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OPERATING AND SERVICING

MANUAL
Portable power pumps EN 14466 PFPN 10 1000
50053 1559 UY 704703 EN 05/09

Contents

Please note

Control elements

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

List of symbols . . . . . . . . . . . . . . . . . . . . . . . . . 17

About this manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


Validity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Highlighted text . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Copyright . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Liability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
State of the art . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4
4
4
4
4
4
4

Conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
After sales . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

For your safety . . . . . . . . . . . . . . . . . . . . . . . . . 7


Proper usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Training and qualification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Emergency starter . . . . . . . . . . . . . . . . . . . . . . 19
Operation
Please note . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Important rules of conduct . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Remove exhaust fumes from the working area . . . . . . . . .
Monitor the water pressure . . . . . . . . . . . . . . . . . . . . . . . . . .
Do not operate without water . . . . . . . . . . . . . . . . . . . . . . .
Frost protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Before starting use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

20
20
20
20
20
20

Activate and switch off . . . . . . . . . . . . . . . . . . 21


To activate the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Before starting the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
To start the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Read the information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


Instruction manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Identifiers and warning signs . . . . . . . . . . . . . . . . . . . . . . . . . .
Other directives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8
8
8
8

Emergency start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

General safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


Exhaust fumes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safe working practice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Media . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Noise emissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Water pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Servicing and care . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8
8
8
9
9
9
9

Switch off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
To switch off the pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
To switch off the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Stopping device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Protection from electrical power . . . . . . . . . . . . . . . . . . . . . . . 10


Never touch live parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Isolate the parts from the supply. . . . . . . . . . . . . . . . . . . . . 10

To activate the pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22


Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Activate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
22
22
22
22

Adjustment and monitoring . . . . . . . . . . . . . . 23


Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Cavitation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Transport and storage . . . . . . . . . . . . . . . . . . 11

Pump operation . . . . . . . . . . . . . . . . . . . . . . . . 25

Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
To carry the portable power pump . . . . . . . . . . . . . . . . . . 11
After transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Intake from open water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25


If the priming device fails . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Storage in the vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11


Refer to other documentation . . . . . . . . . . . . . . . . . . . . . . . 11

Intake from hydrants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Lance operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

To activate the light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Portable power pump EN 14466 PFPN 10 1000 . . . . . . 12

Battery protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Centrifugal pump P 212 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

To clean the light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

PRIMATIC priming device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15


Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

To change a lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Drive engine FIAT FIRE 1242 MPI . . . . . . . . . . . . . . . . . . . . . . 16

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Contents

After use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Centrifugal pump . . . . . . . . . . . . . . . . . . . . . . . 39

Action on the pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Regular operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Action on the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Frost protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Frost protection . . . . . . . . . . . . . . . . . . . . . . . 29

Change the oil in the pump casing . . . . . . . . . . . . . . . . . . . . . . . 39


Check the oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Centrifugal pump and fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Frost protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Dry intake test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40


After the dry intake test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
To pressure test the centrifugal pump with water . . . . . . . 41

Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Programmed servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Troubleshooting
For your safety . . . . . . . . . . . . . . . . . . . . . . . . 30
Technical Helpdesk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
After sales hotline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Possible causes and remedy . . . . . . . . . . . . . . 31


Problems during pump operation . . . . . . . . . . . . . . . . . . . . . . . 31
Problems during engine operation . . . . . . . . . . . . . . . . . . . . . . 33

Jump starting . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Please note . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Jump cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Jump starting procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Engine covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Open the top cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
To remove/fit the rear cover . . . . . . . . . . . . . . . . . . . . . . . . . 42
Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
V-belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Clean the heat exchanger element . . . . . . . . . . . . . . . . . . . .
Emergency starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

42
42
43
43
44
44

Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
To change the oil and oil filter . . . . . . . . . . . . . . . . . . . . . . . .
Throttle control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Spark plugs and ignition system . . . . . . . . . . . . . . . . . . . . . . .
Air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

45
45
45
46
47
47
49

Servicing
Appendices
Please note . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
For your safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exhaust fumes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Media . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Other instructions for safe working practice . . . . . . . . . . .

35
35
35
35
36
36

Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Environmental protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Media . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Frost protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cleaning products . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

37
37
37
37
37

Servicing plan . . . . . . . . . . . . . . . . . . . . . . . . . 38

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Circuit diagram . . . . . . . . . . . . . . . . . . . . . . . . 50
Circuit diagram, part 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Circuit diagram, part 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Declaration of conformity . . . . . . . . . . . . . . . . 52

Please note

GENERAL
Please note

GENERAL
About this manual
Validity

Figures

This manual applies exclusively to the equipment shown on the


front page. The manual contains descriptions of special equipment as well as some abstractions and exemplary illustrations.
The actual equipment may therefore differ in part from the descriptions and illustrations.

Where necessary, the texts are illustrated with figures. Reference


to a figure is made by a figure number in [square brackets]. Capital letters after a figure number, for example [12A] refer to the
corresponding item in the figure.
Copyright

Highlighted text
To simplify legibility and clarity, we have marked various pieces of
information.

All rights to this operating manual and its attachments are owned
by Iveco Magirus Brandschutztechnik GmbH. These documents
are entrusted to the recipient for personal use only.

Sentences that have an arrow at the start contain instructions for


actions.
Complete these instructions in the order in which they appear in the manual.

They may only be copied, reprinted or otherwise reproduced,


even in part, with written consent. The information in this manual
must not be given or made accessible to third parties, particularly
competitors.

The following types of information commence with a hyphen:


Lists
Requirements for the actions described below
Processes that take place after an operation
Descriptions of statuses

Printed in Germany

The information symbol denotes instructions that are a


good idea to ensure that the portable power pump can be
used efficiently and smoothly.
Important text passages that you must follow are highlighted specially:
DANGER
Warns you of direct dangers that can cause serious
injuries or death. The danger text contains instructions to avoid or prevent dangers.
Follow these instructions to the letter.
WARNING
Warns you of risks that can cause serious injuries or
death. The warning text demands safety action to protect the persons concerned.
Follow these instructions to the letter.
CAUTION
Warns you of risks that can cause damage or injuries. The
caution text contains instructions to prevent damage.
Follow these instructions to the letter.

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05-2009

Liability
Iveco Magirus Brandschutztechnik GmbH cannot accept any liability that the information is complete and correct. No claims may
be derived from the content of this manual, in particular no liability can be accepted for damage caused by incorrect operation or
servicing.
State of the art
The information in this manual is state of the art at the time of its
publication.
Publication date 05/2009
Iveco Magirus Brandschutztechnik GmbH reserves the right:
To make changes to the construction and components of the
technical equipment and the device and to use other equivalent components instead of the specified components
without notice in the interests of technical progress.
To change the information contained in this manual.
Any obligation to extend these changes to equipment supplied at
an earlier date is excluded.
The dates shown in the footer show the last amendment date of
the relevant section. Amendments to texts do not necessarily relate to technical modifications. The technical version is therefore
not affected by different dates in the footers.

Please note

GENERAL

Conformity

Abbreviations

The fire-fighting equipment is supplied in perfect technical condition. Only the system supplied by Iveco Magirus Brandschutztechnik GmbH is subject to our declaration of conformity.

DIN = German Institute of Standardisation


EN = European standard
NORM = Austrian Standards Institute
SFV TI = Swiss Fire Service Association, Technical Information
GUV = Statutory Accident Insurance
BGV = Professional Association Regulation

The operation is responsible for any changes, modifications, additional and retrofitted components if this work is not completed
by Iveco Magirus Brandschutztechnik GmbH. This makes the
operator the manufacturer, obliging him to establish that the device conforms to the relevant directives and to supply the requisite documentation.
The portable power pump is designed and built to comply with
the generally acknowledged rules of engineering. The following
relevant standards and directives are among those with which the
equipment complies:
EN 14466: Fire fighting pumps Portable power pumps Safety and power requirements
EN 1028: Centrifugal Pumps
Standards to which reference is made in EN 14466 and EN
1028 and which are required for compliance with them
This portable power pump previously underwent type tests
under DIN 14410-TS 8/8, NORM F 1065-TS12/10 or
SFV TI 01.00-01-Type 2.

