Commander Operation Manual

© 2013 Rosenbauer Motors, LLC

OPERATION MANUAL

PANAMA CANALFIRE DEPARTMENT

VIN #54F2DC603CWM10401

Panama Canal Fire Department Vin# 54F2DC603CWM10401

2 © 2013 Rosenbauer Motors, LLC

Table of Contents Introduction ..................................................................................................................... 4

Warranty and Registration ............................................................................................... 5

Rosenbauer America Warranty Registration Form .................................................... 6

Warranty Procedures ................................................................................................ 7

Vehicle Information .......................................................................................................... 9

Vehicle Identification ................................................................................................. 9

Chassis Specifications ............................................................................................ 11

Safety ............................................................................................................................. 12

Danger, Warning and Caution Statements ............................................................... 12

General Warnings and Cautions .............................................................................. 12

Safety Labels ........................................................................................................... 14

Reporting Safety Defects ........................................................................................ 16

Material Safety Data Sheets (MSDS) ........................................................................ 16

Seatbelts ................................................................................................................. 16

Vehicle Components ...................................................................................................... 17

Driver’s Side View ................................................................................................... 17

Passenger Side View ............................................................................................... 18

Front View ............................................................................................................... 19

Cab Lift Procedure .................................................................................................. 20

Cab Controls .................................................................................................................. 23

Dash Controls and Displays ..................................................................................... 23

Tell-tales ................................................................................................................. 25

Door Ajar Light ........................................................................................................ 25

Brake and Throttle Pedals ....................................................................................... 26

Tilting / Telescoping Lever ....................................................................................... 26

Multifunction Lever .................................................................................................. 26

Hazard Light Switch ................................................................................................ 26

Master Power Disconnect Switch ............................................................................ 27

Parking Brake ......................................................................................................... 27

Transmission Controls ............................................................................................ 28

Dash Panel Dimmer Control ..................................................................................... 29


© 2013 Rosenbauer Motors, LLC 3

Windshield Wipers ...................................................................................................29

Point to Point Controls .............................................................................................30

Auxilary Brake…………………………………………………..…………………………………31

Rear HVAC ............................................................................................................. 312

Preparation for Use ........................................................................................................33

Before Entering the Apparatus ................................................................................33

Before Driving the Apparatus ..................................................................................33

Pre-Start Checklist ..................................................................................................34

Transmission Fluid Level Check ..............................................................................35

Starting and Stopping the Engine ...................................................................................36

Engine ............................................................................................................................38

Overview .................................................................................................................38

Batteries ..................................................................................................................39

Cooling System ........................................................................................................39

Normal Operating Range .........................................................................................40

Specifications (Cummins ISM) .................................................................................40

Fluid Capacities .......................................................................................................41

Belt Routing Diagrams…………………………………………………………………………...42

Tires and Wheels ............................................................................................................43

Options and their Operation ...........................................................................................44

Vehicle Data Recorder ...................................................................................................45

Cleaning and Washing ....................................................................................................45

Wiring Diagrams .............................................................................................................46

Maintenance Schedule ...................................................................................................47

Engine Maintenance (ISM) .......................................................................................47

Transmission Maintenance ......................................................................................48

Maintenance and Repair Record ....................................................................................49



Introduction Welcome, Rosenbauer thanks you for your recent purchase of fire apparatus from us. We are confident that, when properly operated, maintained and serviced, your Rosenbauer fire apparatus will provide you with years of reliable service.

Your fire department was integral in developing the specification for your custom built fire apparatus. This manual is designed to provide general information on operation of your apparatus. For more detailed information, refer to the appropriate section of the component manual that was delivered with your apparatus.

Due to technological advancements, continuous improvement of our products and the products of ourcomponent suppliers as well as the custom nature of your fire apparatus, some variation between this manual and your apparatus may occur. Rosenbauer reservesthe right to change specifications without notification.

Your Rosenbauer dealer is your best source for information, parts, and service. For customer service, please contact:

Jose Fernandez Fire & Rescue Equipment Corp Phone # (507) 261-7238 / (507) 261-3255 Fax # (507) 229-5856 [email protected]

www.firecorp.com.pa

If you need further assistance, please contact the factory Customer Service:

Rosenbauer 5181 260th Street Wyoming, MN 55092 Phone # (651) 462-7570

[email protected] Please have your apparatus VIN when requesting information or assistance; this will allow us to assist you more quickly.

mailto:[email protected]�




Warranty and Registration

Rosenbauer Motors, LLC hereby warrants each new fire & rescue vehicle to be free from defects in material and workmanship for a warranty period of three (3) yearsstarting on the date the vehicle is delivered to original purchaser.

This warranty is further limited by the terms and conditions stated in the Chassis and General Warranty in section titled New Vehicle Limited Warranty .Please review these provisions carefully as they will further limitwarranty.

The warranty of the chassis can be extended if purchased. Body Builder to add own information here…



Rosenbauer America Warranty Registration Form This form must be completed by the end user to register the apparatus and returned to Rosenbauer America. The receipt of this document will activate the Rosenbauer America Warranty.

Please Note: The Rosenbauer America Warranty will begin on the date of the vehicle invoice if the warranty registration form is not returned to Rosenbauer America within thirty days of the delivery date. Please email the form back to: [email protected] or fax to 651-462-1700. Thank You!

If you have a change of address, please notify Rosenbauer America’s customer service department at 651-462-1000.

Owner/ Department

Address

City State Zip Code

Vehicle Identification Number (VIN):

Date Unit Placed In Service:

Mileage When Placed In Service:

Customer Signature: Date:

**Please refer to Warranty Procedures, included in the warranty

section of this Operation Manual. Thank You! **




Warranty Procedures Warranty Registration

1. The Rosenbauer America warranty registration form must be completed and returned to Rosenbauer America upon receipt of the new vehicle. If the warranty registration form is not returned, the date on the invoice for the vehicle will apply as the “in service date”.

2. All other warranty registration forms must be completed and mailed to each respective manufacturer.

Warranty Pre-Authorization Procedure

1. Authorization is required prior to any repairs or parts replacement. 2. Customer / Dealer must contact Rosenbauer America to obtain authorization. 3. Information required for authorization:

a. Vehicle identification number (the last 6 digits) b. In service date c. Mileage d. Description of problem or failure.

4. Rosenbauer America will determine if the problem is covered under warranty. In some cases this may require telephone troubleshooting with our service personal to help determine the problem source.

5. If it is determined to fall under another manufacturer’s warranty (such as non Rosenbauer components) Rosenbauer America will contact that manufacturer in order to obtain authorization to proceed. In some cases, the manufacturer will need to speak directly with the customer / dealer to aid in identifying the problem.

6. Rosenbauer America must authorize the repair facility at which the warranty repairs are to be performed. If another manufacturer’s warranty applies, that manufacturer must authorize the repair facility.

7. Rosenbauer America must be provided with an estimate of the costs associated with the repair, prior to any work being performed, at which time an approval will be given.

Warranty Claim Procedure

1. Contact your Rosenbauer Service Department or Rosenbauer Certified Dealer. 2. Rosenbauer Service Response System (SRS) to be populated with warranty claim

information will notify the service department immediately. 3. Rosenbauer service department will make contact with customer or dealer

immediately.



Warranty Invoicing Procedure

1. Upon completion of the approved repair, contact Rosenbauer America to obtain a warranty authorization number. This number is to be included on the invoice to Rosenbauer America.



Vehicle Information

Vehicle Identification Your Rosenbauer Commander chassis has a unique Vehicle Identification Number (VIN)assigned to it. This information can be found on a plaque located on the driver’s side door panel.

Locating the Vehicle Identification Numbermay be important when referring to the manufacturer in regards to parts or technical issues. It may be helpful to write this number down in the location provided below.

VIN #

5

4 F 2 D C 6 0 3 C W M 1 0 4 0 1

Driver’s Seat

VIN Tag



Gross Vehicle Weight Rating (GVWR) The GVWR is the maximum operating weight/mass of a vehicle as specified by the manufacturer including the vehicle's chassis, body, engine, engine fluids, fuel, accessories, driver, passengers and cargo but excluding that of any trailers.

Gross Combination Weight Rating (GCWR) The GCWR is the maximum allowable combined weight/mass of a towing road vehicle, passengers and cargo in the tow vehicle, plus the mass of the trailer and cargo in the trailer. This rating is set by the vehicle manufacturer. The GCWR is determined by adding the GVWR of the unit and the total maximum weight of a load that can be towed.

Gross Vehicle Weight (GVW) The GVW is the maximum operating weight/mass of a vehicle as specified by the manufacturer including the vehicle's chassis, body, engine, engine fluids, fuel, accessories, driver, passengers and cargo but excluding that of any trailers

Gross Axle Weight Rating (GAWR) The GAWR is the maximum distributed weight/mass that may be supported by an axle of a road vehicle.

Gross Axle Weight (GAW) The GAW is the total weight/mass supported by a single axle while the vehicle is fully loaded.



Chassis Specifications

Engine - Cummins ISM500 HP

Transmission - Allison 4000 EV

Alternator - Leece Neville 270 AMP

Front Axle - Meritor MFS 21,500 Lbs.

Front Suspension - Hendrickson 9 Leaf 22,800 Lbs.

Rear Axle–Meritor31,500 Lbs.

Rear Suspension –Reyco 79KB Spring 31,500 Lbs. Steering Cramp Angle - 46 Degrees



Safety This manual explains the operation of your new fire apparatus. Please carefully read this manual as well as the component manuals included in the binder before attempting to operate this vehicle. Only personnel that are familiar with the manual, the vehicle, and local regulations are qualified to operate this apparatus.

This manual assumes that the operator has been trained by the fire department or other training agency (technical school, fire school, etc.) and is certified to operate fire apparatuses.

The operator should also be familiar with: the basics of water pump operation; the function of each valve, gauge, control, and manual override; so that the operator can change operation with conditions on-scene.

Rosenbauer is not liable for any damage or injury caused by personnel unqualified to operate the apparatus.

Danger, Warning and Caution Statements The following symbols located in this manual alert you of potentially hazardous conditions to the operator, servicer, bystanders, or equipment.

This symbol indicates an immediate hazard which, if not avoided, will result in severe personal injury or death.

This symbol indicates a hazard or unsafe practice which, if not avoided, may result in severe personal injury or death.

This symbol indicates a hazard or unsafe practice which, if not avoided, may result in personal injury or equipment/property damage.

General Warnings and Cautions

Fire apparatus are often used in hazardous environments. The best way to minimize the risk of injury is through experience and information. IF YOU ARE UNSURE OF HOW TO OPERATE THIS APPARATUS OR ANY OF ITS COMPONENTS SAFELY, please ask for help before putting yourself and others at risk. Become familiar with the contents of this manual that you will not have to refer to it on-scene.

Practice emergency shutdown and manual override procedures until they become second nature so that you can respond immediately to an emergency situation.



Death or serious personal injury might occur if proper operating procedures are not followed. The pump operator, as well as individuals connecting supply or discharge hoses to the apparatus must be familiar with these pump operating instructions as well as other operating instructions and manuals for the apparatus, water hydraulics and component limitation.

Be careful when climbing on the apparatus, and when walking along the top of the vehicle. Only walk on areas where NFPA approved walking surface materials have been used. Always maintain three points of contact (i.e. 2 hands and 1 foot or 1 hand and 2 feet) when climbing up or down the apparatus.

Never use the parking brake as a service brake. Loss of vehicle control may result.

Fire helmets shall not be worn by persons riding in enclosed driving and crew areas. Fire helmets are not designed for crash protection and they will interfere with the protection provided by head rests. The use of seat belts is essential to protecting fire fighters during driving.

Seat belts provide protection in the event of an accident and must be correctly fastened at all times to prevent personal injury.

The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects or other reproductive harm.

Before operating this vehicle, ensure that:

o The operator is properly trained.Read carefully all owners’ manuals, service manuals, and/or other instructions.Always follow proper procedures, and use proper tools and safety equipment.

o Equipment is properly loaded and secured. o The vehicle has been serviced according to the manufacturer’s instructions. o All doors and access panels are closed.



Safety Labels Locate, read, and understand the hazard that each warning label on the apparatus describes. If a label comes off or becomes hard to read, contact Rosenbauer for a replacement.



Reporting Safety Defects

If you believe that your vehicle has a defect which could cause a crash or could cause injury or death, you should immediately inform the National Highway Traffic Safety Administration (NHTSA) in addition to notifying Rosenbauer Motors, LLC.

If NHTSA receives similar complaints, it may open an investigation, and if it finds that a safety defect exists in a group of vehicles, it may order a recall and remedy campaign. However, NHTSA cannot become involved in individual problems between you, your dealer, or Rosenbauer Motors, LLC.

To contact NHTSA, you may call the Vehicle Safety Hotline toll-free at 1–888–327–4236 (TTY: 1–800–424–9153); go to http://www.safercar.gov ; or write to: Administrator, NHTSA 400 Seventh Street, SW. Washington, DC 20590 You can also obtain other information about motor vehicle safety fromhttp://www.safercar.gov.

Material Safety Data Sheets (MSDS) Material Safety Data Sheet information can be found on the reference CD supplied with this apparatus.

Seatbelts

All occupants must wear seatbelts when operating or riding in the vehicle.

Seatbelts must be inspected regularly to ensure they remain in proper condition.

This apparatus uses a three point seat belt system. Occupants should always fasten seatbelts before driving. Fasten the three point seat belt by pushing the latch (A) into the buckle (B) until and audible click is heard. To ensure the belt is latched, give the seat belt a slight tug. The shoulder strap should be positioned diagonally across your chest.

A

B

http://www.safercar.gov/�



Vehicle Components

Driver’s Side View

A) HVAC Unit B)

Right Side Marker Light

B

A



Passenger Side View

A)

Left Side Marker Light

A



Front View

A)

Scene Lights

B) HVAC Unit C) Headlights D) Turn Signal

A A

B

E C

E D



Cab Lift Procedure

Before raising or lowering the cab, safety precautions must be taken to avoidpersonal injury or equipment damage. Ensure frontal and overhead clearance issufficient to fully raise cab without hitting electrical wires or dangerous overheadobjects that could result in serious injury or death.

An aluminum cab tilt control instruction plate has been provided with the cab/chassis. The plate must be secured in a location close to the storage place of the remote pendant to allow visibility prior to each pendant usage.

Ensure compartment doors, and the grille, are secured before raising or lowering the cab.

Failure to ensure that the support mechanism is in place may result in personal injury or death.

The cab tilt system is designed to tilt the cab structure only! Additional loads may cause system failure. Before Raising Cab

• Be sure there is adequate clearance in front of and overhead of cab, to fully raise it without damage.

• Vehicle must be parked on level surface with park brake on. • No personnel or loose equipment should remain in cab during tilt system

operations. • Cab doors must be securely closed prior to tilt operations. • All items in the tilt arch (suction swivels, hoses, etc.) must be removed from

bumper. • Master switch must be in the “ON” position. • Ignition switch may be in the “OFF” position, or “ON” position, with or without the

engine running. • All personnel must remain clear from in front of and under the cab at all times the

tilt system is in operation.



Raising Cab (Remote Electric)

1. Plug in cab pendant control if not already connected and verify the cab has sufficient clearance to be raised.

2. Energize the electric/hydraulic pump by depressing and holding the “U” button on the remote pendant.

Failure to ensure that the support mechanism is in place may result in personal injury or death

3. Raise cab until support channel clears the top of the lift cylinder housing and automatically engages against the piston rod. Visually confirm that support mechanism is fully engaged before personnel go under the raised cab.

4. DONOTlower the cab down on to the safety support. 5. Deactivate the electric/hydraulic pump by releasing the "U"

button.

Lowering Cab (Remote Electric)

All personnel must stay clear from under cab when lowering cab or seriouspersonal injury or death may occur.

1. Release safety support mechanism by pulling the support release cable. (The speed at which the cab lowers is preset and cannot be adjusted.)

2. While pulling on the support release cable, activate the electric/hydraulic circuit by depressing and holding the "D" button. The cab will slowly lower, (The support safety cable may be released once support channel is clear of top of cylinder housing.) Continue lowering the cab until the cab locks are fully engage, this may take up to 30 seconds after cab has made contact with latches.



MANUAL CAB TILT INSTRUCTIONS (Optional)

Manually Tilt Cab

1. Set parking brake 2. Check for clearance to tilt 3. Pull left red knob out on pump and rotate 1/4 turn to override extend valve. 4. Operate hand pump to raise cab. 5. Raise cab until safety stop drops in place. 6. Do not lower cab onto safety stop. If cab settles, raise cab off of stop.

Manually Lower Cab

1. Rotate left red knob on pump until it drops into the normal position. 2. Make sure the right knob (retract valve) on the pump is in the normal position (Will

not rotate). 3. Remove plastic cover and rotate dump valve at each cylinder counterclockwise. 4. Make sure all is clear to lower cab. 5. Pull safety stop cable to move stop away from cylinder 6. Pull right red knob out on pump and rotate 1/4 turn to override retract valve and

lower the cab. 7. Allow the cab to drop to the ride position and the latches to automatically lock. 8. Rotate dump valve at each cylinder clockwise until seated and replace the Plastic

cover. 9. Rotate the right red knob on pump until it drops into the normal position.



Cab Controls

Dash Controls and Displays

A) Brake Primary Air Pressure K) Speedometer B) Brake Secondary Air Pressure L) Check Engine Light C) Upper Left Hand Button M) RPM D) Brake Primary Air Pressure Low Warning N) DEF Fluid Level Gauge E) Brake Secondary Air Pressure Low Warning O) Fuel Gauge F) Upper Right Hand Button P) Voltage Meter G) Lower Left Hand Button Q) Low Fuel Warning Light H) Multifunction Display R) Voltage Warning Light I) Lower Right Hand Button S) Oil Pressure Gauge J) MPH Indicator Light T) Engine Coolant Temperature

Display functions will be controlled by 4 switches (C,F,G and I). In normal mode, the switch on the left side will control selection of heading for the corresponding line. The switch on the right side will control selection of parameter for the corresponding line. Pressing and holding the switch for 1 second will restore the previous line item. For full screen items, the switch functions will be displayed.

F C

G

A B

I

H

J

N

M

K

O

Q

R

U

S

T

P

D E

L



The multifunction display menu will include the following headings illustrated as they would appear on the display. Activation of the top left button will move to the next available heading selection. Activation of the top right hand button will select and scroll through the available options under that particular heading.

DIAGNOSTICS

ODOMETER

9,999,999.9 M

SETTINGS

ODOMETER

9,999,999.9 M

TRIP 3

ODOMETER

9,999,999.9 M

TRIP 2

ODOMETER

9,999,999.9 M

TRIP 1

ODOMETER

9,999,999.9 M

VEHICLE

ODOMETER 9,999,999.9 M

Under the VEHICLEheading, the following parameters will be displayed. Please note that parameters will not be displayed when no data is available. -Transmission Oil Temp -Total Vehicle Distance -Battery Potential -Engine Hours -Vehicle Speed -Engine Speed -Fuel Level -DEF Catalyst Tank Level -Engine Oil Pressure -Battery Current -Engine Coolant Temp -Brake Primary Air Pressure -Engine Oil Temp -Average Fuel Economy -Brake Secondary Air Pressure -Engine Intake Manifold Pressure -Aftertreatment Exhaust Gas Temp -Engine Percent Load At Current Speed -Actual Engine Percent Torque -Instantaneous Fuel Economy

Under the TRIPheading, the following parameters will be displayed. -Total Fuel Used -Total Idle Fuel Used Trips 2 and 3 will display the same information as illustrated for trip 1. Trip Distance is reset by pressing and holding the upper right hand button (F) for a period of 2 seconds while trip mileage is displayed.

Under the SETTINGSheading, the following parameters will be displayed. Pressing and holding the right hand button will execute the function -Select Units -Select Contrast

An asterisk will appear next to the “DIAGNOSTICS” heading it active diagnostic codes are present.

Please refer to the supplied dash gauge manual for more information.



Tell-tales

A) Water in fuel J) High Transmission Temperature B) Automatic Traction Control K) Check Transmission C) Engine Pre-heater (Wait To Start) L) High Beam Headlights D) Battery Power On M) Airbag Warning E) Park Brake Engaged N) Low Engine Coolant Level F) High Exhaust System Temperature O) Re-gen Inhibit Switch Engaged G) Air Intake Restriction P) Particle Filter Regeneration H) Left Turn Arrow Q) Right Turn Arrow I) Anti-Lock Brake System

Door Ajar Light

Do Not Move Apparatus if the open door warning light (A) is flashing. If flashing, verify that all doors and compartments are closed, and that all equipment is secured.

The “Do Not Move Apparatus” (door ajar) light is located on the center section of the roof of the cab. This light will blink if a cab or compartment door is open and the parking brake is not engaged. If the “Do Not Move Apparatus” warning comes on while driving, stop the vehicle and secure the open door, open component or loose equipment.

A

A B C D E F G

I K J L M N O P Q H



Brake and Throttle Pedals

Excessive use of the service brakes may result in overheating andbrake fade which will decrease their stopping ability.

The service brake pedal (A) is located on the driver side floorboard of the apparatus. It is the pedal positioned on the left.

The Throttle (accelerator) pedal (B) is located on the driver side floorboard of the apparatus. It is the pedal positioned on the right.

Tilting / Telescoping Lever To accommodate your seating position for maximum comfort and control of the vehicle:

o Push lever down to adjust height of the steering wheel. o Pull lever up to change the angle of the steering wheel.

NOTE:When you are finished driving, the steering wheel should be tilted forward and retracted inward for ease of exit and entry.

Multifunction Lever This is located on the left side of the column below the wheel. It operates the turn signals and headlight dimmer that are similar to a car:

o Push the lever towards the dash to activate the right turn signal.

o Pull the lever towards the seat to activate the left turn signal.

o To turn the high beams on or off raise this lever until it clicks.

Dashboard indicator lights will correspond to the function you have selected.

Hazard Light Switch Located on the steering column, this switch will activate the four way hazard flashers.

o To activate, pull the switch outward from the steering column.

o To deactivate, push switch inward toward the steering column.

Note: The master power disconnect switch must be in the on position to operate the four way hazard flashers.

A B



Master Power Disconnect Switch

Do not turn off the master power disconnect switch while the engine is running, damage to the alternator may result. The master power disconnect switch is used to disconnect electrical power to the vehicle while the vehicle is not in use. The master power disconnect switch is located on the front of the driver’s side cab step. This switch must be turned on in order to operate the apparatus.

