MODELS TL600/TL700 LAVATORY SERVICE TRUCK Property of ... · tl600/tl700 lavatory service truck may...
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MODELS TL600/TL700
LAVATORY SERVICE TRUCK
MAINTENANCE
MANUAL
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PHOENIX METAL PRODUCTS, INC
TL600/TL700 LAVATORY SERVICE TRUCK
2 MAY 2018
COPYRIGHT RELEASE
THIS PUBLICATION IS INTENDED FOR THE SOLE USE OF OWNERS AND OPERATORS OF THE
EQUIPMENT LISTED ON THE COVER. REPRODUCTION AND DISTRIBUTION OF THIS PUBLICATION
IS AUTHORIZED TO THE OWNERS AND OPERATORS OF THE PRODUCT. USE BY OTHERS FOR
PURPOSES NOT DIRECTLY RELATED TO THE FACILITATION OF OPERATION OR MAINTENANCE
OF THIS PRODUCT IS PROHIBITED. MISUSE OF THIS PUBLICATION WILL BE PROSECUTED TO THE
FULL EXTENT OF THE LAW.
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PHOENIX METAL PRODUCTS, INC
TL600/TL700 LAVATORY SERVICE TRUCK
3 MAY 2018
EFFECTIVE CHANGES
THE FOLLOWING IS A LIST OF REVISIONS AS DESCRIBED BELOW WITH
HIGHLIGHTS OF THE REVISIONS. PLEASE DELETE ALL AFFECTED PAGES AND
INSERT THE REVISED PAGES.
CHAPTER SECTION & DESCRIPTION OF CHANGE SERIAL#
PAGE EFFECTIVITY
1-3, PAGE 31 UPDATE PICTURE
2-5, PAGE 52 UPDATE NEW SWITCH OPERATION
3-3, PAGE 92 UPDATE PARTS LIST
3-3, PAGE 93 UPDATE DRAWING
3-6, PAGE 154 UPDATE PARTS LIST
3-6, PAGE 155 UPDATE DRAWING
3-6, PAGE 156 UPDATE PARTS LIST
3-6, PAGE 157 UPDATE PICTURE
2-5, PAGES 58-60 ADD SCHEMATICS FOR 2017 FORD TRUCK
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PHOENIX METAL PRODUCTS, INC
TL600/TL700 LAVATORY SERVICE TRUCK
4 MAY 2018
SAFETY PRECAUTIONS
THE PHOENIX METAL PRODUCTS, INC., MODEL TL600 IS A VEHICLE DESIGNED TO SERVICE
THE LAVATORIES OF COMMERCIAL AND MILITARY AIRCRAFT. THE VEHICLE IS A
COMMERCIAL CHASSIS MODIFIED WITH TANKS AND PUMPING SYSTEMS TO ACCOMPLISH THE
SERVICING OF AIRCRAFT LAVATORIES.
DRIVABILITY
THERE ARE CERTAIN PRECAUTIONS THAT SHOULD BE TAKEN WHILE OPERATING THIS
VEHICLE. THIS VEHICLE IS INTENDED PRIMARILY FOR OFF ROAD USE. ALTHOUGH THE
VEHICLE IS CAPABLE OF HIGHWAY SPEEDS, IT SHOULD NOT BE DRIVEN IN EXCESS OF 35
MPH. THIS VEHICLE IS CAPABLE OF CARRYING THE MAXIMUM DESIGNED LOAD OF THE
CHASSIS. HIGHWAY PERFORMANCE AND HANDLING ARE GREATLY REDUCED WHEN THE
VEHICLE IS CARRYING THE ALLOWABLE PAYLOAD. STOPPING CAPABILITIES ARE REDUCED
DUE TO EXTREME LOAD CAPACITIES. MAKE SURE TO ALLOW FOR AN EXTRA 20 FEET OF
STOPPING DISTANCE WHILE MANEUVERING AROUND OTHER VEHICLES AND AIRCRAFT.
OVERHEAD CLEARANCE
IF THIS VEHICLE IS EQUIPPED WITH A TELESCOPIC PEDESTAL LIFT FOR SERVICING AIRCRAFT
WITH LAVATORY ACCESS HIGHER THAN 8 FEET. EXTREME CAUTION SHOULD BE USED WHEN
OPERATING ANY LIFTING DEVICE. THE OPERATOR MUST ASSURE THAT THERE IS SUFFICIENT
OVERHEAD CLEARANCE BEFORE OPERATING THE PEDESTAL LIFT. ALTHOUGH MOST
OPERATIONS THAT WOULD NORMALLY BE CONDUCTED WITH THIS VEHICLE WOULD NOT BE
DONE AROUND OVERHEAD POWER LINES, IT IS NOT UNTHINKABLE THAT WHILE TESTING,
DEMONSTRATING OR INSTRUCTING PERSONNEL THAT THERE MAY BE SOME TYPE OF
OVERHEAD POWER LINES IN THE VICINITY. ALWAYS MAKE SURE THAT YOU IDENTIFY THE
HAZARDS IN A 360 DEGREE ARC AND 16 FEET ABOVE THE GROUND BEFORE OPERATING THE
PEDESTAL LIFT.
110 VOLT ELECTRIC SUPPLIES
THE TL600 LAVATORY SERVICE TRUCK CAN BE SUPPLIED WITH A COLD WEATHER PACKAGE.
IT MAY CONSIST OF (4) HEATERS—ALL OF WHICH ARE 110 VOLTS. THERE IS A 50 AMP MALE
OUTLET MOUNTED ON THE DRIVERS SIDE, FORWARD MOST PANEL. THAT IS WERE THE
VEHICLE WOULD BE PLUGGED IN FROM A POWER SOURCE FROM THE BUILDING. IT IS VERY
IMPORTANT TO MAKE SURE THE VEHICLE IS NOT PLUGGED IN BEFORE IT IS DRIVEN AWAY.
SEVERE DAMAGE TO THE PLUG AND OUTLET WILL OCCUR IF THE VEHICLE IS DRIVEN AWAY
WHILE IT IS PLUGGED INTO THE BUILDING. EXTREME CARE SHOULD BE USED WHEN
TROUBLE SHOOTING THE HEATING SYSTEM. MAKE SURE THE UNIT IS UNPLUGGED.
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PHOENIX METAL PRODUCTS, INC
TL600/TL700 LAVATORY SERVICE TRUCK
5 MAY 2018
TABLE OF CONTENTS
CHAPTER
/SECTION
PAGE
COPYRIGHT RELEASE 2
REVISIONS /CHANGES 3
SAFETY PRECAUTIONS 4
INTRODUCTION 6
1 GENERAL INFORMATION AND OPERATION INSTRUCTIONS
1-1 SPECIFICATIONS AND CAPABILITIES 7
1-2 SYSTEM DESCRIPTION 15
1-3 OPERATION 20
2 MAINTENANCE AND SERVICING INSTRUCTIONS
2-1 SYSTEM DESCRIPTION 37
2-2 SERVICING/LUBRICATION 39
2-3 INSPECTIONS 41
2-4 ADJUSTMENTS 44
2-5 TROUBLESHOOTING/SCHEMATICS 53
2-6 PREPARATION FOR SHIPMENT 70
2-7 PREPARATION FOR STORAGE 71
2-8 DISASSEMBLY, REPAIR, REASSEMBLY AND REPLACEMENT 72
3 ILLUSTRATED PARTS LIST
OVERVIEW 75
TABLE OF CONTENTS 76
3-1 MAIN ASSEMBLY 77
3-2 PLUMBING 84
3-3 ELECTRICAL 89
3-4 HYDRAULICS 94
3-5 PLACARDS 101
3-6 OPTIONS 102
4 VENDOR DATA
4-1 LIST OF VENDORS 148
4-2 MANUFACTURER DATA 150
WARRANTY INFORMATION 215
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PHOENIX METAL PRODUCTS, INC
TL600/TL700 LAVATORY SERVICE TRUCK
6 MAY 2018
INTRODUCTION
THE TL600 IS DESIGNED TO SERVICE THE LAVATORY SYSTEMS OF ALL MAJOR COMMERCIAL
AND MILITARY AIRCRAFT FITTED WITH COMMERCIAL LAVATORIES. THE TL600 IS MOUNTED ON
A COMMERCIAL CHASSIS. AN ISUZU CAB OVER MODEL NPR , POWERED BY A TURBOCHARGED
AIR COOLED INLINE FOUR CYLINDER DIRECT INJECTION DIESEL ENGINE. ALL FEATURES FOUND
ON HIGHWAY VEHICLES ARE INCORPORATED IN THIS CHASSIS.
