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SECTION 1 | GENERAL INFORMATION & OPERATING PROCEDURES

Flush & Fill Cart SFFC-70/2 | 7

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.

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

Page 1: ...sales stinar com P 651 454 5112 F 651 454 5143 www stinar com REV 10 2020 FLUSH FILL CART O PE R AT I O N M A I N T E NAN CE M AN UAL MODEL SFFC 70 2...

Page 2: ...on 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 Ja...

Page 3: ...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...

Page 4: ...1 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 F...

Page 5: ...erating Instructions Includes a unit description recommended procedures for operation plus specifications and capabilities Section 2 Servicing The Flush Fill Cart Provides unit maintenance information...

Page 6: ...tor and others avoid accident involvement NOTE The word NOTE is used to denote something that can cause minor machine damage or poor performance if ignored IMPORTANT The word IMPORTANT informs the rea...

Page 7: ...lly 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...

Page 8: ...pend 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...

Page 9: ...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 st...

Page 10: ...ERATING PROCEDURES Flush Fill Cart SFFC 70 2 10 COMPONENT DESCRIPTION Level Gauges The gauges are located on the left side of the fresh tank and the right side of the waste tank They indicate the leve...

Page 11: ...ll Cart SFFC 70 2 11 FIGURE 1 1 1 FLUSH FILL CART MODEL SFFC 70 2 Pump Motor Return Hose Supply Hose Bleed Hose Ground Cable Waste Tank Clean Tank Control Box Filter Coolant Fill Port Main Valve Bank...

Page 12: ...Flush Fill Cart SFFC 70 2 12 FIGURE 1 1 1 2 COOLANT SYSTEM FILL MODE...

Page 13: ...the aircraft This diaphragm pump is belt driven by the motor and runs whenever the motor is running Meter The meter measures in gallons the amount of coolant pumped to the aircraft The meter is direc...

Page 14: ...MATION OPERATING PROCEDURES Flush Fill Cart SFFC 70 2 14 COMPONENT DESCRIPTION Electric Motor 10 Horsepower AC Electric Motor 1760 RPM 3Phase Heater Heater 440V 3Ph 60Hertz 12000W W 60 250DegF Intrega...

Page 15: ...Flush Fill Cart SFFC 70 2 15 FIGURE 1 1 1 4 ELECTRICAL SYSTEM THERMOSTAT...

Page 16: ...on the aircraft end of the supply hose Closing this valve prevents water in the hose from spilling after the hose is disconnected from the aircraft Meter The meter is located directly above the main v...

Page 17: ...FC 70 2 17 FIGURE 1 2 3 COOLANT TANK OPERATION Pump Motor Return Hose Supply Hose Bleed Hose Ground Cable Waste Tank Clean Tank Pump ON OFF Heater ON OFF Filter Coolant Fill Port Electric Cable Main V...

Page 18: ...1 2 3 for the location of the return hose NOTE Comply with Airline Operating and Service Manuals for ap proaching aircraft and parking WARNING ALWAYS HAVE THE PUMP SHUT OFF WHEN CHANGING PROCEDURES A...

Page 19: ...Flush Fill Cart SFFC 70 2 19 FIGURE 1 2 3 3 FLUSH AND FILL MODE...

Page 20: ...HEN CONNECTING TO THE SERVICE CART 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 t...

Page 21: ...Flush Fill Cart SFFC 70 2 21 FIGURE 1 2 3 5 DEAERATE MODE...

Page 22: ...n 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...

Page 23: ...Flush Fill Cart SFFC 70 2 23 FIGURE 1 2 3 6 PUMPING OUT OF THE WASTE TANK...

Page 24: ...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 h...

Page 25: ...he 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 dow...

Page 26: ...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 Hor...

Page 27: ...ENERAL INFORMATION OPERATING PROCEDURES Flush Fill Cart SFFC 70 2 27 CLEAN AND CONTAMINATED COOLANT HOSE Length 50 ft 15 24 m Inside Diameter in 19 mm BLEED HOSE Length 75 ft 22 8 m Inside Diameter 3...

Page 28: ...re recommended by the manufacturer and are intended to assist service personnel in developing their own service schedules based on their specific environment No special tools are required other than t...

Page 29: ...rimer and finish paint materials Clean areas that are extremely oily or greasy with mineral solvents and degreasers before painting 2 1 2 Coolant System 2 1 2 1 Coolant Tank The coolant tank may be dr...

Page 30: ...Flush Fill Cart SFFC 70 2 30 FIGURE 2 1 2 1 COOLANT TANK DRAIN V8...

Page 31: ...cal 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...

Page 32: ...ar 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...

Page 33: ...es 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 Cart will not turn left or right T...

Page 34: ...regular flow Pump problem See pump troubleshooting in Appendix B Motor malfunctioning See motor adjustments Motor to pump drive belt damaged Replace belt Water tank breather vent clogged Clean breathe...

Page 35: ...Flush Fill Cart SFFC 70 2 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...

Page 36: ...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 f...

Page 37: ...mended 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 comp...

Page 38: ...g 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...

Page 39: ...SECTION 4 PARTS LIST Flush Fill Cart SFFC 70 2 39 FED SUPPLY CODE MANUFACTURER V32526 Stinar LLC 10061 State Hwy 30 Blooming Prairie MN 55917 4 1 MANUFACTURER IDENTIFICATION...

Page 40: ...d 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...

Page 41: ...nt 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 T...

Page 42: ...Flush Fill Cart SFFC 70 2 42 FIGURE 4 3 1 FLUSH AND FILL CART MODEL SFFC 70 2 10 9 23 15 20 1 21 8 7 12 25 22 14 3 13 11 2 4 5 6...

Page 43: ...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 3140...

Page 44: ...Flush Fill Cart SFFC 70 2 44 FIGURE 4 3 2 FRONT AXLE ASSEMBLY...

Page 45: ...asher V32526 1 5 938084 Hex head Cap Screw 13 1 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...

Page 46: ...Flush Fill Cart SFFC 70 2 46 FIGURE 4 3 3 WHEEL HUB ASSEMBLY A A SECTION A A 1 5 2 4 3...

Page 47: ...QTY 4 3 3 0 603044 Wheel Hub V32526 4 1 603045 Seal 1 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...

Page 48: ...Flush Fill Cart SFFC 70 2 48 FIGURE 4 3 4 COOLANT SYSTEM...

Page 49: ...2526 1 11 403152 Immersion Heater V32526 1 12 302021 1 Gate Valve V32526 2 13 304013 Y Strainer V32526 2 14 315000 Visiflow V32526 1 15 302108 Check Valve V32526 2 16 302167 Check Valve V32526 1 17 30...

Page 50: ...0 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...

Page 51: ...Flush Fill Cart SFFC 70 2 51 FIGURE 4 3 8 ELECTRICAL SYSTEM...

Page 52: ...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...

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