BOH Enviromental FPU Manuel utilisateur

BOH-PM-16-1

FPU®SYSTEMS OPERATION MANUAL

(INCLUDING REPAIR PARTS)

EXPEDITIONARY CONTAINERIZED AUTHORIZED STOCKAGE LIST (ECASL)

BOH FPU Field Pack-up Units

US Patent Number US 6299008

European Patent Number EP 1224127

ECASL #4 (of 5) configuration shown (example)

(Doors removed for clarity)

BOH FPU®SYSTEMS

BOH ENVIRONMENTAL LLC

14520 Avion Parkway, Suite 220

Chantilly, Va. 20151

POC Doug Cresap (985) 674-0725

http://www.bohfpusystems.com

BOH-PM-16-1

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BOH-PM-16-1

WARNING SUMMARY

This warning summary contains general safety warnings and hazardous materials warnings that must be

understood and applied during operation and maintenance of this equipment. Failure to observe these

precautions could result in serious injury or death to persons using equipment.

WARNING

Do not allow the FPU-20-3 container to swing if using an overhead lift. Always

ensure an appropriate sling is used in the lift. Always use properly sized forklift,

crane, or lifting device. Failure to comply could cause injury or damage to the

equipment. WARNING

Use extreme caution when loading or unloading the FPU-20-3 to or from a

transport vehicle. Keep hands, fingers, and feet clear of the container and

components during this operation. Forklift support is required. Make sure all

container inserts are properly seated and locked secure. Failure to comply could

cause serious injury. Failure to follow proper insert connection procedures may

result in damage to the equipment.

Standard forklift principles apply when working with or on the FPU-20-3

container. Ground guides and the Material Handling Equipment (MHE) operators

must insure that personnel are clear of the containers during this operation.

When working with ground guides during the loading or unloading, never move

the container while the ground guide is unseen. Serious injury could occur if the

ground guide is pinned between the FPU-20-3 container and other objects.

Forklift operators must maintain visual contact with their ground guides at all

times.

Always follow standard forklift procedures. A tilt hazard exists when forklift

operators try to lift a FPU-20-3 container from the wrong side. When using a

forklift, Always lift a container via the forklift pockets that are provided. This

places the heavier part of the load back into the tines versus out on the tips. A tilt

situation exists when the heaviest part of the load is out on the tips of the tines,

on uneven ground, with forks fully extended, and while traveling. Operators

should always keep loads low and close to the forklift carriage. Operators should

never travel when the load is in the fork’s extended position.

WARNING

Fall hazards exist when climbing onto or working from the top of the FPU-20-3

container. Always maintain three points of contact to the ladder and container

when climbing onto the container. Never move, step, or walk backwards when

working on top of the system. All movement should be in the forward direction.

A fall can occur if personnel lose concentration and step backwards off of the

edge. Stand erect only if necessary and only away from the edge. Working from

a kneeling position helps reduce the threat of a fall.

The ECASL systems may be used to store various forms of oils, lubricants, and

other potentially slippery substances. Keeping the inside floor of the FPU-20-3

container clean is important, nevertheless, always move with caution inside of

the FPU. Failure to maintain cleanliness and caution could cause a slip and

injury.

BOH-PM-16-1

WARNING SUMMARY

This warning summary contains general safety warnings and hazardous materials warnings that must be

understood and applied during operation and maintenance of this equipment. Failure to observe these

precautions could result in serious injury or death to persons using equipment.

WARNING

The module drawers and pallets can be heavy and awkward to handle by a

single person. This is especially true of the larger components. The adjustment

of these items is a two-person operation. While a forklift is not essential MHE

support to hold the pallets in position while the hardware is installed and secured,

it simplifies the effort. Do not try to adjust the pallets or drawers without

assistance or MHE support. Ensure that all modules are properly locked down

before any movement or transport of the containers.

WARNING

Forklift operator should always use module forklift pockets when moving FPU

modules to prevent tipping. Ground guides must insure no personnel go

underneath modules during movement operations. Failure to comply could

cause injury, death or damage to the equipment.