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Units
All figures in this operating and servicing manual are in current SI
units.
Conversion factors
1 inch = 25.4 mm

1 mm = 0.039 inch

1 foot = 30.48 cm

1 cm = 0.033 foot

1 mph = 1.609 kph

1 kph = 0.621 mph

1 US gallon = 3.785 litres

1 litre = 0.264 US gallons

1 GB gallon = 4.545 litres

1 litre = 0.22 GB gallons

1 cuft/min = 28.32 l/min

1 l/min = 0.035 cuft/min

1 pound = 0.454 kg

1 kg = 2.2 pounds

1 psi = 0.069 bar

1 bar = 14.504 psi

1 lbf.ft = 1.36 Nm

1 Nm = 0.74 lbf.ft

Please note

GENERAL

Warranty
Details of the warranty are set out in the General Terms and
Conditions of Iveco Magirus Brandschutztechnik GmbH.

After sales
In the event of malfunctions please first refer to the instructions
in the section headed Troubleshooting. Our Technical After Sales
Department will be delighted to help if you have any other questions.
Iveco Magirus Brandschutztechnik GmbH
After Sales
Graf-Arco-Strae 30
D-89079 Ulm
Tel. +49 (0)731 408-0
Fax: +49 (0)731 408-2225
E-mail: magirus.brandschutz.service@iveco.com
Internet: www.iveco-magirus.de

Identification
Whenever you make contact with the manufacturer, please quote the data from the pump model plate [1], engine model plate
[2] or portable power pump model plate [3].
Positions:
Pump model plate on the left-hand side of the pump intake
Engine model plate at the top on the cover of the toothed
belt
Portable power pump model plate on the engine mount next
to the generator

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[1]

Pump model plate (example with German text)

[2]

Engine model plate (example with German text)

[3]

Portable power pump model plate (example with German text)

Please note

FOR YOUR SAFETY


Please note

FOR YOUR SAFETY


Proper usage

Training and qualification

WARNING
The incorrect use of the equipment may cause personal injury. In addition, the portable power pump or
other equipment may be damaged.
Only use the portable power pump as described in this manual.
Only use the portable power pump for fire fighting with water or foam.
Do not use the portable power pump to transport inflammable or explosive fluids.
Do not exceed the limit values for pump capacity and pressure when operating the portable power pump, do not allow the portable power pump to overheat.
Have modifications, changes and repairs carried out by persons authorised by the manufacturer only.
Only use the device if it is perfect technical condition.

WARNING
Danger of explosion. Whilst the system is operating,
ignition sources may be generated which can ignite an
explosive atmosphere.
Do not operate the system in a danger area with inflammable liquids, gases or dust.
Comply with the regulations for fire and explosion prevention.
Iveco Magirus Brandschutztechnik GmbH can only guarantee safety, reliability and performance if the device is used
for the purpose for which it is designed.
Unauthorised modifications, changes or improper usage
exclude all liability on the part of the manufacturer for damage resulting therefrom.

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05-2009

WARNING
Operating errors due to a lack of training can cause
serious accidents or place the success of the deployment in jeopardy. The portable power pump can only
be used safely if it is operated and serviced exclusively
by specially trained personnel.
The device must only be operated and serviced by appropriately trained personnel.
The personnel must make themselves acquainted with the
operating instructions before use. A single training session
is not sufficient. Only quality training and instruction from
experienced fire fighting personnel and ongoing practice
drills will ensure that the equipment can be used safely.
Carry out the control procedures again and again in practice drills.
Even in the field it must be ensured that persons with no
specialist training are not allowed to operate the portable
power pump.
Minors and people with no fire service training must not be
allowed to operate the portable power pump.
The operator is responsible for defining responsibilities and
for supervising the personnel. The operator is also responsible for providing adequate training and exercises pursuant
to current directives.

Please note

FOR YOUR SAFETY

Read the information

General safety instructions

WARNING
Improper operation can cause serious accidents.
Safe usage is only possible if all the information required for
safe operation is observed. This includes instruction manuals, identifiers and warning signs as well as other regulations.

The following instructions provide an overview of how to use


the device. The safety instructions in the detailed descriptions
in the various sections supplement this general overview.
You must therefore also comply strictly with the instructions in the various sections.
Exhaust fumes
DANGER
Danger of poisoning from exhaust fumes!

Instruction manuals
Read this operating manual completely before operation and
follow the regulations and safety instructions contained therein to the letter.
Keep the operating manual available for the operator at the
place of use.
Keep the operating manual in a safe place for future use.
Identifiers and warning signs
In addition to the instructions in the operating manual, you
must also read and follow all the warning signs fitted on the
device.
Clean the warning signs regularly to keep them legible.
Replace any missing or damaged signs.
Other directives
Comply with all relevant laws, regulations and directives (for
example national training regulations for fire fighters, accident
prevention regulations, fire fighting service directives, industrial medicine and environmental regulations, national laws for
fire and disaster protection, etc.).

Do not operate the portable power pump in enclosed areas.


If, in exceptional circumstances, the engine must be run in
an enclosed area, extract the exhaust fumes to the outside
using exhaust hoses and adequate ventilation.
If the portable power pump is run at all times in the open air,
use exhaust hoses to remove the fumes from your working
area.
Safe working practice
WARNING
Danger of injury from rotating parts.
When the engine is running do not reach into open rotating
parts (for example the flywheel on the engine on the underside of the portable power pump, V-belt, fan wheel or impeller, etc.).

WARNING
Danger of injury and danger of permanent health damage when transporting and loading the portable
power pump.
The portable power pump should only be lifted and carried
by at least 4 people (weight: 190 kg).
Only hold the portable power pump by the handles provided when transporting it.
Transport the portable power pump at a maximum angle of
35 in all directions.
Accommodate the portable power pump properly in the
vehicle after use and secure it.
WARNING
Risk of injury due to inadequate supervision.

Do not leave the portable power pump unsupervised when


its motor is running.
Secure the portable power pump against unauthorised use.

8 IVECO MAGIRUS
05-2009

Please note

FOR YOUR SAFETY

Water pressure

Media

WARNING
Fire and health risk when handling media such as fuel,
anti-freeze and preservatives.
You must follow the relevant regulations and the working
and safety instructions supplied by the manufacturers.
Do not refuel in enclosed areas and only do so when the
engine is at a standstill and the ignition has been switched
off, if the situation allows you to do so.
When refuelling at an incident watch for sparks, flames, radiated heat, etc. Secure the refuelling point.
Avoid fire and sparks and do not smoke when handling fuel.
Only store media in containers designed for them away
from heat sources.
Dispose of used or spilled media in an environment-friendly
way.

Noise emissions

WARNING
The high pressure water jet can cause serious injuries.
The pressure in the centrifugal pump and in the water
pipes may be up to 17 bar.
Only remove blind couplings from the pressure outlets after they have been depressurised.
Only open shut-off organs if lines are connected downstream.
Never direct the water jet at a person.
Avoid pressure surges and pressure fluctuations. Do not
accelerate the pump without control. Always open or close
the shut-off organ to the selected pressure outlet or jet
pipe slowly.
Ensure that the jet pipe operator has a safe standing area.
Do not operate the jet pipe if there are persons or obstacles in the working area.
It is essential that you observe the specified pressure values
whilst operating the pump and during tests.

The workplace-related noise levels1) are as follows:


At rated capacity to DIN

81 dB(A)

At rated capacity to NORM and SFV

88 dB(A)

At idling speed

69 dB(A)

At maximum speed

92 dB(A)

1) Distance from control panel 1.0 metre, distance to ground 1.6 metres.

Refer to the relevant guidelines and regulations, such as EC


Noise Directive (2003/10/EC) for details of the necessity of
wearing ear plugs.

Servicing and care

9 IVECO MAGIRUS
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WARNING
Improper servicing can cause serious accidents. Safe
usage is only possible if all the information required
for safe servicing is observed.
Only use the device if it is perfect technical condition.
Ensure that it is cleaned thoroughly and serviced regularly.
Rectify damage and defects immediately.
Only carry out the described servicing work yourself.
Have all the other work completed only by specially trained
after sales personnel.
Only use original spare parts from the manufacturer.
After use place the device in a place where it is protected
from the influences of the weather.
For detailed instructions, see section entitled Servicing.

Please note

FOR YOUR SAFETY

Protection from electrical power


At incidents near electrical systems take suitable precautions
to avoid placing persons in danger from electrical power.
Comply with national laws, directives and regulations.
In Germany, for example DIN VDE 0132 Fire fighting near
electrical systems and information the accident prevention regulation Fire services (GUV-V C 53).
DANGER
Danger of death from high voltage!
Avoid contact with overhead electric cables or live system
parts.
Isolate electrical systems at the incident from the supply.
If this is not possible:
When fighting a fire keep a safe distance from electrical systems and lines.
See the national laws, directives and regulations for details of
safety distances.
Never touch live parts.
Overhead electric cables
Live system parts
Parts of electric systems that are live as a result of the effects
of damage. Examples: Metal casings, cables with damaged insulation.
Parts of buildings or properties that conduct electricity as a
result of the effects of damage. Examples: Gutters, metal
fences.
Isolate the parts from the supply.
Have the following action completed by an authorised electrician
Isolate electrical systems at the incident from the supply.
Secure the electrical system to prevent its being switched on
again.
Check that the system has been isolated from the supply.
Earth and short circuit the system.
Cover or cordon off neighbouring parts that are live.
In domestic installations, fire fighters with electrical training
may also isolate the electrical systems.

