Pumping Apparatus Operator Study Material 2023 PDF

Pumping Apparatus Operator Class Fall 2023 Pre-Entrance Study Material DRIVER CERTIFICATION PROCEDURES These serve as general guidelines. As such they are not intended to replace specific apparatus or equipment operation that may be outlined by manufacturers specifications. At all times Department S...

Pumping Apparatus Operator Class Fall 2023 Pre-Entrance Study Material DRIVER CERTIFICATION PROCEDURES These serve as general guidelines. As such they are not intended to replace specific apparatus or equipment operation that may be outlined by manufacturers specifications. At all times Department SOP’s will govern the evaluation. Candidates seeking certification as drivers will be required to meet the following criteria in order to begin Apparatus Operator Class. If any of these criteria are not met, the candidate will have to wait till the next Apparatus Operator Class to attempt again. o All personnel driving apparatus weighing 24,000 pounds or more must be in possession of a valid Kansas Operator’s License (Class A or B). This can be a non-commercial license. o 10 hours of documented driving time in apparatus candidate will be certifying in. o Successful completion of written entrance exam over material contained in this manual. Candidate must score an 80% on the all sections of the exam EXCEPT the Pump Operations Guidelines section, where a 90% score will be required. o Successful completion of the hands on skills “Engaging the Fire Pump”, “Charging a Single Hoseline”, and “Properly Performing a Water Supply Changeover”, with no critical errors. The Apparatus Operator Class will consist of both classroom and practical instruction. On the last day of class, each candidate will report to the Regional Training Center with their assigned apparatus and crew, and be prepared for the following: o A written exam covering all of the material provided before and during class. Candidate must score an 80% on the all sections of the exam EXCEPT the Rule of Thumb Hydraulics section, where a 90% score will be required. o The candidate will be required to successfully perform 5 of the practical skills required of Apparatus Operators, with no critical errors. It will be at the discretion of the certifying training officer whether a failure of part of a skill warrants repeating. If the training officer identifies a critical error during performance of a skill, the candidate will get one attempt to repeat the skill. If the certifying training officer still believes there are deficiencies, it will be at their discretion to fail the candidate and require them to retake the Apparatus Operator Class at the next available time. Once the candidate successfully completes the testing requirements for the Apparatus Operator Class, the candidate will become a certified operator. It will still be at the discretion of the Battalion Chief to allow a certified operator to drive. Page | 2 VEHICLE DYNAMICS The major forces affecting vehicle performance and maneuverability are: kinetic energy, inertia, centripetal and centrifugal force, friction, and traction. Kinetic Energy or the energy of an object in motion increases as the velocity or speed of that object increases. But the increases in energy are not proportional to the increase in speed; it is proportional to the square of the increase in speed. This means if the speed of a given mass is doubled, its kinetic energy is quadrupled. Driving 60 MPH would take 4 times the energy to stop as 30 MPH. In order to stop an object in motion, its kinetic energy must be dissipated. This can take place suddenly such as a collision or more slowly as in braking. Inertia Newton’s first law of Motion states an object at rest tends to stay at rest and an object in motion tends to stay in motion unless acted upon by an outside force. This property is known as inertia. An object moving in a straight line will continue to travel in a straight line unless acted upon by an outside force. Inertias greatest impact on the control and handling of a vehicle has to do with its effect on cornering. If the outside force (traction) is not strong enough, inertia will cause the center of gravity of the mass to continue in the original direction. Inertia affects the three planes of motion that a vehicle can operate in: Roll is the side-to-side motion of a vehicle that is produced in cornering, the higher the center of gravity, the more the roll, and the greater the possibility of actually rolling the vehicle over. Jerking the steering wheel will produce more vehicle roll. Pitch is the movement of a vehicle in the front to back plane, rapid acceleration or braking produce greater amounts of vehicle pitch. Yaw is rotation around the vehicles center of gravity in a plane parallel to the road (spinning during a skid). Correction of yaw is best affected in a smooth and constant manner. Steer into the skid smoothly, do not jerk the steering wheel to try and correct the skid. Centripetal Force is the force needed to overcome inertia in order to change the direction of a vehicle during cornering. It is produced by the traction of tires against the road. Traction is adhesive friction. Friction is the resistance to motion of two objects that touch. Adhesive friction or traction is a non-slipping friction. Page | 3 TYPES OF TRACTION: Driving Traction is the traction produced by the non-slipping friction of the tire against the road that pushes the vehicle. Braking Traction is that which pushes against the road to slow or stop a vehicle. Cornering Traction is the action of tire against the road to produce the centripetal force needed to turn a vehicle. Driving traction and braking traction are opposing forces and cannot exist at the same time. Cornering traction can exist at the same time as either driving or braking traction. When traction forces are combined, these forces cannot exceed the limits of traction available without the resultant loss of control of the vehicle. This means the more driving or braking force applied in a turn the less cornering traction will be available. The more cornering force necessary, the less driving or braking force is available. Maximum cornering traction occurs when there is neither driving nor braking force being applied. You can’t steer if the wheels are locked up or spinning. Both front and rear tire must provide cornering forces for the driver to maintain directional control. So when maximum cornering traction is needed, do not use the accelerator or brakes; just steer. Centrifugal Force resembles kinetic energy. Centrifugal force is related to the square of the velocity. As speed doubles in a turn, the force opposing that force which makes the turn possible is quadrupled. Turning a corner at 60 MPH produces four times the centrifugal force as turning the same corner at 30 MPH. Centrifugal force also is related to the radius of the turn: the tighter the radius the more centrifugal force is produced. Skid Control and Recovery A skid happens whenever tires lose their grip on the road. This is caused in one of four ways: 1. Over-braking. Braking too hard and locking up the wheels, or a loss of braking traction. Skids also can occur when using the speed retarder when the road is slippery. 2. Over-steering. Turning the wheels more sharply than the vehicle can turn, or a loss of cornering traction 3. Over-acceleration. Supplying too much power to the drive wheels, causing them to spin. 4. Driving Too Fast. Most serious skids result from driving too fast for road conditions. Drivers who adjust their driving to conditions don't over- accelerate and don't have to over-brake or over-steer to compensate for excessive forces. Page | 4 DRIVE WHEEL SKID in which the wheels lose traction are by far the most common; Drive-wheel Skids occur due to excessive braking or acceleration. Skids caused by acceleration usually happen on ice or snow. Taking your foot off the accelerator can easily stop them. Drive wheel braking skids occur when the drive wheels lock. Because locked wheels have less traction than rolling wheels, the rear wheels usually slide sideways in an attempt to "catch up" with the front wheels. A Drive-Wheel Braking Skid can be corrected by: Stop Braking. This will let the rear wheels roll again, and keep the rear wheels from sliding any further. Turn Quickly. When a vehicle begins to slide sideways, quickly steer in the direction you want the vehicle to go--down the road. You must turn the wheel quickly but smoothly. Counter steer. As a vehicle turns back on course, it has a tendency to keep right on turning. Unless you turn the steering wheel quickly the other way, you may find yourself skidding in the opposite direction. Front Wheel Skids. Driving too fast for conditions causes most front-wheel skids. Other causes may be lack of tread on the front tires or cargo loaded so that there is not enough weight is on the front axle. In a front-wheel skid, the front end tends to go in a straight line regardless of how much you turn the steering wheel. On a very slippery surface, you may not be able to steer around a curve or turn. When a front-wheel skid occurs, the only way to stop the skid is to let the vehicle slow down to allow the tires to gain cornering traction to steer the vehicle. Stop turning and/or braking so hard. Slow down as quickly as possible without skidding. Page | 5 GENERAL INFORMATION Operating in traffic is never a static action; conditions are constantly changing. Elements that affect the safe flow of traffic are many: road surface, vehicle condition, speed, weather, visibility, congestion, and road configuration are just a few. The most important element in all of this is the DRIVER. Most accidents are attributable to drivers rather than equipment or conditions. We all feel the need for speed in the emergency service. Our adrenaline kicks in, our anticipation increases, the lights the siren, and the rush are all a part of the special feeling we get every time we respond to an incident. There is no sense in ignoring this reality; however, a different reality sets in once we are involved in an accident going to or returning from a call. Responses to and from emergency and non-emergency incidents continue to be the second leading cause of fire fighter fatalities in the United States. As the driver of a Department vehicle you have an enormous responsibility, THE LIFE AND SAFETY OF YOUR CREW as well as every person you encounter on the road. The safe and efficient operation of a vehicle weighing 35,000 to 75,000 lbs. rests with YOU. This responsibility is a function of both your driving skills and your driving attitude. Impatience is one of the largest contributing factors of a poor driving attitude. The inability to accept minor or momentary delays can lead to poor driving judgment, irresponsible actions, and unacceptable risks. All types of people use the road. Some of those people are aware of their surroundings, pay attention, understand their vehicles, and have good driving skills. However, there are many drivers who do not have good driving habits. Impatience with the (do-nots) will not make them change their actions or the way they drive. As a driver with great responsibility you must comprehend the fact that there will be delays. BE PATIENT AND BE SAFE. It is far better to be delayed than to not arrive at all because your impatience results in an accident. The size/power syndrome The tendency is to believe that people will move away from your vehicle because of its size. This is magnified on emergency runs with the siren and air horn. Not everyone on the road will see you, if you assume they will, you may not leave yourself room to maneuver around them. If they see you at the last second, they may make a totally inappropriate response to your presence. DON’T FALL INTO THE SIZE/POWER SYNDROME. Driving is a cooperative effort between the driver and officer. The officer has many responsibilities in route to an incident but should assist in watching the road especially at intersections. When driving “emergency traffic” be aware of other emergency apparatus responding to the same or different address. If driving in the same direction as other “emergency traffic” vehicles NEVER PASS without the knowledge and consent of the vehicle in front of you. As you approach an emergency scene slow down about a block away. This will give the officer a chance to size up the scene. Avoid watching the emergency – all