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Welding / 6-39

MAINTENANCE

Figure 6-11: Connector Disconnect Tag

91-0250

Table 6-8: Electronic Components Disconnect Table (Before Welding)

Before any welding can be done on this unit, you MUST disconnect the following.

Detroit DDEC

Disconnect the three tagged plugs that are on the Detroit 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.
•

Saber® 2014/Enforcer™ - on crossmember behind transmission.

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 Control Module (TCM).
•

Saber® 2014/Enforcer™ - in passenger side instrument panel.

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 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.

Summary of Contents for Enforcer

Page 1: ... 2018 Pierce Manufacturing Inc Part No PM C OM014 SEN 0718 Operator s Manual Saber Enforcer ...

Page 2: ......

Page 3: ... 2 GENERAL WARNINGS AND CAUTIONS 2 2 2 1 3 SAFETY WARNING LABELS 2 2 2 2 BACKING THE VEHICLE 2 7 2 3 VEHICLE HANDLING CHARACTERISTICS 2 7 2 4 ELECTROCUTION HAZARD FROM OVERHEAD POWER LINES 2 8 2 5 HIGH PRESSURE HYDRAULIC FLUID 2 9 2 6 TANKER MOBILE WATER SUPPLY TRUCK CHARACTERISTICS 2 9 2 6 1 DESCRIPTION OF HAZARD 2 9 2 6 2 RECOMMENDATIONS FOR PREVENTION 2 10 2 7 LOCKOUT TAGOUT 2 11 2 8 SAFETY DEF...

Page 4: ...NT REAR SUSPENSION 3 12 3 11 SUSPENSION 3 12 3 11 1 SPRING SUSPENSIONS SPRING U BOLTS 3 12 3 11 2 AIR AND RUBBER SUSPENSIONS 3 12 CHAPTER 4 GENERAL Safe Vehicle Entry and Exit 4 1 VEHICLE ACCESS 4 1 4 1 1 AUTOMATIC STEPS 4 1 4 1 2 SERVICE AREAS 4 1 4 1 3 HIGH LOCATIONS 4 1 4 1 4 NO STEP SURFACES 4 2 4 1 5 DO NOT OCCUPY WITH VEHICLE IN MOTION 4 2 4 2 KEYLESS ENTRY OPTIONAL 4 2 4 2 1 TO UNLOCK OFFIC...

Page 5: ...pections 5 1 PRE TRIP INSPECTION 5 1 5 1 1 REASONS FOR DAILY INSPECTION 5 1 5 1 2 BEGINNING THE INSPECTION 5 1 5 1 3 THINGS TO LOOK FOR DURING INSPECTIONS 5 2 5 1 4 INTERIOR INSPECTION 5 4 5 1 5 EXTERIOR INSPECTION 5 5 5 1 6 BRAKE TESTING 5 8 General Operation 5 2 CAB OCCUPANT CAPACITY 5 10 5 3 COMPARTMENT DOORS 5 10 5 4 CAB TILT OPERATION 5 11 5 4 1 CAB LIFT SYSTEM 5 12 5 4 2 MANUAL PUMP OPERATIO...

Page 6: ...D FORD ENGINE INSTRUMENT ATD PANEL LIGHTS TABLE 5 1 5 22 5 12 2 PASSIVE REGENERATION 5 23 5 12 3 ACTIVE REGENERATION 5 23 5 12 4 PARKED REGENERATION 5 24 FORD PARKED REGENERATION ENGINE SPEEDS TABLE 5 2 5 24 CUMMINS PARKED REGENERATION ENGINE SPEEDS TABLE 5 3 5 24 PERFORMING A PARKED REGENERATION CUMMINS OR FORD TABLE 5 4 5 25 5 12 5 REGENERATION INHIBIT 5 26 5 12 6 MAINTENANCE 5 26 5 13 DETROIT D...

Page 7: ...cle 5 26 TRANSMISSION 5 44 5 26 1 AUTOMATIC TRANSMISSION 5 44 5 26 2 TRANSMISSION OPERATING TEMPERATURE 5 44 5 26 3 NEUTRAL TO DRIVE SHIFT GROWL ALLISON MD TRANSMISSION 5 44 5 26 4 4X4 TRANSFER CASE ALL WHEEL DRIVE 5 45 5 26 5 4X4 ALL WHEEL DRIVE AND TWO SPEED AXLE COMBINATION 5 45 5 26 6 POWER TAKE OFF CONTROL 5 45 5 27 AXLES 5 46 5 27 1 NO SPIN DIFFERENTIAL OPTIONAL 5 46 5 27 2 MERITOR DRIVER CO...

Page 8: ...NG COLUMN ADJUSTMENT 5 58 5 32 TIRE CHAINS 5 58 5 32 1 CHAIN CLEARANCE 5 58 ALL WHEEL STEER TIRE CHAIN AVAILABILITY TABLE 5 10 5 58 5 32 2 AUTOMATIC TIRE CHAINS 5 58 5 33 TIRE PRESSURE MANAGEMENT SYSTEM 5 59 5 33 1 TIRE PRESSURE MANAGEMENT STANDARD 5 59 5 33 2 TIRE PRESSURE MANAGEMENT OPTIONAL 5 59 CHAPTER 6 MAINTENANCE Cab 6 1 CAB TILT SYSTEM 6 1 6 1 1 COLD WEATHER OPERATION 6 1 CAB LIFT CYLINDER...

Page 9: ...ONT AXLE ALIGNMENT 6 9 6 9 3 FRONT AXLE TAK 4 SUSPENSION 6 9 6 9 4 REAR AXLE 6 9 6 9 5 REAR AXLE ALIGNMENT 6 10 6 9 6 REAR AXLE TAK 4 SUSPENSION 6 10 6 10 BRAKES 6 10 6 10 1 BRAKES GENERAL 6 10 6 10 2 BRAKES TAK 4 SUSPENSION 6 11 6 10 3 AIR DRYER 6 11 6 11 REAR SUSPENSION 6 11 6 12 SPRING SUSPENSION FRONT AND REAR 6 11 6 12 1 SPRINGS 6 11 U BOLT FASTENER TORQUE CHART TABLE 6 4 6 12 6 12 2 SUSPENSI...