10 IVECO MAGIRUS
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Please note

TRANSPORT AND STORAGE


Please note

TRANSPORT AND STORAGE


Transport
To carry the portable power pump

WARNING
Danger of injury and danger of permanent health damage when transporting and loading the portable
power pump.
The portable power pump should only be lifted and carried
by at least 4 people (weight 190 kg).
Only hold the portable power pump by the handles on the
carrying frame [4] when transporting it.
Transport the portable power pump at a maximum angle of
35 in all directions.
Disconnect all connectors (hoses, cables, etc.) from the device after use.

After transport
WARNING
Danger of accident by unsecured device.
Secure the portable power pump to prevent its slipping and
tipping.
If possible select a flat area so that the portable power pump
will not slip or tip over. If necessary, secure the portable power pump appropriately.

Storage in the vehicle


There is a special mounting for the portable power pump in the
fire fighting vehicle.
Slide in the portable power pump and secure it for transport.
Always store and secure the portable power pump properly.
Fire fighting vehicles with four-wheel drive can be fitted with a recessed mounting for the portable power pump to order. This
lowers the portable power pump pneumatically to a level from
which it can easily be raised.
Refer to other documentation
Read the operating manual supplied with the vehicle before
storage and comply with the regulations and safety instructions contained therein to the letter.
Refer to the section headed Operation, Frost protection.

11 IVECO MAGIRUS
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[4]

Handles on carrying frame

Please note

EQUIPMENT
Please note

EQUIPMENT

~842

Portable power pump EN 14466 PFPN 10 1000

~1092
[5]

~749

Portable power pump (maximum dimensions to EN)

Type:

EN 14466 PFPN 10 1000

Centrifugal pump:

P 212

Rated pump capacity

1000 l/min at 10 bar

Drive engine

FIAT FIRE 1242 MPI

Engine capacity:

54 kW (75 bhp)
at 6000 rpm

Total mass ready for use:

190 kg

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The portable power pump is a fire fighting centrifugal pump that


is directly connected to the engine by a switched coupling.
The entire unit, consisting of the pump and engine, is mounted
on a portable frame. The unit is carried by the tubular frame. Holes in the bottom runners ensure that it can be stored securely in
the vehicle.
A multi-part plastic cover protects the engine from the effects of
the weather and damage.
The general requirements of EN 14466 apply.
In their standard design, the portable power pump complies with
these standards and the standards and regulations contained therein.
The fire fighting centrifugal pump complies with EN 1028.

Please note

EQUIPMENT

Centrifugal pump P 212


The fire fighting centrifugal pump mainly consists of the components shown in Figure [6]:
A
B
C
D

A B

Intake
Pressure outlets
Pump casing
PRIMATIC priming device

[6]

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Components of the centrifugal pump

Please note

EQUIPMENT

Pump capacities 1) with a 3 m intake head:

1,300 l/min at 10 bar


1,700 l/min at 8 bar
2,050 l/min at 6 bar

Pump capacities 1) with a 7.5 m intake head:

1,050 l/min at 10 bar


1,150 l/min at 8 bar

Number of stages:

Pressure outlets:

Materials:
Casing, impellers and rotors, intake cover, split water rings:
Pump shaft

Alloy (resistant to saltwater)


Stainless steel

Pump shaft bearing:


Intake side:
Drive side:

Plain bearing (maintenance-free)


Ball bearing (oil bath lubrication)

Pump shaft seal:

Slide ring seal (maintenance-free)

Draining:

The drain cock is below the pump casing

Drive side:

Single-disc dry friction coupling, can be switched during


operation

Ambient temperature range

15C to +35C

Range of suitable fluid temperatures

0 C to max. 60 C

Maximum operating pressure pa lim

17 bar

Maximum angle for the portable power pump during operation

15 in all directions

Supply pressure (bar)

1) The tolerances of the engine and pump may change these cables.

Intake heads

Delivery rate (l/min)


[7]

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Characteristic pump curves

Please note

EQUIPMENT

[8]

Lateral and longitudinal sections of centrifugal pump P212

PRIMATIC priming device


The Magirus PRIMATIC is a fully automatic priming system for fire fighting centrifugal pumps.
Function
When the drive is engaged, the diaphragm priming pumps start
at the same time as the centrifugal pump. The centrifugal pump
is primed by the diaphragm pumps until water enters the pump
and the water supply commences. The output pressure of the
centrifugal pump disengages the diaphragm discs for the priming
pumps off the drive unit and thus stops the diaphragm pumps.

[9]

PRIMATIC priming device

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The automatic cut-out and possible restart of the diaphragm priming pumps is controlled directly by the pump pressure. If the
water column fails the outlet pressure from the centrifugal pump,
which shut down the diaphragm pumps, collapses. The diaphragm priming pumps restart until they are shut down again by
the outlet pressure in the centrifugal pump.

Please note

EQUIPMENT

Drive engine FIAT FIRE 1242 MPI

[10] Lateral and longitudinal sections of the Fiat FIRE 1242 MPI

Engine:

Fiat FIRE 1242 MPI


4-cylinder, inline 4-stroke engine,
electronic multi-point injection with
Lambda sensor

Bore and stroke:

70.8 mm x 78.86 mm

Displacement, total:

1,242 cc

Compression ratio:

9,8 0,2

Max. torque:

106 Nm at 4000 rpm

Max. power (DIN):

54 kW (74 bhp) at 6000 rpm

Cylinder block:

Grey cast iron

Crankshaft bearing:

Plain bearing

Cylinder head:

Aluminium

Camshaft:

Overhead, toothed belt drive

Valves:

Two valves (hanging) per cylinder,


tappet activation
opens 7 before TDC,
closes 41 after BDC
opens 43 before BDC
closes 5 after TDC
0.80 mm for checking valve timings
0.35 mm inlet play,
0.40 mm outlet play with a cold engine

Inlet:
Outlet:
Valve play:

Electronically controlled high tension ignition system with engine


speed limiting
Ignition distribution: Control module
Ignition coils
Boost:
1-3-4-2
Firing order:
13 at a speed of 850 rpm
Ignition advance:

Fuel:
Fuel supply:
Fuel tank:
Cooling:

Air filter:

Dry filter, with oil-impregnated cotton fabric

Lubrication:

Pressurised circulating lubrication


with rotor pump
Main flow replaceable filter (0.25 l)
3.25 l with oil filter

Oil filter:
Oil quantity:

Ignition:

16 IVECO MAGIRUS
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Fan:
Volume:
Coolant:

Octane index 95 ROZ


Super unleaded
Electric injection pump
Thermoplastic,
approx. 18 l capacity
Water cooling system, inline with a
radiator with expansion vessel and a
pipe bundle heat exchanger
Electric
3.5 l
Distilled water and Paraflu UP FIAT
at a ratio of 1 : 1

Generator:

Three-phase current 14 V, 38/65 A


V-belt drive

Battery:

12 V, 30 Ah, maintenance-free
May be charged using the charging
socket to DIN 14690, Part 1

1) The electronic systems in the control module have been modified for the
use of the engine in the portable power pump. The maximum speed for
pump operation is limited to approx. 4200 rpm to maintain the closing
pressure. The maximum capacity is thus reduced to around 40 kW
(54 bhp).

Control elements

LIST OF SYMBOLS
Control elements

LIST OF SYMBOLS

Battery control lamp

Coolant control lamp

Engine electronics control


lamp

Oil pressure control lamp

Tank content control lamp

Light

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Control elements

SUMMARY
Control elements

SUMMARY

A B

D
K

J
I
H

F
X

U T S R

Q P O

[11] Control elements for the portable power pump

A Control lamp Tank content

M Engine cover

B Control lamp Engine electronics

N Emergency starter (handle)

C Control panel light

O Fuel tank

D Hour counter

P Charging socket (12 V)

Rotary throttle knob

Q Coupling control lever

Switch Ignition/Start

R Pressure outlet with screw-down valves and couplings

G Switch Light

Drain cock

H Control lamp Oil pressure

T Pressure measurement unit Pump outlet

Control lamp Battery

U Pressure measurement unit Pump inlet

Control lamp Coolant temperature

V Pump intake with coupling

K Light

W Carrying frame with handles

X Pressure outlet with screw-down valves and couplings

Control panel

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Control elements

EMERGENCY STARTER
Control elements

EMERGENCY STARTER
Zero recoil emergency starter, in the form of a reverse
starter [12] [13].
Secured at the front in the centre in front of the crankshaft.
Acts directly on the crankshaft.
Minimum battery capacity for manual starting at an ambient
temperature of -15C: 20% of rated capacity

[12] Emergency starter handle (A)

[13] Emergency starter

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Operation

PLEASE NOTE
Operation

PLEASE NOTE
Important rules of conduct
Remove exhaust fumes from the working area
DANGER
Danger of poisoning from exhaust fumes!
Do not operate the portable power pump in enclosed areas.
If, in exceptional circumstances, the engine must be run in
an enclosed area, extract the exhaust fumes to the outside
using exhaust hoses and adequate ventilation.
If the portable power pump is run at all times in the open air,
use exhaust hoses to remove the fumes from your working
area.

