FLUSH & FILL CART - MODEL: SFFC-70/2 - OPERATION & MAINTENANCE MANUAL - Stinar
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FLUSH & FILL CART O PE R AT I O N & M A I N T E N A N C E M A N UA L MODEL: SFFC-70/2 sales@stinar.com | P 651.454.5112 | F 651.454.5143 | www.stinar.com REV.10.2020
Effective pages SECTION PAGE DATE Title Page 1 January 2021 List of Effective Pages 2 January 2021 Contents 3-4 January 2021 Introduction 5-7 January 2021 SECTION 1 Introduction 8 January 2021 Section 1-1 9-15 January 2021 Section 1-2 16-25 January 2021 Section 1-3 26-27 January 2021 SECTION 2 Introduction 28 January 2021 Section 2-1 29-32 January 2021 Section 2-2 33-35 January 2021 Section 2-3 36 January 2021 SECTION 3 Introduction 37 January 2021 SECTION 4 Introduction 38 January 2021 Section 4-1 39 January 2021 Section 4-2 40 January 2021 Section 4-3 41-52 January 2021 Flush & Fill Cart SFFC-70/2 | 2
Table of Contents MANUAL OVERVIEW ������������������������������������������������������������������������������ 7 SECTION 1 | GENERAL INFORMATION & OPERATING PROCEDURES ������������������������������������������������������������������������������������������� 8 1.1 | Description �������������������������������������������������������������������������������� 11 1.1.1 | Equipment Systems and Components ��������������������������������������11 1.1.1.1 | Cart Chassis �������������������������������������������������������������������������������������� 11 1.1.1.2 Coolant System������������������������������������������������������������������������������������ 11 Figure 1.1.1 | Flush & Fill Cart Model SFFC-70/2��������������������������������������������13 Figure 1.1.1.2 | Coolant System (Fill Mode)����������������������������������������������������14 1.1.1.3 | Electric Motor������������������������������������������������������������������������������������15 1.1.1.4 | Electrical System������������������������������������������������������������������������������15 Figure 1.1.1.4 | Electrical System ��������������������������������������������������������������������17 1.2 | Operation ���������������������������������������������������������������������������������� 18 1.2.1 | Operating Controls and Indicators��������������������������������������������18 1.2.1.1 | Flush and Fill Cart System Controls and Indicators����������������������18 1.2.2 Pre-Operation Checks ��������������������������������������������������������������������18 1.2.3 | Operating Procedures������������������������������������������������������������������19 1.2.3.1 | Filling the Coolant Tank������������������������������������������������������������������19 1.2.3.2 | Draining the contaminated coolant from the aircraft��������������19 Figure 1.2.3 | Coolant Tank operation������������������������������������������������������������20 Figure 1.2.3.2 | Handle Position����������������������������������������������������������������������21 1.2.3.3 | Flushing the system (Figure 1.2.3.3 A) ����������������������������������������� 22 1.2.3.4 Filling the Aircraft with Coolant (figure 1.2.3.3)����������������������������� 22 Figure 1.2.3.3 A | Flush and Fill Mode������������������������������������������������������������23 Figure 1.2.3.3 B | Valve Position����������������������������������������������������������������������24 Figure 1.2.3.4 | Valve Position��������������������������������������������������������������������������25 1.2.3.5 | Deaerate (figure 1.2.3.5 A)������������������������������������������������������������26 1.2.3.6 | Pumping out Waste tank (figure 1.2.3.6)��������������������������������������26 1.2.3.7 | Towing the Flush and Fill Cart��������������������������������������������������������26 Figure 1.2.3.5 A | Deaerate Mode��������������������������������������������������������������������27 Figure 1.2.3.5 B | Valve Position����������������������������������������������������������������������28 Figure 1.2.3.6 A | Pumping out of the Waste tank ��������������������������������������29 Figure 1.2.3.6 B | Valve Position����������������������������������������������������������������������30 1.2.3.7 Storing the Flush and Fill Cart������������������������������������������������������������31 1.3 | Specifications and Capabilities �������������������������������������������� 32 1.3.1 | General Specifications����������������������������������������������������������������������32 1.3.2 | Electric Motor��������������������������������������������������������������������������������������32 1.3.3 | Coolant System ����������������������������������������������������������������������������������32 SECTION 2 | SERVICING THE FLUSH AND FILL CART���������������������� 34 2.1 | Servicing������������������������������������������������������������������������������������� 35 2.1.1 | Cart Chassis������������������������������������������������������������������������������������35 2.1.1.1 | Brake Adjustment ��������������������������������������������������������������������������� 35 2.1.1.1 | Wheels and Tires ����������������������������������������������������������������������������� 35 2.1.1.1 | Sheet, Bar and Tubular Member (Non-Load Bearing)��������������� 35 Flush & Fill Cart SFFC-70/2 | 3
