E-1

Subsidiary of Federal Signal Corp

VEHICLE INSPECTIONS AND SERVICE As with any machine, care should be taken to avoid being injured when performing maintenance or repairs or making any checks. Improper or incomplete service could result in the vehicle not working properly which, in turn, may result in personal injury or damage to the vehicle or its equipment. If you have any question about carrying out any part of the service, have that part of the service done by your authorized Emergency One dealer or your departments mechanic. Remember that Daily and Weekly inspections are the responsibility of the vehicle Driver per NFPA 1002 Fire Apparatus Driver/Operator Professional Qualifications. Your vehicle has been engineered and manufactured to provide economical and trouble-free service. However, it is the owner’s responsibility to see that the vehicle receives proper care and maintenance. The following Inspection and Service sheets are intended to aid in the proper servicing of your Emergency One vehicle. The inspection and service sheets are not intended to supersede the supplied component service literature found in your Emergency One Service Manual. Throughout these service sheets you will find references to the component manufacturer’s service literature. The component manufacturer’s service literature is more detailed and includes specific instructions and procedures. DAILY and WEEKLY INSPECTION SHEETS The person(s) inspecting the unit should use the following codes in the appropriate code box under each component to be inspected: “OK” should be used when a listed component is fully functional with no defect. “R” should be used when a listed component is not fully functional and requires service beyond the inspectors responsibilities. “S” should be used when a listed component had a deficiency that has been corrected by the inspector. “N/A” should be used when a listed component is not applicable to the vehicle being inspected. The person(s) inspecting should list the date that the inspection is being conducted on, the vehicle’s shop order number, the vehicle’s engine hours, and mileage. After the daily inspection is completed the person(s) inspecting should neatly sign his or her name. If necessary, the inspector should write comments on a separate sheet. You will notice the daily inspection sheets are designed to be used for 16 days (this takes 31 day months into consideration). A total of 2 sets of daily inspection sheets should be used for each month. The Daily Inspection Sheets follow this page. The Weekly Inspection Sheets are designed to be used for 5 weeks if the a month requires. After the starting month is over new sheets should be started for ease of tracking inspections. Your department should make as many copies of the Daily and Weekly Inspection Sheets as necessary. The Weekly Inspection Sheets follow the Daily Inspection Sheets after this page. You must always complete the Daily Inspection Sheets before beginning the Weekly Inspection Sheets. Weekly Inspection Sheets build on the Daily Inspection Sheets.

September 1998

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Page 1

Drain Reservoirs Slowly

CAB

Leaks

Seat Belts

Windshield Wipers

Emergency Response Sirens

TRANSMISSION

Air/Electric Horns

Emergency Response Lights

Parking Lights

Driving Lights

Retarder Operation

Operation

ENGINE

Transmission Fluid Level

Unusual Noises

Drive Belt Tightness

Operation

Hi Idle

Idle Speed

Coolant Level

Oil Level

Starter Operation

Engine Alarms/Indicator Lights

DAILY INSPECTION CHECKLIST AIR SYSTEM SHOP ORDER NUMBER

ENGINE HOURS DATE MILEAGE INSPECTED BY

Page 2

Foam Tank Level Gauge

Water Tank Level Gauge

Primer Fluid Reservoir

Primer Operation

Relief Valve/Pressure Governor

TIRES and WHEELS

Panel Lights

Panel Water Temp. Gauge

Panel Oil Pressure Gauge

Panel Tachometer

Panel Throttle

Engagement

Wheel Nuts Signs of Looseness

Tread Condition

AXLES

Air Pressure

Visual Damage

BRAKES

Wheel Seals

Parking Brake

COOLING SYSTEM

Operation

Unusual Noises

Radiator Condition

Coolant Level

DAILY INSPECTION CHECKLIST PUMP SHOP ORDER NUMBER

ENGINE HOURS DATE MILEAGE INSPECTED BY

Page 3

Foam Tank

Water Tank

Axles

Transmission Fluid

GENERATOR

Fuel

Power Steering

Engine Oil

Coolant

Circuit Breakers

Cord Reel(s)

