Mid-Mount Platform Manual

~ 2005 Pierce Manufacturing Inc.
Part No. PM-A-OM181-O305

DRAWEROF PURPOSE
SCOPE
TABLE OF CONTENTS
1
2
OF MANUAL
CHAPTER 1.
SAFETY
.1.1 1-1.1 INTRODUCTION To THE O~ER- OPERATION AND MAINTENANCE OF THIS AERIAl.. 1-1
1-1.2 DESCRIPTION OF "DANGER", "WARNING", AND "CAUTION". 1.1
1.2. HOW TO CONTACT PIERCE 1-1
LIST OF ABBREVIATIONS 1-2
1-4. BEFORE PLACING THE AERIAL IN SERVICE 1-2
1-4.1 HYDRAULIC OIL ANALYSIS. 1-2
1-4.2 INSPECTING THE AERIAL. 1-2
1-5. CUSTOMER INSTALLED EQUIPMENT 1-2
1-5.1 DRILLING HOLES OR WELDING. ,.."",.""."""""."."",..,.".,.""" 1-2
1-5.2 DISSIMILAR METALS... 1-3
1-5.3 AERIAL MOUNTED EQUIPMENT. 1-3
1-6. SAFETY INFORMA TION 1-3
1-6.1 SAFETY INSPECTION OF THE AERIAL BEFORE OPERATING 1-3
1-6.2 SAFETY WARNING lABELS AND DECALS 1-3
CHAPTER 2.
GENERAL
2-1. EQUIPMENT DESCRIPTION, CHARACTERISTICS, & CAPABIUTIES 2-1
2-1.1 DEVICE CHARACTERISTICS 2-1
2-1.2 LADDER ASSEMBLY 2-1
2-1.3 TURNTABLE DECK 21
2-1.4 TORQUE Box AND OU1RIGGERS 2-1
2-1_5 AERIAL POWER AND CONTROlSTATK)NS 2-1
2-1.6 AERIAL WATERWAY 2-2
2-1.7 COMMUNICATIONS SYSTEM 2-2
2-1.8 ELECTRICAL SYSTEM 2-2
2-1.9 Pu~HOUSE 2-2
2-1.10 AERIAL BODY 2-3
2-2. MID-MOUNT PLATFORM SPECIFICA TIONS 2-4
TABLE 2-1 MID-MouNT PLATFORM SPECIFICATIONS 2-4
TABLE 2-2 SPECIFICATIONS FOR SETUP AND N.F.P.A. 1914 TESTING I PIERCE ADJUSTMENT 2-5
2-3. LOCA TlON AND DESCRIPTION OF MAJOR COMPONENTS 2-6
2-3.1 COWAAND ZONE INFORMATION CENTER (CZIC) 2-6
2-3.1.1 MAIN AERIAL SCREEN 2-7
2-3.1.2 AERIAL REACH SCREEN , , ,.." , ,., , 2-7
2-3.1.3 AERIAL LEVEL ScREEN 2-8
2-3.1.4 HYDRAULIC SYSTEM SCREEN ~ 2-8
2-3.2 CAB CONTROLS 2-9
2-3.3 TURNTABLE CONTROL CONSOLE 2-10

21.3-21.3-2 EMERGENCY CONTROlS
01.3-29.3-2 BASKET CONTROlS (CENTER)
8.3-2 BASKET CONTROlS (LEFT)
7.3-26.3-2 STABILIZER CONTROlS
5.3-2 LOWER CONTROL STATION
OIL SAMPLE PORT
BASKET CONTROlS (RIGHT)
LOWER PoWER DISTRIBUTION
.3-3 AERIAL OPERA TION
.7-3 1.7-3 OPTIONAL LYFfTM ACESORIES
EQUIPMENT
-33.1.7-3 2.1.7-3 1.1.7-3 7 . 1.4 l lYFEHoISl'"WlNCH LYFEYETM LYFElADERT)( YFESUPORl'" RAPELUNG OPTION RESCUE OPTION SET-UP OPTION BAsKET SET-UP PROCEDURE
SET-UP OPTION PROCEDURE
PROCEDURE
SET -UP PROCEDURE
CHAPTER 2. GENERAL (continued)
2-3.4 TURNTABLE POWER DISTRIBUTION
2-11
2-12
, 2-13
, 2-15
2-16
2-17
2-18
2-19
2-20
2-4. LOAD CHART INFORMATION 2-21
3-1. CHAPTER PRE-DRIVING 3. OPERA - AND TRUCK TIONPOSITIONING 3-1
3-1.1 PRE-DRMNG CHECKS 3-1
3-1.2 PROCEDURE CONCERNS AT THE SCENE 3-1
3-1.3 POSITIONING THE TRUCK FOR OPERAnON 3-1
3-1.3.1 POSmONING UPHill 3-1
3-1.3.2 PoSmONING DO~Hlll 3-2
3-2. STABILIZER SET-UP PROCEDURE 3-3
3-2.2 1.2-3 WATER CAB CONTROLS TOWER WITH WATER PUMP OPERATION 3-4
3-2.3 STABILIZER DEPLOYMENT 3-4
3-2.4 LEVELING THE TRUCK WITHOUT USING "lEVEL ASSIST" 3-5
3-2.5 SHORT JACKING ON ONE SIDE 3-7
3-4. POST OPERATION STOWING PROCEDURE 3-11
3-4.1 STOWING THE AERIAL 3-11
3-4.2 STOWING THE STABILIZERS 3-12
3-4.3 PREPARING FOR ROAD TRAVEl 3-12
3-5. MANUAL OVERRIDE CONTROLS 3-13
3-5.1 MANuAL STABILIZER CONTROL VALVES 3-13
3-5.2 PlATFORM MANUAL CONTROL VALVES 3-14
3-5.3 EMERGENCY PUMP UNIT (EPU) 3-15
3-5.4 EMERGENCY STop BUTTON 3-16
3-6. COLD WEATHER OPERA TION 3-17
, 3-18
3-18
3-18
3-19
3-20
3-21

TABLE OF CONTENTS (Cant.)
CHAPTER 4.
MAINTENANCE
4-1. HYDRAULIC SYSTEM 4-1
4-1.1 HYDRAULIC SYSTEM COMPONENTS 4-1
4-1.2 HYDRAULIC OIL RECOMMENDATIONS 4-1
4-1.3 HYDRAULIC OIL FILTER RECOMMENDATIONS 4-2
4-2. PREVENTIVE MAINTENANCE CHECKS AND SERVICE 4-2
4-2.1 INTRODUCTION 4-2
4-2.2 EXPLANATION OF COLUMNS 4-2
4-3. PRI MARY INSPECTION ... 4-3
TWENTY FIVE (25) HOURIQUARTERL Y INSPECTION 4-4
FIFTY (50) HOUR/ANNUAL INSPECTION 4-5
4-6. FOUR HUNDRED (400) HOUR/ANNUAL INSPECTION 4-7
4-7. EXTREME ENVIRONMENT MAINTENANCE PRECAUTIONS 4-8
4-7.1 GENERAL TEMPERATURE CONCERNS 4-8
4-7.2 EXTREME HIGH TEMPERATURE CONCERNS 4-8
4-7.3 EXTREME Low TEMPERATURE CONCERNS """"" """" """""" '" 4-8
4-7.4 EXTREME WIND SWEPT SAND & DIRT CONCERNS 4-8
4-7.5 SALT AIR ENVIRONMENT CONCERNS 4-8
4-8. STRESSED FASTENER MAINTENANCE 4-9
4-8.1 INTRODUCTION ,.4-9
4-8.2 IDENTIFICAnON AND APPuCAnON OF BOlT SIZES AND GRADEs 4-9
4-8.3 PROPER TORQUE OF ALL SIZES AND GRADES OF BoLTS 4-10
4-8.4 TORQUE WRENCHES AND ASSOCIATED EQUIPMENT 4-10
4-9. LUBRICATION INSTRUCTIONS 4-12
4-10. LUBRICATION CHART 4-13
EQUIPMENT INSPECTION AND MAINTENANCE
WORKSHEET.
INSIDE BACK COVER

THIS PAGE INTENTIONALLY
LEFT BLANK

FOREWORD
1. PURPOSE OF MANUAL
The infomlation in this manual is for the operation and maintenance of Pierce aerial vehicles. It is intended to serve
as a guide to assist qualified drivers and mechanics in the operation and maintenance of their vehicle.
Keep this manual with the vehicle at all times.
2. SCOPE
NOTE
Some of the details of your vehicle's design and construction may be unique to your
department alone. For this reason, infom1ation contained in this manual may be generic at
times. Questions on major inconsistencies between your vehicle's configuration and the
infonnation contained in this manual should be directed to your Pierce Dealer or Sales
Representative.
This operator's manual provides operating and maintenance instructions for vehicles manufactured by Pierce
Manufacturing Inc.
This manual provides information under the following headings:
Safety. Contains important safety information, requirements before placing a vehicle in service, and information
on installing custom equipment and accessories.
General. Includes equipment specifications, location, and description of major components.
Operation. Contains procedures on normal equipment operation and special operating procedures.
Maintenance. Contains scheduled maintenance and lubrication information.
To order a replacement manual or replacement safety waming labels, call Pierce Manufacturing Inc. at 1-888-974-
3723.

FOREWORD
THIS PAGE INTENnONALL Y LEFT BLANK

SAFETY
1-1. INTRODUCTION
1-1.1 To the Owner- Operation and Maintenance of this Aerial.
The information in this manual is for the operation and maintenance of this aerial. The intent is to instruct operators in
the proper operation of this equipment and to warn of improper procedures and potentially dangerous situation.
Only personnel who are totally familiar with this manual and have training are qualified to operate this aerial. It is the
responsibility of the department owning this equipment to permit only qualified personnel to operate this aerial.
Pierce Manufacturing Inc. provides the services of a delivery technician before the unit is placed into service to train
the department personnel in the safe and proper method of operation. The name of each trainee is recorded as proof
of participation in the training. It is the departmenfs responsibility to provide future training, qualification
documentation, and to qualify its operators.
Qualified drivers of other fire apparatus will require further training for the handling of this aerial.
1-1.2 Description of "Danger", "Warning", and "Caution",
THIS SAFETY SYMBOL A INDICATES IMPORTANT SAFETY MESSAGES IN THIS
MANUAL.
WHEN YOU SEE THIS SYMBOL, CAREFULLY READ THE MESSAGE THAT FOLLOWS THIS
SYMBOL.
BE ALERT TO THE POSSIBILITY OF PERSONAL INJURY OR DEATH.
Warning labels located on the vehicle and warning statements contained in this manual all use the same terminology
to warn of potential hazards. Each of these potentially harmful conditions is described below:
A DANGER
A hazard that will result in death or serious personal injury.
A WARNING
A hazard that might result in death or serious personal injury,
A CAUTION
A hazard that might result in personal injury or damage to property or equipment.
The "signal words. of DANGER, WARNING, and CAUTION have specific meanings to alert you on the relative level
or probability of the hazard.
Take the safety warnings seriously. If you do not understand them or have questions about them, contact Pierce
Manufacturing Inc.
Contact Pierce Manufacturing Inc. directly by calling toll-free, 1-888-974-3723 for any of the following:
You have questions about safe operating procedure.
. You require additional or replacement manuals.
You have questions about information contained in this manual.
. You have questions about this product.

