[Inspection and Preventive Maintenance Services for Fire-Protection Equipment and Appliances]
[From the U.S. Government Publishing Office, www.gpo.gov]

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Document Reserve
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WAR DEPARTMENT TECHNICAL MANUAL
NON-CIRCULATING
INSPECTION and PREVENTIVE
MAINTENANCE SERVICES FOR
FIRE-PROTECTION
EQUIPMENT and APPLIANCES
JF A R DEPARTMENT
J A N UA R Y 1946
N i
.	(Lh. I
VJ I. 35: 5-U7
TECHNICAL MANUAL
TM 5-687 c 1
INSPECTION AND PREVENTIVE MAINTENANCE SERVICES FOR FIRE-PROTECTION EQUIPMENT AND APPLIANCES
Changes No. 1
TM 5-687, 15 January 1946, is changed as follows:
WAR DEPARTMENT Washington 25, D. C., 24 September 1946
Figure 11 Fire extinguisher tag Figure 12 is rescinded.
32.	Form.
* * * [AG 300.7 (13 Sep 46)]
Record tag, WD AGO Form 253 (fig. 11) is printed in two colors: green for carbon dioxide gas extinguishers and buff for all other types. The following information is recorded:
* * * *
By order of the Secretary of War:
DWIGHT D. EISENHOWER
Chiej oj Stajj
Official:
EDWARD F. WITSELL
Major General
The Adjutant General Distribution:
AAF (2); AGF (5); T (Eng) (10); Dept (Eng) (5); Base Comd (10); Def Comd (Eng) (10); HD (Eng) (5); Tech Sv (2) except OCE (75); AAF Comds (Air Instls) (ZI) (10); AAF Comds (Eng) (Overseas) (2); AMA (Air Instls) (5); FC (Eng) (5); BU (Eng) (Overseas) (2); Class HI Instls (Eng) (5); PE (Eng) (5); Ars (Eng) (5); Dep (Eng) (5); Dist 5 (2); Div Eng (10); GH (Eng) (5); RH (Eng) (5); A (2); A (Eng, R&U) (10); D (Eng) (2); Bn (Overseas) (2); AF (Air Instls) (ZI) (5);AF (Eng) (Overseas) (2).
For explanation of distribution formula, see FM 21-6.
AGO 664A—Sept. 705557°—46
U. S. GOVERNMENT PRINTING OFFICE: 1946
WAR DEPARTMENT	TECHNICAL	MANUAL
T M	5-687
INSPECTION and PREVENTIVE
MAINTENANCE SERVICES FOR
FIRE-PROTECTION
EQUIPMENT and APPLIANCES
WAR DEPARTMENT • JANUARY 19 4 6
United States Government Printing Office Washington : 1946
WAR DEPARTMENT
Washington 25, D. C., 15 January 1946
TM 5—687, Inspection and Preventive Maintenance Services for Fire-protection Equipment and Appliances, is published for the information and guidance of all concerned.
[AG 300.7 (12 Dec 45)]
By order of the Secretary of War:
Official :
EDWARD F. WITSELL
Major General
Acting The Adjutant General
DWIGHT D. EISENHOWER Chief of Staff
Distribution :
AAF (2) ; AGF (2) ; ASF (2) ; T of Opns (Eng) (10) ; Dept (Eng) (5) ; S Div ASF (1); Tech Sv (2) except OCE (100); SvC (Eng) (10); FC (Post Eng) (5); Class HI Instls (5); PE (Eng) (5); Sub-PE (Eng) (5); Cargo PE (Eng) (5); Ars (Eng) (5); Dep (Eng) (2); Dist O, 5 (2) ; Div Eng (10) ; GH (Post Eng) (5); ASF Tng C (Eng Sec) (5); D (Eng) (2).
Refer to FM 21—6 for explanation of distribution formula.
CONTENTS
Paragraphs Page
CHAPTER 1.
CHAPTER 2.
Section I.
II.
III.
IV.
V.
VI.
CHAPTER 3.
Section I.
II.
III.
IV.
V.
VI.
VII.
VIII.
CHAPTER 4.
Section I.
II.
III.
IV.
V.
VI.
CHAPTER 5.
GENERAL....................................... 1-4	1
MOTORIZED FIRE APPARATUS AND AUXILIARY PUMPING EQUIPMENT.
General ................................... 5-6	3
Types of fire apparatus.................... 7-10	3
Routine inspections and preventive maintenance services ................................... 11-18	9
Operational	preventive maintenance ......... 19-21	14
Winterization............................... 22-26	15
Records ....................................... 27	17
FIRE EXTINGUISHERS.
General .................................... 28-30	18
Tags ...................................... 31-32	19
Water hand-pump extinguishers.............. 33-35	21
Generated-pressure extinguishers .......... 36-39	24
Carbon tetrachloride extinguishers......... 40-42	32
Carbon dioxide gas extinguishers........... -43 45	35
Miscellaneous extinguishers................. 46-47	44
Winterization of fire extinguishers......... 48-49	44
FIRE HOSE.
