JBT Manual 1

Tempest
Aircraft Deicer
GROUND SUPPORT AROUND THE WORLD
For assistance or questions with set-up, warranty or parts, please contact your closest
JBT AeroTech Sales and Service Center.
Location Warranty and Service Part Sales
Orlando telephones telephones

Headquarters 1.800.327.1686 within USA 1.800.821.3019 within USA
John Bean Technologies Corp. +1.407.850.4207 outside USA +1.407.850.4208 outside USA
7300 Presidents Drive +1.407.850.4221 fax +1.407.850.4221 fax
Orlando, Florida 32809 orlando.service@jbtc.com parts.orders@jbtc.com
USA
Madrid
John Bean Technologies +34.91.877.5880 telephone +34.91.877.5883 telephone
AeroTech S.L. +34.91.877.5881 fax +34.91.877.5884 fax
Autova A-2, Km. 34,400
28805 Alcal de Henares madrid.parts@jbtc.com madrid.parts@jbtc.com
Madrid, Spain
London
John Bean Technologies Ltd.
Arnold Hawker House +44.208.587.0666 telephone +44.208.831.2200 telephone
Central Way +44.208.587.0660 fax +44.208.587.0660 fax
Feltham, England
london.service@jbtc.com london.parts@jbtc.com
Middlesex, United Kingdom
TW14 0XQ
Singapore
John Bean Technologies
Singapore Pte. Ltd. +65.6.542.9255 telephone +65.6.542.9255 telephone
75 Airport Cargo Road +65.6.542.7493 fax +65.6.542.7493 fax
SATS Maintenance Centre
Cargo Complex singapore.asdparts@jbtc.com singapore.asdparts@jbtc.com
Singapore Changi Airport
Singapore 1781
Comments or suggestions
regarding our manuals?
Technical Publications
At JBT AeroTech we are always John Bean Technologies Corp. +1.407.850.4205 telephone
striving to improve our technical 7300 Presidents Drive +1.407.850.4221 fax
documentation. If you have any Orlando, Florida 32809 technical.publications@jbtc.com
comments or suggestions, please USA
contact us!
i
THIS PAGE INTENTIONALLY LEFT BLANK
INTRODUCTION
WARNING
BEFORE ATTEMPTING TO OPERATE OR MAINTAIN THE VEHICLE, COMPLETELY READ AND
UNDERSTAND THE OPERATION AND MAINTENANCE MANUAL, INCLUDING ALL DANGER,
WARNING, AND CAUTION STATEMENTS. VEHICLE MAINTENANCE MUST BE PERFORMED
EXCLUSIVELY BY TRAINED AND QUALIFIED TECHNICIANS AND ACCORDING TO
MAINTENANCE SCHEDULES AND MANUFACTURERS RECOMMENDATIONS. FAILURE TO
COMPLY WITH THIS WARNING MAY RESULT IN SERIOUS BODILY INJURY, DEATH, OR
PROPERTY DAMAGE, INCLUDING DAMAGE TO THE VEHICLE! IF YOU HAVE ANY
QUESTIONS REGARDING THE SAFE OPERATION OR PROPER MAINTENANCE, PLEASE
CONTACT YOUR LOCAL JBT AEROTECH SERVICE CENTER BEFORE PROCEEDING.
1. PURPOSE
This technical manual presents operation, maintenance, service and parts procurement information for
the Tempest Aircraft Deicer manufactured by JBT AeroTech.
2. SCOPE
This manual describes the procedures for safe operation, maintenance and repair of the Tempest
Aircraft Deicer, and ordering of spare parts. This manual does not provide procedures or guidelines
specific to the operation of the vehicle on airports, or specific aircraft requirements.
3. TERMS
Throughout this manual, the Tempest will be referred to as the vehicle or unit. The terms right and
left in the descriptive paragraphs refer to the operators right and left from a normal operating position.
The term driver refers to the person driving the vehicle from the drivers cab, and the term operator
refers to the person who performs deicing/anti-icing operations from the basket attached to the aerial
device. For the one-man drive/operation mode (optional) the operator performs both functions.
Maintenance is defined as, but not limited to, inspections, checks, adjustments, troubleshooting, repairs,
removal, replacement of components, modifications or any other work, required for the vehicle to
operate. For additional terms and acronyms used in this manual refer to Description in Chapter 1,
Section 1.
4. IMPORTANT SAFETY NOTICE
This manual contains instructions, warnings and cautions based on normal operation and maintenance
practices. JBT AeroTech has no control over the actual operation and maintenance of the vehicle and
cannot foresee all possible situations.
Drivers and operators must be aware of all applicable rules and regulations for operating the vehicle in
traffic, on the airport and with aircraft. Also, personnel performing maintenance and repairs must be
skilled and experienced in work on heavy industrial vehicles.
iii
In addition to the instructions in this manual, operators and maintenance personnel should follow all
locally applicable guidelines and regulations, and use common sense to maintain the vehicle in optimum
condition and avoid hazardous situations. For safety and reliability use only JBT AeroTech replacement
parts. A safety conscious operator and a well cared for vehicle make a safe and efficient combination.
Your vehicle may operate slightly different depending on specifications and optional features.
5. VEHICLE MODIFICATIONS
Modifications, including changing of settings, replacement of parts with non OEM parts and addition of
components or features may affect the safety and operational ability of the vehicle. Do not make
modifications without written approval from JBT AeroTech, Orlando, Florida, USA.
6. TECHNICAL ADVISORIES
JBT AeroTech may issue Technical Advisories during the life span of the vehicle. These Technical
Advisories are intended to improve the reliability of the vehicle or address any safety related issues that
may arise. Unless the Technical Advisory instructs otherwise, please insert it immediately after the List
of Warnings and Cautions located in the front of this manual.
To receive these important Technical Advisories it is required that you inform JBT AeroTech in the event
the contact information of the person responsible for this equipment has changed, the vehicle has
moved to a different location, or the vehicle has transferred ownership.
Required Information:
- Equipment type
- Serial number(s)
- Vehicles operating location address
- Technical Advisory mailing information (No P.O. boxes please)
- Contact personnel (GSE Manager, Safety Manager)
- Telephone number(s)
- E-mail address(es)
Please send this information to:
Technical Publications Department

JBT AeroTech, Ground Support Equipment
7300 Presidents Drive
Orlando, Florida 32809
USA
technical.publications@jbtc.com
7. CE COMPLIANCE
This vehicle complies with the following CE requirements:
Machinery Directive - Annex IV, 2006/42/EG
iv
CERTIFICATES ARE ISSUED FOR EACH VEHICLE BASED ON INDIVIDUAL CUSTOMER SPECIFICATION.

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v
8. VEHICLE IDENTIFICATION PLATE
The vehicle identification plate contains specific information about your vehicle such as model,
specification number, serial number, manufacturing date, and other pertinent information. Refer to
Figure 1 for the location of your vehicles identification plate.
NOTE: BE SURE TO HAVE THE INFORMATION FROM THE VEHICLE IDENTIFICATION PLATE
READILY AVAILABLE WHEN CALLING JBT AEROTECH FOR PARTS OR SERVICE.
REAR VIEW OF
THE VEHICLE
LOCATION OF
THE VEHICLE
IDENTIFICATION
PLATE
Figure 1
VEHICLE IDENTIFICATION PLATE
vi
GENERAL TABLE OF CONTENTS
OPERATION AND MAINTENANCE MANUAL

WITH ILLUSTRATED PARTS LIST
Volume I OPERATION AND MAINTENANCE
CHAPTER 1. GENERAL INFORMATION AND OPERATING INSTRUCTIONS
CHAPTER 2. MAINTENANCE AND REPAIR
CHAPTER 3. OVERHAUL
Volume II ILLUSTRATED PARTS LIST
CHAPTER 4. ILLUSTRATED PARTS LIST
CHAPTER 5. MANUFACTURERS APPENDICES
vii
Volume I
OPERATION AND MAINTENANCE MANUAL

Original Instructions
Version 2
Edition 17.2, Revision 6
This volume supersedes all editions and revisions prior to:
March 2014
English Language
For use with equipment serial numbers
TP14002 and subsequent
This volume includes the following options:
- Open and Enclosed Baskets - Premix Type II/IV System (CE) - XR (Extended Reach) Boom
- Cummins QSB T3, T4i Engines - Proportional Mix - OptiMax Heat System
- Mercedes OM 906 LA Engine - BlendUP System - Electronic Heater Controller
- One/Two-man Drive System - AirFirst System - Winterization System
- Premix Type I Fluid System - Washing System - Akron and Elkhart Nozzles
- Premix Type I System Japan - Tempest Diagnostics - CE Compliant Options
Reference Volume II
for Illustrated Parts List
JBT AeroTech, Ground Support Equipment
John Bean Technologies Corporation
7300 Presidents Drive
Orlando, Florida 32809 - USA
+1-407-851-3377 Telephone
+1-407-850-4221 Fax
CONFIDENTIAL
This technical manual contains unpublished work of John Bean Technologies Corporation. All information
herein is confidential and proprietary and cannot be duplicated, used or disclosed in whole or in part, except
with written permission from John Bean Technologies Corporation, Orlando, Florida USA.
20052014 John Bean Technologies Corporation, all rights reserved.
ix
RECORD OF REVISIONS
All pages in this issue are original.
The following pages have had changes incorporated.
Change Edition/
List of Effective Pages Change Description
Date Revision
Sep. 2005 Edition 1 Volume I New edition
Oct. 2005 Revision 1 Chapter 2, Section 1 Updated: grease specifications.
June 2006 Revision 2 Volume I Updated: general information.
July 2006 Revision 3 Chapter 2, Section 5 Added: fluid schematic 624-4953-002.
Added: sound pressure and vibration levels,

Aug. 2006 Revision 4 Chapter 1, Sections 3, and 5
schematic 521-0807.
Added: Mercedes engine, and electrical

schematic 521-1104.
Chapter 1
Nov. 2006 Edition 2 Updated: electrical schematic 521-0807 A,
Chapter 2, Sections 5, and 8
general information.
Deleted: obsolete schematics.
Added: electrical schematic 521-1004, and

Nov. 2006 Revision 1 Chapter 2, Section 5
fluid schematic 624-2230.
Added: electrical schematics 521-0808, and

Chapter 1, Section 2 521-1103.
Dec. 2006 Edition 3
Chapter 2, Section 5 Updated: monitor/camera system, and
vehicle driving instructions.
Jan. 2007 Revision 1 Volume I Updated: general information, new layout.
Mar. 2007 Edition 4 Volume I Added: Prop-mix information.
Apr. 2007 Revision 1 Chapter 2, Section 5 Updated: schematic 624-4953-002 B.
Updated: preventative maintenance for air

July 2007 Revision 2 Chapter 2, Section 1
dryer.
Aug. 2007 Edition 5 Volume I Updated: general information.
Aug. 2007 Revision 1 Chapter 2, Section 5 Updated: schematics.
Aug. 2007 Revision 2 Chapter 2, Section 2 Added: optional diagnostics procedures.
Added: Sections 2-1, and 2-2; schematics.

Oct. 2007 Edition 6 Volume I Updated: manual structure and layout.
Deleted: previous old section 2-8.
xi
Change Edition/
Date Revision
Sep. 2008 Edition 7 Volume I Updated: general information, new logo.
Nov. 2008 Edition 8 Volume I Updated: Tier 3 engines information.
Dec. 2008 Edition 9 Volume I Not released.
Updated: safety information, and latest

Chapter 1
Mar. 2010 Edition 10 product details; CE Machinery Directives,
(Operators Handbook only)
Annex IV, 2006/42/EG.
Apr. 2010 Revision 1 Introduction Updated: Declaration of Conformity form.
May 2010 Revision 2 Volume I Updated: general information.
July 2010 Edition 11 Volume I Updated: XR boom information.
Added: XR boom, and Arvin Meritor axle

July 2010 Revision 1 Chapter 1, Sections 1, 2, and 3
information.
Added: blendUP operational instructions,

electrical and fluid schematic, boom rotator
and enclosed basket rotator maintenance
Chapter 1, Section 2;
procedures; troubleshooting screenshots
Nov. 2010 Edition 12 Chapter 2, Sections 3, 4, 5, 6,
and alarms table.
and 7
Updated: fluid accumulator inspection, and
maintenance specifications and procedures,
fluid schematic.
Updated: electrical schematics 521-1106 A

Dec. 2010 Edition 12.1 Chapter 2, Section 7
and 521-1107 B.
Updated: hydraulic oil recommendations,

Mar. 2011 Edition 13 Chapter 2, Section 4
torque specifications.
Mar. 2011 Edition 13.1 Chapter 2, Section 7 Updated: schematic 521-1210 B.
Added: winterization system, and other

features and options.
Updated: warnings and cautions,
July 2011 Edition 14 Volume I
preventative maintenance schedules,
stability and load tests, and schematics
521-1210 C, 624-4953-102 -.
Updated: XR boom extend/retract,

Chapter 1, Sections 2 and 4; schematics 521-1210 C (final) and
Aug. 2011 Revision 1
Chapter 2, Sections 6 and 7 624-0942 C; alarms for diagnostics,
XR boom, and blendUP.
Updated: electric schematic 521-1011 A,

Oct. 2011 Edition 14.1 Chapter 2, Section 7 hydraulic schematic 624-6461 U, fluid
schematics 624-4954 C, 624-4953-005 B.
xii
Change Edition/
Date Revision
Updated: overall dimensions, diesel fuel

designations, environmental limitations,
Chapter 1, Section 4; lock-out and tag-out procedures, hydraulic oil
Sep. 2012 Edition 15 Chapter 2, Sections 4, 5, 6, recommendations, fluids and lubricants
and 7 specifications and capacities, device
designations, electrical schematic
521-1011 B.
Dec. 2012 Edition 15.1 Chapter 2, Section 7 Added: electrical schematic 521-1211 A.
Updated: schematic 521-1211 B, hydraulic

Mar. 2013 Edition 16 Volume I
schematic 624-6461 V.
Introduction, Chapter 1, Updated: SMP certificate, purging

June 2013 Edition 17
Section 2 procedures.
Updated: Prop-mix and blendUP

Aug. 2013 Revision 1 Chapter 1, Sections 2, and 4
procedures, QSB Tier 4i engine.
Chapter 1, Section 2; Updated: refilling procedures, safety

Aug. 2013 Revision 2
Chapter 2, Section 1 procedures.
Updated: purging pumps and hoses for

Chapter 1, Sections 5, and 6, shipping and long term storage, maintenance
Sep. 2013 Revision 3
Chapter 2, Sections 3, 4, and 5 and check schedules for AirFirst, fluid
heater burner adjustment.
Oct. 2013 Revision 4 Chapter 1, Section 2 Updated: operating procedures.
Nov. 2013 Revision 5 Chapter 1, Section 4 Added: vehicle jacking requirements.
Edition 17.1 Warranty page, Introduction Updated: London office address, SMP
Feb. 2014
Revision 6 Chapter 2, Section 7 certificate, schematic 624-4953-005 C.
Updated: schematics 521-1211 C and

Mar. 2014 Edition 17.2 Chapter 2, Section 7
624-4953-004 A.
xiii
LIST OF WARNINGS AND CAUTIONS USED IN THIS MANUAL
DANGER
A DANGER STATEMENT INDICATES A SITUATION THAT MUST BE AVOIDED. FAILURE TO
COMPLY WITH THE DANGER STATEMENT WILL RESULT IN SERIOUS BODILY INJURY,
DEATH, OR PROPERTY DAMAGE, INCLUDING DAMAGE TO THE VEHICLE!
WARNING
A WARNING INDICATES A PROCEDURE THAT MUST BE FOLLOWED OR A CONDITION THAT
MUST BE OBSERVED. FAILURE TO COMPLY WITH THE WARNING MAY RESULT IN SERIOUS
BODILY INJURY, DEATH, OR PROPERTY DAMAGE, INCLUDING DAMAGE TO THE VEHICLE!
CAUTION
A CAUTION INDICATES A PROCEDURE THAT MUST BE FOLLOWED OR A CONDITION THAT

MUST BE OBSERVED. FAILURE TO COMPLY WITH THE CAUTION MAY RESULT IN DAMAGE
TO VEHICLE, OR OTHER PROPERTY, INCLUDING THE AIRCRAFT!
The following warnings and cautions are used in this manual. Read all of them and follow
the instructions when performing the procedures.
DANGER
DIESEL FUELS, KEROSENE, HYDRAULIC OIL, LUBRICANTS AND GLYCOLS ARE
FLAMMABLE. USE EXTREME CAUTION TO PREVENT SPILLS AND AVOID HEAT OR OPEN
FLAMES. DO NOT OVERFILL THE FUEL TANK WHEN REFUELING. ALWAYS ALLOW ROOM
FOR EXPANSION OF FUEL. FAILURE TO COMPLY WILL RESULT IN SERIOUS BODILY
INJURY, DEATH, OR PROPERTY DAMAGE, INCLUDING DAMAGE TO THE VEHICLE!
DANGER
ELECTRICAL CURRENT FROM FACILITIES POWER, BATTERY, AND LIGHTNING IS
HAZARDOUS. TO REDUCE THE RISK OF ELECTRICAL SHOCK: DO NOT CONNECT OR
DISCONNECT ANY ELECTRICAL CABLES DURING AN ELECTRICAL STORM, CONNECT
FACILITIES POWER UTILIZING ONLY THE PROPER CONNECTORS PROVIDED, USE ONE
HAND ONLY TO CONNECT OR DISCONNECT CABLES, AND TURN OFF AND LOCK OUT ALL
ELECTRICAL POWER SOURCES BEFORE PERFORMING ANY MAINTENANCE ON THE
VEHICLE. FAILURE TO COMPLY WILL RESULT IN SERIOUS BODILY INJURY, DEATH, OR
PROPERTY DAMAGE, INCLUDING DAMAGE TO THE VEHICLE!
xv
DANGER
HIGH VOLTAGE MAY ARC OVER CONSIDERABLE DISTANCE AND EXCEED THE INSULATING
CAPACITY OF STANDARD TOOLS. ENSURE ALL ELECTRIC ENERGY SOURCES ARE
ISOLATED AND RENDERED INOPERATIVE BEFORE PERFORMING ANY MAINTENANCE ON
THE VEHICLE. FAILURE TO COMPLY WILL RESULT IN SERIOUS BODILY INJURY, DEATH, OR
WARNING
TO CALIFORNIA CUSTOMERS: CALIFORNIA PROPOSITION 65 STATES THAT DIESEL
EXHAUST AND SOME OF ITS CONSTITUENTS ARE KNOWN TO THE STATE OF CALIFORNIA
TO CAUSE CANCER, BIRTH DEFECTS, OR OTHER REPRODUCTIVE HARM.
WARNING
FLUIDS USED IN THE DEICER SHOULD ADHERE TO SAE OR ISO STANDARDS AND MUST BE
APPROVED BY JBT AEROTECH FOR COMPATIBILITY WITH THE HEATING AND PUMPING
SYSTEMS. THE SPECIFIC FLUID AND TYPE USED SHOULD BE APPROVED BY THE AIRLINE,
THE FLUID MANUFACTURER, THE LOCAL AVIATION AUTHORITY, AND BASED ON THE
RECOMMENDATIONS OF THE AIRCRAFT MANUFACTURER. THE OPERATOR MUST ALSO
CONFIRM THE APPROPRIATE FLUID MIXTURE WITH A REFRACTOMETER AFTER EVERY
FILL OF THE TANK AND BEFORE EACH USE OF THE DEICER. ENSURE DEICER BODY
ACCESS DOORS ARE FIRMLY SECURED IN THE OPEN POSITION WHEN ACCESSING
CONTROLS AND EQUIPMENT. FAILURE TO COMPLY MAY RESULT IN SERIOUS BODILY
WARNING
THE STORING, PUMPING, HEATING, AND SPRAYING OR DEICING AND ANTI-ICING FLUIDS
WITH THIS DEICER MAY NEGATIVELY AFFECT THE PROPERTIES OF DEICING AND
ANTI-ICING FLUIDS. BEFORE TAKING THE DEICER INTO SERVICE, THE OPERATOR MUST
VERIFY THAT THE PARTICULAR FLUIDS USED WITH THIS DEICER ARE NOT DEGRADED
BEYOND THE MANUFACTURERS LIMITS. FAILURE TO COMPLY MAY RESULT IN SERIOUS
WARNING
NEVER ATTEMPT TO LIFT THE BOOM WITH A LOAD THAT EXCEEDS THE SAFETY RATING.
FAILURE TO COMPLY MAY RESULT IN SERIOUS BODILY INJURY, DEATH, OR PROPERTY
DAMAGE, INCLUDING DAMAGE TO THE VEHICLE!
WARNING
BEFORE ATTEMPTING TO OPERATE OR MAINTAIN THIS VEHICLE, COMPLETELY READ AND
WARNING, AND CAUTION STATEMENTS. FAILURE TO COMPLY MAY RESULT IN SERIOUS
xvi
WARNING
IT IS THE OPERATORS RESPONSIBILITY TO MAKE SURE THE BASKETS MOVEMENT PATH
IS CLEAR AND FREE OF ANY OBJECTS WHILE OPERATING THE VEHICLE. FAILURE TO
COMPLY MAY RESULT IN SERIOUS BODILY INJURY, DEATH, OR PROPERTY DAMAGE,
INCLUDING DAMAGE TO THE VEHICLE!
WARNING
ENSURE THE AREA AROUND THE VEHICLE IS CLEAR OF PERSONNEL WHILE OPERATING
THE VEHICLE. FAILURE TO COMPLY MAY RESULT IN SERIOUS BODILY INJURY, DEATH, OR
WARNING
VEHICLE IS NOT A PERSONNEL TRANSPORT. DO NOT ALLOW PERSONNEL IN THE BASKET
WHILE VEHICLE MOVES AT HIGH SPEED. FAILURE TO COMPLY MAY RESULT IN SERIOUS
WARNING
NEVER EXCEED THE RECOMMENDED MAXIMUM WEIGHT LIMITS FOR THIS EQUIPMENT.
WARNING
NORMAL OPERATIONS SHOULD NOT BE PERFORMED WHILE AIRCRAFT IS BEING
REFUELED, WITHOUT HAVING FACILITY AND REGULATORY APPROVAL. OPERATOR MUST
ENSURE THAT NO HYDRAULIC LEAKS OR UNSAFE CONDITIONS ARE PRESENT ON THE
VEHICLE. FAILURE TO COMPLY MAY RESULT IN SERIOUS BODILY INJURY, DEATH, OR
WARNING
AT THE BEGINNING OF EACH SHIFT ENSURE THAT ALL SCHEDULED SERVICES HAVE BEEN
PERFORMED, INCLUDING VERIFICATION OF TIRE CONDITION, FUEL AND FLUID LEVELS,
AND OVERALL CHECK FOR LOOSE OR MISSING HARDWARE AND GENERAL CONDITION OF
WARNING
AN OBSERVER ON THE GROUND SHOULD BE USED TO AID THE OPERATOR WHEN DRIVING
THE VEHICLE IN REVERSE. FAILURE TO COMPLY MAY RESULT IN SERIOUS BODILY
xvii
WARNING
APPLY THE PARKING BRAKE AND TURN OFF THE IGNITION SWITCH BEFORE LEAVING THE
VEHICLE UNATTENDED. FAILURE TO COMPLY MAY RESULT IN SERIOUS BODILY INJURY,
WARNING
VERIFY THE BOOM, BASKET AND VEHICLE SURROUNDINGS ARE FREE OF OBSTACLES
BEFORE AND DURING ANY MOVEMENT. DO NOT SOLELY RELY ON THE BASKET
PROXIMITY WARNING SYSTEM TO DETECT OBJECTS OR PREVENT A COLLISION. FAILURE
TO COMPLY MAY RESULT IN SERIOUS BODILY INJURY, DEATH, OR PROPERTY DAMAGE,
WARNING
DO NOT ATTEMPT TO USE THE SIDE REACH BYPASS OPTION IF NOT PROPERLY TRAINED.
EXTENDING THE BOOM SIDEWAYS MAY TIP THE VEHICLE TO ONE SIDE. ALWAYS REMOVE
KEY WHEN LEAVING THE VEHICLE UNATTENDED. FAILURE TO COMPLY MAY RESULT IN
SERIOUS BODILY INJURY, DEATH, OR PROPERTY DAMAGE, INCLUDING DAMAGE TO THE
VEHICLE!
WARNING
DO NOT ATTEMPT TO OPERATE THE VEHICLE WITHOUT BEING PROPERLY TRAINED IN
OPERATION AND SAFETY REQUIREMENTS. FAILURE TO COMPLY MAY RESULT IN
VEHICLE!
WARNING
BEFORE STARTING THE POWER UNIT, ENSURE POWER MODULE IS SECURELY FASTENED,
AND ALL PERSONNEL ARE CLEAR OF THE VEHICLE. FAILURE TO COMPLY MAY RESULT
IN SERIOUS BODILY INJURY, DEATH, OR PROPERTY DAMAGE, INCLUDING DAMAGE TO
THE VEHICLE!
WARNING
DOORS MUST BE LATCHED AND SEAT BELTS AND SAFETY HARNESSES PROPERLY WORN
BY OCCUPANTS OF THE CAB AND BASKET AT ALL TIMES WHILE VEHICLE IS IN OPERATION
AND OPERATOR IS IN BASKET. FAILURE TO COMPLY MAY RESULT IN SERIOUS BODILY
WARNING
FOLLOW ALL APPLICABLE PROCEDURES AND REGULATIONS FOR OPERATING IN THE
AIRPORT AND FOR HANDLING AIRCRAFT. FAILURE TO COMPLY MAY RESULT IN SERIOUS
xviii
WARNING
USE CAUTION WHILE REFUELING VEHICLE TO AVOID FUEL SPILLS. CLEAN SPILLS
PROPMTLY. FAILURE TO COMPLY MAY RESULT IN SERIOUS BODILY INJURY, DEATH, OR
WARNING
DO NOT EXCEED 6 KM/H (4 MPH) WITH A PERSON IN THE OPERATORS BASKET. FAILURE
WARNING
DRIVER IN VEHICLE CAB MUST FASTEN SEAT BELT, AND OPERATOR IN THE BASKET MUST
CLOSE AND LATCH THE DOOR, AND EITHER FASTEN THE SAFETY HARNESS (OPEN
BASKET) OR FASTEN THE SEAT BELT (ENCLOSED BASKET). FAILURE TO COMPLY MAY
RESULT IN SERIOUS BODILY INJURY, DEATH, OR PROPERTY DAMAGE, INCLUDING
DAMAGE TO THE VEHICLE!
WARNING
DO NOT OPERATE EQUIPMENT WHILE UNDER INFLUENCE OF DRUGS, ALCOHOL, OR
MEDICATION THAT MAY PREVENT FULL ABILITY TO CONTROL THE VEHICLE. FAILURE TO
WARNING
DO NOT OPERATE BOOM / AERIAL DEVICE WHEN WIND SPEED IS ABOVE 74 KM/H (46 MPH).
WARNING
BOOM CONTROLS ENABLE ANY COMBINATION OF BOOM MOVEMENTS AT THE SAME
TIME. SIMULTANEOUS MOVEMENTS ON DIFFERENT AXIS MAY DECEIVE AN OPERATORS
SENSES, CREATE VERTIGO, AND INCREASE THE CHANCE OF COLLISION, ESPECIALLY
WHEN THE VEHICLE IS DRIVING AT THE SAME TIME. LIMIT BOOM MOVEMENT TO A SINGLE
FUNCTION AT A TIME UNTIL EXPERIENCED WITH THE DEICER AND THE ENVIRONMENT.
xix
WARNING
DEICING PROCEDURES MUST BE CARRIED OUT EXCLUSIVELY BY TRAINED AND
QUALIFIED PERSONNEL PER SAE ARP 4737. FAILURE TO COMPLY MAY RESULT IN
VEHICLE!
WARNING
NEVER DIRECT THE AIR NOZZLE AT A PERPENDICULAR SURFACE, THE AIRCRAFT
WINDSCREEN, SIDE WINDOWS, OR FLIGHT CONTROL SURFACES. NEVER ALLOW THE AIR
NOZZLE TO COME CLOSER THAN 0.60 M (24 IN.) TO ANY SURFACE. FAILURE TO COMPLY
MAY RESULT IN SERIOUS BODILY INJURY, DEATH, OR PROPERTY DAMAGE, INCLUDING
WARNING
WEAR PERSONAL PROTECTION FOR EYES, EARS, SKIN AND TOES, AND AVOID LOOSE
CLOTHING, HAIR AND JEWELRY WHEN PERFORMING DEICING OR ANTI-ICING
OPERATIONS. FAILURE TO COMPLY MAY RESULT IN SERIOUS BODILY INJURY, DEATH, OR
WARNING
THE OPERATOR MUST WEAR PROTECTIVE GLOVES DUE TO THE HIGH TEMPERATURE OF
THE DEICING FLUID MIXTURE. FAILURE TO COMPLY MAY RESULT IN SERIOUS BODILY
WARNING
EXERCISE EXTREME CAUTION DURING TOP FILLING OPERATIONS. FLUIDS MAY BE
SPILLED ON THE WALKWAY CREATING A HAZARD. USE A FALL RESTRAINT SYSTEM,
SCAFOLD OR OTHER DEVICE TO PREVENT A FALL WHEN ACCESSING THE TOP OF THE
WARNING
ONLY APPLY E-STOP TO DISABLE THE VEHICLE IN CASE OF EMERGENCY. PRESSING THE
EMERGENCY STOP PUSH-BUTTON WILL COMPLETELY SHUTDOWN THE VEHICLE.
xx
WARNING
BEFORE TOWING, ATTACH TOW VEHICLE WITH TOW BAR OR CHOCK WHEELS BEFORE
DISENGAGING PARK BRAKE. FAILURE TO COMPLY MAY RESULT IN SERIOUS BODILY
WARNING
THE COMBINED WEIGHT OF THE TOWED AND TOWING VEHICLES MUST BE LESS THAN THE
SUM OF THE GROSS AXLE RATINGS OF THE TOWING VEHICLE. FAILURE TO COMPLY MAY
WARNING
REMOVE THE RELEASE STUD ASSEMBLIES FROM BRAKE CHAMBERS AFTER TOWING IS
COMPLETE. FAILURE TO COMPLY MAY RESULT IN SERIOUS BODILY INJURY, DEATH, OR
WARNING
IF PARK BRAKE IS NOT IMMEDIATELY ENGAGED AFTER TOWING, PLACE A SUITABLE
WARNING SIGN ON VEHICLE TO ENSURE THAT ALL PERSONNEL ARE AWARE OF THE
CONDITION. FAILURE TO COMPLY MAY RESULT IN SERIOUS BODILY INJURY, DEATH, OR
WARNING
BEFORE REMOVING OR INSTALLING VEHICLE COMPONENTS, ENSURE THE VEHICLE IS ON
LEVEL GROUND, WHEELS ARE SECURELY CHOCKED AND ELECTRICAL SYSTEM IS
SWITCHED OFF. FAILURE TO COMPLY MAY RESULT IN SERIOUS BODILY INJURY, DEATH,
OR PROPERTY DAMAGE, INCLUDING DAMAGE TO THE VEHICLE!
WARNING
PERFORM THE RE-COMMISSIONING MAINTENANCE PROCEDURES BEFORE RETURNING
THE VEHICLE INTO SERVICE AFTER STORAGE. FAILURE TO COMPLY MAY RESULT IN
VEHICLE!
WARNING
BEFORE PERFORMING ANY MAINTENANCE, ENSURE VEHICLE IS ON A CLEAN AND LEVEL
SURFACE, WHEELS ARE SECURELY CHOCKED, ENGINE IS OFF, HYDRAULIC
ACCUMULATORS ARE DEPLETED, AND BATTERIES HAVE BEEN DISCONNECTED. PLACE
A HIGHLY VISIBLE TAG ON OR NEAR VEHICLE CONTROLS TO WARN OTHER PERSONNEL
VEHICLE IS BEING WORKED ON. FAILURE TO COMPLY MAY RESULT IN SERIOUS BODILY
xxi
WARNING
LOCK-OUT AND TAG-OUT THE VEHICLE BEFORE PERFORMING ANY MAINTENANCE,
ADJUSTMENTS OR REPAIRS TO THE VEHICLE. FAILURE TO COMPLY MAY RESULT IN
VEHICLE!
WARNING
DO NOT USE THE VEHICLE FOR DEICING OR ANTI-ICING OPERATIONS IF THE VEHICLE DID
NOT PASS THE FLUID SYSTEM TEST. FAILURE TO COMPLY MAY RESULT IN SERIOUS
WARNING
CLOTHING, HAIR AND JEWELRY WHEN PERFORMING MAINTENANCE ON THE VEHICLE.
WARNING
BEFORE STARTING THE VEHICLE, ENSURE ALL PERSONS AND OBJECTS ARE CLEAR OF
THE VEHICLE, AND ALL COMPARTMENT DOORS ARE CLOSED AND SECURED. TIRES AND
WHEELS CAN MOVE WITHOUT WARNING AND CRUSH PERSONNEL. FAILURE TO COMPLY
WARNING
USE A FALL RESTRAINT SYSTEM WHEN ACCESSING THE TOP OF THE VEHICLE. FAILURE
WARNING
USE ONLY PROPER TOOLS AND CALIBRATED MEASUREMENT DEVICES WHEN
PERFORMING VEHICLE MAINTENANCE. FAILURE TO COMPLY MAY RESULT IN SERIOUS
xxii
WARNING
HYDRAULIC SYSTEM OPERATES AT HIGH PRESSURE AND TEMPERATURE. BEFORE
PERFORMING MAINTENANCE, DISABLE ALL HYDRAULIC POWER SOURCES, TURN OFF
THE POWER UNIT, AND DEPLETE SYSTEM PRESSURE AND ACCUMULATORS BEFORE
INSPECTING OR LOOSENING ANY HYDRAULIC CONNECTIONS OR COMPONENTS. KEEP
AWAY FROM HYDRAULIC LEAKS. DO NOT ATTEMPT TO FEEL FOR THE SOURCE OF A
LEAK. PRESSURIZED HYDRAULIC OIL CAN PENETRATE THE SKIN AND CAUSE OTHER
SERIOUS INJURY. FAILURE TO COMPLY MAY RESULT IN SERIOUS BODILY INJURY, DEATH,
WARNING
TORQUE LUG NUTS ACCORDING TO SPECIFICATIONS. FAILURE TO COMPLY MAY RESULT
THE VEHICLE!
WARNING
OPERATE VEHICLE ONLY IN WELL VENTILATED AREAS. ENGINE EXHAUST GASES ARE
POISONOUS. FAILURE TO COMPLY MAY RESULT IN SERIOUS BODILY INJURY, DEATH, OR
WARNING
KEEP FINGERS AND HANDS CLEAR WHEN REMOVING OIL PLUG. HOT OIL MAY CAUSE
BURNS. FAILURE TO COMPLY MAY RESULT IN SERIOUS BODILY INJURY, DEATH, OR
WARNING
COOLANT MAY BE HOT AND CAUSE BURNS. REMOVE ENGINE COOLANT CAP ONLY WHEN
ENGINE IS COOL. CAREFULLY LOOSEN COOLANT CAP, ALLOWING PRESSURE TO
RELEASE BEFORE COMPLETELY REMOVING IT. FAILURE TO COMPLY MAY RESULT IN
VEHICLE!
WARNING
INSPECT, REPLACE AND ADJUST BRAKE COMPONENTS IN ACCORDANCE WITH
MAINTENANCE SCHEDULE. FAILURE TO COMPLY MAY RESULT IN SERIOUS BODILY
WARNING
AVOID SPARKS OR OPEN FLAMES NEAR BATTERIES. LEAD-ACID BATTERIES PRODUCE
EXPLOSIVE HYDROGEN GAS. FAILURE TO COMPLY MAY RESULT IN SERIOUS BODILY
xxiii
WARNING
USE PROPERLY RATED JACK AND MAINTENANCE STANDS TO LIFT AND SUPPORT THE
WARNING
AVOID CONTACT AND INHALATION OF DIESEL FUEL, KEROSENE, HYDRAULIC OIL,
LUBRICANTS AND GLYCOLS. WASH AFFECTED AREAS IMMEDIATELY TO AVOID SKIN
IRRITATION. FAILURE TO COMPLY MAY RESULT IN SERIOUS BODILY INJURY, DEATH, OR
WARNING
DISCONNECT THE BATTERY BEFORE PERFORMING MAINTENANCE ON THE ELECTRICAL
SYSTEM. FAILURE TO COMPLY MAY RESULT IN SERIOUS BODILY INJURY, DEATH, OR
WARNING
REMOVE BOTH POSITIVE AND NEGATIVE BATTERY CABLES BEFORE WELDING ON THE
VEHICLE, AND TAKE PRECAUTIONS TO PREVENT DAMAGE TO ELECTRONIC EQUIPMENT.
REFER TO CHAPTER 3, OVERHAUL FOR REQUIREMENTS. ALSO, REFER TO THE ENGINE
MANUAL IN CHAPTER 5 FOR ADDITIONAL REQUIREMENTS. FAILURE TO COMPLY MAY
WARNING
WELDING, GRINDING, OR ANY KIND OF MODIFICATIONS TO THE AERIAL DEVICE MAY
COMPROMISE THE SAFETY OF THE DEICER. ANY MODIFICATIONS MUST BE APPROVED BY
THE MANUFACTURER. FAILURE TO COMPLY MAY RESULT IN SERIOUS BODILY INJURY,
WARNING
DO NOT LIFT THE SUSPENDED TEST WEIGHT MORE THAN THE SPECIFIED LOAD TEST
HEIGHT FROM THE GROUND SURFACE. FAILURE TO COMPLY MAY RESULT IN SERIOUS
WARNING
DO NOT USE AN OPEN FLAME HEATING SOURCE, HYDRAULIC FLUID IS FLAMMABLE.
xxiv
WARNING
ENSURE CONNECTIONS ARE CLEAN BEFORE ATTACHING BRAKE LINES. ENSURE THERE
ARE NO AIR LEAKS FROM BRAKE SYSTEM UPON COMPLETION OF INSTALLATION.
WARNING
DO NOT ALLOW PERSONNEL IN THE ENCLOSED BASKET, OR UNDER THE BASKET AND
BOOM DURING STABILITY AND LOAD TESTS. FAILURE TO COMPLY MAY RESULT IN
VEHICLE!
WARNING
ALWAYS SUPPORT THE AERIAL DEVICE WHEN EXTENDED FOR MAINTENANCE
PURPOSES. FAILURE TO COMPLY MAY RESULT IN SERIOUS BODILY INJURY, DEATH, OR
WARNING
ALWAYS USE A SAFETY HARNESS AND SECURE THE TETHER TO THE ATTACHMENT
PROVIDED WHEN WORKING ON THE TOP OF THE VEHICLE. FAILURE TO COMPLY MAY
WARNING
OPERATORS MUST CARRY OUT A COMPLETE BOOM LOAD AND STABILITY TEST PRIOR TO
TAKING THE DEICER INTO SERVICE AFTER MAJOR MAINTENANCE OR MODIFICATIONS TO
THE AERIAL DEVICE HAVE TAKEN PLACE. FAILURE TO COMPLY MAY RESULT IN SERIOUS
WARNING
VEHICLE MAINTENANCE MUST BE PERFORMED ONLY BY QUALIFIED PERSONNEL.
WARNING
WHEN REMOVING COMPONENTS FOR REPLACEMENT OR REPAIR, CLEAN COMPONENTS,
IDENTIFY AND MARK ALL CONNECTIONS, SUPPORT PROPERLY FOR REMOVAL, AND
PLACE REMOVED COMPONENTS IN A SAFE AND SECURE LOCATION. FAILURE TO
xxv
WARNING
REMOVE AND INSTALL BOOM PINS ONE BY ONE TO HOLD THE BOOM OVERALL
STRUCTURE. FAILURE TO COMPLY MAY RESULT IN SERIOUS BODILY INJURY, DEATH, OR
WARNING
ENSURE THE BOOM AND BASKET ARE SECURED BEFORE ATTEMPTING TO REMOVE OR
REPLACE ANY BOOM PIN. FAILURE TO COMPLY MAY RESULT IN SERIOUS BODILY INJURY,
WARNING
TECHNICIAN MUST USE A SAFETY LANYARD AND BELT WHEN WORKING ON TOP OF
VEHICLES SHROUD. FAILURE TO COMPLY MAY RESULT IN SERIOUS BODILY INJURY,
CAUTION
ENSURE TO DISCONNECT EXTERNAL AC POWER SOURCE PRIOR TO MOVING THE

VEHICLE. FAILURE TO COMPLY MAY RESULT IN DAMAGE TO VEHICLE, OR OTHER
PROPERTY!
CAUTION
CONTINUOUS OPERATION OF HYDRAULIC EMERGENCY PUMP FOR MORE THAN ONE

MINUTE WILL OVERHEAT THE ELECTRICAL MOTOR. IF EMERGENCY PROCEDURES
CANNOT BE COMPLETED WITHIN ONE MINUTE, PUMP MUST BE ALLOWED TO COOL FOR
AT LEAST 10 MINUTES BEFORE CONTINUING. FAILURE TO COMPLY MAY RESULT IN
DAMAGE TO VEHICLE COMPONENTS!
CAUTION
DO NOT USE HIGH-SPEED RANGE IF VEHICLE IS CLOSER THAN 3 M (10 FT.) TO AIRCRAFT.
FAILURE TO COMPLY MAY RESULT IN DAMAGE TO VEHICLE, OR OTHER PROPERTY,
INCLUDING THE AIRCRAFT!
CAUTION
ALWAYS STOP THE VEHICLE COMPLETELY BEFORE SHIFTING THE TRANSMISSION TO

CHANGE DIRECTION. FAILURE TO COMPLY MAY RESULT IN DAMAGE TO VEHICLE, OR
OTHER PROPERTY, INCLUDING THE AIRCRAFT!
xxvi
CAUTION
WHEN STARTING THE ENGINE, RELEASE THE IGNITION SWITCH IF THE ENGINE FAILS TO
START WITHIN 20 SECONDS. AFTER A SECOND ATTEMPT, ALLOW THE STARTER MOTOR
TO COOL DOWN FOR ONE MINUTE BEFORE ATTEMPTING TO RESTART THE ENGINE.
FAILURE TO COMPLY MAY RESULT IN DAMAGE TO VEHICLE COMPONENTS!
CAUTION
SHUT DOWN ENGINE IMMEDIATELY IF OIL PRESSURE INDICATOR LIGHT DOES NOT TURN
OFF WITHIN THREE SECONDS AFTER STARTING ENGINE. DO NOT ATTEMPT TO RESTART
ENGINE. NOTIFY MAINTENANCE PERSONNEL IMMEDIATELY. FAILURE TO COMPLY MAY
RESULT IN DAMAGE TO VEHICLE COMPONENTS!
CAUTION
ALWAYS USE A HIGH ENOUGH CONCENTRATION MIXTURE TO PREVENT FREEZING OF THE

GROUND REEL HOSE AND NOZZLE. FAILURE TO COMPLY MAY RESULT IN DAMAGE TO
VEHICLE COMPONENTS!
CAUTION
PURGING DOES NOT PREVENT THE WATER TANK FROM FREEZING. EXPANSION OF
WATER DUE TO FREEZING MAY DAMAGE TANKS. TAKE NECESSARY STEPS TO PREVENT
FREEZING. FAILURE TO COMPLY MAY RESULT IN DAMAGE TO VEHICLE COMPONENTS!
CAUTION
DO NOT ENERGIZE HYDRAULIC EMERGENCY PUMP DURING NORMAL VEHICLE

OPERATION. FAILURE TO COMPLY MAY RESULT IN DAMAGE TO VEHICLE, OR OTHER
PROPERTY, INCLUDING THE AIRCRAFT!
CAUTION
REMOVE DRIVE SHAFT BEFORE TOWING THE VEHICLE, UNLESS REAR-LIFT TOWING THE
VEHICLE. FAILURE TO COMPLY MAY RESULT IN DAMAGE TO VEHICLE COMPONENTS!
CAUTION
ENSURE THE PARKING BRAKE IS DISENGAGED WHILE TOWING. FAILURE TO COMPLY

MAY RESULT IN DAMAGE TO VEHICLE COMPONENTS!
CAUTION
DO NOT USE DIESEL FUELS WITH SULFUR CONTENTS GREATER THAN 10 000 PPM (1.0%
BY MASS). FAILURE TO COMPLY MAY RESULT IN DAMAGE TO VEHICLE COMPONENTS!
xxvii
CAUTION
WHEN USING DIESEL FUELS WITH SULFUR CONTENTS BETWEEN 5000 PPM AND 10 000
PPM, THE INTERVAL TO CHANGE THE LUBE OIL MUST BE DECREASED FROM 500 HOURS
TO 250 HOURS. FAILURE TO COMPLY MAY RESULT IN DAMAGE TO VEHICLE
COMPONENTS!
CAUTION
WHEN USING DIESEL FUELS WITH SULFUR CONTENTS GREATER THAN 500 PPM (0.05% BY
MASS) AND THE ENGINE IS EQUIPPED WITH AN EXTERNALLY COOLED EGR (TIER 3
ENGINES), LARGER FILTERS WITH TIGHTER MICRON FILTRATION MUST BE USED.
CONSULT THE ENGINE MANUFACTURER FOR MODIFICATIONS NEEDED. FAILURE TO
COMPLY MAY RESULT IN DAMAGE TO VEHICLE COMPONENTS!
CAUTION
DO NOT USE DIESEL FUELS WITH SULFUR CONTENTS GREATER THAN 15 PPM (0.0015% BY
MASS) IN EPA TIER 4 ENGINES. FAILURE TO COMPLY MAY RESULT IN DAMAGE TO
VEHICLE COMPONENTS AND VOID WARRANTY!
CAUTION
DO NOT USE JET A1 FUEL IN THIS VEHICLE. REFER TO ENGINE MANUFACTURER FOR
SPECIFIC RECOMMENDATIONS. FAILURE TO COMPLY MAY RESULT IN DAMAGE TO
VEHICLE COMPONENTS!
CAUTION
OUTSIDE MIRRORS MUST BE FOLDED INBOARD FOR SHIPPING. FAILURE TO COMPLY MAY
CAUTION
COMPLY WITH ALL LOCAL AND GOVERNMENT REGULATIONS FOR DISPOSING OF

ENVIRONMENTALLY SENSITIVE MATERIALS SUCH AS TIRES, BELTS, BATTERIES, MOTOR
OILS, GREASE, HYDRAULIC OIL, FUELS AND GLYCOLS.
CAUTION
USE CLEAN LINT-FREE RAGS FOR CLEANING OF TANKS AND COMPONENTS. FAILURE TO
xxviii
CAUTION
PLASTIC SHEETING MAY ONLY BE USED FOR INDOOR STORAGE. PLASTIC SHEETING
USED FOR OUTDOOR STORAGE WILL CREATE CONDENSATION WHICH MAY CAUSE METAL
SURFACES TO RUST OR PIT. FAILURE TO COMPLY MAY RESULT IN DAMAGE TO VEHICLE
COMPONENTS!
CAUTION
WHEN CLEANING THE VEHICLE USING A PRESSURE WASHER, CARE MUST BE TAKEN NOT
TO APPLY DIRECT PRESSURE TO ANY EXPOSED ELECTRICAL, HYDRAULIC OR ENGINE
COMPONENTS. DO NOT PRESSURE WASH INSIDE THE ENGINE COMPARTMENT. FAILURE
TO COMPLY MAY RESULT IN DAMAGE TO VEHICLE COMPONENTS!
CAUTION
WHEN PERFORMING A BATTERY JUMP START ON THE VEHICLE, ENSURE JUMP CABLES
ARE PROPERLY CONNECTED TO PREVENT DAMAGE TO THE ELECTRIC SYSTEM AND
COMPONENTS. FAILURE TO COMPLY MAY RESULT IN DAMAGE TO VEHICLE
COMPONENTS AND VOID WARRANTY!
CAUTION
WHEN ELECTRICALLY CHARGING BATTERIES ON THE VEHICLE, ENSURE CHARGER

CABLES ARE PROPERLY CONNECTED TO PREVENT DAMAGE TO THE ELECTRIC SYSTEM
AND COMPONENTS. FAILURE TO COMPLY MAY RESULT IN DAMAGE TO VEHICLE
CAUTION
DO NOT CLEAN RUBBER AND PLASTIC COMPONENTS SUCH AS TIRES, LUBRICANT SEALS,
RUBBER HOSES, OR ELECTRICAL COMPONENTS WITH PETROLEUM-BASED PRODUCTS
SUCH AS KEROSENE, GASOLINE, OR FUEL OIL. FAILURE TO COMPLY MAY RESULT IN
DAMAGE TO VEHICLE, OR OTHER PROPERTY, INCLUDING THE AIRCRAFT!
CAUTION
DO NOT OPERATE THE ENGINE WITH THE OIL LEVEL BELOW THE MIN MARK OR ABOVE
THE MAX MARK ON THE DIPSTICK. FAILURE TO COMPLY MAY RESULT IN DAMAGE TO
VEHICLE, OR OTHER PROPERTY, INCLUDING THE AIRCRAFT!
CAUTION
ENSURE FUEL IS CLEAN AND FREE OF WATER AND DIRT. FAILURE TO COMPLY MAY
xxix
CAUTION
ALLOW THE ENGINE TO COOL BEFORE ADDING WATER OR ANTI-FREEZE SOLUTION.

CAUTION
USE ONLY ETHYLENE-GLYCOL BASED ANTIFREEZE IN CORRECT CONCENTRATIONS TO

PREVENT FREEZING AT THE AMBIENT TEMPERATURE. FAILURE TO COMPLY MAY RESULT
IN DAMAGE TO VEHICLE COMPONENTS!
CAUTION
DO NOT USE WATER WITH SALT OR HIGH MINERAL CONTENT WHEN FILLING THE
COOLANT SYSTEM OR BATTERIES. FAILURE TO COMPLY MAY RESULT IN DAMAGE TO
VEHICLE COMPONENTS!
CAUTION
DO NOT DISCONNECT THE BATTERY OR TURN OFF OPTIONAL BATTERY DISCONNECT

SWITCH WITH THE ENGINE RUNNING. THIS WILL CAUSE A VOLTAGE SURGE IN THE
ALTERNATOR CHARGING SYSTEM. FAILURE TO COMPLY MAY RESULT IN DAMAGE TO
CAUTION
DO NOT MIX HYDRAULIC OILS. WHEN CHANGING FROM ONE TYPE TO ANOTHER, THE
SYSTEM MUST BE DRAINED, CLEANED AND COMPLETELY REFILLED. FAILURE TO
CAUTION
DO NOT CHANGE THE MAXIMUM SPEED SET BY THE ENGINE MANUFACTURER. IF

ADJUSTMENT OF OPERATIONAL HIGH SPEED IS MANDATORY, IT MUST BE SET BELOW
THE MAXIMUM ENGINE SPEED SET BY THE MANUFACTURER. FAILURE TO COMPLY MAY
RESULT IN DAMAGE TO VEHICLE COMPONENTS AND VOID WARRANTY!
CAUTION
WHEN INSTALLING OR REMOVING GAUGES AND FITTINGS, OR REPLACING COMPONENTS

USE EXTREME CAUTION TO PREVENT CONTAMINATION OF THE HYDRAULIC SYSTEM.
xxx
CAUTION
BEFORE WELDING ON THE VEHICLE, DISCONNECT THE VEHICLES POSITIVE AND

NEGATIVE BATTERY CABLES AND ALL ELECTRONIC CONTROLLER HARNESSES.
PROTECT ELECTRONIC EQUIPMENT AND HARNESSES FROM HEAT OR SPARKS. ENSURE
THE WELDERS GROUND CABLE IS ATTACHED TO BARE UNPAINTED METAL AS CLOSE TO
THE WELDING OPERATION AS POSSIBLE. FAILURE TO COMPLY MAY RESULT IN SERIOUS
DAMAGE TO VEHICLE COMPONENTS AND VOID ALL WARRANTIES!
CAUTION
PERFORM A COMPLETE MAINTENANCE CHECK AFTER REPAIRS ARE COMPLETED.

ENSURE THE VEHICLE HAS BEEN PROPERLY SERVICED BEFORE STARTING THE POWER
UNIT. FAILURE TO COMPLY MAY RESULT IN DAMAGE TO VEHICLE COMPONENTS!
CAUTION
WHEN SUPPORTING THE BASKET, USE CAUTION NOT TO DAMAGE ELECTRICAL OR

HYDRAULIC COMPONENTS, AIRFIRST PIPING OR DAMAGE COLLISION SENSORS, IF
EQUIPPED. FAILURE TO COMPLY MAY RESULT IN DAMAGE TO VEHICLE, OR OTHER
xxxi
INFORMATION CAUTION
CUSTOMER SERVICE OVERALL HEIGHT
DANGER CAUTION
POWER LINES MAXIMUM SPEED
40 KM/H (25 MPH) (STD)
WARNING CAUTION
CONFINED SPACE MAXIMUM SPEED
6 KM/H (4 MPH) (STD)
WARNING CAUTION
ATTACH LANYARD HOT EXHAUST
(OPEN BASKET)
NOTICE CAUTION
FASTEN SEAT BELT BLOWER GUARD
CAUTION NOTICE
DO NOT OPEN HARNESS ATTACHMENT
POINT (OPEN BASKET)
xxxiii
NOTICE
DISCONNECT FIRE GROUND HOSE
EXTINGUISHER BEFORE
PERFORMING
MAINTENANCE
CAUTION DIESEL FUEL

BASKET CAPACITY
204 KG (450 LB.)
TIRE PRESSURE FUEL TANK

9.0 BAR (130 PSI)
BATTERIES, 24 VOLTS DEICING FLUID
ANTI-ICING FLUID
REFILL CONNECTION -
DEICING FLUID
NOTICE
EMERGENCY INSTRUCTIONS
FOR LOWERING BOOM
xxxiv
REFILL CONNECTION -
ANTI-ICING FLUID
EMERGENCY INSTRUCTIONS FOR

LOWERING BOOM IN BASKET
PRESSURE REFILL LOWERING BOOM

OPERATION IN EMERGENCY
SUCTION REFILL CAUTION

OPERATION MAXIMUM WIND SPEED
IN CASE OF FIRE PULL CAUTION

PIN AND DEPRESS
PUSH-BUTTON FALL HAZARD
HYDRAULIC OIL BOOM FAST / SLOW

(REFER TO OIL RAISE / LOWERING
SPECIFICATIONS)
DEICE / ANTI-ICE NOZZLE MAXIMUM

SIGHT GAUGE PRESSURE
xxxv
EMERGENCY TOWING EMERGENCY STOP
(REFER TO MANUAL) (REFER TO MANUAL)
DANGER TURN HEATER OFF

RISK OF CUTTING BEFORE OPERATING
FINGERS GROUND HOSE
FIRE SUPPRESSION
AUTOMATIC SYSTEM
PUSH DAILY TO TEST
xxxvi
TABLE OF CONTENTS
Section 1. Description
1. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. MAIN COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
A. CHASSIS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
B. AXLES AND WHEELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
C. ENGINE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
D. FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
E. COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
F. AIR INTAKE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
G. EXHAUST SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
H. TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
I. HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
J. STEERING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
K. AIR BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
L. ELECTRICAL SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
M. DRIVERS CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
N. AERIAL DEVICE (BOOM SYSTEM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
O. OPERATORS BASKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3. DRIVING / OPERATION MODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
A. TWO-MAN OPERATION MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
B. ONE-MAN OPERATION MODE (OPTIONAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4. FLUID CONFIGURATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
A. PROPORTIONAL MIX (PROP-MIX) SYSTEM (OPTIONAL) . . . . . . . . . . . . . . . . . . . . . . . . . 8
B. AIRFIRST SYSTEM (OPTIONAL WITH ENCLOSED BASKET) . . . . . . . . . . . . . . . . . . . . . 8
C. BLENDUP SYSTEM (OPTIONAL). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
5. ADDITIONAL FEATURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
A. EMERGENCY STOPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
B. AUTOMATIC SHUTDOWN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
C. ENGINE STARTER MOTOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
D. HEATER SHUTDOWN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
E. BOOM LIFT CAPABILITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1-Contents
TABLE OF CONTENTS
Page 1
November 2013
F. AERIAL HOLDING VALVE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
G. VEHICLE SPEED LIMITER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
H. BATTERY DISCONNECT SWITCH (OPTIONAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
I. HYDRAULIC EMERGENCY PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
J. AUTOMATIC PARKING BRAKES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
K. ONE-MAN DRIVE / OPERATION MODE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
6. WINTERIZATION SYSTEM (OPTIONAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
A. WATER TANK HEATER (OPTIONAL). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
B. HYDRAULIC TANK HEATER (OPTIONAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
C. ENGINE BLOCK HEATER (STANDARD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
D. BATTERY BLANKETS (OPTIONAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
E. ELECTRICAL CONTROL BOX (OPTIONAL). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
F. DRIVERS CAB HEATER (OPTIONAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
G. ELECTRICAL PLUG-IN RECEPTACLE AND MASTER SWITCH (OPTIONAL) . . . . . . . . . . . 12
Section 2. Operation
1. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. SAFETY PRECAUTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
3. DRIVERS CAB CONTROLS AND INDICATORS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
A. MULTI-FUNCTION CONTROL LEVER SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
B. DRIVERS CAB FLUID HEATER PANEL (STANDARD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
C. DRIVERS CAB FLUID HEATER PANEL - PROP-MIX (OPTIONAL) . . . . . . . . . . . . . . . . . . . 7
D. DRIVERS CAB FLUID HEATER PANEL - BLENDUP (OPTIONAL) . . . . . . . . . . . . . . . . . . 9
E. DRIVERS CAB INDICATORS AND WARNING LIGHTS PANEL . . . . . . . . . . . . . . . . . . . . . . 11
F. DRIVERS CAB HEATER CONTROL PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
G. FLUID TANK LEVEL AND TEMPERATURE GAUGES PANEL . . . . . . . . . . . . . . . . . . . . . . . 14
H. PROPORTIONAL MIX INDICATOR PANEL (OPTIONAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
I. DRIVERS CAB DRIVING PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
J. DRIVERS CAB BOOM CONTROL PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
K. DRIVERS CAB IGNITION SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
L. DRIVERS CAB INSTRUMENT PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
M. DRIVERS CAB ROOF WIPER AND WASHER CONTROL PANEL . . . . . . . . . . . . . . . . . . . . 24
N. EMERGENCY AND LIGHTING PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
O. DRIVERS CAB TOP WINDOW DEFROSTER (OPTIONAL) . . . . . . . . . . . . . . . . . . . . . . . . . 26
4. OPEN BASKET CONTROLS AND INDICATORS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
A. OPEN BASKET BOOM CONTROL PANEL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
B. OPEN BASKET OPERATORS CONTROL PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
C. OPEN BASKET PROP-MIX CONTROL PANEL (OPTIONAL) . . . . . . . . . . . . . . . . . . . . . . . . 34
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5. ENCLOSED BASKET CONTROLS AND INDICATORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
A. ENCLOSED BASKET OPERATOR CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
B. ENCLOSED BASKET AIRFIRST AND PROP-MIX CONTROLS (OPTIONAL). . . . . . . . . . 42
C. ENCLOSED BASKET BLENDUP OPTIONAL CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . 45
D. ENCLOSED BASKET BOOM CONTROL JOYSTICK SWITCH . . . . . . . . . . . . . . . . . . . . . . . 47
E. ENCLOSED BASKET NOZZLE CONTROL JOYSTICK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
F. ENCLOSED BASKET OVERHEAD INDICATOR LIGHTS PANEL . . . . . . . . . . . . . . . . . . . . . 51
G. ENCLOSED BASKET HEATER CONTROL PANEL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
H. AIRFIRST SYSTEM (OPTIONAL WITH ENCLOSED BASKET) . . . . . . . . . . . . . . . . . . . . . 55
I. NOZZLE GAUGES (OPTIONAL WITH ENCLOSED BASKET) . . . . . . . . . . . . . . . . . . . . . . . 56
6. DRIVE AND OPERATION MODE OPTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
A. ONE-MAN DRIVE OPERATION CONTROL JOYSTICK (OPTIONAL). . . . . . . . . . . . . . . . . . 57
B. SIDE REACH BYPASS SWITCH (OPTIONAL WITH ONE-MAN DRIVE) . . . . . . . . . . . . . . . 59
C. MONITOR AND CAMERA CLOSED-CIRCUIT TV (CCTV) SYSTEM . . . . . . . . . . . . . . . . . . 60
7. OPERATING PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
A. STARTING ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
B. DRIVING VEHICLE - TWO-MAN DRIVE OPERATION MODE (STANDARD) . . . . . . . . . . . . 64
C. DRIVING VEHICLE - ONE-MAN DRIVE/OPERATION MODE (OPTIONAL) . . . . . . . . . . . . . 65
D. PARKING VEHICLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
E. HEATER OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
F. AERIAL DEVICE - TWO-MAN DRIVE/OPERATION MODE (STANDARD) . . . . . . . . . . . . . . 69
G. AERIAL DEVICE - ONE-MAN DRIVE/OPERATION MODE (OPTIONAL) . . . . . . . . . . . . . . . 71
H. EXTEND/DEPLOY THE XR BOOM (OPTIONAL). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
I. RETRACT/PARK THE XR BOOM (OPTIONAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
8. DEICING AND ANTI-ICING OPERATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
A. DEICING - TWO-MAN MODE (STANDARD) / ONE-MAN MODE (OPTIONAL). . . . . . . . . . . 76
B. SELECT DEICE FREEZE VALUES FOR BLENDUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
C. ANTI-ICING - TWO-MAN (STANDARD) / ONE-MAN (OPTIONAL) MODES . . . . . . . . . . . . . 84
D. AIRFIRST FORCED AIR AIRCRAFT DEICING (OPTIONAL) . . . . . . . . . . . . . . . . . . . . . . . 84
E. DEICING / ANTI-ICING WITH AIR ASSIST (OPTIONAL WITH AIRFIRST) . . . . . . . . . . . . 85
F. AIRFIRST WITH DEICING / ANTI-ICING FLUID INJECTION (OPTIONAL) . . . . . . . . . . . . 86
G. AIRFIRST WITH A BURST OF FLUID (OPTIONAL WITH AIRFIRST) . . . . . . . . . . . . . . 86
H. GROUND REEL HOSE AND NOZZLE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
I. DEICING SPRAY NOZZLE OPERATION - OPEN BASKET . . . . . . . . . . . . . . . . . . . . . . . . . 88
J. ANTI-ICING SPRAY NOZZLE (OPTIONAL) OPERATION - OPEN BASKET . . . . . . . . . . . . 88
K. NOZZLE CONTROL JOYSTICK FUNCTIONS (ENCLOSED BASKET) . . . . . . . . . . . . . . . . . 90
Table - AIR AND SPRAY FUNCTION CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
9. FLUID REFILL PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
A. DEICING FLUID PRESSURE REFILL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
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B. DEICING FLUID SUCTION REFILL (OPTIONAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
C. DEICE BLENDUP FLUID PRESSURE REFILL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
D. DEICE BLENDUP FLUID SUCTION REFILL (OPTIONAL) . . . . . . . . . . . . . . . . . . . . . . . . . 97
E. TWO-TANK PROP-MIX PRESSURE REFILL (OPTIONAL) . . . . . . . . . . . . . . . . . . . . . . . . . . 97
F. TWO-TANK PROP-MIX SUCTION REFILL (OPTIONAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
G. ANTI-ICING FLUID PRESSURE REFILL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
H. ANTI-ICING FLUID SUCTION REFILL (OPTIONAL). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
I. TOP REFILL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
J. TANK FLUID TEST PORTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
10. DRAIN AND PURGE PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
A. PROCEDURE AFTER DEICING OPERATIONSVERY IMPORTANT! . . . . . . . . . . . . . . . . . 105
B. PURGING BOOM AND GROUND REEL (PROP-MIX AND BLENDUP) . . . . . . . . . . . . . . . 105
C. AUTOMATIC PURGING OF HEATER AND PUMPS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
D. MANUAL PURGE SYSTEM (BLENDUP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
11. WINTERIZATION SYSTEM OPERATION (OPTIONAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
A. EXTERNAL POWER SOURCE CONNECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
B. WINTERIZATION SYSTEM ACTIVATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
C. TEMPERATURE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Section 3. Emergency Procedures
1. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. EMERGENCY STOP PUSH-BUTTONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
3. EMERGENCY PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
4. EMERGENCY BOOM LOWERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
A. OPEN AND ENCLOSED OPERATORS BASKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
B. DRIVERS CAB NORMAL OPERATION (TWO-MAN DRIVE). . . . . . . . . . . . . . . . . . . . . . . . . 3
C. GROUND CONTROL STATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
5. EMERGENCY TOWING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
A. BEFORE TOWING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
B. TOWING PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
6. PARKING BRAKE RELEASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
A. PNEUMATIC RELEASE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
B. MECHANICAL RELEASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
7. PARKING BRAKE RESET. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
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Section 4. Specifications
1. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. MODEL DEFINITION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
3. AIRCRAFT COMPATIBILITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Table - AIRCRAFT COMPATIBILITY CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
4. DIMENSIONAL CHARACTERISTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
A. OPEN BASKET CONFIGURATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
B. ENCLOSED BASKET CONFIGURATION (OPTIONAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
C. XR BOOM CONFIGURATION (OPTIONAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
5. ENGINE SPECIFICATIONS AND OPERATING RPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Table - ENGINE SPECIFICATIONS AND OPERATING RPM . . . . . . . . . . . . . . . . . . . . . . . . 11
6. FUEL SPECIFICATIONS AND RECOMMENDATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Table - FUEL SPECIFICATIONS AND DESIGNATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
7. FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
A. FUEL TYPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
B. FUEL TANK CAPACITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
C. FILTER TYPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
8. COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
9. TIRES AND WHEELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
10. HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
A. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
B. FLUID TYPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
C. HYDRAULIC HOSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
11. BRAKES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
12. ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
13. VEHICLE JACKING REQUIREMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
A. JACK CAPACITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
B. MAINTENANCE STANDS CAPACITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
C. JACK AND MAINTENANCE STANDS SUPPORT SURFACE . . . . . . . . . . . . . . . . . . . . . . . . 15
14. ENVIRONMENTAL LIMITATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
A. OPERATING TEMPERATURES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Table - AMBIENT OPERATING CONDITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
B. WINTERIZATION OPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
15. OPERATORS VIBRATION AND SOUND LEVELS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
A. SOUND LEVEL EMISSION DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Table - SOUND LEVEL EMISSION DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
B. VIBRATION LEVEL DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
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16. UNITS OF MEASUREMENT USED IN THIS MANUAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Table - METRIC AND STANDARD UNITS AND CONVERSIONS . . . . . . . . . . . . . . . . . . . . . 17
17. FLUID CONFIGURATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Table - FLUID CONFIGURATIONS CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Table - PUMP CAPACITIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
18. BASKET CONFIGURATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Table - BASKET CONFIGURATIONS CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Section 5. Shipping and Transportation
1. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. PREPARATION OF THE UNIT FOR SHIPPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
A. DISASSEMBLY AND ASSEMBLY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
B. PREPARATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
3. LOADING AND UNLOADING THE VEHICLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
4. TRANSPORTATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
A. SHIPPING VOLUME AND WEIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
B. TOWING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
C. RESTRAINT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
5. RECOMMENDED SHIPPING TRUCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Section 6. Storage
1. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. STORAGE - ONE MONTH (MAXIMUM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
A. VEHICLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
B. ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
C. BATTERIES AND ELECTRICAL PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
D. TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
E. AXLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
F. WHEELS AND TIRES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
G. HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
H. DEICING AND ANTI-ICING FLUID TANKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
I. DEICING AND ANTI-ICING FLUID PUMPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
J. DEICING FLUID HEATER AND FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
K. GENERAL COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
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3. STORAGE - INDEFINITE PERIOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
A. VEHICLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
B. ENGINE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
C. BATTERIES AND ELECTRICAL PANELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
D. TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
E. AXLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
F. WHEELS AND TIRES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
G. HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
H. DEICING AND ANTI-ICING FLUID TANKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
I. DEICING AND ANTI-ICING FLUID PUMPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
J. DEICING FLUID HEATER AND FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
K. GENERAL COMPONENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
L. EQUIPMENT SHELTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
4. PURGING PUMPS AND HOSES BEFORE SHIPPING OR LONG TERM STORAGE . . . . . . . . . . 6
A. DRAINING DEICING FLUID FROM PUMP AND GROUND HOSE . . . . . . . . . . . . . . . . . . . . 6
B. SIGHT TUBES DRAINING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
C. DRAINING ANTI-ICE FLUID FROM PUMPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
5. RETURNING VEHICLE TO SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
A. RE-COMMISSIONING AFTER A SHORT PERIOD OF STORAGE . . . . . . . . . . . . . . . . . . . . 7
B. RE-COMMISSIONING AFTER AN EXTENDED PERIOD OF INACTIVITY . . . . . . . . . . . . . . 7
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LIST OF FIGURES
1-1 Figure 1 MAIN COMPONENTS - OPEN BASKET (STANDARD) . . . . . . . . . . . . . . . . . . . . 4

1-1 Figure 2 OPERATORS OPEN BASKET. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1-1 Figure 3 OPERATORS ENCLOSED BASKET (OPTIONAL) . . . . . . . . . . . . . . . . . . . . . . . 6
1-1 Figure 4 XR BOOM (OPTIONAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1-1 Figure 5 ENCLOSED BASKET WITH AIRFIRST SYSTEM. . . . . . . . . . . . . . . . . . . . . . . 9
1-1 Figure 6 WINTERIZATION PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1-2 Figure 1 DRIVERS CAB CONTROL PANELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

1-2 Figure 2 MULTI-FUNCTION CONTROL LEVER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1-2 Figure 3 DRIVERS CAB FLUID HEATER PANEL (STANDARD) . . . . . . . . . . . . . . . . . . . 6
1-2 Figure 4 DRIVERS CAB FLUID HEATER PANEL - PICTOGRAMS . . . . . . . . . . . . . . . . . 6
1-2 Figure 5 DRIVERS CAB PROP-MIX FLUID HEATER PANEL (OPTIONAL) . . . . . . . . . . . 8
1-2 Figure 6 DRIVERS CAB PROP-MIX FLUID HEATER PANEL - PICTOGRAMS . . . . . . . . 8
1-2 Figure 7 DRIVERS CAB BLENDUP FLUID HEATER PANEL (OPTIONAL) . . . . . . . . . 10
1-2 Figure 8 DRIVERS CAB BLENDUP FLUID HEATER PANEL - PICTOGRAMS. . . . . . . 10
1-2 Figure 9 DRIVERS CAB INDICATORS AND WARNING LIGHTS PANEL . . . . . . . . . . . . 12
1-2 Figure 10 DRIVERS CAB INDICATORS AND WARNING LIGHTS PANEL -
PICTOGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1-2 Figure 11 DRIVERS CAB HEATER CONTROL PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1-2 Figure 12 FLUID TANK LEVEL AND TEMPERATURE GAUGES PANEL . . . . . . . . . . . . . . 14
1-2 Figure 13 FLUID TANK LEVEL AND TEMPERATURE GAUGES PANEL -
PICTOGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1-2 Figure 14 PROPORTIONAL MIX INDICATOR PANEL (OPTIONAL) . . . . . . . . . . . . . . . . . . 15
1-2 Figure 15 PROPORTIONAL MIX INDICATOR PANEL - PICTOGRAMS . . . . . . . . . . . . . . . 16
1-2 Figure 16 DRIVERS CAB DRIVING PANEL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
1-2 Figure 17 DRIVERS CAB DRIVING PANEL - PICTOGRAMS . . . . . . . . . . . . . . . . . . . . . . . 18
1-2 Figure 18 DRIVERS CAB BOOM CONTROL PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
1-2 Figure 19 DRIVERS CAB BOOM CONTROL PANEL - PICTOGRAMS. . . . . . . . . . . . . . . . 20
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1-2 Figure 20 DRIVERS CAB IGNITION SWITCH PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
1-2 Figure 21 DRIVERS CAB IGNITION SWITCH PANEL - PICTOGRAMS . . . . . . . . . . . . . . . 21
1-2 Figure 22 DRIVERS CAB INSTRUMENT PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
1-2 Figure 23 DRIVERS CAB INSTRUMENT PANEL - PICTOGRAMS . . . . . . . . . . . . . . . . . . . 23
1-2 Figure 24 DRIVERS CAB ROOF WIPER AND WASHER CONTROL PANEL . . . . . . . . . . . 24
1-2 Figure 25 DRIVERS CAB ROOF WIPER AND WASHER CONTROL PANEL -
PICTOGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
1-2 Figure 26 DRIVERS CAB EMERGENCY AND LIGHTING PANEL. . . . . . . . . . . . . . . . . . . . 25
1-2 Figure 27 DRIVERS CAB EMERGENCY AND LIGHTING PANEL -
PICTOGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
1-2 Figure 28 TOP WINDOW DEFROSTER (OPTIONAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
1-2 Figure 29 RECTANGULAR OPEN BASKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
1-2 Figure 30 OPEN BASKET CONTROL PANELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
1-2 Figure 31 OPEN BASKET BOOM CONTROL PANEL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
1-2 Figure 32 OPEN BASKET BOOM CONTROL PANEL - PICTOGRAMS . . . . . . . . . . . . . . . . 30
1-2 Figure 33 OPEN BASKET OPERATORS CONTROL PANEL . . . . . . . . . . . . . . . . . . . . . . . 32
1-2 Figure 34 OPEN BASKET OPERATORS CONTROL PANEL - PICTOGRAMS . . . . . . . . . . 33
1-2 Figure 35 OPEN BASKET PROP-MIX CONTROL PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . 36
1-2 Figure 36 OPEN BASKET PROP-MIX CONTROL PANEL - PICTOGRAMS . . . . . . . . . . . . 37
1-2 Figure 37 ENCLOSED BASKET WITH BOOM AND NOZZLE CONTROL
JOYSTICKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
1-2 Figure 38 ENCLOSED BASKET OPERATOR CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . 40
1-2 Figure 39 ENCLOSED BASKET OPERATOR CONTROLS - PICTOGRAMS . . . . . . . . . . . . 41
1-2 Figure 40 ENCLOSED BASKET AIRFIRST AND PROP-MIX CONTROLS . . . . . . . . . . . . 43
1-2 Figure 41 ENCLOSED BASKET AIRFIRST AND PROP-MIX CONTROLS -
PICTOGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
1-2 Figure 42 ENCLOSED BASKET BLENDUP CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . 46
1-2 Figure 43 ENCLOSED BASKET BOOM CONTROL JOYSTICK (LEFT SIDE POD) . . . . . . . 48
1-2 Figure 44 ENCLOSED BASKET NOZZLE CONTROL JOYSTICK (RIGHT POD). . . . . . . . . 50
1-2 Figure 45 ENCLOSED BASKET OVERHEAD INDICATOR PANEL . . . . . . . . . . . . . . . . . . . 52
1-2 Figure 46 ENCLOSED BASKET OVERHEAD INDICATOR PANEL (CONT.) . . . . . . . . . . . . 53
1-2 Figure 47 ENCLOSED BASKET HEATER CONTROL PANEL . . . . . . . . . . . . . . . . . . . . . . . 54
1-2 Figure 48 ENCLOSED BASKET WITH AIRFIRST SYSTEM (OPTIONAL) . . . . . . . . . . . . 55
1-2 Figure 49 PRESSURE AND TEMPERATURE NOZZLE GAUGES (OPTIONAL) . . . . . . . . . 56
1-2 Figure 50 ONE-MAN DRIVE - OPERATION CONTROL JOYSTICK (OPTIONAL) . . . . . . . . 58
1-2 Figure 51 ONE-MAN SIDE REACH BYPASS SWITCH (OPTIONAL) . . . . . . . . . . . . . . . . . . 59
1-2 Figure 52 CCTV SYSTEM - DRIVERS CAB MONITOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
1-2 Figure 53 CCTV SYSTEM - ENCLOSED BASKET MONITOR . . . . . . . . . . . . . . . . . . . . . . . 61
1-2 Figure 54 CCTV SYSTEM - MONITOR FRONT AND REAR VIEWS . . . . . . . . . . . . . . . . . . 61
1-2 Figure 55 OPTIMAX HEAT SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
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1-2 Figure 56 EXTEND AND RETRACT XR BOOM (OPTIONAL) . . . . . . . . . . . . . . . . . . . . . . . 73
1-2 Figure 57 NOZZLE CONTROL JOYSTICK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
1-2 Figure 58 LOGIN AND MAIN MENU ACCESS SCREEN . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
1-2 Figure 59 BLENDUP MAIN MENU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
1-2 Figure 60 BLENDUP FREEZE VALUES SCREEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
1-2 Figure 61 DEICE FLUID FREEZE VALUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
1-2 Figure 62 CONFIRM FREEZE VALUE SCREEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
1-2 Figure 63 BLENDUP FREEZE VALUE SCREEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
1-2 Figure 64 SPRAY FREEZE VALUE SCREEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
1-2 Figure 65 CONFIRM SPRAY RATIO SCREEN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
1-2 Figure 66 BLENDUP FREEZE VALUES SCREEN - SPRAY ENABLED . . . . . . . . . . . . . 82
1-2 Figure 67 GROUND REEL ENABLE SCREEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
1-2 Figure 68 GROUND REEL ENABLE SCREEN - ENABLED . . . . . . . . . . . . . . . . . . . . . . . . . 83
1-2 Figure 69 GROUND HOSE NOZZLE AND SWITCH PANEL . . . . . . . . . . . . . . . . . . . . . . . . 87
1-2 Figure 70 OPEN BASKET NOZZLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
1-2 Figure 71 DEICING PRESSURE AND SUCTION REFILL (NORTH AMERICAN
UNITS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
1-2 Figure 72 FLUID LEVEL AND REFILL PLACARDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
1-2 Figure 73 DEICING PRESSURE AND SUCTION REFILL (EUROPEAN UNITS) . . . . . . . . 94
1-2 Figure 74 DEICE BLENDUP PRESSURE AND SUCTION REFILL . . . . . . . . . . . . . . . . . 96
1-2 Figure 75 TWO-TANK PROP-MIX PRESSURE AND SUCTION REFILL. . . . . . . . . . . . . . . 98
1-2 Figure 76 ANTI-ICING FLUID PRESSURE REFILL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
1-2 Figure 77 ANTI-ICING FLUID SUCTION REFILL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
1-2 Figure 78 TOP REFILL - STANDARD TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
1-2 Figure 79 TOP REFILL - PROP-MIX TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
1-2 Figure 80 TOP REFILL - DEICE BLENDUP PROP-MIX TANK. . . . . . . . . . . . . . . . . . . . . 103
1-2 Figure 81 TOP REFILL - TWO-TANK PROP-MIX. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
1-2 Figure 82 FLUID TEST PORTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
1-2 Figure 83 THERMOSTAT CONTROL BOX. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
1-3 Figure 1 EMERGENCY STOP PUSH-BUTTON LOCATIONS . . . . . . . . . . . . . . . . . . . . . . 2

1-3 Figure 2 GROUND CONTROL STATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1-3 Figure 3 EMERGENCY BOOM LOWERING PROCEDURES . . . . . . . . . . . . . . . . . . . . . . 5
1-3 Figure 4 MECHANICAL RELEASE OF PARKING BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . 9
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1-4 Figure 1 WORKING POSITIONS CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

1-4 Figure 2 OPEN BASKET CHASSIS DIMENSIONS - LENGTH . . . . . . . . . . . . . . . . . . . . . . 5
1-4 Figure 3 ENCLOSED BASKET CHASSIS DIMENSIONS - LENGTH . . . . . . . . . . . . . . . . . 7
1-4 Figure 4 XR BOOM CHASSIS DIMENSIONS - LENGTH . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1-4 Figure 5 CHASSIS DIMENSIONS - WIDTH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Section 6. Storage
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1. GENERAL
NOTE: FOR EMERGENCY OPERATING PROCEDURES REFER TO CHAPTER 1, SECTION 3.
The Tempest Aircraft Deicer is a deicing and anti-icing vehicle used in airline operations. This vehicle is
equipped with a diesel engine that drives a set of hydraulic pumps which power the hydrostatic
transmission of the vehicle and boom operation.
A hydrostatic drive system, consisting of a transmission gear box coupled to a hydraulic motor, provides
incremental acceleration for better control of the vehicle motion. Conventional heavy-duty axles with
front steering and a rigid drive rear axle are equipped with pneumatic brakes.
Controls for the vehicle systems and boom operation are located in the drivers cabin. The vehicle is
provided with a standard open basket, or an optional enclosed basket, for deicing and anti-icing
operations (refer to Figure 1).
All safety precautions and warnings should be followed as prescribed in this manual and as placarded
on the vehicle.
NOTE: REFER TO SPECIFICATIONS IN CHAPTER 1, SECTION 4 FOR AXLES, ENGINE,

TRANSMISSION, AND OTHER COMPONENTS, AND FOR CONFIGURATIONS AND
OPTIONS AVAILABLE.
2. MAIN COMPONENTS
A. CHASSIS
The vehicle components are mounted on a heavy-duty, low-profile, steel chassis especially
designed for the Tempest Aircraft Deicer. Access to engine, pumps, heater, tanks, and panels is
provided through hoods and covers.
B. AXLES AND WHEELS
The vehicle is equipped with a planetary differential built in the rigid rear axle, powered through a
drive shaft from a hydrostatic transmission with variable speeds. The front axle is steered by
actuating on hydraulic steering cylinders powered by the hydraulic pump and controlled by a
steering valve. Both front and rear axles are suspended by heavy-duty rubber support blocks,
with single wheels on the front axle and twin wheels on each side of the rear axle. All tires are
pneumatic type rubber tires.
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C. ENGINE
The Tempest is provided with an in-line four-cylinder, liquid-cooled diesel injected engine. An
optional six-cylinder engine is provided with the AirFirst system optional for the enclosed basket
(refer to Figure 5). The engine is equipped with a 24-volt starter motor, and a 24-volt DC
alternator and voltage regulator which charge the dual 12-volt DC battery system.
D. FUEL SYSTEM
The fuel tank is located at the left side of the vehicle. A fuel/water separator traps moisture in the
fuel lines. The fuel is forced through the fuel filter and into the fuel injector pump. Fuel returning
from the injector pump flows through return fuel lines back to the fuel tank.
E. COOLING SYSTEM
The cooling system uses both air and liquid coolant components. Proper operating temperature
is maintained by a thermostat that controls flow through the radiator.
A belt-driven fan at the front of the engine draws air through a radiator core, which cools the
circulating fluid. Air is also directed past cooling fins on a separate core that cools circulating
hydraulic fluid.
F. AIR INTAKE
The air intake system filters air going into the engine. The incoming air is spun to remove heavy
particles, and then filtered through the element before it enters into the turbo-charger. The air is
compressed and cooled through a charge air cooler mounted in front of the engine before it
enters the intake manifold on the engine.
G. EXHAUST SYSTEM
Exhaust from the engine flows through the turbo and then to the outside of the vehicle through a
spark arrestor and muffler.
H. TRANSMISSION
The hydrostatic transmission consists of a hydraulic motor coupled to a gear box, and provides for
variable speeds. Travel direction is manually selected and electronically controlled. Speed is
electronically controlled and activated through the accelerator pedal.
Hydraulic power for the traction motor is provided by the hydraulic pump directly coupled to the
diesel engine.
I. HYDRAULIC SYSTEM
The hydraulic system is comprised of a pressure compensated pump, and a closed-centered

circuit that converts engine rotational power into traction, steering, and boom movement through
hydraulic force. The hydraulic pumps are directly coupled in tandem to the diesel engine, and
they are equipped with a flow control and a relief valve.
The hydraulic system has several filters to remove harmful particles from the hydraulic oil fluid.
The tank inlet also contains a filter screen to collect harmful particles when filling the system.
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J. STEERING SYSTEM
Steering of the vehicle is power assisted by hydraulic pressure. All steering components are
connected by hydraulic lines. The hydraulic pump provides continuous flow to the steering
control valve, which diverts flow to the steering cylinders for turning the vehicle as the steering
wheel is rotated.
K. AIR BRAKE SYSTEM
(1) Service Brakes
The service brake system consists of a mechanical actuated brake pedal and linkage
connected to a pneumatic dual valve actuating on brake chambers on the rear wheels. An
air compressor provides air pressure to release the brakes and allow the vehicle to move.
Every time the brake valve is actuated, air pressure is depleted from the chambers, braking
the wheels.
(2) Accumulators
The brake system has integrated air pressure accumulators that are filled after starting the
engine. Air pressure must be created inside the accumulators for the brake chambers to
be re-filled with air pressure after every time the brake valve depletes them. The vehicle
will not move until enough air pressure is built into the accumulators.
(3) Parking Brake
The brake chambers provide the dual function of service brakes, and parking brakes.
When air is depleted from the brake chambers, brakes are applied to the wheels. This
condition happens when the engine is not running and the parking brake valve allows the
springs on the brake chambers to expel the air pressure.
L. ELECTRICAL SYSTEM
Operating electrical current is provided by two 12-volt DC batteries connected in series to provide
24 volts DC to all electrical components. Electrical circuits are protected by circuit breakers
housed in a panel located on the right side of the vehicle.
The batteries are located inside the engine compartment on the right side of the vehicle. A
belt-driven alternator mounted on the engine provides electrical current to the vehicle, while
maintaining the batteries at full capacity.
M. DRIVERS CAB
Main controls and instruments are located in the drivers cab such as steering wheel, parking
brake valve, transmission lever, accelerator and brake pedals, electrical gauges and switches,
warning indicators, aerial device (boom) controls, and emergency stop (E-stop) push buttons.
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DESCRIPTION
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October 2013
OPERATORS AERIAL FLUID FLUID LEVEL ANTI-ICING TANK
BASKET DEVICE TANK GAUGES (OPTIONAL)
DRIVERS FRONT DIESEL FUEL FLUID HYDROSTATIC GROUND CONTROL

CABIN AXLE TANK PUMPS TRANSMISSION STATION
DEICER AIR FILTER HYDRAULIC DIESEL ENGINE ELECTRICAL

HEATER INTAKE PUMPS ENGINE COOLER PANEL
HYDRAULIC REAR DRIVE BATTERIES ENGINE PNEUMATIC GROUND

OIL TANK AXLE EXHAUST ACCUMULATORS HOSE REEL
Figure 1
MAIN COMPONENTS - OPEN BASKET (STANDARD)
1-1
Page 4
October 2013
N. AERIAL DEVICE (BOOM SYSTEM)
(1) Aerial Reach Boom
The boom system hydraulically lifts the operators basket to the desired height for deicing
and anti-icing tasks. Hydraulic power for the boom is also provided by the hydraulic pump
coupled to the diesel engine. Boom controls are mounted inside the drivers cab and in the
operators basket.
(2) Aerial Extended Reach (XR) Boom (Optional)
An extended reach telescoping boom is provided for deicing and anti-icing operations with
large aircraft, such as the Airbus 380 and the Ilyushin IL76. Refer to Specifications in
Chapter 1, Section 4 for maximum working height.
O. OPERATORS BASKET
The basket, mounted at the end of the boom, allows the operator to approach the aircraft for
deicing and anti-icing tasks. Controls for boom movement and spraying deicing and anti-icing
fluids, and an emergency stop push-button are located within the basket. Also, a drive control
box is provided for the optional one-man drive/operation system.
(1) Open Basket
The Tempest is provided with a standard open basket which can be customized with
several available options. Refer to Figure 2, and also to Specifications in Chapter 1,
Section 4 for configurations and options.
RECTANGULAR ROUND
OPEN BASKET OPEN BASKET
(STANDARD) (OPTIONAL)
Figure 2
OPERATORS OPEN BASKET
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DESCRIPTION
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October 2013
(2) Enclosed Basket (Optional)
All boom, nozzle and fluid controls are integrated in the two control joysticks for deicing
without reaching or taking hands off the controls. Refer to Figure 3.
The instruments located in the enclosed basket provide complete operator information
including indicator lights for ready-to-spray, low-fluid level, boom overloads, and boom
positioning (boom centered and boom parked).
A high-back seat, heater and activated-carbon fresh air filter provide operator comfort.
Powerful flood and spotlights and smart interior lighting aid in night time operation.
NOTE: REFER TO FIGURE 5 FOR OPTIONAL AIRFIRST SYSTEM.
VENTILATION
RIGHT SIDE POD FANS
NOZZLE CONTROL
JOYSTICK
ANTI-ICE
NOZZLE
LEFT SIDE
TASK FORCE POD
DEICE NOZZLE
BOOM
CONTROL
JOYSTICK
FUSE BOX
BASKET HEATER
Figure 3
OPERATORS ENCLOSED BASKET (OPTIONAL)
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October 2013
COUNTER WEIGHT MAIN BOOM TELESCOPIC BOOM JIB BOOM
BASKET
Figure 4
XR BOOM (OPTIONAL)
3. DRIVING / OPERATION MODES
A. TWO-MAN OPERATION MODE
Two-man operation mode requires one person (driver) to drive the vehicle around the aircraft,
while a second person (operator) in the basket concentrates on deicing and anti-icing tasks.
An optional intercom is available for both personnel to communicate and coordinate their efforts.
B. ONE-MAN OPERATION MODE (OPTIONAL)
A drive control box with a joystick is provided with this option, allowing one person to operate and
drive the vehicle around the aircraft at reduced speed from the basket. The box, when not in use,
is stored above the heater on the lower left side of the basket. Refer to Figure 5.
4. FLUID CONFIGURATIONS
Several fluid configurations and tank size options allow the Tempest to meet a wide range of deicing/
anti-icing aircraft requirements. Also, depending on the fluid configuration, the number and type of
pumps may vary. Typically, a main tank for deicing fluid and a secondary tank for anti-icing fluid is
provided.
Refer to Fluid Configurations in Specifications, Chapter 1, Section 4 for fluid configurations, tank type
and sizes, pump configuration and other features.
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DESCRIPTION
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October 2013
A. PROPORTIONAL MIX (PROP-MIX) SYSTEM (OPTIONAL)
Provides an adjustable glycol mixture proportion in accordance with the weather conditions at the
time the aircraft is being deiced.
B. AIRFIRST SYSTEM (OPTIONAL WITH ENCLOSED BASKET)
The AirFirst system provides a turret mounted air nozzle on the front of the enclosed basket.
Its purpose is to remove loose snow from the aircraft, blowing air from the air nozzle before
spraying deicing fluid. This system helps reducing overall use of glycol for deicing operations.
Refer to Figure 5.
Deicing and anti-icing operations are also available with the AirFirst system, and those fluid
nozzles are also turret mounted on the front of the basket.
The AirFirst system can also be used as an air assist when applying deicing and anti-icing
fluids. All controls for the AirFirst system, in addition to controls for fluid nozzles and selecting
the fluid system, are mounted on the left and right pods in the operators enclosed basket.
C. BLENDUP SYSTEM (OPTIONAL)
The blendUP system is a specific variant of the Proportional Mix system. Refer to Fluid
Configurations is Chapter 1, Section 4.
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October 2013
RIGHT SIDE POD
NOZZLE CONTROL
JOYSTICK
NOZZLE TURRET ASSEMBLY LEFT SIDE

POD
TASK FORCE BOOM

DEICE NOZZLE CONTROL
JOYSTICK
FUSE BOX
ANTI-ICE NOZZLE
DRIVE CONTROL BOX
AIRFIRST WITH JOYSTICK
NOZZLE (OPTIONAL)
BASKET HEATER
NOTE: VEHICLE MAY BE EQUIPPED WITH JOYSTICKS DIFFERENT THAN SHOWN.
Figure 5
ENCLOSED BASKET WITH AIRFIRST SYSTEM
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DESCRIPTION
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October 2013
5. ADDITIONAL FEATURES
A. EMERGENCY STOPS
The emergency stop (E-stop) push-button switches, when depressed, immediately disable the
engine, heater, fluid pumps, and hydraulics for boom movements, and apply the parking brakes.
B. AUTOMATIC SHUTDOWN
The engine automatically shut downs in the event of low oil pressure, high coolant temperature,
low coolant level, high hydraulic oil temperature, or low hydraulic oil level.
C. ENGINE STARTER MOTOR
The starter motor cannot be engaged while the engine is running. The engine starter is
automatically disabled 48 seconds after the ignition switch is turned on.
D. HEATER SHUTDOWN
The heater will shut down if any of the following conditions occur:
Low fluid level

Low blower speed
Heater outlet temperature exceeds 110 C (230 F)
Heater inlet temperature reaches 82 C (180 F)
Exhaust stack temperature exceeds 760 C (1400 F)
E. BOOM LIFT CAPABILITY
NOTE: REFER TO SPECIFICATIONS IN CHAPTER 1, SECTION 4 FOR VEHICLE

