DRIVER OPERATOR Page 1 of 11 2014 SUTPHEN 100 FT AERIAL PLATFORM The Sutphen Telescopic Aerial Platform consists of an operating platform at the end of a 100 high handrail aerial. The main components of the truck and aerial consist of the outriggers and stabilizers, turntable, boxed construction ladder-way, and a self- contained, hydraulically operated platform. A power-take-off from the main transmission supplies power to the hydraulic pump for the aerial. The aerial has been built to operate at rated capacity at its maximum height and horizontal reach. Several features increase the safety and performance of the aerial including: A safety interlock system that prevents the lifting of the aerial device until all stabilizers are properly set. Tilt-cab construction. An aerial pre-piped nozzle and waterway. Hydraulic generator. Three main aerial controls stations. SUTPHEN CAB This first section will discuss some of the controls and operational procedures located in the cab of the 2014 Sutphen Aerial. POWER PLANT The aerial receives the energy to run its pumps and electrical systems through the Cummins diesel motor. The motor runs the 12-volt DC alternator
DRIVER OPERATOR Page 2 of 11 for the 12-volt emergency lights, flood lamps, nozzle and control stations. It also powers the two hydraulic systems that run the aerial and 120-volt AC generator. The aerial set-up begins in the cab. The road transmission must be placed in neutral before actuating the hydraulic PTO system prior to leaving the cab. Starting the Engine The shift lever must be in the neutral position. Press the ignition switch and allow the self-check to complete before engaging the starter. The self-check is completed after the gauge dials make two full travels and return to the off position. Failure to do so may cause the engine to enter a diagnostic mode delaying starting. Allow the oil pressure to register on the gauge at least 20 PSI before accelerating throttling over 1000 RPM. Lubrication of the free-floating bearings in the turbocharger is required before the turbocharger reaches its maximum speed. Without proper lubrication, damage to the shaft and bearings of the turbocharger can occur. NOTE: Sutphen recommends against house-starting the engine, (i.e. starting the engine to make sure it will run), as a large portion of the engine wear occurs during the first few seconds after starting before the normal flow of oil. Also, condensation on the cold working parts of the engine takes place resulting in corrosion and mixing of water into the fuel. Spotting the Apparatus for Aerial Operations Spotting the truck for aerial operations is a skill developed through study and experience. A poorly positioned truck can limit its use at incidents and a properly placed truck can save lives and property. Where a truck spots is affected by many variables but positioning as close as possible allows for more aerial options. There are fixed and variable factors that affect truck placement and aerial options at fires. Of the fixed factors is the: Layout of the streets, alleys and driveways Overhead obstructions such as power lines The building size Of the variable factors there are: Parked cars and traffic
DRIVER OPERATOR Page 3 of 11 The fire conditions Collapse zones The truck s maximum vertical reach is 100 ft. at 80 degrees which comprises 88 ft. of ladder height plus 12 ft. of truck height. As seen below, as the horizontal distance from the objective is increased the vertical reach decreases. This may or may not be important depending on its mission. If the mission is rescue the importance is obvious. If the mission is nozzle operations the affect is more dependent on variables. Spotting the apparatus 30 to 35 feet from the building will give you the maximum vertical reach. The truck must be placed at least 8 ft. from the building to allow full extension of the outriggers. Spotting the Apparatus at Fires The placement of the truck at fires is very situation dependent. It isn t always known if the aerial will be necessary when we arrive. Planning ahead and placing the truck where it would be needed for aerial operations on arrival will save valuable time if it becomes necessary. Do not place the apparatus in collapse zones. Collapse zones are considered 1 1/2 times the height of the building that may collapse. When in areas of narrow width that do not allow full extension of both outriggers such as alleys, position the apparatus so the outrigger on the side of the fire can be fully extended. The opposite outrigger will need to be short jacked and the aerial will not rotate over that side. Generally, positioning on corners of structures allows the most safety from structure collapse. Spotting the Apparatus at Freeway Incidents The truck is part of any freeway call. The main purpose is to provide a safe working area by positioning the unit to block traffic. The truck should be positioned at an angle to provide a safe exit for the truck crew. It should also be positioned far enough back to provide warning to drivers and a buffer zone for the crews. The front of the truck may be angled in either direction but the tires should be turned so if hit the unit would tend to move in the direction of the tires.