Do not operate without water


CAUTION
Operating the pump without water will result in damage.
Avoid lengthy operating without water.
Frost protection
For deployments in ambient temperatures of below 0C
keep the pump running for as long as possible.
Water should be allowed to flow through all the pressure
outlets and hose lines at least temporarily.
Open unused pressure outlets temporarily.
See instructions in section Frost protection.

Monitor the water pressure


WARNING
If strong pressure fluctuations occur the stability of
the jet pipe operator will be at risk and the pressure
hoses can burst.
Do not open the pressure outlets too quickly or accelerate
suddenly to protect the jet pipe operator and the pressure
hoses.
Adjust the maximum pump pressure to the hose material
you use.
The jet is under high pressure.
Never direct the water jet at a person.
As soon as the pump output pressure measurement unit indicates pressure, slowly open the shut-off organ to the relevant
pressure outlet.
Set the required water pressure using the rotary throttle
knob.
Always set the water pressure high enough to ensure that the
priming device cuts out.
Close the pressure outlets and jet pipe cocks slowly if necessary.
Do not operate the centrifugal pump at full speed whilst outlets are closed, instead set it to moderate speed until water is
required again.
If the water supply is interrupted for a lengthy period, disengage the centrifugal pump and switch it off if necessary.
Do not exceed the maximum operating pressure pa lim (see
section headed Please note, Equipment).
CAUTION
Lengthy operation with cavitation can seriously damage the
centrifugal pump.
Cavitation can be identified by a noise that sound as though
the pump is transporting pebbles. If you hear this noise,
take the following action immediately:
Reduce the intake head.
Reduce the delivery rate or pump speed.

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Before starting use


Check the oil level and top up with oil if necessary.
Check the coolant level and top up with coolant if necessary.

Operation

ACTIVATE AND SWITCH OFF


Operation

ACTIVATE AND SWITCH OFF


To activate the engine
Before starting the engine
Ensure that the coupling control lever is set to position
OFF [14A].
To start the engine
Turn the switch Ignition/Start clockwise to position
Ignition ON [16A].
The control lamps Battery, Oil pressure and Engine electronics
will be lit.
Leave the rotary throttle knob in the idling position [15].
Start the engine by continuing to turn the switch Ignition/Start
clockwise to the resistance point in position Start [16B].
After the engine starts, release the switch Ignition/Start.
The switch will automatically return to position ON.
The engine electronics control lamp will remain lit for a few
seconds during a self-diagnostic and will then go out (see also
section entitled Troubleshooting).

A
[14] Coupling control lever in position OFF (A)

Intake

Do not expose new or cold engines to high engine speeds.


Refer to the instructions in the sections entitled Operation
and Please note.
[15] Rotary throttle knob in idling position

Emergency start
Turn the switch Ignition/Start clockwise to position
Ignition ON [16A].
The control lamps Battery, Oil pressure and Engine electronics
will be lit.
Leave the rotary throttle knob in the idling position [15].
Pull out the handle in the emergency starter [17] until you feel
the resistance.
Quickly pull the handle further.
Return the handle. Ensure that the cable coils up neatly.
Repeat the process if necessary.
The battery must not be completely discharged for an
emergency start. An emergency start will be possible in temperatures as low as -15C with a residual battery capacity of
20% if synthetic engine oil to specification has been used.

A
[16] Switch Ignition/Start in position Ignition ON (A)
Switch Ignition/Start in position Start (B)

[17] Emergency starter handle (A)

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Operation

ACTIVATE AND SWITCH OFF

To activate the pump


Requirements
Engine is running.
On the pump:
Remove the blind couplings.
Close the screw-down valves on the pressure outlets and
drain cock.

Activate
Set the coupling control lever to position ON [18].
To draw in water for priming purposes turn the rotary throttle knob to position Intake [20A].
As soon as the pressure measuring device Pump outlet indicates pressure of 2 3 bar, slowly open the screw-down valve to the selected pressure outlet.
When water starts to appear, continue to open the valve
slowly.

[18] Coupling control lever in position On (A)

Switch the pump outlet pressure so that the priming device is shut down (at least 1.5 bar).
Maximum pump outlet pressure 17 bar.
Do not expose new or cold engines to high engine
speeds.
Refer to the instructions in the sections entitled Operation and Please note.

A
[19] Coupling control lever in position OFF (A)

Switch off
To switch off the pump

Move the rotary throttle knob to the idling position [20B].


Close both screw-down valves.
Set the coupling control lever to position Off [19].
The pump is disengaged.

Intake

Intake

A
To switch off the engine
Allow the engine to run for around two minutes at idling
speed to cool (coolant will circulate).
Turn the switch Ignition/Start anti-clockwise to position
OFF [21].
The engine will shut down.

[20] Rotary throttle knob in position Intake (A),


Rotary throttle knob in idling position (B)

Stopping device
Turn the switch Ignition/Start anti-clockwise to position
OFF [21].
The engine will shut down.
The delivery will be stopped.
[21] Switch Ignition/Start in position OFF

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Operation

ADJUSTMENT AND MONITORING


Operation

ADJUSTMENT AND MONITORING


Setting
Set the required water pressure using the rotary throttle
knob [22B].

Monitoring

Monitor the level in the fuel tank to avoid unnecessary, timeconsuming breaks in the pump operation.
If the control lamp Tank content [22A] is lit whilst the portable
power pump is horizontal, the maximum level is 15%. This
corresponds to an operating period of approx. 20 minutes at
a delivery rate of 1,000 l/min at 10 bar.
Do not exceed the maximum operating pressure pa lim (see
section headed Please note, Equipment).
If the maximum operating pressure pa lim is exceeded, reduce
the engine speed immediately.
WARNING
The portable power pump has no protection against
explosion.
For refuelling during operation, comply with the regulations
pertaining to fire and explosion protection.
If necessary top up the fuel tank.
If the coolant water temperature rises significantly above the normal operating temperature (control lamp):
Set the engine to idling speed immediately, disengage the
pump and allow the engine to run without load to cool it or
allow the engine to run at low speed with the pump engaged.
Identify the cause of the overheating and rectify it.
If the control lamp Battery is lit during operation:
The V-belt may be loose or torn. The battery will then only
have power reserves for the engine for a short time.
Switch off the pump and engine and tension or replace the
V-belt (see section entitled Servicing, Engine).
Notify after sales service if necessary.
If the control lamp Oil pressure is lit during operation:
The lubricating oil supply to the engine may have been interrupted.
Switch off the engine immediately.
Check the oil level and top up if necessary.
Notify after sales service if necessary.
The occasional flickering of the oil pressure control lamp at
low speeds is insignificant.

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[22] Control lamp tank content (A); rotary throttle knob (B)

Operation

ADJUSTMENT AND MONITORING

Cavitation
CAUTION
Lengthy operation with cavitation (formation of bubbles)
can seriously damage the centrifugal pump.
Reduce speed.
Reduce the intake head.
Rectify any possible constriction in the intake line.
Ensure that you operate the pump without cavitation.
Monitor the output pressure.
The output pressure must be greater than the cut-out pressure of the priming pumps.

24 IVECO MAGIRUS
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Operation

PUMP OPERATION
Operation

PUMP OPERATION
Intake from open water
Position the portable power pump as close as possible to the
water and as horizontal as possible.
Connect the intake line and output lines.
CAUTION
Foreign bodies drawn into it may seriously damage the centrifugal pump.
Place the top of the intake cage at least 30 cm below the
surface of the water.
If the bottom is sandy place the intake cage on a solid base
or the like to protect the centrifugal pump.
If the water is very dirty use an intake protection cage.
Start the engine.
Switch on the pump.
Whilst it is running, ensure that the pump is operating without
cavitation.
Monitor the output pressure.
The output pressure must be greater than the cut-out pressure of the priming pumps.
CAUTION
Lengthy operation with cavitation (formation of bubbles)
can seriously damage the centrifugal pump.
Reduce speed.
Reduce the intake head.
Rectify any possible constriction in the intake line.
After use, switch off the pump and stop the engine.
If the priming device fails
Check whether the non-return valve on the intake cage provides a perfect seal.
Open both screw-down valves [23D] pull their locking
pins [23C] and then open the valves fully.
Pour water into a pressure outlet using a funnel until water
comes out of the other pressure outlet.
Close both screw-down valves.
Switch on the pump.

