Rosenbauer FLF 15000 PANTHER User manual

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FLF 15000/1800/500
Panther 8x8 CA-7
© 2014
OPERATION MANUAL
FLF 15000/1800/500 PANTHER
FLF 15000/1800/500 PANTHER
Air Crash Tender
Air Crash Tender
27.02.2014 / Rev. 00 / CSD-TPas

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FLF 15000/1800/500
Panther 8x8 CA-7
© 2014
Table of Contents
Table of Contents
Table of Contents...................................................................... 2
Introduction .............................................................................. 3
Manufacturer and After-Sales-Service Address ....................... 3
List of Conventional Signs........................................................ 4
Technical Data ......................................................................... 6
Technical Description ............................................................ 17
Bracket for Breathing Apparatus ........................................... 23
Switches and Controls in the Drivers Cabin .......................... 25
Operation Elements on the External Control Stations ........... 38
Preparation for Use................................................................ 46
Locker Compartment Doors ................................................... 47
Starting the Drive Engines ..................................................... 48
Engaging the Pump ................................................................ 50
Roof Turret RM 60 C .............................................................. 51
Bumper Turret RM 15 C......................................................... 57
Undertruck Nozzles ................................................................ 62
Manual Pump Operation ........................................................ 63
Stand-by Operation ................................................................ 66
Tank Suction Operation.......................................................... 67
Drafting Operation from Open Water Source........................ 68
Hydrant Operation / Supply Operation .................................. 70
Foam Operation ..................................................................... 72
Watch out during Pump Operation ........................................ 73
Disengaging the Pump System ............................................... 74
Handline Operation................................................................ 75
Twin Agent Rapid Intervention System................................... 76
Rapid Intervention System ...................................................... 78
Filling the Water Tank via the Pump...................................... 81
Filling the Water Tank via Tank Supply Lines ....................... 82
Filling the Foam Compound Tank ......................................... 83
Light Mast Operation ............................................................. 87
Dry Powder Unit .................................................................... 88
Compressed Air Supply .......................................................... 90
Emergency Control of Electro Pneumatic Solenoids ............. 90
Emergency Control of Pneumatic Actuators .......................... 92
Emergency Adjustment of the Foam Proportioning Rate....... 94
Flushing after Foam Operation.............................................. 95
Drainage of the Pump System / Operation in Cold Climates. 97
Inspection Procedures ............................................................ 99
Maintenance Procedures...................................................... 103
Service Procedures ............................................................... 105
Problems and their Solutions ............................................... 115
Repetitive Test Cycle for Electrical Components ................. 116
Hints for Disposal................................................................. 117
Annex
Safety Precautions
Piping Diagram

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FLF 15000/1800/500
Panther 8x8 CA-7
© 2014
Introduction
FAHRZEUGTYPE
VEHICLE TYPE
BAUJAHR
YEAR OF CONSTR.
FAHRGESTELL
CHASSIS
AUFBAU
SUPERSTRUCTURE
Feuerwehrtechnik
Fire Fighting Technology
Rosenbauer International
Aktiengesellschaft
Hersteller
Manufacturer
Nr./No.
Hersteller
Manufacturer
Nr./No.
MOTOR
ENGINE
Hersteller
Manufacturer
Nr./No.
A-4060 Leonding, Paschinger Str.90
Austria 085165-001
Introduction
This operation manual is designed to provide clear answers to
essential questions concerning the operation and maintenance of
this product.
To ensure continuous operational reliability, we strongly recom-
mend that all service, inspection and maintenance work listed in
this manual be carried out on time.
Forthispurpose,Rosenbauerservicestationsareatyourdisposal.
ATTENTION !
Please read this manual carefully before starting operation.
Obey all instructions and hints.
Only personnel familiar with this manual, the vehicle, inclusive
equipment, according operation, local safety regulations and
accident prevention may operate this unit.
Rosenbauer is not liable for any injury or damage caused by
personnelunfamiliarwiththeoperationalproceduresdescribedin
this manual, failing to comply with the operation manual and/or
failing to comply with regulations, subsequent procedures, safety
and accident prevention.
For more information kindly contact the Rosenbauer After Sales
Service Department or your nearest Rosenbauer representative.
Manufacturer and After-Sales-Service Address
Rosenbauer International Aktiengesellschaft
P.O.Box 176
A-4021 Linz
AUSTRIA
Telephone No.: 0043 / 732 - 6794 - 0
Telefax No.: 0043 / 732 - 6794 - 312
e-mail: [email protected]
Internet: www.rosenbauer.com
Works Order Number
Identifying the works order number is important.
Itisstampedatthetypeplateonthe"Superstructure" platelocated
near the co-driver entrance.
Works order number of your vehicle
X 2 S 0 1 6 5
ROSENBAUER and its affiliates thank you for your
confidence in our products and is sure that delivered
products will provide quick, reliable, quality service in
the years to come.
Several models whose principal components are identi-
cal are dealt with in this operation manual. Besides, this
includesoptionalfeatures.Yourunitmay therefore differ
from some of the descriptions and illustrations.
Foryourownsafety,useonlysparepartsandaccessories
from Rosenbauer. Use of other products and resulant
injury, Rosenbauer asumes no liability!

