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STINAR Flush & Fill Cart SFFC-70/2 Manual

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FLUSH & FILL CART
O P E R A T I O N & M A I N T E N A N C E M A N U A L
MODEL: SFFC-70/2
sales@stinar.com
|
P 651.454.5112
|
F 651.454.5143
|
www.stinar.com
REV.10.2020

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Summary of Contents for STINAR Flush & Fill Cart SFFC-70/2

  • Page 1 FLUSH & FILL CART O P E R A T I O N & M A I N T E N A N C E M A N U A L MODEL: SFFC-70/2 sales@stinar.com P 651.454.5112 F 651.454.5143 www.stinar.com REV.10.2020...
  • Page 2 Effective pages SECTION PAGE DATE Title Page January 2021 List of Effective Pages January 2021 Contents January 2021 Introduction January 2021 SECTION 1 Introduction 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 January 2021...

  • Page 3: Table Of Contents

    Table of Contents MANUAL OVERVIEW � � � � � � � � � � � � � � � � � � � � � � � � � � 7 SECTION 1 | GENERAL INFORMATION & OPERATING PROCEDURES � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 8 1�1 | Description �...
  • Page 4 2.1.2 | Coolant System ........35 2.1.2.1 | Coolant Tank .

  • Page 5: 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...

  • Page 6: Procedures

    SECTION 1 | GENERAL INFORMATION & OPERATING PROCEDURES 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.
  • Page 7 • 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.
  • Page 8 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.

  • Page 9: Equipment Systems And Components

    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.
  • Page 10 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.
  • Page 11 FIGURE 1.1.1 | FLUSH & FILL CART MODEL SFFC-70/2 Pump Waste Tank Motor Clean Tank Filter Control Box Coolant Fill Port Return Hose Main Valve Bank Supply Hose Tow Bar Ground Cable Bleed Hose Flush & Fill Cart SFFC-70/2 | 11...
  • Page 12 FIGURE 1.1.1.2 | COOLANT SYSTEM (FILL MODE) Flush & Fill Cart SFFC-70/2 | 12...

  • Page 13: Electric Motor

    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.
  • Page 14 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...
  • Page 15 FIGURE 1.1.1.4 | ELECTRICAL SYSTEM THERMOSTAT Flush & Fill Cart SFFC-70/2 | 15...

  • Page 16: Operating Controls And Indicators

    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.
  • Page 17 FIGURE 1.2.3 | COOLANT TANK OPERATION Pump Waste Tank Motor Clean Tank Heater ON/OFF Pump Coolant Fill Port ON/OFF Filter Electric Cable Return Hose Main Valve Bank Supply Hose Tow Bar Ground Cable Bleed Hose Flush & Fill Cart SFFC-70/2 | 17...

  • Page 18: Operating Procedures

    SECTION 1 | GENERAL INFORMATION & OPERATING PROCEDURES 1.2.3 | Operating Procedures WARNING! ALWAYS HAVE THE PUMP 1.2.3.1 | Filling the Coolant Tank SHUT OFF WHEN CHANGING PROCEDURES AND VALVE The fill coupling for the fresh coolant tank is located on top of the tank. To POSITIONS.
  • Page 19 FIGURE 1.2.3.3 | FLUSH AND FILL MODE Flush & Fill Cart SFFC-70/2 | 19...

  • Page 20: Flushing The System (Figure 1.2.3.3 A)

    SECTION 1 | GENERAL INFORMATION & OPERATING PROCEDURES 1.2.3.3 | Flushing the System (Figure 1.2.3.3) WARNING! 1. Position the flush and fill cart near the aircraft’s service panel and set ENSURE NO POWER IS APPLIED the carts brakes. TO THE POWER CABLE WHEN DISCONNECTING FROM THE 2.
  • Page 21 FIGURE 1.2.3.5 | DEAERATE MODE Flush & Fill Cart SFFC-70/2 | 21...

  • Page 22: Deaerate (Figure 1.2.3.5 A)

    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.
  • Page 23 FIGURE 1.2.3.6 | PUMPING OUT OF THE WASTE TANK Flush & Fill Cart SFFC-70/2 | 23...

  • Page 24: Pumping Out Waste Tank (Figure 1.2.3.6)

    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.

  • Page 25: Towing The Flush And Fill Cart

    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.

  • Page 26: Specifications And Capabilities

    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%...
  • Page 27 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...

  • Page 28: Section 2 | Servicing The Flush And Fill Cart

    SECTION 2 | SERVICING THE FLUSH AND FILL CART 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...

  • Page 29: Cart Chassis

    If such repairs are necessary, 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) •...
  • Page 30 FIGURE 2.1.2.1 | COOLANT TANK DRAIN Flush & Fill Cart SFFC-70/2 | 30...

  • Page 31: Pump

    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.

  • Page 32: Non-Scheduled Service

    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...

  • Page 33: Troubleshooting

    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.
  • Page 34 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.
  • Page 35 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...

  • Page 36: Adjustments

    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.

  • Page 37: Section 3 | Overhaul

    SECTION 3 | OVERHAUL 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.

  • Page 38: Section 4 | Parts List

    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...

  • Page 39: Manufacturer Identification

    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...

  • Page 40: Detailed Parts List

    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...

  • Page 41: Parts Order Form

    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...
  • Page 42 FIGURE 4.3.1 | FLUSH AND FILL CART MODEL SFFC-70/2 15-20 Flush & Fill Cart SFFC-70/2 | 42...
  • Page 43 FIGURE 4.3.1 | FLUSH AND FILL CART MODEL SFFC-70/2 - TABLE VENDOR FIG ITEM # MFG PART # DESCRIPTION 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 ...
  • Page 44 FIGURE 4.3.2 | FRONT AXLE ASSEMBLY Flush & Fill Cart SFFC-70/2 | 44...
  • Page 45 FIGURE 4.3.2 | FRONT AXLE ASSEMBLY - TABLE VENDOR FIG ITEM # MFG PART # DESCRIPTION CODE 4.3.2-0  040147  Front Axle Assembly, 48 in V32526  1  -1  030617 Towbar Assembly V32526 -2  607006 Towbar Latch V32526 -3  940018 Flex-top locknut, ½"-13 V32526 -4 ...
  • Page 46 FIGURE 4.3.3 | WHEEL HUB ASSEMBLY Flush & Fill Cart SFFC-70/2 | 46...
  • Page 47 FIGURE 4.3.3 | WHEEL HUB ASSEMBLY - TABLE VENDOR FIG ITEM # MFG PART # DESCRIPTION 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 ...
  • Page 48 FIGURE 4.3.4 | COOLANT SYSTEM Flush & Fill Cart SFFC-70/2 | 48...
  • Page 49 FIGURE 4.3.4 | COOLANT SYSTEM - TABLE 1 VENDOR FIG ITEM # MFG PART # DESCRIPTION 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 ...
  • Page 50 FIGURE 4.3.4 | COOLANT SYSTEM - TABLE 2 VENDOR FIG ITEM # MFG PART # DESCRIPTION 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” ...
  • Page 51 FIGURE 4.3.8 | ELECTRICAL SYSTEM Flush & Fill Cart SFFC-70/2 | 51...
  • Page 52 FIGURE 4.3.8 | ELECTRICAL - TABLE VENDOR FIG ITEM # MFG PART # DESCRIPTION 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 ...

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