Page 10: ... 21 6 17 5 ENGINE MOUNT ISOLATORS 6 21 6 17 6 ENGINE DIAGNOSTIC SOFTWARE DETROIT 6 21 6 17 7 ENGINE DIAGNOSTIC SOFTWARE CUMMINS 6 21 6 17 8 ENGINE DIAGNOSTIC SOFTWARE FORD 6 21 6 18 COOLING SYSTEM 6 21 6 18 1 GENERAL INSPECTION AND SERVICE 6 22 6 18 2 HOSES 6 22 6 18 3 HOSE CLAMPS 6 22 6 18 4 WATER PUMP 6 22 6 18 5 THERMOSTATS 6 22 6 18 6 COOLANT 6 23 6 18 7 ANTIFREEZE TYPE 6 23 6 18 8 COOLANT FIL...

Page 11: ...RE LIFT METHOD PREFERRED 6 35 6 25 8 LIFT AND TOW USING FRAME FORKS 6 36 Welding 6 26 WELDING INSTRUCTIONS 6 38 6 26 1 WELDING ON FRAMES 6 38 6 26 2 BEFORE WELDING 6 38 ELECTRONIC COMPONENTS DISCONNECT TABLE BEFORE WELDING TABLE 6 8 6 39 6 26 3 BATTERY SYSTEM PROTECTION 6 40 6 26 4 AFTER WELDING 6 40 Wheels and Tires 6 27 TIRES 6 41 6 27 1 FIRE SERVICE RATED TIRES 6 41 6 27 2 FIRE SERVICE RATINGS ...

Page 12: ... 5 YEAR INSPECTIONS 7 6 7 1 8 VENDOR COMPONENT INSPECTIONS 7 7 APPENDIX A MOBILE RADIO INSTALLATION GUIDE A 1 APPENDIX B EXTERIOR CARE OF YOUR VEHICLE B 1 b 1 EXTERIOR CARE OF YOUR VEHICLE b 1 b 1 1 FINISHED SURFACES OF THE VEHICLE b 1 b 2 WASHING THE VEHICLE b 2 b 2 1 PROPER WASHING EQUIPMENT AND METHODS b 2 b 2 2 GENERAL WASHING INSTRUCTIONS b 3 b 2 3 TAR RUST OR OTHER CONTAINMENT REMOVAL b 3 b ...

Page 13: ...d the extent of your knowledge BEFORE operating this vehicle and equipment you the operator or maintainer must read understand and follow the instructions found in this operator and maintenance manual and the operator and maintenance manuals from the manufacturers of major components used on this vehicle or equipment Operating servicing and maintaining this vehicle or equipment can expose you to c...

Page 14: ...safe operation of any aspect of this vehicle or equipment stop immediately and seek further training You are the only person who knows what you 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 this vehicle and equipment under all conditions w...

Page 15: ...3 FOREWORD 1 2 Vehicle Identification Figure 1 1 FMVSS Information Decal 1099 POM0809 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 ...

Page 16: ...s Manager 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 4 Responsibility Study carefully this manual and the manuals for major components such as engine tra...

Page 17: ... 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 tr...

Page 19: ... of the fire department to which the vehicle is assigned DANGER signals an imminently hazardous situation that if not avoided will result in death or serious injury WARNING signals a potentially hazardous situation that if not avoided could result in death or serious injury CAUTION with the safety triangle signals a potentially hazardous situation that if not avoided might result in minor or moder...

Page 20: ... above the ground and unguarded by a railing or structure are designated by a safety line along the outside perimeter of the allowable standing walking surface 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 han...

Page 25: ...ctions If spotting for yourself return to the vehicle and start backing within a few seconds after finishing the walk around This will allow very little time for people and or obstacles to change behind the vehicle Only back without a spotter after gaining as much information as possible about what is behind you Back up alarms will help warn away pedestrians and drivers of other vehicles who may t...

Page 26: ...tical that you leave the vehicle JUMP as far away as possible landing with both feet together Maintain balance or fall forward don t fall back toward the vehicle which could result in the body becoming a pathway between the vehicle and the ground No part of your body should touch the vehicle and the ground at the same time If you are outside of the vehicle that contacts or is energized by a power ...

Page 27: ...Don t be fooled Fluids injected under the skin are highly toxic The injury will lead to gangrene amputation and death if not treated promptly Most Doctors are not trained in treating hydraulic related injuries Make sure they are aware of the potential problems and get the recommend treatment needed to treat the injury 2 6 Tanker Mobile Water Supply Truck Characteristics 2 6 1 Description of Hazard...

Page 28: ...h 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 ...

Page 29: ...ic steps for shutting down isolating blocking and securing machines or equipment to control hazardous energy Specific steps for the placement removal and transfer of lockout devices or tagout devices and the responsibility for them Specific requirements for testing a machine or equipment to determine and verify the effectiveness of lockout devices tagout devices and other energy control measures 2...

Page 31: ...ible 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 weight...

Page 32: ...mpartments with the intended equipment and manpower and obtain front and rear axle weights from a certified scale Compare the results to the axle capacities and axle model numbers 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...

Page 33: ...1 2 Rear 24 x 5 1 2 Front 24 x 5 1 2 Rear 24 x 5 1 2 17 001 21 000 RS21 Front 24 x 5 1 2 Rear 30 x 5 1 2 Front 30 x 5 1 2 Rear 30 x 5 1 2 Front 30 x 5 1 2 Rear 30 x 5 1 2 Front 30 x 5 1 2 Rear 30 x 5 1 2 21 001 24 000 RS23 Front 24 x 5 1 2 Rear 30 x 5 1 2 Front 30 x 5 1 2 Rear 30 x 5 1 2 Front 30 x 5 1 2 Rear 30 x 5 1 2 Front 30 x 5 1 2 Rear 30 x 6 24 001 27 000 RS25 Front 30 x 5 1 2 Rear 30 x 6 F...

