Refurbish Your Apparatus
FEATURES
APPARATUS
The dictionary defines “refurbishing” as: polish up again, do up anew, brighten, renovate. The only part of the definition that I disagree with is “do up anew.” Common sense will tell you that you cannot make an old truck like a new one. If you want a new apparatus, you must buy a new apparatus.
Refurbishing has two basic functions: to extend the life of the apparatus and to reduce the amount of money you must spend for improved service. If you keep that in mind, you can develop a program that will meet the goal of restoration.
EVALUATION PROCESS
If refurbishing is for you, begin the project by acquiring sufficient data for your specifications. Evaluate the apparatus, and then decide what needs to be updated and what new systems you would consider installing. This is not a difficult process. Just make a wish list.
The next step is to evaluate the existing mechanical components of the apparatus and determine what parts need rebuilding or replacing. The best approach is to ask the original equipment manufacturer to inspect the apparatus and make those recommendations.
But don’t stop there.
There are quality refurbishing companies with the technical knowledge and experience that will make your job a lot easier. You should get reports from at least three or four of these companies. The data you collect should contain a certified test report on the pump or aerial component. If the companies will not supply you with a test report, look through advertisements for non-distinctive testing companies that do nothing but test.
Do not continue with the refurbishing program unless you have the test completed. I have seen cases in which a department would spend thousands of dollars to spit and polish a piece of apparatus, and a year later the pump or ladder was no longer serviceable. Don’t put the cart in front of the horse. Do the nuts and bolts first and then the gingerbread.
REFURBISHING QUESTIONS
Writing the specifications
After all data is assembled, you are ready to put the specifications together. The question asked the most often is: “How much do I put into the specs?” Writing specifications is not that difficult. Most people complicate things by using technical terminology that they really don’t understand; or they attempt to write out all other companies, except the one they want to do the work.
Don’t waste your time writing and submitting specifications for advertising and bidding if you already know who you want to do the job. If you have decided on a particular company because of their qualifications and acceptable price, it is better to negotiate with that particular outfit only.
If you are open to choosing between a few companies, prepare the specifications so that these outfits know what you want and what is acceptable for the finished product. Do not tell them how to do the job. The successful bidder may agree to do it your way. But, if your way turns out to be wrong, guess whose problem it is.
Most reliable companies would refuse your instruction anyway, and modify the specifications in order to do the job right. A reputable bidder will submit a proposal that lists exactly what he will do in order to accomplish your objectives.
Performance bond
Another common question is: “Do I need a performance bond?” The answer is always “yes.” And for a good reason. In most cases you are not spending only a few hundred dollars; you are spending many thousands of dollars.
The performance bond guarantees that the successful bidder will complete the refurbishing at the agreed upon price and according to the specifications. It will also protect you from contracting with a company that is in financial difficulty. In most instances, a company in this situation will not be able to meet these requirements and, therefore, will not bid. You should also demand a certificate of insurance that is equal to the value of the apparatus for the period that the truck is in the possession of the successful bidder.
Inspection trips
Another often asked question is: “Do I need to make inspection trips?” Within reason, yes, you do. If you are close by, then it’s no problem. If the company is located far away from your department, that’s a different story.
Let’s face it. You may not want to spend the extra money on this. But, don’t rule out a quality bidder because they are too far away for you to make frequent inspection trips.
I recommend the following: Require at least one inspection trip at “final prime.” This is the period after all major mechanical and body work has been completed and before the apparatus is painted. Ask all bidders to list this as an option price. This will tell you the approximate cost for the trip, according to their calculations. But, you may have a better and more economical way of doing it.
The inspection trip serves as a check and balance for both you and the company. For example, you may see something that can be added or changed to enhance the serviceability of the truck; or you may voice displeasure with a particular item. Now is the time to change your mind, not after the truck is finished, painted, or back at the station.
