1 2 3 4
5
6
7
GENERAL IN INFORMATION OPERATING MANUAL PANELS 3 .1 .1
D ES ES CR CR IP IP TI TI ON ON
3 .2 .2
C AB AB LE LE L IS IS T
MAINTENANCE 4 .1 .1
M AI AI NT NT EN EN AN AN CE CE
4.2
M AI AI N TE TE N AN AN C E C H AR AR TS TS
4 .3 .3
A DJ DJ US US TM TM E NT NT S
HYDRAULIC 5 .1
D IAG RA M
5 .2 .2
P AR AR TS TS L IS IS T
5.3
S P EC EC I AL AL I NS NS T RU RU C TI TI O NS NS
FLUID 6 .1
D IAG RA M
6 .2 .2
P AR AR TS TS L IS IS T
6.3
S P EC EC I AL AL I NS NS T RU RU C TI TI O NS NS
ELECTRICAL 7.1
DIAGRAM
7 .2 .2
T ER ER MI MI NA NA L S UR UR VE VE Y
7 .3 .3
P AR AR TS TS L IS IS T
7.4
S P EC EC I AL AL I NS NS T RU RU C TI TI O NS NS
6 0 0 6 N O T
INDEX CHAPTER
General Information 08.01.2004
Pa P a g e
REV: 000
6 0 0 6 N O T
1.1
INFORMATION ON RATING PLATES
1
1.2
SPECIFICATIONS
1
1.3
APPLICATIONS AND LIMITATIONS
1
1.4 1. 4
COND CONDIITION TIONS S TO TO BE BE CON CONSI SID DERED ERED PRIOR TO USE
2
1.5
TRAINING
3
1.6
SPARE PARTS
3
1.7
DECLARATION OF CONFORMITY
3
INDEX CHAPTER
General Information 08.01.2004
Pa P a g e
REV: 000
6 0 0 6 N O T
1.1
INFORMATION ON RATING PLATES
1
1.2
SPECIFICATIONS
1
1.3
APPLICATIONS AND LIMITATIONS
1
1.4 1. 4
COND CONDIITION TIONS S TO TO BE BE CON CONSI SID DERED ERED PRIOR TO USE
2
1.5
TRAINING
3
1.6
SPARE PARTS
3
1.7
DECLARATION OF CONFORMITY
3
GENERAL INFORMATION
CHAPTER
1.1
INFORMATION ON RATING PLATES (21.09.2005)
Copy of information on rating plates is enclosed in Appendix 1A in this chapter.
1.2
SPECIFICATIONS (21.09.2005)
The toilet servicing unit, the VTS, is manufactured on a standard chassis, on which Vestergaard Company A/S has altered machine room, tanks, platform and basket. Enclosed in Appendix 1B to this chapter you will find a list l ist with specifications on the VTS. The VTS has been manufactured according to the standards EN 1915-1 and EN 1915-2 regarding general requirements for airport equipment, as well as to EN 12312-13 regarding specific requirements for lavatory service equipment. All standards are based on the Machinery Directive, 98/37/EEC.
1.3
APPLICATIONS AND LIMITATIONS (21.09.2005)
The VTS is designed for emptying of aircraft toilets. The following conditions must be observed: •
Neve Neverr try try stu stunt nt driv drivin ing g with with the the VTS VTS;;
•
Always Always be aware aware of conditions conditions affecting affecting the the safety safety as well as the stabili stability ty and overall operation of the VTS, for example humans, wiring, buildings, and aircraft.
In short, operators must realize: NOTE: Stunt
driving and horseplay is not permitted with this this unit
In spite of a careful constructing and detailed calculating, situations causing danger to humans or material, could occur, for example by •
inap inappr prop opri riat atee use use of the the VTS VTS;;
•
lack lack of of trai traini ning ng of of ope opera rato tors rs;;
•
inco incorre rrect ct/mi /miss ssin ing g serv servic icee of the the VTS VTS..
All are situations against which we cannot provide completely when when constructing and designing. It must therefore be emphasized that any use of the VTS requires a thorough reading of and compliance with manuals, service specifications, instructions for operation as well as ongoing training of operators and authorized service staff members.