SAFETY
1-3. LIST OF ABBREVIATIONS
1-4. BEFORE PLACING THE AERIAL IN SERVICE
1-4.1 Hydraulic Oil Analysis.
Pierce Manufacturing Inc. recommends taking a hydraulic oil sample and having it analyzed before putting the aerial
in service. This analysis serves as a baseline for future oil sample analysis taken at subsequent maintenance
inspections. Comparing results with the original oil test data will help determine the condition and requirement for
additional filtering or fluid replacement. The minimum analysis should include spectrochemical, particle count,
viscosity I and water content. The oil sample should be taken from the petcock valve located under the hydraulic oil
reservoir. after the oil has warmed to nomlal system temperature (1150 F or higher).
1-4.2 Inspecting the Aerial.
Before the aerial is put into service, a primary inspection should be performed. The primary inspection is part of the
preventive maintenance forms provided with your new truck. The reason for this inspection is to check for proper
operation and adjustment of components, along with cleaning and lubrication, after initial training use and delivery
travel.
The operators of the aerial should also become familiar with the inspection process. Their knowledge of a properly
adjusted and maintained aerial could prevent a failure or accident by something that has become loose or damaged.
1-5.
CUSTOMER INSTALLED EQUIPMENT
1-5.1 Drilling Holes or Welding.
The drilling of holes or welding to any structural components of the aerial is not permitted. Non-strudural sheet metal
components may be modified. If in doubt, contact Pierce Manufaduring Inc. for approval and assistance. Pierce
Manufacturing Inc. is not responsible for strudural failures or corrosion caused by unauthorized modifications to the
aerial device.
02rX15 PI8C8 ~-~ AI RW* ~
1-2
~PI8IfOrm

SAFETY
1-5.2 Dissimilar Metals.
Consider the type of metal for the application whenever mounting accessories. Dissimilar metals like aluminum, steel,
stainless steel, brass, etc. when placed in direct contact with each other and subjected to moisture can form a
galvanic reaction leading to rapid corrosion and possible failure of the mounting, fastener, or base materials. Select
mounting material and fasteners to avoid dissimilar metals, or coat all mounting surfaces, base materials and
fasteners with a commercial grade rust-proofing agent (such as those conforming to MIL-C-OO83933A specification).
1-5.3 Aerial Mounted Equipment.
Aerial mounted axes, ladders, pike poles, hose boxes, etc. must be mounted securely to withstand road travel and
extreme aerial operating conditions.
The standard Mid-Mount load chart allows for 1so-pounds of optional equipment to the aerial sections. Pierce
Manufacturing Inc may have already mounted some optional equipment and used some of the additional equipment
weight allowance. Check to see what, if any, allowances remain before adding equipment. Too much added
equipment may require de-rating the capacity.
1-6.1. Safety Inspection of the Aerial Before Operating.
The operator is responsible for knowing the condition of the aerial device before operation. This should include a
quick visual scan of (but not limited to) pins, cables, hydraulic cylinders, loose equipment, basket, etc.
1-6.2. Safety Warning Labels and Decals.
The following tags and labels are placed on the aerial and body to warn of potentially hazardous situations. Read and
understand all labels before operating the aerial. Any lost or damaged labels must be replaced immediately.
~ ~ re1
, ..
YOU MUST MOT OPMATETHIS DE9lCE UNtES5
I YOU HAVE BEEN TAA/NEn rliTHE SAFE OPEAATlON OF
mSDEVICE
2 YOU kNOW AHa FOUOW THE SAFE TV AND OPERA TtNG
RECOMMENOATlOHS CONTAIN£D IN THE MAHUFACTURER'S
IWIUAL5. YOUR EMPLOYER'S WORK RULES AHO APPlICABLE
GO'IERHWffT.l. REGU~TIONS
Al1.PER~NE
WEAAlNG A SAf
TO nE DEvICE.
.IT 1$ a*G
! nt£ AERIAL LA~ oa PLATfORM A
BELT PROPERl T A TT ~D
0'fRA TED mn...1TS RATED LOAD c.PAOTY
" ALl StABII.JZ£RS AU ~OPERL Y O£PLOYEON AN
ADEQUATtL l' SOlID SURfACE
" IT MAS lEU ~~ Y II8SF£CTEO fM ~C:TS 8EFCXU
I ~rON AND USE
DEA~ OR SERIOUS INJURY MAY REI~UO~S(RVED,I
l If tME a.8O\I~ STA.tmEtiTS ARE NOTO.~(~.~
ELECTROCUTION HAZARD
THIS MACHINE IS NOT INSULATED
MAINTAIN SAFE CLEARANCES fROM
ELECTRICAL POW£ft LWU ANOAPPAMTUS YOU MUST
ALLOW f~ PLATFOR.. aWAY. ROCM, OR IAo.
TltIS~RIAL DEVICE DOES NOfPROVIOE PROTECTION fROM
CONTACTWtTHORPRQXIUITYTO AHaECTRJCAU;V
CttARGfO CONOtJCTOR.
DEATH OR SERIOUS INJURY W1U.REI
,~~ SUCH c:Of4TACT OR 1fIADE~T£ CL£A~.'
91-9050
91-0115-002
-om PIiiC8 ~ k1C. AI R9* ~ 1-3
~PI8tbm

SAFETY
91-0790
91-0788
STAND CLEAR
OF STABILIZER
TO AVOID CRUSHING INJURY
91-0791
91.4168
91-0168
91-0115.001
91-0796

SAFETY
91-0262 91-0318
OUT
RIGHT
FRONT
BEAM
DOWN
RIGHT
FRONT
JACK
OUT
LEFT
FRONT
BEAM
DOWN OUT DOWN OUT
LEFT
FRONT
JACK
LEFT
REAR
BEAM
LEFT
REAR
JACK
RIGHT
REAR
BEAM
DOWN
RIGHT
REAR
JACK
IN
UP
IN
UP
IN
UP
IN
UP
YOU MUST NOT OPERATE THESE MANUAL OVERRI~ CONTROLS UNLESS:
1. YOU MUST HAVE ~EN TRAINED IN THE SAFE OPERATIONS OF THIS DEVICE.
2. YOU ARE AWARE OF THE AERIAL POSITION. RAISING A STABfUZER JACK MAY CAUSE THE TRUCK TO TIP OVER.
3. YOU HAVE A SECOND PERSON TO MONITOR THE POSITIONING OF STABILIZERS THAT ARE NOT CLEARLY VISIBLE
4. YOU ARE AWARE THAT SAFETY DEVICES ARE BEING OVERRJDDEN.
DEATH OR SERIOUS INJURY WILL RESULT IF THE ABOVE STATEMENTS ARE NOT OBSERVED.
1091772

SAFETY
Tms PAGE INTENTIONALLY LEFT BLANK

GENERAL
2-1. EQUIPMENT DESCRIPTIQN, CHARACTERI~TICS, & CAPABILITIES
2-1.1 Device Characteristics.
This aerial platform is a mid-mounted behind the cab to a torque box sub-weldment, with front and rear outriggers.
The platform reach is 95 feet above ground, as determined by NFPA 1901. The platform has a 1,000 Ib payload
capacity, at full extension 360 degrees. It is capable of operating on up to a 9-degree slope, with 50 mph wind and
9O-degree water stream at 1,500 GPM.
2-1.2 Ladder Assembly.
Five-section steel lattice aerial ladder, with a safety factor of 2: 1 of the rated load and a stability factor of 1 %: 1. Each
ladder section is trussed vertically and diagonally with round steel tubing.
Ladder extension and retraction motion is provided by dual hydraulic powered cylinders and a cable/pulley system.
Rotation motion is through a 54 in. swing bearing/spur gear, driven by two planetary hydraulic drives. Elevation
motion is through two double acting lift cylinders, giving the ladder the capability of SO below horizontal to 75° above
horizontal.
The ladder is equipped with holding valve cartridges and a rotational brake to restrict ladder movement when system
hydraulic pressure is not present.
2-1.3 Turntable Deck.
The turntable deck construction is with a 1.00 in. thick deck material, coated with a non-skid, chemical resistant
material. Access to the turntable deck is from a set of front body stairwells, located on either side of the truck. The
deck area is illuminated with two lights that are activated by the aerial master switch.
2-1.4 Torque Box and Outriggers.
A welded torsion substructure, with two sets of stabilizers, is bolted to the standard chassis C-channel frame. The
torque box is designed with provisions for an integral ladder storage box, water tank mounting, and water way
plumbing.
The unit is stabilized using level assist front and rear stabilizers, capable of leveling the truck on a go slope. Stabilizer
controls are mounted in the rear of the vehicle and are removable on a coiled cord.
2-1.5 Aerial Power and Control Stations.
The aerial controls are electric over hydraulic, fully multiplexed, and proportional. All controls have fail-safe manual
hydraulic overrides. The engine high idle is microprocessor controlled to automatically adjust the engine rpm to match
hydraulic load requirements.
The lower control station, rear compartment, includes:
. Stabilizer remote control.
. Override switch to override microprocessor. System will record condition at override;
. Emergency Power Unit (EPU) switch;
The turntable control station includes:
. Electronic controls for elevation, extension, and rotation;
. Intercom controls;
. Tip I Tracking light switch;
. Emergency Power Unit (EPU) switch;
.
. Operator's load chart;
Aerial speed switch;

GENERAL
. Command Zone Information Center (CZIC), which displays the following information: current ladder load,
remaining breathing air, current height, reach, and extended length, current water flow & total water flowed,
hydraulic oil level, temperature, & pressure, temperature at tip of aerial, rung alignment, hours of operation, all
wamings for load & operation, and access to all stabilizer information.
The basket control station includes:
. Speed switch;
. Electronic controls for elevation, extension, and rotation;
. Intercom;
. Monitor controls;
. 120 VAC receptacle;
. Command Zone Information Center (CZIC), which displays the following information: current ladder load,
remaining breathing air, current height, reach, and extended length, current water flow & total water flowed,
hydraulic oil level, temperature, & pressure, temperature at tip of aerial, rung alignment, hours of operation, all
wamings for load & operation, and access to all stabilizer information.
2-1.6 Aerial Waterway.
The base of the aerial is equipped with 5 in. water swivel,
horizontal. The telescoping anodized waterway is capable
torque box. The electric aerial monitor is also capable of
monitored by the aerial microprocessor.
2-1.7 Communications System.
An Atkinson communication system is installed between the tip of the ladder and the turntable console. A master
control is located at the turntable, with a push-ta-talk button and volume control. A self-contained "hands-off
speaker/microphone is located at the tip of the ladder.
2-1.8 Electrical System.
The aerial is equipped with an elecbical swivel with 36 collector rings, capable of operation through 3600
collector ring is capable of handling a 20 amp load.
2-1.9 Pumphouse.
The pumphouse is located midship, centered in the frame, rear of the turntable. The pump is a Hale 8FG, single
stage, driveline driven midship pump. The piping system utilized on the aerial is stainless steel.
Suction inlet configurations:
. One (1) 6 in. main, located on the driver's side;
. One (1) or two (2) 6 in. main(s), located on passenger's side;
. One (1) air actuated 3 in. tank to pump line.
Discharge outlet configurations:
. Two (2) 2 Yz in., located on driver's side;
. One (1) 2 Yz or 3 in., located on passenger's side;
. One(1)4in.;
. Two (2) 2 in. crosslays;
.
One (1) 1 in. tank fill;
One (1) 4 in. aerial discharge.
capable of 3600 rotation, SO below horizontal to 750 above
of 1,500 gpm. A pressure relief valve is located below the
handling 1 ,500 gpm. The waterftow through the aerial is
Each

GENERAL
2-1.10 Aerial Body.
The 99 in. wide body compartment, fabricated from .125 in. aluminum, is mounted on isolators that isolate chassis
movement from the body structure. Bodies are available in two heights: 9 ft, 10 in. and 10 ft, 8 in. Storage
compartments on the driver's side are full depth on all units. Compartment depth on the passenger side varies,
depending on whether the unit is equipped with a water tank and pump. The standard polypropylene water tank
capacity is 200 gallons. A hose bed is located on the passenger's side, with a capacity of 1.000 ft of 5 in. hose.

