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MANUAL
Portable power pumps EN 14466 PFPN 10 1000
50053 1559 UY 704703 EN 05/09
Contents
Please note
Control elements
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
List of symbols . . . . . . . . . . . . . . . . . . . . . . . . . 17
4
4
4
4
4
4
4
Conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
After sales . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Emergency starter . . . . . . . . . . . . . . . . . . . . . . 19
Operation
Please note . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Important rules of conduct . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Remove exhaust fumes from the working area . . . . . . . . .
Monitor the water pressure . . . . . . . . . . . . . . . . . . . . . . . . . .
Do not operate without water . . . . . . . . . . . . . . . . . . . . . . .
Frost protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Before starting use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20
20
20
20
20
20
8
8
8
8
Emergency start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
8
8
8
9
9
9
9
Switch off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
To switch off the pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
To switch off the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Stopping device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pump operation . . . . . . . . . . . . . . . . . . . . . . . . 25
Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
To carry the portable power pump . . . . . . . . . . . . . . . . . . 11
After transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Lance operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Battery protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
To change a lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
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Contents
After use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Centrifugal pump . . . . . . . . . . . . . . . . . . . . . . . 39
Regular operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Frost protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Frost protection . . . . . . . . . . . . . . . . . . . . . . . 29
Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Centrifugal pump and fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Frost protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Programmed servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Troubleshooting
For your safety . . . . . . . . . . . . . . . . . . . . . . . . 30
Technical Helpdesk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
After sales hotline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Jump starting . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Please note . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Jump cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Jump starting procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Engine covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Open the top cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
To remove/fit the rear cover . . . . . . . . . . . . . . . . . . . . . . . . . 42
Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
V-belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Clean the heat exchanger element . . . . . . . . . . . . . . . . . . . .
Emergency starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
42
42
43
43
44
44
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
To change the oil and oil filter . . . . . . . . . . . . . . . . . . . . . . . .
Throttle control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Spark plugs and ignition system . . . . . . . . . . . . . . . . . . . . . . .
Air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
45
45
45
46
47
47
49
Servicing
Appendices
Please note . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
For your safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exhaust fumes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Media . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Other instructions for safe working practice . . . . . . . . . . .
35
35
35
35
36
36
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Environmental protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Media . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Frost protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cleaning products . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
37
37
37
37
37
Servicing plan . . . . . . . . . . . . . . . . . . . . . . . . . 38
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Circuit diagram . . . . . . . . . . . . . . . . . . . . . . . . 50
Circuit diagram, part 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Circuit diagram, part 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Declaration of conformity . . . . . . . . . . . . . . . . 52
Please note
GENERAL
Please note
GENERAL
About this manual
Validity
Figures
Highlighted text
To simplify legibility and clarity, we have marked various pieces of
information.
All rights to this operating manual and its attachments are owned
by Iveco Magirus Brandschutztechnik GmbH. These documents
are entrusted to the recipient for personal use only.
Printed in Germany
4 IVECO MAGIRUS
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Liability
Iveco Magirus Brandschutztechnik GmbH cannot accept any liability that the information is complete and correct. No claims may
be derived from the content of this manual, in particular no liability can be accepted for damage caused by incorrect operation or
servicing.
State of the art
The information in this manual is state of the art at the time of its
publication.
Publication date 05/2009
Iveco Magirus Brandschutztechnik GmbH reserves the right:
To make changes to the construction and components of the
technical equipment and the device and to use other equivalent components instead of the specified components
without notice in the interests of technical progress.
To change the information contained in this manual.
Any obligation to extend these changes to equipment supplied at
an earlier date is excluded.
The dates shown in the footer show the last amendment date of
the relevant section. Amendments to texts do not necessarily relate to technical modifications. The technical version is therefore
not affected by different dates in the footers.
Please note
GENERAL
Conformity
Abbreviations
The fire-fighting equipment is supplied in perfect technical condition. Only the system supplied by Iveco Magirus Brandschutztechnik GmbH is subject to our declaration of conformity.
The operation is responsible for any changes, modifications, additional and retrofitted components if this work is not completed
by Iveco Magirus Brandschutztechnik GmbH. This makes the
operator the manufacturer, obliging him to establish that the device conforms to the relevant directives and to supply the requisite documentation.