Page 34: ...30 x 5 1 2 Front 30 x 5 1 2 Rear 30 x 5 1 2 42 001 48 000 RT44 RT46 Front 24 x 5 1 2 Rear 30 x 5 1 2 Front 24 x 5 1 2 Rear 30 x 5 1 2 Front 30 x 5 1 2 Rear 30 x 5 1 2 Front 30 x 5 1 2 Rear 30 x 6 48 001 54 000 RT52 Front 24 x 5 1 2 Rear 30 x 6 Front 24 x 5 1 2 Rear 30 x 6 Front 30 x 5 1 2 Rear 30 x 6 Front 30 x 5 1 2 Rear 30 x 6 54 001 58 000 RT58 Front 24 x 5 1 2 Rear 36 x 6 Front 30 x 5 1 2 Rear...

Page 35: ...oth 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 Make sure the driving route is in a safe low traffic area In Service Axle We...

Page 36: ... 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...

Page 37: ...18 24 inches away so you don t damage the surface and graphics b Rinse thoroughly NOTE If you are planning on doing paint repair or graphics on the outside of the truck follow this procedure Wash and rinse as stated above Use an environmentally approved biodegradable mild degreaser and follow their directions for application and removal 3 6 Customer Installed Equipment 3 6 1 Modification This appa...

Page 38: ...market equipment on the vehicle consider the types of metals of the equipment base and fasteners Take precautions to prevent contact between different metal types Refer to Preventing Dissimilar Metal Corrosion on page B 5 for more information on proper prevention of galvanic corrosion 3 7 Radio Equipment Refer to the Mobile Radio Installation Guide on page A 1 for information concerning radio inst...

Page 39: ...nside the cab may prevent the cab from being tilted for service or maintenance Refer to NFPA guidelines when mounting equipment inside the cab to avoid unnecessary risk of injury from flying objects during a collision Exercise caution when drilling into cab walls body walls and headliners when mounting equipment as there may be wiring heater hoses or air conditioning hoses hidden beneath the surfa...

Page 40: ...d pressures and that tread wear is reasonably even from side to side 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 Bala...

Page 41: ...ierce Service Manual group 0152 P 007 TAK 4 Torsion Bar Assembly 3 9 2 Leaf Spring Suspension 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 ...

Page 42: ...l 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 3 11 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 Susp...

Page 43: ...icle If railings are not present then these areas should only be accessed for service or repair in controlled service environments 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 ...

Page 44: ... walk on these surfaces use rubber matting or other ways to provide traction on the surface 4 1 5 Do Not Occupy With Vehicle in Motion This vehicle may have an area that is meant to be occupied with the vehicle in a stationary condition only This restriction may be due to the fact that there are no seats equipped with seat belts Other reasons for restriction may be that there are un mounted seats ...

Page 45: ...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 when pressing buttons while the system is disabled See the Pierce Service Manual group 0810 V 001 TriMark e ASK Keyless entry System for additional informa...

Page 46: ...w 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 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 ...

Page 47: ...en a red illumination condition exists and the parking brake is released or a red illumination condition exists and the transmission is not in N Neutral 4 3 3 Side Roll Protection System Optional 4 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 durin...

Page 48: ...ght 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 ...

Page 49: ... disconnecting the roll sensor remove the electric power The roll sensor monitors the vehicle s angle and rate of roll Cabs may be equipped with a single roll sensor or a master roll sensor 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 dat...

Page 50: ...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...

Page 51: ...he floor and tightly held down until after 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 or Supplemental Restraint Airbags SRA The IGP will activate and pull the belt snugly around the occupant The side air bag will deploy and positi...

Page 52: ...e 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 4 3 4 Frontal Impact Protection Optional The cab may be equipped with a fron...

Page 53: ...oid the warranty and may result in an unsafe condition 4 3 6 SCBA Brackets Mounted in Seat Backs 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 in...

Page 54: ... 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 injury 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 lea...

Page 55: ...here 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 s...

Page 56: ...layer moving toward the side from which you began You will now have two layered coils of hose on the reel 5 Continue guiding the hose onto the reel guiding in a left right right left alternating pattern until the entire length of the hose has been stowed onto the reel 4 6 Instrument Panel Controls Indicators The exact layout of gauges switches indicators and controls on Pierce Custom Chassis varie...

Page 57: ...rontal Air Bag Fault A Low Engine Oil PSI Ind C Battery System On 2 Volt Meter D SRS Fault A Low High Voltage Ind 18 Right Hardwired Indicator Bank 3 Engine Coolant Temperature Gauge A DPF Regeneration Cummins A High Engine Coolant Temp Ind B Low Diesel Exhaust Fluid Level 4 Tachometer with Engine Hourmeter C Grid Heater Wait to Start Cummins 5 Speedometer D Emission System Malfunction 6 Trans Oil...

Page 58: ...m Indicator 42 Washer Control Switch D Low Coolant 49 Battery Switch E Check Engine 50 Diagnostics Panel F Aux Brake Overheat A Eng Trans ABS J1939 Diag Port G Caution B ABS Diag Switch Ind H Warning C DPF Regen Switch Ind I Park Brake Applied D Eng Diag Switch Ind Cummins J Stop Engine Red E Eng Diag Ind Detroit DD13 K DPF Regeneration F DPF Regen Inhibit Switch Ind L ABS Trailer Fault 56 Alarm 1...

Page 59: ...sis uses three wiper blades controlled by a single motor and linkage arrangement to drive the wiper arms providing for synchronous movement Item Description Item Description 39 Directional Switch 101 Vehicle Data Recorder Port 40 Headlight High Low Beam Switch 134 Map Light 43 4 Way Hazard Switch 135 Handheld Spotlight Windshield wipers should not be run on dry windows for an extended length of ti...

Page 60: ...at 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 Stored VDR data can be downloaded and viewed using a laptop computer and the vendor s vehicle data recorder software the software is provided with your vehicle on a CD ROM The VDR software contains three different applications The purpose of each applica...

Page 61: ...icle with a Command Zone system may be programmed to monitor and or control different systems on that vehicle Command Zone III capabilities include but are not limited to an optional 7 touchscreen display data logging and recording enhanced diagnostics prognostics and troubleshooting capabilities GPS and subsystem integration Command Zone III is also WiFi capable acting as its own secure wireless ...

