Chapter 2 Maintenance Instructions

Transcription

1 Chapter 2 Maintenance Instructions Chapter 2 Page 1

2 Chapter 2 Page 2 This Page Intentionally Left Blank

3 Table of Contents Chapter-Section Page Section 1 General Procedures Safety Practices General Work Practices Bolt Torque Procedures Section 2 Servicing Daily Maintenance Check A. Filters B. Truck C. Deicing Unit D. Heater E. Intercom Weekly Maintenance Check Monthly/250 Hour Maintenance Check End-of-Season Maintenance Check Four Year Maintenance Check Section 3 Troubleshooting Section 4 Schematics Deicing Fluid Flow Schematic Section 5 Setup Procedures Aerial Device Operation Speed Setup Fluid Pumps Hydraulic Setup Aerial Device Relief Adjustment M Heater A. General B. Fuel System Setup General Setup Specifications Section 6 Preventative Maintenance Checklists Daily Checklist Weekly Checklist Monthly/250 Hour Checklist End-of-Season Checklist Preseason Checklist Chapter 2/Table of Contents Page 3

4 Chapter-Section Page Section 7 Service Procedures Pivot Pins and Bushings A. Removing Pins B. Pin Wear Tolerance C. Inspecting Bushings D. Reinstalling or Replacing Pins E. Pin Inspection Rotation Worm Gear A. Inspection B. Adjustment Lubrication A. Rotation Bearing B. Rotation Worm Gear Lubrication Diagram Chapter 2/Table of Contents Page 4

5 Section 1 General Procedures The terms warning and caution are used in this manual to indicate situations that could result in death, personal injury, or equipment damage. Warning Indicates a potentially hazardous situation which if not avoided, could result in death or personal injury. 1. Safety Practices Caution Indicates a potentially hazardous situation which if not avoided, could result in damage to equipment. Note: Calls attention to methods which make an operation easier or faster. Treat all of the following safety procedures as Warnings. A. Always apply the parking brake on the truck before making any repairs or completing any maintenance on the deicer. B. Attach a caution sign to the steering wheel to warn other personnel that the unit is being serviced. C. Do not stick hands or tools into any hole in boom sections while power is on or boom sections are moving. D. Do not perform maintenance, adjustment, or repair procedures unless so authorized. E. Do not check for hydraulic leaks with your hands. Hold a piece of cardboard or wood in front of the suspected leak. Hydraulic oil under pressure can penetrate the skin and cause serious injury. F. Keep open flames away from the hydraulic tank. Hydraulic oil is flammable. G. Do not alter the specified flow and pressure settings. (1) Higher than specified flows and pressures can cause damage to the boom cylinders and hydraulic components. (2) Lower than specified flows and pressures can result in a loss of power. H. Place a protective cover over hydraulic lines and electrical components, before welding. I. Disconnect the chassis and auxiliary batteries before welding. Chapter 2/Section 1 Page 5

6 J. Do not remove cylinders until working parts are resting on ground or are securely blocked from movement. K. Use a chain hoist, jacks or blocking to lift heavy components. L. If you must walk on top of the deicer, use extreme caution. The surface is usually very slippery. 2. General Work Practices Treat all of the following safety procedures as Cautions. A. Tag and identify all wires, hoses, and tubes before you disconnect them. B. Before removing a component, match or mark its mounting position in relation to the adjacent component. C. Before disassembling any multiple sections component, mark the position of each section in relation to the other. D. Before removing shims, tie them together and identify their location. E. Before removing a hydraulic component, thoroughly clean the area around it to prevent contaminants from entering the mating component of the hydraulic system. F. After disconnecting hoses and tubes, install plastic plugs or caps on the ends of hoses and tubes and the mating ports of all components to prevent contaminants from entering. G. Use tools that are clean and in proper working condition. H. Clean metal parts in nonflammable safety solvent. I. Clean rubber parts in warm, soapy water. J. Lubricate all parts with proper lubricant, as necessary at assembly. K. Store new components in a clean, dry, indoor location. L. Do not unpack components or remove port plugs until you need to use the component. M. Once unpacked, carefully remove all shipping materials and inspect each component for damage that may have occurred during shipping. N. Clean, flush, and plug or cap all fittings, hoses, and tubes that are not equipped with shipping caps or plugs before using them. (1) Never use rags to cap or plug openings. Chapter 2/Section 1 Page 6

7 O. No factor is more important to the unit s life and economic operation than the quality of the hydraulic oil that is used. Use only the oils recommended to ensure continued high performance. Recommended Oil Ambient Temperature Viscosity Mobil DTE 13M Above 0 C (32 F) ISO Grade 32 Mobil DTE 11M Below 0 C (32 F) ISO Grade 15 Contaminants adversely affect the viscosity, anti-foam, lubrication, and anti-rust characteristics of the oil. High operating temperatures and water, especially, increases the oil s oxidation rate. As the oil oxidizes, sludge and varnish-forming materials are deposited on the hydraulic components, dramatically increasing wear rate. The only way to ensure that all accumulated contaminants are removed from the hydraulic system is to drain the old oil and replace it with new oil. Because the deicer is often operated under dusty, dirty, or otherwise adverse conditions, it is important to check and change the oil frequently. To check the oil, place a sample in a clean glass container. If it smells burnt or rancid, or if it is cloudy or dark, the oil needs to be changed. If water appears on the bottom of the glass after the sample has stood for a while, water may be entering the system. If the condition of the oil is uncertain, it is recommended to have a hydraulic oil analysis conducted by a hydraulic oil specialist. Please feel free to contact Global Ground Support at (913) for further assistance. P. If the differential pressure across the return filter in the aerial device system ever rises above 1.62 kg/cm 2 (23 psi) with the pump at 2,000 rpm, the filter is in the bypass mode and not operating. This may be due to a dirty filter or cold oil. If the system remains in bypass after the oil has warmed up, change the filter immediately instead of waiting for the next maintenance interval. 3. Bolt Torque Procedures Warning Loose or improperly torqued fasteners could result in fatigue failure of the fastener or contribute to reduced component life. Failure to follow proper procedures could result in death or serious personal injury. A. Make sure each fastener is of the correct size, length and grade. Refer to Chapter 4, Illustrated Parts, for fastener descriptions. B. Do not interchange any grade of fasteners with a lower grade of fasteners. C. Use only grade C nuts with grade 8 bolts, unless otherwise instructed. D. Use hardened flat washers under the heads of grade 8 bolts and under each nut. E. Make sure threads are clean and free of burrs. F. Torque fasteners to proper torque values. G. Check torque regularly with a properly calibrated torque wrench. Chapter 2/Section 1 Page 7

