TM 9-4940-531-14 TECHNICAL MANUAL OPERATOR ... - NSN …€¦ · (NSN 4940-01-025-9856) (EIC: ... or fax your comments or DA Form 2028 directly to the U.S. Army TACOM Life Cycle Management

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 avoidelectrical shock.

Wear safety goggles/glasses and gloves to prevent injury from scalding and high watervelocity when operating the steam cleaner in any mode.

Hearing protection is required as the steam cleaner projects high intensity noise duringblowdown; failure to do so could result in hearing loss.

USE CAUTION when using dry cleaning solvent (item 22, appx E). Cleaning solventsevaporate quickly and can irritate exposed skin on contact. In cold weather, contact ofexposed skin with cleaning solvent can cause frost bite.

Do not install steam cleaner in areas containing flammable materials or gases. Severeinjury or death from fire or fumes may result.

Steam cleaner weighs 1365 lb (619.16 kg) wet, 1185 lb (537.52 kg) dry. Generator setweighs 600 lb (272.16 kg) wet, 585 lb (265.36 kg) dry. To avoid injury, do not attemptto 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 withsulfamic acid and sodium hydroxide; refer to paragraph 5-23. Moisture in the skin willactivate the chemical, causing severe irritation or burns.

To avoid injury, do not install steam cleaner in closed areas; proper ventilation is re-quired.

Avoid touching or coming into contact with steam, hot water, or other parts of equip-ment that are subjected to high temperatures to prevent serious burns.

Diesel fuel is FLAMMABLE; DO NOT SMOKE in vicinity while performing servicingoperations. To avoid burns, do not use flammable cleaning materials.

The operator must remain approximately 10 ft (3.05 m) from steam cleaner duringblowdown 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 onthe steam cleaner.

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TM 9-4940-531-14

If control panel must be opened for testing and S2 and S3 sensitive switches heldclosed, 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 com-pressed 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 EMERGENCYOFF switch to OFF position and vacate area.

To avoid injury, if cleaning gun emits superheated steam, turn EMERGENCY OFFswitch 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:

5. Remove old pages and insert new pages as indicated below:

None A(B blank) i-iv i-iv DA 2028 DA 2028

Remove Pages Insert Pages a - b a - b

Cover Cover

6. Replace the following work packages with their revised version.

7. Add the following new work packages.

Work Package Number None

Work Package Number None

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.

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

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 Army0816903

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.

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. Page/WP No. Change No. Front Cover 1 Blank 0 Warning summary (2 pgs) 0 a-b 0 A-(B blank) Added 1 i-iv 1 1-1 thru 1-21/1-22 blank 0 2-1 thru 2-41/2-42 blank 0 3-1 thru 3-21/3-22 blank 0 4-1 thru 4-100 0 5-1 thru 5-178 0 6-1 thru 6-7/6-8 blank 0 A-1 thru A-3/A-4 blank 0 B-1 thru B-10 0 C-1 thru C-5/C-6 blank 0 D-1/D-2 blank 0 E-1 thru E-4 0 F-1 thru F-12 0 FP-1/FP-2 blank 0 FP-3/FP-4 blank 0 FP-5/FP-6 blank 0 FP-7/FP-8 blank 0 Index-1 thru Index-11/Index-12 0blank

Metric Chart 0

PIN 0

A/B blank Change 1

DA 2028 Forms 1

New Text

TECHNICAL MANUAL HEADQUARTERS TM 9-4940-531-14 DEPARTMENT OF THE ARMY

WASHINGTON, D.C. 01 August 1994

Operator’s, Unit, Direct Support, and General Support

Maintenance Manual For

CLEANER, STEAM, HIGH PRESSURE, HOT AND COLD WATER JET, TRAILER MOUNTED (4940-01-025-9856) (EIC: 2BC)

REPORTING ERRORS AND RECOMMENDING IMPROVEMENTS

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

TABLE OF CONTENTS

Page HOW TO USE THIS MANUAL…………………………………………………… iii

CHAPTER 1 INTRODUCTION Page Section I. General Information……………………………………………………………………………1-2 Section II. Equipment Description and Data …………………………………………………………… 1-4 Section III. Principles of Operation ……………………………………………………………………… 1-10 CHAPTER 2 OPERATING INSTRUCTIONS Section I. Description and Use of Operator’s Controls and Indicators……………………………… 2-1 Section II. Operator Preventive Maintenance Checks and Services (PMCS) …………………… 2-9 Section III. Operation Under Usual Conditions………………………………………………………… 2-21 Section IV. Operation Under Unusual Conditions …………………………………………………… 2-41

i

Change 1

TM 9-4940-531-14

CHAPTER 3

Section I.Section Il.Section Ill.

CHAPTER 4

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

CHAPTER 5

Section I.Section Il.

CHAPTER 6

APPENDIX A

APPENDIX B

Section I.Section Il.Section Ill.Section IV.

APPENDIX C

Section I.Section Il.Section Ill.

APPENDIX D

APPENDIX E

Section I.Section Il.

APPENDIX F

PageOPERATOR MAINTENANCE INSTRUCTIONS

Lubrication Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1Troubleshooting Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1Operator’s Maintenance Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16

UNIT MAINTENANCE INSTRUCTIONS

Lubrication instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2Service Upon Receipt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3Preventive Maintenance Checks and Services (PMCS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9Maintenance Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19Preparation for Storage or Shipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-96

DIRECT SUPPORT MAINTENANCE INSTRUCTIONS

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2Maintenance Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-44

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

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

MAINTENANCE ALLOCATION CHART (MAC)

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-1Maintenance Allocation Chart for Steam Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-4Tools and Test Equipment for Steam Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-10Remarks for Steam Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-10

COMPONENTS OF END ITEM (COEI) AND BASIC ISSUEITEMS (BIl) LISTS

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-1Components of End Item . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-2Basic Issue Items . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-5

ADDITIONAL AUTHORIZATION LIST (AAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-1

EXPENDABLE AND DURABLE ITEMS LIST

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-1Expendable and Durable Items List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-2

ILLUSTRATED LIST OF MANUFACTURED ITEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-1

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

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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 alsopertains 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 refer-ences.

b. Nomenclature Cross-Reference List. Gives an alphabetical list of common names usedin the manual and official nomenclature.

c. Malfunction Index. Located just before the troubleshooting table in each maintenancechapter. Lists the possible malfunctions in order of appearance. References pages of the trouble-shooting tables.

e. Alphabetical Index. Located at the end of a manual. An extensive subject index foreverything in the manual. Gives page references.

MAINTENANCE PROCEDURES

There are four maintenance chapters: operator, unit, direct support, and general support. The firstthree maintenance chapters contain a malfunction index, a troubleshooting table, an initial setup, plusstep-by-step procedures.

(1) Malfunction Index. Describes fault symptoms and locates the applicable troubleshootingprocedure.

(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 theequipment:

Tools and Special Tools—Lists tools needed to perform maintenance.

Materials/Parts—Lists expendable/durable materials and 100% replaceable parts. Eachmaterial 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.

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TM 9-4940-531-14

Personnel Required—Lists the number of personnel needed when more than one person isrequired.

References—Lists other publications containing necessary information.

Equipment Conditions—Lists conditions to be met before starting the procedure. The para-graph 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 authorizedin 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.

WARNINGA warning is used to alert the user of hazardous operating and maintenance proce-dures, practices, conditions, statements, etc., that may result in injury to or death ofpersonnel if not strictly observed.

CAUTIONA 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 ofequipment or of mission effectiveness if not strictly observed.

NOTEA note is used to aid in simplifying a task.

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TM 9-4940-531-14

C H A P T E R 1

I N T R O D U C T I O N

CHAPTER INDEXParagraph Page

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.

