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MODELS TL600/TL700

LAVATORY SERVICE TRUCK

MAINTENANCE

MANUAL

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PHOENIX METAL PRODUCTS, INC

TL600/TL700 LAVATORY SERVICE TRUCK

2 MAY 2018

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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3 MAY 2018

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.

CHAPTER SECTION & DESCRIPTION OF CHANGE SERIAL#

PAGE EFFECTIVITY

1-3, PAGE 31 UPDATE PICTURE

2-5, PAGE 52 UPDATE NEW SWITCH OPERATION

3-3, PAGE 92 UPDATE PARTS LIST

3-3, PAGE 93 UPDATE DRAWING


3-6, PAGE 155 UPDATE DRAWING


3-6, PAGE 157 UPDATE PICTURE

2-5, PAGES 58-60 ADD SCHEMATICS FOR 2017 FORD TRUCK

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4 MAY 2018

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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5 MAY 2018

TABLE OF CONTENTS

CHAPTER

/SECTION

PAGE

COPYRIGHT RELEASE 2

REVISIONS /CHANGES 3

SAFETY PRECAUTIONS 4

INTRODUCTION 6

1 GENERAL INFORMATION AND OPERATION INSTRUCTIONS

1-1 SPECIFICATIONS AND CAPABILITIES 7

1-2 SYSTEM DESCRIPTION 15

1-3 OPERATION 20

2 MAINTENANCE AND SERVICING INSTRUCTIONS

2-1 SYSTEM DESCRIPTION 37

2-2 SERVICING/LUBRICATION 39

2-3 INSPECTIONS 41

2-4 ADJUSTMENTS 44

2-5 TROUBLESHOOTING/SCHEMATICS 53

2-6 PREPARATION FOR SHIPMENT 70

2-7 PREPARATION FOR STORAGE 71

2-8 DISASSEMBLY, REPAIR, REASSEMBLY AND REPLACEMENT 72

3 ILLUSTRATED PARTS LIST

OVERVIEW 75

TABLE OF CONTENTS 76

3-1 MAIN ASSEMBLY 77

3-2 PLUMBING 84

3-3 ELECTRICAL 89

3-4 HYDRAULICS 94

3-5 PLACARDS 101

3-6 OPTIONS 102

4 VENDOR DATA

4-1 LIST OF VENDORS 148

4-2 MANUFACTURER DATA 150

WARRANTY INFORMATION 215

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6 MAY 2018

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 , POWERED BY A TURBOCHARGED

AIR COOLED INLINE FOUR CYLINDER DIRECT INJECTION DIESEL 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 PLAT-

FORM. LIGHTS ARE SUPPLIED FOR NIGHT OPERATIONS. THIS PUBLICATION PROVIDES OPERAT-

ING, 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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37 MAY 2018

CHAPTER 2

MAINTENANCE

SECTION 1 - SYSTEM DESCRIPTION

THE FOLLOWING SYSTEMS COMPRISE THE TL600/700 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.

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38 MAY 2018

CHAPTER 2

MAINTENANCE

SECTION 1 - SYSTEMS DESCRIPTION

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 BRONZE 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. REINFORCED 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.

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39 MAY 2018

CHAPTER 2

MAINTENANCE

SECTION 2 - SERVICING/LUBRICATION

THE TL 600/700 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 SIGHT 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 19 U.S. GALLONS

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

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.

USE ONLY ISO 32 OIL

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40 MAY 2018

CHAPTER 2

MAINTENANCE

SECTION 2 - SERVICING/LUBRICATION

(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 PRES

SURE 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

(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.

(3) ALL HINGES AND LATCHES ON MODULE. LUBRICATE WITH A DROP OF 5 WT OIL.

ISO 32

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41 MAY 2018

CHAPTER 2

MAINTENANCE

SECTION 3 - INSPECTIONS

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 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

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42 MAY 2018

INSPECT FOR


PROPER FLOW. PROPER FLOW IS {(18-22) 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

MAINTENANCE



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43 MAY 2018

CHAPTER 2

MAINTENANCE


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.


