Kingspan BlueTruckMaster 200 Instruction Manual

BlueTruckMaster®
Mobile tank for distribution and transport of AdBlue®
Operating and safety manual
November 2016
Ver. 2

BlueTruckMaster® – Operating and safety manual
1. TABLE OF CONTENTS
1. Table of contents ..................................................................................1
2. Safety instructions ................................................................................ 2
3. Introduction ..........................................................................................2
4. BlueTruckMaster® use ..........................................................................3
5. Technical specifications ........................................................................ 3
6. First use................................................................................................. 6
7. Handling ................................................................................................6
8. Transport...............................................................................................7
9. Filling a tank ..........................................................................................8
10. Connecting the pump ...........................................................................8
11. Vehicle refuelling ..................................................................................9
12. Flowmeter............................................................................................. 9
13. Storage ................................................................................................10
14. Maintenance .......................................................................................10
15. Warranty .............................................................................................11
16. Actions in the case of accident ...........................................................11
17. Common problems and solutions.......................................................11
18. Disposal...............................................................................................13
19. Product modification and spare parts ................................................13

BlueTruckMaster® – Operating and safety manual
2. SAFETY INSTRUCTIONS
This manual contains important operating and safety infor-
mation and warnings. Read this manual thoroughly and care-
fully and follow all the guidelines contained therein.
This manual is intended for information purposes only and should not be
regarded as a source of law. Following these guidelines does not release the
user from complying instructions in AdBlue® material safety data sheet, the
local regulations on H&S, fire protection and environmental protection. The
manufacturer is not liable for damages or losses caused by improper use of
the product and failure to comply with applicable regulations.
Store the manual in a safe place for future use. The manufacturer reserves
the right to change the wording of this manual without prior notice.
3. INTRODUCTION
This is the operating and safety manual for a mobile tank for distribution
and transport of AdBlue®.
Before first use, please read this manual and follow its guide-
lines. This manual will be your guide for many years to come and
will allow for safe operation of the product. Furthermore, these
guidelines are part of the warranty conditions. Failure to follow them may
result in the loss of warranty.

BlueTruckMaster® – Operating and safety manual
4. BLUETRUCKMASTER® USE
BlueTruckMaster® is designed for the transport and distribution of Ad-
Blue®
1
. AdBlue®is a trade name for an aqueous urea solution made with
32.5% urea and 67.5% deionized water used as a consumable in selective
catalytic reduction (SCR) in order to lower NOx concentration in the diesel
exhaust emissions from diesel engines. Depending on the country, it is
known also as AUS 32 (aqueous urea solution), DEF (diesel exhaust fluid),
NOXy® etc.1. In the further parts of this text only AdBlue® name is used.
Using the tank for storage, transport or distribution of other liq-
uids it is prohibited without written permission of the manufac-
turer. Moreover, do not use the product for long-term storage
of liquids.
The manufacturer is not liable for damages or losses caused by
improper use or failure to observe the rules applicable to this
type of equipment.
5. TECHNICAL SPECIFICATIONS
BlueTruckMaster® is available in five sizes. Technical data for each product
is presented on the next page. The detailed technical specification of each
tank is dependent on the version of the tank and optional accessories.
1
Registered trademarks are used only for reference.

BlueTruckMaster® – Operating and safety manual
BlueTruckMaster® 200
dimensions (W × D × H) 600 × 800 × 620 mm
nominal capacity 200 L
BlueTruckMaster® 300
dimensions (W × D × H) 600 × 800 × 890 mm
nominal capacity 300 L
BlueTruckMaster® 200
(low profile)
dimensions (W × D × H) 1180 × 860 × 500 mm
nominal capacity 200 L
BlueTruckMaster® 430
dimensions (W × D × H) 1180 × 860 × 910 mm
nominal capacity 430 L
BlueTruckMaster® 900
dimensions (W × D × H) 1140 × 1050 × 1210 mm
nominal capacity 900 L

BlueTruckMaster® – Operating and safety manual
BlueTruckMaster® consists of a polyethylene rotationally moulded tank and
a distribution set that allows refuelling of vehicles and other equipment.
Tank distribution system consists of the following elements (they may vary
depending on the actual specification of the tank):
1. polyethylene tank,
2. lid,
3. vent,
4. inlet,
5. hose/suction pipe fitted with a mesh filter,
6. shut-off ball valve
2
,
7. pump
3
,
8. pump supply cord with clamps or plug,
9. distribution hose,
10. flowmeter (optional),
11. filling nozzle.
2
Only in BlueTruckMaster® 900
3
Available options depend on the model of the tank

BlueTruckMaster® – Operating and safety manual
6. FIRST USE
Before the first use and after any repairs the user should check if the tank
and its equipment are clean. If need be clean with distilled or deionized wa-
ter. If these are not easily available tap water can be also used providing
that the final rinse is done using AdBlue®.
Fill tank as described in Point 9 then pump the first 5 L into an-
other container and use as agricultural fertilizer or dispose of
with the help of a specialised company. This collected AdBlue®
cannot be used in vehicles or discharged into sewage system.
If the above guidelines are not followed, the content of the tank
may get contaminated and this can result in damage to the en-
gine in the vehicle.
7. HANDLING
An empty BlueTruckMaster® can be lifted
using the handles on the sides of the tank.
The weight of the lifted device must not ex-
ceed the limit values specified in the Occupa-
tional Health and Safety regulations for lifted
items.
Each tank comes equipped with special chan-
nels at the bottom for convenient lifting with a forklift when the tank is
filled.
Some tanks also come with lifting points for attaching special
shackles when using a crane or other lifting equipment. Pushing
or moving tanks on the ground is prohibited.

BlueTruckMaster® – Operating and safety manual
8. TRANSPORT
When placed on the vehicle, the tank must be adequately secured to pre-
vent displacement while respecting international and local regulations con-
cerning traffic, securing and transport of cargo, in particular the provisions
of the ADR on international carriage of dangerous goods by road and
EN 12195, which specifies the methods and rules for calculating clamping
force.
Tanks have special features to allow securing of the device to the vehicle by
belts. Examples are shown in figures below.
Prior to transporting the product, make sure that the lid and the
filling nozzle are closed. When handling BlueTruckMaster® 900
make sure that the ball shut-off valve before the pump is locked.
Pump power cord and distribution hose must be rolled up and tucked under
the lid. Filling nozzle should be placed in the designated holder.

BlueTruckMaster® – Operating and safety manual
9. FILLING A TANK
The tank should be filled through inlet (see Point 5) using dispensing noz-
zles, e.g. being the part of dispensing units in gas stations.
It is forbidden to fill the tank directly from a tanker. Moreover,
BlueTruckMaster® can be filled only with AdBlue®. The maxi-
mum filling rate is 100 l/min and it should not be exceeded. Pay
attention to the vent and check if it is not blocked when filling a tank.
10. CONNECTING THE PUMP
Before refuelling, the pump must be connected to a power source. Depend-
ing on the specifications, BlueTruckMaster® can be equipped with a pump
powered by a 12 V DC and/or 24 V or 230 V AC. The supply voltage of the
pump must be consistent with the voltage stated on the pump nameplate.