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Chassis Manual - Northwest Fire Protection District

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1. 4 9 47 85 WAXING INSTR GTIONS i ero itti eee teta 4 10 4 7 6 telle A ne ET 4 10 AT SURFACE RESTORATION te Peso beet ieu 4 10 4 7 8 RE COATING INSTRUCTIONS s sas ss nsa essa sse 4 10 viii Custom Chassis 2010 Pierce Manufacturing Inc All Rights Reserved 4 9 4 10 4 11 4 12 4 13 TABLE OF CONTENTS 4 7 9 GOLDSTAR STRIPING REPAIR INSTRUCTIONS iii 4 11 4 7 10 ABS PLASTIC ACRYLIC CURVED WINDOWS AND CLEAR LEXAN COMPONENT CARE 4 11 4 7 11 PRODUCT AVAILABILITY ete te eb pe E ertt e ee e e 4 11 COMMAND ZONE SYSTEM SELECTED CHASSIS ecciesie nennen nnne nnn nnnn nini 4 11 4 8 1 OVERVIEW 2 ttn cient epe trees ttn uiti d debe dert te di rv 4 11 4 8 2 MULTIPLEX SYSTEM PRINCIPALS OF OPERATION iii 4 12 4 83 7 TROUBLESHOOTING TIPS co os Rt o edi ule DR Reed 4 13 COMMAND ZONE DIAGNOSTICS rc REF eec eere E EE c EET o rg 4 13 INPUT OUTPUT SHEETS l O SHEETS
2. Rear3oxe Rear3oxe Reara0x6 Rear3oxe Reard0x6 EE mut REAR 0042 2 4 Custom Chassis 2010 Pierce Manufacturing Inc All Rights Reserved BEFORE PLACING VEHICLE IN SERVICE 2 4 Brake Burnishing 2 4 1 General Information IMPORTANT Brake noise is an inevitable characteristic of heavy duty truck brakes with aggressive friction materials Total elimination of all brake noise in heavy truck brakes cannot be expected Brakes shoes and pads are most effective after they have been worn in sufficiently so that the surface of the friction material mates consistently with the drum or rotor surface The process of wearing in the friction material is termed burnishing Braking performance and grade holding ability will improve once the brakes are burnished The following burnish procedure is recommended by the axle and brake manufacturer to optimize brake performance and minimize the possibility of developing brake squeal or vibration Pierce recommends a burnishing procedure be done after a new truck has been delivered and has been loaded to it s in service weight This same practice should also be done after new brakes disc brake pads or drum brake shoes have been installed This will ensure that they are broken in properly and will give proper performance during stopping and grade holding 2 4 2 Procedure Make sure the driving
3. 3 75 SYSTEM INFORMATION SCREEN 3 76 MODULE SCREENL s undressed nre ce eh Er o Eau 3 76 3224 4 GHASSIS SGREENS 3 78 DOOR SCREEN 2 ee ten need en tees wate tedesca ones olt deret 3 78 EOAD MANAGER SGREEN nr et 3 78 vi Custom Chassis 2010 Pierce Manufacturing Inc All Rights Reserved 3 22 3 23 3 24 3 25 3 26 3 27 3 28 TABLE OF CONTENTS COMMAND ZONE INFORMATION CENTER CZIC COLOR DISPLAY in nunne nnmnnn nnne 3 79 3 22 1 ITEMS COMMON TO ALL SCREENS 00000 0 naun EEEE AEEA sina sedes sans adesse ds san 3 79 CAUTION AND WARNING MESSAGES s 3 79 252 te Partes edem 3 79 SCREEN NAVIGATION BUTTONS Ve ee Dee 3 79 BASIC EUNGTIONS 7 2 Ra de c ip Po DD a t roto d n e di 3 79 3 22 2 COMMON SCREENS 5 3 atio Mq ta dede ce i deed umet a MERO dunes oo deret vg Ded lag 3 80 DO NOTMOVE za scritte dar D ne tue etes e se eoe tds ae 3 80 ENGINE INFORMATION SCREEN eet Dee terere eee ut eee eee et Rte 3 8
4. 3 88 3 24 2 ELECTRONIC STABILITY CONTROL ESC iii 3 88 3 24 3 SAPE VEHICIE OPERATION ei site bre e 3 88 STEERING NE TIL 3 89 3 25 1 STEERING GOLUMN ADJUSTMENT sui irae he sheet e rose exa Bases a 3 89 3 25 2 ALL STEER ALL WHEEL STEERING OPTIONAL iii 3 89 Diels ldem En idees 3 89 3 25 1 SGHAIN cies fus 3 89 FRONTARIRES 2222822806 mate EI 3 89 REAR TIRES reise ete DEN E 3 90 ALL WHEEL STEER TIRE CHAIN AVAILABILITY TABLE 3 4 3 90 372622 AUTOMATIC TIRE GHAINS deae tete ee tsi eite cos bete 3 90 TIRE PRESSURE MANAGEMENT SYSTEM uaa na es ARRA ERAN RR NR nnen ennnen 3 91 3 27 1 TIRE PRESSURE MANAGEMENT STANDARD enne nennen nena 3 91 3 27 2 TIRE PRESSURE MANAGEMENT OPTIONAL esses nennen 3 91 TRANSMISSION METELLI E Mmem 3 91 3 28 1 AUTOMATIC TRANSMISSION 2 sitis ense 3 91 3 28 2 TRANSMISSION OPERATING TEMPERATURE 0 0 0 000 3 92 3 28 3 NEUTRAL TO DRIVE SHIFT GROWL ALLISON MD TRANSM
5. nanas done ns 4 31 SAFETY RESTRAINTS AND DEVICES 4 32 4 21 SEAT BELTS ai nn Reddere en nn ee en ete 4 32 4 21 2 SIDE ROLL PROTECTION SYSTEM OPTIONAL 9 4 33 FAULT LIGHT INFORMATION oue eue eer Teu eb etre tea aee eu dnd 4 33 PRECAUTIONS WHEN TILTING THE CAB DURING MAINTENANCE ACTIONS 4 33 SPRING SUSPENSION FRONT AND REAR 4 34 MJ Nea EE 4 34 U BOLT FASTENER TORQUE CHART ARROW XT QUANTUM VELOCITY V IMPEL TABLE 4 6 4 34 U BOLT FASTENER TORQUE CHART SABER CONTENDER TABLE 4 7 4 34 4 22 2 SUSPENSION SHACKLES cdd a ae 4 35 CLAMP BOLT TORQUE CHART TABLE 4 8 2 nnn nnns 4 35 x Custom Chassis 2010 Pierce Manufacturing Inc All Rights Reserved 4 23 4 24 4 25 4 26 4 27 4 28 4 29 TABLE OF CONTENTS 4 22 3 SPRING PINS EXCEPT VELOCITY TIMPEL enn nne nenne 4 35 4 224 TAK 4M SUSPENSION 422222 2 Pa 28 cer Eat need nan tte eaa tee eee e 4 35 STEERING ELEM 4 35 4223 1 GENERAL INSPECTION 4 35 4 23 2 LAKS4IM STEERING 51 5 teet ee
6. 3 53 3 12 14a DIESEL FUEL REQUIREMENTS 3 53 3 12 14b ENGINE OIL REQUIREMENTS iii 3 53 3 12 14c DIESEL EXHAUST FLUID DEF 2010 EPA ENGINES us 3 53 3 12 15 HAND THROTTLE 5i tte erant be ehe Punti Poet ca ee P eder Et aa 3 54 3 12 16 COLD WEATHER OPERATION 8 3 55 COLD WEATHER PUMPER OPERATION 2 nennen nnns 3 55 INTER FRONT USAGE e annee shee cay e eue eos 3 55 FIRE SCENE OPERATION sopisi 5c cci Ev et tact pce Te Saco ce v croceo C ORIS ce eS Ie 3 56 3 191 EiGH HEAT SO URGES he etae and e o e e e Pe d efe ne e E ea C d 3 56 3 19 22 EEYING EMBERSS e e IUS oe E cc o US ce doe 3 56 2010 Pierce Manufacturing Inc All Rights Reserved Custom Chassis v TABLE OF CONTENTS 3 14 HEATING VENTILATION AIR CONDITIONING HVAC CONTENDER QUANTUM SABER 3 56 3 14 1 HEATER DEFROSTER ROTARY CONTROLS 3 57 3 14 2 AR CONDITIONING edge tecto quce dub RE dt de x Dod Code uated 3 58 921453 6 gt 200 hie Fem oss tet oon Ede eene far urs T 3 59 3 15 HEATING VENTILATION AIR CONDITIONING HVAC ARROW 0 0 0 8 4 3 60 321521 DEFROSTER RD uid n t Dc e NO a MER ea oleate 3 60 3 15 2 EEOORCEI
7. 3 2 Interior Inspection Safety Equipment 3 2 Introduction 3 71 Iia Eu 4 19 Items Common to All Screens 3 79 K Keyless Enty pee ste peius 3 9 L Latches and Window Regulators 4 16 Index 4 Custom Chassis Legal Requirements 3 1 Lift and Tow 2 4 48 Lift and Tow using Frame Forks Arrow XTTM Velocity Impel 4 46 Lift and Tow using Frame Forks Saber Custom Contender 4 48 Load Manager Screen 3 78 3 80 Low Fuel Warning Light 3 34 Lowest Gab 3 29 Lubrication Procedure Fifth Wheel Bearing 4 27 M Maintenance 2 4 1 Maintenance Screen 3 74 Maintenance Cummins 3 45 3 49 Manual Parking Brake Release 3 22 Manual Pump Operation 3 30 Matching Dual Tires 4 40 Menu Screen RUE 3 75 Meritor Driver Controlled Differential Lock 219 URP RN 3 19 rre ett EP 3 71 Mobile Radio Installation Guide A 1 Module Screen 3 76 3 86 Moisture and Ember Separators 4 21 Monthly Maintenance Schedule 5 2 Multi Ri
8. THANDLE Item Description Engine Oil PSI SHIFTER OPTIONAL LOC 10 NO MOUNTING FRONTAL PROTECTION EQUIPPED VEHICLES NO COMPONENT MOUNTING AT OR BELOW TOP OF GLOVE BOX 1193 Item Description Rear Air PSI Voltmeter Fuel Gauge Engine Coolant Temperature Hard wired Indicator Lights Tachometer Panel Dimmer Control Multiplex Indicator Lights Headlight Parking Light Switch Left Directional Emergency Master E M Button Indicator Right Directional LCD Display High Beam Indicator LCD Multi Function Control Low Coolant High Idle Switch Indicator Check Engine OK to High Idle Indicator Aux Brake Overheat Start Switch Caution Ignition Switch Indicator Warning Battery Switch Park Brake Applied Diagnostics Panel Stop Engine Alarm 1 DPF Regeneration Alarm 2 ABS Trailer Fault Park Brake Wait to Start Interaxle Differential Lock Indicator Traction Control Command Zone System Display Check Transmission Shift Selector Air Restriction Air Shift Pump Control Water in Fuel PUC Pump Control A B C D E F l J K L M N O P Q R Seat Belt Fastened Defroster Controls Rack Down Heater Controls Engine High Exhaust Temp Air Conditioning Controls ABS Tractor Fault Mirror Remote cao Em
9. 3 34 Cleaning nn Aa RUE RENE 4 18 Cold Weather Operation 3 55 4 6 Cold Weather Pumper Operation 3 55 Command Zone Information Center CZIC Color Display 3 79 Command Zone Diagnostics 4 13 Command Zone Information Center CZIC CANTrak Display 3 72 Command Zone Information Center CZIC Morey Display 3 72 Command Zone Information Center CZIC General Information 3 71 Index 2 Custom Chassis Command Zone Information Center CZIC Interior and Exterior Versions 3 72 Command Zone System 3 71 4 11 Common Screens 3 73 3 80 Component LED Heartbeat Red 4 13 Compression Brake 3 24 Configure Video 3 83 Control Systems 1122 3 25 Coolant Fill Procedure 4 16 Cooling System 3 31 4 14 Custom Products 2 2 1 4 Customer Assistance Information 1 6 Customer Installed Equipment and eia ende 2 6 D Daily Maintenance Schedule 5 1 Dana Drive Axle Wheel Differential Lock 3 20
10. 4 42 4 05 2 FRONT TOWING 2 3 ee tiet ete dee t otn Deseo e e b Doe e Are eeu 4 43 4 25 3 BEARSTOWING E Re Ek eer eim 4 43 4 254 TTOWCHOOKS AND TOWEVES iter eee bd a a Cle pev 4 44 4 25 5 TAK 4 SUSPENSION TOWING 4 45 4 25 6 TIRE LIFT METHOD PREFERRED 4 45 4 25 7 LIFT AND TOW USING FRAME FORKS ARROW XT VELOCITY IMPEL 22222222222 4 46 4 25 7a GENERAL PROGEDURE cete tere eee rete t 4 47 4 25 8 LIFT AND TOW USING FRAME FORKS SABERB CUSTOM CONTENDER 4 48 TRANSMISSION ENCEINTE MID 4 48 4 261 FRANSMISSIONSEELUD irren t al eth eee 4 48 4 26 2 TRANSMISSION FLUID ANALYSIS ALLISON TRANSMISSIONS 0 0 0 4 49 4 26 3 EXTERNAL TRANSMISSION COOLERS 4 49 TRANSFER CASE ALL WHEEL DRIVE 2 4 4 50 WELDING INSTRUCTIONS 4 50 ELECTRONIC COMPONENTS DISCONNECT TABLE BEFORE WELDING TABLE 4 12 4 51 WHEELS 2 de 4 52 42 291 5 US
11. Mounted to seat Integral to seat back bolster 0122 1109 Do not sit or lean unnecessarily close to the air curtain Do not place or mount any object over the air curtain or between the air curtain and the occupants Inflatable Head Curtains IHC Supplemental Restraint Airbags SRA are mounted on the seat backs of the outboard rear seats or integral to the outboard seat bolster PS6 seats In the event of a side roll accident the IHC SRA inflates the curtain air bag to protect the head and neck from contact with the cab structure The IHC SRA is designed to work in conjunction with your seat belts ALWAYS WEAR YOUR SEAT BELT 2010 Pierce Manufacturing Inc All Rights Reserved Custom Chassis 3 15 OPERATION 3 3 3d What to Expect During the Deployment of the Side Roll Protection System During a side roll accident the roll sensor will send a signal to deploy the advanced occupant protection devices to restrain and protect the occupants Below is a list of what to expect at each seating position during deployment Driver Position The driver position is equipped with a Suspension Seat Safety System 545 and Inflatable Tubular Structure Side Airbag ITS The 545 device will quickly activate and pull the seat belt tightly around the occupant The ITS side air bag will deploy and position itself next to the driver s head Simultaneously the seat will be pulled toward the floor and tightly held down until aft
12. 4 35 4 23 3 STEERING RESERVOIR A eine Sete dcn eet a sie 4 35 4 23 4 STEERING SYSTEM FASTENER TORQUE 20 400400 0 0 0 00 4 36 STEERING SYSTEM FASTENER TORQUE CHART TABLE 4 9 4 36 4 23 5 ALL STEER ALL WHEEL STEERING OPTIONAL 4 36 TIR S aie 4 37 2 241 TIBE INEEATION 2 6 re eerte erecta nn ci ne 4 37 TIRE DATA CHART TABLE 4 10 nin oru RE ed DENEN 4 38 4 24 2 TIREXEOADING te te e Ee ertet cen tb t reete beet 4 40 MICHELIN SPECIAL RATINGS CHART TABLE 4 11 4 40 4 243 MATCHING EAS e ctae cte esi rettet tiere tbe Mae ceo Re Re ibe Ane Le dep UN 4 40 4 24 4 TIRE WEAR INSPECTION deseo es nete teo seeds ad 4 41 4224 5 TIRE ROTATION et et io e dae Ae he See eere buda 4 41 ERONTLIBES 4 41 REAR TIRES en et sf ad Rires ls ion le th sh air alts 4 41 4 24 6 BALANGCING nn ees sit este Mae 4 42 4 24 7 TIRE PRESSURE MANAGEMENT SENSORS STANDARD 2 4 42 TOWING INSTRUCTIONS 2 Dod ae EE 4 42 4 25 1 PREPARATION FOR TOWING
13. 4 42 Pre Trip Inspection 3 1 Product Availability 4 11 Professional Training and Standards Organizations 1 7 Pump ur e ete iL 3 87 Pyrometer 3 34 Quarterly Maintenance Schedule 5 3 R Radio Equipment 2 6 Radio Installation 3 36 Raise Cab Re 3 29 b e b cs 4 2 Rear Axle Alignment 4 2 Rear Suspension 4 31 Rear 3 90 4 41 Rear Towing 252220 neige pre 4 43 Reasons for Daily Inspection 3 1 Re Coating Instructions 4 10 Refrigerant Recovery and Recycling 4 31 Regeneration ATD Cummins 2010 EPA 3 46 Cummins ISL 2007 EPA 3 43 Detroit Diesel 2007 EPA 3 38 Detroit Diesel 2010 EPA 3 40 2010 Pierce Manufacturing Inc All Rights Reserved INDEX Replacing a Command Zone Information Center 3 72 Responsibility a tics 1 3 Retarder Brake Capacity 3 25 Rim and Wheel Inspection 4 56 Roll S
14. 3 45 3 12 7d DPF BUILD UP WITHOUT REGENERATION iii 3 45 352 76 MAINTENANCE 2 52 5 3 eren ice eiu Tu e eat ISP Ma eds 3 45 3 12 8 AFTER TREATMENT DEVICE ATD REGENERATION CUMMINS ISL amp ISX ENGINES 2010 EPA 3 46 3 12 8a BASIC OPERATION OF THE AFTER TREATMENT DEVICE seems 3 46 3512 80 PASSIVE REGENERATION 5 Ere Let Maa pe E EE van 3 47 3 12 8 ACTIVE REGENERATION nnns iaaii esda sa sas tana 3 48 ACTIVE REGENERATION DURING STATIONARY OPERATIONS 1 42 2022 2 414 enne nnns 3 48 AUTOMATIC ACTIVE REGENERATION DURING DRIVING OR PUMPING CONDITIONS 3 48 3 12 8d DPF BUILD UP WITHOUT REGENERATION iii 3 49 3 12 86 MAINTENANCE irnir a De Tentes 3 49 3 12 8f SELECTIVE CATALYTIC REDUCTION SCR OPERATION 3 49 3 12 9 EMERGENCY SHUTDOWN OPTIONAL 3 50 ES PX E Eel or Ms int hate em ete tien isa tte tes 8 50 3 12 11 STARTING ENGINE USING POWER FROM ANOTHER VEHICLE ie 3 51 3 12 12 OPERATION OF ENGINE IN FUEL RICH ATMOSPHERE 3 52 3 12 13 AIR RESTRICTION INDICATOR is 3 52 3 1214 FLUID REQUIREMENTS mn nn ales tt ave erii tv p
15. 3 7 Brake Testing Test the Rate of Air Pressure Buildup 3 8 Brakes 2 3 21 4 3 Brakes General 4 3 Brakes TAK 4 Suspension 4 3 Bumper Extension Carriage Bolts 4 26 C Cab Dome Light Switch Replacement 4 5 Cab Exterior Equipment 2 6 Cab Interior Equipment 2 7 Cab Lift System 3 29 Cab Occupant Capacity 3 26 Cab Step Operation 3 27 Cab Step System Quantum 4 4 Cab Tilt Operation 3 28 Cab Tilt System sait res 4 6 and Maintenance 3 72 Care of Vehicle 4 7 Cast Spoke Wheels 4 54 Cast Spoke Wheels Installation 4 54 Caution and Warning Messages 3 73 3 79 Chain Clearance 3 89 Chain Clearance Front Tires 3 89 Chassis Alternator Belts Quantum with DDC Series 60 engine 4 22 Chassis and Aerial Information Center Differences 3 72 Chassis Screens sese 3 78 Chrome Cleaning 4 9 Circuit Breakers and Fuses
16. dass 2 6 2 5 4 CAB INTERIOR EQUIPMENT socrii nnana cat rte te Ure ce o abre e e wes Ra ED 2 7 2 5 5 AIR PRESSURE OPERATED EQUIPMENT 04 0 2 nnt sis 2 8 2 6 EQUIPMENT AND CARGO LOADING IRAN RR R4 ROS AR RS AR ARR NR S DAS AR R44 4 maar as ARR 4444 2 8 2 6 1 FRONT SPRING SUSPENSION ADJUSTMENT sese asas nnns ssa s s dns nana 2 9 2 6 1a TAK 4TM INDEPENDENT FRONT SUSPENSION eene eene 2 9 2 6 1b LEAF SPRING SUSPENSION 2 9 2010 Pierce Manufacturing Inc All Rights Reserved Custom Chassis i TABLE OF CONTENTS 2 7 ALL STEERG ALL WHEEL STEERING OPTIONAL 0 2 04 4 000 00 2 9 2 8 SUSPENSION on eec c PL a ae tu 2 10 2 8 1 SPRING SUSPENSIONS SPRING U BOLTS 2 10 2 8 2 AIR AND RUBBER SUSPENSIONS 44 4 0 ener nnns nens stesse assesses sinensis 2 10 SECTION 3 OPERATION 351 PRE TRIP INSPECTION i iei A esegue 3 1 3 11 REASONS FOR DAILY INSPEGTION iii inar T reatu a aae Tp 3 1
17. 2 1 AXleS 3 19 4 1 SEMI E 4 42 Basic Functions 1212222 3 79 Basic Operation of the After Treatment Device Cummins 2010 EPA 3 46 Cummins ISL 2007 EPA 3 43 Detroit Diesel 2007 EPA 3 38 Detroit Diesel 2010 EPA 3 40 Batteries assessment 4 18 Battery MN 3 33 Battery Charging Precautions 3 33 Battery SWITCH 2 etx ehe ceu 3 33 Bearings 4 52 Before Placing Vehicle in Service 2 1 Beginning the Inspection 3 1 Belt Inspection and Installation 4 22 Brake Balance manie d eda eu 2 2 Brake Burnishing 2 5 General Information 2 5 PROCCGUIC i 2 2 5 Brake Burnishing and Grade Holding 3 24 Brake Testing 3 7 Brake Testing Air Compressor Governor Cut In and Cut Out Pressures 3 8 Brake Testing Test Air Leakage Rate 3 8 Brake Testing Test Dual Air Brake System Warning Light and Buzzer 3 7 Brake Testing Test Parking Brake 3 7 Brake Testing Test Service Brake Stopping Action 3 7 Custom Chassis Index 1 INDEX Brake Testing Test That the Spring Brakes Come On Automatically
18. 24 1259 1262 1261 1 Install the frame fork adapters 1 Jerr Dan P N s 7 007 000055 amp 7 007 000056 the crossbar 2 Figure 4 11 2 Install the frame forks 3 Jerr Dan P N 3 454 000057 in the frame fork adapters 1 Figure 4 11 Figure 4 12 Under Lift Towing Fork Positioning amp Securing Vertical Web Frame Rail TIS MAX n Cross Section FRAME FORK 1260 1107 1258 3 Move the crossbar 2 under the front of the truck locating the frame forks 3 under the lift and tow saddle brackets IMPORTANT The frame forks posts are off set The post on the bottom of the fork should be positioned closest to the vertical web of the frame rail 4 Raisethe crossbar and position the frame forks in the opening of the lift and tow saddle brackets 4 just ahead of the tow eye 5 Figure 4 12 5 Safety chains 6 should be installed to the frame fork adapters and through the frame fork tow eyes Figure 4 12 6 Make sure the crossbar is secure Lift the truck and tow carefully 2010 Pierce Manufacturing Inc All Rights Reserved Custom Chassis 4 47 MAINTENANCE 4 25 8 Lift and Tow using Frame Forks Saber amp Custom Contender Saber and Custom Contender can be lifted and towed using a standard under lift device equipped with heavy duty frame forks This is a third towing alternative in addition to tire lift and flatbed transport When applying the frame forks to the frame exten
19. br 3 1 LEGAL REQUIREMENTS inei e cetur eee te e reach idees etae e t deeds 3 1 3 1 2 BEGINNING THE INSPECTION 10 3 1 RECORDS REVIEW ect beste t B en E Ere Bee I ire 3 1 APPROACHING THE VEHIGEE eese eet ee e eet 3 1 3 1 3 INTERIOR INSPECTION ae e oa eden ue ar Pea vile ene ra ne av pee aae a et pe DU E Vu eee e dea va 3 1 ENGINE COMPARTMENT MMMMMMMMMMMMMMMMMMMMMMMMMMEEEEEEEEEEEEEEEEEEEEMEEEMMMMMMMMMMMMM 3 1 GAB INTERIOR 23 tetas nt Door e ot an i b NT Fe He bate de etd Sn qe nl en A 3 2 p Perro Ert ee TEE 3 2 SAFETY EQUIPMENT a eve dv F e ed eve dade e aan Pw eL eet Ue dera ds 3 2 FUNCTIONAL GONTROLS deret dada date tua Pere ek atten 3 2 3 1 4 EXTERIOR INSPEGTION ce CO ne da 3 3 Hil iq TATE EP AE EN 3 3 WEHEEES AND RIMS 5e eee tee edi 3 3 BRAKE DRUMS OR SHOES 3 21 an bete Ta 3 3 STEERING SYSTEM SR nn gale ue ect e bua reta Den mt Hte edunt eroi sd 3 3 SUSPENSION SYSTEM Re e et UTR
20. Before transporting the disabled vehicle ensure that safety chains and tire straps are properly installed and secure Figure 4 9 1254 1255 4 25 7 Lift and Tow using Frame Forks Arrow XT Velocity Impel NOTE Towforks with a minimum of 6 50 spread between tines are required Jerr Dan P N 3 454 000057 Arrow XT Velocity and Impel chassis equipped with either a standard taper leaf spring front suspension or the TAK 4 independent front suspension can be lifted and towed using a standard under lift device equipped with heavy duty frame forks This is a third towing alternative in addition to tire lift and flatbed transport When lifting and towing using frame forks positioned in the disabled vehicles lift and tow saddle brackets care must be taken to ensure that no damage to the chassis occurs Securing the disabled vehicle to the tow vehicle may require some disassembly and is the responsibility of the tow vehicle operator Pierce Manufacturing does not warranty any damage that may occur due to improper towing Figure 4 10 Lift and Tow Saddle Brackets with Integral Tow Eye 1256 1257 4 46 Custom Chassis 2010 Pierce Manufacturing Inc All Rights Reserved MAINTENANCE A lift and tow saddle bracket including an integral tow eye is located beneath the left and right side frame rail extension Figure 4 10 4 25 7a General Procedure Figure 4 11 Frame Fork Adapters Crossbar amp Frame Forks
21. High beam low beam switching is accomplished by pulling on the lever until it clicks e Headlight flash to pass pull on the switch lever to flash the headlights with the headlight switch turned off Pull on the lever gently so that it does not travel to the click position to flash the high beams when the headlights are switched off Windshield wipers rotate the knob at the end of the lever to activate the wipers high low intermittent Windshield washers depending on the model press the knob at the end of the lever or grasp the collar near the end of the stalk and press inward to activate the washers Velocity V Impel V Arrow XT with Command Zone 3 11 14 Warning Lights Warning lights are provided to alert the operator that fluid levels pressures or temperatures are outside the normal operating range These lights may be located together or next to each corresponding gauge depending on chassis model The following warning lights are standard on Pierce Custom Chassis Engine oil pressure Engine coolant temperature e Transmission oil temperature Engine air intake restriction Coolant level Voltage level Air brake pressure front and rear e Fuel level low The following apply to Velocity Impel Arrow XT with Command Zone only Amber engine warning light AWL check engine Auxiliary brake overheat e Red engine stop light RSL Engine diesel particulate filter DPF
22. OPERATION 3 27 Tire Pressure Management System 3 27 1 Tire Pressure Management Standard NOTE The tire must be inflated to the correct pressure before installing the tire sensor valve cap to calibrate and ensure proper operation Your apparatus is equipped with a VECSAFE LED tire alert pressure management system that will monitor the pressure of each tire The VECSAFE valve cap is a chrome plated brass sensor that is installed on the valve stem of each tire This sensor will calibrate to the tire pressure when first installed on the valve stem The sensor will activate an integral battery operated LED when the pressure of that tire drops 8 psi The sensor can be checked for functionality and battery condition by simply unscrewing the cap If it is in working condition the LED will immediately start blinking 3 27 2 Tire Pressure Management Optional Your apparatus may be equipped with a SMARTIRE tire pressure management system that will monitor each tires pressure and temperature A 2 00 gauge located in the cab instrument panel will indicate each tires position pressure and temperature An alarm will sound when the tire pressure deviates 1096 or more A wireless sensor is mounted to each wheel The system has three 3 alert levels e Critical Low Pressure Alert Pressure Deviation Alert High Temperature Alert Each alert will trigger an audible alarm and an indicator light within the gauge to signal the driver of t
23. 1 Flip the control lever to the LOCK position either while the vehicle is stationary or while moving at a steady speed under 25 mph without the wheels slipping spin out 2 Letup momentarily on the accelerator pedal to relieve torque on the gearing and fully engage the clutch 3 When the differential lock is engaged the indicator light will be ON or an audible signal will sound When the differential lock is engaged the vehicle will understeer requiring a longer turning radius for a given turn To disengage 1 To disengage the Wheel Differential Lock flip the control lever to UNLOCK 2 Let up momentarily on the accelerator pedal to relieve torque and allow the clutch to disengage 3 When the differential lock is disengaged the indicator light and or audible signal will go out 3 43 Inter Axle Differential IAD Lock Tandem Axles Lock the Inter Axle Differential only when stopped or moving at a slow speed Never attempt to lock the Inter Axle Differential while the rear wheels are spinning as this may cause shock damage to the axle components and result in costly repairs Never shift a two speed tandem axle from one range to another with the IAD in the LOCKED position This may cause shock damage to axle components and result in costly repairs The inter axle differential provides for necessary differential action between the axles of a tandem drive unit This allows the wheels of either axle to revolve faster or slower
24. 3 29 3 93 SYSTEM VELOCITYTM IMPELTM 1 3 30 TO RASE RTT I 3 30 TO LOWER GABzz 1 edis eaa An Hes dre teta a rcd xb dH cervi eR e Doe a ete dre and 3 30 3 9 4 MANUAL PUMP OPERATION OPTIONAL usines 3 30 SABERB dated erc en S Wels D a a al aw Ee Waa el odd n A d ug t eR T V a 3 30 QUANTUMGB ARROW XT VELOCITY M IMPEL 222000048000 3 30 COOLING SYSTEM votre os aee tuc a E ETE E a Ver ue dune 3 31 dinde m E 3 32 Std ALTERNATOR atit rer t cre rese Pete v ates Pel s er Pelr tid le vere atu 3 32 9211 2 AMMETER OPTIONAL et eta entre ete ate m Dese ere bee ER RR D RR 3 32 9211 9 BATTERY us dieci cc ree cet vem Mana en Hia dn EE La Po ERAT 3 33 3 11 4 BATTERY CHARGING PRECAUTIONS 00 0020 0 esas nine nane 3 33 951405 255 ie de sen et rne dt Pea o e eed Pha de oa 3 33 93 11 6 e eet sen rate ett cv caduta a 3 34 3211 7 GIRCUIT BREAKERS AND F SES a ci vereint pater ea E Re tbe vk E ED MIRA 3 34 3 11 8 EIOURMETER ad ria Qa asi bn tte be an aus Peter 3 34
25. 4 5 6 Step Valve Adjustment 1 Loosen the 1 4 fasteners that attach the valve bracket assembly to the step box side 2 Close the door until the first latch is secured the door is not completely closed 3 While grasping the valve bracket at the closet point near the box side pull firmly until the valve button contacts the door pin and depresses The step will try to retract at this time Hold the step down to prevent it from rising 4 While maintaining pressure on the valve bracket tighten the two 1 4 fasteners tight enough to hold the assembly from shifting 5 Open the door and close gently to the first latch the step should rise at this point Close the door the rest of the way to the second latch 6 Ifthe step does not rise on the first catch close the door the rest of the way to see if it rises at the second catch Judgment is required at this point the distance from the first latch to the second latch is about 1 8 Move the valve bracket this amount and retry Once the proper valve position is attained torque the mounting fasteners to 6 ft Ibs 8 Repeatthis process for the remaining steps 4 5 7 Dome Light Switch Replacement Locate faulty switch and remove Disconnect wire connection at rear of switch Remove switch and discard Reconnect wire to switch D Set switch position 2010 Pierce Manufacturing Inc All Rights Reserved Custom Chassis 4 5 MAINTENANCE 6 The switch will set to th
26. 2010 Pierce Manufacturing Inc Part No PM C OM012 1110 Operator s Manual TABLE OF CONTENTS SECTION 1 TO THE OWNER 1 1 WHO SHOULD USE SERVICE AND MAINTAIN THIS VEHICLE nnne eese nennen ennnen nn nnn 1 1 1 2 WHAT To Do IF YOU LACK KNOWLEDGE ener nnn nhan nmn ns ARA RIS AR RR nr As nnn 1 1 1 3 WARNINGS AND CAUTIONS REI T 1 2 1 3 1 WARNING AND CAUTION STATEMENTS 1 2 1 32 GENERAL WARNINGS AND CAUTIONS 044 siis sa sss sies s sss sn 1 3 1 3 3 SAFETY WARNING LABELS 44 ss sss sn asa esse sana essa sana anna 1 3 1 4 RESPONSIBILITY 2 2 1 3 1 5 CUSTOM PRODUCTS RR EET EET tm 1 4 1 6 VEHICLE HANDLING CHARACTERISTICS nennen nnn nana aa aaa nana 4 SNR SAN E AR ARR nnmnnn manan 1 4 1 7 TANKER MOBILE WATER SUPPLY TRUCK CHARACTERISTICS 22 2 2 00 0 0 0000 1 4 1 7 1 DESCRIPTION OF HAZAR D r 1 4 1 7 2 RECOMMENDATIONS FOR PREVENTION 1 4 1 7 2a DRIVERS SHOULD DO THE FOLLOWING 1 5 1 8 VEHICLE
27. 3 34 Hub Piloted Wheel Installation 4 52 Hydraulic Retarder 3 25 Ignition and Starter Switches 3 35 Inflatable Head Curtain IHC 3 15 Inflatable Tubular Structure Side Airbag ITS 3 14 Initial Inspection Maintenance Schedule 5 1 Input Output Sheets I O Sheets 4 13 Inspection Approaching the Vehicle 3 1 Inspection Brake Drums or Shoes 3 3 Inspection Equipment Loading 3 4 Inspection Exhaust System 3 4 Inspection Pre Trip 3 1 Inspection Records Review 3 1 Inspection Steering System 3 3 Inspection Suspension System 3 4 Inspection Tires esee 3 3 Inspection Wheels and Rims 3 3 Instrument Panel Controls amp Indicators 3 61 Instrument Panel Indicator Lights Cummins 3 69 Instrument Panel Lamps Detroit Diesel 3 68 Integrated Belt Pretensioner IBP 3 15 Integrated Gas Pretensioner IGP 3 15 Inter Axle Differential IAD Lock Tandem Axles 3 20 Interior Inspection esses esee 3 1 Interior Inspection Functional Controls 3 2 Interior Inspection Glass
28. Always use appropriate protective equipment insulated gloves rubber gloves goggles face shield safety shoes protective clothing and insulated tools when working on electrical components circuits of the vehicle Never wear jewelry when working on this equipment Jewelry can conduct electricity resulting in electrical shock or burns and may get caught in moving components causing injury When working on vehicles that have high voltage devices or equipment use appropriate alerting techniques in plain view to warn people that may be in the general area and to prevent inadvertent activation of any disabled high voltage circuit s during service safety signs safety symbols tags barricades cones etc Keep a fire extinguisher close by at all times Extinguishers rated ABC by the National Fire Protection Association are appropriate for use on the electrical system Make sure the extinguisher is properly charged and be familiar with its use Ensure that the high voltage power high voltage power generating equipment and high voltage storage devices are disconnected locked out or otherwise disabled BEFORE working on or around the vehicle its electrical circuits or components Unless disabled Auxiliary Power Units APUs may start at any time without warning when this occurs the circuits associated with the APU become energized with potentially lethal high voltage Some components may require a waiting period or special procedures to disc
29. Check tension when belt is hot but wait until the belt is cool before tightening Multi rib drive designs may use pulleys that have more grooves than the belt One of the pulleys in the drive system will match the belt width Use this pulley to align the belt and install in the correct groove on the wider pulley A straightedge against the face of the aligning pulley will provide an accurate guide for the alignment of the belt Chassis Alternator Belts Quantum with Detroit Diesel Series 60 engine The alternator belt on the Quantum Chassis with a Series 60 engine is too short to allow the use of a Burrows tension gauge Check belt tension by applying 25 Ibs of force at the mid span of the belt Measure the deflection of the belt and compare to the following table Adjust tension in the belt to obtain the proper deflection Alternate method use Dayco Tension Tester P N 93865 Table 4 3 Alternator Belt Deflection Table Belt Deflection Type of Belt of Ribs in V belt 0 50 Inch Wide 0 50 Multi Rib 5 0 25 4 22 Custom Chassis 2010 Pierce Manufacturing Inc All Rights Reserved MAINTENANCE 4 13 4 Multi Rib Belt Fan Drive Quantum Fan clutches can engage and fan blades can spin without warning Keep hands hair and clothes away from fan Never operate the engine with personnel in the vicinity of the fan as the fan may engage without warning Failure to heed this warning may lead t
30. Welding on a truck may cause voltage surges to be distributed throughout the truck s electrical system Electronic components which are connected to the electrical system may be damaged due to these high voltage surges Electronic components may fail at relatively low voltages caused by a brief welding operation done on the truck Before welding disconnect all electronic components listed in Table 4 12 Special electrical system configurations may include additional electronic control units that may require disconnection before welding on the vehicle Most electronic component connectors that require disconnection when welding on the vehicle are identified by a Connector Disconnect Tag P N 91 0250 4 50 Custom Chassis 2010 Pierce Manufacturing Inc All Rights Reserved MAINTENANCE Table 4 12 Electronic Components Disconnect Table Before Welding Before any welding can be done on this unit you MUST disconnect the following DETROIT DIESEL DDEC Disconnect the three tagged plugs that are on the Detroit Diesel ECU Located on the driver side of the engine on Series 60 and Series 50 BOSCH or WABCO ABS Disconnect the tagged plug that attaches to the Bosch or Wabco ECU ABS ECU locations Saber under the first officer side of dash Arrow XT in the PMC box in the dash Arrow XT with Command Zone TM on chassis crossmember or under center tunnel cover e Quantum behind the pump in the frame rai
31. 20222 3 71 321971 ANTROD GTIGDON x ote ee 3 71 3 20 COMMAND ZONE INFORMATION CENTER CZIC GENERAL INFORMATION sense 3 71 3 20 1 CARE AND MAINTENANCE Sie tiber ete be ire tot ete eaten toga 3 72 3 20 2 INTERIOR AND EXTERIOR VERSIONS 3 72 3 20 3 CHASSIS AND AERIAL INFORMATION CENTER DIFFERENCES 44 4 3 72 3 20 4 REPLACING COMMAND ZONE INFORMATION CENTER 00 1 1 3 72 3 21 COMMAND ZONE INFORMATION CENTER CZIC CANTRAK DISPLAY 2 2 2441 1 3 72 3 21 1 SCREEN NAVIGATION BUTTONS sa esses sn 3 72 CANTRAK BUTTON FUNCTIONS TABLE 3 3 iii 3 73 3 21 2 CAUTION AND WARNING MESSAGES 0 0 0 3 73 3 21 3 GOMMON SGREENS 5 2 treten date E 3 73 MAINTENANCE SCREEN n denen Abonnent eei a e 3 74 5 lt 225 lid tee de tee 3 74 MENU SGREEN ES E tla lente tid nales cire seals a ahd Auta OA Eun IUE paie tI LEE 3 75 EEEE RA
32. 3 37 Stud Piloted Wheel Installation 4 53 Supplemental Restraint Airbag SRA 3 15 Surface Restoration 4 10 Suspension eese 2 10 Suspension Seat Safety System 545 3 13 Suspension Shackles 4 35 System Diagnostics 3 86 System Information Screen 3 76 System Menu ssesessseene 3 82 T TACROMELCR 12 ess totae E M 3 34 TAK 4 Steering sees 4 35 TAK 4 Suspension 4 35 TAK 4 Suspension Towing 4 45 Tanker Hazard Prevention 1 4 Tanker Truck Characteristics 1 4 Tanker Description of Hazard 1 4 RD 4 18 Thermostats 221222 4 15 Time and Temperature 3 79 Tire CHaINS gt 4 2 3 89 Tire Inflation 4 37 Tire Lift Method Preferred 4 45 Tire Loading 4 40 Tire PressUre 2 1 Index 6 Custom Chassis Tire Pressure Management Optional 3 91 Tire Pressure Management Standard 3 91 Tire Pressure Management System 3 91 Tire Rotation ee ee eei 4 41 Tire Wear Inspection 4 41 TES EE 4 37 T
33. 32227227473 V 7 0116 Item Description 1 Spacer Band Outer Dual Rim Rear Clamp Inside Rim gt NOTE All 8 5 5 rims require special size hubs and spacer bands 1 Place the inside rim 4 over the cast spoke wheel as far as possible 2 Push the spacer band 1 over the cast spoke wheel with constant pressure on both sides Guard against cocking 4 54 Custom Chassis 2010 Pierce Manufacturing Inc All Rights Reserved MAINTENANCE 3 Place the outer dual rim 2 in position Figure 4 17 Cast Spoke Wheel Nut Tightening Sequence 3 and 6 spoke 5 spoke 0117 4 Alignthe valve locators between the spokes Secure clamps 3 evenly in position Snug up nuts in the sequence shown Do not tighten nuts fully 5 Afterthe nuts are properly seated and the rim is centered on the spoke wheel tighten the nuts one quarter turn at a time in the criss cross sequence until they are tightened to 200 260 ft Ibs This will permit the rims to properly align themselves on the 28 mounting surfaces of the cast spoke wheel 6 Ifthe heel of the rear clamp touches the spoke before reaching 80 of the recommended torque level check to be sure that the proper clamps and spacer bands are being used Wheel Torque Demountable rims are not all the same offset Use the proper size tires rims spacer bands and clamps to get adequate dual spacing and vehicle clearance 1 Be sure to
34. 4 13 COMPONENT LED HEARTBEAT RED 2 4 13 INPUT MODULE CLEAR CASE OPTION 2 4 13 INPUT OUTPUT MODULE CLEAR CASE OPTION 4 13 OUTPUT POWER MODULE CLEAR CASE OPTION 4 14 DATA EINK TROUBLESHOOTING 255 x th terrere hr Y pagg 4 14 NON COMMAND ZONE TM COMPONENTS 4 14 COOLING SYSTEM rcm M 4 14 4 9 1 GENERAL INSPECTION AND SERVICE 4 111 4 14 4 0 2 Sof ohne core 4 15 4 9 3 HOSE CLAMPS iisdem ER edet EE ARA ANTE ERR ARA TER een AERE ie 4 15 4 0 4 WATER PUMP RR sha 4 15 4 0 5 THERMOSTANS onere E Din etie iate iut EE EID 4 15 4 9 6 ANTIFREEZE SOLUTION COOLANT CONDITIONER 2 4 15 4 9 7 COOLANT FILE PROCEDURE arbe eet rerit av pre eb P eas 4 16 DOORS AND WINDOWS E 4 16 4 10 1 LATCHES AND WINDOW REGULATORS 4 16 4 10 2 EXTERIOR DOOR HANDLES VELOCITY IMPEL 4 16 4 10 3 DOOR STRIKERS E 4 16 4 10 4 DOORS QUANTUMG et PER e ER 4 16 4 10 5 HINGES RER E
35. 4 14 1 General Notes for 2007 EPA amp 2010 EPA Engines No modification of the exhaust between the engine Diesel Particulate Filter DPF and Selective Catalytic Reduction SCR is allowed per the EPA Only tailpipes after the SCR are allowed to be changed All customer installed hardware needs to be kept a minimum of 6 inches away from any exhaust pipe and After Treatment Device ATD housing Failure to comply may result in heat related damage to the aftermarket components 4 14 2 Exhaust Diffusers NOTE All 2007 EPA amp 2010 EPA engines with Diesel Particulate Filters DPFs are equipped with exhaust diffusers Some Cummins ISM engines 450 HP and higher do not have DPFs Pierce Custom Chassis may be outfitted with diffuser exhaust tips These devices lower exhaust gas temperatures as they exit the tailpipe Exhaust Diffusers reduce exhaust outlet temperature by mixing ambient air with engine exhaust If equipped the Exhaust Diffuser installed on your truck should not be removed or modified in any way and must be replaced if damaged or missing Consult your Pierce Dealer for exhaust extraction systems that are compatible with the Pierce diffuser tips 4 24 Custom Chassis 2010 Pierce Manufacturing Inc All Rights Reserved MAINTENANCE Performance of the Exhaust Diffuser can be adversely affected by Exhaust Diffuser ambient air inlet obstructions Exhaust Diffuser outlet obstructions Damage to the Exhaust D
36. 4 17 4 10 6 WEATHERSTRIP ribi Haee ttt becas 4 17 DRIVESHAETS cie 4 17 zelo E 4 18 451221 ALTERNATOR die a ae ae ee We een del 4 18 4 122 BATTERIES oire 4 18 TERMINALS edet beatae uo de Lad edu eoe at a ata Sa tea eae 4 18 CARANING aar a EE EM 4 18 4 12 3 WIRE HARNESSES AND ELECTRICAL CONNECTORS iii 4 18 4 12 4 ALTERNATING CURRENT AC SYSTEMS 120 240 4 19 4 12 4 ALTERNATING CURRENT AC 2 4 19 4 12 4b AUXILIARY POWER UNITS APUS 4 19 4 12 46 SHORE POWER ie nee xe aed de een done tetes ad 4 19 4 12 4d INVERTERS iE denis tale Ei bdo Re Er en edat Facit dedecus 4 19 4 12 4e BEFORE SERVICING HIGH VOLTAGE EQUIPMENT 4 20 ENGINE onis iiu ec I E 4 21 45131 AIR INTAKE SYSTEM neuere nn suede o dud ere nn ark o rada 4 21 PERIODIC INSPECTION ERR e padece ga ete d rh 4 21 AR FILTER REPLACEMENT 3523225288 ced cooper etae cha bnt ser as onse ee 4 21 MOISTURE AND EMBER SEPARATORS iii 4 21 2010 Pierce Manufacturing Inc All Rights Reserved Custom Chassis ix TABLE
37. Certain aspects of suspensions will naturally wear in during the first few miles of operation under load Truck springs will wear off the high spots between the leaves friction rates will drop off and the ride height will settle in In most cases a leaf spring pack will settle by up to 0 50 inches in the first few hundred miles This settling phenomenon can also cause certain suspension fasteners to require tightening 2 8 1 Spring Suspensions Spring U Bolts Spring suspension U bolts must be tightened to the proper torque after approximately 500 miles of initial use See Spring Suspension Front and Rear on page 4 34 Ensure that this procedure has been completed prior to placing the unit in service Check other suspension related fasteners and torque as required 2 8 2 Air and Rubber Suspensions Like spring suspensions road shock and vibration can cause some initial settling of components Certain suspensions do require a retorquing procedure after the first 500 miles Refer to the suspension manufacturers service information for any pre delivery inspection or torquing requirements 2 10 Custom Chassis 2010 Pierce Manufacturing Inc All Rights Reserved SECTION 3 OPERATION 3 1 Pre Trip Inspection 3 1 1 Reasons for Daily Inspection To be sure that the vehicle is safe to operate conduct a pre trip inspection at the beginning of every work period Perform a pre trip inspection before each trip to find problems that cou
38. Operate the engine at a fast idle and monitor the pressure at the gauge 2 Listen for the air pressure governor to cut out indicated by a pressure discharge from the air dryer and a halt to the rise of the gauge needle The air governor should cut out the air compressor at about 125 psi 3 Operate the engine at idle 4 Apply and release the brake pedal to reduce the air tank pressure The compressor should cut in at about 110 psi indicated by a rise in the pressure at the gauge 3 2 Vehicle Entry and Exit Failure to exercise due care when entering and exiting vehicles can result in personal injury Entry and exit should be made slowly deliberately and carefully A three point stance should be used three out of four extremities should be in contact with the vehicle at all times Face inward toward steps and handholds when entering and exiting Always keep steps and handholds in continuous good repair Make sure all attaching bolts and hardware are tight thus eliminating any movement of steps and handholds Keep steps grab handles and shoes free of grease mud dirt fuel ice and snow Use extra care during inclement weather Do not step or climb upon any vehicle surface unless it is slip resistant and handholds are provided Certain steps may be of a pivoting or folding design Be certain that such steps are firmly engaged in the weight bearing position before placing full weight on the step Make sure steps are deployed
39. Speedometer Handheld Spotlight Transmission Oil Temperature Gauge Map Light Front Air Pressure Gauge Cigar Lighter Rear Air Pressure Gauge Mirror Remote Ramco Moto left Fuel Gauge Mirror Remote Velvac right of gauges Truck Alarm Steady Tone Tiller Jackknife Alarm Dimmer Control Defroster Fan Headlight Switch Anti Lock Brake System Equipped Tag Wiper Washer Controls 2010 Pierce Manufacturing Inc All Rights Reserved Traction Control System Equipped Tag Custom Chassis 3 65 OPERATION 3 17 4 Typical Velocity Impel Cab Instrument Panel Figure 3 15 Velocity Impel Controls and Indicators OVERHEAD BLANK NO GAUGE ALLOWED BATTERY SWITCH DIAGNOSTIC PANEL 2007 ENGINE REGENERATION SWITCHES OOA Item Description NOT 2 2 MOUNTING SURFACE E y MOUNTING SURFACE OFFICER S SIDE Ig ef 1251 Item Description 1 Engine Oil PSI Gauge 20 Heater Defrost Air Conditioning Switch 2 Voltmeter 21 Air Shift Pump with Indicator Light 3 Engine Coolant Temperature Gauge 22 4 Way Hazard Switch 4 Tachometer 24 Electronic Siren Control 5 Multiplex Indicator Lights 25a High Idle Switch 6 Speedometer 25b OK to Engage High Idle Indicator Light 7 Transmission Oil Temperature Gauge 26 Handheld Spotlight
40. Tires are of the same type not mixed radial and bias type Tires evenly matched same sizes Wheel bearing seals not leaking Right Rear Suspension Q Spring spring hangers shackles U bolts are in good condition Shock absorber shows no sign of excess wear or damage Powered axle s not leaking lube gear oil Torque rod arms and bushings show no sign of excessive wear Right Rear Brake Brake drums or rotors not cracked or worn Hoses show no signs of excessive wear Side Lights and Reflectors Q Side marker lights clean operating and proper color red at rear others amber Side marker reflectors clean and proper color red at rear others amber Rear Lights and Reflectors Rear clearance and identification lights clean operating and proper color red at rear Reflectors clean and proper color red at rear Taillights clean operating and proper color red at rear Rear turn signals operating and proper color red yellow or amber at rear License plate s present clean and secured Splash guards present not damaged properly fastened not dragging on ground or rubbing tires OooOoOCcoOoCOD Rear doors securely closed latched locked Left Rear Fuel tank is securely mounted not damaged or leaking Q Fuel tank contains enough fuel Fuel cap is on and secure Wheel and rim in good condition no missing bent or broken studs clamps or
41. aie enn inerte de nee Ted n aeo ra 3 37 3 12 5 AFTER TREATMENT DEVICE REGENERATION DETROIT DIESEL SERIES 60 2007 EPA 3 38 3 12 5a BASIC OPERATION OF THE AFTER TREATMENT DEVICE sees 3 38 3 12 5b PASSIVE REGENERATION iii 3 38 3 12 5c ACTIVE REGENERATION ote tete oet p tera Ind nnd De dto REA redet ride 3 38 3 12 5d PARKED REGENERATION iii 3 39 3 12 6 AFTER TREATMENT DEVICE REGENERATION DETROIT DIESEL DD13 2010 EPA 3 40 3 12 6a BASIC OPERATION OF THE AFTER TREATMENT DEVICE 3 40 3 12 6b PASSIVE REGENERATION tnn sanat nnta nennt sis tn nasi nes 3 40 3 1260 ACTIVE REGENERATION 5 tree sla es rex nacen ede 3 40 3 12 0d PARKED REGENERATION evt E ri eh re ib aee eei ua 3 41 3 12 6e SELECTIVE CATALYTIC REDUCTION SCR OPERATION ui 3 42 3 12 7 AFTER TREATMENT DEVICE REGENERATION CUMMINS ISL ENGINES 2007 EPA 3 43 3 12 7a BASIC OPERATION OF THE AFTER TREATMENT DEVICE sse 3 43 3212 76 PASSIVE REGENERATION ce Po Lee So ent e re grt rive rane rte 3 44 32 12 76 ACTIVE REGENERATION p ia 3 44 ACTIVE REGENERATION DURING STATIONARY OPERATIONS 3 44 AUTOMATIC ACTIVE REGENERATION DURING DRIVING OR PUMPING CONDITIONS
42. and brightness Changes made to these items are only reflected on the video screen 2010 Pierce Manufacturing Inc All Rights Reserved Custom Chassis 3 83 OPERATION 3 22 3d Set Startup Screen Figure 3 38 Set Startup Screen 0093 Selecting this screen will bring up menu of the default screens available Figure 3 38 The selected screen will be displayed each time the truck battery switch is turned ON To change the Startup screen use the UP and DOWN buttons to scroll to a different screen name then press the SAVE button 3 22 3e Set Date and Time Figure 3 39 Set Date and Time Screen 0094 Pressing this button will allow the operator to change the date and or time which displayed at the top of each Screen Time can be displayed in standard or military format 12 or 24 hour Pressing the NEXT button advances the indicator arrow to the next position The button will decrease the current value and the button will increase the current value 3 84 Custom Chassis 2010 Pierce Manufacturing Inc All Rights Reserved OPERATION 3 22 3f Set Language Figure 3 40 Set Language Screen Set Language 1375 The Set Language screen is used to select the language displayed by the Command Zone screens Available selections are English and Spanish 3 22 3g View Active Alarms Figure 3 41 Active Alarms Screen 1 7 2005 8 17 00 1 7 2005 8 17 00 VO MOD 3 C
43. regeneration light Engine high exhaust temperature HET Engine emissions system malfunction MIL e Check transmission e Air restriction e Water in fuel filter Ladder rack down Vehicles equipped with Command Zone On multiplexed vehicles this warning light information is also monitored by the Command Zone system The Command Zone system operates some dash indicators and all alarms Text messages related to most abnormal conditions are displayed on the Command Zone Information Center CZIC and on the 4 line LCD display on the instrument panel Velocity V Impel V Arrow XT with Command Zone only 3 11 15 Hazard Flashers A switch located on the lower left side of the steering column actuates the hazard flashers The hazard flashers will operate with the battery master switch and ignition switch in the ON position 3 11 16 Starter and Ignition Switches Pierce Custom Chassis are equipped with an ignition switch and a starter switch The ignition switch engages operational power to the chassis The starter switches engage the starter motor for cranking 2010 Pierce Manufacturing Inc All Rights Reserved Custom Chassis 3 35 OPERATION 3 11 17 Radio Installation Failure to follow the installation guidelines even though the equipment may appear to operate satisfactorily may lead to low voltage problems radio frequency interference or poor radio performance Vehicles equipped with Command Zone
44. 1 12 1 14 4 15 2 Bumper Extension Carriage Bolts Torque the 1 00 8 UNC carriage bolts that fasten the bumper extension to the frame assembly to 400 ft lbs 4 15 3 Other Fasteners Refer to the component manufacturer s service publications for the proper torque for fasteners installed into component housings such as axles engine transmission steering gear and suspensions 4 26 Custom Chassis 2010 Pierce Manufacturing Inc All Rights Reserved MAINTENANCE 4 16 Fifth Wheel Lubrication Tiller Only NOTE Every 3 000 miles or 6 months grease the fifth wheel bearing connecting the tractor to the tiller trailer 4 16 1 Grease Fitting Location Figure 4 5 Fifth Wheel Bearing Grease Fittings 1093 There are two grease fittings 1 remotely mounted on the upper fifth wheel weldment 2 directly above the fifth wheel bearing Each fitting is connected to the bearing with grease line tubing spaced 180 degrees apart Each of the grease fittings are easily reached by standing next to the rear chassis tires 4 16 2 Lubrication Procedure If an operator is being used to reposition the vehicle during this procedure the service technician must remain clear of the vehicle when the tractor trailer is being repositioned Failure to comply may result in personal injury or death To distribute the grease throughout the circumference of the bearing the bearing needs to be rotated by pivoting the t
45. 3 11 9 PYROMETER OPTIONAL s rina ne ne men hern tee du nane eaa eaae nn ea eda nn enn Pea 3 34 3 11 10 SPEEDOMETER AND ODOMETER _ sands sn assis nennen 3 34 31111 EoW FUEL WARNING LIGHT Fate itt t Lave f He s pet ea d d PU v P De e eT ead va 3 34 LAGHOME TER rales ure sete Ped eger sat 3 34 3511 19 TURN SIGNAL SWITCH 3 35 WARNING LIGHTS iare eati der iet ser E rx ERE aae Ede ee DRE Dua 3 35 9214 15 HAZARB FEASHERS eta p nan d teres pee EE a re ERE e DAS 3 35 3 11 16 STARTER AND IGNITION SWITCHES 11411 441 esse enne 3 35 iv Custom Chassis 2010 Pierce Manufacturing Inc All Rights Reserved 3 12 3 13 TABLE OF CONTENTS o 1 17 RADIO INSTALLATION 5 Be bat ede ics 3 36 EA 3 36 8 12 STARTING THESENGINE eee aUe LO eed ELE rec 3 36 3 12 21 RUNNING THE ENGINE rtt le re Let a ae santi te eta Leda 3 37 3 12 3 ENGINE SPECIFIC OPERATION INSTRUCTIONS 3 37 371224 STOPPING THE ENGINE
46. 6 Front 30 x 5 1 2 Front 30 x 5 1 2 Front 30 x 5 1 2 Front 30 x 5 8 001 54 000 Rear 30 x 6 Rear 30 x 6 Rear 30 x 6 Rear 30 x 6 Front 30 x 5 1 2 Front 30 x 5 1 2 Front 30 x 5 54 001 58 000 Rear 36 x 6 Rear 36 x 6 Rear 36 x 6 0039 Figure 2 2 Brake Power Chart Disc Brakes Front Cam Brakes Rear FRONT In Service Axle 11 000 14 600 14 601 16 540 16 541 18 000 18 001 21 500 Weights Lb Axle Model FG941 FL941 FL943 Front 24 x 5 1 2 Front 24 x 5 1 2 14000 17000 Rear 24 5 1 2 Rear 24 x 5 1 2 E Front 24 x 5 1 2 Front 24 x 5 1 2 Front 30 x 5 1 2 Front 30 x 5 1 2 17001 21060 521 Rear 30 x 5 1 2 Rear 30 x 5 1 2 Rear 30 x 5 1 2 Rear 30 x 5 1 2 Front 24 x 5 1 2 Front 24 x 5 1 2 Front 30 x 5 1 2 Front 30 x 5 1 2 21 001 24 000 1523 Rear 30 x 5 1 2 Rear 30 x 5 1 2 Rear 30 5 1 2 Rear 30 x6 Front 24 x 5 1 2 Front 24 x 5 1 2 Front 30 x 5 1 2 Front 30 x 5 1 2 21001 27000 nse Rear 30 x 6 Rear 30 x 6 Rear 30 x 6 0x6 jam lt Front 24 x 5 1 2 Front 24 x 5 1 2 Front 30 x 5 1 2 Front 30 x 5 1 2 n 2T R013000 Bonn Rear 36 x 6 Rear 36 x 6 Rear 36 x 6 Rear 36 x 6 34 000 42 000 RT34 Front 24 x 5 1 2 Front 24 x 5 1 2 Front 30 x 5 1 2 Front 30 x 5 1 2 RT40 Rear 30 x 5 1 2 Rear 30 x 5 1 2 Rear 30 x 5 1 2 Rear 30 x 5 1 2 42 001 48 000 RT44 Front 24 x 5 1 2 Front 24 x 5 1 2 Front 30 x 5 1 2 Front 30 x 5 1 2 PU NUM RT46 Rear 30 x 5 1 2 Rear 30 x 5 1 2 Rear 30 5 1 2 Rear 30 x 6 Fro
47. Actions The roll sensor s are programmed to allow for normal cab tilt using the cab lift system Before to performing any maintenance activity that require tilting the cab beyond the capabilities of the cab lift system turn OFF the vehicle power and disconnect the roll sensor s When the maintenance action is complete restore the Side Roll Protection System by turning the vehicle power OFF and reconnecting the roll sensor s connectors ensuring that the red locking tabs are latched Refer to the Pierce Service Manual group 0010 P 020 Side Roll Protection Troubleshooting Guide group 0845 P 001 Side Roll Protection Repair or contact Pierce Customer Service for additional information concerning the maintenance and service of the Side Roll Protection System 2010 Pierce Manufacturing Inc All Rights Reserved Custom Chassis 4 33 MAINTENANCE 4 22 Spring Suspension Front and Rear 4 22 1 Springs Inspect spring leaves for signs of wear cracking or bending Check for damage to spring stops Failure to follow these requirements for torquing and servicing U bolts and nuts may allow the axle to shift on the spring pack causing misalignment of the axles IMPORTANT Pierce Manufacturing does not approve disapprove or endorse the use of any aftermarket or add on suspension systems including aftermarket springs Installation of any such aftermarket or add on system is entirely at the discretion and risk of the customer