Page 63: ...s 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 5 1 2 Beginning the Inspection Perform a pre trip inspection the same way each time to ...

Page 64: ...llowing warning signs 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 changed stop a short while later and recheck tightness of nuts Brake Drums or Shoes Inspect brakes for the following Cracked drum...

Page 65: ...ystems that are damaged and or leaking Any loose cracked broken or missing frame members Broken or damaged torsion bars Cut or torn tape on torsion bars TAK 4 suspension only Refer to Pierce Service Manual group 0152 P 007 TAK 4 Torsion Bar Assembly Exhaust System A broken exhaust system can let poisonous fumes into the cab Check for Loose broken or missing exhaust pipes Diesel Particulate Filter ...

Page 66: ...icking 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 Dimmer switch Turn signal 4 way flashers Clearance identification and marker lights Tire chains when winter conditions require them...

Page 67: ...hafing or damage from heat Batteries Battery box securely mounted to vehicle 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 Left Front Side Driver s door glass should be clean Door latches and window regulato...

Page 68: ...t 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 007 TAK 4 Torsion Bar Assembly Right Front Brake Brake drums or rotors are not cracked or worn Hoses show no signs of excessive wear Right ...

Page 69: ...nse plate s present clean and secured Splash guards present not damaged properly fastened not dragging on ground or rubbing tires Rear doors securely closed latched locked Left Rear Fuel tank is securely mounted not damaged or leaking Fuel tank contains enough fuel Fuel cap is on and secure Left Rear Wheel Wheel and rim are in good condition no missing bent or broken studs clamps or lugs Show no s...

Page 70: ...stem 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 Shut the en...

Page 71: ...s 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 Pressure The air compressor should start pumping at about 100 ...

Page 72: ...t in use Personnel in a hurry may tend to leave doors open after retrieving equipment Always close swing up or swing out compartment doors People can walk into doors left open at lower levels and become injured Swing up door should always be shut when not in use Personnel working on top of the apparatus can mistake an open horizontal door for a walking surface All occupants must be seated and belt...

Page 73: ...mage 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 cov...

Page 74: ... to the LOWER position 5 Leave the control lever in the LOWER position for road operation Cab locks will engage automatically 6 Check to ensure the cab is fully seated and latched before operating vehicle 5 4 2 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 hand...

Page 75: ... 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 5 5 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 s...

Page 76: ... tightly 5 5 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 Check ground or return circuit polarity visually or with a voltmeter before connecting batteries or other voltage producing components into the...

Page 77: ...y a signal from the transmission Electronic Control Unit ECU and will be affected by changes in rear axle ratio or tire size 5 5 11 Low Fuel Warning Light Normally the light blinks when the level in the fuel tank has dropped to the 1 8th mark and burns steady when the level in the fuel tank has dropped to 1 16th tank The light can be adjusted to activate at other fluid levels depending on customer...

Page 78: ...hts are standard on Pierce Custom Chassis 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 Vehicles equipped with Command Zone only 5 5 15 Hazard Flashers A switch located ...

Page 79: ...g the vehicle Check mounting hardware to ensure that mirror heads are secure and will not lose adjustment during operation Careful side view and rear view mirror adjustment is critical to the safe operation of any vehicle Always adjust side and rear view mirrors to optimize visibility before setting the vehicle in motion Use a partner to walk around the vehicle to identify the blind spots and comp...

Page 80: ...ntal and vehicle configuration Therefore no definitive fording capability can be established Avoid depths of water which may partially or fully submerge the axles Water fording is not recommended Any depth of water which may partially submerge the axles or greater is to be avoided Water fording can cause component damage corrosion or catastrophic failure to engine transmission and electrical syste...

Page 81: ...e 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...

Page 82: ...des or features on the load a pinch hazard exists Even if the winch drum is guarded the opening through which the cable passes can present a pinch hazard If the winch drum is not guarded keep away from it during operation Follow lock out or tag out procedures before working on or around a winch Follow these safe practices during winch operation Always stand clear of wire rope and load during opera...

Page 83: ...n may require intervention either by the engine ECU or operator intervention by injecting a small amount of fuel into the DOC which raises exhaust temperatures enough to burn off accumulated soot See Cummins and Ford Regeneration on page 5 22 or Detroit Diesel ATD Regeneration on page 5 27 depending on your engine Selective Catalyst Reduction SCR device The SCR is a catalytic converter that uses v...

Page 84: ...e vehicle should be serviced by an authorized dealer 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 1 On solid low to medium levels of particulate build up The vehicle requires regeneration but should be able to complete its mission before a regeneration is performed Ensure the R...

Page 85: ...atic Active Regeneration or Manually initiate a parked regeneration using the regeneration switch which is located in the cab within reach of the driver Parked Stationary Regeneration 5 12 3a Automatic Active Regeneration During Driving or Pumping Conditions The engine ECU will automatically activate a regeneration when the following vehicle conditions are satisfied DPF light illuminates soot is a...

Page 86: ...complete a parked regeneration See Canceling Stationary Regeneration on page 5 25 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 in an enclosed area i e indoors All internal combustion engines give off hazardous fumes and gasses while running Inhalation of ex...

Page 87: ...discharge pipe must be rated at least 1500 F 816 C 2 Keep foot off the throttle pedal and the brake pedal STAY with the vehicle Monitor the area during the operation if any unsafe conditions occur shut off engine immediately NOTE Diesel Particulate Filter DPF lamp must be ON in order to start a stationary regeneration 3 With the engine running press and hold the vehicle s regeneration switch for s...

Page 88: ...ve regeneration If the pump is engaged the regeneration process should not affect the engine speed 5 12 6 Maintenance Regeneration removes soot from the DPF but accumulated ash remains in the filter Over time the DPF must be removed disassembled and cleaned in a special machine to remove the ash build up CEL will illuminate and a fault code will be set when ash removal is necessary The Ford mainte...

