Oils, greases, and other lubricants used by this Department. Engine oil SAE 15W40 is used in the crankcase of our apparatus, high-fog pump, 1981 American La France road pump transmission and also as a general lubricant on the clevis pins and linkage, and in power steering reservoirs on engines and aerial apparatus. Drip less oil or light machine oil is used on control cables, door latches, and hinges. Chassis lubricant is used on all chassis points which have been provided with grease zerk fittings. ATF Dexron II is used in some aerial ladder hydraulic systems and may also be used in some Allison automatic transmissions. Door Ease Stick is used on door strikers and compartment door latch pins. Engine oil SAE-50 synthetic is used in manual transmissions and all road pump transmissions. 80/140 synthetic gear oil is used in all manual steering gear boxes. Differential oil 80/140 weight is used in apparatus differentials. Molly Dri-Lube is used only on ladder trucks to lubricate the ladder guides and aerials with rollers. Cable lubricant is issued on ladder extension and retraction cables. Chain lubricant is used to lubricate the hose reel chain drives. Break Free is used on Task Force tip nozzles. Lithium-based, all-purpose lubricant is used on non-task Force nozzles, gate valves, hydra assist valves, four ways, and nozzle shut off. Dry Graphite is used on swivel couplings. Blue Grease is used on aerials with slide pods. 291
Before starting lubrication of apparatus: 1. Inspect the supply of lubricants to assure they have not been contaminated with dirt, water, other greases, oils, or foreign materials. 2. Inspect measuring cans, funnels, grease guns, and other equipment used in dispensing lubricants to assure cleanliness. Hydraulic oil reservoir Keep the areas around breathers clean at all times 3. Before removing plugs, such as on the steering gear box, transmission, and hydraulic reservoir, the area around the plug shall be clean. Use a cloth to wipe off all dirt from the grease fittings before lubricating. If the fittings are broken, damaged, or missing, either replace or have them replaced by the area mechanic. 4. All differentials as well as standard road pump transmissions have breathers, usually located at the top of the unit. This is to prevent pressure buildup, thus forcing the lubricant out through seals and gaskets. These breathers shall be kept clean at all times. The area mechanic shall periodically clean breathers. 5. The strain, weight, or pressure on bushings and bearings shall be relieved when lubricating by jacking up wheels, releasing the brakes, and moving the part being lubricated. 6. The filler plug will have either a square lug, recessed square, or will be a large, stamped sheet metal plug. CAUTION: Never remove or loosen a screw or bolt provided with a lock nut, since this would be an adjustment not a filler plug. 292
WEEKLY LUBRICATION The ladder rollers shall be lubricated with chassis lube. The ladder guides and fly support pads at the end of the ladder bed shall be lubricated with Molykote aerosol spray lubricant or Blue Grease furnished by the area mechanic. The ladder extension and retraction cables shall be thoroughly lubricated with chain and cable lubricant aerosol spray furnished by the area mechanic. The cable drum shall be lubricated at each grease zerk fitting with chassis lube. During this operation, the cable shall be inspected for any frayed or broken wire. The turntable center pin shall be lubricated after each use with chassis lube. The hydraulic oil level in all aerial equipment shall be checked each week and after each extensive or prolonged use. Any contamination of the oil shall be reported to the area mechanic. These procedures shall also be performed at such other times as conditions or the aerial ladder warrant. Other lubrication is to be performed as required elsewhere in these instructions or in the equipment manual. Lubricate 5th wheel assembly at all grease zerk fittings with chassis lube until lubricant is visible around joints. Excess lubricant shall be wiped off. Lubricate outriggers at all grease zerk fittings with chassis lube until lubricant is visible around joints. Excess lubricant shall be wiped off. 293
WEEKLY LUBRICATION Ladder rollers The ladder rollers shall be lubricated with chassis lube. Before removing plugs, such as on the steering gear box, transmission, and hydraulic reservoir, the area around the plug shall be clean. Use a cloth to wipe off all dirt from the grease fittings before lubricating. If the fittings are broken, damaged, or missing, either replace or have them replaced by the area mechanic. Always clean area after using grease gun 294
WEEKLY LUBRICATION Ladder Guides Ladder Guides The ladder guides and fly support pads at the end of the ladder bed shall be lubricated with Molykote aerosol spray lubricant or Blue Grease furnished by the area mechanic. Ladder Guides Lube with Blue Grease 295
