LC60 Manual Final

LC60 LAVATORY
SERVICE CART
Operation Manual
Mailing and physical address:
11175 W. Emerald
Boise, ID 83713 USA
Phone: 208-378-9888
Fax: 208-378-9889
Email: staff@aerospecialties.com
Website: www.aerospecialties.com
Please take a moment and fill in the following information

for convenience in parts ordering or service for the
AERO Specialties equipment pertaining to this manual.
The model and serial number are located on a placard
on your equipment.
Model:
Serial Number:
Date Received:
Model:
Serial Number:
Date Received:
Table of Contents
LC60 LAVATORY SERVICE CART
INTRODUCTION ................................................................................................................4
WARRANTY INFORMATION ................................................................................................5
AGREEMENT OF CONFIDENTIALITY ....................................................................................5
SAFETY............................................................................................................................6
GENERAL INFORMATION & OPERATING INSTRUCTIONS ......................................................8
SECTION 1 - DESCRIPTION ..........................................................................................8
SECTION 2 - OPERATION............................................................................................10
SECTION 3 - SPECIFICATIONS ....................................................................................11
Mechanical Dimensions of LC60 Cart..............................................................................12
MAINTENANCE ..............................................................................................................13
SECTION 1 - SERVICING ............................................................................................13
SECTION 2 - REPAIRS................................................................................................14
ILLUSTRATED PARTS LISTS ............................................................................................15
LC60 Parts Breakdown ............................................................................................15
LC60 Standard & Replacement Parts List ..................................................................17
LC60 Options Parts List............................................................................................18
Guzzler 2600 Pump Parts Diagram ............................................................................19
CE-MARK INFORMATION ..................................................................................................20
Safety, Warning & Operation Labels ................................................................................22
AERO Specialties LC60 Lavatory Service Cart v.1/08 3

Questions? Contact Aero Specialties at 208-378-9888
LC60 Lavatory Service Cart
Introduction
Thank you for purchasing AERO Specialties' LC60 Lavatory Service Cart. When used properly, this
cart will provide years of lavatory servicing pleasure for everyone who uses it, especially those with
diminished olfactory senses.
AERO Specialties constructs all of its aircraft service carts from high-quality materials, and assem-
bles them with durable and efficient components. As with any piece of ground support equipment,
parts will need to be replaced occasionally because of normal wear-and-tear. Although AERO
Specialties warranties its new service carts for one year (see Warranty section below for more infor-
mation), we are dedicated to helping you keep your equipment in operation for many years. AERO
stocks all replaceable parts for its service carts, and manufactures its own lav and water fill cou-
plers and fittings. All parts are available for order through AERO's secure online store (www.aerospe-
cialties.com) - with a credit card or a PO# if you have an account with us. Of course you can still
order parts the old fashioned way by giving us a call.
4 AERO Specialties LC60 Lavatory Service Cart v.1/08

