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PHOENIX METAL PRODUCTS, INC TL600/TL700 LAVATORY SERVICE TRUCK

PHOENIX METAL PRODUCTS, INC.

MODEL TL600/TL700 LAVATORY SERVICE TRUCK

OPERATION

AND MAINTENANCE MANUAL

PHOENIX METAL PRODUCTS, INC. 3000 INDUSTRIAL AVENUE THREE

FT. PIERCE, FL. 34946 PHONE :772-595-6386 FAX : 772-595-6389

EMAIL: [email protected]


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COPYRIGHT RELEASE THIS PUBLICATION IS INTENDED FOR THE SOLE USE OF OWNERS AND OPERATORS OF THE EQUIPMENT LISTED ON THE COVER. REPRODUCTION AND DISTRIBUTION OF THIS PUBLICATION IS AUTHORIZED TO THE OWNERS AND OPERATORS OF THE PRODUCT. USE BY OTHERS FOR PURPOSES NOT DIRECTLY RELATED TO THE FACILITATION OF OPERATION OR MAINTENANCE OF THIS PRODUCT IS PROHIBITED. MISUSE OF THIS PUBLICATION WILL BE PROSECUTED TO THE FULL EXTENT OF THE LAW.


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REVISION # ISSUE DATE

CHAPTER, SECTION & PAGE

DESCRIPTION OF CHANGE SERIAL # EFFECTIVITY

RECORD OF REVISIONS/EFFECTIVE CHANGES THE FOLLOWING IS A LIST OF REVISIONS AS DESCRIBED BELOW WITH HIGHLIGHTS OF THE REVISIONS. PLEASE DELETE ALL AFFECTED PAGES AND INSERT THE REVISED PAGES.


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SAFETY PRECAUTIONS THE PHOENIX METAL PRODUCTS, INC., MODEL TL600 IS A VEHICLE DESIGNED TO SERVICE THE LAVATORIES OF COMMERCIAL AND MILITARY AIRCRAFT. THE VEHICLE IS A COMMERCIAL CHASSIS MODIFIED WITH TANKS AND PUMPING SYSTEMS TO ACCOMPLISH THE SERVICING OF AIRCRAFT LAVATORIES.

DRIVABILITY THERE ARE CERTAIN PRECAUTIONS THAT SHOULD BE TAKEN WHILE OPERATING THIS VEHICLE. THIS VEHICLE IS INTENDED PRIMARILY FOR OFF ROAD USE. ALTHOUGH THE VEHICLE IS CAPABLE OF HIGHWAY SPEEDS, IT SHOULD NOT BE DRIVEN IN EXCESS OF 35 MPH. THIS VEHICLE IS CAPABLE OF CARRYING THE MAXIMUM DESIGNED LOAD OF THE CHASSIS. HIGHWAY PERFORMANCE AND HANDLING ARE GREATLY REDUCED WHEN THE VEHICLE IS CARRYING THE ALLOWABLE PAYLOAD. STOPPING CAPABILITIES ARE REDUCED DUE TO EXTREME LOAD CAPACITIES. MAKE SURE TO ALLOW FOR AN EXTRA 20 FEET OF STOPPING DISTANCE WHILE MANEUVERING AROUND OTHER VEHICLES AND AIRCRAFT.

OVERHEAD CLEARANCE IF THIS VEHICLE IS EQUIPPED WITH A TELESCOPIC PEDESTAL LIFT FOR SERVICING AIRCRAFT WITH LAVATORY ACCESS HIGHER THAN 8 FEET. EXTREME CAUTION SHOULD BE USED WHEN OPERATING ANY LIFTING DEVICE. THE OPERATOR MUST ASSURE THAT THERE IS SUFFICIENT OVERHEAD CLEARANCE BEFORE OPERATING THE PEDESTAL LIFT. ALTHOUGH MOST OPERATIONS THAT WOULD NORMALLY BE CONDUCTED WITH THIS VEHICLE WOULD NOT BE DONE AROUND OVERHEAD POWER LINES, IT IS NOT UNTHINKABLE THAT WHILE TESTING, DEMONSTRATING OR INSTRUCTING PERSONNEL THAT THERE MAY BE SOME TYPE OF OVERHEAD POWER LINES IN THE VICINITY. ALWAYS MAKE SURE THAT YOU IDENTIFY THE HAZARDS IN A 360 DEGREE ARC AND 16 FEET ABOVE THE GROUND BEFORE OPERATING THE PEDESTAL LIFT. 110 VOLT ELECTRIC SUPPLIES THE TL600 LAVATORY SERVICE TRUCK CAN BE SUPPLIED WITH A COLD WEATHER PACKAGE. IT MAY CONSIST OF (4) HEATERS—ALL OF WHICH ARE 110 VOLTS. THERE IS A 50 AMP MALE OUTLET MOUNTED ON THE DRIVERS SIDE, FORWARD MOST PANEL. THAT IS WERE THE VEHICLE WOULD BE PLUGGED IN FROM A POWER SOURCE FROM THE BUILDING. IT IS VERY IMPORTANT TO MAKE SURE THE VEHICLE IS NOT PLUGGED IN BEFORE IT IS DRIVEN AWAY. SEVERE DAMAGE TO THE PLUG AND OUTLET WILL OCCUR IF THE VEHICLE IS DRIVEN AWAY WHILE IT IS PLUGGED INTO THE BUILDING. EXTREME CARE SHOULD BE USED WHEN TROUBLE SHOOTING THE HEATING SYSTEM. MAKE SURE THE UNIT IS UNPLUGGED.


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INTRODUCTION THE TL600 IS DESIGNED TO SERVICE THE LAVATORY SYSTEMS OF ALL MAJOR COMMERCIAL AND MILITARY AIRCRAFT FITTED WITH COMMERCIAL LAVATORIES. THE TL600 IS MOUNTED ON A COMMERCIAL CHASSIS. AN ISUZU CAB OVER MODEL NPR 450, POWERED BY A VORTEC V - 8 ELECTRONIC FUEL INJECTED 6.0 L GASOLINE ENGINE. ALL FEATURES FOUND ON HIGHWAY VEHICLES ARE INCORPORATED IN THIS CHASSIS. THE TL600 IS A MODULAR UNIT WITH 2 TANKS SURROUNDED BY A STAINLESS STEEL SHROUD. CONTROLS FOR PUMPING, LIGHTS AND MEASUREMENT OF CHARGING FLUIDS ARE LOCATED ON THE TOP DECK. IF A LIFT IS INSTALLED THERE IS A SET OF CONTROLS ON THE LIFT PLATFORM. LIGHTS ARE SUPPLIED FOR NIGHT OPERATIONS. THIS PUBLICATION PROVIDES OPERATING, SERVICING, MAINTENANCE INSTRUCTIONS AND DETAILED PARTS LIST FOR THE TL600 LAVATORY SERVICE TRUCK. FULL FAMILIARIZATION OF THIS PUBLICATION SHOULD BE ACQUIRED PRIOR TO OPERATING, SERVICING OR PERFORMING MAINTENANCE ON THIS VEHICLE.


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CHAPTER/ SECTION

PAGE

REVISION LOG 3

SAFETY PRECAUTIONS 4

INTRODUCTION 5

1 GENERAL INFORMATION AND OPERATION INSTRUCTIONS

1-1 A. SPECIFICATIONS 7

1-2 B. DESCRIPTION 11

1-3 C. OPERATION 15

2 MAINTENANCE AND SERVICING INSTRUCTIONS

2-1 A. SYSTEM DESCRIPTION 26

2-2 B. SERVICING/ LUBRICATION 30

2-3 C. INSPECTIONS 32

3-4 D. ADJUSTMENTS 35

2-5 E. TROUBLESHOOTING/ DIAGRAMS 38

2-6 F. PREPARATION FOR SHIPMENT 49

2-7 H. STORAGE 50

2-8 G. DISASSEMBLY, REPAIR, REASSEMBLY AND REPLACEMENT 51

3 ILLUSTRATED PARTS LIST

3-1 A. OVERVIEW 54

3-1 B. TABLE OF CONTENTS 55

3-2 C. MAIN ASSEMBLY 56

3-3 D. PLUMBING 66

3-4 E. ELECTRICAL 72

3-5 F. HYDRAULIC 78

3-6 G. MECHANICAL 84

3-7 H. OPTIONS 90

4 VENDOR DATA

4-1 A. LIST OF VENDORS 131

4-2 B. WARRANTY INFORMATION 133

4-3 C. MANUFACTURER TECHNICAL INFORMATION 134

TABLE OF CONTENTS

COPYRIGHT RELEASE 2


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CHAPTER 1

GENERAL INFORMATION AND OPERATION INSTRUCTIONS

SECTION 1 - SPECIFICATIONS AND CAPABILITIES DIMENSIONS: (1) LENGTH: 230“ (2) HEIGHT: 88” (3) WIDTH: 80 “

FIGURE 1

230 ”

60 ” 88”


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CHAPTER 1

SECTION 1 - SPECIFICATIONS AND CAPABILITIES

CONTINUED VEHICLE: (1) DESCRIPTION: ISUZU MODEL NPR 450 CAB OVER - GVWR 12,000 LBS WHEELBASE 132.5” (2) CHASSIS SPECIFICATIONS: (A) ENGINE - VORTEC V - 8 MODEL 6.0 L SEFI ( SEQUENTIAL ELECTRONIC FUEL INJECTION). 300 HP @ 4,400 RPM, TORQUE 360 FT LBS@4000 RPM. HIGH SILICON MOLYBDENUM, CAST NODULAR IRON EXHAUST, CAST ALUMINUM HEADS AND CAST IRON BLOCK. (B) TRANSMISSION– 4L80-E HYDRA-MATIC 4 SPEED AUTOMATIC TRANSMISSION WITH LOCK UP. (C) FRONT AXLE - TAPERED LEAF/MULTI-LEAF SPRINGS (D) REAR AXLE - 4.7 RATIO DUAL WHEEL (E) BRAKES - VACUUM/HYDRAULIC W/4 CHANNEL ABS FRONT - DISK REAR - DRUM (F) TIRES/ WHEELS - 215/85R-16E - 10 PLY TUBELESS STEEL BELTED RADIALS (G) STEERING - INTEGRAL POWER STEERING 20.9:1 RATIO TILT AND TELESCOPIC STEERING COLUMN (H) FUEL TANK - CAPACITY 30 U.S. GALLONS, AFT MOUNTED (I) ELECTRICAL - 12 VOLT, NEGATIVE GROUND, 145 AMP ALTERNATOR WITH INTERNAL REGULATOR (J) FRAME - LADDER TYPE CHANNEL SECTION STRAIGHT FRAME RAIL (K) CAB - ALL STEEL LOW CAB FORWARD, 45 DEGREE TILT WITH TORSION ASSIST. JERSEY NIT COVERED HIGH BACK DRIVERS SEAT WITH (2) OCCUPANT PASSENGER SEAT. TWO WAY ROOF VENTILATOR, DUAL CAB MOUNTED REAR VIEW EXTERIOR MIRRORS. TINTED GLASS.