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

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44 MAY 2018

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 PSI

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 PSI HIGHER THAN THE HIGHEST PRESSURE NEEDED TO OPERATE THE

HIGHEST PRESSURE COMPONENT. IN THIS CASE THE PERSONNEL LIFT CYLINDER

REQUIRES THE HIGHEST PRESSURE TO OPERATE. THE HYDRAULIC SYSTEM PRESSURE

IS REGULATED BY A RELIEF VALVE MOUNTED ON THE HYDRAULIC MANIFOLD

LOCATED IN THE PUMP COMPARTMENT. A TEST PORT IS ACCESSIBLE FROM THE

HYDRAULIC COMPARTMENT.

1

REVISED MAY 2017

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45 MAY 2018

NOTE: THE VEHICLE ENGINE MUST BE RUNNING AND THE IDLE-UP

FUNCTION MUST BE ACTIVATED ON VEHICLE BEFORE MAKING

ANY ADJUSTMENTS OR TAKING ANY MEASUREMENTS ON WATER OR

HYDRAULIC SYSTEMS.

6

LOCATED ON OPPOSITE SIDE OF

HYDRAULIC TEST PORT.

CHAPTER 2


CHECK/ADJUST HYDRAULIC SYSTEM PRESSURE WITH PERSONNEL LIFT

1. INSTALL PRESSURE GAUGE ON HYDRAULIC TEST PORT WITH VEHICLE OFF.

3. START VEHICLE AND ACTIVATE IDLE-UP FUNCTION .

4. LOWER LIFT TO FULL DOWN POSITION.

5. HOLD LIFT DOWN SWITCH WHILE READING GAUGE TO CHECK PRESSURE.

6. IF PRESSURE IS NOT APPROXIMATELY 850 PSI, LOOSEN RELIEF VALVE LOCK NUT

AND USE 3/16 HEX KEY TO ADJUST PRESSURE. ENSURE LIFT DOWN BUTTON IS

HELD WHILE ADJUSTING PRESSURE. CLOCKWISE TURN INCREASES PRESSURE AND

COUNTER CLOCKWISE DECREASES PRESSURE.

7. WHEN PRESSURE IS SET AT 850 PSI, TIGHTEN LOCK NUT, AND REMOVE GAUGE.

REVISED MAY 2017

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46 MAY 2018

CHAPTER 2


CHECK/ADJUST HYDRAULIC SYSTEM PRESSURE WITHOUT PERSONNEL LIFT

1. INSTALL TEST GAUGE ON HYDRAULIC TEST PORT WHILE VEHICLE IS OFF.

2. MAKE SURE CHARGE HOSE CAP IS INSTALLED ON END OF HOSE AND THERE IS

WATER IN CHARGE TANK.

3. TURN ON VEHICLE AND ACTIVATE ENGINE IDLE-UP FUNCTION.

4. ACTIVATE CHARGE PUMP AND CHECK HYDRAULIC PRESSURE ON TEST GAUGE WHILE

PUMP IS OPERATING.

5. IF PRESSURE IS NOT APPROXIMATELY 850 PSI, REMOVE RELIEF VALVE CAP AND

USE A 5/16 HEX KEY TO ADJUST PRESSURE. CLOCKWISE TURN INCREASES PRESSURE

AND COUNTER CLOCKWISE DECREASES PRESSURE.

5. WHEN PRESSURE IS SET AT 850 PSI, REPLACE CAP, TIGHTEN LOCKNUT AND REMOVE

GAUGE.

1




HYDRAULIC SYSTEMS.

4

5

REVISED MAY 2017

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5

CHAPTER 2


2

REVISED MAY 2017

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48 MAY 2018

CHAPTER 2



THE RECOMMENDED FLUID PUMPING SYSTEM SETTINGS FOR AIRCRAFT SERVICING IS (42-45)

PSI. AND (18-22) GALLONS PER MINUTE OF FLOW. THESE SETTINGS ARE ACHIEVED BY USING A

PRESSURE REDUCING VALVE THAT IS REGULATED TO (42-45) PSI AND A PRESSURE RELIEF

VALVE SET AT APPROXIMATELY 80 PSI.

CHECK/ADJUST FLUID PUMPING SYSTEM PRESSURE WITHOUT PERSONNEL LIFT

NOTE: ENSURE HYDRAULIC SYSTEM PRESSURE IS CORRECT BEFORE ADJUSTING

FLUID PUMPING SYSTEM.

