PyroLance L 1000 W-P Technical Manual PyroLance · 6140 S. Gun Club Road · Ste. K6-270 · Aurora, Colorado 80016 USA +1 303.952.5018 · www.pyrolance.com 01-030-20131211 Unit Serial Number ______________________________________
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PyroLance L 1000 W-PTechnical Manual
PyroLance · 6140 S. Gun Club Road · Ste. K6-270 · Aurora, Colorado 80016 USA
+1 303.952.5018 · www.pyrolance.com01-030-20131211
UnitSerialNumber ______________________________________
Table of Contents
2
Unit Specification Nameplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Example of Required Personal Protective Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Material Safety Data Sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2 A Quick Look at How the System Works . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3 System Component Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Plumbing Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Electrical Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Uncrating and Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Installation Procedures and Initial Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
User-Required Installation Material and Labor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Compartment Mounting Installation Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
General Installation Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
5 Making Sure Everything is Working Right . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
6 Transmitter Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Set-Up Transmitter and Receiver Programming . . . . . . . . . . . . . . . . . . . . . . . . . . 20
7 Operation Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Start-up Operation of Power Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Normal Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Emergency Mode Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Recommendations for Selected Materials in Penetration/Cutting . . . . . . . . . . . . . . . . 27
8 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Nozzle Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Replacement of Nozzle and/or Nozzle Retaining Nut . . . . . . . . . . . . . . . . . . . . . 28
Lance Nozzle Hose Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Replacement of Remote Control Signal Transmitter Battery . . . . . . . . . . . . . . . 30
Replacement of Faulty Control Nozzle Mounted Transmitter Unit . . . . . . . . . . 30
Preventive Maintenance Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Pump Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Winterization (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Table of Contents
3
9 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Pump and Plumbing Problems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Lance Nozzle Problems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Electrical Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Anti-Freeze Loading Problems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Hose Reel Problems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
10 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Exploded Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Udor Pump Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Flow Schematic and Major Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Power Unit Electrical Schematic. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Switch Panel Electrical Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Reel Controller Electrical Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
APPENDIX: COMPONENT LITERATURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
4
Unit Specification Name Plate
PYROLANCE North America LLC
6140 S. Gun Club Road
Ste. K6-270
Aurora, Colorado 80016 USA
Phone: +1-303-952-5018
Web Site: www.pyrolance.com
SPECIFICATIONS
PUMP MFGR & MODEL: Udor #GKC-38-20-SH
PUMP FLOW & OPERATING PRESSURE: 10 gpm (40 L/min) 2000 PSI (135 Bar)
UDOR HYDRAULIC PUMP: 20 gpm (80 L/min) 3000 PSI (204 Bar)
REXROTH HYDRAULIC MOTOR: RPM x 2.75 ÷ 231 = flowPump flow rate: 45 cc (2.75 cubic inch)Pump pressure: 2250 PSI (153 Bar)Pump standby pressure: 200 PSI (13.5 Bar)MAX RPM: 2600
FUEL TYPE: No Fuel Required
ABRASIVE: PyroShot 2.5 Gallons (9 L)
DATE OF MFG: 10-1-11 SERIAL NO: L 1000 W-P-10012001-001
5
L 1000 W-P Unit Specifications
Nominal Pump Flow 10 gpm (40 L/min) at pump
Nominal Pump Maximum Pressure 2000 PSI (135 Bar) at pump
Nominal Nozzle Pressure & Flow 1400 PSI at 10 gpm (95 Bar at 40 L/min)
Udor Hydraulic Pump Flow 20 gpm (80 L/min)
Udor Hydraulic Pump Pressure 2200 PSI (153 Bar)
Rexroth Hydraulic Motor Flow rate: 45cc (2.75 cubic inch)Pressure: 2250 PSI (153 Bar)Standby pressure: 200 PSI (13.5 Bar)MAX RPM 2600
Hydraulic Reservoir Capacity 35 Gallons (130 L)
Installation Environment Fire Apparatus Vehicle, exposed or compartment
Remote Controls Line of site, radio frequency control
Water Inlet Pressure Limits 0 PSIG (Atmospheric Pressure) from water tank
Cutting Abrasive Requirements Use only PyroShot abrasive
Nozzle Diameter 0.090“ (2.29 mm)
Cutting Time (per tank of abrasive) Approximately 4 Minutes
Overall Unit Dimensions (L x H x D) 34”L x 26”H x 24”D (914 mm x 660 mm x 610 mm)
Hose Length 150 ft (45 m) x 3/4” (19 mm) x 3125 PSI/215 Bar
Power Unit Weight (Dry) 400 lbs (184 kgs) approximate
Lance Weight 17 lbs (8 kgs) approximate
1 Safety
6
Before attempting to operate or install the PyroLance unit, read all ofthese safety precautions and follow carefully.An ultra-high pressure fire pump system is inherently powerful and potentially hazardous equipment; however,with the proper care and understanding of the instructions, such firefighting units can be operated effectivelyand safely.
A PyroLance firefighting unit must only be operated by qualified personnel who have completelyread and understood this PyroLance Manual.
This manual is intended to reinforce and review safety techniques. It is recommended that qualified userscomplete extensive firefighting exercises prior to placing a unit in service and practice refresher exercises on anannual basis.
It is strongly recommended that this entire instruction manual be reviewed in depth before operating ormaintaining this equipment. Service work should only be performed by individuals who have read and completelyunderstood the operations manual.
1. Always wear eye protection
2. Always wear full personal protective equipment (PPE) for nozzle operator
3. Always inspect hoses and couplings prior to use
4. Observe a minimum of 15 feet (4.6 m) safety radius around the nozzle operator
5. Keep away from exhaust and hot engine components
6. Always ensure pressure vessel cap is de-pressurized prior to removing the cap for filling or
service work
7. Always ensure pressure vessel cap is secure prior to operation
8. Only use ‘PyroShot’ as an abrasive material
9. Follow this Instruction Manual regarding winterization, draining, and protection of the hoses,
pump, and entire plumbing system when exposed to temperatures under 32 degrees F / 0
degrees C
10. Check oil and lubricant levels prior to operation
11. Do not operate equipment unless operator has read this installation and operation manual!
DANGER: Never direct a piercing nozzle at any person or animal.
DANGER: Never direct a water stream towards an electrical power line.
Safety
7
Example of Required Personal Protective Equipment
Helmet andHead Protection
Full BodyStructural Clothing
StructuralGloves
Face Shield or Goggles
WARNINGPyroLance North America is not responsible for damages resulting
from a failure to comply with instructions in this manual.
Please read carefully before use.
Ensure a safe sweep area of at least 15 feet (4.57 m) in any direction while operating the PyroLance nozzle.
Seek immediate medical attention if any unprotected part of thebody comes in contact with the high pressure water stream. Seriouspersonal injury can result from an untreated water injection wound.
Safety
Material Safety Data Sheet(This MSDS Complies with 29 CFR 1910.1200) Date of Issue: December 2006
Section 3 - Physical and Chemical Properties
Physical State: Solid Appearance and Odor: Red, Pink, Whitish Grains or
Powders Odor Threshold: No odor Vapor Pressure: Not Relevant Vapor Density (Air = 1): Not Relevant Specific Gravity (H2O = 1): 3.9 - 4.1 pH: Not Relevant Water Solubility: Not soluble in waterOther Solubilities: Not RelevantBoiling Point: Not RelevantMelting Point: 1,315º C (2,399º F)Viscosity: Not RelevantMean Refractive Index: 1.77 - 1.79Evaporation Rate: Not Relevant
Section 4 - Fire Fighting Measures
Flash Point: Non-flammable solidFlash Point Method: Not RelevantLEL: Not RelevantUEL: Not RelevantFlammability Classification: Not RelevantExtinguishing Media: Use appropriate extinguishing
media for surrounding fire.Unusual Fire or Explosion Hazards: None
Section 5 - Stability and Reactivity
Stability: StablePolymerization: Polymerization can not occur.Chemical Incompatibilities: one knownHazardous Decomposition Products: None known
Section 6 - Health Hazard Information
Acute Effects: (Effects of overexposure)Inhalation: Dust may cause irritation of nasal and
respiratory tract.Eye: Dust may cause irritation.Skin: May cause abrasions.Ingestion: No known effects, however ingestion not
recommended.
