TM 9-4910-531-14 CLEANER STEAM, HIGH PRESSURE, WATER JET, TRAILER MOUNTED

TM 9-4940-531-14 TECHNICAL MANUAL OPERATOR’S, UNIT, DIRECT SUPPORT, AND GENERAL SUPPORT MAINTENANCE MANUAL FOR CLEANER, STEAM, HIGH PRESSURE HOT AND COLD WATER JET, TRAILER MOUNTED (NSN 4940-01-025-9856) (EIC: 2BC)

DISTRIBUTION STATEMENT A: Approved for public release; distribution is unlimited. DESTRUCTION NOTICE: For classified documents, follow procedures in DoD 5200-.22-M, Industrial Security Program Manual, Section II. For unclassified, limited documents, destroy by any method that will prevent disclosure of contents or reconstruction of the document.

HEADQUARTERS, DEPARTMENT OF THE ARMY AUGUST 1994

TM 9-4940-531-14

WARNING Ensure power source is properly grounded before operating steam cleaner to avoid electrical shock. Wear safety goggles/glasses and gloves to prevent injury from scalding and high water velocity when operating the steam cleaner in any mode. Hearing protection is required as the steam cleaner projects high intensity noise during blowdown; failure to do so could result in hearing loss. USE CAUTION when using dry cleaning solvent (item 22, appx E). Cleaning solvents evaporate quickly and can irritate exposed skin on contact. In cold weather, contact of exposed skin with cleaning solvent can cause frost bite. Do not install steam cleaner in areas containing flammable materials or gases. Severe injury or death from fire or fumes may result. Steam cleaner weighs 1365 lb (619.16 kg) wet, 1185 lb (537.52 kg) dry. Generator set weighs 600 lb (272.16 kg) wet, 585 lb (265.36 kg) dry. To avoid injury, do not attempt to lift without proper equipment. Do not allow steam cleaner to produce steam with deliming solution in coil unit assembly. Injury to personnel may result from fumes or hot acid splash. To avoid injury from toxic fumes, when working with acids, always pour acid into water, never water into acid. Proper clothing protection should be worn and all precautions read when working with sulfamic acid and sodium hydroxide; refer to paragraph 5-23. Moisture in the skin will activate the chemical, causing severe irritation or burns. To avoid injury, do not install steam cleaner in closed areas; proper ventilation is required. Avoid touching or coming into contact with steam, hot water, or other parts of equipment that are subjected to high temperatures to prevent serious burns. Diesel fuel is FLAMMABLE; DO NOT SMOKE in vicinity while performing servicing operations. To avoid burns, do not use flammable cleaning materials. The operator must remain approximately 10 ft (3.05 m) from steam cleaner during blowdown to avoid possible burns. Avoid moving parts when steam cleaner is in operation to prevent serious injury. To avoid electrical shock, disconnect electrical power before beginning maintenance on the steam cleaner.

a

TM 9-4940-531-14

If control panel must be opened for testing and S2 and S3 sensitive switches held closed, use extreme caution to prevent electrical shock. When using compressed air, keep nozzle away from exposed skin. To avoid injury, wear eye protection when blowing dust and debris out of steam cleaner with compressed air. To avoid injury, do not tamper with pressure settings of regulating valves. Otherwise, there may be excessive pressure buildup. To avoid injury, if outlet pressure ever exceeds 675 psi (4654 kPa), turn EMERGENCY OFF switch to OFF position and vacate area. To avoid injury, if cleaning gun emits superheated steam, turn EMERGENCY OFF switch of OFF position and vacate area. For information on first aid, refer to FM 21-11.

b

TM 9-4940-531-14 CHANGE NO. 1

HEADQUARTERS DEPARTMENT OF THE ARMY WASHINGTON, D.C., 30 July 2008 TECHNICAL MANUAL OPERATOR’S, UNIT, DIRECT SUPPORT, AND GENERAL SUPPORT MAINTENANCE MANUAL FOR CLEANER, STEAM, HIGH PRESSURE HOT AND COLD WATER JET, TRAILER MOUNTED (NSN 4940-01-9856) (EIC: 2BC)

DISTRIBUTION STATEMENT A: Approved for public release; distribution is unlimited. TM 9-4940-531-14, 01 August 1994, is changed as follows: 1. File this sheet in front of the manual for reference. 2. This change is the result of a different distribution statement. 3. New or updated text is indicated by a vertical bar in the outer margin of the page. 4. Added illustrations are indicated by a vertical bar adjacent to the figure number. Changed illustrations are indicated by a miniature pointing hand adjacent to the updated area and a vertical bar adjacent to the figure number. 5. Remove old pages and insert new pages as indicated below: Remove Pages Insert Pages

a-b

a-b

None i-iv

A(B blank) i-iv

DA 2028

DA 2028

Cover

Cover

6. Replace the following work packages with their revised version. Work Package Number None 7. Add the following new work packages. Work Package Number None

By Order of the Secretary of the Army: GEORGE W. CASEY, JR. General, United States Army Chief of Staff

Official: JOYCE E. MORROW Administrative Assistant to the Secretary of the Army 0816903

Distribution: To be distributed in accordance with the initial distribution number (IDN) 255402, requirements for TM 9-4940-531-14.

TM 9-4940-531-14

LIST OF EFFECTIVE PAGES / WORK PACKAGES NOTE: The portion of text affected by the changes is indicated by a vertical bar in the outer margins of the page. Changes to illustrations are indicated by a vertical bar adjacent to the title. Zero in the “Change No.” column indicates an original page of work package. New Text Date of issue for original manual is: Original . . . . . . . . . . . . . 01 August 1994 Change 1 . . . . . . . . . . . . . 30 July 2008 TOTAL NUMBER OF PAGES FOR FRONT AND REAR MATTER IS 22. Page/WP No. Change No. Front Cover 1 Blank 0 Warning summary (2 pgs) 0 a-b 0 A-(B blank) Added 1 i-iv 1 1-1 thru 1-21/1-22 blank 0 2-1 thru 2-41/2-42 blank 0 3-1 thru 3-21/3-22 blank 0 4-1 thru 4-100 0 5-1 thru 5-178 0 6-1 thru 6-7/6-8 blank 0 A-1 thru A-3/A-4 blank 0 B-1 thru B-10 0 C-1 thru C-5/C-6 blank 0 D-1/D-2 blank 0 E-1 thru E-4 0 F-1 thru F-12 0 FP-1/FP-2 blank 0 FP-3/FP-4 blank 0 FP-5/FP-6 blank 0 FP-7/FP-8 blank 0 Index-1 thru Index-11/Index-12 0 blank DA 2028 Forms 1 Metric Chart 0 PIN 0

Page/WP No.

Change No.

A/B blank Change 1

TECHNICAL MANUAL TM 9-4940-531-14

HEADQUARTERS DEPARTMENT OF THE ARMY WASHINGTON, D.C. 01 August 1994

Operator’s, Unit, Direct Support, and General Support Maintenance Manual For CLEANER, STEAM, HIGH PRESSURE, HOT AND COLD WATER JET, TRAILER MOUNTED (4940-01-025-9856) (EIC: 2BC) REPORTING ERRORS AND RECOMMENDING IMPROVEMENTS You can help improve this publication. If you find any errors, or if you would like to recommend any improvements to the procedures in this publication, please let us know. The preferred method is to submit your DA Form 2028 (Recommended Changes to Publications and Blank Forms) through the Internet, on the Army Electronic Product Support (AEPS) website. The Internet address is https://aeps.ria.army.mil. The DA Form 2028 is located under the Public Applications section in the AEPS Public Home Page. Fill out the form and click on SUBMIT. Using this form on the AEPS will enable us to respond quicker to your comments and better manage the DA Form 2028 program. You may also mail, e-mail, or fax your comments or DA Form 2028 directly to the U.S. Army TACOM Life Cycle Management Command. The postal mail address is U.S. Army TACOM Life Cycle Management Command, ATTN: AMSTA-LC-LMPP / TECH PUBS, 1 Rock Island Arsenal, Rock Island, IL 61299-7630. The e-mail address is [email protected]. The fax number is DSN 793-0726 or Commercial (309) 782-0726. DISTRIBUTION STATEMENT A: Approved for public release; distribution is unlimited. DESTRUCTION NOTICE: For classified documents, follow procedures in DoD 5200-.22-M, Industrial Security Program Manual, Section II. For unclassified, limited documents, destroy by any method that will prevent disclosure of contents or reconstruction of the document. TABLE OF CONTENTS HOW TO USE THIS MANUAL……………………………………………………

CHAPTER 1 Section I. Section II. Section III. CHAPTER 2 Section I. Section II. Section III. Section IV.

INTRODUCTION

Page

iii Page

General Information……………………………………………………………………………1-2 Equipment Description and Data …………………………………………………………… 1-4 Principles of Operation ……………………………………………………………………… 1-10 OPERATING INSTRUCTIONS Description and Use of Operator’s Controls and Indicators……………………………… 2-1 Operator Preventive Maintenance Checks and Services (PMCS) …………………… 2-9 Operation Under Usual Conditions………………………………………………………… 2-21 Operation Under Unusual Conditions …………………………………………………… 2-41 i Change 1

TM 9-4940-531-14 Page CHAPTER 3 Section I. Section Il. Section Ill. CHAPTER 4 Section Section Section Section Section Section

I. Il. Ill. IV. V. VI.

CHAPTER 5 Section I. Section Il.

OPERATOR MAINTENANCE INSTRUCTIONS Lubrication Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 Troubleshooting Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 Operator’s Maintenance Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16 UNIT MAINTENANCE INSTRUCTIONS Lubrication instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 Service Upon Receipt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 Preventive Maintenance Checks and Services (PMCS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9 Maintenance Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19 Preparation for Storage or Shipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-96 DIRECT SUPPORT MAINTENANCE INSTRUCTIONS Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 Maintenance Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-44

CHAPTER 6

GENERAL SUPPORT MAINTENANCE lNSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . 6-1

APPENDIX A

REFERENCES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1

APPENDIX B

MAINTENANCE ALLOCATION CHART (MAC)

Section Section Section Section

I. Il. Ill. IV.

APPENDIX C

Section I. Section Il. Section Ill.

.. Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1 Maintenance Allocation Chart for Steam Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-4 Tools and Test Equipment for Steam Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-10 Remarks for Steam Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-10 COMPONENTS OF END ITEM (COEI) AND BASIC ISSUE ITEMS (BIl) LISTS Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-1 Components of End Item . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-2 Basic Issue Items . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-5

APPENDIX D

ADDITIONAL AUTHORIZATION LIST (AAL)

APPENDIX E

EXPENDABLE AND DURABLE ITEMS LIST

Section I. Section Il. APPENDIX F

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-1

.. Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-1 Expendable and Durable Items List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-2 ILLUSTRATED LIST OF MANUFACTURED ITEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-1

ALPHABETICAL INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Index-1

ii

TM 9-4940-531-14 HOW TO USE THIS MANUAL GENERAL a. All references in this manual are to paragraphs or to another publication. b. Whenever the male gender is mentioned (i.e., crewman, repairman) in the manual, it also pertains to females. INDEXES This manual is organized for quickly finding needed information. There are several useful indexes. a. Table of Contents. Is a list of all chapters, sections, and appendixes. Gives page references. b. Nomenclature Cross-Reference List. Gives an alphabetical list of common names used in the manual and official nomenclature. c. Malfunction Index. Located just before the troubleshooting table in each maintenance chapter. Lists the possible malfunctions in order of appearance. References pages of the troubleshooting tables. e. Alphabetical Index. Located at the end of a manual. An extensive subject index for everything in the manual. Gives page references. MAINTENANCE PROCEDURES There are four maintenance chapters: operator, unit, direct support, and general support. The first three maintenance chapters contain a malfunction index, a troubleshooting table, an initial setup, plus step-by-step procedures. (1) Malfunction Index. Describes fault symptoms and locates the applicable troubleshooting procedure. (2) Troubleshooting Table. Lists malfunctions, checks, and corrective actions to be taken. (3) Initial Setup. Lists everything needed in order to do maintenance on one part of the equipment: Tools and Special Tools—Lists tools needed to perform maintenance. Materials/Parts—Lists expendable/durable materials and 100% replaceable parts. Each material or part is followed by a part number or appendix reference. If more than one part is needed, the quantity needed precedes the part number or reference.

iii

TM 9-4940-531-14

Personnel required.

Required— Lists the number of personnel needed when more than one person is

References—Lists other publications containing necessary information. Equipment Conditions—Lists conditions to be met before starting the procedure. The paragraph reference at the end of the condition is a reference to instructions for setting up the condition. (4) Step-By-Step Procedures. Are illustrated instructions for maintenance that is authorized in the maintenance allocation chart (MAC). For replacement of parts, refer to TM 9-4940-531-24P. WARNINGS, CAUTIONS, AND NOTES Throughout the manual is WARNING, CAUTION, and NOTE data which must be followed. WARNING A warning is used to alert the user of hazardous operating and maintenance procedures, practices, conditions, statements, etc., that may result in injury to or death of personnel if not strictly observed. CAUTION A caution is used to alert the user of hazardous operating or maintenance procedures, practices, conditions, statements, etc., that may result in damage to or destruction of equipment or of mission effectiveness if not strictly observed. NOTE A note is used to aid in simplifying a task.

iv

TM 9-4940-531-14

CHAPTER

1

I N T R O D U C T I O N CHAPTER INDEX Paragraph 1-1. 1-2. 1-3. 1-4. 1-5. 1-6. 1-7. 1-8. 1-9. 1-10. 1-11. 1-12. 1-13. 1-14. 1-15. 1-16. 1-17. 1-18. 1-19. 1-20. 1-21. 1-22. 1-23. 1-24. 1-25. 1-26. 1-27. 1-28. 1-29. 1-30. 1-31.

Page

Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Maintenance Forms and Records . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 1-2 Destruction of Army Materiel to Prevent Enemy Use... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Administrative Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Reporting Equipment Improvement Recommendations (EIR’s) . . . . . . . . . . . . . . . . . . . . . . . . . . . Warranty Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 1-3 Nomenclature Cross- Reference List . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 Corrosion Prevention and Control (CPC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Common Tools and Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 1-4 Special Tools, TMDE, and Support Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Repair Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 Equipment Characteristics, Capabilities, and Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 1-5 Location and Description of Major Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Equipment Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10 Safety ,Care, and Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10 1-10 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Water Sources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11 Adding Detergent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13 1-13 Water Pump Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Automatic Draining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13 Bypass Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14 1-15 Hydraulic Accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Heating Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15 Thermocouple . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17 1-17 Oil BurnerAssembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Steam Cleaning Gun . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-18 Blowdown Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19 Descaling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19 Desooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19 1-20 Safety Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-21 Temperature Control Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-1

TM 9-4940-531-14

Section

1-1. a.

I.

GENERAL

INFORMATION

SCOPE Type of Manual. Operator’s, unit, direct support, and general support maintenance.

b. Model Number and Equipment Name. MIL-C-45996 trailer mounted, high pressure hot and cold water jet steam cleaner. Purpose of Equipment. Removes dirt, grease, mud, and other foreign matter from ground c. support vehicles. 1-2. MAINTENANCE FORMS AND RECORDS Department of the Army forms and procedures used for equipment maintenance will be those prescribed by DA PAM 738-750, The Army Maintenance Management System (TAMMS). 1-3.

DESTRUCTION OF ARMY MATERIEL TO PREVENT ENEMY USE

Refer to TM 750-244-7 for procedures for destruction of the steam cleaner. 1-4. ADMINISTRATIVE STORAGE See paragraph 4-29, Administrative Storage. 1-5.

REPORTING EQUIPMENT IMPROVEMENT RECOMMENDATIONS (EIR'S)

If your steam cleaner needs improvement, let us know. Send us an EIR. You, the user, are the only one who can tell us what you don’t like about your equipment. Let us know why you don’t like the design or performance. Put it on a SF 368 (Product Quality Deficiency Report). Mail it to us at U.S. Army Armament, Munitions and Chemical Command, ATTN: AMSMC-QAD, Rock Island, II 612996000. We’ll send you a reply. 1-6.

WARRANTY INFORMATION

Not applicable.

1-2

TM 9-4940-531-14 1-7.

NOMENCLATURE

CROSS-REFERENCE

LIST

Common Name

Official Nomenclature

CHEMICAL METERING Valve Assembly Coil Inlet Hose Assembly Coil Inlet-to-Differential Pressure Switch Tubing Assembly Coil Inlet-to-Inlet Pressure Gauge Tubing Assembly Coil Lid Coil Outlet-to-Differential Pressure Switch Tubing Assembly Coil Outlet-to-Outlet Pressure Gauge Tubing Assembly Coil Outlet-to-Pressure Switch Tubing Assembly DELlME Light DRAIN Light Drain Plug EMERGENCY OFF Switch Exhaust Flap Facility Power Cable Assembly

Valve Assembly, Metering Hose, Assembly, Nonmetallic Tubing Assembly Tubing Assembly Access Door Tubing Assembly Tubing Assembly Tubing Assembly Light, Indicator Light, Indicator Plug, Pipe Circuit Breaker Access Door Cable Assembly, Special Purpose, Electrical Gage, Liquid Quantity Gage, Pressure, Dial Indicating Fuel Control, Main Tubing Assembly Cock, Plug Cable Assembly, Power, Special Purpose, Electrical Cooler, Fluid, Industrial Door, Access Meter, Totalizing Time Gage, Pressure Dial Cover, Access Bottle, Screw Cap Chain Assembly, Single Leg Switch, Rotary Indicator, Temperature Gage, Pressure Dial Light, Indicator Tubing Assembly Hose Assembly, Nonmetallic Switch, Push Cleaner, Steam, High Pressure, Hot and Cold Water Jet Interconnecting Box Cleaner, Steam, High Pressure, Hot and Cold Water Jet, Trailer Mounted. Caster, Swivel

Fuel Gauge FUEL PRESSURE gauge Fuel Pump Fuel Pump-to-Pressure Gauge Tubing Assembly Fuel Shutoff Valve Generator Power Cable Assembly Heating Coil Hose Rack Access Door HOUR METER INLET PRESSURE Gauge Lifting Bracket Liquid Storage Tank Locking Pin Assembly MODE SELECTOR Switch OPERATING TEMPERATURE Gauge OUTLET PRESSURE Gauge POWER Light Pressure Switch-to-Pressure Switch Tubing Assembly Pressurized Water Hose Assembly PUSH TO START Switch Steam Cleaner Temperature Control Box Trailer Mounted Steam Cleaner

Wheel

1-3

TM 9-4940-531-14 1-8.

CORROSION PREVENTION AND CONTROL (CPC)

Corrosion Prevention and Control (CPC) of Army materiel is a continuing concern. It is impora. tant that any corrosion problems with this item be reported so the problem can be corrected and improvements can be made to prevent the problem in future items. b. While corrosion is typically associated with rusting of metals, it can also include deterioration of other materials such as rubber and plastic. Unusual cracking, softening, swelling, or breaking of these materials may be a corrosion problem. If a corrosion problem is identified, it can be reported using SF 368, Product Quality Deficiency c. Report. Use of keywords such as “corrosion", "rust", "deterioration", or "cracking" will ensure that the information is identified as a CPC problem. d. The form should be submitted to: Commander, U.S. Army Armament, Munitions and Chemical Command, ATTN: AMSMC-QAD/Customer Feedback Center, Rock Island, II 61299-6000. Section

Il.

REPAIR

MEASUREMENT,

AND

AND 1-9.

PARTS;

TOOLS;

DIAGNOSTIC

SUPPORT

SPECIAL

TOOLS;

EQUIPMENT

TEST,

(TMDE);

EQUIPMENT

COMMON TOOLS AND EQUIPMENT

a. For authorized common tools and equipment, refer to the Modified Table of Organization and Equipment (MTOE), CTA 50-970, or CTA 8-100, as applicable to your unit. b. The tool kit assigned to the mechanic is Tool Kit, General Mechanic’s, SC 5180-90-CL-N26. 1-10. SPECIAL TOOLS, TMDE, AND SUPPORT EQUIPMENT Special tools/test equipment are listed in appendix B and in TM 9-4940-531-24P. 1-11. REPAIR PARTS Repair parts for the steam cleaner are listed and illustrated in TM 9-4940-531-24P. For the generator, refer to TM 5-6115-615-24P. For the trailer, refer to TM 9-2330-202-14&P. Section

Ill.

EQUIPMENT

DESCRIPTION

AND

DATA

1-12. EQUIPMENT CHARACTERISTICS, CAPABILITIES, AND FEATURES a. Characteristics. (1) Trailer-mounted. (2) Housed inside enclosure and lift assembly.

1-4

TM 9-4940-531-14 b. Capabilities and Features. (1) Powered by generator set or facility power source. (2) Uses either pressurized or nonpressurized water source. (3) Heat-resistant steam cleaning gun assembly. (4) Delivers high pressure steam and hot or cold water for cleaning. 1-13. LOCATION AND DESCRIPTION OF MAJOR COMPONENTS

WATER INLET ASSEMBLY (1). Located on left side of steam cleaner. Is used with a pressurized water source. WATER TANK ASSEMBLY (2). Mounted on top of fuel tank assembly. pressurized water flow.

Stores and regulates inlet

1-5

TM 9-4940-531-14 1-13. LOCATION AND DESCRIPTION OF MAJOR COMPONENTS (cont)

1-6

TM 9-4940-531-14

1-13. LOCATION AND DESCRIPTION OF MAJOR COMPONENTS (cont) WATER PUMP ASSEMBLY (3). Located on top of fuel tank assembly. Pumps water to coil unit assembly. MOTOR ASSEMBLY (4). Located beside water pump assembly. Provides power to operate water pump assembly. COIL INLET CONTROL ASSEMBLY (5). Situated behind the control box assembly. Controls routing and flow of water to coil. CONTROL BOX ASSEMBLY (6). Located in upper left hand corner of steam cleaner above fire extinguisher. Contains UPPER CONTROL PANEL ASSEMBLY (7) and LOWER CONTROL PANEL ASSEMBLY(8). OUTLET AND WATER DRAIN ASSEMBLY (9). Located on right front of steam cleaner. Is used with steam cleaning gun. LIQUID STORAGE TANK (1O). Mounted on coil unit assembly. Has markings indicating level of cleaning solution. COIL OUTLET ASSEMBLY (11). Located in front of coil unit assembly. Limits system pressure and controls temperature on the outlet side of coil unit assembly. OIL BURNER ASSEMBLY (12). Located in front of coil unit assembly. Houses oil burner controls and fuel igniter. Oil burner control will shut off burner unit if cad cell does not sense a flame. FUEL SHUTOFF ASSEMBLY (13). Located beside oil burner assembly. Controls fuel supply from fuel tank assembly to oil burner assembly. COIL UNIT ASSEMBLY (14). Situated behind the liquid storage tank and oil burner assembly. Allows pressurized cold water to be heated to high temperature in the steam and hot rinse modes. FUEL TANK ASSEMBLY (15). Mounted underneath the control box assembly. Stores and provides fuel for oil burner assembly. FIRE EXTINGUISHER (16). Used to extinguish fires in and around steam cleaner.

1-7

TM 9-4940-531-14 1-13. LOCATION AND DESCRIPTION OF MAJOR COMPONENTS (cont)

HOSE STORAGE COMPARTMENT (17). Provides a storage area for the steam cleaner hoses, gun, and nozzles. WASH HOSE ASSEMBLY (18). Connects steam cleaning gun to steam cleaner. STEAM CLEANING GUN (19). Attaches to wash hose assembly. Hand-held control for directing the steam/water.

1-8

TM 9-4940-531-14

NOZZLES (20). Located in hose storage compartment. Attach to steam cleaning gun. Five different nozzles consisting of three spray nozzles for hot or cold water and two fan nozzles for steam. SUCTION HOSE ASSEMBLY (21). Connects nonpressurized water source to steam cleaner. PRESSURIZED WATER HOSE ASSEMBLY (22). Connects pressurized water source to steam cleaner. FACILITY POWER CABLE ASSEMBLY (23). Connects steam cleaner to facility power source.

GENERATOR POWER CABLE ASSEMBLY (24). Connects generator set to steam cleaner. FLAT BED TRAILER (25). Transports steam cleaner and generator set. Has a leveling-support jack and a rear stabilizer kit. GENERATOR SET (26). Mounted on flatbed trailer in front of steam cleaner. Provides power to steam cleaner when facility power is not available. ENCLOSURE AND LIFT ASSEMBLY (27). Houses steam cleaner unit and provides an attachment point for hoisting steam cleaner from trailer for maintenance.

1-9

TM 9-4940-531-14 1-14. EQUIPMENT DATA Capacity: Steam Hot water Cold water

200 gph (757 Iph) 240 gph (908 Iph) 240 gph (908 Iph)

Weight: Steam cleaner, wet Steam cleaner, dry Generator, wet Generator, dry Trailer Main wheel load/ Iunette,wet Main wheel load/ Iunette, dry Main wheel load/ caster, wet Main wheel load/ caster, dry Lunette load, wet Lunette load, dry Caster wheel load, wet Caster wheel load, dry Total weight, wet Total weight, dry

200 psi (1379 kPa) 400 psi (2758 kPa) 400 psi (2758 kPa)

U.S. CUSTOMARY 1365 lb 1185 lb 600 lb 585 lb 1050 lb 2830 lb

325°F(163°C) 190°F(88°C) ambient METRIC 619.16 kg 537.52 kg 272.16 kg 265.36 kg 476.28 kg 1283.69 kg

2616 lb

1186.62 kg

2680 lb

1215.65 kg

2449 lb

1110.87 kg

185 lb 204 lb 335 lb 371 lb 3015 lb 2820 lb

83.92 92.53 151.96 168.29 1367.60 1279.15

kg kg kg kg kg kg

1-15. SAFETY, CARE, AND HANDLING To ensure safety, read the warning page at the front of this manual carefully. It lists all warnings found in this manual. Also, the warnings and cautions will be found in the text preceding the steps where special attention and care must be taken.

Section III. PRINCIPLES OF OPERATION 1-16. GENERAL a. In many situations, ordinary cleaning methods are insufficient to remove greases, oils, cakedon dirt, etc., especially in confined areas. Standard water main pressure (usually 25 to 125 psi (172 to 862 kPa)) is not high enough, and there is no way to meter a measured amount of detergent into the water stream. In addition, there must be some way to continuously heat large amounts of water (200 gph or greater) to a temperature of 200°F (93 °C) or greater. b. The operation of the steam cleaner is explained in paragraphs 1-17 through 1-31. Refer to figure FO-2 at the back of this manual for electrical schematic.

1-10

TM 9-4940-531-14

1-17. WATER SOURCES

a. Shop Outlet. Water is delivered to the pressurized water inlet assembly from an ordinary cold water supply line and then to the water tank, which acts as a reservoir. The water level in the water tank is regulated by the S4 liquid level (float) switch (1) and the 9SOL solenoid valve (2). When the water level drops below a certain point, S4 is actuated. This causes the 9SOL solenoid valve to open, and water is delivered to the tank. When the water level approaches full, the float opens the switch, cutting off current to the solenoid valve. The valve then closes, cutting off the water flow. The water pump assembly then draws water from the water tank through a strainer (3), which traps any dirt, rust, or scale. Opening ball valve A (4) selects the pressurized water inlet.

1-11

TM 9-4940-531-14 1-17. WATER SOURCES (cont)

1-12

TM 9-4940-531-14 1-17. WATER SOURCES (cont) b. Auxiliary Source. Water also can be drawn from a lake, pond, or stream by using the suction hose assembly. The end of the suction hose that is immersed in water is fitted with a combination strainer and foot valve. The strainer prevents coarse sand and debris from entering the suction hose. The foot valve acts as an anti-siphon device to prevent backflow of water through the suction hose when the steam cleaner is turned off. Another strainer (Y-strainer) (5) traps the finer dirt and debris which might otherwise enter the water circuit. This strainer can be serviced by disassembling and cleaning. Closing ball valve A (4) selects the nonpressurized (suction) water inlet mode. 1-18. ADDING DETERGENT The effectiveness of steam cleaning is enhanced by adding a small amount of cleaning compound (detergent) to the water intake. The liquid storage tank (6) holds a supply of such detergent, which is metered into the water intake by the CHEMICAL METERING valve (7). A knob on the front panel controls the valve and allows the operator to adjust the amount of detergent depending upon the situation. The cleaning compound should be used sparingly. Since chemical action is greater at higher temperatures, the chemical is ordinarily used in the steam and hot water modes, not in the cold water mode. 1-19. WATER PUMP ASSEMBLY The triple piston water pump assembly (8) (powered by a 2-HP, 208-volt, single-phase electric motor (9)) builds the water pressure up to 200-300 psi (1379-2069 kPa). The pump works much like an air compressor but is designed to pump water. 1-20. AUTOMATIC DRAINING Many steam cleaners are damaged by being stored outside during subfreezing weather. The a. water remaining behind in the pump, heating coil, and lines freezes, and the resulting expansion can damage these components. To safeguard against this, the steam cleaner has an automatic draining system to allow water to drain completely when the steam cleaner is turned off from the steam/ blowdown mode. b. There are three drain solenoid valves. The first (1SOL) solenoid (10) is located at the inlet side of the pump, the second (3SOL) solenoid (11) at the inlet side of the heating coil, and the third (4SOL) solenoid (12) at the outlet side of the heating coil. These valves are normally open. When the steam cleaner is turned on, the valves close. When the steam cleaner is turned off, the valves open, permitting water to drain from the heating coil and water lines. In addition, there are two vent valves(13) which aid in draining by allowing air to enter the water circuit to replace the water as it drains out. These are one-way check valves which open at 0.5 psi (3.45 kPa). During pump operation, the water pressurization forces these valves closed.

1-13

TM 9-4940-531-14 1-21. BYPASS MODE

1-14

TM 9-4940-531-14 1-21. BYPASS MODE (cont) Whenever the steam cleaner is on, the water pump assembly is operating. If the steam cleaning a. gun valve is not actuated, the water continues to circulate from the pump outlet back to the pump inlet. This process is called the bypass mode of operation. The pumping of water around this closed loop causes churning of the water which results in a temperature buildup. However, the steam cleaner is designed to limit the temperature of the water in the bypass loop to 190 °F (88 °C). b. The bypass system consists of 5SOL solenoid valve (14) and PS5 pressure switch (15). When the pressure at the pump outlet exceeds 150 psi (1034 kPa), the PS5 pressure switch opens and deenergizes the 5SOL solenoid valve. The valve thus opens and bypasses the water pump. In the same way, when the pressure drops below 150 psi (1034 kPa), the switch closes, energizing the solenoid valve and causing it to close, thus “unbypassing” the pump. The solenoid valve is de-energized during the blowdown cycle so that the pump remains bypassed. c. If for any reason the pump outlet pressure exceeds 500 psi (3448 kPa), the regulating valve (16) automatically opens and bypasses the pump to prevent any further pressure buildup. d. In the steam mode, 6SOL solenoid valve (17) at the water pump outlet is energized, placing the regulating valve (18) in the circuit. This is a normally-closed, self-actuated valve which opens at 300 psi (2069 kPa) or greater pressure. The purpose of this valve is to establish a working pressure not to exceed 300 psi (2069 kPa) in the steam mode. 1-22. HYDRAULIC ACCUMULATOR The hydraulic accumulator (19) is located near the water pump outlet and acts as a hydraulic shock absorber to smooth out the pressure pulsations produced by the water pump assembly. 1-23. HEATING COIL Pressurized water flows through heating coil unit assembly (20) where the water is heated by a. the hot combustion gases from the atomizing, vaporizing oil burner (21). The coil is not made using the “cold-water wrap” technique used in commercial steam cleaners. Instead, the water flow enters at the top of the coil unit assembly and emerges near the bottom in one straight pass. The diameter of the coil spiral decreases and increases along the coil from top to bottom. This prevents the coil from doubling back on itself. Such a design allows the heating coil to drain itself of water by gravity, thus preventing the coil from retaining water which could later freeze up in cold temperature conditions. b. The two 0-1000 psi (0-6895 kPa) pressure gauges (22 and 23) measure the pressure at the inlet and outlet sides of the heating coil.

1-15

TM 9-4940-531-14 1-23. HEATING COIL (cont)

1-16

TM 9-4940-531-14 1-23. HEATING COIL (cont) The pressure drop (difference between the two gauge readings) across the heating coil indicates to what extent it is clogged with rust and scale. The greater the pressure difference, the more the rust/ scale buildup. The heating coil should be descaled when the DELlME light illuminates. A similar function is performed by the PS3 differential pressure switch (24). One side of the c. switch is connected to the coil inlet, the other side to the coil outlet. When the pressure difference exceeds 70 psi (483 kPa), the switch closes and illuminates the DELlME light. 1-24. THERMOCOUPLE The thermocouple (25) is a bimetallic temperature sensing device which is installed directy in the water outlet line. As fluid temperature rises, the DC voltage produced by the thermocouple rises in proportion and registers as a specific reading at the OPERATING TEMPERATURE gauge on the control panel. Cooler temperatures produce lower readings. 1-25. OIL BURNER ASSEMBLY The oil burner assembly used in the steam cleaner is similar to the kind used in oil furnaces but is calibrated to burn diesel fuel. The oil burner consists of four major systems: fuel, air, ignition, and control. (a) Fuel System. Fuel is drawn from the fuel tank (26) and through a strainer (27) by an electric motor-driven fuel pump (28). This pump also pressurizes the fuel and delivers it to a nozzle. Fuel pressure is indicated by the FUEL PRESSURE gauge (29) on the front panel of the steam cleaner. The nozzle contains a fine orifice to atomize the fuel so that it will vaporize. There is also a fuel return line (30) that returns any fuel bypassed (not flowing through the nozzle) to the fuel tank. There are shutoff valves (31) for the fuel lines. A gauge (32) indicates the amount of fuel in the tank. (b) Air System. Air is drawn in through air bands by an electric motor-driven blower which is driven by the same motor that drives the fuel pump. The air bands are adjustable so that proper air/ fuel vapor ratio may be obtained. The blower feeds into an air tube. Near the exit end of the air tube is an air tube cone to speed up the airflow and a deflector (whirler) to make the air stream rotate, or swirl, for maximum vaporization. At the exit of the air tube, the atomized fuel vaporizes and mixes with the air, forming a combustible mixture. (c) Ignition System. The ignition system consists of the ignition (high voltage) transformer (T2, fig. FO-2) and a pair of insulated electrodes. The electrodes form a spark gap. The continuous spark formed at the spark gap ignites the fuel vapor/air mixture. (d) Control System. The control system consists of an electric controller which can turn the burner motor and ignition transformer on and off. The controller is actuated by the cad cell, by safety and temperature regulating switches, and by the temperature control box. See paragraphs 1-30 and 1-31 for additional information.

1-17

TM 9-4940-531-14

1-26. STEAM CLEANING GUN

1-18

TM 9-4940-531-14 1-26. STEAM CLEANING GUN (cont) a. Pressurized water from the coil outlet goes to the steam cleaning gun (33). A trigger-controlled valve on the cleaning gun handle turns the gun on and off. Different kinds of nozzles can be fitted depending on the situation. The standard nozzles are used when a forceful stream of water or steam is wanted. The fan-type nozzle is used in the steam mode when less force is wanted over a broader area. b. It should be noted that in the steam mode, there is not actually steam going through the cleaning gun, but superheated water. The water temperature is approximately 315°F (157°C), which is well above the boiling point of water. The high water pressure (approximately 200 psi (1379 kPa)) prevents the water in the gun from turning into steam. However, when the superheated water is discharged through the orifice in the cleaning gun nozzle, its pressure suddenly drops towards normal atmospheric pressure, causing it to flash (rapidly boil) into saturated (wet) steam coming from the nozzle. 1-27. BLOWDOWN CYCLE a. During steam cleaner operation, lime (calcium deposits) and rust can form on the inside of the heating coil. The buildup (scale) reduces the efficiency of the steam cleaner by reducing the heat transfer from combustion gases to the water circulating through the coil. In addition, the water pump has to work harder to force water through the coil. These deposits, if not removed, can eventually clog the heating coil passages. The buildup is indicated by a 70 psi (483 kPa) or greater pressure difference and /or that the DELlME light is on. The blowdown cycle helps to reduce these buildups. b. During the blowdown cycle, the water pump is bypassed, but the oil burner continues to run. This heats the water in the heating coil until it becomes superheated and flashes (boils rapidly) into steam. The resulting violent action (vibration and sudden blasts of steam) loosens the buildup of scale within the heating coil. The check valve (34) prevents any backflow of water toward the pump under these conditions. When operating in steam mode only, blowdown is initialized every time the steam cleaner is turned off. When the MODE SELECTOR switch is placed in OFF position, the S5 flow switch actuates the flow regulating valve (35), letting steam discharge through the blowdown port under the steam cleaner. This phase of the cycle lasts about 127 seconds. After this, the burner is shut down and water is pumped through the heating coil for about 88 seconds to flush out any loose rust or scale. 1-28.

DESCALING

In spite of repeated blowdown cycles, a certain amount of scale will continue to build up inside the heating coil. In this case, chemical action (descaling) is called for. A solution of water and scale removing compound, which chemically dissolves the scale buildup, is circulated through the coil. Descaling procedures are given in paragraph 5-23. Under average conditions, the cleaner will have to be descaled about every 100 hours of operation. The actual time is determined by the “hardness” of the local water supply. 1-29. DESOOTING In addition to scale buildup on the inside of the heating coil tubing, soot (a byproduct of diesel fuel combustion) can accumulate on the outside of the heating coil tubing. Soot has the same effect on efficiency as scale; it reduces the heat transfer from the hot combustion gases to the heating coil. Desooting procedures are given in table 4-1. 1-19

TM 9-4940-531-14 1-30.

1-20

SAFETY DEVICES

TM 9-4940-531-14 1-30. SAFETY DEVICES (cont) a. The cad cell is a photoelectric cell which “watches” for a flame from the oil burner. If there is no flame after the burner starts up, or if there is a flameout during operation, the cad cell signals the electric controller to shutdown the oil burner. b. Regulating valve (16) is a pressure relief valve that opens at 500 psi (3448 kPa), bypassing the water pump assembly. This valve limits the absolute maximum coil inlet pressure to 500 psi (3448 kPa). c. Regulating valve (36) is a pressure relief valve that opens at 600 psi (4137 kPa) at the coil outlet. It limits the absolute maximum coil outlet pressure to 600 psi (4137 kPa). d. Regulating valve (37) is a pressure relief valve that opens at 400 psi (2758 kPa) at the coil outlet. It limits the pressure to 400 psi (2758 kPa) in the steam mode only. e. FS1 flow switch (38) is normally closed when there is a flow through the switch of 1.5 gpm (5.68 lpm) or greater. At flow rates under 1.5 gpm (5.68 Ipm) the switch opens, cutting off fuel control relay 2CR (fig. FO-2). This interrupts fuel delivery to the oil burner. This safeguard prevents continued heating of the water in the heating coil when there is little or no water flow through it. Otherwise, rapid boiling and the production of potentially dangerous superheated (dry) steam could occur. f. Pressure switches (39) and (40) shut down the oil burner if the coil outlet pressure exceeds established limits. PS1 pressure switch (39) is activated when the MODE SELECTOR switch is in STEAM position; this switch opens if pressure exceeds 400 psi (2758 kPa), which shuts down the oil burner. The PS2 pressure switch (40) is activated when the MODE SELECTOR switch is in HOT or COLD position; this switch opens if pressure exceeds 600 psi (4137 kPa), which shuts down the oil burner. 1-31. TEMPERATURE CONTROL BOX a. Hot Water Mode. Temperature control box (41) maintains the hot water temperature at 200 to 220°F (93 to 104°C) by cycling the oil burner on and off. If temperature reaches 225°F (107 °C), the HOT WATER ALARM lights and C1 circuit breaker trips. b. Steam Mode. Temperature control box (41) maintains the steam mode temperature at 335 to 340°F (168 to 171°C) by cycling the oil burner on and off. If temperature reaches 355°F (179 °C), the STEAM ALARM lights and C1 circuit breaker trips.

1-21/(1-22 blank)

TM 9-4940-531-14

CHAPTER OPERATING

2

INSTRUCTIONS

CHAPTER INDEX Page 2-1. 2-2. 2-3. 2-4. 2-5. 2-6. 2-7. 2-8. 2-9. 2-10. 2-11.

Controls and indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PMCS Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cleaning Agents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Leakage Definitions for Operator PMCS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Preparation for Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Operating Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Decals and Instruction Plates . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Operation in Cold Weather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Operation in Dirt, Dust, Mud, or Sandy Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Operation in Wet Weather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Operation in Hot and Humid Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . .

2-1 2-9 2-10 2-11 2-21 2-31 2-38 2-41 2-41 2-41 2-41

Section I. DESCRIPTION AND USE OF OPERATOR’S CONTROLS AND INDICATORS 2-1. CONTROLS AND INDICATORS

Key

Control or Indicator

Function

1

PUSH TO START Switch

Starts steam cleaner.

2

EMERGENCY OFF Circuit Breaker

Automatically shuts off power in case of electrical overload. Must be reset manually. Also can be turned off manually in an emergency. 2-1

TM 9-4940-531-14 2-1. CONTROLS AND INDICATORS (cont)

Control or Indicator

Function

3

MODE SELECTOR Rotary Switch

Selects desired operating mode (STEAM, OFF, COLD, HOT).

4

DELlME LIGHT

Indicates inlet and outlet pressure difference has exceeded 70 psi (483 kPa).

5

POWER LIGHT

Indicates main power is on.

6

DRAIN LIGHT

Indicates steam cleaner is in drain cycle.

7

HOT WATER ALARM Light

Indicates temperature in hot water mode is 220°F (104°C) or pressure is 600 psi (4137 kPa).

Key

2-2

TM 9-4940-531-14

Key

Control or Indicator

Function

8

STEAM ALARM Light

Indicates temperature in steam mode is 350°F (177°C) or pressure is 400 psi (2758 kPa).

9

HOUR METER

Indicates total hours of operation.

10

OPERATING TEMPERATURE Gauge

Provides water temperature reading after water leaves coil unit assembly.

11

FUEL PRESSURE Gauge

Measures fuel pressure at inlet of oil burner assembly.

12

CHEMICAL METERING Valve

Controls flow rate of cleaning solution in use.

13

CIRCUIT BREAKER Pushbutton

Indicates oil burner circuit breaker has opened and permits manual reset.

2-3

TM 9-4940-531-14 2-1. CONTROLS AND INDICATORS (cont)

Control or Indicator

Function

14

INLET PRESSURE Gauge

Measures water pressure at inlet side of coil unit assembly.

15

OUTLET PRESSURE Gauge

Measures water pressure at outlet side of coil unit assembly.

Key

2-4

TM 9-4940-531-14

Key

Control or Indicator

Function

16

Oil Burner Motor Thermal Overload Switch

Protects oil burner motor from overloads.

17

Oil Burner Electromagnet Relay Reset Button

Resets oil burner electromagnet relay.

2-5

TM 9-4940-531-14 2-1. CONTROLS AND INDICATORS (cont)

Key

Control or Indicator

Function

18

Fuel Gauge

Indicates amount of fuel in fuel tank.

19

Quick Disconnect Cap

Covers the suction inlet. Is removed when suction hose assembly is used for drawing water from a nonpressurized water source.

2-6

TM 9-4940-531-14

Control or Indicator

Function

20

Fuel Tank Shutoff Valve

Controls fuel flow from oil burner assembly to fuel tank.

21

Oil Burner Fuel Shutoff Valve

Controls fuel flow from fuel tank to oil burner assembly.

22

Ball Valve

Controls water entering pump from water tank assembly.

Key

2-7

TM 9-4940-531-14 2-1. CONTROLS AND INDICATORS (cont)

Key

Control or Indicator

Function

23

Steam Cleaning Gun Trigger

Controls flow of water or steam.

24

Spray Nozzle

Emits pinpoint spray of hot or cold water.

25

High Pressure Nozzle

Emits high pressure spray (fog) of hot or cold water.

26

Wide Spray Nozzle

Emits wide spray of hot or cold water.

27

Small Fan Nozzle

Emits narrow flow of steam.

28

Large Fan Nozzle

Emits wide flow of steam.

2-8

TM 9-4940-531-14

Key

29

Control or Indicator

Function

Raises and lowers leveling-support jack.

Leveling-Support Jack Crank Handle

Section

II.

OPERATOR AND

2-2.

PMCS

PREVENTIVE SERVICES

MAINTENANCE

CHECKS

(PMCS)

PROCEDURES

a. General. Preventive Maintenance Checks and Services (PMCS) means systematic caring, inspecting, and servicing of the steam cleaner to keep it in good condition and to prevent breakdowns. b. Do your BEFORE PMCS just before you operate the steam cleaner. Pay attention to WARNINGS, CAUTIONS, and NOTES. c. Do your DURING PMCS while you operate the steam cleaner. Pay attention to WARNINGS, CAUTIONS, and NOTES. d. Do your AFTER PMCS right after operating the steam cleaner. Pay attention to WARNINGS, CAUTIONS, and NOTES. e. Do your WEEKLY PMCS once a week. 2-9

TM 9-4940-531-14 2-2. PMCS PROCEDURES (cont) f. Item No. Column. Checks and services are numbered in chronological order regardless of interval. This column is used as an item number source for the TM Item Number column on DA Form 2404 when recording PMCS results. g. Interval Column. This column tells you when you must do the checks and services; either before, during, or after. h. Location, Item To Check/Service Column. This column contains the name of the item(s) to be checked or serviced. i. Procedure Column. This column tells you how to do the required checks or services. NOTE The terms ready/available and mission capable refer to the same status: equipment is on hand and is able to perform its combat missions. j. Not Fully Mission Capable If: Column. This column identifies the faults of the equipment that will prevent the steam cleaner from being fully mission capable. 2-3. CLEANING AGENTS

WARNING DO NOT use diesel fuel, gasoline, or benzene (benzol) for cleaning. Use only approved cleaning solvents to avoid the possibility of fire or poisoning. Prolonged breathing of fuel vapors can be fatal. DO NOT SMOKE when using cleaning solvent. NEVER USE IT NEAR AN OPEN FLAME. Be sure there is a fire extinguisher nearby and use cleaning solvent only in well-ventilated places. Flash point of solvent is 138°F (59°C). Severe burns or death could result. USE CAUTION when using dry cleaning solvent (item 22, appx E). Cleaning solvents evaporate quickly and can irritate exposed skin on contact. In cold weather, contact of exposed skin with cleaning solvent can cause frostbite. CAUTION Steam cleaner must be COLD (same temperature as outside air) when using cleaning solvent. DO NOT point water or steam directly at any electrical connection. Damage to electrical system may result. Keep cleaning solvents, gasoline, and lubricants away from rubber or soft plastic parts. They will deteriorate material. NOTE Only use those authorized cleaning solvents or agents listed in Appendix E.

2-10

TM 9-4940-531-14 a. Cleaning Electrical Connections. Use denatured alcohol (item 2,appx E) on clean wiping rag (item 18, appx E) to clean terminals. b. Cleaning Rust or Grease. When cleaning grease buildup or rusty places, use dry cleaning solvent (item 22, appx E). Then apply a thin coat of light oil (item 15, appx E) to affected area. 2-4.

LEAKAGE DEFINITIONS FOR OPERATOR PMCS

It is necessary for you to know how fluid leakage affects the status of the steam cleaner. Following are types/classes of leakage an operator needs to know to be able to determine the status of the steam cleaner. Learn these leakage definitions and remember--when in doubt, notify your supervisor. CAUTION Equipment operation is allowable with minor leakage (Class I or II). Of course, consideration must be given to fluid capacity in the item/system being checked/inspected. When in doubt, notify your supervisor. When operating with Class I or II leaks, continue to check fluid levels as required in your PMCS. Class Ill leaks should be reported immediately to your supervisor. a. CLASS I - See page of fluid (as indicated by wetness or discoloration) not great enough to form drops. b. CLASS II - Leakage of fluid great enough to form drops but not enough to cause drops to drip from item being checked/inspected. c. CLASS Ill - Leakage of fluid great enough to form drops that fall from item being checked/ inspected.

2-11

TM 9-4940-531-14 Table 2-1. Operator’s Preventive Maintenance Checks and Services Location Item to Check/ Service

Not Fully Mission Capable If:

Item No.

Interval

1

Before

Electrical Cable Assemblies

Check for worn or damaged insulation and loose or broken connections.

Electrical cables have worn or damaged insulation or if connections are open.

2

Before

V-belts (1)

Check for signs of impending failure, such as fraying, cracks, or cuts. Push down on belts to check for tension.

V-belts are loose or show signs of impending failure.

3

Before

Hoses

Check for loose, damaged, or missing hoses.

Hoses are loose, damaged, or missing.

2-12

Procedures

TM 9-4940-531-14

Table 2-1. Operator’s Preventive Maintenance Checks and Services (cont) Location Item to Check/ Service

Not Fully Mission Capable If:

Item No.

Interval

4

Before

Fuel Tank Assembly

Check for fuel leaks. Check fuel gauge (2) and add fuel (para 2-5) as required.

Fuel leakage of any kind. There is insufficient fuel to perform all required cleaning tasks.