2.1.2 | Coolant System������������������������������������������������������������������������������35 2.1.2.1 | Coolant Tank����������������������������������������������������������������������������������� 35 2.1.2.2 | Strainer��������������������������������������������������������������������������������������������� 35 2.1.2.3 | Filter��������������������������������������������������������������������������������������������������� 35 Figure 2.1.2.1 | Coolant Tank Drain ����������������������������������������������������������������36 2.1.2.4 | Pump ������������������������������������������������������������������������������������������������37 2.1.2.5 | Plumbing ������������������������������������������������������������������������������������������37 2.1.3 | Motor������������������������������������������������������������������������������������������������37 2.1.3.1 | Belt Drive, motor to pump��������������������������������������������������������������37 2.1.3.2 | Motor Servicing��������������������������������������������������������������������������������37 2.1.4 | Electrical System����������������������������������������������������������������������������37 2.1.4.1 | Electric Cables and Wiring������������������������������������������������������������37 2.1.5 | Scheduled Service��������������������������������������������������������������������������37 2.1.6 | Non-scheduled Service ����������������������������������������������������������������38 2.1.7 | Lubrication��������������������������������������������������������������������������������������38 2.1.7.1 | Flush and Fill Cart���������������������������������������������������������������������������� 38 2.2 | Troubleshooting����������������������������������������������������������������������� 39 2.2.1 | Troubleshooting Table������������������������������������������������������������������39 Figure ### | TITLE����������������������������������������������������������������������������������������������41 2.3 | Adjustments ����������������������������������������������������������������������������� 42 2.3.1 | Brake Adjustments������������������������������������������������������������������������42 SECTION 3 | OVERHAUL���������������������������������������������������������������������� 43 SECTION 4 | PARTS LIST ���������������������������������������������������������������������� 44 4.1 | Manufacturer Identification ���������������������������������������������������� 45 4.2 | Detailed Parts List������������������������������������������������������������������� 46 4.2.1 | Understanding the Columns ������������������������������������������������������46 4.2.1.1 | Figure/Item No.������������������������������������������������������������������������������� 46 4.2.1.2 | Manufacturer’s Part No. ��������������������������������������������������������������� 46 4.2.1.3 | Description��������������������������������������������������������������������������������������� 46 4.2.1.4 | Vendor Code ��������������������������������������������������������������������������������� 46 4.2.1.5 | QTY��������������������������������������������������������������������������������������������������� 46 4.2.2 | Instructions for Ordering Parts and Assemblies��������������������46 PARTS ORDER FORM ���������������������������������������������������������������������������� 47 Figure 4.3.1 | Flush and Fill Cart Model SFFC-70/2 ��������������������������������������48 Figure 4.3.1 | Flush and Fill Cart Model SFFC-70/2 - Table��������������������������49 Figure 4.3.3 | Wheel Hub Assembly����������������������������������������������������������������50 Figure 4.3.3 | Wheel Hub Assembly - Table ��������������������������������������������������51 Figure 4.3.4 | Coolant System��������������������������������������������������������������������������52 Figure 4.3.4 | Coolant System - Table ������������������������������������������������������������53 Figure 4.3.8 | Electrical System ����������������������������������������������������������������������55 Figure 4.3.8 | Electrical - Table������������������������������������������������������������������������56 Flush & Fill Cart SFFC-70/2 | 4
MANUAL OVERVIEW This publication provides operating and maintenance instructions, including detailed parts lists for the Flush and Fill Cart model number SFFC-70/2. This cart was manufactured by: Stinar, LLC 10061 State Hwy. 30 Blooming Prairie, MN 55917 Section 1 | General Information & Operating Instructions Includes a unit description, recommended procedures for operation, plus specifications and capabilities. Section 2 | Servicing The Flush & Fill Cart Provides unit maintenance information, service and lubrication data and a troubleshooting guide. Section 3 | Maintenance Presents instructions for component overhaul and repair. Section 4 | Parts List Contains a manufacturers list and illustrated parts lists for the assemblies, sub-assemblies and systems within the unit. Flush & Fill Cart SFFC-70/2 | 5
SECTION 1 | GENERAL INFORMATION & OPERATING PROCEDURES SAFETY ALERT SYMBOL – Look for this symbol to point out important safety precautions. DANGER: The word “DANGER” denotes a most serious specific potential DANGER! hazard. A forbidden practice should definitely be avoided in connection Example with a serious hazard. WARNING: The word “WARNING” is used to denote a specific potential or WARNING! hidden hazard which, if not avoided, has the potential for serious injury. Example CAUTION: The word “CAUTION” is used to denote a general reminder of CAUTION! good safety practices or to direct attention to unsafe practices. Following Example safe behavioral practices consistent with operating and maintenance instructions will help the operator and others avoid accident involvement. NOTE: The word “NOTE” is used to denote something that can cause minor NOTE: machine damage or poor performance if ignored. Example IMPORTANT: The word “IMPORTANT” informs the reader of something they need to know to prevent minor machine damage if a certain procedure is not followed. General Safety • Do not rush • Do not alter your machine • Read and follow all warning labels. Replace any labels that are missing or illegible • Check all controls and operating functions of the machine in a safe area before starting work • Never allow unauthorized persons around machinery when performing operation functions • A Fire Extinguisher and First Aid kit should be carried in the truck at all times • Comply with airline and Facility Regulations when approaching aircraft and parking Flush & Fill Cart SFFC-70/2 | 6