8 BOLT GRADE SAE GRADE 5 SAE GRADE 8 SOCKET HEAD CAP SCREW MINIMUM TENSILE STRENGTH 105,000 PSI 150,000 PSI 170,000 PSI BOLT SIZE GRADE 5 GRADE 8 SOCKET HEAD CAP SCREW UNRC IN./LB FT./LB IN./LB FT./LB IN./LB FT./LB 3/ / / , / , , /8-11 1, , , /4-10 2, , , /8-9 3, , , , , , /8-7 7, , ,032 1, /4-7 10, ,320 1,360 18,420 1, /8-6 13,080 1,090 21,480 1,790 24,120 2, /2-6 17, ,440 2,370 32,040 2,670 The torque values above are based on plated and/or lightly lubricated threads. Figure 1 Common Torque Values Description 5/8-11 x 3 1/2? Socket Head Cap Screw 5/8-11 x 4? Socket Head Cap Screw Location Rotation Bearing Inner Race bottom side of mainframe top plate Rotation Bearing Outer Race top side of turret base plate Torque Value ft lb lubed ft lb lubed Figure 2 Special Torque Values Chapter 2/Section 1 Page 8

9 Section 2 Servicing Periodic inspection of the deicer can help to reduce downtime, lower repair cost, extend equipment life, and lower operating cost. A properly maintained machine is also more efficient and safe to operate. 1. Daily Maintenance Check Perform this check daily or at least once every 24 hour period that the unit is in service. A. Filters B. Truck (1) On newly delivered units, replace the return and pressure filter elements after the first 20 hours of operation. New units may require more frequent filter element changes due to normal wear-in of new parts. After this initial replacement, replace the filters every 500 hours of operation. (2) Check the filter indicators and replace the filters if necessary. (3) If the return filter element pressure gauge indicates the filter is dirty with the engine on and the filter housing warm to the touch, replace the filter element immediately. (1) Check all fluid levels under the truck hood. Levels should be at or above the Add mark. For product specification see the chassis owner s manual. (2) Check fuel level in truck cab. Check truck fuel tank reading on fuel gauge located in the main instrument cluster. (3) Check tires: (a) Visually check the tire side walls for physical damage such as cuts, bruises, etc. (b) Visually check lug bolts and safety rims for signs of damage or slippage. (4) Walk around the unit, checking the body parts for physical damage and looking for any obvious signs of leakage at fluid or oil tanks. Visually check the entire vehicle for missing, damaged or broken parts. Extreme care should be used in respect to the body and frame. Check for broken or cracked glass, mirrors, lights, lenses, and reflectors. (5) Check headlights, brake lights, tail lights, backup lights, cab, dash and instrument lights, turn signals, emergency flashers and basket work lights. (6) Check front windshield and overhead washers and wipers for proper operation. (7) Check the parking brake for proper operation. With the parking brake set and the unit in gear, it should not move. (8) Check level sensor operation. With truck ignition switch On, grasp sensor and pull it to the side as far as possible, off level, to verify that alarm sounds. Chapter 2/Section 2 Page 9

10 C. Deicing Unit (1) Visually check deicing fluid level on tank. Fill as required. (2) Check hydraulic fluid level. Proper level is 1/2 to 2/3 full as seen on the sight gauge. (3) Check all auxiliary engine fluid levels. Levels should be at or above the Add mark. For product specification see the auxiliary engine owner s manual. Make sure the auxiliary engine belts are tight. (4) Start auxiliary engine. Engine rpm should read 1,200 rpm. Turn the throttle switch to High. Engine rpm should increase again to 2,100 rpm and remain constant. Turn pump switch On. (5) Check the filter indicators and replace the filters if necessary. If the return filter element pressure gauge indicates the filter is dirty with the auxiliary engine on and the filter housing is warm to the touch, replace the filter element immediately. (6) Visually inspect all boom and basket pins and fasteners to ensure that all are secure and in place. Also, visually check all hydraulic and fluid lines for leaks. (7) Test the emergency hydraulic pump. Verify that the boom can be lowered from both the ground controls and the basket. (8) Check operation of emergency stops at truck cab, basket and ground locations. Pressing the emergency stop button applies the chassis brakes to stop movement and it also stops the auxiliary engine which stops boom movement, fluid pumping, and operational functions. To resume operations, turn off pumps and heater switches, and auxiliary engine on cab control panel by pulling the emergency stop button out. Restart the auxiliary engine. (9) With boom out of its rest, verify the truck speed is limited to a maximum of 6.4 km/hr (4 mph). (10) Check basket and bumpers for missing or broken parts. (11) Operate the boom to its full limits of travel from the ground controls and then from the basket. Ensure that all boom functions work in the directions on the placards, and that all boom functions including basket leveling operate smoothly. Check for sticky or binding control valves or sudden movement, indicating air in the hydraulic system. Check that all controls return to center Off position after operation in either direction. Chapter 2/Section 2 Page 10

11 D. Heater (1) Visually inspect for hydraulic, fluid or fuel leaks and for any other abnormal indication. (2) Switch the Throttle switch to High. The engine rpm should increase and remain constant. Allow the engine to warm. Turn the Pump switch to On and allow the hydraulic system to warm. (3) Turn the Heater switch to On and wait. The Heater On light on the panel should light up. (4) The engine rpm should remain constant with both the pump and heater on. E. Intercom (1) Check intercom for proper operation. Refer to Chapter 1, Intercom System, for information on the intercom system operation. Note: All body doors should be in place and latched after daily checks. 2. Weekly Maintenance Check Perform this check each week, or every 7 days, that the unit is in service. Perform all items on the Daily Maintenance Check before performing this weekly check. A. Cable Carrier (1) Check carrier hoses and wires in the for leaks or damage such as cracks and chaffing. B. Heater Fuel Pump (1) Drain filter of accumulated water. C. Truck Tires (1) Check truck tire pressure, inflate to 7.38 kg/cm 2 (105 psi) as required. Chapter 2/Section 2 Page 11

12 3. Monthly/250 Hour Maintenance Check GLOBAL GROUND SUPPORT Perform this check each month, or every 250 hours, that the unit is in service. Perform all items on the Weekly Maintenance Check before performing this monthly check. A. Check all lubricant levels and lubricated components in accordance with manufacturer s specifications. Lubricate or fill as necessary with the lubricant listed or and equivalent product. Refer to Section 7 Service Procedures, Lubrication, for more information and the location of lube points. Component Capacity/Lubrication Level Lubricant Deicing Circulation Pump 0.7 liter (24 oz.) Dow Corning No. 44 Deicing Spray Pump 0.7 liter (24 oz.) Dow Corning No. 44 Rotation Bearing 0.43 liter (14 oz) Keystone Moly 29 Open Gear Rotation Worm Gear/Bearing Teeth Coat surface Keystone Moly 29 Open Gear Rotation Worm Gear Bearings 0.43 liter (14 oz) Keystone Moly 29 Open Gear Transmission Fill to full mark ATF Dexron ll Power Steering Fill to full mark ATF Mercon ll Brake Booster Fill to full mark ATF Mercon ll Brakes Fill to full mark DOT 3 Engine Fill to full mark 15W-40 (Diesel) King pins Until excess noticed Mobil AW2 Steering linkage Until excess noticed Mobil AW2 B. Inspect the pattern of the rotation bearing teeth, looking for signs of excessive tooth wear. C. Lubricate the turret rotation system. Component Capacity/Lubrication Level Lubricant Rotation Bearing 0.43 liter (14 oz) Keystone Moly 29 Open Gear Rotation Worm Gear/Bearing Teeth Coat surface Keystone Moly 29 Open Gear Rotation Worm Gear Bearings 0.43 liter (14 oz) Keystone Moly 29 Open Gear Warning Make sure there is sufficient room to swing the boom to its full 360 degree position when lubricating the rotation bearing. The area must be clear of obstruction and personnel. It is possible to become trapped between stationary and moving components. (1) Rotate the turntable slowly through at least one complete 360 degree revolution, stopping at 90 degree intervals to lubricate. Operate the manual grease gun three to five times in each position. (2) The rotation worm gear teeth and the rotation bearing gear teeth require lubrication where they mesh with each other. Chapter 2/Section 2 Page 12 Warning Hands and fingers must be kept off the pinion and rotation bearing gear teeth to avoid serious injury. Apply Keystone Moly 29 Open Gear lubricant to the surface of the worm gear teeth and rotation bearing teeth.