The portable power pump is designed and built to comply with
the generally acknowledged rules of engineering. The following
relevant standards and directives are among those with which the
equipment complies:
EN 14466: Fire fighting pumps Portable power pumps Safety and power requirements
EN 1028: Centrifugal Pumps
Standards to which reference is made in EN 14466 and EN
1028 and which are required for compliance with them
This portable power pump previously underwent type tests
under DIN 14410-TS 8/8, NORM F 1065-TS12/10 or
SFV TI 01.00-01-Type 2.
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Units
All figures in this operating and servicing manual are in current SI
units.
Conversion factors
1 inch = 25.4 mm
1 mm = 0.039 inch
1 foot = 30.48 cm
1 cm = 0.033 foot
1 pound = 0.454 kg
1 kg = 2.2 pounds
1 lbf.ft = 1.36 Nm
1 Nm = 0.74 lbf.ft
Please note
GENERAL
Warranty
Details of the warranty are set out in the General Terms and
Conditions of Iveco Magirus Brandschutztechnik GmbH.
After sales
In the event of malfunctions please first refer to the instructions
in the section headed Troubleshooting. Our Technical After Sales
Department will be delighted to help if you have any other questions.
Iveco Magirus Brandschutztechnik GmbH
After Sales
Graf-Arco-Strae 30
D-89079 Ulm
Tel. +49 (0)731 408-0
Fax: +49 (0)731 408-2225
E-mail: magirus.brandschutz.service@iveco.com
Internet: www.iveco-magirus.de
Identification
Whenever you make contact with the manufacturer, please quote the data from the pump model plate [1], engine model plate
[2] or portable power pump model plate [3].
Positions:
Pump model plate on the left-hand side of the pump intake
Engine model plate at the top on the cover of the toothed
belt
Portable power pump model plate on the engine mount next
to the generator
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[1]
[2]
[3]
Please note
WARNING
The incorrect use of the equipment may cause personal injury. In addition, the portable power pump or
other equipment may be damaged.
Only use the portable power pump as described in this manual.
Only use the portable power pump for fire fighting with water or foam.
Do not use the portable power pump to transport inflammable or explosive fluids.
Do not exceed the limit values for pump capacity and pressure when operating the portable power pump, do not allow the portable power pump to overheat.
Have modifications, changes and repairs carried out by persons authorised by the manufacturer only.
Only use the device if it is perfect technical condition.
WARNING
Danger of explosion. Whilst the system is operating,
ignition sources may be generated which can ignite an
explosive atmosphere.
Do not operate the system in a danger area with inflammable liquids, gases or dust.
Comply with the regulations for fire and explosion prevention.
Iveco Magirus Brandschutztechnik GmbH can only guarantee safety, reliability and performance if the device is used
for the purpose for which it is designed.
Unauthorised modifications, changes or improper usage
exclude all liability on the part of the manufacturer for damage resulting therefrom.
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WARNING
Operating errors due to a lack of training can cause
serious accidents or place the success of the deployment in jeopardy. The portable power pump can only
be used safely if it is operated and serviced exclusively
by specially trained personnel.
The device must only be operated and serviced by appropriately trained personnel.
The personnel must make themselves acquainted with the
operating instructions before use. A single training session
is not sufficient. Only quality training and instruction from
experienced fire fighting personnel and ongoing practice
drills will ensure that the equipment can be used safely.
Carry out the control procedures again and again in practice drills.
Even in the field it must be ensured that persons with no
specialist training are not allowed to operate the portable
power pump.
Minors and people with no fire service training must not be
allowed to operate the portable power pump.
The operator is responsible for defining responsibilities and
for supervising the personnel. The operator is also responsible for providing adequate training and exercises pursuant
to current directives.
Please note
WARNING
Improper operation can cause serious accidents.
Safe usage is only possible if all the information required for
safe operation is observed. This includes instruction manuals, identifiers and warning signs as well as other regulations.
Instruction manuals
Read this operating manual completely before operation and
follow the regulations and safety instructions contained therein to the letter.
Keep the operating manual available for the operator at the
place of use.
Keep the operating manual in a safe place for future use.
Identifiers and warning signs
In addition to the instructions in the operating manual, you
must also read and follow all the warning signs fitted on the
device.
Clean the warning signs regularly to keep them legible.
Replace any missing or damaged signs.
Other directives
Comply with all relevant laws, regulations and directives (for
example national training regulations for fire fighters, accident
prevention regulations, fire fighting service directives, industrial medicine and environmental regulations, national laws for
fire and disaster protection, etc.).
WARNING
Danger of injury and danger of permanent health damage when transporting and loading the portable
power pump.