CAPABILITIES.
Boom operations are interlocked with enclosed basket door and safety belt. A switch to enable
the boom is incorporated on the boom joystick control and actuates a hydraulic valve to enable
the boom.
F. AERIAL HOLDING VALVE
All cylinders used on the aerial device incorporate a holding valve to prevent rapid lowering of the
boom in the event of hydraulic line failure.
G. VEHICLE SPEED LIMITER
The limiter restricts the vehicle to a maximum low speed when the boom is out of the resting
position.
H. BATTERY DISCONNECT SWITCH (OPTIONAL)
Disconnects both positive and negative battery cables, isolating the vehicles electrical system.
The switch lever must be installed and turned on for electrical current to flow into the system.
After disengaging the switch, the lever must be removed.
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October 2013
I. HYDRAULIC EMERGENCY PUMP
A battery powered pump is provided for emergency procedures, such as emergency boom
lowering.
J. AUTOMATIC PARKING BRAKES
Parking brakes are automatically applied when the ignition switch is turned to the off position, or
when an emergency stop (E-stop) push-button is depressed.
K. ONE-MAN DRIVE / OPERATION MODE
Boom operation and vehicle driving are not allowed to be performed simultaneously while in one-
man drive/operation mode.
6. WINTERIZATION SYSTEM (OPTIONAL)
The winterization system heats several main components on the vehicle. The system is provided with
an external receptacle that allows a plug-in connector from an external AC power source to electrically
feed the system.
Refer to Chapter 1, Section 2 for the operation of the winterization system, and Chapter 1, Section 4 for
the winterization system specifications.
A. WATER TANK HEATER (OPTIONAL)
An electric element heats the water in the main water tank, and it is thermostatically controlled.
The thermostat regulates the heat applied to the circulating water, and it is located inside a round
box with a threaded lid, on the left side of the vehicle, inside the fluid pump compartment.
An electric motor drives a hydraulic pump that actuates the water delivery pump and the heater
circulating pump.
B. HYDRAULIC TANK HEATER (OPTIONAL)
An electric heater inside the hydraulic tank heats the hydraulic fluid.
C. ENGINE BLOCK HEATER (STANDARD)
An electric heating element heats the engine block.
D. BATTERY BLANKETS (OPTIONAL)
Vehicle batteries are wrapped with electrically heated blankets.
E. ELECTRICAL CONTROL BOX (OPTIONAL)
The electrical control box is located inside the compartment on the left rear side of the vehicle. It
contains the winterization system circuit breakers, relays, and other electrical components.
F. DRIVERS CAB HEATER (OPTIONAL)
An electric cab heater is also provided with the system, and located between the two seats inside
the drivers cab. The heater has a two-position (ON/OFF) switch to activate it.
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DESCRIPTION
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October 2013
G. ELECTRICAL PLUG-IN RECEPTACLE AND MASTER SWITCH (OPTIONAL)
The receptacle is located on a panel on the left rear side of the vehicle. It is provided with a cover
to protect the electrical male connector from water, dirt, and other weather conditions.
The winterization system is activated by a two-position (ON/OFF) rotary switch to the right of the
receptacle (refer to Figure 6). When the system is plugged in, it is not allowed to switch into drive
mode.
PLUG-IN
RECEPTACLE
RECEPTACLE WINTERIZATION
COVER MASTER SWITCH
626-3527
Figure 6
WINTERIZATION PANEL
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October 2013
WARNING
BEFORE ATTEMPTING TO OPERATE OR MAINTAIN THIS VEHICLE, COMPLETELY READ AND
WARNING
IT IS THE OPERATORS RESPONSIBILITY TO MAKE SURE THE BASKETS MOVEMENT PATH
IS CLEAR AND FREE OF ANY OBJECTS WHILE OPERATING THE VEHICLE. FAILURE TO
WARNING
ENSURE THE AREA AROUND THE VEHICLE IS CLEAR OF PERSONNEL WHILE OPERATING
1. GENERAL
NOTE: FOR EMERGENCY OPERATING INSTRUCTIONS REFER TO CHAPTER 1, SECTION 3.
This section contains operation instructions for the Tempest Aircraft Deicer. A discussion of the
principles of operation is given to aid in understanding of its operation.
The operator must use approved procedures for approaching and departing aircraft, and applying
deicing and anti-icing methods. All procedures followed should be approved by the airline, the local
aviation authority, and based on the recommendations of the aircraft manufacturer.
2. SAFETY PRECAUTIONS
Before operating the vehicle, the operator must read this manual and become completely
familiarized with the vehicle.
Learn how your vehicle is operated. Know the location and functions of all controls, indicators,
caution instructions, and warning and safety devices.
Always perform the maintenance checks.
Follow the correct starting, warm-up, operating, stopping, and parking procedures.
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OPERATION
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October 2013
Remember that it only takes one unsafe action to cause an accident. Use the general safety
guidelines recommended by S.A.E., specification SAE J153, and follow your employers safety
rules and instructions to develop safe working habits.
WARNING
VEHICLE IS NOT A PERSONNEL TRANSPORT. DO NOT ALLOW PERSONNEL IN THE BASKET
WHILE VEHICLE MOVES AT HIGH SPEED. FAILURE TO COMPLY MAY RESULT IN SERIOUS
WARNING
NEVER EXCEED THE RECOMMENDED MAXIMUM WEIGHT LIMITS FOR THIS EQUIPMENT.
WARNING
NORMAL OPERATIONS SHOULD NOT BE PERFORMED WHILE AIRCRAFT IS BEING
REFUELED, WITHOUT HAVING FACILITY AND REGULATORY APPROVAL. OPERATOR MUST
ENSURE THAT NO HYDRAULIC LEAKS OR UNSAFE CONDITIONS ARE PRESENT ON THE
WARNING
AT THE BEGINNING OF EACH SHIFT ENSURE THAT ALL SCHEDULED SERVICES HAVE BEEN
PERFORMED, INCLUDING VERIFICATION OF TIRE CONDITION, FUEL AND FLUID LEVELS,
AND OVERALL CHECK FOR LOOSE OR MISSING HARDWARE AND GENERAL CONDITION OF
WARNING
AN OBSERVER ON THE GROUND SHOULD BE USED TO AID THE OPERATOR WHEN DRIVING
THE VEHICLE IN REVERSE. FAILURE TO COMPLY MAY RESULT IN SERIOUS BODILY
WARNING
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October 2013
3. DRIVERS CAB CONTROLS AND INDICATORS
The drivers cab controls and indicators consist of various panels to accommodate instruments and
controls for the deicing and anti-icing operations, and vehicle driving (refer to Figure 1).
NOTE: CONTROL PANEL CONFIGURATION MAY VARY DEPENDING ON VEHICLES

SPECIFICATIONS.
DRIVERS CAB HEATER FLUID TANK LEVEL

CONTROL PANEL AND TEMPERATURE
FLUID HEATER (Figure 11) GAUGES PANEL
PANEL (Figure 12)
(Figure 3, Figure 5) INDICATORS AND
WARNING LIGHTS PANEL
(Figure 9)
PROP-MIX PANEL
(OPTIONAL)
(Figure 14)
MULTI-FUNCTION
CONTROL LEVER
(Figure 2)
DRIVING
PANEL
(Figure 16)
EMERGENCY
AND LIGHTING
PANEL IGNITION
SWITCH
(Figure 26)
(Figure 20)
CAB ROOF DRIVERS CAB

WIPER CONTROL FUSE BOX
PANEL (Refer to Chapter 2)
(Figure 24) BOOM CONTROL JOYSTICK
(OPTIONAL)
(Figure 18)
INSTRUMENT BOOM CONTROL
PANEL PANEL
(Figure 22) (Figure 18)
Figure 1
DRIVERS CAB CONTROL PANELS
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October 2013
A. MULTI-FUNCTION CONTROL LEVER SWITCH
This multi-function switch allows the driver to actuate the turn signal lights, windshield washer and
wipers, and low- and high-beam headlights (refer to Figure 1 and Figure 2).
(1) Six-position rotary switch to activate the front windshield wiper.
Positions: Off / Intermittent slow / Intermittent medium / Intermittent high / Continuous slow
/ Continuous high.
(2) Lift the lever for indicating a right turn.
(3) Lower the lever for indicating a left turn.
(4) Pull lever towards steering wheel to activate headlights high beam. Push lever away from
steering wheel to deactivate high beam and back to low beam.
(5) Depress button to activate front windshield washer. Note that after switch has been
activated, windshield wipers will continue working for several seconds and stop
automatically.
4
3
Figure 2
MULTI-FUNCTION CONTROL LEVER
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Page 4
October 2013
B. DRIVERS CAB FLUID HEATER PANEL (STANDARD)
The fluid heater panel is located inside the drivers cab on the upper left side of the dash panel
(refer to Figure 1, Figure 3, and Figure 4).
NOTE: HEATER SWITCH, HEATER ON INDICATOR LIGHT, MISFIRE INDICATOR LIGHT, AND
CYCLE COMPLETE INDICATOR LIGHT ARE LOCATED ON THE RIGHT SIDE POD
(ONE-MAN DRIVE OPERATION MODE).
(1) Heater Switch ON with Running Indicator Light (WHITE) - Depressing the top end of
the rocker switch and holding for about five seconds will turn on the deicing fluid heater.
The green indicator light will illuminate to show the heater start and run sequence has
started. The white indicator light illuminates when there is a flame in the heater.
(2) Heater Switch OFF with Start and Run Sequence Indicator Light (GREEN) -
Depressing the bottom end of the rocker switch and holding for about five seconds will turn
off the heater and begin a three minute cool down cycle. The green and white indicator
lights will turn off. The complete ignition cycle takes about 30 seconds before the white
light (1) illuminates.
(3) Heater Misfire Indicator Light (RED) - Illuminates when a flame is not established during
the starting sequence or during a heater error. Refer to Electronic Heater Controller (EHC)
in Chapter 2, Section 8 for fault codes.
(4) Cycle Complete Indicator Light (WHITE) - Illuminates when heating cycle has been
completed and the deicing tank has reached maximum operating temperature.
(5) Deicing Fluid Tank Low Level Indicator Light (AMBER) - Illuminated when deicing fluid
tank is nearly empty and the deicing fluid pump has been shut down. Optionally, the
indicator light flashes when fluid is low.
(6) Anti-icing Fluid Tank Low Level Indicator Light (AMBER) - Illuminates when anti-icing
fluid tank is nearly empty and the anti-icing pump has stopped. Optionally, the indicator
light flashes when fluid is low.
(7) Deicing Pump Switch ON - Press the top end of the rocker switch momentarily to actuate
the deicing pump.
(8) Deicing Pump Switch OFF - Press the bottom end of rocker switch momentarily to stop
the deicing pump.
(9) Ready-to-spray Indicator Light (GREEN) - Illuminates when fluid at the heater outlet is at
the correct temperature to spray. The temperature at which the light illuminates is
adjustable.
(10) Deicing Delivery Pump Running Indicator Light (GREEN) - Illuminates when deicing
delivery pump is energized.
(11) Heater Service Required Indicator Light (AMBER) - Illuminates when heater controller
detects a non-critical fault and requires heater system maintenance. Refer to Electronic
Heater Controller (EHC) in Chapter 2, Section 8 for fault codes. A critical fault is a safety
condition that may come up on the system and would be indicated by the red light (3).
(12) Auto Shutdown Indicator Light (GREEN) (Optional) - Illuminates when ignition system
is in automatic shutdown mode.
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OPERATION
Page 5
October 2013
1 3 5 7 9 11
W R A G A
G W A G G
2 4 6 8 10 12
Figure 3
DRIVERS CAB FLUID HEATER PANEL (STANDARD)
FLUID HEATER PANEL (STANDARD)

1. HEATER TURN ON / 2. TURN OFF HEATER 3. HEATER MISFIRE 4. CYCLE COMPLETE
HEATER RUNNING AND SEQUENCE ON INDICATOR INDICATOR
5. DEICING FLUID 6. ANTI-ICING FLUID 7. TURN ON 8. TURN OFF

TANK LOW LEVEL TANK EMPTY DEICING PUMP DEICING PUMP
9. READY-TO-SPRAY 10. DEICING DELIVERY 11. HEATER SERVICE 12. AUTOMATIC SHUT
INDICATOR PUMP RUNNING REQUIRED DOWN MODE
Figure 4
DRIVERS CAB FLUID HEATER PANEL - PICTOGRAMS
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Page 6
October 2013
C. DRIVERS CAB FLUID HEATER PANEL - PROP-MIX (OPTIONAL)
This deicing option provides the capability to proportionally mix glycol and water according to
specific weather conditions, customer requirements, and standards.
(1) Automatic Circulation Mode - Standby circulation is enabled by setting the three-position
rocker switch to the middle position.
(2) Turn On Circulation ( I ) - Depress the upper section of the three-position rocker switch to
actuate standby circulation in manual mode.
(3) Turn Off Circulation ( 0 ) - Depress the lower section of the three-position rocker switch to
turn off the circulation system.
(4) Heat Water Tank Only - Depress the two-position rocker switch to heat only the water tank
when the heater is running.
(5) Heat Deicer And Water Tank - Depress the two position rocker switch to heat both the
water and deice tanks.
(6) Heater Switch ON With Running Indicator Light (WHITE) - Depressing the top end of
the rocker switch and holding for about five seconds will turn on the deicing fluid heater.
The green indicator light will illuminate to show the heater start and run sequence has
started. The white indicator light illuminates when there is a flame in the heater.
(7) Heater Switch OFF With Start Sequence Indicator Light (GREEN) - Depressing the
bottom end of the rocker switch for about five seconds will turn off the heater and begin a
three minute cool down cycle. The green and white indicator lights will turn off.
(8) Heater Misfire Warning Light (RED) - Illuminates when a flame is not established during
the starting sequence or during a heater error. Refer to Electronic Heater Controller (EHC)
in Chapter 2, Section 8 for manufacturers fault codes.
(9) Water In Tank Heated Indicator Light (WHITE) - Illuminates when the water tank has
reached operating temperature and the heater controller has completed the operating
cycle.
(10) Deicing Fluid Tank Low Level Indicator Light (AMBER) - Illuminates when deicing fluid
tank is nearly empty. This will automatically disable the deicing fluid pump. Optionally, the
(11) Anti-icing Fluid Tank Empty Indicator Light (AMBER) - Illuminates when the anti-icing
fluid tank is empty. This will automatically disabled the anti-icing fluid pump. Optionally,
the indicator light flashes when fluid is low.
(12) Water Tank Empty Indicator Light (AMBER) - Illuminates when water tank is empty. The
proportional mix system and heater will be automatically disabled. Optionally, the indicator
light flashes when fluid is low.
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OPERATION
Page 7
October 2013
2 4 6 8 10 12 14 16 18
H2O H2O
1
W
R R A A G A
G
W W A W G G
D H2O
H2O D
3 5 7 9 11 13 15 17 19
Figure 5
DRIVERS CAB PROP-MIX FLUID HEATER PANEL (OPTIONAL)
FLUID HEATER PANEL - PROPORTIONAL MIX (PROP-MIX) (OPTIONAL)

1. AUTOMATIC 2. TURN ON 3. TURN OFF 4. HEAT WATER
CIRCULATE MODE CIRCULATION CIRCULATION TANK ONLY
(NO GRAPHIC) H2O
5. HEAT DEICER AND 6. HEATER TURN ON 7. TURN OFF HEATER 8. HEATER MISFIRE
WATER TANKS AND RUNNING AND SEQUENCE ON INDICATOR
D H2O
9. WATER IN TANK 10. DEICING FLUID 11. ANTI-ICING FLUID 12. WATER TANK
HEATED INDICATOR TANK LOW LEVEL TANK EMPTY EMPTY INDICATOR
H2O
13. DEICING FLUID 14. TURN ON 15. TURN OFF 16. FLUID SPRAYED AT
HEATED DEICING PUMP DEICING PUMP RIGHT TEMPERATURE
17. DEICING DELIVERY 18. HEATER SERVICE 19. AUTOMATIC SHUT 20.
PUMP RUNNING REQUIRED DOWN MODE
Figure 6
DRIVERS CAB PROP-MIX FLUID HEATER PANEL - PICTOGRAMS
1-2
Page 8
October 2013
(13) Deicing Fluid Heated Indicator Light (WHITE) - Illuminates when the deicing fluid in the
tank has reached the normal operating temperature (adjustable).
(14) Deicing Pump Switch ON - Depress top end of rocker switch momentarily to energize the
deicing pump.
(15) Deicing Pump Switch OFF - Depress bottom end of rocker switch momentarily to stop the
deicing pump.
(16) Ready-to-spray Indicator Light (GREEN) - Illuminates when fluid is at the correct
temperature to spray.
(17) Deicing Delivery Pump Running Indicator Light (GREEN) - Illuminates when deicing
delivery pump is energized.
(18) Heater Service Required Indicator Light (AMBER) - Illuminates when heater controller
detects a non-critical fault and requires heater system maintenance. Refer to Electronic
Heater Controller (EHC) in Chapter 2, Section 8 for fault codes.
(19) Automatic Shutdown Indicator Light (GREEN) (Optional) - Illuminates when heater is in
automatic shutdown mode.
D. DRIVERS CAB FLUID HEATER PANEL - BLENDUP (OPTIONAL)
NOTE: FOR OTHER INDICATORS, SWITCHES, AND FUNCTIONS ON THIS PANEL, REFER TO
B. DRIVERS CAB FLUID HEATER PANEL (STANDARD).
(1) Fault Detected Warning Indicator (RED) (BlendUP Option) - Illuminates when a fault
is detected while the purge system is active.
(2) Pure Fluid Tank Low Level Indicator Light (AMBER) - Illuminates when the pure fluid
tank is nearly empty. This will automatically disable the pure fluid pump. Optionally, the
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OPERATION
Page 9
October 2013
1
W R A G A R
G W A G G A
Figure 7
DRIVERS CAB BLENDUP FLUID HEATER PANEL (OPTIONAL)
FLUID HEATER PANEL - BLENDUP (OPTIONAL)

1. FAULT DETECTED WARNING 2. PURE FLUID EMPTY TANK
INDICATOR INDICATOR (OPTION)
Figure 8
DRIVERS CAB BLENDUP FLUID HEATER PANEL - PICTOGRAMS
1-2
Page 10
October 2013
E. DRIVERS CAB INDICATORS AND WARNING LIGHTS PANEL
This panel contains status indicators and optional gauges, and it is located inside the drivers cab
on the upper right side of the dash panel (refer to Figure 1, Figure 9 and Figure 10).
NOTE: FOR BLINK SEQUENCES AND FAULT CODES, REFER TO THE ENGINE MANUAL IN
CHAPTER 5, MANUFACTURERS APPENDICES.
(1) Non-charging Warning Light (RED) - Illuminates when the engines alternator is not
generating sufficient electrical current for the system, recharging the batteries, or the
built-in regulator stops working. This warning light (G = Generator) will also illuminate
when the ignition switch is in the on position and the engine is not running.
(2) Engine Critical-fault Warning Light (RED) - Illuminates after a critical fault occurrence,
which shutdowns the engine.
(3) Low Fuel Level Indicator Light (AMBER) - Illuminates when level in the fuel tank is low.
As an option, the vehicle shut downs when low fuel level is detected.
(4) Hydraulic Oil Overheating Temperature Indicator Light (RED) - Illuminates when
hydraulic oil temperature is above the normal operating range, and will automatically shut
down the engine.
(5) Basket Parked Indicator Light (GREEN) - Illuminates when the main boom is resting
centered on the boom support frame and the jib boom is fully retracted.
(6) Knuckle Out-of-level Warning Light (RED) - Illuminates when the boom knuckle is out of
level. If this occurs, the automatic boom control system determines that either the basket
or jib has to be repositioned to either remain level or avoid collision with the truck drivers
cab. Boom lowering is inhibited if the light is on.
(7) Air Brake Low Pressure Warning Light (RED) - Illuminates when air pressure in braking
system is below minimum permissible. The parking brake will automatically engage when
indicator light is illuminated.
(8) Wait-to-start Indicator Light (AMBER) - Illuminates when engine is in the warm up stage
prior to being started. When light turns off, warm up cycle is complete and engine is ready
for start-up.
(9) Engine Non-critical Fault Caution Light (AMBER) - Illuminates during a non-critical fault
occurrence. The engine will not shutdown, but service must be performed.
(10) Hydraulic Oil Low Level Warning Light (RED) - Illuminates when hydraulic oil level in
hydraulic tank is below the normal operating level. Engine will shut down when illuminated.
(11) Boom Centered Indicator Light (GREEN) - Illuminates when boom is centered with
respect to the vehicles center line. This light must be on before resting the basket on its
chassis support.
(12) Boom Overload Warning Light (RED) - Illuminates when basket load exceeds the
maximum permissible load. Boom controls remain functional.
(13) Air Pressure Gauges (Optional) - Indicate air pressure in accumulator tanks for front and
rear service brakes.
1-2
OPERATION
Page 11
October 2013
1 2 3 4 5 6 13
AIR AIR
PRESSURE PRESSURE
FRONT SERVICE REAR SERVICE

RESERVOIR RESERVOIR
7 8 9 10 11 12
NOTE: SWITCH CONFIGURATION AND INDICATOR LIGHTS PROVIDED DEPEND ON

THE ENGINE TYPE, AND CUSTOMER OPTIONS.
Figure 9
DRIVERS CAB INDICATORS AND WARNING LIGHTS PANEL
1-2
Page 12
October 2013
INDICATORS AND WARNING LIGHTS PANEL
1. NON-CHARGING 2. ENGINE CRITICAL 3. LOW FUEL LEVEL 4. HYDRAULIC OIL
WARNING LIGHT FAULT WARNING INDICATOR OVER-HEATING.
G
5. BASKET PARKED 6. KNUCKLE 7. AIR BRAKE LOW 8. WAIT-TO-START
INDICATOR OUT-OF-LEVEL PRESSURE INDICATOR
!
9. ENGINE NON- 10. HYDRAULIC OIL 11. BOOM CENTERED 12. BOOM LIFTING
CRITICAL FAULT LOW LEVEL OVERLOAD
Figure 10
DRIVERS CAB INDICATORS AND WARNING LIGHTS PANEL - PICTOGRAMS
F. DRIVERS CAB HEATER CONTROL PANEL
The heater control panel allows the operator to adjust the temperature inside the drivers cabin.
This control panel is located to the right of the steering wheel column on the drivers cabin dash
panel (refer to Figure 11).
1 2
Figure 11
DRIVERS CAB HEATER CONTROL PANEL
1-2
OPERATION
Page 13
October 2013
(1) Ventilator Fan Switch - Four-position rotary switch for selecting heater fan speed.
(2) Heater Temperature Switch - Rotary switch for selecting temperature in vehicle drivers
cabin.
G. FLUID TANK LEVEL AND TEMPERATURE GAUGES PANEL
Located on the upper-right side of the drivers cab control panel, a standard gauge panel displays
fluid tank level and temperature gauge readings. A digital gauge panel is also available (refer to
Figure 12 and Figure 13).
(1) Water Tank Level Gauge (Optional) - Indicates level in water tank (Prop-mix option).
(2) Deicing Fluid Tank Level Gauge - Indicates fluid level in the deicing fluid tank.
(3) Anti-icing Fluid Tank Level Gauge - Indicates fluid level in the anti-icing tank.
(4) Deicing Fluid Temperature Gauge - Indicates the temperature of the deicing fluid in the
heater outlet manifold (water tank temperature on prop-mix).
DIGITAL PANEL
(OPTIONAL)
1 2 3 4
NOTE: DASHED LINE REPRESENTS OPTIONAL FEATURES.
Figure 12
FLUID TANK LEVEL AND TEMPERATURE GAUGES PANEL
1-2
Page 14
October 2013
FLUID TANK LEVEL AND TEMPERATURE GAUGES PANEL
1. WATER FLUID LEVEL 2. DEICING FLUID LEVEL 3. ANTI-ICING FLUID 4. HEATER OUTLET
(PROP-MIX OPTION) GAUGE LEVEL GAUGE TEMPERATURE
Figure 13
FLUID TANK LEVEL AND TEMPERATURE GAUGES PANEL - PICTOGRAMS
H. PROPORTIONAL MIX INDICATOR PANEL (OPTIONAL)
Proportional Mix (Prop-mix) provides pre-determined mix percentages that may vary according to
customer requirements and to comply with deicing standards. Refer to Figure 14 and Figure 15).
(1) Heater Operation Locked-out Indicator Light (AMBER) - Illuminates as heater locks out
when the water tank is empty.
(2) Proportional Mix Fault Indicator Light (RED) - Illuminates when proportional mix system
has failed to produce the proper glycol and water proportion percentages. Engine must be
stopped and restarted before spraying can re-start.
NOTE: PERCENTAGES MAY VARY ACCORDING

TO CUSTOMER REQUIREMENTS AND
DEICING STANDARDS.
1 3
25% 75% 100%
A R
G
R G
2
4 0% 50% 75%
Figure 14
PROPORTIONAL MIX INDICATOR PANEL (OPTIONAL)
1-2
OPERATION
Page 15
October 2013
PROPORTIONAL MIX PANEL (OPTIONAL) - PROPORTIONAL MIX BY %
1. HEATER OPERATION 2. PROPORTIONAL 3. BOOM AND NOZZLE 4. HEATER AND PUMPS
LOCKED-OUT MIX FAULT WARNING FREEZE WARNING PLUMBING FREEZE
INDICATOR INDICATOR WARNING
%
Figure 15
PROPORTIONAL MIX INDICATOR PANEL - PICTOGRAMS
(3) Boom and Nozzle Freeze Protection Warning Indicator Light (GREEN) - Illuminates
when the boom or nozzle contains a fluid proportion above 50%, protected from freezing.
NOTE: IT MAY BE NECESSARY TO MANUALLY INCREASE THE GLYCOL-TO-WATER

PROPORTION OF THE SPRAY MIX TO A RATIO GREATER THAN 50% TO AVOID
FREEZING. ONCE FLUID AT A RATIO OF 50% OR GREATER HAS BEEN SPRAYED
FOR 30 SECONDS, THE GREEN INDICATOR LIGHT WILL ILLUMINATE.
(4) Heater and Pumps Plumbing Freeze Protection Indicator Light (GREEN) - Illuminates
indicating that a safe percentage of deice fluid is in the water system and pumps and
plumbing are protected from freezing. Purging of the pumps and heater is required.
Actuate the purge switch in basket which will begin an automatic process where the water
in the two water pumps, the heater coil, and the associated pipe work will be replaced by
glycol. When the cycle is finished, the green indicator light turns on.
I. DRIVERS CAB DRIVING PANEL
The driving panel is located in the center console inside the drivers cabin. This panel holds
vehicle directional drive switch, drive speed and operation switch, and a two-man and one-man
drive and operation (optional) switch (refer to Figure 16 and Figure 17).
(1) Forward Drive Direction Switch with Indicator (GREEN) - Illuminates when actuated.
Press the top end of the rocker switch to select forward movement of the vehicle.
(2) Reverse Drive Direction Switch with Indicator (GREEN) - Illuminates when actuated.
Press the bottom end of the rocker switch to select reverse movement.
NOTE: AFTER STOPPING THE VEHICLE, POSITION THE F-N-R (FORWARD-NEUTRAL-

REVERSE) SWITCH IN THE MIDDLE POSITION AND APPLY PARKING BRAKE.
(3) Neutral Indicator Light (AMBER) - Illuminates when the drive direction switch is in neutral
position (center position).
(4) Park Brake Warning Light (RED) - Illuminates when parking brakes are applied. This
light must be off before start moving the vehicle.
NOTE: THE PARKING BRAKE PULL AND PUSH SWITCH IS LOCATED IN THE CENTER
CONSOLE INSIDE THE DRIVERS CAB. PULL UP THE SWITCH TO APPLY THE PARK
BRAKE, AND PUSH IN TO RELEASE THE PARK BRAKE.
1-2
Page 16
October 2013
(5) Rabbit Speed Drive Mode Switch (WHITE) - Illuminates when actuated. Press the top
end of the rocker switch to select rabbit speed and put the deicer in propel mode. The
heater can be on when in propel mode, but the fluid delivery system and boom movement
are disabled.
(6) Turtle Speed Drive Mode Switch (WHITE) - Illuminates when actuated. This speed must
be selected for the vehicle to be in deicing operation mode. In deicing or operation mode,
the speed is limited to approximately 6 km/h (4 mph). The fluid delivery systems and the
boom operation are enabled. The engine will run at high idle in deicing mode.
NOTE: WHEN THE BOOM IS OUT OF THE RESTING POSITION, THE VEHICLE IS
AUTOMATICALLY IN DEICING MODE REGARDLESS OF THE POSITION OF THE
DRIVE SPEED MODE SWITCH.
(7) One-man Drive Operation Mode Switch with Indicator Light (AMBER) (Optional) -
Illuminates when actuated. Press the top end of the two-position rocker switch to enable.
(8) Two-man Drive Operation Mode Switch with Indicator Light (GREEN) (Standard) -
Illuminates when actuated. Press the bottom end of the two-position rocker switch to
activate.
1 3 5 7 9
F N 1
P 2
2 4 6 8 10
Figure 16
DRIVERS CAB DRIVING PANEL
1-2
OPERATION
Page 17
October 2013
DRIVERS CAB DRIVING PANEL
1. FORWARD 2. REVERSE 3. NEUTRAL 4. PARK BRAKE 5. RABBIT SPEED
DIRECTION DIRECTION INDICATOR ON INDICATOR DRIVE MODE
F R N P
6. TURTLE SPEED 7. ONE-MAN DRIVE 8. TWO-MAN DRIVE 9. LOW LEVEL FUEL 10. MANUAL
DRIVE MODE OPERATION OPERATION WARNING OVERRIDE
MODE MODE
1 2
Figure 17
DRIVERS CAB DRIVING PANEL - PICTOGRAMS
NOTE: THE VEHICLE IS STANDARD PROVIDED WITH TWO-MAN DRIVE OPERATION MODE.
THE OPTION WITH ONE-MAN DRIVE OPERATION MODE IS AVAILABLE FOR BOTH
THE OPEN AND ENCLOSED BASKET OPTIONS. A TWO-MAN MODE SWITCH IS ALSO
PROVIDED WITH THE ONE-MAN DRIVE OPERATION MODE OPTION.
(9) Low Fuel Level Shutdown (Optional) - When fuel level is low with approximately one
quarter of the fuel tank capacity in reserve, the engine will automatically stop when low fuel
level is detected and the low fuel warning light (amber) on the driving panel illuminates for
over 30 seconds. The engine can only be restarted using the MANUAL OVERRIDE switch
(10).
(10) Manual Override Momentary Switch (Optional) - Pressing and holding this switch will
enable restarting the engine until the fuel tank is refilled.
J. DRIVERS CAB BOOM CONTROL PANEL
The boom control panel is located in the drivers cab on the center console. This panel is
arranged by function, using three-position momentary switches (refer to Figure 18 and Figure 19).
NOTE: BOOM WILL OPERATE AT CREEP SPEED WHEN ACTUATED FROM THE BOOM
CONTROL PANEL. THE CREEP SPEED FOR EACH FUNCTION CAN BE ADJUSTED
BY MAINTENANCE PERSONNEL.
Boom control switches are mostly three-position momentary contact switches (rocker type
switches) spring-loaded to the center (OFF) position when released.
NOTE: THE BOOM ENABLE SWITCH MUST BE HELD DOWN AT THE SAME TIME THE
INTENDED BOOM FUNCTION CONTROL SWITCH IS ACTUATED.
(1) Rotate Boom to the Left - Depress the left end of the rocker switch to rotate the boom to
the left.
(2) Jib Boom Lower - Depress the left end of the rocker switch to lower the jib boom.
1-2
Page 18
October 2013
(3) Boom Lowering - Depress the left end of the rocker switch to lower the boom.
(4) Boom Telescopic Retracting (Optional) - Press down on the left end of rocker switch to
retract the boom when extended. Refer to Specifications in Chapter 1, Section 4 for
maximum extension of the boom.
(5) Boom Enable Switch - Depress the left end of the switch to enable boom controls to
operate the boom. Hold the enable switch down while depressing any other boom function
switch.
11
PARKING
BOOM CONTROL
JOYSTICK (OPTIONAL)
1 6
2 7
8
3
9
4
5
PARKING
10
11
Figure 18
DRIVERS CAB BOOM CONTROL PANEL
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OPERATION
Page 19
October 2013
BOOM CONTROL PANEL
1. BOOM ROTATE 2. JIB BOOM 3. BOOM 4. BOOM 5. BOOM ENABLE
LEFT LOWER LOWERING RETRACTING SWITCH
6. BOOM ROTATE 7. JIB BOOM 8. BOOM 9. BOOM 10. PARKING BRAKE

RIGHT LIFTING LIFTING EXTENDING SWITCH
PARKING
Figure 19
DRIVERS CAB BOOM CONTROL PANEL - PICTOGRAMS
(6) Rotate Boom to the Right - Depress down on the right end of the rocker switch to rotate
the boom to the right.
(7) Jib Boom Lifting Switch -Depress the right end of the rocker switch to elevate the jib
boom.
(8) Boom Lifting Switch - Depress the right end of the rocker switch to elevate the boom.
(9) Boom Telescopic Extending (Optional) - Press down on the right end of rocker switch to
extend the telescopic boom. Refer to Specifications in Chapter 1, Section 4 for maximum
extension of the boom.
(10) Parking Brake Switch - Pull up the parking brake control valve knob to apply the parking
brakes, and push down to release the parking brakes.
(11) Boom Control Joystick (Optional) - The optional joystick allows the driver to perform all
boom functions described in the previous paragraphs (refer to Figure 18).
K. DRIVERS CAB IGNITION SWITCH
NOTE: REFER TO FIGURE 20 AND FIGURE 21.
(1) Ignition Switch - Three-position switch with off, on, and starter positions.
(2) OFF Position ( 0 ) - At this point all electrical circuits in the vehicle are disconnected.
When the switch is moved from the ON position to the OFF position, the engine is shut
down, parking brakes are applied and power is disconnected from the system.
(3) ON Position ( I ) - Moving the switch to the ON position will provide electrical current to all
systems. The ignition is disabled 40 seconds after ignition is switched on.
NOTE: THE WAIT-TO-START INDICATOR (AMBER) IN THE INDICATORS AND WARNING

LIGHTS PANEL WILL ILLUMINATE WHEN THE SWITCH IS TURNED TO THE ON
POSITION. THIS INDICATOR MUST BE OFF BEFORE STARTING THE ENGINE.
1-2
Page 20
October 2013
(4) Start Engine (START) - When turning the switch to the start position, the starter motor
will crank the engine. Once the engine starts, the switch must be released returning to the
ON position.
NOTE: VEHICLES WITH AUTO SHUT DOWN OPTION HAVE A TIMED HEATER AND
SHUTDOWN SEQUENCE. THE IGNITION IS DISABLED FORTY (40) SECONDS AFTER
IGNITION SWITCH IS TURNED ON. IF THE ENGINE HAS NOT STARTED WITHIN THIS
TIME, TURN THE IGNITION SWITCH TO THE OFF POSITION AND TURN IT TO ON
AGAIN BEFORE STARTING THE ENGINE.
Figure 20
DRIVERS CAB IGNITION SWITCH PANEL
DRIVERS CAB IGNITION SWITCH PANEL

1. OFF POSITION 2. ON POSITION 3. ENGINE START
Figure 21
DRIVERS CAB IGNITION SWITCH PANEL - PICTOGRAMS
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OPERATION
Page 21
October 2013
L. DRIVERS CAB INSTRUMENT PANEL
Located to the right of the steering wheel, this panel contains gauges and indicators to monitor
the vehicle while driving (refer to Figure 22 and Figure 23).
(1) Fuel Level Gauge - Displays fuel level in tank in one-eighth increments. If the unit is
placed into one-man drive operation mode, the gauge in the driver's cab is disabled and
the gauge in the operators basket is activated (optional feature).
(2) Speedometer Gauge - Displays vehicle speed in km/h (kilometers per hour) on the inner
dial, and mph (miles per hour) on the outer dial. The embedded odometer records the
accumulated mileage of the vehicle. Refer to Specifications in Chapter 1, Section 4 for
vehicles maximum speeds.
(3) Voltmeter Gauge - Displays battery voltage when the engine is off, and indicates the
electrical system voltage from the charging system when the engine is running.
1 2 3
FUEL VOLT
SPEEDOMETER
TEMP OIL
4 5 6 7 8 9
Figure 22
DRIVERS CAB INSTRUMENT PANEL
1-2
Page 22
October 2013
INSTRUMENT PANEL
1. LEFT TURN SIGNAL 2. HIGH BEAM LIGHTS 3. HAZARD WARNING 4. RIGHT TURN SIGNAL
INDICATOR INDICATOR LIGHTS INDICATOR
Figure 23
DRIVERS CAB INSTRUMENT PANEL - PICTOGRAMS
(4) Coolant Temperature Gauge - Displays engine cooling system temperature in F

(Fahrenheit degrees) on the upper section, and C (Celsius degrees) on the lower section.
(5) Left Turn Signal Indicator Light (GREEN) - Illuminates when directional signal lights to
the left are actuated with the turn signal light lever (multi-function control lever switch).
(6) High-beam Lights Indicator (BLUE) - Headlights produce lighting beams at two heights.
This indicator illuminates when the high beams are activated. This also deactivates the
lower projection beams.
(7) External Power Warning Light (RED) (Optional) - Illuminates to indicate that the vehicle
is connected to an external power source for cold weather conditions.
CAUTION
ENSURE TO DISCONNECT EXTERNAL AC POWER SOURCE PRIOR TO MOVING THE

VEHICLE. FAILURE TO COMPLY MAY RESULT IN DAMAGE TO VEHICLE, OR OTHER
PROPERTY!
(8) Right Turn Signal Indicator Light (GREEN) - Illuminates when directional signal lights to
the right are actuated with the turn signal light lever (multi-function control lever switch).
(9) Oil Pressure Gauge - Displays engine oil pressure in psi (upper section) and kPa (lower
section) when engine is running.
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OPERATION
Page 23
October 2013
M. DRIVERS CAB ROOF WIPER AND WASHER CONTROL PANEL
2 3
Figure 24
DRIVERS CAB ROOF WIPER AND WASHER CONTROL PANEL
WIPER AND WASHER CONTROL PANEL

2. ROOF WIPER SWITCH 3. ROOF WASHER SWITCH
Figure 25
DRIVERS CAB ROOF WIPER AND WASHER CONTROL PANEL - PICTOGRAMS
(1) Hazard Warning Lights Switch - Activates the flashing warning lights to indicate the
vehicle is disabled, moving slow in traffic lanes, or parked. This switch has two positions
ON / OFF.
(2) Drivers Cab Roof Wiper Switch - Three-position (OFF / LOW / HIGH) rocker switch to
activate and select speed for the wiper motor for the drivers cab roof window.
(3) Drivers Cab Roof Washer Switch - Two-position (ON / OFF) rocker switch with a
momentary contact that will return to the off position when released. Activates washer
motor to apply washer fluid on the top view glass.
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Page 24
October 2013
N. EMERGENCY AND LIGHTING PANEL
This panel holds the emergency hydraulic pump switch, emergency stop push-button switch,
chassis work lights, and headlights and parking lights (refer to Figure 26 and Figure 27).
(1) Emergency Hydraulic Pump Switch - Two-position (OFF / ON) momentary rocker switch
to activate the emergency hydraulic pump, which can only be operated when the engine is
not running. Depress the bottom end of the rocker switch to energize the emergency pump
and hold it for continuous operation. Refer to Emergency Procedures in Chapter 1,
Section 3.
(2) Emergency Stop Push-button Switch - Two-position (ON / OFF) push-button switch.
Depress to activate and twist to release. When actuated the engine will shutdown, boom
will cease operation, and parking brakes will engage. All power will be deactivated except
for the emergency pump, and vehicle lights which will remain functioning. The optional red
light will illuminate when the E-stop is depressed (enabled).
1 2 3
Figure 26
DRIVERS CAB EMERGENCY AND LIGHTING PANEL
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OPERATION
Page 25
October 2013
EMERGENCY AND LIGHTING PANEL
1. EMERGENCY 2. PARKING LIGHTS 3. HEADLIGHTS 4. CHASSIS FLOOD
HYDRAULIC PUMP SWITCH LIGHTS
Figure 27
DRIVERS CAB EMERGENCY AND LIGHTING PANEL - PICTOGRAMS
(3) Headlights and Parking Lights Switch - Three-position rocker switch. Depress the
bottom end to turn lights OFF. Depress to the middle position to activate the parking lights.
Depress the top position to activate both the parking lights and headlights.
(4) Chassis Floodlights (Optional) - Two-position (OFF / ON) rocker switch. Depressing the
switch activates optional lighting beneath chassis, increasing ground visibility.
NOTE: EMERGENCY STOP (E-STOP) PUSH-BUTTON SWITCHES ARE LOCATED IN THE

DRIVERS CAB AND OPERATORS BASKET. ON VEHICLES TO BE OPERATED IN THE
EUROPEAN UNION, TWO (2) ADDITIONAL E-STOP SWITCHES ARE LOCATED ON
THE SIDES OF THE VEHICLE.
O. DRIVERS CAB TOP WINDOW DEFROSTER (OPTIONAL)
DRIVERS CAB
TOP WINDOW DEFROSTER
DEFROSTER SWITCH
Figure 28
TOP WINDOW DEFROSTER (OPTIONAL)
1-2
Page 26
October 2013
4. OPEN BASKET CONTROLS AND INDICATORS
The Tempest Aircraft Deicer is provided with one of two configurations: rectangular open basket
(standard), and round open basket (optional). In both cases, the open basket contains controls and
indicators within the control panels (refer to Figure 29 and Figure 30).
NOTE: CONTROL PANEL DESIGNS AND CONFIGURATIONS MAY VARY DEPENDING ON

CUSTOMER SPECIFICATIONS, STANDARDS AND REQUIREMENTS.
INTERCOM
BOX
(OPTIONAL)
OPERATOR
CONTROL
PANEL
FLOOD LIGHTS
(OPTIONAL)
EMERGENCY
STOP
(E-STOP)
JOYSTICK
ASSEMBLY
BOX
NOTE: OPEN BASKET SHOWN WITH LEFT SIDE CONTROLS, AND CENTER
ENCLOSURE FOR JOYSTICK ASSEMBLY (OPTIONAL).
Figure 29
RECTANGULAR OPEN BASKET
1-2
OPERATION
Page 27
October 2013
OPERATORS PROPORTIONAL MIX
BOOM CONTROL CONTROL PANEL CONTROL PANEL
PANEL (Figure 33, Figure 34) (Figure 35, Figure 36)
(Figure 31, Figure 32)
EMERGENCY
STOP
ROUND BASKET (OPTIONAL)
Figure 30
OPEN BASKET CONTROL PANELS
A. OPEN BASKET BOOM CONTROL PANEL
A joystick with operational boom controls is provided standard. Additional controls are available
with the Extended Reach (XR) option (refer to Figure 30, Figure 31 and Figure 32).
(1) Joystick Switch - Multi-position switch for operating the boom. An enable switch is
incorporated in the handle to activate the boom enable valve.
(2) XR Boom Switch (Optional) - Two-position toggle switch to extend and retract the
extended-reach boom.
(3) Boom Fault Light (RED) (XR Only) - Illuminates when a PLC failure is detected.
(4) XR Boom Warning Light (AMBER) (XR Only) - Flashing light is activated if the main
boom has been lowered to an angle of less than 60 when the XR boom is extended.
Further boom lowering will be inhibited.
NOTE: TO RESET THE FLASHING WARNING LIGHT, ELEVATE THE MAIN BOOM OR FULLY
RETRACT THE TELESCOPIC XR BOOM.
1-2
Page 28
October 2013
ENABLE
SWITCH
JOYSTICK SWITCH
XR
3
> 60
6 5
REFER TO FIGURE 32
FOR PICTOGRAMS
625-7892
Figure 31
OPEN BASKET BOOM CONTROL PANEL
1-2
OPERATION
Page 29
October 2013
OPEN BASKET BOOM CONTROL PANEL
TELESCOPIC EXTENDED REACH (XR) OPTION

2) EXTEND XR BOOM 2) RETRACT XR BOOM 3) BOOM FAULT 4) XR BOOM FAULT
INDICATOR WARNING
> 60
STANDARD BOOM FUNCTION

5) JIB MOVE UP 5) JIB MOVE DOWN 6) BOOM UP 6) BOOM DOWN
6) BOOM ROTATE TO THE RIGHT 6) BOOM ROTATE TO THE LEFT
Figure 32
OPEN BASKET BOOM CONTROL PANEL - PICTOGRAMS
(5) Jib Movement Switch - Two-position momentary switch to enable jib adjustment.
(6) Boom Movement - Boom movement up, down, rotate to the right, rotate to the left.
B. OPEN BASKET OPERATORS CONTROL PANEL
Operations from inside the open basket are described below (refer to Figure 33 and Figure 34).
(1) Emergency Pump Switch - Two-position (OFF / ON) momentary contact toggle switch
activates the emergency hydraulic pump. This switch is inactive when the engine is
running.
(2) Low Fuel Level Indicator Light (AMBER) - Illuminates when fuel level in engine fuel tank
is low.
(3) Boom Overload Warning Light (RED) - Illuminates when basket load exceeds maximum
permissible. Boom controls remain functional during boom overload.
(4) Boom In-range Light (AMBER) - Illuminates when boom is within an angle of 20 from
the center.
NOTE: FOR VEHICLES EQUIPPED WITH XR BOOM - INDICATOR LIGHT WILL FLASH IF MAIN
BOOM IS MOVED BEYOND 20 FROM THE CENTER WHEN TELESCOPIC SECTION
OF THE BOOM IS EXTENDED. FURTHER ROTATION OF THE BOOM IS INHIBITED.
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October 2013
(5) Boom Centered Indicator Light (GREEN) - Illuminates when boom is centered.
(6) Basket Parked Indicator Light (GREEN) - Illuminates when basket is resting in clevis on
front bumper of the vehicle, indicating jib is fully retracted.
(7) Knuckle Out-of-level Warning Light (RED) - Illuminates when the boom knuckle is out of
level. If this occurs, the automatic boom control system determines that either the basket
or jib has to be repositioned to either remain level or avoid collision with the truck drivers
cabin. Boom lowering is inhibited.
(8) Basket Proximity Alarm and Warning Light (RED) (Optional) - The basket is optionally
fitted with a warning system that will notify the operator when it is close to an object.
Sensors are located below the basket, warning when the basket is above an object, but it
will not detect objects around or above the basket.
The warning system consists of one visual indicator and one audible alarm. The alarm is
only active while the switch to enable the boom is activated, and the boom is above 15
from the rest position. When the boom is above 15 and the boom enable switch is
actuated and one of the sensors detects an object, the red light will start flashing, the
audible alarm will sound, and the boom motion speed will change to creep mode.
As a test when the boom is at rest, the collision light should flash (the sensor sees the
ground) but the alarm should not sound. Regular inspections must be performed for
proper operation of the warning system. Refer to Preventative Maintenance in Chapter 2,
Section 3.
NOTE: THE WARNING SYSTEM WILL NOT STOP THE BOOM MOVEMENT. THE OPERATOR
IS RESPONSIBLE FOR VISUALLY SURVEYING THE AREA BEFORE MOVING THE
BOOM. THE SYSTEM IS AN AID FOR DETECTING OBJECTS IN BLINDSPOTS.
WARNING
BEFORE AND DURING ANY MOVEMENT. DO NOT SOLELY RELY ON THE BASKET
PROXIMITY WARNING SYSTEM TO DETECT OBJECTS OR PREVENT A COLLISION. FAILURE
1-2
OPERATION
Page 31
October 2013
1 2 3 4 5 6 7
21
20
19
18
8
17
16 9
3M
15 14 13 12 11 10
REFER TO FIGURE 34
FOR PICTOGRAMS
NOTE: DASHED LINES REPRESENT OPTIONAL FEATURES.
Figure 33
OPEN BASKET OPERATORS CONTROL PANEL
1-2
Page 32
October 2013
OPEN BASKET OPERATORS CONTROL PANEL
1 EMERGENCY 2 LOW FUEL 3 BOOM 4 BOOM IN RANGE 5 BOOM IN
PUMP SWITCH INDICATOR OVERLOAD INDICATOR CENTER
7 KNUCKLE OUT 8 ALARM, BASKET 9 BASKET 10 FLOODLIGHT

6 BASKET PARKED
OF LEVEL PROXIMITY LEVELING SWITCH
11 TWO-STEP 12 PRINTER CONTROL SWITCH 13 DEICING PUMP SPEED SWITCH

DEICING ALARM (OPTIONAL) (OPTIONAL)
(OPTIONAL) PRINTER MODE SPRAY MODE RABBIT MODE TURTLE MODE
D
3M
A
15 FLUID SELECT 17 READY TO 18 EMPTY DEICING
14 DEICING PUMP 16 FLUID PUMP
SWITCH SPRAY FLUID TANK
SWITCH INDICATOR
(OPTIONAL) INDICATOR INDICATOR
I D
0 0
A
19 EMPTY ANTI- 21 FIRE
20 EMPTY WATER
ICING FLUID SUPPRESSION
TANK INDICATOR
TANK INDICATOR SYSTEM
Figure 34
OPEN BASKET OPERATORS CONTROL PANEL - PICTOGRAMS
(9) Basket Leveling Switch - Three-position momentary toggle switch to level the basket
when the boom is out of level. This switch is enabled only when the boom is in the rest
position.
(10) Flood Lights Switch - Two-position (OFF / ON) toggle switch activates flood lights.
(11) Two-step Deicing Alarm (Optional) - Available only with Advanced Printer option.
The two-step deicing alarm will activate an audible alarm and red warning light in the
basket, if spraying of deicing fluid has not been followed by spraying of anti-icing fluid
within the three-minute time delay. The alarm can be reset by selecting anti-icing fluid
(item 16) AND spraying anti-icing fluid. The alarm can be temporarily suppressed by
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OPERATION
Page 33
October 2013
actuating the momentary switch (item 12). Unless anti-icing fluid has been sprayed, the
alarm will activate again after the specified time delay.
The two-step deicing alarm is activated by a signal from the Advanced Printer. The time
delay can be changed by using the Handheld Interface of the printer and entering
Advanced Setup. This setup procedure is password-protected and should only be
accessed by authorized personnel. The time delay for the two-step deicing alarm must be
set in accordance with locally applicable procedures and regulations.
(12) Printer Control Switch (Optional) - Enables printer to record fluid usage. Turn switch to
SPRAY (I) position and enter operator and flight details into the printer to allow fluid to be
dispensed. After job is complete, turn switch to PRINT (0) position to generate printed
copy. If printer fails to enable spraying of fluid, a printer override switch is located inside
the basket control panel.
(13) Deicing Pump Speed Switch (Optional) - Two-position toggle switch for selecting speed
of deicing fluid pump. This option is not available with proportional mix (prop-mix).
(a) RABBIT for operating the pump in fast speed for maximum nozzle fluid flow.
(b) TURTLE for operating the pump in slow speed for reduced nozzle fluid flow.
(14) Deicing Pump Switch (Optional) - Two-position (OFF / ON) momentary toggle switch
activates starting and stopping the fluid delivery pump. I is momentary ON and 0 is
OFF.
(15) Fluid Select Switch - Three-position toggle switch which selects deicing fluid (D), or
anti-icing fluid (A). Center position (0) is OFF.
(16) Ready To Spray Indicator Light (GREEN) - Illuminates when fluid spray is at the correct
temperature to spray. On prop-mix vehicles it indicates that the temperature of the fluid
being sprayed is correct.
(17) Fluid Pump Indicator Light (GREEN) - Illuminates when the spray system is enabled.
(18) Empty Deice Tank Indicator Light (AMBER) - Illuminates when deicing fluid tank is
empty and the fluid pump has been shutdown.
(19) Empty Anti-icing Fluid Tank Indicator Light (AMBER) - Illuminates when anti-icing fluid
tank is nearly empty and the fluid pump has been shut down.
(20) Empty Water Tank Indicator Light (AMBER) - Illuminates when water tank is empty and
the fluid pump has been shutdown.
(21) Fire Suppression System Indicator Light (RED) - Illuminates when fire detection system
is activated and vehicle fire extinguishers are actuated.
C. OPEN BASKET PROP-MIX CONTROL PANEL (OPTIONAL)
Operation of this panel from inside the open basket are described below (refer to Figure 35 and
Figure 36).
(1) High and Low Fluid Flow Switch - Two-position (HIGH / LOW) toggle switch to select
fluid flow.
1-2
Page 34
October 2013
(2) Water Tank Temperature Indicator Light (WHITE) - Illuminates when heater has finished
the heat cycle.
(3) Deicing Tank Fluid Temperature Indicator Light (WHITE) - Illuminates when deicing
fluid in the tank reaches the preset (adjustable) level.
(4) Deicing Fluid Pre-defined Percentages Switch - Seven-position rotary switch to select
six pre-defined percentages from 0% to 100% of deicing fluid in proportion with water, and
50% for the reel hose. The reel position must be selected to use the ground reel hose from
the front of the vehicle. These percentages depend on customer specifications. When a
different percentage is selected, continue spraying for a few seconds for the change to
reach the nozzle.
(5) Percentage Selected Ready Indicator Light (GREEN) - Illuminates when the
proportional mix system is enabled and working correctly.
(6) Percentage Fault Warning Light (RED) - Illuminates if the proportional mix system is
unable to maintain the correct ratio for more than 20 seconds. If illuminated, the engine
power must be cycled before spraying can be re-started.
(7) Boom and Nozzle Freeze Protection Indicator Light (GREEN) - Illuminates when the
boom line is protected against freezing. If not illuminated and there is risk of freezing,
select 50% or greater and spray for approximately 30 seconds until the light illuminates.
(8) System Purge Switch - Two-position (OFF / ON) switch to activate the purge system.
The purge system is used when the vehicle is left in freezing conditions for prolonged
periods where there is a risk of the pumps or heater freezing. Actuating the switch will
initiate a fully automatic purge cycle where the water in the pumps and heater will be
replaced with 100% glycol. It takes around two minutes and uses approximately 410 L
(108 U.S. gallons) of glycol.
(9) Deicing Fluid Heater, Pumps, and Plumbing Freeze Protection Indicator Light
(GREEN) - Illuminates when purge cycle is complete. Refer to paragraph (8) above.
(10) Deicing Fluid Heater ON Indicator Light (GREEN) - Illuminates when the deicing fluid
heater is ON and working normally.
(11) Deicing Fluid Heater Switch - Two-position (OFF / ON) switch to operate the deicing fluid
heater. Hold the switch in the UP position for approximately five seconds to start the
heater.
(12) Deicing Fluid Heater No-flame (Misfire) Warning Light (RED) - Illuminates when the
deicing fluid heater has failed to start or gone off during operation. The firing sequence
must be restarted.
1-2
OPERATION
Page 35
October 2013
1 2 3 4 5 6
30%
15% 50%
0% 60%
100%
H 2O D
>50 %
12 11 10 9 8 7
REFER TO FIGURE 36
FOR PICTOGRAMS 624-9176-002
Figure 35
OPEN BASKET PROP-MIX CONTROL PANEL
1-2
Page 36
October 2013
OPEN BASKET PROPORTIONAL MIX CONTROL PANEL
1) DEICING FLUID 2) WATER 3) DEICING FLUID

TEMPERATURE TEMPERATURE
HIGH FLOW LOW FLOW READY TO SPRAY READY TO SPRAY
H 2O D
4) FRONT REEL 5) PROPORTIONAL MIX 6) PROPORTIONAL 7) BOOM AND NOZZLE

SYSTEM ENABLED MIX FAULT FREEZING
8) DEICING FLUID TO 9) FLUID HEATER, 10) DEICING FLUID 12) DEICING FLUID
WATER ABOVE 50% PUMPS, AND HEATER ON HEATER NO-FLAME
PLUMBING FREEZING (MISFIRE)
>50 %
Figure 36
OPEN BASKET PROP-MIX CONTROL PANEL - PICTOGRAMS
1-2
OPERATION
Page 37
October 2013
5. ENCLOSED BASKET CONTROLS AND INDICATORS
The enclosed basket has its rotational point at the center of gravity under the operators seat. This
optional basket has all controls for boom, nozzle, and fluids integrated within two advanced joysticks
that enable the operator for efficient deicing and anti-icing operations (refer to Figure 37).
The two-man drive operation mode is standard for the enclosed basket, and a one-man drive operation
mode is available as an option. Controls in the enclosed basket include:
Left pod with boom control joystick

Right pod with nozzle control joystick
Overhead indicator light panel
Emergency stop push-button (E-stop)
NOTE: THE ENCLOSED BASKET CONTROL PANEL DESIGN CAN VARY DEPENDING ON
CUSTOMER SPECIFICATIONS, STANDARDS AND REQUIREMENTS.
RIGHT SIDE POD DRIVE CONTROL BOX

CONTROLS (ONE-MAN DRIVE OPERATION
MODE OPTION)
NOZZLE CONTROL
JOYSTICK
ANTI-ICE
NOZZLE
LEFT SIDE POD

CONTROLS
TASK FORCE
DEICE NOZZLE
BOOM
CONTROL
JOYSTICK
FUSE BOX
NOZZLE TURRET
ASSEMBLY BASKET HEATER
Figure 37
ENCLOSED BASKET WITH BOOM AND NOZZLE CONTROL JOYSTICKS
1-2
Page 38
October 2013
A. ENCLOSED BASKET OPERATOR CONTROLS
Boom controls are located on the left pod joystick, and nozzle controls on the right pod joystick
(refer to Figure 37 and Figure 38).
(1) Boom Control Joystick Switch - Contains switches to rotate, raise, and lower the boom
(refer to Figure 43).
(2) Drive Control Box (Optional) - This is provided as part of the one-man drive operation
option (refer to Figure 50).
(3) Nozzle Control Joystick Switch - Contains switches to operate the vehicles nozzle (refer
to Figure 44).
(4) Basket Leveling Switch - A momentary contact switch for manual leveling of the enclosed
basket. Depress front of rocker switch to lower front of basket or the back of the rocker to
raise the front of the basket up. The boom must be in the rest position for this switch to be
active.
(5) Boom Overloaded Warning Light (RED) - This light illuminates whenever the momentum
caused by the angle and distance from the center of the vehicle exceeds the maximum
permissible load on the boom.
(6) Basket Door or Seat Belt Not Latched Warning Light (RED) - This warning light
illuminates when the basket door is not properly latched, or when the seat belt is not
buckled up.
(7) Emergency Stop Push Button Switch - Depressing this E-stop push-button will shut
down the vehicle, allowing only to lower the boom as an emergency procedure (refer to
Chapter 1, Section 3, Emergency Procedures).
(8) Left Side Window Washer Switch - Two-position (OFF / ON) momentary rocker switch to
activate the window washer.
(9) Left Side Window Wiper Switch - Three-position (OFF / LOW / HIGH) rocker switch to
activate and select speed for the window wiper.
(10) Nozzle Spotlight Switch - Three-position (OFF / ON / AUTO) rocker switch. In the Auto
position, the lamp is turned off when the spray trigger is pressed.
(11) Lower Front Window Washer Switch - Two-position (OFF / ON) momentary rocker
switch to activate the window washer.
(12) Lower Front Window Wiper Switch - Three-position (OFF / LOW / HIGH) rocker switch
to activate and select speed for the window wiper.
(13) Right Side Window Washer Switch - Two-position (OFF / ON) momentary rocker switch
to activate the window washer.
(14) Right Side Window Wiper Switch - Three-position (OFF / LOW / HIGH) rocker switch to
activate and select speed for the window wiper.
1-2
OPERATION
Page 39
October 2013
NOTE: JOYSTICK MODELS
2 MAY VARY.
1 3
4
DRIVE CONTROL BOX
5 (ONE-MAN DRIVE 16
OPERATION MODE
OPTION)
6
17
11
7
12 18
8 13
9 14
10 15
19
LEFT SIDE POD RIGHT SIDE POD

BOOM CONTROL NOZZLE CONTROL
Figure 38
ENCLOSED BASKET OPERATOR CONTROLS
1-2
Page 40
October 2013
ENCLOSED BASKET CONTROLS
4) BASKET LEVELING 5) BOOM OVERLOADED 6) BASKET DOOR OR 7) EMERGENCY STOP
SWITCH INDICATOR SEAT BELT NOT (E-STOP) PUSH
LATCHED OR FASTEN BUTTON
(NO GRAPHIC)
8) LEFT SIDE WINDOW 9) LEFT SIDE WINDOW 10) NOZZLE SPOTLIGHT 11) FRONT WINDOW
WASHER SWITCH WIPER SWITCH SWITCH WASHER SWITCH
12) FRONT WINDOW 13) RIGHT SIDE WINDOW 14) RIGHT SIDE WINDOW 15) BASKET TOP
WIPER SWITCH WASHER SWITCH WIPER SWITCH FLOODLIGHTS
16) READY TO SPRAY 17) FLUID DELIVERY 18) EMERGENCY PUMP

INDICATOR PUMP RUNNING (E-PUMP) SWITCH
Figure 39
ENCLOSED BASKET OPERATOR CONTROLS - PICTOGRAMS
(15) Basket Top Floodlights - Two-position (OFF / ON) rocker switch to activate floodlights.
(16) Ready-to-spray Indicator Light (GREEN) - Illuminates when the system has reached the
necessary conditions and it is ready to spray the fluid.
(17) Fluid-delivery Pump Running Indicator Light (GREEN) - Illuminates when the pump
that delivers the fluid is energized.
(18) Emergency Pump Switch - Two-position (OFF / ON) momentary rocker switch to activate
the emergency hydraulic pump, which can only be operated when the engine is not
running. Depress the bottom end of the rocker switch to energize the emergency pump
Section 3.
(19) XR Boom Display (Optional) - Set up for the XR Boom system. This display is part of the
XR Boom option. Refer to Troubleshooting in Chapter 2, Section 6 for the corresponding
PDM screens for the XR Boom system, which includes screens for system settings.
1-2
OPERATION
Page 41
October 2013
B. ENCLOSED BASKET AIRFIRST AND PROP-MIX CONTROLS (OPTIONAL)
The following optional controls are offered for one-man drive operation mode, and proportional
mix (refer to Figure 40).
(1) Fuel Gauge (One-man Mode Option) - Indicates vehicle fuel level in the main fuel tank.
(2) Cycle Complete Indicator Light (WHITE) (One-man Mode Option) - Illuminates once
the heater cycle is complete.
(3) Heater Misfire Indicator (RED) (One-Man Mode Option) - Illuminates warning that the
heater flame did not start or extinguished during the heating cycle.
(4) Anti-ice Fluid Level Gauge (One-man Mode Option) - Indicates level of anti-icing fluid in
tank. Optionally Water Level Gauge in Two-tank Prop-mix.
(5) AirFirst Lube System Switch (Optional with AirFirst) - Two-position (OFF / ON)
switch to activate the lube oil system in the AirFirst system. This switch must be ON and
the AirFirst Ready light (9) steady for the AirFirst system to be enabled.
Section 3.
(7) Heater Status Indicator Lights (GREEN / WHITE / CLEAR) (One-man Mode Option) -
Illuminates GREEN when the heater is ON, and WHITE / CLEAR when fluid is circulating.
(8) Deicing Fluid Level Gauge (One-man Mode Option) - Indicates level of deicing fluid in
tank.
1-2
Page 42
October 2013
NOTE: JOYSTICK MODELS MAY VARY.
13
6
1
14
11
50%
2 15
1
7
12 16
3
8
4 17
9
5 18
10
RIGHT SIDE POD RIGHT SIDE POD
ONE-MAN DRIVE MODE ONE-MAN DRIVE MODE

WITH AIRFIRST WITH PROP-MIX
Figure 40
ENCLOSED BASKET AIRFIRST AND PROP-MIX CONTROLS
1-2
OPERATION
Page 43
October 2013
ENCLOSED BASKET AIRFIRST AND PROP-MIX CONTROLS
2) CYCLE COMPLETE 3) HEATER MISFIRE 4) ANTI-ICE FLUID 5) AIRFIRST LUBE
INDICATOR GAUGE INDICATOR LEVEL GAUGE SYSTEM SWITCH
(NO GRAPHIC)
6) EMERGENCY PUMP 7) HEATER STATUS 8) DEICING FLUID 9) AIRFIRST READY

(E-PUMP) SWITCH INDICATOR LEVEL GAUGE INDICATOR
10) AIRFIRST LUBE 13) WATER HEATING 14) DEICING FLUID TANK 15) FAULT DETECTED
SYSTEM WARNING CYCLE COMPLETE TEMPERATURE WARNING INDICATOR
16) PURGE SYSTEM 17) HEATER AND PUMPS 18) BOOM AND NOZZLE
INDICATOR FREEZE INDICATOR FREEZE INDICATOR
Figure 41
ENCLOSED BASKET AIRFIRST AND PROP-MIX CONTROLS - PICTOGRAMS
(9) AirFirst Ready Indicator Light (GREEN) (AirFirst Option) - Flashing light means the
lube system is warming up. Illuminates steady when AirFirst system is ready for use.
(10) AirFirst Lube System Warning Light (RED) (Optional with AirFirst) - Indicates a
lube system failure. Do not use the AirFirst system and immediately notify maintenance
personnel.
(11) Percentage Select Switch (Prop-mix Option) - Seven-position rotary switch to select
pre-defined percentages (0% to 100%) of deicing fluid in proportion with water.
Percentages are dependent on customer specifications. When a different percentage is
selected, spray for a few seconds for change to reach the nozzle.
(12) Purge Enable Switch (Prop-mix Option) - Two-position (OFF / ON) rotary switch to
activate the purge system.
The purge system is used when the vehicle is left in freezing conditions for prolonged
periods where there is a risk of the pumps or heater freezing. Activating the switch will
initiate a fully automatic purge cycle where the water in the pumps and heater will be
replaced with 100% glycol. It takes approximately two minutes and 410 L (108 gal.) of
glycol.
1-2
Page 44
October 2013
(13) Water Cycle Complete Indicator Light (WHITE) (Prop-mix Option) - Illuminates when
the water reaches 82 C (180 F) completing the heating cycle.
(14) Deicing Fluid Tank Temperature Indicator (WHITE) (Prop-mix Option) - Illuminates
when the fluid in the deicing tank reaches a temperature of 40 C (104 F) (adjustable).
(15) Fault Detected Warning Light (RED) (Prop-mix Option) - Illuminates when a fault is
detected while the purge system is active.
(16) Purge System Indicator Light (WHITE) (Prop-mix Option) - Illuminates when the purge
system is active.
(17) Deicing Fluid Heater and Pumps Plumbing Freeze Protection Indicator Light
(GREEN) (Prop-mix Option) - Illuminates when purge cycle is complete.
(18) Boom and Nozzle Freeze Protection Indicator Light (GREEN) (Prop-mix Option) -
Illuminates when the boom is protected against freezing.
If the light is not illuminated and there is risk of freezing, select 50% or greater and spray
for approximately 30 seconds until the light illuminates.
C. ENCLOSED BASKET BLENDUP OPTIONAL CONTROLS
The following optional controls are offered for one-man drive operation mode, and blendUP
NOTE: FOR OTHER INDICATORS, SWITCHES, AND FUNCTIONS RELATED TO THIS PANEL,
REFER TO A. ENCLOSED BASKET OPERATOR CONTROLS, AND B. ENCLOSED
BASKET AirFirst AND PROP-MIX CONTROLS (OPTIONAL). REFER ALSO TO
FIGURE 38 THROUGH FIGURE 41.
(1) BlendUP Display (Optional) - Set up for the blendUP system. This display is part of
the blendUP fluid system option. Refer to Troubleshooting in Chapter 2, Section 6 for
the corresponding PDM screens for this system, which includes screens for system
operation and settings.
(2) Cycle Complete Indicator Light (WHITE) (One-man Mode Option) - Illuminates once
the heater cycle is complete.
(3) AirFirst Ready Indicator Light (GREEN) (AirFirst Option) - Flashing light means the
system is warming up. Illuminates steady when AirFirst system is ready for use.
Section 3.
1-2
OPERATION
Page 45
October 2013
NOTE: REFER TO FIGURE 38 AND FIGURE 40 FOR OTHER GAUGES AND
CONTROLS, AND FIGURE 39 AND FIGURE 41 FOR PICTOGRAMS
INFORMATION.
RIGHT SIDE POD
WITH AIRFIRST AND

BLENDUP OPTIONS
Figure 42
ENCLOSED BASKET BLENDUP CONTROLS
1-2
Page 46
October 2013
D. ENCLOSED BASKET BOOM CONTROL JOYSTICK SWITCH
The boom control joystick is located on the left side pod (refer to Figure 38 and Figure 43).
(1) Push Button Switch - Inactive.
(2) XR Boom Extend (Optional) - Press down to extend the telescopic boom. Refer to
Specifications in Chapter 1, Section 4 for maximum extension of the boom
(3) XR Boom Retract (Optional) - Press down to retract the telescopic boom when extended
(4) Push Button Switch - Inactive.
(5) Jib Boom Retract - Momentary push-button switch lowers the basket by retracting the jib
boom
(6) Jib Boom Extend - Momentary push-button switch raises the basket by extending the jib
boom.
(7) Boom Enable Trigger Switch - This momentary trigger switch must be actuated for any
boom control switch to operate.
NOTE: THE BOOM CONTROL JOYSTICK IS ADJUSTED IN A WAY THAT WHEN ACTUATING
THE JOYSTICK, IT STARTS SLOWLY AND THEN RAMPS UP TO A POINT BEFORE
REACHING THE END OF THE SPECIFIC MOVEMENT. THE SAME EFFECT WILL BE
OBSERVED WHEN MOVING THE BOOM IN THE OPPOSITE SENSE
NOTE: THE BOOM CONTROL JOYSTICK IS A MULTI-SWITCH CONTROL DEVICE THAT

ALLOWS FOR SIMULTANEOUS MOVEMENT OF THE BOOM, SUCH AS ROTATING
AND RAISING, OR LOWERING.
(8) Boom Lower - Momentarily pushing the joystick forward lowers the boom.
(9) Boom Raise - Momentarily pulling the joystick backwards raises the boom.
(10) Boom Rotate Left - Momentarily pushing the joystick to the left rotates the boom to the left
(counterclockwise).
(11) Boom Rotate Right - Momentarily pushing the joystick to the right rotates the boom to the
right (clockwise).
1-2
OPERATION
Page 47
October 2013
2 3
1 4
6 5
FRONT VIEW OF LEFT JOYSTICK
8
10 LOWER BOOM
ROTATE
BOOM
TO THE
7 LEFT
9
11
RAISE BOOM
ROTATE
BOOM
TO THE
RIGHT
SIDE VIEW
OF LEFT
JOYSTICK
Figure 43
ENCLOSED BASKET BOOM CONTROL JOYSTICK (LEFT SIDE POD)
1-2
Page 48
October 2013
E. ENCLOSED BASKET NOZZLE CONTROL JOYSTICK
The nozzle control joystick is located on the right side pod (refer to Figure 38 and Figure 44).
(1) Nozzle Flow Selection Switch - Two-position toggle switch to select between high and
low fluid flow.
(2) Fluid Selection Switch - Three-position toggle switch to select deicing fluid (D) or anti-
icing fluid (A). The switch is OFF at the center position (0).
(3) AirFirst Enable Switch (Optional) - Two-position (ON / OFF) toggle switch. This switch
must be in the ON position for the AirFirst system to operate.
(4) AirFirst Fluid Enable Switch (Optional) - Two-position (ON / OFF) toggle switch. This
switch must be in the ON position for the fluid system to operate in conjunction with the
AirFirst system.
(5) AirFirst Air Injection Switch (Optional) - Three-position momentary rocker switch with
OFF at the center position. Depressing the top of the rocker switch bursts fluid from the
spray nozzle (side by side), and depressing the bottom of the switch injects fluid into the air
stream from AirFirst nozzle.
(6) Spray Pattern Switch - Three-position momentary rocker switch with OFF at the center
position. Depressing the top of the rocker switch adjusts the fluid spray to a straight stream
pattern, and depressing the bottom of the switch adjusts the nozzle to a fan spray pattern.
(7) Fluid Enable Trigger Switch - This momentary trigger switch must be actuated for any
fluid or AirFirst control switch to operate.
NOTE: THE NOZZLE CONTROL JOYSTICK IS A MULTI-SWITCH CONTROL DEVICE THAT

ALLOWS FOR SIMULTANEOUS MOVEMENT OF THE NOZZLE, SUCH AS MOVING
SIDEWAYS, AND RAISING OR LOWERING.
NOTE: MOVING THE NOZZLE UP OR DOWN, AND RIGHT OR LEFT ALLOWS THE OPERATOR
TO CONTROL AND AIM THE FLUID AND AIR STREAM TO THE TARGET AREA OF THE
AIRCRAFT.
(8) Nozzle Lower - Momentarily pushing the joystick forward lowers the nozzle.
(9) Nozzle Raise - Momentarily pulling the joystick backwards raises the nozzle.
(10) Nozzle Left - Momentarily pushing the joystick to the left moves the nozzle to the left.
(11) Nozzle Right - Momentarily pushing the joystick to the right moves the to the right.
(12) Basket Rotate - Momentarily twisting the joystick handle clockwise rotates the operators
basket to the right, and twisting it counter-clockwise rotates the basket to the left.
1-2
OPERATION
Page 49
October 2013
2 3
1 4
6 5
FRONT VIEW OF RIGHT JOYSTICK
8
10
LOWER NOZZLE
MOVE
NOZZLE
TO THE
LEFT
9
RAISE NOZZLE
11
MOVE
NOZZLE
TO THE
RIGHT
12
SIDE VIEW ROTATE 12

OF RIGHT BASKET TO
JOYSTICK THE RIGHT ROTATE
BASKET TO
THE LEFT
Figure 44
ENCLOSED BASKET NOZZLE CONTROL JOYSTICK (RIGHT POD)
1-2
Page 50
October 2013
F. ENCLOSED BASKET OVERHEAD INDICATOR LIGHTS PANEL
This panel is located inside the enclosed basket in the upper section of the basket, in front of the
operators seat (refer to Figure 45 and Figure 46).
(1) Basket Parked Indicator Light (GREEN) - Illuminates when the basket is at the rest point
in the front of the vehicle.
(2) Knuckle Auto Leveling Mode Warning Light (RED) - Illuminates when the boom knuckle
is out of level. If this occurs, the automatic boom control system determines that either the
basket or jib has to be repositioned to either remain level or avoid collision with the truck
drivers cab. Boom lowering is inhibited when illuminated.
(3) Boom Centered Indicator Light (GREEN) - Illuminates when the front of the boom is
located at the center of the vehicle.
(4) Boom In Range Indicator Light (AMBER) - Illuminates when the front of the boom is
between 20 of the vehicle center line.
(5) Fire Suppression Activated Warning Light (RED) - Illuminates when the fire
suppression system is activated.
NOTE: THE OPERATOR MUST SUSPEND DEICING AND ANTI-ICING OPERATIONS AND
LOWER THE BASKET IMMEDIATELY AS A PRECAUTIONARY MEASURE, IF THE FIRE
SUPPRESSION SYSTEM IS ACTIVATED. DO NOT ASSUME THE FIRE SUPPRESSION
SYSTEM WILL SUFFOCATE THE FIRE IMMEDIATELY. TAKE ALL NECESSARY
PRECAUTIONS.
(6) Low Fuel Indicator Light (AMBER) - Illuminates when the level of the diesel fuel in the
tank is low. There is certain amount of fuel left in the tank after this light illuminates, but the
operator must refill the fuel tank as soon as possible.
(7) Deicing Tank Level Low Indicator Light (AMBER) - Illuminates when the level of the
deicing fluid in the tank is below the minimum. The operator must refill the fluid tank before
continuing deicing operations.
(8) Anti-icing Tank Level Low Indicator Light (AMBER) - Illuminates when the level of the
anti-icing fluid in the tank is low. The operator must refill the fluid tank before continuing
anti-icing operations.
(9) Water Tank Level Low Indicator Light (AMBER) (Optional) - Illuminates when the water
level in the tank is low. The operator must refill the water tank before continuing operating.
Pure Fluid Tank Level Low Indicator Light (AMBER) (BlendUP Option) - Illuminates
when the water level in the tank is low. The operator must refill the water tank before
continuing operating.
(10) Proportional Mix (Prop-mix) System Fault Warning (RED) (Optional) - Illuminates
when there is a failure of the prop-mix system.
(11) Deice Mode Selected Indicator Light (WHITE) - Illuminates when the deicing mode has
been activated.
1-2
OPERATION
Page 51
October 2013
1, 2 3, 4 5, 6 7, 8 9, 10 11, 12 13, 14 15, 16 17, 18
% !
OVERHEAD PANEL (OP)
1) BASKET PARKED (GREEN) 7) DEICING TANK LEVEL LOW (AMBER)
2) KNUCKLE AUTO LEVELING MODE (RED) 8) ANTI-ICING TANK LEVEL LOW (AMBER)
3) BOOM CENTERED (GREEN) 9) WATER TANK LEVEL LOW (AMBER)
4) BOOM IN RANGE (AMBER) 10) PROP-MIX SYSTEM FAULT (RED)
5) FIRE SUPPRESSION ACTIVATED (RED) 11) DEICE MODE SELECTED (WHITE)
6) LOW FUEL (AMBER) 12) ANTI-ICE MODE SELECTED (WHITE)
Figure 45
ENCLOSED BASKET OVERHEAD INDICATOR PANEL
1-2
Page 52
October 2013
13) TASK FORCE NOZZLE SELECT (WHITE) 17) XR BOOM LESS THAN 60 (AMBER)
> 60
14) JOHN BEAN NOZZLE SELECT (WHITE) 18) XR BOOM PLC FAILURE (RED)
15) AIRFIRST SYSTEM ON (WHITE) 9) PURE TANK LEVEL LOW (AMBER)
16) AIRFIRST FLUID INJECTION ON (WHITE) (BLENDUP OPTIONAL)
Figure 46
ENCLOSED BASKET OVERHEAD INDICATOR PANEL (CONT.)
(12) Anti-ice Mode Selected Indicator Light (WHITE) - Illuminates when the anti-icing mode
has been activated.
(13) Task Force Nozzle (High Flow) Light (WHITE) - Illuminates when the high flow from the
nozzle control joystick on the right side pod is activated (refer to Figure 44).
(14) John Bean Nozzle (Low Flow) Light (WHITE) - Illuminates when the nozzle control
joystick on the right side pod is activated (refer to Figure 44).
(15) AirFirst ON Indicator Light (WHITE) (Optional) - Illuminates when the AirFirst
system is activated.
(16) AirFirst Fluid Injection ON Indicator Light (WHITE) (Optional) - Illuminates when the
nozzle control switch to inject fluid into the air stream is activated.
(17) Extended Reach (XR) Boom Less Than 60 (AMBER) (Optional) - Illuminates when the
XR boom is at an angle greater than 60 from the horizontal.
(18) Extended Reach (XR) PLC Failure (RED) (Optional) - This warning light illuminates if
there is a failure in the XR booms Programmable Logical Controller (PLC).
1-2
OPERATION
Page 53
October 2013
G. ENCLOSED BASKET HEATER CONTROL PANEL
The heater control panel inside the enclosed basket is located on the left side of the operators
seat (refer to Figure 47).
This diesel fuel reservoir for the heater is located behind the enclosed basket on the left side.
Refer to Specifications in Chapter 1, Section 4 for heater fuel tank capacity.
(1) Heater Control Switch - Five-position rotary switch with OFF (0) and four heat levels from
1 to 4.
(2) Heater Air Selection Switch - Two-position rotary control switch for selecting fresh air or
re-circulate.
(3) Heater and Ventilator Selection Switch - Two-position rocker switch allows for selecting
heater or ventilator.
1 2 3
0
1
4
624-5885-054
Figure 47
ENCLOSED BASKET HEATER CONTROL PANEL
1-2
Page 54
October 2013
H. AIRFIRST SYSTEM (OPTIONAL WITH ENCLOSED BASKET)
The Tempest AirFirst system option has a turret-mounted air nozzle on the front of the enclosed
basket with the purpose of removing loose snow from the aircraft. Fluid nozzles are also
mounted on the turret and are used for de-icing and applying anti-icing fluid (refer to Figure 48).
The AirFirst system can be used as an air assist when applying deicing and anti-icing fluids. All
controls for boom operation, AirFirst system, fluid nozzles, and selecting the fluid system are
located on the two control joystick switches mounted on the left and right pods inside the
enclosed basket.
RIGHT SIDE POD
NOZZLE CONTROL
JOYSTICK
LEFT SIDE
POD
TASK FORCE
DEICE NOZZLE
BOOM
CONTROL
JOYSTICK
AirFirst NOZZLE ANTI-ICE NOZZLE
Figure 48
ENCLOSED BASKET WITH AIRFIRST SYSTEM (OPTIONAL)
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I. NOZZLE GAUGES (OPTIONAL WITH ENCLOSED BASKET)
Pressure and temperature gauges mounted on the nozzle allow the operator to monitor from the
basket the condition of the fluids being sprayed (refer to Figure 49).
PRESSURE
GAUGE
TEMPERATURE
GAUGE
VIEW FROM
ENCLOSED BASKET
OPERATORS SEAT
Figure 49
PRESSURE AND TEMPERATURE NOZZLE GAUGES (OPTIONAL)
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6. DRIVE AND OPERATION MODE OPTIONS
A. ONE-MAN DRIVE OPERATION CONTROL JOYSTICK (OPTIONAL)
The one-man drive operation joystick is located on a control box the operator can use to drive the
vehicle (refer to Figure 37, Figure 38 and Figure 50). The control box is stowed above the
enclosed basket heater when not in use.
NOTE: VEHICLE MAY BE EQUIPPED WITH JOYSTICKS DIFFERENT THAN SHOWN.
(1) One-man Drive Operation Indicator Light (AMBER Flashing) - This light illuminates
flashing when the vehicle system is switched from two-man drive operation mode into
one-man mode.
(2) Parking Brake Warning Light (RED) - This indicator light illuminates whenever the
parking brake is applied.
(3) Hydrostatic Transmission In-neutral Indicator Light (AMBER Steady) - This light
illuminates solid when the propel direction switch (F-N-R) is placed in neutral position.
(4) Propel Direction F-N-R Switch - Three-position switch allows the operator to select
direction of travel F (forward), or R (reverse). The center position N places the vehicle
in neutral.
(5) Horn Push-button Switch - Depressing this momentary switch actuates the vehicles
horn.
(6) Propel Speed Selection Switch - Three-position toggle switch allows the operator to
select travel speed RABBIT (fast), TURTLE (slow), or SNAIL (very slow or creeping).
(7) Drive Enable Trigger Switch - Pulling this trigger switch enables the vehicle to propel
according to the direction of travel selected (forward or reverse) when one-man drive
operation mode is enabled.
NOTE: THE ONE-MAN DRIVE CONTROL JOYSTICK IS A MULTI-SWITCH CONTROL DEVICE

THAT ALLOWS FOR SIMULTANEOUS MOVEMENT OF THE VEHICLE IN MORE THAN
ONE DIRECTION, SUCH AS MOVING FORWARD WHILE STEERING LEFT OR RIGHT.
(8) Steer Left Switch - Moving the joystick to the left proportionally steers the vehicle to the
left.
(9) Steer Right Switch - Moving the joystick to the right proportionally steers the vehicle to the
right.
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2 3
1 4
6 5
F-N-R SWITCH
(ENCLOSED BASKET
FRONT VIEW OF CENTER JOYSTICK (OPEN BASKET) JOYSTICK)
8
STEER
LEFT
7
9
STEER
RIGHT
SIDE VIEW
OF CENTER
JOYSTICK
Figure 50
ONE-MAN DRIVE - OPERATION CONTROL JOYSTICK (OPTIONAL)
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B. SIDE REACH BYPASS SWITCH (OPTIONAL WITH ONE-MAN DRIVE)
WARNING
DO NOT ATTEMPT TO USE THE SIDE REACH BYPASS OPTION IF NOT PROPERLY TRAINED.
EXTENDING THE BOOM SIDEWAYS MAY TIP THE VEHICLE TO ONE SIDE. ALWAYS REMOVE
KEY WHEN LEAVING THE VEHICLE UNATTENDED. FAILURE TO COMPLY MAY RESULT IN
VEHICLE!
This option is available with ONE-MAN DRIVE.
(1) An access key is required to use this optional feature. Normal boom operation does not
require the use of the key.
(2) Insert the key and rotate the switch clockwise to enable SIDE REACH BYPASS.
(3) Return the switch to the initial position to disable this option, and remove the key.
ONE-MAN DRIVE
JOYSTICK (OPTIONAL)
BYPASS KEY
SWITCH
SIDE REACH SIDE REACH

BYPASS DISABLES BYPASS ENABLED
(NORMAL OPERATION) (KEY REQUIRED)
Figure 51
ONE-MAN SIDE REACH BYPASS SWITCH (OPTIONAL)
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C. MONITOR AND CAMERA CLOSED-CIRCUIT TV (CCTV) SYSTEM
The CCTV system is an aid to drive the vehicle (refer to Figure 52, Figure 53 and Figure 54).
NOTE: THE CCTV SYSTEM IS OPTIONAL IN TWO-MAN OPERATION MODE ONLY VEHICLES,
BUT IT IS INCLUDED WITH THE ONE-MAN DRIVE OPERATION MODE OPTION. IF
PROVIDED, THE MONITOR IS LOCATED INSIDE THE CAB OR THE ENCLOSED
BASKET.
(1) LED Indicator (GREEN) - Illuminates when the monitor is ON.
(2) One-man Drive Mode Auto Activate - Monitor will turn on automatically displaying the
view from the rear camera when in one-man drive mode and drive in reverse is selected.
(3) Camera Source Switch - Two-position switch to select either Camera or RCA input
jackets.
(4) Camera Selection Switch - Two-position switch to select either Camera 1 (REAR) or
Camera 2 (FRONT) from the enclosed basket.
(5) Day and Night Switch - Two-position switch to change contrast levels to aid in viewing the
monitor screen.
(6) Contrast Adjustment Knob - Rotate to adjust contrast.
(7) Brightness Adjustment Knob - Rotate to adjust brightness.
(8) Volume Level Adjustment Knob - Rotate to adjust volume. Microphones are built into the
cameras.
MONITOR
DRIVERS CAB
Figure 52
CCTV SYSTEM - DRIVERS CAB MONITOR
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NOTE: THERE ARE TWO DIP SWITCHES ON THE REAR OF THE MONITOR TO SELECT
EITHER NORMAL OR MIRRORED IMAGE FOR EACH CAMERA. CAMERA 1 (REAR)
MUST BE SET TO MIRRORED AND CAMERA 2 (FRONT) MUST BE SET TO
NORMAL.
POWER CAMERA 1 CAMERA 2

INPUT
1 2 NORMAL
OUTPUT
MIRRORED
MONITOR MONITOR
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
2BSK
REAR VIEW FRONT VIEW
Figure 53
CCTV SYSTEM - ENCLOSED BASKET MONITOR
MONITOR FRONT
AND REAR VIEWS
POWER
CONNECTOR
CAMERA 1, CAMERA 2
CONNECTORS INPUT AND OUTPUT
CONNECTORS
Figure 54
CCTV SYSTEM - MONITOR FRONT AND REAR VIEWS
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7. OPERATING PROCEDURES
WARNING
DO NOT ATTEMPT TO OPERATE THE VEHICLE WITHOUT BEING PROPERLY TRAINED IN
OPERATION AND SAFETY REQUIREMENTS. FAILURE TO COMPLY MAY RESULT IN
VEHICLE!
WARNING
BEFORE AND DURING ANY MOVEMENT. FAILURE TO COMPLY MAY RESULT IN SERIOUS
WARNING
BEFORE STARTING THE POWER UNIT, ENSURE POWER MODULE IS SECURELY FASTENED,
AND ALL PERSONNEL ARE CLEAR OF THE VEHICLE. FAILURE TO COMPLY MAY RESULT
THE VEHICLE!
WARNING
DO NOT OPERATE EQUIPMENT WHILE UNDER INFLUENCE OF DRUGS, ALCOHOL, OR
MEDICATION THAT MAY PREVENT FULL ABILITY TO CONTROL THE VEHICLE. FAILURE TO
WARNING
DOORS MUST BE LATCHED AND SEAT BELTS AND SAFETY HARNESSES PROPERLY WORN
BY OCCUPANTS OF THE CAB AND BASKET AT ALL TIMES WHILE VEHICLE IS IN OPERATION
AND OPERATOR IS IN BASKET. FAILURE TO COMPLY MAY RESULT IN SERIOUS BODILY
WARNING
FOLLOW ALL APPLICABLE PROCEDURES AND REGULATIONS FOR OPERATING IN THE
AIRPORT AND FOR HANDLING AIRCRAFT. FAILURE TO COMPLY MAY RESULT IN SERIOUS
WARNING
PROMPTLY. FAILURE TO COMPLY MAY RESULT IN SERIOUS BODILY INJURY, DEATH, OR
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WARNING
DO NOT EXCEED 6 KM/H (4 MPH) WITH A PERSON IN THE OPERATORS BASKET. FAILURE
WARNING
NEVER ATTEMPT TO LIFT THE BOOM WITH A LOAD THAT EXCEEDS THE SAFETY RATING.
WARNING
DO NOT OPERATE BOOM (AERIAL DEVICE) WHEN WIND SPEED IS ABOVE 74 KM/H
(46 MPH). FAILURE TO COMPLY MAY RESULT IN SERIOUS BODILY INJURY, DEATH, OR
CAUTION
DO NOT USE HIGH-SPEED RANGE IF VEHICLE IS CLOSER THAN 3 M (10 FT.) TO AIRCRAFT.
FAILURE TO COMPLY MAY RESULT IN DAMAGE TO VEHICLE, OR OTHER PROPERTY,
INCLUDING THE AIRCRAFT!
CAUTION
ALWAYS STOP THE VEHICLE COMPLETELY BEFORE SHIFTING THE TRANSMISSION TO

CHANGE DIRECTION. FAILURE TO COMPLY MAY RESULT IN DAMAGE TO VEHICLE, OR
OTHER PROPERTY, INCLUDING THE AIRCRAFT!
NOTE: ALL EMERGENCY STOP SWITCHES MUST BE PULLED OUT AND THE VEHICLE MUST
BE IN NEUTRAL WITH THE PARKING BRAKE APPLIED BEFORE STARTING THE
ENGINE.
NOTE: ALLOW ENGINE TO IDLE (LESS THAN 1000 RPM) FOR APPROXIMATELY TWO
MINUTES TO PROPERLY COOL DOWN AND ENGINE TEMPERATURES TO STABILIZE
BEFORE SHUTTING ENGINE DOWN.
A. STARTING ENGINE
(1) Turn optional battery disconnect switch to the ON position.
(2) Place F-N-R switch in NEUTRAL position.
(3) Turn ignition switch to the START position to crank the engine, and release the switch
when the engine starts.
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If the engine fails to start after a few attempts, shutdown the unit and notify maintenance
personnel. Refer to the engine operation manual in Manufacturers Appendices in
Chapter 5.
CAUTION
WHEN STARTING THE ENGINE, RELEASE THE IGNITION SWITCH IF THE ENGINE FAILS TO
START WITHIN 20 SECONDS. AFTER A SECOND ATTEMPT, ALLOW THE STARTER MOTOR
TO COOL DOWN FOR ONE MINUTE BEFORE ATTEMPTING TO RESTART THE ENGINE.
(4) After the engine starts, idle engine until the oil pressure gauge indicates normal oil
pressure. Oil pressure should rise within three seconds.
CAUTION
SHUT DOWN ENGINE IMMEDIATELY IF OIL PRESSURE INDICATOR LIGHT DOES NOT TURN
OFF WITHIN THREE SECONDS AFTER STARTING ENGINE. DO NOT ATTEMPT TO RESTART
ENGINE. NOTIFY MAINTENANCE PERSONNEL IMMEDIATELY. FAILURE TO COMPLY MAY
(5) Observe instrument panel to ensure that all indicators show normal operation and there is
sufficient fuel.
(6) Allow engine to warm up for several minutes.
NOTE: OBSERVE AIR PRESSURE GAUGES FOR PRESSURES IN THE BRAKE PNEUMATIC
ACCUMULATORS AND THAT THE WARNING INDICATOR LIGHT IS NOT ILLUMINATED
WHEN AIR PRESSURE IS ABOVE 4.8 BAR (70 PSI).
B. DRIVING VEHICLE - TWO-MAN DRIVE OPERATION MODE (STANDARD)
(1) Fasten seat belts.
(2) Depress the parking brake control knob to release the parking brakes and observe that
parking brake indicator light is off when brakes are released.
(3) Select F (forward) or R (reverse) depressing the corresponding switch on the drive
panel (drivers cab).
(4) Select RABBIT or TURTLE driving speed mode on the driving panel.
(5) Slowly depress the accelerator pedal to drive the vehicle.
(6) Stop the vehicle after moving a short distance, and ensure the brakes are working properly.
(7) When near the aircraft, stop the vehicle and place DRIVE MODE SELECT SWITCH in
DEICE mode for final positioning and deicing.
NOTE: VEHICLE SPEED IS AUTOMATICALLY LIMITED TO APPROXIMATELY 6 KM/H (4 MPH)