General .................................... 50-51	46
Hose types and their uses................... 52-56	46
Causes of hose injury....................... 57-59	47
Inspection and preventive maintenance...... 60-65	49
Coupling replacement........................... 66	51
Records........................................ 67	53
MISCELLANEOUS EQUIPMENT...... 68-69	54
iii
CHAPTER 1
GENERAL
1.	Purpose and Scope
a.	This manual is written to help post fire department personnel to keep fire-fighting equipment and appliances in serviceable condition. It outlines procedures for preventive maintenance inspections and services and described methods of keeping inspection and maintenance records.
b.	Instructions in this manual do not apply to leased equipment or equipment obtained by special arrangements with municipalities. Instructions cover only equipment and appliances owned by the War Department and installed or maintained for fire protection purposes under Repairs and Utilities program. For detailed information on the responsibilities for fire protection, see TM 5-600. Principles contained herein may be applied as appropriate to similar equipment used for fire protection purposes at War Department installation or by military troop units.
2.	Command Inspections
a.	Purpose. Command inspections, as functions of commanding officers, are made to determine the general condition of fire department equipment, ability of personnel to operate the equipment, cases of neglect or carelessness, and need for additional personnel instruction or training. To evaluate the performance of fire equipment and operating personnel properly, observation at time of fire is essential. However, periodic command inspections in quarters or under test conditions often reveal conditions which can be effectively corrected before fire occurs.
b.	Procedure. Command inspections may be either informal or spot checks. They can be made at any time, preferably without previous notification. Spot checks involving actual tests of representative equipment are particularly effective because they permit observation under operating conditions. Informal and spot-check inspections cover—
(1)	Cleanliness of station and equipment.
(2)	Operating condition of representative pieces of equipment, selected at random.
(3)	Alertness, general knowledge, ability, and discipline of personnel.
(4)	Condition and completeness of records.
3.	Technical Inspections
The fire chief is responsible for the technical efficiency of the fire apparatus and equipment. As part of that responsibility, he makes periodic technical inspections to determine the condition of apparatus and equipment, effectiveness of first- and second-echelon maintenance, to assure continued operation and need for additional instruction or training of personnel in proper operation and care of equipment. These inspections may be made without previous notification. Corrective action is directed for any defects noted. The fire marshal, as administrative head of the fire department, makes certain the fire chief is performing his assigned responsibilities.
4.	Service Command Inspections
Service command technical personnel make periodic inspections to determine the effectiveness of firstand second-echelon preventive maintenance inspections, to familiarize personnel with proper operating and preventive maintenance practices, and to insure uniform procedures at all posts as indicated in paragraph 1A They inspect all apparatus and equipment at least every 6 months; more frequent inspections are desirable if activities and importance of the facilities warrant. Operating personnel help in the inspection so their performance can be observed at the same time.
a. Procedure. (1) Examine the following preventive maintenance records:
(a) WD AGO Form 461.
(&) Previous WD AGO Form 5-5.
1
(c) Hose records.
( pc>;>- c-ss to sew. m-W AU, WKS. /. f.W . .,-x WATER -w
AWRATORI&'-XTEO .
Figure 27. Carbon tetrachloride extinguisher, 1-quart capacity. (Stock No. 58-4276.300-003.)
Figure 28. Carbon tetrachloride extinguisher, 1-gallon capacity. (Stock No. 58-4276.300-010.)
two valves. One valve allows air to escape from the air chamber to the liquid chamber; the other opens the liquid chamber to the discharge hose. A gauge shows the air pressure; the peak hole or sight glass shows the liquid level. Another valve permits air pressure to be obtained either by pumping from attached hand pump or from outside air supply.
c.	Three and one-half-gallon stored air hand-drawn extinguisher. The 3^-gallon hand-drawn extinguisher (fig. 29) is identical with the 1-gallon type except that it has greater capacity, a longer discharge hose, and is mounted on wheels.
41.	Charging
The 1-quart pump type extinguisher is charged with 1 quart of fire-extinguisher liquid, carbon tetrachloride base. The 1-gallon and 3^-gallon stored-pres-sure types have 1 and 3% gallons of this liquid, respectively, in their outer compartments and air under 100 pounds pressure in the inner compartments. Air pressure may be supplied by built-in hand pump or available outside source. Ordinary commercial carbon tetrachloride is unsuitable for fire extinguisher recharging. The standard fireextinguishing carbon tetrachloride solution, and the
33
Figure 29. Carbon tetrachloride hand-drawn chemical engine, Sfe-gallon capacity.
(Stock No. 58-4276.350-035.)
extinguishers during recharging, must be kept entirely free of any traces of moisture to avoid serious corrosion.
