FoamPRO Turbo Stream S108-4008 User manual

INSTALLATION AND
OPERATION MANUAL
Unit
Serial
Number
Form 925
Rev. C
All quality FoamPro products are ruggedly designed, accurately machined, carefully assembled, thoroughly inspected
and tested. In order to maintain the high quality of your unit, and to keep it in a ready condition, it is important to follow
the instructions on care and operation. Proper use and good preventive maintenance will lengthen the life of your unit.
ALWAYS INCLUDE THE UNIT SERIAL NUMBER IN CORRESPONDENCE.
FoamPro • 375 Fifth Avenue NW • New Brighton, MN 55112 USA • [phone] • FAX [phone]
Turbo Stream
Models S108-4008, S108-4008D,
S108-4008H, and S109-4008-10

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Installation and Operation Manual
TABLE OF CONTENTS
Section Page
1 SAFETY ............................................................................................................................3
2 INTRODUCTION...............................................................................................................4
3 SYSTEM COMPONENT DESCRIPTION..........................................................................5
4 INSTALLER SUPPLIED PARTS .......................................................................................6
5 INSTALLATION PLANNING .............................................................................................7
6 PLUMBING COMPONENT INSTALLATION.....................................................................7
7 ELECTRICAL EQUIPMENT INSTALLATION ...................................................................8
8 HYDRAULIC TURBO STREAM REQUIREMENTS ..........................................................8
9 MAKING SURE EVERYTHING IS WORKING RIGHT......................................................9
10 CALIBRATION AND SETUP...........................................................................................10
11 ENGINE OPERATING INSTRUCTIONS ........................................................................11
12 HYDRAULIC OPERATING INSTRUCTIONS .................................................................12
13 MAINTENANCE ..............................................................................................................12
14 TROUBLESHOOTING ....................................................................................................12
15 PARTS IDENTIFICATION...............................................................................................13
16 INSTALLATION DRAWINGS .....................................................................................14-16
17 WARRANTY...................................................................................................... Back Page
NOTE TO SYSTEM INSTALLERS
IMPORTANT: Please provide a copy of the FoamPro manual to the end user of the equipment.
For additional FoamPro manuals, contact Hypro by FAX [phone], web site www.foampro.com,
or call [phone]. Request Form No. 925.

Turbo Stream
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Installation and Operation Manual
1 Safety
1. WARNING: Use pressure relief device on the
discharge side of the pump to prevent damage
from pressure buildup when the pump discharge
is blocked or otherwise closed and the power
source is still running. For trigger gun operation,
or where discharge is frequently shut off,
pressure unloader valves are recommended. The
Turbo Stream system is equipped with a pressure
relief device and should not be removed.
FAILURE TO FOLLOW THIS WARNING MAY
RESULT IN PERSONAL INJURY AND/OR
PROPERTY DAMAGE AND WILL VOID THE
PRODUCTION WARRANTY.
2. WARNING: Do not pump flammable or explosive
fluids such as gasoline, fuel oil, kerosene, etc.
Do not use in explosive atmospheres. The
pump should be used only with liquids that are
compatible with the pump component materials.
Failure to fallow this warning may result in
personal injury and/or damage and will void the
product warranty.
3. Do not pump at a pressure higher than the maximum
recommended pressure. [1450 psi (100 BAR)].
4. Do not run the system at greater than recommended
capacity.
5. Do not permanently remove or alter any guarding
devices or attempt to operate the system when these
guards are removed.
6. Always disconnect the power source before
attempting to service any part of the system.
7. Release all pressure within the system before
servicing any of its components.
8. Drain all concentrate and water from the discharge
system before servicing any of its component parts.
9. Periodically inspect all hoses for wear or worn
conditions. Make sure all connections and fittings are
tight and secure.
10. Use pipe, hose and fittings that are rated at or
above the maximum pressure rating at which the
water pump system may operate.
11. Use pipe, hose and fittings from the hydraulic
oil pump to the foam pump hydraulic motor, which
are rated at 3000 PSI (207 BAR) minimum working
pressure or better and are approved for mobile
hydraulic system use.
12. The components and fittings used in this system
must be compatible with the foam concentrates used
and pressures at which the pump system operates.
13. CAUTION: ENSURE THAT THE ELECTRICAL
SOURCE OF POWER FOR THE UNIT IS THE
APPROPRIATE 12 VOLT NEGATIVE-GROUND DC
SYSTEM.
14. Secure all discharge lines before starting the pump.
A non-secured line may whip, causing personal injury
and/or property damage.
15. Any electrical system has the potential to cause
sparks during service. Take care to eliminate
explosive or hazardous environments during service
and repair.
16. CAUTION: Do not attempt to operate the system
at or above a temperature of 130°F (55°C).
17. CAUTION: Periodically inspect the pump and
the system components. Perform routine
maintenance as required. Failure to perform
routine maintenance may cause damage to
individual system components; pump, motor, and
gearbox assemblies. See the maintenance section
of this manual for recommended maintenance
procedures and intervals between maintenance
work.
18. CAUTION: Read and understand “Operating
Instructions” section before attempting to operate
the unit.
19. CAUTION: The components shipped with each
FoamPro unit are tested at the factory. Improper
handling and forcing connections can damage the
components which could result in other system
damage.
20. CAUTION: Ensure the fuel source for the gas
engine is in the “OFF” position while in transport
or storage mode. This will prevent engine flooding
and fuel leakage.