48. Dana Spicer Driveshafts Inspect driveshafts for signs of wear interference or looseness Observe any loose wires hoses or other components that may become entangled in the spinning shaft and secure properly 2010 Pierce Manufacturing Inc All Rights Reserved Custom Chassis 4 17 MAINTENANCE 4 12 Electrical 4 12 1 Alternator Proper belt tension is essential to avoid squealing slipping or throwing of alternator belts Proper belt tension should be checked using a Burrows Tension Gauge or equivalent Refer to Fan and Accessory Belts on page 4 22 for belt installation instructions and proper belt tension values 4 12 2 Batteries Terminals Make cable connections as corrosion resistant as possible by coating the connections with a heavy general purpose grease or battery terminal protection product Tighten the cable clamps to the battery posts before applying the grease This prevents the grease from getting between the clamps and the posts and thereby restricting the flow of electrical current Cleaning Batteries can be cleaned with a brush dipped in a baking soda or ammonia solution Make sure the battery caps are tight to prevent the solution from entering the battery After cleaning flush with water Clean battery terminals with a steel wool or a wire brush Keep terminals clean and tight Make sure vent holes in the battery caps are open 4 12 3 Wire Harnesses and Electrical Connectors When adding electrical
49. Data Link Troubleshooting 4 14 d Lex 3 61 Defroster Li 3 57 Defroster Arrow XT 3 60 Diesel Exhaust Fluid DEF 3 53 Diesel Fuel Requirements 3 53 Differential Lock Inter Axle IAD Tandem Axles 3 20 Dissimilar Metals esses eene 2 6 Do Not Move Truck Screen 3 80 Door Handles Exterior 4 16 Door Scr en ce eas ecu 3 78 Door Strikers eoi oie ce oe raro 4 16 Bom EE 4 16 Doors and Windows 4 16 Downhill Operation or Heavy Braking 3 21 DPF Build Up Without Regeneration 3 45 3 49 Driveshafls 1 2 sicci een e nacaid aa 4 17 E Electrical ste eee 3 32 4 18 Electromagnetic Retarder 3 25 Electronic Stability Control ESC 3 88 Emergency Parking Brake Release 3 23 Emergency Shutdown 3 50 Engine ie dote erede pones 4 21 2010 Pierce Manufacturing Inc All Rights Reserved Engine Diagnostic Software CUMMINS 4 23 Detroit Diesel 4 23 Engine Information Screen 3 80 Engine Mount Iso
50. Dei ies 3 16 3 3 3 WHAT DO AFTER A DEPLOYMENT iii 3 16 VEHICLE ACCIDENT RESPONSE INFORMATION cccccccceccecseesesaecaecececeecesceceeeseaaaeaecseceeeeeseeeeseeees 3 16 RETURNING TO SERVICE Li erint E en d edo Coi Ca Ra Ru er E 3 17 3 3 4 FRONTAL IMPACT PROTECTION OPTIONAL 2 2 2222 02 6 0000000 0000000000000000 3 17 3 3 5 SCBA BRACKETS MOUNTED IN SEAT BACKS 20 40000 3 18 3 49 06 SEAT ADJUSTMENLT 3 19 3 3 7 ADJUSTABLE FOOT PEDALS OPTIONAL nennen enne enne 3 19 AXLES m eT 3 19 3 4 1 MERITOR DRIVER CONTROLLED DIFFERENTIAL LOCK DCDL OPTIONAL 3 19 3 4 2 DANA DRIVE AXLE WHEEL DIFFERENTIAL LOCK OPTIONAL 3 20 3 4 3 INTER AXLE DIFFERENTIAL IAD LOCK TANDEM AXLES essen 3 20 3244 NTWO SPEED REAR AXLE D b ER decd EE A EE eR Ta LL EA ded 3 20 BRAKES arn nd EN ad a uu E dca wi Tan du RR RR de 3 21 3 5 1 DOWNHILL OPERATION OR HEAVY BRAKING iii 3 21 3 5 2 AIR PRESSURE GAUGE INDICATOR LIGHT AND AUDIBLE ALARM nennen 3 21 3 5 3 ANTILOCK BRAKING SYSTEM ABS iii 3 21 3 5 4 TRACTION CONTROL OPTIONAL raea oa rea aaka ae i rentre 3 22 3 55 PAR
51. Figure 3 29 indicates the status of doors and other items that must be closed or stowed before moving the vehicle This screen displays automatically when the DO NOT MOVE TRUCK warning message becomes active Engine Information Screen Figure 3 30 Engine Information Screen 0086 The Engine Information screen Figure 3 30 displays engine rpm engine temperature engine oil pressure battery voltage and fuel level The color of the box containing the data will be GREEN when the data is within an optimal range YELLOW when the data has entered a caution range and RED when the data has entered a warning range Load Manager Screen Figure 3 31 Load Manager Screen 0087 3 80 Custom Chassis 2010 Pierce Manufacturing Inc All Rights Reserved OPERATION Load management begins to shut off shed major electrical loads in a predetermined sequence as the electrical system voltage decreases The Load Manager screen Figure 3 31 displays the status of each electrical function that has been selected to be load managed Each truck is programmed to include a specific number of electrical devices which will be load managed The load managing sequence is preset at the factory depending on the range of options and their amperage draw This screen can only be viewed when the parking brake is set Seat Belt Screen Optional Figure 3 32 Seat Belt Screen 0088 The Seat Belt screen Figure 3 32 indi
52. High Trans Oil Temp Retarder Engaged Green Low Front Air PSI Red Retarder Overheat Amber Low Rear Air PSI Red Low Coolant Amber Spare Driver s Side Door Open Red DPF Regeneration Required Tower Raised Indicator Red Hi Exhaust Temperature First Officer Side Door Open Red DPF Malfunction zizra rgommsoom Air Restriction Amber Intake Air Heater Active Parking Brake ON Red Shift Selector Ladder Rack Down Red Parking Brake A Battery System ON Green Start Switch Ignition ON Green Heater and Defroster Controls A B C D E F G H l J K L M N O P Q R S U Battery System ON Green Air Shift Pump Control with Indicator Speedometer Mirror Remote Trans Oil Temp Gauge Diagnostic Manual Regen Switch Cummins Front Air Pressure Gauge Seat Belt Monitor Display Rear Air Pressure Gauge 2010 Pierce Manufacturing Inc All Rights Reserved VDR Diagnostic Plug Custom Chassis 3 63 OPERATION 3 17 3 Typical Arrow Cab Instrument Panel Figure 3 13 Arrow XT Controls and Indicators with Command Zone OVERHEAD CONSOLE NOTE 1 19 ARE PART OF A NON MODIFIABLE GAUGE ASSEMBLY BLANK NO GAUGE ALLOWED LOWER CONSOLE fe D e LOC 1 LOC 2 le MAPLT
53. Links 5 2 Custom Chassis 2010 Pierce Manufacturing Inc All Rights Reserved Description Action Miles Time Driveshafts Inspect for signs of damage Weekly Electrical Connectors Inspect for tightness corrosion and integrity Weekly Electrical Harnesses Inspect for rubbing fraying or looseness Weekly and Wires Fan Drive Quantum Check fluid level using sight glass Fill with MOBIL SHC Weekly 630 synthetic oil Inspect coupling for wear or misalignment Frame Fasteners Inspect for looseness wear or corrosion Weekly Fuel System Inspect for signs of damage leaking or chafing Weekly Fuel Water Separator Check water collection bowl and drain condensate Weekly Mirror Hardware Inspect fasteners for tightness and integrity Weekly Seat Belt Assemblies Inspect for signs of damage wear or corrosion See Weekly Seat Belts on page 4 32 for additional information Springs Inspect for signs of wear cracking or bending Weekly Steering Hydraulic Check oil level using dipstick sight glass or electronic Weekly System monitor Fill with DEXRON Ill Steering System Inspect all steering parts for integrity See Steering on Weekly page 4 35 for additional information Suspension Hangers Inspect for signs of wear corrosion or damage Weekly and Shackles Tires Inspect tread depth and check for damage Weekly Wiper Blades Clean wiper blades Weekly Table 5 4 Monthly Maintenance Schedule Description Action Miles
54. MIL light Table 3 2 Cummins Engine Instrument Panel Lights The amber Engine Warning light indicates a non critical system fault with the engine has occurred The operator can drive the vehicle to the end of their shift and call service to remedy the problem The red Engine Stop light indicates a serious engine fault that may result in engine damage has occurred The operator should move the vehicle to a safe location and shutdown the engine The Diesel Particulate Filter DPF light provides an indication that the filter has not been able to regenerate under the previous engine operating conditions and is in need of assistance in order to perform an active regeneration There are progressive stages of need for regeneration indicated by this light as depicted in the following points On solid indicates low to medium levels of particulate build up Flashing indicates medium to high levels of particulate build up and a signal that a DPF regeneration is needed e Flashing with amber Engine Warning light indicates a high level of particulate build up and a DPF cleaning is required immediately The first stage on solid should allow the vehicle to complete a typical shift of operation depending on vehicle duty cycle This provides time for a vehicle to return to a maintenance facility or change duty cycle increase exhaust temperatures by normal truck use without impacting the current mission The DPF light will
55. News Groups rec radio amateur equipment rec radio amateur misc 2010 Pierce Manufacturing Inc All Rights Reserved Custom Chassis A 3 MOBILE RADIO INSTALLATION GUIDE 4 Custom Chassis 2010 Pierce Manufacturing Inc All Rights Reserved Numerics 3 5 Year Maintenance Schedule 5 4 4x4 All Wheel Drive and Two Speed Axle Combination 3 93 4x4 Transfer Case All Wheel Drive 3 92 A ABS Plastic and Clear LEXAN Component 4 11 Acrylic Curved Window Care 4 11 Active Regeneration Cummins 2007 EPA 3 44 Cummins 2010 EPA 3 48 Detroit Diesel 2007 EPA 3 38 Detroit Diesel 2010 EPA 3 40 Aerial Device Boom Support 4 1 Air and Rubber Suspensions 2 10 Air Conditioning 3 58 3 61 4 30 Air Conditioning Sight Glass 4 31 Air Conditioning Unit Arrow XT 3 60 Air DIVO asser 3 23 4 3 Air Filter Replacement 4 21 Air Intake and Charge Air Cooler Hose Clamps techo tee 4 21 Air Intake System 4 21 Air Pressure Gauge Indicator Light and Audible Alarm 3 21 Air Pressure Operated Equipment 2 8 Air Pressure Requi
56. OF CONTENTS 4 14 4 15 4 16 4 17 4 18 4 19 4 20 4 21 4 22 4 13 2 AIR INTAKE AND CHARGE AIR COOLER HOSE CLAMPS 2 2 4 21 4 13 9 FANAND ACCESSORY BELTS s ia ebore eu uk a anu n saute 4 22 BELT INSPECTION AND INSTALLATION 2 2 4 22 BELT TENSION TABLE TABLE 4 2 c cccccccccsccecsssececseeeccsaesesseeeccsaeeecceeeecaeeeeeseeccaeesscseeecsaeeeesaeeees 4 22 CHASSIS ALTERNATOR BELTS QUANTUM WITH DETROIT DIESEL SERIES 60 ENGINE 4 22 ALTERNATOR BELT DEFLECTION TABLE TABLE 4 3 eene 4 22 4 13 4 MULTI RIB BELT FAN DRIVE 2 4 23 4 13 5 ENGINE SERVICE SCHEDULE 4 23 4 13 6 ENGINE MOUNT ISOLATORS teet ette thu te epus taire tete 4 23 4 13 7 ENGINE DIAGNOSTIC SOFTWARE DETROIT DIESEL is 4 23 4 13 8 ENGINE DIAGNOSTIC SOFTWARE CUMMINS nnne 4 23 EXHAUST SYSTEM 5 1 ii ei oia occu tn AEE intenses 4 24 4 14 1 GENERAL NOTES FOR ALL 2007 EPA amp 2010 EPA ENGINES 4 24 4 14 2 EXHAUST DIFFUSERS a d nene ii na stance Fee nA 4 24 FASTENERS dents Sled T decal load a Slat ae id Rei ee ani 4 25 4 15 1 FRAME FASTENERS cccccccsssccsssscecssecessseeesenaecseceeecuaecscaasecssesssseasecssesssseaaececaesecaaaecsesseeessaeeessaeeess 4 25 GRADE 8 COUR
57. Rear Duals 0115 Table 4 13 Wheel Nut Torque Chart Torque Thread Size Ft Lbs Dry 10 Hole 285 75 mm Hub Piloted M22 x 1 5 450 500 10 Hole 285 75 mm Hub Piloted M22 x 1 5 390 450 with Meritor ADB 1560 disc brakes 4 Tighten flange nuts fully using the same alternating sequence In each case be sure to tighten wheel nuts only to the torque level recommended in the table and to maintain them at that level through planned periodic checks 5 Checktorque on wheel nuts after the first 50 to 100 miles of service 4 29 4 Stud Piloted Wheel Installation Optional 1 Mount wheel or inner dual wheel over studs being careful not to damage stud threads 2 Spin on the outer cap nuts on the front wheel or inner cap nut on the rear wheel Figure 4 15 Wheel Nut Tightening Sequences 2 1 9 7 10 8 0 10 8 9 10 o5 30 6 O O3 50 O4 M 79 2 Stud Pilot Stud Pilot Outer Dual Front and Inner Dual POMO115 3 Snug up nuts alternately in the sequence shown DO NOT tighten them fully until all have been seated This procedure will permit the uniform seating of nuts and ensure the even face to face contact of wheels and hub 4 Tighten nuts fully per the values listed in the Torque Chart using a calibrated torque wrench and following the same alternating sequence 5 Mount the outer rear wheel and repeat the entire procedure In each case be sure to tighten wheel nuts only to the torque leve
58. Switch 8 Front Air PSI Gauge 32 Emergency Master Switch 9 Rear Air PSI Gauge 33 AM FM Radio 10 Fuel Gauge 38 Map Light 11 Indicator Lights 39 Cigar Lighter 12 Panel Dimmer Control 40 Air Horn Pushbutton Switch 13 Headlight Switch 41 Digital Clock 14 LCD Display on Gauge Assembly 42 Mirror Remote Controls 15 Ignition Switch with Indicator Light 44 Inter Axle Differential Lock Control 16 Display Location 57 Seat Belt Monitoring Display 17 Shift Selector 61 Low Sulfer Fuel Only Tag 18 Parking Brake 62 VDR Diagnostics Plug 19 Start Switch 3 66 Custom Chassis 2010 Pierce Manufacturing Inc All Rights Reserved OPERATION 3 17 5 Steering Wheel Controls Optional Figure 3 16 Steering Wheel Controls Optional TO Item Description Item Description Air Horn Emergency Master Dome Light Front Mechanical Siren Dome Light Rear 5 Area Lighting Windshield Wipers 2010 Pierce Manufacturing Inc All Rights Reserved Custom Chassis 3 67 OPERATION 3 17 6 Instrument Panel Indicator Lights Detroit Diesel Engines 2007 EPA amp 2010 EPA Detroit Diesel engines have five instrument panel lights to monitor engine and exhaust after treatment status The Check Engine light and Stop Engine light refer to basic engine functions The three after treatment lights
59. Time Axle Rear Check oil level in carrier 10 000 Monthly Battery Posts Clean and grease after cleaning 3 000 Monthly Cab Step Pivot Lubricate with Lubriplate low temperature grease 3 000 Monthly Quantum Cab Tilt Pivot Pins Lubricate with Lithium NLGI Grade EP2 grease 3 000 Monthly except Velicity Impel Cab Tilt Remote Lubricate with NYK corrosion preventative compound 3 000 Monthly Control Receptacle Trucklite 97944 or equivalent Driveshaft Slip Joints Lubricate with Lithium NLGI grade EP2 grease 3 000 Monthly Driveshaft U Joints Lubricate with Lithium NLGI grade EP2 grease 3 000 Monthly Radiator and Charge Clean debris to ensure unimpeded air flow through 3 000 Monthly Air Cooler Cores cores Spring Pins Lubricate with Lithium NLGI grade EP2 grease 3 000 Monthly Steering Intermediate Lubricate with Lithium NLGI grade EP2 grease 3 000 Monthly SERVICE AND LUBRICATION INTERVALS 2010 Pierce Manufacturing Inc All Rights Reserved Description Action Miles Time Wheel Bearings Oil Check fluid level and add as required 3 000 Monthly Front Axle Wheel Nuts Check torque and tighten as required 3 000 Monthly Windshield Wipers Check torque and tighten as required 3 000 Monthly Velocity V Impel TM Table 5 5 Quarterly Maintenance Schedule Description Action Miles Time Cab Lift Cylinder C
60. accessories choose mating connectors and terminals carefully to avoid electrolytic corrosion Joining connectors of dissimilar material can cause a chemical reaction that will quickly corrode the joint and electrical conductivity will be reduced or lost Inspect electrical connections for corrosion looseness or heat damage Clean tighten or replace as necessary Inspect all wire harnesses and look for evidence of broken wires chafing or heat damage Repair or replace as necessary 4 18 Custom Chassis 2010 Pierce Manufacturing Inc All Rights Reserved MAINTENANCE 4 12 4 Alternating Current AC Systems 120V 240V To avoid property damage personal injury or death refer to the manufacturer s service information before working on any high voltage equipment By definition high voltage circuits and components contain voltage levels that may cause equipment damage electrical shock and or electrocution if handled incorrectly All electrical circuits associated with Auxiliary Power Units APUs shore power and inverters should be considered high voltage Only trained technicians may perform service inside high voltage components If you work around or maintain high voltage circuits please seek high voltage training 4 12 4a Alternating Current AC The main difference between AC and Direct Current DC systems if that the voltage levels in DC systems remain constant while the voltage levels in AC systems are c
61. and environmental conditions of operation Check all metal surfaces thoroughly while making tire inspections including areas between duals and on inboard side of wheel Watch for Excessive rust or corrosion buildup Cracks in metal Bent flanges Deep rim tool marks on rings or in gutter areas e Loose missing or damaged nuts or clamps Bentor stripped studs Severe marring or gouging beneath fasteners Damaged or missing rim valve locator plates Incorrectly matched rim parts Mark damaged or broken areas when seen so that rim will be removed from service at the first opportunity Replace the assembly that has damaged rims or wheels Determine the cause of the damage before installing another wheel or rim If nuts are found to require frequent tightening studs break frequently or wheel bolt holes become damaged review hardware and mounting practices to determine cause 4 30 Windshield Wiper System The Velocity Impel windshield wiper control is located on the turn signal lever on the left side of the steering column The Velocity Impel chassis utilize three wiper blades controlled by a single motor and linkage arrangement to drive the wiper arms providing for synchronous movement The windshield wipers on Arrow XT Quantum and Saber have separate motors and switches for the left and right arms 4 56 Custom Chassis 2010 Pierce Manufacturing Inc All Rights Reserved MAINTE
62. are recirculation only systems the A C may be required to dry the air in situations where the windshield might fog over 3 16 2 Heat There are two heater units one under each rear facing seat Each unit has an outlet at the floor blowing rearward and an inlet immediately above in the seat riser In addition each unit has a duct routed to the first officer and driver foot area These outlets are located in the seat riser next to the engine tunnel Controls consist of temperature and fan speed The left and right units are controlled simultaneously 3 16 3 Air Conditioning The air conditioning system has a roof mounted condenser and a ceiling mounted evaporator unit The evaporator is mounted in the center of the cab There are six fully adjustable circular louvers for the driver and first officer and six louvers for the rear seating positions The temperature and fan speed are controlled with electronic keypad style switches One switch controls both front and rear 3 17 Instrument Panel Controls amp Indicators The exact layout of gauges switches indicators and controls on Pierce Custom Chassis varies between models Instrumentation layouts between vehicles of the same model will vary depending on the level of customization The following layouts of controls and indicators are the most common The layout in your Pierce Custom Chassis may vary Refer to the Instrument Panel Layout drawings found in the Electrical System Manual for
63. are the Diesel Particulate Filter DPF light the High Exhaust System Temperature HEST light and the Malfunction Indicator Lamp MIL light In addition 2010 EPA Detroit Diesel engines have an additional Diesel Exhaust Fluid DEF light Table 3 1 Detroit Diesel Engine Instrument Panel Lights The amber Check Engine warning light indicates a fault with the engine controls has occurred The operator can drive the vehicle to the end of their shift and call service to remedy the problem The red Stop Engine warning light indicates a major engine fault that may result in engine damage has occurred The operator should move the vehicle to a safe location and shutdown the engine The Diesel Particulate Filter DPF light will illuminate when a regeneration is necessary There are progressive stages of need for regeneration indicated by this light The first stage on solid should allow the vehicle to complete a typical shift of operation depending on vehicle duty cycle This provides time for a vehicle to return to a maintenance facility or change duty cycle increase exhaust temperatures by normal truck use without impacting the current mission In the event the DPF light has recently activated the truck can be driven onto a highway or put into pump mode to put load on the engine allowing an automatic regeneration to clean the DPF Regeneration should take place within a reasonable amount of time The second stage flashi
64. area with Wax amp Grease Remover or Naphtha 2 If bare metal is exposed any corrosion must be removed This should be done with a fine abrasive Reclean surface if necessary 3 If bare metal is exposed primer should be applied Apply the color coat touch up paint to a sample piece to ensure good a color match Apply a thin coat of color If a second coat is required allow the first coat to dry 4 7 7 Surface Restoration If minor surface scratches or nicks cannot be repaired using methods previously explained a trained professional should make the necessary repairs 4 7 8 Re coating Instructions e Re coat Gold Leaf painted surfaces every 12 to 18 months depending on vehicle duty cycle using a two part polyurethane clear coat Repair any nicks or deep scratches in the paint as soon as discovered with commercially available touch up primers and paints If additional equipment is mounted with screws to a painted surface seal all holes with a commercially available sealant to prevent corrosion starting from the screw holes If possible do not use screws Instead electrically separate dissimilar metals with adhesive sealants tapes or vinyl barriers 4 10 Custom Chassis 2010 Pierce Manufacturing Inc All Rights Reserved MAINTENANCE 4 7 9 Goldstar Striping Repair Instructions Any Goldstar product that is replaced must have all cut edges sealed Seal all cut edges with a two part polyurethane clear coat Paint a
65. can be transferred through the differential to the wheel that has the traction It reduces engine torque when both wheels are spinning to improve traction The ATC light located in the cab will light when the feature is active A traction control switch is provided with the ATC option This function increases available traction on extra soft surfaces like snow mud or gravel by slightly increasing the permissible wheel spin When this feature is selected the ATC indicator light will blink continuously 3 5 5 Parking Brakes When parking on a grade always block wheels and turn the front wheels completely in the direction of the curb Failure to follow these procedures may lead to loss of vehicle control property damage personal injury or death Never attempt to disassemble a spring brake chamber as the release of a powerful spring could result in severe personal injury or death All Pierce Custom Chassis are equipped with spring brakes on the rear axles for parking The spring brakes are applied by operation of the yellow parking brake valve These brakes are intended to hold the vehicle in a parked position or to assist in bringing it to an emergency stop and should not be used for normal driving If air pressure is lost in the rear service brake section the spring brakes will be modulated by pressure from the front brake section allowing a few brake applications before the spring brakes are automatically applied If air pressure
66. caution and reduce speed Properly adjusted seats and seating systems may not compensate completely for severe road conditions Several suspension style seat options are offered for the front seating positions of Pierce fire apparatus Suspension seats improve comfort by absorbing road deflections and vibrations The motion of the seat suspension reduces the available head clearance For suspension type seat adjustment refer to the seat operator s manual or to the decal attached to seat frame as supplied by the seat manufacturer 3 3 7 Adjustable Foot Pedals Optional After adjusting the seat use the pedal adjustment switch to move the throttle and brake pedals to a comfortable position The pedals offer three inches of adjustment 3 4 Axles 3 4 1 Meritor Driver Controlled Differential Lock DCDL Optional When DCDL is engaged an understeer condition can occur when making turns so operate the vehicle carefully When you disengage DCDL normal steering resumes If the vehicle is equipped with DCDL e Engage DCDL only under poor road conditions Do not engage during downhill operation Do not engage DCDL or operate the vehicle at speeds above 25 mph 2010 Pierce Manufacturing Inc All Rights Reserved Custom Chassis 3 19 OPERATION 3 4 2 Dana Drive Axle Wheel Differential Lock Optional Engage Wheel Differential Lock ONLY when vehicle is stationary or moving without wheel slippage To engage
67. component Brake temperatures can vary from side to side on an axle as well as axle to axle Following this procedure should provide sufficient burnishing of the brakes and allow the truck brakes to perform as intended Contact Pierce Customer Service if you have any questions or concerns regarding the brake system or performance 2010 Pierce Manufacturing Inc All Rights Reserved Custom Chassis 2 5 BEFORE PLACING VEHICLE IN SERVICE 2 5 Customer Installed Equipment and Accessories Use the following guidelines when installing accessories or permanently mounted equipment 2 5 1 Dissimilar Metals Consider the metal types whenever mounting accessories Dissimilar metals such as aluminum steel stainless steel brass etc placed in direct contact with each other and subjected to moisture will form a galvanic reaction that will lead to rapid corrosion and possible failure of the mount fastener or base material Select mounting material and fasteners to avoid dissimilar metals or coat all mounting surfaces base material and fasteners with a commercial grade rust proofing agent such as those conforming to MIL C 0083933A specification 2 5 2 Radio Equipment Refer to the Mobile Radio Installation Guide on page A 1 for information concerning radio installation in a Pierce fire apparatus 2 5 3 Cab Exterior Equipment Avoid mounting hose or equipment in a manner that blocks airflow to the grill Large items blocking air to t
68. dead eee ue a e E 4 1 4 2 2 INSPECTION ices te de ten es se tlt al de iR pei 4 1 4 2 3 CONDITION OF LUBE POINTS 004000 0000 4 1 4 3 AXEES Quoc octo au nce ek ots badd 4 1 4527 FRONT AXLE NON DRIVING tenete tecto ence Se th he ste eese to pivot ca 4 1 4 3 2 FRONT AX E ALIGNMENT 22 52 tei rebels gute tha Seat intend 4 2 4 3 3 FRONT AXLE TAK 4 SUSPENSION 04 4 4 0 44 4 2 58 4 REAR AXLE ht iet ated aene 4 2 4 3 5 REAR AXLE ALIGNMENT 2e sels sh etes les Ur le 4 2 4 4 BRAKES te TIDETUR 4 3 4 4 1 BRAKES GENERAL siete cet bts non de tatu etaed uo i e e at eat are ane 4 3 4 4 2 BRAKES TAKAM SUSPENSION teet ter Lee ete ere ren Eee tt LU pee Lacan e re c ete lee 4 3 f E Ee Aie ese ie E 4 3 4 5 STEP SYSTEM QUANTUMO cesses eene nnne nnn ana munmaaa auda amne a RR RR RR RR RR AS AR RR RR 4 S ARR RR 44 na maa da 4 4 4 5 1 GENERAL INSPEGTION 2 5 ee Lettore en cheated lois 4 4 4 5 2 STEP SYSTE
69. doa ace 3 7 ii Custom Chassis 2010 Pierce Manufacturing Inc All Rights Reserved 3 3 TABLE OF CONTENTS 921455 2 ei ta abe tede EU le Pra Ee t Peg v Ra ls tuta d 3 7 TEST PARKING BRAKE rire a Era a aa a eed lanta ta d au 3 7 TEST SERVICE BRAKE STOPPING ACTION 2 70 4 3 7 TEST DUAL AIR BRAKE SYSTEM WARNING LIGHT AND BUZZER 2 3 7 TEST THAT THE SPRING BRAKES COME ON AUTOMATICALLY 000 0 3 7 TEST THE RATE OF AIR PRESSURE BUILDUP 3 8 TEST AIR LEAKAGE RATE eti ena a Eh Pe eee ten iride b REF Exc a a da 3 8 TEST AIR COMPRESSOR GOVERNOR CUT IN AND CUT OUT PRESSURES 3 8 VEHICLE ENTRY AND EXIT Ca a leu To cuu o cu aa Ea Ga Rd wa Cua Eae iv aa Du wa Gru aUa 3 8 3 2 1 KEYLESS ENTRY OPTIONAL ete en ee eee ee tene o een an eene ae le ee 3 9 3 21 UNLOCK OFFICER S 2 4 nn nnn 3 9 3 2 1567 TO UNLOCK ALL DOORS bee ae e to E veg 3 9 3 2 1C LOCKING THE DOORS WITH KEYPAD ii 3 9 3 2 1d ADDITIONAL INFORMATION cccceccccceccccccceeceecucececaeaeaeaeaesesenseseceeceeceeceeecececaeauaesauauauaeasasaese
70. for damaged binding or worn parts Check the kingpins for excessive wear Refer to the axle manufacturer s maintenance manual included in the Pierce Service Manual for maintenance schedules lubrication recommendations and inspection procedures 2010 Pierce Manufacturing Inc All Rights Reserved Custom Chassis 4 1 MAINTENANCE 4 3 2 Front Axle Alignment Most tire wear is caused by incorrect toe settings Do not change camber or caster settings to correct tire wear problems If the axle assembly is bent to change caster or camber the strength of the axle is reduced and the warranty is voided An axle damaged by bending may cause a vehicle accident and result in serious personal injury or death Kingpin inclination and camber are factory set by the axle manufacturer and are not adjustable Caster is set at the factory by including tapered shims in the front spring pack as required Check toe in adjustment by following the instructions in the axle manufacturer s maintenance manual Set toe in to the following values Unloaded Vehicle 1 16 inch 1 32 inch Loaded Vehicle 1 32 inch 1 32 inch 4 33 Front Axle TAK 4 Suspension Refer to the Pierce Service Manual group 0152 P 002 TAK 4 Independent Front Suspension for suspension inspection and alignment information 4 3 4 Rear Axle Inspect the rear axle for damage leaks or interference s with other chassis components Refer to the axle manufacturer s maintenanc
71. in each section of the split air brake system The indicator light will light and the alarm will sound any time the ignition switch is set to the run position and the pressure in either section is less than approximately 60 psi The quick buildup feature allows the pressure to be built up in the rear brake section first to enable release of the parking brakes before the pressure in the front section is adequately charged This is a feature unique to the fire apparatus industry and is part of the NFPA recommendations This feature is meant to allow the vehicle to be driven as soon as possible in the event of an emergency response 3 5 3 Antilock Braking System ABS ABS cannot provide more braking performance than the road conditions will permit Reduce speed during slippery conditions or serious injury or death may result The antilock braking system automatically applies and releases the brakes during low traction or panic brake applications to minimize the stopping distance and improve steering control ABS will prevent wheel lock up at all times Push the pedal steadily do not pump brakes until the vehicle speed has been reduced to the desired level 2010 Pierce Manufacturing Inc All Rights Reserved Custom Chassis 3 21 OPERATION 3 5 4 Traction Control Optional Automatic Traction Control ATC is an optional feature of the ABS system ATC operates in two ways It applies the service brake to a spinning wheel so that the torque
72. in the exhaust stream contains the Diesel Oxidation Catalyst DOC and the Diesel Particulate Filter DPF The DPF will trap particulate matter while the engine is running Over time soot and ash build up in the filter and must be removed Soot build up is removed by heating the filter until the soot oxidizes and turns into carbon dioxide gas This process is commonly known as regeneration Ash build up is removed from the filter by periodic cleaning in a special cleaning machine The typical ATD is equipped with two pressure transducers and three temperature transducers These sensors allow the engine to monitor soot build up for cleaning requirements Engine and ATD status is displayed by instrument panel lights Light functionality is explained in Instrument Panel Indicator Lights Cummins Engines on page 3 69 The second canister in the exhaust system contains the SCR device This device will reduce nitrogen oxide NOx emissions created during the combustion process The SCR is a catalytic converter that uses vaporized diesel exhaust fluid DEF DEF consists of purified water and urea an organic nitrogen compound that becomes ammonia when heated The combination of ammonia and nitrogen oxide in a heated environment creates a chemical reaction The reaction results in the release of nitrogen gas and water vapor both of which are found naturally in the atmosphere 3 46 Custom Chassis 2010 Pierce Manufacturing Inc All Rights Reserved OPE
73. in the step below the grip surface Clean as required e Open petcocks and drain condensation from the step system wet tank and filter located behind the first officer side rear step 4 5 2 Step System Air Dryer To ensure reliable operation replace the desiccant in the step system air dryer annually just prior to the cold weather season Replace desiccant as follows Remove right side fender liner Engine must be off while servicing desiccant dryer e Open drain on coalescing filter to relieve system pressure e Remove air lines going to the dryer assembly e Remove dryer assembly by removing dryer assembly bracket e Remove desiccant dryer e Remove desiccant dryer cover and discard desiccant desiccant is non hazardous Refill dryer follow instructions on package e Inspect filter element inside coalescing filter Replace as necessary e Reinstall desiccant dryer and reconnect air lines Inspect all air lines for leakage Reinstall fender liner 4 5 3 Service Parts Desiccant recharge kit four year supply Pierce P N 55 4940 Filter element for coalescing filter Pierce P N 55 4941 4 5 4 Step System Pressure The step system is designed to operate at 85 psi The pressure regulator is located behind the right hand fender liner beside the air compressor and is preset at the factory Supply pressure to either side of each step cylinder actuator should maintain 85 psi If low air pressure is determined adjust to 8
74. is reduced to approximately 40 psi in both systems the spring brake valve will automatically apply 3 5 6 X Manual Parking Brake Release To avoid the loss of vehicle control resulting in property damage or personal injury block the wheels of the vehicle to prevent motion before attempting to manually release spring brake chambers Spring brake chambers require air pressure to release If sufficient pressure is not available and the vehicle must be towed the spring brakes can be manually released or caged To manually release the spring brake chambers use the caging stud supplied with the spring brake chamber Insert the stud into the chamber and turn to engage the stud in the slots Tighten the nut on the caging stud with a wrench to compress the spring and release the brake After the need for caging the brakes has past charge the spring brake chambers with air pressure and remove the caging stud 3 22 Custom Chassis 2010 Pierce Manufacturing Inc All Rights Reserved OPERATION 3 5 7 Emergency Parking Brake Release Optional The emergency parking brake release feature allows the vehicle to be driven even though service brakes may not have sufficient air pressure to enable sustained or full force braking Never exceed 2 mph with the emergency parking brake release engaged and use extreme caution when operating the vehicle with either air brake section charged to less than 60 psi or property damage or personal injury
75. more information 2010 Pierce Manufacturing Inc All Rights Reserved Custom Chassis 3 61 OPERATION 3 17 1 Typical Quantum Cab Instrument Panel Figure 3 11 Quantum Controls and Indicators DRIVER SIDE OVERHEAD SWITCHES Go V k k k e PASS SIDE OVERHEAD SWITCHES k jJ 2 5 5 006 OFFICER SIDE ko 49 Back 510 0052 Item Description Vents Heating Vent AC Ignition Switch w Indicator Light Prove Out Information Display Volt Meter Engine Coolant Temperature Gauge Tachometer Engine Oil Pressure Gauge Front Air Pressure Gauge Speedometer Rear Air Pressure Gauge High Beam Indicator Transmission Oil Temperature Gauge Fuel Level Gauge Left Turn Signal Indicator Heater Defroster Controls Parking Brake Actuator Transmission Shift Selector Indicator Light Module Electronic Siren Front Wheel Lock Mirror Remote Interaxle Differential Lock Cigar Lighter Air Horn Pushbutton Mechanical Siren Pushbutton Switch Assembly 52 Switch Assembly 53 Switch Assembly 54 Switch Assembly 55 Switch Assembly 56 Switch Assembly 57 Switch Assembly 58 Switch Assembly 59 Switch Assembly 60 Switch Assembly 61 Retarder Warning Tag 2 Co D Do Not Move Truck Check Gauges Seat Belt Tire Chain Warning Tag Fastened Parking Brake Applied Check 1 2 3 B
76. one of three types of cab tilt systems system includes a lever operated hydraulic valve to change the direction of the fluid flow to the lift cylinders in conjunction with a two position toggle switch ON OFF to operate the electric pump Type Il system has two momentary switches Lock Release amp Activate with a Raise Lower switch Type system has a momentary handheld switch on a coiled tether with a Raise Lower switch Every tilt cab has a mechanical means of supporting the cab once it has been tilted Some models employ a stay arm that must be positioned manually Other models incorporate a locking channel as part of one of the lift cylinders 3 28 Custom Chassis 2010 Pierce Manufacturing Inc All Rights Reserved OPERATION 3 9 1 Cab Lift System Saber Always check for people working on or around the cab before raising or lowering the cab Failure to ensure that everyone is clear of the cab could cause severe personal injury or death To Raise Cab 1 Before tilting the cab ensure that the vehicle is on a flat and level surface parking brakes are set loose items in cab are secure and there are no obstructions in the tilt path Ensure that the battery and ignition switches are ON Locate the cab lift controls location varies depending on chassis model Rotate the control lever on the valve to the RAISE position valve not present on some models Activate the li
77. operator Failure to complete proper training could lead to property damage serious injury or death The operation of the ALL STEER all wheel steering system is covered in detail in the ALL STEER Operator s Manual 3 26 Tire Chains 3 26 1 Chain Clearance Front Tires Installation of tire chains on the front tires may cause extensive damage to the cab as well as safety critical parts of the steering and brake systems Damage to these components may lead to serious injury or death Pierce Custom Chassis do not provide clearance for tire chain installation on the front tires 2010 Pierce Manufacturing Inc All Rights Reserved Custom Chassis 3 89 OPERATION Rear Tires Installation of chains on the rear tires may be possible depending on the chassis model tire size suspension type and body style Before installing chains on rear tires ensure that adequate clearance exists between the tire and fender liner at full axle jounce Table 3 4 All Wheel Steer Tire Chain Availability Single Rear Axle Wrap Around Automatic Tire Chains Configuration Chassis Tire Chains Application 26 000 Ib GAWR On Spot Saber amp Quantum Not Available Tandem Rear Axle Wrap Around Automatic Tire Chains Configuration Chassis Tire Chains Application 36 000 Ib GAWR Quantum amp Available 48 000 Ib amp 52 000 Ib GAWR Quantum amp Not Available 3 26 2 Automatic Tire Chai
78. or driving conditions should be adequate 3 Speedometer showing 5 mph or higher vehicle speed When the engine determines that it is appropriate to initiate an active regeneration it adds hydrocarbons to the exhaust stream When the exhaust system temperature goes above 977 F 525 C the HEST light will illuminate Breaking any of the required conditions will stop the regeneration process If excessive soot build up remains in the DPF the DPF light will return to the appropriate indication stage until an adequate regeneration occurs No engine speed or load changes will occur during regeneration in pumping or driving modes 3 12 7d DPF Build Up Without Regeneration If the soot load in the DPF builds up and the necessary conditions for regeneration cannot be achieved the engine lights will indicate a more serious condition If this occurs operators should be mindful of the potential for gradual power de rates due to higher soot loading If the DPF light begins to flash along with a solid check engine light the operator may need to take action This action could be removing the truck from a mission that requires very high load operation changing the duty cycle to allow a regeneration to occur or initiating a stationary regeneration When the soot load is reduced through effective regeneration the engine will return to full torque output 3 12 7e Maintenance As the soot in the filter is removed in the regeneration process a small amount o
79. pose a hazard to nearby objects or pedestrians The fold down steps operate with air pressure stored in the wet tank of the air brake system pressure protection valve allows the steps to be operated as long as the wet tank pressure remains above 85 psi This pressure protection feature ensures that the brake system will always have priority in the event that the main air system pressure drops below 85 psi With the engine running the main air compressor will regenerate the system sufficiently to allow continuous operation of the steps With the engine shut down the wet tank charged to 110 psi and no auxiliary air supply connected the steps will operate for approximately 10 cycles before depleting the reserve volume In the event that normal leakage or maintenance functions have left the vehicle air tanks totally depleted of pressure the air system must be recharged before operating the vehicle The spring brake chambers on the rear axle cannot be released until the main system pressure reaches 60 psi At full governed engine rpm this will occur within approximately 30 seconds at which time the parking brake control valve can be released and the vehicle allowed to move The steps however will not have pressure to raise to their stowed position until the main system pressure reaches 85 psi The door ajar light located in the overhead console will continue to flash until all steps have returned to their stowed position To avoid delay in res
80. power steering fluid hydraulic fluid or battery fluid Electrical wiring insulation shows no sign of excessive wear chafing or damage from heat Cab Interior DDLIDDDDDLDZLD Lower cab and ensure that the parking brake is set Put gearshift in neutral and start the engine Perform the following checks No unusual noises All gauges indicate within normal operating ranges Oil pressure indicates normal within seconds after engine is started Coolant temperature begins a gradual rise to normal operating range Q Q Voltmeter indicates normal electrical voltage Q Q Review indicator lights to ensure all bulbs are functional Glass Check mirrors and windshield Windshield is clear of dirt and ice Windshield is free from cracks or distortion Mirrors are clean and properly adjusted Safety Equipment Ensure that the vehicle is equipped with the following safety equipment Spare electrical fuses unless vehicle has circuit breakers Three red reflective triangles Properly charged and rated fire extinguisher Functional Controls Check all of the following for looseness sticking damage or improper setting Ensure that all are operational Steering wheel Accelerator Brake controls Parking brake Retarder controls if so equipped Transmission controls Interaxle differential lock if so equipped Horn s Windshield wiper washer Lights Headlights D D D D D D
81. radio power leads and the vehicle s electronic modules and wiring Avoid running power leads in parallel with vehicle wiring over long distances 2 3 Antenna Location and Installation Every vehicle model and body style reacts to radio frequency energy differently Antenna location is a major factor is these effects e Permanently installed antennas are preferable over magnetic glass or body lip mounts for anything other than for low power or temporary installations Most of these alternate antennas can reflect significant power back at the feed point this reflected power could then radiate from the feed line inside the passenger compartment and be picked up by the vehicle wiring However a magnetic mount antenna is a good tool for checking the proposed fixed antenna location for unwanted effects on the vehicle since antenna location is a major factor in these effects IMPORTANT The antenna should be tuned properly and reflected power be kept to less than 10 VSWR less than 2 1 Never adjust antenna length while the radio is being keyed NOTE Your installation should be checked periodically for proper SWR and any signs of damage or deterioration to maintain proper operation with your vehicle United States Department of Labor through provisions of the Occupational Safety and Health Act of 1970 5 has established an electromagnetic safety standard which applies to the use of mobile radios Proper installation and use w
82. service or maintenance Always stow work surface while vehicle is in motion Never ride in the seat unless the work surface is stowed Impact with the work surface during a crash will injure or kill Refer to NFPA guidelines when mounting equipment inside the cab to avoid unnecessary risk of injury from flying objects during a collision Exercise caution if drilling into cab walls and headliners to mount equipment as there may be wiring heater hoses or air conditioning hoses hidden beneath the surface 2010 Pierce Manufacturing Inc All Rights Reserved Custom Chassis 2 7 BEFORE PLACING VEHICLE IN SERVICE 2 5 5 Air Pressure Operated Equipment Pressure protection valves are installed in both front and rear brake systems to ensure that no other air pressure requirements of the vehicle are allowed to deplete the vehicle braking system capabilities Addition of any air pressure equipment added by the end user upstream of these pressure protection valves will negate the conformance of the vehicle to this NFPA recommendation and property damage personal injury or death could result Any air operated equipment must only be added to the air system downstream of a pressure protection valve Consider the airflow requirements of any air operated accessory that will draw pressure from the vehicle system The engine air compressor output is but a fraction of its total capacity at engine idle and will not keep up with continuous oper
83. spacers or shims incorrectly may affect spring performance or durability 4 34 Custom Chassis 2010 Pierce Manufacturing Inc All Rights Reserved MAINTENANCE 4 22 2 Suspension Shackles Inspect suspension shackle and hanger clamp bolts Tighten any loose fasteners to the proper values using a calibrated torque wrench Table 4 8 Table 4 8 Clamp Bolt Torque Chart Torque Ft Lbs N m 3 8 16 7 6714 1 243 4 22 3 Spring Pins except Velocity W ImpelT Lubricate spring pins with NLGI grade EP2 grease until grease oozes evenly from ends of each pin If grease will not flow raise chassis to remove the load on the springs and apply grease again If grease will still not flow disassemble spring pins and clean or replace as required 4 22 4 TAK 4 Suspension Refer to the Pierce Service Manual group 0152 P 002 TAK 4TM Independent Front Suspension 4 23 Steering 4 23 1 General Inspection Correct any steering problems immediately Failure to properly maintain the steering system and its components may lead to loss of vehicle control resulting in property damage personal injury or death Ensure that drag link tie rod steering arm and pitman arm retaining nuts and clamps are tight and properly torqued e Check that all cotter pins are installed spread and not corroded Inspect hoses for any signs of leaking kinking chafing or corrosion Maintain power steering reservoir flui
84. speed and hard braking involved in emergency use To account for this duty cycle brakes employed on fire apparatus use more aggressive lining materials than is common in over the road cargo haulers These linings provide the brake performance required but are more sensitive to under loaded conditions Before placing the apparatus in service load all compartments with the intended equipment and manpower and obtain front and rear axle weights from a certified scale Compare the results to the axle capacities listed on the Federal Motor Vehicle Safety Standard FMVSS information decal located inside the cab Refer to the brake power charts to ensure that the brake power will fall within the appropriate guidelines Brake power is indicated on the chart by the size of the chamber in square inches 24 30 or 36 followed by the slack adjuster length in inches 5 5 or 6 0 The proper chart must be referenced based upon the brake type on each axle Table 2 1 Brake Power Chart Reference Table Front Axle Rear Axle Figure 2 1 Cam Brakes Cam Brakes Figure 2 2 Disc Brakes Cam Brakes Figure 2 3 Disc Brakes Disc Brakes Figure 2 4 Disc Brakes ALL STEER Cam Brakes Axle model numbers are listed on the Fluid Capacity Chart located in the cab Brake chamber size is stamped on the components themselves Slack adjuster length can be determined directly by measuring between the camshaft center and the large clevis pin Any modification
85. the combustion chamber bearings shafts etc This is especially important with turbocharged engines The turbocharger contains bearings and seals that are subject to the high heat of combustion exhaust gases While the engine is running this heat is carried away by normal oil circulation If the engine is stopped suddenly the turbocharger temperature may rise as much as 100 F 56 C This may result in seized bearings or loose oil seals Failure to idle the engine for the proper length of time before shutdown can lead to reduced engine life or engine component failure Bring the truck to a complete stop using the service brakes Shift transmission into Neutral Set parking brake Idle engine for 3 to 5 minutes Turn ignition switch to OFF position Turn battery selector switch to OFF position oar D gt 2010 Pierce Manufacturing Inc All Rights Reserved Custom Chassis 3 37 OPERATION 3 12 5 After Treatment Device ATD Regeneration Detroit Diesel Series 60 2007 EPA Parked Regeneration causes high exhaust gas temperatures at zero vehicle speed Keep personnel away from exhaust outlet to avoid serious burns and injury Do not perform parked regeneration while connected to an exhaust extraction system Damage to the exhaust extraction system may result 3 12 5a Basic Operation of the After Treatment Device 2007 EPA engines are required to use an After Treatment Device ATD for controlling emissions This
86. the cab is fully tilted and the stay arm can be lowered Lower the stay arm and lock it in the stowed position Set the control switch to the LOWER position Depress and hold the tether switch to lower the cab Continue to depress the tether switch for at least 5 seconds after the cab comes to rest N Oa 8 Check to ensure the cab is fully seated before operating the vehicle 3 9 4 Manual Pump Operation Optional If the chassis is equipped with a manual pump option the tilt pump can be operated by hand in the event that power is lost on the vehicle Locate the pump handle and insert it in the tube at the pump pivot Use the same procedures as listed above but with the following exceptions Saber Operate the hand pump to supply hydraulic pressure in place of activating the toggle switch Quantum Arrow XT Velocity Impel Do not overtighten the flow control valve Overtightening could cause the valve not to function properly and cause the cab not to tilt or lower as desired Operate the hand pump in place of moving the toggle switch to the RAISE position Operate the hand pump rapidly for the first few strokes so that the fluid flows rapidly enough to close the internal system bypass valve 3 30 Custom Chassis 2010 Pierce Manufacturing Inc All Rights Reserved OPERATION Locate the small push button at the end of the descent valve solenoid on the hydraulic power unit Turn this button counterclockwise and
