GROUND FORCE 717H01 Manual

Ground Force Worldwide
6001 E. Seltice Way
Post Falls, Idaho 83854
1 [phone]
inf[email protected] | www.gfworldwide.com
ORIGINAL INSTRUCTIONS
© Copyright 2009, by Ground Force Worldwide. All rights reserved. No part of this manual may be reproduced in any form or by
any means (including electronic storage and retrieval or translation into a foreign language) without prior agreement and written
consent from Ground Force Worldwide as governed by the United States and International Copyright Laws.
Printing History: First Edition – NOVEMBER 2021
REVISION DATE APPROVED DESCRIPTION
0 11/23/2021 JWEST Initial release
OPERATION & MAINTENANCE MANUAL
WATER PULL
SERIAL # 717H01 •12,000 GALLONS (45,425 LITERS)

WWW.GFWORLDWIDE.COM | [phone]
Valued Ground Force customer:
Thank you for selecting Ground Force Worldwide as your mine equipment supplier.
Our business is based on providing our customers with innovative solutions, manu-
factured of high quality, heavy-duty materials designed to out-perform in the most
extreme applications.
Upon purchase of your equipment, we strive to provide superior service throughout
the life of your product. Our Parts & Product Support Department is here to assist
you by answering technical questions, troubleshooting your equipment when needed,
and expediting your parts ordering. We stock the most commonly used parts for your
equipment and can ship overnight, when needed. Our Parts and Product Support
Representatives (PPSRs) are available 24/7.
Ground Force Worldwide proudly provides superior customer service through
the life of your equipment. Call us anytime at 1 [phone], or e-mail
ser[email protected], and let us assist you.
Sincerely,
Ground Force Worldwide
Documentation Department
CONTACT US
Ground Force Manufacturing, LLC
6001 E. Seltice Way
Post Falls, ID 83854 USA
Phone: [phone]
Fax: [phone]
Parts & Product Support E-mail: [email protected]
Service Department E-mail: Ser[email protected]
General E-mail: inf[email protected]
Web: www.gfworldwide.com
2
INTRODUCTION

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OPERATION & MAINTENANCE MANUAL
INTRODUCTION
CONTENTS
CONTACT US ..............................................................2
INTRODUCTION..........................................................2
OVERVIEW..................................................................4
SPECIFICATIONS........................................................5
SHIPPING DIMENSIONS............................................7
SAFETY.......................................................................8
PRE-COMMISSIONING ............................................15
OPERATION ..............................................................20
WATER CONTROL SYSTEM......................................28
MAINTENANCE SCHEDULES...................................38
TROUBLESHOOTING................................................41
WARRANTY ..............................................................52
PRODUCT REGISTRATION .......................................56
INDEX .......................................................................57
3

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HYDRAULIC LINES
PUSH BLOCK
GRAVITY DRIP BAR
REAR SPRAY BAR
HOSE REEL
SIGHT GAUGE
GROUND LEVEL FILL
ACCESS LADDER
ANODE
LIFTING EYE
SIDE SPRAY
STOP/TURN/
TAIL LIGHTS
LED FLOOD LIGHTS
WATER CANNON
ANTI-SKID TOP OF TANK
36" MANWAY
WATER PUMP
PPE TIE-OFF CABLE
INTERNAL
PLUMBING
INTERNAL BAFFLES
BRAKE ASSEMBLY
TRUNNION
DIESEL TANK
4
OVERVIEW

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SPECIFICATIONS
The Ground Force Worldwide Water Tanker is a
heavy-duty, custom-engineered water delivery tank,
offering solutions for dust suppression, re ghting
and general water truck needs.
Ground Force water tanks are engineered with an
internal endoskeleton and dual-radius semi-elliptical
design. This allows for an optimal center of gravity
while providing the strength needed for the water
tank to last in tough conditions. Ground Force water
tanks are fully bafed to break up water ow and
increase stability.
WARNING
Do not operate the Ground Force water tank in unsafe condi-
tions. Do not operate the Ground Force water tank in a man-
ner that violates local and site-specic laws and regulations.
