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Operations and Maintenance Manual

1. 38 SYSTEM COMPONENTS E D eee vee 38 TRANS NME TON 39 SHIFT SELE C TOR ae 39 ODECHBCR PROCEDURE 39 DIAGNOSTIC INCIDENT DISPLAY 39 TRANSMISSION COOLER eov 39 CHE E Soannen 40 ELECTRICAL aaa 40 CUIT ER T REC EE A T A EEA 40 PATI NR 40 INTERIOR LIGHTING eesesesesesesesesecesecscscseseseseseseseseoecsoscsosesesesesesesesesesececscsesesesesesesesesesessoscscsesesesesesesesesesssscseseso 41 CAB FRONT OV SEE iuo 41 CAB REAR DOME LAMPS RR m 41 Operations and Maintenance Manual Custom Fire Truck Cab amp Chassis Models Rev Aug 2004 LIGHT BULB REPLACEMENT 4 CAB INTERIOR 42 CATET 5 E S 43 CAB TMLT OC OR raps 43 Ree ble tct ap TIT FP 43 43 UAE 77 44 PUTA 44 45 BELT MAINTENANCE REPLACEME
2. 29 HOD O E E E EE E E E O EE E E 29 Turn Signal Lever and High Beam 29 Operations and Maintenance Manual Custom Fire Truck Cab amp Chassis Models Rev Aug 2004 Hazard Four Way Flashers GENERAL INSPECTION AND MAINTENANCE 20 Maintain Steering Column Joint 29 Maintain Hydraulic Power Steering esses ehe senen nnn nene essen nnn eese sena annee esses 30 JU WN SONIS r 30 CUMMINS DIAGNOSTIC CENTER cccccccccccccccccccccccccccccccccccccccccccccccccccccccccccccccccccecccccccccccccesccccccocces 31 IDLE ADJUSTMENT SWIM H 31 Vy A T LO EIE RD I EE 31 ABS TEST SWITCH WITH INDICATOR LIGHTS eere ecccscceccecceccscescesceeccescescescescesceeseescescescascees 32 PUB PRIMER BUTTON OPTIONAL J ta oet To SEE a 32 ILE EAN 32 1818 8 HW PS LAC C M TM 32 BRAKE OPERATION E 33
3. 51 MAINTENANCE SCHEDULE Feed ustut usus vos bdd ru usa 54 OUO Mies 54 ISI 55 VELVET DT oa 55 A 35 SOOO MAES OF 3 MONTS RRTRRR Rw u A AKeM A 55 Miles Or IV ERNRTRRTRPR 56 6 000 Miles or O 7M ORB 57 S O00 VSO 57 DUU Miles or O MOntNS does 56 12000 Miles 58 IS OCU Miles PORRO Tm 59 20 000 Miles 1S CC 59 24 000 Miles or L2 MONIN S 59 23000 Miles or E MONS RETE 59 23 000 Miles or 12 MONIN S eissien tee ENE EEEE EE TE E EEA e e a aa e aa e aria 60 48 000 Miles or 24 MonthS tiva beds ium capud 60 50 000 Miles or MONS 6l 30 000 Miles EB m 61 100 000 Miles OF AZ 61 200000 Miles OF 24
4. Og ett te ttt tt tt Z g t n t O LL Q LLI A 0 gt t e o 14 gt e c c 2 Operations and Maintenance Manual Custom Fire Truck Cab amp Chassis Models Rev Aug 2004 6 Rejected Log Problem Corrected Added Oil Changed Bulb etc Acceptable LEGEND A B C WEIGHT INFORMATION It is important that drivers and maintenance personnel understand weight rating terminology as described below For safety and proper chassis function it is critical that The axle and tire wheel weight ratings are not exceeded Proper tire pressures are maintained The major chassis components supporting the vehicle not to be changed replaced by components with lower ratings e g tires TIRE PRESSURE lire pressures must be monitored closely to assure safe operation of the vehicle Spartan Chassis Inc recommends checking tire pressure daily when the vehicle is in service It is important to understand that a change in weight distribution or the amount of weight added or removed from the vehicle may require a change to tire pressures Refer to the Gross Axle Weight section of this manual and the tire manufacturer s manual for details GROSS VEHICLE WEIGHT RATING GVWR The GVWR is the rating established by Spartan Chassis Inc as the maximum weight of the vehicle including cargo passengers liquids etc or th
5. 11 Open for three optional 2 read only eene eene nnne eeenen nnn n nnne s essa nnne ess nnns 11 CET CIEOTZTGM T 11 STOP 12 TUUS Sr NC 12 DUNO 12 TD SIGUE OC o 12 Normal Engine Shut P 12 Emergency Engine Shut Down 12 qc 13 BREINER S CON SOLE 13 Heating and Air Conditioning aE EE ENNE E ESEE E A EEE 14 Iluminat on E E AA E E EARE E 14 E T COTTON E AEE ET 14 Operations and Maintenance Manual Custom Fire Truck Cab amp Chassis Models Rev Aug 2004 Automatic Traction Chains 1 14 e 14 Secondary Brake On Off Switch optional 14 Electric Remote Mirror Switch hehe nnne nenne ss sssee nnn nnne nennen nns 14 EGGS v YX 14 Master Warmin e
6. ssssssssscscccccccccccccssssssssscscsccccscccscsssccsssesees 4 BEFORE GETTINGIN CAB T 4 BEFORE DRIVING AWAY mw 4 WRIGHT INFORMA TION m EEEE EE 7 TIRE PRE URE NE EE E E E EAE N E E 7 GROSS VEHICLE WEIGHT RATING esee eene eene eene nennen nenenee nene te nennen nete nene nnne enne nnns d GROSS VEHICLE WEIGHT GY WE 7 GROSS AXLE WEIGHT RATING t dex pasa nad vata n des paene Evae sede x a apad 7 GROSS AXLE WG GW 7 TOVIN Co HOMI 8 CONTROLPANE eC E EA E 9 INSTRUMENT PANE E aa O 9 24 Dead Front Warning Lights in 9 Low Oil LCV CLIN GICAIOP T 9 Buit 9 Speedometer with LCD Trip Odometer 10 Tachometer with LCD Engine Hour 10 3 In One Combo Gauge with Large Fuel Gauge Primary and Secondary Air 10 4 In One Combo Gauge with Coolant Temp Oil Pressure Voltmeter and Transmission Temp 10 UV Ha UU TNNT CE
7. 95 C Pressure Cut In 105 psi 5 psi 725 35 kPa Cut Out 130psi 5 psi 895 35 kPa Voltage 13 2 14 0 Volts Operations and Maintenance Manual Custom Fire Truck Cab amp Chassis Models Rev Aug 2004 DRIVER OPERATIONAL PROCEDURES amp PRACTICES The following information is provided as a guideline to assist the driver with vehicle operation BEFORE GETTING IN CAB Insure Drivers Daily Inspection is complete and approved for service A Drivers Daily Inspection Form is available on the following page It may be copied and or altered to accommodate custom usage by the owner operator The appropriate fluid must be added per the engine and transmission manufacturer recommendations with additional information available on the data tag inside the cab If optional auto ejects are not used unplug electric and airlines connected to apparatus e Insure that all personnel understand the 3 points of contact for entering and exiting the cab sately while facing the steps BEFORE DRIVING AWAY e Place master switch in the on position the battery on indicator lamp will light Place the ignition switch in the on position the ignition on indicator lamp will light The instrument gauges and warning buzzers are activated including accessory items such as the heater The telltales in the instrument panel briefly illuminate when the ignition is turned on to check lamp function
8. Auto Mode The setting activates the appropriate system Conditioner or Heater regulating the front and rear fan speeds to achieve the preset cab temperature A C Mode the air conditioning system is activated and the air damper 1s open to allow cooled air to flow into the main portion of the cabin Defrost Mode the heater valve is activated and the air damper is closed to allow all heated air to pass over the windshield This mode should be used whenever there is build up of ice on the windshield Heat Mode the heater valve is activated and the air damper is opened to allow the heated air to flow into the main portion of the cabin Defog Mode the heater valve the air conditioning system the freon compressor and the air damper are activated to allow warm dehumidified air to pass over the windshield This mode should be used whenever there is an excessive build up of condensation on the inside of the windshield 7 HIGH IDLE BUTTON The manual activation deactivation for the high idle control is the green button on the far right of the Vista Display To activate high idle the transmission must be shifted into neutral range the parking brake set and the fire pump disengaged The display screen shows lt High Idle Locked gt indicating that the high idle cannot be activated until the above conditions are met To deactivate the manual high idle the operator may depress and hold the service brake pedal pre
9. An optional multiplex data communication system utilizes the Vista Display that maintains many switch configurations and provides extensive information Refer to the Vista Display Controls section for additional information Heating amp Optional Air Conditioning Headlight Secondary Controls for Headliner Master Switch Brake On Off Switch Evaporator Warning Traction Chains Optional DRIVER S MAIN Automatic N CONSOLE L CONSOLE Wiper Washer Control Instrument Illumination Intensifier Optional Electric Remote Mirror Switches Operations and Maintenance Manual Custom Fire Truck Cab amp Chassis Models Rev Aug 2004 13 HEATING AND AIR CONDITIONING CONTROLS Refer to the Heating and Air Conditioning Controls section These are present with a headliner mounted evaporator only INSTRUMENT ILLUMINATION INTENSIFIER Push rocker to brighten dim instrument illumination WIPER WASHER CONTROL Push lever down to turn on or shut off wipers Move lever up for high speed or down for intermittent feature Push lower button for wash cycle The washer fluid tank fill 15 located in the driver s step or behind the grille AUTOMATIC TRACTION CHAINS OPTIONAL The operating range is 0 to 35 mph and may be engaged at a speed range of 0 to 25 mph Refer to the tire chain manufacturer s manual for maximum speed HEADLIGHT SWITCH Push rocker to first position for parking lights Push rocker to the second position fo
10. Inspect And Clean Radiator Inspect Radiator Hoses Wheel Nut Torque Clean Bugs Leaves Or Other Material From Radiator Core Inspect Radiator Core For Damage Or Leaks Inspect Radiator Cap For Worn OR Missing Gasket Check Radiator Hoses For Leaks Cracks Soft Spots Or Loose Clamps Refer to Initial wheel nut torque must Wheel Service be checked at the first 50 Manual miles 12 000 MILES OR 12 MONTHS Check Or Service Vendor Ref General Information Change Engine Fuel Filter Change Fuel Water Separator Filter Inspect Power Steering Pump and Steering Gear Adjust Steering Gear Relief Plungers Inspect Engine Block Heater Inspect Heater Water Hoses Check Anti Freeze Concentration Refer To Engine Setvice Manual Refer To Engine Service Manual Refer To Power Required Steering Service Manual Refer To Power Check For Leaks Repair If Steering Service Inspect Parts For Deterioration Damage Or Loose Connections Check Hoses For Deterioration Damage Leaks Or Loose Clamps 50 50 Glycol And Water Mixture Operations and Maintenance Manual Custom Fire Truck Cab amp Chassis Models Rev Aug 2004 58 18 000 MILES OR 5 MONTHS Check Or Service Vendor Ref General Information Lubricate Front Axle King Pins Refer To Axle Lubricate With NLGI 1 Manual Or LGI 2 EP 1 Or EP 2 Grease Lubricate Front Axle Tie Rod Ends Refer To Axle Lubricate With NLGI 1 Manual Or LGI 2 E
11. air hole Avoid grease leakage Mechanical Check at 3 000 Maintenance miles No abnormal play rotor stator X Tighten bolts amp screws X Check every 6 000 Check miles 24 000 miles X X X LX X Electtical Maintenance Check at 3 000 Check evety 6 000 Check every miles miles 24 000 miles X Wiring insulation Coil connections Tighten connectors X condition tightness Contactor box Cutoff switch Indicator lights Operations and Maintenance Manual Custom Fire Truck Cab amp Chassis Models Rev Jan 2005 37 COOLING SYSTEM OPERATION AND INSPECTION The following should be inspected and maintained to avoid engine overheating Check fluid level mixture concentration and PH factor Refer to the engine manufacturer s operation and maintenance information for proper fluid specifications When the coolant is cold the coolant level should be at the FULL COLD mark If the coolant is not at this level you may have a leak in the radiator hoses heater hose radiator or somewhere else in the system Check radiator hoses heater hoses and clamps for cracks and or leaks Check condition of fan drive belts always use proper belt tension gauge per belt application Keep radiator core clear and clean NOTE Use of high ait ot water pressure can damage core fins Ensure that recirculation shields are in position and undamaged Inspect ait cleaner element it must be clean and unrestricted Inspect ait
12. 3 Connect Electric and Air Lines to Shore Source The engine stop control is through the ignition switch it cuts power to the fuel solenoid or microprocessor module EMERGENCY ENGINE SHUT DOWN OPTIONAL The emergency shutdown flapper is located in the air intake It is designed to shut down the engine in a fuel vapor cloud where the vapor could enter the air intake and cause the engine to race To activate lift the guard and throw the switch Before resuming operation flapper must be reset and charge air hose expansion rings may need to be repositioned To reset rotate the flapper arm and check adjust if necessary the expansion ring position on all charge air intake hoses Operations and Maintenance Manual Custom Fire Truck Cab amp Chassis Models Rev Jan 2005 12 Pull valve to apply parking brake after vehicle is stopped e push to release until valve stays in and park lamp goes out in warning lamp cluster NOTE The valve will not release until the air system maintains a minimum of 60 psi DRIVER S CONSOLE Switch positions and console layouts may vaty based on console design and customer requested options Not all controls described in this section are included with every product Some controls are optional equipment For supplemental operating information relative to the completed vehicle refer to the respective apparatus builder s literature and component manufacturer s literature
