Rosenbauer FOX User manual

Operation manual
FOX (4th generation)
Portable fire pump
Item number: 11033A-003
Release: 04/2017 (Rev.02)
Language: English
Abbreviation: JWin

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Table of contents
1 Legal notice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.1 Copyright . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.2 Manufacturer and customer service address. . . . . . . . . . . 4
2 Declaration of conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.1 Declaration of conformity . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.1 Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.2 Liability and injury . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.3 Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.4 Use of the operation manual . . . . . . . . . . . . . . . . . . . . . . . 8
3.4.1 Validity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.4.2 Signs and Symbols . . . . . . . . . . . . . . . . . . . . . . . . . 8
4 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4.1 Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4.2 Markings and warning signs . . . . . . . . . . . . . . . . . . . . . . . 10
4.3 Other regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4.4 Training and qualifications . . . . . . . . . . . . . . . . . . . . . . . . . 11
4.5 General safety instructions . . . . . . . . . . . . . . . . . . . . . . . . 12
4.6 List of conventional signs. . . . . . . . . . . . . . . . . . . . . . . . . . 13
4.6.1 Meaning of the warning signs . . . . . . . . . . . . . . . . . 13
4.6.2 Meaning of the prohibitory signs . . . . . . . . . . . . . . . 15
4.6.3 Meaning of the caution signs. . . . . . . . . . . . . . . . . . 16
4.7 Warning notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
5 Product description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
5.1 Area of application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
5.1.1 Requirements for supply facilities . . . . . . . . . . . . . . 25
5.2 Designation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
5.3 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
5.4 Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
5.5 Carrying frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
5.6 Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
5.7 Priming pump Professional . . . . . . . . . . . . . . . . . . . . . . . . 29
6 Technical description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
6.1 Valves and actuators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
6.2 Display unit pilot lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
6.3 Governor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
6.4 Optional equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
7 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
7.1 Preparation for initial operation . . . . . . . . . . . . . . . . . . . . . 45
7.2 Preparation for start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

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7.2.1 Positioning the portable fire pump . . . . . . . . . . . . . 46
7.3 Starting the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
7.3.1 Switch on ignition . . . . . . . . . . . . . . . . . . . . . . . . . . 48
7.3.2 Starten mittels Elektrostarter (Ausführung Arma-
turenbrett AR1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
7.4 Priming from an open water source . . . . . . . . . . . . . . . . . 50
7.4.1 Activate drafting operation from open water source 51
7.5 Hydrant operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
7.6 Monitoring during operation . . . . . . . . . . . . . . . . . . . . . . . 54
7.7 Switching off the engine . . . . . . . . . . . . . . . . . . . . . . . . . . 55
7.8 Flush/drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
7.9 Transporting the portable fire pump . . . . . . . . . . . . . . . . . 58
7.9.1 Manual transport. . . . . . . . . . . . . . . . . . . . . . . . . . . 58
7.9.2 Transport by means of the transport wheels (option-
al) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
7.10 Tilting the engine cover . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
7.11 Fuelling and refuelling: . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
7.11.1 Fuelling operation when engine is running . . . . . . 62
8 Servicing and cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
8.1 Engine component overview. . . . . . . . . . . . . . . . . . . . . . . 64
8.2 Service plan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
8.2.1 Oil change interval . . . . . . . . . . . . . . . . . . . . . . . . . 68
8.2.2 Inspection procedures . . . . . . . . . . . . . . . . . . . . . . 68
8.2.3 Checking for signs of leakage. . . . . . . . . . . . . . . . . 69
8.2.4 Lubrication service . . . . . . . . . . . . . . . . . . . . . . . . . 70
8.3 Lubrication chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
8.4 Torque list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
8.5 Inspection procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
8.6 Service procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
8.6.1 General guidelines for handling electronic compo-
nents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
8.6.2 Storage and transport . . . . . . . . . . . . . . . . . . . . . . . 86
9 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
9.1 Faults and their solutions - pump . . . . . . . . . . . . . . . . . . . 87
9.2 Faults and their solutions - engine . . . . . . . . . . . . . . . . . . 88
10 Environmental protection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
10.1 Disposal of hazardous substances . . . . . . . . . . . . . . . . . . 90
11 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
11.1 Noise measurements . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
12 List of spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
12.1 List of spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
13 List of abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96

Legal notice
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Copyright
ORIGINAL OPERATION MANUAL
1 Legal notice
1.1 Copyright
All rights to this manual and its attachments lie with Rosenbauer
International AG.
The documents are only entrusted to the recipient for their personal use.
Reproduction, reprinting (electronically or mechanically), translations in
other languages or all other duplication, also of parts of the manual, are only
allowed with written permission.
Information from this manual may not be passed on to or made accessible
to third persons, in particular competitors.
1.2 Manufacturer and customer service address
Rosenbauer International AG
Paschinger Strasse 90
4060 Leonding, Austria
The Rosenbauer customer service department or one of our worldwide rep-
resentatives will gladly assist you if you need further information.
Telephone: [phone] - 0
Fax: [phone] - 312
Email: [e-mail]
Internet: www.rosenbauer.com