DRIVER OPERATOR Page 4 of 11 Surfaces for Outriggers and Jacks Placement of the outriggers must be on a solid surface. Every attempt to place them on street concrete or asphalt must be made. Make sure the rear jacks or outriggers are not going to sit on a manhole cover, drain or grates in the street or on sidewalks. Sidewalks are designed for pedestrian traffic and will not support the weight of the truck with the aerial over it. If dirt is used it must be hard packed. If the crew is considering placing the outriggers or jacks on anything besides street concrete or asphalt the IC must authorize it. The Captain, Engineer and Incident Commander must re-evaluate the risk profile and determine if the added risk of having the truck on the surface is warranted. Power Take Off (PTO) In order to use the aerial, the Power Take Off supplying the aerial systems must be engaged. The PTO is engaged by a switch in the cab after first placing the transmission in neutral. The button on the gear shift selector labeled MODE engages the aerial PTO. When engaged the PTO receives it power from the engine and this provides hydraulic power to the system it supplies. Generator System Before exiting the cab, engage the generator. The 120 Volt AC generator is hydraulically driven off of the main road transmission. A rocker switch located in the cab turns on the PTO that engages the generator. Steps to Make the Apparatus Ready for Aerial Operations Position Apparatus Engine must be at idle There must be a minimum of 90 lbs. of air pressure in the system Place transmission in neutral Set brake Activate Aerial PTO Activate hydraulic Generator PTO
DRIVER OPERATOR Page 5 of 11 Inter-Axle Differential Interlock The rear axle interlock equalize traction between all rear wheels. It will maintain rigid traction to all wheels under a specific torque range still allowing the vehicle to negotiate turns smoothly. Above that range it will allow slippage to avoid damaging the differential. When engaged do not exceed 15 mph. The interlock is for dirt roads, loose sand, mud or other off highway conditions. Do not engage for normal driving conditions. The interlock should never be engaged after the wheels are slipping. Switch before wheels slip or entering slippery road conditions. When engaging ease up on the throttle to take pressure off the drive line. When the differential is fully locked, the vehicle will slightly understeer causing a larger turning radius. Also, do not keep the interlock engaged when going down a steep grade. Jacobs Brake The 2014 truck is equipped with an exhaust or compression retarder also known as a Jake or Jacobs Brake. It is coupled to the engine exhaust valve train. When actuated, it prevents power strokes from occurring and the engine works as a retarding force on the vehicle. When ON the brake will function whenever foot pressure is removed from the throttle. The Jake brake is a slowing device, not a stopping device. The Jake brake is controlled by a panelmounted switch that turns the Jake ON or OFF. Next to the On/Off switch is a three position control switch (LOW/MEDIUM/HIGH). The setting is generally Engineer preference, however any less than very dry surfaces it should be in low setting or off. Unlike the transmission retarder the Jake brake will operate whenever it is on and the throttle is at 0 percent. It is linked to the ABS and will turn off in cases of an ABS event. All secondary braking devices operate the brake lights when applied. Operating the retarder while driving on a slippery surface can cause a loss of control and a crash. Do not use the auxiliary braking system on wet, icy or slippery roads. During inclement weather, turn off the auxiliary braking systems at the master control switch.