SECTION 1 | GENERAL INFORMATION & OPERATING PROCEDURES Before Operation 1. Perform a general all-around visual inspection and equipment check of the entire unit 2. Perform any checks required by Airport or Airline Regulations. 3. Check all markings and nameplates for legibility Always determine hydraulic oil level and fill tank to proper level with all hydraulic cylinders fully-retracted. Overfilling may occur if cylinders are not retracted which may damage the system During Operation The procedures outlined in this Manual are suggested general operating procedures. For specific aircraft servicing, follow procedures specified by your airline. After Operation Always unhitch unit on level ground. Block wheels and set brakes before unhitching. Service Safety • Do not clean, adjust or service this unit while it is in motion • Periodically check tightness of nuts and bolts and check for loose, worn or misaligned parts. Use only approved replacement parts. • Any new components installed during repair must include the current safety signs specified by Stinar Corp. • Disconnect power to electrical components before servicing or replacing them • Perform all work in accordance with authorized standard shop practices • To avoid possible injury, be sure tire is deflated before removing tire from rim • Perform no welding, cutting, patching and such on any load bearing or supporting structure. If such repairs are necessary, contact the Engineering Department of Stinar Corporation before making any alterations. • Should there be a hydraulic system associated with this unit, always determine hydraulic oil level and fill tank to the proper level with all hydraulic-actuating cylinders fully-retracted. Otherwise, damage may occur to the tank when the system is operated. • Do not mix hydraulic oils of different specifications. Oils may not be compatible, which may cause damage to the hydraulic system components. Flush & Fill Cart SFFC-70/2 | 7
SECTION 1 | GENERAL INFORMATION & OPERATING PROCEDURES Your safety and the safety of those around you depend upon the operator using care and good judgment in the operation of this unit. Know the positions and functions of all controls before attempting to operate. All equipment has limitations. Understand the speed, braking, steering, stability and load characteristics of the unit before starting operation. READ YOUR OPERATOR’S MANUAL! Flush & Fill Cart SFFC-70/2 | 8
SECTION 1 | GENERAL INFORMATION & OPERATING PROCEDURES 1.1 | DESCRIPTION The Stinar Flush and Fill Cart, Model SFFC-70/2 is a towable service unit designed for draining contaminated air vehicle coolant for storage in the cart and eventual disposal. Heated, filtered and deaerated clean coolant is then pumped from the service cart into the air vehicle in three modes. There is a flush mode that eliminates residual contaminated coolant. There is a fill mode that supplies the aircraft with fresh coolant. The deaerate feature removes all the gases in the system from the coolant. The flush and fill cart consists of a coolant tank, waste tank and coolant-dispensing system mounted on a two-axle trailer. The coolant dispensing system consists of a electric motor-driven diaphragm pump that supplies coolant through a fill hose. A bleed hose is also used on the cart. 1.1.1 | Equipment Systems and Components The major operating systems and components of the flush and fill cart are described in the paragraphs below. See Figure 1.1.1 for locations. 1.1.1.1 | Cart Chassis The flush and fill cart chassis provides a mobile platform for the coolant tank, coolant-dispensing system and electrical system components. The chassis consists of a rectangular steel frame with a fixed rear axle and a pivoting front axle assembly. The front axle assembly includes a tow bar and front wheel brakes engaged by raising and locking the tow bar in an upright position. The cart is equipped with four 4:80 x 4:00 x 8 tires. 1.1.1.2 | Coolant System The coolant-dispensing system is used to pump contaminated coolant from the aircraft. See Figure 1.1.1.2 for coolant system schematic. The fol- lowing paragraphs describe the major system components: Coolant Tank The coolant tank is bolted to the cart frame. The tank is constructed from type 304 stainless steel. Internal safety baffles prevent sloshing and dis- tribute load forces. The coolant tank has the following features: COMPONENT DESCRIPTION The tank vent is located on top of the tank. Vent This vent pipe is covered with a mushroom- type breather/vent cap. Valve beneath the cart allows the tank to be Drain Valve drained. Fill connection for the coolant tank is 2 inches Fill Connection in diameter and provided on the top of the fresh coolant tank. Flush & Fill Cart SFFC-70/2 | 9
SECTION 1 | GENERAL INFORMATION & OPERATING PROCEDURES COMPONENT DESCRIPTION The gauges are located on the left side of the fresh tank and the right side of the waste tank. Level Gauges They indicate the level of liquid in each of the tanks. Flush & Fill Cart SFFC-70/2 | 10
FIGURE 1.1.1 | FLUSH & FILL CART MODEL SFFC-70/2 Pump Waste Tank Motor Clean Tank Control Box Filter Coolant Fill Port Main Valve Bank Return Hose Supply Hose Tow Bar Ground Cable Bleed Hose Flush & Fill Cart SFFC-70/2 | 11
FIGURE 1.1.1.2 | COOLANT SYSTEM (FILL MODE) Flush & Fill Cart SFFC-70/2 | 12
