PyroLance LB 2000 W-D Technical...

PyroLance LB 2000 W-DTechnical Manual

PyroLance · 6140 S. Gun Club Road · Ste. K6-270 · Aurora, Colorado 80016 USA

+1 303.952.5018 · www.pyrolance.com01-060-20131206

UnitSerialNumber ______________________________________

Table of Contents

2

Unit Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

1 Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Example of Required Personal Protective Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Material Safety Data Sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

2 A Quick Look at How the System Works. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

3 System Component Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

4 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Uncrating and Lifting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Installation Procedures and Initial Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

User-Required Installation Material and Labor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Option 1: Skid Mount Installation (standard). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Option 2: Compartment Mounting Installation (optional) . . . . . . . . . . . . . . . . . . . . . . 16

General Installation and Mounting Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

5 Making Sure Everything is Working Right . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

6 Transmitter Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

7 Operation Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Start-up Operation of Power Unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Normal Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Emergency Mode Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

PyroFoam Direct Injection Foam System (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Rotary Gear Pumps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Foam System Flow Schematic and Major Components . . . . . . . . . . . . . . . . . . . . . . . . . 30

Recommendations for Selected Materials in Penetration/Cutting . . . . . . . . . . . . . . . . 31

8 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Engine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Preventative Maintenance Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Engine Oil, Air Filter, Spark Plug and Filter Replacement . . . . . . . . . . . . . . . . . . 33

Fluid Levels, Spark Plug, Points and Filter Replacement . . . . . . . . . . . . . . . . . . . 33

Checking Engine Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Changing Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Table of Contents

3

Changing Engine Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Changing Engine Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Changing Engine Spark Plug. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Nozzle Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Replacement of Nozzle and/or Nozzle Retaining Nut. . . . . . . . . . . . . . . . . . . . . 36

Lance Nozzle Hose Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Replacement of Remote Control Signal Transmitter Battery . . . . . . . . . . . . . . . 38

Replacement of Faulty Control Nozzle Mounted Transmitter Unit . . . . . . . . . . 38

Pump Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Winterization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

9 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Engine Problems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Pump and Plumbing Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Lance Nozzle Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Blitz Nozzle Problems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Electrical Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Anti-Freeze Loading Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Hose Reel Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

PyroFoam System Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

10 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Power Unit Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Exploded Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Udor Pump Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Flow Schematic and Major Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Throttle Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Power Unit Electrical Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

Switch Panel Electrical Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Reel Controller Electrical Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

APPENDIX: COMPONENT LITERATURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

4

Unit Specification Name Plate

SPECIFICATIONS

ENGINE MFGR & MODEL: HATZ 2-M41

PUMP MFGR & MODEL: Udor #NX75/150

PUMP FLOW & OPERATING PRESSURE: 20 gpm (80 L/min) 2000 PSI (138 Bar)

FUEL TYPE: DIesel

ABRASIVE: PyroShot 2.5 Gallons (9.375 L)

DATE OF MFG: 10-1-11 SERIAL NO: LB-2000-WD-10012001-001

LB-2000-WD Unit Specifications

Nominal Pump Flow 20 GPM (80 LPM) at pump

Nominal Pump Maximum Pressure 2000 PSI (136 BAR) at pump

Nominal Nozzle Pressure & Flow Lance 1500 PSI at 10 GPM (100 BAR at 40 LPM)

Nominal Nozzle Pressure & Flow Blitz 1500 PSI at 20 GPM (100 BAR at 80 LPM)

Engine 35 HP, Diesel HATZ 2-M41

Installation Environment Fire Apparatus Vehicle, exposed or compartment

Fuel Requirements Diesel

Fuel Tank Capacity 2.5 Gallons (9.375 Liters)

Remote Controls Line of site, radio frequency control

Water Inlet Pressure Limits 0 PSIG (Atmospheric Pressure) from water tank

Cutting Abrasive Requirements Use only PyroShot abrasive

Nozzle Diameter Lance 0.090“ (2.29 mm)

Nozzle Size Blitz 20 GPM (80 LPM)

Cutting Time (per tank of abrasive) Approximately 4 Minutes

Overall Unit Dimensions (L x H x D) 38”L x 48”H x 40”D (965 mm x 1220 mm x 1020 mm)

Hose Length 150 ft (46 m) x .750” (19 mm) x 3125 PSI/212 Bar

Power Unit Weight (Dry) 1400 lbs (635 kgs) approximate

Lance Weight 21 lbs (10 kgs) approximate

PYROLANCE North America LLC

6140 S. Gun Club Road

Ste. K6-270

Aurora, Colorado 80016 USA

Phone: +1-303-952-5018

Web Site: www.pyrolance.com

5

LB 2000 W-D

6

LB 2000 W-DLB 2000 W-D

ENGINE MFGR & MODEL: HATZ 2-M41PUMP MFGR & MODEL: Udor #NX75/150PUMP FLOW & OPERATING PRESSURE: 20 gpm (80 L/min) 2000 PSI (135 Bar)FUEL TYPE: DieselABRASIVE: PyroShot 2.5 Gallons (9L)

1 Safety

7

Before attempting to operate or install the PyroLance unit, readall of these safety precautions and follow carefully.An ultra-high pressure fire pump system is inherently powerful and potentially hazardous equipment; however,with the proper care and understanding of the instructions, such firefighting units can be operated effectivelyand safely.

A PyroLance firefighting unit must only be operated by qualified personnel who have completelyread and understood this PyroLance Manual.

This manual is intended to reinforce and review safety techniques. It is recommended that qualified userscomplete extensive firefighting exercises prior to placing a unit in service and practice refresher exercises onan annual basis.

It is strongly recommended that this entire instruction manual be reviewed in depth before operating ormaintaining this equipment. Service work should only be performed by individuals who have read andcompletely understood the operations manual.

1. Always wear eye protection

2. Always wear full personal protective equipment (PPE) for operator of nozzle

3. Always inspect hoses and couplings prior to use

4. Observe a minimum of 15 feet (4.6 m) safety radius around the nozzle operator

5. Keep away from exhaust and hot engine components

6. Always ensure pressure vessel cap is de-pressurized prior to removing the cap for filling

or service work

7. Always ensure pressure vessel cap is secure prior to operation

8. Only use ‘PyroShot’ as an abrasive material

9. Follow this Instruction Manual regarding winterization, draining, and protection of the

hoses, pump, and entire plumbing system when exposed to temperatures under 32

degrees F / 0 degrees C

10. Check fuel, oil, and lubricant levels prior to operation

11. Do not operate equipment unless operator has read this operation and instruction

manual!

DANGER: Never direct a piercing nozzle at any person or animal.

DANGER: Never direct a water stream towards an electrical power line.

Safety

8

Example of Required Personal Protective Equipment

Helmet andHead Protection

Full BodyStructural Clothing

StructuralGloves

Face Shield or Goggles

WARNINGPyroLance North America is not responsible for damages resulting

from a failure to comply with instructions in this manual.

Please read carefully before use.

Ensure a safe sweep area of at least 15 feet (4.57 m) in any direction while operating the PyroLance nozzle.

Seek immediate medical attention if any unprotected part of thebody comes in contact with the high pressure water stream. Seriouspersonal injury can result from an untreated water injection wound.

Safety

Material Safety Data Sheet(This MSDS Complies with 29 CFR 1910.1200) Date of Issue: December 2006

Section 3 - Physical and Chemical Properties

Physical State: Solid Appearance and Odor: Red, Pink, Whitish Grains or

Powders Odor Threshold: No odor Vapor Pressure: Not Relevant Vapor Density (Air = 1): Not Relevant Specific Gravity (H2O = 1): 3.9 - 4.1 pH: Not Relevant Water Solubility: Not soluble in waterOther Solubilities: Not RelevantBoiling Point: Not RelevantMelting Point: 1,315º C (2,399º F)Viscosity: Not RelevantMean Refractive Index: 1.77 - 1.79Evaporation Rate: Not Relevant

Section 4 - Fire Fighting Measures

Flash Point: Non-flammable solidFlash Point Method: Not RelevantLEL: Not RelevantUEL: Not RelevantFlammability Classification: Not RelevantExtinguishing Media: Use appropriate extinguishing

media for surrounding fire.Unusual Fire or Explosion Hazards: None

Section 5 - Stability and Reactivity

Stability: StablePolymerization: Polymerization can not occur.Chemical Incompatibilities: one knownHazardous Decomposition Products: None known

Section 6 - Health Hazard Information

Acute Effects: (Effects of overexposure)Inhalation: Dust may cause irritation of nasal and

respiratory tract.Eye: Dust may cause irritation.Skin: May cause abrasions.Ingestion: No known effects, however ingestion not

recommended.

Medical Conditions Aggravated by Long-Term Exposure:Chronic respiratory disease may be aggravated byexposure to nuisance dust.

Emergency and First Aid ProceduresInhalation: Remove to fresh air, if breathing is difficult

administer oxygen, obtain medical assistance, if needed.Eye Contact: Flush with large amounts of water, obtain

medical assistance, if needed.Skin Contact: Thoroughly wash exposed area with soap

and water.Ingestion: Obtain first aid or medical assistance, if

needed.Primary route(s) of entry: Inhalation, Skin Contact

Section 7 - Spill, Leak, and Disposal Procedures

Spill / Leak ProceduresSpills: Sweep or vacuum up material for disposal or

recovery.Disposal: Dispose of in accordance with local, state and

federal regulations. Material contaminated in use mayrequire special disposal requirements.

Section 8 - Exposure Controls / Personal Protection

Ventilation: Provide sufficient mechanical (General and/orLocal Exhaust) ventilation to maintain dust exposurebelow threshold limit value (TLV).

Respiratory Protection: If needed use a NIOSH/MSHAapproved dust respirator, cartridge, or mask.

Eye Protection: Recommend federally approved safetyeyeglasses.

Protective Gloves: As desired by user.

Section 9 - Special Precautions and Comments

No special precautions necessary for normal handling andstorage of the material.

The information set forth herein is believed to be accuratebut is not warranted with respect to the accuracy of theinformation or recommendations. Recipients are advisedto confirm in advance of need that the information iscurrent and applicable to their circumstances and usage.