1. ADJUST THE BOLT ON THE PRESSURE REDUCING VALVE ALL THE WAY IN.

(HIGHEST PRESSURE SETTING)

2. ADJUST THE KNOB ON THE PRESSURE RELIEF VALVE ALL THE WAY OUT, THEN

BACK IT IN (1-1/2) TURNS.

3. INSTALL A PRESSURE GAUGE IN THE PORT AT THE CHARGE LINE PRESSURE RELIEF

VALVE TEE.

4. ATTACH A TEST GAUGE WITH BALL VALVE AND HOSE TO THE END OF THE CHARGE

HOSE.

5. ACTIVATE THE CHARGE PUMP AND RUN UNTIL ALL AIR IS OUT OF THE SYSTEM. KEEP

CHARGE PUMP ON.

6. CLOSE THE BALL VALVE ON THE CHARGE HOSE TEST GAUGE.

7. READ THE GAUGE AT THE CHARGE LINE PRESSURE RELIEF VALVE & ADJUST THE

PRESSURE TO APPROXIMATELY 80 PSI.

8. LOCK THE JAM NUT ON THE CHARGE LINE PRESSURE RELIEF VALVE.

9. DISENGAGE THE CHARGE PUMP SWITCH.

10. BACK THE ADJUSTMENT SCREW ALL THE WAY OUT ON THE PRESSURE REDUCING

VALVE.

11. RE-ENGAGE THE CHARGE PUMP WITH THE TEST GAUGE BALL VALVE CLOSED.

12. READ THE TEST GAUGE ON CHARGE HOSE AND ADJUST THE PRESSURE REDUCING

VALVE TO 42-45 PSI.

13. ZERO THE METER AND OPEN THE TEST GAUGE BALL VALVE, & CHECK THE FLOW

RATE. (18-22 GPM).




HYDRAULIC SYSTEMS.

REVISED MAY 2017

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4

CHAPTER 2


6

2

CHARGE LINE PRESSURE

RELIEF VALVE

7 3

8

1

PRESSURE REDUCING

VALVE

10

12

12

13

REVISED MAY 2017

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50 MAY 2018

CHAPTER 2


PLATFORM LIFT (IF EQUIPPED)

LIFT CYLINDER BLEED PROCEDURE

IF SLOW OR JERKY OPERATION IS EXPERIENCED WHEN RAISING OR LOWERING THE OPTIONAL

PLATFORM LIFT, THEN THERE MAY BE AIR TRAPPED IN THE CYLINDER. THE FOLLOWING IS A

PROCEDURE FOR BLEEDING THE LIFT CYLINDER OF TRAPPED AIR.

A BLEEDER VALVE ASSEMBLY IS REQUIRED TO BLEED THE CYLINDER. THE ILLUSTRATED

PARTS LIST FOR THE BLEEDER KIT IS ON PAGE 52.

1. BEFORE REMOVING THE PLUG IN THE TOP OF THE CYLINDER, MAKE SURE THE

EMERGENCY DOWN BALL VALVE IS IN THE OPEN POSITION AND THAT THE LIFT IS

IN THE FULLY STOWED POSITION.

CYLINDER PLUG

PLUG REMOVED

2. INSTALL THE BLEEDER VALVE ASSEMBLY INTO THE TOP OF THE CYLINDER AND CONNECT

THE HOSE END OF THE ASSEMBLY TO THE HYDRAULIC TANK FILL CONNECTION. MAKE SURE

THE BLEEDER BALL VALVE IS IN THE CLOSED POSITION.

BLEEDER VALVE ASSEMBLY

SHOWN WITH THE BALL VALVE IN

THE CLOSED POSITION

HOSE END OF THE BLEEDER

VALVE ASSEMBLY CONNECTED TO

THE HYDRAULIC TANK FILL

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51 MAY 2018

CHAPTER 2



LIFT CYLINDER BLEED PROCEDURE (CONT’D)

3. WITH THE EMERGENCY BALL VALVE AND THE BALL VALVE ON THE BLEEDER ASSEMBLY

CLOSED, RUN THE LIFT TO THE FULLY UP POSITION.

4. HAVE AN ASSISTANT ON THE GROUND OPEN THE EMERGENCY DOWN VALVE AND LET THE

LIFT LOWER COMPLETELY DOWN TO ITS STOWED POSITION. IF THE LIFT BINDS COMING DOWN

SHAKE THE LIFT TO CONTINUE MOVEMENT.