Page 89: ...neration indicated by this light 1 DPF on solid low to medium levels of particulate build up The vehicle requires regeneration but should be able to complete the current mission Perform a regeneration in a reasonable amount of time Ensure the Regen Inhibit Switch is not activated Initiate a DPF regeneration by switching to a more challenging duty cycle such as highway driving for at least 20 minut...

Page 90: ...atic Active Regeneration or Manually initiate a parked regeneration using the regeneration switch which is located in the cab within reach of the driver Parked Stationary Regeneration 5 13 3a Automatic Active Regeneration During Driving or Pumping Conditions The engine ECU will automatically activate a regeneration when the following vehicle conditions are satisfied DPF light illuminates soot is a...

Page 91: ... gas temperatures at zero vehicle speed Keep personnel away from exhaust outlet to avoid serious burns and injury Do not perform parked regeneration in an enclosed area i e indoors All internal combustion engines give off hazardous fumes and gasses while running Inhalation of exhaust fumes can cause death Do not sit in a parked vehicle for any extended amount of time with the engine running Exhaus...

Page 92: ...safe conditions occur shut off engine immediately NOTE Diesel Particulate Filter DPF lamp must be ON in order to start a stationary regeneration 4 With the engine running at idle and the vehicle parked with the speedometer at 0 mph press and hold the vehicle s regeneration switch for 5 seconds Engine speed increases Series 60 1600 RPM DD13 1100 RPM DEF lamp flashes then turns OFF As hydrocarbons a...

Page 93: ...s going to occur in a location or situation that is not ideal and must be postponed An indicator will appear on the dash panel when this mode is activated The regen inhibit switch should not be used for normal operation It should only be used for hazardous environments Overuse of the regeneration inhibit feature will lead to more frequent need of parked stationary regeneration or the need for serv...

Page 94: ...inate solid DEF level below 1 8 full DEF Fluid Low light will flash DEF level below 1 4 gallon Cummins DEF Fluid Low light flashing and amber Check Engine lit solid The engine will induce a 25 engine torque derate Detroit 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 and system can no longer maintain...

Page 95: ...tinguish the light DEF level between full and an ECM calculated range of 500 miles DEF Fluid Low light will remain OFF DEF level is at an ECM calculated range of below 500 miles DEF Fluid Low light will illuminate solid DEF level range is approaching 0 Check Engine lamp illuminates Remaining range displayed on instrument panel for 60 seconds every five minutes with an audible alarm DEF tank empty ...

Page 96: ...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 partia...

Page 97: ...ay 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 All engine manufacturers warn against excessive engine operating time greater than 5 minutes at low idle speed particularly during cold weather Excessive idling can have the following detrimental effects on the engine Fuel dilution of the lubricating oil ...

Page 98: ...is tripped it must be reset before the engine can be started again 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 the combustion chamber bearings shafts etc This is especially important with turbocharged engines The turbocharger contains bearings and seals that are sub...

Page 99: ...ded periods of time 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 man...

Page 100: ...the engine turn off the warning light master switch 4 Apply the parking brake and shift the transmission to N Neutral in both vehicles 5 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 Fan clutches can engage and fan blades can spin without warning Keep hands hair and cloth...

Page 101: ...s 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 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 Infor...

Page 102: ...e 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 Detroit engines only Engine oil must have sulfate ash levels less than 1 0 weight Oils meeting this requ...

Page 103: ...s accompanied by a DEF fluid only label 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...

Page 104: ... 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 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 ...

Page 105: ...spacing will maintain a gap 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 The use of a winter front increases the need for the operator to carefully monitor engine and transmission temperatures Remo...

Page 106: ...e Shift Growl Allison MD Transmission A growling noise may sometimes be heard in the cab when shifting the transmission from N Neutral to D 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 Increasi...

Page 107: ...ring 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 5 26 6 Power Take Off Control Engage Power Take Off PTO operated accessories with engine at idle speed Ref...

Page 108: ...ential operation and service manual provided by the axle manufacturer for further information and safety instructions Additional copies may be obtained from the manufacturer their website or by contacting Pierce Customer Service Use extreme caution when accelerating or decelerating on slippery or unstable surfaces Vehicles axles equipped with No Slip traction differentials are inherently more sens...

Page 109: ...utch to disengage 3 When the differential lock is disengaged the indicator light and or audible signal will go out 5 27 4 Inter Axle Differential IAD Lock Tandem Axles 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 than the wheels of the other axle in order to compensa...

Page 110: ...verall However this will also cause the rear of the vehicle to swing out farther than one equipped with conventional rear axle s The rear axle s follow the steering angle of the front axle although to a lesser degree Therefore making a wider conventional turn with a greater steering angle will result in the rear axle s steering with a greater angle and swinging out farther than the operator may in...

Page 111: ...gaining normal traction let up on the accelerator then disengage switch 5 27 6 Two Speed Rear Axle The two speed rear axle switch permits selection of either the high or low axle ratio DO NOT operate the vehicle on dry pavement with the differential lock engaged Attempting to operate the vehicle on dry pavement with the differential lock engaged WILL result in damage to the steering system and or ...

Page 112: ...ition 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...

Page 113: ...eration 4x4 Chassis with ESC 5 28 5 Parking Brakes 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...

Page 114: ...Air pressure for the spring brake release is supplied by a dedicated air tank Caged Brakes Will Not Hold Vehicle Never leave a vehicle with caged brakes unattended Park vehicle on a flat surface only Chock wheels in both directions Perform Lockout Tagout to secure vehicle and make sure no one drives it until repairs are complete Failure to follow these procedures may lead to loss of vehicle contro...

Page 115: ...oads 5 28 11 Grade Holding and Brake Burnishing 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 bee...

Page 116: ...exhaust valves so that the engine works as a power absorbing air compressor 5 29 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 t...

Page 117: ... 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 Observe the following cautions when driving a vehicle equipped with a hydraulic...

Page 118: ...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 ma...

Page 119: ... s commanded direction Additionally the system may reduce engine power or operate the transmission to slow the vehicle down ESC can work on any surface from dry pavement to frozen lakes It reacts to and corrects skidding much faster and more effectively than the typical human driver often before the driver is even aware of any imminent loss of control It is important to understand that ESC is not ...