Section 1 - Chemical Product and Company Identification

Product/Chemical Name: Garnet Abrasive Grains and PowdersChemical Formula: (Fe, Mg)3 Al2(SiO4)3CAS Number: 1302-62-1Other Designations: Almandite and Pyrope GarnetGeneral Use: Industrial AbrasivesManufacturer/Distributor: Barton Mines Company, L.L.C., 1557 State Route 9, Lake George, NY 12845

Phone: (518) 798-5462 (7:30 am-5:30 pm EST), FAX: (518) 798-5728Emergency Phone: (518) 798-5462 or (518) 251-2296 or (518) 798-5510

Section 2 - Composition / Information on Ingredients

ACGIH TLVIngredient Name TWA CAS Number % Wt

Primary Ingredient: Almandite and Pyrope Garnet 10 mg/m3 l302-62-1 94 - 99.6%Total Dust

Trace Impurities: 0.4 - 6% misc. trace minerals consisting of Hornblende, Magnetite, and Feldspar.

F

0H 1 0 R

––

NFPA

2 A Quick Look at How the System Works

10

The PyroLance ultra-high pressure system allows theoperator to attack fire from a safe and defensive exteriorposition without a firefighter entering the interior of astructure or aircraft.

The PyroLance system allows the rapid piercing of theouter structure with high-pressure water and abrasive,enabling an exterior attack on the involved structure,vehicle or aircraft. Once the outer structure ispenetrated, the PyroLance then sprays ultra-highpressure mist into the thermal layer which cools theinterior, dropping the temperature from 1,500ºF(2,732°C) to 200ºF (93°C) in a matter of seconds.

The system is extremely effective on closed structuresincluding marine applications, aircraft, buildings,basements, attic spaces, roofs, floors and other areaswhere firefighting and rescue activities are difficult anddangerous to carry out. In addition, the PyroLancesystem has the unique ability to attack the fire in itsthree-dimensional gaseous phase thereby reducing thepotential for flashover or back draft conditions.

The system consists of a portable, high-pressure nozzle(referred to as the Lance in this manual) and a gasoline-powered, high-pressure pumping unit. The Lance useselectronic control signals to remotely activate the powerunit. The unit is typically supplied with a high-pressureattack hose located on an electric rewind hose reel. Pen-etration and cutting is accomplished with a specially for-mulated abrasive (PyroShot) that will not rust and isenvironmentally safe. The proper combination of Pyro -

Shot is automatically mixed with the high-pressure waterstream from a 2.5 gallon (9 L) abrasive vessel. The entireabrasive operation is controlled by the unique inductionsystem.

The unit is equipped with many features to maintain op-erator safety while operating with nozzle pressures inthe 1400-1500 PSI range.

Water mist systems operate on the principle ofgenerating very fine droplets of water and deliveringthem to the fire zone. The advantage of this is that watermist can be very effective at fire suppression due to itshigh specific heat and latent heat of vaporizationcoupled with the increased surface area, allowing fasterheat absorption. The majority of the energy absorbed bywater in heating occurs during the phase change fromliquid to gas.

There are a number of complex interactions that occurbetween water mist and fires, which can lead toextinguishment. The three primary mechanisms ofextinguishment are heat extraction, oxygen depletionand radiation blocking, with secondary mechanismsinvolving air dilution and kinetic effects such as reducedflame velocity.

PyroLance benefits from more modern delivery systems,both in terms of pump units as well as nozzles. In addition,we can apply the “wetting” agents far more efficientlyand concentrate not only on the fuel phase of the fire,but also the gaseous phase. This all gives a new meaningto the very old phrase – where there is smoke, there is fire!

Water Tank

Anti-FreezeTank

Engine and Pump

AggregateVessel

Electric Ball Valves

BulkheadPanelElectric Hose Reels

PyroLance

Electric Valve

PyroLance Power Unit

Wirelss Signal toPower Unit

Blitz Nozzle

How the System Works

#1) 600 lb Slide Out Tray(optional)

#2. 10 ft x 1¼" Flexible Clear Water Supply Hosewith Stainless Steel Clamps

#5) High-amp Fuse Block and Fuse#3) 10 ft x #4/0 Red and BlackBattery Supply Cable

with#4) Abrasion-resistant Plastic Conduit

#6) 2 Hannay Hose Reels

#7) Reel Electrical Box and Wiring

#8) 2 150 ft x 3/4 Ultra High PressureBooster Hose

(Attached to Booster Reel)

3 System Component Description

11

#10) 15 ft. x 3/4 Ultra High Pressure Hosewith Female Swivel couplings

(Power Unit-to- Reel)

#9) Lance Nozzlewith Quick Connect Coupler

#11) Tank-to-Pump Installation Kita. Electric Ball Valve

b. Cable Harness with Connectors

#12) Winterization Installation Kita. 3 ft Clear Plastic Hose

b. Electric Ball Valve (see #11)c. 10-gallon Anti-Freeze Tank

Optional with compartment installation only– standard is manual two-way 1¼” ball valve

ANTI-FREEZE TANK – OPTIONAL

OPTIONAL

System Component Description

12

System Component Description

13

The following components are supplied separately fromthe power unit:

1. One (1) 10 ft (3 m) x 1¾” (38 mm) length of veryflexible clear plastic hose with stainless steelclamps shall be provided for connection from thepower unit to the fire apparatus water tank. (Cutlength as needed.)

2. One (1) 10 ft (3 m) length of #4/0 red and blackbattery power supply cable, with an Deutz femaleconnection end of the cable. The Deutz maleconnection is mounted at the top of the powerunit. The connections at the battery must besupplied by the installer.

3. Two (2) automotive style battery clamps.

4. One (1) abrasion-resistant plastic conduitprotection shall be installed over the batterysupply cable. Plastic wire ties are provided formechanical securement of the cable along thechassis frame area.

5. One (1) high-ampere fuse is provided and must bemounted near the battery location.

6. Two (2) electrically operated Hannay hose reelswith roller assembly and bolts for mounting.

7. One (1) electrical cable assembly with protectiveloom between the power unit and hose reelelectrical boxes, including electrical fittings forconnection to the boxes.

8. Assortment electrical connectors.

9. Two (2) 150 ft (45 m) x ¾” (19 mm) length of 3125PSI (215 Bar) ultra-high pressure booster hosefitted with quick connect high-pressure couplingon the nozzle end and NPT thread coupling onthe reel end of hose.

10. One (1) Lance nozzle equipped with a quickconnection coupling assembly.

11. One (1) Blitz nozzle equipped with a quickconnection coupling assembly.

12. Two (2) 15 ft (5 m) x ¾” (19 mm) length of ultra-high pressure hose to supply the hose reel fromthe power unit. This hose will be equipped withfemale swivel JIC threaded couplings.

13. One (1) 1¼” manual ball valve will be supplied.One (1) 1” manual ball valve shall be supplied ifanti-freeze option is required.

OPTIONAL COMPONENTS:

14. One (1) 600 lb (272 kg) slide out tray assemblycomplete with mounting bolts.

15. Tank-to-pump-line installation kit:a) One (1) 1¼” electric valve. Included with this

valve is a 20 ft (6 m) length of wiringharness from the PyroLance module to thevalve location with plug-in connectors.

b) Included with the valve shall be 1” nipplesand Tee fitting to the anti-freezewinterization supply connection.

16. Winterization installation kit:a) One (1) 3 ft (0.92 m) clear flexible plastic

pick-up ¾” (19 mm) hoseb) One (1) 3-way electric balve valve c/w wiringc) One (1) 20-gallon (80 L) anti-freeze header

tank

RearFront

Top ViewTray Slide

#1 #2Attach Sliding Tray Base to Vehicle Attach Power Unit to Sliding Tray Base

34.500

Latch Handle facesOutside of Vehicle

10.5

00

22.3

75

36.000

24.0

00

4 Installation

14

Vehicle Installation GuideSliding Tray Base Installation

(optional)

Installation

15

Planning

Uncrating and LiftingOpen the shipping crate with care and inspect theequipment for any damage. If found, immediatelycontact PyroLance and the shipping company. In theunit, you will find a sealed instruction sheet outliningsteps to contact PyroLance. If the unit cannot be installedimmediately, leave it in its crate and provide adequateindoor storage to protect the unit against damage.

The LB-2000-WG power unit should be lifted using thelifting eyes and sling provided, such as with a forklift.Four (4) nylon lifting straps (each rated for 500 to 1000lbs (225 to 450 kg) may be used for lifting, with twostraps on each side of the unit.

Installation Procedures and InitialPreparationAfter the unit is uncrated and lifted from its shippingcontainer, immediately ensure the following is performedprior to installation:

1. Fill the engine with the appropriate engine oil.(See link to Engine Manual located in theappendix) • Type of oil: SYNTHETIC 5W-30• Quantity of oil: 78-80 oz.

2. Fill the transfer case of the pump with theappropriate gear oil. (See link to Pump Manuallocated in Appendix A)• Type of gear oil: Udor Lube Premium Pump

Oil or SAE30W Non-Detergent Oil• Quantity of gear oil: 10 oz. 90 wt. gear lube

3. Fill the pump gear drive with the appropriategear oil. (See link to Pump Manual located inAppendix A)• Type of gear oil: Udor Lube Premium Pump

Oil or SAE30W Non-Detergent Oil• Quantity of gear oil: 40 oz.

User-Required Installation Materialand LaborThe installation kit is provided with the PyroLance powerunit to assure the user that few if any additionalmaterials are required. However, due to the hundreds ofvarious types of fire apparatus and body compartmentsthat could be encountered around the world, a user mayneed to supply additional hose or equipment for aproper installation.

The installer should contact PyroLance directly foradditional materials or information when problems arise.

Installation Requirements from the Apparatus

PyroLance units are designed with two differentinstallation options and can either be compartmentmounted as under option 1 or skid-mounted as underoption 2.

1. The PyroLance unit shall be supplied from theapparatus water tank, with a 1¾” (38 mm) tank topump supply line (see installation kit). Most fireapparatus have an existing tank-to-pump line tothe main fire pump OR a “sump” in the bottom ofthe water tank with a threaded 3” (75 mm) NPTplug. The installer needs to connect to one of theselocations for water supply.

2. Water tank shall be at least 100 Gallon (480 L)capacity.

3. Battery connections for the electrical supply to the#4/0 electrical cable.

Installation

Option 1: Skid Mount Installation(standard)

For maximum flexibility the PyroLance power unit shouldbe installed in an open area that is capable of housingthe unit.

Skid Mounting

1. DO NOT block the sides; air flow must be ensuredfor proper operation.

2. Leave adequate space for air flow andmaintenance of the unit.

3. Determine installation location with respect toload-carrying capacity and compartmentrequirements (as previously outlined).