13. Thoroughly Wash Complete Chassis Underbody and Cab Run A C System to Lubricate Components Check Brake Adjustment Slack Throw Inspect Transmission Oil for Contamination of Water Glycol 50 Miles amp after wheel installation Check and Retorque Wheel Nuts U PIO OU 4 LL IEEE 000 Miles or 1 Month Inspect Condenser Coil Inspect Clean A C System Air Filter Inspect Compressor Belt Check Tension Check Condenser Fans for Damage and a Quiet Smooth Operation Lubricate Chassis Inspect Brake Components including brake linkage Lubricate Brake Treadle Valve Hinge Pin Lubricate Axle King Pins Check Front Spring U Bolt Torque Check Rear Spring U Bolt Torque Check Torque Arm Bolt Nut Torque Check Torque Arm Clamp Nut Torque Inspect Spring Pin Locking Bolt Inspect Spring Pin And Bushing Wear Lubricate Spring Pin Inspect All Suspension Components for Damage or Misalignment Inspect Shocks for Damage or Leaks Check Air Suspension Components Torque if Necessary Inspect Drive Shaft for Damage Lubricate Driveline Universal Joints Lubricate Driveline Slip Joint Check Front Axle Wheel Bearing Oil Lubricate Driveline Bearing Assembly Inspect the Air Brake Chambers and Hoses And Check for Proper Operation 000 Miles Break in Only Adjust Front Axle Wheel Bearings Lubricate Front Axle King Pins Lubricate Front Axle Tie Rod Ends Lubricate Cab Hold Down Latches Lu
14. 15320 8 18 OI Dd ual D ed 8 c nee 33 SLACK ADJUSTER INSPECTION wesscaencdnceacisdoncevendindddaueveavslveseaddesnigondesnedOedeisusendedlensuedddandevciosloadindedestovccalnedenddsabievracs 33 CHECK OPERATION OF THE AIR BRAKE SYSTEM cece cccccccnccecceccccesccsccecceccescscescesceeceeseescescscescees 34 AUXILIARY BRAKING iio 02 0 135 2 02509215 0959222202298 82 025222220200 522015 60100022220 80 020 0 f 0 0 0 00 00 20 0 0 040 35 EXHAUST OR COMPRESSION BRAKE OPTIONAL eee 35 IRL T 35 820001 CAD 35 TRANSMISSION OUTPUT RETARDER OPTIONAGL eee emen nnn 35 IR TL OU 35 SAE LS terry 35 ELECTRIC DRIVELINE RETARDER OPTIONAL eee nennen 36 IR edi E R M 36 QUICUM T P 36 Mamtenance Jor Telma Ketard ery 37 COOLING SYSTEM essesesscsesccsesesecseseccesesecsesececseseosesecccsesecccsescosesesecseseoccsescosesesecseseoscsessosesesecsesessesescoseseseeseseosesese 38 OPERATION AND INSPECTION
15. M 62 O weet 63 Operations and Maintenance Manual Custom Fire Truck Cab amp Chassis Models Rev Aug 2004 CHASSIS APPARATUS INTERFACE As a custom manufacturer of cab and chassis products Spartan Chassis Inc Spartan Chassis 15 committed to providing a high quality product to our customers Spartan Chassis works closely with the Apparatus Manufacturers to insure that system integrity is preserved and that the retail purchaser is presented with a quality product It is important to understand that not all information 1n this manual will apply to every unit manufactured Some features are optional Refer to the appropriate apparatus manufacturer s literature for additional information Guidelines for apparatus interface requirements are provided to our Apparatus Manufacturers as published in the Fire Truck Apparatus Builders Manual MAINTENANCE RECORDS It is the owner s responsibility to keep accurate maintenance and repair records including receipts Should the lack of required maintenance be the reason for repair a warranty claim will not be accepted Spartan Chassis reserves the right to request your maintenance and repair records for verification of compliance with required maintenance practices and intervals Spartan Chassis recommends that the maintenance and repair records receipts be maintained as permanent records and kept with the vehicle Acceptable records include
16. Ground Lts Diamond Optics Truck Lite 40203 Sealed Unit 4 Tilt Switched Tunnel Lt Truck Lite 40223 Sealed Unit 1 Diamond Optics Step Light Circular Optics Truck Lite 40244 Sealed Unit 4 Step Light Diamond Optics Truck Lite 40203 Sealed Unit 4 Turn Guide Arrows GE Lighting 1157 Push amp Twist Asm 2 Turn Guide Arrows Whelen 60AO00TAR LED Asm 2 Warning Lights Varies Mfg Catalog Varies NOTE When replacing Halogen and Strobe bulbs it is recommended that gloves or a cloth be used to avoid direct contact with your hands Operations and Maintenance Manual Custom Fire Truck Cab amp Chassis Models Rev Aug 2004 41 CAB INTERIOR Location of Lamp Battery On Ignition On Rocker Switch Panel Back Light Door Panel Lights Door Header Red Clr Lt Open Door Beacon Light Center 3 Way 2 Swivel Dome Lt Center 2 Way Non Directional Lt 7 Inch Round Dome Light Map Light Varies Manufacturer Romar Romar Romar Weldon Weldon Weldon Weldon GE Lighting Truck Lite A Type of Base Qty 12 26 Push In 1 12 26 Push In 1 Varies Contact Mte LED Asm as required 93 Plug In 4 921 Plug In 4 1076 Push amp Twist 1 1003 Push amp Twist 2 921 Plug In 1 1156 Push amp Twist Varies See Mfg Catalog 42 Operations and Maintenance Manual Custom Fire Truck Cab amp Chassis Models Rev Aug 2004 CAB TILT SYSTEM WARNING Before raising or lowering the cab safety precautions must be taken to avoid personal injury equi
17. If equipped with a Low Oil Level indicator switch wait 20 30 seconds before starting the engine If the indicator light comes on the oil level may be low Check the oil level with the dipstick If the engine has been recently running be sure that the oil has had time to drain back into the pan e Depress engine starter button to crank engine Release button when engine starts e Insure that all personnel have seat belts fastened Observe door ajar lamp for any open doors or cab tilt lock down warning indicator is optional not secured e Allow oil and air pressure to build to normal operating range NOTE Turn signal and high beam lamps will not automatically bulb check they may be checked by activating the turn signals and high beams Battery voltage appears on the voltmeter As a quick check to ensure the charging system is functioning compare the voltage reading before the engine is started to the reading after it is started The reading while the truck is running should be higher Adjust driver s seat for pedal position comfort e Check mirrors for adjustment Adjust steering wheel telescopic and tilt to a comfortable position Turn head light switch on and lift turn lever for high low beam to accommodate night driving Operations and Maintenance Manual Custom Fire Truck Cab amp Chassis Models Rev Aug 2004 4 e If conditions require turn on wipers by depressing lever toggle lever up for fast and down fo
18. Start engine and build both air systems to full system capacity approximately 120 130 psi Shut the engine off NOTE System 1 should build up to 90 psi before system 2 starts to change STEP 2 Drain the air from system 2 After the air is drained from system 2 apply the brake pedal The rear brakes should function The park brake valve must be in the off position to perform this test STEP 3 Start the engine and recharge both systems to full capacity approximately 120 130 psi Shut the engine off STEP 4 Drain air from system 1 After the air is drained from system 1 apply the brake pedal The front and rear brakes should both work The park brake valve must be in the off position to perform this test If the truck is not equipped with self adjusting wedge brakes P type S cam with automatic slack adjusters or self adjusting disc brakes then visually inspect brake function by observing slack adjuster travel Travel should not exceed dimension in chart on previous page refer to the appropriate manufacturer s maintenance manual for proper adjustment NOTE Park brake system is integral with rear brakes and they MUST be properly adjusted to insure hold power IF THE BRAKES DO NOT FUNCTION AS DESCRIBED ABOVE CONTACT SPARTAN CHASSIS IMMEDIATELY Operations and Maintenance Manual Custom Fire Truck Cab amp Chassis Models Rev Jan 2005 34 AUXILIARY BRAKING EXHAUST OR COMPRESSION BRAKE OPTIONAL DESCRI
19. THE ELECTRIC HYDRAULIC PUMP BY DEPRESSING AND HOLDING THE UP BUTTON ON THE REMOTE PENDANT provided with the cab chassis The Run cr M UE uL mH x E 4 ENERGIZE THE ELECTRIC HYDRAULIC PUMP BY RELEASING THE UP BUTTON plate must be secured in a location close stotage place of the remote A WARNING PERSONNEL MUST STAY CLEAR FROM UNDER CAB WHEN LOWERING CAB OR PERSONAL INJURY WILL OCCUR pendant to allow visibility prior to each pendant usage CHANISM BY PULLING THE SUPPORT RELEASE CABLE THE CAB MAY NEED TO FIRST BE CH IN ORDER TO REMOVE THE LOAD FROM THE SAFETY SUPPORT MECHANISM RELEASE SAFETY SUPPOR RAISED APPROXIMATELY ONE HILE PULLING ON THE SUPPORT RELEASE CABLE ENGAGE THE ELECTRIC HYDRAULIC CIRCUIT BY DEPRESSING AND HOLDING E 0 W G THE DOWN BUTTON CAB WILL SLOWLY LOWER RED INDICATOR LIGHT ON REMOTE PENDANT WILL LIGHT SUPPORT SAFETY CABLE MUST BE RELEASED ONCE SUPPORT CHANNEL IS CLEAR OF TOP OF CYLINDER HOUSING WHEN RED INDICATOR LIGHT TURNS OFF BOTH CAB LOCKS WILL BE FULLY ENGAGED DE ENERGIZE THE ELECTRIC HYDRAULIC C E R P BY RELEASING THE DOWN BUTTON ENDANT CONTROL AND STOW 1 2 3 4 9 NOTE THE SPEED AT WHICH THE LOWERS IS PRE SET AND CANNOT ADJUSTED 0871 001 CAB TILT PROCEDURE REMOTE ELECTRIC CAB TILT PENDANT The red light on the pend
20. and PH Factor Change Fuel Water Separator Filter Change Engine Fuel Filter Lubricate Steering Slipshafts Lubricate Brake Treadle Valve Hinge Pin OOOO OUL Page 2 12 000 Miles or 12 Months cont Adjust Steering Gear Relief Plungers Inspect Power Steering Pump and Steering Gear 18 000 Miles or 5 Months _ Lubricate Front Axle King Pins Lubricate Front Axle Tie Rod Ends Lubricate Brake Treadle Valve 20 000 Miles or 18 Months Lubricate Steering Slipshafts Replace Pleated Paper Filter in Air Compressor if Equipped 24 000 Miles or 12 Months _ Adjust Engine Valves Inspect Drive Belts Check Drive Belt Tension and Tensioner Bearing 25 000 Miles or 3 Months Inspect Air Brake Air Dryer Lubricate Brake Valve Foot Operated 25 000 Miles or 12 Months Change Automatic Transmission Fluid And Filter Inspect Automatic Transmission Vent Inspect Automatic Transmission Cable Inspect Front Axle Alignment and Component Wear Inspect Wheel Bearings 48 000 Miles or 24 Months Drain Flush and Replace Engine Coolant Inspect Engine Vibration Dampener 50 000 Miles or 3 Months Lubricate Brake Slack Adjuster shoe 50 000 Miles or 6 Months Inspect Air Brake Air Dryer for Proper Operation Inspect Air Compressor Discharge Head Clean and Lubricate Air Brake Treadle Valve Operations and Maintenance Manual Custom Fire Truck Cab amp Chassis Models Rev
21. be set to the same Priority Level Operations and Maintenance Manual Custom Fire Truck Cab amp Chassis Models Rev Aug 2004 19 MULTIPLEX VISTA DISPLAY OPTIONAL The Vista Display 15 utilized with a multiplex data communication system It 15 located in the dash or mounted on a rotating pivot device on the center console It provides access to most of the switching functions for electrical lighting and climate control on the vehicle Back lighting is activated when the headlamp switch is turned on At that time the main display screen dims to accommodate the change with the lighting environment The time is displayed in the upper right corner of the message bar The center area of the display may be programmed to show general information such as temperature settings and an illustrative top view of a fire truck that indicates when a door is ajar Operations and Maintenance Manual Custom Fire Truck Cab amp Chassis Models Rev Aug 2004 20 Spartan Chassis Set Temp Outside 567 Backup Alarm Disable E Master Warning Home System Secondary Heat High Idle Lt Menu Info Menu A C e 1 3 4 5 6 7 C VISTA DISPLAY CONTROL BUTTONS ITEMS 1 7 There are five menu option buttons items 2 through 6 and two control buttons items 1 and 7 on the lower panel of the Vista Display housing An indicator light above each button illuminates when the function is activated by depressing the corresponding