Page 120: ... desired position Adjust the height of the steering wheel by pushing down on the adjustment lever and moving the wheel to the desired position 5 32 Tire Chains 5 32 1 Chain Clearance Front Tires 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 clear...

Page 121: ... sensor valve cap to calibrate and ensure proper operation Your apparatus is equipped with a LED Air Guard tire alert pressure management system that will monitor the pressure of each tire The LED Air Guard 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 can ...

Page 123: ...nkages and regulators The door latch mechanism requires specific attention 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 6 2 2 Exterior Door Handles Exterior handles must be lubricated only...

Page 124: ...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 6 3 Wiper Blades 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 ...

Page 125: ... from sloshing Replace the pad as necessary Inspect all vents for looseness and operation Replace if necessary 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 con...

Page 126: ...ned on wait a few minutes for the system to stabilize then look again Figure 6 1 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 6 4 2b Refrigerant Recovery and Recycling Your Pierce Custom Chassis uses environmentally acceptable...

Page 127: ...UV radiation 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 noticed Figure 6 2 Examples of Seat Belt Webbing Damage 1245A 1248A Do not bleach or dye seat belt webbing Bleaching or dying may cause a severe loss of belt strength This loss of strength cou...

Page 128: ... 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 NEVER attempt to modify the Side Roll Protection Sy...

Page 129: ...d 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 6 8 Fasteners 6 8 1 Interior Fasteners This vehicle...

Page 130: ...t Table 6 3 Grade 8 Fine Thread Fastener Torque Chart 6 8 3 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 6 8 4 Other Fasteners Standard torque requirements can be found in the Pierce Service Manual group 9600 P 001 Fastener Identification Torque Refer to the component manufacturer s service publications fo...

Page 131: ... 9 3 Front Axle TAK 4 Suspension Refer to the Pierce Service Manual group 0152 P 004 TAK 4 Maintenance Inspection and Troubleshooting for suspension inspection information Refer to the Pierce Service Manual group 0601 P 002 TAK 4 Steering Components and Adjustments for alignment information 6 9 4 Rear Axle Inspect the rear axle for damage leaks or interference s with other chassis components Refer...

Page 132: ...6 10 Brakes 6 10 1 Brakes General 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 ...

Page 133: ...ound in the Pierce Service Manual group 0251 V 019 Bendix EB ES Air Drum Brakes 6 10 3 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 lubri...

Page 134: ... 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 spacers or shims incorrectly may affect spring performance or durabi...

Page 135: ... inspection information Refer to the Front Axle Suspension chapter of the Pierce Service Manual for additional TAK 4 service group information 6 13 2 Rear TAK 4 Suspension Refer to the Pierce Service Manual group 0201 P 001 steering or 0201 P 002 non steering TAK 4 Maintenance Inspection and Troubleshooting for suspension inspection information Refer to the Rear Axle Suspension chapter of the Pier...

Page 136: ...e 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 th...

Page 137: ...n 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 I O Module which then causes the I O Module to turn on the i...

Page 138: ...ption 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 Output Power Module Clear Case Option A label identifies the output corresponding to the...

Page 139: ...n 6 15 3 Wire Harnesses and Electrical Connectors 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 6 16 Electrical AC 6 16 1 Alternating Current AC System 120V 240V Introduction This vehicle may be equipped with line volta...

Page 140: ... 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 6 16 4 Inverters NOTE High voltage inverter wiring may NOT be marked for easy identification as high voltage Disconnect power before removing any...

Page 141: ...e 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 ...

Page 142: ...ment 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 All Pierce Custom Chassis are equipped with an ember and moisture separation screen located upstream of the air filter The primary function of this s...

Page 143: ...t of parts with those of inferior quality may lead to lower performance reduced engine life or component failure 6 17 5 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 6 17 6 Engine Diagnostic Software Detroit 2010 EPA 2013 ...

Page 144: ...0 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 Tighten 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 ...

Page 145: ...when removing the radiator cap Always allow engine to cool completely before opening radiator cap Wrap a thick heavy cloth around cap Push down and turn radiator cap to first notch position Pause before opening completely to allow any remaining pressure to escape Failure to comply could result in burns from hot steam or coolant Proper corrosion inhibitor levels must be maintained to prevent premat...

Page 146: ... have a vent petcock in the upper coolant tube between the engine outlet and the radiator inlet If present open the vent petcock and place a container underneath the petcock to capture the small amount of coolant that will flow out during the fill process 3 Remove pressure cap and fill the system at a rate of approximately 2 3 GPM Observe the vent petcock while filling and close it securely after ...

Page 147: ...ortant with all 2010 EPA 2013 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...

Page 148: ...Consult your Pierce Dealer for exhaust extraction systems that are compatible with the Pierce diffuser tips Building exhaust extractor systems used with 2010 EPA 2013 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 these engines All customer installed hardware needs to be k...

Page 149: ...lt of surface film or impregnation and the presence 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 anal...

Page 150: ...entified 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 transmission manufacturer s operator s manual for additional information concerning maintenance schedules lubrication recommendations and inspection procedures Have transmission serviced only by a manufacturer s authorized service facili...

Page 151: ...e Service Manual group 0601 P 006 TAK 4 Rear Steering Components and Adjustments 6 24 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 A replacement type filter element is located in the pump reservoi...

Page 152: ...e Torque Ft Lbs N m Steering Gear Saber 2014 Enforcer Two top bolts securing the steering gear to the frame 7 8 9 UNC 379 513 Steering Gear Saber 2014 Enforcer Two lower bolts the steering gear to the frame 7 8 9 UNC 379 513 Steering Shaft Gear Box Bolts securing 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 ...

Page 153: ...r or attach in a manner that prevents damage to these components 3 Remove any water pipes air intake pipes or accessories that may be damaged during the towing hook up procedure or during transit 4 Attach the towing device 5 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...

Page 154: ...e not meant for long distance towing on public highways 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 ...