4. Install 1¼” (31 mm) tank-to-pump supply hosefrom apparatus water tank to the power unit.

a) Connect to the fire apparatus water tank,then to the inlet fitting with a 1¼” (31 mm)inside diameter hose.

b) Locate the inlet fitting under the bottom ofthe tank to ensure a flooded suction line.

c) Water quality found in domestic watersupplies or fire hydrant water is sufficientfor normal operation. The PyroLance is NOTdesigned to pump water from an unfilteredwater source.

5. Install the 12 volt electrical battery supplyconnection from the apparatus battery box to thepower unit. The cable and abrasion-resistant loomshall be mechanically secured during installation toprotect this cable. The fuse protection shall beinstalled at the battery location.

Option 2: Compartment MountingInstallation (optional)The PyroLance LB-2000-WG can be installed on a slide-out tray for mounting into an apparatus compartment.The unit comes complete with a 600 lb (272 kg) rating,slide-out tray assembly, specified hoses, and fittings toaccommodate installation.

Compartment Mounting

1. Compartment provisions and requirements:

a) Clearance of the compartment dooropening must be a minimum of 40” wide(1016 mm) x 36” (914 mm) high.

b) The inside width of the compartment mustbe a minimum of 48” (1220 mm) wide x 48”(1070 mm) high.

c) Adequate door opening and interiorcompartment clearances for electrical andwater lines must be provided.

d) In a compartment installation, particularcare must be used at the connection pointto the power unit, so that sufficient hose islooped in a semi-circle to allow for theextension of the slide tray assembly.

2. When the unit is to be mounted in a fireapparatus compartment, it must be mountedon the provided slide tray.

3. The unit is NOT designed to be mounted on thefloor of an enclosed compartment withoutusing the slide tray. Also, never try to operatethe power unit with the door(s) closed; theunit must be fully OUT of the compartment onthe tray for proper operation.

4. Installation location must be a level surface, ableto safely and completely support the unit weight.The compartment floor shall be rated to carry aminimum of 750 lbs (340 kgs) of weight.

5. Install 1¼” (31 mm) tank-to-pump supply hosefrom apparatus water tank to the power unit.

a) Connect to the fire apparatus water tank,then to the inlet fitting with a 1¼” (31 mm)inside diameter hose.

b) Locate the inlet fitting under the bottom ofthe tank to ensure a flooded suction line.

c) Water quality found in domestic watersupplies or fire hydrant water is sufficientfor normal operation. The PyroLance is NOTdesigned to pump water from an unfilteredwater source.

6. The slide tray shall be installed on the floor withbolts and nuts as provided with the assembly. Anapproximate 36” (914 mm) x 24” (610 mm) plate of12 gauge steel or 0.188” (4.78 mm) aluminumshould be installed under the compartment floorfor reinforcement when the slide tray is installed.

7. Orient the unit to allow unrestricted access to thecontrol panel and abrasive vessel located on thefront of the unit (control panel must face outwardtowards the operator position).

8. Bolt the unit to the PyroLance power unit to theslide tray with the bolts provided. Four (4)“aligned” holes are provided in the slide tray andpower unit base plate for this purpose.

16

Installation

General Installation Guide (Option 1 or 2)1. Install the Hannay booster reels as desired. It is

recommended the reels be installed within 10 feet(3 m) of the power unit since only 15 ft (4.57 m) ofelectrical wiring and hose is provided. If over 10feet from the power unit, the installer mustprovided additional hose and electrical cable.(Note: these may be ordered on the PyroLance website if desired.)

PLEASE NOTE: Hose reels must beinstalled at a higher point than thetop of the pressure vessel.

2. Install ultra-high pressure hoses and electricalcables between power unit and hose reels.

17

Pump inlet must be below the tank bottom

Water Level

Pump Inlet Location

5 Making Sure Everything is Working Right

18

Preparing the Unit for OperationThe following checklist should be completed in advance,so that the unit is always ready for immediate use. Thisshould be completed on a weekly schedule and/or aftereach use.

1) Check the engine oil. (Download Briggs andStratton Engine Manual – refer to the Appendix.)

2) Check the pump oil. (Download Udor PumpManual – refer to the Appendix.)

3) Check and clean the water inlet strainer.

To inspect and clean this strainer, followthis procedure:

a. Shut off the tank-to-pump valve.

b. Unscrew the filter bowl (turn counterclockwise) and carefully remove the filterassembly.

c. Remove the internal stainless steel strainerassembly (be careful not to damage the finemesh strainer).

d. Inspect the strainer and flush any debriswith clean water.

e. Push strainer back into filter housing.

f. Re-install the water filter bowl assemblycarefully, threading the unit in a clockwiserotation by hand. Tighten the assembly andcheck for leaks after the valve is opened.

g. Turn on the tank-to-pump valve.

4) Check the fuel tank and fill if required.

5) Lubricate the couplings on the end of the reelhose and Lance nozzle connection to the hose.

Remove Internal Stainless Steel Strainer

Unscrew Filter Bowl

Pull and Inspect Strainer

Making Sure Everything is Working Right

6) Connect the Lance/Blitz nozzles to the hose.

1) On the female half of the coupling, alignthe slot with the pin.

2) Slide the collar back over the pin.

3) Insert the male coupling half and pushtogether firmly until connected.

4) Release the collar and then rotate the slotaway from the pin.

7) Fill the abrasive vessel with PyroShot.

The abrasive vessel is located in the front of thepower unit to the right of the control panel (seephotos). The PyroShot abrasive is required for thewater-jet cutting feature of the PyroLance system.

The PyroLance is designed for use with onlyPyroShot abrasive. PyroShot abrasive is packagedin one gallon (3.75 liter) containers and the vesselrequires 2.5 Gallons (9 L) when empty.

The abrasive can be ordered directly fromPyroLance (see the “Replacement Parts” section ofthis manual for ordering information).

19

Abrasive Filler Cap

Turn counterclockwise(CCW) to remove cap

Align slot with pin on female half; slide collar backover pin.

Push coupling together; rotate collar away from pin.

WARNINGAlways verify that the abrasive filler plugis properly installed before operation.Failure to properly install and tighten the filler plug may lead to serious

personal injury or death.

Use only PyroShot abrasive in the PyroLance. The use of any other abrasive

may lead to equipment damage and/or failure.

Serious personal injury or death may result if the abrasive vessel is openedwhile under pressure. Always verify the abrasive pressure gauge reads ZERO before opening the vessel.

Making Sure Everything is Working Right

To load the abrasive vessel, follow this

procedure:

a) Verify the power unit is OFF and theEmergency Stop button is depressed.

b) Verify the system is totally DE-PRESSURIZED.To check: cycle the water valve bydepressing the Lance nozzle trigger andverify zero pressure on the abrasive vesselgauge (see photo).

c) Using a 21/8” (54 mm) wrench, remove thefiller plug by turning it counter clockwisefrom the abrasive vessel.

d) Slowly pour 2.5 Gallons (9 L) of PyroShotabrasive into the abrasive vessel. Note thatwater will spill out (or anti-freeze solution)as the abrasive displaces some of the liquidalready in the vessel (this is normal).

e) Rinse the filler plug threads with water andinspect the plug O-ring. Replace O-ring ifworn or damaged.

f) Thread the filler plug into the vessel andtighten by hand until it bottoms. Carefullyuse a wrench to tighten the plug. DO NOTover tighten as this may lead to permanentdamage of the vessel or cap threads.

8) Verify communication between the Lance nozzletrigger and power unit.

a) Verify the Emergency Stop control switch isin the ON position.

b) Set the ignition switch on the power unit.DO NOT start the engine.

c) Pull the water trigger and verify activationof the throttle solenoid and verifyoperation on dial of ball valve and LEDindicator lights on receiving unit.

d) While holding in the water trigger, activatethe abrasive switch and verify operation ondial of ball valves.

e) If signalling fails, checkbatteries in transmitterunits and power toreceiving unit (seeMaintenance Section). Orelse, refer to Transmitterand ReceiverProgramming setup onnext page.

20

LED Indicator Water Trigger Light / Battery Status Light(flashes 5 times when low)

LED Indicator Lightfor Abrasive Flow

LED WaterRelayLight

LEDAbrasiveRelayLight

6 Transmitter Programming

21

Set-up Transmitter and Receiver ProgrammingTransmitters and receivers must be paired to work together. Before beginning the pairing process, thereceiver must be set up to your desired frequency and digital address. After following the set-up procedure,ensure the receiver is powered on before continuing to the pairing procedure.

Receiver Set-up The unit is shipped from the factory with SEL1 switches in the open positions and the unit is receivingcommands on Address 1/Frequency 1. If you wish to change these default settings, follow theinstructions in the table below.

It is highly recommended that you use all available frequencies BEFORE changing thedigital address of systems. For instance, the first system pairing would be left at thedefault of F1/ A1. The next pairing would be F2/A1. Then continue as follows: F3/A1;F4/A1; F5/A1; F6/A1; F7/A1; F8/A1 (now all frequencies for Address 1 have beenexhausted). The next pairing would be set as F1/A2, then F2/A2; F3/A2; F4/A2; F5/A2;F6/A2; F7/A2; F8/A2. Then F1/A3; F2/A3; F3/A3, etc.

1) Remove power from unit.2) Remove top cover. 3) Select address and/or frequency using table below. 4) Reattach cover and apply power. 5) Address and Frequency Set-Up is now complete.

DIGITAL ADDRESS SET-UP SEL1 Digital Address(SW1-3) SW1 SW2 SW3 1 (default) OPEN OPEN OPEN 2 CLOSED OPEN OPEN 3 OPEN CLOSED OPEN 4 CLOSED CLOSED OPEN 5 OPEN OPEN CLOSED 6 CLOSED OPEN CLOSED 7 OPEN CLOSED CLOSED 8 CLOSED CLOSED CLOSED

FUTURE OPTION SET-UP SEL1 SW4 Unused on this model – leave in open position

FREQUENCY SET-UP SEL1 Frequency(SW5-7) SW5 SW6 SW7 1 (default) OPEN OPEN OPEN 2 CLOSED OPEN OPEN 3 OPEN CLOSED OPEN 4 CLOSED CLOSED OPEN 5 OPEN OPEN CLOSED 6 CLOSED OPEN CLOSED 7 OPEN CLOSED CLOSED 8 CLOSED CLOSED CLOSED

Transmitter Programming

22

Pairing Procedure

The pairing procedure begins by matching the transmitter frequency to the receiver which will befollowed IMMEDIATELY by linking the remote to the receiver, so be sure to have them both readilyavailable.

Note: The Lance/Blitz trigger will be squeezed and released to set up the frequency. Each squeeze andrelease of the trigger will increment the frequency by one. The initial squeeze and release as performedin Step 2 below counts as the first increment and will set the frequency to #1.