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1.4 1.4
GENERAL INFORMATION
COND CONDIT ITIO IONS NS TO BE CONS CONSID IDER ERED ED PRIO PRIOR R TO TO USE USE (21.09.2005)
1.4.1
RISKS RELATING TO PERSONAL SAFETY - WARNINGS
(08.01.2004)
1.4.1.1
Working areas (21.09.2005)
During normal operation, operators are ONLY to be in the chassis cabin and in the basket at the rear end of the unit. Should servicing of aircraft/filling of fluid into the tanks cause that the operator is required to walk on the tanks, he must take necessary precautions against falling. WARNING:
Take precautions for personal safety against falling from the
roof. Do not stand underneath underneath the basket. Do not step onto the platform when the basket is in operation. The operator must also be aware that a galvanized walkway grating must be mounted to allow walking on unit top.
Do not step/walk on unit top if if no walkway grating is mounted - unit top will be damaged. WARNI NG:
1.4.1.2
Wiring (21.09.2005)
As the VTS is not electrically electrically insulated, the basket (when (when mounted) must never be used near conductors.
1.4.1.3
Risk in the induction and blast zone (08.01.2004)
If servicing of aircraft toilets is to take place when aircraft engines are running, the operator must be aware of the risk of induction and blast.
1.4.1.4
Vacuum (21.09.2005)
When vacuum is used during service, make sure never to mount vacuum coupling anywhere else than on corresponding coupling on the aircraft. WARNING: Never
start the vacuum vacuum pump until the coupling coupling has been mounted on aircraft.
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GENERAL INFORMATION
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1.4.1.5
Steam generator (21.09.2005)
When the steam generator is used, necessary protection gear must be worn, according to special instructions. WARNING:
1.4.1.6
Uninsulated parts will be hot - danger of burns and scalds.
Driving the chassis (28.03.2007)
WARNING: Do
not drive chassis chassis while hydraulic system system is ON - risk risk of damage to unit.
1.5
TRAINING (21.09.2005)
Operators and authorized maintenance staff members are designated by the owner and trained occasioned by the owner. Prior to first use of the VTS, the staff must be trained in how to use the unit. It is of vital importance that each member of the personnel keeps up his knowledge of the VTS and its limitations.
1.6
SPARE PARTS (21.09.2005)
If parts/sections of the unit are replaced by some other than the ones specified, provisions on warranty and reliability no longer apply to the manufacturer Vestergaard Company A/S.
1.7
DECLARATION OF CONFORMITY (21.09.2005)
As enclosure in Appendix 1C to this chapter you will find the the EU-Declaration of Conformity with indication of manufacturer's basic data. As enclosure in Appendix 1D to this chapter you will find find a declaration of Noise Emission.
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GENERAL INFORMATION
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Operating Manual 08.01.2004
Page
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2.1
SAFETY MATTERS
1
2.2
START UP OF CHASSIS
1
2.3
PREPARING FOR THE AIRCRAFT SERVICING
6 0 0 6 N O T
1
2.4
OPTION NOT CHOSEN
2.5
OPTION NOT CHOSEN
2.6
SERVICING OF AIRCRAFT
2.7
EMPTYING OF WASTE TANK - OPEN DUMP, HYDRAULICS ACTIVATED 3
2.8
HALT OF CHASSIS
4
2.9
EMERGENCY MANOEUVRING OF BASKET
4
2
2.10 FILLING OF FLUID
4
2.11 EMERGENCY STOP
5
2.12 CLEANING
5
2.13 REVERSING AID
5
OPERATING MANUAL
CHAPTER
In this chapter, we will go through operation of the VTS point by point. When appropriate, references will be made to positions in the Panel Description. Therefore, a close reading through of the Panel Description is a pre-condition of a complete understanding of this chapter. References to the Panel Description will be made as follows: “4P 1” refers to position 4 on panel 1. IMPORTANT: In
case of any alarm situation in functions arising during servicing, search for clarification of the problem in the Panel Description. With regard to the operation of the unit, the operators must be aware that diesel engines are damaged from long periods of unloaded running. During longer pauses the unit must be turned completely off. NOTE:
2.1
SAFETY MATTERS (21.09.2005)
Prior to first use of the VTS, chapter 1 concerning general information and conditions for operating the VTS must be read thoroughly, in order to understand the general terms of the restrictions and safety risks that must be observed by use of the unit.
2.2
START UP OF CHASSIS (21.09.2005)
1.
Check the oil level of the engine by means of the dip stick.
2.
Moreover, check the hydraulic oil level through the inspection glass on the tank; the tank must be completely full. The basket must be in its resting position when making the check.
3.
