TS Up3 GB 10 2014

Translation
Original-Operating Instructions
Portable Pump
ZIEGLER ULTRA POWER 3

PFPN 10-1000
PFPN 10-1500
DIN EN 14466
1 080 534 / BA UP III / GB /01.2014

Copyright © 2014 by Albert Ziegler GmbH
Albert Ziegler GmbH • Postfach 16 80 • 89531 Giengen/Brenz Member of the CIMC Group
Telefon: 07322 951-0 GmbH in Giengen Albert Ziegler GmbH

F orm 99106 9/ 101 4
Fax: 07322 951-211 Amtsgericht Ulm HRB 730059 Kreissparkasse Heidenheim •

Geschäftsführer: Dr. Yinhui Li BLZ 632 500 30 • Kto.: 46 032 386
Internet: www.ziegler.de Geschäftsleitung: Youjun Luan, René Pol IBAN: DE75 6325 0030 0046 0323 86
E-Mail: ziegler@ziegler.de Dirk Schlarmann, Phillip Thompson, BIC: SOLADES1HDH
Briefpost: Postfach 16 80 • 89531 Giengen
Zustellung: Memminger Str. 28 • 89537 Giengen Deutsche Bank AG •
BLZ 700 700 10 • Kto.: 210 951 000
IBAN: DE08 7007 0010 0210 9510 00
UST-IdNr.: DE815465832 Steuer-Nr.: 64003/15367 BIC: DEUTDEMMXXX
General
Manufacturer Albert Ziegler GmbH
Member of the CIMC Group
Memminger Straße 28 89537 Giengen/Brenz

Postfach 16 80 89531 Giengen/Brenz
Telephone: +49 7322 951-0

Telefax: +49 7322 951-211
Email: ziegler@ziegler.de
Internet: http://www.ziegler.de
Technical The technical information, illustrations and data contained in these operating instructions are valid at the
Information time of printing.
Our products undergo continuous further development.
We reserve the right to make modifications and improvements that we consider to be suitable.
This does not imply any obligation to extend such changes this to devices supplied at an earlier stage.
No claims of any kind whatsoever can be derived from the contents of these operating instructions.
Imprint Copyright © 01.2014 by Albert Ziegler GmbH

89537 Giengen/Brenz
Technische Dokumentation
Inhalt: TD (Technical Documentation)
Gestaltung: TD (Technical Documentation)
The reproduction of operating instructions - in part or in whole, reprinting, photocopying, on electronic

data carriers or any other way requires our written consent.
All rights reserved.

Subject to technical alterations at all times and without prior notice.
3. Edition: 01.2014 Order No.: 1 080 534
Printed in the Federal Republic of Germany
1 080 534 / BA UP III / GB /01.2014 I

Inhaltsverzeichnis
1 General
Manufacturer................................................................................................................................................ I
Technical Information.................................................................................................................................. I
Imprint........................................................................................................................................................... I
Table of contents.......................................................................................................................................... II-VII
Designated Use............................................................................................................................................ 1
Use............................................................................................................................................................... 1
Choice of Personnel / Qualifications............................................................................................................ 1
Inadmissible Use.......................................................................................................................................... 2
Information on the manufacturer‘s declaration............................................................................................ 2
Foreword....................................................................................................................................................... 3
Operating Instructions.................................................................................................................................. 3
Operating the Motor..................................................................................................................................... 3
Rules and Regulations.................................................................................................................................. 3
Extras............................................................................................................................................................ 4
Illustrations................................................................................................................................................... 4
Data............................................................................................................................................................... 5
Portable pump.............................................................................................................................................. 5
Type plate on the pump................................................................................................................................ 5
Type plate on the motor................................................................................................................................ 5
Type plate..................................................................................................................................................... 5
2 Safety
Safety Measures........................................................................................................................................... 6
General......................................................................................................................................................... 6
Warning Signs.............................................................................................................................................. 6
Warnings....................................................................................................................................................... 6
Signal words................................................................................................................................................. 6
Safety Instructions / Warning Signs............................................................................................................. 7
Accident Prevention Regulations................................................................................................................. 7
Transporting the Portable Pump.................................................................................................................. 8
Emissions..................................................................................................................................................... 8
Noise emission values.................................................................................................................................. 8
Exhaust Gases.............................................................................................................................................. 8
Handling Fuel................................................................................................................................................ 9
Safety Devices.............................................................................................................................................. 9
Protective Clothing....................................................................................................................................... 9
Operating the Pump..................................................................................................................................... 10
Service and Maintenance............................................................................................................................. 12
Safety Devices.............................................................................................................................................. 12
Electrical Equipment..................................................................................................................................... 13
Battery.......................................................................................................................................................... 14
Disposal........................................................................................................................................................ 14
Spare Parts................................................................................................................................................... 15
Environmental Protection Measures............................................................................................................. 15
Customer Service......................................................................................................................................... 16
II 1 080 534 / BA UP III / GB /01.2014

Inhaltsverzeichnis
3 Technical Description
Technical Data.............................................................................................................................................. 17
Example illustration...................................................................................................................................... 17
Technical Data Fire centrifugal pump........................................................................................................... 17
Equipment.................................................................................................................................................... 18
Performance Curve...................................................................................................................................... 18
Motor............................................................................................................................................................ 19
TROKOMAT „PLUS“..................................................................................................................................... 20
Venting the Centrifugal Fire Pump................................................................................................................ 20
Operating Position for Venting..................................................................................................................... 21
Description................................................................................................................................................... 21
Inoperative Position during Water Delivery.................................................................................................. 22
Description................................................................................................................................................... 22
Interruption of Water Delivery....................................................................................................................... 22
4 Operation
General.......................................................................................................................................................... 23
Suction and Venting Process....................................................................................................................... 23
Series Connection Hydrant Operation......................................................................................................... 24
Angle............................................................................................................................................................. 24
Readiness for Operation............................................................................................................................... 24
Storage......................................................................................................................................................... 24
TOURMAT D............................................................................................................................................... 24
Operating and Checking Devices............................................................................................................... 25
Example illustration...................................................................................................................................... 25
Description Portable Pump.......................................................................................................................... 25
Operating Panel............................................................................................................................................ 26
Description Operating Panel........................................................................................................................ 26
Gauge........................................................................................................................................................... 27
Description Gauge........................................................................................................................................ 27
Suction Inlet.................................................................................................................................................. 28
TROKOMAT.................................................................................................................................................. 28
Coupling Lever............................................................................................................................................. 28
Carrying Frame with Runners....................................................................................................................... 29
Folding Handle............................................................................................................................................. 29
Quick-close Fittings for Side Casing and Lid............................................................................................... 29
Socket according to DIN 14 590.................................................................................................................. 29
Additional socket for preserving the battery charge .................................................................................

29
1 080 534 / BA UP III / GB /01.2014 III

Inhaltsverzeichnis
4 Operation
Spotlight....................................................................................................................................................... 30
B outlet......................................................................................................................................................... 30
B Pressure Valve........................................................................................................................................... 30
Drain Cock.................................................................................................................................................... 30
Filler Inlet of the Fuel Tank............................................................................................................................ 31
Operating Panel............................................................................................................................................ 31
Ignition switch.............................................................................................................................................. 31
Switch „GAS“............................................................................................................................................... 32
TOURMAT D push button...........................................................................................................................

32
Overpressure/Underpressure Manometer for Input Pressure (according to DIN 14 421)............................ 32
Overpressure Manometer for Output Pressure (according to DIN 14 421).................................................. 33
Gauge........................................................................................................................................................... 33
Control lamp tank warning........................................................................................................................... 33
Control lamp tank pre-warning..................................................................................................................... 33
Fuel gauge.................................................................................................................................................... 34
Warning Light Coolant Temperature............................................................................................................. 34
Warning Light Oil Pressure........................................................................................................................... 34
Engine speed indication............................................................................................................................... 34
Running Hour Meter..................................................................................................................................... 34
Signaling lamp battery charge...................................................................................................................... 34
Signaling lamp suction speed limiter............................................................................................................ 34
Filler Inlet Motor Oil...................................................................................................................................... 35
Filling opening coolant................................................................................................................................. 35
Emergency Start Device............................................................................................................................... 36
Safety Measures - Portable Pump.............................................................................................................. 37
Operating the pump..................................................................................................................................... 37
Brief instructions........................................................................................................................................... 38
Transport...................................................................................................................................................... 38
Switch on the Portable Pump..................................................................................................................... 39
Prepare the Pump......................................................................................................................................... 39
Water supply................................................................................................................................................. 39
Prepare Pump............................................................................................................................................... 40
Start Motor (cold or warm).......................................................................................................................... 41
Start Motor................................................................................................................................................... 41
Motor Running.............................................................................................................................................. 41
Start Motor (Emergency Manual Start)...................................................................................................... 42
Preparation................................................................................................................................................... 42
Start Motor................................................................................................................................................... 42
Motor Running.............................................................................................................................................. 42
Suction (Suction Operation)........................................................................................................................ 43
IV 1 080 534 / BA UP III / GB /01.2014

Inhaltsverzeichnis
4 Operation
Operating the Portable Pump..................................................................................................................... 45
Pump Pressure............................................................................................................................................. 45
Monitoring.................................................................................................................................................... 45
Warning Light „Coolant Temperature“.......................................................................................................... 46
Warning Light „Oil Pressure“........................................................................................................................ 46
Warning Light „Battery Charger“.................................................................................................................. 46
Signaling lamp suction speed limiter............................................................................................................ 46
Interrupt Water Delivery................................................................................................................................ 47
TOURMAT D ...............................................................................................................................................

48
Switching on TOURMAT D .........................................................................................................................

48
Switching off TOURMAT D .........................................................................................................................

48
Drainage operation....................................................................................................................................... 50
Switch off the Portable Pump..................................................................................................................... 51
Cool down the Motor.................................................................................................................................... 52
Switch off the Motor..................................................................................................................................... 52
Drain the Pump............................................................................................................................................. 52
Hydrant Operation........................................................................................................................................ 53
Series Connection of Portable Pumps....................................................................................................... 54
Check Readiness for Use............................................................................................................................ 55
Dry Suction Test........................................................................................................................................... 56
Search for Leakages..................................................................................................................................... 56
Prepare for Use............................................................................................................................................ 58
After use....................................................................................................................................................... 58
Short-time Operation.................................................................................................................................... 59
Socket to DIN 14 690................................................................................................................................... 59
Portable Pump when Danger of Frost (Winter Operation)....................................................................... 60
Storage......................................................................................................................................................... 60
Drain the Pump............................................................................................................................................. 60
Inject Anti-freeze Solution............................................................................................................................ 60
5 Faults
Portable Pump.............................................................................................................................................. 61
General......................................................................................................................................................... 61
Safety........................................................................................................................................................... 61
Safety Devices.............................................................................................................................................. 61
Fault Table for Centrifugal Fire Pump......................................................................................................... 62
Fault Table for Motor.................................................................................................................................... 65
1 080 534 / BA UP III / GB /01.2014 V

Inhaltsverzeichnis
6 Service / Maintenance
Safety Measures........................................................................................................................................... 66
General......................................................................................................................................................... 66
Safety Devices.............................................................................................................................................. 66
Spare Parts................................................................................................................................................... 66
Environmental Protection Measures............................................................................................................. 67
Accessories.................................................................................................................................................. 68
Tool Kit.......................................................................................................................................................... 68
Documentation............................................................................................................................................. 68
Other accessories on request (against additional price).............................................................................. 68
Centrifugal Fire Pump.................................................................................................................................. 69
Lubricate Radial Sealing Rings..................................................................................................................... 69
Maintenance Interval.................................................................................................................................... 69
Fuel Quality................................................................................................................................................... 69
Lubricate Pressure Outlets........................................................................................................................... 69
Suction filter................................................................................................................................................. 69
Pump Gear................................................................................................................................................... 70
Check Oil Level............................................................................................................................................. 70
Oil Change.................................................................................................................................................... 70
Fuel Quality................................................................................................................................................... 70
Motor............................................................................................................................................................. 71
Check Spark Plugs....................................................................................................................................... 71
Exchange Spark Plugs................................................................................................................................. 71
Air filter......................................................................................................................................................... 72
Injection system............................................................................................................................................ 72
Motoroil........................................................................................................................................................ 72
Oil exchange................................................................................................................................................. 72
Description cooling system.......................................................................................................................... 73
Coolant additive........................................................................................................................................... 74
Loss of coolant............................................................................................................................................. 74
Check coolant level...................................................................................................................................... 74
Refill coolant................................................................................................................................................. 75
Fill up coolant............................................................................................................................................... 76
Radiator ventilators...................................................................................................................................... 76
Battery.......................................................................................................................................................... 77
Safety Measures........................................................................................................................................... 77
Check the Acid Level.................................................................................................................................... 78
Charge the Battery....................................................................................................................................... 79
VI 1 080 534 / BA UP III / GB /01.2014

Inhaltsverzeichnis
6 Service / Maintenance
Battery charge preservation......................................................................................................................... 79
Inspection service........................................................................................................................................ 80
Remarks....................................................................................................................................................... 80
Exchange engine oil..................................................................................................................................... 81
Engine oil additives....................................................................................................................................... 81
Filter exchange............................................................................................................................................. 82
Full flow oil filter............................................................................................................................................ 82
Dry air filter: cleaning element...................................................................................................................... 82
Replace fuel filter.......................................................................................................................................... 82
Ignition system Motronic.............................................................................................................................. 83
Safety........................................................................................................................................................... 83
Description................................................................................................................................................... 83
Exchange spark plugs.................................................................................................................................. 84
Exchange V-ribbed belt................................................................................................................................ 85
Spare parts................................................................................................................................................... 86
Fuels.............................................................................................................................................................. 87
Fuel............................................................................................................................................................... 87
Lubricants..................................................................................................................................................... 87
Electrical Equipment.................................................................................................................................... 88
Safety Measures........................................................................................................................................... 88
Fuses............................................................................................................................................................. 89
Fuses............................................................................................................................................................ 89
Changing Fuses............................................................................................................................................ 89
Overview Fuse Box....................................................................................................................................... 90
7 Electric wiring diagrams

Hersteller....................................................................................................................................................... 91
8 Annex
Permissible thightening torques for bolts of strength class 8.8.............................................................. 96
Noise emission values................................................................................................................................. 97
1 080 534 / BA UP III / GB /01.2014 VII