87. the paddle actuation to latch release The required adjustment allows the latch trip lever to bottom out before the paddles thus assuring that the paddle will continually trip the latch Adjustment is accomplished by loosening the paddle mounting bolts and relocating the paddle within the cutout If more adjustment is necessary a slight bending of the rod may be required Regularly apply silicone to the rubber door seals on the cab monthly or whenever the truck is washed 4 16 Custom Chassis 2010 Pierce Manufacturing Inc All Rights Reserved MAINTENANCE If adjustment of the door is required due to leaking seals or rattling the seals should be looked at closely for signs of deterioration first If the seals have not been properly maintained they can dry out and take a set If adjustment of the door is required the hinge screws should be loosened and the door hinge adjusted first As a general rule the doors were designed so that they are flush with the sides of the cab Care should be taken that the door is not adjusted too far inboard as the scuff plate may bind on the floor threshold A slip of paper should slide freely between these surfaces when the door is closed Only after the hinge has been adjusted should the striker bolt be relocated adjusted 4 10 5 Hinges IMPORTANT Door hinges should be lubricated by spraying them with a light coating of silicone lubricant After spraying clean over spray from surrounding paint
88. this additive may clog the cooling system Always fill coolant system properly and completely or serious engine damage may result 1 Checkthe engine coolant level with engine stopped The engine water pump can draw air as well as coolant when the coolant level drops below the coolant make up line connection at the radiator or the top of the radiator core 2 Fill radiator or surge tank to proper level with permanent type antifreeze and water Water should be clean and free from any corrosive and scale forming chemicals not softened water Radiators and oil coolers that get dirty inside and outside lose their ability to absorb and radiate heat 4 14 Custom Chassis 2010 Pierce Manufacturing Inc All Rights Reserved MAINTENANCE 3 Clean radiator and charge air cooler using compressed air to remove bugs dirt and other debris Steam clean annually Clean from the side opposite the direction of airflow 4 Check for leaks and straighten bent fins with needle nose pliers 4 9 2 Hoses Check for soft mushy feel or swelling Also look for cracks in the hose around the clamp area Replace defective hoses 4 93 Hose Clamps Constant torque type hose clamps are used on most coolant lines These clamps should be installed during initial assembly or reassembly with to a torque of 100 in lbs The clamp will likely drop in torque value after exposure to hot coolant and should be maintained to a torque of 45 in lbs thereafter Tight
89. tighten wheel nuts to the recommended torque Do not overtighten 2 Afterthe first 50 to 100 miles of operation recheck the torque levels and retighten nuts to the proper torque level 3 Maintain the nut torque at the recommended level through planned periodic checks or at 10 000 mile intervals whichever comes first Individual fleet experience may dictate shorter intervals or allow for longer intervals 4 If air wrenches are used they must be periodically calibrated for proper torque output Use a manual torque wrench to check the air wrench output and adjust the line pressure accordingly to give the correct torque 4 29 6 Aluminum Rear Disc Wheels with Flange Nuts Hub Piloted Prior to reinstalling rear aluminum hub piloted wheels clean each wheel locator pad on the hub of all dirt rust and foreign material Apply a light coat of chassis grease or never seize 2010 Pierce Manufacturing Inc All Rights Reserved Custom Chassis 4 55 MAINTENANCE 4 29 7 Rim and Wheel Inspection Wheels and rims are manufactured with capacity ratings based on maximum tire pressure and load Inflate tires to only the recommended air pressure being sure not to exceed the rim wheel inflation rating Failure to observe these precautions may cause wheel damage leading to loss of vehicle control serious property damage personal injury or death Inspect wheels during all pre trip inspections and at periodic maintenance intervals depending upon road
90. to the brakes to balance the system by reducing brake power must be accompanied by a revision to the Federal Motor Vehicle Safety Standard FMVSS information decal contact Pierce Customer Service for revised tags 2 2 Custom Chassis 2010 Pierce Manufacturing Inc All Rights Reserved BEFORE PLACING VEHICLE IN SERVICE Figure 2 1 Brake Power Chart Cam Brakes on Front and Rear Axles FRONT 11 000 14 600 14 601 16 540 16 541 18 000 18 001 21 500 Axle Model FG941 RF16 145 FL941 FL943 In Service Axle Weights Lb Front 24 x 5 1 2 Front 24 x 5 1 2 14 000 17 000 RS21 Rear 24 x 5 1 2 Rear 24 x 5 1 2 Front 24 x 5 1 2 Front 30 x 5 1 2 Front 30 x 5 1 2 Front 30 x 5 17 001 21 000 985 Rear 30 x 5 1 2 Rear 30 x 5 1 2 Rear 30 x 5 1 2 Rear 30 x 5 Front 24 x 5 Front 30 x 5 1 2 Front 30 x 5 1 2 Front 30 x 5 1 2 Front 30 x 5 Front 30 x 5 1 2 Front 30 x 5 1 2 Front 30 x 5 24001 27000 n Rear 30 x 6 Rear 30 x 6 Rear 30 x 6 Rear 30 x 6 E lt Front 30 x 5 Front 30 x 5 1 2 Front 30 x 5 1 2 Front 30 x 5 27 0015611 000 nose Rear 36 x 6 Rear 36 x 6 Rear 36 x 6 Rear 36 x 6 RT Front 24 x 5 Front 30 x 5 1 2 Front 30 x 5 1 2 Front 30 x 5 34000 42000 RT Rear 30 x 5 Rear 30 x 5 1 2 Rear 30 x 5 1 2 Rear 30 x 5 RT Front 24 x 5 Front 30 x 5 1 2 Front 30 x 5 1 2 Front 30 x 5 42 001 48 000 Rear 30 x 5 Rear 30 x 5 1 2 Rear 30 x 5 1 2 Rear 30 x
91. turn off to acknowledge when effective assistance changing duty cycle or initiating a stationary regeneration has been provided However if assistance has not been provided long enough to complete the regeneration the light will return to the appropriate indication stage 2010 Pierce Manufacturing Inc All Rights Reserved Custom Chassis 3 69 OPERATION The High Exhaust System Temperature HEST light provides an indication to the vehicle operator that an active regeneration has been initiated and that exhaust system temperatures will be elevated above normal levels for the operating condition The HEST light will remain on until the exhaust system temperatures have dropped below 977 F 525 If the HEST light is and the vehicle speed has dropped below the threshold of 5 miles per hour the light will remain ON until the vehicle speed increases 3 mph back above the speed threshold and the regeneration process finishes The Diesel Exhaust Fluid DEF Level Low light 2010 EPA engines only provides an indication to the vehicle operator that the fluid level has reached a level where a refill is needed This light indicates the reservoir has reached a low level The operator should refill the reservoir when refilling the vehicle with diesel fuel or at the end of their shift The Malfunction Indicator MIL light SX 15 2010 EPA engine only provides an indication to the vehicle operator that a fault has occurr
92. type it merely indicates elevated operating temperatures The HEST light will not illuminate if road speed exceeds 5 mph 3 68 Custom Chassis 2010 Pierce Manufacturing Inc All Rights Reserved OPERATION The Malfunction Indicator MIL light provides an indication to the vehicle operator that a fault has occurred on an emission related component This light may illuminate at the same time as the Check Engine light The operator can drive the vehicle to the end of their shift and call service to remedy the problem The Diesel Exhaust Fluid DEF Level Low light 2010 EPA engines only provides an indication to the vehicle operator that the fluid level has reached a level where a refill is needed This light indicates the reservoir has reached a low level The operator should refill the reservoir when refilling the vehicle with diesel fuel or at the end of their shift 3 17 7 Instrument Panel Indicator Lights Cummins Engines 2007 EPA amp 2010 EPA Cummins engines have four instrument panel lights to monitor engine and exhaust after treatment status The Check Engine light and Stop Engine light refer to basic engine functions The two after treatment lights are the Diesel Particulate Filter DPF light and the High Exhaust System Temperature HEST light In addition 2010 EPA Cummins engines have an additional Diesel Exhaust Fluid DEF light ISX 15 2010 EPA engines also have a Malfunction Indicator Lamp
93. using sight glass or electronic monitor Engine Inspect for signs of oil or coolant leaks Daily Engine Oil Inspect for signs of oil leaks Check oil level using Daily dipstick sight glass or electronic monitor Exhaust Inspect for leaks and clamp tightness Daily Throttle Pedal Check for smooth operation and return ability Daily Tires Check inflation pressure Inflate to correct pressure per Daily the tire manufacturer s load inflation recommendations Transmission Fluid Inspect for signs of oil leaks Check level using dipstick Daily or electronic monitor Also note physical appearance of transmission fluid Table 5 3 Weekly Maintenance Schedule Description Action Miles Time Aerial Boom Support Inspect fasteners for tightness and integrity Weekly Air Dryer Test purge pressure Weekly Air Inlet Inspect engine air inlet for dirt debris or plugging Weekly Axle Front Inspect for signs of wear damage or looseness Weekly Belts Inspect for damage and check tension Weekly Brake Linings Inspect for sufficient lining thickness Weekly Brakes Inspect all brake parts for integrity See Brakes Weekly General on page 4 3 Cab Tilt System Check fluid level See Cab Tilt System on page 4 6 Weekly fluid type 2010 Pierce Manufacturing Inc All Rights Reserved Custom Chassis 5 1 SERVICE AND LUBRICATION INTERVALS
94. will need to be held for several seconds before it will activate 3 22 3a Set Display Backlight Figure 3 35 Set Display Brightness Screen Set Daytime Brightness Nighttime Brightness 0091 When this button is selected the operator will be allowed to change the brightness of the display by pressing either the UP or DOWN button Separate adjustments are available for daytime and nighttime settings press the DAY NIGHT to toggle between the two settings The value will be saved when pressing the BACK button 3 82 Custom Chassis 2010 Pierce Manufacturing Inc All Rights Reserved OPERATION 3 22 3b Set Blackout Mode Figure 3 36 Set Blackout Mode Screen Set Blackout Mode 1373 The Set Blackout Mode screen is used to control the blackout mode operation of the display When enabled the blackout mode will turn off the display when the parking brake is released reducing the amount of light the driver is exposed to while driving especially at night The screen will reactivate automatically if an alarm becomes active 3 22 3c Configure Video Figure 3 37 Configure Video Mode Screen onfigure Video 1374 The Configure Video Mode screen Figure 3 37 is used to control remote video inputs The Camera Connected selection must be changed to YES if a video device cameras DVD player etc is present at which point the user will be allowed to change the video screen contrast tint
95. you turn off the engine you may hear a hissing sound from the engine compartment for a short period of time This is a normal condition that occurs if the air conditioning system has been on It is not an indication of a problem with the air conditioning system The mode controls can be set in any of the following positions Off Placing the control in this position shuts off the blower motor and outside air will not come through the outlet Recirc Select Recirc when the outside air contains odors or high humidity This feature allows for recirculation of interior air only Cy Panel Air blows through the outlets located in the instrument panel 2 Bi Level Air blows through the outlets located in the instrument panel and those on the floor Floor Air blows through the floor outlets located under the instrument panel e NOTE The air conditioning compressor will operate when the system is in either Defrost mode regardless of where the blower control is set Defrost Floor Air blows through the floor outlets and the outlets at the base of the windshield We Defroster Air is directed to the windshield through the outlets at the base of the windshield W Blower Control A rotary knob that will increase or decrease blower motor speed 8 Temperature A rotary knob that controls the temperature of the interior air You can choose your degree of Control comfort by positioning the temperature control along the blue red sc
96. 0 LOAD MANAGER SCREEN 0 0 0 3 80 SEAT BELT SCREEN OPTIONAL inisi iieii aeai a eae aae ii aa rian a iarann 3 81 ALARMS SCREEN Hu ET T 3 81 3 223 SYSTEM MENU mn Re ee e 3 82 3 22 3a SET DISPLAY BACKLIGHT 4 4 004 ee ee sns ases dads san sn 3 82 3 22 3b SET BLACKOUT MODE zie et tectae acs dec de eee oe de 3 83 3 22 36 CONFIGURE VIDEO 25 5 re rd edere ne a 3 83 3 22 3d SET STARTUP SCREEN 2 eo uod dee e ede ede 3 84 3 22 3e SET DATE AND TIME 004644000 00 sn sedens sss enda s sana n naa 3 84 3 22 3f SET LANGUAGE met tte Doch etes ce sie a ane a tan ee tt ati 3 85 3 22 39 VIEW ACTIVE ALEARBMS 5 ees dann poeni Fase TERT uM AKAA TURF e AE 3 85 3 22 3h VIEW SYSTEM INFORMATION 3 85 3 22 3i SYSTEM DIAGNOSTICS 2 4040 000 0 0 0 EEEE AEAEE EEAS EEEE AEAEE Ennan nanne 3 86 MODULE SGREEN dr tetas Jot asin ode e Doa De det Mas ee 3 86 3 87 STABILITY CONTROL OPTIONAL ecc ca ausa m lune tete nent ondes ent 3 88 3 24 1 ROLL STABILITY CONTROL 5
97. 3 CANTrak Button Functions BUTTON FUNCTION SCREEN HEADING 3 Menu Help Scroll Up Scroll Down Do Not Move Truck Help Scroll Up Scroll Down Loads Help Scroll Up Scroll Down Maintenance Data Help Scroll Up Scroll Down Enter Warning List Help Scroll Up Scroll Down Enter Lighting Contrast Contrast Lighting Lighting System Help Scroll Up Scroll Down Select Control Module Help Back Inputs Outputs 1 8 or 9 16 Power Module Help Back Input Module Help Back 1 8 or 9 16 Output Module Help Back 1 8 or 9 16 Module Help Back Inputs Outputs CC Module Help Back Inputs Outputs 3 21 2 Caution and Warning Messages Figure 3 19 Typical Warning Message Do Not Move Truck Status Load Manager Status Maintenance Data Varnings List Contrast amp Back Lighting System Information N WARNING messages will appear the warning text box any screen Figure 3 19 The warning triangles dialog box will not appear until a WARNING or CAUTION message is received The message text will flash to attract the attention of the operator If more than one message is received the dialog box will flash the first message twice before flashing the next message Flashing messages will cycle through with two flashes per message until the message is no longer received 3 21 3 Common Screens T
98. 3 96 Custom Chassis 2010 Pierce Manufacturing Inc All Rights Reserved SECTION 4 MAINTENANCE 4 1 Aerial Device Boom Support Inspect the boom support for structural integrity Tighten any loose fasteners to the proper torque per the Frame Fastener Torque Chart Inspect welds for signs of fatigue cracking 4 2 Automatic Lubrication Systems 4 2 1 Reservoir Visually check the reservoir to ensure there is an adequate grease supply for the impending work day If the lubricant level in the reservoir gets too low air will be induced into the system This will not allow pressure to build up which will cause a system fault 4 2 2 Inspection Inspect the vehicle for over or under lubrication before it is washed or pressure cleaned Verify that all originally attached lubrication lines are still connected Pay particular attention to those points closest to the road surface 4 2 3 Condition of Lube Points Inspect all points being lubricated A seal of lubricant around the outside of the bushings should be visible as this assures that bearings are being flushed of contaminants If the entire system appears to be over or under lubricated adjust the control unit accordingly If an individual lubrication point appears to be over or under lubricated replace the metering cap for that line with a different size too wet smaller size too dry larger size 4 3 Axles 4 3 1 Front Axle Non Driving Inspect the front axle
99. 5 psi by rotating the yellow knob on the regulator 4 4 Custom Chassis 2010 Pierce Manufacturing Inc All Rights Reserved MAINTENANCE 4 5 5 Step Pivot Components Use of any lubricant other than the type indicated here may cause binding of the step in cold weather Lubricate the pivot bearings monthly through grease fitting at middle of step pivot tube Use Lubriplate Low Temp multi purpose grease Pierce P N 95 0786 Add grease until clean white colored grease exits at each end of tube Inspect for proper operation of the step pivot bearings and shaft as follows 1 Disengage the auxiliary compressor or unplug all auxiliary air supplies Drain all air from the step system Remove the rod end cylinder mount from the step housing Grasp the sides of a step and attempt to move side to side Any movement greater than 125 at the furthest point from the pivot will indicate bearing wear If excess play is observed disassemble step from step box Inspect shaft for wear marks if required replace with Pierce P N 46 2291 Grooved or noticeably worn shafts should be replaced Remove existing axle bearings and replace After reassembling step into box refill tube with grease as described above 2 a 9 073 9 0 Torque pivot nut to 113 ft lbs 1 Verify that the step without the actuator cylinder attached will rotate freely If the step does not drop quickly and freely remove one 02 inch spacer from the pivot shaft
100. D D D D D 3 2 Custom Chassis 2010 Pierce Manufacturing Inc All Rights Reserved OPERATION Dimmer switch Turn signal 4 way flashers Clearance identification and marker lights Ooovcodo Tire chains when winter conditions require them 3 1 4 Exterior Inspection Perform a walk around inspection Re enter the cab as required during the inspection to check that exterior features are functioning properly Tires Look for tire problems It is dangerous to drive with bad tires Look for problems such as much or too little air pressure Bad wear You need at least 4 32 inch tread depth in every major groove on front wheels You need 2 32 inch on other wheels No fabric should show through the tread or sidewall e Cuts or other damage Dual tires that come in contact with each other or parts of the vehicle Mismatched sizes Radial and bias ply tires used together e Cut or cracked valve stems Re grooved recapped or retreaded tires on the front wheels Wheels and Rims Bad wheels or rims could cause an accident A damaged rim can cause the tire to lose pressure or come off Observe the following warning signs e Rust around wheel nuts may mean the nuts are loose check tightness Missing clamps spacers studs and lugs mean danger Mismatched bent or cracked lock rings are dangerous Wheels or rims that have had welding repairs are not safe After a tire has been chang
101. E EAA E nok Ans sr 4 52 4 29 2 WHEEL INSTALLATION GENERAL n sisse sand EEEE AEEA sedes sanant snis 4 52 4 29 3 HUB PILOTED WHEEL INSTALLATION sense sls n sanis isses sedes sss ann dada 4 52 WHEEL NUT TORQUE CHART TABLE 4 18 rennes 4 53 4 29 4 STUD PILOTED WHEEL INSTALLATION OPTIONAL 2 4 53 WHEEL NUT TORQUE CHART TABLE 4 0 4 54 2010 Pierce Manufacturing Inc All Rights Reserved Custom Chassis xi TABLE OF CONTENTS 4 29 5 GAST SPOKE WHEELS OPTIONAL elec leet ee Mee b edet tr aed e e e recu Pata veg Dea thet 4 54 INSTALLATION PIE P 4 54 WHEEL TORQUE oth tas 4 55 4 29 6 ALUMINUM REAR DISC WHEELS WITH FLANGE NUTS HUB PILOTED 2 4 55 452927 RIM AND WHEEL INSPECTION rrt eL o epe e a ete ue gta 4 56 4 30 WINDSHIELD WIPER SYSTEM ciiin RU en ner enr faune tone 4 56 4 305 BLADES Rs te te shee Saunt E cho Leet E E tale 4 57 SECTION 5 SERVICE AND LUBRICATION INTERVALS INITIAL INSPECTION MAINTENANCE SCHEDULE TABLE 5 1 5 1 DAILY MAINTENANCE SCHEDULE TABLE 5 2 cccccscsscsesecscsesesecsesesessesesecsesecaesesecsesuacsesaecsesasacaesaes 5 1 WEEKLY MAINTENANCE SCHEDULE TABLE 5 3 c cccsssesscscsesecsesesecsesesesesesavsesesecsesasecsesececsesecaeseneens 5 1 M
102. EATER SE sete beet a med aee baee deesse aer TAAA ire eat ed 3 60 3 15 3 AIR CONDITIONING UNIT sss sess sas 3 60 3 16 HEATING VENTILATION AIR CONDITIONING HVAC VELOCITY M IMPEL TM nn eene nnne nennen nn nnn 3 61 3 16 T 4DEEBROST dac etes ord rca dde asas a cd TNT Ten 3 61 3 16 20 Iz uM 3 61 92163 AIRCONDITIONING d crt erneer A ni niet lt 3 61 3 17 INSTRUMENT PANEL CONTROLS amp INDICATORS 3 61 3 17 1 TYPICAL QUANTUM CAB INSTRUMENT 3 62 3 17 2 TYPICAL SABER CUSTOM CONTENDER CAB INSTRUMENT PANEL suisses 3 63 3 17 3 TYPICAL ARROW XTTM CAB INSTRUMENT PANEL 00400 00 n 3 64 3 17 4 TYPICAL VELOCITY IMPEL CAB INSTRUMENT PANEL 0 0440 3 66 3 17 5 STEERING WHEEL CONTROLS OPTIONAL iii 3 67 3 17 6 INSTRUMENT PANEL INDICATOR LIGHTS DETROIT DIESEL ENGINES 3 68 DETROIT DIESEL ENGINE INSTRUMENT PANEL LIGHTS TABLE 3 1 3 68 3 17 7 INSTRUMENT PANEL INDICATOR LIGHTS CUMMINS ENGINES usine 3 69 CUMMINS ENGINE INSTRUMENT PANEL LIGHTS TABLE 3 5 enne 3 69 3 18 MIBBORS UM 3 71 3 19 COMMAND ZONE SYSTEM ARROW XTTM IMPELTM QUANTUM VELOCITYM
103. Failure to follow the installation guidelines may lead to radio frequency interference which can affect the operation of multiplex components Disconnect all solid state devices before welding on the vehicle or equipment damage may result Any radio or other electronic equipment should be installed with the utmost care and craftsmanship by qualified personnel only Refer to the Mobile Radio Installation Guide on page A 1 before installing radio equipment 3 12 Engine 3 12 1 Starting the Engine Diesel engine starting motors require a significant amount of current during the starting process Keep all unnecessary electronic loads turned OFF while starting the engine Use the following steps for starting the engine 1 Verify that the parking brake is engaged Place transmission shifter in Neutral Turn battery master switch to the ON position Move ignition switch to ON position Qv d Vehicles with Command Zone Wait until prove out completes approximately four seconds If this is not done it may cause intermittent alarms to occur 6 Vehicles equipped with Side Roll Protection System The Side Roll Protection System fault light should illuminate bulb check If the fault light does not illuminate or remains lit after 30 seconds contact your Pierce Dealer The vehicle may be driven but should only be done so with the knowledge that the Side Roll Protection System may be partially or completely inoperative
104. IDENTIFICATION esee nennen nnn nane manna ua a anne nee DRAN RN RD name NR RSS anne NR nana ne RR RR 1 6 1 9 SAFETY DEFECT REPORTING 2 esee bonne uen i cien oec a A aaia aeara dinaan draie aaia 1 6 1 10 CUSTOMER ASSISTANCE INFORMATION aaa nunen nunne nannu nnne 1 6 1 11 PROFESSIONAL TRAINING AND STANDARDS ORGANIZATIONS ness ennnen ennnen nnn 1 7 SECTION 2 BEFORE PLACING VEHICLE IN SERVICE 2 1 AXLE WEIGHTS AND AXLE CAPACITY DRE AR RR RR RD aaaea 2 1 2 2 TIRE PRESSURE ETC ERC S Em 2 1 2 3 J BRAKE BALANCE 25 UNE E M 2 2 2 4 BRAKE BURNISHING 2 2 5 2 41 GENERAL INFORMATION 00 0 nn sisi sas ende essi sas se esi sides ese ss sas seras esses ande nna 2 5 24 2 PROC DURE A tentes 2 2 5 CUSTOMER INSTALLED EQUIPMENT AND ACCESSORIES aa haa na as ARR nn 4 RAN nnmnnn nannaa 2 6 2 5 1 DISSIMILAR 2 6 2 52 RADIO EQUIPMENT m m 2 6 2 5 3 EXTERIOR EQUIPMENT sis ce disnei insala sn ases sess
105. ISSION us 3 92 3 28 4 4x4 TRANSFER CASE ALL WHEEL DRIVE iii 3 92 TO ENGAGE FRONT AXLE DRIVE 4 4 4 40000 1 ses ssa sane dia 3 92 TO DISENGAGE FRONT AXLE DRIVE Dee Mate te teinte 3 93 3 28 5 4 4 ALL WHEEL DRIVE AND TWO SPEED AXLE COMBINATION 2 1 20 nennen 3 93 2010 Pierce Manufacturing Inc All Rights Reserved Custom Chassis vii TABLE OF CONTENTS 3228 6 POWER TAKE OFF CONTROL baiarien ate secet eek ie paene Ane ee Eee 3 93 3 29 VEHICLE DATA RECORDER VDR 2 442 4 0 3 93 3 30 WATER FORDING CAPABILITY 2 2 3 94 3 30 1 GENERAL FORDING INSTRUCTIONS 00 00 0010000000001 0000000000000000000000 3 94 3 30 2 FoRDING WATER WITH COMMAND ZONE 2 3 95 3 31 WINCH OPERATION pe EE 3 95 SECTION 4 MAINTENANCE 4 1 AERIAL DEVICE BOOM SUPPORT NR RR NR RR ASAR RR RR 4 aS ARR RR 44 sa maa da 4 1 4 2 AUTOMATIC LUBRICATION SYSTEMS DRAN NR RR RESO nnna NR R4 4 aras 4 1 4 2 HESERVOIR siet teet
106. KING BRAKES EEA AE anda E va ve Ta Even 3 22 3 5 6 MANUAL PARKING BRAKE RELEASE 3 22 3 5 7 EMERGENCY PARKING BRAKE RELEASE OPTIONAL 2 3 23 2010 Pierce Manufacturing Inc All Rights Reserved Custom Chassis iii TABLE OF CONTENTS 3 6 3 10 3 11 3 5 8 AUXILIARY FRONT WHEEL LOCK OPTIONAL 2 3 23 3 5 9 AIR RESERVOIR MOISTURE DRAINING ii 0 3 23 3201 02 atti a e eit n m ne Ea ee red v e AR a 3 23 3 5 11 GRADE HOLDING AND BRAKE BURNISHING 2 1 47 124 47 4444440 3 24 AUXILIARY BRAKING 5 525 du ad etage x PAVO CUR OE e a ed cR TR NO raa u onda cua ad e 3 24 9 64 COMPRESSION BRAKE ec ri deat re en A ER Aen da Ehe e dat 3 24 9 6 2 see un etes ne vasa diet ase 3 24 3 6 3 ELECTROMAGNETIC RETARDER t cuta eva Ha cp Do D ER o eh Rr Op E vv e Pea eu ab aad vas 3 25 3 6 4 HYDRAULIC RETARDER 21 0 4 40 3 25 RETARDER BRAKE CAPACITY bs Pre tn ae alee Pe tea dans 3 25 ONIROIESYSTEMS 3 25 OVERHEAT WARNINGS 4 vi
107. M AIR DRYER 2 52 teet oct Me 4 4 4 53 D SERVICE PARTS bie AEE eeu Pech Dee bid ire Rc dep Eres 4 4 4 5 4 STEP SYSTEM PRESSURE A We ra t Ee Mee oi ct at et 4 4 4 55 STEP PIVOT GOMBPONENTS erexit A Pell 4 5 45 6 STEP VALVE 2 reete Ecos oder ten 4 5 4 5 7 DOME LIGHT SWITCH REPLACEMENT 0 1 ne sess s nannu annasan nennen 4 5 4 6 CAB TIET SYSTEM suena 4 6 4 6 1 COLD WEATHER OPERATION he 4 6 CAB LIFT CYLINDER FLUID CHART TABLE 4 1 iii 4 6 4 6 2 LIFT CYLINDER TRUNNION CLEANING amp LUBRICATION ARROW XT M 4 6 4 7 6 4 7 4 71 GRAPHICS LETTERING AND STRIPING 1e teret ert e C e teo oe e P e ag 4 7 4 7 2 WASHING INSTRUCTIONS 4 8 4 7 3 UNDERCARRIAGE CORROSION 4 9 4 25
108. NANCE 4 30 1 Wiper Blades Windshield wipers should not be run on dry windows for an extended length of time as this will induce higher than normal loads into the system and decrease the life of the motors linkages and wiper blades substantially Inspect wiper blades to ensure proper clearing of the windshield Wipe the blades with a clean towel soaked in windshield washer fluid If this does not remedy wiper blade problems such as chatter and streaking then the blades should be replaced 2010 Pierce Manufacturing Inc All Rights Reserved Custom Chassis 4 57 MAINTENANCE 4 58 Custom Chassis 2010 Pierce Manufacturing Inc All Rights Reserved SERVICE AND LUBRICATION INTERVALS SECTION 5 Refer to the following charts for service and lubrication requirements Perform services at the indicated interval of miles or time whichever comes first Table 5 1 Initial Inspection Maintenance Schedule Description Action Miles Time Spring U Bolts Check torque and tighten as required after initial 500 Initial Inspection delivery Table 5 2 Daily Maintenance Schedule Description Action Miles Time Air Cleaner Check air intake restriction indicator Daily Air Intake Tubes and Inspect for leaks and clamp tightness Daily Clamps Air Tanks Drain water Daily Coolant Inspect for signs of coolant leaks Check coolant level Daily
109. ONTHLY MAINTENANCE SCHEDULE TABLE 5 4 neret nnne 5 2 QUARTERLY MAINTENANCE SCHEDULE TABLE 5 5 ans leto acest arie Ps amd 5 3 SEMI ANNUAL MAINTENANCE SCHEDULE TABLE 5 6 sss tenente tnn 5 3 ANNUAL MAINTENANCE SCHEDULE TABLE 5 7 use m ettet dte re RR ERR bc p d 5 4 3 5 YEAR MAINTENANCE SCHEDULE TABLE 5 8 c ccccccscscsessesesescsesesecsesesacsesavacsesscecsesscecsesacacsenaees 5 4 VENDOR COMPONENT MAINTENANCE SCHEDULE TABLE 5 9 sss 5 4 APPENDIX A MOBILE RADIO INSTALLATION GUIDE cerner 1 xii Custom Chassis 2010 Pierce Manufacturing Inc All Rights Reserved SECTION 1 TO THE OWNER 1 1 Who Should Use Service and Maintain This Vehicle This manual explains the operation and maintenance of a Pierce fire apparatus The manual reviews basic principles of operation highlights common safety concerns and procedures and gives recommendations for using and maintaining the apparatus This manual assumes that you Have already been fully trained and certified to operate fire apparatus Only trained personnel should operate this vehicle or perform maintenance Have had formal education from a technical college or other fire fighter training institution Understand are proficient in and meet all of the requirements set forth in NFPA 1002 Standard on Fire Apparatus Driver Operator Professional Qualifications latest edition Already unders
110. Pierce Custom Chassis is equipped with an air dryer that removes moisture and contaminants from the pressurized air before it reaches the air reservoirs Moisture is collected on the surface of desiccant pellets and is discharged out the bottom of the air dryer each time the governor unloads 2010 Pierce Manufacturing Inc All Rights Reserved Custom Chassis 3 23 OPERATION 3 5 11 Grade Holding and Brake Burnishing The capability of the vehicle to hold on a specific grade may decrease temporarily whenever new friction material is installed Use wheel chocks when parking on a grade to avoid loss of vehicle control resulting in possible property damage personal injury or death The ability of the vehicle to park downhill or uphill is affected by the conformity of the friction material to the brake drum or rotor This conformity improves through the natural burnishing action of brake applications during the early life of the vehicle The ability of the vehicle to hold on a specific grade is determined after the brakes have been fully burnished See Brake Burnishing on page 2 5 for additional information 3 6 Auxiliary Braking System The use of any compression brake or exhaust brake systems during slippery road conditions or inclement weather may cause rear wheel lock up and loss of vehicle control resulting in property damage personal injury or death An Auxiliary Brake System provides braking torque through the driveline
111. RATION Figure 3 7 Cummins AT Regeneration Light Behaviors AT Regeneration Lamp Behaviors Severe Existing Lamps New Lamps Passive Regeneration Mobile Stationary Active oe Si Em pty Auto Low Medium High Stop 1119 3 12 8b Passive Regeneration The passive regeneration process removes collected soot in the Diesel Particulate Filter DPF under normal truck operations and does not require operator interaction The operator will see no difference in vehicle performance during the passive regeneration process When the engine is operating at higher speeds and loads there is enough energy in the exhaust to remove the collected soot in the filter This happens naturally and does not require any action by the engine control system or the operator No extra fuel will be used nor will excessive exhaust temperatures occur during passive regeneration Operators may see the DPF light illuminate and turn off while operating the vehicle This indicates that the soot level in the DPF temporarily reached a moderately high level but because the engine operating conditions were right the passive regeneration process reduced the soot load 2010 Pierce Manufacturing Inc All Rights Reserved Custom Chassis 3 47 OPERATION 3 12 8c Active Regeneration The active regeneration process removes collected soot in the DPF through the addition of hydrocarbons unburned fuel to the exhaust stream When the hydrocarbons enter the DPF asse
112. Reserved MAINTENANCE Figure 4 1 Typical Lift Cylinder Trunnion amp Bracket 1154 1 Apply CORTEC VpCI Super Penetrant to the joints between the trunnions 1 and mounting brackets 2 This penetrant is formulated to free rusted parts and displace any trapped moisture or water Allow chemical to penetrate for three minutes 2 Apply EcoLine Purpose Lubricant liberally to the joints between the trunnions 1 and mounting brackets 2 This lubricant prevents corrosion on un coated and difficult to reach areas as well as contains an extreme pressure additive for extra wear protection 3 Apply CORTEC EcoLine Heavy Duty Grease to the outside exposed surfaces of the trunnion joints after each cleaning and lubrication cycle This grease provides lubrication moisture displacement and corrosion protection 4 7 Care of Vehicle 4 7 1 Graphics Lettering and Striping Pierce Custom Cabs may be adorned with graphics using any or all of the following methods Goldstar A process which encapsulates 22 karat gold leaf paint or vinyl between two laminations for maximum protection Goldstar is applied to the vehicle using an aggressive bonding agent Gold leaf A 22 karat gold leaf applied directly over a painted surface and protected with a clear polyurethane topcoat Reflective Vinyl A vinyl product available in either regular or reflective sheeting using an aggressive bonding agent Paint A lettering enamel brushed
113. SE THREAD FASTENER TORQUE CHART TABLE 4 4 4 26 GRADE 8 FINE THREAD FASTENER TORQUE CHART TABLE 4 5 sse 4 26 4 15 2 BUMPER EXTENSION CARRIAGE BOLTS 4 26 4 15 3 OTHER FASTENERS ete a rh ee Daata i oA etaan daana aeai oedet iabea 4 26 FIFTH WHEEL LUBRICATION TILLER 4 27 4 16 1 GREASE FITTING LOCATION tienne tacta ce auae nee pa ku 4 27 4 16 2 LUBRICATION 4 27 FRAME onere emt aciei EUM A Lr Did Mr ere de Oa er eae 4 28 4 17 1 WELDING FRAMES fie 4 28 FUEL SYSTEM oe ee a a eae 4 28 4 18 1 FUEL DELIVERY SYSTEM ccccccsssccssssccsscecsssecsecceecesaecsesaeeceesssssaeecssesessesaecseseeecaaaecseaseessaaeeeseneeess 4 28 451822 FUEL FILTERS ett tert Mb sit bent teet ape te etre es tab Cae Ced 4 28 HEATING VENTILATION AIR CONDITIONING HVAC 4 0 4 29 4 19 1 HEATER SHUT OFF OPTIONAL fret ds dre nt e e i e o es 4 29 4 19 2 CONDITIONING OPTIONAL crit tra trita 4 30 4 19 2a AIR CONDITIONING SIGHT GLASS 2 4 31 4 19 2b REFRIGERANT RECOVERY AND RECYCLING 2 4 31
114. Schedule Description Action Miles Time Air Dryer Desiccant Replace desiccant See Air Dryer Manual Axle Rear Replace lubricant initial drain and fill See Axle Manual Axle Rear Replace oil amp oil filter if applicable in carrier See Axle Manual Coolant Replace coolant after flushing system See Engine Manual Coolant Filter Replace See Engine Manual Engine Oil Replace with engine manufacturer s recommended See Engine grade and viscosity Manual Engine Oil Filter Replace See Engine Manual Engine Thermostats Test and replace if defective See Engine Manual Fuel Filter Replace element See Engine Manual Rear Suspension Refer to the rear suspension manufacturer s See Rear maintenance manual for maintenance schedules Suspension lubrication recommendations and inspection Manual procedures Transmission Filters Replace with transmission manufacturer s approved filters See Transmission Manual 5 4 Custom Chassis 2010 Pierce Manufacturing Inc All Rights Reserved SERVICE AND LUBRICATION INTERVALS Description Action Miles Time Transmission Fluid Replace with transmission manufacturer s See Transmission recommended fluids and viscosity Manual Wheel Bearings Grease Front Axle Lubricate with Lithium NLGI grade EP2 grease See Axle Manual Wheel Bearings Oil Front Axle Replace lubricant See Axle Manual Additional Information e See the P
115. Single configuration 2 tires per axle D Dual configuration 4 tires per axle Proper inflation is vital Under inflation is a tire s worst enemy Inflation pressure should be checked with an accurate tire pressure gauge only Thumping with a tire bar is not a satisfactory method to use when checking pressure The practice of reducing inflation pressure to attain a softer ride is extremely hazardous especially when steer axle tires are involved Under inflation causes excessive flexing within a tire resulting in heat buildup which can cause a blowout An under inflated tire running at highway speeds and under heavy load can cause severe handling problems 4 38 Custom Chassis 2010 Pierce Manufacturing Inc All Rights Reserved MAINTENANCE Under inflation can also result in general deterioration of the tire body including separation of the tread from the body or fatigue breaks in the body cords If one tire on a dual assembly is severely under inflated the other one is prone to failure from overloading Over inflation detracts from a tire s ability to endure road shocks The tire is more rigid resulting in carcass and bead failures Overinflated tires often exhibit groove cracking and rapid center tread wear and are more likely to be cut or punctured Excessive pressure buildup resulting from overloading or high speed can cause the rim to fail The load carrying capacity of a tire cannot be increased over the maximum rated
116. TA 3 4 EXHAUST SYSTEM 25 060 ex uvae Fe Tv de qu o rene D da ae hn 3 4 EGUIPMENT LOADING RIETI uw 3 4 ERT FRONT SIDE etii rt nn E dan ete ame UP D E PLE 3 4 ET FRONTOWHEEL 2 duties sce ee Ts 3 4 LEFT FRONT SUSPENSION veu dee de ee pe a a RE td ae 3 4 6 lens 3 5 FRONT TEE 3 5 ERONTEIGETS ANDREEBEGTORS Ie POET en aed Dd xe ITI SR AT 3 5 RIGHT FRONT WHEEL 2 eode dee eene 3 5 RIGHT FRONT SUSPENSION rera Pi Fever de va Dee veta reda 3 5 RIGHT FRONT BRAKE 3 5 mM rM 3 5 RIGHT REARS lE 3 6 RIGHT REAR SUSPENSION devant 3 6 RIGHT REAR BRAKE nee 3 6 SIDE LIGHTS AND REFLECTORS 2 3 6 REAR LIGHTS AND REFLECTORS dans nan d mud v d da aa 3 6 e CR 3 6 CEPT REAR SUSPENSION bere e beer darc De Pug de v 3 7
117. The cause of the fault indication must be corrected as soon as possible See Side Holl Protection System Optional on page 4 33 for additional information If the engine does not start within 15 seconds release the starter buttons and allow the starter motor to cool for 60 seconds before attempting to start the engine again 7 Push the starter button 8 When engine starts release the starter button 3 36 Custom Chassis 2010 Pierce Manufacturing Inc All Rights Reserved OPERATION 3 12 2 Running the Engine Internal combustion engines give off hazardous fumes and gases while running Do not operate the engine in an area where exhaust gases can accumulate or serious injury or death may occur Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer birth defects and other reproductive harm The exhaust system can get extremely hot without warning Keep away from exhaust gas and do not park vehicle near flammable material Do not touch exhaust pipes or parts Hot metal and exhaust gas will burn skin 3 12 3 Engine Specific Operation Instructions IMPORTANT Refer to the engine operator s manual for additional information troubleshooting and safety instructions 3 12 4 Stopping the Engine Never stop the engine by turning off the battery switch or alternator damage may result Running the engine at idle allows the lubricating oil and coolant to carry heat away from
118. Torque the U bolt nuts in conjunction with a wheel alignment after the chassis has been operated for 500 miles or six months whichever comes first Re torque nuts thereafter every 24 000 miles or annually whichever comes first Torquing Procedure 1 Clean around the U bolt to nut joint to remove dirt and grime 2 Lubricate joints liberally with Permatex 133k Lubricant 3 Tighten U bolt nuts evenly in a crisscross pattern 4 Torque to proper value using a calibrated torque wrench per the following charts Table 4 6 U Bolt Fastener Torque Chart Arrow XT Quantum Velocity Impel Torque U Bolt Diameter Ft Lbs N m 3 4 16 240 260 325 355 7 8 14 400 420 540 570 17 14 500 520 680 705 Table 4 7 U Bolt Fastener Torque Chart Saber Contender Torque U Bolt Diameter Ft Lbs N m 3 4 16 240 260 325 355 7 8 14 300 320 405 435 17 14 400 420 540 570 Replace U bolts with same size grade 8 U bolts whenever they are removed Reinstall using the torquing procedure noted above Re torque after 500 miles of service Spring seats spacers and shims act to support the spring pack and are important members of the suspension Any additional spacers or shims must be selected properly Upper and lower spring seats and any spacers that are replaced or added to the suspension assembly must be the same length and width as the original equipment Replacing or adding spring seats
119. acks of seats that will not be occupied while the vehicle is in motion SCBA bottles not secured properly in unoccupied seats could cause serious injury or death during a collision Does not pertain to inertia activated hands free SCBA holders Always verify that the seat belt buckle and SCBA harness buckle are in their respective proper receptacle Interchange between the SCBA harness and seat belt buckles will negate the benefit of the seat belt and death or serious injury may result Self Contained Breathing Apparatus SCBA bottle brackets are designed to hold the SCBA bottle in position while the firefighter is riding to the fire scene Bottles mounted in seats without occupants must be fastened using the SCBA mounting bracket manufacturer s restraining device Does not pertain to inertia activated hands free SCBA holders SCBA harnesses are often manufactured using nylon straps and buckles similar in construction to seat belt buckles Care must be taken to ensure that the occupant does not mistake the SCBA harness buckle for the seat belt buckle We strongly recommend that fire companies check all SCBA harnesses to ensure that they are not interchangeable with the seat belt buckles and that all firefighters are trained to become aware of this danger Never operate the vehicle with passengers occupying seats equipped with SCBA brackets without either the SCBA bottles in place or approved back inserts installed to reduce the risk of back inju
120. ale The coldest setting is in the blue and the warmest setting is in the red 3 58 Custom Chassis 2010 Pierce Manufacturing Inc All Rights Reserved OPERATION 3 14 3 Operating Tips Fast Cool Down For a fast cool down turn the Blower Control to the extreme left position turn the mode control to the Panel position and drive with the windows open for the first few minutes Once the hot air has been expelled close the windows and turn mode selector to Recirc When a comfortable condition has been reached choose a mode position and adjust the Temperature Control and Blower Control as necessary to maintain comfort NOTE The Recirc mode opens and closes a door allowing fresh air into the system Check to make sure the door is operating properly Set the control in Recirc mode and look underneath the cab at the right front corner to ensure the door is shut The door opens approximately 1 inch in the fresh air mode Window Fogging In mild but rainy or humid weather windows will fog on the inside To clear the fog off all the windows activate the air conditioning Adjust the Temperature Control and Blower Control to maintain comfort Interior fogging on the windshield can be quickly removed by selecting the Defrost mode WEATHER CONTROL SETTINGS HOT WEATHER Start vehicle and put Mode Control in 2 position and turn on A C Set Blower Control VEHICLE INTERIOR to HIGH Roll windows down to flush out hot air Roll windows up aft
121. all and remedy campaign NHTSA will not become involved in individual complaints between customers dealers and manufacturers To contact NHTSA call the Auto Safety Hotline at 1 800 424 9393 or write to NHTSA U S Department of Transportation Washington D C 20590 1 10 Customer Assistance Information Your satisfaction with your Pierce apparatus is important to your dealer and Pierce Manufacturing Inc Normally any question or concern you may have with your apparatus can be handled by your selling or servicing dealer Your dealer has the facility trained technicians special tools and up to date information to promptly address any issue that may arise Pierce Manufacturing Inc has empowered dealers to make decisions and repair vehicles and they are eager to resolve your issues to your complete satisfaction Should you encounter an issue with your Pierce apparatus that requires service take the following steps Step 1 Contact your authorized Pierce selling or servicing dealer They will make the necessary arrangements to order the necessary parts and make the required repairs 1 6 Custom Chassis 2010 Pierce Manufacturing Inc All Rights Reserved TO THE OWNER Step 2 If they are not able to repair the problem to your satisfaction discuss your concern with a member of dealer management Normally concerns can be quickly resolved at that level If the matter has already been reviewed with the Sales Service or Parts Mana
122. amage personal injury or death When checking air pressure or inflating deflating tires always use the following Aclip on chuck Anin line valve with a pressure gauge or a pre settable regulator A sufficient length of hose between the clip on chuck and in line valve if one is used to allow personnel to stand outside the trajectory area Tire pressure should be checked while the tire is cold Tires that are heated through use may have a 15 psi 103 kPa higher rating Proper tire inflation is essential to safe vehicle performance and handling Tire inflation pressure must match the weight on each axle Before placing the vehicle in service obtain the axle weights with all equipment loaded and tanks full Adjust the tire pressure to match the tire loads See Tire Inflation on page 4 37 Once all of the tires are inflated to the proper air pressure install on each tire the VECSAFE tire pressure managment system valve caps if equipped that were shipped loose with your apparatus 2010 Pierce Manufacturing Inc All Rights Reserved Custom Chassis 2 1 BEFORE PLACING VEHICLE IN SERVICE 2 3 Brake Balance All Pierce Custom Chassis are configured to provide properly matched drivetrain components at the maximum axle capacities listed on the tag located inside the cab Brake operation in fire apparatus service is unique to the trucking industry because of the high horsepower to weight ratios high acceleration high
123. and door latches NEVER LET THE VEHICLE SIT WET Ceiling fans and or floor ventilation is recommended When possible park the vehicle outdoors and open up all vehicle doors to let all areas dry out Clean Goldstar gold leaf vinyl painted surfaces using mild non abrasive liquid wash n wax type solutions Follow manufacturer s mixing instructions Wash with warm water not hot using gentle water pressure and a clean soft cloth Clean anodized aluminum trim using only mild detergents and lukewarm water Damage to these parts can occur if cleaning solutions having excessive acidity or alkalinity are used 4 8 Custom Chassis 2010 Pierce Manufacturing Inc All Rights Reserved MAINTENANCE 4 7 3 Undercarriage Corrosion As arule pressure washing should only be done on the underside of the vehicle Pressure washing should NOT be done on any surface that has Goldstar gold leaf vinyl striping labels or overlays When washing using high water pressure all grease fittings outside and underneath the vehicle chassis must be lubricated after washing to dissipate water and contaminated grease The increased popularity of liquid de icing agents along with traditional road salts has increased the risk of chassis related corrosion Liquid de icing agents wick into narrow gaps even more readily than road salts and cause corrosion when humidity is present The new chlorides tend to stick to surfaces more than traditional road salt Fi
124. annot be initiated during pumping operations The sequence of indicator light s is as follows 1 After usage of the engine for a period of time the DPF light may be illuminated Once this light is lit an active regeneration should be initiated within a reasonable amount of time generally 8 to 10 hours depending on the duty cycle 2 f no regeneration occurs after the DPF light illuminates the DPF light will begin blinking and an active regeneration should be initiated as soon as possible 3 If the flashing DPF light is ignored the Check Engine light will illuminate A parked regeneration must be performed to clean the DPF before further operation The engine will not de rate or shut down in this situation 4 Continuous usage of the vehicle past the previous levels of warning without regeneration will force the need for a thorough cleaning of the DPF The extreme level of soot build up will be identified by the following instrument panel lights blinking DPF Regeneration light solid Check Engine light and solid Stop Engine light Operation of the engine as described in Item 4 may result in excessive soot accumulation In this case contact a Detroit Diesel service representative for assistance 3 12 6d Parked Regeneration To initiate a parked regeneration the following must occur 1 Move the truck to a safe location that prevents the high exhaust heat from causing damage to the road surface or the ground 2 The driver MUST s
125. arked regeneration and engine speed will return to idle Operators may notice a slight increase in vehicle vibration during regeneration The DD13 engine will fire three cylinders during regeneration and operate the other three in engine brake mode This increases engine load during regeneration and increases exhaust temperatures 2010 Pierce Manufacturing Inc All Rights Reserved Custom Chassis 3 41 OPERATION Upon completion of parked regeneration the following should occur 1 The HEST light will remain illuminated until the exhaust outlet temperature is below the temperature threshold or the vehicle speed exceeds 5 mph 2 The DPF light will turn off along with all other associated warning lights If the Check Engine light Stop Engine light or MIL are still illuminated a fault condition exists that should be diagnosed by a Detroit Diesel service representative To cancel the parked regeneration the driver can toggle the regeneration switch to ON for five seconds The DPF light will flash on for one second to show acceptance of the cancellation request and then return to idle If a parked regeneration is interrupted the DPF light will illuminate indicating the need for further regeneration The DPF light will remain illuminated until the regeneration is completed through either automatic regeneration by driving or pumping or by resuming a parked regeneration Parked regeneration is not allowed when the DPF light is not illumin
126. ated 3 12 6e Selective Catalytic Reduction SCR Operation The operation of the SCR device does not require any driver involvement The driver is responsible for filling the diesel exhaust fluid DEF reservoir to maintain the proper amounts of DEF fluid required by the engine The DEF reservoir on Pierce custom fire apparatus is 4 1 2 gallons The fluid level sensor transmits the fluid level directly to the Aftertreatment Control Module ACM The ACM is programmed with specific operational parameters which will trigger the instrument panel DEF indicator light as well as induce vehicle performance derates As the fluid level drops in the DEF reservoir the following reactions will occur DEF level between and 1 4 full DEF Fluid Low light will remain off DEF level between 1 4 full and 1 8 full DEF Fluid Low light will illuminate solid DEF level below 1 8 full DEF Fluid Low light will flash e DEF level below 1 4 gallon DEF Fluid Low light flashing and Check Engine illuminated The engine will induce a 55 MPH speed limit and 25 engine torque derate DEF Tank Empty DEF Low light flashing Check Engine light and Malfunction Indicator Lamp MIL illuminated The engine will induce a 55 MPH speed limit and 25 engine torque derate DEF Tank Empty and Ignored fuel tank refilled by more than 30 or engine start after the consumption of more than 350 gallons of diesel fuel DEF Low light flashing Check Engine light Stop Engi
127. ation of most shop type air tools 2 6 Equipment and Cargo Loading Excessively uneven loading from side to side greater than 550 Ibs can cause the vehicle to pull to one side during braking and or produce a reduction in the rollover threshold of the vehicle Operation of an improperly loaded vehicle could lead to loss of vehicle control causing property damage serious personal injury or death NFPA Standards specify that All equipment required to be used during an emergency response shall be securely fastened Equipment not needed during the response must be secured to 9 Gs Items not secured can injure or kill during a crash Every Pierce custom fire truck is measured prior to leaving the factory to ensure that it sits level Since the apparatus may be configured with heavier options on one side or the other it may be equipped with factory installed shims at the time of delivery As the compartments are filled with equipment of varying weight the initial weight distribution will change which may cause the truck to lean The amount of lean depends on the spring rate of the suspension Vehicles with higher capacity suspensions will lean less when subjected to the same variation in weight To ensure that a vehicle does not lean objectionably careful consideration must be given to the weight and location of equipment The following guidelines will help level a vehicle that has an objectionable lean e Check tire pressure and trea