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

1-21-21-21-21-21-21-31-41-41-41-41-41-51-101-101-101-111-131-131-131-141-151-151-171-171-181-191-191-191-201-21

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TM 9-4940-531-14

S e c t i o n I . G E N E R A L I N F O R M A T I O N

1-1. S C O P E

a. 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 andcold water jet steam cleaner.

c. Purpose of Equipment. Removes dirt, grease, mud, and other foreign matter from groundsupport vehicles.

1-2 . MAINTENANCE FORMS AND RECORDS

Department of the Army forms and procedures used for equipment maintenance will be those pre-scribed 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 . A D M I N I S T R A T I V E S T O R A G E

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 onlyone who can tell us what you don’t like about your equipment. Let us know why you don’t like thedesign 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 61299-6000. 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 AssemblyCoil Inlet Hose AssemblyCoil Inlet-to-Differential Pressure Switch Tubing AssemblyCoil Inlet-to-Inlet Pressure Gauge Tubing AssemblyCoil LidCoil Outlet-to-Differential Pressure Switch Tubing AssemblyCoil Outlet-to-Outlet Pressure Gauge Tubing AssemblyCoil Outlet-to-Pressure Switch Tubing AssemblyDELlME LightDRAIN LightDrain PlugEMERGENCY OFF SwitchExhaust FlapFacility Power Cable Assembly

Fuel GaugeFUEL PRESSURE gaugeFuel PumpFuel Pump-to-Pressure Gauge Tubing AssemblyFuel Shutoff ValveGenerator Power Cable Assembly

Heating CoilHose Rack Access DoorHOUR METERINLET PRESSURE GaugeLifting BracketLiquid Storage TankLocking Pin AssemblyMODE SELECTOR SwitchOPERATING TEMPERATURE GaugeOUTLET PRESSURE GaugePOWER LightPressure Switch-to-Pressure Switch Tubing AssemblyPressurized Water Hose AssemblyPUSH TO START SwitchSteam Cleaner

Temperature Control BoxTrailer Mounted Steam Cleaner

Wheel

Valve Assembly, MeteringHose, Assembly, NonmetallicTubing AssemblyTubing AssemblyAccess DoorTubing AssemblyTubing AssemblyTubing AssemblyLight, IndicatorLight, IndicatorPlug, PipeCircuit BreakerAccess DoorCable Assembly, Special

Purpose, ElectricalGage, Liquid QuantityGage, Pressure, Dial IndicatingFuel Control, MainTubing AssemblyCock, PlugCable Assembly, Power, Special

Purpose, ElectricalCooler, Fluid, IndustrialDoor, AccessMeter, Totalizing TimeGage, Pressure DialCover, AccessBottle, Screw CapChain Assembly, Single LegSwitch, RotaryIndicator, TemperatureGage, Pressure DialLight, IndicatorTubing AssemblyHose Assembly, NonmetallicSwitch, PushCleaner, Steam, High Pressure,

Hot and Cold Water JetInterconnecting BoxCleaner, Steam, High Pressure,

Hot and Cold Water Jet, TrailerMounted.

Caster, Swivel

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TM 9-4940-531-14

1-8. CORROSION PREVENTION AND CONTROL (CPC)

a. Corrosion Prevention and Control (CPC) of Army materiel is a continuing concern. It is impor-tant that any corrosion problems with this item be reported so the problem can be corrected andimprovements 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 ofother materials such as rubber and plastic. Unusual cracking, softening, swelling, or breaking of thesematerials may be a corrosion problem.

c. If a corrosion problem is identified, it can be reported using SF 368, Product Quality DeficiencyReport. Use of keywords such as “corrosion", "rust", "deterioration", or "cracking" will ensure that theinformation is identified as a CPC problem.

d. The form should be submitted to: Commander, U.S. Army Armament, Munitions and ChemicalCommand, ATTN: AMSMC-QAD/Customer Feedback Center, Rock Island, II 61299-6000.

S e c t i o n I l . R E P A I R P A R T S ; T O O L S ; S P E C I A L T O O L S ; T E S T ,M E A S U R E M E N T , A N D D I A G N O S T I C E Q U I P M E N T ( T M D E ) ;

A N D S U P P O R T E Q U I P M E N T

1-9. COMMON TOOLS AND EQUIPMENT

a. For authorized common tools and equipment, refer to the Modified Table of Organization andEquipment (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.

S e c t i o n I l l . E Q U I P M E N T D E S C R I P T I O N A N D D A T A

1-12. EQUIPMENT CHARACTERISTICS, CAPABILITIES, AND FEATURES

a. Characteristics.

(1) Trai ler-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 pressurizedwater source.

WATER TANK ASSEMBLY (2). Mounted on top of fuel tank assembly. Stores and regulates inletpressurized water flow.

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TM 9-4940-531-14

1-13. LOCATION AND DESCRIPTION OF MAJOR COMPONENTS (cont)

1-6

TM 9-4940-531-14


WATER PUMP ASSEMBLY (3). Located on top of fuel tank assembly. Pumps water to coil unit as-sembly.

MOTOR ASSEMBLY (4). Located beside water pump assembly. Provides power to operate waterpump assembly.

COIL INLET CONTROL ASSEMBLY (5). Situated behind the control box assembly. Controls routingand flow of water to coil.

CONTROL BOX ASSEMBLY (6). Located in upper left hand corner of steam cleaner above fire extin-guisher. Contains UPPER CONTROL PANEL ASSEMBLY (7) and LOWER CONTROL PANEL AS-SEMBLY(8).

OUTLET AND WATER DRAIN ASSEMBLY (9). Located on right front of steam cleaner. Is used withsteam cleaning gun.

LIQUID STORAGE TANK (1O). Mounted on coil unit assembly. Has markings indicating level of clean-ing solution.

COIL OUTLET ASSEMBLY (11). Located in front of coil unit assembly. Limits system pressure andcontrols temperature on the outlet side of coil unit assembly.

OIL BURNER ASSEMBLY (12). Located in front of coil unit assembly. Houses oil burner controls andfuel 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 fueltank assembly to oil burner assembly.

COIL UNIT ASSEMBLY (14). Situated behind the liquid storage tank and oil burner assembly. Allowspressurized 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 fuelfor oil burner assembly.

FIRE EXTINGUISHER (16). Used to extinguish fires in and around steam cleaner.

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TM 9-4940-531-14


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 thesteam/water.

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TM 9-4940-531-14

NOZZLES (20). Located in hose storage compartment. Attach to steam cleaning gun. Five differentnozzles 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 steamcleaner.

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 jackand a rear stabilizer kit.

GENERATOR SET (26). Mounted on flatbed trailer in front of steam cleaner. Provides power to steamcleaner when facility power is not available.

ENCLOSURE AND LIFT ASSEMBLY (27). Houses steam cleaner unit and provides an attachmentpoint for hoisting steam cleaner from trailer for maintenance.

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TM 9-4940-531-14

1-14 . EQUIPMENT DATA

Capacity:Steam 200 gph (757 Iph) 200 psi (1379 kPa) 325°F(163°C)Hot water 240 gph (908 Iph) 400 psi (2758 kPa) 190°F(88°C)Cold water 240 gph (908 Iph) 400 psi (2758 kPa) ambient

Weight:Steam cleaner, wetSteam cleaner, dryGenerator, wetGenerator, dryTrailerMain wheel load/

Iunette,wetMain wheel load/

Iunette, dryMain wheel load/

caster, wetMain wheel load/caster, dry

Lunette load, wetLunette load, dryCaster wheel load, wetCaster wheel load, dryTotal weight, wetTotal weight, dry

U.S. CUSTOMARY1365 lb1185 lb600 lb585 lb1050 lb2830 lb

2616 lb

2680 lb

2449 lb

185 lb204 lb335 lb371 lb3015 lb2820 lb

METRIC619.16 kg537.52 kg272.16 kg265.36 kg476.28 kg

1283.69 kg

1186.62 kg

1215.65 kg

1110.87 kg

83.92 kg92.53 kg

151.96 kg168.29 kg

1367.60 kg1279.15 kg

1-15. SAFETY, CARE, AND HANDLING

To ensure safety, read the warning page at the front of this manual carefully. It lists all warningsfound in this manual. Also, the warnings and cautions will be found in the text preceding the stepswhere special attention and care must be taken.