WHEN DEICE MODE (TURTLE) IS SELECTED ON THE DRIVE MODE SWITCH, OR IF
THE BOOM IS NOT STOWED ON THE BOOM REST.
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C. DRIVING VEHICLE - ONE-MAN DRIVE/OPERATION MODE (OPTIONAL)
(1) From driver's cab, ensure the F-N-R switch on the driving panel is in neutral.
(2) From driver's cab, on the driving panel, select DEICE mode (turtle) and ONE-MAN MODE.
(3) Release parking brake.
NOTE: THE PARKING BRAKE IS PROGRAMMED TO AUTOMATICALLY APPLY ONCE THE

DEICER IS PUT INTO ONE-MAN DRIVE/OPERATION MODE.
(4) Enter the enclosed basket and fasten seat belt. Fastening seat belt enables the boom and
one-man drive controls.
(5) Remove the one-man drive control box from storage area and ensure the F-N-R switch is
in NEUTRAL. Insert the drive control box connector in the socket in front of the seat, and
verify a steady light (AMBER) located on the control panel indicates NEUTRAL.
NOTE: THE ONE-MAN OPERATION MODE ACTIVATION WILL BE INDICATED BY A FLASHING

(AMBER) LIGHT LOCATED ON THE CONTROL PANEL.
(6) Select F (forward) or R (reverse) on the steering joystick.
NOTE: WHEN ONE-MAN OPERATION MODE IS SELECTED, JOYSTICK STEERING IS

ACTIVE. WHEN THE JOYSTICK IS RELEASED THE TIRES OF THE DEICER WILL
RETURN TO THE CENTER POSITION.
(7) Select the appropriate propel speed, SNAIL, TURTLE, or RABBIT.
(8) Release the parking brake by depressing the ENABLE switch on the steering joystick.
Verify that the parking brake indicator light is off when the brakes are released. The drive
speed mode can be changed at any time while driving either faster or slower.
NOTE: THE VEHICLE WILL ACCELERATE AND REMAIN AT A CONTROLLED SPEED FOR AS
LONG AS THE ENABLE SWITCH IS ACTIVATED.
(9) To stop the vehicle de-activate the ENABLE switch on the steering joystick. This will
re-apply the parking brake while simultaneously slowing the vehicle in a controlled manner
until the vehicle stops.
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D. PARKING VEHICLE
(1) Lower boom and stow boom on the rest.
(2) Two-man drive mode (Standard) - Apply parking brakes by pulling the parking brake control
valve up. Indicator light (RED) will illuminate when parking brakes are set.
(3) One-man drive mode (Optional) - Release the joystick and the parking brakes will
automatically apply. Return to the drivers cab and activate parking brake from there.
(4) Allow engine to idle (below 1000 rpm) for approximately two minutes to properly cool down
and allow engine temperatures to stabilize.
(5) Turn ignition switch to OFF to shut engine down.
(6) Turn optional battery disconnect switch to the OFF position.
E. HEATER OPERATION
(1) Heater Start-up
(a) Start and warm up engine.
(b) Press on the top end of the heater switch and hold depressed for approximately five
seconds until the HEATER START indicator light (GREEN) is illuminated.
(c) The Electronic Heater Controller (EHC) will automatically start and regulate the
heater for maximum heat increase without damage to the fluids. The EHC monitors
all relevant parameters and will switch off the heater in case of fault.
(d) After the flame has been established in the heater, the HEATER ON indicator light
(WHITE) will be illuminated on the top end of the heater switch and will remain
illuminated until the fluid is elevated to the maximum temperature and the heater
shuts down.
NOTE: IF THE MISFIRE INDICATOR LIGHT (RED) ILLUMINATES DURING THE START-UP OF
THE HEATER, A FLAME WAS NOT ESTABLISHED AND IT WILL REQUIRE ANOTHER
ATTEMPT TO RESTART THE HEATER. DEPRESS AND HOLD THE UPPER SWITCH
UNTIL THE RED INDICATOR LIGHT TURNS OFF.
(e) When the fluid is elevated to the preset temperature, the ready-to-spray (GREEN)
indicator lights on the heater panel and basket panel will illuminate.
NOTE: THE TEMPERATURE THAT THE READY-TO-SPRAY INDICATOR LIGHTS ILLUMINATE

IS ADJUSTABLE FOR SPECIFIC CUSTOMER REQUIREMENTS. THE DEFAULT
TEMPERATURE SETTING IS 82 C (180 F) ON THE EHC.
NOTE: IF THE HEATER FAILS TO START, CHECK THE OVER TEMPERATURE SWITCH ON
THE HEATER OUTLET MANIFOLD FOR BEING TRIPPED. PRESS THE RESET
BUTTON TO RESET THE SWITCH.
(2) Heater Shutdown - Normal Operation
When the fluid has reached the maximum temperature, the EHC will close the fuel valves
to stop all fuel flow and the heater shutdown sequence will begin. The flame indicator light
(WHITE) and the heater on indicator light (GREEN) on the heater start switch will go off
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and the cycle-complete (WHITE) indicator light will illuminate. At the end of the
three-minute purge period the blower and circulating pump will be turned off.
NOTE: DURING THE SHUTDOWN SEQUENCE THE HEATER BLOWER AND THE
CIRCULATING PUMP WILL CONTINUE TO RUN FOR THREE MINUTES TO COOL THE
HEATER DOWN, STABILIZE TEMPERATURES AND PURGE THE HEATER OF FUMES
FROM UNBURNED FUEL.
NOTE: DO NOT TURN OFF THE ENGINE BEFORE THE HEATER HAS COMPLETED THE
SHUTDOWN CYCLE. DOING SO MAY RESULT IN A FIRE ON RE-STARTING.
(3) Heater Shutdown Manually (Standard)
The heater may be shut down at any time by pressing down on the bottom end of the
heater switch until the heater on (WHITE) indicator light turns off.
NOTE: DURING THE SHUTDOWN SEQUENCE THE HEATER BLOWER AND THE
CIRCULATING PUMP WILL CONTINUE TO RUN FOR THREE MINUTES TO COOL THE
HEATER DOWN, STABILIZE TEMPERATURES AND PURGE THE HEATER OF FUMES
FROM UNBURNED FUEL.
NOTE: ALLOW ENGINE TO IDLE (LESS THAN 1000 RPM) FOR APPROXIMATELY TWO
MINUTES TO PROPERLY COOL DOWN AND ENGINE TEMPERATURES TO STABILIZE
BEFORE SHUTTING ENGINE DOWN.
(4) Heater Auto Shutdown (Optional)
The Auto Shutdown option allows the heater to operate until the fluid is to maximum
temperature and complete the heater shut down sequence. At the completion of the
heater shut down, the engine will continue to run an additional 51 seconds for stabilizing
temperatures and will then shut down.
(a) With the fluid heater operating, turn the vehicle ignition switch to the OFF position.
Vehicle lights may be left on.
(b) When fluid reaches maximum temperature, the heater will shut down and the EHC
will complete the heater shut down sequence.
(c) At the completion of heater shutdown the engine will shutdown after approximately
one minute. Vehicle lights will be turned off and parking brakes will remain applied.
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NOTE: NORTH AMERICAN HEAT
SYSTEM SHOWN.
STACK
TEMPERATURE
SWITCH
SET AT 760 C
FUEL (1400 F)
PRESSURE
GAUGE
OVER-TEMP
SWITCH
RESET
SWITCH
ELECTRONIC
HEATER
CONTROLLER
(EHC)
Figure 55
OPTIMAX HEAT SYSTEM
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F. AERIAL DEVICE - TWO-MAN DRIVE/OPERATION MODE (STANDARD)
NOTE: TWO-MAN MODE REQUIRES TWO PERSONS FOR DEICING OPERATIONS, ONE
PERSON IN THE DRIVER'S CAB TO DRIVE THE VEHICLE AND ONE PERSON IN THE
BASKET TO DEICE/ANTI-ICE THE AIRCRAFT.
(1) Driver: Start the engine.
(2) Operator: Enter the operators basket, and close the door.
Open Basket (Standard)
(a) Fasten restrain harness.
(b) Verify that the door indicator light (RED) (optional) next to the boom joystick turns
off.
Enclosed Basket (Optional)
(a) Adjust seat forward or backward accordingly for proper and comfortable reach of
joystick controls.
(b) Fasten seat belt.
(c) Verify that the door/seat belt indicator light (RED) on the left pod turns off.
NOTE: ENCLOSED BASKET CONTROLS WILL NOT BE ACTIVE UNTIL THE BASKET DOOR IS
CLOSED AND LATCHED AND THE OPERATOR HAS FASTENED THE SEAT BELT.
(d) Turn on basket heater (if required). Select fan or heat, and turn the thermostat to
desired temperature. The heater has an automatic purging cycle and takes several
minutes to switch on and off.
(e) Switch on fans, wipers, and interior/exterior lights as required.
(3) Driver/Operator: Check intercom operation. Ensure communication between driver and
operator is clear.
(4) Driver: Depress brake pedal, and depress drive switch in deice mode.
(5) Driver: Depress gear select switch in F (Forward) and proceed driving vehicle safely
towards the aircraft.
(6) Operator: Ensure that the operators basket is level, adjusting the basket level with the
leveling switch on the control panel (open basket) or the left pod (enclosed basket), if
required.
(7) Operator: Raise the jib boom by pressing the red enable trigger on the front of the joystick
and depressing the switch on the boom joystick (left hand joystick for the enclosed basket).
(8) Operator: Once the jib is more than five (5) degrees extended, raise the main boom by
pulling back on the boom joystick. The boom will not raise until the jib is five (5) degrees
extended. Rotate the boom by leaning the joystick over to the left or right. Rotate the
operators basket by twisting the nozzle joystick (right hand joystick for the enclosed
basket).
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NOTE: TO ENSURE SMOOTH MOVEMENTS, DEPRESS THE RED ENABLE TRIGGER
BEFORE MOVING THE JOYSTICK. SIMILARLY, RETURN THE JOYSTICK BACK TO
THE CENTER POSITION TO SMOOTHLY STOP MOVEMENT BEFORE RELEASING
THE ENABLE TRIGGER. BOOM AND BASKET CONTROLS ARE FULLY
PROPORTIONAL: MOVE JOYSTICK SLIGHTLY FOR SLOW MOVEMENT AND ALL THE
WAY FOR FAST MOVEMENT.
NOTE: BOOM AND BASKET CONTROLS REACH THE REQUIRED SPEEDS GRADUALLY
(RAMPING). IF THE CONTROLS ARE OUT OF ADJUSTMENT THE RAMPING
FUNCTION CAN RESULT IN A DELAYED REACTION TO THE CONTROL INPUTS.
QUALIFIED MAINTENANCE PERSONNEL CAN ADJUST BOOM SPEEDS AND
RAMPING TO MATCH THE OPERATIONAL REQUIREMENTS AND ELIMINATE
DELAYED REACTIONS.
(9) Operator: To stow the aerial device, rotate the boom until the centered indicator light
comes on. Lower the boom into the boom rest. If necessary, rotate the operators basket
to observe that the boom lands in the center of the boom rest. After the boom is in the
boom rest retract the jib boom until the basket platform sits in its rest and the boom parked
indicator light (GREEN) illuminates.
NOTE: IF THE BASKET IS NOT IN THE REST, WITH THE JIB BOOM FULLY RETRACTED, USE
THE BASKET LEVELING SWITCH TO RETRACT THE BASKET FURTHER.
NOTE: IF THE JIB BOOM IS RETRACTED, IT WILL RAISE AUTOMATICALLY FIVE (5)
DEGREES DURING BOOM LOWERING. IF THE OPERATORS BASKET IS OUT OF
LEVEL, IT WILL LEVEL AUTOMATICALLY DURING BOOM LOWERING. DURING AUTO
JIB-OUT AND AUTO-LEVELING THE BOOM LOWERING WILL AUTOMATICALLY BE
INTERRUPTED AND THE BASKET OUT-OF-LEVEL INDICATOR LIGHT (RED) WILL
ILLUMINATE.
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G. AERIAL DEVICE - ONE-MAN DRIVE/OPERATION MODE (OPTIONAL)
WARNING
BOOM CONTROLS ENABLE ANY COMBINATION OF BOOM MOVEMENTS AT THE SAME
TIME. SIMULTANEOUS MOVEMENTS ON DIFFERENT AXIS MAY DECEIVE AN OPERATORS
SENSES, CREATE VERTIGO, AND INCREASE THE CHANCE OF COLLISION, ESPECIALLY
WHEN THE VEHICLE IS DRIVING AT THE SAME TIME. LIMIT BOOM MOVEMENT TO A SINGLE
FUNCTION AT A TIME UNTIL EXPERIENCED WITH THE DEICER AND THE ENVIRONMENT.
NOTE: THE ONE-MAN DRIVE/OPERATION MODE ALLOWS ONE PERSON TO OPERATE THE
BOOM AND FLUID DISPENSING SYSTEM, AND ALSO DRIVE THE VEHICLE FROM THE
OPERATORS BASKET.
NOTE: A TEMPEST AIRCRAFT DEICER EQUIPPED WITH THE OPTIONAL ONE-MAN

OPERATION MODE MAY ALSO OPERATE IN TWO-MAN DRIVE/OPERATION MODE.
REFER TO F. AERIAL DEVICE - TWO-MAN DRIVE/OPERATION MODE (STANDARD).
From Drivers Cab (refer to Figure 17)
(1) Place F-N-R switch in N (Neutral).
(2) Start engine.
(3) Depress propulsion speed switch in DEICE mode (Turtle) and select ONE-MAN MODE on
the selector switch.
(4) Release parking brake.
From Operators Basket (refer to Figure 31 and Figure 33 for open basket, and Figure 50 for
enclosed basket)
(5) Enter the operators basket, and close the door.
(6) Open Basket: Fasten restrain harness. Verify that the door indicator light (RED)
(optional) next to the boom joystick turns off.
(7) Enclosed Basket: Fasten seat belt. Verify that the door/seat belt indicator light (RED) on
the left pod turns off.
NOTE: ENCLOSED BASKET CONTROLS WILL NOT BE ACTIVE UNTIL THE BASKET DOOR IS
CLOSED AND LATCHED AND THE SEAT BELT IS FASTENED.
(8) Remove the Drive Control Box from storage area and install in position (in front of the seat
for enclosed basket). Verify that the F-N-R switch is in N (Neutral), which is indicated by
a steady light (AMBER) located on the control panel.
(9) Enclosed Basket: Adjust seat forward/backward accordingly for proper and comfortable
reach of joystick controls.
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(10) Enclosed Basket: Turn on heater (if required). Select fan or heat, and turn the thermostat
to desired temperature. The heater has an automatic purging cycle and takes several
minutes to switch on and off.
(11) Enclosed Basket: Switch on fans, wipers, and interior/exterior lights as required.
(12) Place gear select switch in F (Forward) and proceed driving vehicle safely towards the
aircraft.
(13) Enclosed Basket: Ensure that the operators basket is level, adjusting the basket level
with the leveling switch on the left pod, if required.
(14) Raise the jib boom by pressing the red enable trigger on the front of the joystick and
depressing the switch on the boom joystick (left pod for the enclosed basket).
(15) Once the jib is more than five (5) degrees extended, raise the main boom by pulling back
on the boom joystick. The boom will not raise until the jib is five (5) degrees extended.
Rotate the boom by leaning the joystick over to the left or right. Rotate the operators
basket by twisting the nozzle joystick (right pod for the enclosed basket).
NOTE: TO ENSURE SMOOTH MOVEMENTS DEPRESS THE RED ENABLE TRIGGER BEFORE
MOVING THE JOYSTICK. SIMILARLY, RETURN THE JOYSTICK BACK TO THE
CENTER POSITION TO SMOOTHLY STOP MOVEMENT BEFORE RELEASING THE
ENABLE TRIGGER. BOOM AND BASKET CONTROLS ARE FULLY PROPORTIONAL:
MOVE JOYSTICK SLIGHTLY FOR SLOW MOVEMENT AND ALL THE WAY FOR FAST
MOVEMENT.
NOTE: BOOM AND BASKET CONTROLS REACH THE REQUIRED SPEEDS GRADUALLY
(RAMPING). IF THE CONTROLS ARE OUT OF ADJUSTMENT THE RAMPING
FUNCTION CAN RESULT IN A DELAYED REACTION TO THE CONTROL INPUTS.
QUALIFIED MAINTENANCE PERSONNEL CAN ADJUST BOOM SPEEDS AND
RAMPING TO MATCH THE OPERATIONAL REQUIREMENTS AND ELIMINATE
DELAYED REACTIONS.
(16) To stow the aerial device rotate the boom until the centered indicator light comes on.
Lower the boom into its rest. If necessary, rotate the operator basket until the boom lands
in the center of the boom rest. After the boom is in its rest retract the jib boom until the
basket platform sits in its rest and the BOOM PARKED indicator light (GREEN) illuminates.
NOTE: IF THE BASKET PLATFORM IS NOT IN THE REST, WITH THE JIB BOOM FULLY
RETRACTED, USE THE BASKET LEVELING SWITCH TO RETRACT THE BASKET
FURTHER.
NOTE: IF THE JIB BOOM IS RETRACTED IT WILL RAISE AUTOMATICALLY FIVE (5) DEGREES
DURING BOOM LOWERING. IF THE OPERATORS BASKET IS OUT OF LEVEL IT WILL
LEVEL AUTOMATICALLY DURING BOOM LOWERING. DURING AUTO JIB-OUT AND
AUTO-LEVELING THE BOOM LOWERING WILL AUTOMATICALLY BE INTERRUPTED
AND THE BASKET OUT-OF-LEVEL INDICATOR LIGHT (RED) WILL ILLUMINATE.
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H. EXTEND/DEPLOY THE XR BOOM (OPTIONAL)
Refer to Description in Chapter 1, Section 1 for components of the XR Boom.
Tempest vehicles equipped with the optional XR Boom allow the jib boom and basket to be
raised/extended to the Maximum Reach Line with the boom at the rest position. Refer to the
Working Positions Chart in Specifications, Chapter 1, Section 4. The chart illustrates the reach of
the Standard Boom versus the XR Boom.
The telescopic boom cannot be extended when the boom is at the rest position. The boom must
be raised before the system allows the extension of the telescopic boom. As the main boom is
raised, the control system allows the telescopic boom to be extended to the Maximum Reach
Line.
Refer to Procedure I, items 1 through 7 in Figure 56 for raising/extending the XR Boom.
I 1 2 3 4 5 6 7
MAX
II 1 2 3 4 5 6
624-5885-853
PROCEDURE I: EXTEND/DEPLOY XR BOOM - ITEMS 1 THROUGH 7.
PROCEDURE II: RETRACT/PARK XR BOOM - ITEMS 1 THROUGH 6.
Figure 56
EXTEND AND RETRACT XR BOOM (OPTIONAL)
(1) Enter the operators basket, and latch door.
(2) Fasten seat belt.
(3) Hold boom enable switch in boom joystick.
NOTE: THE ENABLE SWITCH MUST BE HELD WHILE ACTUATING BOOM CONTROLS.
(4) Raise basket out of rest, and adjust level if required.
(5) Raise boom out of rest (boom can be rotated now).
(6) Raise boom to desired height (up to a maximum angle of about 70).
(7) Extend the telescopic boom as necessary.
1-2
OPERATION
Page 73
October 2013
(8) Use joystick controls to rotate the boom, and extend and retract the telescopic boom.
Refer to Figure 43 for Boom Control Joystick operation.
NOTE: REFER TO F. AERIAL DEVICE - TWO-MAN DRIVE/OPERATION MODE (STANDARD),

AND G. AERIAL DEVICE - ONE-MAN DRIVE/OPERATION MODE (OPTIONAL)
PROCEDURES FOR EXTENDING AND RETRACTING THE AERIAL DEVICE.
NOTE: THE CONTROL SYSTEM WILL LIMIT THE EXTENSION OF THE TELESCOPIC BOOM
TO THE MAXIMUM REACH LINE (WORKING POSITIONS CHART). AN INDICATOR
LIGHT (AMBER) IN THE OVERHEAD PANEL WILL ILLUMINATE IF THE BOOM HAS NOT
REACHED THE MINIMUM HEIGHT.
I. RETRACT/PARK THE XR BOOM (OPTIONAL)
The telescopic boom can be retracted at any point, without lowering the main boom. When the
main boom is lowered the telescopic boom will automatically retract to keep the boom and basket
within the Maximum Reach Line.
NOTE: AN INDICATOR LIGHT (AMBER) WILL ILLUMINATE WHEN THE TELESCOPIC BOOM IS
IN AUTO RETRACT MODE.
The operator can bypass the automatic system by retracting the telescopic boom prior to lowering
the main boom.
NOTE: THE CONTROL SYSTEM MONITORS THE EXTENSION OF THE TELESCOPIC BOOM
AND THE ANGLE/HEIGHT OF THE MAIN BOOM TO KEEP THE BASKET WITHIN THE
MAXIMUM REACH LINE.
Refer to Procedure II, items 1 through 6 in Figure 56.
NOTE: THE ENABLE SWITCH MUST BE HELD WHILE ACTUATING BOOM CONTROLS.
(1) Bring the boom to the center of the vehicle.
(2) Retract telescoping boom fully.
(3) Lower boom fully into resting position.
(4) Retract jib boom.
(5) Move basket back into the knuckle. Level basket if necessary.
(6) Release enable trigger switch.
NOTE: REFER TO F. AERIAL DEVICE - TWO-MAN DRIVE/OPERATION MODE (STANDARD),

AND G. AERIAL DEVICE - ONE-MAN DRIVE/OPERATION MODE (OPTIONAL)
PROCEDURES FOR EXTENDING AND RETRACTING THE AERIAL DEVICE.
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October 2013
8. DEICING AND ANTI-ICING OPERATIONS
WARNING
FLUIDS USED IN THE DEICER MUST ADHERE TO SAE OR ISO STANDARDS AND MUST BE
SYSTEMS. THE SPECIFIC FLUID AND TYPE USED MUST BE APPROVED BY THE AIRLINE,
WARNING
WARNING
DEICING PROCEDURES MUST BE CARRIED OUT EXCLUSIVELY BY TRAINED AND
QUALIFIED PERSONNEL PER SAE ARP 4737. FAILURE TO COMPLY MAY RESULT IN
VEHICLE!
WARNING
NEVER DIRECT THE AIR NOZZLE AT A PERPENDICULAR SURFACE, THE AIRCRAFT
WINDSCREEN, SIDE WINDOWS, OR FLIGHT CONTROL SURFACES. NEVER ALLOW THE AIR
NOZZLE TO COME CLOSER THAN 0.60 M (24 IN.) TO ANY SURFACE. FAILURE TO COMPLY
WARNING
CLOTHING, HAIR AND JEWELRY WHEN PERFORMING DEICING/ANTI-ICING OPERATIONS.
1-2
OPERATION
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October 2013
WARNING
THE OPERATOR MUST WEAR PROTECTIVE GLOVES DUE TO THE HIGH TEMPERATURE OF
THE DEICING FLUID MIXTURE. FAILURE TO COMPLY MAY RESULT IN SERIOUS BODILY
A. DEICING - TWO-MAN MODE (STANDARD) / ONE-MAN MODE (OPTIONAL)
NOTE: REFER TO FIGURE 57.
(1) Operator: Select DEICE mode (Turtle) with the fluid selection switch (item 2) on the
nozzle control joystick.
(2) Operator: Turn on printer (if available) and place FLUID ENABLE switch (item 4) to the
ON position.
The FLUID ENABLE switch must be OFF to use forced air only for deicing.
(3) Operator: For Prop-mix rotate knob to select the desired deicing fluid concentration
percentage. Refer to Figure 35, item 4 (Open basket), or Figure 40, item 11.
For blendUP enter the Deice Freeze value for the tank, and desired Spray Freeze value.
Refer to B.SELECT DEICE FREEZE VALUES FOR BlendUP for setting these values.
(4) Operator: Place AirFirst ENABLE switch (item 3) in the OFF position (Optional with
AirFirst)
(5) Operator: Position fluid/air nozzle (air optional) 1.54.5 m (515 ft.) from the aircraft
surface and pull the red trigger switch (item 7) on the NOZZLE JOYSTICK and perform a
sweeping motion. Deicing fluid will be discharged from the fluid nozzle selected while the
trigger switch is held actuated.
(6) Operator: Adjust the spray pattern of the taskforce nozzle as required with the spray
pattern switch (item 5), if large nozzle is selected.
(7) Operator: Fluid nozzle positioning, and movement, is controlled with the nozzle joystick.
To raise the nozzle position, pull back on the joystick, and to lower the nozzle, push the
joystick forward. The nozzle can be moved to the left, or right, by moving the joystick
handle left or right.
(8) Operator: The enclosed basket can be rotated to the left and right, to obtain increased
visibility and nozzle positioning, by twisting the nozzle joystick clockwise (CW) or
counterclockwise (CCW).
(9) Operator (One-man Mode): Drive Control Box propels vehicle as needed. Steering is
achieved by leaning the joystick to the left or right.
NOTE: IN ONE-MAN MODE, THE OPERATOR CANNOT OPERATE THE BOOM AND PROPEL
THE VEHICLE SIMULTANEOUSLY.
(10) Driver (Two-man Mode) or Operator (One-man Mode): Switch off the optional printer at
the end of the operation to produce a print-out with the fluid usage.
1-2
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October 2013
FLUID SELECTION SWITCH 2 3 AIRFIRST ENABLE SWITCH
(OPTIONAL)
1
4
NOZZLE FLOW AIRFIRST FLUID
SELECTION SWITCH ENABLE SWITCH
(OPTIONAL)
5 6
SPRAY PATTERN AIRFIRST AIR
SWITCH INJECTION SWITCH
(OPTIONAL)
FRONT VIEW OF JOYSTICK
MOVE
NOZZLE LOWER NOZZLE
TO THE
LEFT
7
FLUID ENABLE
TRIGGER SWITCH
RAISE NOZZLE MOVE

NOZZLE
TO THE
RIGHT
ROTATE
BASKET TO
THE RIGHT
SIDE VIEW ROTATE

OF BASKET TO
JOYSTICK THE LEFT
Figure 57
NOZZLE CONTROL JOYSTICK
1-2
OPERATION
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October 2013
B. SELECT DEICE FREEZE VALUES FOR BLENDUP
If the vehicle is equipped with the XR Boom and blendUP options, the screen below will be
displayed on the PDM.
OPERATOR
Figure 58
LOGIN AND MAIN MENU ACCESS SCREEN
(1) Press F3 to display the blendUP Main Menu. If the vehicle is equipped with the
blendUP option only, the blendUP Main Menu with the Login option will be displayed.
VEHICLE WITH
XR BOOM
OPTION
OPERATOR VEHICLE WITH OPERATOR

NO XR BOOM
OPTION
NORMAL NORMAL
Login
Figure 59
BLENDUP MAIN MENU
1-2
Page 78
October 2013
(2) Press F3 (More) to display the blendUP Freeze value screen.
10
Figure 60
BLENDUP FREEZE VALUES SCREEN
The screen will read SPRAY DISABLED until the operator enters the Deice Freeze and Spray
Freeze values.
(3) Press F1 to display the Deice Fluid freeze value screen for the deice fluid in the tank.
Figure 61
DEICE FLUID FREEZE VALUE
1-2
OPERATION
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October 2013
NOTE: ON VEHICLES WITH BLENDUP SYSTEM, THE DEICE TANK DOES NOT CONTAIN
PURE WATER BUT A MIXTURE OF WATER AND GLYCOL. ENSURE TO MEASURE
AND ENTER THE CORRECT VALUE.
(4) Rotate encoder knob to adjust the deice freeze value.
(5) Press F1 to accept the value, or F3 to return to the previous screen. If accepting the
value, the Confirm Freeze value screen will be displayed.
Figure 62
CONFIRM FREEZE VALUE SCREEN
(6) Press F1 to accept the value, or F3 to return to the previous screen. If accepting and
confirming a value, the blendUP Freeze value screen will be displayed.
At this point the Freeze Point value for the deice fluid in the tank has been set. In the next screen,
the desired Freeze Point value for spraying is defined. Notice that F2 (Spray F.P.) appears now
on the following screen.
The screen will read SPRAY DISABLED until the operator enters the Spray Freeze value.
1-2
Page 80
October 2013
0
10
Figure 63
BLENDUP FREEZE VALUE SCREEN
(7) Press F2 to display Spray Freeze value screen.
10
Figure 64
SPRAY FREEZE VALUE SCREEN
(8) Rotate encoder knob to adjust the deice freeze value. The system will not accept a value
that is NOT IN RANGE. The spray value must be the same (spraying from the deice fluid
tank), or at least 5% higher than the value entered for the deice fluid in the tank (spraying a
mixture from the deice fluid tank and the pure fluid tank).
1-2
OPERATION
Page 81
October 2013
(9) Press F1 to accept the value, or F3 to return to the previous screen. If accepting the
value, the Confirm Spray Ratio screen will be displayed.
10
Figure 65
CONFIRM SPRAY RATIO SCREEN
(10) Press F1 to accept and confirm the value, or F3 to return to the previous screen. When
accepting and confirming the spray ratio value, the blendUP Freeze values screen will
displayed.
10
SPRAYENABLED
Figure 66
BLENDUP FREEZE VALUES SCREEN - SPRAY ENABLED
1-2
Page 82
October 2013
The screen will read now SPRAY ENABLED.
(11) Press F3 to display the Ground Reel Enable screen, if attempting to spray from the
ground reel.
Start Stop
F1 F2
Figure 67
GROUND REEL ENABLE SCREEN
(12) Press F1 (Start) to ENABLE the ground reel. This will display ENABLED for the Ground
Reel Enable screen, and also will disable spraying from the basket nozzle.
ENABLED
Start Stop
F1 F2
Figure 68
GROUND REEL ENABLE SCREEN - ENABLED
1-2
OPERATION
Page 83
October 2013
(13) Press F2 (Stop) to DISABLE the ground reel. This will display DISABLED for the
Ground Reel Enable screen. This will also enable spraying from the basket nozzle, but
the Deice Freeze and Spray Freeze values must be entered or confirmed before being able
to spray.
(14) Press F3 to return to the blendUP Main Menu.
C. ANTI-ICING - TWO-MAN (STANDARD) / ONE-MAN (OPTIONAL) MODES
(1) Operator: Select ANTI-ICE with the fluid selection switch (item 2) on the nozzle control
joystick.
(2) Operator: Place fluid enable switch (item 4) to the ON position.
(3) Operator: Place AirFirst enable switch (item 3) in the OFF position (Optional with
AirFirst).
(4) Operator: Position fluid nozzle/air nozzle 1.54.5 m (515 ft.) from the aircraft surface,
pull the red trigger switch (item 7) on the nozzle control joystick and perform a sweeping
motion. Anti-icing fluid will be discharged from the fluid nozzle selected while the trigger
switch is held actuated.
(5) Operator: Fluid nozzle positioning, and movement, is controlled with the nozzle joystick.
To raise the nozzle position, pull back on the joystick. To lower the nozzle, push the
joystick forward. The nozzle can be moved to the left, or right, by leaning the joystick
handle to the left or right.
(6) Operator: The enclosed basket can be rotated to the left and right, to obtain increased
visibility and nozzle positioning, by twisting the nozzle joystick clockwise (CW) or
counterclockwise (CCW).
(7) Operator: Drive Control Box propels vehicle as needed. Steering is achieved by moving
the joystick to the left or right.
NOTE: IN ONE-MAN MODE THE OPERATOR CANNOT OPERATE THE BOOM AND PROPEL
THE VEHICLE SIMULTANEOUSLY.
D. AIRFIRST FORCED AIR AIRCRAFT DEICING (OPTIONAL)
NOTE: THIS PROCEDURE APPLIES TO TWO-MAN (STANDARD) AND ONE-MAN (OPTIONAL)

DRIVE / OPERATION MODES. REFER TO FIGURE 57.
NOTE: THE AIRFIRST SYSTEM IS ONLY AVAILABLE AS AN OPTION WITH THE ENCLOSED
BASKET.
(1) Driver (Two-man Mode): In vehicle cab with seat belt fastened and engine running.
(2) Operator: In the basket with door closed and latched, and seat belt buckled.
(3) Driver/Operator (Two-man Mode): Check intercom operation. Ensure communication

between driver and operator is clear.
(4) Driver (Two-man Mode) or Operator (One-man Mode): Start fluid heater (if required).
1-2
Page 84
October 2013
(5) Driver (Two-man Mode) or Operator (One-man Mode): Start deicing fluid delivery pump
if heater is not running.
(6) Driver/Operator: Check that the ready to spray light is illuminated.
(7) Driver (Two-man Mode) or Operator (One-man Mode): Turn on the printer, if supplied.
(8) Driver (Two-man Mode) or Operator (One-man Mode): Enter operator and flight data to
enable the fluid system if operator prompt function is enabled on the JBT AeroTech Deicing
monitor (Optional).
(9) Operator: Activate the AirFirst system by depressing the rocker switch on the right side
pod. The lubricating pump indicator light (GREEN) next to the rocker switch, will start to
flash indicating it is operating, but the lubricating oil for the compressor is NOT up to
operating temperature. When the indicator light (GREEN) stops flashing and becomes
steady ON, the AirFirst system is ready for use.
(10) Operator: Turn the AirFirst system ON by actuating the switch (item 3) on the nozzle
control joystick. The indicator light on the overhead panel will illuminate.
(11) Operator: Select the fluid nozzle to be used, LARGE NOZZLE for deicing, or the SMALL
NOZZLE for anti-icing, with the nozzle select switch (item 1).
(12) Operator: Select the fluid, DEICING or ANTI-ICING, to be dispensed with the FLUID
SELECT switch (item 2). Switch center position is OFF for no fluid.
(13) Operator: Aim the AIR nozzle at the aircraft surface by moving the nozzle joystick left and
right and forward and aft.
(14) Operator: Depress the red trigger switch (item 7) to start the AirFirst compressor for air
delivery from the nozzle.
(a) To remove snow, position nozzle 1.5 to 4.5 meters (5 to 15 feet) from the aircraft
surface, pull the red trigger switch on the NOZZLE JOYSTICK and perform a
sweeping motion. Air will only be discharged from the nozzle while the trigger switch
is held actuated.
(b) Air nozzle positioning, and movement, is controlled with the nozzle joystick. To raise
the nozzle position, pull back on the joystick, and to lower the nozzle, push the
joystick forward. The nozzle can be moved to the left, or right, by moving the
joystick handle left or right.
(15) Operator: The basket can be rotated to the left and right, to obtain increased visibility and
nozzle positioning, by twisting the nozzle joystick CW (clockwise) or CCW
(counterclockwise).
(16) Operator (One-man Mode): Drive Control Box propels vehicle as needed. Steering is
achieved by moving the joystick to the left or right.
NOTE: IN ONE-MAN MODE THE OPERATOR CAN NOT OPERATE BOOM AND PROPEL
VEHICLE SIMULTANEOUSLY.
E. DEICING / ANTI-ICING WITH AIR ASSIST (OPTIONAL WITH AIRFIRST)
(1) With the AirFirst system operating, select DE-ICING or ANTI-ICING fluid with the fluid
select switch (item 2) on the joystick (refer to Figure 57).
1-2
OPERATION
Page 85
October 2013
(2) FLUID ENABLE switch must be in the ON position.
(3) When the red trigger is pulled on the joystick handle, de-icing or anti-icing fluid will be
sprayed from the nozzle selected and air will be delivered from the air nozzle at the same
time.
F. AIRFIRST WITH DEICING / ANTI-ICING FLUID INJECTION (OPTIONAL)
(1) With the AirFirst system operating, select DE-ICING or ANTI-ICING fluid with the fluid
select switch (item 2) on the joystick (refer to Figure 57).
(2) FLUID ENABLE switch (item 4) must be in the OFF position.
(3) Depress the bottom end of the FLUID INJECT switch (item 6) on the joystick.
(4) When the red trigger is pulled on the joystick handle, de-icing or anti-icing fluid will be
injected into the air nozzle and air being discharged from the nozzle will contain de-icing
and anti-icing fluid.
NOTE: WHEN ANTI-ICING FLUID HAS BEEN SELECTED FOR FLUID INJECTION IN THE AIR
STREAM, THE COMPRESSOR FOR DELIVERING AIR TO THE NOZZLE WILL
AUTOMATICALLY DECREASE IN RPM TO REDUCE THE FORCE OF THE AIR BLAST
TO DECREASE THE DEGRADING OF THE ANTI-ICING FLUID.
G. AIRFIRST WITH A BURST OF FLUID (OPTIONAL WITH AIRFIRST)
(1) With the AirFirst system operating, depress, and hold down the top of FLUID INJECT
switch (item 6) on the joystick (refer to Figure 57).
(2) Selected fluid (item 2), will be sprayed with air assist as long as the switch is held
depressed.
H. GROUND REEL HOSE AND NOZZLE OPERATION
WARNING
ENSURE TO HOLD THE GROUND REEL GUN WITH ARROW POINTING AWAY FROM THE
OPERATOR. FAILURE TO COMPLY MAY RESULT IN SERIOUS BODILY INJURY, DEATH, OR
NOTE: THE GROUND HOSE NOZZLE ONLY SPRAYS DEICING FLUID. REFER TO FIGURE 69.
The ground reel nozzle delivers deicing fluid at a 50% concentration (standard). Optionally, the
fluid mixture proportion can be set to a specific ratio before spraying; the system allows to spray
for up to five minutes after turning on the pumps.
(1) Roll out the ground hose to the appropriate length.
(2) In Prop-mix systems, ground reel must be selected from the Prop-mix panel before
activating the fluid delivery pump. An optional switch panel can be located on the vehicles
front bumper.
(3) Turn ON the fluid delivery pump switch.
1-2
Page 86
October 2013
ENSURE ARROW
POINTS FORWARD
NOTE: THE GROUND HOSE NOZZLE ONLY

SPRAYS DEICING FLUID.
TWO-POSITION
NOTE: THE PANEL SHOWN IS OFF-ON DEICING
PROVIDED WITH UNITS FLUID SWITCH
1
WITH A GROUND REEL
HOSE MOUNTED UNDER
THE FRONT RIGHT SIDE
O
OF THE CHASSIS.
1
O
TWO-POSITION
OFF-ON REEL
HOSE RETRACT
MOTOR SWITCH
NOTE: BECAUSE OF THE OUTWARD APPEARANCE, THE SPRAY HEAD ON THE GROUND REEL
NOZZLE COULD EASILY BE POINTED TOWARD THE OPERATOR. BE SURE TO HOLD THE
GROUND REEL NOZZLE WITH ARROW POINTING AWAY FROM THE OPERATOR.
Figure 69
GROUND HOSE NOZZLE AND SWITCH PANEL
1-2
OPERATION
Page 87
October 2013
NOTE: IF EQUIPPED WITH BLENDUP, REFER TO B. SELECT DEICE FREEZE VALUES FOR
BlendUP FOR ENABLING AND DISABLING THE GROUND REEL HOSE.
(4) In systems with adjustable spray mixture option, select the proper mix ratio.
(5) Aim the nozzle with the arrow pointing away from you and squeeze the lever located on the
rear side of the grip.
NOTE: THE DEICING FLUID PUMPS WILL AUTOMATICALLY TURN OFF AFTER TWO
MINUTES, OR UP TO FIVE MINUTES WITH THE TWO-TANK PROP-MIX OPTION. TO
CONTINUE SPRAYING, TURN ON THE DELIVERY PUMP SWITCH AGAIN.
CAUTION
ALWAYS USE A HIGH ENOUGH CONCENTRATION MIXTURE TO PREVENT FREEZING OF THE

GROUND REEL HOSE AND NOZZLE. FAILURE TO COMPLY MAY RESULT IN DAMAGE TO
VEHICLE COMPONENTS!
I. DEICING SPRAY NOZZLE OPERATION - OPEN BASKET
(1) Remove the nozzle from its holster.
(2) Place the hose under the arm and hold the pistol grip firmly.
(3) Adjust the nozzle head for the desired spray pattern.
The spray pattern can be adjusted by turning the black ribbed tip of the nozzle. The spray
pattern should be adjusted to maintain adequate deicing depending on the weather
conditions.
(4) When in position and nozzle settings are correct, grasp the control handle and pull back to
open nozzle.
NOTE: IN OTHER THAN EUROPEAN UNITS THE CONTROL HANDLE IS NOT SPRING
LOADED. IT MUST BE PUSHED FORWARD TO TURN THE FLUID FLOW OFF.
J. ANTI-ICING SPRAY NOZZLE (OPTIONAL) OPERATION - OPEN BASKET
NOTE: THIS NOZZLE HAS A SPRING SETTING OF 3.45 BAR / 345 KPA (50 PSI) AND IS SELF
REGULATING.
(1) Flow rate has been set to provide an optimum flow rate of 6875 L (1820 gal.) per minute.
(2) Aim nozzle and pull back on control handle.
NOTE: THE CONTROL HANDLE IS NOT SPRING LOADED. IT MUST BE PUSHED FORWARD
TO TURN THE FLUID FLOW OFF.
NOTE: ANTIICING OPERATIONS SHOULD BE ACCOMPLISHED WITH THE NOZZLE FULL

OPEN TO REDUCE FLUID DAMAGE FROM THE NOZZLE ORIFICE.
1-2
Page 88
October 2013
TURN TIP TO SELECT
SPRAY PATTERN
PULL BA (DEICING NOZZLE ONLY)
CK TO OPEN
NOZZLE
HOLSTER
FORWARD
BASKET
BACK SIDE
NOZZLE OF BASKET
HOLSTER
Figure 70
OPEN BASKET NOZZLES
1-2
OPERATION
Page 89
October 2013
K. NOZZLE CONTROL JOYSTICK FUNCTIONS (ENCLOSED BASKET)
NOTE: REFER TO FIGURE 57 FOR SWITCH POSITIONS AND FUNCTIONS.
AIR AND SPRAY FUNCTION CHART
Switch No. 1 2 3* 4* 5 6*
Nozzle Fluid AirFirst Fluid Spray Fluid

Nozzle Function
Select Select Enable Enable Pattern Inject**
UP position:
Any Active
Air only ON OFF
position DOWN position:
Available
De-ice only D OFF ON Active
Anti-ice only A OFF ON Active
Air and de-ice D ON ON Active
Air and anti-ice

(Safewing fluid A ON ON Active
only)
UP position:
Air and de-ice N/A
D ON OFF
injection DOWN position:
ON
Air and anti-ice

This method is
injection
not approved for
(50% decrease in
use yet.
air speed)
* Functions for switches 3, 4, and 6 are optional.
** Fluid inject, switch 6 must be held down to inject.
Not applicable.
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Page 90
October 2013
9. FLUID REFILL PROCEDURES
NOTE: DO NOT OVERFILL WATER, DEICING, BLENDUP, OR ANTI-ICING FLUID TANKS.
A. DEICING FLUID PRESSURE REFILL
NOTE: THE DEICING PRESSURE REFILL CONNECTION PORT IN THE LEFT HAND
COMPARTMENT IS ALSO USED FOR DRAINING THE DEICING FLUID TANK. THIS
PORT DOES NOT CONTAIN A CHECK VALVE AND FLUID REMAINING IN THE DEICING
TANK WILL DRAIN WHEN THE PORT DRAIN VALVE IS OPENED. DURING REFILLING,
FLUID IN THE TANK WILL BACK FLOW TO THE FILLING SOURCE IF THE SUPPLY
SOURCE IS NOT PRESSURIZED.
(1) Remove dust cap (if equipped) on the DEICING PRESSURE REFILL port coupling on the
left side of the deicing pump.
(2) With the locking levers fully extended, push the supply hose coupling onto the deicing
pressure refill port coupling and, when seated, force the levers inward to lock the
couplings.
(3) Ensure the DEICING REFILL VALVE handle is closed (normal operating position).
(4) Open the valve on the supply hose to begin refilling the vehicle tank.
DEICING
PRESSURE
REFILL PORT
G
I-ICIN
ANT R
ILLE
REF
ING
DEIC R
ILLE I
REF
0
I
WATER
PUMP
DEICING SUCTION DEICING REFILL VALVES DEICING REFILL

REFILL PORT (CLOSED NORMAL POSITION) SUCTION SWITCH
Figure 71
DEICING PRESSURE AND SUCTION REFILL (NORTH AMERICAN UNITS)
1-2
OPERATION
Page 91
October 2013
(5) Observe the DEICE sight gauge and when the tank is full, close the valve on the supply
hose.
(6) Open locking handles on the supply hose coupling and remove the supply hose.
(7) Reattach the cap on the refill port coupling.
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October 2013
DEICING ANTI-ICING
FLUID FLUID
FLUID RE-FILLER INSTRUCTIONS
PRESSURE REFILLING PROCEDURE
6000
5800
1500
1. CONNECT HOSE
5600
5400
2. REFILL TANK
5200
5000
1300
3. DISCONNECT HOSE
4. REPLACE DUST CAP
4800
4600
4400 1100
LITERS
4200
SUCTION REFILLING PROCEDURE

LITERS
4000
3800
3600
3400
900
1. CONNECT HOSE
3200
3000
2. FULL LEVER OUT
2500
2000
700
3. ACTIVATE SWITCH TO REFILL TANK

4. PUSH LEVER IN
5. DISCONNECT HOSE
6. REPLACE DUST CAP
1700
300
1500
1300
1100
LITERS
DEICING FLUID RE-FILLER

200
900
LITERS
700
PRESSURE REFILLING PROCEDURE
500 100
1. CONNECT HOSE
300
50
2. OPEN VALVE
DEICE ANTI-ICE
3. REFILL TANK
4. CLOSE VALVE
5. DISCONNECT HOSE
FLUID LEVEL SIGHT GAUGES
Figure 72
FLUID LEVEL AND REFILL PLACARDS
1-2
OPERATION
Page 93
October 2013
B. DEICING FLUID SUCTION REFILL (OPTIONAL)
(1) Remove dust cap (if equipped) on the DEICING SUCTION REFILL port coupling on the left
side of the deicing pump.
(2) With the locking levers fully extended, push the suction hose coupling onto the deicing refill
port coupling and, when seated, force the levers inward to lock the couplings.
(3) Pull the DEICING REFILL VALVE handle out.
(4) Hold the DEICING RE-FILLER switch in the UP position to operate pump to refill tank.
(5) Observe the DEICING sight gauge and when the tank is full, release switch and turn the
DEICING REFILL VALVE handle 90 to normal operating position.
DEICING REFILL VALVE -

PULL OUT FOR SUCTION REFILL
G
CIN
TI-I
ANFILLER
RE
I
NG
ICI
DEFILLER 0
RE
DEICING
0
SUCTION
REFILL
SWITCH
DEICING PRESSURE DEICING SUCTION

REFILL PORT REFILL PORT
Figure 73
DEICING PRESSURE AND SUCTION REFILL (EUROPEAN UNITS)
1-2
Page 94
October 2013
C. DEICE BLENDUP FLUID PRESSURE REFILL
(1) Remove dust cap (if equipped) on the DEICE blendUP REFILL port coupling on the left
(2) With the locking levers fully extended, push the supply hose coupling onto the pressure
refill port coupling and, when seated, force the levers inward to lock the couplings.
(3) Ensure the DEICING REFILL VALVE handle is closed (normal operating position).
(5) Observe the DEICE blendUP FLUID sight gauge and when the tank is full, close the
valve on the supply hose.
1-2
OPERATION
Page 95
October 2013
DEICE PUMP
SWITCHES
BLENDUP
REFILL VALVE ANTI-ICE PUMP
DEICE TANK PRESSURE (PULL OUT FOR
REFILL PORT SUCTION
SUCTION REFILL) REFILL PORT
BLENDUP
SUCTION
REFILL PORT
DEICE PUMP
SWITCHES
ANTI-ICE PUMP
BLENDUP
PUMP
DEICING SUCTION ANTI-ICE SUCTION

DEICE PUMP
BLENDUP TANK
PRESSURE
REFILL PORT
Figure 74
DEICE BLENDUP PRESSURE AND SUCTION REFILL
1-2
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October 2013
D. DEICE BLENDUP FLUID SUCTION REFILL (OPTIONAL)
(1) Remove dust cap (if equipped) on the DEICE blendUP SUCTION REFILL port coupling
on the left side of the deicing pump.
(3) Pull the DEICE blendUP REFILL VALVE handle out.
(4) Hold the DEICE blendUP RE-FILLER switch in the OPEN position to operate pump to
refill tank.
(5) Observe the blendUP sight gauge and when the tank is full, release switch and turn the
DEICE blendUP REFILL VALVE handle 90 to normal operating position.
E. TWO-TANK PROP-MIX PRESSURE REFILL (OPTIONAL)
(1) Remove dust cap (if equipped) on the DEICE PRESSURE REFILL port coupling on the left
(2) With the locking levers fully extended, push the supply hose coupling onto the pressure
refill port coupling and, when seated, force the levers inward to lock the couplings.
(3) Ensure the DEICING REFILL VALVE handle is open (normal operating position is closed).
(5) Observe the DEICE FLUID sight gauge and when the tank is full, close the valve on the
supply hose. Do not overfill the tank.
(6) Close the DEICING REFILL VALVE.
1-2
OPERATION
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October 2013
DEICE PRESSURE
REFILL PORT
HEATER
CIRCULATING PUMP
WATER SUCTION
REFILL PORT
DEICE PUMP
WATER PRESSURE DEICE SUCTION

WATER DELIVERY
PUMP
Figure 75
TWO-TANK PROP-MIX PRESSURE AND SUCTION REFILL
1-2
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October 2013
F. TWO-TANK PROP-MIX SUCTION REFILL (OPTIONAL)
(1) Remove dust cap (if equipped) on the DEICE SUCTION REFILL port coupling on the left
(3) Pull out the DEICE REFILL VALVE handle to open.
(4) Activate the DEICE RE-FILLER switch to operate pump to refill tank.
(5) Observe the DEICE sight gauge and when the tank is full, release switch and turn the
DEICE REFILL VALVE handle 90 to close (normal operating position).
G. ANTI-ICING FLUID PRESSURE REFILL
(1) Remove dust cap (if equipped) on the ANTI-ICING PRESSURE REFILL port coupling on
the right side of the anti-icing pump.
(2) With the locking levers fully extended, push the supply hose coupling onto the anti-icing
pressure refill port coupling and, when seated, force the levers inward to lock the
couplings.
(3) Ensure the ANTI-ICING REFILL VALVE handle is pushed in (normal operating position).
(5) Observe the ANTI-ICING sight gauge and when the tank is full, close the valve on the
supply hose.
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OPERATION
Page 99
October 2013
.
ANTI-ICING REFILL VALVE (PUSHED

IN - NORMAL POSITION)
NG
I-ICI
ANT R
ILLE
REF
ING
DEIC R
ILLE I
REF
0
I
ANTI-ICING PRESSURE
REFILL PORT
Figure 76
ANTI-ICING FLUID PRESSURE REFILL
H. ANTI-ICING FLUID SUCTION REFILL (OPTIONAL)
(1) Remove dust cap (if equipped) on the ANTI-ICING SUCTION REFILL port coupling on the
left side of the anti-icing pump.
(2) With the locking levers fully extended, push the suction hose coupling onto the anti-icing
suction refill port coupling and, when seated, force the levers inward to lock the couplings.
(3) Pull the ANTI-ICING REFILL VALVE handle out.
(4) Hold the ANTI-ICING RE-FILLER switch in the UP position to operate pump to refill tank.
(5) Observe the ANTI-ICE sight gauge and when the tank is full, release switch and push the
ANTI-ICING REFILL VALVE handle in to normal operating position.
1-2
Page 100
October 2013
ANTI-ICING REFILL VALVE (PUSHED
IN - NORMAL POSITION)
NG
I-ICI
ANT R
ILLE
REF
ING
DEIC R
ILLE I
REF
0
I
ANTI-ICING SUCTION ANTI-ICING SUCTION

REFILL SWITCH REFILL PORT
Figure 77
ANTI-ICING FLUID SUCTION REFILL
I. TOP REFILL
NOTE: DO NOT OVERFILL FLUID TANKS.
NOTE: REFER TO FIGURE 78, FIGURE 79, FIGURE 80, AND FIGURE 81.
WARNING
EXERCISE EXTREME CAUTION DURING TOP FILLING OPERATIONS. FLUIDS MAY BE
SPILLED ON THE WALKWAY CREATING A HAZARD. USE A FALL RESTRAINT SYSTEM,
SCAFOLD OR OTHER DEVICE TO PREVENT A FALL WHEN ACCESSING THE TOP OF THE
(1) Open latch on top tank fill cover and lift cover.
(2) Swing drop pipe or hose into position and fill as required.
(3) After filling is complete, close cover and ensure spring loaded latch is secured.
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OPERATION
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October 2013
ANTI-ICING FLUID FILL
DEICING
FLUID FILL
Figure 78
TOP REFILL - STANDARD TANK
WATER FILL
DEICING
FLUID FILL
Figure 79
TOP REFILL - PROP-MIX TANK
1-2
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October 2013
DEICE FLUID FILL
BLENDUP
FLUID FILL
Figure 80
TOP REFILL - DEICE BLENDUP PROP-MIX TANK
DEICING FLUID FILL
WATER
TANK FILL
Figure 81
TOP REFILL - TWO-TANK PROP-MIX
1-2
OPERATION
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October 2013
J. TANK FLUID TEST PORTS
Samples of tank fluid can be obtained through the test ports (refer to Figure 82). Tank fluids must
be above a minimum level to obtain a sample.
(1) Open the fluid pump compartment doors.
(2) Place a suitable container to hold the sample at the bottom end of the corresponding test
port hose.
(3) Open the needle valve until the desired sample is obtained. Securely close the valve.
(4) Close and secure the pump compartment doors.
FLUID TEST PORTS NEEDLE VALVES
TEST PORT FLUID PUMPS COMPARTMENT

HOSES (LEFT SIDE OF VEHICLE)
Figure 82
FLUID TEST PORTS
1-2
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October 2013
10. DRAIN AND PURGE PROCEDURES
CAUTION
THE DEICING FLUID PUMP AND THE HEATER MUST BE TURNED OFF PRIOR TO DRAINING
OR PURGING. FAILURE TO COMPLY MAY RESULT IN DAMAGE TO VEHICLE COMPONENTS!
CAUTION
PURGING DOES NOT PREVENT THE WATER TANK FROM FREEZING. EXPANSION OF
WATER DUE TO FREEZING MAY DAMAGE TANKS. TAKE NECESSARY STEPS TO PREVENT
FREEZING. FAILURE TO COMPLY MAY RESULT IN DAMAGE TO VEHICLE COMPONENTS!
A. PROCEDURE AFTER DEICING OPERATIONSVERY IMPORTANT!
After completing deicing operations for the day, take the following actions to prevent the fluids
inside the vehicle from freezing. Temperatures may drop significantly freezing tanks, pumps, and
pipes, causing serious damage to components.
(1) Bleed any accumulated moisture from air brake tanks.
(2) Plug in the cord for the optional engine block heater, if provided.
(3) If the vehicle is equipped with an optional winterization system, place the unit into
winterization mode. Refer to 11. WINTERIZATION SYSTEM OPERATION (OPTIONAL)
within this section.
If the winterization system is not available or cannot be activated, initiate a purge cycle
which will replace all water in the plumbing system with a concentrate glycol mixture.
(4) On a Prop-mix unit, ensure the last mixture sprayed from the basket was at a high enough
concentration that will not freeze for the expected weather conditions (Freeze Protection
GREEN indicator light ON). If not illuminated, select 50% or greater mixture and spray until
the green indicator light is illuminated.
If the unit has adjustable spray mixture on the ground nozzle, ensure that the last mixture
was appropriate to prevent freezing (50% or greater mixture).
B. PURGING BOOM AND GROUND REEL (PROP-MIX AND BLENDUP)
(1) Activate deicing system.
(2) Select a heavy mixture to purge the boom (50% or greater mixture).
(3) Open deice nozzle until deicing fluid is visible at the nozzle, then close nozzle.
(4) First Time Ground Reel Purge
(a) Select a 50/50 mix.
(b) Open reel nozzle for 30 seconds or when deicing fluid is visible at the nozzle.
(c) Close nozzle.
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OPERATION
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October 2013
(5) Turn off deicing system. Boom and reel purge is complete.
C. AUTOMATIC PURGING OF HEATER AND PUMPS
(1) Depress the heater purge switch. Deicing pump runs; water pump may run slowly.
(2) The deicing pumps will run for about 130 seconds. Wait for pumps to stop.
(3) Heater purge is complete.
NOTE: DO NOT PURGE BOOM AND REEL AFTER PURGING THE HEATER.
D. MANUAL PURGE SYSTEM (BLENDUP)
This operation requires at least 750 L (200 gal.) of fluid in the blendUP tank and the main
pre-mixed fluid tank has room to accept the purge fluid. Refer to System Schematics in
Chapter 2, Section 7.
(1) Close purge valve #3 (C6) and open main purge valve #1 (C7).
(2) Turn ON G-pump switch. Allow pump to run for several seconds (circulation pump does
not run).
Purges circulation pump, heater, in-tank heat exchanger and associated lines and pipes to
pre-mixed tank.
(3) Close purge valve #2 (B5). G-pump stalls.
(4) Open main deicing nozzle at basket (G-pump runs). Spray until a darker fluid exits. Close
deicing nozzle.
(5) Open ground reel nozzle, and spray until darker fluid exits. Close nozzle.
(6) Turn OFF G-pump and close purge valve #1 (C7).
(7) Open purge valves #2 and #3.
D-pump, fluid meter, mixer, hoses, reel and pipes to the basket are now purged.
1-2
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October 2013
11. WINTERIZATION SYSTEM OPERATION (OPTIONAL)
DANGER
Refer to Description in Chapter 1, Section 2 for a general description of the winterization system, and
location of the external power source connector, and activation switch.
A. EXTERNAL POWER SOURCE CONNECTION
(1) Ensure the vehicle is completely shut down before attempting to connect the external
power source to the vehicle.
(2) Ensure the winterization system rotary switch is in the OFF position.
(3) Ensure the main switch feeding the plug-in power connector cable is in the OFF position.
An unobstructed line of sight between the main switch and the winterization panel should
be available at all times.
(4) Remove cover from plug-in receptacle connector, turning the outer ring counterclockwise.
(5) Insert the plug-in connector from the external power source cable into the vehicles plug-in
receptacle, and tighten it by turning the outer ring clockwise.
(6) Turn ON power to the plug-in power connector cable.
B. WINTERIZATION SYSTEM ACTIVATION
(1) Once the external plug-in power connector is live, open the fluid pump compartment doors.
(2) Turn ON the winterization panel rotary switch. An operating sound from the electric motor
driving the hydraulic pump for the winterization system should be heard.
(3) Observe that heater circulating pump and water pump are operating.
(4) Verify the operation of the drivers cab heater. Turn it ON, if necessary.
(5) Verify the drivers cab and all compartment doors are properly closed and secure, before
leaving the vehicle unattended.
C. TEMPERATURE ADJUSTMENT
(1) If the operating temperature of the winterization system must be adjusted, allow the system
to run for several minutes before adjusting the temperature.
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OPERATION
Page 107
October 2013
(2) Open the thermostat control box, removing the lid by turning it counterclockwise (refer to
Figure 83).
NOTE: THE THERMOSTAT OPERATES ON A TEMPERATURE RANGE FROM 15 C TO 120 C

(60 F TO 250 F).
(3) Allow the system to reach the desired temperature.
(4) Turn OFF the power and adjust the thermostat reducing the temperature by rotating the
adjustment knob until hearing it clicks.
(5) Close the thermostat control box by replacing the lid and turning it clockwise.
(6) Close and secure the fluid pump compartment doors.
THREADED LID
THERMOSTAT
KNOB
626-3527
Figure 83
THERMOSTAT CONTROL BOX
1-2
Page 108
October 2013
1. GENERAL
WARNING
ONLY APPLY E-STOP TO DISABLE THE VEHICLE IN CASE OF EMERGENCY. PRESSING THE
EMERGENCY STOP PUSH-BUTTON WILL COMPLETELY SHUTDOWN THE VEHICLE.
The vehicle is equipped with an emergency electrical-driven hydraulic pump activated from the drivers
cab or basket, actuating on a spring-loaded two-position switch. This pump allows for operating the
boom if the engine or the hydraulic pump fail, and also to provide pressure for steering the vehicle. Also,
a hand-operated emergency hydraulic pump is provided with the vehicle. This pump has a removable
handle, and can be used for emergency operations when no other hydraulic source or electrical power is
available.
Emergency procedures in this section describe the necessary steps to follow, in case of mechanical
breakdown or equipment malfunctions.
NOTE: IT IS IMPORTANT TO COMPLETELY READ AND UNDERSTAND THIS EMERGENCY

PROCEDURES SECTION BEFORE OPERATING THE VEHICLE.
CAUTION
DO NOT ENERGIZE HYDRAULIC EMERGENCY PUMP DURING NORMAL VEHICLE

OPERATION. FAILURE TO COMPLY MAY RESULT IN DAMAGE TO VEHICLE, OR OTHER
2. EMERGENCY STOP PUSH-BUTTONS
The vehicle is provided with emergency stop push-buttons on the cab control panel, the basket control
panel (open basket) or left side pod (enclosed basket), and on either side of the vehicles chassis (refer
to Figure 1).
NOTE: IF A CONTROL VALVE FAILS, OR THERE IS A NEED TO HALT BOOM MOVEMENT,

PUSHING ANY OF THE EMERGENCY STOP PUSH-BUTTONS WILL COMPLETELY
SHUTDOWN THE UNIT. POWER IS TURNED OFF FOR ALL SYSTEMS, EXCEPT FOR
LIGHTING.
NOTE: ENGINE WILL NOT START UNLESS ALL EMERGENCY STOP PUSH-BUTTONS ARE
PULLED OUT TO THEIR NORMAL OPERATING POSITION.
NOTE: EUROPEAN (CE) UNITS ARE EQUIPPED WITH TWO ADDITIONAL EMERGENCY
STOPS (E-STOPS) AT BOTH SIDES OF THE VEHICLE.
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EMERGENCY PROCEDURES
Page 1
October 2013
EMERGENCY STOP BUTTONS
OVERHEAD INDICATING LIGHTS
DRIVERS CAB CONTROL PANEL
LEFT SIDE POD RIGHT SIDE POD
ENCLOSED BASKET CONTROL PANEL

EMERGENCY STOP BUTTON
OPEN BASKET CONTROL PANEL
Figure 1
EMERGENCY STOP PUSH-BUTTON LOCATIONS
1-3
Page 2
October 2013
3. EMERGENCY PROCEDURES
WARNING
CAUTION
CONTINUOUS OPERATION OF HYDRAULIC EMERGENCY PUMP FOR MORE THAN ONE

MINUTE WILL OVERHEAT THE ELECTRICAL MOTOR. IF EMERGENCY PROCEDURES
CANNOT BE COMPLETED WITHIN ONE MINUTE, PUMP MUST BE ALLOWED TO COOL FOR
AT LEAST 10 MINUTES BEFORE CONTINUING. FAILURE TO COMPLY MAY RESULT IN
DAMAGE TO VEHICLE COMPONENTS!
4. EMERGENCY BOOM LOWERING
Emergency pump toggle switches are provided on the operators basket control panel and on the
drivers control panel. This switch cannot be used when the engine is running.
A. OPEN AND ENCLOSED OPERATORS BASKETS
(1) Actuate and hold the emergency pump switch in the ON position. (Ignition switch must be
in the ON position.)
(2) Lower, or reposition the boom using the joystick switch while holding the emergency pump
switch actuated.
B. DRIVERS CAB NORMAL OPERATION (TWO-MAN DRIVE)
Follow the same procedure as above in paragraph A.
C. GROUND CONTROL STATION
(1) Main Hydraulic Pump or Engine Failure
This emergency procedure can be performed from the drivers cab in a two-man operation
configuration, or from the basket (open or enclosed). Refer to Figure 2 and Figure 3.
(a) With engine not running, turn ignition switch to 1 (ON position).
(b) Use normal boom controls, while actuating on the emergency pump switch.
(c) Once the boom is completely lowered, turn ignition switch to 0 (OFF position).
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Page 3
October 2013
JIB BOOM BOOM ROTATION TO
UP / DOWN RIGHT / LEFT
MAIN BOOM
UP / DOWN
Figure 2
GROUND CONTROL STATION
1-3
Page 4
October 2013
EMERGENCY BOOM LOWERING
OPTION 1
(FOR ENGINE FAILURE OR MAIN HYDRAULIC PUMP FAILURE.)
A. WITH ENGINE NOT RUNNING, TURN IGNITION SWITCH TO "1".
DEPRESS AND HOLD EMERGENCY PUMP SWITCH.
B. USE NORMAL BOOM CONTROLS.
OPTION 2
(IF ENGINE IS FUNCTIONAL,NO ELECTRICAL POWER TO BOOM VALVES.)
A. PUSH AND TWIST/LOCK '30 SOL' MANUAL VALVE OVERRIDE.
B. USE MANUAL BOOM CONTROLS.
UP CW UP
MANUAL BOOM
CONTROL
30 SOL
DOWN CCW DOWN

RED
BLACK
OPTION 3 (MANUAL EMERGENCY PROCEDURE)
A. ON THE EMERGENCY MANUAL BOOM LOWERING VALVE/PUMP,

DEPRESS AND HOLD RED BUTTON.
B. REPEATEDLY PUSH/PULL THE HAND PUMP HANDLE IN AND OUT
TO LOWER BOOM. RELEASE THE RED BUTTON WILL STOP BOOM.
624-3243-001
Figure 3
EMERGENCY BOOM LOWERING PROCEDURES
1-3
Page 5
October 2013
(2) Engine Functional with No Electrical Power to Boom Valves
This emergency procedure must be performed from the ground control station. Refer to
Figure 2 and Figure 3.
(a) Push and twist to manually lock SOL 30 valve override.
(b) Use manual boom controls, while actuating on the emergency pump switch.
(c) Once the boom is completely lowered, unlock SOL 30 to its normal position.
(3) Manual Emergency Procedure
This emergency procedure must be performed from the ground control station. Refer to
Figure 2 and Figure 3.
(a) Depress and hold RED button on the emergency manual boom lowering valve/
pump.
(b) Push and pull the pump handle repeatedly to lower the boom.
(c) Releasing the RED button will stop lowering of the boom.
5. EMERGENCY TOWING
NOTE: REFER TO SPECIFICATIONS IN CHAPTER 1, SECTION 4 AND VEHICLE PLACARD

FOR GROSS VEHICLE WEIGHT.
WARNING
THE COMBINED WEIGHT OF THE TOWED AND TOWING VEHICLES MUST BE LESS THAN THE
SUM OF THE GROSS AXLE RATINGS OF THE TOWING VEHICLE. FAILURE TO COMPLY MAY
WARNING
WARNING
REMOVE THE RELEASE STUD ASSEMBLIES FROM BRAKE CHAMBERS AFTER TOWING IS
COMPLETE. FAILURE TO COMPLY MAY RESULT IN SERIOUS BODILY INJURY, DEATH, OR
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Page 6
October 2013
WARNING
IF PARK BRAKE IS NOT IMMEDIATELY ENGAGED AFTER TOWING, PLACE A SUITABLE
WARNING SIGN ON VEHICLE TO ENSURE THAT ALL PERSONNEL ARE AWARE OF THE
CONDITION. FAILURE TO COMPLY MAY RESULT IN SERIOUS BODILY INJURY, DEATH, OR
CAUTION
REMOVE DRIVE SHAFT BEFORE TOWING THE VEHICLE, UNLESS REAR-LIFT TOWING THE
VEHICLE. FAILURE TO COMPLY MAY RESULT IN DAMAGE TO VEHICLE COMPONENTS!
CAUTION

A. BEFORE TOWING
The boom must be completely lowered to its resting position before towing the vehicle.
Disengage transmission with drive disconnect valve (optional). If no drive disconnect valve is
provided, ensure the drive shaft, or rear drive axle shafts are removed before towing the vehicle.
Wheel hubs ends must be sealed with the supplied cover plates.
If the vehicle is towed with the rear wheels off the ground, there is no need to remove the drive
shaft or rear axle shafts.
B. TOWING PROCEDURES
NOTE: DO NOT TOW THIS VEHICLE FOR MORE THAN 5 MINUTES AT A SPEED OF NO MORE
THAN 4.04.8 KM/H (2.53.0 MPH).
(1) Place the front wheels straight forward.
(2) Allow steering wheel to rotate freely, if forward towing. Otherwise, secure steering wheel
for rear towing.
(3) Ensure that propel by-pass valve has been open. If unit not equipped with by-pass valve,
ensure that drive shaft or the drive axle shafts have been removed.
(4) Ensure the wheel hub ends are covered with supplied cover plates.
(5) Attach the towing device to front or rear towing hookup.
NOTE: THE LIFTING AND TOWING DEVICE IS THE SOLE RESPONSIBILITY OF THE TOWING-
VEHICLE OPERATOR, WHO MUST BE FAMILIAR WITH STANDARD TOWING
INDUSTRY SAFETY MEASURES.
(6) Install and connect any special towing lights required by company, local regulations and
airport authority. Also connect taillights and signal lights.
1-3
Page 7
October 2013
(7) Connect air system from the towing vehicle to the primary air tank quick connector located
behind the fluid pumps on the deicer.
(8) Release the vehicle parking brake by pushing down the parking brake valve in the driver's
compartment.
(9) If no air supply is available, then mechanically release the parking brakes. Refer to
subsection 6. PARKING BRAKE RELEASE for instructions to release the parking brakes.
(10) Verify the towing path is free from personnel and obstacles, and carefully tow the vehicle to
its destination.
(11) After towing has been completed, set the vehicle parking brake by pulling up on the parking
brake control in the driver's compartment.
(12) If the rear axle brakes have been mechanically released, reset both rear brake chambers
to activate the parking brakes. Refer to subsection 7. PARKING BRAKE RESET.
(13) Remove special towing lights, and disconnect taillights and signal lights.
(14) Detach towing device and disconnect towing vehicle.
6. PARKING BRAKE RELEASE
The parking brake in this vehicle is mechanically applied through the force of a spring when air is
depleted from the brake chambers. Air pressure is necessary to release the parking brake that
otherwise would be engaged.
Before attempting the mechanical release of the parking brakes, verify for air pressure in the system.
A. PNEUMATIC RELEASE
When air pressure is supplied to the vehicle, or if air pressure is stored in the accumulators,
manually depressing the parking brake valve inside the drivers cab should release the parking
brake.
B. MECHANICAL RELEASE
NOTE: THE RELEASE STUD ASSEMBLIES USED FOR MECHANICAL RELEASE OF PARKING
BRAKES MUST BE REMOVED FROM BRAKE CHAMBERS AFTER TOWING.
(1) After verifying air supply is exhausted, remove the release stud assembly from stowage on
the brake chamber. Refer to Figure 4.
(2) Remove the dust plug cover on the back of the brake chamber.
(3) Insert the release stud assembly into the brake chamber and rotate the stud one quarter of
a turn to seat the cross pin of the release stud in the pressure plate receptacle.
(4) Turn the nut on the release stud assembly clockwise with a wrench until the brake chamber
spring is fully compressed (caged) to release the brake.
(5) Repeat the procedure for the other wheel brake chamber.
1-3
Page 8
October 2013
Figure 4
MECHANICAL RELEASE OF PARKING BRAKE
7. PARKING BRAKE RESET
Parking brakes must be engaged after towing. If brakes have been mechanically released, the release
stud assemblies must be removed from both brake chambers and then stowed into their carrying
pockets located on each chamber. Proceed in reverse order as of the mechanical release of the parking
brakes.
1-3
Page 9
October 2013
1. GENERAL
This vehicle specification outlines the product definition of the Tempest Aircraft Deicer offered by
JBT AeroTech, Ground Support Equipment.
Vehicles in this line are equipped with a diesel powered engine, hydraulic transmission, rear drive axle,
air brakes, and pneumatic tires.
NOTE: MAINTENANCE SPECIFICATIONS ARE CONTAINED IN CHAPTER 2, SECTION 4. ALL

REFERENCES TO GALLONS ARE FOR U.S. GALLONS.
NOTE: VEHICLE SPECIFICATIONS ARE SUBJECT TO CHANGE WITHOUT NOTICE, DUE TO

DESIGN IMPROVEMENTS AND CUSTOMERS SPECIFIC REQUIREMENTS.
2. MODEL DEFINITION
Vehicle name: Tempest Aircraft Deicer
Designation: Tempest
Vehicle type: Aircraft Deicer, Ground Support Equipment
Power unit: Diesel Cummins QSB 4.5 (standard)

Diesel Cummins QSB 6.7 (optional with AirFirst)
Diesel Mercedes OM 906 LA (optional with AirFirst)
Maximum speed in drive mode: 40 km/h (25 mph) (standard)
Maximum speed in deicing mode: 6 km/h (4 mph) (standard)

(Maximum speeds may be adjusted to a lower speed due to
local regulations.)
Basket configurations: Open rectangular basket (standard)

Open round basket (optional)
Enclosed basket (optional)
Enclosed basket with AirFirst (upgraded engine)
Aerial lift device: Standard boom with jib boom

XR telescopic boom with jib boom (optional)
Boom side reach bypass switch (optional)
Drive and operation configurations: Two-man drive and operation (standard)

One-man drive and operation (optional)
1-4
SPECIFICATIONS
Page 1
November 2013
Fluid system configurations: Type I Premix (standard)
Type II/IV Premix (CE)
Type I Premix (Japan)
Proportional Mix (Prop-mix) (optional)
Two-tank Proportional Mix (optional)
Blend-UP (optional)
Aircraft Washer (optional)
Fluid system features: Tank fluid test ports

Digital fluid flow meter (optional)
Temperature and pressure nozzle gauges (optional)
Other options: OptiMax heater system

Electronic Heater Controller (EHC)
Automatic Fire Suppression system
Winterization system
3. AIRCRAFT COMPATIBILITY
The Tempest can be used to deice any commercial airplane in use, including military aircraft. The
following list shows the most common commercial aircraft.
AIRCRAFT COMPATIBILITY CHART
Manufacturer Aircraft Designations
Airbus A300, A310, A318, A319, A320, A321, A330, A340, A350, A380*
Boeing B707, B717, B727, B737, B747, B757, B767, B777, B787
British Aerospace RJs, BAE146
Douglas DC8, DC9, DC10
Ilyushin IL76*
Lockheed L1011
McDonnell Douglas MD11, MD80, MD81, MD82, MD83, MD90
* Requires the XR boom option.
1-4
Page 2
November 2013
WORKING POSITIONS
Maximum Reach Line AirFirst Nozzle

System Shown
JIB BOOM REACH

FEET
XR BOOM REACH
STANDARD BOOM REACH
FEET
Figure 1
WORKING POSITIONS CHART
1-4
SPECIFICATIONS
Page 3
November 2013
4. DIMENSIONAL CHARACTERISTICS
A. OPEN BASKET CONFIGURATION
NOTE: ALL VALUES ARE APPROXIMATE ONLY AND SUBJECT TO MANUFACTURING

VARIANCES. SPECIFICATIONS SUBJECT TO CHANGE WITHOUT NOTICE.
Overall length (square basket) (standard) . . . . . . . . . . . 9.77 m (384.5 in.)

Overall length (round basket) (optional). . . . . . . . . . . . . 10.26 m (404.0 in.)
Overall width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.74 m (108.0 in.)
Overall height (boom retracted) . . . . . . . . . . . . . . . . . . . 3.61 m (142.0 in.)
Wheelbase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.39 m (173.0 in.)
Turning radius (wall-to-wall) . . . . . . . . . . . . . . . . . . . . . . 10.42 m (410.1 in.)
Working height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.70 m (539.4 in.)
Maximum height to basket floor . . . . . . . . . . . . . . . . . . . 12.00 m (472.4 in.)
Side reach (round basket) . . . . . . . . . . . . . . . . . . . . . . . 10.68 m (420.3 in.)
Boom lifting capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . 204 kg (450 lb.)
Max. tipping moment, load test with tanks empty . . . . . 306 kg (675 lb.)
GROSS VEHICLE WEIGHT (GVW)
Open Basket Tanks Empty Tanks Full
Depending on configuration 11 92013 920 kg 18 97522 225 kg

and options included (26 27030 700 lb.) (41 83049 000 lb.)
VEHICLE AXLE WEIGHTS
Open Basket (Basic Configuration)
Axle Tanks Empty Tanks Full
Front axle 5810 kg (12 800 lb.) 49% 9660 kg (21 300 lb.) 51%
Rear axle 6110 kg (13 470 lb.) 51% 9315 kg (20 530 lb.) 49%
Total weight 11 920 kg (26 270 lb.) 100% 18 975 kg (41 830 lb.) 100%
NOTE: REFER TO SPECIFIC PLACARD IN VEHICLE FOR GVW, AND BY-AXLE AND TOTAL
VEHICLE WEIGHTS FOR THE CONFIGURATION PROVIDED.
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Page 4
November 2013
9766
[384.5]
3606
[142.0]
1943 4394 3429

[76.5] [173.0] [135.0]
RECTANGULAR OPEN BASKET (STANDARD)
10262
[404.0]
3606
[142.0]
1943 4394 3924

[76.5] [173.0] [154.5]
ROUND OPEN BASKET (OPTIONAL)
NOTE: DIMENSIONS IN MM [INCHES] ARE APPROXIMATE ONLY AND SUBJECT TO

MANUFACTURING VARIANCES.
Figure 2
OPEN BASKET CHASSIS DIMENSIONS - LENGTH
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SPECIFICATIONS
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November 2013
B. ENCLOSED BASKET CONFIGURATION (OPTIONAL)

Overall length (standard nozzle) . . . . . . . . . . . . . . . . . . 10.99 m (432.5 in.)

Overall length (AirFirst) (nozzle retracted) . . . . . . . . . 10.72 m (422.0 in.)
Wheelbase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.39 m (173.0 in.)
Turning radius (curb-to-curb) . . . . . . . . . . . . . . . . . . . . . 8.16 m (321.3 in.)
Working height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.70 m (539.4 in.)
Maximum height to basket floor . . . . . . . . . . . . . . . . . . . 12.34 m (485.8 in.)
Side reach (standard nozzle) . . . . . . . . . . . . . . . . . . . . . 11.19 m (440.5 in.)
Enclosed Basket Tanks Empty Tanks Full

Enclosed Basket (Basic Configuration)
Axles Tanks Empty Tanks Full
Front axle 4985 kg (10 990 lb.) 37% 9281 kg (20 461 lb.) 44%
Rear axle 8487 kg (18 711 lb.) 63% 11 812 kg (26 041 lb.) 56%
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November 2013
10986
[432.5]
3606
[142.0]
1943 4394 4662

[76.5] [173.0] [183.5]
ENCLOSED BASKET - STANDARD NOZZLE
10719
[422.0]
3606
[142.0]
1943 4394 4295

[76.5] [173.0] [169.1]
ENCLOSED BASKET - AIRFIRST (OPTIONAL)

Figure 3
ENCLOSED BASKET CHASSIS DIMENSIONS - LENGTH
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SPECIFICATIONS
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November 2013
C. XR BOOM CONFIGURATION (OPTIONAL)

Overall length (standard nozzle) . . . . . . . . . . . . . . . . . . 11.63 m (457.8 in.)