WEEKLY LUBRICATION.The ladder extension and retraction cables shall be thoroughly lubricated with chain and cable lubricant aerosol spray furnished by the area mechanic. The cable drum shall be lubricated at each grease zerk fitting with chassis lube. During this operation, the cable shall be inspected for any frayed or broken wire. Ladder Guides Extension and retraction cables 296
WEEKLY LUBRICATION The lift cylinders: grease zerk fittings with chassis lube until lubricant is visible around joints. Excess lubricant shall be wiped off. Keep the areas lubricated clean at all times Remove cap and use a grease gun, pump until grease is visible around joints 297
WEEKLY LUBRICATION Remove cap and lubricate with grease gun until grease is seen coming from sides There are two zerk fittings on each side of the Quint. The second zerk fitting is located below diamond plate Lubricate 5th wheel assembly at all grease zerk fittings with chassis lube until lubricant is visible around joints. Excess lubricant shall be wiped off. The second zerk fitting is located below diamond plate 298
WEEKLY LUBRICATION Aerial Maintenance Lubricate outriggers at all grease zerk fittings with chassis lube until lubricant is visible around joints. Excess lubricant shall be wiped off. Zerk fitting on outrigger. KME, Lubricate the same as Ladder Guides with Blue Grease KME No zerk fitting on outrigger 299
WEEKLY LUBRICATION Begin on Right Side with ladder in Bed Position Heel Pin Zerk fittings Heel Pin Zerk fittings Aerial ladder heel pin bushing: Start with the right aerial ladder heel pin bushing with the ladder in the bedded position and pump chassis lube grease into the right zerk fitting. Elevate the ladder 10-degrees and pump more chassis lube grease into the zerk fitting Continue to raise the ladder in 10-degree increments and add chassis lube grease at each position until the ladder reaches the 90-degree point. Use a hand pump grease gun and chassis lube grease. Starting on the Right Side, Lube every 10 degrees until you reach 90 degrees. 300
WEEKLY LUBRICATION When you reach 90 degrees on Right side switch to the Left side and lube at every 10 degrees until ladder has been brought back to the bed Aerial ladder heel pin bushing continued: With the ladder in the 90-degree position, change to the left aerial ladder heel pin bushing. Pump chassis lube grease into the left zerk fitting. Lower the ladder 10-degrees and pump more chassis lube grease into the zerk fitting Continue to lower the ladder in 10-degree increments and add chassis lube grease at each position until the ladder reaches the bedded position. Use a hand pump grease gun and chassis lube grease. Do NOT attempt to lubricate the ladder while it is in motion. 301
EVERY SIX MONTHS: a. The aerial ladder shall be cleaned with a solvent-type cleaner to remove all old lubricants and dirt. After cleaning with a biodegradable-type cleaner, the ladder is to be thoroughly washed with water to remove any solvent, and the ladder shall be dried. Particular attention shall be given to those areas where water may be pocketed. b. The turntable rotation ring gear shall be lubricated with chassis lube applied with a brush. Aerial Ladder Cleaning Ladder Cleaning Clean with solvent Remove all old lubricant from ladder Wash with water Thoroughly dry Ladder Lubrication Re-lubricate as per instructions Turntable Lubricate rotation ring gears Chassis lube applied with a brush or spray 302
HYDRAULIC SYSTEM GENERAL KEEP THE SYSTEM CLEAN Contamination causes the majority of system failures. Most hydraulic systems re-circulate the same fluid. Although the system is closed, it is not entirely dirt and chemical proof. Harmful dirt, foreign particles and chemicals may be built in, introduced or produced by wear. Built in contaminants result largely from manufacture of the equipment, and introduce weld, spatter, metal chips, lint and abrasive dust. Introduced contaminants enter the system through seals, dip-stick and breather caps in the reservoir. Lint and other foreign matter enter when the system is opened during parts replacement and filter changes. Chemical contamination is introduced by solvents used when cleaning components. These solvents can easily destroy the effectiveness of the oil. Another source of contamination is replenishing the hydraulic fluid with unfiltered oil. The secret to trouble free operation is proper filter maintenance and clean filtered oil for replenishing. If the system should become contaminated, the best procedure for cleaning the system is to retract all cylinders, remove the oil from the hydraulic tank, and replenish the oil using a filtered system capable of at least three (3) microns (nominal). Change the pressure