S e c t i o n I I I . P R I N C I P L E S O F O P E R A T I O N

1 - 1 6 . G E N E R A L

a. In many situations, ordinary cleaning methods are insufficient to remove greases, oils, caked-on dirt, etc., especially in confined areas. Standard water main pressure (usually 25 to 125 psi (172 to862 kPa)) is not high enough, and there is no way to meter a measured amount of detergent into thewater stream. In addition, there must be some way to continuously heat large amounts of water (200gph 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 figureFO-2 at the back of this manual for electrical schematic.

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TM 9-4940-531-14

1-17 . WATER SOURCES

a. Shop Outlet. Water is delivered to the pressurized water inlet assembly from an ordinary coldwater supply line and then to the water tank, which acts as a reservoir. The water level in the watertank is regulated by the S4 liquid level (float) switch (1) and the 9SOL solenoid valve (2). When thewater 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 waterpump 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.

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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 suctionhose assembly. The end of the suction hose that is immersed in water is fitted with a combinationstrainer 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 hosewhen the steam cleaner is turned off. Another strainer (Y-strainer) (5) traps the finer dirt and debriswhich might otherwise enter the water circuit. This strainer can be serviced by disassembling andcleaning. 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 ismetered into the water intake by the CHEMICAL METERING valve (7). A knob on the front panelcontrols the valve and allows the operator to adjust the amount of detergent depending upon thesituation. The cleaning compound should be used sparingly. Since chemical action is greater athigher temperatures, the chemical is ordinarily used in the steam and hot water modes, not in the coldwater 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 aircompressor but is designed to pump water.

1-20. AUTOMATIC DRAINING

a. Many steam cleaners are damaged by being stored outside during subfreezing weather. Thewater remaining behind in the pump, heating coil, and lines freezes, and the resulting expansion candamage these components. To safeguard against this, the steam cleaner has an automatic drainingsystem 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 sideof 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 steamcleaner is turned on, the valves close. When the steam cleaner is turned off, the valves open, permit-ting 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 waterpressurization forces these valves closed.

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TM 9-4940-531-14

1-21 . BYPASS MODE

1-14

TM 9-4940-531-14

1-21. BYPASS MODE (cont)

a. Whenever the steam cleaner is on, the water pump assembly is operating. If the steam cleaninggun 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 loopcauses churning of the water which results in a temperature buildup. However, the steam cleaner isdesigned 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). Whenthe pressure at the pump outlet exceeds 150 psi (1034 kPa), the PS5 pressure switch opens and de-energizes the 5SOL solenoid valve. The valve thus opens and bypasses the water pump. In thesame way, when the pressure drops below 150 psi (1034 kPa), the switch closes, energizing thesolenoid valve and causing it to close, thus “unbypassing” the pump. The solenoid valve is de-ener-gized 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, placingthe regulating valve (18) in the circuit. This is a normally-closed, self-actuated valve which opens at300 psi (2069 kPa) or greater pressure. The purpose of this valve is to establish a working pressurenot 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 shockabsorber to smooth out the pressure pulsations produced by the water pump assembly.

1-23. HEATING COIL

a. Pressurized water flows through heating coil unit assembly (20) where the water is heated bythe hot combustion gases from the atomizing, vaporizing oil burner (21). The coil is not made usingthe “cold-water wrap” technique used in commercial steam cleaners. Instead, the water flow enters atthe top of the coil unit assembly and emerges near the bottom in one straight pass. The diameter ofthe coil spiral decreases and increases along the coil from top to bottom. This prevents the coil fromdoubling back on itself. Such a design allows the heating coil to drain itself of water by gravity, thuspreventing 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 theinlet and outlet sides of the heating coil.

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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 towhat 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.

c. A similar function is performed by the PS3 differential pressure switch (24). One side of theswitch is connected to the coil inlet, the other side to the coil outlet. When the pressure differenceexceeds 70 psi (483 kPa), the switch closes and illuminates the DELlME light.

1 - 2 4 . T H E R M O C O U P L E

The thermocouple (25) is a bimetallic temperature sensing device which is installed directy in the wateroutlet line. As fluid temperature rises, the DC voltage produced by the thermocouple rises in proportionand 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 iscalibrated to burn diesel fuel. The oil burner consists of four major systems: fuel, air, ignition, andcontrol.

(a) Fuel System. Fuel is drawn from the fuel tank (26) and through a strainer (27) by an electricmotor-driven fuel pump (28). This pump also pressurizes the fuel and delivers it to a nozzle. Fuelpressure is indicated by the FUEL PRESSURE gauge (29) on the front panel of the steam cleaner. Thenozzle 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 shutoffvalves (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 isdriven 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 tubeis an air tube cone to speed up the airflow and a deflector (whirler) to make the air stream rotate, orswirl, for maximum vaporization. At the exit of the air tube, the atomized fuel vaporizes and mixes withthe 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 sparkformed at the spark gap ignites the fuel vapor/air mixture.

(d) Control System. The control system consists of an electric controller which can turn theburner motor and ignition transformer on and off. The controller is actuated by the cad cell, by safetyand temperature regulating switches, and by the temperature control box. See paragraphs 1-30 and1-31 for additional information.

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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-controlledvalve on the cleaning gun handle turns the gun on and off. Different kinds of nozzles can be fitteddepending on the situation. The standard nozzles are used when a forceful stream of water or steamis wanted. The fan-type nozzle is used in the steam mode when less force is wanted over a broaderarea.

b. It should be noted that in the steam mode, there is not actually steam going through the clean-ing gun, but superheated water. The water temperature is approximately 315°F (157°C), which iswell 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 isdischarged through the orifice in the cleaning gun nozzle, its pressure suddenly drops towards normalatmospheric pressure, causing it to flash (rapidly boil) into saturated (wet) steam coming from thenozzle.

1-27 . BLOWDOWN CYCLE

a. During steam cleaner operation, lime (calcium deposits) and rust can form on the inside of theheating coil. The buildup (scale) reduces the efficiency of the steam cleaner by reducing the heattransfer from combustion gases to the water circulating through the coil. In addition, the water pumphas to work harder to force water through the coil. These deposits, if not removed, can eventuallyclog the heating coil passages. The buildup is indicated by a 70 psi (483 kPa) or greater pressuredifference 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) intosteam. The resulting violent action (vibration and sudden blasts of steam) loosens the buildup ofscale within the heating coil. The check valve (34) prevents any backflow of water toward the pumpunder these conditions. When operating in steam mode only, blowdown is initialized every time thesteam cleaner is turned off. When the MODE SELECTOR switch is placed in OFF position, the S5 flowswitch actuates the flow regulating valve (35), letting steam discharge through the blowdown port underthe steam cleaner. This phase of the cycle lasts about 127 seconds. After this, the burner is shut downand 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 theheating coil. In this case, chemical action (descaling) is called for. A solution of water and scaleremoving 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 tobe descaled about every 100 hours of operation. The actual time is determined by the “hardness” of thelocal water supply.

