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.

BlueTruckMaster® – Operating and safety manual
Wires of the DC-powered pumps must also be correctly con-
nected, namely, the black wire must be connected to the nega-
tive and the red wire connected to the positive pole.
More information can be found in the pump manual included with the de-
vice.
11. VEHICLE REFUELLING
Before refuelling, the BlueTruckMaster®pump must be connected to a
power source (see Point 10). Also, when using BlueTruckMaster® 900, make
sure that the ball shut-off valve before the pump is open. Turn on the pump
using the switch and insert the filling nozzle into the AdBlue® tank inlet.
Refuelling will start within two minutes after pressing the nozzle pushbut-
ton.
When handling tanks that are not equipped with automatic fill-
ing nozzles, pay attention to prevent tank overflow as they do
not automatically cut off the flow.
Do not start pumping when BlueTruckMaster® is empty. Therefore, the
pump should be shut off immediately after draining the tank. Otherwise the
pump may be damaged. The maximum pump running time is indicated on
the nameplate or in the pump manual that is included with the device. Do
not exceed the allotted time because otherwise the pump will get over-
heated.
12. FLOWMETER
Depending on the specifications, tanks can be equipped with
a flowmeter. Information on flowmeter usage can be found in
a separate guide included with the device.

BlueTruckMaster® – Operating and safety manual
13. STORAGE
Store the products in a dry place. Protect from sunlight. Only temporary stor-
age of AdBlue® in the tank is allowed, subject to compliance with local fire
protection and Health and Safety regulations.
BlueTruckMaster® should not be stored in temperatures lower than -10°C
unless the tank and its equipment (esp. pump, flowmeter and nozzle) are
absolutely empty. Otherwise freezing liquid may damage these elements.
Prolonged storage of AdBlue® in temperatures higher than 25°C may lead
to its decomposition or excessive evaporation of
water from it. This does not influence the tank and
its equipment.
After use the pump power cord should be
disconnected from the power source and the unit
lid should be closed. The lid is shower proof and
protects the tank and equipment from light and
moderate rain, but is not water tight.
With the exception of BlueTruckMas-
ter® 900, all tanks can be stacked on top
of one another (up to 3), but only if they
are empty. Otherwise they can be damaged.
14. MAINTENANCE
Keep the tank and its equipment clean and in good condition. Before each
use, check the product for damages, in particular check whether the struc-
ture of the tank is not affected, all connections are tight and the pump
power cord is not damaged.
Do not use a damaged or poorly marked tank. A dirty tank or its
equipment may contaminate the stored AdBlue® and as a result
cause engine damage.

BlueTruckMaster® – Operating and safety manual
15. WARRANTY
Prior to leaving the factory, each product was carefully and thor-
oughly checked in terms of safety and operation. If you spot
a defect or damage, contact your dealer or manufacturer.
Warranty details are in a separate document included with the product.
16. ACTIONS IN THE CASE OF ACCIDENT
In the case of leak or overfilling a tank safety actions should be immediately
taken as described in the safety data sheet of AdBlue®.
In particular, quickly and safely stop or reduce the spill of Ad-
Blue® by sealing a tank or cut of the flow of AdBlue® (in the case
of events occurring during the filling of a tank). Depending on
the size of spill and its location transfer spilled AdBlue® into another con-
tainer or soak up with an appropriate absorbent material (e.g. sand) and
dispose of safely following local regulations or use as agricultural fertilizer.
17. COMMON PROBLEMS AND SOLUTIONS
Problems such as those connected with pump or flowmeter operations are
described in separate instructions included with the tank. The following cir-
cumstances may occur when operating the device:

BlueTruckMaster® – Operating and safety manual
Problem
Possible cause
Remedy
Tank walls buckled
slightly when the
tank was full.
Symptom typical for plastic
tanks with no effect on the
functionality of the device.
-
Tank walls col-
lapsed when refu-
elling vehicle.
Vent is clogged or damaged.
Stop refuelling the vehicle and
eliminate the fault / clean or
replace the vent.
The content is con-
taminated.
Tank or its equipment are
dirty.
Empty tank and wash it with
distilled or deionized water
(see Point 6). The contami-
nated AdBlue® can be used as
agricultural fertilizer or dis-
posed with the help of a spe-
cialised company.
Pump does not
work.
No power or inadequate
power is supplied to the pump.
Pump is damaged or blocked.
Check if the pump is connected
to the correct power source.
Repair or replace the pump.
Pump is operating
but no liquid is fed.
The tank is empty.
Ball shut-off valve is closed
(applies to BlueTruckMaster®
900).
The sucking system is blocked.
The turbine of a flow meter is
blocked.
Distribution hose or filling noz-
zle is blocked or there is air in
the pump.
Turn off the pump and fill the
tank.
Open the valve.
Clean the hose / sucking pump,
especially the end filter.
Clean the distribution hose and
filling nozzle.
Clean the turbine and unblock
it.
Wait 2 minutes and if this does
not help, unscrew the filling
nozzle and re-start the pump.
The filling nozzle
prematurely cuts
off the AdBlue®
supply.
Refuelling speed is too high.
The tip of the filling nozzle is
too close to the walls of the in-
let.
Reduce the flow velocity.
Reposition the filling nozzle.

BlueTruckMaster® – Operating and safety manual
Problem
Possible cause
Remedy
The flowmeter LCD
does not work
Batteries are used up.
Replace batteries.
The flowmeter
does not count, but
the flow rate is cor-
rect
Incorrect installation of gears
after cleaning.
Possible electronic card prob-
lems
Repeat the reassembly proce-
dure.
Contact your dealer.
18. DISPOSAL
After use, the tank must not be disposed of with other unsorted waste but
must be disposed of with the help of a specialised company or by delivering
it to the facility accepting electronic waste.
19. PRODUCT MODIFICATION AND SPARE PARTS
Product must not be modified without the written permission
of the manufacturer. When repairing the tank, use only the
OEM spare parts available. Failure to observe this requirement
will result in the loss of warranty rights.
The manufacturer is not liable for damages and losses caused by the modi-
fication of equipment or use of parts other than OEM spare parts.

Kingspan Environmental Sp. z o.o.
ul. Topolowa 5
62-090 Rokietnica, Poland
www.kingspanenviro.com
[email protected]