13 (3) Lubricate the internal bearings on each side of the worm gear on the rotator. Operate the manual grease gun three to five times in each position. D. Check for proper rotation gearbox pinion-to-bearing mesh. Position the boom so that the boom tip is within reach of the ground. When pushing the boom tip back and forth there should be no more than 5.08 cm (2 inches) side-to-side boom movement. Refer to Section 7, Rotation Worm Gear, if adjustment is necessary. E. Lubricate all grease fittings on drive shafts. Check all drive shaft yokes for proper retention. F. Inspect all boom pins for missing fasteners. Inspect hose track at the outer end of the boom for signs of premature wear in hose and wiring clamp area, or loose fasteners. Repair as necessary. G. Visually check the boom for signs of physical damage, cracked welds, of distortion. Immediately report any discrepancies to your supervisor. H. Check basket and all adjoining structure for any signs of physical damage or wear. I. Inspect deicing circulation and spray pumps: (1) Check coupling for looseness, cracks or wear, and proper alignment. (2) Check pump mounting bolts for looseness. (3) Check input and output hoses for cracks and leaks. Check hose clamps for looseness. (4) Check the drive motor mounting bolts for tightness. Inspect hydraulic lines for cracks or leaks. (5) Lubricate pumps with Dow Corning No. 44 or equivalent; no more than 6 pumps with a hand held grease gun to fitting located in the end of pump shaft. J. Inspect aerial device: (1) Inspect all fittings for leakage. Retighten and/or replace O-rings as necessary. (2) Check hoses for cracks, leaks or pressure bubbles. Repair and/or replace as necessary. (3) Inspect the electrical system for frayed or worn insulation, loose connections, etc. (4) Check control cable and leveling system hoses for interference as the basket levels through its full range of motion. (5) Check cylinder seals for leaks. (6) Check electrical system for proper function operation. K. Inspect all hydraulic hoses visually for routing, chaffing, cracks, or leaks. Chapter 2/Section 2 Page 13

14 4. End-of-Season Maintenance Check GLOBAL GROUND SUPPORT Perform this check at the end of the deicing season before storing the unit. Perform all monthly maintenance before performing the End-Of-Season check. A. Inspect hydraulic system: (1) Change hydraulic oil filters. (a) Shut off all power to the hydraulic pumps. (b) Unscrew the filter canisters. (c) Catch any spilled oil in a drain pan. (d) Slightly lubricate the rubber seal on the new filters. (e) Install new filters. (f) Tighten 1/3 turn past contact. (2) Change the hydraulic tank breather. Note: If the differential pressure across the return filter in the aerial device system ever rises above 1.62 kg/ cm 2 (23 psi) with the pump at 2,000 rpm, the filter is in the bypass mode and not operating. This may be due to a dirty filter or cold oil. If the system remains in bypass after the oil has warmed up, change the filter immediately, instead of waiting for the next maintenance interval. B. Inspect electrical system. Check wiring, lights, chassis fuses, and check for loose or corroded terminals. C. Inspect all placards. Check for cleanliness proper positioning, legibility. Replace any illegible or missing placards. D. Inspect welds for cracking, separation or rust bleeding through. Any problems or signs of fatigue should be reported immediately to Global Ground Support. E. Retorque all bolts, including rotation bearing, mainframe mounting bolts, rotation gearbox mounting bolts, fluid tanks and heater-unit mounting bolts. Refer to Chapter 2, Figure 1 and Figure 2. F. Hydraulic system. Check hydraulic system pressures and adjust as necessary. Heater and fluid pumping system pressure should be to kg/cm 2 (1,900 to 2,100 psi) with a deicing pump speed of 3,800 rpm. The boom control valve relief pressure should be 246 kg/cm 2 (3,500 psi). G. Engine. Check the engine for general operation, e.g. fan belts, etc. Chapter 2/Section 2 Page 14

15 H. Aerial device. Component Capacity/Lubrication Level Lubricant Hydraulic Oil Change 113 liters (30 gallons) Mobil DTE Hydraulic Oil Ambient Temperature Viscosity Mobil DTE 13M Above 0 C (32 F) ISO Grade 32 Mobil DTE 11M Below 0 C (32 F) ISO Grade 15 (1) Change hydraulic oil and filter. (2) Check the boom control valve relief pressure. Allow the hydraulic system oil to warm and then hold the boom control lever in the boom down position. The pressure gauge should read 2,600 psi. Adjust the boom control valve pressure relief cartridge if necessary. (3) Check the filter indicators and replace the filters if necessary. I. The following is a continuation of the End-of-Season checklist. This is a more thorough list and involves a complete inspection of the deicer. Depending on seasonal use, some items may be deleted. However, it is strongly recommend that this inspection is followed in its entirety. Some items offer additional inspection criteria for areas previously mentioned. After accomplishing this checklist, repair all deficiencies before returning the deicer to service. (1) Clean Vehicle and All Compartments - with approved solvent/emulsion or steam cleaning procedure. Thoroughly clean all exterior and interior areas with special emphasis on engine compartment, exposed chassis, hydraulic components, lifting systems or other equipment subject to oil and dirt attraction. Remove all visible dirt and grease. Avoid direct spray of cleaning materials and water into electrical components, engine air cleaner, or tank vents. (2) Accomplish Truck Chassis preventative maintenance - Accomplish preventative maintenance on the truck chassis and engine according to the latest government or company standards, regardless of hour meter reading on chassis hour meter. (3) Auxiliary Engine - Inspect the engine belt and replace if necessary. Change the oil and filter. Replace the air and fuel filter also. Test operation of the auxiliary engine operating the deicer. (4) Check Hydraulic and Fluid Pump Mounts - Inspect for loose parts, nuts, bolts, clamps, etc. Secure as needed. Check for oil leaks. (5) Check Hydraulic and Fluid Hoses - Inspect hydraulic lines for leaks, blisters, and worn spots. (6) Grease Fittings - The rotation worm gear has a grease fitting at each end of the rotator, just above the rear of the mainframe top plate. Lubricate these two fittings at 90 degree intervals while rotating the turret to its full 360 degree position. The master and slave leveling cylinders have a grease fitting at the base and rod end. Lubricate universal joints for front and rear drive shafts. Inspect all drive shafts and yokes for proper retention. Chapter 2/Section 2 Page 15

