Inglés Manual Operación Motobomba Magirus

OPERATING AND SERVICING MANUAL

Portable power pumps EN 14466 – PFPN 10 – 1000 50053 1559 UY 70–4703 EN 05/09

Contents

Please note

Control elements

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

List of symbols . . . . . . . . . . . . . . . . . . . . . . . . . 17

About this manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Validity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Highlighted text . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Copyright . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Liability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . State of the art . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 4 4 4 4 4 4

Emergency starter starter . . . . . . . . . . . . . . . . . . . . . . 19

Conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Please note . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 After sales . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

For your safety safety . . . . . . . . . . . . . . . . . . . . . . . . . 7

Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Operation

Important rules of conduct . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Remove exhaust fumes from the working area . . . . . . . . . 20 Monitor the water pressure . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Do not operate without water . . . . . . . . . . . . . . . . . . . . . . . 20 Frost protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Before starting use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Activate and switch off . . . . . . . . . . . . . . . . . . 21

Proper usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Training and qualification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

To activate the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Before starting the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 To start the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Read the information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Instruction manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Identifiers and warning signs . . . . . . . . . . . . . . . . . . . . . . . . . . Other directives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8 8 8 8

Emergency start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 To activate the pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Activate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

General safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Exhaust fumes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safe working practice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Media . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Noise emissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Water pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Servicing and care . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8 8 8 9 9 9 9

Switch off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 To switch off the pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 To switch off the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Stopping device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Adjustment and monitoring monitoring . . . . . . . . . . . . . . 23 Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Protection from electrical power . . . . . . . . . . . . . . . . . . . . . . . 10 Never touch live parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Isolate the parts from the supply. . . . . . . . . . . . . . . . . . . . . 10

Monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Cavitation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Transport and and storage . . . . . . . . . . . . . . . . . . 11

Pump operation operation . . . . . . . . . . . . . . . . . . . . . . . . 25

Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . To carry the portable power pump pump . . . . . . . . . . . . . . . . . . After transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Storage in the vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Refer to other documentation . . . . . . . . . . . . . . . . . . . . . . .

Intake from open water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 If the priming device fails . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

11 11 11 11 11

Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Portable power pump EN 14466 – PFPN 10 – 1000 . . . . . . 12

Lance operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Intake from hydrants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 To activate the light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Centrifugal pump P 212 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Battery protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 To clean the light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

PRIMATIC priming device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

To change a lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Drive engine FIAT FIRE 1242 MPI . . . . . . . . . . . . . . . . . . . . . . 16

2 IVECO MAGIRUS 05-2009

Contents

After use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Centrifugal pump pump . . . . . . . . . . . . . . . . . . . . . . . 39

Action on the pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Regular operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Action on the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Frost protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 Change the oil in the pump casing . . . . . . . . . . . . . . . . . . . . . . . 39 Check the oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Frost protection protection . . . . . . . . . . . . . . . . . . . . . . . 29 Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Centrifugal pump and fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Frost protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Dry intake test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 After the dry intake test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 To pressure test the centrifugal pump with water . . . . . . . 41

Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Programmed servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Troubleshooting

For your safety . . . . . . . . . . . . . . . . . . . . . . . . 30 Technical Helpdesk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 After sales hotline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Possible causes causes and remedy remedy . . . . . . . . . . . . . . 31 Problems during pump operation . . . . . . . . . . . . . . . . . . . . . . . 31 Problems during engine operation . . . . . . . . . . . . . . . . . . . . . . 33

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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 V-belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 Clean the heat exchanger element . . . . . . . . . . . . . . . . . . . . 44 Emergency starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 To change the oil and oil filter . . . . . . . . . . . . . . . . . . . . . . . . 45 Throttle control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Spark plugs and ignition system . . . . . . . . . . . . . . . . . . . . . . . 46 Air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

Servicing Appendices

Please note 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


Circuit diagram . . . . . . . . . . . . . . . . . . . . . . . . 50 Circuit diagram, part 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Circuit diagram, part 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Declaration of conformity conformity . . . . . . . . . . . . . . . . 52

Please note

GENERAL Please note GENERAL About this manual Validity

Figures

This manual applies exclusively to the equipment shown on the front page. The manual contains descriptions of special equipment as well as some abstractions and exemplary illustrations. The actual equipment may therefore differ in part from the descriptions and illustrations.

Where necessary, the texts are illustrated with figures. Reference to a figure is made by by a figure number in [square brackets]. Capi tal letters after a figure number, for example [12A] refer to the corresponding item in the figure. Copyright

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.

Sentences that have an arrow at the start contain instructions for actions. ➔ Complete these instructions in the order in which they appear in the manual.

They may only be copied, reprinted or otherwise reproduced, even in part, with written consent. The information in this manual must not be given or made accessible to third parties, particul arly competitors.

The following types of information commence with a hyphen: – Lists – Requirements for the actions described descri bed below – Processes that take place after an operation – Descriptions of statuses

Printed in Germany

The information symbol denotes instructions that are a good idea to ensure that the portable power pump can be used efficiently and smoothly. Important text passages that you must follow are highlighted specially:

➔

DANGER Warns you of direct dangers that can cause serious injuries or death. The danger text contains instructions to avoid or prevent dangers. Follow these instructions to the letter.

➔

WARNING Warns you of risks that can cause serious injuries or death. The warning text demands safety action to protect the persons concerned. Follow these instructions to the letter.

➔

CAUTION Warns you of risks that can cause damage or injuries. The caution text contains instructions to prevent damage. Follow these instructions to the letter.


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 s tate 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 thi s manual. Any obligation to extend these changes to equipment supplie d 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 condi tion. Only the system supplied by Iveco Magirus Brandschutztechnik GmbH is subject to our declaration of conformity.

DIN = German German Institu Institute te of Standa Standardi rdisati sation on EN = European standard ÖNORM ÖNORM = Austrian Austrian Standa Standards rds Instit Institute ute SFV TI = Swiss Swiss Fire Service Service Associat Association, ion, Technic Technical al Informat Information ion GUV = Statutory Accident Insurance BGV = Professional Association Regulation

The operation is responsible for any changes, modifications, addi tional 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. engineeri ng. The following relevant standards and directives are among those wi th 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, ÖNORM F 1065-TS12/10 or SFV TI 01.00-01-T 01.00-01-Type ype 2.