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CHAPTER 1


CONTINUED LAVATORY SERVICE MODULE (1) TANKS - WASTE TANK - CAPACITY 360 U.S. GALLONS FLUSH TANK - CAPACITY 240 U.S. GALLONS (2) PUMPS - FLUID PUMP - 1” INCH INLET/ 1” OUTLET BRONZE CONSTRUCTION POSITIVE DISPLACEMENT GEAR PUMP - CAPABLE OF 23 GPM @ 60 P.S.I. (3) SERVICING HEIGHTS - THIS VEHICLE IS CAPABLE OF SERVICING ALL AIRCRAFT LAVATORIES WITH A MAXIMUM CONNECTION HEIGHT OF 10 FEET AND FITTED WITH COMMERCIAL AIRCRAFT FITTINGS. (4) CONTROLS - CONTROLS FOR PUMP AND WORK LIGHTS ARE LOCATED AT THE REAR WORK STATION. (5) LIGHTING - AIRCRAFT SPOT LIGHT - 1 ON TOP DECK 1 CONTROL PANEL FLOOD LIGHT.


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CHAPTER 1


CONTINUED (7) HEATING - HEATERS (OPTIONAL) 1 TANK IMMERSION HEATER: 110 VOLTS/ 2000 WATTS EACH 1 AIR HEATER: 12 VOLTS DC/ ENGINE COOLING SYSTEM 110 VOLT HEATER IS CONNECTED TO (1) CONNECTION POINT– A 20 AMP FEMALE INLET LOCATED ON THE DRIVERS SIDE FRONT PANEL. THE AIR HEATER IS SWITCHED FROM THE MODULE CONTROL PANEL

FIGURE 2


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CHAPTER 1

SECTION 2 - DESCRIPTION GENERAL THIS SECTION DESCRIBES THE TL600 LAVATORY SERVICE TRUCK. THE TL600 IS A SELF CON-TAINED VEHICLE SPECIFICALLY DESIGNED FOR SERVICING THE LAVATORIES OF COMMERCIAL AND MILITARY TRANSPORT AIRCRAFT. THE ENTIRE UNIT IS CONSTRUCTED ON A COMMERCIAL VEHICLE CAB AND CHASSIS. ADDITIONAL EQUIPMENT HAS BEEN INSTALLED IN THE ENGINE COMPARTMENT AND CAB TO OPERATE THE PUMPING AND LIFTING DEVICE (OPTIONAL). MAJOR SYSTEMS AND COMPONENTS MODULE THE MODULE IS A STRUCTURAL STAINLESS STEEL TUBE COMPONENT WITH STAINLESS STEEL BOLT ON PANELS. THE MODULE IS INSULATED TOP, BOTTOM AND SIDES WITH POLYSTYRENE INSULATION. THE TOP IS COVERED IN GALVANIZED EXTRUDED GRATING. THERE IS A RECESSED LADDER ON THE DRIVERS SIDE FOR TOP DECK ACCESS. WITH THE EXCEPTION OF THE FRONT PANEL, ALL SIDE PANELS ARE REMOVABLE. THERE ARE (2) DOORS THAT HAVE REMOVABLE STAINLESS STEEL HINGES THAT UTILIZE STAINLESS STEEL LATCHES. THESE DOORS GIVE ACCESS TO ALL ELECTRIC, HYDRAULIC AND PLUMBING COMPONENTS. THE MODULE IS SECURED TO THE CHASSIS USING (8) STAINLESS STEEL TIE DOWN BOLTS. TANKS THERE ARE (2) TANKS - WASTE TANK THE WASTE TANK IS LOCATED IN THE REAR OF THE MODULE. CAPACITY FOR THE WASTE TANK IS 360 U.S. GALLONS. IT IS FABRICATED OF 12 GAUGE 304 STAINLESS STEEL. A TRAY ON THE TOP OF THE WASTE TANK CONTAINS AN INSPECTION HATCH, A DRAIN AND A WASTE HOSE CONNECTOR. THE TRAY PREVENTS EXCESS WASTE FROM THE WASTE HOSE FROM STANDING ON TOP OF THE UNIT. THERE IS A 4 INCH BRONZE BALL VALVE ON THE BOTTOM OF THE TANK. THIS VALVE IS USED TO EMPTY THE TANK. AN EXTENSION HANDLE ALLOWS THE OPERATOR TO OPEN AND CLOSE THE WASTE VALVE FROM THE LEFT OUTSIDE EDGE OF THE MODULE. THERE IS A TANK RINSE SYSTEM INCORPORATED IN THE WASTE TANK. THIS SYSTEM IS INTENDED TO HELP FLUSH THE TANK WHEN EMPTIED. A FITTING IS INSTALLED THAT WILL ALLOW COUPLING OF THE FLUSH SYSTEM HOSE TO THE WASTE TANK.


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CHAPTER 1

SECTION 2 - DESCRIPTION

CONTINUED FLUSH TANK THE FLUSH TANK CAPACITY IS 240 U.S. GALLONS. IT IS USED FOR THE RINSING AND REPLENISHING OF AIRCRAFT LAVATORIES. IT IS FABRICATED OF 12 GAUGE 304 STAINLESS STEEL. THERE IS A 1-1/4 INCH PVC BALL VALVE LOCATED ON THE OUTBOARD RIGHT HAND SIDE, BOTTOM FOR DRAINING. A 2” MALE NIPPLE STANDPIPE IS LOCATED ON THE TOP LEFT HAND SIDE FOR FILLING OF THE FLUSH TANK. A 2” FEMALE THREADED CAP IS TETHERED TO THE STAND PIPE TO CLOSE THE FILL POINT. A LEVEL GAUGE IS LOCATED NEXT TO THE FILL PORT PUMPING SYSTEMS THE PUMPING SYSTEM ON THIS VEHICLE IS FOR RINSING AND REPLENISHING OF CHEMICALS FOR THE AIRCRAFT LAVATORY. THE PUMP SYSTEM IS MANUALLY OPERATED USING A CONTROL SWITCH AT THE WORK PLATFORM. A SPRING REWIND HOSE REEL WITH 25’ OF HOSE IS SUPPLIED TO STOW UNUSED HOSE. THERE IS A FLOW METER TO DETERMINE THE AMOUNT OF FLUID PUMPED INTO THE AIRCRAFT. THE METER IS RESETTABLE. THE METER SHOULD BE RESET AFTER EACH PUMPING OPERATION. THE METER IS LOCATED ON THE TOP DECK AT THE CONTROL STATION. WATER PUMP THE WATER PUMP IS USED TO REPLENISH OR RINSE THE AIRCRAFT LAVATORY. THE PUMP IS A BRONZE CONSTRUCTION, GEAR PUMP AND IS OPERATED BY A HYDRAULIC MOTOR. CONTROL FOR THE OPERATION OF THE PUMP CAN BE DONE FROM THE REAR OF THE TRUCK. A FOOT SWITCH OPERATES THE PUMP CONTROL. A DRAIN BACK CIRCUIT IS ALSO INCORPORATED TO ALLOW FLUID IN THE HOSE AT THE AIRCRAFT END, TO DRAIN BACK WHEN FILLING IS COMPLETE. THIS PREVENTS THE OPERATOR FROM GETTING SPRAYED WHEN DISCONNECTING FROM THE AIRCRAFT. HYDRAULIC SYSTEM THE VEHICLE UTILIZES HYDRAULIC PRESSURE TO OPERATE THE PUMPING SYSTEM. A HYDRAULIC PUMP IS MOUNTED TO THE FRONT OF THE VEHICLE ENGINE AND HYDRAULIC FLOW IS CONTROLLED BY THE USE OF AN ELECTRIC CLUTCH TO TURN THE PUMP ON AND OFF. THERE IS A STAINLESS STEEL HYDRAULIC TANK MOUNTED ON THE PASSENGER SIDE MIDWAY BACK THAT IS INSIDE THE MODULE. THIS RESERVOIR HAS A FILTER, A LEVEL GAUGE AND A FILL PORT. THE FILL PORT IS LOCATED ON THE TOP DECK. THERE IS A SHUTOFF VALVE LOCATED ON THE SIDE RAIL OF THE CHASSIS TO CLOSE OFF THE FLOW OF OIL TO THE PUMP FOR REMOVAL OF THE TANK OR PUMP. A HYDRAULIC SYSTEM RELIEF VALVE IS LOCATED ON THE SIDE OF THE HYDRAULIC TANK TO PROTECT THE SYSTEM FROM EXCESSIVE PRESSURE. THIS DEVICE SHOULD ONLY BE ADJUSTED BY TRAINED MAINTENANCE PERSONNEL.


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CHAPTER 1


CONTINUED ELECTRICAL SYSTEM THE ELECTRICAL SYSTEM IS TIED INTO THE IGNITION CIRCUIT OF THE VEHICLE. POWER FOR OPERATION OF THE SERVICING FUNCTION CAN ONLY BE DONE WHILE THE VEHICLE IS RUNNING AND THE IGNITION IS IN THE ON POSITION. THE REAR CONTROLS AND LIGHTING CIRCUIT ARE PROTECTED BY A CIRCUIT BREAKER. ALL FUNCTION CONTROLS ARE OPERATED BY CONTROL SWITCHES AT EITHER THE LOWER WORK PLATFORM OR (IF INSTALLED) THE LIFT PLATFORM. A TOGGLE SWITCH ON THE METER BOX OPERATES THE AIR HEATER LOCATED IN THE INTERIOR OF THE MODULE. IN ALL CASES, THE VEHICLE ENGINE SHOULD BE RUNNING ANYTIME THE WORK LIGHTS ARE ON. THIS WILL PREVENT THE LIGHTS FROM RUNNING DOWN THE BATTERY. COLD WEATHER EQUIPMENT (OPTIONAL) IF THIS UNIT IS EQUIPPED WITH A COLD WEATHER PACKAGE. THE PACKAGE CONSISTS OF: TANK IMMERSION HEATER , AIR HEATER AND FULL INSULATION. (FIGURE # 2A) HEATERS ALL BUT THE AIR HEATER ARE OPERATED ON 110 VOLTS A.C. A SINGLE 20 AMP/ 110 VOLT FEMALE INLET RECEPTACLE IS LOCATED ON THE DRIVER SIDE BEHIND THE REAR WHEEL WELL, SIDE PANEL. THE AIR HEATER IS TIED TO THE ENGINE COOLING SYSTEM. IT WORKS THE SAME WAY THE HEATER IN THE CAB OF THE VEHICLE WORKS. A FAN BLOWS AIR ACROSS COILS THAT THE HOT ENGINE COOLANT IS RUNNING THROUGH AND WARMS THE AIR INSIDE THE MODULE. THIS HEATER WORKS ONLY AFTER THE ENGINE IS RUNNING AND UP TO TEMPERATURE. THE OTHER HEATERS ARE USED BETWEEN USE AND OVERNIGHT.