Page 155: ...a Front Tire Lift Device To tow with a front tire lifting device the steering dwell mechanism must be disconnected at the input shaft This method will require the steering system to be re timed before the vehicle is placed back into service Refer to the vehicle service manual for steering timing procedure Towing of a vehicle equipped with the TAK 4 front suspension by attaching to or lifting by an...

Page 156: ...r the steering wheel NOTE Match marking is not necessary but may serve as a secondary verification during re timing 2 Match mark steering shaft 1 and dwell mechanism front input shaft 2 3 Remove screw 3 and nut 4 and remove steering shaft 1 from dwell mechanism 5 4 Support steering shaft for transport 5 Before placing the vehicle back into service re time the steering system Refer to TAK 4 Rear St...

Page 157: ...o not lift the front of the disabled vehicle by attaching to or lifting by any component or structure of the TAK 4 suspension Special precautions are necessary when using the tire lift method on a TAK 4 T3 equipped truck in order to prevent damage to the steering system See TAK 4 T3 Rear Steering Axle Towing on page 6 33 A typical Pierce Custom Chassis can be towed using an 138 inch underlift reac...

Page 158: ...t 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 extension 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 ...

Page 159: ... 2018 Pierce Manufacturing Inc All Rights Reserved Towing 6 37 MAINTENANCE Figure 6 10 Possible Frame Fork Attachment Locations POM0104 POM0105 POM0106 POSSIBLE FRAME FORK ATTACHMENT LOCATIONS ...

Page 160: ...ing on the vehicle are identified by a Connector Disconnect Tag P N 91 0250 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 ...

Page 161: ...ber behind transmission 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 Control Module TCM Saber 2014 Enforcer in passenger side instrument panel FOAM PRO FOAM SYSTEM All parts of the Foam Pro system must be disconnected before welding This includes the positive and negative ba...

Page 162: ...e battery terminals 2 Repeat this procedure on the passenger side of the truck with a second Anti Zap Device 3 If there is an isolated battery on the truck then you must also connect a third Anti Zap across its battery terminals 4 Make sure the green indicator is ON and the red indicator is OFF for each of the devices 5 Turn OFF the Battery Switch Figure 6 13 Connecting the Anti Zap Device 1395 6 ...

Page 163: ... cool down 6 27 2 Fire Service Ratings There are two cases where intermittent fire service ratings can apply extra load and extra speed Extra Load In this case the tire is allowed to carry extra load higher than the standard rating Extra Speed In this case the tire is allowed to attain higher speeds than the standard maximum speed rating A fire service rated tire can carry extra load or attain hig...

Page 164: ... 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 capac...

Page 165: ... 13220 D 16895 17820 18770 19690 20720 22700 23110 23520 23800 kg per axle S 4257 4491 4731 4962 5221 5602 5665 5831 6000 D 7664 8083 8514 8931 9399 10297 10483 10669 10800 PSI 75 80 85 90 95 100 105 110 115 lbs per axle S 9980 10560 11140 11740 12310 12910 13480 14060 14780 D 17700 18700 19800 20800 22000 23200 24400 25600 27000 1 kg per axle S 4527 4790 5053 5325 5584 5856 6115 6378 6700 D 8029 ...

Page 166: ...s 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 6 27 6 Tire Wear Inspection Inspect tires for signs of abnormal or excessive wear Sufficient tread depth is essential to proper handling and braking performance Refe...

Page 167: ...nce 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 will also adjust if tires become out of balance due to mud in the tire tread...

Page 168: ...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 6 28 3 Hub Piloted Wheel Installation 1 Slide front wheel or inner rear wheel over studs being careful not to damage stud threads 2 Slide outer rear wheel over studs Improper installation methods or component ...

Page 169: ...ervice 6 28 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 6 15 Wheel Nut Tightening Sequences POM0115 3 Snug up nuts alternately in the sequence shown DO NOT tighten them fully until all have been seated This procedure will per...

Page 170: ...al turns loosen and retighten inner cap nuts and then tighten outer cap nuts Torque to recommended levels as specified in Table 6 11 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 Ta...

Page 171: ...M0117 4 Align the valve locators between the spokes Secure clamps 3 evenly in position Snug up nuts in the sequence shown Do not tighten nuts fully 5 After the 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 lbs This will permit the rims to properly align themselves on...

Page 172: ...ions 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 Loose missing or damaged nuts or clamps Bent or stripped studs Severe marring or gouging beneath fasteners Damaged or missing rim valv...

Page 173: ...ierce vehicle in its basic or most common form Because custom chassis are built with a variety of components from different vendors be sure to refer to the inspection or service documentation for those vendor components installed on your vehicle Many of these vendor documents can be found in the Pierce Service Manual 7 1 1 Initial Inspection Upon Delivery Initial Preventative Maintenance Checks an...

Page 174: ...or signs of oil or coolant leaks Daily Engine Oil Inspect for signs of oil leaks Check oil level using dipstick sight glass or electronic monitor Daily 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 the tire manufacturer s load inflation recommendations Daily Trans...

Page 175: ...s Inspect for tightness corrosion and integrity Weekly Electrical Harnesses and Wires Inspect for rubbing fraying or looseness Weekly 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 integrit...

Page 176: ...or equivalent Monthly 3 000 Driveshaft Slip Joints Lubricate with Lithium NLGI grade EP2 grease Monthly 3 000 Driveshaft U Joints Lubricate with Lithium NLGI grade EP2 grease Monthly 3 000 Radiator and Charge Air Cooler Cores Clean debris to ensure unimpeded air flow through cores Monthly 3 000 Spring Pins Lubricate with Lithium NLGI grade EP2 grease Monthly 3 000 Steering Intermediate Links Lubri...

Page 177: ...d Adjust Spray with silicone lubricant 6 Months Cab Door Latches Lubricate with Lubriplate105 grease or equivalent 6 Months Cab Door Strikers Inspect and adjust 6 Months Door Window Regulators Lubricate with Lithium NLGI grade EP2 grease 6 Months Seat Adjuster Slides Lubricate with Lithium NLGI grade EP2 grease 6 Months Steering Gear Lubricate with Lithium NLGI grade EP2 grease 6 Months Tire Align...