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Installation and Operation Manual
2 Introduction
The FoamPro High Pressure System is a hydraulic
or engine-driven, flow-based proportioning system
that injects foam concentrate at a desired percentage
at a fixed water flow rate. The basic FoamPro High
Pressure System is shown in Figure 1. The system
will accurately deliver from 0.3% to 3.0% foam
concentrate at the rated system pressure and flow rate.
The system will accurately inject foam concentrate
while the system is running at recommended operating
speed and pressure. Foam percentage indication is
instantaneously given on the foam monitoring panel
supplied.
The foam concentrate is directly injected into the
system at the head of the pump. It is then fed as foam
solution into the adjustable foam spray gun.
The pump inlet is equipped with a check valve to
prevent contamination of the water supply.
The FoamPro High Pressure Foam System is designed
for use with most foam concentrate applications with
foam viscosities less than 60 CPS. This includes Class
A and low viscosity Class B foam concentrates. High
viscosity foams, such as AR-AFFF, are not acceptable.
Flushing of the system, especially when using Class B
foams or switching foam concentrates, is required.
21. CAUTION: Use only approved petroleum-based
hydraulic fluids meeting the specifications as
noted in Section 4. Never mix fluid types. Ensure
all hoses and seals are compatible with fluids
used. Do not use water or glycol-based fluids. Do
not use phosphate ester-type fluids.
22. CAUTION: Dirt and contaminants are the primary
causes of premature wear and failure in any
hydraulic system. Use extreme care during assembly
and service to keep contaminants out of the system.
23. CAUTION: All DOT, SAE or other applicable
standards must be followed when installing the
hydraulic supply system. Pay close attention to
engine and transmission manufacturer’s drive
limitations.
24. CAUTION: To ensure the integrity of fitting
connections in the hydraulic system, use only SAE
JIC 37º flare or equal-type hose connections.
Foam
Tank
Water
Tank
Water Inlet Strainer
Water Shut-Off
Valve
Foam Spray Gun
Pump/Gearbox Assy
Engine
Foam Inlet Strainer
Foam
Adjustment &
Flowmeter
Figure 1. FoamPro Turbo Stream

Turbo Stream
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Installation and Operation Manual
3 System Component Description
The following components are packaged with the FoamPro High Pressure System:
Control Panel
Foam Concentrate Strainer
Pump/Engine Assembly
OR
Pump/Hydraulic Motor Assembly
Foam Spray Gun/Wand
Thermal Relief Valve
Water Inlet Check Valve
Inlet Water Strainer