Units All figures in this operating and servicing ser vicing manual are in current SI units. Conversion factors 1 inch = 25.4 mm mm

1 mm = 0.039 inch

1 foot = 30.48 cm cm

1 cm = 0.033 foot

1 mph = 1.609 kph

1 kph = 0.621 mph

1 US US gal gallo lonn = 3.7 3.785 85 litr litres es

1 lit litre re = 0. 0.264 264 US US gal gallo lons ns

1 GB gallon = 4.545 litres

1 litre = 0.22 GB gallons

1 cuft uft/min = 28.32 l/min

1 l/min = 0.035 cuft uft/min

1 pound = 0.454 kg kg

1 kg = 2.2 pounds

1 psi = 0.069 ba bar

1 bar = 14.504 psi

1 lbf.ft = 1.36 Nm 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 ques tions. Iveco Magirus Brandschutztechnik GmbH After Sales Graf-Arco-Straße 30 D-89079 Ulm Tel. +49 (0)731 408-0 Fax: +49 (0)731 408-2225 E-mail: [email protected] Internet: www.iveco-magirus.de

Identification Whenever you make contact with the manufacturer, please quo te the data from the pump model plate [1], [1], engine model plate [2] [2] or portable power pump model plate [3]. [3]. Positions: – Pump model plate on the left-hand side of the pum p intake – Engine model plate at the top on the cover of the toothed belt – Portable power pump pump model plate on the engine mount next to the generator


[1]

Pump Pump mode modell plate plate (examp (example le with with German German text) text)

[2]

Engine Engine model model plate plate (examp (example le with with German German text) text)

[3]

Portab Portable le power power pump pump mode modell plate plate (examp (example le with with German German text) text)

Please note

FOR YOUR SAFETY Please note FOR YOUR SAFETY Proper usage

➔ ➔ ➔ ➔

➔ ➔

➔ ➔

Training and qualification

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, modifications, changes or improper usage exclude all liability on the part of the manufacturer for damage resulting therefrom.


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

FOR YOUR SAFETY

Read the information

General safety instructions

WARNING Improper operation can cause serious accidents. – Safe usage is only possible if all the information information required for safe operation is observed. This includes instruction manuals, identifiers and warning signs as well as other regulations.

The following instructions provide an overview of how to use the device. The safety instructions in the detailed descriptions in the various sections supplement this general overview. ➔ You must therefore also comply strictly with the instructions in the various sections. Exhaust fumes

DANGER Danger of poisoning from exhaust fumes!

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.

➔

Safe working practice

WARNING Danger of injury from rotating parts. ➔

Other directives

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.

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.). ➔ ➔ ➔ ➔

When the engine is running do not reach into open rotating parts (for example the flywheel on the engine on the underside of the portable power pump, V-belt, fan wheel or impeller, 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.

➔ ➔


Do not leave the portable power pump unsupervised when its motor is running. Secure the portable power pump against unauthorised use.

Please note

FOR YOUR SAFETY

Media

Water pressure

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 fire and sparks and and do not smoke smoke when handling fuel. 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.

The workplace-related noise levels1) are as follows: At rated capacity to DIN

81 dB(A)

At rated capacity to ÖNORM and SFV

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.

Servicing and care

➔ ➔ ➔

➔

Refer to the relevant guidelines and regulations, such as EC “Noise” Directive (2003/10/EC) for details of the necessity of wearing ear plugs.

➔ ➔ ➔ ➔ ➔


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

FOR YOUR SAFETY

Protection from electrical power At incidents near electrical systems take suitable precautions to avoid placing persons in danger from electrical power. ➔ Comply with national laws, directives and regulations. – In Germany, for example DIN VDE 0132 Fire fighting near electrical systems and information the accident prevention regulation Fire services (GUV-V C 53) . ➔

DANGER Danger of death from high voltage! Avoid contact with overhead electric cables or live system parts. ➔ Isolate electrical systems at the incident from the supply. If this is not possible: ➔ When fighting a fire keep a safe distance from electrical systems and lines. – See the national laws, directives and regulations for details of safety distances. ➔

Never touch live parts.

– Overhead electric cables – Live system parts – Parts of electric systems that are live as a result of the effects of damage. Examples: Metal casings, cables with damaged insulation. – Parts of buildings or properties that conduct electricity as a result of the effects of damage. Examples: Gutters, metal fences. Isolate the parts from the supply.

Have the following action completed by an authorised electrician ➔ Isolate electrical systems at the incident from the supply. ➔ Secure the electrical system to prevent its being switched on again. ➔ Check that the system has been isolated from the supply. ➔ Earth and short circuit the system. ➔ Cover or cordon off neighbouring parts that are live. In domestic installations, fire fighters with electrical training may also isolate the electrical systems.


Please note

TRANSPORT AND STORAGE Please note TRANSPORT AND STORAGE Transport To carry the portable power pump

➔ ➔ ➔ ➔

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] [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 nnecessary, ecessary, secure the portable power pump appropriately.

Storage in the vehicle There is a special mounting for the portable power pump in the fire fighting vehicle. ➔ Slide in the portable power pump and secure it for transport. ➔ Always store and secure the portable power pump properly. Fire fighting vehicles with four-wheel four-whe el drive can be fitted with a recessed mounting for the portable power pump to order. This lowers the portable power pump pneumatically to a level from which it can easily be raised. Refer to other documentation

Read the operating manual supplied with the vehicle before storage and comply with the regulations and safety instruc tions contained therein to the letter. ➔ Refer to the section headed Operation, Frost protection . ➔


[4] [4]

Hand Handle less on on carr carryi ying ng fra frame me

Please note

EQUIPMENT Please note EQUIPMENT Portable Portable power pump pump EN 14466 – PFPN PFPN 10 – 1000

2 4 8 ~

~1092 [5]

~ 7 49

Portab Portable le powe powerr pump pump (max (maximu imum m dimen dimensio sions ns to to EN) EN)

Type:

EN 14466 – PFPN 10 – 1000

Centrifugal pump:

P 21 2

Rated pump capacity

1 00 000 l/min at 10 bar

Drive engine

FIAT FIRE 1242 MPI

Engine capacity:

54 kW (75 bhp) at 6000 rpm

Total mass ready for use:

190 kg


The portable power pump is a fire fighting f ighting centrifugal pump that is directly connected to the engine by a switched coupling. The entire unit, consisting of the pump and engine, is mounted on a portable frame. The unit is carried carrie d by the tubular frame. Holes in the bottom runners ensure that it can be stored securely in the vehicle. A multi-part plastic cover protects the engine from the effects of the weather and damage. The general requirements of EN 14466 apply. In their standard design, the portable power pump complies with these standards and the standards and and regulations contained therein. The fire fighting centrifugal pump complies with EN 1028.