128. ation or Heavy Braking Always rely on the braking effect of the engine engine brake exhaust brake or retarder when descending a grade or when anticipating frequent heavy deceleration If service brakes alone are used to control vehicle speed excess heat may be developed causing brake fade Brake fade occurs when the brake drums become hot and expand away from the brake shoes and the stroke of the slack adjusters become less effective If service brakes are required to supplement retardation apply the brakes in short durations of 5 to 10 seconds rather than a continuous application This will minimize heat buildup and reduce the possibility of brake fade The brake lining material used on Pierce Custom Chassis has been selected in conjunction with the axle manufacturers to provide the best balance of stopping distance performance grade holding capacity and lining life Brake lining life is dependent on the type of service to which the vehicle is subjected and is heavily influenced by driving habits 3 5 2 Air Pressure Gauge Indicator Light and Audible Alarm The quick buildup feature allows the vehicle to be driven even though the front brake section may not have sufficient air pressure to enable sustained or full force braking Use extreme caution when operating the vehicle with either air brake section charged to less than 60 psi or property damage or personal injury could result The air pressure gauges indicate the amount of pressure
129. ature transducers These sensors allow the engine to monitor soot build up and identify cleaning requirements Engine instrument panel light functionality is explained in Instrument Panel Indicator Lights Cummins Engines on page 3 69 Exhaust temperatures during a normal regeneration event can get up to 1112 F 600 C 2010 Pierce Manufacturing Inc All Rights Reserved Custom Chassis 3 43 OPERATION Figure 3 6 Cummins AT Regeneration Light Behaviors AT Regeneration Lamp Behaviors Severe Existing Lamps New Lamps Static na ry 5 Passive Regeneration Mobile Stationary Active Oniy pies Empty Auto Low Medium High Stop 1119 3 12 7b Passive Regeneration The passive regeneration process removes collected soot in the DPF under normal truck operations and does not require operator interaction The operator will see no difference in vehicle performance during the passive regeneration process When the engine is operating at higher speeds and loads there is enough energy in the exhaust to remove the collected soot in the filter This happens naturally and does not require any action by the engine control system or the operator No extra fuel will be used nor will excessive exhaust temperatures occur during passive regeneration Operators may see the DPF light illuminate and turn off while operating the vehicle This indicates that the soot level in the DPF temporarily reached a moderately high level but bec
130. ause the engine operating conditions were right the passive regeneration process reduced the soot load 3 12 7c Active Regeneration The active regeneration process removes collected soot in the DPF through the addition of hydrocarbons unburned fuel to the exhaust stream When the hydrocarbons enter the DPF assembly the temperature is elevated to a point where removal of the collected soot can occur This can happen while the truck is being driven when in stationary truck operations or during pumping operations The operator will be notified of the need for regeneration by illumination of the DPF light located in the cab When the DPF light goes on the operator can provide assistance by either changing the duty cycle or initiating a stationary regeneration using the regeneration switch which is located in the cab within reach of the driver Active Regeneration During Stationary Operations The following vehicle conditions must be satisfied before a stationary regeneration can be started using the regeneration switch 1 Zero vehicle speed 2 Accelerator pedal remote accelerator at idle 3 44 Custom Chassis 2010 Pierce Manufacturing Inc All Rights Reserved OPERATION 3 Service brake released brake pedal not depressed 4 Thetransmission must be in neutral confirmed by looking at the Allison Transmission Shift Selector and seeing current gear and selected gear are neutral N 5 Engine control mode from accelerator pedal
131. b Belt Fan Drive Quantum built after December 1999 4 23 Multiplex System Principals of Operation 4 12 N Neutral to Drive Shift Growl Allison MD Transmission 3 92 Non Command Zone Components 4 14 Odometer and Speedometer 3 34 Operating Tips 1 3 59 Operation es 3 1 Operation in High Ambient Temperature Conditions 3 26 Operation of Engine in Fuel Rich Atmosphere 3 52 Other Fasteners 4 26 2010 Pierce Manufacturing Inc All Rights Reserved Overheat Warnings 3 26 OVEFVIEW pP 4 11 P Parked Regeneration Detroit Diesel 2007 EPA 3 39 Detroit Diesel 2010 EPA 3 41 Parking Brakes 3 22 Passive Regeneration Cummins EPA 2010 3 47 Cummins ISL 2007 EPA 3 44 Detroit Diesel 2007 EPA 3 38 Detroit Diesel 2010 EPA 3 40 Periodic Inspection 4 21 Power Take Off Control 3 93 Precautions When Tilting the Cab During Maintenance Actions 4 33 Preparation for Towing
132. bile water supply vehicles known as tankers or tenders are widely used to transport water to areas beyond a water supply system or where the water supply is inadequate Incidents involving motor vehicles account for approximately 2096 of U S fire fighter deaths each year cases involving tankers are the most prevalent of these motor vehicle incidents During 1977 1999 73 deaths occurred in 63 crashes involving tankers Of those deaths 54 occurred in 49 crashes in which tankers rolled over no collision and 8 occurred in 6 crashes in which the tankers left the road no collision The other cases involved collision with another vehicle 10 deaths in 7 crashes and collision with stationary object s 1 death NFPA 2000 Tanker drivers may not be fully aware that tanker trucks are more difficult to control than passenger vehicles A tanker truck requires a much greater distance to stop Tankers weigh substantially more and their air brake systems take more time to activate than the hydraulic mechanical brake systems on smaller passenger cars The effect is influenced by the amount of water the tanker is hauling and whether the tanker is baffled 1 7 2 Recommendations for Prevention To reduce the risk of tanker truck rollovers the National Institute for Occupational Safety and Health NIOSH recommends that fire departments take the following precautions e Develop implement and enforce standard operating procedures SOPs for emergency vehicle
133. ble Switch Input Digital Output Device Being Controlled POMO113 4 12 Custom Chassis 2010 Pierce Manufacturing Inc All Rights Reserved MAINTENANCE NOTE The Command Zone Information Center CZIC also has switch input capabilities The functionality of a simple multiplex system is explained in the following paragraphs While the system shown here has a single Input Output I O Module and Power Module typical vehicles have several modules located in various places on the truck Step 1 The operator activates a switch rocker or membrane for a specific function This information is received by the I O Module which transfers this information to the Control Module via the data link Step 2 The change in switch position information is received by the Control Module which interprets the information and verifies that all necessary interlocks have been satisfied if applicable Step 3 The Control Module then sends an indicator light activation message via the data link back to the 1 0 Module which then causes the I O Module to turn on the indicator light located on the switch Step 4 At the same time the indicator light information is processed the Control Module determines which Power Module output should be turned on and sends that information via the data link Step 5 The power module which is constantly monitoring the information on the data link interprets the Control Module information and grounds the app
134. braking effort If constant use of the retarder produces frequent overheat situations consult your Pierce Dealer regarding a change to the control system or capacity setting that will better suit your duty cycle and environmental conditions 3 7 Cab Occupant Capacity All occupants must be seated and belted when the apparatus is in motion or serious injury or death may result Do not ride on the rear step or any other area outside the cab while the vehicle is in motion or death or serious injury may result Never transport more people than the seating capacity of the vehicle Carrying additional personnel may result in death or serious injury The number of occupants that can be safely carried is listed on the Federal Motor Vehicle Safety Standard FMVSS information decal located inside the cab Only those seating positions equipped with factory installed seat belts are to be occupied while the vehicle is in motion Any seat bench or stool not equipped with a factory installed seat belt is to be used by emergency personnel only while the vehicle is stationary with the parking brakes properly applied 3 26 Custom Chassis 2010 Pierce Manufacturing Inc All Rights Reserved OPERATION 3 8 Cab Step Operation Quantum 3 8 1 A Air Pressure Requirements Steps when deployed protrude beyond the legal width of the vehicle Operation of the vehicle with the steps in the down position may result in damage to the steps or
135. breathers can restrict the safe negotiation of high water Since the depth of water that can be safely traversed is a function of water depth and complex hydrodynamics no definitive fording capability can be established Note the location of the air intake port on your Pierce apparatus and avoid operation in standing water that will cause water ingestion into the engine If water ingestion into the air intake system is suspected or the vehicle has been driven in high water conditions then the following procedures should be followed 1 Check air intake for moisture Remove the air intake piping ahead of the air cleaner and check the filter for moisture If the filter is only partially wet with some dry paper area then the chances are very good that no water entered the engine Allow the filter to dry or install a new filter 2 Inspect components for damage If the entire filter element is saturated then proceed to have the engine checked by an authorized service center Check fan for cracks in blades or missing blades Analyze samples of oil from the axles engine and transmission for water content Change fluids as required 3 94 Custom Chassis 2010 Pierce Manufacturing Inc All Rights Reserved OPERATION 3 30 2 Fording Water with Command Zone Vehicles After any high water use where the boxes are partially or fully submerged they should be opened and inspected for moisture If water has entered the box allow to dry com
136. by a loaded engine while pumping water may be high enough to allow passive regeneration The operator will not experience any change in engine performance or engine control during passive regeneration 3 12 5c Active Regeneration Active regeneration can occur in two manners in automatic mode or in parked mode Automatic regeneration occurs when the engine load exhaust temperature and engine speed are within an acceptable range When the conditions are met the engine will begin dosing fuel into the exhaust stream to clean the DPF in a regeneration mode The automatic regeneration cycle does not require an operator to initiate No change of engine control or engine speed is experienced during the automatic regeneration event Automatic regeneration may occur during pumping operations Active regeneration can also occur when the truck is parked Parked regeneration allows the cleaning of the DPF in stationary truck operations and requires operator involvement to initiate The operator will be notified of the need for a parked regeneration by illumination of the DPF light located in the cab Parked regeneration cannot be initiated during pumping operations 3 38 Custom Chassis 2010 Pierce Manufacturing Inc All Rights Reserved OPERATION The sequence of indicator light s is as follows 1 After usage of the engine for a period of time the DPF light may be illuminated Once this light is lit an active regeneration should be initiated wit
137. cancellation request and then return to idle If a parked regeneration is interrupted the DPF light will illuminate indicating the need for further regeneration The DPF light will remain illuminated until the regeneration is completed through either automatic regeneration by driving or pumping or by resuming a parked regeneration Parked regeneration is not allowed when the DPF light is not illuminated 2010 Pierce Manufacturing Inc All Rights Reserved Custom Chassis 3 39 OPERATION 3 12 6 After Treatment Device Regeneration Detroit Diesel DD13 2010 EPA Parked Regeneration causes high exhaust gas temperatures at zero vehicle speed Keep personnel away from exhaust outlet to avoid serious burns and injury Do not perform parked regeneration while connected to an exhaust extraction system Damage to the exhaust extraction system may result 3 12 6a Basic Operation of the After Treatment Device 2010 EPA engines are required to use an After Treatment Device ATD and a Selective Catalytic Reduction SCR for controlling emissions These two canisters have replaced the typical muffler The first canister in the exhaust stream is the ATD which contains the Diesel Oxidation Catalyst DOC and the Diesel Particulate Filter DPF The DPF will trap particulate matter while the engine is running Over time soot and ash build up in the filter and must be removed Soot build up is removed by heating the filter until the so
138. cates when occupant is seated but not wearing seat belt This screen displays automatically when the SEAT BELT NOT BUCKLED warning becomes active and there is no DO NOT MOVE TRUCK warning Alarms Screen Figure 3 33 Alarm Screen Active Alarms 0089 The ALARM button will appear on the Alarms screen Figure 3 33 whenever there is a warning or caution message Pressing this button will list all active messages The messages are displayed in order of occurrence The SILENCE button is used to silence the audible alarm While the silence feature is active the buzzer will continue to chirp for 1 second every 30 seconds for as long as any message is active After silencing the current alarm message the Command Zone system continues monitoring for new alarms If the alarm status changes the silence feature is deactivated and the alarm buzzer will sound 2010 Pierce Manufacturing Inc All Rights Reserved Custom Chassis 3 81 OPERATION 3 22 3 System Menu Figure 3 34 System Menu System Menu 1372 The MENU button will bring up a list of items for setting up the display or will allow maintenance personnel familiar with Command Zone electronics to access troubleshooting and analysis screens An indicator arrow to the left of the list can be moved by pressing the UP or DOWN button Pressing the SELECT button will cause the selected screen to be displayed If the parking brake is not set the MENU button
139. ce of glycol will physically deteriorate clutch plate material Local conditions severity of operation or duty cycle may require more or less frequent fluid change intervals that differ from the published recommended fluid change intervals of Allison Transmission Transmission protection and fluid change intervals can be optimized by use of fluid analysis The user should evaluate individual needs and determine the economics of performing an analysis If it is suspected that foreign materials have entered the fluid System then an analysis needs to be performed immediately Fire trucks are defined as severe vocation due to retarder use and similarity to transit coach operation Fluid should be changed every 12 000 miles 6 months or 500 hours Conditions that indicate water and or glycol in the fluid are Rust or pitted transmission parts spewing out of the breather e Oil in the radiator Gaskets blistered or wrinkled in uncompressed areas Appearance of oil Presence of water in oil when dispersed is a cloudy or gray pink or strawberry color e Steam from the breather Should the user suspect contamination an oil sample should be obtained when transmission oil is at normal operating temperature to assure contaminate if present is thoroughly dispersed in the oil as sampled The analysis of oil sample by the oil supplier or any qualified laboratory will provide the degree of contaminate and possibly a clue as to its sourc
140. cornering causing a loss of directional control or roll over Training is recommended when using either system When operating your vehicle always use safe driving techniques The driver is ALWAYS the most important part of a safe vehicle operation 3 88 Custom Chassis 2010 Pierce Manufacturing Inc All Rights Reserved OPERATION 3 25 Steering Do not adjust the steering column with the vehicle in motion to avoid uncontrolled steering inputs that could lead to property damage personal injury or death IMPORTANT Pay attention to the feel of the steering system during driving Check for looseness pulling strange noises etc Any change in the feel should be investigated by a qualified mechanic 3 25 1 Steering Column Adjustment Adjust the tilt of the steering column by pulling up on the adjusting lever while tilting the column to the desired position Adjust the height of the steering wheel by pushing down on the adjustment lever and moving the wheel to the desired position 3 25 2 ALL STEER All Wheel Steering Optional The use of all wheel steering significantly changes vehicle handling particularly on a slippery road surface caused by rain snow or icy conditions Do not drive a vehicle equipped with the ALL STEER option in any ALL STEER mode until you have thoroughly read the manual and had behind the wheel training from an individual who is an experienced ALL STEERO all wheel steering system vehicle
141. could result The emergency parking brake release option allows the operator to override the parking brake safety feature that prevents the spring brakes from being released until minimum pressure has been built up in the air brake system Air pressure for the spring brake release is supplied by a dedicated air tank 3 5 8 Auxiliary Front Wheel Lock Optional The auxiliary front wheel lock feature uses air brake system pressure to keep the front brakes applied It should be used only with the engine running and a qualified attendant present at all times It is a supplemental brake only which does not meet the FMVSS parking brake criteria and must be used in conjunction with the yellow parking brake valve when parking the vehicle Failure to follow these precautions could lead to loss of vehicle control causing property damage serious personal injury or death The auxiliary front wheel lock feature allows the operator to engage the service brakes on the front axle to gain additional grade holding capability or to improve stability when the aerial device outriggers raise the rear wheels off the ground The parking brake must be engaged before the auxiliary front wheel lock will function 3 5 9 Air Reservoir Moisture Draining Collection of moisture in the air reservoirs due to condensation is normal even though the vehicle is equipped with an air dryer Open the petcocks on each air tank to drain the condensate 3 5 10 Air Dryer Every
142. cting always connect the ground terminal last Do not attempt to jump start a vehicle having a frozen battery because the battery may rupture or explode If a frozen battery is suspected examine all fill vents on the battery If ice can be seen do not attempt to start with jumper cables as long as the battery remains frozen Thaw out battery and recharge Do not check battery condition by shorting across terminals Failure to observe these instructions could result in property damage personal injury or death The standard battery offerings supplied with Pierce Custom Chassis are of a maintenance free design To ensure a proper electrical supply battery terminals must be clean and tight Use hot water and baking soda for removing corrosion and for cleaning the top of the batteries Polish the contact surface of the terminals with steel wool and apply a light coat of dielectric lubricant before installing terminals Ensure that the battery terminals are clamped tightly 3 11 4 Battery Charging Precautions Always disconnect battery leads while charging batteries A fast charger should never be used as a booster for starting the engine Always connect battery charger leads to vehicle battery leads of the same polarity e Check ground or return circuit polarity visually or with a voltmeter before connecting batteries or other voltage producing components into the system 3 11 5 Battery Switch Never turn the battery switch of
143. d Arrow XT chassis also have a 4 line LCD display that is part of the instrument panel This display shows the same 2 line CAUTION WARNING and Command Zone text messages no graphics that appear on the CZIC screens 2010 Pierce Manufacturing Inc All Rights Reserved Custom Chassis 3 71 OPERATION 3 20 1 Care and Maintenance The CZIC screen is manufactured with coatings to reduce glare and resist scratches Despite these design features care should be taken to avoid damage to the lens Clean with mild glass cleaner and a soft cloth Avoid pressure washing around the CZIC particularly toward the back of the unit The CZIC incorporates a micro filter vent on the rear casing that allows the unit to adjust to changes in atmospheric pressure while keeping out dust and moisture High pressure water sprayed directly on this vent may allow damaging moisture to contaminate the electronics 3 20 2 Interior and Exterior Versions The CZIC comes in interior and exterior versions The interior version has a black case and soft touch buttons The exterior version has a gray case and booted buttons The booted buttons are resistant to water and ice and have a heavy tactile feel for ease of use with gloved hands The electronics and connections are identical in each version and either version will operate any position in a Command Zone system 3 20 3 Chassis and Aerial Information Center Differences Pierce apparatus may be equipped wit
144. d condition Tire pressure and tread wear can affect vehicle height by as much as 0 25 inches Ensure that all tires are inflated to recommended pressures and that tread wear is reasonably even from side to side e Inspect the vehicle on a surface that is both flat and level Keep in mind that the variations in height are generally measured in fractions of an inch The tolerance of concrete and asphalt surfaces over the length and width of fire apparatus are rarely within the limits required to provide accurate measurements Transfer load Balance the spring loading by shifting equipment from the low side to the high side of the vehicle Relocate heavy equipment closer to the longitudinal center of the vehicle whenever possible 2 8 Custom Chassis 2010 Pierce Manufacturing Inc All Rights Reserved BEFORE PLACING VEHICLE IN SERVICE NFPA 1901 and 1906 specify that the apparatus when placed in service shall have a side to side tire load variation of no more than 7 of the total tire load for that axle This can be calculated as follows The projections of total equipment payload and mounting locations are essential for proper engineering of a new fire apparatus The purchaser of the fire apparatus should maintain the side to side loading requirement in NFPA 4 13 3 3 as equipment is loaded or installed on the apparatus The percentage difference in side to side tire load should be calculated as shown in the following formula Heavier w
145. d level Inspect steering column joint bolts and steering linkage e Carefully inspect steering gear mounting bracket for signs of damage distortion or fatigue cracking 4 23 2 TAK 4 Steering Refer to the Pierce Service Manual group 0152 P 002 TAK 4TM Independent Front Suspension 4 23 3 Steering Reservoir The power steering pump reservoir must be kept to the proper level and free of air When filling the reservoir start the engine and turn the steering wheel from left to right and continue filling until proper level is maintained 2010 Pierce Manufacturing Inc All Rights Reserved Custom Chassis 4 35 MAINTENANCE A replacement type filter element is located in the pump reservoir Carefully clean any buildup of dirt and grease from the reservoir cover Remove the reservoir cover and filter element Clean inside of reservoir with a lint free cloth Install a new filter element refill with oil and replace cover The filter element should be changed when the oil in the steering system is changed TRW and Sheppard power steering gears require the use of automatic transmission fluid type E or or Dexron IIl Highway vehicles should have the fluid changed annually or every 50 000 miles Off highway vehicles will require more frequent change intervals 4 23 4 Steering System Fastener Torque Inspect all steering system fasteners and tighten as required to the torque specified in Table 4 9 Table 4 9 Steering System Fas
146. ded by interference with door hardware bunker gear attachments SCBA harnesses etc It is important to inspect and maintain seat belt webbing to ensure that it will function properly in a crash To ensure the safety of your fire fighters establish a regimen of seat belt inspection The following photos illustrate various levels of belt damage that can occur if care is not taken IMPORTANT Seat belt webbing should be inspected and replaced if anything beyond slight damage is Figure 4 7 Examples of Seat Belt Damage noticed No Damage Slight Damage Moderate Damage Severe Damage 1245 1248 4 32 Custom Chassis 2010 Pierce Manufacturing Inc All Rights Reserved MAINTENANCE 4 21 2 Side Roll Protection System Optional The following WARNING and CAUTION statements must be followed when working on a vehicle equipped with the Side Roll Protection System NEVER attempt to modify the Side Roll Protection System or remove system components as injury could result Tampering with or removing the roll sensor could cause an accidental deployment of the protective devices NEVER place any object in the deployment pathway of any Side Roll Protection component NEVER tamper with the wiring harnesses of any Side Roll Protection component Always follow labeled warnings and cautions on each component Before to welding on the vehicle turn the vehicle power OFF Ensure the power is removed before disconnecting or connecting the ro
147. directly on top of a painted surface 2010 Pierce Manufacturing Inc All Rights Reserved Custom Chassis 4 7 MAINTENANCE 4 7 2 Washing Instructions Avoid washing with high water pressure hot wash solutions abrasive detergents or rough cleaning motions Washing removes small particulate that can scratch the painted surfaces It also removes contaminants that can etch the paint and accelerate corrosion Your vehicle has been washed at the factory during pre delivery and can be washed any time after delivery Never wash in direct sunlight as the surface temperature may be too hot To wash use a mild non abrasive liquid detergent or a wash and wax type soap that is specifically formulated for vehicle washing 3M Car Wash Soap P N 39000 This type soap has been formulated to have minimal effect on waxed surfaces Mix with warm water at the recommended dilution Pre wet the entire surface to be washed Apply the soapy wash solution with cotton towels or soft bristle brush and a gentle cleaning motion Rinse off all washed areas thoroughly with tap water at gentle pressure before the wash solution has dried Once the entire vehicle has been washed rinse the entire vehicle with pure water from the top down Water is too hard if above 120ppm pH should be between 6 and 8 Water that has a pH below 7 is acidic Acidic water will etch the paint and accelerate corrosion in crevices under hardware and around fasteners Dry all surface
148. dition each unit has a duct routed to the first officer and driver foot area These outlets are located at floor level directly beneath each seat riser Controls consist of temperature and fan speed The left and right units are controlled simultaneously 3 15 3 Air Conditioning Unit The air conditioning system is completely external and consists of two boxes each containing an evaporator and a condenser Each unit has an air intake located in the headliner just behind the driver and first officer seats The air is routed to the crew cab through a headliner plenum and exits through three adjustable ball style louvers per side The driver and first officer each have two adjustable ball style louvers as well Controls consist of fan speed and an on off switch The left and right units are wired through the single control The ball style louvers used allow for shutoff or complete directional control of the airflow these are operator adjustable 3 60 Custom Chassis 2010 Pierce Manufacturing Inc All Rights Reserved OPERATION 3 16 Heating Ventilation Air Conditioning HVAC Velocity ImpelT Figure 3 10 HVAC Control Panel 1100 3 16 1 Defrost This is a heat only recirculation only in dash unit Air intake is through the dash panel upper grill openings The air outlet is through a fixed louvered panel directly below the inlet grill Controls consist of temperature and fan speed IMPORTANT As the defrost and heat
149. ds Water and ethylene glycol can quickly deteriorate and eventually destroy the transmission This type of transmission failure is not covered by the transmission or cooler warranty 2010 Pierce Manufacturing Inc All Rights Reserved Custom Chassis 4 49 MAINTENANCE Daily inspections of the transmission fluid indicating a higher than normal level or showing a change to the normal physical appearance might indicate a possible problem Please refer to Transmission Fluid Analysis Allison Transmissions on page 4 49 Pierce Manufacturing recommends you replace the cooler every 3 5 years depending on the in service demands you put on your vehicle 4 27 Transfer Case All Wheel Drive Refer to the transfer case operator s manual included in the Pierce Service Manual for maintenance schedules lubrication recommendations and inspection procedures 4 28 Welding Instructions Before any welding is done on a multiplexed unit make sure ALL electronic modules and control units ECUS are disconnected Refer to the Pierce Service Manual group 0950 P 008 ECU PMC and Power Module Location Guidelines and the applicable multiplex documentation for component locations Also be sure to disconnect the following as applicable engine ECU transmission ECU anit lock brake system ECU ALL STEER all wheel steering ECU This section defines the requirements for disconnecting electronic components before all welding operations
150. duct However Pierce Manufacturing recommends that air conditioning service be performed by certified dealers or other service facilities using recovery and recycling equipment For additional air conditioning service information refer to the Pierce Service Manual group 0850 V 003 Red Dot Air Conditioning 4 20 Rear Suspension Refer to the rear suspension manufacturer s maintenance manual included in the Pierce Service Manual for maintenance schedules lubrication recommendations and inspection procedures 2010 Pierce Manufacturing Inc All Rights Reserved Custom Chassis 4 31 MAINTENANCE 4 21 Safety Restraints and Devices 4 21 1 Seat Belts Do not bleach or dye seat belt webbing Bleaching or dying may cause a severe loss of belt strength This loss of strength could allow the seat belt to break under stress thus resulting in personal injury The entire seat belt assembly should be inspected for corrosion wear fraying or weak spots The retractor latch and buckle should be checked for proper function and all seat belt mounting bolts should be tight at all times Any seat belt severely strained in a collision should be replaced before the vehicle is placed back in service All seat belts should be replaced at least every five years The unique conditions of fire service application put stress and strain on seat belt assemblies not normally seen in typical automotive applications Webbing can be abra
151. e 4 13 1 Air Intake System Failure to inspect the air intake system for leaks in the tubing and connections may lead to extensive damage to internal engine parts Periodic Inspection Inspect the following Air filter housing for cracks caused by distortion or vibration Flexible ducts for damage and loose fasteners e Air filter mounting for loose fasteners and cracks Airtubing supports Loose or broken supports can cause excessive vibration and open cracks in the system Connecting clamps for dents bends and tightness Tubing and elbow connections by wiping clean and checking thoroughly for cracks Cables control rods hoses or lines for chafing against tubing and connectors Ifthe air intake manifold or the compressor intake flange is suspected of being loose consult the engine manufacturer s manual for torque values and tighten retaining nuts to specifications Air Filter Replacement Replace the air filter or air filter element when indicated by the air intake restriction lamp on the instrument panel When replacing the filter or filter element be careful not to allow dust or dirt from the old filter to contaminate the clean side of the intake plumbing Contact Pierce Customer Service for replacement filters Moisture and Ember Separators Velocity Impel only Velocity V Impel V chassis models are equipped with ember and moisture separation screen located upstream of the air filter The pri
152. e A minimal amount of water may be due to uncovered oil drums or an open transmission filler tube or in the case of glycol the use on an all purpose fill container or a defective transmission oil cooler Any glycol contamination requires a complete disassembly and cleanup of the transmission and replacement of seals gaskets clutch plates and bearings The vehicle cooling system should be pressure tested as a possible source of contamination Nelco Company offers a kit that detects presence of ethylene glycol in oil The kit is identified as GLY TEK Test Kit and can be obtained from Nelco Company 1047 McKnight Road South Saint Paul Minnesota 55119 Telephone Number 651 738 2014 Refer to the Allison Transmission Operator s Manual for additional information concerning maintenance schedules lubrication recommendations and inspection procedures Have transmission serviced only by an authorized Allison service facility 4 26 3 External Transmission Coolers The use of external transmission coolers has become very popular with many transmission applications especially those equipped with retarders These components have a limited lifetime and should be considered a consumable Customer environments with high retarder usage or high ambient temperatures are more likely to experience a shorter cooler lifetime One of the failure modes of these coolers allows for water and coolant from the radiator to be transferred into the transmission flui
153. e degree of overheating but not before the system temperatures have peaked beyond the normal operating range The warning light in the center of the instrument panel will illuminate and an alarm will sound when the transmission output temperature exceeds 330 F or if the transmission sump temperature exceeds 250 F A warning light adjacent to the transmission temperature gauge will illuminate and an alarm will sound if the gauge reading exceeds 335 F This provides a redundant warning to the operator that the critical temperatures have been exceeded If the transmission high temperature warning light is illuminated the transmission ECU will change the shift sequence to hold the transmission in gear longer effectively increasing the rpm of the engine This increases the speed of the cooling fan and water pump which will increase the heat transfer rate of the cooling system and thereby hasten the return of the transmission sump temperature to within the normal operating range Operation in High Ambient Temperature Conditions The influence of retarder use on the cooling system temperatures will vary with the retarder capacity and the control system options The higher capacity settings produce higher amounts of heat Control systems that apply 50 to 100 percent of the retarder as the throttle pedal is released produce the heaviest heat load Frequent cycling on and off the throttle pedal builds up heat rapidly even though the situation may not require
154. e exhaust temperatures leaving the turbo are high enough to remove the soot caught in the DPF No extra fuel will need to be burned in order for this event to occur Passive regeneration is possible while in pump mode operations The heat being generated by a loaded engine while pumping water may be high enough to allow passive regeneration The operator will not experience any change in engine performance or engine control during passive regeneration 3 12 6c Active Regeneration Active regeneration can occur in two manners in automatic mode or in parked mode Automatic regeneration occurs when the engine load exhaust temperature and engine speed are within an acceptable range When the conditions are met the engine will begin dosing fuel into the exhaust stream to clean the DPF in a regeneration mode The automatic regeneration cycle does not require an operator to initiate No change of engine control or engine speed is experienced during the automatic regeneration event Automatic regeneration may occur during pumping operations 3 40 Custom Chassis 2010 Pierce Manufacturing Inc All Rights Reserved OPERATION Active regeneration can also occur when the truck is parked Parked regeneration allows the cleaning of the DPF in stationary truck operations and requires operator involvement to initiate The operator will be notified of the need for a parked regeneration by illumination of the DPF light located in the cab Parked regeneration c
155. e manual included in the Pierce Service Manual for maintenance schedules lubrication recommendations and inspection procedures 4 3 5 Rear Axle Alignment IMPORTANT U bolt nut torque is critical to maintaining rear axle alignment It is natural for the paints and lubricants in the spring pack to compress over time and cause the U bolt clamp force to drop This is particularly true soon after factory assembly or whenever the U bolts are loosened or the springs are replaced It is the owner s responsibility to torque the U bolts after the first 500 miles of operation or six months whichever comes first and then at the recommended maintenance intervals or axle alignment will likely be affected Refer to Spring Suspension Front and Rear on page 4 34 for U bolt torque Check that the rear axle is aligned perpendicular to the chassis frame using high quality and properly calibrated laser alignment equipment operated by a trained technician Slight adjustment may be made by loosening the U bolts and repositioning the axle within the clearance of the axle locating pins 4 2 Custom Chassis 2010 Pierce Manufacturing Inc All Rights Reserved MAINTENANCE 4 4 Brakes 4 4 1 Brakes General All new Pierce Custom Chassis are equipped with non asbestos lining material Even so great care should be taken to avoid the inhalation of brake lining material dust during the servicing of the brakes as brake lining fiber dust may be extr
156. e operating a diesel engine in this type of environment ensure that the vehicle is equipped with a means of shutting off the air intake supply to the engine and that the driver is present to operate the shutdown whenever the engine is running 3 12 13 Air Restriction Indicator A diesel truck engine may consume over 12 500 gallons of air for every gallon of fuel that it burns The air cleaner element filters this air to ensure that dirt and dust are not allowed to contaminate the engine A dirty air cleaner element is a common cause of air restriction The result is too little air to burn all the fuel Some of the excess fuel will cause a smoky exhaust and lost horsepower In addition the excess fuel washes lubricating oil off cylinder walls resulting in seized pistons and bearing failures Regular inspection and maintenance of the air intake tubing and connections is important to prevent any unfiltered air from entering the engine A pressure sensor located in the engine air intake tube triggers the air intake restriction indicator light located on the dash panel Vehicles equipped with Command Zone On multiplexed vehicles air restriction is monitored by the Command Zone system During a restricted air intake condition a text message caution light and chime are activated on the Command Zone Information Center CZIC If the light or CZIC remains activated any of the following conditions may be present The air cleaner filter elem
157. e proper location with the first step retraction 7 Open and close door to verify dome light operation This switch can only be set 1 time If the switch setting needs to be reset a new switch will be required Pierce P N 64 2695 4 6 Tilt System 4 6 1 Cold Weather Operation Cab lift cylinders on all Pierce Custom Chassis tilt cabs include a velocity fuse in the tilt system This is a safety device designed to lock fluid in the cylinders in the event that pressure is lost suddenly due to pump failure or a broken line The velocity fuse becomes more sensitive to actuation at low temperatures To avoid the possibility of locking up the cylinders when lifting the cab in extreme cold weather replace the fluid in the cab lift system as specified in Table 4 1 Table 4 1 Cab Lift Cylinder Fluid Chart Temperature F Fluid Type 0 to 120 18 to 49 DEXRON III Below 0 Below 18 MIL H 5606 Mobil HFA or Equivalent Purge all air from the cab tilt system whenever replacing fluid 4 6 2 Lift Cylinder Trunnion Cleaning amp Lubrication Arrow To prevent corrosion the following procedure should be followed every 90 days or 2 000 miles whichever comes first This procedure should also be performed any time the area is pressure washed Penetrant lubricant and grease required for this procedure can be obtained using Pierce PN 1753125 4 6 Custom Chassis 2010 Pierce Manufacturing Inc All Rights
158. ed stop a short while later and recheck tightness of nuts Brake Drums or Shoes Inspect brakes for the following e Cracked drums or rotors e Shoes or pads contaminated with oil grease or brake fluid e Shoes or pads worn dangerously thin missing or broken Steering System Inspect the steering system for the following M Missing nuts bolts cotter keys or other parts Bent loose or broken parts such as steering column steering gear box pitman arm toe links or steering shafts e Check power steering hoses pump reservoir cooler and fittings for leaks e Steering wheel play of more than 10 degrees approximately 2 inches movement at the rim of a 20 inch steering wheel can make it hard to steer 2010 Pierce Manufacturing Inc All Rights Reserved Custom Chassis 3 3 OPERATION Suspension System The suspension system holds up the vehicle and its load It keeps the axles in place Broken suspension parts can be extremely dangerous Check for e Spring hangers that allow movement of axle from proper position e Cracked or broken spring hangers Missing or broken leaves in any leaf spring If one fourth or more are missing it will put the vehicle out of service but any defect could be dangerous Broken leaves in a multi leaf spring or leaves that have shifted so they might hit a tire or other part Leaking shock absorbers Torque rods or arms U bolts spring hangers or other axle positioni
159. ed on an emission related component which may result in an engine derate or engine protection shutdown When the MIL light illuminates the operator should take the vehicle to a service center as soon as possible 3 70 Custom Chassis 2010 Pierce Manufacturing Inc All Rights Reserved OPERATION 3 18 Mirrors Adjust all side view mirrors before operating the vehicle Check mounting hardware to ensure that mirror heads are secure and will not lose adjustment during operation 3 19 Command Zone System Arrow XT Impel Quantum Velocity 3 19 1 Introduction The Pierce Command Zone system is a control and monitoring device for your vehicle that works in conjunction with the SAE J1939 data bus and J1587 and J1922 data links The Command Zone TM system communicates with assigned components of your vehicle to inform the operator of current status of those components Each vehicle with a Command Zone system may be programmed to monitor and or control different systems on that vehicle 3 20 Command Zone Information Center CZIC General Information Figure 3 17 Command ZoneT Information Center 1108 Command Zone Information Centers CZIC are found on the main instrument panel on the pump panel most trucks and on some Pierce aerial devices They are the operators main source of information and communication with Command Zone system Velocity Impel Quantum an
160. ed surfaces and walk areas Inspect hinge fasteners Tighten loose hinge fasteners as required Inspect the hinge for wear or damage Hinges can be sprung from the weight of crewmembers supporting themselves on the doors during entry This will cause the door to sag and bind on the striker Replace sprung hinges to ensure smooth door operation 4 10 6 Weatherstrip Inspect weatherstrip for tears or excessive abrasion To extent life of rubber spray weatherstrip and window rubber with a light coating of silicone lubricant Clean over spray from surrounding painted surfaces glass and walk areas 4 11 Driveshafts Fire apparatus are equipped with driveshafts and shafts used for Power Take Off PTO operated accessories Never operate the engine with shaft guards removed or with personnel in the vicinity of any rotating shaft as they may engage without warning Hands clothes hair etc can get caught on spinning shafts and U joints Failure to heed this warning may lead to personal injury or death Cease vehicle operation immediately if excessive driveline vibration occurs Continued operation with excessive driveline vibration can cause expensive repairs to transmission axle or pump components For vehicles equipped with air suspensions do not alter the ride height setting or severe driveline vibration and component damage may result Lubricate according to the schedule found in the Pierce Service Manual group 0501 V 001
161. ed to reduce the lean if they are located on one of the high side springs Adding shims If all the above actions have been taken and an objectionable lean still persists additional shims may be installed on the low side of the vehicle Shim thickness should not exceed 0 50 inches on the front and 1 00 inches on the rear Appropriate shim stock may be ordered from the Pierce customer service department Shims must be installed in a manner that maintains the locating pin function between the axle and the springs U bolts should be retightened to the specified torque after 500 miles of road operation Contact Pierce Customer Service concerning any shimming beyond these guidelines 2 7 ALL STEER All Wheel Steering Optional The operation of the ALL STEER all wheel steering system is covered in detail in the ALL STEER Operator s Manual The use of all wheel steering significantly changes vehicle handling particularly on a Suppen road surface caused by rain snow or icy conditions Before placing a vehicle equipped with the ALL STEER option in service all vehicle operators must be thoroughly trained in accordance with the procedures outlined in the ALL STEER Operator s Manual 2010 Pierce Manufacturing Inc All Rights Reserved Custom Chassis 2 9 BEFORE PLACING VEHICLE IN SERVICE 2 8 Suspension Truck suspensions are designed to absorb high forces from road irregularities steering inputs and variations in load
162. een Figure 3 21 displays a scrolling list of alarm messages This screen is intended to assist in system analysis and troubleshooting by operators or maintenance personnel familiar with the Command Zone electronics 3 74 Custom Chassis 2010 Pierce Manufacturing Inc All Rights Reserved OPERATION Predefined warning messages those common to all Command Zone vehicles will be listed alphabetically Warning messages customized for a particular vehicle or series of vehicles is sent to the CANTrak display by the Electronic Control Unit ECU at each initialization and can be found at the beginning of the list Menu Screen Figure 3 22 Menu Screen Do Not Move Truck Status Load Manager Status Maintenance Data Varnings List Contrast amp Back Lighting System Information TRANSMISSION OVERHEAT A vw The Menu screen Figure 3 22 displays a list of all available screens Only available screens will included in the list An indictor arrow to the left of the list can be moved by the up or down soft buttons Pressing the SELECT soft button or the ENTER button will cause the selected screen to be displayed Screen Lighting Figure 3 23 Screen Lighting Display CONTRAST TRANSMISSION OVERHEAT 0079 The contrast and brightness of the display be adjusted Adjust the brightness from the Menu scr
163. een by positioning the indicator arrow to the Contrast amp Back Lighting row Press the ENTER or SELECT button to access the Screen Lighting screen Figure 3 23 Press the appropriate soft button to increase or decrease contrast or brightness Each time the vehicle is powered on the CANTrak display will default to the brightest setting 2010 Pierce Manufacturing Inc All Rights Reserved Custom Chassis 3 75 OPERATION System Information Screen Figure 3 24 System Information Screen SCROLL SYSTBM INFO Y Number Cias gt Power Power Mode Hodik lipit Mode ke Mode Mode ke TRANSMISSION OVERHEAT Ga ON d O Ooo POM0080 Module Screen Figure 3 25 Typical Module Screen Power Module 12 182 F Versions 2 15 CKT CIRCUIT STATUS RetrerNotE gagedhg NC OFF Trans Retarder Not Exgaged ha OFF Trans Retarder Not Esgaged OFF Trans Retirer Not Exgaged hd NCOFF Trans Re tances Not Engaged ha OFF Trans Retard Not Ergaged ha OFF Trans Retarder Not Exgajed ha OFF Trans Not Evgaged lid NCOFF POMO081 The System Information screen Figure 3 24 provides information on each of the Command Zone modules installed on the system The screen lists the module type and module number of each module on the network This is a live screen meaning that if a modu
164. eight Lighter weight 100 Percent difference Total weight After loading the apparatus to its in service condition weigh each wheel position independently to ensure that the side to side specification is met If the variation exceeds 7 shift the load in the compartments until the specification is met 2 6 1 Front Spring Suspension Adjustment Refer to the following paragraphs for front spring suspension adjustment information if needed after equipment and cargo has been loaded 2 6 1a TAK 4 Independent Front Suspension Information concerning the ride height adjustment of the TAK 4 Independent Front Suspension can be found in the Pierce Service Manual group 0152 P 002 TAK 4 Independent Front Suspension 2 6 1b Leaf Spring Suspension Excessive shimming of the front axle can adversely affect steering and braking performance Remove factory installed shims It is likely that any lean induced by the weight from factory installed options such as ladder racks high side compartments and generators was corrected before the vehicle left Pierce by adding shims between the spring pack and the axle pad This action although necessary to provide a level product as delivered may complicate the leveling process once equipment is added If accurate scale measurements indicated that the unit is equally loaded from side to side and an objectionable lean persists inspect each spring for the presence of shims These shims may be remov
165. em and cap OK no serious cuts bulges or excessive tread wear Q Use wrench to test rust streaked lug nuts indicating looseness Hub oil level OK No leaks apparent Right Front Suspension Spring spring hangers shackles U bolts are in good condition Shock absorber shows no sign of excess wear or damage Torsion bar is not damaged and tape is not cut or torn TAK 4 suspension only Refer to Pierce Service Manual group 0152 P 002 TAK 4 Independent Front Suspension Right Front Brake Brake drums or rotors are not cracked or worn Hoses show no signs of excessive wear Right Front Passenger door glass should be clean Door latches and window regulators work properly Primary and safety cab locks engaged Rear of engine not leaking Transmission not leaking Exhaust system secure not leaking not touching wires fuel or air lines Frame and cross members no bends or cracks D D D D D D D LU Air lines and electrical wiring secured against snagging rubbing wearing 2010 Pierce Manufacturing Inc All Rights Reserved Custom Chassis 3 5 OPERATION Right Rear Wheel and rim in good condition no missing bent or broken studs clamps or lugs Show no signs of misalignment Condition of tires properly inflated valve stem and cap OK no serious cuts bulges or excessive tread wear Use wrench to test rust streaked lug nuts indicating looseness