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Installation and Operation Manual
4 Installer Supplied Parts
The FoamPro High Pressure System is provided with
the major components and accessories required for
installation. Due to differences in chassis and apparatus
configurations, the installer must provide plumbing
to satisfy individual installation requirements. The
following paragraphs list the specifications for selection
of these components. Before beginning system
installation, read this section thoroughly to make sure
the proper components are selected. For detailed
system installation instructions, refer to Sections 5, 6,
and 7.
SUCTION LINES
Corrosion-resistant fittings and hoses from the foam
tank to the foam concentrate inlet of the pump must be
used. Use 5/16-inch to 3/8-inch inside diameter hose
for the foam inlet. Corrosion-resistant fittings and hoses
from the water source to the inlet of the pump must
be used. Use only 3/4-inch minimum inside diameter
hose for the water inlet. Use components that are
rated for 23 in [584.2 mm] Hg vacuum and 50 psi [3
bar] pressure or greater for all suction line inlets. The
components used must be compatible with all foam
concentrates to be used. All fittings used must be
made of brass, 300 series stainless or other corrosion-
resistant materials. Before selection of components,
check for compatibility with foam concentrate. The use
of clear suction hose is recommended to allow viewing
of foam and water priming operations.
DISCHARGE LINES
Fittings and hoses from the foam solution discharge of
the pump to the foam spray nozzle must be supplied by
the installer. Hoses and fittings of 1/2-inch [12.7 mm]
minimum INSIDE diameter, rated for 1800 psi [124.1
BAR] minimum working pressure, must be supplied by
the installer. Fittings are required to be 1/2-inch male
NPT on hose ends.
The following guidelines should be followed in choosing
hose length and hose diameters.
Hose ID
Approximate Pressure
Drop Per 1 ft. of Hose
Recommended
Max. Hose Length
1/2” 1.15 50’
5/8” .47 100’
3/4” .23 200’
1” .07 400’
Fittings and hoses must be compatible with all foam
concentrates to be used. Use fittings of brass, 300
series stainless or other corrosion-resistant material
that is compatible with foam concentrates to be used.
Thermal relief valve must be plumbed to discharge
away from operator.
CHECK VALVES
Check valves have been included with the system
at the water inlet to help prevent back flow of foam
concentrate or foam solution. The system should be
disconnected from exterior water supplies when not
in use. A complete system flush should be performed
before storage to prevent component failure due to
evaporation of foam and water within the system.
FOAM CONCENTRATE TANK
A foam concentrate tank must be supplied to suit the
capacity required for the apparatus application. The
tank should meet NFPA minimum standards for the
design capacity, including filler size, venting and drain
facility. A shut-off valve is recommended to allow
cleaning of the strainer.
ELECTRICAL REQUIREMENTS
Electrical wiring must be supplied to the engine starter
switch. Use AWG No. 4 cable for power and ground
connection, not to exceed 5 ft. SEE ENGINE MANUAL
for detailed electrical hook-up specifications.
CAUTION: Always disconnect ground before electrical
arc welding on any FoamPro equipment. Failure to do so
will result in a power surge through the system that could
case irreparable damage to the electronic components.
HYDRAULIC REQUIREMENTS
FoamPro hydraulic-drive Turbo Stream systems
are provided with only the hydraulic motor. All
other components and accessories required for
installation must be provided by the installer due to
differences in chassis and apparatus configurations.
The installer must provide hydraulic pump, controls,
hoses, reservoir, fittings, filters, strainers, cooler and
appropriate oil to satisfy installation requirements.
Before beginning system installation, read this manual
thoroughly to make sure the proper components are
selected. It is the installer’s responsibility to choose
the proper type of hydraulic system, i.e. positive
displacement or load sense to drive the Turbo Stream
at the proper RPM.
CAUTION: All DOT, SAE or other applicable standards
must be followed when installing the hydraulic system.
Pay close attention to engine and transmission
manufacturer’s drive limitations.

Turbo Stream
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Installation and Operation Manual
6 Plumbing Component Installation
5 Installation Planning
The following diagram (Figure 2) provides recommended guidelines for the location of the system components that
handle foam concentrate, water, and foam solution.
Figure 2. FoamPro High Pressure System Plumbing
Foam
Tank
Water
Tank
Water Inlet Strainer
Water Shut-Off
Valve
Foam Spray Gun
Pump/Gearbox Assy
Engine
Foam Inlet Strainer
Foam
Adjustment &
Flowmeter
Because of the potential differences in apparatus
plumbing and foam system configuration, it is not
practical to depict exactly how each FoamPro unit can
best be installed onto a particular apparatus. Most of
the information contained in the following sections,
however, will apply to any situation.
It is recommended that you read the following sections
thoroughly before beginning installation of the FoamPro
system. It is also recommended that you spend time
planning and designing where and how you intend to
install this unit in the apparatus before beginning the
actual installation.
Determine the location of the components to be
installed such as: foam tank, water tank, foam system,
and display panel. Try to position the components to
minimize fittings and hose lengths. Position the system
in an accessible area.
For best performance, the foam system should be
positioned below the foam tank discharge to allow
gravity feed to the pump. The foam system will draft up
to three feet. Place the foam tank where refilling with 5
gallon [19 liter] containers and other methods is suitable
for the end user.
Determine a location for the display panel on the
unit that is visually accessible while the system is in
operation. The display panel should be located on the
same horizontal plane as the system and foam tank for
best possible performance.
Determine a safe place for the thermal relief valve drain
hose, and be sure it drains in a safe location away from
operator.

