Addendum 1 5/20/2013 STATE OF CALIFORNIA GREEN BOOK EXAMPLE TYPE 3 FIRE APPARATUS STATE OF CALIFORNIA The Resources Agency CAL FIRE (1) VEHICLE OPERATION AND MAINTENANCE GUIDE (2) HANDBOOK 6804 2007 MODEL #34 FIRE ENGINE 5 PERSON TYPE III ENGINE CalFire Green Book Page 1 of 54 April 16, 2013
NAVISTAR MODEL 7400 4 WHEEL DRIVE CONTRACTOR Rosenbauer, Central Division 100 Third St P.O. Box 57 Lyons SD 57041 (605-543-5591) (3) Fiscal Year 2006 Build-up Delivery 2007 TABLE OF CONTENTS Foreword... 3 Distribution of Pamphlet... 4 To the operator/cost of Fire Engine.... 5 Fire engine assignments... 6 Safety (seat belts, back up alarms, and chocks)... 8 Engine Data... 9 Vehicle operations Engine... 11 Vehicle daily inspection... 15 Maintenance records...19 Air brake inspection 19 Transmission.. CAUTIONS AND WARNINGS... 20 Rocking out...22 CalFire Green Book Page 2 of 54 April 16, 2013
Transmission overheating... 22 Care and maintenance... 23 Towing... 24 26 Cruise control, Engine brake operations, Submerged axle, and Transfer case operation... 25 - Transmission shifting Driving conditions Temperature control... 27 International Truck line setting ticket (abbreviated)... 30 Engine air restriction gauge... 32 Pumping operations... 33 Foam operations..36 Rosenbauer parts list...41 F O R E W O R D This pamphlet is a regular component of the CAL FIRE Issuance System. Instructions set forth herein must be regarded as specific directives emanating from the Director. The directives contained in this pamphlet were put in this form for the convenience of the drivers of particular vehicles. It will be noted on the cover of this book that it is a pamphlet containing both guiding references and instructions. This pamphlet is an authorized compilation of information and orders having the direct approval of the Director and should be regarded as such. The Issuance Authority is charged with the responsibility of editing the contents of the pamphlet to see that it conforms with the format of the Issuance System, and he/she also CalFire Green Book Page 3 of 54 April 16, 2013
is charged with maintaining a record of the holders of this pamphlet, so that they may receive new or amended materials relevant to the specific vehicle. The designated holder is accountable for the proper use and upkeep of the pamphlet. Because of the particular use intended for pamphlet No. 6804, it was recognized from the beginning that it would be placed in a particular vehicle rather than assigned to any certain individual. For that reason the operator of any vehicle in which the Maintenance 6804 has been placed is in fact the "holder" and is responsible for it during such time as he/she is the operator of the vehicle. It is a primary duty of the operators of vehicles to maintain No. 6804 by keeping the booklet in the location provided for it, by conforming to the directives set forth in the pamphlet, and by making proper insertions and deletions of material. It is the duty of the supervisors of the operators of such vehicles and of the Regional Issuance Officer, to see that the assigned holder of each Maintenance 6804 does properly use and maintain this component of the Issuance System. In the Department's system of written instructions, the proper maintenance of the issued documents is recognized as being equal in importance with the preparation of instructional material. Outdated or partially obsolete orders are generally worse than no written instructions at all. VEHICLE OPERATION and MAINTENANCE GUIDE PAMPHLET 6804 This pamphlet was written and compiled by: CAL FIRE Davis Mobile Equipment CalFire Green Book Page 4 of 54 April 16, 2013
Edited and typed by: Laura Resler We would like express our thanks and appreciation to all of those that contributed information and material for this pamphlet, especially the Mobile Equipment Management staff. This pamphlet is published and furnished by CAL FIRE Mobile Equipment Management Office. Printed: 2007 DISTRIBUTION OF THIS MANUAL One (1) to REMAIN IN EACH VEHICLE listed on pages 6 and 7 One (1) to each Unit Fleet Manager. (4) CalFire Green Book Page 5 of 54 April 16, 2013
TO THE OPERATOR The "OPERATOR'S MANUAL", issued by the manufacturer of this vehicle, if not found in the vehicle can be obtained from the Unit Fleet Manager. It is suggested that the driver read the manual carefully and follows the instructions as they apply to this vehicle. Instructions covering the maintenance and operation of certain additional items of equipment and instruction will not be found in the "OPERATOR'S MANUAL". Therefore, reference should be made to the binder supplied with this vehicle and the 6805 pamphlet. Both of these reference manual are to be carried in the vehicle at all times. They are the guide to better operation and maintenance and contain instructions on maintenance and repair procedures. Information contained in these two (2) books takes precedence over what is found in the "OPERATOR'S MANUAL. COST Total taxpayer cost for this vehicle. $250,000 CalFire Green Book Page 6 of 54 April 16, 2013