22. cleaner intake cap or spatk arrestor for cleanliness Inspect exhaust system for restriction no crushed areas in pipe Inspect fan blade and shroud no pieces missing in shroud or loose blade SYSTEM COMPONENTS Coolant Surge Tank Coolant Surge Tank Pressure Cap 15 PSI Low Coolant Alarm Coolant Sight Glass Engine Coolant Fan FULL COLD Matk HmBUOwWwr Operations and Maintenance Manual Custom Fire Truck Cab amp Chassis Models Rev Aug 2004 38 If an overheated engine condition exists engine converts to an overheat protection mode which alternates firing groups of cylinders to help prevent engine damage In this mode you will notice a loss in power and engine performance This operating mode allows your vehicle to be driven to a safe place in an emergency NOTE To avoid engine damage After driving in the overheated engine protection operating mode allow engine to cool before attempting any repair The engine oil will be severely degraded Repair the cause of coolant loss and change the oil CAUTION Heater and radiator hoses and other engine components can be very hot Do not touch them CAUTION Never remove radiator cap while coolant is hot Remove cap slowly when coolant is at ambient condition A sudden release of pressure from heated cooling system can result in serious personal injury from explosion of hot coolant TRANSMISSION All operators and owners should read the transmissi
23. each axle that has optional differential locks Operations and Maintenance Manual Custom Fire Truck Cab amp Chassis Models Rev Aug 2004 48 TIRES AND WHEELS It is critical that the proper tire pressure is equivalent side to side on the same axle The maximum tire pressure is stated on the vehicle certification label Replacement wheels and tires must have equivalent load carrying capacity as the original equipment Wheels must have the same rim width rim offset and mounting configuration as the original equipment while tires must be of the same size and type and conform to government regulations Wheel nut torque is 450 500 lbs ft INSPECTION Check the condition of the tires daily Look for any bumps blisters cuts punctures cracks uneven wear and tread depth check for proper inflation and tread depth When tread is worn to 4 32 in 3 175 mm replace tire or rotate tire from front axle to rear axle position if equivalent as stated above Replace tire on rear axle when tread is worn to 2 32 in 1 5888 mm Always keep tires inflated to tire manufacturer s recommended pressure for the load being carried Always check inflation pressure when tires are cold WARNING Always maintain your tires in good condition Frequently check and maintain correct inflation pressures as specified by the tire manufacturers Inspect periodically for abnormal wear patterns and replace repair cut or broken tite casing Always use experienc
24. itemized bills dealer work orders owner s vehicle log and service facility receipts which must state the date service was performed mileage kilometers Vehicle Identification Number and service performed SAFETY ALERTS Safety alerts are presented in this manual with the following symbols describing the safety risks and potential outcome for each type of alert WARNING A potentially hazardous condition exists that may result in death or serious injury property damage or destruction if instructions are not strictly observed CAUTION A hazardous condition exists that may result in injury death property damage or destruction if instructions are not strictly observed REPORTING SAFETY DEFECTS If you believe that your vehicle has a defect which could cause a crash injury or death you should immediately advise the National Highway Traffic Safety Administration NHTSA in addition to informing the Spartan Chassis Compliance Department NHTSA cannot become involved with individual issues between the customer and the dealer or any subsidiary However if NHTSA receives similar complaints an investigation may be opened to Operations and Maintenance Manual Custom Fire Truck Cab amp Chassis Models Rev Aug 2004 1 study the possibility of safety defect that may exist in a group of vehicles Should a defect be confirmed a recall or remedy campaign may be ordered For the most up to date contact information for NH
25. of cylinder housing against the piston rod Visually confirm that support mechanism is engaged Deactivate the electric hydraulic pump by releasing the UP button LOWERING CAB WARNING All personnel must stay clear from under cab when lowering cab or serious personal injury or death may occur Release safety support mechanism i Dm i by pulling the support release T P A gt 2 pL me z cable The cab may need to first be raised approximately one inch in order to remove the load from the safety support mechanism 2 While pulling the support telease cable activate the electric hydraulic circuit by depressing and holding the DOWN button Cab slowly lowers and the red indicator on the remote pendant is illuminated Operations and Maintenance Manual Custom Fire Truck Cab amp Chassis Models Rev Jan 2005 44 3 The red light on pendant illuminates any time the tilt system is activated by the DOWN button until the cab locks fully engage The speed at which the cab lowers is pre set and cannot be adjusted 4 he support safety cable may be released once support channel is clear of top of cylinder housing 5 When red indicator light turns off both cab locks will be fully engaged De energize the electric hydraulic circuit by releasing the DOWN button MANUAL TILT PUMP DEVICES OPTIONAL If equipped the tilt pump may be operated manually To lower the cab manually rele
26. operation flapper must be reset To reset rotate the flapper arm and check adjust if necessary the expansion ring position on all charge air intake hoses Refer to shutting down engine for recommended procedure CAUTION It is important to idle an engine for 3 to 5 minutes before shutting down This allows the lubricating oil and coolant to carry heat away from the turbo charger bearings and cylinder walls thus allowing gradual and uniform cooling Operations and Maintenance Manual Custom Fire Truck Cab amp Chassis Models Rev Jan 2005 11 MASTER SWITCH This switch energizes the electrical system from the batteries A green LED indicates switch is in the position IGNITION SWITCH Switches power to the starter button and accessories use to shut down the engine when turned to the off position A green LED indicates switch is in the on position ENGINE START BUTTON Depress button to engage the cranking motor that cranks the engine if the transmission is in neutral TO START ENGINE Gear Selector in Neutral and Parking Brake Set NOTE Pad shifters always shut down to neutral position Disconnect Electric And Air Lines From Shore Source Turn Master Switch On Turn Ignition Switch On Place Transmission Lever In Neutral if equipped with T handle shifter Press Start Button Ca por NORMAL ENGINE SHUT DOWN Gear Selector in Neutral and Parking Brake Set 1 Turn Ignition Off 2 Turn Master Off
27. the INSITE service tool There are three types of system codes Engine electronic control system fault codes Engine protection system fault codes Engine maintenance indicator codes fault codes recorded will be either active fault code 15 currently active on the engine or inactive fault code was active at some time but at the moment 15 not active Most but not all of the electronic fault codes will light a lamp that can be illuminated when a fault code 15 active The CHECK ENGINE lamp 1s yellow and indicates the need to repair the fault at the first available opportunity The STOP ENGINE lamp is red and indicates the need to stop the engine as soon as it can be safely done The engine should remain shut down until the fault can be repaired To check for active engine electronic codes turn the ignition switch to the OFF position and move the diagnostic switch to the ON position Turn the vehicle ignition switch to the ON position If no active fault codes are recorded neither the CHECK nor the STOP lamp will illuminate If active faults are recorded both the CHECK and STOP lamps will illuminate momentarily then begin to flash the codes of the recorded faults The fault code will flash in the following sequence A yellow check lamp will flash There is a short 1 or 2 second pause The fault code will flash on the red STOP lamp There is a short 1 or 2 second pause between each number oe Operations and Mainte
28. 14 127057 eco EE IEEE A O S 14 a AE EIEE E AE E ESE OE O E E E EE 14 Y X A 15 giai cic 15 Headlight Flasher 1 nennen ennenn nnn ness sena ann rese essa aen EE En 15 Automatic High Idle 15 Anti lock Braking System 13 Automatic Traction Control System 16 ADDITIONAL INS TRUMEN TATION scstscccscesecaceccetaesedeauddeecdenastedabadcceadtedeasdnanddcecdendetedstadsetadbedeasdnanddceabendetedsenades 16 Air Filter Restriction Indicator mm 16 TUPE CODBDOR E EE E 16 Ma LO Or LO E E T T E T 16 FC Lamp qODUONA E EE 16 CLASS 1 TOTAL SYSTEM MANAGER OPTIONAL 17 A T TCO ON rrr 17 E PH 17 TOC 18 MULTIPLEX VISTA DISPLAY COPTIONAL o 20 Visia Display Control d 21 IVECO 21 Acknowl edee MM 22 REI AIR ATE RN NE E E A I PEE E O PE
29. AE E E EE N E E E E 22 LM T 22 2s WATE LOMEN DU O 22 HOE VT MU O Mm 22 A SIC U T ENEE 22 VIZ E E E N EEE E E 22 Pano e e EA AE EE A AAE AES 23 Engine Information 23 Transmission 23 E TO TANE EE 23 Maintenance Schedule Menus 23 J Second dry Menu BUON 23 23 COO 24 24 HEATING amp AIR CONDITIONING CONTROLS eeeeeeeeeeeeeeecceccccecccececccccccccccccccccceccccccceccccccecececcccceeceececeeeseeee 25 OVERHEAD HEATING amp AIR CONDITIONING 26 OVERHEAD FRONT CONTROLS AND HEATER c EET eea 21 AUXILIARY COMBINATION UNIT AND CONTROLS cccccccccccccccccceeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeess 21 FRONT AND REAR SHUT OFF VALVE FOR AUXILIARY 28 STEERING SYSTEM AND COLUMN CONTROLS OU ERES EX Ee rYo Ee 28 TILT amp TELESCOPING STEERING 28 To Telescope Wheel 28 ETIA E E E
30. AMMED FOR ACTIVATION BY EITHER SOURCE USER SET POINT VARIABLE TRIP This is the user definable output The user has the option of selecting a trip voltage between 10 5 and 15 0 VDC If the trip point is set to 13 8V or above the output acts as an over voltage indicator and will energize when the voltage drops to the set point AUXILIARY BATTERY MONITORING Terminal 23 can be used to monitor an auxiliary battery There should be no connection to this terminal if a remote battery is not monitored If the auxiliary battery voltage drops below 11 9 bolts it will acttvate the auxiliary battery low output OUTPUT MODES RESPONSE Output is ON only when MODE the Park Brake is NOT set SCENE Output is ON only when MODE the Park Brake S set BOTH Output is ON in both Response and Scene Mode EACH LOAD CAN BE PROGRAMMED FOR RESPONSE MODE SCENE MODE OR BOTH OPERATING VOLTAGE 7 5 TO 20 Volts D C OUTPUTS High Side Drivers Vmain at 0 5 amp source Low Side Drivers Ground at 0 5 amp sink TRANSIENT SUPPRESSION Outputs are protected against thermal overload direct shorts and transient spikes from 50 to 60 volts D C OVERRIDE Outputs 1 through 12 are forced on when the override switch is active Twelve 12 outputs can be programmed by the user to be activated by the ignition or Master Switch tied to Scene Mode Response Mode or Both and assigned a Specific Priority Level More than one output load can
31. Aug 2004 52 MAINTENANCE CHECKLIST Page 3 100 000 Miles or 12 Months LI EJ LI Change Rear Axle Lubricant Change Power Steering Reservoir Filter Change Air Filter Change Front Axle Wheel Bearing Oil 200 000 Miles or 24 Months LIE JE ETE TE JE IE TE E Clean Brake Pressure Protection Valves Inspect Air Compressor Clean Brake Relay Valves Clean Spring Brake Valves Clean Parking Brake Valve Clean Quick Release Valve Inspect Pop off Valve Inspect Air Dryer Desiccant and Oil Filter Clean Single and Double Check Valves Check Air Brake System Before Putting Vehicle Back In Service As Required LI LI LI LI LI LI L Torque Drive Line Cap Screws and Bolts Adjust Steering Gear Relief Plungers Adjust Front Axle Steering Stops Adjust Rear Axle Wheel Bearings Replace Burned Out Light Bulbs Replace Wiper Blades Replace Brake Shoes Operations and Maintenance Manual Custom Fire Truck Cab amp Chassis Models Rev Aug 2004 53 MAINTENANCE SCHEDULE 3 000 MILES OR 1 MONTH Check Or Service Ref Lubricate Brake Linkage Shoe Type Refer to Brake Lubricate With NLGI Grade 2 Manual Grease At Four Fittings Lubricate Cab Hold Down Latches and Lubricate With NLGI 1 Hook Pivots Check Front Spring U Bolt Torque Check Rear Spring U Bolt Torque po Check Torque Arm Bolt Nut Torque Torque to 350 400 Ib ft Torque to 450 lb ft Torque to 450 lb ft Check Torque Arm Clamp Nut
32. Dusty Power Environments It Steering May Be Necessary To Service Reduce The Interval Between Service Change Air Filter NMNMMWES Change Front Axle Wheel Bearing Oil a To GL 5 Gear Lube In Dusty Axle Environments It Manual May Be Necessary To Reduce The Interval Between Service Operations and Maintenance Manual Custom Fire Truck Cab amp Chassis Models Rev Aug 2004 61 200 000 MILES OR 24 MONTHS Check Or Service Vendor General Information Ref Clean Brake Pressure Protection Valves Refer To Ait Brake Inspect Air Compressor Refer To Engine Manual Clean Brake Relay Valves Refer To Handbook Clean Spring Brake Valves Refer To Ait Brake Handbook Clean Parking Valve Refer To Handbook Inspect Air Dryer Desiccant And Oil Refer To Filter Air Brake Handbook Clean Single And Double Check Valve Refer Handbook Inspect Pop Off Valves Refer to Air Handbook Check Air Brake System Before Putting Refer To Vehicle Back In Service Ait Brake Handbook Operations and Maintenance Manual Custom Fire Truck Cab amp Chassis Models Rev Aug 2004 62 AS REQUIRED Check Or Service Torque Driveline Cap Screws And Bolts Adjust Steering Gear Relief Plungers Adjust Front Axle Steering Stops Adjust Rear Axle Wheel Bearings Replace Brake Shoes Ref If Driveline Is Disassembled Torque Cap Screws To 47 51 Ib ft Torque U Bolts To 35 39 b ft Refer To Power Steering Service Manu