Agreement of Confidentiality
This manual is, and shall remain, the property of AERO Specialties, Inc. This manual is provided for
the use of AERO Specialties, Inc.'s customers to aid them in the operation and maintenance of
equipment purchased from AERO Specialties, Inc. The material contained within this manual is
strictly confidential and the distribution of this manual or revealing of its contents is expressly pro-
hibited. The user's acceptance of this manual constitutes acknowledgment of these conditions and
agreement to conform to them.
Any disclosure of the confidential material contained within this manual may result in the immediate
repossession of this manual by AERO Specialties, Inc., and termination of all warranty coverage and
technical support.
Warranty
Subject to the conditions stated herein, AERO Specialties, Inc. warrants that the equipment deliv-
ered to the original purchaser will be free from defects in material and workmanship for a period of
twelve (12) months from the date of delivery. AERO Specialties, Inc. agrees, upon prompt notifica-
tion of defect and confirmation that the equipment has been operated and maintained within the
recommendations of AERO Specialties, Inc., to repair or replace any part or parts proven to our sat-
isfaction to have been defective in materials or workmanship.
Replacement parts will be invoiced in the regular manner with invoices subject to adjustment after
the parts claimed to be defective are examined at our factory. No material or parts will be accepted
at our factory for in-warranty repairs or credit without previous authorization from AERO Specialties,
Inc. If inspection by AERO Specialties, Inc. does not verify defects in material or workmanship, our
regular charges will apply.
No warranty is made or implied with respect to equipment accessories, component parts, or auxil-
iary equipment not warranted by their respective manufacturers, and these warranties are passed
along to purchaser. AERO Specialties, Inc. shall in no event be responsible or liable for modifica-
tions, alterations, misapplication, or repairs made to its equipment by purchaser or others without
the authorization of AERO Specialties, Inc. This warranty does not apply to damage caused by negli-
gence, improper maintenance, accident, overloading, or improper use by purchaser or others. AERO
Specialties, Inc. shall not be liable for any special or consequential damages, such as loss of profits
or revenue, loss of other equipment, down-time costs, costs associated with the removal of equip-
ment from service, or claims of third parties against the purchaser.
Responsibility for damages incurred in transit will be borne by the user, and the user in turn must
file any damage claim against the carrier. All warranty items are F.O.B. our factory, and freight
charges are the responsibility of the user.

SAFETY
Read & Understand This Manual
Described below are general safety precautions and possible hazards involved in using AERO
Specialties lavatory and potable water service carts. It is the user's responsibility to read and
understand this operation manual prior to (and, of course, during) using any of the lavatory or
potable water equipment described herein.
Local Regulations & Procedures

It is further the operator's responsibility to adhere to local procedures and regulations for use of
lavatory and potable water servicing equipment. Users of this equipment are required to develop
and/or adhere to appropriate procedures for use, including safety procedures, with the various air-
craft intended to be serviced, in accordance with the technical regulations and requirements in force
in the jurisdiction where this equipment is used.
Risk of Spillage
Fluid contents of lav and water carts can spill or overflow, creating a variety of potential hazards.
Operators must monitor all actions involving lav or water cart fluids, and take appropriate cautions
against slipping or falling if a spill should occur. The following are some examples of possible
spill/overflow risk:
• Towing or turning the cart at excessive speed. Never exceed 12 MPH on straight roads, and 5
MPH during turns.
• Dragging hoses on the ground while towing. Holes or thin areas can wear in hoses, which will
leak with little or no pressure.
• Not properly maintaining equipment. Hoses, couplings, and plugs can leak if not properly
maintained, or if defects exist in the material. Operators must follow the maintenance sched-
ule and carefully inspect and maintain all components to prevent unexpected spills, leaks, or
over flow of fluid.
• Not monitoring flow of fluids during cart or aircraft servicing. Filling aircraft lavatory reservoirs
requires strict monitoring of fill fluid flow volume. The aircraft toilet will overflow with fill fluid into
the aircraft if excessive fluid is pumped, which will damage the aircraft.
It is the user's responsibility to assure that tanks are not overfilled. AERO Specialties will not be
liable for any damage caused by overfilling tanks or aircraft.

Risk of Exposure to Sewage/Fill Fluid (Lavatory Servicing Carts only)
There is a risk of exposure to human waste and/or lavatory fill fluid (“blue juice”) when servicing air-
craft lavatories or when emptying lav carts. Exposure to human waste, even when mixed with “blue
juice” sanitizing fluid, can cause serious illness. Operators should wear protective gloves and eye-
wear or face masks to prevent accidental exposure to this sewage. If exposed to sewage, wash
thoroughly and immediately with anti-bacterial soap. Fill fluid itself is not toxic, but can cause skin
rashes or other irritations in some people. Some types of fill fluid will stain skin, fabric, and other
material. It is the user's responsibility to be aware of the potential dangers in using their facility's
particular type of fill fluid, and to take appropriate precautions to avoid harmful exposure.