Partial refurbishing
“Can we do a partial refurbish?” I love this question. There’s no such thing as far as I’m concerned. This is an absolute disaster for the department and the company. What usually happens is that the second company or, usually, the individual who is going to complete the refurbishing is a member of the department. He has work related experience in some other industry and convinces you that he can do that part of the job for free in order to “save you money.” You can forget that!!!
What usually happens is that this person moves away, gets sick, can’t find the correct materials, or discovers that he bit off more than he can chew. If he does do the job, he will probably ruin the quality work that has already been performed. There goes the money you saved, and then some.
If your department does not have the money available to pay one company to complete the necessary refurbishing, you should wait until you have sufficient funds to attain a quality product and pay for it once.
Cost of refurbishing
The question that will be asked over and over again is: “How much should I spend on this refurbishing?” It’s really a common sense question that you must consider logically. The age of the equipment is a major factor. Can you really squeeze any more service out of a 30-year-old truck? I doubt it.
You should do a lot of research before you decide to restore an apparatus that is over 20 years old. Review a few of the figures to which you should have access and you will see the logic to this.
Find out what the apparatus cost at the time of purchase. Obtain a replacement cost of the apparatus at today’s prices. Subtract the purchase price from the replacement cost. If you will be spending more than 50% of that figure on your refurbishing, it will most likely not be a worthwhile investment.
Repowering
What about updating the apparatus with some new products and maybe repowering? Now is the time to consider if you need a foam system, additional crosslays or preconnects, pre-piped master appliances, or even a small item such as a water level gauge. You should consider everything that is available but purchase only what is necessary. Don’t inflate the cost of refurbishing by specifying items you do not need.
Repowering may be necessary if the evaluation indicates problems. There are more pros and cons on this subject than any other. Let’s break them down into basic logic first, and then I will give you some technical data to work with.
The first thing you should do is to switch from gas to diesel fuel. What kind of diesel? Two-cycle or four-cycle? What horsepower?
Try to remember that engineering must have a key role in this decision. When repowering a pumper engine, many times we forget that it is more important to match the engine to the pump requirements than it is to ensure good road performance. You must determine the revolutions per minute (rpm) ratio that is necessary in order to attain the rated gallons per minute (gpm) of the pump, and what horsepower level is required to drive the pump efficiently.
What additional cooking capacity will be required? Will the new engine match up to the existing transmission and carry the additional torque? Will the pump transmission and drive line carry the additional torque? Is the rear axle capable of carrying additional torque, and will the ratio need changing?
As you can see, the repowering process requires a great deal of engineering. You also need the appropriate knowledge and background in order to choose the correct engine for your apparatus. The local terrain is also a factor to consider when making this choice.
You should have a company or manufacturer with the appropriate technical knowledge submit a repower specification as part of the refurbishing program. Most refurbishing companies have the capability to perform and submit this type of proposal. Always require road testing as well as certified pump testing in the specification. All warranty and operation manuals should be required as part of the specifications.
You will probably have some non-distinctive testing reports from the evaluation process. Remember to attach these to and make them part of the specifications. You should also meet with each company representative so you can explain or interpret the specifications and tell them what you expect to receive as a finished product. This will help eliminate confusion and enable the company to submit a clear and concise proposal.
SUMMARY
If you are considering refurbishing, do not take the obvious for granted. Question people who are in the fire apparatus industry, not the resident expert. The people in the industry deal with these refurbishing problems on a daily basis and are more likely to have the correct answers. Remember, use common sense and take it one step at a time.
There is one more question that must be on your mind: “What is the extended life expectancy of the apparatus after refurbishing?” I always answer this question with a question: “How good is your preventive maintenance and service program?” Usually, there is a long pause, or someone offers the usual standby answer: “We wash the trucks after every call and at drill day.” This is not preventive maintenance.
In many instances, the reason it is necessary to refurbish your apparatus is because you have not exercised good preventive maintenance. If you initiate an on-going maintenance program, you will achieve positive results over a long period of time.
No one can project how long a refurbished apparatus will be serviceable. It is reasonable to expect 50% more service out of the apparatus if a quality refurbishing job and ongoing preventive maintenance is planned and executed.
