KIFCO Avi-FoamGuard AV-ST3 IRR User manual
P/N 19302390 Revised on 3/1/14, Kifco, Inc.
Introducon
Thank you for purchasing a Kifco Avi-FoamGuard
Please read this manual carefully along with watching the video provided to learn how to operate and service
your Avi-FoamGuard properly before operang your machine for the rst me. Failure to do so can result in
personal injury and/or property damage.
If you have any problems or are unclear regarding any of the instrucons contained herein, contact Kifco prior
to operaon.
Record the model & serial number of your machine in a safe locaon. Should you ever require product support
assistance from our factory; the process will be much quicker if you have this informaon available.
This manual is a permanent part of your Av-FoamGuard and should always be available for reference by the
operator. This manual should remain with the Avi-FoamGuard at all mes.
Measurements
In this manual all measurements are in U.S. SAE units unless otherwise noted.
Warranty
A standard Kifco warranty is provided. Please see the specic warranty statement in this manual for full de-
tails. Neither Kifco nor their representaves are authorized to make excepons to any warranty policy. Any
deviaons from the standard warranty require wrien authorizaon from Kifco, Inc.
The warranty specically excludes:
Alteraons or modicaons to any part of your new machine not previously approved by Kifco in wring.
PE tube that is longer, larger in diameter, or made from non-approved materials will void the warranty on
the enre machine.
Damage caused by normal wear, accident, lack of reasonable care and maintenance, neglect or abuse.
Normal wear items such as belts, gaskets, brake bands, etc. unless these parts are known to be defecve.
Transportaon, mailing, service call, diagnosc costs.
Labor for repairs is also excluded unless unusual circumstances exist and then only if pre-approved.
P/N 19302390 Revised on 3/1/14, Kifco, Inc.
Table of Contents
Introducon 1
Safety 3-6
Handling the Polyethylene Tube 7
Timing 8-9
Set-up & Operaon 10-17
Prepare for Trolley Pull-Out 10
Trolley Pull-Out 11
Trolley Set-Up 12
Prepare for Operaon 12-13
Sanitaon System 13
Plumbing Set-Up 13-14
Booster Pump Start-Up 14-15
Retracon Engine Start-Up 15
Injecon Pumps 16
Applicaon w/ Handheld Nozzle 16
Trolley Retracon 16
Retracon Speed 17
End of Run Procedures 18-19
Winterizaon & Storage 20-21
Required Maintenance 21-24
Wiring Diagram 25
Warranty 26-27
P/N 19302390 Revised on 3/1/14, Kifco, Inc.
Safety
Owner’s Responsibilies:
The owner is responsible for the safe operaon of this product. The important safeguards and instrucons ap-
pearing in this manual are not meant to cover all possible condions and situaons that may occur. Common
sense and cauon should be used at all mes by all operators to prevent damage or injury to the operator.
The owner is responsible for:
Reading and understanding this manual and video. If any instrucons remain unclear contact Kifco for
further instrucons.
Operang the machine strictly according to prescribed limitaons.
Properly training others who may be permied to operate the machine.
Heed the rules of safety, including but not limited to those in these instrucons.
Exercising good judgment relang to safe operaon and safe conduct by operators and spectators whether
invited or not.
Always bringing the safety decals and placards on the machine to the aenon of operators and spectators.
Keeping all shields and guards in place!
Read and Heed The Special Messages!
This safety alert symbol is used to indicate messages related to safety. When you see this safety symbol, obey
the safety message to avoid personal injury, property damage, or both.
A “Cauon” message in this manual or on a machine placard means that you could be injured and/or equipment
or property may be damaged if you do not follow instrucons.
A “Warning” message in this manual or on a machine placard means that a hazard exists
that could result in severe personal injury or death.
A “Danger” message in this manual or on a machine placard means that a hazard exists
that will result in severe personal injury or death.
P/N 19302390 Revised on 3/1/14, Kifco, Inc.
Safety
Learn To Be a Safe Operator:
Read This Manual
Know the controls on the Avi-FoamGuard and how to stop the the water supply, pumps and
engines.
Do not allow anyone to operate this Avi-FoamGuard without proper instrucon.
General Precauons
Never aempt to service the Avi-FoamGuard while it is operang.