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Installation and Operation Manual
7 Electrical Equipment Installation
8 Hydraulic Turbo Stream Requirements
HYDRAULIC REQUIREMENTS
FoamPro Hydraulic Turbo Stream systems are
provided with major components and accessories
required for installation, except for the hydraulic pump
and controls. The standard hydraulic motor is a .976
cubic inch per revolution motor. The hydraulic pump
will need to provide 7.6 GPM at a pressure of 2400
PSI for the Turbo Stream to reach full performance.
The volume should not exceed 8.2 GPM and the
pressure should not exceed 2700 PSI. Due to
differences in chassis and apparatus configurations,
the installer must provide hydraulic pump coolers,
fluids, reservoir, pipe, hoses, tubing and fittings to
satisfy installation requirements. Before beginning
system installation, read this section thoroughly
to make sure the proper components are selected.
PUMP/MOTOR BASE ASSEMBLY
The pump/motor base assembly must be mounted
in the horizontal position. The system can be run at
15 degrees on any plane to the horizontal and may
be run intermittently at 30 degrees to the horizontal
plane. The base of the system must be anchored to
a surface or structure that is ridged and of adequate
strength to withstand the vibration and stresses of
apparatus operation. The main pump has a water
drafting capability not to exceed six feet of vertical lift
and should not be subjected to an inlet pressure of
more than 3 PSI to ensure proper operation of the foam
injection system. The drawings on pages 14, 15, and 16
provide the mounting dimensions for the FoamPro High
Pressure pump/motor base assembly. Flexible hose is
required to make the hose connections to the FoamPro
High Pressure System. DO NOT hard pipe the system.
Protect the hoses and wiring to prevent chafing and
abrasion during operation of the foam system. Protect
the foam pump base unit from excessive spray and
debris. See engine manual for allowed engine operating
conditions.
LINE STRAINERS
There are two line strainers provided with the FoamPro
unit. The pump inlet line strainer has 3/4-inch NPT
female threaded ports and is to be installed on the
water inlet of the foam pump. The water supply hose
should have adequate wall stiffness to withstand the
vacuum of the pump while it is in operation [23 in. (584
mm) Hg and 50 PSI (3 BAR)].
The second strainer has 1/2-inch NPT male and 1/4-
inch NPT female-threaded ports and is to be installed
in the foam inlet before the flow meter. The foam supply
hose should be 1/4 to 3/8- inch and able to withstand
23in/Hg of vacuum and 50 psi. Clear foam supply hose
is recommended so that the operator can see the flow
of foam concentrate in the hose.
NOTE: If a pressurized water flush is incorporated, the
pressure should be limited to 100 PSI (7 BAR).
CHECK VALVES
A 3/4-inch check valve is included at pump inlet. A foam
injection check valve is incorporated in the design.
FLUSHING SYSTEM
Depending on the corrosiveness of the foam
concentrates to be used, a flushing system may be
required in the foam concentrate injection system.
Most Class A foam concentrates (per NFPA 1150) are
less corrosive and therefore may not require flushing.
It is important to flush and drain the entire system
before long periods of storage to prevent component
malfunction.
THERMAL RELIEF VALVE
A thermal relief valve is included with the system to
prevent pump overheating during unloading.
ELECTRICAL CONNECTIONS
See engine manual for detailed electrical connections only if engine is equipped with electric start.