other drivers on the road will be watching it and you need to be watching them. Page | 6 If you are disregarded “En Route” to an emergency call and are approaching an intersection, it may be appropriate to leave your emergency lights and siren on and proceed through the intersection to avoid confusion. Once you have cleared the intersection, shut down your lights and siren. It is possible to become overconfident in your driving abilities. Over confidence can stem from false ideas about the capabilities of a vehicle and a misunderstanding of the forces at work upon a vehicle in motion. A momentary loss of awareness is a major contributing factor of most accidents. DON’T BECOME A COMPLACENT DRIVER. VISION AND HEARING – PERCEPTION LIMITATIONS Visual perception is a prime determinate in safe vehicle operation. Get into the habit of looking a long way down the road. This helps you guide your vehicle because your vantage point is off center and aiming high helps put the position of your vehicle in proper perspective. Be aware that as you increase speed you lessen your visual field. Use your peripheral vision; it will give you information on objects moving into your focal vision. Peripheral vision also gives an impression of speed; yours and theirs. Do not remain focused on any one object. Don’t focus on the car in front of you as this can cause tunnel vision. The more you focus or stare on the car in front of you, the less your peripheral vision works and increases your chance of getting tunnel vision. VISION The eyes have two sets of specialized cells, rods and cones, that function in different ways. Cones function in daylight and see color. Rods function in reduced light and do not register color. Cones see a sharper image than Rods. As light fades red is the first color of the spectrum to be lost to perception and the last to return. In reduced light a red fire truck is only perceived as a dark object. People can't see as sharply at night or in dim light. Also, their eyes need time to adjust to seeing in dim light. Most people have noticed this when walking into a dark movie theater. Driving at Night. You are at greater risk when you drive at night. Drivers can't see hazards as soon as in daylight, so they have less time to respond. Therefore, drivers caught by surprise are less able to avoid a crash. Windshield and Mirrors. It is important to have a clean windshield and mirrors at all times but especially at night. Bright lights at night can cause dirt on your windshield or mirrors to create a glare of its own, blocking your view. Most people have experienced driving toward the sun and found that they can barely see through a windshield that seemed to look ok in the middle of the day. Clean your windshield on the inside and outside for safe driving at night. GLARE Page | 7 Drivers can be blinded for a short time by bright light. Older drivers are especially bothered by glare. Most people are temporarily blinded by the high beams of an oncoming vehicle. Don't look directly at bright lights when driving. Look at the right side of the road. Watch the sidelines when someone coming toward you with very bright lights. Glare Recovery Time. When an approaching vehicle is passed at night it takes 7 – 10 seconds for the eyes to readjust to the dark. This adjustment time increases with age. At 50 MPH, a vehicle travels about 75 feet per second, so during the glare recovery time your apparatus could travel 750 ft. in the time it takes your eyes to fully readjust to the dark. HEADLIGHTS At night your headlights will usually be the main source of light for you to see and for others to see you. With low beams you can see ahead about 250 feet and with high beams about 350-500 feet. You must adjust your speed to keep your stopping distance within your sight distance. This means going slow enough to be able to stop within the range of your headlights. Otherwise, by the time you see a hazard, you will not have time to stop. Drive slower when lighting is poor or confusing. Drive slowly enough so you can stop in the distance you can see ahead. Wig Wags may be one of the best warning devices during the day, but be aware during nighttime hours wig wags or high beam headlights may wash out your other warning lights on your apparatus. This may reduce your warning lights effectiveness making it difficult for other drivers to see you. Other Lights. In order for you to be seen easily, the following must be clean and working properly: Reflectors Marker lights Clearance lights Taillights Identification lights Emergency warning lights HEARING Because of a phenomenon known as the “ZONE OF CONFUSION” the farther away the source of a sound, the more difficult it is to determine its direction. Alternate siren pitches helps to reduce the severity of this phenomenon. Median Plane of Sound. If the sound is coming directly from the front or rear, neither ear is affected more than the other and direction is hard to determine. The direction of an emergency vehicle approaching another vehicle from the front or rear may be difficult to interpret because of this effect. Page | 8 Other factors, which may impede driver’s abilities to hear your siren are: The person could be partially or completely deaf. Internal noises (radio, air conditioner, etc). Car soundproofing continues to improve and limits the ability to hear outside noise. To help overcome some of these problems: 1. Change the siren selection. 2. Sound the air horn to assist in determining direction. Page | 9 3. Position your vehicle for optimum visibility in the car's mirrors. 4. Remain patient and cautious (they probably aren’t intentionally ignoring you). 5. DO NOT PASS until you are convinced the driver is aware of your presence and has committed to some form of action to clear your way. 6. Make eye contact with the driver if at all possible. SAFE DRIVING HABITS Seeing Ahead. All drivers look ahead, but many don't look far enough ahead. Importance of Looking Far Enough Ahead. Because stopping or changing lanes can take a considerable distance, knowing what the traffic is doing on all sides of you is very important. You need to look well ahead to make sure you have room to make these moves safely. How Far Ahead to Look. Most good drivers look 12 to 15 seconds ahead. (Looking ahead the distance you will travel in 12 to 15 seconds). At lower speeds, that's about one block. At highway speeds it's about a quarter of a mile. If you're not looking that far ahead, you may have to stop too quickly or make quick lane changes. Looking 12 to 15 seconds ahead doesn't mean not paying attention to things that are closer. Good drivers shift their attention back and forth, near and far. Mirror Adjustment. Mirror adjustment should be checked prior to driving the apparatus. You should check and adjust each mirror as needed. It's important to know what's going on behind and to the sides. Understanding what You See. Many large vehicles have curved (convex, "fisheye," "spot," 'bug-eye") mirrors that show a wider area than flat mirrors. Curved mirrors make things seem farther away than they really are. It's important to realize this and to allow for it. Use mirrors correctly by checking them quickly and understanding what you see. Lane Changes. Before changing lanes you need to: Check your mirrors: Make sure no one is alongside you Make sure no one is about to pass you. Make sure there is enough room. After you have signaled, check that no one has moved into your blind spot. Right after you start the lane change, double-check that your path is clear. Turns. When turning, check your mirrors to make sure the rear of your vehicle will clear the turn. Page | 10 Merges. When merging, use your mirrors to make sure the gap in traffic is large enough for you to enter safely. Tight Maneuvers. Anytime you are driving in close quarters check your mirrors often. Make sure you have enough clearance. Consider the use of a spotter when feasible. Checking Quickly. When you use your mirrors while driving on the road, check quickly. Look back and forth between the mirrors and the road ahead. Don't focus on the mirrors for too long. Otherwise, you will travel quite a distance without knowing what's happening ahead. Blind Spots. There are "blind spots" on either side of your vehicle that you cannot see in your mirrors. Check your mirrors regularly to know where other vehicles are around you, and to determine if they move into your blind spots. This will allow you to determine if you can make a lane change. Signal Your Intentions Signaling what you intend to do is important for safety. There are three good rules for using turn signals. 1. 2. 3. 4. Signal early. Signal well before you turn. It is the best way to keep others from trying to pass you. Signal continuously. You need both hands on the wheel to turn safely. Don't cancel the signal until you have completed the turn. Cancel your signal. Make sure your signal turns off after you have completed the turn. Lane Changes. Put your turn signal on before changing lanes. Change lanes slowly and smoothly. That way a driver you didn't see may have time to honk his/her horn or take evasive actions to avoid your vehicle. WARN OTHER DRIVERS IN ANY OF THE FOLLOWING SITUATIONS: Trouble Ahead. The size of your vehicle may make it hard for drivers behind you to see hazards ahead. If you see a hazard that will require slowing down, warn the drivers behind by flashing your brake lights. Slowing Down. Warn drivers behind you when you see you'll need to slow down. A few light taps on the brake pedal -- enough to flash the brake lights - should warn following drivers. SPEED AND STOPPING DISTANCES There are three things that add up to total stopping distance: Perception Distance + Reaction Distance + Braking Distance = Total Stopping Distance Page | 11 Perception Distance. This is the distance your vehicle travels from the time your eyes see a hazard until your brain recognizes it. The perception time for an alert driver is about 3/4 second. At 55 mph, you travel 60 feet in 3/4 second. Reaction Distance. The distance traveled from the time your brain tells your foot to move from the accelerator until your foot is actually pushing the brake pedal. The average driver has a reaction time of 3/4 second. This accounts for an additional 60 feet traveled at 55 mph. Braking Distance. The distance it takes to stop once the brakes are applied. At 55 mph on dry pavement with good brakes it can take a heavy vehicle about 170 feet to stop, or 4 1/2 seconds. Total Stopping Distance. At 55 mph it will take about six seconds to stop and your vehicle will travel about the distance of a football field. (60 + 60 + 170 = 290 feet). Perception Distance + Reaction Distance + (Brake Lag Distance + Effective Braking Distance) = Total Stopping Distance. The Effect of Speed on Stopping Distance. (See kinetic energy and inertia). High speeds increase stopping distances greatly. Whenever you double your speed, it takes about four times as much distance to stop and your vehicle will have four times the destructive power if it crashes. The Effect of Vehicle Weight on Stopping Distance. The heavier the vehicle, the more work the brakes must do to stop it and the more heat they absorb. As brakes absorb more heat they will have less braking ability. Brakes, tires, springs, and shock absorbers on heavy vehicles are designed to work best when the vehicle is fully loaded. Empty trucks require greater stopping distances, because an empty vehicle has less traction. It can bounce and lock up its wheels, giving much poorer braking. (This is not usually the case with fire apparatus). Slippery Surfaces. It will take longer to stop and it will be harder to turn without skidding when the road is slippery. You must drive slower to be able to stop in the same distance as on a dry road. Wet roads can double stopping distance. (See braking traction) Reduce speed by about one third (e.g., slow from 55 to about 35 mph) on a wet road. On packed snow, reduce speed by a half, or more. If the surface is icy, reduce speed to a minimum and stop driving as soon as you can safely do so. Identifying Slippery Surfaces. Sometimes it's hard to know if the road is slippery. Here are some signs of slippery roads. Shaded Areas. Shady parts of the road will remain icy and slippery long after open areas have melted. Bridges. When the temperature drops, bridges will freeze before the road surface. Be especially careful when the temperature