166. emely hazardous to your health Read and follow the precautions listed in the Brake section of the Pierce Service Manual or serious personal injury may result IMPORTANT Replace brake parts with genuine OEM equipment only to avoid nullification of warranty coverage IMPORTANT Do not use Lithium base grease on disc brake calipers Lithium base grease may not adequately lubricate the calipers Only use clay based NLGI Grade numbers 1 or 2 or equivalent Disc brake calipers are NOT to be connected to automatic chassis lubrication systems For vehicles equipped with an automatic lubrication system disc brake calipers will need to be greased separately The inherent duty cycle of fire apparatus requires the use of very aggressive brake lining material For this reason fire apparatus vehicles are very sensitive to brake balance Refer to Brake Balance on page 2 2 before addressing brake related service problems Brake wear varies widely depending on vehicle use factors such as operator driving habits terrain speeds road conditions and use of auxiliary braking devices Establish a regular schedule for inspection maintenance and lubrication based on the duty cycle of the vehicle Inspect brake linings weekly until a normal wear rate can be determined and an appropriate inspection schedule established Refer to the axle manufacturer s maintenance manual included in the Pierce Service Manual for maintenance schedules lubrication recommendatio
167. en standard worm drive style clamps to 30 45 in lbs The clamp will likely drop in torque value after exposure to hot coolant and should be maintained to a torque of 30 in lbs thereafter Replace clamps as required with same style as originally supplied 4 9 4 Water Pump Inspect water pump and hose connections for leaks 4 9 5 Thermostats Check thermostats yearly Install new ones if necessary Thermostats are stamped with the opening temperature For example a thermostat marked 175 F 70 C indicates that this is the approximate temperature at which the thermostat starts to open A thermostat is fully open at approximately 20 119 C above the opening temperature Observe engine temperature gauge to check thermostat operation 4 9 6 Antifreeze Solution Coolant Conditioner Proper corrosion inhibitor levels must be maintained to prevent premature engine failure Refer to the engine manufacturer s manuals for proper checking procedures Use a hydrometer to check antifreeze solution Follow the manufacturer s mixing proportions to obtain desired protection Drain flush and refill cooling system annually as follows 1 Open the radiator drain remove plugs from engine block remove plug from thermostat housing base remove plug from oil cooler and loosen or remove radiator cap Remove hoses at any location that is lower than the nearest drain plug After system has drained close valve and replace plugs and hoses Fill sys
168. ensor cesses 3 13 Roll Stability Control RSC 3 88 Running the Engine essssss 3 37 S Safety icitivcdeticwecgivieieentetieisieddayeyidiveneleded 3 1 Safety Defect Reporting 1 6 Safety Restraints and Devices 3 10 4 32 Safety Warning Labels 1 3 SCBA Brackets Mounted in Seat Backs 3 18 SCR Operation Cummins 2010 EPA 3 49 Detroit Diesel 2010 EPA 3 42 Screen Lighting 3 75 Screen Navigation Buttons 3 72 3 79 Seat Adjustment 12122 3 19 Seat Belt Monitoring System 3 11 Seat Belt Screen 3 81 Seat Belts ex eei sete eves 3 10 4 32 Semi Annual Maintenance Schedule 5 3 Service Parts Sou nee ANR vob 4 4 Set Blackout Mode 3 83 Set Date and Time 3 84 Set Display Backlight 3 82 Set Language 3 85 Set Startup Screen 3 84 Set up Diagnostics Screen 3 82 Shore POWOL 2 2 24 ias ke E epa 4 19 Side Roll Protection System 3 11 4 33 Side Roll Protection System Components 3 12 Side Roll Pro
169. ent is dirty and requires replacement The air cleaner filter element has become saturated with water over most or all of the element surface ductwork or screen in front of the air cleaner has become plugged or otherwise restricted The actual level of restriction at which the light comes on varies between chassis models and engine options 3 52 Custom Chassis 2010 Pierce Manufacturing Inc All Rights Reserved OPERATION 3 12 14 Fluid Requirements 3 12 14a Diesel Fuel Requirements Never blend gasoline gasohol alcohol or other volatile substances with diesel fuel This practice creates an extreme fire or explosive hazard that could cause property damage personal injury or death 2007 EPA amp 2010 EPA engines require the use of specific oil and diesel fuel The diesel fuel to be used in any 2007 EPA amp 2010 EPA engine shall be Ultra Low Sulfur Diesel ULSD fuel containing 15 parts per million PPM sulfur content or less Make sure the pump station being used has the proper fuel type when filling your fuel tank If ultra low sulfur fuel is not used the engine will not meet emissions regulations and the After Treatment Device ATD can be damaged Refer to the engine manufacturer s operation manual for additional fuel specifications Filling the fuel tank with other liquids can result in premature failure of the engine and or emission components Refer to the engine manufacturer s operator s manual for prop
170. ent operation of the vehicle under all conditions Wear a seat belt when operating a vehicle Take training to meet the job performance requirements stated in NFPA 1102 before driving and operating the vehicle NFPA 2001 Take refresher driver training at least twice per year Understand the vehicle characteristics capabilities and limitations Be aware of the potential for unpredictable driving by the public excessive speed failure to yield to emergency vehicles inattentiveness etc Adjust speed when driving on wet or icy roads in darkness or fog or under any other conditions that make emergency vehicle operation especially hazardous 2010 Pierce Manufacturing Inc All Rights Reserved Custom Chassis 1 5 TO THE OWNER 1 8 Vehicle Identification Figure 1 1 FMVSS Information Decal 1099 The Vehicle Identification Number VIN can be found in the upper right hand corner of the yellow Federal Motor Vehicle Safety Standard FMVSS information decal found in the driver s side of the cab 1 9 Safety Defect Reporting If you believe that your vehicle has a defect that could cause a crash or could cause serious injury or death it should be reported immediately to the National Highway Traffic Safety Administration NHTSA and to Pierce Manufacturing Inc If NHTSA receives a number of similar complaints it may open an investigation If the investigation reveals a latent safety defect NHTSA may order a rec
171. ention and needs to be lubricated Liberally apply white lithium grease or Alpha 2000 grease between the pivot arm cam shaped lever and the pivot plate of the door latch Operate the regulator and lubricate all moving parts until the lubricant is distributed evenly 4 10 2 Exterior Door Handles Velocity Impel Exterior handles must be lubricated only with dry film lubricants Traditional lubricants can cause dirt and debris to become trapped in the handle mechanism resulting in binding of the handle All other areas of the door mechanism may be lubricated using white lithium grease or Alpha 2000 grease 4 10 3 Door Strikers Inspect the door latch strikers Tighten loose strikers on cab side doors to 55 ft lbs Adjust the striker in or out to obtain an even seal around the door with the latch closed completely If the striker must be adjusted downward to line up with the latch inspect the door hinge for damage or wear To ensure smooth operation avoid excessive seal compression that will require high opening forces at the paddle handle 4 10 4 Doors Quantum e Lubrication of the doors is most important Use spray white lithium grease LUBRIPLATE SPRAY LUBE Paddles must be lubricated at least every 90 days If more frequent lubrication becomes necessary the paddles may need to be replaced Lubricate all moving parts of the latches e Check hinge mounting screws every 90 days for proper torque e Check timing of
172. er Contender Normally the light blinks when the level in the fuel tank has dropped to the 1 8 mark and burns steady when the level in the fuel tank has dropped to 1 1 6 tank The light can be adjusted to activate at other fluid levels depending on customer preference Quantum A caution indicator chime alarm and low fuel text message occurs at 1 8 tank and the warning light steady tone alarm and text message with 1 32 tank Velocity Impel Arrow XT with Command Zone When the level in the fuel tank has dropped to the 1 8 tank mark Light in fuel gauge comes on steady Amber caution light in indicator bank comes on steady e LCD display CAUTION text will flash with LOW FUEL LEVEL message When the level in the fuel tank has dropped to the 1 32 tank mark Red warning light in indicator bank comes on steady e LCD display WARNING text will flash with VERY LOW FUEL LEVEL message Caution alarm will chime 3 11 12 Tachometer The tachometer indicates engine speed in revolutions per minute rpm 3 34 Custom Chassis 2010 Pierce Manufacturing Inc All Rights Reserved OPERATION 3 11 13 Turn Signal Switch The turn signal switch located on the left side of the steering column is self canceling In addition to operating the turn signals this switch also operates the high beam headlights windshield wipers and washers Turn signals raise or depress the lever to operate the turn signal lights
173. er combination Ensure the rear tiller steering is locked out by inserting the steering column lock pin in the steering lockout hole To minimize the possibility of damage to the tractor the front tires should be lifted only as high as necessary to facilitate towing 4 25 3 Rear Towing 1 2 Position the front tires straight ahead and secure the steering wheel in this position Remove any water pipes or accessories that may be damaged during the towing hook up procedure or during transit Attach the towing device 2010 Pierce Manufacturing Inc All Rights Reserved Custom Chassis 4 43 MAINTENANCE 4 25 4 Tow Hooks and Tow Eyes Tow hooks are designed to assist in pulling vehicles for short distance on flat and level surfaces The hooks and mounting structures are designed based on the GVW of the vehicle and its rolling resistance on level ground Vehicles stuck in off road conditions on down slopes or in ditches can exert much higher forces on the tow hooks than they are designed to withstand Towing or pulling in these conditions must be accomplished by experienced towing personnel with attachments to main structural members of the vehicle such as axles or frame rails Towing safety is the sole responsibility of the towing vehicle operator who must be familiar with standard towing industry safety measures Use of tow hooks beyond their safe design limits as stated above may cause serious property damage personal injury o
174. er fuels additives and fueling procedures 3 12 14b Engine Oil Requirements Detroit Diesel engines only Engine oil must have sulfate ash levels less than 1 0 weight 96 Oils meeting this requirement are marked as API CJ 4 oil Using any other oil will cause damage to the ATD Using oil that is not CJ 4 compliant for extended periods of time will damage components and require replacement of the ATD by an approved service facility Cummins engines only Cummins Inc recommends that 2007 EPA amp 2010 EPA engines use a high quality 15W 40 multi viscosity heavy duty engine oil that meets the requirements of Cummins Engineering Standard CES20081 API CJ 4 SL for maximum DPF maintenance intervals Cummins allows the use of CES20078 API CI 4 SL oil with no change in oil drain intervals However the after treatment maintenance interval will be reduced with the use of CES20078 CI 4 oil Maintain engine oil at the proper level Use engine dipstick to check oil level Refer to the engine manufacturer s operator s manual for additional information on engine oil types and procedures 3 12 14c Diesel Exhaust Fluid DEF 2010 EPA engines Acceptable DEF fluid used shall meet ISO 22241 1 or DIN 70700 specifications DEF fluid should be stored at temperatures between 10 F 90 F and has a minimum shelf life of 12 months 2010 Pierce Manufacturing Inc All Rights Reserved Custom Chassis 3 53 OPERATION Figure 3 8 Typical DEF Reservoir Locati
175. er hot air is flushed IS VERY HOT out Turn Mode Control to and set Blower and Temperature as desired once vehicle is cool WARM WEATHER Setthe Mode Control position and turn A C on in sunny weather Choose the 27 position for cloudy or dark conditions with COOL OR COLD Set the Mode Control to 2 and turn the A C on in sunny weather Choose HUMID CONDITIONS the gt position and turn on the in cloudy or dark conditions COLD DRY Use the s position in sunny weather the 4 position in cloudy or dark weather and use CONDITIONS the 7 position in snowy or very cold weather for extra windshield heat 2010 Pierce Manufacturing Inc All Rights Reserved Custom Chassis 3 59 OPERATION 3 15 Heating Ventilation Air Conditioning HVAC Arrow XT Figure 3 9 HVAC Control Panel 1194 3 15 1 Defroster IMPORTANT As the defrost and heat are recirculation only systems the A C may be required to dry the air in situations where the windshield might fog over This is heat only recirculation only in dash unit Air intake is the through the dash panel Air outlets are contained in a fixed panel for maximum defrost performance Defrost controls consist of temperature and fan speed 3 15 2 Floor Heaters There are two heater units one under each rear facing seat Each unit has an outlet at the floor blowing rearward and an inlet immediately above in the seat riser In ad
176. er the vehicle has rolled and stopped All this will occur in a fraction of a second First Officer Position The first officer position is equipped with Integrated Gas Pretensioner IGP Integrated Belt Pretensioner IBP and Inflatable Tubular Structure Side Airbag ITS The IGP will activate and pull the belt snugly around the occupant The ITS side air bag will deploy and position itself next to the occupant s head All this will occur in a fraction of a second The buckle pretensioner will expel some blue smoke during deployment The smoke will have an acrid smell but will not be harmful Rear Occupants The rear occupant positions are equipped with Integrated Gas Pretensioners IGP Integrated Belt Pretensioners IBP and optional Inflatable Head Cushions IHC or Supplemental Restraint Airbags SRA located outboard of the outside seating positions The IGP IBP will activate and pull the belt snugly around the occupant All this will occur in a fraction of a second The buckle pretensioner will expel some blue smoke during deployment The smoke will have an acrid smell but will not be harmful The IHC SRA will inflate to protect the head and neck from contact with the cab structure 3 3 3e What to Do After a Deployment Vehicle Accident Response Information The roll sensor is located in the vehicle headliner Disturbing this area changing the position of the vehicle or the position of the roll sensor within the vehicle may cause the pr
177. eration Because diesel engines are highly efficient they use very little fuel while idling As a result idling in cold weather will not heat the engine to its normal operating temperature Operation of a diesel engine at low idle for extended periods of time can cause engine damage The following cold weather guidelines must be followed Avoid extended idling beyond 10 minutes whenever possible e Use a minimum 45 Cetane diesel fuel or utilize Cetane index improvers from a reputable manufacturer Maintain a minimum of 1250 rpm idle by use of the hand throttle or high idle system Always make sure that parking brake is applied and transmission is in neutral before applying hand throttle Maintain engine cooling system For pumpers Shut off water flow to the auxiliary cooler using the valve at the pump panel and avoid the use of pump panel heaters except when essential Use engine block heaters when possible As diesel engines have increased in efficiency the amount of waste heat available to be drawn from the coolant has decreased particularly when operated at idle under a no load condition In cold weather with all the heaters operating the engine may not reach warm operating temperatures unless it is placed under load Cold Weather Pumper Operation Ensure that the engine cooler valve on the pump panel is in the closed position This valve shuts off the flow of tank water to the auxiliary engine cooler This coo
178. erving the sight glass coolant expansion tank or by checking the low coolant warning indicator on the instrument panel electronic display if equipped Refer to the engine manufacturer operator s manual for proper coolant selection inhibitor levels and mixing procedures Pierce Custom Chassis are configured to engage the fan during pumping operations 2007 EPA amp 2010 EPA engines are configured to engage the fan clutch when the parking brake is applied pump is engaged and the transmission is in 4th gear lockup This is done to prevent water pressure fluctuations that may occur when the fan engages and disengages help cool the steering system improve air conditioning performance and cool exhaust components particularly when trucks are operating at elevated high idles for extended periods of time Arrow XT V Velocity Impel only 2010 Pierce Manufacturing Inc All Rights Reserved Custom Chassis 3 31 OPERATION 3 11 Electrical 3 11 1 Alternator Always observe proper polarity when making connections to the electrical system Improper connection of batteries jumper cables and charging systems can cause damage to the electrical System or to the alternator All alternators in Pierce Custom Chassis are of the self energizing type Start up of the alternator is delayed until the engine oil pressure reaches operating levels This design avoids the situation where the alternator attempts to make up for t
179. es additional shielding between the antenna cable and the vehicle wiring may be helpful 3 Additional Information 3 1 Troubleshooting Should vehicle radio interaction develop following installation the source of the problem should be identified prior to further operation of the vehicle Most interaction problems can be eliminated by following these installation guidelines Possible causes of vehicle radio interaction include Antenna location move antenna to another position Antenna feed line routing locate as far as possible from vehicle electronics and wiring Inadequate shielding or loose corroded connectors associated with the antenna feed line e Mismatched antenna or high SWR Power and ground feeds not connected directly to the vehicle battery or radio power distribution points Power feed routing locate as far as possible from vehicle electronics and wiring If any vehicle radio interaction problems exist after following these guidelines contact your radio manufacturer or the Pierce Customer Service for additional assistance 3 2 Additional Sources of Information Radio Frequency Interference How to Find It and Fix It Giving Two Way Radio Its Voice booklet ISBN 0 87259 375 4 Champion Spark Plug Company The American Radio Relay League Inc Automotive Technical Service Department Newington Connecticut 06111 1494 Box 910 Phone 203 666 1541 Toledo Ohio 43661 Fax 203 665 7531 3 3 Internet
180. f ash is left behind in the filter Over time this ash will build up to the point where it must be removed The engine control system can differentiate between soot build up and ash build up The ash is removed by disassembling the DPF and cleaning the filter in a special machine The target for regular maintenance is a 200 000 400 000 mile interval which is dependent on duty cycle type of oil used and oil consumption rate Using CES20081 API CJ 4 oil will maximize the DPF maintenance interval When the engine senses a build up of ash it will light the check engine light and activate a fault code The ash removal service event is expected to take less than 30 minutes not including removal and installation 2010 Pierce Manufacturing Inc All Rights Reserved Custom Chassis 3 45 OPERATION 3 12 8 After Treatment Device ATD Regeneration Cummins ISL amp ISX Engines 2010 EPA Parked Regeneration causes high exhaust gas temperatures at zero vehicle speed Keep personnel away from exhaust outlet to avoid serious burns and injury Do not perform parked regeneration while connected to an exhaust extraction system Damage to the exhaust extraction system may result 3 12 8a Basic Operation of the After Treatment Device 2010 EPA engines are required to use an After Treatment Device ATD and a Selective Catalytic Reduction SCR for controlling emissions These two canisters have replaced the typical muffler The first canister
181. f transmission fluid to retard the driveline When activated transmission fluid is introduced into the retarder housing and energy is absorbed into the fluid through the opposing action of spinning vanes This retards the vehicle through the rear wheels and adds heat to the transmission fluid This heat is dissipated through the transmission cooler and radiator Retarder Brake Capacity The maximum braking capacity of Allison retarders is determined by the transmission Electronic Control Unit ECU calibration This capacity is specified at the time of purchase to provide the low medium or high capacity setting This capacity setting indicates the maximum retardation force with the system fully applied Low settings will provide auxiliary braking force with moderate cooling system heat loads High settings will provide aggressive auxiliary braking but may limit the amount of time that the retarder can be applied before exceeding the cooling capacity of the vehicle Control Systems The control system may be specified in many versions The most popular control systems are described below Throttle 100 The retarder applies fully whenever the throttle pedal is released Throttle 50 Brake 50 The retarder is applied to half its capacity when the throttle pedal is released and applied to its full capacity when the brake pedal is depressed Throttle 33 Brake 67 The retarder is applied to one third its capacity when the throttle pedal is relea
182. f while the engine is running or damage to the alternator may result The battery switch is used to disconnect electrical power to the vehicle to prevent discharge while the vehicle is not in use 2010 Pierce Manufacturing Inc All Rights Reserved Custom Chassis 3 33 OPERATION 3 11 6 Voltmeter The voltmeter measures the voltage across the battery terminals and gives an indication of the electrical condition of the battery Operating voltage while the alternator is charging may vary between vehicles depending on the regulator setting 3 11 7 Circuit Breakers and Fuses Wire gauge is designed to meet the fuse circuit breaker ratings or transistor trip amperages Do not increase the circuit breaker or fuse size Improper fuse or circuit breaker sizing can cause wires to overheat and burn which could cause personal injury or death Electrical circuits are protected either by circuit breakers or fuses Vehicles equipped with Command Zone also utilize transistors solid state logic 3 11 8 Hourmeter The hourmeter records the number of hours that the engine has run 3 11 9 Pyrometer Optional The pyrometer gauge indicates the exhaust gas temperature 3 11 10 Speedometer and Odometer The speedometer indicates the vehicle speed Speed sensing is provided by a signal from the transmission Electronic Control Unit ECU and will be affected by changes in rear axle ratio or tire size 3 11 11 Low Fuel Warning Light Sab
183. facturing Inc All Rights Reserved MAINTENANCE 4 19 2a Air Conditioning Sight Glass Figure 4 6 Sight Glass Conditions SIGHT GLASS SYSTEM OK OVERCHARGE NO REFRIGERANT LOWON A FEW INTERMITTENT REFRIGERANT BUBBLES DURING FOAM BUBBLES CLUTCH CYCLING OR MIST MAY BE AIR IS OK IN SYSTEM MAY BELOW ON REFRIGERANT STREAKED MAY BE OIL STREAKS AS OIL CIRCULATES DESSICANT BREAKDOWN CLOUDED CONTAMINATED SYSTEM 1115 The sight glass is the only point where you can actually see inside the air conditioner during operation Check the sight glass through the window on top of the receiver drier or the separate in line sight glass If the system is functioning properly and cooling the cab adequately the sight glass should be clear you will not see anything in it If itis not clear when the system is first turned on wait a few minutes for the system to stabilize then look again Figure 4 6 illustrates and explains what you may observe in the sight glass Roof mounted condenser fans may run continuously or cycle on and off If you can t tell by sound you may have to climb a ladder and observe the fan blades 4 19 2b Refrigerant Recovery and Recycling Your Pierce Custom Chassis uses environmentally acceptable refrigerant R 134a Air Conditioning Refrigerant is a hydrofluorocarbon HFC that is endorsed by the Environmental Protection Agency EPA and is an ozone saving pro
184. front of the first officer seating position and suspension seat safety system S4S for suspension seats or belt pretensioners for fixed seats in the driver or forward first officer positions The driver side air bag is mounted in the steering wheel and is designed to protect the head and upper torso of the occupant when used in combination with the seat belt in the event of a frontal or oblique impact The first officer side knee bolster is mounted in the modesty panel below the dash panel and is designed to protect the legs of the occupant when used in combination with the seat belt in the event of a frontal or oblique impact The knee bolster air bag deploys with great force in the event of a crash Do not place people or objects in the path of the bag Objects flying from the bag deployment can injure or kill In the event of a frontal impact the system will deploy the driver air bag and first officer knee bolster and activate the following components that are integrated into the driver and first officer cab seats e Suspension safety seat system 545 will retract the suspension seat to its lowest travel position Belt pretensioners will pretension the seat belts to firmly hold the occupants in place Side Roll Protection air bags if the truck has this option 2010 Pierce Manufacturing Inc All Rights Reserved Custom Chassis 3 17 OPERATION 3 3 5 SCBA Brackets Mounted in Seat Backs Avoid storing SCBA bottles in seat b
185. ft pump toggle switch and hold until the cab is fully tilted Release the stay arm from its stowed position and secure the stay arm in its support position Rotate the control lever on the valve to the lower position and allow the cab to settle onto the stay arm support Return the control lever to the raise position to hydraulically lock the cylinders in place To Lower Cab Rotate the control lever on the valve to the RAISE position Operate the toggle switch to raise the cab and relieve pressure on the stay arm Return the stay arm to the stowed position Rotate the control lever on the valve to the LOWER position Leave the control lever in the LOWER position for road operation Cab locks will engage automatically O mo I c Check to ensure the cab is fully seated and latched before operating vehicle 3 9 2 Cab Lift System Arrow XT Quantum Always check for people working on or around the cab before raising or lowering the cab Failure to ensure that everyone is clear of the cab could cause severe personal injury or death To Raise Cab 1 Turn on the battery and ignition switches Set parking brake 2 Turn the control switch to RAISE position 3 Press the activate switch until the cab is fully tilted and the stay arm is engaged To Lower Cab 1 Turn on the battery and ignition switches Set parking brake 2 Turn control switch to the RAISE position and momentarily activate the lift pump t
186. g capability to the point that towing is not possible For Quantum units equipped with TAK 4 front suspension the use of a flatbed trailer is the only recommended alternative in the event that the truck cannot be towed using a tire lift equipped towing vehicle Pulling the fire truck with chains flat towing is only recommended for extrication purposes or for very short duration towing less than mile and is not recommended for on road towing 4 25 6 Tire Lift Method Preferred A typical Custom Chassis can be towed using an 138 inch underlift reach Aerial Platforms should be towed with at least an 177 inch underlift reach Ensure there will be enough clearance between the towing vehicle and components on the disabled vehicle to turn while being towed Failure to comply may result in damage to equipment IMPORTANT Tire lift attachment should have a minimum capacity rating of 25 000 Ibs Figure 4 8 Underlift Device using Tire Lift Brackets 1253 2010 Pierce Manufacturing Inc All Rights Reserved Custom Chassis 4 45 MAINTENANCE On trucks equipped with TAK 4 independent front suspension lift the front of the disabled vehicle using an underlift device with proper tire lift brackets that support and secure the front tires Figure 4 8 Do not lift the front of the disabled vehicle by attaching to or lifting by any component or structure of the TAK 4 suspension Figure 4 9 Safety Chains and Tire Straps
187. ger contact the owner of the dealership or the General Manager Step 3 If after contacting a member of the dealership management it appears your question or concern cannot be resolved by the dealership without further help you may contact Pierce Manufacturing Inc at 888 Y PIERCE 888 974 3723 1 11 Professional Training and Standards Organizations To keep up to date on knowledge and new standards that affect all facets of fire fighting make sure that you check these organizations catalogues and websites each month National Fire Protection Association for standards and requirements One Batterymarch Park P O Box 9101 Quincy MA 02269 9101 617 770 3000 www nfpa org Make sure you read the latest editions Pierce Manufacturing Inc Customer Service 2600 American Drive P O Box 2017 Appleton WI 54913 888 Y PIERCE 888 974 3723 www piercemfg com and www pierceparts com International Fire Service Training Association for textbooks and other training material Fire Protection Publications Oklahoma State University 930 North Willis Stillwater OK 74079 8045 800 654 4055 www ifsta org 2010 Pierce Manufacturing Inc All Rights Reserved Custom Chassis 1 7 TO THE OWNER 1 8 Custom Chassis 2010 Pierce Manufacturing Inc All Rights Reserved BEFORE PLACING SECTION2 VEHICLE IN SERVICE 2 1 Axle Weights and Axle Capacity Never exceed the gross axle weight ratings printed on the
188. gh load operation changing the duty cycle to allow a regeneration to occur or initiating a stationary regeneration When the soot load is reduced through effective regeneration the engine will return to full torque output 3 12 8e Maintenance As the soot in the filter is removed in the regeneration process a small amount of ash is left behind in the filter Over time this ash will build up to the point where it must be removed The engine control system can differentiate between soot build up and ash build up The ash is removed by disassembling the DPF and cleaning the filter in a special machine The target for regular maintenance is a 200 000 400 000 mile interval which is dependent on duty cycle type of oil used and oil consumption rate Using CES20081 API CJ 4 SL oil will maximize the DPF maintenance interval When the engine senses a build up of ash it will light the check engine light and activate a fault code The ash removal service event is expected to take less than 30 minutes not including removal and installation 3 12 8f Selective Catalytic Reduction SCR Operation The operation of the SCR device does not require any driver involvement The driver is responsible for filling the Diesel Exhaust Fluid DEF reservoir to maintain the proper amounts of DEF fluid required by the engine The DEF reservoir on Pierce custom fire apparatus is 4 1 2 gallons The fluid level sensor transmits the fluid level directly to the Dosing Contro
189. ging authority and access codes etc 2010 Pierce Manufacturing Inc All Rights Reserved Custom Chassis 3 9 OPERATION 3 3 Safety Restraints and Devices 3 3 1 Seat Belts Never ride in or on this vehicle unless properly restrained in a seating position with a seat belt Before fastening seat belts adjust the seat to a position that maintains adequate head clearance see suspension style seats to reduce the risk of head or spinal injury when driving over severe dips or bumps in the pavement Always ride with your seat back upright and the lap belt snug and low about your hips to reduce the risk of serious injury to the abdomen or neck that could be caused by sliding under the safety belts in a collision Fasten seat belt low and snug on the hips and the shoulder belt snug against the chest Never use a single belt for more than one person or across more than one seating position Use the shoulder belt on the outside shoulder only Never wear the shoulder belt under the arm or swing it around the neck over the inside shoulder The effectiveness of an air bag be reduced on vehicles equipped with an extended front bumper Always wear seat belts Fire helmets shall not be worn by persons riding in enclosed driving and crew areas Fire helmets are not designed for crash protection and they will interfere with the protection provided by head rests The use of seat belts is essential to protecting fire fighters duri
190. h Command Zone electronics on the chassis the aerial device or both The chassis and aerial circuits may share some information but for the most part are separate systems A CZIC installed on a chassis Command Zone bus will display chassis data and a CZIC installed on an aerial bus will display aerial information Any exterior version of CZIC has the ability to be installed on either bus without modification 3 20 4 Replacing a Command Zone Information Center Any damaged CZIC can be replaced with any similar CZIC provided the version number and interior or exterior type are the same Once installed the CZIC will read the ground matrix code inherent in the vehicle wire harness to determine whether it is installed in a Command Zone chassis or aerial device and at what location in each Each time the vehicle is powered on the CZIC communicates with the Command Zone control module letting it know that it is present and functional 3 21 Command Zone Information Center CZIC CANTrak Display 3 21 1 Screen Navigation Buttons Figure 3 18 CANTrak Display Screen Navigation Buttons 0074 3 72 Custom Chassis 2010 Pierce Manufacturing Inc All Rights Reserved OPERATION Each CANTrak display is equipped with five soft buttons software controlled Figure 3 18 The function of the soft buttons located along the bottom the CANTrak display changes with each screen as shown in Table 3 3 Table 3
191. h side in the sidewalls behind the driver and first officer area During normal vehicle operation the ITS airbag is stowed around the door frame inside a protective plastic cover In the event of a side roll accident the roll sensor detects the impending roll and signals the ITS system to activate The ITS air bag then inflates and assumes a position between the occupant s head and the side window The ITS is only effective when used with a seat belt ALWAYS WEAR YOUR SEAT BELT 3 14 Custom Chassis 2010 Pierce Manufacturing Inc All Rights Reserved OPERATION Integrated Gas Pretensioner IGP Integrated Belt Pretensioner IBP Figure 3 4 Integrated Gas Pretensioner IGP Integrated Belt Pretensioner IBP Pre Deployment Post Deployment 0119 Keep hands and other objects clear of the retraction path of the seat belt buckle Seat belt pretensioner actuators are located at the base of the seat belt buckle cable in the first officer and crew cab seating positions In the event of a side roll accident the IGP IBP deploys at each non suspension seat location The cable pretensioner retracts the cable and buckle assembly removing up to five inches 120 mm of slack from the belt The buckle pretensioner is only effective when you wear your seat belt ALWAYS WEAR YOUR SEAT BELT Inflatable Head Curtain IHC Supplemental Restraint Air Bag SRA Figure 3 5 Inflatable Head Curtain IHC Supplemental Restraint Air Bag SRA
192. harge the voltage completely Use an appropriate electrical tester and procedures to confirm that the power is disconnected BEFORE performing any work on or near any high voltage components circuits Exercise caution around output circuits even when the input power is off Parallel power sources and energy storage devices can still be dangerous Be familiar with the high voltage equipment installed on the vehicle Some systems contain high voltage condensers that may require time to discharge after power is removed After disconnecting or exposing a high voltage connector or terminal insulate it immediately using insulation tape After completion of any electrical work BEFORE restoring the power verify that parts and or tools are removed from the work area and that the fasteners are firmly tightened to the specified torque and the connectors are correctly connected Voltage can be fatal at levels greater than 60 volts High voltage can jump a larger air gap than low voltage If contact is made with high voltage it may not be possible to simply let go If a high voltage fuse or circuit protection device trips do not re energize the circuit until it has been determined that the circuit is safe See manufacturers troubleshooting procedures before servicing a high voltage system Reference OSHA Regulations as necessary and applicable 4 20 Custom Chassis 2010 Pierce Manufacturing Inc All Rights Reserved MAINTENANCE 4 13 Engin
193. he grill may degrade cooling performance and cause the engine to over heat during heavy use and high ambient temperatures Logos letters numbers or placards should not be attached to the radiator grill Numbers letters flags etc that are painted on the grill are acceptable When mounting equipment to the bumper deck plate of a tilt cab model consider the motion of the cab when tilting to avoid interference in the tilted condition 2 6 Custom Chassis 2010 Pierce Manufacturing Inc All Rights Reserved BEFORE PLACING VEHICLE IN SERVICE 2 5 4 Interior Equipment Installation of equipment in the deployment path of the air bag can result in improper deployment serious injury or death in the event of a collision No part of any equipment may extend within the area shown below extending 4 outward from all sides of the first officer s knee air bag 1186 When installing equipment in trucks equipped with Frontal Impact Protection it is critical that equipment not be mounted in the deployment path of the air bags Additionally no equipment should be placed in the area between the first officer and the dashboard Consider the effect of cab tilt on equipment storage to avoid damage from items falling forward when the cab is tilted for service or maintenance Monitor the weight of items installed in a tilt cab or stored in tilt cab storage areas Too much weight inside the cab may prevent the cab from being tilted for
194. he heavy battery drain caused by starter operation This reduces the cranking torque required and protects the voltage regulator from overload It is therefore normal for the voltmeter to register a lower value for several seconds during and following the starting procedure until the engine oil pressure rises sufficiently to activate the alternator 3 11 2 Ammeter Optional The ammeter displays the amount of current being supplied to the battery by the alternator or the rate of discharge from the battery with the engine running A slight charge to the battery will be indicated even with the batteries fully charged 3 32 Custom Chassis 2010 Pierce Manufacturing Inc All Rights Reserved OPERATION 3 11 3 Battery Batteries give off hydrogen gas that is highly explosive Keep all sources of ignition away when working around batteries Sparks caused by connection of battery terminals jumper cables or charging systems can be a source of ignition Always wear safety goggles and protective clothing when working on or around batteries Inhaling of hydrogen gas produced by the normal operation of the battery could result in partial or permanent damage to the respiratory system Battery posts terminals and related accessories contain lead and lead compounds chemicals known to cause cancer and reproductive harm Wash hands after handling Whenever disconnecting battery terminals always disconnect the ground terminal first When reconne
195. he maximum tire pressure may be limited by the tire capacity as stated on the side wall or by the wheel capacity Do not assume that the tire can be safely operated at the maximum pressure as stated on the sidewall since the wheel may be the limiting factor Refer to the maximum tire pressure listed on the yellow Federal Motor Vehicle Safety Standard FMVSS information decal located in the cab for maximum tire pressure ratings 2010 Pierce Manufacturing Inc All Rights Reserved Custom Chassis 4 37 MAINTENANCE Table 4 10 is for Michelin amp tires only Refer to the tire data book that matches the brand of tire on your vehicle or contact Pierce Customer Service for this information Table 4 10 Tire Data Chart WHEEL DIAMETER 22 5 11R22 5 LRH ALL TIRES PSI Ibs per axle kg per axle 12R22 5 LRH ALL TIRES PSI 115 Ibs 14780 per axle 27000 1 kg 6700 per axle 12250 1 Except 12R22 5 XDN26440 D 315 80R22 5 LRL ALL TIRES PSI Ibs per axle kg per axle 385 65R22 5 ALL TIRES PSI Ibs per axle kg per axle 425 65R22 5 LRL ALL TIRES PSI Ibs per axle kg per axle PSI Ibs per axle kg per axle S
196. he problem 3 28 Transmission 3 28 1 Automatic Transmission Whenever it becomes necessary to leave the vehicle even momentarily while the engine is running place the transmission shift selector in Neutral set the parking brake and chock the wheels Failure to follow this procedure may lead to loss of vehicle control resulting in possible property damage personal injury or death The Allison automatic transmission supplied with most Pierce Custom Chassis will only start in the Neutral mode Select the Drive mode for normal driving Completely stop the vehicle before shifting from any forward range to the Reverse range Turn off the vehicle high idle switch before attempting to shift from Neutral to Drive or Reverse For further information refer to the Allison Transmission Operator s Manual 2010 Pierce Manufacturing Inc All Rights Reserved Custom Chassis 3 91 OPERATION 3 28 2 Transmission Operating Temperature NOTE Thetransmission temperature gauge does not indicate the sump temperature The gauge indicates the temperature of the oil as it exits the torque converter and before the oil enters the transmission cooler This reading provides a much more immediate indication of temperature rise due to heavy use or retarder applications If the sump fluid temperature reaches 250 F the Electronic Control Unit ECU will inhibit operation in the higher ranges Maximum sump operating temperature is 250 Vehicles e
197. he screen name and outside ambient temperature are displayed at the top of each screen 2010 Pierce Manufacturing Inc All Rights Reserved Custom Chassis 3 73 OPERATION Maintenance Screen Figure 3 20 Maintenance Screen MAINTENANCE 22 51 Hours Aerial PTO Hours Ae relier F low 42 ral Total litate r Breatilig Alr Eighe Lev OIl Level Power Ste rig Level PTO 1 Engaged PTO 1 Hours PTO 2 Engaged PTO 2 Hours Pimp Hours TRANSMISSION OVERHEAT o aeo POM0076 The Maintenance screen Figure 3 20 displays a scrolling list of data messages This screen is intended for system analysis and troubleshooting by operators or maintenance personnel familiar with the Command Zone electronics To the right of each item is the value of the data message currently active on the system The value may be a numerical value such as a voltage level or rpm Data on the list can be viewed by scrolling with the up or down arrows Pressing the ENTER button will return a general description for that data item Warnings Screen Figure 3 21 Warnings Screen Y AIS COMM LOST AIR BRAKE PSI LOU BAT VOLT VERY HIGH MAIN BAT VOLTAGE LOW AUX OREATHING LOW CAS RAISED DO NOT MOVE TRUCK EMERGENCY STOP ENGINECOMM LOST GEN OVERHEATING JACK KNIFE WARNING LOW WATER LEVEL POWER HOD 12COMM LOST POWER MOD 14 COMM LOST PUMP OVERHEATING TRANSMISSION OVERHEATING O O OO POM0077 The Warnings scr
198. hedule 5 4 View Active Alarms 3 85 View System Information 3 85 Voltmet r 3 34 2010 Pierce Manufacturing Inc All Rights Reserved W Warning and Caution Statements 1 2 Warning Lights esses 3 35 Warnings and Cautions 1 2 Warnings Screen 3 74 Warnings Overheat 3 26 Washing Instructions 2 4 8 Water Fording Capability 3 94 Water Pump 2 1 ies eee el ay 4 15 Waxing Instructions 2 4 10 Weatherstrip 1 iter 4 17 Weekly Maintenance Schedule 5 1 Welding Instructions 2 1 4 50 Welding on Frames 4 28 What Do If You Lack Knowledge 1 1 Wheel Installation General 4 52 Wheel Torque eene 4 55 Wheels sisi 4 52 Who Should Use Service and Maintain This Vehicle 1 1 Winch Operation 3 95 Windshield Wiper System 4 56 Winter Front Usage 3 55 Wiper Blades 4 57 Wire Harnesses and Electrical Connectors 4 18 2010 Pierce Manufacturing Inc Al
199. heels and ensure that the personnel working around the vehicle will be safe from oncoming traffic 2 Unload equipment when practical to reduce abnormal loads exerted on the chassis components caused by the towing process 3 Drain all water from the water tank 4 42 Custom Chassis 2010 Pierce Manufacturing Inc All Rights Reserved MAINTENANCE 4 25 2 Front Towing 1 5 Single rear axle vehicle Remove the rear most driveshaft Tandem rear axle vehicle Remove axle shafts and cover the ends of the axles with metal plates or plywood cut to fit the axle opening and drilled to fit the axle shaft studs This prevents lubricant from leaking out and contaminants from getting in Remove the front bumper extension and stainless steel bumper or attach in a manner that prevents damage to these components Remove any water pipes air intake pipes or accessories that may be damaged during the towing hook up procedure or during transit Attach the towing device Before releasing the parking brakes secure the connection to the towing vehicle or block the wheels or loss of vehicle control may cause property damage personal injury or death Manually release the parking brakes or release the parking brake button and supply the air brake system with a constant source of air pressure to ensure that the spring brakes remain released during the towing process Additional considerations when towing a Custom Chassis tractor aerial till
200. hin a reasonable amount of time generally 8 to 10 hours depending on the duty cycle 2 f no regeneration occurs after the DPF light illuminates the DPF light will begin blinking and an active regeneration should be initiated as soon as possible 3 If the flashing DPF light is ignored the Check Engine light will illuminate A parked regeneration must be performed to clean the DPF before further operation The engine will not de rate or shut down in this situation 4 Continuous usage of the vehicle past the previous levels of warning without regeneration will force the need for a thorough cleaning of the DPF The extreme level of soot build up will be identified by the following instrument panel lights blinking DPF Regeneration light solid Check Engine light and solid Stop Engine light Operation of the engine as described in Item 4 may result in excessive soot accumulation In this case contact a Detroit Diesel service representative for assistance 3 12 5d Parked Regeneration To initiate a parked regeneration the following must occur 1 Move the truck to a safe location that prevents the high exhaust heat from causing damage to the road surface or the ground 2 The driver MUST stay with the vehicle throughout the regeneration process The procedure will take 20 to 40 minutes Locate the regeneration switch located in the cab within reach of the driver This is a momentary style switch Cycle the parking brake OFF to ON once a
201. ht Rear 3 6 Exterior Inspection Right Rear Brake 3 6 Exterior Inspection Right Rear Suspension 3 6 Exterior Inspection Side Lights and Reflectors 3 6 External Transmission Coolers 4 49 F Fan and Accessory Belts 4 22 Fari Clutch n Eee 3 50 Fasteners Se bee He 4 25 Fault Light Information 4 33 Fifth Wheel Lubrication 4 27 Fire Scene Operation 3 56 Fluid Level Non Maintenance Free Batteries 4 78 2010 Pierce Manufacturing Inc All Rights Reserved Fluid Requirements 3 53 Flying Embers 1 122211 3 56 Foot Pedals Adjustable 3 19 Fording Water with Command Zone Vehicles 3 22 5 liter erede dea 3 95 tisse eset eb reitera Al 4 28 Frame Fasteners 4 25 Front Axle Non Driving 4 1 Front Axle TAK 4 Suspension 4 2 Front Axle Alignment 4 2 Front Axle Drive To Disengage 3 93 Front Axle Drive To Engage 3 92 Front Spring Suspension Adjustment 2 9 Front en i e 4 41 Front Towing 2 00 4 43 Frontal Impact Protec
202. ierce Service Manual group 0152 P 002 TAK 4 Independent Front Suspension for additional TAK 4 suspension service and lubrication requirements See the Pierce Service Manual group 0611 P 001 All Steer 119 Service Manual for additional All Steer 119 service and lubrication requirements 2010 Pierce Manufacturing Inc All Rights Reserved Custom Chassis 5 5 SERVICE AND LUBRICATION INTERVALS 5 6 Custom Chassis 2010 Pierce Manufacturing Inc All Rights Reserved MOBILE RADIO APPENDIXA INSTALLATION GUIDE SPECIAL NOTE The information contained in this guide has been prepared for use by persons installing two way radio equipment transmitters and receivers in Pierce apparatus It has been prepared in accordance with current engineering principles and generally accepted practices using the best information available at the time of publication These guidelines are intended to supplement but not be used in place of detailed instructions for such installations which are the sole responsibility of the manufacturer of the land mobile radio Since it is not possible to cover all possible installations of two way radio equipment Pierce Manufacturing cannot be held responsible for incidental or consequential damages arising from the use of the information contained herein Certain land mobile radios or the way in which they are installed may affect vehicle operations such as the performance of the engine and driver informati
203. iffuser Inadequate building exhaust extractor system flow capacity Reduced Exhaust Diffuser function can result in exhaust temperatures approaching 1200 F 649 at the outlet during or shortly after Diesel Particulate Filter DPF regeneration DPF regeneration can take place and high exhaust temperatures can be present while operating the truck in a stationary pumping mode Building exhaust extractor systems used with 2007 EPA amp 2010 EPA DPF equipped engines must be designed and installed to accommodate the larger diameter pipe accept higher exhaust flow rates and higher exhaust temperatures present with 2007 EPA amp 2010 EPA engines 4 15 Fasteners 4 15 1 Frame Fasteners Inspect all frame assembly fasteners Tighten any loose fasteners using the values in Table 4 4 or Table 4 5 for the proper size thread pitch of hardware Torque fasteners using a calibrated torque wrench Replace frame fasteners with quality hardware of the same type and grade only 2010 Pierce Manufacturing Inc All Rights Reserved Custom Chassis 4 25 MAINTENANCE Table 4 4 Grade 8 Course Thread Fastener Torque Chart Torque In Lbs Ft Lbs 1 4 20 5 16 18 3 8 16 7 16 14 1 2 13 9 16 12 5 8 11 3 4 10 7 8 9 1 8 Table 4 5 Grade 8 Fine Thread Fastener Torque Chart Torque In Lbs Ft Lbs 1 4 28 5 16 24 3 8 24 7 16 20 1 2 20 9 16 18 5 8 18 3 4 16 7 8 14
