Apparatus Supplement: Refurbishing an Aging Fleet

June 1, 2017
Robert Corsi explains the several factors to consider when selecting an apparatus to refurbish.

Download the full PDF of the supplement here.

Today’s fire apparatus are taller and larger, and may not fit in the aging fire stations across the country, especially in the Northeast. As such, many fire departments are opting to refurbish an older piece of equipment, rather than buying new, particularly as they keep an eye on their budget. It is important to remember that reserves can be just as important as first-line apparatus. However, we need to recognize when repairs end up costing more than they are worth, meaning it’s time to call it quits and look for something new. 

Deciding factors

Picking a good, solid truck to update is essential. Some factors to consider include the engine, transmission, pump, water tank, cab, body, aerial (if equipped) and chassis and body corrosion.

One of the first things that should be done when assessing a truck is to thoroughly check the chassis and body for corrosion. If the truck is equipped with a multi-layered chassis, look for bulges between the layers and bulges in the web and spreading in the flanges. Typical areas are over the rear springs, just in front of and behind the front and rear springs. On pumpers, check where the pump mounts to the chassis for corrosion and spreading. Also inspect all body and cab mounts.

On a ladder, check the torque box, outriggers, rotation bearing and gear box, and hydraulic hoses and lines. The stick should be inspected closely for wear to the rails from the slides or rollers, whichever the truck uses. Sometimes, the slides will wear out and make grooves in the rails. Look for ironing (i.e., flat spots) from the rollers and fire-damaged spots in the rails. Pay particular attention to the swivel at the base of the ladder; all the hydraulic and electrical lines and a waterway (if equipped) run through the swivel. Check for leaks and loose mounting brackets. The annual aerial inspection procedure will guide you in this process.

If you find corrosion, you may need to have the truck sandblasted or deslagged. Then, the thickness must be measured ultrasonically to ensure the integrity of the metal. The truck manufacturer can provide you with the acceptable limits. After this, it is necessary to prep the metal and then use a good chassis epoxy paint to prevent future corrosion. Painting over corrosion—although easier—is not a good idea.

Once you have checked out the chassis, you can look at the springs, brakes and rims. Springs and brakes can be easily replaced by a local spring shop, thus saving money. Rims can be reconditioned.

Further, the engines of older trucks (pre-diesel particulate filter emissions) can be overhauled in-chassis. This makes the repair much more cost-effective than to replace the whole engine. By repairing it in-chassis, there is also no need to update to DPF emissions. On pre-DFP apparatus, doghouses are smaller, which creates more space for the driver and officer.

Older trucks can be retrofitted with LED lighting upgrades, lowering electrical loads. Older systems used relays that were overloaded by incandescent lights. With LED lights, the load demand is much lower, so the systems work fine. Newer multiplex systems are not, however, without problems: They can have electrical connection issues. They also take a higher level of expertise to repair them compared to the old relay systems.

Additionally, upgrading to newer and stronger SCBA-mounting brackets improves cab safety in case of an accident. Some older trucks have very high entrance steps leading to injuries. This can be easily changed by adding lower steps to the bottom of the truck, whether it’s the cab or the dovetail. Also, adding a retarder to the braking system can improve stopping distance.

If the truck is equipped with a fire pump, a thorough pump test—which must be conducted annually—should be performed by an EVT-certified mechanic. This will ensure that the priming pump, valving, pump transmission and pressure-regulating system are in good working order.

Tires are an easy fix, but we still need to verify that the tires have not exceeded the recommended usable life.

The newer electronic transmissions generally don’t have mechanical problems; most of the time, a problem will be related to sensors or wiring. Take a look at the wiring harnesses coming out of the transmission. If they look like they’ve been spliced and repaired, you might want to replace them.

Cab design is another factor in this process. Some of the older trucks have non-tilting cabs, which decreases access to the engine, transmission and radiator, which then increases the cost of repair. A tilting cab is especially important when doing an in-chassis overhaul.

The radiator should be visually inspected for corrosion on the cooling fins. When doing an in-chassis overhaul, always flush and pressure test the radiator.

A polypropylene water tank is a good sign that the truck is not too old to upgrade. If it has a steel tank, the truck may be just too old. Most poly tanks have a substantial warranty.

Things to avoid

There are several factors that could signal that an apparatus is not right for a refurb:

  • Old ball-and-socket steering linkage with adjustable sockets
  • Older truck cabs that do not have enough personal space for safety (i.e., head room, leg room)
  • Older engines that have poor track records
  • Under-powered apparatus
  • Trucks with a history of electrical problems or poorly-repaired electrical systems

Before starting a major repair, be sure to consider the rest of the vehicle. There may be multiple parts and systems that need to be changed. Be mindful of the time and costs of the total job.

Finding the diamond in the rough

There are several sources to find used apparatus that are suitable for fire department use. One that we have used is government surplus.

We received a pumper that had a few mechanical problems but, overall, is a very good pick for repurposing as a reserve truck. The chassis and body have virtually no corrosion, and it has a tilt cab and roll-up doors. The pump is in excellent condition, and the engine type—though not my first choice—runs very well.

To make the pumper ready for service, the lighting has been upgraded to LED, and we installed new SCBA brackets and a Federal Q siren. We also added a shore charger to maintain battery voltage and supply power to accessories. 

Another option for used apparatus is a dealer trade-in.

Final thoughts

Annual third-party tests are a good baseline to use as a guide. Remember to always have the vehicle third-party tested once the repairs are completed.

A good source for information on this subject can be found in NFPA 1912: Standard for Fire Apparatus Refurbishing. 

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