The portable power pump should only be lifted and carried
by at least 4 people (weight: 190 kg).
Only hold the portable power pump by the handles provided when transporting it.
Transport the portable power pump at a maximum angle of
35 in all directions.
Accommodate the portable power pump properly in the
vehicle after use and secure it.
WARNING
Risk of injury due to inadequate supervision.
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Please note
Water pressure
Media
WARNING
Fire and health risk when handling media such as fuel,
anti-freeze and preservatives.
You must follow the relevant regulations and the working
and safety instructions supplied by the manufacturers.
Do not refuel in enclosed areas and only do so when the
engine is at a standstill and the ignition has been switched
off, if the situation allows you to do so.
When refuelling at an incident watch for sparks, flames, radiated heat, etc. Secure the refuelling point.
Avoid fire and sparks and do not smoke when handling fuel.
Only store media in containers designed for them away
from heat sources.
Dispose of used or spilled media in an environment-friendly
way.
Noise emissions
WARNING
The high pressure water jet can cause serious injuries.
The pressure in the centrifugal pump and in the water
pipes may be up to 17 bar.
Only remove blind couplings from the pressure outlets after they have been depressurised.
Only open shut-off organs if lines are connected downstream.
Never direct the water jet at a person.
Avoid pressure surges and pressure fluctuations. Do not
accelerate the pump without control. Always open or close
the shut-off organ to the selected pressure outlet or jet
pipe slowly.
Ensure that the jet pipe operator has a safe standing area.
Do not operate the jet pipe if there are persons or obstacles in the working area.
It is essential that you observe the specified pressure values
whilst operating the pump and during tests.
81 dB(A)
88 dB(A)
At idling speed
69 dB(A)
At maximum speed
92 dB(A)
1) Distance from control panel 1.0 metre, distance to ground 1.6 metres.
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WARNING
Improper servicing can cause serious accidents. Safe
usage is only possible if all the information required
for safe servicing is observed.
Only use the device if it is perfect technical condition.
Ensure that it is cleaned thoroughly and serviced regularly.
Rectify damage and defects immediately.
Only carry out the described servicing work yourself.
Have all the other work completed only by specially trained
after sales personnel.
Only use original spare parts from the manufacturer.
After use place the device in a place where it is protected
from the influences of the weather.
For detailed instructions, see section entitled Servicing.
Please note
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Please note
WARNING
Danger of injury and danger of permanent health damage when transporting and loading the portable
power pump.
The portable power pump should only be lifted and carried
by at least 4 people (weight 190 kg).
Only hold the portable power pump by the handles on the
carrying frame [4] when transporting it.
Transport the portable power pump at a maximum angle of
35 in all directions.
Disconnect all connectors (hoses, cables, etc.) from the device after use.
After transport
WARNING
Danger of accident by unsecured device.
Secure the portable power pump to prevent its slipping and
tipping.
If possible select a flat area so that the portable power pump
will not slip or tip over. If necessary, secure the portable power pump appropriately.
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[4]
Please note
EQUIPMENT
Please note
EQUIPMENT
~842
~1092
[5]
~749
Type:
Centrifugal pump:
P 212
Drive engine
Engine capacity:
54 kW (75 bhp)
at 6000 rpm
190 kg
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Please note
EQUIPMENT
A B
Intake
Pressure outlets
Pump casing
PRIMATIC priming device
[6]
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Please note
EQUIPMENT
Number of stages:
Pressure outlets:
Materials:
Casing, impellers and rotors, intake cover, split water rings:
Pump shaft
Draining:
Drive side:
15C to +35C
0 C to max. 60 C
17 bar
15 in all directions
1) The tolerances of the engine and pump may change these cables.
Intake heads
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Please note
EQUIPMENT
[8]
[9]
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The automatic cut-out and possible restart of the diaphragm priming pumps is controlled directly by the pump pressure. If the
water column fails the outlet pressure from the centrifugal pump,
which shut down the diaphragm pumps, collapses. The diaphragm priming pumps restart until they are shut down again by
the outlet pressure in the centrifugal pump.