16 (7) Check Electrical System - Inspect for broken switches, indicator lights and gauges, and readability of placard/name plate data. Check for loose wires, or cables, and loose, broken or missing components. Check that all lights are functional. Electrical schematics are located at the end of this Maintenance section. (8) Check Fluid Level Gauges - Check that fluid level is clearly visible through tubing on sight gauges on the driver s side of tanks. Replace tubing if necessary. (9) Check Tank Fill Couplings for Leaks - Check tank refill quick-disconnect coupling for leaks or damage. (10) Check Washers & Wipers - Check windshield and overhead washers and wipers for proper operation. Replace any worn or defective parts. (11) Check Heater Exhaust System - Inspect exhaust screen for damage or restriction. Clean any rust, scale, or insulation from inner screens. (12) Clean Flame Sensor - Remove flame sensor retention plate and clean any carbon or soot from the lens of the cad cell. Warning Fuel is present - Use care; Avoid sparks or flame. (13) Inspect Fuel Nozzles - Check fuel nozzles of the heater stage #1 and #2. (a) Remove and clean screens. (b) Tighten all loose nozzles. (c) Check for signs of improper burn. (14) Check Heater Internally - Remove the nozzle assemblies and use a good light and inspect the heater coils for any cracks or other forms of damage. Remove any foreign matter such as soot and carbon. Inspect the insulation for sign of deterioration. Reassemble heater heads as required. (15) Inspect end cap for "hot spots." (16) Check Blower rpm - With truck engine running and pumps engaged, verify rpm. Warning Fuel is present - Use care; Avoid sparks or flame. (17) Check Fuel Shut-off Valves - Check that valves do not leak under pressure. (18) Check Fuel System for Leaks - While system is under pressure, check fuel lines and all components for leaks. (19) Turn the pumps on and check the heater outlet pressure gauge behind the curb side rear door. The gauge should indicate to kg/cm 2 (180 to 205 psi). Chapter 2/Section 2 Page 16

17 Adjust the Fulflo relief valve. Remove the cap, loosen the jam nut, and turn the adjusting screw CW to increase pressure or CCW to reduce pressure. Verify that deicer pump speed is 3,800 rpm, adjust if necessary then recheck system pressure. Repeat this step as required to achieve the correct system pressure and deicer pump speed. Retighten jam nut and reinstall cap located under heater. (20) Check Spray Nozzle Operation - Check the operation of the ground line and basket nozzles for spray pattern adjustments. Nozzles should not drip when closed. Check for worn hoses or other damage. (21) Lube & Check Ground Reel Operation - Lube the chain, check the chain tension and reel drag, refer to Chapter 5, Manufacturer s Appendices, Hose Reel. (22) Check Boom, Mainframe and Subframe Structure - Check aerial device boom, mainframe and subframe for weld cracks, missing or loose pins and bolts. If any weld cracks are found contact Global Ground Support at (913) (23) Check Boom Cylinders. (a) Elevate boom. (b) Shut off engine. (c) Push the ground control buttons to maximum topping and basket level. (d) Check for boom drift. (24) Check for proper rotation gearbox pinion-to-bearing mesh. Position the boom so that the boom tip is within reach of the ground and the high tooth marking (light blue paint) on the rotation bearing meshes with the rotation worm gear. When pushing the boom tip back and forth there should be no more than 5.08 cm (two inches) side-to-side boom movement. Refer to Section 7 Service Procedures, Rotation Worm Gear. Apply Keystone Moly 29 Open Gear lubricant to the worm gear and rotation bearing teeth. (25) Retorque Mounting Bolts - Torque the rotation gear assembly, basket bracket, mainframe, auxiliary engine, fluid tanks, and heater mounting bolts. Refer to Chapter 2, Bolt Torque Procedures. (26) Check Basket Self-Level for proper operation. (27) Check Basket Controls and Lights for proper operation. (28) Check Basket and Bumpers for missing or broken parts. (29) Check Boom Controls Full Range - Operate boom to full limits of travel from the ground controls and then from the basket. Check for sticky or binding control valves or sudden movement, indicating air in the hydraulic system. Check that all controls return to center Off position after operation in either direction. Chapter 2/Section 2 Page 17

18 (30) Check Emergency Hydraulic Pump - Verify that the boom can be lowered from both the ground controls and the basket. (31) Check Emergency Stop Buttons from the ground and the basket to ensure that all functions stop except the truck engine. (32) Check Boom Speed - Check the boom speed with both single and multiple functions actuated. (33) Check Hydraulic Pressure Settings - If applicable set pressure on the deicing hydraulic pump. Normal pressure should be about 134 kg/cm 2 (1,900 psi). (34) Check Low Level System for proper operation by pumping fluid into another unit or proper storage container. Unit might cavitate just before pump shutdown. The hydraulic low level has 6 second timer. Deicing Low Level - Deicing pump turns off, engine rpm returns to 1,200 and low level light comes on in cab control panel. Hydraulic Low Level - Deicing and anti-icing pumps turn off, auxiliary engine shuts down, boom functions stop and low level light comes on in cab control panel. (35) Check Intercom Operation - Check that intercom system functions. Refer to Chapter 5, Manufacturer s Appendices, Intercom System for information on the intercom system. (36) Check Body General Conditions - Visually check the entire vehicle for missing, damaged or broken parts. Extreme care should be used in respect to the body and frame. Check for broken or cracked glass, mirrors, lights, lenses, and reflectors. (37) Touch-up Paint and Placard Check - Clean areas of damage to be painted and touch-up as needed. Replace placards and decals as needed. (38) Deicing Pumps Coupling - Inspect the coupling connection between the hydraulic motor and the deicing pump. Ensure proper alignment, security of hardware, wear of shaft gears and taperlocks, and condition of rubber drive component. (39) Fire Suppression System - Replace all fuse links. Be suer to replace fuse links with the same temperature rating at each location. Refer to Chapter 5, Manufacturer s Appendices, Fire Suppression System for information. (40) Check Boom Pins - Inspect boom pins for looseness. If pins are loose, remove and inspect bearings for wear. Replace bearings if signs of wear are indicated. To check, operate boom through all extreme positions and check for movement at pivot pins. Chapter 2/Section 2 Page 18

19 5. Four Year Maintenance Check GLOBAL GROUND SUPPORT Perform the End-of-Season maintenance before performing the Four Year Maintenance Check. A. Inspect Pivot Pins and Bearings. Remove pivot pins for examination. Check the pivot pin bushings with the pivot pins removed. Measure the diameter of the pivot pins. Replace if the diameter has decreased by more than.010 under the nominal diameter size. Apply anti-seize to the pin and bushing when installing a new pin. Refer to Section 7 Service Procedures, Pivot Pins and Bushings for inspection procedure. Chapter 2/Section 2 Page 19