200-gailSta~~~
GENERAL
Table 2-1. Mid-mount Platfonn Specifications
Controls
Electronic over hydraulic,
proportional, multiplexed &
mi~~rcontrolled system
Water Tank Capacity
I
Waterway caP~
~~ gal (optional)
1.500 QDm

~
GENERAL
SPECIFICATIONS
T8b1e 2-2. Specific8tions for set-up and NFPA Testing I Pierce Adjustment
11914 SfD I DATA FOR1914 TESt STANDARD
'E m
'0
c
c:;5
'OW
Q)
I-
...
~
0)
~
-<
a..
u.:
z ...
.g
e
"3
0
~
c
0
~ m
E
M
FOR SETUP AND N.F.P.A.
1914 TESTING
95' PAP
rR"OT A TION ~~ING BOLT SIZE
0.88
BOLT GRADE
BOLT TORQUE-
8
'650
~TORQUE~X MOUNTlfN~-s"iZE
0.75
Bd[f~
8
ROTATION GEAR BnLTTORQUE LUBRICATION- - ~
357
I
A THIN -.O15TO.O30~ FILM OFCLEAN-G~E -
ROTATION - GEAR TO - PINION BACKLASH
~-"jNG RACEC~"Cf.
CE AllOWED OVER NEW
~~x MCumL~-aoiT SIZE --
0.50
---
BOLT GRADE
8
BOlT TORQUE
~ TO'f
rBOoM S(j~RTMOUNTING ~ T SIZf." k1
~
-BOLT GRADE
8
BOLT TOR~UE 41
~COlLE~TORRING INSPECB9N
- DESICCANT MOIST~RE INDICATORS-
IEL~N.CYlINDERDRIff
'0.50
I~ILIARY HYDRAULlf; POWER RELIEF
2500
r~.B-o"ft'[E C~b,=,- ~DLE SETTING
~ENSA TE~SS-OO-:- HYD PU~
~ON DARY ~-:- SYSTE M PRESS J,lB¥.
(BREATHING AIR REGULATED P~RE
ISTABILIZER-.JACK CYLINDER QF31FT
!"MAX. ST~I!iiERfiEPlOYME~TIME
IlADO~OON TWlSf:-OO--'=9~
.g c rEXT~CYONOER D~
'E
tV
~MAXIMUM RATED I.IVE lQ~
'W~TERWAY WORKINs;? PRESSURE.
I~TED WATER SYS~M FLOW
rWA'fE"RWA~V~SE!TlNG
1~ -~.._~~~igh
3000+50/-00
3150 +001-50
~PROX. 80 TO ~9R
~
'-go--
'TOO""
1":00'""
1"000'
'2'50'"
1'500
~
Pierce_Adjustment Specifications
AS REQ'D
...
~ ITEM UNITS
96' PAP
~
C
-:e
I PIJMP"rnFFERENTIAL PRESSURE"
psi.
450 - 475
.s
'S psi.
3400 +/- 25
(/) J[!ff CYL CO~~CE. BARREL
0- f LIfI CYl COUNfER~"CE. ROO
psi.
1500 +/- 25
~ i
- . psi.
1500 +/- 25
0c:
l- ~-CY-L COU~~CE. BARRel
psi.
3900 +/- 25
.
~~ COU~~CE. ROO
...
c:
psi.
1300 +/- 25
0)
rROTATION COUNTERBALANCE
0 ...
~ ~END ~~CYl COUNTERBALANCE psi.
1600 +/- 25
tU
c< [RETRACT LEVEUNG CYL COUt'!~~CE
psi.
3000 +/- 25
E a.. rLOWE~G REiJEF
psi.
~FulFkM
~ c: u: fEXTEN-oTRET~ ~~O RY~-
sec. I 32liiQh,-,19 Std, 50 SkM', +/- 5%-
Z
{ROTATE RAISE / LOWER SP~D SPEED (360~ 60 DEG. ARC sec. 107 High, 128 Std, 205 Slow, +/- 5%
sec 49 Hiah, 61 Std, 95 Slow, +/- 5%-
1208507 REV. B
- 0 ~ P'-C8 ~ K AI ItigID ~ 2-5
~PI8Ibm

GENERAL
2-3.1 COMMAND ZONE INFORMATION CENTER (CZlC)
The function of the Command Zone Information Center (CZIC) is to communicate with both the chassis and aerial
multiplex systems to safely control the aerial and provide information to the user. Thoroughly read all the information
contained in this section of the manual to make sure you understand the operation of the CZIC before you operate the
aerial device on this truck. For additional information concerning the CZIC, refer to the Pierce Custom Chassis
Operation & Maintenance Manual provided with your apparatus.
A CZIC is provided at each of the aerial control locations, giving the operator or maintenance technician information to
perform their duties safely and efficiently.

GENERAL
2-3.1.1 Main Aerial Screen.
The Main Aerial Screen displays the minimum NFPA required information that must be available to the Aerial
operator. The rungs must be aligned and the emergency stop engaged before personnel are allowed to ascend or
descend the ladder.
2-3.1.2 Aerial Reach Screen.
The Aerial Reach Screen displays the tip temperature, ladder reach, extension, angle, and height. This information is
approximate and for operator reference only.

GENERAL
2-3.1.3 Aerial Level Screen.
The Aerial Level Screen indicates the status of Aerial device outriggers as well as the slope and the grade of the
vehicle. The icons will all show half extension any time any single outrigger is not fully retracted. Icons will show fully
extended independently as each outrigger is fully deployed. and as each jack is extended downward. The device is
considered short-jacked anytime the jacks are set out and down unless all outriggers are fully deployed.
2-3.1.4 Hydraulic Systems Screen.
The Hydraulic System Screen displays hydraulic oil pressure & temperature, aerial hours, and PTO hours in a
graphical manner.
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GENERAL
2-3.2 CAB CONTROLS
AERIAL MASTER SWITCH. Activates aerial electrical circuits. Two-position switch. Fully depress to activate
power to the aerial.
2
AERIAL PTO SWITCH. Activates the transmission mounted power take-off, providing rotational input for the
hydraulic pump.
AERIAL PTO ENGAGED INDICA TOR LIGHT. Illuminates when the PTO has engaged successfully

GENERAL
2-3.3 TURNTABLE CONTROL CONSOLE.
4
EMERGENCY STOP BUTTON. Stops all aerial functions. Push down button to stop all aerial functions. Turn
button to reset.
5 EMERGENCY HYDRAULIC POWER SWITCH. Activates the secondary hydraulic system
6
ELEVATION CONTROL LEVER. Pull up on the locking collar to unlock lever. Pull back on the lever to raise
(elevate) the boom. Push forward on the lever to lower the boom. When the lever is released. it will return to
the neutral or center position.
7 ROTATION CONTROL LEVER. Pull up on the locking collar to unlock lever. Pull back on the lever to move the
boom counter clockwise (to the left). Push forward on the lever to move the boom clockwise (to the right).
When the lever is released. it will return to the neutral or center position.
8 EXTENSION CONTROL LEVER. Pull up on the locking collar to unlock lever. Pull back on lever to retract the
boom. Push forward on the lever to extend the boom. When the lever is released, it will return to the neutral
or center position.
9 MONITOR RAISE/LOWER CONTROL SWITCH. Moves the eledric monitor up and down.
10 MONITOR LEFT/RIGHT CONTROL SWITCH. Moves electric monitor left and right.
11 MONITOR PATTERN CONTROL SWITCH. Allows the operator to select straight stream or fog discharge
pattern.
12 AERIAL SPEED SWITCH. Used to control the relative speed of the aerial functions - slow. normal, fast.
13
14
TIP/TRACKING LIGHT SWITCH. Controls power to the tracking lights that illuminate the ladder section and the
tip lights.
INTERCOM (not shown). Provides hands free voice communication to the basket.

GENERAL
2-3.4
TURNTABLE POWER DISTRIBUTION.
15 CALIBRA TION. Electronic key receptacle, used by Pierce aerial technicians to perform initial calibration at the
factory .
16 BASKET LEVEL MODE SWITCH. Used to switch between AUTO and MANUAL basket leveling modes. Push
switch up for AUTO operation; push switch down for MANUAL operation. Switch must be in MANUAL mode
before Manual Basket Level Switch is operational.
17 MANUAL BASKET LEVEL SWITCH. Used to manually adjust basket leveling. Push switch up to raise front of
basket; push switch down to lower front of basket.
18 RELAYS. Refer to truck specific wiring diagrams for additional information.
19 FUSES. Refer to truck specific wiring diagrams for additional information

GENERAL
2-3.5 LOWER CONTROL STATION.
20 STABILIZER REMOTE CONTROL. Used to operate aerial stabilizers. See para 2-3.6 for additional information
21 EMERGENCY STOP SWITCH. Stops all aerial functions. Push down button to stop all aerial functions. Turn
button to reset
22 DIAGNOSTIC RS232 INTERFACE. Used to connect RS232 cable and laptop/palm pilot to Command Zone IITM
system for aerial calibration, diagnostics and system interrogation.
23 OVERRIDE SWITCH. Overrides interlocked circuits for emergency operation.
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GENERAL
2-3.6 STABILIZER CONTROLS.
24 STABILIZER POWER INDICA TOR. When lit, indicates that the stabilizer controls are energized.
25 STABilIZERS NOT STOWED INDICATOR. When lit, indicates when one (or more) of the stabilizers is not in
the stowed position.
26 FRONT RIGHT STABilIZER CONTROL. Controls the operation of the right front stabilizer. Move switch left &
right to control beam extension; move switch up & down to control jack operation.
27 REAR RIGHT STABilIZER CONTROL Controls the operation of the right rear stabilizer. Move switch left &
right to control beam extension; move switch up & down to control jack operation.
28 REAR lEFT STABiliZER CONTROL Controls the operation of the left rear stabilizer. Move switch left & right
to control beam extension; move switch up & down to control jack operation.
29 FRONT LEFT 5T ABILIZER CONTROL. Controls the operation of the left front stabilizer. Move switch left &
right to control beam extension; move switch up & down to control jack operation.
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GENERAL
2-3.6 STABILIZER CONTROLS (CONT).
30
31
32
33
STABILIZER EPU SWITCH. Activates the secondary hydraulic system.
LEVEL ASSIST CONTROL SWITCH. Pushing the switch down causes the stabilizer jacks to initially level the
vehicle within the limits of the system. Operator may have to make finaUadditional adjustments.
STABILIZER FIRM ON GROUND INDICATOR (4). When lit, indicates when the stabilizer jack is in position on
firm ground.
STABILIZER BEAM FULLY EXTENDED INDICATOR (4). When lit, indicates when the stabilizer beam is fully
extended.

GENERAL
2-3.7
LOWER POWER DISTRIBUTION.
34 SPARE FUSES.
35 RELAYS. Refer to truck specific wiring diagrams for additional information
36 FUSES. Refer to truck specific wiring diagrams for additional information.

GENERAL
2-3.8 BASKET CONTROLS (LEFT).
37 UNDER BASKET FLOODLIGHT SWITCH (optional). Controls power to the under basket floodlights.
38 MONITOR PATTERN CONTROL SWITCH. Allows the operator to select straight stream or fog discharge
pattern.
39 MONITOR LEFT/RIGHT CONTROL SWITCH. Moves electric monitor to the left and right.
40 MONITOR RAISE/LOWER CONTROL SWITCH. Moves the electric monitor up and down.
41 AERIAL SPEED SWITCH. Controls the relative speed of aerial functions - slow, normal, fast.
42 120 VAC RECEPTACLE. One receptacle in the basket to provide 20 amps of 120 VAG electrical power.

GENERAL
2-3.9 BASKET CONTROLS (CENTER).
43 EXTENSION CONTROL LEVER. Pull up on the locking collar to unlock lever. Pull back on lever to retract the
boom. Push forward on the lever to extend the boom. When the lever is released, it will return to the neutral
or center position.
44 ROTATION CONTROL LEVER. Pull up on the locking collar to unlock lever. Pull back on the lever to move the
boom counter clockwise (to the left). Push forward on the lever to move the boom clockwise (to the right).
When the lever is released, it will return to the neutral or center position.
45 INTERCOM. Provides hands free voice communication to the turntable control console.
46 ELEVATION CONTROL LEVER. Pull up on the locking collar to unlock lever. Pull back on the lever to raise
(elevate) the boom. Push forward on the lever to lower the boom. W'len the lever is released, it will return to
the neutral or center position.

GENERAL
2-3.10 BASKET CONTROLS (RIGHT).
47 EMERGENCY STOP BUTTON. Stops all aerial functions. Push down button to stop all aerial functions. Turn
and pull up button to reset.
48 BREA THING AIR COUPLING. One coupling is provided with a safety release feature and a dust plug.

GENERAL
2-3.11 EMERGENCY CONTROLS.
NOTE
The EPU should only be used when the main system hydraulic pump is not operating.
The EPU has a limited run time before possible overheating. DO NOT run the EPU for more
than 30 minutes without allowing 30 minutes for cooling down. Limiting loads and pressures
will allow for more efficient use of the EPU and will also generate less heat.
49 AERIAL EMERGENCY POWER/STABILIZER EMERGENCY POWER SWITCH. This switch engages the
secondary hydraulic system. The position of this emergency power unit (EPU) switch is not dependant on
other microprocessor circuits. Push up to provide EPU power for the aerial functions; push down to provide
EPU power for the stabilizer functions.