Check the diesel oil level by means of the gauge on the dash board. The machine room fuelheater uses diesel oil from the chassis tank; therefore, the level must be ample.
4.
Start the chassis motor. Be aware that it might be necessary to preheat in case of cold start. Also check the fluid level in the tanks.
5.
The VTS is now to be operated as any other truck chassis. For more information in that connection, we refer to the chassis instructions.
2.3
PREPARING FOR THE AIRCRAFT SERVICING (12.03.2008)
Before the VTS is ready for operation, the gear selector must be put in neutral position, and the parking brake must be activated. As soon as a function is activated, the PTO will be engaged automatically. When the PTO is engaged, the engine automatically increases its number of revolutions. The VTS is now on “stand-by” and servicing can start.
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2.4
OPTION NOT CHOSEN
2.5
PLATFORM/BASKET (30.06.2014)
The VTS is equipped with a basket, mounted at the rear end of the unit. If the basket is up and the the parking brake is disengaged, the chassis engine will stop.
2.6
SERVICING OF AIRCRAFT (21.09.2005) (M)
Position the chassis to the aircraft. Operate basket by means of switch (7P6+22P6). If necessary, de-ice aircraft hatch and couplings. Mount vacuum and fluid couplings on the aircraft.
2.6.1
HYDRAULIC SYSTEM ON
(21.09.2005))
The hydraulic system is automatically activated with use of any functions.
2.6.2
EMPTYING/FLUSH OF AIRCRAFT TANKS
(11.09.2007))(M)
1.
Start the vacuum pump on switch (3P6) and let the pump build completely up a maximum of vacuum (wait approximately 15 seconds).
2.
Now open the waste valve on the aircraft and then the vacuum valve (5P6). The aircraft tanks will be emptied by means of vacuum.
3.
With the vacuum pump still operating, the water pump (20P6) can be started, in order to flush the aircraft tank thoroughly. Normally, no more than 15-30 litres water will be required for the flushing. If necessary, the procedure can be repeated. Flushing can be made in one of two ways: Either flushing can be done as required by circumstances, or a certain amount of flushing fluid can be entered on 27P6 and 29P6. Indicated on display (23P6).
4.
When servicing is finished, close the waste valve on the aircraft, stop fluid pump (20P6) and vacuum pump (3P6). The vacuum valve (F27) closes automatically. Be aware that the return suction starts automatically when the fluid pumps are turned off. Return suction takes approx. 20 seconds.
2.6.3
FILLING OF FLUSHING FLUID ON AIRCRAFT TANKS – WITH PRESELECTION
(30.06.2008) (M)
1.
Select a certain amount of fluid in advance by means of switch (15P6). The amount of preselected fluid can be read on counter (11P6). Do not forget to add approx. 5 litres in addition to the amount of fluid to be filled onto the aircraft. Filling of flushing fluid is to be started on switch (1P6). When finished, filling of fluid will stop automatically, and return suction starts automatically, too. Return suction takes approx. 20 seconds.
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2.
When return suction has stopped, couplings can be removed. Now basket (if mounted) and hose can move back to their resting positions.
3.
2.6.4
The chassis is ready to drive away, and next tank or aircraft can be serviced
PROTECTION OF PUMPS
(21.09.2005)
The VTS is equipped with a low-level shut-down feature which will protect the pump from running dry. In case the fluid level in one or both tanks is too low, one or both pumps will stop. -
2.6.5
Should this happen, fill the empty tank(s) to put the pumps back in operation.
BLEEDING OF PUMP
(21.09.2005)
After maintenance the pump will be bled automatically during startup. -
2.7
Check that pressure builds up within a few seconds.
EMPTYING OF WASTE TANK - OPEN DUMP, HYDRAULICS ACTIVATED (21.09.2005)
1.
Position the chassis over the drain well.
2.
Open the drain valve by means of the two switches (8P1 and 9P1) simultaneously.
3.
During emptying of waste tanks, the tank is automatically flushed with water from the water tank. Flushing sequence starts 30 sec. after the waste volume goes below 200 l. The flushing continues for 60 sec. IMPORTANT: The manhole cover (F40) must
remain closed during emptying of waste tanks to avoid splashing of water on people nearby and/or on vehicle. 4.
Close the waste valve by means of on-off switch (9P1). Flushing stops automatically when valve is closed. In case waste substances accumulate around the waste valve, wash away these while draining of the waste tank takes place. NOTE: To operate the dump valve the parking brake must be
activated and
the gear selector must be in neutral. When the dump valve is open, the engine will stop if gear selector is moved from neutral. NOTE:
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5.