Medical Conditions Aggravated by Long-Term Exposure:Chronic respiratory disease may be aggravated byexposure to nuisance dust.
Emergency and First Aid ProceduresInhalation: Remove to fresh air, if breathing is difficult
administer oxygen, obtain medical assistance, if needed.Eye Contact: Flush with large amounts of water, obtain
medical assistance, if needed.Skin Contact: Thoroughly wash exposed area with soap
and water.Ingestion: Obtain first aid or medical assistance, if
needed.Primary route(s) of entry: Inhalation, Skin Contact
Section 7 - Spill, Leak, and Disposal Procedures
Spill / Leak ProceduresSpills: Sweep or vacuum up material for disposal or
recovery.Disposal: Dispose of in accordance with local, state and
federal regulations. Material contaminated in use mayrequire special disposal requirements.
Section 8 - Exposure Controls / Personal Protection
Ventilation: Provide sufficient mechanical (General and/orLocal Exhaust) ventilation to maintain dust exposurebelow threshold limit value (TLV).
Respiratory Protection: If needed use a NIOSH/MSHAapproved dust respirator, cartridge, or mask.
Eye Protection: Recommend federally approved safetyeyeglasses.
Protective Gloves: As desired by user.
Section 9 - Special Precautions and Comments
No special precautions necessary for normal handling andstorage of the material.
The information set forth herein is believed to be accuratebut is not warranted with respect to the accuracy of theinformation or recommendations. Recipients are advisedto confirm in advance of need that the information iscurrent and applicable to their circumstances and usage.
Section 1 - Chemical Product and Company Identification
Product/Chemical Name: Garnet Abrasive Grains and PowdersChemical Formula: (Fe, Mg)3 Al2(SiO4)3CAS Number: 1302-62-1Other Designations: Almandite and Pyrope GarnetGeneral Use: Industrial AbrasivesManufacturer/Distributor: Barton Mines Company, L.L.C., 1557 State Route 9, Lake George, NY 12845
Phone: (518) 798-5462 (7:30 am-5:30 pm EST), FAX: (518) 798-5728Emergency Phone: (518) 798-5462 or (518) 251-2296 or (518) 798-5510
Section 2 - Composition / Information on Ingredients
ACGIH TLVIngredient Name TWA CAS Number % Wt
Primary Ingredient: Almandite and Pyrope Garnet 10 mg/m3 l302-62-1 94 - 99.6%Total Dust
Trace Impurities: 0.4 - 6% misc. trace minerals consisting of Hornblende, Magnetite, and Feldspar.
F
0H 1 0 R
––
NFPA
2 A Quick Look at How the System Works
9
The PyroLance ultra-high pressure system allows theoperator to attack fire from a safe and defensive exteriorposition without a firefighter entering the interior of astructure or aircraft.
The PyroLance system allows the rapid piercing of theouter structure with high-pressure water and abrasive,enabling an exterior attack on the involved structure,vehicle or aircraft. Once the outer structure ispenetrated, the PyroLance then sprays ultra-highpressure mist into the thermal layer which cools theinterior, dropping the temperature from 1,500ºF(2,732°C) to 200ºF (93°C) in a matter of seconds.
The system is extremely effective on closed structuresincluding marine applications, aircraft, buildings,basements, attic spaces, roofs, floors and other areaswhere firefighting and rescue activities are difficult anddangerous to carry out. In addition, the PyroLancesystem has the unique ability to attack the fire in itsthree-dimensional gaseous phase thereby reducing thepotential for flashover or back draft conditions.
The system consists of a portable, high-pressure nozzle(referred to as the Lance in this manual) and a gasoline-powered, high-pressure pumping unit. The Lance useselectronic control signals to remotely activate the powerunit. The unit is typically supplied with a high-pressureattack hose located on an electric rewind hose reel. Pen-etration and cutting is accomplished with a specially for-mulated abrasive (PyroShot) that will not rust and isenvironmentally safe. The proper combination of Pyro -
Shot is automatically mixed with the high-pressure waterstream from a 2.5 gallon (9 L) abrasive vessel. The entireabrasive operation is controlled by the unique inductionsystem.
The unit is equipped with many features to maintain op-erator safety while operating with nozzle pressures inthe 1400-1500 PSI range.
Water mist systems operate on the principle ofgenerating very fine droplets of water and deliveringthem to the fire zone. The advantage of this is that watermist can be very effective at fire suppression due to itshigh specific heat and latent heat of vaporizationcoupled with the increased surface area, allowing fasterheat absorption. The majority of the energy absorbed bywater in heating occurs during the phase change fromliquid to gas.
There are a number of complex interactions that occurbetween water mist and fires, which can lead toextinguishment. The three primary mechanisms ofextinguishment are heat extraction, oxygen depletionand radiation blocking, with secondary mechanismsinvolving air dilution and kinetic effects such as reducedflame velocity.
PyroLance benefits from more modern delivery systems,both in terms of pump units as well as nozzles. In addition,we can apply the “wetting” agents far more efficientlyand concentrate not only on the fuel phase of the fire,but also the gaseous phase. This all gives a new meaningto the very old phrase – where there is smoke, there is fire!
How the System Works
3 System Component Description
10
#1) 600 lb Slide Out Tray(optional)
#2) 20 ft x 1¼” FlexibleClear Water Supply Hose
with Stainless Steel Clamps
#3) 10 ft x #4/0 Red and Black Battery Supply Cable with
#4) Abrasion-resistant Plastic Conduit
#5) High-amp Fuse Block and Fuse
#6) Hannay Hose Reel
#7) Reel Electrical Boxand Wiring
System Component Description
11
#8) 150 ft x ¾” Ultra High Pressure Booster Hose
(Attached to Booster Reel)
#9) Lance Nozzle with Quick Connect Coupler
#10) 15 ft. x ¾” Ultra High Pressure Hose
with Female Swivel Couplings (Power Unit-to-Reel)
#11) Tank-to-Pump Installation Kita) Manual Ball Valve – Electric optional
b) Cable Harness with Connectors
3-Way Electric Ball Valve – OPTIONAL
#12) Hydraulic Motor Couples to Water Pump
#13) Hydraulic PumpCouples to PTO
System Component Description
12
The following components are supplied separately fromthe power unit:
� 1. One (1) 600 lb. (270 kg) slide-out tray(Optional).
� 2. One (1) 20 ft (6 m) x 1¼” (31 mm) length ofvery flexible clear plastic hose with stainlesssteel clamps shall be provided for connectionfrom the power unit to the fire apparatuswater tank. (Cut length as needed.)
� 3. One (1) 10 ft (9 m) length of #4/0 red and blackbattery power supply cable, with an Deutzfemale connection end of the cable. Theconnections at the battery must be supplied bythe installer.
� 4. One (1) abrasion-resistant plastic conduitprotection shall be installed over the batterysupply cable. Plastic wire ties are provided formechanical securement of the cable along thechassis frame area.
� 5. One (1) high-ampere fuse is provided and mustbe mounted near the battery location.
� 6. One (1) electrically operated Hannay hose reelwith roller assembly and bolts for mounting.