33. ERING SYSTEM AND COLUMN CONTROLS TILT amp TELESCOPING STEERING COLUMN To provide optimum steering wheel position the steering column is fully adjustable Also featured on the column are the horn button directional switch high beam switch and four way flasher switch Horn Button Turn Signal and High Beam Switch Tilt and Telescoping Control Hazard and Four Way Switch To TELESCOPE WHEEL Push down on the lever located below the directional switch on the left side of the column while simultaneously raising or lowering the wheel to the desired position Operations and Maintenance Manual Custom Fire Truck Cab amp Chassis Models Rev Jan 2005 28 TILT WHEEL Pull up on the lever located below the directional switch on the left side of the column while simultaneously tilting the wheel to the desired position HORN BUTTON The horn button is in the hub of the steering wheel and activated by depressing the button TURN SIGNAL LEVER AND HIGH BEAM SWITCH This is located on the left side of the steering column below the wheel It operates the turn signals and is self canceling type This lever also controls the headlight high beam function To turn the high beams on or off raise this lever until it clicks into position and release An instrument panel indicator blue light will illuminate when you have selected high beam HAZARD FOUR WAY FLASHERS This switch is located under the column towards the left side Pull the slid
34. Fire Truck Chassis OPERATIONS amp MAINTENANCE MANUAL SPARTAN CHASSIS INC SPARTANCHASSIS COM Operations and Maintenance Manual Custom Fire Truck Cab amp Chassis Models Rev Jan 2005 SPARTAN CHASSIS INC OPERATION AND MAINTENANCE MANUAL for CUSTOM FIRE TRUCK CAB amp CHASSIS MODELS Every effort has been made to insure accuracy and quality in publication of this document At the time of printing content is the most current available Due to technological advancements and continuous improvement of our products and the products of our component suppliers Spartan Chassis Inc reserves the right to change specifications without notification Spartan Chassis Inc 1165 Reynolds Rd Charlotte MI 48813 USA 1 517 543 6400 http www spartanchassis com Operations and Maintenance Manual Custom Fire Truck Cab amp Chassis Models Rev Jan 2005 1165 Revnolds Rd Charlotte 48813 Dear Valued Spartan Owner Everyone at Spartan Chassis would like to express our sincere thanks for your confidence in purchasing an emergency vehicle featuring our custom engineered and manufactured cab and chassis This manual describes the proper use and care of your cab and chassis which will help assure years of safe and trouble free operation Before operating the vehicle the owners and operators should have a thorough understanding of vehicle operation and maintenance Once again Thank You for select
35. NOTE Light and alarm shut off at approximately 215 as temperature descends b The engine oil pressure gauge indicates oil galley pressure from the engine ECU and the gauge and light alarm will indicate low oil pressure The lamp illuminates and an alarm 15 activated briefly prior to engine start up See engine manual for proper operating pressure ranges The light and alarm are also activated when the engine oil pressure drops below 6 psi while the engine is running Operations and Maintenance Manual Custom Fire Truck Cab amp Chassis Models Rev Aug 2004 10 c The voltmeter will show the battery voltage and with the engine running should indicate voltage of 13 25 to 14 25 volts The Volts warning lamp alarm will indicate system voltage above 15 4 volt below 11 8 volt d The automatic transmission oil temperature gauge indicates the temperature of oil in the transmission sump lamp illuminates and an alarm 15 activated when the transmission oil reaches 250 ODOMETER SWITCH When vehicle is powered up the odometer is visible by default Press once to toggle between odometer and trip When in trip odometer mode hold to reset trip to zero 6 OPEN FOR THREE OPTIONAL 2 READ ONLY GAUGES STARTING STOPPING Battery ON Indicator lamp Ignition ON Indicator Lamp Master Switch Battery Start Button 8 O ptional Emergency Shut Down Switch Lift guard to throw switch Before resuming
36. NT 46 GST I 46 COMMINS IT ArALP 46 CARCI C 46 DETROIT SERIES 46 46 E E 47 47 DETROIT SERIES G0 BELT miM IE 48 48 TANDEM AXLE OPERA TION OPTIONAL cccesscescecassdecdencssvacececicscecsecsdccnsweuccensnevecetessceccesdvasecsusdsedeusxexeceassdectes 48 OR Ny TE c 49 Rd red alpl M 49 INSTALLATION AND TIGHTENING s Ug votre ie dese petet 49 MAINTENANCE SCHEDULE AND 50 MAINTENANCE CHECKLIST eeeesosssusuc vstzensuvsvtsube v cu avuc usu T pons va etes Tuta pae rRTP De
37. P 1 Or EP 2 Grease Lubricate Steering Slip Shaft Lubricate Glide Coat Spline With Never Seize Grease 20 000 MILES OR 18 MONTHS Check Or Service Vendor Ref General Information Replace Pleated Paper Filter In Air Refer To Air In Dusty Compressor If Equipped Brake Environments Handbook Reduce The Intervals Between Service 24 000 MILES OR 12 MONTHS Check Or Service Adjust Engine Valves Refer To Initial Adjustment Is Engine At 24 000 Miles Service Adjust Every 48 000 Manual Miles Thereafter Inspect Drive Belts Check Drive Belt Refer To Tension And Tensioner Bearing Engine Setvice Manual Inspect Air Dryer Refer To Brake Handbook Lubricate Brake Valve Foot Operated Refer To Brake Handbook Operations and Maintenance Manual Custom Fire Truck Cab amp Chassis Models Rev Aug 2004 59 25 000 MILES 12 MONTHS Check Or Service Vendor Ref General Information Change Automatic Transmission Fluid Refer To Drain Transmission And Filter Transmission Fluid Into A Pan And Service Dispose of It In An Manual Environmentally Safe Manner Industry Environments Reduce The Interval Between Services Inspect Automatic Transmission Vent Refer To Transmission Service Manual Inspect Automatic Transmission Cable Refer To Transmission Service Manual Inspect Front Axle Alignment And Refer to Refer To Alignment Alignment Needs To Component Wear Front Axle Chart Be Done Only If Tire Setvice Wear Is Evident Man
38. PTION The auxiliary brake 15 a vehicle slowing device only not a vehicle stopping device It therefore 15 not a substitute for the service braking system The service brakes must be used to bring the vehicle to a complete stop OPERATION Activating the dash switch will create automatic braking when there 1s no throttle application This is a diesel engine retarder and is power absorbing by exhaust restriction similar to an air compressor a vacuum pump Some auxiliary brake designs have a switch for selection of high low and or medium absorbing capacity The brake operates with or without service brake application All brakes are most effective at governed engine speeds Lower gear selection will give maximum retarding power Transmission pre select can be set for gear range 3 or 2 and will ensure maximum braking when brake is turned on Pre select keeps engine RPM speed at governor shift points for maximum braking and cooling In the case of an ABS event the auxiliary brake is automatically deactivated WARNING Vehicles equipped with an auxiliary braking device may lose control in wet or slippery road conditions if ABS system is in the failure mode and the braking device is activated See auxiliary brake manufacturers manual for safe operating practices TRANSMISSION OUTPUT RETARDER OPTIONAL DESCRIPTION The transmission output retarder absorbs horsepower on the driveshaft and slows the vehicle When using the tran
39. TSA call the DOT Auto Safety Hotline toll free at 1 888 327 4236 or visit the NHTSA website http www nhtsa dot gov for additional information Operations and Maintenance Manual Custom Fire Truck Cab amp Chassis Models Rev Aug 2004 2 PRODUCT INFORMATION SHEET FIRE DEPARTMENT SALES ORDER SO NUMBER The SO Number is the last 6 digits of the VIN Vehicle Identification Number Overall Height Overall Length Measured from the ground to the highest point of the apparatus piece of equipment Overall Width ot vehicle while vehicle is parked on a level surface This is not necessarily top of the Wheel Base cab or antenna Angle of Approach Chassis Clearance Measured from the lowest point of the chassis Angle of Departure to the ground with the vehicle parked on a level surface generally the drive axle bowl GVWR Turning Clearance Radius Front GAWR wall to wall Rear GAWR REFERENCE THE ENGINE AND TRANSMISSION OPERATION AND MAINTENANCE MANUALS FOR INFORMATION SPECIFIC THE SALES ORDER NUMBER Engine Manufacturer Model Diesel Transmission Manufacturer Model Normal Operating Range Some items may have a different specification due to customer requirements Idle 600 700 RPM High Idle 1250 RPM Governor 2100 2400 RPM Minimum Oil Pressure Normal Idle 10 psi 70 kPa 35 45 psi 240 310 kPa 2100 RPM Cooling System 180 200 80 95 Transmission 160 200 70
40. Torque Torque to 175 200 lb ft Inspect Spring Pin Locking Bolt Bolt Washer And Nut Should Be In Position Lubricate Spring Pin Lubricate With NLGI Grade 2 Grease At Eight Fittings Inspect All Suspension Components for Damage Or Misalignment Check Air Suspension Components Torque Lubricate Drive Line Universal Joints Refer to Drive Lubricate With NLGI Grade 2 Line Manual Grease Lubricate Drive Line Slip Joint Lubricate With NLGI Grade 2 Grease Lubricate Wheel Bearing Assembly Clear 90 W Lubricate Anytime Drum Hub Is Removed Operations and Maintenance Manual Custom Fire Truck Cab amp Chassis Models Rev Aug 2004 54 4 000 MILES BREAK IN ONLY Check Service Vendor Ref General Information Adjust Front Axle Wheel Bearings Refer to Axle Check Front Axle Wheel Bearing Oil Manual GL 5 Gear Lubricate Front Axle King Pins Refer to Axle With NLGI Lubricate Front Axle Tie Rod Ends Manual Grade 2 Grease Lubricate Steering Slip Shafts Glide Coat Splines Lube With Never Requires Wiping Clean Seize and Re lubrication 4 000 MILES OR 1 MONTH Check Service Vendor Ref General Information Check Front Axle Wheel Bearing Oil Refer to Axle GL 5 Gear Lube Manual 5 000 MILES BREAK IN ONLY Check Service Vendor Ref General Information Change Rear Axle Lubricant Refer to Rear First Change At 5 000 Axle Service miles Then Every Manual 10 000 Miles or 12 Months The
41. al Refer To Front Axle Service Manual Refer Rear Axle Service Manual Refer Axle Service Operations and Maintenance Manual Custom Fire Truck Cab amp Chassis Models Rev Aug 2004 63
42. als The intervals listed are the maximum and must not be exceeded If your vehicle 1s operated on very hilly terrain or in a vety dusty or sandy environment you may need to reduce the time between scheduled maintenance intervals The maintenance schedule may be copied and used as a check off sheet Perform maintenance at whichever interval occurs first When reaching a particular service level inspect perform all previous maintenance items that may be due Operations and Maintenance Manual Custom Fire Truck Cab amp Chassis Models Rev Jan 2005 50 MAINTENANCE CHECKLIST Page 1 E lt lt Check Engine Oil Level Check for Engine Oil Leaks Check Power Steering Fluid Check Coolant System Level Inspect Accessory Drive Belts Inspect Fan Drive Belts Inspect Fan Belt Tension Inspect Cooling Fan Inspect Coolant Hose Condition Check for Coolant Leaks Check Transmission Fluid Level Check for Transmission Fluid Leaks Voltmeter Reading Engine Running Defroster Fan Wiper Blade Condition Mirrors Adjusted Washer Solvent Level Brake Air Pressure Instrument Lamps Head Lights Tail Lamps Turn Signals Marker Lamps Stop Lamps Warning Lamps Slack Adjuster Adjustment Drain Water from Air Tanks Axle Oil Leaks Wheel Nut Inspection Tire Inflation Tire Condition Water Tank Level Drain Fuel Water Separator Inspect Tires Check Tire Pressure LIII IC I E I Eb p b Lb b b gr b m ur b ur E u eekly