IMPORTANT THIS UNIT MUST BE PLUGGED IN TO THE OUTLET IN WEATHER THAT IS 36 DEGREES AND BELOW. THE DAMAGE TO TANKS AND PLUMBING DUE TO FREEZING TEMPERAURES IS NOT COVERED BY WARRANTY


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CHAPTER 1


FIGURE 2A

12 VDC HOT WATER HEATER

FLUSH TANK IMMERSION HEATER


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CHAPTER 1

SECTION 3 - OPERATION GENERAL OPERATION OF THE PHOENIX TL600 IS FAIRLY SIMPLE. ALL CONTROLS ARE CLEARLY MARKED AND SELF EXPLANATORY. THE FOLLOWING PROCEDURES ARE RECOMMENDED FOR THE OPERATION OF THIS EQUIPMENT. YOUR ORGANIZATION MAY HAVE A MORE DETAILED OR DIFFERENT PROCEDURE FOR OPERATION OF THIS EQUIPMENT. PLEASE CHECK WITH YOUR SUPERVISORS BEFORE OPERATING THIS EQUIPMENT. THERE ARE NO INSTRUCTIONS FOR THE OPERATION OF THE TRUCK PORTION OF THIS VEHICLE SINCE THIS IS A COMMERCIAL VEHICLE AND SHOULD NOT PRESENT ANY PROBLEMS. REFER TO THE TRUCK OWNERS MANUAL FOR OPERATION OF THE TRUCK. PREPARATION FOR USE BEFORE EACH DAY’S USE, THE FOLLOWING INSPECTION/ CHECKS SHOULD BE PERFORMED. WALK AROUND THE UNIT AND MAKE A VISUAL INSPECTION PAYING PARTICULAR ATTENTION TO THE FOLLOWING: (1) CHECK GENERAL CONDITION OF TRUCK CHASSIS, BODY AND THE CONDITION OF THE RUBBER BUMPERS ON THE PLATFORM AND HAND RAILS. (2) NOTE THE CONDITIONS OF THE TIRES AND CHECK FOR PROPER INFLATION. RECOMMENDED PRESSURE SHOULD BE 70 POUNDS IN THE FRONT AND 80 POUNDS IN THE REAR. (3) THE FOLLOWING FLUID LEVELS CAN BE CHECK WITHOUT RAISING THE CAB - (FIGURE # 3) , BRAKE, WINDSHIELD WASHING FLUID AND RADIATOR RESERVOIR. (4) RAISE CAB AND CHECK ENGINE OIL, POWER STEERING, TRANSMISSION CONDITION AND TENSION OF ALL V BELTS. (FIGURE # 3A).

NOTE: BEFORE RAISING THE CAB THE GRILL GUARD MUST BE FULLY LOWERED. DAMAGE TO THE CAB WILL OCCUR IF THE GRILL GUARD IS NOT LOWERED BEFORE UNLATCHING THE CAB.


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FIGURE 3

CHAPTER 1

SECTION 3 - OPERATION

BRAKE FLUID - INSIDE DRIVERS DOOR ON OUTSIDE

OF DASHBOARD—REMOVE PANEL TO EXPOSE RESERVOIR - LEFT SIDE OF

VEHICLE BEHIND CAB RADIATOR RESERVOIR -

RIGHT SIDE OF VEHICLE BELOW CAB

WINDSHIELD WASH FLUID RESERVOIR RIGHT SIDE OF

VEHICLE INSIDE CAB


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CHAPTER 1


(5) CHECK FOR LEAKS ON ENGINE COMPONENTS AND ON GROUND BELOW. (6) START ENGINE AND LISTEN FOR UNUSUAL NOISES. CHECK LIGHTS, TURN SIGNALS, BRAKE LIGHTS, BEACON, HORN. (7) CHECK FUEL GAUGE FOR SUFFICIENT FUEL LEVEL FOR DAY’S OPERATION (8) CHECK OIL PRESSURE GAUGE, CHARGING CIRCUIT GAUGE AND WATER TEMPERATURE GAUGE (9) PUT VEHICLE IN GEAR AND TEST BRAKES.

ENGINE OIL DIPSTICK

FIGURE 3A

TRANSMISSION OIL DIPSTICK

POWER STEERING CHECK & SERVICE


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THIS PAGE INTENTIONALLY LEFT BLANK


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CHAPTER 1


CONTINUED LAVATORY SERVICE EQUIPMENT (1) CHECK LEVEL OF FLUSH TANK LEVEL GAUGE. CAPACITY OF TANK IS 240 U.S. GALLONS. (FIGURE # 4.) (2) ASSURE THAT THE WASTE TANK IS EMPTY OR THAT THERE IS SUFFICIENT CAPACITY REMAINING FOR THE INTENDED USE. CAPACITY FOR WASTE TANK IS 360 U.S. GALLONS. (FIGURE # 4) (3) CHECK CONDITION OF BOTH HOSES, WASTE HOSE AND FILL HOSE. CHECK FOR CUTS, HOLES OR TWISTING OF HOSE. CHECK CONDITION OF BOTH AIRCRAFT COUPLINGS. (FIGURE # 5) (4) CHECK LEVEL OF HYDRAULIC TANK. OPEN HYDRAULIC TANK COMPARTMENT LOCATED ON PASSENGER SIDE OF MODULE. THE SIGHT GAUGE SHOULD READ FULL. IF LEVEL IS BELOW FULL FLUID MUST BE ADDED. (FIGURE # 6) (5) IF UNIT IS BEING USED IN SUB-FREEZING WEATHER, BE SURE TO DISCONNECT THE 110 VOLT AC CABLE FROM THE OUTLET ON DRIVERS SIDE. (FIGURE # 6) (6) CHECK CONDITION OF WASTE TANK DRAIN VALVE. CHECK CONDITION OF WASTE TANK DRAIN VALVE HANDLES. (FIGURE # 5) IF ALL FUNCTIONS AND INSPECTIONS CHECK OUT, THE VEHICLE AND SERVICING MODULE ARE READY FOR OPERATION.

BE SURE DRAIN VALVE IS CLOSED!


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CHAPTER 1


FLUSH TANK

CHECK LEVEL OF FLUSH TANK -

WASTE LEVEL GAUGE

CHECK LEVEL WASTE TANK - (OPTIONAL)

FIGURE 4


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CHAPTER 1


FIGURE 5

FLUID HOSE WASTE HOSE CHECK FOR CONDITION OF BOTH FLUID HOSE AND WASTE HOSE

MAKE SURE VALVE HANDLE IS IN THE CLOSED OR UP POSITION

WASTE TANK VALVE


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CHAPTER 1


FIGURE 6

HYDRAULIC TANK LEVEL GAUGE

CHECK LEVEL OF HYDRAULIC RESERVOIR - LEVEL SHOULD BE AT HIGH MARK

HIGH

110 VOLT HEATER CONNECTION -

DISCONNECT PRIOR TO DRIVING VEHICLE


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CHAPTER 1

SECTION 3 - OPERATION AIRCRAFT SERVICING – (1) CAREFULLY POSITION UNIT TO AIRCRAFT SO THAT THE WASTE AND FLUID HOSES CAN BE CONNECTED TO THE AIRCRAFT WITHOUT ANY SHARP KINKS OR BENDS. (2) SET TRANSMISSION IN PARK POSITION AND SET EMERGENCY BRAKE BY PULLING UP ON HANDLE . (3) REMOVE WASTE HOSE COUPLING FROM STOWAGE NIPPLE IN TRAY OF WASTE TANK. CONNECT WASTE CONNECTOR TO AIRCRAFT WASTE HOLDING TANK. (4) PULL FLUID HOSE FROM DRIVERS SIDE REAR COMPARTMENT ( HOSE STICKS OUT OF MODULE). PULL A SMALL AMOUNT MORE THAN YOU NEED FROM THE COMPARTMENT SO THAT THE REEL WILL LOCK. CONNECT FLUID HOSE TO AIR CRAFT FILL FITTING. (5) DRAIN AIRCRAFT WASTE HOLDING TANK - NOTE: REFER TO YOUR ORGANIZATIONS PROCEDURE FOR RINSING AND CHARGING AIRCRAFT WASTE TANK (6) PUSH FOOT SWITCH TO ENGAGE PUMP AND OBSERVE FLUID METER TO DETERMINE AMOUNT OF FLUSH WATER BEING TRANSFERRED TO AIRCRAFT. (7) ALLOW 10 SECONDS AFTER RELEASING CHARGE OR FLUSH WATER SWITCH FOR FLUID IN HOSE TO RECEDE BEFORE REMOVING FLUID HOSE COUPLING. (8) DETACH WASTE HOSE COUPLING FROM AIRCRAFT AND RETURN TO TOP TRAY STOWAGE NIPPLE. (9) REPLACE FLUID HOSE ON REEL BY PULLING HOSE FROM REEL (APPROXIMATELY 3 INCHES - TO RELEASE REEL LOCK) AND SLOWLY GUIDING EXTENDED HOSE BACK ON THE REEL.


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CHAPTER 1

SECTION 3 - OPERATION LAVATORY EQUIPMENT AND TRUCK SERVICING . (1) EMPTYING OF UNIT (A) DRIVE THE VEHICLE TO A DESIGNATED WASTE DUMPING SITE. (B) POSITION WASTE TANK DRAIN OVER PIT FOR OPEN DUMP. FOR CLOSED DUMP POSITION VEHICLE SO DRAIN HOSE WILL ATTACHED TO WASTE NIPPLE. (C) PLACE TRANSMISSION SELECTOR IN PARK AND SET EMERGENCY BRAKE. (D) SLOWLY LOWER HANDLE OF WASTE TANK DRAIN VALVE TOWARD THE OPEN POSITION (DOWN). WASTE TANK HANDLE IS ON THE DRIVER SIDE. (E) WHEN TANK IS EMPTY-CLOSE VALVE BY RAISING HANDLE TO THE UP POSITION. (2) FILLING FLUSH TANK (A) DRIVE THE VEHICLE TO A DESIGNATED FILL SITE. (B) POSITION VEHICLE SO THAT THE FILL PORT IS CLOSEST TO FILLING HOSE. (C) PLACE TRANSMISSION SELECTOR IN PARK AND SET EMERGENCY BRAKE. (D) FILL THE FLUSH TANK (DRIVERS SIDE). WATCH LEVEL GAUGE LOCATED NEXT TO FILL PORT. DO NOT OVER FILL. CAPACITY OF FLUSH TANK IS 300 GALLONS. WHEN TANK IS FULL REPLACE CAP ON NIPPLE.