717H01
• 12,000-gallon tank for 631K water-pull conversion -
(BSDA) new tank build
SCOPE OF WORK
• 12,000-gallon water tank to convert a new 631K tractor
to a water pull
• For a Ground Force-supplied new Caterpillar 631K Prime
Mover tractor with two tires (tractor side) and Caterpillar
631K - complete rear wheel and brake group, draft arms
and related Caterpillar parts kit to complete conversion
GFM WATER TANK SPECIFICATION
• 12,000-gallon water tank with T1 mold-board
• Brake Saver Drop Arm (BSDA) design
• Additional steel plate on shell bottom
• Ground Force bafing system and endo-skeleton
• GFM to chamfer all sharp edges inside of the tank so the
interior coating can properly adhere
• GFM to cap the ends of the transverse bafe channel
supports so water cannot enter and corrode
• 36" square manway with trash screen/safety grate
• PPE safety tie-off cable, entire length top of tank
• Anti-skid, top of tank
• Sump to be elevated to help prevent damage from debris
• (2) D-ring tie-offs at rear of tank
• Ladder with safety rail, side-mounted
• Trunnions for draft arm connection to tank
• Tank level sight tube with shut-off valves, installed on
front head
• High performance (B4) stainless steel water pump
• Low level shut-off
• Stainless steel rear spray bar with (4) hydraulic-op stag-
gered in-line valves with adjustable fan sprays; 3" NPT
pipe couplers with plugs on each end of spray bar
• (2) 2-1/2" re hose coupling, 3" brass ball valve at
each side of rear spray bar
• Stainless steel ground-level hydrant ll 3" with legal
air gap and bottom 90-degree elbow facing forward;
includes brass ball valve at connection point
• Low-point manual drains on all water circuits
• Includes Ground Force WCS (Water Control System);
WCS quick start guide
• Front-mounted 215-gallon diesel fuel tank
• New heavy-duty rear frame assembly w/ push block
• Painted Caterpillar yellow to match prime mover
• Rear structure mud aps
• Rear LED turn/ tail/ stop lights
• Backup lights
ANODES (4)
• Installation of sacricial (replaceable) anodes in tank for
corrosion resistance
GROUND FORCE ENHANCED CORROSION-
RESISTANT SPRAY PACKAGE
• All interior tank plumbing upgraded to stainless steel
• Rear spray bar upgraded to stainless steel
• Ground level hydrant ll plumbing to be stainless steel
• 4" stainless steel gravity dump bar
• (6) marine-grade alloy valves / spray heads included; (4)
rear spray bar, (2) side sprays
• Maxi spray valve – hydraulic operated, part
#MX80-DA-H-MK2
5
SPECIFICATIONS

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• Pump mounting plate upgraded to heavy-duty stainless
steel
• Stainless steel water pump upgrade (B4)
4" STAINLESS STEEL GRAVITY DUMP BAR
• Width of tank, at rear
• 4" schedule 40 pipe with 3/4" holes on 6" centers
• Operated from cab
HYDRAULIC OPERATED SIDE SPRAY
• Side spray (2) located at upper quadrants - front of tank
(2) HYDRAULIC REWIND HOSE REELS
• (2) water hose reel with 100' x 1-1/2" hose and adjust-
able nozzle
• Mounted on the rear of the machine
• Includes manual in-line shut-off (isolator) valve
• Includes addition of high idle switch box
• Air blow-down and control valve for hose draining
NITRO WATER CANNON
• Hard-wired joystick control operation
• 500 GPM adjustable nozzle
• Includes automatic drain feature to eliminate standing
water in Monitor pipe
(2) 24V LED UTILITY LIGHTS (USES BACKUP
LIGHTS WITH DEDICATED SWITCH)
• (2) 24V LED rear-mounted sealed-beam work lights
• Include control switch/circuit protection in tractor cab
• TYRI 1313 or similar 7,000 Lumens
WATER LEVEL INDICATOR ELECTRIC
• In-cab water level indicator
AUTOMATED GREASING SYSTEM
• Groenwald Beka Twin 3.1 Automated Greasing System
with 8-liter pump, in-cab display, and auxiliary grease
points on Cat 631K water pull with 34 grease points
• Optional add-on, Groenwald Twin 3.1 24V , 8L auto-
mated grease pump F605338
• Optional add-on Groenwald Twin system parts kit (large)
F198737
INTERIOR COATING
• Interior coating per spec provided by Skip Vernon CLT Inc
• NW Sandblast & Paint to sandblast the 12,000-gallon
tank interior to the product preparation specication
• Sandblast the interior of the tank to an SSPC-SP10 near
white metal
• Apply two coats of PPG Amerlock 2 Epoxy @ manufac-
turer’s recommendation of 4-8 mils dft per coat
• Apply caulking on all skip welds prior to applying the
second coat of epoxy (no additional cost)
• Have hold points for outside inspection QA after blast,
each coat of epoxy and caulking
6
SPECIFICATIONS

412"
144"
122"
TANK ONLY SHIPPING INFORMATION
WIDTH: 144"
HEIGHT: 122"
LENGTH: 412"
WEIGHT: (APPROX) 37,000 LBS
SHIPPING COMPANY TO SUPPLY
THEIR OWN DUNNAGE
REVISIONS
REV. ECN. DESCRIPTION DATE ORIGINATOR
D
C
B
A
A
B
C
D
1
2
3
4
5
6
7
8
8
7
6
5
4
3
2
1
DIMENSIONS ARE IN INCHES
TOLERANCES:
FRACTIONAL
1/16
ANGULAR: MACH/BEND .25
TWO PLACE DECIMAL .010
THREE PLACE DECIMAL .003
INTERPRET GEOMETRIC TOLERANCING
PER: ASME Y14.5 M-1982
MATERIAL:
DRAWN
CHECKED
ENG APPR.
DATE NAME
TITLE:
DWG. NO.
REV
SCALE: 1:64
UNLESS OTHERWISE SPECIFIED:
0
WB
8/11/2021
SHIPPING DRAWING
SHEET 1 OF 2
S-717H01
DO NOT SCALE DRAWING
GROUND FORCE MFG.
THE INFORMATION CONTAINED IN THIS
DRAWING IS THE SOLE PROPERTY OF
GROUND FORCE MFG., LLC . ANY
REPRODUCTION IN PART OR AS A WHOLE
WITHOUT THE WRITTEN PERMISSION OF
GROUND FORCE MFG., LLC. IS
PROHIBITED.