Never aempt to make adjustments to the equipment while it is operang.
Perform quarterly maintenance as outlined.
Secure the trailer with wheel chocks before pulling out the trolley
Protect Children
Do NOT allow children to operate the Avi-FoamGuard.
Keep children away while operang the Avi-FoamGuard.
Never allow children to climb or ride on the trolley at any me.
Turn o the power to the infected house before entering and operang the Avi-FoamGuard.
Use Cauon Around Pressurized Lines
For your own protecon, always take care when working with or around pressurized equipment.
Shut o the pump before working with any components. This includes the pump, supply lines,
machine or any related equipment.
Be sure the pressure is relieved from any supply line before it is disconnected.
Never service the equipment while it is pressurized or in operaon.
Cut the Power
Turn o the power to the infected site before entering and operang the Avi-FoamGuard. Also
close all windows to avoid a cross-breeze during operaon.
Transporng Your Avi-FoamGuard
Secure the foam wand and supply hoses on the trailer before transporng.
Lock the foam trolley boom arms before transporng.
If traveling at highway speeds and for a long distance, remove the foam generators and
handheld foam nozzle before transporng, otherwise, be sure to lock the generators and nozzle
for a slow, short transport.
Cauon! Never transport your Avi-FoamGuard unless the An-Reverse Pawl is in
the down posion. The Pawl should always be in the down posion EXCEPT on
trolley pullout!
P/N 19302390 Revised on 3/1/14, Kifco, Inc.
Safety
Learn To Be a Safe Operator - Connued:
Keep Hands and Clothing Away
Do not reach into any part of the Avi-FoamGuard while it is in operaon.
All operators and spectators should keep a safe distance from all moving parts
during operaon.
Keep All Guards and Shields in Place
Never Operate this Machine with Safety Guards Removed!
Know the Controls:
1. 2. 3. 4. 5.
6. 7. 8. 9.
1. Master Switch (On and O) - Controls the power to all
funcons.
2. PTO Rewind (Manual/Automac) - Enables the retrac-
on of the Foam Trolley to be controlled manually or
automacally.
3. Master Power Light – Illuminates when Master Switch is
on.
4. Injecon Pump #1 (On/O) – Acvates foam soluon
pump.
5. Injecon Pump #2 (On/O) – Acvates oponal pump
used for disinfectant or cleaning soluons.
6. Sanizer – Controls both manual and automac sanizer
soluon applicaons.
7. Retract Stop – Stops the Retracon Engine from running
when pressed & held. (Used in emergency situaons).
8. Injecon Pump #1 Prime – Press and hold to prime
Injecon Pump #1.
9. Injecon Pump #2 Prime - Press and hold to prime
Injecon Pump #2.
Control Panel Funcons
P/N 19302390 Revised on 3/1/14, Kifco, Inc.
Safety
11.
10.
12.
13.
14.
15.
10. Foam Generators
11. Hand Held Foam Nozzle (Oponal Piece of Equipment)
12. Safety Chain
13. Foam Trolley Towing Chain
14. Foam Nozzle Valve (Oponal Piece of Equipment)
15. Generator Valves
Know the Controls - Connued:
Foam Trolley Components
P/N 19302390 Revised on 3/1/14, Kifco, Inc.
Polyethylene Tube
Precauons for Handling
The polyethylene irrigaon tube is a durable product that will operate reliably for many years if handled
properly and given a reasonable amount of care.
Medium Density Polyethylene is a semi-rigid product that retains its shape when it is not pressurized but can
also be wound on a drum or spool without damage. This characterisc makes it feasible to pump uid through
it while it is rolled up on a reel.
A few simple precauons need to be observed to prevent damaging the tube when operang your Avi-
FoamGuard.
1. When starng a new Avi-FoamGuard for the rst me, you must pull the tube all the way out in order to
correctly ghten the new tube on the spool. It is also important to follow the ming instrucons on Page 8
of this manual and in the operaonal video that was provided with this manual. The Avi-FoamGuard must
be med on the rst run.
2. Never transport the Avi-FoamGuard with the an-return pawl in the up posion! The tubing will become
loose and tangled. Do not aempt to operate your Avi-FoamGuard if there are any coils of tube that are
loose or misplaced. If loose coils of tube are noced aer pulling the tube out, they must be ghtened by
rotang the spool with the pto hand wheel. If this is not possible, pull all of the tube out before
aempng to rewind the tube.