Step 1. Select the Lance to be paired and remove one of the AA batteries from the transmitter batterypack.

Step 2. Squeeze the trigger and while holding in, replace the AA battery in the battery pack. ThePower/TX LED will illuminate solid RED. Release the trigger to set to Frequency 1, or, within two seconds,stay in programming mode by squeezing and releasing the trigger the number of times equal to thefrequency you are choosing. So the second squeeze and release takes the transmitter to Frequency #2,the third squeeze and release sets its Frequency to #3, and so on. You will use the TX LED to confirmyour setting. After you squeeze and release the number of times you wish the frequency to be set to,observe the LED. It will blink RED or GREEN up to four times depending on the frequency chosen. Seetable below for clarification:

LED Flashes: Indicates Unit is Operating On: RED – one time Frequency 1 RED – two times Frequency 2 RED – three times Frequency 3 RED – four times Frequency 4 GREEN – one time Frequency 5 GREEN – two times Frequency 6 GREEN – three times Frequency 7 GREEN – four times Frequency 8

7 Operation Instructions

23

Start-Up Operation of Power Unit• Ensure power on main pump panel is switched

on.

• Open Lance battery compartment and access thetransmitter unit.

• Remove transmitter unit battery cover.

• Remove both batteries from transmitter.

• Place one battery fully into position.

• Keep the second battery ready but do not insert.

• Depress the Lance trigger. Whilst holding thetrigger insert second battery.

• Depress the Lance trigger once and let go

• LED on Lance battery cover will show solid.

• As soon as LED on Lance cover start flashingpush and hold red learn button (pairing switch)ON SIDE OF RECEIVER BOX IN FOR 5 SECONDSand release.

• Green LED on receiver box will start to flash. DONOT TOUCH ANYTHING UNTILL FLASHING ONRECEIVER BOX STOP.

• Push trigger on Lance and pairing should becomplete.

• Replace both battery covers

It can be a tricky procedure to follow. Please ensurethat the yellow LED starts flashing on the Lance beforeyou push the red learn (pairing button) on the side ofthe receiver box and hold that down for at least 5seconds then release- wait for the green LED on thereceiver to stop flashing before you pull the trigger tosee if it paired.

Emergency Stop Button(Push to Stop Unit,

Twist to Reset)

EngineIgnition Key

Emergency Abrasive ON Button(Only active when Safety Button

is also depressed)

Emergency Override Button

(“Deadman Switch”)

Emergency Water ON Button(Only active when Safety Button is

also depressed)

Discharge CuttingNozzle Assembly

(Lance Tip Assembly)

AdjustableShoulderSupport

Adjustable Grip and Tripod Stand

Foldable RadioAntenna

AbrasiveSwitch

WaterTrigger Trigger

SafetyLever

Operation Instructions

24


Normal Operation

Normal operation of thePyroLance system is defined as:

a) Operator #1: Power unit controlperson. Control of the power unitfrom the Lance nozzle isaccomplished by a remote-controlled wireless radio signal.Should a problem develop withthis signal, a manual (emergencymode) can be used as describedlater in this section.

b) Operator #2: Nozzle controlperson who will control flow ofwater and abrasive via the Lancenozzle water trigger and abrasiveswitch control.

Normal operation shall be asfollows:

1) Normally the Lance nozzle is “pre-connected” to the hose on thehose reel. The hose will be spooledoff the reel to the required lengthto reach the operating area byOperator #2.

2) Operator #1 will engage thepositive latching device on the reel to preventmovement of the reel during operations.

3) Operator #2 will advance the hose and nozzle tothe operating area and place the nozzle shoulderunit against the body.

4) Operator #2 will press the Lance nozzle tip firmlyagainst the target and communicate to Operator#1.

5) Operator #2 will take a firm and stable stancebefore pulling the water trigger.

a) To penetrate the target, pull the watertrigger and activate the abrasive switch.

b) This will activate the power unit and sendhigh-pressure water and abrasive to theLance nozzle.

c) Please note: It will take several seconds forthe abrasive to travel the length of the hoseand begin penetrating the targeted object.

d) Penetration time will be minimized if theLance nozzle tip is held steady.

6) After the target object has been penetrated, de-activate the abrasive switch while continuing todepress the water trigger. The target has beenpenetrated when the external spray stops.

7) The duration of water flow into the fire will varyand is determined by many factors such as:

a) Type and size of the fire

b) Enclosure size.

The decision to stop water flow can be based onan internal temperature reading (if thermalimaging equipment is available) or otherestablished practices.

8) Releasing the water trigger will cause the powerunit to go back to idle.

25

External spray is visible during penetration (cutting) of the target.

Little or no external spray is visible after penetration is complete.

Safety Trigger Engaged Safety Trigger Disengaged


26

Emergency Mode Operation(Control Signal Failure)Should a problem develop with the control signaltransmission between the Lance nozzle and power unit,the following emergency procedure can be used:

1. Operators #1 and #2 must be in continuous verbalcommunication to operate in Emergency Mode.

2. Operator #2 operating the Lance nozzle andOperator #1 operating the power unit controls.(Reference the troubleshooting section forsuggestions to remedy common issues with Lancenozzle communications.)

3. Operator #1: starts up the power unit asdescribed in the Normal Operations section.

4. Operator #2:

a. Unrolls hose from reel, stands in a visiblelocation to Operator #1, and brings theLance nozzle to the target location.

b. Presses the Lance nozzle tip firmly againstthe target and takes a firm and stable stance.

c. Verbal communication takes place fromOperator #2 to Operator #1 to activate thesystem.

WARNINGThe PyroLance can be operated only

by qualified firefighting personnel whohave completely reviewed all safety, service and maintenance, operational,

installation and other pertinentrequirements of this PyroLance

Instruction and Operational Manual.

The trigger mechanism is programmed towork sequentially; when water trigger isactivated, it will then allow activation of

the Emergency Abrasive Button.

Operating the Emergency Abrasive Button prior to activating the Emergency Water

Button will result in zero output from either function.

Note: To operate with abrasive inemergency mode, all THREE buttonsmust be simultaneously depressed.

Water flow activated by holdingEmergency Override Button AND

Emergency Water Button simultaneously

Emergency Stop Button(Push to Stop Unit,

Twist to Reset)

EngineIgnition Key

Emergency Abrasive ON Button(Only active when Safety Button

is also depressed)

Emergency Override Button

(“Deadman Switch”)Emergency Water ON Button(Only active when Safety Button is

also depressed)


5. Operator #1:

a. Operator #1 simultaneously presses andholds Emergency Water Button andEmergency Override Button to activatepower and send high-pressure water toLance nozzle.

b. While continuing to hold both buttons,Operator #1 then presses and holds theEmergency Abrasive Button to activateabrasive flow.

c. Please note: It will take several seconds forthe abrasive to travel the length of the hoseand begin penetrating the target object.Penetration time will be minimized if thelance tip is held steady. The target has beenpenetrated when the external spray stops.

6. Operator #2: After the target object has beenpenetrated, Operator #2 advises Operator #1 torelease the Emergency Abrasive Button andcontinue to hold the Emergency Water ButtonON, while still continuing to hold the EmergencyOverride Button.

7. Operator #1: On audio command from Operator#2, Operator #1 releases all Buttons so that thepower unit will go back to idle.

Please Note: The flow of abrasive can only bestarted while water flow is ON. Pressing theEmergency Abrasive Button alone will donothing. The Water and Abrasive Buttons areonly active while the Emergency Override Buttonis also depressed.

27


28

PyroFoam DirectInjection Foam System(optional)Specifications and OperationInstructions

Foam Procedure

1. The Poly-Tank® Foam Tank must be completelyfilled and covered when not in use.

2. At no time should two different types or brandsof foam be stored in the same foam tank.

3. Foam concentrates should be tested annually toensure optimum performance.

4. When changing foam brands, concentrates orperforming maintenance, the foam tank andsystem must be thoroughly flushed to ensureproper operation. Consult foam manufacturer’sinstructions for proper flush operations.

5. The foam tower has been designed to beremoved to help facilitate the cleaning of thefoam tank. When re-installing the foam tower,torque the bolts to 20 in-lbs, starting with thefour corner bolts. Repeat torque sequence.

6. This equipment complies with all applicable NFPAstandards at time of manufacture.

Foam System Operation

To begin foam operations:

1. Ensure the foam tank(s) contain concentrate.

2. Select the foam tank to be used using the FoamSelector Valve on the pump panel.

3. Select the PyroBlitz on the Hose Selector Valve onthe pump panel.

4. Turn On the Foam On/Off Switch on the pumppanel.

5. Ensure the PyroLance/PyroBlitz system is running,(see General Operations Section) and beginfoaming operations as required.

To change foam concentrates (if equipped with aClass A/B foam system):

1. Ensure the PyroLance/PyroBlitz system is running,(see General Operations Section).

2. Keep the Foam On/Off Switch in the On position.

3. Turn Foam Selector Valve to the Flush position.

4. Open the PyroBlitz nozzle and flow water for aminimum of 12 seconds.

5. Select the foam tank to be used using the FoamSelector Valve on the pump panel.

6. Continue foaming operations as required.

To end foam operations:

1. Ensure the PyroLance/PyroBlitz system is running,(see General Operations Section).

2. Keep the Foam On/Off Switch in the On position.

3. Turn the Foam Selector Valve to the Flushposition.

4. Open the PyroBlitz nozzle and flow water untilthe discharge is flowing only plain water.

5. If Winterization is required, proceed toWinterization Procedures.

6. Turn the Foam On/Off Switch to Off.

Winterization Procedures (added steps):

1. Turn the Foam On/Off Switch to the On position.

2. Turn the Foam Selector Switch to the Flushposition.

3. After, Winterization Operations are complete,turn the Foam On/Off Switch to the Off position.

Maintenance (added steps):

1. Never mix dissimilar concentrates in the foamtank(s).

2. Always flush the entire system with plain waterwhen changing from one concentrate to another,and at the end of foam operations.

3. Winterize the system whenever the system will beexposed to freezing conditions.

4. Inspect and clean Foam Concentrate Strainersweekly.


29

Rotary Gear Pumps

General Description

Pump housings and gears aremade of top quality bronze,shafts are stainless steel 303.Bearings are made of highperformance carbon-graphitematerial selected for wearresistance and long service life.

Gear pumps are positivedisplacement pumps. Each shaft revolution displaces adefinite amount of liquid relatively unaffected by theback pressure in the discharge line. Shaft speed andflow are directly proportional.

