Sutphen SL75 User manual

SINGLE AXLE AERIALS 2012
Manual-2012 _SL75-SA75-SP70.docx Page 1 of 55 8/31/2012
Sutphen Corporation
OPERATION
MANUAL
Models SL75, SA75 & SP7
Aerial Ladders and Aerial Platform

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TABLE OF CONTENTS
INTRODUCTION......................................................................................................................... 4
OPERATION SAFETY POINTS................................................................................................ 5
GENERAL WARNING................................................................................................................ 7
AERIAL TOWER OPERATION ............................................................................................... 8
Do not exceed the rated capacities!...........................................................................................................................8
CAB SET-UP FOR AERIAL OPERATION............................................................................................................8
STEPS FOR PLACING PTO IN GEAR .................................................................................... 9
ENGAGE THE POWER TAKE-OFF (PTO) PLACING PTO IN GEAR..............................................................9
CAB SET-UP FOR PUMP OPERATION................................................................................ 10
SET UP FOR SIMULTANEOUS TOWER AND PUMP OPERATIONS ...........................................................10
AERIAL TOWER SET-UP ....................................................................................................... 12
TOWER OPERATION .............................................................................................................. 15
GROUND STABILIZERS......................................................................................................................................15
RAISE/LOWER ......................................................................................................................................................15
EXTEND AND RETRACT ....................................................................................................................................16
ROTATION.............................................................................................................................................................16
HIGH SPEED CONTROL......................................................................................................... 17
AUXILIARY HYDRAULIC POWER SWITCH .................................................................... 18
SAFETY INTERLOCK SYSTEM............................................................................................ 19
INTERLOCK JACK RELEASE.............................................................................................................................20
WATERWAY AND NOZZLE .................................................................................................. 21
DRAINING OF WATERWAY AND NOZZLE .....................................................................................................21
PLATFORM MOUNTING AND LEVELING SYSTEM....................................................... 22
OPTIONAL BREATHING AIR SYSTEM.............................................................................. 22
RETRACT THE TOWER.......................................................................................................................................23
ROTATE THE TOWER .........................................................................................................................................23
LOWER THE TOWER...........................................................................................................................................23
REMOVE WHEEL CHOCKS................................................................................................................................23
RETRACT THE STABILIZERS ...........................................................................................................................24
AERIAL TOWER LUBRICATION AND SERVICE............................................................. 25
STABILIZERS........................................................................................................................................................25
MAIN LIFT CYLINDERS .....................................................................................................................................25
PIVOT SHAFT BEARINGS ..................................................................................................................................25
TURNTABLE BEARING.......................................................................................................................................25
ROTATION GEAR REDUCER .............................................................................................................................26
DRIVE GEARS.......................................................................................................................................................26
TOWER EXTENSION/RETRACTION CYLINDER (Models SA65, SA75, & SP70)......... Error! Bookmark not
defined.
TOWER EXTENSION/RETRACTION CYLINDER (Model SL75 only) ............................................................26
SHEAVES AND CABLES .....................................................................................................................................27
SLIDE BLOCKS.....................................................................................................................................................29
WATERWAY AND SEALS ....................................................................................................................................29
WATERWAY AND SEALS ...................................................................................... Error! Bookmark not defined.
WATERWAY NOZZLE..........................................................................................................................................30
PLATFORM MOUNTING AND LEVELING SYSTEM......................................................................................30
HYDRAULIC OIL TANK ......................................................................................................................................31
High Pressure Filtration System................................................................................................ 35
MAINTENANCE OF STRUCTURE........................................................................................ 35
ALUMINUM TOWER STRUCTURE ...................................................................................................................35
TURNTABLE ATTACHMENTS...........................................................................................................................35
ATTACHMENT OF SUPPORT STRUCTURE TO TRUCK FRAME ................................................................36
EXTENSION SYSTEM..........................................................................................................................................27

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AERIAL TOWER LUBRICATIONAND MAINTENANCE SCHEDULE.......................... 37
TORQUE SPECIFICATIONS .................................................................................................. 38
....................................................................................................................................................... 44
....................................................................................................................................................... 46