(5) (6) (7) ASSIGNMENT OF (55) 2007 MODEL #34 FIRE ENGINES X NO. UNIT RADIO # VIN 04X100 SAN LUIS OBISPO 3461 1HTWEAZR67J461603 04X007 SANTA CLARA 1661 1HTWEAZR47J526805 04X158 SAN MATEO-SANTA CRUZ 1763 1HTWEAZR77J526801 04X025 TUOLUMNE-CALAVERAS 4452 1HTWEAZR27J526804 04X059 MADERA-MARIPOSA 4267 1HTWEAZRX7J526808 04X159 SAN DIEGO 3368 1HTWEAZR67J526806 04X008 BUTTE 2165 1HTWEAZR67J526837 04X010 SHASTA-TRINITY 2466 1HTWEAZR87J526807 04X014 SISKIYOU 2665 1HTWEAZR07J526803 04X015 TEHAMA-GLENN 2564 1HTWEAZR37J526813 04X019 NEVADA-YUBA-PLACER 2361 1HTWEAZRX7J526811 04X023 TUOLUMNE-CALAVERAS 4468 1HTWEAZR17J526809 04X026 NEVADA-YUBA-PLACER 2360 1HTWEAZR87J526810 04X028 TULARE 4164 1HTWEAZR97J526816 04X030 TEHAMA-GLENN 2554 1HTWEAZR57J516814 04X031 SAN BENITO-MONTEREY 4656 1HTWEAZR07J526817 04X034 RIVERSIDE 3161 1HTWEAZR37J526827 04X035 TULARE 4151 1HTWEAZR17J526812 04X036 RIVERSIDE 3162 1HTWEAZR77J526815 04X037 FRESNO-KINGS 4364 1HTWEAZR57J526828 04X038 SAN BENITO-MONTEREY 4665 1HTWEAZR97J526802 04X039 BUTTE 2161 1HTWEAZR37J526830 04X041 SAN LUIS OBISPO 3466 1HTWEAZR87J526838 04X042 TEHAMA-GLENN 2562 1HTWEAZR87J526841 04X045 SONOMA 1461 1HTWEAZR27J526818 04X047 FRESNO-KINGS 4362 1HTWEAZR77J526829 04X048 MADERA-MARIPOSA 4262 1HTWEAZR47J526819 04X058 LAKE-NAPA 1467 1THWEAZR07J526820 04X013 LASSEN-MODOC 2264 1HTWEAZR88J541261 04X071 MENDOCINO 1165 1THWEAZR47J526822 04X088 TUOLUMNE-CALAVERAS 4464 1HTWEAZR27J526921 04X089 SANTA CLARA 1664 1HTWEAZR97J526833 04X094 SAN BERNARDINO 3562 1HTWEAZR57J526831 04X123 HUMBOLDT-DEL NORTE 1261 1HTWEAZR77J526832 CalFire Green Book Page 7 of 54 April 16, 2013
04X149 SONOMA 1462 1HTWEAZR07J526834 04X174 SANTA CLARA 1660 1HTWEAZR27J526835 04X186 AMADOR-EL DORADO 2754 1HTWEAZR47J526836 04X189 SONOMA 1464 1HTWEAZRX7J526842 04X200 SANTA CLARA 1663 1HTWEAZR17J526843 04X218 HUMBOLDT-DEL NORTE 1262 1HTWEAZRX7J526839 CalFire Green Book Page 8 of 54 April 16, 2013
ASSIGNMENT OF (55) 2007 MODEL #34 FIRE ENGINES (cont.) 04X231 NEVADA-YUBA-PLACER 2363 1HTWEAZR67J526840 04X160 SAN BENITO-MONTEREY 4683 1HTWEAZR37J526844 04X161 TUOLUMNE-CALAVERAS 4462 1HTWEAZR68J541260 RADIO 04X162 SAN BERNARDINO 3581 1THWEAZR57J526845 X NO. UNIT # VIN 04X164 AMADOR-EL DORADO 2751 1HTWEAZR68J541257 04X167 NEVADA-YUBA-PLACER 2370 1HTWEAZR77J526846 04X168 MENDOCINO 1169 1HTWEAZR88J541258 04X170 FRESNO-KINGS 4371 1HTWEAZR98J541267 04X173 SAN DIEGO 3383 1HTWEAZRX8J541259 04X175 RIVERSIDE 3167 1HTWEAZR18J541263 04X181 LASSEN-MODOC 2266 1HTWEAZR38J541264 04X060 MADERA-MARIPOSA 4254 1HTWEAZRX8J541268 04X176 ACADEMY 5566 1HTWEAZR58J541265 04X177 ACADEMY 5567 1HTWEAZR78J541266 04X182 SAN DIEGO 3397 1HTWEAZR08J541262 CalFire Green Book Page 9 of 54 April 16, 2013
SAFETY SEAT BELTS "SAFETY BELTS AND PROPER USE IS FOR EVERYONE" Seat belts shall be worn at all times to avoid personal injury. Before fastening a front seat belt, always adjust the driver's seat to the position in which you will drive. Lap and shoulder (three-point) seat belts with retractor are standard for driver and doorside passengers. An adjustable belt that does not retract is provided for the center passenger on the rear bench seat. ADJUSTABLE LAP AND SHOULDER (THREE-POINT) BELTS To fasten the belt, bring belt across hips and chest and insert tongue into buckle. The web is free to slide through tongue, allowing the belt tension to equalize across hips and chest. The retractor is a locking type which allows webbing to come out to adjust for body movement. The webbing will return to the retractor as the body returns to its original position. The retractor will retain moderate tension across the body in its operator mode. To release, push the button release latch on the buckle. Give the belt a tug to insure it will retract. Make sure belt is not caught in door latching mechanism before shutting the door. NON-RETRACTING, ADJUSTABLE SEAT BELTS FOR CENTER PASSENGER- BENCH SEAT To Adjust: Tip the buckle end downward and pull the buckle until the ends can be joined. Insert tongue into open end of buckle and snap together. Shorten the belt after it is connected by pulling on the loose end, until the belt is snug and comfortable. To Release: Push in the button release latch to release the seat belt. CARE OF SEAT BELTS Clean the belts occasionally with mild soap; do not use cleaning solvents or abrasives. CalFire Green Book Page 10 of 54 April 16, 2013
The entire seat belt assembly should be inspected periodically for corrosion, wear, fraying or weak spots. The retractor, latch and buckle should be checked for proper function, and all seat belt mounting bolts should be tight at all times. Back up alarm Insure the proper operation of the vehicle back up alarm. With brake applied shift into reverse and note audible alarm. Cal Fire policy requires a back up alarm on all vehicles 1 ton and over. Chocks The use of chock blocks is required anytime the vehicle is parked and unattended by the operator in the operator seat position unless other wise specified in the Policy and Procedures Manual section 6851.1. TRUCK DATA ENGINE DATA MODEL #34 CAB AND CHASSIS: International Model 7400 4 wheel drive TRANSMISSION: Allison 3000 EVS P WATER TANK: UPF Poly tank with 500 gallon capacity FIRE PUMP: DARLEY JMP-500 (rated maximum flow 500 GPM@ 150 psi 60 GPM@ 800 psi AUXILIARY PUMP: DARLEY 1.5 AGE (rated 180 GPM@100 psi- 150GPM@130 psi) CalFire Green Book Page 11 of 54 April 16, 2013
ENGINE: DAIHATSU DM950-D (Briggs and Stratton model # 582447) WARRANTY The Vehicle Warranty on the International chassis is as follows: * Cab and chassis is warranted for 5 years with unlimited miles (which ever occurs first) * Engine is warranted for 5years or 100,000 miles (which ever occurs first) * Allison transmission is warranted by Allison for 5 years (no limit on miles) * Meritor front axle has an extended warranty for 7 years or 100,000 miles Warranties on pumps and motor are as follows: * Darley JMP-500 warranted for 5 years * Darley AGE 1.5 warranted for 5 years * Daihatsu DM950 D warranted for 2 years parts and labor (All warranties begin when the vehicle is placed in service as directed by Davis Mobile equipment) Check with your local Unit Fleet Manager for warranties on specific components and restrictions and limitations on all warranties. TRUCK DATA SHEET NAVISTAR 7400 SFA 4x4 ENGINE (8) FILTERS Make.DT570 Horsepower... 330 hp Governed RPM... 2200rpm Crankcase Capacity... 30 quarts Cooling System Capacity... 39 quarts Primary Air..3532799C1 Secondary Air..3532800C1 CalFire Green Book Page 12 of 54 April 16, 2013