THE TL600 IS A MODULAR UNIT WITH 2 TANKS SURROUNDED BY A STAINLESS STEEL SHROUD.
CONTROLS FOR PUMPING, LIGHTS AND MEASUREMENT OF CHARGING FLUIDS ARE LOCATED
ON THE TOP DECK. IF A LIFT IS INSTALLED THERE IS A SET OF CONTROLS ON THE LIFT PLAT-
FORM. LIGHTS ARE SUPPLIED FOR NIGHT OPERATIONS. THIS PUBLICATION PROVIDES OPERAT-
ING, SERVICING, MAINTENANCE INSTRUCTIONS AND DETAILED PARTS LIST FOR THE TL600
LAVATORY SERVICE TRUCK. FULL FAMILIARIZATION OF THIS PUBLICATION SHOULD BE
ACQUIRED PRIOR TO OPERATING, SERVICING OR PERFORMING MAINTENANCE ON THIS
VEHICLE.
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PHOENIX METAL PRODUCTS, INC
TL600/TL700 LAVATORY SERVICE TRUCK
37 MAY 2018
CHAPTER 2
MAINTENANCE
SECTION 1 - SYSTEM DESCRIPTION
THE FOLLOWING SYSTEMS COMPRISE THE TL600/700 LAVATORY SERVICE TRUCK
HYDRAULIC SYSTEM
THE HYDRAULIC SYSTEM FOR THIS VEHICLE IS COMPRISED OF AN ENGINE DRIVEN HYDRAULIC
PUMP, CONTROLLED BY AN ELECTRIC ACTUATED MAGNETIC CLUTCH, HYDRAULIC RESERVOIR,
SYSTEM PRESSURE RELIEF VALVE AND A HYDRAULIC MOTOR FOR THE PUMPING SYSTEM.
HYDRAULIC PUMP
THE HYDRAULIC PUMP IS SECURED TO THE FRONT OF THE ENGINE AND IS DRIVEN BY ONE
AUTOMOTIVE SERPENTINE BELT. THE PUMP IS CONTROLLED BY A MAGNETIC CLUTCH AND IS
IDLE UNTIL A PUMPING FUNCTION IS SIGNALED FOR THROUGH THE ELECTRICAL SYSTEM.
HYDRAULIC RESERVOIR
THE HYDRAULIC SYSTEM IS FED FROM A STAINLESS STEEL HYDRAULIC RESERVOIR LOCATED
IN THE HYDRAULIC TANK COMPARTMENT ON THE PASSENGER SIDE OF THE MODULE. THE
CAPACITY OF THE RESERVOIR IS 17 U.S. GALLONS. FLUID RETURNING TO THE RESERVOIR IS
FILTERED THROUGH THE RETURN FILTER. A BALL VALVE ISOLATES THE HYDRAULIC PUMP
AND THE RESERVOIR. IT IS LOCATED ON THE BOTTOM SIDE OF THE MODULE, ON THE
PASSENGER SIDE IN FRONT OF THE REAR WHEEL WELL.
HYDRAULIC MOTOR
THE HYDRAULIC MOTOR IS COUPLED TO THE FLUID PUMP.
PRESSURE RELIEF VALVE
THE PRESSURE RELIEF VALVE PROTECTS THE HYDRAULIC SYSTEM FROM EXCESSIVE
HYDRAULIC PRESSURE. IT IS SET AT THE FACTORY.
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PHOENIX METAL PRODUCTS, INC
TL600/TL700 LAVATORY SERVICE TRUCK
38 MAY 2018
CHAPTER 2
MAINTENANCE
SECTION 1 - SYSTEMS DESCRIPTION
PUMPING SYSTEM
THE PUMPING SYSTEM FOR THIS VEHICLE CONSISTS OF: FLUID PUMP, FLOW METER, RELIEF
VALVE AND A DRAIN BACK LINE.
FLUID PUMP
THE FLUID PUMP IS A 1 INCH BRONZE GEAR PUMP. THE FLUID PUMP WILL PULL FROM THE
FLUSH WATER TANK; THROUGH A BRONZE SHUT OFF VALVE, AND A 1 INCH T-STRAINER WITH
A REMOVABLE STAINLESS STEEL MESH FILTER.
HOSE REEL
A HOSE REEL STORES 25 FEET OF 1 INCH I.D. REINFORCED PVC HOSE. THE HOSE REEL HAS A
SPRING REWIND AND A RATCHETING LOCKING SYSTEM.
FLOW METER
A 1 INCH FLOW METER TOTALIZES THE FLUID PASSING THROUGH THE PUMPING SYSTEM. A
RESET KNOB ALLOWS FOR TURNING THE COUNTER BACK TO ZERO. LARGE NUMBER DIALS OR
ROUND FACE WITH NUMBERS INDICATE THE AMOUNT OF FLUID PUMPED THROUGH THE
SYSTEM.
RELIEF VALVE
A RELIEF VALVE AT THE INLET OF THE METER REGULATES THE PRESSURE OUTPUT OF THE
FLUID PUMP. THE BYPASSED FLUID RETURNS TO THE FLUSH TANK.
DRAIN BACK VALVE
A 1/4” STATIC LINE IS PLUMBED BACK TO THE FLUSH TANK. THIS ALLOWS FOR FLUID TO
DRAIN BACK TO TANK WHEN PUMPING IS COMPLETED TO PREVENT THE OPERATOR FROM
GETTING SPLASHED WHEN DISCONNECTING FROM AIRCRAFT.
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PHOENIX METAL PRODUCTS, INC
TL600/TL700 LAVATORY SERVICE TRUCK
39 MAY 2018
CHAPTER 2
MAINTENANCE
SECTION 2 - SERVICING/LUBRICATION
THE TL 600/700 REQUIRES LITTLE MORE ATTENTION THAN MOST OTHER CONVENTIONAL
VEHICLES OF ITS TYPE. THERE ARE NO SPECIAL TOOLS REQUIRED OTHER THAN THOSE FOUND
IN ANY MODERN GARAGE OR AIRLINE GROUND SUPPORT EQUIPMENT SERVICING FACILITY.
ALL WORK SHOULD BE PERFORMED IN ACCORDANCE WITH STANDARD SHOP PRACTICES.
1.VEHICLE SERVICING
ENGINE OIL, POWER STEERING, TRANSMISSION, RADIATOR, REAR AXLE AND
BATTERIES; SERVICE THESE ITEMS IN ACCORDANCE WITH CHASSIS MANUFACTURER’S
RECOMMENDATIONS (SEE OWNERS MANUAL).
2. HYDRAULIC SYSTEM
A. HYDRAULIC OIL SERVICING
THE HYDRAULIC SYSTEM RESERVOIR, LOCATED OVER THE RIGHT HAND REAR
WHEEL WELL IS THE ONLY PLACE TO SERVICE THE HYDRAULIC SYSTEM. THE FILL CAP
IS LOCATED ON THE TOP DECK BETWEEN THE FRONT RIGHT CORNER (PASSENGER
SIDE) AND THE RIGHT HAND REAR WHEEL WELL. THE FILL CAP IS PAINTED YELLOW. A
SIGHT LEVEL GAUGE IS LOCATED ON THE REAR SIDE CORNER OF THE RESERVOIR.
WHEN THE HYDRAULIC TANK COMPARTMENT IS OPENED THE SIGHT GAUGE IS IN
PLAIN VIEW ON THE SIDE OF THE TANK. THE GAUGE HAS A LOW AND A HIGH MARK.
FOR UNITS WITH TELESCOPIC LIFTS THE LEVEL SHOULD BE NO LOWER THAN THE
HIGH MARK.
IF HYDRAULIC FLUID IS REQUIRED, START THE ENGINE AND RUN THE PUMPING SYSTEM
AND CHECK FOR LEAKS. IF A LEAK IS FOUND IT MUST BE CORRECTED PRIOR TO FILLING
THE RESERVOIR.
CAPACITY OF THE HYDRAULIC RESERVOIR IS 19 U.S. GALLONS
NOTE: DO NOT USE HYDRAULIC OILS OF DIFFERENT SPECIFICATIONS. THE
OILS MAY NOT BE COMPATIBLE AND COULD RESULT IN DAMAGE TO
THE HYDRAULIC SYSTEM COMPONENTS
B. HYDRAULIC TANK- CLEANING
(1) DRAIN AND REPLACE OIL IF THERE IS A DOUBT AS TO ITS PURITY.