When emptying is completed, open manhole cover (F40) and check the vacuum outlet valve system. Rinse it with water if necessary.
WARNING:
Take precautions for personal safety against falling from the
roof.
2.8
HALT OF CHASSIS (21.09.2005)
The hydraulic system stops automatically. The c hassis itself can be stopped by turning the ignition key.
2.9
EMERGENCY MANOEUVRING OF BASKET (30.06.2008)
The basket can be emergency lowered: •
by pressing the down switch (8P6) - this requires that electrical power supply is available;
•
by pulling the wire located on the elevating system between the rear end of the vehicle and the basket. IMPORTANT: If
the basket is emergency lowered, the hose will not be automatically wound up.
2.10 FILLING OF FLUID (21.09.2005)
Filling of fluid takes place through the manhole on top of the tanks. To avoid overfilling/overflow, do not forget to keep an eye on the fluid level in the tank when filling in fluid. Should filling of fluid into the tanks cause that the operator is required to walk on the tanks, take the necessary precautions against falling. WARNING:
Take precautions for personal safety against falling from the
roof. The operator must also be aware that a galvanized walkway grating must be mounted to allow walking on unit top.
Do not step/walk on unit top if no walkway grating is mounted - unit top will be damaged. WARNING:
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2.11 EMERGENCY STOP (21.09.2005)
In case of an emergency, push emergency stop (9P6). By that all movements are frozen and the situation can be settled. Then reset emergency stop by turning it and resume the procedure.
2.12 CLEANING (21.09.2005)
To promote convenient and easy use of the VTS by the operator, and with view to authorised maintenance staff work, the unit must be kept clean and tidy, inside as well as outside. Cleaning also reduces the risk of infection from waste in the aircraft tanks. IMPORTANT: To
maintain steady operation and long life-time, the valve in top of the vacuum tank must be cleaned daily. Open the manhole cover and check, and if required, clean, the valve which is mounted on the inside of the cover. Flush the vacuum pump once every working day: IMPORTANT: Empty
waste tank before flushing starts.
1.
Place outlet from vacuum pump over drain before starting to flush.
2.
Disconnect suction hose from coupling heater to ensure sufficient airflow to vacuum blower.
3.
4.
Start flushing of the pump by pressing switch (2P2) located on panel P2 in the machine room. The flushing is PLC-controlled and will be made automatically. Flushing stops after approx. 4 min. Reconnect suction hose to coupling heater when flushing has stopped.
2.13 REVERSING AID (18.05.2009)
2.13.1
SENSORS
(18.05.2009)
The unit is equipped with a greensights reversing aid system, that can be a help when reversing against an obstacle.
When reversing close to an airplane with an APU (auxillery power unit) running the reversing aid system can be interferred. IMPORTANT:
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Panel Description 08.01.2004
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3.1 PANEL DESCRIPTION PANEL PANEL 2 PANEL 6 PANEL 26
3.2 CABLE LIST
6 0 0 6 N O T
1 3 13
CHAPTER
PANEL DESCRIPTION
Position:
PANEL 2 1P2
HOUR COUNTER (21.09.2005)
Counts when the engine is running.
2P2
FLUSHING OF VACUUM SYSTEM (21.09.2005)
Switch for start of flushing of vacuum pump system.
7P2
OVERRIDE SAFETY SENSORS (18.09.2014)
IMPORTANT :
DO NOT use during normal aircraft servicing. Only to be used when the unit is to be driven away with defective safety sensors. If the safety sensors fail, do the following: 1 Remove seal. 2. Remove switch plate using screwdriver. 3. Change position of switch. All safety sensors are now disabled and the unit can be driven away.
NOTE : The unit cannot
be used for aircraft servicing when the override of
sefety sensors is active. IMPORTANT :
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Do not use unit when seal is broken.
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PANEL DESCRIPTION
Position:
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PANEL DESCRIPTION
Position:
PANEL 6 1P6
DISPLAY (21.10.2008) (M)
Display on P6 shows fluid level in the tanks as well as status of various components on the VTS. Further, alarms and error messages are shown on the display.