Receptacles

Quartz Lights

BODY

Remote Switches

Oil Level

Start & Stop

Grab Handles

Deck Lights

Hose/Cord Reel Rollers

Hose/Cord Reel Rotation

Inspect Door Ajar Switches

Compartment Door Latching

DAILY INSPECTION CHECKLIST LEAKS SHOP ORDER NUMBER

ENGINE HOURS DATE MILEAGE INSPECTED BY

Page 1

Loose or Corroded Terminals

TILT CAB

Electrolyte Level

Loose Wiring

Switch Operation

Positive Latching

ENGINE

Fluid Leaks

Operation

Reservoir Fluid Level

Fuel Filter (check for leaks or damage)

Oil Filter (check for looseness or leaks)

Air Cleaner (check for looseness or open latches)

WEEKLY INSPECTION CHECKLIST BATTERY SHOP ORDER NUMBER

ENGINE HOURS DATE MILEAGE INSPECTED BY

Page 2

Valves Operation

STEERING SYSTEM

Pressure/Suction Gauges

Transfer Valve

Steering Wheel (check for excessive play)

COOLING SYSTEM

Steering Wheel (check for free turning with engine running)

Hose Clamps (check for tightness)

AIR SYSTEM

Hose Condition (check for worn, frayed, cut, or leaking hoses)

AIR COMPRESSOR

Lines & Hoses (check for chaffing and/or leaks)

Low Air Pressure Indicator

Governor Cut-in & Cut-out

Operation

WEEKLY INSPECTION CHECKLIST FIRE PUMP SHOP ORDER NUMBER

ENGINE HOURS DATE MILEAGE INSPECTED BY

Subsidiary of Federal Signal Corp

1 MONTH, 3 MONTH, 6 MONTH, AND 1 YEAR SERVICE The following 1 MONTH, 3 MONTH, 6 MONTH, and 1 YEAR service sheets are intended to be used by your department’s maintenance mechanics. All information should be neatly written in the boxes at the beginning of the service sheet. This information will help your department maintain accurate service records. The servicing mechanic should fill in each code box with the following appropriate code: “OK” should be used when a listed component is fully functional with no defect. “S” should be used when a listed component had a deficiency or service repaired or completed by the mechanic. “N/A” should be used when a listed component or service is not applicable to the vehicle being serviced. The mechanic should initial the MECH box after the listed component check or service is completed. Any comments concerning the listed component check or service should be entered in the COMMENTS box. Many of the service items below have detailed instructions located in your Emergency One vehicle service manual. Please refer to your Emergency One vehicle service manual whenever a question concerning a procedure arises. The servicing mechanic should sign and print his or her name in the gray boxes at the end of the service sheet. The following service sheets should be copied by your department and used for servicing your Emergency One vehicle according to each service interval.

September 1998

Page 1.2

Subsidiary of Federal Signal Corp

1 MONTH SERVICE SHOP ORDER

ODOMETER

SERVICE FACILITY NAME

HOURS

HOURS SINCE LAST PM

SERVICE F. PHONE #

DATE

SERVICE F. CONTACT PERSON

CUSTOMER NAME

SERVICE F. CITY, STATE

CODE KEY: OK-(Listed component is fully functional) S-(Listed component had a deficiency or service repaired/completed by the mechanic) N/A-(Listed component or service is not applicable to the vehicle being serviced) FIRE PUMP HALE

CODE MECH

COMMENTS

CODE MECH

COMMENTS

Check all drive line and flange bolts to ensure no bolts are missing, all bolts are tight, and bolt used are “Grade 8” strength. Check all plumbing piping for leaks or corrosion. Repair as necessary. Check all valves to insure free movement and no leaks. Repair as necessary. Suction Check Valve: Inspect to insure free movement. Lubricate as necessary. Transfer Valve: Grease (use multi purpose grease). Gearbox: Check fluid level and driveline tightness. Packing Gland: Inspect to insure proper sealing (8-10 drops of water per minute indicates proper sealing). FIRE PUMP WATEROUS Check all drive line and flange bolts to ensure no bolts are missing, all bolts are tight, and bolt used are “Grade 8” strength. Check all plumbing piping for leaks or corrosion. Repair as necessary. September 1998

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Subsidiary of Federal Signal Corp

Check all valves to insure free movement and no leaks. Repair as necessary. Pilot Valves: Check operation and clean strainer. Intake Screens: Check Replace if required.

Condition.