� 7. One (1) electrical cable assembly with protectiveloom between the power unit and hose reelelectrical boxes, including electrical fittings forconnection to the boxes.
� 8. One (1) 150 ft (45 m) x ¾” (19 mm) length of3125 PSI (215 Bar) ultra-high pressure boosterhose fitted with quick connect high-pressurecoupling on the nozzle end and NPT threadcoupling on the reel end of hose.
� 9. One (1) Lance nozzle equipped with a quickconnection coupling assembly.
� 10. One (1) 15 ft (5 m) x ¾” (19 mm) length ofultra-high pressure hose to supply the hose reelfrom the power unit. This hose will beequipped with female swivel JIC threadedcouplings.
11. Tank-to-pump-line installation kit:
� a) One (1) 1¼” (31 mm) manual two-way valve(standard – electric optional). Included with thisvalve is a 20 ft (6 m) length of wiring harnessfrom the PyroLance module to the valvelocation with plug-in connectors. (Optional)
� b) Included with the valve shall be 1” nipples andTee fitting to the anti-freeze winterizationsupply connection. (Optional)
� 12. One (1) hydraulic pump – couples to waterpump.
� 13. One (1) hydraulic pump – couples to PTO(Optional).
� 14. One (1) 35 gallon (130 L) hydraulic reservoir(Optional).
Anti-Freeze(Winterization) Tank
Hose Reel
Power UnitRear View
Bulkhead Panel
Water Supply Tank
Winterization Valve
Color keyColumn 1 Column 2
Blue Water SuctionRed Pressure to ReelGreen Anti-Freeze SuctionBlack Supply Line to Power Unit
Vehicle Installation GuidePlumbing Connections
Anti-Freeze(Winterization) Tank
Hose Reel
Power UnitRear View
Bulkhead Panel
Water Supply Tank
Winterization Valve
Color keyColumn 1 Column 2
Blue Water SuctionRed Pressure to ReelGreen Anti-Freeze SuctionBlack Supply Line to Power Unit
Vehicle Installation GuidePlumbing Connections
Water Supply Connection
"Out" to Hose Reel (High Pressure)
Battery Positive - 12 Volt
Battery Negative - 12 Volt
(OPTIONAL)
Two-Way Electric Banjo with 1-1/4” Fittings
(OPTIONAL)
(Optional)
(Optional)
4 Installation
13
Winterization Valve
Rear
Vehicle Battery Source (12V)Reel Control Box
Hose Reel
Reel Rewind SwitchSwitch Panel
(Winterization Valve)
Bulkhead Panel
Vehicle Installation GuideElectrical Connections
Black to chassis ground
Whi
te
Red
Bla
ck to
cha
ssis
gro
und
Red
Brow
n
Black to battery ground
Bla
ck to
bat
tery
gro
und
Red from battery positive
Red
from
bat
tery
pos
itive
Red
to re
el m
otor
Bla
ck to
bat
tery
gro
und
Two-Way Electric Banjo with 1-1/4” Fittings (Optional)
Two-waymanual standard
(Optional)
(Optional)
Installation
14
Installation
15
Planning
Uncrating and LiftingOpen the shipping crate with care and inspect theequipment for any damage. If found, immediatelycontact PyroLance and the shipping company. In theunit, you will find a sealed instruction sheet outliningsteps to contact PyroLance. If the unit cannot be installedimmediately, leave it in its crate and provide adequateindoor storage to protect the unit against damage.
The L 1000 W-P power unit should be lifted from thetop, such as with a forklift. Four (4) nylon lifting straps(each rated for 500 to 1000 lbs (225 to 450 kg) may beused for lifting, with two straps on each side of the unit.
Installation Procedures and InitialPreparationAfter the unit is uncrated and lifted from its shippingcontainer, immediately ensure the following isperformed prior to installation:
1. Fill the transfer case of the pump with theappropriate gear oil. (See link to Pump Manuallocated in Appendix A)
• Type of gear oil: Udor Lube Premium PumpOil or SAE30W Non-Detergent Oil
• Quantity of gear oil: 10 oz. 90 wt. gear lube
2. Fill the pump gear drive with the appropriategear oil. (See link to Pump Manual located inAppendix A)
• Type of gear oil: Udor Lube Premium PumpOil or SAE30W Non-Detergent Oil
• Quantity of gear oil: 40 oz.
User-Required Installation Materialand LaborThe installation kit is provided with the PyroLance powerunit to assure the user that few if any additionalmaterials are required. However, due to the hundreds ofvarious types of fire apparatus and body compartmentsthat could be encountered around the world, a user mayneed to supply additional hose or equipment for aproper installation.
The installer should contact PyroLance directly foradditional materials or information when problemsarise.
Installation Requirements from the Apparatus
1. The PyroLance unit shall be supplied from theapparatus water tank, with a 1¼” (31 mm) tank topump supply line (see installation kit). Most fireapparatus have an existing tank-to-pump line tothe main fire pump OR a “sump” in the bottom ofthe water tank with a threaded 3” (75 mm) NPTplug. The installer needs to connect to one of theselocations for water supply.
2. Water tank shall be at least 100 Gallon (480 L)capacity.
3. Battery connections for the electrical supply to the#4/0 electrical cable.
Installation
Compartment Mounting InstallationGuidelines1. Compartment provisions and requirements:
a) Clearance of the compartment dooropening must be a minimum of 40” wide(1016 mm) x 36” (914 mm) high.
b) The inside width of the compartment mustbe a minimum of 48” (1220 mm) wide x 48”(1070 mm) high.
c) Adequate door opening and interiorcompartment clearances for electrical andwater lines must be provided.
2. Installation location must be a level surface, ableto safely and completely support the unit weight.The compartment floor shall be rated to carry aminimum of 750 lbs (340 kgs) of weight.
3. Orient the unit to allow unrestricted access to thecontrol panel and abrasive vessel located on thefront of the unit (control panel must face outwardtowards the operator position).
General Installation Guide The following installation and mounting procedure isfor either an exterior-mounted location or acompartment-mounted application.
After installation as described above, for either theexterior or compartment location mountingprocedures, the following steps should be taken:
1. Determine installation location with respect toload-carrying capacity and compartmentrequirements (as previously outlined).
2. Install 1¼” (31 mm) tank-to-pump supply hosefrom apparatus water tank to the power unit.
a) Install 2-way manual valve (2-way banjoelectric balve optional).
b) Connect to the fire apparatus water tank,then to the inlet fitting with a 1¼” (31 mm)inside diameter hose.
c) Locate the inlet fitting under the bottom ofthe tank to ensure a flooded suction line.
d) Install 10 Gallon (40 L) anti-freeze headertank. (Optional)
e) Water quality found in domestic watersupplies or fire hydrant water is sufficientfor normal operation. The PyroLance is NOTdesigned to pump water from an unfilteredwater source.
3. Install the 12 volt electrical battery supplyconnection from the apparatus battery box to thepower unit. The Deutz male battery plug isprovided on the power unit and the femalereceptacle shall be installed on the supply cable.The cable and abrasion-resistant loom shall bemechanically secured during installation to protectthis cable. The fuse protection shall be installed atthe battery location.
4. Install the Hannay booster reel as desired. It isrecommended the reel be installed within 10 feet(3 m) of the power unit since only 15 ft (4.57 m) ofelectrical wiring and hose is provided. If over 10feet from the power unit, the installer mustprovided additional hose and electrical cable.(Note: these may be ordered on the PyroLance website if desired.)
PLEASE NOTE: Hose reel must be installed at ahigher point than the top of the pressure vessel.
