Maintenance manual

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Maintenance manual of Vacuum Toilet
System EC-VAC Oriental.
Page: 1 / 26
Vacuum Toilet System
Rewision
1
EC VAC Oriental
Date
19.04.2017
Maintenance manual of Vacuum Toilet System EC VAC Oriental
Prepared
Checked
Approved
K. Gucwa
L. Janawa
..........................................
19th of April 2017
22th of April 2017
..........................................
Maintenance manual of Vacuum Toilet
System EC-VAC Oriental.
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Vacuum Toilet System
Revision
1
EC VAC Oriental
Date
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Table of changes
No
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
Change
Date
Person
Comment
Maintenance manual of Vacuum Toilet
System EC-VAC Oriental.
Vacuum Toilet System
Revision
1
EC VAC Oriental
Date
19.04.2017
Page: 3 / 26
Scope of activities within the levels maintain toilets EC-VAC Oriental
Tab 1. The scope of activities within the levels maintain toilets EC-VAC Oriental
Frequency of activities
Lp.
(P – maintain level)
Activities description
Comments
P1
P2
P3
P4
P5
X
X
X
X
X
X
X
X
X
1
Check the correct functioning toilets
2
Visual inspection of the toilets EC-VAC
3
Checking the pressure on the reducer
X
X
X
4
Checking the tightness of air connectors
X
X
X
1)
5
Checking the tightness of water connectors
X
X
X
1)
6
Checking the patency of the wires
X
X
X
1)
X
X
1)
X
X
7
Check the correct functioning of the diaphragm
valves
8
Cleaning the inside of the intermediate tank
9
Cleaning the ejector
X
X
10
Cleaning the pressure sensor and air supply lines
X
X
11
Cleaning the water assembly
X
12
Cleaning the flush nozzle
X
13
Replacing the ejektor
X
2)
14
Replacing the pressure sensor
X
2)
15
Cleaning the pump
16
Replacing the diaphragm and pumps spring
X
17
Replacing the water assembly
X
18
Check the correct functioning of the valve
19
Replacing the electrovalve assembly
X
X
X
X
1)
X
Uwagi:
1)
If necessary, replace,
2)
Exchange components before the assumed period of time is accepted In justified cases (visible wear, damage, etc.).
Maintenance manual of Vacuum Toilet
System EC-VAC Oriental.
Vacuum Toilet System
Revision
1
EC VAC Oriental
Date
19.04.2017
Page: 4 / 26
Tab 2. Cycle maintenance Toilets vacuum EC-VAC (calculation for ~ 170 thousand km / year)
P1
P2
P3
P4
P5
Frequency
10 ±1days
90 ±7 days
1 year ±30 days
max 3 years
max 6 years
Time or km
or 5k. km±10%
or 50k. km±10%
170k. km ±10%
500k. km
1 million km
Maintain level
Comments:
1) Frequency of activities to adapt to the inspection scheduled for the vehicle
(Should be at approximately the same time as in the table above, whichever occurs earlier)
2) Times between levels adopted on the assumption that the vehicle is covering approximately 170 thousand km / year,
3) Time periods listed in the table are approximate. They should not, however, be exceeded.
From the operational point of view, the best adapted to the cycles of maintenance of the vehicle traction,
Preparing to disassembly the toilet from the coach.
I.
Toilet desiccation: ..............................................................................................................................5
II.
Disassembly the water and air connector: .........................................................................................6
III.
Disassembly of outflow (Western style only). ...................................................................................7
IV.
Disassembly the toilet system from the laminate cover (Western style only). ..................................7
Scope of activities within the levels maintain toilets EC-VAC Oriental
1.
Check the correct functioning toilets. ................................................................................................8
2.
Visual inspection of the toilets EC-VAC. ..........................................................................................8
3.
Checking the pressure on the reducer. ...............................................................................................9
4.
Checking the tightness of air connectors. ..........................................................................................9
5.
Checking the tightness of hydraulic connectors. .............................................................................10
6.
Check of wire patency. ....................................................................................................................11
7.
Check the correct functioning of the diaphragm valves. .................................................................12
8.