PROPRIETARY AND CONFIDENTIAL
412"
144"
122"
TANK ONLY SHIPPING INFORMATION
WIDTH: 144"
HEIGHT: 122"
LENGTH: 412"
WEIGHT: (APPROX) 37,000 LBS
SHIPPING COMPANY TO SUPPLY
THEIR OWN DUNNAGE
REVISIONS
REV. ECN. DESCRIPTION DATE ORIGINATOR
D
C
B
A
A
B
C
D
1
2
3
4
5
6
7
8
8
7
6
5
4
3
2
1
DIMENSIONS ARE IN INCHES
TOLERANCES:
FRACTIONAL
1/16
ANGULAR: MACH/BEND .25
TWO PLACE DECIMAL .010
THREE PLACE DECIMAL .003
INTERPRET GEOMETRIC TOLERANCING
PER: ASME Y14.5 M-1982
MATERIAL:
DRAWN
CHECKED
ENG APPR.
DATE NAME
TITLE:
DWG. NO.
REV
SCALE: 1:64
UNLESS OTHERWISE SPECIFIED:
0
WB
8/11/2021
SHIPPING DRAWING
SHEET 1 OF 2
S-717H01
DO NOT SCALE DRAWING
GROUND FORCE MFG.
THE INFORMATION CONTAINED IN THIS
DRAWING IS THE SOLE PROPERTY OF
GROUND FORCE MFG., LLC . ANY
REPRODUCTION IN PART OR AS A WHOLE
WITHOUT THE WRITTEN PERMISSION OF
GROUND FORCE MFG., LLC. IS
PROHIBITED.
PROPRIETARY AND CONFIDENTIAL
157"
3987.80mm
683"
17348.20mm
165"
4191mm
TRUCK SHIPPING INFORMATION
WIDTH: 157" 3,988 mm
HEIGHT: 165" 4,191 mm
LENGTH: 683" 17,348 mm
WEIGHT: (APPROX) 112,000 LBS 50,802 kg
SHIPPING COMPANY TO SUPPLY
THEIR OWN DUNNAGE
REVISIONS
REV. ECN. DESCRIPTION DATE ORIGINATOR
D
C
B
A
A
B
C
D
1
2
3
4
5
6
7
8
8
7
6
5
4
3
2
1
DIMENSIONS ARE IN INCHES
TOLERANCES:
FRACTIONAL 1/16
ANGULAR: MACH/BEND .25
TWO PLACE DECIMAL .010
THREE PLACE DECIMAL .003
INTERPRET GEOMETRIC TOLERANCING
PER: ASME Y14.5 M-1982
MATERIAL:
DRAWN
CHECKED
ENG APPR.
DATE NAME
TITLE:
DWG. NO.
REV
SCALE: 1:64
UNLESS OTHERWISE SPECIFIED:
0
WB
8/11/2021
SHIPPING DRAWING
SHEET 2 OF 2
S-717H01
DO NOT SCALE DRAWING
GROUND FORCE MFG.
THE INFORMATION CONTAINED IN THIS
DRAWING IS THE SOLE PROPERTY OF
GROUND FORCE MFG., LLC . ANY
REPRODUCTION IN PART OR AS A WHOLE
WITHOUT THE WRITTEN PERMISSION OF
GROUND FORCE MFG., LLC. IS
PROHIBITED.
PROPRIETARY AND CONFIDENTIAL
157"
3987.80mm
683"
17348.20mm
165"
4191mm
TRUCK SHIPPING INFORMATION
WIDTH: 157" 3,988 mm
HEIGHT: 165" 4,191 mm
LENGTH: 683" 17,348 mm
WEIGHT: (APPROX) 112,000 LBS 50,802 kg
SHIPPING COMPANY TO SUPPLY
THEIR OWN DUNNAGE
REVISIONS
REV. ECN. DESCRIPTION DATE ORIGINATOR
D
C
B
A
A
B
C
D
1
2
3
4
5
6
7
8
8
7
6
5
4
3
2
1
DIMENSIONS ARE IN INCHES
TOLERANCES:
FRACTIONAL
1/16
ANGULAR: MACH/BEND .25
TWO PLACE DECIMAL .010
THREE PLACE DECIMAL .003
INTERPRET GEOMETRIC TOLERANCING
PER: ASME Y14.5 M-1982
MATERIAL:
DRAWN
CHECKED
ENG APPR.
DATE NAME
TITLE:
DWG. NO.
REV
SCALE: 1:64
UNLESS OTHERWISE SPECIFIED:
0
WB
8/11/2021
SHIPPING DRAWING
SHEET 2 OF 2
S-717H01
DO NOT SCALE DRAWING
GROUND FORCE MFG.
THE INFORMATION CONTAINED IN THIS
DRAWING IS THE SOLE PROPERTY OF
GROUND FORCE MFG., LLC . ANY
REPRODUCTION IN PART OR AS A WHOLE
WITHOUT THE WRITTEN PERMISSION OF
GROUND FORCE MFG., LLC. IS
PROHIBITED.