Declaration of conformity
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Declaration of conformity
2 Declaration of conformity
2.1 Declaration of conformity
According to EC Machinery Directive 2006/42/EC, Annex II, part 1A
Herewith declares Rosenbauer International AG
Fire fighting technology
A - 4060 Leonding, Paschinger Str. 90
Address: Postbox 176, 4021 Linz, Austria
Telephone: +43 (0)732 / 6794-0
that the portable fire pump for fire fighting operations
Type FOX portable fire pump (4th generation)
Serial number PC116
complies with the following regulations:
1) 2006/42/EC - EC Machinery Directive
2) 2014/30/EU - Directive on the harmonization of regulations relating to
electromagnetic compatibility
3) ECE R10 - Electromagnetic compatibility for vehicles
The following harmonized standards (or parts thereof) have been ap-
plied:
1) EN 14466:2005+A1:2008, ÖNORM EN 14466:2005+A1:2008, DIN
EN 14466:2005+A1:2008
2) EN 1028-1:2002+A1:2008, EN 1028-2:2002+A1:2008
3) EN 55012:2007+A1:2009, EN 61000-6-2:2005, EN 61000-4-2:2009,
EN 61000-4-3:2006+A2:2010, EN 61000-4-4:2012, EN 61000-4-
6:2014, EN 61000-4-8:2010

Introduction
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Preface
3 Introduction
3.1 Preface
You must read this operation manual in full before starting the portable fire
pump.
Also observe the documents of the corresponding manufacturers supplied
in addition to this manual.
All personnel who will operate and maintain the portable fire pump must be
qualified (see training and qualification).
The operation manual is to be stored carefully (for later reference).
3.2 Liability and injury
Due to the information in this manual Rosenbauer fundamentally accepts
no liability for direct damage or consequential damage, which arise from in-
correct operation or maintenance, as well as by unauthorised changes of
components or this manual.
The product may only be operated by persons who are familiar with the
manual, the product as well as the national laws, guidelines and regulations
pertaining to work, safety and accident prevention.
Rosenbauer assumes no responsibility for injury to persons or material
damage, which are caused by untrained personnel, also through non-com-
pliance with the regulations regarding work, safety and accident prevention.
If this manual contains a technical error or a typographical error,
Rosenbauer reserves the right to make change at any time and without no-
tice.
This manual may contains figures and descriptions, that are not built into
the delivered product.
No claims may be made for products that have already been delivered from
the information, figures and descriptions in this manual.
For your own safety only use spare parts and accessory products from
Rosenbauer. Rosenbauer accepts no liability for the use of other products
and the resulting damage!
Check the delivery immediately for transport damage and completeness.
• Faults and damages must be documented in writing immediately.
• Photograph damaged components.
• Send written damage report to the manufacturer - see chapter "Manu-
facturer and customer service address".

Introduction
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Identification
3.3 Identification
Identifying the serial number is important when referring to the manufactur-
er in regards to spare parts and technical issues.
The serial number of the portable fire pump is located on the operator side,
facing away from the area of the engine frame, on the chassis type plate.
►Enter the serial number of the portable fire pump in the table.
PC116L

Introduction
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Use of the operation manual
3.4 Use of the operation manual
3.4.1 Validity
This manual contains information needed for the operation of the product.
This manual contains descriptions of special equipment as well as some
abstractions and exemplary illustrations. The actual equipping of your prod-
uct may therefore differ in part from the descriptions and illustrations.
3.4.2 Signs and Symbols
Highlighted Text
To simplify legibility and clarity, there are marked various pieces of informa-
tion.
These symbols indicate the following meaning:
►Perform action in the hierarchy to be maintained as described.
Reactions to the actions performed (results).
•Lists.
Further Information about this topic.
Notes for additional information to operate the unit.
Read/obey additional information in the manufacturer documentation.
Figures
Where necessary, the text is illustrated with drawings. A caption is provided
below the illustration. The reference from the text to a position within the il-
lustration is given by inserted figures (e.g. S1).

Introduction
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Use of the operation manual
Warning notices
The safety information warns the user of risk and informs them how these
risks can be avoided.
Safety information stands at the beginning of a chapter before handling in-
structions from which a dangerous situation can occur. Further safety infor-
mation is found at the start of this manual.
Safety instructions that must be followed without fail are highlighted as fol-
lows:
DANGER!
This symbol warns of an extremely dangerous situation, in which non-
observation of the danger warning will lead to death or serious irreversible
injury.
WARNING!
This symbol warns of a dangerous situation, in which non-observation of
the danger warning can lead to death or serious irreversible injury.
CAUTION!
This symbol warns of a dangerous situation, in which non-observation of
the danger warning can lead to slight reversible injury.
NOTICE
This symbol warns of situations, in which non-observation of the warning
can lead to material damage.
Additionally the information in the operation manual in the “Technical data“
chapter and the safety information in the supplier documentation supplied
must be observed.

