WATER TRUCK MANUAL 1300 998 784 STGGLOBAL.NET
2 WATER TRUCK MANUAL Operation Manual Suggested operating procedure.. Page 3 Filling the tank. Page 5 Spray heads Page 5 Self fill/dam fill....page 7 Recommended Maintenance...Page 8 Refilling using tank water.....page 9 Engaging & disengaging PTO & Hydraulics.Page 10 Schematics
3 SUGGESTED OPERATING PROCEDURE Prior to engine start up, it is the operator s responsibility to complete a daily check over the truck. Maintain a log of daily Pre-Start Checklists to ensure all checks are carried out Check the tyre pressures daily - Refer to the tyre manufacturers specifications on the wall of the tyre (max cold 120psi is normal) Check fluid levels - engine oil, transmission oil, coolant Grease all moving parts daily - drive shaft, suspension etc. make sure you have located all grease nipples for your individual truck as positions may vary from truck to truck Check water level in water tank Look for leaks under the truck - oil, water, coolant Check for worn or rubbing hoses on the water tank If the water pump is operated by hydraulics, check hydraulic oil level Check that the hydraulic oil cooler fan is working, the fan will come on when the PTO is engaged, and you will hear it working. (If it is not working DO NOT operate the water pump and report immediately to maintenance, failure to fix will result in serious hydraulic component failure which is very expensive) Grease PTO Shaft daily - the shaft from the PTO to the water pump / hydraulic pump. (The PTO is mounted on the side of the transmission) REPORT ALL FAULTS TO THE MAINTENANCE DEPARTMENT BEFORE COMMENCEMENT OF WORK Upon starting the truck, check the AIR PRESSURE gauges to assess air pressure. If the air pressure is not sufficient, due to leaks in the truck s air system, allow the truck to idle until full air pressure is achieved. This will be indicated on the gauges. Gear selection in an AUTOMATIC truck when pressure is low will not be possible, and engaging PTO while pressure is low will cause the sprays on the water tank to leak water as they require a full air supply to close them. It is important to know the trucks height, failure to be aware of this could lead to damage to the truck and even public property, for which the operator is responsible -The height of the truck is to the absolute highest point, which would include ROPS (if fitted) and any beacons mounted to it. Refer to the warning and advisory stickers, located above the driver s seat, they are there for your safety and others around you.
4 Ensure truck has enough fuel (diesel) to carry out the days requirements as running out of fuel can cause damage to the trucks engine, which can be costly, and also has the potential to cause an accident, for which the operator would be responsible. Once the above has been CHECKED and OBSERVED, operation of the truck/water cart can commence. To select GEAR (if automatic), place foot firmly on the brake pedal and select the gear required on the transmission pedestal, if the truck has a MANUAL gear box normal manual gear box procedures apply. *NOTE: The park brake must be released for an AUTOMATIC transmission to be able to select gear. To engage the PTO, (it is important that this be done at a very low truck speed i.e. no more than 10kph) locate the PTO switch, which will be found on the dash to the left hand side (should be clearly labeled) and switch it to the ON position. *NOTE: Prior to engaging the PTO, be sure that the water tank has enough water, if the PTO is engaged while tank is empty; failure of the water pump could result. Inspect water level on the indicators on the water tank, which are positioned at the front driver s side of the water tank and also at the passenger side rear of the tank. Once water level has been checked, and the PTO is engaged, select the required switch for the job at hand, which is located on the CONTROL BOX and engage it. Water volume will depend on ENGINE RPM. *NOTE: Truck should not be revved at more than 1800-2000rpm, as this is not required. Best performance for the water pump fitted to this truck is between those ranges. To dis-engage the PTO, ensure that all switches on the control box are in the off position and once again at low truck speed around 10kph, switch the PTO to the OFF position. ***It is very important to switch off the PTO when it is not required. PTO s are not designed to travel long distance at high speed.***
5 FILLING THE TANK There are 3 options for filling the water tank. OPTION 1: Hydrant Fill The port for hydrant fill is located at the rear of the tank on the passenger side, it is visible by the 3 brass valve. Remove the camlock cap, connect the fill hose to the camlock and connect the other end of the hose to the hydrant. Turn hydrant on and allow the tank to fill, using the water level indicator as a reference. *NOTE: Use of hydrants requires permits be sure yours is current as fine may apply. OPTION 2: Overhead Fill This is mainly used on large construction sites. When using overhead fill observe site rules in regards to filling, and follow them. A large funnel on top of the water tank accommodates this method of filling. OPTION 3: Self Fill / Dam Fill The water truck is equipped with this option. Please refer to the Self Fill/Dam Fill procedure page, which is in this folder. Please read instructions for this procedure carefully. SPRAY HEADS ALL SPRAY HEADS The spray heads fitted to the tank have an adjustable collar on them which enables you to adjust the volume of water you require. The spray heads are fitted to the tank with the collar in place at its finest adjustment, so that each customer can adjust them as required.