Chain Drive Transmission: Check lubricant level. (refer to Waterous Service in Service Manual). REAR AXLE

CODE MECH

COMMENTS

Check lubricant level. SERVICING MECHANIC (SIGN NAME)

September 1998

SERVICING MECHANIC (PRINT NAME)

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Subsidiary of Federal Signal Corp

3 MONTH or 125 HOUR SERVICE SHEET SHOP ORDER

ODOMETER

SERVICE FACILITY NAME

HOURS

HOURS SINCE LAST PM

SERVICE F. PHONE #

DATE

SERVICE F. CONTACT PERSON

CUSTOMER NAME

SERVICE F. CITY, STATE

CODE KEY: OK-(Listed component is fully functional) S-(Listed component had a deficiency or service repaired/completed by the mechanic) N/A-(Listed component or service is not applicable to the vehicle being serviced) ENGINE

CODE MECH

COMMENTS

CODE MECH

COMMENTS

CODE MECH

COMMENTS

CODE MECH

COMMENTS

Fluid Leaks: Visually inspect for oil, water or fuel leaks, tighten fittings as required. Drive belt tension: Adjust as required (should have between 1/2” and 3/4” deflection). Engine Mounting Bolts: Torque to maintain tightness. TRANSMISSION Breather: Inspect. Clean or replace if necessary (refer to Transmission Service in Service Manual). AIR COMPRESSOR Compressor Mounting Bolts: Torque to maintain tightness. Filter: Replace (refer to Compressor Air Filter Service in Service Manual). AIR SYSTEM Low Air Warning System: Check for proper cut-in at 70 psi and below. Adjust as required. Air Dryer: Perform serviceability check. (refer to Air Dryer Service in Service Manual). Hoses: Inspect all hoses and connections for cracks, cuts, kinks, chaffing, or loose fittings. Repair or replace as necessary. September 1998

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Subsidiary of Federal Signal Corp

COOLING SYSTEM

CODE MECH

COMMENTS

CODE MECH

COMMENTS

Mounting Bolts: Check radiator for tightness. Tighten as necessary. Hoses: Check for worn, frayed, cut, or leaking hoses. Repair or replace as necessary. Hose Clamps: Check for loose, cracked, or corroded clamps. Repair or replace as necessary. Radiator Condition: Check for damage or leaks.. Repair as necessary. Shroud: Check to insure tightness and condition. Repair as necessary. Fan: Check for looseness, bent, or broken blades. Repair or replace as necessary. Coolant Concentration (Detroit Diesel Only): Check with test kit. Should be 50/50 mix (refer to Detroit Diesel Service in Service Manual). STEERING SYSTEM Power Steering Pump: Check fluid level and pump for leaks. Add fluid, repair leaks as necessary (refer to Steering Fluid Reservoir in Service Manual). Power Steering Pump: Check mounting bolts for tightness. Torque if required. Steering Gear: Check for leaks, repair as necessary (refer to Sheppard Power Steering in Service Manual). Steering Gear: Lubricate bearing cap (refer to Sheppard Power Steering in Service Manual). Miter Box: Lubricate miter box (refer to Sheppard Power Steering in Service Manual).

September 1998

Page 1.6

Subsidiary of Federal Signal Corp

BRAKES

CODE MECH

COMMENTS

CODE MECH

COMMENTS

CODE MECH

COMMENTS

CODE MECH

COMMENTS

CODE MECH

COMMENTS

Foot Operated Brake Valve: Lubricate mechanical parts with light oil (refer to Bendix Service in Service Manual). Operation: Check for uneven action, dragging, slow or spongy action, and squealing or chatter. Repair as necessary. REAR AXLE Check for leaks. Repair as necessary (refer to Axle Service in Service Manual). TIRES AND WHEELS Wheels: Inspect for damage. Replace as necessary (refer to Accuride Wheels in Service Manual). Wheel Nuts: Re-torque to proper specifications (refer to Accuride Wheels in Service Manual). DRIVELINE Lubricate: Universal joints, slip yoke, and splines (refer to Shafts and U-Joints in Service Manual for proper lubricants). SUSPENSION Spring Pins: Lubricate. Shackles: Lubricate. Bronze Center Bushings (Tandem): Lubricate. F&R Spring U-Bolts: Torque (refer to Torque Procedures in Service Manual). Shock Absorbers: Torque shock absorber bracket to frame bolts (refer to Torque Procedures in Service Manual). SERVICING MECHANIC (SIGN NAME)