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FLF 15000/1800/500
Panther 8x8 CA-7
© 2014
Signs and Symbols
Warning Signs
- This warning sign indicates possible danger to the life and
health of persons involved.
- This warning sign indicates electrical hazards.
- This warning sign indicates fire hazards.
- This warning sign indicates danger of cauterization.
List of Conventional Signs
This sign indicates optional equipment that means:
The described position may not be installed on your unit, but it is
a customer specific installation.
CAUTION !
This warning indicates possible danger to life and health of persons.
ATTENTION !
This warning indicates other dangers.
*
Note: For all valve descriptions DN stands for Internal DiameterDN

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FLF 15000/1800/500
Panther 8x8 CA-7
© 2014
Signs and Symbols
Prohibition Signs
- No smoking
- Handling of open flames is prohibited.
- Keep your distance! Be extremely careful!
Mandatory Signs
- Use ear protection.
- Wear helmet.
- Wear protective eye glasses.
- Wear protective work boots.
- Wear protective work gloves.
ATTENTION !
All superstructural components (e.g. hinged steps, doors, ladder,
etc.), are to be used for their intended purpose only.
For example:
Jumping out of the crew cabin onto the last step, transportation of
heavyequipmentonahingedsteporfixingropestotheladder,are
all contrary to their intended purpose.

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FLF 15000/1800/500
Panther 8x8 CA-7
© 2014
Technical Data
ATTENTION !
Always use similar tyres when chang-
ing or replacing a tyre to allow maxi-
mum driving performance!
Itisstrictlyprohibitedtouseretreaded
tyres.
When changing the tyre type call for
written approval from Rosenbauer.
For further technical data please refer
to chassis operation manual.
Technical Data
Chassis
Type: RBI 52.1250 8x8 CA-7 RHD
Engine: 2 x CAT C 18 Tier 3
Performance: 2 x 470 kW at 1800 - 2100 rpm
Voltage of consumers: 24 Volt
Batteries engine I: 2 x 12 Volt / 180 Ah
Batteries engine II: 2 x 12 Volt / 180 Ah
Generator: 2 x 28 Volt / 140 Ampere
Transmission: 2 x Allison 4800 R with Retader
with collectivetransfercase (cTv)
Power Take Off (P.T.O.)
for N 100 pump: on collectivetransfercase
Ratio: nengine x 1.48
Rotating direction: counterclockwise
Performance: 310 kW at 2300 rpm(engine speed)
Wheel base: 1600 mm + 5000 + 1600 mm
Tyres: Michelin 445/80 R 25 XGC
Powered axle: 8 x 8 permanent
Cabin: 1 + 1 + 1 + 1 + 2 men
Dimensions: Length......................... 13100 mm
Width ............................ 3350 mm
Height ........................... 3650 mm
Permissible weight: Front axle I .......................13000 kg
Front axle II............................13000 kg
Rear axle I ........................13000 kg
Rear axle II .......................13000 kg
Gross vehicle weight ..........52000 kg
Ramp angles: Angle of approach ..................... 30 °
Ramp angle .............................. 12 °
Angle of departure ..................... 30 °
ATTENTION !
The vehicle should be operated by
trained and certified personnel.
When driving on inclines, uneven or
slippery roads / surfaces, as well as
duringcuresorexpectingalanechange,
a prudent and precautionary driving
style should be used.
The instructions in the chassis opera-
torsmanualshouldbestrictlyfollowed,
in particular when driving in off-road
conditions.