5. Install ultra-high pressure hose and electrical cablebetween power unit and hose reel.
6. Connect hydraulic supply and return line from PTOto pump (allow adequate movement of hose toextend unit slide tray).
16
Pump inlet must be below the tank bottom
Water Level
Pump Inlet Location
5 Making Sure Everything is Working Right
17
Preparing the Unit for OperationThe following checklist should be completed in advance,so that the unit is always ready for immediate use. Thisshould be completed on a weekly schedule and/or aftereach use.
1) Check the pump oil. (Download Udor PumpManual – refer to the Appendix.)
2) Check and clean the water inlet strainer.
To inspect and clean this strainer, followthis procedure:
a. Shut off the two-way valve (turn to the anti-freeze ON position). (OPTIONAL)
b. Unscrew the filter bowl (turn counterclockwise) and carefully remove the filterassembly.
c. Remove the internal stainless steel strainerassembly (be careful not to damage the finemesh strainer).
d. Inspect the strainer and flush any debriswith clean water.
e. Push strainer back into filter housing.
f. Re-install the water filter bowl assemblycarefully, threading the unit in a clockwiserotation by hand. Tighten the assembly andcheck for leaks after the valve is opened.
g. Open the 2-way anti-freeze/water tankcontrol valve to the water tank ON position(optional). (Optional 3-way to accommodatethe antifreeze tank.)
3) Lubricate the couplings on the end of the reelhose and Lance nozzle connection to the hose.
4) Connect the Lance nozzle to the hose.
1) On the female half of the coupling, alignthe slot with the pin.
2) Slide the collar back over the pin.
Pull and Inspect Strainer
Filter Location
Align slot with pin on female half; slide collar back over pin.
Making Sure Everything is Working Right
3) Insert the male coupling half and pushtogether firmly until connected.
4) Release the collar and then rotate the slotaway from the pin.
7) Fill the abrasive vessel with PyroShot.
The abrasive vessel is located in the front of thepower unit to the right of the control panel (seephotos). The PyroShot abrasive is required for thewater-jet cutting feature of the PyroLance system.
The PyroLance is designed for use with onlyPyroShot abrasive. PyroShot abrasive is packagedin one gallon (3.75 liter) containers and the vesselrequires 2.5 Gallons (9 L) when empty.
The abrasive can be ordered directly fromPyroLance (see the “Replacement Parts” section ofthis manual for ordering information).
To load the abrasive vessel, follow thisprocedure:
a) Verify the power unit is OFF and theEmergency Stop button is depressed.
b) Verify the system is totally DE-PRESSURIZED.To check: cycle the water valve bydepressing the Lance nozzle trigger andverify zero pressure on the abrasive vesselgauge (see photo).
c) Using a 21/8” (54 mm) wrench, remove thefiller plug by turning it counter clockwisefrom the abrasive vessel.
d) Slowly pour 2.5 Gallons (9 L) of PyroShotabrasive into the abrasive vessel. Note thatwater will spill out (or anti-freeze solution)as the abrasive displaces some of the liquidalready in the vessel (this is normal).
e) Rinse the filler plug threads with water andinspect the plug O-ring. Replace O-ring ifworn or damaged.
f) Thread the filler plug into the vessel andtighten by hand until it bottoms. Carefullyuse a wrench to tighten the plug. DO NOTover tighten as this may lead to permanentdamage of the vessel or cap threads.
18
WARNINGAlways verify that the abrasive filler plug
is properly installed before operation.Failure to properly install and tighten
the filler plug may lead to seriouspersonal injury or death.
Use only PyroShot abrasive in the PyroLance. The use of any other abrasive
may lead to equipment damage and/or failure.
Serious personal injury or death may result if the abrasive vessel is openedwhile under pressure. Always verify the abrasive pressure gauge reads ZERO before opening the vessel.
Abrasive Filler Cap
Turn counterclockwise(CCW) to remove cap
Push coupling together; rotate collar away from pin.
Making Sure Everything is Working Right
8) Verify communication between the Lance nozzletrigger and power unit.
a) Verify the Emergency Stop control switch isin the ON position with PTO disengaged.
b) Pull the water trigger and verify activation ofthe throttle solenoid and verify operationon dial of ball valve and LED indicatorlights on receiving unit.
c) While holding in the water trigger, activatethe abrasive switch and verify operation ondial of ball valves.
d) If signalling fails, checkbatteries in transmitterunits and power toreceiving unit (seeMaintenance Section). Orelse, refer to Transmitterand Receiver Programmingsetup on next page.
19
LED Indicator Water Trigger Light / Battery Status Light(flashes 5 times when low)
LED Indicator Lightfor Abrasive Flow
LED WaterRelayLight
LEDAbrasiveRelayLight
6 Transmitter Programming
20
Set-up Transmitter and Receiver ProgrammingTransmitters and receivers must be paired to work together. Before beginning the pairing process, thereceiver must be set up to your desired frequency and digital address. After following the set-up procedure,ensure the receiver is powered on before continuing to the pairing procedure.
Receiver Set-up The unit is shipped from the factory with SEL1 switches in the open positions and the unit is receivingcommands on Address 1/Frequency 1. If you wish to change these default settings, follow theinstructions in the table below.
It is highly recommended that you use all available frequencies BEFORE changing thedigital address of systems. For instance, the first system pairing would be left at thedefault of F1/ A1. The next pairing would be F2/A1. Then continue as follows: F3/A1;F4/A1; F5/A1; F6/A1; F7/A1; F8/A1 (now all frequencies for Address 1 have beenexhausted). The next pairing would be set as F1/A2, then F2/A2; F3/A2; F4/A2; F5/A2;F6/A2; F7/A2; F8/A2. Then F1/A3; F2/A3; F3/A3, etc.
1) Remove power from unit.2) Remove top cover. 3) Select address and/or frequency using table below. 4) Reattach cover and apply power. 5) Address and Frequency Set-Up is now complete.
DIGITAL ADDRESS SET-UP SEL1 Digital Address(SW1-3) SW1 SW2 SW3 1 (default) OPEN OPEN OPEN 2 CLOSED OPEN OPEN 3 OPEN CLOSED OPEN 4 CLOSED CLOSED OPEN 5 OPEN OPEN CLOSED 6 CLOSED OPEN CLOSED 7 OPEN CLOSED CLOSED 8 CLOSED CLOSED CLOSED
FUTURE OPTION SET-UP SEL1 SW4 Unused on this model – leave in open position
FREQUENCY SET-UP SEL1 Frequency(SW5-7) SW5 SW6 SW7 1 (default) OPEN OPEN OPEN 2 CLOSED OPEN OPEN 3 OPEN CLOSED OPEN 4 CLOSED CLOSED OPEN 5 OPEN OPEN CLOSED 6 CLOSED OPEN CLOSED 7 OPEN CLOSED CLOSED 8 CLOSED CLOSED CLOSED
Transmitter Programming
21
Pairing Procedure
The pairing procedure begins by matching the transmitter frequency to the receiver which will befollowed IMMEDIATELY by linking the remote to the receiver, so be sure to have them both readilyavailable.
Note: The Lance/Blitz trigger will be squeezed and released to set up the frequency. Each squeeze andrelease of the trigger will increment the frequency by one. The initial squeeze and release as performedin Step 2 below counts as the first increment and will set the frequency to #1.
Step 1. Select the Lance to be paired and remove one of the AA batteries from the transmitter batterypack.