Turbo Stream
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Installation and Operation Manual
CAUTION: All DOT, SAE or other applicable
standards must be followed when installing the
hydraulic system. Pay close attention to engine
and transmission manufacturer’s drive limitations.
Hydraulic Pump Drive Selection
The foam pump for the FoamPro Hydraulic Turbo
Stream system is powered by hydraulics. Power for
the system comes from hydraulic oil supplied by a
hydraulic pump attached to the apparatus engine. To
obtain optimum performance from the hydraulic motor-
driven foam pump, FoamPro has designed the Turbo
Stream system to use a constant volume hydraulic
motor. The customer-provided pump must provide the
proper hydraulic fluid flow with reduced heat load, torque
and horsepower requirements.
Oil Reservoir
A hydraulic reservoir will be required to be installed in
the apparatus. The recommended minimum reservoir
capacity is 8 gallons. A larger reservoir may be installed
and is recommended if the apparatus is to run at
maximum capacity for an extended period of time and to
allow air to settle out of the oil. The reservoir must have
a diffuser on the inlet to prevent entrapment of air into
the system. A particle screen, of 100 mesh, on the oil
inlet is recommended to help keep dirt out of the system.
A replaceable-type oil filter is recommended with at least
a 10 micron absolute rating. A baffle to separate the inlet
and outlet sections should be installed in the reservoir.
A vented, filtered breather of sufficient size to allow
filling of oil is required, and an oil drain is recommended.
A sight gauge, with thermometer, is also recommended
for easy checking of the oil level and to monitor oil
temperature. The oil reservoir should be mounted away
from heat sources, such as exhaust systems, and be a
location that allows easy access for checking and filling
the oil.
Oil Cooler
An oil cooler, capable of maintaining the temperature
of the hydraulic oil at 140° to 180°F (60° to 82°C),
is required. Use of an air-to-oil radiator-type heat
exchanger mounted on the apparatus should provide
adequate cooling for the hydraulic system oil. An electric
fan attached to the oil cooler permits mounting of the
oil cooler anywhere fresh air circulation is available.
A thermostat is required to be included for quick
warm-up of the oil in cold climates. The installer is
responsible to properly size the cooler. The required
cooling will be approximately 150 BTU/min. at 8 GPM.
Hydraulic Oil
Ratings and data for the FoamPro Hydraulic Turbo
Stream system are based on operating with premium
hydraulic fluids containing oxidation, rust and foam
inhibitors. These premium fluids include premium
turbine oils, API CD engine oils per SAE J183, M2C33F
or G automatic transmission fluids (ATF), Dexron (ATF)
meeting Allison C-3 or Caterpillar TO-2 requirements.
The recommended hydraulic fluid operating
viscosities are typically 70 to 278 SUS
(12 to 60 cSt) for optimum performance.
Hydraulic Hoses and Fittings
High pressure hydraulic hoses and fittings are to
be rated at 3000 PSI (207 BAR) minimum working
pressure. To reduce the potential for leaks at the
hydraulic fittings, use SAE 37° flare JIC-type fittings
or SAE straight thread o-ring fittings. On the Hydraulic
Turbo Stream, the motor inlet port is 7/8-14 UN-2B SAE
(J5145) o-ring straight thread. The outlet port is 1-1/6-12
UN-2B SAE (J5145) o-ring straight thread. Return line
pressure should not exceed 25 PSI.
9 Making Sure Everything is Working Right
SYSTEM CHECK
Check fuel level and oil level per engine manual prior
to running system. Check pump and gear case oil level
prior to running system. Pump and gear case should be
filled with oil per manual instructions.
Check the function of all components before using the
system. Also check that all plumbing and components
are tight and functional.
Check to see that water supply lines, strainers and foam
tank lines are free of debris and plumbed correctly. Any
leaks in the system will cause poor system performance
and operation.

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Installation and Operation Manual
10 Calibration & Setup
CALIBRATION
The FoamPro High Pressure System has been
calibrated at the factory. To check calibration of the
system, the following procedure should be used:
1) Start the system. Run the engine to an RPM that
produces 8 GPM (3345 Engine RPM) of pump water
inlet flow. Tools needed for the test are a pilot tube
or other calibrated flowmeter to test the system
inlet water flow, a graduated bucket to remove and
calibrate foam concentrate, and a stop watch to
measure volume unit/time of foam concentrate and
water flow.
2) Open the control knob of the display panel to start
foam injection, while holding the spray gun in the
on position, run the system for a few minutes. The
system will not inject foam concentrate while the
system is unloading.
3) Turn the injection control knob to the desired foam
injection calibration point. Start the stop watch and
record the necessary volumes or flow rates of foam
concentrate and water.
4) Measure the amount of foam concentrate in the
container and compare that to the calculated
amount. (Main flow rate X injection rate X minutes
flowed [8.00 GPM X 0.005 (0.5%) injection rate X
5 minutes = 0.20 gallons]).
5) CAUTION: Long periods of pump deadheading
may result in pump damage due to overheating of
water in the system. The system is equipped with a
thermal relief valve to eliminate damage to the pump
during unloading. It is recommended to idle down
the system during unloading if the system must stay
running during transportation.
6) CAUTION: System may only be calibrated with
foams with a viscosity from 60 CPS. Use of
other higher viscosity foams will create an error
in calibration and setup. Use only quality foam
concentrate.
7) Measure the amount of concentrate injected over
time and compare to the level indicated on the
display panel during this time. The output of the
FoamPro High Pressure System must be set at a
constant 8 GPM + 0.20 GPM/-0.5 GPM. Injection
rate is easily changed by turning the foam % control
knob on the display panel. The foam percentage is
indicated on the display panel and is read using the
largest diameter of the foam percent float. Repeat at
each indicated % if desired.
8) The water inlet flow rate may be adjusted by
changing the engine RPM. Increasing the engine
RPM will increase the flow rate. Decreasing the
engine RPM will decrease the water inlet flow rate.
Varying engine RPM will change calibration settings.
NOTE: The viscosity of different foam concentrates may
have an effect on the amount of foam concentrate that
is injected into the water stream. When checking the
calibration of the system, use the foam concentrate that
will be used most frequently during normal operations.
When different viscosity foam concentrates are used, the
actual concentrate injection may vary as much as 100%.
PRESSURE RELIEF VALVE ADJUSTMENT
The pressure relief-unloader valve is factory tested, but
not preset and adjustment is required before system
is used on a continual basis. After setting the valve
properly, no other adjustments will be required. The
following procedure is provided for proper adjustment.
1) Start the system and run the pump to maximum
RPM with the foam spray gun in the open position.
2) Turn the adjustment knob so the pressure on the
gauge is at 1200 PSI (83 BAR).
3) While observing the pressure gauge, slowly
increase the pressure by turning the adjustment
knob clockwise until the pressure gauge is no longer
moving.
4) Turn off the foam spray gun and open it again to
ensure the pressure is at the same pressure as set.
5) Turn off the spray gun and shut off the engine.
Remove the adjustment cap and lock the adjustment
nut into place. Replace the adjustment cap.