WARNING

Use extreme caution when loading or unloading FPU modules from and into FPU

containers. Forklift operator should maintain visual contact with ground guides at

all times. Ground guides should never come between the module and container

during loading process. If visual contact with ground guide is lost, immediately

suspend all operations, turn off forklift and set emergency brake. Failure to

comply could cause serious injury, death or damage to the equipment.

WARNING

Always follow standard forklift procedures. A tilt hazard exists when forklift

operators try to lift an FPU module, without inserting forklift tines into module

forklift pockets. Operators should always keep loads low and close to the forklift

carriage. Operators should never travel when the load is in the fork’s extended

position. Ensure hands, feet and limbs are clear of the container and

components during any forklift or lifting operation. Failure to comply could cause

injury or damage to the equipment.

WARNING

The modules, containers and their contents are heavy and could

cause injury or death if they fall onto or strike personnel. A tilt

hazard exists when the module is not properly locked down to the

adapter. As a rule, always work on one pallet or drawer at a time.

Never have more than one drawer extended in the full open position

at a time, especially if loaded. Ensure that all drawers, modules and

components are properly locked latched and secured in place prior

to any movement of the container or modules.

BOH-PM-16-1

WARNING SUMMARY

This warning summary contains general safety warnings and hazardous materials warnings that must be

understood and applied during operation and maintenance of this equipment. Failure to observe these

precautions could result in serious injury or death to persons using equipment.

WARNING

Always inspect the working areas, insure that the front, rear and sides of the

modules are free of oils, lubricants, and other potentially slippery substances.

The module drawers may be used to store various forms of lubricants, and other

potentially slippery substances. Keeping the drawers and the work area around

the module clean, to prevent spillage and slippery surfaces. Personnel should

never stand on a drawer or pallet.

Container Overhead Power Line Warning

WARNING

Overhead power lines and obstructions can cause serious injury or damage to property. Forklift

operators, truck drivers, and ground guides should always clear overhead when loading,

unloading, moving the FPU container and modules or when accessing FPU container roof.

WARNING

Protective gloves should be worn when handling metal parts in high temperatures. Failure to

wear gloves may result in burning or blistering of the skin upon contact.

WARNING

Protective gloves should be worn when handling metal parts in below freezing temperatures.

Failure to wear gloves may result in skin freezing to the metal upon contact and cause tearing

of the flesh when attempting to pull away from the metal.

WARNING

The FPU is NOT designed to be operated in contaminated NBC Environments. The FPU is

designed to operate outside an established NBC safety perimeter.

Do not operate the FPU in contaminated NBC environments. If possible, cease operation of

the FPU prior to an NBC event and do the following:

1. Close and secure all doors. External surfaces of the FPU Container are CARC

painted and can be decontaminated; however, whenever possible avoid

contamination of the internal areas of the FPU Container System.

2. Decontaminate the exterior surfaces of the FPU in accordance with FM 3-5. Only

Qualified NBC NCO’s should check for residual contamination before opening the

container.

3. Remain in MOPP 4 posture when opening the doors and have the NBC NCO check

for contamination on interior surfaces.

4. If thorough decontamination is required, refer to NBC NCO and FM 3-5 for

procedures.

BOH-PM-16-1

GENERAL WARNINGS

HEAVY PARTS - heavy object on human figure shows that heavy parts present a danger to life or limb.

HEAVY PARTS - heavy object pinning human figure against wall shows that heavy, moving parts present

a danger to life or limb.

HEAVY PARTS - hand with heavy object on top shows that heavy parts can crush and harm.

HEAVY PARTS - foot with heavy object on top shows that heavy parts can crush and harm.

SLICK FLOOR - wavy line on floor with legs prone shows that slick floor presents a danger for slipping or

falling.

HEAVY OBJECT - human figure stooping over heavy object shows physical injury potential from

improper lifting technique.

ELECTRICAL - electrical wire to arm with electricity symbol running through human body shows that

shock hazard is present.

ELECTRICAL - electrical wire to hand with electricity symbol running through hand shows that shock

hazard is present.