September 1998

SERVICING MECHANIC (PRINT NAME)

Page 1.7

Subsidiary of Federal Signal Corp

6 MONTH or 250 HOUR SERVICE SHOP ORDER

ODOMETER

SERVICE FACILITY NAME

HOURS

HOURS SINCE LAST PM

SERVICE F. PHONE #

DATE

SERVICE F. CONTACT PERSON

CUSTOMER NAME

SERVICE F. CITY, STATE

CODE KEY: OK-(Listed component is fully functional) S-(Listed component had a deficiency or service repaired/completed by the mechanic) N/A-(Listed component or service is not applicable to the vehicle being serviced) ENGINE Drive belt necessary.

condition:

Replace

CODE MECH

COMMENTS

CODE MECH

COMMENTS

CODE MECH

COMMENTS

CODE MECH

COMMENTS

if

Oil and Filter: Change oil and filter (refer to Engine Service in Service Manual). Crankcase: Clean crankcase breather (refer to Engine Service in Service Manual). TRANSMISSION Oil Cooler: Inspect for damage or leaks. Repair as necessary. Neutral Safety: Check operation to insure vehicle will not start out of neutral. Repair if necessary. Filter: Change (refer to Transmission Service in Service Manual). TRANSFER CASE Change oil. Mounting Bolts: Check for tightness. Tighten if necessary. Check for leaks. Repair as necessary. AIR INTAKE Filter: Change element. Inspect piping and clamps for cracks or looseness. Repair as necessary. September 1998

Page 1.8

Subsidiary of Federal Signal Corp

AIR SYSTEM CODE MECH Pressure Control Valve: Conduct operation and leakage test (refer to Pressure Control Valve Service in Service Manual).

COMMENTS

COOLING SYSTEM CODE MECH Coolant Concentration (Detroit Diesel and Cummins): Check with test kit. Should be 50/50 mix (refer to Detroit Diesel or Cummins Service in Service Manual).

COMMENTS

Coolant Filter (if equipped): Replace (refer to Cooling System in Service Manual if equipped). FUEL SYSTEM CODE MECH Fuel/Water Separator: Change element (refer to Racor Service in Service Manual). Fuel Filters: Change elements (refer to Engine Service in Service Manual). STEERING SYSTEM CODE MECH Power Steering Reservoir: Replace element (refer to Steering Fluid Reservoir in Service Manual).

COMMENTS

COMMENTS

Inspect drag link, K-pin, and tie rod for wear or damage. Repair as necessary. (refer to Sheppard Power Steering in Service Manual). BRAKES CODE MECH Park Control Valve: Disassemble and clean (refer to Midland Brake in Service Manual). Disc Brake Pads: Inspect. Replace if necessary. Lubricate Auto Slack Adjusters (refer to Cam Brakes in Service Manual for proper procedures and recommended lubricates).

COMMENTS

Lubricate: S cam brake components; camshaft bushing, and anchor pins. Lubricate: Disc brake calipers. September 1998

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Subsidiary of Federal Signal Corp

AXLES

CODE MECH

COMMENTS

CODE MECH

COMMENTS

CODE MECH

COMMENTS

CODE MECH

COMMENTS

CODE MECH

COMMENTS

Front Axle: Check wheel ends oil level (if equipped refer to Front Axle Service in Service Manual). Rear Axle: Drain and refill (refer to Axle Service in Service Manual). Rear Axle: Clean breather and magnetic fill plug (refer to Axle Service in Service Manual).. SUSPENSION Shock Absorbers: Inspect for leakage. Replace if necessary. EXHAUST SYSTEM Flange Bolts: Check for tightness. Tighten if necessary. Flange Gaskets: Check for leaks. Repair if necessary. Pipe Condition: Inspect for damage. Repair if necessary. Flex Pipe Condition: Inspect damage. Repair if necessary.

for

Clamps: Check for tightness or deterioration. Tighten or repair if necessary. FIRE PUMP HALE Vacuum test Pump Cooler: Inspect for leaks. Repair as necessary. FIRE PUMP WATEROUS Chain Drive Transmission: Replace gear lube (refer to Waterous Service in Service Manual). Anodes: Check Condition. Replace if necessary. Impeller Shaft Bearings: Add grease. Mechanical Seal: Flush seal chamber (refer to Waterous Service in Service Manual).

