refurb to 1912 standards

1. REFURB TO 1912 STANDARDS FDSOA 2009 Apparatus Specification & Vehicle Maintenance Symposium Tuesday, January 20

3. Standard contains 6 chapters Ch. 1: Administration Ch. 2: Referenced publications Ch. 3: Definitions Ch. 4: General requirements Ch 5: Level 1 refurbishing Ch 6: Level 2 refurbishing

4. and 5 annexes Explanatory Material Fire Apparatus Refurbishing Specifications Weights and Dimensions for Common Equipment Guidelines for First Line and Reserve Apparatus Informational References

5. Ch. 1: Administration Scope Applicable to who performs the refurb, i.e. the fire department, local gov�t maintenance facilities, private contractors, or apparatus manufacturers Purpose Minimum requirements

6. Ch. 1: Administration (cont.) Application All contracts awarded on or after 7-1-06 Equivalency Must be documented to the AHJ

7. Ch. 2: Referenced Publications NFPA: 1901 (apparatus) 1906 (wildland apparatus) 1911 (service, testing, maintenance) 1931 (ground ladders) 1961 (hose) 1964 (nozzles)

8. Ch. 2: Referenced Publications(cont.) Merriam-Webster�s Collegiate Dictionary Nat�l Electrical Manufactures (NEMA) NEMA Z535.4: Std. for Product Safety Signs and Labels

9. Ch. 3: Definitions 58 listed Key definitions: Shall v. should AHJ �An organization , office, or individual responsible for enforcing the requirements of a code or standard, or for approving equipment, materials, and installation, or a procedure.�

10. Ch. 3: Definitions(cont.) Key definitions: Refurbishing Level 1: �The assembly of a new fire apparatus by the use of a new chassis frame, driving and crew compartment, front axle, steering and suspension components, and the use of either new components or components from an existing apparatus for the remainder of the apparatus.�

11. Ch. 3: Definitions(cont.) Key definitions: Refurbishing Level 2: �The upgrade of major components or systems of a fire apparatus with components or systems that comply with the applicable standards in effect at the time of the original apparatus was manufactured.�

12. Ch. 4: General Requirements Level 1 refurb must meet the applicable standards of the current edition of NFPA 1901 or 1906. Level 2 refurb must meet the applicable chapters of the NFPA 1901/1906 edition that was in effect when the apparatus was manufactured.

13. Ch. 4: General Requirements(cont.) Responsibility of the Purchaser Specify details Required performance elevations above 2,000� grades steeper than 6% max. number of ff�s riding added electrical loads that exceeds the minimum of the standard Added equipment that exceeds the minimum of the standard (esp. hose and ground ladders)

14. Ch. 4: General Requirements(cont.) Responsibility of the apparatus and equipment remains with the contractor until accepted by the purchaser. Responsibility of the Contractor Detailed description of the refurbed unit List of equipment to be furnished Other construction details to which the apparatus must conform

15. Ch. 4: General Requirements(cont.) If the following NEW components are used, they must meet the current edition of the applicable standard: Pumps Tanks Aerial Devices CAFS Line Voltage

16. Ch. 4: General Requirements(cont.) If the following NEW components are used, they must meet the current edition of the applicable standard: Command and Communications Air System Winch System Chassis Components Engine Transmission/Transfer Case

17. Ch. 4: General Requirements(cont.) If the following NEW components are used, they must meet the current edition of the applicable standard: -Braking system -Axle(s) -Suspension, Wheels, and Tires -Cooling system -Low voltage systems

18. Ch. 4: General Requirements(cont.) If the following NEW components are used, they must meet the current edition of the applicable standard: -Frame -Driveline -Lubrication system -Fuel and air system -Exhaust system -Driving and Crew Compartments

19. Ch. 4: General Requirements(cont.) Must comply with all federal and state motor vehicle laws Personnel Protection Guards, shields, other protection added as necessary Electrical insulation or isolation must be provided to prevent shock No sharp or rough edges All warning signs, labels must meet NEMA Z535.4