GENERAL
2-3.12 OIL SAMPLE PORT.
50 OIL SAMPLE PORT. Used to obtain sample of hydraulic oil for analysis

GENERAL
2-4.
LOAD CHART INFORMATION
WATERWAY DRY and 50 MPH WIND CONDITION
ELEVATION
BASKET
FLY
UPPER MID
CENTER MID
LOWER MID
BASE
-8109
1,000
10m19
1,000
250
20 to 29
1,000
250
250
30 to 39
1,000
250
250
250
40 to 49
1,000
250
250
250
500
50 to 59
~
250
250
250
250
500
60 to 75
1.000
250
250
250
500
750
DEGREE OF
ELEVATION
BASKET
FLY
UPPER MID
CENTER MID
LOWER MID
BASE
-8 to 9
500
WATERWAY
10 to 19
500
CHARGED and 50 MPH WIND CONDITION
20 to 29
500
250
301039
500
-250
250
401049
500
250
250
250
501059
500
250
250
250
500
60 to 75
500
250
250
250
250
500
2.
3.
REDUCED LOADS AT THE BASKET CAN BE REDISTRIBUTED IN 250 LB INCREMENTS TO THE FLY, MID SECTIONS, OR BASE
SECTIONS AS NEEDED.
CAPACmES ARE BASED ON THE FOLLO~NG CONDITIONS:
. APPARATUS IS SET UP ACCORDING TO THE OPERATOR'S MANUAL AND LEVELED TO WITHIN SAFE OPERATING LIMITS.
. THE LADDER IS FULLY EXTENDED AND UNSUPPORTED, 360" CONnNUOUS ROTATION.
. FOR ICING CONDITIONS, REFER TO SEPARATE LOAD CHART IN THIS OPERATOR'S MANUAL
RATED:
VERnCAL HEIGHT: 95 FT
HORIZONTAL REACH: 0" = 88 FT, 6 IN
4SO = 63 FT, 6 IN
75° = 24 FT
.
.
A DANGER
Do not exceed load limits as shown.
Do not attempt to operate the apparatus unless you have had proper training and read and
understand the operator's manual.
Serious injury or death may occur.

GENERAL
NOTE
The following capabilities shall be based upon continuous 3600 rotation and aerial at full
extension with 0.25 in. of ice build-up.
.
.
A DANGER
Do not exceed load limits as shown.
Do not attempt to operate the apparatus unless you have had proper training and read and
understand the operator's manual.
Serious injury or death may occur.

OPERATION
3-1. PRE-DRIVING AND TRUCK POSITIONING
NOTE
The following procedures are intended for safe operation of the aerial. Deviation from these
procedures is not recommended.
3-1.1 Pre-Driving Checks.
. Make sure the aerial device is properly stowed.
. Make sure the stabilizers are properly stowed for travel.
3-1.2 Procedure Concerns at the Scene.
. Is the unit to be used for water tower operations or as a rescue unit?
. Take note of all overhead obstructions.
. Position the unit for best attack.
3-1.3 Positioning The Truck For Operation.
A CAUTION
NEVER bridge across ditches, culverts or any opening with the ground pads.
The truck can be positioned facing uphill or downhill - each method has its advantages and disadvantages. In either
condition, the truck must be capable of being leveled to within the safe operating limits as described in para 3-2,
Stabilizer Set-Up, of this manual.
The area around the unit must be clear for stabilizer extension.
Full stabilizer extension is required for unlimited aerial operation.
. The area where the stabilizer ground pads make contact with the ground must be firm and capable of supporting
75 PSI. DO NOT set up over manhole covers, storm drains, or underground parking facilities that cannot
meet these requirements.
3-1.3.1 Positioning Uphill.
Advantages of positioning unit uphill:
Extending
. In the set-up position, the front tires will still be in contact with the ground.
the rear stabilizer jacks will raise the rear of the truck, thereby reducing the grade.
. Raising the rear axle(s) off of the ground adds to the truck's ballast weight offering greater stability.
. The rear tires can be left on the ground if no grade correction is required, to offer more resistance to sliding.
Disadvantages of positioning unit uphill:
. With the rear tires off the ground, the truck has less resistance
to sliding downhill.
. Because of the added height, access to storage compartments is more difficult.

OPERATION
3-1.3.2 Positioning Downhill.
Advantages of positioning unit downhill:
. Storage compartments are closer to the ground for easier access.
Disadvantages of positioning unit downhill:
. The stabilizer jacks cannot be extended to reduce the downhill grade without raising the front tires off the ground.
. There are aerial device reach limitations when operating over the front of the truck.

OPERATION
3-2.
STABILIZER SET-UP PROCEDURE
3-2.1 Cab Controls.
(1) Shift the truck transmission to NEUTRAL.
(2) Apply the PARKING BRAKE and FRONT WI-IEEL LOCK.
NOTE
Most trucks are equipped with built-in safety interlocks. If either of the above steps are
not followed, the aerial PTO will not engage.
All Emergency Stop Buttons must be in the UP position or the aerial electronics will not
function.
(3) Set the AERIAL MASTER switch to the ON position.
(4) Set the AERIAL PTO switch to the ON position. The PTO indicator light will illuminate when the PTO has
successfully engaged.
NOTE
Continue with the stabilizer set-up procedure (para 3-2.3) if the water pump is not going to be
used.

OPERA TION
3-2.2
Water Tower with Water Pump Operation.
NOTE
If the aerial is already set-up, stop all aerial functions. The engine must be at idle to engage
the pump.
(1) Check the parking brake; it must be ON.
(2) Check the transmission; it must be in NEUTRAL.
(3) Push PUMP SHIFT switch down to engage pump.
(4) Place transmission in DRIVE.
(5) Refer to the water pump manufacturers operation manual for more detailed information.
3-2.3
NOTE
The automatic aerial throttle control will be deactivated and the water pump will control the
engine throttle. During pump operation the engine RPM is sufficient to operate all aerial
functions.
Stabilizer Deployment.
NOTE
. Placement of the wheel chocks depends on the characteristics of the truck and the
ground.
. Always place the wheel chocks where they will give the most resistance to truck
movement, usually this is the front wheels.
. When facing downhill, the front wheels may be completely off the ground. The chocks
may be better utilized if they are placed at the rear wheels.
(1) Set the wheel chocks in place.
(2) Open the door at the rear of the truck to gain access to the lower control station and stabilizer remote control.
(3) Verify that the stabilizer power light is illuminated. You now have hydraulic power to function the stabilizer
controls. The warning alarms will only activate when a stabilizer function has been selected.

OPERATION
NOTE
To avoid having to fe-level the unit, level the low side of the apparatus before leveling the high
side.
(4) Extend the stabilizer beams. Push the stabilizer control switches to the outboard position to fully extend the
stabilizer beams.
(5) Position all stabilizer ground pads under the vertical jacks. The handles on the ground pads should be facing
up and inboard to prevent a tripping hazard.
(6) Push down on the stabilizer control switches to lower the jacks. Lower each jack until the firm on ground
indicator is illuminated for all stabilizers.
NOTE
. The level assist funtion will not work until all jacks are "Set OK".
. The truck can be leveled manually without using the Level Assist function if desired.
Refer to the following paragraph for specific instructions.
(7) Push and hold the LEVEL ASSIST switch to initially level the truck to within the limits of the system. Hold the
switch down until leveling is complete. The operator may have to make additional/final adjustments.
3-2.4
Leveling
the Truck Manually Without Using "Level Assist",
NOTE
. The preferred set-up is an uphill position with the rear stabilizers supporting enough
weight to remove the bulge from the rear tires. The front stabilizers should be firmly
planted on the ground but leaving the front suspension compressed allowing for full aerial
operation. Actual ground conditions may necessitate deviation from the preferred set-up.
. When positioning uphill, raise the rear of the truck until the truck is level. Front stabilizers
should be set until they are firm on ground.
. When positioning downhill, raise the front of the truck until the truck is level. Rear
stabilizers should be set until they are firm on the ground and begin to lift the truck.
. Some tires should remain in contact with the ground whenever possible. They will give
added resistance to sliding.
(1) Activate the stabilizer jack switches until the truck is as close to level, both front to rear and side to side.
NOTE
When the front suspension is not compressed, the aerial operation is limited to within an
envelope of 72 feet parallel to the front of the truck.
(2) Check the CZIC Display (Aerial Level Screen) and confirm that the truck has been leveled to within the safe
operating limits and full load capabilities of the aerial. Refer to the following charts:

OPERATION
TABLE 3-1. SAFE OPERATING LIMITS
GROUND SLOPE
10 DEG
13 DEG
>13 DEG
TRUCK SLOPE
0 to 5.0 DEG
5.1 to 8.0 DEG
>8.0 DEG
CAPACITY
FULL
HALF
ZERO
GROUND GRADE
7DEG
10 DEG
>10 DEG
TRUCK GRADE
0 to 5.0 DEG
5.1 to 8.0 DEG
>8.0 DEG
CAPACITY
FULL
HALF
ZERO
NOTE
Anytime the truck tips beyond 8° from level, a WARNING will be displayed on the CZIC display
and all functions will be disabled. Use the override switch to safely retract and rotate back to
a stable condition.
(3)
Install all jack safety pins into the highest available hole on the jack.
A CAUTION
DO NOT raise the jacks with the safety pins installed or allow the outer jack box to contact the
pin during operation.

OPERATION
(4)
(5)
Set the wheel chocks in place. In back of the front wheels if facing uphill; in front of the rear wheels if
facing downhill.
Confirm that the CZIC display indicates that all beams are out and all jacks are down.
3-2.5 Short Jacking on One Side.
On occasion it may be necessary to set-up in a confined space where the stabilizers cannot be extended on one side.
Operation shall and will be limited to the side where the stabilizers are fully extended.
(1) On the short jack side, it will be necessary to extend the beam far enough to remove the safety pin from
its storage bracket and install it into the jack assembly.
(2) After completing the short jack procedure, a short jack graphic will appear on the CZIC display indicating
a short jack condition.
(3) If aerial operation is attempted on the unsafe side, the aerial will automatically stop, a WARNING will be
displayed, and the control in that direction will no longer function.

OPERA TION
3-3. AERIAL OPERATION
.
A WARNING
NEVER exceed load limits as stated on the load charts found in Para 2-4, Load Chart
Infonnation, of this manual. Serious injury or death may result. Always adhere to the
load chart specifications, regardless of what the Command Zone Information Center
(CZIC) is displaying.
The operator is responsible for knowing the condition of the aerial device before
operating. This includes performing a quick visual scan of (but not limited to) pins,
cables, hydraulic cylinders, loose equipment, basket, etc.
Before beginning aerial operations, the operator must be aware of stabilizer set-up and
grade & slope angles. If the truck is not within +/- 50 angle, refer to Table 3-1, Safe
Operating Limits.
Personnel on the aerial should wear safety belts at all times.
During aerial operations, the safety chains must be hooked across the turntable openings.
.
(1)
(2)
(3)
(4)
(5)
NOTE
The aerial will not operate until the CZIC display indicates that all jacks are set.
Open the control console cover.
Tum on lighting switches as required.
View the CZIC display during the power-up self-test.
Select "MAIN AERIAL SCREEN".
View the CZIC display for capacity, air, flow, and rung alignment.