Please note
EQUIPMENT
[10] Lateral and longitudinal sections of the Fiat FIRE 1242 MPI
Engine:
70.8 mm x 78.86 mm
Displacement, total:
1,242 cc
Compression ratio:
9,8 0,2
Max. torque:
Cylinder block:
Crankshaft bearing:
Plain bearing
Cylinder head:
Aluminium
Camshaft:
Valves:
Inlet:
Outlet:
Valve play:
Fuel:
Fuel supply:
Fuel tank:
Cooling:
Air filter:
Lubrication:
Oil filter:
Oil quantity:
Ignition:
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Fan:
Volume:
Coolant:
Generator:
Battery:
12 V, 30 Ah, maintenance-free
May be charged using the charging
socket to DIN 14690, Part 1
1) The electronic systems in the control module have been modified for the
use of the engine in the portable power pump. The maximum speed for
pump operation is limited to approx. 4200 rpm to maintain the closing
pressure. The maximum capacity is thus reduced to around 40 kW
(54 bhp).
Control elements
LIST OF SYMBOLS
Control elements
LIST OF SYMBOLS
Light
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Control elements
SUMMARY
Control elements
SUMMARY
A B
D
K
J
I
H
F
X
U T S R
Q P O
M Engine cover
O Fuel tank
D Hour counter
Switch Ignition/Start
G Switch Light
Drain cock
K Light
Control panel
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Control elements
EMERGENCY STARTER
Control elements
EMERGENCY STARTER
Zero recoil emergency starter, in the form of a reverse
starter [12] [13].
Secured at the front in the centre in front of the crankshaft.
Acts directly on the crankshaft.
Minimum battery capacity for manual starting at an ambient
temperature of -15C: 20% of rated capacity
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Operation
PLEASE NOTE
Operation
PLEASE NOTE
Important rules of conduct
Remove exhaust fumes from the working area
DANGER
Danger of poisoning from exhaust fumes!
Do not operate the portable power pump in enclosed areas.
If, in exceptional circumstances, the engine must be run in
an enclosed area, extract the exhaust fumes to the outside
using exhaust hoses and adequate ventilation.
If the portable power pump is run at all times in the open air,
use exhaust hoses to remove the fumes from your working
area.
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Operation
A
[14] Coupling control lever in position OFF (A)
Intake
Emergency start
Turn the switch Ignition/Start clockwise to position
Ignition ON [16A].
The control lamps Battery, Oil pressure and Engine electronics
will be lit.
Leave the rotary throttle knob in the idling position [15].
Pull out the handle in the emergency starter [17] until you feel
the resistance.
Quickly pull the handle further.
Return the handle. Ensure that the cable coils up neatly.
Repeat the process if necessary.
The battery must not be completely discharged for an
emergency start. An emergency start will be possible in temperatures as low as -15C with a residual battery capacity of
20% if synthetic engine oil to specification has been used.
A
[16] Switch Ignition/Start in position Ignition ON (A)
Switch Ignition/Start in position Start (B)
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Operation
Activate
Set the coupling control lever to position ON [18].
To draw in water for priming purposes turn the rotary throttle knob to position Intake [20A].
As soon as the pressure measuring device Pump outlet indicates pressure of 2 3 bar, slowly open the screw-down valve to the selected pressure outlet.
When water starts to appear, continue to open the valve
slowly.
Switch the pump outlet pressure so that the priming device is shut down (at least 1.5 bar).
Maximum pump outlet pressure 17 bar.
Do not expose new or cold engines to high engine
speeds.
Refer to the instructions in the sections entitled Operation and Please note.
A
[19] Coupling control lever in position OFF (A)
Switch off
To switch off the pump
Intake
Intake
A
To switch off the engine
Allow the engine to run for around two minutes at idling
speed to cool (coolant will circulate).
Turn the switch Ignition/Start anti-clockwise to position
OFF [21].
The engine will shut down.
Stopping device
Turn the switch Ignition/Start anti-clockwise to position
OFF [21].
The engine will shut down.
The delivery will be stopped.
[21] Switch Ignition/Start in position OFF
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Operation
Monitoring
Monitor the level in the fuel tank to avoid unnecessary, timeconsuming breaks in the pump operation.
If the control lamp Tank content [22A] is lit whilst the portable
power pump is horizontal, the maximum level is 15%. This
corresponds to an operating period of approx. 20 minutes at
a delivery rate of 1,000 l/min at 10 bar.
Do not exceed the maximum operating pressure pa lim (see
section headed Please note, Equipment).
If the maximum operating pressure pa lim is exceeded, reduce
the engine speed immediately.
WARNING
The portable power pump has no protection against
explosion.
For refuelling during operation, comply with the regulations
pertaining to fire and explosion protection.
If necessary top up the fuel tank.
If the coolant water temperature rises significantly above the normal operating temperature (control lamp):
Set the engine to idling speed immediately, disengage the
pump and allow the engine to run without load to cool it or
allow the engine to run at low speed with the pump engaged.