20. Ch. 4: General Requirements(cont.) Carrying Capacity must have adequate GVWR Contractor must provide estimated in-service weight including: Chassis, body and full tank(s) Fuel, lubricants, and other fluids 200 lbs for each seated position

21. Ch. 4: General Requirements(cont.) Contractor must provide estimated in-service weight 70 lbs of PPE for each seated position Pumps, aerial devices, generators, reels, and air systems Ground ladders and hose Misc. equipment

22. Ch. 5: Level 1 Refurbishing Carrying capacity: Cannot exceed GVWR Stability: Center of gravity must not exceed limits set by manufacturer Front to rear weight must not exceed limits set by the manufacturer Front axle loads not less than min. specified by manufacturer Side to side tire load must have no more than 7% of the total tire load for that axle

23. Ch. 5: Level 1 Refurbishing(Cont.) Must have a new frame Thorough examination of drive train components if re-used Contractor must provide in writing any damage to drive train components If new drive train components are used, installation must meet manufacturer�s recommendations

24. Ch. 5: Level 1 Refurbishing(Cont.) Engine and engine system design If original engine used, thorough inspection required Check for wear, fluid leaks, loss of power, etc. All belts and filter must be replaced If engine and system are replace, it must meet current NFPA requirements EPA certification of engine must be provided

25. Ch. 5: Level 1 Refurbishing(Cont.) Cooling system Thorough inspection for leaks, blockages, wear and other problems System must be flushed and new coolant added If system replace, it must meet current NFPA 1901 or 1906

26. Ch. 5: Level 1 Refurbishing(Cont.) Lubrication System If original system used, thorough inspection must be performed to look for leaks, blockages, etc. Contractor must provide purchaser of any problems in writing If new system is installed, it must meet the current requirements of NFPA 1901/1906

27. Ch. 5: Level 1 Refurbishing(Cont.) Fuel and Air Systems must be replaced to meet current NFPA 1901/1906 Exhaust system must be replaced to meet current NFPA 1901/1906

28. Ch. 5: Level 1 Refurbishing(Cont.) Braking system Contractor must certify that system meets current requirements of NFPA 1901/1906 New system or components must be certified by manufacturer that they meet current requirements of NFPA 1901/1906 Parking brakes must control rear wheels or all wheels and must be positive, mechanically actuated

29. Ch. 5: Level 1 Refurbishing(Cont.) Braking system Parking brake must hold apparatus on 20% grade Lock-up device to retain applied pressure on hydraulically actuated service brake systems, or use of the �park� position on an automatic transmission must not be substituted for a parking brake system GVWR over 36,000 requires auxiliary braking system

30. Ch. 5: Level 1 Refurbishing(Cont.) Suspension, Wheels and Tires Suspension must be replaced to meet current NFPA 1901/1906 If existing axle(s), wheels, or tires are used, contractor must inspect and verify condition of these components for emergency service use. Damaged components shall be repaired or replaced Contractor must certify that axles, wheels, & tires meet federal GVWR requirements

31. Ch. 5: Level 1 Refurbishing(Cont.) Transmission/Transfer Case If existing units are used, the contractor shall inspect mountings and accessories for wear, damage and leaks Contractor must notify purchaser in writing of any problems All fluids and filters must be changed If new or rebuilt unit is installed, the contractor must certify it meets the manufacturer�s specifications

32. Ch. 5: Level 1 Refurbishing(Cont.) The following must be replaced to meet current NFPA 1901/1906 Steering system Fuel tank Low voltage electrical systems and warning devices Driving and Crew Compartments

33. Ch. 5: Level 1 Refurbishing(Cont.) Body, Compartmentation, and Hose Storage If original body used, must be inspected for serviceability and upgraded to current NFPA 1901/1906 If body is replaced, components must meet current 1901/1906 If compartments are added to an existing body, current 1901/1906 must be met Metal finish must meet current 1901/1906

34. Ch. 5: Level 1 Refurbishing(Cont.) Fire Pump and Associated Equipment If original pump is used, must be inspected to include mountings, wear, damage, and leaks Contractor must notify purchaser in writing of any problems New or upgraded components must meet current 1901/1906 Pump packing shall be adjusted according to pump manufacturer�s recommendation