Overall length (AirFirst) (nozzle retracted) . . . . . . . . . 11.28 m (444.0 in.)
Overall height (AirFirst) (boom retracted) . . . . . . . . . . 3.72 m (146.4 in.)
Wheelbase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.39 m (173.0 in.)
Turning radius (curb-to-curb) . . . . . . . . . . . . . . . . . . . . . 8.16 m (321.3 in.)
Working height with XR boom . . . . . . . . . . . . . . . . . . . . 17.20 m (677.2 in.)
Maximum height to basket floor with XR boom . . . . . . . 15.75 m (620.1 in.)
Side reach (AirFirst) (nozzle extended) . . . . . . . . . . . 12.04 m (474.1 in.)
Enclosed Basket Tanks Empty Tanks Full

Enclosed Basket (XR Boom Configuration)
Axles Tanks Empty Tanks Full
Front axle 5680 kg (12 522 lb.) 37% 10 400 kg (22 930 lb.) 44%
Rear axle 9670 kg (21 328 lb.) 63% 13 250 kg (29 220 lb.) 56%
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Page 8
November 2013
11630
[457.8]
3632
[143.0]
2587 4394 4662

[101.8] [173.0] [183.5]
ENCLOSED BASKET - STANDARD NOZZLE
11264
[443.4]
3719
[146.4]
2587 4394 4295

[101.8] [173.0] [169.1]
ENCLOSED BASKET - AIRFIRST (OPTIONAL)

Figure 4
XR BOOM CHASSIS DIMENSIONS - LENGTH
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SPECIFICATIONS
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November 2013
NOTE: DIMENSIONS IN MM (INCHES) ARE APPROXIMATE ONLY AND SUBJECT TO
NOTE: DIMENSIONS APPLY TO ALL VEHICLES WITH OPEN AND ENCLOSED

BASKETS. VEHICLE SHOWN WITH ENCLOSED BASKET.
2656
[104.6]
2669
[105.1]
2743
[108.0]
FRONT VIEW
Figure 5
CHASSIS DIMENSIONS - WIDTH
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November 2013
5. ENGINE SPECIFICATIONS AND OPERATING RPM
ENGINE SPECIFICATIONS AND OPERATING RPM

LOW IDLE
MODEL* MIDDLE/ PEAK TORQUE** RATED POWER**
HIGH IDLE
Mercedes Diesel,
800 rpm
OM 906 LA, 6 cylinders 1000 Nm (738 lbf-ft.) 190 kW (255 hp)
N/A
6.4 L (390 cu.in.) @ 1400 rpm @ 2200 rpm
2200 rpm
EPA Tier 3, EU Stage IIIA
Cummins Diesel,
10751150 rpm
QSB 4.5, 4 cylinders 624 Nm (460 lbf-ft.) 119 kW (160 hp)
N/A
4.5 L (275 cu.in.) @ 1500 rpm @ 2200 rpm
2200 25 rpm
Cummins Diesel,
10751150 rpm
N/A
4.5 L (275 cu.in.) @ 1500 rpm @ 2200 rpm
2200 25 rpm
EPA Tier 4i, EU Stage IIIB
Cummins Diesel,
10751150 rpm
1800 25 rpm
6.7 L (408 cu.in.) @ 1500 rpm @ 2200 rpm
2200 25 rpm
* All engines four-stroke, direct injection, turbocharged and air charge cooled, liquid cooling system.
** Approximated information data. Refer to specific placard on engine, and to the engine manual in
Chapter 5, Manufacturers Appendices for additional information.
6. FUEL SPECIFICATIONS AND RECOMMENDATIONS
FUEL SPECIFICATIONS AND DESIGNATIONS
SULFUR % BY FUEL EPA

FUEL TYPE
CONTENTS MASS DESIGNATION REQUIREMENT
Non-road diesel fuel 10 000 ppm 1.0% High-sulfur diesel EPA Tier 1
Non-road diesel fuel 5000 ppm 0.5% High-sulfur diesel EPA Tier 2
Non-road diesel fuel >500 ppm >0.05% Low-sulfur diesel EPA Tier 2
Non-road diesel EPA Tier 2

<500 ppm <0.05% Low-sulfur diesel
Highway diesel fuel* EPA Tier 3
Non-road diesel fuel** Ultra-low sulfur EPA Tier 3

15 ppm 0.0015%
Highway diesel fuel* diesel EPA Tier 4
* EPA mandated for the U.S. that by October 2010 all on-road diesel fuel must be 15 ppm Ultra-Low
Sulfur Diesel (ULSD), and off-road diesel fuel must be 500 ppm. The exception is the State of
California that required all diesel fuels to be 15 ppm ULSD since January 2007, and it applies to all
vehicles and equipment with no exceptions. EPA also required for all the U.S. that 2007 model year
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SPECIFICATIONS
Page 11
November 2013
and newer vehicles must use ULSD fuel, called also Sulfur-free diesel fuel.
** In 2004, EPA defined Tier 4 standards to be phased-in over 20082015, requiring substantial
emission reductions and more stringent limits through the use of control technologies.
CAUTION
DO NOT USE DIESEL FUELS WITH SULFUR CONTENTS GREATER THAN 10 000 PPM (1.0%
BY MASS). FAILURE TO COMPLY MAY RESULT IN DAMAGE TO VEHICLE COMPONENTS!
CAUTION
WHEN USING DIESEL FUELS WITH SULFUR CONTENTS BETWEEN 5000 PPM AND 10 000
PPM, THE INTERVAL TO CHANGE THE LUBE OIL MUST BE DECREASED FROM 500 HOURS
TO 250 HOURS. FAILURE TO COMPLY MAY RESULT IN DAMAGE TO VEHICLE
COMPONENTS!
CAUTION
WHEN USING DIESEL FUELS WITH SULFUR CONTENTS GREATER THAN 500 PPM (0.05% BY
MASS) AND THE ENGINE IS EQUIPPED WITH AN EXTERNALLY COOLED EGR (TIER 3
ENGINES), LARGER FILTERS WITH TIGHTER MICRON FILTRATION MUST BE USED.
CONSULT THE ENGINE MANUFACTURER FOR MODIFICATIONS NEEDED. FAILURE TO
CAUTION
DO NOT USE DIESEL FUELS WITH SULFUR CONTENTS GREATER THAN 15 PPM (0.0015% BY
MASS) IN EPA TIER 4 ENGINES. FAILURE TO COMPLY MAY RESULT IN DAMAGE TO
VEHICLE COMPONENTS AND VOID WARRANTY!
CAUTION
DO NOT USE JET A1 FUEL IN THIS VEHICLE. REFER TO ENGINE MANUFACTURER FOR
SPECIFIC RECOMMENDATIONS. FAILURE TO COMPLY MAY RESULT IN DAMAGE TO
VEHICLE COMPONENTS!
7. FUEL SYSTEM
A. FUEL TYPE
Refer to Fuel Specifications and Recommendations, and Cautions above.
Diesel fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ASTM D 975-88, No. 1-D and 2-D

Turbine fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . Jet A-1, ASTM No. 2-GT (only if fuel
lubricity is adequate; special filters
required)
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November 2013
B. FUEL TANK CAPACITY
Fill capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . 379 L (100 gal.)
C. FILTER TYPE
Primary filter . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel and water separator with screen

filtration
Secondary filter . . . . . . . . . . . . . . . . . . . . . . . . . Canister type (spin-on)
Hand prime pump on fuel and water separator . Standard
Heated fuel and water separator . . . . . . . . . . . . Optional
NOTE: FUEL WAXING MAY OCCUR AT LOW TEMPERATURES, CLOGGING THE FUEL
SYSTEM AND REDUCING THE ENGINE EFFICIENCY. IF THE AMBIENT
TEMPERATURE IS LESS THAN 0 C (32 F), WINTER-GRADE FUEL (SUITABLE DOWN
TO -10 C [15 F]) SHOULD BE USED. FOR TEMPERATURES BELOW -10 C (15 F)
REFER TO THE ENGINE OPERATION MANUAL.
NOTE: FOR OPERATION AT TEMPERATURES BELOW -23 C (-10 F), THE FUEL FILTER
HEATER OPTION IS RECOMMENDED. REFER TO ENGINE MANUFACTURERS
MANUAL IN CHAPTER 5 FOR FURTHER INFORMATION.
8. COOLING SYSTEM
Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Radiator, mounted in front of engine

Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Water and ethylene-glycol
Flow type (external exchanger) . . . . . . . . . . . . . . . . . . Air-sucking fan driven by the engine
Oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Integrated at bottom of radiator
9. TIRES AND WHEELS
Tire type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rubber pneumatic, radial tubeless

Tire brand and sizes (front and rear) . . . . . . . . . . . . . . 315/80 R22.5 Toyo (Standard)
315/80 R22.5 Goodyear (Optional)
NOTE: FOR TIRES INFLATION PRESSURE AND WHEEL LUG NUT TORQUE, REFER TO
MAINTENANCE SPECIFICATIONS IN CHAPTER 2, SECTION 4.
10. HYDRAULIC SYSTEM
A. GENERAL
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Closed centered, pressure

compensated
B. FLUID TYPE
NOTE: SPECIFICATIONS AND CHARACTERISTICS OF THE HYDRAULIC FLUID TO BE USED

WITH THE VEHICLE WILL DEPEND ON THE WEATHER OPERATING CONDITIONS.
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SPECIFICATIONS
Page 13
November 2013
Refer to Maintenance Specifications in Chapter 2, Section 4 for fluid types and oil operating
temperature ranges.
C. HYDRAULIC HOSES
Pressure Hoses
Diameters 6.412.7 mm (0.250.5 in.). . . . . . . . SAE 100R2, SAE standard J517

Diameters 1931.8 mm (0.751.25 in.) . . . . . . . SAE 100R12, SAE standard J517
Suction Hoses
All diameters . . . . . . . . . . . . . . . . . . . . . . . . . . . SAE 100R4, SAE standard J517
11. BRAKES
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Air (service brakes)

Service brakes air compressor . . . . . . . . . . . . . . . . . . . Engine mounted, 8 bar (116 psi),
425 L/min. (15 cfm) @ 2200 rpm
12. ELECTRICAL SYSTEM
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 VDC with numbered circuit wiring

harnesses
Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dual 12-volt DC battery system in
series, 950 CCA, deep cycle, 195
minutes reserve capacity
Starter motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 VDC, 4 kW
Charge system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 VDC, 100 Ah
Winterization system (optional) . . . . . . . . . . . . . . . . . . 240 VAC 60 A, male connector
Body, tank, and cab heater (optional) . . . . . . . . . . . . . . 240 VAC 60 A, built-in thermostat,
smart limit protection, blower fan
External electrical connector (optional) . . . . . . . . . . . . 24 VDC NATO plug
Battery disconnect switch (optional) . . . . . . . . . . . . . . . Two-pole ON / OFF switch,
removable key and chain lanyard
13. VEHICLE JACKING REQUIREMENTS
A. JACK CAPACITY
Minimum working capacity (each axle) . . . . . . . 20 000 kg (44 000 lb. [22 ton])
B. MAINTENANCE STANDS CAPACITY
Minimum number of stands . . . . . . . . . . . . . . . . Four (2 front, 2 rear)

Minimum working capacity (each) . . . . . . . . . . . 10 000 kg (22 000 lb. [11 ton])
Stress exerted by vehicle . . . . . . . . . . . . . . . . . . 9660 kPa (1400 psi)
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Page 14
November 2013
C. JACK AND MAINTENANCE STANDS SUPPORT SURFACE
Reinforced concrete surface (required) . . . . . . 24 MPa (3500 psi) minimum
NOTE: SOME CONCRETE AND MOST ASPHALT SURFACES MAY NOT COMPLY WITH THE
MINIMUM RESISTANCE REQUIRED. INCREASING SUPPORT PAD AREA OF JACKS
AND MAINTENANCE STANDS CAN REDUCE THE STRESS ON THE GROUND
SUPPORT SURFACE.
NOTE: ENSURE THE SUPPORT SURFACE IS STRONG ENOUGH TO WITHSTAND THE

STRESS EXERTED BY THE VEHICLE WEIGHT, TRANSFERED THROUGH THE JACKS
AND MAINTENANCE STANDS.
14. ENVIRONMENTAL LIMITATIONS
A. OPERATING TEMPERATURES
AMBIENT OPERATING CONDITIONS
OPERATING AMBIENT TEMPERATURE

RECOMMENDATION
CONDITION RANGE*
-29 C to +51 C
Normal Engine does not require assisted starts.
(-20 F to +123 F)
Requires vehicle to be pre-heated (engine

Extremely cold Below -29 C (-20 F)
block, oil pan, and fuel filter).
Extremely hot Above +51 C (+123 F) Requires special hydraulic oil.
* Refer to Manufacturers Appendices in Chapter 5 for engine operating temperature ranges and
oil specifications, and related information for other components. Contact JBT AeroTech,
Ground Support Equipment for operating in extreme weather.
B. WINTERIZATION OPTION
The Tempest is designed with an engine that will start with no additional aids other than the
standard grid heater set down to -18 C (0 F). The winterization option has battery heaters,
immersion engine block heater, and hydraulic tank immersion heaters which maintain functionality
at a minimum of -40 C (-40 F).
Wiring harness connections are fitted with boot seals for harsh environments.
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SPECIFICATIONS
Page 15
November 2013
15. OPERATORS VIBRATION AND SOUND LEVELS
A. SOUND LEVEL EMISSION DATA
SOUND LEVEL EMISSION DATA
Test Locations and Conditions*
Drivers Cab Open / Enclosed Basket Exterior
Engine Standstill Driving Standstill Driving Driving
Cummins QSB 4.5 72 dB 74 dB 78 dB / 78 dB 78 dB / 74 dB 80 dB
Cummins QSB 6.7 72 dB 75 dB 78 dB / NA 79 dB / NA 80 dB
Mercedes OM 906 N/A N/A N/A N/A N/A
* All sound tests performed with hush kit installed.
Standard. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EN 1915-4 and ISO 4871
Driver position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Sitting (two-man mode)
Operator position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Standing (open basket)

Sitting (enclosed basket)
Sound power tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Stationary, driving
Test uncertainty (K = 1.6R) . . . . . . . . . . . . . . . . . . . . . 4 dB
Technical measures for noise reduction. . . . . . . . . . . . . Not applicable
Possible ways to minimize noise exposure . . . . . . . . . . Wearing hearing protection
B. VIBRATION LEVEL DATA
Standard. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EN 1915-3
Driver position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Sitting (two-man mode)
Operator position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Standing (open basket)

Sitting (enclosed basket)
Vibration Values
On open basket floor . . . . . . . . . . . . . . . . . . . . . . awzF = 6.9 m/s2 (22.6 ft./s2)
On enclosed basket seat . . . . . . . . . . . . . . . . . . . awzS = 7.2 m/s2 (23.6 ft./s2)
Test Uncertainty (K = 0.3 awz)
Open basket . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.0 m/s2 (6.6 ft./s2)

Enclosed basket . . . . . . . . . . . . . . . . . . . . . . . . . 2.2 m/s2 (7.2 ft./s2)
Technical measures for vibration reduction . . . . . . . . . . Not applicable
Possible ways to minimize vibration exposure . . . . . . . . Not applicable
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Page 16
November 2013
16. UNITS OF MEASUREMENT USED IN THIS MANUAL
Base and derived units of measurement used in this manual are in accordance to the International
System of Units (SI) of the International Bureau of Weights and Measures (BIPM).
METRIC AND STANDARD UNITS AND CONVERSIONS
Metric to Standard Standard to Metric
mm (millimeter) x 0.039 = in. x 25.4 = mm

in. (inch)
x 39.37 = in. x 0.0254 = m
m (meter) x 3.281 = ft. ft. (foot) x 0.3048 = m
x 1.094 = yd. yd. (yard) x 0.914 = m
km (kilometer) x 0.621 = mi. mi. (mile) x 1.609 = km
km/h (kilometers per
x 0.621 = mph mph (miles per hour) x 1.609 = km/h
hour)
m2 (square meter) x 10.764 = sq.ft. sq.ft. (square foot) x 0.093 = m2
m3 (cubic meter) x 35.315 = cu.ft. cu.ft. (cubic foot) x 0.028 = m3

x 61.024 = cu.in. cu.in. (cubic inch) x 0.0164 = L
x 0.264 = gal. gal. (gallon) x 3.785 = L
L (liter)
x 1.057 = qt. qt. (quart) x 0.946 = L
x 0.035 = cu.ft. cu.ft. (cubic foot) x 28.317 = L
L/min. (liters per gpm (gallons per
x 0.264 = gpm x 3.785 = L/min.
minute) minute)
kg (kilogram) x 2.205 = lb. x 0.454 = kg
lb. (pound)
x 2204.6 = lb. x 0.00045 = t
t (tonne) (metric ton)
x 1.102 = tn tn (ton) (short) x 0.907 = t
bar (pressure) x 14.504 = psi psi (pounds per x 0.069 = bar
kPa (kilopascal) x 0.145 = psi square inch) x 6.895 = kPa
x 0.738 = lbf-ft. lbf-ft. (foot-pound) x 1.356 = Nm
Nm (Newtonmeter)
x 8.851 = lbf-in. lbf-in. (inch-pound) x 0.113 = Nm
N (Newton) x 0.225 = lbf lbf (pound force) x 4.448 = N
kW (kilowatt) x 1.341 = hp hp (horse power) x 0.746 = kW
C (Celsius) x 1.8 + 32 = F F (Fahrenheit) - 32 / 1.8 = C
C (temperature F (temperature
x 1.8 = F (diff.) x 0.556 = C (diff.)
differential*) differential*)
* Temperature differential refers to the difference between two temperature points as opposed to a
specific temperature expressed in both C and F.
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SPECIFICATIONS
Page 17
November 2013
17. FLUID CONFIGURATIONS
FLUID CONFIGURATIONS CHART

Type I Premix
Fluid Configurations(1) Proportional Mix (2)
Two-Tank Prop Mix (2)
blendUP
AW (3)
Total tank capacity
7570 L (2000 gal.) X X X X
8328 L (2200 gal.) X X X
Deice fluid tank capacity
6056 L (1600 gal.) X X X
5488 L (1450 gal.) X
2650 L ( 700 gal.) X
Pure fluid tank capacity
1325 L ( 350 gal.) X
TANKS
2840 L ( 750 gal.) X

4088 L (1080 gal.) X
Anti-ice fluid tank capacity
1514 L ( 400 gal.) X X X X X
Water tank capacity
4165 L (1100 gal.) X
4240 L (1120 gal.) X
5488 L (1450 gal.) X
6056 L (1600 gal.) X
Detergent tank capacity
1514 L ( 400 gal.) X
Deice fluid pump
Meyers centrifugal X X
Hardi rotary diaphragm (I) X X X X
Anti-ice fluid pump
Hardi rotary diaphragm (II) X X X X X
PUMPS
Water pump
Meyers centrifugal X
Hardi rotary diaphragm (I) X X
Detergent pump
Hardi rotary diaphragm (II) X
Heater circulating pump
Meyers centrifugal X X X
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Page 18
November 2013
FLUID CONFIGURATIONS CHART (CONT.)
Type I Premix
Fluid Configurations(1) Proportional Mix (2)
Two-Tank Prop Mix (2)
blendUP
AW (3)
OptiMax heater
with mild steel coils X X X
with stainless steel coils X X X
Digital fluid flow meter X X X X
OTHER
Operator mix selections

Five-ratio selections available X
Multi-ratio selections available X X
Body insulation X X X
Comprehensive winterization X
(1) All capacities in gallons and quarts of gallons refer to U.S. gallons, except when otherwise noted.
(2)
The two-pump, and the two-tank Prop-mix systems are provided with no anti-ice fluid system.
(3)
AW = Aircraft Washing vehicle.
PUMP CAPACITIES
Meyers Centrifugal Hardi Rotary Diaphragm (I) Hardi Rotary Diaphragm (II)
208246 L/min. (5565 gpm) 208246 L/min. (5565 gpm) 95 L/min. (25 gpm)
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SPECIFICATIONS
Page 19
November 2013
18. BASKET CONFIGURATIONS
BASKET CONFIGURATIONS CHART
Basket Options Open Basket Enclosed Basket
Features Square Round Basic AirFirst
Basket rotation angle 180 160
Basket heater* X X
Top window defroster (optional) X X
Wipers: front, and sides X X
Wipers: top window (optional) X X
Operators safety harness X X
High-back seat with seat belts X X
Nozzles
Hand-held nozzles X
Deice nozzle, rolling turret X
Dual deice and anti-ice nozzles X X
High/Low volume, electronic control X X
Joystick controls
Boom operation
X X X X
Fluid application
X X
One-man drive and operation
X X X X
(optional)
Upgraded engine
Cummins QSB 6.7, 6 cylinders X
Mercedes OM 906 LA, 6 cylinders X
Air nozzle with patented rubber tip,

45 kg/min. @ 1 bar (100 lb./min. @ 14 psi) X
Hydrostatic gear driven compressor

lubricity system with heating and cooling X
* The basket heater operates on diesel fuel. The heater tank has a capacity of 4.7 L (1.25 gal.) and it
is located on the back of the enclosed basket.
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Page 20
November 2013
1. GENERAL
This section contains general information, and preparation of the Tempest Aircraft Deicer for
transportation. Check regulations of the states and countries through which the vehicle will be
transported, for specific requirements such as dimensional limitations, and whether or not the vehicle
can be transported with fuel, fluids, etc. Also review Storage in Chapter 1, Section 6 for storage
requirements and information on protection that may be required if time en route is expected to be more
than three days.
The unit is shipped from the factory with deicing, anti-icing, and water tanks empty. It is recommended
to transport this vehicle with those tanks empty.
NOTE: THE EQUIPMENT PRE-OPERATIONAL CHECKLIST SHOULD BE UTILIZED WHEN

COMMISSIONING NEW EQUIPMENT, AND FOR RE-COMMISSIONING AFTER A
MAJOR REPAIR, OVERHAUL, RECOMMENDED ANNUAL MAINTENANCE, OVER-THE-
ROAD TRANSPORTATION, AND IF THE MACHINE HAS BEEN OUT OF SERVICE FOR
MORE THAN SIX MONTHS.
NOTE: REFER TO EQUIPMENT PRE-OPERATIONAL CHECKLIST IN CHAPTER 2, SECTION 3.
NOTE: REFER TO SPECIFICATIONS IN CHAPTER 1, SECTION 4 FOR WEIGHT, GENERAL

DIMENSIONS, AND OTHER DETAILS BEFORE TRANSPORTING THE VEHICLE.
2. PREPARATION OF THE UNIT FOR SHIPPING
WARNING
BEFORE REMOVING OR INSTALLING VEHICLE COMPONENTS, ENSURE THE VEHICLE IS ON
LEVEL GROUND, WHEELS ARE SECURELY CHOCKED AND ELECTRICAL SYSTEM IS
SWITCHED OFF. FAILURE TO COMPLY MAY RESULT IN SERIOUS BODILY INJURY, DEATH,
NOTE: IT IS RECOMMENDED TO TRANSPORT THE VEHICLE WITH THE DEICING,

ANTI-ICING, AND WATER TANKS EMPTY.
NOTE: REFER TO PURGING PUMPS AND HOSES BEFORE SHIPPING OR LONG TERM
STORAGE IN STORAGE, CHAPTER 1, SECTION 6.
A. DISASSEMBLY AND ASSEMBLY INSTRUCTIONS
The vehicle is shipped with the parking brake released, engine switch Off, electrical power
disconnected and traction circuit disengaged. Fragile components are packed in separate
box(es).
(1) Rest and secure boom on its support prior to transportation.
(2) Protect outside mirrors with plastic wrapper or similar material, and fold them inboard.
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(3) It is recommended to empty all tanks prior to transportation.
(4) Verify the load capacity of the truck to be used for transportation.
B. PREPARATION
Preparation of the vehicle is very important, especially if transportation will be by sea, or it is

expected to last for more than a week. It must be considered that the vehicle may be exposed to
unusual weather conditions during transportation.
(1) Lubrication (refer to Recommended Lubricants in Maintenance Specifications in Chapter 2,

Section 4).
(a) Apply grease to exposed cylinder rods.
(b) Disconnect battery cables and apply grease to cable ends.
(c) Apply grease to door hinges and latches.
(2) Remove batteries and crate for shipment. Cover terminals with protective grease.
(3) Protect engine. If shipment will keep the vehicle out of service for an extended period of
time, follow storage instructions on the engines manual (refer to Manufacturers
Appendices in Chapter 5).
3. LOADING AND UNLOADING THE VEHICLE
The Tempest has a profile similar to a standard truck. Its ground clearance differs due to the extended
rear chassis, and the basket at rest in the front of the vehicle. These clearances may present limitations
to load and unload the vehicle.
Verify that clearance angles are greater than those of trucks and loading ramps to avoid the vehicle to
get stuck while loading or unloading.
4. TRANSPORTATION
CAUTION
OUTSIDE MIRRORS MUST BE FOLDED INBOARD FOR SHIPPING. FAILURE TO COMPLY MAY
The following information is given for a standard vehicle with tanks empty, and the boom and basket
resting on their supports in the frame of the vehicle.
A. SHIPPING VOLUME AND WEIGHT
Open basket (Standard) . . . . . . . . . . . . . . . . . . . . . . . . . 93 m3 (3285 cu.ft.)
Open basket (Round without top) . . . . . . . . . . . . . . . . . 98 m3 (3460 cu.ft.)
Enclosed basket (Standard nozzle) . . . . . . . . . . . . . . . . 106 m3 (3745 cu.ft.)
Enclosed basket (AirFirst) . . . . . . . . . . . . . . . . . . . . . 102.5 m3 (3620 cu.ft.)
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NOTE: REFER TO SPECIFICATIONS IN CHAPTER 1, SECTION 4 FOR WEIGHTS AND
DIMENSIONS OF THE SPECIFIC CONFIGURATION TO DETERMINE LOAD CARRYING
REQUIREMENTS FOR THE VEHICLE TO BE USED FOR TRANSPORTATION.
B. TOWING
Release the parking brake after attaching the deicer to the towing vehicle. Ensure the air system
from the towing vehicle is connected to primary air tank on the deicer.
Towing of this vehicle must be done very slowly and only for short distances. If the distance the
vehicle must be towed is more than 15 m (50 ft.), the vehicle must be towed with the rear axle
lifted, or the drive shaft must be removed.
NOTE: REFER TO EMERGENCY PROCEDURES IN CHAPTER 1, SECTION 3 FOR

INSTRUCTIONS FOR TOWING THE VEHICLE AND REMOVING THE DRIVE SHAFT, IF
NECESSARY.
CAUTION

C. RESTRAINT
The Tempest must be restrained attaching tie-down straps or chains to the front and rear axles,
on both sides of the vehicle.
Restrain the vehicle with chains and over-center tensioning devices, and chocks. Inspect all
attaching points to ensure the restraints are secure and straps (if used) do not bear against
surfaces, causing failure en route due to chafing or vibration.
Also, secure the vehicle hooking up chains to the front and rear sections of the chassis to hook
points, if available. Towing points may be used for restraining the vehicle. Additional chains and
cables may be necessary, depending on the truck platform or deck used for transportation.
5. RECOMMENDED SHIPPING TRUCK
A low-profile, removable goose-neck trailer is recommended for transportation of this vehicle.
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October 2013
Section 6. Storage
1. GENERAL
It is very important to properly prepare a vehicle that will be de-commissioned, or removed from service
for an extended period of time. The purpose of proper preparation before storage is to avoid potential
damage due to moisture, rust and corrosion, and possible component seizing.
In addition, proper preparation of the vehicle prior to storage, as well as periodic verification during
storage, will allow to readily place the vehicle back into service with minimum effort, and without major
problems.

NOTE: REFER TO EQUIPMENT PRE-OPERATIONAL CHECKLIST IN CHAPTER 2, SECTION 3.
NOTE: MAINTENANCE SPECIFICATIONS ARE CONTAINED IN CHAPTER 2, SECTION 4.
CAUTION

OILS, GREASE, HYDRAULIC OIL, FUELS AND GLYCOLS.
2. STORAGE - ONE MONTH (MAXIMUM)
A. VEHICLE
No special action needed.
B. ENGINE
(1) Drain the engine crankcase.
(2) Fill the crankcase to the proper level with the recommended viscosity and grade oil.
(3) Fill the fuel tank with the recommended grade of fuel oil. Operate the engine for two
minutes, or until the engine is warm, at 1200 rpm at no load.
(4) Check the air cleaner. Service the air cleaner, if necessary.
(5) If freezing weather is expected during the storage period, add an ethylene glycol-based
antifreeze solution in accordance with the manufacturers recommendations.
(6) Clean outside of engine (except electrical system) with fuel oil. Dry with compressed air.
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(7) Seal all engine openings. The material used for this purpose must be waterproof, vapor-
proof and possess sufficient physical strength to resist puncture or damage from the
expansion of entrapped air.
C. BATTERIES AND ELECTRICAL PANEL
Disconnect and remove batteries and store them in a cool and dry location. Connect them to a
float charger, if possible.
D. TRANSMISSION
E. AXLES
F. WHEELS AND TIRES
Chock drive wheels front and rear to prevent movement in any direction. If possible, raise vehicle
and chock axles to prevent tire contact with ground, and reduce tire pressure to 100 kPa / 1 bar
(15 psi).
G. HYDRAULIC SYSTEM
H. DEICING AND ANTI-ICING FLUID TANKS
I. DEICING AND ANTI-ICING FLUID PUMPS
Purge pumps, hoses, delivery lines and nozzles.
J. DEICING FLUID HEATER AND FUEL TANK
K. GENERAL COMPONENTS
Coat all exposed unpainted metal surfaces with rust preventative.
3. STORAGE - INDEFINITE PERIOD
A. VEHICLE
(1) Touch up all worn or damaged paint to prevent rust.
(2) Ensure that all points are lubricated with specified grease, oil, etc.
(3) Attach a tag on the steering wheel stating: CAUTION: ALL LUBRICANTS HAVE BEEN
DRAINED FROM THIS VEHICLE.
(4) Once all recommended steps are performed, refer to Equipment Shelter below in this
section for recommended protection of the equipment.
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B. ENGINE
(1) Drain the cooling system and flush with clean, soft water. Refill with engine manufacturers
recommended coolant.
(2) Remove, check and recondition the injectors, if necessary, to make sure they will be ready
to operate when the engine is restored to service.
(3) Reinstall the injectors, time them and adjust the exhaust valve clearance.
(4) Circulate the coolant by operating the engine until normal operating temperature is
reached.
(5) Turn off the engine.
(6) Drain the engine crankcase, then reinstall and tighten the drain plug. Install new lubricating
oil, filter elements and gaskets.
(7) Fill the crankcase to the proper level with engine manufacturers recommended crankcase
lubricating oil.
(8) Drain the fuel tank. Refill with enough clean No. 1 diesel fuel (or pure kerosene) to permit
the engine to operate for about ten minutes. If it is not convenient to drain the fuel tank,
use a separate supply of the recommended fuel.
(9) Drain and disassemble the fuel filter and strainer. Discard the used elements and gaskets.
Wash the shells in clean No. 1 diesel fuel and insert new elements.
(10) Fill the cavity between the element and shell with No. 1 diesel fuel (or pure kerosene) and
reinstall on the engine. If spin-on fuel filters and strainers are used, discard the used
cartridges, fill the new ones with No. 1 diesel fuel and install on the engine.
(11) Operate the engine for five minutes to circulate the clean fuel oil throughout the fuel
system.
(12) Service the air cleaner.
(13) Apply a non-friction, rust preventive compound to all exposed parts.
(14) Remove and clean the battery and battery cables with a baking soda solution and rinse
them with fresh water. Do not allow the soda solution to enter the battery.
(15) Apply belt dressing to pulleys and belts to prevent sticking.
(16) Seal all openings in the engine, including the exhaust outlet, with moisture-resistant tape.
Use cardboard, plywood or metal covers where practical.
(17) Clean and dry the exterior, painted surfaces of the engine and spray with a suitable liquid
automobile body wax, a synthetic resin varnish, or a rust preventative compound.
NOTE: REFER TO MANUFACTURERS APPENDICES IN CHAPTER 5 FOR ADDITIONAL

INFORMATION ON ENGINE MAINTENANCE AND PRESERVATION.
(18) Outdoor storage of engines (or transmissions) is not recommended. Nevertheless, in

some cases, outdoor storage may be unavoidable. If units must be kept outdoors, follow
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the preparation and storage instructions already given. Protect units with quality weather-
resistant tarpaulins (or other suitable covers) arranged to provide air circulation.
C. BATTERIES AND ELECTRICAL PANELS
(1) After batteries have been removed from the vehicle, add distilled water to the electrolyte, if
necessary, and fully charge them.
(2) Store batteries in a cool, dry place, not exposed to direct sunlight; never below 0 C (32 F)
or above 32 C (90 F). Do not leave batteries directly on the ground or concrete floor.
(3) Keep batteries fully charged. Connect them on a float charger, if possible.
(4) Check the level and the specific gravity of the electrolyte.
(5) Cover batteries for protection against dirt and moisture.
(6) Install new moisture inhibitors inside electrical panels. Apply plenty dielectric grease to all
exposed electrical connectors.
D. TRANSMISSION
(1) Drain transmission fluid.
(2) Seal with moisture-proof covers.
(3) Spray four ounces of atomized NOX RUST VCI No. 10 oil into drain hole. This fluid is
covered and approved per MIL-D-46002 and MIL-I-23310.
(4) Dip, spray, or brush all exposed, unpainted surfaces with NOX RUST X-110. This includes
shafts, flanges, seals, etc.
NOTE: PROLONGED STORAGE MAY BE DETRIMENTAL TO THE OIL SEALS IN THE

TRANSMISSION.
E. AXLES
F. WHEELS AND TIRES
Raise the vehicle and block chassis or axles to prevent contact of tires with ground. Reduce tire
pressure to 100 kPa / 1 bar (15 psi). Spray tires with a rubber preservative.
G. HYDRAULIC SYSTEM
CAUTION
(1) Coat exposed hydraulic cylinder rods with grease or rust preventative.
(2) Seal with moisture-proof covers.
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(3) Periodically inspect the hydraulic system. If there are any indications of rust or corrosion,
corrective steps must be taken to prevent damage to the hydraulic components.
H. DEICING AND ANTI-ICING FLUID TANKS
(1) Fill up tanks with their appropriate fluids (deicing, anti-icing, and water).
(2) If tanks made of stainless steel, they can be drained completely and washed with clean
water. Allow to dry thoroughly, and protect them from moisture.
I. DEICING AND ANTI-ICING FLUID PUMPS
Refer to PURGING PUMPS AND HOSES BEFORE SHIPPING OR LONG TERM STORAGE
within this section.
(1) Drain pumps completely.
(2) Seal and protect pumps.
J. DEICING FLUID HEATER AND FUEL TANK
(1) Drain heater from all fluids.
(2) Fill up fuel tank, and add a fuel stabilizer if necessary, depending on weather conditions.
K. GENERAL COMPONENTS
Coat all exposed unpainted metal surfaces with rust preventative.
L. EQUIPMENT SHELTER
Ideally, the vehicle should be stored in a shelter to protect it from the weather, since outdoor
storage of engines and transmissions is not recommended. Nevertheless, in some cases,
outdoor storage may be unavoidable. If the vehicle must be kept outdoors, follow all preparation
and storage instructions.
(1) Protect the engine with a good, weather-resistant tarpaulin and store it under cover,
preferably in a dry building which can be heated during the winter months.
(2) Protect the vehicle with quality, weather-resistant tarpaulins (or other suitable covers)
ensuring proper air circulation.
(3) Cover and tape instrument panels to provide a moisture-proof seal.
CAUTION
PLASTIC SHEETING MAY ONLY BE USED FOR INDOOR STORAGE. PLASTIC SHEETING
USED FOR OUTDOOR STORAGE WILL CREATE CONDENSATION WHICH MAY CAUSE METAL
SURFACES TO RUST OR PIT. FAILURE TO COMPLY MAY RESULT IN DAMAGE TO VEHICLE
COMPONENTS!
(4) The stored vehicle should be inspected periodically. If there are any indications of rust or
corrosion, corrective steps must be taken to prevent further damage. Perform a complete
inspection at the end of one year and apply additional treatment as required.
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4. PURGING PUMPS AND HOSES BEFORE SHIPPING OR LONG TERM STORAGE
A. DRAINING DEICING FLUID FROM PUMP AND GROUND HOSE
(1) Remove plug and install a male air fitting in deicing fluid pump port (0.25 in. MNPT) to
connect hose from air compressor. Save the plug to reinstall later.
(2) Turn gate valve clockwise (CW) to close.
(3) Remove fluid nozzle from holster and place in drum. Ensure nozzle is closed.
(4) Install air hose to the fitting previously installed on the pump. Turn on air from compressor
and allow air into the pump to reach full pressure.
(5) Open fluid nozzle and allow fluid to drain into the drum. It should drain 150190 liters (40
50 gallons) out of the nozzle.
(6) Close the fluid nozzle and allow air to reach full pressure again.
(7) Open ground hose nozzle to fully drain fluid into a bucket or drum.
(8) Close ground hose nozzle.
B. SIGHT TUBES DRAINING
(1) Remove hoses from sight tubes located at left front of the shroud and allow to drain
completely into a bucket.
(2) Close sight tube valves located on left side of fluid tank.
(3) Turn off air from compressor, and remove air hose and air fitting from fluid pump, and
reinstall plug on pump.
(4) Ensure fluid nozzle and ground hose nozzle are completely closed.
(5) Reconnect sight tubes.
C. DRAINING ANTI-ICE FLUID FROM PUMPS
(1) Remove plug and install a male air fitting in anti-icing fluid pump port (0.25 in. MNPT) to
connect hose from air compressor. Save the crush washer with the plug to reinstall later.
(2) Turn valve handles clockwise (CW) to close valves for hoses coming from the anti-icing
pump and going into the fluid tank.
(3) Remove fluid nozzle from holster and place in drum. Ensure nozzle is closed.
(4) Install air hose to the fitting previously installed on the pump. Turn on air from compressor
and allow air into the pump to reach full pressure.
(5) Open anti-ice fluid nozzle and allow fluid to drain into the drum.
(6) Close the anti-ice fluid nozzle.
(7) Remove air compressor hose from pump and reinstall the plug with the crush washer.
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5. RETURNING VEHICLE TO SERVICE
WARNING
PERFORM THE RE-COMMISSIONING MAINTENANCE PROCEDURES BEFORE RETURNING
THE VEHICLE INTO SERVICE AFTER STORAGE. FAILURE TO COMPLY MAY RESULT IN
VEHICLE!
A. RE-COMMISSIONING AFTER A SHORT PERIOD OF STORAGE
When returning the equipment to service after a short time period, the following must be
performed:
(1) Perform a general inspection of the vehicle in accordance to recommendations (refer to the
EQUIPMENT PRE-OPERATIONAL CHECKLIST in Chapter 2, Section 3).
(2) Replenish or replace all fluids, including oil, fuel, and coolant, according to maintenance
and lubrication recommendations and guidelines (refer to Preventative Maintenance in
Chapter 2, Section 3).
(3) Inspect tires for damage, cracks, and dry rot. Inflate to specifications, and remove vehicle
from raising blocks.
(4) As a minimum, perform the recommended daily and quarterly maintenance according to
Maintenance Schedules in Chapter 2, Section 3.
(5) Replenish deicing and anti-icing fluid, and water according to specifications and operation
requirements.
B. RE-COMMISSIONING AFTER AN EXTENDED PERIOD OF INACTIVITY
It is very important to properly prepare the vehicle, before placing it into service after an extended
storage period. An exhaustive inspection, and a comprehensive maintenance should be
performed on the equipment to ensure proper operation, and minimize breakdown and downtime.
(1) Perform a general inspection of the vehicle in accordance to recommendations (refer to the
EQUIPMENT PRE-OPERATIONAL CHECKLIST in Chapter 2, Section 3).
(2) Replenish or replace all fluids, including oil, fuel, and coolant, according to maintenance
and lubrication recommendations and guidelines (refer to Preventative Maintenance in
Chapter 2, Section 3, and Manufacturers Appendices in Chapter 5).
(3) Inspect tires for damage, cracks, and dry rot. Inflate to specifications, and remove vehicle
from raising blocks.
(4) Before placing the vehicle into operation, fully recharge the batteries before installing them
back in the vehicle.
(5) Perform ALL the recommended maintenance (daily, quarterly, and annually) according to
Maintenance Schedules in Chapter 2, Section 3.
(6) Replenish deicing and anti-icing fluid, and water according to specifications and operation
requirements.
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TABLE OF CONTENTS
Section 1. Safety Precautions
1. INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. PREPARING THE UNIT FOR MAINTENANCE (LOCK-OUT AND TAG-OUT) . . . . . . . . . . . . . . . . 1
Table - ENERGY SOURCES AND DEVICES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3. WARNINGS AND CAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Section 2. Systems Overview
1. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. CHASSIS AND POWER MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
A. FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
B. COLD WEATHER FUEL SYSTEM (OPTIONAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
C. DIESEL ENGINE WINTERIZATION KIT (OPTIONAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3. HYDRAULIC SYSTEM - GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
A. HYDRAULIC PROPULSION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
B. SERVICES PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
C. AIRFIRST SYSTEM (OPTIONAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
D. LOAD SENSING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
E. MAIN RELIEF VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
F. EMERGENCY PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
G. FILTRATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4. HYDRAULIC SYSTEM - AERIAL DEVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
A. BOOM HYDRAULIC OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
B. BOOM RAISE AND LOWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
C. BOOM ROTATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
D. JIB BOOM RAISE AND LOWER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
E. OPERATORS BASKET ROTATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
F. OPERATORS BASKET LEVELING RAISE AND LOWER . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
5. HYDRAULIC SYSTEM - FLUID SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
A. DEICING DELIVERY PUMPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
B. DEICE AND WATER DELIVERY PUMPS (PROP-MIX) (OPTIONAL) . . . . . . . . . . . . . . . . . . 9
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C. ANTI-ICE AND RE-FILLER PUMPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
D. BLOWER DRIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
E. FLUID HEATER FUEL PUMP DRIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
F. HEAT EXCHANGER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
6. ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
A. DRIVERS CAB ELECTRICAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
B. POWER MODULE ELECTRICAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
C. BATTERY DISCONNECT SWITCH (OPTIONAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
D. MONITOR AND CAMERA SYSTEM (OPTIONAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
E. ELECTRONIC HEATER CONTROLLER (EHC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
F. BOOM ELECTRICAL OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
G. OPERATORS OPEN BASKET ELECTRICAL INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . 14
H. OPERATORS ENCLOSED BASKET ELECTRICAL INSTALLATION . . . . . . . . . . . . . . . . . . 15
7. FLUIDS SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
A. DEICING SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
B. ANTI-ICING FLUID SYSTEM (OPTIONAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
8. AERIAL DEVICE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
A. ROTATOR ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
B. BOOM LIFT CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
C. KNUCKLE AND LEVELING CYLINDERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
D. JIB BOOM AND LIFT CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
E. BASKET PLATFORM AND ROTATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
F. OPEN BASKET ASSEMBLY OPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
G. OPERATORS ENCLOSED BASKET OPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
9. OPTIMAX HEAT SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
10. BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
11. INTERFACE MODULE (PDM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
A. INTERFACE MODULE NAVIGATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
B. TEMPEST DIAGNOSTICS PDM SCREENS (OPTIONAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
C. BLENDUP SYSTEM PDM SCREENS (OPTIONAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
D. BLENDUP FREEZE POINT ENTRY SCREENS (OPTIONAL). . . . . . . . . . . . . . . . . . . . . . . 29
E. XR BOOM SYSTEM PDM SCREENS (OPTIONAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
F. BLENDUP WITH XR SYSTEM PDM SCREENS (OPTIONAL) . . . . . . . . . . . . . . . . . . . . . . 31
Section 3. Preventative Maintenance
1. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. BEFORE COMMISSIONING A UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
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3. EQUIPMENT PRE-OPERATIONAL CHECKLIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Table - EQUIPMENT PRE-OPERATIONAL CHECKLIST . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
4. BREAK-IN PERIOD. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
5. PERIODIC MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
6. MAINTENANCE SCHEDULE TABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Table - MAINTENANCE SCHEDULEEVERY 8 HOURS (DAILY) . . . . . . . . . . . . . . . . . . . . 9
Table - MAINTENANCE SCHEDULEEVERY 500 HOURS (QUARTERLY). . . . . . . . . . . . . 11
Table - MAINTENANCE SCHEDULEEVERY 2000 HOURS (YEARLY) . . . . . . . . . . . . . . . 19
7. HYDRAULIC OIL RECOMMENDATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
8. LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
A. GREASE FITTINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
B. FRICTION POINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
C. FILL POINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Table - LUBRICATION AND REFILL CHART. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Section 4. Maintenance Specifications
1. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. HYDRAULIC OIL RECOMMENDATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Table - OIL OPERATING TEMPERATURE RANGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
3. HYDRAULIC OIL OPERATING TEMPERATURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
4. RECOMMENDED FLUIDS AND LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
A. NORMAL OPERATING TEMPERATURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Table - FLUIDS AND LUBRICANTS SPECIFICATIONS CHART . . . . . . . . . . . . . . . . . . . . . 2
Table - LUBRICANTS REFERENCE CHART. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
B. EXTREME WEATHER OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
5. EQUIPMENT ADJUSTMENT SETTINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Table - ADJUSTMENT SETTINGS CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
6. HYDRAULIC PRESSURE SETTINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Table - PRESSURE SETTINGS CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
7. OPERATIONAL SETTINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Table - OPERATIONAL SETTINGS CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
8. STABILITY AND LOAD TEST SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Table - STABILITY AND LOAD TEST SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
9. BOLT IDENTIFICATION CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Table - STANDARD AND METRIC STEEL BOLTS AND NUTS . . . . . . . . . . . . . . . . . . . . . . 14
10. BOLT TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Table - STANDARD STEEL BOLTS TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . 14
Table - METRIC STEEL BOLTS TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . 15
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Table - 18-8 AND 316 STAINLESS STEEL BOLTS TORQUE SPECIFICATIONS. . . . . . . . . 16
Table - TERMINAL BLOCKS TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Section 5. Maintenance Procedures
1. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
A. INDIVIDUAL MANUFACTURER'S INSTRUCTION SERVICING SCHEDULE . . . . . . . . . . . . 1
B. FLUID SYSTEM DRAIN PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2. ENGINE ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
A. ENGINE IDLE SPEED ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
B. ENGINE HIGH SPEED ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
3. HYDRAULIC SYSTEM ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
A. LOAD SENSING PRESSURE ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
B. COMPENSATOR AND MAIN RELIEF VALVE PRESSURE ADJUSTMENTS . . . . . . . . . . . . 6
C. HEATER BLOWER MOTOR, LOW SPEED ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . 8
D. HEATER BLOWER, HIGH SPEED ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
E. HEATER FUEL PUMP MOTOR SPEED ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
F. ANTI-ICE PUMP DRIVE MOTOR PRESSURE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . 12
G. ANTI-ICE PUMP, DRIVE MOTOR SPEED ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
H. ANTI-ICE PUMP (REFILL) DRIVE MOTOR SPEED ADJUSTMENT . . . . . . . . . . . . . . . . . . . 14
I. CIRCULATION AND DELIVERY PUMP PRESSURE ADJUSTMENT . . . . . . . . . . . . . . . . . . 16
J. CIRCULATION AND DELIVERY PUMP (35 GPM) DRIVE MOTOR SPEED . . . . . . . . . . . . . 17
K. CIRCULATION AND DELIVERY PUMP (60 GPM) DRIVE MOTOR SPEED . . . . . . . . . . . . . 18
L. POWER STEERING PRESSURE ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
M. BOOM VALVE, MAXIMUM FLOW ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Table - PROPORTIONAL VALVES ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
N. BOOM LOWERING RELIEF VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
O. BOOM RAISE RELIEF VALVE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
P. JIB BOOM LOWERING RELIEF VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Q. JIB BOOM RAISE RELIEF VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
R. BOOM ROTATION RELIEF VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
S. ENCLOSED BASKET LEVELING RELIEF VALVES, TILT BASKET UP. . . . . . . . . . . . . . . . . 25
T. ENCLOSED BASKET LEVELING RELIEF VALVES, TILT BASKET DOWN . . . . . . . . . . . . . 27
U. ENCLOSED BASKET DUAL COUNTERBALANCE VALVE, LEFT ROTATION . . . . . . . . . . . 28
V. ENCLOSED BASKET DUAL COUNTERBALANCE VALVE, RIGHT ROTATION . . . . . . . . . . 29
4. AERIAL DEVICE - BOOM ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
A. BOOM ROTATOR BACK LASH ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
B. ENCLOSED BASKET ROTATOR BACK LASH ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . 33
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5. HEATER ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
A. FLUID HEATER FUEL PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
B. ELECTRODE ANGLE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
C. HEATER BURNER HEAD ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
D. BURNER NOZZLE ASSEMBLY - DEPTH SETTING, STAGES 1 THROUGH 4 . . . . . . . . . . 37
E. AIR PRESSURE SWITCH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
F. FLUID TEMPERATURE GAUGES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
G. FLUID TEMPERATURE SWITCHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
6. HYDROSTATIC DRIVE CONTROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
A. NEW CONTROLLER CALIBRATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
B. CALIBRATION AFTER INSTALLING NEW SENSOR (FORCE NEW VALUES) . . . . . . . . . . 43
C. CALIBRATION AFTER FOOT PEDAL ADJUSTMENT (FORCE NEW VALUES) . . . . . . . . . 44
D. STEERING CONTROLLER CALIBRATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
7. PROGRAMMING CONTROLLERS FOR BOOM PROPORTIONAL VALVES . . . . . . . . . . . . . . . . 46
A. STEPS TO PROGRAM 519 CONTROLLER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
B. REFERENCE TABLES FOR CONTROLLER VALUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Table - JIB BOOM - LEFT ARM POD - 1VC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Table - BOOM - LEFT ARM POD - 3VC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Table - ROTATOR - LEFT ARM POD - 4VC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Table - ENCLOSED BASKET - RIGHT ARM POD - 5VC. . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
8. MISCELLANEOUS MAINTENANCE PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
A. REPLACE FUEL FILTER ELEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
B. INSPECTION FOR CARBON BUILD-UP ON HEATER COILS . . . . . . . . . . . . . . . . . . . . . . . 53
C. CHECK FUEL SOLENOID VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
D. CLEAN FUEL NOZZLE STRAINERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
E. BRAKES INSPECTION AND ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
F. GEAR BOX OIL LEVEL CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
G. FLUID ACCUMULATORS INSPECTION AND PRESSURE CHECK . . . . . . . . . . . . . . . . . . . 56
H. WHEEL REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
I. WHEEL INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
J. WHEEL LUG NUT TORQUE PROCEDURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
9. AERIAL DEVICE STABILITY AND LOAD TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
A. STABILITY TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
B. LOAD TEST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
10. FLUID SYSTEM TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
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Section 6. Troubleshooting
1. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
A. BEFORE TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
B. HYDRAULIC SYSTEM CLEANLINESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
A. PRESSURE READINGS AND ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
B. MALFUNCTIONS ISOLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
C. MANUAL OVERRIDE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
D. TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
3. ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
A. MAIN PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
B. MAIN COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
C. OTHER COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
D. TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
4. TROUBLESHOOTING GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
A. SCOPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
B. DIAGNOSTIC TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
C. HYDRAULIC OIL CONTAMINATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
D. COMPONENTS REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
5. TROUBLESHOOTING GUIDE TABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Table 1 - ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Table 2 - ENGINE AIR INTAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Table 3 - ENGINE COOLING SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Table 4 - ENGINE FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Table 5 - TRANSMISSION GEAR BOX. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Table 6 - AXLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Table 7 - DRIVE SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Table 8 - HYDRAULICS (STEERING) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Table 9 - HYDRAULICS (PUMPS). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Table 10 - HYDRAULICS (AERIAL DEVICE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Table 11 - PNEUMATIC BRAKES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Table 12 - ELECTRICAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Table 13 - FLUID HEATER MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Table 14 - DRIVERS CAB AND ENCLOSED BASKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
6. TEMPEST DIAGNOSTIC ALARMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Table - Tempest DIAGNOSTIC ALARMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Table - Tempest XR BOOM ALARMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Table - Tempest BlendUP ALARMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Table - Tempest MONITOR POINT ALARMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
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7. ELECTRONIC CONTROLLERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
A. FAULT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Table - ELECTRONIC CONTROLLER FAULT TYPES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Table - ELECTRONIC CONTROLLER FAULT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
B. STEERING CONTROLLER FAULT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Table - STEERING CONTROLLER FAULT TYPES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Table - STEERING CONTROLLER FAULT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Section 7. System Schematics
1. GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
A. BEFORE TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
B. HYDRAULIC SYSTEM CLEANLINESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. ELECTRICAL SCHEMATICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Table - Tempest ELECTRICAL SCHEMATICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3. HYDRAULIC SCHEMATICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Table - Tempest HYDRAULIC SCHEMATICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
4. AIR BRAKE SCHEMATICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Table - Tempest AIR BRAKE SCHEMATICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
5. FLUID SYSTEM SCHEMATICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Table - Tempest FLUID SYSTEM SCHEMATICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Section 8. Electronic Heater Controller (EHC)
1. ELECTRONIC HEATER CONTROLLER (EHC) OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

A. INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
B. AUTO MODE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
C. MANUAL MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
D. CALIBRATION (CAL.) MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
E. ERROR MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Table - CONTROLLER ERROR CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2. ELECTRONIC HEATER CONTROLLER (EHC) CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 5
A. DEUTSCH CONNECTOR PIN OUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Table - DEUTSCH CONNECTOR PINS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
B. OUTPUT LISTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Table - CONNECTOR OUTPUTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
C. INPUT LISTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Table - CONNECTOR INPUTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
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D. ERROR CODES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Table - CONNECTOR ERROR CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
E. RESISTIVE THERMAL DEVICE (RTD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
F. TIMING SEQUENCE CHART - TEMPEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
G. TEMPEST HEATER CYCLE CUT-OUTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Table - HEATER TEMPERATURE STAGES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3. ELECTRONIC HEATER CONTROLLER (EHC) CALIBRATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
A. CALIBRATION INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Table - CALIBRATION COEFFICIENTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
B. RESISTIVE THERMAL DEVICE (RTD) CALIBRATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
4. TROUBLESHOOTING GUIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
A. INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
B. NON-CRITICAL ERRORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
C. CRITICAL ERRORS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Table - NON-CRITICAL ERROR CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
D. MANUALLY OPERATING OUTPUTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Table - CRITICAL ERROR CODES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
E. TROUBLESHOOTING REFERENCE GUIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Table - TROUBLESHOOTING QUICK REFERENCE GUIDE. . . . . . . . . . . . . . . . . . . . . . . . . 21
Section 9. AirFirst System (Optional)
1. DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. SERVICING THE AIRFIRST SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
A. LUBRICATION SYSTEM, AIRFIRST SERVICE KIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
B. LUBRICATION SYSTEM, AIRFIRST COMPRESSOR ANNUAL SERVICE . . . . . . . . . . . . 2
3. AIRFIRST SYSTEM, INSTALLING OR REPLACING COMPONENTS . . . . . . . . . . . . . . . . . . . . . 3
A. REPLACING AIRFIRST HYDRAULIC PUMP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
B. REPLACING AIRFIRST HYDRAULIC MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
C. REPLACING AIRFIRST COMPRESSOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
D. REPLACING AIRFIRST P-Q CONTROL CARD. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
4. AIRFIRST COMPRESSOR SET-UP PROCEDURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
A. START-UP PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
B. ADJUSTING THE P-Q CONTROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Table 1 - AirFirst COMPRESSOR CONTROLLER PANEL . . . . . . . . . . . . . . . . . . . . . . . . . 6
Table 2 - AirFirst OIL TEMPERATURE AND PRESSURE. . . . . . . . . . . . . . . . . . . . . . . . . . 8
Table 5 - AirFirst COMPRESSOR CONTROLLER PANEL . . . . . . . . . . . . . . . . . . . . . . . . . 10
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LIST OF FIGURES
2-1 Figure 1 LOCATIONS OF ENERGY SOURCES AND DEVICES . . . . . . . . . . . . . . . . . . . . 5
2-2 Figure 1 POWER MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

2-2 Figure 2 CUMMINS QSB DIESEL ENGINES (TYPICAL) . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2-2 Figure 3 POWER MODULE HYDRAULIC PUMPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2-2 Figure 4 BOOM HYDRAULIC CYLINDERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2-2 Figure 5 HEAT EXCHANGER LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2-2 Figure 6 OPEN BASKET ELECTRICAL COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2-2 Figure 7 ENCLOSED BASKET ELECTRICAL COMPONENTS . . . . . . . . . . . . . . . . . . . . . 15
2-2 Figure 8 FLUID SYSTEM WITH PROP-MIX (OPTIONAL) . . . . . . . . . . . . . . . . . . . . . . . . . 18
2-2 Figure 9 FLUID SYSTEM WITH MEYERS PUMP (OPTIONAL) . . . . . . . . . . . . . . . . . . . . . 19
2-2 Figure 10 OPTIMAX HEAT SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
2-2 Figure 11 PDM - INTERFACE MODULE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
2-2 Figure 12 TEMPEST DIAGNOSTICS MAIN MENU (OPTIONAL). . . . . . . . . . . . . . . . . . . . . 24
2-2 Figure 13 TEMPEST DIAGNOSTICS PDM NAVIGATION DIAGRAM . . . . . . . . . . . . . . . . . 25
2-2 Figure 14 TEMPEST BLENDUP MAIN MENU (OPTIONAL). . . . . . . . . . . . . . . . . . . . . . . 26
2-2 Figure 15 TEMPEST BLENDUP PDM NAVIGATION DIAGRAM - PART 1 . . . . . . . . . . . 27
2-2 Figure 16 TEMPEST BLENDUP PDM NAVIGATION DIAGRAM - PART 2 . . . . . . . . . . . 28
2-2 Figure 17 TEMPEST XR BOOM MAIN MENU (OPTIONAL) . . . . . . . . . . . . . . . . . . . . . . . . 29
2-2 Figure 18 TEMPEST XR BOOM PDM NAVIGATION DIAGRAM . . . . . . . . . . . . . . . . . . . . . 30
2-2 Figure 19 TEMPEST BLENDUP WITH XR BOOM MENU (OPTIONAL). . . . . . . . . . . . . . 31
2-3 Figure 1 VEHICLE MAINTENANCE LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

2-3 Figure 2 STANDARD BOOM PIN LUBRICATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
2-3 Figure 3 EXTENDED REACH (XR) BOOM PIN LUBRICATION. . . . . . . . . . . . . . . . . . . . . 27
2-3 Figure 4 HYDRAULIC OIL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
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2-4 Figure 1 LUBRICATION SPECIFICATIONS - OPEN BASKET VEHICLES . . . . . . . . . . . . . 5

2-4 Figure 2 LUBRICATION SPECIFICATIONS - ENCLOSED BASKET VEHICLES . . . . . . . . 6
2-5 Figure 1 HYDRAULIC PUMPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

2-5 Figure 2 HYDRAULIC MANIFOLD - FRONT AND TOP VIEWS . . . . . . . . . . . . . . . . . . . . . 7
2-5 Figure 3 HYDRAULIC MANIFOLD - END VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2-5 Figure 4 HEATER BLOWER MOTOR SPEED ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . 9
2-5 Figure 5 HEATER BLOWER SPEED ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2-5 Figure 6 HEATER FUEL PUMP ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2-5 Figure 7 ANTI-ICE PUMP DRIVE MOTOR ADJUSTMENTS. . . . . . . . . . . . . . . . . . . . . . . . 12
2-5 Figure 8 ANTI-ICE FLUID PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2-5 Figure 9 DEICING AND ANTI-ICING FLUID PUMPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2-5 Figure 10 CIRCULATION AND DELIVERY PUMP PRESSURE ADJUSTMENT . . . . . . . . . 16
2-5 Figure 11 CIRCULATION AND DELIVERY PUMP MOTOR SPEED ADJUSTMENTS . . . . . 17
2-5 Figure 12 POWER STEERING PRESSURE REDUCING VALVE . . . . . . . . . . . . . . . . . . . . . 19
2-5 Figure 13 BOOM GROUND CONTROL STATION - VALVE ASSEMBLY . . . . . . . . . . . . . . . 20
2-5 Figure 14 BOOM WITH TEST WEIGHT ATTACHED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
2-5 Figure 15 OPEN BASKET LEVELING RELIEF VALVES. . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
2-5 Figure 16 COUNTERBALANCE VALVE LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
2-5 Figure 17 COUNTERCLOCKWISE (LEFT) ROTATION ADJUSTMENT . . . . . . . . . . . . . . . . 31
2-5 Figure 18 CLOCKWISE (RIGHT) ROTATION ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . 31
2-5 Figure 19 ENCLOSED BASKET ROTATION RELIEF VALVES . . . . . . . . . . . . . . . . . . . . . . 32
2-5 Figure 20 BOOM ROTATOR BACK LASH ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . 33
2-5 Figure 21 ENCLOSED BASKET ROTATOR ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
2-5 Figure 22 HEATER BURNER SETTINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
2-5 Figure 23 BURNER NOZZLE ASSEMBLY ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . 38
2-5 Figure 24 HEATER CONTROLLER PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
2-5 Figure 25 FLUID TEMPERATURE SWITCHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
2-5 Figure 26 P-Q CONTROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
2-5 Figure 27 GEAR BOX OIL LEVEL CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
2-5 Figure 28 FLUID PRESSURE ACCUMULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
2-5 Figure 29 CRISS-CROSS TORQUE PATTERN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
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2-8 Figure 1 ELECTRONIC HEATER CONTROLLER (EHC) . . . . . . . . . . . . . . . . . . . . . . . . . . 1

2-8 Figure 2 UP AND DOWN BUTTONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2-8 Figure 3 ERROR MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2-8 Figure 4 RESISTIVE THERMAL DEVICE (RTD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2-8 Figure 5 TIMING SEQUENCE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2-8 Figure 6 CALIBRATION MODE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2-8 Figure 7 ENTER CALIBRATION MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2-8 Figure 8 ENTER CONTROLLER PASSWORD. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2-8 Figure 9 PASSWORD ACCEPTED READY TO START. . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2-8 Figure 10 INLET RTD CONNECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2-8 Figure 11 CONTROLLER DISPLAY TEMPERATURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2-8 Figure 12 SETTING CA1 TEMPERATURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2-8 Figure 13 SETTING CA3 TEMPERATURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2-8 Figure 14 TANK TEMPERATURE SETTINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2-8 Figure 15 DISPLAY TEMPERATURE IN FAHRENHEIT OR CELSIUS . . . . . . . . . . . . . . . . 16
2-8 Figure 16 SETTING CAD CELL LIMITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2-8 Figure 17 ACCESSING ERROR CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2-9 Figure 1 AIRFIRST COMPRESSOR LUBRICATION SYSTEM. . . . . . . . . . . . . . . . . . . . 12

2-9 Figure 2 AIRFIRST HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2-9 Figure 3 AIRFIRST P-Q CONTROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2-Figures
LIST OF FIGURES
Page 3
October 2013
1. INTRODUCTION
The main purpose of this chapter is to provide all the necessary information for technicians to safely
inspect, and maintain the Tempest Aircraft Deicer. Before operating or maintaining the equipment, all
operating instructions should be read and completely understood. Refer to all sections in Chapter 1.
Section 1, Safety Precautions, presents warnings and cautions for the operator and technician to better
understand the items that require special care and attention to avoid personal injury and property
damage. Emphasis should always be placed on safety, not only for personnel working with the
equipment, but also for personnel in regards to property served with this vehicle.
Section 2, System Overview, presents an overall review of the vehicle to allow operators and
technicians better understanding on how equipment and most components work.
Section 3, Preventative Maintenance, presents a commissioning check list, an operators daily check,
and periodic maintenance schedules.
Section 4, Maintenance Specifications, provides information required for performing regular

maintenance and procedures.
Section 5, Maintenance Procedures, outlines the necessary procedures for mechanical, hydraulic, and
electrical adjustments for the vehicle.
Section 6, Troubleshooting, provide useful troubleshooting guidelines for locating and solving general
potential problems with the equipment, if they should arise.
Section 7, System Schematics, contains electrical and hydraulic schematics for the vehicle to be used in
conjunction with information in Section 6, Troubleshooting.
Section 8, Electronic Heater Controller (EHC), provides general information about calibration and
troubleshooting of the heater controller.
Section 9, AirFirst System (Optional), presents general information about servicing the system, as
well as for installing or replacing components, and adjustment procedures.
It is also important to properly maintain the equipment according to maintenance schedules and
manufacturers recommendations to avoid potential accidents and costly mechanical breakdowns.
2. PREPARING THE UNIT FOR MAINTENANCE (LOCK-OUT AND TAG-OUT)
The lock-out and tag-out procedures, also referred to as out-of-service notification procedures, must
be followed before performing any maintenance on the vehicle to prevent accidental starting of the
2-1
SAFETY PRECAUTIONS
Page 1
October 2013
engine, energizing of the electrical or hydraulic system, closing of any hoods and hatches or any other
operation that can injure personnel or damage equipment. Refer to Figure 1 and table below.
Energy sources in the vehicle should be isolated and rendered inoperative prior to performing any
maintenance. The main energy sources in the Tempest are the diesel engine and cooling system,
electrical batteries, fuel tank, hydraulic system, fluid system, and air pressure and fluid accumulators.
The engine must be switched off and allowed to cool down, prior to starting maintenance work. Refer to
NFPA 70E and OSHA 29 CFR 1910.147 and 1910.333 on lock-out and tag-out procedures.
Additional procedures, regulations, and other locally applicable standards may be required at specific
locations.
The pneumatic pressure in the accumulators must be depleted by depressing the brake pedal 20 times
with the engine off. The electrical batteries must be isolated by removing the battery cables and
securing them so they cannot accidentally contact battery posts. The vehicle contains many heavy
components, hoods and hatches, which also contain potential energy in a raised position and should be
lowered, closed or properly secured.
The vehicle ignition switch, or key, should not be used as the sole lock out device, since in many cases
duplicate keys circulate and are not tightly controlled. The battery disconnect switch also should not be
used as the sole lock-out device, since the switch can be easily re-actuated.
Please note that when working with movable scaffolding, cranes or jacks during maintenance work,
these also should be locked or tagged out.
DANGER
DANGER
HIGH VOLTAGE MAY ARC OVER CONSIDERABLE DISTANCE AND EXCEED THE INSULATING
CAPACITY OF STANDARD TOOLS. ENSURE ALL ELECTRIC ENERGY SOURCES ARE
ISOLATED AND RENDERED INOPERATIVE BEFORE PERFORMING ANY MAINTENANCE ON
THE VEHICLE. FAILURE TO COMPLY WILL RESULT IN SERIOUS BODILY INJURY, DEATH, OR
WARNING
FOLLOW THE REQUIRED PROCEDURES TO PREPARE THE UNIT FOR MAINTENANCE (LOCK
OUT AND TAG OUT). FAILURE TO COMPLY MAY RESULT IN SERIOUS BODILY INJURY,
2-1
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October 2013
ENERGY SOURCES AND DEVICES
Step /
Energy Source* Hazard Type Action
Location
Park vehicle in a clean and level

Vehicle may lower or surface. Chock wheels securely, or jack
roll and crush up vehicle installing maintenance stands
mechanic** (refer to Specifications in Chapter 1,
Section 4 for requirements).
1 Vehicle Install an OSHA approved lock-out and
tag-out tag or highly visible label on, or
directly beside the ignition panel. The
Multiple
tag or label should clearly warn against
starting, operating or re-energizing the
equipment.
Turn ignition off and a allow engine to
2 Diesel engine Multiple
cool down.
Ensure winterization systems are
Winterization system Electrical shock or disconnected from external power
3
(if equipped) burns outlets, and secure cables to prevent
anybody from re-connecting them.
Battery disconnect Electrical shock or Turn off battery disconnect and remove
4
(if equipped) burns handle.
Disconnect negative battery cable and
Batteries Electrical shock or
5 secure to avoid accidental contact with
Electrical panel burns
battery posts.
Fire suppression Disconnect the control cable from the
Explosion, blow, or
6 system automatic fire suppression system, and
burns
(if equipped) remove the pressure cartridge.
Pneumatic Release pressure by actuating the brake
7 Explosion or blow
accumulators pedals several times with engine off.
Allow engine and other components
sufficient time to cool down completely
before starting maintenance work.
8 Engine cooler Burns
Pressure inside the cooling system will
be significantly reduced after the cool-
down period.
9 Engine exhaust Burns Allow exhaust to cool down.
Hydraulic oil injection Turn ignition off, release hydraulic
10 Hydraulic pumps
and burns pressure, and allow to cool down.
Release hydraulic pressure and allow
Hydraulic oil tank Hydraulic oil injection hydraulic fluid to cool down.
11
Hydraulic cylinders and burns Allow components to cool down before
removal.
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SAFETY PRECAUTIONS
Page 3
October 2013
ENERGY SOURCES AND DEVICES (CONT.)
Step /
Energy Source* Hazard Type Action
Location
Hydraulic oil injection

and burns Release hydraulic pressure and allow
Transmission and drive
12 Drive shafts may fall components to cool down.
shafts
and crush Secure drive shafts before removal.
mechanic**
13 Fuel tank Fire and burns Avoid open flames.
Deplete all pneumatic pressure in the
14 Pneumatic tires Explosion or blow tires before working on wheels, rims and
tires.
Open hoods and hatches and securely
15 Hoods and hatches Crush or pinch** support them before starting any
maintenance on the vehicle.
Power module may
Secure power module when keeping
16 Power module swing when open and
open.
crush mechanic**
Install guard rails or fall restraint system
17 Height Risk of falling
when accessing the top of the vehicle.
Deicer heater and Allow items to cool down before working
18 Burns
heater exhaust on heater and exhaust.
Fluid injection and Ensure fluid pressure is released, and
19 Fluid pumps
burns allow to cool down.
20 Fluid tanks Fire and burns Allow fluids to cool down.
21 Ground hose reel
burns wait for cool down.
22 Fluid nozzles
burns wait for cool down.
Basket may lower,
Support and secure basket to avoid
23 Operators basket fall, or rotate crushing
lowering, rotating or falling.
mechanic**
Boom may lower, fall,
Support and secure boom to avoid
24 Aerial device (boom) or rotate crushing
lowering, rotating or falling.
mechanic**
NOTE: VERIFY THAT ALL ENERGY SOURCES ARE EFFECTIVELY DISABLED.
* Refer to Figure 1 for energy sources and devices locations.
** Objects in a raised position hold kinetic energy that can cause injury when unexpectedly rotate,
lower, or fall crushing body parts.
2-1
Page 4
October 2013
23. OPERATORS 24. AERIAL DEVICE 20. FLUID 15. HOODS AND 11. HYDRAULIC 18. DEICER HEATER /
BASKET (BOOM) TANKS HATCHES CYLINDERS HEATER EXHAUST
17
21. GROUND 7. PNEUMATIC 13. DIESEL 19. FLUID 7. PNEUMATIC 3. WINTERIZATION

HOSE REEL ACCUMULATORS FUEL TANK PUMPS ACCUMULATOR SYSTEM
6. FIRE 3. HOODS AND 13. HYDRAULIC 2. DIESEL 8. ENGINE 5. ELECTRICAL

SUPPRESSION HATCHES PUMPS ENGINE COOLER PANEL
22. FLUID
NOZZLES
1
14
11. HYDRAULIC 12. TRANSMISSION / 4, 5. 9. ENGINE 16. POWER 21. GROUND

OIL TANK DRIVE SHAFTS BATTERIES EXHAUST MODULE HOSE REEL
Figure 1
LOCATIONS OF ENERGY SOURCES AND DEVICES
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SAFETY PRECAUTIONS
Page 5
October 2013
3. WARNINGS AND CAUTIONS
WARNING
WARNING
SURFACE, WHEELS ARE SECURELY CHOCKED, ENGINE IS OFF, HYDRAULIC PRESSURE IS
DEPLETED, AND BATTERIES HAVE BEEN DISCONNECTED. PLACE A HIGHLY VISIBLE TAG
ON OR NEAR VEHICLE CONTROLS TO WARN OTHER PERSONNEL VEHICLE IS BEING
WORKED ON. FAILURE TO COMPLY MAY RESULT IN SERIOUS BODILY INJURY, DEATH, OR
WARNING
VEHICLE!
WARNING
DO NOT USE THE VEHICLE FOR DEICING AND ANTI-ICING OPERATIONS IF THE VEHICLE DID
WARNING
WARNING
BEFORE STARTING THE VEHICLE, ENSURE ALL PERSONS AND OBJECTS ARE CLEAR OF
THE VEHICLE, AND ALL COMPARTMENT DOORS ARE CLOSED AND SECURED. TIRES AND
WHEELS CAN MOVE WITHOUT WARNING AND CRUSH PERSONNEL. FAILURE TO COMPLY
2-1
Page 6
October 2013
WARNING
USE A FALL RESTRAINT SYSTEM WHEN ACCESSING THE TOP OF THE VEHICLE. FAILURE
WARNING
USE ONLY PROPER TOOLS AND CALIBRATED MEASUREMENT DEVICES WHEN
PERFORMING VEHICLE MAINTENANCE. FAILURE TO COMPLY MAY RESULT IN SERIOUS
WARNING
WARNING
TORQUE LUG NUTS ACCORDING TO SPECIFICATIONS. FAILURE TO COMPLY MAY RESULT
THE VEHICLE!
WARNING
OPERATE VEHICLE ONLY IN WELL VENTILATED AREAS. ENGINE EXHAUST GASES ARE
POISONOUS. FAILURE TO COMPLY MAY RESULT IN SERIOUS BODILY INJURY, DEATH, OR
WARNING
KEEP FINGERS AND HANDS CLEAR WHEN REMOVING OIL PLUG. HOT OIL MAY CAUSE
BURNS. FAILURE TO COMPLY MAY RESULT IN SERIOUS BODILY INJURY, DEATH, OR
WARNING
PROMPTLY. FAILURE TO COMPLY MAY RESULT IN SERIOUS BODILY INJURY, DEATH, OR
2-1
SAFETY PRECAUTIONS
Page 7
October 2013
WARNING
COOLANT MAY BE HOT AND CAUSE BURNS. REMOVE ENGINE COOLANT CAP ONLY WHEN
ENGINE IS COOL. CAREFULLY LOOSEN COOLANT CAP, ALLOWING PRESSURE TO
RELEASE BEFORE COMPLETELY REMOVING IT. FAILURE TO COMPLY MAY RESULT IN
VEHICLE!
WARNING
INSPECT, REPLACE AND ADJUST BRAKE COMPONENTS IN ACCORDANCE WITH
MAINTENANCE SCHEDULE. FAILURE TO COMPLY MAY RESULT IN SERIOUS BODILY
WARNING
AVOID SPARKS OR OPEN FLAMES NEAR BATTERIES. LEAD-ACID BATTERIES PRODUCE
EXPLOSIVE HYDROGEN GAS. FAILURE TO COMPLY MAY RESULT IN SERIOUS BODILY
WARNING
USE PROPERLY RATED JACK AND MAINTENANCE STANDS TO LIFT AND SUPPORT THE
WARNING
AVOID CONTACT AND INHALATION OF DIESEL FUEL, KEROSENE, HYDRAULIC OIL,
LUBRICANTS AND GLYCOLS. WASH AFFECTED AREAS IMMEDIATELY TO AVOID SKIN
IRRITATION. FAILURE TO COMPLY MAY RESULT IN SERIOUS BODILY INJURY, DEATH, OR
WARNING
DISCONNECT THE BATTERY BEFORE PERFORMING MAINTENANCE ON THE ELECTRICAL
SYSTEM. FAILURE TO COMPLY MAY RESULT IN SERIOUS BODILY INJURY, DEATH, OR
WARNING
REMOVE BOTH POSITIVE AND NEGATIVE BATTERY CABLES BEFORE WELDING ON THE
VEHICLE, AND TAKE PRECAUTIONS TO PREVENT DAMAGE TO ELECTRONIC EQUIPMENT.
REFER TO CHAPTER 3, OVERHAUL FOR REQUIREMENTS. ALSO, REFER TO THE ENGINE
MANUAL IN CHAPTER 5 FOR ADDITIONAL REQUIREMENTS. FAILURE TO COMPLY MAY
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Page 8
October 2013
WARNING
WELDING, GRINDING, OR ANY KIND OF MODIFICATIONS TO THE AERIAL DEVICE MAY
COMPROMISE THE SAFETY OF THE DEICER. ANY MODIFICATIONS MUST BE APPROVED BY
THE MANUFACTURER. FAILURE TO COMPLY MAY RESULT IN SERIOUS BODILY INJURY,
CAUTION
WHEN CLEANING THE VEHICLE USING A PRESSURE WASHER, CARE MUST BE TAKEN NOT
TO APPLY DIRECT PRESSURE TO ANY EXPOSED ELECTRICAL, HYDRAULIC OR ENGINE
COMPONENTS. DO NOT PRESSURE WASH INSIDE THE ENGINE COMPARTMENT. FAILURE
TO COMPLY MAY RESULT IN DAMAGE TO VEHICLE COMPONENTS!
CAUTION
WHEN PERFORMING A BATTERY JUMP START ON THE VEHICLE, ENSURE JUMP CABLES
ARE PROPERLY CONNECTED TO PREVENT DAMAGE TO THE ELECTRIC SYSTEM AND
COMPONENTS. FAILURE TO COMPLY MAY RESULT IN DAMAGE TO VEHICLE
CAUTION
WHEN ELECTRICALLY CHARGING BATTERIES ON THE VEHICLE, ENSURE CHARGER

CABLES ARE PROPERLY CONNECTED TO PREVENT DAMAGE TO THE ELECTRIC SYSTEM
AND COMPONENTS. FAILURE TO COMPLY MAY RESULT IN DAMAGE TO VEHICLE
CAUTION
DO NOT CLEAN RUBBER AND PLASTIC COMPONENTS SUCH AS TIRES, LUBRICANT SEALS,
RUBBER HOSES, OR ELECTRICAL COMPONENTS WITH PETROLEUM-BASED PRODUCTS
SUCH AS KEROSENE, GASOLINE, OR FUEL OIL. FAILURE TO COMPLY MAY RESULT IN
DAMAGE TO VEHICLE, OR OTHER PROPERTY, INCLUDING THE AIRCRAFT!
CAUTION
DO NOT OPERATE THE ENGINE WITH THE OIL LEVEL BELOW THE MIN MARK OR ABOVE
THE MAX MARK ON THE DIPSTICK. FAILURE TO COMPLY MAY RESULT IN DAMAGE TO
CAUTION
ENSURE FUEL IS CLEAN AND FREE OF WATER AND DIRT. FAILURE TO COMPLY MAY
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SAFETY PRECAUTIONS
Page 9
October 2013
CAUTION
ALLOW THE ENGINE TO COOL BEFORE ADDING WATER OR ANTI-FREEZE SOLUTION.

CAUTION
USE ONLY ETHYLENE-GLYCOL BASED ANTI-FREEZE IN CORRECT CONCENTRATIONS TO

PREVENT FREEZING AT THE AMBIENT TEMPERATURE. FAILURE TO COMPLY MAY RESULT
IN DAMAGE TO VEHICLE COMPONENTS!
CAUTION
DO NOT USE WATER WITH SALT OR HIGH MINERAL CONTENT WHEN FILLING THE
COOLANT SYSTEM OR BATTERIES. FAILURE TO COMPLY MAY RESULT IN DAMAGE TO
VEHICLE COMPONENTS!
CAUTION
DO NOT DISCONNECT THE BATTERY OR TURN OFF OPTIONAL BATTERY DISCONNECT

SWITCH WITH THE ENGINE RUNNING. THIS WILL CAUSE A VOLTAGE SURGE IN THE
ALTERNATOR CHARGING SYSTEM. FAILURE TO COMPLY MAY RESULT IN DAMAGE TO
CAUTION

OILS, GREASE, HYDRAULIC OIL, FUELS, AND GLYCOLS.
CAUTION
DO NOT MIX HYDRAULIC OILS. WHEN CHANGING FROM ONE TYPE TO ANOTHER, THE
SYSTEM MUST BE DRAINED, CLEANED AND COMPLETELY REFILLED. FAILURE TO
CAUTION
2-1
Page 10
October 2013
1. GENERAL
NOTE: FOR ADDITIONAL INFORMATION ABOUT THIS VEHICLE, REFER TO DESCRIPTION IN

CHAPTER 1, SECTION 1, AND SPECIFICATIONS IN CHAPTER 1, SECTION 4.
This section presents and overview of the vehicle and its system components. The Tempest is a self-
propelled two-wheel drive vehicle, driven and operated by two persons, or optionally by only one person.
The vehicle is diesel and hydraulically powered, and electrically controlled. The hydraulic system is a
closed-center system powering the aerial device, traction and steering system, and fluid system and
components. Pneumatic service brakes are mounted on all wheels and air pressure is provided by an
engine-mounted compressor, assisted by air pressure accumulators. The parking brake function is also
provided by the pneumatic service brake system.
2. CHASSIS AND POWER MODULE
All components are mounted on a steel chassis. Latched lifting doors provide access to the power
module, fluid pumps, ground control system, heater, and other compartments around the vehicle.
The power module consists of the engine assembly, cooling radiator system, batteries, hydraulic pumps,
emergency hydraulic pump, and engine electrical panel and supplies all electrical and hydraulic power
for the vehicle. It is mounted on a swing-out frame which can be removed from the vehicle to perform
major repairs. Refer to Figure 1 for power module location, and Figure 2 for diesel engines.
POWER MODULE LIFTING DOORS SWING-OUT POWER MODULE
Figure 1
POWER MODULE
2-2
SYSTEMS OVERVIEW
Page 1
October 2013
CUMMINS QSB 4.5
AIR INTAKE FILTER
RADIATOR
FUEL FILTER
GENERATOR
EXHAUST MUFFLER OIL DIP STICK OIL FILTER TURBO CHARGER
CUMMINS QSB 6.7

AIR INTAKE FILTER
RADIATOR
FUEL FILTER
GENERATOR
EXHAUST MUFFLER OIL DIP STICK OIL FILTER TURBO CHARGER
Figure 2
CUMMINS QSB DIESEL ENGINES (TYPICAL)
2-2
Page 2
October 2013
The diesel engine provides mechanical power to drive two hydraulic pumps for traction and services on
the standard vehicle. A third pump is provided with an upgraded engine to provide power for the
AirFirst system (optional). The engine assembly also contains an electrical generator, exhaust
system, and air intake filter.
The engine exhaust is routed from the engine to the muffler, then under the power module to the right
hand side of the vehicle.
A. FUEL SYSTEM
The fuel tank is mounted just aft of the front wheel on the left side of the vehicle. Three separate
fuel lines are connected to the tank. One line supplies fuel to the power module, another supplies
fuel to the fluid heater, and the other line provides a combined fuel return to the tank.
A mechanically driven lift pump on the engine drafts fuel from the tank for the engine. The fuel
passes through a fuel and water separator and a fuel filter en route to the injector pump. These
components are mounted on the engine and may vary with different engines. The fluid heater
fuel pump is driven by a hydraulic motor and drafts from the tank.
B. COLD WEATHER FUEL SYSTEM (OPTIONAL)
A cold weather option provides an electrically heated fuel and water separator and electrically
heated fuel supply hoses for the engine and heater.
C. DIESEL ENGINE WINTERIZATION KIT (OPTIONAL)
The winterization kit aids engine starting under extreme cold weather conditions. Various
connectors are offered in compliance with electrical grid requirements for the specific operating
location.
3. HYDRAULIC SYSTEM - GENERAL
The Tempest Aircraft Deicer has two hydraulic engine-driven pumps to power all deicing systems. The
first pump is bolted and coupled directly to the engine and is used for the propulsion or drive system,
only. This pump has a through drive shaft and an additional mounting pad on the rear portion of the
pump for driving the second pump which provides hydraulic power for services.
Tempest units equipped with the optional AirFirst system have three hydraulic pumps driven in tandem
to power the three separate hydraulic systems. The first pump is bolted and coupled directly to the
engine and is used for driving the AirFirst compressor. This pump has a through drive shaft and an
additional mounting pad on the rear portion of the pump for driving the second pump (propulsion). This
pump has a through drive shaft and an additional mounting pad on the rear portion of the pump for
driving the third pump (services). Refer to Figure 3.
A. HYDRAULIC PROPULSION SYSTEM
The propulsion pump is a swash-plate design, variable displacement, axial piston pump which
drives the closed-circuit hydrostatic transmission. The system incorporates a charge pump, a
charge pressure relief valve, a charge pump filter, two combination high-relief and make-up check
valves and integrated pressure limiters. The pump flow is controlled by 24 VDC proportional
solenoids. By energizing a solenoid, pump output flow is directly proportional to input current.
2-2
SYSTEMS OVERVIEW
Page 3
October 2013
The propulsion motor is a bent axis, variable displacement unit. The motor is furnished with an
integral flushing valve that provides the rotating parts with cooled filtered fluid from the main
pumps charge pump circuit. The propulsion motor is also furnished with an integrated 24 VDC
solenoid valve for shifting the motor to maximum displacement thus giving the vehicle a low gear
for negotiating grades.
B. SERVICES PUMP
The services hydraulic pump is an axial piston, pressure compensated and load sensing pump,
that is mounted to a pad located on the back of the propulsion pump. The pressure compensator
feature is designed to protect the system against the failure of other components. In normal
operation the pressure system will never be high enough to cause the pump to compensate. This
pump receives oil from the reservoir and delivers it to a closed valve at the inlet of each system
where it maintains pressure while pumping only enough oil to replace flow going back to the tank.
C. AIRFIRST SYSTEM (OPTIONAL)
The pump powering the AirFirst option is a swash-plate design, variable displacement, over
center axial piston pump. The pump incorporates a charge pump, combination high pressure
relief and make-up check valves and an integrated pressure cut-off valve.
(1) The hydraulic motor driving the AirFirst compressor is a bent axis, fixed displacement
unit. The motor is furnished with an integral flushing valve which provides the rotating parts
with cooled, filtered fluid from the main pumps charge pump circuit.
(2) Other components in the AirFirst system include an external charge pump relief valve, an
air-to-oil heat exchanger, and a lubrication and cooling system for the AirFirst
compressor gear case.
D. LOAD SENSING SYSTEM
Each individual hydraulic circuit is fitted with an opening, either fixed or variable, which is sized to
provide the desired flow at a specific pressure drop across the opening. When a circuit is
actuated and the valve is opened, the pump maintains a specific pressure above the operating
pressure and provides the correct flow through the opening.
The hydraulic manifold assembly is located on the left rear fender. Located in the hydraulic
manifold assembly is a two-position, two-way solenoid valve that blocks supply pressure to the
boom valve when de-energized. This immediately stops the pump flow when the power is turned
off or any of the emergency stop switches are pushed.
E. MAIN RELIEF VALVE
A relief valve is located in the body of the hydraulic manifold for protection in the event the pump
compensator fails. This relief valve is set at a specified pressure above the compensator setting
and should never relieve.
2-2
Page 4
October 2013
OW
FL
W
FLO
W
FLO
W
FLO
SERVICES PUMP PROPULSION PUMP EMERGENCY PUMP
624-9253 A
Figure 3
POWER MODULE HYDRAULIC PUMPS
2-2
SYSTEMS OVERVIEW
Page 5
October 2013
F. EMERGENCY PUMP
The Tempest Aircraft Deicer has an electrically powered hydraulic pump for use in an emergency
such as the failure of the engine or main pump while the operator is elevated in the operator's
compartment. This pump can be used to rotate and lower the boom.
A check valve prevents the emergency pump flow from back-flowing through the main pump in
the event of a failure of the main pump. The emergency pump is electrically interlocked to
prevent it from being operated when the engine is on (refer to Figure 3).
G. FILTRATION
Fluid returning to the hydraulic tank, and fluid from the case drain port of the services hydraulic
pump and motor for the propulsion system pass through separate filters with built-in bypass relief
valves. All charge pump flow from the propulsion pump passes through an integral filter located
on the side of the propel pump. This filter is also furnished with a built-in bypass relief valve.
Air entering the hydraulic tank is filtered through a breather mounted on top of the tank.
4. HYDRAULIC SYSTEM - AERIAL DEVICE
A. BOOM HYDRAULIC OPERATION
Hydraulic cylinders provide movement to the boom, jib boom, and leveling functions (refer to
Figure 4).
Valves for controlling all boom functions are located in manifold assemblies installed on the left
rear fender of the vehicle. All boom controls are electrically interlocked. The boom controls are
only activated when the deicer is in the travel mode, the enclosed basket door is latched closed
and the seat belt is fastened. Vehicle speed will be automatically limited.
All boom controls, except basket leveling and rotation, become enabled when the trigger on the
boom control joystick is squeezed. To ensure that the boom clears the driver's cab, and the
basket rest, the boom raise and lower function is disabled in the lower range unless the jib boom
is raised at least five degrees.
B. BOOM RAISE AND LOWER
The boom raise and lower cylinder is hydraulically controlled by a valve on the boom proportional
valve assembly mounted on the left rear fender of the chassis. The electrical signals to the valve
coils for raising and lowering are generated by a PQ control card in the left hand arm pod in the
operators basket.
Maximum speed of the boom during raise and lowering is preset with the adjustable flow control
valves incorporated in the proportional valve body.
A relief valve controls pressure going to the cap end of the boom cylinder to prevent lifting an
operator's basket that is overloaded. A relief valve also controls pressure going to the opposite
rod end of the boom cylinder to limit the pressure while lowering the boom.
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Page 6
October 2013
JIB BOOM LEVELING SLAVE CYLINDER
CYLINDER
LEVELING MASTER
CYLINDER
(INSIDE BOOM)
MAIN BOOM
CYLINDER
Figure 4
BOOM HYDRAULIC CYLINDERS
2-2
SYSTEMS OVERVIEW
Page 7
October 2013
There is a counterbalance valve at the cap end port of the boom cylinder to prevent the boom
from lowering in the event of the failure of a hose or directional valve. When the cylinder is being
retracted hydraulically, the counterbalance valve is piloted open. The boom raise and lower valve
has a manually operated lever which can be used to override the valve controls and lower the
operator in case of an electrical failure.
C. BOOM ROTATION
The boom is rotated by a hydraulic motor through a gear reduction. Fluid flow for this motor is
supplied from a valve on the boom proportional valve assembly mounted on the left rear fender of
the chassis. The electrical signals to the valve coils for rotating the boom clockwise, or
counterclockwise, are generated by a PQ control card in the left hand arm pod in the operators
basket.
Maximum speed of the boom during rotation is preset with the adjustable flow control valves
incorporated in the proportional valve body. The boom rotation valve has a manually operated
lever which can be used to override the valve controls in case of an electrical failure.
D. JIB BOOM RAISE AND LOWER
The jib boom extend and retract cylinder is hydraulically controlled by a proportional valve on the
boom valve assembly mounted on the left rear fender of the deicer. The electrical signal to the
valve coil for raise and lower speed is generated by a PQ control card located in the left hand arm
pod of the operators basket. The PQ control card receives its input from the jib extend and
retract momentary push buttons on the boom control joystick in the operators basket, from the
boom control switches in the drivers cabin, or from the proximity switches on the rotator and
knuckle.
If the jib boom is less than five degrees raised while the boom is less then 15 degrees raised, the
proximity switches will send a signal to the coil to extend the jib boom. This auto jib out function
ensures that the boom will clear the drivers cabin and basket rest when the boom is lowered.
The jib boom raise and lower valve is equipped with a manually operated lever for overriding the
valve controls in case of an electrical failure.
E. OPERATORS BASKET ROTATION
The operators basket rotator is controlled by a proportional valve, located on the right hand front
fender, behind the electrical panel. The electrical signal to the valve coil for basket rotation is
generated by a PQ control card located in the right hand arm pod of the operators enclosed
basket. This PQ control card receives its input from the twist function of the nozzle joystick in the
operators basket.
A dual overcenter valve is incorporated in the hydraulic circuit, between the control valve and the
hydraulic motor, to prevent rotational movement (drifting) of the basket when there is no hydraulic
flow from the control valve. This valve is located on the left side of the basket platform.
F. OPERATORS BASKET LEVELING RAISE AND LOWER
This feature applies to both the open and enclosed baskets. The operators basket is
automatically kept level by a slave cylinder mounted between the boom and the knuckle. This
cylinder is fed from a basket leveling master cylinder mounted between the rotator and the boom
2-2
Page 8
October 2013
To compensate for the occasional loss of oil flow from the system, the level of the operators
basket can be adjusted with oil flow controlled by a proportional valve on the boom valve
assembly, mounted on the left hand rear fender of the vehicle.
The electrical signal to the valve coil for the leveling the operators basket is controlled by a
switch, mounted in the operators basket console. This switch is only functional when the vehicle
is in deice mode and when the boom is in the boom rest.
The valve coil for leveling will also automatically receive a signal from proximity switches on the
rotator and knuckle if the basket is out of level when the boom is 15 degrees raised. This auto
leveling function is automatically activated every time the boom passes through the 15 degree
position.
5. HYDRAULIC SYSTEM - FLUID SYSTEM
A. DEICING DELIVERY PUMPS
The centrifugal pump (Prop-mix system) or diaphragm pump (AirFirst system) that delivers
deicing fluid is driven by a fixed displacement motor. Hydraulic fluid for this motor is supplied
through a solenoid valve located on the hydraulic manifold assembly. The flow rates to this motor
are hydraulically controlled by flow control valve cartridges screwed into sandwich valves directly
under the solenoid valve. These flow control valves are adjustable.
B. DEICE AND WATER DELIVERY PUMPS (PROP-MIX) (OPTIONAL)
The proportional mix control system consists of hydraulic and electronic components necessary
to automatically adjust the mix ratio to a preset level.
The proportional hydraulic controls consists of a simple manifold that controls the speed of the
hydraulic motors driving each of the fluid pumps. The manifold contains two pressure
compensated proportional flow controls. The flow controls are electrically adjustable and are
adjusted automatically by a micro controller based on a feed back signal from the pumps. The
proportional hydraulic manifold is mounted directly above the integrated circuit manifold
assembly.
Maximum flow to the proportional hydraulic valves is limited by a solenoid valve located on the left
side of the integrated circuit manifold assembly (refer to Figure 3). Pressure to the proportional
hydraulic valves is regulated by a pressure reducing valve cartridge screwed into a sandwich
valve located directly under the solenoid valve. Maximum flow rate to the proportional hydraulic
valve is controlled by flow control valve cartridges screwed into a sandwich valve directly under
the pressure reducing valve.
C. ANTI-ICE AND RE-FILLER PUMPS
The diaphragm pump that delivers the anti-ice fluid is driven by a fixed displacement motor.
Hydraulic fluid for this motor is supplied from a solenoid valve on the hydraulic manifold. The flow
rate to this motor is controlled by a flow control valve cartridge screwed into a sandwich valve
located on top of the manifold. This flow control valve is adjustable. Pressure to the drive motor
is regulated by a pressure reducing valve cartridge located directly under the solenoid valve. This
valve cartridge provides constant pressure anti-ice fluid to the nozzle independent of the flow
rate. When the nozzle is closed, the hydraulic system maintains a constant static pressure at the
nozzle.
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October 2013
D. BLOWER DRIVE
The blower fan for the fluid heater is driven by a fixed displacement motor and has two speeds,
slow speed for starting and high speed for normal operation. When the heater is started the slow
speed solenoid valve is energized and allows hydraulic fluid to flow to the blower motor through
an adjustable flow control valve. This flow control valve is adjusted to limit the flow of hydraulic
fluid for the amount of fluid required for slow speed of the motor, and the blower fan, during the
initial ignition of the heater fuel. After the heater has established a flame the high speed solenoid
valve is energized and additional hydraulic fluid is supplied, through an adjustable flow control
valve, to increase the blower motor speed for the proper amount of air necessary for normal
operation.
E. FLUID HEATER FUEL PUMP DRIVE
The fuel pump for the diesel fired fluid heater is driven at a constant speed by a hydraulic motor.
Hydraulic fluid to drive the motor is supplied by a solenoid valve through a pressure compensated
flow control valve. Constant fuel pressure is maintained by a relief valve between the fuel pump
and the burner nozzles.
F. HEAT EXCHANGER
Two oil to air heat exchangers are installed in the hydraulic system to prevent the hydraulic fluid
from over heating. Both heat exchangers are located at the rear of the unit above the rear
bumper. The heat exchangers have electric motor driven fans to move cool air through the fins of
the oil coolers. A temperature switch located on the hydraulic reservoir controls the fan motors.
Refer to Figure 5.
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October 2013
HEAT EXCHANGER
(REAR OF THE VEHICLE)
Figure 5
HEAT EXCHANGER LOCATION
A. DRIVERS CAB ELECTRICAL
The cab electrical consists of a cab control panel in which most of the deicer controls and
indicators are located.
B. POWER MODULE ELECTRICAL
Two 12-volt batteries, connected in series, provide the 24 volt DC stored energy for lighting and
starting the vehicle engine. The 24 volt, engine driven, generator provides all operating current
requirements and recharges the batteries when they are below the full charge state. The
batteries will only supply current to the electrical system when the load requirement exceeds the
current output of the engine driven generator.
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The main electrical panel, on the right front fender, contains the majority of the electrical
components, i.e., relays, contactors, timers, fuses, etc., and the terminal strips. Most wiring
harnesses are connected to this panel with removable plugs. A smaller electrical panel on the
power module contains the main components for the engine and drive controls.
If the deicer is equipped with AirFirst (optional equipment) an electrical panel containing the
controls for the AirFirst system is installed on the left front fender.
C. BATTERY DISCONNECT SWITCH (OPTIONAL)
Disconnects both positive and negative cables from the vehicle battery bank. The switch lever
must be installed and turned to the ON position to feed the battery current to the electrical
system. After turning the switch to the OFF position, the lever must be removed for safety.
D. MONITOR AND CAMERA SYSTEM (OPTIONAL)
The monitor and camera system consists of two (2) cameras and one (1) monitor. The front
camera is mounted on the vehicle dash and the rear camera is located at the vehicle shroud, with
one looking forward and the other looking aft.
The forward view is normally shown. The rear view is a mirror image (just as in a rear view mirror
on a car) and is automatically displayed when the 1-man drive is placed in reverse. The black
and white monitor is mounted in the enclosed basket to the operators left.
All controls for operating the video camera system are provided on the face of the monitor.
E. ELECTRONIC HEATER CONTROLLER (EHC)
The EHC is mounted to the left, adjacent to the front of the heater, and is designed to control the
four stage burner that is used for heating the deicing fluids used in the JBT AeroTech Tempest
Deicers. The controller monitors the fluid temperature at the heater inlet manifold to determine
which stages will be active and when the heating cycle is complete. The controller also monitors
a number of potential error conditions by reading various inputs and indicating errors as they
occur. Refer to Electronic Heater Controller, Chapter 2, Section 8.
When the heater is operating the controller may turn on the error light, and flash the error mode
LED, to indicate a non-critical error has occurred. This could range from an open to a short circuit
on any particular output. The heater will remain operating as long as the controller does not
register a critical shutdown error.
F. BOOM ELECTRICAL OPERATION
(1) Boom Controls
The boom can be operated by the control switches in the drivers cab on the center console
or by the joystick in the operators basket. In normal operation (Two-man Drive) the
drivers controls have priority, for safety purposes, and will override the operators controls.
During One-man Drive operation the operator can not operate the boom and propel the
vehicle at the same time; to operate propel the boom must be in range.
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(2) Boom Operation Speeds
The boom raise and lower, boom rotation, jib extend and retract, and basket rotation
speeds are controlled by electronic modules. The boom functions operate at the following
three speeds as directed by angularity:
(a) Creep Speed
Activated only when the boom control switches in the drivers cabin are used.
(b) Mid Speed
Used at the beginning and end of each function when the operator actuates the
switches in the enclosed basket.
(c) High Speed
Function speed after the initial movement when the switches are actuated in the
enclosed basket.
Proximity switches on the boom automatically switch the boom into mid or high speed at
the appropriate points, to ensure both smooth and fast boom operations. Each individual
card can be programmed to set the speeds and the ramping and to adapt the card to the
characteristics of the hydraulic components that it controls.
NOTE: MID SPEED IS USED DURING BASKET ROTATION, AND CREEP SPEED IS USED AT
THE END OF BASKET ROTATION TO ENSURE SMOOTH MOVEMENT.
(3) Beacon Light
An amber (optional red) beacon light is mounted on the aft end of the boom. This beacon
light flashes (optional non-flashing) when the ignition switch is in the ON position.
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October 2013
G. OPERATORS OPEN BASKET ELECTRICAL INSTALLATION
The basket electrical consists of the basket console, boom joystick control, emergency stop
switch and basket floodlights. Refer to Figure 6.
FLOOD LIGHTS
BOOM JOYSTICK
CONTROL BASKET CONSOLE
EMERGENCY
STOP
OPERATORS CONSOLE AREA
Figure 6
OPEN BASKET ELECTRICAL COMPONENTS
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October 2013
H. OPERATORS ENCLOSED BASKET ELECTRICAL INSTALLATION
The operators basket electrical system consists of the boom joystick, nozzle joystick, drive
control box for one-man drive (optional), AirFirst controls (optional), indicator light panel, left
hand electrical pod, right hand electrical pod, floodlights, nozzle assembly, enclosed basket front
and rear camera system (refer to Figure 7).
INDICATOR
LIGHT PANEL
OVERHEAD INDICATING LIGHTS
ONE-MAN DRIVE
CONTROL BOX
FLOODLIGHTS (OPTIONAL)
NOZZLE
JOYSTICK
NOZZLE
ASSEMBLY
BOOM
JOYSTICK
AirFirst
CONTROLS
(OPTIONAL)
OPERATORS
ENCLOSED BASKET
CONTROLS
LEFT HAND RIGHT HAND

ELECTRICAL POD ELECTRICAL POD
Figure 7
ENCLOSED BASKET ELECTRICAL COMPONENTS
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October 2013
7. FLUIDS SYSTEM
WARNING
FLUIDS USED IN THE DEICER SHOULD ADHERE TO SAE OR ISO STANDARDS AND MUST BE
SYSTEMS. THE SPECIFIC FLUID AND TYPE USED SHOULD BE APPROVED BY THE AIRLINE,
WARNING
A. DEICING SYSTEM
The Tempest deicing fluid system has been designed to receive, store, heat and dispense hot
aircraft deicing fluids to remove frost, snow and ice from the surface of commercial and military
aircraft. The system includes storage reservoir, pumping system(s), fluid heater and aerial
platform with associated plumbing and nozzles (refer to Figure 8).
The system consists of a combination delivery and circulating deicing fluid pump with an optional
anti-icing fluid pump.
(1) Storage Reservoir
The storage reservoir comes in a variety of sizes for deicing fluid only or a combination of
deicing and optional anti-icing fluid. The reservoir is constructed of stainless steel.
Exterior man holes have been supplied for cleaning and maintenance. The reservoir for
the deicing fluid is thermally insulated and is separated by an air gap from the optional
anti-ice reservoir.
(2) Pumping System
The deicing delivery pump is a centrifugal pump (Prop-mix) or diaphragm pump (AirFirst)
used to circulate deicing fluid through the heater. This pump also delivers the deicing fluid
to the nozzles on the operator basket and ground reel hose. Plumbing from the reservoir
to this pump includes service valves, stainless plumbing, and high temperature hose.
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October 2013
(3) Fluid Heater
The heater is self-controlled and regulating during operation and will automatically turn off
when the reservoir has reached deicing temperatures. The internal heating flame is fully
enclosed allowing heating operations around aircraft. The heater will raise the fluid
temperature very quickly. The fluid is returned to the reservoir during heater operation,
rapidly heating the stored deicing fluid. The unit is also plumbed for last-pass heating,
which sends hot fluid directly to the nozzle instead of the tank if spraying while heating.
Fluids can be damaged when the fluids have been heated repeatedly without being used
(more than five [5] heat cycles).
Fluids can be damaged when any setting of the fluid or heating system has been changed
(flow rate, pump speed, temperatures, pressures, etc.).
(4) Heater Exhaust
The heater exhaust is ducted through a rectangular port directly to the exhaust screen
weldment on the aft end of the heater module.
(5) Aerial Platform
Aircraft deicing can be accomplished with the operators basket deicing nozzle. Boom
movement is controlled with the operators boom joystick or, when necessary, the drivers
cab controls.
B. ANTI-ICING FLUID SYSTEM (OPTIONAL)
An anti-icing system may be installed for coating the aircraft skin immediately after deicing
operations to increase holdover times.
(1) Storage Reservoir
When this system is installed, the main reservoir is partitioned off to contain the anti-icing
fluid.
(2) Pumping System
An additional positive displacement diaphragm anti-icing fluid pump, associated plumbing,

and optional nozzle is used to dispense the anti-icing fluid. This fluid is not heated.
NOTE: THERE IS NO OFF-ON SWITCH FOR THE ANTI-ICING PUMP. THE ANTI-ICING PUMP
IS ACTIVE WHENEVER THE ENGINE IS RUNNING AND SUFFICIENT FLUID IS
AVAILABLE.
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October 2013
SPRING REWIND
HOSE REEL
ANTI-ICING PUMP
DEICING PUMP
WATER PUMP
(OPTIONAL WITH
PROP-MIX SYSTEM) 623-8125-011 -
Figure 8
FLUID SYSTEM WITH PROP-MIX (OPTIONAL)
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October 2013
ANTI-ICING PUMP
MYERS
DEICING PUMP 623-8125-002 G
Figure 9
FLUID SYSTEM WITH MEYERS PUMP (OPTIONAL)
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October 2013
8. AERIAL DEVICE SYSTEM
The aerial device consists of an elevating boom, mounted on top of the deicer on a rotator assembly and
has an operators basket attached to the end of the jib boom. Certain components of the aerial device
are made with high strength steel. Main bearings have synthetic bushings with a PTFE liner and do not
require lubrication (refer to Figure 4).
A. ROTATOR ASSEMBLY
The rotator assembly contains the rotation drive assembly and is supported by the bearing on top
of the pedestal. This assembly rotates the boom left or right from the center position. The boom
control joystick in the operators enclosed basket, or the boom control switches in the drivers cab,
control the boom rotation drive.
B. BOOM LIFT CYLINDER
The boom lift hydraulic cylinder is attached to the boom and the rotator for raising and lowering
the boom. The boom control joystick in the operators basket, or the boom control switches in the
drivers cab, control the raising and lowering of the boom.
C. KNUCKLE AND LEVELING CYLINDERS
The knuckle is mounted between the boom and the jib boom. A slave leveling cylinder, mounted
between the boom and the knuckle, keeps the knuckle level when the boom is raised or lowered.
A master leveling cylinder is mounted between the rotator and the boom and transfers hydraulic
fluid to the slave cylinder to maintain the level of the enclosed basket when the boom is raised or
lowered.
D. JIB BOOM AND LIFT CYLINDER
The jib boom consists of four (4) linkages mounted between the knuckle and the basket platform.
The jib lift cylinder is mounted between the rear knuckle pin and the front enclosed basket
platform pin for raising or lowering the jib boom.
The geometry of the jib boom keeps the platform level with the knuckle when the jib boom is
raised and lowered. In the middle of the stroke the platform is tilted downward slightly to improve
visibility during the deicing operation. The deicing and anti-icing delivery valves are mounted on
the jib boom.
E. BASKET PLATFORM AND ROTATOR
The rotator assembly for the enclosed basket is attached to the basket platform support weldment
on the end of the jib boom. The basket rotator consists of a hydraulic motor with a worm gear
drive that will rotate the basket to either side of the center position. The rotation angle will depend
on selected options (refer to Specifications in Chapter 1, Section 4).
Fluid lines, basket heater fuel line, electrical harness, and optional AirFirst ducting are all routed
through the rotation center line under the basket platform.
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October 2013
F. OPEN BASKET ASSEMBLY OPTION
The basket is made of steel and painted for preservation. Work floodlights are mounted on each
side of the basket for visibility. Rubber bumpers are provided on the corners to prevent damage
to the basket and other equipment. Refer to Specifications in Chapter 1, Section 4 for
measurements and other specific information related to the basket.
G. OPERATORS ENCLOSED BASKET OPTION
The operators enclosed basket protects the operator from the elements and fluid spray during
deicing operations and has large windows for maximum visibility. The operators basket is
supported by a steel base plate.
The enclosed basket has a diesel oil fired heater, fans, windshield wipers and washers, internal
lights and floodlights for a comfortable working environment. An optional fuel tank which supplies
fuel for the operators basket heater may be mounted to the left-side rear of the enclosed basket.
9. OPTIMAX HEAT SYSTEM
The Tempest deicer uses the OptiMax heat system for the heater module assembly. This system will
raise the fluid temperature from normal ambient storage temperatures up to 8588 C (185190 F).
This will require the operator to use gloves when handling the deicing nozzles. The fluid is returned to
the fluid storage reservoir during heater operation, rapidly heating the stored deicing fluid.
The OptiMax heat system is self-controlled and regulating during operation and will automatically shut
down when the reservoir deicing fluid has reached deicing temperatures.
The heater system is located behind the fluid tank on the right hand side of the unit. The heater fuel
pump is located under the heater. Refer to Figure 10.
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October 2013
STACK
TEMPERATURE
SWITCH
FUEL BLOWER
PRESSURE
BURNER
ASSEMBLY
AIR
PRESSURE IGNITER
SWITCH
FLAME
FUEL SENSOR
VALVES
RELIEF
VALVE
BY-PASS
VALVE
OVER-TEMP.
SWITCH
FLOW RESET
SWITCH
PRESSURE
GAUGE
ELECTRONIC
HEATER
CONTROLLER RTD
(EHC) TEMPERATURE
GAUGE
TEMPERATURE
SWITCH
Figure 10
OPTIMAX HEAT SYSTEM
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October 2013
10. BRAKE SYSTEM
The Tempest is equipped with heavy duty air brakes and an emergency stopping system that will apply
the brakes on the rear axle when there is insufficient air pressure in the system reservoirs for safe
operation.
The air supply is provided by an air compressor on the engine in the power module and the air passes
through an air dryer to remove moisture before entering the primary receiver for the pneumatic system.
Each wheel brake assembly is equipped with an automatic slack adjuster that will maintain the correct
shoe-to-drum clearance for maximum braking efficiency.
Brake assemblies on the rear axle are equipped with spring brake actuators that will apply the brakes for
parking when the parking brake control valve is manually actuated in the drivers cab.
Should there be a loss of air pressure in the system the air in the spring brake chambers, holding the
springs compressed and the brakes released, will automatically be exhausted and the springs will apply
the brakes.
The parking brakes will be applied automatically when the ignition switch is in the OFF position.
NOTE: THE PARKING BRAKE WILL BE APPLIED AUTOMATICALLY WHEN ANY EMERGENCY
STOP SWITCH IS ACTUATED.
11. INTERFACE MODULE (PDM)
A. INTERFACE MODULE NAVIGATION
Push-buttons F1 through F6 can be used to navigate through the different screens available.
The title of each screen will be displayed on the top center section of the LCD unless prevented
by space constraints. Depending on the screen displayed the function of the push buttons
change. The function assigned to each push button or the number corresponding to the function
is indicated on the bottom row of the LCD. If the last row contains numbers, the function screen
associated with that number can be accessed by actuating it.
On screens where values are to be changed, the OK knob can be used to access the Variable
Adjustment Tool screen and from there increment or decrement each value.
On certain screens an abbreviated function description will appear above the push button.
Actuation of the corresponding push button will cause the PLC to perform that function.
From the subsequent screen the last item on the bottom row normally displays F5 (BACK) and
F6 (NEXT). When the F5 push button is depressed, it causes the Interface Module to display
the previous screen.
NOTE: ON SOME SCREENS, PUSHING THE F5 PUSH BUTTON CAUSES THE PREVIOUS
SCREEN IN THE SCREEN HIERARCHY TO BE DISPLAYED; NOT NECESSARILY THE
PREVIOUS VIEWED SCREEN.
NOTE: INTERFACE MODULE MAY LOOK DIFFERENT THAN SHOWN. ALL PDM SCREENS
ARE SUBJECT TO CHANGE WITHOUT NOTICE.
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October 2013
LCD
OK KNOB PUSH BUTTONS

(F1 THROUGH F6)
F1
ESC F2 F3 F4 F5 F6
Figure 11
PDM - INTERFACE MODULE
B. TEMPEST DIAGNOSTICS PDM SCREENS (OPTIONAL)
NOTE: REFER TO FIGURE 13, AND Tempest DIAGNOSTIC ALARMS IN CHAPTER 2, SECTION
7 FOR A LIST OF DIAGNOSTICS ALARMS.
Figure 12
TEMPEST DIAGNOSTICS MAIN MENU (OPTIONAL)
The Main Menu is the first screen that appears when the PDM is started. From this screen, the various
sub-menus can be accessed by pressing the corresponding function key, F1 to F6, located on front and
bottom of the display. Press F1 to access software information and press F2 to access active alarms.
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October 2013
Tempest Main Menu
F1 - Information F2 - Alarms F3 - E-pump Status F4 - PLC Status F5 - Comm Status F6 - Options
Tempest E-Pump Status Menu CAN Bus Tempest

Software Activation Communications Options
Alarm Help Active Alarms Reset Alarms
Alarm History
Rev. 2011-07-07
Status Menu
F3 - PLC1 Status F4 - PLC1E Status F5 - PLC2 Status F6 - Main Menu
PLC1 Analog PLC1E Digital PLC2 Analog

Input Status Input Status p.1 Input Status Main Menu
PLC1 Digital PLC1E Digital PLC2 Digital

Input Status p.1 Input Status p.2 Input Status p.1


Figure 13
TEMPEST DIAGNOSTICS PDM NAVIGATION DIAGRAM
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October 2013
C. BLENDUP SYSTEM PDM SCREENS (OPTIONAL)
The main menu screen appears upon completion of power up sequence, and allows the following
access modes:
Service Mode - The technician must login to the PDM to gain access to the vehicles
adjustable variables and control screens.
Guest Mode - This mode is when not logged into the system, and access is read-only.
This is the default mode.
Operator Mode - This login level allows the operator to enter the deice and spray ratios
(set and acknowledge fluid settings). This option is configurable through the Custom
Controls screen accessible from Configuration Menu.
Navigation through menus and screens, allows for login, and system status; alarm status, history,
and detection; PLC inputs and outputs, including PWM; device control and service mode select
(deice and pure pumps control), interlocks, configuration, and custom controls; pump variables,
and variable adjustment and calibration; and mix and spray ratios.
Also, extended alarm help screens provided assist in the diagnosing of alarms. These help
screens may be accessed from the Active Alarm screen, or through the Alarm History screen for
help on past alarms.
Figure 14
TEMPEST BLENDUP MAIN MENU (OPTIONAL)
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October 2013
Tempest blendUP Main Menu Control Menu
F1 - Main Menu F2 - Status F3 - More F1 - Config F2 - Devices F3 - Main Menu
Main Menu Status Menu Control Menu Configuration Device Main Menu
Menu Control Menu
Rev. 2011-07-07
blendUP Status Menu Configuration Menu
F1 - Alarms F2 - PLC Status F3 - Main Menu F1 - Adjust F2 - Custom Ctrls F3 - Return
Active Alarms Pump Custom

PLC3 Digitizers Main Menu Variables Controls Control Menu
Alarm History Digital Inputs
Software
Version PWM Outputs
Digital Outputs
Device Control Menu Pump Variables
F1 - Service Mode F2 - Devices F3 - Device Menu F1- Calibrate Deice F2 - Calibrate Pure F3 - Return
Acknowledge Deice Pump Device Menu Deice Cracking Pure Cracking Config Menu
Service Mode Control Calibration Calibration
Pure Pump Deice Main Pure Main Variable

Control Nozzle Cal. Nozzle Cal. Adjust Tool*
*Adjust Tool screen is utilized for Deice and Pure calibrations.
Figure 15
TEMPEST BLENDUP PDM NAVIGATION DIAGRAM - PART 1
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October 2013
Device Menu
F1 - Config F2 - Control F3 - System Ctrl
Pump Adjust Control Menu blendUP

Sys Control
Rev. 2011-07-07
blendUP System Control blendUP System Control
F1 - Mix Ratios F2 - Device Menu F3 - Main Menu F1 - Freeze Points F2 - Device Menu F3 - Main Menu
blendUP Device Menu Main Menu blendUP Device Menu Main Menu
Mix Ratios Freeze Points
This Menu will be shown for blendUP Mix Ratios Option. This Menu will be shown for blendUP Freeze Points Option.
blendUP Mix Ratios blendUP Freeze Points
F1 - Deice Ratio F2 - Spray Ratio F3 - Ground Reel F1 - Deice F. P. F2 - Spray F. P. F3 - Ground Reel
Deice Fluid Spray Ratio Ground Reel Deice Spray Ground Reel
Enable Freeze Point Freeze Point Enable
Confirm Confirm Config Menu Confirm Confirm Spray Config Menu

Deice Ratio Spray Ratio Freeze Point Freeze Point
Spray Ratio Spray F. P.