42.	Inspection and Maintenance
a. Monthly. Service carbon tetrachloride extinguishers monthly as follows:
(1) General. Perform general services outlined in paragraph 35«(1).
(2) Extinguisher, (a) Examine nozzle opening for stoppage or leakage; notify fire department of
faulty nozzles. Fire department personnel may clear obstructions by operating extinguisher, catching fluid in clean glass container for return to chamber.
(&) Check 1-quart type for leakage. Leakage may be caused by air pressure, which may be relieved by removing filler cap. If this does not remedy trouble, replace extinguisher.
(c) Stop leakage on 1-gallon and d^-gallon types by closing valve; replace extinguishers if leakage cannot be stopped.
(d) Check hose for deterioration, cracking, or other signs of failure. Procure hose assembly replacements from manufacturer.
(c) Inspect for external corrosion or damage, replacing extinguishers showing signs of possible failure.
Caution: Major external repairs and all internal repairs must be made by trained personnel having special equipment.
(3)	Contents, (a) See that any seals are unbroken. Seals are used to prevent any tampering.
(b)	Make sure 1-quart types are full of fluid by tilting extinguisher to splash liquid.
(c)	Check contents bf 1-gallon and 3^-gallon types by sight gauge, tilting extinguisher to move liquid against glass so level of liquid can be readily determined. Fill to correct level if necessary.
(d)	Check air-pressure gauge on 1-gallon and 3^-gallon types. Bring pressure to 100 pounds by pump or outside source.
(4)	Records. Note inspection on tag. Replace tag if lost.
b. Semiannually. Make the following checks semiannually:
(1)	General. Perform general services described in paragraph 35&(1).
(2)	Extinguisher. Lubricate running gear on 3y2-gallon size.
(3)	Contents. Discharge some fluid into clean glass container to test for proper operation. Replace fluid used for test. Refill fire extinguisher if necessary.
Caution: Do not contaminate fluid with moisture, which corrodes the unit and causes failure.
(4)	Records. Record inspection properly in fire department records.
34
Section VI. CARBON DIOXIDE GAS EXTINGUISHERS
43.	Types
Two types of carbon dioxide gas extinguishers are regularly issued: 15-pound hand type (fig. 30) and 50-pound hand-drawn wheeled type (fig. 31). How-
ever, 2-, 4-, 71/£-, 10-, and 20-pound hand types and 77- and 100-pound hand-drawn wheeled types are also in service. (See fig. 32.) These units have a steel cylinder for liquefied carbon dioxide, an operating valve, and discharge hose and horn. The pressure in carbon dioxide extinguishers varies with the outside temperature, cylinder pressure being
Figure 30. Carbon dioxide hand extinguisher, 15-pound capacity. Regularly issued at military installations.
{Stock No. 58-4276.200-150.)
Figure 31. Carbon dioxide hand-drawn chemical engine, 50-pound capacity. Regularly issued at military installations. {Stock No. 58-4276.200-500.)
35
103 pounds per square inch (psi) at —50° F., 285 psi at 0° F., 834 psi at 70° F., 1,450 psi at 100° F., 2,530 psi at 140° F., and 3,090 psi at 160° F. Therefore, carbon dioxide extinguishers should not be installed near heating equipment and must be protected from the direct sun rays during hot weather. Conversely, discharge pressure is materially less in subzero operation. When using these extinguishers, especially in unventilated spaces, such as small rooms, closets, or confined spaces, personnel must
Q
Figure 32. Various other carbon dioxide types, ranging from 2-pound to 100-pound sizes.
use caution to avoid breathing excessive gases produced. A siphon tube connected to the outlet valve is incorporated in manufacture to expel liquid carbon dioxide from the bottom of the extinguisher. I his requires that the extinguisher be in a nearly upright position while discharging and not lying on its side.
a.	Fifteen-pound hand extinguisher. The 15-pound hand extinguisher has a container of liquefied carbon dioxide, fitted with a special quick-opening valve which releases gas through a hand hose and specially designed nozzle-and-horn assembly. When liquid carbon dioxide is released into the horn, it changes to a gas almost instantaneously. Carbon dioxide gas is inert and slightly heavier than air, blanketing the fire by excluding the oxygen.
b.	Fifty-pound hand-drawn wheel type extinguisher. The 50-pound hand-drawn wheel type extinguisher operates like the 15-pound type. It has a larger cylinder and horn, a longer discharge hose, and is mounted on wheels.