Designated Use General
Use ZIEGLER ULTRA POWER 3 „PFPN 10-1000“ and „PFPN 10-1500“ portable pumps are built for standard
fire service implementationtasks.
Due to its construction and equipment the portable pimp should be used exclusively for the following
tasks:
For fire fighting in conjunction with water for fire fighting, standardized and authorized fire
extinguishing instruments and fire extinguishing agends.
As a reinforcement pump or feed pump for increasing the pressure when water is being
delivered over long distances.
As a bilge pump.
Uses above and beyond those mentioned above are considered contrary to the designated use of
the portable pump!
The manufacturer accepts no liability for damage resulting from unauthorized alterations to the device
and incorrect operation or use not in accordance with its designated use.
If the portable pump is used for purposes other than those mentioned above situations may occur that
are dangerous to persons and material may be damaged!
Operating the machine within the limits of its designated use also involves adhering to the operating,
service and maintenance instructions prescribed by the manufacturer.
Choice of All persons operating, servicing and maintaining the device must have read and understood the
Personnel
Qualifications Operating instructions
Safety regulations
Safety instructions contained in the individual chapters and sections.
Operating, maintenance, inspection and assembly personnel must possess the necessary qualifications
to carry out this work. The sphere of responsibility and monitoring of personnel must be precisely defined
by user.
If personnel does not have the required specialist knowledge, then it must be trained and instructed by
the operator.
The portable pump should only be operated by persons who have trained as an operator for fire engines
according to FwDV 2/1 ( Fire Service Rules and Regulations), Chapter 4.2 or have undergone similar
training.
Persons who are not qualified are not permitted to operate the device!
1 080 534 / BA UP III / GB /01.2014 1

Designated Use General
Inadmissible Use The portable pump is not intended for operation in potentially explosive atmospheres!
The operational safety of the device is only guaranteed when it is used in accordance with its designated
use.
CAUTION! Incorrect operation!
¾¾ The operating instructions should remain in safe keeping for future use!
¾¾ In order to avoid operating errors and damage to persons and property and to guarantee
touble-free operation of the portable pump, the user / operator must always have access
to all operating instructions!
¾¾ All operating instructions must be accessible at all times at the place of operation!
Information on the As regards the conformity declaration we would like to point out the following:
manufacturer‘s
declaration Only the vehicle/device supplied by ZIEGLER ex manufacturing plant is subject to our
conformity declaration.
Persons subsequently altering the vehicle/device whilst assembling, installing or converting

same will themselves become the manufacturer.
The customer is responsible for modifications or alterations and must then (on his own
authority) establish conformity of the vehicle/device with the EC directives and issue the
necessary accompanying documents.
The same applies to the subsequent installation of electrical and electronic systems.
2 1 080 534 / BA UP III / GB /01.2014

Foreword General
You have chosen a ZIEGLER portable pump. We thank you for placing your confidence in our product.
This device was produced using modern manufacturing processes and extensive quality assurance
measures.
Due to its advanced construction, carefully selected materials and the conscientious work of devoted
staff ZIEGLER fire service equipment are well-tried companions used in fire fighting.
They have a high performance level and operational safety even under difficult conditions.
The portable pump is as powerful as a vehicle pump and can be used in areas that are not accessible to
fire engines.
Transported on the fire engine they can also be used as an additional pump or for increasing pressure
when delivering water for fire fighting over long distances.
The ZIEGLER ULTRA POWER 3 „PFPN 10-1000“ and „PFPN 10-1500“ portable pumps are innovations
in the portable centrifugal fire pump sector. It integrates decades of experience and findings in pump
construction. For instance, the pump is characterized by:
very environmentally friendly,
operational safety - the VW industrial engine CKYA is a moder fuel-injection engine,
high readiness for start event at low temperatures due to electronic ignition and injector,
minimized noise due to water cooling.
Operating The portable pump conforms to the relevant regulations and standards.
Instructions
The operating manual includes a description for operation and maintenance. Before commissioning the
plant, familiarize yourself with it and therefore read the present operating manual.
Operating the Operation and maintenance of the engine is covered by the operating manual of the engine manufacturer
Motor supplied with the portable power pump.
Rules and Universally applicable laws, rules and regulations should be observed, in particular trainee regulations for
Regulations the fire service and the relevant, valid regulations for the prevention of accidents.
1 080 534 / BA UP III / GB /01.2014 3

Foreword General
Extras The operating instructions also contain information on extras and additional equipment that are not
included in the normal scope of delivery. The scope of delivery is based on your order. Equipment and
extras for your device may therefore differ somewhat from the descriptions and the illustrations.
Extras are marked with . They are either only available as standard extras for certain designs or as extras
for specific devices.
Should your device comprise equipment that is not described or illustrated in these operating
instructions, please contact ZIEGLER.
Our customer service will inform you of the correct operation and maintenance.
Illustrations All illustrations, dimensions and technical data contained in the manual are non-binding.
The operating instructions are an important element of your portable pump.
Should the device be resold please supply the new owner with the operating instructions.
The same applies to the spare parts list and the operating manual for the engine!
4 1 080 534 / BA UP III / GB /01.2014

Data General
Portable Pump These operating instructions apply to the following device:
ZIEGLER ULTRA POWER 3 PFPN 10-1000

PFPN 10-1500
Please enter the following information in the blocks below before initial operating.
This facilitates enquiries regarding service, repairs and spare parts.
Type plate on the

pump Type:
Factory no.:
Year of construction:
Type plate on the

motor Typ:
Motor-Nr.:
Baujahr:
Type plate
1 080 534 / BA UP III / GB /01.2014 5

Safety Measures Safety
General Before initial operating read the operating instructions
carefully. These will enable you to operate and maintain the
portable pump correctly and to avoid injuries or damage to
the device
The portable pump is a state-of-the-art construction and

manufactured in accordance with the recognized safety
regulations. Risks for the user or other persons can how-
ever arise.
Only use the device in a technically perfect state and in

accordance with its designated use and in awareness of
safety and dangers involved.
Faults that have an adverse effect on safety should be
eliminated immediately. If necessary contact the ZIEGLER-
Customer Service.
The portable pump should only be operated by persons

who have received training as operators of fire engines
according to FwDV 2/1, Chapter 4.2 or who have
undergone similar training.
Continuous training on the portable pump and training by

experienced and skilled firefighters guarantee safe
handling.
Warning Signs Meaning
All safety instructions are marked with this sign in the

operating instructions.
It signifies danger of injury.
Comply with all safety instructions and accident prevention

regulations!
Warnings
Nature and source of the hazard!
DANGER!
Consequences in case of failure to observe the warning!
 Measures to be taken!
Signal words DANGER!: In case of high risk, life-threatening haz-

ards, serious injuries.
WARNING!: In case of medium risk, injuries, serious
injuries.
CAUTION! In case of low risk, minor damage.
Information on the economical use of the device plus

additional information on service and maintenance
work.
Information and useful tips for avoiding problems.
6 1 080 534 / BA UP III / GB /01.2014

Safety Instructions The safety instructions contained in the operating instruc-
Warning Signs tions and all the warning signs attached to the portable
pump should be carefully read and observed!
Ensure that the warning signs are legible at all times and
immediately replace missing or damaged signs!
Ensure that you are familiar with the functions of all

equipment and operating elements.
Never allow persons without specialist knowledge to

operate the plant.
Accident In addition to the information contained in these operating

Prevention instructions observe the following rules:
Regulations
Universally applicable safety and accident pre-
vention regulations of the accident insurance
company!
Generally recognized regulations on industrial

medicine and traffic!
Directives and generally recognized technical

regulations [e.g. DIN standards (German Institute
for Standardization), VDE regulations (Association
of German Electricians)]!
The most important accident prevention regulations of the

statutory accident insurance are listed below:
GUV-V A1 (Statutory accident insurance)

UVV (Accident prevention regu-
lations) General requirements
GUV-V A2 (Statutory accident insurance)
lations) Electricalsystems and
operating equipment
GUV-V 5 (Statutory accident insurance)
lations) Power-driven operating
equipment
GUV-V B3 (Statutory accident insurance)
lations) Noise
GUV-V C53 (Statutory accident insurance)
lations) Fireservices
GUV-G 9102 (Statutory accident insurance)
Test principles for fire service
equipment andapparatus
Accident prevent regulations are not recommendations,

they are statutory!
The regulations apply to all fire department employees!
Always ensure that the portable pump is in good working

order. Unauthorized alterations impair the function,
operational safety and service life of the device.
1 080 534 / BA UP III / GB /01.2014 7

Transporting the The portable pump weighs approx. 195 kg.
Portable Pump
The same number of persons should transport the portable
pump as handles are available. Lift the device evenly and
simultaneously.
Place the portable pump slowly and evenly on the ground.
When removing the portable pump from the fire engine

observe the training regulations!
When transporting the portable pump over steep

embankments, on ice and in snow allow it to slide on its
runners. For this purpose, secure the portable power pump
using cords. No persons may be standing in falling
direction!
Emissions
Noise emission Please refer to the annex of this operating manual for the
values noise emission values.
Exhaust Gases The combustion engine emits toxic exhaust gases when
the portable pump is in operation!
Exhaust gases may cause severe damage to health!
Do not operate the portable pump in closed, non-ventilated

rooms!
Mortal danger due to carbon monoxide (CO) poisoning!
When pumping out deep cellars, manholes etc. do not

place the portable pump in the cellar or manhole!
There is a death hazard due to exhaust gases.
When motor driven connect the exhaust hose! Divert the

exhaust gases so that there is no risk to persons due to
emissions and hot exhaust hose!
Observe the relevant valid regulations applicable at the

place of operation!
Do not lay exhaust hose on inflammable surface!
8 1 080 534 / BA UP III / GB /01.2014

Handling Fuel Care should be taken when handling fuel - greater danger
of fire!
Only refuel when the motor is off - smoking prohibited!
Do not refuel in closed rooms - Fuel vapours are toxic and

can explode!
Always remove spilt fuel in the correct manner!
Avoid fires by keeping the motor and fuel tank free from
dirt.
When refuelling during application there is a greater danger

of accident and fire!
Pay attention to flying sparks, sparking flames and intensive

heat etc.!
Safety Devices Do not operate the portable pump before all safety devices
have been installed in the correct position!
Before removing safety devices switch off the motor and

ignition!
Protective Clothing For protection against dangers that arise in the fire
service during training and when in action normal protective
clothing and safety equipment should be worn!
Personal protective equipment is above all:
Fire-protective clothing
Fire-protective helmet with neck guard
Fire-protective gloves
Fire-protective boots
1 080 534 / BA UP III / GB /01.2014 9

Operating the The pump may only be operated by people having had
Pump training as mechanic for fire fighting vehicles according to
FwDV 2/1, Chapter 4.2 or similar training.
The portable pump should not be operated when the

operation sequences are not fully clear. Read the operating
instructions and the rules on safety carefully!
The individual operational processes should be repeated

during training.
One-time instruction is not sufficient!
Only connect or disconnect the pump when the motor is

idling!
When opening and closing grasp the pressure valves with

the entire hand at the handwheel. Do not reach with the
fingers into the handwheel openings - danger of injury!
Avoid pressure surges! Do not open the throttle erratically

and open and close the blockage and control units slowly.
When the pump is operating only open the blockage and
control units when feed lines are connected.
Remove cap fire hose couplings from all pressure outlets,

even those that are not being used. Check that the pressure
outlets not being used are closed.
When removing the cap fire hose couplings from the

pressure outlets ensure that no pressure has built up
between the valve and the coupling, e.g. when valve is
leaking!
When removing the coupling this can be catapulted off
under pressure.
Reduce the pressure between the valve and coupling in the
following manner:
zz Do not remove the cap fire hose coupling!

Coupling can be catapulted off!
Reduce the pressure, by:
zz Slowly increasing pump pressure to approx.

8 bar thus producing a pressure compensation
between the pressure valve and the pump.
zz Opening the pressure valve slowly, pull the

locking pin and open the valve fully.
zz Reduce the pump pressure slowly.
zz Switch off the pump and drain.
zz Remove the cap fire hose coupling.
zz Close the pressure valve.
Never use force when removing cap fire hose couplings that
are under pressure!
Remove pressure as described above!
Fluids discharged under high pressure can cause serious

injuries!
10 1 080 534 / BA UP III / GB /01.2014

Operating the Do not operate the pump under high pressure when the
Pump pressure outlets are closed. The pump casing and the fluid
being delivered become extremely hot. Danger of injury
when fluid being delivered is discharged!
When delivering water from open waters attach the filter

basket and the filter protection basket to the suction
pipeline!
Never remove the suction filter in the air intakes of the

pump when the pump is operating!
Observe the maximum operating pressure of the pump -

observe the measuring instruments!
If the portable pump is standing on uneven ground ensure

at the pump operating panel that it is in a secure position.
All operating equipment must be easily accessible and all
checking devices easily visible!
The place of operation and operating panel must be appro-

priately illuminated and cordoned off!
The pipes and hose lines at the pump should be checked

for damage and correct fitting at regular intervals!

injuries!
WARNING! Incorrect operation on building up pressure!
Uncontrolled movements of hoses and fittings

connected!
 Only „open throttle“ once all outlet hoses connected

are completely filled!
¾¾Only actuate TOURMAT D pushbutton if the pressu-

re is at least 3 bar!
¾¾If the fire centrifugal pump is switched on, only

open and close outlet valves or shut-off fittings
slowly!
1 080 534 / BA UP III / GB /01.2014 11

Service and Service and maintenance work should only be carried out
Maintenance by persons who are familiar with the device, who possess
special knowledge and who are aware of the safety and
accident prevention regulations.
When carrying out maintenance work switch off the motor

and ignition!
Ensure that the portable pump stands firmly on the ground!
Safety Devices If protective and safety devices have to be disassembled

when carrying out service and maintenance work (e.g. heat-
proof exhaust guards, suction filter) they must be replaced
immediately after completion of work and checked that
they are in full working order!
The portable pump should undergo a visual and functional

check at regular intervals!
Defective equipment and devices should be withdrawn

immediately - danger of accident!
12 1 080 534 / BA UP III / GB /01.2014

Electrical Work on electrical equipment should only be carried out by
Equipment a skilled electrician or persons who have been instructed
accordingly under the guidance of a skilled electrician
according to electrotechnical regulations!
When working on electrical equipment always remove the

cable from the negative pole of the battery!
Ensure that the battery is connected correctly - first the

positive pole and then the negative pole!
Do not place any metal items on the battery - danger of

short circuit!
Only use original fuses! The use of fuses that are too strong
will damage the equipment!
The electrical equipment of the portable pump should be

checked at regular intervals!
Loose connections and/or scorched cables must be
removed immediately!
1 080 534 / BA UP III / GB /01.2014 13