Cleaning of the interior of the intermediate tank. ............................................................................13
9.
Ejector cleaning. ..............................................................................................................................14
10.
Cleaning the pressure sensor and the air supply hose. .....................................................................15
11.
Cleaning the water assembly. ..........................................................................................................16
Maintenance manual of Vacuum Toilet
System EC-VAC Oriental.
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Vacuum Toilet System
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EC VAC Oriental
Date
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12.
Cleaning flush nozzle. ......................................................................................................................17
13.
Ejector exchange. .............................................................................................................................17
14.
Pressure sensor exchange. ................................................................................................................18
15.
Pump cleaning ..................................................................................................................................19
16.
Replacement of diaphragm and pumps spring. ................................................................................21
17.
Replacement of water assembly.......................................................................................................23
18.
Checking of the correctness working of the valve set .....................................................................24
19.
Replacement of valve set .................................................................................................................25
There is a distinction between the levels of maintenance performed on a
toilet mounted on the coach ("Checking the function of the toilet", " Visual
inspection of the toilets EC-VAC ") and activities requiring the removal toilet
of a coach.
Below the steps which have to do before the toilet removal.
I.
Toilet desiccation:
The drainage of the toilet should be started by closing the water supply to the toilet and then
pressing and holding the right button for about 5 seconds on the diagnostic control.
Fig. 1 Diagnostic controller with marked desiccation button.
Maintenance manual of Vacuum Toilet
System EC-VAC Oriental.
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II.
Vacuum Toilet System
Revision
1
EC VAC Oriental
Date
19.04.2017
Disassembly the water and air connector:
Disassembly takes place by disconnected wires from the connectors. All connectors are present on
the Fig. 2.
Fig. 2 Air and water connector
1. Air connector,
2. Water connector.
Maintenance manual of Vacuum Toilet
System EC-VAC Oriental.
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III.
Vacuum Toilet System
Revision
1
EC VAC Oriental
Date
19.04.2017
Disassembly of outflow (Western style only).
Disassembly takes place by removing rubbery pipe from the outflow diaphragm valve. Disconnected
are present on the Fig.3.
Fig. 3 Outflow disassembly
IV.
Disassembly the toilet system from the laminate
(Western style only).
After removing outflow pipe should unscrew two screw M6 (presented on the Fig.4).
Fig. 4 Disassembly the toilet from the laminate cover.
cover
Maintenance manual of Vacuum Toilet
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Vacuum Toilet System
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Once you have removed the toilet module, place it gently in the area where the inspection will be
carried out. It is recommended to use a special rack for easy access to all toilet elements while protecting
against damage at the same time.
Inspection activities in the framework of maintaining
the levels of P1 to P5:
1.
Check the correct functioning toilets.
To check the performance of the EC-VAC vacuum toilet, must start the toilet cycle and visually
verify that it is operating as intended. The correct toilet cycle should be as follows:
a. Driver initialization after pressing the flush button,
b. Filling the toilet bowl,
c. Creating a vacuum,
d. Emptying the toilet bowl,
e. Production of overpressure in the intermediate tank,
f. Dropping the contents of the intermediate tank into the vehicle's main tank,
g. Flush the bowl with a small amount of water,
h. Releasing the pressure from the siphon valve and creating a siphon,
i. After the work is finished a standby message should appear on the controller.
2.
Visual inspection of the toilets EC-VAC.
To visually inspect the toilet, check out the occurrence of any visible mechanical damage (cracked
laminate – Western style). Is there a lack of leakage symptoms manifested by water leaks. Do the toilet
nozzles point in the right direction, rinsing the inside of the toilet bowl properly. In case of nonconformity
proceed to repair the components.
Maintenance manual of Vacuum Toilet
System EC-VAC Oriental.
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3.
Vacuum Toilet System
Revision
1
EC VAC Oriental
Date
19.04.2017
Checking the pressure on the reducer.
The pressure on the regulator is checked on the toilet mounted on the coach. After the air pressure has
been connected to the connector 1 of Fig. 2, the pressure on the pressure regulator must be checked. The
nominal pressure set on the regulator is 4.2 bar. At 3.5 bar pressure the toilet will be blocked. If
necessary, adjust the pressure using the regulator knob.