SECTION 1 - DESCRIPTION
GENERAL INFORMATION & OPERATING INSTRUCTIONS
General
The LC60 is a self-contained mobile cart designed for servicing the lavatory facilities of corporate
and business aircraft. The LC60 tanks are made of heavy-duty, rotationally molded plastic, and the
chassis and towbar are galvanized steel. The fill/flush pumping system consists of an easy-to-oper-
ate heavy-duty hand pump. The LC60 includes all required hoses and fittings to service any applica-
ble aircraft. It is designed for light towing by hand or vehicle (under 12 MPH).
Major Components
A. Chassis
The chassis is constructed of galvanized U-Channel steel. The steering unit consists of a pneumatic
swivel caster attached to a galvanized towbar with positive braking when in the upright position. The
rear axle is welded to the member for additional strength. The tow bar is made of galvanized heavy
wall steel pipe and a ring towing eye. The running gear consists of steel rims, replaceable 5/8”
bearings, and pneumatic rubber tires.
B. Tank Assemblies
The fill and waste tanks are constructed of rotationally molded, cross-link translucent polyethylene.
The translucency of the tanks allows operators to view the fluid level in each tank. The vertically
interlocking tanks have no seams, are UV-protected, and include molded-in graphics. The waste
tank capacity is 35 US Gallons, and the fill/flush tank capacity is 28 US Gallons. The fill tank fea-
tures a threaded 1-1/2” fill port, and a steel-screened dome vent per FDA requirements.
The waste tank slopes from front-to-back (eliminating the need for a dump pump). The 3” PVC gate
valve for gravity draining features a bayonet attachment for: a) the locking cap secured by a lanyard;
and b) the 10-foot cart-to-ground hose included with the unit. A no-cost optional dump configuration
consists of a 90-degree-downturn PVC elbow for operators dumping straight into a ground disposal.
The waste tank features an external channel and coupling stow flange to store the waste hose and
coupling when not in use.
C. Pumping System
The LC60 features a Guzzler 2600 hand pump for the fill/flush tank (4 strokes to the gallon). The
10-foot fill hose is clear nylon-braid-reinforced 1” hose. The fill coupler is an AERO Specialties 1”
gold anodized aluminum general aviation coupler, which will fit all aircraft. The coupler comes
installed on the fill hose, and features a plug attached to a lanyard to prevent leaking when not in
use. There is a drain-back valve on the fill hose near the hand pump to allow fill fluid to flow back
into the fill tank before disconnecting the fill coupler from the aircraft, thus preventing those annoy-
ing bluejuice spills. An optional in-line digital flow meter can be added to the fill hose for monitoring
the volume of fill fluid pumped into the aircraft.

D. Waste Hose & Fittings
The LC60 is equipped with a 6'-3” long by 4” diameter waste hose of translucent blue urethane with
a crush-proof internal nylon helix coil. The aircraft end of the hose features a 4” GA waste coupler,
which is secured to the cart when not in use by an FDA-required waste coupler stow flange.

SECTION 2 - OPERATION
A. General
Operation of the AERO Specialties LC60 Lavatory Service Cart is fairly simple. The following recom-
mendations are made for the operation of the unit. Refer to your company policies for their specific
procedures in the operation of ground support equipment.
B. Pre-operational Check
Walk around the unit and make a visual inspection, paying particular attention to the following:
• Check general condition of unit
• Note the condition of tires and wheels.
• Make sure all hoses are secure.
• Make sure waste tank lid and fill tank port are closed and secure.
• Check the waste dump valve, make sure it is closed and cap is locked.
• Check fluid level of fill tank.*
C. Towing
1. Pull unit to aircraft at a safe speed.
2. Position unit so that rear of cart is adjacent to aircraft service point and such that no sharp
kinks will be in waste or flush hose when attached to the aircraft.
D. Aircraft Servicing
1. Remove the 4” waste coupler from stow flange on top of unit and secure to aircraft.
2. Drain aircraft waste container tank. Caution: BE SURE DUMP VALVE ON WASTE TANK IS
CLOSED and capped or you will have one very ugly mess!
3. Connect the 1” fill coupler to aircraft.
4. Close drain-back valve near pump and begin pumping hand pump - 4 strokes = 1 US Gallon (1
stroke = up AND down).
5. Fill aircraft flush tank with appropriate amount of fluid. Count the strokes to determine the
amount of fluid you have pumped into plane. If flow meter is installed, watch the meter to
determine the amount of fluid pumped into aircraft you are servicing.
6. When aircraft flush tank is filled:
a. Open drain-back valve to allow fluid in hose to return to fill tank.
b. Remove fill coupler fitting at aircraft and insert coupler plug into the coupler.
c. Return fill hose to its stow position the top of the unit, and close drain-back valve.
d. Reset flow meter (if applicable).
7. Remove waste hose from aircraft and replace coupling in the plastic stow flange.
8. Make sure that all hoses and fittings are secure and that there are no obstructions around
unit before pulling away.