44.	Charging
All carbon dioxide extinguishers must be provided with two seals: one, a piece of fine copper wire with lead seal attached to the valve handle or wheel; the other, a plastic hood placed over the safety valve. Install plastic seals used to cover the frangible pressure-release disk by soaking in water until they become soft and pliant. Then put them in place and allow to dry before the extinguisher is returned to service. These seals, made of special materials, must be standard replacement items as designed by the manufacturers of carbon dioxide extinguishers to insure proper operation. Recharge extinguishers when they fall below 10 percent of rated weight capacity. Depending on the facilities available, transfer pumps, bypass filling units, dry-ice converters, or commercial charging plants are used to charge all types of carbon dioxide hand and wheeled type extinguishers.
a.	Commercial charging plants. Send extinguishers to the nearest commercial charging plant if adequate facilities are not available on the post. A list of charging plants for this work is usually furnished by the manufacturer with each extinguisher.
b.	Transfer pumps. The transfer-pump unit has a small high-pressure pump, electric or gasoline motor, scales, spare 50-pound commercial cylinders,
36
Figure 32. Various other carbon dioxide types, ranging from 2-pound to 100-pound sizes—Continued.
tilting rack, and necessary piping and fittings. Because the unit pumps carbon dioxide in liquid form only, the amount of liquid in a fully charged cylinder varies with pressure and temperature. A standard commercial 50-pound cylinder contains approximately 38 pounds of liquid carbon dioxide and 12 pounds of gas at 70° F. With a transfer pump, the cooler the supply cylinder and extinguisher cylinder being recharged, the more efficient the transfer becomes. Moreover, the time required to charge an empty cylinder increases with the temperature of the cylinders. All cylinders should be kept as cool as possible. Follow the instructions below when recharging cylinders with transfer pumps.
(1)	General instructions, (a) When starting pump after unit has been idle for some time, allow it to run for about 2 minutes to work oil into bearings before starting charging operations.
(&) When recharging an extinguisher cylinder, it
is desirable to invert it to keep it cooler and permit faster filling. (See fig. 33.) Larger cylinders which cannot be easily inverted may be placed horizontally on the scale, if possible with the bottom of the extinguisher blocked up. If the supply cylinder has a siphon tube, it need not be inverted.
(c) Efficient transfer stops after all the liquid carbon dioxide, approximately 80 percent of the net contents, is transferred from the supply cylinder. Use a new, fully charged supply cylinder to bring the extinguisher cylinder to full-rated capacity. Most of the gas in the other supply cylinder can be used to start another empty extinguisher cylinder, the gas transferring itself under its own pressure until the pressure in both cylinders is equal.
(tZ) When ordering supply cylinders from commercial manufacturers of carbon dioxide, specify a normal discharge-outlet opening of at least %-inch diameter and a valve-passage opening of %6-inch
37
Figure 32. Various other carbon dioxide types, ranging pram 2-pound to 100-pound sizes—Continued.
diameter. These measurements prevent the expansion of carbon dioxide in the supply hose, which clogs it with carbon dioxide snow.
(?) Use only sealing and safety disks which are standard replacement items designed by the manufacturer of the particular extinguisher being recharged.
(/) Always store carbon dioxide cylinders in a cool place.
(g) Use the transfer unit for carbon dioxide only, not for oxygen or other gases.
(2)	Preparation, (a) With transfer unit, scale, and tilt racks in place, check the supply cylinder. If
supply cylinder has no siphon tube, place it in rack, tighten with chain securely about cylinder, and invert. If supply cylinder has a siphon tube, use it in a vertical position.
(&) Connect pump inlet hose to supply-cylinder outlet. Connection adapter of this hose is fitted with screen to keep foreign matter from transfer unit or cylinder being recharged. Do not open supply-cylinder valve.
(c) Complete procedures for extinguishers with valves of seat and disk type, including use of adapters of filling bonnets and sealing disks for recharging, are given in (5) (a) and (&) below. See these instructions before proceeding with the following steps.
(if) Connect pump outlet hose to filling bonnet or recharging adapter on the cylinder to be recharged. The pump outlet hose has a shut-off valve.
(?) Check all connections to insure they are properly and securely made. When making connections, use a 12-inch wrench with a slow, steady pull. Do not jerk or hit wrench with a hammer.
(/) Be sure shut-off valve in pump outlet hose is in tightly closed position and valve or filling bonnet of cylinder being recharged is in open position.
(’
/	L>Pf~~> oj/a	1|V	TILTING RACK
V
Figure 33. Transfer pump in operation.
3.	Close filling bonnet or valve of cylinder being recharged. (See (5) (a) and (&) below for correct procedure.)
Caution: Do not close filling bonnet, valve of cylinder being recharged, or shut-off valve in pump outlet hose while transfer unit is pumping.
(4)	Disconnecting, (a) Disconnect hose from cylinder being recharged very slowly to allow pressure trapped between shut-off valve and cylinder being recharged to escape. Then remove filling bonnet or adapter.
(&)	Weigh recharged cylinder carefully.
(c) After recharging is complete, close supplycylinder valve tightly and open shut-off valve in pump outlet hose very slowly, allowing all gas in pump to discharge.
(d) Install plastic safety seal. (See (1)(^) above.)