Primary Fuel (kit)1842638c91 Oil Filter..1841606C1 Allison Transmission Filter..(2 filter kit) Allison #29548988 Power steering reservoir filter.2503221c1 8pack 8pack) BELT Alternator & Fan.1874774C1 (Dayco 21-01-0196 FLUIDS (TYPE) (QUANTITY) (PART #) Engine crankcase 15/40W CJ4 30 qts (with filter) Transmission Transynd TMS6812 42 pts (aprox) 3560640C1 Transfer case 50W synthetic 9 pts 2645218R1 Rear axle 75/90W synthetic 39 pts 2644029R1 Front axle 75/90W synthetic 8 qts 2644029R1 Coolant Red extended life 39 qts Rotella ELC Power steering 15/40W CJ4 8.4 pts CalFire Green Book Page 13 of 54 April 16, 2013
Engine VEHICLE OPERATIONS This vehicle is equipped with an International DT 570. It is your responsibility to be completely familiar with the safe operation and maintenance described in the International Operator s Manual which came with this vehicle. The following directives listed in the 6804 are only and overview of operational and maintenance procedures for this particular vehicle. ENGINE OPERATION! Warning: Always shift transmission to neutral, stop engine, set parking brake and remove start key before permitting anyone to inspect, clean, lubricate, adjust, or repair any part of the engine or its attachments. STARTING AN ENGINE EQUIPPED WITH AIR HEATER! Warning: To avoid serious personal injury, possible death, or damage to the engine do not use ether on an engine equipped with an intake air heater. Ether starting fluid is highly flammable and toxic. With new trucks and well as old, proper engine start up and shut down is important to the long life of the engine and components. Whenever possible warm the engine to operating temperature for a minimum of 5 minute at or below 1000 RPM (For fire engines and other emergency response vehicles this should done at the beginning of each day.) The warm up period provides time for the lubricating oil to establish a film between parts. It is not always permissible to allow a 5 minute warm up for emergency response. In those instances warming the engine at the start of a shift and maintaining reasonable intervals between start ups will ensure sufficient lubrication of the engine and components. Engine oil pressure should exceed 40 PSI minimum within CalFire Green Book Page 14 of 54 April 16, 2013
seconds after Starting Lube Oil Pressure Specifications (normal operating temperature) At low idle 15 psi min (typical) At high idle 40 70 psi!caution: To avoid damage to the engine, if the gauge fluctuates or drops to 40 psi or less under load, stop the engine immediately and correct the cause!caution: To avoid damage to the engine: Do not increase engine speed until the oil pressure gauge indicates normal. Shut down engine if oil pressure is not registered on the gauge within 20-30 seconds!caution: To avoid damage to the do not depress the accelerator pedal while starting engine.!caution: When welding on the vehicle: Always disconnect engine and chassis harness connectors at the Engine Control Module (ECM) and the Injector Drive Module (IDM).!CAUTION: Prevent engine damage by avoiding CalFire Green Book extended low idle periods. Page 15 of 54 April 16, 2013
ENGINE SHUTDOWN Idling the engine is recommended when an engine has been running at maximum horse power Idle the engine for several minutes prior to shutdown Idling allows heat to dissipate from iron mass of the engine block HIGH IDLE SPEED!CAUTION: When driving downhill, avoid engine damage by making sure the engine is NOT operated above the high idle speed. The International DT 570 has a high idle speed of 2300 RPM ENGIINE COOLING Normal engine operating temperature is between 190 F to 225 F The AMBER indicator lamp will be activated at engine cooling temperatures above 229 F!CAUTION: Intermittent coolant operating temperatures up to 235 F are permissible. Operation of engine above 230 F may cause internal damage. Intermittent coolant high operating CalFire Green Book temperatures are not Page to exceed 16 of 54 1 hour accumulated April time 16, for 2013 every 25 hours of operation
CalFire Green Book Page 17 of 54 April 16, 2013
Vehicle Inspection The CHP Compliance Handbook states: CCR Chapter 13 sec. 1215 a. Daily inspection. Prior to operation, the driver shall inspect each vehicle daily to as certain that it is in safe condition, it is equipped as required by all provisions of law, and all equipment is in good working order. There is no legal provision for this task to be delegated to someone other than the driver, such as to a mechanic who may arrive at work early to start all of the trucks or buses and check them out. There is nothing wrong with having a mechanic or other person start and checks the vehicles, but that does not satisfy the requirement in CCR Chapter 13 sec.1215 a. for the driver s daily inspection. Daily walk around: CalFire Green Book Page 18 of 54 April 16, 2013
