Aerial ladder Maintenance (General)

Question 1

Tires shall be replaced when tread depth is at or less than ___” measured at any point on a major tread groove. The measurements shall NOT be made where the tie bars, humps or fillets are located.

Answer 1

4/32”

Question 2

Tires showing evidence of the tread separating from the tire case must be replaced as soon as possible.

Tires showing ANY exposed fabric through tread or sidewall area are to be replaced ______.

Answer 2

immediately

Question 3

_____ inflation imposes excessive strain on the tire cords, weakening their resistance to impact. This could cause tire rupture and blowouts.

Answer 3

Over

Question 4

______ inflation is the principal enemy of tire life and one of the primary causes of tire failure. Increased flexing due to underinflation causes heating, reduced strength, breakdown, and possible separation of the tire components. Low inflation also increases the rolling resistance of the tire which increases fuel consumption and reduces tread life.

Answer 4

Under

Question 5

Inflation pressures should always be checked when tires are ____. NEVER bleed air from tires when hot to relieve
normal pressure buildup.

Answer 5

cold

Question 6

______ Inflation on a set of dual tires causes more of the load to be absorbed by one tire than the other. This overload condition may cause an overheat condition leading to premature failure of one or both tires.

Answer 6

Unequal

Question 7

2006-2009 Tire PSI

Front ____

Rear ____

Tiller ____

Answer 7

Front - 100 PSI

Rear - 95 PSI

Tiller - 115 PSI

Question 8

2000-2003 Tire PSI

Front ____

Rear ____

Tiller ____

Answer 8

Front - 100 PSI

Rear - 95 PSI

Tiller - 110 PS

Question 9

1995-1996 Tire PSI

Front ____

Rear ____

Tiller ____

Answer 9

Front - 105 PSI

Rear - 100 PSI

Tiller - 110 PS

Question 10

When calling for apparatus tire replacement, the following information may be required to determine the closest replacement match:

1. Apparatus make
2. Shop number
3. Tire size
4. Tire location
5. Tread design
6. Tread groove depth (if necessary for match up)
7. Circumference or height (if necessary for match up)
8. Inner or outer
9. Finish on wheel

Answer 10

reference

Question 11

Engine oil type

Answer 11

15W-40 Motor Oil

Question 12

Road Transmission Fluid type

Answer 12

ATF (Dexron II)

Question 13

Drive Axle Fluid type

Answer 13

90W-140 Oil

Question 14

Axle Hubs fluid type

Answer 14

90W-140 Oil

Question 15

Engine Coolant type

Answer 15

S&M supplied coolant mix

Question 16

Power Steering (2 reservoirs) fluid

Answer 16

15W-40 Motor Oil

Question 17

Aerial Hydraulic Reservoir fluid type

Answer 17

AW Hyd. Oil 32 Chevron

Question 18

Cab Lift Hydraulic fluid type

Answer 18

ATF (Dexron II)

Question 19

Onan Generator Oil type

Answer 19

15W-40 Motor Oil

Question 20

Onan Generator Coolant

Answer 20

S&M supplied coolant mix

Question 21

Swing Drive Oil fluid type

Answer 21

90W Gear Oil

Question 22

KingPins (Steering Axles)

The correct method for lubricating the front axle kingpin thrust bearings is to jack up each wheel at the axle. This will remove the load on the bearings.

Answer 22

reference

Question 23

Universal Joints

When lubricating the universal joints, it is most important to observe the grease seeping past all four cross bearing seals. If grease does not show at any of the seals, tap the
opposite side yoke firmly with a plastic or similar type hammer while applying lube gun pressure. If you are unable to get the grease through, report this condition to the Shops.

Answer 23

reference

Question 24

Driveshaft Slip Yoke

To prevent drive shaft slip yoke galling or seizure, it is necessary to apply grease to the fitting until it appears at the relief hole in the end of the yoke plug

Answer 24

reference

Question 25

Brake Caliper Assembly 1995-2006

NOTE: Your apparatus has plugs instead of grease fittings, do not remove. The brake caliper assembly takes a special, high temperature, high-pressure grease required by Rockwell. The Shops will lube these parts at Annual Aerial Test or whenever a brake job is performed.

Answer 25

reference

Question 26

Fifth Wheel

When lubricating the fifth wheel, inject grease with the tractor inline, ____ degrees to the left and ____ degrees to the right of the trailer. This will allow the grease to travel completely around the fifth wheel race.