Battery Follow the safety instructions on the battery!
Danger of explosion!
When charging batteries a highly explosive oxyhydrogen

gas mixture is produced!
Fire, sparks, unshielded lights and smoke are prohibited!
Avoid sparking when handling cables and electrical

devices!
Avoid short circuits!
Danger of injury due to caustic substances!
Battery acid is highly caustic, therefore:
Always wear protective gloves
Always wear protective glasses
Do not tip the battery, acid may be discharged

from the air vents.
Discharged batteries can freeze, therefore only store in a

frost-free room!
Disposal Disused batteries should be disposed of at a collecting

depot in a manner compatible with the environment.
14 1 080 534 / BA UP III / GB /01.2014

Spare Parts If parts require replacing during service and maintenance
work on the portable pump, only original ZIEGLER spare
parts may be used!
The use of spare parts and accessories that did not

originate from ZIEGLER and were not tested and approved
by ZIEGLER can have a negative affect on the characteris-
tics or on the functional efficiency and thus influence the
operational safety.
For safety reasons therefore, only original ZIEGLER spare

parts should be used.
Reliability, safety and suitability of third-party parts cannot
be assessed by ZIEGLER - even if in some cases
certification by TÜV or official approval may have been
granted - inspite of continuous monitoring of the market!
ZIEGLER is in no way liable for damage to persons and

property resulting from the use of parts, accessories or
attachments obtained from outside sources!
Environmental Oils, fuels, batteries and filters should be disposed of in a

Protection manner compatible to the environment and in accordance
Measures with statutory rules and regulations!
Never dispose of waste in the earth, sewage system or

waters!
Fuels should only be stored in the prescribed containers!
Before disposing of parts, observe the correct disposal

(recycling) procedure!
1 080 534 / BA UP III / GB /01.2014 15

Customer Service Should problems arise during service or maintenance work
on the portable pump please contact our Customer Service.
Albert Ziegler GmbH

Zentraler Kundendienst
Abteilung: ZKD
Memminger Straße 28
89537 Giengen/Brenz
Telephone: +49 7322 951-0

Telefax: +49 7322 951-724
E-Mail: zkd@ziegler.de
16 1 080 534 / BA UP III / GB /01.2014

Technical Data Technical Description
Example illustration
Technical data
Manufacturer ALBERT ZIEGLER GmbH
Fire centrifugal
pump Type PFPN 10-1000 PFPN 10-1500
DIN EN 14466 14466

Test no. AZ 10101P108 AZ 10151P108
No. of stages 1 1
Nominal flow rate 1000 l/min 1500 l/min
Nominal delivery head 10 bar 10 bar
Geodetic suction height 3m 3m
Ventilation TROKOMAT „PLUS“ 2 x
Max. permissible during transport: 35° at all sides
inclination angle in operation: 15° at all sides
Temperature range -15 °C to +35 °C ambient temperature
Maximum operating 17 bar 17 bar
pressure palim
Weight Approx. 195 kg Approx. 195 kg
Dimensions (L x W x H) ca. 1045 x 710 x 820 mm
Max. liquid temperature + 60 °C, short duration,
cooling system capable of supporting continuous full throttle up to + 35 °C
water feed temperature
1 080 534 / BA UP III / GB /01.2014 17

Equipment
Connections
Suction inlet 1x A solid fire hose coupling DIN 14 309
A cap fire hose coupling DIN 14 313
Pressure outlet 2x B solid fire hose coupling DIN 14 308
B cap fire hose coupling DIN 14 312
Materials
Water carrying parts, e.g. Seawater-resistant aluminium alloy
pump casing, impeller
etc.
Pump shaft Stainless steel
Fissure water rings
Seals
Pump shaft Radial sealing ring in easy-to-change sealing bush
Power Transmission
Motor - Pump Single-plate dry clutch with hand lever operation
Performance Curve
Delivery flow Q (l/min)

18
16
Total delivery pressure p ges (bar)
14
12
7,5 m
10 geod.
suction
height
8 6m
geod. 1, 5 m
6 suction geod.
height suction
4,5 m
geod. 3m height
4 suction geod.
height suction
2 height
0 400 800 1200 1600 2000 2400
Guarantee point for PFPN 10 - 1000: 3 m geod. suction height
Guarantee point for PFPN 10 - 1500: 3 m geod. suction height
18 1 080 534 / BA UP III / GB /01.2014

Motor
Otto-Cycle Engine
Manufacturer VOLKSWAGEN AG
Type CKYA
Operating mode Four-stroke Otto motor with electronic injection
Cylinder 3
Performance 1) 45 kW (61 PS) at 5200 1/min
Stroke 1198 ccm
Carburetion Electronic multipoint petrol injection with knock sensor
Ignition Battery ignition without points, individual ignition coils, interference
suppressed
Spark plugs 3 x Bosch F7 HER02
Dynamo 12 V, 70 A
Cooling Water cooling with heat exchanger and additional cooler
Starting equipment Electrical start with emergency start
Battery 12 V, 30 Ah, 180 A
Exhaust system Exhaust silencer with pre-expansion box
Material
Motor block, cylinder, High-quality aluminium alloy
cylinder heads and
pistons
Cylinder faces GG bushings
Connecting rod Steel, quadruple bearing
and crankshaft
Exhaust system Steel / stainless steel
Fuels
Petrol premium grade gasoline, unleaded RON 95 (RON 91 possible due to knock
sensor)
Lubrication Circular pressure lubrication with oil filter
Oil Multigrade engine oil SAE 5W30, SAE 5W40, SAE 0W30 or SAE 20W50
(see engine operating instructions)
Coolant Water with 40 % coolant VW G12A, Plus (see motor
operating instructions)
1 080 534 / BA UP III / GB /01.2014 19

TROKOMAT „PLUS“ Technical Description
Venting the The ZIEGLER TROKOMAT_PLUS is a dry piston venting pump that automatically performs the actual
Centrifugal Fire venting process.
Pump
The bearing flanges and cylinder heads are attached at both sides of the gear casing and/or pump casing
of the centrifugal fire pump. In each of these is a piston that is driven via an eccentric on the pump shaft.
1 Pump connection 4 Spring

2 Bearing flange 5 Cylinder head
3 Piston
20 1 080 534 / BA UP III / GB /01.2014

Operating Position
for Venting Output stroke Intake stroke
1 Compression spring 5 Inlet diaphragm

2 Outlet diaphragm 6 Bore for leaking water
3 Bearing flange 7 Piston, complete
4 Cylinder cap
Description The pistons (7) are moved backwards and forwards by the rotary movement of the eccentric connected
to the pump shaft.
The air from the pump and the suction pipeline is suctioned out via the intake ports when the piston
moves.
The air flows past the inlet diaphragm (5) that is in the process of opening into the piston displacement.
The springs (1) and the external air pressure press the pistons (7) back again.
The pistons (7) compress the air in the space under the pistons. The compressed air closes the inlet
diaphragms (5) and flows through the piston bores past the outlet diaphragm (2) that is in the process of
opening and into the open.
This procedure is repeated automatically until the pump and suction pipeline are void of air and water
enters the pump.
The centrifugal fire pump thus starts to deliver the water.
1 080 534 / BA UP III / GB /01.2014 21

Inoperative
Position during
Water Delivery
1 Compression spring 5 Inlet diaphragm

2 Outlet diaphragm 6 Bore for leaking water
3 Bearing flange 7 Piston, complete
4 Cylinder cap 8 Reclosing valve
Description As soon as water is being delivered it flows through the intake ports into the TROKOMAT and past the
intake diaphragms (5) that are in the process of opening.
The water flowing in raises the piston (7) from the eccentric because the water pressure on the inside of
the piston is greater than that on the outside.
The pistons (7) are pressed outwards until the outlet diaphragms (2) touch the sealing surface of the
cylinder heads and the piston bores are sealed.
The eccentric on the pump shaft now runs idle without touching the piston rod and thus prevents the
TROKOMAT from revolving unnecessarily.
Interruption of If, for any particular reason, the water delivery is interrupted there is no longer any water pressure on the
Water Delivery piston (7).
The pressure springs (1) now press the pistons (7) back onto the eccentric again and the suction process
is automatically repeated.
22 1 080 534 / BA UP III / GB /01.2014

General Operation
Suction and The ZIEGLER TROKOMAT is a modern dry piston venting pump that automatically performs the venting
Venting Process process and thus considerably facilitates the pumping operation.
The TROKOMAT applies dry suction i.e. without other mediums e.g. water or oil.
It is automatically switched by the delivered water and requires no auxiliary control.

For obtaining optimum performance the following points should be observed:
In order to avoid greater geodetic suction heights during suction operation the portable pump
should be placed firmly and as near as possible to the place of withdrawal of the water.
The surface of the filter basket must be at least 30 cm under the surface of the water.
The angle of the filter basket must be greater than 30° so that the return valve closes
automatically.
When assembling the portable pump ensure that there is no air pocket in the suction pipeline
when it is fed into the water. This would make suctioning considerably more difficult if not
impossible.
Correct
(As a rule)
Incorrect Correct
Incorrect Correct
1 080 534 / BA UP III / GB /01.2014 23

General Operation
Series Connec- When the hydrant is in operation or a number of pumps are being used consecutively or in series
tion connection for increasing the pressure when water is being delivered over long distances the input
Hydrant Opera- pressure must be at least 1,5 bar.
tion
If the input pressure drops below this value the pressures hoses contract.
The input pressure is displayed on the black scale of the overpressure/underpressure manometer.
Angle The portable pump has been constructed to allow absolutely safe operation at an angle of up to 15° in all
directions.
Readiness for If not being used for a considerable length of time the TS 8/8 should be run under load every 4 weeks for
Operation approx. 15 min.
The preservability of fuel is limited.

Trial runs at regular intervals ensure that the fuel does not become overaged.
Storage If trial runs are not made the following must be performed at the latest before a six month intermission:
The fuel tank must be drained,
Empty the injector,
Drain off the motor oil whilst still warm,
Refill new motor oil,
Clean spark plugs.
Otherwise starting problems may occur!
Clean the portable pump thoroughly.
Drain the pump carefully particularly in winter or when there is a danger of frost!
TOURMAT D The pressure control TOURMAT D is an automated pump pressure control. Pressure changes due to
different water output, for instance due to opening and closing of nozzles, are detected when they occur
and quickly balanced out.
The required pump pressure is preselected via a knob and activated by pressing a TOURMAT D push
button.
The pump pressure may be modified at any time using the rotating knob.
In case of deactivated TOURMAT D, the pump pressure may be adjusted manually using the rotating
controller.
24 1 080 534 / BA UP III / GB /01.2014

Operating and Checking Devices Operation
Example illustration
10
7 9
9 11
8
6
6
5 9
5
1
1 9
4 13
3
2
1 12
Description
1 Folding down carrying handle 9 Quick-close cover
Portable Pump
2 Pump casing 10 Fuel tank filler
3 Drain cock 11 Operating panel
4 A suction inlet 12 Carrying frame
5 B pressure outlets 13 TROKOMAT „PLUS“
6 B pressure valves
7 Portable spotlight
8 Coupling lever
1 080 534 / BA UP III / GB /01.2014 25

Operating Panel
14 15 16 17 18 19
Description
14 Ignition switch
Operating Panel
15 Gauge and indicators
16 Twist grip „GAS“
17 TOURMAT D ON/OFF push button
18 Pressure measuring instrument Pump suction side
19 Pressure gauge for outlet pressure
26 1 080 534 / BA UP III / GB /01.2014

Gauge
23 24
25
22
21 26
20 27
28
Description
20 Tank warning control lamp
Gauge
21 Tank pre-warning control lamp
22 Fuel gauge
23 Warning Light Coolant Temperature
24 Warning Light Oil Pressure
25 Engine speed indication
26 Signaling lamp battery charge
27 Signaling lamp suction speed limiter
28 Running Hour Meter
1 080 534 / BA UP III / GB /01.2014 27

Suction Inlet Suction inlet (4) with a solid fire hose coupling size A
according to DIN 14 309 and a cap fire hose coupling size
A according to DIN 14 313.
When water is supplied externally use a collector A-2B DIN
14 355 or adapter A-B DIN 14 343.
Connection couplings for other systems (e.g. British

Standard) are also available on request.
4 13
TROKOMAT Fully automatic dry piston venting pump (13).
Coupling Lever When motor-operated the coupling lever (8) is used to

switch the pump on and off.
After pump operation couple.
8
Symbol Function
Pump disengaged
Pump engaged
CAUTION! Damage to material!
Danger of accident!
If the pump is coupled at high speed, it could result in

the following:
The motor or the pump may be damaged,

High water pressure may suddenly develop in
the connected delivery lines therefore danger
of high reactive power at the jet pipes,
In case of high water pressure due to jerky
operation of armatures, like for instance
distributors, a health hazard may exist,
Delivery hoses and bindings may be damaged!
 Never couple or uncouple the pump at high motor

speeds!
If the pump is uncoupled at high speed the motor is

free of load and is revved to the limiting speed of
approx. 3500 1 / min.
28 1 080 534 / BA UP III / GB /01.2014

Carrying Frame Welded aluminium frame (12) with runners.
with Runners
Folding Handle The carrying frame has four folding handles (1). The
handles have manual protection, can be swivelled 90° and
opened in both directions.
1 12
Quick-close The side trim panel can be unlocked and removed using the
Fittings for Side catches (9). 9
Casing and Lid 9
Symbol Function
Casing „OPEN“
Casing „CLOSE“
9
Socket according The plug for the power cable from a battery charging device
to DIN 14 590 is plugged into the socket (29).
CAUTION! Damage due to incorrect operation!

29
 When charging the battery, the charging current
may not exceed 4 A!
Additional socket Optionally, the portable power pump may be fitted with an
for preserving the additional 3-pole socket for preserving the battery charge.
battery charge The socket is located above the socket DIN 14960. It
serves permanent connection to a charge preserving
device, which supplies power to the TS battery from the
vehicle battery.
CAUTION! Damage due to incorrect charging equipment!
 Only the original charge preserving device may be

used, which has been supplied together with the
portable power pump.
1 080 534 / BA UP III / GB /01.2014 29

Spotlight The spotlight (7) is used to illuminate the place of
operation.
zz Loosen the catch (30) and pull the spotlight out 7

to the desired height.
zz Screw the catch (30) tight.
CAUTION! Increased risk of accident if lighting is inadequate!