1. Look at general condition of vehicle as you approach it. * damage * leaning to one side * fluid leaks under the vehicle * hoses, wires, etc. hanging below vehicle * general overall look of appearance 2. Make sure the parking brake and chocks are set. 3. Check vehicle records. * Make sure there are no ME14 s for outstanding safety issues. * Are the inspections and maintenance up to date 4. Begin your Walk Around inspection Remember, when you get behind the wheel, you (not the mechanic) are responsible for the safe operation of the vehicle. (DMV handbook) CalFire Green Book Page 19 of 54 April 16, 2013
Walk around Position 1 Left Position front wheel 1 (cont.) *Wheels- look for rust Left front around nuts and wheels, suspension cracks, bent rims, *Tires-cuts *Condition or of bulges, springsspring hanger, tread depth uneven inflation, wear shackles and U *Hubs- bolts, no (you leaks are looking Left for front cracks suspension of shifted *Condition parts. of springsspring hanger, shackles and U *Shocks-loose, bolts, (you are looking for leaking cracks of shifted parts. *Shocks-loose, leaking Left front brakes *Drums or rotors-cracks or breaks, *Hoses- chafed or worn *Brake pots-cracked, or leaking air *Slack adjusters- pushrods, missing parts, past 90 when applied 8 1 7 2 6 3 4 5 CalFire Green Book Page 20 of 54 April 16, 2013
2 Position 2 Front axle *Steering- damaged or missing parts, loose parts, p/s leaks * U bolts tight *Windshield- damage, clean *Wipers- condition *Lights- clean, broken or cracked (visual for light components) 7 8 1 3 4 5 6 Position 3 Right side *check all as you did on the left side front CalFire Green Book Page 21 of 54 April 16, 2013
Walk around 2 Position 3 Right front *check all components as you did on the left side 8 7 1 Position 6 Rear of truck *Lights- components *Reflectors 6 5 4 3! Be sure to check air filter and cab ember screens for chaff. Position 4 Right side *Batteries- secure, terminals for corrosion, age, bulges or cracks *Lights and reflectors-side markers, scene lights, *Visual for other componentstransmission, engine, leaks, driveshafts, exhaust, hoses and wiring Position 5 Right rear axle *Wheels- cracks, rust around wheel nuts *Tires- inflation, cuts, wear touching of duals, debris between duals *Springs- cracks, hangers (bolts in place), spring pins bolted, U bolts tight *Brakes- lining good condition (not worn, cracks or breaks), drums, hoses chaffing or rubbing, brake pots, *Wheel seal- leaking CalFire Green Book Page 22 of 54 April 16, 2013
Walk around 2 Position 7 Left rear axle *Wheels- cracks, rust around wheel nuts *Tires- inflation, cuts, wear, duals touching and, debris between duals *Springs- cracks, hangers (bolts in place), spring pins bolted, U bolts tight *Brakes- lining good condition (not worn, cracks or breaks), drums, hoses chaffing or rubbing, brake pots, *Wheel seal- leaking 8 7 1 6 5 4 3 CalFire Green Book Page 23 of 54 April 16, 2013
Position 8 Pump panel *Check pump- vacuum, pressure / volume, leaks, gauges, throttle *Pressure relief *Aux motor and pump *Lights- panel lights, side markers, scene 8 1 2 4 3 7 5 6 Vehicle Inspection (cont.) In the Cab COMPLIANCE AND MAINTENANCE RECORDS Check for: 90 day compliance *In the 6805 or ME15 A and B services * Up to date * Due within the immediate future? Pump test current Uncorrected ME14s AIR BRAKE INSPECTION *You have already checked the air compressor belt and brake components on the walk around. CalFire The chocks Green are Book set. Page 24 of 54 April 16, 2013 1. Start the engine to build air pressure. 2. This is a good time to note the operation of all the dash gauges and lights, and wipers 3. Release the service brake (foot pedal) 4. Fully charge the system --governor cut out:
TRANSMISSION This Engine is equipped with an Allison EVS (Emergency Vehicle Series) transmission. It is your responsibility to be completely familiar with the safe operation and maintenance described in the Allison Operator s Manual which came with this vehicle. The following directives listed in the 6804 (Green Book) are only and overview of operational and maintenance procedures for this particular vehicle. Warnings and Cautions CalFire Green Book Page 25 of 54 April 16, 2013
! Warning: The transmission incorporates a hold feature to prohibit upshifting above the range selected during normal driving. For downhill operation, select a lower transmission range. If the engine governed speed is exceeded in the held range, however, the transmission will upshift to the next higher range to prevent engine damage. To avoid injury and/or property damage due to loss of vehicle control, use the vehicle brakes to PREVENT EXCEEDING ENGINE GOVERNED SPEED IN THE HELD RANGE! Warning: Using a retarder or engine brake on wet or slippery roads may cause loss of traction on the drive wheels YOUR VEHCILE MAY SLIDE OUT OF CONTROL. To help avoid injury or property damage, turn the retarder or engine brake to the OFF position on wet or slippery roads! Warning: R (Reverse) / D (Drive) may not be attained due to an active inhibitor. Always apply the service brakes when selection R (Reverse) / D (Drive) to prevent unexpected vehicle movement and because a service brake inhibit may be present. When R / D is flashing it indicates the shift to R (Reverse)/ D (Drive) is inhibited. Check for active diagnostic codes if R (Reverse) / D (Drive) is not attained. See DOWNSHIFT AND DIRECTION CHANGE INHIBITOR FEATURE in the DRIVING TIPS section of the operator s manual TRANSMISSION (cont.) Note: The oil level sensor is a standard feature on Emergency Vehicle Series transmission. CalFire Fluid level Green information Book is displayed after Page pressing 26 of 54 both the Up and Down arrow April buttons 16, 2013 simultaneously. Simultaneously press both buttons again to obtain diagnostic data.