Level screen
The main screen on the display is the Level screen. The fill levels of the 2 tanks are shown as 2 bar graphs with indication of filling percentage. An explanation of the different icons on the screen is below. View
Description
Water tank Waste tank Water pump Grey background - pump stopped Green background - pump is running Flashing - return suction Vacuum pump Grey background - pump stopped Green background - pump is running Vacuum valve Grey background - valve is closed Green background - valve is open
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PANEL DESCRIPTION
Position:
View
Description
Immobilizing - when shown, do as follows: On display P6: Toggle switch to view screen
PTO info - only shown on display P6 Flashing on display while the PTO is engaging
“Not in neutral” info - only shown on display P6 Flashing if a function is activated and chassis transmission is not in neutral Alarm - when shown, do as follows: On display P6: Toggle switch to view screen Error - when shown, do as follows: On display P6: Toggle switch to view screen
Immobilizing screen l
NOTE :
Immobilizing is a natural part of servicing an aircraft. When the VTS is immobilized, the movement will stop when parking brake is disen gaged.
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PANEL DESCRIPTION
Position:
Normal
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Flashing
Description
How to remedy
Normal: No error Flashing: Fluid coupling assembly is not in holder
Place coupling assembly in holder
Normal: No error Flashing: Waste coupling assembly not in holder
Place coupling assembly in holder
Normal: No error Flashing: Waste valve is open
Close waste valve
Normal: No error Flashing: Platform is not in lower position
Use switches on P6 to move the platform down
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PANEL DESCRIPTION
Position:
Alarms and errors
When an alarm or error arises, a flashing "!" (exclamation mark) will appear in upper right corner of and P6. - Toggle switch "A" on display P6 to display the error screen.
Normal
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Flashing
Type
How to remedy
Not shown
Alarm
Flashing Alarm is on
Switch to error screen for explanation of alarm See manual
Not shown
Error
Flashing Error is present
Switch to error screen for explanation of error See manual
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Description
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PANEL DESCRIPTION
Position:
For an explanation of the errors, see table below:
Normal
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Flashing
Type
Description
How to remedy
Error
Normal: No errors Flashing: No communication between display and PLC
Check connection to the PLC as well as wiring between display and PLC. See manual
Error
Normal: No errors Flashing: No communication between node in P2 and PLC
Check connection to the node as well as wiring between node and PLC. See manual
Error
Normal: No errors Flashing: No communication between node in P6 and PLC
Check connection to the node as well as wiring between node and PLC. See manual
Error
Normal: No errors Flashing: No communication between node in P58 and PLC
Check connection to the node as well as wiring between node and PLC. See manual
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PANEL DESCRIPTION
Position:
Normal
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Flashing
Type
Description
How to remedy
Error
Normal: No errors Flashing: No communication between chassis and PLC
Check wiring between chassis and PLC
Error
Normal: No errors Flashing: Emergency stop activated
Reset emergency stop and restart chassis
Error
Normal: No errors Flashing: Oil level in hydraulic tank is too low
Refill oil. For quantity and type, see manual. After refill, restart chassis.
Error
Normal: No errors Flashing: Hydraulic oil is too hot
Leave the oil cooling. After cooling, restart chassis.
Error
Normal: No errors Flashing: No water flow detected
Check that disin pump is working and that hose is not clogged or broken
Alarm
Normal: No alarm. Flashing: Low level in VTS water tank
Refill disin
Alarm
Normal: No alarm. Flashing: High level in VTS waste tank
Empty waste tank of VTS
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PANEL DESCRIPTION
Position:
Normal
3P6
Flashing
Type
Description
How to remedy
Alarm
Normal: No alarm. Flashing: Vacuum pump must be flushed
Flush pump at next emptying operation
VACUUM PUMP - ON/OFF (21.09.2005)
3P6 - position “ON” When 3P6 is placed in position “ON”, the vacuum pump starts and vacuum will be build up in the waste tank.
3P6 - position “OFF” When 3P6 is placed in position “OFF”, the vacuum pump stops.
5P6
VACUUM VALVE OPEN/CLOSE (21.09.2005)
5P6 - position “OPEN” When 5P6 is activated, the vacuum valve opens.
5P6 - position “CLOSE” When 5P6 is activated, the vacuum valve closes.
7P6
PLATFORM UP - PLATFORM DOWN/FLUID HOSE IN (21.09.2005)(M)
7P6 - position “UP” When in this position, the basket will be lifted. The hose follows it.
7P6 - position “DOWN” When the switch is in this position, the basket will be lowered at the same time as the hose is being wound up.