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CHAPTER 1

SECTION 3 - OPERATION COLD WEATHER OPERATIONS IN SUB-FREEZING CONDITIONS THE FLUID IN THE TANK AND PLUMBING CAN FREEZE. IF A FREEZING CONDITION OCCURS THE TANKS AND/ OR PLUMBING COMPONENTS CAN BURST.

THE HEATERS WORK ON 110 VOLT (HOUSE) CURRENT. THE UNIT MUST BE PLUGGED IN TO A DESIGNATED SOURCE FOR THE HEATERS TO WORK. (1) CONNECTING UNIT TO 110 VOLT CIRCUIT THE FOLLOWING HEATER (S) ARE IN THE HEATER CIRCUIT: FLUSH TANK IMMERSION HEATER (A) DRIVE THE VEHICLE TO THE DESIGNATED STORAGE FOR COLD WEATHER PARKING. (B) POSITION VEHICLE SO THAT THE DRIVER SIDE REAR PANEL IS LOCATED NEAR THE OUTLET/ CORD FOR 110 VOLT POWER. THIS OUTLET MUST BE ON A 20 AMP CIRCUIT. (C) PLACE TRANSMISSION SELECTOR IN PARK, SET EMERGENCY BRAKE AND TURN ENGINE OFF. (D) INSERT PLUG INTO OUTLET (E) PLUG CORD IN AT WALL

THIS CONDITION IS NOT COVERED UNDER WARRANTY

IT IS VERY IMPORTANT TO ANTICIPATE COLD WEATHER CONDITIONS AND TAKE THE APPROPRIATE ACTION TO PREVENT FREEZING OF THE UNIT.

WHEN VEHICLE IS READY TO BEGIN SERVICE IT IS VERY IMPORTANT TO REMOVE PLUG FROM OUTLET BEFORE ATTEMPTING TO DRIVE AWAY.


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CHAPTER 1


CONTINUED (2) 12 VOLT AIR HEATER (1) DURING SUB FREEZING CONDITIONS AND AFTER THE VEHICLE ENGINE TEMPERATURE HAS RISEN, THE AIR HEATER INSIDE THE LAVATORY MODULE WILL SUPPLY WARM AIR TO THE PLUMBING CIRCUIT. A TOGGLE SWITCH LOCATED ON THE METER BOX CONTROLS THE HEATER. FUEL SERVICING THE FUEL TANK ON THIS VEHICLE IS LOCATED IN THE AFT OF THE CHASSIS. THE FUEL FILL IS LOCATED ON THE DRIVER SIDE REAR OF MODULE JUST BEHIND THE REAR WHEEL. (1) POSITION VEHICLE SO THAT THE FILL PORT IS ON THE SIDE OF THE FUEL PUMP. (2) PLACE TRANSMISSION SELECTOR IN PARK POSITION AND SET EMERGENCY BRAKE. (3) TURN ENGINE OFF. (4) REMOVE CAP AND BEGIN FILLING. (5) FILL TANK TO DESIRED LEVEL. (6) REPLACE CAP


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CHAPTER 2

MAINTENANCE

SECTION 1 - SYSTEMS DESCRIPTION THE FOLLOWING SYSTEMS COMPRISE THE 600 LAVATORY SERVICE TRUCK. HYDRAULIC SYSTEM THE HYDRAULIC SYSTEM FOR THIS VEHICLE IS COMPRISED OF AN ENGINE DRIVEN HYDRAULIC PUMP, CONTROLLED BY AN ELECTRIC ACTUATED MAGNETIC CLUTCH, HYDRAULIC RESERVOIR, SYSTEM PRESSURE RELIEF VALVE AND A HYDRAULIC MOTOR FOR THE PUMPING SYSTEM. HYDRAULIC PUMP THE HYDRAULIC PUMP IS SECURED TO THE FRONT OF THE ENGINE AND IS DRIVEN BY ONE AUTOMOTIVE SERPENTINE BELT. THE PUMP IS CONTROLLED BY A MAGNETIC CLUTCH AND IS IDLE UNTIL A PUMPING FUNCTION IS SIGNALED FOR THROUGH THE ELECTRICAL SYSTEM. HYDRAULIC RESERVOIR THE HYDRAULIC SYSTEM IS FED FROM A STAINLESS STEEL HYDRAULIC RESERVOIR LOCATED IN THE HYDRAULIC TANK COMPARTMENT ON THE PASSENGER SIDE OF THE MODULE. THE CAPACITY OF THE RESERVOIR IS 17 U.S. GALLONS. FLUID RETURNING TO THE RESERVOIR IS FILTERED THROUGH THE RETURN FILTER. A BALL VALVE ISOLATES THE HYDRAULIC PUMP AND THE RESERVOIR. IT IS LOCATED ON THE BOTTOM SIDE OF THE MODULE, ON THE PASSENGER SIDE IN FRONT OF THE REAR WHEEL WELL. HYDRAULIC MOTOR THE HYDRAULIC MOTOR IS COUPLED TO THE FLUID PUMP. PRESSURE RELIEF VALVE. THE PRESSURE RELIEF VALVE PROTECTS THE HYDRAULIC SYSTEM FROM EXCESSIVE HYDRAULIC PRESSURE. IT IS SET AT THE FACTORY.


28

CHAPTER 2

SECTION 1 - SYSTEMS DESCRIPTION

CONTINUED PUMPING SYSTEM THE PUMPING SYSTEM FOR THIS VEHICLE CONSISTS OF : FLUID PUMP, FLOW METER, RELIEF VALVE AND A DRAIN BACK LINE. FLUID PUMP THE FLUID PUMP IS A 1 INCH BRONZE GEAR PUMP. THE FLUID PUMP WILL PULL FROM THE FLUSH WATER TANK; THROUGH A BONZE SHUT OFF VALVE, AND A 1 INCH “T” STRAINER WITH A REMOVABLE STAINLESS STEEL MESH FILTER. HOSE REEL A HOSE REEL STORES 25 FEET OF 1 INCH I.D. RE-ENFORCED PVC HOSE. THE HOSE REEL HAS A SPRING REWIND AND A RATCHETING LOCKING SYSTEM. FLOW METER A 1 INCH FLOW METER TOTALIZES THE FLUID PASSING THROUGH THE PUMPING SYSTEM. A RESET KNOB ALLOWS FOR TURNING THE COUNTER BACK TO ZERO. LARGE NUMBER DIALS OR ROUND FACE WITH NUMBERS INDICATE THE AMOUNT OF FLUID PUMPED THROUGH THE SYSTEM. RELIEF VALVE A RELIEF VALVE AT THE INLET OF THE METER REGULATES THE PRESSURE OUTPUT OF THE FLUID PUMP. THE BYPASSED FLUID RETURNS TO THE FLUSH TANK. DRAIN BACK VALVE A 1/4” STATIC LINE IS PLUMBED BACK TO THE FLUSH TANK. THIS ALLOWS FOR FLUID TO DRAIN BACK TO TANK WHEN PUMPING IS COMPLETED TO PREVENT THE OPERATOR FROM GETTING SPLASHED WHEN DISCONNECTING FROM AIRCRAFT


29

CHAPTER 2

SECTION 1 - SYSTEMS DESCRIPTION

CONTINUED ELECTRICAL THE ELECTRICAL CIRCUIT CONSISTS OF THE VEHICLE IGNITION SYSTEM, ELECTRIC CLUTCH, FOOT SWITCH TO ACTUATE THE ELECTRIC CLUTCH, WORK LIGHTS AND 12 VOLT HEATER FAN SWITCHES. THE ELECTRICAL CIRCUIT IS PROTECTED BY A 30 AMP RESETTABLE CIRCUIT BREAKER. VEHICLE IGNITION CIRCUIT THE VEHICLE IGNITION CIRCUIT CONTROLS ALL POWER TO THE MODULE FUNCTIONS. THE IGNITION SWITCH MUST BE ON TO OPERATE ANY CONTROLS. HYDRAULIC PUMP CLUTCH THE HYDRAULIC PUMP IS CONTROLLED BY A MAGNETIC CLUTCH MOUNTED ON THE DRIVE PULLEY OF THE PUMP. THE CLUTCH IS PULLED IN BY DEPRESSING THE REAR WORK PLATFORM MOUNTED FOOT SWITCH.. A RELAY CONTROLS THE INPUT OF CURRENT INTO THE CLUTCH. THE RELAY IS ENERGIZED ONLY WITH THE VEHICLE TRANSMISSION IS IN THE PARK POSITION. WORK LIGHTS THERE ARE (2) WORK LIGHTS. ONE LIGHT IS MOUNTED ON THE RIGHT HAND SIDE TOP FRONT CORNER OF THE MODULE AND IS USED FOR ILLUMINATING THE AIRCRAFT WORK AREA. THE SECOND WORK LIGHT IS USED FOR ILLUMINATING THE METER/ REAR WORK PLATFORM AREA. POWER IS SUPPLIED FROM THE VEHICLE IGNITION CIRCUIT. THE LIGHTS ARE CONTROLLED BY A TOGGLE SWITCH MOUNTED ON THE RIGHT HAND SIDE OF THE METER BOX MOUNTED AT THE LEFT HAND REAR OF THE MODULE. HOT WATER HEATER THE HOT WATER HEATER CONSISTS OF A FAN MOTOR. THE FAN IS CONTROLLED BY A TOGGLE SWITCH LOCATED ON THE FRONT RIGHT FACE OF THE METER BOX. COLD WEATHER HEATER THE VEHICLE COLD WEATHER PACKAGE CONSISTS OF A 110 VOLT TANK IMMERSION HEATER. THE HEATER IS CONNECTED TO A 20 AMP U GROUND FEMALE INLET (STANDARD HOUSE HOLD EXTENSION CORD). WHEN THE INLET IS CONNECTED TO A POWER SUPPLY THE HEATER WILL TURN ON. THE HEATER THERMOSTAT IS SET FOR 50 DEGREES FAHRENHEIT. WHEN THE WATER TEMPERATURE REACHES 50 DEGREES THE HEAT WILL SHUT OFF.