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INTRODUCTION
This manual has been written by service and engineering specialists. This manual will help
acquaint you with the operation and maintenance of your apparatus, as well as the set-up and
use of the tower during emergencies. You are urged to read this manual carefully. Following
the instructions and recommendations in this manual will help assure the safe and reliable
operation of your apparatus.
After you have read this manual, it should be stored in the apparatus or another location for
quick and easy reference for all firefighters.
Throughout this manual safety alerts are provided at sections where special attention should
exercised. These areas are identified with the following signal words and symbols.
DANGER indicates a hazardous situation which, if not avoided, will result in
death or serious injury.
WARNING indicates a hazardous situation which, if not avoided, could result in
death or serious injury.
CAUTION indicates a hazardous situation which, if not avoided, could result in
minor or moderate injury.
NOTICE is used to address practices not related to physical injury.
Safety Instructions signs indicate specific safety-related instructions or
procedures.
These serve as reminders to follow all instructions carefully. Failure to follow instructions could
cause personal injury or damage to your apparatus.
There may be circumstances that arise throughout the life of this apparatus which do not
appear in this manual. At all times, common sense and safety should be your first
consideration.
Thank you for purchasing your apparatus from Sutphen. We work toward giving you complete
satisfaction. Sutphen knows your apparatus best and has the parts and factory-trained
technicians available. Please do not hesitate to contact Sutphen at 1-8 -343-2712.

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OPERATION SAFETY POINTS
The aerial tower is only as good or as safe as the operator is competent. Continued training
and familiarization is essential.
Personnel should not climb the aerial tower until the ground operator indicates it is safe to do
so.
Do not operate turntable controls while personnel are climbing the tower.
Personnel should use a life belt when operating off aerial tower.
At night, the entire aerial tower should be well lighted.
Do not forcefully extend the end of the tower against a structure.
Never use the tower as a battering ram.
Never use the aerial tower for pulling down walls or structural members.
Never willingly or intentionally abuse an aerial tower by careless handling, overloading, or use
for which it was not designed.
Operate the aerial tower with deliberate motions and smooth application of power.
The operator should always remain at the aerial controls while the aerial tower is in use.
Stabilizers with ground pads should always be used when operating the aerial tower.
Safety locks on stabilizers should always be in place.
Most problems encountered with operation of the tower are caused by inadequate
maintenance. To keep the tower fully operational, routine maintenance policies must be
followed.
Frequently inspect the chassis and running gear, and maintain in good mechanical condition
following recommended schedules in this manual. The aerial tower is of no use unless it can be
transported to where it is needed. Careful, safe driving rules should be observed for the same
reason.
Carefully and frequently check and inspect the entire aerial tower equipment for loose bolts or rivets;
unlubricated bearing surfaces; bent, warped, or twisted parts; hydraulic leaks; defective electric

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control equipment; etc. Follow the recommended maintenance schedules in this manual.
All members should frequently practice the different phases of aerial tower operations.
Never set up the aerial tower on marshy ground, freshly filled ground, or other soft surfaces.
Never apply opposing alternating control when operating the aerial tower, either in a side to
side motion, a front to rear motion, or an up and down motion. This may set up an accelerated
oscillation which could put undue strain on the structure, cause immediate or eventual failure
of the aerial tower, or cause injury to the occupants or bystanders.
Do not overload the tower. Observe the load limit. The load limit is 1 lbs. on the 75’ aerials
and 7 ’ platform without water in the waterway, in any position of operation. Do not exceed
the number of persons it can hold.
Although the tower is designed for a one person operation, it is a good safety practice to
designate a person to observe the right side stabilizer when the stabilizers are being set up.
This person can place the stabilizer pad, observe that it is placed evenly and correctly, and
make sure the stabilizer is set properly.
Do not permit an untrained person, or a person who is not thoroughly familiar with this tower,
to operate it unless constantly supervised.
The operator must:
1. Be capable of spotting the tower properly.
2. Be able to stabilize the tower properly.
3. Know the location of every control.
4. Know what each control does and how it works.
5. Be able to operate all controls smoothly and safely6. Know the location of safety devices,
how they work and how to operate.
7. Be familiar with the loads that the tower can safely accommodate under various operating
conditions.
8. Be aware of how to operate the tower under unusual circumstances.
When you consider the lives at stake, the cost of an aerial tower and the damage that could
occur to the equipment, the importance of training and practice becomes very clear.