Each time the engine is started, the CHECK TRANS light will illuminate, then turn off after a few seconds. This momentary lighting is to show that the status light circuits are working properly. If the CHECK TRANS light does not illuminate during ignition, or if the light remains on after ignition, the system should be checked immediately. The transmission will not shift into range if a CHECK TRANS code is active. When the display shows R or D has been requested and the display is flashing the requested range has not been achieved due to an inhibit function Some inhibit functions are vehicle related (brake pressure, Note: If a CHECK TRANS light comes on the transmission is designed with a limp home mode. The limp home mode allows you to continue to operating with reduced capabilities. Before turning off the ignition and shifting the transmission to N (Neutral) the transmission can be operated for a short time in the selected range in order to limp home (safe place) for service assistance. Turning off the ignition or shifting ranges in limp home mode can disable the transmission preventing its operation. Service should be performed immediately to minimize the potential damage for damage to the transmission CalFire Green Book Page 27 of 54 April 16, 2013
ROCKING OUT If the vehicle is stuck in deep sand, snow, or mud, it may be possible to rock it out using the following procedure: 1. Shift to D (Drive) and supply, light throttle (never full throttle) 2. When the vehicle has rocked forward as far as it will go, apply and hold the vehicle service brakes. 3. When the engine has returned to idle, select R (Reverse). 4. Release the brakes and apply a steady, light throttle allowing the vehicle to rock in R (Reverse as far as it will go. 5. Again, apply and hold the service brakes and allow the engine to return to idle. This procedure may be repeated in D (Drive) and R (Reverse) if each directional shift continues to move the vehicle a greater distance.! NEVER MAKE N (NUETRAL)-TO-D (DRIVE) OR DIRECTIONAL SHIFT CHANGES WHEN THE ENGINE RPM IS ABOVE IDLE.! NEVER APPLY FULL THROTTLE FOR MORE THAN 10 SECONDS IN EITHER D (DRIVE) OR R (REVERSE) IF THE WHEELS ARE STUCK OR NOT TURNING. Full throttle under this condition will cause the transmission to over heat TRANSMISSION OVERHEATING If the transmission temperature gauge indicates a high temperature (300 F), the transmission is probably overheated. Stop the vehicle and check the cooling system. If it appears to be functioning properly, run the engine at 1200-1500 rpm with the transmission in N (Neutral). This should reduce the transmission and engine temperatures to normal operating levels in 2 to 3 minutes. If temperatures do not decrease, reduce the engine rpm. If the engine temperature indicates a high temperature, an engine or radiator problem in indicated. If high temperature in either the engine or transmission persists, stop the engine and have the overheating investigated by maintenance personnel. CalFire Green Book Page 28 of 54 April 16, 2013
NOTE: Over heating may be caused by low transmission oil level TRANSMISSION CARE AND MAINTENANCE PERIODIC INSPECITONS Careful attention to the fluid level and connections for the electronic and hydraulic circuits is very important. For easier inspections, the transmission should be kept clean. Make periodic inspections and check: For loose bolts For leaking fluid around fittings, lines, and transmission openings The condition of the electrical harness The engine cooling system for presence of transmission fluid and check the transmission fluid for the presence of coolant, which would indicate a faulty oil cooler. The breather to make sure it is clean and free from dirt or debris. Report any abnormal condition to service management. Shifting feels odd Transmission leaks Unusual transmission-related sounds (changes in sound caused by normal engine thermostatic fan cycling, while climbing a long grade with a heavy load, have be mistaken for transmission-related sounds). CHECK TRANS light comes on frequently CHECKING THE TRANSMISSION FLUID The engine must be at operating temperature (160 F 200 F anything less or higher will give and invalid reading) The vehicle must be on a flat level surface Shift the transmission into N (Neutral) Be sure the engine is at low idle (500-800 rpm) Set the parking brake and make sure they are properly engaged Set chock blocks to prevent vehicle from moving Clean around the fill tube before removing the dipstick. This will aid in preventing dirt or foreign matter from entering the hydraulic system, which can cause: * Valves to stick * Undue wear of transmission parts * Clogged passages CalFire Green Book Page 29 of 54 April 16, 2013
Remove the dipstick and wipe it clean. Insert it into the fill tube, pushing it down until it stops. Remove the dipstick and observe the fluid level. The safe operating level is anywhere within the HOT RUN band on the dipstick. Re-check to make sure Do not overfill the Transmission! NOTE: The transmission fluid level can also be check from the shift selector. See the Allison Operator s Manual for this procedure. TOWING CalFire Green Book Page 30 of 54 April 16, 2013
CRUISE CONTROL-ENGINE BRAKE OPERATION Operating a vehicle on cruise control with the engine brake turned on and controlled by the transmission TCM/ECU, may cause an unwanted application of the engine brake when the cruise control decelerates for downhill grades. Eliminate this condition by turning off the engine brake while operating the vehicle on cruise control. CalFire Green Book Page 31 of 54 April 16, 2013
Please refer to the Allison Operator s Manual furnished with this vehicle for further safety, driving, and maintenance information. VEHICLE OPERATION CalFire Green Book Page 32 of 54 April 16, 2013