Drive Arrangement

Close coupled pumps are mounted directly to the electricmotor by means of a suitable adapter bracket. The pumpdrive shaft is connected to the motor shaft by a flexiblecoupling.

Liquids and Temperature

These pumps are suitable for all liquids that arecompatible with bronze. Most common liquids arewater, oil, and mild chemicals in the pH-range of 4 to 11.Viscous liquids require reduced shaft speeds of 1150 RPMor lower. Consult factory.

Liquids containing solids, abrasives, powders or paintpig- ments are definitely not recommended for gearpumps. If abrasives are unavoidable, use a very low shaftspeed. The recommended liquid temperature range is32°F to 140°F for longest pump life. If more extremetemperature conditions exist, our factory should beconsulted. Freezing of water-filled pumps can causedamage and must be avoided. Oils at low temperaturesare very viscous requiring a lower speed or extra power.

Suction Lift

As a general rule, the suction lift should be kept at anabsolute minimum by placing the pump as close to theliquid source as possible. A gear pump in new conditioncan lift 20 feet of water in the suction line. A foot valve(preferably with built-in strainer) is recommended at thebeginning of the suction line. For a first start-up, thepump should be primed to avoid dry running. Minimumsize of the suction pipe is the size of the pump inlet port.For longer suction lines (over 3 feet), or for viscousliquids, the pipe size should be at least one size or twosizes larger than the pump inlet port.

For complete Oberdorfer Pump literature, go topyrolance.com.

Rotation and Relief ValveThe relief valve is not intended to be a metering or flowcontrol device. Its main purpose is to function as adischarge pressure relief when the spring tension isexceeded by the discharge pressure. Overheating canoccur within 5-10 minutes if the discharge line iscompletely shut off for extended periods.

Unless otherwise specified, the pump motor unit issupplied by the factory for shaft rotation clockwise fromshaft end. Reversing the motor rotation will reverse the“in” and “out” ports and also requires changing therelief valve location. The relief valve is always on thedischarge side in this pump series. The factory pressuresetting is 50 PSIG. To increase pressure, turn the reliefvalve adjusting screw in a clockwise direction.

To reverse single phase motors, find instructions on theinside of the junction box cover or on the name plate ofthe motor.

Three phase motors are not wired for any particularrotation. They can be reversed by interchanging any two(2) wires of the three (3) wire leads.

PerformanceWater 70° F

1725 R.P.M. Pump & Motor No.

PSI GPM HPReq.

HPMotor

MotorFrame

SinglePhase

ThreePhase

0 23.3 0.90 1 56C N990HN26 N990HN95

20 22.9 1.19 1 1/2 145TC N990JT45 N990JT95

40 22.5 1.53 1 1/2 145TC N990JT45 N990JT95

60 22.1 1.92 2 145TC N990JW 45 N990JW 95

80 21.7 2.25 3 182TC N990KY45 N990KY95

100 21.3 2.70 3 182TC N990KY45 N990KY95

125* 20.7 3.15 3 182TC N990KY45 N990KY95

150* 20.1 3.70 5 184TC N990KX45 N990KX95

1150 R.P.M. Pump & Motor No.

PSI GPM HPReq.

HPMotor

MotorFrame

SinglePhase

ThreePhase

0 15.3 0.58 3/4 56C N990HM46 N990HM96

20 15.0 0.77 3/4 56C N990HM46 N990HM96

40 14.7 1.10 1 145TC N990JN46 N990JN96

60 14.4 1.40 1 1/2 145TC N990JT46 N990JT96

80 14.1 1.80 2 182TC N990KW46 N990KW96

100 13.7 2.10 2 184TC N990KW46 N990KW96

125* 13.1 2.60 3 213TC N990LY46 N990LY96

150* 12.5 3.10 3 213TC N990LY46 N990LY96

*For pressures over 100 psi, the above selections are suitable forpumping fluids with lubricity (e.q. oils, polymers). Service life willdecrease for fluids without lubricity (e.q. water, solvents).

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Foam System Flow Schematic and Major Components


30


Recommendations for SelectedMaterials in Penetration/Cutting The PyroLance has been specifically designed to performpenetration/ cutting operations at a much reducedpressure and flow rate. The unit is optimized for ARFFand structural applications in particular.

1. ARFF

The PyroLance has the capability of penetrating/ cuttingaluminum, composites, structural extrusions, and steel ofvarying thicknesses. Multiple layers of compositematerials (such as those found on 5th generation aircraft)can be penetrated or cut through using the hand-heldLance nozzle in either the static or dynamic mode.

It is possible to penetrate or cut thinner compositematerial by flowing water only, thereby eliminatingcollateral damage to sensitive interior structures and/orequipment and allowing a much safer penetration/cutting environment.

2. Structural

The PyroLance is capable of penetrating most structuralmaterial and cutting through thinner sheeting such asroofing material and coverings. It is important to attackstructural materials at their weakest points, which isnormal for fire service operations. This will enable thequickest penetration/ cutting times and conservevaluable abrasive capacity.

3. Material Penetration/Cutting

a) Brick: Structural brick can easily bepenetrated using abrasive. Cutting of brickcan be more of a challenge using the Lancenozzle dynamically and should only beconsidered as a last resort.

b) Roofing: It is possible to penetrate roofingmaterial very quickly. It is also possible torun ventilation cuts using the Lance nozzlein the dynamic mode while flowingabrasive. Maximum distance between Lancenozzle tip and roofing material should notexceed 3 ft (1 m).

c) Reinforced Concrete: Fairly difficult topenetrate in thicker constructionsdepending on different hardness. Maximumdepth that could be attempted should notexceed 2” (50 mm). Cutting of reinforcedconcrete is not advisable.

d) Cinder Block: It is possible to penetrate

through multiple layers of cinder blockacross internal spacing without anyproblem. Limited cutting of cinder block ispossible but will require substantial use ofabrasive to achieve a proper cutting effect.

e) Mild steel: The difficulty increases with thethickness. It is possible to penetrate mildsteel up to a maximum depth of 1” (25 mm).

f) Aircraft Aluminum: Penetration of aircraftaluminum is easily achieved and can beattempted using water only. Limited cuttingis possible with the use of abrasive onthinner sheets of aluminum.

g) Laminated glass: It is easy to penetrate athickness of up to 1” (25 mm) of laminatedglass quickly. Cutting of laminated glass ispossible using abrasive and limited tothinner panels or windows.

h) Rubber: Rubber can be penetrated fairlyeasily in the static mode. Cutting operationswill be limited depending on the thicknessof the rubber.

i) Wood: Penetrating wood can be a challengesince the more porous the wood is, themore the water will be diverted away fromits path. Cutting wood panels/sheeting ispossible even from a distance of 3 ft (1 m)away while flowing abrasive.

j) Plexiglas: Penetration of Plexiglas is easilyachieved even without flowing abrasive.Cutting of Plexiglas is also possible whileflowing abrasive.

4. Duration of Abrasive Supply

The abrasive vessel has a capacity of 2.5 gallons (9 L) andthe induction rate will allow approximately four minutesof continuous flow of abrasive.

NOTE: After flowing the abrasive, it is imperative to flushthe system and clear the hose of all abrasive prior toshutting the unit down.

Should the nozzle become clogged, it will be necessaryto remove the Lance nozzle from the hose reel and flushthe excess abrasive from the system prior toreconnecting the nozzle.

31

8 Maintenance

Engine MaintenanceMaintenance on this unit should be restricted toauthorized personnel who have read and understood thePyroLance Instruction and Operation Manual. Review thismanual, especially the safety information section, priorto performing any service on this equipment.

If the engine is to be replaced during the life cycle of thepower unit, the following information is provided on theBriggs and Stratton engine. Newer versions or alternateengines for replacement purposes must be approved byPyroLance prior to installation.

The PyroLance LB-2000-WG utilizes thefollowing engine:

a. Briggs & Stratton Engine b. Van Guard Seriesc. Type: Horizontal V-Twin engine d. Gross Horsepower: 35HP at 3600 RPMe. Fuel:

1. Gasoline 2. Type: leaded or non-leaded3. Octane range: 85 to 904. Fuel tank capacity: 2.5 gallons

PLEASE NOTE: When shipped the PyroLance power unit,fire pump, and pump gear box are shipped without fluids.IMMEDIATELY fill the components with lubrication fluidsafter removing the power unit from the box. Theplumbing system is filled with anti-freeze solution; uponstart-up operation the anti-freeze solution should beflushed prior to use.

Reference Information on Engineand Pump Maintenance The Udor pump and Briggs and Stratton engineinstruction, operation, and maintenance manuals in PDFformat are located in the Appendix of this manual.

Specific information can be found in various sections ofthe manual for the following:

a) Briggs & Stratton engine 1. Oil Types, Manufacturers, and Viscosity

Range2. Engine Oil Fill Location & Procedures3. Routine Scheduled Maintenance

Information4. Troubleshooting Guide for the Engine

b) Udor pump1. Gear Oil Types, Manufacturers, and Viscosity

Range2. Pump and Gear Box Fill Locations and

Procedures

3. Routine Scheduled MaintenanceInformation

4. Troubleshooting Guide for the Pump

c) PLEASE NOTE: The user MUST ensure thelubricate levels are correct prior to starting theengine. Dry starting the engine without oil canlead to engine failure and is not covered underthe PyroLance warranty or the separate Briggs &Stratton warranty.

d) USE OF PDF MANUALS: Please refer to the Briggs& Stratton Engine Manual and the Udor PumpManual for fluid level information and/or seespecific information as follows to verify thecorrect oil type, quantity, and viscosity prior tostart-up operations.

32

WARNINGThe PyroLance power unit emergency shutoff control must be in the OFF positionprior to performing any service work.

For major work, the Deutz electrical plug to the battery system must beunplugged and disconnected entirely.

Unauthorized replacement of any part may lead to catastrophic equipment failure and serious personal injury.

Use only replacement parts that aresupplied by or approved by PyroLance.

Use of any other parts may lead to equipment failure and

severe personal injury.

Maintenance

Engine Oil, Air Filter, Spark Plug andFilter ReplacementThe Briggs & Stratton engine oil needs to be checkedand/or changed regularly.

Use the following guide as a template:a. 5 hours of initial operation – change engine oil

and filter.b. 8 hours of operation/Daily – check engine oil

level.c. 100 hours of operation or annually:

• Change engine oil and filter.• Change engine air filter.• Change engine spark plug.• Clean engine of foreign debris.

d. 250 hours of operation or annually:• Check engine valve clearance (it may be

necessary to have this service preformed atan Authorized Briggs & Stratton servicecenter).

e. 400 hours of operation or annually:• Change air filter.• Change fuel filter.