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D
C
B
A

[23] A intake (A); pressure outlets (B) with screw-down valves (D) and
locking pins (C)

Operation

PUMP OPERATION

Lance operation
Position the portable power pump as close as possible to the
lance position and as horizontal as possible.
Connect the intake line and output lines.
CAUTION
Dirt drawn into it may seriously damage the centrifugal
pump.
If the bottom is dirty place the intake cage on a solid base
or the like to protect the centrifugal pump.
If the water is very dirty use an intake protection cage.
The procedure for lance operation is identical to that for intake from open water.

Intake from hydrants


Rinse the hydrant briefly before connecting the line.
Place the portable power pump no further than 40 m from
the hydrant if possible and in a horizontal position.
Connect the manifold to the intake connection.
Connect the hydrant line to the manifold.
Start the engine.
Switch on the pump.
CAUTION
Danger of damaging the centrifugal pump if the intake pressure falls below 1.5 bar when drawing water from hydrants.
Reduce the pump speed or partly close the outputs.
CAUTION
Excessive intake pressure may cause function failures and
damage to the centrifugal pump.
Do not exceed the maximum operating pressure
Max. operating pressure: See section Please note, Equipment

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Operation

LIGHTS
Operation

LIGHTS
WARNING
Danger of eye damage caused by bright light.
Do not look directly into the intensive light.
Do not use the light in small, enclosed areas.

To activate the light


CAUTION
Danger of fire.

Maintain a minimum distance of 1 m between the light and


flammable materials.

Direct the light using the handle [24A].


Undo the clamp screw [24C].
Align the light as required using the handle.
If necessary, extend the stand.
Tighten the clamp screw.
Start the engine.
Activate the light on the control panel.

C
[24] Light in transport position

After operation
Always move the light to the transport position [24] and secure it with the clamp screw.

Battery protection
When the engine is not running and during the starting process
the auxiliary consumers will be shut down automatically to maintain the full battery voltage for starting the engine.
The light cannot be operated unless the engine is running.
If the light is activated when the engine is not running and the
ignition is switched on, it will cut out again automatically after
10 seconds. If the engine is then started, the light will automatically cut in again.

To clean the light


CAUTION
Danger of fracturing the hot light lens.
Allow the light to cool before cleaning it with water.
Clean the light with solvent-free soap suds.

To change a lamp
Remove the 4 screws [24B] and carefully open the casing.
Replace the lamp, ensuring that you do not touch the glass
with your bare fingers.
Lamp: Halogen, 12 V, 55 W
Close the casing and tighten the screws.

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[25] Light in working position

Operation

AFTER USE
Operation

AFTER USE
Action on the pump
After every use with water, the following work must be carried
out:
After drawing in water from open water or after drawing in
seawater, rinse the entire pump with clean sweet water.
Open both pressure outlets and the drain cock [26A].
When no more water runs out, close both the screw-down
valves.
Open the screw-down valves one turn to protect the seals.
Always leave the drain cock open.
Check the seals on the outlet and intake couplings.
Clean dirty seals and replace damaged seals immediately.
Clean the intake screen in the A intake.
WARNING
Danger of injury from rotating impeller.

[26] Drain cock (A)

Never reach into the intake whilst the pump is running.

Fit the blind couplings.


Conduct a dry intake test.
Check the oil level in the pump casing using the oil
dipstick [27B].
If the oil level is below the minimum mark:
Unscrew the primer cap on the top of the bearing
casing [27A].
Top up the oil (multi-grade oil SAE 15W40).
Do not fill above the maximum mark.

[27] Filling opening (A) and oil dipstick (B) for the pump

Set the coupling control lever to position ON [28A].

If there is a risk of frost, follow the instructions in the section


entitled Frost protection.

Action on the engine


Check the oil level and top up with oil if necessary.
Check the coolant level and top up with coolant if necessary.
Refuel (Super unleaded fuel, octane index 95 ROZ), tank capacity: approx. 18l).

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[28] Coupling control lever in position On (A)

Operation

FROST PROTECTION
Operation

FROST PROTECTION
Bearing
Keep the portable power pump in enclosed, heated rooms if
possible.
In addition, if there is a risk of frost, refer to the following
points.

Centrifugal pump and fittings


CAUTION
Danger of damage if the pump freezes.
Drain the pump and fittings with special care.

A
B

For deployments in ambient temperatures of below 0C


keep the pump running for as long as possible.
Water should be allowed to flow through all the pressure
outlets at least temporarily.
After draining, start the centrifugal pump again without water
to remove all the water residue from it and out of the priming
device.
Open both screw-down valves [29A] pull their locking
pins [29B] and then open the valves fully.
Remove the blind couplings.

Engine
Check the density of the engine coolant and correct it if necessary (see section entitled Servicing).
Check the charge in the battery (see section entitled Servicing).
Minimum acid density 1.20 g/ml, minimum closed-circuit voltage 12.2 V

Frost protection
Prepare the centrifugal pump and fittings for winter by adding
anti-freeze (see section entitled Servicing).

29 IVECO MAGIRUS
05-2009

[29] Pressure outlets with screw-down valves (A) and locking pins (B)

Troubleshooting

FOR YOUR SAFETY


Troubleshooting

FOR YOUR SAFETY


WARNING
Improper attempted repairs can endanger the operational safety of the portable power pump and cause
serious accidents.
Only carry out the described troubleshooting work yourself.
All other work should be carried out by specially trained,
authorised after sales personnel or at a FIAT workshop.
Only use original spare parts from the manufacturer.
The fuses are below the engine cover on the top of the side
of the pump on the engine (for further information about
fuses refer to the section entitled Servicing).

After sales
Technical Helpdesk
Iveco Magirus Brandschutztechnik GmbH
After sales
Graf-Arco-Strasse 30
D-89079 Ulm
Telephone: +49 (0)731 408-2594
Fax: +49 (0)731 408-2225
E-mail: magirus.brandschutz.service@iveco.com
Internet: www.iveco-magirus.de
After sales hotline
A German-speaking after sales technician can deal with urgent inquiries at weekends, on public holidays and from Monday to Friday from 5 pm to 7 am.
After sales hotline: +49 (0)731 408-4080

30 IVECO MAGIRUS
05-2009

Troubleshooting

POSSIBLE CAUSES AND REMEDY


Troubleshooting

POSSIBLE CAUSES AND REMEDY


Problems during pump operation
The table below shows the possible causes of faults during pump operation and how to rectify them.
Fault

Possible causes

Pressure measurement unit Pump inlet shows no va- Pump not connected.
cuum.
The pump and intake line have not been primed.
Screw-down valves and drain cock
open.

Remedy
Set the coupling control lever to
position ON.
Close the screw-down valves
and drain cock.

Inlet or outlet membranes on the dia- Set the throttle lever to idling
phragm pump soiled or worn.
and switch off the pump.
Only operate the pump from
hydrants.
After use:
Rinse the pump with clean water whilst the diaphragm pump is
running.
If the error continues to occur:
Notify after sales service.
Pump or intake line leaking.

Check the pump and intake line


for leaks (conduct a dry intake
test, if necessary conduct a pressure test on the pump with water).
Replace defective seals.
If the error continues to occur:
Notify after sales service.

No pressure build up.


The pump transports irregular quantities or absolu- The screen in intake cage or in the
tely no water although the pressure measuring unit
pumps intake inlet is blocked.
Pump inlet indicates a vacuum.
Non-return valve in the intake cage is
jammed.

Notify after sales service.


Clean the intake screen.
Release the non-return valve by
tapping gently, for example with
a hammer handle.

The intake line passes over a height


(for example wall, bridge railing). An
air bubble has formed at the raised
section.

Lay the intake line without a raised section.

The intake cage is not deep enough


under water so that air is also being
drawn in.

Extend the intake hose or


move the centrifugal pump
closer to the water.

Intake head too great.

Reduce the intake head.

Water transport stops when the screw-down valves are opened.

The screw-down valves were opened


too quickly.

Close the screw-down valves


and open them slowly.