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21 Section 3 Troubleshooting Problem Chassis Engine Engine will not crank. Engine cranks, but will not start. Engine stops and will not restart and unit needs to be moved. Chassis Brakes Parking brake does not release with the handle. Possible Cause Transmission is not in neutral. Battery discharged or faulty. Faulty starter or starter solenoid. Faulty start/neutral circuit. Other starter problems. Fuel tank is empty. Fuel filter is clogged. Faulty fuel pump. Other starter problems. Refer to above. Emergency stop braking system is engaged. Testing/Corrective Action Shift transmission selector to neutral and try to restart engine. Recharge or replace battery. Test with a jumper wire by removing the red/blue starter wire and jumping from the battery to the starter post. If the engine starts, replace the solenoid with a Ford approved part. If the engine does not start with direct current applied to it with the jumper wire, the starter is faulty and should be replaced. Place the transmission in neutral, set the parking brake, and turn the ignition switch off. Test the neutral switch for continuity using an ohmmeter. Very high or infinite resistance indicates the neutral switch is faulty. Replace the switch if necessary. Refer to chassis owner s manual. Fill fuel tank. Install pressure gauge in the fuel line between the fuel pump and the cylinder head. Check for proper fuel pressure. Replace the filter. Refer to chassis owner s manual. Refer to chassis owner s manual. Release the parking brake to allow the unit to be pushed or towed. Turn the auxiliary engine ignition switch On, then Off to release the emergency stop braking system. Chapter 2/Section 3 Page 21

22 Problem Auxiliary Engine Engine will not crank. Engine cranks, but won t start. Deicing Drive The truck will not go into 4 mph mode when the boom is raised out of the rest. The truck stays into 4 mph mode when the boom is in the rest. Pump High Throttle Faulty operation with Pump switch in the On position. Pump does not operate at high throttle, refill tank light is on. Pump switch is in the On position. Pump and high throttle do not operate. Refill tank light is not on. Possible Cause Battery isolation switch in the Isolated position. Battery discharged or faulty. Emergency stop switch activated. Fuel tank is empty. Fuel actuator not going to full stroke. The boom stow switch is not operating properly. The boom stow proximity switch is not properly adjusted. Hydraulic fluid level is low. Low fluid tank level. Faulty low level sensor or relay. Faulty high throttle pump relay. Testing/Corrective Action Place the switch in the Connected position. Recharge or replace battery. Turn Auxiliary Engine start switch Off and reset the emergency stop switches. Fill fuel tanks. Check actuator for binding or sticking. Check for power on wire 522A at the proximity switch connector. If power is present, check the proximity switch for continuity. If there is no continuity, replace the switch. Verify that the red indicator light is on when the boom is in the rest. If the light is not on, adjust the switch position upward until the light comes on. Fill the hydraulic reservoir with approved fluid. Proper level is 1/2 to 2/3 full as seen on the sight gauge. Fill tanks with proper fluid. Verify operation of low level relay CR-S5. If OK, check sensor on passenger side of tank. Verify operation of high throttle pump relay CR-S8. Ground must be supplied from high throttle switch. This ground supplies both the relay and the light. Chapter 2/Section 3 Page 22

23 Problem Pump High Throttle High throttle operates properly, but the deicing pump does not. Intercom System Intercom system doesn t work. Aerial Device Boom operates too slow. Basket is slow to level as the boom is raised or lowered. Hydraulic System Low hydraulic pressure at the boom control valve only. Hydraulic pressure drops at low rpm. Unit operates very slow. Excessive hydraulic fluid on cylinder rods, or fluid leaks from cylinder. Cylinder rod creeping. Cylinder holding valve fluid leak. Any fluid leak between cylinder case and head. Possible Cause Faulty Lovejoy coupler. Faulty solenoid dump valve. Faulty headset. Low hydraulic pressure. Air in leveling circuit. Unloader spool stuck in the unload position. Main hydraulic pump is worn. Worn cylinder rod seal. Worn piston seals. Counterbalance valve out of adjustment. Worn O-ring seal. Testing/Corrective Action Verify proper operation of Lovejoy coupler between the deicing pump and the motor. Check hydraulic pressure to deicing control solenoid. Verify operation with headset that is known to operate. Adjust or replace system relief valve. Purge air from the hydraulic system. Build up pressure by retracting the boom lift cylinder and continuing to retract it, then release. Check the pressure filter. Remove the unloader spool and clean if necessary. Measure pump flow rate. Replace or repair if necessary. Rebuild the cylinder, replacing the rod seal and wiper. Rebuild cylinder, replacing the piston seals. Adjust counterbalance valve to the setting indicated on the Hydraulic Schematic. Rebuild cylinder, replacing the O-rings. Chapter 2/Section 3 Page 23

24 Additional troubleshooting information may be found in the Manufacturer s Appendices for the following: Auxiliary Engine Deutz Intercom System David Clark Flow Monitor Signet Scientific Company Flow Monitor Sage 1.0 M Heater Sage Chapter 2/Section 3 Page 24

25 Section 4 Schematics Figure 3 Deicing Fluid Flow Schematic Chapter 2/Section 4 Page 25

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27 Section 5 Setup Procedures Use these setup procedures after replacing a major component such as a pump or boom control valve. 1. Aerial Device Operation Speed Setup A. Position the truck so the boom can be move through its full range of motion. B. All speed adjustments must be done at high engine speed so that proper pump flow is attained. C. A stopwatch is needed to time the function speeds. The operator in the basket should run the stopwatch while operating the function and then report the results to the person on the ground using the truck intercom system. The person on the ground can then make the necessary adjustments to the flow control cartridges. D. The aerial device function speeds are set by adjusting the flow control cartridges on the boom control valve, refer to Figure 4. This requires an open-end wrench and an Allen wrench. Turning the screws CW decreases function speed. Turning the screw CCW increases function speed. Function Cycle Time Tolerance Boom Lift 40 seconds Up/40 seconds Down +/- 5 seconds Swing 34 seconds for 90 degree rotation +/- 5 seconds Note: Make sure all of the jam nuts are tightened after adjustment of a function is complete. Basket Level Up Swing CCW Boom Lift Up Basket Level Down Swing CW Boom Lift Down Figure 4 Boom Control Valve Chapter 2/Section 5 Page 27

28 2. Fluid Pumps Hydraulic Setup A. Main Hydraulic System Pump GLOBAL GROUND SUPPORT (1) With the auxiliary engine off, install a 350 kg/cm 2 (5,000 psi) pressure gauge in the system pressure gauge on the boom control valve filter head. System Pressure Gauge Port Anti-Icing Pump Control Valve Heater Fuel Pump Control Valve System Relief Adjustment Figure 5 Pump Control Valve Chapter 2/Section 5 Page 28