is close to 32 degrees. Melting Ice. Slight melting will make ice wet. Wet ice is much more slippery than ice that is not wet. Page | 12 Black Ice. Black ice is a thin layer that is clear enough that you can see the road underneath it. It makes the road look wet. Any time the temperature is below freezing and the road looks wet, watch out for black ice. Vehicle Icing. An easy way to check for ice is to open the window and feel the front of the mirror, mirror support, or antenna. If there's ice on these, the road surface is probably starting to ice up. Just After Rain Begins. Right after it starts to rain, the water mixes with oil left on the road by vehicles. This makes the road very slippery. If the rain continues, it will wash the oil away. Hydroplaning. Tires lose their contact with the road and have little or no traction. You may not be able to steer or brake. It does not take a lot of water to cause hydroplaning. Hydroplaning is more likely if tire pressure is low or the tread is worn. (The grooves in a tire carry away the water; if they aren't deep, they don't work well). Be especially careful driving through puddles. Hydroplaning can occur at speeds as low as 30 mph if there is a lot of water. When hydroplaning you can regain control by releasing the accelerator. This will slow your vehicle and let the wheels turn freely. If the vehicle is hydroplaning, do not use the brakes to slow down. Speed and Curves. Drivers must adjust their speed for curves in the road. If you take a curve too fast, two things can happen. The tires can lose their traction and continue straight ahead, so you skid off the road. Or, the tires may keep their traction and the vehicle rolls over. (See vehicle dynamics) Tests have shown that trucks with a high center of gravity can roll over when traveling at the posted speed limit for a curve. Slow to a safe speed before you enter a curve. Braking in a curve is dangerous because it is easier to lock the wheels and cause a skid. Slow down as needed. Don't ever exceed the posted speed limit for the curve. Speed and Distance Ahead. You should always be able to stop within the distance you can see ahead. Fog, rain, or other conditions may require that you slow down to be able to stop in the distance you can see. At night, you must slow down and be able to stop within the distance you can see with your headlights. DRIVERS WHO ARE HAZARDS In order to protect yourself and others, you must know when other drivers may do something hazardous. Some clues to this type of hazard are discussed below: Blocked Vision People who can't see others are a very dangerous hazard. Be alert for drivers whose vision is blocked. I.E. Vans, loaded station wagons, and cars with the rear window blocked are examples. Rental trucks should also be watched carefully. Their drivers are often not used to the limited vision they have to the sides and rear of the truck. In winter, vehicles with frosted, ice covered, or snow covered windows are hazards. Vehicles may be partly hidden by blind intersections or alleys. If you only see the rear or front end of a vehicle but not the driver, then he or she can't see you. Be alert because he/she may back out or enter into your lane. Page | 13 Delivery trucks can present a hazard. Packages or vehicle doors often block the driver’s vision. Drivers of step vans, postal vehicles, and local delivery vehicles often are in a hurry and may suddenly step out of their vehicle or drive their vehicle into the traffic lane. People getting out of parked vehicles can be hazards. Or a parked vehicle may suddenly start up and drive into your path. Watch for movement inside a parked vehicle or movement of the vehicle. Watch for brake lights or backup lights, exhaust, and other clues that a driver is about to move. Be careful of a stopped bus. Passengers may cross in front of, or behind the bus, and often can't see you. Pedestrians and bicyclists can also be hazards. Walkers, joggers, and bicyclists may be on the road with their back to the traffic. Sometimes, they wear portable stereos with headsets, so they can't hear you either. On rainy days, pedestrians may not see you because of hats or umbrellas or they may be hurrying to get out of the rain and may not pay attention to the traffic. Children. Children tend to act quickly without checking traffic. Children playing with one another may not look for traffic and are a serious hazard. Talkers. Drivers or pedestrians talking to one another may not be paying close attention to the traffic. Workers. People working on or near the roadway are a hazard. The work creates a distraction for other drivers and the workers themselves and therefore they may not see you. Ice Cream Truck. Someone selling ice cream is a hazard. Children may be nearby and may not see you. Disabled Vehicle. Drivers changing a tire or fixing an engine often do not pay attention to the danger that roadway traffic is to them. Jacked up wheels or raised hoods are hazard clues. Shoppers. People in and around shopping areas are often not watching traffic because they are looking for stores or looking into store windows. Confused Drivers. Confused drivers often change direction suddenly or stop without warning. Confusion is common near freeway or turnpike interchanges and major intersections. Tourists unfamiliar with the area can be very hazardous. Clues to tourists include car-top luggage and out- of-state license plates. Unexpected actions (stopping in the middle of a block, changing lanes for no apparent reason, backup lights suddenly going on) are also clues to confusion. Hesitation is another clue, including driving very slowly, using brakes often, or stopping in the middle of an intersection. You may also see drivers who are looking at street signs, maps, and house numbers. Page | 14 Slow Drivers. Motorists who fail to maintain normal speed are hazards. Seeing slow moving vehicles early can prevent a crash. Some vehicles, by their nature, are slow and seeing them is a hazard clue (mopeds, farm machinery, construction machinery, tractors, etc).. Some of these may have "slow moving vehicle" symbol to warn you. Drivers signaling a turn may be a hazard. Drivers signaling a turn may slow more than expected or stop. If they are making a tight turn into an alley or driveway, they may go very slow. If pedestrians or other vehicles block them, they may have to stop on the roadway. Vehicles turning left may have to stop for oncoming vehicles. Drivers in a Hurry. Drivers entering the road may pull in front of you in order to avoid being stuck behind you, causing you to brake. Be aware of this and watch for drivers who are in a hurry. Impaired Drivers. Drivers who are sleepy, have had too much to drink, on drugs, or who are ill are hazards. Some clues to these drivers are: Weaving across the road or drifting from one side to another. Leaving the road (dropping right wheels onto the shoulder, or bumping across a curb in a turn). Stopping at the wrong time (stopping at a green light, or waiting for too long at a stop). Open window in cold weather. Speeds up or slows down suddenly, driving too fast or too slow.. Driver Body Movement As a Clue. Drivers look in the direction they are going to turn. You may sometimes get a clue from a driver's head and body movements that they may be going to make a turn even though their turn signals aren't on. Drivers making over-the-shoulder checks may be going to change lanes. These clues are most easily seen in motorcyclists and bicyclists. Conflicts. You are in conflict when you have to change speed and/or direction to avoid hitting someone. Conflicts occur at intersections where vehicles meet, at merges (such as highway on ramps) and where there are needed lane changes (such as the end of a lane or construction areas forcing a move to another lane of traffic). Other situations include slow moving or stalled traffic in a traffic lane and accident scenes. Watch for other drivers who are in conflict because they are a hazard to you. Drive Defensively. You should always be looking for hazards. Continue to learn to see hazards on the road. However, don't forget why you are looking for the hazards: they may turn into emergencies. You look for the hazards in order to have time to plan a way out of any emergency. When you see a hazard, think about the emergencies that could develop and figure out what you would do. Always be prepared to take action based on your plans. In this way, you will be a prepared, defensive driver who will improve not only your own safety but also the safety of all road users. Page | 15 Emergency Actions Following the safety practices in this manual can help prevent emergencies. But if an emergency does happen, your chances of avoiding a crash depend upon how well you take action. Actions you can take are discussed below. Stopping is not always the safest thing to do in an emergency. When you don't have enough room to stop, you may have to steer away from what’s ahead. Remember, you can almost always turn to miss an obstacle more quickly than you can stop. (However, top-heavy vehicles may flip over). Keep Both Hands on the Steering Wheel. In order to turn quickly, you must have a firm grip on the steering wheel with both hands. The best way to have both hands on the wheel, if there is an emergency, is to keep them there all the time. How to Turn Quickly and Safely. A quick turn can be made safely, if it’s done the right way. Here are some points that safe drivers use: Do not apply the brake while you are turning. It’s very easy to lock your wheels while turning. If that happens, you may skid out of control. Do not turn any more than needed to clear whatever is in your way. The more sharply you turn, the greater the chances of a skid or rollover. Be prepared to "counter steer," that is, to turn the wheel back in the other direction, once you've passed whatever was in your path. Unless you are prepared to counter steer, you won't be able to do it quickly enough. You should think of emergency steering and counter steering as a single steer – corner steer maneuver. If you have been using your mirrors, you'll know which lane is empty and can be safely used. If the shoulder is clear, going right may be best. No one is likely to be driving on the shoulder but someone may be passing you on the left. If you are blocked on both sides, a move to the right may be best. At least you won't force anyone into an opposing traffic lane and a possible head-on collision. LEAVING THE ROAD In some emergencies, you may have to drive off the road. It may be less risky than facing a collision with another vehicle. Most shoulders are strong enough to support the weight of a large vehicle and therefore, offer an available escape route. Here are some guidelines, if you do leave the road. Avoid Braking. If possible, avoid using the brakes until your speed has dropped to about 20 mph. Then brake very gently to avoid skidding on a loose surface. If braking is necessary apparatus with anti-lock brakes will help compensate for dissimilar road surfaces. Keep One Set of Wheels on the Pavement If Possible. This helps to maintain control. Page | 16 Stay on the Shoulder. If the shoulder is clear, stay on it until your vehicle has come to a stop. Signal and check your mirrors before pulling back onto the road. Returning to the Road. If you are forced to return to the road before you can stop, use the following procedure: Hold the wheel tightly and turn sharply enough to get right back on the road safely. Don't try to edge gradually back on the road. If you do, your tires might grab unexpectedly and you could lose control. When both front tires are on the paved surface, counter steer immediately. The two turns should be made as a single "steer- counter steer" maneuver. MANAGING SPACE To be a safe driver, you need space all around your vehicle. When things go wrong, space gives you time to think and take action. To have space available when something goes wrong, you need to manage space. While this is true for all drivers, it is very important for large vehicles. They take up more space and require more space for stopping and turning. Of all the space around your vehicle, it is the area ahead of the vehicle -- the space you're driving into - that is most important. The Need for Space Ahead. You need space ahead in case you must suddenly stop. According to accident reports, the vehicle that trucks and buses most often run into is the one in front