5

Before

Liquid Storage Tank (3)

Check and add cleaning solution (para 2-5) as required.

There is insufficient cleaning solution to perform all required cleaning tasks.

6

Before

Fire Extinguisher (4)

Check that fire extinguisher is present.

Fire extinguisher is missing.

7

Before

Leveling Support Jack (5) and Rear Stabilizer (6)

Check that leveling support jack and rear stabilizer are not bent, broken, or inoperable. Check that pneumatic tire has 35 pounds (241 kPa) of pressure.

Leveling support jack and/or rear stabilizer are bent, broken, or inoperable. If pneumatic tire is underinflated.

8

Before

Generator Set

Refer to TM 5-6115615-12 for applicable Before PMCS.

9

Before

Flat Bed Trailer

Refer to TM 9-2330-20214&P for applicable Before PMCS.

Procedures

2-13

TM 9-4940-531-14 Table 2-1. Operator’s Preventive Maintenance Checks and Services (cont)

Item No.

2-14

Interval

Location Item to Check/ Service

Procedures

Not Fully Mission Capable If:

TM 9-4940-531-14 Table 2-1. Operator’s Preventive Maintenance Checks and Services (cont) Location Item to Check/ Service

Not Fully Mission Capable If:

Item No.

Interval

10

During

Wash Hose Assembly (7), Pressurized Water Hose Assembly (8), and Suction HOSE Assembly (9)

Check for leakage (some water dripping is normal). Tighten any loose connections. Clean Y-strainer and foot valve on suction hose assembly (para 3-6) as required. When drawing from a turbid (unclear) water source, check Ystrainer and foot valve of suction hose assembly (para 3-6) every 4 hours of operation and clean as necessary.

Any hose assemblies are missing or leaking excessively, or if Ystrainer or foot valve is clogged.

11

During

Steam Cleaning Gun (10) and Nozzles.

Check for leaks, irregular spray pattern, and proper on/off operation.

Steam cleaning gun is leaking or does not show normal on/off operation, or nozzles are producing an irreguIar spray pattern.

12

During

Water Tank Assembly (11).

Check that when ball valve (12) is opened, water tank fills but does not overflow.

Water tank does not begin filling when ball valve is opened, or if tank overflows at any time.

13

During

Fuel Tank and Lines

If fuel tank and/or lines have any fuel seepage, shut down the steam cleaner and notify unit maintenance.

There is any fuel seepage.

14

During

Water Lines, Valves, Connections, and Water Pump

Check all water lines, valves, connections, and water pump for water leakage. (Some water dripping is normal.)

There is excessive leakage or any missing hoses.

Procedures

2-15

TM 9-4940-531-14 Table 2-1. Operator’s Preventive Maintenance Checks and Services (cont) Location Item to Check/ Service

Not Fully Mission Capable If:

Item No.

Interval

15

During

Oil Drain Line (13)

Check fittings and line for leakage.

There are Class Ill oil leaks.

16

During

Water Pump Assembly (14)

If water pump assembly has class Ill oil leakage, shut down steam cleaner and notify unit maintenance.

There is class III leakage of oil from the water pump.

17

During

Coil Exhaust Opening (15)

Observe if exhaust contains black smoke after steam cleaner has reached operating temperature. If so, shut down steam cleaner and notify unit maintenance.

There is black smoke coming from exhaust opening after warmup period.

2-16

Procedures

TM 9-4940-531-14 Table 2-1. Operator’s Preventive Maintenance Checks and Services (cont) Location Item to Check/ Service

Not Fully Mission Capable If:

Item No.

Interval

18

During

OPERATING TEMPERATURE Gauge (16)

Check that OPERATING TEMPERATURE gauge reads 180 to 200°F (82 to 93°C) for HOT water mode and 315 to 335°F (157 to 168°C) for STEAM mode.

OPERATING TEMPERATURE gauge is inoperative or erratic.

19

During

HOUR METER (17)

Check that HOUR METER is working.

Hour meter is not working.

20

During

Indicator Lights (18)

Check that correct indicator light illuminates at the proper time during the indicated function. If DELlME LIGHT, HOT WATER ALARM light, or STEAM ALARM light illuminates, shut down steam cleaner and notify unit maintenance.

Indicator lights do not function properly or if DELlME LIGHT, HOT WATER ALARM light, or STEAM ALARM light is on.

Procedures

2-17

TM 9-4940-531-14 Table 2-1. Operator’s Preventive Maintenance Checks and Services (cont)

Item No.

2-18

Interval

Location Item to Check/ Service

Procedures

Not Fully Mission Capable If:

During

INLET PRESSURE Gauge (19) and OUTLET PRESSURE Gauge (20)

Check for pressure indication when water pump is on. If inlet and outlet pressure difference causes DELlME LIGHT to illuminate, shut down steam cleaner and notify unit maintenance.

Gauges are inoperative or erratic, or if DELlME LIGHT illuminates.

During

FUEL PRESSURE Gauge (21)

Check that gauge indicates between 90 and 110 psi (621 and 758 kPa when oil burner is on.

Gauge is inoperative or erratic.

During

CHEMICAL METERING Valve (22)

Check that valve is not stuck, operates smoothly, and meters chemical into the water stream.

CHEMICAL METERING valve is stuck or does not operate properly.

TM 9-4940-531-14 Table 2-1. Operator’s Preventive Maintenance Checks and Services (cont) Location Item to Check/ Service

Not Fully Mission Capable If:

Item No.

Interval

24

During

Generator Set

Refer to TM 5-6115-61512 for applicable During PMCS.

25

During

Flat Bed Trailer

Refer to TM 9-2330-20214&P for applicable During PMCS.

26

After

Leveling Support Jack (5) and Rear Stabilizer (6)

Check that leveling support jack and rear stabilizer are not bent, broken or inoperative. Check that pneumatic tire has 35 pounds (241 kPa) of pressure.

Leveling support jack and/or rear stabilizer are bent, broken, or inoperable; or if pneumatic tire is underinflated.

27

After

Hoses

Check for loose, damaged, or missing hoses.

Hoses are loose, damaged, or missing.

Procedures

2-19

TM 9-4940-531-14

Table 2-1. Operator’s Preventive Maintenance Checks and Services (cont)

TM 5-6115-615-12

TM 9-2330-202-14&P

para 3-5

2-20

TM 9-4940-531-14

Section 2-5.

Ill.

OPERATION

UNDER

USUAL

CONDITIONS

PREPARATION FOR USE WARNING • Do not install steam cleaner in areas containing flammable material or gases. Severe injury or death from fire or fumes may result. • Install steam cleaner in properly ventilated areas to avoid possible insufficient supply of oxygen. If poorly-vented area is a necessity, outside air may be piped to oil burner assembly and a fan may be installed to bring fresh air into the area. • For inside installation, use exhaust stack to prevent fumes from collecting inside building. Minimum exhaust stack is 10 inches (25.40 cm). Exhaust stack must be warm for sufficient draw; in cold areas of operation, exhaust stack should be insulated. Cold exhaust stack invites downdraft. Severe injury or death could result if exhaust is not vented. • Items to be cleaned should be approximately 12 feet (3.66 m) from steam cleaner to avoid direct spray of steam cleaning gun coming into contact with steam cleaner. Excess moisture reaching generator and electrical controls will reduce life of steam cleaner unit and components and may cause shorts which may result in electrical shock. • Diesel fuel is FLAMMABLE; DO NOT smoke in vicinity while performing servicing operations. Severe injury or death may result. • Ensure generator is properly grounded before operating steam cleaner to avoid electrical shock. CAUTION Incoming power supply must be 208 VAC ±10%, 50/60 Hz, single phase; otherwise, equipment damage can result.

2-21

TM 9-4940-531-14 2-5. PREPARATION FOR USE (cont) a. Installation Site Precautions. (1) Steam cleaner should be located on a level surface with consideration given to accessibility for filling of cleaning solution and fuel oil. Location for electricity, water connections, and maintenance should also be considered. If generator set will be used, ground generator set before operation. Refer to TM 56115-615-12. (2) Ensure steam cleaner is properly stabilized before operating. Turn levelingsupport jack crank handle (1) clockwise to raise flat bed trailer (2) and disengage it from towing vehicle. Turn leveling-support jack crank handle (1) counterclockwise to lower and stabilize the flat bed trailer (2).

(3) Go to the opposite end of flat bed trailer (2). Lift handle (3) to release rear stabilizer (4) from the travel position. Turn base of leg assembly (5) as necessary to adjust height of rear stabilizer (4) to ensure solid contact with the ground while in the locked position. (4) When using commercial power source, steam cleaner should be wired to a fused- or breaker-protected electrical grounded circuit or outlet of at least 20 amp capacity.

2-22

TM 9-4940-531-14

b.

Initial Checks and Services.

NOTE For initial checks and services of generator set, refer to TM 5-6115-615-12. For initial checks and services of flat bed trailer, refer to TM 9-2330-202-14&P. (1) Check fuel gauge (1). If necessary, remove fuel tank cap (2) and add proper grade of diesel fuel. Use grade 1 (item 10, appx E) at 32°F (0 °C) and below; use grade 2 (item 11, appx E) above 32°F (0 °C).

2-23

TM 9-4940-531-14 2-5. PREPARATION FOR USE (cont) b. Initial Checks and Services. (cont)

(2) Open fuel shutoff valves (3 and 4). (3) Check that float (5) in water tank assembly (6) operates freely. (4) Check all fuel lines for loose connections and leaks.

2-24

TM 9-4940-531-14

Ensure liquid storage tank is positioned as shown. (5) Remove webbing strap (7) and liquid storage tank (8). Remove cap (9) and fill liquid storage tank with cleaning compound (item 7, appx E). Reinstall liquid storage tank and webbing strap. (6) Using cross-tip screwdriver, remove access cover (10). Using flashlight, check oil level in water pump assembly (11). Add oil (item 14, appx E) as required.

2-25

TM 9-4940-531-14

2-5. PREPARATION FOR USE (cont) b. Initial Checks and Services. (cont)

When using generator power, observe correct hookup of cable to prevent damage to equipment. (7) If using commercial power, connect facility power cable assembly (12) to commercial power source. If using generator power, ensure that generator power cable assembly (13) is connected to generator terminals (14). Refer to TM 5-6115-615-12. (8) Attach wash hose assembly (15) to steam cleaner pipe coupling (16) and attach steam cleaning gun (17). Do not attach a nozzle when performing the Initial Start Up procedures in paragraph c., following. 2-26

TM 9-4940-531-14 Initial Start Up. The following steps provide steam cleaner initial starting procedures.

c.

WARNING Always use ear protection. During operation, the generator set exceeds permissible decibel levels. The steam cleaner also exceeds permissible decibel levels during operation in the steam mode and during blowdown. Failure to observe this warning could result in permanent hearing injury. Wear safety goggles/glasses and gloves to prevent injury when operating the steam cleaner in any mode. CAUTION Do not use the steam cleaner in any mode on surfaces having a petroleum-based undercoating. Otherwise erosion/removal of such undercoating can result. NOTE Read through operating procedures prior to operation.

(1) If steam cleaner is to be operated from a pressurized water source, perform the following steps: (a)

Open exhaust flap (1).

(b)

Connect pressurized water hose assembly (2) to water inlet assembly (3) on steam

cleaner.

2-27

TM 9-4940-531-14 2-5. PREPARATION FOR USE (cont) c.

Initial Start Up. (cont)

(c)

Ensure coupler cap (4) is tightened securely.

(d)

Rotate ball valve (5) to ON position.

(e)

Turn on water supply and fill water tank assembly (6).

(f

If present, remove nozzle from steam cleaning gun (7). Open trigger (8).

(g)

Check that the CHEMICAL METERING valve (9) is in the closed position.

(h)

If using generator power, refer to TM 5-6115-615-12 and start generator set.

(i)

Check that EMERGENCY OFF circuit breaker (10) is in ON position.

(j)

Rotate MODE SELECTOR (11) to COLD.

CAUTION Keep water and steam away from the oil burner electromagnet relay. Moisture can permanently damage internal parts. (k) Press PUSH TO START switch (12). Steam cleaner should start immediately. (l) When a steady stream of clear water is discharged from steam cleaning gun (7), steam cleaner is flushed and ready for operation. 2-28

TM 9-4940-531-14

(2) If steam cleaner is to be operated from a nonpressurized water source, perform the following steps: (a) Open exhaust flap (1). (b) Unscrew coupler cap (2) and connect suction hose assembly (3) to water pump assembly (4). (c) Rotate ball valve (5) to OFF position. (d) Place foot valve/strainer end of suction hose assembly at least 6 in. (15 cm) below water surface. (e) If present, remove nozzle from steam cleaning gun (6).

Open trigger (7).

2-29

TM 9-4940-531-14 2-5. PREPARATION FOR USE (cont) c.

Initial Start Up. (cont)

(f) Check that the CHEMICAL METERING valve (8) is in the closed position. (g) If using generator power, refer to TM 5-6115-612-12 and start generator set. (h) Check that EMERGENCY OFF circuit breaker (9) is in ON position. (i) Rotate MODE SELECTOR (10) to COLD. CAUTION Keep water and steam away from the oil burner electromagnet relay. Moisture can permanently damage internal parts. (j) Press PUSH TO START switch (11). Steam cleaner should start immediately. (k) If water pump does not prime within 3 minutes, stop steam cleaner by rotating MODE SELECTOR (10) to OFF. Refer to Table 3-1, Operator Troubleshooting. (l) When a steady stream of water is discharged from steam cleaning gun (6), steam cleaner is flushed and ready for operation.

2-30

TM 9-4940-531-14 2-6.

OPERATING PROCEDURE WARNING Always use ear protection. During operation, the generator set exceeds permissible decibel levels. The steam cleaner also exceeds permissible decibel levels during operation in the steam mode and during blowdown. Failure to observe this warning could result in permanent hearing injury. Wear safety goggles/glasses and gloves (item 12, appx E) when operating the steam cleaner in any mode to prevent injury from scalding and high water velocity. CAUTION Do not use the steam cleaner in any mode on surfaces having a petroleum-based undercoating. Otherwise erosion/removal of such undercoating can result. NOTE Read through operating procedures before operating the steam cleaner. In most instances, equipment should be washed by starting at ground level and working up, and rinsed by starting at the top and working down.

General Theory of Operation. The steam cleaner can deliver steam or hot or cold water, a. all at high pressure, as selected by the MODE SELECTOR on the upper control panel assembly. When MODE SELECTOR is turned to OFF position from the hot or cold water position, steam cleaner will automatically go into a drain cycle. When MODE SELECTOR is turned to OFF position from steam operation, steam cleaner will automatically start the blowdown cycle.

2-31

TM 9-4940-531-14

2-6. OPERATING PROCEDURE (cont) b. Cold Rinse.

(1) Perform initial startup procedure (para 2-5c.). (2) Install appropriate nozzle on steam cleaning gun (1) (para 2-1). (3) If using generator power, refer to TM 5-6115-615-12 and start generator set. (4) Rotate MODE SELECTOR (2) to COLD. (5) Press PUSH TO START switch (3). Steam cleaner should start immediately. WARNING To avoid possible injury to personnel, if outlet pressure exceeds 600 psi (4137 kPa), turn EMERGENCY OFF switch to OFF position and notify unit maintenance. (6) OUTLET PRESSURE gauge (4) reading should build up to a minimum of 400 psi (2758 kPa). Maximum pressure in this mode is 600 psi (4137 kPa). Steam cleaner is now ready to use in the cold rinse mode. (7) To turn off cold rinse mode, rotate MODE SELECTOR (2) to OFF. (8) If using generator power, refer to TM 5-6115-615-12 and stop generator set. (9) If finished with steam cleaner, refer to paragraph e. for shutdown procedure.

2-32

TM 9-4940-531-14

c.

Hot Wash/Rinse.

(1) Perform initial startup procedure (para 2-5c.). (2) Install appropriate nozzle on steam cleaning gun (1) (para 2-1). (3) If using generator power, refer to TM 5-6115-615-12 and start generator set. (4) Rotate MODE SELECTOR (2) to COLD. (5) Press PUSH TO START switch (3). Steam cleaner should start. (6) After lines have filled with water, rotate MODE SELECTOR (2) to HOT. 2-33

TM 9-4940-531-14 2-6. c.

OPERATING PROCEDURE (cont) Hot Wash/ Rinse. (cont)

WARNING To avoid possible injury to personnel, if outlet pressure exceeds 600 psi (4137 kPa), turn EMERGENCY OFF switch to OFF position and notify unit maintenance. (7) OUTLET PRESSURE gauge (4) reading should build up to a minimum of 400 psi (2758 kPa). Maximum pressure in this mode is 600 psi (4137 kPa). (8) FUEL PRESSURE gauge (5) should read between 90 and 110 psi (620.6 and 758.5 kPa) when oil burner cycles on. (9) OPERATING TEMPERATURE gauge (6) should build to between 180 and 200°F (82.2 and 93.3 °C). Steam cleaner is now ready to use in the hot wash/rinse mode. If HOT WATER ALARM light comes on, turn MODE SELECTOR to COLD. If light goes off, resume operation. If light stays on, turn MODE SELECTOR to OFF and contact unit maintenance. (10) If using cleaning solution, open CHEMICAL METERING valve (7) to desired setting and allow sufficient time for cleaning solution to reach steam cleaning gun. (11) To shut off cleaning solution, close CHEMICAL METERING valve (7) and allow sufficient time for cleaning solution to clear steam cleaning gun. (12) To turn off hot wash/rinse mode, rotate MODE SELECTOR (2) to COLD. Allow steam cleaning gun to cool, then rotate MODE SELECTOR (2) to OFF. (13) If using generator power, refer to TM 5-6115-615-12 and stop generator set. (14) If finished with steam cleaner, refer to paragraph e. for shutdown procedure. 2-34

TM 9-4940-531-14

d.

Steam.

(1)

Perform initial startup procedure (para 2-5c.).

(2)

Install appropriate nozzle on steam cleaning gun (1) (para 2-1).

(3)

If using generator power, refer to TM 5-6115-615-12 and start generator set.

(4)

Rotate MODE SELECTOR (2) to COLD.

(5)

Press PUSH TO START switch (3). Steam cleaner should start immediately.

(6)

After lines have filled with water, rotate MODE SELECTOR (2) to STEAM. WARNING

To avoid possible injury to personnel, if outlet pressure exceeds 400 psi (2758 kPa), turn EMERGENCY OFF switch to OFF position and notify unit maintenance. (7) OUTLET PRESSURE gauge (4) reading should build up to a minimum of 200 psi (1379 kPa). Maximum pressure in this mode is 400 psi (2758 kPa). (8) OPERATING TEMPERATURE gauge (5) should build to between 315 and 335°F (157.2 and 168.3 °C) in 4 to 5 minutes. Steam cleaner is now ready to use in the steam mode. If STEAM ALARM light comes on, turn MODE SELECTOR to COLD. If light goes off, resume operation. If light stays on, turn MODE SELECTOR to OFF and contact unit maintenance. (9) FUEL PRESSURE gauge (6) should read between 90 and 110 psi (620.6 and 758.5 kPa) when oil burner cycles on. 2-35

TM 9-4940-531-14 2-6.

OPERATING

PROCEDURE

(cont)

d. Steam. (cont)

(10) If using cleaning solution, open CHEMICAL METERING valve (7) to desired setting and allow sufficient time for cleaning solution to reach steam cleaning gun. (11) To shut off cleaning solution, close CHEMICAL METERING valve (7) and allow sufficient time for cleaning solution to clear steam cleaning gun.

The blowdown cycle lasts about 4 minutes and emits excessive steam and noise. The operator must remain approximately 10 feet (3.05 m) from steam cleaner during blowdown to prevent possible burns from steam and hot water. Hearing protection is required as the steam cleaner projects high intensity noise; failure to do so could result in permanent hearing loss.

Ensure steam cleaning gun is turned off before entering blowdown cycle. Extreme heat will damage wash hose and steam cleaning gun. (12) To turn off steam mode, rotate MODE SELECTOR (2) to OFF. This will start the automatic blowdown cycle, flushing coil residue out through the blowdown pipe (8). (13) Allow steam cleaner to blowdown automatically and shut off. (14) If using generator power, refer to TM 5-6116-615-12 and stop generator set. (15) If finished with steam cleaner, refer to paragraph e. for shutdown procedure. 2-36

TM 9-4940-531-14

e.

Shutdown Procedure.

NOTE Cleaning solution will be siphoned out when steam cleaner is shut down unless CHEMICAL METERING valve is closed. (1)

Ensure that MODE SELECTOR (1) is turned to OFF.

(2)

Turn EMERGENCY OFF circuit breaker (2) to off position.

(3) Turn both the fuel tank shutoff valve (3) and the oil burner fuel shutoff valve (4) to the off position. (4) (5) water. (6)

If using pressurized water, turn off water supply spigot. If drawing water from nonpressurized source, pull the suction hose assembly (5) out of the

If operating outdoors, close the exhaust flap (6) and all access doors (7).

(7) Wipe off steam cleaning gun (8) and wash hose assembly (9) with a clean wiping rag (item 18, appx E).

2-37

TM 9-4940-531-14 2-7. DECALS AND INSTRUCTION PLATES. The following illustrations show all of the decals and instruction plates that are used on the steam cleaner, along with their respective locations.

2-38

TM 9-4940-531-14

2-39

TM 9-4940-531-14 2-7. DECALS AND INSTRUCTION PLATES (cont)

2-40

TM 9-4940-531-14

Section IV. O P E R A T I O N

UNDER

UNUSUAL

CONDITIONS

2-8. OPERATION IN COLD WEATHER WARNING Operation of the steam cleaner in below freezing (below 32°F (0°C)) weather can result in injury caused by ice formation on and around equipment. Do not attempt to operate the steam cleaner in below freezing weather. CAUTION When the steam cleaner is stored outside in cold weather, condensation can build up in the water pump assembly oil sump. The condensed water can mix with oil, forming sludge and/or freezing. This can cause damage to the water pump assembly components. Change the water pump oil more frequently under cold weather conditions. OPERATION IN DIRT, DUST, MUD, OR SANDY CONDITIONS

2-9.

a. All protective covers should be in place to prevent dust, dirt, and foreign material from reaching components. Close the access doors and exhaust flap when steam cleaner is not in use. b. Clean Y-strainer in suction hose assembly every 4 hours. c. Clean dirt and mud from steam cleaner after job is completed or daily. d. Clean sand from the steam cleaner by brushing with a soft bristle brush. 2-10.

OPERATION IN WET WEATHER CAUTION If it starts raining, stop steam cleaning operations and close all access doors to prevent water from damaging steam cleaner control panel or other components.

2-11. OPERATION IN HOT AND HUMID CONDITIONS Provide adequate circulation around steam cleaner to ensure proper oil burner assembly and generator set operation.

2-41/(2-42 blank)

TM 9-4940-531-14

CHAPTER OPERATOR

3

MAINTENANCE

INSTRUCTIONS

CHAPTER INDEX Page

Paragraph 3-1. 3-2. 3-3. 3-4. 3-5. 3-6.

Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 Trailer-Mounted Steam Cleaner—Maintenance Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16 Steam Cleaner Nozzles—Maintenance Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17 Fuel Strainer Assembly—Maintenance Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18 Suction Hose Assembly—Maintenance Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21 Section

3-1.

l.

LUBRICATION

INSTRUCTIONS

LUBRICATION

a.

There is no operator level lubrication for the steam cleaner.

b.

Refer to TM 5-6115-615-12 for generator set lubrication.

c.

Refer to TM 9-2350-202-14&P for flat bed trailer lubrication. Section

3-2.

Il.

TROUBLESHOOTING

PROCEDURES

TROUBLESHOOTING

a. This table lists common malfunctions that you may find with your equipment. Perform the tests, inspections, and corrective actions in the order they appear in the table. b. This table cannot list all the malfunctions that may occur, all the tests and inspections needed to find the fault, or all the corrective actions needed to correct the fault. If the equipment malfunction is not listed, or actions listed do not correct the fault, notify unit maintenance. c. The malfunction index can be used as a quick guide to troubleshooting. Common malfunctions are listed in order of appearance within table 3-1, with a page number reference to the page where a test or inspection and corrective action are provided.

3-1

TM 9-4940-531-14 3-2. TROUBLESHOOTING (cont) MALFUNCTION INDEX

Troubleshooting Procedure (Page)

STEAM CLEANER POWER LIGHT does not come on when PUSH-TO-START button is pressed .... and released . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 POWER LIGHT comes on and then goes off when PUSH-TO-START button is pressed and released . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 Water pump runs but there is low or no water output from nozzle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 Normal water output but oil burner will not start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11 Oil burner motor runs but FUEL PRESSURE gauge indicates low or fluctuating fuel pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13 Oil burner runs but excessive smoke comes from coil exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13 Oil burner motor runs but oil burner fails to ignite or goes out prematurely . . . . . . . . . . . . . . . . . . . . . . . . 3-14 HOT WATER ALARM or STEAM ALARM light comes on while operating steam ... cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-15 FLAT BED TRAILER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15 GENERATOR SET

3-2

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-15 ..

TM 9-4940-531-14 Table 3-1. Operator Troubleshooting MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION

1.

POWER LIGHT (1) DOES NOT COME ON WHEN PUSH-TO-START BUTTON (2) IS PRESSED AND RELEASED. Step 1.

Check that MODE SELECTOR (3) is in COLD position. Turn MODE SELECTOR to COLD.

Step 2. Check if CIRCUIT BREAKER (4) tripped. Reset CIRCUIT BREAKER. 3-3

TM 9-4940-531-14 3-2. TROUBLESHOOTING (cont) Table 3-1. Operator Troubleshooting (cont) MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION STEAM CLEANER (cont)

Step 3.

Check that EMERGENCY OFF switch (5) is in ON position. Turn EMERGENCY OFF switch to ON.

Step 4.

Check that steam cleaner is connected to 208 VAC power (para 2-5). Connect steam cleaner to facility or generator power.

Step 5.

Check if safety interlock switches (6) are engaged. Loosen four tapping screws (7) on upper control panel assembly (8), push in upper right-hand portion of cover and while holding, tighten screws. Ensure upper control panel assembly cover is securely closed.

3-4

TM 9-4940-531-14

Table 3-1. Operator Troubleshooting (cont) MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION

2.

POWER LIGHT (1) COMES ON AND THEN GOES OFF WHEN PUSH-TO-START BUTTON (2) IS PRESSED AND RELEASED. Check that EMERGENCY OFF switch (3) is in ON position. If EMERGENCY OFF switch is in OFF position, turn MODE SELECTOR (4) to OFF and reset EMERGENCY OFF switch.

3 - 5

TM 9-4940-531-14 3-2. TROUBLESHOOTING (cont) Table 3-1. Operator Troubleshooting (cont) MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION STEAM CLEANER (cont)

3.

WATER PUMP (1) RUNS BUT THERE IS LOW OR NO WATER OUTPUT FROM NOZZLE.

To prevent damage, do not operate water pump longer than 3 minutes without water flowing. 3-6

TM 9-4940-531-14 Table 3-1. Operator Troubleshooting (cont) MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION NOTE Low water output can be determined as follows: Deliver the water discharge into a 5gallon bucket for 1 minute. Minimum accumulation should be as follows: Cold or Hot Water Mode 4 gallons (15.14 liters)

Steam Mode 3.5 gallons (13.25 liters) condensate

a. Pressurized Water Source. Step 1.

Check that ball valve (2) is fully open (in ON position). Turn ball valve to ON position.

Step 2. Check if blowdown valve (3) is open, allowing excessive water to escape from drain pipe (4). Turn MODE SELECTOR (5) to OFF, then COLD. If water continues to drain, notify unit maintenance. Step 3. Check that correct size nozzle is installed (para 2-1). Install correct nozzle for the selected cleaning mode. Step 4.

Remove nozzle, check if it is plugged with debris. Clean nozzle (para 3-4).

Step 5. Check that CHEMICAL METERING valve (6) is closed or liquid storage tank (7) is sufficiently filled if valve is left open. Close CHEMICAL METERING valve and refill liquid storage tank (para 2-5). Step 6.

Check water supply. Check that facility supply faucet is turned on, that hose is not kinked, and that there is normal pressure at the faucet.

Step 7.

Check that coupler cap (8) is installed tightly. Tighten coupler cap.

Step 8. Visually check for loose V-belts (9). If V-belts appear loose, notify unit maintenance.

3-7

TM 9-4940-531-14 3-2. TROUBLESHOOTING (cont) Table 3-1. Operator Troubleshooting (cont) MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION

3.

WATER PUMP RUNS BUT THERE IS LOW OR NO WATER OUTPUT FROM NOZZLE. (cont) b. Nonpressurized Water Source. Step 1.

Check that ball valve (2) is closed (in OFF position). Turn ball valve to OFF position.

3-8

TM 9-4940-531-14 Table 3-1. Operator Troubleshooting (cont) MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION Step 2. Check if blowdown valve (3) is open, allowing excessive water to escape from drain pipe (4). Turn MODE SELECTOR (5) to OFF, then ON. If water continues to drain, notify unit maintenance. Step 3. Check that correct size nozzle is installed (para 2-1). Install correct nozzle for the selected cleaning mode. Step 4.

Remove nozzle, check if it is plugged with debris. Clean nozzle (para 3-4).

Step 5. Check that CHEMICAL METERING valve (6) is closed or liquid storage tank (7) is sufficiently filled if valve is left open. Close CHEMICAL METERING valve and refill liquid storage tank (para 2-5). Step 6. Check for proper water pump (1) priming: a.

Momentarily open and close CHEMICAL METERING valve (6).

b.

If step a. procedure does not work, take the following steps: (1) Using a clean container, fill water tank (10) with water. (2) Open ball valve (2), then close it after a few seconds. Repeat several times until water pump primes.

Step 7. Check that suction hose assembly strainer (11) is not clogged (para 3-6). Clean suction hose assembly strainer. Step 8. Check that foot valve strainer (12) is not clogged (para 3-6) and that foot valve is completely submerged. Clean foot valve strainer and place foot valve/strainer end of suction hose assembly at least 6 in. (15.24 cm) below water surface. Step 9. Check that source water level does not exceed 15 ft (4.57 m) below water pump centerline. Relocate steam cleaner to a different position or water source that will not exceed the 15 ft (4.57 m) suction limit.

3-9

TM 9-4940-531-14 3-2. TROUBLESHOOTING (cont) Table 3-1. Operator Troubleshooting (cont) MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION STEAM CLEANER (cont)

3-10

TM 9-4940-531-14 Table 3-1. Operator Troubleshooting (cont) MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION

4.

NORMAL WATER OUTPUT BUT OIL BURNER (1) WILL NOT START. Step 1.

Check that MODE SELECTOR (2) is on HOT or STEAM. Move MODE SELECTOR from COLD to HOT or STEAM.

Step 2. Check that control panel CIRCUIT BREAKER (3) is not tripped. Press CIRCUIT BREAKER button once. If it trips again, notify unit maintenance. Step 3. Check if thermal overload switch (4) on motor housing is tripped. Reset once if tripped. If thermal overload switch trips immediately after being reset, notify unit maintenance. NOTE In the following step, it is normal for the electromagnet relay not to reset for up to 15 minutes after tripping. Step 4. Check if reset button (5) on oil burner electromagnet relay is tripped. Reset once if tripped. If reset button trips immediately after being reset wait 15 minutes and reset again. If it trips, notify unit maintenance.

3-11

TM 9-4940-531-14 3-2. TROUBLESHOOTING (cont) Table 3-1. Operator Troubleshooting (cont) MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION

3-12

TM 9-4940-531-14 Table 3-1. Operator Troubleshooting (cont) MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION 5.

OIL BURNER MOTOR (1) RUNS BUT FUEL PRESSURE GAUGE (2) INDICATES LOW OR FLUCTUATING FUEL PRESSURE. Step 1.

Check fuel gauge (3) to ensure there is fuel in fuel tank. Fill fuel tank (para 2-5) if empty.

Step 2. Check that fuel tank shutoff valve (4) and oil burner fuel shutoff valve (5) are open. Open shutoff valves. Step 3. Check for dirt or water in fuel strainer assembly (6). Clean fuel strainer assembly (para 3-5). Step 4. Check if diesel fuel has jelled due to freezing temperatures. Move steam cleaner indoors and warm to above 32°F (0°C).

6.

OIL BURNER (1) RUNS BUT EXCESSIVE SMOKE COMES FROM COIL EXHAUST. Check that exhaust flap (2) is fully open. Open exhaust flap fully.

3-13

TM 9-4940-531-14 3-2. TROUBLESHOOTING (cont) Table 3-1. Operator Troubleshooting (cont) MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION STEAM CLEANER (cont)

7.

OIL BURNER MOTOR (1) RUNS BUT OIL BURNER (2) FAILS TO IGNITE OR GOES OUT PREMATURELY. Check if reset button (3) on oil burner electromagnet relay is tripped. Reset once if tripped. If reset button trips immediately after being reset, wait 15 minutes and reset again. If it trips, notify unit maintenance.

3-14

TM 9-4940-531-14 Table 3-1. Operator Troubleshooting (cont) MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION

8.

HOT WATER ALARM (1) OR STEAM ALARM (2) LIGHT COMES ON WHILE OPERATING STEAM CLEANER. No further tests or inspections required. Turn EMERGENCY OFF switch (3) to off. Notify unit maintenance. FLAT BED TRAILER

Refer to TM 9-2330-202-14&P. GENERATOR SET Refer to TM 5-6115-615-12.

3-15

TM 9-4940-531-14 3-4. STEAM CLEANER NOZZLES—MAINTENANCE INSTRUCTIONS THIS TASK COVERS: a. R e m o v a l

b. I n s p e c t i o n

c. C l e a n i n g

d. Installation

INITIAL SETUP Tools/Materials Compressed air (if available) Equipment Conditions Steam cleaner shut down (para 2-6)

NOTE There are five different nozzles used on the steam cleaner. The following procedure applies to any one of them. REMOVAL Remove nozzle (1) from steam cleaning gun (2) by pulling back on quick-disconnect collar (3). INSPECTION Examine nozzle for dirt and foreign material.

CAUTION Cleaning the nozzle with a metal tool of any kind can damage the nozzle and cause an irregular spray pattern. Remove any dirt or foreign material from nozzles using a wooden or plastic rod-shaped tool and/ or by blowing out with compressed air. INSTALLATION Install nozzle (1) on steam cleaning gun (2). 3-17

TM 9-4940-531-14 3-5. FUEL STRAINER ASSEMBLY—MAINTENANCE INSTRUCTIONS THIS TASK COVERS: a. Disassembly

b. Cleaning

c. Reassembly

INITIAL SETUP Materials/Parts Wiping rag (item 18, appx E) Equipment Conditions Steam cleaner shut off (para 2-6) and allowed to cool down. DISASSEMBLY

WARNING Diesel fuel is FLAMMABLE; DO NOT smoke in vicinity while performing servicing operations. Injury or death could result. 1

3-18

Close fuel shutoff valves (1) in front of fuel tank (2).

TM 9-4940-531-14

2

Close shutoff valve (3) on fuel strainer assembly (4).

3

Loosen nut (5) on bottom of fuel strainer assembly (4) and swing wire retainer (6) to side.

4

Remove bowI (7).

5

Remove strainer (8) and gasket (9) from bowl (7).

CLEANING Wipe off strainer and bowl with clean wiping rag (item 18, appx E).

REASSEMBLY

1

Install gasket (1) and strainer (2) in bowl (3).

2

Install bowl (3).

3

Reposition wire retainer (4), and tighten nut (5) on bottom of fuel strainer assembly (6).

4 Open shutoff valve (7) on fuel strainer assembly (6).

3-19

TM 9-4940-531-14 3-5. FUEL STRAINER ASSEMBLY—MAINTENANCE INSTRUCTIONS (cont) REASSEMBLY (cont)

5 Open fuel shutoff valves (8) in front of fuel tank (9). 6

3-20

Start steam cleaner (para 2-6) and check fuel strainer assembly (6) for leaks.

TM 9-4940-531-14 3-6. SUCTION HOSE ASSEMBLY—MAINTENANCE INSTRUCTIONS THIS TASK COVERS: Cleaning INITIAL SETUP Tools and Special Tools 8 in. adjustable wrench (appx D) Equipment Conditions Suction hose assembly removed (para 2-6) CLEANING

1

Remove foot valve (1) from bushing (2). Hold foot valve (1) under running tap water to clean. Reinstall foot valve (1) onto bushing (2).

2

Remove cap (3) and strainer (4) from Y-strainer (5). Hold strainer (4) under running tap water to clean. Reinstall strainer (4) and cap (3) onto Y-strainer (5).

3-21/(3-22 blank)

TM 9-4940-531-14

CHAPTER UNIT

MAINTENANCE

4 INSTRUCTIONS

CHAPTER INDEX Paragraph 4-1. 4-2. 4-3. 4-4. 4-5. 4-6. 4-7. 4-8. 4-9. 4-10. 4-11. 4-12. 4-13. 4-14. 4-15. 4-16. 4-17. 4-18. 4-19. 4-20. 4-21. 4-22. 4-23. 4-24. 4-25. 4-26. 4-27. 4-28. 4-29.

Page

Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 . Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-3 4-3 Checking Unpacked Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 .. Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 4-5 Installation Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PMCS Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . 4-6 Leakage Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9 4-19 General Maintenance Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19 Trailer-Mounted Steam Cleaner-Maintenance Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22 Steam Cleaner-Maintenance Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-42 Oil Burner Assembly-Maintenance Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-53 Fuel Tank Assembly-Maintenance Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-64 V- Belts- Maintenance Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-66 Water Inlet Assembly-Maintenance Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-67 Pump Inlet Assembly-Maintenance Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lower Control Panel Assembly and CHEMICAL METERING Valve Assembly4-69 Maintenance Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Control Panel Assembly and Electrical Components Assembly4-71 Maintenance Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . 4-74 Wash Hose Assembly-Maintenance Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Enclosure and Lift Assembly and Hose Rack Access DoorMaintenance Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-75 4-86 Facility Power Cable Assembly-Maintenance Instructions . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . 4-87 Outlet and Water Drain Assembly-Maintenance Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-91 Suction Hose Assembly-Maintenance Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-93 Generator Power Cable Assembly-Maintenance Instructions . . . . . . . . . . . . . . . . . . . . . . . . 4-95 Flat Bed Trailer-Maintenance Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-96 Administrative Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-96

4-1

TM 9-4940-531-14

Section 4-1.

I.

LUBRICATION

INSTRUCTIONS

LUBRICATION

CAUTION Do not overfill water pump assembly with oil. Too much oil will destroy water pump seals. If oil level is above center of sight glass, drain excess in accordance with paragraph b. below. The following lubrication instructions are mandatory. a. Remove four screws (1) and access cover (2). Using flashlight, check oil level sight glass (3) in water pump assembly (4). If low, remove oil filler cap (5) and add oil (item 14, appx E) to center of sight glass. Reinstall oil filler cap (5). If overfilled, drain excess oil. b. Change oil in water pump assembly after every 100 hours of operation or after every 30 days as follows: (1) Shut down steam cleaner (para 2-6). (2) Remove oil filler cap (5) from water pump assembly (4). (3) Remove drain plug (6) and empty oil into suitable container. Reinstall drain plug. (4) Add oil (item 14, appx E) to required level indicated and reinstall oil filler cap (5).

4-2

TM 9-4940-531-14

c. Lubricate water pump assembly (4) monthly with 3 drops of lubricating oil (item 15, appx E) applied to three lubricating holes. d. Lubricate all hinged doors quarterly with 3 to 4 drops of lubricating oil (item 15, appx E) applied to hinges. e. Refer to TM 9-2330-202-14&P for lubrication instructions for the flat bed trailer. f. Refer to TM 5-6115-615-12 for lubrication instructions for the generator set.

Section 4-2.

II.

SERVICE

UPON

RECEIPT

GENERAL

This section contains instructions for determining whether a new or reconditioned steam cleaner upon receipt has been properly prepared and conditioned for service. 4-3.

UNPACKING

a. Remove all packing material, including wood, paper, plastic covering, and tiedowns. b. Check for shipment of TM 9-4940-531-14, TM 9-4940-531-24P, TM 5-6115-615-12, TM 5-6115615-34, TM 5-6115-615-24P, and TM 9-2330-202-14&P. 4-4.

CHECKING

UNPACKED

EQUIPMENT

a. Inspect the equipment for damage incurred during shipment. If the equipment has been damaged, report the damage on SF Form 364, Report of Discrepancy (ROD). b. Check the equipment against the packing slip to see if the shipment is complete. Report all discrepancies in accordance with the instructions of DA PAM 738-750. 4-5.

INSPECTION

a. Visually inspect rubber hoses and tires for tears, rips, holes, and punctures. b. Visually inspect all metal components for rust, distortion, cracks, and broken welds. c. Visually inspect instruments, pressure lines, and fuel lines for damage.

4-3

TM 9-4940-531-14 4-6.

SERVICE

a. Check fuel gauge (1) to ensure fuel tank assembly (2) is empty. With suitable container in Place. remove drain plug (3) to drain any condensation or old fuel-from fuel tank assembly; reinstall drain plug. b. Remove filler opening cap (4) and fill fuel tank assembly (2) with grade 1 or 2 diesel fuel (item 10 or item 11, appx E). c. Check that liquid level switch (5) operates freely in water tank assembly (6). CAUTION Do not overfill water pump assembly with oil. Too much oil will destroy water pump seals. If oil level is above center of sight glass, drain excess oil. d. Remove four screws (7) and access cover (8). Using flashlight, check oil level sight glass (9) in water pump assembly (10). If low, remove oil filler cap (11) and add oil (item 14, appx E) to center of sight glass. Reinstall oil filler cap (11). If overfilled, drain excess oil.

4-4

TM 9-4940-531-14

e. Unfasten retaining strap (12) and remove liquid storage tank (13). Remove cap (14) and fill liquid storage tank with cleaning compound (item 7, appx E). Reinstall as shown. f. If generator set will be used, ground generator set before operation (TM 5-6115-615-12). 4-7. INSTALLATION INSTRUCTIONS For inside installation, install an exhaust stack to prevent fumes from collecting inside the building. Refer to paragraph 2-5. The exhaust stack should be at least 30 in. (76.2 cm) long with a 14-in. inner diameter. The exhaust stack should be connected/adapted to the steam cleaner vent using a downdraft diverter.

4-5

TM 9-4940-531-14

Section 4-8.

Ill.

PREVENTIVE

MAINTENANCE

CHECKS

AND

SERVICES

(PMCS)

PMCS PROCEDURES

a. General. Preventive Maintenance Checks and Services (PMCS) means systematic caring, inspecting, and servicing of the steam cleaner to keep it in good condition and to prevent breakdowns. b. Item No. Column. Checks and services are numbered in chronological order regardless of interval. This column is used as an item number source for the TM Item Number column on DA Form 2404 when recording PMCS results. c. Interval Column. This column tells you when you must do the checks and services; either quarterly or hours of operation. d. Location, Item To Check/Service Column. This column contains the name of the item(s) to be checked or serviced. e. Procedure Column. This column tells you how to do the required checks or services. NOTE The terms ready/available and mission capable refer to the same status: equipment is on hand and is able to perform its combat missions. f. Not Fully Mission Capable If: Column. This column identifies the faults of the equipment that will prevent the steam cleaner from being fully mission capable. 4-9. LEAKAGE DEFINITIONS It is necessary for you to know how fluid leakage affects the status of the steam cleaner. Following are types/classes of leakage an operator needs to know to be able to determine the status of the steam cleaner. Learn these leakage definitions and remember--when in doubt, notify you supervisor. CAUTION Equipment operation is allowable with minor leakage (Class I or II). Of course, consideration must be given to fluid capacity in the item/system being checked/inspected. When in doubt, notify you supervisor. When operating with Class I or II leaks, continue to check fluid levels as required in your PMCS. Class Ill leaks should be reported immediately to your supervisor. a. CLASS I - Seepage of fluid (as indicated by wetness or discoloration) not great enough to form drops. b. CLASS II - Leakage of fluid great enough to form drops but not enough to cause drops to drip from item being checked/inspected. c. CLASS Ill - Leakage of fluid great enough to form drops that fall from item being checked/inspected. 4-6

TM 9-4940-531-14 Table 4-1. Preventive Maintenance Checks and Services for Steam Cleaner Item No.

Interval

Location Item to Check/ service

Procedure

Not Fully Mission Capable if:

1

100 Hours or 30 Days

Water Pump Assembly Crankcase (1)

Change oil (item 14, appx E) (para 4-1).

2

Quarterly

Hinged Doors

Lubricate (item 15, appx E) hinges and latches.

3

Quarterly

Trailer Mounted Steam Cleaner

Check all painted surfaces for chipping and abrasion. Spot paint (items 5, 6, and 7, appx E) as required (refer to TM 43-01 39).

Oil level is below minimum or if oil is dirty or contaminated.

4-7

TM 9-4940-531-14 Table 4-1. Preventive Maintenance Checks and Services for Steam Cleaner (cont)

para 4-14

appx E

appx E

4-8

TM 9-4940-531-14

Section 4-10.

IV.

TROUBLESHOOTING

TROUBLESHOOTING

a. This table contains troubleshooting information for locating and correcting many of the operating troubles which may develop in the steam cleaner. Perform the tests, inspections, and corrective actions in the order they appear in the table. b. This table cannot list all malfunctions that may occur, all the tests and inspections needed to find the fault, or all the corrective actions needed to correct the fault. If the equipment malfunction is not listed, or actions listed do not correct the fault, notify your supervisor. c. The malfunction index can be used as a quick guide to troubleshooting. Common malfunctions are listed in order of appearance within table 4-2, with a page number reference to the page where a test or inspection and corrective action are provided. MALFUNCTION INDEX

STEAM CLEANER

Troubleshooting Procedure Page

4-10 POWER LIGHT does not come on when PUSH-TO-START button is pressed . . . . . . . Water pump runs but there is low or no water output from nozzle . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11 4-12 Water pump and motor run but vibrate or are unusually noisy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13 Normal water output but oil burner will not start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil burner has delayed ignition (noisy starts) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14 Oil burner runs but excessive smoke comes from coil exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15 Steam cleaning gun does not spray properly from steam nozzle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16 Detergent cannot be added to water stream when CHEMICAL METERING valve is opened and/or detergent flow does not stop when CHEMICAL METERING valve is closed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17 FLAT BED TRAILER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 -18 GENERATOR SET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-18 .. Table 4-2. Unit Maintenance Troubleshooting MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION STEAM CLEANER I WARNING To avoid the danger of electrical shock, remove electrical power before performing maintenance on electrical components. NOTE When troubleshooting electrical malfunctions, refer to the schematics and wire list (figures FO-2 and FO-3 and appx F) in the back of this TM. 4-9

TM 9-4940-531-14 4-10. TROUBLESHOOTING (cont) Table 4-2. Unit Maintenance Troubleshooting (cont) MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION STEAM CLEANER (cont)

1.

POWER LIGHT (1) DOES NOT COME ON WHEN PUSH-TO-START BUTTON (2) IS PRESSED. Check if cartridge fuse F1 (6.25A) (3) is blown (para 4-20). a.

If fuse is blown, replace F1 one time. If it blows immediately when power is applied, notify direct support maintenance.

b. If fuse is good, notify direct support maintenance.

4-10

TM 9-4940-531-14

Table 4-2. Unit Maintenance Troubleshooting (cont) MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION

2

. WATER PUMP (1) RUNS BUT THERE IS LOW OR NO WATER OUTPUT FROM NOZZLE. Step 1.

Check for leaks and cracks in plumbing components on inlet side of water pump and from water pump itself. Notify direct support maintenance.

Step 2. Check 1 SOL solenoid valve (2) for leakage. Replace defective solenoid valve (para 4-18).

4-11

TM 9-4940-531-14 4-10. TROUBLESHOOTING (cont) Table 4-2. Unit Maintenance Troubleshooting (cont) MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION

3.

WATER PUMP (1) AND MOTOR (2) RUN BUT VIBRATE OR ARE UNUSUALLY NOISY. Step 1.

Check oil level in water pump (para 4-1). Fill water pump with oil (item 14, appx E) to center of sight glass (3).

Step 2. Check that V-belts (4) have correct tension (para 4-16). Adjust V-belts to correct tension. Step 3. Check mounting brackets of water pump and motor for loose hardware. Tighten mounting hardware. Step 4. Check motor pulley (5) for loose or faulty bearings. If motor pulley shows excess play, notify direct support maintenance.

4-12

TM 9-4940-531-14

Table 4-2. Unit Maintenance Troubleshooting (cont) MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION

4.

NORMAL WATER OUTPUT BUT OIL BURNER (1) WILL NOT START. Step 1.

Check if window of cad cell (2) is dirty (para 4-14). Clean cad cell window as needed.

Step 2. Check for faulty fuel solenoid (3) by checking FUEL PRESSURE gauge (4) for very low or no fuel pressure. If fuel solenoid is faulty, notify direct support maintenance. 4-13

TM 9-4940-531-14 4-10. TROUBLESHOOTING (cont) Table 4-2. Unit Maintenance Troubleshooting (cont) MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION STEAM CLEANER (cont)

5. OIL BURNER (1) HAS DELAYED lGNITION (NOISY STARTS). Step 1.

Check FUEL PRESSURE gauge (2) for too low fuel pressure (para 4-14). Adjust fuel pressure.