Out of Range Out of Range
F. P. = Freeze Point.
Figure 16
TEMPEST BLENDUP PDM NAVIGATION DIAGRAM - PART 2
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October 2013
On the Ground Reel Enable screen (within blendUP Mix Ratios Menu), when not locked press
F1 to enable the ground reel, and F2 to disable it.
Within the Pump Variables screen where calibration and adjustments can be performed, Start
Ramp and Stop Ramp settings are the same for both Deice, and Pure pumps.
When spraying, if communication with PLC 3 is lost, spraying will be disabled and a warning
screen will be displayed.
NOTE: IF COMMUNICATION WITH PLC 3, OR PLC 3 FAILS, THE EMERGENCY STOP WILL
BECOME AVAILABLE TO OVERRIDE THE SYSTEM MANUALLY. IF EVERYTHING IS
WORKING PROPERLY, THE EMERGENCY STOP WILL NOT WORK.
D. BLENDUP FREEZE POINT ENTRY SCREENS (OPTIONAL)
The blendUP mix ratios are determined by entering the Freeze Points of both the Deice fluid in
the tank and the desired spray concentrations. The PDM converts the freeze points into the
corresponding ratios and transmit that data to the blendUP PLC. Refer to Figure 16.
E. XR BOOM SYSTEM PDM SCREENS (OPTIONAL)
The XR Main Menu is provided with the XR boom option. This screen appears upon completion
of power-up.
Press F1 to access the Login screen, and press F2 to access the Status Menu.
Figure 17
TEMPEST XR BOOM MAIN MENU (OPTIONAL)
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October 2013
Tempest XR Main Menu Control Menu
F1 - Login F2 - Status F3 - More F1 - Config F2 - Devices F3 - Main Menu
XR Security Status Menu Control Menu Configuration Devicel Main Menu

Login Menu Control Menu
Rev. 2011-07-07
Status Menu Configuration Menu
F1 - Alarms F2 - Status F3 - Main Menu F1 - Adjust F2 - Calibrate F3 - Control Menu
Active Alarms Boom Lower Joystick

Analog Inputs Main Menu Variables Calibration Control Menu
Boom Raise
Alarm History Digital Inputs Variables
Variable
Adjustment Tool
Software Telescope
Version PWM Outputs Extend Variables
Telescope
Digital Outputs Retract Variables
Device Control Menu
F1 - Service Mode F2 - Devices F3 - Control Menu
Acknowledge Boom Control Control Menu

Service Mode
Telescope
Control
Figure 18
TEMPEST XR BOOM PDM NAVIGATION DIAGRAM
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October 2013
F. BLENDUP WITH XR SYSTEM PDM SCREENS (OPTIONAL)
The Main Menu is the screen that appears upon completion of power-up. The PDM has been
designed to incorporate the XR boom screen into the blendUP PDM program.
Pressing F1 will access the Login screen, and pressing F2 and F3 will access the XR Menu and
blendUP Menu, respectively.
The Tempest Software screen will also display the version information for the PLC 1, PLC 3, and
PDM 4.
Figure 19
TEMPEST BLENDUP WITH XR BOOM MENU (OPTIONAL)
Press F2 to access the XR Main Menu [refer to E. XR BOOM SYSTEM PDM SCREENS
(OPTIONAL)] and press F3 to access the blendUP Main Menu [refer to C. BlendUP
SYSTEM PDM SCREENS (OPTIONAL)].
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October 2013
1. GENERAL
This section contains equipment checklists, maintenance schedules, and pertinent information for
maintaining the Tempest Aircraft Deicer. A program of periodic maintenance is necessary to ensure the
maximum performance of your vehicle. Proper maintenance consists of complete lubrication at
specified intervals, periodic inspections, and replacement of worn parts. As with any equipment, the
vehicle may become hazardous if proper service and maintenance are neglected. Therefore, it is
essential to perform all described inspections, lubrication, and fault isolation on a regularly scheduled
basis.
2. BEFORE COMMISSIONING A UNIT
The pre-operational checklist that follows, allows for a comprehensive verification of the unit, and its
components. It is highly recommended the checklist be followed to be sure everything is in working
condition, before placing the unit into service. If you are unsure about how to perform certain checks,
refer to Maintenance Procedures in Chapter 2, Section 5 for mechanical, hydraulic, and electrical
adjustments.

NOTE: REFER TO SPECIFICATIONS IN CHAPTER 1, SECTION 4 FOR GENERAL

SPECIFICATIONS AND FLUID CAPACITIES, AND MAINTENANCE SPECIFICATIONS IN
CHAPTER 2, SECTION 4 FOR RECOMMENDED LUBRICANTS, AND OPERATIONAL,
PRESSURE AND ADJUSTMENT SETTINGS.
NOTE: COPIES OF THE EQUIPMENT PRE-OPERATIONAL CHECKLIST CAN BE MADE AS

PART OF A MAINTENANCE LOG.
NOTE: BEFORE SERVICING UNDERNEATH THE VEHICLE, BE SURE THE VEHICLE IS

SAFELY SUPPORTED ON APPROPRIATE SUPPORTING DEVICES RATED TO
HANDLE 150% (1-1/2 TIMES) THE GROSS VEHICLE WEIGHT.
NOTE: THE VEHICLE USES BOTH SAE AND METRIC FASTENERS (NUTS, BOLTS, AND
SCREWS). BE SURE THAT THE CORRECT FASTENERS ARE USED FOR REPAIR
AND SERVICE OF THE VEHICLE.
2-3
PREVENTATIVE MAINTENANCE
Page 1
October 2013
WARNING
WARNING
VEHICLE!
NOTE: REFER TO THE SUBSECTION PREPARING THE UNIT FOR MAINTENANCE IN

CHAPTER 2, SECTION 1, SAFETY PRECAUTIONS.
2-3
Page 2
October 2013
3. EQUIPMENT PRE-OPERATIONAL CHECKLIST
EQUIPMENT PRE-OPERATIONAL CHECKLIST
DESCRIPTION CHECK ()
INSPECTION
Vehicle Walk-around
Open all compartments and perform a walk-around inspection and check for obvious
damage, missing parts, and any fluid leaks.
Inspect seats, and seat belts for damage and verify proper operation. Make sure they
are properly adjusted and securely mounted.
Check charge of fire extinguisher(s), and access to be free of obstacles, if applicable.
Engine Compartment
Check engine mounts, isolators, brackets, and hardware to make sure they are
securely mounted, and not damaged. Check engine and other components for leaks.
Check crankcase oil level (with engine off). The level should be between the Max and
Min marks on the dipstick.
Inspect all fuel lines and fittings for leaks and damage.
Inspect belts and hoses for cracks and wear.
Check coolant drain cocks to be securely closed.
Check coolant level (cold with engine off). Remove radiator cap slowly. Coolant level
should be approximately one inch below the top of the radiator tank.
Check engine coolant freezing point for temperatures below -40 C (-40 F) using a
hydrometer.
Check radiator for obstructions of air flow. Remove all dirt or foreign material with a soft
brush or compressed air.
Inspect air cleaner, and cleaner element to be clean and undamaged, and ensure the
intake duct is free of obstructions.
Inspect the engine exhaust, ensuring all clamps and fittings are tight and free of
potential leaks.
Check hydraulic pumps and components to ensure they are securely mounted, and free
of dirt or foreign material. Use only petroleum-free solvents to clean them.
Drain water from fuel and water separator by opening the drain cock at the bottom of
the separator bowl.
Check electrolyte level in battery, if applicable. Clean battery terminals and exterior
surfaces using a baking soda and water solution. Ensure battery terminals and holder
are tight.
Heater and Hydraulic Tank Compartment
Check level of oil in hydraulic oil tank (with engine off). Ensure fluid level is between the
Max and Min marks in the sight gauge.
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Page 3
October 2013
EQUIPMENT PRE-OPERATIONAL CHECKLIST (CONT.)
Electrical Panel
Check all accessible wiring and harnesses to ensure they are in good condition,
securely connected, and properly supported.
Inspect relays to be properly seated, clips in place, and fuses to be complete and
undamaged.
Front Axle
Check the front axle ensuring it is securely mounted, and suspension blocks intact.
Inspect steering system components, hoses, and connections for leaks, and verify they
are securely mounted and free of dirt or foreign material.
Inspect steering cylinders for leaks, dents, or bent rods. Clean any accumulated dirt or
grease using only petroleum-free solvents.
Examine all steering arms, rods, and connections, making sure they are securely
mounted, and properly lubricated.
Inspect hydraulic lines, fittings, and connections for leaks and damage.
Inspect air brake lines, and connectors for damage.
Inspect tie rods and joints for damage and excessive play.
Verify that tire treads are free of debris, cuts and damage. Check tire air pressure (cold)
according to specifications (refer to Chapter 2, Section 4). Confirm that valve stems are
undamaged, and valve caps to be installed and finger-tight.
Inspect that all lug nuts are present and undamaged. Re-torque wheel lug nuts to
specification (refer to Chapter 2, Section 4 for torque specification, and Chapter 2,
Section 5 for wheel torque procedure).
Rear Axle
Check the rear axle ensuring it is securely mounted, and suspension blocks intact.
Check gear box fluid level.
Inspect hydraulic lines, fittings, and connections for leaks and damage.
Inspect air brake lines, and connections for damage.
Inspect pivot joint for damage and excessive play.
Verify that tire treads are free of debris, cuts and damage. Check tire air pressure (cold)
according to specifications (refer to Chapter 2, Section 4). Confirm that valve stems are
Inspect that all lug nuts are present and undamaged. Re-torque wheel lug nuts to
specification (refer to Chapter 2, Section 4 for torque specification, and Chapter 2,
Section 5 for wheel torque procedure).
Aerial Device
NOTE: REFER TO MAINTENANCE PROCEDURES IN CHAPTER 2, SECTION 5.
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Page 4
October 2013
Inspect pins, and retainers for proper location ensuring they are undamaged and free of
corrosion.
Visually inspect that all bolts on the rotator are present and undamaged.
Visually inspect basket mounting bolts.
Inspect that the safety harness and lanyard for the operators open basket are available
and undamaged.
AirFirst System (Optional)
Check compressor oil level with boom stowed. Open compressor compartment and
remove dipstick using a screwdriver or a coin. Verify that oil level is between the Max
and Min mark on the dipstick.
Check air cleaner (inside right compartment of compressor package on boom).
Inspect hoses for leaks and damage.
Ensure no water or debris is in the air hoses under the basket, and inspect piping to be
clear and free of obstructions.
OPERATIONAL VERIFICATION
NOTE: ENSURE ALL COMPARTMENT DOORS ARE CLOSED AND PROPERLY LATCHED
BEFORE STARTING THE ENGINE.
Drivers Cab
Start the engine and verify fuel and fluid level gauges, indicators, turn signals and lights
for proper operation.
Check operation of windshield washers, wipers, heaters, auxiliary fans, mirror controls,
and horn.
Check operation of reverse driving alarm, beacons, strobe lights, and rear view
cameras (if applicable).
Leave the engine running, and walk around the vehicle inspecting for leaks and unusual
sounds.
Operational Check
Return to the cab before performing the following tests:
Verify the emergency stop (e-stop) shutdowns the engine when depressed.
Actuate the emergency pump switch and check that the emergency pump operates with
the e-stop depressed.
Verify parking brake released and applied for proper operation.
Initiate heating cycle, and check each stage for proper operation
(refer to Operation in Chapter 1, Section 2).
Drive the vehicle forward and reverse without exceeding 6 km/h (4 mph) and verify
operation of the service brakes and steering wheel.
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Page 5
October 2013
Check boom operation by using controls on the cab.

Verify that speed is limited to 6 km/h (4 mph) when boom is out of rest.
Operators Basket
Verify the emergency stop (e-stop) shutdowns the engine when depressed.
Actuate the emergency pump switch and check that the emergency pump operates with
the e-stop depressed.
Check fuel and fluid level gauges, indicators, turn signals and lights for proper
operation.
Verify that one-man drive controls operate properly.
Check operation of windshield washers, wipers, heaters, fans, and horn.
Verify nozzle operation spraying deicing and anti-icing fluid, and AirFirst (if
applicable).
Load Test
Perform load test as per procedure in Chapter 2, Section 5.
Fluid System Test
Perform fluid system test as per procedure in Chapter 2, Section 5. Ensure the vehicle
passes the fluid system test.
Additional Notes or Comments
Make performance checks (refer to performance specifications).

EQUIPMENT SERIAL NUMBER: HOURMETER:
EQUIPMENT CHECK PERFORMED BY: DATE:
EQUIPMENT CHECK APPROVED BY: DATE:
NOTE: COPIES OF THIS CHECKLIST CAN BE MADE AS PART OF A MAINTENANCE LOG.
2-3
Page 6
October 2013
4. BREAK-IN PERIOD
The vehicle must be thoroughly inspected after the first 200 hours of operation. The 8-hour (daily) and
500-hour (quarterly) schedules should be used as a guide for the 200-hour break-in maintenance
inspection.
There is no need to replace the engine oil as part of the break-in maintenance. The manufacturer
provides the engine with a high-grade lubricant, and recommends to change the oil at least every 500
hours of operation or yearly. If any other lubricant is used after the first oil change, more frequent
intervals should be observed.
The transmission and drive train should be inspected for leaks and signs of potential problems, but no oil
change is required as part of the break-in maintenance. A pre-charge accumulator pressure check
should be made as outlined in Maintenance Procedures, Chapter 2, Section 5.
Refer to Manufacturers Appendices in Chapter 5 for maintenance recommendations for each specific
component.
5. PERIODIC MAINTENANCE
Regular maintenance is required to ensure optimum equipment performance and long life for machine
components. Maintain the vehicle by performing periodic maintenance at the intervals listed in the
Maintenance Schedule tables within this section.
Specific operating conditions will determine the scope and frequency of maintenance work required. If
in doubt about any service intervals or maintenance operations recommended within this manual,
please refer to the manufacturers recommendations for the specific component.
If the vehicle is operated under severe weather conditions such as extreme heat or cold, or in sandy,
dusty, or snowy areas, increase the frequency of periodic maintenance as necessary, but always refer to
specific manufacturers recommendations.
Maintenance records must be kept as evidence of regular and proper maintenance, an essential
requirement the manufacturer may request in the event of a warranty claim.
CAUTION

6. MAINTENANCE SCHEDULE TABLES
The following pages contain three tables with required maintenance at recommended intervals.
Every 8 hours or daily (performed by operator)

Every 500 hours or quarterly (performed by maintenance personnel)
Every 2000 hours or annually (performed by maintenance personnel)
Depending on the duty demands and severity of the climate, it may be necessary to perform
maintenance procedures at more frequent intervals.
2-3
Page 7
October 2013
The number of hours specified for each recommended interval is based on the vehicle or engine
operation cumulative hours that represent a portion of idling time, while several components such as
traction axles, wheel hubs, and other equipment may be subject to significantly less hours of effective
operation. Always refer to manufacturers recommendations to ensure proper maintenance for all
components.
NOTE: REFER TO SPECIFICATIONS IN CHAPTER 1, SECTION 4 FOR GENERAL

SPECIFICATIONS AND FLUID CAPACITIES, AND MAINTENANCE SPECIFICATIONS IN
CHAPTER 2, SECTION 4 FOR RECOMMENDED LUBRICANTS, AND OPERATIONAL,
PRESSURE AND ADJUSTMENT SETTINGS.
NOTE: REFER TO MANUFACTURERS APPENDICES IN CHAPTER 5 FOR THE

CORRESPONDING MANUAL FOR EACH COMPONENT AND REVIEW DETAIL
INFORMATION FOR PROPER MAINTENANCE AND WARRANTY REQUIREMENTS.
NOTE: COPIES OF THE FOLLOWING TABLES CAN BE MADE AND USED AS A PART OF THE
VEHICLES MAINTENANCE LOG.
2-3
Page 8
October 2013
MAINTENANCE SCHEDULEEVERY 8 HOURS (DAILY)
(PERFORMED BY THE OPERATOR)
PROCEDURE CHECK()
NOTE: NOTIFY MAINTENANCE PERSONNEL OF ANY ISSUES OR PROBLEMS FOUND.

Vehicle Walk-around
Open all compartments and perform walk-around inspection of vehicle and check for
obvious damage, missing parts, and any fluid leaks.
Inspect seats, and seat belts for damage and verify proper operation. Ensure they are
properly adjusted and securely mounted.
Check fuel level in fuel tank, and refill if necessary, but do not overfill it.
Verify that tire threads are free of debris, cuts, and damage. Inspect that all lug nuts are
present and undamaged.
Inspect that the safety harness and lanyard for the operators open basket are available
and undamaged.
Check charge of fire extinguisher(s), and access to be free of obstacles, if applicable.
Engine Compartment
Check crankcase oil level (with engine off). The level should be between the Max and
Min marks on the dipstick.
Check coolant level (cold with engine off). Remove radiator cap slowly. Coolant should
be approximately one inch below the top of the radiator tank.
Check oil level in hydraulic tank with engine off. Ensure fluid level is between the Max
and Min marks in the sight gauge. A floater in the sight glass indicates the fluid level.
If visible through the opening, the oil level is full. If it is not visible, or is in the lower part
of the glass, add hydraulic oil.
Check hydraulic filter condition indicators with the system running at high idle.
Indicators are normally color coded:
Green = Good
Red, or approaching red = Replace
NOTE: NOTIFY MAINTENANCE PERSONNEL IMMEDIATELY IF A FILTER NEEDS TO BE
REPLACED.
Anti-icing Fluid System (If equipped)
Grease anti-icing pump.
Check compressor oil level with boom stowed. Open compressor compartment and
remove dipstick using a screwdriver or a coin. Verify that oil level is between the Max
and Min marks on the dipstick.
Check air filter (inside compressor compartment on boom), clean if needed.
Inspect hoses for leaks and damage.
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Page 9
October 2013
MAINTENANCE SCHEDULEEVERY 8 HOURS (DAILY) (CONT.)
(PERFORMED BY THE OPERATOR)
PROCEDURE CHECK()
Drivers Cab
Start the engine and verify fuel and fluid level gauges, indicators, turn signals and lights
Check fluid level in windshield washer reservoir.
Check operation of windshield washers, wipers, heaters, auxiliary fans, mirror controls,
and horn.
Check operation of reverse driving alarm, beacons, strobe lights, and rear view
cameras (if applicable).
Leave the engine running, and walk around the vehicle inspecting for leaks and unusual
sounds.
Operational Check
Return to the cab and verify that the emergency stop (E-stop) shutdowns the engine
when depressed.
Actuate the emergency pump (E-pump) switch and verify that the E-pump operates with
the E-stop depressed.
Release E-stop and start engine. Verify parking brake released and applied for proper
operation.
Verify operation of the service brakes and steering wheel.
Operators Basket
Verify that the emergency stop (E-stop) shutdowns the engine when depressed.
Actuate the emergency pump (E-pump) switch and verify that the E-pump operates with
the E-stop depressed.

DAILY CHECK PERFORMED BY: DATE:
DAILY CHECK VERIFIED BY: DATE:
NOTE: COPIES OF THIS TABLE CAN BE MADE AS PART OF A MAINTENANCE LOG.
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Page 10
October 2013
MAINTENANCE SCHEDULEEVERY 500 HOURS (QUARTERLY)
(PERFORMED BY MAINTENANCE PERSONNEL)
PROCEDURE CHECK() NOTES
NOTE: THE 500-HOUR MAINTENANCE SCHEDULE SHOULD BE PERFORMED ALSO AT

MULTIPLES OF 500 HOURS AT 1000 AND 1500 HOURS, AND AT 2000 HOURS AS PART
OF THE 2000-HOUR OR ANNUAL MAINTENANCE. IF OPERATING LESS THAN 500
HOURS IN A QUARTER, PERFORM VEHICLE SERVICE QUARTERLY.
Chassis And Body
Check all latches, hinges, and fasteners. Verify that they
lock and fasten securely.
Clean electrical parts such as alternator, junction boxes,
switches, and wiring. Use a clean, lint-free cloth moistened
with dry cleaning solvent.
Remove accumulated dirt, tar and grease. For cleaning
exterior parts, use a vapor pressure sprain rinse cleaner.
Engine Compartment
Check engine mounts, isolators, brackets, and hardware to
ensure they are securely mounted, and not damaged.
Check engine and other components for leaks.
Check serpentine belt to be in good condition, and ensure
belt tensioner works properly. No adjustment needed.
Drain and refill engine oil, and replace oil filter.
NOTE: THE ENGINE OIL AND OIL FILTER MUST BE REPLACED AT LEAST EVERY 500 HOURS
OR YEARLY, WHICHEVER COMES FIRST.
Refer to the engine manual in Chapter 5, Manufacturers Appendices for additional maintenance
requirements, and procedures.
Check fuel filter for possible contamination, and replace filter
element, if necessary. Check the fuel lift pump.
Inspect accelerator linkage, adjust as required.
Check coolant drain cocks to be securely closed.
Check coolant level (cold with engine off). Remove radiator
cap slowly. Coolant level should be approximately one inch
below the top of the radiator tank.
Check engine coolant freezing point for temperatures below
-40 C (-40 F) using a hydrometer.
Check radiator for obstructions to air flow. Remove all bugs,
dirt or foreign material with a soft brush or cloth.
Inspect air cleaner, and cleaner element to be clean and
undamaged, and ensure the intake duct is free of
obstructions.
2-3
Page 11
October 2013
MAINTENANCE SCHEDULEEVERY 500 HOURS (QUARTERLY) (CONT.)
Inspect the engine exhaust, ensuring all clamps and fittings

are tight and free of potential leaks.
Check hydraulic pumps and components to ensure they are
securely mounted, and free of dirt or foreign material. Use
only petroleum-free solvents to clean them.
Replace main pump case drain filter.
Verify system pressure at compensator and main relief valve
(refer to Pressure Settings Chart in Chapter 2, Section 4).
Drain water from fuel and water separator by opening the
drain cock at the bottom of the fuel and water separator
bowl.
Check air brake system for leakage and drain moisture from
air tanks.
Check electrolyte level in battery, if applicable. Clean
battery terminals and exterior surfaces using a baking soda
and water solution. Ensure battery terminals and holder are
tight.
Check oil level in hydraulic tank with engine off. Ensure fluid
level is between the Max and Min marks in the sight
gauge. A floater in the sight glass indicates the fluid level. If
visible through the opening, the oil level is full.
If it is not visible, or is in the lower part of the glass, add
hydraulic oil.
Check hydraulic filter condition indicators with the system
running at high idle. Indicators are normally color coded:
Green = Good
Red, or approaching red = Replace
Inspect hydraulic filters; with engine at high idle speed check
indicators for differential pressures and clean, or replace
accordingly, if necessary.
Inspect hydraulic system components for leaks and signs of
potential problems.
Hydrostatic Transmission
Inspect for leaks and signs of potential problems. Check oil
level in gear box and replace, if necessary.
Refer to Chapter 5, Manufacturers Appendices, and follow
guidelines provided by the manufacturer.
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Page 12
October 2013
Electrical Panel
Check all accessible wiring and harnesses to ensure they
are in good condition, securely connected, and properly
supported.
Inspect relays to be properly seated, clips in place, and
fuses to be complete and undamaged.
Front Axle
Check the front axle ensuring it is securely mounted, and
suspension blocks intact.
Inspect front axle wheel hubs for leaks and signs of potential
problems.
Inspect steering system components, hoses, and
connections for leaks, and verify they are securely mounted
and free of dirt or foreign material.
Inspect steering cylinders for leaks, dents, or bent rods.
Clean any accumulated dirt or grease using only petroleum-
free solvents.
Inspect all steering arms, rods, and connections, ensuring
they are securely mounted, and properly lubricated.
Inspect hydraulic lines, fittings, and connections for leaks
and damage.
Inspect service brake linings, adjust as friction material
wears, and replace if needed. Refer to Manufacturers
Appendices for recommended procedures.
Inspect tie rods and joints for damage and excessive play.
Verify that tire treads are free of debris, cuts and damage.
Check tire pressure (cold) according to specifications (refer
to Chapter 2, Section 4). Confirm that valve stems are
Inspect that all lug nuts are present and undamaged.
Re-torque wheel lug nuts to specification (refer to Chapter 2,
Section 4, and Section 5).
Rear Drive Axle
NOTE: REFER TO CHAPTER 5, MANUFACTURERS APPENDICES, AND FOLLOW GUIDELINES
PROVIDED BY THE MANUFACTURER FOR GEAR BOX, REAR AXLE, AND WHEEL
HUBS.
2-3
Page 13
October 2013
Check the rear axle ensuring it is securely mounted, and

suspension blocks intact.
Inspect rear axle and wheel hubs for leaks and signs of
potential problems. Check oil level in differential carrier
housing and axle wheel hubs.
Check gear box fluid level, and inspect for leaks and signs of
potential problems.
Inspect hydraulic lines, fittings, and connections for leaks
and damage.
Inspect service brake linings, adjust as friction material
wears, and replace if needed. Refer to Manufacturers
Appendices for recommended procedures.
Inspect pivot point for damage and excessive play.
Lubricate axle shaft universal joints.
Verify that tire treads are free of debris, cuts and damage.
Check tire pressure (cold) according to specifications (refer
to Chapter 2, Section 4). Confirm that valve stems are
Inspect that all lug nuts are present and undamaged.
Re-torque wheel lug nuts to specification following the
specific procedure (refer to Chapter 2, Sections 4, and 5).
Deicing Fluid System
NOTE: REFER TO CHAPTER 2, SECTION 5 FOR MAINTENANCE PROCEDURES, AND FLUID
SYSTEM SCHEMATICS SUBSECTION, IN CHAPTER 2, SECTION 7 FOR ALL FLUIDS.
Check accumulator charge pressure on European and
Prop-mix units.
Purge fluid system (as required).
Check reel hose nozzle for flow rate and spray pattern
operation.
Anti-Icing Fluid System (If equipped)
Drain Anti-icing tank.
Check hydraulic motor and anti-icing pump coupling.
Aerial Device
NOTE: REFER TO MAINTENANCE PROCEDURES IN CHAPTER 2, SECTION 5.
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Page 14
October 2013
Inspect rotator: grease rotator bearing, check boom rotation,

check all pins, and inspect for damage.
Inspect knuckle: check all pins and check for hose wear or
damage.
Inspect main boom: check cylinder pins, pin eyes, and
basket pin, check cylinder pin eyes, check for damage.
Operate boom to full limits of travel from both basket and
driver's cab. Check for sticky or binding joystick and valves
or sudden boom movement, indicating air in hydraulic
system.
Check hoses for wear or damage.
Check basket for cracks at mount holes and latch.
Check for fluid leaks.
Test downward creep of the aerial device with recommended
maximum load in basket (refer to Maintenance
Specifications in Chapter 2, Section 4).
With the engine shut down, place the EMERGENCY
HYDRAULIC PUMP switch in the ON position and ensure
the joystick lowers the boom.
Confirm the proximity alarm and warning system (optional)
Fluid Heater
Replace fuel filter element (located underneath the fluid
heater).
Inspect for carbon buildup on coils.
NOTE: REFER TO COMPRESSOR MANUAL IN CHAPTER 5, MANUFACTURERS APPENDICES
FOR MAINTENANCE PROCEDURES.
Check hydraulic pump for operation.
Check compressor oil level with boom stowed. Open
compressor compartment and remove dipstick using a
screwdriver or a coin. Verify that oil level is between the
Max and Min marks on the dipstick.
Check fittings, hoses and oil lines for leaks.
Check air hoses, piping and nozzle for leaks and wear.
2-3
Page 15
October 2013
OPERATIONAL VERIFICATION
NOTE: DO NOT PERFORM THIS OPERATIONAL VERIFICATION IF ALSO PERFORMING THE
500-HOUR MAINTENANCE AS PART OF THE ANNUAL MAINTENANCE. FOLLOW THE
EQUIPMENT PRE-OPERATIONAL CHECKLIST AFTER COMPLETING THE ANNUAL
MAINTENANCE SCHEDULE. THE OPERATIONAL VERIFICATION IS INCLUDED IN THE
EQUIPMENT PRE-OPERATIONAL CHECKLIST.
Drivers Cab
Start the engine and verify fuel and fluid level gauges,
indicators, turn signals and lights for proper operation.
Check operation of windshield washers, wipers, heaters,
auxiliary fans, mirror controls, and horn.
Check operation of reverse driving alarm, beacons, strobe
lights, and rear view cameras (if applicable).
Leave the engine running, and walk around the vehicle
inspecting for leaks and unusual sounds.
Operational Check
Return to the cab before performing the following tests:
Verify the emergency stop (E-stop) shutdowns the engine
when depressed.
Actuate the emergency pump switch and check that the
emergency pump operates with the e-stop depressed.
Verify parking brake released and applied for proper
operation.
Initiate heating cycle, and check each stage for proper
operation (refer to Operation in Chapter 1, Section 2).
Drive the vehicle forward and reverse without exceeding
6 km/h (4 mph) and verify operation of the service brakes
and steering wheel.
Check boom operation by using controls on the cab.
Verify that speed is limited to 6 km/h (4 mph) when boom is
out of rest.
Operators Basket
Verify the emergency stop (e-stop) shutdowns the engine
when depressed.
2-3
Page 16
October 2013
Actuate the emergency pump switch and check that the

emergency pump operates with the e-stop depressed.
Check fuel and fluid level gauges, indicators, turn signals
and lights for proper operation.
Verify that one-man drive controls operate properly.
Check operation of windshield washers, wipers, heaters,
fans, and horn.
Verify nozzle operation spraying deicing and anti-icing fluid,
and AirFirst (if applicable).
NOTE: THE 8-HOUR (DAILY) CHECK MUST BE ALSO PERFORMED AS PART OF THE
500-HOUR MAINTENANCE SCHEDULE.
NOTE: MAKE SURE TO PERFORM THE OPERATIONAL CHECKS AS STATED ON THE
EQUIPMENT PRE-OPERATIONAL CHECKLIST.
MAINTENANCE PERFORMED BY: DATE:
MAINTENANCE VERIFIED BY: DATE:
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Page 17
October 2013
MAINTENANCE SCHEDULEEVERY 2000 HOURS (YEARLY)
NOTE: THE 500-HOUR (QUARTERLY) MAINTENANCE SCHEDULE SHOULD BE ALSO

PERFORMED AS PART OF THE ANNUAL MAINTENANCE SCHEDULE.
Chassis And Body
Inspect condition of drivers cab, and operators basket (if
applicable) wiper blades and check windshield wiper and
washer operation.
Engine
Refer to the engine manual in Chapter 5, Manufacturers Appendices for additional maintenance
requirements that may be necessary to perform.
Check turbocharger and air cooler; clean if necessary.
Check the alternator, starter motor, governor, water pump,
etc., and replace any component that might interfere with the
proper functioning of the engine.
Adjust valve tappets if needed.
Clean crank case ventilation system.
Inspect engine protection devices for proper operation.
Check engine RPM for proper idle and high throttle settings
using a photo tachometer.
Clean engine, engine compartment and radiator as required
by manufacturer (refer to Chapter 5).
Drain sediment from fuel tank.
Clean the lift pump sediment chamber.
Replace fuel filter element.
Flush and refill cooling system. Use only clean water and
antifreeze solution. Use a hydrometer if necessary.
Hydraulic System
NOTE: REFER TO HYDRAULIC OIL RECOMMENDATIONS IN CHAPTER 2, SECTION 4,
MAINTENANCE SPECIFICATIONS, FOR HYDRAULIC FLUID INFORMATION AND
CAPACITIES, AND CHAPTER 1, SECTION 4 FOR GENERAL SPECIFICATIONS.
NOTE: IN MANY CASES THE HYDRAULIC OIL MAY STILL BE SERVICEABLE, AND CAN BE
FILTERED INSTEAD OF REPLACED.
Take an oil sample and have it analyzed by a reputable
source.
Replace or filter hydraulic oil based on analysis results.
Clean the unit for any spillage that may occur.
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Page 19
October 2013
MAINTENANCE SCHEDULEEVERY 2000 HOURS (YEARLY) (CONT.)
Verify that all filters in the hydraulic system have been

inspected and tested for differential pressures, and that they
have been cleaned or replaced accordingly.
Examine all hydraulically operated components such as
pumps, steering valves, tank, steering cylinders, oil cooler,
etc. Ensure all components are securely mounted.
Clean and dry all hydraulic system components using
petroleum-free solvents. Ensure no residue remains.
Check boom lower, raise and rotation relief valves.
Check hoses and lines; replace if necessary.
Replace hydraulic oil tank breather.
Hydrostatic Transmission
NOTE: REFER TO CHAPTER 5, MANUFACTURERS APPENDICES, AND FOLLOW GUIDELINES
PROVIDED BY THE MANUFACTURER.
Drain and replace lubricating oil in transmission. Ensure the
use and correct level of the recommended oil.
Tighten transmission components hardware.
Front Steering Axle
Repack bearings on steer wheel hubs.
Inspect and re-tighten mounting hardware and suspension
components. Replace components if damaged.
Inspect and re-tighten tie rods and joints.
Inspect wheel steering for proper operation.
Rear Drive Axle
NOTE: REFER TO CHAPTER 5, MANUFACTURERS APPENDICES AND FOLLOW GUIDELINES
PROVIDED BY THE MANUFACTURER.
Drain and replace lubricating oil in differential carrier
housing. Ensure correct level and use of recommended
lubricating oil.
Drain and replace lubricating oil in wheel hubs, if needed.
Ensure correct level and use of recommended oil.
Inspect and re-tighten mounting hardware and suspension
components. Replace components if damaged.
Fluid Systems
Verify deicing pump fluid pressure.
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Page 20
October 2013
Verify anti-icing nozzle fluid pressure.

Air Dryer System
Check fuse 2CP-2, and replace if needed.
Inspect air dryer heater for proper operation.
Aerial Device
Re-torque bolts attaching rotator weldment to bearing.
Re-torque bearing to pedestal bolts.
Check rotator drive and re-torque attachment bolts (refer to
Maintenance Procedures in Chapter 2, Section 5).
Check that flow rate and pattern adjustments on basket
nozzles function with engine at High throttle.
Fluid Heater
Check fuel valve solenoids (refer to Maintenance
Procedures in Chapter 2, Section 5 for inspection
procedure).
Check air switch and blower speed (refer to Chapter 2,
Section 5 for check and adjustment procedures).
Clean fuel nozzle strainers (remove burner assembly from
heater, and remove and disassemble nozzles to clean
strainers).
Check fuel pressure.
Check air cone setting.
Check ignition electrode gap.
Check burner tube depth setting.
Clean exhaust screen. Remove heater exhaust screen and
clean with hot soapy water.
Clean carbon buildup from burner assembly. Remove
burner assembly for heater. Use small wire brush to clean
any carbon build up from all parts of the burner. Pay
particular attention to the area around the electrodes on
stage 1.
Check blower assembly. Check blower wheel and housing
for cracks, or loose fasteners. Ensure inlet is securely
attached.
Check exhaust duct. Inspect exhaust duct for cracks and
loose fasteners.
2-3
Page 21
October 2013
Check heater for leaks. Inspect heater for hydraulic fluid,

fuel, or deicing water fluid leaks.
NOTE: REFER TO COMPRESSOR MANUAL IN CHAPTER 5, MANUFACTURERS APPENDICES
FOR MAINTENANCE PROCEDURES.
Replace compressor oil with boom stowed. Verify that oil
level is between the Max and Min marks on the dipstick.
Clean air inlet, and replace air filter.
General
Verify that all recommended maintenance have been
performed, and clean the vehicle of tar, grease, and dirt.
NOTE: ENSURE TO PERFORM ALL THE CHECKS AS STATED ON THE EQUIPMENT

PRE-OPERATIONAL CHECKLIST.
NOTE: THE EQUIPMENT PRE-OPERATIONAL CHECKLIST SHOULD BE USED TO VERIFY THE
PROPER EQUIPMENT OVERALL OPERATING CONDITION.
MAINTENANCE PERFORMED BY: DATE:
MAINTENANCE VERIFIED BY: DATE:
2-3
Page 22
October 2013
7. HYDRAULIC OIL RECOMMENDATIONS
Refer to Maintenance Specifications in Chapter 2, Section 4 for recommended hydraulic oil.
8. LUBRICATION
A. GREASE FITTINGS
Wipe grease fittings clean and apply lithium base grease. Before coating other surfaces with
grease, clean surfaces to remove dirt and foreign material. It is important to get the grease in
through the greasing nipples to avoid grease hardening and potential plugging of channels.
NOTE: GREASE MUST BE PUMPED INTO GREASE NIPPLES UNTIL CLEAN GREASE EXITS
FROM ALL SIDES AROUND THE CIRCUMFERENCE OF THE BEARING OR PIN.
B. FRICTION POINTS
Door hinges, locks, and latches. Apply oil with brush or oil can as appropriate.
C. FILL POINTS
Refer to Figure 1 for maintenance locations.
NOTE: CHECK AT INTERVALS LISTED AND LUBRICATE AS REQUIRED. IN SEVERE

WEATHER CONDITIONS, CHECK AT MORE FREQUENT INTERVALS.
LUBRICATION AND REFILL CHART
ITEM DESCRIPTION CHANGE AND REFILL INTERVALS
1 Friction points
As required 500 hours or 3 months
2 Grease fittings
As per maintenance
3 Hydraulic fluid 2000 hours or yearly
schedule
As per maintenance
4 Engine oil 500 hours or yearly
schedule
5 Engine coolant
As per maintenance
6 Gear box 2000 hours or yearly
schedule
7 Drive axle lubricating oil
8 Boom, and jib pins
9 Boom and jib cylinder pins

As required 500 hours or 3 months
10 Tie rod ends and axle joints
11 Steering cylinder pins
2-3
Page 23
October 2013
LUBRICATION AND REFILL CHART (CONT.)
ITEM DESCRIPTION CHANGE AND REFILL INTERVALS
12 Front wheel hubs As per maintenance

2000 hours or yearly
13 Rear wheel hubs schedule
14 Rotator bearing and gear As per maintenance

2000 hours or yearly
15 Rotator drive schedule
Deicing pump, mechanical

16
seal (Myers)
As per maintenance
8 hours or daily
17 Deicing pump (Hardi) schedule
18 Anti-icing pump (Hardi)
19 Boom rotator bearing teeth

As per maintenance
Basket rotator bearing teeth 2000 hours or yearly
20 schedule
(enclosed basket only)
21 Nozzle pivot joints As per maintenance

8 hours or daily
22 AirFirst compressor schedule
NOTE: REFER TO RECOMMENDED LUBRICANTS IN MAINTENANCE SPECIFICATIONS,

CHAPTER 2, SECTION 4 FOR THE SPECIFIC LUBRICANT FOR EACH ITEM.
NOTE: NEW HARDI #463 REPLACEMENT PUMPS ARE SUPPLIED DRY (UN-LUBRICATED)
FROM THE MANUFACTURER. REPLACEMENT PUMPS SHOULD BE FILLED WITH
THE RECOMMENDED LUBRICANT (REFER TO MAINTENANCE SPECIFICATIONS IN
CHAPTER 2, SECTION 4).
2-3
Page 24
October 2013
JIB BOOM JIB BOOM FLUID HYDRAULIC MAIN BOOM
PIVOTS CYLINDERS PUMPS CYLINDERS PIVOTS
BASKET FRONT DIESEL FUEL HYDROSTATIC TRANSMISSION MAIN BOOM

PIVOTS AXLE TANK TRANSMISSION DRIVE SHAFT ROTATOR
DEICER CONTROL HYDRAULIC DIESEL ENGINE ELECTRICAL

HEATER PANEL PUMPS ENGINE COOLER PANEL
HYDRAULIC REAR DRIVE BATTERY PNEUMATIC COMPARTMENT DOOR HINGES

OIL TANK AXLE / HUBS BANK ACCUMULATORS HINGES / LATCHES AND LOCKS
Figure 1
VEHICLE MAINTENANCE LOCATIONS
2-3
Page 25
October 2013
2-3
Page 26
October 2013
Figure 2
STANDARD BOOM PIN LUBRICATION
OPEN BASKET ENCLOSED BASKET NOTE: REFER TO CHAPTER 2, SECTION 4,
MAINTENANCE SPECIFICATIONS FOR
SPECIFIC LUBRICANTS.

Figure 3
EXTENDED REACH (XR) BOOM PIN LUBRICATION
OPEN BASKET ENCLOSED BASKET NOTE: REFER TO CHAPTER 2, SECTION 4,
MAINTENANCE SPECIFICATIONS FOR
SPECIFIC LUBRICANTS.
October 2013
Page 27
2-3
OIL TANK OIL FILTER CONDITION OIL TANK
FILL INLET INDICATOR BREATHER
RETURN FROM
BLOWER
MOTOR
OIL TANK
LEVEL GAUGE
RETURN FILTER FROM

SERVICE PUMP
OIL TANK
DRAIN
OIL FILTER
RETURN FILTER FROM

HEAT EXCHANGER
OIL TANK FILTER
RETURN
Figure 4
HYDRAULIC OIL TANK
2-3
Page 28
October 2013
1. GENERAL
This section includes information on specifications required for performing regular maintenance and
adjustment procedures for the Tempest Aircraft Deicer.
It includes recommendations for hydraulic oil fluids, recommended lubricants, mechanical adjustment
settings, pressure settings for hydraulic equipment and components, and other settings necessary to
tune-up the vehicle for optimal performance. For general vehicles specifications and general
information, refer to Specifications in Chapter 1, Section 4.
2. HYDRAULIC OIL RECOMMENDATIONS
NOTE: STUDIES HAVE SHOWN THAT NEARLY 90% OF THE FAILURES OF HYDRAULIC
COMPONENTS ARE CAUSED BY HYDRAULIC FLUID CONTAMINATION.
The ISO, or International Standards Organization, has established a code index system as a guideline
for machine builders and end users. This ISO code specifies different levels of oil cleanliness and is
based on the type of component used in the machine which is the most sensitive in relation to fluid
borne contaminants. According to this, the axial piston pumps and motors used on most JBT AeroTech
equipment require an ISO 4406:1999 code level of 18/16/13. This code level is a means of measuring
three sizes of particles contained in 1 milliliter of fluid. The particle sizes are measured in microns, also
known as micrometers. The first number, 18 is a measurement of particles equal to or greater than 4
microns. The second number, 16 is for particles equal to or greater than 6 microns, while the last
number, 13, is for particles equal to or greater than 14 microns.
Whether you are adding, replenishing hydraulic oil to the tank or changing the oil entirely, JBT AeroTech
recommends the new oil should be filtered to meet the ISO 18/16/13 spec. Always add oil to the tank
through the in-tank filter installed in the reservoir. The fill ports are color coded, yellow with a blue bar.
JBT AeroTech strongly recommends that owners work with their hydraulic oil suppliers to establish a
comprehensive sampling program to check the oil for excessive contaminants on a regular basis.
Use appropriate hydraulic oil with the viscosity grade corresponding to the operating temperature range
listed below.
OIL OPERATING TEMPERATURE RANGE
RECOMMENDED MINIMUM START-UP MAXIMUM OPERATING

HYDRAULIC OIL TEMPERATURE (OIL TANK) TEMPERATURE (OIL TANK)
ISO VG 15 -40 C (-40 F) 66 C (150 F)
ISO VG 32 -29 C (-20 F) 74 C (165 F)
ISO VG 46 0 C (32 F) 82 C (180 F)
ISO VG 68 10 C (50 F) 82 C (180 F)
2-4
MAINTENANCE SPECIFICATIONS
Page 1
October 2013
3. HYDRAULIC OIL OPERATING TEMPERATURE
Normal operating temperature . . . . . . . . . . . . . . . . . . . 52 C to 60 C (125 F to 140 F)
4. RECOMMENDED FLUIDS AND LUBRICANTS
A. NORMAL OPERATING TEMPERATURE
FLUIDS AND LUBRICANTS SPECIFICATIONS CHART
START-UP TEMPERATURE
ITEM DESCRIPTION -29 C TO 51 C CAPACITIES
(-20 F TO 123 F)
1 Oil (friction points) SAE 30
As required
2 Grease fittings NLGI 2
Tank: 416 L (110 gal.)
ISO VG 32
Hydraulic oil Hoses: 57 L (15 gal.)
3 (Minimum viscosity index 140)
Total: 473 L (125 gal.)
Refer to HYDRAULIC OIL RECOMMENDATIONS within this section.
Engine oil
Mercedes OM 906 LA 29 L (7.7 gal.)
SAE 15W-40
Cummins QSB 4.5 T3 11 L (2.9 gal.)
4 API CI-4, CH-4, CG-4, CF-4
Cummins QSB 6.7 T3 16.3 L (4.3 gal.)
Refer to the engine manual in Manufacturers Appendices, Chapter 5 for lube oil and
coolant, and for service intervals, warranty requirements, and additional information
Engine coolant
Mercedes OM 906 LA Ethylene glycol 50% 25.3 L (6.7 gal.)
5 Water 50%
Cummins QSB 4.5 T3 21 L (5.5 gal.)
Glycol spec TMC RP329
Cummins QSB 6.7 T3 or Det. Diesel 7SE298 24 L (6.25 gal.)
Hypoid Gear Oil
6 Gear box oil SAE 80W-90 As required
API GL5 - MIL-L-2105 B
Hypoid Gear Oil
Rear drive axle
7 SAE 75W-90 As required
lubricating oil
API GL5 - MIL L-2105 B
8 Boom, and jib pins
Boom and jib cylinder
9
pins
NLGI 2 As required
Tie rod ends and axle
10
joints
11 Steering cylinders
2-4
Page 2
October 2013
FLUIDS AND LUBRICANTS SPECIFICATIONS CHART (CONT.)
START-UP TEMPERATURE
ITEM DESCRIPTION -29 C TO 51 C CAPACITIES
(-20 F TO 123 F)
Hypoid Gear Oil
12 Front wheel hubs SAE 80W-90 As required
Hypoid Gear Oil
13 Rear wheel hubs SAE 75W-90 As required
Rotator bearing and
14
gear NLGI 2
15 Rotator drive
OPW #864 Mobilith AW,
Deicing pump,
16 Mobilux EP111
mechanical seal (Myers)
SAE 30 oil
17 Deicing pump (Hardi)
NLGI 2 Lithium As required
18 Anti-icing pump (Hardi)
Boom rotator bearing NLGI 2 Moly 29
19
teeth open gear compound
Basket rotator teeth
20 NLGI 2
(enclosed basket only)
21 Nozzle pivot joints SHC-100
22 AirFirst compressor MIL-L-7808 or BPTO 2389
NOTE: REFER TO MANUFACTURERS APPENDICES FOR FLUIDS AND LUBRICANTS

SPECIFICATIONS FOR ALL COMPONENTS.
NOTE: NEW HARDI #463 REPLACEMENT PUMPS ARE SUPPLIED DRY (UN-LUBRICATED)
FROM THE MANUFACTURER. REPLACEMENT PUMPS SHOULD BE FILLED WITH
NLGI 2 EP MULTI-PURPOSE GREASE.
2-4
Page 3
October 2013
LUBRICANTS REFERENCE CHART
REFERENCE TYPE DESCRIPTION
A Grease NLGI 2 EP multi-purpose
B Grease OPW #864, Mobilith AW, Mobilux EP 111
C Grease NLGI 2 Lithium
D Oil SAE 30
E Grease NLGI 2 Moly 29 Open Gear Compound
F Grease SHC-100 or #28 below -26 C (-15 F)
G Grease MIL-L-7808 or BPTO 2389
NOTE: REFER TO FIGURE 1 AND FIGURE 2 FOR SPECIFIC LUBRICATION ITEMS.
2-4
Page 4
October 2013
E
A
B
REFER TO LUBRICANTS REFERENCE TABLE IN PREVIOUS PAGE.

A
A
C
D
B
NOTE:
A
A
A
A
A
Figure 1
LUBRICATION SPECIFICATIONS - OPEN BASKET VEHICLES
2-4
Page 5
October 2013
E
REFER TO LUBRICANTS REFERENCE TABLE IN PREVIOUS PAGE.

A
A
C
D
F
A
E
NOTE:
A
A
A
AA
F
Figure 2
LUBRICATION SPECIFICATIONS - ENCLOSED BASKET VEHICLES
2-4
Page 6
October 2013
B. EXTREME WEATHER OPERATION
For operating outside the normal weather operating temperature range, take precautions for
proper operation, such as avoiding cavitation (extremely cold weather) and overheating (hot
weather).
NOTE: REFER TO COMPONENT MANUALS IN MANUFACTURERS APPENDICES, CHAPTER

5, FOR SPECIFICATIONS ON FLUIDS AND LUBRICANTS FOR OPERATING UNDER
EXTREME WEATHER CONDITIONS.
5. EQUIPMENT ADJUSTMENT SETTINGS
The following adjustment settings are recommended for the properly functioning of the vehicle.
ADJUSTMENT SETTINGS CHART
ADJUSTMENT OPERATION SETTING ADJUSTMENT LOCATION
PLC Engine screen and

Engine idle speed 10751150 rpm
engines injection pump
Engine mid speed 17751825 rpm Cummins QSB 6.7 only
Engine, and injection pump, if
Engine high speed 21752225 rpm
needed
Heater blower motor
Low speed 2700 25 rpm Flow control adjusting screw
High speed 4500 25 rpm Flow control adjusting screw
Heater fuel pump motor speed 2850 25 rpm Heater fuel pump
Anti-ice drive motor speed 250 25 rpm
Anti-ice refill pump drive motor
450 25 rpm
speed
Circulation delivery pump drive
motor speed
132 L/min. (35 gpm) 2200 50 rpm
227 L/min. (60 gpm) 3700 50 rpm
Heater Burner Assembly
Electrodes angles
- Original 45 At tip of each ignition electrode.
- Adjusted 40
Flame retention ring From face of flame retention ring
36 mm (1.42 in.)
(Adjustment X) to tip of nozzle.
Electrodes glass base From holding clamp to end of
67.2 mm (2.65 in.)
(Adjustment Y) electrode porcelain insulator.
Electrodes distance from From retention ring face to tip of
18.0 mm (0.71 in.)
ring face (Adjustment Y) ignition electrodes.
2-4
Page 7
October 2013
ADJUSTMENT SETTINGS CHART (CONT.)
Electrodes distance from From retention ring brace tips to

23.2 mm (0.91 in.)
ring tips (Adjustment Y) tip of ignition electrodes.
Ignition electrodes spark Tips of ignition electrodes, head
4.18 mm (0.165 in.)
gap (Adjustment Y) of burner assembly.
Electrodes angles, upper
= 78 Head of burner assembly, near
and lower electrodes
(Adjustment Y) = 156 retention ring and fuel nozzle.
Burner tube adjustment From inside of supporting plate

465.83 mm (18.34 in.)
(Dimension B) to front edge of retention ring.
Burner nozzle depth Dimension A measured inside
setting (Dimensions A 6.35 mm (0.25 in.) heater air tubes, which may
minus B) vary.
Air pressure switch adjustment
Blower low speed 2500 rpm Flow control valve on hydraulic
Decreased blower speed 2400 rpm manifold
Fluid temperature gauges
Temperature range 37.793.3 C (100200 F)
Heater outlet manifold
Temperature tolerance 1.7 C (3 F)
Fluid temperature switches
Over temperature switch 110 C (230 F) 6 TAS
Temperature switch 90.6 C (195 F) 11 TAS
Temperature tolerance 1.7 C (3 F)
Brake lining minimum
1.60 mm (0.0625 in.) Brake shoe
thickness
0.2540.508 mm
Service brake pedal travel Brake valve plunger
(0.0100.020 in.)
Parking brake adjustment Not applicable Not applicable
896 kPa / 9.0 bar
Tire inflation pressure All tires
(130 psi)
Front axle wheel nuts torque Front wheels
610 Nm (450 lbf-ft.) Rear wheels (inner and outer
Rear axle wheel nuts torque
lug nuts)
Fan belt tension 267 N (60 lbf) Engine front end
Drive shaft joint (yoke) bolts
57 Nm (42 lbf-ft.) Drive shaft joints
torque
Gear box bolts torque 44 Nm (32.5 lbf-ft.) Gear box mounts
Between center tooth on rotator
Boom rotator drive gear teeth 0.2540.305 mm
drive gear pinion, and boom
tolerance (0.0100.012 in.)
bearing gear
2-4
Page 8
October 2013
ADJUSTMENT SETTINGS CHART (CONT.)
Boom rotator drive gear Bolts holding rotator drive gear

10.2 Nm (90 lbf-ft.)
assembly bolts torque assembly
Enclosed basket rotator drive Support end of jib boom under
6.2 Nm (55 lbf-ft.)
assembly bolts torque enclosed basket
Refer to Bolt Torque
Refer to Bolt Identification Chart
Mounting bolts Specifications Chart
within this section
within this section
6. HYDRAULIC PRESSURE SETTINGS
NOTE: 1 bar = 100 kPa = 0.1 MPa = 14.5 psi.
The following pressure adjustment settings are recommended for the properly functioning of the vehicle.
PRESSURE SETTINGS CHART
ADJUSTMENT OPERATION PRESSURE LEVEL ADJUSTMENT LOCATION
1724 69 kPa
17 0.7 bar Hydraulic services pump
Load sense pressure (250 10 psi)
- Services circuit 2413 69 kPa
Hydraulic services pump
24 0.7 bar
XR boom option only
(350 10 psi)
2413 kPa / 24 bar (350 psi)
Charge pressure set AirFirst only
@ 2200 rpm
22 752 kPa / 228 bar
Main relief set
(3300 psi)
20 684 kPa / 207 bar
Compensator set
(3000 psi)
Pressure compensator
19 995 kPa / 200 bar Adjustment screw in pressure
- Services circuit: Initial
(2900 psi) compensator (hydraulic pump)
maximum pressure
Main relief valves pressure 19 305 kPa / 193 bar Adjustment screw in main relief
- Services circuit (2800 psi) valve
Monitor system pressure at
17 237 172 kPa gauge port TP1 using quality
Pressure compensator
172 1.7 bar 0350 bar (05000 psi) gauge.
- Services circuit
(2500 25 psi) Adjustment screw in pressure
compensator (hydraulic pump)
2-4
Page 9
October 2013
PRESSURE SETTINGS CHART (CONT.)
NOTE: PRESSURE SETTINGS SHOWN BELOW AS INDICATED PRESSURE HAVE ADDED

THE STAND-BY PRESSURE OF 17 BAR (250 PSI). INDICATED PRESSURE IS WHAT
WOULD BE OBTAINED FROM A READING ON THE CORRESPONDING PRESSURE
GAUGE. REFER TO MAINTENANCE PROCEDURES IN CHAPTER 2, SECTION 5, FOR
DETAILS ON ADJUSTMENTS AND PRESSURE READINGS.
12 066 345 kPa
120 3.4 bar
(1750 50 psi)
Anti-ice pump drive motor
INDICATED PRESSURE:
pressure
13 790 345 kPa
138 3.4 bar
(2000 50 psi)
12 066 345 kPa
120 3.4 bar
(1750 50 psi)
Circulation delivery pump
INDICATED PRESSURE:
pressure
13 790 345 kPa
138 3.4 bar
(2000 50 psi)
8274 172 kPa
83 1.7 bar
(1200 25 psi)
Power steering pressure
INDICATED PRESSURE:
- Two-man operation
9997 172 kPa
100 1.7 bar
(1450 25 psi)
11 376 172 kPa
114 1.7 bar
(1650 25 psi)
Power steering pressure
INDICATED PRESSURE:
- One-man operation
13 100 172 kPa
131 1.7 bar
(1900 25 psi)
6895 345 kPa
69 3.4 bar
(1000 50 psi)
Boom lowering relief valve INDICATED PRESSURE:
8618 345 kPa
86 3.4 bar
(1250 50 psi)
2-4
Page 10
October 2013
6895 345 kPa

69 3.4 bar
(1000 50 psi)
Jib boom lowering relief valve INDICATED PRESSURE:
8618 345 kPa
86 3.4 bar
(1250 50 psi)
16 547 345 kPa
165 3.4 bar
Boom rotation relief valves (2400 50 psi)
- Counterclockwise and INDICATED PRESSURE:
clockwise 18 271 345 kPa
183 3.4 bar
(2650 50 psi)
15 168 172 kPa
152 1.7 bar
(2200 25 psi)
Basket leveling relief valves
INDICATED PRESSURE:
- Tilt basket up
16 892 172 kPa
169 1.7 bar
(2450 25 psi)
8963 172 kPa
90 1.7 bar
(1300 25 psi)
Basket leveling relief valves
INDICATED PRESSURE:
- Tilt basket down
10 687 172 kPa
107 1.7 bar
(1550 25 psi)
Enclosed basket rotation dual
689 345 kPa
- Counterbalance valve LEFT
69 3.4 bar
(counterclockwise) rotation
(1000 50 psi)
- Relief valve
Enclosed basket rotation dual
689 345 kPa
- Counterbalance valve RIGHT
69 3.4 bar
(clockwise) rotation
(1000 50 psi)
- Relief valve
Fluid heater fuel pressure 2172 kPa / 22 bar
- Static (315 psi)
Fluid heater fuel pressure 2068 kPa / 21 bar
- All four stages firing (300 psi)
Brake system air pressure 621 kPa / 6.2 bar
(minimum) (90 psi)
2-4
Page 11
October 2013
15 858 345 kPa

159 3.4 bar
(2300 50 psi)
Stability test and load test
INDICATED PRESSURE:
system pressure
17 582 345 kPa
176 3.4 bar
(2550 50 psi)
17 23720 684 kPa
Normal operating pressure 172207 bar
(25003000 psi)
22 063 kPa / 221 bar
Main system maximum pressure
(3200 psi)
22 063 kPa / 221 bar
Safety pressure relief
(3200 psi)
13 790 kPa / 138 bar Steering pressure reducing
Steering pressure
(2000 psi) valve
13 790 kPa / 138 bar
Steer cylinder pressure Steer control valve
(2000 psi)
Emergency pump normal 17 237 kPa / 172 bar
operation pressure (2500 psi)
15 996 kPa / 160 bar
Emergency pump relief Pressure relief valve
(2320 psi)
Dynamic braking pressure Not applicable Not applicable
Converter outlet pressure to 689 kPa / 6.9 bar
Gauge pressure reading
heat exchanger (maximum) (100 psig)
Lube circuit inlet pressure from 689 kPa / 6.9 bar
Gauge pressure reading
heat exchanger (maximum) (100 psig)
2413 kPa / 24 bar
Inlet pressure from filter Gauge pressure reading
(350 psig)
758896 kPa
Discharge fluid accumulator Ground control compartment
7.69.0 bar
pressure (Euro Pre-mix systems)
(110130 psi)
689827 kPa Ground control compartment
Discharge fluid accumulator
6.98.3 bar (Euro Deice, blendUP, and
pressure
(100120 psi) Prop-mix systems)
689827 kPa Fluid pumps compartment
Deice fluid pump accumulator
6.98.3 bar (Euro Deice, Pre-mix, and
pressure
(100120 psi) Prop-mix systems)
2-4
Page 12
October 2013
NOTE: REFER TO HYDRAULIC SCHEMATICS IN CHAPTER 2, SECTION 7 FOR LOCATION
POINTS, AND SYSTEM OVERVIEW IN CHAPTER 2, SECTION S FOR PDM SCREENS
AND NAVIGATION.
7. OPERATIONAL SETTINGS
The following adjustment settings are recommended for the properly functioning of the vehicle.
OPERATIONAL SETTINGS CHART
Maximum vehicle forward speed 40 km/h (25 mph)) DP controller

Maximum vehicle reverse speed 10 km/h (6 mph) DP controller
NOTE: THESE OPERATIONAL SETTINGS ALSO APPLY TO THE OPERATIONAL TESTING

PROCEDURE LOCATED IN CHAPTER 2, SECTION 5.
NOTE: REFER TO SCHEMATICS IN CHAPTER 2, SECTION 7 FOR ALL REFERENCES.
8. STABILITY AND LOAD TEST SPECIFICATIONS
NOTE: REFER TO MAINTENANCE PROCEDURES IN CHAPTER 2, SECTION 5 FOR STABILITY

AND LOAD TEST PROCEDURES.
STABILITY AND LOAD TEST SPECIFICATIONS
Height from ground level to

Stability and load test
610 mm (24 in.) bottom of suspended weight
- Maximum height
under operators basket
Load test drift

3.175 mm (0.125 in.)
- Maximum tolerance Measured from bottom of the
Load test drift basket, or test weight
15 minutes
- Time between measurements
Tests Open Basket Enclosed Basket
Suspended static test weights

- Maximum normal load 204 kg (450 lb.) 136 kg (300 lb.)
- Overload (Max. plus 20%) 245 kg (540 lb.) 163 kg (360 lb.)
- Stability (Max. plus 50%) 306 kg (675 lb.) 204 kg (450 lb.)
2-4
Page 13
October 2013
9. BOLT IDENTIFICATION CHART
STANDARD AND METRIC STEEL BOLTS AND NUTS
SAE HEX BOLTS SAE HEX NUTS
GRADE 1 OR 2 GRADE 5 GRADE 8 GRADE 1 OR 2 GRADE 5 GRADE 8
METRIC HEX BOLTS METRIC HEX NUTS
5.8 8.8 9.8 10.9 9 10
CLASS 5.8 CLASS 8.8 CLASS 9.8 CLASS 10.9 CLASS 9 CLASS 10
10. BOLT TORQUE SPECIFICATIONS
NOTE: THESE TORQUE VALUES ARE FOR REFERENCE ONLY. USE ONLY IF NOT
OTHERWISE GIVEN FOR A SPECIFIC MAINTENANCE PROCEDURE. IF NO TORQUE
IS PROVIDED FOR A SPECIFIC BOLT OR SCREW, REFER TO SAE, ISO, OR OTHER
STANDARD FOR THE CORRESPONDING TORQUE SPECIFICATION.
STANDARD STEEL BOLTS TORQUE SPECIFICATIONS
Standard Dry Torque in Newtonmeters and Foot-Pounds
Coarse SAE Grade 5 SAE Grade 8

Bolt Size
Threads 827 MPa (120 000 psi) 1034 MPa (150 000 psi)
(inches)
per inch Med. Carbon Heat T. Steel Med. Carbon Alloy Steel
Nm lbf-ft. Nm lbf-ft.
1/4 (0.250) 20 13.6 10 19.0 14
5/16 (0.313) 18 25.8 19 39.3 29
3/8 (0.375) 16 44.7 33 63.7 47
7/16 (0.438) 14 73.2 54 105.8 78
1/2 (0.500) 13 105.8 78 161.3 119
9/16 (0.563) 12 154.6 114 229.1 169
5/8 (0.625) 11 208.8 154 311.8 230
2-4
Page 14
October 2013
STANDARD STEEL BOLTS TORQUE SPECIFICATIONS (CONT.)
Standard Dry Torque in Newtonmeters and Foot-Pounds
Coarse SAE Grade 5 SAE Grade 8

Bolt Size
Threads 827 MPa (120 000 psi) 1034 MPa (150 000 psi)
(inches)
per inch Med. Carbon Heat T. Steel Med. Carbon Alloy Steel
3/4 (0.750) 10 348.4 257 515.2 380
7/8 (0.875) 9 517.9 382 813.5 600
1 (1.000) 8 795.9 587 1220.2 900
1-1/8 (1.125) 7 1076.5 794 1938.8 1430
1-1/4 (1.250) 7 1498.2 1105 2677.7 1975
1-3/8 (1.375) 6 2033.7 1500 3592.9 2650
1-1/2 (1.500) 6 2406.6 1775 4338.6 3200
1-5/8 (1.625) 5.5 3287.9 2425 5965.6 4400
1-3/4 (1.750) 5 4270.8 3150 7660.4 5650
1-7/8 (1.875) 5 5694.4 4200 10 304.2 7600
2 (2.000) 4.5 6169.0 4550 11 117.7 8200
METRIC STEEL BOLTS TORQUE SPECIFICATIONS
Standard Dry Torque in Newtonmeters and Foot-pounds
Class 8.8 (Old 8G) Class 10.9 (Old 10K)

Bolt Size Coarse
785 MPa (113 800 psi) 980 MPa (142 200 psi)
(mm) Thread Pitch
Med. Carbon Steel Med. Carbon Steel
6 1.00 8.1 6 10.8 8
8 1.00 21.7 16 29.8 22
10 1.25 54.2 40 61.0 45
12 1.25 73.2 54 94.9 70
14 1.25 120.7 89 158.6 117
16 2.00 179.0 132 237.3 175
18 2.00 246.8 182 320.0 236
2-4
Page 15
October 2013
METRIC STEEL BOLTS TORQUE SPECIFICATIONS (CONT.)
Standard Dry Torque in Newtonmeters and Foot-pounds
Class 8.8 (Old 8G) Class 10.9 (Old 10K)

Bolt Size Coarse
785 MPa (113 800 psi) 980 MPa (142 200 psi)
(mm) Thread Pitch
Med. Carbon Steel Med. Carbon Steel
22 2.50 385.1 284 534.2 394
24 3.00 568.1 419 772.8 570
18-8 AND 316 STAINLESS STEEL BOLTS TORQUE SPECIFICATIONS
Standard Dry Torque in Newtonmeters and Inch-pounds

Bolt Size Threads
18-8 Stainless Steel 316 Stainless Steel
# per Inch
Nm lbf-in. Nm lbf-in.
40 0.59 5.2 0.62 5.5

#4
48 0.75 6.6 0.78 6.9
40 0.87 7.7 0.92 8.1

#5
44 1.06 9.4 1.11 9.8
32 1.08 9.6 1.14 10.1

#6
40 1.37 12.1 1.43 12.7
32 2.24 19.8 2.34 20.7

#8
36 2.49 22.0 2.60 23.0
24 2.58 22.8 2.69 23.8

#10
32 3.58 31.7 3.74 33.1
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Page 16
October 2013
TERMINAL BLOCKS TORQUE SPECIFICATIONS
Standard Dry Torque in Newtonmeters, Inch-pounds, and Foot-pounds
Wire Size (AWG) Type Nm lbf-in. lbf-ft.
2214 DIK 1.5 0.50.6 4.45.3 0.370.44
2214 DIKD 1.5 0.50.6 4.45.3 0.370.44
2212 USK4 0.60.8 5.37.1 0.440.59
2212 MBK 2.5/E 0.60.8 5.37.1 0.440.59
188 USK10 1.51.8 13.315.9 1.101.33
188 USLKG10 1.51.8 13.315.9 1.101.33
182 UIK35 3.23.7 28.332.7 2.362.73
182 UISLKG35 3.23.7 28.332.7 2.362.73
181/0 USLKG35 3.23.7 28.332.7 2.362.73
64 UKH25 4.04.5 35.439.8 2.953.32
61/0 UKH50 6.08.0 53.170.8 4.435.90
31/0 USLK650 6.08.0 53.170.8 4.435.90
2-4
Page 17
October 2013
NOTE: FOR SETTINGS AND ADJUSTMENT VALUES FOR ALL MAINTENANCE PROCEDURES
IN THIS SECTION, REFER TO MAINTENANCE SPECIFICATIONS IN CHAPTER 2,
SECTION 4, SPECIFICATIONS IN CHAPTER 1, SECTION 4, AND MANUFACTURERS
APPENDICES IN CHAPTER 5.
1. GENERAL
WARNING
The following procedures outline the necessary steps for adjustment of components for their proper
operation. These procedures may be necessary to be performed during regular maintenance, or after
replacement or repair of components. Refer to Chapter 3, Overhaul for component removal and
installation.
Refer to the List of Warnings and Cautions used in this Manual at the beginning of this volume, and to
Chapter 2, Section 1, Safety Precautions. All warnings and cautions must be read, understood, and
observed to ensure safety of operation and maintenance personnel.
NOTE: DRIVE SIDE AND PASSENGER SIDE REFERENCES ARE BASED ON U.S.
AUTOMOTIVE STANDARDS, WHERE THE DRIVER IS LOCATED ON THE LEFT HAND
SIDE OF THE VEHICLE, AND THE RIGHT HAND AND LEFT HAND SIDE ARE RELATIVE
TO A DRIVER SITTING DIRECTLY BEHIND A STEERING WHEEL FACING FORWARD.
WARNING
A. INDIVIDUAL MANUFACTURER'S INSTRUCTION SERVICING SCHEDULE
(1) Servicing of power unit engine should be done in compliance with manufacturer's
recommended schedule.
(2) Heater Servicing - Refer to information contained within this section. Further servicing and
investigation of specific problems not covered in this section should be performed by a
qualified service technician.
(3) Deicing and Anti-icing pump servicing - The pumps should be serviced as recommended.
2-5
MAINTENANCE PROCEDURES
Page 1
October 2013
(4) Servicing of the drive and steering axles should be done in compliance with the
manufacturer's recommended schedule.
B. FLUID SYSTEM DRAIN PROCEDURE
(1) Open all suction and return valves on tank.
(2) Open drain valves with handles located in the bottom of the tank.
(3) Let system drain until flow stops.
(4) Close all suction and return valves.
2. ENGINE ADJUSTMENTS
A. ENGINE IDLE SPEED ADJUSTMENT
(1) Locate low speed adjusting screw at the base of the engine throttle. Refer to the engine
manual in Chapter 5, Manufacturers Appendices.
(2) Engine idle speed should be adjusted with no load. Refer to Adjustment Settings Chart in
Chapter 2, Section 4, Maintenance Specifications for recommended idle speed for the
engine included in the current configuration.
(3) Read engine speed (rpm), and adjust as necessary. Refer to the engine manufacturer
manual for additional details.
B. ENGINE HIGH SPEED ADJUSTMENT
CAUTION
DO NOT CHANGE THE MAXIMUM SPEED SET BY THE ENGINE MANUFACTURER. IF

ADJUSTMENT OF OPERATIONAL HIGH SPEED IS MANDATORY, IT MUST BE SET BELOW
THE MAXIMUM ENGINE SPEED SET BY THE MANUFACTURER. FAILURE TO COMPLY MAY
RESULT IN DAMAGE TO VEHICLE COMPONENTS AND VOID WARRANTY!
(1) Locate high speed adjusting screw. Refer to the engine manual in Chapter 5,
Manufacturers Appendices.
(2) Engine high speed should be adjusted with no load. Refer to Adjustment Settings Chart
in Chapter 2, Section 4, Maintenance Specifications for recommended idle speed for the
engine included in the current configuration.
(3) Read engine speed (rpm), and adjust as necessary. Refer to the engine manufacturer
manual for additional details.
2-5
Page 2
October 2013
3. HYDRAULIC SYSTEM ADJUSTMENTS
WARNING
WARNING
CAUTION
WHEN INSTALLING OR REMOVING GAUGES AND FITTINGS, OR REPLACING COMPONENTS

USE EXTREME CAUTION TO PREVENT CONTAMINATION OF THE HYDRAULIC SYSTEM.
NOTE: REFER TO MAINTENANCE SPECIFICATIONS IN CHAPTER 2, SECTION 4 FOR

INDICATED PRESSURES AND SETTING VALUES FOR THE SUBSEQUENT
ADJUSTMENT PROCEDURES.
NOTE: THE HYDRAULIC OIL MUST BE AT NORMAL OPERATING TEMPERATURE WHEN

MAKING PERFORMANCE CHECKS, HYDRAULIC SYSTEM PRESSURE CHECKS, OR
HYDRAULIC SYSTEM ADJUSTMENTS.
NOTE: REFER TO MAINTENANCE SPECIFICATIONS IN CHAPTER 2, SECTION 4 FOR

HYDRAULIC OIL INFORMATION.
NOTE: IN MOST CASES SPECIFIED PRESSURE + STAND-BY PRESSURE = INDICATED

PRESSURE.
NOTE: AN ASSISTANT MAY BE REQUIRED WHEN MAKING ADJUSTMENTS. SOME SPEED

ADJUSTMENTS WILL REQUIRE A PHOTO TACHOMETER TO CHECK RPM.
NOTE: OVER-TIGHTENING THE JAM NUT WILL BREAK THE ADJUSTING SCREW.
The hydraulic system is a closed loop system that automatically regulates pump displacement. When
there is no system demand, the pump stands by at near zero flow and low pressure.
2-5
Page 3
October 2013
A. LOAD SENSING PRESSURE ADJUSTMENT
NOTE: THE LOAD SENSE AND COMPENSATOR CONTROL VALVE IS ATTACHED TO THE
SIDE OF THE PUMP. REFER TO FIGURE 1.
(1) Remove the access panel at the left rear of the deicer body.
(2) With the engine turned off, remove the 05000 psi pressure gauge on the left side of the
hydraulic manifold and replace it with a 040 bar (0600 psi) pressure gauge. (Hydraulic
manifold is located on top of the left rear wheel fender.)
(3) Remove wire #86 from the spade terminal on 6SOL solenoid valve (refer to Figure 2).
(4) Remove the load sense hydraulic hose from the fitting in port X on the control valve
attached to the side of the pump and install a plug in the hose (refer to Figure 1).
(5) Start the engine.
(6) Remove the acorn nut from the load sense adjusting screw and loosen the locknut. (The
load sense adjusting screw is the outboard adjustment on the control valve.)
(7) Turn the load sense adjusting screw clockwise to increase, or counterclockwise to
decrease, the load sense pressure until the gauge indicates the pressure as per
specification. Refer to Pressure Settings Chart in Chapter 2, Section 4.
(8) Tighten the locknut and install the acorn nut.
(9) Shut the engine off and reinstall the 05000 psi pressure gauge that was removed in
step 2.
(10) Reinstall wire #86 on 6SOL that was removed in step 3.
(11) Reconnect the load sense hose that was disconnected in step 4.
2-5
Page 4
October 2013
TRACTION PUMP
SERVICES PUMP
EMERGENCY
PUMP
ADJUSTMENT C.
ADJUSTMENT A.
LOAD SENSE
PORT X
Figure 1
HYDRAULIC PUMPS
2-5
Page 5
October 2013
B. COMPENSATOR AND MAIN RELIEF VALVE PRESSURE ADJUSTMENTS
NOTE: THE PRESSURE COMPENSATOR ADJUSTMENT SCREW IS THE LARGER OF THE

TWO ADJUSTMENT SCREWS ON THE SIDE OF THE HYDRAULIC PUMP. REFER TO
FIGURE 1.
The main pressure relief valve is located on the front, at the right side, of the hydraulic
manifold. Refer to Figure 2.
(1) Disconnect the hydraulic hose and install a plug in the hose and a cap on the elbow fitting
installed in port B on the hydraulic manifold. Port B is located on the left side, at the top,
on the hydraulic manifold (refer to Figure 3).
(2) Remove wire #86 from the spade terminal on 6SOL solenoid valve.
(3) Loosen the locknut and turn the compensator adjusting screw on the pump control valve
counterclockwise to the minimum setting position.
(4) Loosen the locknut and turn the main relief valve adjusting screw fully clockwise to the
maximum setting position (refer to Figure 2).
(5) Have assistant start the engine.
(6) Manually actuate 18SOL solenoid valve by turning the manual override on the valve.
(18SOL is located on the front, at top left, of the hydraulic manifold.) Refer to Figure 2.
(7) Turn the compensator adjusting screw clockwise until obtaining the reading for the
maximum initial pressure, observed on the hydraulic manifold pressure gauge. Refer to
Figure 1, and to Pressure Settings Chart in Chapter 2, Section 4.
(8) Turn the main relief valve adjusting screw counterclockwise until reading the pressure as
per specification, observed on the manifold pressure gauge, and tighten the locknut on the
adjusting screw.
(9) Very quickly, turn the pump compensator adjusting screw counterclockwise to reduce the
pressure to the specified value, and tighten the adjusting screw locknut.
Speed is essential for this step because the engine horsepower is being converted to heat
in the hydraulic fluid while the main relief valve is venting fluid to the reservoir.
(10) Shut the engine down.
(11) Remove the cap and plug in the hydraulic hose and fitting and reconnect the hose that was
removed in step 1.
(12) Install wire #86 on 6SOL that was removed in step 2.
(13) Reset the manual override to the normal operating position on 18SOL.
2-5
Page 6
October 2013
ADJUSTMENT C.
6SOL
ADJUSTMENT D.
17SOL
RPGC
18SOL
30SOL P1
FRONT VIEW
MAIN RELIEF VALVE
16SOL 4SOL
5SOL
30SOL
17SOL
6SOL
18SOL
4SOL-A
TOP VIEW
Figure 2
HYDRAULIC MANIFOLD - FRONT AND TOP VIEWS
2-5
Page 7
October 2013
PORT B
18SOL
B
17SOL
G
30SOL
P2
GAUGE PORT
END VIEW
Figure 3
HYDRAULIC MANIFOLD - END VIEW
C. HEATER BLOWER MOTOR, LOW SPEED ADJUSTMENT
(1) Install a strip of reflective marker on the blower fan (refer to Figure 4).
(3) Manually actuate 17SOL solenoid valve by turning the manual override on the valve.
(Valve 17SOL is located on the left end of the hydraulic manifold, refer to Figure 2).
(4) Check the fan speed using a photo tachometer.
(5) Adjust fan speed to specification (refer to Adjustment Settings Chart in Chapter 2,
Section 4).
(6) Loosen locknut and turn low speed flow control adjusting screw counterclockwise to
increase fan speed and clockwise to decrease fan speed (refer to Figure 2). Tighten
locknut after making an adjustment.
(7) Reset the manual override to the normal position on 17SOL.
(8) Shut down the engine.
2-5
Page 8
October 2013
REFLECTIVE TAPE
Figure 4
HEATER BLOWER MOTOR SPEED ADJUSTMENT
D. HEATER BLOWER, HIGH SPEED ADJUSTMENT
(1) Install a strip of reflective marker on the blower fan, if not done yet (Refer to Figure 4).
(3) Manually actuate 17SOL and 18SOL solenoid valves by turning the manual override on the
valves. Valve 17SOL is located on the left end and 18SOL is on the front, at the upper left,
of the hydraulic manifold (refer to Figure 3).
(4) Check the fan speed using a photo tachometer.
(5) Adjust fan speed as specified in Adjustment Settings Chart in Chapter 2, Section 4.
NOTE: BLOWER FAN LOW SPEED MUST BE SET TO SPECIFICATION BEFORE MAKING ANY
ADJUSTMENTS FOR BLOWER FAN HIGH SPEED.
(6) Loosen locknut and turn high speed flow control adjusting screw counterclockwise to
increase fan speed and clockwise to decrease fan speed. Tighten locknut after making an
adjustment.
(7) Reset the manual overrides to the normal operating position on 17SOL and 18SOL
solenoid valves.
2-5
Page 9
October 2013
E. HEATER FUEL PUMP MOTOR SPEED ADJUSTMENT
(1) Install a strip of reflective marker on the motor shaft (refer to Figure 6).
(3) Have assistant start the heater.
(4) Check the shaft speed on the fuel pump motor using the photo tachometer. Shaft speed
should be as specified in Adjustment Settings Chart in Chapter 2, Section 4.
(5) Loosen locknut and turn low speed flow control adjusting screw clockwise to increase
speed and counterclockwise to decrease speed (refer to Figure 5 and Figure 6).
(6) Tighten locknut after making an adjustment.
(7) Shut down the heater.
(8) After the post purge cycle is complete, shut down the engine.
ADJUSTMENT E.
16SOL
Figure 5
HEATER BLOWER SPEED ADJUSTMENT
2-5
Page 10
October 2013
FUEL PRESSURE
ADJUSTMENT
HYDRAULIC
MOTOR
APPLY REFLECTIVE TAPE
TO SHAFT FOR SPEED
ADJUSTMENT
PRESSURE ADJUSTMENT PRESSURE

OUTLET
(TO HEATER)
INLET FROM TANK

RETURN TO TANK
Figure 6
HEATER FUEL PUMP ADJUSTMENTS
2-5
Page 11
October 2013
F. ANTI-ICE PUMP DRIVE MOTOR PRESSURE ADJUSTMENT
(2) Have assistant open the anti-ice nozzle.
(3) Observe the pressure gauge on the hydraulic manifold for the indicated pressure as per
specification. The indicated pressure is the sum of the pump pressure and the load sense
pressure. Refer to Pressure Settings Chart in Chapter 2, Section 4.
(4) Adjust pressure by loosening the locknut and turn the adjusting screw on the pressure
reducing valve clockwise to increase pressure and counterclockwise to decrease pressure
(refer to Figure 2 and Figure 7).
(5) Tighten the locknut on the adjusting screw.
(6) Have assistant close the anti-icing nozzle and shut down the engine.
5SOL 6SOL
ADJUSTMENT F.
ADJUSTMENT G. ADJUSTMENT H.
Figure 7
ANTI-ICE PUMP DRIVE MOTOR ADJUSTMENTS
2-5
Page 12
October 2013
G. ANTI-ICE PUMP, DRIVE MOTOR SPEED ADJUSTMENT
(1) Install a strip of reflective marker on the end of the delivery pump shaft (refer to Figure 8).
(3) Have assistant open the anti-ice nozzle fully.
(4) Check the shaft speed of the pump shaft using a photo tachometer. Shaft speed should be
as specified in Adjustment Settings Chart in Chapter 2, Section 4.
(5) Loosen locknut and turn low speed flow control adjusting screw clockwise to increase
speed and counterclockwise to decrease speed (refer to Figure 7).
(7) Close nozzle fully on anti-ice nozzle.
REFLECTIVE TAPE
Figure 8
ANTI-ICE FLUID PUMP
2-5
Page 13
October 2013
H. ANTI-ICE PUMP (REFILL) DRIVE MOTOR SPEED ADJUSTMENT
(1) Install a strip of reflective marker on the end of the pump shaft (refer to Figure 8).
(2) Disconnect connecting link from the outboard anti-icing refill valve as shown in Figure 9.
(4) Open the outboard anti-icing refill valve by pulling the handle (refer to Figure 9).
(5) Actuate and hold the anti-icing refill switch in the ON position (refer to Figure 9).
DEICE FLUID ANTI-ICE FLUID DISCONNECT LINK FROM HANDLE
NG
I-ICI
ANT R
ILLE
REF
ING
DEIC R
ILLE I
REF
0
I
REFLECTIVE TAPE FOR CIRCULATING AND ANTI-ICING PUMP

SPEED ADJUSTMENT DEICING PUMP
Figure 9
DEICING AND ANTI-ICING FLUID PUMPS
2-5
Page 14
October 2013
(6) Check the shaft speed of the pump shaft using a photo tachometer. Shaft speed should be
as specified in Adjustment Settings Chart in Chapter 2, Section 4.
(7) Loosen locknut and turn the speed flow control adjusting screw counterclockwise to
increase speed and clockwise to decrease speed (refer to Figure 2 and Figure 7).
(9) Release the anti-icing refill switch.
(10) Close the anti-icing refill valve by pushing the handle in.
(11) Reconnect the linkage to the outboard handle that was removed in step 2.
2-5
Page 15
October 2013
I. CIRCULATION AND DELIVERY PUMP PRESSURE ADJUSTMENT
(1) Install a strip of reflective marker on the delivery pump shaft (refer to Figure 9).
(3) Start the fluid delivery pump by actuating the FLUID DELIVERY pump switch momentarily
to the ON position. The GREEN indicator will be illuminated when the pump is operating.
NOTE: ENGINE SPEED WILL NOT INCREASE TO HIGH IDLE.
(4) Observe the pressure gauge on the hydraulic manifold for the indicated pressure as per
specification (refer to Pressure Settings Chart in Chapter 2, Section 4).
(6) Shut the pump off.
4SOL 4SOL-A
ADJUSTMENT I.
Figure 10
CIRCULATION AND DELIVERY PUMP PRESSURE ADJUSTMENT
2-5
Page 16
October 2013
J. CIRCULATION AND DELIVERY PUMP (35 GPM) DRIVE MOTOR SPEED
(1) Install a strip of reflective marker on the delivery pump shaft or coupling.
(3) Place the DEICE MODE switch in the TRAVEL position.
to the ON position. The GREEN indicator light directly above the switch will be illuminated
and the engine speed will not increase to high idle.
(5) Check the circulating pump speed using a photo tachometer. Shaft speed should be as
indicated in Adjustment Settings Chart in Chapter 2, Section 4.
(6) Loosen locknut and turn low speed flow control adjusting screws (2) counterclockwise to
increase pump speed and clockwise to decrease pump speed (refer to Figure 11). Tighten
locknuts after making an adjustment.
(7) Turn the fluid delivery pump off by actuating and holding the FLUID DELIVERY pump
switch in the OFF position until the GREEN indicator light is not illuminated. The engine
will return to low idle speed.
4SOL 4SOL-A
ADJUSTMENT K.
ADJUSTMENT J. ADJUSTMENT J.
Figure 11
CIRCULATION AND DELIVERY PUMP MOTOR SPEED ADJUSTMENTS
2-5
Page 17
October 2013
K. CIRCULATION AND DELIVERY PUMP (60 GPM) DRIVE MOTOR SPEED
(1) Install a strip of reflective marker on the delivery pump shaft or coupling.
(3) Place the DEICE MODE switch in the DEICE position. The engine speed will increase to
high idle.
to the ON position. The GREEN indicator light directly above the switch will illuminate.
(5) Check the circulating pump speed using a photo tachometer. Shaft speed should be as
specified in Adjustment Settings Chart in Chapter 2, Section 4.
(6) Loosen locknut and turn speed flow control adjusting screw counterclockwise to increase
pump speed and clockwise to decrease pump speed (refer to Figure 11).
(8) Turn the fluid delivery pump off by actuating and holding the FLUID DELIVERY pump
switch in the OFF position until the GREEN indicator light is not illuminated. The engine
will return to low idle speed.
L. POWER STEERING PRESSURE ADJUSTMENT
(2) Have assistant turn steering wheel fully in one direction (left or right) and hold the wheel
firmly to until adjustment has been completed.
(3) Observe the pressure gauge on the hydraulic manifold for the indicated pressure as
specified for two-man operation mode, and one-man operation mode. Refer to Pressure
Settings Chart in Chapter 2, Section 4.
(6) Release the steering wheel and shut the engine down.
2-5
Page 18
October 2013
ADJUSTMENT L.
LOCKNUT
Figure 12
POWER STEERING PRESSURE REDUCING VALVE
M. BOOM VALVE, MAXIMUM FLOW ADJUSTMENTS
NOTE: DO NOT PERFORM THESE ADJUSTMENTS IF NOT ABSOLUTELY NECESSARY.