SUBMERGE AXLE OPERATION: Whenever it is necessary to stand or move the vehicle with either or both axles submerged in mud or water, notify your Equipment Manager as soon as practical so an inspection of the axles and steering knuckles can be made. Water and mud will contaminate the lubricants and may cause serious damage to bearings, knuckles, gears, brakes and other parts. TRANSFER CASE CONTROLS AND OPERATION This vehicle is equipped with electric over air switches for high and low range of transfer case and front axle, engage and disengage. They will illuminate when in operation. Operation of these units is as follows: The front axle has to be engaged before transfer case can be shifted to low range. Care must be exercised to insure that the transfer case and front axle shifts have been completed. This is accomplished by moving gear shift lever to neutral, shift transfer case and front axle. A light will illuminate to indicate front axle engagement. (see owner s manual for complete instrucitons) WARNING: DO NOT KEEP THE FRONT AXLE ENGAGED WHEN OPERATING ON DRY, HARD SURFACES. TRANSFER CASE SHIFING The transfer case control is used to select the high or low speed range of the transfer case. When either up shift or down shift is to be made, stop the truck, move Allison transmission selector to neutral and complete shift. It may be necessary to momentarily release brakes, and/or move transmission selector, to a drive position, in order to align transfer case spur gears for engagement. Transfer case shifts should not be made while truck is moving. The torque converter in the Allison transmission will not permit precise output shaft speeds needed to allow alignment of transfer case spur gears. WARNING: When it is necessary to operate with both the transfer case and the transmission in low gear, the front axle drive must be engaged to avoid excessive torque load on the rear axle. CalFire Green Book Page 33 of 54 April 16, 2013
VEHICLE OPERATION (Continued) ALLISON AUTOMATIC TRANSMISSION R (reverse) For backing the vehicle. The vehicle should be completely stopped before shifting from a forward gear to reverse or from reverse to forward. The back-up warning signal must activate when the range selector is in this position. Reverse has only one gear. Reverse operation also provides the greatest traction advantage. N (neutral) Use this position when you start the engine. If the engine starts in any other position, the neutral safety switch is malfunctioning and must be repaired. This position is also used during stationary fire pump operation - always apply the parking brake, set the chock blocks. D (drive) For all normal driving conditions. The vehicle will start in 1st gear, and as you depress the accelerator, the transmission will shift to 2 nd gear, 3 rd gear, 4 th gear and 5 th gear automatically. As the vehicle slows down, the transmission will downshift to the correct gear, automatically. 2 & 3 Occasionally, the road, load, or traffic conditions will make it desirable to restrict the automatic shifting to a lower range. When the conditions improve, return the range selector to the normal driving position. These positions also provide progressively greater engine braking power (the lower the gear range, the greater the engine braking effect.) 1 This is low gear- use this one when pulling through mud & snow or driving up steep grades. This position also provides maximum engine braking power. In the lower ranges (1, 2 and 3), the transmission will not upshift above the highest gear selected unless the recommended engine governed speed for that gear is exceeded. DOWNSHIFT CONTROL: The transmission can be downshifted or up-shifted, even at full throttle and although there is no speed limitation in up-shifting, there is on downshifting and reverse. Good driving practices will avoid downshifting when the vehicle is above the maximum governed speed for the next lower gear. However, protection against improper downshifts and reverse shifts is inherent in CalFire Green Book Page 34 of 54 April 16, 2013
the design of the transmission. If a downshift or reverse shift is made at too high speed, the system automatically prevents the shift taking effect until a safe, lower speed is reached. VEHICLE OPERATION (Continued) USING THE ENGINE TO SLOW THE VEHICLE: To use the engine as a braking force, shift the range selector to the next lower range. If the vehicle is exceeding the maximum speed for a lower gear, use the service brakes to slow the vehicle to an acceptable speed where the transmission may be downshifted safely. While driving the vehicle be aware of the possibility for the engine speed to reach an excess of the maximum recommended RPM, causing the engine to upshift. In other words, on a downhill grade the vehicle should never be pushing the engine RPM any faster than the engine would normally be operating in the same gear pulling a load. With a little experience in driving the automatic, you will learn to decelerate a bit sooner, or brake until automatic downshifts will occur. This will reduce the need for manual downshifting. ENGINE BRAKE: To use the engine compression brake for auxiliary braking force (this is only an assist and not the vehicle s primary braking system), turn on switch located on left side of dash, this will allow the engine brake to work automatically whenever the operator releases the accelerator pedal to the idle position. Shift the range selector to the next lower range. If the vehicle is exceeding the maximum speed for a lower gear, use the service brakes to slow vehicle to an acceptable speed until the transmission may be downshifted safely. Caution! Do not use this function whenever road conditions are wet or slippery; this could cause a loss of control. Always turn off engine brake switch whenever vehicle is idling or parked. DRIVING ON ICE OR SNOW: The ALLISON AUTOMATIC continually provides proper balance between required power and good traction. The driver CalFire Green Book Page 35 of 54 April 16, 2013
