Operating Instructions 3

SECTION 3

OPERATING INSTRUCTIONS
3.1 EARTHING & BONDING PROCEDURES
3.2 TO ENGAGE/DISENGAGE POWER TAKE OFF (PTO)
3.3 INTAKE HOSE STOWAGE RAIL, STABILISER JACKS &
BOOM OPERATION.
3.4 FUELLING METER & MASTERLOAD DISPLAY
3.5 TO RAISE/LOWER THE ELEVATING PLATFORM &
PANTOGRAPH
3.6 TO REEL OUT/REWIND THE REEL HOSES
3.7 TO COMMENCE FUEL FLOW
3.8 TO TAKE A FUEL SAMPLE.
3.9 TO DEPRESSURISE THE HOSES
3.10 CAB CONTROLS
3.11 EMERGENCY ENGINE & FUELLING STOPS
3.12 BRAKE INTERLOCKS & OVERRIDE
3.13 RECOVERY TANK EMPTYING
3.14 BONDING & LANYARD REELS
3.15 DIFFERENTIAL PRESSURE SWITCH SENSOR

If the Operating Company’s procedures differ from those listed below, they should always
take precedence.

The Hydrant Dispenser intake valve is normally left open and is only closed for
maintenance purposes. The flow control valve(s) should always be closed when a
refuelling operation is completed.

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Control Station

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Instrument Panel

3.1 Earthing & Bonding Procedures

Two manual rewind bonding reels c/w insulated cable

terminating with a robust alligator clip are provided on
the hosereel and the right hand side of the vehicle. All
components in the fuelling system maintain electrical
continuity with the chassis.

The bonding clips are fitted on interlocked stowages,

the reels must be rewound and the clips properly
stowed to release the vehicle brakes.

Ensure that earthing and bonding procedures are carried out at all times. Connect
the bonding cable to the pit valve before connecting the intake coupling. Before
fuelling operations commence, bond the vehicle to the aircraft with the bonding cable
before connecting the fuelling hose(s). On completion of fuelling disconnect the
fuelling hose(s) before removing the bonding cable and remove the intake coupling
before removing the bonding cable from the pit valve.

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3.2 To Engage/Disengage the Power Take Off (PTO)

The PTO drives a hydraulic pump, which powers various services on the
superstructure.

Before engaging the PTO ensure:-

• The vehicle has stooped and the parking brake fully applied.
• The gear change lever is in neutral, check if the indicator is pointing at "N".
• Before pressing the PTO switch, confirm that the vehicle engine speed is at idle.
• Air pressure is above 65psi.

Engaging the PTO:-

Check the status of the vehicle (see above),

and then press the PTO switch.

When the PTO is correctly engaged the white

light on top of the dash panel will illuminate, if
it fails to do so return the switch to the
disengaged position and repeat the process
until the light illuminates.

Dis-engaging the PTO:-

Ensure the gear lever in neutral and confirm that the gear indicator is pointing at "N".
Press the PTO switch. The PTO engaged light will extinguish. If it does not repeat
the process.

3.3 Intake Hose Stowage Rail, Stabilisers & Boom Operation.

To lower the stowage rail and stabiliser jacks

push the operating valve lever forward against
the spring and allow the legs to lower until the
feet are firmly grounded but without lifting the
vehicle.

With the rail lowered the hose trolley’s can be

unhooked.

To raise the jacks pull the operating valve lever back against the spring and allow the
leg to rise until the jacks are fully closed and the interlock switches have operated.

If there is a hydraulic failure the stabiliser jacks can

raised by opening the manual raising valve and
allowing the jacks to lift under pressure exerted by the
internal springs.

The hinged fuelling boom is stowed on the left hand

side of the vehicle, to release lift the latching handle
upward and pull the boom away from the vehicle.

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3.4 Fuelling Meter & Masterload Display

Fuel delivery is metered by a constant displacement capsule monitored by an

electronic 'Masterload' control unit on the platform and a mechanical register at the
control station.

Switch on the vehicle master switch, the display unit should show an ‘8’ in all
segments of the display windows for approximately 3 seconds as a display test. If
any display segment is missing the unit will require repair. The check maybe
repeated by pressing the RESET button.

The display unit now shows ‘0’ in the ‘batch’ and ‘rate of
flow’ windows with the ‘tote’ window showing the current
total.