Step 2. Check air louvers (3) for improper air adjustment (para 4-14). Adjust air louvers. Step 3. Check cad cell (4), transformer contacts (5), and electrodes (6) for dirt or corrosion. Remove and clean cad cell (para 4-14). Clean transformer contacts and installed electrodes with alcohol (item 2, appx E) and clean wiping rag (item 18, appx E).

4-14

TM 9-4940-531-14

Table 4-2. Unit Maintenance Troubleshooting (cont) MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION

6.

OIL BURNER (1) RUNS BUT EXCESSIVE SMOKE COMES FROM COIL EXHAUST (2). Step 1.

Check FUEL PRESSURE gauge (3) for incorrect fuel pressure (para 4-14). Adjust fuel pressure.

Step 2. Check for air starvation due to improperly adjusted air louvers (4) (para 4-14). Adjust air louvers.

4-15

TM 9-4940-531-14 4-10. TROUBLESHOOTING (cont) Table 4-2. Unit Maintenance Troubleshooting (cont) MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION STEAM CLEANER (cont)

7.

STEAM CLEANING GUN (1) DOES NOT SPRAY PROPERLY FROM STEAM NOZZLE.

To prevent possible burns, ensure steam cleaner is shut down and cool before removing nozzles. Remove nozzle and check water flow from steam cleaning gun. a.

If flow is good, clean or replace nozzle (para 4-13).

b. If flow is restricted, remove steam cleaning gun (1) from wash hose assembly (2) and check water flow. If flow is good, clean (backflush with air) or replace steam cleaning gun (para 4-13). c.

4-16

If flow remains restricted after above checks, notify direct support maintenance.

TM 9-4940-531-14

Table 4-2. Unit Maintenance Troubleshooting (cont) MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION

8.

DETERGENT CANNOT BE ADDED TO WATER STREAM WHEN CHEMICAL METERING VALVE (1) IS OPENED AND/OR DETERGENT FLOW DOES NOT STOP WHEN CHEMICAL METERING VALVE IS CLOSED. Step 1.

Check for insufficient water flow from water pump (2). If water pump is not functioning properly, notify direct support maintenance.

Step 2. Check for loose hose clamps and kinked or clogged hoses. Tighten any loose hose clamps, remove kinks, and clean or replace clogged hoses (para 4-13).

4-17

TM 9-4940-531-14 4-10. TROUBLESHOOTING (cont) Table 4-2. Unit Maintenance Troubleshooting (cont) MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION STEAM CLEANER (cont)

8.

DETERGENT CANNOT BE ADDED TO WATER STREAM WHEN CHEMICAL METERING VALVE IS OPENED AND/OR DETERGENT FLOW DOES NOT STOP WHEN CHEMICAL METERING VALVE IS CLOSED. (cont) Step 3. Check INLET PRESSURE gauge (3) when CHEMICAL METERING valve (1) is opened. If inlet pressure does not drop when CHEMICAL METERING valve is opened, replace defective CHEMICAL METERING valve (para 4-19). Step 4. Check water stream for detergent after CHEMICAL METERING valve (1) has been closed. If detergent flow does not stop, replace defective CHEMICAL METERING valve (para 4-19). FLAT BED TRAILER Refer to TM 9-2330-202-14&P. GENERATOR SET Refer to TM 5-6115-615-12.

4-18

TM 9-4940-531-14

Section

V.

MAINTENANCE

PROCEDURES

4-11. GENERAL MAINTENANCE INSTRUCTIONS a. Before performing any of the maintenance procedures, make sure that the handbrakes are engaged, rear stabilizer is lowered into position, and leveling-support jack is in place (para 2-5). b. Clean all external parts during maintenance with wiping rags (item 18, appx E) and cleaning compound (item 7, appx E).

Cleaning solvent vapors are toxic. Do not use solvent in a confined space. Avoid long periods of breathing solvent vapors and/or contact with skin to avoid death or injury to personnel. c. Clean metal parts with cleaning solvent (item 22, appx E) and wiping rags (item 18, appx E). Do not use solvent to clean rubber parts. d. Prior to installation of any pipe thread fitting, wrap first three threads of fitting with antiseizing tape (item 24, appx E). e. Be familiar with the warnings that are listed on the warning page located inside the front cover of this TM.

4-12. TRAILER-MOUNTED STEAM CLEANER—MAINTENANCE INSTRUCTIONS THIS TASK COVERS: a. Generator cable assembly removal b. Decal removal c. Inspection/repair Decal installation d. e. Generator cable assembly installation INITIAL SETUP Tools and Special Tools General mechanic’s tool kit (item 2, appx B) Equipment Conditions Generator set turned off Steam cleaner shut down (para 2-6)

4-19

TM 9-4940-531-14 4-12. TRAILER-MOUNTED STEAM CLEANER—MAINTENANCE INSTRUCTIONS (cont) GENERATOR CABLE ASSEMBLY REMOVAL

1

Disconnect generator cable assembly (1) from steam cleaner (2).

2

Disconnect three generator cable wires from terminal block (3) on generator set (4) and remove generator cable assembly (1).

4-20

TM 9-4940-531-14 DECAL REMOVAL

1

If necessary for replacement, remove four identification markers (1) from trailer (2).

2

If necessary for replacement, remove hearing decal (3) from generator set (4).

3

If necessary for replacement, remove four blind rivets (5) and identification plate (6) from steam cleaner (7).

INSPECTION/REPAIR 1

Check for broken, damaged, or missing parts.

2

Repair is by replacement of damaged or unserviceable parts.

DECAL INSTALLATION 1

If removed, install new identification plate (1) and four new rivets (2) to steam cleaner (3). If necessary to install identification plate (1) onto new lower left panel (4), use identification plate (1) as template and drill four 0.131 ±0.002 in. (0.333 ±0.005 cm) holes before installing identification plate (1) and four rivets (2).

2

If removed, install new hearing decal (5) onto generator set (6).

3

If removed, install four new identification markers (7) onto trailer (8).

4-21

TM 9-4940-531-14 4-12. TRAILER-MOUNTED STEAM CLEANER—MAINTENANCE INSTRUCTIONS (cont) GENERATOR CABLE ASSEMBLY INSTALLATION

Connect three generator cable wires (1) to terminal block (2) on generator set (3). Install generator cable assembly (4) onto steam cleaner (5). 4-13. STEAM CLEANER—MAINTENANCE INSTRUCTIONS THIS TASK COVERS: a. D i s a s s e m b l y

b. Inspection/repair

c. Reassembly

INITIAL SETUP Tools and Special Tools General mechanic’s tool kit (item 2, appx B) Material/Parts Blind rivet (16) (M24243/1-B402) Self-locking nut (3) (MS17828-06C) Self-locking nut (2) (MS51922-1) Self-locking nut (MS51988-3) Self-locking nut (MS51988-5) Tapping screw (4) (MS51850-85) Tapping screw (3) (MS51869-23) Tiedown strap (MS3367-6-0) Equipment Conditions EMERGENCY OFF switch in OFF position and external power cable disconnected Water tank assembly drained Clean diesel fuel container available 4-22

TM 9-4940-531-14

Remove parts only if damaged or if necessary for access to damaged items. Tag and label all hoses prior to removal. 1

Remove four hearing caution markers (1), two moving parts warning markers (2), and diesel fuel warning marker (3) from enclosure and lift assembly (4).

2

Remove sixteen blind rivets (5), output capacity identification plate (6), identification plate (7), and two weight and dimension plates (8) from enclosure and lift assembly (4).

4-23

TM 9-4940-531-14 4-13. STEAM CLEANER—MAINTENANCE INSTRUCTIONS (cont) DISASSEMBLY (cont)

3

Remove fuel decal (9) from top of fuel tank assembly (10). Remove high temperature warning marker (11) from chemical holder weldment (12).

4

Remove two identification markers (13 and 14) from pressure gauge assembly (15).

5

4-24

Remove steam cleaning gun (16), facility power cable assembly (17), suction hose assembly (18), three wash hose assemblies (19), pressurized water hose assembly (20), wide spray nozzle (21), large fan nozzle (22), small fan nozzle (23), high pressure nozzle (24), and spray nozzle (25) from hose rack access door (26).

TM 9-4940-531-14

6

Remove self-locking nut (27) and open lower control panel assembly (28).

7

Loosen tubing nut (29) and disconnect fuel pump-to-pressure gauge tubing assembly (30) from elbow (31).

8

Remove three self-locking nuts (32), three machine screws (33), and FUEL PRESSURE gauge (34) from lower control panel assembly (28). Remove elbow (31) from FUEL PRESSURE gauge.

9

Remove chemical bottle-to-metering valve hose (35) from liquid storage tank (36) and drain hose into suitable container.

10

Remove webbing strap (37) and liquid storage tank (36) from chemical holder weldment (12).

4-25

TM 9-4940-531-14 4-13. STEAM CLEANER—MAINTENANCE INSTRUCTIONS (cont) DISASSEMBLY (cont)

11

Remove two hose clamps (38). Disconnect metering valve-to-water pump hose (39) and chemical bottle-to-metering valve hose (35) from metering valve assembly (40). Remove chemical bottle-to-metering valve hose (35).

12

Remove three tapping screws (41) and lower control panel assembly (28) from control box assembly (42).

4-26

TM 9-4940-531-14

13 Remove hose clamp (43) and metering valve-to-water pump hose (39) from water pump assembly (44). 14 Remove fire extinguisher (45), four tapping screws (46), and bracket (47) from fuel tank assembly (10).

To avoid burns, be sure fuel tank has been drained before removing fuel hoses from oil burner. 15 Loosen filler opening cap (48) and, with suitable container in place, remove drain plug (49) to drain fuel from fuel tank assembly (10). Reinstall drain plug (49) and tighten filler opening cap (48).

4-27

TM 9-4940-531-14 4-13.

STEAM

C L E A N E R — M A I N T E N A N C E INSTRUCTIONS (cont)

DISASSEMBLY (cont)

16 Remove two hose clamps (50) and disconnect fuel shutoff-to-oil burner hose (51) and oil burner to-fuel strainer hose (52) from oil burner assembly (53). 17 Remove fuel pump-to-pressure gauge tubing assembly (30).

4-28

TM 9-4940-531-14

18

Remove four hose clamps (54) and disconnect fuel shutoff-to-fuel tank hose (55), fuel tank-to-fuel shutoff hose (56), fuel strainer-to-fuel shutoff hose (57), and fuel shutoff-to-oil burner hose (51) from fuel shutoff assembly (58). Remove fuel shutoff-to-oil burner hose (51).

19

Remove two hose clamps (59), fuel shutoff-to-fuel tank hose (55), and fuel tank-to-fuel shutoff hose (56) from fuel tank assembly (10).

20

Remove two hose clamps (60), oil burner-to-fuel strainer hose (52), and fuel strainer-to-fuel shutoff hose (57) from fuel strainer assembly (61).

21

Remove two self-locking nuts (62) and blowdown drainpipe U-bolt (63) from fuel shutoff assembly (58).

22

Remove two capscrews (64) and fuel shutoff assembly (58) from platform skid (65).

23

Remove two capscrews (66) and fuel strainer assembly (61) from platform skid (65). 4-29

TM 9-4940-531-14 4-13. STEAM CLEANER—MAINTENANCE INSTRUCTIONS (cont) DISASSEMBLY (cont)

24

Disconnect thermocouple probe (67) and pipe-to-tube straight adapter (68) from pipe bushing (69). Remove pipe-to-tube straight adapter.

25

Remove self-locking nut (70) and machine bolt (71) to disconnect chain assembly (72) from steam outlet support assembly (73).

26

Remove chain assembly (72), pipe coupling (74), pipe elbow (75), pipe nipple (76), and pipe bushing (69) from pipe tee (77).

27

Remove pipe tee (77) and pipe nipple (78) from outlet and water drain assembly (79).

28

Remove tiedown strap (80).

29

Remove two hose clamps (81) and two coil outlet hoses (82 and 83) from two coil outlet assembly fluid regulating valves (84 and 85).

4-30

TM 9-4940-531-14

30 Remove hose clamp (86) and drain hose (87) from outlet and water drain assembly (79). 31 Remove hose clamp (88) and drain hose (89) from blowdown assembly solenoid valve (90).

32 Remove 27 capscrews (91) and front panel (92) from steam cleaner (93). 33 Remove hose clamp (94) and coil inlet hose (95) from coil inlet assembly solenoid valve (96). 4-31

TM 9-4940-531-14 4-13.

STEAM

CLEANER—MAINTENANCE

INSTRUCTIONS

(cent)

lNSPECTION/REPAIR 1

Check for damaged, broken, or missing parts.

2

Repair is by replacement of damaged or unserviceable parts.

3

Hoses are manufactured items, refer to appendix F.

4

Oil burner assembly is a repairable assembly, refer to paragraph 4-14.

5

Lower control panel assembly is a repairable assembly, refer to paragraph 4-19.

6

Wash hose assembly is a repairable assembly, refer to paragraph 4-21.

7

Fuel strainer assembly is a repairable assembly, notify direct support maintenance.

8

Fuel shutoff assembly is a repairable assembly, notify direct support maintenance.

9

Facility power cable assembly is a repairable assembly, refer to paragraph 4-23.

10

Suction hose assembly is a repairable assembly, refer to paragraph 4-25.

11

Generator power cable assembly is a repairable assembly, refer to paragraph 4-26.

1

Install coil inlet hose (1) onto coil inlet assembly solenoid valve (2) with hose clamp (3).

2

Install front panel (4) onto steam cleaner (5) with 27 capscrews (6).

4-32

TM 9-4940-531-14

3

Install drain hose (7) onto blowdown assembly solenoid valve (8) with hose clamp (9).

4

Install drain hose (10) onto outlet and water drain assembly (11) with hose clamp (12).

5

Install two coil outlet hoses (13 and 14) onto two coil outlet assembly fluid regulating valves (15 and 16) with two hose clamps (17). Secure hoses to platform skid (18) with new tiedown strap (19).

4-33

TM 9-4940-531-14 4-13.

STEAM

CLEANER—MAINTENANCE

INSTRUCTIONS

(cont)

REASSEMBLY (cont)

6

Install pipe nipple (20) and pipe tee (21) onto outlet and water drain assembly (11).

7

Install pipe bushing (22), pipe nipple (23), pipe elbow (24), pipe coupling (25), and chain assembly (26) onto pipe tee (21).

8

Install chain assembly (26) onto steam outlet support assembly (27) with machine bolt (28) and new self-locking nut (29).

9 Connect thermocouple probe (30) to pipe-to-tube straight adapter (31). Install pipe-to-tube straight adapter (31) onto pipe bushing (22).

4-34

TM 9-4940-531-14

10

Install fuel strainer assembly (32) onto platform skid (18) with two capscrews (33).

11

Install fuel shutoff assembly (34) onto platform skid (18) with two capscrews (35).

12

Install blowdown drain pipe U-bolt (36) onto fuel shutoff assembly (34) with two new self-locking nuts (37).

13

Install fuel strainer-to-fuel shutoff hose (38) and oil burner-to-fuel strainer hose (39) onto fuel strainer assembly (32) with two hose clamps (40).

14

Install fuel tank-to-fuel shutoff hose (41) and fuel shutoff-to-fuel tank hose (42) onto fuel tank assembly (43) with two hose clamps (44).

15

Install fuel shutoff-to-oil burner hose (45), fuel strainer-to-fuel shutoff hose (38), fuel tank-to-fuel shutoff hose (41), and fuel shutoff-to-fuel tank hose (42) onto fuel shutoff assembly (34) with four hose clamps (46).

16 Install fuel pump-o-pressure gauge tubing assembly (47) onto oil burner assembly (48). 17 Install oil burner-to-fuel strainer hose (39) and fuel shutoff-to-oil burner hose (45) onto oil burner assembly (48) with two hose clamps (49). 4-35

TM 9-4940-531-14

4-13. STEAM CLEANER—MAINTENANCE INSTRUCTIONS (cont) REASSEMBLY (cont)

18

Install metering valve-to-water pump hose (50) onto water pump assembly (51) with hose clamp (52).

19

Install bracket (53) onto fuel tank assembly (43) with four new tapping screws (54). Install fire extinguisher (55) on bracket.

4-36

TM 9-4940-531-14

20 Install lower control panel assembly (56) onto control box assembly (57) with three new tapping screws (58). 21 Install chemical bottle-to-metering valve hose (59) and metering valve-to-water pump hose (50) onto metering valve assembly (60) with two hose clamps (61).

22 Install webbing strap (62) and liquid storage tank (63) onto chemical holder weldment (64). 23 Install chemical bottle-to-metering valve hose (59) onto liquid storage tank (63).

4-37

TM 9-4940-531-14 4-13. STEAM CLEANER—MAINTENANCE INSTRUCTIONS (cont) REASSEMBLY (cont)

24 Install elbow (65) onto FUEL PRESSURE gauge (66). Install FUEL PRESSURE gauge onto lower control panel assembly (56) with three machine screws (67) and three new self-locking nuts (68). Connect fuel pump-to-pressure gauge tubing assembly (47) to elbow (65). Tighten tubing nut (69). 25 Close lower control panel assembly (56) and install new self-locking nut (70). 4-38

TM 9-4940-531-14

26 Place spray nozzle (71), high pressure nozzle (72), small fan nozzle (73), large fan nozzle (74), wide spray nozzle (75), pressurized water hose assembly (76), three wash hose assemblies (77), suction hose assembly (78), facility power cable assembly (79), and steam cleaning gun (80) into hose rack access door (81).

4-39

TM 9-4940-531-14

4-13. STEAM CLEANER—MAINTENANCE INSTRUCTIONS (cont) REASSEMBLY (cont)

27

Install two identification markers (82 and 83) onto pressure gauge assembly (84).

28

Install fuel decal (85) onto top of fuel tank assembly (43). Install high temperature warning marker (86) onto chemical holder weldment (64).

4-40

TM 9-4940-531-14

29

Install two weight and dimension plates (87), identification plate (88), and output capacity identification plate (89) onto enclosure and lift assembly (90) with-sixteen new blind rivets (91).

30

Install diesel fuel warning marker (92), two moving parts warning markers (93), and four hearing caution markers (94) onto enclosure and lift assembly (90).

31

To fill fuel tank assembly, refer to paragraph 2-5.

4-41

TM 9-4940-531-14 4-14.

OIL

BURNER

ASSEMBLY—MAINTENANCE

THIS TASK COVERS: Removal/disassembly a. b. Inspection/repair c . Reassembly/installation Fuel pressure adjustment d. Cad cell cleaning and adjustment e. f. Cad cell test g . Adjustment using smoke analyzer INITIAL SETUP Tools and Special Tools General mechanic’s tool kit (item 2 appx B) Smoke test kit (item 3, appx B) Material/Parts Antiseizing tape (item 24, appx E) Filter paper (item 16, appx E) Gasket (11024877) Lens paper (item 17, appx E) Self-locking nut (3) (MS51988-7) Smoke chart (item 19, appx E) Personnel Required: 2 Equipment Conditions EMERGENCY OFF switch in OFF position Main power to steam cleaner off

4-42

INSTRUCTIONS

TM 9-4940-531-14

1

Close two fuel shutoff assembly valves (1).

2

Disconnect fuel pump-to-pressure gauge tubing assembly (2) from oil burner assembly (3).

3

Remove two hose clamps (4) and disconnect fuel shutoff-to-oil burner hose (5) and oil burner-tostrainer hose (6).

4-43

TM 9-4940-531-14 4-14. OIL BURNER ASSEMBLY—MAINTENANCE INSTRUCTIONS (cont) REMOVAL/DISASSEMBLY (cont)

NOTE Some parts not shown for clarity. 4

Loosen two screws (7) and slide electromagnet relay cover (8) to access wire connections.

NOTE Be sure all wires are tagged and labeled before removal. 5

Remove five conduit splices (9) and disconnect four wires no. 5, 4, 3, and 6 (10) entering electromagnet relay (11) from conduit assembly no. 209 (12).

6

Remove conduit connector locknut (13) and disconnect conduit assembly no. 209 (12) from electromagnet relay (11).

7

Loosen tapping screw (14) and rotate retaining strap (15) to open power transformer lid (16) to accesscapscrew (17). Close power transformer lid after access is obtained.

4-44

TM 9-4940-531-14

8

Remove three self-locking nuts (1 8), three capscrews (17), three flat washers (19), oil burner assembly (3), and gasket (20) from coil unit assembly (21).

9

Disconnect tubing assembly (22) from pipe elbow (23).

10

Remove plug (24), two pipe elbows (23 and 25), pipe tee (26), and pipe nipple (27).

11

Remove two straight adapters (28) and pipe elbow (29).

lNSPECTION/REPAIR 1

Check for broken, damaged, or missing parts.

2

Repair is by replacement of damaged or unserviceable parts

3

Atomizing vaporizing oil burner is a repairable assembly, notify direct support maintenance.

4-45

TM 9-4940-531-14 4-14. OIL BURNER ASSEMBLY—MAINTENANCE INSTRUCTIONS (cont)

Some parts not shown for clarity. 1

Wrap all pipe threads with antiseizing tape (item 24, appx E)

2

Install pipe elbow (1) and straight adapter (2) into fuel pump (3). Install straight adapter (4) into pipe elbow (1).

3

Install pipe nipple (5), pipe tee (6), two pipe elbows (7 and 8), and plug (9).

4

Install pipe elbow (8) to tubing assembly (10).

5

Position new gasket (11) and install oil burner assembly (12) onto coil unit assembly (13) with three flat washers (14), three capscrews (15), and three new self-locking nuts (16). Open power transformer lid (17) as needed to gain access for capsrew (15).

4-46

TM 9-4940-531-14

6

Close power transformer lid (17) and secure with retaining strap (18) and tapping screw (19).

7

Position conduit assembly no. 209 (20) in electromagnet relay (21) and secure with conduit connector locknut (22).

8

Install conduit splices (23) to connect four wires no. 6, 3, 4, and 5 (24) to electromagnet relay (21).

9 Slide electromagnet relay cover (25) into position and tighten two screws (26).

4-47

TM 9-4940-531-14 4-14. OIL BURNER ASSEMBLY—MAINTENANCE INSTRUCTIONS (cont) REASSEMBLY/lNSTALLATION (cont)

10 Connect fuel shutoff-to-oil burner hose (27) and oil burner-to-strainer hose (28). Install two hose clamps (29). 11 Connect fuel pump-to-pressure gauge tubing assembly (30).

12 Open two fuel shutoff assembly valves (31).

FUEL PRESSURE ADJUSTMENT 1

With steam cleaner operating in steam mode, FUEL PRESSURE gauge should read between 90 and 110 psi (621 and 758 kPa).

2

If pressure is not within range in preceding step, adjust pressure regulating screw inside nut (1) on fuel pump (2). Turn pressure regulating screw inside nut (1) clockwise to increase fuel pressure and counterclockwise to decrease fuel pressure.

4-48

TM 9-4940-531-14 CAD CELL CLEANING AND ADJUSTMENT

WARNING To avoid electrical shock, make sure main power to steam cleaner is off. NOTE The electromagnet relay is a safety control that senses flame through a cad cell. If cad cell does not sense flame, it will shut off oil burner assembly. Electromagnet relay is a manual reset control and will not come back on until operator depresses reset button. 1

Turn EMERGENCY OFF switch (1) to OFF.

4-49

TM 9-4940-531 -14 4-14. OIL BURNER ASSEMBLY-MAINTENANCE INSTRUCTIONS (cont) CAD CELL CLEANING AND ADJUSTMENT (cont)

1 2

Loosen tapping screw (2) and slide retaining strap (3) from power transformer (4).

3

Move power transformer (4) back on the hinges, exposing cad cell (5).

Moisture is the most common problem preventing cad cell from functioning correctly. Ensure cad cell is free of water, moisture, oil, or condensation. 4

Cad cell (5) is a plug-in type sensor. Remove cad cell (5) from socket (6). Clean cad cell window with lens paper (item 17, appx E) to prevent scratches. Cad cell (5) must be clear of soot and dirt to sense flames.

5

Cad cell (5) and socket (6) must be held firmly by bracket (7).

6

Align cad cell (5) with hole in air deflection disc (8).

7

Close power transformer (4) and secure with retaining strap (3) and tapping screw (2).

8

If electromagnet relay (9) will not reset, notify direct support maintenance. 4-50

TM 9-4940-531-14

CAD CELL TEST NOTE Test cad cell if cleaning of the cad cell window fails to restore proper oil burner operation. 1

Remove two screws (1) and disconnect two cad cell lead wires (2) from terminals F and F of electromagnet relay (3).

2

Start steam cleaner (para 2-6).

3

After oil burner starts, place a temporary jumper wire (4) between terminals F and F.

4

Connect ohmmeter to cad cell lead wires. Resistance reading should be under 1600 ohms.

5

Shut off steam cleaner and remove temporary jumper.

6

With oil burner off, dark cell resistance with ohmmeter connected to cad cell lead wires should be greater than 20,000 ohms.

7

Notify direct support maintenance if resistance does not meet specified requirements.

8

Reconnect lead wires (2) to terminals F and F with two screws (1).

ADJUSTMENT USING SMOKE ANALYZER NOTE Steam cleaner must be running at normal operating temperature when sampling with smoke analyzer. 1

Adjust fuel pressure. Refer to fuel pressure adjustment on page 4-48.

2

Using smoke analyzer (1), check exhaust at top of coil unit assembly (2) for proper air and fuel mixture as follows.

4-51

TM 9-4940-531-14 4-14. OIL BURNER ASSEMBLY—MAINTENANCE INSTRUCTIONS (cont) ADJUSTMENT USING SMOKE ANALYZER (cont)

3

Tear sample strip from filter paper (item 16, appx E) along perforated line. Loosen clamp screw (3) on smoke analyzer, insert filter paper sheet (4) in slot (5), and tighten clamp screw (3).

4

Insert sampling tube into the exhaust stack.

5

Pump smoke analyzer handle 10 full pump strokes.

6

Remove filter paper sheet (4) from slot (5).

7

Match smoke spot on filter paper sheet (4) to closest color shade on smoke chart (6) (item 19, appx E). If smoke spot reads no. 2 or less, no air adjustment is required. NOTE The darker the spot, the more fuel is burning. To lighten the spot, increase air flow.

4-52

TM 9-4940-531-14

8

If air adjustment is required, loosen screw (7) on vaporizing oil burner (8) and rotate air louvers (9). Opening air louvers (9) provides increased primary air flow; closing air louvers (9) decreases air flow. Tighten screw (7). NOTE Air louvers must be fastened tightly after adjustment. Louvers can vibrate out of position if screws are not tightened sufficiently.

9

Repeat another sembly support

steps 1 thru 8 preceding to take smoke sample. If oil burner ascannot be adjusted, notify direct maintenance.

4-15. FUEL TANK ASSEMBLY—MAINTENANCE INSTRUCTIONS THIS TASK COVERS: a. D i s a s s e m b l y

b. Inspection/repair

c. R e a s s e m b l y

INITIAL SETUP Tools and Special Tools Crescent wrench, 12-in. (item 1, appx B) Crescent wrench, 14-in. (item 1, appx B) General mechanic’s tool kit (item 2, appx B) Materials/Parts Antiseizing tape (item 24, appx E) Conductor splice (2) (M7928/5-4) Conductor splice (2) (11024917) Crescent wrench, 12-in. (item 5, appx B) Crescent wrench, 14-in. (item 5, appx B) Grommet (MS35489-17) Lockwasher (2) (MS35338-46) Oil (item 13, appx E) Self-locking nut (2) (MS51988-1) Self-locking nut (7) (MS51988-3) Self-locking nut (2) (MS51988-7) Equipment Conditions Clean oil and diesel fuel containers available Fuel tank assembly drained (para 4-6)

4-53

TM 9-4940-531-14 4-15. FUEL TANK ASSEMBLY—MAINTENANCE INSTRUCTIONS (cont)

NOTE Remove parts only if damaged or if necessary for access to damaged items. 1

Remove oil filler cap (1) from water pump assembly (2).

2

With suitable container in place, unscrew chain assembly (3) and drain oil from water pump assembly (2).

3 Remove two self-locking nuts (4), machine screw (5), and chain assembly (3) from oil drain

4

Remove 27 capscrews (7) and front panel (8) from enclosure and lift assembly (9). Remove two self-locking nuts (10), two capscrews (11), two plain nuts (12), two Iockwashers (13), two capscrews (14), and front post assembly (15).

4-54

TM 9-4940-531-14

5

If damaged, remove four identification markers(16, 17, 18, and 19).

6

Remove two hose clamps (20) and water inlet-to-water tank hose (21) from water inlet assembly (22) and water tank assembly (23).

7

Remove two self-locking nuts (24) and two capscrews (25) from water inlet assembly (22).

8

Remove fitting (26), flat washer (27), and water inlet assembly (22) from saddle and fuel tank weldment (28).

4-55

TM 9-4940-531-14 4-15. FUEL TANK ASSEMBLY—MAINTENANCE INSTRUCTIONS (cont) DISASSEMBLY (cont)

4-56

TM 9-4940-531-14 WARNING To avoid electrical shock, shut down steam cleaner and remove power source. 9

Remove two hose clamps (29) and nonmetallic hose (30) from pump inlet assembly (31) and water pump assembly (2)

10 Remove hose clamp (32) and disconnect pump inlet-to-water pump hose (33) from pump inlet assembly (31). NOTE Pipe union (34) and suction inlet assembly nonmetallic hose (35) cannot be replaced at this level of maintenance. 11 Uncouple pipe union (34) and remove suction inlet nonmetallic hose assembly (35) with attached pipe union half (36) from suction inlet assembly (37). NOTE Tag and label wires before removal. Junction box cover (38), screws (39), and conduit assembly no. 221 (40) cannot be replaced at this level of maintenance. 12 Loosen two screws (39) and remove junction box cover (38). Remove two conductor splices (41) and disconnect wires no. 22 and 24 (42 and 43). Remove conduit connector locknut (44) and conduit assembly no. 221 (40) from 303 junction box (45).

13 Remove two self-locking nuts (46), U-bolt (47), and pump inlet assembly (31) with attached parts. 14 Remove suction inlet nonmetallic hose assembly (35) and conduit assembly no. 221 (40) from pump inlet assembly (31). 15 Remove two conductor splices (48) and remove two wires no. 22 and 24 (42 and 43) from 1SOL solenoid valve (49).

4-57

TM 9-4940-531-14 4-15. FUEL TANK ASSEMBLY—MAINTENANCE INSTRUCTIONS (cont) DISASSEMBLY (cont)

16 Remove three self-locking nuts (50), three capscrews (51), and angle bracket (52) from saddle and fuel tank weldment (28). 17 Remove hose clamp (53), pump inlet-towater pump hose (33), and grommet (54).

18 Remove six hose clamps (55) and three water pump-to-coil inlet hoses (56, 57, and 58) from water pump assembly (2) and coil inlet control assembly (59). 19 With suitable container in place, remove filler opening cap (60), fuel gauge (61), and drain plug (62) from saddle and fuel tank weldment (28).

4-58

TM 9-4940-531-14

INSPECTION/REPAIR 1

Check for broken, damaged, or missing parts.

2

Repair is by replacement of damaged or unserviceable parts.

3

Water inlet assembly is a repairable assembly, refer to paragraph 4-17.

4

Pump inlet assembly is a repairable assembly, refer to paragraph 4-18.

5

Hoses are manufactured items, refer to appendix F.

REASSEMBLY

1

Wrap all pipe threads with antiseizing tape (item 24, appx E).

2

Install drain plug (1), fuel gauge (2), and filler opening cap (3) onto saddle and fuel tank weldment (4).

3

Install three water pump-to-coil inlet hoses (5, 6, and 7) onto water pump assembly (8) and coil inlet control assembly (9) with six hose clamps (10). 4-59

TM 9-4940-531-14 4-15. FUEL TANK ASSEMBLY—MAINTENANCE INSTRUCTIONS (cont) REASSEMBLY (cont)

4

Install new grommet (11) into saddle and fuel tank weldment (4). Install pump inlet-to-water pump hose (12) onto water pump assembly (8) and secure with hose clamp (13).

5

Install angle bracket (14) onto saddle and fuel tank weldment (4) with three capscrews (15) and three new self-locking nuts (16).

4-60

TM 9-4940-531-14

6

Connect two wires no. 22 and 24 (17 and 18) to 1SOL solenoid valve (19) with two new conductor splices (20).

7

Install conduit assembly no. 221 (21) onto 1SOL solenoid valve (19). Install suction inlet nonmetallic hose assembly (22) onto pump inlet assembly (23).

8

Install pump inlet assembly (23) onto angle bracket (14) with U-bolt (24) and two new self-locking nuts (25).

9

Install conduit assembly no. 221 (21) into 303 junction box (26) with conduit connector locknut (27). Connect wires no. 24 and 22 (18 and 17) with two new conductor splices (28). Install junction box cover (29) and tighten two screws (30).

4-61

TM 9-4940-531-14 4-15. FUEL TANK ASSEMBLY—MAINTENANCE INSTRUCTIONS (cont) REASSEMBLY (cont) NOTE Some parts not shown for clarity. 10

Connect pipe union half (31) with attached suction inlet nonmetallic hose assembly (22) to suction inlet assembly (32). Couple pipe union.

11

Install pump inlet-to-water pump hose (12) through grommet (11) and secure with hose clamp (33).

12

Install nonmetallic hose (34) onto water pump assembly (8) and pump inlet assembly (23) with two hose clamps (35).

13

Install water inlet assembly (36) onto saddle and fuel tank weldment (4) with two capscrews (37) and two new self-locking nuts (38).

14

Install flat washer (39) and fitting (40) onto water inlet assembly (36).

15

Install water inlet-to-water tank hose (41) on water inlet assembly (36) and water tank assembly (42) with two hose clamps (43).

16

If removed, install four identification markers (44, 45, 46, and 47) onto saddle and fuel tank weldment (4).

4-62

TM 9-4940-531-14

17 Install front post assembly (48) on enclosure and lift assembly (49) with two capscrews (50), two new Iockwashers (51), two plain nuts (52), two capscrews (53), and two new self-locking nuts (54). Install front panel (55) with 27 capscrews (56).

18

Install chain assembly (57) on oil drain assembly (58) with machine screw (59) and two new selfIocking nuts (60).

19

Secure chain assembly (57) and fill water pump assembly (8) with oil; refer to paragraph 4-1.

20

Install oil filler cap (61) onto water pump assembly (8).

21

Fill fuel tank; refer to paragraph 2-5. 4-63

TM 9-4940-531-14

4-16. V-BELT—MAINTENANCE INSTRUCTIONS THIS TASK COVERS: Belt replacement and adjustment INITIAL SETUP Tools and Special Tools GeneraI mechanic’s tool kit (item 2, appx B) Equipment Condition EMERGENCY OFF switch in OFF position and external power cable disconnected

BELT REPLACEMENT AND ADJUSTMENT

4-64

TM 9-4940-531-14

1

Check tension of V-belts (1), using belt tension gauge (2). Deflection should measure 0.50 in. (1.27 cm) at 15 lb force.

2

Check alignment of V-belts(1). The alignment of the pulleys on the water pump assembly (3) and the motor assembly (4) should be within 0.125 in. (0.318 cm).

3

If tension or alignment of V-belts (1) is not correct, V-belts must be replaced. NOTE V-belts are a matched set and must be replaced together.

4

Replace belts as follows: a. Loosen four self-locking nuts (5) and move water pump assembly (3) to slacken belts. b. Remove and discard defective V-belts (1). Install new V-belts.

5

Adjust belt tension as follows: NOTE Water pump assembly mount is slotted. a. Loosen four self-locking nuts (5). b. Move water pump assembly (3) in appropriate direction to lessen or increase belt tension. c. Tighten four self-locking nuts (5). d. Check belt tension, using belt tension gauge (2). e. If tension is not correct, repeat steps a. thru d. above.

6

Double check V-belt (1) alignment. Visually check that the center grooves of both motor assembly and water pump assembly pulleys are exactly aligned and that V-belts are tracking smoothly.

4-65

TM 9-4940-531-14 4-17. WATER INLET ASSEMBLY—MAINTENANCE INSTRUCTIONS THIS TASK COVERS: a. Disassembly

b. Inspection/repair

INITIAL SETUP Tools and Special Tools General mechanic’s tool kit (item 2, appx B) Materials/Parts Antiseizing tape (item 24, appx E) Equipment Conditions Water inlet assembly removed (para 4-15)

DISASSEMBLY 1

Remove straight adapter (1) and pipe nipple (2) from angle bracket (3).

2

Remove straight adapter (4) and pipe elbow (5) from angle bracket (3).

INSPECTION/REPAIR 1

Check for broken or damaged parts.

2

Repair is by replacement of damaged or unserviceable parts.

REASSEMBLY 1

Wrap all pipe threads with antiseizing tape (item 24, appx E).

2

Install pipe elbow (5) and straight adapter (4) onto angle bracket (3).

3 Install pipe nipple (2) and straight adapter (1) onto angle bracket (3).

4-66

c. Reassembly

TM 9-4940-531-14 4-18. PUMP INLET ASSEMBLY—MAINTENANCE INSTRUCTIONS THIS TASK COVERS: a. Disassembly

b. Inspection/repair

c. Reassembly

INITIAL SETUP Tools and Special Tools Crescent wrench, 12-in. (item 5, appx B) Crescent wrench, 14-in. (item 5, appx B) General mechanic’s tool kit (item 2, appx B) Materials/Parts Antiseizing tape (item 24, appx E) Equipment Conditions Pump inlet assembly removed (para 4-15) DISASSEMBLY

1

Uncouple and remove pipe union halves (1 and 2) from pipe (3) and pipe nipple (4). Remove hose barb (5) and reducer (6) from pipe (3).

2

Remove hose clamp (7) and hose (8) from solenoid valve (9).

3

Remove straight adapter (10) and solenoid valve (9) from pipe tee (11).

4

Remove straight adapter (12) and pipe elbow (13) from solenoid valve (9).

5

Remove pipe nipple (4), pipe tee (14), pipe bushing (15), and two pipe nipples (16) from pipe tee (11).

4-67

TM 9-4940-531-14 4-18. PUMP INLET ASSEMBLY-MAINTENANCE INSTRUCTIONS (cont) INSPECTION/REPAlR 1

Check for broken, damaged, or missing parts.

2

Repair is by replacement of damaged or unserviceable parts.

3

Pipe and hoses are manufactured items. Refer to appendix F.

REASSEMBLY

1

Apply antiseizing tape (item 24, appx E) to all pipe threads.

2

Install two pipe nipples (1), pipe bushing (2), pipe tee (3), pipe nipple (4), and pipe union half (5) onto pipe tee (6).

3

Install pipe elbow (7) and straight adapter (8) onto solenoid valve (9).

4

Install straight adapter (10) and solenoid valve (9) onto pipe tee (6).

5

Install hose (11) onto solenoid valve (9) with hose clamp (12).

6

Install pipe (13), reducer (14), and hose barb (15) onto pipe union half (16). Couple pipe union.

4-68

TM 9-4940-531-14 4-19. LOWER CONTROL PANEL ASSEMBLY AND CHEMICAL METERING VALVE ASSEMBLY—MAINTENANCE INSTRUCTIONS THIS TASK COVERS: a. Disassembly

b. Inspection/repair

c. Reassembly

INITIAL SETUP Tools and Special Tools General mechanic’s tool kit (item 2, appx B) Materials/Parts Antiseizing tape (item 24, appx E) White enamel (item 26, appx E) Equipment Conditions Lower control panel assembly removed and partially disassembled (para 4-13) DISASSEMBLY

1

Loosen setscrew (1) and remove knob (2), two nuts (3), flat washer (4), and CHEMlCAL METERING valve assembly (5) from indicator panel (6).

2

If necessary for replacement, remove calibration plate (7).

3

If necessary for replacement, remove CHEMICAL METERING identification marker (8) and FUEL PRESSURE identification marker (9).

4

Remove two straight adapters (10) and two pipe elbows (11) from regulating valve (12).

4-69

TM 9-4940-531-14 4-19. LOWER CONTROL PANEL ASSEMBLY AND CHEMICAL METERING VALVE ASSEMBLY-MAINTENANCE INSTRUCTIONS (cont) INSPECTION/REPAIR 1

Check for broken, damaged, or missing parts.

2 Repair is by replacement of damaged or unserviceable parts.

REASSEMBLY

1

Wrap all pipe threads with antiseizing tape (item 24, appx E).

2

Install two pipe elbows (1) and two straight adapters (2) onto regulating valve (3).

3

If removed, install new CHEMICAL METERING identification marker (4) and new FUEL PRESSURE identification marker (5) onto indicator panel (6).

4

If removed, install new calibration plate (7). Ensure calibration plate (7) is installed so zero mark is 60 degrees above its horizontal center line and to the left of hole center line as shown.

5

If replaced, paint a stripe on new knob (8) using white enamel (item 26, appx E).

6

Install CHEMICAL metering valve assembly (9) on indicator panel (6) with flat washer (10) and two nuts (11). Install knob (8) so indicator line points to zero when valve is closed. Tighten setscrew (12).

4-70

TM 9-4940-531-14 4-20. CONTROL PANEL ASSEMBLY AND ELECTRICAL COMPONENTS ASSEMBLY— MAINTENANCE INSTRUCTIONS THIS TASK COVERS: a. b. c.

Replacing cartridge fuse Inspecting identification markers Replacing identification markers

INITIAL SETUP Tools and Special Tools General mechanic’s tool kit (item 2, appx B) Materials/Parts Cartridge fuse (F09B250V6-1/4A) Denatured alcohol (item 2, appx E) Wiping rag (item 18, appx E) Tapping screw (4) (MS51861-46) Equipment Conditions Steam cleaner shut down (para 2-6) and power disconnected NOTE Some parts not shown for clarity. REPLACING CARTRIDGE FUSE

1

Remove four tapping screws (1) and open control panel assembly (2).

2

Remove and discard cartridge fuse (3) from power transformer (4). Install new cartridge fuse (3).

3

Close control panel assembly (2) and install four new tapping screws (1).

INSPECTING IDENTIFICATION MARKERS Check for damaged or missing control panel identification markers. If damaged, replace identification markers as follows.

4-71

TM 9-4940-531-14 4-20. CONTROL PANEL ASSEMBLY AND ELECTRICAL COMPONENTS ASSEMBLY— MAINTENANCE INSTRUCTIONS (cont)

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 15. 16.

4-72

PUSH TO START identification marker MODE SELECTOR position identification marker MODE SELECTOR identification marker OPERATING TEMPERATURE identification marker HOUR METER identification marker HOT WATER ALARM identification marker STEAM ALARM identification marker CIRCUIT BREAKER identification marker DRAIN LIGHT identification marker POWER LIGHT identification marker DELlME LIGHT identification marker EMERGENCY OFF identification marker 208 VOLTS identification marker ELECTRICAL COMPONENT LOCATION identification marker

TM 9-4940-531-14

1

Remove identification markers (1 thru 12) from control panel assembly (13).

2

Remove four tapping screws (14) and open control panel assembly (13).

3

Remove identification markers (15 and 16).

4

Ensure surface is clean and dry before applying identification marker. Remove any dirt, grease, or adhesive from previous identification marker using denatured alcohol (item 23, appx E) and wiping rag (item 18, appx E).

5

If removed, install two new identification markers (15 and 16) as shown.

6

Close control panel assembly (13) and install four new tapping screws (14).

7

If removed, center new identification markers (1 thru 12) as shown and install.

4-73

TM 9-4940-531-14 4-21. WASH HOSE ASSEMBLY—MAINTENANCE INSTRUCTIONS THIS TASK COVERS: a. Disassembly

b. Inspection/repair

c. Reassembly

INITIAL SETUP Tools and Special Tools General mechanic’s tool kit (item 2, appx B) Material/Parts Antiseizing tape (item 24, appx E) Equipment Conditions Wash hose assemblies removed (para 4-13)

NOTE There are three wash hose assemblies. The following procedures are written for one wash hose assembly; repeat as necessary.

DISASSEMBLY 1

Loosen two hose clamps (1) and remove two hose nipples (2 and 3) from hose (4). hose clamps (1).

2

Remove pipe coupling (5) from hose nipple (3).

INSPECTION/REPAIR 1

Check for broken, damaged, or missing parts.

2

Repair is by replacement of damaged or unserviceable parts.

3 Hose is a manufactured item. Refer to appendix F.

4-74

Remove two

TM 9-4940-531-14

1

Wrap threads of hose nipples with antiseizing tape (item 24, appx E).

2

Install pipe coupling (5) onto hose nipple (3).

3

Install two hose nipples (2 and 3) and two hose clamps (1) onto hose (4). NOTE Hose clamps must be tightened evenly or wash hose assembly will leak.

4

Tighten two hose clamps (1) evenly.

4-22. ENCLOSURE AND LIFT ASSEMBLY AND HOSE RACK ACCESS DOOR— MAINTENANCE INSTRUCTIONS THIS TASK COVERS: a. Disassembly

b. Inspection/repair

c. Reassembly

INITIAL SETUP Tools and Special Tools General mechanic’s tool kit (item 2, appx B) Materials/Parts Blind rivet (6) (M24243/1-A804) Cotter pin (2) (MS24665-493) Cotter pin (2) (MS24665-353) Lockwasher (6) (MS35338-44) Lockwasher (10) (MS35338-45) Lockwasher (5) (MS35338-46) Self-locking nut (8) (MS17829-3C) Self-locking nut (2) (MS51922-9) Self-locking nut (4) (MS51988-7) Tapping screw (4) (MS51861-46) Tapping screw (2) (MS51861-65) Personnel Required: 2 Equipment Conditions Steam cleaner shut down and cooled (para 2-5) External cable and hoses removed

4-75

TM 9-4940-531-14 4-22. ENCLOSURE AND LIFT ASSEMBLY AND HOSE RACK ACCESS DOOR— MAINTENANCE INSTRUCTIONS (cont) DISASSEMBLY

1

Remove two tapping screws (1) and exhaust flap (2) from steam cleaner lift assembly (3).

2

Remove twelve capscrews (4) and top right cover (5).

3

Remove eight capscrews (6) and top left cover (7).

4

Remove four tapping screws (8) and access cover (9).

5

Remove five capscrews (10), left front door assembly (11), and door hinge spacer (12).

4-76

TM 9-4940-531-14 6

Remove self-locking nut (13), Iockwasher (14), chain assembly (15), flat washer (16), machine bolt (17), and flat washer (18) from left rear access door (19).

7

If damaged or illegible, remove six hex nuts (20), six Iockwashers (21), six capscrews (22), six flat washers (23), and technical instructions sheet (24) from left rear access door (19).

8

Remove two cotter pins (25 and 26), flat washer (27), spring (28), flat washer (29), retaining band (30), and flat washer (31) from left rear access door (19) and steam cleaner lift assembly (3).

9

Remove eight capscrews (32) and left rear access door (19) from steam cleaner lift assembly (3).

10 Remove nine capscrews (33), flat washer (34), chain assembly (35), and left rear panel (36). —

11 Remove 15 capscrews (37), lower left panel (38), and side mounting rail (39).

4-77

TM 9-4940-531-14 4-22. ENCLOSURE AND LIFT ASSEMBLY AND HOSE RACK ACCESS DOOR— MAINTENANCE INSTRUCTIONS (cont)

NOTE Left post assembly is direction and location sensitive; mark before removal. 12 Remove two capscrews (40), plain nut (41), Iockwasher (42), capscrew (43), and left post assembly (44).

4-78

TM 9-4940-531-14 13 Remove two cotter pins (45 and 46), flat washer (47), spring (48), flat washer (49), retaining band (50), and flat washer (51) from right rear access door (52) and steam cleaner lift assembly (3). 14 Remove eight capscrews (53), right rear access door (52), and rear door spacer (54) from steam cleaner lift assembly (3). NOTE Structural channel is direction and location sensitive; mark before removal. 15 Remove two self-locking nuts (55), two capscrews (56), two plain nuts (57), two Iockwashers (58), two capscrews (59), and structural channel (60).

NOTE Ensure all equipment is removed before removing hose rack access door. 16 Remove 22 capscrews (61) and hose rack access door (62). 17 Remove nine capscrews (63) and steam cleaner hose rack (64).

4-79

TM 9-4940-531-14 4-22. ENCLOSURE AND LIFT ASSEMBLY AND HOSE RACK ACCESS DOOR— MAINTENANCE INSTRUCTIONS (cont)

18

Remove self-locking nut (65), Iockwasher (66), machine bolt (67), flat washer (68), chain assembly (69), and flat washer (70) from hose rack cover (71).

19

Remove eight hex nuts (72), eight Iockwashers (73), eight machine bolts (74), access rack door (75), and door hinge spacer (76) from hose rack cover (71).

20

Remove six blind rivets (77) and two hasps (78) from access rack door (75).

21

Remove eight self-locking nuts (79), eight flat washers (80), eight machine screws (81), and two hasps (82) from hose rack cover (71).