Identify the cause of the overheating and rectify it.
If the control lamp Battery is lit during operation:
The V-belt may be loose or torn. The battery will then only
have power reserves for the engine for a short time.
Switch off the pump and engine and tension or replace the
V-belt (see section entitled Servicing, Engine).
Notify after sales service if necessary.
If the control lamp Oil pressure is lit during operation:
The lubricating oil supply to the engine may have been interrupted.
Switch off the engine immediately.
Check the oil level and top up if necessary.
Notify after sales service if necessary.
The occasional flickering of the oil pressure control lamp at
low speeds is insignificant.
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[22] Control lamp tank content (A); rotary throttle knob (B)
Operation
Cavitation
CAUTION
Lengthy operation with cavitation (formation of bubbles)
can seriously damage the centrifugal pump.
Reduce speed.
Reduce the intake head.
Rectify any possible constriction in the intake line.
Ensure that you operate the pump without cavitation.
Monitor the output pressure.
The output pressure must be greater than the cut-out pressure of the priming pumps.
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Operation
PUMP OPERATION
Operation
PUMP OPERATION
Intake from open water
Position the portable power pump as close as possible to the
water and as horizontal as possible.
Connect the intake line and output lines.
CAUTION
Foreign bodies drawn into it may seriously damage the centrifugal pump.
Place the top of the intake cage at least 30 cm below the
surface of the water.
If the bottom is sandy place the intake cage on a solid base
or the like to protect the centrifugal pump.
If the water is very dirty use an intake protection cage.
Start the engine.
Switch on the pump.
Whilst it is running, ensure that the pump is operating without
cavitation.
Monitor the output pressure.
The output pressure must be greater than the cut-out pressure of the priming pumps.
CAUTION
Lengthy operation with cavitation (formation of bubbles)
can seriously damage the centrifugal pump.
Reduce speed.
Reduce the intake head.
Rectify any possible constriction in the intake line.
After use, switch off the pump and stop the engine.
If the priming device fails
Check whether the non-return valve on the intake cage provides a perfect seal.
Open both screw-down valves [23D] pull their locking
pins [23C] and then open the valves fully.
Pour water into a pressure outlet using a funnel until water
comes out of the other pressure outlet.
Close both screw-down valves.
Switch on the pump.
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D
C
B
A
[23] A intake (A); pressure outlets (B) with screw-down valves (D) and
locking pins (C)
Operation
PUMP OPERATION
Lance operation
Position the portable power pump as close as possible to the
lance position and as horizontal as possible.
Connect the intake line and output lines.
CAUTION
Dirt drawn into it may seriously damage the centrifugal
pump.
If the bottom is dirty place the intake cage on a solid base
or the like to protect the centrifugal pump.
If the water is very dirty use an intake protection cage.
The procedure for lance operation is identical to that for intake from open water.
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Operation
LIGHTS
Operation
LIGHTS
WARNING
Danger of eye damage caused by bright light.
Do not look directly into the intensive light.
Do not use the light in small, enclosed areas.
C
[24] Light in transport position
After operation
Always move the light to the transport position [24] and secure it with the clamp screw.
Battery protection
When the engine is not running and during the starting process
the auxiliary consumers will be shut down automatically to maintain the full battery voltage for starting the engine.
The light cannot be operated unless the engine is running.
If the light is activated when the engine is not running and the
ignition is switched on, it will cut out again automatically after
10 seconds. If the engine is then started, the light will automatically cut in again.
To change a lamp
Remove the 4 screws [24B] and carefully open the casing.
Replace the lamp, ensuring that you do not touch the glass
with your bare fingers.
Lamp: Halogen, 12 V, 55 W
Close the casing and tighten the screws.
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Operation
AFTER USE
Operation
AFTER USE
Action on the pump
After every use with water, the following work must be carried
out:
After drawing in water from open water or after drawing in
seawater, rinse the entire pump with clean sweet water.
Open both pressure outlets and the drain cock [26A].
When no more water runs out, close both the screw-down
valves.
Open the screw-down valves one turn to protect the seals.
Always leave the drain cock open.
Check the seals on the outlet and intake couplings.
Clean dirty seals and replace damaged seals immediately.
Clean the intake screen in the A intake.
WARNING
Danger of injury from rotating impeller.
[27] Filling opening (A) and oil dipstick (B) for the pump
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Operation
FROST PROTECTION
Operation
FROST PROTECTION
Bearing
Keep the portable power pump in enclosed, heated rooms if
possible.