Step 2. Squeeze the trigger and while holding in, replace the AA battery in the battery pack. ThePower/TX LED will illuminate solid RED. Release the trigger to set to Frequency 1, or, within two seconds,stay in programming mode by squeezing and releasing the trigger the number of times equal to thefrequency you are choosing. So the second squeeze and release takes the transmitter to Frequency #2,the third squeeze and release sets its Frequency to #3, and so on. You will use the TX LED to confirmyour setting. After you squeeze and release the number of times you wish the frequency to be set to,observe the LED. It will blink RED or GREEN up to four times depending on the frequency chosen. Seetable below for clarification:
LED Flashes: Indicates Unit is Operating On: RED – one time Frequency 1 RED – two times Frequency 2 RED – three times Frequency 3 RED – four times Frequency 4 GREEN – one time Frequency 5 GREEN – two times Frequency 6 GREEN – three times Frequency 7 GREEN – four times Frequency 8
Abrasive ON Button(Only active when Safety Button
is also depressed)
Override Button(“Deadman Switch”)
Water ON Button(Only active when Safety Button is
also depressed)
Master/Emergency Stop
7 Operation Instructions
22
Start-Up Operation of Power UnitBefore starting the PyroLance power unit, review allsafety requirements found in Section 3. PyroLance unitscan only be operated by qualified firefighters who haveread and understood this instruction and operatingmanual.
The following steps should be taken in start-upoperations:
1) Operator #1: Verifies the unit has been properlyinspected and is in a total “operational” state.
2) Operator #1: Verifies the Emergency StopButton (see photo) is released by twistingclockwise, which is the ON position.
3) Operator #2: Verifies that the Lance nozzle isproperly connected and water trigger controlactivates the power unit as described above.
4) Operator #2: Should NOT pull the Lance nozzlewater trigger until the hose is unwound to thedesired length. Lock hose reel prior to activatingthrottle to prevent uncoiling of hose on the hosereel drum. The hose will be hard to unroll ifpressurized.
5) Operator #1: Warns personnel that the unit willnow be started.
6) Operator #1:Engages hydraulic PTO in cab.
PLEASE NOTE: The Lance nozzle trigger mechanism isprogrammed to work sequentially.
a) The water trigger must be activated prior to theabrasive switch to allow activation of the abrasiveflow control valve.
b) Operating the abrasive switch prior to activatingthe water control valve will result in zero outputfrom either function.
Discharge CuttingNozzle Assembly
(Lance Tip Assembly)
AdjustableShoulderSupport
Adjustable Grip and Tripod Stand
Foldable RadioAntenna
AbrasiveSwitch
WaterTrigger Trigger
SafetyLever
Operation Instructions
23
Normal Operation
Normal operation of the PyroLance system isdefined as:
a) Operator #1: Power unit control person. Controlof the power unit from the Lance nozzle isaccomplished by a remote-controlled wirelessradio signal. Should a problem develop with thissignal, a manual (emergency mode) can be usedas described later in this section.
b) Operator #2: Nozzle control person who willcontrol flow of water and abrasive via the Lancenozzle water trigger and abrasive switch control.
Normal operation shall be as follows:
1) Normally the Lance nozzle is “pre-connected” tothe hose on the hose reel. The hose will bespooled off the reel to the required length toreach the operating area by Operator #2.
2) Operator #1 will engage the positive latchingdevice on the reel to prevent movement of thereel during operations.
3) Operator #2 will advance the hose and nozzle tothe operating area and place the nozzle shoulderunit against the body.
4) Operator #2 will press the Lance nozzle tip firmlyagainst the target and communicate to Operator#1.
5) Operator #2 will take a firm and stable stancebefore pulling the water trigger.
a) To penetrate the target, pull the watertrigger and activate the abrasive switch.
b) This will activate the power unit and sendhigh-pressure water and abrasive to theLance nozzle.
c) Please note: It will take several seconds forthe abrasive to travel the length of the hoseand begin penetrating the targeted object.
d) Penetration time will be minimized if theLance nozzle tip is held steady.
Safety Trigger Engaged
Safety Trigger Disengaged
Operation Instructions
6) After the target object has been penetrated, de-activate the abrasive switch while continuing todepress the water trigger. The target has beenpenetrated when the external spray stops.
7) The duration of water flow into the fire will varyand is determined by many factors such as:
a) Type and size of the fire
b) Enclosure size.
The decision to stop water flow can be based onan internal temperature reading (if thermalimaging equipment is available) or otherestablished practices.
8) Releasing the water trigger will cause the powerunit to go back to idle.
24
External spray is visible during penetration (cutting) of the target.
Little or no external spray is visible after penetration is complete.
Abrasive ON Button(Only active when
Safety Button is also depressed)
Override Button(“Deadman Switch”)
Water ON Button(Only active when
Safety Button is alsodepressed)
Master/Emergency Stop
Operation Instructions
Emergency Mode Operation(Control Signal Failure)NOTE: The Master/Emergency Stop switch must be leftON in emergency mode as well as having the PTO switchin the cab engaged.
Should a problem develop with the control signaltransmission between the Lance nozzle and power unit,the following emergency procedure can be used:
1. Operators #1 and #2 must be in continuous verbalcommunication to operate in Emergency Mode.
2. Operator #2 operating the Lance nozzle andOperator #1 operating the power unit controls.(Reference the troubleshooting section forsuggestions to remedy common issues with Lancenozzle communications.)
3. Operator #1: starts up the power unit asdescribed in the Normal Operations section.
4. Operator #2:
a. Unrolls hose from reel, stands in a visiblelocation to Operator #1, and brings theLance nozzle to the target location.
b. Presses the Lance nozzle tip firmly againstthe target and takes a firm and stablestance.
c. Verbal communication takes place fromOperator #2 to Operator #1 to activate thesystem.
WARNINGThe PyroLance can be operated only
by qualified firefighting personnel whohave completely reviewed all safety,
service and maintenance, operational,installation and other pertinentrequirements of this PyroLance
Instruction and Operational Manual.
The trigger mechanism is programmed towork sequentially; when water trigger isactivated, it will then allow activation of
the Emergency Abrasive Button.
Operating the Emergency Abrasive Button prior to activating the Emergency Water
Button will result in zero output from either function.
25
Operation Instructions
5. Operator #1:
a. Operator #1 simultaneously presses andholds Emergency Water Button andEmergency Override Button to activatepower and send high-pressure water toLance nozzle.
b. While continuing to hold both buttons,Operator #1 then presses and holds theEmergency Abrasive Button to activateabrasive flow.
c. Please note: It will take several seconds forthe abrasive to travel the length of the hoseand begin penetrating the target object.Penetration time will be minimized if thelance tip is held steady. The target has beenpenetrated when the external spray stops.
6. Operator #2: After the target object has beenpenetrated, Operator #2 advises Operator #1 torelease the Emergency Abrasive Button andcontinue to hold the Emergency Water ButtonON, while still continuing to hold the EmergencyOverride Button.
7. Operator #1: On audio command from Operator#2, Operator #1 releases all Buttons so that thepower unit will go back to idle.
Please Note: The flow of abrasive can only bestarted while water flow is ON. Pressing theEmergency Abrasive Button alone will donothing. The Water and Abrasive Buttons areonly active while the Emergency Override Buttonis also depressed.
26
Operation Instructions
Recommendations for SelectedMaterials in Penetration/Cutting The PyroLance has been specifically designed to performpenetration/ cutting operations at a much reducedpressure and flow rate. The unit is optimized for ARFFand structural applications in particular.
1. ARFF
The PyroLance has the capability of penetrating/ cuttingaluminum, composites, structural extrusions, and steel ofvarying thicknesses. Multiple layers of compositematerials (such as those found on 5th generation aircraft)can be penetrated or cut through using the hand-heldLance nozzle in either the static or dynamic mode.
It is possible to penetrate or cut thinner compositematerial by flowing water only, thereby eliminatingcollateral damage to sensitive interior structures and/orequipment and allowing a much safer penetration/cutting environment.