The pressure on the pressure measuring unit Pump


outlet and the vacuum on the pressure measuring
unit Pump inlet suddenly drop to zero.

Water column in the intake line has


collapsed due to the ingress of air.

Replace intake hose.

The water column collapses constantly although the


pump and intake line are not leaking.

31 IVECO MAGIRUS
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If the error continues to occur:


Notify after sales service.

Troubleshooting

POSSIBLE CAUSES AND REMEDY

Fault

Possible causes

The pressure on the pressure measuring unit Pump


outlet rises. The vacuum on the pressure measuring
unit Pump inlet falls.

Delivery rate reduced by using smaller Set the required pump pressure
orifices or shutting down pressure outwith the throttle lever.
lets.

The pressure on the pressure measuring unit Pump


outlet falls. The vacuum on the pressure measuring
unit Pump inlet rises.

Set the required pump pressure


Other valves on the distributor have
with the throttle lever.
been opened too quickly or the delivery rate has been increased by using larger orifices or additional hose lines.

The centrifugal pump transports less water as the


vacuum increases.

The water jet from the jet pipe is not emitted evenly
but is interrupted by loud air surges.

Remedy

Pressure hose burst.

Replace the pressure hose.

The intake cage or intake screen in the


pumps intake inlet is blocked.

Clean intake cage or screen.

Rubber coating on the intake line has


peeled.

Replace intake hose.

The pumps water lines are constricted.

Notify after sales service.

There is still air in the pump or intake


line, which is being emitted bit by bit.

Use intake hoses that do not


leak.

If the air surges do not stop the pump


or intake line has a leak.

If the error continues to occur:


Notify after sales service.

The intake cage is not deep enough


under water so that air is also being
drawn in.

Extend the intake line or


Move the centrifugal pump
closer to the water.

32 IVECO MAGIRUS
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Troubleshooting

POSSIBLE CAUSES AND REMEDY

Problems during engine operation


The table below shows the possible causes of faults during engine operation and how to rectify them.
Fault

Possible causes

Remedy

Control lamp Water temperature is lit during pump


operation.

Engine overheating due to


coolant lever being too low,
defective coolant pump,
dirty heat exchanger element.

Switch off the engine immediately.


Allow the engine to cool and
rectify the causes.
Clean heat exchanger element
(see section , Servicing Engine).
If the error continues to occur:
Notify after sales service.

Water overheating in the pump due to


zero delivery rate.

Add fresh water:


Drain the heated water through
a free pressure outlet.
If both pressure outlets are in
use, drain the heated water
through the jet pipe.
If the delivery rate is zero, reduce the engine speed or disconnect the pump.
Note:
The engine coolant temperature
can be reduced most effectively
by adding cold fresh water.

Control lamp Battery is lit during pump operation.

V-belt torn. The battery only has pow- Switch off the pump and engine
er reserves for the engine for a short
and replace the V-belt.
time.

Control lamp Oil pressure is lit during pump operation.

Supply of lubricating oil to the engine


interrupted.

Switch off the engine immediately.


Check the oil level and top up if
necessary.
If the error continues to occur:
Notify after sales service

Control lamp Tank is lit during pump operation.

Tank content below 15% of the total


tank capacity.

Top up with fuel.

Control lamp Engine electronics is lit during pump


operation or does not go out after a few seconds of
the self-diagnostic after starting.

Fault in the injection system

Operation can be terminated (possible loss of power and misfires).


End use with throttled engine.
After operation have the engine
inspected and the fault rectified
by a FIAT workshop.
Note:
Sporadic and brief lighting of the
control lamp is insignificant.

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Troubleshooting

JUMP STARTING
Troubleshooting

JUMP STARTING
If the battery is discharged the engine may be started using jump
cables connected to a battery of the same or higher capacity in
another vehicle.

Please note

WARNING
Improper operation can cause serious accidents and
injuries.
Read the operating manual supplied by the chassis manufacturer carefully before jump starting and follow the regulations and safety instructions contained therein to the letter.
Before connecting the jump cables, ensure that you have
the same battery voltage (12 V or 24 V).
A discharged battery can freeze in temperatures below 10C. The battery must be thawed before jump starting the
vehicle.
Danger of acid burns. Do not bend over the batteries when
you are attempting to jump start the vehicle.
WARNING
Danger of gas explosion from sparking.

Provide good ventilation.


Avoid spark formation. Connect the negative terminals on
the jump cables to the earth points, do not connect them
to the negative poles on the batteries.
CAUTION
Voltage peaks can destroy electronic circuits.
Before jump starting, ensure that all electronic systems on
the other vehicle are switched off.

Jump cables

Only use jump cables, do not use a high speed charger.


Only use jump cables that satisfy the following requirements:
standard jump cables pursuant to DIN 72 553,
minimum cable cross-section 25 mm2,
insulated pole terminals.

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Jump starting procedure

Switch off the ignition.


Remove the pole covers on the batteries.
Connect the positive poles.
Connect the negative terminals to the earth points, do not
connect them to the negative poles on the batteries.
Start the engine of the vehicle with the charged battery and
increase its engine speed.
Start the portable power pump engine and run it at idling
speed.
Adjust the engine of the vehicle providing the power to idling
speed.
If the engine will not start after several attempts, do not
continue to make useless attempts, but notify the after
sales personnel or a FIAT workshop.
To remove the jump cables:
First disconnect the negative cable.
Then disconnect the cable from the positive poles.
Press the pole covers back into position.

Servicing

PLEASE NOTE
Servicing

PLEASE NOTE
For your safety

WARNING
Improper servicing can cause serious accidents. Safe
usage is only possible if all the information required
for safe servicing is observed.
Only use the device if it is perfect technical condition.
Rectify damage and defects immediately.
Ensure that it is cleaned thoroughly and serviced regularly.
Read this servicing manual before starting work and follow
all the safety instructions and regulations to the letter.
Only carry out the described servicing work yourself.
Have all the other work completed only by specially trained
after sales personnel or a FIAT workshop.
Only use original spare parts from the manufacturer.
Conduct a function test after all servicing or repair work.
Keep records of all servicing work. The service plan in this
manual can be copied for this purpose.

Exhaust fumes
DANGER
Danger of poisoning from exhaust fumes!
Remove exhaust fumes using exhaust hoses and adequate
ventilation away from the device and operator to the open
air.
Media

Regulations
Observe and comply with the latest versions of all the relevant regulations and directives when you carry out servicing
and repair work.
Examples:
Workplace Directive
Accident prevention regulations
Professional association regulations for health and safety at
work
Equipment Safety Law
Recycling and Waste Law
Safety data sheets for all the media, cleaning and preservative
products you use

35 IVECO MAGIRUS
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WARNING
Fire and accident risk when handling media. Media
such as fuel, anti-freeze and preservatives may be
harmful.
You must follow the relevant regulations and the working
and safety instructions supplied by the manufacturers.
Do not refuel in enclosed areas and only do so when the
engine is at a standstill and the ignition has been switched
off. (Exception: Topping up the fuel tanks during a deployment)
Avoid fire and sparks and do not smoke when handling fuel.
Do not smoke or use devices that do not have explosion
protection.
Only store media in containers designed for them.
Dispose of used or spilled media in an environment-friendly
way.

Servicing

PLEASE NOTE

Electrical system

Cleaning

DANGER
Danger of death due to the high voltage on the ignition system. The high voltage can cause fatal heart flutter or a heart attack. Potentially fatal arrhythmia may
even occur a few days after a shock.
Never touch the ignition leads or spark plugs whilst the engine is running or the ignition switched on.
Disconnect the negative pole on the batteries before starting any work.

WARNING
Volatile components in cleaning products may be
harmful.
You must follow the relevant regulations and the working
and safety instructions for the cleaning and preservatives.

If, despite all your precautions, somebody suffers an electric


shock on the ignition system:
Seek immediate medical assistance from a doctor or hospital, even if the person does not feel poorly physically.
Other instructions for safe working practice
WARNING
Danger of injury from rotating parts.
When the engine is running, and in particular if the engine
covers have been removed, do not reach into rotating parts
(such as the engines flywheel on the underside of the portable power pump. V-belts or fan wheel in the cover near
the exhaust manifold).

36 IVECO MAGIRUS
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CAUTION
A steam or high pressure jet directed at electrical components will cause damage.
Do not direct a jet at control panels, switches, sensors or
plug connectors.

Equipment
The type, timing, scope and completion of the required tests on
fire service equipment (for example intake hoses) are set out in
the relevant national regulations and the corresponding standards.

Environmental protection
Only store media, cleaning and preservative products in suitable containers.
Comply with the statutory environmental protection regulations when disposing of discharged batteries, media and parts
that have come into contact with media.
Deposit used oil and other media as well as replaced parts at
collection points or FIAT workshops. Never pour used oil or
media into open water or the sewer.