of them. The most frequent cause is following too closely. If the vehicle ahead of you is smaller than yours, it can probably stop faster than you can. How Much Space? How much space should you keep in front of you? A good rule of thumb is to allow at least one second for each 10 feet of vehicle length at speeds below 40 mph. At greater speeds, you must add one second for safety. For example, if you are driving a 40-foot vehicle, you should leave four seconds between you and the vehicle ahead. In a 60-foot rig, you" need six seconds. Over 40 mph, you'd need five seconds for a 40-foot vehicle and seven seconds for a 60-foot vehicle. Space to the Side. Fire apparatus are wide and take up most of a lane. Therefore, you have little room to spare. Safe drivers will manage what little space they have. You can do this by keeping your vehicle centered in your lane and keep safe clearance on either side. Avoid driving alongside others, either speed up or slow down to keep adequate space. Traveling Next to Others. There are two dangers in traveling alongside other vehicles: Another driver may change lanes suddenly and turn into you. You may be trapped when you need to change lanes or respond on an alarm. Find an open spot where you aren't near other traffic. When traffic is heavy, it may be hard to find an open spot. If you must travel near other vehicles, try to keep as much space as Page | 17 possible between you and them. Also, drop back or pull forward so that you are sure the other driver can see you. Overhead clearance. Don't assume that the heights posted at bridges and overpasses are correct. Re-paving or packed snow may have reduced the clearances since the heights were posted. Some roads can cause a vehicle to tilt. There can be a problem clearing objects along the edge of the road, such as signs, trees, or bridge supports. Where this is a problem, drive a little closer to the center of the road. Before you back into an area, check for overhanging objects, such as trees, branches, or electric wires. It’s easy to miss seeing them while you are backing. (Also check for other hazards at the same time). Even though you have a backer you are responsible for the apparatus. Space for Turns The space around fire apparatus is important in turns. Because of wide turning, large vehicles can hit other vehicles or objects during turns. Check your mirrors frequently when making any turn. Right Turns. Here are some rules to help prevent right-turn crashes: Turn slowly to give yourself and others more time to avoid problems. If you are driving an apparatus that cannot make the right turn without swinging into another lane, turn wide as you complete the turn. Keep the rear of your vehicle close to the curb. This will stop other drivers from passing you on the right. Don't turn wide to the left as you start the turn. A following driver may think you are turning left and try to pass you on the right. You may crash into the other vehicle as you complete your turn. If you must cross into the oncoming lane to make a turn, watch out for vehicles coming toward you. Give them room to go by or to stop. However, don't back up for them, because you might hit someone behind you. Left Turns. On a left turn, make sure you have reached the center of the intersection before you start the left turn. If you turn too soon, the left side of your vehicle may hit another vehicle because of off tracking. If there are two turning lanes, always take the right-hand turn lane. Don't start in the inside lane because you may have to swing right to make the turn. Drivers on your left can be more readily seen. Be aware of the size and weight of your vehicle when you cross or enter traffic. Here are some important things to keep in mind: Because of slow acceleration and the space large vehicles require, you may need a much larger gap to enter traffic than you would in a car. Page | 18 Acceleration varies with the load. Large fire apparatus weigh 35,000 to 75,000 lbs. and require more space. Before you start across a road, make sure you can get all the way across before traffic reaches you. Railroad Crossings. Railroad crossings are always dangerous. Every such crossing must be approached with the expectation that a train is coming. Never attempt to race a train to a crossing. It is extremely difficult to judge speed of an approaching train. Reduce speed. Speed must be reduced in accordance with your ability to see approaching trains in any direction, and speed must be held to a point which will permit you to stop short of the tracks in case a stop is necessary. Don't expect to hear a train. Because of noise in the cab and headsets you cannot expect to hear the train horn until the train is dangerously close to the crossing. Don't Rely on Signals. You should not rely solely upon the presence of warning signals, gates, or flagmen to warn of the approach of trains. Double tracks require a double check. Remember that a train on one track may hide a train on the other track. After one train has cleared a crossing, be sure no other trains are near before starting across the tracks. Never permit traffic conditions to trap you in a position where you have to stop on the tracks. Be sure you can get all the way across the tracks before you start across. DRIVER FUNCTIONS The following information is designed to provide drivers with information of operational procedures to enhance the safety of personnel and longevity of equipment. Daily Inspection The driver is responsible for keeping the apparatus and it's equipment in good operating order, by performing daily and weekly maintenance and inspections. Maintenance is defined as keeping the apparatus in a state of readiness. Equipment refers to the portable items carried on the apparatus that are not permanently mounted. Periodic maintenance and repair of the apparatus is carried out by mechanics. Objective The driver/operator shall perform routine inspections, and servicing functions required to assure proper operational status of fire department apparatus, equipment and properly document his/her actions on the applicable forms. Page | 19 DRIVER SAFETY A. Under wet, foggy or any other hazardous weather or road conditions. Drivers of fire department vehicles should drive with extreme CAUTION. Do not drive faster than conditions will allow and in no case exceed the posted speed limit. We must respond and react according to the conditions encountered; neither poor road conditions, inclement weather, nor the actions of other drivers relieves the driver in the slightest degree of his/her responsibility to drive safely. These are situations likely to be encountered at any time and we must drive accordingly. Use of emergency lights will require usage of headlights in responding to an emergency, day or night. At nighttime, turn headlights off after arriving on scene to avoid creating a blind spot. B. During an Emergency Response, drivers of fire department vehicles shall bring the vehicle to a complete stop for any of the following: 1. When directed by a law enforcement officer. 2. Red traffic lights. 3. Stop signs. 4. Negative right-of-way intersections. 5. Blind intersections. 6. When the driver cannot account for all lanes of traffic in an intersection, irrespective of right of way. 7. When other hazards are present. 8. When encountering a stopped school bus with flashing lights. Driver shall proceed through intersections only when the driver can account for all lanes of traffic in the intersection. C. During emergency response or non-emergency travel, drivers of fire department vehicles shall come to a complete stop at all unguarded railroad grade crossings (unguarded refers to no signal lights). Drivers shall assure that it is safe to proceed before crossing the railroad tracks. Drivers shall also use caution when approaching and crossing any guarded grade railroad crossing. D. Avoid backing where possible. Where backing is unavoidable, use back-up guides. When it becomes necessary to operate an apparatus in a backward or reverse motion, a firefighter shall be stationed to the rear of the apparatus, in view of the rear-vision mirror to aid and direct driver. The driver shall stop anytime the firefighter stationed to the rear of the apparatus is out of view of the rear-vision mirror. The only exception to the above is in an Page | 20 emergency situation where guides are unavailable. When guides are unavailable during extreme circumstances, walk completely around the apparatus before backing. E. All City of Wichita employees and passengers are required to use seat belts when driving or riding in a city vehicle. All members will remain seated and secured in seats provided at all times when a vehicle is in motion. Never ride in or on any vehicle unless properly restrained in a seated position with a seat belt. Safety belts provide the best restraint when: 1. The seat back is upright 2. The occupant is sitting upright (not slouched) 3. The lap belt is snug and low on the hips 4. The shoulder belt is snug against the chest. The knees are straight forward Before fastening seat belts, adjust the seat to a position that maintains adequate head clearance (see suspension style seats) to reduce the risk of head or spinal injury when driving over severe dips or bumps in the pavement. Always ride with your seat-back upright and the lap belt snug and low about your hips to reduce the risk of serious injury to the abdomen or neck that could be caused by sliding under the safety belts in a collision. Fasten seat belt low and snug on the hips and the shoulder belt snug against the chest. Never use a single belt for more than one person or across more than one seating position. Use the shoulder belt on the outside shoulder only. Never wear the shoulder belt under the arm or swing it around the neck over the inside shoulder. F. Standing while vehicle is in motion is specifically prohibited. Firefighters will not be permitted to ride on/in tailboards, front - end platforms, pick-up beds, fenders, or other external parts of a fire apparatus. NO EXCEPTIONS! G. During an emergency response, fire vehicles should avoid passing other emergency vehicles. If unavoidable, the passing arrangement should be conducted through radio communication. H. Equipment responding on alarms for grass, trash, rubbish, and wash downs, will not exceed the posted speed limit by more than 10 MPH. Provisions of the city code 11.16.060 Regulates the operation, parking and standing of vehicles and shall apply to authorized emergency vehicles. Page | 21 1. The driver of any authorized emergency vehicle, when responding to an emergency call or when responding to but not upon returning from a fire alarm, may exercise the privileges set forth in this section, but subject to the conditions herein stated. 2. The driver of an authorized emergency vehicle, except when otherwise directed by a Police Officer, may: - Park or stand, irrespective of the provisions of this title; - Exceed the maximum speed limits so long as he/she does not endanger life or property; - Disregard regulations governing direction of movement or turning specified directions; 3. The exemptions herein granted to authorized emergency vehicles shall apply only when such vehicle is making use of audible and visual signals meeting the requirements of this section 11.60.230 and 11.60.200. 4. The forgoing provisions shall not relieve the driver of an emergency vehicle from the duty to drive with regard to safety of all persons, nor shall such provisions protect the driver from the consequences of reckless disregard for safety. 5. When an emergency vehicle is responding to an emergency, the emergency vehicle must stop for a school bus loading or unloading, as would a private vehicle. In most instances, if the driver sees you coming, he/she will close the door and hold the students on the bus. Proceed with caution when the driver signals you to pass. 6. School zone Speed limits will be complied with at all times. This includes emergency runs. 7. Proceed with caution through open intersections or intersections with green lights. RAISING OF STATION DOORS/AUTO DOOR OPENERS 1. As a guide to prevent damage to station doors and apparatus, a two inch wide line has been painted on the inside of the front doors and the outside of the rear doors, for apparatus clearance. 2. At no time will the driver move the apparatus until the station door has cleared this line and come to a complete stop. 3. At no time will the automatic opener be operated unless crew has full view of the apparatus doors. 