In addition, if there is a risk of frost, refer to the following
points.
A
B
Engine
Check the density of the engine coolant and correct it if necessary (see section entitled Servicing).
Check the charge in the battery (see section entitled Servicing).
Minimum acid density 1.20 g/ml, minimum closed-circuit voltage 12.2 V
Frost protection
Prepare the centrifugal pump and fittings for winter by adding
anti-freeze (see section entitled Servicing).
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[29] Pressure outlets with screw-down valves (A) and locking pins (B)
Troubleshooting
After sales
Technical Helpdesk
Iveco Magirus Brandschutztechnik GmbH
After sales
Graf-Arco-Strasse 30
D-89079 Ulm
Telephone: +49 (0)731 408-2594
Fax: +49 (0)731 408-2225
E-mail: magirus.brandschutz.service@iveco.com
Internet: www.iveco-magirus.de
After sales hotline
A German-speaking after sales technician can deal with urgent inquiries at weekends, on public holidays and from Monday to Friday from 5 pm to 7 am.
After sales hotline: +49 (0)731 408-4080
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Troubleshooting
Possible causes
Pressure measurement unit Pump inlet shows no va- Pump not connected.
cuum.
The pump and intake line have not been primed.
Screw-down valves and drain cock
open.
Remedy
Set the coupling control lever to
position ON.
Close the screw-down valves
and drain cock.
Inlet or outlet membranes on the dia- Set the throttle lever to idling
phragm pump soiled or worn.
and switch off the pump.
Only operate the pump from
hydrants.
After use:
Rinse the pump with clean water whilst the diaphragm pump is
running.
If the error continues to occur:
Notify after sales service.
Pump or intake line leaking.
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Troubleshooting
Fault
Possible causes
Delivery rate reduced by using smaller Set the required pump pressure
orifices or shutting down pressure outwith the throttle lever.
lets.
The water jet from the jet pipe is not emitted evenly
but is interrupted by loud air surges.
Remedy
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Troubleshooting
Possible causes
Remedy
V-belt torn. The battery only has pow- Switch off the pump and engine
er reserves for the engine for a short
and replace the V-belt.
time.
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Troubleshooting
JUMP STARTING
Troubleshooting
JUMP STARTING
If the battery is discharged the engine may be started using jump
cables connected to a battery of the same or higher capacity in
another vehicle.
Please note
WARNING
Improper operation can cause serious accidents and
injuries.
Read the operating manual supplied by the chassis manufacturer carefully before jump starting and follow the regulations and safety instructions contained therein to the letter.
Before connecting the jump cables, ensure that you have
the same battery voltage (12 V or 24 V).
A discharged battery can freeze in temperatures below 10C. The battery must be thawed before jump starting the
vehicle.
Danger of acid burns. Do not bend over the batteries when
you are attempting to jump start the vehicle.
WARNING
Danger of gas explosion from sparking.
Jump cables
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Servicing
PLEASE NOTE
Servicing
PLEASE NOTE
For your safety
WARNING
Improper servicing can cause serious accidents. Safe
usage is only possible if all the information required
for safe servicing is observed.
Only use the device if it is perfect technical condition.
Rectify damage and defects immediately.
Ensure that it is cleaned thoroughly and serviced regularly.
Read this servicing manual before starting work and follow
all the safety instructions and regulations to the letter.
Only carry out the described servicing work yourself.
Have all the other work completed only by specially trained
after sales personnel or a FIAT workshop.
Only use original spare parts from the manufacturer.
Conduct a function test after all servicing or repair work.
Keep records of all servicing work. The service plan in this
manual can be copied for this purpose.
Exhaust fumes
DANGER
Danger of poisoning from exhaust fumes!
Remove exhaust fumes using exhaust hoses and adequate
ventilation away from the device and operator to the open
air.
Media
Regulations
Observe and comply with the latest versions of all the relevant regulations and directives when you carry out servicing
and repair work.
Examples:
Workplace Directive
Accident prevention regulations
Professional association regulations for health and safety at
work
Equipment Safety Law
Recycling and Waste Law
Safety data sheets for all the media, cleaning and preservative
products you use
35 IVECO MAGIRUS
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WARNING
Fire and accident risk when handling media. Media
such as fuel, anti-freeze and preservatives may be
harmful.
You must follow the relevant regulations and the working
and safety instructions supplied by the manufacturers.