Turbo Stream
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Installation and Operation Manual
11 Engine Operating Instructions
PREPARATIONS BEFORE STARTING THE
SYSTEM
1) Fuel: Check fuel level in tank. Do not overfill tank.
Use fresh, clean automotive fuel. NOTE: DO NOT
FILL FUEL TANK WHEN ENGINE IS RUNNING.
2) Engine Oil: Before checking or refilling with engine
oil, make sure the engine is stopped and placed on
a stable, level surface. Use oil recommended for
ambient air temperatures at which the engine will
be running. Change oil according to manufacturer’s
recommendation. (At least once after the first 20
hours and every 100 hours thereafter.)
3) Pump Oil: Before checking or refilling with pump
oil, make sure the engine is stopped and placed on
a stable, level surface. Use oil recommended for
ambient air temperatures at which the pump will be
running. Change oil according to manufacturer’s
recommendation, using SAE 30 weight non-
detergent oil. Check oil level before running the
system using the oil level dip stick on the pump.
4) Gear Case Oil: Before checking or refilling with
gear case oil, make sure the gear case and engine
are stopped and placed on a stable level surface.
Use oil recommended for ambient air temperatures
at which the gear case will be running at. Change
oil according to manufacturer’s recommendation,
using SAE 90 weight non-detergent oil. Check oil
level before running the system using the oil level
hole on the side of the gear case.
5) Check to see that water supply lines, strainers and
foam tank lines are free of debris and plumbed
correctly. Any leaks in the system will cause poor
system performance and operation.
STARTING THE SYSTEM
IMPORTANT: Before starting engine, be sure
discharge hose is secure.
1) Turn the engine switch located by the recoil starter
to the ON position.
2) Turn the fuel cock to the ON position.
3) Push the throttle lever to a slightly open position.
4) Operation of the choke lever
a) When engine is cold:
i) In cold weather, start engine with choke in
the fully-closed position.
ii) In warm weather, start engine with choke in
half-closed position.
b) When engine is warm:
i) Start engine with choke in fully open position.
5) Open the gun by pulling the trigger. This will allow
easier starting of the engine.
6) Start the engine with electric start key or recoil
starter.
OPERATION OF THE SYSTEM
1) Idle the engine for 3 to 5 minutes or until operating
temperature is achieved.
2) CAUTION: Do not run the FoamPro High Pressure
System for long periods during unloading. Long
periods of pump deadheading may result in pump
damage due to overheating of water in the system.
3) Open the throttle lever to the upper zone after
engine has reached operating temperature.
4) Once the system is primed, you will note a load on
the engine; adjust RPM to proper speed for your
pumping application.
5) Adjust the foam concentrate injection percentage
with the display panel to the desired percentage
while the system is running at full capacity (8 GPM).
STOPPING THE SYSTEM
1) Stop pump for a short time:
a) Run throttle all the way down (fully to the right).
b) Turn engine switch to OFF position.
c) Turn the fuel cock to the OFF position. This
valve should be closed for transporting the
unit also.
2) Stopping pump for storage:
a) Turn fuel cock to OFF position instead of
turning the engine off.
b) Let the engine idle for 2 to 3 minutes until fuel
in the carburetor is depleted and engine stops.
c) Drain the pump and flush pump after use.
d) Drain all fuel from engine.
e) Store system in clean, dry environment.