*NOTE ON FILL FLUID: Please carefully follow manufacturer instructions for mixing or diluting lavato-
ry fill fluid or powder. Fill fluid not adequately dissolved or diluted will clog and damage pump and
flow meter parts.
IMPORTANT: Always wear proper clothing and protective gloves as required by local code.
IMPORTANT: Follow all local regulations regarding handling and disposal of human waste.
SECTION 3 - SPECIFICATIONS
Dimensions:
Length overall: 42 inches (107 centimeters)
Height: 27 inches (69 centimeters)
Width: 30 inches (76 centimeters)
Weight (empty): 85 lbs. (38.5 kilograms)
Shipping information: Palletized & shrink-wrapped, 45” x 40” x 30”, 125 lbs.
(114 cm x 102 cm x 76 cm, 57 kilograms).
Capacity:
Waste Tank: 35 U.S. Gallons/132.5 liters
Fill/Flush Tank: 28 U.S. Gallons/106 liters
Pumping & Waste System:

Guzzler 2600 Heavy-Duty diaphragm hand pump
Fill Hose: 1” I.D. reinforced PVC hose, 10 feet
Fill coupler: 1” short grip AERO Specialties anodized aluminum fill coupler, with plug
Flow Meter (optional): GPI 01N31GM Digital In-Line meter, 3-30 GPM
Waste Hose: 4” I.D. nylon helix-reinforced, translucent blue nylon hose, 6'-3”
Waste Coupler: Kaiser composite general aviation straight coupler
Chassis:
Custom galvanized U-channel steel
Tires\Wheels: steel wheels and 2.80 x 4 pneumatic tires, with 5/8” bearings
Caster: steel wheel and 2.80 x 4 pneumatic tire, with 1/2” bearings

Mechanical Dimensions of LC60 Cart
Total Length: 47” or 109.4 cm
Total Height: 28”

or 71.2 cm (not
including towbar)
Deck Height:
16.75” or 42.5 cm
Ground Clearance
(Frame): 3.25” or 8.3 cm
Ground to top of
latched towbar:
50.5” or 128.3 cm
Ground to top of cart:

22.5” or 57.2 cm
Total Width: 30” or 76.3 cm

MAINTENANCE
SECTION 1 - SERVICING
General
Servicing the AERO Specialties LC60 lavatory service cart can be accomplished with standard
mechanical hand tools. All work should be performed in accordance with standard shop practices.
Chassis and Tanks