4.
Checking the tightness of air connectors.
After connecting the air pressure to the connector 1 of Fig. 2, the water to the connector 2 of Fig. 2
and the drain of the toilet, several times the toilet flush cycle must be started. When operating toilets,
spray the sensitive points (marked in yellow on Fig. 5) with a foam to detect leaks and observe for blisters
caused by air leakage.
Fig. 5 Checking the tightness of air connectors.
Maintenance manual of Vacuum Toilet
System EC-VAC Oriental.
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5.
Vacuum Toilet System
Revision
1
EC VAC Oriental
Date
19.04.2017
Checking the tightness of hydraulic connectors.
After connecting the air pressure to the connector 1 of Fig. 2, the water to the connector 2 of Fig. 2
and the drain of the toilet, several times the toilet flush cycle must be started. When operating toilets,
spray the sensitive points (marked in yellow on Fig. 6).
Fig. 6 Checking the tightness of water connectors
Maintenance manual of Vacuum Toilet
System EC-VAC Oriental.
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6.
Vacuum Toilet System
Revision
1
EC VAC Oriental
Date
19.04.2017
Check of wire patency.
Unclip the pneumatic and hydraulic lines by checking their airflow with pressure air. In the absence
of patency, they should be replaced. Pay special attention to the connecting cable between pressure sensor
and the intermediate tank (Fig. 7).
Fig. 7 The cables connecting the ejector and a pressure sensor with a intermediate tank
Maintenance manual of Vacuum Toilet
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7.
Vacuum Toilet System
Revision
1
EC VAC Oriental
Date
19.04.2017
Check the correct functioning of the diaphragm valves.
Once the air pressure has been connected to the connector 1 of Fig. 2, each air pressure must be
supplied to each valve to verify its operation. The pressure should be supplied "manually" by overrunning
the valve valve by pressing the button on the valve (marked in Figure 8).
Fig. 8 Marking the valve of the valve set.
Button 1 is used to control the siphon diaphragm valve.
Button 2 is used to control the ejector diaphragm valve.
Button 3 is used to control the outflow diaphragm valve.
The correct functioning of the diaphragm valves manifests itself in closing the flow. When the
pressure is supplied, the valve closes (it is accompanied by a distinctive sound) and there are no leaks on
the diaphragm (no sound of outgoing air).
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8.
Vacuum Toilet System
Revision
1
EC VAC Oriental
Date
19.04.2017
Cleaning of the interior of the intermediate tank.
The cleaning operation of the interior of the intermediate tank takes place on the toilet removed from
the coach. First remove the connecting hoses from the ejector and pressure sensor so that the sensor and
ejector are not damaged. Then connect the plugs with plug plugs (Fig. 9).
Fig. 9 a) Terminal plugs for tank connections (Western style), b) Place of insertion lance for pressure cleaning
(Western style)
Fig. 10 Terminal pluss and place of insertion lance for pressure cleaning (Oriental)
After closing the connections to the interior of the intermediate tank through the drain, you will need
to introduce a lance for cleaning with pressurized water. For better results, use a Atlas Dimer cleansing
preparation or similar formulation that does not adversely affect stainless steel. Cleaning should be
carried out until rinsing of the impurities contained in the intermediate tank. After cleaning, rinse the
intermediate tank with clean water and assemble the wires to the pressure sensor and ejector.
Maintenance manual of Vacuum Toilet
System EC-VAC Oriental.
Vacuum Toilet System
Revision
1
EC VAC Oriental
Date
19.04.2017
Page: 14 / 26
9.
Ejector cleaning.
The ejector cleaning operation takes place on the toilet removed from the laminate. The first step is to
remove the ejector from the toilet module. Do this by unplugging the pneumatic wires on the yellow
connector in Fig. 11. Then use the 10mm wrench to unscrew the ejector from the tank (blue).
Fig. 101 a) Ejector Disassembly (Western style) b) Ejector Disassembly (Oriental style)
After removing the ejector from the intermediate tank, disassemble the silencer from the diaphragm
valve from the ejector (Figure 12) (Western style).