Fluid Levels, Spark Plug, Points andFilter Replacement The “first level” of normal maintenance includes thefollowing:a. Engine Oil:

Manufacturers: All high quality detergent oils areacceptable if classified for service SF, SG, SH,SJ or higher

Type Oil: Synthetic 5W-30Viscosity Range: 5W-30Quantity (including the filter): 78-80 oz.

b. Oil Filter:Manufacturers: Briggs & StrattonModel: Briggs & Stratton Part No. 842921

c. Fuel Filter:Manufacturers: Briggs & StrattonModel: Briggs & Stratton Part No. 691035

d. Air Filter:Manufacturers: Briggs & Stratton Low ProfileModel: Briggs & Stratton Part No. 692519

e. Spark Plug:Manufacturers: Long Life PlatinumModel: Briggs & Stratton Part No. 5066

f. Spark Plug Gap:Manufacturers: Long Life PlatinumModel: Briggs & Stratton Part No. 5066 – Spark

Plug Gap Setting: 0.030 in. (.076 mm)

33

After Monthly Every 3 Every 6 Every 3Every Use Months or Months or Years or

100 Hours* 200 Hours* 1,500 Hours*

Check nozzle and end nut for wear and replace if necessary XCheck engine oil and add if low 1 XCheck pump oil and add if low 2 XReplace engine oil and oil filter 1 XReplace engine fuel filter 1 XReplace engine air filter 1 XCheck water strainer XCheck radio battery (located in Lance) XInspect hose for wear or damage 3 XReplace hoses X* Whichever comes first1 See engine manufacturer’s literature found in the Appendix for additional recommendations. 2 See pump manufacturer’s literature found in the Appendix for additional recommendations. 3 If any damage to the hose is found, replace immediately.

Preventive Maintenance Recommendations

Maintenance

Checking Engine Oil Level Prior to checking oil, be sure the engine is located on alevel and horizontal surface. Safely clean the oil fill areaand remove any debris.

The user should follow the indicated steps inchecking the engine oil on a Briggs & Strattonengine:

Step 1: Remove the dipstick from the engine andwipe the dipstick with a clean dry cloth.

Step 2: Re-insert the dipstick into the engine fromwhich it was removed.

Step 3: Remove the dipstick from the engineagain and verify that the oil level is correct. Theoil level should be near or at the top of theindicator marks located on the dipstick.

Step 4: If the oil level is found to be low:

a) Remove the oil fill cap and safely add thecorrect viscosity to the engine; based on howlow the oil level is found in Step 3.

b) To verify the correct viscosity oil, refer to theBriggs & Stratton Manual.

c) After adding the correct amount of oil, waitapproximately 60 seconds for the oil tomove through the engine.

Step 5: Wipe the dipstick with a clean dry clothand safely re-insert the dipstick fully into theengine.

Step 6: Safely remove the dipstick from theengine and verify the oil level. Again, the oil levelshould be near or at the top of the oil of theindicator marks found on the dipstick.

Step 7: If the oil level is still found to be low,repeat Steps 4, 5 and 6 until the oil level is correct.

Step 8: Replace the oil fill cap that was removedin Step 4.

Changing Engine Oil Prior to changing oil, be sure the engine is located on alevel and horizontal surface. Safely clean the oil fill areaand remove any debris.

The user should follow the indicated steps in changingthe engine oil on a Briggs & Stratton engine:

Step 1: Safely remove drain plug from engineturning a counter clockwise direction and capturethe used oil as it drains from the engine. Disposeof the used waste oil in an environmentally safeway.

Step 2: Wipe the drain plug with a clean dry ragand re-install into the engine, turning in aclockwise direction until it is hand tight. Use anappropriate size wrench to torque the drain plugto its recommended specifications. See Briggs &Stratton Manual for correct torque specifications.

Step 3: Safely remove the engine oil filter, turningit in a counter clockwise direction. Capture anyresidual oil and dispose of it in environmentallysafe way.

Step 4: Prepare to re-install a new oil filter.Lubricate the oil filter gasket with a thin layer offresh, clean oil. Install oil filter onto engine,turning in a clockwise direction until the oil filtergasket comes in contact with the base of theengine. Hand tighten the oil filter an additional½ to ¾ turn until the filter is seated properly tothe engine oil filter adapter.

Step 5: Prior to filling the engine with oil, pleasecheck earlier in this section for oil quantity andtype. The oil should be suitable for yourtemperatures and altitudes.

Changing Engine Air Filter To change the air filter in the Briggs & Stratton engine,the following steps must preformed:

Step 1: Remove air cleaner latches and safelyremove air filter from the air filter assemblyhousing.

Step 2: Dispose of air cleaner in anenvironmentally safe way.

Step 3: Re-install new air cleaner into air filterassembly housing and re-latch retainer latches.

34

Maintenance

Changing Engine Fuel Filter To change the fuel filter in the Briggs & Stratton engine,the following steps must be performed:

Step 1: Close fuel shut-off valve. Failure to do socould cause an explosion leading to injury or death.

Step 2: Using pliers, gently squeeze the fuel filterretaining clamp tabs and remove the fuel filterfrom the fuel lines. A twisting motion may beneeded to remove the filter.

Step 3: Safely dispose of the fuel filter in anenvironmentally safe way.

Step 4: Re-install a new Briggs & Stratton orapproved fuel filter and re-install fuel retainingclamps to fuel filter and fuel lines.

Step 5: Turn on the fuel valve.

Changing Engine Spark Plug To replace the spark plugs in the Briggs & Strattonengine, the following steps must be preformed:

Step 1: Remove spark plug caps from spark plugs.Then using a proper-sized socket wrench, safelyremove spark plugs from engine, turning in acounter clockwise motion.

Step 2: Dispose of used spark plugs in anenvironmentally safe way.

Step 3: Replace spark plugs with new Briggs &Stratton or approved replacement spark plugs.Re-install into engine, turning in a clockwisedirection until seated properly. (Refer to Briggs &Stratton Manual for proper torque settings.)

Step 4: Replace spark plug wire caps.

Gasoline Engine Service ManualThe gasoline engine requires routine maintenance similarto a car engine. Oil must be checked and changed regu-larly. Oil, air and fuel filters must be checked and changedregularly. For detailed information on these routine main-tenance requirements as well as other service recommen-dations, please see the Briggs and Stratton Manualreferenced in the Appendix.

Pump Service ManualThe Udor high-pressure water pump requires minimalmaintenance. The pump and gear box gear oil should bechecked on a regular basis. For detailed information onthese routine maintenance requirements as well as otherservice recommendations, please see the Udor PumpManual referenced in the Appendix.

35

Additional MaintenanceProcedures IF EQUIPPED WITHPYROFOAM SYSTEM1. Never mix dissimilar concentrates in the foam

tank(s).

2. Always flush the entire system with plain waterwhen changing from one concentrate to another,and at the end of foam operations.

3. Winterize the system whenever the system will beexposed to freezing conditions.

Inspect and clean Foam Concentrate Strainers weekly.

Maintenance

Nozzle MaintenanceReplacement of Nozzle and/or NozzleRetaining NutThe hydro jet and nozzle head are wear parts andfrequent replacement should be expected. A wornnozzle will not cut well or give maximum extinguishingeffect. After each use of the PyroLance system, inspectthe hydro jet and nozzle head for wear and replace ifrequired.

Nominal orifice diameter for the PyroLance Model L 1000W-G is 0.090” (2.286 mm). Refer to the replacement partsection of this manual for ordering information.

PLEASE NOTE THE FOLLOWING:

1. Replace the hydro jet when pressure decreases bymore than 350 PSI (21 Bar) from pump dischargepressure of 2000 PSI (135 Bar). Please note: Thiswill require reading the power unit pressuregauge and user must install a test gauge at thenozzle. (Please note: Complete this test withoutthe abrasive flowing.)

2. Replace the nozzle head and washer when anywear is visible.

3. To replace the Lance nozzle tip assembly, thefollowing steps should be performed:

a) Verify unit is OFF and depressurized.Disconnect Lance nozzle from the hose reeland hose.

b) Unscrew the nozzle head, counter clockwisefully and remove.

c) Slide the hydro jet and washer out of thenozzle head.

d) Replace any and all worn parts.

e) Insert the washer and nozzle into the nozzlehead.

f) Thread the nozzle head back onto thenozzle housing and turn clockwise fully byhand until it bottoms. It is not necessary totighten the nozzle head more than handtight.

36

O-Ring Sealing Washer Nozzle HousingBarrel End Hydro JetSeal BushingNozzle Head

1. Unscrew Nozzle Head, CCW 2. Remove Seal Bushing and Hydro Jet 3. Reassemble, Turn Nozzle Head CW

Maintenance

Lance Nozzle Hose ReplacementIf the hose shows ANY signs of wear or damage, replaceit immediately and refer to the replacement parts sectionof this manual for ordering information.

The following steps should be performed inthe Lance nozzle hose replacement process:

1) Verify power unit emergency control switch is inthe OFF position.

2) Totally depressurize the entire plumbing system.Check to see if pressure gauges are at zero andremove the plug from the abrasive vessel (seeabrasive vessel fill procedures) to ensure nopressure is trapped in the vessel.

3) Disconnect the Lance nozzle from the hose.

4) Using a 3/16” (4.765 mm) Allen wrench, loosenboth set screws holding the Lance tip to the Lancenozzle barrel.

5) Slide the nozzle housing and hose out of thebarrel approximately 6” (152 mm).

6) While holding the hose firmly, turn the Lancenozzle housing in a counter clockwise directionby hand to loosen and remove (do not discard).

7) Slide the hose out of the Lance barrel.

8) Replace with a PyroLance supplied hose, completewith the proper end fittings.

9) Slide the new hose through the Lance barrel withthe male SAE O-ring fitting first.

10) Thread the Lance nozzle housing assembly ontothe hose and tighten by hand only. Note thatthis fitting uses a straight thread and O-ring forsealing. Do not use any pipe sealant or Teflontape.

11) Slide the Lance nozzle tip back onto the Lancebarrel.

12) Tighten both set screws, turning them inclockwise direction.

37

1. Loosen Set Screw CCW (2 places)

4. Nozzle Housing removed. Slide Hose out of Lance Barrel3. Hold Hose firm, Twist Nozzle Housing CCW until removed

2. Pull out Nozzle Housing

Maintenance

Replacement of Remote ControlSignal Transmitter BatteryThe Lance/Blitz nozzles use a battery-powered, radiotransmitter to send control signals to the power unit. Thebatteries should be replaced every six months orwhenever there are communication problems betweenthe Lance nozzle and the power unit.