2. Structural
The PyroLance is capable of penetrating most structuralmaterial and cutting through thinner sheeting such asroofing material and coverings. It is important to attackstructural materials at their weakest points, which isnormal for fire service operations. This will enable thequickest penetration/ cutting times and conservevaluable abrasive capacity.
3. Material Penetration/Cutting
a) Brick: Structural brick can easily bepenetrated using abrasive. Cutting of brickcan be more of a challenge using the Lancenozzle dynamically and should only beconsidered as a last resort.
b) Roofing: It is possible to penetrate roofingmaterial very quickly. It is also possible torun ventilation cuts using the Lance nozzlein the dynamic mode while flowingabrasive. Maximum distance between Lancenozzle tip and roofing material should notexceed 3 ft (1 m).
c) Reinforced Concrete: Fairly difficult topenetrate in thicker constructionsdepending on different hardness. Maximumdepth that could be attempted should notexceed 2” (50 mm). Cutting of reinforcedconcrete is not advisable.
d) Cinder Block: It is possible to penetratethrough multiple layers of cinder blockacross internal spacing without anyproblem. Limited cutting of cinder block ispossible but will require substantial use ofabrasive to achieve a proper cutting effect.
e) Mild steel: The difficulty increases with thethickness. It is possible to penetrate mildsteel up to a maximum depth of 1” (25 mm).
f) Aircraft Aluminum: Penetration of aircraftaluminum is easily achieved and can beattempted using water only. Limited cuttingis possible with the use of abrasive onthinner sheets of aluminum.
g) Laminated glass: It is easy to penetrate athickness of up to 1” (25 mm) of laminatedglass quickly. Cutting of laminated glass ispossible using abrasive and limited tothinner panels or windows.
h) Rubber: Rubber can be penetrated fairlyeasily in the static mode. Cutting operationswill be limited depending on the thicknessof the rubber.
i) Wood: Penetrating wood can be a challengesince the more porous the wood is, themore the water will be diverted away fromits path. Cutting wood panels/sheeting ispossible even from a distance of 3 ft (1 m)away while flowing abrasive.
j) Plexiglas: Penetration of Plexiglas is easilyachieved even without flowing abrasive.Cutting of Plexiglas is also possible whileflowing abrasive.
4. Duration of Abrasive Supply
The abrasive vessel has a capacity of 2.5 gallons (9 L) andthe induction rate will allow approximately four minutesof continuous flow of abrasive.
NOTE: After flowing the abrasive, it is imperative to flushthe system and clear the hose of all abrasive prior toshutting the unit down.
Should the nozzle become clogged, it will be necessaryto remove the Lance nozzle from the hose reel and flushthe excess abrasive from the system prior toreconnecting the nozzle.
27
8 Maintenance
Nozzle MaintenanceReplacement of Nozzle and/or NozzleRetaining NutThe hydro jet and nozzle head are wear parts andfrequent replacement should be expected. A wornnozzle will not cut well or give maximum extinguishingeffect. After each use of the PyroLance system, inspectthe hydro jet and nozzle head for wear and replace ifrequired.
Nominal orifice diameter for the PyroLance Model L 1000W-G is 0.090” (2.286 mm). Refer to the replacement partsection of this manual for ordering information.
PLEASE NOTE THE FOLLOWING:
1. Replace the hydro jet when pressure decreases bymore than 350 PSI (21 Bar) from pump dischargepressure of 2000 PSI (135 Bar). Please note: Thiswill require reading the power unit pressuregauge and user must install a test gauge at thenozzle. (Please note: Complete this test withoutthe abrasive flowing.)
2. Replace the nozzle head and washer when anywear is visible.
3. To replace the Lance nozzle tip assembly, thefollowing steps should be performed:
a) Verify unit is OFF and depressurized.Disconnect Lance nozzle from the hose reeland hose.
b) Unscrew the nozzle head, counter clockwisefully and remove.
c) Slide the hydro jet and washer out of thenozzle head.
d) Replace any and all worn parts.
e) Insert the washer and nozzle into the nozzlehead.
f) Thread the nozzle head back onto thenozzle housing and turn clockwise fully byhand until it bottoms. It is not necessary totighten the nozzle head more than handtight.
28
O-Ring Sealing Washer Nozzle HousingBarrel End Hydro JetSeal BushingNozzle Head
1. Unscrew Nozzle Head, CCW 2. Remove Seal Bushing and Hydro Jet 3. Reassemble, Turn Nozzle Head CW
Maintenance
29
Lance Nozzle Hose ReplacementIf the hose shows ANY signs of wear or damage, replaceit immediately and refer to the replacement parts sectionof this manual for ordering information.
The following steps should be performed inthe Lance nozzle hose replacement process:
1) Verify power unit emergency control switch is inthe OFF position.
2) Totally depressurize the entire plumbing system.Check to see if pressure gauges are at zero andremove the plug from the abrasive vessel (seeabrasive vessel fill procedures) to ensure nopressure is trapped in the vessel.
3) Disconnect the Lance nozzle from the hose.
4) Using a 3/16” (4.765 mm) Allen wrench, loosenboth set screws holding the Lance tip to the Lancenozzle barrel.
5) Slide the nozzle housing and hose out of thebarrel approximately 6” (152 mm).
6) While holding the hose firmly, turn the Lancenozzle housing in a counter clockwise directionby hand to loosen and remove (do not discard).
7) Slide the hose out of the Lance barrel.
8) Replace with a PyroLance supplied hose, completewith the proper end fittings.
9) Slide the new hose through the Lance barrel withthe male SAE O-ring fitting first.
10) Thread the Lance nozzle housing assembly ontothe hose and tighten by hand only. Note thatthis fitting uses a straight thread and O-ring forsealing. Do not use any pipe sealant or Teflontape.
11) Slide the Lance nozzle tip back onto the Lancebarrel.
12) Tighten both set screws, turning them inclockwise direction.
1. Loosen Set Screw CCW (2 places)
4. Nozzle Housing removed. Slide Hose out of Lance Barrel3. Hold Hose firm, Twist Nozzle Housing CCW until removed
2. Pull out Nozzle Housing
Maintenance
30
Replacement of Remote ControlSignal Transmitter BatteryThe Lance nozzle uses a battery-powered, radiotransmitter to send control signals to the power unit. Thebatteries should be replaced every six months orwhenever there are communication problems betweenthe Lance nozzle and the power unit.
The control signal transmitter uses two (2) Lithium IonAAA size batteries. (Note that the frequency settings aremaintained in a flash memory during batteryreplacement).
To replace the batteries follow theseprocedures:
1. Using a Philips screwdriver, remove the six screwsholding the cover (see Photo 1 on next page).
2. Remove the cover (see Photo 2)
3. Lift out the transmitter
4. Use a Philips screwdriver to remove one screwholding down the battery cover on transmitterunit.
5. Lift off battery cover from transmitter unit (seePhoto 3).
6. Remove two AAA batteries as shown and replace.
7. Replace battery cover on transmitter unit.
8. Place transmitter unit back into compartment.
9. Replace compartment cover and tighten down sixscrews using Philips screwdriver, ensuring tight fit.
NOTE: BATTERY STATUS LED WILL ILLUMINATESOLID WHEN WATER TRIGGER IS ACTIVATED.BATTERY STATUS LED WILL FLASH WHEN BATTERYSTATUS IS LOW (see Photo 4).
NOTE: DO NOT DEPRESS THE TRIGGER OR CYCLETHE ABRASIVE SWITCH WHILE BATTERIES AREREMOVED. THIS WILL DELETE THE MEMORY ANDREQUIRE REPROGRAMMING OF THETRANSMITTER/RECEIVER UNIT.
Replacement of Faulty ControlNozzle Mounted Transmitter UnitIf it is determined that the remote control Lance nozzlesignal transmitter unit requires replacement, return theentire Lance to PyroLance for repair.