can have better control of his vehicle because of this smooth, constant flow of power through the drive train. However, when driving on ice or snow, any acceleration or deceleration should be made gradually. PARKING BRAKE: There is no "park" position in the transmission shift pattern. Therefore, always apply the parking brake to hold the vehicle when it is unattended. Be sure the selector is in neutral and set chock blocks. TEMPERATURES: The transmission oil temperature is indicated in all vehicles by a gauge specifically designed for this purpose and in some vehicles by the engine coolant VEHICLE OPERATION (Continued) temperature indicator. Extended operations at low vehicle speeds with the engine at full throttle can cause excessively high oil temperatures in the transmission. These temperatures may tend to overheat the engine cooling system as well as cause possible transmission damage. If the engine coolant temperature gauge indicates excessive temperature, stop the vehicle and determine the cause. If the cooling system appears to be functioning properly, the transmission is probably overheated. Shift to neutral and accelerate the engine to 1200-1500 rpm. This should reduce the sump temperature to operating level within a short time. If high temperature persists, stop the engine and have the overheating condition investigated by maintenance personnel. If the transmission oil temperature gauge indicates excessive temperature, stop the vehicle and shift to neutral. Accelerate the engine to 1200-1500 rpm. The temperature should return to normal (within two or three minutes) before the vehicle resumes operation. Normal coolant temperature for both on and off highway operation is 160-220 F. Transmission oil temperature should never exceed 300 Fahrenheit for on-highway operation or off-highway operation. CAUTION: The engine should never be operated at full throttle with the transmission in gear and the output stalled. Prolonged operation of this type will cause the transmission oil temperature to become excessively high and will result in severe overheat damage to the transmission. If the transmission overheats during normal operation, check the oil level in the CalFire Green Book Page 36 of 54 April 16, 2013
transmission. INTERNATIONAL TRUCK LINE SETTING TICKET (ABREVIATED FOR HANDBOOK 6804) BRAKES BRAKES BRAKES BRAKES BRAKES AIR BRAKE ABS {Bendix AntiLock Brake 0004AZA System} Full Vehicle Wheel Control System (4- Channel) 0004EBT AIR DRYER {Bendix AD-IP} With Heater BRAKES, FRONT, AIR CAM S-Cam; 16.5" x 0004JBL 5.0"; Includes 20 Sq. In. MGM Long Stroke Brake Chambers BRAKES, REAR, AIR CAM 16.5" x 7.0"; Includes MGM TR3030 Long Stroke Brake 0004NCE Chamber and Heavy DutySpring Actuated Parking Brake AIR COMPRESSOR {Bendix Tu-Flo 550} 13.2 0004SBC CFM Capacity SUSPENSION 0003ADC SUSPENSION FRON, SPRINGS Parabolic,taper leaf;12000lb capacity FRONT AXLES 0002WLA AXLE, FRONT DRIVING, LUBE {EmGard 75W- CalFire Green Book Page 37 of 54 April 16, 2013
90} Synthetic Oil; 1 thru 29.99 Pints AXLE, FRONT DRIVING {Meritor MX-12-120} FRONT AXLES 0002ESB Single Reduction, 12,000-lb Capacity AXLE, REAR, SINGLE {Meritor RS-23-160} REAR AXLES, 0014051 Single Reduction 23,000-lb Capacity With 200 SUSPENSIONS Wheel Ends REAR AXLES, AXLE, REAR, LUBE {EmGard 75W-90} 0014WLB SUSPENSIONS Synthetic Oil; 30 thru 39.99 Pints REAR AXLES, SPRINGS, REAR AUXILIARY Multileaf; 4,500-0014SZB SUSPENSIONS lb Capacity REAR AXLES, SUSPENSION, RR, SPRING, SINGLE Vari-Rate; 0014SAN SUSPENSIONS 23,500-lb Capacity TRANSMISSION OIL {Castrol TranSynd} TRANSMISSION 0013WLD Synthetic; 29 thru 42 Pints TRANSFER CASE LUBE {EmGard 50W} TRANSMISSION 0013WDB Synthetic; 1 thru 14.99 Pints OIL COOLER, AUTO TRANSMISSION TRANSMISSION 0013WAW {Modine} Water to Oil, for Allison or CEEMAT Transmission TRANSFER CASE {Meritor T-4210 2} 2 Spd, TRANSMISSION 0013TKA 10000 lb-ft Total Capacity, With Provision for PTO, With Electric Over Air Control TRANSMISSION, AUTOMATIC {ALLISON 3000EVS_P} Close Ratio, 5-Speed; Includes Oil TRANSMISSION 0013ADN Level Sensor, With Provision for PTO, Less Retarder DRIVESHAFT {Dana Spicer} SPL170XL Series DRIVELINES 0006DBY in lieu of SPL140 ELECTRICAL ALTERNATOR {Leece-Neville 4949PA} Brush 0008GDY SYSTEMS Type; 12 Volt 270 Amp. Capacity, Pad Mounted ELECTRICAL STARTING MOTOR {Delco Remy MT-42 Type 0008871 SYSTEMS 450} 12-Volt; with Thermal Over-Crank Protection RADIATOR Cross Flow, Series System; 940 SqIn ENGINE 0012UVW Aluminum Radiator Core and 1025 SqIn Charge Air Cooler FAN DRIVE {Horton Drivemaster} "Two Speed" ENGINE 0012THT Direct Drive, With Residual Torque Device for Disengaged Fan Speed ENGINE, DIESEL {International DT570} 50 State, ENGINE 0012NRB 330 HP, 950 lb-ft Torque @ 1200 RPM, 2200 RPM Governed Speed, # 2 Bell Housing CalFire Green Book Page 38 of 54 April 16, 2013
REFER TO COMPLETE LINE SETTING TICKET IN BINDER FOR ADDITIONAL PARTS CalFire Green Book Page 39 of 54 April 16, 2013
E N G I N E A I R R E S T R I C T I O N G A U G E O P E R A T I O N AIR RESTRICTION GAUGE The air restriction gauge indicates how much engine air cleaner filter capacity has been used and how much filter capacity remains. It measures maximum restriction of filter element when the engine is operated at full load. The gauge will be mounted on the instrument panel. DO NOT open air cleaner, disturb seals or element until gauge registers maximum restriction. Replacement of air cleaner element is not to be judged by appearance. Air cleaner element may look dirty but still be in satisfactory condition. Notify your Unit Fleet Manager when the air cleaner needs service. NOTE: Air cleaner elements should only be changed at the C Service or when restriction gauge warrants change and then extreme care is to be used to make sure elements are sealed and installed correctly. CalFire Green Book Page 40 of 54 April 16, 2013