PROPRIETARY AND CONFIDENTIAL
157"
3987.80mm
683"
17348.20mm
165"
4191mm
TRUCK SHIPPING INFORMATION
WIDTH: 157" 3,988 mm
HEIGHT: 165" 4,191 mm
LENGTH: 683" 17,348 mm
WEIGHT: (APPROX) 112,000 LBS 50,802 kg
SHIPPING COMPANY TO SUPPLY
THEIR OWN DUNNAGE
REVISIONS
REV. ECN. DESCRIPTION DATE ORIGINATOR
D
C
B
A
A
B
C
D
1
2
3
4
5
6
7
8
8
7
6
5
4
3
2
1
DIMENSIONS ARE IN INCHES
TOLERANCES:
FRACTIONAL
1/16
ANGULAR: MACH/BEND .25
TWO PLACE DECIMAL .010
THREE PLACE DECIMAL .003
INTERPRET GEOMETRIC TOLERANCING
PER: ASME Y14.5 M-1982
MATERIAL:
DRAWN
CHECKED
ENG APPR.
DATE NAME
TITLE:
DWG. NO.
REV
SCALE: 1:64
UNLESS OTHERWISE SPECIFIED:
0
WB
8/11/2021
SHIPPING DRAWING
SHEET 2 OF 2
S-717H01
DO NOT SCALE DRAWING
GROUND FORCE MFG.
THE INFORMATION CONTAINED IN THIS
DRAWING IS THE SOLE PROPERTY OF
GROUND FORCE MFG., LLC . ANY
REPRODUCTION IN PART OR AS A WHOLE
WITHOUT THE WRITTEN PERMISSION OF
GROUND FORCE MFG., LLC. IS
PROHIBITED.
PROPRIETARY AND CONFIDENTIAL
412" 144"
122"
TANK ONLY SHIPPING INFORMATION
WIDTH: 144"
HEIGHT: 122"
LENGTH: 412"
WEIGHT: (APPROX) 37,000 LBS
SHIPPING COMPANY TO SUPPLY
THEIR OWN DUNNAGE
REVISIONS
REV. ECN. DESCRIPTION DATE ORIGINATOR
D
C
B
A
A
B
C
D
1
2
3
4
5
6
7
8
8
7
6
5
4
3
2
1
DIMENSIONS ARE IN INCHES
TOLERANCES:
FRACTIONAL
1/16
ANGULAR: MACH/BEND .25
TWO PLACE DECIMAL .010
THREE PLACE DECIMAL .003
INTERPRET GEOMETRIC TOLERANCING
PER: ASME Y14.5 M-1982
MATERIAL:
DRAWN
CHECKED
ENG APPR.
DATE NAME
TITLE:
DWG. NO.
REV
SCALE: 1:64
UNLESS OTHERWISE SPECIFIED:
0
WB
8/11/2021
SHIPPING DRAWING
SHEET 1 OF 2
S-717H01
DO NOT SCALE DRAWING
GROUND FORCE MFG.
THE INFORMATION CONTAINED IN THIS
DRAWING IS THE SOLE PROPERTY OF
GROUND FORCE MFG., LLC . ANY
REPRODUCTION IN PART OR AS A WHOLE
WITHOUT THE WRITTEN PERMISSION OF
GROUND FORCE MFG., LLC. IS
PROHIBITED.
PROPRIETARY AND CONFIDENTIAL
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SHIPPING DIMENSIONS

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OPERATION & MAINTENANCE MANUAL
SAFETY
8

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GUIDELINES
Equipment and vehicles must be maintained to be safe and reliable. Due to Ground Force Worldwide’s global
presence and distribution, and the myriad of local, state, and federal regulations, it is impractical to provide
specic details of these regulations. The following are basic guide lines, which do NOT supersede on-site
requirements and regulations, which MUST be followed.
• Ensure that ALL operators have been trained on the
equipment they use and operate.
• Check vehicles at the beginning of each shift to
ensure that parts, equipment and accessories are
in safe operating condition. Repair or replace any
defective parts or equipment prior to use.
• Ensure the service, emergency and park brake sys-
tems are operational. Verify audible backup alarm
system is operational and working. Headlights, tail
lights, and brake lights MUST be operational. Verify
the windshield is clear and the windshield wipers
are operational.
• DO NOT operate the vehicle in reverse with an
obstructed rear view, unless it has a signal alarm
capable of being heard above ambient noise levels
or a signal observer indicates that it is safe to move
vehicle. Some operational areas require a spotter at
all times.
• Equipment should have roll-over protection, and
protection from falling debris as required by law.
• Ensure that vehicles used to transport workers have
seat belts, rmly secured and adequate for the
number of workers to be carried or transported.
• DO NOT modify the equipment’s capacity or safety
features without written approval from the Ground
Force Mfg. Engineering Department.
• Prior to permitting equipment or vehicles onto an
access roadway or grade, verify that the roadway
or grade is constructed and maintained to safely
accommodate the equipment, vehicles and loads
involved.
• Vehicles and equipment loaded from the top must
have cab shields or canopies to protect the operator
while loading.
• Verify the Pre-Shift Inspection has been completed
and signed off.
• Based on site conditions, you may choose to have
the chassis supplier lock out the top gears to pre-
vent excessive speed.
This safety guide is provided by Ground Force Worldwide to assist you in making
a safer workplace. Specic regulations at the site of operations supersede all basic
recommendations provided in following sections.
For more information contact your national, state, or local authority. The following
links are provided to assist you in compliance:
Occupational Safety and Health Administration
Mine Safety and Health Administration
Canadian Centre for Occupational Health and Safety
European Agency for Safety and Health at Work
Safe Work Australia
9
SAFETY

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WARNING
DO NOT attempt to use this equipment until you have thor-
oughly read this manual. It includes important safety pre-
cautions, detailed starting, operating and maintenance
instructions, and parts lists.