CRYOGENIC - hand in block of ice shows that the material is extremely cold and can injure human skin

or tissue.

FIRE - flame shows that a material may ignite and cause burns.

BOH-PM-16-1

FPU®SYSTEMS OPERATION MANUAL

(INCLUDING REPAIR PARTS)

EXPEDITIONARY CONTAINERIZED AUTHORIZED STOCKAGE LIST (ECASL)

BOH FPU Field Pack-up Units

REPORTING ERRORS & IMPROVEMENTS

REPORTING ERRORS AND RECOMMENDING IMPROVEMENTS

You can help improve this manual. Please let us know if you find any mistakes or if you know of a way to improve the

procedures. You may send in your recommended changes by E-mail directly to: dcresap@bohfpusystems.com. A reply will

be furnished directly to you.

TABLE OF CONTENTS WP Sequence No.

WARNING SUMMARY ............................................................................................................................................................a

HOW TO USE THIS MANUAL................................................................................................................................................iii

CHAPTER 1 – INTRODUCTORY INFORMATION WITH THEORY OF OPERATION

General Information.................................................................................................................................................0001 00

Theory of Operation.................................................................................................................................................0002 00

Equipment Characteristics, Components and Accessories.......................................................................................0003 00

Equipment Data Labels, Identifications, Markings, and Airlift Certification................................................................0004 00

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CHAPTER 2 – OPERATOR INSTRUCTIONS

Preparation for Movement........................................................................................................................................0005 00

Operation of FPU Containers...................................................................................................................................0006 00

Operation of Bulk Storage Aids................................................................................................................................0007 00

Operation of Parts Storage Aids...............................................................................................................................0008 00

Operation of Bulk Storage Module ...........................................................................................................................0009 00

Operation of FPU Standard Storage Modules..........................................................................................................0010 00

Operation under Unusual Conditions .......................................................................................................................0011 00

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CHAPTER 3 - TROUBLESHOOTING PROCEDURES

Introduction..............................................................................................................................................................0012 00

Troubleshooting Indexes..........................................................................................................................................0013 00

Troubleshooting Procedures....................................................................................................................................0014 00

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CHAPTER 4 – OPERATOR MAINTENANCE INSTRUCTIONS

Introduction to Preventative Maintenance Checks and Services (PMCS).................................................................0015 00

PMCS Table............................................................................................................................................................0016 00

Cleaning and Lubricating .........................................................................................................................................0017 00

FPU-20-3 Doors.......................................................................................................................................................0018 00

FPU-20-3 Folding Steps...........................................................................................................................................0019 00

Parts/Bulk Storage Aid Vertical Rack Frame............................................................................................................0020 00

Bulk Storage Aid Pallet ............................................................................................................................................0021 00

Bulk Storage Aid Pallet Ledge..................................................................................................................................0022 00

Standard Storage Modules ......................................................................................................................................0023 00

Bulk Storage Module................................................................................................................................................0024 00

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BOH-PM-16-1

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CHAPTER 5 – UNIT MAINTENANCE INSTRUCTIONS

FPU-20-3 Door Assemblies .....................................................................................................................................0025 00

FPU-20-3 Door Seals...............................................................................................................................................0026 00

FPU-20-3 Folding Steps...........................................................................................................................................0027 00

Parts/Bulk Storage Aid Vertical Rack Frame............................................................................................................0028 00

Parts Storage Aid Drawer Assembly........................................................................................................................0029 00

Parts Storage Aid Drawer Slide................................................................................................................................0030 00

Bulk Storage Aid Pallet ............................................................................................................................................0031 00

Bulk Storage Aid Pallet Ledge..................................................................................................................................0032 00

Removable Cradle (8 ft. compartment of the FPU-20-3)...........................................................................................0033 00

Removable Cradle Lock Device ..............................................................................................................................0034 00

FPU-20-3 Rear Roller Assembly..............................................................................................................................0035 00

Bulk Storage Module................................................................................................................................................0036 00

Bulk Storage Module Shelf Reposition.....................................................................................................................0037 00