4-80

TM 9-4940-531-14 22 Remove 20 capscrews (83) and front panel (84) from steam cleaner lift assembly (3). NOTE Front post assembly is direction and location sensitive; mark before removal. 23 Remove two self-locking nuts (85), two capscrews (86), two plain nuts (87), two Iockwashers (88), two capscrews (89), and front post assembly (90). INSPECTION/REPAIR 1

Inspect that components are free of burrs and sharp edges. File or smooth as necessary.

2

Check for broken, damaged, or missing parts.

3 Repair is by replacement of damaged or unserviceable parts. 4

Steam cleaner lift assembly is a repairable assembly. Notify direct support maintenance.

1

Install front post assembly (1) onto steam cleaner lift assembly (2) with two capscrews (3), two new Iockwashers (4), two plain nuts (5), two capscrews (6), and two new self-locking nuts (7).

2

Install front panel (8) with 20 capscrews (9).

4-81

TM 9-4940-531-14 4-22. ENCLOSURE AND LIFT ASSEMBLY AND HOSE RACK ACCESS DOOR— MAINTENANCE INSTRUCTIONS (cont)

3

Install two hasps (10) onto hose rack cover (11) with eight machine screws (12), eight flat washers (13), and eight new self-locking nuts (14).

4

Install two hasps (15) onto access rack door (16) with six new blind rivets (17).

5

Install door hinge spacer (18) and access rack door (16) onto hose rack cover (11) with eight machine bolts (19), eight new Iockwashers (20), and eight hex nuts (21).

6

Install flat washer (22), chain assembly (23), flat washer (24), machine bolt (25), new Iockwasher (26), and new self-locking nut (27) onto hose rack cover (11).

7

Position steam cleaner hose rack (28) onto steam cleaner lift assembly (2) and secure with nine capscrews (29).

8

Install steam cleaner hose rack (28) and hose rack access door (30) with 22 capscrews (31).

4-82

TM 9-4940-531-14

9

Install structural channel (32) with two capscrews (33), two new Iockwashers (34), two plain nuts (35), two capscrews (36), and two new self-locking nuts (37).

10

Install right rear access door (38) and rear door spacer (39) with eight capscrews (40).

11

Install flat washer (41), retaining band (42), flat washer (43), spring (44), flat washer (45) and two new cotter pins (46 and 47) onto right rear access door (38) and steam cleaner lift assembly (2).

12

Install left post assembly (48) with capscrew (49), new Iockwasher (50), plain nut (51), and two capscrews (52).

4-83

TM 9-4940-531-14 4-22. ENCLOSURE AND LIFT ASSEMBLY AND HOSE RACK ACCESS DOOR— MAINTENANCE INSTRUCTIONS (cont)

13 Install side mounting rail (53) and lower left panel (54) with 15 capscrews (55). 14 Install left rear panel (56), chain assembly (57), and flat washer (58) with nine capscrews (59). 15

4-84

Install left rear access door (60) onto steam cleaner lift assembly (2) with eight capscrews (61).

TM 9-4940-531-14 16 Install flat washer (62), retaining band (63), flat washer (64), spring (65), flat washer (66), and two new cotter pins (67 and 68) onto left rear access door (60) and steam cleaner lift assembly (2). 17 If removed, install new technical instructions sheet (69) onto left rear access door (60) with six flat washers (70), six capscrews (71), six new Iockwashers (72), and six hex nuts (73). 18

Install flat washer (74), machine bolt (75), flat washer (76), chain assembly (77), new lockwasher (78), and new self-locking nut (79) onto left rear access door (60).

19 Install door hinge spacer (80) and left front door assembly (81) onto steam cleaner lift assembly (2) with five capscrews (82). 20 Install access cover (83) with four new tapping screws (84). 21 Install top left cover (85) with eight capscrews (86). 22 Install top right cover (87) with twelve capscrews (88). 23 Install exhaust flap (89) with two new tapping screws (90).

4-85

TM 9-4940-531-14 4-23. FACILITY POWER CABLE ASSEMBLY—MAINTENANCE INSTRUCTIONS THIS TASK COVERS: a. Inspection

b. Disassembly

c. Repair

INITIAL SETUP Tools and Special Tools General mechanic’s tooI kit (item 2, appx B) Equipment Conditions Facility power cable assembly removed (para 4-13)

INSPECTION 1

Check for broken, damaged, or missing parts.

2

If cable is damaged, order new facility power cable assembly.

3

If electrical plug connectors are unserviceable, proceed to disassembly.

NOTE Electrical plug connector style may vary slightly.

4-86

d. Reassembly

TM 9-4940-531-14 DISASSEMBLY 1

Remove two screws (1), clamp (2), and three screws (3). Slide cover (4) back onto power cable (5). Remove three screws (6) and disconnect three wires (7) from electrical plug connector (8). Remove cover (4).

2

Remove two screws (9), clamp (10), and three screws (11). Slide cover(12) back onto power cable (5). Remove three screws (13) and disconnect three wires (7) to remove power cable (5) from eletrical plug connector (14). Remove cover (12).

REPAIR Repair is by replacement of damaged or unserviceable parts. REASSEMBLY 1

Slide cover (12) onto power cable (5). Connect three wires (7) to electrical plug connector 14) as shown and secure with three screws (13).

2

Install cover (12) onto electrical plug connector (14) with three screws (11). Secure clamp (10) to power cable (5) with two screws (9).

3 4

Slide cover (4) onto power cable (5). Connect three wires (7) to electrical plug connector (8) as shown and secure with three screws (6). Install cover (4) onto electrical plug connector (8) with three screws (3). Secure clamp (2) to power cable (5) with two screws (1).

4-24. OUTLET AND WATER DRAIN ASSEMBLY—MAINTENANCE INSTRUCTIONS THIS TASK COVERS: a. D i s a s s e m b l y

b. Inspection/repair

c. R e a s s e m b l y

INITIAL SETUP Tools and Special Tools Crescent wrench, 12-in. (item 1, appx B) Crescent wrench, 14-in. (item 1, appx B) General mechanic’s tool kit (item 2, appx B) Material/Parts Antiseizing tape (item 24, appx E) Self-locking nut (2) (MS51988-5) Equipment Conditions Steam cleaner shut down (para 2-6) and power disconnected Oil burner assembly removed (para 4-13) Thermocouple and attached parts removed (para 4-13)

4-87

TM 9-4940-531-14 4-24. OUTLET AND WATER DRAIN ASSEMBLY—MAINTENANCE INSTRUCTIONS (cont)

NOTE Remove parts only if damaged or if necessary for access to damaged items. 1

Remove two self-locking nuts (1) and two machine bolts (2) to remove chain assembly (3) and release outlet and water drain assembly (4) from steam outlet support assembly (5).

2

Remove hose clamp (6) and drain hose (7) from 3SOL solenoid valve (8).

3

Remove straight adapter (9) and pipe elbow (10) from 3SOL solenoid valve (8). Uncouple pipe union (11). Remove pipe union half from pipe nipple (12).

4-88

TM 9-4940-531-14

4

Remove pipe union half (13), pipe nipple (14), pipe elbow (15), and pipe nipple (16) from pipe tee (17).

5

Remove mounting bracket (18), pipe nipple (19), pipe elbow (20), and pipe nipple (21).

6

Remove pipe tee (17), pipe bushing (22), and pipe nipple (23) from 3SOL solenoid valve (8).

INSPECTION/REPAIR 1

Check for broken, damaged, or missing parts.

2

Repair is by replacement of damaged or unserviceable parts.

4-89

TM 9-4940-531-14 4-24. OUTLET AND WATER DRAIN ASSEMBLY—MAINTENANCE INSTRUCTIONS (cont) REASSEMBLY

1

Wrap all pipe threads with antiseizing tape (item 24, appx E).

2

Install pipe nipple (1), pipe bushing (2), and pipe tee (3) onto 3SOL solenoid valve (4).

3

Install pipe nipple (5), pipe elbow (6), pipe nipple (7), and mounting bracket (8) onto pipe tee (3).

4

Install pipe nipple (9), pipe elbow (10), pipe nipple (11), and pipe union half (12).

4-90

TM 9-4940-531-14 5

Install pipe union half (13) onto pipe nipple (14). Couple pipe union. Install pipe elbow (15) and straight adapter (16) onto 3SOL solenoid valve (4).

6

Install drain hose (17) onto 3SOL solendoid valve (4) with hose clamp (18).

7

Secure outlet and water drain assembly (19) and chain assembly (20) onto steam outlet support assembly (21) with two machine bolts (22) and two new self-locking nuts (23).

4-25. SUCTION HOSE ASSEMBLY—MAINTENANCE INSTRUCTIONS THIS TASK COVERS: a. Disassembly

b. Inspection/repair

c. Reassembly

INITIAL SETUP Tools and Special Tools General mechanic’s tool kit (item 2, appx B) Materials/Parts Antiseizing tape (item 24, appx E) Gasket (MS27030-2) Equipment Conditions Suction hose assembly removed (para 4-13)

DISASSEMBLY

1

Remove foot valve (1) and bushing (2) from straight adapter (3).

2

Remove quick coupler plug with chain (4), gasket (5), and female quick coupler (6) from inlet strainer (7).

3

Remove inlet strainer (7), nipple (8), bushing (9), and 45-degree elbow (10) from straight adapter (11). 4-91

TM 9-4940-531-14 4-25. SUCTION HOSE ASSEMBLY—MAINTENANCE INSTRUCTIONS (cont) INSPECTION/REPAIR 1

Check straight adapters (1 and 2) for damaged threads, burrs, and sharp edges.

2

Inspect hose (3) for deterioration or damage.

3

If straight adapters or hoses are unserviceable, requisition new suction hose assembly.

4

Check for broken, damaged, or missing parts.

5

Inspect foot valve for debris. Clean as needed (para 3-6).

6

Disassemble and inspect inlet strainer for debris. Clean as needed (para 3-6).

7

Repair is by replacement of damaged or unserviceable parts.

REASSEMBLY

1

Wrap all pipe threads with antiseizing tape (item 24, appx E).

2

Install 45-degree elbow (1), bushing (2), nipple (3), and inlet strainer (4) onto straight adapter (5).

3

Install female quick coupler (6), new gasket (7), and quick coupler plug with chain (8) onto inlet strainer (4).

4

Install bushing (9) and foot valve (10) onto straight adapter (11).

4-92

TM 9-4940-531-14 4-26.

GENERATOR

POWER

CABLE

ASSEMBLY—MAINTENANCE

INSTRUCTIONS

THIS TASK COVERS: a. Inspection

b. Disassembly

c. Repair

d. Reassembly

INITIAL SETUP Tools and Special Tools General mechanic’s tool kit (item 2, appx B) Materials/Parts Solder (item 21, appx E) Equipment Conditions Generator power cable assembly removed (para 4-12) INSPECTION 1

Check for broken, damaged, or missing parts.

2

If power cable is damaged, order new generator power cable assembly.

3

If insulation sleeving or electrical plug connector is unserviceable, proceed to disassembly.

NOTE Electrical plug connector style may vary slightly. 1

Remove two screws (1), clamp (2), three screws (3), and cover (4) from electrical plug connector (5). Slide cover (4) back onto power cable (6).

2

Remove three screws (7) and disconnect three wires (8, 9, and 10) from electrical plug connector (5). Remove cover (4).

3

If damaged, remove insulation sleeving (11) from power cable (6).

4-93

TM 9-4940-531-14 4-26. GENERATOR POWER CABLE ASSEMBLY—MAINTENANCE INSTRUCTIONS (cont) REPAIR 1

Repair is by replacement of damaged or unserviceable parts.

2

Insulation sleeving is a manufactured item. Refer to appendix F.

REASSEMBLY

1

Slide cover (1) onto power cable (2). Connect three wires (3, 4, and 5) to electrical plug connector (6) with three screws (7) as shown.

2

If removed, install new insulation sleeving (8) over power cable (2) and wire ends.

3

Dip three exposed wire ends (3, 4, and 5) in solder (item 21, appx E) per MIL-STD-454.

4

Install cover (1) onto electrical plug connector (6) with three screws (9). Secure clamp (10) to power cable (2) with two screws (11).

4-94

TM 9-4940-531-14 4-27.

FLAT

BED

TRAILER—MAINTENANCE

INSTRUCTIONS

THIS TASK COVERS: a. Removal of reflectors

b. Inspection/repair

c. Installation of reflectors

INITIAL SETUP Tools and Special Tools General mechanic’s tool kit (item 2, appx B) Materials/Parts Self-locking nut (4) (MS17829-3C) Tapping screw (4) (MS51861-65)

NOTE Refer to TM 9-2330-202-14&P for additional information on unit level maintenance of the trailer. REMOVAL OF REFLECTORS

1

Remove four tapping screws (1) and two red indicating reflectors (2) from fenders of trailer chassis (3).

2

Remove four self-locking nuts (4), four machine screws (5), and two red indicating reflectors (6) from frame of trailer chassis (3).

4-95

TM 9-4940-531-14 4-27. FLAT BED TRAILER—MAINTENANCE INSTRUCTIONS (cont) INSPECTION/REPAIR 1

Check for broken, damaged, or missing parts.

2

Repair is by replacement of damaged or unserviceable parts.

INSTALLATION OF REFLECTORS 1

Install two red indicating reflectors (1) onto frame of trailer chassis (2) with four machine screws (3) and four new self-locking nuts (4).

2

Install two red indicating reflectors (5) onto fenders of trailer chassis (2) with four new tapping screws (6).

Section

VI.

PREPARATION

FOR

STORAGE

OR

SHIPMENT

4-28. GENERAL Unit commanders are responsible for ensuring that all materiel issued or assigned to their command is maintained in a serviceable condition and properly cared for, and that personnel under their command comply with technical instructions. 4-29. ADMINISTRATIVE STORAGE a. Definition of Administrative Storage. (1) The placement of equipment in administrative storage can be for short periods of time when: (a) An organization lacks operating funds, personnel, other resources, or normal usage of its organic materiel. (b) Materiel which exceeds the capability of the owning organization to operate or maintain must be retained by that organization for contingency or other cogent reasons. (2) Installation or organization commanders may authorize the administrative storage of their materiel within guidance furnished by MACOM commanders and AR 750-1. The steam cleaner should be ready for use within the time factors as determined by the directing authority. (3) During the storage period, appropriate maintenance records will be kept. 4-96

TM 9-4940-531-14 b. Scope. The requirements specified herein are necessary to maintain steam cleaner in administrative storage in such a way as to achieve the maximum readiness condition. c. General. (1) Except as indicated in paragraphs 4-29f and 4-29g, equipment that is placed in administrative storage should be capable of being readied to perform its mission within a 24-hour period or as otherwise may be prescribed by the approving authority. Before equipment is placed in administrative storage, current maintenance services, shortcomings, and deficiencies should be corrected, and all modification work orders (MWO’s) should be applied. (2) Report equipment in administrative storage in Materiel Readiness and Unit Readiness reports as prescribed for all reportable equipment. See AR 220-1. NOTE Touchup painting will be in accordance with TM 43-0139. (3) Records and reports to be maintained for equipment in administrative storage are those prescribed by DA PAM 738-750 for equipment in use. (4) Ten percent variance is acceptable on time running hours used to determine maintenance actions required. d. Storage Site. (1) Select the best available site for administrative storage. Separate stored equipment from equipment in use. Conspicuously mark the area “Administrative Storage.” (2) Covered space is preferred. When sufficient covered space for all steam cleaners to be stored is not available, select an open site. (3) Open sites should be improved hardstand, if available. Unimproved sites should be firm, well-drained, and kept free of excessive vegetation. e. Storage Plan. (1) Store equipment so as to provide maximum protection from the elements and to provide access for inspection, maintenance, and exercising. Anticipate removal or deployment problems and take suitable precautions. (2) Take into account environmental conditions, such as extreme heat or cold; high humidity; blowing sand, dust, or loose debris; soft ground; mud; heavy snows; or combinations thereof and take adequate precautions. (3) Establish a fire plan and provide for adequate firefighting equipment and personnel. f. Maintenance Services and Inspection. Prior to storage, perform the next scheduled major preventive maintenance service (monthly, quarterly, or semiannually).

4-97

TM 9-4940-531-14 4-29. ADMINISTRATIVE STORAGE (cont) g. Corrections of Shortcomings and Deficiencies. Correct all shortcomings and deficiencies prior to storage, or obtain a deferment from the approving authority. h. Lubrication. Lubricate equipment in accordance with paragraph 4-1. i. General Cleaning, Painting, and Preservation. (1) Clean the equipment of dirt, grease, and other contaminants. CAUTION Do not direct water or steam under pressure against air duct inlets/outlets, exhaust outlets, unsealed electrical systems, or any exterior opening which will damage a component. (2) Remove rust and damaged paint by scraping, wire brushing, sanding or buffing, and spot painting as required. (3) After cleaning and drying, immediately coat unpainted metal surfaces with an oil or grease as appropriate. (4) Sunlight, heat, moisture (humidity), and dirt tend to accelerate deterioration. Install all covers authorized for the equipment. Close and secure all openings except those required for venting and draining. Seal openings to prevent the entry of rain, snow, or dust. Place equipment and provide blocking or framing to allow for ventilation and water drainage. NOTE Air circulation under draped covers reduces deterioration from moisture and heat. j. Maintenance Services. After equipment has been placed in administrative storage, suspend all regularly scheduled preventive maintenance services and inspect and exercise as specified herein. Do not reduce Prescribed Load List. See AR 735-5. k. Inspection. Inspection will usually be visual and must consist of at least a walk-around examination of all equipment to observe any deficiencies that may have occurred. Inspect equipment in open storage weekly and equipment in covered storage monthly. Immediately after any severe storm or environmental change, inspect all equipment. The following are examples of things to look for during visual inspection: (1) Leaks: coolant, fuel, oil, or cleaning solution. (2) Condition of preservatives, seals, and wraps. Seals may develop leaks during storage, during exercise, or shortly thereafter. If leaking continues, refer to the repair procedures in this manual or notify support maintenance. (3) Corrosion or other deterioration. (4) Missing or damaged parts.

4-98

TM 9-4940-531-14 (5) Water in compartments. (6) Any other readily recognizable shortcomings or deficiencies. l. Receipt For Storage. Prepare SF 364 for all shipments received in a damaged or otherwise unsatisfactory condition due to deficiencies in preservation, packaging, marking, handling, loading, or storage. m. Rotation. To assure utilization of all assigned materiel, rotate items in accordance with any rotational plan that will keep equipment in an operational condition and reduce maintenance effort. n. Removal From Administrative Storage. Remove preservative materials. Perform the next scheduled preventive maintenance service and prepare equipment for service. o. Servicing. Resume the maintenance service schedule in effect at the commencement of storage per DD Form 314. See DA PAM 738-750. p. Short-Term Storage Preparation. (1) Prior to storage, turn MODE SELECTOR switch to COLD and allow steam cleaner to cool with cold water running through coil unit assembly and steam cleaning gun until water is clear. Turn MODE SELECTOR switch to OFF. (2) Turn water source off and allow system to drain until no water flows from steam cleaning gun. Disconnect water source and allow any residual water to drain from steam cleaner. (3) Disconnect cable assembly from power source. Coil cable assembly and tie coils in three places with heavy cord (item 8, appx E). (4) Remove liquid storage tank. (5) Drain suction hose assembly and wash hose assembly and stow in hose storage compartment. (6) Seal all open steam cleaner and hose connections with antiseizing tape (item 24, appx E). Tie each coiled hose with heavy cord (item 8, appx E) in three places (120 degrees apart). (7) Drain and stow steam cleaning gun and nozzles in holders in hose storage compartment. (8) Drain fuel from fuel tank (para 4-16). Reinstall drain plug. (9) Brush any dirt/dust from external surfaces. (10) Cover steam cleaner with tarpaulin or other suitable cover.

4-99

TM 9-4940-531-14 4-29. ADMINISTRATIVE STORAGE (cont) q. Long-Term Storage Preparation. (1) Turn off water source and allow system to drain until no water flows from steam cleaning gun. Disconnect water source and allow any residual water to drain from steam cleaner. (2) Disconnect cable assembly from power source. Coil cable assembly and tie coils in three places with heavy cord (item 8, appx E). (3) Remove liquid storage tank. (4) Drain suction hose assembly and wash hose assembly and stow in hose storage compartment. (5) Seal all open steam cleaner and hose connections with antiseizing tape (item 24, appx E). Tie each coiled hose with heavy cord (item 8, appx E) in three places (120 degrees apart). (6) Drain and stow steam cleaning gun and nozzle in holders in hose storage compartment. (7) Drain fuel from fuel tank (para 4-6). Reinstall drain plug. (8) Brush any dirt/dust from external surfaces. (9) Touch up exposed surfaces and nicks with black, brown, and green paint (items 4,5, and 6, appx E). Refer to TM 43-0139. r. Packing, Marking, and Shipping Instructions. (1) After steam cleaner has been prepared for storage, mark for shipment in accordance with MIL-STD-129. (2) Prepare all Army shipping documents in accordance with AR 725-50.

4-100

TM 9-4940-531-14

DIRECT

CHAPTER 5 SUPPORT MAINTENANCE

INSTRUCTIONS

CHAPTER INDEX Paragraph

Page

5-1. 5-2. 5-3. 5-4. 5-5. 5-6. 5-7.

5-2 5-44 5-44 5-48 5-53 5-58

5-8. 5-9. 5-10. 5-11. 5-12. 5-13. 5-14. 5-15. 5-16. 5-17. 5-18. 5-19. 5-20. 5-21. 5-22. 5-23. 5-24. 5-25. 5-26. 5-27. 5-28. 5-29. 5-30. 5-31. 5-32. 5-33.

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. General Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . Trailer-Mounted Steam Cleaner - Maintenance instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Steam Cleaner (Enclosure and Lift Assembly) - Maintenance Instructions . . . . . . . . . . . . . . Steam Cleaner (Pressure Gauge Assembly) - Maintenance Instructions . . . . . . . . . . . . . . . . . Steam Cleaner (Control Box Assembly) - Maintenance Instructions . . . . . . . . . . . . . . . . . . . . . . . . Steam Cleaner (PS1, PS2, and PS3 Pressure Switches)Maintenance Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Steam Cleaner (Coil Inlet Assembly) - Maintenance Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Steam Cleaner (Coil Outlet Assembly and Outlet and Water Drain Assembly) Maintenance Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Steam Cleaner (Fuel Tank Assembly and Coil Unit Assembly) Maintenance Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Coil Inlet Assembly - Maintenance Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Coil Outlet Assembly - Maintenance Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Blowdown Assembly and Valve and Switch Assembly Maintenance Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . Atomizing Vaporizing Oil Burner - Maintenance Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel Tank Assembly - Maintenance Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Suction Inlet Assembly - Maintenance Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Water Tank Assembly - Maintenance instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Water Pump Assembly - Maintenance Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Motor Assembly- Maintenance Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Coil Inlet Control Assembly - Maintenance Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil Drain Assembly- Maintenance Instructions . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . Control Box Assembly, Upper Control Panel Assembly, and Electrical Components Assembly - Maintenance Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Steam Cleaner Lift Assembly - Maintenance Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Coil Outlet-to-Pressure Switch Tubing Assembly and Pressure Switch-to-Pressure Switch Tubing Assembly - Maintenance Instructions . . . . . . . . . . . . . Coil Outlet-to-Differential Pressure Switch Tubing Assembly and Coil Inlet-to-Differential Pressure Switch Tubing Assembly - Maintenance Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Coil Inlet-to-inlet Pressure Gauge Tubing Assembly, Coil Outlet-to-Outlet Pressure Gauge Tubing Assembly, and Fuel Pump-to-Pressure Gauge Tubing Assembly - Maintenance Instructions . . . . . . . . . . . . . . Fuel Strainer Assembly - Maintenance Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel Shutoff Assembly - Maintenance Instructions . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . Coil Unit Assembly - Maintenance Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Connection Diagram, Wire Assembly, and Conduit Assembly - Maintenance Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Flat Bed Trailer - Maintenance Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Leveling-Support Jack - Maintenance Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Brake Line Tube Assembly - Maintenance Instructions . . . . . . . . . . . . . . . . . . . . . .. . . .

5-64 5-73 5-78 5-90 5-100 5-102 5-107 5-110 5-118 5-123 5-124 5-126 5-128 5-129 5-137 5-138 5-146 5-149

5-150

5-151 5-152 5-154 5-156 5-167 5-170 5-177 5-178 5-1

TM 9-4940-531-14

Section 5-1.

I.

TROUBLESHOOTING

TROUBLESHOOTING WARNING • Use extreme caution when testing electrical circuits. Injury or death could result. • To avoid electrical shock, use extreme caution when overriding safety interlocks and remove power completely when performing maintenance on electrical components. • To avoid electrical shock, use extreme caution when depressing S2 and S3 sensitive switches. Do not touch any other part of steam cleaner while depressing switches. NOTE • When troubleshooting electrical malfunctions, refer to the schematics and wire list (figures FO-2, FO-3, and FO-4) in the back of this TM. • Defective components in the 110 VAC circuit will trip F1 cartridge fuse. Defective components in the 220 VAC circuit will trip CB circuit breaker.

a. This table contains troubleshooting information for locating and correcting many of the operating troubles which may develop in the steam cleaner. Perform the tests, inspections, and corrective actions in the order they appear in the table. b. This table cannot list all malfunctions that may occur, all the tests and inspections needed to find the fault, or all the corrective actions needed to correct the fault. If the equipment malfunction is not listed, or actions listed do not correct the fault, notify your supervisor. c. The malfunction index can be used as a quick guide to troubleshooting. Common malfunctions are listed in order of appearance within table 5-1, with a page number reference to the page where a test or inspection and corrective action are provided. MALFUNCTION INDEX Troubleshooting Procedure (Page) STEAM CLEANER POWER LIGHT does not come on when PUSH-TO-START button is pressed . . . . . . . . . . . . ..5-5 POWER LIGHT comes on when PUSH-TO-START button is pressed and then goes off when PUSH-TO-START button is released . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..5-9 POWER LIGHT comes on but water pump motor will not start . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11 EMERGENCY OFF circuit breaker trips after a short operation time . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...5-13 Cartridge fuse F1 blows repeatedly- cold mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..5-15 Cartridge fuse F1 blows repeatedly- hot mode . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . .5-16 Cartridge fuse F1 blows repeatedly- steam mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-17 Water pump runs but there is low or no water output from nozzle . . . . . . . . . . . .. . . . . . . . . . . . ..5-19 5-2

TM 9-4940-531-14 Troubleshooting Procedure (Page)

Water output is delivered but working pressure fluctuates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-25 Water pump vibrates and/or is noisy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-26 Steam cleaning gun emits dry (superheated) steam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-27 Oil burner motor will not start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .5-28 Oil burner has delayed ignition (noisy starts) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-31 Oil burner motor runs but oil burner fails to ignite or goes out prematurely . . . . . . . . . . . . . . . . . . . . . 5-33 OPERATING TEMPERATURE gauge indicates abnormal water temperature . . . . . . . . . . . . . ...5-35 OUTLET PRESSURE gauge indicates low outlet pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-37 OUTLET PRESSURE gauge indicates high outlet pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-38 Water pump motor will not stop and water does not drain when MODE SELECTOR switch is set to OFF position from COLD or HOT modes . . . . . . . . . . . . . . . . . . . . .. . . . . . . 5-39 Blowdown cycle malfunctions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-43 FLAT BED TRAILER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-43 GENERATOR

SET

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-43

L 5-3

TM 9-4940-531-14

5-1.

TROUBLESHOOTING (cont) Table 5-1. Direct Support Troubleshooting

MALFUNCTION TEST OR lNSPECTION CORRECTIVE ACTION STEAM CLEANER

5-4

TM 9-4940-531-14 Table 5-1. Direct Support Troubleshooting (cont) MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION 1. POWER LIGHT(1) DOES NOT COME ON WHEN PUSH-TO-START BUTTON (2) IS PRESSED. NOTE If steam cleaner starts and POWER LIGHT does not come on, replace 1LT indicator light (para 5-22). Before performing any electrical checks, be sure to check the circuits first for any loose or broken wires. Step 1.

Check for incoming power. Repeat procedures in table 3-1, malfunction 1, page 3-3.

NOTE When checking for voltage, make sure that S2 and S3 sensitive switches (3) and PUSH TO START button (2) are all depressed. Step 2. Check operation of S2 and S3 sensitive switches (3). Check line terminals of S1 EMERGENCY OFF switch (4) while depressing S2 and S3 sensitive switches. Multimeter should show line voltage (approximately 208 VAC). a.

If there is no voltage: (1) Check voltage from S2 to ground and S3 to ground. Voltage should measure approximately 104 VAC. If not, replace defective sensitive switch (para 5-22). (2) Check voltage from the back of power receptacle (5) wire 37 white to ground and wire 38 black to 21 green (ground). Voltage should measure approximately 104 VAC. If not, replace defective power receptacle (para 5-22), facility or generator power cable assembly (para 4-13 or 4-12), or power source.

5-5

TM 9-4940-531-14 5-1. TROUBLESHOOTING (cont) Table 5-1. Direct Support Troubleshooting (cont) MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION STEAM CLEANER (cont)

5-6

TM 9-4940-531-14 Table 5-1. Direct Support Troubleshooting (cont) MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION 1. POWER LIGHT DOES NOT COME ON WHEN PUSH-TO-START BUTTON IS PRESSED. (cont) b.

If there is incoming voltage: (1) Turn S1 EMERGENCY OFF switch (4) ON. Check voltage across the two load terminals. Voltage should measure approximately 208 VAC. If not, replace S1 EMERGENCY OFF switch (para 5-22). (2) Depress PB1 PUSH TO START button (2) and measure voltage from terminals 1B to ground and 2B to ground. Voltage should measure approximately 104 VAC. If not, replace PB1 PUSH TO START switch (para 5-22). (3) Check 1CR electromagnet relay (6). Measure voltage from AUX terminals wire 51 black or 42 black to ground and 52 white or 44 white to ground. Voltage should measure approximately 104 VAC. If not, replace 1CR electromagnet relay (para 5-22). (4) Check T1 power transformer (7). Measure voltage from terminals H1 to ground and H2 to ground. Measure voltage from terminal X1 of T1 power transformer (7) to ground. Voltage should measure approximately 104 VAC. If not, replace T1 power transformer (para 5-22).

5-7

TM 9-4940-531-14 5-1.

TROUBLESHOOTING (cont) Table 5-1. Direct Support Troubleshooting (cont)

MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION STEAM CLEANER (cont)

5-8

TM 9-4940-531-14 Table 5-1. Direct Support Troubleshooting (cont) MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION

2. POWER LIGHT (1) COMES ON WHEN PUSH-TO-START BUTTON (2) IS PRESSED AND THEN GOES OFF WHEN PUSH-TO-START BUTTON IS RELEASED. NOTE • Before performing any electrical checks, be sure to check the circuits first for any loose or broken wires. • When checking for voltage, make sure that S2 and S3 sensitive switches (3) and PUSH TO START button (2) are all depressed. Measure voltage across terminals A and B of 1CR electromagnet relay (4). a.

If voltage is present, replace 1CR electromagnet relay (para 5-22)

b.

If no voltage is present, replace 8CR relay-switch (5) (para 5-22).

5-9

TM 9-4940-531-14

5-1. TROUBLESHOOTING (cont) Table 5-1. Direct Support Troubleshooting (cont) MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION STEAM CLEANER (cont)

5-10

TM 9-4940-531-14

Table 5-1. Direct Support Troubleshooting (cont) MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION

3. POWER LIGHT (1) COMES ON BUT WATER PUMP MOTOR (2) WILL NOT START.

l

•

NOTE Before performing any electrical checks, be sure to check the circuits first for any loose or broken wires. When checking for voltage, make sure that S2 and S3 sensitive switches (3) and PB1 PUSH TO START button (4) are all depressed. Check voltage across 1CR electromagnet relay (5) terminals T1 and T2 for 208 VAC. a. If voltage is present, replace 1MOT motor (2) (para 5-15). b. If no voltage is present, replace 1CR electromagnet relay (para 5-22). 5-11

TM 9-4940-531-14 5-1.

TROUBLESHOOTING (cont) Table 5-1. Direct Support Troubleshooting (cont)

MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION STEAM CLEANER (cont)

5-12

TM 9-4940-531-14

Table 5-1. Direct Support Troubleshooting (cont) MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION

4. EMERGENCY OFF CIRCUIT BREAKER (1) TRIPS AFTER A SHORT OPERATION TIME. Check for shorts in T1 power transformer (2) primary, in 9SOL solenoid valve (3), or in their wiring. Replace defective components (para 5-22 and 5-17 and fig. FO-3) as required.

5-13

TM 9-4940-531-14 5-1.

TROUBLESHOOTING

(cont)

Table 5-1. Direct Support Troubleshooting (cont) MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION STEAM CLEANER (cont)

5-14

TM 9-4940-531-14

Table 5-1. Direct Support Troubleshooting (cont) MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION

5. CARTRIDGE FUSE F1 (1) BLOWS REPEATEDLY - COLD MODE. Step 1.

Perform procedures in malfunction 4 above. NOTE

Before performing any electrical checks, be sure to check the circuits first for any loose or broken wires. Step 2.

After installing new F1 cartridge fuse (1), remove 8CR relay-switch (2) while holding PB1 PUSH-TO-START button (3) and S2 and S3 sensitive switches (4) depressed. If fuse blows again, replace 2 SOL solenoid valve (5) (para 5-13). Reinstall 8CR relay-switch (2).

Step 3. Check for shorts in 1CR electromagnet relay (6), HM HOUR METER (7), 1 SOL solenoid valve (8), 3SOL solenoid valve (9), 4SOL solenoid valve (10), 3CR relay-switch (11), 5SOL solenoid valve (12), and 2SOL solenoid valve (5). Replace defective component(s) (para 5-22, 4-18, 5-11, and 5-13) as required. 5-15

TM 9-4940-531-14

5-1.

TROUBLESHOOTING

(cont)

Table 5-1. Direct Support Troubleshooting (cont) MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION STEAM CLEANER (cont)

6. CARTRIDGE FUSE F1 (1) BLOWS REPEATEDLY - HOT MODE. Step 1.

Perform procedures in malfunction 4 above.

NOTE Before performing any electrical checks, be sure to check the circuits first for any loose or broken wires. Step 2. Check for shorts in 4CR relay-switch (2). Replace 4CR relay-switch (para 5-22). 5-16

TM 9-4940-531-14 Table 5-1. Direct Support Troubleshooting (cont) MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION

7. CARTRIDGE FUSE F1 (1) BLOWS REPEATEDLY - STEAM MODE. Step 1.

Perform procedures in malfunction 4 above.

NOTE Before performing any electrical checks, be sure to check the circuits first for any loose or broken wires. Step 2. Check for shorts in 4CR relay-switch (2). Replace 4CR relay-switch (para 5-22). Step 3. Check for shorts in 5CR (3), 6CR (4), and 9CR (5) relay-switches; in 6SOL (6) and 7SOL (7) solenoid valves; and in their wiring. Replace defective component(s) (para 5-12, 5-20, and 5-22 and fig. FO-3) as required. 5-17

TM 9-4940-531-14

5-1.

TROUBLESHOOTING

(cont)

Table 5-1. Direct Support Troubleshooting (cont) MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION STEAM CLEANER (cont)

5-18

TM 9-4940-531-14 Table 5-1. Direct Support Troubleshooting (cont) MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION

8. WATER PUMP (1) RUNS BUT THERE lS LOW OR NO WATER OUTPUT FROM NOZZLE. CAUTION To prevent damage, do not operate water pump longer than 3 minutes without water flowing. NOTE • If there is inadequate water flow, oil burner will not ignite. • Low water output can be determined as follows: deliver the water discharge into a 5gallon bucket for 1 minute. Minimum accumulation should be as follows:

—

Cold or Hot Water Mode

Steam Mode

4 gallons (15.14 liters)

3.5 gallons (1 3.25 liters)

Step 1. For nonpressurized water source only, remove nozzle and observe water flow from steam cleaning gun. If air bubbles are observed, check for air leakage at input side of water pump (1). Tighten any loose fittings and/or replace broken fittings (para 4-13 and 5-11). Step 2.

For pressurized water source only, check that 208 VAC is available at S4 liquid level switch (2) and 9SOL solenoid valve (3) (switch should be closed except when the float is at the top of its range). Replace defective S4 liquid level switch, 9SOL solenoid valve, or any defective wiring (para 5-17).

Step 3. Check that vent valve (4) is closed. Vent valve is defective if water comes out of elbow (5). Replace defective vent valve (para 5-11). Step 4. Check for leaks and cracks in plumbing components on inlet side of water pump (1) and for leaks coming from the water pump itself. Replace damaged plumbing components and water pump (para 4-13, 5-11, and 5-15).

5-19

TM 9-4940-531-14

5-1.

TROUBLESHOOTING (cont) Table 5-1. Direct Support Troubleshooting (cont)

MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION STEAM CLEANER (cont)

5-20

TM 9-4940-531-14 Table 5-1. Direct Support Troubleshooting (cont) MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION 8. WATER PUMP RUNS BUT THERE IS LOW OR NO WATER OUTPUT FROM NOZZLE. (cont) NOTE When checking for voltage, make sure that S2 and S3 sensitive switches (6) and PUSH TO START button (7) are all depressed. Step 5.

Measure voltage between TB1 terminal strip (8) terminal 8B (wire 1 red) and 3CR relay-switch (9) terminal 6 (wire 2 white), to check operation of 5SOL solenoid valve (1O). Voltage should measure 120 VAC. If voltage is present, replace defective 5SOL solenoid valve (para 5-20).

Step 6.

Measure voltage between TB1 terminal strip (8) terminal 6B (wire 9 black) and TB2 terminal strip (11) terminal 2B (wire 50 white), to check operation of 6SOL solenoid valve (12). Voltage should measure 120 VAC. If voltage is present, replace defective 6SOL solenoid valve (para 5-20).

Step 7. Check that 300 psi (2069 kPa) and 500 psi (3448 kPa) regulating valves (13 and 14) are not opening prematurely. Perform adjustment procedure (para 5-20). If adjustment does not correct malfunction, replace defective regulating valve(s) (para 5-20) and readjust.

5-21

TM 9-4940-531-14 5-1 .

TROUBLESHOOTING (cont) Table 5-1. Direct Support Troubleshooting (cont)

MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION STEAM CLEANER (cont)

5-22

TM 9-4940-531-14 Table 5-1. Direct Support Troubleshooting (cont) MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION

8. WATER PUMP RUNS BUT THERE IS LOW OR NO WATER OUTPUT FROM NOZZLE. (cont) Step 8. Check 1SOL solenoid valve (15), 3SOL solenoid valve (16), and 4SOL solenoid valve (17) for leakage. Replace defective solenoid valve(s) (para 4-18, 5-9, and 5-11). Step 9. Check for external leakage from drain valves, plumbing, and blowdown regulating valve (18). If water is observed from blowdown drain, clean or replace blowdown regulating valve as necessary (para 5-13). Check 2SOL solenoid valve (19) and replace if necessary (para 5-13). Step 10. Check water pump (1) for excessive noise, vibration, leakage, or failure. Repair or replace defective water pump (para 5-18 or 5-15).

5-23

TM 9-4940-531-14 5-1.

TROUBLESHOOTING (cont) Table 5-1. Direct Support Troubleshooting (cont)

MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION STEAM CLEANER (cont)

5-24

TM 9-4940-531-14 Table 5-1. Direct Support Troubleshooting (cont) MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION 9. WATER OUTPUT IS DELIVERED BUT WORKING PRESSURE FLUCTUATES. NOTE • Periodic pressure fluctuations between 150 and 600 psi (1034 and 4137 kPa) are normal while in bypass mode with steam cleaning gun off. • Before performing any electrical checks, be sure to check the circuits first for any loose or broken wires. Step 1.

Hydraulic accumulator (1) must function properly to prevent excessive pressure pulsation in water circuit. Replace defective hydraulic accumulator (para 5-20).

Step 2. Refer to malfunction 8, step 5, to check 5SOL solenoid valve (2). Replace defective 5SOL solenoid valve (para 5-20). Step 3. Check water pump (3) for presence of water in the oil. Repair (para 5-18) or replace (para 5-15) defective water pump.

5-25

TM 9-4940-531-14 5-1.

TROUBLESHOOTING

(cont)

Table 5-1. Direct Support Troubleshooting (cont) MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION STEAM CLEANER (cont)

10. WATER PUMP (1) VIBRATES AND/OR IS NOISY. Step 1.

Check inlet hoses and fittings to water pump (1) for leakage. Tighten fittings (para 5-18) and/or replace defective inlet hoses (para 4-15).

Step 2. Check for loose or missing mounting nuts (2). Tighten loose mounting nuts and/or replace missing mounting nuts (para 5-15). Step 3. Check for water pump wear (seals) or internal failure Repair (para 5-18) or replace (para 5-15) defective water pump. 5-26

TM 9-4940-531-14 Table 5-1. Direct Support Troubleshooting (cont) MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION

11.

STEAM CLEANING GUN EMITS DRY (SUPERHEATED) STEAM. No further test or inspection needed. Replace TC1 temperature control box (1) (para 5-22).

5-27

TM 9-4940-531-14

5-1.

TROUBLESHOOTING (cont) Table 5-1. Direct Suppport Troubleshooting (cont)

MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION STEAM CLEANER (cont)

OIL BURNER MOTOR (1) WILL NOT START. Step 1.

Check for clogged fuel line (2) and/or oil burner nozzle (3) (para 5-14). Clean clogged fuel line and/or oil burner nozzle.

NOTE Before performing any electrical checks, be sure to check the circuits first for any loose or broken wires. When checking for voltage, make sure that S2 and S3 sensitive switches (4) and PUSH TO START button (5) are all depressed.

5-28

TM 9-4940-531-14 Table 5-1. Direct Support Troubleshooting (cont) MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION

Step 2. Check for voltage across terminals 4 and 6 of 4CR relay-switch (6). a.

If 208 VAC is present, replace defective 2MOT oil burner motor (para 5-14).

b.

If 208 VAC is not present, check for 120 VAC across terminals A and B of 4CR relay-switch. (1) If there is 120 VAC, replace 4CR relay-switch (para 5-22). (2) If not, proceed to step 3.

5-29

TM 9-4940-531-14 5-1.

TROUBLESHOOTING (cont) Table 5-1. Direct Support Troubleshooting (cont)

MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION

12. OIL BURNER MOTOR WILL NOT START. (cont) Step 3.

If there is not 120 VAC across terminals A and B or 4CR relay-switch (6), turn off power and check continuity of sections RS2 and RS3 of MODE SELECTOR switch (7) and 7CR relay-switch (8) as follows: a. In HOT mode, RS3 to ground should be closed. b. In STEAM mode, RS2 to ground should be closed. c. Remove 7CR relay-switch and check continuity between terminals 1 and 7, they should be closed. Replace defective MODE SELECTOR switch and/or 7CR relay-switch (para 5-22).

5-30

TM 9-4940-531-14 Table 5-1. Troubleshooting (cont) MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION

13. OIL BURNER (1) HAS DELAYED IGNITION (NOISY STARTS). Step 1.

Check oil burner nozzle (2) for obstruction. Clean oil burner nozzle (para 5-14).

Step 2. Check electrodes (3) for proper adjustment. Adjust electrodes (para 5-14).

5-31

TM 9-4940-531-14

5-1.

TROUBLESHOOTING (cont) Table 5-1. Direct Support Troubleshooting (cont)

MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION STEAM CLEANER (cont)

5-32

TM 9-4940-531-14 Table 5-1. Direct Support Troubleshooting (cont) MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION 14. OIL BURNER MOTOR (1) RUNS BUT OIL BURNER (2) FAILS TO IGNITE OR GOES OUT PREMATURELY. WARNING Injury or death can occur as a result of explosion if excess fuel has accumulated in bottom of fire pot. NOTE Ignition must occur and cad cell resistance change applied to oil burner electromagnet relay within 15 seconds of turning to HOT or STEAM mode, or the electromagnet relay will trip. Before performing any electrical checks, be sure to check the circuits first for any loose or broken wires. Step 1.

Check cad cell (3) for correct operation (para 5-14). Replace defective cad cell.

Step 2. Check ignition electrodes (4) for improper adjustment, for cracked or broken insulators, or for eroded spark-gap conductors (para 5-14). Adjust for correct sparkgap or replace defective electrodes (replace both electrodes, as a pair). NOTE When checking for voltage, make sure that S2 and S3 sensitive switches (5) and PUSH TO START button (6) are all depressed. Step 3.

Remove oil burner electromagnet relay (7) (para 5-14) and check for approximately 208 VAC across primary side of T2 power transformer (8). a.

If voltage is present, replace T2 power transformer (para 5-14).

b.

If no voltage is present, replace oil burner electromagnet relay (para 5-14).

Step 4. Check FUEL PRESSURE gauge (9). If FUEL PRESSURE gauge shows low or no fuel pressure: a.

Check 8SOL fuel solenoid valve (10) for continuity. If solenoid coil is open, replace 8SOL fuel solenoid valve (para 5-14).

b. Check that fuel pump (11) is operating. If not pumping fuel, replace fuel pump (para 5-14).

5-33

TM 9-4940-531-14

5-1.

TROUBLESHOOTING (cont) Table 5-1. Direct Support Troubleshooting (cont)

MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION STEAM CLEANER (cont)

14.

OIL BURNER MOTOR RUNS BUT OIL BURNER FAILS TO IGNITE OR GOES OUT PREMATURELY. (cont) Step 5. Check for 208 VAC between white and black wires from oil burner electromagnet relay (7). If there is no voltage: Check 2CR relay-switch (12), PS2 pressure switch (13), and TC1 temperature control box (14) if in HOT mode; or check 2CR relay-switch (12), PS1 pressure switch (15), and TC1 temperature control box (14) if in STEAM MODE (para 5-7 and 5-22). Replace defective component(s).

5-34

TM 9-4940-531-14 Table 5-1. Direct Support Troubleshooting (cont) MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION

15.

OPERATING TEMPERATURE GAUGE (1) INDICATES ABNORMAL WATER TEMPERATURE. NOTE Before performing any electrical checks, be sure to check the circuits first for any loose or broken wires. Step 1.

Turn MODE SELECTOR switch (2) to another mode and check OPERATING TEMPERATURE gauge (1). If temperature does not change, proceed to step 2 below.

Step 2. Check thermocouple probe (3) for correct positioning and tight connections. Reposition thermocouple probe, tighten connections, or replace defective thermocouple (para 4-13).

5-35

TM 9-4940-531-14 5-1.

TROUBLESHOOTING

(cont)

Table 5-1. Direct Support Troubleshooting (cont) MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION STEAM CLEANER (cont)

15. OPERATING TEMPERATURE GAUGE INDICATES ABNORMAL WATER TEMPERATURE. (cont) Step 3.

Remove end of thermocouple probe (3) and place in container of boiling water. Measure water temperature with thermometer and compare with OPERATING TEMPERATURE gauge (1) reading. If temperatures differ by more than 15°F (8.3 °C), calibrate OPERATING TEMPERATURE gauge (para 5-22) and test again. Replace defective OPERATING TEMPERATURE gauge.

5-36

TM 9-4940-531-14 Table 5-1. Direct Support Troubleshooting (cont) MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION Step 4.

16.

If oil burner (4) is on and the HOT mode is selected and the temperature is too high, or if the STEAM mode is selected and the temperature is too low, check 5CR relay-switch (5). a.

Replace defective 5CR relay-switch (para 5-22).

b.

Replace defective TC1 temperature control box (6) (para 5-22).

OUTLET PRESSURE GAUGE (1) INDICATES LOW OUTLET PRESSURE. With steam cleaning gun off, compare INLET PRESSURE gauge (2) and OUTLET PRESSURE gauge (1) readings. If readings differ by more than 30 psi (207 kPa), replace the gauge (para 5-5) showing lower pressure reading and test again. 5-37

TM 9-4940-531-14

5-1.

TROUBLESHOOTING (cont) Table 5-1. Direct Support Troubleshooting (cont)

MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION STEAM CLEANER (cont)

17. OUTLET PRESSURE GAUGE (1) lNDICATES HIGH OUTLET PRESSURE. Step 1.

HOT or COLD mode: Check 500 psi (3448 kPa) regulating valve (2) for restrictions and defects. Adjust or replace defective 500 psi (3448 kPa) regulating valve (para 5-20).

Step 2.

STEAM mode:

a. Check 6SOL solenoid valve (3). Replace defective 6SOL solenoid valve (para 5-20). b. Check 300 psi (2069 kPa) regulating valve (4) for restrictions and defects. Adjust or replace defective 300 psi (2069 kPa) regulating valve (para 5-20).

5-38

TM 9-4940-531-14

Table 5-1. Direct Support Troubleshooting (cont) MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION

18.