Page 178: ... grease Annual 100 000 Cab Mounting Bolts Check torque and tighten as required Annual Spring U Bolts Check torque and tighten as required Annual 24 000 Steering Drag Link Ball Joints Lubricate with Lithium NLGI grade EP2 grease Annual 100 000 Steering Hydraulic System Replace filter and hydraulic fluid in power steering reservoir s with TES 389 approved fluid Annual Comments or Additional Items 3 ...

Page 179: ...ge See Air Dryer Manual Axle Rear Replace lubricant initial drain and fill See Axle Manual Axle Rear Replace oil 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 grade and viscosity See Engine Manual Engine Oil Filter Replace See Engi...

Page 181: ...tion 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...

Page 182: ...haust manifolds and moving parts steering shaft throttle linkage fans etc Maintain as great a distance as possible between mobile 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 ...

Page 183: ...a 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...

Page 185: ...ing the vehicle in service and free of corrosion or other issues B 1 1a Graphics Lettering and Striping Pierce Custom Cabs may be adorned with graphics using any or all of the following methods Graphics Type Description 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 bondin...

Page 186: ... or Detergents Use a mild non abrasive detergent soap or a wash and wax type soap specifically formulated for vehicle washing This type soap has been formulated to have minimal effect on waxed surfaces Harsher de greasing soaps i e dish soap can be abrasive to the surface including graphics and or strip the protective wax Mix with cool or luke warm water at the recommended dilution B 2 1b Water NO...

Page 187: ...can be rinsed clean before the soap dries Do not allow soap to dry on the surface 3 Apply the soapy wash solution using a sponge mitt or soft brush from the top of the vehicle down with a gentle cleaning motion Rinse the applicator often Be sure to wash all spaces cracks and crevices including compartments door sills jams behind rub rails etc 4 Dry all surfaces with a clean soft non abrasive cloth...

Page 188: ...tible with each other Apply a rust proofing compound to the undercarriage of the apparatus Pierce recommends an annual application of Carwell Carwell is an oil based product designed to prevent or stop corrosion It is available from Pierce dealers trained in its application or it can be applied by yourself It is an inexpensive way to reduce corrosion on frame rails supports etc Other rust proofing...

Page 189: ...ls are subject to moisture Electrons will begin to pass from the least corrosion resistant metal to the other similar to the way a dry cell battery works This leads to rapid corrosion known as galvanic corrosion Even a small scratch on a painted surface can be enough to create galvanic corrosion The more dissimilar the metals i e aluminum and stainless steel the more rapid the corrosion rate Howev...

Page 190: ...f 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 Repair any nicks or deep scratches in the paint as soon as discovered with commercially available touch up primers and paints 1 Clean the area with Wax Grease Remo...

Page 191: ...6 23 Antilock Braking System ABS 5 50 Automatic Active Regeneration Cummins Engines 5 23 Detroit Diesel 5 28 Automatic Lubrication System 6 7 Additional Information 6 9 Condition of Lube Points 6 7 Inspection 6 7 Reservoir 6 7 Automatic Transmission 5 44 Auxiliary Braking System 5 54 Auxiliary Front Wheel Lock 5 53 Auxiliary Power Units APUs 6 18 Axle Weights and Axle Capacity 3 1 Axles 5 46 6 9 N...

Page 192: ...and Windows 6 1 Downhill Operation or Heavy Braking 5 50 Drilling Holes 3 8 Driveshafts 6 27 E Electrical 5 13 Before Servicing 6 19 Electrical AC 6 17 Introduction 6 17 Electrical DC 6 17 Electrocution Hazard from Overhead Power Lines 2 8 Electromagnetic Retarder 5 54 Electronic Stability Control ESC 5 57 Emergency Parking Brake Release 5 52 Emergency Shutdown 5 36 Engine 6 20 Running the Engine ...

Page 193: ...hrottle 5 42 Hazard Flashers 5 16 Heater Shut Off 6 2 Heating Ventilation Air Conditioning HVAC 6 2 High Heat Sources 5 17 High Pressure Hydraulic Fluid 2 9 Hinges 6 2 Hose and Hose Reels 4 14 Hose Clamps 6 22 Hoses 6 22 Hourmeter 5 15 Hub Piloted Wheel Installation 6 46 HVAC Velocity Impel Saber 2014 Enforcer 4 13 HVAC Velocity Impel 4 13 HVAC Velocity Impel Air Conditioning 4 13 Defroster 4 13 H...

Page 194: ...uel Rich Atmosphere 5 39 Oshkosh TAK 4 Rear Axles 5 48 Other Fasteners 6 8 Overheat Warnings 5 55 Overview 6 14 P Paint Touch Up B 6 Parked Stationary Regeneration Cummins 5 24 Detroit Diesel 5 29 Parking Brakes 5 51 Passive Regeneration Cummins 5 23 Detroit Diesel 5 28 Periodic Inspection 6 20 Power Take Off Control 5 45 Precautions When Tilting the Cab During Maintenance Actions 6 6 Preparation ...

Page 195: ...ment 5 58 Steering Reservoir 6 29 Steering System Fastener Torque 6 30 Stopping the Engine 5 36 Stud Piloted Wheel Installation 6 47 Supplemental Restraint Airbag SRA 4 8 Surface Restoration B 6 Suspension 3 12 Suspension Seat Safety System S4S 4 7 Suspension Shackles 6 12 T Tachometer 5 16 TAK 4 Rear Axles 5 48 TAK 4 Steering 6 29 TAK 4 Suspension 6 13 TAK 4 Suspension Towing 6 33 Tanker 2 9 Char...

Page 196: ...5 16 Warnings and Cautions 2 1 Warnings Overheat 5 55 Washing the Vehicle B 2 Water Fording Capability 5 18 Water Pump 6 22 Waxing Instructions B 5 Weatherstrip 6 2 Weekly Inspections 7 3 Welding 3 8 Welding Instructions 6 38 After Welding 6 40 Battery System Protection 6 40 Before Welding 6 38 Welding on Frames 6 38 Wheel Installation General 6 46 Wheel Torque 6 50 Wheels 6 46 Who Should Use Serv...

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