3. Never try to move or relocate the machine if the tube is not fully rewound onto the machine.
4. Never pull the tube o the machine other than by pulling on the foam cart (straight out from the machine).
5. Never run over the tube with any kind of vehicle and avoid pinching or pulling the tube around objects.
Never bend the tube sharper than 25 mes the inner diameter of the tube.
6. If the tube is frequently pulled out only a poron of its complete length the tube remaining on the drum
will become loose. Occasionally it will be necessary to pull all the tube o the drum, leaving only several
coils remaining on the drum, to ghten the remaining coils.
7. Be careful when operang other equipment near the tube. Make sure the tube doesn’t get gouged or
punctured.
8. Avoid rewinding the tube when it is not pressurized. When the tube is not pressurized during rewind the
tube will become aened or egg-shaped and the rewind mechanism will not funcon properly. Keep the
tube pressurized to 100 PSI when rewinding!
Remember, polyethylene tube is semi-rigid and subject to being crimped. The foregoing precauons will reduce the
possibility of kinking or damaging your tube.
P/N 19302390 Revised on 3/1/14, Kifco, Inc.
Timing
Proper ming of the levelwind mechanism is essenal to the successful operaon of the Avi-FoamGuard. A machine
that is not in me will result in miswrapped tube. Timing is the coordinaon between the levelwind fork and the rota-
on of the spool or drum which allows for the ght and neat coiling of the tube on the reel of the unit.
Note: You must verify ming before the rst run of the Avi -
FoamGuard!
Verify Timing:
Step 1 - Make certain the trailer is secured with wheel chocks. Li the An-Reverse Pawl and slide the holding pin
under it to hold the pawl in place.
Step 2 - Pull the tube out 100%. This is
the only me you pull the tube out its
enre length. The elbow to which the
tube is fastened must be 45° behind the
axle center line on the boom of the
spool once the tube is completely pulled
out. Be especially careful not to pull the
tube o the elbow.
Step 3 - Remove the four bolts that hold
the levelwind fork in place and remove
the fork. Observe the posion of the
hose guide carrier drive lug (special hose
guide link) on the secondary chain. (The
chain that runs le to right just in back
of the auto shut o bar). The drive lug
should be in the most extreme posion (half way around the sprocket) and on the same side of the drum as the spool
elbow. When these condions are met, the machine should be in me and ready to wind in (See Fig. 1 below). Fig. 2
illustrates a machine that is not in me.
Machine Must Be Timed
on First Run!
Fig. 1 Fig. 2
P/N 19302390 Revised on 3/1/14, Kifco, Inc.
Timing
Adusng Timing:
Step 1 - Remove the levelwind guard
Step 2 - Remove the 2 bolts on the levelwind input sprocket. Now you can manually adjust the levelwind mechanism by
grabbing the sprocket with a pair of channel locks, holding the sprocket sll and making adjustments unl you see the
drive lug in the correct posion. Once the drive lug is in the correct posion, your machine is in me.
Step 3 - Replace the Levelwind guard and then replace the fork, being especially careful not to have any over-hang on
the chain side of the mounng plate as shown below.
Remove Bolts &
Make Adjustments
Remove Guard
Cauon! Over-hang on the chain side of the mounng plate when replacing
the fork will cause damage to the unit during operaon!
P/N 19302390 Revised on 3/1/14, Kifco, Inc.
Prepare Foam Trolley for Pull Out:
The success of the Avi-FoamGuard system depends a great deal on using the proper pull out and start-up procedure.
Do not aempt to operate the Avi-FoamGuard unl you read and understand the preceding secon tled
"Handling the Polyethylene Tube"! Place the Avi-FoamGuard system into posion with the foam trolley pointed
squarely towards the long axis of the house or area to be foamed. Be especially careful to have the machine square
and in good alignment with the foaming path. Be sure the Avi-FoamGuard is on a level surface. If the machine is
mounted on a trailer; chock the wheels on the trailer to prevent movement while the foam trolley is being pulled out
and retracted.
The following steps are
important!
Step 1 - Li the An-Reverse Pawl.
Once the pawl is up, slide the hold-
ing pin under it to hold the pawl in
place.