43. ance manual for proper procedures such as checking the transmission fluid when engine 1s running The type of fluid for each component 15 listed on the fluid label located inside the cab CAUTION It is very important that the proper fluids are used Fluid types should be mixed unless the system has been completely flushed Refer to component manufacturer s documentation for additional information ELECTRICAL INFORMATION CIRCUIT BREAKERS The circuit breakers are SAE J553 type 1 2 or 3 BATTERY Battery removal and terminal maintenance Always remove all negative battery terminals first and positive last When replacing cables install positive terminal first and install m negative terminal last Battery terminals should be cleaned and installed with a dielectric compound or coated with battery terminal spray or clear polyurethane spray Battery jumper studs are provided CAUTION Placing a wrench on the positive terminal without removal of the negative connection first or contact of a wrench between posts can result in a spark that could explode the battery Disconnect batteries and ECU connectors when performing electrical service or welding on apparatus to protect the microprocessors on chassis Proper eye and apparel protection is required Operations and Maintenance Manual Custom Fire Truck Cab amp Chassis Models Rev Aug 2004 40 INTERIOR LIGHTING CAB FRONT DOME LAMPS There is a clear light above
44. ant will illuminate any time the tilt system is energized by the DOWN button until the cab locks have fully engaged BEFORE RAISING CAB 1 Insure frontal and overhead clearance to fully raise cab without damage 2 Vehicle must be parked on level surface with park brake 3 No personnel or loose equipment should remain in cab during tilt system operations The cab tilt system 15 designed to tilt the cab structure only Additional loads may cause system failure 4 Cab doors must be securely closed prior to tilt operations Operations and Maintenance Manual Custom Fire Truck Cab amp Chassis Models Rev Aug 2004 43 eu e p J All items in the tilt arch suction swivels hoses etc must be removed from bumper apron Master electrical switch must be in the ON position Ignition switch must be in the OFF position All personnel must remain clear from front and under cab at all times the tilt system is in operation Cab safety support mechanism must be fully engaged before personnel go under the raised cab RAISING CAB 10 Plug in cab pendant control 11 Energize the electric hydraulic pump by depressing and holding the UP button on the remote 12 13 pendant WARNING Failure to insure that the support mechanism is in place may result inpersonal injury or death Raise cab until support channel clears the right side of the tilt cylinder housing and automatically engages on top
45. ase the safety support cable and turn the T handle counter clockwise using an appropriate device Insure cab locks are engaged and turn T handle clockwise to fully seat cab drifts down if not seated Release T Handle If equipped the jacking rod is mounted on the side of the pump To raise the cab manually insert the jacking rod into the jacking device and jack the cab up until the safety support channel clears the right side tilt cylinder housing and automatically engages on top of the cylinder housing against the piston rod Visually confirm safety engagement Operations and Maintenance Manual Custom Fire Truck Cab amp Chassis Models Rev Jan 2005 45 BELT MAINTENANCE REPLACEMENT Refer to the engine operation and maintenance manuals use the recommended belts or an equivalent product 3911560 CUMMINS Cummins Bridgeway 3289314 with TM21 ISM Length 70 5 in 1790 7 mm Cummins Bridgeway ai Compressor with Leece Neville Length 55 in 1397 mm 270 or 320 with TM16 Air Compressor 3289279 Cummins Bridgeway with Fan Clutch CUMMINS Length 70 in 1778 mm with TM21 ISC ISL with Leece Neville Alternator Air Compressor 270 or 320 without Fan Clutch with TM21 Air Compressor 25 080830 NAPA Length 83 75 in 2127 25 mm with Leece Neville Alternator CAT 270 or 320 with TM21 C10 C12 Air Compressor 25 080839 NAPA Length 84 38 in 2143 25 with Nieoff Alter
46. be more effective during a braking event OPERATION The Electric Driveline Retarder is activated by brake pedal application The level of effectiveness 15 increased as the pedal is further depressed The levels of progression are displayed by the four amber indicator lights on the instrument panel When the retarder 15 activated the brake lights illuminate The toggle switch on off located on the switch panel near the headlight switch will enable or disable the Retarder operation This switch is used to disable the retarder in the event of slippery road surfaces Transmission pre select can be set for gear range 3 or 2 and ensures maximum braking when brake is turned on It keeps engine RPM speed at governor shift points for maximum braking and alternator output CAUTION The retarder will not work when vehicle speed is below 3 m p h You must apply the chassis brake to bring the vehicle to a full stop WARNING Vehicles equipped with an auxiliary braking device may lose control in wet or slippery road conditions if ABS system is in the failure mode and the braking device 15 activated See auxiliary brake manufacturers manual for safe operating practices Operations and Maintenance Manual Custom Fire Truck Cab amp Chassis Models Rev Jan 2005 36 MAINTENANCE FOR TELMA RETARDERS FREQUENCY Twice a year METHOD Pressurized water ait dry Greasing Fill grease fitting until grease appears at SUPERTELMACO 3
47. bricate Steering Slipshafts 5 000 Miles Break in Only L Change Rear Axle Lubricant 5 000 Miles or 3 Months Inspect the Fuel Cap Fuel Tank Tank Vent and Fuel Lines for Leaks Operations and Maintenance Manual Custom Fire Truck Cab amp Chassis Models Rev Jan 2005 51 MAINTENANCE CHECKLIST 5 000 Miles or 6 Months Clean and Replace Air Compressor Sponge Strainer if equipped Clean Drive Axle Vent Change Drive Axle Lubrication Clean Battery Posts and Terminals Inspect Alternator Test Anti Freeze PH Factor Re Torque Steering Balls Bolts Rods Drag Links Frame Bolts Suspension Hangers and Components _ Inspect Frame and Cross Member for Corrosion or Loss of Paint 000 Miles or 6 Months Change the Engine Oil and Oil Filter Inspect Air Intake System Inspect Charge Air Cooler Inspect Single and Double Air Brake Check Valves Lubricate Steering Slipshafts Inspect Air Filter Lubricate Brake Camshaft Change Coolant Filter Lubricate Steering Drag Link Ball Joints Lubricate Brake Treadle Valve Pin Lubricate Power Steering Housing S 8 000 Miles or 1 Month _ Inspect Air Brake Chambers and Hoses Check Air Brakes for Proper Operation 10 000 Miles or 6 Months Inspect and Clean Radiator Inspect Radiator Hoses 12 000 Miles or 12 Months Inspect Engine Block Heater Inspect Heater Water Hoses Check Anti Freeze Concentration
48. button The red Master button and the green High Idle button are toggle controls that activate deactivate the function when depressed E Master Warning system Secondary Heat High Idle a Lt Menu Home Info Menu AIC 2 a MULTI FUNCTION BUTTONS ITEM 8 There are four multi function buttons item 8 on each side of the Vista Display The active menu determines the function of each button When a menu function 15 active the background area of the button s text is darker than that of a non active function In the illustration above Dome Lights Msg Ack and Air Horn are enabled functions Operations and Maintenance Manual Custom Fire Truck Cab amp Chassis Models Rev Jan 2005 21 MESSAGE ACKNOWLEDGE MSG The message bar is located above the display screen When activated the Msg Ack function clears the current message and displays the next existing message Important messages that need acknowledgement by the user are displayed at the top of the screen in the order that they are received Node 1 Pin 5 Set Temp Outside TOT 56 F BACKUP ALARM DISABLE The backup alarm is enabled by default It may be disabled by pressing the Backup Alarm Disable button The alarm may be re enabled by pressing the button again and is automatically re enabled after cycling the Master Power battery switch 1 E MASTER BUTTON The on off control for the Master Warning Lights is a red button located on th
49. ch is activated If the indicator light comes on the oil level may be low and should be checked with the dipstick If the engine has been recently running be sure to allow sufficient time after shutting engine off for oil to drain back into pan Pre programmed settings for the switch include a 10 second delay and do not permit functionality when engine is above 300 RPM The Low Level switch 15 available with the Detroit Diesel Series 60 engine and the Cummins ISL and ISC engines BUILT IN DIAGNOSTICS The gauges reset to zero and the pointers vibrate briefly when the ignition is first activated indicating that the gauges are operational If communication between the chassis and gauges 1s lost the warning lights flash in a track pattern Operations and Maintenance Manual Custom Fire Truck Cab amp Chassis Models Rev Jan 2005 9 SPEEDOMETER WITH LCD TRIP ODOMETER speedometer and a trip odometer operate from signal received by the world transmission tail shaft output speed sensor A small rocker switch on the instrument panel will switch the LCD display between odometer and trip odometer modes Pressing the switch for 1 to 3 seconds will switch modes Pressing the switch for more than 4 seconds will reset the trip odometer TACHOMETER WITH LCD ENGINE HOUR METER The tachometer reads engine revolutions per minute RPM from the engine ECU digital liquid crystal display LCD hour meter reads the hours of engine ru
50. e far left side of the Vista Display control panel It toggles all warning lights on and off 2 WARNING LT MENU BUTTON The Warning Light Menu accesses the controls for the individual warning lights By pressing the multi function button associated with a specific type of warning light the button toggles the light on or off NOTE All clear warning lights deactivate automatically when the park brake is set blocking mode per NFPA 1901 3 HOME MENU BUTTON When first powered up the Vista Display shows the Home Menu A typical Home Menu display is shown on the previous page The information may be customized to the user s specifications 4 SYSTEM INFO BUTTON Pressing the System Info button accesses the Vehicle Information Menu VEHICLE INFORMATION MENU This menu allows access to the Diagnostic and Maintenance Menus as well as the Engine Transmission and Chassis Information Menus Operations and Maintenance Manual Custom Fire Truck Cab amp Chassis Models Rev Jan 2005 22 DIAGNOSTIC MENU Pressing the Diagnostic Menu accesses the onboard diagnostics of the multiplex system Load Levels monitors the load shedding level of the nodes Shorts Opens monitors the circuit short open status of nodes and pins Node Info verifies the Vista Display operating system and the version of System Designer programming software Net Stats displays network information such as incoming outgoing buffer overflows and
51. e load carrying capacity that the components of the vehicle are designed to support This rating excludes any towed item GROSS VEHICLE WEIGHT GVW The GVW is the total actual weight of a fully loaded vehicle also known as the in service weight This includes the vehicle cargo passengers and any liquids fuels This rating excludes any towed item The GVW must not exceed the GVWR GROSS AXLE WEIGHT RATING GAWR The GAWR 1s the maximum weight rating that an axle assembly is designed to support the load carrying capacity Axle assembly components include the axle suspension tires wheels and brakes GROSS AXLE WEIGHT GAW The 15 the total actual weight supported by a single axle when the vehicle is fully loaded The GAW of each axle must not exceed the corresponding GAWR for the axle Weight distribution on an axle must be as equal side to side as possible to avoid overloading one side Therefore individual wheel position weights must be taken to avoid this condition If one side 15 overloaded by more than 5 of the total axle rating GAWR it is necessary to redistribute the load appropriately For example if the GAWR of one axle on your vehicle is 10 000 pounds 5 of that is 500 pounds This means that the actual weight difference between the left and right side of the axle must be within 500 pounds In addition the actual weight on one side of a single axle must never exceed 50 or 1 half of the GAWR for that axle whic
52. e switch out to turn on and push in to turn off GENERAL INSPECTION AND MAINTENANCE e Ask your service mechanic to examine the steering mechanism Minor adjustments could head off problems Check tie rod drag link end clamp bolts and ball joints They must be kept tight Check for installation and spread of cotter pins and tightness of nuts at both ends of tie rod and drag links e Check to see that the pitman arm steering arm at steering gear mountings are tight and locked Check system for leaks or hose chafing and if necessary replace at once e Check for proper steering gear and power steering pump lubricant levels Regularly inspect steering column joint bolts and steering linkage particularly for body to chassis clearance WARNING Failure to maintain the steering system in proper condition can cause reduced steering ability resulting in personal injury and property damage Have any steering problems corrected by a qualified mechanic MAINTAIN STEERING COLUMN JOINT BOLTS As a good maintenance practice it is recommended that steering column joint bolts be checked for tightness a minimum of every 50 000 miles 80 000 m or annually whichever occurs first Tighten bolts to the torque specified in the table DO NOT OVER TIGHTEN Operations and Maintenance Manual Custom Fire Truck Cab amp Chassis Models Rev Jan 2005 29 MAINTAIN HYDRAULIC POWER STEERING SYSTEM Whenever the hydraulic power