(5) Special instructions, (a) For recharging type B, seat type valve (fig. 34) :
1.	For the 2-pound unit, unscrew horn from tube, using wrench on flats of horn nut. Attach adapter to end of tube and connect to gas supply. For 4-pound to 20-pound units, unscrew tube and discharge-horn assembly at cylinder-valve connection. Attach adapter to cylindervalve connection and connect to gas supply.
2.	Turn handwheel to open extinguisher valve.
3.	Fill cylinder with proper weight of gas.
39
4.	Turn hand wheel and close valve tightly.
5.	Loosen setscrew of adjustable ring or collar under handwheel. Turn collar until hole in collar and handwheel align before inserting locking pin. Then tighten setscrew of lock-pin ring.
6.	Attach lead seal and wire to locking pin and test for leaks under water.
7.	If cylinder valve cannot be shut tightly by hand, tap handwheel lightly with a small hammer.
6.	Unscrew filling bonnet, and test entire cylinder-valve assembly for leakage under water.
7.	See that cutter is not damaged and has a sharp edge. Insert locking pin in handwheel of cutter head. Attach lead seal and wire.
8.	Attach cutter head to cylinder valve and tighten lightly with wrench.
(6) Maintenance of transfer unit. Because different transfer pumps vary to some extent, no detailed
< I
FW	aTU
ADAPTER J Q I	ADAPTER	X
■ED
13/16^(14 TPI>	13/16" (14 TPI)
V4" STD PIPE THREAD	1/2 STD P’PE THREAD
*4- TO 15-POUND SIZE	20-POUND SIZE AND LARGER
Figure 34. Parts for seat-valve extinguisher.
(&)	For recharging type A, disk type valve (fig- 35):
1.	Unscrew cutter head engaging cylinder valve with left-hand thread.
2.	Unscrew disk bushing with special wrench from filling bonnet. See that disk seat in cylinder valve is clean.
3.	Screw disk bushing in cylinder valve until disk seats lightly.
4.	Replace wrench in filling bonnet; seat wrench in slots of disk bushing and screw filling bonnet on cylinder valve.
Caution: Because filling bonnet has left-hand thread and disk bushing a right-hand thread, be sure in screwing bonnet on cylinder valve that disk bushing is not unscrewed. .When filling bonnet is screwed down on cylinder valve firmly, back off on wrench, unscrewing disk bushing about turns.
5.	Fill cylinder with proper weight of gas and screw disk bushing down tightly with special wrench in filling bonnet.
maintenance instructions are given in this manual.
(«) Follow carefully directions furnished by the manufacturer for monthly lubrication and care of this equipment. All manufacturers publish complete operating instructions which can be obtained on request.
(b) For proper maintenance of electric motor, follow preventive maintenance procedures given for electric motors in TM 5-681.
(c) Examine all flexible pipe (hose) and fittings on transfer unit monthly and before use for signs of defects. Replace any item showing signs of weakness because high pressures in lines requires that all pipes and fittings be in perfect condition.
c. Bypass filling unit. The carbon dioxide bypass filling assembly (fig. 36) recharges portable cylinders without using pumping equipment. The filling assembly is connected between a standard commercial cylinder and the portable extinguisher being recharged. Transfer of carbon dioxide using the
40
bypass method depends on a difference of temperature and corresponding difference in pressure between two cylinders. As gas is compressed in filling an empty fire extinguisher cylinder, that cylinder is heated; as gas under pressure leaves a supply cylinder, that cylinder is cooled. Therefore, a supply
cylinder must be allowed to return to room temperature after recharging each hand extinguisher. Because it carries such high pressures, inspect this unit frequently for defects in hose and fittings and replace immediately any part showing weaknesses or defects.
(1)	To recharge carbon dioxide portable units, use standard 50-pound carbon dioxide supply cylinders inverted and connected to the extinguisher by the bypass assembly. (See fig. 37.)
(2)	Place extinguisher on a platform scale horizontally or preferably inverted. A spring-balance scale may be used instead of the platform scale. For more efficient transfer, see that extinguisher cylinder being recharged is kept cooler than the supply cylinder.
(3)	With valve on extinguisher open, open valve on supply cylinder until a few pounds of carbon dioxide are admitted.
(4)	Close valve on supply cylinder and open bypass valve in hose to allow carbon dioxide to flow out of portable extinguisher to atmosphere. This cools the extinguisher and permits a faster transfer of gas because of the difference in temperature between supply cylinder and extinguisher.
(5)	Close bypass valve and open valve on supply cylinder again until extinguisher is filled. If extinguisher does not take a full charge, repeat operation in (4) above to cool cylinder further.
(6)	Close valve on supply cylinder, then close valve on extinguisher. Bleed bypass filling assembly of gas and disconnect it.