MAKING THESE ADJUSTMENTS MAY REQUIRE EXTENSIVE RE-ADJUSTMENT OF
OTHER VALVES AND DEVICES.
NOTE: THE BOOM VALVE ASSEMBLY (PROPORTIONAL VALVES) IS LOCATED ON TOP OF

THE LEFT REAR FENDER. REFER TO FIGURE 13. IF NEEDED, ADJUSTMENTS
SHOULD BE MADE WITH THE ENGINE NOT RUNNING.
(1) Loosen the locknuts from the two adjusting screws on the face of each of the four
proportional valve bodies.
(2) Turn each screw clockwise to its full inwards position, then turn each screw
counterclockwise (outwards) for the appropriate function. Tighten locknuts.
PROPORTIONAL VALVES ADJUSTMENT
Function Flow Control Number of Turns Out
Boom up FB 4
Boom down FA 3
Boom rotate clockwise FB 5
Boom rotate counterclockwise FA 5
Jib boom up FB 1
Jib boom down FA 1
Basket leveling up FB 1/2
Basket leveling down FA 1/2
2-5
Page 19
October 2013
BOOM CLOCKWISE
RELIEF VALVE
ADJUSTMENT R.
BOOM RAISE
JIB BOOM RAISE RELIEF VALVE
RELIEF VALVE
ADJUSTMENT O.
ADJUSTMENT Q.
MAXIMUM FLOW
(8 PLACES)
JIB BOOM LOWER ADJUSTMENT M.
RELIEF VALVE
ADJUSTMENT P. BOOM
COUNTERCLOCKWISE
FA FA FA FA RELIEF VALVE
FB FB FB FB
ADJUSTMENT R.
BOOM LOWERED
RELIEF VALVE
ADJUSTMENT N.
BASKET LEVEL
VALVE
BOOM LIFT VALVE
JIB BOOM
VALVE
BOOM ROTATION
VALVE
BOOM GROUND CONTROL STATION
Figure 13
BOOM GROUND CONTROL STATION - VALVE ASSEMBLY
2-5
Page 20
October 2013
N. BOOM LOWERING RELIEF VALVE
NOTE: THE BOOM VALVE ASSEMBLY (PROPORTIONAL VALVE) IS LOCATED ON TOP OF

THE LEFT REAR FENDER. REFER TO FIGURE 13. THE BOOM LOWERING RELIEF
VALVE IS PART OF THE BOOM VALVE ASSEMBLY AND IS ADJACENT TO THE BOOM
DIRECTIONAL VALVE.
NOTE: BEFORE ADJUSTING THIS RELIEF VALVE, VERIFY THAT THE LOAD SENSE
PRESSURE IS CORRECTLY SET AS PER SPECIFICATION.
(1) Lower the boom completely into the rest position.
(2) Loosen the locknut on the relief valve adjustment screw.
(3) Have assistant hold the Boom valve lever down on the proportional valve to power the
boom down into its rest while watching the pressure gauge for an indicated reading of the
specified value in Pressure Settings Chart in Chapter 2, Section 4.
(4) Turn the adjustment screw clockwise to increase pressure, or counterclockwise to

decrease pressure.
(5) Tighten the locknut.
O. BOOM RAISE RELIEF VALVE

THE LEFT REAR FENDER. REFER TO FIGURE 13. THE BOOM RAISE RELIEF VALVE
IS PART OF THE BOOM VALVE ASSEMBLY AND IS ADJACENT TO THE BOOM
DIRECTIONAL VALVE.
NOTE: BEFORE ADJUSTING THIS VERIFY THAT THE LOAD SENSE PRESSURE IS
CORRECTLY SET AS PER SPECIFICATION.
(1) Open valve 30SOL manually and using the ground station controls position boom, with jib
boom extended and level with the boom, to the side of the chassis as shown in Figure 14.
(2) Suspend a static Overload weight exactly as specified in the STABILITY AND LOAD TEST
SPECIFICATIONS table in Chapter 2, Section 4 (refer to Figure 14). This is the maximum
boom load plus 20%. Open basket test weights are heavier than enclosed basket test
weights. Attach weight with slings directly behind the enclosed basket rotation gear
assembly, or under the clevis for the open basket.
(3) Raise the boom to the level position with the weight attached not higher than the specified
height, as shown in Figure 14.
(4) Loosen locknut on the boom raise relief valve adjusting screw, and turn adjusting screw
counterclockwise two to three turns (refer to Figure 13).
2-5
Page 21
October 2013
ENCLOSED BASKET SHOWN
TEST WEIGHT LOAD TEST HEIGHT (MAX.)
NOTE: TEST WEIGHTS FOR OPEN BASKET ARE HEAVIER THAN FOR ENCLOSED BASKET.
NOTE: REFER TO STABILITY AND LOAD TEST SPECIFICATIONS TABLE IN MAINTENANCE

SPECIFICATIONS, CHAPTER 2, SECTION 4 FOR LOAD TEST HEIGHT AND TEST
WEIGHTS.
Figure 14
BOOM WITH TEST WEIGHT ATTACHED
WARNING
DO NOT LIFT THE SUSPENDED TEST WEIGHT MORE THAN THE SPECIFIED LOAD TEST
HEIGHT FROM THE GROUND SURFACE. FAILURE TO COMPLY MAY RESULT IN SERIOUS
(6) Have assistant hold the boom valve lever UP on the proportional valve to power the boom
raise.
(7) Slowly turn the adjusting screw on the relief valve clockwise until the boom just starts to
rise then turn the valve counterclockwise until the boom just stops rising. Tighten the
locknut on the adjusting screw.
(8) With the weight suspended stationary and holding the manual lever in the raise position,
adjust pressure switch BOL-PS to just actuate and illuminate the BOOM OVERLOADED
indicator lights on the drivers cab dash, and on the operators left side pod in the enclosed
basket or open basket panel.
2-5
Page 22
October 2013
(9) Lower the boom to rest the test weight on the ground and adjust it to exactly the Maximum
Load weight as specified in the STABILITY AND LOAD TEST SPECIFICATIONS table in
(10) Verify that the boom can be raised with the Maximum Load weight without illuminating the
BOOM OVERLOADED indicator lights on the drivers cab dash, and on the operators left
side pod in the enclosed basket or on the open basket panel. DO NOT raise the load
above the specified maximum test height.
(11) Lower the boom and remove the weight.
(12) Return the boom and jib boom to the rest position and put 30SOL back to the normal
position.
P. JIB BOOM LOWERING RELIEF VALVE

THE LEFT REAR FENDER. REFER TO FIGURE 13. THE JIB BOOM LOWERING
RELIEF VALVE IS PART OF THE BOOM VALVE ASSEMBLY AND IS ADJACENT TO THE
JIB BOOM DIRECTIONAL VALVE.
PRESSURE IS CORRECTLY SET AS SPECIFIED.
(1) With the Boom raised a short distance and positioned to the side of the chassis, have
assistant hold the Jib Boom valve lever DOWN on the proportional valve to power the Jib
Boom fully down to dead head the hydraulic cylinder.
(2) Loosen the lock nut on the relief valve adjusting screw and turn the adjusting screw
clockwise to increase, or counterclockwise to decrease, the indicated pressure reading on
the hydraulic manifold gauge should be as specified in Pressure Settings Chart in
Q. JIB BOOM RAISE RELIEF VALVE

THE LEFT REAR FENDER (REFER TO FIGURE 13). THE JIB BOOM RAISE RELIEF
VALVE IS PART OF THE BOOM VALVE ASSEMBLY AND IS ADJACENT TO THE JIB
BOOM DIRECTIONAL VALVE.
(1) Open valve 30SOL manually and using the ground station controls position boom, with jib
boom extended and level with the boom, to the side of the chassis as shown in Figure 14.
(2) Suspend a static Overload weight exactly as specified in the STABILITY AND LOAD TEST
SPECIFICATIONS table in Chapter 2, Section 4 (refer to Figure 14). This is the maximum
boom load plus 20%. Open basket test weights are heavier than enclosed basket test
weights.
2-5
Page 23
October 2013
Attach weight directly behind the enclosed basket rotation gear assembly, or under the
clevis for the open basket.
(3) Raise the boom to the level position with the weight attached not higher than the specified
height, as shown in Figure 14.
NOTE: A FORKLIFT WILL BE REQUIRED TO LIFT THE WEIGHT CLEAR OF THE GROUND, AS
THE MAIN BOOM SHOULD NOT BE ABLE TO LIFT THIS WEIGHT.
(4) Loosen locknut on the jib boom raise relief valve adjusting screw, and turn adjusting screw
counterclockwise two to three turns (refer to Figure 13).
(6) Have assistant hold the jib boom valve lever UP on the proportional valve to power the jib
boom raise.
(7) Slowly turn the adjusting screw on the relief valve clockwise until the jib boom just starts to
rise, then turn the valve counterclockwise until the jib boom just stops rising.
(8) Lower the boom to rest the test weight on the ground and adjust it to exactly the Maximum
Load weight as specified in the STABILITY AND LOAD TEST SPECIFICATIONS table in
(9) Verify that the jib boom can be raised with the Maximum Load weight. DO NOT raise the
load above the specified maximum test height.
(10) Lower the boom and remove the weight.
(11) Return the boom and jib boom to the rest position and put 30SOL back to the normal
position.
R. BOOM ROTATION RELIEF VALVES

THE LEFT REAR FENDER (REFER TO FIGURE 13). THE BOOM ROTATION RELIEF
VALVE IS PART OF THE BOOM VALVE ASSEMBLY AND IS ADJACENT TO THE JIB
BOOM DIRECTIONAL VALVE.
NOTE: BEFORE ADJUSTING THE BOOM ROTATION RELIEF VALVES, VERIFY THAT THE
LOAD SENSE PRESSURE IS CORRECTLY SET AS PER SPECIFICATION.
NOTE: THERE ARE TWO ADJUSTMENTS REQUIRED FOR THIS PROCEDURE, CLOCKWISE
AND COUNTERCLOCKWISE.
(1) Have assistant start the engine and raise the boom above the boom rest.
(3) With the boom straight out, have assistant lift and hold the lever UP on the proportional
valve to rotate the boom CLOCKWISE to its full travel and stops moving.
(4) With the valve lever held in the UP position, observe the pressure gauge on the hydraulic
manifold for an indicated pressure as specified in Pressure Settings Chart, Chapter 2,
Section 4.
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October 2013
(5) Adjust pressure by loosening the locknut and turn the adjusting screw on the clockwise
relief valve clockwise to increase pressure, and counterclockwise to decrease pressure
(6) Tighten locknut after the adjustment is made.
(7) Have assistant hold the lever DOWN on the proportional valve to rotate the boom
COUNTERCLOCKWISE to its full travel and stops moving.
(8) With the valve lever held in the DOWN position, observe the pressure gauge on the
hydraulic manifold for an indicated pressure as specified in Pressure Settings Chart,
(9) Adjust pressure by loosening the locknut and turn the adjusting screw on the clockwise
relief valve clockwise to increase pressure, and counterclockwise to decrease pressure on
the manifold gauge (refer to Figure 13).
(11) Have assistant rotate the boom to the front of the chassis and place the boom in the rest
and shut the engine down.
S. ENCLOSED BASKET LEVELING RELIEF VALVES, TILT BASKET UP

THE LEFT REAR FENDER. REFER TO FIGURE 13 AND FIGURE 15.
NOTE: THE ENCLOSED BASKET DUAL RELIEF VALVE PACK ASSEMBLY IS MOUNTED ON
THE INSIDE OF THE RIGHT WALL OF THE BOOM ROTATOR AND HAS TWO RELIEF
VALVES. THE RELIEF VALVES ARE USED TO LIMIT THE PRESSURE IN THE
CYLINDER EXTEND AND RETRACT CIRCUITS FOR LEVELING THE BASKET. REFER
TO FIGURE 15.
NOTE: THERE ARE TWO RELIEF VALVES ON THIS VALVE PACK FOR ADJUSTING MAXIMUM
HYDRAULIC PRESSURE WHEN TILTING THE FRONT OF BASKET UP OR TILTING
FRONT OF BASKET DOWN.
(1) Have assistant start the engine and raise the boom above the boom rest and rotate the
boom COUNTERCLOCKWISE until the enclosed basket is to the rear of the chassis.
(2) Have assistant push in the manual over ride on the proportional valve 32SOL to extend the
cylinder and tip the front of the basket to maximum up.
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October 2013
TILT UP
ADJUSTMENT S.
TILT DOWN
ADJUSTMENT T.
NOTE: BOOM HAS BEEN REMOVED FOR CLARITY.
Figure 15
OPEN BASKET LEVELING RELIEF VALVES
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October 2013
(3) Have assistant observe the pressure gauge on the hydraulic manifold for an indicated
pressure as specified in Pressure Settings Chart, Chapter 2, Section 4.
NOTE: ASSISTANT WILL HAVE TO COMMUNICATE VERBALLY INSTRUCTIONS TO RAISE,

OR LOWER, THE PRESSURE ADJUSTMENT.
(4) Adjust pressure by loosening the locknut and turn the adjusting screw on the
counterclockwise relief valve clockwise to increase pressure, and counterclockwise to
decrease pressure. Refer to Figure 15.
T. ENCLOSED BASKET LEVELING RELIEF VALVES, TILT BASKET DOWN

THE LEFT REAR FENDER. REFER TO FIGURE 13 AND FIGURE 15.
NOTE: THE ENCLOSED BASKET DUAL RELIEF VALVE PACK ASSEMBLY IS MOUNTED ON
THE INSIDE OF THE RIGHT WALL OF THE BOOM ROTATOR AND HAS TWO RELIEF
VALVES. THE RELIEF VALVES ARE USED TO LIMIT THE PRESSURE IN THE
CYLINDER EXTEND AND RETRACT CIRCUITS FOR LEVELING THE BASKET. REFER
TO FIGURE 15.
NOTE: THERE ARE TWO RELIEF VALVES ON THIS VALVE PACK FOR ADJUSTING MAXIMUM
HYDRAULIC PRESSURE WHEN TILTING THE FRONT OF BASKET UP OR TILTING
FRONT OF BASKET DOWN.
(1) Have assistant start the engine and raise the boom above the boom rest and rotate the
boom counter-clockwise (CCW) until the enclose basket is to the rear of the chassis.
(2) Have assistant push in the manual over ride on the proportional valve 31SOL to retract the
cylinder and tip the front of the basket to maximum down.
(3) Have assistant observe the pressure gauge on the hydraulic manifold for the indicated
pressure as specified in Pressure Settings Chart, Chapter 2, Section 4.
NOTE: ASSISTANT WILL HAVE TO VERBALLY COMMUNICATE INSTRUCTIONS TO RAISE,

OR LOWER THE PRESSURE ADJUSTMENT.
(4) Adjust pressure by loosening the locknut and turn the adjusting screw on the
counterclockwise relief valve clockwise to increase pressure, and counterclockwise to
decrease pressure (refer to Figure 15).
(6) Return the boom to the front of the chassis and place in the rest, then shut the engine
down.
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October 2013
U. ENCLOSED BASKET DUAL COUNTERBALANCE VALVE, LEFT ROTATION
NOTE: THE DUAL COUNTERBALANCE VALVE IS LOCATED ON THE LEFT SIDE OF THE
BASKET PLATFORM. REFER TO FIGURE 16 THROUGH FIGURE 19.
NOTE: THE PURPOSE OF THE COUNTERBALANCE VALVE IS TO PREVENT THE BASKET

FROM DRIFTING AFTER IT HAS BEEN ROTATED TO A DESIRED POSITION.
NOTE: THE VALVE PACK CONTAINS TWO COUNTERBALANCE VALVES (CLOCKWISE AND
COUNTERCLOCKWISE) FOR ADJUSTING THE HYDRAULIC PRESSURE THAT WILL
OPEN THE VALVE TO ALLOW FLUID TO RETURN TO THE RESERVOIR.
(1) With the engine off, remove the hydraulic hoses from the fittings in ports V1 and C2 on the
counterbalance valve (refer to Figure 17).
(2) Install a T fitting on the end of the hydraulic hose that was removed from port V1.
(3) Install a short hydraulic hose from the T fitting to the existing fitting in port C2 on the
counterbalance valve.
(4) Install a 0140 bar (02000 psi) pressure gauge in the remaining port in the T fitting.
(5) Have assistant start the engine, then actuate and hold the basket rotate switch to left
(counterclockwise) rotate.
(6) Loosen the locknut on the adjusting screw on the right side counterbalance valve and turn
the valve out (counterclockwise) until the pressure reading on the gauge is less than the
specified pressure, then turn the adjusting screw in (clockwise) slowly until the pressure is
as specified in Pressure Settings Chart, Chapter 2, Section 4. Tighten the locknut on the
adjusting screw.
NOTE: IF THE PRESSURE CANNOT BE RAISED TO THE SPECIFIED PRESSURE, INCREASE

THE PRESSURE SETTING ON THE RELIEF VALVE LOCATED DIRECTLY UNDER
33SOL. THIS VALVE IS LOCATED ON THE RIGHT FRONT FENDER, DIRECTLY
BEHIND THE ELECTRICAL ENCLOSURE. REFER TO FIGURE 19.
(7) After adjusting the counterbalance valve, proceed to adjust the relief valve below 33SOL.
Loosen the locknut on the adjusting screw on the relief valve and turn the valve out
(counterclockwise) until the pressure reading on the gauge is less the specified pressure,
then turn the adjusting screw in (clockwise) slowly until the pressure is as specified in
Pressure Settings Chart, Chapter 2, Section 4.
(8) Tighten the locknut.
(9) Have assistant release the switch and shut the engine down.
(10) Remove the hydraulic hose, pressure gauge and T fitting installed for making the
adjustments and connect the hoses to the counterbalance valve.
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October 2013
V. ENCLOSED BASKET DUAL COUNTERBALANCE VALVE, RIGHT ROTATION
NOTE: THE DUAL COUNTERBALANCE VALVE IS LOCATED ON THE LEFT SIDE OF THE
BASKET PLATFORM. REFER TO FIGURE 16 THROUGH FIGURE 19.
NOTE: THE VALVE PACK CONTAINS TWO COUNTERBALANCE VALVES (CLOCKWISE AND
COUNTERCLOCKWISE) FOR ADJUSTING THE HYDRAULIC PRESSURE THAT WILL
OPEN THE VALVE TO ALLOW FLUID TO RETURN TO THE RESERVOIR.
NOTE: THE PURPOSE OF THE COUNTERBALANCE VALVE IS TO PREVENT THE BASKET

FROM DRIFTING AFTER IT HAS BEEN ROTATED TO A DESIRED POSITION.
(1) With the engine off, remove the hydraulic hoses from the fittings in ports V2 and C1 on the
counterbalance valve (refer to Figure 16).
(2) Install a T fitting on the end of the hydraulic hose that was removed from port V2.
(3) Install a short hydraulic hose from the T fitting to the existing fitting in port C1 on the
counterbalance valve.
(4) Install a pressure gauge 0140 bar (02000 psi) in the remaining port in the T fitting.
(5) Have assistant start the engine, then actuate and hold the basket rotate switch for RIGHT
(clockwise) rotate.
(6) Loosen the locknut on the adjusting screw on the right side counterbalance valve and turn
the valve out (counterclockwise) until the pressure reading on the gauge is less than the
specified value, then turn the adjusting screw in (clockwise) slowly until the pressure is as
specified in Pressure Settings Chart, Chapter 2, Section 4. Tighten the locknut on the
adjusting screw.
NOTE: IF THE PRESSURE CANNOT BE RAISED TO THE SPECIFIED VALUE, INCREASE THE
PRESSURE SETTING ON THE RELIEF VALVE LOCATED DIRECTLY UNDER 34SOL.
(REFER TO FIGURE 19). THIS VALVE IS LOCATED ON THE RIGHT FRONT FENDER,
DIRECTLY BEHIND THE ELECTRICAL ENCLOSURE.
(7) After adjusting the counterbalance valve adjust the relief valve below 34SOL, proceed to
adjust the relief valve. Loosen the locknut on the adjusting screw on the relief valve and
turn the valve out (counterclockwise) until the pressure reading on the gauge is less than
the specified pressure, then turn the adjusting screw in (clockwise) slowly until the
pressure is as specified in Pressure Settings Chart, Chapter 2, Section 4.
(9) Have assistant release the switch and shut the engine down.
(10) Remove the hydraulic hose, pressure gauge and T fitting installed for making the
adjustments and connect the hoses to the counterbalance valve.
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October 2013
ADJUSTMENT V. ADJUSTMENT U.
Figure 16
COUNTERBALANCE VALVE LOCATION
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October 2013
33SOL 34SOL
SET @
103.4 BAR
SET @ (1000 PSI)
103.4 BAR
(1000 PSI)
SET @
103.4 BAR
(1000 PSI)
COUNTERBALANCE VALVE
ENCLOSED BASKET
LEFT ROTATION
PRESSURE
GAUGE
Figure 17
COUNTERCLOCKWISE (LEFT) ROTATION ADJUSTMENT
33SOL 34SOL
SET @
103.4 BAR
SET @ (1000 PSI)
103.4 BAR
(1000 PSI)
SET @
103.4 BAR
(1000 PSI)
COUNTERBALANCE VALVE
ENCLOSED BASKET
PRESSURE RIGHT ROTATION
GAUGE
Figure 18
CLOCKWISE (RIGHT) ROTATION ADJUSTMENT
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October 2013
33SOL
CLOCKWISE (RIGHT) COUNTERCLOCKWISE (LEFT)

BASKET ROTATION BASKET ROTATION
RELIEF VALVE RELIEF VALVE
Figure 19
ENCLOSED BASKET ROTATION RELIEF VALVES
4. AERIAL DEVICE - BOOM ADJUSTMENTS
A. BOOM ROTATOR BACK LASH ADJUSTMENT
NOTE: REFER TO FIGURE 20. REFER TO MAINTENANCE SPECIFICATIONS IN CHAPTER 2,

SECTION 4 FOR TOLERANCE BETWEEN GEAR TEETH, AND TORQUE VALUE FOR
DRIVE GEAR ASSEMBLY BOLTS.
(1) Remove boom rotator cover; two bolts on each side, and nine bolts on top of the cover.
(2) Move basket out of rest and raise the boom slightly, so it can rotate freely.
(3) Rotate boom slightly until the teeth on both the boom bearing annular gear and the drive
gear pinion are aligned.
(4) Loosen four bolts that hold the rotator drive gear assembly. Bolts must be slightly tighten,
but allowing the assembly to shift to either side for adjustment.
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October 2013
(5) Using a pin punch and a hammer, punch the eccentric adjustment ring under the drive gear
pinion. Punch to the LEFT to move the gear assembly to the RIGHT, and punch to the
RIGHT to move the gear assembly to the LEFT.
(6) The tolerance between the teeth on both sides of the centered pinion gear tooth must be as
specified.
(7) Tighten, and torque the four bolts holding the rotator drive gear assembly.
(8) Re-attach boom rotator cover, and tighten retaining bolts.
TOLERANCE MUST BE MEASURED AT

BOTH SIDES OF THE CENTERED TOOTH
OF THE DRIVE GEAR PINION
BOOM ROTATOR
DRIVE GEAR
(REAR RIGHT SIDE
OF VEHICLE)
Figure 20
BOOM ROTATOR BACK LASH ADJUSTMENT
B. ENCLOSED BASKET ROTATOR BACK LASH ADJUSTMENT
NOTE: REFER TO FIGURE 21. REFER TO MAINTENANCE SPECIFICATIONS IN CHAPTER 2,

SECTION 4 FOR TORQUE VALUE FOR ENCLOSED BASKET DRIVE GEAR BOLTS,
AND LUBRICANT FOR THE ROTATOR TEETH.
(1) Remove enclosed basket operators seat to gain access to the rotator assembly setting
upper screws. Seat screws can be removed from under the basket.
(2) Loosen lower screws (12) from the support end of the jib boom under the enclosed basket.
Washers should rotate freely, but do not remove the screws.
(3) Loosen the three socket head screws on the rotator, through the hole under the seat.
(4) Push gear into the worm gear from the opposite end till there is no backlash; tighten the
three socket head screws.
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October 2013
(5) Recheck that there is no backlash. Back lash is the amount of free movement between the
two gears by rotating the larger gear. If necessary, repeat steps (3) and (4).
(6) Once the backlash adjustment has been done, remove lower screws one at a time, apply
Loctite 242 and tighten. Torque screws (12) following a crisscross pattern, according to
torque specification.
(7) Reinstall operators seat and tighten holding screws.
(8) Apply compound lubricant to the gear teeth, all the way after removing old grease.
PUSH GEAR INTO WORM

GEAR FROM THIS POINT APPLY COMPOUND
LUBRICANT TO ALL
GEAR TEETH
SOCKET HEAD
SCREWS
NOTE: ENCLOSED
BASKET REMOVED
FOR CLARITY.
Figure 21
ENCLOSED BASKET ROTATOR ASSEMBLY
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October 2013
5. HEATER ADJUSTMENTS
A. FLUID HEATER FUEL PRESSURE
The fluid heater fuel pump is located underneath the fluid heater. Refer to Pressure Settings
Chart in Chapter 2, Section 4 for fuel pump pressures for static and all-firing stages (refer to
Figure 6).
(1) Verify that the fuel pump speed is as specified in Adjustment Settings Chart (Chapter 2,
Section 4).
(2) Remove pressure adjustment access screw on the fuel pump to expose the set screw.
(3) Turn set screw clockwise to increase and counterclockwise to decrease fuel pressure.
B. ELECTRODE ANGLE ADJUSTMENT
The ignition electrodes come new set at an angle that must be changed (bent) before installing to
the burner head. The Original angle, normally 45, must be changed to the Adjusted angle as
specified in the Adjustment Settings Chart (refer to Figure 22, Electrode Angle Adjustment).
C. HEATER BURNER HEAD ADJUSTMENTS
NOTE: REFER TO HEATER BURNER ASSEMBLY IN THE ADJUSTMENT SETTINGS CHART

(CHAPTER 2, SECTION 4) FOR DIMENSIONAL DISTANCES AND ANGLES FOR THE
CORRESPONDING ADJUSTMENTS.
NOTE: SOME ADJUSTMENT DIMENSIONS ARE DEPENDENT BETWEEN EACH OTHER, AND
MAY REQUIRE TO RE-CHECK ANGLES AND DIMENSIONS AFTER ADJUSTMENT.
NOTE: USE CAUTION WHEN MAKING ADJUSTMENTS TO PREVENT DAMAGE TO

PORCELAIN INSULATORS WHICH CAN BE EASILY CRACKED IF FORCED TO
ROTATE WITH TOOLS OR TIGHTENED TO HARD.
(1) Remove the burner assembly from the heater, if not removed yet.
(2) Measure the distance between the tip of the nozzle and the face of the flame retention ring
(refer to Figure 22, Retention Ring Adjustment X).
(3) Adjust to the specified distance loosening the Adjustment Screw X. Tighten screw after
verifying the correct measurement.
(4) Loosen clamp on porcelain insulators (glass) by loosening both Adjustment Screws Y.
(5) Ensure the ignition electrodes have been adjusted to the specified angle.
(6) Set distance between the clamp and the tip of the porcelain insulator for both electrodes as
specified, refer to Figure 22, Electrodes Adjustment Y (Glass). Slightly tighten both
Adjustment Screws Y allowing porcelain insulators to rotate within the clamp.
(7) Set distance between the tip of both electrodes and the face of the retention ring. Verify
the distance to the retention ring brace tips. Refer to Figure 22, Electrodes Adjustment Y
(from Ring Face, and from Brace Tips).
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October 2013
DETAIL A
BURNER TUBE ADJUSTMENT

RETENTION RING
ELECTRODES ADJUSTMENT X
ADJUSTMENT
Y (GLASS) ELECTRODES VIEW B-B
ADJUSTMENT Y ELECTRODES ANGLES ON
(FROM RING FACE) RETENTION RING
ELECTRODES GAP ORIGINAL

ADJUSTMENT Y
ADJUSTMENT ADJUSTED
SCREWS Y ELECTRODES
ADJUSTMENT ADJUSTMENT Y
SCREW X (FROM BRACE TIPS)
DETAIL A
BURNER HEAD ADJUSTMENTS ELECTRODES
ANGLE
ADJUSTMENT
Figure 22
HEATER BURNER SETTINGS
2-5
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October 2013
(8) Rotate insulators to set angles and for both electrodes (refer to Figure 22, View
B-B).
(9) Verify the spark gap distance between both ignition electrodes to be within specifications
(refer to Figure 22, Detail A).
(10) If spark gap is not within specification, verify and repeat steps (5) through (9).
(11) Lock and secure the clamp against both electrode insulators by tightening both Adjustment
Screws Y after making and verifying these adjustments.
D. BURNER NOZZLE ASSEMBLY - DEPTH SETTING, STAGES 1 THROUGH 4
NOTE: THIS ADJUSTMENT MUST BE PERFORMED FOR ALL FOUR BURNER NOZZLE
ASSEMBLIES. REFER TO FIGURE 23.
(1) Remove the burner assembly from the heater, if not done already.
(2) Measure the distance from the inside edge of each air tube to the face of the burner
mounting plate to obtain dimension A and record.
(3) Dimension B is calculated for each burner nozzle assembly by subtracting 6.35 mm
(0.25 in.) from the measured dimension A.
Dimension B (mm) = A - 6.35 mm, or
Dimension B (in.) = A - 0.25 in.
(4) Loosen the locking set screw in the collar and slide the burner nozzle assembly in or out to
obtain dimension B (from Front Edge of Flame Retention Ring to Inside Face of Burner
Supporting Plate).
(5) Tighten locking set screw securely on collar after adjusting the burner nozzle assembly.
(6) Repeat steps (2) through (5) for the other three burner nozzle assemblies.
(7) Install and secure burner assembly to heater.
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October 2013
INSIDE EDGE FRONT EDGE OF
OF AIR TUBE FLAME RETENTION RING
FACE OF BURNER INSIDE FACE OF BURNER

MOUNTING PLATE SUPPORTING PLATE
LOCKING
SET SCREW
DIMENSION DIMENSION
A B
COLLAR
BURNER NOZZLE ASSEMBLIES
Figure 23
BURNER NOZZLE ASSEMBLY ADJUSTMENT
E. AIR PRESSURE SWITCH
(1) Install a strip of reflective marker on the blower fan (refer to Figure 4).
(2) Start the engine and allow it to warm up.
(3) Manually actuate 17SOL on the hydraulic manifold (refer to Figure 2).
(4) Adjust blower low speed flow control valve on the hydraulic manifold to the initial speed as
specified in Adjustment Settings Chart in Chapter 2, Section 4, (refer to Figure 2,
Adjustment C.)
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October 2013
NOTE: TURN ADJUSTING SCREW CLOCKWISE TO DECREASE FAN SPEED AND
COUNTERCLOCKWISE TO INCREASE FAN SPEED.
(5) Observe the red indicator light (LED) I6 on the heater controller for being illuminated (refer
to Figure 24).
(6) Remove the protective cap over the pressure adjustment screw, on the base of the switch
assembly, and turn the adjusting screw counter-clockwise until the indicator light is off, then
slowly turn the adjusting screw clockwise until the indicator light just illuminates.
(7) Decrease the fan speed to the decreased blower speed as specified in Adjustment
Settings Chart, Chapter 2, Section 4, by turning the adjusting screw on the flow control
valve.
(8) The red indicator light must go off at that speed.
LED I6
CONTROLLER
Figure 24
HEATER CONTROLLER PANEL
(9) Verify switch adjustment by increasing the fan speed to the specified value as per
Adjustment Settings Chart (Chapter 2, Section 4) and observe that the indicating light is
illuminated.
NOTE: THIS IS A PRECISE ADJUSTMENT AND IT MAY REQUIRE SEVERAL VERY SMALL
ADJUSTMENTS TO PROPERLY ADJUST THE PRESSURE SWITCH.
(10) Replace the protective cover over the adjusting screw.
Adjust blower speed as outlined in paragraph 3. HYDRAULIC SYSTEM ADJUSTMENTS,

adjustment C.
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October 2013
F. FLUID TEMPERATURE GAUGES
NOTE: ACCURATE FLUID TEMPERATURE GAUGES (THERMOMETERS) ARE REQUIRED TO

MONITOR HEATER PERFORMANCE AND FOR CHECKING THE ELECTRONIC
HEATER CONTROLLER (EHC). REFER TO FIGURE 25.
NOTE: A DIGITAL READOUT METER AND THERMOCOUPLE WITH KNOWN ACCURACY ARE
REQUIRED FOR VERIFYING THE ACCURACY OF FLUID TEMPERATURE GAUGES.
(1) Remove the mechanical temperature gauges (thermometers) from the inlet and outlet
manifolds.
NOTE: INSTALL PLUGS IN MANIFOLDS TO PREVENT FLUID LOSS WHEN TEMPERATURE

GAUGES ARE REMOVED.
(2) Immerse the element of the temperature gauges and the thermocouple in a container of
water on top of a heating source (Hotplate).
(3) Heat the water and compare the temperature gauge and digital readout. Reading should
be according to the range and tolerance specified in Adjustment Settings Chart, Chapter 2,
Section 4.
G. FLUID TEMPERATURE SWITCHES
NOTE: FLUID TEMPERATURE SWITCHES MUST BE ACCURATE AND ACTUATE AT THE

INDICATED TEMPERATURE SETTING TO PREVENT DAMAGE TO THE DEICING
FLUID OR THE HEATER. REFER TO FIGURE 25.
NOTE: A DIGITAL READOUT METER AND THERMOCOUPLE WITH KNOWN ACCURACY ARE
REQUIRED FOR VERIFYING THE ACCURACY OF FLUID TEMPERATURE SWITCHES.
(1) Remove the temperature actuated switches from the heater outlet manifold.
NOTE: INSTALL PLUGS IN MANIFOLDS TO PREVENT FLUID LOSS WHEN THE

TEMPERATURE ACTUATED SWITCHES ARE REMOVED.
(2) Connect an ohmmeter to the normally closed (NC) contacts on the switch.
(3) Immerse the element of the temperature gauges and the thermocouple in a container of
water on top of a heating source (hotplate).
NOTE: THE USE OF HYDRAULIC FLUID IS RECOMMENDED WHEN CHECKING OR SETTING

SWITCHES NEAR AND ABOVE THE BOILING POINT OF WATER.
WARNING
DO NOT USE AN OPEN FLAME HEATING SOURCE, HYDRAULIC FLUID IS FLAMMABLE.
(4) Heat the hydraulic fluid and note the ohmmeter for when the contacts actuate open and the
temperature that the contacts actuated. Adjust the switch to actuate open within the
specified temperature tolerance of the required settings for 6TAS, and 11TAS. Refer to
Adjustment Settings Chart in Chapter 2, Section 4.
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October 2013
NOTE: REPOSITION INDICATOR TO MATCH TEMPERATURE SETTING SHOWN ON THE
ADJUSTING KNOB, IF NECESSARY.
STACK
TEMPERATURE
SWITCH
FUEL
PRESSURE
STAGE 1 - 19SOL
STAGE 2 - 20SOL
IGNITER
3PS AIR
PRESSURE
SWITCH
STAGE 3 - 21SOL
STAGE 4 - 22SOL
J RESET
B
DEICE
PRESSURE
GAUGE
6TAS OVER TEMP.
SWITCH
HEATER OUTLET
TEMPERATURE GAUGE
11TAS TEMP.
RTD SWITCH 2FLS FLOW
SWITCH
Figure 25
FLUID TEMPERATURE SWITCHES
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October 2013
6. HYDROSTATIC DRIVE CONTROLLER
NOTE: FOR HYDROSTATIC DRIVE CONTROLLER FAULT CODES REFER TO

TROUBLESHOOTING IN CHAPTER 2, SECTION 6.
A. NEW CONTROLLER CALIBRATION
The throttle pedal (1PED) and the brake pressure transducer (1BPT) must be calibrated to the
HYDROSTATIC DRIVE CONTROLLER (1HDB) to enable the controller to respond to the
sensors.
NOTE: HYDRAULIC FLUID MUST BE AT NORMAL OPERATING TEMPERATURE, AND ENGINE

IDLE SPEED SET AS PER SPECIFICATIONS.
NOTE: AIR PRESSURE FOR THE BRAKE SYSTEM MUST BE AT THE SPECIFIED VALUE, OR
HIGHER (REFER TO PRESSURE SETTINGS CHART IN CHAPTER 2, SECTION 4).
(1) When a new controller is installed, remove the wire harnesses from the foot pedal (1PED)
and the brake pressure transducer (1BPT).
(2) Start and warm up the engine and hydraulic oil, ensure that the air pressure in the air tank
for the braking system is as specified or higher, and engine idle speed is as per
specifications. Shut the engine down.
(3) Connect the wire harnesses to the foot pedal (1PED) and the brake transducer (1BPT).
(4) In the main panel, connect a jumper wire from terminal 2 (battery) to the wire #27 on 5CON
to energize the contactor.
- The controller is now being calibrated for low end of 1PED and 1BPT sensors.
(5) Depress the accelerator pedal fully down and hold steady for seven seconds.
NOTE: THIS IS NECESSARY FOR THE CONTROLLER TO READ A STEADY VOLTAGE.
- The controller is now calibrated for 1PED.
(6) Depress the brake pedal fully down and hold steady for seven seconds.
(7) Enter enclosed basket (one-man drive option only).
(8) Close door and fasten seat belt (one-man drive option only).
(9) High speed actuate ENABLE switch and ensure in NEUTRAL (one-man drive option only).
(10) Remove the jumper wire from 5CON that was installed in step (4).
(12) Check the controller 1HDB in the main panel for a successful calibration. There are four
LED's that can be illuminated.
(a) The two top LED's (GREEN) should be illuminated.
(b) The third LED (AMBER) should be flashing.
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(c) The bottom LED (RED) should be OFF.
(13) If the calibration was not successful, see fault codes for the error. Refer to Troubleshooting
in Chapter 2, Section 6.
B. CALIBRATION AFTER INSTALLING NEW SENSOR (FORCE NEW VALUES)
The HYDROSTATIC DRIVE CONTROLLER (1HDB) must be calibrated with new values when the
throttle pedal (1PED), brake pressure transducer (1BPT), or the fluid delivery (1FLD) sensor is
replaced.
The throttle pedal (1PED) and the brake pressure transducer (1BPT) must be calibrated to the
HYDROSTATIC DRIVE CONTROLLER (1HDB) to enable the controller to respond to the
sensors.
NOTE: HYDRAULIC FLUID MUST BE AT NORMAL OPERATING TEMPERATURE, AND ENGINE

IDLE SPEED SET AS PER SPECIFICATIONS.
NOTE: AIR PRESSURE FOR THE BRAKE SYSTEM MUST BE AT THE SPECIFIED VALUE, OR
HIGHER (REFER TO PRESSURE SETTINGS CHART IN CHAPTER 2, SECTION 4).
(1) When a fault is indicated on the controller, and it is determined that a sensor has failed,
shut the engine down and replace the sensor.
(2) When a new sensor is installed, foot pedal (1PED) or brake pressure transducer (1BPT),
do not connect the wire harness to the new sensor.
(3) In the main panel, connect a jumper wire from terminal 2 (battery) to the wire #27 on 5CON
to energize the contactor.
(4) Connect the wire harnesses to the foot pedal (1PED) and the brake transducer (1BPT).
- The controller is now being calibrated for low end of 1PED and 1BPT sensors.
(6) Depress the brake pedal fully down and hold steady for seven seconds.
- The controller is now calibrated for 1BPT.
(7) Enter enclosed basket (one-man drive option only).
(8) Close door and fasten seat belt (one-man drive option only).
(9) High speed actuate ENABLE switch and ensure in NEUTRAL (one-man drive option only).
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(12) Check the controller 1HDB in the main panel for a successful calibration. There are four
(a) The two top LED's (GREEN) should be illuminated.
C. CALIBRATION AFTER FOOT PEDAL ADJUSTMENT (FORCE NEW VALUES)
To force new calibration values for 1-PED when it is necessary to readjust the stop bolt on the
pedal to obtain the correct signal voltage when pedal is in the released position.
(1) After the initial calibration a fault code indicates the voltage signal is out of range is on the
controller, and an adjustment is made to the pedal stop to obtain the correct low end
voltage of 0.250.75 VDC, it will be necessary to force new calibrations for the controller.
(2) After adjusting the stop on the foot pedal (1PED) disconnect the wire harness to the foot
pedal.
(3) With the engine shutdown, connect a jumper wire from terminal 2 (battery) to the wire #27
on 5CON to energize the contactor in the main panel.
(4) Connect the wire harnesses to the foot pedal (1PED).
- The controller is now being calibrated for low end of 1PED.
(8) Check the controller 1-HDB in the main panel for a successful calibration. There are four
(a) The two top LEDs (GREEN) should be illuminated.
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D. STEERING CONTROLLER CALIBRATION
To force new calibration values for 1PED when it is necessary to readjust the stop bolt on the
pedal to obtain the correct signal voltage when pedal is in the released position.
(1) Start vehicle.
(2) Release parking brake and place vehicle in DEICE mode.
(3) Place the F-N-R switch in FORWARD and drive the vehicle approximately 9 m (30 ft.).
This allows tires to find true center.
(4) Set the parking brake and place the FNR switch in NEUTRAL.
(5) Shut off vehicle.
(6) Move the toggle switch to the CAL (UPPER) position.
(7) Start vehicle and place the vehicle into one-man drive.
(8) Release the CAL switch.
This will out the SX in calibration mode and un-calibrate all inputs and valve output.
(9) Place mode switch into STANDBY mode.
(10) Calibrate the joystick input by performing the following:
(a) Push the joystick to the left fully and hold it in position for seven seconds.
(b) Push the joystick to the right and hold it in position for seven seconds
NOTE: DUE TO THE JOYSTICK BEING SELF-CENTERING THE CENTER IS ALREADY

CALIBRATED.
(11) Calibrate the ST-POT by performing the following:
(a) Toggle the JOG switch to the LEFT and the tires will start turning left. Hold the
JOG switch until the tires can not turn any more and continue holding for an
additional five seconds.
(b) Toggle the JOG switch to the RIGHT and the tires will start turning right. Hold the
JOG switch until the tires can not turn any more and continue holding for an
additional five seconds.
NOTE: DUE TO THE TIRES HAVING BEEN PLACED ON CENTER, THE CENTER POSITION IS
AUTOMATICALLY CALIBRATED.
(12) Confirm that the calibration is complete by placing the MODE switch into RUN mode and
the tires should go from the current position (RIGHT) back to CENTER. If tires do not
return to CENTER it means that one or more of the calibration inputs is not correct.
(a) The joystick voltages should be as follows:
Center position . . . . . . . . . . . . . . . . . . . . . . 2.5 0.1 VDC
Left position . . . . . . . . . . . . . . . . . . . . . . . . 0.5 0.1 VDC
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Right position. . . . . . . . . . . . . . . . . . . . . . . 4.5 0.1 VDC
(b) The steering sensor voltages should be as follows:
Center position . . . . . . . . . . . . . . . . . . . . . 2.5 0.1 VDC
Left position . . . . . . . . . . . . . . . . . . . . . . . . 3.0 0.1 VDC
Right position. . . . . . . . . . . . . . . . . . . . . . . 2.0 0.1 VDC
If the joystick sensor is disconnected while the power is still ON, a fault is indicated by the
RED status LED (see fault codes). In addition, the calibration points are set to zero and the
calibration state is changed to un-calibrated.
When the sensor is re-connected, the calibration procedure will need to repeated in order
to put the sensor back into the calibrated state.
Refer to Troubleshooting in Chapter 2, Section 6 for fault codes.
7. PROGRAMMING CONTROLLERS FOR BOOM PROPORTIONAL VALVES
This procedure applies only to the enclosed basket.
The PQ-519 controllers are located in both arm pods in the operators enclosed basket. Each
proportional valve has a controller, and the controller is to be adjusted to the values indicated on the
table for the function (refer to Figure 26).
NOTE: THE VEHICLE ENGINE MUST BE RUNNING AND THE HYDRAULIC OIL MUST BE AT
NORMAL OPERATING TEMPERATURE.
NOTE: PARKING BRAKE MUST BE SET AND THE DRIVE MODE SWITCH IN TURTLE (DEICE
MODE) TO ENABLE THE BOOM CONTROLS IN THE OPERATORS BASKET.
A. STEPS TO PROGRAM 519 CONTROLLER
(1) Sit in the operators seat, buckle the seat belt and close the basket door.
(2) Raise the left side pod to access the PQ controllers for the boom.
(3) Extend the jib boom until it clears the rest.
(4) Actuate, and hold, the Red Trigger switch on the boom joystick to apply current to the
controllers in the left side pod.
NOTE: BOOM ROTATE P-Q CONTROLLER WILL NOT BE ACTIVE WHEN THE JIB BOOM IS IN
THE REST POSITION.
(5) Place controller into programming mode by pushing down on the ARROW DOWN,
ARROW UP and PROGRAM STORE switches simultaneously and the display will show
P-0.
NOTE: IF YOU PRESS THESE SWITCHES MULTIPLE TIMES YOU WILL GO TO DIFFERENT
DEFAULT SETTINGS (P-0, P-1, P-2 OR P-3) AND THE SETTINGS STORED IN P-0
WILL BE CHANGED. PRESSING SELECT CANCEL ONCE WILL ALLOW SETTINGS
TO BE CHANGED FOR P-0.
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October 2013
(6) LED A or B will be illuminated indicating which output has been selected to be
programmed.
(7) Pressing the ARROW UP or ARROW DOWN switches will scroll through each setting
and when you continue to scroll through the top or bottom bar LED, you will proceed to the
other output A or B.
(8) Go to the High Max Amps and press SELECT CANCEL in program mode.
(9) The bar LED will flash, indicating you are programming that particular function.
(10) To actuate the function you are programming, example BOOM RAISE, output A LED will
be illuminated and the HIGH AMPS MAX bar LED will be illuminated and flashing.
(11) Ensure value displayed is 0.20, or less.
BAR LED
DIGITAL
DISPLAY
Figure 26
P-Q CONTROLLER
(12) Push boom control joystick to its maximum position.
(13) Slowly increase the controller setting by pushing ARROW UP switch, with about one
second delay between presses, until the boom just moves and note the reading.
(14) Press ARROW DOWN switch and decrease the value 0.05 to 0.07 and then slowly
increase the value again to verify the point the boom just starts to move.
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NOTE: THIS IS THE VALUE THAT IS REQUIRED TO MOVE THE VALVE SPOOL TO ALLOW
THE FUNCTION TO START ITS OPERATION.
(15) When the reading (value) is consistent in steps (12) and (13), decrease the value exactly
0.05 by pressing the ARROW DOWN switch, in steps, slowly.
(16) Depress the PROGRAM STORE switch. This value now stored in the P-0 program; this is
the operating program for the controller.
(17) Enter this value as the RECORDED VALUE on the chart for the function the controller is
driving to enable the setting of the other values.
(18) To change a value in the P-0 program:
(a) Scroll the bar LEDs to select the setting to be programmed with the UP ARROW, or
DOWN ARROW.
(b) Depress SELECT CANCEL switch. (The bar LED will begin flashing.)
(c) Change the value displayed to the new value, using the UP ARROW or DOWN
ARROW.
(d) Depress the PROGRAM STORE switch to enter the value in the P-0 program.
(19) To determine the values to program the controller for HIGH MAX AMPS, MID MAX AMPS
and CREEP MAX AMPS, refer to notes 1, 2, 3 and 4 on each table. The sequence to enter
the values is:
(a) Establish the RECORDED VALUE, steps (4) to (16).
(b) Set HIGH MAX AMPS
(c) Set MID MAX AMPS
(d) Set CREEP MAX AMPS
(e) Set RAMP UP
(f) Set RAMP DOWN
(g) Set LOW AMPS
(20) Scroll down the LED bar until output B is illuminated, then repeat entering the values for the
output B.
(21) Complete the programming procedure by verifying MAX SIGNAL%, DEADBAND%, AUX
TRIP% and FREQUENCY Hz are the same as indicated on the tables.
(22) Use the appropriate table when making boom adjustments.
(a) Use JIB BOOM - LEFT ARM POD - 1VC for jib boom settings.
(b) Use BOOM - LEFT ARM POD - 3VC for boom settings.
(c) Use ROTATOR - LEFT ARM POD - 4VC for boom rotator settings.
(d) Use ENCLOSED BASKET - RIGHT ARM POD - 5VC for enclosed basket (rotation)
settings.
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B. REFERENCE TABLES FOR CONTROLLER VALUES
JIB BOOM - LEFT ARM POD - 1VC
A B
SETTING
RAISE LOWER
Low Amps Note 1 Note 1

High, Max Amps Note 2 Note 2
Mid, Max Amps Note 3 Note 3
Creep, Max Amps Note 4 Note 4
Ramp Up, Seconds 2.0 2.0
Ramp Down, Seconds 0.7 0.7
Max Signal% 100 100
Deadband% 30 30
Aux. Trip% 20 20
Frequency Hz 250 250
30 5 Seconds, Full Travel Recorded Values
Initial Function Movement -0.05

Note 1. Recorded Value +
Note 2. Recorded Value + 0.15 0.10
Jib requirements for setting:
Deice mode
Enclosed basket door closed and latched
Enclosed basket seat belt secured
Boom joystick enable activated
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October 2013
BOOM - LEFT ARM POD - 3VC
A B
SETTING
RAISE LOWER
Max Signal% 100 100
Deadband% 30 30
Aux. Trip% 20 20
35 5 Seconds, Full Travel Recorded Values
Boom requirements for setting:
Deice mode
Jib raised to clear jib retracted slow zone
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October 2013
ROTATOR - LEFT ARM POD - 4VC
B
A
SETTING COUNTER-
CLOCKWISE
CLOCKWISE
Max Signal% 100 100
Deadband% 30 30
Aux. Trip% 20 20
35 5 Seconds, for 90 rotation Recorded Values
Rotator requirements for setting:
Deice mode
Jib raised to clear jib retracted slow zone
Boom raised out of boom stowed bracket
NOTE: ROTATOR CARD WILL NOT POWER UP UNTIL ALL OF THE ABOVE IS DONE.
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ENCLOSED BASKET - RIGHT ARM POD - 5VC
B
A
SETTING COUNTER-
CLOCKWISE
CLOCKWISE
Max Signal% 100 100
Deadband% 030 030
Aux. Trip% 020 020
15 5 Seconds, for 90 rotation Recorded Values
Enclosed basket requirements for setting:
Deice mode
Enclosed seat belt secured
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8. MISCELLANEOUS MAINTENANCE PROCEDURES
A. REPLACE FUEL FILTER ELEMENT
(1) Fuel filter is connected to the burner head fuel manifold.
(2) Disconnect fuel tube from filter canister; disassemble canister and replace filter element.
B. INSPECTION FOR CARBON BUILD-UP ON HEATER COILS
(1) Remove burner assembly.
(2) Inspect interior of heater through air inlet tubes.
(3) Remove any carbon buildup with wire brush and vacuum.
(4) Check coils for any sign of heat damage or leakage.
(5) Reinstall burner assembly.
(6) If heater appears to have high exhaust temperatures (in excess of 538 C [1000 F]) or
flame is observed at the exhaust screen, refer to Manufacturers Appendices in Chapter 5
for carbon cleaning of heating coils.
C. CHECK FUEL SOLENOID VALVES
(1) Fill fluid tank with several hundred liters (amount divided by four for gallons) of cold fluid.
(2) Turn on heater. After 30 second pre-purge period, voltage will be seen at stage one fuel
valve solenoid (19SOL) and heater will initiate combustion. At successive five second
intervals voltage will be seen at stage 2 fuel valve solenoid (20SOL), stage 3 fuel valve
solenoid (21SOL), and stage 4 fuel valve solenoid (22SOL).
(3) Fuel valves should also be checked by viewing in the four sight glasses to verify the stage
is firing when the voltage is applied to it.
D. CLEAN FUEL NOZZLE STRAINERS
(1) Remove burner assembly from heater.
(2) Remove and disassemble nozzles to clean strainers.
E. BRAKES INSPECTION AND ADJUSTMENT
WARNING
ENSURE CONNECTIONS ARE CLEAN BEFORE ATTACHING BRAKE LINES. ENSURE THERE
ARE NO AIR LEAKS FROM BRAKE SYSTEM UPON COMPLETION OF INSTALLATION.
The brakes should be inspected as recommended in the Maintenance Schedules, Chapter 2,

Section 3. Also, if a defect is suspected or potential problems such as vehicle pulling to one side
when the brake is applied, noises, leaks, pulsating pedal, or excessive brake pedal travel.
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(1) Prepare the vehicle to remove the wheel. Chock and lift the vehicle.
(2) Ensure the parking brake is not applied. You may need to mechanically release the brakes
before removing the brake drum. Refer to Emergency Procedures in Chapter 1, Section 3
for this procedure.
(3) Remove the wheel.
(4) Remove the brake drum.
(5) Carefully brush any accumulations of dirt and dust. Do not blow the dust with compressed
air or inhale the dust which may be a health hazard.
(6) Inspect the thickness of the brake lining. If the thickness is within 1.6 mm (0.063 in. [1/16
in.]) of the recessed rivets or metal backing, the brake shoes must be replaced.
(7) Inspect brake shoes for cracks, glaze, or signs of contamination, and if present, replace the
brake shoes.
(8) Inspect all brake components such as springs, cylinders, and retainers. Replace worn and
defective parts.
(9) Inspect the inside of the brake drum for cracks, scores, deep scratches, and hard spots,
which will show as discolored sections. The drum may need to be resurfaced. If
imperfections cannot be removed, replace the drum.
(10) Reinstall the brake components replacing the necessary components, and parts found in
proper condition.
(11) Reinstall the brake drum.
(12) Install the wheel and tight the lug nuts following a criss-cross pattern. Torque lug nuts
according to specifications (refer to Chapter 2, Sections 4 and 5).
(13) Repeat steps (1) through (12) for the other wheels.
F. GEAR BOX OIL LEVEL CHECK
(1) Chock the vehicle and stop the engine.
(2) Locate oil level access and filling point cap on the front lower area of the gear box (refer to
Figure 27).
(3) Remove cap and insert finger into adapter. Level is correct if finger reaches oil inside the
adapter.
(4) If oil level is low, add oil through this adapter. Do not overfill. Refer to Maintenance
Specifications in Chapter 2, Section 4, and Manufacturers Appendices in Chapter 5 for oil
specifications and capacity.
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October 2013
LEFT SIDE VIEW
OIL LEVEL CHECK

ACCESS AND FILLING
POINT CAP OIL FILL AND VENT
(AS PER
MANUFACTURER)
OIL LEVEL DIP

STICK (AS PER
GEAR BOX MANUFACTURER)
GEAR SHAFT
REAR VIEW TO REAR AXLE
Figure 27
GEAR BOX OIL LEVEL CHECK
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October 2013
G. FLUID ACCUMULATORS INSPECTION AND PRESSURE CHECK
NOTE: ACCUMULATORS ARE CHARGED AND TESTED AT THE FACTORY. REFER TO

MAINTENANCE SPECIFICATIONS IN CHAPTER 2, SECTION 4, AND SYSTEM
SCHEMATICS IN CHAPTER 2, SECTION 7 FOR CHARGE PRESSURE VALUES.
(1) Set up the vehicle to spray deicing fluid, and verify that fluid can be sprayed. This will
prove all interlocks and switch settings.
(2) Disconnect the hydraulic solenoid valve for the delivery. Refer to the corresponding
schematic.
Spray deicing fluid again. A small amount of fluid should be discharged initially, and
nothing after that.
(3) Turn off the vehicle, and verify that no fluid pressure is present inside fluid lines and piping.
(4) Remove the accumulator. As the accumulator is loosened, if there is still pressurized fluid
coming out, allow it to reduce to a trickle before removing the accumulator completely.
(5) Charge the accumulator with compressed air or nitrogen, according to pressure
specifications.
NOTE: IF AIR OR NITROGEN COMES OUT OF THE FLUID PORT, THEN THE ACCUMULATOR
IS DEFECTIVE AND MUST BE REPLACED.
(6) Reinstall the accumulator, and reconnect the hydraulic valve. Perform deice fluid spray
test.
FLUID ACCUMULATOR
Figure 28
FLUID PRESSURE ACCUMULATOR
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October 2013
H. WHEEL REMOVAL
(1) Lift and support the axle end with a properly rated jack, without lifting the wheel from the
ground.
(2) Loosen all the outer hex lug nuts. For rear wheels, when removing the inner wheel from
the rear axle, also loosen the inner square lug nuts.
(3) Lift the wheel from the ground and support the wheel to prevent it from falling when
removing the lug nuts.
(4) Remove all the hex lug nuts. If also removing the inner wheel, support the wheel and
remove all the square lug nuts.
I. WHEEL INSTALLATION
(1) For rear wheels, If inner wheel was removed, install it first and firmly tighten the square lug
nuts. Torque all inner wheel square lug nuts to specification in two steps as per procedure
in paragraph J.
NOTE: FOR THE REAR WHEELS, THE INNER WHEEL SQUARE LUG NUTS MUST BE FULLY
TORQUED TO SPECIFICATION, BEFORE INSTALLING THE OUTER WHEEL.
(2) Install the outer wheel and firmly tighten the hex lug nuts. Do not remove support jacks
before torquing all lug nuts.
(3) Torque all outer wheel hex lug nuts to specification in two steps as per procedure in
paragraph J.
J. WHEEL LUG NUT TORQUE PROCEDURE
NOTE: WHEEL LUG NUTS MUST BE RE-TORQUED TO SPECIFICATION BEFORE PLACING

THE VEHICLE INTO SERVICE WHEN COMMISSIONING OR RE-COMMISSIONING THE
VEHICLE, AND WHEN PERFORMING THE 500-HOUR MAINTENANCE SCHEDULE.
REFER TO EQUIPMENT PRE-OPERATIONAL CHECKLIST IN CHAPTER 2, SECTION 3.
NOTE: REFER TO MAINTENANCE SPECIFICATIONS IN CHAPTER 2, SECTION 4 FOR WHEEL

LUG NUT TORQUE SPECIFICATION, AND FIGURE 29 FOR CRISS-CROSS TORQUE
PATTERN.
(1) Lift and support the axle end with a properly rated jack, without lifting the wheel from the
ground.
NOTE: WHEEL LUG NUTS MUST BE TORQUED IN TWO STEPS, INITIALLY APPLYING HALF
THE TORQUE SPECIFICATION, THEN THE FULL SPECIFIED TORQUE VALUE.
ALWAYS FOLLOW A CRISS-CROSS PATTERN AS SHOWN IN FIGURE 29. DO NOT
OVER-TORQUE LUG NUTS.
(2) If re-torquing the rear wheels, loosen all the hex lug nuts holding the outer wheel. Torque
the square inner wheel lug nuts to specification in two steps, using a 20 mm (13/16 in.)
square socket.
NOTE: FOR THE REAR WHEELS, THE INNER WHEEL SQUARE LUG NUTS MUST BE FULLY
TORQUED TO SPECIFICATION, BEFORE TORQUING THE OUTER WHEEL HEX LUG
NUTS.
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October 2013
(3) Torque the outer wheel hex lug nuts to the specified torque value in two steps, using a
38 mm (1.5 in.) 6-point hex socket. This step also applies when torquing the front wheels.
(4) Lower the axle end, and remove support jack.
(5) Repeat steps (1) through (4) for the remaining wheels.
10 1
INNER WHEEL
3 SQUARE LUG NUT
8 (REAR WHEELS
ONLY)
5 6
4 OUTER WHEEL
7 HEX LUG NUT
2 9
Figure 29
CRISS-CROSS TORQUE PATTERN
9. AERIAL DEVICE STABILITY AND LOAD TEST
WARNING
DO NOT ALLOW PERSONNEL IN THE BASKET, OR UNDER THE BASKET AND BOOM DURING
STABILITY AND LOAD TESTS. FAILURE TO COMPLY MAY RESULT IN SERIOUS BODILY
NOTE: VERIFY HYDRAULIC OPERATING PRESSURES TO BE SET CORRECTLY BEFORE

PERFORMING STABILITY AND LOAD TESTS (REFER TO PRESSURE SETTINGS
CHART IN CHAPTER 2, SECTION 4).
NOTE: CHECK TIRE PRESSURE BEFORE PERFORMING STABILITY AND LOAD TESTS. USE
GROUND STATION CONTROLS FOR BOOM POSITIONING.
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October 2013
NOTE: AN ASSISTANT IS REQUIRED FOR THESE PROCEDURES. HYDRAULIC FLUID MUST
BE AT NORMAL OPERATING TEMPERATURE.
A. STABILITY TEST
(1) Park vehicle on level paved surface, and set parking brakes.
(2) Ensure that fluid tanks are empty or nearly empty.
(4) Raise the boom out of rest and to the horizontal position.
(5) Extend the jib boom straight forward until it is level with the main boom.
(6) Attach Stability test weight under the basket. Refer to STABILITY AND LOAD TEST
SPECIFICATIONS table in Chapter 2, Section 4 for exact weight for this test (maximum
load plus 50%). Test weights are heavier for open basket than for enclosed basket.
NOTE: THE VEHICLE WILL NOT BE ABLE TO LIFT THE BOOM WITH THE STABILITY TEST
WEIGHT ATTACHED UNDER THE BASKET. TEST WEIGHT MUST BE LIFTED TO THE
SPECIFIED HEIGHT USING A FORKLIFT.
(7) Adjust lifting slings to keep stability test weight within the specified height from the ground
when weight is suspended from the basket (refer to Figure 14).
(8) Rotate the boom 90 to the left and verify that a sheet of paper cannot be slid under the
right rear wheels.
(9) Rotate the boom back to the center, and then 90 to the right of the vehicle and verify that a
sheet of paper cannot be slid under the left rear wheels.
NOTE: IF A SHEET OF PAPER CAN BE SLIDED UNDER THE REAR WHEELS WHILE
PERFORMING THE STABILITY TEST, IMMEDIATE REPAIRS ARE REQUIRED BEFORE
PERSONNEL ARE ALLOWED IN THE BASKET.
(10) Rotate the boom to the front of the deicer and remove test weight.
(11) Inspect basket, boom, jib boom, rotator, and all welds for indications of permanent
deformation or structural damage.
B. LOAD TEST
(1) Park vehicle on level paved surface, and set the parking brakes.
(3) Extend the jib boom straight forward until it is level with the main boom.
(4) Raise the boom out of rest to 15 above the horizontal position.
(5) Attach Stability test weight under the basket. Refer to STABILITY AND LOAD TEST
SPECIFICATIONS in Chapter 2, Section 4 for exact weight for this test (maximum load
plus 50%). Test weights are heavier for open basket than for enclosed basket.
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October 2013
NOTE: THE VEHICLE WILL NOT BE ABLE TO LIFT THE BOOM WITH THE STABILITY TEST
WEIGHT ATTACHED UNDER THE BASKET. TEST WEIGHT MUST BE LIFTED TO THE
SPECIFIED HEIGHT USING A FORKLIFT.
(6) Adjust lifting slings to keep test weight within the specified height from the ground when
weight is suspended from the basket (refer to Figure 14).
(8) Immediately measure from the bottom of the basket, or from the suspended weight, to the
ground level, and from the boom knuckle to ground level. Record the measurements.
(9) After waiting the specified time re-measure at the same points in step (8) to check for drift.
Refer to STABILITY AND LOAD TEST SPECIFICATIONS in Chapter 2, Section 4 for load
test drift maximum tolerance.
NOTE: IF THE DRIFT OBSERVED IS MORE THAN THE MAXIMUM ALLOWED, ADDITIONAL
TESTS AND MEASUREMENTS MAY BE NEEDED TO DETERMINE THE CAUSE OF
DRIFT. REPAIRS MAY BE REQUIRED BEFORE PERSONNEL ARE ALLOWED IN THE
BASKET.
(10) If drift is noted at the knuckle, replace counterbalance valve cartridge in base of the boom
cylinder and recheck for drifting under load.
(11) If, after replacing counterbalance valve cartridge, drifting is still observed, replace the boom
cylinder.
(12) If drift is noted on the basket measurement, replace the counterbalance valve cartridge in
the base of the jib boom cylinder and recheck for drifting under load.
(13) If after replacing counterbalance valve cartridge, drifting is still observed, replace jib boom
cylinder.
(14) Lower the boom, and remove test weight.
10. FLUID SYSTEM TEST
WARNING
DO NOT USE THE VEHICLE FOR DEICING AND ANTI-ICING OPERATIONS IF THE VEHICLE DID
Refer to the Field Viscosity Test for Aircraft Anti-icing Fluids document issued by the G-12 ADF
(Aircraft Deicing Fluids) Committee, under the SAE Aerospace Information Report (AIR) document
AIR5704, for the required fluid system tests.
The AIR5704 document provides a description of a screening method for use in the filed for verifying an
AMS 1428 anti-icing fluid is above its minimum low shear viscosity as published with holdover time
guidelines. The test will determine if the fluid is satisfactory, unsatisfactory, or borderline needing more
advanced viscosity testing. Other field tests may be required to determine if an anti-icing fluid is usable,
such as refractive index, appearance or other tests as may be recommended by the fluid manufacturer.
Refer to SAE International - www.sae.org.
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1. GENERAL
The Tempest Aircraft Deicer is an hydraulically operated, and electrically controlled vehicle. The
hydraulic and electrical systems are complex and require a thorough understanding to determine the
cause of a malfunction, or failure of a component. System diagnosis is mandatory to locate a
component that is out of adjustment or has failed, in the minimum amount of time.
The information contained in this section is provided as a guide to assist technical service personnel in
troubleshooting operational malfunctions in the Tempest hydraulic and electrical systems. The
information should be used in conjunction with the Troubleshooting section, Schematics, Reference
Designators, and Adjustment Procedures incorporated in this manual.
A. BEFORE TROUBLESHOOTING
Before starting troubleshooting procedures, verify that the correct operating procedures were
used. An incorrect operating procedure can cause apparent malfunctions.
Make sure all circuit breakers and fuses have continuity. Inspect all electrical connections and
suspected defective parts to verify that there are no open circuits, or defective grounding.
B. HYDRAULIC SYSTEM CLEANLINESS
A very important practice to observe when working on the hydraulic system is cleanliness.
Serious damage can result quickly from foreign material (contamination) in the hydraulic system.
When a hydraulic system is opened, cap or plug all ports and openings to keep foreign material
and moisture-laden air (contamination) from entering the system. DO NOT use Teflon tape or
pipe compound on straight threads.
2. HYDRAULIC SYSTEM
A. PRESSURE READINGS AND ADJUSTMENTS
Test ports are provided, and hydraulic system diagnosis is accomplished by observing pressure
readings on a test gauge when a particular hydraulic circuit is actuated. The hydraulic
schematics and adjustment procedures indicate the correct setting for each pressure adjustment.
B. MALFUNCTIONS ISOLATION
The first step in diagnosing a malfunction is to isolate the malfunction to the hydraulic system or to
the electrical control system.
C. MANUAL OVERRIDE
All solenoid actuated control valves in the hydraulic system are equipped with a manual override
that can be used to actuate the valve should there be a loss of electrical current. The manual
override shifts the valve spool and permits oil flow for the function to operate.
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TROUBLESHOOTING
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October 2013
NOTE: TO OBTAIN OIL FLOW AND PRESSURE AT THE VALVE ASSEMBLIES, IT IS
NECESSARY TO ACTUATE THE PILOT VALVE WITH THE DIRECTIONAL CONTROL
VALVE IN HYDRAULIC CIRCUITS WITH A PILOT VALVE.
D. TROUBLESHOOTING
Refer to the Troubleshooting Guide (Table 8 through Table 10) to assist in locating the cause of a
malfunction when incorrect pressure or incorrect flow has been determined. Also, for hydraulic
components and locations, refer to Chapter 4, Illustrated Parts List.
The Tempest electrical system components are located in the main panel. Sensors detect a specific
position of a mechanical component for the actuation and interlocking of electrical circuits.
A. MAIN PANEL
The main panel is located in the drivers cab and contains relays, fuses, contactors and electrical
devices associated with the operation of the unit.
CAUTION

B. MAIN COMPONENTS
The accelerator pedal in the drivers cab is electrically operated. Refer to System Overview in
Chapter 2, Section 2 for more details.
C. OTHER COMPONENTS
The main electrical harness feeds the main electrical components, including connectors for work
lights, headlights, backup alarms, and other lights.
D. TROUBLESHOOTING
Refer to the Troubleshooting Guide (Table 12) to assist in locating the cause of a malfunction
when no current or improper functioning has been determined. Also, for electrical components
and locations, refer to Chapter 4, Illustrated Parts List.
4. TROUBLESHOOTING GUIDELINES
A. SCOPE
Troubleshooting guide tables list malfunctions and some possible causes of a listed malfunction.
When there is a problem or malfunction of the vehicle, read through the list on the left side of the
chart. Possible causes are listed to the right.
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Page 2
October 2013
This guide lists the most common problems that could be encountered, but is not meant to
replace troubleshooting procedures that require diagnosing a system malfunction using the
hydraulic and electrical schematics.
B. DIAGNOSTIC TOOLS
The status panel in the drivers cab, and an accurate voltmeter, must be used to identify electrical
problems. Electrical schematics must be referred to when troubleshooting the Tempest electrical
system. Proximity switches and pressure switches must be adjusted to specifications when they
are replaced (refer to Maintenance Procedures in Chapter 2, Section 5).
Hydraulic troubleshooting can be done connecting a liquid-filled pressure gauge to the test ports
in conjunction with the hydraulic schematics.
C. HYDRAULIC OIL CONTAMINATION
Hydraulic component problems are usually caused by oil contamination and many components
can be made serviceable by a thorough cleaning. Hydraulic filter elements must be replaced
when a system has been cleaned of contamination. The hydraulic filter element must be replaced
whenever the warning indicator is visible.
D. COMPONENTS REPLACEMENT
When a component is repaired or replaced, always check the hydraulic circuit for the correct
indicated pressure and correct actuator speeds. Refer to Maintenance Procedures (Chapter 2,
Section 5), and Specifications (Chapter 1, Section 4).
The Troubleshooting Guide does include some obvious causes such as burned out light bulbs,
loose wire connections, physical damage to wire harnesses, components, etc., but it is assumed
that the technician will check these items before proceeding with detailed troubleshooting
procedures and adjustments.
5. TROUBLESHOOTING GUIDE TABLES
The following pages contain the Troubleshooting Guides (Table 1 through Table 14) to assist in
locating the causes of malfunctions. Also, for components and locations, refer to Electrical
Schematics, and Hydraulic Schematics in Chapter 2, Section 7.
For troubleshooting of Electronic Heater Controller (EHC), refer to Troubleshooting Guide in

Chapter 2, Section 8, Electronic Heater Controller (EHC).
WARNING
ALWAYS SUPPORT THE AERIAL DEVICE WHEN EXTENDED FOR MAINTENANCE
PURPOSES. FAILURE TO COMPLY MAY RESULT IN SERIOUS BODILY INJURY, DEATH, OR
2-6
TROUBLESHOOTING
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October 2013
TROUBLESHOOTING GUIDE
TABLE 1 - ENGINE
SYMPTOM PROBABLE CAUSE ACTION
Batteries are weak. Recharge or replace.

Starter or starter switch inoperative. Repair or replace defective parts.
This can be due to extended idle or
storage periods, or to improper
preparation of the engine for storage,
in which case the parts may be rusted,
Engine locked or seized.
corroded or seized. Broken piston
rings, gear, etc., may also cause
seizing. Repair or replace defective
parts.
This can be due to rain water entering
uncovered air intake or exhaust pipe
Hydro-static lock.
leaking into cylinder head. Repair or
replace defective parts.
See symptom Low cranking speed
Low cranking speed.
below.
Fuel tank is empty. Fill the tank.
Faulty stop control. Repair or replace as needed.
Engine will not
start Blocked fuel feed pipe. Clean out pipe.
Faulty fuel lift pump. Repair or replace the pump.
Choked fuel filter. Clean or replace the filter.
Air in the fuel system. Bleed air from system.
Faulty fuel injection pump. Repair or replace the pump.
Faulty atomizers or wrong type. Replace atomizers with proper type.
Wrong use of cold start equipment. Use the cold start equipment correctly.
Faulty cold starting equipment. Repair or replace the faulty part(s).
Broken fuel injection pump drive. Repair or replace the faulty part(s).
Wrong fuel pump timing. Time the fuel pump correctly.
Incorrect valve timing. Time the valves correctly.
Drain the fuel system. Fill with correct
Incorrect type or grade of fuel.
grade and type.
Refer to Poor compression
Poor compression.
subheading.
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Page 4
October 2013
TABLE 1 - ENGINE (CONT.)
Worn cylinder bores. Repair or replace as needed.

Engine will not Pitted valves and seats. Repair or replace as needed.
start (Cont.)
Broken, worn, or sticking piston Service, repair, or replace parts as
ring(s). necessary.
Charge the batteries or install new
Battery capacity is low.
batteries as needed.
Bad electrical connections. Repair or replace defective.
Low cranking Faulty starter motor. Repair or replace.
speed
Check all engine controls for proper
Engine controls out of adjustment.
adjustment and operation.
Drain oil. Refill with the correct grade
Incorrect grade of lubricating oil.
of oil.
Refer to symptom Low cranking
Low cranking speed.
speed above.
Check fuel level in tank. Fill with the
Insufficient fuel in fuel tank.
specified fuel if necessary.
Drain fuel system. Fill the tank with the
Incorrect type or grade of fuel.
specified fuel.
Faulty stop control operation. Repair or replace parts as needed.
Clogged fuel filter or blocked fuel feed Replace filter or clean out the fuel feed
pipe. pipe.
Repair air leaks in low pressure side of
Engine hard to Air in the fuel system.
fuel system. Prime fuel systems.
start
Insufficient air supply to cylinders. Clean air cleaner and intake manifold.
Replace worn piston rings or
Poor compression. Piston rings or
cylinders. Perform cylinder leak down
cylinders are worn.
test.
Recondition or replace valves and
Valves are warped or pitted.
guides.
Faulty fuel injection pump. Faulty or Repair or replace faulty parts as
incorrect type of atomizers. needed.
Incorrect use of or faulty cold starting Be sure the equipment is used
equipment. properly. Repair or replace as needed.
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TROUBLESHOOTING
Page 5
October 2013
Blocked fuel tank vent. Clean out the vent.

Inspect and clean out the exhaust
Engine hard to Exhaust pipe restriction.
pipe.
start (Cont.)
Clean, repair, or replace the affected
Valves are sticking.
parts.
Idling speed too low. Adjust low idle speed.
Restricted fuel supply. Chocked fuel Check fuel system for blockage.
filter. Replace filter.
Fuel supply stopped by shut-off
Engine stops Check fuel solenoid.
solenoid.
frequently
Restriction in air cleaner system. Inspect and clean out the system.
Prime the fuel system. Check for air
Air in the fuel system. leaks on suction side of fuel transfer
pump.
Fill fuel tank with specified fuel and
Out of fuel.
prime fuel system.
Restricted fuel supply or fuel return Check fuel system for blocked lines
line. and clogged filter.
Radiator air passages clogged. Remove debris from radiator core.
Fan belts loose. Adjust fan belts to proper tension.
Engine stops
suddenly Test the thermostat for proper
Thermostat inoperative.
operation.
Malfunctioning fuel solenoid, or safety Check fuel solenoid, and other safety
switch. shut down switches.
Check for proper operation of engine
Poor engine lubrication.
oil pump.
Water pump malfunctioning. Repair or replace the water pump.
Perform cylinder leak-down test.
Major engine failure.
Inspect rod and crankshaft bearings.
Clean air intake system. Clean
Engine shows loss Insufficient supply of air to cylinders.
exhaust system.
of power
Insufficient supply of fuel to cylinders.
Check fuel system. Replace fuel filter.
Water may be in fuel system.
Governor not operating properly. Check engine operating speed.
2-6
Page 6
October 2013
Prime fuel system. Check for air leaks

Air in fuel system.
on suction side of fuel transfer pump.
Clogged fuel filter. Change filter.
Improper valve lash. Adjust valve lash clearance.
Blocked fuel feed pipe. Clean out the feed, pipe.
Faulty fuel lift pump. Repair or replace as needed.
Faulty fuel injection pump. Faulty or Repair or replace faulty or incorrect
wrong type of atomizers. parts.
Incorrect valve timing or fuel pump Check the valve and fuel pump timing.
timing. Correct the timing as needed.
Blocked fuel tank vent. Clean out the vent.
Drain the fuel tank and refill with proper
Incorrect fuel tank vent.
fuel.
Engine shows loss
of power (Cont.) Sticking throttle or restricted Service, repair, or replace affected
movement. parts as needed.
Cylinder head gasket is leaking. Replace gasket.
Refer to symptom, Overheating,
Overheating.
below.
Cold running. Allow to reach normal temperature.
Recondition or replace the valves,
Pitted valves and seats.
seats and guides.
Turbocharger impeller is damaged or Clean, repair, or replace parts as
dirty. needed.
Induction system leaks (turbocharged
Find and repair leaks in the system.
engines.)
Loss of compression.
subheading.
Incorrect idle speed. Adjust idle speed.
Engine runs Valves in bad condition. Recondition valves and seats.
unevenly and
vibrates Fuel supply erratic or insufficient air
Check fuel system and air intake.
excessively intake.
Plugged fuel filter. Replace filter.
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TROUBLESHOOTING
Page 7
October 2013
Faulty fuel injection pump. Faulty or

Repair or replace the parts as needed.
incorrect atomizer type.
Sticking throttle or restricted Service, repair, or replace parts as
movement. needed.
Poor compression.
subheading.
Overheating. See Overheating below.
Engine runs
unevenly and Service, repair, or replace parts as
Sticking valves.
vibrates needed.
excessively (Cont.) Incorrect high pressure pipes. Install the correct high pressure pipes.
Broken, worn, or sticking piston rings. Repair or replace parts as needed.
Service, repair, or replace parts as
Piston seizure or pickup.
needed.
Damaged fan. Repair or replace as needed.
Faulty engine mounting (housing). Repair or replace as needed.
Incorrectly aligned flywheel housing or Check flywheel housing and flywheel.
flywheel. Align properly.
Air system clogged. Check engine air intake system.
Improper fuel. Drain fuel system and refill.
Faulty fuel injection pump. Faulty or
Repair or replace parts as needed.
incorrect type atomizers.
Faulty cold starting equipment. Repair or replace as needed.
Engine emits black timing. Correct the timing as needed.
smoke from
exhaust Refer to Poor compression
Poor compression.
subheading.
Exhaust pipe restriction. Clean out the exhaust pipe.
Check the tappets and adjust them
Incorrect tappet adjustment.
correctly.
2-6
Page 8
October 2013

needed.
Cylinder bores are worn. Repair or replace as needed.
Pitted valves and seats. Repair or replace as needed.
Engine emits black
smoke from Broken, worn, or sticking piston
Repair or replace parts as needed.
exhaust (Cont.) ring(s).
Turbocharger impeller is damaged or Clean, repair, or replace the impeller
dirty. as needed.
Repair or replace.
engines).
Engine operating temperature too low. Check thermostat operation.
Make cylinder leak-down test and
Low compression.
necessary repairs.
Drain oil and refill with correct grade of
Incorrect grade of lubricating oil.
oil.
timing. Correct the timing as needed.
Engine emits Cold running. Allow to reach normal temperature.

bluish-white smoke Worn cylinder bores. Repair or replace as needed.
from exhaust
ring(s). needed.
Over-full air cleaner. Clean or replace air filter.
Worn valve stems and guides. Repair or replace the parts as needed.
needed.
Damaged valve stem oil deflectors (if
fitted).
Turbocharger lubricating oil seal
Replace the oil seal.
leaks.
2-6
TROUBLESHOOTING
Page 9
October 2013
Loose bearings. Replace bearings.

ring(s). needed.
Check tightness of flywheel bolts.
Loose flywheel.
Tighten or replace parts as required.
Incorrect valve timing or fuel pump Check the valve and the fuel pump
timing. timing. Correct the timing as needed.
Foreign material in cylinder(s). Make necessary repairs.
Faulty atomizers or incorrect type. Replace as needed.
Engine detonates
Drain oil and refill with the correct type
or knocks Incorrect type or grade of oil.
and grade.
Overheating. See symptom, Overheating, below.
Check tappets and adjust them
correctly.
necessary.
Worn cylinder bores. Repair or replace as needed.
Over-full air cleaner. Clean or replace air filter.
Piston seizure or pickup. Repair or replace as needed.
Incorrect piston height. Correct the problem.
Broken valve spring. Replace the spring.
Insufficient oil in crankcase. Fill crankcase to proper level
Oil pressure gauge inoperative. Replace gauge or sending unit.
Remove and clean the screen or
Oil pickup cracked or clogged.
No oil pressure replace pickup assembly.
Oil pump inoperative. Repair or replace oil pump.
Clean, repair, or replace regulating
Regulating valve stuck open.
valve.
2-6
Page 10
October 2013
Check gauge and sending unit.

Oil pressure gauge inaccurate.
Replace if necessary.
Improper crankcase oil or diluted with Fill crankcase with specified crankcase
fuel. oil.
Oil pressure relief valve or regulator
Clean, repair, or replace affected parts.
valve stuck in open position.
Main or connecting rod bearing worn. Replace bearings.
Low oil pressure
with proper oil Insufficient oil in sump. Add oil.
level in crankcase
Broken relief valve spring Replace as needed.
Faulty suction pipe. Repair or replace as needed.
Choked oil filter. Replace oil filter.
Blocked sump strainer. Clean or replace as needed.
Camshaft bearings worn. Replace bearings.
Oil pump is worn. Repair or replace oil pump.
Check gauge and sending unit.
Oil pressure gauge inaccurate.
Replace if necessary.
Excessive oil
Oil pressure relief valve is sticking Clean, repair, or replace relief valve as
pressure
open. needed.
Improper crankcase oil. Fill crankcase with specified oil.
Overheating of Insufficient oil in crankcase. Fill crankcase to proper level.

lubricating oil Engine oil cooler clogged. Clean or replace the oil cooler.
External oil leakage (gaskets, etc.) Correct all external leaks.
Engine oil seals worn or damaged. Replace oil seals.
Engine oil diluted with fuel. Fill crankcase with specified oil.
Excessive oil Pistons, rings, or cylinder bores worn. Replace or repair affected parts.
consumption
Rings stuck in piston ring grooves. Clean ring grooves and replace rings.
Replace valve guides. Check related
Valve guides and seals worn.
parts.
Plugged breather. Clean breather.
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TROUBLESHOOTING
Page 11
October 2013
Excessive oil Allow more time for break-in. Make

consumption certain specified crankcase oil is used
Rings not seated properly.
during first 250 and engine is at operating
hours of operation temperature.
and no signs of
improvement Pistons or cylinders scored. Check cylinder leakage.
Fill system with clean engine oil.

Crankcase oil is contaminated.
Rapid wear on Replace engine oil filter.
engine parts Improper engine lubrication oil is Fill system with crankcase oil of proper
being used. specifications.
Blocked fuel feed pipe. Clean out the pipe.
Choked fuel filter. Replace the fuel filter.
Air in the fuel system. Remove air from fuel system.
Faulty fuel injection pump. Repair or replace as needed.
Faulty or incorrect type of atomizers. Replace the atomizers.
Engine misfires timing. Correct the timing as needed.
Poor compression.
subheading.
Overheating. See Overheating below.
Incorrect tappet adjustment. Check and adjust tappets as needed.
Sticking valves. Service or replace parts as needed.
Incorrect high pressure pipes. Replace with correct pipes.
Pitted valves and seats. Replace the parts as needed.
Restriction in air cleaner induction
Remove the restriction(s).
system.
Incorrect valve timing. Time the valves correctly.
Poor compression
Check the tappets and time them
correctly.
2-6
Page 12
October 2013

Sticking valves.
needed.
Worn cylinder bores. Replace parts as needed.
Pitted valves and seats. Replace the parts as needed.
Poor compression
(Cont.)
ring(s). needed.
Worn valve stems and guides. Replace worn parts.
Incorrect piston height. Replace with correct pistons.
Broken valve spring. Replace broken parts.
Restriction in air cleaner or induction
Remove the restriction(s).
system.
Replace atomizers with the correct
Faulty or incorrect type of atomizers.
type.
Incorrect valve timing or fuel pump Check valve and fuel pump timing.
timing. Correct timing as needed.
Exhaust pipe restriction. Clean out the exhaust pipe.
Overheating Cylinder head gasket is leaking. Replace gasket.

Service, repair, or replace the parts as
needed.
Faulty thermostat. Replace the thermostat.
Restriction in water jacket. Remove the restriction.
Loose fan belt. Tighten fan belt properly.
Drain, flush and refill with proper fluid
Choked radiator.
mixture.
Faulty water pump. Repair or replace as needed.
Coolant level is too low. Fill to proper level.
Excessive
Worn cylinder bores. Replace parts as needed.
crankcase
pressure Broken, worn, or sticking piston Service, repair, or replace parts as
ring(s). needed.
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TROUBLESHOOTING
Page 13
October 2013
Worn valve stems and guides. Replace worn parts.

Excessive Piston seizure or pickup.
needed.
crankcase
pressure (Cont.) Choked breather pipe. Clean out the pipe.
Fault in the exhauster or vacuum pipe
leaks.
Faulty stop control operation Operate the stop control correctly.
Blocked fuel feed pipe. Clear blockage from pipe.
Faulty fuel lift pump. Repair or replace the pump.
Choked fuel filter. Replace the filter.
Air in the fuel system. Remove air from fuel system.
Replace the atomizers with the correct
type.
Poor compression.
subheading.
Blocked fuel tank vent. Remove the blockage.
Engine runs
Sticking throttle or restricted Service, repair, or replace parts as
erratically
movement. needed.
Overheating. See symptom, Overheating, above.
Incorrect tappet adjustment. Correct the tappet adjustment.
Sticking valves.
needed.
Incorrect high pressure pipes. Replace with correct pipes.
ring(s). needed.
Over-full air cleaner or use of incorrect Replace the air cleaner. Drain oil and
grade of oil. replace with the proper grade of oil.
Service, repair or replace parts as
needed.
Broken valve spring. Replace with new spring.
2-6
Page 14
October 2013
Restriction in air cleaner. Replace the air cleaner.