OPERA TION
(6) To raise the aerial, pull up on the locking collar to unlock lever. Pull back on the RAISE control lever to raise
the aerial above the boom support cradle and any body or cab mounted lighting and/or equipment.
m
(8)
A WARNING
Do not extend or retract the ladder sections with personnel standing on the ladder sections,
as legs and feet may be jammed between the rungs.
To extend the aerial, pull up on the locking collar to unlock lever. Move the EXTEND control lever forward.
When the platform nears the desired extension, make small adjustments in extension or retraction until the
words RUNGS ALIGNED .YES' appears on the CZIC display. This ensures that all rungs are opposite each
other, making the ladder easier and safer to climb and descend.
To rotate the turntable clockwise, pull up on the locking collar to unlock lever. Push forward on the
ROTATION control lever. To rotate counterclockwise, pull back on the ROTATION lever.
A WARNING
Electrical storms can pose a serious hazard to anyone on or near the aerial unit.
discretion is advised.
User
Ii. WARNING
When using the aerial for rescue operations, try to approach victims from above, to avoid
victims jumping down on the platform, which can cause an overload situation.
A WARNING
Do not set the platform on the ground, roof, etc. Any aerial loading or operation of the
lowering control while the aerial device is in this condition could cause a back-bending
negative load to the aerial sections and may cause serious damage.
A WARNING
When using the aerial in extreme cold conditions, be aware of the possibility of ice build-up.
Excessive ice build-up may cause overload or damage to the aerial.
A WARNING
During operation, continually monitor aerial loading and restrict additional loading and/or any
operation that may exceed the limits as shown on the load chart and CZIC display.
C 2005 ~ M8nuf8dwWIg Inc. All RIgID R--* 3-9
Mid-Mo~ PIa~

OPERA TION
(9)
(10)
(11)
A WARNING
An operator must be stationed at the turntable controls at all times during any aerial
operation. This primary operator is responsible for observing all operations and warning (or
overriding) any potential dangerous condition or movement of a secondary operator.
Activate the control levers as required for positioning and use of the device.
Switch on the intercom and establish communications.
NOTE
The shut-off valve on the breathing air bottle must be open to view the remaining air volume.
Turn on the breathing air valves at the air bottles (optional) and check the gauge on the control consoles for
available volume.

OPERATION
3-4. POST OPERATION STOWING PROCEDURE
.
A CAUTION
The following information is based on the assumption that all aerial systems are functional.
Emergency systems can still be used in emergency situations where they are necessary to stow
the aerial or stabilizers. The operator must be aware that the aerial may not be properly bedded
and precautions are needed to return the unit for service.
To avoid equipment damage during road travel, the following precautions must be observed.
DO NOT use the aerial manual override control levers in conjunction with the emergency pump to
stow the aerial. This will apply a greater load then intended to the boom support area. Depending
on set up terrain, this action could also cause an undesired twist in the aerial device.
DO NOT use the stabilizer manual override control levers in conjunction with the emergency
pump to stow the stabilizers. The aerial will not complete its stowing cycle with this control
combination.
DO NOT use the stabilizer manual override control levers in conjunction with the main hydraulic
pump. The aerial will not complete its stowing cycle with this control combination.
DO NOT use the stabilizer controls (electric toggle switches) in conjunction with the emergency
pump. This will not provide proper boom support pressure for road travel.
NOTE
The aerial stowing process is not complete until the stabilizer up function is activated. The aerial
continues to lower and obtains proper bedding pressure only at that time. Using the main
hydraulic pump system provides the necessary flow and pressure. The purpose of this process is
to assure proper boom support loading regardless of setup terrain or uneven stabilizer jack
placement.
The aerial SHOULD be stowed in the boom support using the main system intended for aerial
operation. The system provides electric controllers on the turntable control console and uses the
PTO driven hydraulic pump.
As an alternate method, the emergency pump switch on the turntable console COULD BE used in
conjunction with the electric controller to stow the aerial.
3-4.1
(1)
(2)
(3)
(4)
Stowing the Aerial.
Retract the aerial sections.
Rotate the aerial to align the aerial with the boom support. The CZIC display will indicate when the ladder is
properly aligned for stowing.
A CAUTION
Use visual contact when stowing to confinn proper alignment.
Lower the aerial until contact is made with the boom support.
NOTE
The Command Zone software will shut off the hydraulic system when the correct bedding
force has been obtained.
Continue lowering the aerial until the bedding sequence has completed. Hold the Elevation Control in the
LOWER position until the basket is parallel with the truck body. This could take several seconds after the
ladder has stopped lowering. No damage will be done to the aerial device or the truck by holding the
Elevation Control in the LOWER position after motion has stopped.

OPERA TION
(5)
(6)
Tum off lighting, intercom, and breathing air valve.
Close console cover.
3-4.2
(1)
(2)
(3)
(4)
3-4.3
(1)
(2)
(3)
Stowing the Stabilizers.
it. CAUTION
Stowing stabilizers to their road travel position MUST follow aerial stowing. It is also
necessary to use the main system for this process. The main system provides electric
switches on a remote control box and uses the PTO driven hydraulic pump. USE THE MAIN
HYDRAUUC SYSTEM ONLY FOR THIS PROCESS.
Remove stabilizer jack safety pins and place them in their storage brackets.
Push up on the stabilizer control switches to raise jacks to their stowed positions.
Push the stabilizer control switches to the inboard position to retract the stabilizer beams to their stowed
positions.
NOTE
A WARNING light in the cab will flash if the jack safety pins, vertical jacks, or horizontal
beams are not properly stowed.
Confirm on the CZIC display that all jacks and beams are property stowed.
Preparing for Road Travel.
Close and secure all control doors.
Retum the stabilizer ground pads and wheel chocks to their storage brackets.
Tum the aerial master switch and PTO switch in the cab to the OFF position.

OPERATION
3-5.
MANUAL OVERRIDE CONTROLS
AWARNING
Any time that an override or manual control is used, Abb safety systems are overridden.
operator must be absolutely sure that all safety operating parameters are being met.
The
3-5.1 MANUAL STABILIZER CONTROL VALVES.
The manual stabilizer override controls are located behind an access door in the left front step well. Opening the door
will indicate to the Command Zone Information Center (CZIC) that an override is in progress; a message will ~
displayed at the turntable display. Manually pushing or pulling on each of the handles will operate the stabilizer
beams and jacks. A label indicating the function of each lever is attached to the inside of the door. Refer to Para 3-
5.3, Emergency Pump Unit, for additional information on the operation of these control valves.
A WARNING
You must not operate these manual override controls unless:
. You have been trained in the safe operation of this device;
. You are aware of the aerial position. Raising a stabilizer jack may cause the truck to tip
over.
. You have a second person to monitor the positioning of the stabilizers that are not clearly
visible.
. You are aware that safety devices are being overridden.
Death or serious injury may result if the above statements are not observed.
.
NOTE
No automatic high idle is provided with the function of the manual controls.
The manual override door must be closed at all times during normal operation.

OPERATION
3-5.2 PLATFORM MANUAL CONTROL VALVES.
NOTE
Ladder manual control valve handles are located under an access panel in the turntable floor.
1 AERIAL LOWERING OVERRIDE BUTTON. This button is used only if a lowering relief system failure causes
the aerial not to lower during normal operation. Push and hold this override button, while operating either the
electric or manual controls, to lower the aerial.
A CAUTION
When lowering the aerial with the aerial lowering override button depressed, do not allow the
aerial to apply any downward force into the boom support. Damage to the aerial may occur.
2 EMERGENCY STOP PTO BYPASS SWITCH. Allows operation of the manual aerial controls when the
Emergency Stop switch is depressed.
3
4
5
LOWER/RAISE CONTROL VALVE HANDLE. Pull up on the control valve handle to lower the aerial; push
down on the control valve handle to raise the aerial.
RIGHT/LEFT CONTROL VALVE HANDLE. Pull up on the control valve handle to move the aerial right
(clockwise); push down on the control valve handle to move the aerial left (counter-clockwise).
EXTEND/RET ACT CONTROL VALVE HANDLE. Pull up on the control valve handle to extend the aerial; push
down on the control valve handle to retract the aerial.
6 TURNTABLE ALIGNMENT ARROWS. \l\'hen arrows are aligned, the aerial device is in proper alignment with
the cradle for proper bedding.
CI 2005 Pierce MlrKJf~g I~. All RigID R..-v8d 3-14 ~ PI.rorm

OPERA TION
3-5.3 EMERGENCY PUMP UNIT (EPU)
If the main hydraulic system is not functioning, the EPU provides back-up power to the main hydraulic system pump.
A momentary switch is provided to activate the EPU.
NOTE
The EPU should only be used when the main system hydraulic pump is not operating.
The EPU has a limited run time before overheating. DO NOT run the EPU for more than 30
minutes without allowing an additional 30 minutes for cooling down. Limiting loads and
pressures will allow for more efficient use of the EPU, and will also generate less heat.
Turntable Console
Stabilizer Remote
Manual Stabilizer Controls
(4)
(5)
NOTE
The EPU will be activated only after the desired function is selected.
At the turntable control console or the stabilizer remote control, hold the EPU switch in the ON position, then
activate the desired function.
NOTE
If the electronic system has failed, and the manual aerial or stabilizer controls are being used,
the EPU switch at the manual stabilizer controls will be the only one active.
At the manual stabilizer control station, the EPU will be activated as soon as the switch is held in the ON
position. The proper sequence of operation is to activate the desired function, then place the EPU switch in
the ON position until the operation is complete, then release the switch before returning the manual control
handle to the neutral position.

OPERA TION
3-5.4 EMERGENCY STOP BUTTON.
An emergency stop button is provided at three locations: lower control station, turntable control console, and aerial
basket controls. Pushing down any of these buttons will stop all aerial functions. Hydraulic oil flow will be blocked
from all aerial functions and all electrical controls will be inoperative. To reset, turn and pull up on the emergency stop
button.
To restore hydraulic functions only, leave the Emergency Stop switch depressed and hold the turntable Emergency
Stop Bypass switch. Operate the aerial device using the manual controls.
e ~ PieR:e ~ I~. AI RighIs R..- 3-16' ~ ~

OPERATION
3-6. COLD WEATHER OPERATION
During extreme cold weather, certain precautions must be applied to the operation and use of aerial devices. 'M1en
operation is necessary in extreme cold temperatures, use the following precautions:
(1) Continued use of the aerial functions will circulate the oil, delaying the ambient temperature cooling effect.
(2) Slow attentive operation after a period of non-use will be less harmful to the device and may allow the
operator time to react to potential problems.
(3) Continually monitor the hydraulic oil pressure gauge to wam of excessively high pressures that are building
during the operation of a function.
(4) Pay particular attention to electric cables and hoses that are running up the aerial sections. These will
become stiff and want to take a set, causing them to track improperly.
(5) Before shutting off the flow of water through the aerial telescopic waterway, raise the aerial to an elevation
that will allow quick evacuation of the water in the tubing, before retracting the aerial sections. Retract the
aerial slowly and watch for excessive hydraulic pressure to retract. Ice in the tubing may cause damage,
which will require waterway reconditioning.
(6)
The recommended minimum start up temperature for the hydraulic system will vary according to the viscosity
grade class oil that is installed in your aerial. A label located on the hydraulic reservoir indicates the grade of
oil that is installed in your unit. Refer to Chapter 4 for additional details.

OPERATION
3-7. OPTIONAL EQUIPMENT
3-7.1 LyfeDf Accessories.
All Lyfe~ accessories that are available mount to the permanent accessory brackets that are provided at the front of
the platform. Each of the LyfeTM accessories mounts to these brackets in the same manner.
3-7.1.1 LyfeEyeN Rappelling Option Set-Up Procedure.
w,en property installed. each rappelling arm has a rated capacity of 300 Ibs
(1) Attach rappelling arm to bracket at front of platform with pins
(2)
NOTE
If additional lifting capacity is required, rings are provided under the basket and are rated at
500 Ibs each. *AII additional weight must be subtracted from the platform capacity.
Attach rope and rigging to eye at the end of the rappelling arm.
PLATFORM RATING REDUCTION EXAMPLE:
1,000 Ibs Rated Platfonn Capacity
(-XXX ba)
Weight of Rope and Rigging
( -250 ft)S) NFPA Fire Fighter (Load)
( -XXX Ibsl AddfOOnaI ~~
XXX Ibs
Remaining Platform Capacity

OPERA TION
3-7.1.2 LyfeLadder'rM Option Set-Up Procedure.
The LyfeLadderTM can be attached to the basket for external entrance to the basket or descending to a lower surface.
When properly installed, it has a rated capacity of 500 Ibs.
-
DO NOT CLIMB THE PINNED LADDER HORIZONTAL. TO THE
BASKET OR ABOVE TH! TOP OF THe BASKeT.
DEATH OR SERIOUS INJURY CAN RESULT FROM
THE PfNNED LADDER PIVOT1NG DOWNWARD.
DO NOT ALLOW THE PINNED LADDER TO COME
IN COHTACTWlTH A FIXED SURFACE.
THE ~NED L.AODER IS NOTRECOMMENOEDFOR
A FLOWING WATER ReSCUE.
THE PINNED LADDER IS RATED FOR 100 POUNDS.
THE WEIGHT ON TttE PtNNED LADDER MUST
~ SUBTRACTED FROM THE PLATFORM
RATED CAPACI'rY.
DO NOT FLOW WATER J:ROM PLATFORM MONITOR(SI
WHLE THE PtlNED LADDER to IN USE.
&1mM
:1)
NOTE
The Duo-Safety Model 875A (19-inch) Ladder is the only ladder certified for this operation.
Attach two LyfeLaddef"rM brackets to mounting brackets at front of platform with pins.
(2)
(3)
(4)
(5)
(6)
Position cross rod in hole and place ladder between mounting brackets.
Slide ladder out to the desired rung for length of ladder and push cross rod through both ladder rung holes
and opposite mounting brackets.
Secure lynch pin to cross rod.
With the ladder hanging in the vertical position, secure the rung latch to the appropriate ladder rung.
LyfeLadderrM brackets should be stored in a body compartment before driving the apparatus.
LyteLadde(TM brackets are left pinned to the platform they will increase the overall height of the truck.
If the