The chassis is made from galvanized steel and requires no maintenance. The polyethylene tanks
should be washed with a mild detergent on a regular basis. The corrosive nature of the chemicals
used to service the lavatory systems of aircraft will reduce the life of the unit if regular washing is
not completed. Any part of the LC60 structure that becomes damaged should be replaced or
repaired. Replacement tanks - in the case of a puncture or freezing-related crack, for example - are
available through AERO Specialties.
Plumbing System
The pump, hoses, and couplings should be inspected for wear, leaks, or other damage. The hoses
should be checked for cracks, cuts or other defects that will cause leakage. Those items should be
repaired or replaced. All replaceable parts can be ordered from AERO Specialties.
Pump
The Guzzler 2600 Hand Pump should be inspected regularly. The rubber diaphragm and flapper
valves (on the pump inlet and outlet) should be inspected for cracks or holes, and should be
replaced if damaged. The Guzzler pump and all of its parts can be ordered from AERO Specialties.
Running gear
The wheels and tires should be inspected daily. Unusual tire wear, cuts, leakage, or missing and
damaged fasteners need to be replaced or repaired at once. The wheel bearings should be inspect-
ed every six (6) months. The wheel bearings should be greased monthly using the grease fitting in
the hub. A common wheel bearing grease should be used.
Waste Valve
The dump valve, located at the lower rear of the cart, is a gate valve. The lever should be inspected
for proper operation and the gasket checked for proper sealing. Repair or replace damaged compo-
nents. All replacement parts can be ordered from AERO Specialties.

SECTION 2 - REPAIRS
General
Repairs should be limited to the removal and replacement of detail parts and assemblies. Repairs
of plumbing components should be limited to common shop practices. Repairs of the pump assem-
bly should follow recommended procedures identified in the manufacturer manual.
If repairs are necessary to the structural members or suspension, it is advised to contact AERO
Specialties for the proper procedure.

ILLUSTRATED PARTS LISTS: LC60
Parts Breakdown
(See Parts List on page 16)
18. Waste hose

17. Pump handle
20. Waste coupler
23. Stow flange
for waste coupler 3. Waste tank cap
13. Guzzler 2600

Hand Pump 19. Fill hose
See pump chart
on page 12
21. Fill coupler
25. Fill tank vent
22. Plug for fill

coupler
2. Waste tank
7. Pneumatic Tire
& Wheel assembly
1. Fill tank
8. Waste valve
9. Cover for
waste valve
5. Chassis
26. Fill port plug

24. Fill hose drain
back assembly
Pressure relief 10. Outlet hose
valve (cart to ground)
11. Hose adapter
12. Bayonet ring:

Standard on
6. Towbar waste valve,
optional on 90∞
downturn waste
valve option
9. Waste valve cover
4. Caster

LC60 Standard & Replacement Parts List
Item Part No. Description
1 LC60 Fill Tank Fill Tank - 28 gallons (gray tank)
2 LC60 Waste Tank Waste Tank - 35 gallons (blue tank)
3 LC60 8” Cap Waste Tank cap - 8” screw-in cap w/ring assembly
4 LC60 Caster Front swivel caster assembly, 5/8” bearings
5 LC60 Frame Galvanized chassis, includes corner skid plates (2)
6 LC60 Towbar Galvanized towbar, welded ring, non-marring shoe
7 LC60 Wheel-Tire Pneumatic Tire & Wheel Assembly, 5/8” bearings
8 STD Valve LC60 Waste valve & cap assembly, incl. seal & mounting screws
9 Cover 3” - 01664 Replacement cover for waste valve assembly
10 Dump Hose 3”x10' Waste outlet hose (cart to ground) - 3” x 10'
11 Hose Adapter 3” - 01665 Hose adapter for waste outlet hose
12 Bayonet Ring 3” - 01639 Bayonet ring for attaching waste valve cover or hose adapter
13 Guzzler 2600 Pump Guzzler 2600 Hand Pump
14 Service Kit 2600 Service kit for Guzzler 2600: includes 1 diaphragm & 2 flapper valves
15 Button 2600 Steel button for either side of Guzzler 2600 diaphragm (2 required)
16 Handle Bracket 2600 Handle bracket assembly for Guzzler 2600
17 Handle 2600 Handle for Guzzler 2600
18 Waste Hose 6'3” Blue Waste hose - aircraft to cart, 6'-3” translucent blue w/nylon helix
19 Fill Hose Lav 1” Fill hose - 1” x 12' reinforced clear nylon hose
20 4” LAV Coupler-GA Waste coupler - 4” composite
21 LAV Coupler Fill coupler - 1” anodized aluminum, gold color
22 LAV Plug Plug for fill coupler - 1” anodized aluminum, gold color
23 4” Plug Stow flange (plug) 4” for waste coupler
24 Drainback Kit-LC60 Drain-back assembly for fill hose, incl. brass nipples, hose & valve
25 Dome Vent 1” Stainless Fill tank vent, domed with stainless steel screen (FDA requirement)
26 Plug Poly 1.5” TH Fill Port Plug, 1-1/2” hex plug, PVC