(7)	In practice, after two hand extinguishers are charged from a single supply cylinder, the pressure difference is enough for only a small amount of gas to enter a third cylinder. Use these nearly depleted supply cylinders to put a few pounds of carbon dioxide in an empty extinguisher. Then release this gas to atmosphere, cooling the extinguisher and providing enough temperature difference so carbon dioxide can flow down from a new supply cylinder at room temperature.
d. Dry-ice converter. The dry-ice converter (fig. 38) is supplied in 300- and 600-pound sizes, both well suited for filling hand and wheel type extinguishers. This recharging method is probably the simplest of any described.
(1) Procedure. To recharge extinguishers with a dry-ice converter—
41
LEAD & WIRE ((	)) AX' SEAL
( 25
MTM GW-cutter head
CYLINDER	rud* ~ —A X.N.
VALVE -----
STEM —
STEM------eUTl
X—1	FILLING
f	----BONNET
Vi" (14 TP^
DISK	frfJuL
BUSHING	X XTTTUx
5?	? /> CYLINDER
VAlVE
Figure 35. Parts for disk-valve extinguisher.
NOTE:
FOR TYPE A PORTABLES A FILLING-BONNET ASSEMBLY AND NEW SEALING-DISK BUSHING ARE ALSO REQUIRED
>---BYPASS VALVE
rn	HOSE	__
STANDARD CqmmercZ^
\	\	SWIVEL CONNECTION
\	k EMPTY CYLINDER SWIVEL CONNECTION
\-PORTABLE ADAPTER
Figure 36. Bypass filling unit. (Stock No. 58-5410.500-500.)
PORTABLE CYLINDER BEING RECHARGED
RACK FOR INVERTING PORTABLES
BYPASS FILLING ASSEMBLY (BYPASS VALVE, 3-FOOT HOSE WITH SWIVEL COUPLING AND ADAPTER)
TILTING RACK
Figure 37. Bypass filling unit in operation.
STANDARD COMMERCIAL CYLINDER (WITHOUT SYPHON TUBE)
42
(a) Fill one or more of the 150-pound converter tanks with dry ice and convert to liquid carbon dioxide by applying hot water outside the tank. As dry ice is converted, pressure rises until it is ample for filling extinguisher cylinders. Observe caution in applying hot water to control rate of pressure rise within limits of pressure-release safety disk.
(&) Place empty extinguisher cylinder on scale and weigh carefully. Add desired weight of carbon dioxide to weight of empty cylinder and set scale at that point.
(c) Make a pipe connection with the converter tank. When pipe-line valve is opened, carbon dioxide flows from tank to extinguisher. Close pipe-line valve when scale indicates that proper amount has been delivered. Close valve in extinguisher and disconnect pipe-line.
(X\hOSE'	----
FEMALE	EXPANSION RINGS '/
RUBBER GASKETS x
Figure 39. Fire-hose couplings.
hose. Rubber-covered rubber-lined hose is supplied in 1-, 3-, 4-, and 4^-inch sizes. The 1-inch size is used for booster lines on fire trucks and discharge lines on 40-gallon soda-acid chemical engines. The 3-, 4-, and 4%-inch sizes are hard suction hose. The 3-inch size is used on the class 300 brush truck and class 325 fire truck, the 4-inch size on the class 500 truck, and the 4%-inch size on the class 750 truck.
56.	Unlined Linen Hose
Unlined linen hose consists of one or two jackets of woven linen without rubber lining or cover. It is issued only in the 1%-inch size for use on stand-pipe systems.
Section III. CAUSES OF HOSE INJURY
57.	Mechanical Injury
a.	Dragging. Dragging hose along the ground results in cuts, abrasions, punctures, and damaged coupling threads or lugs. Carry hose correctly at all times.
b.	Pulsation and vibration. Pulsations in the pump cause suction and discharge hose sections to vibrate, chafing hose jackets against surfaces they touch. If surfaces are rough or have sharp edges, serious hose injury results. Hose closest to the engine is chafed most severely; farther away, pump
vibration is absorbed by elasticity of the hose. Vibration may be almost imperceptible, yet may weaken hose so much that failure occurs in a relatively short time. To prevent chafing—
(1)	Insert chafing blocks between hose line and ground.
(2)	If chafing blocks are not available, place burlap, gunnysack, or rope cushions around hose at affected points.
c.	Excessive pressures. Hose can be damaged by improper operation of the shut-off nozzle. Closing the shut-off nozzle quickly causes a sudden increase in pressure which may rupture the hose. If the nozzle is opened quickly, the operator may lose control of the hose and injury to hose or personnel may result.
d.	Driving over hose. One of the commonest causes of hose injury is driving heavy equipment across hose lines. Serious damage is less likely when hose is under good pressure, but when it is empty or under low pressure the jacket may be separated from the lining or the hose may be ruptured or torn from the coupling. This type of damage can be prevented by any of the following measures:
(1)	Build two standard bridges (fig. 40) and carry them on truck at all times. After hose lines are stretched, set bridges across hose, about 3% to 4 feet apart. If standard bridges are not available, build an expedient bridge with materials found at scene of fire. A simple bridge consists of planks
47
on each side of hose, thick enough to keep wheels from striking hose as they cross.