When opening a flow control valve to instigate a delivery

the batch window displays the delivery in progress with
the rate of flow. If density, temperature or differential
pressure are required during a delivery these can be
obtained by pressing the reset button.

3.5 To Raise/Lower the Elevating Platform & Pantograph

The platform is controlled by means of a

pneumatic valve mounted on the fuelling deck
guard-rail, this operates through a master
hydraulic control valve. Lift the control valve
lever to raise the deck, depress the lever to
lower the deck. Release the lever when the
desired deck height has been attained. An
audible alarm will sound when the deck is
raised or lowered.

Two emergency manual lowering valves are provided

one accessible from ramp level and one on the
platform. These will lower the platform without
hydraulic power.

Note: The audible alarm will not sound when the

manual lowering valves are used. Always close
these valves immediately after use.

A secondary platform control valve is placed at ramp level and is used when carrying
out maintenance on the platform.

The hydraulic pantograph, which lifts the deck hoses as the deck raises, is
independent of the vehicle hydraulic system and operates from a pressurised
accumulator.

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3.5 To Raise/Lower the Elevating Platform & Pantograph (Continued)

When the desired deck height has been

attained, opening the HEPC stowage lid to gain
access to the nozzles this will lock the
pantograph in place. The nozzles have to be
stowed and the lid closed to unlock the
pantograph to allow it to lower when the deck is
lowered.

If the pantograph fails to lower due to a fault in

the system it can be lowered manually by
turning the black knob below the hydraulic
accumulator anti-clockwise to release the
pressure. Tighten this valve after the pantograph has lowered.

3.6 To Reel Out/Rewind the Reel Hoses

These operations are controlled by 3-position control valve located adjacent to the
nozzle stowage. To reel out the hose, position the control valve lever in the mid
position and pull off the hose. To rewind the hoses pull the control valve lever out
against a spring pressure (do not allow the nozzle to drag along the ground). When
the hose has been rewound and the nozzle stowed, push the control valve lever to
the innermost position to lock the hose reel and prevent it
rotating.

Hosereel Control Valve Operation

3.7 To Commence Fuel Flow

NOTE: Intake valve should be left open for

operational use and only closed for maintenance
purposes.

Position the vehicle in the best position to give clear

access to the hydrant pit and the aircraft.

If refuelling with the deck hoses, position the vehicle directly below the fuelling
connections under the aircrafts wing.

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3.7 To Commence Fuel Flow (Continued)

After taking the necessary safety precautions such as connecting the bonding
cable, connect the intake coupling to the hydrant pit valve, open the poppet valve
and connect the opening connector to the pit valve. Attach the lanyard to the pit
valve.

Raise the platform and connect the

bonding cable. Remove the aircraft
refuelling point covers, un-stow the HEPC
nozzles, connect to the aircraft and open the
poppet valves.

Reset the meter, open the platform hoses

flow control valve and activate the deadman
handswitch.

The vehicle is equipped with a deadman

timer to prevent misuse of the deadman
system. The timer will stop the fuel flow after
2 ½ - 3 minutes unless the operator generates a reset signal. Releasing and
regripping the handswitch generates the reset signal. Two handswitches are
provided, one on a cable reel at the control station the second on the platform.

A green lamp, on top of the

instrument panel, emits
continuous illumination while
deadman handswitch is
closed until the prompt signal
is generated. At this point, the
lamp will flash for the prompt
period. A reset signal can be
generated at any time during
the timer cycle whether
prompted or not.

NOTE: In an emergency, flow can be stopped within 5 seconds by releasing the

deadman handswitch.

Always close the flow control valve when the refuelling operation is complete
After refuelling remove and stow the nozzles and hoses and replace the aircrafts
refuelling point covers. Remove and stow the bonding cable. Lower and secure the
elevating platform.

If refuelling from the reel hose, connect the bonding cable, reel out the hose and
connect the nozzle to the aircraft. Open the reel hose flow control valve and activate
the deadman handswitch. After refuelling, close the flow control valve, reel in the
hose and stow the nozzle, do not allow the nozzle to drag along the floor.
Remove and stow the bonding cable.

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3.8 To Take A Fuel Sample

The Visual Check Fuel Sampler (VCFS) is located on top of

the recovery tank. A sample from either the upstream or
downstream side of the filter can be taken at any time
during a fuelling operation by opening the appropriate
VCFS fill valves.