30
 Ensure that the place of use and operation are
adequately illuminated!
B outlet There are two pressure outlets (5) on the pump each with
a solid fire hose coupling size B DIN 14 308 and a cap fire 6
hose coupling size B DIN 14 312.
5
Connection couplings for other systems are also available 6
on request (e.g. British Standard).
B Pressure Valve The B pressure valve (6) is used to open or close the
pressure outlet.
5
Even when the spindle is not fully in position the valve
closes during the suction process and opens as soon
as the pump has been pressurized!
CAUTION! Risk of injury on opening and closing the outlet valves!
 Take a firm grip of the handwheel when opening and

closing the outlet valves!
 Do not reach with the fingers into the handwheel
opening - danger of injury!
 Only open the B pressure valves during pump
operation when the pressure hose lines are
connected!
Drain Cock The pump is drained using the drain valve (3) or vented
after the vacuum test.
When the pump is in operation close the cock,

otherwise:
The pump cannot be vented (suction

operation) 3
Water can be discharged under pressure
(hydrant operation).
30 1 080 534 / BA UP III / GB /01.2014

Filler Inlet of the The lid (10) of the filler inlet is equipped with a ventilation
Fuel Tank labyrinth.
10
Only fill the fuel container to a max. 2 cm below the

bottom edge of the filler neck!
Operating Panel The operating panel (11) is equipped with all the
necessary operating and control instruments.
CAUTION! Risk of accident on uneven ground!

11
 Ensure that the portable pump stands firmly on
uneven ground!
 All operating elements must be easily accessible
and all control instruments clearly visible!
Ignition switch There are three settings for the ignition switch (14) :
Symbol Function
Switch setting for shutdown,
the ignition is shut off.
Switch setting during operation, 14

the ignition is switched on.
Switch setting for operating the electrical

starter. After letting go of the ignition switch,
it returns to the setting „I“.
CAUTION! Danger of injury!
A sudden pressure build-up can cause the hose lines

to make snake-like movements and result in injury to
persons due to flying couplings and jet pipes!
 Never start the motor accidentally!
 Before switching off, allow the motor to cool down

approx. 2 minutes whilst idling!
1 080 534 / BA UP III / GB /01.2014 31

„GAS“ Switch The switch (16) is used to control the motor speed and set
the pump pressure.
The engine speed is indicated on the gauge (15).

15
16
Turn the switch to the position „S“ to ensure
optimum suction speed during the suction
process.
Suction speed The built-in suction speed limiter is activated in case

limiter of a pump pressure of less than 1 bar. In this operating
mode, a suction speed of 3500 rpm cannot be
exceeded, even if the twist grip „GAS“ is turned
beyond the setting „S“.
If the pump pressure rises above 1 bar, then the speed
limiter is deactivated and a pump pressure correspon-
ding to setting of the twist grip occurs.

connected!



slowly!
TOURMAT D TOURMAT D is switched on and off via the push button 16

pushbutton (17) . 17
When TOURMAT D is switched on, the control lamp on

the push button lights up and an output pressure may be
preselected via the knob (16) .
This output pressure is maintained at a constant level by

the control electronics.
The set pressure value may be read off the outer scale on
the knob.
If TOURMAT D is switched off, the output pressure may be

selected manually.
18
Overpressure/ The manometer (18) indicates the underpressure (red
Underpressure section) on the suction side of the centrifugal fire pump
Manometer for during suction and the actual input pressure (black section)
Input Pressure during supply from an external source (hydrant operation,
(according to series connection).
DIN 14 421)
32 1 080 534 / BA UP III / GB /01.2014

Overpressure The manometer (19) indicates the actual operating
Manometer for pressure on the pressure side of the centrifugal fire pump.
Output Pressure 19
(according to
DIN 14 421)
 For short pressure hose lines the output pressure of

the pump should be approx. 5-6 bar. This prevents
too high reactive power at the jet pipes and thus
reduces danger of injury.
Recommendation:
Output pressure of approx. 8 bar when delivering water

over long distances.
Output pressure of approx. 8-10 bar when using foam.
Gauge The gauge (15) provides information on the following data:
Fire centrifugal pump speed

Fuel contents
Operating hours counter 15
Tank warning indication
Tank pre-warning indication
Coolant temperature indication
Oil pressure indication
Battery charging indication
Priming speed limiting indication
Control lamp The “tank warning” control lamp (20) flashes if the fuel
tank warning level drops below 15% (= 3 litres) of the fuel capacity.
21
Control lamp The yellow “tank pre-warning” control lamp (21)

tank pre-warning illuminates if the fuel level drops below 25% (= 5 litres)
of the fuel capacity.
20
1 080 534 / BA UP III / GB /01.2014 33

Fuel gauge The gauge (22) indicates the amount of fuel left in litres.
22
Warning Light When the coolant is overheated the display (23) lights up.
Coolant
Temperature
CAUTION! Damage due to overheating!
23 24
 Switch off the motor immediately!
Warning Light When the oil pressure drops the display (24) lights up.
Oil Pressure
 Switch off the motor immediately!
Engine speed The indication (25) shows the actual speed of the fire
indication centrifugal pump.
25
Running The running hour meter (28) indicates the accumulated

Hour Meter operating hours of the portable pump.
To ascertain the maintenance intervals check the

operating hours!
28
Signaling lamp The signaling lamp (26) is lit in case of a fault concerning
battery charge the battery charge.
26
Signaling lamp In case of a pump pressure of less than 1 bar, the signaling
suction speed lamp (27) is always lit.
limiter The signaling lamp shows that the suction speed limiter has
been activated.
27
34 1 080 534 / BA UP III / GB /01.2014

Filler Inlet Motor oil is filled via the inlet (31).
Motor Oil
31
CAUTION! Danger of fire!
Damage to material!
 When refilling oil should not come into contact with

hot motor parts!
 Only use motor oil approved by the motor
manufacturer!
The oil level is checked via the dip-stick (32).
 The oil level must not be above the MAX. marking! 32

Otherwise oil may be burnt with the fuel!
 The oil level must never be below the MIN. marking!
Otherwise, if the portable fire pump is positioned at
an angle the lubrication of the engine will no longer
be assured. (Oil pressure control lamp illuminates)
Filling opening Coolant is filled up using the opening (33).

coolant 33
The filling level of the coolant is visible from outside through
the transparent coolant container.
In case of a cold engine, the level must be between the

marks „MIN“ and „MAX“.
When using other coolant additives, grave corrosion

damage to the engine may occur!
 It is only allowed to use the Volkswagen coolant

additive G 12 Plus!
Do not fill up using any other coolant additives!
1 080 534 / BA UP III / GB /01.2014 35

Emergency Start In case of insufficient battery charge, the engine may be

Device started using the emergency manual starter (34).
34
CAUTION! Risk of injury!
 Never reach into the opening for the manual pull

starter when the engine is running!
36 1 080 534 / BA UP III / GB /01.2014

Safety Measures-Portable Pump Operation
Operating the The pump should only be operated by persons who have
Pump received training as operators of fire engines according to
FwDV 2/1, Chapter 4.2 or similar training.
The portable pump should not be operated when the

operation sequences are not fully clear. Read the operating
instructions and the rules on safety carefully!
The individual operational processes should be repeated

during training.
One-time instruction is not sufficient!
Only connect or disconnect the pump when the motor is

idling!
When opening and closing grasp the pressure valves with

the entire hand at the handwheel. Do not reach with the
fingers into the handwheel openings - danger of injury!
Avoid pressure surges! Do not open the throttle erratically

and open and close the blockage and control units slowly.
When the pump is operating only open the blockage and
control units when feed lines are connected.
Remove cap fire hose couplings from all pressure outlets,

even those that are not being used. Check that the pressure
outlets not being used are closed.

leaking.
The cap fire hose coupling is difficult to remove manually:

The coupling can be catapulted off!
Reduce the pressure between the valve and coupling in the

following manner:

8 bar thus producing a pressure compensation
between the pressure valve and the pump.

zz Reduce the pump pressure slowly.
Never use force when removing cap fire hose couplings that
are under pressure!

injuries!
1 080 534 / BA UP III / GB /01.2014 37

Safety Measures-Portable Pump Operation
Operating the Do not operate the pump under high pressure when the
Pump pressure outlets are closed. The pump casing and the fluid
being delivered become extremely hot. Danger of injury
when fluid being delivered is discharged!
When delivering water from open waters attach the filter

basket and the filter protection basket to the suction
pipeline!
Never remove the suction filter in the air intakes of the

pump when the pump is operating!
Observe the maximum operating pressure of the pump -

observe the measuring instruments!
If the portable pump is standing on uneven ground ensure

at the pump operating panel that it is in a secure position.
All operating equipment must be easily accessible and all
checking devices easily visible!
The place of operation and operating panel must be

appropriately illuminated and cordoned off!
The pipes and hose lines at the pump should be checked

for damage and correct fitting at regular intervals!

injuries!

connected!



slowly!
Brief instructions A weatherproof brief instruction guide is affixed to the

portable pump.
Transport The portable pump may only be transported with a suitable

shipping brace as featured ex works.
Protect the pump against impact and other mechanical

influences!
Protection against the elements is not required.
38 1 080 534 / BA UP III / GB /01.2014

Switch on the Portable Pump Operation
Prepare the Pump Connect the B pressure valves (6) to the
pressure outlets. 6
5 6
Close the drain cock (3)
Remove the cap fire hose couplings from the 5

pressure outlets (5) and the suction inlet (4).
Water supply The pipe diameter should be selected to assure that the
required pump rate is achieved. 4
ATTENTION! Danger of injury!
 When removing pay attention to residual pressure

that may be present between the B pressure valve
and the cap fire hose coupling!
 Remove the cap fire hose couplings from all
pressure outlets, also those that are not being used!
Connect the suction pipeline to the suction

inlet (4).
Lay the suction pipeline so that it rises continually from

the water level!
Fasten the suction pipeline securely!
When assembling the portable pump ensure that when

the suction pipeline is fed into the water there is no air
pocket. This would make suctioning considerably more
difficult, if not impossible.
When delivering water from open waters attach the

filter basket and the filter protection basket to the
suction pipeline!
The angle of the filter basket must be greater than 30°

so that the return valve closes automatically.
Connect the delivery line to the pressure

outlets (5).
Connect the exhaust hose to the exhaust pipe. 5 5
1 080 534 / BA UP III / GB /01.2014 39

Switch on the Portable Pump Operation
Prepare Pump
ATTENTION! Danger of injury!
The combustion engine emits toxic exhaust gases

when the portable pump is in operation!
Exhaust gases may cause severe health damage!
 Do not operate the portable pump in closed, non-

ventilated rooms! Mortal danger due to carbon
monoxide (CO) poisoning!
 When pumping out deep cellars, manholes etc. do

not place the portable pump in the cellar or manhole!
There is a hazard for life due to exhaust gases.
 When motor driven connect the exhaust hose! Divert

the exhaust gases so that there is no risk to persons
due to emissions and hot exhaust hose!
 Make sure that no easily flammable materials are

located near the hot exhaust gas hose - fire hazard!
 Observe the relevant valid regulations applicable at

the place of operation!
Check the fuel contents (22).
Check the motor oil and coolant level. 22
Connect the pump.
By setting the coupling lever (8) at the position

„Coupling on“.
40 1 080 534 / BA UP III / GB /01.2014

Start Motor (cold or warm) Operation
Start Motor zz Turn ignition switch (14) to (A) position and
release as soon as the motor starts.
A
14

Motor Running zz Adjust the motor speed using the „GAS“ switch 16
(16) and set the desired pump pressure.
zz Pay attention to the pressure gauge for the outlet

pressure (19).
 In case of a cold engine, slowly open the throttle

and - if possible - avoid high revolutions!
Note!
25
On this topic also refer to the section “Priming”!
19
1 080 534 / BA UP III / GB /01.2014 41

Start Motor (Emergency Manual Start) Operation
If the battery charge is insufficient for an electrical start,
then it is possible to make an emergency start using the
emergency manual starter (34) . 20% battery charge are
sufficient for this.
34
Never reach into the opening for the manual pull


starter when the engine is running!
Preparation zz Insert emergency manual starter into the opening

(covered on the photography).
zz Set ignition switch (14) to the setting (B).
zz Set twist grip „GAS“ (16) to the setting (C). 16

C
B
CAUTION! Danger of accident!
When starting using the crank handle, make sure to be

standing securely!
 Step on the slide of TS with your left foot to secure

it against sliding away!
Start Motor zz Take hold of the manual pull starter (34) with
both hands and pull firmly until the engine starts. 14
Should the engine not start up:
zz Prior to each starting attempt using the 16

manual emergency starter, switch the ignition
off and on briefly.
Motor Running zz Pull out manual pull starter.
zz Regulate the speed of the motor using the „GAS“

switch (16) and set the desired pump pressure.
zz Pay attention to the pressure gauge for the outlet

pressure (19).
Note!
19
On this topic also refer to the section “Priming”!

42 1 080 534 / BA UP III / GB /01.2014

Suction (Suction Operation) Bedienung
TROKOMAT The ventilation of the pump and the connected suction

pipeline is performed fully independently by the
automatic suction mechanism of the ZIEGLER
TROKOMAT.
S
16
The TROKOMAT already starts suctioning at low
speeds.
Optimum suction is achieved at a motor speed of

approx. 3500 1/min.
By:
zz Turning the „GAS“ switch (16) to the (S)

position.
The shortest suction times are achieved at this speed.
The TROKOMAT operates automatically (rattling noise)

and the needle of the overpressure/underpressure
manometer deflects into the red scale range. Inlet pressure Outlet pressure
At a water pressure of approx. 2 bar in the pump the

TROKOMAT automatically switches off and the rattling
noise is no longer heard.
Water is no longer discharged from the ejector tubes
of the TROKOMAT.
2-3 bar
Suction speed The standard suction speed limiter is activated in case

limiter of a pump pressure of less than 1 bar.
In this operating state the priming speed of 3500 1/min

cannot be exceeded, even if the “GAS” knob is turned
past the position (S).
When the pump pressure increases above 1 bar, the

speed limit is removed and a pump pressure as defined
by the position of the knob is built up.
If the lifting pressure falls below 1 bar during pump

operation (drawing in air), then the engine speed is
automatically reduced to the suction speed of
3500 rpm.
Activation of the suction speed limiter is signaled by

means of the yellow signaling lamp (27).
27
1 080 534 / BA UP III / GB /01.2014 43

Suction (Suction Operation) Operation
As soon as the overpressure manometer (19) indicates
pressure and water is discharged from the ejector tubes of
the TROKOMAT:
Slowly open the B pressure valve (6) at the

pressure outlets with the connected pressure hose
lines by turning slightly.
As soon as the water flows in the hose lines, open

the B pressure valve (6) fully.
Regulate the speed of the motor using the „GAS“

switch (16) and set the desired pump pressure. 19
Suction speed If a pump pressure of 1 bar is not reached in setting

limiter (S) of the twist grip gas (16) (drainage operation), 6
then the suction speed limiter prevents increase of the
engine speed above 3500 rpm.
The following steps must be taken to deactivate the 6

suction speed limiter and make use of the full engine
power:
Slightly close B pressure valves (6), until the

pump pressure increases above the value of
1 bar.
The automatic suction speed limiter is deactivated and

the yellow signaling lamp (27) on the operating panel
is off.
Turn the twist grip „GAS“ (16) beyond the

setting (S).
16
The engine speed increases.
Completely open the B pressure valves (6).
Set the desired pump pressure using the twist

grip „GAS“ (16).
CAUTION! Risk of injury on opening and closing the outlet valves!
 Take a firm grip of the handwheel when opening and

closing the outlet valves!
 Do not reach into the opening on the handwheels!
 Only open the B pressure valves during pump
operation when pressure hose lines are connected!
27
44 1 080 534 / BA UP III / GB /01.2014

Operating the Portable Pump Operation
Pump Pressure zz Regulate the speed of the motor using the „GAS“
switch (16) and set the desired pump pressure.