WATER PUMP MOTOR (1) WILL NOT STOP AND WATER DOES NOT DRAIN WHEN MODE SELECTOR SWITCH (2) IS SET TO OFF POSITION FROM COLD OR HOT MODES. NOTE Before performing any electrical checks, be sure to check the circuits first for any loose or broken wires. When checking for voltage, make sure that S2 and S3 sensitive switches (3) and PUSH TO START button (4) are all depressed. Step 1.

Check voltage across 1CR electromagnet relay (5). If voltage does not measure approximately 208 VAC, replace defective 1CR electromagnet relay (para 5-22).

5-39

TM 9-4940-531-14

5-1.

TROUBLESHOOTING (cont) Table 5-1. Direct Support Troubleshooting (cont)

MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION STEAM CLEANER (cont)

5-40

TM 9-4940-531-14 Table 5-1. Direct Support Troubleshooting (cont) MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION

18. WATER PUMP MOTOR WILL NOT STOP AND WATER DOES NOT DRAIN WHEN MODE SELECTOR SWITCH IS SET TO OFF POSITION FROM COLD OR HOT MODES. (cont) Step 2.

Check voltage across 8CR relay-switch (6), RS7 of MODE SELECTOR switch (2), 5CR relay-switch (7), and 7CR relay-switch (8). If voltage does not measure approximately 110 VAC, replace defective component(s) (para 5-22).

Step 3.

Check voltage across 3SOL and 4SOL solenoid valves (9 and 10). If voltage does not measure approximately 115 VAC, replace defective solenoid valves(s) (para 5-9 and 5-11).

Step 4.

Check that blowdown regulating valve (11) opens. Clean and/or replace blowdown regulating valve (para 5-13). 5-41

TM 9-4940-531-14 5-1.

TROUBLESHOOTING (cont) Table 5-1. Direct Support Troubleshooting (cont)

MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION STEAM CLEANER (cont)

5-42

TM 9-4940-531-14 Table 5-1. Direct Support Troubleshooting (cont) MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION

19. BLOWDOWN CYCLE MALFUNCTIONS. NOTE Before performing any electrical checks, be sure to check the circuits first for any loose or broken wires. Step 1.

If steam cleaner does not enter blowdown cycle when shut down from STEAM mode:

a. If water pump motor (1) stops, check 5CR, 7CR, and 9CR relay-switches (2, 3, and 4) for continuity. Replace defective component(s) (para 5-22). b. If oil burner (5) stops, check blowdown regulating valve (6); S5 flow switch (7); and 6CR, 5CR, 2CR, and 9CR relay-switches(8, 2, 9, and 4). Clean blowdown regulating valve and/or replace defective component(s) (para 5-13 and 5-22). Step 2.

If water does not resume flow and oil burner does not stop after 127 seconds, check 1TDC delay line (10) and 7CR relay-switch (3). Replace faulty 1TDC delay line and/or 7CR relay-switch (para 5-22).

Step 3. If water pump motor (1) does not stop and L1 POWER LIGHT (11) stays on beyond 78 to 98 seconds after oil burner stops, check 2TDC delay line (12). Replace faulty 2TDC delay line (para 5-22). FLAT BED TRAILER Refer to TM 9-2330-202-14&P. GENERATOR SET Refer to TM 5-6115-615-34.

5-43

TM 9-4940-531-14

Section Il. MAINTENANCE PROCEDURES 5-2.

GENERAL

MAINTENANCE

Refer to general maintenance instructions on page 4-19.

5-3.

TRAILER-MOUNTED

STEAM

CLEANER—MAINTENANCE

INSTRUCTIONS

THIS TASK COVERS: a. Disassembly

b. Inspection/repair

INITIAL SETUP Tools and Special Tools General mechanic’s tool kit (item 2, appx B) Electric repair shop equipment (item 1, appx B) Materials/Parts Rubber strip (2) (11024796) Self-locking nut (4) (MS51922-33) Tapping screw (4) (MS51861-65) Personnel Required: (2) References TM 9-6115-615-34 Equipment Conditions Generator set turned off (TM 9-6115-515-12) Leveling support jack and rear stabilizer kit lowered into position Generator power cable assembly removed (para 4-12) External hose assemblies disconnected Suitable lifting device and lifting straps available

5-44

c. Reassembly

TM 9-4940-531-14

1 Remove four tapping screws (1) and two amber indicating reflectors (2) from generator set(3). WARNING Generator set weighs 600 lb (272.16 kg) wet, 585 lb (265.36 kg) dry. To avoid injury, do not attempt to lift generator set without proper equipment. 2 Attach suitable lifting device (4) to generator set lifting ring (5) using lifting strap (6). 3 Remove four self-locking nuts (7), four flat washers (8), four capscrews (9), and four flat washers (10). Lift generator set (3) away from flat bed trailer (11). 4 Remove two rubber strips (12) and generator platform (13) from flat bed trailer (11).

5-45

TM 9-4940-531-14 5-3. TRAILER-MOUNTED STEAM CLEANER—MAINTENANCE INSTRUCTIONS (cont) DISASSEMBLY (cont)

WARNING Steam cleaner weighs 1365 lb (619.16 kg) wet, 1185 lb (537.52 kg) dry. To avoid injury, do not attempt to lift steam cleaner without proper equipment. 5 Attach suitable lifting device (4) to steam cleaner lifting ring (14) using lifting strap (6). NOTE To remove steam cleaner with skid from flat bed trailer, perform step 6. To remove enclosure and lift assembly, refer to paragraph 5-4. 6 Remove four machine bolts (15) and four flat washers (16). Lift steam cleaner (17) away from flat bed trailer (11).

INSPECTION/REPAIR 1 Check for broken, damaged, or missing parts. 2 Repair is by replacement of damaged or unserviceable parts. 3 Generator platform is a manufactured item, refer to appendix F. 4 Generator set is a repairable assembly, refer to TM 5-6115-615-34. 5 Steam cleaner is a repairable assembly, refer to paragraphs 5-4 thru 5-10. 6 Flat bed trailer is a repairable assembly, refer to paragraph 5-31.

5-46

TM 9-4940-531-14 REASSEMBLY

1

Position leveling support jack (1) and rear stabilizer kit (2) to level flatbed trailer (3).

2

Attach suitable lifting device (4) to steam cleaner lifting ring (5) with lifting strap (6). Position steam cleaner (7) on flat bed trailer (3).

3

Secure steam cleaner (7) to flat bed trailer (3) with four flat washers (8) and four machine bolts (9).

4

Install generator platform (10) and two new rubber strips (11) onto flat bed trailer (3).

5

Attach suitable lifting device (4) to generator set lifting eye (12) with lifting strap (6). Position generator set (13) on generator platform (10).

6

Secure generator set (13) to flat bed trailer (3) with four flat washers (14), four capscrews (15), four flat washers (16), and four new self-locking nuts (17).

7

Install two amber indicating reflectors (18 and 19) onto generator set (13) with four new tapping screws (20) as follows: a.

Locate amber indicating reflector (18) on right panel (21) 7 in. (1 7.78 cm) from base and 8 in. (20.32 cm) from front panel of generator set. If generator set has been replaced, drill two holes at 0.228 +0.006 -0.001 in. (0.58 +0.0150.003 cm).

b. Locate amber indicating reflector (19) on left panel (22) 6 in. (15.24 cm) from base and 7 in. (1 7.78 cm) from front panel. If generator set has been replaced, drill two holes at 0.228 +0.006 -0.001 in. (0.58 +0.015 -0.003 cm).

5-47

TM 9-4940-531-14 5-4. STEAM CLEANER (ENCLOSURE AND LIFT ASSEMBLY)—MAINTENANCE INSTRUCTIONS THIS TASK COVERS: a. Removal of enclosure and lift assembly b. Inspection/repair Installation of enclosure and lift assembly c. INITIAL SETUP Tools and Special Tools General mechanic’s tool kit (item 2, appx B) Electric repair shop equipment (item 1, appx B) Materials/Parts Lockwasher (14)(MS35338-46) Self-locking nut (4)(MS51988-5) Self-locking nut (4)(MS51988-7) Personnel Required: (2) Equipment Conditions Lifting strap and suitable lifting device available Steam cleaner shut down (para 2-6) External power cable and hoses removed Hoses removed from hose rack Left rear access door and left rear panel removed (para 4-22) Water inlet fitting and flat washer removed (para 4-15) REMOVAL OF ENCLOSURE AND LIFT ASSEMBLY

NOTE Illustrations show the steam cleaner removed from the trailer. This procedure can be performed when steam cleaner is installed on the trailer. 1 Attach suitable lifting device (1) to enclosure and lift assembly lifting ring (2) with lifting strap (3).

5-48

TM 9-4940-531-14

2 Remove two nuts (4), two Iockwashers (5), two capscrews (6), and gauge support bracket (7) with attached parts from structural channel (8). Reinstall structural channel with two capscrews (6), two Iockwashers (5), and two nuts (4). 3 Remove seven capscrews (9) holding side mounting rail (10) and left post assembly (11) onto saddle and fuel tank weldment (12).

5-49

TM 9-4940-531-14 5-4. STEAM CLEANER (ENCLOSURE AND LIFT ASSEMBLY)—MAINTENANCE INSTRUCTIONS (cont)

4 Remove four self-locking nuts (13) and four capscrews (14) holding structural channel (8) and front post assembly (15)onto platform skid (16). 5 Remove 12 nuts (17), 12 Iockwashers (18), and 12 machine screws (19) holding enclosure and lift assembly (20) onto platform skid (16). Remove two self-locking nuts (21) and two machine screws (22) from left rear of steam cleaner. Remove two self-locking nuts (23) and two machine bolts (24) from right rear of steam cleaner. 6 Close and secure hose rack access door (25) with chain assembly (26). 7 Remove 23 capscrews (27) holding enclosure and lift assembly (20) onto platform skid (16). 8 Using suitable lifting device(1), remove enclosure and lift assembly (20) from platform skid (16). lNSPECTION/REPAIR 1 Check for broken, damaged, or missing parts. 2 Enclosure and lift assembly is a repairable assembly, refer to paragraph 4-22. 3 Repair is by replacement of damaged or unserviceable parts. 5-50

TM 9-4940-531-14

INSTALLATION OF ENCLOSURE AND LIFT ASSEMBLY

NOTE Ensure hose rack access door (1) is closed and secured with chain assembly (2). 1

Using suitable lifting device (3), position enclosure and lift assembly (4) on platform skid (5).

2

Secure enclosure and lift assembly (4) onto platform skid (5) with 12 machine screws (6), 12 new Iockwashers (7), and 12 nuts (8). Install two machine screws (9) and two new self-locking nuts (10) into left rear of steam cleaner. Install two machine bolts(11) and two new self-locking nuts (12) into right rear of steam cleaner.

3

install enclosure and lift assembly (4) onto platform skid (5) with 23 capscrews (13).

4

Install front post assembly (14) and structural channel (15) onto platform skid (5) with four capscrews (16) and four new self-locking nuts (17).

5-51

TM 9-4940-531-14 5-4. STEAM CLEANER (ENCLOSURE AND LIFT ASSEMBLY)—MAINTENANCE INSTRUCTIONS (cont) INSTALLATION OF ENCLOSURE AND LIFT ASSEMBLY (cont)

5 Install left post assembly (18) and side mounting rail (19) onto saddle and fuel tank weldment (20) with seven capscrews (21). 6 Remove two nuts (22), two Iockwashers (23), and two capscrews (24) holding structural channel (15) onto enclosure and lift assembly (4). Install gauge support bracket (25) with attached parts onto structural channel (15) with two capscrews (24), two new Iockwashers (23), and two nuts (22).

5-52

TM 9-4940-531-14

7

5-5.

Detach lifting device (3) and lifting strap (26) from enclosure and lift assembly lifting ring (27).

STEAM CLEANER INSTRUCTIONS

(PRESSURE

GAUGE

ASSEMBLY)-MAINTENANCE

THIS TASK COVERS: a. b. c.

Removal/disassembly of pressure gauge assembly Inspection/repair Reassembly/installation of pressure gauge assembly

INITIAL SETUP Tools and Special Tools General mechanic’s tool kit (item 2, appx B) Electric repair shop equipment (item 1, appx B) Materials/Parts Lockwasher (5) (MS35338-46) Equipment Conditions Steam cleaner shut down (para 2-6)

5-53

TM 9-4940-531-14 5-5. STEAM CLEANER (PRESSURE GAUGE ASSEMBLY)-MAINTENANCE INSTRUCTIONS (cont) REMOVAL/DISASSEMBLY OF PRESSURE GAUGE ASSEMBLY

WARNING To avoid injury to personnel, ensure that INLET and OUTLET PRESSURE gauges show no pressure before beginning maintenance. 1

Disconnect coil inlet-to-inlet pressure gauge tubing assembly (1) and pipe bushing (2) from INLET PRESSURE gauge (3).

2

Disconnect coil outlet-to-outlet pressure gauge tubing assembly (4) and pipe bushing (5) from OUTLET PRESSURE gauge (6).

3

Remove three nuts (7), three Iockwashers (8), three capscrews (9), two flat washers (10), gauge upper clamp (11), gauge lower clamp (12), and diaphram support bracket (13) from control box assembly (14).

5-54

TM 9-4940-531-14

4 Remove two nuts (15), bracket (16), and INLET PRESSURE gauge (3) from gauge support bracket (17). 5 Remove two nuts (18), bracket (19), and OUTLET PRESSURE gauge (6) from gauge support bracket (17). 6 Remove two nuts (20), two Iockwashers (21), two capscrews (22), and gauge support bracket (17) from enclosure and lift assembly (23). Reinstall two capscrews (22), two Iockwashers (21), and two nuts (20) into enclosure and lift assembly (23). INSPECTION/REPAIR 1 Check for broken, damaged, or missing parts. 2 Repair is by replacement of damaged or unserviceable parts.

5-55

TM 94940-531-14

5-5. STEAM CLEANER (PRESSURE GAUGE ASSEMBLY)—MAINTENANCE INSTRUCTIONS (cont) REASSEMBLY/lNSTALLATION OF PRESSURE GAUGE ASSEMBLY

1 Remove two nuts (1), two Iockwashers (2), and two capscrews (3) from enclosure and lift assembly (4). Install gauge support bracket (5) onto enclosure and lift assembly (4) with two capscrews (3), two new Iockwashers (2), and two nuts (1). 2 Install OUTLET PRESSURE gauge (6) onto gauge support bracket (5) with bracket (7) and two nuts (8). 3 Install INLET PRESSURE gauge (9) onto gauge support bracket (5) with bracket (10) and two nuts (11).

5-56

TM 9-4940-531-14

4 Install diaphram support bracket (12), gauge lower clamp (13), and gauge upper clamp (14) onto control box assembly (15) with two flat washers (16), three capscrews (17), three new Iockwashers (18), and three nuts (19). Do not tighten hardware. 5 Connect pipe bushing (20) and coil outlet-to-outlet pressure gauge tubing assembly (21) to OUTLET PRESSURE gauge (6). 6 Connect pipe bushing (22) and coil inlet-to-inlet pressure gauge tubing assembly (23) to INLET PRESSURE gauge (9). 7 Install OUTLET PRESSURE gauge (6) and INLET PRESSURE gauge (9) onto diaphram support bracket (12). Tighten three capscrews (17).

5-57

TM 9-4940-531 -14 5-6. STEAM CLEANER (CONTROL BOX ASSEMBLY)-MAINTENANCE INSTRUCTIONS THIS TASK COVERS: a. b. c.

Removal of control box assembly Inspection/repair Installation of control box assembly

INITIAL SETUP Tools and Special Tools General mechanic’s tool kit (item 2, appx B) Electric repair shop equipment (item 1, appx B) Materials/Parts Tapping screw (MS51869-23) (6) Tapping screw (MS51861-46) (4) Equipment Conditions Steam cleaner shut down (para 2-6) and power source removed Lower control panel assembly removed (para 4-13) Left rear access door and left rear panel removed (para 4-22) REMOVAL OF CONTROL BOX ASSEMBLY NOTE Some parts not shown for clarity.

5-58

TM 9-4940-531-14

1 Remove four tapping screws (1) and open control box assembly (2). 2 Remove two screws (3) and disconnect two thermocouple probe leads (4) from TC1 temperature control box (5). Reinstall two screws (3). 3 For access to wire terminals and conduit assemblies, remove relay-switches (6) as needed. NOTE l Be sure all wires and conduit assemblies are tagged and labeled before removal. l Refer to schematic on FO-1 for conduit/wire connections. The listed conduit and wire numbers are from the schematic. The callout number refers to this disassembly text. 4 Disconnect 26 wires entering control box assembly (2) through the following conduit assemblies: Conduit no. 201 202 203 204 205 206 207 208 211

Wire no. 1,2 15,16,17,18,19,20 9, 50 28, 29, 87 23, 26, 121, 123 30, 31 91,139 58, 81, 136 12, 13

Callout no. 7 8 9 10 11 12 13 14 15

5 Remove nine conduit connector locknuts (16) and disconnect nine conduit assemblies (7 thru 15) from control box assembly (2).

5-59

TM 9-4940-531-14 5-6. STEAM CLEANER (CONTROL BOX ASSEMBLY)—MAINTENANCE INSTRUCTIONS (cont) REMOVAL OF CONTROL BOX ASSEMBLY (cont)

6 Reinstall relay-switches (6). 7 Close control box assembly (2). Remove 10 capscrews (17) and side mounting rail (18) from saddle and fuel tank weldment (19). Remove four tapping screws (20) and control box assembly (2).

5-60

TM 9-4940-531-14 INSPECTIONREPAIR 1 Check for broken, damaged, or missing parts. 2 Repair is by replacement of damaged or unserviceable parts. 3 Control box assembly is a repairable assembly. Refer to paragraph 5-22. INSTALLATION OF CONTROL BOX ASSEMBLY

1 Install control box assembly (1) onto saddle and fuel tank weldment (2) with four new tapping screws (3). Install side mounting rail (4) with 10 capscrews (5). Open control box assembly (1). 2 For access to wire terminals and conduit assemblies, remove relay-switches (6) as needed. 5-61

TM 9-4940-531-14 5-6. STEAM CLEANER (CONTROL BOX ASSEMBLY)—MAINTENANCE INSTRUCTIONS (cont) INSTALLATION OF CONTROL BOX ASSEMBLY (cont)

NOTE Refer to schematic on FO-1 for conduit/wire connections. The listed conduit and wire numbers are from the schematic. The callout number refers to this reassembly text. 3 Connect nine conduit assemblies (7 thru 15) to control box assembly (1) with nine conduit connector locknuts (16). 4 Connect 26 wires entering control box assembly (1) through the following conduit assemblies: Conduit no. 201 202 203 204 205 206 207 208 211 5-62

Wire no. 1,2 15,16,17,18,19,20 9, 50 28, 29, 87 23, 26, 121, 123 30,31 91,139 58, 81, 136 12,13

Callout no. 7 8 9 10 11 12 13 14 15

TM 9-4940-531-14

NOTE Some parts not shown for clarity.

5 Reinstall relay-switches (6). 6 Remove two screws (17) from TC1 temperature control box (18). Connect two thermocouple probe leads (19) to TC1 temperature control box (18) with two screws (17). 7 Close control box assembly (1) and install four new tapping screws (20).

5-63

TM 9-4940-531-14 5-7. STEAM CLEANER (PS1 , PS2, AND PS3 PRESSURE S W I T C H E S ) - M A I N T E N A N C E INSTRUCTIONS THIS TASK COVERS: a. b. c.

Removal of PS1, PS2, and PS3 pressure switches Inspection/repair Installation of PS1, PS2, and PS3 pressure switches

INITIAL SETUP Tools and Special Tools General mechanic’s tool kit (item 2, appx B) Electric repair shop equipment (item 5, appx B) Materials/Parts Self-locking nut (9) (MS51988-3) Equipment Conditions Steam cleaner shut down (para 2-6) and power source removed REMOVAL OF PS1, PS2, AND PS3 PRESSURE SWITCHES

NOTE Some parts not shown for clarity.

5-64

TM 9-4940-531-14 WARNING To avoid injury to personnel, ensure that INLET and OUTLET PRESSURE gauges show no pressure before beginning maintenance. NOTE Be sure all wires, conduits, and tubing are labeled before removal. 1 Disconnect coil inlet-to-differential pressure switch tubing assembly (1), coil outlet-to-differential pressure switch tubing assembly (2), and two pipe bushings (3) from PS3 differential pressure switch (4).

2 Remove two machine screws (5) and cover (6) from 301 junction box (7). 3 Remove four screws (8) and cover (9) from PS3 differential pressure switch (4). 4 Disconnect two wires no. 10 and 15 (10 and 11). Remove conduit connector locknut (12) and disconnect conduit assembly no. 212 (13). 5 Disconnect conduit connector locknut (14). Remove conduit assembly no.212 (13) and conduit connector locknut (14) from 301 junction box (7). 6 Remove two self-locking nuts (15), two machine screws (16), and PS3 differential pressure switch (4) from switch plate assembly (17).

5-65

TM 9-4940-531-14 5-7. STEAM CLEANER (PS1, PS2, AND PS3 PRESSURE SWITCHES)—MAINTENANCE INSTRUCTIONS (cont) REMOVAL OF PS1, PS2, AND PS3 PRESSURE SWITCHES (cont)

7

Remove four screws (18) and cover (19) from PS2 pressure switch (20).

8

Disconnect two wires no. 19 and 20 (21 and 22). Remove conduit connector locknut (23) and disconnect conduit assembly no. 213 (24).

9

Loosen conduit connector locknut (25). Remove conduit assembly no. 213 (24) and conduit connector locknut (25) from 301 junction box (7).

10

5-66

Disconnect coil outlet-to-pressure switch tubing assembly (26) from pipe tee (27).

TM 9-4940-531-14

11

Remove two self-locking nuts (28), two machine screws (29), and PS2 pressure switch (20) from switch plate assembly (17).

12

Remove pressure switch-to-pressure switch tubing assembly (30), pipe tee (27), pipe nipple (31), and two pipe bushings (32) from PS2 and PS1 pressure switches (20 and 33).

13

Remove four screws (34) and cover (35) from PS1 pressure switch (33).

14

Disconnect two wires no. 17 and 18 (36 and 37).

15

Remove conduit connector locknut (38). Disconnect conduit assembly no. 202 (39) from 301 junction box (7).

16

Remove electrical locknut (40), 301 junction box (7), and electrical locknut (41) from PS1 pressure switch (33).

17

Remove pipe nipple (42), two self-locking nuts (43), two machine screws (44), and PS1 pressure switch (33) from switch plate assembly (17).

5-67

TM 9-4940-531-14 5-7. STEAM CLEANER (PS1, PS2, AND PS3 PRESSURE SWITCHES)—MAINTENANCE INSTRUCTIONS (cont) REMOVAL OF PS1, PS2, AND PS3 PRESSURE SWITCHES (cont)

18 Remove self-locking nut (45), capscrew (46), two self-locking nuts (47), two capscrews (48), and switch plate assembly (17) from coil unit assembly (49) and coil inlet control assembly (50).

5-68

TM 9-4940-531-14

lNSPECTION/REPAIR 1 Check for broken, damaged, or missing parts. 2 Repair is by replacement of damaged or unserviceable parts. INSTALLATION OF PS1, PS2, AND PS3 PRESSURE SWITCHES

1 Install switch plate assembly (1) onto coil inlet control assembly (2) and coil unit assembly (3) with two capscrews (4), two new self-locking nuts (5), capscrew (6), and new self-locking nut (7).

5-69

TM 9-4940-531-14 5-7. STEAM CLEANER (PS1, PS2, AND PS3 PRESSURE SWITCHES)—MAINTENANCE INSTRUCTIONS (cont) INSTALLATION OF PS1, PS2, AND PS3 PRESSURE SWITCHES (cont)

2

Install pipe nipple (8) into PS1 pressure switch (9). Secure 301 junction box (10) to PS1 pressure switch (9) with electrical locknut (11) and electrical locknut (12).

3

Connect conduit assembly no. 202 (13) to 301 junction box (10) with conduit connector locknut (14).

4

Install PS1 pressure switch (9) onto switch plate assembly (1) with two machine screws (15) and two new self-locking nuts (16).

5

Connect two wires no. 17 and 18 (17 and 18) to PS1 pressure switch (9).

6

Install cover (19) onto PS1 pressure switch (9) with four screws (20).

5-70

TM 9-4940-531-14

7 Install two pipe bushings (21), pipe nipple (22), pipe tee (23), and pressure switch-to-pressure switch tubing assembly (24) onto PS1 and PS2 pressure switches (9 and 25). 8

Install PS2 pressure switch (25) onto switch plate assembly (1) with two machine two new self-locking nuts (27). —

SC rews

(26) and

9 Connect coil outlet-to-pressure switch tubing assembly (28) to pipe tee (23). 10 Connect conduit assembly no. 213 (29) to 301 junction box (10) and PS2 pressure switch (25) with two conduit connector locknuts (30 and 31). Connect two wires no. 19 and 20 (32 and 33) to PS2 pressure switch (25). 11 Install cover (34) onto PS2 pressure switch (25) with four screws (35).

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TM 9-4940-531-14

5-7. STEAM CLEANER (PS1, PS2, AND PS3 PRESSURE SWITCHES)—MAINTENANCE INSTRUCTIONS (cont) INSTALLATION OF PS1, PS2, AND PS3 PRESSURE SWITCHES (cont)

12

Install PS3 differential pressure switch (36) onto switch plate assembly (1) with two machine screws (37) and two new self-locking nuts (38).

13

Connect conduit assembly no. 212 (39) to PS3 differential pressure switch (36) and 301 junction box (10) with two conduit connector locknuts (40 and 41). Connect two wires no. 10 and 15 (42 and 43) to PS3 differential switch (36).

14

Install cover (44) onto PS3 differential pressure switch (36) with four screws (45)

15

Install cover (46) onto 301 junction box (10) with two machine screws (47).

16 Install two pipe bushings (48) into PS3 differential pressure switch (36). Connect coil outlet-to-differential pressure switch tubing assembly (49) and coil inlet-todifferential pressure switch tubing assembly (50).

5-72

TM 9-4940-531-14 5-8.

STEAM CLEANER (COIL INLET ASSEMBLY)—MAINTENANCE INSTRUCTIONS

THIS TASK COVERS: a. Removal of coil inlet assembly

b. Inspection/repair

c. Installation of coil inlet assembly

INITIAL SETUP Tools and Special Tools Crescent wrench, 12-in. (item 1, appx B) Crescent wrench, 14-in. (item 1, appx B) General mechanic’s tool kit (item 2, appx B) Electric repair shop equipment (item 1, appx B) Materials/Parts Conductor splice (2) (M7928/5-4) Conductor splice (2) (11024917) Equipment Conditions Steam cleaner shut down (para 2-6) and power source removed Front panel removed (para 4-22) Hose removed (para 4-13)

NOTE Be sure wires are tagged and labeled before removal. REMOVAL OF COIL INLET ASSEMBLY 1 Loosen two screws (1) and remove cover (2) from 303 junction box (3).

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TM 9-4940-531-14 5-8. STEAM CLEANER (COIL INLET ASSEMBLY)—MAINTENANCE INSTRUCTIONS (cont) REMOVAL OF COIL INLET ASSEMBLY (cont)

2 Remove two conductor splices (4) and disconnect two wires no. 23 and 26 (5 and 6). 3

Remove conduit connector locknut (7) and disconnect conduit assembly no. 216 (8) from 303 junction box (3).

4

Disconnect conduit assembly no. 216 (8) from 3SOL solenoid valve (9).

5

Remove two conductor splices (10) and two wires no. 23 and 26 (5 and 6).

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TM 9-4940-531-14

6

Disconnect coil inlet-to-differential pressure switch tubing assembly (11) and coil inlet-to-inlet pressure gauge tubing assembly (12) from coil inlet assembly (13).

7

Uncouple pipe union (14). Remove coil inlet hose assembly (15) from coil inlet assembly (13) and coil inlet control assembly pipe reducer (16).

8

Uncouple pipe union (17) and remove coil inlet assembly (13) from pipe nipple (18).

9

Remove halves of two pipe unions (14 and 17) from coil inlet hose assembly (15) and pipe nipple (18).

INSPECTION/REPAIR 1 Check for broken, damaged, or missing parts. 2 Repair is by replacement of damaged or unserviceable parts. 3 Coil inlet assembly is a repairable assembly. Refer to paragraph 5-11.

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TM 9-4940-531-14 5-8. STEAM CLEANER (COIL INLET ASSEMBLY)—MAINTENANCE INSTRUCTIONS (cont) INSTALLATION OF COIL INLET ASSEMBLY

1 Install halves of two pipe unions (1 and 2) onto pipe nipple (3) and coil inlet hose assembly (4). 2 Install coil inlet assembly (5) to pipe nipple (3). Couple pipe union (1). 3 Connect coil inlet-to-inlet pressure gauge tubing assembly (6) and coil inlet-to-differential pressure switch tubing assembly (7) to coil inlet assembly (5). 4 Install coil inlet hose assembly (4) onto coil inlet control assembly pipe reducer (8). Connect coil inlet hose assembly (4) to coil inlet assembly (5). Couple pipe union (2).

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TM 9-4940-531-14

5 Connect two wires no. 23 and 26 (9 and 10) to 3SOL solenoid valve (11) with two new conductor splices (12). 6 Connect conduit assembly no. 216 (13) to 3SOL solenoid valve (11). 7 Connect conduit assembly no. 216 (13) to 303 junction box (14) with conduit connector locknut (15). 8 Connect two wires no. 23 and 26 (9 and 10) with two new conductor splices (16). 9 Install cover (17) onto 303 junction box (14) and tighten two screws (18).

5-77

TM 9-4940-531-14 5-9. STEAM CLEANER (COIL OUTLET ASSEMBLY AND OUTLET AND WATER DRAIN ASSEMBLY)--MAINTENANCE INSTRUCTIONS THIS TASK COVERS: Removal of coil outlet assembly and outlet and water drain assembly a. b. Disassembly of outlet and water drain assembly Inspection/repair c. d. Reassembly of outlet and water drain assembly Installation of coil outlet assembly and outlet and water drain assembly e. INITIAL SETUP Tools and Special Tools Crescent wrench, 12-in. (item 1, appx B) Crescent wrench, 14-in. (item 1, appx B) General mechanic’s tool kit (item 2, appx B) Electric repair shop equipment (item 1, appx B) Materials/Parts Conductor splice (5) (M7928/5-4) Conductor splice (3) (11024917) Lockwasher (2) (MS35338-44) Self-locking nut (2) (MS51922-1) Self-locking nut (MS51988-5) Self-locking nut (2) (MS51988-7) Equipment Conditions Steam cleaner shut down (para 2-6) and power source removed Hoses removed (para 4-13) Outlet and water drain assembly partially disassembled (para 4-24) Top left cover removed (para 4-22)

WARNING To avoid injury to personnel, ensure that INLET and OUTLET PRESSURE gauges show no pressure before beginning maintenance. NOTE Be sure wires are tagged and labeled before removal.

5-78

TM 9-4940-531-14 REMOVAL OF COIL OUTLET ASSEMBLY AND OUTLET AND WATER DRAIN ASSEMBLY

1 Disconnect coil outlet-to-differential pressure switch tubing assembly (1), coil outlet-to-pressure switch tubing assembly (2), and coil outlet-to-outlet pressure gauge tubing assembly (3) from coil outlet assembly (4). 2 Uncouple pipe union (5). Remove coil inlet control-to-blowdown hose assembly (6) from coil inlet control assembly (7) and blowdown assembly (8). Remove halves of pipe union (5) from coil inlet control-to-blowdown hose assembly (6) and coil inlet control assembly (7).

5-79

TM 9-4940-531-14 5-9. STEAM CLEANER (COIL OUTLET ASSEMBLY AND OUTLET AND WATER DRAIN ASSEMBLY)—MAINTENANCE INSTRUCTIONS (cont) REMOVAL OF COIL OUTLET ASSEMBLY AND OUT LET AND WATER DRAIN ASSEMBLY (cont)

5-80

TM 9-4940-531-14

3

Disconnect two wires no. 91 and 139 from control box assembly (9).

4

Remove conduit connector locknut (10) and disconnect conduit assembly no. 207 (11) from control box assembly (9).

5

Remove conduit assembly no. 207 (11), two conductor splices (12), and two wires no. 91 and 139 (13 and 14) from S5 flow switch (15).

6

Disconnect two wires no. 12 and 13 from control box assembly (9).

7

Remove conduit connector locknut (16) and disconnect conduit assembly no. 211 (17) from control box assembly (9).

8

Remove conduit assembly no. 211 (17), two conductor splices (18), and two wires no. 12 and 13 (19 and 20) from 2SOL solenoid valve (21).

9 Disconnect three wires no. 58, 59, and 136 from control box assembly (9). 10 Remove conduit connector locknut (22) and disconnect conduit assemby no. 208 (23) from control box assembly (9).

5-81

TM 9-4940-531-14 5-9. STEAM CLEANER (COIL OUTLET ASSEMBLY AND OUTLET AND WATER DRAIN ASSEMBLY)—MAINTENANCE INSTRUCTIONS (cont) REMOVAL OF COIL OUTLET ASSEMBLY AND OUTLET AND WATER DRAIN ASSEMBLY (cont)

11 Remove two screws (24) and cover (25) from 304 junction box (26). 12 Remove two conductor splices (27 and 28) and disconnect three wires no. 58, 59, and 136 (29, 30, and 31) from 4SOL solenoid valve (32). 13 Loosen conduit connector locknut (33) and disconnect conduit assembly no.217 (34).

5-82

TM 9-4940-531-14

14 Disconnect conduit assembly no. 217 (34) from 7SOL solenoid valve (35). Remove two conductor splices (36) and remove two wires no. 59 and 81 (30 and 37) from 7 SOL solenoid valve (35). Remove conduit assembly no. 217 (34). 15 Remove two conduit connector locknuts (33 and 38), conduit assembly no. 208 (23), and two wires no. 58 and 136 (29 and 31). 16 Remove 304 junction box (26) with attached 4SOL solenoid valve (32).

17

Remove two self-locking nuts (39) and U-bolt (40) holding blowdown assembly (8) to fuel shutoff bracket (41).

18

Uncouple pipe union (42) from coil unit assembly (43). Remove halves of pipe union (42) from coil unit assembly (43) and coil outlet assembly (4).

19

Remove two self-locking nuts (44), two capscrews (45), self-locking nut (46), flat washer (47), machine bolt (48), and steam outlet support assembly (49) with attached parts from platform skid (50) and coil unit assembly (43).

5-83

TM 9-4940-531-14 5-9. STEAM CLEANER (COIL OUTLET ASSEMBLY AND OUTLET AND WATER DRAIN ASSEMBLY)—MAINTENANCE INSTRUCTIONS (cont) REMOVAL OF COIL OUTLET ASSEMBLY AND OUTLET AND WATER DRAIN ASSEMBLY (cont)

20 Remove two nuts (51), two lockwashers (52), U-bolt (53), pipe support (54), and coil outlet assembly (4) from steam outlet support assembly (49).

DISASSEMBLY OF OUTLET AND WATER DRAIN ASSEMBLY 1 Remove electrical conduit locknut (1) and 304 junction box (2) from pipe nipple (3). 2 Remove electrical conduit locknut (4) and pipe nipple (3) from 4SOL solenoid valve (5). INSPECTION/REPAIR 1 Check for broken, damaged, or missing parts. 2 Coil outlet assembly is a repairable assembly, refer to paragraph 5-12. 3 Repair is by replacement of damaged or unserviceable parts. REASSEMBLY OF OUTLET AND WATER DRAIN ASSEMBLY 1 Install pipe nipple (1) and electrical conduit locknut (2) onto 4SOL solenoid valve (3). 2 Install 304 junction box (4) and electrical conduit locknut (5) onto pipe nipple (1).

5-84

TM 9-4940-531-14

INSTALLATION OF COIL OUTLET ASSEMBLY AND OUTLET AND WATER DRAIN ASSEMBLY

1 Install coil outlet assembly (1) onto steam outlet support assembly (2) with pipe support (3), U-bolt (4), two new lockwashers (5), and two nuts (6).

2 Install steam outlet support assembly (2) with attached parts onto coil unit assembly (7) and platform skid (8) with machine bolt (9), flat washer (10), new self-locking nut (11), two capscrews (12), and two new self-locking nuts (13). 3 Install halves of pipe union (14) on coil outlet assembly (1) and coil unit assembly (7). Install coil outlet assembly (1) to coil unit assembly (7). Couple pipe union (14). 4 Install blowdown assembly (15) onto fuel shutoff bracket (16) with U-bolt (17) and two new selfIocking nuts (18).

5-85

TM 9-4940-531-14 5-9. STEAM CLEANER (COIL OUTLET ASSEMBLY AND OUTLET AND WATER DRAIN ASSEMBLY)—MAINTENANCE INSTRUCTIONS (cont) INSTALLATION OF COIL OUTLET ASSEMBLY AND OUTLET AND WATER DRAIN ASSEMBLY (cont)

5-86

TM 9-4940-531-14

5 Connect conduit assembly no.208 (19) to 304 junction box (20) with conduit connector Iocknut (21). 6 Connect two wires no. 59 and 81 (22 and 23) to 7 SOL solenoid valve (24) with two new conductor splices (25). Connect conduit assembly no. 217 (26) to 7SOL solenoid valve (24). 7 Install conduit assembly no. 217 (26) to 304 junction box (20) with conduit connector locknut (27). 8 Connect three wires No. 58, 59, and 136 (28, 22, and 29) to 4SOL solenoid valve (30) with two new conductor splices (31 and 32). 9 Install cover (33) onto 304 junction box (20) with two screws (34).

10 Install conduit assembly no. 208 (19) onto control box assembly (35) with conduit connector locknut (36). 11 Connect three wires no. 58, 59, and 136 to control box assembly (35).

5-87

TM 9-4940-531-14 5-9. STEAM CLEANER (COIL OUTLET ASSEMBLY AND OUTLET AND WATER DRAIN ASSEMBLY)—MAINTENANCE INSTRUCTIONS (cont) INSTALLATION OF COIL OUTLET ASSEMBLY AND OUTLET AND WATER DRAIN ASSEMBLY (cont)

12

Connect two wires no. 12 and 13 (37 and 38) to 2SOL solenoid valve (39) with two new conductor splices (40). Install conduit assembly no. 211 (41).

13

Install conduit assembly no. 211 (41) onto control box assembly (35) with conduit connector Iocknut (42).

5-88

TM 9-4940-531-14

14 Connect two wires no. 12 and 13 to control box assembly (35). 15 Connect two wires no. 91 and 139 (43 and 44) to S5 flow switch (45) with two new conductor splices (46). Connect conduit assembly no. 207 (47). 16 Install conduit assembly no. 207 (47) onto control box assembly (35) with conduit connector locknut (48). 17

Connect two wires no. 91 and 139 to control box assembly (35).

18 Install halves of pipe union (49) on coil inlet control-to-blowdown hose assembly (50) and coil inlet control assembly (51). Install coil inlet control-to-blowdown hose assembly (50) onto blowdown assembly (15) and coil inlet control assembly (51). Couple pipe union (49). 19 Connect coil outlet-to-outlet pressure gauge tubing assembly (52), coil outlet-to-pressure switch tubing assembly (53), and coil outlet-to-differential pressure switch tubing assembly (54) to coil outlet assembly (1).

5-89

TM 9-4940-531-14 5-10. STEAM CLEANER (FUEL TANK ASSEMBLY AND COIL UNIT ASSEMBLY)MAINTENANCE INSTRUCTIONS THIS TASK COVERS: Removal of fuel tank assembly and coil unit assembly a. b. Inspection/repair Installation of fuel tank assembly and coil unit assembly c. INITIAL SETUP Tools and Special Tools General mechanic’s tool kit (item 2, appx B) Electric repair shop equipment (item 1, appx B) Materials/Parts Conductor splice (9) (M7928/5-4) Conductor splice (3) (11024917) Self-locking nut (4) (MS51922-17) Self-locking nut (4) (MS51988-7) Tapping screw (6) (MS51869-12) Equipment Conditions Steam cleaner shut down (para 2-6) and power source removed Oil burner assembly removed (para 4-14) Lower control panel assembly removed (para 4-19) Enclosure and lift assembly removed (para 5-4) Pressure gauge assembly removed (para 5-5) Control box assembly and conduit assemblies removed (para 5-6) PS1, PS2, and PS3 pressure switches removed (para 5-7) Coil inlet assembly removed (para 5-8) Coil outlet assembly removed (para 5-9) Liquid storage tank removed (para 4-13) Pump inlet assembly removed (para 4-15) Water inlet assembly removed (para 4-15) Outlet and water drain assembly removed (para 5-9) Hoses removed (para 4-13)

5-90

TM 9-4940-531-14

NOTE Be sure wires are tagged and labeled before removal. REMOVAL OF FUEL TANK ASSEMBLY AND COIL UNIT ASSEMBLY 1

Loosen two screws (1) and remove cover (2) from 303 junction box (3).

2

Remove two conductor splices (4) and disconnect two wires no. 122 and 123 (5 and 6) from S4 liquid level switch (7). Loosen conduit connector locknut (8) and disconnect conduit assembly no. 215 (9).

3

Remove conduit assembly no. 215 (9) from 9SOL solenoid valve (10). Remove two conductor splices (11) and disconnect two wires no. 121 and 122 (12 and 5).

4

Remove two conduit connector locknuts (8 and 13), conduit assembly no. 205 (14), and four wires no. 23, 26, 121, and 123 (15, 16, 12 and 6).

5-91

TM 9-4940-531-14 5-10. STEAM CLEANER (FUEL TANK ASSEMBLY AND COIL UNIT ASSEMBLY)— MAINTENANCE INSTRUCTIONS (cont) REMOVAL OF FUEL TANK ASSEMBLY AND COIL UNIT ASSEMBLY (cont)

5 Remove conduit assembly no. 203 (17), two conductor splices (18), and two wires no. 9 and 50 (19 and 20) from 6SOL solenoid valve (21). 6 Remove conduit assembly no. 201 (22), two conductor splices (23), and two wires no. 1 and 2 (24 and 25) from 5SOL solenoid valve (26). 5-92

TM 9-4940-531-14

7 Remove two machine screws (27) and cover (28) from 302 junction box (29). 8 Remove two conductor splices (30 and 31) and disconnect three wires no. 28, 29, and 82 (32, 33, and 34) from PS5 pressure switch (35). 9 Loosen conduit connector locknut (36). Disconnect conduit assembly no. 214 (37) from 302 junction box (29). 10 Remove conduit assembly no. 214 (37) from FS1 flow switch (38). Remove two conductor splices (39). Disconnect wire no. 87 (40) and remove wire no. 82 (34). 11 Remove two conduit connector locknuts (36 and 41), conduit assembly no. 204 (42) and three wires no. 28, 29 and 87 (32, 33, and 40) from 302 junction box (29).

5-93

TM 9-4940-531-14

5-10. STEAM CLEANER (FUEL TANK ASSEMBLY AND COIL UNIT ASSEMBLY)MAINTENANCE INSTRUCTIONS (cont) REMOVAL OF FUEL TANK ASSEMBLY AND COIL UNIT ASSEMBLY (cont)

12 Remove four self-locking nuts (43), four capscrews (44), four flat washers (45), and fuel tank assembly (46) from platform skid (47). 13 Remove six tapping screws (48) and chemical holder weldment (49) from coil unit assembly (50). 14 Remove four self-locking nuts (51), four flat washers (52), four capscrews (53), four recessed washers (54), and coil unit assembly (50) from platform skid (47). INSPECTION/REPAIR 1 Check for broken, damaged, or missing parts. 2 Repair is by replacement of damaged or unserviceable parts. 3 Fuel tank assembly is a repairable assembly, refer to paragraph 5-15. 4 Coil unit assembly is a repairable assembly, refer to paragraph 5-29.

5-94

TM 9-4940-531-14 INSTALLATION OF FUEL TANK ASSEMBLY AND COIL UNIT ASSEMBLY

1 Install coil unit assembly (1) onto platform skid (2) with four recessed washers (3), four capscrews (4), four flat washers (5), and four new self-locking nuts (6). 2 Install chemical holder weldment (7) onto coil unit assembly (1) with six new tapping screws (8). 3 Install fuel tank assembly (9) onto platform skid (2) with four flat washers (10), four capscrews (11), and four new self-locking nuts (12).

5-95

TM 9-4940-531-14 5-10. STEAM CLEANER (FUEL TANK ASSEMBLY AND COIL UNIT ASSEMBLY)MAINTENANCE INSTRUCTIONS (cont) INSTALLATION OF FUEL TANK ASSEMBLY AND COIL UNIT ASSEMBLY (cont)

4 Connect two wires no. 82 and 87 (13 and 14) to FS1 flow switch (15) with two new conductor splices (16). Connect conduit assembly no. 214 (17). 5 Connect conduit assembly no. 214 (17) to 302 junction box (18) with conduit connector locknut (19). 6 Install conduit assembly no. 204 (20) onto 302 junction box (18) with conduit connector locknut (21 ). 7 Connect three wires no. 28, 29, and 82 (22, 23, and 13) to PS5 pressure switch (24) with two new conductor splices (25 and 26). 8 Install cover (27) onto 302 junction box(18) with two machine screws (28).

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TM 9-4940-531-14

9 Connect two wires no. 9 and 50 (29 and 30) to 6SOL solenoid valve (31) with two new conductor splices (32). Connect conduit assembly no. 203 (33). 10 Connect two wires no. 1 and 2 (34 and 35) onto 5SOL solenoid valve (36) with two new conductor splices (37). Connect conduit assembly no. 201 (38).

5-97

TM 9-4940-531-14 5-10. STEAM CLEANER (FUEL TANK ASSEMBLY AND COIL UNIT ASSEMBLY)MAINTENANCE INSTRUCTIONS (cont) INSTALLATION OF FUEL TANK ASSEMBLY AND COIL UNIT ASSEMBLY (cont)

11 Connect two wires no. 121 and 122 (39 and 40) to 9SOL solenoid valve (41) with two new conductor splices (42). Connect conduitassembly (no. 215 (43).

5-98

TM 9-4940-531-14

12 Install conduit assembly no. 215 (43) onto 303 junction box (44) with conduit connector locknut (45). 13 Connect conduit assembly no. 205 (46) with conduit connector locknut (47). Install four wires no. 23, 26, 122, and 123 (48, 49, 40, and 50) into conduit assembly no. 205 (46). Connect two wires no. 122 and 123 (40 and 50) to S4 liquid level switch (51) with two new conductor splices (52). 14 Install cover (53) onto 303 junction box (44). Tighten two screws (54). 5-99

TM 9-4940-531-14 5-11.

COIL

INLET

ASSEMBLY—MAINTENANCE

INSTRUCTIONS

THIS TASK COVERS a. Disassembly

b. Inspection/repair

INITIAL SETUP Tools and Special Tools Crescent wrench, 12-in. (item 1, appx B) Crescent wrench, 14-in. (item 1, appx B) General mechanic’s tool kit (item 2, appx B) Electric repair shop equipment (item 1, appx B) Materials/Parts Antiseizing tape (item 24, appx E) Equipment Conditions Coil inlet assembly removed (para 5-8) Coil inlet hose removed (para 4-13)

5-100

c. Reassembly

TM 9-4940-531-14 DISASSEMBLY 1

Remove pipe elbow (1), pipe nipple (2), and pipe elbow (3) from pipe nipple (4).

2

Remove check valve (5) and two pipe nipples (4 and 6).

3

Uncouple pipe union (7).

4

Remove pipe bushing (8), pipe union half (9), pipe nipple (10), pipe union half (11), and pipe nipple (12) from pipe tee (13).

5

Remove pipe union half (14), pipe nipple (15), pipe union half (16), pipe tee (17), and two pipe nipples (18 and 19).

6

Uncouple pipe union (20).

7

Remove pipe tee (21), pipe nipple (22), pipe bushing (23), pipe tee (24), pipe nipple (25), pipe union half (26), and pipe nippIe (27) from pipe elbow (28).

8

Remove pipe union half (29), pipe bushing (30), pipe nipple (31), pipe nipple (32), and straight adapter (33) from solenoid valve (34).

lNSPECTION/REPAIR 1 Check for broken, damaged, or missing parts. 2 Repair is by replacement of damaged or unserviceable parts. REASSEMBLY 1 Apply antiseizing tape (item 24, appx E) to all fittings. 2 Install straight adapter (33), pipe nipple (32), pipe nipple (31), pipe bushing (30), and pipe union half (29) onto solenoid valve (34). 3 Install pipe union half (26), pipe nipple (27), pipe elbow (28), pipe nipple (25), pipe tee (24), pipe bushing (23), pipe nipple (22), and pipe tee (21). Couple pipe union (20). 4 Install pipe nipple (19), pipe tee (17), two pipe nipples (15 and 18), and two pipe union halves (14 and 16). 5 Install pipe union half (11), pipe nipple (12), pipe tee (13), pipe nipple (10), pipe union half (9), and pipe bushing (8). Couple pipe union (7). 6 Install pipe nipple (6), check valve (5), and pipe nipple (4). 7 Install pipe elbow (3), pipe nipple (2), and pipe elbow (1).