Parking Brake

When parking on a grade, always chock wheels and turn the front wheels completely in the direction of the curb.

The parking brake is only intended to hold the vehicle in a parked position. The parking brake may be used to assist the apparatus to a stop, but only in an emergency. The parking brake should not be used to stop the vehicle during normal driving. The parking brakes are applied by operation of the yellow parking brake valve shown.

o When the lever is forward (towards dash panel), the park brake is released.

o When the lever is rearward (away from dash panel), the park brake is applied.

While ignition is switched on, an indicator lamp will illuminate on the driver’s display panel when the parking brake is applied. NOTE: SETTING THE PARKING BRAKE WILL AUTOMATICALLY PLACE THE TRANSMISSION IN NEUTRAL. The transmission selector must be put into neutral (by the driver) after this safety over ride has taken effect in order for system become fully functional.



Transmission Controls

If you leave the vehicle and the engine isrunning, the vehicle can move unexpectedly and you orothers could be injured. If you must leave the engine running, do not leave the vehicle until you havecompleted all of the following procedures:

1. Put the transmission in N (Neutral). 2. Be sure the engine is at low idle (500–800 rpm). 3. Apply the parking brakes and emergency brake andmake sure they are properly

engaged. 4. Chock the wheels and take any other stepsnecessary to keep the vehicle from

moving.

This truck is equipped with an electronically controlled Allison automatic transmission. It has 5 forward gears. All drivers should read the ALLISON operators manual tofamiliarize themselves with the features of this transmission.

The pushbutton shift selector has the following components: • R (Reverse)—Press this button to select Reverse • N (Neutral)—Press this button to select Neutral • D (Drive)—Press this button to select Drive. The highest forward range available

will appear in the digital display window. The transmission will start out in the lowest available forward range and advance automatically to the highest range.

• ↑(Up) Arrow—Press the ↑(Up) Arrow when in D (Drive) to request the next higher range. Continually pressing the ↑(Up) Arrow will request the highest range available.

• ↓(Down) Arrow—Press the ↓(Down) Arrow when in D (Drive) to request the next lower range. Continually pressing the ↓(Down) Arrow will request the lowest range available.

Displays current gear. Also used for reading transmission oil level.

Displays highest gear selected. Also used for reading transmission oil level.

Truck must be stationary before selecting Reverse.

Select Neutral when applying park brake.

Truck must be stationary before selecting Drive.

Used for Diagnostics. See Allison Transmission Manual.

Used to select a specific gear.



Dash Panel Dimmer Control The Dash Panel Dimmer Control (M) allows the driver to set the amount of light being emitted from the dash gauges. The switch may be moved up and down to adjust brightness.

M) Dimmer Switch

A) Wipers on/off

B) Washer on/off

Windshield Wipers

Do not run windshield wipers dry for extended periods of time or excessive wear and damage may accrue to components.

The lever to operate the windshield wiper features is located by the steering wheel (right side) and functions as follows: A) – Turns wipers on/off On the dash there is a wiper control switch and functions as follows: B) – Activates windshield washer fluid and adjusts thevariable speed of the wipers.

M

A

B



Point to Point Controls

A) Fan Control

B) Directional Control

C) Temperature Control

D) E) F) G) H) I) J) K) L) M) N)

A/C Switch Defrost Switch E-Master Switch On/Off Aerial Control High Idle Control On/Off Lights On/Off Dimmer Switch Wiper Control Switch Engine Brake Control Engine Brake Low-High Air Vents

A B C

G F

E

D

H

L M

N

K J I

N N



A) Engine and Transmission ECM Communications Port

Auxiliary Brake The buttons to operate the auxiliary engine braking features are located on the steering wheel (right side) and function as follows: L) – Turns auxiliary engine braking on/off. M) - Adjusts engine braking from low to high

A

L M



Rear HVAC

The rear HVAC controls are located on the roof mounted HVAC unit. Knob A adjusts the fan speed. To increase airflow, turn knob A clockwise. To shut the rear HVAC off, turn knob A to the farthest counterclockwise position. Knob B controls the temperature of the rear HVAC unit. Turing the knob to the left and right adjusts the temperature cooler and warmer, respectively.

A B



Preparation for Use The following Pre-Start checklist is a guide for inspection after each operation. Any defects should be reported to the Maintenance personnel for disposition and, if necessary, corrected before the truck is placed back in service.

Equipment improperly prepared for operation is unsafe foruse.If something is noticed and requires attention, have itchecked before the apparatus leaves for operation. Even minormechanical defects can lead to accidents or personal injury. Pay attention to the operation manuals of equipment andapparatus carried in the vehicle.

Fire helmets shall not be worn by persons riding in enclosed driving and crew areas. Fire helmets are not designed for crash protection and they will interfere with the protection provided by head rests. The use of seat belts is essential to protecting fire fighters during driving.

Before Entering the Apparatus o The Pre-Start Checklist (next page) should be completed after every operation. o Unless the truck is equipped with optional auto ejects, unplug electric and air

shorelines connected to apparatus. o All occupants must understand the 3 pointsof contact for entering and exiting the

cab safely. This means that at least three points of your body, either two hands and one foot or one hand and two feet, must be in touch with the apparatus or the ground while ascending into or descending out of the cab.

Before Driving the Apparatus o Turn the master power disconnect switch to the “on” position. o Start the engine according to the “Starting and Stopping the Engine” section of this

manual. o While engine is warming up, check all gauges and tell-tales to ensure all systems

are operating within normal operating ranges. o Adjust driver's seat for proper pedal position thenadjust steering wheel. o Make sure that all occupants have their seat belts fastened. o Check door ajar light to ensure that all doors are securely closed. o Check mirrors for proper alignment. o In dark, low light, and/or foggy conditions, turn on headlights. o If conditions require, turn on windshield wipers. o Adjust HVACcontrols to desired temperature and output setting. o If emergency warning lights are required, switch on. o While holding service brakes, release park brake. o Place vehicle into drive and advance forward.



Pre-Start Checklist Entire Vehicle

Check all locks and hold down devices for proper operation. Check vehicle exterior for dents or damage. Clean all lights, reflectors and mirrors, and check for broken glass. Check for missing bolts, loose or damaged hoses and damaged wires. Take inventory of removable equipment. Replace any missing or damaged items. Turn on all truck lights and check for correct function. Check air system for leaks. Inspect all fire-fighting equipment for corrosion, damage or other defects.

Chassis

Inspect wheel hugs, axles, transfer casing, and transmission for signs of leakage. Check under the vehicle for fuel, oil, or coolant leakage. Check engine belts. Check engine coolant level. Check engine oil level. Check transmission fluid level. Inspect all glass for cracks and discoloration. Check operation of sliding windows in cab. Check operation and condition of seat adjusting mechanism. Visually inspect each tire for correct inflation. Refer truck to maintenance if the tire has low pressure.

(Tires have tire pressure indicators installed) Inflate every tire to the recommended air pressure when tires are cold. Inspect tires for uneven wear, chinks, or cuts. Inspect rims for damage and inspect lug nuts. To prevent damage, tires must not be cleaned with a high pressure steam jet. Observe operation of all gauges. Operate windshield washer and wiper. Operate warning lights and alarm system. Operate traffic guidance light and check proper operation. Operate the horn, heater, and defroster. Operate the communication system. Check fuel level, add fuel if necessary. Check level of windshield washing agent, add if necessary. Check service brakes for proper function. Check for uneven or spongy action, dragging, squealing, or chatter when braking. Test parking brake for proper function. Check operation and general condition of cabin / compartment doors and roller shutters. Visually inspect seals around doors for looseness and/or damage.

Vehicle Body

Engage water pump and check that it functions correctly. Check function and condition of valves, instruments and gauges. Check level in water tank visually. Check condition of the screen fitted on the suction connection. Refill the fuel tank and tanks of firefighting agents.



Transmission Fluid Level Check

A low or high fluid level can cause overheating andirregular shift patterns. Incorrect fluid level can damage thetransmission.

o Park the vehicle on a level surface. o Shift to Neutral and apply the parking brake. o Press the Up andDown Arrow buttons simultaneously once.

NOTE:The fluid level check may be delayed until the following conditions have been met:

• The fluid temperature is above 60°C (140°F) and below 104°C (220°F). • The transmission is in Neutral. • The engine is at idle. • The transmission output shaft is stopped. • The vehicle has been stationary for approximately two minutes to allow the fluid

to settle. A delayed fluid level check is indicated by a “—” in the single digit display followed by a numerical countdown. The countdown, from 8 to 1, indicates the time remaining in the two minute waiting period.

If the fluid level is correct, the display will show the following: SELECT MONITOR Description o L Represents Fluid (oil) Level Check Mode o K Fluid level is within the correct fluid levelzone

NOTE:The sensor display and the dipstick may not agree exactly because the OLS compensates for fluid temperature.

o If the fluid level is low, the display will show the following: SELECT MONITOR Description o L Represents Fluid (oil) Level Check Mode L o Represents Low Oil Level 0 2 The number of quarts the transmission is low o If the fluid level is high, the display will show the following: SELECT MONITOR Description o L Represents Fluid (oil) Level Check Mode H I Represents High Oil Level 0 1 The number of quarts of fluid the transmission is overfull o If there is a system problem, the display will show the following: SELECT MONITOR Description o L Represents Fluid (oil) Level Check Mode – – The dashes are followed by a numericaldisplay which is a

fault code that indicatesconditions are not proper to receive the fluidlevel information or there is a systemmalfunction. Refer to the transmission manual for further interpretation of these codes.

o To exit the fluid level display mode, press any range button on the pushbutton shift selector.



Starting and Stopping the Engine

Exhaust fumes are toxic. Ensure that the engine is shut down whenever the apparatus is inside an enclosed area, or steps are taken to evacuate the exhaust fumes.

Diesel exhaust fumes are classified by the state of California to cause cancer, birth defects, and other reproductive harm.

The engine exhaust system will become extremely hot during engine operation. DO NOT operate near flammable or explosive material. Hot exhaust components will cause severe burns.

If the engine does not start within 20 seconds, release the starter button and allow the starter motor to cool for one minute before attempting to start the engine again.

Do NOT use starting fluids such as ETHER. Starting the Engine

o Turn the Master Switch (E) to the “ON” position. NOTE:The Master Switch controls all electrical power to the vehicle. This switch must be on to run any electrical component on the vehicle.

o Push the Ignition Switch (F) to the “ON” position. The apparatus will go through a series of self-checks; wait for the checks to complete and notify Maintenance of any problems. If “wait to start lamp” is on, wait until it turns off, then proceed to the next step.

o Push the Engine Start Button (G). o When engine starts, release the Engine Start Button. o As the engine idles, check voltage, oil pressure, and

all other gauges.

F G

E



Stopping the Engine

o Ensure that the Park Brake is set. o Ensure that the Transmission is in Neutral. o Turn the Ignition Switch to the “OFF” position to shut down engine. o Turn the MasterSwitch to the “OFF” position.



Engine

Overview

A) Engine Oil Fill B) Power Steering Reservoir C) Engine Coolant Filter D) Cab Heater Shutoff Valves E) Chassis Air Drier F) Engine Air Intake Filter

C

A

D

B

F

E



Batteries

Batteries (N) can give off explosive gases. Always wear protective clothing and eye protection. To reduce the risk of injury, vent battery compartmentbefore servicing and alwaysdisconnect the negative ground (-) wire first and attach the negative ground (-) wire last.

When using jumper cables to start the engine, make sure to turn master battery switch off and connect the positive (+) cable to the positive (+) terminal and the negative (-) cable to the negative (-) terminal. Remove all negative battery terminals first when disconnecting a battery. When installing a battery, install the positive terminals first. Install the negative terminals last. Clean all battery terminals to assure a proper connection. Battery terminals may be installed with a dielectric compound, coated with battery terminal spray, or clear polyurethane spray.

Cooling System

Do not touch heater hoses, radiator hoses, or other engine components they can be very hot.

Never remove radiator cap while engine coolant is hot. A positive de-aeration cooling system comprised of a surge tank and vent line from the engine and radiator along with a fill line from the surge tank to the engine water pump is used on this apparatus. Coolant Type and Filling Instructions: NOTE: Do not mix coolant types. If coolant type is changed, it is recommended that a complete coolant flush be done.

1. Refer to data provided in the chassis or engine manual for acceptable types of coolant and coolant capacity.

2. Use only approved coolant to; fill coolant system through the fill neck on the top of the surge tank.

3. Run engine at max torque until the thermostat opens (190 – 195 F).

N

O O

O N



Note: It may be necessary to regulate the air flow through the radiator to get the coolant temperature high enough for the thermostat to open.

4. Once operating temperature is achieved, shut off engine and refer to sight glass to check the fluid level. (Coolant level should be in the middle of sight glass.)

5. Add necessary quantity of appropriate coolant to bring coolant level entirely into the sight glass.

Note: Coolant may need to be topped off after normal operation of the engine ifservice work has been performed.

Normal Operating Range Idle: 600 – 750 rpm High Idle: 1250 rpm/Varies Governor: 2100 – 2400 rpm Min. Oil Pressure @ Normal Idle: 10 psi (70 kPa) 35 - 45 psi (240 – 310 kPa) Cooling System: 160°F (71°C) Transmission: 160 - 225°F (70 – 95°C) Air Pressure: Cut In: 105 – 110 psi (725 – 758 kPa)

Cut Out: 120 – 140 psi (827 – 965 kPa) Voltage: 13.2 / 14.0 Volts

Specifications (Cummins ISM) Advertised Horsepower 500 hp at 1800 rpm Peak Torque 1500 ft-lb 2102 N•m Governed Speed 2100 rpm 2100 rpm Clutch Engagement Torque 700 ft-lb 949N•m Number of Cylinders 6 6 Oil System Capacity 10.7 U.S. gallons 38.6 liters System Weight 2,070lb 940 kg Engine (Dry) 2,070lb 940 kg



Use Ultra-Low Sulfur Diesel Fuel Only!

Fluid Capacities Engine Oil 48 U.S. quarts

Engine Coolant 44 U.S. quarts Fuel Tank 50U.S. gallons Transmission Fluid 51 U.S. quarts

Power Steering Fluid 8 U.S. quarts



Belting RoutingDiagram

Cummins® ISM Fan Belt Routing



Tires and Wheels

Always make sure tires are in good condition and inflated to the correct tire pressure. Frequently check and maintain correct inflation pressures as specified by the tire manufacturer. Periodically examinetires for abnormal wear and other damage. Only properly trained personnel with the correct equipment and procedures should mount or remove tires.

Check for proper inflation, tread depth, andthe condition of the tires daily. Look for any bumps, blisters, cuts, punctures, cracks, or uneven wear. Tire condition and pressures must be monitored closely to assure safe operation of the vehicle. Installing Front Wheels Completely remove rust, dirt, and other foreign materials from all surfaces. It is especially important to clean the areas used for mounting the wheel to the vehicle. Slide front wheel over studs. Be careful not to damage the stud threads. Snug up nuts in the sequence shown in figure. Do not tighten them fully until all have been seated. This procedure will permit the uniform seating of nuts and ensure the even, face-to face contact of wheels, hub, and drum. Tighten nuts to 450-500 ft.-lbs. (dry) using the same crisscross sequence. Installing Dual Rear Wheels Completely remove rust, dirt, and other foreign materials from all surfaces. It is especially important to clean the areas used for mounting the wheel to the vehicle. Slide the inner dual wheel over studs. Be careful not todamage the stud threads. Snug up nuts in the sequence shown in figure. Do not tighten them fully until all have been seated. This procedure will permit the uniform seating of nuts and ensure the even, face-to-face contactof wheels, hub, and drum. Tighten nuts to 450-500 ft.-lbs. (dry) using the same crisscross sequence.Align the hand holes of the outer dual wheel to those of the inner dual wheel to allow access to the air valves.Slide the outer dual wheel over the inner cap nuts. Repeat the entire procedure except using the nut tightening sequence in figure. Tighten the outer cap nut to 450-500 ft.-lbs. Note: After the first 50 to 100 miles of operation, recheck the torque level and retighten nuts to the proper torque level. Before inner cap nuts are retightened, be sure to loosen the outer cap nuts first, tighten inner cap nuts, and thenretighten outer cap nuts toproper torque level. Replacement When replacing wheels and tires on this apparatus,the replacement equipment must have the same load carrying capacity as the original. Wheels must have the same characteristics such as rim width, rim offset, and mounting configuration, while tires must be of the same size and type, and must conform to government regulations.



Options and their Operation



Vehicle Data Recorder Your vehicle is equipped with a Class 1 Vehicle Data Recorder (VDR) System. The VDR records and sends the following information to the Class 1 VDR Module:

o Vehicle and engine speed o Engine throttle position o ABS event o Seat occupied status o Seatbelt status o Transmission range information o Position of the park brake o Much more

Cleaning and Washing

High pressure cleaning equipment must not be used; the paintwork will likely be damaged.

o If the compartments and driver´s cabin require cleaning, do not use a high pressure hose or running water. Loose dirt should be removed with a vacuum cleaner, and then moist towels should be used to wipe surfaces.

o Use moist towels to clean the control panels. Excess water can damage electric components. Do not use solvents.

o Wash the vehicle frequently with cold or lukewarm (never hot) water. Do not use household soap or detergent. Use a reliable car shampoo to dissolve traffic film.

o When a hose is used, the water should not be turned onto the body at full pressure, as this tends to drive grit and dirt into the paintwork.

o After the surplus of dirt has been washed off, clean the body with a sponge and plenty of water.

o Wash the windshield wiper blades by using clean water. o Wash the wheel wells. o Avoid open drainage holes. o Rinse off with cold water, and then rub down with a clean chamois leather. o On occasion, after washing and drying the vehicle thoroughly, apply a body polish for

a lasting water-resistant finish. o Never rub the vehicle down with a dry cloth when it is dirty because this causes

cracks in the paintwork which progressively destroy it. o Any tar or asphalt spots on the body may be removed with a tar cleaner and a soft

cloth. o Keep the chrome plated parts clean and free from rust. These parts should be

cleaned periodically with chrome cleaner. o Upholstery can be suitably cleaned with interior cleaner. Never use polishes, oils,

petroleum, or a dry cleaning fluid.



Wiring Diagrams Information pertaining to the following information can be found on the reference CD supplied with this apparatus: Low voltage and line voltage systems including the following information:

• Pictorial representation of circuit logic for all electrical components and wiring • Fuse identification and locations • Circuit identification • Connector pin identification • Zone location of electrical components • Safety interlocks • Alternator – battery power distribution circuits • Input / Output assignment sheets or equivalent circuit logic implemented in

multiplexing systems



Maintenance Schedule

Engine Maintenance(ISM 500)

Please refer to your Cummins® supplied operator’s manual for the most detailed information.

Maintenance Item Miles/Kilometers Hours Months

Oil and Filter* 15,000 mi / 24,000 km 500 6

Primary Fuel Filter** 15,000 mi / 24,000 km 500 6

Secondary Fuel Filter 30,000 mi / 48,000 km 1,000 12

Coolant Filter None*** None*** None***

Overhead Adjustment 150,000 mi / 241,500 km 5,000 48

Standard Coolant Change**** 60,000 mi / 96,000 km 2,000 24

DEF Filter 200,000 mi / 320,000 km

Particulate FilterCleaning 200,000 mi / 320,000 km 6,500

Coalescing Filter Every 3rd to 4th Oil Change Interval

*Assuming severe duty cycle for fire/emergency vehicle applications. **OEM-supplied; intervals may vary. *** If engine is equipped with an optional coolant filter, it will need to be replaced on the same intervals as the oil filter. Regardless if the engine is or is not equipped with a coolant filter, SCA/DCA additive levels must be checked according to the interval listed in the Owner’s Manual. **** Extended coolant and drain/flush/fill intervals may be followed when certain requirements are met. For more information on these requirements, refer to Cummins Coolant Requirements and Maintenance Service Bulletin 3666132.



Transmission Maintenance Please refer to your Allison® Transmission supplied operator’s manual for the most detailed information.

This Allison Transmission has an available prognostics feature which monitors the transmission’s fluid, filters, and overall health. The wrench icon illuminates when remaining fluid life reaches 1%. Afterwards, every time the vehicle is started and D (Drive) is selected the wrench icon illuminates again and stays on for two minutes to remind the operator a fluid change is needed. This occurs until service is performed and the oil life monitor is reset.

The wrench icon flashes on and off for two minutes after D (Drive) is selected. Once the filter life monitor mode has been accessed via the shift selector, the “oK” or “Lo” message is displayed in the selector display window. “oK” means the filters do not need to be changed, and “Lo” means the filters need to be changed.

Calendar based fluid requirements still apply with prognostics (refer to Allison manual). If the oil life monitor has not indicated the need for a fluid change before 60 months for TES 295 fluid, or 24 months for TES 389 fluid, it is necessary to change the fluid and filters per calendar requirements and then reset the oil life monitor.

Instructions on how to read and reset the oil life monitor and filter life monitor can be found in the Allison® Transmission supplied operators manual.



Maintenance and Repair Record

This section is provided for your convenience to track maintenance and repairs performed on the apparatus. Copy this sheet as needed.

Date Problem Repair Technician

Panama Canal B68R22 (73570)

© 2013 Rosenbauer America LLC. All Rights Reserved.

The aerial portion of this manual has been prepared with the assistance of service and engineering specialists to acquaint you with the operation and maintenance of your new aerial. You are urged to read these publications carefully. Following the instructions and recommendations in this manual will help assure the safe and enjoyable operation of your aerial.

When it comes to service, remember that your manufacturer’s dealer knows your aerial best and has factory-trained technicians and specialists who are interested in your satisfaction. To ensure the full period of your warranty all service work should be done by Rosenbauer or a Rosenbauer approved facility.

To maintain the structural warranty, it is the responsibility of the department to have the unit inspected by an authorized independent testing company on an annual basis. Copies of all such inspection forms are to be supplied to Rosenbauer at the following address.:

Rosenbauer Aerials870 S. Broad St.

Fremont, NE 68025P & F: (402) 721-7622

OPERATORS TRAININGDesignated Rosenbauer personnel offers preventative maintenance and hands-on operating familiarization prior to the department operating the unit.