16
For short pressure hose lines the output pressure of
the pump should be approx. 5-6 bar.
This prevents too high reactive power at the jet pipes

and thus reduces danger of injury.
Recommendation: Output pressure of approx. 8 bar
when delivering water over long
distances.

Output pressure of approx. 8-10
bar when using foam.
Monitoring The operator remains on the operating side of the portable
pump.
zz Observe, if the fire fighting rotary pump leaks. Output pressure Input pressure
zz Check the input (18) and output (19) pressure

manometers continuously.
zz Check the fuel consumption (22).
zz Have fuel handy.
zz Refill before fuel runs out.

18 19
CAUTION! Risk of accident and fire!
Use caution when handling fuels - increased danger of 22

fire!
 Only refill fuel when motor is off -

smoking prohibited!
 Increased danger of accident and fire when
refuelling during use!
 Pay attention to flying sparks, sparking flames and
intensive heat etc.!
 When refuelling switch off motor and ignition!
 Observe maximum operating pressure of the pump!

Avoid pressure surges!
 Open the throttle slowly, do not race and open or

close the blockage and control units slowly. Only
open the blockage and control units in pump
operation when feed lines are connected!
 With series connection of several pumps there is a

risk that the highest permissible pressure for hoses
and pumps is exceeded. Utmost caution is
necessary otherwise danger of injury due to
bursting instruments or ruptured hoses.
1 080 534 / BA UP III / GB /01.2014 45

DANGER! Mortal Danger!
 Always keep at a safe distance from overhead lines

- Mortal danger when touched by water jet!
Warning Light zz Check warning lights.

„Coolant
Temperature“ When the coolant is overheated the display (23) lights up.
Switch off the motor immediately!
zz Check whether there is sufficient coolant. 23
CAUTION! Danger of Scalding!
Exercise caution when opening the coolant container.

Hot water can be discharged when the hot motor is
under pressure.
 Allow the motor to cool down, open the lid slowly.
If the engine is started anew while the electrical ventilators

are still running, then the signaling lamp (23) will shortly
remain lit until the coolant temperature has once again
fallen.
This is not a fault!

24
Warning Light When the oil pressure drops display (24) lights up.
„Oil Pressure“
Switch off motor immediately.
Check the oil level and if necessary refill. Check whether the
permissible angle of inclination of the portable pump was
exceeded, if necessary choose a site that is not as inclined.
The warning light „oil pressure“ is not an oil level

display. Check oil level regularly.
Warning Light A fault in the battery charger is indicated when the display
„Battery Charger“ (26) lights up.
The portable pump can however still be operated if need be

but the battery will slowly run down. In this case switch off
26
spotlight.
Signaling lamp The signaling lamp (27) is always lit in case of a pump
suction pressure of below 1 bar.
speed limiter The signaling lamp shows that the suction speed limiter is
activated.
27
46 1 080 534 / BA UP III / GB /01.2014

Interrupt zz Turn twist grip „GAS“ (16) to the setting (S).
Water Delivery
The engine is running at idling speed. S
The pump pressure falls. 16
zz Slowly close the B pressure valve (6).
If water feed is interrupted:
zz Disengage pump using the clutch lever (8).
Injury hazard in case of emitting transmission fluid!

8
 Do not operate the pump under high pressure with
closed discharge openings. The pump housing and
the transmission fluid are strongly heated up in this
6
case.
zz Monitor the temperature of the pump housing.

6
CAUTION! Danger of burning!
 Take care when touching pipes and the pump!
If the housing has heated up so that it can no longer be

touched with your bare hand:
zz Disengage pump using the clutch lever (8) or

shortly open the load (spray pipe).
This performs a water exchange in the pump and the heat

buildup is relieved.
1 080 534 / BA UP III / GB /01.2014 47

Portable pump operation Operation
TOURMAT D The TOURMAT D* automatic pump pressure control

(special accessory) regulates the motor speed so that the
required output pressure is maintained at a constant level
regardless of the volume of water discharged.
If jet pipes are opened or closed when the TOURMAT D* is

switched on, the motor speed will be adjusted
automatically.
Switching on
TOURMAT D

16
17
connected!



slowly!
During pump operation:
zz Actuate the push button (17).

The green control lamp on the push button lights
up and the automatic pump pressure control is
activated.
zz Preselect the required output pressure via the

knob (16).
Switching off zz Actuate the push button (17) again.

TOURMAT D The automatic pump pressure control is switched
off and the green control lamp on the push button
goes out.
zz The pump pressure may now be set manually via

the knob (16).
48 1 080 534 / BA UP III / GB /01.2014

Portable pump operation Operation
The TOURMAT D must not be switched on when the

pump runs close to the cavitation at delivery of large
water quantities and /or large suction heighs.
In this operating condition no increase of pressure will

be caused by an increase of the pump rpm.
If the adjusted pump pressure is higher than the actual

reached the control will try in vain to compensate it by
increasing the rpm.
CAUTION! Material damage!
In bilge mode and in the case of major suction heights

the pump must always be operated at reduced speed,
adapted to the suction height, to avoid damage caused
by cavitation!
 Running with these operating status is therefore

only permitted when TOURMAT D* is switched off!
Should a frozen or defective pressure sensor on the

pump enclosure not permit the motor speed to
increase beyond the intake speed, the portable pump
may be operated without TOURMAT D* once the
connection plug has been removed.
The intake speed limiter is hereby also deactivated.
1 080 534 / BA UP III / GB /01.2014 49

Drainage operation
DANGER! Mortal Danger!
 For pumping out deep basements, shafts, etc., do

not locate the portable power pump in the
basement or shaft!
There is a hazard to life due to exhaust gases.
 In case of engine operation, connect up the exhaust
gas hose! Discharge the exhaust gases so that no
person is endangered by the emissions and the hot
exhaust gas hose!
 Observe the regulations applying to the respective
location!
Start up the pump as described and begin drawing

operation.
After venting:
16
zz Increase the engine speed using the twist grip
„GAS“ (16).
zz If necessary, close the B-pressure valves (6) and

throttle the water flow until the shut-off pressure
required for TROKOMAT is reached and
TROKOMAT shuts down. During draining
operation in case of large delivery quantities,
TROKOMAT shuts down at about 0.5 bar
Suction speed If a pump pressure of 1 bar is not reached in setting

6
limiter (S) of the twist grip gas (drainage operation), then the
suction speed limiter prevents increase of the engine 6
speed above 3500 rpm.
The following steps must be taken to deactivate the

suction speed limiter and make use of the full engine
power:
zz Slightly close B pressure valves (6), until the

pump pressure increases above the value of
1 bar.
The automatic suction speed limiter is deactivated and

the yellow signaling lamp „S“ on the operating panel
is off.
zz Turn the twist grip „GAS“ (16) beyond the

setting (S).
The engine speed increases.
zz Completely open the B pressure valves (6).
zz Set the desired pump pressure using the twist

grip „GAS“ (16).
50 1 080 534 / BA UP III / GB /01.2014

Switch off the Portable Pump Operation
To avoid cavitation damage during drainage operation,

the following must be observed:
 Switch off TOURMAT D.
 Only operate at reduced speed adjusted to the

suction height.
 Full speed does not increase the delivery quantity.
 Reduce the speed accordingly for increased suction

height.
1 080 534 / BA UP III / GB /01.2014 51

Switch off the Portable Pump Operation
Cool down the zz Switch off TOURMAT D automatic pump
Motor pressure control.
14 C 16
zz Turn the „GAS“ switch (16) to the „-“ (C)
position.
D
zz Disconnect the pump with the coupling lever (8).
Allow the motor to idle for approx. 2 min until it has cooled
down.
Whilst it is cooling down:
zz Slowly close the B pressure valves (6).
zz Disconnect the pressure hoses from the pressure

outlets (5).
zz Disconnect the suction pipeline from the suction

inlet (2). 6 8
5
Switch off the After cooling down (approx. 2 minutes):
6
Motor
zz Set ignition switch (14) to setting (D).
5
Drain the Pump zz Open the drain cock (3). 4
zz Allow the remaining water to drain off.
zz Close the drain cock (3).

3
zz Connect the pump with the coupling lever (8).
zz Connect the cap fire hose couplings to the

suction inlet (4) and the pressure outlets (5).
zz Perform dry suction test.
On this topic also refer to the section “Checking

readiness” - vacuum test!
52 1 080 534 / BA UP III / GB /01.2014

Hydrant Operation Operation
When using with water supply systems with low

6
pressure install the portable pump no further than 1 to
2 B pressure hose lengths from the hydrant. 5
This is necessary to ensure an adequate flow rate.
6
zz Give the hydrant a short rinse. 5

4
zz Remove the cap fire hose couplings from the
pressure outlets (5) and the suction inlet (4).
zz Connect the adapter A-B (DIN 14 343) or collector

A-2B (DIN 14 355) to the suction inlet.
zz Connect the B pressure hoses to the hydrant and

to the collector.
zz Connect the B delivery lines to the pressure

outlets (5).
Inlet pressure Outlet pressure
zz Start the motor.
zz Open the hydrant.
As soon as the overpressure manometer (19) indicates

pressure and water flows out of the ejector tubes of the
TROKOMAT:
zz Slowly turn the B pressure valve (6) slightly at

the pressure outlets with connected pressure 18 19
hose lines.
zz As soon as the water flows into the hose lines

open the B valves (6) fully.
zz Adjust the motor speed with the „GAS“ switch

(16) and set the desired pump pressure. 16
zz Continuously check the overpressure/
underpressure manometer (18).
The water must be under pressure when it enters
the centrifugal fire pump.
CAUTION! Incorrect operation!
 When supplied from an outside source the input

pressure must be at least 1,5 bar.
Set the motor speed accordingly.
 If the input pressure drops below this value the

pressure hoses contract when the adapter A-B is
used. If a collector A-2B is used in conjunction with
only a B pressure hose line air can be suctioned in.
 In this case reduce the pump speed immediately or

partially close the B pressure valve at the respective
pressure outlet and/or do not use as many jet pipes.
1 080 534 / BA UP III / GB /01.2014 53

Series Connection of Portable Pumps Operation
The output pressure of a portable pump is not

6
sufficient for delivering water over long distances.
5
It is therefore necessary to use several successively
6
connected portable pumps as reinforcement or feed
pumps for increasing the pressure.
5
4
zz Remove the cap fire hose coupling from the
pressure outlets (5) and suction inlet (4).
zz Connect the adapter A-B (DIN 14 343) or collector

A-2B (DIN 14 355) to the suction inlet.
zz Connect the B pressure hoses to the connected

portable pump and to the collector.
zz Connect the B delivery lines to the pressure

outlets (5).
16
zz Start the motor.
zz Build up the input pressure with the connected

portable pump.
zz Slowly turn the B pressure valve (6) slightly at

the pressure outlets with connected pressure
hose lines.
zz As soon as the water flows into the hose lines

open the B pressure valves (6) fully.
zz Adjust the motor speed with the „GAS“ switch

(16) and set the desired pump pressure.
18
CAUTION! Damage!
 Check maximum operating pressure of the pump -

check manometers!
zz Continuously check the overpressure/

underpressure manometer (18).
The water must be under pressure when it enters
the centrifugal fire pump.
CAUTION! The input pressure must be at least 1,5 bar. Set the
motor speed accordingly.
 If the input pressure drops below this value the

pressure hoses contract when using the adapter
A-B.
 If a collector A-2B is used in conjunction with only a

B pressure hose line air can be suctioned in.
54 1 080 534 / BA UP III / GB /01.2014

Check Readiness for Use Operation
Dry Suction After every initial operation, however at least 1 x a

6
Test month perform a dry suction test.
The purpose of this test is to: 5
6
Determine faults or damage that have occurred during
operation.
Check vacuum tightness. 5
Remaining water in the pump is discharged

(particularly important in winter).
zz Remove the cap fire hose couplings from the

pressure outlets (5).
zz The tightness of the B pressure valves (6) can

only be checked when the cap fire hose couplings
have been removed.

leaking.
 The coupling is difficult to remove manually.

Reduce the pressure between the valve and
coupling in the following manner:

The coupling can be catapulted off!
 Reduce the pressure, by:

8 bar thus producing a pressure
compensation between the pressure valve
and the pump.

zz Reduce the pump pressure slowly, pressure

valve remains fully open.
 Never use force when removing cap fire hose

couplings that are under pressure!
 Remove pressure as described above!
 Fluids discharged under high pressure can cause

serious injuries!
1 080 534 / BA UP III / GB /01.2014 55

Dry Suction Test zz Close the B pressure valves (6).
6 8
zz Close the suction inlet (4) with the cap hose 5
coupling.
6
zz Connect the pump to the coupling lever (8). 5

4
zz Start the motor.
If the motor is running:
zz Turn the „GAS“ switch (16) to the (S) position. 3

(Suction speed)
zz Check the overpressure/underpressure

manometer.
The needle must be in the red scale range after max. 16

20 sec. S
If the overpressure/underpressure manometer indicates -
0,8 bar in the red scale range:
zz Disconnect the pump with coupling lever (8).
zz Switch off the motor.
zz Check the overpressure/underpressure

manometer.
The indicated underpressure should not drop more

than 0,1 bar within 1 minute whilst the pump is idle.
If the vacuum is not achieved or of the vacuum

displayed decreases quickly (more than 0.1 bar/min),
then the pump leaks.
This means that air is flowing into the pump and
correct suction is no longer possible.
zz Open the drain cock (3) and vent the pump.
The max. permissible dry run time for the centrifugal

fire pump is 10 minutes.
Search for zz Visually check sealing rings in A solid fire hose

Leakages coupling (4) and A cap fire hose coupling.
6
zz Check pressure outlets for leakages.
By:
zz Fit B blanking couplings (5) and open outlet

valves (6).
zz Performing dry suction test again.
If the pump is no longer leaking replace the sealing rings 5 5

on the pressure valves (5) as necessary or adjust the valve
seat.
56 1 080 534 / BA UP III / GB /01.2014

Search for If the pump is still leaking test under pressure with water:
Leakages 6
zz Close B pressure valves (6). 5
zz Remove the cap fire hose couplings from the 6

pressure outlets (5).
zz Connect the collector A-2B (DIN 14 355) to the 5

suction inlet. 4
zz Connect the B pressure hose to the hydrant and
collector.
zz Put portable pump into operation.
zz Open hydrant.
zz With closed pressure valves increase the pressure

in the pump slowly until a pressure of approx. 19
16 bar is indicated on the overpressure
manometer.
zz Check entire pump for leakage.
Fluids discharged under high pressure can result in

severe injuries!
 Wear protective clothing and safety glasses!
Dismantle the pump if necessary and check the

sealing sleeve.
Seal the pump and repeat dry suction test.
Customer If the leakage cannot be eliminated after applying

Service above measures request the ZIEGLER Customer
Service.
1 080 534 / BA UP III / GB /01.2014 57

Prepare for Use Operation
After use zz Clean the pump.
6
zz Clean the suction inlet and filter at the suction 5
inlet (4).
6
Damage to If salty seawater or strongly contaminated water has
material! been moved using the fire fighting rotary pump, then
the pump and all armatures must be thoroughly 5
flushed using clear water (hydrant) after completion of 4
the mission.
This prevents salt or dirt from being deposited in the

pump and stopping the impeller from functioning.
3
zz Check that the B pressure valves (6) are

operating smoothly.
zz Open the drain cock (3) and drain the pump

thoroughly.
zz Remove the A cap fire hose coupling (4).
zz Operate the pump for a few seconds to drain the

TROKOMAT fully.
zz Perform a dry suction test after draining.
zz Open the B pressure valve (6) slightly.