2.1 READ INSTRUCTIONS
• Read and follow the Owner’s Manual
carefully before installing, operating, or ser-
vicing equipment. Read safety information
at the beginning of the manual and in each
section. Heed warning labels on equipment
• Use only genuine replacement parts from the
manufacturer
• Perform maintenance and service according to the
owner’s manual
• ALWAYS follow national, state, and local codes
2.2 GENERAL SAFETY HAZARDS
• Always ensure vehicle is CLEAR of per-
sonnel before starting vehicle
• Always use wheel chocks when servicing
or working on vehicle
2.3 ENGINE EXHAUST CAN KILL
• Operate in open, well-ventilated areas or
vent exhaust outside
2.4 MOVING PARTS CAN INJURE OR KILL
• Do not operate with doors open or
guards off or removed
• Stop engine before servicing
• Keep hands, hair, loose clothing and
tools away from moving parts and machinery
2.5 BATTERY FUMES AND EXPLOSIONS
• Follow battery manufacturer’s instruc-
tions when working on or near a battery
• Stop engine before disconnecting or
connecting battery cables, battery charging
cables, or servicing battery
• Always wear a face shield, rubber gloves and protec-
tive clothing when working on battery
• Batteries produce explosive gases during normal
operation and when being charged. Keep sparks,
ames, cigarettes and other ignition sources away
from batteries
• Observe correct polarity (+ and -) on batteries
• Disconnect negative cable (-) rst and reconnect nega-
tive (-) cable last
• DO NOT tip battery
• Replace battery if damaged
• Do NOT charge a frozen battery
• Do NOT charge battery in a closed area or where venti-
lation is restricted
• In case of battery acid getting on face, on skin, or in
eyes, ush immediately with water for 5 minutes and
seek medical attention as soon as possible
2.6 FIRE HAZARDS
• Stop engine while fueling
• DO NOT smoke while fueling
• DO NOT leave nozzle unattended while
fueling
• Wipe up spilled fuel and allow fumes to clear before
starting engine
• DO NOT overll the fuel tank, fuel expansion may
cause overow
2.7 ELECTRICAL SHOCK CAN KILL
• DO NOT touch electrically live parts with
skin or wet clothing
• Insulate yourself from work and use
safety ground
• Always wear dry insulated gloves when working on
electrical equipment
• Always lockout/tagout equipment before performing
electrical work
10
SAFETY

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2.8 FALL HAZARDS
• Equipment operators and maintenance
personnel are susceptible to falls from
equipment during repair and servicing.
Prevent falls and slips by following these
guidelines:
• ON-SITE FALL HAZARD requirements supersede all
of the guidelines listed below. Closely follow on-site
safety rules.
• Know and identify what slip, fall and trip hazards are,
and what preventative measures are required
• Survey work area on and around equipment for slip
and fall hazards and remove hazards from area
• Never jump from equipment to the ground
• Use three points of contact when climbing equipment
• Where there is a danger of falling use a FALL
PROTECTION SYSTEM per OSHA AND MSHA
requirements.
• Always follow national, state and local codes:
https://www.osha.gov/SLTC/fallprotection/
2.9 PINCH POINT HAZARDS
• Never place yourself between a piece
of heavy equipment or machinery and an
immovable object
• Never work within the swing radius of
rotating equipment
• Always work at a safe distance from equipment
• Caught-in hazards exist when workers remove or dis-
able guards. Use extra caution when removing this
safety equipment as required for servicing
• Never place your hands or body near moving parts
• Gloves, long sleeve shirts, hair, and loose tting cloth-
ing can be hazardous if caught in moving parts
• Never exceed maximum load limits according to the
equipment and machinery specications
• All workers should wear bright protective clothing.
Signs that are highly visible should be set up in a way
to warn and discourage nonworkers from entering site
• Never forget one simple rule: PARKING BRAKES. They
are easy to operate and can save lives
• Always use wheel chocks when working on or near a
vehicle
• Always verify that vehicle is clear before starting
2.10 LOCK-OUT / TAG-OUT
1. IDENTIFY the types of energy sources used, potential
hazards, and control devices.
2. NOTIFY all affected employees.
3. TURN OFF all operating controls.
4. LOCATE all energy sources
5. ISOLATE all energy sources by blocking, bleeding
and ventilating stored energy as found in springs,
hydraulic systems, electrical systems and pneumatic
systems.
6. LOCK-OUT all switches and energy controls in the OFF
or SAFE position.
7. TEST operating controls. Put all controls in ON posi-
tion. Be sure no one can get hurt before testing.
8. RETURN all operating controls to the OFF position.
9. PERFORM required task.
10. REMOVE lock-out devices only after the equipment is
fully assembled and all affected employees have been
notied. Each lock-out device must be removed by the
person who put it on.
DANGERDANGER
DO NOT
OPERATE
EQUIPMENT
LOCK-OUT
TAG & LOCK ONLY TO BE REMOVED BY:
DATE:
11
SAFETY

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2.11 CONFINED SPACE SAFETY
Some maintenance procedures on Ground Force
Worldwide water trucks require entering the tank
itself. Working inside a conned space such as a
water tank is highly dangerous. Technicians work-
ing inside the tank must follow safety guidelines.