4. Equipment leaving stations shall not exceed 5 MPH until sidewalks have been crossed in front of station. Page | 22 HEARING PROTECTION 1. It is each officer's responsibility to insure all windows in their respective apparatus be in the up position while responding 10-39 traffic. APPARATUS COMPARTMENT DOORS 1. At no time will compartment doors be left opened. It is the officers’ responsibility to ensure that all compartment doors that are of the "GULL" design have a flag vertically hanging when door is in the open position. The flag shall be hung so that it is fully visible from the cab mirror. 2. A “Danger, Do not operate this equipment” sign shall be hung on the steering wheel, whenever the vehicle is not in the ready to respond condition. STEPPING AND WALKING SURFACES All surfaces intended for stepping or walking are designed or treated with slip-resistant material. NEVER step or walk on surfaces not designed for stepping or walking, such as: 1. Chromed surfaces or objects 2. Painted surfaces 3.Hose rollers 4. Compartment doors or hatches 5. Valves 6. Controls 7. Inlet or Outlet Connections 8. Equipment brackets Page | 23 PROCEDURES TO PREVENT EQUIPMENT FREEZING DURING COLD WEATHER: 1. It is vital that the necessary precautions be taken to protect all equipment that may be damaged or made inoperative by water freezing. 2. The following actions shall AT A MINIMUM be taken to prevent freeze ups: a. After notification from the dispatcher that the temperature is expected to be 15 degrees F all charged pumps and booster lines shall, as soon as possible, be drained and remain drained as long as the temperature is 15 degrees F. or lower. Drain all exposed component parts where applicable. If necessary, completely drain the tank, plumbing, and pump. b. DO NOT leave equipment exposed to the (below freezing) weather for extended periods except in emergency situations (i.e. for training, inspection, etc).. IMMEDIATELY NOTIFY MAINTENANCE IF FREEZING IS IMMINENT or EQUIPMENT WILL BE EXPOSED FOR OVER 5 HRS TO BELOW FREEZING CONDITIONS. If it is not possible to drain the pump you may 1. Circulate water through the pump and lines to keep them from freezing. 2. Place tarps over exposed areas. DO NOT PLACE OVER HOT EXHAUST PIPES. c. When pumps and booster lines are used after the pump has been drained, check with the dispatcher for temperature reading. Provided the temperature has moderated to 16 degrees F. or higher, it will not be necessary to re-drain. d. When the dispatcher gives advance notice of an expected low temperature, all pumps are to be drained. No temperature readings other than those given by the dispatcher are to be complied with. Page | 24 Pierce “Dash” Pumper WEIGHT GVWR 45,000 lbs. 18,000 lbs. front axle 27,000 lbs rear axle Approximate height 10’2” Approximate length 33’9” Fuel tank capacity 75 Gallons Water tank capacity 600 Gallons Tire pressures Front 120 lbs. Rear 110 lbs. Page | 25 Page | 26 Page | 27 Pump Operation To Engage the Pump: 1. Bring apparatus to a complete stop. 2. Make sure engine is at an idle. 3. Pull Parking Brake to Apply to prevent vehicle from rolling. NOTE: If the parking brake is OFF, safety interlocks prevent hand throttles or pressure governors from operating. 4. Shift Transmission Into Neutral (N). 5. Turn headlights off/park. 6. Engage the Pump Shift Control The pump shift control is located in the cab. Move Pump Shift Control down to PUMP position. 7. Look at Indicator Light Look at the PUMP ENGAGED indicator light. This indicator light turns ON when the pump shift control is moved from the ROAD position to the PUMP position. It confirms that air pressure has been sent to the pump shift actuator in the pump house and the actuator has moved. This means that the pump transmission has shifted. CAUTION: The pump will fail to shift if the gear teeth fail to mesh. In this case: 1. Shift chassis transmission into Neutral (N) 2. Shift chassis transmission into Reverse (R) 3. Shift chassis transmission into Neutral (N) 4. Transmission should shift into pump. 5. Repeat as necessary. 8. Wait 4 seconds after PUMP ENGAGED light has illuminated for transmission to engage. 9. Shift the Transmission into Drive (D) NOTE: A driveline-driven pump has a “Pump in Drive” label. It says that the transmission must be shifted into DRIVE for pumping. 10. Look at Indicator Light The “OK TO PUMP” light turns ON only when: Pump Shift Control has successfully engaged the pump. Transmission has been successfully shifted into DRIVE. Transmission torque converter is in the locked mode. 11. Look at Speedometer Look for the speedometer showing some value of road speed, in the range of 12 to 18 MPH. If the speedometer indicates approximately 12 to 18 MPH and the vehicle is NOT moving, then the pump is successfully engaged. Page | 28 NOTE: If the parking brake is applied, but then released during pump operation, the hand throttle or pressure governor will be disconnected, and the engine speed will fall to IDLE. A loss of water pressure will result. Manual Pump Shift Override The manual pump shift control is located on the pump panel and controls the shift lever on the pump. If the air shift fails to engage the pump, THEN use the manual pump shift instead of the air shift. This is a manual override and may require two people to operate. Practice using the manual pump shift, so you and a partner can do it automatically if the air shift fails. 1. Bring apparatus to a complete stop. 2. Make sure engine is at an idle. 3. Pull Parking Brake to Apply to prevent vehicle from rolling. NOTE: If the parking brake is OFF, safety interlocks prevent hand throttles or pressure governors from operating. 4. Position One Person in the Driver’s Seat and One Person at the Pump Panel 5. Shift the Transmission into Neutral (N). 6. Turn headlights off/park 7. Move the Pump Shift Control located in the cab into the middle or NEUTRAL position. 8. Pull Manual Shift Handle out with steady pressure CAUTION: If person at pump panel is unable to move the manual shift handle then it will be necessary to: 1. Shut off the apparatus 2. Bleed all air out of the air system by pumping brake pedal 3. Turn on Ignition switch 4. Pull the Manual Shift Handle 5. Look at PUMP ENGAGED Indicator Light: a. If shift is successful and light illuminates, start apparatus and move the in-cab shift control into PUMP b. If shift is not successful, start apparatus and shift into REVERSE and back to NEUTRAL, while person at pump panel attempts to engage pump by pulling out Manual shift lever 6. Repeat until shift is successful and PUMP ENGAGED Indicator Light illuminates 9. Move the in-cab shift control into PUMP 10. Wait 4 seconds after PUMP ENGAGED light has illuminated for transmission to engage. 11. Shift the Transmission into Drive (D) Page | 29 12. A driveline-driven pump has a “Pump in Drive” label. It says that the transmission must be shifted into DRIVE for pumping. 13. Look at Indicator Light The “OK TO PUMP” light turns ON only when: Pump Shift Control has successfully engaged the pump. Transmission has been successfully shifted into DRIVE. Transmission torque converter is in the locked mode. 14. Look at Speedometer Look for the speedometer showing some value of road speed, in the range of 12 to 18 MPH. If the speedometer indicates approximately 12 to 18 MPH and the vehicle is NOT moving, then the pump is successfully engaged. Supply Water to Pump 1. Open Tank-to-Pump Valve The Tank-to-Pump valve controls the flow between the water tank and pump inlet. With this valve OPEN, water from the tank floods the pump intake manifold and slowly primes the pump. 2. Open Primer Valve If the pump is dry, engage primer to expel air in the pump to get prime. 3. Open Tank Fill or Recirculating Valve The Tank Fill valve opens the connection from the discharge side of the pump to the water tank. Open Tank Fill Valve to refill the water tank from a water source that is connected to an intake fitting. With the Tank-to-Pump valve and the Tank Fill valve both OPEN water recirculates from the tank, through the pump, and back to the tank. This cools the pump before you begin flowing water to a discharge line. 4. To assist with keeping the pump cool crack open the Tank Fill Valve when running the pump. If you fail to continuously circulate water through the pump chamber, the water trapped in the pump chamber heats to boiling in seconds. Boiling water and steam can injure people. It also damages pump seals and gaskets. When recirculating water, the water in the tank will eventually become too hot to cool the pump. Exchange tank water with fresh water to keep pump cooled. Page | 30 Keep track of water temperature: Touch the outlet pipe to see how warm it is. If it is hot to the touch, it is time to bring fresh, cool water into the water tank or turn OFF pump. Open Engine Cooler Valve OPEN the Engine Cooler Valve to provide more engine cooling when air temperature is above 80 degrees F, or if engine overheats. Heavy pumping in hot temperatures requires extra engine cooling. The Engine Cooler transfers heat to the pump discharge water through a heat exchanger. Turn the knob one-quarter turn counterclockwise to the left to OPEN the valve. To CLOSE the valve again, turn the knob one-quarter turn clockwise to the right. CLOSE the Engine Cooler Valve for road operation during cold weather for more cab heat. CAUTION Engine Cooler adds engine heat to the pump water. Tank water will heat up faster when engine cooler valve is open. Observe Pump-Overheat Indicator Watch the Pump-Overheat indicator during pumping operations to make sure that the pump stays cool. If the Overheat indicator light turns ON, add fresh water, recirculate, discharge water, or shut engine OFF to cool the pump. Page | 31 Page | 32 Class 1 Electronic Engine Pressure Governor All Wichita Fire Department Pierce Dash (2001-2007) apparatus are equipped with a Class 1 Pressure Governor that controls pump discharge pressure. The Class 1 Pressure Governor is designed to maintain a selected pump pressure or engine speed setting. When the pump is first engaged the display will show "MODE" and the engine will remain at idle until the mode switch is pressed and held to select the desired operating mode "PRESSURE" or "RPM" NOTE: It was previously policy that all pump operators begin operations off their booster tank in the “RPM” mode of operation until a water supply was established and only after that would they operate in “PRESSURE” mode. After extensive review of this policy, it was determined that operating in “RPM” mode prior to and during the changeover process is actually more likely to cause pressure spikes and/or damage or injury. The biggest concern as it relates to changeover to a supplied water source while operating in “PRESSURE” mode is introducing air into the pump which can be easily managed by proper use of bleeder/drain valves. Page | 33 Engine Speed and Pump Pressure Regulating the engine speed controls the pump pressure. If the apparatus is equipped with a pressure governor, the governor will regulate the engine speed automatically to maintain the desired pump pressure. The Class1 Pressure Governor is designed to maintain a selected pump pressure or engine speed setting. Controlling Engine Speed, Pumping – Vehicles Equipped with a Pressure Governor If the apparatus is equipped with a pressure governor, the governor will regulate the engine speed automatically to maintain the desired pump pressure. Select Pressure Mode Place pressure governor in the Pressure Mode. Switching methods will vary depending on the manufacturer of the pressure governor.. Adjust Desired Pressure Use the INCREASE or DECREASE controls to change the desired pressure setting. Apparatus equipped with pressure governors normally do not have pressure relief valves. The pressure governor performs the function of the relief valve. CAUTION: Pumping in RPM mode can cause high pressure and/or pressure spikes. Pressure spikes can injure or kill. When placed in the Pressure Mode, the system will monitor pressure, increasing or decreasing the engine speed to maintain the set pressure. The THROTTLE mode allows the operator to increase engine speed when not pumping, to increase alternator output, warm the engine, or other non-pumping operations. Modes of Operation Power On When the unit is first powered up, the display will