Boardman Engines (SGT) - FireNotes



BOARDMAN ENGINE OPERATION/MAINTENANCE MANUAL

TABLE OF CONTENTS

BOARDMAN ENGINES GENERAL SPECIFICATIONS 2

INTAKES & DISCHARGES 3

GLADIATOR 3

DIAMOND 3

1871 SERIES 3

CAB INTERIOR CONTROLS & INSTRUMENTS 3

CHASSIS: (Interior Cab Controls, Instrumentation) 3

INTERIOR CAB CONTROLS 3

INSTRUMENTATION 3

CHASSIS: (Warning Lights & Buzzers) 4

DRIVING PROCEDURES 4

PRE-TRIP INSPECTION 4

STARTING INSTRUCTIONS 5

DRIVING/STOPPING 5

PARKING 6

PUMPING PROCEDURES 6

INSTRUMENTS AND CONTROLS 6

CONTROLS 6

GAUGES AND REMAINING FEATURES 7

ENGAGING THE PUMP 7

PUMPING 7

PRIMING THE PUMP 7

RELIEF VALVE OPERATION; SETTING THE RELIEF VALVE: 8

DISENGAGING THE PUMP 8

MANUAL PUMP SHIFT OVERRIDE 8

DISENGAGING THE MANUAL PUMP SHIFT 8

CAB TILT 9

ENGINE OIL 9

COOLING SYSTEM 9

TRANSMISSION 9

POWER STEERING 9

PUMP IN GENERAL 9

PUMP TRANSMISSION 9

PRIMER RESERVOIR 9

RELIEF VALVE/PILOT VALVE 9

INTAKES & DISCHARGES 9

BOARDMAN APACHE TOWER - MODEL T-55D

PART I - SECTION A IMPORTANT SAFETY INSTRUCTIONS AND WARNINGS 10

SAFETY INTERLOCKS AND WARNING DEVICES 10

BASE FRAME 10

STABILIZERS 11

REAR CONTROL STATION 11

BOOM ASSEMBLY 11

CYLINDERS 11

MAIN PIVOT PIN 11

HYDRAULIC SYSTEM 11

WATER SYSTEM 12

BOOM NOZZLE 12

OPERATING SPEEDS 12

PART II - SECTION A – OPERATION INTRODUCTION 12

TRAINING PROGRAM FOR OPERATORS 12

LIMITATIONS ON LOADING AND RANGE OF MOVEMENT 13

PLACEMENT OF UNIT FOR OPERATION 14

BOOM OPERATION 14

BOOM ACTUATION 15

NOZZLE OPERATION AND WATER DELIVERY 15

SHUTDOWN AND STORAGE 16

EMERGENCY OPERATION 16

OPERATION WITH POWER PACK 16

OPERATION WITH COMPLETE HYDRAULIC SUPPLY FAILURE 16

STABILIZER (JACK)/BOOM INTERLOCK FAILURE OPERATION 17

SAFETY PRECAUTIONS 17

INSPECTION BEFORE GARAGING 17

PART III - SECTION A NORMAL INSPECTIONS & MAINTENANCE 17

MAINTENANCE CHART 17

BOARDMAN ENGINES GENERAL SPECIFICATIONS

|MODEL |GLADIATOR (LFD) |DIAMOND (SFD) |1871 SERIES |

|MAKE |Spartan |HME,INC. |

|MODEL |Detroit Diesel |Cummins C8.3 |Detroit Diesel |

|TRANSMISSION |Allison HD-4060P |Allison MT-647 |Allison 4T740 |

| |5-speed automatic |4-speed automatic |4-speed automatic |

|WHEELBASE |201” (16' 9”) |174” (14' 6”) |173” (14' 5”) |

|OVERALL LENGTH |412” (34' 4”) |346” (28' 10”) |403” (33' 7”) |

|OVERALL HEIGHT |123” (10' 3') |123” (10' 3”) |139” (11' 7”) |

|WITH CAB TILTED |176” (14' 8”) |160” (13' 4”) |170” (14' 2”) |

|OVERALL WIDTH AT MIRRORS |115” (9' 7”) Same f/ All 3 Rigs |

|ANGLE APPROACH |9.5 degrees |13 degrees |11 degrees |

|ANGLE DEPARTURE |11.3 degrees |14 degrees |12 degrees |

|GROUND CLEARANCE |12 inches Same f/ All 3 Rigs |

|TURNING RADIUS |38 feet |34 feet |35 feet |

|FRONT AXLE RATING |18,000 Ibs. |14,400 lbs. |18,000 lbs. |

|REAR AXLE RATING |24.400 lbs. Same f/ Gladiator/Diamond |26,400 lbs. |

|G.V.W.R. |42,000 lbs. |38,400 lbs. |44,400 lbs. |

|FRONT TIRES |315/80R22.5;20P.R. |12R22.5;16P.R. |315/80R22.5 |

|REAR TIRES |I 1 R22.5;16P.R. |12R22.5;16P.R. |12R22.5 “H” |

|STEERING |Ross TAS-85, power assist, |Ross TAS-65, power assist, |Ross TAS-85, power assist, |

| |tilt-telescoping |tilt-telescoping |tilt-telescoping |

|TOP SPEED |65 mph. approx. |70 mph. approx. |63 mph. approx. |

|BRAKES |FULL AIR;S-CAM, PARKING BRAKE Same f/ All 3 Rigs |

|RETARDER |Telma Focal 191 Same f/ All 3 Rigs |

|PUMP |Waterous CSYBX,single stage Same f/ All 3 Rigs |

|PUMP CAPACITY |1250 GPM Same f/ All 3 Rigs |

|BOOSTER TANK |750 or 500 gallon |750 gallon |500 gallon |

|ALL BOOSTER TANK FILL TOWERS ARE RED, AND ARE ON THE LEFT SIDE OF THE HOSEBED. |

|FOAM TANK |30 gallon Same f/ All 3 Rigs |

|ALL FOAM TANK FILL TOWERS ARE BLACK, AND ARE ON THE RIGHT SIDE OF THE HOSEBED. |

|FUEL TANK |50-gallon Same f/ All 3 Rigs |

|ALL FUEL TANKS ARE REAR MOUNTED, AND FILL ON THE LEFT SIDE OF THE APPARATUS. |

|PRIMER TANK |5 quart, inside right pump |5 quart, above pump compartment |

| |access door. |Same f/ Diamond/1871 |

|INTAKES |DISCHARGES |

|GLADIATOR |

|6” Steamer inlets one each side of the|Four Rated 2 1/2” #1 and #2 left side, #3 and #4 right side. |

|pump panel. |Rated 3” with a 4” Storz connection is on the right side. This is the large discharge. |

|5” gated front suction right side of |Rated 3” deluge gun is located above the operator's panel and it is top mounted. |

|front bumper. |Two Speedlays are located below the top mount panel. |

|Two 2 1/2” gated inlets one each side |Crosslay located behind the top mount panel. |

|of the pump panel. |Booster Reel is located in the lower open rear compartment. |

|3 1/2” booster tank to pump line. |Rapid Deployment is on the front bumper extension. |

| |Tank Refill has a 1 1/2” line and is controlled at the top mount. |

| |Engine cooler has a 3/8” circulation line to the exchanger. |

| |Foam system is an around the pump Feecon APH 1.5 400 gpm unit. |

|DIAMOND |

|6” Steamer inlets one each side of the|Rated 2 1/2” #1 and #2 left side #3 and #4 right side. |

|pump panel. |Rated 3” with 4” Storz #5 right side. |

|2 1/2” inlets one on each side of the |Rated 3” deluge gun above operator's panel top mount. |