NOTE: THE TANK MUST HAVE A MINIMUM OF 100 GALLONS OF FLUID WHEN THE HEATER IS ON TO PREVENT PREMATURE FAILURE OF THE HEATING ELEMENT.


30

CHAPTER 2

SECTION 2 - SERVICING/ LUBRICATION THE TL 600 REQUIRES LITTLE MORE ATTENTION THAN MOST OTHER CONVENTIONAL VEHICLES OF ITS TYPE. THERE ARE NO SPECIAL TOOLS REQUIRED OTHER THAN THOSE FOUND IN ANY MODERN GARAGE OR AIRLINE GROUND SUPPORT EQUIPMENT SERVICING FACILITY. ALL WORK SHOULD BE PERFORMED IN ACCORDANCE WITH STANDARD SHOP PRACTICES. 1.VEHICLE SERVICING ENGINE OIL, POWER STEERING, TRANSMISSION, RADIATOR, REAR AXLE AND BATTERIES; SERVICE THESE ITEMS IN ACCORDANCE WITH CHASSIS MANUFACTURER’S RECOMMENDATIONS (SEE OWNERS MANUAL). 2. HYDRAULIC SYSTEM A. HYDRAULIC OIL SERVICING THE HYDRAULIC SYSTEM RESERVOIR, LOCATED OVER THE RIGHT HAND REAR WHEEL WELL IS THE ONLY PLACE TO SERVICE THE HYDRAULIC SYSTEM. THE FILL CAP IS LOCATED ON THE TOP DECK BETWEEN THE FRONT RIGHT CORNER (PASSENGER SIDE) AND THE RIGHT HAND REAR WHEEL WELL. THE FILL CAP IS PAINTED YELLOW. A SIGHT LEVEL GAUGE IS LOCATED ON THE REAR SIDE CORNER OF THE RESERVOIR. WHEN THE HYDRAULIC TANK COMPARTMENT IS OPENED THE SITE GAUGE IS IN PLAIN VIEW ON THE SIDE OF THE TANK. THE GAUGE HAS A LOW AND A HIGH MARK. FOR UNITS WITH TELESCOPIC LIFTS THE LEVEL SHOULD BE NO LOWER THAN THE HIGH MARK. IF HYDRAULIC FLUID IS REQUIRED, START THE ENGINE AND RUN THE PUMPING SYSTEM AND CHECK FOR LEAKS. IF A LEAK IS FOUND IT MUST BE CORRECTED PRIOR TO FILLING THE RESERVOIR. CAPACITY OF THE HYDRAULIC RESERVOIR IS 17 U.S. GALLONS USE ONLY I.S.O. 32 OIL .

B. HYDRAULIC TANK- CLEANING (1) DRAIN AND REPLACE OIL IF THERE IS A DOUBT AS TO ITS PURITY. (2) TO DRAIN TANK PLACE A CONTAINER UNDER HYDRAULIC TANK DRAIN LOCATED IN FRONT OF THE RIGHT REAR WHEELS. REMOVE CAP, DRAIN AND DISCARD FLUID.

NOTE: DO NOT USE HYDRAULIC OILS OF DIFFERENT SPECIFICATIONS. THE OILS MAY NOT BE COMPATIBLE AND COULD RESULT IN DAMAGE TO THE HYDRAULIC SYSTEM COMPONENTS


31

CHAPTER 2

SECTION 2 - SERVICING/ LUBRICATION

CONTINUED (3) REPLACE CONTAINER UNDER DRAIN. FLUSH INTERIOR OF TANK WITH MINERAL SPIRITS BY OPENING DRAIN AND FILLING TANK FROM FILL PORT. ALLOW TIME FOR THE CLEANING MATERIAL TO DRAIN AND TANK TO DRY. A JET OF LOW PRESSURE AIR WILL SPEED THE DRYING TIME. (4) REPLACE DRAIN PLUG AND FILL TANK WITH RECOMMENDED OIL TO PROPER LEVEL ON LEVEL GAUGE. RECOMMENDED OIL IS I.S.O. 32. (5) START ENGINE AND OPERATE SYSTEM. RECHECK OIL LEVEL. ADD OIL IF REQUIRED. C. FILTER, HYDRAULIC OIL (1) CHANGE FILTER ELEMENT EVERY THREE MONTHS. (2) TO REMOVE ELEMENT, PLACE SMALL CONTAINER UNDER FILTER ELEMENT. UNSCREW ELEMENT FROM FILTER HOUSING. (3) DISCARD ELEMENT AND O-RING SEAL BETWEEN FILTER HOSING AND ELEMENT. (4) INSTALL NEW FILTER ELEMENT USING NEW O-RING SEAL. (5) TIGHTEN ELEMENT TO A MAXIMUM OF 20 FOOT POUNDS. (6) START UNIT AND OPERATE HYDRAULIC SYSTEM - CHECK FOR LEAKS D. LUBRICATION (1) LUBRICATE THE VEHICLE CHASSIS IN ACCORDANCE WITH THE MANUFACTURER’S RECOMMENDATIONS. (2) LUBRICATION POINTS ON THE SERVICE MODULE ARE MINIMAL. THE FOLLOWING POINTS NEED TO BE LUBRICATED. (A) ALL HINGES AND LATCHES ON MODULE. LUBRICATE WITH A DROP OF 5 WT OIL.


32

CHAPTER 2

SECTION 3 - INSPECTIONS

CONTINUED PERIODIC INSPECTIONS THE FOLLOWING TABLE IS SUGGESTED AS A GUIDE FOR THE USER IN CONDUCTING PERIODIC INSPECTIONS. THE FREQUENCIES SHOWN ARE FOR THE UNIT OPERATING IN AVERAGE U.S. CLIMATES. IF THE UNIT IS OPERATED IN ADVERSE CLIMATIC CONDITIONS; IE SALT SPRAY, EXTREME COLD OR SANDY/ DUSTY ENVIRONMENTS, THE INSPECTIONS SCHEDULES SHOULD BE ADJUSTED FOR THOSE CONDITIONS.

TABLE –1 PERIODIC INSPECTIONS

INSPECT FOR GENERAL INSPECT TRUCK CHASSIS IN ACCORDANCE WITH MANUFACTURER’S RECOMMENDED MAINTENANCE SCHEDULES. INSPECT AND SERVICE VEHICLE ENGINE PER RECOMMENDED MAINTENANCE SCHEDULES ENTIRE UNIT FOR GENERAL OVERALL APPEARANCE AND CLEANLINESS SECURITY OF FASTENERS AND MOUNTINGS FUEL, PLUMBING, HEATING AND COOLING SYSTEMS SERVICED TANK ASSEMBLIES FOR LEAKS, INCLUDING WASTE VALVE WASTE HOSE, FLUID HOSE AIRCRAFT CONNECTORS FOR LEAKS, CUTS OR MISSING PARTS HYDRAULIC SYSTEM PERFORM A COMPLETE OPERATIONAL CHECK AND OBSERVE THE FOLLOWING. HYDRAULIC LINES, FITTINGS, PUMP AND MOTOR LEAKAGE AND PROPER FUNCTION. FLEXIBLE LINES FOR ABRASIONS, KINKS, LEAKAGE AND SECURITY CONDITION OF HYDRAULIC FILTER

FREQUENCY (HOURS) A/R A/R 80 250 A/R 80 80 80 80 80 500


33

CHAPTER 2


CONTINUED


INSPECT FOR GENERAL INSPECT TRUCK CHASSIS IN ACCORDANCE WITH MANUFACTURER’S RECOMMENDED MAINTENANCE SCHEDULES. INSPECT AND SERVICE VEHICLE ENGINE PER RECOMMENDED MAINTENANCE SCHEDULES ENTIRE UNIT FOR GENERAL OVERALL APPEARANCE AND CLEANLINESS SECURITY OF FASTENERS AND MOUNTINGS FUEL, PLUMBING, HEATING AND COOLING SYSTEMS SERVICED TANK ASSEMBLIES FOR LEAKS, INCLUDING WASTE VALVES WASTE HOSE, FLUID HOSE AIRCRAFT CONNECTORS FOR LEAKS, CUTS OR MISSING PARTS HYDRAULIC SYSTEM PERFORM A COMPLETE OPERATIONAL CHECK AND OBSERVE THE FOLLOWING. HYDRAULIC LINES, FITTINGS, PUMP AND MOTOR LEAKAGE AND PROPER FUNCTION. FLEXIBLE LINES FOR ABRASIONS, KINKS, LEAKAGE AND SECURITY CONDITION OF HYDRAULIC FILTER FLUID PUMPING SYSTEM WHILE PERFORMING THE OPERATIONAL CHECK FOR THE HYDRAULIC SYSTEM, ALSO CHECK THE FUNCTION OF THE FLUID PUMPING SYSTEM PULL HOSE FROM HOSE REEL-REMOVE CAP ON FLUID HOSE - REMOVE CAP ON FLUSH TANK FILL - CONNECT FLUID HOSE TO FILL NIPPLE OR IN-SERT INTO STAND PIPE. ENGAGE CHARGE PUMP SWITCH AND OBSERVE

FREQUENCY (HOURS) A/R A/R 80 250 A/R 80 80 80 80 80 500 250


34

INSPECT FOR FLUID PUMPING SYSTEM PROPER FLOW. PROPER FLOW IS 20 U.S. GALLONS PER MINUTE. INSPECT AREAS AROUND WATER PUMP, RELIEF VALVE, DRAIN BACK LINE, METER AND HOSE REEL. WASTE SYSTEM DISCONNECT WASTE HOSE FROM STOWAGE NIPPLE ON TOP TRAY CON-NECTOR. FILL WASTE HOSE WITH CLEAN WATER. FILL HOSE APPROXI-MATELY HALF FULL. CONNECT WASTE HOSE BACK ON TOP TRAY CON-NECTOR. CHECK FOR LEAKS IN WASTE HOSE, CONNECTIONS AT STOWAGE NIPPLE . ELECTRICAL SYSTEM INSPECT THE ELECTRICAL SYSTEM FOR SECURITY OF WIRING, ROUTING, TIES AND CLAMPS TURN LIGHTS ON AND CHECK FOR FUNCTION TURN 12 VOLT HEATER ON AND CHECK FOR FAN FUNCTION CHECK CONDITION OF 110 VAC OUTLET ON DRIVER SIDE OF SERVICE MODULE