OPERA TION
3-7.1.3 LyfeHoisP Winch Option Set-Up Procedure.
The LyfeHoistTN winch is used for lifting tools and supplies. It is NOT rated for any tvoe of human SUDOOrt or
transoortation. When properly installed, it has a rated capacity of 500 Ibs.
(1)
(2)
(3)
Attach the LyfeHoistni winch bracket to the mounting brackets at the front of the platform with pins.
Plug the winch eledr1cal cord into 11 O-volt receptacle.
For further instructions on the operation of the winch, refer to the Operator's manual supplied with the winch
PLATFORM RATING REDUCTION
EXAMPlE
1,000 Ibs Ra1ed Platronn Capacity
( -500 lis) Maximum Load Weight
( -80 b) ~ht of ~
440 lIS Remaining Platform Capacity

~
OPERATION
3-7 .1.4 LyfeSuppo~ Re.cue Basket Option Set-Up Procedure.
'M1en properly installed, tile LyfeSUpportTM rescue basket supports will support a rescue basket for patient transport
RESCUE
RESCUE BASKET SUPPORT ARMS 8UST
BE _STALLED PEA THE ADDEtG)UM
IN THE OPERATORS MANUAL.
DEATH OR seRIOUS INJUAY CAN RE8\I.T
FROM HOT FOLLOWING THE ADDEtmUM.
Attach LyfeSupportTM rescue basket arms to mounting brackets at the front of platform with pins
(2)
AWARNING
. The belt straps must pass through the side openings on the rescue basket.
. The belt straps must be latched to each other straight across the basket.
. The belt straps must be property tensioned to prevent basket movement.
Make sure each belt strap is fastened through the holes at each end of the LyfeSupportTM rescue basket
arms.
ii ~
Pien:e ~ I~. AI ~ ~ 3-21
--
M~~

OPERATION
THIS PAGE INTENTIONALLY
LEFT BLANK

~
MAINTENANCE
4-1.
HYDRAULIC SYSTEM
4-1.1 Hydraulic System Components.
The hydraulic system consists of a reservoir that supplies oil to a PTO driven, variable displacement, piston pump.
The hydraulic oil supplied from the pump pressurizes two electric-over-hydrauliclosed-center valves. One valve
controls the oil flow to the stabilizer system components including the beam extension cylinders and the jack support
cylinders. The second valve operates the ladder lift cylinders, extension cylinders, and the rotation drive unit.
A smaller emergency power unit containing a gear pump provides back-up hydraulic power in the event of the failure
of the main system.
4-1.2 Hydraulic Oil Recommendations.
Table 4-1, Hydraulic Oil Recommendations, shows five grades of hydraulic oil recommendations for aerial devices.
Each grade has a minimum start up and normal operating range. One of these grades was used in the initial fill of the
system, based on your operating region. Check the oil tag next to the reservoir fill cap for the initial fill grade. Your
normal start up and operating temperature should most closely match the initial fill oil chosen for your unit.
The minimum start-up column shows an oil temperature where the viscosity is at its highest value (thickest point).
This is the minimum operating temperature authorized by the pump and valve manufacturers for the given grade of
oil. Start-up below this temperature should be infrequent and carefully executed.
The operating range listed provides the optimum oil viscosity for the hydraulic system. Operation below this range
may result in slower aerial operation, while operating above this range will reduce system efficiency and may increase
component wear.
Oil
Mobil
DTE IBM
Mobil
DTE 16M
Mobil
OTE 15M
Mobil
DTE13M
Mobil
DTE 11M
Table 4-1. Hvdraulic Oil Recommendations
ISO
~
100
Minimum Start
Up Tempe~ture
400F
68 21"F
46
32
15
100F
OOF
-SSOF
~~
RJ
Kanp
78°F to 197°F
6~F to 181°F
45°F to 1600F
3JOF to 14Z'F
24°F to 1000F
NOTE
The above minimum start-up is based on a viscosity of 4,000 SUS. The operating range is
based on a viscosity range from 1,000 to 80 SUS. When choosing an alternate oil, the
temperature values in the above chart will change. Ask your oil supplier what temperature the
oil will be for 4,000, 1,000, and 80 SUS viscosity.
Mobil Oil is shown in Table 4-1, but other high quality caparable oils may be substituted.
Substitute oils should have multi-grade viscosity characteristics, with low temperature flow
properties and high antiwear protection.
We recommend taking an initial sample of hydraulic oil and having it analyized to serve as a
baseline for future oil analysis results.
Your Pierce aerial was shipped with a hydraulic oil cleanliness level of 18/15/13, per the latest
ISO Standard 4406. Any changes of or additions to the aerial hydraulic oil should be with the
appropriate type, filtered to the same cleanliness level. Un-filtered oil may have an affect on
the life or operation of some components.

MAINTENANCE
4-1.3 Hydraulic Oil Filter Recommendations.
The following hydraulic filters are used in the aerial hydraulic system of your Pierce vehicle
should be carefully collected and disposed of properly as required by law.
Used oil and filters
Table 4-2. Hydraulic Oil FIlters
. NOTE: For Aerials built before June 2002, use 53-0383
4-2.1 Introduction.
These checks and services have been provided to help you keep your equipment in good operating condition and inservice.
The preventive maintenance section is intended to formally maintain and document the aerial device on a regular
schedule. This schedule is intended as a minimum and is greatly dependent on operating conditions. Heavy use and
extreme environmental conditions such as heat, cold, sand, or salt spray will demand increased inspection and
maintenance.
This preventive maintenance section is not intended to replace or negate any routine pre-operation safety inspections.
The aerial operator must be aware of the condition of the aerial equipment before operating. A pre-operational visual
safety inspection should alwavs be performed, including checking stabilizers, aerial pivot pins & retaining hardware,
cables, sheaves, basket pivot pins, retaining hardware, etc.
An Equipment Inspection and Maintenance Worksheet should be completed each time an inspection is performed. A
supply of blank worksheets follows this section of the manual. (Additional worksheets may be photocopied.) A copy
of the completed worksheet should be retained by the customer as a permanent record of the maintenance actions
performed.
During the warranty period, and thereafter, inspections and maintenance schedules must be performed according to
the specified Pierce Manufacturing Inc. standards.
Failure to comply with these requirements will be considered grounds or conditions that may void the warranty on
individual components, assemblies, or the entire Pierce aerial device.
4-2.2 Explanation of Columns.
Item No. - Numbers in this column are to be used as a source of the item number for the "Item No." column on the
Equipment Inspection and Maintenance Worksheet
Item to Check/Service - This column tells you the item to be checked or serviced.
Procedural Steps - This column tells you how to perform the required check or service.
0 ~ ~ --~ Irw:. M - ~
R.-!iiii
4-2
~PI8tbm

MAINTENANCE
NOTE
Perform this inspection within the first 10 hours of operation and with each inspection
thereafter.
T8b1e 4-3. PrWn8ry Inspection
ITEM TO CHECK/SERVICE PROCEDURE ~~~,:;::;~;;!
check""ihatswitct\"OPerates ~ - this indudes ~al PTO s~ch
and aerial master switch.
1
PTO Operation
2 Check that PTO indicator light is fundional.
3 Verify the operation of the neutral safety interlock. This is checked by
shifting the transmission into drive or reverse - the PTO should disengage
in both gears. Also, check for PTO disengagement with the transmission
in neutral and - the paoonQ - brake released-,- - --
NOTE
-
2 Hydraulic Oil LeV«
The aerial must be cradled with all stabilizers in the stowed
position to obtain a proper oil reading.
3 Hydraulic Pressure Lines
4
Stabilizer/Aeriallnteriocks &
Indicators
Check th~ oil level as_displayed ~ the CZICdispiay
T~es shou~ ch«k:8d1Or lea"iC8geat fiUifijS8nd atcnmp on e"iidi:
AI$O. insoect. hose routina and_check for a!)v sians of hose chafinQ.
~ the stabmmrs stowed~ to oPerate the aerial up fu~n using the
turntable control console controls. If there is no aerial movement, or increase
on the system pressure gauge, the inteftock is functioning property.
Set the stabilizers to see that the interlock indicator lights illuminate
5 Swbilizer Pads
Check that the switches that operate these lights are fundional, mounted
properly_and secure.
Inspe:ctthe 8"tabifizer paas- for proper InStallation and freedOm Of movement
These are the feet attached to the bottom of the jack beams, on which the
stabilizers sit.
Check ~e wo~ lightS (white liQhb under the ~biljzer wells) for proper
6
Stabilizer ~ Lights & Flashing operation.
Lights
Check the jack flashing lights on the inside of the j-=k beam. Also. check the
lens for ~ any damaQe. - - --
Check the-stabilizer safety pins for proper fastening to the beam and for proper
7 Stabilizer Safety Pins
lnsertion int~- the holes on the inner jack box.
Insp8Ct 8i8dricai""iines and ~ that piOVIde ~ the ladder tip. Inspect
8 EIedOC.aI Lines & Hoses
exposed areas for any_chaflnQor ~r. -
C""heck-the ~ves and mer assem~ for anyaamage, and Whether it
9 Sheaves & Carrier Assembly
travels property through the guide brackets while the aerial is extending and
retracting. Also check for proper tension. Adjustments can be made at the
cable anchor ooint.
10' - Safety Waterway Decals - Che-a-- Yiaterwav""iOr proper -aijQnment'~~c8tiOO:
.
I Make sure that all decals and ~ ooe~ ~s are in ~.
Check intercom system for proper operation. If ~ an inte~ I~t
IntercomS ystem
the pU~ D81ef. it stnJld also be inloeded. -
:
Check that rung covers are secure and do not turn. Also, inspect if they are
13 Rung Covers & CIiPI
tom.
C~ea"thing air syst-em-- for 1e8~nd prope;r~n (optional
equipment).
14 Breathing Air System
1S f applicable, open tank valve to charge low Pf88SUr8 skje. Close tank valve
and note the pressure on the low pressure gauge. Leave system set for onehour
. . After a one-hour period, check for pressure drop.
"""1"1

MAINTENANCE
ITEMTO CHECKiSERVJCE
PROCEDURE ' -"~~C;
" '- ::' '""",,',,; ',;..,:;,;::
- "';.".,~;;
-Perfam aerial function check from ~ tumtabte ~ conade and from
15
~
Aerial Fundion Check
basket conb'ol oanel.
.-- -
Check operation of aerial indicators
Check operation of rung alignment light
18 Aerial Indicators
Check rung alignment switch at front of base Iedion for proper alignment
Check angle indicator on the end of the base sedion fa- damage
17
18
W
-~- .
Manual Overrides
Emergency Hydraulic Pump
Lubrication
Check operation of ~I ~ gauges, switches. and indicator lights on at
control panels,_-
I Check ooeration of man-ualOVerride cor1"i"ii>iS
I ~-~(gency hyd~l!IiC~p ~fOrstabiljzer a~d aerial ~
-rLublicate com~ aerial unit-referto the lubnCatk)n ~~4-10)
NOTE
Every 25 hours of aerial operation or quarterly (whichever occurs first), perform the primary
inspection, then the following maintenance procedures:
Table 4-4. 25 hour I Quarterty Inspection
ITEM NO.
ITEM TO CHECK/SERVICE
1 EIecb'o-Hydraulic Swivel
PROCEDURE
Check the desiccator plug indicator(s) on the swivel. If the center of 1'8
indicato!_~pink. replace ~ desiccator plug.