DRIVER OPERATOR Page 6 of 11 Transmission Retarder A second auxiliary braking device on the 2014 Truck is an output shaft retarder. The retarder should be in the off position on wet, slippery or icy road conditions. A transmission retarder provides secondary vehicle braking via the transmission. They are usually more effective than engine brakes at lower RPMs; at higher RPMs they tend to even out. Transmission retarders generate a lot of heat and their maximum braking horsepower is usually limited by the truck s cooling system. Allison s hydraulic retarder is basically a vaned flywheel in the transmission housing. The transmission directs oil into the retarder housing to absorb the vehicle s energy through the drive shaft. The absorbed energy is converted to heat and dissipated through the vehicle s cooling system. If the transmission temperature exceeds 250 degrees a light and buzzer will activate. In this case shut off the retarder with the cab control and adjust driving accordingly. Resistance to the flywheel, augmented by stators on the inside of the housing, delivers braking power to the driving wheels. More oil in the housing means stronger braking. Our retarders are activated by a foot pedal valve and full retarder power correlates to a fully depressed foot pedal. There is an OFF/ON switch for the retarder in the cab. When operated the retarder activates the brake lights. Operating the retarder while driving on a slippery surface can cause a loss of control and a crash. Do not use the auxiliary braking system on wet, icy or slippery roads. During inclement weather, turn off the auxiliary braking systems at the master control switch. Stopping The Engine A hot engine has a great deal of heat stored up in its iron mass. Let the engine idle at 1000 RPM for 5 minutes before shutting down. This will allow circulating coolant and lubricating oil to carry heat away from the cylinder head, valves, pistons, liners, and bearings preventing warping of engine parts due to uneven cooling. Stopping suddenly after a hard run can cause an increase of 100 degrees Fahrenheit. Turbo-chargers are particularly vulnerable to this increase in heat where bearings can seize and oil seals can loosen. Cab Tilt System The Sutphen truck has a tilt cab, which consists of two hydraulically, actuated piston and cylinder assemblies that raise or lower the cab. Two latching cylinder assemblies lock the cab in the down position and release when the cab is raised. The cab when tilted requires 13ft clearance above and 3 additional feet in front. Velocity fuses are incorporated in the cab tilt cylinder ports. They serve to control the cab s free fall rate. The velocity fuses also act as a safety valve to prevent the cab from falling unchecked in case of a system failure, such as a broken hydraulic
DRIVER OPERATOR Page 7 of 11 line. The controls for the cab tilt system are located in the stabilizer control compartment. Locked Unlocked Raising and Lowering the Cab Pushing and holding the cab tilt rocker switch in the UP position raises the cab. This action opens the hydraulic system to the PUSH circuit, releasing the hold-down latches as hydraulic pressure builds up in the cab latch and tilt cylinders. The cab holddown hooks release at a lower pressure than that required to raise the cab. As pressure increases, the cab tilt pistons extend, raising the cab. When fully raised, there is a safety latch on the Captain s side. This latch is designed to prevent the accidental lowering of the cab. When the cab is raised fully, switch the toggle switch to the engaged position to raise the lock. Once the cab lock is in place, the cab is safely held in the open position. Disengaging the cab lock switch located in the stabilizer control compartment, and pushing and holding the cab tilt toggle switch in the CAB LOWER position lowers the cab. WARNING! Before raising the cab, visually check and ensure that ALL equipment is safely secured! Failure to secure all equipment could lead to a broken front window.