September 1998

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Subsidiary of Federal Signal Corp

BODY

CODE MECH

COMMENTS

CODE MECH

COMMENTS

CODE MECH

COMMENTS

Hose Reel Chain: Lubricate and check for slack. Adjust if necessary. Hose Reel Mounting Bolts: Check for tightness. Tighten if necessary. Cord Reel Chain: Lubricate and check for slack. Adjust if necessary. Cord Reel Mounting Bolts: Check for tightness. Tighten if necessary. GENERATOR Oil: Change (refer to Generator Service in Service Manual). Oil Filter: Change (refer to Generator Service in Service Manual). Fuel Filter: Change (refer to Generator Service in Service Manual). Mounting Bolts: Check for tightness. Tighten if necessary. Wiring: Check for corrosion, chafing, or deterioration. Repair as necessary. ELECTRICAL Check battery hold down clamps for tightness or corrosion. Repair as necessary. Battery: Check specific gravity. Adjust if necessary. Wiring: Inspect for chaffing, corrosion, or other deterioration. Repair as necessary. Terminals: Inspect for corrosion or looseness. Repair as necessary. Alternator: Inspect mounting bolts for looseness. Tighten as necessary. SERVICING MECHANIC (SIGN NAME)

September 1998

SERVICING MECHANIC (PRINT NAME)

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Subsidiary of Federal Signal Corp

1 YEAR or 500 HOUR SERVICE SHOP ORDER

ODOMETER

SERVICE FACILITY NAME

HOURS

HOURS SINCE LAST PM

SERVICE F. PHONE #

DATE

SERVICE F. CONTACT PERSON

CUSTOMER NAME

SERVICE F. CITY, STATE

CODE KEY: OK-(Listed component is fully functional) S-(Listed component had a deficiency or service repaired/completed by the mechanic) N/A-(Listed component or service is not applicable to the vehicle being serviced) ENGINE Engine Mounts: Inspect for cracks or deterioration. Replace if necessary. TRANSMISSION Fluid: Change (refer to transmission Service in Service Manual). AIR SYSTEM Air Dryer: Change desiccant cartridge (refer to Air Dryer Service in Service Manual) . COOLING SYSTEM Cooling Fins: Inspect for damage or clogging. Repair or clean as necessary. FUEL SYSTEM Tank: Inspect for damage, leaks, or loose hardware/fittings. Repair as necessary. Tank: Drain fuel to remove all condensation from tank and refill. STEERING SYSTEM Inspect steering stop screws for proper setting. Adjust as required (refer to Sheppard Steering Service in Service Manual). Road Test: Inspect for wander or other signs of an out-of-alignment condition. Repair as necessary. September 1998

CODE MECH

COMMENTS

CODE MECH

COMMENTS

CODE MECH

COMMENTS

CODE MECH

COMMENTS

CODE MECH

COMMENTS

CODE MECH

COMMENTS

Page 1.12

Subsidiary of Federal Signal Corp

TIRES AND WHEELS Wheel Bearings: Check for wear or damage. Repair as necessary (refer to Axle Service in Service Manual) Tires: Inspect for signs of uneven wear. Repair as necessary. Road Test: Inspect for shimmy or tire hop. Repair as necessary. DRIVELINE Inspect for signs of wear or misalignment. Repair as necessary. Check bearing capscrews for proper tightness. Lubricate: Universal joints, slip yoke, and splines. SUSPENSION Springs: Inspect for broken leaves. Repair as necessary. Check clamps, hangers, and hardware for damage, wear, or corrosion. Repair as necessary. FIRE PUMP HALE Gauges: Check calibration Transfer Cylinder: Lubricate (refer to Hale Pump Service in Service Manual). Pump: Annual Test. AutoLube assembly oil level check; fill or replace oil (refer to Hale Pump Service in Service Manual). ELECTRICAL Alternator: Inspect for wear of brushes or slip rings. Repair as necessary. Alternator: Conduct an output test (refer to Alternator Service in Service Manual). SERVICING MECHANIC (SIGN NAME)

September 1998

CODE MECH

COMMENTS

CODE MECH

COMMENTS

CODE MECH

COMMENTS

CODE MECH

COMMENTS

CODE MECH

COMMENTS

SERVICING MECHANIC (PRINT NAME)

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