Faulty fuel injection pump. Repair or replace the pump.
Replace the atomizers with the correct
type.
Incorrect valve timing or fuel pump Correct the timing of the valve and the
timing. fuel pump.
Poor compression
subheading.
Drain the tank and fill with the correct
Incorrect grade or type of fuel.
grade and type.
Sticking throttle or restricted Service, repair, or replace the parts as
Excessive fuel movement. needed.
consumption
Exhaust pipe restriction. Clean out exhaust pipe.
Incorrect tappet adjustment. Adjust tappets correctly.
Sticking valves.
needed.
Worn cylinder bores. Repair or replace worn parts.
Pitted valves and seats. Repair or replace worn parts.
ring(s). needed.
Repair or replace.
engines).
2-6
TROUBLESHOOTING
Page 15
October 2013
TABLE 2 - ENGINE AIR INTAKE SYSTEM
Inspect air cleaner, pipe, connection

hoses, gaskets, etc., thoroughly for
Dirt being admitted with intake air. cracks or openings which would allow
air to enter without passing through the
Rapid wear on air cleaner. Make necessary repairs.
engine parts Drain fuel tank and fill with proper fuel.
It is important that fuel be within the
Improper fuel being used. specified limits or ash, carbon sulfur,
etc., to prevent excessive wear on
engine parts.
Insufficient air
Air cleaner clogged. Replace air filter.
supply to cylinders
TABLE 3 - ENGINE COOLING SYSTEM
Check gauge and sending unit if

Temperature gauge inoperative.
necessary.
Radiator air passages restricted. Clean exterior of radiator.
Thermostat inoperative. Replace thermostat.
Loose or broken fan belts. Adjust or replace fan belts.
Engine operating Lime deposits in water passages of
temperature too radiator, cylinder head or cylinder Thoroughly clean affected areas.
high with ample block.
coolant in system
Coolant passage in oil cooler
Remove and clean oil cooler core.
restricted.
Water pump inoperative. Replace water pump.
Engine pulling excessive load. Reduce load.
Adjust speed to within specified rpm
Engine speed set too high.
limits.
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Page 16
October 2013
TABLE 3 - ENGINE COOLING SYSTEM (CONT.)
External leaks. Repair affected parts.

Ruptured oil cooler core (coolant in Replace oil cooler core. Replace
Engine operating oil). engine oil and filter.
temperature too
Replace gasket and torque cylinder
high due to loss of Engine cylinder gasket leaking.
head bolts as specified.
coolant
Engine cylinder head cracked. Replace cylinder head.
Engine cylinder block cracked. Replace cylinder block.
Engine operating Thermostat stuck in open position. Replace thermostat.

temperature too Provide covers for radiator and engine
low Operating in extremely cold weather.
side openings.
TABLE 4 - ENGINE FUEL SYSTEM
Fill fuel tank with specified fuel. Prime

No fuel in fuel tank.
fuel systems.
Fuel pump diaphragm spring is weak. Replace spring.
Fitting loose or cracked. Tighten fittings or replace.
Clean fuel system components replace
Fuel lines and fuel filter clogged.
fuel filter.
Fuel pump screen clogged. Clean pump screen.
Fuel line cracked or broken. Replace fuel line.
Low fuel pump
pressure Faulty injectors tip assemblies. Replace faulty injectors.
Temperature less than 6 C (10 F) Refer to fuel specifications for the
above pour point of fuel. recommended grade of fuel.
If valve is adequate, clean and inspect
Relief valve not seating.
the valve seat assembly.
Replace the gear and shaft assembly
Worn gears or pump body.
or pump body.
Check the condition of the fuel pump
Fuel pump not rotating.
drive and replace defective parts.
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TROUBLESHOOTING
Page 17
October 2013
TABLE 4 - ENGINE FUEL SYSTEM (CONT.)
High fuel pump Diaphragm spring too strong or

Replace spring.
pressure improper spring.
Fuel filter clogged. Replace filter.
Low fuel pump Injector pump inlet line obstructed, or
Locate problem and correct.
volume with leaks.
normal pressure
Restriction in fuel supply line to fuel
Replace fuel line.
pump.
Fuel pump leaks Diaphragm defective. Fittings loose. Replace diaphragm. Tighten fittings.
Fuel pump retaining bolts loose. Tighten bolts.
Fuel pump leaks oil
Mounting gasket defective. Replace gasket.
Clean the spray tip as outlined under
Spray tip or orifices partially plugged.
Clean Injector Parts.
Replace the needle valve and spray tip
Spray tip orifices enlarges.
assembly.
Refer to the engine manufacturers
Carbon build-up in spray tip.
service manual.
Replace the plunger and bushing with
Worn plunger and bushing.
a new assembly.
Worn or damaged needle valve quill.
assembly.
Worn or damaged needle valve spring
Replace the spring seat.
Incorrect injector seat.
output Worn or broken valve spring. Replace the valve spring.
Cracked check valve cage, spring
Replace the cracked parts.
cage or spray tip.
Improperly lapped surfaces. Lap the sealing surfaces.
Foreign material between valve and Disassembly the injector and clean all
seat. of the parts.
Assembly the gear with the drill spot
Rack and gear not in time. mark on the tooth engaged between
the two marked teeth on the rack.
Replace the spray tip and the plunger
Spray tip-plunger and bushing
and bushing assembly to provide the
combination provides incorrect output.
correct output.
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Page 18
October 2013
TABLE 4 - ENGINE FUEL SYSTEM (CONT.)
Poor bushing to body fit. Lap the injector body.

Tighten the injector nut to 95-108 Nm
Injector nut not tightened to specified
(70-80 lbf-ft.) torque. Do not exceed
torque.
specified torque.
Excessive plunger to bushing
Replace the plunger and bushing.
clearance.
Cracked spray tip.
assembly.
Insufficient injector Worn or eroded needle valve or valve Replace the needle valve and spray tip
holding time seat. assembly.
Worn or broken needle quill.
assembly.
Worn or broken valve spring. Replace the valve spring.
Worn or damaged valve spring seat. Replace the valve spring seat.
Defective seal ring. Replace the seal ring.
Disassembly the injector and clean all
Dirt or foreign material in injector.
of the parts.
Worn or eroded needle valve or valve Replace the needle valve and spray tip
seat in spray tip. assembly.
Worn or damaged needle valve quill.
assembly.
Low valve opening
Worn or damaged needle valve spring
pressure Replace the spring seat.
seat.
Worn or broken valve spring. Replace the valve spring.
Disassembly the injector and clean all
Dirt or foreign material in injector.
of the parts.
Remove the carbon in the spray tip
with tip reamer J9464-01 which is
Carbon or foreign material in spray tip.
especially designed and ground for this
High valve opening purpose.
pressure
Check the size of the spray tip orifices.
Carbon in spray tip orifices. Then using tool J4298-1 with the
proper size wire, clean orifices.
2-6
TROUBLESHOOTING
Page 19
October 2013
TABLE 5 - TRANSMISSION GEAR BOX
Insufficient or excessive lubricating oil. Adjust oil level.

Contaminated oil. Flush interior and fill with new oil.
Change oil with one with the proper
Gear box is Improper oil viscosity.
viscosity.
overheating
Bearings improperly mounted. Reassemble and tighten properly.
Shaft improperly connected. Align properly,
Air vent port closed. Remove rubber plug from oil cap.
Bearings damaged or worn. Replace bearings.
Insufficient oil. Adjust oil level.
Oil seal not wet with oil. Lubricate.
Excessive noise
Improper installation or connection. Adjust.
Bearings improperly mounted. Reassemble and tighten properly.
Gear teeth worn. Replace wheel.
Excessive
Bearings damaged or worn. Replace bearings.
vibration
Mounting bolts loose. Tighten bolts.
Wheel improperly aligned. Replace wheel.
Input and output Teeth seizure. Replace worm and wheel.
shafts do not rotate
at all Bearings damaged or worn. Replace bearings.
Wheel teeth worn. Replace wheel.

Input shaft rotates Wheel boss or shaft key damaged. Replace wheel and key.
but output shaft
does not rotate Input shaft or worm teeth damaged. Replace shaft and worm.
Input shaft broken. Replace shaft.
Insufficient oil. Adjust oil level.
Teeth worn
Change oil with one with the proper
Improper oil viscosity.
viscosity.
2-6
Page 20
October 2013
TABLE 5 - TRANSMISSION GEAR BOX (CONT.)
Improper connection. Replace case, and reassemble.

Body cracks Changing direction of travel without
Replace case, and reassemble.
completely stopping.
Improper connection. Replace case, and reassemble.
Shaft broken Changing direction of travel without
Replace case, and reassemble.
completely stopping.
Oil seal defective. Replace oil seal.
Cover mounting bolts loose. Tighten bolts.
Oil leaks Excessive oil. Adjust oil level.
Gear case cavities or fissures. Replace case.
Improper installation. Reassemble and adjust.
TABLE 6 - AXLES
Check level; fill with correct grade and

Incorrect lubricant, or level too low.
type of lubricant.
Wheel bearings scored or damaged. Replace bearings.
Wheel bearings improperly adjusted. Adjust bearings.
Noise Gear teeth excessively worn or

Replace gear.
damaged.
Planetary gears or ring gear teeth
Replace gears or ring.
worn.
Bushings in planetary gears worn or
Replace gear shafts and bearings.
broken.
Lubricant level too high. Drain excess.
Lubricant foams excessively. Drain and refill.
Lubricant leaks at planetary hub
Oil leaks Tighten cap screws or replace gasket.
cover.
Worn or broken oil seal on axle
spindle housing (oil leak from behind Replace oil seal.
wheel into brake compartment).
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TROUBLESHOOTING
Page 21
October 2013
TABLE 6 - AXLES (CONT.)
Worn or broken drive axle shaft oil

seal between axle and spindle (oil Replace oil seal.
level in differential rises)
Oil leaks (Cont.)
Worn drive pinion oil seal. Replace oil seal.
Scored or worn differential drive yoke. Replace yoke.
Incorrect lubricant, or level.
type of lubricant.
Pinion or ring gear bearing worn. Replace bearing.
Differential
overheats Pinion or ring gear teeth excessively
Replace.
worn or damaged.
Replace with a new matched pinion
Unmatched pinion and ring gear.
and ring gear.
Worn planet or side gears. Replace.
Axle U-joints worn or damaged. Lubricate or replace.
Noise when turning Insufficient limited slip additive in gear Replace gear oil or add limited slip
oil. additive.
Insufficient lubrication in king pins. Lubricate king pin bearings.
Incorrect lubricant or level too low.
type of lubricant.
Noise when driving
Pinion and ring gear adjustment too
Adjust to proper torque.
tight.
Pinion or ring gear bearings damaged. Replace
Noise when
coasting Pinion and ring gear adjustment too
Adjust to proper torque.
loose.
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Page 22
October 2013
TABLE 7 - DRIVE SHAFT
Check grease seals in slip joints and

Lack of lubricant.
universal.
Backlash due to worn universal spider
Noise Replace.
or bearings.
Mounting yokes loose. Tighten mounting bolts.
Worn splines in drive shaft slip joints. Replace drive shaft.
Drive shaft sprung or bent. Replace shaft.
Universal joint bearings not seated
Vibration Correct or replace.
properly.
Mounting yokes loose. Tighten mounting bolts.
TABLE 8 - HYDRAULICS (STEERING)
Low hydraulic fluid level. Add fluid.

Worn or malfunctioning pump. Replace pump.
Adjust system pressure as
Improper pump pressure.
recommended in specification section.
Slow steering, hard Worn pump compensator allowing the
steering, or loss of system pressure to be less that Replace pump and compensator.
power assist specified.
Malfunctioning steering valve. Inspect and repair or replace.
Malfunctioning relief valve allowing
the system pressure to be less than Replace the relief valve.
specified.
Air in the system due to low level of Correct problem causing air to get into
oil, cavitating pump, leaky fitting, system, add hydraulic fluid and bleed
Vehicle wanders, pinched hose, etc. system.
will not stay in a Worn mechanical linkage. Repair or replace.
straight line
Bending of linkage or cylinder rod. Repair or replace.
Loose cylinder pitch. Repair or replace.
2-6
TROUBLESHOOTING
Page 23
October 2013
TABLE 8 - HYDRAULICS (STEERING) (CONT.)
Leaky anti-cavitation valve or

Repair or replace the accessory valve.
Vehicle wanders, crossover relief valve in cylinder lines.
will not stay in a
Severe wear in steering control unit. Replace the steering control unit.
straight line (Cont.)
Vehicle drifts or Single rod end cylinder slowly extends A small rate of extension may be
veers slowly in one without turning the wheel normal on a closed center system.
direction Worn or damaged steering linkage. Replace linkage and align front end.
Slip: a slow Leakage of cylinder position seals or

movement of accessory valve between cylinder Replace cylinders or accessory valve.
steering wheel fails lines of ports.
to cause any
Worn steering control unit meter. Replace steering control unit.
movement of
steered wheels Malfunctioning steering valve. Inspect and repair or replace.
Temporary hard
Check unit for proper operation and
steering or hang- Thermal shock.
cause of thermal shock.
up
NOTE: FORCED STEERING DURING THERMAL SHOCK CONDITIONS
MAY DAMAGE STEERING VALVE.
NOTE: THERMAL SHOCK IS A CONDITION CAUSED WHEN THE HYDRAULIC SYSTEM IS
OPERATED FOR SOME TIME WITHOUT TURNING THE STEERING WHEEL SO THAT
FLUID IN THE RESERVOIR AND SYSTEM IS HOT AND THE STEERING CONTROL UNIT
IS RELATIVELY COOL (MORE THAN 28 C [50 F] TEMPERATURE DIFFERENTIAL).
WHEN THE STEERING WHEEL IS TURNED QUICKLY, THE RESULT IS TEMPORARY
SEIZURE AND POSSIBLE DAMAGE TO INTERNAL PARTS OF THE STEERING
CONTROL UNIT. THE TEMPORARY SEIZURE MAY BE FOLLOWED BY TOTAL FREE-
WHEELING.
Low level of oil. Check oil level and refill if needed.
Check oil level and bleed air out of
Cavitating pump.
system.
Air in system. Bleed air out of system.
Erratic steering Loose cylinder piston. Replace cylinder.

Hydraulic lines or fittings leaking. Check for leaks and repair.
Thermal shock damage. Replace steering control unit.
Sticking flow control spool. Replace flow control valve.
2-6
Page 24
October 2013
Bleed air out of system. Placing ports

Spongy or soft Air in hydraulic system. Most likely air
on top of the cylinder will help prevent
steering trapped in cylinders or lines.
air trapping.
Steering column upper shaft is loose
Tighten steering wheel nut.
or damaged.
Lower splines of column be
Free wheeling: Repair or replace column.
disengaged or broken.
steering wheel
turns freely with no Steering control unit meter has a lack
feeling of pressure of oil. This can happen on start-up Usually starting engine will cure
and no steered after repair, or after long periods of no problem.
wheels use.
No flow to steering caused by low fluid
Add fluid, replace hose, or replace the
level, ruptured hose or internal
unit.
steering control damage.
Free wheeling: Leaking crossover relief valve. Repair or replace the valve.
steering wheel
turns with slight
resistance, but Determine cause. Correct and replace
result is little or no Piston seal blown out.
seal.
steered wheel
action
Loose steering wheel nut. Steering
column shaft worn or damaged. Repair or replace steering wheel
There should be very little free play in connection or column.
the unit itself.
Excessive free play
at steering wheel Check for loose fitting bearings and
Broken or worn linkage between
anchor points in steering linkage
cylinder and steering wheels.
between cylinder and steered wheels.
Leaky cylinder seals. Replace cylinder seals.
Binding or misalignment in steering Align column pilot and spline to
column or splined input connection. steering control unit.
High back pressure in tank line can
cause slow return to center. Should Revise circuit return line.
Binding or poor
not exceed 300 psi.
centering of
steering wheel Clean the unit and filter the oil. If
another component has failed,
Large particles can cause binding
generating contaminants, flush the
between the spool and sleeve.
system while bypassing the steering
control unit.
2-6
TROUBLESHOOTING
Page 25
October 2013
Large particles in meter section. Clean the unit.

Steering unit locks
Scored worn or broken pin. Replace the unit.
up
Thermal shock. Replace the unit.
Steering wheel Parts assembled wrong. Steering unit

Correct timing.
oscillates or turns improperly timed.
by itself Lines connected to wrong ports. Reconnect lines correctly.
Steering wheels
turn in wrong
Lines connected to wrong cylinder
direction when Reconnect lines correctly.
ports.
operator activates
steering wheel
Steering wheel
No inlet check valve on steering
kicks at start of Install a check valve.
control unit.
steering
TABLE 9 - HYDRAULICS (PUMPS)
Defective pump. Replace.

Worn cylinders. Replace cylinders.
Internal crack. Replace valve assembly.
Poor steering
system Reservoir low on oil. Fill tank.
performance or
System filters clogged. Remove and discard old filters.
failure
Replace filter elements and clean
Restriction in lines.
reservoir.
Pressure too low. Check pump for proper pressure.
Excessive oil Improper type or viscosity oil. Refill with proper grade specification.
foaming Restriction in pump suction line. Check line for kinks or blockage.
Excessive oil
Incorrect viscosity or type of oil. Refill with proper grade specification.
temperature
2-6
Page 26
October 2013
TABLE 9 - HYDRAULICS (PUMPS) (CONT.)
Lint-worn, frayed or damaged cylinder

Replace cylinder packing.
Foreign material in packing.
reservoir screen Chip-worn pump or damage in
Replace parts.
cylinders.
Insufficient Worn pump components causing
Rebuild pump.
pressure build-up internal leakage.
Shaft sheared. Replace parts.
Reservoir-to-pump intake pipe Check strainer for foreign material.
Pump does not restricted. Clean if necessary.
deliver fluid
Fluid viscosity too heavy. Replace fluid with correct viscosity.
Worn pump gears. Replace.
Low oil supply. Fill tank.
Cavitation in hydraulic pump. Clear obstruction to pump oil supply.
Air in pump oil supply. Bleed air from hydraulic system.
Drain hydraulic system and refill with
Pump making Excessive fluid foaming.
proper type and viscosity fluid.
noise
Excessive pump speeds. Adjust engine governed speeds.
High engine speeds with cold
Warm-up period required.
hydraulic oil.
Hydraulic oil viscosity too high. Replace oil with correct viscosity.
Loss of charge or overcharge. Check charge pressure reset.
Slow reaction, Unloading valve or pump low pressure
Adjust to higher pressure.
accumulator set too low.
Relief valve set too low or stuck open. Reset or clean valve.
Viscosity of oil or pour point too high at
start-up conditions. Change to oil with
Sluggish operation during warm-up lower viscosity or better viscosity index
period. and lower pour point. An immersion
heater placed in the oil may help under
Erratic action, severe cold conditions.
steering cylinder
Check for gum or dirt deposit. Check
oil quality and clarity. Check for air in
Valves sticking or binding. system. Check for worn or damaged
parts. Excessive wear may be due to
oil contamination or degradation.
2-6
TROUBLESHOOTING
Page 27
October 2013
Check for dirt, gummy deposits, or air

leaks as above. Check for
Cylinder sticking or binding.
misalignment, worn parts, defective
packing, or body deformation.
Bleed air and check for leaks. Check
to see that oil intake is well below
surface of oil in reservoir. Check pump
packing and line connections on intake
Erratic action,
side by pouring hydraulic oil over or
steering cylinder Air in system.
pressing suspected leak. If noise
(Cont.)
stops, the leak has been located.
Tighten joints or change packing (or
gaskets) where necessary. Oil spilling
into reservoir: correct piping.
Repair or replace worn parts and loose
packing. Check oil to see that
Internal leakage in cylinder.
viscosity is not too low. Check for
excessive contamination or wear.
Replace cylinder piston seals. Check
Will not hold
Piston seal leak rod out. by plugging rod end port; load rod end
cylinder
out.
Plugged cartridge. Replace cartridge.
Partial bypass continuous. Correct filter size and oil viscosity.
Dirty oil filter Check particle size and switch to

Improper micron rating.
proper size rating.
Correct maintenance procedure or add
Improper changes.
bypass indicator.
Remove downstream restriction or
Broken filter Too much pressure. change to corresponding higher
housing pressure or flow rated filter.
Too much mechanical shock. Add shock absorbing material.
Contaminants in the hydraulic oil Install adequate filter or replace oil
being circulated through the system. filter more often.
Excessive wear in
Viscosity of oil too low at working Check pump manufacturer for
hydraulic system
conditions. Oil lacks additives. minimum viscosity recommendations.
Pump and motor misalignment. Check and correct.
2-6
Page 28
October 2013
Sustained high pressure above

Reduce system pressure to minimum
continuous maximum pump rating or
Excessive wear in required for satisfactory operation.
higher than system requirements.
hydraulic system
(Cont.) Air recirculation causing erratic Remove air from system. Correct
operation in system and accelerated causes: return line not submerged,
wear. leaky suction lines, etc.
Valve installed backwards or free flow
Flow stoppage at Correct installation.
arrow has incorrect direction.
check valves
Parts broken. Disassembly and check.
Valve too small. Change valve.
Incorrect pressure
drop, check valves Incorrect spring (in the case of pilot
Correct.
pressure relief).
Fails to hold Change seat to correct seat type or

Seat is damaged (shock).
pressure, check eliminate cause of damage.
valves Seat is hydra-eroded. Change to larger size.
TABLE 10 - HYDRAULICS (AERIAL DEVICE)
Loss of hydraulic
Main hydraulic pump failure.
power
Loss of aerial
Motor failure.
device rotation
Boom raise relief valve failure.

Unable to lift boom
Boom cylinder failure.
Holding valve leakage.
Emergency lowering needle valve

Boom creeps down
leakage.
Internal boom cylinder leakage.
Boom will not

Boom lowering relief valve.
lower
2-6
TROUBLESHOOTING
Page 29
October 2013
TABLE 10 - HYDRAULICS (AERIAL DEVICE) (CONT.)
Boom moves from Boom circuit fuse

manually actuated
Joystick trigger switch not depressed
solenoid valves,
but not from basket Boom relief valve malfunction
Loss of all aerial

Dump valve malfunction
device operation
Incorrect pressure flow settings

Failure of any
Hydraulic motor failure
deicing fluid drive
Valve solenoid coil malfunction
TABLE 11 - PNEUMATIC BRAKES
Cylinder head gasket failure. Overhaul compressor cylinder head.

Pipe lines blocked. Remove blockage.
Heavy leak in circuit between
Check lines and all joints. Replace
compressor and system protection
hose assembly.
Air pressure not valve.
building up in both Heavy leak through compressor or air
gauges Repair or replace assembly.
filter top cover.
Heavy leak through reservoir weld
Repair or replace assembly.
joint or drain valve.
Heavy external leak from valve
assembly.
Cylinder head gasket failure. Overhaul compressor cylinder head.
Pipe lines blocked. Remove blockage.
Delay in building
up system air Leak in circuit between compressor Check lines and all joints. Replace
pressure and system protection valve. hose assembly.
Leak through compressor or air filter
top cover.
2-6
Page 30
October 2013
TABLE 11 - PNEUMATIC BRAKES (CONT.)
Delay in building Leak through reservoir weld joint or

up system air drain valve.
pressure (Cont.) External leak from valve assembly. Repair or replace assembly.
System protection valve not
Repair or replace valve.
functioning.
Air pressure not
building in one Dual brake valve, or relay valve
Repair or replace defective valves.
gauge only leaking.
Air gauge defective. Repair air gauge.
System protection valve leaking. Repair or replace valve.
Spring brake actuators leaking. Repair or replace actuators.
Pressure drops Repair or replace defective
Hose, pipes, and fittings leaking.
when vehicle is connections and components.
parked
Dual brake valve, or relay valve
Repair or replace defective valves.
leaking.
Foot control valve leaking. Repair or replace valve.
Spring brake O-rings or gaskets defective. Replace o-rings and gaskets.

actuators leaking Diaphragm leaking. Replace diaphragm.
Slack adjusters too loose. Adjust slackers.
Excessive clearance between drum
Reduce clearance.
Brake binding and brake lining.
No free play between brake pedal and Increase clearance between brake
valve. pedal and valve.
Excessive clearance between drum
Reduce clearance.
and brake lining.
Poor braking
Valve not working properly. Repair or replace valve.
Low system pressure. Adjust and rectify system air pressure.
Vehicle pulling to Wrong shaft in slack adjuster. Repair or replace assembly.

one side while Brake chamber and spring brake
braking Repair or replace assembly.
actuators defective.
Low pressure Low pressure switch defective. Replace low pressure switch.
warning system
not working Circuit wiring open or defective. Correct defective circuit.
2-6
TROUBLESHOOTING
Page 31
October 2013
TABLE 11 - PNEUMATIC BRAKES (CONT.)
Stop lamp bulb defective or burned. Replace bulb.

Stop light not
Stop light switch defective. Replace switch.
working
Circuit wiring open or defective. Correct defective circuit.
Compressor coupling gear loose. Repair or replace.
Crankshaft bearing damage. Replace bearings.
Noise from
compressor Excess carbon deposit at piston top or
Remove carbon deposits.
delivery valve.
Damage or excess wear of gear tooth. Repair or replace assembly.
Pedal kickback
Drain line too restricted to release Remove restriction in the line or
when brakes are
volume of oil quickly. increase drain line size.
released
Parking brakes do
not immobilize Park brake pack out of adjustment. Adjust brake pack.
vehicle
TABLE 12 - ELECTRICAL
Batteries discharged. Test battery and charge or replace.

Poor electrical connections. Clean and tighten.
Defective starter switch. Repair or replace starter.
Loose motor ground connections. Clean and tighten broken wiring.
Check alternator operation and tension
Starting motor Alternator not charging.
on drive belt.
failure
Check regulator adjustments.
High electrolyte temperature. Alternator voltage must not exceed
27.5 volts.
Fill all cells with distilled water so
Electrolyte level low. plates are adequately covered. Do not
overfill.
2-6
Page 32
October 2013
TABLE 12 - ELECTRICAL (CONT.)
Flush all cells affected with clear

water. Refill cells with electrolyte
Contaminated electrolyte.
adjusted to 1.35 specific gravity, and
charge battery.
Remove batteries from vehicle and
Battery discharged Infrequent usage.
place on slow charge.
Keep battery tops clean. Remove
Dirt and acid deposits on battery case,
deposits with ammonia or sodium
allowing current to flow between
bicarbonate solution, then rinse with
terminals.
clean water.
Tape abraded area. Look for cause of
abrasion, and either pad the surface,
Abraded insulation.
pad the wires, or secure wires with
clamps or ties.
Splice or replace wires to maintain
Broken wires.
continuity.
Defective lights
Bulb burned out. Replace.
Correct short circuit or replace
Wire short-circuited.
selective parts.
Defective switch. Replace.
Loose or dirty wiring connections. Clean and tighten.
Loose terminal at meter, alternator,
Voltage Tighten connections.
battery, or in operating circuit.
fluctuations
Defective alternator. Check alternator. Repair or replace.
Dirt accumulations in alternator. Remove dirt with compressed air.
Brushes worn. Replace if less that 3/16 inch long.
Low alternator Loose ground connection. Clean connection and tighten.
output
Adjust to proper tension. Replace
Loose drive belt.
belts that can not be properly adjusted.
Defective regulator. Replace unit.
2-6
TROUBLESHOOTING
Page 33
October 2013
TABLE 12 - ELECTRICAL (CONT.)
Battery connection corroded or

Clean and tighten or replace.
broken.
Starter motor does Excessively worn brushes. Replace when half of original length.
not engage Starter switch defective. Replace.
Corrected reading must be above
Low electrolyte specific gravity.
1.230 at 27 C (80 F).
TABLE 13 - FLUID HEATER MODULE
Blower not running Flow control valves improperly

Adjust or replace flow control valves.
at right speed adjusted or defective.
during stage 2 and
3 burn Pump or motors damaged. Repair or replace pump and motors.
Defective bulb. Replace bulb.

Heater enable
Fluid temperature is above 82 C
GREEN light does Inspect tank temperature switch.
(180 F).
not illuminate when
heater is started Tank temperature 82 C (180 F)
Adjust or replace temperature switch.
switch misadjusted or inoperative.
Heater enable
GREEN light stays
on, but flame
WHITE light never
illuminates
Flame WHITE light Check JBT AeroTech EHC (Electronic Heater Controller) read-out display for
illuminates for fault codes when there is a heater problem.
approximately five
seconds then goes
out
Heater runs but is

slow to heat
2-6
Page 34
October 2013
TABLE 14 - DRIVERS CAB AND ENCLOSED BASKET
Wiper restricted by ice or other

obstruction.
Windshield wiper
inoperative Wiper motor failure.
Circuit fuse burned.
Washer restricted by ice or other

obstruction.
Windshield washer
inoperative Washer motor failure.
Circuit fuse burned.
2-6
TROUBLESHOOTING
Page 35
October 2013
6. TEMPEST DIAGNOSTIC ALARMS
NOTE: THE FOLLOWING ALARMS ARE ONLY AVAILABLE ON MACHINES EQUIPPED WITH
THE TEMPEST DIAGNOSTICS OPTION.
TEMPEST DIAGNOSTIC ALARMS

De
Sche-
Alarm Input bounce
matic Failure Action
Description Signals Rung*
Time
(sec.)
E-Pump Activated for
more than 1 second.
This alarm will be data
Alarm 001:
logged only.
Emergency Create screen to view data.
19 ON > 10 sec.
Pump On Too 19, 39 156* Access screen through Main
(# times)
Long Menu.
19 ON > 30 sec.
Tier 2 Only
(# times)
19 ON > 60 sec.
(# times)
Alarm 001:
Not used
Tier 3 Only
Alarm 002: Contact JBT AeroTech
Fire Suppression
Fire 159*, customer service for
23B System has deployed 2
Suppression 532 instructions on replacing
or has malfunctioned.
Activated system and repair of deicer.
Alarm 003 to
Not used
Alarm 004:
1. Check fuse 2CP-2 in the
Alarm 005: main panel.
473*, Blown Fuse on Air
Air Dryer 2CP-2 27, 115 2. Check the Operation of 2
1367 Dryer Detected
Fuse Fault the Air Dryer for the
Brakes.
1. Check relay 28CR and
Alarm 006: 702*, Oil Cooler Relay Coil replace if damaged.
27, 301
Oil Cooler 1602- or Contact 2. Verify proper operation of 2
302
Relay Failure 1604 has Failed. cooling fans 9MTR and
10MTR.
702*, Blown Fuse on Oil
Oil Cooler Fuse 27, 300 2. Check the Operation of 2
1602 Cooler Detected
Failure the Oil Cooler fans 9MTR
and 10MTR.
Alarm 008: Blown Fuse on main panel.
734*,
ESPAR Heater 2, 327B Enclosed Basket 2. Check the Operation of 2
1660
Fuse Blown Heater the Enclosed Basket
Heater.
2-6
Page 36
October 2013
TEMPEST DIAGNOSTIC ALARMS (CONT.)
De
Sche-
Alarm Input bounce
Time
(sec.)
Alarm 009: 1. Check fuse 2CP-8 in the

main panel.
Propel 1203*, Blown Fuse on Sauer
27, 500 2. Check for fault codes on 2
Controller Fuse 2403 Propel controller
the propel controller SDB
Blown in the engine panel.
Alarm 010: 502A, 1. Check signal from

1206*, Forward Propel footpedal 1PED.
Forward Drive 505, 517, 2
2406 inoperative 2. Check Sauer drive board
Inoperative 531D, 39 for fault codes.
Alarm 011:
Check Magnetic pickup
Magnetic Pick- 19, 27
1213* Magnetic Pickup Error signal, wire #504 when 2
Up Error 504
engine is running.
Tier 2 Only
Alarm 011:
Not used
Tier 3 Only
Alarm 012: Pressure switch 4PS-A may
10, 531, 1269*, Brake Pressure Switch
Brake Pressure have failed or wiring has 2
532 2469 Fault
Switch Fault become compromised.
Alarm 013 to
Not used
Alarm 020:
603*, Blown Fuse on Tank 2. Check the Heater
Heater Fuse 27, 200 2
1503 Heater System Controller (EHC) and
Blown 2CP-4 associated wiring for
shorts.
Check Heater Controller
Alarm 022: (EHC) for displayed non-
609*,
Service Heater 22 Service Heater Soon critical fault code. Refer to 2
1509
Soon manual for repair
instructions.
Check Heater Controller
Alarm 023: 617*, Deicer Tank Heater (EHC) for displayed critical
247 2
Heater Misfire 1517 Misfire fault code. Refer to manual
for repair instructions.
Alarm 024 to
Not used
Alarm 030:
Alarm 031: 347*,
Deice Pump 78, 227 618*, Heater flow switch Check flow switch 2FLS and
5
Flow Switch 89A 812, 2FLS error associated wiring.
Error 1518
2-6
TROUBLESHOOTING
Page 37
October 2013
De
Sche-
Alarm Input bounce
Time
(sec.)
Alarm 032:
363*,
Anti-Ice Tank 86A Anti-ice Tank empty Refill Anti-ice tank. 5
948
Empty
Alarm 033:
374*,
Deice Tank 89A Deice Tank empty Refill Deice tank 5
970
Empty
Alarm 034: left arm pod.
Fluid Spray 310, 1142*, Blown fuse on Spray 2. Check spray joystick 2
Control Fuse 488A 2310 controls 3JOY and associated
Blown wiring inside right arm
pod.
Alarm 035 to
Not used
Alarm 040:
Check wiring in boom
Alarm 041: 397, 401
903*, Basket enable valve circuitry and components
Basket Joystick 404, 411 2
1912 failed to engage 30CR, 10TD, 31CR and
Enable Fault 507
32CR.
Basket enable valve
Alarm 042: Check wiring in boom
401, 411 906*, failed to engage when
Cab Joystick circuitry and components 2
397 1934 operated from truck
Enable Failure 31CR, 10TD and 32CR.
cab.
Do not use deicer. Check for
19, 401A 910*,
Alarm 043: shorts in wiring or relays in
411, 917*, Boom Enable Valve
Boom Enabled boom circuit welded shut. 2
474A 1918, On at the wrong time.
in Travel Mode Check for Stuck or
516 1934
Overridden 30SOL.
Instruct operators to use
Alarm 044:
deicer only with safety
Door or 914*, Door not closed or
404 interlocks activated. Check 1
Seatbelt Not 1928 seat belt not engaged.
door switch and seat belt
Engaged
switch for correct operation.
Check for correct operation
941*,
Alarm 045: of boom in range proximity
427, 976*, Boom in range, boom
Boom in Range, 2PRS, relay 33CR-A or 2
427A 2064, centered fault
Centered Fault adjustment for operation of
2069
4LS boom centered switch.
2-6
Page 38
October 2013
De
Sche-
Alarm Input bounce
Time
(sec.)
1. Check fuse 2CP-7 in
Alarm 046: main panel
Boom Sensors 13, 415, 941*, Blown fuse on boom 2. Check for shorted wiring 2
Fuse Blown 39 2002 sensors on boom harnesses.
2CP-7 3. Check for shorted boom
sensors.
Alarm 047: 455,
944*, Boom fast speed Check relay 34CR or
Boom Speed 463A, 10
2005 inoperative proximity switch 3PRS.
Failure 397
Alarm 048: 465A,
953*, Rotator fast speed Check relay 37CR or
Rotator Speed 469A, 15
Failure 397
Alarm 049: 438,
958*, Jib fast speed Check relay 39CR or
Jib Speed 440A, 5
Failure 397
1. Boom weight limit
exceeded, remove
Alarm 050: 970*, excess weight.
426 Boom Overloaded 2
Boom Overload 2059 2. Check operation and
adjustment of pressure
switch BOL-PS.
Alarm 051: Check adjustment for
415, 427 973*, Boom centered switch
Boom Center operation of 4LS boom 2
516 2064 fault
Switch Fault centered switch.
1. Check fuse 4CP-14 in left
arm pod.
Alarm 052: 2. Check for shorted wiring
on boom harnesses or
Valve Cards 1001*, Blown fuse on boom wiring in left arm pod.
27, 429 2
Fuse Blow 2101 valve drive cards
3. Check for shorted valve
2CP-14 drive cards.
4. Check for shorted boom
valves.
Check voltage between
Alarm 053:
440, 404, 1019*, Jib Command Out Of wires 440 and 444.
Jib Command 2
397, 39 2119 Range Acceptable range is 1 to 4
Out Of Range
volts.
440,
Alarm 54: Jib Valve Card 1VC
440A, 1024*, Check Jib valve drive card
Jib Valve Card Failed, No Output with 2
404, 397, 2124 1VC in left arm pod.
1VC Failed Input
39
2-6
TROUBLESHOOTING
Page 39
October 2013
De
Sche-
Alarm Input bounce
Time
(sec.)
458A,
Alarm 055:
463A, Boom Valve Card 3VC
Boom Valve 1048*, Check boom valve drive card
404, 397, Failed, No Output with 2
Card 3VC 2148 3VC in left arm pod.
39, 507, Input
Failed
472J
Alarm 056: 458A, Check voltage between
Boom 404, 397, 1048*, Boom Command Out wires 458A and 462.
2
Command Out 39, 2148 Of Range Acceptable range is 1 to 4
Of Range 507,472J volts.
Alarm 057: 468A, Check voltage between
Rotator 404, 397, 1063*, Rotator Command Out wires 468A and 462.
2
Command Out 39, 2163 Of Range Acceptable range is 1 to 4
Of Range 507,472J volts.
468A,
Alarm 058:
469A, Rotator Valve Card
Rotator Valve 1066*, Check rotator valve drive
404, 397, 4VC Failed, No Output 2
Card 4VC 2166 card 4VC in left arm pod.
39, with Input
Failed
507,472J
Alarm 059:
1111*, Knuckle has run out of Reported instance of knuckle
Knuckle Auto- 472J 0.5
2230 level out of level.
Leveling Mode
Basket auto-level
Alarm 060: Check master-slave leveling
1112*, mode was unable to
Jib Failed to 472J and auto-level systems for 5
2231 correct basket level in
Correct proper operation.
specified time limit.
1115*, 1. Check boom in rest
Alarm 061: sensor 1PRS.
472K, 1244*, Boom stowed Sensor
Boom Stowed 2
516 2237, failure 2. Check basket parked
Sensor Failure sensor 12PRS.
2445
Alarm 062: Take deicer out of service
1123*, Basket lower valve
Basket Lower 476 and check operation of 6
2251 stuck on.
Valve Failure 31SOL from 53RS.
Take deicer out of service
Alarm 063:
1124*, Basket raise valve and check operation of
Basket Failed to 477 6
2254 stuck on. 33SOL from 53RS and
Raise
CLU-CR (auto level mode).
Check voltage between
Alarm 064: Enclosed Basket
481, 413, 1133*, wires 481 and 483.
Basket Rotate Rotate Command Out 2
39 2263 Acceptable range is 1 to 4
Range Failure Of Range
volts.
2-6
Page 40
October 2013
De
Sche-
Alarm Input bounce
Time
(sec.)
Alarm 065:
474A, Enclosed Basket Check Enclosed Basket
Enclosed 1133*,
481, 413, Rotate Command rotate valve drive card 5VC 2
Basket Rotation 2263
39 Signal Fault in right arm pod.
Fault
Alarm 066:
Jib Movement 440, 1024*, Un-commanded jib
and check operation of 1VC 2
Without 440A 2124 movement
and associated wiring.
Command
Alarm 067:
Boom 458A, 1048*, Un-commanded boom
Movement 463A 2148 movement
Without CMD
Alarm 068:
Rotator 468A, 1067*, Un-commanded
Movement 469A 2167 rotator movement
Without CMD
Alarm 069 to
Not used
Alarm 078:
1. Ensure that PLC2 has
Alarm 079: power and is running.
CAN 2. Check that the CAN Bus
connection is made.
Communication 1
Loss PLC2 3. With power turned off,
measure CAN Bus with
Tier 2 Only digital ohmmeter and
measure 60 ohm.
1. Ensure that PLC2 has
Alarm 079: power and is running.
CAN 2. Check that the CAN Bus
connection is made.
Communication 1
Loss PLC9 3. With power turned off,
measure CAN Bus with
Tier 3 Only digital ohmmeter and
measure 60 ohm.
Alarm 080: Service deicer batteries
103*, Battery voltage critical;
Battery Voltage 2, 15 immediately and verify 2
403 below 20 VDC
Critical Low charging of alternator.
Alarm 081:
103*, Battery voltage below Service deicer batteries and
Battery Voltage 2, 15 5
403 22 VDC verify charging of alternator.
Very Low
2-6
TROUBLESHOOTING
Page 41
October 2013
De
Sche-
Alarm Input bounce
Time
(sec.)
Alarm 082:
Check fuse 4FU and
5CON / 4FU 130*, 5CON or 4FU
10, 27 contactor 5CON in the 2
Input 427 inoperative
engine panel.
Disagreement
Alarm 083:
Check fuse 5FU and
11, 14A contactor 2CON in the 2
engine panel.
Disagreement
Alarm 084:
Check fuse 6FU and
27, 310 contactor 3CON in the 2
engine panel.
Disagreement
Alarm 085:
20, 25 136*, 4CR-A or fuse 5CP-7 Check fuse 5CP-7 and relay
4CR-A Input 2
23B 433 inoperative 4CR-A in the engine panel.
Disagreement
1. Check alternator
Alarm 086: 2. Check hydraulic fluid
level
Engine 157*, Engine has failed to
19B, 39 3. Check hydraulic oil 2
Shutdown 462 run
temperature
Warning
4. Check fault codes in
engine panel
Alarm 087: Reported instance of
164*, E-stop has been
Emergency 13, 20 emergency shutdown of 1
467 activated
Stop Activated deicer.
1. Check alternator
Alarm 088: 2. Check 1CR in engine
175*, Engine has failed to
Engine Starting 15, 39 panel 10
509 start
Failure 3. Check fault codes in
engine panel
Alarm 089: 223*, Engine controller fault Check fault codes in engine
31E 10
Engine Fault 550 code reported panel
170*, 1. Check alternator
Alarm 090:
19, 27 225*, 2. Check 1CR in engine
Alternator Alternator failure 10
39 410, panel
Failure
606
Alarm 091:
235*, Hydraulic tank low
Hydraulic Low 45, 25 Check hydraulic fluid level 2
620 level shutdown
Level
Alarm 092:
239*, Hydraulic tank high Check hydraulic oil
Hydraulic High 46, 25 2
625 temperature shutdown temperature
Temperature
2-6
Page 42
October 2013
De
Sche-
Alarm Input bounce
Time
(sec.)
1. Check diesel fuel tank
Alarm 093: 256*, level.
52, 25 Fuel tank low level 2
Low Fuel 647 2. Check operation of fuel
level sensor 1FS.
Alarm 094: Not used
left arm pod.
Alarm 095:
ELKHART 832*, Blown fuse on Elkhart 2. Check for motor or gear
310, 387 failures on Elkhart 2
Nozzle Fuse 1846 nozzle controller monitor.
4CP-12 3. Check for 12VDC output
of DC-DC converter.
1. Check relay AC-CR,
1517*, AC-TD and 6CP-2 fuse in
the AirFirst panel.
Alarm 096: 1525 -
Air compressor valve 2. Check valve drive card
Air Compressor 807, 813 37*, 8VC in the AirFirst panel.
2
failed to activate.
Valve Failure 3330,
3. Check resistors 23R, 24R
3355 and 25R in the AirFirst
panel.
1. Check AirFirst lube oil
Alarm 097: filter
AirFirst Lube AirFirst lube system 2. Check for lube tank high
822 1547* temperature
2
Failure failure
Tier 2 Only 3. Check operation of lube
flow switch
Alarm 097 to
Alarm 099: Not used
Tier 3 Only
Alarm 098: 1. Check fuse 6CP-4 in
Lube Tank AirFirst panel
Blown fuse on lube
Relay and Fuse 834, 837 1566* 2. Check relay HT-CR in 2
heater or relay fault AirFirst panel
Fault
Tier 2 Only
Alarm 099: 1. Check fuse 6CP-5 in
Lube Tank Fuse 10, 838, Blown fuse on lube AirFirst panel
1570* 2
and Relay Fault 839 pump or relay fault 2. Check relay LP-CR in
Tier 2 Only AirFirst panel
Alarm 100: Not used
* References to Tier 2 schematics. All other references for Tier 3 engines.
2-6
TROUBLESHOOTING
Page 43
October 2013
TEMPEST XR BOOM ALARMS
De
Sche-
Alarm Input bounce
Time
(sec.)
Alarm 101 to
Not used
Alarm 102:
Alarm 103: 1. Check the status of PLC-

PLC-1 Health check 1
PLC1 Health I0105 3452 5
signal is false 2. Check the wiring between
Check Fault PLC1(13) and PLC1(29).
Alarm 104: Not used
Alarm 105: 1. Check the Feedback
Boom Pos. The boom position Connector.
I0100 3442 5
Sensor Open signal is open 2. Check the wiring of input
Circuit I0100 at PLC1(08).

Boom Pos. The boom position Connector.
I0100 3442 2. Check the wiring of input 5
Sensor Short signal is shorted

Telescope Pos. Telescope position Connector.
I0101 3444 5
Sensor Open signal is open 2. Check the wiring of input

Telescope Pos. Telescope position Connector.
I0101 3444 2. Check the wiring of input 5
Sensor Short signal is shorted

Joystick 458A, 3430, Joystick position signal Connector.
1
Position Open I0102 3446 is open 2. Check the wiring of input

Joystick 458A, 3430, Joystick position signal Connector.
1
Position Short I0102 3446 is shorted 2. Check the wiring of input
Alarm 111: 1. Check if PRS7 is being

PRS7 flagged.
Telescope 420, 2023, PRS7 telescope 2. Check the wiring PRS7.
2
Retracted I0115 3464 retract failed on 3. Replace as necessary.
Detected Failed
On
Alarm 112 to
Not used
Alarm 115:
2-6
Page 44
October 2013
TEMPEST BLENDUP ALARMS
De
Sche-
Alarm Input bounce
Time
(sec.)
Alarm 116:
968, The Premix tank is
Premix Tank is 88, I0314 Refill the Premix tank. 5
2765 empty
Empty
Alarm 117:
86B, 957, The Pure tank is
Pure Tank is Refill the Pure tank. 5
I0315 2765 empty
Empty
Alarm 118: 1. Check the status of

PLC-3 Health check PLC3.
signal is false 2. Check the wiring between
Check Fault PLC3(13) and PLC3(20).
1. Check the wiring of the

Alarm 119:
digitizer.
Telescope Pos. Premix digitizer signal
I0101 2. Check for flow from 5
Sensor Open present fault 62SOL.
Circuit
3. Replace as necessary.

Alarm 120:
digitizer.
Telescope Pos. Pure digitizer signal
I0101 2. Check for flow from 1
Sensor Short present fault 64SOL.
Circuit
3. Replace as necessary.
Alarm 121 to
Not used
Alarm 123:

Alarm 124: Premix digitizer does digitizer.
Premix Pump Q0301, not produce signal
2805 2. Check for flow from 10
No Flow 758C when the pump is 64SOL.
Detected commanded 3. Replace as necessary.

Pure digitizer does not digitizer.
Alarm 125:
Q0300, produce signal when
Pure Pump No 2803 2. Check for flow from 10
758B the pump is 62SOL.
Flow Detected
commanded 3. Replace if necessary.
Q0300, 1. Re-calibrate the Premix

Alarm 126: pump.
758B, 2803, The mix ratio is
blendUP Ratio 10
Q0301, 2805 detected being too rich 2. Re-calibrate the Pure
Too Rich Fault pump.
758C
Q0300, 1. Re-calibrate the Premix

Alarm 127: The mix ratio is pump.
758B, 2803,
blendUP Ratio detected being too 10
Q0301, 2805 2. Re-calibrate the Pure
Too Lean Fault lean pump.
758C
2-6
TROUBLESHOOTING
Page 45
October 2013
TEMPEST BLENDUP ALARMS (CONT.)
De
Sche-
Alarm Input bounce
Time
(sec.)
Alarm 128: 1. Check the wiring to

Premix Pump Q0301, Premix pump coil 62SOL.
15
Coil Open 758C open circuit 2. Check the wiring at
Circuit PLC3(45).

Premix Pump Q0301, Premix pump coil 62SOL.
15
Coil Short 758C short circuit 2. Check the wiring at
Circuit PLC3(45).

Q0300, Pure pump coil open 64SOL.
Pure Pump Coil 15
758B circuit 2. Check the wiring at
Open Circuit PLC3(44).

Q0300, Pure pump coil short 64SOL.
Pure Pump Coil 15
758B circuit 2. Check the wiring at
Short Circuit PLC3(44).
Alarm 132: PLC1 Extended 1. Check the CAN wiring at

PLC1 Loss of Reach is not PLC1.
1
Communication communicating over 2. Check that PLC1 is
s the CAN Bus operational.
Telemetry freeze point

Alarm 133:
from Remote Blend Contact the Iceman to
RBC Out of 1
Control (RBC) is out of update the freeze point.
Range
range
Alarm 134 to
Not used
Alarm 150:
2-6
Page 46
October 2013
TEMPEST MONITOR POINT ALARMS
De
Sche-
Alarm Input bounce
Time
(sec.)
The control system has 1. With power off, check for
Alarm 151: detected a loss of CAN 60 ohm between terminals
3522, CH1 and CL1.
PDM6 Loss of CH1, CL1 communication 2
3525 2. Check wiring and power
Communications between cab PDM6
supplies.
and PLC5
3516, CH1 and CL1.
PDM7 Loss of CH1, CL2 communication 2
3518 2. Check wiring and power
Communications between cab PDM7
supplies.
and PLC5
Alarm 153: 60 ohm between terminals
detected a loss of CAN
Heater 3509, CH2 and CL2.
CH2, CL2 communication 2
Controller Lost 3512 2. Check wiring and power
between cab ECH and
Communications supplies.
PLC5
Alarm 154: 60 ohm between terminals
detected a loss of CAN
blendUP Control 3516, CH1 and CL1.
CH1, CL1 communication 2
Lost 3518 2. Check wiring and power
between cab PLC3 and
Communications supplies.
PLC5
3537, CH3 and CL3.
Telemetry Lost CH3, CL3 communication 2
3540
Communications between cab Telemetry 2. Check wiring and power
supplies.
and PLC5
The control system has 1. Check PLC5s status light

Alarm 156: and ensure that it is
detected that PLC5s flashing green.
health check bit has
Check Failed 2. Check PLC5 wiring and
failed off power.
The control system has 1. Check the wiring, power
Alarm 157: and installation for the
I0503, 3547, detected that the
Refractometer refractometer. 5
910 3647 refractometer sensor
Circuit Open 2. Replace if necessary.
has failed open
Alarm 158: and installation for the
I0503, 3547, detected that the
Refractometer refractometer. 5
910 3647 refractometer sensor
Circuit Short 2. Replace if necessary.
has failed shorted
Alarm 159: and installation for Diesel
I0507, detected that the Diesel
Diesel Monitor 3556 fuel level sensor. 5
25P fuel level sensor has
Circuit Open 2. Replace as necessary.
failed open
2-6
TROUBLESHOOTING
Page 47
October 2013
TEMPEST MONITOR POINT ALARMS (CONT.)
De
Sche-
Alarm Input bounce
Time
(sec.)
Alarm 160: and installation for Diesel
I0507, detected that the Diesel
Diesel Monitor 3556 fuel level sensor. 5
25P fuel level sensor has
Circuit Short 2. Replace as necessary.
failed short
Alarm 161: and installation for RTD
detected that the
Premix Tank I0504, #1.
3550 Premix tank 5
Temp.Circuit 25P 2. Replace as necessary.
temperature sensor has
Open
failed open
detected that the
Premix Tank I0504, #1.
3550 Premix tank 5
Temp.Circuit 25P 2. Replace as necessary.
temperature sensor has
Short
failed short
I0505, detected that the spray
Nozzle Temper. 3552 #2. 5
25P nozzle temperature
sensor has failed open
I0505, detected that the spray
Nozzle Temper. 3552 #2. 5
25P nozzle temperature
Circuit Short
sensor has failed short 2. Replace as necessary.
I0506, detected that the Pure
Pure Tank Temp 3556 #3. 5
25P tank temperature
sensor has failed open
I0506, detected that the Pure
Pure Tank Temp 3556 #3. 5
25P tank temperature
Circuit Short 2. Replace as necessary.
sensor has failed short
Alarm 167 to
Not used
Alarm 169:
The control system has 1. Select value within range.
detected that the 2. Call JBT Field Service.
Alarm 170:
Outside Air
O.A.T. Selection 5
Temperature (O.A.T.)
Out of Range
selected either <15% or
>55% ratio
Alarm 171 to
Not used
Alarm 180:
2-6
Page 48
October 2013
7. ELECTRONIC CONTROLLERS
A. FAULT CODES
Description of BLINK code algorithm
Type 1: If there is no application loaded into the controller, the LED's will blink as in 1 under
TYPE in the table below.
Type 2: If the application software is loaded into the controller and there is no error, the
LED's will blink as in 2 under TYPE in the table below. This is the normal
condition of the controller.
Type 3: If the application software is loaded into the controller and there is an error (system
fault), the LED's will blink as in TYPE 3 in the table.
ELECTRONIC CONTROLLER FAULT TYPES
YELLOW LED
TYPE RED LED (MODE) SYSTEM STATUS
(MODE)
1 10 Hz blink rate OFF No application loaded
Application loaded,
2 1 Hz blink rate OFF
no controller error
4-bit blink code Application loaded,

3 1 Hz blink rate
for error type controller error
NOTE: A 1 HZ BLINK RATE = 1 FLASH PER SECOND.
The system fault can be decoded by deciphering a four bit code flashed by the red (status) LED.
The following describes the diagnostic procedure for TYPE 3 errors:
A long flash of ~1 second is a high bit ()

A short flash of ~0.5 second is a low bit ()
An off state of ~0.5 second separates the four flashes.
After the fourth bit is displayed, a pause of 34 seconds separates the next series of four
bit codes.
When more than one fault is detected, each fault will be displayed in sequence before the
first fault code is repeated.
2-6
TROUBLESHOOTING
Page 49
October 2013
ELECTRONIC CONTROLLER FAULT CODES
FAULT CODES
Fault Flash Bit Device Machine

Cause of Fault
Code Sequence At Fault Response
Voltage signal out of range Wire

#502 voltage:
Vehicle will not drive
0.250.75 VDC, throttle pedal
1 Cab Foot Pedal in deice mode from
relaxed
cab
depressed
Voltage signal out of range

Wire #503 voltage: Vehicle will not drive
2 Brake Pedal 0.250.75 VDC, brake pedal relaxed in travel mode from
3.754.75 VDC, brake pedal cab
depressed
Both Forward and Reverse signals Vehicle will not move

at once in deice or travel
3 F-N-R switch
Wires #517 and #518 24.028.0 mode from cab or
VDC basket
Frequency <= 250 Hz.

Wires #504 disconnected or Pulse Vehicle will not drive
4 Engine PPU
Pickup Unit (PPU) speed sensor in travel mode
faulty
Current commanded does not equal

the measured value
5 Pump Coil in deice or travel
Wires #505 or #506 disconnected or
mode
coils faulty
Voltage signal out of range

Wire #502B voltage:
6 Basket Pedal in deice mode from
relaxed
basket
depressed
2-6
Page 50
October 2013
B. STEERING CONTROLLER FAULT CODES
Description of BLINK code algorithm
Type 1: If there is no application loaded into the controller, the LED's will blink as in 1 under
TYPE 1 in the table below.
Type 2: If the application software is loaded into the controller and there is no error, the
LED's will blink as in 2 under TYPE in the table below. This is the normal
condition of the controller.
Type 3: If the application software is loaded into the controller and there is an error (system
fault), the LED's will blink as in TYPE 3 in the table.
STEERING CONTROLLER FAULT TYPES
YELLOW LED
TYPE RED LED (MODE) SYSTEM STATUS
(MODE)
1 10 Hz blink rate OFF No application loaded
Application loaded,
2 1 Hz blink rate OFF
no controller error
4-bit blink code to Application loaded,

3 0.5 Hz blink rate
describe fault controller error
The system fault can be decoded by deciphering a four bit code flashed by the red (status) LED.
The following describes the diagnostic procedure for TYPE 3 errors:
A long flash of ~1 second is a high bit ()

A short flash of ~0.5 second is a low bit ()
An off state of ~0.5 second separates the four flashes.
After the fourth bit is displayed, a pause of 34 seconds separates the next series of four
bit codes.
When more than one fault is detected, each fault will be displayed in sequence before the
first fault code is repeated.
2-6
TROUBLESHOOTING
Page 51
October 2013
STEERING CONTROLLER FAULT CODES
FAULT CODES
Fault Flash Bit Device Machine

Cause Of Fault
Code Sequence At Fault Response
Command
1
POT3
Command
2
POT2
Command Voltage signal out of range or input is

3 un-calibrated.
Angle
4 Offset Proportional
Derivative (PD) loop
5 Feedback POT3 disabled. JOG
switches still work.
6 Feedback POT2
Feedback
7 Voltage signal out of range.
Sensor
Voltage signal out of range or input is

8 Feedback Angle
un-calibrated.
9 Valve Not calibrated.
Output is disabled
10 Valve Output Open Circuit. until controller is re-
powered.
2-6
Page 52
October 2013
1. GENERAL INFORMATION
The schematics contained in this section are provided as a guide to assist technical service personnel in
troubleshooting operational malfunctions in the Tempest hydraulic and electrical systems. These
schematics should be used in conjunction with the troubleshooting, reference designators, and
maintenance procedures sections incorporated in this manual.
A. BEFORE TROUBLESHOOTING
Before starting troubleshooting procedures, verify that the correct operating procedures were
used. An incorrect operating procedure can cause apparent malfunctions.
Make sure all circuit breakers and fuses have continuity. Inspect all electrical connections and
suspected defective parts to verify that there are no open circuits, or defective grounding.
B. HYDRAULIC SYSTEM CLEANLINESS
A very important practice to observe when working on the hydraulic system is cleanliness.
Serious damage can result quickly from foreign material (contamination) in the hydraulic system.
When a hydraulic system is opened, cap or plug all ports and openings to keep foreign material
and moisture laden air (contamination) from entering the system. DO NOT use Teflon tape or
pipe compound on straight threads.
2-7
SYSTEM SCHEMATICS
Page 1
March 2014
2. ELECTRICAL SCHEMATICS
NOTE: THIS SECTION MAY NOT CONTAIN ALL SCHEMATICS LISTED. REFER TO THE
PRODUCT SPECIFICATION AT THE FRONT OF THE MANUAL FOR THE APPLICABLE
SCHEMATICS FOR YOUR EQUIPMENT.
TEMPEST ELECTRICAL SCHEMATICS
Schematic
Operators Engine Fluid System / Other Options
Number
Open Basket Configurations
Cummins QSB EU / N.A. Deicing, Prop-mix, Basket

One / Two 521-0809 A
4.5 Tier 3 Proximity, Fluid Meter, XR Boom
Cummins QSB EU / N.A. Deicing, Prop-mix, 3-pump (EU

One / Two 521-0810 C
4.5 Tier 3 2-pump), Basket Proximity, Fluid Meter
EU / N.A. Deicing, Prop-mix (IQ), Basket

Cummins QSB
One / Two Proximity, Boom Telescope, Tank High-level 521-1008 B
4.5 Tier 3
Alarm, XR Boom
Prop-mix, 2-pump, No EHC, EU Heater

Cummins QSB
One / Two Pump, Basket Proximity, Boom Telescope, 521-1010 A
4.5 Tier 3
Tank High-level Alarm, XR Boom
Cummins QSB
One / Two Prop-mix, 4-pump 521-1011 B
4.5 Tier 3
Enclosed Basket Configurations
EU / N.A. Deicing, Prop-mix, Elkhart Nozzle

Cummins QSB
One / Two Controller, Basket Proximity, CCTV, Fluid 521-0903 A
4.5 Tier 3
Meter, XR Boom
N.A. Deicing, Pre-mix, Prop-mix, 3-pump,

Cummins QSB
One / Two Elkhart Nozzle Controller, Basket Proximity, 521-0904 A
4.5 Tier 3
CCTV, Fluid Meter, XR Boom
Prop-mix (IQ), 4-pump, Elkhart Nozzle

Cummins QSB Controller, Basket Proximity, Boom
One / Two 521-1009 A
4.5 Tier 3 Telescope, CCTV, Tank High-level Alarm,
XR Boom
Cummins QSB AirFirst, Akron Nozzle Controller, Basket

One / Two 521-1105 D
6.7 Tier 3 Proximity, CCTV, Fluid Meter, XR Boom
2-7
SYSTEM SCHEMATICS
Page 3
March 2014
TEMPEST ELECTRICAL SCHEMATICS (CONT.)
Schematic
Number
AirFirst, Akron Nozzle Controller, 3-pump,

Cummins QSB
One / Two Basket Proximity, CCTV, Fluid Meter, 521-1106 A
6.7 Tier 3
XR Boom
Cummins QSB Prop-mix, AirFirst, Akron Nozzle Controller,

One / Two 521-1107 B
6.7 Tier 3 Basket Proximity, CCTV, XR Boom
Cummins QSB
One / Two AirFirst, CCTV, Fluid Meter, XR Boom 521-1108 -
6.7 Tier 3
Cummins QSB
One / Two EU Deicing, 3-pump, AirFirst, XR Boom 521-1109 -
6.7 Tier 3
Cummins QSB AirFirst, Akron Nozzle Controller, Basket

One / Two 521-1201 -
6.7 Tier 3 Proximity, CCTV, blendUP, XR Boom
Open / Enclosed Basket Configurations
Cummins QSB
6.7 Tier 3 AirFirst, Akron Nozzle Controller, Basket
One / Two 521-1210 C
Mercedes OM Proximity, CCTV, blendUP, XR Boom
906 LA 6.4 Tier 3
Cummins QSB
6.7 Tier 3 AirFirst, Akron Nozzle Controller, Basket
One / Two 521-1211 C
Mercedes OM Proximity, CCTV, blendUP, XR Boom
906 LA 6.4 Tier 3
Electrical Option Schematics
NOTE: OPTION SCHEMATICS ARE PART OF A CUSTOM OPTION. COMPONENTS CAN BE

LOCATED IN THE ILLUSTRATED PARTS LIST CHAPTER OF THE MANUAL.
2-7
Page 4
March 2014
3. HYDRAULIC SCHEMATICS
TEMPEST HYDRAULIC SCHEMATICS
Schematic
Number
One / Two All All 624-6461 V
Hydraulic Option Schematics

2-7
SYSTEM SCHEMATICS
Page 5
March 2014
8 7 6 5 4 3 2 1
CHANGES ITEM
NO
PART NUMBER PER
ASSY DESCRIPTION CHANGES ITEM
NO
PART NUMBER PER
ASSY DESCRIPTION
NOTES: F 61 102-1858 1 ADPTR,M16X2 X -4MNPT 1 624-3936 1 RESERVOIR, HYDRAULIC-ASSY
F 62 624-5077 1 RESERVOIR, HYDRAULIC-ASSY RK 2 627-7023 1 PUMP, PISTON 80CC
H 63 625-9254 1 BREATHER, HYD. RESERVOIR 3 623-9484 1 VALVE, ASSY
1. ALL PRESSURE SETTINGS ARE 25 PSI, UNLESS OTHERWISE SPECIFIED.
J 64 627-0121 1 VALVE,P O CHECK 4 623-0907 1 VALVE ASSY-BOOM
L 65 627-3283 1 CYLINDER,BOOM EXTENSION P 5 620-2565 1 GAUGE, PRESSURE
2. ALL FLOW SETTINGS ARE 1 GPM, UNLESS OTHERWISE SPECIFIED. R 66 620-3481 1 VALVE,PRESS.COMP FLOW CONTROL A 6 622-4457 1 MOTOR, HYDRAULIC-ASSY
R 67 627-7223 1 VALVE, 2 POS, 3 WAY 7 624-3148 1 VALVE, ASSY
D 3. ALL RPM SETTINGS ARE 25 RPM UNLESS OTHERWISE SPECIFIED. S 68 627-8461 1 MANIFOLD,ASSY NO HEATER 8 623-2121 3 MOTOR, HYDRAULIC-ASSY D
S 69 627-7975 1 CYLINDER,BOOM W/SNSR 9 620-8433 2 MOTOR, HYDRAULIC-ASSY
4. PRESSURES AND FLOWS ARE STATED IN UNITS OF PSI (POUNDS PER SQUARE S 70 627-7976 1 CYLINDER,BOOM EXTENSION W/SNSR 10 620-0460 1 FILTER, IN-TANK RETURN
INCH) & GPM (U.S. GALLONS PER MINUTE). S 71 627-8654 2 MOTOR,HYD 100CC 11 620-0461 2 ELEMENT, FILTER
S 72 102-1819 2 ADPTR,M16X2 X -4MORB 12 624-5069 1 CYLINDER, MASTER, LEVELING
TO CONVERT PSI TO "BAR",DIVIDE PSI BY 14.5.
S 73 622-5831 1 MOTOR,HYD 41CC 13 624-5070 1 CYLINDER, SLAVE, LEVELING
TO CONVERT TO kPa (KILOPASCAL), MULTIPLY PSI BY 6.895. S 74 623-9687 1 GAGE,SIGHT W/LEVEL SWITCH 14 519-2076 1 MANIFOLD, RETURN
S 75 514-4745 1 SWITCH,TEMP NO 180F 15 623-5504 3 EXCHANGER, HEAT
TO CONVERT GPM TO LPM (LITRES PER MINUTE), MULTIPLY GPM BY 3.785.
S 76 620-7747 1 SWITCH,TEMP NO 140F G 16 624-9798 1 PUMP, EMERGENCY
S 77 625-9254 1 BREATHER 17 623-9744 1 MANIFOLD, MOTOR BYPASS
5. REFERENCE PRESSURES ARE SHOWN AT THE POINT OF APPLICATION, i.e. V 78 627-4366 1 CHECK VALVE, IN-LINE 18 620-1738 1 VALVE, PRESSURE REDUCING
A SPECIFIC FUNCTION. WHEN READING THIS PRESSURE, AT THE PRESSURE
V 79 628-2201 1 FLOW DIVIDER K 19 621-5556 1 FILTER, ASSY
GAUGE INSTALLED IN THE MANIFOLD ON THE LEFT REAR FENDER, THE LOAD
SENSING OR "STANDBY" PRESSURE MUST BE CONSIDERED. V 80 628-2232 1 POWER UNIT, 2.2KW K 20 621-5556-002 1 ELEMENT, FILTER
V 81 628-2234 1 VALVE, RELIEF 21 620-0128 3 VALVE, SHUTTLE
EXAMPLE, 2500 PSI REQUIRED, GAUGE WILL READ 2750 PSI.
V 82 627-9374 2 CHECK VALVE, IN-LINE 22 623-9483 1 PUMP, ASSY-PROPULSION
(ACTUAL PRESSURE+LOAD SENSE PRESSURE [250 PSI] = GAUGE READING).
V 83 3647013 1 VALVE, CHK MINTR #8FJIC 23 623-9482 1 MOTOR, ASSY-PROPULSION
V 24 623-5403 1 VALVE, STEERING-DUAL DISP.
25 623-0910 1 AH, VALVEPAC, LEVELING
G 26 623-9488-001 2 CYLINDER, STEERING
7 MAIN BOOM & JIB "RAISE" RELIEF VALVES TO BE SET W/LOAD: 27 620-0810 2 VALVE, NEEDLE
A. 450 LB FOR ENCLOSED CABIN TO MOTOR
28 624-3151 1 VALVE, ASSY
B. 675 LB FOR OPEN BASKET MANIFOLD "P"
SHT 2,4,5,6, G 29 625-3398 1 VALVEPAC, HANDPUMP
C 8. HYDRAULIC SYMBOLS ARE IN ACCORDANCE WITH DIN-ISO 1219 STANDARDS. 9,12,13 OR 14 30 624-5074 1 CYLINDER,JIB C
31 624-5065 1 CYLINDER, BOOM
32 624-3176 1 VALVE, ASSY
D 33 624-6439 1 MOTOR, HYDRAULIC-ASSY
D 34 624-6874 1 MANIFOLD, ASSY-1 MAN
OUTLET
35 624-5085-001 1 MANIFOLD ASSY-ENC. CAB
36 HG 36 625-9411 1 FILTER, HIGH PRESSURE
HIGH HG 37 625-9411-001 1 ELEMENT, FILTER
PRESSURE E 38 623-4763-001 1 PUMP, ASSY, AIR-FIRST
RETURN FROM FILTER 39 623-9352 1 MOTOR, ASSY, AIR-FIRST
MOTOR MANIFOLD,
PUMP MOTORS AND 37 40 623-6047 1 VALVE, RELIEF
BOOM MANIFOLD 41 623-8009 1 FILTER, MED. PRESSURE
INLET 1 ELEMENT, FILTER, MED. PRESSURE
TO MOTOR 42 623-8009-001
MANIFOLD "P2" 43 519-7954-001 1 FILTER, HIGH PRESSURE
SHT 2,4,5,6, 14
44 519-7954-009 1 ELEMENT, HIGH PRESS. FILTER
9,12,13 OR 14 FROM B
MOTOR 45 624-6870 1 MOTOR, HYDRAULIC, CAB ROTATE
15 MANIFOLD 46 623-2151 1 VALVE, ASSY, PROPORTIONAL
LS1 47 623-2119 1 VALVE, ASSY,
SHT 2,4,5,6, 160 HP ENGINE SPEED:
0-80cc DRIVE 1150-2200 RPM 48 624-4766 1 AE-SWITCH, PRESSURE
9,12,13 OR 14
DEICE 2200 RPM A 49 519-1777 1 VALVE, DUAL COUNTERBALANCE
EA 50 624-6248 2 MOTOR, HYDRAULIC
RETURN FROM GC 51 232-3419-206 2 VALVE, CHECK, IN-LINE
2500 AIRFIRST 260 HP ENGINE SPEED:
B PSI SHT7 1 DRIVE 1150 - 2200 RPM C 52 515-9570 1 VALVE, COUNTERBALANCE B
21 DEICE 1800 RPM D 53 624-9246 1 FILTER, HIGH PRESSURE
AUXILIARY 3 X D 54 624-9246-001 1 ELEMENT, FILTER, HIGH PRESSURE
AIRFIRST 2200 RPM
PUMP 10 2 D 55 624-6871 1 MANIFOLD ASSY-1 MAN & ENC. CAB
(OPTIONAL)
24 FROM H E 56 623-9483-002 1 ELEMENT, FILTER-REPLACEMENT
VDC 25
PSI TANK RETURN STEERING F 57 625-6135 1 CYLINDER,BOOM EXTENSION
EM FILTER VALVE 2
16 LS F 58 625-6314 1 A-VALVE,PROPORTIONAL
14 11 L S
SHT 11 F 59 625-6221 1 VALVE,DIRECTIONAL
STANDARD PUMP SETTINGS:
STANDBY: 350 10 PSI F 60 519-4173 1 MODULE,FLOW CONTROL
COMPENSATOR: 3200 PSI
V
12TAS 77
140 F
76
3FS
1TAS
180 F
75 1 OR 62 74
TANK, FILTERS & PUMPS
FIRST USED
CONFIDENTIAL PROPERTY
OF JOHN BEAN TECHNOLOGIES
CORP., NOT TO BE COPIED,
-
A USED, OR SHOWN TO OTHERS
WITHOUT WRITTEN AGREEMENT.
DO NOT SCALE DRAWING

UNLESS OTHERWISE SPECIFIED,
DIMENSIONS ARE IN INCH [MM].
TOLERANCES:
A
THIRD ANGLE PROJECTION X.XX = 0.06
JOHN BEAN TECHNOLOGIES CORPORATION X.XXX = 0.030
V ADDED WINTERIZATION OPTION 62031 TO 02/13
ORLANDO, FL, USA-ALCALA de HENARES, SPAIN ANGULAR = 2
U ADDED 3-PUMP EURO PROP MIX, LEV. PRESSURE CHG'D 60488 TO 9/11 TITLE MODEL:TEMPEST II
T ADDED NO-HEATER AND BLEND-UP OPTIONS 57886 CF DRAWN HEH
7/09 09/01
SHEET 1 OF 15
R ADDED INT. BLWR. SPEED/EURO PREMIX OPT. 57077 BH 03/09 CHKD CLF 09/01 COMPOSITE HYD SCHEMATIC-DEICER DRAWING SIZE: D
- PRODUCTION RELEASE 45126 BH 09/01 APVD JV 09/01
DWG NO.
MATERIAL: SEE PARTS LIST WEIGHT
REV DESCRIPTION ECN NO. BY DATE SCALE N/A COATING: N/A
LB: -
KG: -
624-6461
8 7 6 5 4 3 2 1 NX
8 7 6 5 4 3 2 1 100%
CAB BOOM
D LEVELING JIB ROTATION BOOM D
31SOL 32SOL 24SOL-A 23SOL-A 28SOL 27SOL 24SOL 23SOL
LWR RAISE LWR RAISE CCW CW LWR RAISE
2X 2X 2X
1000 2400 1000
LS 7 PSI PSI 7 PSI
NEEDLE P
VALVE
T
OPEN
1/8 TURN 27 4 A B A B A B A B
14
TO PORT LS2 LINE F LINE E
SHT 2,4,5,6,
9,12,13 OR 14 LINE H LINE G
48
53 V1 V2
V1 V2
C 54
LINE I
25
52 C
2003- 1000 9
2010 2950 PSI
PSI
T
BOOM ROTATE
1900 C1 C2
FROM PORT P1A MOTOR
PSI LINE B LINE A
SHT 2,4,5,6, 49cc 0-348 RPM
9,12,13 OR 14 C1 C2
ROTATE 180
35 5 SEC
38:1 GEAR BOX
110/14 GEAR
298.57:1 TOTAL RET EXT
GEAR REDUCTION
P
RET EX EXT EXT W/OPTIONAL
MASTER POSITION
P
CYLINDER SENSOR
69 U
3.00X1.75/18.00 OR G FULL STROKE
35 5 SEC
31
FULL STROKE 12 30 5.00X2.75/32.00
35 5 SEC
RET EX BOOM RAISE
JIB RAISE CYLINDER
B CYLINDER B
3.25X2.50/21.78
FULL STROKE
35 5 SEC G P
RET EX FROM CABIN OPTIONAL

ROTATE MOTOR MANUAL HAND
SLAVE CASE DRAIN PUMP
CYLINDER SHEET 11
3.00X1.75/18.00 29
T
FULL STROKE
35 5 SEC FROM ITEM 64
13 PORT "2"
SHEET 11
BOOM VALVE
FIRST USED
-

TOLERANCES:
A
TITLE MODEL:TEMPEST II
DRAWN HEH 09/01
SHEET 2 OF 15
V CHKD CLF 09/01
COMPOSITE HYD SCHEMATIC-DEICER
DRAWING SIZE: D
DWG NO.
LB: -
KG: -
624-6461
8 7 6 5 4 3 2 1 NX
8 7 6 5 4 3 2 1 100%
D 56
D
B N A
M5 M4
D E
38 39
SOL SOL
a b
FWD REV
M3
X4 M4 M3
A A M1
A A1
M1
L2
6325
PSI
C 350
6250
58-250cc C
PSI
PSI
160 HP ENGINE SPEED:
MAX
TRAVEL 1150 - 2200 RPM DISP
25.8cc
WORK 2200 RPM
6250
PSI
6325
PSI M2
0-100cc
B
41 L1
23 SOL
17
B
M2
B B1
M5
OPTIONAL
22 MOTOR BY-PASS
TOWING VALVE
LEGEND-PORT CONNECTIONS FOR PROPEL MOTOR:
L2 L1 S A,B...High Pressure Ports
L1,L2...Case Drain Ports
B M1...Gauge Port-System Pressure A
M2...Gauge Port-System Pressure B B
LEGEND-PORT CONNECTIONS FOR PROPEL PUMP: M3...Gauge Port-Servo Pressure
A,B...High Pressure Ports M4...Gauge Port-Servo Pressure
L1,L2...Case Drain Ports M5...PCOR Signal to Control
M1...Gauge Port-System Pressure A X4...PCOR Signal to Control
15
M2...Gauge Port-System Pressure B
M3...Gauge Port-Charge Pressure
M4...Gauge Port-Servo Pressure
M5...Gauge Port-Servo Pressure
19
5
PSI
20
PROPULSION
FIRST USED
-

TOLERANCES:
A
DRAWN HEH 09/01
SHEET 3 OF 15
V CHKD CLF 09/01 COMPOSITE HYD SCHEMATIC-DEICER DRAWING SIZE: D
DWG NO.
REV DESCRIPTION ECN NO. BY DATE SCALE N/A
COATING: N/A
LB: -
KG: -
624-6461
8 7 6 5 4 3 2 1 NX
8 7 6 5 4 3 2 1 42-43%
D A D
15 350
PSI
0.063
40 OUT ORIFICE
2.63 GPM 5600 RPM
43
30cc
44
IN
B
47 39
SOL
72 42
b a 41
INACTIVE PS FE MB
R T1 T2 FA FA1
-4
C -
C
??TAS
B
0.047 240 F
ORIFICE A
1.30 GPM
0.8 0.8
mm mm
260 HP ENGINE SPEED: 7400 RPM
TRAVEL 750 - 2450 RPM - B
19cc
DEICE 1800 RPM 5500
PSI
AIRFIRST 2200 RPM
2 AND 22
19.6cc ARE ADDITIONAL PUMPS
2.0
DRIVEN IN TANDEM FROM
0-90cc mm
THIS PUMP
-
6000 ??TAS
PSI 240 F
0.031
A ORIFICE B
0.57 GPM
7400 RPM
-
B 38
A
16cc B
-4
X1 X2 G MH S FS MA
72
ITEM 38 SPECIFICATIONS:
CHARGE PUMP FLOW...APPROX 10 GPM

CHARGE PUMP RELIEF SETTING...350 PSI
HIGH PRESSURE RELIEF VALVES...SET @ 5650 PSI
PRESSURE OVERRIDE...SET @ 5500 PSI
ITEM 38 LEGEND-PORT CONNECTIONS:
A ...High Pressure Port

B ...High Pressure Port
T1 ...Case Drain or Filling Ports
T2 ...Case Drain Port
MA ...Gauge Port-System Pressure A
MB ...Gauge Port-System Pressure B
- OPTIONAL -
R ...Case Vent Port
S ...Charge Suction Port
X1 ...Stroking Pressure Port
X2 ...Stroking Pressure Port
AIR FIRST
G ...Charge Pressure Gauge Port CONFIDENTIAL PROPERTY
FIRST USED
PS ...Control Pressure Gauge Port OF JOHN BEAN TECHNOLOGIES

-
A FA ...Filter Outlet
FA1...Filter Outlet (for Integral Filter Assy)
USED, OR SHOWN TO OTHERS

TOLERANCES:
A
FE ...Filter Inlet THIRD ANGLE PROJECTION X.XX = 0.06
FS ...Port from Filter to Suction Line (Cold Start) ORLANDO, FL, USA-ALCALA de HENARES, SPAIN ANGULAR = 2
MH ...Gauge Port-High Pressure
DRAWN HEH 09/01
SHEET 4 OF 15
DWG NO.
COATING: N/A
LB: -
KG: -
624-6461
8 7 6 5 4 3 2 1 NX
1 MAN 49 - 15%
8 7 15 - 7% 6 5 4 CABIN ROTATE 54 - 58% 3 2 1
OPTIONAL
TELESCOPIC BOOM
OPTIONAL
ONE MAN AND/OR ENCLOSED STEERING SYSTEM
CABIN OPERATION
D D
26 25
SOL SOL LEFT RIGHT
55 (BOTH ENC. CAB & ONE MAN OP.) (SHOWN)
2.00X1.06/13.25 2.00X1.06/13.25
a b OR
FULL
RETRACT EXTEND 35 (ONE MAN ONLY-PROPORTIONAL VALVING) 26 STROKE 26
TO ITEM 4 2.5 SEC
PORT "P" OR
P T B A
SEE SHEET 8 FROM (ENCLOSED CAB ONLY-PROPORTIONAL VALVING)
34
NEEDLE VALVE
LS 1 SHT 8
61 2
3
21
G
1000
58
PSI FOR ENCLOSED CAB ONE MAN OPERATION
P T B A CAB ROTATION STEERING
TO
MOTOR MANIFOLD "LS2" RIGHT LEFT RIGHT A B LEFT
A B
SHT 2,4,5,6,9,10
12,13 OR 14 33 34 43 44
14
SOL P T SOL SOL P T SOL
-8 -6
2 L R
C LINE D
LINE C 3
24 C
64 21
1
1450
2 PSI FOR USE WITH
1 ENCLOSED CAB
TO ITEM 29 AND ONE MAN
3
PORT "T" E DR R OPERATION
SEE SHEET 8 1450 OPTION
PSI
54 P P
53
P STEERING
T WHEEL
T
W/OPTIONAL
POSITION A B A B
1 70
.125 PSI SENSOR
FROM PORT "P1A" 1000 OR
SEE SHEET 2 1000
PSI 65
LINE J 0-100 RPM
PSI INPUT
FULL STROKE OR 14
35 5 SEC U LINE K P LS T
3.50X2.50/144.00 G 57
18
2 1 14
V1 V2
FROM
49 MOTOR MANIFOLD
B TO ITEM 30
PO CHECK PILOT PORT
FROM ITEM 29
PORT "P" "P1" 1650 B
SEE SHEET 8 SHT 2,4,5,6,9,10 PSI
SEE SHEET 8 SET @ 12,13 OR 14
1000 PSI 1 2
(TYP) 3
3
C1 C2 21
51 TO ITEM 21-
31.6cc SEE SHEET 1
OPTIONAL
BLEND-UP MOTORS B A
45
0-160
64 SOL RPM
P 100cc
FROM
P
FC1 PC1
M1
71
BLEND-UP
5-140 RPM
SET SPEED
W/O FLUID (DRY) STEERING AND OPTIONS
MOTOR MANIFOLD "4"
SHT 2,4,5,6,9,10, LS
12,13 OR 14 62 SOL CONFIDENTIAL PROPERTY
FIRST USED
SV1 OF JOHN BEAN TECHNOLOGIES
-
A M2 P 100cc 40-450 RPM

TOLERANCES:
A
SET SPEED THIRD ANGLE PROJECTION X.XX = 0.06
71 W/O FLUID (DRY) JOHN BEAN TECHNOLOGIES CORPORATION X.XXX = 0.030
FC2 PC2 46 DEICE ORLANDO, FL, USA-ALCALA de HENARES, SPAIN ANGULAR = 2
DRAWN HEH 09/01
SHEET 5 OF 15
14 - PRODUCTION RELEASE 45126 BH 09/01 APVD JV 09/01
DWG NO.
LB: -
KG: -
624-6461
8 7 6 5 4 3 2 1 NX
8 7 6 5 4 3 2 1 1% OFFERED
D D
DEICING DELIVERY
PUMP 80.3cc
B A 300/450 25 RPM
8
SPEEDS SET W/O DEICING FLUID (DRY)
FUEL PUMP 3.59cc

A B
6 2850 50 RPM
SET WET(WITH FUEL) DEICING
DELIVERY/REFILL
CIRCULATION
55 GPM 35 GPM
BLOWER 3.18cc 4SOL
-A 4SOL
50 FAST: 4500 25 RPM
MED: 3400 25 RPM
C SLOW: 2700 25 RPM 27 C
METERED
FLOW
FUEL PUMP
67 CONTROLLED
FLOW
3
2 66 16SOL
FAST 1
BLOWER
ENABLE INACTIVE INACTIVE 1750
50
15 PSI
SOL B
17SOL 18SOL
1
14 2
BLOWER BLOWER
RUN RUN 3
SLOW FAST 4
5
P
T
B FROM
AUXILIARY
G B
PUMP 3400
P2
SHT 1 PSI
P1 V
TO PRESSURE 14
REDUCING VALVE
"2" 30SOL
SHT 11
BOOM
ENABLE MOTOR MANIFOLD 32
P P1A LS1 LS2
FROM
NEEDLE
VALVE
FROM
HIGH
SHT 8
EURO 1-PUMP PRE MIX
PRESSURE
FILTER
TO
PUMP
DIAPHRAGM DEICING DELIVERY/CIRCULATION PUMP
"OUTLET" "X"
SHT 1 SHT 1
FIRST USED
-
A TO
WITHOUT WRITTEN AGREEMENT. UNLESS OTHERWISE SPECIFIED,
TOLERANCES:
A
FILTER DO NOT SCALE DRAWING
"INLET" JOHN BEAN TECHNOLOGIES CORPORATION X.XXX = 0.030
SHT 8 ORLANDO, FL, USA-ALCALA de HENARES, SPAIN ANGULAR = 2
DRAWN HEH 09/01
SHEET 6 OF 15
DWG NO.
LB: -
KG: -
624-6461
8 7 6 5 4 3 2 1 NX
8 7 6 5 4 3 2 1
V
OPTIONAL PROP MIX
WINTERIZATION
EXISTING EXISTING
MOTORS HYDRAULIC
LINES TO
D TANK D
B A
WATER HEATER
DELIVERY CIRCULATING
EXISTING
82 82 HYDRAULIC
HEATER LINES TO
CIRCULATING VALVE
PUMP 3.18cc
50 2800 50 RPM
SET WET (W/WATER & HYD OIL @ NORMAL OP. TEMP)
1800 PSI 1800 PSI
FUEL 124 BAR 124 BAR
PUMP 3.59cc
6 A B 2850 50 RPM
SET WET
WITH FUEL 79
BLOWER 3.18cc HEATER PROP MIX 1000 PSI
CIRCULATING ENABLE 69 BAR
FAST: 4500 25 RPM 78
50
MED: 3400 25 RPM 81
C SLOW: 2700 25 RPM 27 4SOL
-A 4SOL
83 C
METERED
FLOW FUEL PUMP
67 CONTROLLED 2875 RPM

FLOW
3 16SOL 1750
2 66 1500 80
PSI
FAST PSI
1
BLOWER INACTIVE
ENABLE
15SOL
B
64 SOL
17SOL 18SOL 1 80.3cc
M1 A B 0-450 25 RPM
2 SET SPEED
14 BLOWER BLOWER 8 W/O FLUID (DRY)
RUN 3 DEICE
RUN FC1 PC1
SLOW FAST 4 P
LS
62 SOL
P SV1
80.3cc
T A B 0-450 25 RPM
M2
SET SPEED
B FROM
AUXILIARY
G 46 FC2 PC2
8 WATER
W/O FLUID (DRY) B
PUMP 3400
P2
SHT 1 PSI
P1 V SEE SHEET 11
TO PRESSURE
REDUCING VALVE FOR OPTIONAL
"2" BLEND-UP MOTORS
30SOL
SHT 11
BOOM
P P1A LS1 LS2 14
FROM
EURO 3-PUMP PROP MIX
NEEDLE
VALVE
DIAPHRAGM DEICING DELIVERY PUMP
FROM
HIGH
SHT 8
DIAPHRAGM WATER DELIVERY PUMP
PRESSURE
FILTER
TO
PUMP
CENTRIFUGAL WATER CIRCULATING PUMP
"OUTLET" "X"
SHT 1 SHT 1
FIRST USED
-
A TO
TOLERANCES:
A
DRAWN HEH 09/01
SHEET 7 OF 15
DWG NO.
COATING: N/A
LB: -
KG: -
624-6461
8 7 6 5 4 3 2 1 NX
8 7 6 5 4 3 2 1 43 - 58%
D DEICING DELIVERY D
PUMP 14.8cc
33 2200/3750 50 RPM
PUMP SPEEDS SET WITH WATER ONLY
ANTI-ICE/
REFILLER
B A 49.2cc
9 250 25 RPM ANTI-ICE
450 25 RPM REFILLER
SPEEDS SET W/O DEICING FLUID DRY
FUEL PUMP 3.59cc
6 2850 50 RPM
SET WET(WITH FUEL)
DEICING
DELIVERY/REFILLER
CIRCULATION
55 GPM 35 GPM
BLOWER 3.18cc 4SOL
ANTI-ICE 4SOL
DELIVERY/REFILLER -A
50 FAST: 4500 25 RPM
MED: 3400 25 RPM
C SLOW: 2700 25 RPM 27 C
METERED 5SOL 6SOL
FLOW
FUEL PUMP
67 CONTROLLED
FLOW
3 16SOL
2 66
1700
FAST 1 PSI C
BLOWER
ENABLE INACTIVE
1750
PSI
15SOL
17SOL 18SOL
1
2
14 BLOWER BLOWER
RUN 3
RUN
SLOW FAST 4
P
T
B FROM
AUXILIARY
G B
PUMP 3400
P2
SHT 1 PSI
P1 14
TO PRESSURE V
REDUCING VALVE
"2" 30SOL
SHT 11
BOOM
ENABLE MOTOR VAVLE 7
P P1A LS1 LS2
FROM
NEEDLE
VALVE
NORTH AMERICAN 2-PUMP PRE MIX
FROM
SHT 8
CENTRIFUGAL DEICING DELIVERY/REFILLER/CIRCULATION PUMP
HIGH
PRESSURE
FILTER
TO
PUMP
DIAPHRAGM ANTI-ICING/REFILLER PUMP
"OUTLET" "X"
SHT 1 SHT 1
FIRST USED
-
A TO
TOLERANCES:
A
DRAWN HEH 09/01
SHEET 8 OF 15
DWG NO.
COATING: N/A
LB: -
KG: -
624-6461
8 7 6 5 4 3 2 1 NX
8 7 6 5 4 3 2 1
NO LONGER OFFERED
D D
ANTI-ICE/
NEAT TYPE II
PUMP 49.2cc
B A 250 25 RPM ANTI-ICE
9
SET SPEED W/O DEICING FLUID (DRY)
FUEL PUMP 3.59cc

A B 2850 50 RPM
6
SET WET (WITH FUEL)
STANDBY
BLOWER 3.18cc CIRCULATION ANTI-ICE/ PROP MIX
SYSTEM NEAT TYPE II ENABLE
50 FAST: 4500 25 RPM
MED: 3400 25 RPM
C SLOW: 2700 25 RPM 27 60SOL
5SOL 4SOL
C
6SOL
METERED
FLOW
FUEL PUMP
67 CONTROLLED
FLOW
3 16SOL
2 66
FAST 1 550 1700 1625
BLOWER PSI PSI PSI
ENABLE
15SOL
B
64 SOL
17SOL 18SOL
1 80.3cc
M1 A B 0-450 RPM
2
14 BLOWER BLOWER SET SPEED
3 8 DEICE
RUN RUN W/O FLUID (DRY)
FC1 PC1
SLOW FAST 4 P
LS
62 SOL
P SV1
80.3cc
T
M2 A B 0-450 RPM
SET SPEED
B FROM
AUXILIARY 46
8
WATER W/O FLUID (DRY) B
3400 FC2 PC2
PUMP P2
SHT 1 PSI
P1 V FREE FLOW SEE SHEET 11
TO PRESSURE FOR OPTIONAL
REDUCING VALVE BLEND-UP MOTORS
"2" 30SOL
SHT 11
51
BOOM
P P1A LS1 LS2

14
FROM
NEEDLE
VALVE
SHT 8 DIAPHRAGM DEICING DELIVERY PUMP
FROM
HIGH
PRESSURE TO
DIAPHRAGM WATER DELIVERY/CIRCULATING PUMP
FILTER
"OUTLET"
PUMP
"X" DIAPHRAGM ANTI-ICING/REFILLER PUMP
SHT 1 SHT 1
FIRST USED
-
A TO
TOLERANCES:
A
TITLE MODEL: TEMPEST II
DRAWN HEH 09/01
SHEET 9 OF 15
V CHKD CLF 09/01
COMPOSITE HYD SCHEMATIC-DEICER
DRAWING SIZE: D
DWG NO.
REV DESCRIPTION ECN NO. BY DATE SCALE N/A LB: - 624-6461
COATING: N/A KG: -
8 7 6 5 4 3 2 1 NX
8 7 6 5 4 3 2 1 24 - 19%
D D
ANTI-ICE/
REFILLER
PUMP 49.2cc
9 B A 250 25 RPM ANTI-ICE

HEATER 450 25 RPM REFILLER
CIRCULATING SET DRY W/O FLUID
PUMP 3.18cc
50 2800 50 RPM
SET WET (W/WATER & HYD OIL @ NORMAL OP. TEMP)
FUEL
PUMP 3.59cc
6 A B 2850 50 RPM
SET WET
WITH FUEL
BLOWER 3.18cc HEATER ANTI-ICE PROP MIX
CIRCULATING DELIVRY/REFILLER ENABLE
50 FAST: 4500 25 RPM
MED: 3400 25 RPM
-A 5SOL 6SOL 4SOL
C
METERED
FLOW FUEL PUMP
67 CONTROLLED
FLOW
3 16SOL 1750
2 66 1500 1700 PSI
PSI PSI
FAST 1
BLOWER
ENABLE
15SOL
B
64 SOL
17SOL 18SOL 1 80.3cc
M1 A B 0-450 25 RPM
2 SET SPEED
14 BLOWER BLOWER 8 W/O FLUID (DRY)
RUN 3 DEICE
RUN FC1 PC1
SLOW FAST 4 P
LS
62 SOL
P SV1
80.3cc
T A B 0-450 25 RPM
M2
SET SPEED
B FROM
AUXILIARY
G 46 FC2 PC2
8 WATER
W/O FLUID (DRY) B
PUMP 3400
P2
SHT 1 PSI
P1 V SEE SHEET 11
TO PRESSURE
REDUCING VALVE FOR OPTIONAL
"2" BLEND-UP MOTORS
30SOL
SHT 11
BOOM
P P1A LS1 LS2 14