To work safely in a conned space, the entrant
must be able to communicate with the attendant
who is on duty outside the space. A system of com-
munication must be set up prior to beginning work.
The attendant must always be aware of what is
going on inside the space in order to be able to
react in event of an emergency.
Oxygen-decient atmospheres have less than 19.5
percent available oxygen by volume while normal
air contains approximately 21 percent oxygen.
Deviations from normal concentrations are a major
concern in conned spaces.
Ground Force water truck tanks are considered
“Permit-Required Conned spaces," based on the
following guidelines:
• Contains or has a potential to contain a hazardous
atmosphere.
• Contains a material that has the potential for engulf-
ing an entrant.
• Has an internal conguration such that an entrant
could be trapped or asphyxiated by inwardly converg-
ing walls or by a oor which slopes downward and
tapers to a smaller cross-section.
• Contains any other recognized serious safety or health
hazard, ex., reduced visibility, darkness, etc.
Equipment will include at a minimum:
• Ventilation Fans (1 minimum for Assembly, 2 minimum
for Fabrication) and hoses.
• A calibrated and tested air monitor.
• PPE appropriate to the tasks or jobs being performed.
• Lighting equipment appropriate to the task or jobs
being performed.
• Signs posting the conned space and restricting
access.
• Stanchions or other barriers restricting the access of
non-permit personnel.
• Radio equipment as necessary to support communica-
tion between the attendant(s) and entrant(s)
• Rescue equipment tested and in a place near the
conned space and readily available for rescue
personnel.
• OSHA requires that a standby person be present with
suitable rescue equipment when self-contained
breathing apparatus or hose masks with blowers are
used in atmospheres immediately dangerous to life or
health.
The following are other hazards you should consider when
evaluating a conned space:
• Temperature extremes can have an adverse effect on
entrants. For example, if a space has been steam-
cleaned, it must cool before any entry is made.
• Engulfment hazards such as loose material (grain,
sand, coal, etc.) can crust over in a bin and break
loose under your weight and trap you during entry.
• Noise can become excessive in a conned space and
can not only damage hearing but can affect communi-
cation, causing warnings to go unheeded.
• Slick/wet surfaces can cause slips and falls and
increase the chances of electric shock.
• Falling objects are a danger if work is being done
above the entrant in a conned space.
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2.12 FIRE EXTINGUISHER USE
WARNING
If you have the slightest doubt about your ability to ght a
re, EVACUATE IMMEDIATELY
Sound the re alarm and call the re department,
if appropriate. Identify a safe evacuation path
before approaching the re. Do not allow the re,
heat, or smoke to come between you and your
evacuation path. Select the appropriate type of re
extinguisher.
Discharge the extinguisher within its effective
range using the PASS method (Pull, Aim, Squeeze,
Sweep).
Back away from an extinguished re in case it
ames up again. Evacuate immediately if the extin-
guisher is empty and the re is not out. Evacuate
immediately if the re progresses beyond the incip-
ient stage.
Most re extinguishers operate using the follow-
ing P.A.S.S. technique:
1. PULL - Pull the pin. This will also break the tamper seal.
2. AIM - Aim low, pointing the extinguisher nozzle (or its
horn or hose) at the base of the re.
3. NOTE: Do not touch the plastic discharge horn on CO2
extinguishers. It gets very cold and may damage skin.
4. SQUEEZE - Squeeze the handle to release the extin-
guishing agent.
5. SWEEP - Sweep from side to side at the base of the
re until it appears to be out. Watch the area. If the
re re-ignites, repeat steps 2 - 4.
2.13 COMPRESSED AIR HAZARDS
FOLLOW ON-SITE COMPRESSED AIR HAZARDS
SAFETY REQUIREMENTS FOR PLACE OF
OPERATIONS. THE FOLLOWING ARE ONLY
BASIC GUIDELINES:
• Incorrect installation or operation of this unit could
result in equipment failure and personal injury. Only
qualied persons should install, operate, and service
this unit according to the owner’s manual, and indus-
try standards, always in compliance with national,
state and local codes
• DO NOT exceed the rated output or capacity of the
compressor or any equipment in the compressed air
system Before working on the compressed air sys-
tem, follow the in house (on site) LOCKOUT/TAG-OUT
procedure of the unit
• Turn off and follow above lockout/tag out procedure;
ensure that the pressure is released from the system,
and cannot accidently be applied
• The air compressor can start up at any time the switch
is “on.” Use caution any time the switch is on
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2.14 PERSONAL PROTECTIVE EQUIPMENT
• Hard hats. All persons shall wear suitable hard hats when in an area where fall-
ing objects may create a hazard.
• Protective footwear. All persons shall wear suitable protective footwear when
in or around an area where a hazard exists which could cause an injury to the
feet.
• Eye protection. All persons shall wear safety glasses, goggles, or face shields
or other suitable protective devices when in or around an area where a hazard
exists which could cause injury to unprotected eyes.
• Safety belts and lines. Safety belts and lines shall be worn when persons work
where there is danger of falling; a second person shall tend the lifeline when
bins, tanks, or other dangerous areas are entered.
• Reective clothing. Wear reective clothing which is highly visible (360
degrees) when the arms are up or down or when the body is in any position and
even on top of hard hat.
• Ear protection. Ear protection must be worn when the noise exposure level is
above 85 dBA.