|pump panel. |Two Speedlays are below mid-ship pump panel. |

|3 1/2” line from the booster tank to |Booster Reel is rear mounted in open compartment. |

|the pump. |Rapid Deployment is above lower right side compartments. |

| |Tank Refill is a 1 1/2” line that is controlled at the top mount. |

| |Pump cooler has a 3/8” recirculation line to the booster tank. |

| |Engine cooler has a 3/8” line to the exchanger. |

| |Foam system is an around the pump Feecon AP 1.0-a 400 gpm. unit. |

|1871 SERIES |

|6” steamer inlet on the right side |Four Rated 2 1/2” #1 and #2 left side, #3 and #4 right side. |

|pump panel. |Rated 3” with Storz connection #5 right side pump panel. |

|5” steamer inlet on the right side |2”- Four at left rear, One at front and One to rapid deployment. |

|front bumper. |Booster Reel is over the pump. |

|3” gated inlet right side pump panel |Rapid Deployment is above the lower right side compartments. |

|3 1/2” booster tank to pump line. |Tank Refill is controlled at the top mount. |

| |Pump Cooler has a 3/8” recirculation line to the tank. |

| |Engine Cooler has a 3/8” line to the exchanger. |

| |Foam System is an around the pump Feecon AP 1-5, 1400 gpm. unit. |

CAB INTERIOR CONTROLS & INSTRUMENTS

CHASSIS: (Interior Cab Controls, Instrumentation)

INTERIOR CAB CONTROLS

|Battery Master Switch |Hazard Light Switch |

|Engine Ignition Switch/Shut-Down Switch |Test Button |

|Starter Button |Driver Seat Adjustment |

|Service Brake Pedal |Steering Wheel Adjustment |

|Parking Brake Control |Mirror Adjustment |

|Accelerator Pedal |Defroster/Heater Controls |

|Transmission Shift Console |Air Conditioner Controls |

|Telma Retarder Controls and Indicator Lights |Interior Cab Lighting Controls |

|Windshield Wiper Controls |Warning Lights Switch Console |

|Headlight/Parking/Instruments Lighting & Intensity Switch |Audible Warning Devices Controls |

|Turn Signal Control Switch |Pump Shift Control Switch and Indicator Lights |

|Headlight High Beam Switch |On-Spot automatic tire chains - |

| |Emergency Engine Shut-Down Control |

INSTRUMENTATION

|Speedometer |Voltmeter |

|Tachometer |Fuel Level Gauge |

|Engine Oil Pressure Gauge |Air Pressure Gauges (Front & Rear) |

|Coolant Temperature Gauge |Air Cleaner Restriction Gauge |

CAB INTERIOR CONTROLS & INSTRUMENTS - continued

CHASSIS: (Warning Lights & Buzzers)

WARNING LIGHTS & BUZZERS

1. “Battery Switch On” Indicator Light

2. “Ignition Switch On” Indicator Light

3. “Low Oil Pressure” Warning Light & Buzzer

4. “High Coolant Temperature” Warning Light & Buzzer

5. “High Transmission Temperature” Warning Light & Buzzer

6. “Open Door” Indicator Light (Cab or Compartments)

7. “High Beam” Headlight Indicator Light

8. Instrument Panel Illumination Light/Intensity Control

9. “Turn Signal/Hazard” Indicator Lights

10. “Pump Shift” Indicator Light (Pump Engaged)

11. “Pump Shift” Indicator Light (Transmission Engaged)

12. “Telma Engaged” Indicator Light

13. “Telma Stage” Indicator Lights

14. “Warning Lights & Master Warning Switch” Illumination

15. “Transmission Selector Console” Illumination

DRIVING PROCEDURES

PRE-TRIP INSPECTION

1. DRIVER'S WALK-AROUND SAFETY INSPECTION

a. Note general condition. If apparatus is leaning it may indicate one or more of the following: a broken or weak spring, poor load distribution or insufficient air pressure in tire(s).

b. Insure the parking brake is set. Look for signs of any fluids such as fuel, oils, transmission fluid, power steering fluid, anti-freeze or water leaking under the apparatus.

c. Review last vehicle inspection report. Note any defects reported by previous driver. Confirm necessary repairs were made.

2. ENGINE COMPARTMENT INSPECTION

a. Check all hoses for signs of leakage, seeping or wear.

b. Check all wiring for cracked or worn insulation.

3. INSIDE CAB

a. Start engine - listen for any unusual noise.

b. Check all gauges and warning devices on instrument panel.

c. Check conditions of all controls; steering, accelerator, foot brake, park brake, retarder controls, transmission controls, headlights, dimmer switch, turn signals, 4-way flashers, clearance lights & markers, wiper/washers, horns, emergency response warning devices.

d. Check visibility through windshield, windows and mirrors. Check seat(s), seat belts.

4. FRONT OF CAB

a. Check steering system for loose, worn, bent, damaged or missing parts.

b. Check headlights, turn signals, emergency flashers and warning lights.

c. Check suspension both sides. Leaf alignment or damage, friction or wear between parts; loose, cracked or broken U-bolts, mounting-hardware or pins.

d. Check front brakes and brake lines for loose, missing or damaged components and for proper operation. Check for air leaks.

5. LEFT SIDE OF APPARATUS

a. Check front wheels for cracks, damage or defects. Check for broken, missing or loose lug nuts. Check for “bleeding” rust stains, elongated stud holes. Check valve stem.

b. Check tires for bulges, leaks, sidewall separation, cuts, exposed fabric, worn spots and proper tread depth Check for proper inflation. Check for tire contact with any part of the vehicle.

c. Check frame for cracking or sagging rails. Check for loose or broken bolts or brackets.

d. Check and insure that all equipment inside compartments and inside the cab is secured to eliminate shifting Check all fittings, adapters and other externally mounted equipment or devices to insure they are tight and/or securely mounted.

e. Check all doors to insure they are properly latched.

f. Check fuel fill cap. Check for leaks or damage to fill neck or tank.

DRIVING PROCEDURES - continued

PRE-TRIP INSPECTION - continued

6. REAR OF APPARATUS

a. Check frame for cracking or sagging rails. Check for loose or broken bolts or brackets

b. Check and insure that all equipment inside compartments is secured to eliminate shifting. Check all fittings adapters and other externally mounted equipment or devices to insure they are tight and/or securely mounted

c. Check all doors to insure they are properly latched.

7. RIGHT SIDE OF APPARATUS

a. Check front and wheels for cracks, damage or defects. Check for broken, missing or loose lug nuts. Check for bleeding rust stains, elongated stud holes. Check valve stem.

b. Check tires for bulges, leaks, sidewall separation, cuts,-exposed fabric, worn spots and proper tread depth - Check for proper inflation. Check for tire contact with any part of the vehicle.

c. Check frame for cracking or sagging rails. Check for loose or broken bolts or brackets.

d. Check and insure that all equipment inside compartments is secured to eliminate shifting. Check all fittings adapters and other externally mounted equipment or devices to insure they are tight and/or securely mounted

e. Check all doors to insure they are properly latched.

STARTING INSTRUCTIONS

Before starting and driving this apparatus, complete the “PRE-TRIP INSPECTIONS” section of this manual.

The following sequence is to be followed:

A. Before entering the cab;

1. Remove wheel chocks and store in their proper place.

2. Check parameters of the apparatus; move, remove or disconnect any articles obstructing movement of the vehicle.

B. After entering the cab;

1. Park brake set.

2. Transmission selector in the “N” (neutral) position.

3. Battery switch in the “ON” position.

4. Ignition switch in the “ON” position.

5. Push starter button.

NOTES: A) If engine does not start within 15-20 seconds after cranking, release starter button, wait

approximately 30 seconds and repeat “or” double check Items 1 through 6.