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Installation and Operation Manual
13 Maintenance
14 Troubleshooting
The FoamPro Turbo Stream system is designed to be easy to diagnose and service. There are several major
components (see Figure 2). Servicing the system involves isolation of the failed component and replacing it.
Following the trouble-shooting guide will allow quick diagnosis of the problem and the corrective action to take.
1. Daily: Inspect wiring, hoses, pump, gear case,
engine and connectors for tightness, corrosion,
leaks and/or damage.
2. Daily: Check hydraulic/engine oil level and refill as
necessary.
3. Monthly: Remove and clean the foam and pump
inlet strainer screens. Flush as required.
4. Monthly: Check pump gear case oil level and refill
as necessary.
5. Monthly: Check gear case oil level and refill as
necessary.
6. Monthly: Change engine oil every month or every
100 hours, whichever comes first. First oil change is
to be done at 20 hours.
7. Annually: Drain the pump oil and refill pump gear
case with SAE 30 weight non-detergent oil. Check
for foreign materials in the drained oil (water or
debris).
8. Annually: Drain the gearbox oil and refill gearbox
with SAE 90 weight gear lube. Check for foreign
materials in drained oil.
Note: Water quality, flushing and storage
techniques, environment and usage may have an
effect on your maintenance schedule. To ensure
equipment longevity, it is recommended to adjust
your schedule accordingly.
Caution: Release all pressure and drain all
concentrate and water from the system before
servicing any of its components.
12 Hydraulic Operating Instructions
PREPARATIONS BEFORE STARTING THE
SYSTEM
1) Check hydraulic fluid level in reservoir. Do not
overfill reservoir. The installer is responsible for
choosing the proper type of hydraulic fluid for the
system and temperature range the Turbo Stream
will operate in.
2) Pump Oil: Use oil recommended for ambient
air temperatures at which the pump will be
running. Change oil according to manufacturer’s
recommendation, using SAE 30 weight non-
detergent oil. Check oil level before running the
system using the oil level dip stick on the pump.
3) Check to see that water supply lines, strainers and
foam tank lines are free of debris and plumbed
correctly. Any leaks in the system will cause poor
system performance and operation.
STARTING THE SYSTEM
IMPORTANT: Before starting the hydraulics, be sure
discharge hose is secure.
1) The installer is responsible for providing the
customer with hydraulic system operating
instructions.
Symptom Probable Cause(s) Corrective Action
Pump runs but produces no flow. Pump is not primed. Pull trigger on foam sprayer gun while priming pump.
Pump loses prime, chattering
noise, pressure fluctuates.
Air leak in suction hose or inlet fittings. Remove suction hose and test for leaks by pressurizing hose with water. Make
sure thread sealant has been used on all fittings.
Suction line is blocked, collapsed or too small. Remove suction line and inspect it for a loose line or debris lodged in hose.
Avoid all unnecessary bends. Do not kink hose.
Clogged suction strainer. Clean strainer.
Foam pump capacity below rating. Net Positive Suction Head required. If foam does not flow freely, modification of piping and pump location is
required.
Engine RPM Check engine RPM
Engine does not run or runs poorly. See engine manual.

Turbo Stream
13
Installation and Operation Manual
15 Parts Identification
2414B-G1P
Pump/Gearbox Assy.
(8000-0021 Gearbox)
PowerProTM Engine 2541-0048
Honda Engine 2541-0057
HATZ Diesel Engine 2581-0001
3312-0005
Thermal Relief Valve
2500-0117
Hydraulic Motor
2640-0004
Pressure Gauge
6032-0078
Control Panel
3320-0063
Inlet Check Valve
3350-0085
Foam Inlet Strainer
3350-0044
Water Inlet Strainer
3381-0045
Gun/Wand Assembly
with Low Pressure 3385-4500 Nozzle (approx. 400 PSI)
Nozzles
High Pressure 3385-2300 (1450 PSI)
Medium Pressure 3385-3000 (750 PSI)
2900-0049
Bypass Hose

14
Installation and Operation Manual
21.44 31.31
17.94
Pulse Hose Connection
Foam Concentrate Inlet
3/8-18 NPT
Water Inlet Port
3/4-14 NPT
Solution Outlet
1/2-14 NPT
6.69
5.31
.38
.22 Dia (4)
2.25
3
16 Installation Drawings
.44 Dia (6 Holes)
18.25
5.62
2.63
7.68
3.75