SECTION 1 | GENERAL INFORMATION & OPERATING PROCEDURES The following coolant system components are located on the Flush and Fill Cart. COMPONENT DESCRIPTION This gate valve is located at the tank outlet into the pump suction line. When closed, this Tank Shutoff Valves valve allows service to be performed on the system without draining the tank. (V6 & V7) This gate valve is located underneath the tank Tank Drain Valves to allow coolant to be drained from the tank. The filter between the supply hose and the pump filters impurities from the coolant Filter leaving the pump. This filter is a 5-micron absolute filter and has a removable element. The strainer prevents particles from entering Y Strainer the pump. The strainer is located just after the tank shutoff valve. The pump delivers coolant from the coolant tank to the aircraft. This diaphragm pump is Pump belt-driven by the motor and runs whenever the motor is running. The meter measures, in gallons, the amount of coolant pumped to the aircraft. The meter Meter is directly above the main valves. It may be reset to zero using a knob on the meter housing. The sight glass allows the operator to visually Sight Glass see that coolant is moving through the service hoses and into the waste tank. Two check valves are installed in the system. They are located before valve 4 to ensure Check Valves that coolant does not flow back through the strainers and into the tanks. Refer to the coolant schematic (Fig. 1.1.1.2) 1.1.1.3 | Electric Motor The motor is mounted parallel to the pump in the center of the cart. The drive shaft of the motor drives through a belt to the diaphragm pump. Op- erating controls for the motor are located on the control panel. 1.1.1.4 | Electrical System The electrical system for the cart is a 480 volt three phase AC system. Electrical Components The primary electrical components are described below: Flush & Fill Cart SFFC-70/2 | 13
SECTION 1 | GENERAL INFORMATION & OPERATING PROCEDURES COMPONENT DESCRIPTION 10 Horsepower AC Electric Motor Electric Motor 1760 RPM - 3Phase Heater-440V-3Ph-60Hertz-12000W Heater W/60/250DegF Intregal Adjustable Thermostat Flush & Fill Cart SFFC-70/2 | 14
FIGURE 1.1.1.4 | ELECTRICAL SYSTEM THERMOSTAT Flush & Fill Cart SFFC-70/2 | 15
SECTION 1 | GENERAL INFORMATION & OPERATING PROCEDURES 1.2 | OPERATION Prior to operating the Stinar Flush and Fill Cart SFFC-70/2, all operators and maintenance personnel should become thoroughly familiar with the instructions given in this Manual. No instructions are given for positioning the cart, as airline policy should be followed. 1.2.1 | Operating Controls and Indicators 1.2.1.1 | Flush and Fill Cart System Controls and NOTE: The pump operates whenever Indicators the motor is running. COMPONENT DESCRIPTION See motor controls, pre-starting checks and Electric Motor operating instructions for the motor. This push button ON/START switch for the START Button motor is located on the control box. This push button OFF/STOP switch for the STOP Button motor is located on the control box. This ON/OFF switch for the heater is located Heater Control on the control box. A ball valve is installed on the aircraft end of the supply hose. Closing this valve prevents Shutoff Valve, Hose water in the hose from spilling after the hose is disconnected from the aircraft. The meter is located directly above the main Meter valves. It measures, in gallons, the amount of coolant dispensed to the aircraft. This float gauge on the left side of the fresh tank Tank Level Gauge and the right side of the waste tank indicates the amount of coolant present in the tank. This gate valve is located at the bottom of the tank in the pump suction line on both Tank Shutoff Valve fresh and waste tanks. It must be open when pumping coolant and should be closed only during maintenance. 1.2.2 Pre-Operation Checks The following checks should be performed at the beginning of each day or shift: 1. Make sure brakes operate properly. 2. Check hoses for cracks and wear. 3. Check the tank level gauge to make sure there is ample coolant in the tank. Make sure the tank vent is not plugged before filling tank. 4 . Check condition of the tires and wheels. Flush & Fill Cart SFFC-70/2 | 16
FIGURE 1.2.3 | COOLANT TANK OPERATION Pump Waste Tank Motor Clean Tank Heater Pump ON/OFF Coolant Fill Port ON/OFF Filter Electric Cable Main Valve Bank Return Hose Supply Hose Tow Bar Ground Cable Bleed Hose Flush & Fill Cart SFFC-70/2 | 17
SECTION 1 | GENERAL INFORMATION & OPERATING PROCEDURES WARNING! 1.2.3 | Operating Procedures ALWAYS HAVE THE PUMP SHUT OFF WHEN CHANGING 1.2.3.1 | Filling the Coolant Tank PROCEDURES AND VALVE The fill coupling for the fresh coolant tank is located on top of the tank. To POSITIONS. fill tank: 1. Flip up hatch on two-inch fill port. 2. Also fill coolant until the tank is full. 1.2.3.2 | Draining the contaminated coolant from the NOTE: Comply with Airline Operating aircraft and Service Manuals for ap- 1. Position the flush and fill cart near the aircraft’s service panel. proaching aircraft and parking. 2. Set tow vehicle brakes. If cart is disconnected from tow vehicle, set cart brakes by manually raising and latching tow bar in upright position. 3. See figure 1.2.3 for the location of the return hose. CAUTION! Do not kink, bend sharply, mash or otherwise deform the supply and return hoses. 4. Ensure that V1, V2, V3, V4 and V5 are positioned so that the handle is pointed towards the side of the cart (handles can only be positioned towards the side or the rear). 5. Open the aircraft service panel. Connect the quick-release coupling on the water fill hose to the aircraft inlet. 6. Drain the liquid from the air vehicle per applicable aircraft technical order. 7. Tow the servicing unit to an approved waste disposal facility and drain the contaminated coolant through the drain valve. (V-9) Flush & Fill Cart SFFC-70/2 | 18
FIGURE 1.2.3.3 | FLUSH AND FILL MODE Flush & Fill Cart SFFC-70/2 | 19