Fig. 112 Disassembly the ejector silencer
After removing the silencer, place the ejector in a 10% citric acid solution for about 2-3 hours. Then
rinse with water under high pressure (bringing it to joint 1 and then 2) and dry.
WARNING!!! - Do not wet the air silencer.
Maintenance manual of Vacuum Toilet
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Vacuum Toilet System
Revision
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EC VAC Oriental
Date
19.04.2017
10. Cleaning the pressure sensor and the air supply hose.
The first step is to disassemble the pressure line to the pressure sensor. Then remove the pressure
sensor and unscrew the plug-in connector.
Fig. 123 Cleaning the pressure sensor.
Clean the pressure sensor cable and plug connections with water under pressure. Clean the pneumatic
sensor of the pressure sensor with a cotton cloth on a thin piece, allowing it to reach the inside of the
pneumatic connection. Perform a very gentle cleaning operation. If necessary, soak the cloth with neutral
diluted detergent. Then dry the connection with a dry cloth.
ATTENTION !!! - Do not use benzene-based diluents.
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Vacuum Toilet System
Revision
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EC VAC Oriental
Date
19.04.2017
11. Cleaning the water assembly.
The first step is to dismantle the water assembly from the toilet module. Do this by unplugging the
hydraulic hoses and the hose from the pneumatic valve on the yellow connector in Fig. 14. Then use a
10mm spanner to unscrew the water assembly from the tank..
Fig. 134 Disassembly the water assembly
After disassembly the water tank from the toilet tank, the pneumatic valve must be secured with
the cap shown in Fig. 15.
Rys. 14 Cleaning water assembly a) Western style, b) Oriental style
The prepared water assembly should be placed in a 10% citric acid solution for about 2-3 hours.
After this time, rinse the water assembly with clean water and assemble in the opposite direction to the
disassembly.
WARNING!!! - Do not allow inside of the pneumatic valve to be flooded
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Vacuum Toilet System
Revision
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EC VAC Oriental
Date
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12. Cleaning flush nozzle.
The nozzle cleaning operation is performed on the toilet removed from the laminate. The nozzle feed
pipes must be disconnected from the nozzles and then plugged into their pipes by means of which the
high pressure water is supplied with the decaling agent. The couplings are shown in Fig. 16.
Fig. 156 Cleaning flush nozzle a) Western style,
b) Oriental style
13. Ejector exchange.
The act of exchanging the ejector takes place on the toilet removed from the laminate. The first step is
to remove the ejector from the toilet module. Do this by unplugging the air hoses on the yellow connector
in Fig. 17. Then use a 10mm spanner to unscrew the ejector attachment from the tank.
Fig. 167 Ejector exchange
After this time, assemble ejector in the opposite direction to the disassembly.
Maintenance manual of Vacuum Toilet
System EC-VAC Oriental.
Vacuum Toilet System
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Page: 18 / 26
14. Pressure sensor exchange.
The first step is to disassemble the pressure line to the pressure sensor. Then remove the pressure
sensor with a 3mm spanner and unplug the electrical connector indicated by the arrow in Figure 17. After
removing the sensor with the fixing plate, unscrew it from the fixing plate with a 2mm spanner and
unscrew the plug.
Fig. 18 Pressure sensor exchange
The assembly process is carried out in reverse order of disassembly. Be sure to plug the electrical cable
into the sensor and seal the thread by screwing in the plug connector to the sensor.
Lackness of the electrical connection to the pressure sensor may result in faulty operation of the
toilet. It is recommended to replace the angle joint.
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Vacuum Toilet System
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EC VAC Oriental
Date
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15. Pump cleaning
The first step is to disconnect the hydraulic lines that supply water to the system.
Fig. 17 Disassembly wires from the pump
After disassembly the hydraulic hoses, than unscrew 4 screw M6 marked on Fig. 20.
Fig. 20 Disassembly the pump module
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Vacuum Toilet System
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EC VAC Oriental
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After disassembly the pump module from the fixing plate, proceed to unscrew the other screws by
which the pump bodies are connected. The disassembled pump (Fig. 21) must be cleaned.