29 (2) Loosen the set screw on the pump pressure compensator. Turn the adjustment screw counterclockwise to release the spring pressure. Turn the adjustment screw until the end of the screw is flush with the housing. Pressure Compensator Adjustment Screw Set Screw Figure 6 Pump Pressure Compensator Adjustment (3) Start the auxiliary engine and run at idle until the hydraulic fluid has reached normal operating temperature. (4) Make sure the deicing tank is partially filled. Turn on the pumps switch in the truck cab. (5) Turn the adjustment screw until system pressure reaches 134 kg/cm 2 (1,900 psi), as indicated on the pressure gauge. Clockwise rotation will increase the setting, counterclockwise rotation will decrease the setting. If the pressure does not increase, the aerial device relief on the boom control valve may need adjustment. (6) Using a photo tachometer, check the speed of the deicing pump. Refer to Figure7. There should be a small piece of reflective tape on the coupling that serves as a target for the photo tachometer. If there is not, clean off the pump/motor coupling and install one. Tape For Tach Reading Figure 7 Deicing Pump Speed Adjustments Chapter 2/Section 5 Page 29

30 (7) The pump speed should 3,800 rpm. Readjust the main hydraulic system pump pressure as described in Step 5 to achieve 3,800 rpm. (8) While holding the position of the adjustment screw, tighten the set screw. The torque value for this set screw is 6.8 Nm (5 ft lb). (9) Shut off the auxiliary engine and remove the pressure gauge and replace the port plug. 3. Aerial Device Relief Adjustment (1) Locate the system pressure gauge port behind the boom control valve filter. Refer to Figure 7. Install a 352 kg/cm 2 (5,000 psi) pressure gauge. (2) Remove the hex head cap from the relief valve. Using the manual controls, move the boom down control down and hold down. Loosen the jam nut and using an Allen wrench, adjust the cartridge CCW for less pressure or CW for more pressure until a reading of kg/cm 2 (2,600 psi) is indicated on the pressure gauge. (3) Tighten the jam nut and reinstall the hex head cap. Remove the pressure gauge M Heater A. General (1) All settings to be performed at normal operating temperatures. For example: Engine warmed up. Hydraulic Oil within acceptable operating temperature range. Hydraulic system pressure adjusted to proper psi. All field components to be installed and connected. (2) All fluid components to be purged of media For example: Hydraulics Fuel Circulation Pump Spray Pump (3) Direction of rotation must be verified on all rotation sensitive components. For example: Blower Wheel Fuel Pump Chapter 2/Section 5 Page 30

31 B. Fuel System Setup (1) Verify that the direction of rotation for the fuel pump is correct. (2) From a point of no rotation, slowly bring the fuel pump into service. (3) Purge the fuel pump and fuel lines of air. There is an internal relief valve in the fuel pump which must be adjusted to provide 225 psi to 250 psi when the system is operating at peak output. This is two step process. This initial adjustment of the internal relief is accomplished by turning the 1/8" Allen head adjustment screw completely in (CW). The screw is the backed out one full turn (CCW). 5. General Setup Specifications Functions Settings Pressures Main Hydraulic System Pump kg/cm 2 (1,900 psi) Heater Fuel Pump kg/cm 2 (225 psi) Deicing Nozzle Operating Pressure kg/cm 2 (140 psi) Aerial Device Relief kg/cm 2 (2,600 psi) Tires kg/cm 2 (105 psi) Speeds Deicing Pump... 3,800 rpm Auxiliary Engine idle... 1,200 rpm Auxiliary Engine high... 2,100 rpm Drive Speed boom out of rest km/hr (4 mph) Fuel Pump... 3,250 rpm Boom Lift; Topping Up/Down...38 to 42 seconds Swing CCW/CW 90 degree...32 to 36 seconds Chapter 2/Section 5 Page 31

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33 Section 6 Preventative Maintenance Checklists Daily Checklist Perform this check daily or at least once every 24 hour period that the unit is in service. Unit Number: Date: Inspector Truck engine oil level to Full mark. Truck engine coolant level to Full mark. Truck engine serpentine belt tight. Transmission fluid level to Full mark. Power steering fluid to Full mark. Hydraulic tank oil level between Full and Add marks. Fuel tank level adequate for the job. Visually check tire side walls for damage. Visually check lug bolts and rims for signs of damage or looseness. Check washer fluid levels; windshield and overhead window. Check wiper blades: windshield and overhead window. Test the parking brake. Start truck engine and allow it to reach operating temperature. With the parking brake on, put the transmission selector in gear. Unit should not move. Test the foot brake. Allow the truck to move and step on foot brake. Unit should stop. Check that backup alarm is audible. Check level sensor operation. With truck ignition switch On, grasp sensor and pull it to the side as far as possible, off level, to verify that alarm sounds. Deicing tank level adequate for the job. Visually check the unit for fluid leaks. Visually check the body for damage. Auxiliary engine oil level to Full mark. Auxiliary engine coolant level to Full mark. Auxiliary engine belts tight. Start auxiliary engine. Engine rpm should be 1,200. Place Throttle switch in the High position. The engine rpm should increase to 2,100. Turn pumps on. Visually inspect all pins and fasteners to insure that none are loose or missing. Check all lights: Head, tail, backup, turn signal, emergency flashers, instrument panels, dome, basket, and boom flashing light. Visually check the heater for signs of leaking oil, fluid, or flame. Turn heater on. The green heater On light should come on and stay on. Test intercom system for proper operation. Chapter 2/Section 6 Page 33

34 Daily Checklist Perform this check daily or at least once every 24 hour period that the unit is in service. Unit Number: Date: Inspector Check emergency stop buttons for proper operation; truck cab, basket, and ground controls. Test operation of the emergency hydraulic pump from the ground controls and basket. Check basket and bumpers for missing or broken parts. With the boom out of the its rest, verify the truck speed is limited to a maximum of 6.4 km/hr (4 mph). Test operate the aerial device to its full limits of travel from the ground controls and then from the basket. Make sure that all controls return to the center Off position after actuation in either direction. Make sure that all functions including basket level operate properly. Weekly Checklist Perform this check each week or once every 7 day period that the unit is in service. Unit Number: Date: Inspector Perform items on Daily Checklist. Check hoses and wires in cable carrier. Drain heater fuel pump of any accumulated water. Check heater fuel pressure before heater ignition: 15.8 kg/cm 2 (225 psi). Check truck tire pressure, inflate to 7.38 kg/cm 2 (105 psi) as required. Chapter 2/Section 6 Page 34