• Respirators. A respirator should be worn if there is danger of harmful dusts,
fogs, smokes, mists, gases, vapors, and sprays.
• Hand protection. Wear appropriate gloves if there is danger of skin absorption
of harmful substances, chemical or thermal burns, electrical dangers, bruises,
abrasions, cuts, punctures, fractures or amputations.
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OPERATION & MAINTENANCE MANUAL
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PRE-SHIFT INSPECTION
1. Check for and tighten any hydraulic ttings that may loosen. Fittings will frequently
loosen and drip the rst few weeks of operation.
2. Visually inspect the area around the truck for leakage. Repair any leaks identied
during inspection. This inspection should include the interior of all compartments.
3. Visually inspect the body mounts daily for tightness. Loose body mounts are
indicated by mud build-up cracking away, or by visible gaps between mounting
components. Refer to maintenance section and tighten any loose mounts before
operating vehicle.
4. Visually inspect all tanks mounts using step #4 as a guideline.
5. Check for loose hoses and/or wiring harnesses which may become entangled
during operations. Secure any loose items before operating the vehicle.
6. Perform any other pre-operation inspections as required by the chassis
manufacturer or required by local procedures.
7. On hose reels, if so equipped, apply one pump with a manual grease gun to the
reel bearing every 2 months.
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3.1 PRE-OPERATION NOTE
Because of strict regulations which govern the over-
seas shipment of equipment, any uids or oils which
are not necessary for movement of this unit have
most likely been removed or drained.
Any and all gate valves or ball valves pertaining to the
hydraulic oil tank have been closed to help eliminate
any interior contamination to the tank.
3.2 POST-SHIPMENT PREPARATION
This unit has been specially prepared to eliminate the
damage that can occur to equipment during ocean
transport. There are a few procedures that may need
to be addressed prior to operation of this unit.
• Remove all shipping lm. This lm is typically
applied with a paint spray gun. This is meant to pro-
vide protection directly on non-painted, machined
surfaces. The lm may be removed by wiping down
the surface with a rag soaked with lacquer thinner
or strong grade rubbing alcohol. Because this lm is
very tacky and is not soluble with water or most oils,
all surfaces must be cleaned thoroughly to prevent
the malfunction of moving parts.
3.3 PHYSICAL INSPECTION
After delivery of the unit, it should be inspected to
ensure that components did not loosen during shipping.
Particular attention should be paid to the following:
• Body Mounts - The rubber skirt board will allow for
some settling of the body during transport. Refer
to the maintenance instructions provided in the
Ground Force Worldwide Parts Manual for body
mount locations and torque specications. Be sure
that the rubber skirt board between the sub frame
and the chassis frame is in the correct location, and
re-torque all body mounting fasteners as dened in
the maintenance section of this manual.
• Compartments - Inspect all compartments and
remove any loose parts. Check that all hose reels,
control panels, pumps, etc. are securely fastened to
their respective mounting brackets.
3.4 OPTIONAL ACCESSORIES
There are a variety of accessories available on water
trucks, with some options only available on specic
chassis types.
General options available on all vehicles:
• Anodes
• Manway access hatch
• Fill chute
• Low-level shut off
• Side spray
• Visual water level
indicator
• Electric water level
indicator
• Foam injection system
• Auxiliary air compressor
• Gravity dump bar
• Pressure bar
• On load/ll pump
• Pressure washer system
• Remote controlled
water cannon
• Suction loading system
• Clearance light system
• High performance
pump
• Intermittent spray
package
Platform-specic
options:
• Hydraulic cylinder lift
• Platform with hydraulic
step
WATER TRUCK COMMISSIONING PROCEDURE
The following procedures apply to units that have
been mounted on the chassis at the factory. This
procedure is written to provide the mechanics in the
eld with a list of steps and checks to be performed
to ensure that the unit is ready to be placed in ser-
vice. Most of these steps are very general in nature
and assume that the technician performing them is
already familiar with the basic operations of a water
vessel. Truck-specic operating instructions will be
found in the Operations section of the Ground Force
Worldwide Owner’s manual. Any drawings that may
be necessary for eld installation of components are
provided as separate documents (in crate with loose
parts). If further guidance or clarication is required,
please contact:
Ground Force Worldwide Service Department
E-mail: ser[email protected]
Telephone: [phone]
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3.5 LOOSE PARTS
The oodlights are removed from the truck after test-
ing and shipped as loose parts. This is to prevent
damage during shipping. The oodlights should be
re-installed and re-connected. There may be other
loose parts shipped as well (bumpers, handrails,
wheel chock holders, etc.) Refer to the overview
drawings (or any specic instructions provided) and
install these parts in their proper locations.
3.6 LIGHTING SYSTEMS
Note that lighting systems will only work on this body
with the ignition key on. Refer to the Ground Force
Worldwide Owner’s Manual for specic information.
• Verify that all headlights, marker lights, turn signals,
beacons, etc. work properly. Also check that the back-
up alarm works.
• Check all exterior oodlights for proper operation.
• Check that any interior compartment lights are working
properly.
3.7 CUSTOMER-INSTALLED COMPONENTS
Some components required for operation of this truck
are supplied by the customer. These include items
such as additional lighting or visibility items, quick
disconnect (QD) couplings for tank lling, extra re
extinguishers or re suppression systems, placards
and signs relating to specic products to be placed in
the product tanks, etc. Determine what components
(if any) are required and install them prior to lling
any product or foam tanks or placing truck in service.