This relieves the pressure on the seal at the valve
heads.

pressure outlets (5) and suction inlet (4).
zz Check the oil level in the pump gear.
zz Refill fuel.
CAUTION!  Care should be taken when handling fuel - greater

danger of fire!
 Only refuel when the motor is off - smoking

prohibited!
 Do not refuel in closed rooms - Fuel vapours are

toxic and can explode!
 Always remove spilt fuel in the correct manner!
zz Check level of motor oil and coolant..
WARNUNG! Danger of Burning!
Danger of burning due to vapour and hot water!
 Do not remove the cap on the coolant tank whilst

the motor is still hot!
58 1 080 534 / BA UP III / GB /01.2014

Prepare for Use Operation
If not being used for a longer period of time the

portable pump should be run (under load) every 4
weeks for approx. 15 min.
The preservability of fuel is limited.

Trial runs at regular intervals ensure that the fuel is not
overaged.
If trial runs are not made the following must be performed

at the latest before a six month intermission
zz the fuel tank must be drained,
zz empty the injector,
zz drain off the motor oil whilst still warm,
zz refill new motor oil.
Otherwise starting problems may arise!
Clean the portable pump thoroughly.
Drain the pump carefully particularly in winter or when there

is a danger of frost!
Short-time To ensure that the device starts well:

Operation
zz After starting run the motor in under load.
zz Avoid unnecessary cold starts without a

subsequent warm-up period.
Socket to The plug for the electrical lead of a battery charging device
DIN14 690 is inserted in the socket (29).
CAUTION! Damage!
29
 On charging the battery the charging current may
not exceed max. 4 A!
1 080 534 / BA UP III / GB /01.2014 59

Portable Pump when Danger of Frost (Winter Operation) Operation
Storage Store the portable pump in a heated room.
8
If the storage room is not heated: 5
zz Drain the pump thoroughly and protect against

frost.
Drain the Pump zz Open the drain cock (3).

5
4
Drain off the remaining water.
zz Connect the pump with the coupling lever (8).

3
suction inlet (4) and the pressure outlets (5).
zz Perform dry suction test.
zz Disconnect pump with coupling lever (8).
zz Open drain cock (3).
zz Remove cap fire hose coupling from the suction

inlet (4).
zz Connect the pump and operate at idle-running

speed.
Inject zz Whilst pump is running inject approx. 0,1 liter

Anti-freeze anti-freeze solution into the suction inlet using an
Solution appropriate plastic bottle.
zz Disconnect pump.
zz Open the drain cock (3) and drain off the

remaining anti-freeze solution.
zz Close the drain cock.
zz Switch off motor.
60 1 080 534 / BA UP III / GB /01.2014

Portable Pump Faults
General Malfunctions are often due to the incorrect operation and
servicing of the portable fire pump in the hectic of fire-
fighting operations.
When faults occur re-read the information on how to

correctly operate and service the portable pump.
Refer to the fault table on the following pages.

Simple faults can be eliminated by skilled personnel by
following the given instructions.
If you cannot determine or eliminate a fault yourself, please

contact the ZIEGLER Customer Service.
Work involved in searching for faults should only be carried

out by persons who are acquainted with this type of work,
who possess special knowledge and are aware of the
safety and accident prevention regulations.
Safety zz When searching for faults switch off the motor!
zz Disconnect the negative pole from the battery!
Safety Devices If it is necessary to remove protective and safety

devices when searching for faults these must be
reinstalled immediately upon completion of all work
and their ability to function checked!
1 080 534 / BA UP III / GB /01.2014 61

Fault Table for Centrifugal Fire Pump Faults
Faults Possible Causes Remedial Measures
Pump and suction pipeline are not Pressure valves or drain cock are not Close pressure valves.
vented. completely closed. Close drain cock.
Pump does not suction. Pump or suction pipeline are leaking. Check seals at the suction couplings.
Check that suction pipeline is not
Underpressure is not indicated on the leaking.
overpressure/underpressure manometer.
Pressure test pump and seal leaks.

(See Chapter „Dry suction test“)
Filter basket at the suction pipeline is not The filter basket should, if possible, be
deep enough in the water. 30 cm under the surface of the water.
Lengthen the suction pipeline and/or

move the portable pump nearer to the
water point.
Manometer clogged, frozen or defective. Clean the manometer, defrost or replace.
Pump is not delivering water although Filter basket or filter at suction inlet of the Clean the filter basket or filter.
the overpressure/underpressure pump is clogged. (leaves, paper etc.)
manometer indicates sufficient
underpressure.
The inner rubber coating in one or more Check the suction hoses. Replace
of the suction hoses has become loose. defective suction hoses.
The return valve in the filter basket has Release the return valve.
become stuck.
The water column is continually Filter basket at the suction pipeline is not Filter basket should if possible, be 30 cm
interrupted although the pump and the deep enough in the water. under the surface of the water.
suction pipeline are not leaking.
Lengthen the suction pipelines and/or
move the portable pump nearer to the
water point.
Water delivery is interrupted as soon as a Pump and suction pipeline have not Terminate venting process completely.
pressure valve is opened. been fully vented.
Pressure valve was opened too quickly. Open pressure valve slowly.
Water delivery is irregular or stops. The filter basket is no longer deep Lengthen the suction pipeline and/or
enough in the water as the water level move the portable pump nearer to the
has dropped. water point.
TROKOMAT switches on and off. Air leaks into the suction pipeline. Seal the suction pipeline or replace the
suction hose.
The suction pipeline has been laid over Lay the suction pipeline correctly.
a rise in the ground and an” air pocket”
has formed in the line.
62 1 080 534 / BA UP III / GB /01.2014

No delivery of water after temporary Water has returned because the return Repeat suction.
standstill of pump. valve in the filter basket does not close
tightly. After use or operating pump repair the
return valve.
Underpressure at the overpressure / The filter basket or filter at the suction Clean the filter basket or filter. (leaves,
underpressure manometer rises, the inlet is clogged. paper etc.)
water delivery drops.
The paths of the water in the pump are Check the pump.
constricted. If necessary clean the impeller and water
channels.
The inner rubber coating in one or more Check the suction hoses.
of the suction hoses has become loose. Replace defective suction hoses.
Underpressure at the overpressure/ Other pressure valves at the adapter are Adjust the motor speed accordingly and
underpressure manometer rises. open. set the desired pump pressure.
Pressure at the overpressure manometer
drops. Due to the use of larger nose pieces or
additional hose lines the flow rate was
increased.
Burst pressure hose. Replace the defective pressure hose.
Underpressure at the overpressure/ Due to the use of smaller nose pieces Adjust the motor speed accordingly and
underpressure manometer drops. or switching off individual hose lines the set the desired pump pressure.
Pressure at the overpressure manometer flow rate was reduced..
rises.
Pressure indicator at the overpressure The water column in the suction pipeline Repeat suction.
and overpressure/underpressure is interrupted.
manometer drops suddenly to zero. Check the suction pipeline for leakage if
it occurs again.
1 080 534 / BA UP III / GB /01.2014 63

The cap fire hose coupling at the ‚ The cap fire hose coupling was not Before putting the pump into operation
pressure outlet cannot be easily removed before putting the pump into remove the cap fire hose couplings from
disconnected. operation. all pressure outlets, also those that are
not being used.
When releasing the coupling under
pressure the cap fire hose coupling can
be catapulted off.
Pressure has built up in the space Reduce the pressure between the valve
between the valve head of the B pressure and coupling in the following manner:
valve and the cap fire hose coupling.
(e.g. when pressure valve is leaky). ATTENTION!
Danger of injury!
zz Do not remove the cap fire

The pressure cannot drop due to the hose coupling! The coupling
return function of the valve plate. can be catapulted off!

zz Reduce the pressure, by:

zz Slowly increasing pump
pressure to approx. 8 bar thus
producing a pressure
compensation between the
pressure valve and the pump.
zz Opening the pressure valve

slowly, pull the locking pin and
open the valve fully.
zz Reduce the pump pressure

slowly, pressure valve remains
fully open.

zz Remove the cap fire hose

coupling.
ATTENTION!
Danger of injury!
Never use force when removing cap fire

hose couplings that are under pressure!
Cap fire hose couplings that are

catapulted off due to pressure can result
in severe injuries!
64 1 080 534 / BA UP III / GB /01.2014

Fault Table for Motor Faults
The motor runs intermittently, even Fuel tank is empty. Fill with fuel.
though all signaling lamps show
problem-free operation.
Fault on the engine. Have error memory in the controller read

by ZIEGLER customer service or VW
garage.
Sediment filter in the tank or the fuel line Remove dirt trap from the petrol pipe and
are contaminated. replace. If necessary, drain fuel and clean
the fuel pump’s pre-filter.
The red signaling lamp „coolant Loss of coolant due to a leak in the Determine leakage and eliminate, refill
temperature“ is lit during pump operation cooling system. coolant with original VW coolant additive
G12 Plus.
Switch off the motor immediately! Pump was operated too long without Open supply line so that cold water can
removal of water. flow into the pump.
The red signaling lamp „coolant Accumulated heat in the motor when it None. The display is extinguished after
temperature“ will shortly light up until the was switched off during full-load the motor has cooled down,
water temperature has fallen if the engine operation without a cool-down phase. approx. 1-2 min.
has been restarted while the ventilators
are still running.
This is not a fault.
The red signaling lamp „oil pressure“ is lit Motor oil level is too low. Refill motor oil. Only use motor oil
during operation. recommended by the manufacturer.
Check motor for leakages.
Switch off the motor immediately! The permissible angle of inclination Set up portable power pump with a lower
of 15° of the portable pump has been tilting angle.
exceeded.
The red signaling lamp „battery charge“ The ribbed V-belt is faulty. Replace ribbed V-belt.
is lit during operation.
The dynamo or electrical equipment are Go to a Volkswagen service station or
defective. ZIEGLER customer service.
Information:
Before starting the motor at the ignition switch position „Operation“ all three warning lights must light up.
The light bulbs can thus be checked for correct functioning.
If the above remedial measures were ineffective contact the ZIEGLER Service or the nearest Volkswagen authorized
repairer.
1 080 534 / BA UP III / GB /01.2014 65

Safety Measures Service / Maintenance
General Service and maintenance work should only be carried out
by persons who are familiar with the device, who possess
special knowledge and who are aware of the safety and
accident prevention regulations.
When carrying out maintenance work:
zz Switch off the motor!
zz Disconnect the negative pole from the battery.
zz Ensure that the portable pump stands firmly on

the ground!
Safety Devices If protective and safety devices have to be disassembled

when carrying out service and maintenance work they must
be replaced immediately after completion of work and
checked that they are in full working order!
Spare Parts If parts require replacing during service and maintenance

work on the portable pump, only original ZIEGLER spare
parts may be used!
The use of spare parts and accessories that did not

originate from ZIEGLER and were not tested and approved
by ZIEGLER can have a negative affect on the
characteristics or on the functional efficiency and thus
influence the operational safety.
For safety reasons therefore, only original ZIEGLER spare

parts should be used.
Despite continuous market observation ZIEGLER cannot
assess and is not responsible for the reliability, safety and
suitability of parts obtained from outside sources - even
when in isolated cases the parts have been approved by
the technical control board or an official body!
ZIEGLER is in no way liable for damage to persons and

property resulting from the use of parts, accessories or
attachments obtained from outside sources!
Please also observe the spare parts list supplied with the
portable pump.
66 1 080 534 / BA UP III / GB /01.2014

Safety Measures Service / Maintenance
Environmental Dispose of oils, fuels, cooling water, batteries and filters
Protection according to statutory regulations and in an environmentally
Measures compatible manner!
Never dispose of waste in the earth, sewage system or

waters!
Fuels should only be stored in the prescribed containers!
Before disposing of parts, observe the correct disposal

(recycling) procedure!
1 080 534 / BA UP III / GB /01.2014 67

Accessories Service / Maintenance
Tool Kit The tool kit is stored in a special tool bag.
Complete toolkit: Article number: 064048
It comprises the following parts:
Position Quant. Name Item No.

1 1 Tool box for TS 8 - tool 64311
2 1 Grease gun 98821
3 1 Cleaning wire 103906
4 1 Pin-type wrench, hexagon, 5mm DIN 9111 61837
5 1 Crosshead screwdriver 61431
6 1 Screwdriver 260 mm lg. 8 mm 61423
7 1 Car fuse 4 A pink 125242
8 1 Car fuse 7,5 A brown 125244
9 1 Car fuse 5 A beige 125243
10 1 Car fuse 18 A red 125245
11 3 Car fuse 15 A blue 125246
12 1 Car fuse 25 A white 125248
13 1 Single-head open-ended wrench 32 mm 894 61812
14 1 Single-head open-ended wrench 30 mm 894 61813
15 1 Double-head open-ended wrench 24 x 27 895 61816
22 1 Double-head open-ended wrench, opening 16 212130
23 1 Box wrench, opening 17 134315
24 1 Mandrel 10 x 200 117002
Documentation Quant. Name Item No.

(Item No.: 1 080 513)
1 Operator’s booklet for portable fire pump 1052264
1 Water pumping table 1052262
1 Spare parts list for TS Ziegler Ultra Power 3 1080537
1 Operating instructions for TS Ziegler Ultra Power 3 1080534
1 Operating instructions for motor ???????
1 Service schedule for motor ???????
Other accessories on request Name Item No.