Servicing

PLEASE NOTE

Media
CAUTION
Danger of machine damage.
Do not mix different types of oil or lubricants unless expressly permitted by the manufacturer.
Oil
Application

Recommended

Multi-grade oil (engine)

SAE 15W40
SAE 5W401)

for temperatures over 0C


for temperatures under 0C

Multi-grade oil (pump)

SAE 15W40

for all temperatures

1) Emergency starting with SAE 15W40 oil in temperatures below 0C would be very difficult.

Frost protection
Application

Recommended

Anti-freeze for the engine (added anti-freeze)

FL SELENIA Paraflu UP

Anti-freeze for the centrifugal pump

Glysantin (or similar)

Grease
Application

Recommended

Grease for slides and mechanical mechanisms

Acid-free multi-purpose grease, for example Vaseline

Cleaning products
Application

Recommended

Cleaning plastic parts and coated surfaces

Solvent-free soap suds

Degreasing

Grease-dissolving cleaning products

37 IVECO MAGIRUS
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Servicing

SERVICING PLAN
Servicing

SERVICING PLAN
Every Every Every Every Every Every Annu- Every Every Every Every
6
4
100 150 200 300 month ally
3
50
2
hours hours hours hours hours
years years years years
Check the oil level in the pump and top up if necessary.

Check the oil level in the engine and top up if necessary.

Check the coolant level in the engine and top up if

necessary.
Check the battery (voltage, acid density) and charge if

necessary
1) 1)
1) 1)
Change the oil in the pump casing

Change the oil and oil filter

Check the air filter insert for dirt and clean it if

necessary
Check the spark plugs

Check the exhaust, fuel and coolant lines and replace

them if necessary
Check the coolant density

Check the emergency starter cable

Grease the throttle control

Replace the spark plugs, check the leads and replace

them if necessary
Replace the fuel filter

Check the V-belt tension and retension it if necessary

Check the intake and exhaust manifolds to ensure they


are secure
Check the condition of the toothed belt for the valve
controller
Check the crank casing ventilation system

Servicing

1) For the first time after 10 hours

Hours: _____________________h

Date: _____________

Name: _______________________________

Signature: ________________________________

To be carried out by Iveco Magirus after sales personnel or a FIAT workshop:

Check the ignition/injection system (diagnostic


connector)
Check the adjustment of the tappet play
Check the function of the Lambda sensor

Every Every Every Every


100 150 200 300
hours hours hours hours

Every Every Every Every


2
3
4
6
years years years years

Hours: _____________________h

Date: _____________

Workshop: _______________________________

Stamp,
Signature: ________________________________

38 IVECO MAGIRUS
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Servicing

CENTRIFUGAL PUMP
Servicing

CENTRIFUGAL PUMP
Regular operation
CAUTION
Lengthy down time and dry operation may result in damage.
Operate the centrifugal pump with water at least once per
month.

A
B

Frost protection
CAUTION
The centrifugal pump can freeze.
If there is a risk of frost, refer to the instructions in the sections entitled Operation, Frost protection.

[30] Filling opening (A) and oil dipstick (B) for the pump

Protect the pump from freezing with anti-freeze.


With the centrifugal pump running spray approx. 0.5 litres of
anti-freeze into the open intake using a spray can.
Anti-freeze: See section Servicing, Please note.
Then conduct a dry intake test.
Dispose of the anti-freeze in an environment-friendly way after it has been drained.

Change the oil in the pump casing


Change the oil after the first 10 hours of use, then after ever 50
hours, but at least every year.
Unscrew the drain screw on the underside of the bearing casing [31] and drain the oil.
Dispose of the used oil properly.
Screw in the drain screw with a new seal.
Tightening torque: 32 Nm
Unscrew the primer cap on the top of the PRIMATIC and
add around 0.4 l of oil [30A].
Oil: See section Servicing, Please note.
Check the oil level
Check the oil level in the pump casing using the oil dipstick
[30B].
The oil level must be between the minimum and maximum
marks.
If necessary drain oil out or added more oil.

39 IVECO MAGIRUS
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[31] Drain screw (A)

Servicing

CENTRIFUGAL PUMP

Dry intake test


WARNING
Danger of poisoning from exhaust fumes!
Position the portable power pump outdoors.
Remove the engine emissions from your working area using
exhaust hoses.
Leave the blind couplings on the intake.
Close the screw-down valves and drain cock.
Set the coupling control lever to position Off [32] and start
the engine.
Set the coupling control lever to position On.
To draw in water for priming purposes turn the rotary throttle knob to position Intake [33A].
After 10 to 20 seconds a vacuum of 0.8 bar should be achieved.
As soon as the pointer on the pressure measuring device Pump
inlet stops moving:
Move the rotary throttle knob to the idling position [33B].
Disengage the centrifugal pump (control level in position Off)
and switch off the engine.
If the pressure drops after a minute by no more than 0.1 bar,
the centrifugal pump is not leaking.
If the pressure falls by more than 0.1 bar or if the pointer on
the pressure measuring device Pump inlet does not move during the intake process, the centrifugal pump is leaking.

A
[32] Coupling control lever in position OFF (A)

Intake

Intake

[33] Rotary throttle knob in position Intake (A)


Rotary throttle knob in idling position (B)

After the dry intake test


Open the drain cock and leave it open [34].
Open the screw-down valves one turn to protect the seals.

[34] Drain cock (A)

40 IVECO MAGIRUS
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Servicing

CENTRIFUGAL PUMP

To pressure test the centrifugal pump with water


If you are unable to find the leak, despite careful checks, conduct
a pressure test on the pump with water.
CAUTION
The pump intake pressure should not exceed 5 bar for
pressure testing with water (engine not running).
The maximum pressure must not exceed 17 bar.
Close the screw-down valves and drain cock.
Connect the hydrant line direct to the intake.
Open the hydrant, allow air to escape through the pressure
outlet until water is emitted.
Close the pressure outlet.
Water will escape through the leak.
CAUTION
Incorrectly completed repairs may cause function failures
and damage to the portable power pump.
Only replace defective seals yourself.
If the leaks are elsewhere notify the after sales service immediately.

41 IVECO MAGIRUS
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Servicing

ENGINE
Servicing

ENGINE
Programmed servicing

Programmed servicing work must be carried out after every 50


hours of use or at least every year. Some servicing work can only
be carried out by authorised after sales personnel or by a FIAT
workshop.

Engine covers
The engine is protected from the effects of the weather by two
covers.
Open the top cover
Swing the light forwards.
Open the top cover completely.
The cover is held in its limit position by a gas spring.

[35] Seal on the engine covers (A)

To remove/fit the rear cover


Open the side locks [35] by turning them 90 anti-clockwise
and remove the cover.
To fit the cover first insert the bottom rubber wedge [36],
then close the side locks.

Check
V-belt
Every 100 hours (at least every two years) Check the V-belt tension and condition of the belt.
The V-belt [37] is correctly tensioned if it can be pressed
down around 1 cm by finger pressure.

[36] Rubber wedge (A) to secure the rear cover

To retension the V-belt


Remove the rear cover.
Undo the fastening screws for the generator, push the generator to the outside and tighten the screws again.
CAUTION
Excessive tension will cause high bearing stress.
To change the V-belt (request after sales service if necessary)
Remove the rear cover.
Remove the emergency starter and engine speed sensor.
Undo the fastening screws for the generator, push the generator against the engine block and remove the V-belt.
Fit a new V-belt (of the same size) and fit the components
again in reverse order.
Tightening torque for fastening screws: 85 Nm

42 IVECO MAGIRUS
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A
[37] V-belt (A)

Servicing

ENGINE

Oil level
Check the engine oil level every month and regularly before use.
Ensure that the engine has been switched off for at least 10
minutes.
Check the engine oil level on the oil dipstick [38A].
The oil level must be between the minimum and maximum
marks.

If the oil level is below the minimum mark:


Top up the oil through the filler opening [38B].
Oil between minimum and maximum: Around 1 litre.
Oil: See section Servicing, Please note.

[38] Oil dipstick (A) and filling opening (B) for the engine

Coolant
WARNING
Danger of scalding. The cooling system is pressurised.

B
A

Only open the filling open when the engine is cold.