3.8 PRE-START CHECKS
Refer to the vehicle owner’s manual and perform all
new unit break-in and pre-startup inspections.
3.9 ENGAGING HYDRAULIC SYSTEM
Once all of the above steps are complete, start the
truck and engage the hydraulic system. When the
hydraulic system is properly engaged and there is no
hydraulic demand, the system standby pressure will be
indicated on the system pressure gauge at the opera-
tor’s station. This indicated pressure will rise and fall
based on hydraulic system demand.
3.10 WATER PUMP ROTATION
Reversing the operation of a centrifugal water pump
will result in poor water pump performance and will
lead to water pump damage. Verify the direction of
the water pump’s rotation before initial testing.
The water pump will not operate without water in the
tank above the low-level shut off set point. If it is nec-
essary to test without water in the tank, jumper the
wires on the low-level oat on the front head of the
tank. Contact Ground Force for more information.
WARNING
Do not run the pump for more than a couple of seconds.
Running a dry pump can cause pump damage.
3.11 ELECTRICAL CONTROL CHECKS
Perform the below checks with the ignition key on
but the engine not running. It is often convenient to
perform these checks before lling the water tank. It
may be necessary to engage the hydraulic system for
some of these checks.
• Check all lighting circuits and the back-up alarm.
• The low level shutdown circuit must be tested prior
to lling the tank with water. Turn the water pump
control switch to on while observing the low level
shutdown timer. The timer should shift and break the
pump’s electrical control circuit after ve seconds.
• Check that the spray head controls energize the
correct solenoid coil. Check that the buttery valve
controls operate the correct valve in the proper
direction.
• Verify that the water cannon responds correctly to
the directional controls.
3.12 INITIAL START UP
1. Start the truck and allow the engine to warm up
according to the manufacturer’s instructions.
2. Verify that the hydraulic system engages and
that the water pump direction of rotation is
correct.
3. Refer to the Operation section in this manual.
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Test all delivery functions according to these
instructions.
4. Reset the water level if equipped with analog
water level gauge (oat switches are installed on
the tank). Press buttons 1, 3, 4 & 5 at the same
time to open the water level reset option.
5. Press the Reset Water Level button, then press
X to return to the main screen.
Once all operational tests are complete, the water
truck is ready to be placed in service.
3.13 TANK FILLING
Once all of the loose components have been re-
installed and the controls have been veried, the
water truck is ready to be lled in preparation for an
operational test. Refer to the Water Control System
section and check for proper operation of all water
delivery systems.
• Before lling the water tank, verify that all low point
drain valves are shut, and that all low point drain
plugs are re-installed.
• After the drains are veried sealed, ll the water
tank according to local procedures. Observe any
tank level indicator system that may be installed to
verify operation during water tank lling.
• Engage the hydraulic system and start the water
pump. Verify direction of rotation if not already
performed. Reverse operation of a centrifugal water
pump will result in poor water pump performance
and often lead to water pump damage.
• Cycle each spray head individually and adjust collar
for proper spray pattern.
• Engage the spray head timers and verify that the
timers are working correctly and respond to opera-
tor input.
• Open the water cannon isolation valve and verify
acceptable water cannon performance. It is nec-
essary to raise engine speed to achieve optimum
performance.
3.14 DIESEL-FIRED HEATING SYSTEM
If a heating system is installed, check its operation
as follows:
• Verify that the system surge tank level is a minimum of
halfway up the lower sight gauge. Fill this tank as neces-
sary with engine coolant.
• Refer to the manufacturer’s start-up instructions and
start the heater.
• Monitor the heater’s operation, and the level in the
surge tank. It may be necessary to re-prime the heater’s
recirculation pump as air bubbles work out of the
system.
• The heater is thermostatically controlled, and the burner
will cycle on and off automatically. The system should
be allowed to run until the burner cycles three or four
times with no drop in surge tank level or re-priming of
the recirculation pump.
• Even after this initial testing is complete, it is still pos-
sible for air pockets to be trapped in the system. These
trapped air pockets will work themselves out of the
system within the rst few days of truck operations with
the heater’s recirculation pump running. During this
time frame, the level in the surge tank must be carefully
monitored to prevent allowing the pump to run dry and
cause damage to the pump.
NOTICE
For further information contact Ground Force Technical
support to request the manufacturer’s manual by writing
to ser[email protected].
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OPERATION & MAINTENANCE MANUAL
OPERATION
SECTION 4
WATER DELIVERY SYSTEMS
4.1 OPERATOR'S STATION
All components and systems installed by Ground
Force Worldwide are electrically controlled unless
otherwise noted. Operator controls are located in
the cab of the chassis.
Some components and systems may be controlled
from the operator’s station at the rear of the body.
Electrical power for all body-mounted systems is
supplied from the fuse panel in the relay enclosure.
This enclosure is physically located at the front of
the water tank.
4.2 NOISE LEVELS
Noise levels present at the operator's station may
vary, and depend on the equipment under service,
the specic functions active, and the status of exter-
nal doors. Use caution and evaluate each work site
for the specic site-specic levels of airborne noise
emissions. Hearing protection is mandatory when
operating for extended periods or in noisy environ-
ments that exceed 85 dBa. Refer to the chassis
manufacturer's information regarding internal cab
sound rating.
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