It will be the responsibility of the department to permit only qualified operators, as determined by Fire Department, to operate the aerial apparatus. The operators must be aware of the proper fire ground tactics, practice all known safety rules such as ground support for proper stabilizer placement, use of auxiliary pads and awareness of overhead wires. It is also vital the operator understands the load chart as well as the capabilities and limitations of the device.

HYDRAULIC OIL ANALYSISRosenbauer recommends that when the department receives the truck a hydraulic sample should be taken and tested to be used as a baseline for future maintenance checks. The analysis should included but is not limited to the partial count, spectrochemical, water content and viscosity. The oil sample should be taken from the aerial oil tank after oil has been warmed to normal system operation temperatures (115 degrees or higher)

AERIAL INSPECTIONRosenbauer recommends a primary inspection be done after the delivery and operation familiarization are completed on the aerial. The inspection will help the operator become familiar with preventative maintenance procedures as well as the up keep of the boom including but not limited to lubrication, cylinders and operations. The operator’s awareness of how a properly adjusted boom operates could prevent future failures or damage to the device.

Before operating unit, read and understand all operating and safety information in manual.

WARNING!



STRUCTURAL ADJUSTMENTSRosenbauer will not be held responsible for any adjustments or changes made to the elevated water tower and/or aerial deivce including but not limited to drilling of holes or welding of any sort. If modifications need to be made to the device, written consent will need to be obtained from the Rosenbauer Aerials.

SAFETY OPERATIONSIt is the responsibility of the operator to know the condition of the elevated water tower before operating. A quick and accurate visual check should be preformed of the following (but not limited to) cylinders, pins, equipment, switches, monitors, intercoms etc.

ELECTROCUTION HAZARDTHIS MACHINE IS NOT INSULATE

DEATH OR SERIOUS INJURY WILL RESULT FROM:CONTACT WITH OR INADEQUATE CLEARANCE FROM ENERGIZED CONDUCTORS. MAINTAIN SAFE CLEARANCE AREA FROMELECTRICAL POWER LINES AND APPARATUS. YOU MUST ALLOW FOR AERIAL SWAY, ROCK OR SAG.IF VEHICLE SHOULD BE ELECTRICAL CHARGES KEEP CLEAR OF TRUCK AND ATTACHMENTS

STAND CLEAR OF OUTRIGGER OUTRIGGERS CAN CAUSE SERIOUS CRUSHING INJURY

FAILURE TO OBEY THE FOLLOWING CAN RESULT IN DEATH OR SERIOUS INJURY. INSPECT VEHICLE AND AERIAL DEVICE INCLUDING OPERATION DAILY PRIOR TO USE.

FOR STATIONARY OPERATION VEHICLE MUST BE SECURELY PARKED AND STABILIZED BEFORE THE WORK TO BE PREFORMED AND BEFORE THE AERIAL DEVICE CAN BE OPERATED.

OUTRIGGERS MUST BE ON SOLID FOOTING TO PREVENT TIP OVER.

OPERATORS SHOULD WEAR A BODY BELT AND ATTACHED WITH LINEAR TO AERIAL.

OPERATE ALL CONTROLS SLOWLY FOR SMOOTH MOTION.

DO NOT LOAD BEYOND RATED CAPACITY.

OPERATOR MUST WEAR PROPER PROTECTION GEAR.

WHEN ROTATING LADDER ON SAME WHEN ROTATING LADDER ON SAME SIDE AS SHORT-SET OUTRIGGERS.SIDE AS SHORT-SET OUTRIGGERS.

OPERATING AERIAL WHILE PERSONNEL OPERATING AERIAL WHILE PERSONNEL IS ON LADDER MAY RESULT IN SERIOUS IS ON LADDER MAY RESULT IN SERIOUS INJURY OR DEATHINJURY OR DEATH

DO NOT WELD, DRILL OR ALTER THIS AERIAL DEVICE DO NOT WELD, DRILL OR ALTER THIS AERIAL DEVICE OR SUPPORTING STRUCTURE WITHOUT PRIOR OR SUPPORTING STRUCTURE WITHOUT PRIOR APPROVAL OF THE AERIAL MANUFACTURER.APPROVAL OF THE AERIAL MANUFACTURER.

LIVE LOAD RATING 500 LBS AT TIP WITH 1,000 LIVE LOAD RATING 500 LBS AT TIP WITH 1,000 GPM OF WATER AT 90 DEGREES TO SIDE.GPM OF WATER AT 90 DEGREES TO SIDE.

ELECTROCUTION HAZARD. ELECTROCUTION HAZARD. MINIMUM POWER LINE CLEARANCE MINIMUM POWER LINE CLEARANCE

IS 10 FEET. DO NOT OPERATE IS 10 FEET. DO NOT OPERATE DURING ELECTRICAL STORMS.DURING ELECTRICAL STORMS.

AN UNTRAINED OPERATOR SUBJECTS HIMSELF AN UNTRAINED OPERATOR SUBJECTS HIMSELF AND OTHERS TO DEATH OR SERIOUS INJURY. AND OTHERS TO DEATH OR SERIOUS INJURY. YOU MUST NOT OPERATE THIS MACHINE UNLESS:YOU MUST NOT OPERATE THIS MACHINE UNLESS:YOU HAVE BEEN TRAINED IN THE SAFE OPERATION YOU HAVE BEEN TRAINED IN THE SAFE OPERATION OF THE MACHINEOF THE MACHINEYOU READ, UNDERSTAND AND FOLLOW THE YOU READ, UNDERSTAND AND FOLLOW THE SAFETY AND OPERATION RECOMMENDATIONS SAFETY AND OPERATION RECOMMENDATIONS CONTAINED IN THE MACHINE MANUALS. CONTAINED IN THE MACHINE MANUALS. YOUR EMPLOYERS WORK, RULES AND YOUR EMPLOYERS WORK, RULES AND APPLICABLE GOVERNMENT REGULATIONS.APPLICABLE GOVERNMENT REGULATIONS.



ELEVATED WATER TOWER CONSTRUCTION COMPONENTSThe elevated water tower is made to assist firefighters and civilians in potential life threatening situations. The booms main members are constructed out of 40,000 PSI aluminum.

If the elevated water tower was purchased with an aerial each section consist of diagonals, k-braces, handrails and rungs. The rungs are covered with a high traction cover to ensure a safe climbing environment. The rungs are round in shape to ensure a large stepping area.

The aerial will be sealed with a primer and paint to protect the aerial from corrosion.

TURNTABLE CONSTRUCTION COMPONENTSThe turntable is connected to the bearing plate using grade 8 bolts. It is the connecting point of the aerial hoist cylinders and the operators station. The walking surface for the turntable is skid-resistant aluminum tread brite.

TORQUE BOX CONSTRUCTION COMPONENTSThe torque tube is designed to accommodate the correct strength to weight ratio. It is the substructure of the elevated water tower and the turntable is connected to it.

The torque box will either be sealed with a primer and paint to prevent the torque box from corrosion or be hot dipped galvanized in a vat of molten zinc to protect the entire interior and exterior from corrosion.

ELEVATION SYSTEMOne elevating cylinders are connected from the underside of the base section to the aerial turntable. They allow the aerial to elevate from -10 degrees to +75 degrees. Each cylinder has counterbalance valves connected directly to the barrel of the cylinder. The cylinders have spherical bushings to minimize cylinder rod wear. A pressure-reducing valve limits the force of the aerial when lowering and the system pressure limits the force when elevating the aerial.

EXTENSION/RETRACTION SYSTEMTwo extension cylinder is connected from the base boom to the fly boom. The extension cylinder has a counter balance valve mounted directly to the rod side of the cylinder.



ROTATION SYSTEMOne hydraulically motor operate planetary gearbox is installed on the turntable to allow for continuous 360 degree rotation. The turntable bearing bolts are required to be checked and re-torqued at regular intervals, the bolts are able to be easily re-torqued from the top of the turntable. The bearing is bolted to the bearing base plate using twenty-eight (28) .625” SAE Grade 8 bolts. The bearing is bolted to the turntable using thirty (30) .625” SAE Grade 8 bolts. One hydraulic release/spring brake provides a positive lock to prevent rotation. One pressure reducing valve controls the force of the rotation and the side loads on the aerial.

ROTATION INTERLOCK A rotation interlock has been put into place to prevent the rotation of the boom into an unsafe or potential tip over situation.

BOOM SUPPORTA heavy duty boom support is provided behind the cab and connected to the frame rails of the chassis to support the aerial device. The boom support doubles as the oil tank reservoir.

OPERATION CONTROL LOCATIONSTwo control boxes are located one on the left and one on the right of the back of the truck for operation of the outriggers. One box is located in the lower center of the back of the truck to serve as an overall information and operation station for both outrigger control and the boom operations. Addtional operation stations could be supplied as specified.



IMPORTANT:The following operating procedures are intended to assist in safe operation of the boom. Any deviation from these procedures is not recommended and is done so at the risk of the operator.

Pre-Driving ChecksIt is important to check the following items before driving the truck. 1. Boom fully stowed in the bed. Door ajar light will illuminate indicating ladder is not stowed

(optional).2. Outriggers stowed for travel. Door ajar light will illuminate indicating outriggers are not

stowed.3. Aerial Master switch (or aerial master/PTO switch) is in the Off position (switch located in

cab).

Positioning the Truck for Operation1. Determine if the boom will be used as a water tower or for rescue.2. Make sure to note ALL overhead obstructions.3. Scan scene to position the truck for best attack.

NOTE: For the best positioning, a corner of a building is highly suggested. This gives the operator access to two sides of the structure as well as the roof.

REMINDER: The operator should always observe the placement of the fire fighting vehicle to be sure that there is enough space for the stabilizers to be set and the aerial to be operated without any obstructions.

Obstructions to be most aware of include, but are not limited to: adjacent buildings, curbs, drop-offs at road edges, man holes, vehicles, trees, over head electrical wires, ditches and culverts.

The apparatus can be set up one of two ways, uphill or downhill. Depending on the situation one method could prove to be more accommodating then the other. Operators should be aware of the advantages and disadvantages of each method to determine how the tuck will be positioned. In either condition, the truck is capable of being leveled within safe operating parameters.

SETTING FRONT OF TRUCK TO UPHILL GRADESWith maximum grades the truck should be positioned with the cab facing uphill. Aerial should be operated over the rear.Advantages:• Can reduce the truck’s grade by extending the rear outrigger stabilizer jacks.• When truck is set up the front tires will be in contact with the ground.• With the outriggers set operator has more ballast for the operation of the aerial

Should the boom come into contact with an electrical wire the operator needs to stay on the truck as all personnel has become part of the charge of the wire . Should the operator need to get off the truck the operator should do so by jumping off and not stepping. Stepping off will cause a surge from the ground to the truck using the operator as it’s electrical passageway causing serious injury or death.

DANGER!



Disadvantages:• Since only the front tires are on the ground there is less resistance to prevent truck

movement.• The rear compartment and aerial access step are more difficult to access.

SETTING FRONT OF TRUCK TO DOWNHILL GRADEAdvantages:• Rear compartments are closer to the ground for easier access.• Better resistance to keep the truck from sliding by having more tires in contact with the

ground.

Disadvantages:• Can not reduce the trucks grade by extending the front outrigger stabilizer jacks. FRONT

TIRES MUST STAY ON THE GROUND WHEN OPERATING OVER THE FRONT OF THE TRUCK. • It is possible that the truck will teeter if the aerial is operated over the front stabilizers with

the front tires off the ground.• Their will be less ballast for aerial operations with the rear tires on the ground.• When setting up the stabilizers the ground must be firm. It is highly recommended that

the operator uses the outrigger pads provided. Setting up over manholes, underground parking facilities or storm drains could cause serious damage to the operator and/or serious damage to the truck. The area must be able to support 75 PSI.

With a Rear Mounted truck positioned down hill the front tires must stay in contact with the ground if operating the aerial with the ladder over 50% extended and within 45 degrees rotation either side of the cab.

SETTING THE CAB 1. Place the transmission into the neutral position2. Set the park brake3. Switch on the aerial master. When the aerial master is switched on there is electrical power

to the aerial system. At this time flashing lights on the outriggers will begin to operate.4. Switch on the Power Take-Off (PTO).

Note: It is important to note that step # 4 cannot be performed before step # 3 has been completed and step # 2 cannot be completed until step # 1 has been completed. Some trucks will have the aerial master and PTO switch combined .

The transmission must be in neutral or 4th gear for the water pump to be engaged. The parking brake must be set before the ladder power will operate. If the water pump is engaged, the high idle of the aerial will be disengaged.

A qualified operator, as determined by the fire department, is now ready to set the stabilizers.



1. Monitor Controls2. Change Hydraulic Filter with light is on 3. Aerial Power Switch4. High Idle Switch5. Rungs Aligned Light6. Radio Remote Switch7. Hour Meter8. Boom Aligned with Bed Light9. Tip Lights Switch

10. Tracking Lights Switch11. Emergency Back Up Pump Switch12. System Pressure Gauge13. Flow Meter14. Flow Meter Totalizer15. Aerial Controls

1

2

3

4

5

8

9

10

11

7

6

12

14

13



Stabilizer Deployment ControlsThe left and right stabilizers control the deployment of the stabilizers. Press down on the respective switch to deploy the right or left stabilizer. Once the stabilizer is supporting sufficient load the left or right light, respectively, will illuminate. To stow the stabilizers press up on the switch or use the all jacks up switch. The stabilizer on/off switch is located at the rear of the truck.

LEFT RIGHT



1. Monitor ControlsThree monitor toggle switches or the manufactured monitor controls will control the monitor (stream/shape, right/left, lower/raise). Push up on the individual switches to activate the stream, right & lower functions of the monitors. Push down on the individual switches to activate the shape, left and lower functions of the monitors. To turn off the switches the operator will need to release the switch to the neutral position.

2. Change Hydraulic Filter Light When this light is illuminated the high pressure and return hydraulic filters are dirty

an need to be changed, both filters are connected to the same light.

3. Aerial Power SwitchTo run the aerial this switch needs to be placed up in the on position.

4. High Idle SwitchThis switch will activate the high idle and raise the RPM’s. Push up on the switch to activate. The switch must be activated in order to operate the outriggers or the boom. The high idle will not work if the water pump is engaged.

5. Rungs Aligned LightThe rung alignment light will illuminate when the rungs are aligned. While extending or retracting the aerial this light will flash on and off in accordance with the rungs being aligned. It is recommended that the rungs be aligned when personnel are climbing the aerial for personal safety.

6. Wireless Radio Remote SwitchIn order to operate the aerial from the Wireless Radio Remote place this switch to the on position. The operator at the turntable control stand can override the Wireless Radio Remote at anytime by placing the radio remote switch to the off position.

7. Hour MeterThe Hour Meter keeps record of the hours the aerial has operated (only while the aerial is moving).

8. Boom Aligned With Bed LightThe boom aligned with bed light will be illuminated when the boom is aligned with the bed and ready to be stowed.

9. Tip Lights SwitchTo activate the tip lights (lights located on the fly section) this switch will need to be placed in the on position. This switch will activate all AC and DC lights at the tip. Most AC and DC lights provided also include a switch on the lamp head itself. If personnel switched the switch on the lamp head to the off position the operator will not be able to override it from the control panel. The switch will need to be reengaged from the lamp head.



10. Tracking Lights SwitchTo activate the tracking lights (lights located on the base section in front of the elevation cylinders) this switch will need to be placed in the on position. This switch will activate all AC and DC tracking lights as well as the panel light and optional rung lighting. Most AC and DC lights provided also include a switch on the lamp head itself. If personnel switched the switch on the lamp head to the off position the operator will not be able to override it from the control panel. The switch will need to be reengaged from the lamp head.

11. Emergency Back Up Pump SwitchThe sole purpose of the Emergency Back-Up Pump is to stow the aerial in case of hydraulic failure. To Use Emergency Back-Up Pump

1. Select the operation required (outrigger or aerial) and move switch to the on position.

2. Engage the outrigger or aerial control handle. 3. Activate momentarily the Emergency 12V Back-Up Pump

To ensure that the Emergency Back-Up Pump doesn’t over heat, it can only operate 5 minutes out of 60.

12. System Pressure GaugeThis gauge shows the current hydraulic system pressure while the aerial is operating.

13. FlowmeterThe flowmeter will give a continues reading of the water flowing from the monitor. Depending on options this could be a combination pressure and flow gauge and will vary by manufacturer.

14. Flowmeter TotalizerThe totalizer button only comes with certain flow gauges. Press the button to get the total amount of water flown.

15. Manual Aerial Control HandlesThe three controllers will operate the aerial functions (extend/retract, left/right & raise/lower). In order to activate the controller push the aerial on/off switch to the on position. Push or pull the appropriate controller to move the aerial. See aerial operations.



SETTING THE STABILIZERS:With tire chocks set, the operator will proceed to the outrigger station.

1. Move High Idel On/Off Switch to the ON position• This will cause the high idle to engage and the warning alarm will begin. The alarm

alerts all other personnel the outriggers are being positioned. If the water pump is engaged the high idle of the aerial will be disengaged.

3. Position outrigger pads under jack locations 2. Use the Stabilizer Deployment Controllers to set the stabilizers

• The stabilizer controls are located to the back, outside of the truck to provide the operator a good clear vision to set up the stabilizers.

• The controllers are designed to move in the same direction as the corresponding stabilizer. (Example: To lower the right stabilizer push the switch down to lower and up to stow.)

Outrigger operation set up is completed. NOTE: The aerial safety interlock control system will not activate until the outriggers are placed securely on the ground.



LOAD CHART & SHORT JACKED OUTRIGGER CHART



STOWING THE OUTRIGGERS:With the boom bedded in the boom support, the stabilizers are now ready to be stowed.

1. Activate the high idle switch.• This will cause the high idle to engage and. The alarm alerts all other personnel the

outriggers can be moved. If the water pump is engaged the high idle of the aerial will be disengaged.

2. Raise outrigger jacks• The controllers are designed to move in the same direction as the corresponding

outrigger. (Example: To raise the right outrigger you would pull up on the controller.)3. Return outrigger pads to their proper location4. Use Controllers to Retract Outriggers.

• The outrigger controls are located to the back, outside of the truck to provide the operator a good clear vision to set up the outriggers.

• The controllers are designed to move in the same direction as the corresponding outrigger. (Example: To retract the right outrigger you would push the controller to the left to retract and to the right to extend.)

5. When outriggers are fully stowed turn the Outrigger On/Off Switch to the OFF position.



AERIAL OPERATIONSBefore operating the aerial, the operator must be aware of all the load limitations, angle indicators and stabilizer set up.

• The operator is responsible for knowing the condition of the aerial device before operating. This should include a quick visual scan of, but not limited to pins, cables, cylinders, loose equipment, ladder placement, etc..

• During aerial operations safety chains must be connected to close exit/entry position or the optional spring loaded ManSaver safety bar must be across the turntable exit/entry position.

• The operator should be stationed at the turntable control station at all times while the aerial is out of the bedded position.

• All personnel on ladder should wear safety belts at all times.

Do not extend or retract the ladder sections with personnel standing on the ladder sections, as legs and feet may be jammed between the rungs.

OPERATING THE AERIAL1. Turn the aerial power switch to the on position. 2. Turn on the required switches for lighting. 3. To raise the aerial, activate the high idle switch. Pull back on the raise lever to raise

the aerial out of the boom support. Raise aerial high enough to avoid any body or cab mounted lighting or equipment.

WARNING!

WARNING!

5. To extend the aerial, activate the high idle switch. Push forward on the extend lever. As the aerial extends the rung alignment light will illuminate when the rungs are aligned. When the aerial is at the desired extension make sure the light is illuminated. This will ensure a easier and safer climbing surface.

6. To rotate the turntable clockwise (right), activate the high idle switch and push the rotation lever forward. To rotate counterclockwise (left), pull back on the rotation lever.

NOTE: Steps four through six can be repeated as many times as needed to set the aerial to the desired position.

The aerial has the capability to have the elevation, extension, and rotation functions be performed simultaneously. It is strongly recommended that only one function be performed at a time. If in situations of extreme emergency which require performing more than one function at a time it is recommended the aerial be operated by an experienced operator.



STOWING THE AERIALAfter aerial operations are complete fully retract the aerial and rotate it over the ladder bed. When the ladder is aligned with the bed the ladder aligned with bed light will illuminate. Lower the aerial into the ladder bed for proper storage.

STOWING THE OUTRIGGERSOnce the aerial is bedded the outriggers need to be stowed.1. Turn the outrigger on/off switch to the on position. This will cause the alarm to sound. 2. Retract and stow the outrigger, these operations can be done simultaneously.

• Note: Make sure the outrigger pads have been picked up and stowed in the designated location on the truck.

3. Turn the outrigger on/off switch to the off position.

Before driving the truck make sure to turn the aerial master switch or switch in the cab to the off position. Also, check to make sure all doors are secure and equipment has been stowed. If the door ajar light is illuminated the aerial (optional) or outriggers may not be stowed correctly.



1. Aerial Extend/Retract2. Aerial Clockwise/Counter Clockwise3. Aerial Lower/Raise4. On/Off5. Enable/Frequency6. 100%/50%7. Auto Bedding Switch8. Feedback Screen9. Left Monitor/Right Monitor (Option)10. Monitor Shape/Stream11. Monitor Clockwise/Counter Clockwise12. Monitor Raise/Lower

Wireless Radio Remote Controls (Option)

OPERATING THE WIRELESS RADIO REMOTEIn order the use the wireless radio remote the radio remote switch needs to be turned to the on position on the turntable control console.

1. Turn the on/off switch to the on position 2. Push the enable switch and operate one of the aerial functions within two seconds. If the

aerial functions have ceased for more than 5 seconds the enable switch must be pushed again to start aerial operations.

NOTE: If no aerial or monitor operation occurs, release the enable switch and move it to the frequency side to find a new frequency and then back to enable to operate aerial or monitor function. 3. If you want to run the aerial at 100% speed turn the 100%/50% switch to 100%. If you want

to run it at approximately half speed switch it to 50%. 4. Use the aerial extend/retract, clockwise/counterclockwise and lower/raise joysticks to

operate the aerial to the desired location.

For monitor controls the radio transmitter must be turned on and the monitor switched will be activated. The monitor controls run the monitor stream/shape, clockwise/counterclockwise and raise/lower momentary switches.

The feedback screen will give the operator continuous readings of aerial position including extension, rotation, elevation, aerial load, outrigger deployment and breathing air levels.