(against additional price)
Fuel can 10 liter, metal 56882
Filler neck for fuel can 56991
Exhaust hose 50 mm, 1,5 m long, DIN 14572 83221
Manual emergency starter 210737
Container for manual emergency starter 213008
Trolley 20061
Charger 12V/ 12V with discharge protection, with function indicator 1047145
Charger 12V/ 12V with discharge protection, without function indicator 1047184
Charger 12V/ 12V without discharge protection, with function indicator 1047183
Charger 12V/ 12V without discharge protection, without function indicator 1047144
Charger 12V/ 12V with discharge protection, with function indicator 1047146
Charger 12V/ 12V with discharge protection, without function indicator 1047185
Charger 12V/ 12V without discharge protection, with function indicator 1047186
Charger 12V/ 12V without discharge protection, without function indicator 1047147
Tools and accessories for the portable pump can be ordered from ZIEGLER specifying
the corresponding item no.
68 1 080 534 / BA UP III / GB /01.2014

Centrifugal Fire Pump Service / Maintenance
Lubricate Radial The nipple (35) is behind the pump casing.
Sealing Rings
Maintenance After 20 operating hours,

Interval however, at least 1 x annually.
zz Lubricate by pressing the grease gun approx. 35

5 times on the nipple (35).
Fuel Quality Only use branded grease, e.g.
Special pump grease Multitherm 2 or BE 31-222
Texaco grease F 020
or pump grease of similar quality.
Spare Parts The special pump grease Multitherm 2 is available

directly from ZIEGLER under item no. 98 813.
Lubricate
Pressure Outlets
Maintenance Oil or grease the spindles of the B pressure valves (6)

Interval slightly according to use.
6 6
Suction filter Following each deployment:
zz Remove suction filter (36).
zz Clean intake and suction filter (36). 36
zz Replace suction filter (36).
CAUTION! Risk of accident!

Material damage!
 The pump must never be operated without the

suction filter!
1 080 534 / BA UP III / GB /01.2014 69

Centrifugal Fire Pump Service / Maintenance
Pump Gear
37
Check Oil Level
Maintenance Every 10 operating hours,

Interval at least 1 x monthly.
zz Stand the pump in a horizontal position.
zz Unscrew the oil dip rod (37), remove and wipe

with a cloth.
zz Replace the oil dip rod (37) and screw tight.
zz Unscrew the oil dip rod (37) again and remove.
The upper edge of the visible oil film must be between both
markings on the oil rod.
Oil Change
Maintenance At least 1 x annually

Interval
Filling amount: 0,4 l
Fuel Quality Only use branded gear lubricant oil with a viscosity of
SAE 80!
The exact oil level in the pump gear after changing oil
should correspond with the mark on the scale.
70 1 080 534 / BA UP III / GB /01.2014

Motor Service / Maintenance
Regular motor inspections should be performed in
accordance with the VW motor operating instructions.
Check Spark Plugs As per VW service schedule
Exchange Exchange frequency see VW service plan.

Spark Plugs
Typ: Bosch F7 HER 02
No other spark plug models may be used!
Suction speed The standard suction speed limiter prevents an

limiter increase of the engine speed above 3500 rpm for a
pump pressure of less than 1 bar.
If the speed is to be increased beyond this for testing

of the engine without operating the pump using water,
then the pump must be disengaged and one of the two
connecting cables of the pressure switch (see arrow)
must be pulled off from the pump housing.
TOURMAT D If the portable pump is fitted with the TOURMAT D*

automatic pump pressure control, instead of the
pressure switch, a pressure sensor will be located on
the pump enclosure.
Once the locking screw is loosened (see arrow) the

connection plug may be removed in order to deactivate
the intake speed limiter.
1 080 534 / BA UP III / GB /01.2014 71

Air filter In normal dust conditions, it is sufficient to clean the air
filter during the regular inspection of the engine as per the
VW service schedule.
1
In dusty conditions, clean after 50 operating hours at the
2
latest. 1
Cleaning:
zz Unscrew clips (1) on the suction hose (2) and

remove hose.
zz Unscrew filter element (3) from the housing (4).
zz Remove filter from the damper pipe (5).
zz Wash out filter in petrol and blow out with com-

pressed air from the outside inward.
zz Assemble in the reverse order of removal.

3
Injection system Faults can be identified and rectified in a VW garage or by

ZIEGLER customer service using the diagnostics connector.
4
Motor oil Multigrade engine oil
SAE 5W30,
SAE 5W40,
SAE 0W30 (can be used in temperature range
from -30°C to + 40°C) or
SAE 20W50 (can be used in temperature range
from -15 °C to + 40°C)
as per the VW specifications
VW 502 00,
VW 503 00,
VW 504 00 or
VW 501 01.
Oil exchange zz Let engine warm up.
zz Shutdown engine.
zz Take off upper part of the cover.
zz Perform oil and oil filter exchange according to

VW engine operating manual.
72 1 080 534 / BA UP III / GB /01.2014

Description cooling The watercooled engine is fitted with a closed-circuit
system cooling system comprising of the components heat
exchanger, radiator with electrical ventilator and balancing
vessel.
During water transport using the ZIEGLER portable power

pump, the greatest share of the engine waste heat is
transmitted to the delivered water of the fire fighting rotary
pump using the heat exchanger.
The coolant mixture of the engine circuit emits cooled off

from the heat exchanger, flows through the balancing
vessel with filling level marks and the relief valve in the
cover.
Subsequently, the coolant enters the radiator, where it is

cooled further using two electrical ventilators. During the
engine operation, the two electrical ventilators are
constantly running and therefore make sure of sufficient
cooling air throughput in the engine compartment.
After shutting off the engine, the ventilators may

automatically turn on to discharge the stored heat.
In case of dry operation of the portable power pump, no

heat can be discharged through the heat exchanger. In this
operating mode, the additional radiator prevents
overheating of the cooling system.
The cooling system must be filled using a mixture made of

water and a 40% share of the coolant additive G12 Plus
(glycol-based antifreeze with corrosion protection
additives).
This mixture not only offers the necessary antifreeze

properties up to -25°C, but especially protects the light
metal parts in the cooling system against corrosion. Also,
they prevent lime deposits and substantially increase the
boiling point of the coolant.
Therefore, the concentration of the coolant may not be

reduced by filling up using water even during the hot
season respectively in hot countries.
The coolant additive share must be at least 40%.
Observe the hints on safety.
If stronger antifreeze protection is required for climate

reasons, then the share of coolant additive G12 Plus may
be increased, but only up to 60% (antifree protection up to
about -40°C), because otherwise the antifreeze protection
is reduced again and also the cooling effect deteriorates.
1 080 534 / BA UP III / GB /01.2014 73

Coolant additive Only our G 12 Plus respectively an additive having the
specification TL-VW 774 F
(observe container labeling) may be used as coolant
additive. The coolant is available from Volkswagen
dealerships.
Other coolant additives may especially substantially

impair the corrosion protection effect!
Corrosion damage caused by this may lead to loss of

coolant and subsequently to severe motor damage!
Loss of coolant Loss of coolant is mainly due to leaks. In this case, the
cooling system should be immediately checked by a VW
dealership. It is not enough to fill up coolant.
In case of a leak-free system, losses can only occur if the

coolant boils due to overheating and is therefore pressed
out of the cooling system.
Check coolant level
CAUTION! Risk of injury and scalding!
 Hazard of scalding! - Never open the engine cover

when you see steam or coolant emitting. Wait until
no steam or coolant is emitting anymore.
 The coolant level can only be correctly checked with

engine standing still.
The correct coolant level is important for perfect function of

the cooling system.
Therefore, the coolant level should be regularly checked!
The coolant level must be visible between the MIN. and the
MAX. marking for a cold engine; in case of a warm engine,
it may be a little above the MAX. mark.
To check the coolant level, the cap of the balancing vessel

does not have to be taken off, because the vessel is
opaque.
CAUTION! Damage!
If the coolant level is below the MIN marking, engine

cooling will be impaired and the engine may be dam-
aged.
74 1 080 534 / BA UP III / GB /01.2014

Refill coolant First turn off the engine and let it cool down. Then, cover
the cap of the balancing vessel with a cloth and carefully
unscrew the cap counterclockwise.
CAUTION! Risk of injury and scalding!
The cooling system is under pressure!
 Do not open the cap of the balancing vessel with a

hot engine - scalding hazard!
If, in case of emergency, only water may be filled up, then

the correct mixture with the prescribed coolant additive (see
previous page) must be reinstated as soon as possible.
Do not fill up beyond the MAX. mark of the balancing

vessel:
Excess coolant is pressed out of the cooling system

through the relief valve in the cap when warming up!
Tightly close the cap.
The coolant additive and the coolant form a health

hazard!
 The coolant additive must therefore be kept in the

original container and especially secured against
access by children.
 If the coolant has to be drained, then it should
normally not be reused; it must be disposed of
under observation of environmental protection
regulations.
If the coolant is drained for repairs, then the cooling system

must subsequently be filled and vented as follows.
zz Fill up premixed coolant up to the maximum mark

of the balancing vessel.
1 080 534 / BA UP III / GB /01.2014 75

Fill up coolant zz Check coolant level when the engine is cold and
top-up to the MAX. mark if necessary.
zz Unscrew top and leave engine to run at idle until

the expansion vessel is warm.
zz Run engine briefly at 3500 1/min several times to

remove air bubbles.
zz Leave engine to cool down, check coolant and

top-up again if necessary.
Radiator ventilators The radiator ventilators are electrically driven and

constantly operate during engine operation.
After shutting down the engine, the ventilators may,

even with ignition switched off, run on for some time
(up to about 10 minutes).
But they may suddenly switch on after some time, if
zz the coolant temperature rises due to stored

heat.
 Therefore, special care is required for any work on

the engine!
76 1 080 534 / BA UP III / GB /01.2014

Battery Follow the safety instructions on the battery!
Safety Measures Danger of explosion!
When charging batteries a highly explosive mixture of

oxyhydrogen gas is produced!
Fire, sparks, unshielded light and smoking are prohibited!
Avoid sparking when handling cables and electrical

equipment!
Avoid short circuits!
Danger of injury due to caustic substances!
Battery acid is extremely caustic, therefore:
zz Always wear protective gloves.
zz Always wear protective glasses.
zz Do not tip the battery, acid can flow out of the air
vent inlet.
After coming into contact with battery acid wash

immediately under running water or with 10% boracic acid
solution.
Run-down batteries can freeze, therefore store in a frostfree

room!
Dispose of old batteries at the respective collecting depot

in an environmentally compatible manner.
1 080 534 / BA UP III / GB /01.2014 77

Check the
Acid Level
Maintenance Check the acid level at least 1 x monthly.

Interval
zz Remove the side casing.
zz Undo clamping strap on the battery.
zz First disconnect the pole terminal from the

„negative cable“ and then the „positive cable“.
 When handling the battery wear protective gloves

and glasses and observe the safety regulations!
zz Remove the battery from its mount.
Do not tip the battery when removing to prevent acid

from flowing out of the vent bores!
 The acid level must reach the markings otherwise

fill up with distilled water.
 Check the pole terminals.
 If necessary clean the pole terminals carefully with

a brush.
 Grease the pole ends and terminals with acid-free

battery grease.
 Insert the battery.
CAUTION! Danger of accident!
When inserting the battery ensure that it is connected

correctly.
 First the positive pole and then the negative pole!
CAUTION! Damage!
 The drain hose on the ventilation opening on the

battery must always be fitted to prevent damage if
any acid escapes!
78 1 080 534 / BA UP III / GB /01.2014

The battery should be well charged to ensure

readiness for start at all times particularly at low
outside temperatures.
Check the charged state of the battery at regular

intervals.
Charge the Battery To charge the installed battery the vent plugs must not be
removed.
The battery can be charged when already installed via the

socket DIN 14 690.
CAUTION! Charging current: max. 4 ampere.
 Store the battery in a well ventilated room.
 Only use approved electronically controlled battery

chargers!
 The battery housing should only stay hand warm

when charging!
Battery charge Optionally, the portable power pump may be fitted with
preservation an additional 3-pole socket for charge preservation. The
socket is located above the socket DIN 14960. It serves
permanent connection to a charge preserving device, which
supplies power to the TS battery from the vehicle battery.
 Only the original charge preserving device may be

used, which has been supplied together with the
portable power pump.
1 080 534 / BA UP III / GB /01.2014 79

Inspection service Service / Maintenance
Remarks For servicing your Volkswagen engine, the far-reaching
network of Volkswagen dealerships with trained specialists,
modern equipment and all necessary special tools is
available.
Here, you will find expert advice and quick and effective
assistance.
Should it be the case that in exceptions different specialist

workshop must be charged with inspection service due,
then all testing and adjusting work to be performed in this
connection is described on the following pages. Please
also observe the information given in the service plan of the
engine operating manual!
If repairs are required, then the engine must be brought to a

Volkswagen workshop. There, it will find the best
specialists.
80 1 080 534 / BA UP III / GB /01.2014

Exchange engine The engine oil must be exchanged with the frequency
oil stated in the service plan. Have the oil exchange performed
by a Volkswagen workshop.
If you want to perform the engine oil exchange

yourself, then indispensably observe the following
items:
 First let the engine cool down to avoid the burning

hazard due to hot engine oil.
 For draining oil, use a container provided for this

purpose which is large enough to accept the oil
filling quantity of your engine.
 Wear eye protection.
 If you unscrew the oil drain plug with your fingers,
then hold yours arms level so that draining oil will
not run down your arms.
 If you get into contact with engine oil with your
hands, then you must subsequently thoroughly
wash them.
 Waste oil must be stored securely protected against

children until it is disposed of according to
regulations.
In no case may oil get into the sewer network or soil!
Due to the disposal problem and the necessary specialist

knowledge, the engine oil and filter exchange should best
be performed by a Volkswagen workshop.
Engine oil additives No additional lubricant should be mixed into the engine oil.
Damage incurred due to such agents is excluded from the

warranty.
1 080 534 / BA UP III / GB /01.2014 81

Filter exchange
Full flow oil filter Unscrew the top on the filter housing using the spanner
(36 AF).
Fit the filter element and lightly oil the sealing ring in the
top.
Dry air filter: In normal dust conditions, it is sufficient to clean the air
cleaning element filter during the regular inspection of the engine as per the
VW service schedule.
1
In dusty conditions, clean after 50 operating hours at the
2
latest. 1
Cleaning:
zz Unscrew clips (1) on the suction hose (2) and

remove hose.
zz Unscrew filter element (3) from the housing (4).
zz Remove filter from the damper pipe (5).
zz Wash out filter in petrol and blow out with com-

pressed air from the outside inward.
zz Assemble in the reverse order of removal.