CAUTION
Danger of engine damage by mixing coolant types.
Mixing different types of coolant additives may severely adversely affect their anti-corrosive effect.
Never mix different types of coolant. If necessary only add
coolant with the same coolant additive.
Never fill the cooling system with pure water without coolant additive.
Check the coolant level regularly before use
Ensure that the engine is cool.
Check the coolant level on the expansion vessel [39A].
The coolant must be above the MIN mark. Normal level:
57 cm above the MIN mark.
If the coolant level is below the MIN mark:
Top up with coolant [39B].
Use a mixture of distilled water and coolant additive at a ratio
of 1:1.
Coolant additive: See section Servicing, Please note.
Every 50 hours but at least annually
Check the coolant density with a conventional density meter.
Frost protection to -35C.
Mixing ratio 1:1 with coolant additive, but at least 1/3 of the
total coolant volume must consist of coolant additive (anticorrosive effect).
Coolant additive: See section Servicing, Please note.

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[39] Coolant level indicator (A) and filling opening on the expansion
vessel (B)

Servicing

ENGINE

Clean the heat exchanger element


If necessary:
Drain the coolant.
Undo the screw connection in the water line between the
heat exchanger and pump on the operators side of the
pump [40B].
Undo the casing screws on the heat exchanger.
Take the cover off the operators side [40A] and take the
heat exchanger element (pipe bundle) [41A] out of the casing.
Clean the heat exchanger element with a strong jet of water
and fit it again.
Check the round sealing rings in both sides of the casing and
replace them if necessary.
Ensure that the sealing rings are not stressed as you fit them
(danger of leaks).
Assembly the heat exchanger casing and connect the water
line to the pump.
Tightening torque for casing screws: 8 Nm
Fill the system with coolant.

A
B
[40] Heat exchanger

Emergency starter
Every 50 hours but at least annually
Pull out the nylon cable for the emergency starter [42], clean
it and check it for signs of damage.
Replace a damaged emergency starter as soon as possible.

[41] Heat exchanger element (pipe bundle, A)

WARNING
Danger of injury if the cable is damaged.

[42] Emergency starter

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Servicing

ENGINE

Lubrication
To change the oil and oil filter
Change the oil and oil filter every 50 hours, but at least every year.
Medium:
Use only brand oil to suit the ambient temperature.
Oil: See section Servicing, Please note.
Drain the oil
Only drain the oil when the engine is warm.
Remove the stopper on the filling opening [43B] and oil dipstick [43A].
Unscrew the drain screw on the oil tank.
Drain the oil and dispose of it correctly.
Do not insert and tighten the drain stopper for at least 10 minutes.
Tightening torque: 32 Nm
Change the oil filter
Unscrew the oil filter from the oil pump casing on the engine
side between the engine block and the exhaust silencer [44].
Residual oil may escape as you do so.
Wet the sealing ring on the new filter with oil, screw the new
filter on and tighten it by hand.
Only use a filter of the same type.
Fill with oil
Place oil in the filling opening [43B] until the oil level on the
dipstick is between the maximum and minimum marks.
Total oil volume around 3.25 litres including the content of
the oil filter
Run the engine briefly, wait for 10 minutes and then check the
oil level again.
Throttle control
Medium: Acid-free multi-purpose grease, for example Vaseline
Every 50 hours but at least annually
Grease the throttle control cable [43C].

45 IVECO MAGIRUS
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B
A
C

[43] Oil dipstick (A) and filling opening (B) for the engine, throttle (C)

A
[44] Position of the oil filter

Servicing

ENGINE

Spark plugs and ignition system

CAUTION
Spark plug types with different heat values or a different
service life may cause faults.
Only use spark plugs of the specific type.

Spark plug types: NGK DCPR7E-N-10


The spark plugs are on the right of the cylinder head in the
cavities of the intake section, looking from the pump
side [45A].
Check the spark plugs every 50 hours but at least annually
Unscrew the spark plugs and check them for deposits.
Remove all the carbon deposits between the porcelain insulation on the centre electrode and the spark plug body.
Set the electrode spacing to 1.0 mm.
Every 100 hours, but at least every two years:
Change the spark plugs.
Notes for working on the ignition system:
Do not disconnect the battery cable or high tension leads
when the engine is running.
Do not start the engine with the high tension cables disconnected.
Do not check current or voltage by sparking.
Do not switch on the ignition system if the ignition coil holder
is not connected to earth.
CAUTION
Inexpert work on the ignition system may result in damage
to the engine electronics and cause a danger of fire.
Servicing and repair work to the ignition systems electronics may only be carried out by authorised after sales personnel or a FIAT workshop.

46 IVECO MAGIRUS
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[45] Installation position of the spark plugs (A), air filter (B)

Servicing

ENGINE

Air filter
Every 50 hours but at least annually, if operated in a lot of dust
more frequently:
Check the air filter element for dirt [45B].
If there is a coating of dust of 1 mm or more on the filter:
Carefully tap the filter element and, if necessary, remove the
remaining dust carefully with a brush.
CAUTION
Blow out any damage to the filter element caused by compressed air.
Cleaning products may damage the filter element components.
Clean the filter element as described above.
Battery

Use only maintenance-free batteries with a rated value of 12


V, 30 Ah [46A].
DANGER
Danger of acid burns. Battery fluid is toxic and corrosive (caustic).
Avoid contact with the skin and eyes. Wear safety gloves
and goggles.
Rinse out any battery acid that gets into your eyes immediately with lots of clean, lukewarm water. Consult an ophthalmologist immediately.
Rinse out any battery acid that gets on to your skin immediately with lots of clean water.
Inexpert handling of the battery may result in spark formation
or even cause the battery to explode.
Avoid fire, sparks and naked flames and do not smoke when
handling batteries.
Avoid short circuits.
Never place metal objects on the battery.
CAUTION
Inexpert handling of the battery may cause damage to the
battery or the engine electronics.
Never disconnect the battery whilst the battery is connected or the ignition switched on.
Never swap the connections to the battery poles.
Ensure that the battery terminals are secure.

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[46] Battery (A) and charging socket (B)

Servicing

ENGINE

At least monthly
Check that the connection poles are clean and grease them
with anti-corrosion grease.
Check the acid level in the battery.
The level should be between the MIN and MAX marks when
the battery is horizontal.
If the acid level falls below the minimum mark, top up the appropriate cells with distilled water.
Check the charge condition using the acid density or closedcircuit voltage.
If the acid density is less than 1.2 g/ml or the closed-circuit voltage is below 12.2 V, charge the battery.
If the battery is kept for a lengthy period of time with less
than 50% charge there is a risk that it will be damaged due
to sulphatation. This will reduce its starting capacity and increase the risk of its freezing (in temperatures of -10C or
below).
Charge the battery
Refer to the operating manual supplied with the charger.
Only use controlled chargers that operate on the basis of the
IU or WU characteristic curve (DIN 41772).
The charging socket to DIN 14690 [46B] may be used as a
supply if the charger is fitted with a suitable plug.
If the self-discharge of the battery is to be compensated by a
maintenance charge, only use chargers specially designed for
this purpose.
Fast charge the battery
Remove the battery.
Refer to the operating manual supplied with the charger.
Check the acid level if you intend to fast charge the battery.
Jump starting
Never use a jump starting charger.
For details of the jump starting process see the section entitled Troubleshooting, Jump starting.

48 IVECO MAGIRUS
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Servicing

ENGINE

Fuses
There are four conventional flat terminal fuses under the top engine cover above the engine [47].
They protect the following circuits:

Item

Current

Protected circuits

5A

Charging socket

15 A

Light, Lambda sensor

20 A

Control panel, complete, engine controller,


engine sensors, petrol pump

30 A

Fan blower

C
D

D
B
C

[47] Fuses

49 IVECO MAGIRUS
05-2009

Appendices

CIRCUIT DIAGRAM
Appendices

CIRCUIT DIAGRAM
Circuit diagram, part 1
Lambda sensor

Air tempe- Coolant temAbsolute pres- rature sen- perature sensor


sure sensor
sor

Potentiometer
Throttle valve

Fuse for Lambda sensor and


light

Fuse for
charging
socket

Control lights

Charging socket

Light plug casing

Control panel light

Hour counter

Radiator blower

Light switch

Ignition / Start switch

Relay for immobiliser

Relay for radiator


Fuse for
blower

Main fuse

50 IVECO MAGIRUS
05-2009

Starter motor

Electric petrol pump


with spare sensor

Appendices

CIRCUIT DIAGRAM

Circuit diagram, part 2


Electric injection valves

I.A.W. control unit

Double relay

Diagnostic
tap for injection system

Ignition coils

Speed and
OT sensor

Step servomotor

Spark plugs

Temperature switch

Battery

Generator

Oil pressure
switch

51 IVECO MAGIRUS
05-2009

Appendices

DECLARATION OF CONFORMITY
Appendices

DECLARATION OF CONFORMITY

52 IVECO MAGIRUS
05-2009