FLUSH & FILL CART - MODEL: SFFC-70/2 - OPERATION & MAINTENANCE MANUAL - Stinar

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FLUSH & FILL CART - MODEL: SFFC-70/2 - OPERATION & MAINTENANCE MANUAL - Stinar
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
FLUSH & FILL CART - MODEL: SFFC-70/2 - OPERATION & MAINTENANCE MANUAL - Stinar
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
FLUSH & FILL CART - MODEL: SFFC-70/2 - OPERATION & MAINTENANCE MANUAL - Stinar
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
FLUSH & FILL CART - MODEL: SFFC-70/2 - OPERATION & MAINTENANCE MANUAL - Stinar
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
FLUSH & FILL CART - MODEL: SFFC-70/2 - OPERATION & MAINTENANCE MANUAL - Stinar
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
FLUSH & FILL CART - MODEL: SFFC-70/2 - OPERATION & MAINTENANCE MANUAL - Stinar
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
FLUSH & FILL CART - MODEL: SFFC-70/2 - OPERATION & MAINTENANCE MANUAL - Stinar
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
FLUSH & FILL CART - MODEL: SFFC-70/2 - OPERATION & MAINTENANCE MANUAL - Stinar
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
FLUSH & FILL CART - MODEL: SFFC-70/2 - OPERATION & MAINTENANCE MANUAL - Stinar
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
FLUSH & FILL CART - MODEL: SFFC-70/2 - OPERATION & MAINTENANCE MANUAL - Stinar
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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