5. ONCE THE LIFT IS COMPLETELY DOWN, CLOSE THE EMERGENCY DOWN VALVE AND OPEN

THE BALL VALVE ON THE BLEEDER ASSEMBLY. OPERATE THE LIFT’S DOWN CONTROL FOR A

FEW SECONDS AND NOTE ANY AIR BLEEDING THROUGH THE DRAIN HOSE TO THE TANK.

6. CLOSE BOTH THE EMERGENCY AND BLEEDER BALL VALVES AND REPEAT THE PROCESS

UNTIL THE CYLINDER HAS BEEN COMPLETELY BLED OF ALL AIR.

7. REPLACE AND TIGHTEN THE PLUG INTO THE TOP OF THE CYLINDER.

EMERGENCY DOWN

BALL VALVE Pro

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52 MAY 2018

CHAPTER 2



LIFT CYLINDER BLEED PROCEDURE (CONT’D)

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53 MAY 2018

CHAPTER 2

SECTION 5 - TROUBLESHOOTING/SCHEMATICS

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,

RACKS 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 OR CUT OR SPLICE ANY LOAD BEARING OR SUPPORT

STRUCTURES PRIOR TO CONTACTING THE ENGINEERING DEPARTMENT OF PHOENIX METAL

PRODUCTS

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CHAPTER 2


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.

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55 MAY 2018

CHAPTER 2


TROUBLE SYMPTOM ELECTRICAL HYDRAULIC MECHANICAL

LIMITED OR NO HYDRAULIC

POWER, AND/OR ERRATIC LIFT

FUNCTION OR PUMPING FUNCTION

E3, E15 H4, H6, H8, H9;H11,

H15, E16 M9

NOISY HYDRAULIC PUMP E16 H4 M9

HYDRAULIC FLUID MILKY OR

DISCOLORED H3, H5, H10

HYDRAULIC SYSTEM RUNNING HOT H1, H2, H4, H5,

H6

SQUEALING FROM HYDRAULIC

PUMP BELTS OR SMELL OF

BURNING RUBBER

H2, H7 M9

PUMP TURNS ON AND SHUTS OFF

REPEATEDLY

E1, E2, E3, E4,

E6, E16

LIFT WILL NOT STABILIZE AND

HOLD IN THE UP POSITION H7, H13, H14, H15

FLUID PUMP DOES NOT PUMP FROM

ONE TANK BUT DOES FROM THE

OTHER

E2, E3, E4, E8 M12, M13

FLUID PUMP - PUMPS SLOWLY H1, H2, H4, H6,

H8, H11, H13, H16

M9, M12, M13,

M14, M15, M16,

M17

FLUID TRANSFERS TO PLANE BUT

DOES NOT REGISTER ON METER M14

ENGINE RUNNING/NO LIFT OR PUMP

FUNCTIONS

E1, E2, E3, E7,

E9, E16 H4, H6, H8, H9 M9

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56 MAY 2018

CHAPTER 2


TROUBLE SYMPTOM ELECTRICAL HYDRAULIC MECHANICAL

FLOW METER NOT

OPERATING CORRECTLY M20

FLUID PUMP OPERATES/NO

OUTPUT FROM HOSE END

E2, E3, E4, E8

M12, M15, M16,

M17

FLUID WILL NOT DRAIN

BACK FROM HOSE AFTER

SERVICING AIRCRAFT

M18

WASTE PUMP DOES NOT

PULL FLUID FROM

AIRCRAFT

E2, E4, E5, E8 H11, H12, H13, H16 M2, M3, M19

WHEN WASTE TANK IS FULL/

WASTE DRAINS OUT OF

WASTE HOSE

M19

SPOT LIGHTS DO NOT WORK E1, E2, E3, E4, E5, E12

HOT WATER HEATER DOES

NOT WORK/WORKS BUT NO

WARM AIR

E1, E2, E6, E17 M9, M11

110 VOLT HEATER (S)

DO NOT OPERATE E1, E2, E4, E18

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57 MAY 2018

CHAPTER 2

SECTION 5 - TROUBLE /SHOOTING/SCHEMATICS

ELECTRICAL

CODE # PROBABLE CAUSE TEST /REMEDY

E1 FUSE/CIRCUIT BREAKER BLOWN CHECK FOR SHORT CIRCUIT. REPLACE FUSE

E2 WIRING DISCONNECTED/LOOSE

CHECK CONTINUITY FROM POINT TO POINT.