SECTION 1 | GENERAL INFORMATION & OPERATING PROCEDURES 1.2.3.3 | Flushing the System (Figure 1.2.3.3) WARNING! ENSURE NO POWER IS APPLIED 1. Position the flush and fill cart near the aircraft’s service panel and set TO THE POWER CABLE WHEN the carts brakes. DISCONNECTING FROM THE 2. See figure 1.2.3 for the location of hoses, grounding cable and SERVICE CART. power cable. 3. Connect the power cable to 480-volts, 3-phase, 60 Hz power source. 4. Connect the supply hose, return hose and bleed hose to the air vehicle. 5. Position valves V1, V2, V3 and V5 with the handles pointed towards the side of the cart. 6. Set the heater switch to ON. 7. Allow the coolant temperature in the supply tank to stabilize at 90 degrees Fahrenheit. (Refer to the supply temperature gauge, figure 1.2.3) 8. Push the Pump ON button. 9. Flush the cooling system per applicable aircraft technical order. 10. When flushing is complete, push the Pump OFF button. 11. Set the Heater switch to OFF. 12. Disconnect the supply hose, the return hose and the bleed hose from the aircraft. WARNING! ENSURE NO POWER IS APPLIED 1.2.3.4 Filling the Aircraft with Coolant (figure 1.2.3.3) TO THE POWER CABLE WHEN 1. Position the flush and fill cart near the aircraft’s service panel and set CONNECTING TO THE SERVICE the carts brakes. CART. 2. See figure 1.2.3 for the location of hoses, grounding cable and power cable. Flush & Fill Cart SFFC-70/2 | 20
FIGURE 1.2.3.5 | DEAERATE MODE Flush & Fill Cart SFFC-70/2 | 21
SECTION 1 | GENERAL INFORMATION & OPERATING PROCEDURES 3. Connect the power cable to 480-volts, 3-phase, 60 Hz power source. CAUTION! 4. Connect the supply hose, return hose and bleed hose to the air vehicle. Do not kink, bend sharply, mash 5. Set the Heater switch to ON. or otherwise deform the supply and return hoses. 6. Allow the coolant temperature in the supply tank to stabilize at 90 degrees Fahrenheit. (refer to the supply temperature gauge, figure 1.2.3) 7. Set valves V1, V2, V3, V4 and V5 so that the handles point toward the side of the cart. 8. Push the Pump On button to start. 9. Fill the liquid-cooling system per applicable aircraft technical order. 10. When fill operation is complete, push the Pump OFF button. 11. Set the Heater switch to OFF. 12. Disconnect the supply hose, the return hose and the bleed hose from the aircraft. 13. Tow the flush and fill cart to an approved waste disposal facility to drain the contaminated reservoir through drain valve v-9 located at the bottom of the waste tank. 1.2.3.5 | Deaerate (figure 1.2.3.5) 1. Position the flush and fill cart near the aircraft’s service panel and set the carts brakes. 2. See figure 1.2.3 for the location of hoses, grounding cable and power cable. 3. Connect the power cable to 480-volts, 3-phase, 60 Hz power source. 4. Connect the supply hose, return hose and bleed hose to the air vehicle. Flush & Fill Cart SFFC-70/2 | 22
FIGURE 1.2.3.6 | PUMPING OUT OF THE WASTE TANK Flush & Fill Cart SFFC-70/2 | 23
SECTION 1 | GENERAL INFORMATION & OPERATING PROCEDURES 5. Set the Heater switch to ON. WARNING! 6. Allow the coolant temperature in the supply tank to stabilize at 90 ENSURE THAT NO POWER IS degrees Fahrenheit. (refer to the supply temperature gauge, figure APPLIED TO THE POWER CABLE WHEN CONNECTING TO THE SERVICE CART. CAUTION! Do not kink, bend sharply, mash or otherwise deform the supply and return hoses. 1.2.3) 7. Position valves V1, V2, V3 and V5 so that the handles are pointed towards the side of the cart. 8. Position valve V4 so that the handle is pointed toward the rear of the cart. WARNING! 9. Push the Pump button to ON. ENSURE THAT NO POWER IS APPLIED TO THE POWER CABLE 10. Deaerate the liquid cooling in conjunction with the fill procedures in WHEN CONNECTING TO THE applicable aircraft technical order. SERVICE CART. 11. When deaerate operation is complete, push the Pump OFF 12. Set the Heater switch to OFF 13. Disconnect the supply hose, the return hose and the bleed hose from the aircraft. WARNING! ENSURE NO POWER IS APPLIED 1.2.3.6 | Pumping out Waste Tank (figure 1.2.3.6) TO THE POWER CABLE WHEN 1. Position the flush and fill cart near a waste disposal facility and set DISCONNECTING FROM THE the carts brakes. SERVICE CART. 2. See figure 1.2.3 for the location of hoses, grounding cable and power cable. 3. Connect the power cable to 480-volts, 3-phase, 60 Hz power source. CAUTION! Do not kink, bend sharply, mash or otherwise deform the supply and return hoses. Flush & Fill Cart SFFC-70/2 | 24
SECTION 1 | GENERAL INFORMATION & OPERATING PROCEDURES 4. Set valves V1, V3 and V5 so that the handles point toward the rear of the cart. 5. Set valves V2, V4 so that the handle points toward the side of the cart. 6. Push the Pump On button to start. 7. When drain operation is complete, push the pump OFF button. 1.2.3.7 | Towing the Flush and Fill Cart The flush and fill cart is intended for use on paved airport service roads and service areas. Do not tow or park the cart on soft or unstable ground where it might get bogged down or topple over. 1. Connect tow bar to tow vehicle 2. Tow unit to vicinity of aircraft. Do not exceed a towing speed of 10 MPH (16 km/hr), especially when cornering with carts in tow. 1.2.3.8 Storing the Flush and Fill Cart If the cart will be stored in an unheated area, prepare the cart for storage as follows: 1. Drain all coolant from tank and hoses. Flush & Fill Cart SFFC-70/2 | 25
SECTION 1 | GENERAL INFORMATION & OPERATING PROCEDURES 1.3 | SPECIFICATIONS 1.3.1 | General Specifications AND CAPABILITIES OVERALL DIMENSIONS Overall Length Tow bar Up 114 in. (2896 mm) Tow bar Down 116 in. (3987 mm) Overall Width 48 in. (1219 mm) Overall Height 47 in. (1194 mm) Rear Bumper Height 22.5 in (572 mm) Ground Clearance 4 in (102 mm) Wheelbase 73 in. (1854 mm) Wheel Track 42 in. (1067 mm) Tires (4) 4:80 x 4:00 x 8 pneumatic, 4 ply Brakes Front wheel, tow bar operated 1.3.2 | Electric Motor Manufacturer Stinar Model 426003 Type 220/460 AC Service Factor 1.15 Efficiency 89.5% Frame 215T Horsepower, Maximum 10 Hp @ 1800 RPM 1.3.3 | Coolant System COOLANT TANK Material Type 304 stainless steel Capacity 70 U.S. gal (266 liter) Vent 3/4 in (19 mm) Fill Connection 2 in (25.4 mm) PUMP (DRIVEN BY ELECTRIC MOTOR) Manufacturer UDOR U.S.A., Inc. Model RO-106 Type Diaphragm Maximum Pressure 300 PSI Maximum Flow 26 GPM Maximum RPM 540 RPM Flush & Fill Cart SFFC-70/2 | 26
SECTION 1 | GENERAL INFORMATION & OPERATING PROCEDURES CLEAN AND CONTAMINATED COOLANT HOSE Length 50 ft (15.24 m) Inside Diameter ¾ in (19 mm) BLEED HOSE Length 75 ft (22.8 m) Inside Diameter 3/8” (9.525 mm) Flush & Fill Cart SFFC-70/2 | 27