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FLF 15000/1800/500
Panther 8x8 CA-7
© 2014
Technical Data
Water tank
Manufacturer: ROSENBAUER
Capacity: 15000 l
Maximum tank pressure: 0.2 bar
Material: PP
polypropylene plastic
Manhole: removable ø 450 mm cover
Overflow: 2 x with over- and under pressure
diaphragm
Tank level indicator: fludometer
and visual gauge on the left and
right hand sides
Hydrant fill connection: 2 x DN 65 butterfly valves with 21/2"
BSSmalecouplingsandanonreturn
valve on the tank flange. These
connectionsareontheleftandright
hand sides.
Pump fill connection: DN 50 ball valve
Suction connection: DN 200 butterfly valve
Tank roof: PP with anti-slip coating
Drainage: DN 50 ball valve

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FLF 15000/1800/500
Panther 8x8 CA-7
© 2014
Foam compound tank
Manufacturer: ROSENBAUER
Capacity: 1800 l
+ 5% reserve
Maximum tank pressure: 0.2 bar
Material: PP
polypropylene plastic
Location: integrated into the rear part of the
water tank
Manhole: removable ø 450 mm cover
Overflow: with lamellar case
Tank level indicator: fludometer
and visual gauge placed on the
engines module on the left and right
hand sides
Service valve: DN 65 butterfly valve
Suction connection: DN 65 butterfly valve
Outside fill- /drain
connection: DN 40 ball valve with Storz 38
coupling on the left hand side
Technical Data

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FLF 15000/1800/500
Panther 8x8 CA-7
© 2014
Technical Data
Pump
Manufacturer and type: ROSENBAUER N 100
Performance at tank
suction operation: 9000 l/min at 11 bar
Closing pressure: 13.5 bar
Design: single stage
Pump speed: max. 1800 rpm
Pump shaft seal: mechanical seal
Rotating direction of pump: counterclockwise
Material of casing, bronze
diffusers and impellers: bronze
Operating ability: from -15˚ C to +50˚ C ambient
temperature
Allowed fluids: firefightingwaterordrinkingwater
Fluid temperature
range: from +4 ° to +60 ° C
Tank suction connection: DN 200 butterfly valve
Drafting connection: DN125butterflyvalvewith4"BSRT
male coupling on the left hand side
Pressure outlets: 2 x DN 65 butterfly valves with 21/2"
BSS female couplings;
These connections are on the left
and right hand sides.
Main pump valve: DN 150 butterfly valve
Roof turret: DN 125 butterfly valve
Bumper turret: DN 65 butterfly valve
Untertruck nozzles: DN 50 ball valve
Tank fill line: DN 50 ball valve
Rapid intervention con.: 2 x DN 40 ball valves
Foam drafting- and DN 50 ball valve with Storz C
flushing connection: coupling on the left hand side
Pump drain valve: DN 20 ball valve
Internal flushing valve: DN 40 ball valve
Drive: propeller shaft from cTv