204. ill result in exposure below the OSHA limit Antennas must be located at least two feet 0 6 meters from vehicle operators and passengers unless shielded by a metallic surface 2 Custom Chassis 2010 Pierce Manufacturing Inc All Rights Reserved MOBILE RADIO INSTALLATION GUIDE e Pierce Manufacturing recommends that mobile antennas be located as near the center of the cab roof as possible e Antennas should not be located within six inches 15 24 cm of roof mounted equipment e g emergency lights air conditioner evaporators 2 4 Antenna Cable Routing e Always use a high quality one piece coaxial cable at least 95 shield coverage Connector quality and termination techniques are just as important The ARRL handbook provides excellent guidelines for terminating coaxial cables cables should be kept as short as possible to minimize RF loss for all frequency ranges except 470 512 Mhz When the antenna operates in the 470 512 Mhz range do not cut the antenna cable unless absolutely necessary If the cable must be shortened refer to the table on the antenna kit tag for proper output setting antenna cable should be treated in the same way as the control and power cables Avoid sharp edges and pinches and keep the cable as short as possible Avoid routing the antenna cable in parallel with vehicle wiring over long distances If itis necessary to cross over wiring cross at right angles In some cas
205. in both vehicles Connect the first jumper cable from the positive terminal of the dead battery or the positive terminal of the jump start stud to the positive terminal on the booster battery Connect one end of the second jumper cable to the negative terminal on the booster battery and the other end to the frame of the disabled vehicle at least 18 inches 450 mm away from the battery Do not attach the other end directly to the battery negative terminal because a spark could occur and cause explosion of gases normally present around the battery With the jumper cables properly attached start the engine of the vehicle with the good charged battery Run the engine at moderate speed Start the engine in the vehicle with the discharged battery Remove the battery cables by reversing the above sequence exactly 2010 Pierce Manufacturing Inc All Rights Reserved Custom Chassis 3 51 OPERATION 3 12 12 Operation of Engine in Fuel Rich Atmosphere Diesel engines do not require a spark for ignition and will continue to run as long as there is fuel available Varying the amount of fuel introduced into the chambers controls the speed of a diesel engine If the engine is operated in an atmosphere that is laden with fuel vapors such as is found at a fuel spill the engine may increase speed uncontrollably Turning the ignition switch or battery switch off in this situation will not affect the speed of the engine Befor
206. in the down position before exiting cab Failure to deploy steps properly can lead to falls and possible injury Automatic deploying side entry steps fold out and down to provide easy access to the cab When properly adjusted these steps will retract into the cab on either the first or second catch of the door Other steps may also be of a folding or pivoting design 3 8 Custom Chassis 2010 Pierce Manufacturing Inc All Rights Reserved OPERATION 3 2 1 Keyless Entry Optional 3 2 1a Unlock Officer s Door Enter access code Listen for double beep e Within three seconds press the 1 2 button 3 2 1b Unlock All Doors Enter access code Listen for double beep e Within three seconds press the 3 4 button 3 2 1 Locking the Doors with Keypad Press and hold down the 1 2 button for 1 2 seconds 3 2 1d Additional Information The dome light is activated for a timed duration 20 seconds whenever the system is unlocked from keypad or fob transmitter After repeated attempts to enter incorrect codes 20 button presses without enabling the keypad enters an inactive mode that disables button for 1 minute This helps prevent undesired access by entering random codes No beep will sound with button press while the system is disabled See the Pierce Service Manual group 0810 V 001 TriMark e ASK Keyless entry System for additional information on the keyless entry system programming fob transmitters chan
207. ing as contents may shift or drop causing property damage or personal injury Never work around or under a tilted cab unless the stay arm or mechanical support is secured in the support position Hydraulic cylinders can leak or drift and cannot be relied upon to support the cab on their own Failure to ensure that the stay arm is securely in its support position could cause severe personal injury or death Check front bumper extension to ensure that covers are shut and plumbing swivels are rotated forward before tilting cab to avoid possible interference and subsequent property damage when cab is fully tilted Always ensure that the vehicle is on a flat and level surface before tilting the cab Tilting the cab on an inclined or non flat surface may produce interference between components as the cab is lowered causing damage to the air intake seal and engine tunnel If the cab fails to lower after following the proper instructions do not attempt to force it Have the system checked by a qualified mechanic refer to Cab Tilt System on page 4 6 in the Maintenance section of this manual and the Cab section of the Service manual The air conditioning system should be shut down prior to tilting the cab Failure to do so will result in water condensation build up in the evaporator cover This water will drip out through the openings in the cover and can pour out as the cab is tilted down after service Pierce Custom Chassis may be equipped with
208. ission System Malfunction Defrost Fans Speedometer PUC Display Transmission Oil Temp Airhorn Pushbutton Switch Front Air PSI 3 64 Custom Chassis Mechanical Siren Pushbutton 2010 Pierce Manufacturing Inc All Rights Reserved OPERATION Figure 3 14 Arrow XT Controls and Indicators without Command Zone SERRES INDE DERE Item Description Engine Oil PSI Gauge 0054 Item Description Ignition Switch w Indicator Light Prove Out Voltmeter Gauge Panel Indicators Engine Coolant Temperature Gauge High Engine Coolant Tachometer w Engine Hourmeter Low Engine Oil Pressure Indicator Light Module Check Transmission Check Engine Low High Voltage High Beam Left Directional Stop Engine Right Directional ABS Low Fuel ASR High Transmission Oil Temperature Low Coolant zomm o on x Low Front Air Pressure Auxiliary Brake Engaged J Low Rear Air Pressure Auxiliary Brake Overheat Shift Selector Air Restriction Parking Brake Parking Brake Start Switch Ignition ON Heater Controls Battery ON Air Shift Pump w Indicator Parking Brake Ladder Rack Down Defroster Controls Driver s Door Open Air Conditioner Controls Tower Raised Electronic Siren ozzrme zrgommoomm First Officer Door Open Front Wheel Lock
209. istance tread compound 4 24 3 Matching Match dual tires so that tires worn to the same diameter are placed together Do not mount tires together that vary by more than 1 4 inch in diameter or 3 4 inch in circumference Match dual tires on tandem axles as directed above but do not place the four largest tires on one axle as this may cause high axle oil temperatures and reduced axle life For 4x4 chassis match front drive tires to the rear axle tires so that the rolling radius does not create a ratio difference between front and rear axles 4 40 Custom Chassis 2010 Pierce Manufacturing Inc All Rights Reserved MAINTENANCE 4 24 4 Tire Wear Inspection Never operate a vehicle without sufficient tire tread depth or loss of vehicle control property damage personal injury or death may result Inspect tires for signs of abnormal or excessive wear Sufficient tread depth is essential to proper handling and braking performance Refer to the tire manufacturer s owner s manual for minimum tread depth requirements Replace tires before minimum tread depth is reached Tire tread life is dependent on many factors including the following Tire load Proper inflation pressure Tire footprint area of rubber in contact with the road Frequency of dry steer maneuvers steering the vehicle in the absence of forward motion Tandem scrub inherent to all non steering tandem suspensions Engine ho
210. it necessary to maintain battery charge or when the electrical demand requires it 4 12 4c Shore Power NOTE High voltage shore power wiring may NOT be marked for easy identification as high voltage Shore power is a connection from a vehicle to and external 120V AC power source The vehicle is equipped with an exterior receptacle that allows connection to an external shore power source 4 12 4d Inverters NOTE High voltage inverter wiring may NOT be marked for easy identification as high voltage 2010 Pierce Manufacturing Inc All Rights Reserved Custom Chassis 4 19 MAINTENANCE Inverters are electronic devices used to change Direct Current DC to Alternating Current AC Some inverters contain converters that also convert AC to DC for battery charging and or running 12V equipment 4 12 4e Before Servicing High Voltage Equipment Be aware of ALL high voltage equipment on the vehicle review the high voltage equipment found on the electrical diagrams and in the service manual BEFORE starting any work When working on this equipment remain alert at all times Never work on the equipment when you are physically or mentally fatigued and never work alone near high voltage equipment Always stand on an insulated dry surface when working on any electrical circuit Do not handle any kind of electrical device while standing in water while barefoot or while hands or feet are wet Always work in an adequately illuminated area
211. l Rights Reserved INDEX Custom Chassis Index 7 INDEX INDEX 8 Custom Chassis 2010 Pierce Manufacturing Inc All Rights Reserved
212. l Unit DCU The DCU is programmed with specific operational parameters which will trigger the DEF indicator as well as induce vehicle performance derates As the fluid level drops in the DEF reservoir the following reactions will occur DEF level between full and 1 4 full DEF Fluid Low light will remain off DEF level between 1 4 full and 1 8 full DEF Fluid Low light will illuminate solid DEF level below 1 8 full DEF Fluid Low light will flash e DEF level below 1 4 gallon DEF Fluid Low light flashing and amber Check Engine lit solid The engine will induce a 25 engine torque derate DEF tank empty and system can no longer maintain DEF pressure DEF Fluid Low light flashing amber Check Engine lit solid and MIL light lit solid The engine will induce an engine torque derate that begins a 2596 and ramps to 4096 at a rate of 196 per minute of operation DEF Tank Empty and engine intentionally shut down or in extended idle DEF Fluid Low light flashing amber Check Engine lit solid red Stop Engine lit solid and MIL light lit solid The engine will induce an engine rpm limit of 1000 rpms a 5 MPH vehicle speed limit and a 40 engine torque derate Refilling the DEF tank will deactivate any torque derates speed limits and warning lights 2010 Pierce Manufacturing Inc All Rights Reserved Custom Chassis 3 49 OPERATION 3 12 9 Emergency Shutdown Optional The emergency shutdown device is meant for occasional use
213. l recommended in the table and to maintain them at that level through planned periodic checks 2010 Pierce Manufacturing Inc All Rights Reserved Custom Chassis 4 53 MAINTENANCE Never check torque on a fastener that has already been tightened This will give a false torque reading To obtain the correct torque on a fastener that has already been tightened break the fastener loose and then retighten to the appropriate torque NOTE Whenever the outer cap nut is loosened always loosen and retighten the inner cap nut before torquing the outer cap nut 6 Checktorque on wheel nuts including inner cap nuts on duals after the first 50 to 100 miles of service When inner cap nuts are tightened be sure to first loosen outer cap nuts several turns loosen and retighten inner cap nuts and then tighten outer cap nuts Torque to recommended levels as specified in Table 4 14 To avoid loosing the seating of the outer wheel when checking the inner wheel torque first loosen alternate outer nuts Then tighten the inner nuts and retighten the outer nuts Then loosen the remaining outer nuts tighten the inner nuts and retighten the outer nuts Table 4 14 Wheel Nut Torque Chart Torque Thread Size Ft Lbs Dry 10 Hole 11 25 inch Stud Piloted 450 500 10 Hole 11 25 inch Stud Piloted 1 8 450 500 4 29 5 Cast Spoke Wheels Optional Installation Figure 4 16 Cross Section of Cast Spoke Wheel vga gt
214. label inside the cab Exceeding these ratings could lead to reduced component life personal injury or death Due to the highly custom nature of fire apparatus itis very important to consider weight distribution and axle capacity during the specification stage of the procurement procedure Before shipment every Pierce fire apparatus is weighed with all loose equipment removed to ensure that the axle suspension tire and wheel capacities provide for the applicable NFPA allowances of men and equipment As it is impossible to predict the manner in which the vehicle will be loaded after delivery Pierce assumes that allowances for personnel will be centered over the front axle while the combined effect of hose load and equipment allowances will be centered over the rear axle Before placing the apparatus in service load all compartments with the intended equipment and manpower and obtain front and rear axle weights from a certified scale Compare the results to the axle capacities listed on the Federal Motor Vehicle Safety Standard FMVSS information decal located inside the cab In service weights must not exceed the axle capacities listed on the tag 2 2 Tire Pressure Maintain tire pressure at the tire manufacturer s pressure recommendations for the correct tire size type load range ply rating and measured in service axle load of the vehicle Failure to maintain proper tire pressure may result in loss of vehicle control property d
215. lators 4 23 Engine Oil Requirements 3 53 Engine Service Schedule 4 23 Engines General Notes 4 24 Engine Specific Operation Instructions 3 37 Equipment and Cargo Loading 2 8 ExhaustBrake 3 24 Exhaust Diffusers 4 24 Exhaust System 4 24 Exterior Door Handles 4 16 Exterior Inspection 3 3 Exterior Inspection Front 3 5 Exterior Inspection Front Lights and Reflectors e e eos 3 5 Exterior Inspection Left Front Brake 3 5 Exterior Inspection Left Front Side 3 4 Exterior Inspection Left Front Suspension 3 4 Exterior Inspection Left Front Wheel 3 4 Exterior Inspection Left Rear 3 6 Exterior Inspection Left Rear Brake 3 7 Exterior Inspection Left Rear Suspension 3 7 Exterior Inspection Rear Lights and Reflectors 3 6 Exterior Inspection Right Front 3 5 Exterior Inspection Right Front Brake 3 5 Exterior Inspection Right Front Suspension 3 5 Exterior Inspection Right Front Wheel 3 5 Exterior Inspection Rig
216. ld cause a crash or breakdown Although the inspection can be completed by a single individual it is most effectively accomplished with two This way one person can be operating interior controls while the second person is checking for exterior functions such as turn signal lamps flashers brake lights etc Since the performance of a pre trip inspection as mandated for holders of a Commercial Driver s license would be impractical in emergency response situations it is important that these inspections occur as part of the daily firehouse routine Safety Safety is the most important and obvious reason for inspecting regularly Inspecting your vehicle helps you to know your vehicle is safe Legal Requirements Federal and State laws require inspection by the driver Federal and State inspectors also inspect commercial vehicles An unsafe vehicle can be put out of service until the driver or owner fixes it 3 1 2 Beginning the Inspection Perform a pre trip inspection the same way each time to reduce the probability that something will be missed Records Review Review last vehicle inspection report Drivers may have to make a vehicle inspection report in writing each day The vehicle owner should repair any items in the report that affects safety You should look at the last report to find out what was the matter if anything Inspect the vehicle to find out if problems were fixed Approaching the Vehicle Check that the parking brakes are on a
217. le goes off line the module will not be shown on this list and a warning message indicating the Module Comm Loss will be displayed If the module comes back online the module name and number will reappear on the System Information page If further information is required for a module move the indicator arrow to the correct module name number and press the ENTER button A Module screen similar to that shown in Figure 3 25 will appear At the top of the screen will be the module name and number The time date and outside ambient temperature are located adjacent to the module name All of this information combined makes the page heading Below the page heading is the software version of the module 3 76 Custom Chassis 2010 Pierce Manufacturing Inc All Rights Reserved OPERATION Listed is information about each individual input and or output of that module Starting at the left the information is as follows nput output number e Circuit number connected to that input or output Circuit name item connected to the circuit Ablank line indicates that the input output is not programmed e Status of the input or output all module types Inputs On Off e G Ground at the input will activate the input B Battery power at the input will activate the input e Analog signal at the input No value is given e Outputs On e Off Flashing e Additional Status Power Module Outputs only diagnostic infor
218. lean and lubricate cab lift cylinder trunnion joints See 2 000 Quarterly Trunnion Joints Lift Cylinder Trunnion Cleaning amp Lubrication Arrow Arrow XT page 4 6 for additional information Table 5 6 Semi Annual Maintenance Schedule Description Action Miles Time Air Conditioning Inspect sight glass See Air Conditioning Sight Glass 6 Months on page 4 31 for additional information Automatic Slack Lubricate with clay based NLGI Grade 1 or 2 grease 6 Months See Adjusters See Meritor lube chart for additional information Axle Manual Disc Brake Calipers Lubricate with clay based NLGI Grade 1 or 2 grease 6 Months See See Meritor lube chart for additional information Axle Manual Door Hinges Inspect and Adjust Spray with silicone lubricant 6 Months Door Latches Lubricate with Lubriplate105 grease or equivalent 6 Months Door Strikers Inspect and adjust 6 Months Door Window Lubricate with Lithium NLGI grade EP2 grease 6 Months Regulators Fifth Wheel Tiller Lubricate the fifth wheel bearing connecting the tractor 3 000 6 Months Only to the tiller trailer See Fifth Wheel Lubrication Tiller Only on page 4 27 for additional information Hood Velocity Lubricate hinges with Lithium NLGI grade EP2 grease 6 Months Impel Seat Adjuster Slides Lubricate with Lithium NLGI grade EP2 grease 6 Months Shock Absorbers Replace 6 000 Front Arrow XT with conventional spring suspen
219. ler is only required during pumping in high ambient conditions Keep the pump panel heater if so equipped in the off position when not required This will draw less heat from the engine during warm up Turn the crew cab heater fan to low or off when the crew cab is not occupied This will draw less heat from the engine during warm up e Operation of the engine in a high idle mode will increase the engine heat output somewhat but is of limited benefit unless the engine is under load To provide a load on the engine during long periods of idle time operate the pump in the recirculation mode with the engine at 1500 rpm Refer to the engine manufacturer s operator s manual for further information Winter Front Usage The use of a winter front increases the need for the operator to carefully monitor engine and transmission temperatures Remove the winter front before operating the vehicle in warm temperatures Excessive engine and transmission operating temperatures created by the inappropriate use of a winter front can cause operational failure leading to costly equipment damage Winter fronts are not necessary except in extremely cold temperatures or when light engine loads are combined with a high rate of engine idling If a winter front is used it must be placed over the grill on the outside of the vehicle only never directly onto the face of the charge air cooler or radiator On Pierce Custom Chassis this spacing will maintain a gap
220. ll end borders with matching color lettering enamel before applying clear coat Failure to apply clear coat to the edges of cut Goldstar products will cause delaminating 4 7 10 ABS Plastic Acrylic Curved Windows and Clear LEXAN Component Care 1 Wash with a mild solution of soap or detergent and lukewarm water 2 Using a soft cloth or sponge gently wash the sheet to loosen dirt and grime and rinse well with water 3 To prevent spotting thoroughly dry with chamois or cellulose sponge Avoid the use of abrasive cleaners and or cleaning implements such as brushes that may mar or gouge the coating 4 7 11 Product Availability e products soap wax and polish are readily available for sale Detailed information is available at http mmm com market automotive e Culligan is a good source for water testing and purifying equipment Detailed information is available at http www culligan com Raabe is a good source for touch up paint Detailed information is available at http Awww raabecorp com 4 8 Command Zone System selected chassis 4 8 1 Overview Figure 4 2 Traditional Electrical System 111 2010 Pierce Manufacturing Inc All Rights Reserved Custom Chassis 4 11 MAINTENANCE Figure 4 3 Pierce Command Zone Multiplex System DATA LINK SWITCH INPUTS 3OVJH3 NI 319IH3A 0112 The multiplex electrical system is different from most traditional electrical
221. ll sensor s Disconnect both connectors from the master roll sensor and the slave roll sensor if installed When welding is completed reconnect the connectors Make sure the red locking tabs are latched Refer to Welding Instructions on page 4 50 for additional welding information The Side Roll Protection System is designed to be maintenance free and fully functional for 20 years after installation Service the Side Roll Protection System only if you are a Pierce authorized technician The Suspension Seat Safety System S4S Inflatable Tubular Structure Side Airbags ITS Integrated Gas Pretensioners IGP Integrated Belt Pretensioners IBP and Inflatable Head Curtains IHC Supplemental Restraint Air Bag SRA must be replaced every 20 years as measured from the date of manufacture appearing on the FMVSS information decal See FMVSS Information Decal on page 1 6 Expired devices may not provide protection in a crash Fault Light Information If the Side Roll Protection fault light remains lit or does not light during vehicle prove out the vehicle should be brought to a Pierce Manufacturing authorized service facility In certain cases turning OFF the ignition and vehicle power and then turning them back ON may reset the fault light The roll sensor s record all fault codes which may be read with a diagnostic reader at a Pierce Manufacturing authorized service facility Precautions When Tilting the Cab During Maintenance
222. load by increasing the inflation pressure A tire that has become hot from normal use will have a higher pressure than it will when cool Never bleed pressure from a hot tire that has increased pressure as a result of the normal pressure buildup Always check tire pressure when the tire is cold 2010 Pierce Manufacturing Inc All Rights Reserved Custom Chassis 4 39 MAINTENANCE 4 24 2 Tire Loading Never load a tire beyond its rated capacity or sudden tire failure leading to a loss of vehicle control property damage personal injury or death may result IMPORTANT If tire manufacturer s maximum inflation and resulting load carrying capacity does not match the vehicle axle weight ratings the tire has a special fire service rating Contact Pierce Customer Service for the correct specifications and operating requirements for your tire and application or refer to Michelin amp special ratings chart for Michelin tires Table 4 11 Michelin amp Special Ratings Chart MICHELIN SPECIAL APPROVAL FOR FIRE TRUCK SERVICE ONLY INTERMITTENT SERVICE NOT TO EXCEED ONE HOUR LOADED TRAVEL WITH A ONE HOUR COOL DOWN PRIOR TO RETURN TIRE SIZE TREAD SINGLE 11R22 5 XZE 14600 XDN XDE A T 12R22 5 XZE XDN 315 80R22 5 XZA1 XZY 1 XDY 385 65R22 5 XTE2 20000 XZY 20000 425 65R22 5 XTE2 22800 XZY 22800 445 65R22 5 XTE2 26000 XZY 26000 XZL L 26000 cut and chip res
223. ls Velocity V Impel M on the chassis cab lockdown crossmember CUMMINS ISM ISC Disconnect plugs on the Cummins C83 Electronic Engine Located on the Cummins ISC engine ALLISON TRANSMISSION Disconnect plugs on the Allison Transmission ECU Allison Transmission ECU locations in driver side instrument panel Arrow XT on backside of brake cover Arrow XT with Command Zone in the first officer side front distribution enclosure Quantum behind the driver s seat under the wire cover Velocity Impel in the cab power distribution enclosure in front of the first officer seat FOAM PRO FOAM SYSTEM All parts of the Foam Pro system must be disconnected before welding This includes the positive and negative battery cable and vendor supplied cable to the pump and gauges ALL STEER ALL WHEEL STEER ECU AWS Disconnect both plugs on the ECU Located in the cab AWS II Disconnect the VIM Located inside the first officer side frame rail just in front of the rear axle ALL FLASHERS Check electrical layouts for locations SIDE ROLL PROTECTION Disconnect both connectors from the Master Roll Sensor and the Slave Roll Sensor if installed COMMAND ZONE If TIG welding on a Command Zone truck all Command Zone modules must be disconnected Before disconnecting any electronic component connection place the Battery Switch in the OFF posi
224. lugs Show no signs of misalignment Q Condition of tires properly inflated valve stem and cap OK no serious cuts bulges or excessive tread wear Q Use wrench to test rust streaked lug nuts indicating looseness Tires are of the same type not mixed radial and bias type Tires evenly matched same sizes Wheel bearing seals not leaking 3 6 Custom Chassis 2010 Pierce Manufacturing Inc All Rights Reserved OPERATION Left Rear Suspension Spring spring hangers shackles U bolts are in good condition Shock absorber shows no sign of excess wear or damage Powered axle s not leaking lube gear oil Torque rod arms and bushings show no sign of excessive wear Left Rear Brake Brake drums or rotors are not cracked or worn Hoses show no signs of excessive wear 3 1 5 Brake Testing Secure all loose articles in cab fasten seat belts and start the engine Proceed with functional brake tests as follows Test Parking Brake 1 Allow vehicle to move forward slowly 2 Apply parking brake If vehicle does not stop bring it to a stop using the service brakes and have the problem repaired by a qualified truck service facility Test Service Brake Stopping Action 1 Accelerate to about five miles per hour 2 Push brake pedal firmly Excessive pulling to one side or the other unusual brake pedal feel or delayed stopping action may indicate a problem Have the problem diagnosed and re
225. m that will be activated when a red illumination condition exists and the parking brake is released or a red illumination condition exists and the transmission is not in park 3 3 3 Side Roll Protection System Optional 3 3 3a General Description IMPORTANT The Side Roll Protection System is only designed to activate during a vehicle side roll accident or whenever the front air bags are deployed It will not activate during Side impacts Rear impacts e End over end accidents Other accidents not involving a side roll The Side Roll Protection System is a Supplemental Restraint System SRS consisting of pyrotechnically actuated advanced protective devices working in conjunction with the seats and seat belts of the vehicle to provide the occupant a lower probability for injury during a side roll up to 90 from vertical A roll sensor located in the cab headliner of the vehicle triggers the system The roll sensor analyzes the vehicle roll angle and rate of roll to determine when the Side Roll Protection System will activate 2010 Pierce Manufacturing Inc All Rights Reserved Custom Chassis 3 11 OPERATION 3 3 3b General Warnings and Cautions The Side Roll Protection System will only enhance safety if the seat belt is worn ALWAYS WEAR YOUR SEAT BELT The seat belt will pretension and restrain the occupant during a vehicle side roll accident If the seat belt is not worn the occupant will move out of position and become unpr
226. mary function of this screen is to remove water particles from the intake air before it reaches the air filter The screen can be removed for cleaning Inspect the screen for buildup of dirt or debris This screen must be kept clean to minimize air intake restriction to the engine and ensure peak engine output Remove the screen and clean with soap and water Quantum only The Quantum chassis employs an air intake snorkel to remove moisture from the engine air intake stream Moisture particles impinge on the back of the snorkel elbow and the water drains from a hole where the snorkel meets the vertical pipe This hole must be kept free of dirt and debris Inspect the drain hole to ensure that it is clear of dirt Clean as required A wide mesh screen keeps large particles from entering the snorkel Remove any debris from the screen using a soft brush Saber only The Saber chassis draws air for the air filter through perforations in the engine tunnel These small perforations located in a protected spot behind the grill and dispersed over a large area act to prevent moisture particles from entering the Saber air intake stream Inspect the perforated tunnel surface to ensure that the perforations are free from dirt or debris Clean as required with a soft brush 4 13 2 Air Intake and Charge Air Cooler Hose Clamps Tighten T Bolt style hose clamps to 90 100 in lbs Tighten Spring T bolt clamps to 45 70 in lbs 2010 Pierce Manufacturing I
227. matic active regeneration 1 Accumulation of soot in the filter to the point where the engine control system looks for opportunities to actively regenerate the DPF 2 Sufficient exhaust flow and temperature conditions typical pumping or driving conditions should be adequate 3 Speedometer showing 5 mph or higher vehicle speed When the engine determines that it is appropriate to initiate an active regeneration it adds hydrocarbons to the exhaust stream When the exhaust system temperature goes above 977 F 525 C the HEST light will illuminate Breaking any of the required conditions will stop the regeneration process If excessive soot build up remains in the DPF the DPF light will return to the appropriate indication stage until an adequate regeneration occurs No engine speed or load changes will occur during regeneration in pumping or driving modes 3 48 Custom Chassis 2010 Pierce Manufacturing Inc All Rights Reserved OPERATION 3 12 8d DPF Build Up Without Regeneration If the soot load in the DPF builds up and the necessary conditions for regeneration cannot be achieved the engine lights will indicate a more serious condition If this occurs operators should be mindful of the potential for gradual power de rates due to higher soot loading If the DPF light begins to flash along with a solid Check Engine light the operator may need to take action This action could be removing the truck from a mission that requires very hi
228. mation e OC Over current or short to ground The system can only detect this condition if the output status is on e SB Short to battery The system can only detect this condition if the output status is off e NC No connection or open The system can only detect this condition if the output status is off On modules that contain more than 8 inputs and or outputs a soft button will appear at the bottom right hand corner of the System Information screen Pressing the associated soft button will toggle the inputs outputs shown on the screen While in the Module screen press the BACK button to return to the System Information screen On power modules a soft button will appear at the bottom right hand corner of the Module screen Pressing the associated soft button will toggle the status and the amp draw of the outputs shown on the screen While in the Module screen press the BACK button to return to the System Information screen 2010 Pierce Manufacturing Inc All Rights Reserved Custom Chassis 3 77 OPERATION 3 21 4 Chassis Screens The CANTrak display will display two chassis related data screens Door screen and Load Manager screen Door Screen Figure 3 26 Door Screen 0082 Door Screen Figure 3 26 indicates the status of doors hatches or other items which must be in their closed or stowed position before moving the vehicle and which are sensed by the vehicle interlock circuitry This sc
229. mbly the temperature is elevated to a point where removal of the collected soot can occur This can happen while the truck is being driven when in stationary truck operations or during pumping operations The operator will be notified of the need for regeneration by illumination of the DPF light located in the cab When the DPF light goes on the operator can provide assistance by either changing the duty cycle or initiating a stationary regeneration using the Regeneration Switch found in the following locations Quantum located next to the engine diagnostic connector and diagnostic switch below the dash panel Velocity M ImpelTM located next to the engine diagnostic connector and diagnostic switch below the dash panel Arrow with Hardwired Electrical Systems located on the switch panel right of the dash panel Arrow XTTM with Multiplexed Electrical Systems located next to the engine diagnostic connector and diagnostic switch below the dash panel Saber Custom Contender same switch as the diagnostic switch located on the right hand side of the steering column below the dash panel Active Regeneration During Stationary Operations The following vehicle conditions must be satisfied before a stationary regeneration can be started using the regeneration switch Zero vehicle speed 2 Accelerator pedal remote accelerator at idle 3 Service brake released brake pedal not depressed 4 Thetransmis
230. means a special canister has replaced the typical muffler This canister contains a Diesel Oxidation Catalyst DOC and a Diesel Particulate Filter DPF The DPF will trap particulate matter while the engine is running Over time soot and ash will build up in the filter and must be removed Soot build up is removed by heating the filter until the soot oxidizes and turns into carbon dioxide gas This process is commonly known as regeneration Ash build up is removed from the filter by periodic cleaning in a special machine The typical ATD is equipped with two pressure transducers and three temperature transducers These sensors allow the engine to monitor soot build up and identify cleaning requirements Engine instrument panel light functionality is explained in Instrument Panel Indicator Lights Detroit Diesel Engines on page 3 68 3 12 5b Passive Regeneration The passive regeneration process allows cleaning of the DPF under normal engine operation and does not require operator interaction The operator will see no difference in vehicle performance or vehicle control When the engine has an adequate amount of exhaust heat the DPF can go through a passive regeneration process This occurs when the exhaust temperatures leaving the turbo are high enough to remove the soot caught in the DPF No extra fuel will need to be burned in order for this event to occur Passive regeneration is possible while in pump mode operations The heat being generated
231. n ignition cycle Parking Brake must be ON Engine speed should be at idle deo Cycle the transmission from Drive to Neutral The transmission must be in neutral confirmed by looking at the Allison Transmission Shift Selector and seeing current gear and selected gear are neutral N 7 Mehicle speed must be 0 mph 8 Hold the regeneration switch to the ON position for five seconds and release When the request is accepted the DPF light will illuminate for one second and then go off for the rest of the parked regeneration The engine speed will increase to 1600 rpm during a parked regeneration The HEST light will not illuminate until exhaust temperatures exceed the temperature threshold Breaking any of the required conditions will stop the parked regeneration and engine speed will return to idle Upon completion of parked regeneration the following should occur 1 The HEST light will remain illuminated until the exhaust outlet temperature is below the temperature threshold or the vehicle speed exceeds 5 mph 2 The DPF light will turn off along with all other associated warning lights If the Check Engine light Stop Engine light or MIL are still illuminated a fault condition exists that should be diagnosed by a Detroit Diesel service representative To cancel the parked regeneration the driver can toggle the regeneration switch to ON for five seconds The DPF light will flash on for one second to show acceptance of the
232. n ohm reading of approximately 120 ohms indicates a terminating resistor that is missing or a data link that is open loose connection A 40 ohm reading indicates that an extra terminating resistor plug has been installed in the data link Non Command Zone Components Never assume that the cause of the problem is the multiplex system Check the device it may be defective Perform all basic electrical checks fuses circuit breakers wiring connections terminals etc before assuming the worst 4 9 Cooling System The most efficient cooling system is one that keeps the coolant at proper temperature for efficient engine operation regardless of engine speed or load When coolant temperature is below normal fuel may not burn readily or produce its full power When water temperature is excessive and the engine is operating under full load lubricating oil may get so hot and thin that it cannot lubricate effectively Every part of the cooling system requires attention 4 9 1 General Inspection and Service Always allow the engine to cool before opening the pressure cap Wrap a thick heavy cloth around the cap Push down and turn the cap to the first notch position Pause before opening completely to allow any remaining pressure to escape Follow this procedure to avoid burns from hot steam or coolant Wear safety goggles when blowing debris from radiator or damage to eyes may result Do not use antifreeze with a stop leak additive as
233. n power modules a soft button will appear at the bottom right hand corner of the Module screen Pressing the associated soft button will toggle the status and the amp draw of the outputs shown on the screen Press the BACK button to return to the System Information screen 3 23 Pump IMPORTANT In the event that the throttle control at the pump operator s panel becomes inoperative the accelerator pedal in the cab may be used as an alternative means to control the engine speed while pumping Detroit Diesel engines only Some Pierce fire apparatus are equipped with a driveline driven water pump For pump operating information refer to the Pierce Pumpers Operation amp Maintenance Manual PM P OM260 or the Pierce Ultimate Configuration Pumpers Operation amp Maintenance Manual PM P OM420 as well as the pump manufacturer s literature provided with the unit 2010 Pierce Manufacturing Inc All Rights Reserved Custom Chassis 3 87 OPERATION 3 24 Stability Control Optional 3 24 1 Roll Stability Control RSC Roll Stability Control RSC is an Anti Lock Braking System ABS based system that senses when impending rollover conditions occur and if detected intervenes in the operation of the truck by automatically reducing the vehicle speed All measuring and processing needed to calculate and continuously update the rollover risk is done within the ABS Electronic Control Unit ECU RSC is automatic It bec
234. n reach 1350 F during an active regeneration cycle An active regeneration cycle could occur automatically whenever the speedometer indicates a speed above 5 mph This can occur when the vehicle is in motion or when the apparatus is operating in stationary pump mode with an engine rpm sufficient to indicate 5 mph on the speedometer An exhaust temperature mitigation device is included at the tailpipe to reduce high exhaust temperatures before the exhaust exits the tailpipe Extreme caution should always be used when working in the vicinity of the exhaust outlet Failure to heed this warning may lead to personal injury or death IMPORTANT Periodic exhaust inspection is particularly important with all 2007 EPA amp 2010 EPA diesel engines The muffler is part of the Diesel Particulate Filter DPF The exhaust pipe ahead of the DPF will be wrapped with heat insulation The insulation is critical to the DPF active regeneration performance If the insulation is damaged or missing the internal DPF temperature may not be high enough to burn off the particulates soot Likewise if pipe clamps are loose critical heat may escape affect the regeneration performance and emissions compliance Inspect exhaust pipe connections to check for loose clamps or corrosion Repair or replace as necessary Refer to the engine manufacturer s maintenance manual for additional information on the Diesel Oxidation Catalyst DOC and Diesel Particulate Filter DPF
235. n to the hazard it describes Practice all the time to avoid the hazard so you develop a habit to avoid the hazard 1 4 Responsibility Study carefully this manual and the manuals for major components such as engine transmission and other allied equipment Make sure that all operators and other users also completely understand their contents The warnings cautions and procedures listed in these manuals must be part of the fire department s safety program As the operator of this vehicle and pumping equipment you are responsible for Understanding the function of each component of the fire apparatus Understanding how to adjust each control to obtain the results you want Maintaining control of the fire apparatus at all times Remaining proficient in use so at a fire you can operate and make successful changes in the operation quickly without having to read the operator s instructions or safety warning labels Practicing proper manual override and emergency shutdown procedures so you can respond immediately in an emergency or during the failure of a component Remember stress is high Your failure to practice increases the odds you will forget or do it wrong in the heat of the moment 2010 Pierce Manufacturing Inc All Rights Reserved Custom Chassis 1 3 TO THE OWNER 1 5 Custom Products Your department developed specifications for this fire apparatus It purchased a Pierce apparatus that is built to mee
236. nc All Rights Reserved Custom Chassis 4 21 MAINTENANCE 4 13 3 Fan and Accessory Belts Belts should be checked for frayed areas cracks and general wear Always replace all belts in a set even though only one may be defective Belt Inspection and Installation Proper belt tension is critical to maintaining belt life Too much tension will overstress the belt as well as the pulleys and bearings Too little tension will allow the belt to slip during heavy loading This will glaze the belt surface reduce surface friction increase slippage and ultimately lead to belt failure Inspect belt tension weekly Tension all new belts to the values indicated in the Belt Tension Table Belt tension must be measured with a Burrows Tension Gauge Dayco P N 93862 or an equivalent gauge Multi groove drive belts with automatic tensioning devices are not adjustable New belts will stretch after run in To prevent slippage it is important that new belts be tightened after running the engine for 3 to 5 minutes After run in allow the belt to cool and reset the tension to the value recommended in the In Service column of Table 4 2 shown below Table 4 2 Belt Tension Table Tension at Initial In Service Tension Type of Belt Number of Ribs Installation Belt Cold V belt 0 50 Inch Wide 130 Ibs 105 lbs Multi Rib 150 lbs 100 Ibs Multi Rib 150 lbs 100 Ibs Multi Rib 150 lbs 100 Ibs Multi Rib 180 Ibs 120 Ibs Multi Rib 180 Ibs 120 Ibs
237. nd or wheels chocked Notice general condition Look for damage or the vehicle leaning to one side Look under the vehicle for fresh oil coolant grease or fuel leaks Check the area around the vehicle for hazards to vehicle movement people other vehicles objects low hanging wires or limbs etc 3 1 3 Interior Inspection Engine Compartment NOTE Secure loose items in cab and ensure the vehicle is on a flat and level surface before tilting Tilt the cab or open the engine compartment doors and check the following Engine oil level OK Q Automatic transmission fluid level and physical appearance OK Refer to Transmission Fluid Analysis Allison Transmissions on page 4 49 for additional information Coolant level in radiator OK Power steering fluid level OK Windshield washer fluid level OK Hoses show no signs of excessive wear damage or leaking OoCcCdL 2010 Pierce Manufacturing Inc All Rights Reserved Custom Chassis 3 1 OPERATION Battery box securely mounted to vehicle Batteries secured against movement Batteries not broken or leaking Fluid in batteries at proper level except maintenance free type Cell caps present and securely tightened except maintenance free type Vents in cell caps free of foreign material except maintenance free type Belts are tight and show no sign of excessive wear With engine off press belt to test that it is snug No apparent leaks of fuel coolant oil
238. nd provides adequate ventilation Locate transceiver for remote radios away from other electronic devices and as near to the vehicle body side as possible Before using screws to mount the transceiver equipment be sure to check for vehicle wiring behind the instrument panel which could be pinched cut or otherwise damaged 2 2 Radio Wiring and Routing Transceiver power connections should be made directly to the battery or radio power and ground distribution terminals and appropriately fused at that location Any negative lead from a handset or control unit must return to battery negative It is preferable that the positive lead for a handset or control unit be connected directly to the radio power distribution terminal also recommended that the handset or control unit positive and negative leads be appropriately fused separately from the transceiver positive and negative leads When possible solder should be applied to power and ground wire terminations e Use caution when routing wires between the passenger and engine compartments to avoid chafing or pinching of wires Use grommets over any exposed sharp edges and strain reliefs to keep wires in place Seal all holes to prevent moisture intrusion Route and secure all under hood wiring away from mechanical hazards such as exhaust manifolds and moving parts steering shaft throttle linkage fans etc Maintain as great a distance as possible between mobile
239. nd rate of roll Cabs may be equipped with a single roll sensor or two roll sensors a master and a slave In the event of a side roll accident the roll sensor sends a signal to deploy the advanced occupant protection devices The roll sensor stores in memory a ten second stream of roll angle and rate data that can be retrieved in the event of an incident Suspension Seat Safety System 545 Figure 3 2 Suspension Seat Safety System 545 Pre Deployment Post Deployment 0100 2010 Pierce Manufacturing Inc All Rights Reserved Custom Chassis 3 13 OPERATION Keep hands and other objects clear of the deployment path of seat seat belt and suspension components The 545 actuator is located immediately behind the driver s suspension seat In the event of a side roll accident the 545 unit deploys pretensioning the seat belt and pulling the seat to its lowest position The SAS is only effective when you wear your seat belt ALWAYS WEAR YOUR SEAT BELT Inflatable Tubular Structure Side Airbag ITS Figure 3 3 Inflatable Tubular Structure Side Airbag ITS Pre Deployment 0101 0102 Do not sit or lean unnecessarily close to the air bag Do not place or mount any object over the air bag or between the air bag and the occupants ITS is an inflatable air bag that inflates next to the occupant s head and provides a cushion in case of a side roll accident Two air bag inflators are located one eac
240. nd waxing Goldstar and vinyl surfaces Wax solutions frequently consist of small abrasive materials These materials will scratch and dull the vinyl surface Hand wax around these products to avoid abrasion Wax makes the painted surfaces easier to clean and dry Waxes produce a durable high gloss finish that fills and minimizes minor surface scratches Wax should be reapplied when water no longer beads up on the surface Recommended products are Wax 3M Perfect It Show Car Wax P N 39021 and Polish 3M One Step Cleaner Wax P N 39006 Follow manufacturer s recommendations for application and removal Paintfinish may be hand waxed 90 days after delivery with a non abrasive wax applied lightly and softly buffed Do not wax any of the Goldstar gold leaf or other vinyl Wax around it e Never wax in direct sunlight as the surface temperature may be too hot Properly wash vehicle first Bright metals may be polished using a non abrasive polish e Polish be used in the event that surface contaminants remain on the surface after washing and waxing or if there are minor scratches in the painted surface that have reduced the gloss 4 7 6 Touch Up Touch up paint if the surface has been nicked or scratched and the undercoat primer or bare metal has been exposed Is bare metal is left untreated moisture will penetrate the paint and corrosion will start Once corrosion starts it will continue to grow 1 Clean the
241. ne light and MIL illuminated The engine will induce a 5 MPH speed limit and a 2596 engine torque derate Refilling the DEF tank will deactivate any torque derates speed limits and warning lights 3 42 Custom Chassis 2010 Pierce Manufacturing Inc All Rights Reserved OPERATION 3 12 7 After Treatment Device ATD Regeneration Cummins ISL Engines 2007 EPA Parked Regeneration causes high exhaust gas temperatures at zero vehicle speed Keep personnel away from exhaust outlet to avoid serious burns and injury Do not perform parked regeneration while connected to an exhaust extraction system Damage to the exhaust extraction system may result 3 12 7a Basic Operation of the After Treatment Device 2007 EPA engines are required to use an After Treatment Device ATD for controlling emissions This means a special canister assembly has replaced the typical muffler This assembly contains a Diesel Oxidation Catalyst DOC and a Diesel Particulate Filter DPF The DPF is a ceramic filter that captures soot and ash from the exhaust Over time soot and ash build up in the filter and must be removed Soot build up is removed by heating the filter until the soot oxidizes and turns into carbon dioxide gas This process is commonly known as regeneration Ash build up is removed from the filter by periodic cleaning in a special cleaning machine The Cummins DPF assembly is equipped with a differential pressure transducer and three temper
242. ng indicates that the filter has become loaded to a point where a regeneration is required immediately This requires the operator to initiate a regeneration immediately to clean the DPF This can be accomplished through either automatic regeneration driving or pumping or a parked regeneration The DPF light will turn off during the parked regeneration event The third stage DPF flashing and Check Engine light illuminated indicates that an automatic regeneration will no longer be allowed The vehicle should be moved to a safe location where a parked regeneration can be immediately initiated The fourth stage DPF flashing Check Engine light illuminated and Stop Engine light illuminated indicates that damage to the after treatment device is eminent and a parked regeneration should be performed immediately As the DPF limits are exceeded the engine will shut down to prevent complete failure of the DPF In this situation the engine can be restarted but a parked regeneration must be initiated within the first 30 seconds or the engine will shutdown again The High Exhaust System Temperature HEST light provides an indication to the vehicle operator that an active regeneration has been initiated and that the exhaust system temperature is elevated beyond the temperature threshold This light will flash when parked regeneration is in process and the system has not reached proper temperatures This light does not indicate a failure of any