SECTION 2 | SERVICING THE FLUSH AND FILL CART This section contains servicing and lubrication information for the Stinar NOTE: Flush and Fill Cart, Model SFFC-70/2. The instructions in this section are Perform all work in recommended by the manufacturer and are intended to assist service accordance with authorized personnel in developing their own service schedules based on their standard shop practices. specific environment. No special tools are required, other than those found in a modern automotive garage or airline service facility for ground support equipment. Flush & Fill Cart SFFC-70/2 | 28
SECTION 2 | SERVICING THE FLUSH AND FILL CART 2.1 | SERVICING 2.1.1 | Cart Chassis 2.1.1.1 | Brake Adjustment Check operation of brake mechanism before each use. Adjust brake linkage if needed. See Adjustment section of this chapter for procedure. WARNING! Perform no welding, cutting, 2.1.1.2 | Wheels and Tires patching and such on any load • Check tires for condition before each use. bearing or supporting structure. If such repairs are necessary, • Repair tires as required. contact the Engineering de- • Check operation of brake mechanism before each use. Adjust brake partment of Stinar Corporation linkage if required. before making any alterations. 2.1.1.3 | Sheet, Bar and Tubular Member (Non-Load Bearing) • Repair cracks or metal fatigue failures by stop-drilling, welding, patching or splicing. • Prime and paint marred, rusted or damaged finish using a high CAUTION! grade primer and finish paint materials. Do not attempt any welding • Clean areas that are extremely oily or greasy with mineral solvents on tank unless top access and degreasers before painting. cover is removed. 2.1.2 | Coolant System 2.1.2.1 | Coolant Tank • The coolant tank may be drained by opening the valve at the bottom of the tank (V8 fig. 2.1.2). To drain contaminated reservoir, open valve at the bottom of contaminated reservoir (V8). Drain contaminated coolant only at an approved waste disposal facility. • The tank is constructed of type 304 stainless steel. If welding is necessary, use only type 308 rod or wire. • The coolant tank interior and coolant system may be cleaned with a mild detergent. Flush thoroughly after repairs and cleaning. 2.1.2.2 | Strainer A strainer is located in the line running from the coolant tank to the pump on both tanks. A gate valve adjacent to the strainer allows service to be performed on the strainer without draining the coolant tank. Clean strainer screen every 100 hours. 2.1.2.3 | Filter A filter is located between the flow meter and the supply hose. Replace the filter element according to the filter condition indicator. When the green indicator turns red, it is time to replace the filter element. Flush & Fill Cart SFFC-70/2 | 29
FIGURE 2.1.2.1 | COOLANT TANK DRAIN V8 Flush & Fill Cart SFFC-70/2 | 30
SECTION 2 | SERVICING THE FLUSH AND FILL CART 2.1.2.4 | Pump The pump requires no lubrication or regular servicing. Check coupling to motor periodically or if a vibration is noticed. 2.1.2.5 | Plumbing Check tank, hose, valves and fittings for leaks and proper function daily. Tighten any loose connections. Replace hoses if cracked, cut or worn. 2.1.3 | Motor 2.1.3.1 | Belt Drive, Motor to Pump Check the belt drive to the pump every 100 hours. 2.1.3.2 | Motor Servicing See motor manual for full maintenance schedule, procedures and illustrations. Following is a very basic servicing guide. 2.1.4 | Electrical System 2.1.4.1 | Electric Cables and Wiring Ensure that all cables and wiring are securely attached. Inspect wiring for damage on a regular basis. Check for damaged insulation and connectors and check for loose connections at terminals. 2.1.5 | Scheduled Service Scheduled service consists of preventive maintenance procedures, which will assure long and dependable operation of the unit if they are performed on a regular schedule. Perform scheduled service in accordance with the guidelines below: SERVICE INTERVAL METHOD PROCEDURE Service motor Various See engine manual. Check wiring for 50 hours Visual inspection. corrosion Check motor to pump 100 hours Visual inspection. belt drive Check coolant system hoses, components and fittings for 50 hours Visual inspection. looseness or leaks. Tighten or replace as needed Flush & Fill Cart SFFC-70/2 | 31
SECTION 2 | SERVICING THE FLUSH AND FILL CART SERVICE INTERVAL METHOD PROCEDURE Close the tank shut-off Remove and clean 100 hours valve and unscrew the strainer strainer element. See lubrication Lubrication paragraph (at end of See lubrication paragraph. this section) Unscrew the filter When Green Replace filter element when pump is indicator turns red off. 2.1.6 | Non-scheduled Service Non-scheduled service consists of adjustments and maintenance operations, which are not required at regular intervals, but are performed as required. The table below lists common non-scheduled service needs. SERVICE PROCEDURE PERFORM WHEN Tighten or replace leaking fittings. Leaks are evident. Replace cracked, cut or Inspection reveals hoses are deteriorated hoses. deteriorated or leaks are evident. 2.1.7 | Lubrication 2.1.7.1 | Flush and Fill Cart Grease fittings on the Flush and Fill Cart should be lubricated monthly using an automotive-grade lithium grease. See the following table for locations of fittings: SERVICE PROCEDURE INTERVAL METHOD Axle Swivel Shaft (1 fitting) Monthly Lithium grease Wheel bearings (4) Yearly Lithium grease Tow bar Monthly Light oil Brake Bar Pivots Monthly Light oil Tow Bar Latch Monthly Light oil Flush & Fill Cart SFFC-70/2 | 32