Please note

EQUIPMENT

Centrifugal pump P 212 The fire fighting centrifugal pump mainly consists of the components shown in Figure [6]: [6]: A B C D

A B

C

B

Intake Pres Pressu surre outl outlet etss Pump casing ing PRIM PRIMATI ATIC C primi priming ng dev device ice

D

[6]


Co Comp mpon onen ents ts of of the the cent centrif rifug ugal al pum pumpp

Please note

EQUIPMENT

Pump capacities 1) wi with a 3 m intake head:

1,300 l/min at 10 bar 1,700 l/min at 8 bar 2,050 l/min at 6 bar

Pump capacities 1) wi with a 7.5 m intake head:

1,050 l/min at 10 bar 1,150 l/min at 8 bar

Number of stages:

2

Pressure outlets:

2

Materials: Casing, impellers and rotors, intake cover, split water rings: Pump shaft

Alloy (resistant to saltwater) Stainless steel

Pump shaft bearing: Intake side: Drive side:

Plain bearing (maintenance-free) Ball bearing (oil bath lubrication)

Pump shaft seal:

Slide ring seal (maintenance-free)

Draining:

The drain cock is below the pump casing

Drive side:

Single-disc dry friction coupling, can be switched during operation

Ambient temperature range

–15°C

Range of suitable fluid temperatures

0 °C to max. 60 °C

Maximum operating pressure pa lim

17 bar

Maxi Maximu mum m angl anglee for for the the port portab able le powe powerr pump ump durin uringg oper operat atio ionn

15° 15° in all all dire direct ctio ions ns

to +35°C

1) The tolerances of the engine and pump may change these cables.

) r a b ( e r u s s e r p y l p p u S

Intake heads

Delivery rate (l/min) [7]


Char Charact acter eris istic tic pump pump curv curves es

Please note

EQUIPMENT

[8]

Latera Laterall and longi longitud tudina inall section sectionss of centrif centrifuga ugall pump pump P212

PRIMATIC priming device The Magirus PRIMATIC is a fully automatic priming system for fire fighting centrifugal pumps. Function

When the drive is engaged, the diaphragm priming pumps start at the same time as the centrifugal pump. The centrifugal pump is primed by the diaphragm pumps until water enters the pump and the water supply commences. The output pressure of the centrifugal pump disengages the diaphragm discs for the priming pumps off the drive unit and thus stops the diaphragm pumps.

[9] [9]

PRIM PRIMAT ATIC IC prim primin ingg devi device ce


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 cen trifugal 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 centrif ugal pump.

Please note

EQUIPMENT

Drive engine FIAT FIRE 1242 MPI

[10] Lateral and longitud longitudinal inal sections sections of the Fiat FIRE FIRE 1242 MPI

Engine:

Fiat FIRE 1242 MPI 4-cylinder, inline 4-stroke engine, electronic multi-point injection with Lambda sensor

Bore and stroke:

70.8 mm x 78.86 mm

Displacement, total:

1,242 cc

Compression ratio:

9,8 ± 0,2

Max. torque:

106 Nm at 4000 rpm

Max. power (D (DIN): N):

54 kW kW (7 (74 bh bhp) at at 60 6000 rp rpm

Cylinder block:

Grey cast iron

Crankshaft be bearing:

Plain be bearing

Cylinder head:

Aluminium

Camshaft:

Overhead, toothed belt drive

Valves:

Two valves (hanging) per cylinder, tappet activation opens 7° before TDC, closes 41° after BDC opens 43° before BDC closes 5° after TDC 0.80 mm for checking valve timings 0.35 mm inlet play, 0.40 mm outlet play with a cold engine

Inlet: Outlet: Valve play:

Electronically controlled high tension ignition system with engine speed limiting Ignition distribution: Control module Boost: Ignition coils Firing order: 1-3-4-2 Ignition advance: 13° at a speed of 850 rpm

Fuel: Fuel supply: Fuel tank: Cooling:

Air filter:

Dry filter, with oil-impregnated cot ton fabric

Lubrication:

Pressurised circulating lubrication with rotor pump Main flow – replaceable filter (0.25 l) 3.25 l with oil filter

Oil filter: Oil quantity:

Ignition:


Fan: Volume: Coolant:

Octane index 95 ROZ Super unleaded Electric injection pump Thermoplastic, approx. 18 l capacity Water cooling system, inline with a radiator with expansion vessel and a pipe bundle heat exchanger Electric 3.5 l Distilled water and Paraflu UP FIAT at a ratio of 1 : 1

Generator:

Three-phase current 14 V, 38/65 A V-belt drive

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

Battery control lamp

Coolant control lamp

Engine electronics control lamp

Oil pressure control lamp

Tank content control lamp

Light


Control elements

SUMMARY Control elements SUMMARY

A B

C

D K

J I H

L

M

E

G

F X

W

V

U T S

R

Q P O

[11] Control Control elements elements for the portabl portablee power power pump pump

A Co Cont ntro roll la lamp Tank content

M Engi Engine ne cove cover r

B Control la lamp Engine electronics

N Emergen Emergency cy starte starterr (han (handle) dle)

C Co Cont ntro roll pane panell ligh lightt

O Fuel Fuel tank

D Hour Hour coun counte ter r

P Char Chargi ging ng sock socket et (12 (12 V) V)

E Rota Rotary ry thro thrott ttle le knob knob

Q Co Coup uplin lingg contr control ol leve lever r

F Switch Ignition/Start

R Pressure Pressure outlet outlet with with screw-d screw-down own valves valves and and coupling couplingss

G Switch Light

S Drain cock

H Co Cont ntro roll lamp lamp Oil pressure

T Press Pressur uree measu measure remen mentt unit unit Pump outlet

I

Control la lamp Battery

U Press Pressur uree measur measureme ement nt unit unit Pump inlet

J

Control lamp Coolant temperature

V Pump Pump int intak akee with with coup couplin lingg

K Light

W Carryin Carryingg frame frame with handles handles

L Control panel

X Pressure outlet with screw-down screw-down valves valves and couplings couplings


N

Control elements

EMERGENCY STARTER Control elements EMERGENCY STARTER – Zero recoil emergency starter, in the form of a reve rse starter [12 starter [12]] [13]. [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 -15 °C: 20% of rated capacity

A

[12] Emerge Emergency ncy starte starterr handle handle (A)

A

[13] [13] Emer Emerge genc ncyy sta start rter er


Operation

PLEASE NOTE Operation PLEASE NOTE Important rules of conduct Remove exhaust fumes from the working area

Do not operate without water

DANGER Danger of poisoning from exhaust fumes! ➔ ➔

➔

CAUTION Operating the pump without water will result in damage.

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.

➔

Avoid lengthy operating without water.

Frost protection ➔ ➔ ➔ ➔

For deployments in ambient temperatures of below 0°C keep the pump running for as long as possible. Water should be allowed to flow through all the pressure outlets and hose lines at least temporarily. Open unused pressure outlets temporarily. See instructions in section Frost protection .