OLD HOSE SPLIT OPEN
Figure 40. Standard hose bridge.
(2)	Whenever possible, stretch the first hose lines from hydrant on same side of road as fire. Lay lines parallel to curb, but not so close to curb that acid or oil floating down the gutter may come in contact with them.
(3)	If a street or areaway must be crossed, stretch hose parallel to curb on same side of street as hydrant, up to a point opposite fire, then across the street. Thus equipment that follows need not ride over hose unless it must pass to far side of building.
e.	Mishandling frozen hose. In winter, hose is often damaged by rough handling. When frozen, cotton fibers are weakened and warp threads, which run lengthwise of the hose, may break if hose is not handled carefully. If hose has frozen to street, free it by carefully chopping away the ice beneath it. Do not remove ice that remains attached to hose. Place hose in truck with least possible bending or forcing and take it back to station. After frozen hose thaws out, clean it and stretch it out to dry. (See par 64.)
Caution: Handle frozen hose as little as possible.
f.	Dropping hose. Carry fire hose carefully to avoid dropping it. Most damage to couplings occurs when hose is dropped. If possible, carry hose at the couplings.
58.	Heat Injury
a.	Burning. Fire hose is often unavoidably burned at fires. Inspect carefully all hose that has been close to the fire. If more than one-third of any section is burned, turn the entire section in for salvage. If less than one-third is burned, cut out damaged portion and recouple the balance. (See par. 66.)
b.	Hot liquids. Hot liquids penetrate the cotton cover and loosen the rubber lining, weakening the
hose. For correct methods of cleaning hose, see paragraph 64.
c.	Storage. For proper care of stored hose to prevent heat damage, see paragraph 63.
59.	Chemical Injury
Chemical injury cannot always be prevented, especially during fire at chemical depots or warehouses. In addition, it is almost impossible to know whether water flowing out of a burning building contains injurious chemicals. Hose is therefore frequently damaged by exposure to chemicals without the source of exposure being known. To guard against chemical damage, apply the corrective measures described below whenever exposure to chemicals is suspected.
a. Acids. Acid, even in dilute solution, damages fire hose irreparably by destroying the hose jacket. Some acids brown the hose jacket instantly; others turn the cotton fiber to powder.
(1) Acid may come in contact with fire hose in a number of ways.
(a) Acid may be spilled on the fire-station floor when extinguishers are being recharged or when batteries are being tested with a hydrometer.
(&) Hose may be damaged by acid at fires in automobile repair shops, battery stations, storage warehouses, garages, hangars, and processing, salvage, and manufacturing shops.
(c) Damage may result when hose is shipped along with acid containers, such as storage batteries and carboys, which may leak from rough handling.
(2) When acid contact with hose is suspected, examine hose closely as soon as possible for brown or powdery spots. Wash hose which may have been exposed to acid promptly and thoroughly with baking soda solution.
b.	Gasoline. Gasoline causes rapid deterioration of the rubber lining. In addition, even a small amount of gasoline on the jacket works its way through and dissolves the cement holding the lining to the jacket, freeing the lining. When this hose is used, the lining may tear apart and pile up in one end of the hose, causing a partial or complete stoppage.
c.	Oils and greases. Thin oils and greases, which go through the hose jacket readily, are more serious than the thicker oils and greases, which tend to stay on the outside. Oils that soak through the jacket reach the rubber lining and spread along the rubber, destroying it rapidly.
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d.	Paint and paint thinner. Paints are harmful . to fire hose because of the oils they contain. Fire hose must therefore be protected from paint as much as from grease and oils. Do not use paint to mark fire hose; instead, stencil hose with indelible ink, using only enough ink on the brush to color the hose surface. When hose is used in paint or varnish storeroom fires, take particular care to keep it out of paints, grease, and similar materials.
e.	Strong soaps. Never use strong soaps for cleaning hose. The chemical content of strong soap tends to weaken the cotton cover and deteriorate the rubber lining. For proper cleaning procedure, see paragraph 64.