(2) TO DRAIN TANK PLACE A CONTAINER UNDER HYDRAULIC TANK DRAIN LOCATED
IN FRONT OF THE RIGHT REAR WHEELS. REMOVE CAP, DRAIN AND DISCARD FLUID.
USE ONLY ISO 32 OIL
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PHOENIX METAL PRODUCTS, INC
TL600/TL700 LAVATORY SERVICE TRUCK
40 MAY 2018
CHAPTER 2
MAINTENANCE
SECTION 2 - SERVICING/LUBRICATION
(3) REPLACE CONTAINER UNDER DRAIN. FLUSH INTERIOR OF TANK WITH MINERAL
SPIRITS BY OPENING DRAIN AND FILLING TANK FROM FILL PORT. ALLOW TIME
FOR THE CLEANING MATERIAL TO DRAIN AND TANK TO DRY. A JET OF LOW PRES
SURE AIR WILL SPEED THE DRYING TIME.
(4) REPLACE DRAIN PLUG AND FILL TANK WITH RECOMMENDED OIL TO PROPER
LEVEL ON LEVEL GAUGE. RECOMMENDED OIL IS
(5) START ENGINE AND OPERATE SYSTEM. RECHECK OIL LEVEL. ADD OIL IF
REQUIRED.
C. FILTER, HYDRAULIC OIL
(1) CHANGE FILTER ELEMENT EVERY THREE MONTHS.
(2) TO REMOVE ELEMENT, PLACE SMALL CONTAINER UNDER FILTER ELEMENT.
UNSCREW ELEMENT FROM FILTER HOUSING.
(3) DISCARD ELEMENT AND O-RING SEAL BETWEEN FILTER HOSING AND ELEMENT.
(4) INSTALL NEW FILTER ELEMENT USING NEW O-RING SEAL.
(5) TIGHTEN ELEMENT TO A MAXIMUM OF 20 FOOT POUNDS.
(6) START UNIT AND OPERATE HYDRAULIC SYSTEM - CHECK FOR LEAKS
D. LUBRICATION
(1) LUBRICATE THE VEHICLE CHASSIS IN ACCORDANCE WITH THE MANUFACTURER’S
RECOMMENDATIONS.
(2) LUBRICATION POINTS ON THE SERVICE MODULE ARE MINIMAL. THE FOLLOWING
POINTS NEED TO BE LUBRICATED.
(3) ALL HINGES AND LATCHES ON MODULE. LUBRICATE WITH A DROP OF 5 WT OIL.
ISO 32
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PHOENIX METAL PRODUCTS, INC
TL600/TL700 LAVATORY SERVICE TRUCK
41 MAY 2018
CHAPTER 2
MAINTENANCE
SECTION 3 - INSPECTIONS
TABLE –1 PERIODIC INSPECTIONS
INSPECT FOR
GENERAL
INSPECT TRUCK CHASSIS IN ACCORDANCE WITH MANUFACTURER’S
RECOMMENDED MAINTENANCE SCHEDULES.
INSPECT AND SERVICE VEHICLE ENGINE PER RECOMMENDED
MAINTENANCE SCHEDULES
ENTIRE UNIT FOR GENERAL OVERALL APPEARANCE AND CLEANLINESS
SECURITY OF FASTENERS AND MOUNTINGS
FUEL, PLUMBING, HEATING AND COOLING SYSTEMS SERVICED
TANK ASSEMBLIES FOR LEAKS, INCLUDING WASTE VALVES
WASTE HOSE, FLUID HOSE AIRCRAFT CONNECTORS FOR LEAKS, CUTS OR
MISSING PARTS
HYDRAULIC SYSTEM
PERFORM A COMPLETE OPERATIONAL CHECK AND OBSERVE THE
FOLLOWING.
HYDRAULIC LINES, FITTINGS, PUMP AND MOTOR LEAKAGE AND PROPER
FUNCTION.
FLEXIBLE LINES FOR ABRASIONS, KINKS, LEAKAGE AND SECURITY
CONDITION OF HYDRAULIC FILTER
FLUID PUMPING SYSTEM
WHILE PERFORMING THE OPERATIONAL CHECK FOR THE HYDRAULIC
SYSTEM, ALSO CHECK THE FUNCTION OF THE FLUID PUMPING SYSTEM
PULL HOSE FROM HOSE REEL-REMOVE CAP ON FLUID HOSE - REMOVE
CAP ON FLUSH TANK FILL - CONNECT FLUID HOSE TO FILL NIPPLE OR IN-
SERT INTO STAND PIPE. ENGAGE CHARGE PUMP SWITCH AND OBSERVE
FREQUENCY
(HOURS)
A/R
A/R
80
250
A/R
80
80
80
80
80
500
250
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PHOENIX METAL PRODUCTS, INC
TL600/TL700 LAVATORY SERVICE TRUCK
42 MAY 2018
INSPECT FOR
FLUID PUMPING SYSTEM
PROPER FLOW. PROPER FLOW IS {(18-22) U.S. GALLONS PER MINUTE.
INSPECT AREAS AROUND WATER PUMP, RELIEF VALVE, DRAIN BACK
LINE, METER AND HOSE REEL.
WASTE SYSTEM
DISCONNECT WASTE HOSE FROM STOWAGE NIPPLE ON TOP TRAY CON-
NECTOR. FILL WASTE HOSE WITH CLEAN WATER. FILL HOSE APPROXI-
MATELY HALF FULL. CONNECT WASTE HOSE BACK ON TOP TRAY CON-
NECTOR.
CHECK FOR LEAKS IN WASTE HOSE, CONNECTIONS AT STOWAGE NIPPLE .
ELECTRICAL SYSTEM
INSPECT THE ELECTRICAL SYSTEM FOR
SECURITY OF WIRING, ROUTING, TIES AND CLAMPS
TURN LIGHTS ON AND CHECK FOR FUNCTION
TURN 12 VOLT HEATER ON AND CHECK FOR FAN FUNCTION
CHECK CONDITION OF 110 VAC OUTLET ON DRIVER SIDE OF SERVICE
MODULE
FREQUENCY
(HOURS)
250
250
250
500
500
500
500
500
CHAPTER 2
MAINTENANCE
SECTION 3 - INSPECTIONS
TABLE –1 PERIODIC INSPECTIONS
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PHOENIX METAL PRODUCTS, INC
TL600/TL700 LAVATORY SERVICE TRUCK
43 MAY 2018
CHAPTER 2
MAINTENANCE
SECTION 3 - INSPECTIONS
PERIODIC INSPECTIONS
THE FOLLOWING TABLE IS SUGGESTED AS A GUIDE FOR THE USER IN CONDUCTING PERIODIC
INSPECTIONS. THE FREQUENCIES SHOWN ARE FOR THE UNIT OPERATING IN AVERAGE U.S.
CLIMATES. IF THE UNIT IS OPERATED IN ADVERSE CLIMATIC CONDITIONS; IE SALT SPRAY,
EXTREME COLD OR SANDY/DUSTY ENVIRONMENTS, THE INSPECTIONS SCHEDULES SHOULD BE
ADJUSTED FOR THOSE CONDITIONS.
TABLE –1 PERIODIC INSPECTIONS
INSPECT FOR
GENERAL
INSPECT TRUCK CHASSIS IN ACCORDANCE WITH MANUFACTURER’S
RECOMMENDED MAINTENANCE SCHEDULES.
INSPECT AND SERVICE VEHICLE ENGINE PER RECOMMENDED
MAINTENANCE SCHEDULES
ENTIRE UNIT FOR GENERAL OVERALL APPEARANCE AND CLEANLINESS
SECURITY OF FASTENERS AND MOUNTINGS
FUEL, PLUMBING, HEATING AND COOLING SYSTEMS SERVICED
TANK ASSEMBLIES FOR LEAKS, INCLUDING WASTE VALVE
WASTE HOSE, FLUID HOSE AIRCRAFT CONNECTORS FOR LEAKS, CUTS
OR MISSING PARTS
HYDRAULIC SYSTEM
PERFORM A COMPLETE OPERATIONAL CHECK AND OBSERVE THE
FOLLOWING.
HYDRAULIC LINES, FITTINGS, PUMP AND MOTOR LEAKAGE AND
PROPER FUNCTION.