Bulk Storage Module Bearing Replacement.............................................................................................................0038 00

Bulk Storage Module 8” Bin Kit ................................................................................................................................0039 00

Standard Storage Modules ......................................................................................................................................0040 00

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CHAPTER 6 – PARTS SUPPORTING INFORMATION

Introduction to Maintenance Allocation Chart (MAC)................................................................................................0041 00

Maintenance Allocation Chart (MAC) .......................................................................................................................0042 00

Introduction to Repair Parts List...............................................................................................................................0043 00

Repair Parts List (ECASL Configurations #1 - #5)....................................................................................................0044 00

Repair Parts List (FPU-20-3)....................................................................................................................................0045 00

Repair Parts List (Standard Modules) ......................................................................................................................0046 00

Repair Parts List (Bulk Storage Module) ..................................................................................................................0047 00

00 ECASL SYSTEMS

01 ECASL CONFIGURATIONS

0101 ECASL #1

0102 ECASL #2

0103 ECASL #3

0104 ECASL #4

0105 ECASL #5

02 FPU-20-3 CONTAINER

0201 Door Assembly

0202 Folding Steps

0203 Rear Roller Assembly

0204 Vertical Rack Frame

0205 Parts Storage Aids

020501 Drawer Assembly

0206 Bulk Storage Aids

020601 Pallets

020602 Pallet Ledges

0207 Removable Cradle

0208 Tie-Down Rings

0209 Wall Vent Kit

0210 Floor Riv-Nuts

03 STANDARD MODULES

0301 Module #26

0302 Module #23

0303 Module #22

0304 Module #21

0305 Module Drawers and Bearing Slide

04 BULK MODULE

0401 Bulk Module #3

040101 FPU Bulk Chassis

040102 Bulk Tray 1000 lb.

040103 8” Bulk Bin Adapter Kit

040104 Latch and Bearing Assemblies

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BOH-PM-16-1

iii

NSN Index...............................................................................................................................................................0048 00

Part Number Index...................................................................................................................................................0049 00

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REAR MATTER

BOH Product Warranty

HOW TO USE THIS MANUAL

This manual contains general information, operating instructions, Preventative Maintenance Checks and Services (PM CS), and

maintenance/repair instructions for the ECASL Systems.

Front matter consists of front cover, warning summary, title block, table of contents, "how to use this manual" pages, and

provides information on the ECASL Systems and their associated equipment. Chapter 1 provides equipment description

and data as well as the theory of operation. Chapter 2 provides instructions for operating under usual and unusual

conditions. Chapter 3 contains troubleshooting procedures authorized at the Operator and Unit level. Chapter 4 contains

Preventive Maintenance Checks and Services (PMCS) and Operator Maintenance Instructions. Chapter 5 contains Unit

Maintenance Instructions. Chapter 6 contains the Maintenance Allocation Chart (MAC); it also includes the Repair Parts List

that identifies parts unique to the operation and maintenance of the ECASL Systems.

Manual Organization and Page Numbering

This manual is divided into six major chapters that detail the topics mentioned above. Within each chapter are work

packages covering a wide range of topics. Each work package is numbered sequentially at page 1, and has its own page

numbering scheme that is independent of the page numbering used by other work packages. Each page of a work package

has a page number of the form "XXXX YY-ZZ", where "XXXX YY" is the work package number (e.g. 0010 00 is work

package 10) and "ZZ" represents the number of the page within that work package. Blank pages will be labeled “This page

was intentionally left blank”.

Finding Information

The Table of Contents permits the reader to quickly find information in the manual. The reader should start here first when

looking for a specific topic. The Table of Contents lists the topics contained within each chapter and the work package

sequence number where it can be found.

Types of notations

Warnings - Warnings are posted immediately prior to text covering any area that would present a situation that may result in

injury or death. Compliance is mandatory.

Cautions - Cautions will be found on the same page and preceding the text covering any area that would present a situation

that may result in damage to equipment.

Notes - Notes will precede text covering an area with the intent to alter normal procedures for unique situations or

equipment, or point out areas of special concern.

BOH-PM-16-1

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