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GENERAL WARNING
DO NOT OPERATE THIS APPARATUS UNTIL YOU ARE:
•THOROUGHLY FAMILIAR WITH THIS INSTRUCTION MANUAL.
•THOROUGHLY TRAINED IN THE OPERATION OF THIS APPARATUS.
•ABLE TO OPERATE THIS APPARATUS IN STRICT ACCORDANCE WITH THE
MANUFACTURER'S RECOMMENDATIONS.
•ABLE TO OPERATE THIS APPARATUS IN ACCORDANCE WITH DEPARTMENTAL RULES
AND REGULATIONS.
NOTE: FAILURE TO DO SO COULD RESULT IN DAMAGE TO THIS APPARATUS.
AND/OR RESULT IN INJURY OR DEATH TO PERSONS OPERATING, OR WORKING ON
OR AROUND THIS APPARATUS.

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AERIAL TOWER OPERATION
RATED CAPACITIES:
65’ 75’ Aerials (built prior to August 18, 2 6)
The rated capacity of the 65’ and 75’ aerials is 5 lbs. with or without water in
the waterway, in any position of operation.
70’ Platforms (SP70) (built prior to August 18, 2 6)
The rated capacity of the 7 ’ aerial platform is 5 lbs. with or water in the
waterway, 75 lbs. without water in the waterway, in any position of operation.
75’ Aerials(SA75) and 70’ Platforms (SP70) (built after to August 18, 2 6)
The rated capacity of the 7 ’ aerial platform and 75’ box boom is 75 lbs. with
water in the waterway, 1 lbs. without water in the waterway, in any position
of operation.
75’ Aerials(SL75)
The rated capacity of the 75’ aerial ladder is 75 lbs. with water in the waterway,
1 lbs. without water in the waterway, in any position of operation.
Do not exceed the rated capacities!
CAB SET-UP FOR AERIAL OPERATION
1. Spot the rig about 2 feet from the building when possible.
2. Set the parking brake and place the transmission in neutral.

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STEPS FOR PLACING PTO IN GEAR
ENGAGE THE POWER TAKE-OFF (PTO) PLACING PTO IN GEAR
The PTO operates the hydraulic pump, which provides pressure to the hydraulic system.
An electric switch located near the center of the cab dash panel activates the
PTO. A pilot light will come on when the PTO switch is moved to the "in" position.
A. Engine must be at idle R.P.M.
B. Be sure there is at least 9 lbs. air pressure on truck air system.
C. Truck must be at complete stop, parking brake set, and transmission in neutral.
D. Move PTO switch on dash to "in" position. (Wait about 2 seconds.)
The cab controls are now set to operate the tower. The operator should move to the hydraulic
system control compartment, located on the driver's side, at the first door, left of the pump
panel.
If the fire pump is not in use, proceed to AERIAL TOWER SET-UP on page 12 of these
instructions.

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CAB SET-UP FOR PUMP OPERATION
See Fire Pump Manufacturer’s Manual for more detailed information.
TO PLACE FIRE PUMP IN GEAR:
1. Truck must be stopped and parking brake set.
2. Truck transmission should be in "neutral" position.
3. Engine must be at idle R.P.M.
4. Move the pump shift lever from "road" position to "pump" position. Do this by pulling
back on the lever. At the same time the pump shift is activated, the lock-up for the
automatic transmission is also engaged. The pump shift lever holds the transmission in
the pumping gear position.
5. Shift transmission to Drive position. Power from the engine is now being transferred to
the pump drive gear and pump impellers are turning. Observe the illuminated green
indicator light next to the shift lever. If the light is not lit, the pump is not engaged, and
you need to repeat steps 1-5 and observe for pump engagement.
6. Leave transmission selector in "neutral" for the pump to be ready to operate without
churning. For pump operations, put transmission selector in Drive.
SET UP FOR SIMULTANEOUS TOWER AND PUMP OPERATIONS
1Follow STEPS FOR PLACING PTO IN GEAR on page 9.
2Follow AERIAL TOWER SET-UP instructions on page 12.
3Leave transmission selector in "neutral" for the pump to be ready to operate without
churning.
4Repeat steps 4 through 6 for placing pump in gear on this page.
When arriving at a structure fire or on occasion where the tower is not immediately needed,
but the fire pump is being used, place the PTO in gear and deploy the ground stabilizers
before placing the fire pump in gear. Then, if the need to use the tower arises while the fire
pump is being used, the stabilizers can be set and the tower will be ready for immediate use.
If the PTO is not engaged before the pump is set up, then slow the engine to idle before
engaging PTO.

