This document is an operation and maintenance manual for a Ground Force Worldwide Water Pull, a heavy-duty, custom-engineered water delivery tank designed for dust suppression, firefighting, and general water truck needs. The manual covers various aspects of the device, from its technical specifications and operational procedures to maintenance schedules and troubleshooting.
Function Description
The Ground Force Worldwide Water Pull is a specialized water tanker that integrates with a Caterpillar 631K tractor for water-pull conversion. Its primary function is to deliver water for dust suppression, firefighting, and other water truck applications. The tank features an internal endoskeleton and a dual-radius semi-elliptical design, which optimizes the center of gravity and provides structural strength for demanding conditions. The water tanks are baffled to manage water flow and enhance stability during operation.
The Water Pull is equipped with a Water Control System (WCS) display/control module, encoder, and keypad, allowing the operator to adjust water delivery parameters based on current conditions without stopping the truck. This system enables the operator to select and modify various spray programs, manage water pump operations, and monitor water levels.
Important Technical Specifications
- Tank Capacity: 12,000 gallons (45,425 liters).
- Conversion: Designed for conversion with a new Caterpillar 631K tractor.
- Tank Design: T1 mold-board, Brake Saver Drop Arm (BSDA) design, additional steel plate on shell bottom, Ground Force baffling system, and endo-skeleton.
- Safety Features: Chamfered sharp edges inside the tank for coating adherence, capped baffle channel supports to prevent corrosion, 36" square manway with trash screen/safety grate, PPE safety tie-off cable along the entire top of the tank, anti-skid top surface, elevated sump to prevent debris damage, (2) D-ring tie-offs at the rear, side-mounted ladder with safety rail, trunnions for draft arm connection, tank level sight tube with shut-off valves on the front head.
- Water Pump: High performance (B4) stainless steel water pump with low-level shut-off.
- Spray System: Stainless steel rear spray bar with (4) hydraulic-operated staggered in-line valves and adjustable fan sprays, 3" NPT pipe couplers with plugs. (2) 2-1/2" fire hose couplings with 3" brass ball valves at each side of the rear spray bar.
- Hydrant Fill: Stainless steel ground-level hydrant fill (3") with legal air gap and bottom 90-degree elbow, including a brass ball valve.
- Water Control System (WCS): Includes Ground Force WCS with a quick start guide.
- Fuel Tank: Front-mounted 215-gallon diesel fuel tank.
- Frame Assembly: New heavy-duty rear frame assembly with push block, painted Caterpillar yellow to match the prime mover.
- Lighting: Rear structure mud flaps, rear LED turn/tail/stop lights, backup lights.
- Corrosion Resistance: (4) sacrificial (replaceable) anodes in the tank. Enhanced corrosion-resistant spray package with all interior tank plumbing, rear spray bar, and ground-level hydrant fill plumbing upgraded to stainless steel. 4" stainless steel gravity dump bar. (6) marine-grade alloy valves/spray heads (4 rear, 2 side). Maxi spray valve (hydraulic operated, part #MX80-DA-H-MK2).
- Gravity Dump Bar: 4" stainless steel, width of tank at rear, 4" schedule 40 pipe with 3/4" holes on 6" centers, operated from cab.
- Side Spray: (2) hydraulic operated side sprays located at upper quadrants (front of tank).
- Hose Reels: (2) hydraulic rewind hose reels with 100' x 1-1/2" hose and adjustable nozzle, mounted on the rear of the machine, includes manual in-line shut-off (isolator) valve, high idle switch box, air blow-down and control valve for hose draining.
- Water Cannon: Hard-wired joystick control operation, 500 GPM adjustable nozzle, automatic drain feature.
- Utility Lights: (2) 24V LED rear-mounted sealed-beam work lights (uses backup lights with dedicated switch), includes 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 with 8-liter pump, in-cab display, and auxiliary grease points on Cat 631K water pull (34 grease points). Optional add-ons available.
- Interior Coating: Per spec provided by Skip Vernon CLT Inc, NW Sandblast & Paint to SSPC-SP10 near white metal, two coats of PPG Amerlock 2 Epoxy (4-8 mils dft per coat), caulking on all skip welds.