Step 2 - Disengage the Gearbox by
pulling the clutch lever out.
NOTE: If the An-Reverse Pawl will not li,
relieve pressure by aaching the pto hand
wheel to the gearbox pto sha and turning it
counterclockwise unl the spool rocks back.
This will take pressure o the pawl so that it
can be lied. Only turn the spool just enough
to release the an-reverse pawl. Over rotang
can cause the coils of tube to loosen. The
gearbox needs to be in high (H) or low (L) gear
for the spool to turn.
Clutch Lever Disengaged
An-Reverse Pawl Lied
Holding Pin
Never pull the trolley out with the gearbox engaged, this will severely damage
the gearbox!!
Aach Hand Wheel - Turn Counter-Clockwise
Set-up & Operaon
P/N 19302390 Revised on 3/1/14, Kifco, Inc.
Step 3 - Firmly pull back on the stop rod to
release the shuto switch.
Stop Rod
Shut O Switch
Step 1 - Hook up to the foam trolley towing
chain with a winch or other means to pull the
trolley into starng posion.
Step 2 - Slowly pull the trolley to the edge of
the trailer and stop.
Step 5 - SLOWLY pull the foam trolley down the
trailer ramp; steady the foam trolley with a rm
guiding hand as it moves down the trailer ramp.
Once the foam trolley is on level ground, begin
to pull at a slow, even pace (40 Feet Per Mi-
nute) unl it has reached the desired starng
point to begin foaming.
Step 6 - Disconnect the foam trolley towing
chain and return to holder.
Step 4 - Temporarily start the retracon
engine . Slowly pull back on the shuto bar to
test the auto shuto feature. This should
acvate the shuto switch and stop the
retracon engine.
Set-up & Operaon
Trolley Pull Out:
P/N 19302390 Revised on 3/1/14, Kifco, Inc.
Trolley Set-Up:
Step 1 - Unlock both Boom Arms and pull
them out to the desired width. Once posi-
oned, lock them into place.
Step 2 - Unlock the Foam Generator Swivel
Locks and aim both generators outward.
Note: The direcon of the generators can be
changed if needed aer observing the foam
applicaon.
Step 1 - Lower the An-Reverse Pawl. NOTE:
The Pawl should always be in the down posi-
on except during trolley pull-out!
Step 2 - Engage the gearbox by pushing in the
Clutch Lever.
Step 3 - Reset the gearbox by rmly pulling out
the stop rod once again. Note: This must be
done before the machine will go into gear.
Prepare for Operaon:
Set-up & Operaon
Step 3 - Open both Foam Generator Valves
(valve handle in the up/down posion - inline
with hose when open).
Step 4 - Secure the Foam Trolley safety chain.
P/N 19302390 Revised on 3/1/14, Kifco, Inc.
Set-up & Operaon
Step 4 - Put the machine in gear by pushing
the gear selecon rod in for high gear or
pulling it out for low gear.
Sanitaon System - Tube Cleaning:
Step 1 - Fill the Sanitaon Tank with the appropriate
soluon.
Step 2 - Open the valve on the Sanitaon Tank.
Step 3 - Place the Sanizer switch on the control panel
into the Automac posion. Note: This allows for the
applicaon of soluon to the tube ONLY during trolley
retracon.
Kifco’s Avi-FoamGuard is equipped with an automac polyethylene tube cleaning and sanitaon opon. As the
tube passes through the hose guide fork, three nozzles will clean and apply sanitaon soluon to the polyeth-
ylene tube as it is rewound onto the spool of the machine.
Prepare for Operaon (connued):
Plumbing Set-up:
NOTE: The Avi-FoamGuard can draw from several dierent water sources: a municipal water main, tanker truck or
holding pool.
Step 1 - Connect the sucon hose/supply
line to the booster pump intake pipe and to
your water source.
Step 2 - Turn on your water supply at the
water source.
P/N 19302390 Revised on 3/1/14, Kifco, Inc.
Set-up & Operaon
Plumbing Set-up (Connued):
Step 3 - Insert the Soluon Wand into the drum or pail of foam
concentrate.
NOTE: The injecon pumps cannot pump into the Intake Pipe if the
pressure of the water source is above 50 psi.
Step 4 - Open the valve to Injecon Pump #1.