5-101

TM 9-4940-531-14 5-12.

COIL

OUTLET

ASSEMBLY—MAINTENANCE

THIS TASK COVERS: Disassembly a. b. Inspection/repair Reassembly c. d. Adjustment of pressure regulating valves INITIAL SETUP Tools and Special Tools Crescent wrench, 12-in. (item 1, appx B) Crescent wrench, 14-in. (item 1, appx B) General mechanic’s tool kit (item 2, appx B) Electric repair shop equipment (item 1, appx B) Materials/Parts Antiseizing tape (item 24, appx E) Equipment Conditions Coil outlet assembly removed (para 5-9) Hose assemblies removed (para 4-13)

DISASSEMBLY

1 Remove blowdown assembly (1) from pipe adapter (2).

5-102

INSTRUCTIONS

TM 9-4940-531-14

CAUTION To prevent damage to equipment, do not tamper with pressure settings of regulating valves. If adjustment is necessary, refer to adjustment procedure below. 2

Uncouple pipe union (3). Remove pipe union half (4) and pipe nipple (5) from 600 psi (41 37 kPa) regulating valve (6). Remove pipe plug (7), straight adapter (8), and pipe elbow (9) from 600 psi (4137 kPa) regulating valve (6). -

3 Remove pipe union half (10) and pipe nipple (11) from pipe tee (12).

4

Uncouple pipe union (13).

5 Remove pipe union half (14), pipe elbow (15), pipe nipple (16), 7SOL water solenoid valve (17), pipe nipple (18), pipe plug (19), straight adapter (20), pipe elbow (21), and pipe nipple (22) from 400 psi (2758 kPa) regulating valve (23). 6 Remove pipe union half (24) and pipe nipple (25) from pipe tee (26).

5-103

TM 9-4940-531-14 5-12. COIL OUTLET ASSEMBLY—MAINTENANCE INSTRUCTIONS (cont) DISASSEMBLY (cont)

7 Remove pipe tee (27), pipe nipple (28), pipe tee (29), pipe nipple (30), and pipe bushing (31) from pipe tee (32). 8 Remove pipe nipple (33), pipe tee (26), pipe nipple (34), pipe tee (12), pipe nipple (35), and pipe tee (32) from pipe adapter (2). INSPECTION/REPAIR 1 Check for broken, damaged, or missing parts. 2 Repair is by replacement of damaged or unserviceable parts. 3 Blowdown assembly is a repairable assembly. Refer to paragraph 5-13.

1 Apply antiseizing tape (item 24, appx E) to all fittings. 2 Install pipe tee (1), pipe nipple (2), pipe tee (3), pipe nipple (4), pipe tee (5), and pipe nipple (6) onto pipe adapter (7). 3 Install pipe bushing (8), pipe nipple (9), pipe tee (10), pipe nipple (11), and pipe tee(12) onto pipe tee (1). 5-104

TM 9-4940-531-14

4

Install pipe nipple (13) and pipe union half (14) onto pipe tee (5) CAUTION To prevent damage to equipment, do not tamper with pressure settings on regulating valves. If adjustment is necessary, refer to adjustment procedure below.

5

Install pipe nipple (15), pipe elbow (16), straight adapter (17), and pipe plug (18) onto 400 psi (2758 kPa) regulating valve (19). Install pipe nipple (20), 7SOL water solenoid valve (21), pipe nipple (22), pipe elbow (23), and pipe union half (24) onto 400 psi (2738 kPa) regulating valve (19).

6

Couple pipe union (25).

7

Install pipe nipple (26) and pipe union half (27) onto pipe tee (3).

8

Install pipe elbow (28), straight adapter (29), and pipe plug (30) onto 600 psi (4137 kPa) regulating valve (31). Install pipe nipple (32) and pipe union half (33) onto 600 psi (4137 kPa) regulating valve (31).

9

Couple pipe union (34).

5-105

TM 9-4940-531-14 5-12. COIL OUTLET ASSEMBLY—MAINTENANCE INSTRUCTIONS (cont) REASSEMBLY (cont)

10 Install blowdown assembly (35) onto pipe adapter (7).

ADJUSTMENT OF PRESSURE REGULATING VALVES

5-106

TM 9-4940-531-14

1 Install coil outlet assembly (para 5-9) and hose assembly (para 4-13). NOTE . This procedure requires two people. . Perform this procedure only after replacing a defective coil outlet assembly regulating valve or if OUTLET PRESSURE gauge (1) displays reading above normal pressure limits (para 2-6). 2 After initial startup procedure (para 2-5), install appropriate nozzle for mode selected and secure cleaning gun trigger (2) in the open position. 3 Adjust regulating valves in the following order: a. Set regulating valve (3) to 650 psi; set regulating valve (4) to 450 psi. b. Set regulating valve (5) to 600 psi; set regulating valve (6) to 400 psi. c. Set regulating valve (3) to 500 psi; set regulating valve (4) to 300 psi. 4 When adjustment is complete, release steam cleaning gun trigger (2).

5-13. BLOWDOWN ASSEMBLY AND VALVE AND SWITCH ASSEMBLY-MAINTENANCE INSTRUCTIONS THIS TASK COVERS: a. Disassembly

b. Inspection/cleaning/repair

c. Reassembly

INITIAL SETUP Tools and Special Tools Crescent wrench, 12-in. (item 1, appx B) Crescent wrench, 14-in. (item 1, appx B) General mechanic’s tool kit (item 2, appx B) Electric repair shop equipment (item 1, appx B) Materials/Parts Antiseizing tape (item 24, appx E) Gasket (1 1025019) Equipment Conditions Blowdown assembly removed (para 5-12) Drain hose and clamp removed (para 4-13) 5-107

TM 9-4940-531-14 5-13. BLOWDOWN ASSEMBLY AND VALVE AND SWITCH ASSEMBLY—MAINTENANCE INSTRUCTIONS (cont)

1

Remove pipe elbow (1), drain pipe (2), and pipe elbow (3) from valve and switch assembly (4).

2

Remove straight adapter (5) from 2SOL solenoid valve (6).

3

Uncouple pipe union (7) and remove 2SOL solenoid valve (6) with attached parts.

4

Remove pipe elbow (8), pipe union half (9), two pipe nipples (10 and 11), and two bushing adapters (12 and 13) from 2SOL solenoid valve (6).

5

Remove pipe union half (14) and pipe nipple (15) from S5 flow switch (16).

6

Remove S5 flow switch (16) and straight pin (17) from fluid regulating valve (18).

7

Remove fluid regulating valve (18), ball (19), valve seat (20), and gasket (21) from metal pipe assembly (22).

5-108

TM 9-4940-531-14 lNSPECTION/CLEANING/REPAIR 1 Check for broken, damaged, or missing parts. 2 Separate fluid regulating valve and remove any foreign matter. Rinse components and reassemble fluid regulating valve. 3 Repair is by replacement of damaged or unserviceable parts. REASSEMBLY 1 Apply antiseizing tape (item 24, appx E) to all pipe fittings. 2 Install new gasket (21), valve seat (20), ball (19), and fluid regulating valve (18) onto metal pipe assembly (22). 3 Install straight pin (17) and S5 flow switch (16) onto fluid regulating valve (18). 4 Install pipe nipple (15) and pipe union half (14) onto S5 flow switch (16). 5 Install two bushing adapters (13 and 12), two pipe nipples (11 and 10), pipe elbow (8), and pipe union half (9) onto 2SOL solenoid valve (6). 6 Install 2SOL solenoid valve (6) with attached parts to pipe union half (14). 7 Couple pipe union (7). 8 Install straight adapter (5) onto 2SOL solenoid valve (6). NOTE Pipe elbow (1) must point toward front of steam cleaner. 9 Install pipe elbow (3), drain pipe (2), and pipe elbow (1) onto valve and switch assembly (4).

5-109

TM 9-4940-531-14 5-14. ATOMIZING VAPORIZING OIL BURNER—MAINTENANCE INSTRUCTIONS THIS TASK COVERS: a. b. c. d.

Disassembly Inspection/repair Reassembly Electrode adjustment and replacement

INITIAL SETUP Tools and Special Tools General mechanic’s tool kit (item 2, appx B) Electric repair shop equipment (item 1, appx B) Materials/Parts Antiseizing tape (item 24, appx E) Tapping screw (3) (MS51851-106) Tapping screw (2) (MS51869-15) Equipment Conditions Atomizing vaporizing oil burner removed (para 4-14) Steam cleaner assembled and operational to perform electrode adjustment and replacement DISASSEMBLY

NOTE Be sure all wires are tagged and labeled before removal. 1

Remove two screws (1) and disconnect two wires (2) from terminals F and F of electromagnet relay (3). Remove two screws (4) and disconnect wire no. 49 (5) from terminals T and T. Reinstall four screws (1 and 4).

2

Remove tapping screw (6) and retaining strap (7) from blower housing (8).

3

Swing power transformer (9) open and remove thermal resistor (10) which houses cad cell (11).

5-110

TM 9-4940-531-14

4

Loosen two screws (12) and separate electromagnet relay (3).

5

Remove conductor splice (13) and disconnect orange wire (14).

6

Remove top half (15) of electromagnet relay.

7

Remove two tapping screws (16) and electromagnet relay junction box (17).

8

Remove two tapping screws (18) and power transformer (9).

9

Disconnect fuel solenoid valve-to-oil burner conduit (19) from blower housing (8).

10

If necessary for replacement of electrodes and/or oil burner nozzle, remove fuel pumpto-oil burner tubing assembly (20) and nut (21), loosen screw (22), slide plate (23), and remove burner assembly (24). Remove two electrodes (25 and 26) and oil burner nozzle (27) from burner assembly (24).

5-111

TM 9-4940-531-14 5-14. ATOMIZING VAPORIZING OIL BURNER—MAINTENANCE INSTRUCTIONS (cont) DISASSEMBLY (cont)

11 Remove feed-through bolt (28), 8SOL solenoid valve (29), and washer (30) from fuel pump (31).

12 Remove two machine bolts (32) and fuel pump (33) from blower housing (8). 13 Remove two machine bolts (34) and motor (35). 14 Loosen setscrew (36) and remove burner fan (37) from motor (35).

5-112

TM 9-4940-531-14 INSPECTION/REPAIR 1 Check for broken, damaged, or missing parts. 2 Repair is by replacement of damaged or unserviceable parts. 3 If blower housing is unserviceable, order a new atomizing vaporizing oil burner. REASSEMBLY

1 Apply antiseizing tape (item 24, appx E) to threads of all pipe fittings. 2 If removed, install burner fan (1) onto motor shaft (2) and tighten setscrew (3). 3 Install motor (4) onto blower housing (5) with two machine bolts (6). 4 Insert fuel pump shaft (7) into burner fan coupling (8) and secure fuel pump (9) to blower housing (5) with two machine bolts (10).

5-113

TM 9-4940-531-14 5-14.

ATOMIZING

VAPORIZING

OIL

BURNER—MAINTENANCE INSTRUCTIONS (cont)

REASSEMBLY (cont)

5 Install washer (11) and 8SOL solenoid valve (12) onto fuel pump (9) with feedthrough bolt (13).

6

If removed, install oil burner nozzle (14) and two electrodes (15 and 16) onto burner assembly (17). Check electrode dimensions; refer to steps 6 and 7 of electrode adjustment and replacement procedure.

7

Install burner assembly (17), adjust plate (18), tighten screw (19), and install nut (20). Install fuel pump-to-oil burner tubing assembly (21).

8

Connect fuel solenoid valve-to-oil burner conduit (22) onto blower housing (5).

9

Install power transformer (23) with two new tapping screws (24).

10

Install electromagnet relay junction box (25) with two new tapping screws (26).

5-114

TM 9-4940-531-14

11

Connect orange wire (27) from electromagnet relay (28) and red wire (29) from 8SOL solenoid valve (12) with conductor splice (30).

12

Position top half (31) of electromagnet relay (28) onto junction box (25) and secure with two screws (32).

13

Secure bracket of thermal resistor (33) onto power transformer (23).

14

Close power transformer (23). Install retaining strap (34) onto blower housing (35) with new tapping screw (36).

15

Remove four screws (37 and 38). Connect wire no. 49 (39) onto terminals T and T of electromagnet relay (28) with two screws (37). Connect two wires (37) onto terminals F and F with two screws (38).

5-115

TM 9-4940-531-14 5-14. ATOMIZING VAPORIZING OIL BURNER—MAINTENANCE INSTRUCTIONS (cont) ELECTRODE ADJUSTMENT AND REPLACEMENT

1 Turn two fuel shutoff assembly cocks (1) to CLOSED position. 2 Disconnect fuel pump-to-oil burner tubing assembly (2). Plug tubing assembly to prevent fuel from draining.

3 Remove tapping screw (3) and move retaining strap (4). Swing power transformer (5) back on the hinges, exposing burner assembly (6). 4 Remove nut (7). Loosen screw (8), slide plate (9), and remove burner assembly (6). 5-116

TM 9-4940-531-14

5 Check that oil burner electrodes (10) correspond to dimensions shown. 6 If electrodes (10) need adjustment, loosen two screws (11) and slide electrodes in appropriate direction until a 1/8-in. (0.32-cm) gap exists between two electrodes. Tighten two screws (11) and measure gap. Repeat procedure if tolerance has been lost. 7 If electrodes (10) need replacement, remove two screws (11) and two electrodes (10). Adjust new electrodes to 1/8-in. (0.32-cm) dimension.

8 Install burner assembly (6), adjust plate (9), tighten screw (8), and install nut (7). 9 Close power transformer (5), secure with retaining strap (4), and tighten tapping screw (3).

5-117

TM 9-4940-531-14

1

Uncouple pipe union (1) and remove nonmetallic hose assembly (2) from water pump assembly (3) and coil inlet control assembly (4). Remove pipe union (1) halves from nonmetallic hose assembly (2) and water pump assembly (3).

2

Remove four capscrews (5) and coil inlet control assembly (4) from saddle and fuel tank weldment (6).

3

Remove four self-locking nuts (7), two Vbelts (8), and motor assembly (9).

4 Remove two hose clamps (10) and nonmetallic hose (11) from water pump assembly (3) and oil drain assembly (12). 5 Remove two self-locking nuts (13), two machine bolts (14), and oil drain assembly (12) from saddle and fuel tank weldment (6). 6 Remove four self-locking nuts (15) and water pump assembly (3).

5-119

TM 9-4940-531-14 5-15. FUEL TANK ASSEMBLY—MAINTENANCE INSTRUCTIONS (cont)

DISASSEMBLY (cont)

7

Remove self-locking nut (16), two capscrews (17), and lift water tank assembly (18) from saddle and fuel tank weldment (6).

8

Remove hose clamp (19) and disconnect suction inlet-to-water tank hose (20) from straight pipe adapter (21). Remove water tank assembly (18).

9

Remove suction inlet assembly (22).

10

Remove two self-locking nuts (23), two capscrews (24), pipe coupling (25), straight pipe adapter (21), and elbow (26).

11

Remove two straight adapters (27) and two pipe elbows (28).

INSPECTION/REPAIR 1 Inspect for broken, damaged, or missing parts. 2 Repair is by replacement of damaged or unserviceable parts. 3 The suction inlet assembly is a repairable assembly, refer to paragraph 5-16 5-120

TM 9-4940-531-14

4 The water tank assembly is a repairable assembly, refer to paragraph 5-17. 5 The water pump assembly is a repairable assembly, refer to paragraph 5-18. 6 The motor assembly is a repairable assembly, refer to paragraph 5-19. 7 The coil inlet control assembly is a repairable assembly, refer to paragraph 5-20. REASSEMBLY

1

Wrap all pipe threads with antiseizing tape (item 24, appx E).

2

Install two pipe elbows (1) and two straight adapters (2) onto saddle and fuel tank weldment (3).

3

Install elbow (4) and straight adapter (5) on pipe coupling (6). Install pipe coupling (6) with two capscrews (7) and two new self-locking nuts (8).

4

Install suction inlet assembly (9).

5

Position water tank assembly (10) on saddle and fuel tank weldment (3). Install suction inlet-towater tank hose (11) onto straight pipe adapter (5) with hose clamp (12).

6

Install water tank assembly (10) onto saddle and fuel tank weldment (3) with two capscrews (13) and new self-locking nut (14). 5-121

TM 9-4940-531-14 5-15. FUEL TANK ASSEMBLY—MAINTENANCE INSTRUCTIONS (cont) REASSEMBLY (cont)

7

Install water pump assembly (15) with four new self-locking nuts (16).

8

Install oil drain assembly (17) with two machine bolts (18) and two new self-locking nuts (19).

9

Install nonmetallic hose (20) onto oil drain assembly (17) and water pump assembly (15) with two hose clamps (21).

10

Install motor assembly (22) and two V-belts (23) and secure with four new self-locking nuts (24).

11

Install coil inlet control assembly (25) with four capscrews (26).

12

Install pipe union (27) halves onto water pump assembly (15) and nonmetallic hose assembly (28). Couple pipe union (27). Install nonmetallic hose assembly (28) onto coil inlet control assembly (25).

5-122

TM 9-4940-531-14 5-16. SUCTION INLET ASSEMBLY—MAINTENANCE INSTRUCTIONS THIS TASK COVERS: a. Disassembly

b. Inspection/repair

c. Reassembly

INITIAL SETUP Tools and Special Tools Crescent wrench, 12-in. (item 1, appx B) Crescent wrench, 14-in. (item 1, appx B) General mechanic’s tool kit (item 2, appx B) Electric repair shop equipment (item 1, appx B) Materials/Parts Antiseizing tape (item 24, appx E) Equipment Conditions Suction inlet assembly removed (para 5-15) DISASSEMBLY 1 Remove nipple (1), 45-degree elbow (2), and nipple (3) from ball valve (4). 2 Uncouple pipe union (5). Remove pipe union (5) halves from pipe nipple (6) and hose assembly (7). Remove pipe nipple (6), elbow (8), and nipple (9) from ball valve (4). 3 If damaged, remove identification marker (10) from ball valve (4). INSPECTION/REPAIR 1 Check for broken, damaged, or missing parts. 2 Repair is by replacement of damaged or unserviceable parts. REASSEMBLY 1 Apply antiseizing tape (item 24, appx E) to all pipe fittings. 2 If removed, install new identification marker (10) on ball valve (4). 3 Install nipple (9), elbow (8), and pipe nipple (6) on ball valve (4). Install pipe union (5) halves on pipe nipple (6) and hose assembly (7). Couple pipe union (5). 4 Install nipple (3), 45-degree elbow (2), and nipple (1) on ball valve (4). 5-123

TM 9-4940-531-14 5-17. WATER TANK ASSEMBLY—MAINTENANCE INSTRUCTIONS THIS TASK COVERS: a. Disassembly

b. Inspection/cleaning/repair

c. Reassembly

INITIAL SETUP Tools and Special Tools General mechanic’s tool kit (item 2, appx B) Electric repair shop equipment (item 1, appx B) Materials/Parts Antiseizing tape (item 24, appx E) Equipment Conditions Water tank assembly removed (para 5-15)

DISASSEMBLY 1 Remove hose clamp (1), suction inlet-to-water tank hose (2), straight adapter (3), and pipe elbow (4) from water tank (5). 2 Remove straight adapter (6), pipe elbow (7), 9SOL solenoid valve (8), pipe nipple (9), pipe nipple (10), and two pipe elbows (11) from water tank (5). 3 If present, remove two screws (12) and junction box cover (13). 4 Remove locknut (14), junction box (15), locknut (16), and S4 liquid level switch (17) from water tank (5). 5 Remove strainer element (18) from water tank (5). INSPECTION/CLEANING/REPAIR 1 Check for broken, damaged, or missing parts. 2 Clean strainer element by tapping gently on a hard surface and/or rinsing in clean water. 3 Repair is by replacement of damaged or unserviceable parts.

5-124

TM 9-4940-531-14

1 Wrap all pipe fittings with antiseizing tape (item 24, appx E). 2 Press strainer element (18) into well of water tank (5), centering over tank outlet. 3 Install S4 liquid level switch (17), locknut (16), junction box (15), and locknut (14) onto water tank (5). 4 Install junction box cover (13) onto junction box (15) with two screws (12). 5 Install two pipe elbows (11), pipe nipple (10), pipe nipple (9), 9SOL solenoid valve (8), pipe elbow (7), and straight adapter (6) onto water tank (5). 6 Install pipe elbow (4) and straight adapter (3) onto water tank (5). install suction inlet-to-water tank hose (2) onto straight adapter (3) with hose clamp (1).

5-125

TM 9-4940-531-14 5-18. WATER PUMP ASSEMBLY—MAINTENANCE INSTRUCTIONS THIS TASK COVERS: a. Disassembly

b. Inspection/repair

c. Reassembly

INITIAL SETUP Tools and Special Tools Crescent wrench, 12-in. (item 1, appx B) Crescent wrench, 14-in. (item 1, appx B) General mechanic’s tool kit (item 2, appx B) Electric repair shop equipment (item 1, appx B) Pulley puller (item 1, appx B) Materials/Parts Antiseizing tape (item 24, appx E) Gasket (MS27030-2) References TM 9-4940-531-24P Equipment Conditions Water pump assembly removed (para 5-15)

1

Uncouple pipe union (1). Remove four straight adapters (2). Remove pipe elbow (3), pipe tee (4), pipe nipple (5), pipe tee (6), pipe nipple (7), pipe tee (8), and pipe nipple (9) from pipe union half (10).

2

Remove two straight adapters (11), two pipe elbows (12), pipe union half (13), and pipe nipple (14) from reciprocating pump (15).

3

Remove hose elbow (16), pipe union half (17), pipe nipple (18), tee (19), and pipe nipple (20) from pipe tee (21).

4

Remove coupler cap (22), gasket (23), male coupler (24), pipe tee (21), nipple (25), pipe elbow (26), and pipe nipple (27) from reciprocating pump (15).

5

Remove two screws (28) and cap (29) from pulley (30).

6

Remove pulley (30) and machine key (31) from reciprocating pump (15).

7

Remove two pipe plugs (32) from reciprocating pump (15).

INSPECTION/REPAIR 1 Check for broken, damaged, or missing parts. 2 Repair is by replacement of damaged or unserviceable parts. 3 Refer to paragraph 4-1 for oil change procedure. 4 Reciprocating pump can be reconditioned. Refer to TM 9-4940-531-24P to order seal kit (an instruction sheet is included). 5-126

TM 9-4940-531-14

REASSEMBLY 1

Wrap all pipe threads with antiseizing tape (item 24, appx E).

2

Install two pipe plugs (32) onto reciprocating pump (15).

3

Install pulley (30) and machine key (31) on reciprocating pump (15).

4

Install cap (29) onto pulley (30) with two screws (28).

5

Install pipe nipple (27), pipe elbow (26), nipple (25), pipe tee (21), male coupler (24), new gasket (23), and coupler cap (22).

6

Install pipe nipple (20), tee (19), pipe nipple (18), pipe union half (17), and hose elbow (16) on pipe tee (21).

7

Install pipe nipple (14), pipe union half (13), two pipe elbows (12), and two straight adapters (11) on reciprocating pump (15).

8

Install pipe nipple (9), pipe tee (8), pipe nipple (7), pipe tee (6), pipe nipple (5), pipe tee (4), pipe elbow (3), and four straight adapters (2) onto pipe union half (10). Couple pipe union (1).

5-127

TM 9-4940-531-14 5-19. MOTOR ASSEMBLY—MAINTENANCE INSTRUCTIONS THIS TASK COVERS: a. Disassembly

b. Inspection/cleaning/repair

INITIAL SETUP Tools and Special Tools General mechanic’s tool kit (item 2, appx B) Electric repair shop equipment (item 1, appx B) Pulley puller (item 1, appx B) Materials/Parts Wiping rag (item 18, appx E) Equipment Conditions Motor assembly removed (para 5-15)

DISASSEMBLY Loosen setscrew (1) and remove pulley (2) and machine key (3) from motor (4).

INSPECTION/CLEANING/REPAIR 1 Check for broken, damaged, or missing parts. 2 Remove all surface dirt with clean wiping rag (item 18, appx B). 3 Repair is by replacement of damaged or unserviceable parts.

REASSEMBLY Install machine key (3) and pulley (2) on motor (4). Tighten setscrew (1).

5-128

c. Reassembly

TM 9-4940-531-14

5-20. COIL INLET CONTROL ASSEMBLY—MAINTENANCE INSTRUCTIONS THIS TASK COVERS: Disassembly a. Inspection/repair b. Reassembly c. d. Adjustment of pressure regulating valves INITIAL SETUP Tools and Special Tools Crescent wrench, 12-in. (item 1, appx B) Crescent wrench, 14-in. (item 1, appx B) General mechanic’s tool kit (item 2, appx B) Electric repair shop equipment (item 1, appx B) Materials/Parts Antiseizing tape (item 24, appx E) Lockwasher (6) (MS35338-44) Tapping screw (4) (MS51861-65) Equipment Conditions Coil inlet control assembly removed (para 5-15)

NOTE Make sure all wires are tagged and labeled before removal. 1 If present, remove two machine screws (1), cover (2), two electrical locknuts (3), and junction box (4) from pressure switch (5). 2 Remove pressure switch (5), pipe bushing (6), pipe elbow (7), pipe coupling (8), and pipe bushing (9) from pipe tee (10).

5-129

TM 9-4940-531-14 5-20. COIL INLET CONTROL ASSEMBLY—MAINTENANCE INSTRUCTIONS (cont) DISASSEMBLY (cont)

3

Remove pipe tee (10), pipe nipple (11), and hydraulic accumulator (12) from pipe cross (13).

4

Remove pipe reducer (14), pipe nipple (15), flow switch (16), pipe nipple (17), and pipe bushing (18) from pipe cross (13).

5

Remove two nuts (19), two Iockwashers (20), U-bolt (21), and pipe support (22) from plumbing support assembly (23).

6

Remove pipe cross (13), pipe nipple (24), pipe elbow (25), and check valve (26) from pipe nipple (27).

7

Uncouple pipe union (28) from pipe nipple (29). Remove pipe union (28) halves from pipe nipple (29) and pipe nipple (30). Remove pipe nipple (30), solenoid valve (31), pipe nipple (32), and pipe elbow (33) from straight adapter (34).

5-130

TM 9-4940-531-14

CAUTION To prevent damage to equipment, do not tamper with pressure settings of regulating valves. If adjustment is necessary, refer to adjustment procedure below. 8 Uncouple pipe union (35). Remove pipe union (35) halves from two pipe nipples (36 and 37). Remove pipe nipple (36), straight adapter (38), pipe elbow (39), pipe elbow (40), pipe nipple (41), pipe elbow (42), and pipe nipple (43) from 500 psi (3448 kPa) regulating valve (44).

9

10

Remove two hex nuts (45), two Iockwashers (46), U-bolt plate (47), U-bolt (48), and pipe support (49). Uncouple pipe union (50). Remove pipe union (50) halves from pipe nipple (51) and pipe elbow (52). Remove pipe nipple (51), solenoid valve (53), pipe nipple (54), pipe plug (55), straight adapter (56), pipe elbow (57), and pipe nipple (58) from 300 psi (2069 kPa) regulating valve (59).

5-131

TM 9-4940-531-14 5-20. COIL INLET CONTROL ASSEMBLY—MAINTENANCE INSTRUCTIONS (cent) DISASSEMBLY (cont)

11

Remove pipe elbow (52) and pipe nipple (60) from pipe cross (61).

12 Remove pipe elbow (62), pipe nipple (63), pipe elbow (64), pipe nipple (65), vent valve (66), pipe nipple (67), pipe bushing (68), and pipe elbow (69) from pipe cross (61). 13 Remove two hex nuts (70), two Iockwashers (71), U-bolt plate (72), and U-bolt (73). 14 Remove three pipe nipples (37, 27, and 29), pipe tee (74), and pipe nipple (75) from pipe cross (61). 15 Remove four tapping screws (76) and two support plates (77) from plumbing support assembly (23). lNSPECTION/REPAIR 1 Check for broken, damaged, or missing parts. 2 Repair is by replacement of damaged or unserviceable parts.

5-132

TM 9-4940-531-14

1

Wrap all pipe threads with antiseizing tape (item 24, appx E).

2

Install two support plates (1) onto plumbing support assembly (2) with four new tapping screws (3).

3

Install two pipe nipples (4 and 5) onto pipe tee (6). Install two pipe nipples (7 and 8) and pipe tee (6) onto pipe cross (9).

4

Secure pipe cross (9) onto plumbing support assembly (2) with U-bolt plate (10), U-bolt (11), two new Iockwashers (12), and two hex nuts (13).

5

Install pipe elbow (14), pipe bushing (15), pipe nipple (16), vent valve (17), pipe nipple (18), pipe elbow (19), pipe nipple (20), and pipe elbow (21) onto pipe cross (9).

6

Install pipe nipple (22) and pipe elbow (23) onto pipe cross (9).

5-133

TM 9-4940-531-14 5-20. COIL INLET CONTROL ASSEMBLY—MAINTENANCE INSTRUCTIONS (cont) REASSEMBLY (cont)

CAUTION To prevent damage to equipment, do not tamper with pressure settings of regulating valves. If adjustment is necessary, refer to adjustment procedure below. 7

Install pipe union (24) halves onto pipe nipple (25) and pipe elbow (23). Assemble pipe nipple (25), solenoid valve (26), pipe nipple (27), 300 psi (2069 kPa) regulating valve (28), pipe plug (29), pipe nipple (30), pipe elbow (31), and straight adapter (32). Couple pipe union (24).

8

Secure solenoid valve (26) and 300 psi (2069 kPa) regulating valve (28) onto plumbing support assembly (2) with U-bolt plate (33), pipe support (34), U-bolt (35), two new Iockwashers (36), and two hex nuts (37).

9

Install pipe union (38) halves onto two pipe nipples (8 and 39). Assemble pipe nipple (39), 500 psi (3448 kPa) regulating valve (40), pipe nipple (41), pipe elbow (42), pipe nipple (43), pipe elbow (44), pipe elbow (45), and straight adapter (46). Couple pipe union (38).

5-134

TM 9-4940-531-14

10

Install pipe union (47) halves onto pipe nipple (4) and pipe nipple (48). Assemble pipe nipple (48), solenoid valve (49), pipe nipple (50), pipe elbow (51), and straight adapter (52). Couple pipe union (47).

11

Install check valve (53), pipe elbow (54), pipe nipple (55), and pipe cross (56) onto pipe nipple (5).

12

Secure solenoid valve (49) onto plumbing support assembly (2) with pipe support (57), U-bolt (58), two new Iockwashers (59), and two nuts (60).

13

Install pipe bushing (61), pipe nipple (62), flow switch (63), pipe nipple (64), and pipe reducer (65) onto pipe cross (56).

14

Install hydraulic accumulator (66), pipe nipple (67).

15

Install pipe bushing (69), pipe coupling (70), pipe elbow (71), pipe bushing (72), and pressure switch (73) onto pipe tee (68).

16

Install junction box (74) onto pressure switch (73) with two electrical locknuts (75). If removed, install cover (76) with two machine screws (77).

5-135

TM 9-4940-531-14 5-20. COIL INLET CONTROL ASSEMBLY—MAINTENANCE INSTRUCTIONS (cont) ADJUSTMENT OF PRESSURE REGULATING VALVES

1 Install coil inlet control assembly (para 5-15) and fuel tank assembly (para 5-10). NOTE l This procedure requires two people. l Preform this procedure only after replacing a defective coil inlet control assembly regulating valve or if INLET PRESSURE gauge (1) displays reading above normal pressure limits (para 2-6). 2 After initial startup procedure (para 2-5), install appropriate nozzle for mode selected and secure cleaning gun trigger (2) in the open position. 3 Adjust regulating valves in the following order: a. Set regulating valve (3) to 600 psi; set regulating valve (4) to 400 psi. b. Set regulating valve (5) to 500 psi; set regulating valve (6) to 300 psi. 4 When adjustment is complete, release steam cleaning gun trigger (2).

5-136

TM 9-4940-531-14

5-21. OIL DRAIN ASSEMBLY —MAINTENANCE INSTRUCTIONS THIS TASK COVERS: a. Disassembly

b. Inspection/repair

c. Reassembly

INITIAL SETUP Tools and Special Tools General mechanic’s tool kit (item 2, appx B) Electric repair shop equipment (item 1, appx B) Materials/Parts Antiseizing tape (item 24, appx E) Equipment Conditions Oil drain assembly removed (para 5-15)

DISASSEMBLY Remove straight adapter (1) and pipe bushing (2) from oil drain bracket assembly (3). INSPECTION/REPAIR 1 Check for broken, damaged, or missing parts. 2 Repair is by replacement of damaged or unserviceable parts. REASSEMBLY 1 Wrap all pipe threads with antiseizing tape (item 24, appx E). 2 Install pipe bushing (2) and straight adapter (1) to oil drain bracket assembly (3).

5-137

TM 9-4940-531-14 5-22. CONTROL BOX ASSEMBLY, UPPER CONTROL PANEL ASSEMBLY, AND ELECTRICAL COMPONENTS ASSEMBLY—MAINTENANCE INSTRUCTIONS THIS TASK COVERS: a. Disassembly b. Inspection/repair Reassembly c. d. Calibration of OPERATING TEMPERATURE indicator INITIAL SETUP Tools and Special Tools General mechanic’s tool kit (item 2, appx B) Electric repair shop equipment (item 1, appx B) Materials/Parts Grommet (MS35489-17) Lockwasher (6) (MS35338-44) Self-locking nut (2) (MS17828-06C) Self-locking nut (4) (MS51988-3) Tapping screw (22) (MS51861-25) Tapping screw (8) (MS51861-37) Tapping screw (13) (MS51861-46) Equipment Conditions Control box assembly removed (para 5-6) Upper control panel assembly partially disassembled (para 4-20) Accurate thermometer available for calibration procedure DISASSEMBLY

5-138

TM 9-4940-531-14

1 If present, remove four tapping screws (1) and open upper control panel assembly (2). 2 Tag and disconnect all wires from temperature control box (3). 3 Remove four self-locking nuts (4), four capscrews (5), four flat washers (6), and temperature control box (3) from access door (7). 4 Remove five tapping screws (8) and access door (7). 5 Tag and disconnect all wires from components of upper control panel assembly (2) 6

Remove four tapping screws (9) and upper control panel assembly (2) from control box weldment (1

NOTE The spring clips and hardware in steps 7 thru 13 cannot be requisitioned individually; they are components of their respective parts. 7 Remove five spring clips (11) and DELlME LIGHT, POWER LIGHT, DRAIN LIGHT, HOT WATER ALARM, and STEAM ALARM indicator lights (12) from control panel (13). 8 Remove four machine screws (14), switch guard (15), and EMERGENCY OFF circuit breaker (16). 9 Remove plug nut (17). Loosen nut (18), and remove CIRCUIT BREAKER (19) and nut (18). 10 Remove nut (20). Loosen nut (21), and remove PUSH TO START push switch (22) and nut (21). 11 Remove nut (23), washer (24), and MODE SELECTOR rotary switch (25). 12 Remove three nuts (26), three screws (27), and OPERATING TEMPERATURE indicator (28). 13 Remove three nuts (29), three screws (30), and HOUR METER (31). 5-139

TM 9-4940-531-14 5-22. CONTROL BOX ASSEMBLY, UPPER CONTROL PANEL ASSEMBLY, AND ELECTRICAL COMPONENTS ASSEMBLY—MAINTENANCE INSTRUCTIONS

(cont)

DISASSEMBLY (cont)

14

Remove four nuts (32) and four machine screws (33), tag and disconnect wires, and remove electromagnet relay (34) from control box weldment (10).

15

Tag and disconnect wires. Remove ten screws (35) and two terminal jumpers (36) from terminal board (37). Reinstall ten screws. Remove four tapping screws (38) and terminal board (37).

16

Tag and disconnect wires. Remove two self-locking nuts (39), two flat washers (40), two machine screws (41), two flat washers (42), and two sensitive switches (43).

17

Tag and disconnect wires. Remove five screws (44) and terminal jumper (45) from terminal board (46). Reinstall five screws. Remove four tapping screws (47) and terminal board (46).

18

Tag and disconnect wires. Remove two tapping screws (48) and receptacle connector (49).

19

Remove grommet (50).

20

Remove four nuts (51), four Iockwashers (52), four capscrews (53), electrical components assembly (54), and four panel mounting spacers (55).

5-140

TM 9-4940-531-14

21 Tag and disconnect wires. Remove sixteen tapping screws (56) and eight relayswitches (57) from mounting panel (58). 22 Tag and disconnect wires. Remove four tapping screws (59) and two delay lines (60). 23 Tag and disconnect wires. Remove two nuts (61), two Iockwashers (62), two capscrews (63), and power transformer (64) from mounting panel (58).

INSPECTION/REPAIR 1 Check for broken, damaged, or missing parts. 2 Check for faulty or burnt wiring. 3 Repair is by replacement of damaged or unserviceable parts.

1 Install power transformer (1) onto mounting panel (2) with two capscrews (3), two new Iockwashers (4), and two nuts (5). Connect wires. 2 Install two delay lines (6) with four new tapping screws (7). Connect wires. 3 Install eight relay-switches (8) with sixteen new tapping screws (9). Connect wires.

5-141

TM 9-4940-531-14 5-22. CONTROL BOX ASSEMBLY, UPPER CONTROL PANEL ASSEMBLY, AND ELECTRICAL COMPONENTS ASSEMBLY—MAINTENANCE INSTRUCTIONS

(cont)

4

Install electrical components assembly (10) onto control boxweldment (11) with four panel mounting spacers (12), four capscrews (13), four new Iockwashers (14), and four nuts (15).

5

Install new grommet (16).

6

Install receptacle connector (17) with two new tapping screws (18). Connect wires.

7

Install terminal board (19) with four new tapping screws (20). Remove five screws (21). Install terminal jumper (22) onto terminal board (19) with five screws. Connect wires.

8

Install two sensitive switches (23) with two flat washers (24), two machine screws (25), two flat washers (26), and two new self-locking nuts (27). Connect wires.

9

Install terminal board (28) with four new tapping screws (29). Remove ten screws (30). Install two terminal jumpers (31) onto terminal board (28) with ten screws. Connect wires.

10

Connect wires and install electromagnet relay (32) onto control box weldment (11) machine screws (33) and four nuts (34).

5-142

with four

TM 9-4940-531-14

11

Install HOUR METER (35) onto control panel (36) with three screws (37) and three nuts (38).

12

Install OPERATING TEMPERATURE indicator (39) with three screws (40) and three nuts (41).

13

Install MODE SELECTOR rotary switch (42) with washer (43) and nut (44).

14

Install nut (45) and PUSH TO START push switch (46). Install nut (47) and tighten nut (45).

15

Install nut (48) and CIRCUIT BREAKER (49). Install plug nut (50) and tighten nut (48).

16

Install EMERGENCY OFF circuit breaker (51) and switch guard (52) with four machine screws (53).

17

Install DELlME LIGHT, POWER LIGHT, DRAIN LIGHT, HOT WATER ALARM, and STEAM ALARM indicator lights (54) with five spring clips (55).

5-143

TM 9-4940-531-14 5-22. CONTROL BOX ASSEMBLY, UPPER CONTROL PANEL ASSEMBLY, AND ELECTRICAL COMPONENTS ASSEMBLY—MAINTENANCE INSTRUCTIONS (cont) REASSEMBLY (cont)

18

Install upper control panel assembly (56) onto control box weldment (11) with four new tapping screws (57).

19

Connect all wires to components of upper control panel assembly (56).

20

Install access door (58) with five new tapping screws (59).

21

Install temperature control box (60) onto access door (58) with four flat washers (61), four capscrews (62), and four new self-locking nuts (63).

22

Connect all wires to temperature control box (60).

23

If removed, close upper control panel assembly (56) and install four new tapping screws (64).

5-144

TM 9-4940-531-14

CALIBRATION OF OPERATING TEMPERATURE INDICATOR

NOTE Thermocouple wire length is important to OPERATING TEMPERATURE indicator accuracy. DO NOT CUT WIRE. Indicator is calibrated for 6 ft (1 .83 m) length. Short-

ening the leads by 1 in. (2.54 cm) will make thermocouple read one degree higher. 1 Install control box assembly (para 5-6) and completely assemble upper control panel assembly (para 4-20). WARNING To avoid personal injury, be sure no pressure registers on INLET and OUTLET PRESSURE gauges (1 and 2) before disconnecting temperature probe. 2 Disconnect temperature probe (3) from outlet and water drain assembly (4). Place temperature probe so ambient temperature may be measured. 3 Mount small, accurate thermometer next to temperature probe (3). 4 Turn adjusting screw (5) on OPERATING TEMPERATURE indicator (6) until needle reads ambient temperature. 5-145

TM 9-4940-531-14 5-23. STEAM CLEANER LIFT ASSEMBLY—MAINTENANCE INSTRUCTIONS THIS TASK COVERS: a. Disassembly

b. Inspection/repair

c.

Reassembly

INITIAL SETUP Tools and Special Tools General mechanic’s tool kit (item 2, appx B) Electric repair shop equipment (item 1, appx B) Materials/Parts Lockwasher (24) (MS35338-46) Equipment Conditions: Enclosure and lift assembly removed (para 5-4) Enclosure and lift assembly disassembled (para 4-22) DISASSEMBLY

1 Remove four nuts (1), four Iockwashers (2), four machine screws (3), and lifting assembly tube (4). 2 Remove four nuts (5), four Iockwashers (6), four machine screws (7), left latch support (8), and right latch support (9).

5-146

TM 9-4940-531-14

3 Remove 16 nuts (10), 16 Iockwashers (11), 16 machine screws (12), four corner post assemblies (13 and 14), two left and right top angles (15), and two front and rear top angles (16).

inspection/REPAIR 1 Check for broken, damaged, or missing parts. 2 Inspect components for burrs and sharp edges. Remove any burrs or sharp edges. 3 Repair is by replacement of damaged or unserviceable parts.

6-147

TM 9-4940-531-14 5-23. STEAM CLEANER LIFT ASSEMBLY REASSEMBLY

1 Install two front and rear top angles (1) and two left and right top angles (2) onto four corner post assemblies (3 and 4) with 16 machine screws (5), 16 new Iockwashers (6), and 16 nuts (7).

2

Install right latch support (8) and left latch support (9) with four machine screws (10), four new Iockwashers (11), and four nuts (12).

3

Install lifting assembly tube (13) with four machine screws (14), four new Iockwashers (15), and four nuts (16).

5-148

TM 9-4940-531-14

5-24. COIL OUTLET-TO-PRESSURE SWITCH TUBING ASSEMBLY AND PRESSURE SWITCH-TO-PRESSURE SWITCH TUBING ASSEMBLY—MAINTENANCE INSTRUCTIONS THIS TASK COVERS: a. Disassembly

b. Inspection/repair

c. Reassembly

INITIAL SETUP Tools and Special Tools General mechanic’s tool kit (item 2, appx B) Electric repair shop equipment (item 1, appx B) Equipment Conditions Coil outlet-to-pressure switch tubing assembly (para 5-7 and 5-9) and/or pressure switch-topressure switch tubing assembly removed (para 5-7) DISASSEMBLY NOTE This procedure is written for one tubing assembly, but applies to both coil outlet-to-pressure switch and pressure switch-to-pressure switch tubing assemblies. Repeat as needed. 1

Remove two straight adapters (1).

2

If necessary for replacement of parts, cut tubing (2) and remove two tube coupling nuts (3).

INSPECTION/REPAIR 1 Check for broken, damaged, or missing parts. 2 Repair is by replacement of damaged or unserviceable parts. 3 Tubing is cut to a length of 19 in. (48.26 cm) for coil outlet-to-pressure switch tubing assembly and 6 in. (15.24 cm) for pressure switch-to-pressure switch tubing assembly. If tubing is shortened, discard and replace with new tubing. Refer to appendix F. REASSEMBLY 1 Install two tube coupling nuts (3) onto tubing (2). 2 Flare tubing (2) at both ends to a 90-degree angle. Diameter of flare should be 0.325 to 0.315 in. (0.826 to 0.800 cm). 3 Couple two straight adapters

(1) to two tube coupling nuts (3). 5-149

TM 9-4940-531-14 5-25. COIL OUTLET-TO-DIFFERENTIAL PRESSURE SWITCH TUBING ASSEMBLY AND COIL INLET-TO-DIFFERENTIAL PRESSURE SWITCH TUBING ASSEMBLY— MAINTENANCE INSTRUCTIONS THIS TASK COVERS: a. Disassembly

b. Inspection/repair

c. Reassembly

INITIAL SETUP Tools and Special Tools General mechanic’s tool kit (item 2, appx B) Electric repair shop equipment (item 1, appx B) Equipment Conditions Coil outlet-to-differential pressure switch tubing assembly (para 5-7 and 5-9) and/or coil inletto-differential pressure switch tubing assembly removed (para 5-7 and 5-8) DISASSEMBLY NOTE This procedure is written for one tubing assembly, but applies to both coil outlet-to-differential pressure switch and coil inlet-to-differential pressure switch tubing assemblies. Repeat as needed. 1 Remove straight adapter (1) and male pipeto-tube elbow (2). 2 If necessary for replacement of parts, cut tubing (3) and remove two tube coupling nuts (4). lNSPECTION/REPAIR 1 Check for broken, damaged, or missing parts. 2 Repair is by replacement of damaged or unserviceable parts. 3 Tubing is cut to a length of 19 in. (48.26 cm) for coil outlet-to-differential pressure switch tubing assembly and 24.5 in. (62.23 cm) for coil inlet-to-differential pressure switch tubing assembly. If tubing is shortened, discard and replace with new tubing. Refer to appendix F. REASSEMBLY 1 Install two tube coupling nuts (4) onto tubing (3). 2 Flare tubing (3) at both ends to a 90-degree angle. Diameter of flare should be 0.325 to 0.315 in. (0.826 to 0.800 cm). 3 Couple straight adapter (1) and male pipe-to-tube elbow (2) to two tube coupling nuts (4). 5-150

TM 9-4940-531-14 5-26.

COIL INLET-TO-INLET PRESSURE GAUGE TUBING ASSEMBLY, COIL OUTLETTO-OUTLET PRESSURE GAUGE TUBING ASSEMBLY, AND FUEL PUMP-TOPRESSURE GAUGE TUBING ASSEMBLY—MAINTENANCE INSTRUCTIONS

THIS TASK COVERS: a. Disassembly

b. Inspection/repair

c. Reassembly

INITIAL SETUP Tools and Special Tools General mechanic’s tool kit (item 2, appx B) Electric repair shop equipment (item 1, appx B) Equipment Conditions Coil inlet-to-inlet pressure gauge tubing assembly (para 5-5 and 5-8), coil outlet-to-outlet pressure gauge tubing assembly (para 5-5 and 5-9), and/or fuel pump-to-pressure gauge tubing assembly removed (para 4-14 and 5-5) DISASSEMBLY

This procedure is written for one tubing assembly, but applies to coil inlet-to-inlet pressure gauge coil outlet-to-outlet pressure gauge, and fuel pump-to-pressure gauge tubing assemblies. Repeat as needed. 1 Remove straight adapter (1) and male pipe-to-tube elbow (2). 2 If necessary for replacement of parts, cut tubing (3) and remove two tube coupling nuts (4). INSPECTION/REPAIR 1 Check for broken, damaged, or missing parts. 2 Repair is by replacement of damaged or unserviceable parts. 3 Tubing is cut to a length of 23.5 in. (59.69 cm) for coil inlet-to-inlet pressure gauge tubing assembly, 12 in. (30.48 cm) for coil outlet-to-outlet pressure gauge tubing assembly, and 36 in. (91.44 cm) for fuel pump-to-pressure gauge tubing assembly. If tubing is shortened, discard and replace with new tubing. Refer to appendix F. REASSEMBLY 1 Install two tube coupling nuts (4) onto tubing (3). 2 Flare tubing (3) at both ends to a 90-degree angle. Diameter of flare should be 0.325 to 0.315 in. (0.826 to 0.800 cm). 3 Couple straight adapter (1) and male pipe-to-tube elbow (2) to two tube coupling nuts (4). 5-151

TM 9-4940-531-14 5-27. FUEL STRAINER ASSEMBLY—MAINTENANCE INSTRUCTIONS THIS TASK COVERS: a. Disassembly

b. Inspection/cleaning/repair

INITIAL SETUP Tools and Special Tools General mechanic’s tool kit (item 2, appx B) Electric repair shop equipment (item 1, appx B) Materials/Parts Antiseizing tape (item 24, appx E) Gasket (MS51091-4) Wiping rag (item 18, appx E) Equipment Conditions Fuel strainer assembly removed (para 4-13)

5-152

c. Reassembly

TM 9-4940-531-14 DISASSEMBLY 1 Remove straight adapter (1), reducer elbow (2), and pipe nipple (3) from sediment strainer (4). 2 Remove straight adapter (5), reducer elbow (6), and pipe nipple (7) from pipe coupling (8). NOTE Nut (9) and washer (10) are components of pipe coupling (8), and cannot be requisitioned individually. 3 Remove pipe coupling (8), washer (10), mounting plate (11), nut (9), pipe nipple (12), pipe elbow (13), and pipe nipple (14) from sediment strainer (4). NOTE Sediment bowl (15) is a component of the sediment strainer (4) and cannot be requisitioned individually. 4 Remove sediment bowl (15), strainer element (16), and gasket (17). lNSPECTION/CLEANING/REPAIR 1 Check for broken, damaged, or missing parts. 2 Wipe off strainer element and sediment bowl with a clean wiping rag (item 18, appx E). 3 Repair is by replacement of damaged or unserviceable parts. REASSEMBLY 1

Wrap all pipe fittings with antiseizing tape (item 24, appx E).