CHECK FOR DAMAGED OR DISCONNECTED

TERMINALS

E3 BAD GROUND CONNECTION CHECK AND RE-GROUND

E4 CONNECTOR DAMAGED OR LOOSE TIGHTEN CONNECTOR OR REPLACE

E5 SWITCH CONTACT NOT CLOSING REPLACE SWITCH OR CONTACT

E6 SWITCH CONTACTS SHORT

CIRCUITED TEST. REPLACE CONTACT OR SWITCH

E7 RELAY/SOLENOID COIL OPEN–

CIRCUITED TEST. REPLACE RELAY

E8

SELECTOR VALVE SOLENOID COIL

OPEN CIRCUITED

TEST. REPLACE COIL

E9 RELAY CONTACTS NOT CLOSING TEST. REPLACE RELAY

E10 RELAY CONTACTS WELDED SHORT TEST. REPLACE RELAY

E12 BULB DEFECTIVE REPLACE BULB

E13 DIODE DEFECTIVE TEST. REPLACE DIODE

E14 EMERGENCY KILL SWITCH ON PULL TO RELEASE SWITCH

E15

LOW VOLTAGE

CHECK VOLTAGE FROM ENGINE ALTERNATOR

IF LESS THAN 12 VOLTS OR MORE THAN 15

VOLTS. REPLACE ALTERNATOR

E16

PUMP CLUTCH COIL NOT HOLDING

CHECK VOLTAGE. IF VOLTAGE IS GOOD

REPLACE CLUTCH

E17 FAN MOTOR DEFECTIVE REPLACE FAN MOTOR OR HEATER ASSEMBLY

E18 THERMOSTAT IMPROPERLY

ADJUSTED OR DEFECTIVE

CHECK CONNECTIONS ON IMMERSION

HEATER–CHECK SETTING FOR APPROX. 60 ºF.—

REPLACE HEATER ASSEMBLY

E19 HEATER ELEMENT DEFECTIVE REPLACE HEATER ELEMENT

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CHAPTER 2


HYDRAULICS

CODE # PROBABLE CAUSE TEST/REMEDY

H1

HYDRAULIC HOSE BLOCKED OR

PINCHED

REMOVE AND INSPECT . REPLACE IF

NECESSARY

H2 RETURN FILTER CLOGGED REPLACE ELEMENT

H3

RESERVOIR CONTAMINATED

OPEN RESERVOIR AND CHECK FOR

CONTAMINATION. DRAIN AND CLEAN

RESERVOIR WITH MINERAL SPIRITS. FLUSH

SYSTEM AND REFILL WITH NEW OIL

H4 FLUID LEVEL LOW CHECK. FILL AS NECESSARY

H5

WRONG TYPE HYDRAULIC FLUID

OR CONTAMINATION

OPEN RESERVOIR AND CHECK FOR

CONTAMINATION. DRAIN AND CLEAN

RESERVOIR WITH MINERAL SPIRITS. FLUSH

SYSTEM AND REFILL WITH NEW OIL

H6 RELIEF VALVE NOT ADJUSTED CHECK PRESSURE AND ADJUST

H7 PILOT CHECK VALVE DEFECTIVE REPLACE VALVE

H8

PRESSURE REGULATOR SPRING

DEFECTIVE

REMOVE AND INSPECT REPLACE SPRING OR

RELIEF VALVE

H9 HYDRAULIC PUMP DEFECTIVE REPLACE OR REPAIR PUMP

H10 HYDRAULIC PUMP SEAL LEAKING REPAIR

H11 HYDRAULIC MOTOR DEFECTIVE REPLACE OR REPAIR MOTOR

H12

HYDRAULIC MOTOR SHAFT KEY

BROKEN

REMOVE HYDRAULIC MOTOR, CHECK SHAFT

KEY REPLACE IF NECESSARY

H13

SELECTOR VALVE SPOOL

STICKING

REMOVE COIL, SPOOL AND CLEAN WITH

MINERAL SPIRITS AND REPLACE

H14

EMERGENCY DOWN VALVE

LEAKING

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.