1 2 3

4 5 6 8 9 10 11 127

Operating the aerial with the wireless radio remote without having a clear vision of the aerial could cause serious injury or death and severe damage to the aerial device.

CAUTION!



Size

Grade 2 Grade 5 Grade 8

Clamp Load (lb)

Assembly Torque Clamp Load (lb)

Assembly Torque Clamp Load (lb)

Assembly Torque

Dry (lb) Lub.* (lb) Dry (lb) Lub.* (lb) Dry (lb) Lub.* (lb)

4-40 250 5” 4” 380 8” 6” 540 12” 9”

4-48 275 6” 5” 420 9” 7” 600 13” 10”

6-32 375 10” 8” 580 16” 12” 820 23” 17”

6-40 420 12” 9” 640 18” 13” 920 25” 19”

8-32 580 19” 14” 900 30” 22” 1260 41” 31”

8-36 610 20” 15” 940 31” 23” 1320 41” 32”

10-24 725 27” 21” 1120 43” 32” 1580 60” 45”

10-32 825 31” 23” 1285 49” 36” 1800 68” 51”

1/4-20 1320 66” 50” 2000 8’ 75” 2850 12’ 9’

1/4-28 1500 76” 56” 2300 10’ 86” 3250 12’ 10’

5/16-18 2160 11’ 8’ 3350 17’ 13’ 4700 25’ 18’

5/16-24 2400 12’ 9 3700 19’ 14’ 5200 25’ 20’

3/8-16 3200 20’ 15’ 4950 30’ 23’ 7000 45’ 35’

3/8-24 3620 23’ 17’ 5600 35’ 25’ 7900 50’ 35’

7/16-14 4390 32’ 24’ 6800 50’ 35’ 9550 70’ 55’

7/16-20 4900 36’ 27’ 7600 55’ 40’ 10650 80’ 60’

1/2-13 5850 50’ 35’ 9000 75’ 55’ 12750 110’ 80’

1/2-20 6600 55’ 40’ 10250 90’ 65’ 14375 120’ 90’

6/16-12 7500 70’ 55’ 1160 110’ 80’ 16375 150’ 110’

9/16-18 8400 80’ 60’ 13000 120’ 90’ 18250 170’ 130’

5/8-11 9350 100’ 75’ 14400 150’ 110’ 20350 220’ 170’

5/8-18 10550 110’ 85’ 16375 180’ 130’ 23000 240’ 180’

3/4-10 13800 175’ 130’ 21300 260’ 200’ 30100 380’ 280’

3/4-16 15400 200’ 150’ 23800 300’ 220’ 3350 420’ 320’

7/8-9 11450 170’ 170’ 29450 430’ 320’ 41600 600’ 460’

7/8-14 12600 180’ 140’ 32450 470’ 360’ 45900 660’ 500’

1-8 15000 250’ 190’ 38600 640’ 480’ 54500 900’ 680’

1-12 16800 270’ 210’ 42300 710’ 530’ 59700 1000’ 740’

1-14 16800 280’ 210’ 43400 730’ 540’ 61200 1020’ 760’

1-1/8-7 18900 350’ 270’ 42300 800’ 600’ 68900 1280’ 960’

1-1/8-12 21200 400’ 300’ 47500 880’ 660’ 77000 1440’ 1080’

1-1/4-7 24000 500’ 380’ 53800 1120’ 840’ 87200 1820’ 1360’

1-1/4-12 26600 550’ 420’ 59600 1240’ 920’ 96600 2000’ 1500’

1-3/8-12 28600 670’ 490’ 64100 1460’ 1100’ 104000 2380’ 1780’

1-3/8-12 32500 750’ 560’ 73000 1680’ 1260’ 118400 2720’ 2040’

1-1/2-6 34800 870’ 650’ 78000 1940’ 1460’ 126500 3160’ 2360’

1-1/2-12 39100 980’ 730’ 87700 2200’ 1640’ 142200 3560’ 2660’

NOTE: When maximum torque values have been exceeded, the fastener must be replaced.* “Lubricated” includes lubricant, lubrizing plating, and hardened washers

Assembly Torque Values to Produce Corresponding Bolt Loads

http://www.fandisc.com/tti.htm



NOTE: SAE standards require the manufacturer’s logo or trademark to be included in the head pattern. Certain bolts may be marked in a similar manner and not meet the specifications set forth in these standards. Bolts purchased from distributor other than the original equipment manufacturer (OEM) should be accompanied by certification documents to ensure the integrity of the equipment is maintained.

Bolts of the same diameter may differ greatly from one another in terms of strength. Depending on the material composition and manufacturing process, the tensile strength of a bolt can vary from 64,000 psi to 180,000 psi. The relative strength of a fastener is indicated by the head shape and standard markings designated for this purpose. Hex head cap screws, commonly found on aerial equipment will be marked with diagonal lines, numbering from two to six.

PROPER TORQUE OF ALL SIZES AND GRADES OF BOLTSIdentification of bolt grade is always necessary. When marked as a high-strength fastener (Grade 5, Grade 8 etc), the mechanic must be aware that these are highly stressed components and must be torqued accordingly. Special attention should be given to lubrication, plating and other factors that would dictate a deviation from the standard torque values.

TORQUE WRENCHES AND ASSOCIATED EQUIPMENTTORQUE WRENCHESThese wrenches are precision instruments and must be handled with care to ensure proper calibration accuracy. Calibration checks should be made on a regularly scheduled basis. Whenever a torque wrench may have been over-stressed or damaged, it should be removed from service until recalibrated or replaced. Rigid click-type torque wrenches, which have torque-limiting devices that can be preset to the required torque values are recommended. When using the torque value chart, values close to the mid-range are recommended to allow for torque wrench calibration tolerances. Erratic or jerking motion of the wrench can easily result in excessive torque values. Always use slow, even wrench movements and stop when the predetermined value has been reached. ASSOCIATED EQUIPMENTCertain accessories used in conjunction with the torque wrench enable maintenance personnel to properly service the stressed fasteners encountered on aerial device. The proper use of these tools and their intended application are outlined in the following paragraphs.

NOTE: A torque multiplier increases the output force of the socket by approximately four times the value that is introduced by the torque wrench. Factoring the torque value typically one-fourth the desired manufacturer’s instructions for the specific torque multiplier.

Torque multiplier provide the maintenance personnel with fastener-tightening power that requires approximately one-fourth the force required using conventional tools. They provide safe, convenient tightening power when confronted with the need for high-torque values within a limited amount of working or leverage space.

Always replace screws/bolts with the same grade as the original fastener.CAUTION!



These checks and services have been provided to help you keep you aerial in good operating condition and in service.

The preventive maintenance section is intended to formally maintain and document the aerial device on a regular schedule. This schedule is intended as a minimum and is greatly dependent on operating conditions. Heavy use and extreme environmental conditions such as heat, cold, sand, or salt spray will demand increased inspection and maintenance.

The preventive maintenance section is not intended to replace or negate any routine pre-operation safety inspections. The aerial operator must be aware of the condition of the aerial equipment before operating. A pre-operational visual safety inspection should always be preformed, including checking stabilizers, aerial pivot pins and retaining hardware, cables, sheaves, basket pivot pins, retaining hardware, etc.

Fill out the information below and return with the check list. This will allow us to keep a maintenance history of your aerial for future reference. Any additional information found during the inspection should be included with the check list. See mailing and fax information in the introduction section of this manual.

TRUCK INFORMATION FORM

Fire Department: _________________________________________________________________________

Address: ________________________________________________________________________________

City/State/Zip: ___________________________________/____________________/___________________

Inspected by: ____________________________________________________________________________

Date of inspection: _______________________________________________________________________

Aerial model number: ______________________ Manufacturing job number: __________

Hours of operation: _______________________________

Type of inspection: Weather conditions: 25 hour/ Primary Inspection Approximate temperature: __________ 50 hour/ Annual Inspection Overcast 100 hour/ Annual Inspection Snow 400 hour/Annual Inspection Partly Cloudy Rain Clear



PRIMARY INSPECTION: 25 Hours of Operation Review Date:_____/_____/_____Symbols: = Okay = Repairs needed IMPORTANT NOTE: Preform primary inspection within the first 25 hours of operation and with each inspection there after.

STATUS ITEM CORRECTIVE ACTION DATE REPAIR COMPLETED

PTO Engages Properly

Aerial Master Switch

Neutral Safety

Outrigger High Idle Switch

Aerial High Idle Switch

Stabilizer Interlock

Aerial Interlock

Safety Decals

Outrigger Safety Pins

Aerial Pivot Pins, Cylinder Hoist Pins & Extension Pins

Intercoms

Rung Covers

Breathing Air

Aerial Controls

Rung Alignment Indicator

Aerial Load Gauge

Aerial Control Gauges, Switches & Indicator Lights

Outrigger Override

Aerial Override

Retractable Waterway

Radio Remote Controls (optional)

Emergency Power

Hydraulic Oil Level

Hydraulic Oil Return Filter





Hoist Cylinder Leaks

Extension Cylinder Leaks

Electrical Lines & E-Chain

Waterway Alignment & Mounting

Completely Grease Aerial

Clean Entire Aerial Device

Hydraulic Pump/PTO

Waterway Slip Tubes

Waterway Lubrication

Waterway Function





Stabilizer Setup for Each Stabilizer

Scoring on Stabilizer Up & Down Jacks

Stabilizer Alignment

Scoring on Stabilizer Beams

Snap Rings on Stabilizer Pins

Security of Bottom Pins on Outrigger Pads

Security of Hydraulic Lines on Outrigger Extension Cylinders/Outrigger Roll Hoses

Leaks in Hydraulic Lines on Jack Cylinders

Leaks in Hydraulic Lines on Main Pressure & Return

Leaks in Outrigger Valves & Hoses

Swing Brake Mounting & Leaks

Planetary Mounting

Hydraulic Motor for Ladder Rotation

Swing Brake Manifold & Adjustment

Operation of Swing Brake

Adjust Extension/Retraction Cables/Sheaves Tension

Cable Sheaves Alignment

Rear Slide Pads (all sides, rear & bottom)

All Front Section Slide Pads (all side & bottom)

Inspect Bull Gears

Grease Rotation Bearing

Grease Bull Gear

Stainless Steal Scuff Pad on Base (optional)

Deutsche Electrical Connection

Sealed Electrical Connections





Stabilizer Wear Pads

Stabilizer Cylinder Drift Down for all Stabilizers (1/4” per hour)

Synchronized Operation of Hoist Cylinder

Aerial Hoist Cylinder Drift Down: Right Cylinder (1/2” per hour tolerance)

Aerial Hoist Cylinder Drift Down: Left Cylinder (1/2” per hour tolerance)

Extension Cylinder Drift Down (1/2” per hour)

Stabilizer Extension Cylinder Proper Timing for All Stabilizers

Synchronized Operation of Hoist Cylinders

Take Sample of Hydraulic Oil from Reservoir

Pinion Gear Back Lash

Aerial Bed Cradle Mounting

Re-Torque Frame Mounting Bolts

Aerial Bed Cradle Weldments

Swivel Water Mounting/Leaks

Swivel Hydraulic Mounting/Leaks

Swivel Electrical Mounting/Leaks

Retorque Aerial Turntable Bearing (top & bottom)

Aerial Functional Time

Job#73570 .

2013 Rosenbauer America 1

.Operation & Familiarization Manual

AUTORIDAD del CANAL De PANAMA

JOB #73570

CUSTOM PUMPER

Job#73570


. Table of Contents Safety First! ........................................................................................................................... 4

Safety Information ................................................................................................................. 7

Siren ............................................................................................................................... 7

Relief Valve ..................................................................................................................... 7

Winch .............................................................................................................................. 8

Pump ............................................................................................................................ 10

Generator ..................................................................................................................... 11

Extend-a-Gun ................................................................................................................ 16

Introduction ......................................................................................................................... 17

Siren ............................................................................................................................. 19

A Manual- Activates the siren as set by the Selector Knob (C). Does not operate in “Radio” mode. ............................................................................................................................ 19

Winch ............................................................................................................................ 20

Vehicle Components............................................................................................................ 23

Front ................................................................................................................................... 27

Hose .................................................................................................................................... 28

Positioning the Apparatus ................................................................................................... 28

Pump Operation .................................................................................................................. 29

Pump Engagement ..................................................................................................... 29

Pump ............................................................................................................................ 30

Pump Shifting Procedure .............................................................................................. 30

Stationary Pumping ....................................................................................................... 31

Class1 TPG + Pressure Governor ............................................................................... 32

Tank Supply Operation ............................................................................................... 41

Drafting Operation ..................................................................................................... 41

Suction Hose Considerations ..................................................................................... 42

Pressurized Inlet Operation (Hydrant or Relay) .......................................................... 43

Auxiliary Pump Functions ........................................................................................... 44

Disengaging the Pump ............................................................................................... 45

Draining the Pump ...................................................................................................... 45

Relief Valves .............................................................................................................. 45

Generator Operation ........................................................................................................... 46

Job#73570


.Generator ..................................................................................................................... 46

Monitor Operation ............................................................................................................... 49

Monitor ......................................................................................................................... 50

Extend-a-Gun ................................................................................................................ 52

Extend-a-Gun ................................................................................................................ 54

Nozzle ........................................................................................................................... 56

Inspection ........................................................................................................................... 58

Vehicle cleaning &washing .................................................................................................. 60

Maintenance ........................................................................................................................ 61

Winch ............................................................................................................................ 61

Relief Valve Pressure Setting ........................................................................................ 62

WARNING .................................................................................................................. 62

Open the relief valve strainer flush valve during every operation at 50-100 PSI supply pressure to insure against foreign material blocking the screen. ............................... 63

The relief valve, pilot unit, and strainer assemblies should be taken apart for inspection and cleaning at least annually or as often as found necessary to insure trouble free performance. ............................................................................................................. 63

Pump ............................................................................................................................ 64

Generator ..................................................................................................................... 66

Foam ................................................................................... Error! Bookmark not defined.

ENGINE THROTTLE ............................................................ Error! Bookmark not defined.

Monitor ......................................................................................................................... 69

Extend-a-Gun ................................................................................................................ 70

Troubleshooting .................................................................................................................. 71

Siren ............................................................................................................................. 71

Pump ............................................................................................................................ 72

Generator ..................................................................................................................... 75

Monitor ......................................................................................................................... 77

Extend-a-Gun ................................................................................................................ 77

Job#73570


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Safety First!

NOTE This manual explains the operation of your new fire apparatus. Please carefully read this manual as well as the component manuals included in the binder before attempting to operate this vehicle. Only personnel that are familiar with the manual, the vehicle, and local regulations are qualified to operate this apparatus.

This manual assumes that the operator has been trained by the fire department or other training agency (technical school, fire school, etc.) and is certified to operate fire apparatus.

The operator should also be familiar with: the basics of water pump operation; the function of each valve, gauge, control, and manual override; so that the operator can change operation with conditions on-scene.

Rosenbauer is not liable for any damage or injury caused by personnel unqualified to operate the apparatus.

The following symbols located in this manual alert you to potentially hazardous conditions to the operator, servicer, bystanders, or equipment.

DANGER This symbol indicates an immediate hazard which, if not avoided, will result in severe

personal injury or death.

WARNING This symbol indicates a hazard or unsafe practice which, if not avoided, may result in severe

personal injury or death.

CAUTION This symbol indicates a hazard or unsafe practice which, if not avoided, may result in

personal injury or equipment/property damage.

WARNING Fire apparatus are often used in hazardous environments. The best way to minimize the risk

of injury is through experience and information. IF YOU ARE UNSURE OF HOW TO OPERATE THIS APPARATUS OR ANY OF ITS COMPONENTS SAFELY, please ask for help before putting yourself and others at risk. Become familiar with the contents of this manual that you will not have to refer to it on-scene.

WARNING Practice emergency shutdown and manual override procedures until they become second

nature so that you can respond immediately to an emergency situation.

Job#73570


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CAUTION Before operating this vehicle, ensure that:

o The operator is properly trained. Read carefully all owner's manuals, service manuals, and/or other instructions. Always follow proper procedures, and use proper tools and safety equipment.

o Equipment is properly loaded and secured. o The vehicle has been serviced according to the manufacturer’s instructions. o All doors and access panels are closed.

WARNING Death or serious personal injury might occur if proper operating procedures are not

followed. The pump operator, as well as individuals connecting supply or discharge hoses to the apparatus must be familiar with these pump operating instructions as well as other operating instructions and manuals for the apparatus, water hydraulics and component limitation.

WARNING Be careful when climbing on the apparatus, and when walking along the top of the vehicle.

Only walk on areas where NFPA approved walking surface materials have been used. Always maintain three points of contact (i.e. 2 hands and 1 foot or 1 hand and 2 feet) when climbing up or down the apparatus.

WARNING Never use the parking brake as a service brake. Loss of vehicle control may result.

Safety Labels

If a label comes off or becomes hard to read, contact Rosenbauer for a replacement.

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WARNING Fire helmets shall not be worn by persons riding in enclosed driving and crew areas. Fire

helmets are not designed for crash protection and they will interfere with the protection provided by head rests. The use of seat belts is essential to protecting fire fighters during driving.

WARNING The engine exhaust from this product contains chemicals known to the State of California to

cause cancer, birth defects or other reproductive harm.

Safety Information

Siren

WARNING

Sirens are an integral part of an effective audio/visual emergency warning system. However, sirens are only short range secondary warning devices. The use of a siren does not ensure that all drivers can or will observe or react to an emergency warning signal, particularly at long distances or when either vehicle is traveling at a high rate of speed. Sirens should only be used in a combination with effective warning lights and never relied upon as a sole warning signal. Never take the right of way for granted. It is the operator’s responsibility to be sure you can proceed safely before entering an intersection, driving against traffic, or responding at a high rate of speed.

The operator should check the equipment daily to insure that all features of the device operate correctly.

To be effective, sirens must produce high sound levels that potentially can inflict hearing damage. Vehicle operators and occupants should assess their exposure to siren noise and determine what steps, such as consultation with professionals or use of hearing protection should be implemented to protect their hearing.

This equipment is intended for use by authorized personnel only. It is the user’s responsibility to understand and obey all laws regarding emergency warning devices. The user should check all applicable city, state and federal laws and regulations.

Relief Valve

WARNING The Pressure Relief Valve will open to relieve excess pressure but it may not have enough

flow capacity to protect against large pressure spikes such as those caused by water hammer. Excess pressure can cause equipment failure and directly or indirectly lead to injury or death. Always operate valves slowly to avoid the risk of water hammer.

Job#73570


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Winch

WARNING Do not use winch to lift or move people!

CAUTION Do not use winch in hoisting applications due to required hoist safety factors and features.

A minimum of five wraps of cable around the drum barrel is necessary to hold the rated load. Cable clamp is not designed to hold the load.

Keep yourself and others a safe distance to the side of the cable when pulling under load.

Don't step over a cable, or near a cable under load.

Use supplied hook strap when handling hook for spooling wire rope.

Don't move the vehicle to pull a load on the winch cable. This could result in cable breakage.

Use a heavy rag or gloves to protect hands from burrs when handling winch cable.

Apply blocks to wheels when vehicle is on an incline.

Winch clutch should be disengaged when winch is not in use and fully engaged when in use.

Do not modify, alter, or make any changes to the winch.

Keep the duration of your pulls as short as possible. If the motor becomes uncomfortably hot to the touch, stop and let it cool for a few minutes. Do not pull more than two minutes at or near rated load.

Do not maintain power to the winch if the motor stalls. Electric winches are for intermittent usage and should not be used in constant duty applications.

Disconnect the remote control switch from the winch when not in use

Do not exceed maximum line pull ratings shown in tables.

To re spool correctly, it is necessary to keep as light load on the cable. This is accomplished by(wearing gloves) holding the cable with one hand and the remote control switch with the other, starting as far back and in the center as you can, walking up keeping load on the cable as the winch is powered in. Do not allow the cable to slip through your hand and do not approach the winch too closely. Turn off the winch and repeat the procedure until all the cable except a few feet is on the spool. Disconnect the remote control switch and finish spooling in cable by rotating the drum by hand with clutch disengaged. On hidden winches, spool in cable under power but keep hands clear.

Job#73570


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Don't underestimate the potential danger in winching operations. Neither should you fear them. Learn the basic dangers and avoid them.

The uneven spooling of cable, while pulling a load, is not a problem, unless there is a cable pileup on one end of drum. If this happens, reverse the winch to relieve the load and move your anchor point further to the center of the vehicle. After the job is done you can unspool and rewind for a neat lay of the cable.

Store the remote control switch inside your vehicle where it will not become damaged. Inspect it for frayed wires or broken covering before you plug it in for each use.

When ready to begin spooling in, plug in remote control switch with clutch disengaged. Do not engage clutch with motor running.

CAUTION Never connect the hook back to the cable. This causes cable damage. Always use a sling or chain of suitable strength as shown in the illustration in the Operation section.

Observe your winch while winching, if possible, while standing at a safe distance. If you use vehicle drive to assist, stop and get out every few feet to assure the cable is not piling up in one corner. Jamming cable can break your winch.

Do not attach tow hooks to winch mounting apparatus. They must attach to vehicle frame.

When double lining during stationary winching, the winch hook should be attached to the chassis of the vehicle.

Since the greatest pulling power is achieved on the innermost layer of your winch, it is desirable to pull off as much line as you can for heavy pulls (remember, you must leave 5 wraps min. on the drum). If this is not practical, use a snatch block and double line arrangement (see illustration).

Neat, tight spooling avoids cable binding which is caused when a load is applied and the cable is pinched between two others. If this happens, alternately power the winch in and out a few inches.

Do not attempt to work a bound cable under load, free by hand.

Job#73570


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o

Pump

WARNING

Never operate the controls of the Power Take-Off or other driven equipment from any position that could result in getting caught in the moving machinery.

Cold Weather Operation of Power shift P.T.O.

WARNING

During extreme cold weather operation [32°F (0°C) and lower], a disengaged Power shift Power Take-Off can momentarily transmit high torque that will cause unexpected output shaft rotation. This is caused by the high viscosity of the transmission oil when it is extremely cold. As slippage occurs between the Power Take-Off clutch plates, the oil will rapidly heat up and the viscous drag will quickly decrease.

The Power Take-Off output shaft rotation could cause unexpected movement of the driven equipment resulting in serious personal injury, death, or equipment damage.