1-29 . DESOOTING

In addition to scale buildup on the inside of the heating coil tubing, soot (a byproduct of diesel fuelcombustion) can accumulate on the outside of the heating coil tubing. Soot has the same effect onefficiency 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. SAFETY DEVICES

1-20

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 noflame after the burner starts up, or if there is a flameout during operation, the cad cell signals the electriccontroller to shutdown the oil burner.

b. Regulating valve (16) is a pressure relief valve that opens at 500 psi (3448 kPa), bypassing thewater pump assembly. This valve limits the absolute maximum coil inlet pressure to 500 psi (3448kPa).

c. Regulating valve (36) is a pressure relief valve that opens at 600 psi (4137 kPa) at the coiloutlet. 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 coiloutlet. 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 controlrelay 2CR (fig. FO-2). This interrupts fuel delivery to the oil burner. This safeguard prevents contin-ued 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 exceedsestablished limits. PS1 pressure switch (39) is activated when the MODE SELECTOR switch is inSTEAM position; this switch opens if pressure exceeds 400 psi (2758 kPa), which shuts down the oilburner. The PS2 pressure switch (40) is activated when the MODE SELECTOR switch is in HOT orCOLD position; this switch opens if pressure exceeds 600 psi (4137 kPa), which shuts down the oilburner.

1-31 . TEMPERATURE CONTROL BOX

a. Hot Water Mode. Temperature control box (41) maintains the hot water temperature at 200 to220°F (93 to 104°C) by cycling the oil burner on and off. If temperature reaches 225°F (107 °C), theHOT WATER ALARM lights and C1 circuit breaker trips.

b. Steam Mode. Temperature control box (41) maintains the steam mode temperature at 335 to340°F (168 to 171°C) by cycling the oil burner on and off. If temperature reaches 355°F (179 °C), theSTEAM ALARM lights and C1 circuit breaker trips.

1-21/(1-22 blank)

TM 9-4940-531-14

C H A P T E R 2O P E R A T I N G I N S T R U C T I O N S

CHAPTER INDEX

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 . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . .

Section I. DESCRIPTION AND USE OF OPERATOR’SCONTROLS AND INDICATORS

2-1. CONTROLS AND INDICATORS

Key

1

2

Control orIndicator

PUSH TO STARTSwitch

EMERGENCY OFFCircuit Breaker

Page

2-12-92-102-112-212-312-382-412-412-412-41

Function

Starts steam cleaner.

Automatically shuts off power in case of electricaloverload. Must be reset manually. Also can be turned offmanually in an emergency.

2-1

TM 9-4940-531-14

2-1. CONTROLS AND INDICATORS (cont)

Key

3

4

5

6

7

Control orIndicator

MODE SELECTORRotary Switch

DELlME LIGHT

POWER LIGHT

DRAIN LIGHT

HOT WATER ALARMLight

Function

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

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

Indicates main power is on.

Indicates steam cleaner is in drain cycle.

Indicates temperature in hot water mode is220°F (104°C) or pressure is 600 psi (4137 kPa).

2 - 2

TM 9-4940-531-14

8

9

10

11

12

13

KeyControl orIndicator

STEAM ALARM Light

HOUR METER

OPERATING TEM-PERATURE Gauge

FUEL PRESSUREGauge

CHEMICAL METERINGValve

CIRCUIT BREAKERPushbutton

Function

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

Indicates total hours of operation.

Provides water temperature reading after waterleaves coil unit assembly.

Measures fuel pressure at inlet of oil burnerassembly.

Controls flow rate of cleaning solution in use.

Indicates oil burner circuit breaker has opened and per-mits manual reset.

2-3

TM 9-4940-531-14


Control orKey Indicator Function

14 INLET PRESSURE Measures water pressure at inlet side of coil unit

Gauge assembly.

15 OUTLET PRESSURE Measures water pressure at outlet side of coil unitGauge assembly.

2 - 4

TM 9-4940-531-14

Key

16

17

Control orIndicator

Oil Burner MotorThermal OverloadSwitch

Oil BurnerElectromagnetRelay Reset Button

Function

Protects oil burner motor from overloads.

Resets oil burner electromagnet relay.

2 - 5

TM 9-4940-531-14


Key

18

19

Control orIndicator

Fuel Gauge

Quick Disconnect Cap

Function

Indicates amount of fuel in fuel tank.

Covers the suction inlet. Is removed when suction hoseassembly is used for drawing water from a nonpres-surized water source.

2 - 6

TM 9-4940-531-14

Key

20

21

22

Control orIndicator

Fuel TankShutoff Valve

Oil Burner FuelShutoff Valve

Ball Valve

Function

Controls fuel flow from oil burner assembly to fueltank.

Controls fuel flow from fuel tank to oil burnerassembly.

Controls water entering pump from water tank assembly.

2-7

TM 9-4940-531-14


Key

23

24

25

26

27

28

Control orIndicator

Steam Cleaning GunTrigger

Spray Nozzle

High Pressure Nozzle

Wide Spray Nozzle

Small Fan Nozzle

Large Fan Nozzle

Function

Controls flow of water or steam.

Emits pinpoint spray of hot or cold water.

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

Emits wide spray of hot or cold water.

Emits narrow flow of steam.

Emits wide flow of steam.

2 - 8

TM 9-4940-531-14

Control orKey Indicator Function

29 Leveling-Support Jack Raises and lowers leveling-support jack.

Crank Handle

S e c t i o n I I . O P E R A T O R P R E V E N T I V E M A I N T E N A N C E C H E C K SA N D S E R V I C E S ( P M C S )

2 - 2 . P M C S P R O C E D U R E S

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 WARN-INGS, 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 ofinterval. This column is used as an item number source for the TM Item Number column on DA Form2404 when recording PMCS results.

g. Interval Column. This column tells you when you must do the checks and services; eitherbefore, during, or after.

h. Location, Item To Check/Service Column. This column contains the name of the item(s) tobe checked or serviced.

i. Procedure Column. This column tells you how to do the required checks or services.

NOTEThe terms ready/available and mission capable refer to the same status: equipment ison hand and is able to perform its combat missions.

j. Not Fully Mission Capable If: Column. This column identifies the faults of the equipmentthat will prevent the steam cleaner from being fully mission capable.

2-10

2 - 3 . C L E A N I N G A G E N T SWARNING

DO NOT use diesel fuel, gasoline, or benzene (benzol) for cleaning. Use only ap-proved cleaning solvents to avoid the possibility of fire or poisoning. Prolonged breath-ing of fuel vapors can be fatal.

DO NOT SMOKE when using cleaning solvent. NEVER USE IT NEAR AN OPENFLAME. Be sure there is a fire extinguisher nearby and use cleaning solvent only inwell-ventilated places. Flash point of solvent is 138°F (59°C). Severe burns or deathcould result.

USE CAUTION when using dry cleaning solvent (item 22, appx E). Cleaning solventsevaporate quickly and can irritate exposed skin on contact. In cold weather, contact ofexposed skin with cleaning solvent can cause frostbite.

CAUTIONSteam cleaner must be COLD (same temperature as outside air) when using cleaningsolvent. DO NOT point water or steam directly at any electrical connection. Damage toelectrical system may result.

Keep cleaning solvents, gasoline, and lubricants away from rubber or soft plastic parts.They will deteriorate material.

NOTEOnly use those authorized cleaning solvents or agents listed in Appendix E.

TM 9-4940-531-14

a. Cleaning Electrical Connections. Use denatured alcohol (item 2,appx E) on clean wipingrag (item 18, appx E) to clean terminals.

b. Cleaning Rust or Grease. When cleaning grease buildup or rusty places, use dry cleaningsolvent (item 22, appx E). Then apply a thin coat of light oil (item 15, appx E) to affectedarea.

2-4. LEAKAGE DEFINITIONS FOR OPERATOR PMCS

It is necessary for you to know how fluid leakage affects the status of the steam cleaner. Followingare types/classes of leakage an operator needs to know to be able to determine the status of thesteam cleaner. Learn these leakage definitions and remember--when in doubt, notify your supervisor.

CAUTIONEquipment operation is allowable with minor leakage (Class I or II). Of course, consid-eration 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 inyour 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 formdrops.

b. CLASS II - Leakage of fluid great enough to form drops but not enough to cause drops to dripfrom 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

ItemNo.