show [MODE] and the engine will remain at idle until the mode switch is pressed and held to select the desired operating mode (PRESSURE or RPM). If the pump is engaged and the OK to Pump LED is illuminated, PRESSURE will be the first mode selected otherwise THROTTLE will be the first mode. RPM Mode Page | 34 When the unit is in RPM mode, the display will read “THROTTLE” and the green RPM LED will be illuminated. Engine speed is controlled by the INCrease and DECrease switches, the display will indicate “INCREASE” or “DECREASE” as appropriate when these switches are depressed. The governor will maintain the last output signal attained with these switches. The engine will maintain an RPM appropriate for the throttle signal being sent. NOTE: IF WHILE OPERATING IN RPM MODE THE PRESSURE INCREASES MORE THAN 50 PSI FROM THE PRESSURE LOGGED AT THE LAST SWITCH PRESS, THE GOVERNOR WILL LIMIT THE PRESSURE INCREASE TO NO MORE THAN A 50 PSI DIFFERENTIAL. THE GOVERNOR MAY REDUCE ENGINE RPM TO ACHIEVE THIS AND THE MESSAGE PSI LIMIT WILL BE DISPLAYED IN THEMESSAGE CENTER. NOTE: THE GOVERNOR WILL NOT ATTEMPT TO REGULATE PRESSURE IN THIS MODE, ONLY LIMIT THE DIFFERENTIAL PRESSURE TO 50 PSI FROM THE PRESSURE PRESENT WHEN THE LAST SWITCH WAS PRESSED. Pressure Mode When the unit is operating in the Pressure Mode, the display will show “PRESSURE” and the amber PRESSURE LED will be illuminated. Pump pressure is set by using the INCrease and DECrease switches. The governor will attempt to maintain the last pressure achieved with these switches. The display will indicate “INCREASE” or “DECREASE” as appropriate. The governor maintains pump pressure by controlling engine RPM in response to a signal from the pressure transducer mounted on the pump. When controlling in this manner, the display will show CTRL DEC or CTRL INC. Switch Session Pressure If the INC switch is held the governor will not allow a change greater than 80 PSI without releasing the INC switch and pressing it again. This is only applicable when the pressure is above 90 PSI. This prevents high pressures from being introduced by a distracted operator. Switching between modes Pressing the mode switch will change the governor from RPM to Pressure Mode without a significant change in engine speed or pump pressure. The message center will indicate “PRESSURE” or “THROTTLE” as appropriate once the mode change has been made. When switching to PRESSURE, the pressure set point is whatever pressure is on the transducer at the change. NOTE: You need not go to IDLE to change modes, but all interlocks must be present. Page | 35 Preset Mode Pressing the PRESET switch in either mode will control the engine to attain the preset RPM or pump pressure programmed in governor memory. If there is more than 10 PSI pressure on the pump, the RPM Preset is disabled. If the Preset Switch is pressed, DISABLED will be displayed momentarily. Pressure / Water Loss If the discharge pressure drops below 30 PSI for any reason, engine speed will not be increased. The governor will reduce to the last known value (engine RPM) where the pressure set point was obtained. The display will flash -INTAKE- during this low pressure condition. If the pressure increases above 30 PSI, OPERATOR will flash and the governor will not increase output unless the operator presses the INC or PRESET switches. If pressure above 30 PSI is not regained within 5 seconds, the governor will return the engine to idle and display LoSupply. The operator must make certain that the water supply is adequate and then reinstate governing using the MODE, INC and/or PRESET switches. Pressure Recovery / Cavitation (TRIM) The governor has a trim adjustment; this can be set between 5% and 20% of maximum throttle. This parameter limits the governor’s maximum increase in a pressure recovery attempt. The message center will flash OPERATOR when this limit is reached and the RPM will not increase further. The operator must take positive action to restore discharge pressure. If pressure is not restored within 4 seconds, the governor will reduce output to the last known output where pressure was maintained. The operator must input a new set point with the INC/DEC or PRESET switches. If the pressure rises above the original set point and the governor decreases the engine speed, the governor will resume normal governing operations. PSI Enable The pressure governor will not control pressure until a discharge pressure of 70 PSI is attained. It will act as a throttle until this pressure point is achieved. Pressure Preset While the governor is attempting to reach the preset PSI, the increase is tested at intervals and if the pressure is not increasing, the governor will maintain the engine speed at the point the pressure stops increasing and uses that as the pressure set point. Switch Session Pressure If the INC switch is held and the operating pressure is above 90 PSI, the governor will not allow a change greater than 80 PSI without releasing the INC switch and pressing it again. This is to prevent high pressures from being introduced by a distracted operator. Page | 36 New Messages OPERATOR will flash anytime the governor can’t achieve a desired pressure. This indicates that the governor will not increase engine speed until the pump operator intervenes. INTAKE- will be displayed anytime the governor is operating in Pressure Mode and the discharge pressure drops below 30 PSI. If pressure remains below 30 PSI, the display will change to LoSupply and engine speed will be reduced to idle. At this point, the operator must correct the supply or discharge problem and reinstate governing OPERATOR will be displayed anytime the governor can’t achieve a function or pressure. This indicates that the governor will not increase engine speed until the pump operator intervenes. CTRL INC will be flash in the display if the governor cannot regain the set pressure. It will change to OPERATOR (flashing) if pressure cannot be regained within 4 seconds. During these periods, the governor will not command an increase in engine speed and will return to the last known engine speed command where the set point was achieved. Tank Supply for pre-connects or small diameter hose. Upon arrival at the scene, position the apparatus and shift into pump gear. At the pump panel, the three interlock LED’s must be ON, and the governor Message Center should display [MODE] If the Throttle Ready Interlock is not present, NO INTLK will be displayed in the message center when the MODE switch is pressed and the governor will not respond to an increase or decrease request. The governor will check for a valid pressure transducer signal at power up, if none is found, SENSOR will be displayed. If this is the case, the governor will operate as a throttle only. It cannot react to pressure changes. The MODE switch must be depressed to select a governing mode. Ensure that water is available to the pump by checking the Master Discharge Gauge for pressure. Prime the pump and establish water prior to pressing the governor Preset Switch. Once Pressure Mode is selected, the PRESET switch may be depressed to quickly bring the pump up to the preset operating pressure. The governor will respond to increase and decrease commands from the INC and DEC switches within the operating capabilities of the engine. When the INCrease switch is pressed, INCREASE is displayed in the message center. When the DECrease switch is pressed, DECREASE is displayed. Whenever the governor adjusts the engine speed to maintain the established RPM, CTRL INC or CTRL DEC will be displayed while the governor is actively adjusting engine speed to maintain the set point. The message center will display: Page | 37 THROTTLE or PRESSURE to indicate the current operating mode. Whenever operating with a limited water supply, always be aware of the possibility of running out of water. When the governor is operating in Pressure Mode it will attempt to recover from a discharge pressure loss and increase engine RPM to compensate. If water is introduced to the pump while the engine RPM is advanced, a pressure spike will result. The magnitude will be a factor of pump speed and water quantity. It is not uncommon to lose water and regain it during operation with extremely low water levels due to the position and configuration of the tank sump. Transferring from tank to pressurized water source. The transition from tank to hydrant or relay is an operation that needs to be approached with awareness. Resultant pressure with no change in pump speed is a combination of the operating pressure prior to the change plus the incoming pressurized supply. If operating at 125 PSI and adding a 100 PSI pressurized water source, the resultant discharge pressure will be 225 PSI. The governor will compensate, but it will not be instantaneous. Any time the pump receives air or an air-water mixture, the discharge pressure will drop and the governor operating in Pressure Mode will increase pump speed to maintain the set pressure. Every effort should be made to purge or bleed air from the system. When pressurized water hits the impeller, a significant pressure spike can occur. When the unit is in RPM mode, the display will read "THROTTLE" and the green RPM LED will be illuminated. Engine speed is controlled by the increase and decrease switches, the display will indicate "INCREASE" or "DECREASE" matching the switch that is depressed. The governor will maintain the last speed attained with these switches. Operators should note that when in the RPM mode, there is no pressure protection provided to lines being pumped therefore, if incoming pressure is increased or decreased, the pump pressure would increase proportionally. When the unit is operating in the Pressure Mode, the display will show "PRESSURE" and the amber PRESSURE LED will be illuminated. Pump pressure is set by using the increase and decrease switches. The governor will maintain the last pressure achieved with these switches. The display will indicate "INCREASE" or "DECREASE" as appropriate. The governor-maintains pump pressure by controlling engine RPM in response to a signal from the pressure transducer mounted on discharge side of the pump. Anytime the governor is operating in a "PRESSURE" mode and there is a loss of incoming pressure, due to lack of water volume and/or air in the pump, the governor will attempt to recover from a discharge pressure loss by increasing engine RPM to compensate. If water is introduced to the pump while the engine RPM is advanced, a pressure spike will result. Page | 38 STEP-BY-STEP Procedure Open Air Bleed Valve for Intake BEFORE Cap is Removed Intake connections with a shut-off (or gate) valve can trap pressure if the valve is opened and left closed with the cap in place. ALWAYS OPEN the Intake Air Bleed Valve to let trapped pressure escape BEFORE removing cap. Intake cap under pressure will blow off with explosive force. Exploding cap will injure or kill. Air in lines can cause pressure spikes. Air forced from nozzle can increase intensity of fire or pressure surge. To make sure that all air pressure is removed from the system, keep the Air Bleed Valves OPEN until you start flowing water. Only then may you close it. Remove Intake Cap Remove the Intake Cap only after you are certain that trapped pressure has escaped. Make sure to OPEN the Air Bleed Valve or Drain Valve so that trapped air pressure escapes. Connect the Intake Hose Connect the Intake Hose that has been laid from the hydrant to the intake connection. Charge the Intake Line (Pressurized Supply - Hydrant and remove crimp if 3" hose) NOTE: Make sure that the air bleed valve is open before charging. The air will escape out the air bleed valve as it is forced from the hose by the incoming water. Close Air Bleed Valve Close the Air Bleed Valve after the air is gone from the intake line. Open the Intake Gate Valve (pressure supply line) OPEN the Intake Gate Valve slowly to change the flow to the external supply. Always open the Intake Gate Valve slowly. Air in the intake line will then enter the pump slowly. Air will be sucked through with a steady flow of water. If a large pocket of air enters the pump, the pump can lose prime. Centrifugal pumps cannot pump air. If prime is lost, the attack lines will lose water pressure. Page | 39 Transferring from tank to draft. The transition from tank to draft is another scenario that requires a knowledgeable operator/ engineer. A positive water supply must be established prior to changing the water source. If this is not accomplished, the governor will increase pump speed and when the supply is established, the pressure will be more than desired. If the engine RPM increases dramatically, press IDLE, establish the water supply, press MODE and then PRESET to return to pressure governed operation. The total time should be less than 3 seconds. Portable Tank Operation The transition from onboard tank to portable tank is a tank to draft operation. When the portable tank is refilled is a time when the pump operator must control the situation. When the tank gets low, air can be introduced into the system. The operator must control this so that a pressure spike is not introduced. When the tank is refilled from a dump, a wave action can be set up that would allow running away from water for a short period of time. Switching to RPM mode temporarily while the tank is refilled can control this. Page | 40 Pierce “PUC” Pumper WEIGHT GVWR 46,500 lbs. 18,000 lbs. front axle 27,000 lbs rear axle Approximate height 10’, 3/4” Approximate length 32’ 9 3/4” Fuel tank capacity 63 Gallons Water tank capacity 600 Gallons Tire pressures Front 125 lbs. Rear 120 lbs. Page | 41 Item # 1. 