Monitor the water pressure

➔

➔

WARNING If strong pressure fluctuations occur the stability of the jet pipe operator will be at risk and the pressure hoses can burst. Do not open the pressure outlets too quickly or accelerate suddenly to protect the jet pipe operator and the pressure hoses. Adjust the maximum pump pressure to the hose material you use.

The jet is under high pressure. ➔ Never direct the water jet at a person. ➔

➔ ➔ ➔ ➔

➔ ➔

➔ ➔

As soon as the pump output pressure measurement unit indi indicates pressure, slowly open the shut-off organ to the relevant pressure outlet. Set the required water pressure using the rotary throttle knob. Always set the water pressure high enough to ensure that the priming device cuts out. Close the pressure outlets and jet pipe cocks slowly if necessary. Do not operate the centrifugal pump at full speed whilst outlets are closed, instead set it to moderate speed un til water is required again. If the water supply is interrupted for a lengthy period, disengage the centrifugal pump and switch it off if necessary. Do not exceed the maximum operating pressure pa lim (see section headed Please note, Equipment ).). CAUTION Lengthy operation with cavitation can seriously damage the centrifugal pump. Cavitation can be identified by a noise that sound as though the pump is transporting pebbles. If you hear this noise, take the following action immediately: Reduce the intake head. Reduce the delivery rate or pump speed.


Before starting use ➔ ➔

Check the oil level and top up with oil if necessary. Check the coolant level and top up with coolant if necessary.

Operation

ACTIVATE AND SWITCH OFF Operation ACTIVATE AND SWITCH OFF To activate the engine Before starting the engine ➔

Ensure that the coupling control lever is set to position OFF [14A]. [14A].

To start the engine

Turn the switch Ignition/Start clockwise clockwise to position Ignition ON [16A]. [16A]. ➔ The control lamps Battery , Oil pressure and Engine electronics will be lit. [15]. ➔ Leave the rotary throttle knob in the idling position [15]. ➔ Start the engine by continuing to turn the switch Ignition/Start clockwise to the resistance point in position Start [16B]. [16B]. ➔ After the engine starts, release the switch Ignition/Start . ➔ The switch will automatically return to position ON. – The engine electronics con trol lamp will remain lit for a few seconds during a self-diagnostic and will then go out (see also section entitled Troubleshooting ).). ➔

A [14] Cou Coupli pling ng contro controll lever lever in positio positionn OFF (A) (A)

Intake

Do not expose new or cold engines to high engine speeds. Refer to the instructions in the sections entitled Operation and Please note. [15] Rotary Rotary throt throttle tle knob knob in idling idling posi positio tionn

Emergency start Turn the switch Ignition/Start clockwise clockwise to position [16A]. Ignition ON [16A]. ➔ The control lamps Battery , Oil pressure and Engine electronics will be lit. [15]. ➔ Leave the rotary throttle knob in the idling position [15]. emergen cy starter [17] [17] until you feel ➔ Pull out the handle in the emergency 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 tem-

A [16] 16] Switc itch Ignition/Start in in position Ignition ON (A) Switch Ignition/Start in in position Start (B)

peratures as low as -15°C with a residual battery capacity of 20% if synthetic engine oil to specification has been used.

A

[17] Emerge Emergency ncy starte starterr handl handlee (A) (A)


B

Operation

ACTIVATE AND SWITCH OFF

To activate the pump Requirements

– Engine is running. On the pump: ➔ Remove the blind couplings. ➔ Close the screw-down valves on the pressure outlets and drain cock.

A

Activate ➔ ➔ ➔

➔

Set the coupling control lever to position ON [18]. [18]. To draw in water for priming purposes purpose s turn the rotary throttle knob to position Intake [20A]. [20A]. As soon as the pressure measuring device Pump outlet indi indicates pressure of 2 – 3 bar, slowly slowl y 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.

[18] Cou Coupli pling ng contro controll lever lever in positio positionn On (A)

➔


Switch off To switch off the pump

Move the rotary throttle knob to the idling position [20B]. [20B]. ➔ Close both screw-down valves. ➔ Set the coupling control lever to position Off [19]. [19]. – The pump is disengaged. ➔

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). anti-clockwise to position ➔ Turn the switch Ignition/Start anti-clockwise [21]. OFF [21]. – The engine will shut down. ➔

[20] Rotary Rotary thro throttle ttle knob knob in in positio positionn Intake (A), Rotary throttle knob in idling position (B)

Stopping device

Turn the switch Ignition/Start anti-clockwise anti-clockwise to position OFF [21]. [21]. – The engine will shut down. – The delivery will be stopped. ➔

[21] 21] Switc itch Ignition/Start in in position OFF


B

Operation

ADJUSTMENT AND MONITORING Operation ADJUSTMENT AND MONITORING Setting ➔

Set the required water pressure using the rotary throttle knob [22B]. [22B].

Monitoring

A

Monitor the level in the fuel tank to avoid unnecessary, timeconsuming breaks in the pump operation. – If the control lamp Tank content [22A] [22A] is lit whilst the portable power pump is horizontal, the maximum level is 15%. This corresponds to an operating period of approx. 20 min utes 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 is lit during operation: – The V-belt may be loose or torn. The battery will then on ly 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 oi l pressure control lamp at low speeds is insignificant.


B

[22] Control Control lamp tank content content (A); rotary throttle throttle knob knob (B)

Operation

ADJUSTMENT AND MONITORING

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. ➔


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. th at the pump is operating without ➔ Whilst it is running, ensure that 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] [23D] pull their locking pins [23C] [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.


D C B A

[23] A intake intake (A); pressur pressuree outlets (B) with screw-d screw-down own valves valves (D) and 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 in take from open water.

Intake from hydrants ➔

Rinse the hydrant briefly before connecting the line.

Place the portable power pump no further than 40 m from the hydrant if possible and in a horizontal position . ➔ Connect the manifold to the intake connection. ➔ Connect the hydrant line to the manifold. ➔ Start the engine. ➔ Switch on the pump. ➔

CAUTION Danger of damaging the centrifugal pump if the intake pressure falls below 1.5 bar when drawing water from hydrants. ➔Reduce the pump speed or partly close the outputs. CAUTION Excessive intake pressure may cause function failures and damage to the centrifugal pump. ➔ Do not exceed the maximum operating pressure – Max. operating pressure: See section Please note , Equipment


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.

A

To activate the light CAUTION Danger of fire.

B

➔

Maintain a minimum distance of 1 m between the light and flammable materials.

C

➔

Direct the light using the handle [24A]. [24A]. Undo the clamp screw [24C]. [24C]. Align the light as required using the handle. If necessary, extend the stand. Tighten the clamp screw. Start the engine. Activate the light on the control panel.