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FLF 15000/1800/500
Panther 8x8 CA-7
© 2014
Technical Data
Pump gearbox for N 100
Manufacturer and type: ROSENBAUER gearbox N 100
Ratio
with reversal of rotation: Z1=64 : Z2=79 -> i=0,81 *
from counterclockwise to clockwise
without reversal
of rotation: Z1=53:Z2=64:Z3=79->itot=0.67
Casing material: light alloy
Priming pump
Manufacturer and type: ROSENBAUER KAP 600
Double Piston Priming Pump
Material: light alloy
Method of operation: displacement
Type of drive: double V-belt via the N 100 pump
shaft
Control: pneumaticallywithmanualcontrol *
electrically with automatic control
Lubrication: oil bath lubrication
Performance of the
priming pump: 100 l to 75% vacuum within 10 sec

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FLF 15000/1800/500
Panther 8x8 CA-7
© 2014
Foam proportioning system
Manufacturer and type: ROSENBAUER RVME 600 MID
Material: light alloy
Measuring range
water flow: 200 - 10000 l/min
foam compound flow: 10 - 600 l/min
Performance: upto600l/minfoamcompoundwith
a viscosity of 10 cSt
Proportioning rate
electronically: adjustable by switches to
3% or 6% or 8%
electronically: * continuously adjustable to
1% - 8% at 1000 - 7500 l/min
1% - 3% at 1000 - 10000 l/min
1% - 6% at 1000 - 10000 l/min
Proportioning accuracy: according to NFPA 1901
from the range of 1-3%: -0 to +30% relative (from adjusted value)
over the range of 3%: max. +1% absolute (to adjusted value)
Technical Data

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FLF 15000/1800/500
Panther 8x8 CA-7
© 2014
Technical Data
Roof turret
Manufacturer and type: ROSENBAUER RM 60 C
Location: mounted on the roof of the cabin
Material: light alloy
Nozzle: HSD 6000 CFD
Performance with
full output: 6000 l/min at 10 bar
reduced output: 3000 l/min at 10 bar
Throwing range: approx. 85 m with full output
approx. 70 m with reduced output
Control: remotely controlled from driver's
cabin
or via cable remote control *
(via programmable CAN BUS
module)
or manually from the vehicle's roof
Slewing range:
Elevation: -15 ° to +70 °
Rotation: 270 °
Options: search lights 2 x 50 Watt / 24 Volt

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FLF 15000/1800/500
Panther 8x8 CA-7
© 2014
Technical Data
Undertruck nozzles
Manufacturer: ROSENBAUER
Number: 3 nozzles in front of the front axle I
Performance: 75 l/min at 10 bar per nozzle
Range: 170 ° , 2 m radius
Number: 1 nozzle between the front axles
1 nozzle behind the front axle II
1 nozzle in front of the rear axle I
1 nozzle between the rear axles
Performance: 50 l/min at 10 bar per nozzle
Range: 360 ° , 3 m radius
Control: all together from drivers cabin
Bumper turret
Manufacturer and type: ROSENBAUER RM 15 C
Location: mounted on the front bumper
Material: light alloy
Nozzle: HSD 1500 CFD
Performance: 1500 l/min at 10 bar
Throwing range: approx. 65 m with full output
Control: remotely controlled from driver's
cabin(viaprogrammableCANBUS
module)
Slewing range:
Elevation: -30 ° to +70 °
Rotation: 180 °
Options: searchlight24Volt/55Watt/H7 *

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FLF 15000/1800/500
Panther 8x8 CA-7
© 2014
Rapid intervention system
Manufacturer and type: ROSENBAUER
low pressure hose reel 06
Material: ABS/PE plastic
Brake: friction brake
Rewinding device: manually by crank
and electrically
Location: in the right locker compartment
swivelableby45 ° and90 ° indriving
direction
Nozzle: RB 101
Performance: 115 - 230 - 360 - 475 l/min at 7 bar
Equipment: with a 30 m DN 32 non-collapsible
rubber hose
Technical Data
Rapid intervention system
Manufacturer and type: REELCRAFT 2400 Series
Twin-Agent Hose Reel
Brake: mechanical brake
Rewinding device: manually by crank
and electrically
Location: in the left locker compartment
Nozzle: Twin-Agent nozzle
Performance with
water/foam discharge: 230 l/min at 15 bar
dry powder discharge: 2.3 kg/sec
Equipment: with2x30mDN25non-collapsible
rubber hose