53. each door which activates when the door is opened This same light may be used when the door is closed by pressing the switch on the light housing Additionally there may be lights recessed into each door panel or ground lamps that come on when that door 15 opened The red dome light must be switched on manually with the switch at the lamp CAB REAR DOME LAMPS Rear doors have two lights above them The clear lights will come on when the rear door s 1s opened ot can be switched manually on when all doors are closed The red dome light must be switched on manually with the switch at the lamp LIGHT BULB REPLACEMENT To insure proper replacement inspect lens and or bulb to identify the appropriate manufacturer CAB EXTERIOR Replacement Type of Location of Lamp Manufacturer P Bulb E ce Qty Roof Mounted Matker Light GE Lighting 904 Plug In 5 Face Mounted Matker Light Grote 45103 Sealed Unit 5 Face Mounted Matker Light Weldon 9186 1500 20 Sealed Unit 5 Side Marker Beehive Light GE Lighting 1157 Push amp Twist 2 Head Light High Beam GE Lighting H4656 Sealed Beam Plug In 2 Head Light High Beam GE Lighting 9007 Plug amp Twist 2 Head Light Low Beam GE Lighting H4651 Sealed Beam Plug In 2 Head Light Low Beam GE Lighting 9007 Plug amp Twist 2 Front Mounted Turn Signal GE Lighting H4651 Sealed Beam Plug In 2 Front Mounted Turn Signal GE Lighting 3157NA Plug amp Twist 2 Ground Lts Circular Optics Truck Lite 40244 Sealed Unit 4
54. ed properly trained personnel with the correct equipment and procedures to mount or remove tires Failure to adhere to these warnings could result in tire malfunction damage to your vehicle personal injury and possible death INSTALLATION AND TIGHTENING Before installing wheels clean all mounting surfaces with a wire brush Check to make sure the threads are clean Refer to the wheel manufacturer s installation and maintenance manual included with this manual for the proper inspection and installation procedures Initially tighten all wheel nuts to 50 Ib ft using the pattern shown below Complete wheel nut tightening to the torque value specified by the wheel manufacturer For example the torque for a hub piloted M22 X 1 5 standard wheel application is 450 500 Ib ft Maintain wheel nut torque by retorquing at the first 50 miles 80 km and routinely at 10 000 miles or 6 months after that O pat 3 OE 2 3 Operations and Maintenance Manual Custom Fire Truck Cab amp Chassis Models Rev Aug 2004 49 MAINTENANCE SCHEDULE AND CHECKLIST Maintenance must be performed to keep vehicle in good operating condition It is necessaty to perform maintenance checks inspections lubrication cleaning or other types of service Regular maintenance helps avoid potential problems and may help correct problems before they become setious The following maintenance schedule is arranged into mileage and time interv
55. edal and modulate intensity as required for safe deceleration WARNING If any type of problem develops with the ABS system or any other portion of the braking system immediately contact an authorized service center or contact the manufacturer The ABS test switch is used to perform diagnostic checks on the system The information pertaining to these checks can be found in the Meritor Wabco maintenance manual supplied with the vehicle Operations and Maintenance Manual Custom Fire Truck Cab amp Chassis Models Rev Jan 2005 15 AUTOMATIC TRACTION CONTROL SYSTEM OPTIONAL The ATC function is similar to that of a limited slip differential When wheel spin occurs braking automatically applies to the spinning drive wheel Engine speed is also decreased as needed until traction is achieved to move the chassis The green low traction indicator light illuminates when wheel slip is detected If it is desired to rock the vehicle and ATC has cut the throttle back depress the mud and snow switch CAUTION Use reasonable care when depressing the mud and snow switch When wheel tire suddenly regains traction component damage can occur ADDITIONAL INSTRUMENTATION AIR FILTER RESTRICTION INDICATOR A vacuum transducer attached to the clean air side of the air filter indicates restriction and the air filter requires servicing NOTE Replace the filter when lamp is illuminated FUEL PRIMING PUMP OPTIONAL An optional
56. electric fuel priming pump can be mounted in the frame or on a cross member over the rear fuel tank The fuel primer is activated by a momentary switch and is for priming the fuel filters ot the fuel system in the event the tank has been run out of fuel Many engines are self priming and do not require the optional electric fuel pump Cummins ISB ISC and ICL are self priming engines WAIT IO START LAMP The engine ECU checks the intake manifold temperature to determine how long to energize the air heater before extinguishing the pre heat lamp This 15 for the pre heat phase WARNING DO NOT USE STARTING FLUIDS ETHER ETC WATER IN FUEL LAMP OPTIONAL A sensor located in the fuel filter housing activates the Water In Fuel WIF lamp WIF lamp illuminates indicating that the filter needs to be drained from the fuel filter assembly Operations and Maintenance Manual Custom Fire Truck Cab amp Chassis Models Rev Jan 2005 16 CLASS 1 TOTAL SYSTEM MANAGER OPTIONAL SEQUENCING To reduce strain on the chassis charging system any loads controlled by the load manager can be programmed to turn on in sequence when the activating switch either ignition or master warning light switch 15 closed Each load can be assigned to one of eight sequence stages The loads will sequence off in reverse order SHEDDING To reduce the demand on chassis charging system nonessential loads controlled by the load manager can be p
57. endor Ref General Information Change The Engine Clean Air Brake Governor Refer To Air Brake Handbook Inspect Single And Double Air Brake Refer To Air Check Valves Brake Handbook Lubricate Power Steering Drag Rod Refer Lubricate With NLGI Grade 2 Power Grease At Two Fittings Steering Service Manual Lubricate Power Steering Housing Lubricate With NLGI 2 Grease At Fitting In Housing Inspect Air Intake System Refer To Inspect Air Intake Ducts And Engine Pipes For Damage Cracks Or Manual Loose Connections Inspect Air Filter Refer To Inspect The Air Filter For Tears In Dusty Engine Or Holes Replace If Any Are Environmen Manual Found Replace If Air ts Reduce Restriction Gauge Indicates The Interval The Filter Is Clogged Between Service Gree Brake Manual Grease Lose Connections Change Coolant Filter Check PH Factor Determine Replacement Filter Charge Lubricate Axle King Pins With NLGI Grade 2 Grease at Fittings Lubricate Steering Slip Shafts Lubricate Glide Coat Spline With Never Seize Grease 8 000 MILES OR 1 MONTH Check Or Service Vendor Ref General Information Inspect The Air rake Chambers And Refer Hoses And Check Air Brake For Proper Handbook Operation Operations and Maintenance Manual Custom Fire Truck Cab amp Chassis Models Rev Aug 2004 57 10 000 MILES OR 6 MONTHS Check Or Service Vendor Ref General Information
58. engine handbook for code legends DOOR AJAR SYSTEM Whenever a cab or compartment door is open and the parking brake is not engaged a red light flashes to alert of the condition The light is located overhead between the driver and passenger WARNING DO NOT MOVE VEHICLE WHEN LIGHT IS ON If the red Door light illuminates while driving the vehicle must be stopped to check for an open door Operations and Maintenance Manual Custom Fire Truck Cab amp Chassis Models Rev Jan 2005 32 The chassis has air brake system To prevent brake bounce the driver should make brake application by placing heel of foot on the floor while applying a smooth even force on the treadle valve pedal brake pedal with the ball of foot WARNING Frequent use of the service brakes will cause them to heat up and reduce their stopping ability in dangerous brake fade BRAKE INSPECTION Regular inspection is required including the proper draining of any water from air tanks This will indicate if the air dryer and check valves between tank systems are functioning properly SLACK ADJUSTER INSPECTION Inspect Slack Stroke To Insure Automatic Adjuster Is Working Stroke Indicator On Chamber Rod Color or Knurled Band Exposed Indicates Slack Needs Adjusting Refer to Free Stroke below an U S DOT Stroke Limits 0 90 psi 550 620K pa Pressure i
59. ent damage to components removal of front bumper and other equipment may be necessary For towing from the rear front tires must be positioned straight ahead and the steering wheel secured in that position Operations and Maintenance Manual Custom Fire Truck Cab amp Chassis Models Rev Jan 2005 9 CONTROL PANELS INSTRUMENT PANEL 24 DEAD FRONT WARNING LIGHTS IN CLUSTER STOP CHECK RIGHT ENGINE ENGINE TURIN GREEN AIR FILTER RED YELLOW GREEN f YELLOW YELLOW GREEN Active Device Indicator YELLOW Caution Indicator Warning Indicator CHECK CHECK PARK HIGH LOW ed TURN ENGINE ENGINE TRANS BEAM BRAKE IDLE FUEL 2201 TURN GREEN RED YELLOW YELLOW CREEN BLUE RED GREEN RED YELLOW RED GREEN LOW HIGH HIGH WATER LOW VOLTS OIL COOLANT TRANS UOS as TON iN Elen COOLANT RED PRESS TEMP TEMP YELLOW opery FUEL veri ow LEVEL LEVEL RED RED RED YELLOW RED RED SECONDARY _ 140 PRIMARY 140 pe 120 60 0 S s JAN 0 60 Low OIL LEVEL INDICATOR If equipped with a Low Level indicator switch wait 20 30 seconds before starting the engine after the initial bulb check ignition swit
60. h would be 5000 pounds for the preceding example Refer to the axle manufacturer s literature for additional information Operations and Maintenance Manual Custom Fire Truck Cab amp Chassis Models Rev Aug 2004 7 TOWING DO NOT LIFT RAISE OR SUPPORT THE CHASSIS USING THE TOW HOOKS OR EYE HOOKS ON THE FRAME WARNING Follow industry safety measures when preparing and towing a vehicle Failure to do so may lead to personal injury or death If a unit must be towed for any reason subject to the options available for the vehicle tow hooks and eyes are available for this purpose Positioning of the lifting and towing device is the sole responsibility of the towing vehicle operator A towing device must be attached to the frame assembly or axle if allowed by the axle manufacturer WARNING Do not release the parking brakes unless wheels are properly chocked blocked the vehicle is securely attached to the towing vehicle Refer to the appropriate transmission axle and suspension manufacturer s literature for specific towing instructions Depending on the reason for towing the vehicle must be properly prepared Wheels must be chocked blocked and people must be safe from on coming traffic Insure that water is emptied from water tanks and unload any equipment that may cause abnormal load exertion on chassis cab components For towing from the front refer to the axle manufacturer s recommended practices To prev
61. ing a premium emergency vehicle featuring a world class custom product manufactured by Spartan Chassis Inc If at any time you have questions pertaining to your cab and chassis please contact the Spartan Chassis Inc Customer Assistance Group at 1 800 543 5008 The fax number for our Fire Truck Warranty Parts Department is 517 543 7764 The fax number for our Fire Truck Non Warranty Parts Department 15 517 543 9264 Sincerely Spartan Chassis Inc Operations and Maintenance Manual Custom Fire Truck Cab amp Chassis Models Rev Aug 2004 Not all information contained in this manual may pertain to your vehicle If you have any questions about the operation of your cab amp chassis or the manual please contact Spartan Chassis Inc Customer Assistance Center 1 800 543 5008 TABLE OF CONTENTS CITASSIS APPARATUS INTBREAGC 002 tears 1 MAINFENANCE RECORD DEL 1 SAFELY E Y c eases eden ae ned 1 REPORTING SAFETY DEFEC EE AE ES 1 PRODUCT INFORMATION Ve oua 3 DRIVER OPERATIONAL PROCEDURES amp PRACT ICES