6 If the water volume is not sufficient to complete the task at hand, simply loosen the single bolt that is holding the collar in place and slide it down to open up the mouth of the spray head OR remove the collar all together. FRONT SPRAY HEADS Depending on your requirements the simultaneous use of both front sprays will provide good water volume with relatively good pressure, but if greater pressure is required for other purposes, it is advisable that only one spray be used.
7 SELF FILL/DAM FILL This truck is equipped with self / dam fill. To operate this feature there is a toggle switch on the main control box inside the cab. See warning below before using this method. STEP 1: With the PTO disengaged, flick the toggle switch down, which will close off suction from the tank. Remove the camlock cap from the suction port on the front driver s side of the tank. Connect the hose onto the camlock at the front of the tank on the driver s side and place the other end of the hose into the water source. STEP 2: Flick the toggle switch up to open the suction port, this primes the suctions hose (leave it in the open position for about 5 seconds). After 5 seconds, engage the PTO and then flick the toggle switch down again to close the suction port. The tank will start filling. Once the tank is full, disengage the PTO, disconnect the hoses, refit the camlock cap and then flick the toggle switch back up which will open the suction port and the truck is ready for use. Warning. WHEN YOU ARE FILLING THE TANK USING THIS METHOD, IT IS IMPORTANT THAT THE TANK IS NOT COMPLETELY EMPTIED PRIOR TO RE-FILLING. WATER IS REQUIRED TO BE LEFT IN THE TANK FOR PRIMING THE SUCTION HOSE. FAILURE TO DO THIS WILL RESULT IN AIR LOCKS IN THE PUMPING SYSTEM! ***
8 RECOMMENDED MAINTENANCE This information does not act to replace the routine maintenance suggested by the vehicle manufacturer. It is additional maintenance required for optimal operating efficiency and longevity of your Water Truck. Inspect water pump daily for leaks Inspect water hoses often for wear/rubbing If the water truck is running a hydraulic system for the water pump, check the thermo fan daily Check hydraulic fluid levels daily Service hydraulics every 6 months using Hydraulic 68 oil If the tank is fitted with water cannon, be sure to check the mounting bolts often for tension. Cannons are fitted with grease cartridges, ensure that the cannon always has a grease supply to all moving parts Check for any air leaks throughout the air system (All sprays and valves are fitted with 6mm airline) It is a good idea to check the tension of the tank mount bolts often PTO SHAFT Greasing of the PTO shaft is vital for the long life of this component. Failure to grease the PTO shaft will result in premature wear of the uni s and in turn failure of the water pump. If the uni s fail, this creates vibration, which goes through, the pump shaft and destroys the bearings (x2) and the pump seal (x1). REMEMBER, if the pump fails, the water truck is useless. Note: The PTO shaft should be ideally greased daily or at least every 2 nd to 3 rd day. TANK INSPECTION On the top of the tank are 2 inspection ports. These ports are fitted with mesh grates to prevent debris from entering the tank. However, depending on the method of filling the tank, small rocks and other foreign matter does make its way into the tank. As the impeller on the pump is cast alloy, they are easily damaged, therefore cleaning the tank OR checking the tank often for cleanliness is of great importance. DRAIN AIR TANKS DAILY Draining the air tanks on a daily basis is important, not only for the sake of the truck, but also for the air system which has been fitted to the truck to operate the spray heads etc.
9 Failure to drain air tanks daily may not only void any warranty that might be available from the manufacturer, but will also cause premature failure of the components which have been fitted. AIR REGULATORS This truck has been fitted with twin air regulators, which control the air pressures required for different needs of the water truck. These air regulators are fitted with water traps, which catch any water in the system before it enters the control box, which is located in the cab of the truck. If these water traps are not drained often, water will enter the control box and cause the air toggle switches to fail. Therefore again rendering your water truck as useless. REFILLING USING TANK WATER STEP 1: To use water from the tank, make sure that the valve on the front driver s side of the tank is in the OPEN position. This is the port where the pump draw s its water from. Refer to Picture No. 1 Picture No. 1
10 STEP 2: When using water from the tank, the valve at the rear of the tank on the driver s side must be in the CLOSED position. If this valve is open, no water pressure will result, as the water will be continually circulating. Refer to Picture No. 2 * WHEN USING TANK WATER, FRONT VALVE IS OPEN, AND THE REAR VALVE IS CLOSED Picture No. 2 ENGAGING & DISENGAGING PTO AND HYDRAULICS ENGAGING It is best to engage the PTO with the truck in a stationary position. But it can also be engaged with the truck moving at a slow pace (around 10kph). Once the PTO is engaged, the hydraulics needs to be switched on. The switch for the hydraulics is located on top of the control box, which houses the switches for the tank s sprays etc. The hydraulic system fitted to this truck is set up with dial up. This allows the operator of the truck to adjust the amount of water required for the task at hand. The dial up controller has a range from 0% to 100%. The optimum performance is around 80%, but going beyond that won t cause any harm to the hydraulic system.
11 DISENGAGING To dis-engage the PTO and Hydraulics, turn the dial up controls to 0% and switch the power switch off, (the red light will disappear), then switch off the PTO. It is important to dis-engage the PTO and Hydraulics once watering is not required. Failure to do so could result in system overheating and costly repair.
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