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
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F-1 thru F-12
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FP-3/FP-4 blank
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FP-5/FP-6 blank
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FP-7/FP-8 blank
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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 tacomlcmc.daform2028@us.army.mil. 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).
5-71
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).
5-73
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).
5-74
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.
5-75
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).
5-76
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).
5-96
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
‘ Crew
** Unit
*** Direct Support
**** General Support
INDEX 2
TM 9-4940-531-14
Subject
Page
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.)
l Crew
- Unit
“ Direct Support
**** General Support
INDEX 3
TM 9-4940-531-14
Page
Subject
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
l Crew
** Unit
*** Direct Support
*** General Support
INDEX 4
TM 9-4940-531-14
Page
Subject
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.)
l Crew
** Unit
*** Direct Support
**** General Support
INDEX 5
TM 9-4940-531-14
Page
Subject
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
TM 9-4940-531-14
Subject
Page
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
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