Location Not FullyItem to MissionCheck/ Capable

Interval Service Procedures If:

1

2

3

2-12

Before

Before

Before

Electrical CableAssemblies

V-belts (1)

Hoses

Check for worn or dam-aged insulation and looseor broken connections.

Check for signs ofimpending failure, suchas fraying, cracks, or cuts.Push down on belts tocheck for tension.

Check for loose, dam-aged, or missing hoses.

Electrical cables haveworn or damagedinsulation or if connec-tions are open.

V-belts are loose orshow signs of impend-ing failure.

Hoses are loose, dam-aged, or missing.

TM 9-4940-531-14

ItemNo.

4

5

6

7

8

9

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

Interval

Before

Before

Before

Before

Before

Before

LocationItem toCheck/Service

Fuel TankAssembly

Liquid StorageTank (3)

Fire Extinguisher(4)

Procedures

Check for fuel leaks.Check fuel gauge (2) andadd fuel (para 2-5) asrequired.

Check and add cleaningsolution (para 2-5) asrequired.

Check that fire extinguish-er is present.

LevelingSupport Jack (5)and Rear Stabi-lizer (6)

Generator Set

Flat BedTrailer

Check that levelingsupport jack and rearstabilizer are not bent,broken, or inoperable.Check that pneumatictire has 35 pounds(241 kPa) of pressure.

Refer to TM 5-6115-615-12 for applicableBefore PMCS.

Refer to TM 9-2330-202-14&P for applicableBefore PMCS.

Not FullyMissionCapableIf:

Fuel leakage of anykind. There is insuffi-cient fuel to performall required cleaningtasks.

There is insufficientcleaning solution toperform all requiredcleaning tasks.

Fire extinguisheris missing.

Leveling support jackand/or rear stabilizerare bent, broken, orinoperable. If pneu-matic tire is underin-flated.

2-13

TM 9-4940-531-14


Location Not FullyItem to Mission

Item Check/ CapableNo. Interval Service Procedures If:

2-14

TM 9-4940-531-14

ItemNo.

10

11

12

13

14


Interval

During

During

During

During

During

LocationItem toCheck/Service

Wash HoseAssembly (7),PressurizedWater HoseAssembly (8),and Suction HOSE

Assembly (9)

Steam CleaningGun (10) andNozzles.

Water TankAssembly (11).

Fuel Tank andLines

Water Lines,Valves, Connec-tions, and WaterPump

Procedures

Check for leakage (somewater dripping is normal).Tighten any loose con-nections. Clean Y-strainerand foot valve on suctionhose assembly (para 3-6)as required. When draw-ing from a turbid (unclear)water source, check Y-strainer and foot valve ofsuction hose assembly(para 3-6) every 4 hoursof operation and clean asnecessary.

Check for leaks, irregularspray pattern, and properon/off operation.

Check that when ballvalve (12) is opened,water tank fills but doesnot overflow.

If fuel tank and/or lineshave any fuel seepage,shut down the steamcleaner and notify unitmaintenance.

Check all water lines,valves, connections, andwater pump for waterleakage. (Some waterdripping is normal.)


Any hose assembliesare missing or leakingexcessively, or if Y-strainer or foot valveis clogged.

Steam cleaning gunis leaking or does notshow normal on/offoperation, or nozzlesare producing anirreguIar spray pattern.

Water tank does notbegin filling when ballvalve is opened, or iftank overflows at anytime.

There is any fuelseepage.

There is excessiveleakage or any missinghoses.

2-15

TM 9-4940-531-14

ItemNo.


Interval

Location Not FullyItem to MissionCheck/ CapableService Procedures If:

15

16

17

2-16

During

During

During

Oil Drain Line(13)

Water PumpAssembly (14)

Coil ExhaustOpening (15)

Check fittings and line forleakage.

If water pump assemblyhas class Ill oil leakage,shut down steam cleanerand notify unit mainte-nance.

Observe if exhaust con-tains black smoke aftersteam cleaner hasreached operating tem-perature. If so, shut downsteam cleaner and notifyunit maintenance.

There are Class Ill oilleaks.

There is class III leak-age of oil from thewater pump.

There is black smokecoming from exhaustopening after warmupperiod.

TM 9-4940-531-14

ItemNo.


LocationItem toCheck/

Interval Service Procedures

18

19

20

During

During

During

OPERATINGTEMPERATUREGauge (16)

HOUR METER(17)

Indicator Lights(18)


Check that OPERATINGTEMPERATURE gaugereads 180 to 200°F (82 to93°C) for HOT watermode and 315 to 335°F(157 to 168°C) forSTEAM mode.

Check that HOURMETER is working.

Check that correct indica-tor light illuminates at theproper time during theindicated function. IfDELlME LIGHT, HOTWATER ALARM light, orSTEAM ALARM light il-luminates, shut downsteam cleaner and notifyunit maintenance.

OPERATING TEM-PERATURE gauge isinoperative or erratic.

Hour meter is notworking.

Indicator lights do notfunction properly or ifDELlME LIGHT, HOTWATER ALARM light,or STEAM ALARM lightis on.

2-17

TM 9-4940-531-14


Location Not FullyItem to Mission

Item Check/ CapableNo. Interval Service Procedures If:

During

During

During

INLET PRES-SURE Gauge(19) and OUTLETPRESSUREGauge (20)

FUELPRESSUREGauge (21)

CHEMICALMETERINGValve (22)

Check for pressure indica-tion when water pump ison. If inlet and outletpressure differencecauses DELlME LIGHTto illuminate, shut downsteam cleaner and notifyunit maintenance.

Check that gauge indi-cates between 90 and110 psi (621 and 758 kPawhen oil burner is on.

Check that valve is notstuck, operates smoothly,and meters chemical intothe water stream.

Gauges are inopera-tive or erratic, or ifDELlME LIGHT illu-minates.

Gauge is inoperativeor erratic.

CHEMICAL METERINGvalve is stuck or doesnot operate properly.

2-18

TM 9-4940-531-14

ItemNo.

24

25

26

27


LocationItem toCheck/

Interval Service

During Generator Set

During

After

After

Flat Bed Trailer

Procedures

Refer to TM 5-6115-615-12 for applicable DuringPMCS.

Refer to TM 9-2330-202-14&P for applicableDuring PMCS.


Leveling SupportJack (5) andRear Stabilizer(6)

Hoses

Check that leveling sup-port jack and rear stabi-lizer are not bent, brokenor inoperative. Checkthat pneumatic tire has35 pounds (241 kPa) ofpressure.

Check for loose, dam-aged, or missing hoses.

Leveling support jackand/or rear stabilizerare bent, broken, orinoperable; or if pneu-matic tire is under-inflated.

Hoses are loose, dam-aged, or missing.

2-19

para 3-5

TM 9-2330-202-14&P

TM 5-6115-615-12

TM 9-4940-531-14


2-20

TM 9-4940-531-14

S e c t i o n I l l . O P E R A T I O N U N D E R U S U A L C O N D I T I O N S

2-5. PREPARATION FOR USE

WARNING

• Do not install steam cleaner in areas containing flammable material or gases. Severeinjury or death from fire or fumes may result.

• Install steam cleaner in properly ventilated areas to avoid possible insufficient supply ofoxygen. If poorly-vented area is a necessity, outside air may be piped to oil burnerassembly 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 build-ing. Minimum exhaust stack is 10 inches (25.40 cm). Exhaust stack must be warm forsufficient draw; in cold areas of operation, exhaust stack should be insulated. Coldexhaust stack invites downdraft. Severe injury or death could result if exhaust is notvented.

• Items to be cleaned should be approximately 12 feet (3.66 m) from steam cleaner toavoid direct spray of steam cleaning gun coming into contact with steam cleaner.Excess moisture reaching generator and electrical controls will reduce life of steamcleaner unit and components and may cause shorts which may result in electricalshock.