FROM
NEEDLE
VALVE
SHT 8 DIAPHRAGM WATER DELIVERY PUMP
FROM
HIGH
PRESSURE TO
FILTER
"OUTLET"
PUMP
"X"
CENTRIFUGAL WATER CIRCULATING PUMP
SHT 1 SHT 1
FIRST USED
-
A TO
TOLERANCES:
A
DRAWN HEH 09/01
SHEET 10 OF 15
DWG NO.
COATING: N/A
LB: -
KG: -
624-6461
8 7 6 5 4 3 2 1 NX
8 7 6 5 4 3 2 1 1% OFFERED
D D
ANTI-ICE/
REFILLER
PUMP 49.2cc
B A
9 250 25 RPM ANTI-ICE
450 25 RPM REFILLER
ANTI-ICE
DELIVERY/REFILLER
C C
5SOL 6SOL
1700
C
14 PSI
INACTIVE INACTIVE INACTIVE
1
2
3
P
5
T
B FROM
AUXILIARY
G B
PUMP 3400
P2
SHT 1 PSI
P1 V 14
TO PRESSURE
REDUCING VALVE
"2" 30SOL
SHT 11
BOOM
P P1A LS1 LS2
FROM
NEEDLE
VALVE
EURO 1-PUMP ANTI-ICEING
FROM
HIGH
SHT 8
PRESSURE TO
FILTER PUMP
"OUTLET" "X"
SHT 1 SHT 1
FIRST USED
-
A TO
TOLERANCES:
A
DRAWN HEH 09/01
SHEET 11 OF 15
DWG NO.
LB: -
KG: -
624-6461
8 7 6 5 4 3 2 1 NX
8 7 6 5 4 3 2 1
1% / NA XR BOOM
D 33
D
DEICING
DELIERY PUMP
14.8cc
3750 50 RPM
33
SPEED SET WITH WATER ONLY
ANTI-ICE/
REFILLER 49.2cc
9 250 RPM ANTI-ICE

HEATER 450 RPM REFILLER
CIRCULATING SPEEDS SET W/O DEICING FLUID DRY
PUMP 3.18cc
B A
50 2800 50 RPM
FUEL PUMP 3.59cc

A B 2850 50 RPM
6 SET WET(WITH FUEL)
BLOWER 3.18cc HEATER DEICING

CIRCULATING ANTI-ICE DELIVERY
50 FAST: 4500 RPM DELIVERY/REFILLER
MED: 3400 RPM 55 GPM
C SLOW: 2700 RPM 27 4SOL
-A
4SOL C
METERED 5SOL 6SOL
FLOW
FUEL PUMP
67 CONTROLLED
FLOW 1750
3 16SOL
2 66 1500 1700 PSI
FAST PSI PSI
1
BLOWER
ENABLE
15SOL
B
17SOL 18SOL 1
2
14 BLOWER BLOWER 3
RUN RUN
SLOW FAST
4
5 P
B FROM
AUXILIARY
G B
PUMP 3400
P2
SHT 1 PSI
P1 14
TO PRESSURE V
REDUCING VALVE
"2" 30SOL
SHT 11
BOOM
P P1A LS1 LS2
FROM
NEEDLE
NORTH AMERICAN 3-PUMP PRE MIX
VALVE
SHT 8
CENTRIFUGAL DEICING DELIVERY PUMP
FROM
HIGH DIAPHRAGM ANTI-ICING DELIVERY/REFIL PUMP
PRESSURE TO
FILTER
"OUTLET"
PUMP
"X"
CENTRIFUGAL HEATER CIRCULATING PUMP
SHT 1 SHT 1
FIRST USED
-
A TO
TOLERANCES:
A
DRAWN HEH 09/01
SHEET 12 OF 15
DWG NO.
LB: -
KG: -
624-6461
8 7 6 5 4 3 2 1 NX
8 7 6 5 4 3 2 1 30 - 24%
DEICING 80.3cc
DELIERY PUMP B A
D 8 450 RPM D
SPEED SET W/O DEICING FLUID (DRY)
ANTI-ICE/ 49.2cc
REFILLER B A
9 250 RPM ANTI-ICE
HARDI
CIRCULATING 450 RPM REFILLER
PUMP 49.2cc SPEEDS SET W/O DEICING FLUID DRY
(ADDED) B A
9 425 RPM
FUEL PUMP 3.59cc

A B 2850 50 RPM
6
SET WET(WITH FUEL)
DEICING DELIVERY
55 GPM
4SOL
HEATER
BLOWER 3.18cc CIRCULATING ANTI-ICE
DELIVERY/REFILLER
50 FAST: 4500 25 RPM
MED: 3400 25 RPM
-A 5SOL 6SOL
C
METERED
FLOW FUEL PUMP
67 CONTROLLED
FLOW 16SOL
3
2 66 1450 1700
FAST PSI PSI
1
BLOWER 1750
ENABLE PSI
15SOL
B
17SOL 18SOL 1
2
14 BLOWER BLOWER 3
RUN RUN
SLOW FAST
4
5 T
B FROM
AUXILIARY
G B
PUMP 3400
P2
SHT 1 PSI
P1 14
TO PRESSURE V
REDUCING VALVE
"2" 30SOL
SHT 11
BOOM
P P1A LS1 LS2
FROM
EURO 3-PUMP PRE MIX
NEEDLE
VALVE
FROM
HIGH
SHT 8
DIAPHRAGM ANTI-ICING DELIVERY PUMP
PRESSURE
FILTER
TO
PUMP
HEATER CIRCULATING PUMP
"OUTLET" "X"
SHT 1 SHT 1
FIRST USED
-
A TO
TOLERANCES:
A
DRAWN HEH 09/01
SHEET 13 OF 15
DWG NO.
LB: -
KG: -
624-6461
8 7 6 5 4 3 2 1 NX
8 7 6 5 4 3 2 1 5% - OFFERED
D D
PROP MIX
ENABLE
C 4SOL C
1750
PSI
INACTIVE INACTIVE INACTIVE
64SOL
17
SOL 1
M1 80.3cc 0-450 RPM
2
BLOWER A B SET SPEED
RUN 3 W/O FLUID (DRY)
FC1 PC1 8 DEICE
SLOW P LS
4
62SOL
P SV1
T 80.3cc
5 M2 0-450 RPM
SET SPEED
B FROM
AUXILIARY
G
46 FC2 PC2 8
A B
WATER W/O FLUID (DRY) B
PUMP 3400
P2
SHT 1 PSI
P1 V
TO PRESSURE SEE SHEET 11
REDUCING VALVE 30SOL FOR OPTIONAL
"2" BLEND-UP MOTORS
SHT 11
BOOM
P P1A LS1 LS2

14
FROM
NEEDLE
VALVE
FROM
HIGH
SHT 8
DIAPHRAGM WATER DELIVERY PUMP
PRESSURE
FILTER
TO
PUMP
(WITHOUT ANTI-ICE AND HEATER)
"OUTLET" "X"
SHT 1 SHT 1
FIRST USED
-
A TO
TOLERANCES:
A
DRAWN HEH 09/01
SHEET 14 OF 15
DWG NO.
LB: -
KG: -
624-6461
8 7 6 5 4 3 2 1 NX
8 7 6 5 4 3 2 1
NO LONGER OFFERED
D DEICING DELIVERY D
PUMP 80.3cc
8 300/450 25 RPM
ANTI-ICE/ SPEEDS SET W/O DEICING FLUID (DRY)
REFILLER
49.2cc
9 ANTI-ICE: 250 25 RPM

REFILLER: 450 25 RPM
CHARGE PUMP 40.9cc
A B 475 25 RPM
73 SPEEDS SET W/O DEICING FLUID (DRY)
FUEL PUMP 3.59cc

A B 2850 50 RPM
6 SET WET(WITH FUEL) DEICING
DELIVERY/REFILLER
CIRCULATION
-OPTIONAL- 55 GPM 35 GPM
BLOWER 3.18cc GROUND REEL
ANTI-ICE 4SOL 4SOL
CHARGE -A
50 FAST: 4500 RPM DELIVERY/REFILLER
MED: 3400 RPM
C SLOW: 2700 RPM 27 4SOL
-B
C
METERED 5SOL 6SOL
FLOW
FUEL PUMP
67 CONTROLLED
FLOW
3 16SOL
2 66 1450
PSI 1700
FAST 1 PSI
BLOWER
ENABLE
1750
PSI
15SOL
B
17SOL 18SOL
1
2
14 BLOWER BLOWER 3
RUN RUN
SLOW FAST 4
T
5
B FROM
AUXILIARY
G B
PUMP P2 3400
SHT 1 PSI
P1 14
TO PRESSURE V
REDUCING VALVE
"2" 30SOL
SHT 11
BOOM
P P1A LS1 LS2
FROM
NEEDLE
VALVE
SHT 8
EURO 2-PUMP PRE MIX
FROM
HIGH DIAPHRAGM DEICING DELIVERY/REFILLER PUMP
PRESSURE TO
FILTER
"OUTLET"
PUMP
"X"
DIAPHRAGM ANTI-ICING DELIVERY/REFILLER PUMP
SHT 1 SHT 1
FIRST USED
-
A TO
TOLERANCES:
A
DRAWN HEH 09/01
SHEET 15 OF 15
DWG NO.
LB: -
KG: -
624-6461
8 7 6 5 4 3 2 1 NX
4. AIR BRAKE SCHEMATICS
TEMPEST AIR BRAKE SCHEMATICS
Schematic
Number
One / Two All All 624-0942 C
Air Brake Option Schematics

2-7
SYSTEM SCHEMATICS
Page 7
March 2014
5. FLUID SYSTEM SCHEMATICS
NOTE: REFER TO FLUID CONFIGURATIONS SUBSECTION IN CHAPTER 1, SECTION 4 FOR

SPECIFICATIONS.
TEMPEST FLUID SYSTEM SCHEMATICS
Schematic
Region Fluids* Fluid System / Other Options
Number
Open Basket Configurations
N.A. A, D Standard deicing, 2-pump 624-0941 B
CE A, D Standard deicing, type II fluid, 2-pump 624-2230 C
CE A Anti-ice only, type II fluid 624-2230-001 A
CE A, D Pre-mix, type II fluid, 3-pump 624-2230-003 B
Pre-mix, type II fluid, 3-pump, XR boom

CE A, D 624-2230-006 B
(enclosed basket also)
Jib boom and basket optional piping

All All 624-4954 C
(open and enclosed baskets)
Enclosed Basket Configurations
CE A, D, W Prop-mix, type II fluid, 3-pump 624-4953 B
N.A. A, D, W Prop-mix, 4-pump 624-4953-002 D
CE A, D, W Prop-mix, type II fluid, 4-pump, XR boom 624-4953-004 A
N.A. A, D, P BlendUP, 4-pump, AirFirst 624-4953-005 C
Special A, W Prop-mix, 2-pump, no heater (IGS) 624-4953-006 B
Special D, W Prop-mix, 3-pump, 2 tanks 624-4953-102 -
N.A. A, D Pre-mix, 1-2 pumps, anti-ice optional 624-6203 C
CE A, D Pre-mix, type II, 1-2 pumps, anti-ice optional 624-6204 C
CE A, D Pre-mix, 2-3 pumps, anti-ice optional 624-6204-003 A
N.A. D Standard deicing, 2-pump 624-9891 C
* Fluids: A = Anti-ice, D = Deicing, P = Pure, W = Water.
2-7
SYSTEM SCHEMATICS
Page 9
March 2014
Fluid System Option Schematics

2-7
Page 10
March 2014
1. ELECTRONIC HEATER CONTROLLER (EHC) OPERATION
Figure 1
ELECTRONIC HEATER CONTROLLER (EHC)
NOTE: THIS SECTION COVERS THE JBT AEROTECH EHC, REVISION 3.
A. INTRODUCTION
The JBT AeroTech EHC is designed to control a four-stage burner that is used to heat deicing
fluid used in JBT AeroTech deicers. The EHC monitors the current inlet temperature of the heater
in order to determine which stages should be active and when the heating cycle is complete. The
EHC also monitors a number of potential error conditions by reading in various inputs and
reporting errors as they occur.
The EHC has four operating modes. The default mode is AUTO mode. It is in this mode that the
heater executes its preprogrammed logic and attempts to heat the tank. In MANUAL mode, the
user can manually turn on the outputs. In CALIBRATION (CAL.) mode, the user can set various
calibration coefficients and set points. Finally, in ERROR mode, the user can review the last
sixteen errors that have occurred.
2-8
Page 1
October 2013
B. AUTO MODE
In AUTO mode, the heater will attempt to heat the tank by executing its preprogrammed logic.
The user will start the sequence by activating the start switch for two seconds. The module will
then initiate its logic to bring the heater to its operational state. The EHC will control the heater in
a similar manner as older relay style control boxes. The sequences are the same. The following
is a brief summary of the primary sequence of logic under normal operation.
The system first activates the system latch (O1), the low blower (O15), and the high blower
(O16). Three seconds later the heater pump (O2) will activate. Fifteen seconds after the start,
the fuel pump and spark igniter will activate. After another fifteen seconds, the trial for ignition
sequence is initiated. At this point, the high blower turns off and the stage-one fuel (O10) turns
on.
The system will then look for flame for five seconds. If there is no flame, the system will misfire
and enter a 3 minute post purge. If flame is successfully detected, stages two through four (O11
through O13) will then activate in succession on five-second intervals. At this point, the system
activity is dependent upon the tank and heater outlet temperature.
As the tank temperature rises, the stages will be shut off in descending order according to the set
points described in the calibration coefficients. Once the final set point is reached, Cycle
Complete (O8) will light, and the system will enter post purge. At this point, the heater has
completed its task successfully and the logic stops executing until another Start and Run
sequence is requested.
Please note that this is only a brief summary of the functions the heater performs. During this
time, the system is constantly monitoring for error conditions and keeping track of various
peripheral functions. For a complete listing and description of error codes please see the
APPENDIX and TROUBLESHOOTING sections.
While in this mode, the AUTO mode LED will be lit. The three-digit display will show the current
heater inlet temperature with an LED indicating whether the value is in Fahrenheit or Celsius. If
an error occurs, the display will change to display the most recent error. An E, followed by a two
digit code and a blinking Error LED indicate that an error is being displayed. To clear this error
from the display, press the (>) button. This can be done while running without affecting
operation. If the measured temperature drops below 0 C (32 F), the display will show all dashes
as this is out of the readable scale. The heater controller will operate but the display will be
dashed if fluid temperature falls below 0 C (32 F).
As in all modes, to enter the next mode, the user must press the (up) and (down) buttons at the
same time. Controller is locked in AUTO mode while operating until post-purge completes. While
operating, inlet temperature can be viewed by pressing and holding (up), outlet temperature by
pressing and holding (down), and flame sensor value by pressing and holding (>). Refer to
CALIBRATION section.
NOTE: NO CHANGE WILL OCCUR IN DISPLAY IF COEFFICIENT C15 INPUT IS SET FOR THE
CORRESPONDING TEMPERATURE BEING DISPLAYED.
2-8
Page 2
October 2013
C. MANUAL MODE
In MANUAL mode, the user can manually activate each output. While in this mode, the MANUAL
mode LED will be lit, and the display will show the currently selected output (refer to APPENDIX
for listing). To select another output, press either the (up) or (down) buttons. To actually turn on
the selected output channel, the user should press the (>) button.
Figure 2
UP AND DOWN BUTTONS
This mode will also show any open connections or short circuits. If a short has occurred, an S will
appear in the left-most digit. A lowercase o in the same place indicates an open connection. An
open connection error will automatically go away once the problem has been fixed. Due to the
fact that the system can not continuously check for short circuits without damaging the hardware,
the user must ask the system to check if the error still exists. The user does this by pressing the
(>) button with the problematic output channel selected. The system will then check if the error is
still there. If the problem has been cleared up, the S will disappear. If the problem still exists, the
S will remain.
NOTE: FLAGS INDICATE HARDWARE OR WIRING ERRORS THAT ARE EXTERNAL TO THE
FLUID HEATER CONTROLLER MODULE.
NOTE: ON VERSION 2.3 AND LATER, THE CONTROLLER WILL INHIBIT THE MANUAL
OUTPUT FOR 5 SECONDS AFTER EACH TRY.
For safety reasons, the user cannot manually activate the Spark Relay (O14). Also, when
energizing High Blower (O16), please note that Low Blower (O15) will also become energized for
blower adjustment purposes.
D. CALIBRATION (CAL.) MODE
Allows variables to be set for proper operation and monitoring. Refer to subsection
3. ELECTRONIC HEATER CONTROLLER (EHC) CALIBRATION.
E. ERROR MODE
In this mode, the Error Log Mode LED will be lit. The last sixteen errors that have occurred can
be reviewed here. The user can review them by pressing either the (up) or (down) buttons. To
clear out the log, the user should press the (>) button for each error. If no errors are currently in
the log, the display will show E - -.
2-8
Page 3
October 2013
Figure 3
ERROR MODE
The following is a list and description of all the error codes. A brief summary of this list can be
found in the APPENDIX.
CONTROLLER ERROR CODES
ERROR DESCRIPTION
Premature Flame. This error code indicates that flame was detected before the trial
E01
for ignition sequence was activated.
No Flame. This error code indicates that flame was not established during the trial
E02
for ignition sequence.
Loss of Flame. This error code indicates that flame was at one point detected, but
E03
then it was lost.
No Air Pressure. This error code indicates that air pressure was not detected at the
E04
proper time.
Loss of Air Pressure. This error code indicates that air pressure was detected, but
E05
then it was lost.
No Fluid Flow. This error code indicates that fluid flow was not detected at the
E06
proper time.
Loss of Fluid Flow. This error code indicates that fluid flow was detected, but then it
E07
was lost.
Heater Overtemp. This error code indicates that the heater over-temp input signal
E08
was lost, thus indicating an over-temp of outlet temp > 110 C (230 F).
Stack Overtemp. This error code indicates that the stack over-temp input signal
E09
was lost, indicating a stack temp > 760 C (1400 F).
CAD Cell Short. This error code indicates that the CAD Cell input has shorted.
E10
This represents an error external to the module.
RTD 1 ERROR: This error code indicates a problem with heater inlet RTD, most
E11
likely an open circuit.
2-8
Page 4
October 2013
CONTROLLER ERROR CODES (CONT.)
ERROR DESCRIPTION
Heater Flow Switch (2FLS) Error. This error code indicates a stuck or
E12
malfunctioning Flow Switch.
E13 Outlet temperature exceeded allowable limit during preheat mode.
Open Connection. These error codes indicate an open connection on outputs O2

E22E36
O16, respectively. These errors will prevent the heater from latching.
Short Circuit. These error codes indicate a short circuit on outputs O1O16,
E41E56
respectively. These errors will prevent the heater from latching.
To enter the next mode, the user must press the (up) and (down) buttons at the same time.
2. ELECTRONIC HEATER CONTROLLER (EHC) CONNECTIONS
A. DEUTSCH CONNECTOR PIN OUT
DEUTSCH CONNECTOR PINS
PIN FUNCTION DESCRIPTION
1 OUTPUT 1 Heater Latch
2 OUTPUT 2 Heater Fluid Pump
3 OUTPUT 3 Ready to Spray Light (Optional)
4 OUTPUT 4 Service Heater Soon Light
5 V+ (24V) Power
6 OUTPUT 6 Purge Light (Optional)
7 OUTPUT 7 Fuel Pump
8 OUTPUT 8 Cycle Complete Light
9 OUTPUT 9 Misfire Light
10 OUTPUT 10 Stage 1 Fuel, Heater Run Lamp
11 OUTPUT 11 Stage 2 Fuel
12 INPUT 6 Air Pressure Switch
13 INPUT 5 Deice Tank Not Low
14 INPUT 4 Auto Shutdown (Optional)
15 OUTPUT 5 Unused
16 GROUND Power Ground
2-8
Page 5
October 2013
DEUTSCH CONNECTOR PINS (CONT.)
PIN FUNCTION DESCRIPTION
17 INPUT 3 Prop Mix Water Heater Cycle (Optional)
18 INPUT 2 North American Fluid System (Optional)
19 INPUT 1 Start and Run
22 INPUT 12 Preheat option enable
23 INPUT 11 Heater Outlet Below 90 C (195 F)
24 INPUT 10 Heater Stack Overtemp Below 760 C (1400 F)
25 INPUT 9 Heater Outlet Temperature Below 110 C (230 F)
26 INPUT 8 Unused
27 INPUT 7 Fluid Flow in Heater
28 GROUND CAD Cell Return (Flame Sensor)
29 CAD CELL CAD Cell Input (Flame Sensor)
30 OUTPUT 14 Spark Relay
31 OUTPUT 15 Low (Slow) Blower (High Throttle LMD Only)
32 RTD1S RTD1 Source (Tank) (Inlet)
33 RTD1+ RTD1 +V (Inlet)
34 RTD1- RTD1 -V (Inlet)
35 GROUND RTD1 Return (Inlet)
36 RTD2S RTD2 Source (Outlet) optional on LMD
37 RTD2+ RTD2 +V (Outlet) optional on LMD
38 RTD2- RTD2 -V (Outlet) optional on LMD
39 GROUND RTD2 Return (Outlet) optional on LMD
40 OUTPUT 16 High (Fast) Blower
2-8
Page 6
October 2013
B. OUTPUT LISTING
CONNECTOR OUTPUTS LIST
OUTPUT DESCRIPTION
1 Heater Latch
2 Heater Fluid Pump
3 Ready to Spray Light (Optional)
4 Fault light (service heater soon) (Optional)
5 Unused
6 Purge Light (Optional)
7 Fuel Pump
8 Cycle Complete Light
9 Misfire Light
10 Stage 1 Fuel Solenoid
14 Spark Relay
15 Low Blower Solenoid
16 High Blower Solenoid
C. INPUT LISTING
CONNECTOR INPUTS LIST
INPUT* DESCRIPTION
1 Start and Run
2 North American Fluid System (Optional)
3 Prop Mix Water Heater Cycle (Optional)
4 Auto Shutdown Not Enabled** (Optional)
5 Deice Tank Not Low
6 Air Pressure Established
7 Fluid Flow in Heater
2-8
Page 7
October 2013
CONNECTOR INPUTS LIST (CONT.)
INPUT* DESCRIPTION
8 Unused
9 Heater Outlet Temperature Below 110 C (230 F)
10 Stack Temperature Below 760 C (1400 F)
11 Heater Outlet Below 90 C (195 F)
12 Preheat option
* Input LEDs are lit if condition is in TRUE state.
** On units with Auto Shutdown Option installed, the input (I04) LED will be lit even if ignition is
off. This is a normal condition.
D. ERROR CODES
CONNECTOR ERROR CODES
CODE DESCRIPTION
1 Premature Flame
2 No Flame
3 Loss of Flame
4 No Air Pressure
5 Loss of Air Pressure
6 No Fluid Flow
7 Loss of Fluid Flow
8 Heater outlet temperature over 110 C (230 F)
9 Stack temperature over 760 C (1400 F)
10 CAD Cell Short (flame sensor)
11 RTD1 Error (Heater Inlet)
12 Heater Flow Switch Error (2FLS)
13 Outlet temperature exceeded allowable limit during preheat mode
2236 Open Connection on output 216, respective
4156 Short Circuit on output 116, respective
2-8
Page 8
October 2013
E. RESISTIVE THERMAL DEVICE (RTD)
The use of a four wire RTD increases accuracy. All four wires must be connected to the
controller. Error 11 may be indicating a wire breakage when heater outlet is greater than 90 C
(195 F). It is a device that accurately and repeatedly changes resistance due to temperature
changes.
At 0 C (32 F), the resistance will be 100.00 ohms and at 82 C (180 F), the resistance will be
131.6 ohms.
red
1
2
red
Changes resistance consistently

with a change in temperature.
RTD
Res.
wht (ohms)
3
4 100
wht
32 Temp.(F)
Figure 4
RESISTIVE THERMAL DEVICE (RTD)
2-8
Page 9
October 2013
2-8
F.
Page 10
October 2013
HIGH THROTTLE
LOW THROTTLE
HI BLOW (16)
LOW BLOW (15)
FLUID PUMP (02)
SPARK (14)
FUEL PUMP (07)

TIMING SEQUENCE CHART - TEMPEST
TRIAL FOR IGN
Figure 5
FLAME
STAGE I (10)
TIMING SEQUENCE CHART

STAGE 2 (11)
STAGE 3 (12)
STAGE 4 (13)
TIME (SEC) 0 3 5 10 15 20 25 30 35 40 45 0 30 60 90 120 150 180 210 240
TANK TEMP (F) 80
100 110
130 145
160 180181

G. TEMPEST HEATER CYCLE CUT-OUTS
The one function that occurs during a heat cycle that is not shown in the diagram is the fact that
whenever the heater outlet temperature reaches 90 C (195 F), it will turn off the highest working
stage momentarily. This stage will remain off until the outlet temp falls below 90 C (195 F) at
which time that stage will re-light.
The highest working stage will be based upon tank temperature as follows.
HEATER TEMPERATURE STAGES
TANK TEMPERATURE STAGE ACTION
Will cycle ON / OFF with outlet temp.

Less than 38 C (100 F) 4
Will be LOCK OUT.

Will be LOCK OUT.

Will be LOCK OUT.
Will continue until reaching higher than this

temperature, then cycle is complete.
3. ELECTRONIC HEATER CONTROLLER (EHC) CALIBRATION
A. CALIBRATION INSTRUCTIONS
Figure 6
CALIBRATION MODE
(1) To enter CALIBRATION mode, press both the (UP) and (DOWN) buttons simultaneously
until the CALIBRATION LED is illuminated (3 pushes from AUTO mode). If the heater is in
operation (Low Blower ON) the controller is locked in AUTO mode. You must wait until
post-purge cycle is completed to change modes. This protects the long term life of the
heater coils.
2-8
Page 11
October 2013
Figure 7
ENTER CALIBRATION MODE
(2) The controller will then prompt you for the 3 digit security password. The display will show
3 digits. The flashing digit will prompt the user for a number. The number is selected by
using the (up) and (down) buttons. Once the first digit is selected, the (>) button is pushed
to enter the number. This same procedure is done for the remaining two digits. The
factory default code is 255. If the code is incorrectly entered, the user is booted out into the
error log mode.
Figure 8
ENTER CONTROLLER PASSWORD
(3) When the code is entered correctly the display will show CA1. There are 19 calibration
points (CA1C19).
Figure 9
PASSWORD ACCEPTED READY TO START
2-8
Page 12
October 2013
The following is a list and description of all the calibration coefficients with the standard settings
from the vendor.
CALIBRATION COEFFICIENTS LIST
CAL. COEFF. DESCRIPTION
Inlet Temp Resistive Thermal Device (RTD) Low point calibration at

CA1 134
0 C (32 F).
Outlet Temp RTD. Same as CA1, but for RTD2.

CA2 134
Standard on Tempest. Optional on LMD.
CA3 122 Inlet Temp RTD High point calibration at 82 C (180 F).
Outlet Temp RTD. Same as CA3, but for RTD2.

CA4 122
Standard on Tempest. Optional on LMD.
CA5 2 CAD Cell short circuit low limit.
CAD Cell flame detection threshold. Dark is ~225, 4346 = flame

CA6 180
present.
CA7 255 Calibration security entry code.
Indicates the tank temperature that Stage 4 will shut off. Coefficients
CA8 120 CA8 through C11 are in F (Fahrenheit degrees) regardless of how C14
is set. Tempest value = 80.
Indicates the tank temperature that Stage 3 will shut off.

CA9 140
Tempest value = 110.
Indicates the tank temperature that Stage 2 will shut off.

C10 160
Tempest value = 145.
Indicates the tank temperature that Stage 1 will shut off (Cycle
C11 180
Complete).
C12 180 Ready To Spray Temp Adjust Point (4985 C [120185 F]).
C13 --- Current CAD Cell analog value (for display purposes only).
C14 Fah Toggle Auto Mode display between Fahrenheit (F) and Celsius (C).
Toggle Auto Mode display between Inlet (IN) and Outlet (OUT)
C15 In
temperature.
C16 Ready to spray limit turn off temperature (49 C [120 F] to C12-1).
C17 Preheat inlet temperature limit (182 C [33179 F]).
C18 Preheat auto restart temp (Range = 0 C [32 F] to C17).
C19 Preheat mode outlet temp limit (182 C [33179 F]).
2-8
Page 13
October 2013
B. RESISTIVE THERMAL DEVICE (RTD) CALIBRATION
(1) Procedure for Setting CA1 and CA3 (Inlet Temperature RTD) Calibration
It requires use of calibration tool if the settings are out of calibration. The controller should
come precalibrated. Contact JBT AeroTech Engineering or Service Parts for calibrator
information.
(a) Have engine at idle and controller in AUTO mode.
(b) Disconnect the Inlet RTD connector (4 pin) and plug the RTD Calibration tool into the
harness connector. Flip switch on tool to low setting.
Figure 10
INLET RTD CONNECTOR
(c) Observe temperature reading on controller display. The goal is to set this to 0 C
(32 F).
Figure 11
CONTROLLER DISPLAY TEMPERATURE
(d) Enter calibration mode and select CA1. Press the (>) button to see the current
setting. This number is a relative number used by the EHC (it is not an actual
temperature value). If the display in step (c) was higher than 0 C (32 F), lower the
value in CA1. The display will show - - - if it is below 0 C (32 F) so if - - - is
shown, the CA1 value should be increased. Each time the value is changed press
the (>) button to save it. Make sure calibration tool is removed and RTD is
reconnected when these steps are completed.
2-8
Page 14
October 2013
Figure 12
SETTING CA1 TEMPERATURE
(e) Now return to AUTO mode to display the actual temperature. If it is not 0 C (32 F),
repeat step (d).
(f) Once the CA1 is set to 0 C (32 F), flip the calibration tool to the HIGH setting. Now
observe the display temperature. It should be 82 C (180 F). Adjust CA3
accordingly if it is not 82 C (180 F). This is the same procedure as step (d) for
CA1.
Figure 13
SETTING CA3 TEMPERATURE
(g) The adjustment of one setting will slightly affect the other so repeat steps (c) through
(f) until CA1 = 0 C (or 32 F) and CA3 = 82 C (or 180 F) on the temp display in
AUTO mode. This may take a couple times. Each time it is performed, the gap will
get smaller.
Once calibrated, it will not be necessary to repeat unless the controller is replaced.
(h) If the machine is equipped with an outlet RTD sensor (standard on Tempest and
optional on LMD), the same procedures should be repeated to calibrate CA2 and
CA4. The temperature of outlet RTD can be viewed while in AUTO mode by
pressing and holding the (down) button. C15 should be set to IN normally, while
operating in AUTO mode.
As an alternative, you can set C15 to OUT while setting CA2 and CA4.
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October 2013
(2) Procedure for Adjusting Tank Temperature Settings
These settings will come preset as CA8 = 100 F (37.8 C), CA9 = 130 F (54.4 C),
C10 = 160 F (71.1 C), and C11 = 181 F (82.8 C). These can easily be checked or
modified by selecting CA8 through C11 using the (UP) and (DOWN) buttons to select the
coefficient and changing the value and the (>) button to view the value and save a new
value.
Figure 14
TANK TEMPERATURE SETTINGS
(3) Setting Temperature in Fahrenheit (F) or Celsius (C)
For units shipping in the USA, C14 will stay in the FAH setting but units going oversees
need to have C14 toggled to CEL. This is done by selecting C14, pressing the (UP) and
(DOWN) buttons to change the value and then the (>) button to save it.
Figure 15
DISPLAY TEMPERATURE IN FAHRENHEIT OR CELSIUS
(4) Procedure for Setting Security Code (CA7)
The customers will only do this if desired. The default code of 255 will be used at the
factory. This code will need to be entered upon entering CALIBRATION mode. It is done
per steps one and two above. In case the code is forgotten, a special override code does
exist that would allow entry. Please call JBT AeroTech Engineering if this occurs.
(5) Procedure for Setting Cadmium (CAD) Cell Limits (CA5, CA6, C13)
CA5 is used to set the low-level limit from the flame sensor. When the sensor detects light,
the resistance will decrease. The stronger the light, the lower the resistance. If a wire to
the sensor is shorted, the controller must detect it. That is why CA5 is set to 2 nominally. If
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Page 16
October 2013
the wires were shorted, the resistance would fall below the CA5 limit and send an error
message to the display.
CA6 is the upper limit and is set to 82 C (180 F). Typically when the flame sensor is in
the heater and there is no spark or flame, the value will be around 110 C (230 F). When
the flame is on it should be below 82 C (180 F) and above -17 C (2 F), typically dark is
~107 C (~225 F), flame present is ~68 C (~4346 F).
C13 is a way of seeing the real time value of the flame sensor if the burner is not lit. This
will allow you to look at the value of the sensor when screwed into the heater (dark) and
when it is unscrewed and looking at a light source. This will allow verification that sensor is
working properly. The flame sensor value can also be viewed while in AUTO mode by
pressing and holding (>) or in manual mode without holding (>).
Figure 16
SETTING CAD CELL LIMITS
(6) Procedure for Setting Ready-to-spray Light (C12)
This setting should be set to 82 C (180 F) on all trucks except those customers with a
specific request for change. This sets the trip point to which the outlet temperature turns
on the ready-to-spray indicator light in the basket. This is standard feature on Tempest, but
an option on LMDs.
NOTE: C12 IS ALWAYS SET IN FAHRENHEIT DEGREES (F), EVEN IF C14 IS TOGGLED TO
DISPLAY CELSIUS (C) IN AUTO MODE.
To determine what to set C12 to if unit operates in Celsius, convert Ready-to-spray Temp
in degrees Celsius to degrees Fahrenheit, and enter this value in C12.
To exit the CALIBRATION mode and return to AUTO, press both the (UP) and (DOWN) buttons
simultaneously three times until the AUTO mode LED is illuminated and the display reads the current
temperature.
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October 2013
4. TROUBLESHOOTING GUIDE
Figure 17
ACCESSING ERROR CODES
A. INTRODUCTION
This section is intended to be a guide in troubleshooting the JBT AeroTech heater system, using
the EHC as a tool. The MANUAL and ERROR modes will be covered in more detail and a listing
of problem and causes will be reviewed.
B. NON-CRITICAL ERRORS
Non-critical errors are indicated by the Service Soon lamp, (output 04) and a flashing error mode
LED. A non-critical error could range from an open or short circuit on any particular output. The
controller will remain running as long as it does not register a critical shutdown error. Errors are
not retained when power is removed.
Errors E22E56 are non-critical errors in the sense that most of them could occur during
operation and not shut off the heater. The heater would be able to run, but with reduced
efficiency.
For example, if stage #4 fuel solenoid had a short circuit, the controller would shut down that
output, but the heater would continue to run with 3 stages. It would take longer to heat. The
(service soon) light as well as the error mode LED would show that something was not correct but
the heater would not shut down.
NOTE: NON-CRITICAL (SERVICE SOON) OPEN CIRCUIT ERROR CODES ARE ONLY
DISPLAYED FOR OUTPUTS 7 AND 1016. E22 ON O2 IS SUPPRESSED (BECAUSE OF
WIRING TO RE-FILLER SWITCH) UNLESS HEATER IS LIT.
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October 2013
NON-CRITICAL ERROR CODES
SHORT OPEN
OUTPUT OUTPUT DESCRIPTION
CODE CODE
E41 -- 1 Heater Latch

E42 E22 2 Heater Fluid Pump
E43 -- 3 Ready -to-spray Light
E44 -- 4 Fault Light (Service Heater Soon)
E45 -- 5 Unused
E46 -- 6 Purge Light
E47 E27 7 Fuel Pump
E48 -- 8 Cycle Complete
E49 -- 9 Misfire
E50 E30* 10 Stage 1 Fuel, Heater Run Light
E51 E31 11 Stage 2 Fuel
E54 E34 14 Spark Relay
E55 E35** 15 Low Blower and High Throttle (LMD)
E56 E36 16 High Blower
* Both Stage 1 fuel solenoid and heater run light must be disconnected to get E30.
** On LMD units, both low blower solenoid and high throttle enable must be disconnected to get
E35. On Tempest units the low blower solenoid, relay coil and diode D1 (if auto-shutdown
option installed), must all be disconnected to get E35.
- - Indicates open code error is non-existent (lamp outputs only).
C. CRITICAL ERRORS
Critical errors are E01E13. When a critical error occurs, it will shut down the heater and initiate
a post purge cycle. The controller will allow the heater a restart attempt during this time. It will
reset the display when restarted, but the errors will be stored in memory. This allows the
troubleshooter to make many attempts at starting while logging the errors.
To clear the display of the error message in order to view the inlet temperature, simply push the
(>) button. This will clear the display. In order to clear the memory of all error messages, wait
until post-purge is complete, go to ERROR mode and push the (>) button until E - - is displayed,
for each error message.
NOTE: LOGGED ERRORS ARE CLEARED IF CONTROLLER IS POWERED DOWN.
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October 2013
CRITICAL ERROR CODES
ERROR
DESCRIPTION
CODE
E01 Premature Flame

E02 No Flame
E03 Loss of Flame
E04 No Air Pressure
E05 Loss of Air Pressure
E06 No Fluid Flow
E07 Loss of Fluid Flow
E08 Heater Temp over 110 C (230 F).
E09 Stack Temp over 760 C (1400 F).
E10 CAD Cell Short (Flame Sensor)
E11 RTD 1 error (Heater Inlet)
E12 Heater Flow Switch error (2FLS)
E13 Output temp exceeded allowable limit during preheat mode
D. MANUALLY OPERATING OUTPUTS
MANUAL mode can be used when troubleshooting. Every output except (014 - spark) can be
manually energized by using the (>) button momentarily. This will allow the troubleshooter to
verify the operation of the mechanical parts. For example, the blower outputs can be manually
energized in order to measure and adjust the speeds. While energizing these outputs,
verification can be made that air pressure switch is correctly functioning by observing the input
i06. The heater pump can also be energized to verify the flow switch input i07 is functioning.
These are only two examples of what can actually be done.
To select an output to energize in manual mode, use the (UP) or (DOWN) buttons to select the
output desired. The output number will be shown on the display. Push and hold the (>) button to
energize the output. This button is momentary and the output will only remain energized while it
is being pressed.
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October 2013
E. TROUBLESHOOTING REFERENCE GUIDE
TROUBLESHOOTING QUICK REFERENCE GUIDE
ERROR
MEANING PROBABLE CAUSE RECOMMENDED ACTION
CODE
E01 Sensor not in housing Check that sensor is tightly threaded in

properly heater.
1. Check alignment. It should not look
directly at spark.
Sensor not aimed 2. Go to calibration mode and check value
correctly of C12. It should be above the value on
Premature CA6 when inserted into unlit heater.
Flame 3. Check CA6 setting.
If a direct short, the E10 should have been
Wiring pinching to ground
reported.
Pull burner head out, using MANUAL mode
Leaking stage 1 fuel
energize output O7 (fuel pump). Observe
solenoid
stage 1 fuel sol for leakage.
E02 Electrodes not adjusted Remove burner head assembly and check
correctly gap and placement and wires.
Air pressure not adjusted Manually energize O15 / O16 and
correctly measure blower speed. Adjust.
No Flame Manually operate O7 and view fuel pressure
Fuel system
gauge.
Stage 1 fuel solenoid
Check solenoid for damage.
inoperable
Igniter Check igniter wiring, check flame sensor.
E03 1. Check for adequate fuel supply.
Fuel pressure
2. Check for adequate fuel pressures.
Loss of Flame Air pressure Check blower adjustments.
Check flame sensor if loss is at 5 seconds
Flame sensor
after lighting.
E04 1. Check blower speeds.
2. Check hydraulic blower motor.
Pressure switch 3. Check pressure switch input by manually
No Air energizing O15 and looking for input
I6. If no input, check switch and wiring.
Pressure
Manually energize O15 / O16 and
Blower speeds
measure blower speeds.
Hydraulic settings
E05 Pressure switch
Loss of Air
Blower speeds
Pressure
Hydraulic settings
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October 2013
TROUBLESHOOTING QUICK REFERENCE GUIDE (CONT.)
ERROR
MEANING PROBABLE CAUSE RECOMMENDED ACTION
CODE
E06 Pump
Hydraulics
No Fluid Flow Flow switch
Plumbing
Low tank level
E07 Pump
Hydraulics.
Loss of Fluid
Flow switch
Flow
Plumbing
Low tank level
E08 Check pump for leaking and ruptured
Heater Heater pump speed
diaphragms.
Overtemp
Outlet temp switch setting
E09 Blower speeds
Stack Solenoid valves (fuel)
Overtemp Exhaust
Stack switch
E10 CAD Cell Cadmium (CAD) cell
Short Wiring
E11 1. Check wiring at RTD and at EHC.
Wires to RTD are open 2. Verify wires are crimped into pins in
RTD 1 Error connectors.
91 C (195 F) Check wiring to 91 C (195 F) temperature
temperature switch switch or switch itself.
E12 Flow Switch Check to ensure flow switch is not stuck.
Flow Switch Heater Pump Check that wiring is correct.
Error Hydraulics
Plumbing
E?? Igniter wiring or ground
Check for bad ground wiring or splices.
Jittering problem
Digits Igniter high voltage leads Remove burner head assembly, check for
loose loose high voltage wiring.
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October 2013
1. DESCRIPTION
The pump powering the AirFirst option is a swash-plate design, variable displacement, over center
axial piston pump. It has been designed exclusively for closed circuit hydrostatic transmissions where a
self contained pump package is required. The pump design incorporates a charge pump, combination
high pressure relief and make-up check valves and an integrated pressure cut-off valve.
Pump flow is infinitely variable from 0 to 100% and is proportional to an electric current. A proportional
amplifier provides a Pulse Width Modulated (PWM) signal to power solenoid b. The signal is
controlled in the range of 200 to 600 mA at 24 VDC, supplied to solenoid b. The electrical energy is
converted to a force action on the control spool. The spool then directs control oil in and out of the
stroking piston to stroke the pump as required. A feedback lever, connected to the stroking piston,
maintains the pump flow for any given current within the control range.
High pressure flow is provided at B port with low-pressure return at A port. With the solenoid
de-energized, flow is zero. The internal pressure cut-off valve varies the swash plate angle, as required,
to limit maximum pressure. The pressure cut-off valve prevents continuous dumping of excess flow, at
load pressures, through the cross port relief valves in the pump. This eliminates unnecessary heating of
the oil and protects the pump and motor during rapid acceleration or deceleration, or when the drive
stalls, causing the pump to deadhead.
The hydraulic motor driving the AirFirst compressor is a bent axis, fixed displacement unit designed
for use in closed loop applications. The motor has an integral flushing valve that provides the rotating
parts with cooled, filtered fluid from the main pump's charge pump circuit.
Other components in the AirFirst system include an external charge pump filter located on the front
section of the hydraulic reservoir, charge pump relief valve, an air to oil heat exchanger located beneath
the reservoir and a lubrication or cooling system for the AirFirst compressor gear case Load Sensing
System.
2. SERVICING THE AIRFIRST SYSTEM
A. LUBRICATION SYSTEM, AIRFIRST SERVICE KIT
AirFirst Service Kit, JBT AeroTech P/N 624-2922-002 is available for servicing the compressor
lubrication system, and contains the following items:
Air BP Turbo Oil, BPTO 2389, P/N 105-1281 . . . . . . . . . 1.89 L (0.5 gal.)
Element, Filter, 3 micron, P/N 519-7954-011 . . . . . . . . . 1
Recharger Filter Care Service Kit, P/N 623-5058-001 . . 1
The hydraulic system return filter element, P/N 623-8009-001, is recommended to be replaced
when servicing the compressor lubrication system (not included in the AirFirst Service Kit).
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AIRFIRST SYSTEM (OPTIONAL)
Page 1
October 2013
B. LUBRICATION SYSTEM, AIRFIRST COMPRESSOR ANNUAL SERVICE
(1) Park the deicer on a level surface and set the parking brake. Leave the vehicle engine
running.
(2) Start the AirFirst lubrication system by depressing the rocker switch on the operators
right side pod. Green indicator light will illuminate, indicating the system is activated.
(3) Allow the system to operate for 1 hour before proceeding with servicing the system.
(4) Turn the lubrication system OFF, then raise the boom high enough to access the oil drain
plugs on the compressor oil tank mounted on the boom. Shut the vehicle engine OFF.
(5) Immediately remove the rear drain plug from the oil tank and allow the tank to completely
drain (approximately 7.6 L [2 gal.]).
WARNING
ALWAYS USE A SAFETY HARNESS AND SECURE THE TETHER TO THE ATTACHMENT
PROVIDED WHEN WORKING ON THE TOP OF THE VEHICLE. FAILURE TO COMPLY MAY
(6) Reinstall the drain plug and tighten the plug securely when the tank is empty.
(7) Remove the filter canister and discard the used filter element.
NOTE: HOLD THE FILTER HEAD WITH A 76.2 mm (3 in.) OPEN END WRENCH WHEN
TURNING THE 7/8 in. NUT ON THE BOTTOM OF THE CANISTER WHEN REMOVING
AND REPLACING THE FILTER ELEMENT.
(8) Install a new filter element in the canister and install to the filter head. Torque the 7/8 in.
nut on the canister to 61 Nm (45 lbf-ft.) while holding the filter head with a 76.2 mm (3 in.)
open end wrench.
(9) Start the engine and lower the boom into the rest.
(10) Fill the tank with approximately 1.89 L (2 quarts) of oil. Wipe off top of the oil can before
opening and pour the oil directly from the can into the tank.
(11) Operate the lube pump for five minutes and check the oil level. The correct oil level is
63.5 mm (2.5 in.) above the bottom of the oil tank when the deicer is on a level surface and
the boom is in the rest.
NOTE: DO NOT OVERFILL THE OIL TANK. ADD, OR REMOVE OIL, TO ADJUST OIL LEVEL TO
63.5 mm (2.5 in.) ABOVE THE TANK BOTTOM.
(12) Check for oil leaks on lubrication system.
(13) Check the lubricating system oil pressure on the gauge attached to the relief valve.
Pressure indicated should be 345 kPa (50 psi). Adjust the relief valve to obtain a 345 kPa
(50 psi) indicated reading, if required.
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October 2013
(14) Service the intake air cleaner. Instructions for servicing the intake air cleaner are included
in the Recharger Filter Care Service Kit.
(15) Replace the AirFirst hydraulic system return filter element (recommended). It requires a
JBT AeroTech Filter Element.
3. AIRFIRST SYSTEM, INSTALLING OR REPLACING COMPONENTS
A. REPLACING AIRFIRST HYDRAULIC PUMP
(1) Fill the pump case at least half full with clean hydraulic fluid.
(2) Adjust the mechanical stop on the right side (inboard). Using a 19 mm (or 0.75 in.) crow's
foot and a 6 mm hex Allen wrench, make sure that the set screw is turned in exactly one
turn.
(3) Follow AirFirst Compressor Set-up Procedure when replacing the pump.
B. REPLACING AIRFIRST HYDRAULIC MOTOR
(1) Coat the motor shaft splines with Never-seez, Dow Corning GN Assembly PASTE, or
grease containing molybdenum disulfide when installing the motor.
(2) Fill the motor case, at least half full, with clean hydraulic fluid.
(3) Follow AirFirst Compressor Set-up Procedure when replacing the motor.
C. REPLACING AIRFIRST COMPRESSOR
(1) Coat the motor shaft splines with Never-seez, Dow Corning GN Assembly Paste, or
grease containing molybdenum disulfide when installing the motor on the compressor.
(2) Follow AirFirst Compressor Set-up Procedure when replacing the compressor.
D. REPLACING AIRFIRST P-Q CONTROL CARD
Follow AirFirst Compressor Set-up Procedure when replacing the P-Q control card.
4. AIRFIRST COMPRESSOR SET-UP PROCEDURE
A. START-UP PROCEDURE
(1) Check lubricant level in AirFirst lube tank. Maintain a level of 76.2 mm (2.5 in.) above
the bottom of the tank measured with the deicer on a level surface and the boom in the
rest. Add, or remove, lubricant as required. Use only the recommended oil.
(2) Install a 0345 bar (05000 psi) gauge in pump port MB and a 035 bar (0500 psi)
gauge in pump port MA. Both ports are SAE-04, straight thread O-ring.
(3) Start the vehicle engine and turn the AirFirst lube system ON.
(4) Check the lube system oil pressure and adjust the relief valve to an indicated pressure of
3.45 bar (50 psi), if required (refer to Figure 1).
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Page 3
October 2013
(5) If the compressor is turning slowly (as viewed from inlet with air cleaner removed), null
the pump with the screw and jam nut located on top of the pump controller.
(6) Switch the fluid heater ON then to OFF to start the heater post purge cycle, which will
operate the engine under load for three (3) minutes. Verify that the engine speed is
2200 50 rpm under load.
(7) Adjust charge pressure to 24.1 bar (350 psi), observed at port MA, with the engine
operating at 2200 50 rpm.
(8) Allow the lube pump to operate for one hour before proceeding with adjusting the P-Q
Controller.
B. ADJUSTING THE P-Q CONTROLLER
NOTE: WHEN ADJUSTING THE CONTROLLER AFTER INSTALLING A NEW COMPONENT IN

THE AIRFIRST SYSTEM, PROCEED SLOWLY AS THE AMPERAGE IS INCREASED
FOR HIGH, MAX AMPS. THIS IS THE BREAK-IN PERIOD FOR NEW COMPONENTS
AND A MINIMUM OF THIRTY (30) MINUTES SHOULD BE ALLOWED FOR ENTERING
THE VALUES. HYDRAULIC OIL PRESSURE, AT A GIVEN TEMPERATURE, WILL
DETERMINE THE VALUES TO BE ENTERED.
(1) Turn on the AirFirst system with the switch on the nozzle joystick.
(2) Actuate, and hold, the RED TRIGGER switch on the nozzle joystick to power the controller
to drive the compressor motor.
(3) Place controller into the programming mode by pushing down on the ARROW DOWN,
ARROW UP and PROGRAM STORE switches simultaneously and the display will show
P-0 (refer to Figure 3).
NOTE: IF YOU PRESS THESE SWITCHES MULTIPLE TIMES, YOU WILL GO TO DIFFERENT
DEFAULT SETTINGS (P-1, P-2 OR P-3). THE SETTINGS STORED IN P-0 WILL BE
CHANGED IF PROGRAM STORE SWITCH IS DEPRESSED AND THERE IS A VALUE
SHOWN IN P-1, P-2, OR P-3.
NOTE: PRESSING SELECT CANCEL ONCE PERMITS SCROLLING THROUGH THE P-Q
PROGRAM BAR LED WITH THE ARROW UP AND ARROW DOWN SWITCHES AND
NEW VALUES CAN BE ENTERED. THE P-0 PROGRAM WILL ONLY BE CHANGED IF
THE PROGRAM STORE SWITCH IS PRESSED.
(4) Ramp Up Setting (refer to Figure 3)
(a) Scroll the bar LED'S until the RAMP UP SEC LED is illuminated.
(b) Press SELECT CANCEL switch again. The bar LED will begin flashing.
(c) Enter 0.3 (from Table 1 - AirFirst COMPRESSOR CONTROLLER PANEL) in the
display with the ARROW UP and ARROW DOWN switches, then depress the
PROGRAM STORE switch to enter the NEW VALUE in P-0.
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Page 4
October 2013
(5) Ramp Down Setting (refer to Figure 3)
(a) Scroll the bar LED'S until the RAMP DOWN SEC LED is illuminated.
(c) Enter 0.3 (from Table 1 - AirFirst COMPRESSOR CONTROLLER PANEL) in the
(6) Max Signal% Setting (refer to Figure 3)
(a) Scroll the bar LED'S until the MAX SIGNAL% LED is illuminated.
(c) Enter 100 (from Table 1 - AirFirst COMPRESSOR CONTROLLER PANEL) in the
(7) Deadband% Setting (refer to Figure 3)
(a) Scroll the bar LED'S until the DEADBAND% LED is illuminated.

(8) Aux. Trip% Setting (refer to Figure 3)
(a) Scroll the bar LED'S until the AUX TRIP% LED is illuminated.

(9) Frequency Hz Setting (refer to Figure 3)
(a) Scroll the bar LED'S until the FREQUENCY Hz LED is illuminated.
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October 2013
TABLE 1 - AIRFIRST COMPRESSOR CONTROLLER PANEL
AIRFIRST COMPRESSOR A
CONTROLLER CLOCKWISE
Low Amps Note 1

High, Max Amps Note 2
Mid, Max Amps Note 3
Creep, Max Amps Note 4
Ramp Up, Seconds 0.3
Ramp Down, Seconds 0.3
Max Signal% 100
Deadband% 020
Aux. Trip% 020
Frequency Hz 100
Recorded Value
Initial Compressor Rotation -0.05

Note 2. Recorded Value + XXX
NOTE: SET VALUE BY INCREASING P-Q OUTPUT CURRENT UNTIL THE COMPRESSOR
MOTOR JUST STARTS TO ROTATE.
NOTE VALUE ON P-Q CARD AND SUBTRACT 50 (RECORDED VALUE).
(10) Establishing The Recorded Value (refer to Figure 3)
NOTE: THE RECORDED VALUE IS THE MILLI-AMP OUTPUT, LESS 0.05 MILLI-AMP FROM
THE CONTROLLER APPLIED TO THE COIL OF THE PROPORTIONAL VALVE TO SHIFT
THE VALVE SPOOL FOR OIL FLOW.
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October 2013
(a) Place controller into the programming mode by pushing down on the ARROW
DOWN, ARROW UP and PROGRAM STORE switches simultaneously and the
display will show P-0.
(b) Press SELECT CANCEL once and scroll through the P-Q program bar LED, with
the ARROW UP and ARROW DOWN switches, and select HIGH MAX AMPS,
then press the SELECT CANCEL switch again. The bar LED will begin to flash.
(c) Increase the value shown in the display 1 or 2 times to increase the value, then
depress the PROGRAM STORE switch to enter the new value.
(d) Check the compressor for beginning to rotate.
(e) Repeat steps, (a) through (d), until compressor just starts to rotate.
(f) Verify the reading on the display by lowering the value, and then increasing the
value until the compressor begins to rotate.
(g) Subtract 0.05 from the displayed value and record this value on Table 1 - AirFirst
COMPRESSOR CONTROLLER PANEL for the controller. This is referred to as the
RECORDED VALUE.
(11) Low Amps Setting (refer to Figure 3)
(a) Scroll the bar LED'S until the LOW AMPS LED is illuminated.
(c) Enter the RECORDED VALUE (from Table 1 - AirFirst COMPRESSOR

CONTROLLER PANEL) in the display with the ARROW UP and ARROW DOWN
switches.
(d) Press the PROGRAM STORE switch to enter the NEW VALUE in P-0.
(12) High Max Amps Setting (refer to Figure 3)
NOTE: THE VALUE FOR THIS SETTING IS DETERMINED BY THE TEMPERATURE AND
PRESSURE OF THE HYDRAULIC FLUID AND IS NOTE 2 AT THE BOTTOM OF Table 1
- AirFirst COMPRESSOR CONTROLLER PANEL FOR THE CONTROLLER.
the ARROW UP and ARROW DOWN switches, and select HIGH MAX AMPS.
(c) Press the SELECT CANCEL switch again. The bar LED will begin to flash.
(d) Enter the RECORDED VALUE (from Table 1 - AirFirst COMPRESSOR

switches.
(e) Press the PROGRAM STORE switch to enter the NEW VALUE in P-0.
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October 2013
(f) Increase the value shown in the display by pressing the ARROW UP switch 1 or 2
times to increase the value, then depress the PROGRAM STORE switch to enter
the new value.
(g) Enter new values slowly during the breaking-in period of new components.
(h) Each time a new value is entered check the oil pressure on the gauge connected to
Port MB on the hydraulic pump, and the temperature of the hydraulic oil. Refer to
Table 2 - AirFirst OIL TEMPERATURE AND PRESSURE for the oil pressure and
temperature.
(i) When oil pressure and temperature match a reading shown in Table 2 - AirFirst
OIL TEMPERATURE AND PRESSURE, enter this value in Note 2 at the bottom of
table. This is the value for HIGH, MAX AMPS.
TABLE 2 - AIRFIRST OIL TEMPERATURE AND PRESSURE
OIL TEMPERATURE HYDRAULIC PRESSURE

C (F) BAR (PSI)
37.8 (100) 324.1 (4700)

43.3 (110) 318.9 (4625)
48.9 (120) 313.7 (4550)
54.4 (130) 308.5 (4475)
60.0 (140) 303.4 (4400)
NOTE: SET VALUE BY INCREASING P-Q OUTPUT CURRENT UNTIL THE APPROPRIATE OIL
PRESSURE CAN BE MEASURED AT AIRFIRST PUMP AT PORT MB NOTING OIL
TEMPERATURE.
(13) Mid Max Amps And Creep Max Amps Setting (refer to Figure 3)
NOTE: THE VALUE FOR THIS SETTING IS DETERMINED BY THE TEMPERATURE AND
PRESSURE OF THE HYDRAULIC FLUID AND IS NOTE 3 AND NOTE 4 AT THE BOTTOM
OF Table 1 - AirFirst COMPRESSOR CONTROLLER PANEL FOR THE CONTROLLER.
the ARROW UP and ARROW DOWN switches, and select MID, MAX AMPS.
(c) Press the SELECT CANCEL switch again. The bar LED will begin to flash.
(d) Enter the RECORDED VALUE (from Table 1 - AirFirst COMPRESSOR

switches.
(e) Press the PROGRAM STORE switch to enter the NEW VALUE in P-0.
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October 2013
(f) Increase the value shown in the display by pressing the ARROW UP switch 1 or 2
times to increase the value, then depress the PROGRAM STORE switch to enter
the new value.
(g) Enter new values slowly during the breaking-in period of new components.
(h) Each time a new value is entered check the oil pressure on the gauge connected to
Port Mb on the hydraulic pump, and the temperature of the hydraulic oil. Refer to
Table 2 - AirFirst OIL TEMPERATURE AND PRESSURE for the oil pressure and
temperature.
(i) When oil pressure and temperature match a reading shown in Table 1 - AirFirst
COMPRESSOR CONTROLLER PANEL, enter this value in Notes 3 and Note 4 at
the bottom of Table 1 - AirFirst COMPRESSOR CONTROLLER PANEL. This is
the value for MID, MAX AMPS and CREEP, MAX AMPS.

C (F) BAR (PSI)
37.8 (100) 234.4 (3400)

43.3 (110) 229.3 (3325)
48.9 (120) 224.1 (3250)
54.4 (130) 218.9 (3175)
60.0 (140) 213.7 (3100)
PRESSURE CAN BE MEASURED AT AIRFIRST PUMP AT PORT MB NOTING OIL
TEMPERATURE.
NOTE: SET VALUE BY INCREASING P-Q OUTPUT CURRENT UNTIL THE COMPRESSOR
MOTOR JUST STARTS TO ROTATE. NOTE VALUE ON P-Q CARD AND SUBTRACT 50
(RECORDED VALUE).
2-9
Page 9
October 2013
TABLE 4 - AIRFIRST COMPRESSOR CONTROLLER PANEL
AIRFIRST COMPRESSOR A
CONTROLLER CLOCKWISE
Low Amps Note 1

High, Max Amps Note 2
Mid, Max Amps Note 3
Creep, Max Amps Note 4
Ramp Up, Seconds 0.3
Ramp Down, Seconds 0.3
Max Signal% 100
Deadband% 020
Aux. Trip% 020
Frequency Hz 100
Recorded Value
Initial Compressor Rotation -0.05

PRESSURE CAN BE MEASURED AT AIRFIRST PUMP @ PORT MB NOTING OIL
TEMPERATURE.

C (F) BAR (PSI)
37.8 (100) 324.1 (4700)
43.3 (110) 318.9 (4625)
48.9 (120) 313.7 (4550)
54.4 (130) 308.5 (4475)
60.0 (140) 303.4 (4400)
2-9
Page 10
October 2013

C (F) BAR (PSI)
37.8 (100) 234.4 (3400)
43.3 (110) 229.3 (3325)
48.9 (120) 224.1 (3250)
54.4 (130) 218.9 (3175)
60.0 (140) 213.7 (3100)
2-9
Page 11
October 2013
1.9 L/min.
COMPRESSOR (0.5 gpm)
RELIEF VALVE
PRESSURE
GAUGE
3.4 bar (50 psi)
5.4 L/min.
(1.43 gpm)
7.3 L/min. (1.93 gpm)

at 5.2 bar (75 psi)
Figure 1
AIRFIRST COMPRESSOR LUBRICATION SYSTEM
2-9
Page 12
October 2013
AirFirst
PORT CONNECTIONS FOR PUMP

A, B . . . . . . HIGH PRESSURE PORTS
T1 . . . . . . . CASE DRAIN OR FILLING PORTS
T2 . . . . . . . CASE DRAIN PORT
MA . . . . . . . GAUGE PORT, SYSTEM PRESSURE A
MB . . . . . . . GAUGE PORT, SYSTEM PRESSURE B
R . . . . . . . . CASE VENT PORT
S . . . . . . . . CHARGE SUCTION PORT
X1, X2 . . . . STROKING PRESSURE PORTS
G . . . . . . . . CHARGE PRESSURE GAUGE PORT
PS . . . . . . . CONTROL PRESSURE GAUGE PORT
Fa . . . . . . . FILTER OUTLET
Fa1 . . . . . . . FILTER OUTLET (FOR INTEGRAL FILTER ASSEMBLY)
Fe . . . . . . . FILTER INLET
FS . . . . . . . PORT FROM FILTER TO SUCTION LINE (COLD START)
MH . . . . . . . GAUGE PORT, HIGH PRESSURE
Figure 2
AIRFIRST HYDRAULIC SYSTEM
2-9
Page 13
October 2013
LEDS BAR DIGITAL DISPLAY
Figure 3
AIRFIRST P-Q CONTROLLER
2-9
Page 14
October 2013
TABLE OF CONTENTS
CHAPTER 3. OVERHAUL
Section 1. Overhaul Procedures
1. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. EQUIPMENT RE-COMMISSIONING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
3. REMOVAL AND INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
4. ADJUSTMENTS AFTER REPAIRS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
5. PRECAUTIONS BEFORE WELDING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Section 2. Removal and Installation
1. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. HEATER REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
A. HEATER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
B. HEATER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
3. HEATER COIL REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
A. HEATER COIL REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
B. HEATER COIL INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
4. BLOWER HOUSING REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
A. BLOWER HOUSING REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
B. BLOWER HOUSING INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
5. BLOWER MOTOR REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
A. BLOWER MOTOR REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
B. BLOWER MOTOR INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
6. BOOM CYLINDER REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
A. BOOM CYLINDER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
B. BOOM CYLINDER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
7. BOOM PINS REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
A. PREPARATION, STAGING, AND TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
B. PIN REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
C. MASTER CYLINDER PIN REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3-Contents
TABLE OF CONTENTS
Page 1
October 2013
D. XR BOOM PIN REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
E. STANDARD BOOM AND XR BOOM PIN LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
8. FUEL TANK SENDING UNIT REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
A. FUEL TANK SENDING UNIT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
B. FUEL TANK SENDING UNIT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
9. ANTI-ICING PUMP REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
A. ANTI-ICING PUMP REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
B. ANTI-ICING PUMP INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
10. DEICING PUMP REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
A. DEICING PUMP REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
B. DEICING PUMP INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
11. MASTER AND SLAVE LEVELING BLEEDING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
3-Contents
OVERHAUL
Page 2
October 2013
LIST OF FIGURES
CHAPTER 3. OVERHAUL
3-2 Figure 1 BOOM STAGING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

3-2 Figure 2 ENCLOSED BASKET SUPPORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3-2 Figure 3 OPEN BASKET SUPPORT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3-2 Figure 4 OPEN BASKET PLUMBING REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3-2 Figure 5 OPEN BASKET PLUMBING HARDWARE REMOVAL. . . . . . . . . . . . . . . . . . . . . 9
3-2 Figure 6 PIN KEEPERS AND RETAINING HARDWARE . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3-2 Figure 7 JIB BOOM LOWER PINS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3-2 Figure 8 UPPER BOOM AND CYLINDER PINS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3-2 Figure 9 AIRFIRST HARDWARE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3-2 Figure 10 BOOM SUPPORT - MASTER CYLINDER PIN REMOVAL . . . . . . . . . . . . . . . . . 12
3-2 Figure 11 SECURING HOSES AND HARNESSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3-2 Figure 12 BASE PIN OF MASTER CYLINDER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3-2 Figure 13 MASTER CYLINDER ROD END PIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3-2 Figure 14 XR BOOM - OUTER WELDMENT PIN REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . 15
3-2 Figure 15 XR BOOM - INNER WELDMENT PIN REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . 15
3-2 Figure 16 STANDARD BOOM PIN LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3-2 Figure 17 XR BOOM PIN LOCATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3-2 Figure 18 MASTER AND SLAVE CYLINDERS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
3-2 Figure 19 MASTER CYLINDER BLEEDER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
3-2 Figure 20 SLAVE CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
3-2 Figure 21 BLEEDER ACCESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
3-Figures
LIST OF FIGURES
Page 1
October 2013
CHAPTER 3. OVERHAUL
1. GENERAL
The sections that cover the component or system should be read in full and understood completely
before attempting any part of an overhaul. If an overhaul of a major component or system is required,
refer to Manufacturers Appendices in Chapter 5, for pertinent information.
Units operating in extreme conditions (such as high or low temperatures, long periods of sustained
operation, continued operation in sand or dust, or continued exposure to sea air or moisture) need
regular inspection. Overhaul periods can be set as necessary.
WARNING
For the adjustment of components, refer to Maintenance Procedures in Chapter 2, Section 5.
CAUTION
PERFORM A COMPLETE MAINTENANCE CHECK AFTER REPAIRS ARE COMPLETED.

ENSURE THE VEHICLE HAS BEEN PROPERLY SERVICED BEFORE STARTING THE POWER
UNIT. FAILURE TO COMPLY MAY RESULT IN DAMAGE TO VEHICLE COMPONENTS!
2. EQUIPMENT RE-COMMISSIONING
After an overhaul, or major repair, the equipment must be thoroughly inspected, and serviced as stated
in the corresponding Maintenance Schedules in Chapter 2, Section 3, Preventative Maintenance.
Also, before placing the vehicle back into service, it must be re-commissioned utilizing the EQUIPMENT
PRE-OPERATIONAL CHECKLIST (refer to Preventative Maintenance in Chapter 2, Section 3).

ROAD TRANSPORTATION, AND IF THE EQUIPMENT HAS BEEN OUT OF SERVICE
FOR MORE THAN SIX MONTHS.
3-1
OVERHAUL PROCEDURES
Page 1
October 2013
CAUTION

ENVIRONMENTALLY SENSITIVE MATERIALS, SUCH AS TIRES, BELTS, BATTERIES, MOTOR
3. REMOVAL AND INSTALLATION
Main components may be necessary to be removed and replaced during overhaul procedures. The
section on removal and installation in this chapter includes the main assemblies and sub-assemblies,
and it is not intended to cover all components that could possibly be removed or repaired.
Refer to Chapter 4, Illustrated Parts List, and Chapter 5, Manufacturers Appendices for information on
specific components, and for the list of spare parts.
For safety and reliability use only JBT AeroTech replacement parts.
4. ADJUSTMENTS AFTER REPAIRS
WARNING
OPERATORS MUST CARRY OUT A COMPLETE BOOM LOAD AND STABILITY TEST PRIOR TO
TAKING THE DEICER INTO SERVICE AFTER MAJOR MAINTENANCE OR MODIFICATIONS TO
THE AERIAL DEVICE HAVE TAKEN PLACE. FAILURE TO COMPLY MAY RESULT IN SERIOUS
To ensure proper operation of assemblies and overall components, it is necessary to follow the
corresponding adjustment procedures stated in this manual, and perform the recommended tests.
Refer to Maintenance Procedures in Chapter 2, Section 5 for the adjustment of components, and
Manufacturers Appendices in Chapter 5 for additional information.
5. PRECAUTIONS BEFORE WELDING
Proper precautions must be taken to prevent damage to electronic equipment.
CAUTION

3-1
OVERHAUL
Page 2
October 2013
1. GENERAL
The following procedures for removal and installation of vehicle components outline the steps and
precautions to take when removing items for replacement or repair. Make sure to read and understand
each procedure before attempting to perform it.
In addition, after removing and replacing components, adjustments must be performed. Refer to
Maintenance Procedures in Chapter 2, Section 5 for this purpose.
WARNING
WARNING
VEHICLE MAINTENANCE MUST BE PERFORMED EXCLUSIVELY BY TRAINED AND
QUALIFIED TECHNICIANS. FAILURE TO COMPLY MAY RESULT IN SERIOUS BODILY
WARNING
WARNING
WHEN REMOVING COMPONENTS FOR REPLACEMENT OR REPAIR, CLEAN COMPONENTS,
IDENTIFY AND MARK ALL CONNECTIONS, SUPPORT PROPERLY FOR REMOVAL, AND
PLACE REMOVED COMPONENTS IN A SAFE AND SECURE LOCATION. FAILURE TO
3-2
REMOVAL AND INSTALLATION
Page 1
October 2013
2. HEATER REMOVAL AND INSTALLATION
A. HEATER REMOVAL
(1) Remove rear half of deicer shroud.
(2) Disconnect fuel lines to heater.
(3) Disconnect hydraulic lines to blower motor.
(4) Disconnect hydraulic lines to fuel pump motor.
(5) Disconnect all wiring harnesses to heater.
(6) Close fluid inlet and outlet valves to heater.
(7) Disconnect groove couplings on heater inlet and outlet piping.
(8) Disconnect bolts attaching heater to frame.
(9) Remove hydraulic heat exchangers and mounting brackets.
(10) Position forks of lift truck in slots provided in heater frame and remove heater from deicer.
Lift truck minimum capacity should be 1800 kg (4000 lb.).
B. HEATER INSTALLATION
(1) Position forks of lift truck in slots provided in heater frame and lift heater onto deicer. Lift
truck minimum capacity should be 1800 kg (4000 lb.).
(2) Install bolts attaching heater to floor.
(3) Connect groove couplings on heater inlet and outlet piping.
(4) Open fluid inlet and outlet valves to heater.
(5) Connect all wiring harnesses to heater.
(6) Connect hydraulic lines to fuel pump motor. Motor must spin clockwise as viewed from
shaft end.
(7) Connect hydraulic lines to blower motor. Motor must spin clockwise as viewed from shaft
end.
(8) Connect fuel lines to heater.
(9) Install hydraulic heat exchangers and mounting brackets.
(10) Install rear half of deicer shroud.
3. HEATER COIL REMOVAL AND INSTALLATION
NOTE: BEFORE WORKING WITH INTERIOR OF HEATER, PROPER PRECAUTIONS SHOULD

BE TAKEN TO AVOID SKIN CONTACT AND INHALATION OF THE FIBERS INSIDE THE
HEATER. REFER TO WARNINGS AT THE BEGINNING OF THIS SECTION.
3-2
OVERHAUL
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October 2013
A. HEATER COIL REMOVAL
(1) Remove heater from unit. Refer to paragraph 2.A. HEATER REMOVAL.
(2) Remove grooved fittings that are screwed into inlet and outlet pipes of heater.
(3) Remove circular clamp at front end of heater (end opposite the burner head).
(4) Using handles provided, remove exterior end cap.
(5) Remove insulation disks (2).
(6) Grind the weld that holds interior end cap and remove cap.
(7) Remove insulation disks (3).
(8) Cut out outer sheet metal in front of the fluid inlet pipe (vertical pipe in bottom of heater) to
allow pipe to slide out the end of the heater.
(9) Remove heat deflector caps (2).
(10) Slide coil weldment out of heater.
B. HEATER COIL INSTALLATION
(1) Slide coil weldment into heater. Align fluid outlet pipe with hole in aft end (burner head
end) of heater.
(2) Weld filler plate in outer sheet metal around fluid inlet pipe (vertical pipe).
(3) Fill ceramic moldable compound in spaces between coils in the end of the outer coil.
(4) Install flame deflector caps. Fill any gaps with ceramic moldable compound.
(5) Install insulation disks (2).
(6) Install interior end cap and weld in place.
(7) Install insulation disks (2).
(8) Install exterior end cap.
(9) Install circular clamp to hold in end cap.
(10) Install grooved fitting into inlet and outlet piping.
(11) Install heater into deicer unit. Refer to paragraph 2. B. HEATER INSTALLATION.
4. BLOWER HOUSING REMOVAL AND INSTALLATION
A. BLOWER HOUSING REMOVAL
(1) Remove bolts holding circular motor adapter plate to blower housing.
(2) Slide motor and blower wheel assembly out of housing and set aside.
(3) Remove bolt holding housing to burner head. Remove housing.
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Page 3
October 2013
B. BLOWER HOUSING INSTALLATION
(1) Position housing over rectangular hole in burner head and install bolts (6).
(2) Insert motor blower wheel assembly into housing and install fasteners (8).
5. BLOWER MOTOR REMOVAL AND INSTALLATION
A. BLOWER MOTOR REMOVAL
(1) Remove hoses from blower motor and drain.
(2) Remove blower guard from housing. Air inlet cone will also come off.
(3) Loosen set screws in hub of blower wheel.
(4) Slide blower wheel off motor shaft.
(5) Remove mount bolts for blower motor and remove motor.
B. BLOWER MOTOR INSTALLATION
(1) Install motor onto adapter plate of blower housing and secure fasteners. Port B should
be toward rear.
(2) Slide blower wheel onto motor shaft. Be sure key is positioned under set screw in blower
hub.
(3) Tighten set screws (2) in hub of blower wheel.
(4) Install air inlet cone and blower guard onto housing. Air inlet cone points inward with cone
edge even with edge of blower wheel. If not, reposition blower wheel on motor shaft.
(5) Tighten guard mount bolts (4).
(6) Install hoses onto blower motor. Pressure hose is to be mounted to port B of motor.
6. BOOM CYLINDER REMOVAL AND INSTALLATION
A. BOOM CYLINDER REMOVAL
(1) Support aerial device with a lifting device of 1800 kg (4000 lb. [2 ton]) minimum capacity.
(2) Remove pin keeper bolts from both pins and remove pins.
(3) Disconnect cylinder and cap lines.
B. BOOM CYLINDER INSTALLATION
(1) Put the cylinder in place at elbow and insert pin and keeper bolts. Connect hydraulic lines.
(2) Actuate boom cylinder to align it with pin position at boom. Insert pin and pin keeper bolt.
(3) Operate boom cylinder to remove air.
3-2
OVERHAUL
Page 4
October 2013
7. BOOM PINS REMOVAL AND INSTALLATION
A. PREPARATION, STAGING, AND TOOLS
Stage vehicle in an area where the boom can be rotated to the side. Use a fork lift, wood blocks
or some means to support the basket.
WARNING
REMOVE AND INSTALL BOOM PINS ONE BY ONE TO HOLD THE BOOM OVERALL
STRUCTURE. FAILURE TO COMPLY MAY RESULT IN SERIOUS BODILY INJURY, DEATH, OR
(1) Stage the deicer with the boom to the left or right side of the vehicle (refer to Figure 1).
Boom must be rotated so ladders can be used on both sided of the boom allowing access
to pin removal and installation. The same staging applies to both open and enclosed
baskets.
(2) Once the boom is set to the side, support the basket with a forklift, wood blocks, or some
other means to relieve the stress on the boom and pins. Be very cautious and ensure the
boom remains stable at all times. (Refer to Figure 2).
When lowering the boom onto wood blocks, adjust the jib to an angle for the basket bottom
to rest flat over the wood blocks. Lower down the boom gently until the basket is fully
supported by the wood blocks. When using a fork lift, leave the boom slightly up from full
down and bring the fork blades up until the boom is slightly lifted.
CAUTION
WHEN SUPPORTING THE BASKET, USE CAUTION NOT TO DAMAGE ELECTRICAL OR

HYDRAULIC COMPONENTS, AIRFIRST PIPING OR DAMAGE COLLISION SENSORS, IF
EQUIPPED. FAILURE TO COMPLY MAY RESULT IN DAMAGE TO VEHICLE, OR OTHER
3-2
Page 5
October 2013
BOOM CONTROLS INSIDE THE CAB OR MANUAL
CONTROLS AT THE BOOM GROUND CONTROL
VALVE CAN BE USED TO STAGE THE BOOM.
FOLLOW INSTRUCTIONS ON THE DECAL INSIDE.
12 3 4 5
12345
Figure 1
BOOM STAGING
BASKET SUPPORT AREA
Figure 2
ENCLOSED BASKET SUPPORT
3-2
OVERHAUL
Page 6
October 2013
On an open basket, wood cribbing can be used to support the basket from underneath
Ensure the boom is staged as stated in paragraph (1) above before supporting the basket.
(3) Open basket: Remove plumbing from both sides to access upper pin for removal.
Remove clamps observing the hardware being removed, so re-installation can be done
exactly as disassembly (refer to Figure 4 and Figure 5).
B. PIN REMOVAL AND INSTALLATION
(1) Remove pin keepers and retaining hardware, starting with the lower pins (refer to Figure 6
and Figure 7).
(2) Using a brass hammer or similar, lightly tap on the pin.
WARNING
ENSURE THE BOOM AND BASKET ARE SECURED BEFORE ATTEMPTING TO REMOVE AND/
OR REPLACE ANY BOOM PIN. FAILURE TO COMPLY MAY RESULT IN SERIOUS BODILY
(3) Drive out the old pin using the new pin, ensuring proper alignment of retaining hardware
hole with retaining point on weldment. Keep arms, hands, and fingers out of pinch points.
Inspect bushings for any damage. If damage does occur, replace the damaged bushing.
(4) Install retaining hardware and tighten securely. If it is a retaining pin and screw, apply blue
Loctite 242 and torque screw to 8.59.0 Nm (7580 lbf-ft.).
(5) Open basket: Reinstall plumbing on both sides of basket. Reinstall clamps ensuring the
hardware previously removed is reinstalled exactly as it was before disassembly.
(6) Repeat steps (1) to (5) above for removing the remaining pins. Refer to Figure 7, Figure 8
and Figure 12 for pin locations.
NOTE: FOR BOOM CONFIGURATIONS AND PIN LOCATIONS REFER TO Figure 16

(STANDARD BOOM) AND Figure 17 (XR BOOM).
3-2
Page 7
October 2013
PLACE WOOD IN THESE LOCATIONS, ENSURING
THEY EXTEND THE WIDTH OF THE BASKET AND
DEEP ENOUGH TO CLEAR THE CENTER SUPPORTS
VIEW A
VIEW A
VIEW A
VIEW
Figure 3
OPEN BASKET SUPPORT
REMOVE PLUMBING
CLAMPS AND GUIDES
Figure 4
OPEN BASKET PLUMBING REMOVAL
3-2
OVERHAUL
Page 8
October 2013
PIPE SUPPORT PIPE SUPPORT
HARDWARE HARDWARE
MOVE FLUID PIPES

ENOUGH TO ACCESS
THE PIN BEHIND THEM
FLUID PIPES
DEICING ANTI-ICING
UPPER PIN UPPER PIN
Figure 5
OPEN BASKET PLUMBING HARDWARE REMOVAL
TYPES OF RETAINING HARDWARE
RETAINING PIN
AND SCREW
RETAINING SCREW
WITH LOCK NUT
Figure 6
PIN KEEPERS AND RETAINING HARDWARE
3-2
Page 9
October 2013
UPPER PIN
PART NUMBER
624-5838
LOWER PIN
PART NUMBER
624-5839
Figure 7
JIB BOOM LOWER PINS
PIN P/N
624-5836
PIN P/N
624-5845
PIN P/N
624-5838
PIN P/N PIN P/N

624-5845 624-5839
PIN P/N
624-5845
Figure 8
UPPER BOOM AND CYLINDER PINS
3-2
OVERHAUL
Page 10
October 2013
AirFirst SYSTEM
(OPTIONAL)
REMOVE SUPPORT
HARDWARE TO ACCESS
PINS BEHIND PIPES
DO NOT REMOVE
PIPE CLAMPS
Figure 9
AirFirst HARDWARE REMOVAL
C. MASTER CYLINDER PIN REPLACEMENT
NOTE: A WOOD BLOCK OF APPROXIMATELY 0.30 m x 0.30 m (12 in. x 12 in.) TO SUPPORT
THE BOOM WHEN RESTING WILL BE NEEDED FOR THIS PROCEDURE.
(1) Raise boom and rotate back to center of truck.
WARNING
TECHNICIAN MUST USE A SAFETY LANYARD AND BELT WHEN WORKING ON TOP OF
VEHICLES SHROUD. FAILURE TO COMPLY MAY RESULT IN SERIOUS BODILY INJURY,
(2) Lower the boom until it rests on the wood block to relieve pressure and allow access to the
master cylinder rod pin (refer to Figure 10).
(3) Move hoses and harnesses out of the way to allow access to the base of the master
cylinder, and secure them out of the way using a large tie-wrap or rope (refer to Figure 11).
(4) Repeat the step (3) above on the passenger side inside the rotator (refer to Figure 11).
(5) Remove pin keepers and retaining hardware; start with the lower pins (refer to Figure 12).
(6) Using a brass hammer or similar, lightly tap on the pin.
3-2
Page 11
October 2013
WARNING
Inspect bushings for any damage. If damage does occur, replace the damaged bushing.
(9) Remove rod end pin of master cylinder repeating steps (6) to (8) above. Refer to Figure 12
and Figure 13 for pin locations. If there is difficulty aligning pin, loosen bleeder to relieve
pressure and allow alignment. Clean up any oil spilled, and use caution of potential oil in
shroud.
(10) Remove tie-wraps or ropes holding hoses and harnesses, and verify all retaining hardware
is in place and properly tighten and torqued, as applicable.
(11) Clean up any grease and oil spills.
WOOD BLOCK TO
SUPPORT BOOM
Figure 10
BOOM SUPPORT - MASTER CYLINDER PIN REMOVAL
3-2
OVERHAUL
Page 12
October 2013
PASSENGER SIDE
TIE-WRAPS TO
SUPPORT HOSES
DRIVER SIDE
ACCESS TO PINS
HYDRAULIC
HOSES
Figure 11
SECURING HOSES AND HARNESSES
ACCESS TO PIN
ACCESS TO PIN
Figure 12
BASE PIN OF MASTER CYLINDER
3-2
Page 13
October 2013
REMOVE PIN
REMOVE PIN
Figure 13
MASTER CYLINDER ROD END PIN
D. XR BOOM PIN REPLACEMENT
This procedure applies to replacement of pins in the outer and inner weldments.
WARNING
(1) Using a brass hammer or similar, lightly tap on the pin to verify how loose it is. Refer to
Figure 14 for pin location.
Inspect bushings for any damage. If damage does occur, replace the damaged bushing
with a new one.
(4) Replace inner weldment pin repeating steps (1) to (3) above. Refer to Figure 15 for pin
location.
3-2
OVERHAUL
Page 14
October 2013
REMOVE PIN
Figure 14
XR BOOM - OUTER WELDMENT PIN REMOVAL
REMOVE PIN
Figure 15
XR BOOM - INNER WELDMENT PIN REMOVAL
3-2
Page 15
October 2013
3-2
Page 16
E.
October 2013
Figure 16
STANDARD BOOM AND XR BOOM PIN LOCATIONS
STANDARD BOOM PIN LOCATIONS

OPEN BASKET ENCLOSED BASKET NOTE: REFER TO CHAPTER 4, ILLUSTRATED
PARTS LIST FOR SPECIFIC PART
NUMBERS FOR EACH LOCATION.
OVERHAUL
Figure 17
XR BOOM PIN LOCATIONS
OPEN BASKET ENCLOSED BASKET NOTE: REFER TO CHAPTER 4, ILLUSTRATED
PARTS LIST FOR SPECIFIC PART
NUMBERS FOR EACH LOCATION.
October 2013
Page 17
3-2
8. FUEL TANK SENDING UNIT REMOVAL AND INSTALLATION
NOTE: CAUTION SHOULD BE USED WHEN FUEL TANKS ARE OPEN TO THE AIR. REFER TO
DANGER, WARNING, AND CAUTION STATEMENTS AT THE BEGINNING OF THE
MANUAL.
A. FUEL TANK SENDING UNIT REMOVAL
(1) Locate sending unit on top of tank and remove sender wire.
(2) Remove screws holding sending unit in tank and remove senders.
(3) Cover tank sender hole.
B. FUEL TANK SENDING UNIT INSTALLATION
(1) Locate mounting hole on top of tank and place sending unit in hole with gasket in place.
(2) Attach sending unit with screws and attach sender wire. The sender only fits one way.
(3) Remove tank filler cap. Actuate sender float using a long non-metallic bar placed through
the filler opening. With truck ignition on, verify proper operation.
(4) Place filler cap and access plate.
9. ANTI-ICING PUMP REMOVAL AND INSTALLATION
A. ANTI-ICING PUMP REMOVAL
(1) Close tank suction valve at fluid tank.
(2) Disconnect pressure and suction hoses from top of pump.
(3) Disconnect chain coupling from hydraulic pump or remove hydraulic hoses.
(4) Remove pump mounting bolts and remove pump.
B. ANTI-ICING PUMP INSTALLATION
(1) Position pump and insert pump mounting bolts.
(2) Connect chain coupling or hydraulic hoses.
(3) Connect pressure and suction hoses to top of pump.
(4) Open tank suction valve at fluid tank.
(5) Check for leaks.
10. DEICING PUMP REMOVAL AND INSTALLATION
A. DEICING PUMP REMOVAL
(1) Close water suction valve at fluid tank.
(2) Remove pressure and suction hoses. Trapped fluid will drain from hoses.
3-2
OVERHAUL
Page 18
October 2013
CAUTION

ENVIRONMENTALLY SENSITIVE MATERIALS, SUCH AS TIRES, BELTS, BATTERIES, MOTOR
(3) Disconnect hydraulic motor and coupling or remove hydraulic hoses.
(4) Remove pump mounting bolts.
(5) Remove pump.
B. DEICING PUMP INSTALLATION
(1) Position pump and insert pump mounting bolts.
(2) Connect hydraulic motor and coupling or hydraulic hoses.
(3) Connect pressure and suction hoses.
(4) Open water suction valve at fluid tank.
11. MASTER AND SLAVE LEVELING BLEEDING PROCEDURE
NOTE: EXTREME CAUTION MUST BE USED WHEN PERFORMING THIS PROCEDURE.
(1) Rotate boom to side of unit.
(2) Block up underside of basket to ensure it is secure.
(3) Obtain a 4 L (1 gal.) container and two hoses of 6.4 mm (0.25 in.) of internal diameter by
610 mm (24 in.) of length.
(4) Using a ladder hang the bottle from the back of the boom where the cylinders are attached.
(5) Install the hose on the rear and forward bleeders of the master cylinder. Refer to Figure 18
and Figure 19.
(6) With the engine off, loosen the bleeders with a 10 mm wrench and secure the hoses with
tie-wraps to prevent them from shifting while bleeding.
3-2
Page 19
October 2013
SLAVE
CYLINDER
MASTER
CYLINDER
Figure 18
MASTER AND SLAVE CYLINDERS
MASTER
CYLINDER
BLEEDER
Figure 19
MASTER CYLINDER BLEEDER
3-2
OVERHAUL
Page 20
October 2013
NOTE: THE FORWARD BLEEDER IS ACCESSIBLE THROUGH A HOLE IN THE REAR SIDE OF
THE BOOM OR THROUGH THE BACK (REFER TO FIGURE 21).
(7) Start engine and activate wires 476 then alternately 477, for a period of four seconds on
each one, using a jumper wire from a 24 VDC power source. Watch the bottle so that it fills
2 liters (approx. 2 quarts) minimum with the bleeding.
(8) Shut the engine off, tighten the bleeders and remove the hoses.
(9) Move to the front of the Tempest and hang the bottle from the slave cylinder (refer to Figure
20).
(10) With the engine off, attach the hoses to the bleeders and loosen bleeders.
(11) Secure hoses with tie-wraps to prevent them from shifting while bleeding.
(12) Start engine and activate wires 476 then alternately 477, for a period of four seconds on
each one, using a jumper wire from a 24 VDC power source. Watch the bottle so that it fills
2 liters (approx. 2 quarts) minimum with the bleeding.
(13) Shut the engine off, tighten the bleeders and remove the hoses.
(14) Check leveling with the switch in the basket to ensure proper operation.
(15) Using the manual control or override controls in cab operate boom to full extend and back
down and view the basket leveling for proper operation.
(16) Check for leaks from the bleeders.
FRONT
SLAVE BLEEDER
CYLINDER
COUNTER BALANCE
VALVE
Figure 20
SLAVE CYLINDER
3-2
Page 21
October 2013
NOTE: THE REAR BLEEDER IS ACCESSIBLE THROUGH A HOLE IN THE SIDE OF THE
BOOM. REFER TO FIGURE 21.
REAR
BLEEDER
SLAVE
CYLINDER
Figure 21
BLEEDER ACCESS
3-2
OVERHAUL
Page 22
October 2013

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Location Warranty and Service Part Sales

Orlando telephones telephones

4. IMPORTANT SAFETY NOTICE

Please send this information to:

Technical Publications Department

This vehicle complies with the following CE requirements:

Machinery Directive - Annex IV, 2006/42/EG

      

+ ,      *

OPERATION AND MAINTENANCE MANUAL

Volume I OPERATION AND MAINTENANCE

CHAPTER 1. GENERAL INFORMATION AND OPERATING INSTRUCTIONS

CHAPTER 2. MAINTENANCE AND REPAIR

Volume II ILLUSTRATED PARTS LIST

CHAPTER 4. ILLUSTRATED PARTS LIST

CHAPTER 5. MANUFACTURERS APPENDICES

OPERATION AND MAINTENANCE MANUAL

All pages in this issue are original.

The following pages have had changes incorporated.

Sep. 2005 Edition 1 Volume I New edition

Oct. 2005 Revision 1 Chapter 2, Section 1 Updated: grease specifications.

June 2006 Revision 2 Volume I Updated: general information.

July 2006 Revision 3 Chapter 2, Section 5 Added: fluid schematic 624-4953-002.

Added: sound pressure and vibration levels,

Added: Mercedes engine, and electrical

Added: electrical schematic 521-1004, and

Added: electrical schematics 521-0808, and

Jan. 2007 Revision 1 Volume I Updated: general information, new layout.

Mar. 2007 Edition 4 Volume I Added: Prop-mix information.

Apr. 2007 Revision 1 Chapter 2, Section 5 Updated: schematic 624-4953-002 B.

Updated: preventative maintenance for air

Aug. 2007 Edition 5 Volume I Updated: general information.

Aug. 2007 Revision 1 Chapter 2, Section 5 Updated: schematics.

Aug. 2007 Revision 2 Chapter 2, Section 2 Added: optional diagnostics procedures.

Added: Sections 2-1, and 2-2; schematics.

Sep. 2008 Edition 7 Volume I Updated: general information, new logo.

Nov. 2008 Edition 8 Volume I Updated: Tier 3 engines information.

Dec. 2008 Edition 9 Volume I Not released.

Updated: safety information, and latest

Apr. 2010 Revision 1 Introduction Updated: Declaration of Conformity form.

May 2010 Revision 2 Volume I Updated: general information.

July 2010 Edition 11 Volume I Updated: XR boom information.

Added: XR boom, and Arvin Meritor axle

Added: blendUP operational instructions,

Updated: electrical schematics 521-1106 A

Updated: hydraulic oil recommendations,

Mar. 2011 Edition 13.1 Chapter 2, Section 7 Updated: schematic 521-1210 B.

Added: winterization system, and other

Updated: XR boom extend/retract,

Updated: electric schematic 521-1011 A,

Updated: overall dimensions, diesel fuel

Updated: schematic 521-1211 B, hydraulic

Introduction, Chapter 1, Updated: SMP certificate, purging

Updated: Prop-mix and blendUP

Chapter 1, Section 2; Updated: refilling procedures, safety

Updated: purging pumps and hoses for

Oct. 2013 Revision 4 Chapter 1, Section 2 Updated: operating procedures.

Nov. 2013 Revision 5 Chapter 1, Section 4 Added: vehicle jacking requirements.

Updated: schematics 521-1211 C and

A CAUTION INDICATES A PROCEDURE THAT MUST BE FOLLOWED OR A CONDITION THAT

ENSURE TO DISCONNECT EXTERNAL AC POWER SOURCE PRIOR TO MOVING THE

CONTINUOUS OPERATION OF HYDRAULIC EMERGENCY PUMP FOR MORE THAN ONE

ALWAYS STOP THE VEHICLE COMPLETELY BEFORE SHIFTING THE TRANSMISSION TO

+ , *