2. 3. 4. 5. 6. Description Item # Description Engine Oil PSI Gauge/Indicator Voltmeter/Indicator Engine Coolant Temperature Gauge/Indicator Tachometer Speedometer Transmission Oil Temperature Gauge/ Indicator 20. 26. 27. 29. 30. 31. LCD Multi-Function Control Ignition Switch/Indicator Start Switch Headlight/Parklight Switch Dimmer Control High Idle Switch/Indicator 7. 8. 9. 10. 16. Front Air Pressure Gauge/Indicator Rear Air Pressure Gauge/Indicator Fuel Gauge/Indicator Diesel Exhaust Fluid Level Gauge/Indicator Multiplex Indicator Lights: Left Directional, Right Directional, High Beam Indicator, Low Coolant, Check Engine, Aux Brake Overheat, Caution, Warning, Park Brake Applied, Stop Engine, DPF Regen, ABS Trailer Fault, Grid Heater - Wait to Start, Traction Control, Check Transmission, Air Restriction, Water in Fuel, Fasten Seatbelts, Rack Down, Engine High Exhaust Temp, ABS Tractor Fault, Emission System Malfunction 32. 33. 39. 40. 41. 42. 43. 49. 50. 17. Left Hardwired Indicator Light Bank: Side Roll Fault, Frontal Air Bag Fault, Battery System ON, SRS Fault 65. 78. 87. 95. OK to High Idle Indicator Emergency Master E-M Button/Indicator Directional Switch Headlight Hi/Low Beam Switch Wiper Control Switch Washer Control Switch 4-way Hazard Switch Battery Switch Diagnostic Panel: DPF Regen Inhibit Switch/ Indicator, ABS Diagnostic Switch/Indicator, Engine/ABS Diagnostic Port, Roll Sensor Diagnostic Port, DPF Regen Switch, Engine Diagnostic Switch/Indicator, Frontal Sensor/Transmission Diagnostic Port, Command Zone Diagnostic Port Park Brake Command Zone System Display Shift Selector & Indicator Defroster Controls 96. 98. Heater Controls Mirror Remote 18. Right Hardwired Indicator Light Bank: Low Diesel Exhaust Fluid Level 19. LCD Display on Gauge Assembly: Odometer, Trip Odometer, Outside Air Temperature, PTO A Hours, PTO B Hours, Engine Hours Page | 43 Operation of Pump Never run the pump dry except momentarily and at low speeds. Do not use this pump for hose testing. A Rear Engine Power Take-off (REPTO) transmits power to the pump transmission input shaft whenever the chassis engine is operating. The fire pump impeller is engaged or disengaged through a high capacity, multi-plate, electric clutch. This configuration enables the pump transmission to power an auxiliary pump transmission mounted Power Take-off (PTO) independent of pump impeller engagement. To Engage the Pump—Stationary Operation 1. Pull Parking Brake Auto Neutral feature automatically engages transmission to NEUTRAL. If you fail to apply the parking brake, safety interlocks prevent operation of the hand throttle or pressure governor. NOTE: If the parking brake is released during pump operation, the hand throttle or pressure governor is disconnected AND the engine speed falls to IDLE. Water pressure to the hose will drop. The pump speed will then be controlled only by the driver's throttle pedal. That is the manual override. 2. Turn headlights off/park. 3. Observe the OK to Stationary Pump indicator lamp: The OK TO STATIONARY PUMP indicator light should be on whenever the parking brake is applied. Engage pump only at engine idle speed. Begin pumping water immediately after engaging pump. Circulate water if hoses are not ready to keep water cool. Running pump dry for more than a few minutes will cause damage. 4. Engage the Pump Confirm engine is at idle rpm. Activate the WATER PUMP switch located on the driver's panel in the cab. 5. Observe the Pump Engaged indicator lamp: The WATER PUMP indicator light will turn ON when: — Pump is engaged, AND — Pump is spinning. Page | 44 Engaging Pump when Vehicle is Driving – Basic Package (Standard) The basic pump and roll mode will use the same operation sequence as stationary pumping mode with a few additional steps. After the vehicle is setup for stationary pumping, the operator will leave the cab and setup the pump panel to discharge at the desired outlet(s). Upon returning to the cab, the operator will disengage the parking brake. An “OK to Pump & Roll” indicator will illuminate on the cab switch panel. First gear on the transmission gear selector will be selected by the operator for pump and roll operations. The operator will apply the foot throttle and brake pedal as needed. Pump and roll mode will be maintained unless the transmission shifts out of first gear or the “Water Pump” switch is disengaged. Pump-and-roll operation is dangerous. NEVER ride outside the cab when the vehicle is moving. Keep personnel walking to the side of the vehicle and in sight of driver at all times. Drive slowly. The foot throttle controls both the ground speed and pump pressure. 1. Stop Vehicle 2. Pull Parking Brake Auto Neutral feature automatically engages transmission to NEUTRAL. 3. Engage the Pump Engage pump only at engine idle speed. Begin pumping water immediately after engaging pump. Circulate water if hoses are not ready to keep water cool. Running pump dry for more than a few minutes will cause damage. Figure 4-1: Water Pump & Foam System Control Switches (Basic Package) Confirm engine is at idle rpm. Activate the desired water pump or foam system control switch located on the driver's panel in the cab. Switches are multi-function; See Table 4-1. Page | 45 4. Observe Indicator Light The PUMP ENGAGED indicator lights only when PTO has been engaged and the pump is spinning. 5. Provide Water Supply to Pump Operator must leave the cab and set up Pump at Pump Panel: — Open the Tank-to-Pump valve to provide water to the pump. — Open the Recirculating Valve (if applicable), or crack open the tank fill valve, to allow water to circulate. 6. Shift Transmission into 1st Gear For pump-and-roll operation the transmission must be in the 1st Gear (1) position. 7. Release Parking Brake 8. Look at Indicator Light The OK TO PUMP AND ROLL light turns ON when: — Parking Brake is released. 9. Use foot throttle and brake pedal as needed Pump will maintain Pump and Roll mode unless transmission shifts out of 1st gear, OR WATER PUMP control switch is turned OFF. Supply Water to Pump 1. Open Tank-to-Pump Valve Figure 4-2: Typical Tank-to-Pump Valve The Tank-to-Pump valve (Figure 4-2) controls the flow between the water tank and pump inlet. With this valve OPEN, water from the tank floods the pump intake manifold and slowly primes the pump. 2. Open Primer Valve If the pump is dry, engage primer to expel air in the pump to get prime. Page | 46 1 1 Keep pump water cool. ALWAYS circulate fresh water through the pump. Pump can heat trapped water to boiling in seconds. Burst lines can spray personnel with scalding water. Scalding water can injure or kill. 3. Open Tank Fill or Recirculating Valve Figure 4-3: Tank Fill or Recirculating Valve The Tank Fill valve (Figure 4-3) opens the connection from the discharge side of the pump to the water tank. Open Tank Fill Valve to refill the water tank from a water source that is connected to an intake fitting. With the Tank-to-Pump valve and the Tank Fill valve both OPEN, water recirculates from the tank, through the pump, and back to the tank. This cools the pump before you begin flowing water to a discharge line. ALWAYS crack open the Tank Fill Valve when running the pump. If you fail to continuously circulate water through the pump chamber, the water trapped in the pump chamber heats to boiling in seconds. Boiling water and steam can injure people. It also damages pump seals and gaskets. When recirculating water, the water in the tank will eventually become too hot to cool the pump. Exchange tank water with fresh water to keep pump cooled. Keep track of water temperature: a. Touch the outlet pipe to see how warm it is. If it is hot to the touch, it is time to bring fresh, cool water into the water tank or turn OFF pump. b. Watch tank temperature gauge (if your fire department selected this option). When temperature reaches 175° F, then add fresh cool water or turn OFF pump. Page | 47 1 1 4. Open Recirculating Valve (Optional) A dedicated Recirculating Valve (Figure 4-4) opens a small water flow from the pump to the tank. The flow through this line cools the pump. The recirculating line does not let water flow from the tank to the pump, so it works only if the Tank to Pump valve is OPEN, or if the intake is supplied by a water source. 5. Observe Pump-Overheat Indicator (Optional) Figure 4-5: Pump-Overheat Indicator Watch the Pump-Overheat indicator (Figure 4-5) during pumping operations to make sure that the pump stays cool. If the Overheat indicator light turns ON, add fresh water, recirculate, discharge water, or shut engine OFF to cool the pump. Manual Pump Engagement Manual pump engagement is intended for limited use in the event of a failure in the primary control system. If conditions warrant the use of this override, pumping operations may continue, but the truck should be examined by a service technician upon return to the station to identify and repair the cause of the failure. NOTE: If this override is used, make sure it is disengaged once pump operations are complete. If power is lost to the pump shift switch in the cab, the following steps can be used to manually engage the pump. 1. Ensure the parking brake is set and the pump shift in the cab is in the OFF position. 2. Proceed to the pump operator’s panel. 3. Open the access panel door located in the lower right of the pump panel. 4. Flip up the switch guard. 5. Turn the switch to the ON position. 