FLEXIBLE LINES FOR ABRASIONS, KINKS, LEAKAGE AND SECURITY
CONDITION OF HYDRAULIC FILTER
FREQUENCY
(HOURS)
A/R
A/R
80
250
A/R
80
80
80
80
80
500
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PHOENIX METAL PRODUCTS, INC
TL600/TL700 LAVATORY SERVICE TRUCK
44 MAY 2018
CHAPTER 2
SECTION 4 - ADJUSTMENTS
ADJUSTMENTS
THERE ARE THREE PERFORMANCE FACTORS THAT WILL REQUIRE SOME
ATTENTION. THE HYDRAULIC SYSTEM PRESSURE , THE FLUID PUMPING PRESSURE
AND THE FLUID PUMPING SYSTEM FLOW. ALTHOUGH THE SYSTEMS ARE SET
AT THE FACTORY, THEY MAY NEED TO BE CHECKED WHEN A NON CONFORMING
RESULT IS ENCOUNTERED WHILE OPERATING THE SYSTEMS.
HYDRAULIC SYSTEM PRESSURE
THE HYDRAULIC SYSTEM PRESSURE RELIEF VALVE PROTECTS THE SYSTEM FROM
OVER PRESSURE. THE HYDRAULIC PUMP IS CAPABLE OF APPROXIMATELY 3500 PSI
IF CONDITIONS ARE RIGHT. THE COMPONENTS IN THE SYSTEM CAN NOT TAKE THAT
PRESSURE ON A MORE THAN OCCASIONAL INSTANCE. THE RELIEF VALVE IS SET FOR
200– 300 PSI HIGHER THAN THE HIGHEST PRESSURE NEEDED TO OPERATE THE
HIGHEST PRESSURE COMPONENT. IN THIS CASE THE PERSONNEL LIFT CYLINDER
REQUIRES THE HIGHEST PRESSURE TO OPERATE. THE HYDRAULIC SYSTEM PRESSURE
IS REGULATED BY A RELIEF VALVE MOUNTED ON THE HYDRAULIC MANIFOLD
LOCATED IN THE PUMP COMPARTMENT. A TEST PORT IS ACCESSIBLE FROM THE
HYDRAULIC COMPARTMENT.
1
REVISED MAY 2017
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PHOENIX METAL PRODUCTS, INC
TL600/TL700 LAVATORY SERVICE TRUCK
45 MAY 2018
NOTE: THE VEHICLE ENGINE MUST BE RUNNING AND THE IDLE-UP
FUNCTION MUST BE ACTIVATED ON VEHICLE BEFORE MAKING
ANY ADJUSTMENTS OR TAKING ANY MEASUREMENTS ON WATER OR
HYDRAULIC SYSTEMS.
6
LOCATED ON OPPOSITE SIDE OF
HYDRAULIC TEST PORT.
CHAPTER 2
SECTION 4 - ADJUSTMENTS
CHECK/ADJUST HYDRAULIC SYSTEM PRESSURE WITH PERSONNEL LIFT
1. INSTALL PRESSURE GAUGE ON HYDRAULIC TEST PORT WITH VEHICLE OFF.
3. START VEHICLE AND ACTIVATE IDLE-UP FUNCTION .
4. LOWER LIFT TO FULL DOWN POSITION.
5. HOLD LIFT DOWN SWITCH WHILE READING GAUGE TO CHECK PRESSURE.
6. IF PRESSURE IS NOT APPROXIMATELY 850 PSI, LOOSEN RELIEF VALVE LOCK NUT
AND USE 3/16 HEX KEY TO ADJUST PRESSURE. ENSURE LIFT DOWN BUTTON IS
HELD WHILE ADJUSTING PRESSURE. CLOCKWISE TURN INCREASES PRESSURE AND
COUNTER CLOCKWISE DECREASES PRESSURE.
7. WHEN PRESSURE IS SET AT 850 PSI, TIGHTEN LOCK NUT, AND REMOVE GAUGE.
REVISED MAY 2017
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PHOENIX METAL PRODUCTS, INC
TL600/TL700 LAVATORY SERVICE TRUCK
46 MAY 2018
CHAPTER 2
SECTION 4 - ADJUSTMENTS
CHECK/ADJUST HYDRAULIC SYSTEM PRESSURE WITHOUT PERSONNEL LIFT
1. INSTALL TEST GAUGE ON HYDRAULIC TEST PORT WHILE VEHICLE IS OFF.
2. MAKE SURE CHARGE HOSE CAP IS INSTALLED ON END OF HOSE AND THERE IS
WATER IN CHARGE TANK.
3. TURN ON VEHICLE AND ACTIVATE ENGINE IDLE-UP FUNCTION.
4. ACTIVATE CHARGE PUMP AND CHECK HYDRAULIC PRESSURE ON TEST GAUGE WHILE
PUMP IS OPERATING.
5. IF PRESSURE IS NOT APPROXIMATELY 850 PSI, REMOVE RELIEF VALVE CAP AND
USE A 5/16 HEX KEY TO ADJUST PRESSURE. CLOCKWISE TURN INCREASES PRESSURE
AND COUNTER CLOCKWISE DECREASES PRESSURE.
5. WHEN PRESSURE IS SET AT 850 PSI, REPLACE CAP, TIGHTEN LOCKNUT AND REMOVE
GAUGE.
1
NOTE: THE VEHICLE ENGINE MUST BE RUNNING AND THE IDLE-UP
FUNCTION MUST BE ACTIVATED ON VEHICLE BEFORE MAKING
ANY ADJUSTMENTS OR TAKING ANY MEASUREMENTS ON WATER OR
HYDRAULIC SYSTEMS.
4
5
REVISED MAY 2017
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PHOENIX METAL PRODUCTS, INC
TL600/TL700 LAVATORY SERVICE TRUCK
47 MAY 2018
5
CHAPTER 2
SECTION 4 - ADJUSTMENTS
2
REVISED MAY 2017
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PHOENIX METAL PRODUCTS, INC
TL600/TL700 LAVATORY SERVICE TRUCK
48 MAY 2018
CHAPTER 2
SECTION 4 - ADJUSTMENTS
FLUID PUMPING SYSTEM
THE RECOMMENDED FLUID PUMPING SYSTEM SETTINGS FOR AIRCRAFT SERVICING IS (42-45)
PSI. AND (18-22) GALLONS PER MINUTE OF FLOW. THESE SETTINGS ARE ACHIEVED BY USING A
PRESSURE REDUCING VALVE THAT IS REGULATED TO (42-45) PSI AND A PRESSURE RELIEF
VALVE SET AT APPROXIMATELY 80 PSI.
CHECK/ADJUST FLUID PUMPING SYSTEM PRESSURE WITHOUT PERSONNEL LIFT
NOTE: ENSURE HYDRAULIC SYSTEM PRESSURE IS CORRECT BEFORE ADJUSTING
FLUID PUMPING SYSTEM.
1. ADJUST THE BOLT ON THE PRESSURE REDUCING VALVE ALL THE WAY IN.
(HIGHEST PRESSURE SETTING)
2. ADJUST THE KNOB ON THE PRESSURE RELIEF VALVE ALL THE WAY OUT, THEN
BACK IT IN (1-1/2) TURNS.
3. INSTALL A PRESSURE GAUGE IN THE PORT AT THE CHARGE LINE PRESSURE RELIEF
VALVE TEE.
4. ATTACH A TEST GAUGE WITH BALL VALVE AND HOSE TO THE END OF THE CHARGE
HOSE.
5. ACTIVATE THE CHARGE PUMP AND RUN UNTIL ALL AIR IS OUT OF THE SYSTEM. KEEP
CHARGE PUMP ON.
6. CLOSE THE BALL VALVE ON THE CHARGE HOSE TEST GAUGE.
7. READ THE GAUGE AT THE CHARGE LINE PRESSURE RELIEF VALVE & ADJUST THE
PRESSURE TO APPROXIMATELY 80 PSI.
8. LOCK THE JAM NUT ON THE CHARGE LINE PRESSURE RELIEF VALVE.
9. DISENGAGE THE CHARGE PUMP SWITCH.
10. BACK THE ADJUSTMENT SCREW ALL THE WAY OUT ON THE PRESSURE REDUCING
VALVE.
11. RE-ENGAGE THE CHARGE PUMP WITH THE TEST GAUGE BALL VALVE CLOSED.
12. READ THE TEST GAUGE ON CHARGE HOSE AND ADJUST THE PRESSURE REDUCING
VALVE TO 42-45 PSI.