B) If engine does not start after 3 or 4 times, stop and refer to service manual. Caution: Repeated or prolonged operation of starter may result in overheating, damage, pre-mature wear of starter components, and/or drainage on electrical system.

6. When the engine starts immediately release starter button.

7. Check all instrumentation, gauges and warning devices.

8. Set all necessary lighting and devices to the desired positions.

9. Apply the brake pedal and release the parking brake.

10. Place the transmission selector in the desired position. (D” for drive or “R” for reverse).

11. Proceed with caution.

DRIVING/STOPPING

NOTE: Before driving this apparatus the driver(s) must be thoroughly familiar with the chassis operation manual.

Driver(s) are urged to use good judgment and to drive with extreme care. The following are extremely important safety factors:

1. Do not operate Telma retarder under wet, icy or slick road conditions.

2. Apply service brakes slowly to avoid locking the brakes and subjecting the vehicle to a skid situation.

3. Observe the traffic situation up to a minimum 1 /4 mile ahead of your vehicle.

4. Allow ample distance between your vehicle, other vehicles or obstructions ahead of and around your vehicle.

5. Keep in mind the restrictions and limitations of this vehicle: height, width, length, weight, turning radius, angle of approach, departure, etc.

DRIVING PROCEDURES - continued

PARKING

Park the vehicle as follows:

1. Bring the apparatus to a smooth and complete stop on a level surface by using the service brakes.

2. Set the spring set parking brake by pulling the control in the outward position.

3. Place the transmission selector in the “N” (neutral) position.

4. Turn all auxiliary-devices such as headlights, warning lights, retarder, etc., to the “OFF” position.

5. Check all gauges, instruments, and warning devices for a proper operating status.

6. Turn the ignition switch to the “OFF” position.

7. Turn the battery switch to the “OFF” position after the engine has completely stopped.

8. Exit the vehicle and place the wheel chocks in proper position.

9. Make Post-Trip walk-around inspection following the Pre-Trip inspection section of this manual.

PUMPING PROCEDURES

INSTRUMENTS AND CONTROLS

The following controls, gauges, warning devices, instructional data plates, etc.; are located at the pump operators position.

CONTROLS

1. Pump panel light switch, push/pull type

2. Vernier hand throttle

3. Pump cooler control valve

4. Pump primer push/pull control

5. Relief valve, pilot valve controls and indicator lights

6. Individual control levers as follows:

7. Auxiliary engine cooler control valve

8. Drain for pilot valve

9. Feecon foam metering valve.

10. Flush control for the Feecon foam system

|HME 1871 SERIES |Gladiator & Spartan |1871 |Gladiator |

| |Models | |& Spartan |

|Discharge #1 | |2 1/2” |curb side |street side |Yellow/Black letters |

|Discharge #2 | |2 1/2” |curb side |street side |White/Black letters |

|Discharge #3 | |2 1/2” |curb side |Blue/White letters |

|Rapid Deployment |Tank | |3 1/2” |above right side |booster tank to |Blue/White |

| | | | |compartments |pump | |

|Discharge #4 |Discharge #4 3” | |2 1/2” |curb side |Black/White letters |

| |w/4” Storz | | | | |

|Large Discharge |Discharge #5 | |3” |curb side | |Yellow/White |Yellow/Black (White|

| | | |w/Storz | | | |border) |

|Hose Reel | | |above pump panel|rear compartment |Grey/White |Gray/Black |

|Rear Discharge #1 |Speedlay #1 |1 1/2” |2 1/2” | |upper bin |Orange/Black |

|Front Discharge |Rapid Deploy |1 1/2” |1 1/2” |front bumper |over right |Pale White/Black |Blue/White |

| | | | | |compartments | | |

| |Tank Fill | |1 1/2” | |booster tank | |Blue/White |

| | | | | |refill line | | |

|Rear Discharge #2 |Water |1 1/2” | | |discharge to foam |Red/White |Blue/White |

| | | | | |eductor | | |

|Foam |Foam | | |foam tank to |foam tank to |Red/White |Red/White |

| | | | |eductor |eductor | |(White Border) |

|Foam water |Deck Gun | |3” |water to eductor|Above center top |Red/White |Silver/Black |

| | | | | |panel | | |

|Foam Flush |Speedlay #2 | |1 1/2” | |lower bin |Red/White |

PUMPING PROCEDURES - continued

GAUGES AND REMAINING FEATURES

a. 4 1/2” master inlet pressure gauge

b. 4 1/2” master discharge pressure gauge

c. Ten (10) 3 1/2” individual discharge pressure gauges located directly above the respective RC control handle

d. Engine coolant temperature gauge

e. Engine oil pressure gauge

f. Warning light and buzzer system for high coolant temperature or low engine oil pressure

g. Electric tachometer

h. Relief valve indicator lights

i. MC-5, five light tank level indicator with test button

j. Underwriters half engine speed hand counter outlet

k. Two (2) 1/4” plugged test outlets, for suction and discharge

l. Pump manufacturer's data plate

m. Boardman pumper data plate

n. Feecon foam system instruction plate

o. Mike compartment on the front left face of the panel

ENGAGING THE PUMP

1. Bring the apparatus to a complete stop.

2. With the truck engine at idle, place the transmission selector in the “N” (neutral) position while applying the service brakes.

3. Set the park brake and release the service brakes.

4. Lift the safety cover over the pump shift switch.

5. Flip the pump switch “down” to engage the pump transmission.

NOTE: The top green light indicating “PUMP ENGAGED” should be illuminated. If this light is off, flip the switch up/down and wait for light. DO NOT continue if light remains off. Refer to the “MANUAL PUMP SHIFT OVERRIDE” section of this manual.

6. With the “PUMP ENGAGED” light illuminated, shift the transmission selector to the “DATE” (drive) or 4th gear position to drive the pump. At this time the second green indicator light, “OK TO PUMP”, should be illuminated.

7. Exit the cab and “CHOCK THE WHEELS”.

8. Proceed to the pump operator's panel.

NOTE: Insure that the green “OK TO ADVANCE THROTTLE” light is illuminated before continuing.

PUMPING

CAUTION: With the pump engaged it is extremely important to provide circulation through a discharge valve, the tank refill line or through a discharge outlet. Prolonged lack of circulation will cause overheating of the water inside the pump and may cause damage or personal injury. This pump is capable of producing pressures up to 350 psi; using the relief valve properly is extremely important. Open and close all suction and discharge valves slowly to prevent water hammer. Monitor all gauges and controls closely. Take necessary actions to avoid damage and/or personal injury.

PRIMING THE PUMP

1. Whether pumping from a pressurized source, the booster tank or from draft it may become necessary to prime the pump.

2. Check all discharge controls and unused intakes to make sure the valves are in the “CLOSED” position.

3. Insure water supply is available to the intake side of the pump.

4. Pull the primer control “T” handle until air is evacuated from the pump.

NOTE: If pump does not prime within 15 seconds, check primer tank oil level and repeat steps 1 through 4. Do not repeat more than 3 times; refer to your service manual.

5. Proceed pumping per the guidelines established in the Waterous Training Video and Training Manual, and your departmental policies.

PUMPING PROCEDURES - continued

RELIEF VALVE OPERATION; SETTING THE RELIEF VALVE:

With the pump engaged and the engine at idle, proceed as follows:

1. Relief valve in the “OFF” position, football shaped pressure control dial counterclockwise “BACKED OFF” all the way.

2. Tank to pump line “OPENED”, prime the pump and open the tank refill line.

3. Advance the throttle until 150 psi is shown on the Master discharge pressure gauge.

4. Turn the-Relief Valve control switch_ to the “ON” position. (Pressure will drop down to approximately 50 psi).

NOTE: The amber “OPEN” indicator light will come on.