LC60 Options Parts List
Item Part No. Description
1 Flow Meter GPI Flow meter: GPI in-line digital meter, 3-30 GPM
2 4” Lav Coupler - Y Y-Coupler - 4” composite (with integrated donut removal tool)
3 4” Lav Coupler - Yw/GA adapter Y-Coupler - 4” composite with GA nipple adapter (for connecting straight coupler to Y-Coupler
4 Lear Adapter Set Lear Adapter Set, for waste & fill connections on Lear 45 & 60
5 T-Handle T-Handle for removing airline waste donuts without Y Coupler
Waste valve: 90-degree downturn valve assembly for dumping cart straight into ground.
6 90-valve LC60
Does not include bayonet ring and valve cover
7 Potti Power Case Potti Power lav fill juice - Six 1-gallon jugs, 500:1 dilution
1 2 3
4 5 6

Guzzler 2600 Pump Parts Diagram

CE-MARK INFORMATION
AERO Specialties Lavatory and Potable Water Service carts have been tested by TUV America
against the EU Directives specified in the attached report from TUV. Based on the test results from
TUV, AERO Specialties certifies that the LC60 lavatory service cart meets or exceeds all CE require-
ments for applicable aircraft ground support equipment.

Safety, Warning & Operation Labels: CE-marked carts
The labels pictured below are used on the LC60 lavatory service cart. Replacement labels are avail-
able from AERO Specialties.

11175 West Emerald
Boise, Idaho, 83713 USA
Phone: 208-378-9888
Fax: 208-378-9889
Email: sales@aerospecialties.com
Website: www.aerospecialties.com

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LC60 LAVATORY

Please take a moment and fill in the following information

AERO Specialties LC60 Lavatory Service Cart v.1/08 3

4 AERO Specialties LC60 Lavatory Service Cart v.1/08

AERO Specialties LC60 Lavatory Service Cart v.1/08 5

Local Regulations & Procedures

6 AERO Specialties LC60 Lavatory Service Cart v.1/08

AERO Specialties LC60 Lavatory Service Cart v.1/08 7

8 AERO Specialties LC60 Lavatory Service Cart v.1/08

AERO Specialties LC60 Lavatory Service Cart v.1/08 9

10 AERO Specialties LC60 Lavatory Service Cart v.1/08

Pumping & Waste System:

AERO Specialties LC60 Lavatory Service Cart v.1/08 11

Total Height: 28”

Ground to top of cart:

Total Width: 30” or 76.3 cm

12 AERO Specialties LC60 Lavatory Service Cart v.1/08

Chassis and Tanks

AERO Specialties LC60 Lavatory Service Cart v.1/08 13

14 AERO Specialties LC60 Lavatory Service Cart v.1/08

18. Waste hose

13. Guzzler 2600

22. Plug for fill

AERO Specialties LC60 Lavatory Service Cart v.1/08 15

11. Hose adapter

12. Bayonet ring:

9. Waste valve cover

16 AERO Specialties LC60 Lavatory Service Cart v.1/08

AERO Specialties LC60 Lavatory Service Cart v.1/08 17

18 AERO Specialties LC60 Lavatory Service Cart v.1/08

AERO Specialties LC60 Lavatory Service Cart v.1/08 19

20 AERO Specialties LC60 Lavatory Service Cart v.1/08

22 AERO Specialties LC60 Lavatory Service Cart v.1/08

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