WARNING

M12000 FEATURES:

o 12,000 lb(5,440 kg) pulling capacity o 125’ of 3/8”(38 m of 9.5 mm) wire rope

fairlead o Remote with 12’(3.7m) lead

MOVING PART HAZARD To prevent serious injury and property damage: o Do not operate or install winch without

reading and understanding the operator’s manual.

o Keep hands clear of wire rope, hook and fairlead opening during operation and when spooling.

o Stand clear of wire rope and load during operation.

o Keep others away. o Inspect winch installation and wire rope

condition before operating winch. o Do not exceed winch’s rated capacity. o Never touch wire or rope while in tension. o This winch is capable of exceptionally high

line speeds and may exceed published line speeds. Use extreme caution when handling hook and wire rope during spooling operations.

o This is a winch, not a hoist! Use only to slide loads. Never lift a load by the winch.

o Maximum single line pulling capacity: 5443kg. o Intermittent duty rating: 30 second run time @

rated load; 10 minute cool down time. o 12 volts DC.

SAFETY PRECAUTIONS

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To avoid personal injury or equipment damage: o Driven equipment must have separate controls. o The driven equipment must be left in the disengaged position when not in operation. o Do not operate the driven equipment until the vehicle is allowed to warm up.

Rotating Auxiliary Driveshaft

WARNING

Rotating driveshaft is dangerous. You can snag clothes, skin, hair, hands, etc. This may cause serious injury or death.

Do not go under the vehicle when the engine is running. Do not work on or near an exposed shaft when the engine is running. Shut off the engine before working on the Power Take-Off or driven equipment. Exposed rotating driveshaft must be guarded.

NOTE

Safety Information and Owner's Manual Power Take-Offs are packaged with safety information decals, instructions, and owner's manual. Read the owner's manual before operating the P.T.O. Always install the safety information decals according to the instructions provided. Place the owner's manual in the vehicle glove compartment.

Generator

DANGER GENERATOR VOLTAGE IS DEADLY! Generator electrical output connections must be made by a trained and experienced

electrician in accordance with applicable codes. Use caution when working on live electrical equipment. Remove jewelry, make sure clothing

and shoes are dry, stand on a dry wooden platform or rubber insulating mat and use tools with insulated handles.

WARNING Use extreme caution when handling, storing and using fuels. All fuels are highly explosive in

a vaporous state. Store fuel in a well ventilated area away from spark producing equipment. Keep fuels and all chemicals out of the reach of children. Never add fuel to the tank while the engine is running. Spilled fuel may ignite on contact with hot parts or from ignition spark. Always keep fuel lines and connections tight and in good condition. Don’t replace flexible fuel lines with rigid lines. If you notice any fuel leakage, fuel accumulation or electrical sparks, DO NOT OPERATE THE GENERATOR SET.

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DANGER The gases generated by a battery being charged are highly explosive. Do not smoke or

permit any flames or sparks to occur near a battery at any time, especially when it is being charged. Avoid contact between terminals with tools to prevent sparks and possible burns. Always remove wristwatch, rings, or other jewelry before handling a battery. Any compartment containing batteries should be well ventilated to prevent the accumulation of explosive gases. To avoid sparks never disturb the battery charging connections while the battery is being charged. Always turn off the battery charger before disconnecting terminal clips.

Keep hands, feet, and clothing away from belts and related pulleys when unit is running. Replace guards, covers, and screens before operating the generator set. Serious personal injury may occur from contact with moving parts.

WARNING Failure to install a generator set with an electrical system consistent with governing

regulations and standards is UNLAWFUL and may cause ELECTROCUTION of vehicle occupants. Your generator set must not be used to “Back Feed” by connecting it to a building or outdoor electrical circuit. Back feeding can cause serious injury or death to utility personnel working to repair a power outage and may also seriously injure persons in your vehicle. Unauthorized connections are unlawful in some states and/or localities. A transfer switch must be installed to prevent interconnection of the generator set power and outside power.

Remember the function of a generator set is to produce electricity. Wherever electricity is present there is a potential danger of electrocution. Apply the same precautions to the vehicles electrical appliances as you would for any home appliance. Keep away from electrical circuits and wiring while the generator set is running. Have electrical service performed only by qualified electricians. Be sure any unauthorized person; especially children are denied access to the generator set. Keep the compartment door securely latched or locked at all times. Be sure the generator is properly grounded. Never touch electrical leads or appliances with wet hands, or when standing on wet ground.

DANGER Never connect the negative (-) battery cable to the positive (+) connection terminal of the

starter solenoid, or test the battery by shorting terminals together. This could ignite fuel vapors or cause the battery to explode. To disconnect the battery remove the negative battery cable first and reconnect it last. Do not modify the fuel tank or propulsion engine fuel system. Your vehicle must be equipped with a fuel pick-up arrangement as described in the Fuel System section of this manual. Fuel tank and installation must conform to applicable regulations.

Allow engine to cool and release pressure from the cooling system before opening the radiator pressure cap. To release the pressure, cover the radiator cap with a thick cloth then turn it slowly counterclockwise to the first stop. After the pressure is released and the engine has cooled, remove the cap.

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DANGER Never operate the generator set without an adequate muffler or with a faulty exhaust system.

Exposure to excessive noise can lead to a hearing impairment. A battery can cause electrical burns and shocks. Use reasonable care when working near

the battery to avoid electrical connections by contacting the battery terminals with tools. Remove wristwatch, rings and all jewelry when working on the generator set.

WARNING A sudden backfire can cause serious burns. Do not operate your generator set without its air

cleaner / flame arrestor in place. A sudden flash fire can cause serious burns. To avoid the possibility of a flash fire do not

smoke or permit a flame or spark to occur near the carburetor, fuel lines, fuel filter, fuel pump or other potential source of spilled fuel or vapors.

Be careful when parking your vehicle to prevent grass fires from being started by hot exhaust gases or exhaust system. Keep away from hot engine and generator parts to avoid burning yourself. Keep the generator set and compartment clean and free of debris, especially combustible materials. Never store fuel, oil or rags in the generator compartment.

CAUTION

Cautious operation is your best insurance against an accident. Read and understand this section carefully before operating the engine. All operators, no matter how knowledgeable they may be, should read this and other related manuals before operating the engine or any equipment attached to it. It is the owner’s responsibility to instruct all operators in safe operation. Be sure to observe the following for safe operation.

Observe Safety Instructions o Read, understand and follow this OPERATORS MANUAL and labels

on the generator before starting and operating the engine. o Learn how to operate and work safely. Know your equipment and its

limitations. Always keep the generator in good condition. o Before allowing other people to use your generator, explain how to

operate and have them read this manual before operation. o DO NOT modify the generator. UNAUTHORIZED MODIFICATIONS to the engine may

impair the function and/or safety and affect engine life.

Wear Safety Clothing o DO NOT wear loose, torn or bulky clothing around machinery. o Entanglement in rotating parts, controls or projections may cause personal injury. o Use additional safety items, e.g. hardhat, eye protection, gloves, etc., as appropriate or

required. o DO NOT operate machinery or equipment while under the influence of alcohol,

medication, or other drugs, or while fatigued. o DO NOT wear radio or music headphones while operating generator.

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.Check Before Operating the Generator o If the engine is malfunctioning, DO NOT operate until repairs are made. o Be sure all guards and shields are in place before operating the generator. Replace any

that are damaged or missing. o Check to see that the area around the engine is clear of foreign objects before starting. o DO NOT start the engine by shorting across starter terminals.

Keep Area around the Engine Clean o Be sure to stop the engine before cleaning. o Keep the engine clean and free of accumulated dirt, grease and trash. o DO NOT stop the engine without idling; Temperatures around the engine may rise

suddenly. Allow the engine to idle for about 5minutes before stopping.

Safe Handling of Fuel and Lubricants o Always stop the engine before refueling or lubricating. o DO NOT smoke or allow flames or sparks in your working area. Fuel is extremely

flammable and explosive. Never store flammable liquids in the engine compartment. o Refuel at a well-ventilated and open place. If fuel or lubricants spill, clean up immediately

and properly dispose of the spill materials. o DO NOT mix gasoline or alcohol with diesel fuel. The mixture can cause a fire.

Exhaust Gases and Fire Prevention o Engine exhaust fumes can be very harmful if allowed to accumulate. Be sure to run the

engine in a well-ventilated area where there are no people or livestock nearby. o The exhaust gas from the muffler is very hot. To prevent a fire, do not expose dry grass,

oil or any other combustible materials to exhaust gas. Keep the engine and mufflers clean all the time.

o To avoid a fire, be alert for leaks of flammables from hoses and lines. Be sure to check for leaks from hoses and pipes, such as fuel and hydraulic by following the maintenance check list.

o To avoid a fire, do not short across power cables and wires. Check to see that all power cables and wires are in good condition. Keep all power connections clean. Bare wire or frayed insulation can cause a dangerous electrical shock and personal injury.

Keep Hands and Body Away From Rotating Parts o Keep your hands and body away from all rotating parts, such as cooling fan, v-belts,

pulleys and flywheel. Contact with these rotating parts can cause serious personal injury. o Be sure to stop the engine before adjusting belt tension or checking the cooling fan. o DO NOT run the engine without safety guards installed. Be sure the safety guards are

properly aligned and securely fastened before operating the engine.

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Monitor

WARNING

Injury or death may occur by attempting to use a damaged monitor. Before using the monitor inspect it for damage resulting from: o Failure to drain monitor followed by exposure to freezing conditions o Exposure of monitor to temperatures in excess of 160°F o Structural damage caused by over-pressurization o Missing parts, physical abuse, exposure to severe chemicals o Deformed or cracked flanges due to excessive bolt torque or wrong tightening

sequence

Injury can result from an inadequately supported monitor. The monitor mount must be capable of supporting 1100 lbs (500 kg) of nozzle reaction force.

The stream exiting a monitor is very powerful and capable of causing injury and property damage. Make sure the monitor is securely attached to the base and pointing in a safe direction before water to the monitor is turned on. Use care in directing the stream.

The monitor may be damaged if frozen while containing sufficient amounts of water. Such damage may be difficult to detect visually and can lead to possible injury or death. Any time the monitor is subject to possible damage from freezing, it must be hydrostatically tested by qualified personnel before being considered safe for use.

CAUTION

The electric monitor may be remotely operated. The electric drives are current limited but may still produce enough force to cause injury. Keep hands and fingers away from pinch points on the monitor.

Do not use the manual override knobs while the electric controls are in operation. The electric drives produce enough torque to cause injury.

Maximum flow and pressure is 1500 gpm and 200 psi. Damage or injury may result if the monitor is operated beyond these limits.

On many vehicle installations, the monitor is the highest point on the apparatus. Be sure there is sufficient clearance to safely pass under any doors or overhead obstructions. Always check parked position of the monitor before moving.

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Extend-a-Gun

DANGER When operating the Extend-A-Gun, you may be in a precarious position. Watch your footing on top of the truck. It can become very slippery. It is possible to fall off the truck.

WARNING Reaction forces generated by master stream flows are very powerful and capable of causing injury and property damage. The Extend-A-Gun RC must be securely mounted to rigid truck support members.

CAUTION

The Extend-A-Gun may be used in either the raised or the lowered position, but not in-between. Make sure that the slide bar is down and both pawls are flush with the housing before use. If the word "UNLOCKED" is visible, the Extend-A-Gun is unlocked and may rise suddenly if it is in the lowered position and the water is turned on or fall suddenly if it is in the raised position and the water is turned off. When the pawls are flush with the housing, and the water is turned on, the pawls are locked in position and prevent the latch mechanism from operating. The unit may become damaged if the water is turned on in any position other than fully extended or retracted.

WARNING Master stream flows are very powerful and capable of causing injury and property damage. Make sure the monitor is pointing in a safe direction before water to the monitor is turned on. Use care in directing the stream.

CAUTION

Do not lift the slide bar when water is flowing, the mechanism will not unlatch, but the mechanism can be damaged. Do not lift the slide bar to lower the deck gun without supporting the weight of the deck gun. It can fall and cause injury.

WARNING Keep the upper and lower brackets as far apart as possible to minimize the amount of stress on the upper and lower brackets.

WARNING The forces acting on the mounting brackets, when the Extend-A-Gun RC is in the extended position, are higher than the forces in a normal deck gun installation. Failure to properly secure the Extend-A-Gun RC could result in damaged equipment and serious injury.

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CAUTION

The Extend-A-Gun RC has current limiting capabilities which stop the motor if an obstruction is encountered. The Extend-A-Gun RC must be installed as instructed using the correct controls and electrical boxes. Failure to do so will result in damage to the electric motor and loss of current limiting controls. This may result in injury.

CAUTION

Do not plug or cap the Extend-A-Gun RC or mounted deck gun while it is in the raised position. This will prevent the Extend-A-Gun RC from being lowered to the park position. Damage may occur if the truck drives under a low hanging object, while the Extend-A-Gun RC is extended.

Introduction Welcome, Rosenbauer thanks you for your recent purchase of fire apparatus from us. We are confident that, when properly operated, maintained and serviced, your Rosenbauer fire apparatus will provide you with years of reliable service.

Your fire department was integral in developing the specification for your custom built fire apparatus. This manual is designed to provide general information on operation of your apparatus. For more detailed information, refer to the appropriate section of the component manual that was delivered with your apparatus.

Due to technological advancements, continuous improvement of our products and the products of our component suppliers as well as the custom nature of your fire apparatus, some variation between this manual and your apparatus may occur. Rosenbauer reserves the right to change specifications without notification.

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. Your Rosenbauer dealer is your best source for information, parts, and service. For customer service, please contact:

Jose Fernandez Fire & Rescue Equipment Corp Ph. (507) 261-7238 / (507) 261-3255

Fax (507) 229-5856 [email protected]

www.firecorp.com.pa

If you need further assistance, please contact the factory Customer Service:

Rosenbauer 5181 260th street P.O. Box 549 Wyoming Mn 55092 651 462-7570 [email protected]

Please have your apparatus VIN when requesting information or assistance; this will allow us to assist you more quickly.

http://www.firecorp.com.pa/�


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Siren

Siren Tones - Industry standard Wail, Yelp, and Hi-Lo tones.

A Manual- Activates the siren as set by the Selector Knob (C). Does not operate in “Radio” mode. B Air Horn-Produces electronic air horn sound in all selector positions except Radio.

C Function Selector Knob – Operates as follows

P.A.- Public Address override of all siren functions when the microphone Push-to-Talk key is pressed.

Radio – Re-broadcast two-way radio audio over siren speakers. The sirens will not operate in this position.

Standby - This is the standby mode. If the MANUAL button is depressed, the Manual wail tone will ramp up until it reaches a peak then ramp down when released. If the AIR HORN button is depressed, the Air Horn sound will be produced.

Wail - This position activates the Wail tone. Pushing the MANUAL button produces the Yelp tone for 7 seconds. Depressing the AIR HORN button will produce the Air Horn sound and when released will return siren to Wail.

Yelp - This position produces the Yelp tone. Pushing the MANUAL button continues to produce the Yelp tone. If the AIRHORN button is pushed, the Air Horn sound will be produced and when released will return the siren to Yelp.

Hi-Lo - This position produces the Hi-Lo tone. Pushing the MANUAL button will now produce the Yelp tone for 7 seconds. If the AIRHORN button is pushed, the Air Horn sound will be produced and when released will return siren to Hi-Lo.

D P.A. Vol. – Controls volume of Public Address system when keying the microphone and speaking into it. This also controls the Radio Re-broadcast level when in the "Radio" position.

E Microphone Jack - Keying the microphone will automatically override all siren modes & broadcast public address messages over the siren speaker. PTT operates in all positions of the Selector switch.

Figure 4

A B C

E D

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. Winch The best way to get acquainted with how your winch operates is to make a few test runs before you actually need to use it. Plan your test in advance.

Remember to hear your winch as well as see it operate. Familiarize yourself with the sound of a light steady pull, a heavy pull, and sounds caused by load jerking or shifting. Soon you will gain confidence in operating your winch and its use will become second nature with you.

When pulling a heavy load, place a blanket, jacket or tarpaulin over the cable five or six feet from the hook. It will slow the snap back in the event of a broken cable.

Rigging for the Pull

Preparing to winch starts with connecting the remote control. Free spool the winch and engage the clutch. After putting on your leather gloves, you may then pull the winch line to the anchor point, attach the clevis. Be sure to check the wire rope…make sure it is free from kinks, and at least five wraps are left on the winch drum. Lay a blanket or heavy coat over the winch line, protecting all from the possibility of rope or anchor point failure. Clear the area and begin winching with your remote control. Always assess every situation for maximum safety and winch technique.

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Winches equipped with cable guide fairleads can pull from several directions. Pull from an angle only to straighten up the vehicle-otherwise you can damage structural members or other parts of your vehicle and cause excess cable buildup on one end of the winch drum. For a direct pull of 2,000 Ibs., hitch truck to a tree or solid anchor, and take out of gear.

To double the pull, use 2-part line with snatch block and tie off to chassis. Take out of gear.

The RAM-LOK™ semi-automatic clutch provides free spooling and clutch engagement with the cable drum. With the clutch disengaged, the cable can be pulled off the drum by hand. For winching in the load, the clutch must be fully engaged with the drum.

To disengage the clutch, run the winch in the reverse (“reel out”) direction until the load is off the cable and the cable drum stops turning. Pull outward on the clutch handle, rotate it counterclockwise 90° and release. The clutch is now locked out and the cable may be pulled by hand.

A straight line from the winch to the object to the object being pulled is critical. (This minimizes wire rope collection off-siding on the drum which can damage rope.) If you don’t have a straight line to the vehicle you’re winching, you can effectively change pulling direction with the help of a snatch block. Secure the snatch block to a point directly in front of the vehicle. This lets you maintain proper drum spooling and achieve extra winching power.

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NOTE

If the clutch handle cannot be pulled out, again run the winch momentarily in reverse to relieve pressure on the clutch jaws.)

WARNING Do not attempt to disengage the cable drum when there is a load on the cable.

To engage the clutch, pull outward on the handle, rotate it clockwise 90° and release. Run the winch in reverse until the clutch handle snaps fully in or until the cable drum starts turning. At this point make sure the clutch handle is all the way in. The plastic plug in top of clutch housing maybe removed, for inspection of clutch to assure total engagement.

After the clutch is fully engaged, the winch is ready for winching in the cable

Extra Pulling Power

To achieve extra power, a snatch block provides mechanical advantage. The snatch block is an amazingly efficient tool to utilize, easily doubling your winch capacity. At the same time, using a snatch block also cuts your line speed in half, making it easier to stabilize objects.

Using a snatch block is particularly useful in situation where your vehicle is closer to the winching situation. A fuller winch drum means less power. Power you can regain, and increase, by using a snatch block.

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. Vehicle Components Driver’s Side

A. Pump Panel B. Pump Operators Platform C. Front Stabilizer D. Stabilizer Pads E. Rear Stabilizer F. Scene Lights G. Generator H. S.C.B.A Bottle Storage I. Fuel Fill J. Circuit Breaker

A B C D E

F J G

H

I

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.Officer side

1. Warning Light 2. Rear Stabilizer 3. S.C.B.A. Storage 4. Stabilizer Pads 5. Front Stabilizer 6. Hard Suction 7. Scene Lights 8. Cord Reel

D 3 2

1

4 5

6

7

8

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. Pump Panel Controls

1 2 3 4 5

6

7 8 9 10

11 12

13

14

15 16

mgoldeman

Typewritten Text

mgoldeman

Typewritten Text

10. Water Tank Level Gauge 11. Aux. Eng Cooler 12. Pump Cooling 13. Water Pump Suction 14. Priming Pump 15. Pump Drain 16. External Foam System

mgoldeman

Typewritten Text

1. Williams Foam System 2. Discharge Pressure Gauge 3. Panel Light Switch 4. Generator 5. Pump over heat test switch 6. Foam Level Gauge 7. Pump over heat buzzer 8. Pressure Governor 9. Eng Status Alarm

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. Rear view

1. Drivers Side Stabilizer 2. Rear LDH/Aerial Intake 3. Aerial Intercom 4. Ladder Controls 5. Officer Side Stabilization Controls

1

3

2

4

5

mgoldeman

Typewritten Text

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. Front

A. Fog Lights B. Air Horn C. Winch D. Siren Speaker

A B C

D B

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Hose Hose can be stored in a variety of locations:

o Body Compartments o Bumper Compartments o Crosslays o Speedlays o Hose Bed o Reel

WARNING Hose must be secured with restraints (covers, doors, nets, etc.) after repacking to prevent it

from deploying while the vehicle is in motion, causing injury to personnel, bystanders, and damage to equipment.

Hose may be stored in hose beds in a variety of ways, depending on the size & type of hose and the layout of the hose bed. Experiment with different methods of packing the hose bed to determine which allows the hose to deploy in the safest and quickest manner. Learn the maximum vehicle speed for deploying hose.

WARNING Never ride on the apparatus. Always use a spotter when backing up the apparatus. Flying hose is hazardous – keep people away from hose being deployed by a moving vehicle. Pressurized hose can rupture without warning – always wear protective gear. Inspect fittings and hoses for cracks, tears, chips, and other signs of damage. Replace as

needed.

Positioning the Apparatus o Heat from a fire can damage many components on a fire truck, such as electrical

insulation, anything made of rubber or plastic like seals, grommets, & hosebed covers. o Whenever possible, park upwind from a fire to minimize the amount of heat reaching the

apparatus. o Have an escape route. If the on-scene situation changes, moving the apparatus quickly

retains the ability to fight the fire. o If forced to park on a road or highway, position the apparatus so that it protects

personnel from oncoming traffic. o Do not park under electrical lines; they may weaken and fall on the apparatus.

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Pump Operation

WARNING Prior to connection or removal of hoses, caps or other closures with pump intake or pump

discharge connections, relieve pressure by opening drains.

WARNING Fire apparatus are very loud when pumping. Always wear hearing protection. Ensure that all suction and discharge connections are secure before operating pump. A

connection failure may cause a “whipping” hose.

WARNING Failure to properly shift transmission in accordance to the transmission operating

instructions may result in unexpected truck movement which may result in serious personal injury or death.

Pump Engagement

CAUTION Do not run the pump for more than a few

seconds without water, except when priming the pump. Running the pump dry will damage the pump.

Always use an intake screen (A) to protect the pump.

CAUTION Gradually increase & decrease engine speeds

to ease loads on the pump, driveshaft, and engine.