Do not refuel in enclosed areas and only do so when the
engine is at a standstill and the ignition has been switched
off. (Exception: Topping up the fuel tanks during a deployment)
Avoid fire and sparks and do not smoke when handling fuel.
Do not smoke or use devices that do not have explosion
protection.
Only store media in containers designed for them.
Dispose of used or spilled media in an environment-friendly
way.
Servicing
PLEASE NOTE
Electrical system
Cleaning
DANGER
Danger of death due to the high voltage on the ignition system. The high voltage can cause fatal heart flutter or a heart attack. Potentially fatal arrhythmia may
even occur a few days after a shock.
Never touch the ignition leads or spark plugs whilst the engine is running or the ignition switched on.
Disconnect the negative pole on the batteries before starting any work.
WARNING
Volatile components in cleaning products may be
harmful.
You must follow the relevant regulations and the working
and safety instructions for the cleaning and preservatives.
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CAUTION
A steam or high pressure jet directed at electrical components will cause damage.
Do not direct a jet at control panels, switches, sensors or
plug connectors.
Equipment
The type, timing, scope and completion of the required tests on
fire service equipment (for example intake hoses) are set out in
the relevant national regulations and the corresponding standards.
Environmental protection
Only store media, cleaning and preservative products in suitable containers.
Comply with the statutory environmental protection regulations when disposing of discharged batteries, media and parts
that have come into contact with media.
Deposit used oil and other media as well as replaced parts at
collection points or FIAT workshops. Never pour used oil or
media into open water or the sewer.
Servicing
PLEASE NOTE
Media
CAUTION
Danger of machine damage.
Do not mix different types of oil or lubricants unless expressly permitted by the manufacturer.
Oil
Application
Recommended
SAE 15W40
SAE 5W401)
SAE 15W40
1) Emergency starting with SAE 15W40 oil in temperatures below 0C would be very difficult.
Frost protection
Application
Recommended
FL SELENIA Paraflu UP
Grease
Application
Recommended
Cleaning products
Application
Recommended
Degreasing
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Servicing
SERVICING PLAN
Servicing
SERVICING PLAN
Every Every Every Every Every Every Annu- Every Every Every Every
6
4
100 150 200 300 month ally
3
50
2
hours hours hours hours hours
years years years years
Check the oil level in the pump and top up if necessary.
necessary.
Check the battery (voltage, acid density) and charge if
necessary
1) 1)
1) 1)
Change the oil in the pump casing
necessary
Check the spark plugs
them if necessary
Check the coolant density
them if necessary
Replace the fuel filter
Servicing
Hours: _____________________h
Date: _____________
Name: _______________________________
Signature: ________________________________
Hours: _____________________h
Date: _____________
Workshop: _______________________________
Stamp,
Signature: ________________________________
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Servicing
CENTRIFUGAL PUMP
Servicing
CENTRIFUGAL PUMP
Regular operation
CAUTION
Lengthy down time and dry operation may result in damage.
Operate the centrifugal pump with water at least once per
month.
A
B
Frost protection
CAUTION
The centrifugal pump can freeze.
If there is a risk of frost, refer to the instructions in the sections entitled Operation, Frost protection.
[30] Filling opening (A) and oil dipstick (B) for the pump
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Servicing
CENTRIFUGAL PUMP
A
[32] Coupling control lever in position OFF (A)
Intake
Intake
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Servicing
CENTRIFUGAL PUMP
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Servicing
ENGINE
Servicing
ENGINE
Programmed servicing
Engine covers
The engine is protected from the effects of the weather by two
covers.
Open the top cover
Swing the light forwards.
Open the top cover completely.
The cover is held in its limit position by a gas spring.
Check
V-belt
Every 100 hours (at least every two years) Check the V-belt tension and condition of the belt.
The V-belt [37] is correctly tensioned if it can be pressed
down around 1 cm by finger pressure.
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A
[37] V-belt (A)
Servicing
ENGINE
Oil level
Check the engine oil level every month and regularly before use.
Ensure that the engine has been switched off for at least 10
minutes.
Check the engine oil level on the oil dipstick [38A].
The oil level must be between the minimum and maximum
marks.
[38] Oil dipstick (A) and filling opening (B) for the engine
Coolant
WARNING
Danger of scalding. The cooling system is pressurised.
B
A
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[39] Coolant level indicator (A) and filling opening on the expansion
vessel (B)
Servicing
ENGINE
A
B
[40] Heat exchanger
Emergency starter
Every 50 hours but at least annually
Pull out the nylon cable for the emergency starter [42], clean
it and check it for signs of damage.