35. Ch. 5: Level 1 Refurbishing(Cont.) Water Tanks If reused, contractor must inspect for serviceability and report any defects in writing If new tank, must meet current NFPA 1901/1906 New water tank must not result in completed apparatus exceeding GVWR

36. Ch. 5: Level 1 Refurbishing(Cont.) Aerial devices Must be inspected and tested according to NFPA 1911 Test shall be performed prior to refurbishing to determine condition of aerial device If original device is used, must meet requirements of standard in effect at time of manufacturer

37. Ch. 5: Level 1 Refurbishing(Cont.) If the following are new, they must meet the applicable NFPA standard: Ground ladders 1931 Hose 1961 Nozzles 1964

38. Ch. 5: Level 1 Refurbishing(Cont.) Testing and Certification Pump tested and certified same as new apparatus Tank to pump Engine overload test Pressure control test Priming system test Vacuum test Aerial must be certified

39. Ch. 5: Level 1 Refurbishing(Cont.) Testing and Certification Documentation Water Tank Capacity Piping hydrostatic test Electrical systems Foam systems Road tests Brake tests

40. Ch. 5: Level 1 Refurbishing(Cont.) Testing and Certification Documentation New pump test plate if new pump installed Label certifying compliance to applicable FMVSS

41. Ch. 6: Level 2 Refurbishing(Cont.) All new or upgraded components must meet current edition of 1901/1906 Purchaser must specify which components and systems are to be upgraded All components must be compatible GVWR must not be exceeded Vehicle stability requirements same as Level 1

42. Ch. 6: Level 2 Refurbishing(Cont.) Frame Must be inspected for wear, damage, broken or loose bolts Contractor must notify purchaser in writing of any problems found

43. Ch. 6: Level 2 Refurbishing(Cont.) Drive train requirements basically same as Level 1 Engine requirements basically the same as level 1 except must meet 1901/1906 edition at time of manufacture Cooling system requirements basically the same as Level 1 Lubrication system must meet engine manufacturer�s requirements rather than NFPA�s

44. Ch. 6: Level 2 Refurbishing(Cont.) Fuel and Air systems not required to be replaced, but contractor must certify that upgrades meet current edition of 1901/1906 Exhaust system, braking system, suspension, wheels, tires, steering, fuel tank, low voltage systems, and warning devices requirements same as above

45. Ch. 6: Level 2 Refurbishing(Cont.) Transmission/transfer case requirements same as level 1 Specific requirements for electrical loads not specified in Level 1 Audible warning devices requirements almost identical to new apparatus.

46. Ch. 6: Level 2 Refurbishing(Cont.) Driving and Crew Compartment Existing cab areas must be inspected for mountings, damage, wear and corrosion Found damage must be reported to purchaser in writing New cab must meet current 1901/1906 Airflow through the radiator must remain sufficient If open cab is converted to enclosed cab, 1901 requirements must be met

47. Ch. 6: Level 2 Refurbishing(Cont.) Body, compartments, hose beds, etc. Inspect for wear, damage, and corrosion Contractor notifies purchaser in writing of any problems New body or additional compartments must meet current edition of NFPA 1901/1906

48. Ch. 6: Level 2 Refurbishing(Cont.) Metal finish Must comply with 1901/1906 including reflective striping Paint or coating must conform the paint or coating manufacturer�s recommendations Purchaser must specify whether non-metal components are to painted Purchaser must specify any lettering, numbering, or decorative striping

49. Ch. 6: Level 2 Refurbishing(Cont.) Fire Pump and Associated Equipment Inspect mountings and accessories for wear, damage, and leaks Notify purchaser in writing of any problems. Packing must be adjusted to pump manufacturer�s recommended tolerances

50. Ch. 6: Level 2 Refurbishing(Cont.) Water Tank Existing water tank examined and any problems reported to purchaser in writing New tank must meet current edition of NFPA 1901/1906 New tank must not compromise overall GVWR