1. 2.
3. 4.
Maintenance
Pump MaintenanceWinterization (Optional)The abrasive vessel, fire pump and plumbing system areequipped with an optional winterization kit whichincludes a filling system and valves to permit theintroduction of an anti-freeze liquid into the completesystem. The anti-freeze kit includes a header tank, 3-waycontrol valve and related plumbing.
The unit must be immediately winterized whentemperatures are below 32°F (0°C) to avoid freezing.Total system displacement is approximately 10 Gallons(40 L), excluding the hose reels.
NOTE: Use only RV type (– 50°F) undiluted anti-freezesolution.
To winterize the PyroLance Power Unit,follow these steps:
STEP #1: Flush Procedure
1. The PyroLance unit should be in the OFF position.
2. Disconnect the Lance nozzle from the hose reel,but leave the hose on the reel.
3. Start the PyroLance unit (with nozzle removed)and simultaneously push the following buttonson the control panel:
a) Emergency Override Buttonb) Emergency Water Buttonc) Emergency Abrasive Button
4. Run the PyroLance unit for 3 to 4 minutes to flushthe entire system of abrasive. Visually check thewater flow from the hose to ensure the water isclear of abrasive. If not, continue to flow wateruntil water is clean.
5. Disengage PTO in cab.
STEP #2: Anti-Freeze Filling Procedure
Following this procedure will ensure all the criticalsystem components exposed to water are filled withanti-freeze solution:
1. Pull out the Emergency Stop Button so that themodule is in the ON position. The electric switchon the pump panel should be moved from theTANK TO PUMP VALVE OPEN position toWINTERIZATION OPEN position.
2. Start the PyroLance unit with Lance removed andsimultaneously push the following buttons on thecontrol panel:a) Override Buttonb) Water Buttonc) Abrasive Button
3. Run the unit until anti-freeze solution isdischarging in full color (without water) out theend of the hose.
31
After Monthly Every 3 Every 6 Every 3Every Use Months or Months or Years or
100 Hours* 200 Hours* 1,500 Hours*
Check nozzle and end nut for wear and replace if necessary XCheck pump oil and add if low 1 XCheck oil level on hydraulic reservoir (every use or once a week) XCheck water strainer XCheck radio battery (located in Lance) XInspect hose for wear or damage 2 XRplace hydraulic oil filter XReplace hoses X* Whichever comes first1 See pump manufacturer’s literature found in the Appendix for additional recommendations. 2 If any damage to the hose is found, replace immediately.
Preventive Maintenance Recommendations
Maintenance
4. Disengage PTO in cab.
5. Quickly re-attach the Lance nozzle to the hoseand then rewind the hose onto the reel.
6. Shut off the anti-freeze valve.
7. Remove the abrasive fill cap and replenish theabrasive into the vessel. The abrasive will displacethe anti-freeze solution in this process (which isnormal). When filled completely, replace theabrasive vessel cap. (Please see the fillingprocedure section of this manual for this segmentto assure proper replenishment.)
8. The unit is now protected against freezing andthe power unit can be returned to the storageposition.
STEP #3: Re-Activation of System for NormalOperations
1. Activate the tank to pump control switch (valvelocated between the apparatus water tank andthe PyroLance power unit) by moving the three-way valve from “anti-freeze open” position tothe “water tank open” position.
2. Start the unit and operate per the Operationsection of this manual.
32
9 Troubleshooting
Hydraulic Pump ProblemsRefer to REXROTH Pump website:www.boschrexroth.com
Pump and PlumbingProblems1. PUMP IS UNDER PRESSURE AND WILL NOT
TURN.a) Check that the bypass/relief valve is not
stuck in the closed position.b) Check that the EZ-Start valve is in operation.
2. PUMP IS CAVITATING OR WATER ISSURGING.a) Check water tank level.b) Check that tank to pump valve is in fully
open position.c) Check that bypass/relief valve is not stuck.d) Check that pump water is not overheating by
observing thermal relief valve discharge port.
3. BYPASS/RELIEF VALVE CONTINUOUSLYCYCLING.a) Check for water leaks in plumbing system.b) Check for blocked water filter strainer.c) Check pump-to-tank valve is fully open.d) Check that KZCO valves operate properly.
Lance Nozzle Problems1. WATER DOES NOT EXIT THE LANCE NOZZLE
UNDER LOAD a) Check if the tank-to-pump valve is open.b) Prime the system.c) Check the water level in the tank.d) Check for leakages in plumbing system.e) Check if the water filter element – remove
and clean.f) Check to see if the Lance nozzle orifice is
blocked.
2. AFTER RELEASING THE WATER TRIGGER,WATER IS STILL GOING OUT OF THE LANCENOZZLE.a) Check for air bubble in the abrasive vessel.b) Stop the engine, with power still ON, and
cycle the water trigger, observe operationfrom the KZCO ball valve indicator dial.
3. PENETRATING/CUTTING OPERATION DOESNOT MAKE HEADWAY.a) Check abrasive level in vessel.b) Check operation of abrasive flow control
valve.c) Check operating pressure on pressure vessel
(loss of more than 500 PSI (35 Bar) willindicate worn-out nozzle).
d) Adjust abrasive flow controller by turningthe adjustment knob a quarter-turn at atime – minimum adjustment to be not lessthan 1½ turns from fully closed.
4. EXCESSIVE SPRAYBACK FROM LANCENOZZLE TIP OR FLARING OF STREAM.a) Check for worn end plate.b) Check for worn nozzle tip.c) Check that end plate is properly secured.d) Check Lance nozzle angle of attack and re-
position to better operating angle.
Electrical Problems1. POWER UNIT IS NOT RESPONDING TO
LANCE INPUTS.a) Check that Emergency Stop control is
released and power is ON.b) Check that batteries in Lance nozzle are
fully charged.c) Check that fuses work in main power unit
electrical box.d) Check that green LED flashes on the remote
control wireless receiver box.
Anti-Freeze LoadingProblems(OPTIONAL)
1. ANTI-FREEZE SYSTEM DOES NOT LOAD ORWORK PROPERLY.a) Check tank-to-pump valve and ensure it is in
the anti-freeze position.b) Check anti-freeze container for contents.c) Check that UHP pump is primed.
33
Troubleshooting
Hose Reel Problems1. THE REEL DOES NOT REWIND.
a) Check if battery is connected. b) Check if the fuse reel electrical box is
operational.c) Check wiring connections in power unit
electrical box and reel electrical box forloose connections.
d) Check the reel rewind button on the frontpanel for proper operation.