Replace a damaged emergency starter as soon as possible.
WARNING
Danger of injury if the cable is damaged.
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Servicing
ENGINE
Lubrication
To change the oil and oil filter
Change the oil and oil filter every 50 hours, but at least every year.
Medium:
Use only brand oil to suit the ambient temperature.
Oil: See section Servicing, Please note.
Drain the oil
Only drain the oil when the engine is warm.
Remove the stopper on the filling opening [43B] and oil dipstick [43A].
Unscrew the drain screw on the oil tank.
Drain the oil and dispose of it correctly.
Do not insert and tighten the drain stopper for at least 10 minutes.
Tightening torque: 32 Nm
Change the oil filter
Unscrew the oil filter from the oil pump casing on the engine
side between the engine block and the exhaust silencer [44].
Residual oil may escape as you do so.
Wet the sealing ring on the new filter with oil, screw the new
filter on and tighten it by hand.
Only use a filter of the same type.
Fill with oil
Place oil in the filling opening [43B] until the oil level on the
dipstick is between the maximum and minimum marks.
Total oil volume around 3.25 litres including the content of
the oil filter
Run the engine briefly, wait for 10 minutes and then check the
oil level again.
Throttle control
Medium: Acid-free multi-purpose grease, for example Vaseline
Every 50 hours but at least annually
Grease the throttle control cable [43C].
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B
A
C
[43] Oil dipstick (A) and filling opening (B) for the engine, throttle (C)
A
[44] Position of the oil filter
Servicing
ENGINE
CAUTION
Spark plug types with different heat values or a different
service life may cause faults.
Only use spark plugs of the specific type.
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[45] Installation position of the spark plugs (A), air filter (B)
Servicing
ENGINE
Air filter
Every 50 hours but at least annually, if operated in a lot of dust
more frequently:
Check the air filter element for dirt [45B].
If there is a coating of dust of 1 mm or more on the filter:
Carefully tap the filter element and, if necessary, remove the
remaining dust carefully with a brush.
CAUTION
Blow out any damage to the filter element caused by compressed air.
Cleaning products may damage the filter element components.
Clean the filter element as described above.
Battery
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Servicing
ENGINE
At least monthly
Check that the connection poles are clean and grease them
with anti-corrosion grease.
Check the acid level in the battery.
The level should be between the MIN and MAX marks when
the battery is horizontal.
If the acid level falls below the minimum mark, top up the appropriate cells with distilled water.
Check the charge condition using the acid density or closedcircuit voltage.
If the acid density is less than 1.2 g/ml or the closed-circuit voltage is below 12.2 V, charge the battery.
If the battery is kept for a lengthy period of time with less
than 50% charge there is a risk that it will be damaged due
to sulphatation. This will reduce its starting capacity and increase the risk of its freezing (in temperatures of -10C or
below).
Charge the battery
Refer to the operating manual supplied with the charger.
Only use controlled chargers that operate on the basis of the
IU or WU characteristic curve (DIN 41772).
The charging socket to DIN 14690 [46B] may be used as a
supply if the charger is fitted with a suitable plug.
If the self-discharge of the battery is to be compensated by a
maintenance charge, only use chargers specially designed for
this purpose.
Fast charge the battery
Remove the battery.
Refer to the operating manual supplied with the charger.
Check the acid level if you intend to fast charge the battery.
Jump starting
Never use a jump starting charger.
For details of the jump starting process see the section entitled Troubleshooting, Jump starting.
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Servicing
ENGINE
Fuses
There are four conventional flat terminal fuses under the top engine cover above the engine [47].
They protect the following circuits:
Item
Current
Protected circuits
5A
Charging socket
15 A
20 A
30 A
Fan blower
C
D
D
B
C
[47] Fuses
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Appendices
CIRCUIT DIAGRAM
Appendices
CIRCUIT DIAGRAM
Circuit diagram, part 1
Lambda sensor
Potentiometer
Throttle valve
Fuse for
charging
socket
Control lights
Charging socket
Hour counter
Radiator blower
Light switch
Main fuse
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Starter motor
Appendices
CIRCUIT DIAGRAM
Double relay
Diagnostic
tap for injection system
Ignition coils
Speed and
OT sensor
Step servomotor
Spark plugs
Temperature switch
Battery
Generator
Oil pressure
switch
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Appendices
DECLARATION OF CONFORMITY
Appendices
DECLARATION OF CONFORMITY
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