➔ ➔ ➔ ➔ ➔ ➔

[24] Light Light in in trans transpor portt positi position on

After operation ➔ Always move the light to the transport position [24] [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 main tain the full battery voltage for starting the engine. – The light cannot be operated unless the engine is running. – If the light is activated 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 automa tically cut in again.

To clean the light CAUTION Danger of fracturing the hot light lens. ➔

Allow the light to cool before cleaning it with water.

➔

Clean the light with solvent-free soap suds.

To change a lamp Remove the 4 screws [24B] [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. ➔


[25] Light Light in workin workingg posi position tion

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]. [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.

A

[26] [26] Drai Drain cock cock (A) (A)

A

➔

Never reach into the intake whilst the pump is running.

➔

Fit the blind couplings.

➔

Conduct a dry intake test.

➔

Check the oil level in the pump casing using the oil dipstick [27 dipstick [27B]. B].

B

If the oil level is below the minimum mark: ➔ Unscrew the primer cap on the top of the bearing casing [27A]. [27A]. ➔ Top up the oil (multi-grade oil SAE 15W40). ➔ Do not fill above the maximum mark.

[27] Filling opening opening (A) (A) and oil dipstick dipstick (B) for for the pump

➔

Set the coupling control lever to position ON [28A]. [28A].

➔

If there is a risk of frost, follow the instructions in the section entitled Frost protection .

A

Action on the engine ➔ ➔ ➔

Check the oil level and top up with oil if necessary. Check the coolant level and top up with coolant if necessary. Refuel (Super unleaded fuel, octane index 95 ROZ), tank capacity: approx. 18l).


[28] Coupling control lever in position On (A)

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.

Centrifugal pump and fittings A

CAUTION Danger of damage if the pump freezes. ➔

B

Drain the pump and fittings with special care.

For deployments in ambient temperatures of below 0°C keep the pump running for as long as possible. – Water should be allowed to flow through all the press ure outlets at least temporarily. ➔

After draining, start the centrifugal pump again without water to remove all the water water residue from it and out of the priming priming device. [29A] pull their locking ➔ Open both screw-down valves [29A] pins [29B] [29B] and then open the valves fully. ➔ Remove the blind couplings. ➔

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 mi nimum closed-circuit vol tage 12.2 V

Frost protection ➔

Prepare the centrifugal pump and fittings for wi nter by adding anti-freeze (see section entitled Servicing ).).


[29] Pressure Pressure outlets outlets with screw-d screw-down own valves valves (A) and and locking locking pins pins (B)

Troubleshooting

FOR YOUR SAFETY Troubleshooting FOR YOUR SAFETY

➔ ➔ ➔

WARNING Improper attempted repairs can endanger the operational safety of the portable power pump and cause serious accidents. Only carry out the described troubleshooting work yourself. All other work should be carried out by specially trained, authorised after sales personnel or at a FIAT workshop. Only use original spare parts from the manufacturer. The fuses are below the engine cover on the top of the side of the pump on the engine (for further information about fuses refer to the section entitled Servicing ). ).

After sales Technical Helpdesk

Iveco Magirus Brandschutztechnik GmbH After sales Graf-Arco-Strasse 30 D-89079 Ulm Telephone: Telephone: +49 (0)731 408- 2594 Fax: +49 (0)731 (0)731 408- 2225 E-mail: [email protected] Internet: www.iveco-magirus.de After sales hotline

A German-speaking after sales technician can deal wi th 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


Troubleshooting

POSSIBLE CAUSES AND REMEDY Troubleshooting POSSIBLE CAUSES AND REMEDY Problems during pump operation The table below shows the possible causes of faults during pump operation and how to rectify them. Fault

Possible causes

Pressure measurement unit Pump inlet shows shows no va- – Pump not connected. cuum. The pump and intake line have not been primed. – Screw-down valves and drain cock open. – Inlet or outlet membranes on the diaphragm pump soiled or worn.

Remedy ➔

Set the coupling control lever to position ON.

➔

Close the screw-down valves and drain cock.

➔

Set the throttle lever to idling and switch off the pump. Only operate the pump from hydrants.

➔

After use: ➔ Rinse the pump with clean wa ter whilst the diaphragm pump is running. If the error continues to occur: ➔ Notify after sales service. – Pump or intake line leaking.

Check the pump and intake line for leaks (conduct a dry intake test, if necessary conduct a pressure test on the pump with wa ter). ➔ Replace defective seals.

➔

If the error continues to occur: ➔ Notify after sales service. – No pressure build up. The pump transports irregular quantities or absolu- – The screen in intake cage or in the tely no water although the pressure measuring unit pump’s intake inlet is blocked. indicates a vacuum. Pump inlet indicates – Non-return valve in the intake cage is jammed.

➔

Notify after sales service.

➔

Clean the intake screen.

➔

Release the non-return valve by tapping gently, for example with a hammer handle.

– The intake line passes over a height (for example wall, bridge railing). An air bubble has formed at the raised section.

➔

Lay the intake line without a raised section.

The water column collapses constantly although the – The intake cage is not deep enough pump and intake line are not leaking. under water so that air is also being drawn in.

➔ ➔

Extend the intake hose or move the centrifugal pump closer to the water.

– Intake head too great.

➔

Reduce the intake head.

– The screw-down valves were opened too quickly.

➔

Close the screw-down valves and open them slowly.

➔

Replace intake hose.

Water transport stops when the screw-down valves are opened.

The pressure on the pressure measuring unit Pump – Water column in the intake line has and the vacuum on the pressure measuring collapsed due to the ingress of air. outlet and unit Pump inlet suddenly suddenly drop to zero.


If the error continues to occur: ➔ Notify after sales service.

Troubleshooting

POSSIBLE CAUSES AND REMEDY

Fault

Possible causes

Remedy

The pressure on the pressure measuring unit Pump – Delivery rate reduced by using smaller rises. The vacuum on the pressure measuring orifices or shutting down pressure outoutlet rises. unit Pump inlet falls. falls. lets.

➔

Set the required pump pressure with the throttle lever.

The pressure on the pressure measuring unit Pump – Other valves on the distributor have falls. The vacuum on the pressure measuring been opened too quickly or the deliveoutlet falls. unit Pump inlet rises. rises. ry rate has been increased by using larger orifices or additional hose lines.

➔

Set the required pump pressure with the throttle lever.

– Pressure hose burst.

➔

Replace the pressure hose.

– The intake cage or intake screen in the pump’s intake inlet is blocked.

➔

Clean intake cage or screen.

– Rubber coating on the intake line has peeled.

➔

Replace intake hose.

– The pump’s water lines are cons tricted.

➔

Notify after sales service.