FREQUENCY (HOURS) 250 250 250 500 500 500 500 500

CHAPTER 2


CONTINUED



35

CHAPTER 2

SECTION 4 - ADJUSTMENTS ADJUSTMENTS THERE ARE THREE PERFORMANCE FACTORS THAT WILL REQUIRE SOME ATTENTION. THE HYDRAULIC SYSTEM PRESSURE , THE FLUID PUMPING PRESSURE AND THE FLUID PUMPING SYSTEM FLOW. ALTHOUGH THE SYSTEMS ARE SET AT THE FACTORY, THEY MAY NEED TO BE CHECKED WHEN A NON CONFORMING RESULT IS ENCOUNTERED WHILE OPERATING THE SYSTEMS. HYDRAULIC SYSTEM PRESSURE THE HYDRAULIC SYSTEM PRESSURE RELIEF VALVE PROTECTS THE SYSTEM FROM OVER PRESSURE. THE HYDRAULIC PUMP IS CAPABLE OF APPROXIMATELY 3500 P.S.I. IF CONDITIONS ARE RIGHT. THE COMPONENTS IN THE SYSTEM CAN NOT TAKE THAT PRESSURE ON A MORE THAN OCCASIONAL INSTANCE. THE RELIEF VALVE IS SET FOR 200– 300 POUNDS HIGHER THAN THE HIGHEST PRESSURE NEEDED TO OPERATE THE HIGHEST PRESSURE COMPONENT. THE WATER PUMP HYDRAULIC MOTOR IS THE ONLY COMPONENT IN THE SYSTEM THAT REQUIRES PRESSURE. THE PRESSURE REQUIRED TO PUMP WATER AT THE REQUIRED SPECIFICATIONS OF 45 P.S.I AND 20 GALLONS PER MINUTE IS APPROXIMATELY 600 P.S.I. THERE-FORE THE HYDRAULIC SYSTEM PRESSURE IS SET @ 900 POUNDS PER SQUARE INCH.


36

CHAPTER 2

SECTION 4 - ADJUSTMENTS

CONTINUED . CHECKING AND ADJUSTING HYDRAULIC SYSTEM PRESSURE RELIEF VALVE SETTING 1. REMOVE HYDRAULIC MOTOR PRESSURE LINE AT HYDRAULIC SYSTEM RELIEF VALVE (FIGURE #13). 2. INSTALL PRESSURE GAUGE. (FIGURE # 14). 3. START TRUCK AND ENERGIZE PUMP FOOT SWITCH BRIEFLY. CHECK PRESSURE GAUGE. IF PRESSURE IS OVER 1200 P.S.I., REMOVE TOP CAP OF RELIEF VALVE , LOOSEN STEM LOCKING NUT AND TURN STEM COUNTER CLOCKWISE 10 FULL TURNS. 4. ENERGIZE FOOT SWITCH AND HOLD WHILE CHECKING GAUGE. SCREW STEM CLOCKWISE TO INCREASE SYSTEM RELIEF PRESSURE OR COUNTER CLOCKWISE TO REDUCE PRESSURE. 5. WHEN PRESSURE IS SET AT 900 P.S.I. TIGHTEN LOCK NUT REPLACE TOP NUT AND REMOVE GAUGE.

HYDRAULIC SYSTEM TEST GAUGE

HYDRAULIC SYSTEM RELIEF VALVE LOCATED ON INBOARD SIDE OF HYDRAULIC RESERVOIR

FIGURE 13 FIGURE 14

HYDRAULIC MOTOR PRESSURE LINE


37

CHAPTER 2

SECTION 4 - ADJUSTMENTS

CONTINUED FLUID PUMPING SYSTEM THE FLUID PUMPING SYSTEM HAS (2) BASIC REQUIREMENTS: PRESSURE AND FLOW. COMMERCIAL AIRCRAFT HAVE A CHECK POPPET IN THE LAVATORY FILL THAT REQUIRES PRESSURE TO OVERCOME FOR FILLING. SOME COMMERCIAL AIRCRAFT ALSO HAVE CLOSED TANKS FOR THEIR LAVATORY FLUSH SYSTEMS. OVER PRESSURE CONDITIONS CAN DAMAGE THEM. THE FLUID PUMPING SYSTEM SETTINGS FOR THOSE FUNCTIONS IS 40-45 P.S.I. AND 20 GALLONS PER MINUTE OF FLOW. THERE IS A RELIEF VALVE ON THE OUTPUT OF THE FLUID PUMP AND A FLOW METER ON THE TOP DECK CHECKING AND ADJUSTING FLUID PUMPING SYSTEM PRESSURE 1. INSTALL A SHUTOFF VALVE AND A GAUGE ( 0 - 100 P.S.I. ) ON THE END OF THE FLUID HOSE.. (FIGURE # 15) 2 . PUT END OF HOSE INTO FILL OF TANK BEING PULLED FROM 3. START ENGINE; WITH SHUTOFF VALVE OPEN, PUMP 10 GALLONS OF FLUID INTO TANK. 4. PUMP FLUID AGAIN AND SLOWLY CLOSE SHUTOFF VALVE. 5. READ PRESSURE GAUGE. IF PRESSURE IS NOT 40—45 P.S.I. THEN ADJUST RELIEF VALVE BY LOOSENING LOCK NUT AND TURNING HANDLE WHILE CONTINUING TO OPERATE PUMP. WHEN PRESSURE IS SET TIGHTEN RELIEF VALVE LOCKING NUT 6. WHEN PRESSURE IS SET– OPEN SHUTOFF VALVE. RESET METER TO “0” AND PUMP FOR A TIMED MINUTE AND VERIFY THAT 20 GALLONS IS THE OUTPUT.

FIGURE 15

HOSE TO TANK

RELIEF VALVE LOCK NUT RELIEF VALVE HANDLE

FLUID HOSE

GAUGE

SHUTOFF VALVE


38

CHAPTER 2

SECTION 5 - TROUBLE SHOOTING GENERAL THIS SECTION CONTAINS TROUBLESHOOTING INFORMATION RELATIVE TO THE TRUCK MOUNTED SYSTEMS ONLY AND DOES NOT COVER AREAS DIRECTLY RELATED TO THE BASIC TRUCK CHASSIS OR CAB. TROUBLESHOOTING THE CHASSIS-CAB PROBLEMS IS ACCOMPLISHED IN ACCORDANCE WITH THE MANUFACTURER’S RECOMMENDATIONS. THE SUCCESS IN DIAGNOSING PROBLEMS ON THE SERVICE MODULE WILL DEPEND ON COMMON SENSE AND GOOD WORKING KNOWLEDGE OF 12 VDC, HYDRAULIC AND PLUMBING SYSTEMS. SINCE ALL THE FUNCTIONS ARE ELECTRO-HYDRAULIC ( I.E. ELECTRICALLY CONTROLLED AND HYDRAULICALLY POWERED) THE ELECTRICAL, HYDRAULIC AND PLUMBING SYSTEMS MAY REQUIRE CHECKING TO DETERMINE THE CAUSE OF THE PROBLEM. A. STRUCTURAL/ MECHANICAL STRUCTURAL COMPONENTS ON THE SERVICE MODULE INCLUDE: THE SERVICE MODULE STRUCTURE, SHEET METAL SIDES, DOORS, TANKS, TOP DECK, REAR BUMPER AND THE TANK DRAIN VALVE HANDLE. BY VISUALLY INSPECTING THE VEHICLE PRIOR TO USE THE OPERATOR SHOULD NOTICE IF STRUCTURAL DAMAGE IS PRESENT. DURING PREVENTATIVE MAINTENANCE CHECKS THE MODULE AND ALL THE ITEMS LISTED ABOVE SHOULD BE INSPECTED FOR DENTS, CRACKS AND EASE OF OPERATION. MOST STRUCTURAL DAMAGE OCCURS FROM IMPACT. IMPACT DAMAGE IS EASILY NOTICEABLE. DAMAGE CAUSED BY MECHANICAL BINDING OR FATIGUE IS GENERALLY LESS LIKELY TO BE NOTICED UNTIL A FAILURE HAS OCCURRED. IF STRUCTURAL DAMAGE IS PRESENT, FIRST TRY TO DETERMINE IF THE PROBLEM IS IMPACT OR OVERLOAD RELATED OR IF BINDING OR FATIGUE IS THE PROBLEM. REPAIR OR REPLACEMENT OF SHEET METAL PARTS MAY BE NECESSARY. STRUCTURAL DAMAGE CAN BE ACCOMPLISHED AFTER CONTACTING THE MANUFACTURER.

WARNING:

DO NOT WELD, CUT OR SPLICE ANY LOAD BEARING OR SUPPORT STRUCTURES PRIOR TO CONTACTING THE

ENGINEERING DEPARTMENT OF PHOENIX METAL PRODUCTS


39

CHAPTER 2

SECTION 5 - TROUBLE SHOOTING

CONTINUED B. HYDRAULIC THE HYDRAULIC SYSTEM OF THE LAVATORY SERVICE TRUCK IS FAIRLY SIMPLE. THE HYDRAULIC SYSTEM POWERS THE (2) PUMPING SYSTEMS AND PROVIDES THE POWER FOR THE PERSONNEL LIFT VERTICAL TRAVEL. THE HYDRAULIC SYSTEM HAS A RESERVOIR, PUMP, SELECTOR VALVES, AND MOTORS. THE HYDRAULIC PUMP IS IN IDLE MODE UNTIL CALLED UPON BY AN ELECTRIC SIGNAL TO THE HYDRAULIC PUMP CLUTCH.. THE VEHICLE MUST BE IN THE PARK POSITION FOR THE HYDRAULIC PUMP CLUTCH TO OPERATE. THE TRUCK ENGINE DRIVES THE HYDRAULIC PUMP. IF THE ENGINE IS NOT RUNNING THERE WILL BE NO HYDRAULIC POWER TO OPERATE ANY FUNCTIONS. SELECTOR VALVES MUST BE OPERATED FOR THE DIFFERENT MOTORS TO PERFORM THEIR FUNCTIONS AND A SELECTOR VALVE MUST BE OPERATED FOR VERTICAL TRAVEL OF THE LIFT. C. ELECTRICAL THE ELECTRICAL CIRCUIT GETS POWER FROM THE IGNITION SWITCH. ALL FUNCTIONS FOR SERVICING THE AIRCRAFT ARE POWERED BY THE VEHICLE IGNITION. THE COMPARTMENT LIGHTS ARE CONTROLLED BY THE VEHICLE LIGHTING SYSTEM. THE COMPARTMENT LIGHTS WILL NOT WORK IF THE TRUCK LIGHTS ARE NOT ON. D. PUMPING SYSTEM THE PUMPING SYSTEM IS DEPENDENT ON THE HYDRAULIC SYSTEM FOR POWER AND THE ELECTRICAL SYSTEM FOR SELECTING ONE OF THE (2) PUMPS. BOTH HYDRAULIC AND ELECTRICAL SYSTEMS MUST BE WORKING PROPERLY FOR THE PUMPING SYSTEM TO WORK. TROUBLESHOOTING GUIDES ARE COVERED IN (3) GENERAL CATEGORIES. ELECTRICAL, HYDRAULIC AND MECHANICAL. THE TROUBLESHOOTING GUIDE FOR THE PLUMBING CIRCUIT IS COMBINED IN ALL (3) CATEGORIES. REFER TO THE SCHEMATICS THAT CORRESPOND TO THE SYSTEM THAT IS BEING DIAGNOSED AND THE TROUBLESHOOTING TABLES FOR THOSE SYSTEMS. THE FOLLOWING TABLES WILL GIVE SPECIFIC PROBLEMS THAT MAY ARISE DURING THE NORMAL LIFE CYCLE OF THIS UNIT. TABLE # 2 LISTS THE POSSIBLE SYMPTOMS AND IS DIVIDED INTO THE SPECIFIC OPERATIONAL SYSTEMS (I.E. ELECTRICAL HYDRAULIC, AND MECHANICAL). NEXT TO EACH SYMPTOM IS A CODE. THE POSSIBLE CAUSES AND THE APPROPRIATE REMEDIES ARE FOUND ON TABLE # 3..