MAINTENANCE
NOTE
Every 50 hours of aerial operation or annually (whichever occurs first), perfonn the primary
inspection, the 25 hour/quarterly inspection, then the following maintenance procedures:
Table 4-5. 50 hour I Annual Inspection
Set the unit up with the stabilizers as described in the normal set-up
4 Stabilizer Jack CyindeB procedures. Using a marking pencil of some type, mark all four of the inner
jack boxes, ~ under the outer box. Let the unit sit for a one-hour period
There is a drifting problem that needs to be repaired if the stabilizer traveled
beyond the Y2 inch mark.
Ch8Ck the eIectro-hydraulic swivel for mounting seaxity and check for leaks.
5 Electro-Hydraulic Swivel
Also check eledrical wires for wear. - -
~ Remove the fill plug from the swing drive gearbox; if the ~Ilevef is within one
6 Swing Drive Gear Oil Leve.
inrJ1 of the lu . the unit has a sufficient amount of ~I.
Iniped the lift. cylinders for ~ mounting.
Check cylinder pins and retaining bolts for security
7 Lift Cylinders
Check cylinder rod for any unusual leakage.
Check pins at turntable and on the aerial base section for seaJrity, as well as
their lock bolts.
Check all hoses to the
r routir'lO and chafintl
Inspea hydraulic cyii proper m ing.
8
Hydraulic Cylinders
Main Extension &
Basket leveling
Check cylinder rod for any unusual leakage
Check security of all cyiinder mounting bolts and pins
Check all hoses to the hydraulic cylinders for proper rouq, 1e8kage, and
chafina. - ---
Inspect base side and bottom~ for ~per- adjustment
9 Base Side & Bottom Pads
To check adjustment on side thrust pads be sure that pads are making contact
with sides of mid rung rails and that the mid section is centered in the base
sedion .
I.
Check bottom pads to see if the mid section is traveing on top of these peds
and not the base section itself. The minimum clearance to the base section is
1 in . -

~
MAINTENANCE
:. ~
TOCHECK/SERVICE ; ~~-"
..~ ~
PROCEDURE -~
CAUTION
Both the left and right cables must have an equal amount of
tension. If the tension is not equal, the sections may not
track properly.
10 Extension & Retradion Cables
NOTE
Adjusting the cables will change the relationships of the
ladder sections. Make adjustments so as to maintain
proper rung alignmenL
Adjust extension and retraction cablel
To check tension, extend ladder to one-half extension. Stop extending ladder
at a location where the rung indicator is lit. Check the tension on all cables. If
there is more that Yz inch slack, an adjustment is needed.
11 Eledricel Cables
To adjust: place a wrench on the cable end and loosen jamb nuts. Tighten
cables until there is less than 1/2 inch of slack on the cables. Retighten jamb
nuts when cablft ad~ustment is cnml)ieted.
-Check andd ~ledrical cables if necessary. "MOi1~ these ~ ~
Insped ~diust aiignment the tension!f of ladder necessary.
- 88dions and aqust/repiace guide ~ Ifnecessary.
12 Ladder Alignment
13
Ba-se- Section Pivot Pins- & Uft
Cvlinder Pins
Check base ~ pivot pins and lift cylinder pins fcx security or aacking
Pedorm aerial function r.r.-e-cl1eckS
14 Aerial Fundioo Time Checks
NOTE
Differences in times to raise, lower, extend, and retract
functions are to be expected. However, times required to
rotate 360 degrees to the right and left should be
approximately the same. A difference in time of 10 seconds
is allowable.
Aerial fully retJ'aded, elevate from 0 degrees to 75 degrees - record time
Aerial fully retracted, lower from 75 degrees to 0 degrees - record Une
Elevate aerial to 75 degrees, fully retracted, extend ladder fully - record time
~ aerial remaining at 75 degrees, retract ladder fully - record time
Rotate 360 degrees to left, with aerial raised 75 degrees - recad time
I R~ 360 dem'ees to rioht, with aerial raised 75 de(.,ees - record tkM.
I C~ ~~d ~~-~~~ip~s~~~-at-h~h-id~: - --- - - - - ~-
Main relief pressure is checked by dead heading against a fundion and
recording the pressure registered on the console control gauge.
Fully retracted lower pressure is obtained with aerial in a downward motion
15 Aerial Pressures
Fully retracted raise pressure is obtained with aerial in an upward motion
Elevated to 45 degrees extend pressure is obtained in nXJtion
Elevated to 45 degrees retrad pressure is obtained in motion
16 Waterway & Water Monitor
Left and right swing pressures may be obtained at any elevaOOn in moOOn with
the aerial fullv retraded.
I CheCk waterWay andwater moit'ftor fQr seCurity a""rIdTeakage.

MAINTENANCE
20 Uft Cylinders
21 Pink)n ~r 8ofta
JaCk Cylindei
23 Extension Cylinders
Fully extend and elevate the aerial to 6O-degr8elevation; turn truck off.
Toggle the manual control valve handle to remove pressure and wait 10
minutes. Measure from rod gland to a mark on the piston rod. Allow aerial to
remain at this elevation for a period of one hour. Re-measure. If aerial drifts
down more ~~~ there is a problem with the unit. ~
C~nd~tOrQue the pinion gear bolts on the rotation shaft.
~eck the security of the ~ bolts on the jack cylinders.
NOTE
This check may be j)6w-:v.rned toget:".af' with the lift cylinder
drift teet and 8tabilizer jack cylinder drift teet.
NOTE
If the system oil temperature differs from the ambient
temperature, an additional wait time is required for the oil
temperature to equalize. This will prevent drift errors due
to the expansion or contraction of the oil.
Perform extension cylinder drift-down chedc on both cylinders together:
Fully extend and elevate aerial to 6O-degre8 elevation; turn tnx:k off. Toggle
the manual control valve handle to remove pressure and wait 10 minutes.
Mark the end of the mid section rung rails in relation to the base section. Allow
aerial to remain at this elevation for a period of one hour. Re-measure. If
aerial ~own ~ than 1 inch, there is a problem with the ~it.
I ITE~ NO. f:
NOTE
Every 400 hours of aerial operation or annually (whichever occurs first), perform the primary
inspection, the 25 hour/quarterly inspection, the 50 hour/annual inspection, then the following
maintenance procedures:
T8ble 4-6. 400 hour I Annual Inspection
ITEM
Replace hyaraulic return and pressurelilters. Emphasis should be made that
Hydraulic Filters dirt is a maior fador in hYdraulic system failures.
Pierce Manufacturing Inc. recornrne-na5 taking a sample of hydraulic oil and
2
Hydraulic Oil
having it analyzed by a local company. The sample should be taken foIk)wing
30 minutes of aerial operation.
I '3 I EIedro-HydrauIic SWivel Bob '-~ Re-torque the eIectro-hydraulic swivel mounting bolts (1fl in.) to 2~0 ~. ~.
Re-torque the rotation bearing to torque box and turntable mounting bolts (top
4
Rotation Bearing Botts and bottom) (7/8 in.) to 650 fllb., using a torque m~ier. Refer to the torque
multir"ier instructions for the proper conversDt DQue.
5 I Pinion Gear ~
I Check the pinion gear beddash (.018 to .025) and a~u~ if necessarY.
Re-torque the boom s~ mountWtg bofts (3/4 in.) to 357 ft. lb., ~ a
6 Boom Support
torque multiplier. Refer to the torque multiplier instructioos for the proper
conversion torQue. -- -
Re-torque the swing drive bolts on the turntable:
7
Swing Drive Bolts
Ring to turntable bolts (1/2 in.) to 101 ft. lb.
. Ring to planetary drive bolts (9/16 in.) to 163 ft. lb.
Re-torque the aerial torque box mounting bolts (3/4 in.) to 357 ft. lb., using a
8
Aerial TorqueBox ~ rnulBo!ts I =rs":'IU=~ torque ~ltiplier. r\BT8f Refer W to U1a the wrque torque multiplier instrudions for the proper
conversion ue

MAINTENANCE
The type of service and regional area could be detrimental in the operation and longevity of this device.
temperature and environmental conditions are significant.
Both
4-7.1 General Temperature Concerns.
The recommended start up temperatures for the hydraulic system depends on the viscosity grade of hydraulic oil
installed in your aerial. A label located on the hydraulic oil reservoir indicates the grade of oil installed in your unit.
4-7.2 Extreme High Temperature Concerns.
1) During high temperature periods, monitor the hydraulic oil temperature and avoid any unnecessary use of the
aerial. Continued use above the maximum recommended operating range may reduce the life of some aerial
components. (Refer to Table 4-1, Hydraulic Oil Recommendations,
the beginning of this maintenance section
to determine the temperature range of hydraulic oils used in Pierce aerial units.)
2) In high temperature climates where low temperatures are unlikely, use grease with a high melting point for the
rotation gear/pinion to provide extended coverage of these areas.
4-7.3 Extreme Low Temperature Concerns.
1) During cold weather periods, monitor the hydraulic oil temperature. If it falls slightly below the recommended
operating range, the function speed may diminish. If the oil temperature falls below the recommended start-up
temperature. the continuous running of an aerial function will help to warm the oil. (Refer to Table 4-1, Hydraulic
Oil Recommendations, at the beginning of this maintenance section to determine the temperature range of
hydraulic oils used in Pierce aerial units.)
CAUTION
Do not use multiple functions until the temperature is above the recommeded minimum startup
temperature, otherwise pump cavitation and damage may occur.
2) Maintain only a thin film of low melting point grease on the rotation gear/pinion. Allowing a build-up of heavy
grease will degrade the aerial operation.
3) Continued use of the aerial functions will circulate the oil, delaying the ambient cooling effects.
4-7.4 Extreme Wind Swept Sand & Dirt Concerns.
In environments where wind swept sand and dirt find their way into all areas of the aerial, more frequent cleaning is
required.
1) Remove contaminated grime from the telescopic waterway tubes. They should be dean at all times. A light coat
of very thin oil will improve the lubricity, however too much oil will only attract more contamination.
2) The wire rope cables should be clean. DO NOT use solvents on the cables. Using solvent on the cables will
remove the intemal lubrication from the cables. Use only a "penetrating" cable lubricant when lubricating the
cables.
3) Clean and remove contaminated grease from the rotation bearing gear and pinion gear. These should have only
a light coating of clean grease.
4-7.5 Salt Air Environment Concerns.
1) Touch-up painted areas showing signs of rust to prevent further corrosion.
2) Clean and lubricate unpainted areas such as pins and cables. Use only a -peneb"ating- cable lubricant when
lubricating the cables.
- -
0 ~ ~ ~ ". AI RigID :a.;-.-ac: 4-8
Yd-abn~
--

MAINTENANCE
4-8.
STRESSED FASTENER MAINTENANCE
4-8.1 Introduction.
The purpose of these instructions is to emphasize the importance of the role in which nut and bolt combinations play
in providing the structural strength required by Pierce aerial devices. These fasteners are not only critical for
structural strength, they also affect performance and reliability. Improper variation in torque may cause distortion,
binding, or fatigue failure of components.
The following material gives complete information on all aspects of stressed fastener maintenance for all models of
Pierce aerial devices, including:
1) Identification and application of bolt sizes and grades.
2) Proper torque of all sizes and grades of bolts.
3) Torque wrench information and associated equipment.
Adhering to these recommendations will add materially to the life and safety of your Pierce Manufacturing Inc. Aerial
Division product.
4-8.2 Identification and Application of Bolt Sizes and Grades.
How to determine the size of a stressed fastener:
1) Diameter - measure the head size of the bolt; refer to Table 4-7
HEAD SIZE
1-1rr
1:5jie-
*1=1W
*1-1/8"
1-5/16"
~
Table 4-7. Bolt Sizes
BOLT
THREAD
DIA.
1-
om-
W
~ 5/8-
1~
NC (Course)
THREAD!
IN.
8
9
10
10
11
-1i:
NF (Fine)
THREAD!
IN.
12
14
16
16
18
20
* if the bolt head measures 1-1/4" or 1-1/8", the diameter of the bolt is 3/4".
2) Length - at a minimum, bolts must extend into the threaded area of the bearing, tapered shaft, or plate that they
secure a distance equal to the diameter of the bolt being used.
Further penetration of the bolt into the threaded area is desirable, as long as the bolt does not bottom out.
For nut/bolt combinations, the bolt length should be sufficient to allow the bolt to extend through the materials
being clamped, locking devices (washers), and nut so a minimum of 1-1/2 threads are protruding through the nut,
after the desired level of tightness (torque) is attained.
3) Grade - bolts of the same diameter may differ greatly from one another in terms of strength. Depending on the
material composition and manufacturing process, the tensile strength of a bolt can vary from 64,000 PSI to
180,000 PSI.
The relative strength of a fastener is indicated by the head shape and standard markings designated for this
purpose.
Hex head cap screws, commonly found on Pierce Manufacturing Inc. aerial equipment will be marked with
diagonal lines, numbering from two to six.