Section IV. INSPECTION AND PREVENTIVE MAINTENANCE
60.	General
a.	Maintenance responsibility. The fire chief is responsible for maintenance of all fire hose. The various phases of hose maintenance are carried out by all fire-fighting personnel under his direction.
b.	Importance. Hose maintenance consists of periodic inspection and servicing of hose in use, care of hose in storage, and continuing examination of all hose for signs of injury or deterioration. (See sec. HI of this ch.) Fire department personnel must be trained to recognize the importance of hose maintenance and to apply instructions in this manual completely. Improper or incomplete hose maintenance shortens hose life and may result in hose failure at a critical time.
c.	Basic principles. Hose maintenance is complicated by the fact that hose components present entirely dissimilar problems. The cotton jacket and rubber lining deteriorate with age, whether or not the hose is used. Rubber deterioration can be delayed if the lining is kept moist. The jacket, on the other hand, deteriorates rapidly if kept wet since the moisture causes mildew, a fungus growth that destroys cotton fiber. Keeping the rubber moist and the cotton clean and dry requires periodic handling which may damage the hose couplings. Couplings do not deteriorate and are not affected by water; however, they are made of soft metal and rough or careless handling can damage them severely. Methods of meeting the problems in hose care are discussed below.
61.	Inspecting Rubber-lined Hose
Inspect cotton-jacket rubber-lined hose and rubber-covered rubber-lined hose daily, after each use, monthly, and semiannually, using procedures outlined below.
a.	Daily inspection. Make the following inspections every day:
(1)	Check hose on trucks to see that it is dry and correctly loaded in hose body, hose basket, or on hose reel.
(2)	Inspect hose on drying rack to see that it is correctly laid out.
(3)	Make sure drippings from ends of hose on the upper rack are not falling on hose below. Drippings may contain a mild acid formed by combination of water and the sulfur in the rubber lining, which would destroy cotton jackets. For proper construction of drying racks to prevent damage from dripping, see paragraph 64L
b.	Inspection after use. On return to the station after a fire, inspect and clean all hose and couplings as follows:
(1)	Two and a half-inch cotton-jacket rubber-lined hose, (a) Remove from the truck all 21/f>-inch cotton-jacketed rubber-lined hose that was used or is wet. Clean hose carefully, examine couplings ((4) below), and place hose on drying racks.
(&) If necessary, take remaining hose from truck and clean and dry truck hose compartment. Couple clean dry hose, inspecting all couplings and gaskets as connections are made, and reload hose compartment.
(2)	Rubber-covered booster and hard suction hose. Remove rubber-covered booster and hard suction hose from rack, basket, or reel. Wipe hose clean and replace it on truck.
(3)	Cotton-jacket rubber-lined soft suction hose. Wash all used cotton-jacket rubber-lined soft suction hose; for procedure see paragraph 64. Lay out hose to dry near truck so it can be replaced on truck immediately if needed.
(4)	Couplings, (a) Examine coupling threads; if injured or defective, replace coupling. (See par. 66.)
(&) Clean dirty or jammed couplings, using soapy water to loosen hardened lubricant. Lubricate female coupling by immersing it in a mixture of mild soap and water and allow to dry. Do not use
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strong soap, chemicals, gasoline, oil, or grease to clean or lubricate couplings because they may injure hose jacket or lining.
(c) Inspect gaskets and replace them if they are worn or damaged. Make sure gaskets do not project into waterway, particularly at nozzle coupling, because this will cause a ragged stream.
c. Monthly inspection. Remove all 1%- and 21/2~inch cotton-jacket rubber-lined hose that has been on a truck continuously for 30 days. Examine it visually and if it is satisfactory, repack it in hose body. When rolling hose, lay it out on a clean floor and start roll at male coupling. Take care not to have too sharp a fold at coupling, and make sure folds are not made at the same points as before. If hose is rolled or packed with folds always at the same point, it will crack.
d. Semiannual inspection. Inspect all discharge and suction hose every 6 months, using the procedure below.
(1) Make a hydrostatic test of all hose to find whether it can safely withstand operating pressures. Test discharge hose in single 50-foot lengths or in
lines up to 300 feet; the latter is recommended. Use the following test pressures:
Hose	Pressure (psi)
1-inch rubber-covered .................... 200
iy2~ and 2%-inch single-cotton-jacket rubber-lined ....................... 150
iy2- and 2%-inch double-cotton-jacket rubber-lined ....................... 200
3- and 4-inch double-cotton-jacket rubber-lined soft suction.................. 100
3-, 4-, and 4%-inch rubber-covered hard suction ............................ 100
(a) Test cotton-jacket rubber-lined hose and rubber-covered rubber-lined chemical and high-pressure hose as follows:
1.	Attach suction hose between hydrant and pumper.
2.	Attach hose to be tested to discharge gates of pumper.
3.	Partially dose discharge nozzle at end of hose and open discharge gate at pump.
4.	When water flows freely, close discharge nozzle at end of hose.
5.	Place pump in operation and increase to required test pressure given in list above.
(&)	Test rubber-covered rubber-lined suction
hose as follows, using one or two lengths at one time.
1.	Drain pump.
2.	Close drain cocks and discharge valves.
3.	Remove suction cap and connect hose.
4.	Place cap on other end of hose after checking gasket.
5.	Using the primer, create a minimum vacuum of 23 inches of mercury.
6.	Test hose under pressure, using procedure in (