Step 5 - Prime the foam soluon into the booster pump intake pipe by turning on the Master Control Switch on the
control panel. The Injecon Pump #1 switch does not need to be in the “On” posion in order for the pump to prime.
Press and hold the Injecon Pump #1 Prime switch unl the foam soluon reaches the booster pump intake pipe and
then release. Do not over prime. Once the soluon has reached the pump intake pipe, stop immediately.
Step 6 - If Injecon Pump #2 is being ulized, open the valve to Injecon Pump #2 and follow step 5 to prime Injecon
Pump #2.
Booster Pump Start-up:
Check the uid & oil levels in the booster pump prior to operaon. If your water source is pressurized, priming
the pump will not be necessary. If your water source has no pressure or ow, you must prime the pump.
Step 1 - Turn the fuel supply on to the Booster
Pump.
Step 2 - Open the choke and turn the key on the
booster pump control panel to start the pump.
Once started close the choke.
Booster Pump Fuel Supply
Choke
Prime
P/N 19302390 Revised on 3/1/14, Kifco, Inc.
Set-up & Operaon
Step 3 - Open the valve on the pump housing and pull the Primer Lever on the booster pump control panel out. This
lever is labeled Pull to Prime. Water will begin to exit the exhaust tube once the pump is primed.
Step 4 - Once water exits the exhaust tube, quickly close the valve on the pump housing and push the Primer Lever on
the control panel back in. Note: The booster pump will start registering pressure when the pump is primed.
Pump Housing Valve
Step 5 - Slowly open the main supply valve allowing water to the unit.
Pressure needs to reach 125 PSI at the reel before water/foam will begin to ow from the generators. In-
crease the Booster Pump engine speed unl the pressure on the reel inlet pressure gauge reaches approxi-
mately 125 PSI.
Exhaust Tube
Main Supply Valve
Booster Pump Start-up:
Step 1 - Turn the fuel supply on to the Retracon
Engine.
Step 2 - Open the choke and turn the key to start
the retracon engine. Once started close the
choke. Let the engine run at an idle speed.
Retracon Engine Start-up:
Check the uid & oil levels in the retracon engine prior to operaon. IMPORTANT: Before starng the retrac-
on engine, conrm the PTO Rewind Switch on the control panel is in the center or o posion.
Fuel Supply
Choke
Speed Adjustment Lever
P/N 19302390 Revised on 3/1/14, Kifco, Inc.
Set-up & Operaon
Step 1 - Once foam reaches the generators, turn both generator valves o.
Step 2 - Turn the supply valve to the handheld nozzle on.
Step 3 - Once the nozzle is in posion, open the valve on the nozzle itself to begin applying foam.
To return to normal foaming, close both valves to the Handheld Nozzle and reopen both Generator Valves.
Applicaon with Oponal Handheld Nozzle
If your unit is equipped with the oponal Handheld Nozzle, the trolley operator can apply foam using the
handheld nozzle to reach the corners of the house. Before using the handheld nozzle, the trolley operator
must rst wait for foam to appear at the generators.
Step 1 - Turn on the Injecon Pump #1 switch on the control panel.
Step 2 - If the secondary tank is being ulized for foam addives, turn on Injecon Pump #2 switch.
With the reel inlet pressure at 125 PSI it will take several minutes for the water/foam soluon to reach the required
consistency and begin to ll house.
Injecon Pumps:
Valve on Nozzle
Handheld Nozzle Supply Valve
Step 1 - Place the PTO Rewind switch on the control panel in the Manual or Automac posion to begin retracon.
Manual Retracon:
When the PTO Rewind switch is set to “Manual” the foam trolley will begin retracng. Retracon can be stopped for
any length of me by moving the PTO Rewind switch to the center or o posion.
Automac Retracon:
When the PTO Rewind switch is set to “Automac” the foam trolley will begin retracng. Retracon can be controlled
by the trolley operator in the “Automac” posion. The operator can interrupt retracon by shung all of the valves
(Foam Generator and Handheld Nozzle) o. When this happens, the electric clutch on the Retracon Engine will dis-
engage and the Injecon Pump(s) will stop. Foam ow and retracon will begin when any of the valves are reopened.