35 Monthly/250 Hour Checklist Perform the following service items every 250 meter hours that the unit is in service. Unit Number: Date: Inspector Perform items on Weekly Checklist. Change truck engine oil. Replace truck fuel filter. Change auxiliary engine oil. Replace auxiliary engine fuel filter. Replace heater fuel filter. Look for signs of excessive rotation worm gear/rotation bearing tooth wear. Check for proper rotation gearbox pinion-to-bearing mesh. Inspect boom pins and retainer bolts. Inspect booms for signs of wear, damage, cracked welds, or distortion. Inspect basket for signs of wear, damage, cracked welds, or distortion. Inspect deicing pump coupling for looseness, cracks, wear, and proper alignment. Check deicing pump mounting bolts for looseness. Check input and output hoses for cracks and leaks. Check hose clamps for looseness. Check deicing pump drive motor mounting bolts for looseness. Check deicing pump drive motor hydraulic lines for cracks or leaks. Inspect hydraulic hoses for cracks, kinks, and chaffing. Inspect hydraulic fittings for leaks. Retighten and/or replace O-rings as necessary Inspect all electrical wires and cables for frayed or worn insulation, loose connections, etc. Check basket control cables and leveling system hoses for interference as the basket levels through its full range of motion. Inspect deicing hose for cracks, kinks, and chaffing. Check cylinder seals for leaks. Check electrical system for proper function operation. Lubricate deicing pumps. Lubricate rotation worm gear and rotation bearing. Lubricate king pins and steering linkage. Chapter 2/Section 6 Page 35

36 End-of-Season Checklist Perform the following service items at the end of the deicing season before storing the unit. Unit Number: Date: Inspector Perform items on Monthly Checklist. Inspect hydraulic tank shut off valves and tie wrap them in the open position. Inspect and retorque the rotation bearing bolts. Refer to Figure 2, page 7. Inspect and retorque the subframe mounting bolts. Refer to Figure 2, page 7. Change both heater fuel filters. Visually inspect boom pins and retainer bolts. Inspect aerial device booms for cracked or damaged welds. Visually inspect deicing pumps coupling and the pump and motor mounting bolts. Inspect deicing fluid hose in boom for cracks, kinks, and chaffing. Inspect all hoses on unit for cracks, kinks, and chaffing. Inspect all electrical wires and cables on unit. Inspect hydraulic hoses and fittings for signs of cracks and leaking. Inspect fluid tanks for signs of leaking. Check deicing drive speed with boom out of the rest: 6.4 km/hr (4 mph) limit. Inspect and tighten all electrical connections. Lubricate rotation bearing through full 360 degree rotation. Lubricate rotation worm gear. Lubricate hose reel chain. Change hydraulic fluid. Fluid level between 1/2 to 2/3 full as seen on the sight gauge. Change hydraulic fluid filters. Check rotation pinion-to-bearing gear mesh: maximum boom movement 5.08 cm ( 2? ) side-to-side. Inspect and retorque the rotation gearbox mounting bolts. Check gauges on control console in truck cab for proper operation. Check operation of low level system: hydraulic and deicing fluid. Test emergency stop buttons for proper operation; truck cab, basket, and ground controls. Test operation of the emergency hydraulic pump from the ground controls and basket. Check operation of deicer fluid nozzle. Chapter 2/Section 6 Page 36

37 End-of-Season Checklist Perform the following service items at the end of the deicing season before storing the unit. Unit Number: Date: Inspector Check speed of boom lift Up function: full range of motion seconds. Check speed of boom lift Down function: full range of motion seconds. Check speed of turret rotation CW function: 90 degrees of motion seconds. Check speed of turret rotation CCW function: 90 degrees of motion seconds. Inspect engine belt: replace if necessary. Replace air filter. Replace fuel filter. Change oil and filter. Auxiliary Engine Check deicer operation with auxiliary engine off; booms. Check deicer operation with auxiliary engine running; booms. Replace electrodes. Clean and check cad cell eyes. Check fuel nozzles. Check heater for carbon buildup. Heater Check inside of heater for signs of structural damage. With pumps on, check heater outlet pressure: kg/cm 2 ( psi). Adjust Fulflo relief valve, if necessary, to achieve proper system pressure and deicer pump speed. Check spark gap of heater stage #1. Refer to Sage heater manual. Check heater operation: should maintain temperature range of 77 C (170 F) to 91 C (195 F). Chapter 2/Section 6 Page 37

38 End-of-Season Checklist Perform the following service items at the end of the deicing season before storing the unit. Unit Number: Date: Inspector Inspect and lubricate drivelines and U-joints. Chassis Check the engine belts for cracks and looseness: serpentine, power steering, etc. Replace if necessary. Inspect transmission shift selector and cable. Inspect power steering pump for signs of leaking. Power steering fluid to Full mark. Visually inspect steering components. Lubricate front springs and steering components. Lubricate rear springs. Transmission fluid to Full mark. Replace air filter. Change engine oil and filter. Replace fuel filter. Visually check fuel tanks for signs of leaking. Check rear axle lubricant: add per chassis manufacturer specifications if necessary. Chapter 2/Section 6 Page 38

39 Preseason Checklist Perform this check at the end of the deicing season before putting the unit in service. Unit Number: Date: Inspector Perform items on the Daily Checklist. Visually inspect the unit for signs of damage. Check truck tire pressure, inflate to 7.38 kg/cm 2 (105 psi) as required. Visually inspect wheels for loose or missing lug bolts. Check all lights: Head, tail, backup, turn signal, emergency flashers, instrument panels, dome, basket, and boom flashing light. Check wiper blades; windshield and overhead window. Check washer operation and fluid levels; windshield and overhead window. Visually check truck engine for fluid leaks. Visually check auxiliary engine for fluid leaks. Visually check deicing tank for fluid leaks. Visually check the unit for hydraulic fluid leaks. Check truck transmission fluid level to Full mark. Check the truck engine belts for cracks and looseness; serpentine, power steering, etc. Auxiliary engine belts tight. Test emergency stop buttons for proper operation; truck cab, basket and ground controls. Test operation of the emergency hydraulic pump from the ground controls and basket. Test operation of the aerial device functions from the ground controls and then from the basket. All movement should be smooth and in direction of placard. Test intercom system for proper operation. Lubricate deicing pumps. Lubricate hose reel chain. Verify that all operational and safety placards and decals are legible; replace if necessary. Check sight tube on deicing fluid tank. Check basket boom joystick deadman trigger. Check basket boom joystick operation. All movement should be smooth and in direction of placard. Chapter 2/Section 6 Page 39

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41 1. Pivot Pins and Bushings GLOBAL GROUND SUPPORT Section 7 Service Procedures Inspection of the pivot pins and bearings is part of the Four Year Maintenance Check. All pivot pins shall be removed for inspection and all bushings are to be inspected. Both pins and bearings are to be replaced if necessary. A device such as a hoist, crane, or forklift capable of lifting or supporting a minimum of 907 kg (2,000 lb) is required to lift or support the boom at various locations while removing the pivot pins for inspection. A. Removing Pins Remove all snap rings and buckeye pins on the ends of the pins as necessary. Use a brass punch and brass hammer or steel punch and brass hammer to drive the pins through the bushings. Do not use a steel punch and steel hammer to remove pins; no steel to steel contact is recommended. The length and size of the punch should match the pin size and length for proper removal. B. Pin Wear Tolerance Inspect each pin for noticeable signs of wear, cracks, or damage. Measure the diameter of each pin. If the wear is greater than.010? from the original nominal diameter, replacement the pin. C. Inspecting Bushings Original Nominal Diameter Minimum Acceptable Diameter 1.00? 0.99? 1.25? 1.24? 1.50? 1.49? 1.75? 1.74? 2.00? 1.99? Inspect bushings for noticeable signs of wear, cracks, or damage. D. Reinstalling or Replacing Pins When reinstalling or replacing pins, it is recommended to use an anti-seize lubricant. Use only a brass, or steel, punch and a brass hammer to drive the pins back into their proper location. E. Pin Inspection Use the following procedure for removing, inspecting, and reinstalling the pins and bushings. (1) Remove the basket pivot pin. Refer to Figure 8. Inspect the pin and bushing. Reinstall or replace the pin and bushing as necessary. Chapter 2/Section 7 Page 41