MAINTENANCE
NOTE
SAE standards require the manufacturer's logo or trademark to be included in the head
pattern. Certain bolts may be marked in a similar manner and not meet the specifications set
forth in these standards. Bolts purchased from distributors other than the original equipment
manufacturer (OEM) should be accompanied by certification documents to assure the
integrity of the equipment is maintained.
4-8.3 Proper Torque of all Sizes and Grades of Bolts.
Identification of bolt grade is always necessary. '.'\'hen marked as a high-strength fastener (Grade 5, Grade e, etc.),
the mechanic must be aware that these are highly stressed components and must be torqued accordingly.
Special attention should be given to lubrication, plating and other factors that would dictate a deviation from the
standard torque values.
4-8.4 Torque Wrenches and As8ociated Equipment.
Torque Wrenches - These wrenches are precision instruments and must be handled with care to assure proper
calibration accuracy. Calibration checks should be made on a regularly scheduled basis. \'\'henever a torque wrench
may have been over-stressed or damaged, it should be removed from service until recalibrate or repfaced.
Rigid click-type torque wrenches, which have torque limiting devices that can be preset to the required torque values,
are recommended.
When using the torque value chart, values close to the mid-range are recommended to allow for torque wrench
calibration tolerances. Erratic or jerking motion of the wrench can easily result in excessive torque values. ALWAYS
use slow, even wrench movements and.§1Q.Q when the predetermined value has been reached.
Associated Equipment - Certain accessories used in conjunction with the torque wrench enable maintenance
personnel to properly service the stressed fasteners encountered on Pierce Manufacturing Inc. aerial devices. The
proper use of these tools and their intended application are outlined in the following paragraphs.
NOTE
A torque multiplier increases the output force of the socket by approximately four times the
value which is introduced by the torque wrench. Factoring the torque value (typically onefourth
the desired value) to provide the desired torque is necessary when using a torque
multiplier. Follow the manufacturer's instructions for your specific torque multiplier.
Torque multipliers provide the maintenance personnel with fastener tightening power that requires approximately onefourth
the force required using conventional tools. They provide safe. convenient tightening power when confronted
with the need for high torque values within a limited amount of working or leverage space.
c ~ P'-ce ~ R. AI ~ Resefwd
4-10
~PIatbm

MAINTENANCE
SUGGESTED ASSEMBLY
TORQUE VAWES TO PRODUCE CORRESPONDING
BOLT LOADS
0
0
0 Grade 8
Clamp
Load
(Lbs)
540
600
820
920
1~
1320
1580
1800
2850
3250
4700
5200
7tXX)
7900
9550
1~
12750
14375
16375
18250
20350
23000
30100
33500
41600
45900
54500
59700
61200
68900
771XX>
87200
96600
104000
118400
126500
142200
Grade 5
Clamp
Load
(Lbs)
380
420
580
640
900
940
1120
1285
2000
2300
3350
3700
4950
5600
6800
7600
9000
10250
11~
13000
14400
16375
21300
~
29450
32450
38600
42300
43400
42300
47500
53800
59mO
64100
~
78000
87700
Grade 2
Clamp
Load
(Lbs)
250
275
375
420
580
610
725
825
1320
1500
21m
2400
3200
3620
~
4900
5850
6600
7500
8400
9350
10550
13800
15400
11450
12600
15000
16400
16800
18900
21200
24000
~
28600
32500
34800
39100
Assembly
Torque
Dry
Lub.*
(Lbs)
(Lbs)
Assembly Torque
Dry
Lub.-
(Lbs)
(Lbs)
Assembly
Torque
Dry
Lub.*
(Lbs)
(Lbs)
Size
12.i\
13-i1
23-i1
25-i'1
41-i\
43-in
~
68-i1
12.ft
14-ft
250ft
25-ft
45-ft
5O-ft
7o.ft
8().ft
110-ft
120.t
150-ft
170.ft
22o.t
240.ft
38G-ft
42G-ft
600-ft
66G-ft
9O0-ft
1(KX)..ft
1020.ft
1280-ft
144G-ft
182G-ft
2(KX)..ft
2380.ft
2720-ft
3160.ft
3560-ft
9-iI
10-il
17-i\
19-i1
31-iI
32-iI
45-iI
51-i\
9-1
10-ft
18-ft
200ft
35-t
35-ft
55-ft
eo-ft
ao-ft
~ft
110-ft
13D-ft
17o.ft
18O-ft
28o-ft
32D-ft
46D-ft
5OO-ft
68O-ft
740-ft
76D-ft
96D-ft
1(8)..ft
1~ft
15OO-ft
1m-ft
2040-ft
25ft
266D-ft
&-in
&-i1
16-i1
18-i1
3O-iI
31-i1
43-iI
49-iI
Soft
100ft
17-ft
19-ft
3o.ft
35-ft
5Q.ft
550ft
75-ft
g().ft
1100ft
120-1
150-ft
1~ft
260-1
300-1
~I
470-1
640..
710.ft
730..
800-1
~
112o.ft
1240.ft
1460.ft
1680.ft
1940.ft
2200.ft
&-in
7-i1
12-i\
13-m
22-in
23-in
32-i1
36-in
75-in
86-i1
13-ft
14-ft
23-ft
250ft
35-ft
400ft
55-ft
65-ft
8O-ft
9O-ft
11G-ft
13o.ft
2OO-ft
22o.ft
320-ft
36().ft
480-ft
530-ft
540.ft
600-ft
66().ft
840.ft
920.ft
1100-ft
126G-ft
146G-ft
1640-ft
5-in
6-iI
1o-in
12-iI
19-iI
2G-m
27-i1
31-in
66-in
76-in
110ft
120ft
200ft
23-ft
32-ft
3&-ft
5O-ft
550ft
7o.ft
8O-ft
100-ft
11o-ft
175-ft
200-ft
170.ft
180-ft
25D-ft
27D-ft
28G-ft
350-ft
400-ft
SOO-ft
55O-ft
67D-ft
750-ft
87o.ft
980-ft
4-i\
5-i1
8-i1
9-i1
14-i\
15-in
21-iI
23-i\
SO-i\
56-in
8.ft
90ft
1S-1
17-1
24-1
27-1
350ft
40-1
ss..t
&).1
75-.
B5-t
130.ft
150-t.
17G-ft
140.1
19G-ft
210-1
210-ft
27o-tt
300-ft
~G-ft
42G-t.
490-ft
560-ft
650-ft
73G-ft
4-40
4-48
6-32
6-40
8-32
8-36
10024
10032
114-20
114-28
5/16-18
5/16-24
311-16
3$-24
7/16-14
7/16-20
1fl-13
1fl-20
9/16-12
9/16-18
5/8-11
5/8-18
3/4-10
3/4-16
7/8-9
7/8-14
1-8
1-12
1-14
1-1/8-7
1-1/&-12
1-114-7
1-1/4-12
1-3/8-12
1-3/8-12
1-1fl~
1-1fl-12
~: When the maximum
torque values have been exceeded,
the fastener must be replaced.
t8Lubricated"
includes
lubricants
Iubrizing,
platinQ
and hardened
washer.

~
MAINTENANCE
4-9. LUBRICATION INSTRUCTIONS
1 1
2 4
WATER S~L
Table 4-8. Lubrication Instructions
IN BASKET
WATERWAY BEARINGS
3 1 WATER SVtWEl, FRONT OF LADDER
4
LADDER SECTION GUIDE PADS &
SLIDING SURFACES
(BRASh on outside and bottom of fly & mid
sections and inside of base & mid
sedions - where guide pads rub.)
TYPE OF LUBRICANT
~
PIERCE MANUFACTURING
CARTRIDGE PN #1003040 or SYNCO
SUPER LUBE PN #41150
-(X"-
PIERCE MANUFACTURING
5 Ib TUB PN #1003044 or SYNCO
SUPER LUBE PN #41050
-(X"-
PIERCE MANUFACTURING
30 Ib PAIL PN #1003046 (X" SYNCO
SUPER LUBE PN #41030
5
2 MONITOR
6 2
7 2
BASKET LEVELING CYLINDER PINS
(Rod end only)
BASKET LEVELING MASTER
CYLINDER PINS (Rod end only)
8 4
LIFT CYUNDER PINS
9 1
TURNTABLE ROTATION BEARING
10 ROTATION BEARING TEETH
PIERCE MANUFACTURING
CARTRIDGE PN #95-0903
-or-
EXXON NLG1 No. 2 GRADE GREASE
~MOlY
-(X"-
EQUIVALENT HEAVY DUTY No. 2
GRADE GREASE WITH MOLY
11 4
12 1
13 1
BOTTOM OF STABILIZER BEAMS
HYDRAULIC SYSTEM RESERVOIR
ROTATION GEAR BOX ON TURNTABLE
(See Figures 1 & 2 for specific
instructions)
SEE HYDRAULIC OIL TAG ON
RESERVOIR
API-Gl5 No. 80 OR 90
14 WATF:RWAY TUBES
15
BASKET LEVELING PUMP
18 WtRE ROPE CABLES
DEXTRON II AUTOMATIC
TRANSMISSION FlUID (OR
EQUIVALENT)
LUBRJPLATE CHAIN AND CABLE FLUID
(OR EQUIVAlENT)

MAINTENANCE
4-10. LUBE CHART
~
.c.
(J)
"0
z
@
@

MAINTENANCE
Figure 2.
1 ) If necessary, rotate the aerial until the
planetary sun gears are clear of the fill hole
and a measuring device can be inserted
between the planetary gears.
2) The correct oil level should reach the middle
of the primary planetary gear face (see
Figure 2.)
3) 'M1en properly filled the oil level should be
between 1.25 - 1.50 inches below the top of
Figure 1

I CI~
I
I~
Equipment Inspection and Maintenance Worksheet
~pmentMcM!el
I PI8Iw Job f«I. Miles tb88
I Publlcalioo Dele
I~~~
! CoIwnn A. - Enc. TM l18li N ~ ProcedUIV
I Coh8nn B. - e ~ ~ ~ 1YInbOiC- b8kMt
I CokMnn C. - Enter a ~ of ~ --' ~.
Column
l ox.. - ~ . ddcIency In DIe ~ 11181*088 it In 81 ~ -..
1kJII.
"X"- ~ . ".c;.w:y, ~. !he ~ may be ~
und.- 8p8CiIc ~ as d-'-' by !he ~ ~ jurisdiction. untl
c:on8CIiWe 8daIa ~ be ~.
Descriptions
M~
I Type ~ In8pec:tioo
~ 0. - Show C«rdve action peIbm8d for ~"it ~.~-oi u..d In ~n c.
~ E. - E.- ... In the IXMIIIm of ~ of who ~ con9CIV8 Uion.
Equipment Status Symbols
~ w - IrMIc-. . ~ d8I8ct. «*Ier "- . ~. wI1k;h must be ~ 10
m- 8IIcIIncy or 10 make lie 118m ~ ~
LAST NAME INITIAL - I~ ~. ~~. ~ ...
HORIzr;,lfA!.. DASH i-r - ~ th8t a IwqI*wd ~, ~,.;x; ;; ..
~. M n ~ cheok Is due WI h88 lid ~ --hed,
or 811 ~ i~ '- lid ~~.
AI /n$PBCIiaJS .nd ~ condIions reccxded on ttWs - bm have been .18(..." rJC: In sccaf1Bnce w;th the /nspecIkJn ~ .nd
~
stBIwiards contained in 1hsSCt:arJ8Jyk Ig mBIXJaJ.
~~
"ITIAL
ITEM NO.
W
~TUS
(8)
DEFICIENCY/SI-IORTCOMING (C)
caRCTlVEACT1C»I(O}
MEN
~
IECTED
IE)