34
10 Specifications
35
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2
4
67
8
Lance Pistol Grip Handle
Lance Handle Assembly
DESCRIPTIONPART NUMBERQTYITEMHandle095-45-03-101011Mounting Plate095-45-03-101112Holder, LED095-45-03-101213Antenna_Folding_4in_RP-TNCm 14Bolt_PanHead_10_24x750 25Bolt_PanHead_8_32x500 16Bulkhead_RP-TNCf 17LED_BSI_3mm_Red_MicroPrecision 18
DESCRIPTIONPART NUMBERQTYITEMBolt_PanHead_8-32x5/8 51Bolt_Shoulder_1/4x1/2x10-24 12Spring_11/32x1in 13Spring Roll Pin_1/8x9/16 14Bolt_FlatHead_10-24x3/4 25Bushing_Igus_Trigger Pivot 16Switch_Micro 17Grip/Trigger Housing095-45-02-101018Trigger095-45-02-101219Safety Lever095-45-02-1013110Trigger Guard095-45-02-1014111Spring Keeper095-45-02-1015112Cover095-45-02-1016113
101 4
2
6
9
112
37
138
6
3
52
8
1
4
7
DESCRIPTIONQTYITEMBolt_ButtonHeadSocket_1/4-20x131Bolt_ButtonHeadSocket_1/4-20x1/232Bolt_FlatHead_10-24x1/223Bolt_PanHead_10_24x1/244Bolt_PanHead_4-40x9/1625Bolt_PanHead_8-32x1/266Screw_Set_1/4-20x1/427Bolt_SocketHeadCapScrew_10-24x2-1/248JunctionBlock, 8Wire19LED_BSI_3mm_Yellow_MicroPrecision110RubberBushing_WireSeal512Switch_Toggle_On/Off113Transmitter, RF, Air Eagle114
1014
3
13
5
9
7
4
12
12
8
2
1
2
6
7
1
Specifications
36
Specifications
37
Lance Barrel
Lance Hose Assembly
DESCRIPTIONPART NUMBERQTYITEMBarrell End095-45-04-101111Barrel095-45-04-101012Bolt_PanHead_10_24x750 44NOZZLE, WASHER, PRESSURE SEALING 15NOZZLE, SEAL BUSHING 16NOZZLE, ORING - 907 17NOZZLE, HYDRO JET 18NOZZLE, HEAD 19NOZZLE, HOUSING 110
6 7 21085149
3
Bi-Pod Handle Assembly
DESCRIPTIONPART NUMBERQTYITEMNut_NylonLocking_Thin_250_20 11Bolt_PanHead_250_20x1 250 12SpacingStud_375_16x2_625x1 13Bolt_HangerBolt_375_16 14Upper Clamp095-45-05-101015Lower Clamp095-45-05-101116Knurled Handle095-45-05-101227
4
7
2
3
6
5
1
Specifications
38
FRONT VIEW(DOOR REMOVED)
PUMP ANDMOTOR
KZCO ELECTRIC ABRASIVEAND WATER DISCHARGE
CONTROL VALVES
RADIO RECEIVERUNIT
AIR TO OILCOOLER
2.5 GALLONPRESSURE VESSEL
BYPASSPRESSURE
RELIEF VALVE
Specifications
39
Udor Pump PartsGKC 38/20-S
Maximum Flow ......................10.0 GPMMaximum Pressure .................3000 PSIRated Pump Speed ..............1450 RPMOil Capacity............40 oz. UDOR LUBE
or SAE 30WNon-Detergent Oil
Valve Kit .............................04-KIT UD-3Seal Kit.............................04-KIT UD-12Brass Kit ..........................04-KIT UD-19Plunger Bolt Kit .................04-KIT UD-6Plunger Part # ......................04-1205.34Plunger Diameter........................28 MM
GKC 38/20-S Quick Reference
Revised 10-1-2005
Flow Schematic and Major Components
Tee-
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e-Fi
tting
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Wat
er In
let
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ine
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r
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rtVa
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rV
alve
Ther
mal
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ief
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e
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tric
Bal
l Val
veW
ater
+ A
ggre
gate
Elec
tric
Bal
l Val
veW
ater
Onl
y
Agg
rega
tePr
essu
re V
esse
l
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er O
utle
t
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elie
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raul
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otor Met
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Specifications
40
Power Unit Electrical Schematic
Specifications
41
Switch Panel Electrical Schematic
Specifications
42
Specifications
43
9 - Electrical Wiring DiagramHose Reel
Reel Controller Electrical Schematic
Appendix: Component Literature
44
Electronic versions of all vendor supplied instruction and operating manuals, plus othersupplementary information has been linked in Adobe PDF format.
Udor Pump Pump DrawingModel # GKC38/20-SH Pump Spare Parts Drawing
www.udorusa.com
Hannay Reel Hannay PDF Instruction and Operating ManualModel # E4038-17-18RT/LT H5M www.hannay.com
Hannay Contant Tension Reel Aerial Hannay PDF Instruction and Operating ManualLadder Application (optional) www.hannay.comModel # 818-39-40-205A SRH4M
receiver, Model 38-2000-DC
Receiver/Transmitter Lance Transmitter Data SheetModel # Air Eagle SR 2,4 GHz RF Power Unit Receiver Data Sheet
receiver, Model 38-2000-DC www.bwieagle.com
Cat Pumps Throttle Controller Cat Pumps PDF Instruction ManualModel # 8100 www.catpumps.com/products/pdfs/8100_B.pdf
Bosch Rexroth Pump Bosch Rexroth PDF Operating ManualModel # A10V045 DFR1 (DRG) / www.boschrexroth.com52R (L) VXC62N00
45
WarrantyPyroLance warrants to the original purchaser, eachsystem or other product of its own manufacture, for aperiod of 18 months from the date of shipment fromthe factory or 12 months from the unit being placed inservice, to be free from defects in material andworkmanship under normal use and service. “Normaluse and service” means not in excess of recommendedmaximum speeds, pressures, and temperatures, orhandling fluids not compatible with componentsmaterials, as noted in applicable PyroLance productcatalogs, technical literature and instructions.
This warranty shall not apply to any system or otherproduct that has been repaired or altered, includingthe addition of foam systems or other components thatare not factory-installed, to adversely affect theperformance or reliability of the system or otherproduct.
Neither will this warranty, nor any implied warranty,apply to damage or harm caused by any or all of thefollowing:
(1) Freight damage;(2) Freezing damage;(3) Damage caused by parts and/or accessories or
components not obtained from or approved byPyroLance;
(4) Any consequential or incidental damages,arising from the use of the PyroLance systemand equipment;
(5) Damage due to mis-application, mis-installation and/or misuse; and
(6) Normal wear of moving parts or componentsaffected by moving parts.
The liability of PyroLance under the foregoingwarranty is limited to the repair or replacement atPyroLance’s option without charge for labor ormaterials of any parts upon return of the entire systemor any particular part to the PyroLance factory withinthe warranty period, at the sole expense of thepurchaser, which part shall upon examination appearto PyroLance’s satisfaction to have been defective inmaterial and workmanship.
The liability of PyroLance under any theory of recovery(except any express warranty where the remedy is setforth in the above paragraph) for loss, harm ordamage, shall be limited to the lesser of the actual loss,
harm or damage, or the purchase price of the systemor component part as delivered by PyroLance to thepurchaser.
PyroLance expressly warrants its systems and otherproducts as stated above. There are NO OTHEREXPRESSED WARRANTIES, nor any implied warranties,including implied warranty of merchantability or offitness for a particular purpose. Our warranty is limitedin duration to 18 months from the date of shipmentfrom the factory, or 12 months from the unit beingplaced in service by the original purchaser.
Again, there is no implied warranty of fitness for aparticular purpose or merchantability when thisproduct is put to any other application or use.
No person is authorized to make any representation orwarranty concerning PyroLance’s products on behalf ofPyroLance, or to assume for PyroLance the obligationscontained in this warranty. PyroLance reserves the rightto make changes in design and other changes andimprovements upon its products without imposing anyobligations upon itself to install the same features onits existing products then in process or beingmanufactured.
We would suggest our Web site for additionalwarranty information and use of our “Return GoodsAuthorization” (RGA) requirements.
It is imperative to package all PyroLance componentsproperly, before return shipment including therequired “Return Goods Authorization” forms. SomePyroLance systems and components contain electroniccomponents that may be damaged if improperlypackaged for shipping!
All PyroLance components shipped back to PyroLancewill pass through Quality Control Inspection, and maybe photographed after the box is opened. Thepurchaser is responsible for any physical damageoccurring to PyroLance components at user’s facilityand during shipment back to PyroLance.
PyroLance appreciates your attention in this matter aswe feel it will help us to serve you in a better fashion,while keeping the cost of the PyroLance productcompetitive and providing above-average service andwarranty assistance.
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