Watch the pump pressure gauge and open throttle only enough to give the desired pressure. The pressure may raise high enough to burst the discharge hose when using small nozzles, if the engine is given full throttle (except pumps equipped with pressure regulators set for desired pressure).

Never run engine at high speeds except when pump is primed and ready to discharge water.

A

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Pump

CAUTION

Do not run the pump dry except momentarily and at low speeds for priming.

WARNING

Do not use this pump for hose testing.

Pump Shifting Procedure This pump is driven by a transmission mounted (SAE) PTO. Depending on the PTO and transmission configuration, the PTO may be either a sliding gear type or "hot shift" clutch type.

This power take-off is normally shifted from within the driver's compartment. The PTO should only be engaged at a low engine rpm, idle up to 1000 rpm maximum. Review and understand the PTO manufacturer’s safety and operating instructions before attempting operation.

CAUTION

Failure to follow proper shifting or operating sequences will result in premature PTO failure with possible damage to other components.

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. Stationary Pumping

1. Apply the park brake. 2. Shift Transmission to neutral. 3. Ensure that engine is at low idle (less than 1000RPM). 4. Engage the PTO by pulling and flipping up PTO engaged switch (A). 5. Wait 5 seconds for the pump shift to complete its operation. The “Pump Engaged”

light (B) will illuminate. 6. Push “D” on the transmission selector pad. The “OK to Pump” light (C) will illuminate. 7. A light on the pump panel will come on when the pump is engaged. 8. Confirm that the ''Throttle Ready" indicator at the pump operator's panel is now

illuminated. 9. Prime the pump. Primer should be engaged within 2 minutes of PTO engagement.

Pump should then prime within 1 minute of primer operation. If the pump cannot be primed within 3 minutes of PTO engagement, disengage PTO and troubleshoot priming difficulty.

10. Observe discharge pressure gauge on panel while increasing engine speed, to ensure that it is indicating pressure. If Pump is not engaged, no pressure will show.

11. To ensure maximum operational life for the PTO, driveline, and pump components, increase engine speed to 1000 rpm minimum when the PTO is engaged and the pump is flowing water. This slight increase in rpm induces a small load on the drive system. This load will eliminate the system rattle produced by the clearances in the PTO and pump gears being excited by the combustion engine power strokes.

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.Electric Priming Pump The electric primer will develop up to 25 in.Hg in an air tight pumping system.

The Primer is activated by a combination spring return on-off valve and electric switch. Pulling the valve out opens the valve and closes the electrical circuit to start the motor.

Before the pump can be primed, booster line valves, drain valves, cooling line valve, and all other openings into the pump must be closed and absolutely air tight. The discharge side of the pump is sealed by a check valve; therefore the main discharge valves need not be closed.

When operating from draft, suction hose connections must be tight and free of air leaks.

Make certain the suction hose strainer is properly submerged and free of foreign material.

The main pump drive should remain disengaged until priming is complete to prevent possible damage to impeller seal rings by running "dry".

Pull the primer shutoff valve all the way out to start priming and hold open until water discharges from primer pump exhaust port. Push valve all the way in to shut off primer motor and seal tight.

If water does not discharge from primer exhaust within about 30 seconds (45 seconds with 2-20' lengths) stop primer pump, check for air leaks and make sure primer pump is receiving lubricant from its reservoir.

Engage "Pump" shift to start pumping water.

When pumping from hydrants, the primer is not needed and must be kept closed. It may be necessary to use the primer momentarily when pumping from a booster tank when the suction head is insufficient to force all the air out of the pump.

Class1 TPG + Pressure Governor OVERVIEW

The Total Pressure Governor Plus (TPG+) p/n 118710 is an SAE J1939 Controller Area Network(CAN) device that controls engine speed using data communications directly to the engine ECU or through with an analog control signal. By operating on the J1939 network, the governor is able to monitor engine RPM and other pertinent data directly from the engine ECU. Engine information is available directly so that NFPA required instrumentation is delivered through a single unit saving panel space and delivering engine specific warnings as determined by each engine manufacturer.

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. Control algorithms are optimized to take advantage of the J1939 CAN data to yield crisp and accurate control of engine and subsequently pump speed and pressure output.

For engines that may not support the data link control, an analog output signal is available to provide precise control of the engine speed and pressure.

The TPG+ saves pump panel space by incorporating easy to read numeric displays for Pump Intake pressure, Pump Discharge pressure, and engine RPM in accordance with NFPA standards.

o Info Center Display o The display shows status, warning, and information messages.

o Interlock status indicators

o Backlit text indicates the status of the three (3) interlocks: pump engaged, okay to pump, and throttle ready. Throttle ready and pump engaged are physical inputs into the gray 12-pin connector (pins 2 and 10 respectively) of the TPG+.Okay to pump becomes active when both the throttle ready and pump engaged interlocks are present.

o Switch Panel – The six (6) control switches are color coded and labeled for easy identification. o IDLE

o The IDLE switch (red) forces the governor to idle mode (standby). Pressing and holding this button for one second while in rpm or pressure mode will cause the engine to ramp down to its idle position.

o

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. o MENU / SILENCE

o The MENU/SILENCE switch (blue) is used to silence the alarm, cycle through the display items, and enter the setup menu.

o PRESET o The PRESET switch (orange) sets the governor to the configured

preset engine RPM while in throttle mode, or preset pressure while in pressure mode.

o MODE o The MODE switch (green) sets the governor to either throttle mode

(RPM) or pressure mode (PSI). The correct interlocks must be present for the system to begin governor operation: throttle ready for RPM mode, throttle ready, pump engaged, and okay to pump for PSI mode.

o INC o The INC [increase] switch (yellow) is used to increase the engine RPM

or pressure set point. o DEC

o The DEC [decrease] switch (yellow) is used to decrease the engine RPM or pressure set point.

o Mode Indicator o The mode indicator consists of two (2) LEDs to show the governor’s current operating

mode. The PSI LED (yellow)indicates the governor is operating in pressure mode and the RPM LED (blue) indicates the governor is operating in throttle mode. When both LEDs are OFF the governor is in idle mode (standby).

o Engine RPM Display o The engine RPM display shows the current engine RPM as reported by the Electronic

Engine Controller 1 (EEC1)SAE J1939 network data message transmitted by the vehicle ECU.

o Battery Voltage Monitor o The battery voltage monitor is comprised of three (3) LEDs (green, yellow, and red).

The active LED color indicates the current system voltage’s range as measured by the power and ground inputs pins. The alarm will activate when the voltage monitor is in condition RED.

• GREEN 12.5VDC and higher • YELLOW 12.4VDC to 11.9VDC • RED 11.8VDC and lower

o Coolant Temperature Monitor o The coolant temperature monitor is comprised of three (3) LEDs (green, yellow, and

red). The active LED color indicates the status of the coolant temperature as reported by the Diagnostic Message 1 (DM1) SAE J1939 network data message transmitted by the vehicle ECU. The coolant temperature status can also be set to react to user desired points. The alarm will activate when the coolant temperature monitor is in condition RED.

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. • GREEN No active error reported by engine for coolant temp • YELLOW Coolant Temp high WARNING – SPN 110, FMI 16 • RED Coolant Temp high CRITICAL – SPN 100, FMI 0

o Oil Pressure Monitor o The oil pressure monitor is comprised of three (3) LEDs (green, yellow, and red). The

active LED color indicates the status of the oil pressure as reported by the Diagnostic Message 1 (DM1) SAE J1939 network data message transmitted by the vehicle ECU. The oil pressure status can also be set to react to user desired points. The alarm will activate when the oil monitor is in condition RED.

• GREEN No active error reported by engine for oil pressure • YELLOW Oil pressure low WARNING – SPN 100, FMI 18 • RED Oil pressure low CRITICAL – SPN 100, FMI 1

o Pump Intake Pressure Display o The pump intake pressure display shows the pressure as determined by the intake

pressure sensor. By default, this display shows positive pressure in pounds per square inch (PSI) and negative pressure (vacuum) in inches of mercury (inHg), but it may be set up to display in metric units.

o Pump Discharge Pressure Display o The pump discharge pressure display shows the pressure as determined by the

discharge pressure sensor. By default, this display only shows positive pressure in pounds per square inch (PSI), but it may be set up to display in metric units.

o Stop Engine and Check Engine Indicators o The stop engine and check engine indicators are turned ON and OFF as directed by

the Diagnostic Message 1 (DM1)SAE J1939 network data message transmitted by the vehicle ECU.

OPERATION

Initialization

The TPG+ has a six (6) second power initialization cycle during this time the display will show:

First second after the power on cycle:

The TPG+ lights all indicators and shows “8.8.8.8.“ in the pump intake, pump discharge, and RPM display windows. The Info Center shows “Class 1 TPG-X”. The last letter of this display indicates the configured control method of the TPG+.

TPG-C – CFPG control method TPG-P – PGN0 control method TPG-A – Analog control method TPG-S – Scania control method

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Seconds 2 through 4 after the power on cycle:

The TPG+ continues to light all indicators and shows“8.8.8.8. “ in the pump intake, pump discharge, and RPM display windows.

The Info Center shows the software version of the TPG+.

The final two seconds after the power on cycle:

The TPG+ turns off all of the indicators and lights only the decimals of the pump intake, pump discharge, and RPM display windows.

The Info Center shows “Initializing”.

After the initialization the TPG+ begins normal operation.

Operating mode selection The TPG+ has two operating modes: throttle mode (RPM) and pressure mode (PSI).

Press the MODE switch to select an operating mode. An operating mode will only be activated if the required interlock(s) are in place (see section 4.3).

There is no variation in engine RPM or pump pressure when changing between throttle mode and pressure mode.

Note: Pressure mode is the desired operating mode because it offers protection from pressure changes that could injure personnel.

Throttle Mode Throttle mode (RPM) maintains a set engine RPM and will not deviate until the operator changes the RPM with the control switches on the TPG+.

Throttle mode is typically used when: - Priming the Pump - The water supply pressure stability is questionable - Connected to a stand pipe - Acting as a relay pumper

Press the MODE switch to select throttle mode. The display will momentarily show “GOV=THROTTLE” and the RPM mode indicator LED will illuminate blue.

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. Press the INC switch to increase or the DEC switch to decrease the engine RPM set point.

Press the PRESET switch to set the engine speed to the configured preset RPM - as long as the pump pressure is less than 10 PSI.

Press the IDLE switch at any time to set the TPG+ back to standby. The display will momentarily show “IDLE” and both mode indicator LEDs will be off.

Pressure Mode Pressure mode (PSI) maintains a set pump pressure by monitoring the discharge pressure transducer and modifying the pump speed by adjusting the engine RPM. The operator can modify the set pump pressure with the control switches on the TPG+.

Note: Pressure mode (PSI) affords the most safety to the operator by not allowing potentially hazardous pressure spikes. The TPG+ will maintain the set pump pressure even when discharge lines are actively opened and closed as long as the water supply is sufficient. The TPG+ will automatically increase engine speed when pump pressure has decreased due to discharge lines being opened. The increase in engine speed will return the pump pressure to the desired set pressure (and vice-versa when discharge lines are closed).

Press the MODE switch to select pressure mode. The display will momentarily show “GOV=PRESSURE” and the PSI mode indicator LED will illuminate yellow. It may be necessary to press the MODE switch twice depending on the configured first mode.

Press the INC switch to increase or the DEC switch to decrease the pressure set point.

Press the PRESET switch to set the pump pressure to the configured preset. The TPG+ will adjust the engine RPM to maintain the preset pressure value. Configure the pressure mode preset through the Setup Menu.

Press the IDLE switch at any time to set the TPG+ back to standby. The display will momentarily show “IDLE” and both mode indicator LEDs will be off.

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. There are four control properties which can be modified to improve pressure mode performance: pressuresensitivity, pressure time-out, pressure gain, and pressure lag.

Required Interlocking The TPG+ requires interlocks before engine control operations are permitted. The TPG+ provides two interlock inputs that allow easy separation of pumping operations and throttle/high idle operations through two inputs dedicated as system interlocks: THROTTLE READY and PUMP ENGAGED. “Pump Engaged” illuminates to signify that the pump shift operation was successful. “Throttle Ready” illuminates to signify that the parking brake is engaged and the transmission is in the proper gear for pumping. When both of these lights are on, “OK to Pump” illuminates to signify that pumping operations may begin.

PRESET Switch Operation The PRESET switch brings the discharge pressure (or engine RPM, in throttle mode) to the configured preset point.

Using the PRESET switch is a method of smoothly and expeditiously attaining water pressure and flow, but it is not intended to be the initial attack pressure. Attack pressures and flows should be determined by the actual fire status and manually achieved for best operation.

PRESET is an operational convenience and needs to be considered as a fixed point (higher or lower than the current point) that can be achieved with a single switch press.

Note: Initiating pumping operations is simplified by bringing the pump to a preset pressure with a single switch press. Consequently, securing or regaining control operations can be aided by returning to this fixed pressure point with a single switch press.

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. IDLE Switch Operation Press and hold the IDLE switch for one second to release engine RPM control back to the engine ECU. The engine RPM will promptly go to its configured curb idle.

Note: In view of the fact that driveline stress can be induced by quick changes in engine speed, depending on rpm and torque load, the engine speed is ramped to idle over a short duration to minimize the effect of driveline kick.

MENU / SILENCE Switch Operation The MENU/SILENCE switch allows viewing (within the info center display) of the status of engine and pump related items and silencing of an active alarm.

Press the MENU/SILENCE switch to cycle through the engine and pump related display items (see below).

The active alarm can be silenced by pressing and holding the MENU/SILENCE switch for one second. The info center display will show ALARM SIL=10 to indicate that the alarm has been silenced for the standard time of 10minutes. Continue holding the MENU/SILENCE switch to increase the silenced time frame to 15 or 20 minutes.

Press and hold the MENU/SILENCE switch for one second to silence the alarm for the standard time (10minutes).

Continue holding the MENU/SILENCE switch to increase the alarm silence time (15 or 20 minutes).

• The alarm silenced time frame is reset to the standard 10 minutes once all alarm conditions have been cleared.

• The alarm will remain silenced for the selected time frame even if another alarm condition becomes active.

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...Status and Warning Messages The table below details the status and warning messages of the TPG+.

• These codes will flash on the Info Center display while the error/warning is active. • Multiple errors/warnings may be sequenced on the display. • Press and hold the MENU/SILENCE switch for one second to silence the active alarm.

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Automatic Display Brightness The indicators and displays on the TPG+ can be user configured for brightness in both a DAY mode and a NIGHT mode. The TPG+ utilizes a light sensor on its front panel to determine if it is operating in DAY or NIGHT mode. The sensitivity of the light sensor is not configurable.

• When the light sensor detects light the TPG+ is set to DAY mode. • When the light sensor detects a low light condition the TPG+ is set to NIGHT mode.

The transition from DAY to NIGHT (or vice-versa) takes thirty (30) seconds.

Note: The TPG+ will remain in NIGHT mode if the light sensor is blocked by stickers, tape, etc.

For more information regarding the TPG+ please refer to your supplied Class1 manual.

Tank Supply Operation o Engage the pump (see Pump Operation section) o Open the Tank-to-Pump valve. o Evacuate any air in the pump by pulling the Primer handle. o Open the appropriate discharge valve slowly. o Increase pump speed via engine speed control until desired discharge pressure is

reached.

NOTE Tank to Pump operation allows the water stored in the tank to flow into the pump for initial

operations while a water source is being established. Be aware that this supply will only last a few minutes and that a sustained source (hydrant or draft) is necessary as soon as possible.

Monitor the water tank level gauge during this transition so that personnel have enough time to react in the event the water supply is depleted. When a sustained source has been established, the booster tank can be refilled via the Tank Refill procedure outlined below.

Drafting Operation

CAUTION Do not draft without a suction strainer to reduce foreign matter from entering the pump. If

the suction strainer must rest on a soft bottom, using a board or piece of metal will reduce the amount of debris (mud, sand, etc.) that is carried into the pump. A floating strainer is recommended if this type of drafting is done often.

Close drain valves and ensure there is no air leakage before attempting to prime pump If water doesn’t discharge from the primer in 45 seconds, stop priming and check for air

leaks. Watch for declining water source level.

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Use only non-collapsible suction hose for drafting.

Position truck as close as possible to water source. o Connect Suction line to desired pump inlet. o For best pump performance, ensure that the entire suction

strainer is at least 10” below water level, and at least 12” above the bottom of the source.

o Engage the pump. o Open appropriate suction valve. o Pull the Primer handle and hold until water is discharged

from primer or discharge pressure reaches 30psi. o Release Primer handle. o Open the appropriate discharge valve slowly. o Increase pump speed via throttle control or governor until desired discharge pressure

is reached. o If the pump will not prime or loses prime, check the following:

o Are all drains & valves closed, including pump cooling and tank refill? o Is the suction strainer completely submerged? o Are the suction gaskets in place? o Are all suction hose connections tight?

Suction Hose Considerations Suction Hose Size

o Pump performance is significantly affected by suction hose size. Water flow to the pump is inhibited by the frictional loss of the suction hose. This friction loss must be included with the height of the pump above the water (static lift) to determine the “total lift”.

o When the entire suction capacity of the pump is used to bring water to the pump, the pump performance is limited. This performance can be increased only by decreasing total lift, either by reducing the length of the suction hose, increasing the suction hose diameter, or reducing the height of the pump above the water.

o Pump capacity is rated at a static lift of 10 feet, with 20 feet of recommended suction hose at sea level.

o An excessively long suction hose is an impediment to any pump, as it reduces capacity through extra friction loss; it slows down priming; and it promotes cavitation, which is the rapid formation and collapse of air pockets in the suction water stream.

CAUTION Cavitation is very harmful for pump systems, and should be avoided.

o If a long suction hose must be used, the pump engine speed should be raised gradually, the discharge valves opened gradually, and the capacities of the pump should be held within the range of smooth performance.

10” min

12” min

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Air Traps o Air traps are formed when the suction hose is

routed so part of it is higher than another part nearer to the pump, (i.e. “runs downhill”) as when hose is laid over an obstruction.

o Air traps form at the highest part of the hose when the air cannot be sucked out by the primer. Trapped air travels to the pump with the water. When it reaches the pump, prime may be immediately lost.

o Suction hose should be routed so that it slopes continuously upward from water source to pump. If this is impossible, the pump can still be primed by running the primer until all the trapped air in the hose has been carried to the pump and evacuated by the primer.

Air Leaks Leaks in the pump system will make it more difficult to prime the pump, and will contribute to losing prime and poor pump performance. Check for air leaks as follows:

o Cap all intakes and discharges. o Run electric primer until maximum vacuum is shown on the gauge. The vacuum

should hold for several minutes before satisfactory performance of pump can be expected.

o If excessive leakage of air occurs, the source of leaks can be located by shutting off primer motor, with vacuum at its highest point, and listening for the hiss of air.

o In the absence of a vacuum gauge, the vacuum in pump may be judged by closing suction opening with the flat of hand or a rubber pad.

o If more convenient, water or air pressure may be applied to pump casing to test for air leakage.

WARNING DO NOT pressurize with air beyond 10 PSI.

Pressurized Inlet Operation (Hydrant or Relay) o Connect line to appropriate intake suction. o Open the bleeder on the intake. This may be a push-pull type drain or a ¼-turn type. o Pressurize the line by opening the hydrant or engaging the relay pump. o When all the air is bled out of the line, close the bleeder valve. o Open the intake valve. o Engage the pump as described above. o Run Primer as necessary to remove any remaining air. o Open the appropriate discharge valve slowly. o Increase pump speed via throttle control or governor until desired discharge pressure

is reached. o Monitor intake pressure to be prepared for changing conditions. Recommended

minimum pressure is 20psi. o If the intake gauge shows negative pressure (vacuum), all of the available

hydrant/relay water supply is being used. Reduce pump discharge flow or improve the water supply.

Air trap

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WARNING

CAUTION Use a hydrant strainer to prevent foreign matter from the hydrant system from entering the

pump.

Auxiliary Pump Functions

Filling the water tank o While pumping water, crack open the Tank Fill line. o Monitor the tank level indicator to prevent overfilling the tank. o Overfilling the tank will cause water to spill out the overflow.

NOTE The tank may also be filled by connecting a pressurized source to the Direct Tank Fill valves.

NOTE Always refill the tank as soon as possible, to allow for continued pumping if the water source

is lost, or quick repriming if prime is lost.

CAUTION Never fill the tank at more than 100PSI to prevent tank damage.

Pump Cooling The pump cooling line allows a small amount of water to be pumped into the tank, keeping the pump cool if all discharges are closed. This line is opened by a ¼-turn valve. Open the recalculating valve to allow cool tank water to flow to the pump, also. If the water in the tank becomes too hot to effectively cool the pump, exchange the tank water for fresh, cool water to restore its cooling capacity.

Water that is trapped in a running pump can boil in seconds, damaging pump seals. Steam

that travels to the end of the discharge hose can scald attack personnel.

Engine Cooling The engine cooling valve controls water flow to a liquid-to-liquid heat exchanger. Heat from the engine coolant transfers to the pump water to provide extra engine cooling capacity. This line is opened by a ¼-turn valve. Use as required in warm environments to keep engine temperatures under control.\

CAUTION should not be opened until pressure develops in the pump, and pump should never be operated under prolonged heavy loads The cooling line without an adequate supply of cooling water flowing.

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Engine coolant temperatures should never be allowed to exceed 200°F while pumping and 180°F is usually taken as a safe operating temperature.

Always shut off cooling lines when finished pumping.

Disengaging the Pump o Return the engine to low idle (less than 1000RPM). o Push “N” on the transmission selector pad. o Wait 5 seconds for the transmission to complete its shift.

Draining the Pump o If any contaminated or salty water was pumped, flush the pump with clean water. o Open all individual drain valves. o Open Master Drain on pump. o Remove all intake and discharge hoses. o Open discharges to release any trapped water. o Replace intake and discharge caps (if temperature is above freezing). o Drain the relief valves.

NOTE If pump is kept full of water when not in use, make sure water is clean and non-corrosive.

Make sure the pump is completely full or completely drained – never partially full.

CAUTION Freezing water can damage the plumbing, pump, valves, drains, etc. If an apparatus is carrying water in freezing conditions, ensure that all valves (other than

Tank to Pump & Tank Fills) are open halfway and all caps are removed. Purge the primer of water by running it for a few seconds. Drain water from the relief valves. If an apparatus will be stored in freezing conditions with no water load, open the tank valves

halfway as well.