Safety
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Intended use
4 Safety
4.1 Intended use
The portable fire pump:
• may only be used in fire fighting operations
• may only be used with drinking water and fire fighting water (wastewa-
ter-
capable)
• may only be operated under supervision
• must not be permanently installed in fire vehicles
• is not suitable for use in areas with explosion hazards
proper.
4.2 Markings and warning signs
Safe use is only possible, if all necessary information for a safety operation
are observed. These informations are especially including safety- and
warning instructions.
In addition to the instructions in this operating manual read and observe all
the safety- and warning signs affixed to the product.
►Replace missing or damaged signs.
►Keep the safety- and warning signs clean and legible.
4.3 Other regulations
In addition to this manual the relevant national legislation, regulations and
directives in the latest version are to be observed (e.g. guidelines for per-
sonal protective equipment, road traffic regulations, country-specific train-
ing regulations for the fire department, accident prevention guidelines, fire
department duty regulations, occupational medicine and technical environ-
mental rules, country legislation for fire and disaster protection).

Safety
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Training and qualifications
4.4 Training and qualifications
Operator errors caused by inadequate qualifications can cause serious ac-
cidents or jeopardise the success of the operation. Safe operations can be
assured only when operation and consistent maintenance of the product is
performed exclusively by specially trained personnel.
Only qualified training by experienced firefighting experts and continuous
practice of operating procedures ensure safe operations.
A one-off briefing is not enough!
The portable fire pump may only be operated by persons who have suc-
cessfully completed training as a machine operator in firefighting (fire trucks
/ fire pumps).
Persons without qualified training may not operate the product.
The operator is responsible for defining responsibilities and supervision of
personnel as well as for adequate instruction and training according to ap-
plicable regulations.
Even during operation, make sure that persons without technical knowl-
edge never operate the product.
Personnel must exhibit physical and mental aptitude. Minors and persons
without qualified training may not operate the product.
Modifications and conversions to the product may be performed only with
written authorisation from Rosenbauer and must be performed by a manu-
facturer-authorised person.

Safety
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General safety instructions
4.5 General safety instructions
The following instructions give an overview of how the product is used safe-
ly. This general overview will be supplemented by the safety instructions in
the individual chapters.
Take note of general danger possibilities that could occur when handling
machines.
Use the prescribed personal protective equipment.
Make sure that the product corresponds to the respective valid safety reg-
ulations and the local fire departments guidelines and is always ready for
use.
On contact with dangerous chemicals (e.g. dry powder) make sure that the
manufacturer's safety datasheets and information is followed.
Dry powder and foam compound can endanger the environment.
►Do not dispose of dry powder and foam compound in bodies of water
or in the sewage system.
Foam compound and dry powder in particular are very corrosive.
►Carefully clean the product of extinguishing agent residue after every
operation.
When working inside the water or extinguishing agent tank, always ensure
good ventilation and ensure the safety of this work by having an additional
person outside the tank.
Should emergencies occur where people are injured, appropriate first aid
measures must be taken and, if necessary, emergency personnel are to be
called to provide professional treatment.
Observe the operation and maintenance manuals of additional products.
If you cannot rectify faults yourself or repairs cannot be performed by spe-
cially trained workshop personnel, Rosenbauer or the nearest Rosenbauer
service partner must be contacted immediately.

Safety
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List of conventional signs
4.6 List of conventional signs
4.6.1 Meaning of the warning signs
Danger from electricity.
Impending risk of explosion.
Risk from oxidising materials.
Risk of harmful or irritating materials.
Impending risk of explosion.
Impending acid burn risk.
Impending hearing damage.
Risk of inhalation of toxic vapours.
Risk from hot fluids and vapours.
Risk from hot surfaces.

Safety
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List of conventional signs
Impending crushing risk.
Danger from high pressure.
Threat of environmental contamination.
Impending shearing risk.
Impending risk of tripping.
Risk of hand injury.
S

Safety
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List of conventional signs
4.6.2 Meaning of the prohibitory signs
Handling fire and naked flames forbidden!
Do not touch or reach in!
Do not stay in the danger area!

Safety
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List of conventional signs
4.6.3 Meaning of the caution signs
Use hearing protection.
Wear safety goggles or a safety mask.
Wear a protective helmet.
Wear protective gloves.
Wear a protective suit.
Maintain distance.
Special caution.
Observe environmental protection.