and return line filters. Operate the unit in-service for at least 20 operating hours. Take a sample and have it analyzed. Change the filters and continue in-service operations. If the system is still contaminated, professional help may be required. Components may have to be removed, cleaned or replaced, and re-installed. This is an expensive and time consuming operation and should only be used as a last resort. Also, the acid level of the oil must be checked. Oil can actually become sour and is actually sour to taste. The proper PH level is7. Oil that has a PH of 6 or below should be replaced. The acid level will deteriorate seals, etc. BE CAREFUL WHEN YOU ADD OR CHANGE OIL Be sure the system is clean each time you change or add oil. If you are simply adding make up oil, be sure that the oil in the system is clean. If not, drain the system as soon as possible. Refill the system with a change of new oil that will give satisfactory performance under existing conditions. When you add or change oil it should be filtered to at least 3-micron nominal. The mixing of oil brands is not recommended because they usually are not compatible. This can cause chemical contamination. If the oil brand is to be changed, then a flushing solution should be used first. 303
WEEKLY LUBRICATION Hydraulic Oil Reservoir The hydraulic oil level in all aerial equipment shall be checked each week and after each extensive or prolonged use. Any contamination of the oil shall be reported to the area mechanic. FILLING With the Aerial device stowed in travel position (all cylinders retracted with ladder in cradle) fill the reservoir within four (4) inches of the top of the tank. Oil reservoir breather, 1/4 turn, do not over tighten Oil dip stick located here, hand tight HYDRAULIC OIL RESERVOIR The hydraulic reservoir provides storage for the Aerialcat's hydraulic system oil. Capacity of the reservoir is 28 gallons. The reservoir incorporates a filler cap with dipstick and drain plug. The tank is equipped with integral baffles that aid in cooling the oil before it re-circulates through the system and also prevents the oil from sloshing during travel. 304
EVERY THREE YEARS: The hydraulic oil in aerial ladder trucks is to be changed. Hydraulic oil reservoir Hydraulic oil dip stick Hydraulic oil reservoir breather Procedure for changing hydraulic oil 1. Set up the unit on level ground with both outrigger and jack cylinders fully extended. 2. Raise and extend the aerial to the fully elevated and extended position. At this point there is oil remaining in the barrel side of the hydraulic cylinders only. 3. Shut down the unit and replace the hydraulic filters. Remove the hydraulic tank lid. 4. Pump out the remaining oil in the tank and wipe clean. 5. Remove the return line and re-route the hose to a waste oil drum to capture the remaining oil in the system. 6. Fill the clean reservoir with new hydraulic fluid. 7. With an operator at the turntable, another person holding the return line in the waste drum start the truck, engage the hydraulics. At the same time have the operator at the turntable pull the retract lever fully. 8. As the ladder is retracting there is new fluid being pumped in the cylinders and the old fluid is being pushed out to the waste oil drum. 9. Once the ladder is fully retracted immediately start lowering the ladder. You must watch the oil level in both the waste oil drum and the hydraulic reservoir. Shut down the hydraulic system to refill the reservoir and empty the waste tank as needed. 10. Once the ladder is set in the cradle shut down the hydraulic system. 305
EVERY THREE YEARS: The hydraulic oil in aerial ladder trucks is to be changed. 11. The turntable operator must then move to the outrigger control station. 12. Turn the hydraulic system back on and have the operator retract the down jacks fully. Watch the oil level in both the reservoir and the waste tank. 13. Immediately retract the outrigger beams fully. 14. Once the outriggers have been retracted fully immediately turn the hydraulic system off. 15. Fill the reservoir to the proper level re-connect the return line back to the hydraulic system and re-seal the lid. 16. Cycle the outriggers and the ladder cylinders a minimum of 10 times each. 17. Change the hydraulic filters and return to service. 18. Re-sample the hydraulic oil after approximately 10 hrs of operation. 306
Lubricants currently available from warehouse GREASE-GUN-CARTRIDGE -14 OZ-HD - By BOX (I13A2) #0409050 LUBRICANT-DRY MOLLY - By EA (I23C1) #0424209 LIQUID WRENCH - By PINT (I35C1) #2854412 LUBRICANT-PENETRANT-11OZ SPRAY - By EA (I16C1) #2462505 307
Lubricants currently available from warehouse OIL-ENGINE-DIESEL-15/40 WT -CMW-55GL - By DRUM (BAY- 1) #0413427 OIL-MOTOR-5W-30/QT - By QT (D3A1) #0413002 OIL-MOTOR-N.DETERGENT -30W/QT - By QT (D4A2) #0413000 308