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Attempting to place the PTO in gear with the pump in gear will result in
serious damage to the PTO and transmission -- unless engine RPMs are at
idle -- approximately 700 RPM.

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AERIAL TOWER SET-UP
1. Leave transmission in neutral.
2. Set parking brake.
3. Engage PTO at engine idle.
4. Exit cab.
5. Place wheel chocks approximately 3” in front of and behind rear tires.
6. Pull out operator's step.
7. Set ground pads and stabilizers. Do this by pressing the “LOWER” control switch (See
figure 1). This is located near the control box, on the vertical face of the compartment
adjacent to the pump panel. Next, use the high speed until the jacks are all the way out
and down. Then, set the pins in place and ensure that both locks are down.
Power lines should always be observed and avoided at all times.
This Aerial Device is rated for service in winds up to 30 mph sustained or
50 mph gusts.

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Figure 1
The aerial is now ready for operation. The automatic jack locks should have engaged, and
hydraulic power diverted to the aerial controls. (See figures 2 & 3).
Figure 2


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Figure 3
The aerial ladder must be operated with respect, discretion, and proper training. The aerial
ladder should move on low speed when there is any danger, electric wires, buildings, at close
operations, returning to the cradle, and during operation around the cab. When the aerial is
returned to the cradle, remove jack pins and push the "Jack Release" switch. A hydraulic valve
will transfer power from the aerial to the jacks, locking out the aerial ladder functions and
allowing jack operation.
Always place pads under stabilizers to ground the truck in the event the
tower comes in contact with power lines. Failure to do so could result in
serious injury or death.
Operator must install safety pins and locks on stabilizers.
Operator must always stand on the operator's step to help prevent operator
from becoming the ground in the event tower comes in contact with power
lines. Failure to do so could result in serious injury or death.
8. Switch ON the "Upper Power" and "Bucket Power" switches (if equipped) located on the
pump panel.
All operating controls at the turntable are hydraulic.
All operating controls in the platforms are electric.
"Upper Power" switch controls lighting, intercom (if equipped) and rung alignment light (if
equipped).
9. Verify with all personnel that the tower is ready to operate. When stabilizers and ground
pads are properly set on stable ground, the tower is designed to operate at optimum
operational height and horizontal reach with rated payload. Always operate the tower
with precaution so it does not strike the cab or any other portion of the truck.

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TOWER OPERATION
Never operate the tower without first deploying the stabilizer jacks with
proper ground pads beneath them.
At all times, the ground operator must be at the controls, standing on the
slide out step, for safe operation.
GROUND STABILIZERS
The ground stabilizers of the underslung design, consists of an outrigger with inner and outer
tube and a down jack hydraulic cylinder. The inner tube extends out from the outer tube of the
outrigger; this assembly is angled down to the ground by the jack cylinder, for a total span of 16
feet.
Operate the stabilizers by depressing the lower switch, located near the control box.
When operating jacks, the "high speed" switch should always be used to
increase engine RPMs and to apply correct pressures on the stabilizers.
Always place metal pads under stabilizers to ground the truck in the event
the tower comes in contact with power lines. Failure to do so could result in
serious injury or death.
RAISE/LOWER
When lifting the tower from the cradle, the first motion of the tower should be “Tower Raise”.
This should continue until the tower is well above the truck.
Raise the tower by pulling the right lever, located at the control box, outward.
Lower the tower by pushing the right lever, located at the control box, inward.
Controls in platforms (if equipped) are duplicates of lower controls.
When raising the tower, extreme caution must be used near power lines.
The operator must see the tower structure from base to tip to make sure
the tower is clear.