Relief Valves Intake Relief Valve

This valve minimizes the possibility of “Water Hammer” by responding to pressure variations on the inlet side of the pump. This valve discharges the excess water through a pipe that ends below the apparatus. The relief valve is set to open when the incoming pressure exceeds 125 PSI. The valve will automatically close when the intake pressure drops below 125 PSI. A length of hose may be attached to the discharge to direct the water away from the truck. This relief valve is adjustable. If a different relief pressure is required, refer to the component manual.

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2. SYSTEM OVERVIEW

The Williams Hot Shot II Single Tank Controls provides an operator friendly method of controlling the foam concentrate from and to the on-board foam storage tank to and from the balanced pressure foam system of an apparatus. The Hot Shot II Single Tank Controls also provides operator control of foam system flushing water supply from the fire pump discharge and by way of a panel mounted indicator light alerts the operator in the event the foam system suction strainer becomes excessively restricted. All control panel switches feature guards to minimize unintentional switch actuation. The system control panel includes: (1) RUN / FLUSH mode selector switch and indicator lights (1) TANK TO PUMP valve control switch with OPEN indicator light (1) TANK FILL valve control switch with OPEN indicator light (1) STRAINER RESTRICTED indicator light

FIGURE 1

RUN / FLUSH SELECTOR

SWITCH

RUN MODE INDICATOR

LIGHT

FLUSH MODE INDICATOR

LIGHT

TANK FILL VALVE

CONTROL

TANK FILL VALVE ‘OPEN’

INDICATOR LIGHT

TANK TO PUMP VALVE

CONTROL

TANK TO PUMP VALVE

INDICATOR LIGHT

STRAINER RESTRICTED INDICATOR

LIGHT

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3. PRINCIPLES OF OPERATION The Williams Hot Shot II Single Tank Controls allows operation of the TANK TO PUMP and TANK FILL valve(s) of the on-board foam concentrate storage tank and system FLUSH valve. The RUN / FLUSH selector switch provides operator selection of the RUN mode to supply chassis 12/24VDC power to the system TANK TO PUMP and TANK FILL control switches or activation of the system FLUSH valve. Should the operator select the FLUSH function, any tank control valve(s) open at the time of selection change will automatically close due to chassis power being removed from both TANK TO PUMP and TANK FILL control switches. The STRAINER RESTRICTION indicator light provides visual indication for the operator in the event the foam suction strainer should become clogged with debris or contaminated foam during normal system operation. The STRAINER RESTRICTION indicator light operation is controlled by a vacuum switch located within the foam suction piping between the suction strainer and foam pump suction port to allow monitoring suction restriction under all operating conditions. Chassis 12/24VDC power to the Hot Shot II Single Tank Controls panel is supplied from one of the following sources:

1) Hot Shot II Chassis Interface Box 2) Foam pump PTO engage circuit 3) Ignition ‘ON’ circuit

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D. System FLUSH Operation - Foam Concentrate Discharge / Flush Outlet

1. Establish water supply to fire pump and engage fire pump.

NOTE: Minimum fire pump water pressure is required for flushing operations. A Maximum of 50psi is recommended for normal flushing of the system and piping.

2. Connect and secure discharge line from Foam Concentrate Discharge / Flush

Outlet. 3. Assure TANK TO PUMP and TANK FILL selector switches are in CLOSE

position. 4. Lift red RUN / FLUSH selector switch cover and move toggle switch to

FLUSH position.

WARNING: Where no reverse flow check valve is provided by the apparatus manufacturer, Auxiliary Foam Intake / Flush Inlet valve MUST be closed prior to activating FLUSH valve or sudden uncontrolled discharge of flushing water will result from Auxiliary Foam Intake / Flush Inlet and external pick-up hose and tube which may result in personal injury, death and/or damage to equipment.

NOTE:

Chassis 12/24VDC power is removed from both TANK TO PUMP and TANK FILL selector switches when RUN / FLUSH selector switch is moved to FLUSH position which in turn automatically closes TANK TO PUMP and/or TANK FILL valve(s) if left open prior to start of flushing operations.

5. Open Foam Concentrate Discharge / Flush Outlet valve. 6. Engage foam system by selecting MANUAL mode. 7. Establish flushing water flow from Foam Concentrate Discharge / Flushing

Outlet by rotating foam system MANUAL PRESSURE CONTROL to INCREASE position until desired flow rate is achieved by observing flow rate from flushing discharge line.

CAUTION:

A maximum of 50psi water pressure should be maintained during flushing operations. The minimum water pressure required to avoid foam pump cavitation depends on flushing water discharge rate flowing from Foam Concentrate Discharge / Flush Outlet as controlled by foam system MANUAL PRESSURE CONTROL.

8. Continue flushing operations until flushing water runs clear. 9. Shut down is in reverse order.

RUN / FLUSH MODE SELECTOR SWITCH ‘FLUSH’ POSITION

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10. Drain flushing water from foam system piping as needed. 11. Resume operations as needed or desired.

NOTE:

This flushing procedure will NOT flush any of the individual foam capable discharge metering valves or their foam supply lines.

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.. WARNING The relief valve outlet should never be capped. If a hose is connected to this pipe to divert

the water, the hose must be secured to a fixed object to prevent an uncontrolled line hen water is discharged.

Generator Operation

Generator Engine Starting Controls

Cab Generator Pump Panel

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2013 Rosenbauer Ameria 62

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Generator Layout

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Monitor Operation

DANGER When operating the monitor you may be in a precarious position. Watch your footing on top

of the truck. It can become very slippery. It is possible to fall. Never operate the monitor while the vehicle is in motion.

WARNING The Extend-A-Gun may be used in either the raised

or the lowered position, but not in-between. Make sure that the slide bar is down and both pawls are flush with the housing before use. If the word "UNLOCKED" is visible, the Extend-A-Gun is unlocked and may rise suddenly if it is in the lowered position and the water is turned on or fall suddenly if it is in the raised position and the water is turned off. When the pawls are flush with the housing, and the water is turned on, the pawls are locked in position and prevent the latch mechanism from operating.

Do not plug or cap the Extend-A-Gun or mounted deck gun while it is in the raised position. This will prevent the Extend-A-Gun from being lowered all the way and the latch pawls will not lock.

Do not attempt to raise the Extend-A-Gun with water pressure. Rapid upward movement of the Extend-A-Gun can cause injury to persons by striking them, or knocking them off the fire truck. It can also cause damage to the Extend-A-Gun, monitor, or other equipment.

Master stream flows are very powerful and capable of causing injury and property damage. Make sure the monitor is pointing in a safe direction before water to the monitor is turned on. Use care in directing the stream.

Do not lift the slide bar to lower the deck gun without supporting the weight of the deck gun. It can fall and cause injury.

CAUTION Do not lift the slide bar when water is flowing, the mechanism will not unlatch, but the

mechanism can be damaged. Do not move the truck with the Extend-A-Gun raised. There is a light on the cab dash

indicating the position of the Extend-A-Gun.

WARNING Before flowing water from this device, check that all personnel (fire service and civilian) are

out of the stream path. Ensure that stream direction will not cause property damage.

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.. Never exceed rated monitor flow. Never aim the jet of the turret at a person.

Water can conduct electricity. Do not aim turret or nozzle (extinguishing agent jet) high voltage power lines or other high voltage electrical circuits.

Monitor

Rotation Hand wheel

Elevation Hand wheel

Rotation Lock

Tiller Bar

Elevation Lock

Manual Override

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.. Horizontal Rotation Control A hand wheel controls the monitor’s horizontal rotation direction. Clockwise rotation of the hand wheel moves the nozzle to the left and counter-clockwise rotation to the right. Approximately 14 turns of the hand wheel will give a 90° change in horizontal rotation direction.

Elevation Control A hand wheel controls the monitor’s elevation direction. Clockwise rotation of the hand wheel lowers the elevation and counterclockwise raises it. About 18 turns of the hand wheel will give the complete 135° elevation travel range of the monitor.

Tiller Bar Model On the Tiller Bar model the horizontal rotation is changed by pushing or pulling horizontally on the Tiller Handle. Twisting the Rotation Locking Knob clockwise will increase the drag on the lower swivel joint to “lock” the monitor in a particular direction

Recommended Park Position For truck mounted applications it is recommended that the monitor be parked in a position such that the monitor’s nozzle rests against a bracket or support surface. If a support surface is not available, run the elevation against one of its travel stops to take some of the backlash out of the gear drive. This will minimize bouncing of the nozzle when the apparatus is traveling. Always be sure the monitor is properly parked before moving the truck and know the overall height to avoid damage from overhead obstructions such as doors or bridges.

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Override Knobs In the event of electrical system failure on the monitor or fire truck the monitor is factory supplied with knobs so the monitor may be manually operated. To make the monitor more compact the manual override knobs may be removed. The drive shafts have a hex so a wrench or socket may be used for manual override. Each drive shaft also has a secondary hex at mid shaft so the shaft may be shortened by cutting and still have a wrenching hex.

Extend-a-Gun

CAUTION

Clear all obstructions away from the Extend-A-Gun RC before lowering. Anything caught underneath the monitor, could become crushed, when lowered.

WARNING The Extend-A-Gun may be used in either the extended or retracted position, but not in-between. Ensure the slide bar is down and both pawls are flush with the housing before use. The word "UNLOCKED" located on the top of the pawls should not be visible. When in use, the pawls are locked in position and prevent the latch mechanism from operating.

WARNING Do not attempt to raise the Extend-A-Gun with water pressure. Rapid upward movement of the Extend-A-Gun can cause injury to persons by striking them, or knocking them off the fire truck. It can also cause damage to the Extend-A-Gun, monitor, or other equipment.

CAUTION

Do not lift the slide bar when flowing water. The mechanism will not unlatch, but the mechanism can be damaged.

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Extend 1. Make certain the valve to the monitor is closed. 2. Lift the slide bar on the Extend-A-Gun latch mechanism with one hand and lift the deck

gun straight up with your other hand. The slide bar should be released after the deck gun has moved out of the retracted position. Notice the word "UNLOCKED" appear on the top surface of the pawls.

3. When the deck gun is in the extended position it will not be possible to lift it any higher. The pawls will retract, the slide bar will move down flush with the housing and the word "UNLOCKED" is no longer visible.

4. Make certain that the pawls are flush with the sides of the housing and that the word "UNLOCKED" is not visible before operating the valve to the deck gun.

5. Make certain the valve to the monitor is closed. 6. Press and release the “UP/AUX1” button on any RC monitor operator station or the panel

mount operator station to extend the mechanism. The tube will automatically extend fully, and then stop. Pressing the button while the RC Extend-A-Gun is in motion will cause the motor to switch directions. This system is controlled with current limiting. When the Extend-A-gun RC is being raised, the unit is provided with maximum allowable current to lift and still protect the mechanism from damage when an obstruction is encountered.

7. Position monitor to desired position. 8. Turn on water.

CAUTION

Clear all personnel and obstructions away from the Extend-A-Gun RC before lowering. This unit relies on electronic braking and may lower quickly in the event of a failure. Anything caught underneath the monitor, could become crushed, when lowered.

Retract 1. Make certain the valve to the monitor is closed. 2. Lift the deck gun slightly with one hand to take the weight off the latch mechanism and lift

the slide bar with your other hand. Notice the word "UNLOCKED" appears on the top surface of the pawls.

3. Lower the deck gun to the retracted position. The slide bar should be released after the deck gun leaves the extended position.

4. Make certain that both pawls are flush with the sides of the housing and that the word "UNLOCKED" is not visible before opening the valve to the deck gun.

5. Make certain the valve to the monitor is closed. 6. Return the monitor to its park position. 7. On systems connected to the RC monitor communication link, at the completion of the

PARK pattern, the RC Extend-A-Gun will automatically start to retract.

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8. To manually retract, press and release the “DOWN/AUX1” button on any RC monitor operator station or the panel mount operator station to retract the mechanism The tube will automatically retract completely, and then stop. Pressing the button while the RC Extend-A-Gun is in motion will cause the motor to switch directions. This system is controlled with current limiting. When the RC Extend-A-Gun is being lowered, the current is reduced and the unit is slowed down. This provides a safer lowering of the unit and prevents a crushing injury in case someone is under the unit when it is lowered. (Note: Monitor will automatically perform PARK pattern if not “AT PARK” position.)

Extend-a-Gun

CAUTION

The Extend-A-Gun RC may become damaged if it is allowed to freeze while containing water. Always drain after use to avoid damage and possible loss of use. Master stream flows are very powerful and capable of causing injury and property damage. Make sure the monitor is pointing in a safe direction before water to the monitor is turned on. Use care in directing the stream.

CAUTION

The drive train will extend and retract only when there is no water pressure. If the buttons are pushed while under water pressure, the current limiting will engage and not allow the Extend-A-Gun RC to move. This prevents damage to the unit.

CAUTION

The Extend-A-Gun RC must be lowered in the park position before the truck is driven or moved. Damage or injury may occur if the truck drives under a low hanging object, while the Extend-A-Gun RC is extended.

CAUTION

The Extend-A-Gun RC may be used in either the raised or the lowered position, but not in between. The unit may become damaged if the water is turned on in any position other thankfully extended or retracted.

CAUTION

Do not plug or cap the Extend-A-Gun RC or mounted deck gun while it is in the raised position. This will prevent the Extend-A-Gun RC from being lowered in the park position. Damage may occur if the truck drives under a low hanging object, while the Extend-A-Gun RC is extended.

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.. Indicator Light The Extend-A-Gun RC has a built in switch to control an indicator light on the truck dashboard showing that the Extend-A-Gun RC is in the extended position. This is to help prevent damage that would occur if the deck gun hits a low overhanging object. Do not move the truck with the Extend-A-Gun RC in the extended position.

Operation Below Freezing Temperatures The apparatus that the Extend-A-Gun is mounted to may be stored in sub-freezing conditions. However, the Extend-A-Gun RC is not designed to operate in sub-freezing conditions. If in the rare instance that the Extend-A-Gun becomes inoperable due to a frozen condition, it may still be used in the lowered position.

Continuous Operations The Extend-A-Gun RC is designed to produce a short burst of maximum lifting power. This is provided by a combination of a powerful motor and a high torque gearbox. The motor/gearbox combination means that heat quickly builds up in the motor. As the heat increases, the efficiency decreases, thus reducing power and speed.

Current Limiting The Extend-A-Gun RC is designed to produce a short burst of maximum lifting power. The drive train is protected by a current limiting setting. When the Extend-A-Gun RC is being raised, the unit is provided with maximum allowable current to lift and still protect the mechanism from damage when an obstruction is encountered. When the Extend-A-Gun RC is being lowered, the drive is programmed to run at a slower speed and the current limit is reduced.

Use with Salt Water Use with salt water is permissible provided the Extend-A-Gun is thoroughly cleaned with fresh water after each use. The service life of the Extend-A-Gun may be shortened due to the effects of corrosion and is not covered under warranty.

Manual Override Each Extend-A-Gun RC is equipped with an override knob. In the event of power loss, turn the knob clockwise to raise the tube or counterclockwise to lower it.

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.. Removing Override Knob The manual override knob may be removed if desired. A hex is provided for wrenches with 1/2” (13mm) wrench or socket.

Nozzle The nozzle is simply screwed onto the Hurricane RC monitor’s exit threads. Insure that the nozzle’s coupling does not make contact with the elevation drive housing when the monitor is in its highest elevation.

Caution: TFT’s Master Stream 1250 Nozzle Electric Actuator Box must be on the TOP Side for its Edge to line up with Monitor Waterway Top Body, as shown.

½” Hex for Manual extension/retraction

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Flows and Pressures

Stacked Tips Flow and Reach

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NOTE

Stream quality and reach, especially with stacked tip (smooth bore) nozzles, is generally improved with a stream straightened because the water must make many bends before it reaches the nozzle.

When using a fog nozzle, it is recommended that no stream straightened be used since the fog nozzle’s flow path generally serves as a stream straightened. Use of a stream straightened with a fog nozzle will increase the stress on the monitor’s gear train and may lead to premature wear

Inspection The following checklist is a guide for inspection after each operation. Any defects should be reported to the Maintenance personnel for disposition and, if necessary, corrected before the truck is placed back in service.

CAUTION Equipment improperly prepared for operation is unsafe for use. If something is noticed and requires attention, have it checked before the apparatus leaves

for operation. Even minor mechanical defects can lead to accidents or personal injury. Pay attention to the operation manuals of equipment and apparatus carried in the vehicle.

Entire Vehicle:

o Check all locks and hold down devices for proper operation. o Check vehicle exterior for dents or damage. o Clean all lights, reflectors and mirrors, and check for broken glass. o Check for missing bolts, loose or damaged hoses and damaged wires. o Take inventory of removable equipment. Replace any missing or damaged

items. o Turn on all truck lights and check for correct function. o Check air system for leaks. o Inspect all fire-fighting equipment for corrosion, damage or other defects.

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.. Chassis:

o Inspect wheel lugs, axles, transfer casing, and transmission for signs of lubrication leakage.

o Check under the vehicle for fuel, oil, or coolant leakage. o Check engine belts. o Inspect chassis according to instructions listed in the manufacturer’s manual. o Check operation and general condition of cabin /compartment doors and roller

shutters. Visually inspect seals around doors for looseness and/or damage. o Inspect all glass for cracks and discoloration. Check operation of sliding

windows in cab. o Check operation and condition of seat adjusting mechanism. o Visually inspect each tire for correct inflation. If the tire appears to be low in

pressure, refer truck to maintenance. o Maintain the recommended air pressure in every tire. Inflate to correct pressure

(refer to sticker on doorjamb) when tires are cold. o Inspect tires for uneven wear, chinks, or cuts. o Inspect rims for damage and inspect lug nuts. o Observe operation of all gauges. o Operate windshield washer and wiper. o Operate warning lights and alarm system. o Operate traffic guidance light and check proper operation. o Operate the horn, heater, and defroster. o Operate the communication system. o Check fuel level, add fuel if necessary. o Check level of windshield washing agent, add if necessary. o Check service brakes for proper function. o Check for uneven or spongy action, dragging, squealing, or chatter when

braking. o Test parking brake for proper function. o Check Neutral Safety Interlocks. o Check High Idle for function & setting.

Vehicle Body: o Engage water pump and check that it functions correctly. o Check function and condition of valves, instruments and gauges. o Check turret condition. o Check level in water tank visually. o Check condition of the screen fitted on the suction connection. o Refill the fuel tank and tanks of fire fighting agents.

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Vehicle cleaning &washing o If the compartments and driver´s cabin require cleaning, do not use a high

pressure hose or running water. Loose dirt should be removed with a vacuum cleaner, and then moist cloths.

o Use moist towels to clean the control panels. Excess water can damage electric components. Do not use solvents.

o Wash the vehicle frequently with cold or lukewarm (never hot) water. Do not use household soap or detergent. Use a reliable car shampoo to dissolve traffic film.

o To prevent damage, tires must not be cleaned with a high pressure steam jet. o When a hose is used, the water should not be turned onto the body at full

pressure, as this tends to drive grit and dirt into the paintwork.

CAUTION High pressure cleaning equipment must not be used; the paintwork will likely be damaged.

o After the surplus of dirt has been washed off, clean the body with a sponge and plenty of water.

o Wash the windshield wiper blades by using clean water. o Wash the wheel wells. o Avoid open drainage holes. o Rinse off with cold water, and then rub down with a clean chamois leather. o On occasion, after washing and drying the vehicle thoroughly, apply a body

polish for a lasting water-resistant finish. o Never rub the vehicle down with a dry cloth when it is dirty because this causes

cracks in the paintwork which progressively destroy it. o Any tar or asphalt spots on the body may be removed with atar cleaner and a

soft cloth. o Keep the chrome plated parts clean and free from rust. These parts should be

cleaned periodically with chrome cleaner. o Upholstery can be suitably cleaned with interior cleaner. Never use polishes,

oils, petroleum, or a dry cleaning fluid.

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.. Maintenance

Winch

Wire Rope

Inspecting your wire rope before and after each winching operation goes a long way towards safe, reliable operation. You’re checking for kinking or fraying. Either situation warrants rope replacement. Also, inspect the winch hook and hook pin for signs of wear or damage, and replace if necessary.

Synthetic Rope

If you have synthetic rope (such as with an Olympus 25), the outer line filaments may “fuzz up” with mild abrasion. Typically, this won’t affect the performance of the winch line. When fibers become melted or fused from excessive loads the winch line needs to be replaced. Also check for:

o Inconsistent diameter (or reduction by 25%) o Exposure to hard chemicals o Exposed core strands (the grey synthetic cover is worn through) o Cuts, melting or glazing of internal core strands (these are tan colored)

Also replace your synthetic winch line every three years, only with WARN Severe Duty Winch Line

Cleaning

Improve the life of your winch by keeping winch, rope and switch control clean. Use a clean rag or towel to remove dirt and debris. If necessary, unwind the winch (leaving at least five wraps on the spooling drum), wipe it clean, and rewind properly before storage. Light oil on the wire rope and winch hook can prevent rust and corrosion.

Vehicle Battery

Operating an electric winch for long periods places a burden on your vehicles battery. Check and maintain battery and cables according to manufacturer’s guidelines.

Remote

Inspect remote for damage. Cap the remote socket to keep dirt and debris out.

Lube

No lubrication required for the life of the winch, unless submersed in water, then winch must be replaced, or brought in for service to avoid malfunction.

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Relief Valve Pressure Setting To set the relief valve pressure turn the adjusting screw on the relief valve housing until the surface of the screw is even with the desired pressure.

WARNING Do not cap or plug discharge opening.

WARNING The Pressure Relief Valve will open to relieve excess pressure but it may not have enough

flow capacity to protect against large pressure spikes such as those caused by water hammer. Excess pressure can cause equipment failure and directly or indirectly lead to injury or death. Always operate valves slowly to avoid the risk of water hammer.

The Pressure Relief Valve requires no routine maintenance but should be tested regularly. Since the Pressure Relief Valve may not need to open in normal use it is important that it be inspected at least quarterly for proper function per NFPA 1962 section 8.2. In particular assure that:

o There is no damage such as cracks or dents o There is no corrosion o Setting indications are readable o The waterway is clear of obstructions o The valve opens at the set pressure (see below for test instructions)

If any problems are found, the Pressure Relief Valve should be removed from service until the problem is corrected. Any repaired Pressure Relief Valve must be tested before being placed in service.