Answer 26

60 degrees

Question 27

Clean aerial ladder prior to lubing. Stabilize the apparatus, raise ladder, rotate to the side, lower ladder to horizontal and extend ladder fully. Clean all residual grease from
the sliding surfaces that are in contact with each other. Use red rags and an approve cleaning solution to do this. Do not use a wire brush to clean with. With the ladder horizontal and fully extended, inspect all pulleys for worn bushings. Also inspect the surfaces of the ladder beams for excessive wear, dents and cracks. When complete,
hoist ladder to ____ degrees and then retract. This will prevent the newly applied grease from being scraped off when the ladder is retracted.

Answer 27

60

Question 28

Aerial Daily Maintenance

1. Fuel supply
2. Oil, engine
3. Coolant
4. Oil, Onan engine
5. Coolant, Onan engine
6. Brakes, air reservoir pressure Verify that system pressure in both primary and secondary systems is at least 90 psi at start of shift. Perform one-minute brake application leak down test.
7. Tires/wheels Perform visual check on wheels and tires.
8. Signal & lighting system Inspect ALL lights for proper operation.
9. Electrical system Check system voltage with engine off and all electrical accessories off (12.9 Volts minimum).
   Start and run engine, engage high idle and check voltage again (13.7 Volts minimum).
10. Engine Look for any signs of fluid leakage.
11. Running Gear (Powertrain) Look for condition/tightness of bolts, nuts, fittings, shafts, cables, etc.
12. Seat belts

Weekly Schedule Check List

1. Engine - Run engine for 10 minutes at high idle (1000
   rpm) with air conditioning at maximum cool and all electrical accessories activated. Monitor dash gauges during test for any abnormal readings. After test inspect for any fluid leakage under and around engine.
2. Parking brakes  Set parking brake. Start engine Depress and hold brake pedal. Place transmission in D (Drive). Remove foot pressure from brake pedal and
   observe if brakes hold apparatus.
3. Windshield wipers
4. Aux front wheel lock Engine off. Wheels chocked. Set parking brake (pull out yellow knob). Set aux front wheel lock (push in black knob). Have assistant observe that the front axle brake push rods have actuated. Listen for any leaks. Release parking brake. Aux. brake control knob should “pop” out.
5. Brakes Check disc brake lining thickness: at 1/4” note
   and report. Less than 1/4” call in and schedule brake job. Inspect rotors for any cracks extending to the edge of the rotor. Look for any excess oil or grease on brake rotors/lining and calipers.
6. Water filter Inspect for proper fluid color, level & leaks.
7. Tires Check pressures by gauge. Check for loose, broken, and/or missing wheel lugs.
8. Fuel Filter/Water Separator Check for water or debris. Drain as needed.
9. Air tanks Drain each and every air tank of water and oil contaminants.
10. Air conditioning unit (Cab full tilt position). Check belts for wear and proper tension. Check for any leaks in A/C
    system (these will show up as an oily residue around the leak).
11. Batteries (Cab full tilt position). Check that all battery
    connections are clean and tight. Observe battery “self-check eye” for green color. If not green, note and report.
12. Power steering (Cab full tilt position). Manually check for proper steering fluid level using dipstick.
13. Exhaust system (Cab full tilt position). Inspect exhaust system for evidence of leaks, damage; loose/missing
    fasteners, clamps, etc;
14. Engine water pump (Cab full tilt position). Check water pump for evidence of coolant leakage. Look at condition of coolant hose and connections.
15. Transmission fluid (Cab full tilt position). Perform manual “cold check” of transmission fluid
16. Springs, suspension and frame (Cab full tilt position). Inspect springs for broken or missing leafs, clamps U-bolts, shackles, etc. Inspect shocks for proper mounting and condition. Inspect frame rails and frame members
    for breaks, cracks, bad welds, loose rivets and bent sections.
17. Emergency Power Unit (EPU) Run EPU, circulate fluid, check operation and check for leaks.
18. Aerial swing drive Check fluid level.
19. Axle hubs (Front & Tiller) Check fluid level.
20. Aerial ladder Operate and test aerial and outrigger jacks. Inspect drive pinion bearing gear teeth for wear,
    alignment and lubrication. Inspect aerial control console and communication system. Inspect collector rings under turntable for corrosion and brushes for wear. Inspect hoses, lines, etc. under turntable.
21. Hydraulic oil reservoir Check fluid level.
22. Tiller cab Inspect door hinges and latches.
23. Onan generator Run the engine with an electrical load until warm. Check operation and check for leaks.
24. Fifth wheel pivot shafts Lubricate at each pivot shaft zero.