5. Rotate the football shaped pressure control dial clockwise to the desired pressure control setting indicated by the master discharge pressure gauge.

6. Reduce the engine RPM using the Vernier throttle control until the “GREEN” closed indicator light comes on.

NOTES: Proper pumping operation is with the relief valve in the “CLOSED” position. The relief valve operating range is limited to 50 lb. “ABOVE” the net intake pump pressure.

DISENGAGING THE PUMP

1. Return the engine to idle by screwing in the Vernier hand throttle on the operator's panel.

NOTE: Releasing the throttle by pushing the button is recommended for emergency use only.

2. Shut-down all necessary controls, discharges, relief valve, panel lights, etc.

3. Return to cab and place the transmission selector in the “N” (neutral) position. The bottom green “OK TO PUMP” light should go off at this time.

4. Lift the safety latch over the pump shift control while watching the speedometer. As the speedometer reaches Zero -0- MPH, flip the switch UP to disengage the pump. Both green indicator lights should be OFF at this time.

5. Conduct a pre-trip inspection per Section III of this manual before moving the vehicle.

MANUAL PUMP SHIFT OVERRIDE

In the event of electrical pump shift failure the following steps may be taken:

1. With the engine running, transmission in “N” (neutral), and the park brake set; exit the cab and “CHOCK THE WHEELS”.

2. Go to the left side pump panel and pull the lever labeled “CAM”. This will release the manual pump shift lever.

3. Push the pump shift lever “IN” and release the “CAM” to shift the pump.

4. Return to the cab and place the transmission selector in “D” (drive).

5. Switch the pump shift into the pump position to activate the 4th gear lock-up.

6. Proceed with pumping section of the manual.

DISENGAGING THE MANUAL PUMP SHIFT

1. Return the engine to idle. Enter the cab and-place the transmission selector valve in the “N” (neutral) position.

2. Switch the pump shift switch to road position.

3. Go to the left side pump panel and pull the lever labeled “CAM”. This will release the manual pump shift lever.

4. Pull the pump shift lever “OUT” and release the “CAM” to disengage the pump.

5. Return to the cab and place the transmission selector in “D” (drive).

6. Proceed with Pre-Trip Safety Inspection section of this manual.

MAINTENANCE CHECKS AND INSTRUCTIONS - CHASSIS

CAB TILT

CAUTION:

1. SECURE ALL LOOSE ARTICLES INSIDE THE CAB BEFORE TILTING. DO NOT ATTEMPT TO TILT THE CAB IN AN AREA WITH OVERHEAD OBSTRUCTIONS. THIS REQUIRES A MINIMUM OF 160”.

2. LIFT CAB UNTIL SAFETY LATCH IS ENGAGED OVER THE LIFT CYLINDER

3. RELEASE TILT SAFETY LATCH BEFORE ATTEMPTING TO LOWER THE CAB.

4. LOWER CAB UNTIL THE CAB LATCH INDICATOR LIGHT IS OFF.

Cab tilt is an electric/hydraulic pump system located at the lower forward portion of the right side pump panel, inside the pump compartment. Up/Down control switch and indicator light for cab tilt are located on the lower forward portion of the right side pump panel. Once the cab is lifted beyond 45 degrees a safety latch will engage over the right side lift cylinder. The release for this safety latch is a “T” handle pull lever located forward of the walkway on the right hand side. To lower the cab, release the safety latch, hold the cab tilt switch in the down position, and maintain the switch down until the red indicator light is off. The light being off indicates that the cab is properly latched.

ENGINE OIL

▪ CHECK DAILY!

▪ Oil level dip stick is located at the left rear of the engine and may be checked by tilting the cab.

COOLING SYSTEM

▪ CHECK DAILY!

▪ Coolant level is located at the front center of the engine and may be checked by lifting the engine cover inside the cab or while the cab is tilted.

▪ CAUTION: REMOVE RADIATOR CAP ONLY WHEN ENGINE IS COLD.

TRANSMISSION

▪ CHECK DAILY!

▪ Operating temperature, in neutral, park brake set.

▪ Transmission dip stick is extended above the center of the engine and may be checked by lifting the engine cover inside the cab, or while the cab is tilted.

POWER STEERING

▪ CHECK DAILY!

▪ Reservoir and dip stick are located at the rear of the engine and may be checked by tilting the cab.

▪ CAUTION: DO NOT OVER FILL.

PUMP IN GENERAL

▪ If running with a “WET” pump, insure pump stays completely filled.

▪ If running with a “DRY” pump, insure pump stays completely drained.

▪ Grease pump every three (3) months. Grease fitting is located on the right side pump panel and is labeled.

PUMP TRANSMISSION

▪ CHECK DAILY!

▪ Pump transmission sight level is located to the left at the rear of the pump transmission case. Fill plug is located at the right rear of the transmission case.

▪ CAUTION: DO NOT OVER FILL.

PRIMER RESERVOIR

▪ CHECK DAILY OR AFTER EACH USE!

▪ Primer reservoir is located above and behind the pump panel on the right hand side. Fill level dip stick is attached to the cap.

RELIEF VALVE/PILOT VALVE

▪ CHECK WEEKLY OR AFTER EACH USE!

▪ Pilot valve is located on the pump operator's panel. Screen filter is located on the pilot valve panel.

INTAKES

▪ CHECK MONTHLY OR AFTER EACH USE!

▪ Check for torn, dry or cracked gaskets.

▪ Check suction screens for debris or other foreign objects, and deterioration.

▪ Close or cap all intakes and discharges and pull a 30 second vacuum on the pump to check for leaks

DISCHARGES

▪ CHECK MONTHLY OR AFTER EACH USE!

▪ Check for torn, dry or cracked gaskets.

▪ Close all gated discharges, open nozzles and remove caps, pressurize pump and check for leaking valves.

▪ Check all valve controls for proper operation.

BOARDMAN APACHE TOWER - MODEL T-55D

PART I - SECTION A IMPORTANT SAFETY INSTRUCTIONS AND WARNINGS

1. Keep this manual readily available at all times.

2. This manual contains important safety and operating instructions for the APACHE TOWER T-55D telescoping tower. It is important to read these instructions carefully prior to operating the T-55D telescoping tower. Failure to operate the unit other than by the methods described herein, may cause personal injury or damage to the unit or surrounding structures and void the warranty.

3. ALWAYS chock the truck wheels BEFORE operating the boom.

4. Set the parking brake before engaging the PTO. PTO WILL NOT ENGAGE WITHOUT THE PARKING BRAKE SET.

5. The transmission MUST BE IN NEUTRAL or in the DRIVE POSITION with the driveline to the rear axle DISENGAGED BEFORE the PTO will engage.

6. Operate the T-55D ONLY WHILE STANDING on the rear step.

7. Set the stabilizers BEFORE performing ANY boom motions.

8. The override controls for the stabilizer (jack)/boom interlock are for EMERGENCY USE ONLY. OVERTURNING OF THE UNIT IS POSSIBLE IF THE STABILIZERS ARE NOT SET PROPERLY BEFORE BOOM MOVEMENT.

9. ANYTIME the unit is operated, place the bearing pads under the stabilizers. It is REQUIRED to use the bearing pads at all times.

10. An alarm will sound when the circuit to the stabilizers is being used along with a red flashing warning light above the stabilizers at any time the control station is activated.