Fig. 181 Pump cleaning
Condensate must be removed from the inside of the pump by the water.
It is forbidden to mechanically clean the pump diaphragm.
If you notice excessive wear or cracks in the diaphragm, replace the diaphragm.
The assembly process is carried out in reverse order of disassembly. When installing the pump
housings, care must be taken to ensure that the diaphragm is properly seated in the body grooves and that
the spring is in the groove of the pump housing. Screw the screws evenly over the entire circumference,
without causing the diaphragm to move which could affect the tightness of the pump.
Maintenance manual of Vacuum Toilet
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Vacuum Toilet System
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EC VAC Oriental
Date
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16. Replacement of diaphragm and pumps spring.
The first step is to disconnect the hydraulic lines that supply water to the system.
Fig. 22 Disassembly wires from the pump
After disassembly the hydraulic hoses, than unscrew 4 screw M6 marked on Fig. 23.
Fig. 23 Disassembly the pump module
Maintenance manual of Vacuum Toilet
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Vacuum Toilet System
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EC VAC Oriental
Date
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After disassembling the pump module from the mounting plate, the remaining screws must be
unscrew by means of which the pump bodies are connected. Disassemble the pump (Fig. 20) and
disengage the M12 screw that secures the diaphragm. Remove the steel washers from the diaphragm.
Then take the new diaphragm, spring and proceed to assembly.
Fig. 194 Replacement of diaphragm
Pump assembly operations in reverse order of disassembly. Before assembly, clean the pump housing
from the sludge. When screwing the pump housings, care must be taken to ensure that the diaphragm is
properly seated in the body grooves and that the spring is in the groove of the pump body. Screw the
screws evenly over the entire circumference, without causing the diaphragm to move which could affect
the tightness of the pump.
Maintenance manual of Vacuum Toilet
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Vacuum Toilet System
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EC VAC Oriental
Date
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17. Replacement of water assembly.
The first step is to dismantle the water assembly from the toilet module. Do this by unplugging the
hydraulic hoses and the hose from the pneumatic valve on the yellow connector in Fig. 25. Then use a
10mm spanner to unscrew the water assembly from the tank..
Fig. 25 Disassembly the water assembly
Assembly the water assembly in the reverse order of disassembly. Pay attention to the correct
connection of all wires.
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Vacuum Toilet System
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EC VAC Oriental
Date
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18. Checking of the correctness working of the valve set
Connect the air and water pressure hose to the toilet module. We check using the buttons marked in
Fig. 25.
Fig. 206 Manual checking the working of the valve set.
Checking should be done by briefly pressing each key individually. The valve terminal, when
properly operating, should react to the signals from the buttons by feeding air to the individual
components of the toilet module.
Button 1 - Air supply to the ejector,
Button 2 - Closing the siphon valve,
Button 3 - Closing the ejector valve,
Button 4 - Closing the overflow valve,
Button 5 - Dosing of water to the toilet bowl,
Button 6 - Opening the siphon valve.
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Vacuum Toilet System
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EC VAC Oriental
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19. Replacement of valve set
Activities start with removing the pneumatic wires shown in Fig 27
Fig. 217 Disassembly the pneumatic wires
After disconnecting the pneumatic hoses, disconnect the power cord to the valve terminal coils.
Fig. 28 Disconnected the electric cord
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Vacuum Toilet System
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After unplugging the electrical connector, proceed to disassemble the valve terminal from the control
panel. It is screw by 3 M6 screws.
Fig. 29 Disassembly the valve terminal
The assembly of the valve terminal should be done in the reverse order of disassembly. Be sure to
connect the pneumatic wires and the electrical cord of the valve terminal coils.
Maintenance-related activities EC-VAC vacuum toilets can only be operated by
qualified personnel.
Qualified personnel are understood to be people with experience and relevant
instructor and knowledge of the construction and operation of the toilet.
Maintenance operations from P3 to P5 should be made in protective overalls,
gloves, masks and safety goggles. The person performing these activities should have
a number of vaccines to ensure safety when working in contaminated environments.
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