Opening the ball valve built

into the base of the unit
empties the VCFS. In areas
of high humidity it may be
desirable to leave the sample
jar filled until immediately before the next sampling
operation in order to avoid condensation from misting
up the inside of the glass tube.

3.9 To Depressurise the Hoses

Pressure locked into the system following a

refuelling operation is normally released into the
recovery tank automatically when the deadman
handswitch is released. If pressure is still locked
into the system it can be released by actuating the
manual depressurising valve.

A pressure maintaining valve ensures 1 bar (15

p.s.i.) is left in the hoses to prevent kinking and to
ensure that metering accuracy is not impaired by draining the delivery hoses.

3.10 Cab Controls

The controls and warning lamps fitted inside the cab

are enclosed in a box mounted beside the drivers
seat. These include the following:-

• Night operation light on/off switch *.

• Worklamps on/off switch *.
• Beacon on/off switch *.
• Interlock override switch.
• High DP sensor override switch.
• High DP sensor reset switch (key).
• Low air pressure warning light (red).

* These switches have green ‘on’ indicators.

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3.11 Emergency Engine & Fuelling Stops

The superstructure is equipped with

three push button emergency engine
stop controls. One is located on the
control station instrument panel, one
on the platform upper rail and the third
is located on right hand side of the
vehicle. Pressing any one of these
controls stops the engine.

Three fuelling stop

switches are also
fitted, one on the instrument panel one on the platform upper rail
and the third is located on right hand side of the vehicle, all
adjacent to the engine stops. Pressing one of these controls shuts
off the intake coupling deadman valve and stops the flow of flue.

Note: These stops have to be reset after

use, the engine stop by rotating
clockwise until the button pops out, the
fuelling stops by pulling out the button.
Failure to do this will prevent the engine
from starting or the deadman valve opening.

Two additional engine stops are fitted on the fuelling deck rails
these operate if they come into contact with the aircraft’s wing.

Note: Should one of these switches be operated, the

fuelling deck will have to be manually lowered slightly
before the engine can be restarted.

3.12 Brake Interlocks & Override

The brake interlock system automatically applies the vehicle brakes or prevents them
from being released when:

• The elevating platform is not fully lowered.

• The pantograph is not fully lowered.
• The intake coupling is not fully stowed.
• The intake rail is not fully stowed.
• The intake boom is not fully stowed.
• The delivery nozzles are correctly stowed.
• The bonding reels are not stowed.

An amber light, on the cab dash will flash when the

brake interlocks are in operation and the item(s)
unstowed are displayed on the cab Fueltronic panel.

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3.12 Brake Interlocks & Override (Continued)

A Brake Interlock override switch is fitted

for use in an emergency only. Operating
this switch will release the vehicles brake
and allow it to be moved from a potential
hazard. This switch is located on the cab
enclosure box under a hinged red cover
(see 3.10).

A red light, on the cab dash will flash

when the brake interlocks are overridden.

3.13 Recovery Tank & Emptying

The product recovery tank provided drains the following lines:-

System depressurising, air eliminator return, thermal pressure relief valves

discharge, manual depressurising system discharge, the differential pressure gauge
and the Closed circuit fuel sampler (VCFS).

An automatic hydraulically powered recovery tank emptying system is fitted which

pumps the contents of the recovery tank into the dispenser pipework upstream from
the filter during the refuelling operation. The system is automatically controlled via a
high/low level float switch and always leaves a deadstock in the recovery tank.

The hydraulic control valve can be activated manually by

operating the green push button switch on the instrument
panel. This should only occur when a refuelling
operation is taking place.

The recovery tank float switch also activates an audible

alarm and illuminates a red light on top of the instrument
panel if the tank becomes full.

Periodically draw off the entire contents of the tank using the
tank gravity drain valve.

3.14 Lanyard Reel

A manually rewound lanyard reel is fitted above the intake

coupling lifter, this allows remote operation of the hydrant
valve.

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3.15 Differential Pressure Switch Sensor

A sensor is fitted to the Filter Monitor Differential Pressure Gauge. This detects when
the differential pressure across the filter elements is too high and illuminates a lamp
on the instrument panel and closes the deadman valve.

A key switch is fitted to the cab console to reset the sensor after it has been activated
(see cab controls).

A test switch is fitted, to the left of the differential pressure gauge on the instrument
panel, pressing the green test button illuminates the lamp and alarm if the system is
operational. Reset with the key switch after test.

An override switch is also fitted to the cab console to override the sensor should the
need arise (see cab controls).

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