51. Ch. 6: Level 2 Refurbishing(Cont.) Aerial Devices Inspect mountings, controls, and accessories and report any problems in writing to purchaser New or replacement parts must be compatible with design of original aerial device and meet NFPA requirements at time of original manufacturer New aerial device must meet current requirements of NFPA 1901/1906

52. Ch. 6: Level 2 Refurbishing(Cont.) Equipment New ground ladders must meet NFPA 1931 New hose must meet NFPA 1961 New nozzles must meet NFPA 1964

53. Ch. 6: Level 2 Refurbishing(Cont.) Pump Tests Independently certified at contractor�s approved facility If unit has water tank, a tank to pump test must be performed New pumps must be tested to current edition of NFPA 1901/1906 If original pump is used, must be tested to edition of NFPA 1901/1906 in effect at time of manufacture

54. Ch. 6: Level 2 Refurbishing(Cont.) Pump Tests If a new or upgraded pump is used, an engine overload test required to meet current edition of NFPA 1901/1906 If original pump is used, an engine overload test required to meet edition of NFPA 1901/1906 in effect at time of apparatus manufacture

55. Ch. 6: Level 2 Refurbishing(Cont.) Pressure Control Device, Priming System and Piping (vacuum test), and Tank-to-Pump New or upgraded device(s) must be tested to current edition of NFPA 1901/1906 Original device(s) used must be tested in accordance with NFPA 1911

56. Ch. 6: Level 2 Refurbishing(Cont.) Aerial Device Test New or upgraded device must be tested to current edition of NFPA 1901/1906 at manufacturer�s approved test facility and certified by an independent third party If original device is used, it must be tested in accordance with NFPA 1911

57. Ch. 6: Level 2 Refurbishing(Cont.) Water Tank Capacity Test New tank must meet current NFPA 1901/1906 Existing tank must meet edition of NFPA 1901/1906 in effect at time of apparatus manufacturer

58. Ch. 6: Level 2 Refurbishing(Cont.) Low Voltage System Tests Line-Voltage System Tests Foam System Test Road Tests �Substantial� changes must meet current edition of NFPA 1901/1906 If existing system left in tact, test must be to edition in effect at time of apparatus manufacturer

59. Ch. 6: Level 2 Refurbishing(Cont.) Upon delivery, contractor must supply: Engine manufacturer�s certified brake horsepower curve if new engine installed Record of refurbishment showing compliance to NFPA 1911 Pump manufacturer�s certified suction capabilities and hydrostatic piping test for new pumps Certification of required inspections and tests Weight documents from a certified scale

60. Ch. 6: Level 2 Refurbishing(Cont.) Testing and Certification Documentation New pump test plate if new pump installed Label certifying compliance to applicable FMVSS

61. Annexes Annex A: Explanatory Material Annex B: Refurb Specification Form Annex C: Equipment Weights and Dimensions Form Annex D: Guidelines for First Line and Reserve Apparatus Annex E: Informational References

62. Making Older Apparatus Safer LED Lights

63. Making Older Apparatus Safer Hose Containment

64. Making Older Apparatus Safer Chevrons

65. Making Older Apparatus Safer Alert Drivers of Hazards

66. Making Older Apparatus Safer Responder Safety Vests

67. Making Older Apparatus Safer Traffic Cones

68. Making Older Apparatus Safer Flares

69. Making Older Apparatus Safer Signage

70. Making Older Apparatus Safer Advance Warning

71. Making Older Apparatus Safer Seat Belt Monitoring

72. Making Older Apparatus Safer SCBA Brackets

73. Making Older Apparatus Safer Helmet Holders

74. Making Older Apparatus Safer Install CAFS

75. Making Older Apparatus Safer Improve Step Slip Resistance

76. Making Older Apparatus Safer Add steps

77. Making Older Apparatus Safer Add Slide-out Trays and Tool Boards

78. Making Older Apparatus Safer Vehicle Data Recorders

79. Making Older Apparatus Safer To get a copy of NFPA 1912 or NFPA 1901, go to www.nfpa.org

80. Thanks for attending I can be reached at: RTutterow@ci.charlotte.nc.us