13. ZERO THE METER AND OPEN THE TEST GAUGE BALL VALVE, & CHECK THE FLOW
RATE. (18-22 GPM).
NOTE: THE VEHICLE ENGINE MUST BE RUNNING AND THE IDLE-UP
FUNCTION MUST BE ACTIVATED ON VEHICLE BEFORE MAKING
ANY ADJUSTMENTS OR TAKING ANY MEASUREMENTS ON WATER OR
HYDRAULIC SYSTEMS.
REVISED MAY 2017
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PHOENIX METAL PRODUCTS, INC
TL600/TL700 LAVATORY SERVICE TRUCK
49 MAY 2018
4
CHAPTER 2
SECTION 4 - ADJUSTMENTS
6
2
CHARGE LINE PRESSURE
RELIEF VALVE
7 3
8
1
PRESSURE REDUCING
VALVE
10
12
12
13
REVISED MAY 2017
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PHOENIX METAL PRODUCTS, INC
TL600/TL700 LAVATORY SERVICE TRUCK
50 MAY 2018
CHAPTER 2
SECTION 4 - ADJUSTMENTS
PLATFORM LIFT (IF EQUIPPED)
LIFT CYLINDER BLEED PROCEDURE
IF SLOW OR JERKY OPERATION IS EXPERIENCED WHEN RAISING OR LOWERING THE OPTIONAL
PLATFORM LIFT, THEN THERE MAY BE AIR TRAPPED IN THE CYLINDER. THE FOLLOWING IS A
PROCEDURE FOR BLEEDING THE LIFT CYLINDER OF TRAPPED AIR.
A BLEEDER VALVE ASSEMBLY IS REQUIRED TO BLEED THE CYLINDER. THE ILLUSTRATED
PARTS LIST FOR THE BLEEDER KIT IS ON PAGE 52.
1. BEFORE REMOVING THE PLUG IN THE TOP OF THE CYLINDER, MAKE SURE THE
EMERGENCY DOWN BALL VALVE IS IN THE OPEN POSITION AND THAT THE LIFT IS
IN THE FULLY STOWED POSITION.
CYLINDER PLUG
PLUG REMOVED
2. INSTALL THE BLEEDER VALVE ASSEMBLY INTO THE TOP OF THE CYLINDER AND CONNECT
THE HOSE END OF THE ASSEMBLY TO THE HYDRAULIC TANK FILL CONNECTION. MAKE SURE
THE BLEEDER BALL VALVE IS IN THE CLOSED POSITION.
BLEEDER VALVE ASSEMBLY
SHOWN WITH THE BALL VALVE IN
THE CLOSED POSITION
HOSE END OF THE BLEEDER
VALVE ASSEMBLY CONNECTED TO
THE HYDRAULIC TANK FILL
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PHOENIX METAL PRODUCTS, INC
TL600/TL700 LAVATORY SERVICE TRUCK
51 MAY 2018
CHAPTER 2
SECTION 4 - ADJUSTMENTS
PLATFORM LIFT (IF EQUIPPED)
LIFT CYLINDER BLEED PROCEDURE (CONT’D)
3. WITH THE EMERGENCY BALL VALVE AND THE BALL VALVE ON THE BLEEDER ASSEMBLY
CLOSED, RUN THE LIFT TO THE FULLY UP POSITION.
4. HAVE AN ASSISTANT ON THE GROUND OPEN THE EMERGENCY DOWN VALVE AND LET THE
LIFT LOWER COMPLETELY DOWN TO ITS STOWED POSITION. IF THE LIFT BINDS COMING DOWN
SHAKE THE LIFT TO CONTINUE MOVEMENT.
5. ONCE THE LIFT IS COMPLETELY DOWN, CLOSE THE EMERGENCY DOWN VALVE AND OPEN
THE BALL VALVE ON THE BLEEDER ASSEMBLY. OPERATE THE LIFT’S DOWN CONTROL FOR A
FEW SECONDS AND NOTE ANY AIR BLEEDING THROUGH THE DRAIN HOSE TO THE TANK.
6. CLOSE BOTH THE EMERGENCY AND BLEEDER BALL VALVES AND REPEAT THE PROCESS
UNTIL THE CYLINDER HAS BEEN COMPLETELY BLED OF ALL AIR.
7. REPLACE AND TIGHTEN THE PLUG INTO THE TOP OF THE CYLINDER.
EMERGENCY DOWN
BALL VALVE Pro
perty
of A
mer
ican
Airline
s
PHOENIX METAL PRODUCTS, INC
TL600/TL700 LAVATORY SERVICE TRUCK
52 MAY 2018
CHAPTER 2
SECTION 4 - ADJUSTMENTS
PLATFORM LIFT (IF EQUIPPED)
LIFT CYLINDER BLEED PROCEDURE (CONT’D)
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PHOENIX METAL PRODUCTS, INC
TL600/TL700 LAVATORY SERVICE TRUCK
53 MAY 2018
CHAPTER 2
SECTION 5 - TROUBLESHOOTING/SCHEMATICS
GENERAL
THIS SECTION CONTAINS TROUBLESHOOTING INFORMATION RELATIVE TO THE TRUCK
MOUNTED SYSTEMS ONLY AND DOES NOT COVER AREAS DIRECTLY RELATED TO THE BASIC
TRUCK CHASSIS OR CAB. TROUBLESHOOTING THE CHASSIS-CAB PROBLEMS IS ACCOMPLISHED
IN ACCORDANCE WITH THE MANUFACTURER’S RECOMMENDATIONS.
THE SUCCESS IN DIAGNOSING PROBLEMS ON THE SERVICE MODULE WILL DEPEND ON COMMON
SENSE AND GOOD WORKING KNOWLEDGE OF 12 VDC, HYDRAULIC AND PLUMBING SYSTEMS.
SINCE ALL THE FUNCTIONS ARE ELECTRO-HYDRAULIC ( I.E. ELECTRICALLY CONTROLLED AND
HYDRAULICALLY POWERED) THE ELECTRICAL, HYDRAULIC AND PLUMBING SYSTEMS MAY
REQUIRE CHECKING TO DETERMINE THE CAUSE OF THE PROBLEM.
A. STRUCTURAL/MECHANICAL
STRUCTURAL COMPONENTS ON THE SERVICE MODULE INCLUDE: THE SERVICE MODULE
STRUCTURE, SHEET METAL SIDES, DOORS, TANKS, TOP DECK, REAR BUMPER AND THE
TANK DRAIN VALVE HANDLE.
BY VISUALLY INSPECTING THE VEHICLE PRIOR TO USE THE OPERATOR SHOULD NOTICE
IF STRUCTURAL DAMAGE IS PRESENT. DURING PREVENTATIVE MAINTENANCE CHECKS
THE MODULE AND ALL THE ITEMS LISTED ABOVE SHOULD BE INSPECTED FOR DENTS,
RACKS AND EASE OF OPERATION. MOST STRUCTURAL DAMAGE OCCURS FROM IMPACT.
IMPACT DAMAGE IS EASILY NOTICEABLE. DAMAGE CAUSED BY MECHANICAL BINDING
OR FATIGUE IS GENERALLY LESS LIKELY TO BE NOTICED UNTIL A FAILURE HAS
OCCURRED.
IF STRUCTURAL DAMAGE IS PRESENT, FIRST TRY TO DETERMINE IF THE PROBLEM IS
IMPACT OR OVERLOAD RELATED OR IF BINDING OR FATIGUE IS THE PROBLEM. REPAIR
OR REPLACEMENT OF SHEET METAL PARTS MAY BE NECESSARY. STRUCTURAL
DAMAGE CAN BE ACCOMPLISHED AFTER CONTACTING THE MANUFACTURER.
WARNING- DO NOT WELD OR CUT OR SPLICE ANY LOAD BEARING OR SUPPORT
STRUCTURES PRIOR TO CONTACTING THE ENGINEERING DEPARTMENT OF PHOENIX METAL
PRODUCTS
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PHOENIX METAL PRODUCTS, INC
TL600/TL700 LAVATORY SERVICE TRUCK
54 MAY 2018
CHAPTER 2
SECTION 5 - TROUBLESHOOTING/SCHEMATICS
B. HYDRAULIC
THE HYDRAULIC SYSTEM OF THE LAVATORY SERVICE TRUCK IS FAIRLY SIMPLE. THE
HYDRAULIC SYSTEM POWERS THE (2) PUMPING SYSTEMS AND PROVIDES THE POWER
FOR THE PERSONNEL LIFT VERTICAL TRAVEL. THE HYDRAULIC SYSTEM HAS A
RESERVOIR, PUMP, SELECTOR VALVES, AND MOTORS. THE HYDRAULIC PUMP IS IN IDLE
MODE UNTIL CALLED UPON BY AN ELECTRIC SIGNAL TO THE HYDRAULIC PUMP
CLUTCH. THE VEHICLE MUST BE IN THE PARK POSITION FOR THE HYDRAULIC PUMP
CLUTCH TO OPERATE.