8P6
EMERGENCY LOWERING OF BASKET (21.09.2005)
In an emergency, the basket can be lowered by pressing 8P6. I t requires electrical power supply, however.
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PANEL DESCRIPTION
Position:
9P6
EMERGENCY STOP (21.09.2005)
When you press emergency stop, build-up will stop.
20P6
WATER ON/OFF (18.09.2014)
20P6 - position “ON” When 20P6 is placed in position “ON”, the fluid pump starts and water will be filled onto the water tanks of the aircraft.
20P6 - position “OFF” The fluid pump stops and the return suction starts automatically when 20P6 is placed in position “OFF”. Water will be sucked from the pressure hose and the aircraft pipe system back to the water tank. Return suction takes about 16 seconds, then it stops automatically. After return suction, the hose is emptied of water. IMPORTANT: When
the aircraft is to be filled with water, always add 5 litres of fluid. This is the approximate fluid volume in the hose which will be sucked back to the tank during return suction.
22P6
OPERATION OF PLATFORM (04.04.2011)
Activate this switch together with switch 7P6 to raise platform.
23P6
DISPLAY (04.04.2011)
For description, see 1P6.
25P6
B (04.04.2011)
Refers to text on display for selection of function.
26P6
A (04.04.2011)
Refers to text on display for selection of function.
27P6
PRESELECTION UP/DOWN X1 (18.09.2014)
Press up/down to increase or decrease preselection by 1 litre.
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PANEL DESCRIPTION
Position:
28P6
NOT USED (18.09.2014)
29P6
PRESELECTION UP/DOWN X10 (18.09.2014)
Press up/down to increase or decrease preselection by 10 litre.4
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PANEL DESCRIPTION
Position:
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PANEL DESCRIPTION
Position:
PANEL 26 2P26
LAMP FOR HYDRAULIC SYSTEM (07.01.2004)
The lamp will light when the hydraulic system is connected.
4P26
LIGHT (21.09.2005)
Switch for working light and light in the machine room.
8P26
DUMP VALVE (21.09.2005)
Open dump valve F96 with this switch. 8 P1 must be operated simultaneously with 9P1 in order to open dump valve.
9P26
DUMP VALVE (21.09.2005)
Open/close dump valve F96 with this switch. 9 P1 must be operated simultaneously with 8P1 in order to open dump valve.
16P26 AMBER FLASHING BEACON ON/OFF (21.09.2005)
26P26 HYDRAULIC ERROR (08.10.2007)
If 26P1 goes ON, an error occurred in the hydraulic system - either the oil temperature in the tank is too hot (>85°C) or the oil level in the tank is below minimum. When 26P1 goes on, the hydraulic system (PTO) will automatically disconnect, and the chassis engine will automatically stop. It is not possible to reengage the hydraulic system, as long as the oil is too hot.
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Position:
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Position:
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Position:
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Position:
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Position:
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PANEL DESCRIPTION
Position:
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20.11.2008 REV: 000
INDEX CHAPTER
Maintenance 08.01.2004
Page
REV: 000
4.1 MAINTENANCE 1.
BASIC UNIT
1
2.
CHASSIS
2
3.
FLUID SYSTEM
2
45.
OPTIONS
3
4.2 MAINTENANCE CHARTS 1.
BASIC
2
2.
CHASSIS
3
3.
FLUID
3
4.
OPTIONS
3
4.3 ADJUSTMENT
6 0 0 6 N O T
CHAPTER
4.1
MAINTENANCE
MAINTENANCE The following are comments to the schematic maintenance program presented in the end of this chapter.
1.
BASIC UNIT (21.09.2005)
1.2
Cleaning of hydraulic tank (21.09.2005)
At least once a year the hydraulic tank must be cleaned and rinsed thoroughly.
1.3
Hydraulic filters (08.01.2004)
At least once a year, filters H19 and H41 must be exchanged.
1.4
Hydraulic system - overall check (21.09.2005)
-
Check the hydraulic system for leakages daily. To be able to locate any leakage, for example at connections and couplings, keep all hoses, pipes, valves and cylinders constantly clean. This is to ensure the operationality of the hydraulic system.
1.6
Inspection of fluid tank (21.09.2005)
At least once a year the fluid tank should be inspected thoroughly.
1.9
Check of fluid counter (21.09.2005)
1.
To check the fluid counter, start the water pump.
2.