➔

Use intake hoses that do not leak.

The centrifugal pump transports less water as the vacuum increases.

The water jet from the jet pipe is not emitted evenly – There is still air in the pum p or intake but is interrupted by loud air surges. line, which is being emitted bit by bit.

– If the air surges do not stop the pump If the error continues to occur: or intake line has a leak. ➔ Notify after sales service. – The intake cage is not deep enough under water so that air is also being drawn in.


➔ ➔

Extend the intake line or Move the centrifugal pump closer to the water.

Troubleshooting

POSSIBLE CAUSES AND REMEDY

Problems during engine operation The table below shows the possible causes of faults during engine operation and how to rectify them. Fault

Possible causes

Control lamp Water temperature is lit during pump Engine overheating due to operation. – coolant lever being too low, – defective coolant pump, – dirty heat exchanger element.

Remedy Switch off the engine immedia tely. ➔ Allow the engine to cool and rectify the causes. ➔ Clean heat exchanger element (see section , Servicing – – Engine). If the error continues to occur: ➔ Notify after sales service. ➔

– Water overheating in the pump due to Add fresh water: zero delivery rate. ➔ Drain the heated water through a free pressure outlet. ➔ If both pressure outlets are in use, drain the heated water through the jet pipe. ➔

If the delivery rate is zero, reduce the engine speed or disconnect the pump.

Note: ➔ The engine coolant temperature can be reduced most effectively by adding cold fresh water. Control lamp Battery is is lit lit duri during ng pump pump oper operat atio ion. n.

– V-be V-beltlt torn. torn. The The bat batte tery ry only only has powpower reserves for the engine for a short time.

Control lamp Oil pressure is lit during pump opera- – Supply of lubricating oil to the engine tion. interrupted.

➔

Switch off the pump and engine and replace the V-belt.

Switch off the engine immedia tely. ➔ Check the oil level and top up if necessary. ➔

If the error continues to occur: ➔ Notify after sales service Control lamp Tank is is lit lit duri during ng pump pump oper operat atio ion. n.

– Tank Tank cont conten entt bel below ow 15% 15% of of the the tota totall tank capacity.

Control lamp Engine electronics is lit during pump – Fault in the injection system operation or does not go out after a few seconds of the self-diagnostic after starting.

➔

Top up with fuel.

Operation can be terminated (possible loss of power and misfires). ➔ End use with throttled engine. ➔ After operation have the engine inspected and the fault rectified by a FIAT workshop. Note: – Sporadic and brief lighting of the control lamp is insignificant.


Troubleshooting

JUMP STARTING Troubleshooting JUMP STARTING If the battery is discharged the engine may be s tarted using jump cables connected to a battery of the same or higher capacity in another vehicle.

Jump starting procedure ➔ ➔ ➔

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 10°C. 10 °C. 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.

➔ ➔

➔ ➔

If the engine will not start after several attempts, do not continue to make useless attempts, but notify the after sales personnel or a FIAT workshop. To remove the jump cables: ➔ First disconnect the negative cable. ➔ Then disconnect the cable from the positive poles. ➔

Provide good ventilation. Avoid spark formation. Connect the negative terminals on the jump cables to the earth points, do not connect them to the negative poles on the batteries. CAUTION Voltage peaks can destroy electronic circuits.

➔

➔

Before jump starting, ensure that all electronic systems on the other vehicle are switched off.

Jump cables Only use jump cables, do not use a high speed charger. ➔ Only use jump cables that satisfy the following requirements: – standard jump cables pursuant to DIN 72 553, – minimum cable cross-se ction 25 mm2, – insulated pole terminals. ➔


Switch off the ignition. Remove the pole covers on the batteries. Connect the positive poles. Connect the negative terminals to the earth points, do not connect them to the negative poles on the batteries. Start the engine of the vehicle with the charged battery and increase its engine speed. Start the portable power pump engine and run it at idling speed. Adjust the engine of the vehicle providing the power to idling speed.

Press the pole covers back into position.

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! ➔

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 ➔


Remove exhaust fumes using exhaust hoses and adequate ventilation away from the device and operator to the open air.

➔

➔ ➔

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.

If, despite all your precautions, somebody suffers an electric shock on the ignition system: ➔ Seek immediate medical assistance from a doctor or hospital, even if the person does not feel poorly physically.

➔

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.

Other instructions for safe working practice

WARNING Danger of injury from rotating parts. ➔

➔

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.

When the engine is running, and in particular if the engine covers have been removed, do not reach into rotating parts (such as the engine’s flywheel on the underside of the portable power pump. V-belts or fan wheel in the cover near the exhaust manifold).


Environmental protection Only store media, cleaning and preservative products in sui table containers. ➔ Comply with the statutory environmental protection regula tions when disposing of discharged batteries, media and parts that have come into contact with media. ➔ Deposit used oil and other media as well as replace d 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

Multi-grade oil (engine)

SAE 15W40 SAE 5W401)

for temperatures over 0°C for temperatures under 0°C

Multi-grade oil (pump)

SAE 15W40

for all temperatures

1) Emergency starting with SAE 15W40 oil in temperatures below 0°C would be very difficult.

Frost protection

Application

Recommended

Anti-freeze for the engine (added anti-freeze)

FL SELENIA Paraflu UP

Anti-freeze for the centrifugal pump

Glysantin (or similar)

Grease

Application

Recommended

Grease fo for slides an and me mechanical me mechanisms

Acid-free mu multi-purpose gr grease, fo for ex example Va Vaseline

Cleaning products

Application

Recommended

Cleaning plastic parts and coated surfaces

Solvent-free soap suds

Degreasing

Grease-dissolving cleaning products


Servicing

SERVICING PLAN Servicing

SERVICING PLAN Every Every Every Every Every Every Annu- Every Every Every Every 50 100 150 200 300 month ally 2 3 4 6 hours hours hours hours hours years years years years Check the oil level in the pump and top up if necessary. Check the oil level in the engine and top up if necessary. Check the coolant level in the engine and top up if necessary. Check the battery (voltage, acid density) and charge if necessary Change the oil in the pump casing Change the oil and oil filter Check the air filter insert for dirt and clean it if necessary Check the spark plugs Check the exhaust, fuel and coolant lines and replace them if necessary Check the coolant density Check the emergency starter cable Grease the throttle control Replace the spark plugs, check the leads and replace them if necessary Replace the fuel filter Check the V-belt tension and retension it if necessary Check the intake and exhaust manifolds to ensure they are secure Check the condition of the toothed belt for the valve controller Check the crank casing ventilation system Servicing

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1) For the first time after 10 hours

Hours: __ _ ____________________h

Date: _____________

Name: _______________________________

Signature: ________________________________ Signature: ________________________________

To be carried out by Iveco Magirus after sales personnel or a FIAT workshop: Every Every Every Every 100 150 200 300 hours hours hours hours Check the ignition/injection system (diagnostic connector) Check the adjustment of the tappet play Check the function of the Lambda sensor

Every Every Every Every 2 3 4 6 years years years years

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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 opening (A) and oil oil dipstick dipstick (B) (B) for the pump pump

Protect the pump from freezing with anti-freeze. ➔ With the centrifugal pump running spray approx. 0.5 litres of anti-freeze into the open intake using a spray can. – Anti-freeze: See section Servicing , Please note. ➔ Then conduct a dry intake test. ➔ Dispose of the anti-freeze in an environment-friendly way af ter it has been drained.