SECTION 2 | SERVICING THE FLUSH AND FILL CART 2.2 | This section includes troubleshooting information for the Stinar installed systems of the SFFC-70/2. For troubleshooting motor problems, refer to TROUBLESHOOTING the motor manual The troubleshooting information that follows provides trouble analysis for possible malfunctions. Included are possible problems, probable causes and suggested remedies for problems that may occur. Refer to the coolant system schematic (Figure 2.2) for assistance with troubleshooting this system. The troubleshooting data provided for the electrical system presupposes that common circuitry checks will be made and that no open leads or loose connections exist. 2.2.1 | Troubleshooting Table TROUBLE PROBABLE CAUSE REMEDY Cart Chassis Tow bar locked in raised Release foot latch and position. lower tow bar. Cart will not turn Adjust brake tension. left or right. Brakes set too tight. See ADJUSTMENT section following. Damaged tire(s). Repair tire(s). Brakes set too loose. Adjust brake tension. Unattached brake rod, Reattach rod, bolt or bolt or nut. nut. Broken rod, bolt or nut. Replace rod, bolt or nut. Brakes will not lock. Broken or missing Repair or replace brake brake bar. bar. Broken or missing tow Replace foot latch. bar foot latch. Cart Chassis (continued) Clean and repack Seized or broken wheel Wheel will not turn. bearing or replace bearing. bearing. Coolant System (See Figure 2.2 for Schematic) Flush & Fill Cart SFFC-70/2 | 33
SECTION 2 | SERVICING THE FLUSH AND FILL CART TROUBLE PROBABLE CAUSE REMEDY Tank shutoff valve Open shutoff valve. closed. In-line filter clogged. Remove and clean filter. Check hoses and No coolant flow. connections for leaks. Leaks in system. Repair or replace, as required. Insufficient coolant in Fill tank. tank. See pump Pump problem. troubleshooting in Appendix B. Motor malfunctioning. See motor adjustments. Motor to pump drive Replace belt belt damaged. Low or irregular Water tank breather Clean breather. flow. vent clogged. Ice in tank-to-pump line. Thaw out line. Check hoses and Kinked or leaking hose connections. Repair or or loose connection. replace as needed. Check valve clogged or Clean, repair or replace broken. valve. Electrical System Repair or replace Start switch problem. switch. Motor cannot be Troubleshoot and started Motor problem. repair. See Motor manual. Flush & Fill Cart SFFC-70/2 | 34
FIGURE 2.2 | COOLANT SYSTEM (Flush and Fill Mode) For Deaerate Mode and Waste Tank Pump Mode refer to Figures 1.2.3.5 and 1.2.3.6 Flush & Fill Cart SFFC-70/2 | 35
SECTION 2 | SERVICING THE FLUSH AND FILL CART 2.3 | ADJUSTMENTS 2.3.1 | Brake Adjustments When the tow bar is raised, a brake bar is pulled against the two front wheels, braking the cart. To adjust brakes, proceed as follows: 1. Unlatch and lower tow bar. Be sure cart is on a level surface or the wheels are blocked. 2. Loosen the lock nuts securing the brake rod to the yokes. 3. Turn the brake rod to move the brake bar closer or farther from the tires as needed. 4. Raise the tow bar. The brake bar should slide forward firmly against the tires. 5. If necessary, repeat above procedure until the brake is properly adjusted. 6. Tighten the lock nuts on the brake rod against the yokes. Flush & Fill Cart SFFC-70/2 | 36
SECTION 3 | OVERHAUL Compliance with recommended maintenance schedules will help eliminate the need for overhauling the Flush and Fill Cart on the basis of hours of operation or years of service. Repairs should be limited to the repair of components that develop defects or show signs of wear. Flush & Fill Cart SFFC-70/2 | 37
SECTION 4 | PARTS LIST This chapter contains a Manufacturer Identification List and detailed parts lists. Use this information for requisitioning, storing, issuing and identification of parts and components of the Flush and Fill Cart, manufactured by Stinar Corporation. The manufacturer identification list identifies the vendor sources by name, address and supply code. The detailed parts lists include Stinar manufactured assemblies, sub- assemblies and detail parts, plus detailed breakdowns for selected vendor manufactured parts. Flush & Fill Cart SFFC-70/2 | 38
SECTION 4 | PARTS LIST 4.1 | MANUFACTURER FED SUPPLY CODE MANUFACTURER IDENTIFICATION Stinar, LLC V32526 10061 State Hwy. 30 Blooming Prairie, MN 55917 Flush & Fill Cart SFFC-70/2 | 39
SECTION 4 | PARTS LIST 4.2 | DETAILED 4.2.1 | Understanding the Columns PARTS LIST 4.2.1.1 | Figure/Item No. This column lists the figure on which the item is shown and the item number assigned to the part. 4.2.1.2 | Manufacturer’s Part No. This column lists the part number assigned by the manufacturer and is required to procure the part. The abbreviation COMM (Commercial) indicates that several manufacturers produce the part and that it is usually available from local sources. EX: standard pipe fittings. 4.2.1.3 | Description This column presents the complete item name required for identification and procurement and may include the vendor’s name. 4.2.1.4 | Vendor Code This column shows the vendor code. This code is a U.S. Dept. of Defense CAGE code preceded by the letter V. 4.2.1.5 | QTY This column indicates the quantity used per assembly. 4.2.2 | Instructions for Ordering Parts and Assemblies Direct all inquiries to: Stinar, LLC 10061 State Hwy. 30, P.O. Box 127, Blooming Prairie, MN 55917 651-454-5112 | sales@stinar.com | www.stinar.com Flush & Fill Cart SFFC-70/2 | 40
PARTS ORDER FORM Stinar, LLC 10061 State Hwy. 30, P.O. Box 127, Blooming Prairie, MN 55917 651-454-5112 | sales@stinar.com | www.stinar.com Print or copy this page and send via email, fax or mail to Stinar, LLC. Please make sure to complete all fields. Note: Part Numbers and Product Illustrations are included in this Manual STINAR SERIAL NUMBER TRUCK CHASSIS OR OTHER COMPONENT SERIAL NUMBER PART OR COMPONENT DESCRIPTION QUANTITY SHIPPING METHOD NAME COMPANY NAME SHIP TO ADDRESS PHONE # FAX # Flush & Fill Cart SFFC-70/2 | 41
FIGURE 4.3.1 | FLUSH AND FILL CART MODEL SFFC-70/2 13 10 15-20 8 9 7 22 14 12 3 25 11 6 5 4 2 23 21 1 Flush & Fill Cart SFFC-70/2 | 42