When water flows out of the hose, press “STOP” and “reset”. By that there will be no return suction.
3.
Start the pump again and let a certain amount of water flow into a reservoir.
4.
Stop the pump again.
5.
Crosscheck the amount of fluid in the reservoir and the amount indicated on the fluid counter. For more information, we refer to the special instructions.
1.12
Check of pumps
(08.01.2004)
When servicing the fluid pump, follow the special instructions. This is to ensure the operationality of the fluid system.
1.13
Fluid system - overall check
(21.09.2005)
-
Check the fluid system for leakages daily. To be able to locate any leakage, for example at connections and couplings, keep all hoses, pipes and valves constantly clean. The cleaning includes as well the inside as the outside of the fluid system.
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CHAPTER
1.18
MAINTENANCE
Inspection of waste tank
(21.09.2005)
At least once a year the waste tank ought to be inspected thoroughly. The inspection can be done by entering the tank through the manhole.
1.19
Vacuum pump
(28.03.2007)
Flush vacuum pump every day - see chapter 2, section 2.13, Cleaning, for description.
1.20
Waste system - overall check
(21.09.2005)
-
Check the waste system for leakages daily. To be able to locate any leakage, for example at connections and couplings, keep all hoses, p ipes and valves constantly clean. The cleaning includes as well the inside as the outside of the waste system.
1.22
Vacuum check valve F192
(12.03.2008)
In order to ensure an optimum of vacuum in the tank during servicing, the vacuum valve must be inspected and cleaned every day. -
Open manhole cover F40 to access the vacuum valve.
We recommend that you verify the vacuum after inspection and cl eaning - 0,25 bar should be created when in operation. Refer also to section 1.19 for daily flushing of the vacuum pump.
1.23
Breather filter F35
(21.09.2005)
-
2.
Check filter for clogging. Replace if required.
CHASSIS (21.09.2005)
2.1
Chassis - overall check (21.09.2005)
Service on the chassis is to be carried out in accordance with the manufacturer’s recommendations. However, it must be noticed that this kind of operation is very unusual (few kilometres of driving, but many working hours with the engine running idle), and the maintenance procedure must be adapted accordingly. To increase serviceability/lifetime of the chassis and due to the environment the unit works in, we recommend that a yearly complete paint/corrosion inspection is done on chassis parts like framework, springs, stabilizers, axles, engine, air system etc. including bolts/nuts. Should any parts show signs of missing paint or beginning corrosion, we recommend that the parts are thoroughly cleaned and repainted/retreated against corrosion to avoid corrosion to develop.
3.
FLUID SYSTEM (21.09.2005)
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4.1
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31.03.2009 REV: 000
CHAPTER
4.
MAINTENANCE
OPTIONS (31.03.2009)
4.1.2
Elevating platform
(31.03.2009)
As specified int the maintenance charts, the lifting system must be inspected throughly both with regard to construction elements, welding and the hydraulic components. Further the tightening of all bolts and nuts must be checked as specified. For service and maintenance instructions, please refer to special instructions in chapter 8.
31.03.2009 REV: 000
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MAINTENANCE
TON 6006 4
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MAINTENANCE CHARTS
CHAPTER
4.2
MAINTENANCE CHARTS For more detailed maintenance information, see chapter 4-1. Service intervals have been organized in the following groups:
Service intervals
A
B
C
After working hours
8
250
500
or every
Day
3 months
year
Service codes are as follows : Service code
Service to be done
C
Check
E
Exchange
L
Lubricate/Replenish
A
Adjust
Cl
Clean
Lubricants to be used when performing the service: Lubricants No.
Recommended type
Article no.