40

CHAPTER 2


TABLE # 2 - POSSIBLE SYMPTOMS

TROUBLE SYMPTOM

LIMITED OR NO HYDRAULIC POWER, AND/ OR ERRATIC LIFT FUNCTION OR PUMPING FUNC-TION

NOISY HYDRAULIC PUMP

HYDRAULIC FLUID MILKY OR DIS-COLORED

HYDRAULIC SYSTEM RUNNING HOT

SQUEALING FROM HYDRAULIC PUMP BELTS OR SMELL OF BURN-ING RUBBER

LIFT WILL NOT STABILIZE AND HOLD IN THE UP POSITION

FLUID PUMP DOES NOT PUMP FROM ONE TANK BUT DOES FROM THE OTHER

FLUID PUMP - PUMPS SLOWLY

FLUID TRANSFERS TO PLANE BUT DOES NOT REGISTER ON METER

ENGINE RUNNING/ NO LIFT OR PUMP FUNCTIONS

ELECTRICAL

E3, E15

E16

E2, E3, E4, E8

E1, E2, E3, E7, E9, E16

HYDRAULIC

H4, H6, H8, H9 H11, H15, E16

H4

H3, H5, H10

H1, H2, H4, H5, H6

H2, H7

H7, H13, H14, H15

H1, H2, H4, H6, H8, H11, H13, H16

H4, H6, H8, H9

MECHANICAL

M9

M9

M9

M12, M13

M9, M12, M13, M14, M15, M16, M17

M14

M9,


41

CHAPTER 2


TABLE # 2 - POSSIBLE SYMPTOMS

TROUBLE SYMPTOM

FLUID PUMP OPERATES/ NO OUT-PUT FROM HOSE END

FLUID WILL NOT DRAIN BACK FROM HOSE AFTER SERVICING AIRCRAFT

WASTE PUMP DOES NOT PULL FLUID FROM AIRCRAFT

WHEN WASTE TANK IS FULL/ WASTE DRAINS OUT OF WASTE HOSE

SPOT LIGHTS DO NOT WORK

HOT WATER HEATER DOES NOT WORK/ WORKS BUT NO WARM AIR

110 VOLT HEATER (S) DO NOT OPERATE

ELECTRICAL

E2, E3, E4, E8,

E2, E4, E5, E8

E2, E3, E4, E5, E12

E1, E2, E6, E17

E1, E2, E4, E18

HYDRAULIC

H11, H12, H13, H16

MECHANICAL

M12, M15, M16, M17

M18

M2, M3, M19

M19

M9, M11


42

CHAPTER 2


TABLE # 3 - PROBABLE CAUSE/ REMEDIES

ELECTRICAL

PROBABLE CAUSE

FUSE/ CIRCUIT BREAKER BLOWN

WIRING DISCONNECTED/ LOOSE

BAD GROUND CONNECTION

CONNECTOR DAMAGED OR LOOSE

SWITCH CONTACT NOT CLOSING

SWITCH CONTACTS SHORT CIRCUITED

RELAY/ SOLENOID COIL OPEN–CIRCUIT

SELECTOR VALVE SOLENOID COIL OPEN CIRCUITED

RELAY CONTACTS NOT CLOSING

RELAY CONTACTS WELDED SHORT

BULB DEFECTIVE

DIODE DEFECTIVE

EMERGENCY KILL SWITCH ON

LOW VOLTAGE

PUMP CLUTCH COIL NOT HOLDING

FAN MOTOR DEFECTIVE

THERMOSTAT IMPROPERLY ADJUSTED OR DEFECTIVE

HEATER ELEMENT DEFECTIVE

TEST/ REMEDY

CHECK FOR SHORT CIRCUIT. REPLACE FUSE

CHECK CONTINUITY FROM POINT TO POINT. CHECK FOR DAMAGED OR DISCONNECTED TER-MINALS

CHECK AND RE-GROUND

TIGHTEN CONNECTOR OR REPLACE

REPLACE SWITCH OR CONTACT

TEST. REPLACE CONTACT OR SWITCH

TEST. REPLACE RELAY

TEST. REPLACE COIL

TEST. REPLACE RELAY

TEST. REPLACE RELAY

REPLACE BULB

TEST. REPLACE DIODE

TURN TO RELEASE BOTH SWITCHES

CHECK VOLTAGE FROM ENGINE ALTERNATOR IF LESS THAN 12 VOLTS OR MORE THAN 15 VOLTS REPLACE ALTERNATOR

CHECK VOLTAGE. IF VOLTAGE IS GOOD REPLACE CLUTCH

REPLACE FAN MOTOR OR HEATER ASSEMBLY

CHECK CONNECTIONS ON IMMERSION HEATER– CHECK SETTING FOR APPROX. 50 DEGREES F.— REPLACE HEATER ASSEMBLY

REPLACE HEATER ELEMENT

CODE #

E1

E2

E3

E4

E5

E6

E7

E8

E9

E10

E12

E13

E14

E15

E16

E17

E18

E19


43

CHAPTER 2 SECTION 5 - TROUBLE SHOOTING

TABLE # 3 - PROBABLE CAUSE/ REMEDIES HYDRAULIC

PROBABLE CAUSE

HYDRAULIC HOSE BLOCKED OR PINCHED

RETURN FILTER CLOGGED

RESERVOIR CONTAMINATED

FLUID LEVEL LOW

WRONG TYPE HYDRAULIC FLUID OR CONTAMINATION

RELIEF VALVE NOT ADJUSTED

PILOT CHECK VALVE DEFECTIVE

PRESSURE REGULATOR SPRING DEFECTIVE

HYDRAULIC PUMP DEFECTIVE

HYDRAULIC PUMP SEAL LEAKING

HYDRAULIC MOTOR DEFECTIVE

HYDRAULIC MOTOR SHAFT KEY BROKEN

SELECTOR VALVE SPOOL STICKING

EMERGENCY DOWN VALVE LEAKING

EMERGENCY DOWN VALVE MANUAL OVERRIDE IS ENGAGED

FLOW CONTROL NOT ADJUSTED

TEST/ REMEDY

REMOVE AND INSPECT . REPLACE IF NECESSARY

REPLACE ELEMENT

OPEN RESERVOIR AND CHECK FOR CONTAMINA-TION. DRAIN AND CLEAN RESERVOIR WITH MIN-ERAL SPIRITS. FLUSH SYSTEM AND REFILL WITH NEW OIL

CHECK. FILL AS NECESSARY

OPEN RESERVOIR AND CHECK FOR CONTAMINA-TION. DRAIN AND CLEAN RESERVOIR WITH MIN-ERAL SPIRITS. FLUSH SYSTEM AND REFILL WITH NEW OIL

CHECK PRESSURE AND ADJUST

REPLACE VALVE

REMOVE AND INSPECT REPLACE SPRING OR RELIEF VALVE

REPLACE OR REPAIR PUMP

REPAIR

REPLACE OR REPAIR MOTOR

REMOVE HYDRAULIC MOTOR, CHECK SHAFT KEY REPLACE IF NECESSARY

REMOVE COIL, SPOOL AND CLEAN WITH MINERAL SPIRITS AND REPLACE

RAISE LIFT. ISOLATE VALVE BY REMOVING LINE TO MANIFOLD AT THE MANIFOLD PUT END OF HOSE IN SMALL CONTAINER AND CHECK FOR FLUID FLOW. IF FLUID CONTINUES TO DRAIN AND LIFT SLOWLY COMES DOWN REPLACE VALVE.