Pumping Operations The Rosenbauer model #34 is equipped with a Darley JMP 500gpm PTO driven 2 stage main pump. It is also equipped with a Darley 1½ AGE auxiliary pump powered by a Briggs dst tt V ddi l i f bil tt k! CAUTION: Before any pumping operations Spot the engine into position Hold brake application Shift transmission into neutral Set parking brake Turn off cruise control Set chocks PRIMER OPERATION This engine is equipped with a fluidless (no antifreeze or oil) Darley electric primer pump. The vanes in the pump are made from special material requiring no lubricant to seal for vacuum. (If the primer is disassembled a thin coat of factory lubricant will need to be used in assembly of the vanes and housing.) Before the pump can be primed all booster line valves, drain valve, cooling line valves, and all other openings in 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 may not need to be closed. When operating from a draft, suction connections must be tight and free of air leaks. (inspect O rings) The main pump should remain disengaged until priming is complete to prevent damage to impeller seal rings by running dry. Engage primer switch and hold until water is discharged out the primer exhaust port or 15 to 45 psi is obtained. (If water does not discharge from the primer exhaust port with 30 to 40 seconds or pressure does not build, check for air leaks.) CalFire Green Book Page 41 of 54 April 16, 2013
Engage pump to pump water (Note: It may be necessary to use the primer momentarily when initiating pumping from the booster tank to force all of the air out of the pump. STATIONARY PUMPING OPERATION For stationary pumping transmission must be in neutral. Pumping operation for main pump: 1. At low idle RPM shift pump toggle from road to engage 2. Note the pump engaged ok to pump light is illuminated Pumping from tank: 1. Close or cap all suction / intake lines and valves 2. Close all discharge valves and lines 3. Close all drain valves 4. Open tank to pump valve 5. Rpm should remain at idle until minimum pressure is established 6. Engage primer until at least 15 psi discharge pressure is reached or a steady flow of water is being discharged from the primer* 7. Switch governor to from RPM to pressure 8. Build pressure from 50psi to 100psi 9. Slowly open discharge valve 10. Set desired pressure on governor (may be pre-set) Pumping from draft or hydrant: 1. RPM should remain at idle until minimum pressure is established 2. Engage primer to remove air from pump (this will be indicated by a steady discharge psi above 45 psi* 3. Return to pressure mode on the governor 4. Slowly open discharge line or tank fill maintaining at least 50psi 5. Set desired pressure on governor CalFire Green Book Page 42 of 54 April 16, 2013
valves *If primer takes longer than 30 seconds to prime check for open To shut down pumping: 1. Return to low idle 2. Shift from pump engage to road 3. Note ok to pump light goes out This apparatus is equipped with a two-stage pump (pressure/volume). To change between pressure or volume a toggle switch is located on the pump panel with engagement indication lights on the pump panel. Pump pressure must be below 50 psi to safely operate the change over valve from pressure to volume and from volume to pressure. (9)!NOTE: DO NOT SHIFT BETWEEN PRESSURE AND VOLUME (10) ABOVE 50 PSI Pressure Position: Flows less than half of rated capacity. Volume Position: Flows more than half of rated capacity. (11) MOBILE ATTACK (Pumping from Auxiliary pump: Pumping from the auxiliary pump follows the same basic steps except for the usage of the pressure governor to control RPM and pressure. Open tank-to-pump valve. Prime pump (this may not be necessary because of the check valve in the system to hold water at the pump head.) Start auxiliary motor and note pressure rise (if there is no rise in the pressure the pump may need to be primed) NOTE: It is recommended to mobile attack in first gear with transfer case in low CalFire Green Book Page 43 of 54 April 16, 2013
range and front axle engaged for better all around performance and control of vehicle (12) PUMP COOLING (main pump) Make provision to ensure water circulation (pump cooling) if water flow is stopped (hose lines shut down.) Open the tank fill and tank to pump valves for main pump operation. Don't rely on relief value operation for pump cooling. but hose at (NOTE: The auxiliary pump has a re-circulating line for pump cooling, lines should not be shut down for extended periods of time while running maximum RPM or pressures.) Always allow for water circulation! CalFire Green Book Page 44 of 54 April 16, 2013
CalFire Green Book Page 45 of 54 April 16, 2013
CalFire Green Book Page 46 of 54 April 16, 2013
CalFire Green Book Page 47 of 54 April 16, 2013
CalFire Green Book Page 48 of 54 April 16, 2013
CalFire Green Book Page 49 of 54 April 16, 2013
FOAMPRO 1600 ELECTRICAL WIRING DIAGRAM NOTE; The simulated flow switch is OFF in the down position. If the simulated flow switch is left in the ON position there will be no foam percentage control; it will produce maximum foam flow. CalFire Green Book Page 50 of 54 April 16, 2013
CalFire Green Book Page 51 of 54 April 16, 2013
CalFire Green Book Page 52 of 54 April 16, 2013
CalFire Green Book Page 53 of 54 April 16, 2013
CalFire Green Book Page 54 of 54 April 16, 2013