DRIVER OPERATOR Page 8 of 11 Freeing a Cylinder Lock-up In the event that a sudden drop of the cab occurs, the velocity fuses will function as safety check valves. The cylinders can be unlocked by actuating the toggle switch in the opposite direction of the fall, then lowering the cab in the normal manner. Example: If the cylinders have locked-up in the free-fall to full tilt position and there are no leaks or broken hydraulic lines, hold the toggle switch in the cab lower position. After unlocking the fuses, hold the toggle switch in the cab raise position. Manual Cab Release Operation The truck is equipped with a manual operation mode for raising and lowering the cab in case of an electrical failure. There is a manual cab lift system located under the front left part of the cab. Inserting the handle, found in the stabilizer control compartment, operates the manual system. The system operates in a fashion similar to a hydraulic floor jack. Close the hydraulic bleed valve, a clockwise turn, then begin to raise the cab by pumping the handle. To lower the cab, depress the cab lower switch in the stabilizer control compartment, then slowly open the bleed valve, a counterclockwise turn. The rate of descent is controlled by the flow of hydraulic fluid. It takes approximately 280 strokes to manually tilt the cab. Cab Warning Devices The safety warning systems in the cab include both lights and audible warning alarms. These warning systems are required for safe operation of the truck. There are several warning light systems in the cab. The overhead Seat Belt Monitor and warning lights Safety check lights Master switch panel. Overhead warning lights Four warning lights above the front windshield provide safety information to the operator prior to moving the vehicle. Left - Compartment door open Second from the left - Cab door open Second from right - Jacks out; a steady light that is always on when a jack is extended Right Jacks down
DRIVER OPERATOR Page 9 of 11 VDR Seat Belt Monitor NFPA mandates a vehicle data recorder and seat belt monitor for fire apparatus. A red light on the indicator panel indicates someone seated without their seat belt on. If the vehicle exceeds 5 mph an audible alarm will sound. It is the policy of the Escondido Fire Department and state law that seat belts will be worn whenever the vehicle is in operation. It is also forbidden to connect the belt behind the passenger in order to circumnavigate the seat belt monitor. If the seat cushion does not sense an occupant for 5 seconds whether someone is there or not the red light will display. The only way to reset the red light is to release the seat belt and re-buckle it. Safety Check Lights There are several warning lights and gauges located on the dashboard/ instrument panel of the truck. Some of these indicators are listed below Check engine will come on with startup. If it doesn t turn off after 5 seconds, the unit must be diagnosed or serviced. Stop engine Notifies the driver when a potentially damaging condition exists such as low coolant or oil. The cause must be determined as soon as possible. High exhaust temperature light- normal when regeneration is occurring do not turn off engine unless exhaust temperature is a concern for nearby flammables. Differential lock light is illuminated when the differential is in the locked position.
DRIVER OPERATOR Page 10 of 11 Parking brakes is illuminated when parking brakes are engaged. Low air warning light is illuminated when the air supply drops below 65 psi. The ignition must be on for the low air system to operate. PTO engaged is illuminated when the PTO is engaged and the brake is engaged. 2 nd PTO is illuminated for the generator PTO High engine temperature. Set at 205 degrees F. If it comes on bring engine to idle and let cool before proceeding. Low oil pressure. Transmission temperature light is illuminated when the oil temperature exceeds 330. Auto Spin Response light illuminates when the system is compensating to improve traction when on slippery roads Retarder engaged, the light is illuminated when the retarder pedal is depressed. Retarder temperature light and dashboard buzzer. The buzzer operates and the light is illuminated when the transmission oil temperature exceeds the safe operating temperature. Upper power light is illuminated when the upper power switch in the stabilizer control compartment is on. Master Switch Panel The master switch panels are located in the overhead area of the cab and next to the gear shift to the right of the driver s seat. Top Row Master emergency switch controls the power to all emergency light switches. The Opticom switch turns off the opticom despite the other emergency lights being on. Allows the warning lights on the cab to be switched off despite the other emergency lights being on. Allows the warning lights on the body to be switched off despite the other emergency lights being on. Allows the alternating headlights to be turned off. Turns on/off the rear scene lights Manual siren versus the electric siren
DRIVER OPERATOR Page 11 of 11 Manual siren brake Bottom Row Jacobs Brake auxiliary braking on/off Jacobs Brake auxiliary brake power settings Transmission retarder auxiliary braking on/off Air horn or electric air horn Manually places engine into a higher idle when in neutral and with the brake set PTO activation for hydraulic generator Silence the backup alarm