• Diesel fuel is FLAMMABLE; DO NOT smoke in vicinity while performing servicingoperations. Severe injury or death may result.

• Ensure generator is properly grounded before operating steam cleaner to avoid electri-cal shock.

CAUTIONIncoming 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 ona level surface with consideration given toaccessibility for filling of cleaning solution andfuel oil. Location for electricity, water connec-tions, and maintenance should also be consid-ered. If generator set will be used, groundgenerator set before operation. Refer to TM 5-6115-615-12.

(2) Ensure steam cleaner is properlystabilized before operating. Turn leveling-support jack crank handle (1) clockwise to raiseflat bed trailer (2) and disengage it from towingvehicle. Turn leveling-support jack crank handle(1) counterclockwise to lower and stabilize theflat 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- orbreaker-protected electrical grounded circuit or outlet of at least 20 amp capacity.

2-22

TM 9-4940-531-14

b. Initial Checks and Services.

NOTEFor initial checks and services of generator set, refer to TM 5-6115-615-12. For initialchecks 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 ofdiesel 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


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 liquidstorage tank with cleaning compound (item 7, appx E). Reinstall liquid storage tank and webbingstrap.

(6) Using cross-tip screwdriver, remove access cover (10). Using flashlight, check oil level inwater 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 toequipment.

(7) If using commercial power, connect facility power cable assembly (12) to commercialpower source. If using generator power, ensure that generator power cable assembly (13) is con-nected 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 steamcleaning gun (17). Do not attach a nozzle when performing the Initial Start Up procedures in para-graph c., following.

2-26

TM 9-4940-531-14

c. Initial Start Up. The following steps provide steam cleaner initial starting procedures.

WARNINGAlways use ear protection. During operation, the generator set exceeds permissibledecibel levels. The steam cleaner also exceeds permissible decibel levels duringoperation in the steam mode and during blowdown. Failure to observe this warningcould result in permanent hearing injury.

Wear safety goggles/glasses and gloves to prevent injury when operating the steamcleaner in any mode.

CAUTIONDo not use the steam cleaner in any mode on surfaces having a petroleum-basedundercoating. Otherwise erosion/removal of such undercoating can result.

NOTERead through operating procedures prior to operation.

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

(a)

(b)cleaner.

Open exhaust flap (1).

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

2-27

TM 9-4940-531-14

2-5. PREPARATION FOR USE (cont)

c. Initial Start Up. (cont)

(c)

(d)

(e)

(f

(g)

(h)

(i)

(j)

Ensure coupler cap (4) is tightened securely.

Rotate ball valve (5) to ON position.

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

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

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

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

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

Rotate MODE SELECTOR (11) to COLD.

CAUTIONKeep water and steam away from the oil burner electromagnet relay. Moisture canpermanently 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), steamcleaner 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 follow-ing steps:

(a) Open exhaust flap (1).

(b) Unscrew coupler cap (2) and connect suction hose assembly (3) to water pump assem-bly (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) belowwater surface.

(e) If present, remove nozzle from steam cleaning gun (6). Open trigger (7).

2-29

TM 9-4940-531-14


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.

CAUTIONKeep water and steam away from the oil burner electromagnet relay. Moisture canpermanently 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 MODESELECTOR (10) to OFF. Refer to Table 3-1, Operator Troubleshooting.

(l) When a steady stream of water is discharged from steam cleaning gun (6), steamcleaner 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 permissibledecibel levels. The steam cleaner also exceeds permissible decibel levels duringoperation in the steam mode and during blowdown. Failure to observe this warningcould result in permanent hearing injury.

Wear safety goggles/glasses and gloves (item 12, appx E) when operating the steamcleaner in any mode to prevent injury from scalding and high water velocity.

CAUTIONDo not use the steam cleaner in any mode on surfaces having a petroleum-basedundercoating. Otherwise erosion/removal of such undercoating can result.

NOTERead through operating procedures before operating the steam cleaner.

In most instances, equipment should be washed by starting at ground level and workingup, and rinsed by starting at the top and working down.

a. General Theory of Operation. The steam cleaner can deliver steam or hot or cold water,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 cleanerwill automatically go into a drain cycle. When MODE SELECTOR is turned to OFF position fromsteam 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.

WARNINGTo 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 (2758kPa). Maximum pressure in this mode is 600 psi (4137 kPa). Steam cleaner is now ready to use inthe 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 and93.3 °C). Steam cleaner is now ready to use in the hot wash/rinse mode. If HOT WATER ALARMlight comes on, turn MODE SELECTOR to COLD. If light goes off, resume operation. If light stayson, turn MODE SELECTOR to OFF and contact unit maintenance.

(10) If using cleaning solution, open CHEMICAL METERING valve (7) to desired setting andallow sufficient time for cleaning solution to reach steam cleaning gun.

(11) To shut off cleaning solution, close CHEMICAL METERING valve (7) and allow sufficienttime for cleaning solution to clear steam cleaning gun.

(12) To turn off hot wash/rinse mode, rotate MODE SELECTOR (2) to COLD. Allow steamcleaning gun to cool, then rotate MODE SELECTOR (2) to OFF.



2-34

TM 9-4940-531-14

d. Steam.

(1)

(2)

(3)

(4)

(5)

(6)

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

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

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

Rotate MODE SELECTOR (2) to COLD.

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

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 (157.2and 168.3 °C) in 4 to 5 minutes. Steam cleaner is now ready to use in the steam mode. If STEAMALARM light comes on, turn MODE SELECTOR to COLD. If light goes off, resume operation. If lightstays 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 andallow sufficient time for cleaning solution to reach steam cleaning gun.

(11) To shut off cleaning solution, close CHEMICAL METERING valve (7) and allow sufficienttime 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 duringblowdown to prevent possible burns from steam and hot water.

Hearing protection is required as the steam cleaner projects high intensity noise; failureto do so could result in permanent hearing loss.

Ensure steam cleaning gun is turned off before entering blowdown cycle. Extreme heatwill damage wash hose and steam cleaning gun.

(12) To turn off steam mode, rotate MODE SELECTOR (2) to OFF. This will start the automaticblowdown cycle, flushing coil residue out through the blowdown pipe (8).

(13) Allow steam cleaner to blowdown automatically and shut off.



2-36

TM 9-4940-531-14

e. Shutdown Procedure.

NOTECleaning solution will be siphoned out when steam cleaner is shut down unlessCHEMICAL METERING valve is closed.

(1)

(2)

(3)position.

(4)

(5)water.

(6)

(7)

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

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

Turn both the fuel tank shutoff valve (3) and the oil burner fuel shutoff valve (4) to the off

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).

Wipe off steam cleaning gun (8) and wash hose assembly (9) with a clean wiping rag (item18, appx E).

2-37

TM 9-4940-531-14

2-7. DECALS AND INSTRUCTION PLATES. The following illustrations show all of the decalsand 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

S e c t i o n I V . O P E R A T I O N U N D E R U N U S U A L C O N D I T I O N S

TM 9-4940-531-14

2-8 . OPERATION IN COLD WEATHER

WARNINGOperation of the steam cleaner in below freezing (below 32°F (0°C)) weather canresult in injury caused by ice formation on and around equipment. Do not attempt tooperate the steam cleaner in below freezing weather.

CAUTIONWhen the steam cleaner is stored outside in cold weather, condensation can build up inthe water pump assembly oil sump. The condensed water can mix with oil, formingsludge and/or freezing. This can cause damage to the water pump assembly compo-nents. Change the water pump oil more frequently under cold weather conditions.

2-9. OPERATION IN DIRT, DUST, MUD, OR SANDY CONDITIONS

a.

b.

c.

d.

2-10.

All protective covers should be in place to prevent dust, dirt, and foreign material from reach-ing components. Close the access doors and exhaust flap when steam cleaner is not in use.