42 Master Leveling Cylinder Base and Rod End Pins 1.25? Base Boom Pivot Pin 1.75? Boom Lift Cylinder Base End Pin 1.75? Boom Lift Cylinder Rod End Pin 1.50? Slave Leveling Cylinder Base and Rod End Pins 1.25? Basket Pivot Pin 1.25? Figure 8 Pin Location and Original Nominal Diameter (2) Remove the slave leveling cylinder rod end pin. Do not remove the cylinder base end pin as this pin will support the cylinder while the rod end pin is being removed. Inspect the pin and bushing and reinstall or replace the pin and bushing as necessary. (3) Remove the slave leveling cylinder base pin, supporting the cylinder by hand. Inspect the pin and bushing and reinstall or replace the pin and bushing as necessary. Return the boom to the boom rest. (4) Remove the master leveling cylinder rod end pin. Do not remove the cylinder base end pin as this pin will support the cylinder while the rod end pin is being removed. Inspect the pin and bushing and reinstall or replace the pin and bushing as necessary. (5) Remove the master leveling cylinder base pin, supporting the cylinder by hand. Inspect the pin and bushing and reinstall or replace the pin and bushing as necessary. (6) Support the boom weldment by locating a strap behind the boom rest and lifting with a hoist or crane. (7) Support the boom lift cylinder with blocks or cribbing and a hoist. Remove the boom lift cylinder rod end pivot pin. Lower to cylinder rod end with the hoist. Inspect the pin and bushing and reinstall or replace the pin and bushing as necessary. (8) Raise the boom as needed for clearance and remove the boom lift cylinder base end pin. Inspect the pin and bushing and reinstall or replace the pin and bushing as necessary. (9) Lower the boom back to the boom rest and relocate the strap to the back third area of the base boom section for support. (10) Remove the base boom weldment pivot pin. Inspect the pin and bushing and reinstall or replace the pin and bushing as necessary. Chapter 2/Section 7 Page 42

43 2. Rotation Worm Gear The rotation worm gear mounting position is adjustable to allow proper gear mesh between the worm gear and the rotation bearing. Proper adjustment minimizes wear and backlash between the worm gear and rotation bearing gear teeth. Excessive backlash will appear as excessive side-to-side boom movement. A. Inspection To inspect the gear backlash, the boom must be positioned so that the boom tip is within reach of the ground and the high tooth marking on the rotation bearing meshes with the rotation worm gear. Use the following procedure to inspect for proper mesh between the rotation worm gear and the rotation bearing. (1) Position the unit in an area that will allow the boom to be positioned to the side of the vehicle. Warning Hands and fingers must be kept off the worm gear and rotation bearing gear teeth to avoid serious injury. (2) While watching for the high tooth location on the rotation bearing, have someone rotate the boom to the position where the paint mark on the bearing meshes with the gearbox pinion. The rotation bearing high tooth is marked with light blue paint blue. Turn off the truck engine. Note: If the high tooth can not be identified by the blue paint, refer to Chapter 5, Manufacturers Appendices, Rotation Worm Gear for more information. (3) Push the boom tip back and forth. There should be no more than 5.08 cm ( 2? ) side-to-side boom movement. B. Adjustment Refer to Chapter 5, Manufacturers Appendices, Rotation Worm Gear for information on proper adjustment of the worm gear/rotation bearing gear mesh. Chapter 2/Section 7 Page 43

44 3. Lubrication Proper component lubrication will extend the life of the equipment and help to avoid future maintenance problems. The Lubrication Diagram (refer to Figure 9) identifies the location of the component on the deicer and references a figure which shows the lubrication points of that component and lists the frequency and the type of lubricant to use. Any brand of lubricant that meets or exceeds the specifications of the products listed is acceptable. There are three intervals of lubrication, Monthly, End-of-Season, and Preseason. Always wipe grease fittings clean before lubricating to keep foreign material from entering the lubrication point. To avoid bearing damage, use a manually operated grease gun. Air driven grease guns may have enough force to cause bearing damage. A. Rotation Bearing The rotation bearing ball path is lubricated by a grease fitting on the inner race of the bearing. Warning Make sure there is sufficient room to swing the boom to its full 360 degree position when lubricating the rotation bearing. The area must be clear of obstruction and personnel. It is possible to become trapped between stationary and moving components. (1) Rotate the turntable slowly through at least one complete 360 degree revolution, stopping at 90 degree intervals to lubricate. Operate the manual grease gun three to five times in each position. (2) The rotation bearing gear teeth and the rotation worm gear teeth require lubrication where they mesh with each other. Warning Hands and fingers must be kept off the worm gear and rotation bearing gear teeth to avoid serious injury. Caution Use extreme caution when access covers have been removed to service the unit. Pinch points and shear points may exist between moving parts. Replace the access covers immediately after servicing. (3) Apply Keystone Moly 29 Open Gear lubricant to the surface of the worm gear teeth and rotation bearing teeth. B. Rotation Worm Gear The bearings on the rotation worm gear requires periodic lubrication. No more than three pumps with a manually operated grease gun will be enough to adequately lubricate the bearings. Chapter 2/Section 7 Page 44

45 Rotation Worm Gear/Rotation Bearing Mesh Figure 10 Rotation Bearing Figure 11 Rotation Worm Gear Bearings Figure Deicing Spray and Circulation Pumps Figure 13 Hose Reel Drive Chain Figure 14 Master Leveling Cylinder Figure 15 Slave Leveling Cylinder Figure 16 Figure 9 Lubrication Diagram Chapter 2/Section 7 Page 45

46 Monthly Using Keystone Moly 29 Open Gear Lubricant Figure 10 Rotation Worm Gear/Rotation Bearing Mesh Monthly Using Keystone Moly 29 Open Gear Lubricant; Lubricate Grease Fitting on Inner Race at 90 Degree Intervals While Swinging The Boom To Its Full 360 Degree Position Figure 11 Rotation Bearing Chapter 2/Section 7 Page 46

47 Monthly Using Keystone Moly 29 Open Gear Lubricant; No More Than Three Pumps With A Hand Held Grease Gun Figure 12 Rotation Worm Gear Bearings Every 30 to 40 Operating Hours With Dow Corning No. 44; No More Than Six Pumps With A Hand Held Grease Gun Figure 13 Deicing Circulation and Spray Pumps Chapter 2/Section 7 Page 47