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FLF 15000/1800/500
Panther 8x8 CA-7
© 2014
Technical Data
Dry powder unit
Manufacturer: MINIMAX
Type: P-BCsv 500 (2x250) epn
Dry powder: 2 x 250 kg Combi Troxin BC
compatible to foam compound
Control: electro-pneumatically
Propellant gas bottle: 25 ltr
Propellant gas: nitrogen
Filling pressure: 200 bar
Number: 1 + 1
Powder outlet:
Rapid intervention
installation 2.5 kg/sec
For further information please refer to
manufacturer's operation manual.

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FLF 15000/1800/500
Panther 8x8 CA-7
© 2014
Deluge system
Manufacturer: ROSENBAUER
Capacity: connected to the water tank
Drawing connection: DN25 ball valve on the front lowest
partition of the water tank
Deluge pump: 24 VDC
Nozzle: 4 nozzles above the windscreen
1 nozzle above the left and right
doors
Light mast
Manufacturer and type: FIRECO CS 8518 NZ
Location: in the right engine's compartment
Search lights: 4 x 43 Watt LED / 24 Volt
Lifting height: approx. 6.0 m above ground
Control: electropneumatically and
via remote control
Power supply: from drive engine's generator
Technical Data

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FLF 15000/1800/500
Panther 8x8 CA-7
© 2014
Technical Description
Technical Description
Pump
The pump consists mainly of the pump pressure casing, impeller,
pump shaft, diffuser, and pump shaft sealing.
The water penetrates the impeller via the suction inlet. This
process is called axial feed, since the water flows in the direction
of the central axis.
The water which enters through the suction inlet is then seized by
theimpeller(impellerblades);therebythewaterisdeflectedby90 °
andflung out ofthe impeller inthedirection verticallytothe shaft.
This is called radial discharge.
The water delivery depends mainly on the effect of centrifugal
force, therefore this type of pump is called a centrifugal pump.
Between the impeller and the diffuser, there is a small gap and the
diffuser, fixed on the pump casing, is stationary. The gap is
necessary in order to prevent the impeller and diffuser from
touching.
The energy of a streaming liquid is composed of velocity and
pressureforces andthe energyof velocitycan betransformed into
pressure. The water is discharged from the impeller at high
velocity and this transformation of velocity into pressure takes
place in the diffuser.
The cross sectional area through which the water passes from
entering the diffuser until leaving it, is enlarged gradually. The
velocitydecreaseswhilethestreamingquantityremainsunchanged.
Thepipecrosssectionsaredimensionedastobelargeenoughthat
the proportion of the velocity of the total energy at the pressure
outlet of the pump is so small that it can be ignored in comparison
to the proportion of pressure. Therefore only the suction lift of the
pump (which is the sum of the indications on the manometer and
vacuummeter) is mentioned.
Be certain that the pump is not operated with closed valves for a
long period; a temperature increase results.
Disengage the pump if no water is discharged for a long period!
ATTENTION !
Itisstrictlyprohibited tomakeanymodificationsonpumpwithout
approval of ROSENBAUER.