Clean Y-strainer in suction hose assembly every 4 hours.

Clean dirt and mud from steam cleaner after job is completed or daily.

Clean sand from the steam cleaner by brushing with a soft bristle brush.

OPERATION IN WET WEATHER

C A U T I O NIf it starts raining, stop steam cleaning operations and close all access doors to preventwater 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 genera-tor set operation.

2-41/(2-42 blank)

TM 9-4940-531-14

C H A P T E R 3O P E R A T O R M A I N T E N A N C E I N S T R U C T I O N S

CHAPTER INDEX

Paragraph Page

3-1.3-2.3-3.3-4.3-5.3-6.

3-1.

a.

b.

c.

3-2.

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

S e c t i o n l . L U B R I C A T I O N I N S T R U C T I O N S

LUBRICATION

There is no operator level lubrication for the steam cleaner.

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

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

S e c t i o n I l . T R O U B L E S H O O T I N G P R O C E D U R E S

T R O U B L E S H O O T I N G

a. This table lists common malfunctions that you may find with your equipment. Perform thetests, 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 neededto find the fault, or all the corrective actions needed to correct the fault. If the equipment malfunctionis 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 malfunc-tions are listed in order of appearance within table 3-1, with a page number reference to the pagewhere a test or inspection and corrective action are provided.

3-1

TM 9-4940-531-14

3 - 2 . T R O U B L E S H O O T I N G ( c o n t )

MALFUNCTION INDEX

STEAM CLEANER

TroubleshootingProcedure

(Page)

POWER LIGHT does not come on when PUSH-TO-START button is pressedand released . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-3

POWER LIGHT comes on and then goes off when PUSH-TO-STARTbutton 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 fluctuatingfuel 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 steamcleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-15

FLAT BED TRAILER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15

GENERATOR SET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-15

3-2

TM 9-4940-531-14

Table 3-1. Operator Troubleshooting

MALFUNCTIONTEST OR INSPECTION

CORRECTIVE ACTION

1. POWER LIGHT (1) DOES NOT COME ON WHEN PUSH-TO-START BUTTON (2) ISPRESSED 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


Table 3-1. Operator Troubleshooting (cont)


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, tightenscrews. Ensure upper control panel assembly cover is securely closed.

3-4

TM 9-4940-531-14



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 SELEC-TOR (4) to OFF and reset EMERGENCY OFF switch.

3 - 5

TM 9-4940-531-14




CORRECTIVE ACTION


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 waterflowing.

3-6

TM 9-4940-531-14



CORRECTIVE ACTION

NOTELow water output can be determined as follows: Deliver the water discharge into a 5-gallon bucket for 1 minute. Minimum accumulation should be as follows:

Cold or Hot Water Mode Steam Mode4 gallons (15.14 liters) 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 fromdrain pipe (4).

Turn MODE SELECTOR (5) to OFF, then COLD. If water continues todrain, 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




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



CORRECTIVE ACTION

Step 2. Check if blowdown valve (3) is open, allowing excessive water to escape fromdrain pipe (4).

Turn MODE SELECTOR (5) to OFF, then ON. If water continues todrain, 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.

b.

Momentarily open and close CHEMICAL METERING valve (6).

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. Repeatseveral 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 valveis completely submerged.

Clean foot valve strainer and place foot valve/strainer end of suctionhose 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 waterpump centerline.

Relocate steam cleaner to a different position or water source that willnot exceed the 15 ft (4.57 m) suction limit.

3-9

TM 9-4940-531-14




CORRECTIVE ACTION


3 - 1 0

TM 9-4940-531-14



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 unitmaintenance.

Step 3. Check if thermal overload switch (4) on motor housing is tripped.

Reset once if tripped. If thermal overload switch trips immediately afterbeing reset, notify unit maintenance.

NOTEIn the following step, it is normal for the electromagnet relay not to reset for up to 15minutes 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 resetwait 15 minutes and reset again. If it trips, notify unit maintenance.

3-11

TM 9-4940-531-14




CORRECTIVE ACTION

3-12

TM 9-4940-531-14



CORRECTIVE ACTION

5. OIL BURNER MOTOR (1) RUNS BUT FUEL PRESSURE GAUGE (2) INDICATES LOW ORFLUCTUATING 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) areopen.

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




CORRECTIVE ACTION


7.

3-14

OIL BURNER MOTOR (1) RUNS BUT OIL BURNER (2) FAILS TO IGNITE OR GOES OUTPREMATURELY.

Check if reset button (3) on oil burner electromagnet relay is tripped.

Reset once if tripped. If reset button trips immediately after beingreset, wait 15 minutes and reset again. If it trips, notify unitmaintenance.

TM 9-4940-531-14



CORRECTIVE ACTION

8. HOT WATER ALARM (1) OR STEAM ALARM (2) LIGHT COMES ON WHILE OPERATINGSTEAM 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.

Refer to TM 5-6115-615-12.

GENERATOR SET

3-15

TM 9-4940-531-14

3-4 . STEAM CLEANER NOZZLES—MAINTENANCE INSTRUCTIONS

THIS TASK COVERS:

a. Remova l b. Inspec t ion c. C l e a n i n g d. Instal lat ion

INITIAL SETUP

Tools/MaterialsCompressed air (if available)

Equipment ConditionsSteam cleaner shut down (para 2-6)

NOTEThere are five different nozzles used on the steam cleaner. The following procedureapplies 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.

Cleaning the nozzle with a metal tool of any kind can damage the nozzle and cause anirregular spray pattern.

CAUTION

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/PartsWiping rag (item 18, appx E)

Equipment ConditionsSteam cleaner shut off (para 2-6) and allowed to cool down.

DISASSEMBLY

3-18

WARNINGDiesel fuel is FLAMMABLE; DO NOT smoke in vicinity while performing servicingoperations. Injury or death could result.

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

TM 9-4940-531-14

2 Close shutoff valve (3) on fuel strainerassembly (4).

3 Loosen nut (5) on bottom of fuel strainerassembly (4) and swing wire retainer (6) toside.

4 Remove bowI (7).

5 Remove strainer (8) and gasket (9) frombowl (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 strainerassembly (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 Start steam cleaner (para 2-6) and check fuel strainer assembly (6) for leaks.

3-20

TM 9-4940-531-14

3-6 . SUCTION HOSE ASSEMBLY—MAINTENANCE INSTRUCTIONS

THIS TASK COVERS:

Cleaning

INITIAL SETUP

Tools and Special Tools8 in. adjustable wrench (appx D)

Equipment ConditionsSuction 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 toclean. Reinstall strainer (4) and cap (3) onto Y-strainer (5).

3-21/(3-22 blank)

TM 9-4940-531-14

C H A P T E R 4U N I T M A I N T E N A N C E I N S T R U C T I O N S

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.

Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Checking Unpacked Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Installation Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PMCS Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . .Leakage Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .General Maintenance Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Trailer-Mounted Steam Cleaner-Maintenance Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Steam Cleaner-Maintenance Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Oil Burner Assembly-Maintenance Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Fuel Tank Assembly-Maintenance Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .V- Belts- Maintenance Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Water Inlet Assembly-Maintenance Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Pump Inlet Assembly-Maintenance Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Lower Control Panel Assembly and CHEMICAL METERING Valve Assembly-

Maintenance Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Control Panel Assembly and Electrical Components Assembly-

Maintenance Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . .Wash Hose Assembly-Maintenance Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Enclosure and Lift Assembly and Hose Rack Access Door-

Maintenance Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Facility Power Cable Assembly-Maintenance Instructions . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . .Outlet and Water Drain Assembly-Maintenance Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Suction Hose Assembly-Maintenance Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Generator Power Cable Assembly-Maintenance Instructions . . . . . . . . . . . . . . . . . . . . . . . .Flat Bed Trailer-Maintenance Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Administrative Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Page

4-24-34-34-34-34-44-54-64-64-94-194-194-224-424-534-644-664-67

4-69

4-714-74

4-754-864-874-914-934-954-964-96

4-1

TM 9-4940-531-14

S e c t i o n I . L U B R I C A T I O N I N S T R U C T I O N S

4-1. LUBRICATION

CAUTIONDo not overfill water pump assembly with oil. Too much oil will destroy water pumpseals. If oil level is above center of sight glass, drain excess in accordance with para-graph 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) inwater pump assembly (4). If low, remove oil filler cap (5) and add oil (item 14, appx E) to center ofsight 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 asfollows:

(1)

(2)

(3)

(4)

4-2

Shut down steam cleaner (para 2-6).