Safety
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Warning notes
4.7 Warning notes
DANGER!
Danger of fatal injury or health hazard due to inhalation of toxic
exhaust fumes!
Combustion engines working in enclosed areas build toxic exhaust fumes.
Is there the need of working in enclosed areas, obey following:
Extract the exhaust fumes outside using exhaust hoses.
Make sure for adequate ventilation.

Safety
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Warning notes
WARNING!
Danger of injury and accidents!
Danger of injury and accidents due to malfunctioning or improper used
safety devices!
Do not override safety and protective devices.
Do not manipulate or render safety and protective devices.
Check safety and protective devices for proper function.
Danger of shearing in the area of the extinguishing equipment!
Body parts can be cut off.
Do not linger in the danger zone.
Personal injuries and damage to property can occur due to a
restricted view of movable machine parts.
Do not linger in the danger zone.
Follow the training and operation manual.
Mortal danger or serious injuries can arise through failure to use
protective equipment.
Wear protective equipment.
Potentially fatal injuries due to the engine taking in flammable gases!
Do not operate the engine in areas with a heavy concentration of
flammable vapors such as e. g. diesel, gas or propane.
When handling flammable liquids and gases, always shut off the
engine immediately.
Danger of crushing and sheering of limbs due to moving or rotating
parts!
Do not reach into or grasp moving or rotating parts.
Observe a safety distance to the danger zone.
Use protective equipment.
Potentially fatal injuries and danger of explosion!
Danger of explosion occurs at operation of the unit in explosive areas..
Do not operate the unit in explosive areas.

Safety
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Warning notes
Explosion risk from flammable fuel!
When working on fuel systems the fuel may ignite and cause life-
threatening injuries..
Do no smoke.
Keep fuel away from naked flame.
If you are handling fuel keep a fire extinguisher to hand.
Danger of serious injury and damage due to explosion, fire and
chemical burns!
When charging vehicle batteries, a highly explosive electrolytic gas mixture
(hydrogen and oxygen) is released; it is easily flammable and may release
highly acidic battery acid.
Wear safety goggles whenever servicing a battery.
Follow safety instructions on the outside of the battery.
Do not smoke.
Avoid fire, open flame and sparks.
Avoid sparks when handling cables and electrical devices, and through
electrostatic discharge.
Do not connect the minus pole of the battery jumper cable near to the
discharged battery (generates sparks).
Always remove negative battery ground cables first and install them
last to avoid sparks.
The vehicles must not touch (sparks will occur on connecting the
positive poles).
Never short-circuit the battery.
Ventilate batteries thoroughly before any external start.
When connecting the connecting lead, do not bend over the battery.
Avoid skin and eye contact with any battery acid that escapes.
Keep unauthorized persons clear of the battery.
Ensure that the battery voltage matches.
Never disconnect the batteries while the engine is running.

Safety
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Warning notes
Serious injury to persons and damage due to water hammer effect!
If water delivery via a pipe or hose is interrupted abruptly, a pressure impact
known as the water hammer effect occurs; this is noticeable as a harsh
noise (like a hammer hitting a pipe). This water hammer can cause severe
injury when handling fire-fighting equipment, as well as damage to lines,
hoses, pumps, valves or other pieces of equipment.
Perform adjustments of nozzles, hydrants, valves etc. slowly.
Before opening a discharge outlet, keep a tight hold on the tips and
nozzles.
Before uncoupling a hose, relieve the pressure.
In case of danger for persons (e.g. due to a burst hose) immediately
reduce the pump speed or close the affected discharge outlet. Switch
off the pump system if needed.
Danger to life from electric shock!
Water, fire fighting foam and metallic components conduct electricity.
Do not point turrets or nozzles (extinguishing agent jet) directly at high-
voltage lines or other electrical installations.
Observe the safety distance from voltage-carrying parts at all times.
Foam ban for firefighting involving electrical systems.
Do not handle or use metal ladders near high-voltage lines or other
electrical installations.
Safety distance with C/HP-nozzle for fire fighting on low-voltage systems
Voltage Extinguishing sys-
tem Extinguishing agent Safety distance
up to 1 kV C-nozzle Water spray jet, dry powder,
extinguishing gas
1 m (3 ft)
C-nozzle Full water jet 5 m (16 ft)
HP- nozzle Full water jet 5 m (16 ft)
Safety distance with C/HP-nozzle for fire fighting on high-voltage systems
Voltage Extinguishing sys-
tem Extinguishing agent Safety distance
1 kV - 380 kV C-nozzle Water spray jet, dry powder,
extinguishing gas
5 m (16 ft)
C-nozzle Full water jet 10 m (32 ft)
HP-nozzle Full water jet 10 m (32 ft)
Water turret Full water jet 30 m (98 ft)
Water spray jet 10 m (32 ft)