Usage Features
The Water Pull is designed for ease of operation and precise water delivery.
- Water Control System (WCS): The WCS allows operators to adjust water delivery parameters on the fly. It features a display screen with icons for timer control, settings menu, system options, water level bar graph, curb side spray, driver side spray, work lights, safety beacon, timer/staggered mode indicator, onload pump, active program, highlighted program, water cannon, side spray, water tank, gravity drain valve, drip bar, rear spray bar spray head, and water pump indicator.
- Program Selection: Operators can select from pre-programmed spray patterns (P1-P6) using the encoder. The active program is indicated in green, and selected programs are highlighted in white.
- Program Editing: The WCS allows editing of existing programs to customize spray valve configurations, timed modes (ON-OFF-ON), and staggered modes (RIGHT-LEFT-RIGHT). PIN protection can be applied to individual programs.
- Water Pump Operation: The water pump is started by pressing and holding two lower buttons on the encoder simultaneously. It automatically shuts off when the water level reaches a low-level set point to prevent damage. A low-level bypass function allows temporary pump operation for 15 seconds.
- Water Cannon: Operated via a joystick or push-button remote, allowing directional control of the water stream. Engine speed can be increased to extend the range of the water cannon.
- Hose Reel: Spring-rewind hose reels are operated by engaging the water pump and opening a ball valve. Hoses are locked in place by a ratchet and pawl system and rewind automatically.
- Ground Speed Control: A variable speed option for the water pump allows water distribution to match the chassis's ground speed, preventing over-watering or incomplete coverage.
- Freeze Protection: Procedures are outlined to drain water from the tank, spray heads, water cannon, and pump housing to prevent freezing damage.
- Safety Features: The manual emphasizes safety guidelines, including pre-shift inspections, proper use of personal protective equipment (PPE), and lockout/tag-out procedures for maintenance.
Maintenance Features
The manual provides comprehensive maintenance schedules and troubleshooting guides to ensure the longevity and reliable operation of the Water Pull.
- Maintenance Log: Daily, monthly, 2-month, 4-month, 6-month, yearly, and 2-year maintenance schedules are provided.
- Daily Maintenance: Includes visual inspection of hydraulic fluid level, body mounts, rear body pins, tank mounts, pump mounting bolts, hoses and fittings for leaks, secure hoses and wiring harnesses, fluid levels for auxiliary heater fuel and expansion tank, hydraulic control valve operation, safety equipment presence and functionality, and auxiliary heating system operation.
- Monthly Maintenance: Change hydraulic filters, inspect for damage/loose screws/leaks (hoses, fittings, pumps, motors, couplers), adjust water pump stuffing box (drip rate 40-60 DPM), and operate auxiliary heater for 10 minutes.
- 2-Month Maintenance: Lubricate water pump, hose reel fairlead rollers, and hose reels and swing joints.
- 4-Month Maintenance: Inspect hydraulic oil.
- 6-Month Maintenance: Inspect oil cooler and anodes (replace if necessary).
- Yearly Maintenance: Inspect for damage/loose clamps/cracks, inspect PPE tie-off cable on top of tank, inspect PPE tie-off points on rear and bottom of tank, clean water pump suction strainer, and service auxiliary heat system.
- 2-Year Maintenance: Replace oil cooler.
- Vendor-Supplied Components: Maintenance information for non-Ground Force components is to be found in the respective manufacturer's manuals.
- Oil Cooler Maintenance: Instructions for inspecting for leaks (water ingress into hydraulic oil) and winterizing the oil-to-water cooler by draining water and purging with compressed air.
- Troubleshooting: Detailed sections for electrical, water pump, spray heads, hydraulics, and water cannon issues, providing causes and solutions. For example, solutions for blown fuses, low-level shut-off issues, pump shaft/coupler breakage, and water cannon malfunctions are provided.
- Warranty: A limited warranty covers defects in materials, workmanship, and design for one calendar year or 5,000 hours of operation. A product registration form must be completed within 45 days of commissioning to activate the warranty. The distributor warranty policy outlines labor credit, job number assignment, and claim procedures.
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