3
Replace fuel filter The fuel filter is integrated in the housing for the fuel
pressure regulator (system pressure 4 bar).
Replace the filter as per VW service schedule.
82 1 080 534 / BA UP III / GB /01.2014

Ignition system To avoid injury to persons and/or destruction of the fuel
Motronic injection and ignition system, observe the following items:
Safety zz Do not touch or remove spark plug connectors

when the engine is running or is turning over on
the starter.
zz Close and separate lines of the fuel injection and

ignition system - also measuring instrument lines
- only with ignition switched off.
zz If the engine is to be operated at starting speed

without actually starting up, for instance for a
compression pressure test, pull off the plug from
the Hall generator (on the camshaft near the
ignition distributor.
Description Use the VW repair guideline on the Motronic fuel injection

and ignition system for the engine model CKYA for
maintenance and repair work on the fuel injection and
ignition system. Special tools are required, like for instance
the fault reading device V.A.G. 1551, so that this work can
only be performed by a Volkswagen workshop or the
ZIEGLER customer service.
The engine for the ZIEGLER portable power pump deviates

in some respects in comparison with the vehicle engine,
which are described below.
Mixture controlled by pre-programmed Lambda

data, Lambda probe not used.
Two-stage speed limiting at 3500 1/min and

5950 1/min.
The following change must be considered in the Motronic

repair guideline:
Control device for the fuel injection and ignition system
Control device version SIM0S 9.1 with ZIEGLER data protection

Part no ZIEGLER Art.No.: 1070987
Speed limiter 3500 rpm and 5950 rpm
1 080 534 / BA UP III / GB /01.2014 83

Exchange Due to technical reasons, sparkplugs may change in short
spark plugs terms. It is therefore recommended to only purchase them
from Volkswagen workshops - there are informed about the
current situation.
Sparkplug model: VW part number:
- Bosch F7 HER02 - 101 905 601 F
VOLKSWAGEN
The tightening torque is 25 - 30 Nm.
84 1 080 534 / BA UP III / GB /01.2014

Exchange V-ribbed Required special tools, test equipment and auxiliary
belt material
Torx bit T 50
Round bar 3 mm (e.g. shoulder 3 mm)
Procedure:
zz Mark the running direction of the V-ribbed belt.
zz Drain coolant and collect for re-use.
zz Remove radiator trim panel and radiator.
zz Using the Torx bit, lift belt tensioner against the

force of the spring and fix in position by inserting
the round bar in the hole underneath.
zz Take off respectively install V-ribbed belt.
 When installing the V-ribbed belt, please take care

to observe correct position of the belt between the
belt pulleys.
zz After fitting the ribbed V-belt, slightly raise the

belt tensioner using the Torx bit, remove round
bar and allow the belt tensioner to return to its
operating position.
zz Check correct seating of the belt in the belt pulley.
zz Fit radiator and radiator trim panel.
zz Fill with coolant.
zz Perform test run.
It is also possible to replace the ribbed V-belt without

removing the radiator, however exact knowledge of the
position of the Torx bolts and the hole for round bar are
required.
For this reason this procedure is not recommended the
first time this work is performed.
1 080 534 / BA UP III / GB /01.2014 85

Spare parts All spare parts for the CKYA engine are available from the
network of Volkswagen dealers. Only parts for the cooling
system, the exhaust system and engine management unit
with ZIEGLER data protection are to be found in the
ZIEGLER spare parts list and are to be procured from
ZIEGLER.
The delivery status of the Volkswagen engines should not

be modified without deliberation. If technological
modifications are made to the engine or subsequently parts
must be replaced, then the following hints must be VOLKSWAGEN
observed in this respect:
zz Before performing technological modifications,

always consultation with a Volkswagen partner
should be performed, because due to close
cooperation with us, the Volkswagen organization
is especially competent.
zz In your interest, we recommend to only use

original Volkswagen parts for your Volkswagen
engine. These parts were approved as reliable,
safe and suitable.
zz Third party products cannot be assessed by us,

inspite of constant monitoring of the market, and
we do not assume any warranty - even if, in some
cases, there may be certification by an officially
recognized testing and monitoring association or
official approval.
zz You will receive original Volkswagen parts from

Volkswagen partners. Of course, assembly will be
performed in an expert manner there as well.
zz If technological modifications are to be

performed, then our guidelines must be
observed. This ensures that no damage to the
engine is made, operating safety is preserved and
that the modifications are approved. The
Volkswagen partner will be performing this work
in an expert manner as well, or in specific cases
will refer you to a specialist workshop.
86 1 080 534 / BA UP III / GB /01.2014

Fuels Service / Maintenance
Fuel
Petrol
Quality Super petrol, lead-free at least RON 95,
if necessary normal petrol, lead-free at least RON 911)
Tank contents approx. 19,5 liter
Service life At least 1 operating hour at rated performance 1500 l/min and 10 bar
Lubricants
Motor
Motor Oil Multigrade engine oil
SAE 5W30, SAE 5W40, SAE 0W30 or SAE 20W50
as per the VW specifications
VW 502 00, VW 503 00, VW 504 00 or VW 501 01.
Oil Filling Amount Oil change incl. filter change 2.85 litre
Pump
Viscosity SAE 80
Filling Amount approx. 0,4 liter 2)
Radial Sealing Rings Pump grease BE 31-222 ZIEGLER art. no.: 098809 or equivalent pump
grease
B Pressure valve spindles Machine or motor oil
Motor
Coolant Mixture Water with VW coolant additive G12 Plus.
Mixing ratio as prescribed by manufacturer.
Filling Amount approx. 3,3 liter 2)
1)
he use of unleaded regular gasoline leads to a slight loss of power because the engine control takes
T
back the ignition point.
If unleaded fuel is not available, the portable fire pump can also be operated with leaded fuel.
2)
The exact oil level in pump operation should correspond with the mark on the measuring rod!
1 080 534 / BA UP III / GB /01.2014 87

Electrical Equipment Service / Maintenance
Safety Measures Work on electrical equipment should only be carried out by
a skilled electrician or persons who have been instructed
accordingly under the guidance of a skilled electrician
according to electrotechnical regulations!
When working on electrical equipment always remove the

cable from the negative pole of the battery!
Ensure that the battery is connected correctly - first the

positive pole and then the negative pole!
Do not deposit any items on the battery - short circuit

hazard!
Only use original fuses! The use of fuses that are too strong
will damage the equipment!
The electrical equipment of the portable pump should be

checked at regular intervals!
Loose connections and/or scorched cables must be
removed immediately!
88 1 080 534 / BA UP III / GB /01.2014

Fuses Service / Maintenance
Fuses The individual electrical circuits of the electrical equipment
have safety fuses.
When working on electrical equipment always remove

the cable from the negative pole of the battery!
Only use original fuses!

Fuses that are too strong destroy the electrical
equipment!
Fuses should not be repaired or bypassed!
Before replacing a burnt-out fuse eliminate the cause of

the short-circuit!
Always have a few fuses on hand in case of an

emergency.
Changing Fuses zz Turn the ignition switch to the „0“ position.
zz Remove the side casing.
zz Screw off the cap of the fuse box (1).
zz Refer to the circuit diagrams or the fuse tables in

the socket to determine which fuse belongs to the
load circuit that has failed.
The metal strip of damaged motor fuses has melted 1

through.
With glass fuses with LED the LED lights up.
zz Remove the burnt out fuse and replace with a

new fuse of the same strength.
Damage to If a new fuse burns out soon after replacing the

material! electrical equipment must be checked as quickly as
possible by an authorized repairer or the ZIEGLER
Customer Service.
1 080 534 / BA UP III / GB /01.2014 89

Fuses Service / Maintenance
Overview Fuse Box
F 1.1 F 1.2 F 1.3 F 1.4 F 1.5 F 1.6 F 2.1 F 2.2

15A 15A 15A 5A 15A 4A 25A 7,5A
(bl) (bl) (bl) (bg) (rd) (pk) (wh) (br)
Term. 30 Term. 87 Term. 87 Term. 15 Term. 15 Term. 15 Term. 30 Term. 30

Normally Normally
open contact open contact
relay term. relay term.
Normally Injection Ignition Normally open Fuel Pump Control panel Starter Lights
open contact valves modules contact relay Press. switch Fans Charg. socket
relay 30 Simos term. 86 Pressure
Immobiliser controller Simos controller transducer
Diagn. con- Immobiliser
nector Diagn.
connector
1040596-000
90 1 080 534 / BA UP III / GB /01.2014

Service / Maintenance
1 080 534 / BA UP III / GB /01.2014 91

92 1 080 534 / BA UP III / GB /01.2014

1 080 534 / BA UP III / GB /01.2014 93

94 1 080 534 / BA UP III / GB /01.2014

1 080 534 / BA UP III / GB /01.2014 95

Annex
Permissible tight- All bolts (quality: at least galvanised) must be tightened using a torque wrench.
ening torques for The tightening torque for the individual bolt sizes is given in the following table.
bolts of strength
class 8.8
Thread Tightening torque Thread Tightening torque
MA 0,9 in Nm MA 0,9 in Nm
M8 25 M8x1 27
M 10 49 M 10 x 1,25 52
M 12 86 M 12 x 1,25 95
M 14 135 M 12 x 1,5 90
M 16 210 M 16 x 1,5 225
M 18 290 M 20 x 1,5 460
M 20 410 M 24 x 2 780
M 22 550 M 30 x 2 1600
M 24 710
96
96 1 080 534 / BA UP III / GB /01.2014
Noise emission values Annex
PFPN 10-1000-1 Ultra Power 3
TWO-FIGURE NOISE EMISSION DATA

- Measured A-weighted sound pressure level:
92,5
LpA, referred to 20 µPa, at the operating position (dB):.........................................................................
2,5
Uncertainty, KpA, (dB).........................................................................................................................
- Measured A-weighted sound power level:
108,0
LWA, referred to 1pW (dB):.................................................................................................................
2,5
Uncertainty, KWA, (dB)........................................................................................................................
The values were determined as per the noise measurement in accordance with EN 14466: 2005, Annex E,
with the application of the basic standard EN ISO 3744 and EN ISO 11203.
PFPN 10-1500-1 Ultra Power 3
TWO-FIGURE NOISE EMISSION DATA

- Measured A-weighted sound pressure level:
93,0
LpA, referred to 20 µPa, at the operating position (dB):.........................................................................
2,5
Uncertainty, KpA, (dB).........................................................................................................................
- Measured A-weighted sound power level:

109,6
LWA, referred to 1pW (dB):.................................................................................................................
2,5
Uncertainty, KWA, (dB)........................................................................................................................
The values were determined as per the noise measurement in accordance with EN 14466: 2005, Annex E,
with the application of the basic standard EN ISO 3744 and EN ISO 11203.
1 080 534 / BA UP III / GB /01.2014 97


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ZIEGLER ULTRA POWER 3

1 080 534 / BA UP III / GB /01.2014

Telefon: 07322 951-0 GmbH in Giengen Albert Ziegler GmbH

Fax: 07322 951-211 Amtsgericht Ulm HRB 730059 Kreissparkasse Heidenheim •

Memminger Straße 28 89537 Giengen/Brenz

Telephone: +49 7322 951-0

Our products undergo continuous further development.

Imprint Copyright © 01.2014 by Albert Ziegler GmbH

The reproduction of operating instructions - in part or in whole, reprinting, photocopying, on electronic

All rights reserved.

3. Edition: 01.2014 Order No.: 1 080 534

Printed in the Federal Republic of Germany

1 080 534 / BA UP III / GB /01.2014 I

II 1 080 534 / BA UP III / GB /01.2014

1 080 534 / BA UP III / GB /01.2014 III

IV 1 080 534 / BA UP III / GB /01.2014

1 080 534 / BA UP III / GB /01.2014 V

VI 1 080 534 / BA UP III / GB /01.2014

7 Electric wiring diagrams

1 080 534 / BA UP III / GB /01.2014 VII

1 080 534 / BA UP III / GB /01.2014 1

CAUTION! Incorrect operation!

 Persons subsequently altering the vehicle/device whilst assembling, installing or converting

2 1 080 534 / BA UP III / GB /01.2014

 very environmentally friendly,

 operational safety - the VW industrial engine CKYA is a moder fuel-injection engine,

 minimized noise due to water cooling.

1 080 534 / BA UP III / GB /01.2014 3

The operating instructions are an important element of your portable pump.

4 1 080 534 / BA UP III / GB /01.2014

ZIEGLER ULTRA POWER 3 PFPN 10-1000

Type plate on the

Type plate on the

1 080 534 / BA UP III / GB /01.2014 5

The portable pump is a state-of-the-art construction and

Only use the device in a technically perfect state and in

The portable pump should only be operated by persons

Continuous training on the portable pump and training by

Warning Signs Meaning

All safety instructions are marked with this sign in the

Comply with all safety instructions and accident prevention

Signal words DANGER!: In case of high risk, life-threatening haz-

Information on the economical use of the device plus

Information and useful tips for avoiding problems.

6 1 080 534 / BA UP III / GB /01.2014

Ensure that you are familiar with the functions of all

Never allow persons without specialist knowledge to

Accident In addition to the information contained in these operating

 Generally recognized regulations on industrial

 Directives and generally recognized technical

The most important accident prevention regulations of the

 GUV-V A1 (Statutory accident insurance)

Accident prevent regulations are not recommendations,

Always ensure that the portable pump is in good working

1 080 534 / BA UP III / GB /01.2014 7

When removing the portable pump from the fire engine

When transporting the portable pump over steep

Exhaust gases may cause severe damage to health!

Do not operate the portable pump in closed, non-ventilated

When pumping out deep cellars, manholes etc. do not

When motor driven connect the exhaust hose! Divert the

Observe the relevant valid regulations applicable at the

Persons subsequently altering the vehicle/device whilst assembling, installing or converting

very environmentally friendly,

operational safety - the VW industrial engine CKYA is a moder fuel-injection engine,

minimized noise due to water cooling.

ZIEGLER ULTRA POWER 3 PFPN 10-1000

Signal words DANGER!: In case of high risk, life-threatening haz-

Generally recognized regulations on industrial

Directives and generally recognized technical

GUV-V A1 (Statutory accident insurance)

zz Do not remove the cap fire hose coupling!

zz Slowly increasing pump pressure to approx.

zz Opening the pressure valve slowly, pull the

 Only „open throttle“ once all outlet hoses connected

¾¾Only actuate TOURMAT D pushbutton if the pressu-

¾¾If the fire centrifugal pump is switched on, only

Always wear protective gloves

Always wear protective glasses

Do not tip the battery, acid may be discharged