CHECK MANUAL OVERRIDE SCREW. UNSCREW UN-TIL FULLY RETRACTED

ADJUST FLOW CONTROL ON SELECTOR VALVE

CODE #

H1

H2

H3

H4

H5

H6

H7

H8

H9

H10

H11

H12

H13

H14

H15

H16


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CHAPTER 2


TABLE # 3 - PROBABLE CAUSE/ REMEDIES

MECHANICAL

PROBABLE CAUSE

HINGE OR LATCH BINDING

CONNECTING ROD BROKEN

DIAPHRAM LEAKING

STABILIZER TUBE OUT OF ADJUSTMENT

STABILIZER TUBES DENTED OR DAMAGED

DRAIN VALVE CLOGGED

DRAIN VALVE STEM BROKEN

HOSE REEL REWIND SPRING BROKEN

BELT SLIPPAGE

FAN BLADES BENT

LOW COOLANT SYSTEM FLUID

LOW FLUID IN TANK

OBSTRUCTION IN LINE

METER DEFECTIVE

WYE STRAINER CLOGGED

FLUID PRESSURE RELIEF VALVE

PRESSURE RELIEF VALVE SPRING BROKEN

DRAIN BACK HOSE OBSTRUCTED

WASTE PUMP FLAPPER VALVES OB-STRUCTED OR DEFECTIVE

TEST/ REMEDY

CHECK FOR ALIGNMENT/ ALIGN AND LUBRICATE. REPLACE IF NECESSARY

REMOVE COVER– OPERATE PUMP– INSPECT ROD REPLACE IF NECESSARY

REMOVE COVER– INSPECT DIAPHRAM—LOOK FOR FLUID ON TOP SIDE OF DIAPHRAM

RUN LIFT FULL UP/ DOWN—ADJUST STABILIZER BY LOOSENING BOTTOM BOLTS AND ALLOWING STABILIZER TO FIND CENTER WHILE OPERATING FULL UP/ FULL DOWN. TIGHTEN BOLTS

EXTEND LIFT CHECK FOR DISTORTION OR DINGS IN TUBES. REMOVE AND REPAIR AS NECESSARY

OPEN TANK INSPECTION DOOR INSPECT VALVE FOR DEBRIS REMOVE DEBRIS AS NECESSARY

INSPECT BALL VALVE STEM. REPLACE BALL VALVE IF NECESSARY

REPLACE SPRING HOUSING ASSEMBLY

CHECK TENSION OF HYDRAULIC PUMP BELTS. CHECK CONDITION OF BELTS. ADJUST TENSION OR REPLACE BELTS

INSPECT FAN BLADES FOR INTERFERENCE. REPAIR OR REPLACE BLADE OR FAN MOTOR

CHECK FOR LEAKS IN VEHICLE COOLANT SYSTEM. REPAIR LEAKS AND FILL SYSTEM

FILL TO REQUIRED LEVEL

REMOVE LINE AND CLEAR OBSTRUCTION

FLUSH METER WITH WARM FRESH WATER—REPLACE METER

REMOVE SCREEN AND FLUSH—RE-INSTALL

ADJUST

REPLACE

REMOVE OBSTRUCTION

REMOVE OBSTRUCTION OR REPLACE VALVES

CODE #

M1

M2

M3

M4

M5

M6

M7

M8

M9

M10

M11

M12

M13

M14

M15

M16

M17

M18

M19


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CHAPTER 2


SCHEMATICS


46

CHAPTER 2



47

CHAPTER 2


SCHEMATICS

OPTIONAL


48

CHAPTER 2


SCHEMATICS

HYDRAULIC

Item No.Airline

Use Part Number Nomenclature EFFUnits Per

Assy.

1 2062-20-16S ADAPTER 12 1SA16F-JA16 HOSE FITTING 13 2062-12-8S ADAPTER 34 2021-8-8S ADAPTER 15 2083-8-8S ADAPTER 16 2024-12-8S ADAPTER 17 2083-12-12S ADAPTER 1

RETURN FILTER

WATER PUMP MOTOR

SYSTEM PRESSURE RELIEF VALVE

HYDRAULIC PUMP


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CHAPTER 2

SECTION 6 - PREPARATION FOR SHIPMENT THIS SECTION WILL DESCRIBE THE NECESSARY PROCEDURE TO PREPARE THIS UNIT FOR SHIPMENT. 1. DRIVING UNIT A. REMOVE WASTE HOSE FROM ITS ATTACHMENT POINT. STORE THE HOSE IN THE CAB. NOTE: SEE SECTION 3 FOR INSTRUCTIONS FOR CLEANING WASTE HOSE B. REMOVE THE REAR FLAGS AND STORE THEM BEHIND THE SEAT IN THE CAB. C. MAKE SURE BOTH DRAIN VALVES ARE CLOSED. D. ALL SERVICING TANKS MUST BE EMPTY OF FLUID. E. CHECK ALL DRIVING FUNCTIONS AND OPERATING LIGHTS. 2. TRANSPORTATION BY TRUCK A. THE FUEL TANK OF THIS VEHICLE MUST HAVE NO MORE THAN 4 GALLONS OF FUEL IN THE TANK FOR TRANSPORT ON COMMERCIAL TRUCKING LINES. THE LEVEL GAUGE MUST READ 1/8 TANK OR LESS. DRAIN OR RUN THE VEHICLE TO ACHIEVE THE VOLUME NECESSARY TO TRANSPORT THIS VEHICLE. B. REMOVE WASTE HOSE FROM ITS ATTACHMENT POINT. STORE THE HOSE IN THE CAB. C. REMOVE THE REAR FLAGS AND STORE THEM BEHIND THE SEAT IN THE CAB. D. MAKE SURE BOTH DRAIN VALVES ARE CLOSED. E. ALL SERVICING TANKS MUST BE EMPTY OF FLUID. 3. TRANSPORTATION BY WATER A. THE FUEL TANK OF THIS VEHICLE MUST HAVE NO MORE THAN 2 GALLONS OF FUEL. THE LEVEL GAUGE MUST READ EMPTY. DRAIN OR RUN THE VEHICLE TO ACHIEVE THE VOLUME NECESSARY TO TRANSPORT THIS VEHICLE. B. REMOVE WASTE HOSE FROM ITS ATTACHMENT POINT. STORE THE HOSE IN THE CAB. C. REMOVE THE REAR FLAGS AND STORE THEM BEHIND THE SEAT IN THE CAB. D. MAKE SURE BOTH DRAIN VALVES ARE CLOSED. E. ALL SERVICING TANKS MUST BE EMPTY OF FLUID.


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CHAPTER 2

SECTION 7 - PREPARATION FOR STORAGE THIS SECTION WILL DESCRIBE THE NECESSARY PROCEDURE TO PREPARE THIS UNIT FOR STORAGE. 1. SERVICE MODULE A. DRAIN FLUID TANK AND RINSE WITH FRESH WATER. B. FILL TANK WITH FRESH WATER AND ADD (1/2) QUART OF BLEACH TO THE TANK. C. HOOK FLUID HOSE TO FILL COUPLING ON TANK AND RUN FLUID PUMP TO CYCLE FLUID THROUGH TANK (120 GALLONS). D. DRAIN WASTE AND FLUSH WITH FRESH WATER. E. CLOSE DRAIN AND PUMP CONTENTS OF FLUID TANK WITH BLEACH INTO THE WASTE TANK THROUGH THE INSPECTION HATCH. FILL THE TANK TO THE TOP WITH FRESH WATER AND LET THEM SOAK FOR (1) HOUR. F. DRAIN WASTE TANK AND FLUID TANKS. CLOSE ALL DRAIN VALVES. G. REMOVE WASTE HOSE FROM ITS ATTACHMENT POINT. SUFFICIENTLY RINSE THE INSIDE OF THE HOSE WITH A WARM SOAP SOLUTION FOLLOWED BY A SOLUTION OF 75 % WATER/ 25 % BLEACH. H. STORE THE HOSE IN THE WASTE TANK— HOSE CAN BE INSERTED THROUGH THE INSPECTION/ CLEAN OUT HATCH. I. REMOVE THE FLAGS FROM THE REAR BUMPER AND STORE IN THE CAB OF THE VEHICLE BEHIND THE SEATS. J. PLUG AND CAP THE WASTE HOSE CONNECTION AND THE WASTE TRAY STAND PIPE . 2. TRUCK A. THE FUEL TANK OF THIS VEHICLE MUST HAVE NO MORE THAN 2 GALLONS OF FUEL FOR STORAGE. THE LEVEL GAUGE MUST READ EMPTY. DRAIN OR RUN THE VEHICLE TO ACHIEVE THE VOLUME NECESSARY.


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CHAPTER 2

SECTION 8 - DISASSEMBLY, REPAIR, REASSEMBLY AND REPLACEMENT DISASSEMBLY THERE ARE (3) PRIMARY AREAS FOR DISASSEMBLY OF THE LAVATORY SERVICE MODULE. THE MODULE, WASTE AND FLUID TANKS AND HYDRAULIC AND PLUMBING COMPONENTS. MODULE REMOVAL THE MODULE IS A STRUCTURAL COMPONENT AND SHOULD NOT NEED TO BE REMOVED UNLESS THE CHASSIS IS BEING REPLACED. 1. TO REMOVE THE MODULE ALL ELECTRICAL WIRING, HYDRAULIC LINES TO CHASSIS AND HEATER LINES MUST BE DISCONNECTED AND CAPPED OR TAPED OFF. 2. REMOVE THE TIE DOWN NUTS AND PLATES ON BOTTOM OF CHASSIS RAIL (4) PLACES. 3. IF A FORK LIFT IS BEING USED RAISE THE REAR OF THE MODULE FROM THE REAR BUMPER APPROXIMATELY 12—18 INCHES AND PLACE TWO 4” X 4” X 12” LONG HARDWOOD BLOCKS BETWEEN THE EXTREME REAR OF THE CHASSIS RAIL AND THE BOTTOM OF THE MODULE. LOWER THE MODULE ONTO THE BLOCKS. 4. FROM THE SIDE OF THE UNIT POSITION THE LIFT CENTERED OVER THE REAR WHEEL. PLACE FORKS UNDER BOTH LONGITUDINAL SUPPORTS AND LIFT MODULE OFF OF CHASSIS. 5. RE-INSTALL BY REVERSING STEPS 1-4.


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CHAPTER 2

SECTION 8- DISASSEMBLY, REPAIR, REASSEMBLY AND REPLACEMENT REMOVAL OF FLUID TANKS 1. DRAIN TANK REMOVE THE FILL PORT, VENT, RAILS ON THE SIDES. REMOVE DRAIN VALVE FROM UNDERSIDE OF TANK. REMOVE FRONT SIDE PANEL AND DISCONNECT IMMERSION HEATER AND SUCTION HOSE. REMOVE IMMERSION HEATER. REMOVE TOP DECK AND TOP INSULATION. REMOVE TANK TIE DOWN 2. CONNECT LIFTING CHAIN TO BOTH LIFTING EYES ON TOP OF TANK. LIFT TANK OUT OF MODULE. 3. RE-INSTALL BY REVERSING STEPS 1-2.


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SECTION 8 - DISASSEMBLY, REPAIR, REASSEMBLY AND REPLACEMENT REMOVAL OF WASTE TANK 1. DRAIN TANK. REMOVE DRAIN VALVE FROM UNDERSIDE OF TANK. REMOVE CENTER TOP DECK. REMOVE INSULATION. FROM THE WASTE HOSE COMPARTMENT; DISCONNECT WASTE HOSE FROM WASTE PUMP AND REMOVE FITTINGS FROM TANK. FROM THE HYDRAULIC COMPARTMENT; REMOVE DRAIN BACK VALVE AND REMOVE FITTINGS FROM TANK. REMOVE (2) TIE DOWNS ON TOP OF TANK. 2. CONNECT CHAIN TO (2) LIFTING EYES ON TOP OF WASTE TANK AND LIFT OUT OF MODULE.

3. REASSEMBLE REVERSING STEPS 1-2.

LIFTING EYES

TIE DOWNS

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