50 PSI 200 PSI

Adjusting Screw

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... WARNING The Pressure Relief Valve may be damaged if frozen while containing significant amounts of

water. Such damage may be difficult to detect visually and can lead to possible injury or death. Any time the Pressure Relief Valve is subject to possible damage due to freezing, it must be hydrostatically tested by qualified personnel before being considered safe for use.

It is important that your pressure relief valve is functioning properly at all times while in service. A properly functioning PRV prevents dangerous situations and reduces possible injury. In order to ensure the PRV is functioning properly, it should be tested regularly.

NFPA 1962 Sections 8.2 and 8.3 set forth the minimum standards and procedures for use of these valves. It is strongly recommended that you read and follow these procedures. In addition, Rosenbauer recommends testing the PRV semi-annually to the following test procedures:

1. Set up the line with a pressure gage upstream from the appliance and pressure relief valve.

2. Make sure the PRV is set to your operating pressure, and close all appliance outlets. 3. Fill the appliance with water using pressure less than where the PRV is set, being sure to

bleed all air out of the system. 4. Carefully increase the pressure on the appliance to the set pressure. Check to see if the

valve has opened to allow water to escape. If the valve has not opened and there is no water, increase the pressure by 5 PSI. If the valve has not opened, the valve has failed and should be taken out of service immediately

Any valves taken out of service due to failure should be returned to the factory for repair or replacement. If you have any questions regarding the testing or maintenance of your pressure relief valve, please call Rosenbauer.

Open the relief valve strainer flush valve during every operation at 50-100 PSI supply pressure to insure against foreign material blocking the screen.

The relief valve, pilot unit, and strainer assemblies should be taken apart for inspection and cleaning at least annually or as often as found necessary to insure trouble free performance.

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TO SET RELIEF VALVE

1. Turn four-way valve OFF.

2. Open at least one discharge valve and increase engine throttle setting until pressure gage indicates the pressure at which relief valve is to open.

3. Turn four-way valve ON.

4. If gage reading drops below pressure set in step 2, turn hand wheel clockwise until pressure returns to set point.

5. If gage reading does not drop, turn hand wheel counter clockwise until pressure drops 5 to 10 PSI below set point. Then slowly turn hand wheel clockwise until pressure returns to pressure set in step 2.

The relief valve will now prevent the discharge pressure from rising above that for which it is set, and requires no further attention.

Pump Injection Type Stuffing Box Adjustment

WARNING

Prop 65 Warning: This product contains lead, a chemical known to the State of California to cause cancer, birth defects, and other reproductive harm. Wash hands after handling.

CAUTION

Do not attempt to use anything but Rosenbauer/Darley injection packing. Using the wrong packing material in your pump may cause catastrophic failure of the pump shaft sealing components.

Only use Rosenbauer/Darley plastallic injection packing material. It is made of a special composition of shredded fibers, and a special bonding and lubricating compound.

It is important that the stuffing box is completely filled solid with packing and compressed firm during adjustment to prevent formation of voids and excessive leakage.

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To pack the stuffing box when empty and assembled in the pump:

o Remove the packing screw and nut assembly. o Insert pellet form packing into the packing plunger guide. o Replace the packing screw assembly using a hand speed wrench to force the pellets

into the gland.

CAUTION

Do not use a power tool!

o Repeat pellet additions while turning the impeller shaft by hand until resistance to turning is felt when the stuffing box is almost full.

o Continue turning packing screw by hand using a standard 6" long 9/16" end wrench until 4 lb. of force is felt at the end of the wrench. This is equivalent to 2 ft-lb. or 24 in-Ib. of torque.

o Continue turning until a few flakes of packing are extruded out the opening between the impeller shaft and the stuffing box hole. The gland is now ready for pressure testing or pumping.

After priming the pump with water, start the pump and raise the discharge pressure to 50 psi. Tighten the packing screw using a 6" long 9/16" end wrench until 4 lb. of force is felt at the end of the wrench (24 in-Ib. of torque). Continue operating the pump at 50 psi for 5 minutes to dissipate packing pressure against the shaft and permit cooling water to flow between the shaft and stuffing box hole. Make sure that water actually does come through before operating pump at any higher pressure. The normal drip rate may vary between 5 and 60 drops per minute.

Operate the pump for 10 minutes at the highest normal operating pressure flowing sufficient water to prevent overheating. Do not run the pump blocked tight. Lower discharge pressure to 50 psi and repeat the packing screw tightening procedure outlined above.

The pump may now be operated for any time period required within its rated capacity. However, the drip rate should be monitored more frequently during the first few hours, and adjusted if necessary to achieve a stable flow rate. Several more adjustments may be required.

For a list of approximate quantity of packing pellets required by model (completely repacked), see below:

Model Approximate # of Pellets A .................................. 6 2BE .............................. 6 EM ............................. 15 H .................................. 8 JM ................................ 8 KD ............................. 10

Model Approximate # of Pellets KS ............................... 8 LD ............................. 15 LS ................................ 9 P ................................ 10 U2 ............................... 5 U4 ............................. 10

© 2011 Rosenbauer 2-1-11

Oil Level Check oil level in the pump transmission after every 25 hours of operation or 3 months, and change it after every 50 hours of operation or 6 months.

Keep the pump gear case filled with oil to the level of the oil level plug/dipstick.

Generator Anti-Freeze and Disposal of Fluids o Anti-freeze contains toxic chemicals. Wear rubber gloves when handling anti-freeze.

In case of contact with skin, wash immediately to avoid personal injury. o DO NOT mix different types of Anti-freeze. The mixture can produce a chemical

reaction resulting in the formation of harmful substances. o Be mindful of the environment. Before draining any fluids, be prepared to dispose of

them in a manner consistent with environmental protection regulations in your location.

o When draining fluids from the engine, use appropriate containers to hold the different fluids, do not mix fuel, oil or coolant together.

o Dispose of spent filter cartridges and batteries properly. o DO NOT pollute the soil, or any water source. Never pour fluids down a drain.

Conducting Safety Checks and Maintenance

WARNING o When performing safety checks or engine service, be sure the engine is level and well

supported. Use approved stands designed for this type of service. o An engine and exhaust system may get extremely hot while running. Do not work on a

generator until it has cooled. o DO NOT service an engine that is only supported by a lift jack or hoist. o Detach the battery from the engine before conducting service. Put a “DO NOT

OPERATE!” tag in the key switch to avoid accidental starting. o To avoid sparks from an accidental short circuit always disconnect the 12V DC power

at the battery. o To prevent accidental starting on the units with remote start / stop switch, always

disconnect the battery by removing the negative (-) terminal first and then the positive (+). Always disconnect the unit in this manner before working on the generator or any equipment connected to it.

o Be sure to stop the engine and remove the key when conducting daily and periodic maintenance, servicing and cleaning.

o Check or conduct maintenance after the engine, radiator, muffler, or muffler cover has cooled off completely.

o Always use the appropriate tools and jig-fixture when performing any service work. Be sure to understand and follow the instructions included with these tools.

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o Use ONLY correct engine barring techniques for manually rotating the engine. DO NOT attempt to rotate the engine by pulling or prying on the cooling fan and V-belt. Serious personal injury or damage to the cooling fan may occur.

o Replace fuel hoses and hose clamps every 2 years or earlier whether they are damaged or not. They are made of rubber and are aged gradually.

o When service is performed with two or more people present, take care to perform all work safely. Be aware of their location especially when starting the engine.

o Keep a first aid kit and fire extinguisher handy at all times.

Daily Check To prevent future engine problems from occurring, it is important to know and keep track of the engines condition. Below are items to be inspected and checked on a daily basis.

CAUTION

To avoid personal injury:

o Be sure all safety shields and guards are attached to the engine when operating. o To prevent a fire hazard, keep foreign materials, fuel and oil away from the battery,

wiring, muffler and engine. Check and clear them daily. Be aware of the muffler and exhaust gas heat underneath the engine compartment, this heat may ignite grass or other flammable materials.

o Follow all safety precautions as outlined in the “SAFE OPERATION” section. 1. For accurate readings the engine should be on level ground when checking engine

fluids. 2. Check fluids before starting the engine. (Cold Engine)

o Lubrication System: Check Engine oil level Check for Engine oil leaks

o Cooling System: Check coolant level and condition Check for coolant leaks Check for proper installation of the radiator cap

o Fuel System: Check for sufficient quantity of fuel Check for fuel leaks

3. Check engine after starting. (Warm Engine) o Proper Operation: Check for easy engine start

Check for fluid leaks Check for abnormal engine noises Check for abnormal exhaust gas

Periodically check for and tighten any fasteners that may have become loose from vibration or road shock. Serious damage may possibly occur if components become dislodged or misaligned.

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. Monitor The Rosenbauer/TFT Hurricane Monitor requires little maintenance. The monitor should be kept clean and free of dirt. All controls should be checked for freedom of movement and proper operation before each use. Consult factory for recommended service procedure. Any inoperable or damaged parts should be repaired or replaced immediately.

o Make sure that the monitor’s hand wheels (if equipped) rotate freely and without binding throughout its range of travel.

o Make sure that there are no leaks when the monitor is flowing water. o Make sure the nozzle is free of debris.

Lubrication The monitor generally should not require greasing. In the event that the operation becomes stiff grease may be applied to the horizontal rotation and elevation worm gears. The grease is applied by removing the plugs at the grease ports and replacing with grease fittings that have ¼-28 male threads. See figure below for grease fitting locations. Use medium viscosity automotive chassis grease. Apply only enough grease to restore normal operation. If normal operation is not restored by greasing than inspect for other causes of stiff operation.

NOTE Do not over pump grease. The monitor’s greased areas lead to large chambers that

could trap several pounds of grease before becoming visible.

Elevation Swivel Grease Fitting

Rotation Swivel Grease Fitting

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. Extend-a-Gun The Extend-A-Gun RC requires little maintenance. The Extend-A-Gun RC should be kept clean and free of dirt. All controls should be checked for freedom of movement and proper operation before each use. Any inoperable or damaged parts should be repaired or replaced immediately. Consult factory for recommended service procedure.

Ensure that the Extend-A-Gun RC operates freely and without binding throughout its range of travel.

Ensure that there are no leaks when the Extend-A-Gun RC is flowing water.

Lubrication The Extend-A-Gun RC is permanently lubricated on the cup seal. If lubricant has been removed during service, then apply a thin film of White Lithium Grease on seal surfaces.

Recommended Seal and

lubrication surfaces

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. Troubleshooting Siren

Symptom Probable Cause Corrective Action No siren output Shorted speaker or speaker

wires. Siren in over current protection mode.

Check connections.

External 20A fuse blows. Amplifier Power Wires Reversed Polarity

Check polarity. Replace Speaker(s).

No output from speaker, tones heard inside Amp. Module.

Speaker not connected/open circuit in speaker wiring Defective speakers

Check speaker wiring. Replace speaker(s).

Siren tones volume too low/garbled

Low voltage to siren amplifier High resistance in wiring/defective speaker Speakers phased improperly

Check wiring forbad connections/check vehicle charging system. Check speaker(s)wiring/replace speaker(s). Refer to of siren manual for proper phasing.

High rate of speaker failure

Vehicle battery voltage too high 58W speaker connected to 100W terminal.

Check vehicle charging system. Use correct speaker. Check terminals.

P.A. Volume low or no P.A. at all. Volume control fully clockwise.

Defective microphone Microphone not completely plugged in Common microphone circuit not properly wired Incorrect microphone

Replace microphone. Plug microphone in securely. Check wiring. Call Rosenbauer for list of adaptable microphones.

RRB volume low or no RRB at all. Volume control fully clockwise.

Maximum radio rebroadcast trimmer misadjusted RRB wires not connected to two-way radio external speaker

Refer to set-up and adjustment section in siren manual. Check RRB connections.

Siren sounds by itself Remote switch (horn ring)wiring from terminal remote shorting out.

Check wiring for any shorting.

Power distribution section not working

Supply fuse open Siren terminal negative not grounded

Replace fuse. Reconnect terminal negative to ground.

Siren runs properly but shuts down while running, then starts running again after a few minutes

Vehicle circuit breakers areoverheating, or are not functioning properly

Refer to specifications section of siren manual. Use a breaker with1.25x the amperage rating for the wattage being used

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. Pump Symptom Probable Cause Corrective Action Pump will not engage

Transmission not in neutral Parking brake not set Insufficient air in shift system Air leaks in shift system

Place transmission in neutral. Repeat recommended shift procedures. Release braking system momentarily. Then reset brake and repeat recommended shifting procedures. Repeat recommended shift procedures. Check system for loss of air supply. Check system for loss of air. If necessary, employ manual override procedures:

1. Turn off the engine. 2. Hole is provided in shift shaft to accomplish

emergency shifting. 3. Complete shift of control in cab to neutral and

proceed to complete shift of lower control manually. Attempt to locate and repair leak(s). Leakage, if external, may be detected audibly. Leakage could be internal and not as easily detected.

Pump loses prime or it will not prime

Defective Priming System Suction lifts too high Blocked suction strainer Suction connections Primer not operated long enough. Air Trap in Suction Line Pump Pressure too low when nozzle is opened

Check priming system by performing “Dry Vacuum Test” per NFPA standards. If pump holds vacuum, but primer pulls less than 22 inches of vacuum, replace primer due to excessive wear. Do not attempt lifts exceeding 22 feet except at low elevation. Remove obstruction from suction hose strainer. Clean and tighten all suction connections. Check suction hose and hose gaskets for possible defects. Proper priming procedures should be followed. Do not release the primer control before assuring a complete prime. Open the discharge valve slowly during completion of prime to ensure same. NOTE: Do not run the primer over 45 seconds. If prime is not achieved in 45 seconds, stop and look for causes (e.g., air leaks or blocked suction). Avoid placing any part of the suction hose higher than the suction intake. Suction hose should be laid with continuous decline to water supply. If trap in hose is unavoidable, repeated priming may be necessary to eliminate air pocket in suction hose. Prime the pump again and maintain higher pump pressure while opening discharge valve slowly.

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. Symptom Probable Cause Corrective Action

Air Leaks

Attempt to locate and correct air leaks using the following procedure.

1. Perform dry vacuum test on pump per NFPA standards with 22 inches of Hg minimum vacuum required with loss not to exceed 10 inches of vacuum in 5 minutes.

2. If a minimum of 22 inches of vacuum cannot be achieved, the priming device or system may be defective, or the leak is too big for the primer to overcome (e.g. an open valve). The loss of vacuum indicates leakage and could prevent priming or cause loss of prime.

3. Attempt above dry prime and shut off engine. Audible detection of a leak is often possible.

4. Connect the suction hose from the hydrant or the discharge of another pumper to pressurize the pump with water, and look for visible leakage and correct. A pressure of 100 PSI should be sufficient. Do not exceed pressure limitations of pump, pump accessories, or piping connections.

5. Check pump packing during attempt to locate leakage. If leakage is in excess of recommendations, adjust accordingly following instructions in pump manual.

6. The suction side relief valve can leak. Plug the valve outlet connection and retest.

Insufficient Pump Capacity or Pressure

Insufficient engine power Relief Valve improperly set Engine Governor set incorrectly Truck transmission in wrong gear or clutch is slipping Air Leaks

Engine power check or tune up may be required for peak engine and pump performance. If relief valve control is set too low, it will allow relief valve to open and bypass water. Reset Relief Valve control per the Operation section. Other bypass lines (e.g. foam system or inline valves) may reduce pump capacity or pressure. Engine governor, if set too low when on automatic, will decrease engine speed before desired pressure is achieved. Reset the governor per manufacturer’s procedures. Recheck the pumping procedure for the recommended transmission or gear range. Use mechanical speed counter on the pump panel to check speed against possible clutch or transmission slipping or inaccurate tachometer. See air leaks under “Pump loses prime or will not prime”.

Remote Shift Control Difficult To Operate

Lack of lubrication Lubricate the remote control linkages and collar with oil.

Engine Speeds Too High For Required Capacity Or

Truck transmission in wrong range or gear Lift too high, suction

Recheck the pumping procedure for therecommended transmission or gear range. Higher than normal lift (10 feet) will cause higher engine

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. Symptom Probable Cause Corrective Action Pressure hose too small

Defective suction hose Blockage of suction hose entry Worn pump impeller(s) and clearance rings Impeller blockage

speeds, high vacuum and rough operation. Use larger suction hose. Inner line of suction hose may collapse when drafting and is usually undetectable. Try a different suction hose on same pump; test for comparison against original hose. Clean suction hose strainer of obstruction and follow recommended practices for laying suction hose. Keep off the bottom of the water supply but at least 2 feet below the surface of the water. Installation of new parts required. Blockage in the impeller can prevent loss of both capacity and pressure. Back flushing of pumps from discharge to suction may free blockage. Removal of one half of the pump body may be required (this is considered a major repair).

Engine speed (RPMs) increase, but discharge pressure does not (pump is cavitating)

Blocked strainer Suction hose too small Insufficient hydrant flow Insufficient flow from tank

Clean strainer. Change to correct size hose. Reduce discharge flow. Reduce discharge flow.

Noisy pump Gear clatter at low speed Pump cavitation Pump “dead headed” No or little water flow at normal pressure

Increase engine speed (RPMs). Reduce Flow &/or engine speed (RPMs). Reduce engine speed (RPMs). Reduce discharge pressure. Open tank fill line slightly. Flow water out of discharge.

Relief valve does not relieve pressure when valves are closed

Incorrect setting of Control (Pilot) Valve Relief Valve inoperative

Check and repeat proper procedures for setting relief valve system. Possibly in need of lubrication. Remove relief valve from pump; dismantle; clean and lubricate. Weekly use of the Relief Valve is recommended.

Relief Valve Does Not Recover And Return To Original Pressure Setting After Opening Valves

Dirt in system causing sticky or slow reaction

Relief valve dirty or sticky. Follow instructions for disassembling, cleaning, and lubricating. Blocked relief valve. Clean the valve with a small wire or straightened paper clip.

Relief Valve Opens When Control Valve Is Locked Out

Drain hole in housing, piston, or sensing valve blocked

Clean the hole with a small wire or straightened paper clip. Dismantle and clean the sensing valve.

Unable to obtain Wrong procedure Check instruction for setting the relief valve and reset.

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. Symptom Probable Cause Corrective Action proper setting on relief valve

Blocked strainer Foreign matter in the Control Valve Hunting condition

Check and clean the strainer in the supply line from the pump discharge to the control valve. Check the truck manual for the exact location. Check and clean tubing lines related to the relief valve and control valve. Remove the control valve and clean. Insufficient water supply coming from the pump to the control valve. Check the strainer in the Relief Valve system. Remove the control valve and clean.

Discharge Valves Difficult To Operate

Lack of lubrication Valve in need of more clearance

Recommended weekly lubrication of discharge and suction valve, use a good grade of petroleum base or silicone grease. Add gasket to the valve cover per the truck manual. Multi-gasket design allows additional gaskets for more clearance and smooth operation. NOTE Addition of too many gaskets to the valve will permit leakage.

Generator Symptom Possible Cause Corrective Action

Engine starts but won’t run

Remote Control malfunction Low Oil Pressure Faulty Oil Pressure Switch High Water Temperature Faulty Water Temperature Switch Faulty Run Solenoid

Disconnect Remote Connection. If engine operates normally, the Remote is defective. Call Rosenbauer. Check Oil Pressure. If OK, call Rosenbauer. Disconnect Oil Pressure Switch. If engine begins operating normally, replace switch. Check water temp. If OK, ensure that the cooling system is operating normally. Call Rosenbauer. Disconnect Water Temperature Switch. If engine begins operating normally, replace switch. Replace.

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. Engine runs rough or slow

Insufficient Fuel to Engine Oil Level too High Dirty Air Filter Engine overheated or overloaded. Faulty Glow Plugs

Fill Fuel tank. Check Fuel Filter. Replace if needed. Check Fuel Pump. Repair/replace. Indicated by blue exhaust. Remove oil until at the proper level. Indicated by black exhaust. Clean/Replace. Indicated by black exhaust. Reduce load on engine. Indicated by gray/white exhaust. Check glow plugs. Replace if needed.

Engine cranks slow but will not start

Fuel tank empty Oil viscosity too high Battery voltage too low

Fill fuel tank. Replace with lighter grade of oil. Check battery. Charge/Replace if needed.

Engine cranks normally but will not start

Spark arrester clogged Faulty Glow Plugs Insufficient Fuel to Engine Fuel relay damaged

Clean/Replace as needed. Indicated by gray/white exhaust. Check glow plugs. Replace if needed. Fill Fuel tank. Check Fuel Filter. Replace if needed. Check Fuel Pump. Repair/Replace. Check Fuel Solenoid. Repair/Replace. Replace.

Engine does not crank

Battery is low or terminals are dirty. Crank relay damaged or on board fuse is blown.

Clean terminals and re-charge battery. Replace battery if necessary. Replace relay or fuse.

Zero or Low Voltage

Blown Fuse Main Breaker OFF Faulty Exciter or Voltage Regulator

Replace Fuse. Turn ON. Replace.

High Voltage Faulty Voltage Regulator

Replace.

Generator shuts off Overloaded Reduce electrical load on generator.

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.Monitor

Symptom Probable Cause Corrective Action Leaks Debris or damage in seal area Clean out debris or replace damaged

parts Elevation or Rotation Binding

Debris or damage to elevation drive parts Lack of lubricant

Clean out debris or replace damaged parts Grease

Extend-a-Gun Symptom Probable Cause Corrective Action Leaks Debris or damage in seal area Clean out debris or replace damaged parts Binding, Erratic operation

Low Voltage (see below) See Below

Does not raise

Low voltage due to:wire gage too small, wire length too long, poor connection, inadequate apparatus electrical system Mechanical Binding Damage to chain drive

Check connections and wiring per manual. Verify voltage is above 8 volts. Use manual override to verify mechanical operation. Call Rosenbauer

Does not lower

Low voltage due to: wire gage too small, wire length too long, poor connection, inadequate apparatus electrical system Mechanical Binding Monitor not in PARK position. Damage to chain drive

Check connections and wiring per manual. Verify voltage is above 8 volts. Use manual override to verify mechanical operation Perform Monitor PARK operation. Consult Factory

Job#73570


Maintenance & Repair Record

This section is provided for your convenience to track maintenance and repairs performed on the apparatus. Copy this sheet as needed.

Date Problem Repair Technician

Commander Operation Manual

Documents

Transcript of Commander Operation Manual