Alternative
1
Nulon LEP82
0003912
Statoil Greaseway CaH 92 or Shell Albida EP2 (0028009)
2
Shell Tellus S32
0028212
Statoil Hydraway HM32 Texaco Rando HD 32 Esso Univis N32 Elf Elfolna DS 32 Castrol Hyspin AWS 32 Agip OSO 32
3
SAE 15W - 40
4
Copper paste PBC Grade 492
5
SAE 20W - 50
31.03.2009 REV: 000
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CHAPTER
MAINTENANCE CHARTS
Maintenance of VTS
A
B
C-L
C-L
C
Type
X
1. BASIC 1.1 (01.06.2006)
1.2 (21.09.2005)
1.3
Level check of hydraulic oil. Renew oil every 2nd year
E-C-Cl
Cleaning of hydraulic tank
CI
Hydraulic filters H19
E
2
(21.09.2005)
1.4 (21.09.2005)
1.5 (21.09.2005)
1.6
Hydraulic fittings, valves, and pipes
C
Pumps and motors H1+H2+H3+H4
Cl
Cl
See special instructions
Fluid tank, Inspection
C
(21.09.2005)
1.7 (21.09.2005)
1.8 (21.09.2005)
1.9 (21.09.2005)
1.10 (21.09.2005)
1.12
Manhole covers F39 and F40
L
L
1
Bearings of hose reel, F34,
L
L
1
Check fluid flow indicator / fluid counter
C
C
Check fluid pressure: F13
C-A
C-A
Pumps F2
See special instructions
(21.09.2005)
1.13 (21.09.2005)
1.15 (21.09.2005)
1.17
Fluid fittings, valves, pipes,tank
C
Cl
Cl
Check all functions on operation panel
C
C
Door hinges
L
L
1
(21.09.2005)
1.18
Waste tank, inspection
C
(21.09.2005)
1.19
Vacuum pump, F1
Cl
Waste fittings, valves, pipes, tank
C
CI
CI
Vacuum check valve, F192
CI-A
CI-A
CI-A
(21.10.2008)
1.20 (21.09.2005)
1.22 (30.06.2008)
1.23
Breather filter, F38
C (E)
(21.09.2005)
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4.2
PAGE
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31.032009 REV: 000
CHAPTER
MAINTENANCE CHARTS
Maintenance of VTS
A
B
C
Type
X
2. CHASSIS 2.1
CHASSIS
(21.09.2005)
Maintenance of chassis
See manual for chassis
Oil level in chassis engine Type to be specified by manufacturer
C-L
C-L
C-L
Oil level in gearbox Type to be specified by manufacturer
C-L
C-L
C-L
Chassis engine - coolant level Type: Original coolant/ liquid
C-L
C-L
C-L
Tyre: Pressure: General conditions. Pressure (see chassis specification)
C-L
C-L
C-L
3. FLUID 4. HEATING 4.1
Fuel heating system
C
(21.09.2005)
4.2
Option not chosen
4.3
Option not chosen
4.4
Option not chosen
4.5
Option not chosen
4.6
Steam generator
C
Elevating platform
C-A
(21.09.2005)
5. OPTIONS 5.1.2 (31.03.2009)
5.1.5
Option not chosen
(02.12.2005)
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CHAPTER
4.2
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MAINTENANCE CHARTS
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ADJUSTMENTS
CHAPTER
4.3
ADJUSTMENTS
4.3.1
ADJUSTMENT OF HYDRAULIC SYSTEM
(17.08.2011)
4.3.1.1.
Adjustment of hydraulic pressure and flow: (17.08.2011) (M)
Check and adjustment of hydraulic presure: -
Mount presure gauge in H85.
-
Activate lift down in basket (keep activating until fully down)
-
Keep activation lift down. Adjust H9 to 180 bar.
-
Remove pressure gauge in H85
Check and adjustment of hydraulic flow:
4.3.2
-
Activate water pump in basket;
-
Adjust H31so that F2 rotates with 3100 ± 200 rev/min.
ADJUSTMENT OF WATER SYSTEM
(17.08.2011) (M)
Rev. of water pump -
Speed (3100 rpm)
Tolerance ±200 rpm
Adjust on: H31
Adjust maximum pressure of the individual pumps according to the diagram.
Pressure adjustment procedure is as follows: -
Mount a coupling counter part with a ball valve on F41.
-
Engage water pump in basket.
-
Close ball valve on counter part slowly.
-
Read actual pressure on F19.
-
Adjust F13 to pressure indicated in fluid diagram.
-
Disengage water pump, open ball valve to release water pressure and dismount coupling counter part.
17.08.2011 REV: 000
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CHAPTER
4.3
PAGE
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ADJUSTMENTS
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INDEX CHAPTER
Hydraulic 08.01.2004
Page
REV: 000
5.1 Hydraulic diagram Symbols for the hydraulic diagram 5.2 Parts list 5.3 Special instructions
6 0 0 6 N O T
H1 2 1
INDEX CHAPTER
Fluid 08.01.2004
Page
REV: 000
6.1 Fluid diagram Symbols for Fluid diagram 6.2 Parts list 6.3 Special instructions (
6 0 0 6 N O T
F1 2 1