2

Install new gasket (17), strainer element (16), and sediment bowl (15) onto sediment strainer (4).

3

Install pipe nipple (7), pipe elbow (6), straight adapter (5), washer (10), mounting plate (11), nut (9), and pipe nipple (12) onto pipe coupling (8).

4

Install pipe elbow (13), pipe nipple (14), sediment strainer (4), pipe nipple (3), pipe elbow (2), and straight adapter (1) onto pipe nipple (12).

5-153

TM 9-4940-531-14 5-28. FUEL SHUTOFF ASSEMBLY—MAINTENANCE INSTRUCTIONS THIS TASKS COVERS: a. Disassembly

b. Inspection/repair

INITIAL SETUP Tools and Special Tools General mechanic’s tool kit (item 2, appx B) Electric repair shop equipment (item 1, appx B) Material/Parts Antiseizing tape (item 24, appx E) Equipment Conditions Fuel shutoff assembly removed (para 4-13) All hoses and hose clamps removed (para 4-13)

5-154

c. Reassembly

TM 9-4940-531-14 DISASSEMBLY 1 Remove four straight adapters (1) from two adapter bushings (2) and two pipe elbows (3). NOTE Nuts and washers are components of adapter bushings and cannot be requisitioned individually. 2 Remove two nuts (4), two washers (5), and fuel shutoff bracket (6) from two adapter bushings (2). 3 Remove two adapter bushings (2), two pipe nipples (7), two pipe elbows (8), and two pipe elbows (3) from two plug cocks (9). INSPECTION/REPAIR 1 Check for broken, damaged, or missing parts. 2 Repair is by replacement of damaged or unserviceable parts. REASSEMBLY 1 Wrap all pipe threads with antiseizing tape (item 24, appx E). 2 Install two pipe elbows (3), two pipe elbows (8), two pipe nipples (7), and two adapter bushings (2) onto two plug cocks (9). 3 Install fuel shutoff bracket (6) onto two adapter bushings (2) with two washers (5) and two nuts (4). 4 Install four straight adapters (1) onto two pipe elbows (3) and two adapter bushings (2).

5-155

TM 9-4940-531-14 5-29.

COIL

UNIT

ASSEMBLY—MAINTENANCE

INSTRUCTIONS

THIS TASK COVERS: a. b. c. d.

Disassembly Inspection/repair Reassembly Cleaning/deliming

INITIAL SETUP Tools and Special Tools General mechanic’s tool kit (item 2, appx B) Electric repair shop equipment (item 1, appx B) Materials/Parts Fire-resistant adhesive (item 1, appx E) Lockwasher (3) (MS35338-48) Red litmus paper (item 25, appx E) Sodium hydroxide (item 20, appx E) Sulfamic acid (item 23, appx E) Tapping screw (16) (MS51861-45) Equipment Conditions Coil unit assembly removed (para 5-10) to perform disassembly/reassembly Two suitable 5-gal. (18.9-1) plastic containers available for cleaning/deliming Steam cleaner assembled and operational to perform cleaning/deliming procedures

5-156

TM 9-4940-531-14

1 Remove metal pipe assembly (1) from heating coil (2). 2 Remove eight tapping screws (3) from outer cover assembly (4). 3 Using three lifting brackets (5), remove exhaust head assembly (6) with attached parts from outer cover assembly (4). 4 Remove three hex nuts (7), three Iockwashers (8), three lifting brackets (5), three capscrews (9), and exhaust head assembly (6) from heating coil (2). 5 If necessary for replacement of parts, remove pipe nipple (10) from heating coil (2). 6 If necessary for replacement of parts, remove four tapping screws (11) and conduit outlet cover

7 Remove eight tapping screws (13) and lift up outer cover assembly (4) to remove. 8 Remove coil shield (14), insulation blanket (15), and fire pot(16) from access cover (17). 9 If necessary for replacement of parts, remove insulation blanket (18) from outer cover assembly (4). 5-157

TM 9-4940-531-14 5-29. COIL UNIT ASSEMBLY—MAINTENANCE INSTRUCTIONS (cont) INSPECTION/REPAIR 1 Check for broken, damaged, or missing parts. 2 Repair is by replacement of damaged or unserviceable parts.

1 If either insulation blanket(1) or outer cover assembly (2) was replaced, install fire-resistant adhesive (item 1, appx E) in 0.50 x 6.00-in. (1.27 x 15.24-cm) long strips to inside surface of outer cover assembly (2). Install new insulation blanket (1) in outer cover assembly (2). 2 Position fire pot (3) and insulation blanket (4) on access cover (5). Install coil shield (6) on fire pot (3). 3 Install outer cover assembly (2) over assembled parts and secure with eight new tapping screws (7).

5-158

TM 9-4940-531-14

4

If removed, install pipe nipple (8) onto heating coil (9).

5 Install exhaust head assembly (10) onto heating coil (9) and secure with three lifting brackets (11), three capscrews (12), three newIockwashers (13), and three hex nuts (14). 6 Install exhaust head assembly (10) with attached parts into outer cover assembly (2) and secure with eight new tapping screws (15). 7 Install metal pipe assembly(16) onto heating coil (9). If removed, install conduit outlet cover (17) onto outer cover assembly (2) with four new tapping screws (18). CLEANING/DELIMING 1 Prior to implementation of these procedures, the user should contact the local safety organization having jurisdiction to establish policies and procedures regarding industrial toxicology and environmental impact of the deliming chemicals. 2 Chemical deliming should be done only after the blowdown procedure has failed to reduce the difference in coil inlet and outlet pressure to less than 70 psi (483 kPa) or when the DELlME LIGHT illuminates. Tests have shown that regular blowdown greatly increases the intervals between chemical deliming. Mineral deposits in the coil unit assembly and coil outlet fittings are the result of the effects of heat on undissolved solids in the water used. These deposits must be periodically removed to prevent the coil unit assembly from becoming clogged. 3 Personnel should refer to chapter 2 in this manual for guidance concerning controls and component location before proceeding with deliming procedure. 4 Prior to deliming procedure, read and follow all warnings, first aid procedures, cautions, and notes.

5-159

TM 9-4940-531-14 5-29. COIL UNIT ASSEMBLY—MAINTENANCE INSTRUCTIONS (cont) CLEANING/DELIMING (cont) WARNING Inhibited coil descaling (deliming) powder contains sulfamic acid and is a poison and a corrosive chemical. When working with acids always pour acid into water, never water into acid. Sulfamic acid and sodium hydroxide should not be handled unless the user is properly clothed, including rubber boots, rubber apron, rubber gloves, and a full face shield. All protective clothing must be kept on until deliming solution is neutralized and work site is cleaned up. Rubber gloves must be thoroughly washed prior to removal and should be the last item removed. The user should read and understand the following procedure, along with the precautions printed on the acid container. Failure to do so could result in severe or possibly fatal injury to personnel. Do not handle sulfamic acid or sodium hydroxide bare-handed. Moisture in the skin will activate the chemical, causing severe irritation or burns. Operations must be performed in a well-ventilated area. Carbon dioxide vapors are released during this procedure. Injury to personnel may result if proper ventilation is not provided. Personnel should not eat, drink, or smoke in the immediate work area during the deliming operation. FIRST AID PROCEDURES Sulfamic acid, sodium hydroxide, and their solutions can cause severe irritation or burns to eyes and skin. In cases of eye contact, immediately flush the eyes with plenty of water for at least 15 minutes. Call a physician. In cases of skin contact, immediately flush area with plenty of water for at least 15 minutes while removing contaminated clothing/shoes. Wash area with soap and water. Call a physician. Wash clothing/shoes before reuse. In cases of ingestion of sulfamic acid or sodium hydroxide, immediately drink large amounts of water. DO NOT induce vomiting. Call a physician. Read the Material Safety Data Sheet packed with the sulfamic acid and sodium hydroxide containers before use. CAUTION Only authorized personnel who have read and who understand this procedure should be permitted to perform the cleaning/deliming function. Excess amounts of sulfamic acid can cause serious damage to water pump. Adhere closely to directions.

5-160

TM 9-4940-531-14

5

Close CHEMICAL METERING valve (1) and valve (2) to water tank.

6

Fill 5 gal. (18.9 l) or larger plastic container (3) with clean water:

7

Clean suction hose assembly (4) (para 3-6).

8

Install suction hose assembly (4) onto water pump assembly (5).

9

With steam cleaner in normal operating mode and power off, remove nozzle from steam cleaning gun (6) and tie trigger (7) so water will flow. Put suction end of suction hose assembly (4) and spray end of steam cleaning gun (6) into plastic container (3) so water will recirculate.

10

Turn MODE SELECTOR switch (8) to COLD. Operate steam cleaner (9) on COLD long enough to clear out all soap solution and loose scale (5 minutes minimum).

11

Shut down steam cleaner (9) and empty water from plastic container (3).

5-161

TM 9-4940-531-14 5-29. COIL UNIT ASSEMBLY—MAINTENANCE INSTRUCTIONS (cont) CLEANING/DELIMING (cont)

5-162

TM 9-4940-531-14

12

FiII plastic container (3) no more than 60 percent full of clean water.

Temperature of deliming solution must be kept well below steam point. Do not allow steam cleaner to produce steam with the cleaning solution circulating, as injury to personnel may result from fumes or hot acid splash. Sulfamic acid is a poisonous and corrosive chemical. NOTE Carbon dioxide is released as long as scale and sulfamic acid are present. After scale is completely dissolved, gases cease to form. 13

Pour 2 lb (1 kg) of sulfamic acid (item 23, appx E) into plastic container (3). Place suction end of suction hose assembly (4) and spray end of steam cleaning gun (6) into plastic container (3), as in step 9, and allow solution to circulate. To clean nozzles, place them in a separate container of the deliming solution. After 30 minutes, turn off steam cleaner (9) and check solution strength using red litmus paper (item 25, appx E). Dip test litmus paper into solution. If a reddish color is present, the solution is strong enough to remove the scale. If the litmus paper turns blue, the solution is spent. Repeat litmus paper test, adding 2 lb (1 kg) of sulfamic acid at 30-minute intervals until the solution tests a reddish color on the litmus paper. During this procedure, turn MODE SELECTOR switch (8) to HEAT just long enough for the steam cleaning gun (6) to feel warm but not hot. It may be necessary to stop steam cleaner (9) from time to time to pump excess solution into another container to avoid overflowing plastic container. This excess solution must be subsequently neutralized, using sodium hydroxide mixture as follows. WARNING Sodium hydroxide is a poisonous and corrosive chemical.

14

Before draining the solution from steam cleaner (9), it must be neutralized. Turn on steam cleaner and add sodium hydroxide (item 20, appx E) in 1-oz (28-g) increments. Using red litmus paper (item 25, appx E), dip litmus paper into the solution and wait until the solution just begins to change from red to blue. When this change occurs, the solution is neutralized. It then can be flushed into a sanitary sewer with equal parts of water.

15

Stop steam cleaner and remove end of steam cleaning gun (6) from plastic container and place discharge end of steam cleaning gun (6) in a drain or other location for disposal of solution. Check with your local Safety, Health, and Environmental Office prior to discharging the solution into a sanitary or storm water system.

16

Turn on either pressurized or nonpressurized water supply to steam cleaner (9). Operate on COLD and flush water through steam cleaner for 5 minutes.

17

Any areas that may have been splashed with acid solution should be flushed with water.

18

Clean water tank strainer and water inlet fittings in accordance with equipment manual operating instructions.

5-163

TM 9-4940-531-14 5-29. COIL UNIT ASSEMBLY—MAINTENANCE INSTRUCTIONS (cont) CLEANING/DELIMING (cont)

19

Install pressure tip or steam nozzle (10) on steam cleaning gun (6).

20

Press PUSH TO START switch (11) and check INLET PRESSURE gauge (12) with OUTLET PRESSURE gauge (13). If pressure differential is more than 70 psi (483 kPa), the heating coil of the coil unit assembly (14) may need a second treatment.

5-164

TM 9-4940-531-14

21

If a second treatment fails to reduce the pressure differential as specified, the heating coil (15) may need to be removed (p 5-157) and soaked in a solution of sulfamic acid as follows:

NOTE Ensure EMERGENCY OFF switch is in off position and CHEMICAL METERING valve is closed. a. Following disassembly procedure above, remove heating coil (15) from coil unit assembly and soak in a solution of 5.0 lb (2.3 kg) of sulfamic acid (item 23, appx E) added to 10 gal. (38 l) of water. Enough solution should be mixed in a suitable plastic container (16) to cover the heating coil completely. Check the solution by using red litmus paper (item 25, appx E). Dip litmus paper into the solution. If a reddish color is present, the solution is strong enough to remove scale. If the litmus paper turns a blue color, the solution is spent. Allow the heating coil (15) to soak between 3 to 5 hours. This will allow the solution to work its way throughout the heating coil (15). Periodically check the solution strength with litmus paper (item 25, appx E). If the litmus paper turns a blue color, add 2 lb (1 kg) of sulfamic acid (item 23, appx E) and carefully agitate the solution for 2 minutes. Repeat at 30-minute intervals until litmus paper tests a reddish color. b. Before draining the solution from the heating coil container, it must be neutralized as specified in step 14. Rinse heating coil with water for 5 minutes and install into coil unit assembly. Check for leaks. c. Reassemble coil unit assembly (p 5-158).

5-165

TM 9-4940-531-14

5-29. COIL UNIT ASSEMBLY—MAINTENANCE INSTRUCTIONS (cont) CLEANING/DELIMING (cont)

22 T u r n EMERGENCY OFF switch (17) to on position and press PUSH TO START switch (11). 23 When steam cleaning gun (6) emits clear water, turn EMERGENCY OFF switch (17) to off position. 24 Install nozzle (10) in steam cleaning gun (6). Steam cleaner (9) is now ready for normal operation.

5-166

TM 9-4940-531-14 5-30.

CONNECTION DIAGRAM, WIRE ASSEMBLY, AND CONDUIT ASSEMBLY— MAINTENANCE INSTRUCTIONS

THIS TASK COVERS: a. b. c.

Inspection/repair of wire assembly PN 11024261 Inspection/repair if wire assembly PN 11025004 Inspection/repair of conduit assembly

INITIAL SETUP Tools and Special Tools General mechanic’s tool kit (item 2, appx B) Electric repair shop equipment (item 1, appx B) Equipment Conditions Wire assemblies removed (para 5-6, 5-7, 5-8, 5-9, 5-10, 5-12, and 5-22) Conduit assemblies removed (para 5-6, 5-7, 5-8, 5-9, 5-10, and 5-12) INSPECTION/REPAIR OF WIRE ASSEMBLY PN 11024261

NOTE Procedure is written for one wire assembly. Repeat as needed for all wire assemblies. 1 Check for broken, damaged, or missing parts. 2 Repair is by replacement of damaged or unserviceable parts. 3 Wire assembly is a manufactured item, refer to appendix F. Cut wire to length and add terminal lugs as specified. 4 Strip 0.50 in. (1.27 cm) from ends of wire (1), position and crimp new terminal lugs (2 and 3) as applicable. 5 For installation of wire assembly, refer to schematics on pages FP-3 thru FP-5. 5-167

TM 9-4940-531-14 5-30. CONNECTION DIAGRAM, WIRE ASSEMBLY, AND CONDUIT ASSEMBLY— MAINTENANCE INSTRUCTIONS (cont) lNSPECTION/REPAIR OF WIRE ASSEMBLY PN 11025004

NOTE Procedure is written for one wire assembly. Repeat as needed for other wire assembly. 1 Check for broken, damaged, or missing parts. 2 Repair is by replacement of damaged or unserviceable parts. 3 Strip 0.50 in. (1.27 cm) from ends of wire (1), position and crimp new terminal lugs (2) as shown. 4 For installation of wire assembly, refer to schematics on pages FP-3 thru FP-5. INSPECTION/REPAIR OF CONDUIT ASSEMBLY

NOTE Procedure is written for one conduit assembly. Repeat as needed for all conduit assemblies. Electrical box connectors will vary, but repair procedures remain the same. 1 Check for broken, damaged, or missing parts.

5-168

TM 9-4940-531-14 NOTE Electrical box connectors are only replaceable as a whole, their component parts cannot be requisitioned. 2

Check conductor locknuts and seals for damage.

3

Remove box connector housing (1) from back nut (2) and slide back nut (2) onto flexible metal conduit (3). Remove conduit sleeve insert (4) from flexible metal conduit (3).

4

Remove back nut (2) and check bushing (5) for damage.

5

Remove box connector housing (6) from back nut (7) and slide back nut (7) onto flexible metal conduit (3). Remove conduit sleeve insert (8) from flexible metal conduit (3).

6

Remove back nut (7) and check bushing (9) for damage.

7

Repair is by replacement of damaged or unserviceable parts.

8

Conduit assemblies are manufactured items, refer to appendix F. Cut flexible metal conduit to length specified.

9

Install bushing (9) into back nut (7).

10

Slide back nut (7) onto flexible metal conduit (3). Install conduit sleeve insert (8) onto flexible metal conduit (3).

11

Install connector housing (6) onto back nut (7).

12

Install bushing (5) into back nut (2).

13

Slide back nut (2) onto flexible metal conduit (3). Install conduit sleeve insert (4) onto flexible metal conduit (3).

14

Install connector housing (1) onto back nut (2).

15

Install wire assemblies in conduit assemblies in accordance with schematics on pages FP-3 thru FP-5.

16

For installation of conduit assembly, refer to schematics on pages FP-3 thru FP-5.

5-169

TM 9-4940-531-14 5-31. FLAT BED TRAILER-MAINTENANCE INSTRUCTIONS THIS TASK COVERS: a. Disassembly

b. Inspection/repair

INITIAL SETUP Tools and Special Tools General mechanic’s tool kit (item 2, appx B) Electric repair shop equipment (item 1, appx B) Materials/Parts Cotter pin (MS24665-319) Lockwasher (8) (MS35338-46) Retaining ring (2) (MS16624-1062) Self-locking nut (MS51922-9) Self-locking nut (2) (MS51922-17) Self-locking nut (3) (MS51988-2) Tapping screw (5) (MS24629-46) Tapping screw (4) (MS51861-65) References TM 9-2330-202-14&P TM 9-4940-531-24P Equipment Conditions Handbrake engaged Master brake cylinder drained (TM 9-2330-202-14&P) Generator removed (para 5-3) Steam cleaner removed (para 5-3) Red indicating reflectors removed (para 4-27) Support blocks available

5-170

c. Reassembly

TM 9-4940-531-14

DISASSEMBLY

1

Support front and rear of flat bed trailer. If brake lines require replacement, bleed and drain lines in accordance with TM 9-2330-202-14&P.

2

Remove two tapping screws (1), two loop clamps (2), and brake line tube assembly (3) from trailer chassis (4).

3

Remove three self-locking nuts (5), three machine screws (6), three loop clamps (7), and brake line tube assembly (8).

4

Remove nonmetallic hose assembly (9).

5

Remove front brake line tube assembly (10).

5-171

TM 9-4940-531-14 5-31. FLAT BED TRAILER—MAINTENANCE INSTRUCTIONS (cont) DISASSEMBLY (cont)

6 Remove eight hex nuts (11), eight Iockwashers (12), eight capscrews (13), and two vehicular fenders (14). NOTE Hardware and bracket in steps 7 and 8 are component parts of rear stabilizer kit and cannot be requisitioned individually. 7 Remove two nuts (15), two Iockwashers (16), two bolts (17), and bracket (18). 8 Remove two nuts (19), two Iockwashers (20), two bolts (21), and rear stabilizer kit (22).

5-172

TM 9-4940-531-14

9

Remove self-locking nut (23), machine bolt (24), quick release pin (25), and flat washer (26).

10 Remove two retaining rings (27), headless grooved pin (28), and leveling-support jack (29). 11 Remove cotter pin (30), headed straight pin (31), locking pin assembly (32), and drawbar locking arm (33). 12 If damaged, or if necessary for replacement of electrical parts, remove four tapping screws (34), three tapping screws (35), and three loop clamps (36). 13 Loosen self-locking nut (37) and remove self-locking nut (38), hook bolt (39), and self-locking nut (37). lNSPECTION/REPAIR 1 Check for broken, damaged, or missing parts. 2 Repair is by replacement of damaged or unserviceable parts. 3 Leveling-support jack is a repairable assembly, refer to paragraph 5-32. 4 Brake line tube assemblies are repairable assemblies, refer to paragraph 5-33. 5 The flatbed trailer is a modification of the standard M116A2 trailer. The modifications are performed by general support maintenance. If the trailer chassis requires replacement, notify general support maintenance. 5-173

TM 9-4940-531-14 5-31. FLAT BED TRAILER—MAINTENANCE INSTRUCTIONS (cont) REASSEMBLY

NOTE No paint is permitted on threads or inside diameter of tube. 1

Support front and rear of flat bed trailer.

2

Install new self-locking nut (1), hook bolt (2), and new self-locking nut (3) onto trailer chassis (4).

3

If removed, install three loop clamps (5), three new tapping screws (6), and four new tapping screws (7).

4

Install drawbar locking arm (8), locking pin assembly (9), headed straight pin (10), and new cotter pin (11).

5

Install leveling-support jack (12), headless grooved pin (13), and two new retaining rings (14).

6

Install flat washer (15), quick release pin (16), machine bolt (17), and new self-locking nut (18).

5-174

TM 9-4940-531-14

7 Install rear stabilizer kit (19) with two bolts (20), two Iockwashers (21), and two nuts (22). 8 Install bracket (23) with two bolts (24), two Iockwashers (25), and two nuts (26). 9 Install two vehicular fenders (27) with eight capscrews (28), eight new Iockwashers (29), and eight hex nuts (30). NOTE Brake lines will need to be bent as needed at installation. The minimum inside bend radius is 0.50 in. (1.27 cm).

5-175

TM 9-4940-531-14 5-31. FLAT BED TRAILER—MAINTENANCE INSTRUCTIONS (cont) REASSEMBLY (cont)

10 Install front brake line tube assembly (31). 11 Install nonmetallic hose assembly (32). 12 Install brake line tube assembly (33), three loop clamps (34), three machine screws (35), and three new self-locking nuts (36). 13 Install brake line tube assembly (37), two loop clamps (38), and two new tapping screws (39). 14 Add brake fluid and bleed brake lines, refer to TM 9-2330-202-14&P.

5-176

TM 9-4940-531-14 5-32. LEVELING-SUPPORT JACK—MAINTENANCE INSTRUCTIONS THIS TASK COVERS: a. Disassembly

b. Inspection/repair

c. Reassembly

INITIAL SETUP Tools and Special Tools General mechanic’s tool kit (item 2, appx B) Electric repair shop equipment (item 1, appx B) Materials/Parts Self-locking nut (MS51922-17) References TM9-4940-531-24P Equipment Conditions Leveling-support jack removed (para 5-31) DISASSEMBLY 1 Remove four hex nuts (1), four capscrews (2), and wheel (3) from inner housing assembly (4). 2 Remove self-locking nut (5), capscrew (6), and inner housing assembly (4) from upper jack assembly (7). INSPECTION/REPAIR 1 Check for broken, damaged, or missing parts. 2 If upper jack assembly or inner housing assembly is damaged, replace entire leveling-support jack (TM 9-4940-531-24P). 3 Repair is by replacement of damaged or unserviceable parts. REASSEMBLY 1 Install inner housing assembly (4) onto upper jack assembly (7) with capscrew (6) and new selfIocking nut (5). 2 Install wheel (3) onto inner housing assembly (4) with four capscrews (2) and four hex nuts (1). Inflate tire with 35 pounds of air pressure.

5-177

TM 9-4940-531-14 5-33. BRAKE LINE TUBE ASSEMBLY—MAINTENANCE INSTRUCTIONS THIS TASK COVERS: a. b. c. d.

Service Disassembly Inspection/repair Reassembly

INITIAL SETUP Tools and Special Tools General mechanic’s tool kit (item 2, appx B) Electric repair shop equipment (item 1, appx B) Equipment Conditions Brake line tube assembly removed (para 5-31) SERVICE If brake lines are leaking, tighten connections. If they continue to leak after being tightened, perform procedure below. NOTE This procedure is written for one brake line tube assembly, but applies to all brake line tube assemblies. Repeat as needed. DISASSEMBLY If brake line tubing (1) is damaged, but coupling (2) and two tube nuts (3) are serviceable, cut brake line tubing (1) and remove components. INSPECTION/REPAIR 1 Check for broken, damaged, or missing parts. 2 Brake line tubing is a manufactured item, refer to appendix F. 3 Repair is by replacement of damaged or unserviceable parts. REASSEMBLY 1 Cut brake line tubing (1) to length specified in appendix F. 2 Install two tube nuts (3) on new brake line tubing (1). Flare tubing ends to 90-degree angle. Diameter of flare should be 0.239 to 0.249 in. (0.607 to 0.632 cm). 3 Install coupling (2) to tube nut (3). 5-178

TM 9-4940-531-14

CHAPTER GENERAL

SUPPORT

6

MAINTENANCE

INSTRUCTIONS

CHAPTER INDEX Paragraph

Page

6-1. General Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . 6-1 6-2. M116A2 Trailer Chassis Modification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . 6. - 1 6-1. GENERAL MAINTENANCE Refer to general maintenance instructions in paragraph 4-11. 6-2. M116A2 TRAILER CHASSIS MODIFICATION THIS TASK COVERS: Modification of M116A2 trailer chassis INITIAL SETUP Tools and Special Tools General mechanic’s tool kit (item 2, appx B) Electric repair shop equipment (item 1, appx B) Materials/Parts Black paint (item 4, appx E) Brown paint (item 5, appx E) Green paint (item 6, appx E) Support blocks available References MIL-C-53072 MIL-STD-171 TM9-237 TM9-2330-202-14&P Equipment Conditions M116A2 trailer chassis and all modification parts received Master brake cylinder drained (TM 9-2330-202-14&P) Support blocks available

6-1

TM 9-4940-531-14 6-2. M116A2 TRAILER CHASSIS MODIFICATION (cont) MODIFICATION OF M116A2 TRAILER CHASSIS

1 Support front and rear of trailer chassis(1). 2 Disconnect wiring from main sill and protect from damage. Refer to TM 9-2330-202-14&P. While welding and machining, refer to TM 9-237. 3 Remove and drain all hydraulic lines from master cylinder in front to flex line in rear. Refer to TM 9-2330-202-14&P. NOTE Ensure all points are tack welded and all sharp corners are ground. 4 Weld six generator support covers (2) to two generator supports (3) as shown. 5 Weld two generator supports (3) to intermediate main frame sill (4).

6-2

TM 9-4940-531-14

6 Weld jack support bracket assembly (5) and mounting bracket (6) to trailer chassis (1). 7 Weld jack support angle (7) to two generator supports (3) and jack support bracket assembly (5). 8 Weld two drawbar locking anchors (8) to trailer chassis (1).

6-3

TM 9-4940-531-14

6-2. M116A2 TRAILER CHASSIS MODIFICATION (cont) MODIFICATION OF M116A2 TRAILER CHASSIS (cont)

9 Weld two right support fenders (9) and two left support fenders (10) to trailer chassis (1). 10 Weld tread plate support (11) to tread plate (12) and weld tread pIate (12) to trailer chassis (1). 6-4

TM 9-4940-531-14

11

Weld four threaded plates (13) to trailer chassis (1).

12

Weld right front main sill reinforcement (14) and left front main sill reinforcement (15) to trailer chassis (1).

13

Weld two top sill reinforcements (16) and two bottom sill reinforcements (17) to trailer chassis (1).

6-5

TM 9-4940-531-14 6-2. M116A2 TRAILER CHASSIS MODIFICATION (cont) MODIFICATION OF M116A2 TRAILER CHASSIS (cont)

14

Weld two rear main sill reinforcements (18) to trailer chassis (1) as shown.

15

Drill two holes 0.228+0.006-0.002 in. (0.58 + 0.015-0.005 cm) in trailer chassis 3.94 in. (10.01 cm) rearward of original position (View L-L).

16

Drill four holes 0.250±0.005 in. (0.635±0.01 3 cm) in trailer chassis (1) (View L-L).

17

Drill four 0.562+0.005-0.003 in. (1.32+0.0127-0.007 cm) holes in two top sill reinforcements (16) above four threaded plates (13) (Section F-F).

6-6

TM 9-4940-531-14

18 Drill five 0.406 ± 0.010 in. (1.03 ± 0.02 cm) holes for rear stabilizer (View K-K). 19 Remove burrs and break all sharp edges. 20 Remove leg (19), bracket (20), and all related removable hardware. Refer to TM 9-2330-20214&P. 21 Apply finish (1.9.4.2 of MIL-STD-171) and paint with black, brown, and/or green paint (items 4, 5, and 6, appx E) in accordance with MlL-STD-171 and MIL-C-53072. 22 Install all brake line tubing assemblies, refer to paragraph 5-31. Fill brake cylinder with brake fluid and bleed brake lines per TM 9-2330-202-14&P. 23 Connect all wiring to main sill per TM 9-2330-202-14&P. 6-7/(6-8 blank)

TM 9-4940-531-14

APPENDIX A REFERENCES A-1. TECHNICAL MANUALS TM 5-6115-615-12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Operator and Organizational Maintenance Manual: Generator Set, Diesel Engine Driven, and Single Phase 120/240 Volts AC and 28 Volts DC DoD Model MEP-016; Class Utility; Mode 60 Hz; (NSN 6115-01-150-4140); DoD Model MEP-021B; Class Utility; Mode 400 Hz; (6115-01-151-8126); DoD Model MEP-026B; Class Utility; Mode 28 VDC;(6115-150-0367) TM 5-6115-615-24P . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Organizational, Direct Support, and General Support Repair Parts and Special Tools List; Generator Set, Diesel Engine Driven, Tactical, Skid Mounted, 3Kw, 3 Phase 120/240 Volts AC and 28 Volts DC: DoD Model MEP-016B; Class Utility; Mode 60 Hz; (NSN 6115-01-150-4140); DoD Model-021 B; Class Utility; Mode 400 Hz; (6115-01-151-8126); Model MEP-026B; Class Utility; Mode 28 VDC; (6115-01-150-0367) TM 5-6115-615-34 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Intermediate (Field) (Direct and General Support) Maintenance Manual; Generator Set Diesel Engine Driven, Tactical Skid Mounted, 3 Kw, 3 Phase 120/208 and Single Phase 120/240 Volts AC and 28 Volts DC; DoD Model MEP-016B; Class Utility; Mode 60 Hz (NSN 6115-01-150-4140); DoD Model MEP-021B; Class Utility; Mode 400 Hz (6115-01150-8126); DoD Model MEP-026B; Class Utility; Mode 28 VDC; (6115-01-150-0367) TM 9-237 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Operator’s Manual for Welding Theory and Application TM 9-2330-202-14&P . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Operator’s, Organizational, Direct Support and General Support Maintenance Manual Including Repair Parts and Special Tools List for Trailer, Cargo: 3/4-Ton, 2-Wheel, M101 (NSN 2330-00738-9509), M101A1 (2330-00-898-6779), M101A2 (2330-01-102-4697) and Chassis, Trailer: 3/4-Ton, 2-Wheel, M116 (2330-00-542-5987), M116A1 (2330-00-898-6780) and M116A2 (2330-01-1018434)

A-1

TM 9-4940-531-14 A-1. TECHNICAL MANUALS (cont) TM 9-4940-531-24 P . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . .Unit, Direct Support, and General Support Maintenance Repair Parts and Special Tools List for Cleaner, High Pressure, Hot and Cold Water Jet, Trailer Mounted (4940-01 -025-9856) (EIC: 2BC) TM 43-0139 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Painting Instructions for Army Materiel TM 750-244-7 . . . . . . . . . . . . . . . . . .. . . . . . . . Procedures for Destruction of Equipment in Federal Supply Classifications 1000, 1005, 1010, 1015, 1020, 1025, 1030, 1055, 1090 and 1095 to Prevent Enemy Use A-2.

FORMS

DA Form 2028 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . Recommended Changes to Publications and Blank Forms DA Form 2028-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Recommended Changes to Equipment Technical Publications DA Form 2404 . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . Equipment Inspection and Maintenance Worksheet DA Form 2408-9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Equipment Control Record DD Form 314 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Preventive Maintenance Schedule and Record SF 364 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Report of Discrepancy (ROD) SF 368 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Product Quality Deficiency Report A-3.

MISCELLANEOUS

Wood/Wood Based; Construction and A- A-55057 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Panels, . Decorative AR 220-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Unit Status Reporting Receipt, and Issue System AR 725-50 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Requisitioning, . AR 735-5 . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . Policies and Procedures for Property Accountability AR 750-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Army Materiel Maintenance Policy and Retail Maintenance Operations ASTMB75 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Standard Specification for Seamless Copper Tube A-2

TM 9-4940-531-14

CTA 8-100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Army Medical Department Expendable/Durable Items CTA 50-970 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Expendable/Durable Items (Except: Medical, Class V, Repair Parts and Heraldic Items) DA PAM 738-750 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Functional Users Manual for The Army Maintenance Management System (TAMMS) DoD 5200.22-M . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Industrial Security Program Manual FED-STD-H28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Screw-Thread Standards for Federal Services FED-STD-595 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . .Colors Used in Government Procurement FM 21-11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . First Aid for Soldiers MIL-C-53072 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Chemical Agent Resistant Coating (CARC) System Application Procedures and Quality Control Inspection MIL-H-13444 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . Hose and Hose Assemblies, Rubber: Fuel and Oil MIL-STD-129 . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . Marking for Shipment and Storage MIL-STD-171 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . .Finishing of Metal and Wood Finishes MIL-STD-339 . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . Selection and Installation of Wiring and Wiring Devices for Combat and Tactical Vehicles MIL-T-7928 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . General Specification for Terminals, Lugs, Splices, Conductors: Crimp Style, Copper SC 4940-95-CL-B05 . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . Shop Equipment, Electric Repair, Semitrailer Mounted SC 5180-90-CL-N26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tool Kit, General Mechanic’s, Automotive

A-3/(A-4 blank)

TM 9-4940-531-14

APPENDIX MAINTENANCE

B

ALLOCATION

SECTION

l.

CHART

(MAC)

INTRODUCTION

B-1. THE ARMY MAINTENANCE SYSTEM MAC This introduction (section l) provides a general explanation of all maintenance and repair a. functions authorized at various maintenance levels under the standard Army Maintenance System concept. b. The Maintenance Allocation Chart (MAC) in section II designates overall authority and responsibility for the performance of maintenance functions on the identified end item or component. The application of the maintenance functions to the end item or component will be consistent with the capacities and capabilities of the designated maintenance levels, which are shown on the MAC in column (4) as: Unit — includes two subcolumns, C (operator/crew) and O (unit) maintenance. Direct Support — includes an F subcolumn. General Support — includes an H subcolumn. Depot — includes a D subcolumn. c. Section Ill lists the tools and test equipment (both special tools and common tool sets) required for each maintenance function as referenced from section Il. d. Section IV contains supplemental instructions and explanatory notes for a particular maintenance function. B-2. MAINTENANCE FUNCTIONS. Maintenance functions are limited to and defined as follows: Inspect. To determine the serviceability of an item by comparing its physical, mechanical, a. and/or electrical characteristics with established standards through examination (e.g., by sight, sound, or feel). b. Test. To verify serviceability by measuring the mechanical, pneumatic, hydraulic, or electrical characteristics of an item and comparing those characteristics with prescribed standards. c. Service. Operations required periodically to keep an item in proper operating condition; e.g., to clean (includes decontaminate, when required), to preserve, to drain, to paint, or to replenish fuel, lubricants, chemical fluids, or gases. Adjust. To maintain or regulate, within prescribed limits, by bringing into proper position, or by d. setting the operating characteristics to specified parameters.

B-1

TM 9-4940-531-14 B-2. MAINTENANCE FUNCTIONS (cont) Align. To adjust specified variable elements of an item to bring about optimum or desired e. performance. Calibrate. To determine and cause corrections to be made or to be adjusted on instruments f. or test, measuring, and diagnostic equipment used in precision measurement. Consists of comparisons of two instruments, one of which is a certified standard of known accuracy, to detect and adjust any discrepancy in the accuracy of the instrument being compared. Remove/lnstall. To remove and install the same item when required to perform service or g. other maintenance functions. Install may be the act of emplacing, seating, or fixing into position a spare, repair part, or module (component or assembly) in a manner to allow the proper functioning of an equipment or system. Replace. To remove an unserviceable item and install a serviceable counterpart in its place. h. Replace is authorized by the MAC and assigned maintenance level is shown as the 3d position code of the SMR code. Repair. The application of maintenance services’ including fault location/troubleshooting 2, i. removal/installation, and disassembly/assembly 3 procedures, and maintenance actions 4 to identify troubles and restore serviceability to an item by correcting specific damage, fault, malfunction, or failure in a part, subassembly, module (component or assembly), end item, or system. Overhaul. That maintenance effort (service/action) prescribed to restore an item to a comj. pletely serviceable/operational condition as required by maintenance standards in appropriate technical publications (i.e., DMWR). Overhaul is normally the highest degree of maintenance performed by the Army. Overhaul does not normally return an item to like new condition. Rebuild. Consists of those services/actions necessary for the restoration of unserviceable k. equipment to a like new condition in accordance with original manufacturing standards. Rebuild is the highest degree of materiel maintenance applied to Army equipment. The rebuild operation includes the act of returning to zero those age measurements (e.g., hours/miles) considered in classifying Army equipment/components.

1

Services-Inspect, test, service, adjust, align, calibrate, and/or replace.

2

Fault location/troubleshooting—The process of investigating and detecting the cause of equipment malfunctioning; the act of isolating a fault within a system or unit under test (UUT). 3

Disassembly/assembly—The step-by-step breakdown (taking apart) of a spare/functional group coded item to the level of its least component, that is assigned an SMR code for the level of maintenance under consideration (i.e., identified as maintenance significant). 4

Actions—Welding, grinding, riveting, straightening, facing, machining, and/or resurfacing.

B-2

TM 9-4940-531-14

B-3. EXPLANATION OF COLUMNS IN THE MAC, SECTION II a. Column 1, Group Number. Column 1 lists functional group code numbers, the purpose of which is to identify maintenance significant components, assemblies, subassemblies, and modules with the next higher assembly. b. Column 2, Component/Assembly. Column 2 contains the item names of components, assemblies, subassemblies, and modules for which maintenance is authorized. Column 3, Maintenance Function. Column 3 lists the functions to be performed on the item listed in column 2. (For detailed explanation of these functions, see paragraph B-2.) d. Column 4, Maintenance Level. Column 4 specifies each level of maintenance authorized to perform each function listed in column 3, by indicating work time required (expressed as man-hours in whole hours or decimals) in the appropriate subcolumn. This work-time figure represents the active time required to perform that maintenance function at the indicated level of maintenance. If the number or complexity of the tasks within the listed maintenance function varies at different maintenance levels, appropriate work-time figures are to be shown for each level. The work-time figure represents the average time required to restore an item (assembly, subassembly, component, module, end item, or system) to a serviceable condition under typical field operating conditions. This time includes preparation time (including any necessary disassembly/assembly time), troubleshooting/fault location time, and quality assurance time in addition to the time required to perform the specific tasks identified for the maintenance functions authorized in the maintenance allocation chart. The symbol designations for the various maintenance levels are as follows: .... or crew maintenance C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Operator . . . . . maintenance O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Unit support maintenance .... F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Direct .... Repair Activity (SRA) 5 L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Specialized H .......................................................................................G . eneral support maintenance maintenance .... D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Depot e. Column 5, Tools and Test Equipment Reference Code. Column 5 specifies, by code, those common tool sets (not individual tools), common TMDE, and special tools, special TMDE, and special support equipment required to perform the designated function. Codes are keyed to tools and test equipment in section Ill. f. Column 6, Remarks. When applicable, this column contains a letter code, in alphabetical order, which is keyed to the remarks contained in section IV.

5

This maintenance level is not included in section II, column (4) of the Maintenance Allocation Chart. Functions to this level of maintenance are identified by a work-time figure in the H column of section II, column (4), and an associated reference code is used in the Remarks column (6). This code is keyed to section IV, Remarks, and the SRA complete repair application is explained there.

B-3

TM 9-4940-531-14 B-4. EXPLANATION OF COLUMNS IN TOOL AND TEST EQUIPMENT REQUIREMENTS, SECTION Ill a. Column 1, Reference Code. The tool and test equipment reference code correlates with a code used in the MAC, section II, column 5. b. Column 2, Maintenance Level. The lowest level of maintenance authorized to use the tool or test equipment. c.

Column 3, Nomenclature. Name or identification of the tool or test equipment.

d. Column 4, National Stock Number. The National stock number of the tool or test equipment. Column 5, Tool Number. The manufacturer’s part number, modelnumber, model number, or type number.

e.

B-5. EXPLANATION OF COLUMNS IN REMARKS, SECTION IV a.

Column 1, Remarks Code. The code recorded in column 6, section Il.

b. Column 2, Remarks. This column lists information pertinent to the maintenance function being performed as indicated in the MAC, section Il.

Section

Il.

MAINTENANCE

ALLOCATION

(1)

(2)

(3)

Group Number

Component/ Assembly

Maintenance Function

00

01

0101

0102

B-4

Steam Cleaner, Trailer Mounted (11024645)

Steam Cleaner (11024000)

CHART

FOR

STEAM

(4) Maintenance Level Direct General Support Support Depot Unit C

O

Inspect Service Replace Repair

0.5 0.5

0.3 0.7

Inspect Service Replace Repair

0.1 0.5

3.0 0.3 0.7 1.5

Inlet Assembly, Coil (11024109)

Inspect Service Repair

0.1

Outlet Assembly, Coil (11024170)

Inspect Service Adjust Repair

0.1

0.5

0.8

F

0.5 2.0

H

D

CLEANER

(5)

(6)

Tools and Equipment Ref Code

Remarks Code

1,2

0.5 0.5 4.0

1,2

0.1 0.5 1.5

1,2

0.1 0.1 0.5 2.0

1,2 1,2

TM 9-4940-531-14 MAINTENANCE ALLOCATION CHART FOR STEAM CLEANER (cont) (1)

(2)

(3)

Group Number

Component/ Assembly

Maintenance Function

010201

01020101

0103

010301

0104

010401

010402

010403

010404

Blowdown Assembly (11024956)

Inspect Service Repair

Valve and Switch Assembly (11024941)

Inspect Service Repair

Oil Burner Assembly (11024215)

Inspect Service Adjust Repair

Burner, Oil, Vaporizing, Atomizing (11024220)

Inspect Test Service Adjust Replace Repair

Fuel Tank Assembly (11024222)

(4) Maintenance Level

0.1

Depot

O

F

H

D

0.1

0.2 0.5 2.0

1,2

0.1 0.5 0.9

1,2

0.1 0.2 0.3 0.8 0.1

0.1

Inspect Service Adjust Repair

0.1 0.2

Inlet Assembly, Suction (11024018)

Inspect Repair

0.1

Tank Assembly, Water (11024130)

Inspect Service Repair

0.1

Pump Assembly (11024146)

Inspect Service Repair

0.1 0.4

Inspect Repair

0.1

Inlet Assembly, Water (11024185)

General Support

0.1

0.2 0.3 0.5

0.1 0.2 0.1 2.0

0.1 0.5

0.1 0.4

3 2 0.5 0.1 0.5

3

2.5

1,2

0.5

12.0

2 1,2

0.1 2.5

1,2

0.3 0.5 3.0

1,2

0.3 2.5

0.1 1.0

(6)

Tools and Equipment Remarks Ref Code Code

Direct Support

Unit C

(5)

1,2

2

B-5

TM 9-4940-531-14

MAINTENANCE ALLOCATION CHART FOR STEAM CLEANER (cont) (1)

(2)

(3)

Group Number

Component/ Assembly

Maintenance Function

010405

010406

010407

010408

0105

010501

0106

010601

010602

0107

B-6

Inlet Assembly, Pump (11024195)

Inspect Repair

Motor Assembly (11024208)

Inspect Service Repair

(4) Maintenance Level Unit C

O

0.1

0.2 1.3

0.1

Drain Assembly, Oil (11024872)

Inspect Repair

0.1

Lower Control Panel Assembly (11024303)

Inspect Repair

0.1

Valve Assembly, Metering (11024304)

Inspect Repair

0.1

Control Box Assembly (11024370)

Inspect Repair

Control Panel Assembly (11024322)

Inspect Service Calibrate Repair

Hose Assembly, Wash (11024408)

Inspect Remove/ Install Repair

Depot

F

H

D

Tools and Equipment Ref Code

Remarks Code

2

0.1

Inspect Service Adjust Repair

Inspect Repair

General Support

(6)

0.5

Control Assembly, Coil Inlet (11024584)

Electrical Components Assembly (11024363)

Direct Support

(5)

0.1 0.5

1,2

0.1 0.5 0.5 1.5

1,2 1,2

0.1 1.5

1,2

0.1 1.5

2

0.1 1.5

2

0.1

0.1 0.2

2.5

0.8 3.8

1,2

0.1

0.8

1.0

0.2 2.2

1,2 1,2

0.5 2.0

1,2

0.1

1.2

2

TM 9-4940-531-14 MAINTENANCE ALLOCATION CHART FOR STEAM CLEANER (cont) (1)

(2)

Group Number

Component/ Assembly

0108

010801

010802

0109

0110

0111

0112

0113

(3)

Maintenance Function

(4) Maintenance Level Unit C

O 0.1 0.8 2.0

Enclosure and Lift Assembly (11024520)

Inspect Service Repair

0.1

Door, Access (Hose Rack) (11024412)

Inspect Replace Repair

0.1

Lift Assembly, Steam Cleaner (11024481)

Inspect Repair

Cable Assembly, Special Purpose, Electrical (Facility Power) (11024763)

Inspect Replace Repair

0.1

Tubing Assembly (Coil Outlet-toPressure Switch) (11024820-1)

Inspect Repair

0.1

Tubing Assembly (Coil Outlet-toDifferential Pressure Switch) (11024820-2)

Inspect Repair

0.1

Tubing Assembly (Coil Inlet-to-Inlet Pressure Gauge) (11024820-3)

Inspect Repair

0.1

Tubing Assembly (Coil lnlet-todifferential Pressure Switch) 11024820-4)

Inspect Repair

0.1

Direct, Support

F

General Support

H

Depot D

(5)

(6)

Tools and Equipment Ref Code

Remark: Code

0.1 2.6

1,2

0.1 0.5 1 .0

2 0.1 2.0

0.1 0.1 1.0

1,2

2

0.1 1.2

1,2

0.1 1.2

1,2

0.1 1.2

1,2

0.1 1.2

1,2

B-7

TM 9-4940-531-14

MAINTENANCE ALLOCATION CHART FOR STEAM CLEANER (cont) (1)

(2)

(3)

Group Number

Component/ Assembly

Maintenance Function

0114

0115

0116

0117

0118

0119

0120

0121

B-8

(4) Maintenance Level Unit C

Tubing Assembly (Coil Outlet-toOutlet Pressure Gauge) (11024820-5)

Inspect Repair

0.1

Tubing Assembly (Pressure Switchto-Pressure Switch) (11024820-6)

Inspect Repair

0.1

Tubing Assembly (Fuel Pump-toPressure Gauge) (11024820-7)

Inspect Remove/ Install Repair

0.1

Outlet and Water Drain Assembly (11024848)

Inspect Service Repair

0.1

Strainer Assembly, Fuel (11024870)

Inspect Service Remove/ Install Repair

0.1 0.5

Inspect Remove/ Install Repair

0.1

Shutoff Assembly, Fuel (11024886)

Coil Unit Assembly (11024903)

Diagram, Connection (11024915)

Inspect Replace Service Repair

O

Direct Support

F

General Support

Depot D

(5)

(6)

Tools and Equipment Ref Code

Remarks Code

0.1 1.2

1,2

0.1 1.2

1,2

0.1 0.6

0.1 0.3 1.5

1.2

1,2

0.1 0.3 0.6

1,2

0.1 0.8 1.2

1,2

0.1 0.5

0.1

0.5

1.5

1,2

0.1

0.2 2.0 2.0 3.0

1,2 A

TM 9-4940-531-14

MAINTENANCE ALLOCATION CHART FOR STEAM CLEANER (cont)

B-9

TM 9-4940-531-14

MAINTENANCE ALLOCATION CHART FOR STEAM CLEANER (cont) (2)

(3)

Component/ Assembly

Maintenance Function

(1)

Group Number 0404

0405

05

(4) Maintenance Level Unit C

Tube Assembly, Brake Line (11024822-2)

Inspect Repair

0.1

Tube Assembly, Brake Line (11024822-3)

Inspect Repair

0.1

Generator Set, Diesel (MEP-701A)

Replace

Direct Support

General Support

F

H

O

(5)

Depot D

(6)

Tools and Equipment Remarks Ref Code

0.2 1.5

1,2

0.2 1.5

1,2

1.0

Code

1,2

D

Section Ill. TOOLS AND TEST EQUIPMENT FOR STEAM CLEANER TOOL OR TEST EQUIPMENT MAINTENANCE LEVEL REF CODE

TOOL NUMBER

1

F

Shop Equipment, Electric Repair

4940-00-294-9517 SC4940-95-CL-B05

2

O

Tool Kit, General Mechanic’s

5180-00-177-7033 SC5180-90-CL-N26

3

O

Smoke Test Kit

6695-01-059-9474

21-7006

4

H

Welding Shop, Trailer Mounted

3431-01-090-1231

ModeI 491996

5

O

Tool Set, Common No. 1

4910-00-754-0654 SC4910-95-CL-A74

Section

IV.