FIGURE 4.3.1 | FLUSH AND FILL CART MODEL SFFC-70/2 - TABLE VENDOR FIG ITEM # MFG PART # DESCRIPTION QTY CODE 4.3.1-0 SFFC-70/2 Flush and Fill Cart, per Dwg No 049001 Rev D V32526 1 -1 049002 Rev D Cart Frame Weldment V32526 1 -2 030613 Rev G Front Axle Assembly. See Figure 4.3.2. V32526 1 -3 030617 Rev G Tow bar V32526 1 -4 603044 Wheel Hub. See Figure 4.3.3 V32526 4 -5 613007 Tire and Rim V32526 4 -6 030615 Rev H Rear Axle Assembly, Welded to cart frame. V32526 1 -7 049003 Rev D Tank, 70 gal. V32526 1 -8 049004 Rev C Waste Tank, 70 gal V32526 1 -9 426003 Electric Motor. V32526 1 -10 316130 Diaphragm Pump. V32526 1 -11 049000 Rev G Coolant System. See Figure 4.3.4. V32526 1 -12 049006 Rev C Electrical System. See Figure 4.3.8 V32526 1 -13 314000 Vent Mushroom ¾” V32526 2 -14 509024 2” Fill with hasp V32526 1 -15 049005 Rev B Belt Guard V32526 1 -16 705001 Pulley 1 3/8” bore V32526 1 -17 705002 Pulley Bushing V32526 1 -18 705003 Pulley 1” bore V32526 1 -19 705004 Pulley Bushing V32526 1 -20 702079 V-Belt 3VX500 V32526 1 -21 307052 Static Discharge Reel V32526 1 -22 308016 Flow Meter, Gals. V32526 1 -23 307057 Supply Reel V32526 2 -24 307004 Return Reel V32526 1 -25 307056 Bleed Reel V32526 1 Flush & Fill Cart SFFC-70/2 | 43
FIGURE 4.3.2 | FRONT AXLE ASSEMBLY Flush & Fill Cart SFFC-70/2 | 44
FIGURE 4.3.2 | FRONT AXLE ASSEMBLY - TABLE VENDOR FIG ITEM # MFG PART # DESCRIPTION QTY CODE 4.3.2-0 040147 Front Axle Assembly, 48 in V32526 1 -1 030617 Towbar Assembly V32526 1 -2 607006 Towbar Latch V32526 1 -3 940018 Flex-top locknut, ½"-13 V32526 1 -4 941013 SAE Flat Washer, ½" V32526 1 -5 938084 Hex-head Cap Screw, ½"-13, 1 ½" V32526 1 -6 508169 Bearing Disc V32526 1 -7 508168 Front Axle Swivel Shaft Housing V32526 1 -8 508170 Front Axle Swivel Shaft V32526 1 -9 030613 Front Axle Assembly, 48 in V32526 1 -10 706043 Yoke, ¾"-10 V32526 2 -11 940030 Flex-top Locknut, ¾"-10 V32526 2 -12 030378 Brake Rod, ¾"-10 x 22" V32526 2 -13 906002 Collar Shaft w/ Set Screw 1" V32526 2 -14 045008 Front Swivel Pin V32526 2 Flush & Fill Cart SFFC-70/2 | 45
FIGURE 4.3.3 | WHEEL HUB ASSEMBLY A A 3 SECTION A-A 1 5 2 4 Flush & Fill Cart SFFC-70/2 | 46
FIGURE 4.3.3 | WHEEL HUB ASSEMBLY - TABLE VENDOR FIG ITEM # MFG PART # DESCRIPTION QTY CODE 4.3.3-0 603044 Wheel Hub V32526 4 -1 603045 Seal, 1 ½” V32526 2 -2 603047 Race V32526 2 -3 603048 Bearing V32526 2 -4 1449 Grease Fitting V32526 1 -5 18907 Hub V32526 1 -6 5999 Flange, welded to Hub, Item 5 V32526 1 -7 14034 Flange, welded to Hub, Item 5 V32526 1 -8 603049 Bolt V32526 5 -9 603053 Nut, not shown V32526 5 Flush & Fill Cart SFFC-70/2 | 47
FIGURE 4.3.4 | COOLANT SYSTEM Flush & Fill Cart SFFC-70/2 | 48
FIGURE 4.3.4 | COOLANT SYSTEM - TABLE 1 VENDOR FIG ITEM # MFG PART # DESCRIPTION QTY CODE 4.3.4-0 049000 Rev G Coolant system- (flush and fill mode) V32526 1 -1 316130 Pump V32526 1 -2 302063 ¾” 3-way Ball Valve V32526 2 -3 302118 1 ¼” 3-way Ball Valve V32526 1 -4 205006 Pressure Gauge V32526 1 -5 308016 Flow Rate Meter V32526 1 -6 206072 5 micron Absolute Filter V32526 1 -7 302066 Pressure Relief valve V32526 1 -8 302018 Rev A 1” Gate Valve V32526 2 -9 049004 Rev C 70 Gal Waste Tank V32526 1 -10 049003 Rev D 70 Gal Coolant Tank V32526 1 -11 403152 Immersion Heater V32526 1 -12 302021 1 ¼” Gate Valve V32526 2 -13 304013 Y Strainer V32526 2 -14 315000 ¾” Visiflow V32526 1 -15 302108 Check Valve V32526 2 -16 302167 Check Valve V32526 1 -17 302057 Hose Reel ¾” X 50’ V32526 2 -18 305056 Hose Reel ⅜” X 75’ V32526 1 -19 512006 Schrader Air Valve V32526 1 -20 315001 1” Visiflow V32526 2 -21 307004 Hose Reel 1” X 50’ V32526 1 -22 107033 Hose HYD. 1525 PSI 100R1 ¾” x 50’ V32526 50’ -23 107031 Hose HYD. 6GIT ⅜” X 75’ V32526 75’ -24 107034 Hose HYD. 16G1 1” X 50’ V32526 50’ -25 108033 Stem ⅜” 6-6F JK V32526 2 -26 108069 Hydraulic Fitting 12G-12MXP V32526 2 -27 108073 FTTG HYD 16G-16MP V32526 2 -28 310014 Hose Stop ¾” V32526 1 -29 310015 Hose Stop 1” V32526 1 -30 310011 Hose Stop ⅜” V32526 1 -31 302064 1” 3-way ball valve V32526 1 Flush & Fill Cart SFFC-70/2 | 49
FIGURE 4.3.4 | COOLANT SYSTEM - TABLE 2 VENDOR FIG ITEM # MFG PART # DESCRIPTION QTY CODE Coolant system 4.3.5-0 V32526 1 Brass -1 101033 Str- 45 Elbow ¾” V32526 1 -2 101032 Str-90 Elbow ¾” V32526 3 -3 101031 90 Elbow ¾” V32526 3 -4 101026 Nipple ¾” x 2” V32526 2 -5 101020 Nipple Brass comb ½” V32526 4 -6 101025 Nipple Brass Close ¾” V32526 6 -7 101038 Brass Tee ¾” V32526 2 -8 101009 Brass Tee ¾ x ¼” V32526 1 -9 101030 Brass Nipple ¾” x 6 V32526 2 -10 101060 Brass Nipple Comb 1” V32526 2 -11 101053 Brass Nipple 1 x 3” V32526 1 -12 101054 Brass Nipple 1 x 4” V32526 1 -13 101051 Brass Nipple Close 1” V32526 2 -14 101063 Brass Tee 1” V32526 1 -15 101076 Brass Nipple Close 1 ¼” V32526 7 -16 101128 Brass Nipple Comb 1 ¼” V32526 5 -17 101197 Str 45 Elbow 1 ¼” V32526 4 -18 101081 Str 90 Elbow 1 ¼” V32526 3 -19 101110 Hx Brass Bushing V32526 3 -20 101115 Hx Brass Bushing ½ x ⅜” V32526 1 -21 101095 Hx Brass Bushing ½ x 1” V32526 2 -22 101138 Hx Brass Bushing 1 ¼ x ¾” V32526 1 -23 101102 Nipple close 2” V32526 1 24 102071 Hydr Fitting 16MB-12FB V32526 2 Flush & Fill Cart SFFC-70/2 | 50
FIGURE 4.3.8 | ELECTRICAL SYSTEM Flush & Fill Cart SFFC-70/2 | 51
FIGURE 4.3.8 | ELECTRICAL - TABLE VENDOR FIG ITEM # MFG PART # DESCRIPTION QTY CODE 4.3.8-0 049006 Rev C Electrical System V32526 1 -1 426003 10 HP Motor V32526 1 -2 -3 402002 Cable 14-4 10 ft V32526 2 -4 402074 Cable 10-4 50 ft V32526 1 -5 400330 3 Pole AC Contactor V32526 2 -6 404171 Nema-4 Enclosure V32526 1 -7 404172 Enclosure Mount Kit V32526 1 -8 410043 Din Mount V32526 1 -9 400326 Switch, Rd Push button V32526 1 -10 400327 Rd Boot V32526 1 -11 400325 Switch, Gn Push button V32526 1 -12 400328 Gn Boot V32526 1 -13 403152 Immersion Heater V32526 1 -14 419004 Transformer 50kva Solacontrol V32526 1 -15 415021 ¾” Cord grip – Plus Seal 415005 V32526 7 -16 415003 ¾” Cord Grip -Nut V32526 7 -17 400329 Overload Relay V32526 1 -18 400332 Selector Switch V32526 1 -19 414091 Plug V32526 1 Inline Fuse (not shown), Transformer-mounted -20 421056 V32526 1 250V, 5 Amp Flush & Fill Cart SFFC-70/2 | 52
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