243. ng 90 degree steering shaft gear box to the cab 3 8 16 UNC 44 60 Steering Shafts Keyway and spline clamp bolts 3 8 24 UNF 48 65 Pitman Arm Clamp bolt 3 4 10 UNC 226 306 Drag Link Clamp bolts 5 8 11 UNC 125 169 Drag Link Ball joint nuts 7 8 14 UNF 150 205 Steering Assist Cylinder Ball joint nuts 7 8 14 UNF 150 205 Steering Assist Cylinder Clamp bolts 5 8 11 UNC 125 169 Steering Wheel Center nut 60 85 4 23 5 ALL STEER All Wheel Steering Optional Refer to the Oshkosh ALL STEER service group 0611 P 001 included in the Pierce Service Manual for maintenance schedules lubrication recommendations and inspection procedures 4 36 Custom Chassis 2010 Pierce Manufacturing Inc All Rights Reserved MAINTENANCE 4 24 Tires 4 24 Tire Inflation Maintain tire pressure at the tire manufacturer s pressure recommendations for the correct tire size type load range ply rating and measured in service axle load of the vehicle Failure to maintain proper tire pressure may result in loss of vehicle control property damage personal injury or death Consult tire manufacturer s load and inflation tables for proper inflation pressures at a given in service axle weight Maximum inflation pressures either published or special fire service recommendations are only to be used on axles at or near the maximum rated capacity Also follow the load and inflation tables for axles at less than maximum capacity T
244. ng driving Failure to comply may result in serious injury or death to personnel The use of seat belts help to restrain you and your passengers in case of a collision In most states the law requires their use Safety belts provide the best restraint when The seat back is upright The occupant is sitting upright not slouched The lap belt is snug and low on the hips The shoulder belt is snug against the chest The knees are straight forward Failure to use care in closing the door can cause seat belt damage if the seat belt is caught in the door latch and striker In certain apparatus configurations the seat belt retractor may not retract the belt quickly or completely enough to prevent it being caught in the door In these instances it is necessary for the belt to be placed manually inside the door before it is closed 3 10 Custom Chassis 2010 Pierce Manufacturing Inc All Rights Reserved OPERATION 3 3 2 Seat Belt Monitoring System Most Pierce apparatus are equipped with a Seat Belt Monitoring System SBMS The SBMS is capable of monitoring up to ten 10 sensors indicating the status of each seating position in the cab with green and red LED indicators as follows e Green Seat occupied and seat belt buckled e Red Seat occupied and seat belt unbuckled Red No occupant in seat and seat belt buckled Illuminated No occupant in seat and seat belt unbuckled The SBMS will include an audible alar
245. ng parts that are cracked damaged or missing Air suspension systems that are damaged and or leaking e Any loose cracked broken or missing frame members e Broken or damaged torsion bars Cut or torn tape on torsion bars TAK 4 suspension only Refer to Pierce Service Manual group 0152 P 002 TAK 4 Independent Front Suspension Exhaust System A broken exhaust system can let poisonous fumes into the cab Check for Loose broken or missing exhaust pipes mufflers tailpipes or vertical stacks Loose broken or missing mounting brackets clamps bolts or nuts e Exhaust system parts rubbing against fuel system parts tires or other moving parts of vehicle Exhaust system parts that are leaking e M Missing or damaged insulation or heat shields Exhaust temperature mitigation device damage Equipment Loading e Inspect for cargo overloading and correct balance and securement before each trip If the cargo contains hazardous materials inspect for proper papers and placarding Left Front Side Driver s door glass should be clean Q Door latches and window regulators work properly Left Front Wheel Wheel and rim in good condition no missing bent or broken studs clamps or lugs Show no signs of misalignment Condition of tires properly inflated valve stem and cap OK no serious cuts bulges or excessive tread wear Use wrench to test rust streaked lug nuts indicating loo
246. not PTO remote PTO cruise control etc When a stationary regeneration event is initiated the DPF light will go off As the engine adds hydrocarbons to the exhaust stream the exhaust system temperature goes up When the exhaust temperature goes above 977 525 C the HEST light will illuminate Engine speeds will be increased and the sound coming from the turbocharger will change during the stationary active regeneration process ISM engines will increase speed to 1400 rpm and ISL ISC engines will increase speed to 1000 rpm The procedure will take 20 to 40 minutes depending on the amount of soot accumulated in the filter Breaking any of the required conditions will stop the regeneration process and engine operation will return to normal If excessive soot build up remains in the DPF the DPF light will return to the appropriate indication stage until an adequate regeneration occurs After completion of regeneration the HEST light will remain illuminated until the exhaust outlet temperature is below 977 F 525 C or the vehicle speed exceeds 5 mph Automatic Active Regeneration During Driving or Pumping Conditions The following vehicle conditions must be satisfied before the engine will initiate an automatic active regeneration 1 Accumulation of soot in the filter to the point where the engine control system looks for opportunities to actively regenerate the DPF 2 Sufficient exhaust flow and temperature conditions typical pumping
247. ns Automatic tire chains are designed to provide additional traction during slippery conditions at slow vehicle speeds only Do not operate vehicle with automatic tire chains engaged at speeds over 35 mph On trucks equipped with Command Zone D Series modules Arrow XT Impel Quantum Velocity M The tire chains will activate instantly if the parking brake is set and the switch is activated Ifthe parking brake is released the switch must be held for two seconds before the tire chains will activate to prevent accidental activation Engage automatic chains before reaching slippery conditions Engage automatic chains while traveling at vehicle speeds between 2 and 25 mph Vehicle can be stopped and started again as long as the control switch remains in the engaged position Disengage automatic chains while traveling at vehicle speeds between 2 and 35 mph To engage chains when the vehicle is already stuck spin tires up to 5 mph and engage chains Stop spinning the tires and proceed slowly once the action of the chains is apparent On trucks equipped with All Steer all wheel steering AWS the AWS system monitors the system and prevents the engagement of the tire chains in those conditions where the chains could damage the body or other components Refer to the chain system manufacturer s instructions for maintenance and service requirements 3 90 Custom Chassis 2010 Pierce Manufacturing Inc All Rights Reserved
248. ns and inspection procedures Inspect the entire brake system for the following Air leaks Condition of drums rotors brake chambers and slack adjusters e Condition of hoses fittings and tubes e Proper operation of service and parking brakes 4 4 2 Brakes TAK 4 Suspension Brake information for the TAK 4 suspension can be found in the Pierce Service Manual group 0251 V 016 Bendix SB 6 amp SB 7 Air Disc Brakes 4 43 Air Dryer Inspect the air dryer to ensure that it is exhausting properly at each cycle of the air compressor governor Replace the desiccant cartridge every 2 to 3 years or more often depending on usage Refer to the air dryer maintenance manual included in the Pierce Service Manual for maintenance schedules lubrication recommendations and inspection procedures 2010 Pierce Manufacturing Inc All Rights Reserved Custom Chassis 4 3 MAINTENANCE 4 5 Step System Quantum 4 5 1 General Inspection e Observe operation Retract and deploy times should average less than 3 seconds in either direction Speed may vary between steps due to slight manufacturing variances Open each door and then close it gently making sure that the door closes to the first latch catch only If any step fails to retract with the door closed to the first latch catch follow valve adjustment procedure below Ensure that step surfaces are clean and that dirt ice or debris has not been trapped
249. nt 24 x 5 1 2 Front 24 x 5 1 2 Front 30 x 5 1 2 Front 30 x 5 1 2 48 001 54 000 EL Rear 30 x 6 Rear 30 x 6 Rear 30 x 6 Rear 30 x 6 Front 24 x 5 1 2 Front 30 x 5 1 2 Front 30 x 5 1 2 Rd LE Rear 36 x 6 Rear 36 x 6 Rear 36 x 6 0040 2010 Pierce Manufacturing Inc All Rights Reserved Custom Chassis 2 3 BEFORE PLACING VEHICLE IN SERVICE Figure 2 3 Brake Power Chart Disc Brakes Front Disc Brakes Rear FRONT In Service Axle 11 000 14 600 14 601 16 540 16 541 18 000 18 001 21 500 Weights Lb Axle Model FG941 FL941 FL943 Front 24 x 5 1 2 Front 24 x 5 1 2 14 600 17 000 RS21 Rear 24 x 5 1 2 Rear 24 x 5 1 2 o Te Front 24 x 5 1 2 Front 24 x 5 1 2 Front 30 x 5 1 2 Front 30 x 5 1 2 11001 22000 Ree Rear 30 x 5 1 2 Rear 30 x 5 1 2 Rear 30 x 5 1 2 Rear 30 x 5 1 2 Front 24 x 5 1 2 Front 24 x 5 1 2 Front 30 x 5 1 2 Front 30 x 5 1 2 Rear 30 x 5 1 2 Rear 30 x 5 1 2 Rear 30 x 5 1 2 Rear 30 x 5 1 2 22 001 24 000 24 001 27 000 REAR 27 001 31 000 Front 24 x 5 1 2 Front 24 x 5 1 2 Front 30 x 5 1 2 Front 30 x 5 1 2 5 000 42 000 Rear 30 x 5 1 2 Rear 30 x 5 1 2 Rear 30 x 5 1 2 Rear 30 x 5 1 2 Front 24 x 5 1 2 Front 24 x 5 1 2 Front 30 x 5 1 2 Front 30 x 5 1 2 42 001 48 000 Rear 30 x 5 1 2 Rear 30 x 5 1 2 Rear 30 x 5 1 2 Rear 30 x 5 1 2 48 001 54 000 0041 Figure 2 4 Brake Power Chart Disc Brakes Front ALL STEER Cam Brakes Rear Weights Lb
250. o Lower Cab 3 29 To The Owner disedia naa es 1 1 4 10 Tow Hooks and Tow Eyes 4 44 Towing Instructions 4 42 Towing Lift and Tow 4 48 Traction Control 3 22 Transfer Case All Wheel Drive 4 50 Transmission 3 91 4 48 Transmission Fluid 4 48 Transmission Fluid Analysis Allison Transmissions 4 49 Transmission Operating Temperature 3 92 Transmission Automatic 3 91 Troubleshooting Tips 4 13 Turn Signal Switch 1 1122 3 35 Two Speed Rear Axle 3 20 Typical Arrow XT Cab Instrument Panel 3 64 Typical Quantum Cab Instrument Panel 3 62 Typical Saber amp Cab Instrument Panel 3 63 Typical Saber amp Custom Contender amp Cab Instrument 55 oo oe ees 3 63 Typical Velocity Impel Cab Instrument Panel REESE 3 66 U Undercarriage Corrosion 4 9 V Vehicle Data Recorder 3 93 Vehicle Entry and Exit 3 8 Vehicle Handling Characteristics 1 4 Vehicle Identification 1 6 Vendor Component Maintenance Sc
251. o ensure the stay arm will clear the cylinder 3 Setthe control switch to the LOWER position Press and hold the lock release switch and press the activate button 5 Hold the activate switch for at least 5 seconds after the cab comes to rest 2010 Pierce Manufacturing Inc All Rights Reserved Custom Chassis 3 29 OPERATION 6 Checkto ensure the cab is fully seated before operating vehicle 3 9 3 Cab Lift System Velocity ImpelT Always check for people working on or around the cab before raising or lowering the cab Failure to ensure that everyone is clear of the cab could cause severe personal injury or death To Raise Cab 1 Before tilting the cab ensure that the vehicle is on a flat and level surface engine is off transmission is in neutral and the parking brakes are set Turn on the battery and ignition switches Set the parking brake Turn the control switch to RAISE position Depress the tether switch until the cab is fully tilted Remove the stay arm from its stowed position and raise it into the stay arm pocket on the engine tunnel o Turn the control switch to the LOWER position and depress the tether switch until the top of the stay arm is inside the stay arm pocket and the cab is lightly resting on the stay arm To Lower Cab 1 Turn on the battery and ignition switches Set the parking brake 2 Turn the control switch to the RAISE position and momentarily activate the tether switch until
252. o personal injury or death The belt driven cooling fans on the Quantum Chassis built after December 1999 are equipped with a clutched fan powered by the engine crankshaft via a drive shaft connected to a multi rib belt drive assembly The belt drive assembly consists of a drive hub a fan clutch a multi rib v belt and an automatic tensioning device that eliminates belt tension inspection Periodic belt inspection is required Replace belt if any signs of cracking or glazing appear Replacement of this belt requires that the fan be unbolted from the hub and leaned forward within the shroud Remove the drive shaft from the lower drive pulley Use a one half inch drive socket wrench on the automatic tensioner to remove the tension from the belt With the tension off the belt work the belt off the lower pulley and remove from the upper pulley Reverse this process to install the new belt The fan clutch will automatically engage if any of the following conditions occur When the engine coolant or air intake temperature reaches the engine manufacturer s preset temperature for fan engagement When truck is placed in pump mode the fan clutch will engage e When any generator PTO drive is activated the fan clutch will engage 4 13 5 Engine Service Schedule Maintenance lubrication and inspection schedules vary among engine models and manufacturers Refer to the engine manufacturer s maintenance manual for maintenance schedules lubrica
253. of 6 to 14 inches between the winter front and the heat exchanger cores This installation will restrict the flow of air through the cooling system to that which can be drawn from below the bumper and will avoid cutting off cooling airflow entirely 2010 Pierce Manufacturing Inc All Rights Reserved Custom Chassis 3 55 OPERATION 3 13 Fire Scene Operation 3 13 1 High Heat Sources Direct exposure of the vehicle to extreme high temperatures can cause damage to electrical systems rubber seals and gaskets and plastic components Always operate vehicle a safe distance away from flames or heat source 3 13 2 Flying Embers To avoid the risk of engine fire leading to property damage serious injury or death do not operate the vehicle in an area where burning embers can be ingested directly into the air intake system Diesel engines consume as much as 1200 cubic feet of clean air every minute when operating under full load Hot embers sucked into the air intake can cause the air cleaner element to ignite Although Pierce Custom Chassis are equipped with ember barriers composed of mesh screens or perforated metal they are not a foolproof guarantee of protection 3 14 Heating Ventilation Air Conditioning HVAC Contender Quantum Saber Comfort controls can be set to obtain a desired interior condition Refer to the Instrument Panel Layout located in the Electrical System Manual for specific locations of HVAC con
254. omes active when the ECU senses lateral acceleration that exceeds thresholds It then attempts to quickly reduce vehicle speed until the lateral acceleration falls below the determined threshold The type and magnitude of an RSC intervention depends on the amount that the actual vehicle lateral acceleration exceeds the control limit Intervention starts with an engine torque reduction command you may sense a decrease in engine power followed by application of the engine brake if the vehicle has an engine brake you will feel the additional deceleration and if necessary application of the drive axle brakes you will feel braking take place For additional RSC information refer to the Pierce Service Manual group 0251 V 015 Meritor Wabco Anti Lock Braking System ABS and group 0995 V 003 Meritor Roll Stability Control RSC Driver Tips 3 24 2 Electronic Stability Control ESC Electronic Stability Control ESC is a system that can apply any and all brakes of the vehicle in an effort to regain control when the vehicle becomes directionally unstable ESC contains lateral measurement for roll with the addition of sensing for skidding or drift out 3 24 3 Safe Vehicle Operation Note that RSC and ESC systems cannot prevent accidents and or loss of control of the vehicle RSC and ESC systems are not a reason to take unnecessary risks A driver can still exceed the physical limitations of the system with either excess speed and or extreme
255. omm Loss 1 7 2005 8 17 00 1 7 2005 8 16 59 0095 Selecting this will display all active messages Figure 3 41 The active messages are sorted by occurrence SILENCE button will silence the audible alarm See Alarms Screen on page 3 81 for specific alarm screen details 3 22 3h View System Information Figure 3 42 System Information Screen System Information 1376 2010 Pierce Manufacturing Inc All Rights Reserved Custom Chassis 3 85 OPERATION The System Information screen Figure 3 42 is intended for system analysis and troubleshooting by operators or maintenance personnel who are familiar with Command Zone electronics To the right of each item is the value of the data currently active on the system 3 22 3i System Diagnostics Figure 3 43 System Diagnostics Screen 0097 The System Diagnostics screen Figure 3 43 provides information for each of the Command Zone modules installed on the system The screen lists the module type and module number of each module on the network This is a live screen meaning that if a module goes off line the module will not be shown on this list and a warning message indicating the Module Comm Loss will be displayed Module Screen Figure 3 44 Module Screen 0098 If the user wishes to troubleshoot individual circuits within a given module move the indicator arrow to the correct module name number and press the ENTER butt
256. on The Diesel Exhaust Fluid reservoir is typically located in the driver s side rear wheel fender behind the forward air bottle storage door The DEF reservoir location on your apparatus may be different depending on the rear body design The reservoir has a blue cap and is accompanied by a DEF fluid only label Filling the DEF tank with other liquids can result in premature failure of the engine and or emissions components In the event that the incorrect fluid has been added to the DEF tank such as but not limited to Water Diesel Fuel Hydraulic Fluid Coolant Windshield Washer Fluid Contact Pierce Customer Service to determine the appropriate repair action If only water has been added to the DEF tank drain the DEF tank flush with distilled water and refill with new and or known good DEF Do NOT add any chemicals additives to the DEF in an effort to prevent freezing If chemicals additives are added to the DEF the aftertreatment system may be damaged DEF will freeze around 11 F 12 C The DEF system on the vehicle is designed to accommodate this and does not require any intervention from the operator 3 12 15 Hand Throttle Never attempt to use a hand throttle as a cruise control Doing so may cause lack of vehicle control resulting in property damage personal injury or death 3 54 Custom Chassis 2010 Pierce Manufacturing Inc All Rights Reserved OPERATION 3 12 16 Cold Weather Op
257. on The Module screen Figure 3 43 will appear The module name and number will appear at the top of the screen The module s software version can be found to the right of the module name 3 86 Custom Chassis 2010 Pierce Manufacturing Inc All Rights Reserved OPERATION Listed is information about each individual input and or output of that module Starting at the left the information is as follows nput output number e Circuit number connected to that input or output Circuit name item connected to the circuit Ablank line indicates that the input output is not programmed e Status of the input or output all module types Inputs On Off e G Ground at the input will activate the input B Battery power at the input will activate the input e Analog signal at the input No value is given e Outputs e On Of FLA Flashing Additional Status Power Module Outputs only diagnostic information e OC Over current or short to ground The system can only detect this condition if the output status is on SB Short to battery The system can only detect this condition if the output status is off On modules that contain more than 8 inputs and or outputs a soft button will appear at the bottom right hand corner of the System Information screen Pressing the associated soft button will toggle the inputs outputs shown on the screen Press the BACK button to return to the System Information screen O
258. on entertainment and electrical charging systems Expenses incurred to protect the vehicle systems from any diverse effect of any such installation are not the responsibility of Pierce Manufacturing 1 General Information Pierce apparatus are designed and tested for safe operation with properly installed and properly used land mobile radio communications equipment with up to 150 watts of transmitter power Special design considerations are incorporated into all Pierce apparatus electronic systems to provide immunity to radio frequency signals In addition Pierce installed electrical systems and components are designed to control undesired electromagnetic radiation and radio frequency interference resulting from the use of such equipment To maintain compatibility with vehicle electronic systems mobile two way radio and telephone equipment must be installed properly by trained personnel observing these general guidelines Power and ground connections should be made directly to the battery or radio power and ground distribution terminals located inside the chassis power distribution box When possible solder should be applied to power and ground wire terminations Avoid cigar lighter or power point receptacles as power sources for radio communication equipment radio equipment circuit protection devices fuses should be installed as close as possible to the power ground source e Antennas for two way radios
259. only Continual use of this device will place unnecessary stress on intake plumbing and engine parts and may lead to reduced component life The emergency shutdown feature provides positive shutdown capability even in the event that the engine is operated in an atmosphere rich in fuel vapors The shutdown device is a clapper valve located in the air intake pipe or the charge air cooler pipe that blocks all airflow to the intake manifold The valve is tripped electrically or pneumatically from a switch located at the driver s station or pump panel Once the valve is tripped it must be reset before the engine can be started again 3 12 10 Fan Clutch Fan clutches can engage and fan blades can spin without warning Keep hands hair and clothes away from fan Never operate the engine with personnel in the vicinity of the fan as the fan may engage without warning Failure to heed this warning may lead to personal injury or death Engines equipped with a fan clutch will provide airflow to cool the engine when one or more of the following conditions are met engine coolant or air intake temperature reaches the engine manufacturer s preset temperature for fan engagement Placing the truck in pump mode may activate the fan clutch e Activation of any generator PTO drive may engage the fan clutch 3 50 Custom Chassis 2010 Pierce Manufacturing Inc All Rights Reserved OPERATION 3 12 11 Starting Engine Using Power From Ano
260. onstantly changing When measuring an AC system it is important to know that the average voltage is zero and that is why A VOLTMETER SET TO DC WILL NOT INDICATE THE PRESENCE OF AC VOLTAGE WHEN CONNECTED TO AN AC CIRCUIT High voltage can be lethal Always refer to the high voltage equipment manufacturer s service information when maintenance or repairs are needed In most cases diagnostics and repair are performed after the high voltage circuits are disabled If you work around or maintain high voltage circuits please seek high voltage training To avoid property damage personal injury or death circuits must be checked using a voltmeter for the presence of both DC and AC voltages A voltmeter set to DC will not indicate the presence of AC voltage when connected to an AC circuit Contacting an unknown AC or DC voltage may cause equipment damage electrical shock and or electrocution Only trained technicians may perform service inside high voltage components If you work around or maintain high voltage circuits please seek high voltage training 4 12 4b Auxiliary Power Units APUs NOTE High voltage APU wiring may NOT be marked for easy identification as high voltage APUs are basically small diesel powered generator units that are integrated into the vehicle s electrical system APUs are utilized in combination with inverters and battery chargers APUs are often set up to automatically start when the electrical management system deems
261. or other vehicle driveline components 3 28 4 4x4 Transfer Case All Wheel Drive Operation of the vehicle in all wheel drive mode increases the wear on the driveline components tires and axles Avoid engaging the front axle drive except in slippery or off road conditions or premature component wear may result Use extreme caution when backing up a steep grade while the front drive axle is engaged Weight transfer from the rear axle to the front axle can cause overloading of the front drive gear and component damage may result Most Pierce Custom Chassis with all wheel drive use a power divider rear axle with integral transfer case Torque to the front axle is delivered via a clutched differential The front drive axle can be engaged or disengaged while the vehicle is in motion To Engage Front Axle Drive 1 Reduce vehicle speed to less than 50 mph Ensure that rear wheels are not spinning faster than the front wheels and that the steering wheel is centered Remove foot pressure from the accelerator pedal and allow vehicle to coast Shift engagement switch D Proceed with caution 3 92 Custom Chassis 2010 Pierce Manufacturing Inc All Rights Reserved OPERATION To Disengage Front Axle Drive 1 Remove foot pressure from the accelerator pedal and allow vehicle to coast 2 Shift engagement switch 3 Proceed with caution 3 28 5 4x4 All Wheel Drive and Two Speed Axle Combination On certain chassis model
262. ot oxidizes and turns into carbon dioxide gas This process is commonly known as regeneration Ash build up is removed from the filter by periodic cleaning in a special cleaning machine The typical ATD is equipped with two pressure transducers and three temperature transducers These sensors allow the engine to monitor soot build up for cleaning requirements Engine and ATD status is displayed by instrument panel lights Light functionality is explained in Instrument Panel Indicator Lights Detroit Diesel Engines on page 3 68 The second canister in the exhaust system contains the SCR device This device will reduce nitrogen oxide NOx emissions created during the combustion process The SCR is a catalytic converter that uses vaporized diesel exhaust fluid DEF DEF consists of purified water and urea an organic nitrogen compound that becomes ammonia when heated The combination of ammonia and nitrogen oxide in a heated environment creates a chemical reaction The reaction results in the release of nitrogen gas and water vapor both of which are found naturally in the atmosphere 3 12 6b Passive Regeneration The passive regeneration process allows cleaning of the DPF under normal engine operation and does not require operator interaction The operator will see no difference in vehicle performance or vehicle control When the engine has an adequate amount of exhaust heat the DPF can go through a passive regeneration process This occurs when th
263. otected The driver s seat pull down system and side air bags are ineffective unless the occupant wears the seat belt Children 12 years old and under should be seat belted in a back seat Never install a child seat in the front seat Pregnant women should consult their doctor concerning the proper use and positioning of seat belts Death or serious injury can occur Occupants 5 feet 1 4 inch tall or less weighing less than 107 5 Ibs or having a sitting height of 31 3 inches or less must ride in the crew cab seating area Death or serious injury can occur The Side Roll Protection System is a dynamic system that contains pyrotechnic devices that can be dangerous if modified or removed When activated in a side roll accident they will exhaust harmless blue smoke Never service attempt to salvage or reuse Side Roll Protection System components Never weld or apply heat on or near Side Roll Protection System components Never grind puncture or drill on Side Roll Protection System components The Side Roll Protection System will decrease the occupant s probability for injury when used properly In the event of a vehicle side roll accident the system will activate and there will be rapidly moving components Keep hands and other objects away from air bags seat belt buckles and suspension seat components Information on all component caution and warning labels must be complied with Labels are placed in visible locations on each component of
264. otective devices to fire ALWAYS deactivate the side roll protection system when performing an extrication if unfired protective devices are present Protective device actuators have cylinders containing high pressure gases and or pyrotechnics Hot pressurized gases are present in cylinders even after they have fired These cylinders should not be cut or punctured under any circumstances In case it is necessary to perform the extrication of an occupant of this vehicle performing any one of the following will disable the roll sensor and any unfired protective devices Deactivating the battery switch OR Deactivating the ignition switch OR Disconnecting the batteries OR e Cutting the wires to the protective device actuators 3 16 Custom Chassis 2010 Pierce Manufacturing Inc All Rights Reserved OPERATION Fired protective devices pose no toxic threat to rescue personnel After a side roll accident the seat belts on all the occupants will be tight but have specially designed buckles that can be released under belt tension Use extreme care when releasing seat belt buckles and exiting a damaged vehicle The ITS side air bag will be deployed and across the doorframe opening on the driver and first officer sides The ITS may be cut loose with a knife or scissors to facilitate egress of the occupants It is recommended to cut the black tethers to remove the side airbags The bags will be filled with warm inert gases The gase
265. ou don t know You must speak up about the things you don t know so you can learn about them before someone is injured or killed because of your lack of knowledge You are responsible for learning how to operate the fire apparatus under all conditions without having to read this manual at a fire or other emergency 2010 Pierce Manufacturing Inc All Rights Reserved Custom Chassis 1 1 TO THE OWNER 1 3 Warnings and Cautions 1 51 Warning and Caution Statements Throughout this manual you will find warnings and cautions Warnings will point out a procedure that must be taken or action that must be avoided to guard against the possibility of serious personal injury or death Cautions will advise you that there is a risk of damage to property if certain precautions are not followed Study this manual and the component operator manuals found in the service manual carefully and ensure that all operators and other users are fully familiar with their contents The warnings cautions and procedures listed in these manuals must be incorporated into the safety program of the fire department to which the vehicle is assigned 1 2 Custom Chassis 2010 Pierce Manufacturing Inc All Rights Reserved TO THE OWNER 1 3 2 General Warnings and Cautions Fire helmets shall not be worn by persons riding in enclosed driving and crew areas Fire helmets are not designed for crash protection and they will interfere with the protection pro
266. ox will not appear until WARNING or CAUTION message is received If a WARNING message is active the box will be red If a CAUTION message is active the box will be yellow If more than one message is active the active messages will alternate every two seconds Time and Temperature The time will be displayed in the upper left corner and the outside ambient temperature in the upper right corner Screen Navigation Buttons Each color display is equipped with five buttons The function of each button located along the bottom of the color display will change with each screen Basic Functions The MENU button will bring up a list of items for setting up the display or will allow maintenance personnel familiar with Command Zone electronics to access troubleshooting and analysis screens See Setup Diagnostics for additional information When the video function is enabled a camera or other video source can be viewed by pressing the VIDEO button The color display has an NTSC compatible video input This is generally used with a backup camera The PAGE button will toggle through screens with information pertaining to the vehicle or apparatus The screens vary depending on the options and status of the vehicle 2010 Pierce Manufacturing Inc All Rights Reserved Custom Chassis 3 79 OPERATION 3 22 2 Common Screens Do Not Move Truck Screen Figure 3 29 Do Not Move Truck Screen 0085 The Do Not Move Truck screen
267. paired by a qualified truck service facility Test Dual Air Brake System Warning Light and Buzzer A dual air brake system has two separate air brake systems that use a single set of brake controls Each system has its own air tank hoses lines etc One system typically operates the regular brakes on the rear axle or axles The other system operates the regular brakes on the front axle The first system is called the primary system The other is called the secondary system 1 Allow time for the air compressor to build up a minimum of 110 psi pressure in both the primary and secondary systems 2 Shutthe engine off when the air pressure rises sufficiently to shut off the low pressure light and buzzer 3 Shutthe ignition switch off and step on and off the brake pedal to reduce air tank pressure 4 Note the pressure at which the low air pressure warning signal alarm begins Alarm should signal before the pressure drops to less than 60 psi in the air tank with the lowest air pressure If the warning signal doesn t work the vehicle could lose air pressure without the knowledge of the operator This will reduce the effectiveness of the brakes and increase stopping distance Have the problem diagnosed and repaired by a qualified truck service facility Test That the Spring Brakes Come On Automatically The parking brakes should engage any time brake pressure drops below 40 psi Test this function as follows 1 Chockthe wheels 2 Allow air
268. pletely before using the vehicle Battery box distribution may be located under the driver s side battery box Battery box distribution is not waterproof but its components are and can be fully submerged Chassis rear distribution is located behind the fuel tank on units with aerial devices and in the substructure on pumpers If water has entered the box inspect the lid seal and ALL wires that pass through for leaks Seal or repair as instructed by Pierce Customer Service 3 31 Winch Operation Make only straight winch pulls and do not double the cable back to the vehicle using a snatch block Failure to observe these limitations may over stress the bumper or winch mounting and cause component failure leading to property damage personal injury or death Read the winch operators manual included in the Pierce Service Manual carefully before operating the winch and follow all winch manufactures safety precautions and guidelines Exercise extreme caution when operating any winch device Inspect the cable carefully before operation to ensure that there are no cut strands kinks or corrosion Operate the winch only with the remote control unit when under load and stand well clear of the path of the cable should it fail Orient the vehicle so that the winch cable will pull in a line perpendicular to the axis of the winch drum no side pulls 2010 Pierce Manufacturing Inc All Rights Reserved Custom Chassis 3 95 OPERATION
269. ponding to fire calls keep the vehicle connected to an external air pressure source whenever parked in the fire station If an external air source is unavailable the optional 120 volt on board compressor or optional 12 volt on board compressor can be used in its place If so equipped the vehicle should be supplied with a shoreline to operate the 120 volt compressor or a battery charger to supply the 12 volt compressor The compressor is located above the first officer side cab fender liner and can be accessed for service by removing the center section of the liner 3 8 2 Speed of Operation The speed at which the steps extend and retract is governed in part by the setting of the pressure regulation valve located above the fender liner on the first officer side of the cab This pressure has been preset at the factory to provide quick and smooth operation while minimizing objectionable noise The speed of operation will vary slightly with changes in temperature valve adjustment and lubrication 3 8 3 Step Actuation The air valves that control the extension and retraction of each step are located below the cab floor These brackets are designed to flex as the doors are closed Each step should retract as soon as the cab door is closed to the first catch of the latch 2010 Pierce Manufacturing Inc All Rights Reserved Custom Chassis 3 27 OPERATION 3 9 Cab Tilt Operation Remove all loose items from the cab compartment before tilt
270. pressure to build sufficiently to release the parking brakes 3 Step on and off the brake pedal to reduce the air tank pressure The parking brake knob should pop out when the air pressure falls to 40 psi This will engage the spring brakes and help to prevent the vehicle from moving 2010 Pierce Manufacturing Inc All Rights Reserved Custom Chassis 3 7 OPERATION Test the Rate of Air Pressure Buildup Time the rise in pressure from 85 to 100 psi with the engine at operating rpm Pressure should build from 85 to 100 psi within 45 seconds If the vehicle has larger than minimum air tanks the buildup time can be longer and still be safe If air pressure does not build up fast enough pressure may drop too low during driving requiring an emergency stop Do not drive until the problem has been repaired Test Air Leakage Rate 1 Run the engine to fully charge the air system to 125 psi 2 Turn off the engine and release the service brake 3 Time the air pressure drop The loss rate should be less than 2 psi in one minute for single vehicles 4 Apply 90 psi or more with the brake pedal After the initial pressure drop the pressure should not fall more than 3 psi in one minute If the leakage rate is greater than 3 psi per minute check for air leaks and fix before driving the vehicle Test Air Compressor Governor Cut In and Cut Out Pressures Pumping by the air compressor should start at about 100 psi and stop at about 125 psi 1
271. pull out in place of moving the toggle switch to the LOWER position To raise the cab this button must be pushed in and rotated clockwise 3 10 Cooling System Always allow the engine to cool before opening the pressure cap Wrap a thick heavy cloth around the cap Push down and turn the cap to the first notch position Pause before opening completely to allow any remaining pressure to escape Follow this procedure to avoid burns from hot steam or coolant Do not operate the engine if the cooling fan is worn notched bent damaged in any manner or comes in contact with any other chassis component while spinning or personal injury or death may result The optional emergency radiator refill feature allows the engine cooling system to be replenished with water supplied by the fire pump and tank This option should be used only in a true emergency Use of this option could lead to cooling system contamination clogging water pump damage or other problems If this option is used the cooling system should be flushed and refilled with properly conditioned clean coolant as soon as possible If the coolant is extremely low and the engine is very hot allow the engine to cool for at least 15 minutes before adding coolant to avoid thermal shock to the engine block resulting in serious engine damage or reduced component life Adequate coolant must be maintained in the cooling system to prevent engine overheat Check the coolant level by obs
272. quipped with Command Zone On multiplexed vehicles this information is monitored by the Command Zone system During a high temperature condition a text message caution light and chime tone are displayed on the Command Zone Information Center CZIC 3 28 3 Neutral to Drive Shift Growl Allison MD Transmission A growling noise may sometimes be heard in the cab when shifting the transmission from neutral to drive This is caused by electric solenoids within the transmission that control modulate the clutch hydraulic pressure These solenoids modulate clutch pressure by turning on and off very fast similar to the operation of an alternator voltage regulator Increasing or decreasing the time the solenoid spends in the on state controls the clutch pressure The rapid on off operation of the solenoids results in pressure oscillations at the clutch These pressure oscillations result in a cyclical piston load on the clutch which can cause torque oscillations These torque oscillations are transferred through the transmission and driveline into the axle axle shafts and any suspension members attached to the drivetrain If vehicle components such as body panels drivelines and frame members are excited by the frequency of the torque oscillations an audible noise may be heard inside the cab These torque oscillations and resulting noise are well below the design limits of the transmission and do not affect the life of the transmission
273. r death Tow hooks are provided to assist in pulling the vehicle from directly in front of or directly behind the vehicle with all wheels in contact with the ground Do not lift and tow vehicle from the tow hooks front bumper extension or rear platform Failure to observe these cautions may cause serious property damage Tow hooks and tow eyes may be found on the front or rear of many Pierce apparatus The specific location will vary based on the options selected These tow eyes and tow hooks may be used for towing disabled vehicles for short distances on flat and level surfaces in an emergency They are not meant for long distance towing on public highways 4 44 Custom Chassis 2010 Pierce Manufacturing Inc All Rights Reserved MAINTENANCE 4 25 5 TAK 4 Suspension Towing Towing of a vehicle equipped with the TAK 4 front suspension by attaching to or lifting by any component or structure of the TAK 4 assembly may result in damage to these components or assembly With some configurations of TAK 4 equipped apparatus towing will not be possible with the available equipment provided through local towing services Pierce Manufacturing recommends using the tire lift method for towing TAK 4TV however in many cases the lift system the truck configuration or both are not rated for the vehicle s weight on the front axle In the case of platform aerials the reach required for the lift device may degrade the device s liftin
274. ractor trailer combination during the procedure Failure to follow this procedure completely may result in areas of the bearing being under lubricated 1 Position the tractor trailer in a jackknife condition 90 degrees to one side 2 Putthe transmission in NEUTRAL and apply the parking brake 2010 Pierce Manufacturing Inc All Rights Reserved Custom Chassis 4 27 MAINTENANCE 3 Using a grease gun dispense two pumps of grease into each grease fitting Reposition the unit approximately 20 degrees from the jackknife position 70 degrees from straight ahead put transmission in neutral apply parking brake and dispense two more pumps of grease into each fitting 5 Repeatthis procedure every 20 degrees a total of 10 grease positions until the unit is in the opposite jackknife position 4 17 Frame 4 17 1 Welding on Frames Do not weld on heat treated frame rails or frame failure leading to property damage personal injury or death may result Pierce Custom Chassis frames are manufactured from high strength heat treated steel that will lose its strength when welded upon Do not weld on frame rails 4 18 Fuel System 4 18 1 Fuel Delivery System Inspect fuel system for signs of damage leaking or chafing Replace or repair as necessary 4 18 2 FuelFilters Diesel fuel injection nozzles are manufactured to an accuracy of a few thousandths of a millimeter and are matched precisely to each other Imp
275. re apparatus is no exception The following are some suggestions that may inhibit the effects of corrosion Thoroughly pressure wash the undercarriage of the apparatus frequently with plain water to remove salt and chemicals Apply a rust proofing compound to the undercarriage of the apparatus such as Ziebart Inspect the undercarriage regularly to identify any corrosion at an early stage Once identified the area should be cleaned thoroughly coated with a rust inhibiting system such as POR 15 and then painted Information on POR 15 can be found on their website at www por15 com Remove water from the floor where the apparatus sits Use a fan to keep the area dry Hose out the radiator with plain water Keep mud flaps in good repair to minimize salt chemical spray Avoid splicing into wiring If repairs are needed use shrink terminals Clean out electrical connectors regularly with plain water and re grease with dielectric grease 4 7 4 Chrome Cleaning Wash chrome parts using mild soap and water with a clean non abrasive towel After washing rinse with water and hand dry chrome parts If needed apply a soft non abrasive chrome polish Never use any products that scratch or chemicals that are abrasive as this will dull the chrome finish Do not use any acid or hydrozide based chemicals 2010 Pierce Manufacturing Inc All Rights Reserved Custom Chassis 4 9 MAINTENANCE 4 7 5 Waxing Instructions Avoid ha
276. reen displays automatically when the NOT MOVE TRUCK warning message is active Pressing any of the soft buttons on the right will cause that screen to appear Load Manager Screen Figure 3 27 Load Manager Screen v Volts 121 Air Cond Heater Fan DC Flood Lats Scene Lgts DS Scene Lats PS Scene Lots LR Scene Lots RR Compt Lats DS Compt Lats PS Compt Lots RR 500 4 OU amp Wh 0083 Load Manager Screen Figure 3 27 displays the status of each electrical function selected to be terminated as the electrical load exceeds the chassis alternator capacity Each truck is programmed to include a specific number of electrical devices that will be load managed and load sequenced Load management begins to shut off major electrical loads in a predetermined sequence as the vehicle electrical loads exceed the alternator capacity This Screen shows the real time status of the major electrical loads The load managing sequence is preset at the factory depending on the range of options and alternator capacity 3 78 Custom Chassis 2010 Pierce Manufacturing Inc All Rights Reserved OPERATION 3 22 Command Zone Information Center CZIC Color Display Figure 3 28 Command Zone Information Center CZIC Color Display 0084 3 22 1 Items Common to All Screens Caution and Warning Messages Messages will appear in a text box at the top of all screens The text b
277. rements 3 27 Air Reservoir Moisture Draining 3 23 Air Restriction Indicator 3 52 Alarms Screen 3 81 ALL STEERO All Wheel Steering 2 9 3 89 4 36 Alternating Current AC 4 19 Alternating Current AC Systems 120V 240V sers mate trei 4 19 Alternator 2 2 2 2 3 32 4 18 Aluminum Rear Disc Wheels with Flange Nuts Hub Piloted 4 55 Ammelter initie e E DRE EORR URNA RERO iE 3 32 Annual Maintenance Schedule 5 4 Antifreeze Solution Coolant Conditioner 4 15 Antilock Braking System ABS 3 21 2010 Pierce Manufacturing Inc All Rights Reserved INDEX Automatic Active Regeneration During Driving or Pumping Conditions Cummins 3 45 3 48 Automatic Lubrication System 4 1 Additional Information 4 1 Condition of Lube Points 4 1 Inspection 4 1 Reservoir 4 1 Automatic Tire Chains 3 90 Automatic Transmission 3 91 Auxiliary Braking System 3 24 Auxiliary Front Wheel Lock 3 23 Auxiliary Power Units APUS 4 19 Axle Weights and Axle Capacity
278. ropriate output pin location on the Power Module which in turn activates the device 4 8 3 Troubleshooting Tips Make sure you are properly trained before attempting to service a multiplex system Because of significant differences between traditional electrical systems and the multiplex system different tools and skills are required to troubleshoot multiplexing faults Command Zone Diagnostics This computer software is used to connect a conventional laptop PC to the vehicle s control module The software allows a mechanic to interrogate components within the multiplex system to determine the status of individual input and output circuits Input Output Sheets I O Sheets IMPORTANT 1 0 sheets be required to diagnose some multiplex related faults These sheets should be kept with the vehicle at all times Replacement I O sheets be obtained by contacting Pierce Manufacturing These vehicle specific information sheets are generated during the design of a new vehicle and are invaluable for troubleshooting Due to the wide range of custom equipment found on Pierce apparatus each electrical system is designed for that specific application sheets provide instructions for the specific input and output locations for each electrical circuit on the vehicle Limited wiring diagram information is also included on the sheets Component LED Heartbeat Red This is a blinking LED that is located on all multiplex modules Thi
279. route is in a safe low traffic area Before starting the brake burnish procedure make sure the brake chamber slack adjuster strokes both free and applied are within the brake supplier specifications For brakes without slack adjusters ensure that the caliper running clearance is correct Refer to the axle manufacturer s maintenance manual included in the Pierce Service Manual for maintenance schedules lubrication recommendations and inspection procedures The brake burnish procedure is called 30 30 30 and 5 Under safe conditions make 30 stops from 30 mph with a 30 second interval of time between each stop to allow the brakes to cool slightly The time it should take to stop from 30 mph to 0 mph is 5 seconds This will equate to a gentle stop During the burnishing procedure for new pads or shoes it is common to smell the resins coming out of the lining material This odor may disappear near the end of the burnish or shortly after the truck goes into service The brakes may also appear to be smoking Again these are the resins and other organic materials getting baked out of the linings If you suspect one of the brakes is not performing the way it should measure the brake rotor or drum temperature using an infrared hand held thermometer The infrared thermometer readings can vary depending on the location of the infrared beam on the object Try to get within 12 inches of the drum or rotor and always try to check the same area of the
280. rs to give each VDR a unique name This beneficial for customers whose vehicle fleet contain several vehicles equipped with VDRs e Extraction Tool This application is used to download data from the vehicle s VDR to a laptop computer Once downloaded the data is viewed using the Viewer Tool e Viewer Tool This application is used to view and manipulate the downloaded VDR data 3 30 Water Fording Capability 3 30 1 General Fording Instructions If the rear axle breathers are submerged for more than a brief period drain and replace the lubricant See axle manufacturer s lubrication specifications found in the Service Manual After fording lubricate all grease fittings below the fording depth to displace water and contaminated grease Failure to follow these precautions may lead to premature wear or damage to the axles suspension and driveline components For vehicles equipped with electromagnetic driveline retarders turn off retarder before fording water Inspect for debris and grease unit before returning the vehicle to service after fording Failure to follow these precautions may lead to damage of the retarder Low engine tunnel designs in some Pierce Custom Chassis models require the engine air intake port to be located at or below frame level This configuration places inherent restrictions on the ability of the apparatus to negotiate areas of high water Certain chassis components such as cooling fans and axle