REMARKS

REMARKS CODE

B-10

NATIONAL STOCK NUMBER

NOMENCLATURE

FOR

STEAM

CLEANER

REMARKS

A

Maintenance times are considered under groups 012101, 012102, and 121203.

B

Time per maintenance action. Not total time for entire assembly.

C

Refer to TM 9-2330-202-14&P.

D

Refer to TM 5-6115-615-12.

TM 9-4940-531-14

APPENDIX COMPONENTS

OF

END

C ITEM

(COEI)

AND BASIC ISSUE ITEMS (Bll) LISTS

Section C-1.

I.

INTRODUCTION

SCOPE

This appendix lists components of the end item and basic issue items for the steam cleaner to help you inventory the items required for safe and efficient operation of the equipment. C-2. GENERAL The Components of End Item (COEI) and Basic Issue Items (BII) Lists are divided into the following sections: a. Section II. Components of End Item. This listing is for information purposes only, and is not authority to requisition replacements. These items are part of the steam cleaner. As part of the end item, these items must be with the end item whenever it is issued or transferred between property accounts. Items of COEI are removed and separately packaged for transportation or shipment only when necessary. Illustrations are furnished to help you find and identify the items. b. Section Ill. Basic Issue Items. These essential items are required to place the steam cleaner in operation, operate it, and to do emergency repairs. Although shipped separately packaged, Bll must be with the steam cleaner during operation and when it is transferred between property accounts. This list is your authority to request/requisition them for replacement based on authorization of the end item by the TOE/MTOE. Illustrations are furnished to help you find and identify the items. C-3. EXPLANATION OF COLUMNS a. Column (1) - Illus Number. Gives you the number of the item illustrated. b. Column (2) - National Stock Number. Identifies the stock number of the item to be used for requisitioning purposes. c. Column (3) - Description and Usable On Code. Identifies the Federal item name (in all capital letters) followed by a minimum description when needed. The last line below the description is the Contractor and Government Entity Code (CAGEC) (in parentheses) and the part number. d. Column (4) - U/l (Unit of Issue). Indicates how the item is issued for the National Stock Number shown in column two. e. Column (5) - Qty Rqd. Indicates the quantity required.

C-1

TM 9-4940-531-14

Section II. COMPONENTS OF END ITEM

U/I

ELECTRICAL SPECIAL PURPOSE (FACILITY POWER) CABLE ASSEMBLY (59678) 11024763

EA

1

6150-01-283-4355

ELECTRICAL SPECIAL PURPOSE POWER(GENERATOR POWER) CABLE ASSEMBLY (59678) 11024764

EA

1

3

4730-01-275-8091

EMULSION FLUID SPRAY NOZZLE (59678) 11024391

EA

1

4

2910-01-285-3087

EMULSION LARGE FAN NOZZLE (59678) 11024401

EA

1

5

2910-01-281-1663

EMULSION SMALL FAN NOZZLE (59678) 11024396

EA

1

(2) National Stock Number

1

6150-01-283-4354

2

C-2

(4)

(5) Qty Rqd

(1) Illus Number

Description and UsableOnCode

(3)

TM

9-4940-531-14

COMPONENTS OF END ITEM (cont)

(4) U/l

(5) Qty Rqd

EMULSION HI PRESSURE (FOGGER) NOZZLE (59678) 11024393

EA

1

4210-00-555-8837

FIRE EXTINGUISHER WITH BRACKET (81349) MIL-E-52031

EA

1

8

2330-01-283-4357

FLAT BED TRAILER (59678) 11024780

EA

1

9

4730-01-275-8090

FLUID-EMULSION SPRAY NOZZLE (59678) 11024388

EA

1

10

6115-01-234-5966

GENERATOR SET (30554) MEP-701A

EA

1

11

4720-00-203-3912

NONMETALLIC (PRESSURIZED WATER) HOSE ASSEMBLY (31348) L-H-520

EA

1

(1) Illus Number

(2) National Stock Number

6

4730-01-276-6629

7

Description and Usable On Code

(3)

C-3

TM 9-4940-531-14 COMPONENTS OF END ITEM (cont)

U/l

STEAM CLEANER (59678) 11024000

EA

1

STEAM CLEANING GUN (59678) 11024235

EA

1

NA

SUCTION HOSE ASSEMBLY (59678) 11024270

EA

1

NA

WASH HOSE ASSEMBLY (59678) 11024408

EA

3

(2) National Stock Number

12

4940-01-275-2556

13

4940-01-279-1810

14

15

C-4

(4)

(5) Qty Rqd

(1) Illus Number

Description and Usable On Code

(3)

TM 9-4940-531-14

Section Ill. BASIC ISSUE ITEMS

(4)

(3) Description and Usable on Code

U/l

NA

TM 5-6115-615-12

EA

1

2

NA

TM 5-6115-615-34

EA

1

3

NA

TM 5-6115-615-24P

EA

1

4

NA

TM 9-2330-202-14&P

EA

1

5

NA

TM 9-4940-531-14

EA

1

6

NA

TM 9-4940-531-24P

EA

1

(1) Illus Number

(2) National Stock Number

1

(5) Qty Rqd

C-5/(C-6 blank)

TM 9-4940-531-14

APPENDIX ADDITIONAL

D

AUTHORIZATION

Section

I.

LIST

(AAL)

INTRODUCTION

D-1 . SCOPE This appendix lists additional items that you are authorized for the support of the steam cleaner. D-2.

GENERAL

This list identifies items that do not have to accompany the steam cleaner and that do not have to be turned in with it. These items are authorized to you by CTA, MTOE, TDA, or JTA. D-3. EXPLANATION OF LISTING National Stock Numbers, description, and quantities are provided to help you identify and request the additional items you require to support this equipment. Section

Il.

ADDITIONAL

AUTHORIZATION

(1)

(2)

National Stock Number

Description CAGEC & Part Number

Used On Code

LIST (3)

(4)

U/M

Qty Auth

6230-00-264-8261

Flashlight (81349) MIL-F-3747

EA

1

5120-00-234-8913

Screwdriver, Cross Tip (19207) 11655777-12

EA

1

5120-00-240-5328

Wrench, Adjustable (58536) AA-2344

EA

1

D-1/(D-2 blank)

TM 9-4940-531-14

APPENDIX EXPENDABLE

AND

Section

I.

E

DURABLE

ITEMS

LIST

INTRODUCTION

E-1 . SCOPE This appendix lists expendable and durable items you will need to maintain the steam cleaner. This listing is for informational purposes only and is not authority to requisition the listed items. These items are authorized to you by CTA 50-970, Expendable/Durable Items (Except Medical, Class V, Repair Parts, and Heraldic Items). E-2. EXPLANATION OF COLUMNS a. Column (1) - Item Number. This number is assigned to the entry in the listing and is referenced in the narrative instructions to identify the material (e.g., “Use cleaning compound, item 7, appx E.”). b. the listed C O F H

Column (2) - Level. This column identifies the lowest level of maintenance that requires item. - Operator/Crew - Unit Maintenance - Direct Support Maintenance - General Support Maintenance

c. Column (3) - National Stock Number. This is the National stock number assigned to the item; use it to request or requisition the item. d. Column (4) - Description. Indicates the Federal item name and, if required, a description to identify the item. The last line for each item indicates the Contractor and Government Entity Code (CAGEC) in parentheses followed by the part number. e. Column (5) - Unit of Measure (U/M)/Unit of Issue (U/I). Indicates the measure used in performing the actual maintenance function. This measure is expressed by a two-character alphabetical abbreviation (e.g., ea, in., pr). If the unit of measure differs from the unit of issue, requisition the lowest unit of issue that will satisfy your requirements.

E-1

TM 9-4940-531-14

Section

Il.

EXPENDABLE

AND

DURABLE

ITEMS

LIST

(4)

(5)

Description

U/M/U/l

(1)

(2)

Item Number

Level

(3) National Stock Number

1

F

8040-00-273-8707

ADHESIVE, FIRE RESISTANT (81349) MiL-A-3316

CN

2

O

6810-00-201-0906

ALCOHOL, DENATURED, grade III 16-fl oz (0.48-l) bottle (81348) O-E-760

BT

3

C

6135-00-835-7210

BATTERY, DRY, D-size, 1.5 V (81349) BA-3030/U

PG

4

O

8010-01-141-2419

CARC, BLACK (37030) MIL-C-46168

QT

5

O

8010-01-160-6744

CARC, BROWN, NO. 383 (30051) MIL-C-46168

QT

6

O

8010-01-160-6741

CARC, GREEN, NO. 383 (34094) MIL-C-46168

QT

7

C

6850-00-753-4998

CLEANING COMPOUND, HIGH PRESSURE CLEANER (81348) MIL-C-22542

GL

8

O

4020-00-240-2154

CORD, FIBROUS, 500-yd(457-m)spool (81349) MIL-C-5040

YD

9

0

4940-01-154-8269

DESOOTER, RED DEVIL (94774) 1002-1-05

PT

10

C

9140-00-286-5286

DIESELFUEL,grade 1 (81348) DF1Wl

GL

11

C

9140-00-286-5294

DIESELFUEL,grade 2 (81348) DF2Wl

GL

12

C

8415-00-268-7859

GLOVES, GAUNTLET (81348) KK-G-486

PR

13

C

6240-00-155-8675

LAMP, INCANDESCENT, 3V (81348) W-L-001 11/36

EA

E-2

TM 9-4940-531-14

EXPENDABLE AND DURABLE ITEMS LIST (cont) (1)

(2)

Item Number

Level

(3) National Stock Number

14

C

9150-00-402-4478

LUBRICATING OIL, ENGINE, low temperature (arctic) (81349) MIL-L-46167

QT

15

C

9150-00-889-3522

LUBRICATING OIL, SEMIFLUID (LSA) 40z (118.3ml) (81349) MIL-L-46000

BT

16

O

6695-01-059-9973

PAPER, FILTER (05083) 21-0019

PG

17

O

6640-00-663-0832

PAPER, LENS (81348) NNN-P-40

SH

18

C

7920-00-205-1711

RAG, WIPING (80244) DDD-R-30

EA

19

O

6695-01-059-9475

SMOKE SCALE (05083) 21-0018

EA

20

F

6810-00-270-8177

SODIUM HYDROXIDE, TECHNICAL (81348) O-S-598

OZ

21

O

3439-00-003-8601

SOLDER, LEAD-TIN ALLOY, 1-lb (0.45-kg) can (81348) SN-50, SN-60

LB

22

C

6850-00-281-1985 23

F

6850-01-174-9548

(4)

(5)

Description

U/M/U/I

SOLVENT, DRY CLEANING liquid, white, 140 degree flash point (SD-2) (58536) A-A-711 8-oz (236.6-ml) can SULFAMIC ACID, 10-lb (4.54-kg) can (81348) P-S-120

CN LB

E-3

TM 9-4940-531-14 EXPENDABLE AND DURABLE ITEMS LIST (cont) (4)

(5)

Description

U/M/U/I

(1)

(2)

Item Number

Level

(3) National Stock Number

24

O

8030-00-889-3535

TAPE, ANTISEIZING (81349) MIL-T-27730

EA

25

F

6630-00-226-0920

TEST PAPER AND COLOR CHART, HYDROGEN AND ION (81348) OP94

EA

26

O

8010-00-664-7653

WHITE ENAMEL, 1-qt (0.95-1) can (81348) TT-E-489

QT

E-4

TM 9-4940-531-14

APPENDIX ILLUSTRATED F-1 .

LIST

OF

F

MANUFACTURED

ITEMS

INTRODUCTION

This appendix includes complete instructions for making items authorized to be manufactured a. or fabricated at unit or direct support maintenance level. b. A part number index in alphanumeric order is provided for cross-referencing the part number of the item to be manufactured to the figure which covers fabrication criteria. c. All bulk materials needed for manufacture of an item are listed by part number or specification number in a tabular list on the illustration. F-2. MANUFACTURED ITEMS PART NUMBER INDEX Part Number

Figure Number

M16878 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-4 M23053/2-109-OX.75 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-1 11024136 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-2 11024254 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-3 11024261 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-4 11024410 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-5 11024415 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-6 11024665 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-7 11024727 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-8 11024795 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-9 11024831 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-10 11024846 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-11 11024849 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-12 11024882 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-13 11024913 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-13 F-3. MANUFACTURED ITEMS ILLUSTRATIONS

Figure F-1. Insulation Sleeving, M23053/2- 109-OX.75. NOTE: DIMENSIONS SHOWN ARE IN INCHES (CENTIMETERS). PROCEDURE: FABRICATE FROM INSULATION SLEEVING, PN M23053/1-205-0, NSN 5970-01-085-0673. F-1

TM 9-4940-531-14 F-3. MANUFACTURED ITEMS ILLUSTRATIONS (cont)

Figure F-2. Nonmetallic Hose 11024136. NOTES: 1. 2.

DIMENSIONS SHOWN ARE IN INCHES (CENTIMETERS). TOLERANCES ARE +/-0.12 (0.30).

PROCEDURE: FABRICATE FROM RUBBER HOSE, 0.50 (1.27) I.D., GRADE I OR GRADE Ill, CLASS I, IAW ZZ-H-601, NSN 4720-00-221-8758.

Figure F-3. Nonmetallic Hose 11024254. NOTES: 1. 2.

DIMENSIONS SHOWN ARE IN INCHES (CENTIMETERS). TOLERANCES ARE +/-0.06 (0.15).

PROCEDURE: FABRICATE FROM RUBBER HOSE, 0.250 (0.635) I.D., GRADE 3, CLASS 1, IAW ZZ-H-601 , NSN 4720-00-230-6477.

F-2

TM 9-4940-531-14

Figure F-4. Wire Assembly 11024261. NOTES: 1. 2.

3.

LENGTHS LISTED ARE IN INCHES (CENTIMETERS). LENGTH TOLERANCES ON WIRES: FOR “L” LESS THAN 10.00 (25.40); i 0.12 (0.30) FOR “L” GREATER THAN 10.00 (25.40); S k 0.50 (1.27) FOR IDENTIFICATION OF ITEMS IN FROM AND TO COLUMNS, SEE FO-2 AND FO-3.

PROCEDURES: 1.

2. 3.

FABRICATE FROM ELECTRICAL WIRE: PN M16878/1BJE2, NSN 6145-00-754-8082 PN M16878/1BJE9, NSN 6145-00-643-0650 PN M16878/1BJE0, NSN 6145-00-822-1427 PN M16878/1BJE4, NSN 6145-00-542-6573 PN M16878/1BJE5, NSN 6145-00-822-1425 PN M16878/1BJE6, NSN 6145-00-822-1424 PN M16878/3BLE0, NSN 6145-00-727-0244 PN M16878/3BLE9, NSN 6145-00-643-0643 CUT TO LENGTH SPECIFIED IAW MIL-STD-339(AT) SECTION 1200. INSTALL TERMINALS IAW MIL-T-7928.

Wire Assembly Chart WIRE ASSY PART NO. 11024261-1 11024261-2 11024261-3 11024’261-4 11024261-5 11024261-6 11024261-7 11024261-8 11024261-9 11024261-10 11024261-11

WIRE PART NO.

COLOR

LEFT TERMINAL

WIRE LENGTH

RIGHT TERMINAL

RED WHITE WHITE BLACK YELLOW RED BLACK WHITE BLACK RED

11024914 11024914 11024914 11024914 : 11022304-2 11024914 11024914 11024914 11024914 11024914

30 (76) 30 (76) 72 (183) 72 (183) 78 (198) 60(152) 10 (25) 36 (91) 24 (61) 71 (180)

STRIPPED .50 (1.27) STRIPPED .50 (1.27) STRIPPED .50 (1.27j STRIPPED .50 (1.27) STRIPPED .50 (1.27) STRIPPED .50 (1.27) 11024914 11024914 STRIPPED .50 (1.27) 11024914

FROM

TO

F-3

TM 9-4940-531 -14 F-3. MANUFACTURED ITEMS ILLUSTRATIONS (cont) Wire Assembly Chart (cont)

F-4

TM 9-4940-531-14 Wire Assembly Chart (cont)

F-5

TM 9-4940-531-14 F-3.

MANUFACTURED

ITEMS

I L L U S T R A T I O N S (cont)

Figure F-5. Nonmetallic those 11024470. NOTES: DIMENSIONS SHOWN ARE IN INCHES (CENTIMETERS). 1. 2. TOLERANCES ARE +/-4.00 (10.16). PROCEDURE: FABRICATE FROM NONMETALLIC HOSE, PN 232MB2IN, NSN 4720-00-146-0449.

Figure F-6. Nonmetallic Hose 11024415. NOTES: 1.

DIMENSIONS SHOWN ARE IN INCHES (CENTIMETERS). 2. TOLERANCES ARE +/-0.12 (0.30). PROCEDURE: FABRICATE FROM 0.25 (0.64) I.D. RUBBER HOSE, GRADE I, CLASS I, IAW ZZ-H-601 , NSN 4720-00-230-6477. F-6

TM 9-4940-531-14

Figure F-7. Tubing 11024665. NOTES: 1. 2.

DIMENSIONS SHOWN ARE IN INCHES. TOLERANCES ARE +/-0.12 (0.30).

PROCEDURES: 1. 2.

FABRICATE FROM 0.25 O.D. COPPER TUBING, 0.032 WALL, SEAMLESS, TEMPER H58, IAW ASTMB75, NSN 4710-00-277-5525. REMOVE BURRS AND BREAK ALL SHARP EDGES.

F-7

TM 9-4940-531-14 F-3. MANUFACTURED ITEMS ILLUSTRATIONS (cont)

Figure F-8. Nonmetallic Hose 11024727. NOTES: 1. 2.

DIMENSIONS SHOWN ARE IN INCHES (CENTIMETERS). TOLERANCES ARE +/-2.00 (5.08).

PROCEDURE: FABRICATE FROM NONMETALLIC HOSE, PN 232MB1-250, NSN 4720-00-141-3100.

F-8

TM 9-4940-531-14

Figure F-9. Generator Platform 11024795. NOTES: 1. 2.

DIMENSIONS SHOWN ARE IN INCHES (CENTIMETERS). TOLERANCES ARE +/-0.06 (0.15).

PROCEDURES: 1. 2. 3.

FABRICATE FROM 0.62 (1.57) THICK PLYWOOD, GROUP A, TYPE I, GRADE 1, IAW NN-P-530, NSN 5530-00-129-2121. USE WOOD PRESERVATIVE TREATMENT 25.3 IAW MlL-STD-171. FINISH 5.1.1 PLUS 20.24 IAW MIL-STD-171. COLOR SHALL BE 34094 IAW FED-STD-595. APPLY IAW MIL-C-53072.

F-9

TM 9-4940-531-14 F-3. MANUFACTURED ITEMS ILLUSTRATIONS (cont)

Figure F-10. Brakeline Tubing 11024831. NOTES: 1.

DIMENSIONS SHOWN ARE IN INCHES (CENTIMETERS). 2. TOLERANCES ARE +/-0.12 (0.30).

FABRICATE FROM 0.187 (0.475) O.D. X 0.035 (0.089) WALL THK, SEAMLESS STEEL TUBING, ANNEALED, COLD DRAWN, IAW SAE J524, PN 13207E4733-13, NSN 4710-01-049-0642.

Figure F-11. Brass Pipe 11024846. NOTES: 1.

DIMENSIONS SHOWN ARE IN INCHES (CENTIMETERS). 2. TOLERANCES ARE +/-0.06 (0.15).

PROCEDURES: FABRICATE FROM 0.75 (1.91) NPS BRASS PIPE, SEAMLESS, CLASS I, IAW WWP351, NSN 4710-00-277-6084. 2. REMOVE BURRS AND BREAK ALL SHARP EDGES. 3. THREAD IAW FED-STD-H28. 1.

F-10

TM 9-4940-531-14

Figure F-12. Nonmetallic Hose 11024849. NOTES: 1. 2.

DIMENSIONS SHOWN ARE IN INCHES (CENTIMETERS). TOLERANCES ARE +/-0.12 (0.30).

PROCEDURE: FABRICATE FROM 0.250 (0.635) I.D. RUBBER HOSE, TYPE I, IAW MIL-H-13444, NSN 4720-00005-5008.

F-1 1

TM 9-4940-531-14 F-3. MANUFACTURED ITEMS ILLUSTRATIONS (cont)

Figure F-13. Conduit Assembly 11024913. NOTES: 1. 2.

DIMENSIONS SHOWN ARE IN INCHES (CENTIMETERS). LENGTH TOLERANCE ON FLEXIBLE CONDUIT IS +0.12 (0.30).

PROCEDURES: 1. 2.

FABRICATE FROM FLEXIBLE METAL CONDUIT (11024882) PN 47002, NSN 5975-00-9835239 CUT TO LENGTH SPECIFIED. INSTALL CONNECTORS IAW MIL-T-7928. PART NO. D

FROM

TO

11024885

PART NO. C 11024883

11024882-1

CONT BOX

5 SOL

11024883

11024883

11024882-2

CONT BOX

11024885

11024883

11024882-3

CONT BOX

301 JCT BOX 6 SOL

13.0 (33.0)

11024885

11024883

11024882-4

CONT BOX

302 JCT BOX

21.0 (53.3)

11024885

11024883

11024882-5

CONT BOX

11024913-6 11024913-7

13.5 (34.3) 20.0 (50.8)

11024883 11024883

11024882-6 11024882-7

CONT BOX CONT BOX

303 JCT BOX S4 1 MOT

11024913-8 11024913-9

36.0 (91.4) 34.0 (86.4)

11024883 11024883 11024883 11024883

11024883 11024833

11024882-8 11024882-9

CONT BOX CONT BOX

304 JCT BOX BURNER

11024913-11

9.0 (22.9)

11024885

11024883

11024882-11

CONT BOX

2 SOL

11024913-14

14.0 (35.6)

11024882-14 11024882-15

FS1

9.0 (22.9)

11024885 11024883

302, JCT BOX

11024913-15

11024883 11024885

9 SOL

303 JCT BOX S4

LENGTH A

PART NO. B

11024913-1

15.0 (38.1)

11024913-2

12.0 (30.0)

11024913-3

19.0 (48.3)

11024913-4 11024913-5

, ASSY NO.

S5

11024913-16

8.0 (20.3)

11024883

11024885

11024882-16

3 SOL

11024913-17

8.0 (20.3)

11024885

11024885

11024882-17

304, JCT BOX

303 JCT BOX S4 7 SOL

11024913-21

34.0 (86.4)

11024885

11024883

11024882-21

1 SOL

303 JCT BOX S4

F-12

FP-1/(FP-2 blank)

FP-3/(FP-4 blank)

FP-5/(FP-6 blank)

FP-7/(FP-8 blank)

TM 9-4940-531-14

ALPHABETICAL

INDEX Page

Subject

A Additional authorization list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

D-1

Administrative storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

D-1

D-1

D-1

4-96 4-96 4-96

Atomizing vaporizing oil burner—maintenance instructions: Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electrode adjustment and replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . inspection/repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-110 5-116 5-113 5-113

B Basic issue items . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

C-5

C-5 C-5 C-5

Blowdown assembly and valve and switch assembly—maintenance instructions: Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection/cleaning/repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-108 5-109 5-109

Brake line tube assembly—maintenance instructions: Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection/repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-178 5-178 5-178 5-178

C Cable assembly, facility power—maintenance instructions: Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

l “ *** ****

4-87 4-86 4-87 4-87

Crew Unit Direct Support General Support INDEX1

TM 9-4940-531-14 Page

Subject

C Cable assembly, generator power—maintenance instructions: Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-93 4-93 4-94 4-94

Checking unpacked equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-3

Cleaning agents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-10

Coil inlet assembly—maintenance instructions: Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ... Inspection/repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-101 5-101 5-101

Coil inlet control assembly-maintenance instructions: Adjustment of pressure regulating valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection/repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-136 5-129 5-132 5-133

Coil outlet assembly—maintenance instructions: Adjustment of pressure regulating valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection/repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-106 5-102 5-104 5-104

Coil unit assembly—maintenance instructions: Cleaning/deliming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection/repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-159 5-157 5-158 5-158

Common tools and equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-4

1-4

1-4

1-4

Components of end item and basic issue items . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-1 C-1 C-1 C-1

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Connection diagram, wire assembly, and conduit assembly-maintenance instructions: Inspection/repair of conduit assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection/repair of wire assembly PN 11024261 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection/repair of wire assembly PN 11025004 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-169 5-167 5-168

Control box assembly, upper control panel assembly, and electrical components assembly—maintenance instructions: Calibration of operating temperature indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection/repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-145 5-138 5-141 5-141

Control panel assembly and electrical components assembly— maintenance instructions Inspecting identification markers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacing cartridge fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacing identification markers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-71 4-71 4-72

Controls and indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

2-1

2-1

2-1

1-4

1-4

1-4

1-4

Corrosion Prevention and Control (CPC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D Decals and instruction plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-38

Deliming of coil unit assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-159

Desooting of coil unit assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Destruction of Army materiel to prevent enemy use.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-8 1-2

1-2

1-2

1-2

E Electrical components assembly, control box assembly, and upper control panel assembly (See Control box assembly, upper control panel assembly, and electrical components assembly.)

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E Enclosure and lift assembly and hose rack access door—maintenance instructions: Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection/repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-76 4-81 4-81 1-4 1-4

1-4

Equipment characteristics, capabilities, and features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-4

Equipment data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..

1-10 1-10 1-10 1-10

Equipment description and data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-4

1-4 1-4

1-4

Expendable and durable items list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

E-1

E-1

E-1

E-1

F Facility power cable assembly—maintenance instructions: Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reassembly . . . . . . . . . . . . . . . . . . . . ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-87 4-86 4-87 4-87

Flat bed trailer—maintenance instructions: Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection/repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation of reflectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal of reflectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-171 4-96 5-173 4-96 5-174 4-95

Fuel shutoff assembly—maintenance instructions: Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection/repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-155 5-155 5-155

Fuel strainer assembly—maintenance instructions: Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18 Inspection/cleaning/repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19

5-153 5-153 5-153

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Fuel tank assembly—maintenance instructions: Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection/repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-54 5-119 4-59 5-120 4-59 5-121

G General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-2

1-2

1-2

1-2

General maintenance instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-19 5-44 6-1

Generator power cable assembly—maintenance instructions: Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-93 4-93 4-94 4-94

H Hose rack access door and enclosure and lift assembly (See Enclosure and lift assembly and hose rack access door.) I Illustrated list of manufactured items . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-1

F-1

Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-3

Installation instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-5

F-1

F-1

J Jack, leveling support (See leveling support jack.)

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L Leakage definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11 4-6 Leveling support jack—maintenance instructions: Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection/repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-177 5-177 5-177

Lift assembly, enclosure and lift assembly (See Enclosure and lift assembly.) Location and description of major components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5 1-5 1-5 1-5 Lower control panel assembly and chemical metering valve assembly—maintenance instructions: 4-69 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-70 Inspection/repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-70 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-1

4-2

Maintenance Allocation Chart (MAC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1 B-1 B-1 B-1 Maintenance forms and records . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 1-2 1-2 1-2 Manufactured items illustrations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-1 F-1 F-1 F-1 Metering valve assembly and lower control panel assembly (See Lower control panel assembly and metering valve assembly.) Motor assembly—maintenance instructions: Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection/cleaning/repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ml16A2 trailer chassis modification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-128 5-128 5-128 6-1

N Nomenclature cross-reference list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 1-3 1-3 1-3 l Crew ** Unit *** Direct Support **** General Support INDEX 6

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O Oil burner assembly—maintenance instructions: Adjustment using smoke analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cad cell cleaning and adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cad cell test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel pressure adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection/repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reassembly/installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal/disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-51 4-49 4-51 4-48 4-45 4-46 4-43

Oil burner, atomizing vaporizing (See Atomizing vaporizing oil burner.) Oil drain assembly—maintenance instructions: Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection/repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-137 5-137 5-137

Operating procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-31 In cold weather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-41 In dirt, dust, mud, or sandy conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-41 In hot or humid conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-41 In wet weather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . -41 Outlet and water drain assembly—maintenance instructions: Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection/repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-88 5-84 4-89 5-84 4-90 5-84

P Preparation for use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21 Pressure gauge assembly and steam cleaner (See Steam cleaner and pressure gauge assembly.) Preventive Maintenance Checks and Services (PMCS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9 4-6 Principles of operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10 1-10 1-10 1-10 Pump inlet assembly—maintenance instructions: Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection/repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-67 4-68 4-68

l Crew “ Unit ‘* Direct Support **** General Support INDEX 7

TM 9-4940-531-14 Page

Subject

R References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

A-1

A-1

A-1

A-1

Repair parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-4

1-4

1-4

1-4

Repair parts; tools; special tools; Test, Measurement, and Diagnostic Equipment (TMDE); and support equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 1-4 1-4 1-4 Reporting Equipment Improvement Recommendations (EIR’s) . . . . . . . . . . . . . . . . . . . . 1-2 1-2 1-2 1-2 S Safety, care, and handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-10 1-10 1-10 1-10

Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-4

Service upon receipt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-3

Special tools, TMDE, and support equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 1-4 1-4 1-4 Steam cleaner—maintenance instructions: Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection/repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-23 4-32 4-32

Steam cleaner (coil inlet assembly)—maintenance instructions: Inspection/repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation of coil inlet assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal of coil inlet assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-75 5-76 5-73

Steam cleaner (coil outlet assembly and outlet and water drain assembly)— maintenance instructions: Disassembly of outlet and water drain assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection/repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation of coil outlet assembly and outlet and water drain assembly . . Reassembly of outlet and water drain assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal of coil outlet assembly and outlet and water drain assembly . . . . .

5-84 5-84 5-85 5-84 5-79

l Crew ** Unit *** Direct Support **** General Support

INDEX 8

TM 9-4940-531-14 Subject

Page

Steam cleaner (control box assembly)—maintenance instructions: Inspection/repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation of control box assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal of control box assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-61 5-61 5-58

Steam cleaner (enclosure and lift assembly)—maintenance instructions: Inspection/repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation of enclosure and lift assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal of enclosure and lift assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-50 5-51 5-48

Steam cleaner (fuel tank assembly and coil unit assembly)— maintenance instructions: Inspection/repair.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation of fuel tank assembly and coil unit assembly . . . . . . . . . . . . . . . . . . . . . . . . . . Removal of fuel tank assembly and coil unit assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-94 5-95 5-91

Steam cleaner (pressure gauge assembly)—maintenance instructions: Inspection/repair.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reassembly/installation of pressure gauge assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal/disassembly of pressure gauge assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-55 5-56 5-54

Steam cleaner (PS1, PS2, and PS3 pressure switches)— maintenance instructions: Inspection/repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation of PS1, PS2, and PS3 pressure switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal of PS1, PS2, and PS3 pressure switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-69 5-69 5-64

Steam cleaner lift assembly: Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection/repair.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-146 5-147 5-148

Steam cleaner nozzles—maintenance instructions: Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17 Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17 Steam cleaner, trailer mounted (See trailer-mounted steam cleaner.) l Crew “ Unit *** Direct Support **** General Support INDEX 9

TM 9-4940-531-14 Page

Subject

S Suction hose assembly—maintenance instructions: Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21 4-91 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-92 Inspection/repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-92 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Suction inlet assembly—maintenance instructions: Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection/repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-123 5-123 5-123

T Trailer, flat bed (See Flat bed trailer.) Trailer-mounted steam cleaner—maintenance instructions: Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Decal installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Decal removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection/repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Generator cable assembly installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Generator cable assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-16 4-21 4-21 5-45 4-21 5-46 4-22 4-20 5-47

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 4-9 5-2 Tubing assembly: Brake line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Coil inlet-to-differential pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Coil inlet-to-inlet pressure gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Coil outlet-to-differential pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Coil outlet-to-outlet pressure gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Coil outlet-to-pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel pump-to-pressure gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pressure switch-to-pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

* ** ‘“ ****

Crew Unit Direct Support General Support

5-178 5-150 5-151 5-150 5-151 5-149 5-151 5-149

TM 9-4940-531-14

Page

Subject

U Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-3

V V-belts-maintenance instructions: Belt replacement and adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-64

Valve and switch assembly and blowdown assembly (See Blowdown assembly and valve and switch assembly.) W Warranty information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 1-2 1-2 1-2 Wash hose assembly—maintenance instructions: Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection/repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-74 4-74 4-75

Water inlet assembly—maintenance instructions: Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . inspection/repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-66 4-66 4-66

Water pump assembly—maintenance instructions: Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . inspection/repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-126 5-126 5-127

Water tank assembly—maintenance instructions: Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection/cleaning/repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-124 5-124 5-125

Wire assembly, conduit assembly, and connection diagram (See connection diagram, wire assembly, and conduit assembly.)

l ** *** ****

Crew Unit Direct Support General Support INDEX 11 /(lNDEX 12 blank)

By Order of the Secretary of the Army:

GORDON R. SULLIVAN General, United States Army Chief of Staff Offcial: MILTON H. HAMILTON Administrative Assistant to the Secretary of the Army 06962 DISTRIBUTION: TO be distributed in accordance with DA Form 12-25-E, block 5402 requirements for TM 9-4940-531-14.

*U.S. GOVERNMENT PRINTING OFFICE: 1994 - 546-042/00010

RECOMMENDED CHANGES TO PUBLICATIONS AND BLANK FORMS For use of this form, see AR 25-30; the proponent agency is ODISC4.

Use Part II (reverse) for Repair Parts and Special Tool Lists (RPSTL) and Supply Catalogs/Supply Manuals (SC/SM).

TO: (Forward to proponent of publication or form) (Include ZIP Code)

FROM: (Activity and location) (Include ZIP Code)

AMSTA-LC-LMPP / TECH PUBS, TACOM-RI 1 Rock Island Arsenal Rock Island, IL 61299-7630

Your mailing address

DATE

Date you filled out this form.

PART I – ALL PUBLICATIONS (EXCEPT RPSTL AND SC/SM) AND BLANK FORMS Title PUBLICATION/FORM NUMBER DATE

TM 9-4940-531-14 ITEM NO.

PAGE NO.

PARAGRAPH

01 Aug 94 LINE NO. *

TYPED NAME, GRADE OR TITLE

Your Name DA FORM 2028, FEB 74

FIGURE TABLE NO. NO.

Operator & Support Maint Manual for Cleaner Steam, High Pressure, Hot & Cold, Trailer Mounted RECOMMENDED CHANGES AND REASON (Provide exact wording of recommended changes, if possible).

*Reference to line numbers within the paragraph or subparagraph. TELEPHONE EXCHANGE/AUTOVON, PLUS EXTENSION Signature

Your Signature

REPLACES DA FORM 2028, 1 DEC 68, WHICH WILL BE USED.

USAPPC V3.00

TO: (Forward direct to addressee listed in publication)

FROM: (Activity and location) (Include ZIP Code)

AMSTA-LC-LMPP / TECH PUBS, TACOM-RI 1 Rock Island Arsenal Rock Island, IL 61299-7630

Your address

PUBLICATION NUMBER

TM 9-4940-531-14 PAGE NO.

COLM NO.

LINE NO.

DATE Date you filled out this form

PART II – REPAIR PARTS AND SPECIAL TOOL LISTS AND SUPPLY CATALOGS/SUPPLY MANUALS TITLE Operator & Support Maint Manual for Cleaner DATE 01 Aug 94 Steam, high Pressure, Hot & Cold, Trailer Mounted NATIONAL STOCK REFERENCE FIGURE ITEM NO. NO. NO. NUMBER

TOTAL NO. OF MAJOR ITEMS SUPPORTED

RECOMMENDED ACTION

SAMPLE

PART III – REMARKS

(Any general remarks or recommendations, or suggestions for improvement of publications and blank forms. Additional blank sheets may be used if more space is needed.)

TYPED NAME, GRADE OR TITLE

Your Name

TELEPHONE EXCHANGE/AUTOVON, PLUS EXTENSION

SIGNATURE

Your Signature USAPPC V3.00

RECOMMENDED CHANGES TO PUBLICATIONS AND BLANK FORMS

Use Part II (reverse) for Repair Parts and Special Tool Lists (RPSTL) and Supply Catalogs/Supply Manuals (SC/SM). For use of this form, see AR 25-30; the proponent agency is ODISC4.

TO: (Forward to proponent of publication or form)(Include ZIP Code)

DATE

FROM: (Activity and location) (Include ZIP Code)

AMSTA-LC-LMPP / TECH PUBS, TACOM-RI 1 Rock Island Arsenal Rock Island, IL 61299-7630

PART I – ALL PUBLICATIONS (EXCEPT RPSTL AND SC/SM) AND BLANK FORMS

PUBLICATION/FORM NUMBER

DATE

TM 9-4940-531-14 ITEM NO.

PAGE NO.

PARAGRAPH

01 Aug 94 LINE NO. *

FIGURE TABLE NO. NO.

TITLE Operator & Support Maint Manual for Cleaner Steam, High Pressure, Hot & Cold, Trailer Mounted RECOMMENDED CHANGES AND REASON (Provide exact wording of recommended changes, if possible).

*Reference to line numbers within the paragraph or subparagraph. TYPED NAME, GRADE OR TITLE

DA FORM 2028, FEB 74

TELEPHONE EXCHANGE/AUTOVON, PLUS EXTENSION

SIGNATURE

REPLACES DA FORM 2028, 1 DEC 68, WHICH WILL BE USED.

USAPPC V3.00

TO: (Forward direct to addressee listed in publication)

DATE

FROM: (Activity and location) (Include ZIP Code)

AMSTA-LC-LMPP / TECH PUBS, TACOM-RI 1 Rock Island Arsenal Rock Island, IL 61299-7630 PUBLICATION NUMBER

PART II – REPAIR PARTS AND SPECIAL TOOL LISTS AND SUPPLY CATALOGS/SUPPLY MANUALS TITLE Operator & Support Maint Manual for Cleaner DATE

01 Aug

TM 9-4940-531-14 PAGE NO.

COLM NO.

LINE NO.

NATIONAL STOCK REFERENCE FIGURE NO. NO. NUMBER

PART III – REMARKS

TYPED NAME, GRADE OR TITLE

94 ITEM NO.

Steam, High Pressure, Hot & Cold, Trailer Mounted TOTAL NO. OF MAJOR ITEMS SUPPORTED

RECOMMENDED ACTION

(Any general remarks or recommendations, or suggestions for improvement of publications and blank forms. Additional blank sheets may be used if more space is needed.)

TELEPHONE EXCHANGE/AUTOVON, PLUS EXTENSION

SIGNATURE

USAPPC V3.00

RECOMMENDED CHANGES TO PUBLICATIONS AND BLANK FORMS For use of this form, see AR 25-30; the proponent agency is ODISC4.

Use Part II (reverse) for Repair Parts and Special Tool Lists (RPSTL) and Supply Catalogs/Supply Manuals (SC/SM).

DATE

TO: (Forward to proponent of publication or form) (Include ZIP Code) FROM: (Activity and location) (Include ZIP Code)

AMSTA-LC-LMPP / TECH PUBS, TACOM-RI 1 Rock Island Arsenal Rock Island, IL 61299-7630 PUBLICATION/FORM NUMBER TM 9-4940-531-14

ITEM NO.

PAGE NO.

PARAGRAPH

LINE NO. *

DATE 01 Aug 94 FIGURE NO.

TABLE NO.

TITLE Operator & Support Maint Manual for Cleaner Steam, High Pressure, Hot & Cold, Trailer Mounted RECOMMENDED CHANGES AND REASON (Provide exact wording of recommended changes, if possible).

*Reference to line numbers within the paragraph or subparagraph. TYPED NAME, GRADE OR TITLE

DA FORM 2028, FEB 74

TELEPHONE EXCHANGE/AUTOVON, PLUS EXTENSION

SIGNATURE

REPLACES DA FORM 2028, 1 DEC 68, WHICH WILL BE USED.

USAPPC V3.00

TO: (Forward direct to addressee listed in publication)

FROM: (Activity and location) (Include ZIP Code)

DATE

AMSTA-LC-LMPP / TECH PUBS, TACOM-RI 1 Rock Island Arsenal Rock Island, IL 61299-7630 PUBLICATION NUMBER

PART II – REPAIR PARTS AND SPECIAL TOOL LISTS AND SUPPLY CATALOGS/SUPPLY MANUALS TITLE Operator&Support Maint Manual for Cleaner DATE

TM 9-4940-531-14 PAGE NO.

COLM NO.

LINE NO.

PART III – REMARKS

TYPED NAME, GRADE OR TITLE

01 Aug 94

NATIONAL STOCK REFERENCE FIGURE NO. NO. NUMBER

ITEM NO.

Steam, High Pressure, Hot & Cold, Trailer Mounted TOTAL NO. OF MAJOR ITEMS SUPPORTED

RECOMMENDED ACTION

(Any general remarks or recommendations, or suggestions for improvement of publications and blank forms. Additional blank sheets may be used if more space is needed.)

TELEPHONE EXCHANGE/AUTOVON, PLUS EXTENSION

SIGNATURE

USAPPC V3.00

THE METRIC SYSTEM AND EQUIVALENTS LINEAR MEASURE

SQUARE MEASURE

1 Centimeter = 10 Millimeters = 0.01 Meters = 0.3937 Inches 1 Meter = 100 Centimeters = 1000 Millimeters = 39.37 Inches 1 Kilometer = 1000 Meters = 0.621 Miles

1 Sq Centimeter = 100 Sq Millimeters = 0.155 Sq Inches 1 Sq Meter = 10,000 Sq Centimeters = 10.76 Sq Feet 1 Sq Kilometer = 1,000,000 Sq Meters = 0.386 Sq Miles

WEIGHTS

CUBIC MEASURE

1 Gram = 0.001 Kilograms = 1000 Milligrams = 0.035 Ounces 1 Kilogram = 1000 Grams = 2.2 Lb 1 Metric Ton = 1000 Kilograms = 1 Megagram = 1.1 Short Tons

1 Cu Centimeter = 1000 Cu Millimeters = 0.06 Cu Inches 1 Cu Meter = 1,000,000 Cu Centimeters = 35.31 Cu Feet

LIQUID MEASURE

TEMPERATURE

1 Milliliter = 0.001 Liters = 0.0338 Fluid Ounces 1 Liter = 1000 Milliliters = 33.82 Fluid Ounces

5/9 (oF -- 32) = oC 212o Fahrenheit is equivalent to 100o Celsius 90o Fahrenheit is equivalent to 32.2o Celsius 32o Fahrenheit is equivalent to 0o Celsius 9/5 Co + 32) = Fo

APPROXIMATE CONVERSION FACTORS TO CHANGE

TO

Inches . . . . . . . . . . . . . . . . . . . . . . . . . Feet . . . . . . . . . . . . . . . . . . . . . . . . . . . Yards . . . . . . . . . . . . . . . . . . . . . . . . . Miles . . . . . . . . . . . . . . . . . . . . . . . . . . Square Inches . . . . . . . . . . . . . . . . . . Square Feet . . . . . . . . . . . . . . . . . . . . Square Yards . . . . . . . . . . . . . . . . . . . Square Miles . . . . . . . . . . . . . . . . . . . Acres . . . . . . . . . . . . . . . . . . . . . . . . . Cubic Feet . . . . . . . . . . . . . . . . . . . . . Cubic Yards . . . . . . . . . . . . . . . . . . . . Fluid Ounces . . . . . . . . . . . . . . . . . . . Pints . . . . . . . . . . . . . . . . . . . . . . . . . . Quarts . . . . . . . . . . . . . . . . . . . . . . . . . Gallons . . . . . . . . . . . . . . . . . . . . . . . . Ounces . . . . . . . . . . . . . . . . . . . . . . . . Pounds . . . . . . . . . . . . . . . . . . . . . . . . Short Tons . . . . . . . . . . . . . . . . . . . . . Pound--Feet . . . . . . . . . . . . . . . . . . . . Pounds per Square Inch . . . . . . . . . Miles per Gallon . . . . . . . . . . . . . . . . Miles per Hour . . . . . . . . . . . . . . . . . .

Centimeters . . . . . . . . . . . . . 2.540 Meters . . . . . . . . . . . . . . . . . 0.305 Meters . . . . . . . . . . . . . . . . . 0.914 Kilometers . . . . . . . . . . . . . . 1.609 Square Centimeters . . . . . . 6.451 Square Meters . . . . . . . . . . 0.093 Square Meters . . . . . . . . . . 0.836 Square Kilometers . . . . . . . 2.590 Square Hectometers . . . . . 0.405 Cubic Meters . . . . . . . . . . . . 0.028 Cubic Meters . . . . . . . . . . . . 0.765 Milliliters . . . . . . . . . . . . . . . 29.573 Liters . . . . . . . . . . . . . . . . . . 0.473 Liters . . . . . . . . . . . . . . . . . . 0.946 Liters . . . . . . . . . . . . . . . . . . 3.785 Grams . . . . . . . . . . . . . . . . 28.349 Kilograms . . . . . . . . . . . . . . 0.454 Metric Tons . . . . . . . . . . . . . 0.907 Newton--Meters . . . . . . . . . 1.356 Kilopascals . . . . . . . . . . . . . 6.895 Kilometers per Liter . . . . . . 0.425 Kilometers per Hour . . . . . . 1.609

MULTIPLY BY

TO CHANGE

TO

Centimeters . . . . . . . . . . . . . . . . . . . . Meters . . . . . . . . . . . . . . . . . . . . . . . . Meters . . . . . . . . . . . . . . . . . . . . . . . . Kilometers . . . . . . . . . . . . . . . . . . . . . Square Centimeters . . . . . . . . . . . . . Square Meters . . . . . . . . . . . . . . . . . . Square Meters . . . . . . . . . . . . . . . . . . Square Kilometers . . . . . . . . . . . . . . Square Hectometers . . . . . . . . . . . . Cubic Meters . . . . . . . . . . . . . . . . . . . Cubic Meters . . . . . . . . . . . . . . . . . . . Milliliters . . . . . . . . . . . . . . . . . . . . . . . Liters . . . . . . . . . . . . . . . . . . . . . . . . . . Liters . . . . . . . . . . . . . . . . . . . . . . . . . . Liters . . . . . . . . . . . . . . . . . . . . . . . . . . Grams . . . . . . . . . . . . . . . . . . . . . . . . . Kilograms . . . . . . . . . . . . . . . . . . . . . . Metric Tons . . . . . . . . . . . . . . . . . . . . Newton--Meters . . . . . . . . . . . . . . . . . Kilopascals . . . . . . . . . . . . . . . . . . . . Kilometers per Liter . . . . . . . . . . . . . Kilometers per Hour . . . . . . . . . . . . .

Inches . . . . . . . . . . . . . . . . . 0.394 Feet . . . . . . . . . . . . . . . . . . . 3.280 Yards . . . . . . . . . . . . . . . . . . 1.094 Miles . . . . . . . . . . . . . . . . . . . 0.621 Square Inches . . . . . . . . . . 0.155 Square Feet . . . . . . . . . . . 10.764 Square Yards . . . . . . . . . . . 1.196 Square Miles . . . . . . . . . . . . 0.386 Acres . . . . . . . . . . . . . . . . . . 2.471 Cubic Feet . . . . . . . . . . . . . 35.315 Cubic Yards . . . . . . . . . . . . . 1.308 Fluid Ounces . . . . . . . . . . . . 0.034 Pints . . . . . . . . . . . . . . . . . . . 2.113 Quarts . . . . . . . . . . . . . . . . . 1.057 Gallons . . . . . . . . . . . . . . . . . 0.264 Ounces . . . . . . . . . . . . . . . . 0.035 Pounds . . . . . . . . . . . . . . . . . 2.205 Short Tons . . . . . . . . . . . . . . 1.102 Pound--Feet . . . . . . . . . . . . 0.738 Pounds per Square Inch . . 0.145 Miles per Gallon . . . . . . . . . 2.354 Miles per Hour . . . . . . . . . . 0.621

MULTIPLY BY

PIN: 072808-000