THE TRUCK ENGINE DRIVES THE HYDRAULIC PUMP. IF THE ENGINE IS NOT RUNNING
THERE WILL BE NO HYDRAULIC POWER TO OPERATE ANY FUNCTIONS.
SELECTOR VALVES MUST BE OPERATED FOR THE DIFFERENT MOTORS TO PERFORM
THEIR FUNCTIONS AND A SELECTOR VALVE MUST BE OPERATED FOR VERTICAL
TRAVEL OF THE LIFT.
C. ELECTRICAL
THE ELECTRICAL CIRCUIT GETS POWER FROM THE IGNITION SWITCH. ALL FUNCTIONS
FOR SERVICING THE AIRCRAFT ARE POWERED BY THE VEHICLE IGNITION. THE
COMPARTMENT LIGHTS ARE CONTROLLED BY THE VEHICLE LIGHTING SYSTEM. THE
COMPARTMENT LIGHTS WILL NOT WORK IF THE TRUCK LIGHTS ARE NOT ON.
D. PUMPING SYSTEM
THE PUMPING SYSTEM IS DEPENDENT ON THE HYDRAULIC SYSTEM FOR POWER AND
THE ELECTRICAL SYSTEM FOR SELECTING ONE OF THE (2) PUMPS. BOTH HYDRAULIC
AND ELECTRICAL SYSTEMS MUST BE WORKING PROPERLY FOR THE PUMPING SYSTEM
TO WORK.
TROUBLESHOOTING GUIDES ARE COVERED IN (3) GENERAL CATEGORIES.
ELECTRICAL, HYDRAULIC AND MECHANICAL. THE TROUBLESHOOTING GUIDE FOR THE
PLUMBING CIRCUIT IS COMBINED IN ALL (3) CATEGORIES.
REFER TO THE SCHEMATICS THAT CORRESPOND TO THE SYSTEM THAT IS BEING
DIAGNOSED AND THE TROUBLESHOOTING TABLES FOR THOSE SYSTEMS.
THE FOLLOWING TABLES WILL GIVE SPECIFIC PROBLEMS THAT MAY ARISE DURING
THE NORMAL LIFE CYCLE OF THIS UNIT. TABLE # 2 LISTS THE POSSIBLE SYMPTOMS
AND IS DIVIDED INTO THE SPECIFIC OPERATIONAL SYSTEMS (I.E. ELECTRICAL
HYDRAULIC, AND MECHANICAL). NEXT TO EACH SYMPTOM IS A CODE. THE POSSIBLE
CAUSES AND THE APPROPRIATE REMEDIES ARE FOUND ON TABLE # 3.
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PHOENIX METAL PRODUCTS, INC
TL600/TL700 LAVATORY SERVICE TRUCK
55 MAY 2018
CHAPTER 2
SECTION 5 - TROUBLESHOOTING/SCHEMATICS
TROUBLE SYMPTOM ELECTRICAL HYDRAULIC MECHANICAL
LIMITED OR NO HYDRAULIC
POWER, AND/OR ERRATIC LIFT
FUNCTION OR PUMPING FUNCTION
E3, E15 H4, H6, H8, H9;H11,
H15, E16 M9
NOISY HYDRAULIC PUMP E16 H4 M9
HYDRAULIC FLUID MILKY OR
DISCOLORED H3, H5, H10
HYDRAULIC SYSTEM RUNNING HOT H1, H2, H4, H5,
H6
SQUEALING FROM HYDRAULIC
PUMP BELTS OR SMELL OF
BURNING RUBBER
H2, H7 M9
PUMP TURNS ON AND SHUTS OFF
REPEATEDLY
E1, E2, E3, E4,
E6, E16
LIFT WILL NOT STABILIZE AND
HOLD IN THE UP POSITION H7, H13, H14, H15
FLUID PUMP DOES NOT PUMP FROM
ONE TANK BUT DOES FROM THE
OTHER
E2, E3, E4, E8 M12, M13
FLUID PUMP - PUMPS SLOWLY H1, H2, H4, H6,
H8, H11, H13, H16
M9, M12, M13,
M14, M15, M16,
M17
FLUID TRANSFERS TO PLANE BUT
DOES NOT REGISTER ON METER M14
ENGINE RUNNING/NO LIFT OR PUMP
FUNCTIONS
E1, E2, E3, E7,
E9, E16 H4, H6, H8, H9 M9
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PHOENIX METAL PRODUCTS, INC
TL600/TL700 LAVATORY SERVICE TRUCK
56 MAY 2018
CHAPTER 2
SECTION 5 - TROUBLESHOOTING/SCHEMATICS
TROUBLE SYMPTOM ELECTRICAL HYDRAULIC MECHANICAL
FLOW METER NOT
OPERATING CORRECTLY M20
FLUID PUMP OPERATES/NO
OUTPUT FROM HOSE END
E2, E3, E4, E8
M12, M15, M16,
M17
FLUID WILL NOT DRAIN
BACK FROM HOSE AFTER
SERVICING AIRCRAFT
M18
WASTE PUMP DOES NOT
PULL FLUID FROM
AIRCRAFT
E2, E4, E5, E8 H11, H12, H13, H16 M2, M3, M19
WHEN WASTE TANK IS FULL/
WASTE DRAINS OUT OF
WASTE HOSE
M19
SPOT LIGHTS DO NOT WORK E1, E2, E3, E4, E5, E12
HOT WATER HEATER DOES
NOT WORK/WORKS BUT NO
WARM AIR
E1, E2, E6, E17 M9, M11
110 VOLT HEATER (S)
DO NOT OPERATE E1, E2, E4, E18
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TL600/TL700 LAVATORY SERVICE TRUCK
57 MAY 2018
CHAPTER 2
SECTION 5 - TROUBLE /SHOOTING/SCHEMATICS
ELECTRICAL
CODE # PROBABLE CAUSE TEST /REMEDY
E1 FUSE/CIRCUIT BREAKER BLOWN CHECK FOR SHORT CIRCUIT. REPLACE FUSE
E2 WIRING DISCONNECTED/LOOSE
CHECK CONTINUITY FROM POINT TO POINT.