The control signal transmitter uses two (2) Lithium IonAAA size batteries. (Note that the frequency settings aremaintained in a flash memory during batteryreplacement).

To replace the batteries follow theseprocedures:

1. Using a Philips screwdriver, remove the six screwsholding the cover (see Photo 1 on next page).

2. Remove the cover (see Photo 2)

3. Lift out the transmitter

4. Use a Philips screwdriver to remove one screwholding down the battery cover on transmitterunit.

5. Lift off battery cover from transmitter unit (seePhoto 3).

6. Remove two AAA batteries as shown and replace.

7. Replace battery cover on transmitter unit.

8. Place transmitter unit back into compartment.

9. Replace compartment cover and tighten down sixscrews using Philips screwdriver, ensuring tight fit.

NOTE: BATTERY STATUS LED WILL ILLUMINATESOLID WHEN WATER TRIGGER IS ACTIVATED.BATTERY STATUS LED WILL FLASH WHEN BATTERYSTATUS IS LOW (see Photo 4).

NOTE: DO NOT DEPRESS THE TRIGGER OR CYCLETHE ABRASIVE SWITCH WHILE BATTERIES AREREMOVED. THIS WILL DELETE THE MEMORY ANDREQUIRE REPROGRAMMING OF THETRANSMITTER/RECEIVER UNIT.

Replacement of Faulty ControlNozzle Mounted Transmitter UnitIf it is determined that the remote control Lance/Blitznozzle signal transmitter unit requires replacement,return the entire Lance to PyroLance for repair.

38

1. 2.

3. 4.

Maintenance

Pump MaintenanceWinterization (optional)The abrasive vessel, fire pump and plumbing system areequipped with a winterization kit which includes a fillingsystem and valves to permit the introduction of an anti-freeze liquid into the complete system. The anti-freezekit includes a header tank, 3-way control valve andrelated plumbing.

The unit must be immediately winterized whentemperatures are below 32°F (0°C) to avoid freezing.Total system displacement is approximately 10 Gallons(40 L), excluding the hose reels.

NOTE: Use only RV type (– 50°F) undiluted anti-freezesolution.

To winterize the PyroLance Power Unit,follow these steps:

STEP #1: Flush Procedure1. The PyroLance unit should be in the OFF position.

2. Disconnect the Lance/Blitz nozzles from the hosereels, but leave the hose on the reel.

3. Start the PyroLance unit (with nozzles removed)and simultaneously push the following buttonson the control panel:a) Emergency Override Buttonb) Emergency Water Buttonc) Emergency Abrasive Button

4. Run the PyroLance unit for 3 to 4 minutes to flushthe entire system of abrasive. Visually check thewater flow from the hose to ensure the water isclear of abrasive. If not, continue to flow wateruntil water is clean.

5. Shut off the PyroLance engine using the OFFswitch.

STEP #2: Anti-Freeze Filling Procedure

Following this procedure will ensure all the criticalsystem components exposed to water are filled withanti-freeze solution:

1. Pull out the Emergency Stop Button so that themodule is in the ON position. The electric switchon the pump panel should be moved from theTANK TO PUMP VALVE OPEN position toWINTERIZATION OPEN position.

2. Start the PyroLance unit with Lance/Blitz removedand simultaneously push the following buttonson the control panel:a) Emergency Override Buttonb) Emergency Water Buttonc) Emergency Abrasive Button

3. Run the unit until anti-freeze solution isdischarging in full color (without water) out theend of the hose. Switch the divertor valvebetween Lance and Blitz and ensure both hosereels are adequately treated and filled with anti-freeze.

4. Shut off the PyroLance engine using the OFFbutton.

5. Quickly re-attach the Lance/Blitz nozzles to thehose and then rewind the hose onto the reel.

6. Shut off the anti-freeze valve.

7. Remove the abrasive fill cap and replenish theabrasive into the vessel. The abrasive will displacethe anti-freeze solution in this process (which isnormal). When filled completely, replace theabrasive vessel cap. (Please see the fillingprocedure section of this manual for this segmentto assure proper replenishment.)

8. The unit is now protected against freezing andthe power unit can be returned to the storageposition.

STEP #3: Re-Activation of System for NormalOperations 1. Pull the PyroLance unit outward on the slide out

tray from the compartment storage position.

2. Activate the tank to pump control switch (valvelocated between the apparatus water tank andthe PyroLance power unit) by moving the three-way valve from “anti-freeze open” position tothe “water tank open” position.

3. Start the unit and operate per the Operationsection of this manual.

Additional WinterizationProcedures IF EQUIPPED WITHPYROFOAM SYSTEM1. Turn the Foam On/Off Switch to the On position.

2. Turn the Foam Selector Switch to the Flushposition.

3. After, Winterization Operations are complete,turn the Foam On/Off Switch to the Off position.

39

WARNINGProper winterization procedures

must be immediately followed after use to avoid freezing in temperatures

below 32°F (0°C).

Winterization must also be completed prior to shipping and storage.

9 Troubleshooting

Engine Problems1. ENGINE DOESN’T START UP.

a) Check if the Emergency Stop control isreleased.

b) Check the fuses located at the main powerunit electrical box.

c) Check if the Deutz connector to the batteryterminals are securely connected and poweris being supplied to the power unit from thevehicle’s battery system.

d) Check the fuel level in the fuel tank.

2. THE ENGINE DOESN’T SPEED UP WHENPULLING THE WATER TRIGGER. a) Check for power supply and steady green

light at the receiver. b) Check battery condition or replace the

battery in the Lance nozzle transmitterassembly.

c) Check the fuses located at the main powerunit electrical box.

Pump and PlumbingProblems1. PUMP IS UNDER PRESSURE AND WILL NOT

ALLOW ENGINE TO TURN.a) Check that the bypass/relief valve is not

stuck in the closed position.b) Check that the EZ-Start valve is in operation.c) Check that vehicle batteries are in a “fully

charged” condition.d) Check the battery supply cable from the

vehicle batteries to the power unit.

2. PUMP IS CAVITATING OR WATER ISSURGING.a) Check water tank level.b) Check that tank to pump valve is in fully

open position.c) Check that bypass/relief valve is not stuck.d) Check that pump water is not overheating

by observing thermal relief valve dischargeport.

3. BYPASS/RELIEF VALVE CONTINUOUSLYCYCLING.a) Check for water leaks in plumbing system.b) Check for blocked water filter strainer.c) Check pump-to-tank valve is fully open.d) Check that KZCO valves operate properly.

Lance Nozzle Problems1. WATER DOES NOT EXIT THE LANCE NOZZLE

UNDER LOAD a) Check if the tank-to-pump valve is open.b) Prime the system.c) Check the water level in the tank.d) Check for leakages in plumbing system.e) Check if the water filter element – remove

and clean.f) Check to see if the Lance nozzle orifice is

blocked. g) Check divertor valve setting.

2. AFTER RELEASING THE WATER TRIGGER,WATER IS STILL GOING OUT OF THE LANCENOZZLE.a) Check for air bubble in the abrasive vessel.b) Stop the engine, with power still ON, and

cycle the water trigger, observe operationfrom the KZCO ball valve indicator dial.

3. PENETRATING/CUTTING OPERATION DOESNOT MAKE HEADWAY.a) Check abrasive level in vessel.b) Check operation of abrasive flow control

valve.c) Check operating pressure on pressure vessel

(loss of more than 500 PSI (35 Bar) willindicate worn-out nozzle).

4. EXCESSIVE SPRAYBACK FROM LANCENOZZLE TIP OR FLARING OF STREAM.a) Check for worn end plate.b) Check for worn nozzle tip.c) Check that end plate is properly secured.d) Check Lance nozzle angle of attack and re-

position to better operating angle.

Blitz Nozzle Problems1. WATER DOES NOT EXIT THE BLITZ NOZZLE

UNDER LOAD a) Check if the tank-to-pump valve is open.b) Prime the system.c) Check the water level in the tank.d) Check for leakages in plumbing system.e) Check if the water filter element – remove

and clean.f) Check to see if the Blitz nozzle orifice is

blocked. g) Check diverter valve setting.

40

Troubleshooting

Electrical Problems1. POWER UNIT IS NOT RESPONDING TO

LANCE INPUTS.a) Check that Emergency Stop control is

released and power is ON.b) Check that batteries in Lance nozzle are

fully charged.c) Check that fuses work in main power unit

electrical box.d) Check that green LED flashes on the remote

control wireless receiver box.

Anti-Freeze LoadingProblems (optional)1. ANTI-FREEZE SYSTEM DOES NOT LOAD OR

WORK PROPERLY.a) Check tank-to-pump valve and ensure it is in

the anti-freeze position.b) Check anti-freeze container for contents.c) Check that UHP pump is primed.

Hose Reel Problems1. THE REEL DOES NOT REWIND.

a) Check if battery is connected. b) Check if the fuse reel electrical box is

operational.c) Check wiring connections in power unit

electrical box and reel electrical box forloose connections.

d) Check the reel rewind button on the frontpanel for proper operation.

PyroFoam SystemProblems1. Foam does not exit the nozzle

a) Ensure that foam selector valve is in eitherclass A or B mode.

b) Ensure those foam tank to pump valves areopen.

c) Ensure that foam pump master switch isactivated.

d) Ensure that foam proportioner is adequatelyset.

e) Ensure that there is foam in tanks.

2. Foam pump master switch is on but foampump is not workinga) Ensure that foam tank level switch is not

activated by ensuring that adequate foam intanks and that the red low foam warninglights are not illuminated.

b) Ensure that micro switch located at throttlecontroller is operating properly.

3. Foam pump does not switch off whenengine goes to idle a) Faulty micro switch at throttle controller.

Isolate pump using foam pump masterswitch and replace micro switch as soon aspossible.

4. Foam pump cavitates a) Adjust foam proportioning system to lower

level until cavitation stops.b) Check viscosity of foam concentrate.

5. Foam quality poora) Adjust foam proportioner until proper foam

quality is achieved.b) Ensure that correct type of foam compound

is in relevant tanks.

6. Winterizationa) Ensure that foam tank to pump valves are

closed.b) Flush foam system completely.c) Select either class A or B system and run

foam pump for no longer than 15 secondsdry.