11. BE AWARE and STAY CLEAR of obstructions that would PREVENT SECURELY SETTING the stabilizers.

12. The SLOPE of the terrain SHOULD BE AS LEVEL AS POSSIBLE when placing the unit for operation.

13. EXERCISE GOOD JUDGEMENT AND CAUTION WHEN MAKING BOOM POSITION CHANGES.

PART 1 - SECTION B GENERAL SPECIFICATIONS FOR APACHE TOWER MODEL T-55D

*Vertical Reach - Ground to Nozzle 55' 5 1/4”

Horizontal Reach - Center Rotation to Nozzle 46' 8”

Overall Length - Stored for Transport 32' 3 3/4”

Travel Height - Above Chassis Frame Rail 8' 5”

*Travel Height - Above Ground 11' 7”

*Based upon a 38” loaded chassis height.

SAFETY INTERLOCKS AND WARNING DEVICES

▪ The T-55D is equipped with several interlocks and warning devices for the safe operation of this unit.

▪ Chassis spring brakes have to be set and the transmission has to be in neutral or in the drive position with the driveline to the rear axle disengaged before hydraulic power is sent to the rear control panel.

▪ Stabilizer (jack)/boom interlock with override.

▪ An alarm that sounds when operating in the jack mode.

▪ A red warning light will flash over the stabilizers at any time the control station at the rear is active. A rung alignment light indicates to the operator when the ladder rungs are aligned for safe climbing.

BASE FRAME

High strength rectangular tubular stringers spaced at 34” lateral outside dimension with box cap plates top and bottom running forward of the pedestal and butting to a stabilizer slide box at the rear. The rear of the pedestal is closed by two stainless steel control panels, which are readily removable so that access can be had to the boom control valves, the two part hydraulic collector, the electric slip ring, the 4” butterfly waterway valve, the water system pressure gauge, hydraulic system pressure gauge, and the hydraulic oil filter, all housed in the pedestal.

PART 1 - SECTION B GENERAL SPECIFICATIONS FOR APACHE TOWER MODEL T-55D - continued

STABILIZERS

▪ Two telescopic tubular welded steel stabilizers (one each side of the base pedestal) just behind the rear wheels.

▪ Stabilizer slides have fixed ground pads and are extended and retracted under the action of completely enclose hydraulic cylinders with pad mounted locking valves.

▪ The stabilizers slant downward at about a 40 degree angle from a vertical reference line to provide optimum spread a ground contact, but remain within the legal width limits when stored for transport.

REAR CONTROL STATION

Switches, levers and handles for controlling the operation of the various boom functions project from the stainless steel panels covering the rear of the base frame pedestal. The controls and instruments available to an operator standing on the rear step are as follows:

▪ Three joysticks for controlling the three functions of the boom - extension, rotation and elevation.

▪ A spinner handle for opening and closing the waterway shutoff valve.

▪ Panel light shrouded by a stainless steel hood.

▪ Panel light control switch.

▪ Fast idle switch and/or Vernier throttle control.

▪ Water pressure gauge.

▪ Hydraulic oil pressure gauge.

▪ Three SPDT switches to control the nozzle functions.

▪ Master power switch.

▪ Auxiliary pump switch.

▪ Rung alignment indicator light.

▪ Flowmeter for the water system.

▪ Stabilizer (jack)/boom interlock controls and override key switches.

▪ Two SPDT momentary switches for controlling the stabilizers are located outboard of the pedestal and arranged so that the operator may view the stabilizers in motion (one on left side and one on right side).

BOOM ASSEMBLY

Telescopic type having a base and extendable section constructed of rectangular aluminum tubes. Boom tubes are made by welding interlocking high strength aluminum heat treated alloy extruded channels. Boom is extended and retracted by the action of a double acting hydraulic cylinder. A two section telescopic ladder is bracket mounted on top of the boom and equipped with 1” aluminum hand rails with a standard 12” minimum height above the centerline of the ladder rungs. The rungs are covered with corrugated rubber. A rung alignment indicator is mounted on the ladder to indicate to the operator when the ladder rungs are aligned.

CYLINDERS

Rear Stabilizer Slides 2 1/2” Bore X 36” Stroke 1 3/8” diameter rod.

Boom Elevation 4 1/2” Bore X 34-3/8” Stroke 2 1/4” diameter rod.

Boom Extension 2 1/2” Bore X 204” Stroke 1 1/2” diameter rod.

Monitor Cylinder 2 1/2” Bore X 10” Stroke 5/16” diameter rod.

Nozzle Pattern Cylinder 1 1/8” Bore X 9/16” Stroke.

MAIN PIVOT PIN

Base boom/turntable pivot pin is chrome plated stress proof steel running in straight bronze bushings in the boom pivot

HYDRAULIC SYSTEM

▪ A dual pressure split system is provided for boom, stabilizer and nozzle operation.

▪ The PRIMARY system (for operating the boom and stabilizers) is fed from the constant flow port of a 4 GPM priority valve and operating pressure is governed by the load requirements and may go to 3,000 PSI maximum as limited by the main control valve relief.

▪ The SECONDARY system (for operating the nozzle motions) feeds a closed center 3 spool 4 way solenoid valve. The system has a solenoid vented relief valve which will allow a pressure of 500 PSI with flow and operating speed determined by line restrictors for each nozzle function when the nozzle functions are used. The solenoid allows the system to dump to tank when not used to reduce heat build up by the relief valve in the oil.

▪ A suction strainer is installed in the 30 gallon reservoir and a 10 micron spin on return line filter is installed in the line leading to the reservoir inlet. Total oil volume in the system is about 38 gallons.

PART 1 - SECTION B GENERAL SPECIFICATIONS FOR APACHE TOWER MODEL T-55D - continued

WATER SYSTEM

▪ A 4” water line is routed from the midship pump, through the base frame box into a cast steel manifold in the pedestal to a 4” butterfly valve, a packed, vertical, combination, slip joint/swivel, and into a vertical run of 4” water pipe terminating below the boom pivot in a cast aluminum reducing “Y” section.

▪ The outlets of the “Y” connect-with cast aluminum swivel elbows through 3” straight aluminum pipes. The swivel elbows are pinned to the main pivot pin in the turntable and in turn are connected to a pair of telescopic water pipes (one on either side of the boom) made of anodized aluminum tubing, packed with “molythane” “U” rings, nylon support rings and having a minimum I.D. of 2 1/2”. The outer ends of the telescopic water pipes are coupled to the nozzle trunnion base near the tip of the boom.

▪ Three 2 1/2” inlets/outlets are available on either side of the pedestal and below the control panel to serve as inlets from other pumpers and sources or outlets when the water tower boom is not in use.

▪ The 4” butterfly valve may be used to shut off water supply to the boom or to throttle the water to the recommended maximum of 200 PSI at the inlet gauge if the midship pump is delivering a higher pressure.

▪ A relief valve preset at 220 psig is placed in the water system.

BOOM NOZZLE

▪ Range of elevation - 305 degrees

▪ Range of side sweep - 180 degrees; 360 degrees continuous in certain elevation positions.

▪ Stream pattern - Variable from straight stream to full fog.

▪ Flow capacity - 250 to 1000 GPM; nozzle automatically adjusts to available flow to maintain a pressure drop across the nozzle of 85 to 100 PSI to maximize the effective reach of the stream.

▪ The three nozzle adjustments may be controlled either from a switch panel near the base of the nozzle or remotely from the control station at the rear of the pedestal. In certain conditions of extreme emergency, where electric power may have failed, the solenoid valve cover may be removed and the valves may be shifted directly by mechanical operating plungers.