62. king Brake is set and the Load Manage Enable input is grounded NOTE voltage drops to this point UNSHED POINTS Level 1 11 4 Level 2 11 6 Level 3 12 0 Level 4 12 2 Level 5 12 4 Level 6 12 6 Level 7 12 8 Level 8 13 0 FAST IDLE A fast Idle output is activated whenever the system voltage is reduced to 12 8 VDC for at least one minute The fast idle output will remain ON for a minimum of 10 minutes and until 13 0 VDC is achieved The fast idle output is dependent on the Parking Brake and Load Manage Enable inputs NOTE 1 This output should only be used as part of a fast idle control system when the proper safety interlocks are present NOTE 2 The FAST IDLE output will turn off immediately when the Load Manage Enable input is removed from ground potential LOW VOLTAGE ALARM Whenever the system voltage drops below 11 9 VDC a low voltage alarm output ground is activated This complies with the NFPA 1901 requirements SHED POINT is the voltage that will cause a load to be turned off if the system UNSHED POINT is the voltage that must be achieved before a load is turned back on once it has been shed Operations and Maintenance Manual Custom Fire Truck Cab amp Chassis Models Rev Aug 2004 18 SWITCH SOURCES IGNITION Loads will sequence on when the vehicle ignition switch 15 turned off MASTER Loads will sequence on when WARNINdG the master warning switch 15 turned ON EACH LOAD CAN BE PROGR
63. lay LOW VOLTAGE LIGHT The load manager provides a LOW BATTERY light in the load manager display and activates the alarm when the system voltage falls below 11 9 volts Operations and Maintenance Manual Custom Fire Truck Cab amp Chassis Models Rev Jan 2005 17 LOAD MANAGER DISPLAY The load manager comes standard with a status display that fits conveniently in a standard rocker switch cutout The display has LED tell tales POWER ON LOW BATTERY and FAST IDLE Operational Data SHED POINTS Level 0 Never Shed Level 1 11 0 Volts Level 2 11 4 Volts Level 3 11 8 Volts Level 4 12 0 Volts Level 5 12 2 Volts Level 6 12 4 Volts Level 7 12 6 Volts Level 8 12 7 Volts SEQUENCING Electrical loads will turn on sequentially in priority order from 1 to 8 when their respective switch is activated either ignition or warning master and the vehicle is operated in the mode selected for that output response and or scene Loads will sequence off in reverse order Priority zero loads will be sequenced on and off but will not shed SHEDDING Electrical loads will be turned off shed when the system voltage drops to the shed point for a minimum of one minute this prevents load shedding due to momentary system power loading such as high current start up devices Once shed loads will remain off for a minimum of five minutes and until the unshed voltage is achieved for a minimum of one minute Loads will only shed if the Par
64. n Air Chamber Clamp Type Air Cleaner MEASURE FREE STROKE Adjust the stroke as short as possible without the brakes dragging The vehicle may be put out of service if the stroke is not Chamber Type Size less than 1 3 8 34 9 mm less than 1 3 8 34 9 mm less than 1 3 4 44 4 mm less than 1 3 4 44 4 mm less than 1 3 4 44 4 mm less than 2 50 8 mm less than 2 1 4 57 1 mm Stroke Indicator Free Stroke Y minus X DRUM brake tree stroke must be 1 2 aE 12 7 15 9 mm DISC brake free stroke must be 3 4 7 8 19 1 22 2 mm Refer to Manufacturer s Service Manual for Proper Adjustment Procedure Operations and Maintenance Manual Custom Fire Truck Cab amp Chassis Models Rev Jan 2005 33 CHECK OPERATION OF THE AIR BRAKE SYSTEM Weekly or when air tanks are normally bled off for water content the air brake system should be checked for proper function This test assures the check valves are cycled in the system and ensures proper performance of dual air system When performing pedal applications depress and hold while listening for air leaks A visual inspection of the slack adjuster travel must also be made to ensure the slack adjusters are properly adjusted Refer to the slack adjuster inspection section for further details NOTE Vehicle must be parked on level surface wheel chocks or curbing installed at the front and tear tires and park brake in the off position SIEP 1
65. n time from the engine ECU it 1s located within the tachometer gauge 3 IN ONE COMBO GAUGE WITH LARGE FUEL GAUGE PRIMARY AND SECONDARY AIR PRESSURE a Ihe fuel gauge operates from a 0 90 ohm sendet in the fuel tank and should have a nominal 5 to 7 gallon reserve at the empty mark The low fuel lamp illuminates when the tank is 1 4 full The warning buzzer will cycle on for 3 seconds and off for 3 minutes while the tank is below 1 4 b The air gauge for system one labeled Primary Air in the left hand combo gauge shows tapid air build up A buzzer and light activate at pressures below 65 psi After system one air builds rapidly to 90 psi it supplies and builds system two labeled Secondary The system one tank supplies the park brake and rear brakes The primary tank 15 divided into 2 sections a wet tank and a dry tank Air options such as air horns are supplied by an isolated tank often referred to as the auxiliary tank that draws from system one and has a pressure protection valve in place c The air gauge for system two indicates brake air It supplies the front brakes as well as the park brake The low air light activates at pressures below 65 psi 4 IN ONE COMBO GAUGE WITH COOLANT TEMP OIL PRESSURE VOLTMETER AND TRANSMISSION TEMP a The engine coolant temperature gauge indicates the coolant temperature in the engine block A lamp illuminates and an alarm activates when a temperature of 220 15 reached
66. nance Manual Custom Fire Truck Cab amp Chassis Models Rev Aug 2004 3 When the number has finished flashing in red a yellow check lamp will appear again The fault code will repeat the same sequence Each fault code flashes two times before advancing to the next code To skip to the next fault code move the IDLE SPEED ADJUST switch momentarily to the position You can go back to the previous fault code by momentarily moving the IDLE SPEED ADJUST switch to the position If only one active fault code is recorded the ISC control system will continuously display the same fault code even with either the or selected When not using the diagnostic system turn OFF the Diagnostic Switch If the Diagnostic Switch is left in the ON position the electronic control module ECM will not log some fault codes ABS TEST SWITCH WITH INDICATOR LIGHTS The ABS light 1s amber and comes on at start up on the diagnostic panel The light turns off after ECU check out comes on any time there is a failure in the ABS system The low traction Low Trac light is green and will illuminate when wheel slip is detected FUEL PRIMER BUTTON OPTIONAL Used after a filter change or prior to starting vehicle that has been refueled after running out of fuel ENGINE TEST SWITCH Used to receive diagnostic codes from the engine by turning on and counting blink codes NOTE Always recotd all logged codes and toggle switch to display codes Check
67. nator 290 a 3 17470 DETROIT Dayco Dayco with TM21 SERIES 60 with Leece Neville Aternator Air Compressor 270 or 320 5080720 with Leece Neville Alternator Air Compressor 270 a The quantity of belts required in a matched set is shown in parenthesis x preceding the belt part number Always replace all belts in a matched set even if it is not necessary b Dayco belt length is represented by the last 3 digits of the part number multiply inches by 25 4 to arrive at mm e g the length of belt 5080570 is 57 in e g the length of belt 17485 is 48 5 in Operations and Maintenance Manual Custom Fire Truck Cab amp Chassis Models Rev Aug 2004 46 ISC ISL BELT ROUTING Accessory Air Compressor Belt Lo X ISM BELT ROUTING Operations and Maintenance Manual Custom Fire Truck Cab amp Chassis Models Rev Aug 2004 Accessory Air Compressor Belt 47 Alternator Air Compressor Belt Fan Belt The label to show routing of the alternator belt 15 located on the front right corner of the gear case below the alternator TANDEM AXLE OPERATION OPTIONAL A driver control differential lock switch is located on the console panel In slippery and off road conditions apply lock up at low torque application This will provide evenly distributed drive to both leads and rear axles NOTE This is independent of the side to side differential in
68. olts the automatic high idle system will raise the engine RPMs to increase alternator output The system will only operate with the transmission in neutral the park brake applied and the fire pump disengaged The automatic high idle will stay engaged for a minimum of 10 minutes and until the system voltage has reached 13 0 volts Application of the setvice brake will override the automatic high idle for 1 minute ANTI LOCK BRAKING SYSTEM ABS This system continuously monitors individual wheel speed If a wheel lockup condition 15 sensed the brake pressure to that wheel will automatically be modulated when brakes are applied to prevent slippage This allows for better stability of the vehicle during stops by avoiding skidding The ABS system will enable reduced stopping distances on a variety of road surfaces while maintaining vehicle stability When the engine is started the ABS amber warning light illuminates and goes out after system 1s checked If a system failure occurs only the affected wheel returns to normal braking function while the remaining wheels operate with ABS Should total failure develop the vehicle returns to standard braking without losing any of its normal efficiency NOTE The ABS system 15 interfaced with the auxiliary braking device circuit In the event of a wheel slip the auxiliaty braking device 15 disabled With air brake equipped vehicles it is not advisable to pump the brake pedal Keep steady pressure on the p
69. on operation manual before operating the vehicle SHIFT SELECTOR The transmission shift selector is either pushbutton or t handle lever full description and function for each type of selector 1s included in the transmission operation manual supplied with your vehicle OIL CHECK PROCEDURE Fluid level 15 critical to the transmission operation Refer to the transmission operation manual to determine the appropriate method of obtaining the oil level reading Weekly check transmission oil for contamination of water glycol via the dipstick The engine should be running for this inspection DIAGNOSTIC INCIDENT DISPLAY PROCEDURE To check for diagnostic codes be sure the vehicle 15 safely stopped the park brake 15 activated and the transmission is in neutral Refer to the transmission operation manual for a detailed explanation of accessing viewing and clearing code information TRANSMISSION COOLER Every 3 years 32 000 miles or 2 500 hours of operation the transmission cooler should be replaced Operations and Maintenance Manual Custom Fire Truck Cab amp Chassis Models Rev Jan 2005 39 FLUID CHECKS The transmission engine oil power steering and coolant fluid levels should be checked each shift Fluid levels should be checked while the vehicle 1s on a level surface the parking brake engaged appropriate wheel chocks in place and the transmission is in neutral Refer to the manufacturer s operation and or mainten
70. ower Speed Switch Operations and Maintenance Manual Custom Fire Truck Cab amp Chassis Models Rev Jan 2005 25 OVERHEAD HEATING amp AIR CONDITIONING UNIT Filter may be removed for cleaning when neccessary 4 For optimal performance clean filter regularly with war soapy water and dry before reinstalling Headliner Center Section Shown Driver and Passenger Headliner Sections Shown CAUTION Always check operation and adjust diffusers prior to driving the truck Operations and Maintenance Manual Custom Fire Truck Cab amp Chassis Models Rev Jan 2005 26 OVERHEAD FRONT CONTROLS AND HEATER Optional defroster fans are not shown Fan Speed Switch Heater Temperature Switch AUXILIARY COMBINATION UNIT AND CONTROLS Temperature Switch Air Conditioning ON OFF Switch Be ere Fan Speed Switches CAUTION Always check operation and adjust diffusers prior to driving the truck Operations and Maintenance Manual Custom Fire Truck Cab amp Chassis Models Rev Jan 2005 21 FRONT AND REAR SHUT OFF VALVE FOR AUXILIARY UNITS NOTE seasonal hot water shut off valve located under the cab behind the passenger step above the air cleaner must be turned off by rotating the lever 90 during warm weather when air conditioning is required x p 2 NX z My wW RA Heater Shut Off Valve Under The Cab Shown in The On Position STE
71. pment damage Insure frontal and overhead clearance 15 sufficient to fully raise cab without hitting electrical wires or dangerous overhead objects that could result in serious injury or death CAUTION Insure headlamps B TILT CONTROL INSTRUCTIONS EFER TO THE OPERATOR S MANUAL FOR COMPLETE compartment doors and the grille are OPERATING INSTRUCTIONS AND FOR OPERATING s STRUCTIONS ON THE OPTIONAL MANUAL CAB TILT SYSTE secuted before raising or lowering the cab HEAD CLEARANCE TO FULLY RAISE CAB WITHOUT DAMAGE ED ON LEVEL GROUND WITH PARK BRAKE ON 1 2 as E EQUIPMENT SHOULD REMAIN IN CAB DURING TILT SYSTEM OPERATIONS THE CAB TILT SYSTEM CAB STRUCTURE ONLY ADDITIONAL LOADS MAY CAUSE SYSTEM FAILURE 4 CURELY CLOSED PRIOR TO TILT OPERATIONS 5 ALL RCH SUC SWIVELS HOSES ETC MUST BE REMOVED FROM BUMPER APRON 6 ER ELI L CH MUST BE THE ON POSITION e Fa ON SW E THE OFF POSITION e 8 ALL PERSO EMAIN CLEAR OF FRONT A UNDER CAB AT ALL TIMES THE TILT SYSTEM IS IN OPERATION CAUTION An aluminum cab tilt 9 SAFE POR ECHANISM MUST BE FULLY ENGAGED BEFORE PERSONNEL GO UNDER THE RAISED CAB 4 RAISING control instruction plate has been LINDEN 2 ERGIZE