H15 EMERGENCY DOWN VALVE

MANUAL OVERRIDE IS ENGAGED

CHECK MANUAL OVERRIDE SCREW. UNSCREW

UNTIL FULLY RETRACTED

H16 FLOW CONTROL NOT ADJUSTED ADJUST FLOW CONTROL ON SELECTOR VALVE

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59 MAY 2018

CHAPTER 2


MECHANICAL

CODE PROBABLE CAUSE TEST/ REMEDY

M1

HINGE OR LATCH BINDING

CHECK FOR ALIGNMENT/ALIGN AND LUBRICATE.

REPLACE IF NECESSARY.

M2

CONNECTING ROD BROKEN

REMOVE COVER– OPERATE PUMP– INSPECT ROD

REPLACE IF NECESSARY.

M3

DIAPHRAGM LEAKING

REMOVE COVER– INSPECT DIAPHRAGM—LOOK FOR

FLUID ON TOP SIDE OF DIAPHRAGM.

M4

STABILIZER TUBE OUT OF

ADJUSTMENT

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.

M5

STABILIZER TUBES DENTED OR

DAMAGED

EXTEND LIFT CHECK FOR DISTORTION OR DINGS IN

TUBES. REMOVE AND REPAIR AS NECESSARY.

M6

DRAIN VALVE CLOGGED

OPEN TANK INSPECTION DOOR INSPECT VALVE FOR

DEBRIS REMOVE DEBRIS AS NECESSARY.

M7

DRAIN VALVE STEM BROKEN

INSPECT BALL VALVE STEM. REPLACE BALL VALVE IF

NECESSARY.

M8 HOSE REEL REWIND SPRING

BROKEN REPLACE SPRING HOUSING ASSEMBLY.

M9

BELT SLIPPAGE

CHECK TENSION OF HYDRAULIC PUMP BELTS. CHECK

CONDITION OF BELTS. ADJUST TENSION OR REPLACE

BELTS.

M10

FAN BLADES BENT

INSPECT FAN BLADES FOR INTERFERENCE. REPAIR OR

REPLACE BLADE OR FAN MOTOR.

M11

LOW COOLANT SYSTEM FLUID

CHECK FOR LEAKS IN VEHICLE COOLANT SYSTEM.

REPAIR LEAKS AND FILL SYSTEM.

M12 LOW FLUID IN TANK CHECK FOR LEAK. FILL TO REQUIRED LEVEL.

M13 OBSTRUCTION IN LINE REMOVE LINE AND CLEAR OBSTRUCTION.

M14

METER DEFECTIVE

FLUSH METER WITH WARM FRESH WATER—REPLACE

METER.

M15 TEE STRAINER CLOGGED REMOVE SCREEN AND FLUSH—RE-INSTALL.

M16 FLUID PRESSURE RELIEF VALVE ADJUST

M17

PRESSURE RELIEF VALVE SPRING

BROKEN

REPLACE

M18 DRAIN BACK HOSE OBSTRUCTED REMOVE OBSTRUCTION.

M19 WASTE PUMP FLAPPER VALVES

OBSTRUCTED OR DEFECTIVE REMOVE OBSTRUCTION OR REPLACE VALVES.

M20 DAMAGE FROM UNDISSOLVED/

IMPROPERLY DILUTED FLUID

CHECK METER PARTS FOR CLOGS OR GRANULE BUILD-

UP /CLEAN OR REPLACE PARTS AS NEEDED

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60 MAY 2018

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61 MAY 2018

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62 MAY 2018

NO LIFT

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63 MAY 2018

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64 MAY 2018

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65 MAY 2018

ISUZU GAS HEATER

HOSE LAYOUT

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66 MAY 2018

FORD HEATER

HOSE LAYOUT

WITH ENGINE BAY

PUMP

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67 MAY 2018

CHAPTER 2


HYDRAULIC SCHEMATIC - WITHOUT LIFT

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68 MAY 2018

CHAPTER 2


HYDRAULIC SCHEMATIC - WITH LIFT

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69 MAY 2018

CHAPTER 2



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70 MAY 2018

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


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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71 MAY 2018

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


FUEL FOR STORAGE. THE LEVEL GAUGE MUST READ EMPTY. DRAIN OR RUN

THE VEHICLE TO ACHIEVE THE VOLUME NECESSARY.

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72 MAY 2018

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


REMOVABLE 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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74 MAY 2018

CHAPTER 2


REMOVAL 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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