CHECK FOR DAMAGED OR DISCONNECTED
TERMINALS
E3 BAD GROUND CONNECTION CHECK AND RE-GROUND
E4 CONNECTOR DAMAGED OR LOOSE TIGHTEN CONNECTOR OR REPLACE
E5 SWITCH CONTACT NOT CLOSING REPLACE SWITCH OR CONTACT
E6 SWITCH CONTACTS SHORT
CIRCUITED TEST. REPLACE CONTACT OR SWITCH
E7 RELAY/SOLENOID COIL OPEN–
CIRCUITED TEST. REPLACE RELAY
E8
SELECTOR VALVE SOLENOID COIL
OPEN CIRCUITED
TEST. REPLACE COIL
E9 RELAY CONTACTS NOT CLOSING TEST. REPLACE RELAY
E10 RELAY CONTACTS WELDED SHORT TEST. REPLACE RELAY
E12 BULB DEFECTIVE REPLACE BULB
E13 DIODE DEFECTIVE TEST. REPLACE DIODE
E14 EMERGENCY KILL SWITCH ON PULL TO RELEASE SWITCH
E15
LOW VOLTAGE
CHECK VOLTAGE FROM ENGINE ALTERNATOR
IF LESS THAN 12 VOLTS OR MORE THAN 15
VOLTS. REPLACE ALTERNATOR
E16
PUMP CLUTCH COIL NOT HOLDING
CHECK VOLTAGE. IF VOLTAGE IS GOOD
REPLACE CLUTCH
E17 FAN MOTOR DEFECTIVE REPLACE FAN MOTOR OR HEATER ASSEMBLY
E18 THERMOSTAT IMPROPERLY
ADJUSTED OR DEFECTIVE
CHECK CONNECTIONS ON IMMERSION
HEATER–CHECK SETTING FOR APPROX. 60 ºF.—
REPLACE HEATER ASSEMBLY
E19 HEATER ELEMENT DEFECTIVE REPLACE HEATER ELEMENT
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TL600/TL700 LAVATORY SERVICE TRUCK
58 MAY 2018
CHAPTER 2
SECTION 5 - TROUBLESHOOTING/SCHEMATICS
HYDRAULICS
CODE # PROBABLE CAUSE TEST/REMEDY
H1
HYDRAULIC HOSE BLOCKED OR
PINCHED
REMOVE AND INSPECT . REPLACE IF
NECESSARY
H2 RETURN FILTER CLOGGED REPLACE ELEMENT
H3
RESERVOIR CONTAMINATED
OPEN RESERVOIR AND CHECK FOR
CONTAMINATION. DRAIN AND CLEAN
RESERVOIR WITH MINERAL SPIRITS. FLUSH
SYSTEM AND REFILL WITH NEW OIL
H4 FLUID LEVEL LOW CHECK. FILL AS NECESSARY
H5
WRONG TYPE HYDRAULIC FLUID
OR CONTAMINATION
OPEN RESERVOIR AND CHECK FOR
CONTAMINATION. DRAIN AND CLEAN
RESERVOIR WITH MINERAL SPIRITS. FLUSH
SYSTEM AND REFILL WITH NEW OIL
H6 RELIEF VALVE NOT ADJUSTED CHECK PRESSURE AND ADJUST
H7 PILOT CHECK VALVE DEFECTIVE REPLACE VALVE
H8
PRESSURE REGULATOR SPRING
DEFECTIVE
REMOVE AND INSPECT REPLACE SPRING OR
RELIEF VALVE
H9 HYDRAULIC PUMP DEFECTIVE REPLACE OR REPAIR PUMP
H10 HYDRAULIC PUMP SEAL LEAKING REPAIR
H11 HYDRAULIC MOTOR DEFECTIVE REPLACE OR REPAIR MOTOR
H12
HYDRAULIC MOTOR SHAFT KEY
BROKEN
REMOVE HYDRAULIC MOTOR, CHECK SHAFT
KEY REPLACE IF NECESSARY
H13
SELECTOR VALVE SPOOL
STICKING
REMOVE COIL, SPOOL AND CLEAN WITH
MINERAL SPIRITS AND REPLACE
H14
EMERGENCY DOWN VALVE
LEAKING
RAISE LIFT. ISOLATE VALVE BY REMOVING
LINE TO MANIFOLD AT THE MANIFOLD PUT
END OF HOSE IN SMALL CONTAINER AND
CHECK FOR FLUID FLOW. IF FLUID CONTINUES
TO DRAIN AND LIFT SLOWLY COMES DOWN
REPLACE VALVE.
H15 EMERGENCY DOWN VALVE
MANUAL OVERRIDE IS ENGAGED
CHECK MANUAL OVERRIDE SCREW. UNSCREW
UNTIL FULLY RETRACTED
H16 FLOW CONTROL NOT ADJUSTED ADJUST FLOW CONTROL ON SELECTOR VALVE
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PHOENIX METAL PRODUCTS, INC
TL600/TL700 LAVATORY SERVICE TRUCK
59 MAY 2018
CHAPTER 2
SECTION 5 - TROUBLESHOOTING/SCHEMATICS
MECHANICAL
CODE PROBABLE CAUSE TEST/ REMEDY
M1
HINGE OR LATCH BINDING
CHECK FOR ALIGNMENT/ALIGN AND LUBRICATE.
REPLACE IF NECESSARY.
M2
CONNECTING ROD BROKEN
REMOVE COVER– OPERATE PUMP– INSPECT ROD
REPLACE IF NECESSARY.
M3
DIAPHRAGM LEAKING
REMOVE COVER– INSPECT DIAPHRAGM—LOOK FOR
FLUID ON TOP SIDE OF DIAPHRAGM.
M4
STABILIZER TUBE OUT OF
ADJUSTMENT
RUN LIFT FULL UP/DOWN—ADJUST STABILIZER BY
LOOSENING BOTTOM BOLTS AND ALLOWING
STABILIZER TO FIND CENTER WHILE OPERATING FULL
UP/FULL DOWN. TIGHTEN BOLTS.
M5
STABILIZER TUBES DENTED OR
DAMAGED
EXTEND LIFT CHECK FOR DISTORTION OR DINGS IN
TUBES. REMOVE AND REPAIR AS NECESSARY.
M6
DRAIN VALVE CLOGGED
OPEN TANK INSPECTION DOOR INSPECT VALVE FOR
DEBRIS REMOVE DEBRIS AS NECESSARY.
M7
DRAIN VALVE STEM BROKEN
INSPECT BALL VALVE STEM. REPLACE BALL VALVE IF
NECESSARY.
M8 HOSE REEL REWIND SPRING
BROKEN REPLACE SPRING HOUSING ASSEMBLY.
M9
BELT SLIPPAGE
CHECK TENSION OF HYDRAULIC PUMP BELTS. CHECK
CONDITION OF BELTS. ADJUST TENSION OR REPLACE
BELTS.
M10
FAN BLADES BENT
INSPECT FAN BLADES FOR INTERFERENCE. REPAIR OR
REPLACE BLADE OR FAN MOTOR.
M11
LOW COOLANT SYSTEM FLUID
CHECK FOR LEAKS IN VEHICLE COOLANT SYSTEM.
REPAIR LEAKS AND FILL SYSTEM.
M12 LOW FLUID IN TANK CHECK FOR LEAK. FILL TO REQUIRED LEVEL.
M13 OBSTRUCTION IN LINE REMOVE LINE AND CLEAR OBSTRUCTION.
M14
METER DEFECTIVE
FLUSH METER WITH WARM FRESH WATER—REPLACE
METER.
M15 TEE STRAINER CLOGGED REMOVE SCREEN AND FLUSH—RE-INSTALL.
M16 FLUID PRESSURE RELIEF VALVE ADJUST
M17
PRESSURE RELIEF VALVE SPRING
BROKEN
REPLACE
M18 DRAIN BACK HOSE OBSTRUCTED REMOVE OBSTRUCTION.
M19 WASTE PUMP FLAPPER VALVES
OBSTRUCTED OR DEFECTIVE REMOVE OBSTRUCTION OR REPLACE VALVES.
M20 DAMAGE FROM UNDISSOLVED/
IMPROPERLY DILUTED FLUID
CHECK METER PARTS FOR CLOGS OR GRANULE BUILD-
UP /CLEAN OR REPLACE PARTS AS NEEDED
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TL600/TL700 LAVATORY SERVICE TRUCK
60 MAY 2018
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TL600/TL700 LAVATORY SERVICE TRUCK
61 MAY 2018
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TL600/TL700 LAVATORY SERVICE TRUCK
62 MAY 2018
NO LIFT
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TL600/TL700 LAVATORY SERVICE TRUCK
63 MAY 2018
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TL600/TL700 LAVATORY SERVICE TRUCK
64 MAY 2018
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TL600/TL700 LAVATORY SERVICE TRUCK
65 MAY 2018
ISUZU GAS HEATER
HOSE LAYOUT
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TL600/TL700 LAVATORY SERVICE TRUCK
66 MAY 2018
FORD HEATER
HOSE LAYOUT
WITH ENGINE BAY
PUMP
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PHOENIX METAL PRODUCTS, INC
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67 MAY 2018
CHAPTER 2
SECTION 5 - TROUBLESHOOTING/SCHEMATICS
HYDRAULIC SCHEMATIC - WITHOUT LIFT
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PHOENIX METAL PRODUCTS, INC
TL600/TL700 LAVATORY SERVICE TRUCK
68 MAY 2018
CHAPTER 2
SECTION 5 - TROUBLESHOOTING/SCHEMATICS
HYDRAULIC SCHEMATIC - WITH LIFT
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PHOENIX METAL PRODUCTS, INC
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69 MAY 2018
CHAPTER 2
SECTION 5 - TROUBLESHOOTING/SCHEMATICS
FLUID PUMPING SYSTEM
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TL600/TL700 LAVATORY SERVICE TRUCK
70 MAY 2018
CHAPTER 2
SECTION 6 - PREPARATION FOR SHIPMENT
THIS SECTION WILL DESCRIBE THE NECESSARY PROCEDURE TO PREPARE THIS UNIT
FOR SHIPMENT.
1. DRIVING UNIT
A. REMOVE WASTE HOSE FROM ITS ATTACHMENT POINT. STORE THE HOSE IN
THE CAB.