F-377 Bi-Monthly Preventive Maintenance

1. Steering Box and Steering Linkage

(Engine shut down). Position front wheels straight ahead
(wheels on ground). Have an assistant move the steering wheel back and forth with short (40 to 06) rapid movements. At the same time inspect steering linkage and connections for any looseness or excessive movement. You can place your finger on the two mating parts of each steering connection and “feel” for any disproportionate movement between the two. Any
detectable movement should be noted and reported. The
following steering components can be checked in this fashion:
 Steering box input shaft/slip joint/u-joints.
 Steering box mounts.
 Steering box output shaft/Pittman arm.
 Pittman arm/drag link ball joint connection.
 Draglink/steering arm ball joint connection.
 Right and left side tie-rod ball joints.
 Right side steering arm/idler arm ball joint.

2. Steering Column Grasp top of steering column and attempt to move back and forth. If any movement is detected make note and report.
3. Brakes (Engine shut down). Inspect all mechanical components for looseness, wear, breakage and/or missing components. Inspect air lines for leakage, wear and/or breaks. Inspect brake linings and rotors for wear, cracks and breaks. Inspect brake push rod travel for a maximum 2” stroke on all six wheels. When applying and holding the brakes for brake push rod travel measurement, grasp and shake the brake line(s) to the brake chamber and listen for any air leakage.
4. Drive Line Park apparatus on level surface, chock wheels and release parking brake. Inspect drive line(s) tubes for damage (cracked welds, bending, misalignment). Inspect driveline u-joints for wear/looseness. The most effective procedure is to position yourself directly under the u-joint, place both hands on the end of the drive line tube next to the u-joint and try to move the tube up and down. Try to observe or “feel” for any measurable up and down movement. If any movement is detected it should be noted and reported. Any excess movement in the road transmission and drive axle bearings can be detected in this manner. Check all drive lines and u-joints in this manner.
5. Differential Check oil level. Oil level should be even with the plug opening.
6. Radio Inspect all accessible components for secure mounting. Inspect wiring for proper connections, cleanliness and routing.
7. Air Cleaner (Cab full tilt) Inspect hose(s), ducts, pipe, connections, etc. between air cleaner and engine intake for wear, breaks, and mounting. Air cleaner element is to be replaced every other year or on an “as needed” basis. This is determined by the amount of inlet restriction measured by the engine’s diagnostic system.
8. Air Compressor (Cab full tilt) Inspect for secure mount to engine, audible air leaks, water and oil leaks around compressor area and general condition of hose(s) attached to compressor.
9. Alternator (Cab full tilt) Inspect for secure mount to engine. Inspect belts for wear and tension. Inspect wiring to alternator for signs of looseness, corrosion, chafing/rubbing and proper routing. Start engine and observe alternator LED. The LED should emit a “green” color if it is functioning properly.
10. Fuel pump (Cab full tilt) Inspect fuel pump for signs of loose mounting and examine fuel lines for hard or spongy condition.
11. Cooling System (Cab full tilt) Inspect radiator for secure mount, signs of leakage, obstruction of cooling fins (front and rear sections of radiator), fit of radiator cap, proper coolant level. Inspect coolant hoses for signs of leakage, wear, bulging, chafing, cuts and incorrect routing. Inspect radiator sight glass for signs of contamination. Coolant should be green in color. Inspect water pump for proper mount and any signs of leakage around the “weep” hole and the pump to block mount area. Inspect fan for cracks, missing blades, shroud to blade clearance.
12. Drive Belts (Cab full tilt) Inspect all belts for wear, cuts and tension. Report defect if belt tension is loose enough to allow more than 1/2” deflection measured at a point midway between pulleys.
13. Starter (Cab full tilt) Inspect starter for mounting and wiring. Operate starter motor and listen for any unusual noise or operating characteristics. While cranking, observe starter for any movement; movement will indicate looseness at mounts.
14. Wiring (Cab full tilt) Perform visual ONLY of all wiring in engine compartment for routing, connections, wear and/or corrosion.
15. Engine Mounts (Cab full tilt) Inspect engine mounts for looseness and/or damage to rubber mounts.
16. Tires With the approved tire tread depth gauge, measure depth at the center of the tire tread. A reading of 1/8” or less should be reported on the F-377 and called in for needing replacement.
17. Door Hinges/Locks Check for worn hinges, proper alignment and lock mechanism function.
18. Odometer Reading Note and record current mileage.
19. Engine Hours Note and record current engine hours.
20. Aerial Hours Note and record current aerial hours.
21. Generator Hours Note and record current Onan generator hours.

Answer 28

reference

Question 29

How often do you check for bent tire rims?

Answer 29

Daily

Question 30

How often do you check the aerial ladder pinion bearing gear teeth for wear, alignment and lubrication?

Answer 30

weekly