A

Change the oil in the pump casing Change the oil after the first 10 hours of use, then after ever 50 hours, but at least every year. Unscrew the drain screw on the underside of the bearing casing [31] [31] and drain the oil. ➔ Dispose of the used oil properly. ➔ Screw in the drain screw with a new seal. – Tightening torque: 32 Nm ➔ Unscrew the primer cap on the top of the PRIMATIC and add around 0.4 l of oil [30A]. [30A]. – Oil: See section Servicing , Please note . ➔

Check the oil level

Check the oil level in the pump casing using the oil dipstick [30B]. [30B]. – The oil level must be be tween the minimum and maximum marks. ➔ If necessary drain oil out or added more oil. ➔


[31] [31] Dra Drain scr screw ew (A) (A)

Servicing

CENTRIFUGAL PUMP

Dry intake test WARNING Danger of poisoning from exhaust fumes! ➔ ➔

Position the portable power pump outdoors. Remove the engine emissions from your working area using exhaust hoses.

Leave the blind couplings on the intake. Close the screw-down valves and drain cock. [32] and start ➔ Set the coupling control lever to position Off [32] the engine. ➔ Set the coupling control lever to position On. purpose s turn the rotary thrott➔ To draw in water for priming purposes le knob to position Intake [33A]. [33A]. – After 10 to 20 seconds a vacuum of 0.8 bar should be achieved. ➔ ➔

As soon as the pointer on the pressure measuring device Pump inlet stops stops moving: ➔ ➔


Intake

Intake

Move the rotary throttle knob to the idling position [33B]. [33B]. Disengage the centrifugal pump (control level in position Off ) and switch off the engine.

– If the pressure drops after a minute by no more than 0.1 bar, the centrifugal pump is not leaking. – If the pressure falls by more than 0.1 bar or if the pointer on the pressure measuring device Pump inlet does does not move during the intake process, the centrifugal pump is leaking.

A

B

[33] Rotary Rotary thro throttle ttle knob knob in in positio positionn Intake (A) Rotary throttle knob in idling position (B)

After the dry intake test ➔ ➔

Open the drain cock and leave it open [34]. [34]. Open the screw-down valves one turn to protect the seals.

A

[34] [34] Drai Drain cock cock (A) (A)


Servicing

CENTRIFUGAL PUMP

To pressure test the centrifugal pump with water

If you are unable to find the leak, despite careful checks, conduct a pressure test on the pump with water. CAUTION The pump intake pressure should not exceed 5 bar for pressure testing with water (engine not running). The maximum pressure must not exceed 17 bar. Close the screw-down valves and drain cock. ➔ Connect the hydrant line direct to the intake. ➔ Open the hydrant, allow air to escape through the pressure outlet until water is emitted. ➔ Close the pressure outlet. – Water will escape through the leak. ➔

➔ ➔

CAUTION Incorrectly completed repairs may cause function failures and damage to the portable power pump. Only replace defective seals yourself. If the leaks are elsewhere notify the after sales service immediately.


Servicing

ENGINE Servicing ENGINE Programmed servicing

A

Programmed servicing work must be carried out after every 50 hours of use or at least every year. Some servicing work can only be carried out by authorised after sales personnel or by a FIAT workshop.

Engine covers The engine is protected from the effects of the weather by two covers. Open the top cover [35] Seal Seal on the engine engine covers covers (A)

Swing the light forwards. ➔ Open the top cover completely. – The cover is held in its li mit position by a gas spring. ➔

To remove/fit the rear cover

Open the side locks [35] [35] by turning them 90° anti-clockwise and remove the cover. [36], ➔ To fit the cover first insert the bottom rubber wedge [36], then close the side locks. ➔

A

Check V-belt

Every 100 hours (at least every two years) Check Che ck the V-belt tension and condition of the belt. – The V-belt [37] [37] is correctly tensioned if it can be pressed down around 1 cm by finger pressure.

[36] Rubber Rubber wedge wedge (A) (A) to secure secure the the rear cove cover r

To retension the V-belt ➔ Remove the rear cover. ➔ Undo the fastening screws for the generator, push the generator to the outside and tighten the screws again. CAUTION Excessive tension will cause high bearing stress. To change the V-belt (request after sales service if necessary) ➔ Remove the rear cover. ➔ Remove the emergency starter and engine speed sensor. ➔ Undo the fastening screws for the generator, push the generator against the engine block and remove the V-belt. ➔ Fit a new V-belt (of the same size) and fit the components again in reverse order. – Tightening torque for fastening screws: 85 Nm


A [37] [37] V-be V-belt lt (A) (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. [38A]. ➔ Check the engine oil level on the oil dipstick [38A]. – The oil level must be be tween the minimum and maximum marks.

B

If the oil level is below the minimum mark: [38B]. ➔ Top up the oil through the filler opening [38B]. – Oil between minimum and maximum: Around 1 litre. – Oil: See section Servicing , Please note . ➔

A

[38] Oil dipstick dipstick (A) and and filling filling opening opening (B) for for the engine

Coolant

WARNING Danger of scalding. The cooling system is pressurised. ➔

➔ ➔

B A

Only open the filling open when the engine is cold. CAUTION Danger of engine damage by mixing coolant types. Mixing different types of coolant additives may severely adversely affect their anti-corrosive effect. Never mix different types of coolant. If necessary only add coolant with the same coolant additive. Never fill the cooling system with pure water without coolant additive.

Check the coolant level regularly before use ➔ Ensure that the engine is cool. ➔ Check the coolant level on the expansion vessel [39A]. [39A]. – The coolant must be above the MIN mark. Normal level : 5–7 cm above above the MIN mark. mark. If the coolant level is below the MIN mark: [39B]. ➔ Top up with coolant [39B]. Use a mixture of distilled water and coolant additive at a ratio of 1:1. – Coolant additive: See section Servicing , Please note . Every 50 hours but at least annually ➔ Check the coolant density with a conventional density meter. – Frost protection to -35°C. – Mixing ratio 1:1 with coolant additive, but at least 1/3 of the total coolant volume must consist of coolant additive (anticorrosive effect). – Coolant additive: See section Servicing , Please note .