NOTE:
SEE SECTION 3 FOR INSTRUCTIONS FOR CLEANING WASTE HOSE
B. REMOVE THE REAR FLAGS AND STORE THEM BEHIND THE SEAT IN THE CAB.
C. MAKE SURE BOTH DRAIN VALVES ARE CLOSED.
D. ALL SERVICING TANKS MUST BE EMPTY OF FLUID.
E. CHECK ALL DRIVING FUNCTIONS AND OPERATING LIGHTS.
2. TRANSPORTATION BY TRUCK
A. THE FUEL TANK OF THIS VEHICLE MUST HAVE NO MORE THAN 4 GALLONS OF
FUEL IN THE TANK FOR TRANSPORT ON COMMERCIAL TRUCKING LINES. THE
LEVEL GAUGE MUST READ 1/8 TANK OR LESS. DRAIN OR RUN THE VEHICLE
TO ACHIEVE THE VOLUME NECESSARY TO TRANSPORT THIS VEHICLE.
B. REMOVE WASTE HOSE FROM ITS ATTACHMENT POINT. STORE THE
HOSE IN THE CAB.
C. REMOVE THE REAR FLAGS AND STORE THEM BEHIND THE SEAT IN THE CAB.
D. MAKE SURE BOTH DRAIN VALVES ARE CLOSED.
E. ALL SERVICING TANKS MUST BE EMPTY OF FLUID.
3. TRANSPORTATION BY WATER
A. THE FUEL TANK OF THIS VEHICLE MUST HAVE NO MORE THAN 2 GALLONS OF
FUEL. THE LEVEL GAUGE MUST READ EMPTY. DRAIN OR RUN THE VEHICLE
TO ACHIEVE THE VOLUME NECESSARY TO TRANSPORT THIS VEHICLE.
B. REMOVE WASTE HOSE FROM ITS ATTACHMENT POINT. STORE THE
HOSE IN THE CAB.
C. REMOVE THE REAR FLAGS AND STORE THEM BEHIND THE SEAT IN THE CAB.
D. MAKE SURE BOTH DRAIN VALVES ARE CLOSED.
E. ALL SERVICING TANKS MUST BE EMPTY OF FLUID.
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PHOENIX METAL PRODUCTS, INC
TL600/TL700 LAVATORY SERVICE TRUCK
71 MAY 2018
CHAPTER 2
SECTION 7 - PREPARATION FOR STORAGE
THIS SECTION WILL DESCRIBE THE NECESSARY PROCEDURE TO PREPARE THIS UNIT
FOR STORAGE.
1. SERVICE MODULE
A. DRAIN FLUID TANK AND RINSE WITH FRESH WATER.
B. FILL TANK WITH FRESH WATER AND ADD (1/2) QUART OF BLEACH TO
THE TANK.
C. HOOK FLUID HOSE TO FILL COUPLING ON TANK AND RUN FLUID PUMP TO
CYCLE FLUID THROUGH TANK (120 GALLONS).
D. DRAIN WASTE AND FLUSH WITH FRESH WATER.
E. CLOSE DRAIN AND PUMP CONTENTS OF FLUID TANK WITH BLEACH
INTO THE WASTE TANK THROUGH THE INSPECTION HATCH. FILL THE TANK
TO THE TOP WITH FRESH WATER AND LET THEM SOAK FOR (1) HOUR.
F. DRAIN WASTE TANK AND FLUID TANKS. CLOSE ALL DRAIN VALVES.
G. REMOVE WASTE HOSE FROM ITS ATTACHMENT POINT. SUFFICIENTLY RINSE
THE INSIDE OF THE HOSE WITH A WARM SOAP SOLUTION FOLLOWED BY A
SOLUTION OF 75 % WATER/25 % BLEACH.
H. STORE THE HOSE IN THE WASTE TANK— HOSE CAN BE INSERTED THROUGH
THE INSPECTION/CLEAN OUT HATCH.
I. REMOVE THE FLAGS FROM THE REAR BUMPER AND STORE IN THE CAB OF
THE VEHICLE BEHIND THE SEATS.
J. PLUG AND CAP THE WASTE HOSE CONNECTION AND THE WASTE TRAY
STAND PIPE .
2. TRUCK
A. THE FUEL TANK OF THIS VEHICLE MUST HAVE NO MORE THAN 2 GALLONS OF
FUEL FOR STORAGE. THE LEVEL GAUGE MUST READ EMPTY. DRAIN OR RUN
THE VEHICLE TO ACHIEVE THE VOLUME NECESSARY.
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PHOENIX METAL PRODUCTS, INC
TL600/TL700 LAVATORY SERVICE TRUCK
72 MAY 2018
CHAPTER 2
SECTION 8 - DISASSEMBLY, REPAIR, REASSEMBLY AND REPLACEMENT
DISASSEMBLY
THERE ARE (3) PRIMARY AREAS FOR DISASSEMBLY OF THE LAVATORY SERVICE
MODULE. THE MODULE, WASTE AND FLUID TANKS AND HYDRAULIC AND PLUMBING
COMPONENTS.
MODULE REMOVAL
THE MODULE IS A STRUCTURAL COMPONENT AND SHOULD NOT NEED TO BE REMOVED
UNLESS THE CHASSIS IS BEING REPLACED.
1. TO REMOVE THE MODULE ALL ELECTRICAL WIRING, HYDRAULIC LINES TO
CHASSIS AND HEATER LINES MUST BE DISCONNECTED AND CAPPED OR TAPED
OFF.
2. REMOVE THE TIE DOWN NUTS AND PLATES ON BOTTOM OF CHASSIS RAIL (4)
PLACES.
3. IF A FORK LIFT IS BEING USED RAISE THE REAR OF THE MODULE FROM THE REAR
BUMPER APPROXIMATELY 12—18 INCHES AND PLACE TWO 4” X 4” X 12” LONG
HARDWOOD BLOCKS BETWEEN THE EXTREME REAR OF THE CHASSIS RAIL AND
THE BOTTOM OF THE MODULE. LOWER THE MODULE ONTO THE BLOCKS.
4. FROM THE SIDE OF THE UNIT POSITION THE LIFT CENTERED OVER THE REAR
WHEEL. PLACE FORKS UNDER BOTH LONGITUDINAL SUPPORTS AND LIFT MODULE
OFF OF CHASSIS.
5. RE-INSTALL BY REVERSING STEPS 1-4.
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PHOENIX METAL PRODUCTS, INC
TL600/TL700 LAVATORY SERVICE TRUCK
73 MAY 2018
CHAPTER 2
SECTION 8 - DISASSEMBLY, REPAIR, REASSEMBLY AND REPLACEMENT
REMOVABLE OF FLUID TANKS
1. DRAIN TANK REMOVE THE FILL PORT, VENT, RAILS ON THE SIDES. REMOVE
DRAIN VALVE FROM UNDERSIDE OF TANK. REMOVE FRONT SIDE PANEL AND
DISCONNECT IMMERSION HEATER AND SUCTION HOSE. REMOVE IMMERSION
HEATER. REMOVE TOP DECK AND TOP INSULATION. REMOVE TANK TIE DOWN
2. CONNECT LIFTING CHAIN TO BOTH LIFTING EYES ON TOP OF TANK. LIFT TANK OUT
OF MODULE.
3. RE-INSTALL BY REVERSING STEPS 1-2.
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PHOENIX METAL PRODUCTS, INC
TL600/TL700 LAVATORY SERVICE TRUCK
74 MAY 2018
CHAPTER 2
SECTION 8 - DISASSEMBLY, REPAIR, REASSEMBLY AND REPLACEMENT
REMOVAL WASTE TANK
1. DRAIN TANK. REMOVE DRAIN VALVE FROM UNDERSIDE OF TANK. REMOVE CENTER
TOP DECK. REMOVE INSULATION. FROM THE WASTE HOSE COMPARTMENT;
DISCONNECT WASTE HOSE FROM WASTE PUMP AND REMOVE FITTINGS FROM TANK.
FROM THE HYDRAULIC COMPARTMENT; REMOVE DRAIN BACK VALVE AND REMOVE
FITTINGS FROM TANK. REMOVE (2) TIE DOWNS ON TOP OF TANK.
2. CONNECT CHAIN TO (2) LIFTING EYES ON TOP OF WASTE TANK AND LIFT OUT OF
MODULE.
3. REASSEMBLE REVERSING STEPS 1-2.
LIFTING EYES
TIE DOWNS
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