NOTE: The Foam Trolley Operator CANNOT adjust retracon speed. The only funcon the Trolley Operator can
control is stopping and starng trolley retracon. The Retract Stop switch on the control panel will only stop the Re-
tracon Engine. If this is needed, press and hold the Retract Stop switch unl the retracon engine stops.
Begin Trolley Retracon:
NOTE: You do not want to start retracng the trolley unl foam has reached the corners of the house and is the
proper height.
P/N 19302390 Revised on 3/1/14, Kifco, Inc.
Controlling Retracon Speed:
The Avi-FoamGuard dispenses a xed volume of foam per minute. The height of foam achieved in a given area
depends on the speed at which the trolley is retracted. There are two ways to control retracon speed:
throle adjustment or changing gears.
Set-up & Operaon
Speed Adjustment Throle
Throle Adjustment:
To vary retracon speed without changing gears,
simply move the throle on the Retracon Engine,
sliding it to the le for faster speeds or to the right
for slower speeds.
Changing Gears:
If you need to switch from High or Low gear during operaon, move the PTO Rewind switch on the control
panel to the center or o posion. Now you can switch to high or low gear by pushing the gear selecon
rod in for high gear or pulling it out for low gear. Note: It may somemes be necessary to momentarily
bump the PTO Rewind switch on the control panel from the center posion while you are trying to get the
unit to go into the dierent gear. This will allow the gear selecon lever to engage the dierent speed
range of the gearbox. Cauon: Follow these steps precisely! Failure to do so will damage the gearbox!
P/N 19302390 Revised on 3/1/14, Kifco, Inc.
End of Run Procedures
Step 1 - Once the trolley is retracted clear from the
house, move the PTO Rewind switch to the center or
o posion to temporarily stop retracon.
Step 2 - Purge the Avi-FoamGuard system of the
water/foam soluon by turning o the injecon pump
on the control panel. Allow the Booster Pump to con-
nue running water through the system with the reel
inlet pressure remaining at 120 PSI.
Step 3 - Remove the foam wand from the foam con-
centrate drum and place it into a 5 gallon bucket of
water. Press and hold the prime buon for Injecon
Pump #1 to begin drawing water from the bucket to
ush the line. Rell and ush again if necessary.
Step 4 - Close the valve to Injecon Pump #1
Purge the System:
NOTE: It will take several minutes for the system to purge and for water to begin to run clear from the
generators.
Step 5 - Once water runs clear from the generators,
slowly throle down the Booster Pump and turn o
the key. Turn o the fuel to the Booster Pump.
Step 6 - Close the main supply valve.
P/N 19302390 Revised on 3/1/14, Kifco, Inc.
End of Run Procedures
Sanize Unit:
Once the trolley is retracted clear from the house or area being foamed, temporarily stop retracon so the trolley
and unit can be cleaned and sanized before being fully retracted onto the trailer.
Step 1 - Conrm the Master Control Switch on the control
panel is in the “On” posion and place the Sanizer switch
into the “Manual” posion.
Step 2 - Use a pressure washer or garden hose to rinse the
foam and debris from the trolley and unit.
Step 3 - Sanize the trolley and unit with the spray wand on
the sanitaon tank. The pump on the sanitaon tank is an
“on demand” pump. It will begin pumping as soon as the
trigger is acvated. When nished, place the Sanizer
switch on the control panel in the center or o posion and
turn o the Master Switch on the control panel.
Step 4 - Resume trolley retracon by placing the PTO Re-
wind switch in the Manual posion. Slow the Retracon
Engine down and retract slowly. Once the trolley reaches
the shuto bar, the stop rod will acvate the shuto switch
and the retracon engine will shut down automacally.
Note: If the engine fails to shut down, press and hold the
Retract Stop switch on the control panel unl the retrac-
on engine stops. Once stopped, turn the fuel supply
valve o on the retracon engine.
Winterizaon & Storage
Expel Water:
Step 1 - Remove the supply line
from the Reel inlet and allow all
water to drain. Once drained, con-
nect the air supply ng.
Step 2 - Remove the drain plug from
the front of the trolley.
Step 3 - Loosen the 6 bolts that con-
nect the trolley to the supply hose,
but do not remove completely.
Once loosened, water will begin to
expel from the connecon.
Drain Plug
Removed
6 Bolts Loosened
Table of contents