6. LED lights at the top of the Pump Compartment will illuminate if the pump is engaged. Repeat if necessary. Page | 48 1 1 PRESSURE GOVERNOR, TANK VOLUME INDICATOR, AND ENGINE MONITORING DISPLAY MODEL PMA300 7 Page | 49 INTRODUCTION Overview The Pierce pressure governor and all-in-one instrument panel uses state of the art programmable microprocessor technology. It will maintain a steady pump discharge pressure by controlling engine speed or hold a selected engine RPM. It offers complete engine control and remote display with tank indicator in a single compact unit. The governor operates in one of two modes, Pressure or RPM. In Pressure Mode it maintains a constant pump discharge pressure. The discharge pressure is monitored and compared to the selected pressure setting, the engine RPM is varied to keep the discharge pressure at the selected setting. In RPM mode the governor maintains a constant engine RPM. The pump discharge pressure is monitored and can vary but, as a safety feature it will be limited to an increase of 30 PSI. If the discharge pressure increases 30 PSI or more in the RPM mode, the governor will automatically lower the engine RPM to prevent a high pressure surge. The panel has a 4-digit LED display for engine RPM. The LEDs are more than 1/2" high. There are five LED bar graphs that provide a constant display of the safe operating ranges for engine coolant temperature, engine oil pressure, battery voltage, fuel level, and pump transmission temperature. (For detailed information with the exact numbers and units of measure the MENU button is pressed). The message display will show pressure and RPM settings; fault and error code information; detailed engine data and program features. All controls and indicators are located on the front of the control module. Features Automatic Regulation of Pump Discharge Pressure Manual Control of Pressure or Engine RPM Settings Field Programmable Presets Diagnostic Capabilities No Pressure or RPM Variation When Changing Modes Limits Increase of Pressure When in RPM Mode Recognition of No Water Condition With Automatic Response Interlock Signal Recognition and Throttle Ready LED Return to Engine Idle With the Push of a Button Accumulated Engine and Pump Hours Displays and LEDs Automatically Adjusted for Day or Night Operation Page | 50 GENERAL DESCRIPTION All controls and indicators are located on the front of the control module. Components The pressure governor, tank volume indicator, and engine monitoring display consist of the following components: Control Module Tank Pressure Sensor Discharge Pressure Sensor Audible Alarm Buzzer Control Module The control module is waterproof and takes up 12 by 4 inches of panel space. All controls, indicators, and displays are located on the front of the control panel. (Refer to Controls and Indicators). Tank Pressure Sensor The pressure sensor is mounted on a side of the tank near the bottom. It provides a signal that is proportional to the volume of liquid in the tank to the input of the control module. The electrical connector is waterproof and molded into the pressure sensor housing. The standard pressure sensor is used on tanks between 1 and 10 feet in vertical height. For tanks taller than 10 feet contact the factory for options. Discharge Pressure Sensor The pressure sensor is mounted on the pump discharge manifold. It provides an input signal to the control module that is proportional to the discharge pressure. High Idle The governor programming includes a high idle function. Note: The pump must NOT be engaged when using the high idle function. The high idle is set to 1000 RPM at the factory. (This value will vary depending on the specific engine). Page | 51 Controls and Indicators All controls and indicators are located on the front of the control module. (Refer to Figure 1). RPM Display Shows the engine RPM during normal operations. CHECK ENGINE / STOP ENGINE LED Repeats the engine warnings from the cab. Engine Coolant Temperature LED Display Shows temperature in safe range with green LEDs. The LEDs will flash red when the temperature is high. Engine Oil Pressure LED Display Shows pressure in safe range with green LEDs. The LEDs will flash red when the pressure is low. Battery Voltage LED Display Shows voltage in safe range with green LEDs. The LEDs will flash red when the voltage is outside normal limits. Fuel Level LED Display Shows fuel level with green LEDs. The LEDs will flash red when the fuel level is low. Pump Transmission Temperature LED Display Shows temperature in safe range with green LEDs. The LEDs will flash red when the temperature is high. Tank Volume Indicator The 9 LED display shows the volume of liquid in the tank. The top LED will be green when the tank is full. SILENCE Button Suppresses audi alarms and is used when programming. MENU Button Used when accessing detailed information and program features. Detailed information shown includes engine coolant temperature, engine oil pressure, battery voltage, fuel level, pump transmission temperature, engine hours, pump hours and transmission temperature (optional) with the exact measure and units. PRESSURE CONTROL LED The amber LED is on to indicate operation in the Pressure Mode. RPM CONTROL LED The red LED is on to indicate operation in the RPM mode. Page | 52 Message Display The message display shows the pressure or RPM setting during normal operations, warning alarms as they occur, and detailed information when the menu button is pressed. It shows the time and date when the throttle ready LED is off. It is also used to show stored data and program features. CONTROL MODE Button Selects the pressure or RPM control mode of operation. Light Sensor Automatically adjusted the displays and LEDs for day or night operations. For day time operations the displays and LEDs are at the brightest. When the amount of light on the sensor drops below a set threshold for more than 3 seconds, the brightness of the displays and LEDs will be dimmed by 25%. The dimmed setting is for night operations. THROTTLE READY LED This LED will be on when the required interlock conditions are met and the governor is ready to begin operations. PRESET Button Press to change/select a pre-programmed value for pressure or RPM setting. Control Knob When rotated changes the pressure or RPM setting. The setting will increase or decrease proportionally to the speed and direction the control knob is rotated. IDLE Button When pressed immediately sets the engine RPM to idle. This button can be used in an emergency or for normal shut down after operations. When pressed it will take the governor out of pressure or RPM control mode. Page | 53 OPERATION On power-up the governor will be at idle (no control mode selected). The RPM display will show engine RPM, the five LED bar graphs will be green indicating readings within normal ranges, and the message display will alternate between showing the date and time. If a monitored function is not within normal parameters the display will flash, the RPM display will show an error or fault warning code and a description will show in the message display. (Refer to Table 2. Error Codes or Table 3. Fault Warning Codes). If one of the inputs displayed by the LED bar graphs is not within normal range the LEDs will be red and flashing. When all necessary throttle enables are active and the interlock circuit is complete the THROTTLE READY LED will light and the governor will be ready to control the engine RPM. Select a control mode to start operations. Controls Control Knob The control knob is used to adjust PSI and RPM settings. The governor will sense how fast and in what direction the control knob is rotated and send a signal to the ECM to increase or decrease the engine RPM proportionally. If the control knob is rotated quickly; the engine RPM will change quickly. If the control knob is rotated slowly; the engine RPM will change slowly. Rotate the control knob clockwise to increase engine RPM. Rotate the control knob counterclockwise to decrease engine RPM. Press the red IDLE button to immediately return the engine to idle (This will also deselect the control mode). CONTROL MODE Button Switches between pressure and RPM control. MENU Button Shows detailed information in the message display. SILENCE Button The silence button is used to suppress an optional audible alarm. PRESET Button Selects a pre-programmed value for pressure or RPM setting. (Note: When in RPM mode with the pump discharge pressure above 20 PSI, the PRESET button is disabled). Page | 54 Error Codes and Fault Warnings RPM Display Message Display E01 NO DATA E02 NO RPM E03 E04 E05 E07 E08 E10 Table 2. Error Codes NO TRANS SENSOR NO OIL SENSOR NO D. PSR SENSOR NO ENG T SENSOR NO WATER SENSOR NO FUEL SENSOR Probable Cause Note: Not all inputs are used for all engines. For systems that use a datalink to pass information the datalink cable and connectors or ECM programming would be the probable cause. >Datalink cable not connected / connected to wrong port >Broken wire / bad connector contact on datalink cable Engine RPM not detected >Datalink cable not connected / connected to wrong port >Engine not running / ignition key on >Broken wire / bad connector contact on alternator cable No Transmission Data Detected (w/sensor input at pin 26 >Sensor cable not connected >Broken wire / bad connector contact on sensor cable >Defective temperature sensor No Engine Oil Pressure Data Detected (w/sensor input at pin 36) >Sensor cable not connected >Broken wire / bad connector contact on sensor cable >Defective pressure sensor No Discharge Pressure Sensor Detected >Sensor cable not connected >Broken wire / bad connector contact on sensor cable >Defective pressure sensor No Coolant Temperature Data Detected (w/sensor input at pin 37 >Sensor cable not connected >Broken wire / bad connector contact on sensor cable >Defective temperature sensor No Water Tank Pressure Sensor Detected >Sensor cable not connected >Broken wire / bad connector contact on sensor cable >Defective pressure sensor No Fuel Sensor Detected (w/sensor input at pin 17) >Sensor cable not connected >Broken wire / bad connector contact on sensor cable >Defective temperature sensor Table 3. Fault Warning Codes RPM Display Message Display F01 F02 HI BATT VOLTAGE LOW BATT VOLTAGE High Battery Voltage Factory Default Setting 15.5 V Low Battery Voltage 11.8 V* F03 F04 HI TRANS TEMP LOW OIL PRESSURE High Transmission Temperature Low Engine Oil Pressure 300 °F 8 PSI F07 F08 HI ENG TEMP NO WATER High Engine Coolant Temperature Out of Water Mode 220 °F F09 ENG NOT RESPOND F10 F11 CHECK TRANS LOW FUEL F12 PUMP T. OVERHEAT Description Engine Does Not Respond Transmission Fault Low Engine Fuel Level High Pump Transmission Temperature 25% 200 °F * 11.8 with engine running, 11.7 engine off. Page | 55 Pressure Mode Operation In the Pressure Mode of operation the PRESSURE CONTROL LED will be on. The governor will maintain a constant discharge pressure within system capabilities. It will adjust the engine RPM automatically to compensate for variations in pressure. In case of a pressure sensor failure an E5 error code will flash and the governor will not operate in Pressure Mode. To pump, the operator will have to select the RPM mode. Note: When starting from idle with no control mode selected, pressing the CONTROL MODE button will select the Pressure Mode. When changing from RPM to Pressure Mode during operations, hold the CONTROL MODE button for 3 seconds. Note: When changing from RPM mode to Pressure Mode the pressure setting will be the pressure that the pump was operating at in RPM mode. 1. 2. 3. Press CONTROL MODE button to select the Pressure Mode. Result: PRESSURE CONTROL LED goes on. Press PRESET and/or rotate the control knob to select pressure setting. Result: Message display shows pressure setting, engine RPM changes. Press IDLE button after operations to bring engine to idle RPM. Result: Message display shows IDLE ENGINE, PRESSURE CONTROL LED goes off, engine returns to idle RPM. Opening/Closing Discharge Valves In Pressure Mode the governor will maintain the pressure setting regardless of the number of discharge lines that are opened or closed providing there is a sufficient water supply. As lines are opened the discharge pressure will start to drop and the governor will raise the engine RPM to maintain the required pressure. As lines are closed the discharge pressure will start to rise and the governor will lower the engine RPM to maintain the required pressure. Running Away From Water, Low Water, or No Supply Water There are situations during pump operations when there may be low or no supply water. This can be due to an empty water tank, a problem on the intake line, air in the pump, changing the water source, or an insufficient water supply. The governor constantly monitors the discharge pressure and compares it to the engine RPM. It is programmed to limit RPM increases when conditions arise that fall outside normal operating parameters. Page | 56 Running Away From Water: If the discharge pressure starts dropping while operating in Pressure Mode, the governor will increase the engine RPM and attempt to maintain the selected pressure setting. If pressure drops and an increase in RPM does not bring the pressure back up, the governor will recognize this as a running away from water condition. When this condition occurs the governor will switch to the RPM limit mode and limit the engine RPM accordingly. RPM Limit Mode: When the RPM limit mode is in effect the PRESSURE CONTROL LED will stay on. To alert the operator the RPM CONTROL LED and the RPM display will flash, and the message display will flash LO WATER. When the pressure comes back up, the RPM limit mode is canceled and the governor switches back to normal operation in Pressure Mode with the existing pressure setting. In some cases the pressure may not come back up but remains at a level above 45 PSI. In the RPM Limit Mode the governor will behave like a manual throttle and the operator can raise or lower the engine RPM by rotating the control knob. In this mode the pressure setting will not change, the PRESET button is disabled, and if the engine is set to idle using the IDLE button, the governor will come out of RPM Limit Mode and cancel the pressure setting. L