[39] Coolant Coolant level indicator indicator (A) (A) and filling filling opening opening on on the expansion expansion vessel (B)

Servicing

ENGINE

Clean the heat exchanger element

If necessary: ➔ Drain the coolant. ➔ Undo the screw connection in the water line between the heat exchanger and pump on the operator’s side of the pump [40B]. [40B]. ➔ Undo the casing screws on the heat exchanger. [40A] and take the ➔ Take the cover off the operator’s side [40A] heat exchanger element (pipe bundle) [41A] [41A] out of the casing. eleme nt with a strong jet of water ➔ Clean the heat exchanger element and fit it again. ➔ Check the round sealing rings in both sides of the casing and replace them if necessary. Ensure that the sealing rings are not stressed as you fit them (danger of leaks). ➔ Assembly the heat exchanger casing and connect the water line to the pump. – Tightening torque for casing screws: 8 Nm ➔ Fill the system with coolant.

A B [40] [40] Heat Heat exc excha hang nger er

A

Emergency starter

Every 50 hours but at least annually em ergency starter [42], [42], clean ➔ Pull out the nylon cable for the emergency it and check it for signs of damage. ➔ Replace a damaged emergency starter as soon as possible.

[41] Heat Heat exchang exchanger er element element (pipe (pipe bundl bundle, e, A)

WARNING Danger of injury if the cable is damaged.

A

[42] [42] Emer Emerge genc ncyy sta start rter er


Servicing

ENGINE

Lubrication To change the oil and oil filter

Change the oil and oil filter every 50 hours, but at least every y ear. Medium: ➔ Use only brand oil to suit the ambient temperature. – Oil: See section Servicing , Please note .

B

Drain the oil ➔ Only drain the oil when the engine is warm. [43B] and oil dip➔ Remove the stopper on the filling opening [43B] stick [43A]. [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

A

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]. [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 [43B] until the oil level on the ➔ Place oil in the filling opening [43B] dipstick is between the maximum and minimum marks. – Total oil volume around 3.25 litres including inclu ding 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-pu rpose grease, for example Vaseline Every 50 hours but at least annually [43C]. ➔ Grease the throttle control cable [43C].


C

[43] Oil dipstick dipstick (A) and and filling filling opening opening (B) for the the engine, engine, throttle throttle (C)

A [44] Positio Positionn of of the the oil filter filter

Servicing

ENGINE

Spark plugs and ignition system

➔

A

CAUTION Spark plug types with different heat values or a different service life may cause faults. Only use spark plugs of the specific type.

B

– Spark plug types: NGK DCPR7E-N-10 – The spark plugs are on the right of the cylinder he ad in the cavities of the intake section, looking from the pump side [45A]. [45A]. Check the spark plugs every 50 hours but at least annually ➔ Unscrew the spark plugs and check them for deposits. ➔ Remove all the carbon deposits between the porcelain insulation on the centre electrode and the spark plug body. ➔ Set the electrode spacing to 1.0 mm. Every 100 hours, but at least every two years: ➔ Change the spark plugs. Notes for working on the ignition system: ➔ Do not disconnect the battery cable or high tension leads when the engine is running. ➔ Do not start the engine with the high tension cables disconnected. ➔ Do not check current or voltage by sparking. ➔ Do not switch on the ignition system if the ignition i gnition coil holder is not connected to earth.

➔

CAUTION Inexpert work on the ignition system may result in damage to the engine electronics and cause a danger of fire. Servicing and repair work to the ignition system’s electronics may only be carried out by authorised after sales personnel or a FIAT workshop.


[45] Installation Installation position position of the the spark spark plugs plugs (A), air filter filter (B)

Servicing

ENGINE

Air filter

Every 50 hours but at least annually, if operated in a lot of dust more frequently: [45B]. ➔ 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 ➔

➔ ➔

➔

B

Use only maintenance-free batteries with a rated value of 12 V, 30 Ah [46A]. [46A]. DANGER Danger of acid burns. Battery fluid is toxic and corrosive (caustic). Avoid contact with the skin and eyes. Wear safety gloves and goggles. Rinse out any battery acid that gets into your eyes immediately with lots of clean, lukewarm water. Consult an ophthalmologist immediately. Rinse out any battery acid that gets on to your skin immediately with lots of clean water.

Inexpert handling of the battery may result in spark formation or even cause the battery to explode. ➔ Avoid fire, sparks and naked flames and do not smoke when handling batteries. ➔ Avoid short circuits. ➔ Never place metal objects on the battery.

➔ ➔ ➔

CAUTION Inexpert handling of the battery may cause damage to the battery or the engine electronics. Never disconnect the battery whilst the battery is connected or the ignition switched on. Never swap the connections to the battery poles. Ensure that the battery terminals are secure.


[46] Battery Battery (A) (A) and and chargi charging ng socke sockett (B)

A

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 minimu m 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 vol tage 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 -10 °C 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] [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 compens ated 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 en titled Troubleshooting , Jump starting .


Servicing

ENGINE

Fuses

There are four conventional flat terminal fuses under the top engine cover above the engine [47]. [47]. They protect the following circuits:

A

Item

Current

Protected ci circuits

A

5A

Charging socket

B

15 A

Light, Lambda sensor

20 A

Contr ontrol ol pane panel,l, comp comple lette, engi engine ne cont contro rollller er,, engine sensors, petrol pump

30 A

Fan blower

C D

D B C

[47] Fuses


Appendices

CIRCUIT DIAGRAM Appendices CIRCUIT DIAGRAM Circuit diagram, part 1 Lambda sensor

Air tempe- Coolant temAbsolute pres- rature sen- perature sensure sensor sor sor

Fuse for LambPotentiometer da sensor and Throttle valve light

Fuse for charging socket

Control lights

-

+

t e k c o s g n i g r a h C

g n i s a c g u l p t h g i L

Control panel light Hour counter

Light switch

r e w o l b r o t a i d a R

Ignition / Start switch

Relay for immobiliser

Relay for radiator Fuse for blower

Main fuse


Starter motor

Electric petrol pump with spare sensor

Appendices

CIRCUIT DIAGRAM

Circuit diagram, part 2 Double relay

Electric injection valves

t i n u l o r t n o c . W . A I .

Diagnostic tap for injec tion system

Ignition coils

Speed and Step servomotor OT sensor Spark plugs

Tempera ture switch

Battery Generator

Oil pressure switch


Appendices

DECLARATION OF CONFORMITY Appendices DECLARATION OF CONFORMITY


Inglés Manual Operación Motobomba Magirus

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