OPERATING SPEEDS

▪ Extend rear stabilizers full 36” each side 10 to 23 seconds depending on engine speed.

▪ Elevate boom from storage to 90 degrees - 29 to 37 sec.

▪ Extend boom to full limit (17 ft:) - 27 to 51 sec.

▪ Above speeds will vary with operator, operating conditions and adjustments.

PART II - SECTION A – OPERATION INTRODUCTION

Hazardous or unsafe operation of this equipment could endanger the life and limb of those people operating, using, and in the proximity of this equipment. The operator must be completely familiar with the location and operation of all controls, and always operate the equipment in a safe manner. Because this equipment must be ready for use on a moment's notice, there is generally no time for operational checks immediately prior to use. Therefore, these checks should be made after last use of the equipment prior to garaging for standby readiness. In addition, periodic inspections per the Inspection Table of Part III, Section A, should be performed

TRAINING PROGRAM FOR OPERATORS

Each person who may be responsible for using the MODEL T-55D should be given a careful program of training. While this unit has many safety and overload devices and a generous structural safety factor, operation by untrained personnel could result in injury to operators, users, and bystanders, and damage to the unit and adjacent property. Anyone with normal manual dexterity and reflexes should be easily able to operate this equipment, as the controls are few and easily understood. However, the training program should begin with a study of the manual, in terms of general theory of operation but with particular emphasis on general operational procedures and precautions. Following a study of the manual, the unit should be placed in operation, again referring to the operational procedures portion of this section. After proceeding with setting up and placing the unit in all modes of operation for a number of times by the instructor, each trainee should be given the opportunity to go through this sequence himself with the instructor standing by to comment and prevent any errors. After each trainee is familiar with and reasonably proficient at operation, the unit should be moved to several different sites that simulate actual fire situations typical of your area, and each operator should again be given the chance to observe and operate the boom in these conditions.

PART II - SECTION A – OPERATION INTRODUCTION - continued

TRAINING PROGRAM FOR OPERATORS - continued

A strict policy of adhering to the rules listed below will be an invaluable aid to assuring the safe, efficient operation to minimize the hazard to people and property.

A. ASSIGN operators for the operation of this unit.

B. Be certain that all operators ASSIGNED to the unit have undergone a training course which included:

1. Study of this manual

2. Supervised practice in an open area until they control the boom smoothly and naturally

3. A training stint which includes placing the unit, erecting the boom, and flowing water at several sites which simulate actual fire conditions for your area.

C. Each ASSIGNED operator must be familiar with the capacities and operating procedures for the unit.

D. A second review of the precautions that must be observed for safe operations.

E. Have repairs and adjustments performed only by qualified mechanics who have a working familiarity wit' pertinent contents of this manual.

F. Consult with, and obtain written consent from the Engineering Department of the TBC Fabrication, Inc. before modifying your MODEL T-55D.

LIMITATIONS ON LOADING AND RANGE OF MOVEMENT

CAPACITY - BOOM AND LADDER

The boom and ladder of the MODEL T-55D may be loaded either by flowing water from the nozzle, by placing people on the ladder, or a combination of both. When the nozzle is discharging 1000 GPM with a pressure of 100 PSI at the nozzle inlet, it will be imposing on the boom tip a reaction force of about 505 pounds. If the stream is directed approximately 90 degrees to the length of the boom at any position in a plane perpendicular to the boom axis (either in the plane of boom swing or 90 degrees to the side or any intermediate angle), the boom will be highly loaded. In addition to the live loads due to nozzle reaction and the distribution of people on the ladder, the dead weight of the boom structure must be considered, and this affects boom capacity most greatly when the boom is fully extended and nearly horizontal. A general rule of thumb in evaluating the effects of the various loads on the boom capacity and truck tipping is that the greater the horizontal distance from a load weight to the centerline of the truck, and the greater the radius to the line of action of the nozzle stream from the boom pivot, the greater their effect on boom stresses and truck tipping moments (see Figure 1). In many cases, the nozzle reaction will actually be in such a direction that it might assist the elevation cylinder in supporting the boom and the stabilizers in stabilizing the vehicle but this should never be relied on, since a loss of water pressure or supply or a change in nozzle attitude could remove this force as a positive contribution and perhaps even make it a negative one. Reference should now be made to Figure 2, which is a gravity circle diagram for a typical MODEL T-55D boom. This diagram illustrates in plain view the path of the center of gravity of the combined boom and truck with the boom at maximum reach and rated boom load and the truck at minimum weight; i.e., no water in the booster tanks, etc., as the boom rotates. The closer the gravity circle comes to the tipping lines, the less stability margin the unit has. The stability margin to the front and rear is generous and this permits the unit to be operated parked on an upgrade or downgrade without stability problems. The margin over the sides is not so generous and the truck should be leveled as carefully as possible side to side. Generally speaking with telescopic booms, they are least stable when they are closest to the ground, but with the possibility of large nozzle reactions being applied in any boom position, high tipping moments can occur at all boom elevations and the truck should always be carefully stabilized per the following sections:

Specifically, the boom loads should be limited to the following:

1. When the boom is in the elevation range from 10 degrees below horizontal to 90 degrees above, fully extended, tip unsupported and no persons on the ladder, it may be subjected to and will support the full nozzle reaction in any direction with 1000 GPM delivery from the nozzle.

2. With the boom in the elevation range of 45 degrees to 90 degrees above horizontal, fully extended, tip unsupported, nozzle discharging 1,000 GPM in any direction, a 250 pound load may be placed at the tip or 500 pounds may be uniformly distributed along the ladder.

3. With no water being discharged from the nozzle, the ladder only in use and the boom in the elevation range of 10 degrees below to 45 degrees above horizontal, a load of 500 pounds may be placed on the boom tip, or 1000 pounds evenly distributed along the ladder.

4. With no water being discharged from the nozzle, the ladder only in use, and the boom in the elevation range of 45 to 90 degrees above horizontal. a load of 750 pounds may be placed on the boom tip, or 1500 pounds evenly distributed along the ladder.

5. With the tip resting on a firm support and the boom at any angle in the elevation range from 10 degrees below to 75 degrees above horizontal, a 1500 pound load may be evenly distributed over the length of the ladder.

NEVER RELY ON THE WALL OF A BURNING BUILDING TO SUPPORT THE TIP, AS SUCH WALLS MAY BE IN DANGER OF COLLAPSE. OBSERVE THE ABOVE CAPACITY LIMITATIONS STRICTLY IN ORDER TO NOT ENDANGER LIVES OR EQUIPMENT.

PART II - SECTION A – OPERATION INTRODUCTION - continued

PLACEMENT OF UNIT FOR OPERATION

To safely utilize the capabilities of the MODEL T-55D to its greatest advantage, exercise good judgment when spotting the unit at the fire or rescue site. Pay particular attention to the following:

1. Overhead obstructions which might limit the range through which the boom can be moved. By its telescopic nature the MODEL T-55D boom can be aimed and sent through fairly small holes, but the truck must be placed so that the boom ends up in the desired position.

2. Contact with overhead electrical wires, transformer banks, lights, etc., presents great danger to personnel on or near the unit. Even spraying water through high voltage wires could present a hazard.

3. Obstructions such as curbs, automobiles, storm drains, manhole covers, etc., which would prevent securely setting the stabilizers at maximum spread.

4. Slope of the terrain on which the unit must be placed and operated. The site should be as level as possible, but if it is not, try to park the truck either heading up or down the grade, or if the grade is side to side, try to spot the vehicle so that all work is done to the high side.