41

10 Specifications

42

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Lance Pistol Grip Handle

Lance Handle Assembly

DESCRIPTIONPART NUMBERQTYITEMHandle095-45-03-101011Mounting Plate095-45-03-101112Holder, LED095-45-03-101213Antenna_Folding_4in_RP-TNCm 14Bolt_PanHead_10_24x750 25Bolt_PanHead_8_32x500 16Bulkhead_RP-TNCf 17LED_BSI_3mm_Red_MicroPrecision 18

DESCRIPTIONPART NUMBERQTYITEMBolt_PanHead_8-32x5/8 51Bolt_Shoulder_1/4x1/2x10-24 12Spring_11/32x1in 13Spring Roll Pin_1/8x9/16 14Bolt_FlatHead_10-24x3/4 25Bushing_Igus_Trigger Pivot 16Switch_Micro 17Grip/Trigger Housing095-45-02-101018Trigger095-45-02-101219Safety Lever095-45-02-1013110Trigger Guard095-45-02-1014111Spring Keeper095-45-02-1015112Cover095-45-02-1016113

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DESCRIPTIONQTYITEMBolt_ButtonHeadSocket_1/4-20x131Bolt_ButtonHeadSocket_1/4-20x1/232Bolt_FlatHead_10-24x1/223Bolt_PanHead_10_24x1/244Bolt_PanHead_4-40x9/1625Bolt_PanHead_8-32x1/266Screw_Set_1/4-20x1/427Bolt_SocketHeadCapScrew_10-24x2-1/248JunctionBlock, 8Wire19LED_BSI_3mm_Yellow_MicroPrecision110RubberBushing_WireSeal512Switch_Toggle_On/Off113Transmitter, RF, Air Eagle114

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43

Specifications

44

Lance Barrel

Lance Hose Assembly

DESCRIPTIONPART NUMBERQTYITEMBarrell End095-45-04-101111Barrel095-45-04-101012Bolt_PanHead_10_24x750 44NOZZLE, WASHER, PRESSURE SEALING 15NOZZLE, SEAL BUSHING 16NOZZLE, ORING - 907 17NOZZLE, HYDRO JET 18NOZZLE, HEAD 19NOZZLE, HOUSING 110

6 7 21085149

3

Bi-Pod Handle Assembly

DESCRIPTIONPART NUMBERQTYITEMNut_NylonLocking_Thin_250_20 11Bolt_PanHead_250_20x1 250 12SpacingStud_375_16x2_625x1 13Bolt_HangerBolt_375_16 14Upper Clamp095-45-05-101015Lower Clamp095-45-05-101116Knurled Handle095-45-05-101227

4

7

2

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6

5

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Specifications

45

Valve Kit ...........................04-KIT UD-93Seal Kit .............................04-KIT UD-12Brass Kit...........................04-KIT UD-19Plunger Bolt Kit .............04-KIT UD-123

Maximum Flow .........................20 GPMMaximum Pressure .................2200 PSIRated Pump Speed ..............1450 RPMOil Capacity............44 oz. UDOR LUBE

or SAE 30WNon-Detergent Oil

Plunger Part #............................1205.42Plunger Diameter........................28 MM

NX 75/150 Quick Reference

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Flow Schematic and Major Components

Specifications

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Specifications

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Throttle Controller

Cat Pumps Model 8100System Saver Throttle Controller

SpecificationsMax. System Pressure 4000 PSI 275 BAR

Actuation Pressure 250 PSI 18 BAR

Max. Temperature 160°F 71°C

Fitting Size 3/8" NPTM 10 mm

Cable Length 48" 1219 mm

Weight 22 oz. 0.62 kg

Dimensions 5.25 x 1.75" 133 x 45 mm

InstallationThe Throttle Controller will function in any position,however, a minimum number of bends should be in thethrottle cable to insure smooth consistent operation. Ifmultiple discharge ports are available, install directlyinto the discharge manifold port. If not, tee into thedischarge line between the unloader valve and thepump.

OperationWhen the shut-off gun is closed (trigger released) theunloader will go into by-pass and drop the systempressure to 250 PSI or less. This change in pressure movesthe piston in the throttle controller, reducing the tensionon the throttle cable to permit the engine to idle.

NOTE: The Throttle Controller cannot be used with apressure regulator as a regulator maintains systempressure and will not give the required low pressuredrop to activate the piston in the Controller.

Setting and AdjustmentConnect the Throttle Controller cable by turning thethreaded cable end into the cable retainer. Thread handtight until Locking Nut and Housing are flush with thecable retainer. Then secure locking nut with wrench.Torque to 100 in/lbs. Slide cable wire through the holein the “L” connecting rod. Apply a small amount ofLoctite 242® to the I.D. of the socket head screw.

Only partially thread onto “L” connecting rod untilremaining connection is made. Slide “Z” end of cablethrough the housing clamp. Then insert “Z” end intocable insert on the engine throttle rack. Only partiallytighten screw on housing clamp now to allow later finetuning of the throttle cable. With the engine in idleposition, tighten the socket head screw on the “L”connecting rod. Torque to 8-10 in/lbs.

Start the engine and make the necessary pressureadjustment to your unit to obtain full operating pressureat rated RPM. Check this pressure with the trigger gunopen. Leave gun open and adjust the engine to full RPMby sliding the cable housing back and forth to obtain aminimum of 5/1000ths of a gap at the stop on the enginethrottle rack. When the engine gap is reached tightenscrew on cable housing clamp. Torque to 10 in/lbs.

Caution:The engine throttle should not be allowed to hammeragainst the throttle rack stop. Be certain to leave asmall air gap between the throttle and the stop toprevent stress on the cable, the throttle stop and the“L” connecting rod (see Tech Bulletin 061).

TroubleshootingWater leaking around “L” connecting port:O-ring worn. Replace as needed.

Engine does not drop to idle• Regulator incorrectly installed or pressure lock-up

unloader incorrectly installed. Use only Unloaderwith low pressure of less than 250 PSI in by-pass.

• Plugged orifice in throttle controller. Clean asneeded.

• Cable broken or restricted with severe bends.

Engine does not return to full system RPM• Cable broken or restricted with severe bends. • Cable extremely dirty. Lubricate and resume

operation.

Cat Pumps Model 8100System Saver Throttle Controller

Schematic

Specifications

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Specifications

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Power Unit Electrical Schematic

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010203

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Switch Panel Electrical Schematic

Specifications

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Reel Controller Electrical Schematic

Specifications

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Appendix: Component Literature

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Electronic versions of all vendor supplied instruction and operating manuals, plus othersupplementary information has been linked in Adobe PDF format.

Briggs & Stratton Gasoline Engine Engine Owner’s ManualModel # 540477-0120-G1 Engine Service Manual

Engine Troubleshooting GuideEngine Maintenance ScheduleEngine Spare Parts Listwww.briggsandstratton.com

Udor Pump Pump DrawingModel # GC-38/15-GR Pump Spare Parts Drawing

www.udorusa.com

Hannay Reel Hannay PDF Instruction and Operating ManualModel # E4038-17-18RT/LT H5M www.hannay.com

Cat Pumps Throttle Controller Cat Pumps PDF Instruction ManualModel # 8100 www.catpumps.com/products/pdfs/8100_B.pdf

Receiver/Transmitter Lance Transmitter Data SheetModel # Air Eagle SR 2,4 GHz RF Power Unit Receiver Data Sheet

receiver, Model 38-2000-DC www.bwieagle.com

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WarrantyPyroLance warrants to the original purchaser, eachsystem or other product of its own manufacture, for aperiod of 18 months from the date of shipment fromthe factory or 12 months from the unit being placed inservice, to be free from defects in material andworkmanship under normal use and service. “Normaluse and service” means not in excess of recommendedmaximum speeds, pressures, and temperatures, orhandling fluids not compatible with componentsmaterials, as noted in applicable PyroLance productcatalogs, technical literature and instructions.

This warranty shall not apply to any system or otherproduct that has been repaired or altered, includingthe addition of foam systems or other components thatare not factory-installed, to adversely affect theperformance or reliability of the system or otherproduct.

Neither will this warranty, nor any implied warranty,apply to damage or harm caused by any or all of thefollowing:

(1) Freight damage;(2) Freezing damage;(3) Damage caused by parts and/or accessories or

components not obtained from or approved byPyroLance;

(4) Any consequential or incidental damages,arising from the use of the PyroLance systemand equipment;

(5) Damage due to mis-application, mis-installation and/or misuse; and

(6) Normal wear of moving parts or componentsaffected by moving parts.

The liability of PyroLance under the foregoingwarranty is limited to the repair or replacement atPyroLance’s option without charge for labor ormaterials of any parts upon return of the entire systemor any particular part to the PyroLance factory withinthe warranty period, at the sole expense of thepurchaser, which part shall upon examination appearto PyroLance’s satisfaction to have been defective inmaterial and workmanship.

The liability of PyroLance under any theory of recovery(except any express warranty where the remedy is setforth in the above paragraph) for loss, harm ordamage, shall be limited to the lesser of the actual loss,

harm or damage, or the purchase price of the systemor component part as delivered by PyroLance to thepurchaser.

PyroLance expressly warrants its systems and otherproducts as stated above. There are NO OTHEREXPRESSED WARRANTIES, nor any implied warranties,including implied warranty of merchantability or offitness for a particular purpose. Our warranty is limitedin duration to 18 months from the date of shipmentfrom the factory, or 12 months from the unit beingplaced in service by the original purchaser.

Again, there is no implied warranty of fitness for aparticular purpose or merchantability when thisproduct is put to any other application or use.

No person is authorized to make any representation orwarranty concerning PyroLance’s products on behalf ofPyroLance, or to assume for PyroLance the obligationscontained in this warranty. PyroLance reserves the rightto make changes in design and other changes andimprovements upon its products without imposing anyobligations upon itself to install the same features onits existing products then in process or beingmanufactured.

We would suggest our Web site for additionalwarranty information and use of our “Return GoodsAuthorization” (RGA) requirements.

It is imperative to package all PyroLance componentsproperly, before return shipment including therequired “Return Goods Authorization” forms. SomePyroLance systems and components contain electroniccomponents that may be damaged if improperlypackaged for shipping!

All PyroLance components shipped back to PyroLancewill pass through Quality Control Inspection, and maybe photographed after the box is opened. Thepurchaser is responsible for any physical damageoccurring to PyroLance components at user’s facilityand during shipment back to PyroLance.

PyroLance appreciates your attention in this matter aswe feel it will help us to serve you in a better fashion,while keeping the cost of the PyroLance productcompetitive and providing above-average service andwarranty assistance.

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