15
Installation and Operation Manual
Turbo Stream

Installation and Operation Manual
16
5.62
4.94
15.4 21.5
11.2
5.9
8.8
9.6
6.6
Solution Outlet
1/2-14 NPT
Water Inlet Port
3/4-24 NPT
Outlet Port (opposite side)
1-1/16-12 UNF-2B
SAE (J514B) O-ring
Straight Thread
Motor Inlet Port
7/8”-14 UNF-2B
SAE (J514B) O-ring
Straight Thread
Foam Concentrate Inlet
3/8-18 NPT
Pulse Hose Connection
4X .44

17
Installation and Operation Manual
Turbo Stream
•NOTES•

18
Installation and Operation Manual
•NOTES•

19
Installation and Operation Manual
Turbo Stream
•NOTES•

Installation and Operation Manual
FoamPro warrants to the original purchaser, each new pump, system or other product of its own manufacture, for a period of one year from the
date of shipment from the factory, to be free from defects in material and workmanship under normal use and service. “Normal use and service”
means not in excess of recommended maximum speeds, pressures, and temperatures, or handling fluids not compatible with components
materials, as noted in applicable FoamPro product catalogs, technical literature, and instructions. This warranty shall not apply to any pump, system
or other product which shall have been repaired or altered to adversely affect the performance or reliability of the pump, system or other product.
Neither this warranty nor any implied warranty apply to damage or harm caused by any or all of the following: (1) Freight damage; (2) Freezing
damage; (3) Damage caused by parts and/or accessories or components not obtained from or approved by FoamPro; (4) ANY CONSEQUENTIAL
OR INCIDENTAL DAMAGES, OTHER THAN INJURY TO THE PERSON, ARISING FROM THE USE OF ANY PUMP OR OTHER PRODUCT
MANUFACTURED BY FOAMPRO EXCEPT in states that do not allow the exclusion or limitation of incidental or consequential damages; (5)
Damage due to misapplication and/or misuse; (6) Normal wear of moving parts or components affected by moving parts.
The liability of FoamPro under the foregoing warranty is limited to the repair or replacement at FoamPro’s option without charge for labor or
materials of any parts upon return of the entire pump, system or other product or of the particular part to the FoamPro factory within the warranty
period, at the sole expense of the purchaser, which part shall upon examination appear to FoamPro’s satisfaction to have been defective in material
and workmanship.
The liability of FoamPro under any theory of recovery (except any express warranty where the remedy is set forth in the above paragraph) for loss,
harm or damage, shall be limited to the lesser of the actual loss, harm or damage or the purchase price of the involved pump, system or other
product when sold by FoamPro to its customer.
FoamPro expressly warrants its pumps and other products as above stated. THERE ARE NO OTHER EXPRESS WARRANTIES. ANY IMPLIED
WARRANTIES, INCLUDING IMPLIED WARRANTY OF MERCHANTABILITY OR OF FITNESS FOR A PARTICULAR PURPOSE, ARE LIMITED
IN DURATION TO ONE YEAR FROM THE DATE OF PURCHASE BY THE ORIGINAL PURCHASER EXCEPT in states that do not allow time
limitations on implied warranties. THERE IS NO IMPLIED WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE OR MERCHANTABILITY
WHEN THIS PRODUCT IS PUT TO RENTAL USE.
No person including any dealer or representative of FoamPro is authorized to make any representation or warranty concerning FoamPro products
on behalf of FoamPro, or to assume for FoamPro the obligations contained in this warranty. FoamPro reserves the right to make changes in design
and other changes and improvements upon its products without imposing any obligations upon itself to install the same, upon its existing products
then in process or manufacture.
This warranty gives you specific legal rights, and you may also have other rights which vary from state to state.
IMPORTANT NOTICE
It is imperative to package all FoamPro components properly, before shipment (with Return Goods Authorization attached) back to FoamPro. The
FoamPro contains electronic components that may receive damage from improper shipping procedures! All FoamPro components shipped back to
FoamPro will pass through Quality Control Inspection, and will be photographed after the box is opened. Any shipping damage, such as superficial
scratches, nicks, etc., to the unit makes it unusable (even after the internal warranty problem is repaired) and thus must be refinished to “like-new”
condition during the warranty process. You are responsible for any physical damage occurring to FoamPro components at your facility and during
shipment back to FoamPro.
Package the FoamPro, complete with all the recommended parts the Customer Service representative requires (i.e., Digital Display control with all
premolded wire cables etc.) in its original carton with the Styrofoam and other packaging materials, as it was received at your facility.
FoamPro appreciates your attention in this matter, as we feel it will help us to serve you in a better fashion, while keeping the cost of the FoamPro
product competitive. Thank you.
17 Warranty
FoamPro (8/13)
Printed in USA