5. Capacity limitations of the boom assembly.

6. Operating reaches of the boom assembly.

BOOM OPERATION

A. BEFORE LEAVING THE CAB:

With the vehicle located for optimum use of the boom, and the engine running:

1. Set the parking brakes per vehicle instructions.

2. Engage the power take off (PTO). With manual shift transmissions, this is done by depressing the clutch, putting the shift lever in neutral, moving the PTO control to engage and then SLOWLY releasing the clutch. With automatic transmissions, engage PTO with the engine at idle speed. Power Shift PTO's: Engine is engaged. See PTO instructions in PART IV - SECTION E: Technical Data.

B. PRIOR TO RAISING THE ROOM:

1. ALWAYS chock the wheels.

2. Verify that no overhead power lines and/or obstructions will come in contact with the boom.

3. Flip “on” the master switch at the control console. This action will provide power for the panel lights, the emergency power pack relay solenoid, rung alignment indicator, the nozzle control solenoid valves, and the stabilizer (jack)/boom interlock control solenoid valve.

4. Advance the engine speed with the fast idle switch and/or Vernier throttle control.

5. Flip the 3-position (center off) jack/boom switch to the “JACKS” position (located on the top section of the control panel). The “OK TO SET JACKS” indicator light should be on.

STABILIZER (JACK) BOOM INTERLOCK

1. This interlock allows the boom to be moved only after the stabilizers have been set to-obtain a proper stabilization base for operating the boom through its full range at rated capacity. The interlock also prevents the moving of the stabilizers unless the boom is in the travel position. The override controls should be used with extreme care. The override controls are designed for emergency use only: in the case of limit switch failure or wire breakage. If a failure in the interlock system occurs, the unit should be serviced and the problem resolved immediately.

2. Set the stabilizers. As illustrated in Figure 2, these elements are vital to obtaining the proper stabilization base for operating the boom through its full range at rated capacity. The stabilizer pads contact the ground outside the normal rear wheel tread and the stabilizer slides provide a solid strut to transfer the chassis weights and boom moments to the ground with very little springiness. The stabilizers must be set one at a time. The following procedures and precautions should be observed when setting the stabilizers

a. Place bearing pads under the stabilizers. It is REQUIRED that bearing pads be used at all times.

b. Be sure that the stabilizers extend clear of any obstructions such as curbs, parked autos, etc., that would prevent full extension and firm contact with the ground.

c. When the truck is parked on a level surface, extend all stabilizers successively until they contact the bearing pads on the ground. Then, alternately increase the extension of the rear stabilizers until the rear step has raised 3 to 4 inches to remove chassis weight from the rear wheels and transfer it to the stabilizers and the “OK TO BOOM” light is on.

d. When the truck is parked on side slopes, the stabilizers on the downhill side should be extended first to bring the chassis back to level; then the uphill stabilizer should be extended to firm contact with the ground. If the side slope is considerable, it may be necessary to place a thick block under the downhill stabilizer pads. On very uneven terrain, the same general procedure should be observed. and it may be necessary to place blocks under all stabilizer pads to get adequate weight transfer.

PART II - SECTION A – OPERATION INTRODUCTION - continued

BOOM ACTUATION

▪ Exercise judgment and caution when making boom position changes. Do not make position changes with personnel on the boom ladder, except in emergency situations. Give adequate warning to all personnel on or around the boom before making position changes. Be alert for obstructions which may interfere with boom movement.

▪ Flip the 3-position (center off) jack/boom switch to the “BOOM” position. With the stabilizers set, the “OK TO USE BOOM” indicator light should be on.

▪ The MODEL T-55D is equipped with three separate joysticks capable of controlling 3 functions: extension of the boom, rotation of the turntable, and elevation of boom.

1. EXTENSION

a. Raise the joystick upward to cause the boom to extend (increase length).

b. Lower the joystick downward to retract the boom.

2. ROTATION

a. Raise the joystick to make the boom rotate clockwise.

b. Lower the joystick to make the boom rotate counterclockwise.

3. ELEVATION

a. Raise the joystick to decrease boom elevation.

b. Lower the joystick to increase boom elevation.

▪ Always move the joystick slowly as the operating region is approached to meter the oil so that the load starts moving smoothly. Continue to move the joystick until the desired operating speed is obtained and hold that position until the boom approaches the position desired. Slowly move the joystick away from the operating region toward the neutral position until the boom slows down and arrives at the position desired. At this point, move the joystick to neutral to stop the boom motion. Smooth operation is easily obtained with practice and contributes to reduced maintenance and increased life of the equipment.

▪ Always raise the boom out of the rest and sufficiently high to clear same before rotation is attempted. Exercise caution when depressing the boom below horizontal, as there are many areas of the truck where interference between the cab or body and boom will occur. Normally, such operation is possible only over the side and rear.

NOZZLE OPERATION AND WATER DELIVERY

▪ No adjustment of the nozzle position is possible until the master switch at the control console is flipped on. This action will provide power for the panel lights, the emergency power pack relay solenoids, and the nozzle control valve solenoids.

▪ NO WATER SHOULD BE DELIVERED TO THE NOZZLE UNTIL IT IS POINTED IN THE DIRECTION IT IS INTENDED TO BE USED. NEVER AIM IT AT PERSONS ON OR NEAR THE UNIT.

▪ Prior to nozzle operation, the boom should be erected and positioned to best advantage for directing the water stream.

▪ If it has not already been done, the master switch should now be turned on.

▪ Next, the nozzle elevation switch should be operated to bring it out of storage position until the nozzle can, by operation of the sweep control, be swung in a plane that will aim it toward the fire.

▪ Water can now be delivered to the nozzle. This may be accomplished either by operating from the truck pump if the unit is a pumper, or by connecting hoses to the three 2 1/2” inlets at the rear of the unit, whether or not the unit is a pumper.

▪ When a water supply is available from the truck mounted pump, leave the ball valves at the rear inlets closed, and open the pump to water tower valve. Gradually turn the handwheel at the control panel on the rear of the pedestal to open the butterfly valve until water is delivered from the nozzle. Open the butterfly valve until the control panel gauge reads about 120 PSI. NEVER EXCEED 200 PSI. Increase engine speed with the Vernier throttle at the pump panel if so equipped until the nozzle is delivering an adequate stream or the pressure is in the 150 PSI range.

▪ When the water supply is from a source independent of the MODEL T-55D truck, after the hoses are connected and pressure is available to the rear inlets (being sure that the valve between the water tower piping and the truck mounted pump is closed, if it is a pumper unit that is being fed externally), open the ball valves and then slowly open the butterfly valve in the pedestal until water is delivered from the nozzle and the panel gauge reads about 150 PSI.

▪ Now final adjustment to the boom position and nozzle direction and pattern can be made.

▪ The pressure available at the nozzle varies approximately 38 PSI between the lowest possible nozzle position (boom 10 degrees below horizontal) and the boom fully extended and elevated (75 feet nozzle elevation) because of the additional water column height which is being pumped against. The pressure required will also increase about 5 PSI between a fully retracted and a fully extended boom condition because of the extra line length through which the water must travel. Refer to the following chart to estimate the gauge pressure necessary to deliver various amounts of water from the nozzle.

SHUTDOWN AND STORAGE

Prior to moving the truck from the operating site, the following sequence of operations should be performed

1. Shut down the water supply and disconnect external hoses, if any.

2. Open the rear inlet ball valves to drain as much water as possible from the boom lines.

3. Bring the boom in line with the storage rest and gently lower it to the rest pad.

4. Apply a slight amount of down pressure by the boom on the rest pad to minimize bouncing in transit

5. Bring the nozzle in line with the boom and operate the elevation control to swing it into the storage pocket in the nozzle base.

