ...... 4-36 Periodic Operation ...... 4-24, 4-34 Pick-Up Hose ...... 2-9 Preventive Maintenance Checks and Service 4-35 Priming System ...... 3-7 Programming ...... 4-21 Purpose of Manual ...... v

Quarterly Inspection ...... 4-37

Recommendations, Hydraulic Oil ...... 4-37 Recommended Hydraulic Oil for Husky 12 Proportioning System ...... 4-37 Reset Maintenance Reminders ...... 4-17