72. r intermittent Check that all windows are closed Adjust air conditioner or heater to desired temperature setting and insure all diffuser registers are open and properly aimed for defrosting defogging the windshield Do not drive without open and adjusted registers NOTE heater shut off valve is located on the right outside rail near the cab pivot point e If emergency warning lamps are required switch on Release park brake e Put shift selector into drive and proceed forward e Disengagement declutching of the four wheel drive and tandem interaxle differentials to be done on dry or hard surfaces A maintenance checklist and schedule are available at the end of this manual MAINTENANCE PRACTICES e Ensure daily weekly and stated maintenance interval checklist items are performed If any information should seem unclear please contact Spartan Chassis Inc Customer Assistance Group at 1 800 543 5008 Operations and Maintenance Manual Custom Fire Truck Cab amp Chassis Models Rev Jan 2005 5 Joy 4 fons Wos4 SeT Jae MORPUOD gj i 1 me TTT Sye sermono III TTT WRG dog SIeub S uin fh ju 9unsn foy d C DD IDIILIILLLLLLLLLLL peor eJnsso Jy Big S891 05 9230 S389 Im 19 91
73. r headlights SECONDARY BRAKE ON OFF SWITCH OPTIONAL The auxiliary brake must be turned off while driving in wet or slippery conditions It must be used during normal driving conditions as stated in the manufacturer guidelines for the secondary braking device ELECTRIC REMOTE MIRROR SWITCH The electric remote mirror switches adjust the mirror flat areas to the desired position by using the left or right switch MAIN CONSOLE MASTER WARNING SWITCH The master warning provides power to the other warning light switches on the rocker switch console LIGHT BAR Controls operation of the light bar located on the cab roof zone upper WARNING FRONT Controls operation of the warning lights generally located above or below the headlights zone A lower They may alternately flash or rotate when activated Operations and Maintenance Manual Custom Fire Truck Cab amp Chassis Models Rev Jan 2005 14 WARNING SIDE Controls operation of the warning lights located in the sides of the front bumper or the sides of the cab body zone and zone D WARNING REAR Controls operation of the warning lights located at the rear of the body zone upper and lower HEADLIGHT FLASHER OPTIONAL When in response mode controls the flashing of only the high beams High beams will not flash when the high beam switch 15 in the on position AUTOMATIC HIGH IDLE OPTIONAL If the system voltage drops to 12 4 v
74. reafter 5 000 MILES OR 3 MONTHS Check or Service Vendor Ref General Information Inspect The Fuel Cap Fuel Tank Repair Leaks As Required Tank Vent and Fuel Lines For Leaks Fuel Tank Vent Must Remain Open For Proper Operations Inspect Cable Refer To Inspect Cable For Engine Damage And Proper Manual Connections Operations and Maintenance Manual Custom Fire Truck Cab amp Chassis Models Rev Aug 2004 55 5 000 MILES OR 6 MONTHS Check Service Vendor Ref General Information Clean And Replace Air Compressor Refer To Air In Dusty Sponge Strainer If Equipped Brake Environments Reduce the Interval Between Setvices Clean Rear Axle Vent Refer Rear Clean While Axle Service Doing Fluid Manual Check Clean Battery Posts Clean More Often If Corrosion Appears Inspect Alternator Refer BENT Alternator Manual Check PH Factor On Radiator Coolant Serious Corrosion Will Occur If Correct Charge Is Not Used To Balance PH Factor Change Rear End Carrier Lubrication Refer To Drive Axle Manual Re Torque All Steering Balls And Bolts Tie Rods Drag Links Suspension Hangers And Components And Frame Bolts Inspect For Frame And Cross Member Scrap Grind Or Sand Use A Quality Corrosion Or Loss Of Paint Effected Areas Primer And Paint And Re Coat Areas Operations and Maintenance Manual Custom Fire Truck Cab amp Chassis Models Rev Aug 2004 56 6 000 MILES OR 6 MONTHS Check Or Service V
75. rogrammed to turn off under conditions of extreme electrical load Eight of the twelve outputs controlled by the load manager can be assigned to shed at one of eight priority levels The lowest priority loads will begin to shed when the system voltage drops to 12 7 volts and all loads programmed to shed will turn off after the system voltage drops to 11 0 volts In order for a load TOTAL to shed the system voltage must drop below the shed point voltage for a SYSTEM minimum of one minute Shed loads will remain off for a minimum of 5 minutes and will not turn on again until the system voltage rises above MANAGER the unshed point for one minute Load shedding is only active with the patk brake set scene mode Each load controlled by the load manager can be given a shed priority independent of its sequence AUTOMATIC HIGH IDLE OPTIONAL To increase alternator output under conditions of extreme electrical load the load manager will boost the engine idle speed after the system voltage drops below 12 8 volts for at least one minute The high idle will remain active for at least 10 minutes and until the system voltage has stabilized above 13 0 volts Automatic high idle will only be available with the park brake set transmission in neutral and when fire pump is disengaged The automatic high idle function can be deactivated by depressing the brake pedal Automatic high idle mode is indicated by the FAST IDLE light in the load manager disp
76. smission output retarder the energy is transferred to heat to be dispatched by the cooling system OPERATION A switch mounted on the dash turns on the retarder Completely removing foot from the accelerator applies the first one third of the retarder Applying pressure to the brake pedal applies the second one third of the retarder capacity The transmission temperature must be monitored TURN OFF if it reaches the 300 level Operations and Maintenance Manual Custom Fire Truck Cab amp Chassis Models Rev Jan 2005 35 Transmission pre select can be set for gear range 3 2 and will ensure maximum braking when brake is turned on Pre select keeps engine RPM speed at governor shift points for maximum braking and cooling to retarder and fan speed CAUTION The retarder will not bring the vehicle to a stop You must apply the chassis brake to bring the vehicle to a full stop WARNING Vehicles equipped with an auxiliary braking device may lose control in wet or slippery road conditions if ABS system is in the failure mode and the braking device 15 activated See auxiliary brake manufacturers manual for safe operating practices ELECTRIC DRIVELINE RETARDER OPTIONAL DESCRIPTION The Electric Driveline Retarder is an auxiliary braking device located in the driveline Its purpose 15 to supply additional braking torque to avoid fading of the chassis brakes that result from frequent stopping This will allow the chassis brakes to
77. ss the manual high idle button changes the display to High Idle Unlocked or release the parking brake Operations and Maintenance Manual Custom Fire Truck Cab amp Chassis Models Rev Jan 2005 24 HEATING amp AIR CONDITIONING CONTROLS Your truck may be equipped with a combination heating and air conditioning system a single overhead heater defroster system or a system that includes various auxiliary heaters If the truck has a multiplex electrical system the heating and air conditioning controls are accessed through the Vista Display non multiplex system includes controls located on the Switch Console Center for headliner evaporators and controls for the overhead heater defroster systems located on the driver s side of the overhead unit The controls for the auxiliary tunnel mounted combination heating and air conditioning unit may be located on the front of the unit most common or on the Switch Console Center To adjust the temperature rotate the temperature control switch to the desired level To adjust air speed rotate the blower control switch es to low medium or high fan speed For combination units the air conditioning switch must be in the on position for cold air operation It will be necessary to adjust the diffusers as necessary to direct the airflow Mode Control Switch Air Conditioning Mode Switch Temperature Control Switch Rear Blower Speed Switch Front Bl
78. steering system has been opened for any reason air MUST be removed from the system before placing the vehicle in service SEAT CONTROLS seats are equipped with three point seat belts Push the red button on the receiver to release The controls for adjustable seats are located at the front of the seat frame below the cushion Seat adjustments are activated by a mechanical lever an air pressure switch or an electronic switch depending upon the options selected The available seat comfort adjustments for fore and aft raise and lower back angle adjustment leg angle adjustment and lumbar is determined by the ordered option WARNING Occupants must be seated and seat belts must be securely fastened when vehicle 15 in motion or death or serious injury may result Operations and Maintenance Manual Custom Fire Truck Cab amp Chassis Models Rev Jan 2005 30 CUMMINS DIAGNOSTIC CENTER IDLE ADJUSTMENT SWITCH Use the middle switch to adjust the engine idle speed Each time the switch is pressed briefly to the minus position the idle speed 1s decreased by 25 RPM When the switch is pressed briefly to the plus position the idle speed 15 increased by 25 RPM ENGINE TEST SWITCH The control system can show and record operation anomalies that present themselves as fault codes These codes make troubleshooting easier The fault codes are recorded in the ECM They can read using the fault lamps in the dash or with
79. the number of sent received messages ENGINE INFORMATION MENU Engine Information displays the engine serial number filter part numbers and fluid fill information for the engine TRANSMISSION INFO MENU Transmission Info displays the transmission serial number filter part numbers and fluid fill information for the transmission CHASSIS INFO MENU Chassis Info displays the VIN sales order SO number and paint numbers MAINTENANCE SCHEDULE MENUS The Maintenance Sch 1 and Maintenance Sch 2 Menus provide important mileage horizons that need special attention 5 SECONDARY MENU BUTTON The Secondary Menu contains additional controls that are not programmed into the other menus 6 HEAT A C BUTTON The Heat A C button allows access to the Climate Control Menu Climate Control 2 70 F 70 F Set Temp Down Set Temp Up Climate Mode Auto Operations and Maintenance Manual Custom Fire Truck Cab amp Chassis Models Rev Jan 2005 23 CLIMATE CONTROL MENU The Climate Mode button allows the user to scroll through each available mode The fan speed 15 adjustable in any mode position except off Adjust the fan speed by pressing the up down arrows fot the front and rear of the vehicle Set Temp control buttons are used as stated up down to adjust the inside cab temperature to the desired setting Climate Mode button allows the user to scroll through the available operational modes using the Climate Mode button
80. ual Inspect Wheel Bearings Refer To Front Axle Service Manual 48 000 MILES OR 24 MONTHS Check Or Service General Information Ref Drain Flush And Replace Engine Refer To Use A 50 50 Mixture Of Drain Old Coolant Coolant Engine Ethylene Glycol And Mixture Into A Pan Service Water And Dispose of It In Manual An Environmentally See Engine Manual For Safe Manner Proper Use OF Propylene Glycol Inspect Engine Vibration Damper Refer Check Index Lines Replace If Out Of Engine Alignment By More Service Than 1 16 Manual Operations and Maintenance Manual Custom Fire Truck Cab amp Chassis Models Rev Aug 2004 60 50 000 MILES OR 3 MONTHS Check Or Service General Information Ref Lubricate Brake Slack Adjuster Shoe Refer To Lubricate With Standard Type Brake Slack Chassis Lubricant At Two Adjuster Fittings On Each Wheel Manual 50 000 MILES OR 6 MONTHS Check Or Service General Information Ref Inspect Air Brake Air Dryer For Proper Refer To Operation Air Brake Manual Inspect Air Compressor Discharge Head Refer To Ait Brake Manual 100 000 MILES OR 12 MONTHS Check Or Service General Information Ref Check Rear Axle Lubricant Refer To Drain Old Oil Into A Rear Axle Pan And Dispose of Service It In AN Manual Environmentally Safe Manner In Dusty Environments It May Be Necessary To Reduce The Interval Between Service Change Power Steering Reservoir Filter Refer To In

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