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FLF 15000/1800/500
Panther 8x8 CA-7
© 2014
Technical Description
Pump
The Rosenbauer pump N 100 is a single-stage high volume pump
with spiral casing and diffusor.
Becauseofthelownominalpumpspeed,thepumpisbestsuitedfor
direct connection (without a pump gearbox) to a low rpm engine,
therefore a dramatic reduction of noise and harmful emission is
achieved.
The hydraulic dimensioning and the high efficiency makes a very
flat pump-curve with a differantial pressure between rated- and
close off pressure of only 2 bar at constant output. Based on the T-
typesuctioncover,thepumphasverycompactdimensionsandcan
be integrated into pipework very easily. The stainless steel pump
shaft is supported on the suction side by a cylinder roller bearing
and on the pressure side by a taper and a ball bearing.
A maintenance free axial face seal seals the pump on the pressure
side and on suction side two shaft seals are installed.
The pump shaft is directed through the suction cover and ends in
a belt drive to drive auxiliary units.
Thecentrifugalwaterpumpwithdiffuserandimpelleraremadeof
corrosion resistant light alloy or bronze.
pump shaft
pump casing
impeller suction cover
Drive and gearbox
The pump is powered by a separate pump engine. If necessary, a
pump gearbox delivers the required capacity by a set ratio in
relation to the engine speed and output capacity. If necessary, the
pump gearbox is equipped with a separate cooler whereby dis-
charged water cools down the gearbox oil.
The pump system works completely independent of the drive
engine,thereforeallowingunlimiteddrivingoperationduringfire
fighting.
drive flange brake for propeller shaft
pump gearbox

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FLF 15000/1800/500
Panther 8x8 CA-7
© 2014
Technical Description
Priming system KAP 600
Sinceacentrifugalpumpisnotaselfsuctionpump,aprimingpump
system is installed, which removes air from the pump allowing the
subsequentvacuumtofillthepumpwithwater.Thepistonpriming
pump is mounted with a pivot on the suction cover. It is driven by
two V-belts and a belt tightening device. The priming pump has to
be engaged only for the priming procedure.
The housing and the pistons are made of corrosion resistant light
alloy. The cylinder liners are made of stainless steel.
Two pistons, provided with sealing and guide rings, are fitted
together in a single unit. This double piston is driven by a sliding
pad, which is driven by an eccentric shaft.
Themoving parts areoilbath lubricated andsuctionand pressure
valves are concentrically arranged in the cylinder heads (valve
covers).
Computing maximum lift
Liftis measured fromthe surface ofthe
static source to the centerline of the
pump. The height of possible lift is not
affectedbytheangleofthe intakehose,
but depends on the vacuum that the
pump(primingpump)canproduceand
the atmospheric pressure.
Theoretically, at sea level a pump can
lift water 10 m (33.8 feet). A perfect
vacuum is impossible with a fire pump
andtherewillbe loss duetofriction,so
the maximum lift is nearer to 6 - 7.6 m
(20 to 25 feet).
The height that water can be lifted
decreases with altitude by about 0.3 m
(1 foot) for each 300 m (1000 feet) of
elevation.
The weather also affects drafting, but
to a smaller degree.
priming pump
Working principle:
Upon engaging the priming pump (**) the ball valve mounted in
the suction line will be opened. At the same time, the V-belts for
driving the piston priming pump are tightened by a pneumatic
cylinder. The priming pump now has approximately twice the
speed of the centrifugal pump.
The rotating eccentric moves the piston to and fro. By the move-
ments of the piston the vacuum (priming stroke) and simultaneous
pressure (pressure stroke) are produced. The diaphragm-design
valves are concentrically placed in the suction covers. The pump
system is evacuated and water is forced into the water pump.
As soon as water is discharged from the piston priming pump the
primingprocedureiscompleted(**).Thesuctionvalveclosesand
the V-belts are released from tension via a pneumatic cylinder.
When the water column breaks, this procedure is to be repeated.
** As an option the priming pump is controlled automatically.

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FLF 15000/1800/500
Panther 8x8 CA-7
© 2014
Technical Description
Cutaway view of piston priming pump
Pumpengehäuse
Pump Housing
Ventildeckel
Valve Cover
Absaugleitung
Priming Line
Ausstoßöffnung
Exhaust Line
Ausstoßöffnung
Exhaust Line
Saugventilplatte
Suction Valve Plate
Druckventilplatte
Pressure Valve
Saugventilplatte
Suction Valve Plate
Ventildeckel
Valve Cover
Druckventilplatte
Pressure Valve
Absaugleitung
Priming Line
Exzenter
Eccentric