6. Open the drain cocks at the bottom of the junction pipe below the pedestal vertical pipe. Leave the butterfly valve open while draining.

7. Retract the stabilizers by raising each operating lever in sequence until each stabilizer slide is fully retracted.

8. Place all aerial tower electrical power switches in the off position.

9. Disengage the PTO by operating control in the cab, after which the unit is ready to be moved. Draining, if any, may continue while driving.

10. Close the butterfly valve in the pedestal when draining is complete.

EMERGENCY OPERATION

There are three classes of emergency operation that might at some time or other have to be resorted to:

OPERATION WITH POWER PACK

1. The first class of emergency operation is one where the vehicle engine, transmission, PTO, or main hydraulic pump has failed and it is desired to continue to operate the boom at the scene of a fire or to bring it into storage for transport. For this purpose, an emergency power pack, which is a small hydraulic gear pump driven by a starter type motor powered from the truck batteries, is provided. This unit is placed in operation by operating the battery toggle switches at the boom control station, which energizes a starter type, solenoid operated relay to run the pump motor.

2. This motor pump should only be operated when required, since it can draw currents in the range of several hundred amperes. It will operate the boom and nozzle quite a bit more slowly than the normal pump and may not be powerful enough to move the boom against nozzle reactions so water may have to be shut off when performing boom motions. Do not operate the power pack for periods longer than needed to perform the required motion. When the power pack is running, boom and stabilizers are operated by moving their control handles in the normal manner.

OPERATION WITH COMPLETE HYDRAULIC SUPPLY FAILURE

The second class of emergency operation is one where there is a complete hydraulic failure, such as a broken feed line to the directional control valves, or a complete loss of fluid, etc., so that neither the main nor the auxiliary pump are effective in operating the unit. For this situation, several different emergency procedures must be employed. These are not normal procedures, as they involve disconnecting hydraulic lines, adjustment and readjustment of holding valves and similar expedient measures and should not be included in any operator training sessions. However, it is necessary for service personnel to be familiar-with the procedures that follow.

1. Boom Retraction - If the boom is elevated at a sufficiently high angle, it is sometimes possible to obtain retraction under the action of gravity by backing off the holding valve adjusting screw (see Part IV, Commercial Data) on the boom extension cylinder and having an operator move the hand control in the retraction direction. If this is not feasible or successful, it is best to bring the boom into the rest in the extended condition as explained in the following sections and either correct the hydraulic system problem so that the boom can be retracted by normal operation, or disconnect in the turntable the two hoses that feed the extension cylinder and temporarily connect them to an external hydraulic source and reservoir, such as a Porta-Power type hand pump, another truck with a hydraulic system, etc.. This external hydraulic source should be capable of at least 1,500 PSI operating pressures.

2. Turntable Rotation - Remove the cover plate from the top rear of the turntable brackets. Carefully loosen the hydraulic hose connections at the rotation motor, then manually push the boom in the desired direction. -

3. Boom Lowering - Refer to the Part IV, Commercial Data Section, for a cut of the elevation cylinder holding valve. There are two adjusting screws, sometimes capped by acorn nuts, projecting from this holding valve. Locate the one which is in the same vertical plane as the port which is connected to the blind end of the elevation cylinder. Place an operator at the hand control and have him actuate the joystick in the direction to lower the boom. On the adjusting screw just located, remove the acorn nut, loosen the jam nut, and carefully back off the adjusting screw until the boom begins to lower. The operator at the hand control must now control the speed of descent by moving the joystick toward neutral. Continue until the boom is in the rest, readjusting the turntable rotation if necessary.

4. Stabilizer Retraction - Connect a Porta-Power type hand pump (or other external hydraulic source) to the tee at the pilot port of a stabilizer cylinder holding check. To do this, the tubing run from this tee which leads into the pedestal, must be disconnected to make a connection point available. Operate the external hydraulic source until the stabilizer is retracted and repeat for the other side. It may also be desirable to run a temporary line from the cylinder port of the check valve to the reservoir of the external hydraulic source to provide replenishing fluid.

STABILIZER (JACK)/BOOM INTERLOCK FAILURE OPERATION

▪ The third class of emergency operation is one where the limit switches for the stabilizer (jack)/boom interlock fail or the interlocks do not function properly, resulting in loss of power to the stabilizers and/or boom control circuit.

▪ The key switches are designed to override the interlock in case of failure.

▪ Flip the mode switch to the desired mode of operation. Next, turn and hold the key switch to override the interlock which has failed. Now the valve for the mode chosen should have hydraulic power. Notice the light for the mode chosen to be used is now lighted. Choose the joystick to be used and carefully move the joystick in the direction needed.

▪ Exercise extreme care while operating stabilizers and boom while the override controls are engaged. Overturning of the unit is possible if the stabilizers are not set properly before boom movement or if the stabilizers are moved while boom is in use.

▪ THE OVERRIDE SHOULD ONLY BE USED IN CASE OF EMERGENCY.

SAFETY PRECAUTIONS

A. ALWAYS chock the truck wheels before operating the boom.

B. Anytime the unit is operated, place bearing pads under the stabilizers. It is REQUIRED that bearing pads be used at all times.

C. Set the stabilizers before performing any boom motions.

D. Operate the-T-55D only while standing on the rear step.

E. DO NOT make contact between the boom and overhead electrical wires and equipment. Exercise extreme care while operating near overhead electrical wires and warn all persons not to touch the truck.

F. If the boom should be in contact with overhead electrical wires and it is necessary to leave the truck, jump clean with both feet. Do not return until electrical power has been disconnected.

G. Store the boom before raising the stabilizers or moving the truck.

H. Raise the stabilizers before moving the vehicle.

I. DO NOT exceed a 200 PSI water pressure reading at the control console gauge.

INSPECTION BEFORE GARAGING

A. Check hydraulic oil reservoir level to be sure that oil is visible in the screened filler opening. If it is not, add hydraulic oil of the proper type to this level.

B. Set the stabilizers and inspect for leaks, whole holding extension pressure on each cylinder.

C. Operate the boom through the full range of extension, elevation, and rotation; and inspect for leaks during operation. Not any abnormal operation.

D. While the boom is extended, inspect the inner water pipes for scratches, nicks, dents and bends.

E. If during the last use of the boom it was operated in tight quarters, against walls, or otherwise subjected to unusual operating conditions, inspect for damage to those parts of the unit most likely to have been affected by the abnormal operation.

F. Retract the stabilizers and hold them under retraction pressure while inspecting for leaks.

G. Check the hydraulic return line filter condition if your unit has a condition gauge.

H. Take corrective action for any deficiencies found in the above checks.

PART III - SECTION A NORMAL INSPECTIONS & MAINTENANCE

|MAINTENANCE CHART |

|Check |Frequency |Procedure |

|Hydraulic Oil Level |After every use & monthly |Remove filler cap and determine if oil is visible in the screened filler |

| | |opening. If not, add oil to within 2” of the lower edge of the filler |

| | |opening. |

|Hydraulic System |After every use |Check all hose ends and tube fittings for signs of leakage, while their |

| | |circuit is pressurized. |

| | |Warning: Do not use bare hands to check for leaks while the system is |

| | |under pressure, since a high velocity jet of fluid could rupture the skin. |

| | |Check for worn, frayed, twisted, or kinked hoses. |

| | |Correct all defects noted. |

|Grease Turntable Bearing |Annually |Rotate the turntable until all grease fittings come into view and ring |

| | |grease them as they do. |

| | |See lubricant list for recommendations. |

................
................

In order to avoid copyright disputes, this page is only a partial summary.

Google Online Preview   Download