281. rsepower Brake power e Frequency of tight cornering maneuvers Driving habits of acceleration and braking e Suspension alignment Expect faster tread wear on fire apparatus when compared to standard line haul trucks Fire apparatus accelerate faster brake harder corner tighter and have more horsepower flowing through the tires to the road than other heavy duty trucks with the possible exception of waste haulers Tandem axle aerial apparatus are particularly susceptible to accelerated tire wear due to the combination of the tandem scrub phenomenon and high suspension loading Over the road tractor tandems do not exceed 34 000 pounds loading whereas typical aerial apparatus tandems may be loaded from 44 000 pounds to 58 000 pounds or higher Since most aerial apparatus only operate in congested areas with taller buildings it is natural that they will experience a much greater proportion of their time in accelerating braking and cornering three of the most detrimental influences on tire life While the steering action of the ALL STEER all wheel steering option will reduce the negative influence of tandem scrub when cornering this advantage can be offset if the vehicle is subjected to dry steer or crab steer operation The single tires on the ALL STEER axle are also subjected to a higher load per footprint area and will naturally tend to wear faster than will dual tires at the same loading 4 24 5 Tire Rotation NOTE When rotating
282. ry caused by contact with protruding parts of the SCBA bracket during a collision Movable headrests must be placed in the closed position while the vehicle is in motion to reduce the risk of head injury during a collision Always leave the SCBA harness loose when riding in the seat Tight SCBA straps will add the weight of the occupant to the bottle and will pull the bottle out of the holder in the event of a crash The bottle restraining devices are designed for the weight of the bottle only SCBA bottles that are not secured properly can injure or kill in the event of a crash Seats equipped with SCBA brackets may be used by occupants without SCBA bottles by installing the seat back inserts Many SCBA bracket equipped seats include movable headrests that allow the SCBA bottle to be removed without interference with the headrest Refer to the SCBA manufacturer s operation manual for proper use instructions 3 18 Custom Chassis 2010 Pierce Manufacturing Inc All Rights Reserved OPERATION 3 3 6 Seat Adjustment Certain suspension style seats must be adjusted individually for each occupant to maintain adequate head clearance while the vehicle is in motion or death or serious injury may result Do not adjust driver s seat while vehicle is moving The seat could suddenly or unexpectedly move causing the driver to lose control of the vehicle Operating this vehicle over rough roads or surfaces can result in personal injury Use
283. s particularly with regard to the use of seat belts 1 4 Custom Chassis 2010 Pierce Manufacturing Inc All Rights Reserved TO THE OWNER Ensure that drivers have necessary driving skills and experience and provide them with periodic refresher training Consider terrain weather and bridge and road conditions when purchasing a mobile water supply vehicle Adhere to the requirements of NFPA 1915 for keeping a vehicle on a maintenance schedule and documenting the performance of the maintenance NFPA 20011 Inspect the complete vehicle at least once per year to comply with Federal and State motor vehicle regulations Adhere to the requirements of NFPA 1901 for an approved mobile supply vehicle NFPA 2001 Equip all vehicles with seat belts Ensure that water tank capacity is adequate and has proper tank mounting and sufficient front and rear weight distribution Ensure that the weight of the fully loaded vehicle does not exceed the gross axle weight rating of any axle and the gross vehicle weight rating of the chassis Ensure that the center of gravity of the vehicle does not exceed the chassis manufacturer s specified center of gravity Provide proper baffles to control water movement for all vehicles equipped with water tanks Verify that vehicles are of proper design and have adequate suspension steering and braking ability 1 7 2a All Drivers Should Do the Following Recognize that they are responsible for the safe and prud
284. s 3 9 SAFETY RESTRAINTS AND DEVICES sceceeceeeeceseccececececececssscssesenensneeeeeseseeseseseesoecececacscesssesesseseneneneeeees 3 10 eiu An Pt Se 3 10 3 32 SEAT BELT MONITORING SYSTEM 3 11 3 33 SIDE ROLL PROTECTION SYSTEM OPTIONAL 3 11 3 3 34 GENERAL DESCRIPTION 3 11 3 3 3b GENERAL WARNINGS AND CAUTIONS 2 1 444 0006 3 12 3 3 3 SIDE ROLL PROTECTION SYSTEM COMPONENTS 1 1 0444 8 3 12 ROLE SENSOR Rts ss rete T rte Mee tuta 3 13 SUSPENSION SEAT SAFETY SYSTEM 546 iii 3 13 INFLATABLE TUBULAR STRUCTURE SIDE AIRBAG 5 0040000 3 14 INTEGRATED GAS PRETENSIONER IGP INTEGRATED BELT PRETENSIONER IBP 3 15 INFLATABLE HEAD CURTAIN IHC SUPPLEMENTAL RESTRAINT AIR BAG SRA 3 15 3 3 34 WHAT TO EXPECT DURING THE DEPLOYMENT OF THE SIDE ROLL PROTECTION SYSTEM 3 16 DRIVER POSITION avene Ma zo av ae Dr sed e d Evae 3 16 FIRST OFFICER POSITION itor e tb ed ee eO e HR Exe a e rea 3 16 REAR OCCUPANTS teaser E verd tees eeu
285. s LED blinks at the rate of one blink per second and indicates that the module is capable of communicating with other modules on the data link Also a steady green LED indicates battery and ground to each module Input Module Clear Case Option A label identifies the input corresponding to the LED If the LED is on the module is seeing an input from a device Input Output Module Clear Case Option A label identifies the input output corresponding to the LED If the LED is on the module is seeing an input from a device or the module output is active 2010 Pierce Manufacturing Inc All Rights Reserved Custom Chassis 4 13 MAINTENANCE Output Power Module Clear Case Option A label identifies the output corresponding to the LED If the LED is on the module output is active Data Link Troubleshooting The data link consists of three wires two insulated wires and one shielding wire The two insulated wires are called CAN L and CAN H CAN Lis a green wire Pin CAN H is a yellow wire Pin A Secondary locks are installed on all data link connectors to prevent the data link from coming apart A 120 ohm terminating resistor plug is installed at each end of each J1939 data link When the system is functioning properly the system will read 59 61 ohms across pins A and B of the data link connector If this resistance is not maintained an intermittent system fail or communication lost message may appear on the CZIC A
286. s a 4x4 option is offered in conjunction with a two speed rear axle option This configuration is provided for those departments that require maximum grade climbing ability and 4x4 operation while still desiring normal highway speed capability This configuration provides an interlock so that the 4x4 mode is available only when the two speed axle is in low range Follow the same instructions for shifting into and out of 4x4 mode as outlined above but be sure that the two speed axle is in low range 3 28 6 Power Take Off Control During extremely cold weather hot shift PTO clutches may momentarily transmit power even though they are disengaged Never operate the engine with personnel in the vicinity of any driveshaft as it may engage without warning Hands clothes hair etc can get caught on spinning shafts and U joints Failure to heed this warning may lead to personal injury or death Engage Power Take Off PTO operated accessories with engine at idle speed Consult the PTO operator s manual for further explanation Refer to the Power Take Off Operation section of the Allison Transmission Operator s Manual for additional operation instructions 3 29 Vehicle Data Recorder VDR Most Pierce apparatus are equipped with a Vehicle Data Recorder VDR The VDR is capable of reading and storing the most recent 100 hours of vehicle information The VDR is capable of operating in a voltage range from 8VDC to 16VDC and will continue opera
287. s essential to safe economical trouble free service Use only the specified sizes of studs nuts and clamps Check all parts for damage including wheels and rims Ensure that studs nuts and mounting faces of hub and wheels are sound clean and free from grease Clean hub surfaces with wire brush if scale is present Do not lubricate wheel studs Replace any damaged parts Consult wheel manufacturer s installation procedures for detailed instructions and replacement part recommendations 4 29 3 Hub Piloted Wheel Installation Hubs designed for steel hub piloted wheels may not have sufficient depth or stud length to properly accommodate aluminum wheels Installation of hub piloted wheels on a hub with insufficient pilot depth or stud length may cause wheel assembly failure leading to loss of vehicle control personal injury or death Slide front wheel or inner rear wheel over studs being careful not to damage stud threads Slide outer rear wheel over studs Snug up flange nuts alternately in the sequence shown Rotate wheel assembly one half turn to allow the wheel to seat DO NOT tighten them fully until all have been seated This procedure will permit the uniform seating of nuts and ensure the even face to face contact of wheels and hub 4 52 Custom Chassis 2010 Pierce Manufacturing Inc All Rights Reserved MAINTENANCE Figure 4 14 Wheel Nut Tightening Sequences 10 8 3 o 50 4 Hub Pilot Front and
288. s will be nearly invisible but will have an acrid smell The gases pose no harm to occupants or rescue personnel Pierce Customer Service must be notified whenever the Side Roll Protection System has been activated DO NOT remove or tamper with any Side Roll Protection System components except to extricate the occupants Returning to Service Do not attempt to remove any Side Roll Protection System components Any component that did not completely deploy requires special precautions Contact Pierce Manufacturing for disposal instructions for system components After the system is activated the major components of the Side Roll Protection System will be deployed and cannot be reused The Suspension Seat Safety System S4S Inflatable Tubular Structure Side Airbags ITS roll sensor s Integrated Gas Pretensioners IGP Integrated Belt Pretensioners IBP and Inflatable Head Curtains IHC Supplemental Restraint Airbags SRA must be replaced In addition the wiring harnesses will require inspection and possible replacement After all system components are inspected and or replaced the integrity of the system must be checked by a Pierce authorized technician This service must be performed by Pierce Manufacturing or a Pierce authorized service facility 3 3 4 Frontal Impact Protection Optional The cab may be equipped with a frontal impact protection system consisting of an air bag in front of the driver a knee bolster air bag in
289. s with a clean soft non abrasive cloth or chamois Allow to completely dry in an environment where relative humidity is below 6096 As a rule pressure washing should only be done on the underside of the vehicle Pressure washing should not be done on any surface that has Goldstar gold leaf vinyl striping labels or overlays When washing using high water pressure all grease fittings outside and underneath the vehicle chassis must be lubricated after washing to dissipate water and contaminated grease Wash the vehicle only when dirty Excessive daily washing should be avoided unless the vehicle is dirty To remove light dust without getting the truck wet wipe off with a clean damp cloth or chamois A dry wash commercial product can also be used to remove light soils Follow product manufacturer s instructions Wash all soils off as soon as possible especially road salts fuel industrial fallout etc from inside and outside surfaces Tar removal can be done with Naphtha thinner applied with soft tissue or with a commercially available tar remover follow product manufacturer s instructions Rust and tarnish removal can be cleaned away with a special mixture of 1 part laundry detergent 1 part kerosene and 1 part lukewarm water After washing and rinsing or after vehicle use in the rain always blow dry or wipe dry with a soft cotton towel especially areas that will trap water Open up all doors and dry off the interior surfaces
290. se and throat To remove R134A from air conditioning system use equipment certified to meet SAE J2210 If R134A discharge occurs ventilate work area before resuming service Additional health and safety information may be obtained from refrigerant and lubricant manufacturers The air conditioning system should be shut down prior to tilting the cab Failure to do so will result in water condensation build up in the evaporator cover This water will drip out through the openings in the cover and can pour out as the cab is tilted down after service NOTE Do not add refrigerant unless the system is checked for leaks and any leaks found are repaired The air conditioning system should be checked at the start of the warm weather season The service should include cleaning of the condenser fins and a refrigerant level check Charge requirements for the system can be found on a tag on the rear unit Drive belt tension should also be checked at this time Some units will have air intake filters This filter must be replaced if it becomes dirty Condition of the filter will be based on conditions and use Overhead units have a drain pan and hoses to direct condensed water to the outside of the vehicle Clean the pan and make sure hoses are not blocked The pan may have a foam pad that prevents water from sloshing Replace the pad as necessary Inspect all vents for looseness and operation Replace if necessary 4 30 Custom Chassis 2010 Pierce Manu
291. sed and applied to its full capacity when the brake pedal is depressed Hand Lever Control The retarder is applied when the throttle pedal is released The percent of application is controlled by a six position hand lever Foot Pedal The retarder is applied when a dedicated foot pedal is depressed Retardation force increases proportionally as the pedal is depressed farther 2010 Pierce Manufacturing Inc All Rights Reserved Custom Chassis 3 25 OPERATION Overheat Warnings Because the retardation force is created by the churning action of transmission fluid within the retarder housing a significant amount of waste heat is generated This heat is transferred to the radiator coolant via a shell and tube heat exchanger The radiator is thus ultimately required to dissipate heat generated both during vehicle acceleration engine and transmission heat load and during braking retarder heat load During heavy use and high ambient temperatures the extra heat load created by the retarder may exceed the rate at which the cooling system can dissipate the transmission fluid heat load at the shell and tube cooler or the total heat load at the radiator The vehicle operator must observe the transmission temperature gauge amp warning lights and reduce retarder use if the transmission fluid temperature climbs too high When the cooling system capacity is exceeded the transmission ECU will begin to cut back on the retardation output to limit th
292. seness Hub oil level OK No leaks apparent Left Front Suspension Spring spring hangers shackles U bolts are in good condition Shock absorber shows no sign of excess wear or damage Torsion bar is not damaged and tape is not cut or torn TAK 4 suspension only Refer to Pierce Service Manual group 0152 P 002 TAK 4 Independent Front Suspension 3 4 Custom Chassis 2010 Pierce Manufacturing Inc All Rights Reserved OPERATION Left Front Brake Brake drums or rotors are not cracked or worn Hoses show no signs of excessive wear Front Front axle shows no signs of damage or excessive wear Steering linkages are tight and show no signs of damage Grasp each steering link and test for looseness Windshield is clean and shows no sign of cracks or other damage Perimeter seal is holding windshield glass firmly in place Windshield wiper arms have proper spring tension Wiper blades are in good condition Front Lights and Reflectors Parking clearance and identification lights clean operating and proper color amber at front Reflectors clean and proper color amber at front Q Turn signal lights clean operating and proper color amber or white on signals facing forward Right Front Wheel Wheel and rim are in good condition no missing bent or broken studs clamps or lugs Show no signs of misalignment Condition of tires properly inflated valve st
293. should be permanently mounted on the roof of the vehicle antenna cable should be high quality fully shielded coaxial cable and kept as short as practical Avoid routing the antenna cable in parallel with vehicle wiring over long distances Carefully match the antenna and cable to the radio to achieve a low Standing Wave Ratio SWR and to avoid HF currents on the antenna cable shield All installations should be checked for possible interference between the communications equipment and vehicle electronics Mobile radio equipment with greater than 150 watts output may require special precautionary measures beyond those outlined in this document This pamphlet is provided as a supplement to the radio manufacturer s installation instructions for installing communications equipment in Pierce apparatus Additional sources of information are listed in Additional Information on page A 3 Radio transmitters are regulated by the Federal Communications Commission FCC in the United States Compliance with FCC regulations is the responsibility of the manufacturer and or user of the transmitter equipment not Pierce Manufacturing 2010 Pierce Manufacturing Inc All Rights Reserved Custom Chassis A 1 MOBILE RADIO INSTALLATION GUIDE 2 Installation Guidelines 2 1 Transceiver Location A transceiver location should be selected that provides a solid mounting point which does not interfere with the vehicle operator controls a
294. sion Steering Gear Lubricate with Lithium NLGI grade EP2 grease 6 Months Tire Alignment Front Check toe in on front tires 6 Months Axle Transmission Fluid Trucks in severe duty applications or trucks equipped 12 000 6 months or with transmission retarders should have transmission 500 hours fluid tested for water and glycol contamination See Transmission Fluid Analysis Allison Transmissions on page 4 49 for additional information Custom Chassis 5 3 SERVICE AND LUBRICATION INTERVALS Table 5 7 Annual Maintenance Schedule Description Action Miles Time Air Cleaner Replace air cleaner or filter element Annual or as required Axle Front Kingpin Lubricate with Lithium NLGI grade EP2 grease 100 000 Annual Axle Tie Rod Ball Lubricate with Lithium NLGI grade EP2 grease 100 000 Annual Joints Spring U Bolts Check torque and tighten as required 24 000 Annual Steering Drag Link Ball Lubricate with Lithium NLGI grade EP2 grease 100 000 Annual Joints Steering Hydraulic Replace filter and hydraulic fluid in power steering Annual System reservoir s with DEXRON III Table 5 8 3 5 Year Maintenance Schedule Description Action Miles Time External Transmission Replace external transmission cooler See External 3 5 years Cooler Transmission Coolers on page 4 49 for additional information Table 5 9 Vendor Component Maintenance
295. sion care must be taken to ensure that no damage to the chassis occurs Securing the disabled vehicle to the tow vehicle may require some disassembly and is the responsibility of the tow vehicle operator Pierce Manufacturing does not warranty any damage that may occur due to improper towing The figures below give suggested areas where the frame forks may be attached to the frame extension Figure 4 13 Possible Frame Fork Attachment Locations POSSIBLE FRAME FORK ATTACHMENT LOCATIONS 0104 0105 0106 4 26 Transmission 4 26 1 Transmission Fluid When changing to a different type of transmission fluid care should be taken to purge the system of the old fluid before installing the new fluid See the transmission manufacturer s Operator s manual for recommended fluids and viscosity grades 4 48 Custom Chassis 2010 Pierce Manufacturing Inc All Rights Reserved MAINTENANCE 4 26 2 Transmission Fluid Analysis Allison Transmissions The presence of water and or ethylene glycol coolant mixtures in the transmission oil is detrimental to the reliability and durability of the internal components This foreign liquid has a deteriorating effect on non metallic components rubber gasket material etc and on highly loaded steel parts such as bearings and gears due to reduced lubricity Frictional capacity of drive clutch plates can be greatly reduced as a result of surface film or impregnation and the presen
296. sion must be in neutral confirmed by looking at the Allison Transmission Shift Selector and seeing current gear and selected gear are neutral N 5 Engine control mode from accelerator pedal not PTO remote PTO cruise control etc When a stationary regeneration event is initiated the DPF light will go off As the engine adds hydrocarbons to the exhaust stream the exhaust system temperature goes up When the exhaust temperature goes above 977 525 C the HEST light will illuminate Engine speeds will be increased and the sound coming from the turbocharger will change during the stationary active regeneration process ISL engines will increase speed to 1000 rpm ISX 11 9 engines will increase speed to 960 rpm ISX 15 engines will increase speed to 900 rpm The procedure will take 20 to 40 minutes depending on the amount of soot accumulated in the filter Breaking any of the required conditions will stop the regeneration process and engine operation will return to normal If excessive soot build up remains in the DPF the DPF light will return to the appropriate indication stage until an adequate regeneration occurs After completion of regeneration the HEST light will remain illuminated until the exhaust outlet temperature is below 977 F 525 C or the vehicle speed exceeds 5 mph Automatic Active Regeneration During Driving or Pumping Conditions The following vehicle conditions must be satisfied before the engine will initiate an auto
297. sitant Pa RD A E A DER RR 3 26 OPERATION IN HIGH AMBIENT TEMPERATURE CONDITIONS 2 201 1 66 3 26 OCCUPANT CAPACITY r wd AN P n a a www 3 26 STEP OPERATION QUANTUM 3 27 3 8 1 AIR PRESSURE REQUIREMENTS 3 27 3 8 2 SPEED OF OPERATION 21 2 3 27 328 3 STEP ACTUATION 0 3 27 GAB TILT OPERATION 024 E RW R Un a o Gua pa sans 3 28 3 971 GAB JEIET SYSTEM SABERDB ins bid a c addc 3 29 JTOPRAISEIGAB N eps E A e hereto T o e EORR RAN 3 29 TO LOWER ge deed drea e aver New ve tia va lat un adu dena eov e ea Pa sd wr D va ru ve ro d daa n de 3 29 3 9 2 LIFT SYSTEM ARROW XT QUANTUM ss nennen 3 29 TO RAISE CAB c eria te oque ed d date ann a bre c oo dE es un o Odd d 3 29 TOSEOWER GAB dde s ons Ferro aan costed OR
298. systems Traditional truck electrical Systems Figure 4 2 use individual wires switches and components to operate discrete systems This usually results in the use of large power distribution boxes and large main wiring harnesses Many electro mechanical relays are also needed to perform operational interlock functions The Pierce Command Zone multiplex system Figure 4 3 uses a single three wire wire harness or data link to connect switches and controls inputs to system loads and devices outputs The use of this single data link vastly reduces the amount of wiring used within an electrical system System inputs and outputs are connected to modules located along the single data link The input from several switches is combined together in an input output or input module which connects to the data link Similarly many outputs are connected together in an output module or power module which also connects to the data link In most cases the power module controls the higher amperage load of the components A control module is used to interpret switch functions facilitate communications with other multiplex devices and perform desired interlock functions Additional information on the Command Zone system can be found in the Pierce Service Manual group 0950 P 009 Command Zone Advanced Electronics 4 8 2 Multiplex System Principals of Operation Figure 4 4 Pierce Multiplex System Operation Data Link Cable Data Link Ca
299. t those specifications The information in this manual will be generic at times Due to the highly customized nature of each Pierce fire apparatus the exact location of each component in the pumper system will vary This manual describes basic controls Not every apparatus will have all controls Some will have extra controls as determined by each fire department s specification Pictures describe typical components or devices Actual parts might vary from those pictured You must learn the location and function of all controls switches gauges valves inlets and discharges Major inconsistencies between your vehicle and the information contained in this manual should be directed to your Pierce Dealer or Sales Representative 1 6 Vehicle Handling Characteristics Safe operation of any vehicle is the responsibility of the driver Heavy trucks have a significantly higher rollover tendency than other types of vehicles due to a higher center of gravity To reduce the risk of rollover avoid making sharp turns at excessive speeds and other abrupt maneuvers In the event of a rollover crash an unbelted person is significantly more likely to become injured or die than a person wearing a seat belt Unbuckled occupants can also become a hazard to other occupants as they may be thrown around inside the cab in the event of a crash ALWAYS BUCKLE UP 1 7 Tanker Mobile Water Supply Truck Characteristics 1 7 1 Description of Hazard Mo
300. tand fire apparatus operation and or maintenance All Pierce vehicles are delivered with a set of manuals for major components that your fire department selected If you need replacement manuals or safety warning labels contact your authorized Pierce selling or servicing dealer BEFORE operating the fire apparatus you the operator or maintainer must read understand and follow the instructions found in Pierce operator and maintenance manuals e Operator and maintenance manuals from the manufacturers of major components used on the apparatus such as engine transmission etc FSTA Pumping Apparatus Driver Operator Handbook latest edition Proper tools and service equipment must be used taking appropriate precautions as required by accepted safety practices to prevent personal injury and or equipment damage 1 2 What To Do If You Lack Knowledge Fire apparatus control systems require you to understand the function of each switch gauge valve control etc Before your fire department allows you to operate this fire apparatus you already must be educated and trained in fire apparatus operations You also must know the principles of operation so you can change operation when circumstances change Each switch gauge valve and control has an important function If you are uncertain about the function or don t know something inform your fire department s training officer You are the only person who knows what y
301. tay with the vehicle throughout the regeneration process The procedure will take 20 to 40 minutes 3 Locate the regeneration switch located in the cab This is a momentary style switch Quantum located next to the engine diagnostic connector and diagnostic switch below the dash panel Velocity Impel located next to the engine diagnostic connector and diagnostic switch below the dash panel Arrow with Hardwired Electrical Systems located on the switch panel right of the dash panel Arrow XTTM with Multiplexed Electrical Systems located next to the engine diagnostic connector and diagnostic switch below the dash panel Cycle the parking brake OFF to ON once an ignition cycle Parking Brake must be ON Engine speed should be at idle 6 Cycle the transmission from Drive to Neutral The transmission must be in neutral confirmed by looking at the Allison Transmission Shift Selector and seeing current gear and selected gear are neutral N 7 Vehicle speed must be 0 mph 8 Hold the regeneration switch to the ON position for five seconds and release When the request is accepted the DPF light will illuminate for one second and then go off for the rest of the parked regeneration The engine speed will increase to 1100 rpm during a parked regeneration The HEST light will not illuminate until exhaust temperatures exceed the temperature threshold Breaking any of the required conditions will stop the p
302. tection System General Warnings and Cautions 3 12 Side Roll Protection System Returning to ince ike 3 17 Side Roll Protection System What to Do After a Deployment 3 16 Side Roll Protection System What to Expect During the Deployment 3 16 Speed of Operation 3 27 Speedometer and Odometer 3 34 Spring PINS Tm 4 35 Custom Chassis Index 5 INDEX Spring Suspension Front and Rear 4 34 Spring Suspensions Spring U Bolts 2 10 eoe 4 34 Stability Control 3 88 Starter and Ignition Switches 3 35 Starting Engine Using Power From Another Vehicle 3 51 Starting the Engine 3 36 St rindi 3 89 4 35 Steering Column Adjustment 3 89 Steering Reservoir 4 35 Steering System Fastener Torque 4 36 Steering Wheel Controls 3 67 Step Actuation 3 27 Step Pivot Components 4 5 Step System Air Dryer 4 4 Step System Pressure 4 4 Step Valve Adjustment 4 5 Stopping the Engine
303. tem with clean water Run engine until warm shut off engine reopen radiator drain valve and remove plugs Repeat these steps until the water drained from the system runs clear Close the radiator drain valve tightly and replace plugs NOOR D Fill system with coolant 2010 Pierce Manufacturing Inc All Rights Reserved Custom Chassis 4 15 MAINTENANCE 4 9 7 Coolant Fill Procedure Do not overfill with coolant as this may degrade cooling system performance Park vehicle on level surface Set all heater controls to the hottest position and verify that heater shut off valves are open Fill system with the proper coolant mixture to the top of the sight glass D Run engine at idle speed for 3 minutes full throttle for 5 minutes and idle again for 2 minutes Note any electronic warning system messages displayed on the instrument panel If the low coolant warning is displayed shut off engine immediately and add coolant up to the level of the sight glass and repeat this step 5 Shut off engine and add coolant up to the level of the sight glass if required 4 10 Doors and Windows 4 10 1 Latches and Window Regulators Door latches and window regulators require lubrication to reduce component wear and continue to operate smoothly To ensure smooth operation remove the door panel and lubricate all moving parts on latches paddle handles linkages and regulators The door latch mechanism requires specific att
304. tener Torque Chart Torque Component Location Fastener Size Ft Lbs N m Steering Gear Saber amp Two top bolts securing the steering gear to the frame 7 8 9 UNC 364 494 Steering Gear Saber amp Two allen head bolts securing steering gear to the bracket 7 8 9 UNC 576 781 Steering Gear Saber amp Lower left bolt securing bracket to the frame 5 8 11 UNC 201 272 Steering Gear Saber amp Lower right bolt securing bracket to the frame 3 4 10 UNC 357 484 Steering Gear Quantum Two top bolts securing the steering gear to the bracket 7 8 9 UNC 364 494 Steering Gear Quantum Two top bolts securing the bracket to the frame 3 4 10 357 484 Steering Gear Quantum amp Two bottom bolts securing the bracket to the frame 7 8 9 UNC 364 494 Steering Gear Arrow Top bolt securing the steering gear to the bracket 7 8 14 UNF 635 860 XT Velocity Impel Steering Gear Arrow Six lower bolts securing the steering gear to the bracket 3 4 16 UNF 398 539 XT Velocity Impel Steering Gear Arrow Four Bolt pattern securing steering gear bracket to frame 3 4 10 UNC 357 484 XT Velocity Impel Steering Gear Arrow Six bolt pattern securing steering gear to bracket 3 4 16 UNF 398 539 XT Velocity Impel Steering Gear Arrow Lower bolt securing steering gear to bracket 7 8 14 UNF 635 860 XT Velocity Impel Steering Shaft Gear Box Bolts securi
305. than the wheels of the other axle in order to compensate for cornering uneven road surfaces and slightly different tire sizes When encountering soft or slippery road conditions the IAD can be locked out eliminating any differential action between the axles Lock the inter axle differential and achieve maximum pulling power when approaching slippery or poor road conditions After engaging the IAD Lock switch and proceeding at a slow even speed let up momentarily on the accelerator pedal to allow the lock to engage Proceed over the poor road conditions cautiously Once road conditions have improved move the IAD Lock switch to the UNLOCK position while maintaining vehicle speed Let up momentarily on the accelerator to allow the lock to disengage Resume driving at normal speed 3 44 Two Speed Rear Axle The two speed rear axle switch permits selection of either the high or low axle ratio Downshift Move selector switch to low Release and depress the accelerator quickly Upshift Move the selector switch to the high range with the accelerator depressed Release the accelerator and pause until the shift is complete 3 20 Custom Chassis 2010 Pierce Manufacturing Inc All Rights Reserved OPERATION 3 5 Brakes Brakes and brake systems must be maintained and adjusted properly Failure to properly maintain or adjust the brakes can lead to reduced brake performance property damage or personal injury 3 5 1 Downhill Oper
306. the Side Roll Protection System If labels have been removed or are not visible please contact your Pierce Dealer for the proper replacement labels Keep hands and other objects out of deployment path of side air bags suspension seat and seat belt buckles Such objects could prevent the air bag from inflating properly or cause injury or death to the occupant when the devices activate 3 3 3c Side Roll Protection System Components The system is composed of the following major components Roll Sensor Suspension Seat Safety System 545 Inflatable Tubular Structure Side Air Bag ITS Integrated Gas Pretensioner IGP or Integrated Belt Pretensioner IBP and Inflatable Head Cushion IHC or Supplemental Restraint Air Bag SRA optional 3 12 Custom Chassis 2010 Pierce Manufacturing Inc All Rights Reserved OPERATION Roll Sensor Figure 3 1 Roll Sensor 0099 The roll sensor triggers air bags and seat restraints Accidental deployment can cause serious injury e Service the roll sensor s only if you are an authorized technician Never remove the roll sensor Removing the roll sensor will turn OFF and or trigger deployment of the air bags and seat restraints BEFORE welding disconnect the roll sensor and refer to Welding Instructions on page 4 50 for additional welding information e BEFORE disconnecting the roll sensor remove the electric power The roll sensor monitors the vehicle s angle a
307. the transmission range selected 3 24 Custom Chassis 2010 Pierce Manufacturing Inc All Rights Reserved OPERATION 3 6 3 Electromagnetic Retarder The electromagnetic retarder Telma or equivalent may be mounted in the driveline or attached directly to the rear axle When activated electrical power is supplied to a series of coils in the retarder that create an electromagnetic field This field inhibits the rotation of the rotor and creates a braking torque at the rear wheels Various options allow the retarder to be applied in stages either manually or by combinations of brake and accelerator pedal settings Heat generated by the retardation effect is dissipated by cooling fins on the retarder 3 6 4 Hydraulic Retarder Observe the following cautions when driving a vehicle equipped with a hydraulic retarder Apply and operate the retarder only when the engine is at closed throttle Observe transmission and engine temperature limits at all times Select the lowest possible transmission range to increase the cooling system capacity and total retardation available In the event of overheating decrease the use of the retarder use service brakes Observe the retarder over temp light to ensure that the vehicle control system is functioning properly Refer to the Allison Transmission operator s manual for additional cautions The hydraulic retarder Allison Transmission Retarder or equivalent uses the viscous property o
308. ther Vehicle Pierce Custom Chassis have a 12 volt negative ground electrical system Before using jumper cables make sure the booster vehicle also has a negative ground system negative terminal attached to a metal part of the vehicle If unsure of the booster vehicle s voltage or ground do not attempt to jump start as personal injury or severe damage to the electrical system may result The following procedures must be performed exactly as outlined Otherwise injury to the face eyes body limbs and respiratory system could result from fire or acid due to battery explosion Property damage could also result To avoid damage to vehicle electronic components voltage supplied to a vehicle s electrical system must not exceed 16 0 volts If the battery charge is insufficient to crank the engine the following procedure may be used to supplement battery power 1 8 To prevent shorting of the electrical system remove metal rings watches or other metallic accessories and do not allow metal tools to contact positive terminal of battery Position the vehicles so the jumper cables will reach easily between the batteries Do not allow the vehicles to touch Turn off all electric motors and accessories in each vehicle Turn off all lights not needed to protect the vehicles or to light the work area In each vehicle stop the engine turn off the warning light master switch Apply the parking brake and shift the transmission to Neutral
309. tion 3 17 Fuel Delivery System 4 28 ie caca euni secca e eee 4 28 Fuel System 4 28 Fuses and Circuit Breakers 3 34 G General Fording Instructions 3 94 General Inspection 4 4 4 35 General Inspection and Service 4 14 General Warnings and Cautions 1 3 Goldstar Striping Repair Instructions 4 11 Grade Holding and Brake Burnishing 3 24 Graphics Lettering and Striping 4 7 Grease Fitting Location Fifth Wheel Bearing 4 27 H Hand Throttle 3 54 Hazard Flashers 3 35 Heat 3 61 Heater raser erede zie eoe Dyer d ends 3 57 Heater Shut Off 2 4 29 Heater Defroster 3 57 Heaters Floor Arrow XT 3 60 Heating Ventilation Air Conditioning HVAC 3 56 3 60 4 29 Heating Ventilation Air Conditioning HVAC 3 61 High Heat Sources 3 56 High Voltage Equipment Before Servicing 4 20 Custom Chassis Index 3 INDEX HINGES ss paire tI 4 17 Hose CAMP ci 25 aet dete eer Rod 4 15 HOSES Re I MIL ne 4 15 FOU TTietet rea iex oe ee need
310. tion The switch remains in the OFF position throughout the welding process Before disconnecting any electronic component connection disconnect the negative battery connection from each bank of batteries The battery cables remain disconnected throughout the welding process Electronic components are reconnected after all welding is completed After reconnecting the required electronic component connections reconnect the negative battery connection for each bank of batteries 2010 Pierce Manufacturing Inc All Rights Reserved Custom Chassis 4 51 MAINTENANCE 4 29 Wheels 4 29 1 Bearings Inspect wheel bearings in accordance with the axle manufacturer s recommended schedule Use inspection procedures found in the axle manufacturer s maintenance manuals 4 29 2 Wheel Installation General Improper installation methods or component selection can cause loss of torque broken studs or cracked wheels Improperly seated wheels can run loose cause stud breakage or disengage from the vehicle Any of these problems may lead to loss of vehicle control serious property damage personal injury or death Wheel nuts must be checked for proper torque after the first 50 to 100 miles of service then frequently as part of periodic maintenance Failure to verify wheel nut torque may lead to loss of vehicle control serious property damage personal injury or death Proper installation of rims and wheels on a vehicle i
311. tion recommendations and inspection procedures It is the owner s responsibility to ensure that the engine is maintained properly Retain all service reports and receipts and transfer these records in the event that the vehicle changes hands Use only genuine Original Equipment Manufacturer OEM parts or parts of equivalent quality and functionality when servicing engines Replacement of parts with those of inferior quality may lead to lower performance reduced engine life or component failure 4 13 6 Engine Mount Isolators Inspect the engine and transmission isolators for cracks debonding or other signs of excessive wear Replace worn isolators with Pierce supplied parts only to ensure that proper isolation is maintained 4 13 7 Engine Diagnostic Software Detroit Diesel 2010 EPA Detroit Diesel engines require Detroit Diesel Diagnostic Link DDDL software version 7 06 for diagnostic support The DDDL 7 06 package supports both 2010 EPA and older engines Contact a Detroit Diesel service location to obtain a copy of DDDL 4 13 8 Engine Diagnostic Software Cummins 2010 EPA Cummins engines require Cummins Insite software version 7 4 2 or newer for diagnostic support Contact a Cummins service location to obtain a copy of Cummins Insite 2010 Pierce Manufacturing Inc All Rights Reserved Custom Chassis 4 23 MAINTENANCE 4 14 Exhaust System On all 2007 EPA amp 2010 EPA diesel engines the exhaust temperature ca
312. tion upon termination of power or at voltages below 8VDC for a minimum of 10ms The VDR will not interfere with suspend or delay any communications that may exist on the CAN data link during the power up initialization runtime or power down sequence The vehicle data recorder is capable of recording the following data via hard wired and or CAN inputs e Vehicle Speed MPH Acceleration MPH sec e Deceleration MPH sec e Engine Speed RPM Engine Throttle Position of Full Throttle ABS Event On Off e Seat Occupied Status Yes No by Position 1 6 Seating Capacity e Seat Belt Buckled Status Yes No by Position 1 6 Seating Capacity Master Optical Warning Device Switch On Off Time 24 Hour Time Date Year Month Date 2010 Pierce Manufacturing Inc All Rights Reserved Custom Chassis 3 93 OPERATION Stored VDR data can be downloaded and viewed using a laptop computer and the Weldon Vehicle Data Recorder Software provided with your vehicle on a CD ROM Pierce PN PV C SW490 This software can also be downloaded from www weldoninc com The Weldon Vehicle Data Recorder Software contains three different software applications The purpose of each software application is explained below e Configuration Tool This application is used to name individual VDR modules change the password required to access data and synchronize the clock if necessary The ability to name individual VDRs permits custome
313. tires with Counteract balancing beads the technician should strike the tire tread to dislodge the beads to promote rebalancing in the new axle position See Balancing on page 4 42 Front Tires If irregular tire wear is found on the front axle tires they should be moved to the rear axle position if same size and tread pattern or replaced Rear Tires If irregular wear such as heel and toe or alternate lug wear occurs the tires should be rotated to reverse the rotation of the tires In tandem axle units swap the right rear tire pair with the left front pair keeping the outside tires in the outside position Swap left rear and right front pairs in the same manner 2010 Pierce Manufacturing Inc All Rights Reserved Custom Chassis 4 41 MAINTENANCE 4 24 6 Balancing Wheel and tire assemblies should be balanced to avoid vibration or shimmy during road operation Pierce balances all tires and wheels by adding Counteract balancing beads to the tire wheel during assembly Once the balancing beads are installed inside the tire it is not possible to see them no lead weights are used The beads automatically balance the complete wheel assembly as the tire rotates The beads balance not only the tire and wheel but also the hub and brake assembly of the axle The beads continually adjust to changes on the tire and wheel to maintain balance As the tire wears the beads will adjust properly so the assembly is always in balance The beads
314. to the rear wheels The use of an auxiliary brake reduces brake wear reduces brake heat buildup and can help to minimize the occurrence of brake fade during heavy or frequent braking An Electronic Control Unit ECU in the Antilock Braking System ABS monitors the wheels and turns off the auxiliary brake if it senses that the wheels are not spinning at the same speed The ABS ECU does not know to turn off the auxiliary brake until an ABS event has already occurred In the split second between the ABS sensing the skid and the time it takes for the auxiliary brake to shut off there may be a skid initiated For this reason Pierce Manufacturing recommends turning off the Auxiliary Brake System during slippery conditions 3 6 1 Compression Brake The compression brake Jake Brake or equivalent is an electronically actuated mechanical system added to the engine valve train When activated the compression brake alters the operation of the engine s exhaust valves so that the engine works as a power absorbing air compressor 3 6 2 Exhaust Brake The exhaust brake Extarder Blue Ox or equivalent consists of a flapper valve installed in the exhaust pipe between the engine and the muffler When activated the flapper restricts the passage of the exhaust gases and increases the back pressure in the cylinders during the exhaust stroke This increases the natural retardation effect of the engine Braking torque at the wheels will vary depending on
315. trols To maximize air conditioning performance shut off the heater valves during the summer months Locate the heater lines on the engine and close the hand valves 3 56 Custom Chassis 2010 Pierce Manufacturing Inc All Rights Reserved 3 14 1 OPERATION Heater Defroster Rotary Controls The mode controls can be set in any of the following positions Off Panel Bi Level LA Floor ld Defrost Floor we Defroster W Blower Control 8 Temperature Control 2010 Pierce Manufacturing Inc All Rights Reserved Placing the control in this position shuts off the blower motor and outside air will not come through the outlet Air blows through the outlets located in the instrument panel Air blows through the outlets located in the instrument panel and those on the floor Air blows through the floor outlets located under the instrument panel Air blows through the floor outlets and the outlets at the base of the windshield Air is directed to the windshield through the outlets at the base of the windshield A rotary knob that will increase or decrease blower motor speed A rotary knob that controls the temperature of the interior air You can choose your degree of comfort by positioning the temperature control along the blue red scale The coldest setting is in the blue and the warmest setting is in the red Custom Chassis 3 57 OPERATION 3 14 2 Air Conditioning NOTE When
316. urities in the fuel can subject fuel injector components to premature damage or wear Replace fuel filters in accordance with the engine manufacturer s recommendations 4 28 Custom Chassis 2010 Pierce Manufacturing Inc All Rights Reserved MAINTENANCE 4 19 Heating Ventilation Air Conditioning HVAC 4 19 1 Heater Shut Off Optional Use of the heater shut off valve will prevent warm air from circulating through the defroster system and may lead to a reduced ability to clear humidity from the windshield and subsequent reduced driver visibility Close heater line valves during warm weather to eliminate the warming affect of heater coils by slow leakage past the control valve 2010 Pierce Manufacturing Inc All Rights Reserved Custom Chassis 4 29 MAINTENANCE 4 19 2 Air Conditioning Optional Use only refrigerants approved by Pierce Manufacturing for your air conditioning system Some unapproved refrigerants are flammable and can explode causing injury to personnel Other unapproved refrigerant can cause the system to fail requiring costly repairs The air conditioning system contains refrigerant under high pressure To avoid risk of personal injury or damage to the system adding refrigerant or any repair requiring lines to be disconnected should be done by a certified repairman Air conditioning system contains R134A Avoid breathing refrigerant and lubricant vapor or mist Exposure may irritate eyes no
317. uzzer Tag Engine Stop Engine ABS ATC Battery ABS Equipped Tag System ON Air Restriction Check Traction Control System Equipped Tag Transmission Low Coolant Panel Lights Dimmer Headlights Start Button 3 62 Custom Chassis Steering Column Switch Headlight Dimmer Turn Signal Windshield Wiper Washer Hazard Lights 2010 Pierce Manufacturing Inc All Rights Reserved OPERATION 3 17 2 Typical Saber amp Custom Contender amp Cab Instrument Panel Figure 3 12 Saber amp Custom Contender Controls and Indicators Item Description Engine Oil Pressure Gauge e B SWITCH ASSY 3 OOOO SWITCH ASSY 4 100000 SWITCH ASSY 45 60 5514SH3 Fuel Gauge Volt Meter Truck Alarm steady tone Engine Coolant Temperature Gauge Dimmer Control Tachometer with Engine Hourmeter Headlight Switch Indicator Light Module Wiper Washer Controls Left Directional Green Ignition Switch High Beam Blue Gauge Panel Indicators Right Directional Green High Engine Coolant Red Check Engine Amber Low Engine Oil Pressure Red Stop Engine Red Low Aux Battery Voltage Red Check Transmission Amber Check Transmission Red PMC Fault Amber Low Voltage Red ABS Amber Low Fuel Amber ASR Amber
318. vided by head rests The use of seat belts is essential to protecting fire fighters during driving Failure to comply may result in serious injury or death to personnel Use extreme caution when walking on the top of the vehicle hosebed hosebed cover top of cab etc Use extra caution in wet icy snowy or muddy conditions Failure to comply may result in slipping or falling causing injury or death Care must always be taken when climbing on and off the vehicle Always face the vehicle use steps and grab handles and maintain three points of contact with the vehicle two feet one hand or two hands one foot Keep steps grab handles and walkways clean Be extra careful in wet icy snowy or muddy conditions Failure to comply may result in slipping or falling causing injury or death Fire apparatus are often equipped with Power Take Off PTO operated accessories Never operate the engine with personnel in the vicinity of any driveshaft as they may engage without warning Hands clothes hair etc can get caught on spinning shafts and U joints Failure to heed this warning may lead to personal injury or death Internal combustion engines give off hazardous fumes and gases while running Do not operate the engine in an area where exhaust gases can accumulate or serious injury or death may occur 1 3 3 Safety Warning Labels Walk around the fire apparatus Locate each safety warning label Read the label Identify and pay attentio
319. will also adjust if tires become out of balance due to mud in the tire tread or stuck to the wheel 4 24 7 Tire Pressure Management Sensors Standard NOTE The tire must be inflated to the correct pressure before installing the tire sensor valve cap to calibrate and ensure proper operation The VECSAFE valve cap tire pressure sensor can be checked for functionality and battery condition by simply unscrewing the cap If it is in working condition the LED will immediately start blinking The sensor will activate an integral battery operated LED when the pressure of that tire drops 8 psi If replacing a defective valve cap inflate tire to the proper operating pressure see Tire Inflation on page 4 37 and install the new sensor on the valve stem 4 25 Towing Instructions Due to the many variables that exist in towing positioning attaching and lifting of the vehicle towing is the sole responsibility of the towing vehicle operator who must be familiar with standard towing industry safety measures Failure to follow standard industry safety measures may lead to property damage personal injury or death Towing of a vehicle equipped with an automatic transmission even in neutral for even short distances may cause serious damage to the transmission components NOTE The towing vehicle used to develop this procedure was a Jerr Dan Model HDL1000 565 50 Ton Wrecker Integrated 4 25 1 Preparation for Towing 1 Block the w

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