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Make sure the tower has cleared the truck body, cab, and lights before
rotating. The recommended procedure for tower operation is a slow,
steady movement of the control lever. This will produce a smooth tower
operation.
Rapid movement of the control levers will result in rough jerking of the
tower. This will create excessive loading on the tower structure. This kind
of operation is unsafe and will lead to premature wear and possible
structure failure.
The tower can be elevated from minus 4 degrees to plus 75 degrees from horizontal while in
any position that does not cause an interference with the body or cab.
EXTEND AND RETRACT
Extend the tower by pushing the left control lever, located at the control box, inward.
Retract the tower by pulling the left control lever, located at the control box, outward.
ROTATION
Rotate the tower to the left by pushing the center control lever, located at the control box,
inward.
Rotate the tower to the right by pulling the center control lever, located at the control box,
outward.
The tower can rotate a continuous 36 degrees either to the left or to the right.

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HIGH SPEED CONTROL
A "High-Speed" switch is located on or adjacent to the pump panel. This switch increases the
engine speed and hydraulic pressure at the same time. The speed of any operation of the
tower can be increased with this switch. CAUTION MUST BE TAKEN WHEN USING THIS "HIGH-
SPEED" SWITCH.
Before engaging the "High-Speed" switch, the operations control lever must be
in position. When coming off "High-Speed", release the switch, then release the
control lever to complete movement. This will give a smooth and safe operation.
When extending the tower and using the "High-Speed" control, release the "High-
Speed" switch before reaching maximum extension. Tower extension will stop at
maximum extension of the tower. (There is no signal device for indicating full
extension.)
When retracting the tower and using the "High-Speed" switch, the same
procedure applies to the use of the "High-Speed" control. Make sure to release
the "High-Speed" switch before reaching full retracted position.
The tower can rotate a continuous 360 degrees to the left or right. Use the "High-
Speed" switch, if it is necessary to rotate the tower at a faster speed.
The rotation control lever must be engaged before engaging the "High-Speed"
switch. When coming off "High-Speed", release the "High-Speed" switch before
releasing the rotational control lever. This will give a smooth operation. WHILE
ROTATING THE TOWER, THE OPERATOR SHOULD NOT CHANGE DIRECTIONS
BEFORE THE TOWER COMES TO A COMPLETE STOP! If the operator accidentally
changes rotation direction with the tower not coming to a complete stop, a built-
in relief valve is provided to reduce the shock. However, in no way should this be
an operational practice!

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AUXILIARY HYDRAULIC POWER SWITCH
The auxiliary hydraulic power switch is to be used only to place the
ladder back
into cradle and to raise the jacks - not to be used for normal operations.
The auxiliary hydraulic power switch is located inside the hydraulic compartment. Use the
auxiliary hydraulic power switch if a main hydraulic pump fails in the tower or if the truck
engine fails. The auxiliary power is an electric motor, operating from the truck battery system
which operates the auxiliary hydraulic pump.
Operate the motor by activating the momentary auxiliary power switch.
All tower functions can be operated on auxiliary power.
Prolonged operation could cause the motor to overheat. The operator should
avoid overheating and burning out the motor. If the motor becomes hot,
shut down and allow it to cool. Failure to do so could result in serious
damage to the motor.

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SAFETY INTERLOCK SYSTEM
The safety interlock system prevents operating the tower until the stabilizers are properly set.
The system is an electric hydraulic locking device. When the stabilizers are properly set,
hydraulic power is transferred to the aerial controls.
To operate, place the PTO in gear according to the instructions in the cab. To operate the aerial
properly, pull out the step at the pump panel. Depress the “LOWER” switch. Use the "Hi-
Speed" until the jacks are completely out and down. Set the pins.
The aerial is now ready for operation. The hydraulic transfer valve should have shifted from
jack to aerial position, allowing the controls to operate the aerial ladder. The aerial ladder must
move on low speed when there is any danger, electric wires, buildings, at close operations,
returning to the cradle, and during operation around the cab. Return the aerial to the cradle,
remove jack pins, and push the "Jack Release" switch. The hydraulic circuit will transfer, locking
out the aerial ladder functions and allowing jack operation. The aerial ladder must be operated
with respect, discretion, and proper training.
The stabilizers must be visually checked by the operator or a designated
person to make sure the stabilizers and pads are properly set and safety pins
inserted.

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INTERLOCK JACK RELEASE
The safety interlock system is provided with a "Jack Release" switch. (See figure 4)
Figure 4
Never operate the tower unless the stabilizers and pads are properly set.
The "Jack Release" switch, when activated, transfers operation to the stabilizers. Use this
switch only when operations are complete and ladder is back in cradle.