Remove oil filler cap (5) from water pump assembly (4).

Remove drain plug (6) and empty oil into suitable container. Reinstall drain plug.

Add oil (item 14, appx E) to required level indicated and reinstall oil filler cap (5).

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) appliedto 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.

S e c t i o n I I . S E R V I C E U P O N R E C E I P T

4 - 2 . G E N E R A L

This section contains instructions for determining whether a new or reconditioned steam cleaner uponreceipt 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 5-6115-615-34, 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 dam-aged, 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 alldiscrepancies 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 drainplug.

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).

CAUTIONDo not overfill water pump assembly with oil. Too much oil will destroy water pumpseals. 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) inwater pump assembly (10). If low, remove oil filler cap (11) and add oil (item 14, appx E) to center ofsight 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 fillliquid 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 . I N S T A L L A T I O N I N S T R U C T I O N S

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. innerdiameter. The exhaust stack should be connected/adapted to the steam cleaner vent using adowndraft diverter.

4-5

TM 9-4940-531-14

S e c t i o n I l l . P R E V E N T I V E M A I N T E N A N C E C H E C K S A N D S E R V I C E S ( P M C S )

4-8. 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 ofinterval. This column is used as an item number source for the TM Item Number column on DA Form2404 when recording PMCS results.

c. Interval Column. This column tells you when you must do the checks and services; eitherquarterly or hours of operation.

d. Location, Item To Check/Service Column. This column contains the name of the item(s) to bechecked or serviced.

e. Procedure Column. This column tells you how to do the required checks or services.

N O T EThe terms ready/available and mission capable refer to the same status: equipment ison hand and is able to perform its combat missions.

f. Not Fully Mission Capable If: Column. This column identifies the faults of the equipment thatwill prevent the steam cleaner from being fully mission capable.

4 - 9 . L E A K A G E D E F I N I T I O N S

It is necessary for you to know how fluid leakage affects the status of the steam cleaner. Followingare types/classes of leakage an operator needs to know to be able to determine the status of thesteam cleaner. Learn these leakage definitions and remember--when in doubt, notify you supervisor.

CAUTIONEquipment operation is allowable with minor leakage (Class I or II). Of course, consid-eration 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 inyour 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 formdrops.

b. CLASS II - Leakage of fluid great enough to form drops but not enough to cause drops to dripfrom item being checked/inspected.

c. CLASS Ill - Leakage of fluid great enough to form drops that fall from item being checked/in-spected.

4-6

TM 9-4940-531-14

Locat ionI t e m t oCheck/ service

Procedure

Table 4-1. Preventive Maintenance Checks and Services for Steam Cleaner

ItemNo.

Interval

if:

Not FullyMissionCapable

1

2

3

100 Hoursor 30 Days

Quarterly

Quarterly

Water PumpAssemblyCrankcase (1)

Hinged Doors

Trailer MountedSteam Cleaner

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

Oil level is belowminimum or ifoil is dirty orcontaminated.

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

Check all painted surfacesfor chipping and abrasion.Spot paint (items 5, 6, and7, appx E) as required(refer to TM 43-01 39).

4-7

para 4-14

appx E

appx E

TM 9-4940-531-14

Table 4-1. Preventive Maintenance Checks and Services for Steam Cleaner (cont)

4-8

TM 9-4940-531-14

S e c t i o n I V . T R O U B L E S H O O T I N G

4-10 . TROUBLESHOOTING

a. This table contains troubleshooting information for locating and correcting many of the operatingtroubles which may develop in the steam cleaner. Perform the tests, inspections, and correctiveactions 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 findthe fault, or all the corrective actions needed to correct the fault. If the equipment malfunction is notlisted, 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 malfunctionsare listed in order of appearance within table 4-2, with a page number reference to the page where atest or inspection and corrective action are provided.

MALFUNCTION INDEXTroubleshooting

ProcedurePage

STEAM CLEANER

POWER LIGHT does not come on when PUSH-TO-START button is pressed . . . . . . . 4-10Water pump runs but there is low or no water output from nozzle . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11Water pump and motor run but vibrate or are unusually noisy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12Normal water output but oil burner will not start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13Oil burner has delayed ignition (noisy starts) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14Oil burner runs but excessive smoke comes from coil exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15Steam cleaning gun does not spray properly from steam nozzle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16Detergent cannot be added to water stream when CHEMICAL METERING

valve is opened and/or detergent flow does not stop when CHEMICALMETERING valve is closed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17

FLAT BED TRAILER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-18

GENERATOR SET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18

Table 4-2. Unit Maintenance Troubleshooting


CORRECTIVE ACTION

ISTEAM CLEANER

WARNINGTo avoid the danger of electrical shock, remove electrical power before performingmaintenance on electrical components.

NOTEWhen troubleshooting electrical malfunctions, refer to the schematics(figures FO-2 and FO-3 and appx F) in the back of this TM.

and wire list

4-9

TM 9-4940-531-14

4-10 . TROUBLESHOOTING (cont )

Table 4-2. Unit Maintenance Troubleshooting (cont)


CORRECTIVE ACTION


1. POWER LIGHT (1) DOES NOT COME ON WHEN PUSH-TO-START BUTTON (2) ISPRESSED.

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 whenpower is applied, notify direct support maintenance.

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

4-10

TM 9-4940-531-14



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 waterpump 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




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



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 FUELvery low or no fuel pressure.

If fuel solenoid is faulty, notify direct support

PRESSURE gauge (4) for

maintenance.

4-13

TM 9-4940-531-14




CORRECTIVE ACTION


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 orcorrosion.

Remove and clean cad cell (para 4-14). Clean transformer contactsand installed electrodes with alcohol (item 2, appx E) and clean wipingrag (item 18, appx E).

4-14

TM 9-4940-531-14



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




CORRECTIVE ACTION


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 remov-ing 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 washhose assembly (2) and check water flow. If flow is good, clean(backflush with air) or replace steam cleaning gun (para 4-13).

c. If flow remains restricted after above checks, notify direct supportmaintenance.

4-16

TM 9-4940-531-14



CORRECTIVE ACTION

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

Step 1. Check for insufficient water flow from water pump (2).

If water pump is not functioning properly, notify direct support mainte-nance.

Step 2. Check for loose hose clamps and kinked or clogged hoses.

Tighten any loose hose clamps, remove kinks, and clean or replaceclogged hoses (para 4-13).

4-17

TM 9-4940-531-14




CORRECTIVE ACTION


8. DETERGENT CANNOT BE ADDED TO WATER STREAM WHEN CHEMICAL METERINGVALVE IS OPENED AND/OR DETERGENT FLOW DOES NOT STOP WHEN CHEMICALMETERING 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 isopened, replace defective CHEMICAL METERING valve (para 4-19).

Step 4. Check water stream for detergent after CHEMICAL METERING valve (1) hasbeen closed.

If detergent flow does not stop, replace defective CHEMICAL METER-ING 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

S e c t i o n V . M A I N T E N A N C E P R O C E D U R E S

4-11 . GENERAL MAINTENANCE INSTRUCTIONS

a. Before performing any of the maintenance procedures, make sure that the handbrakes areengaged, 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 cleaningcompound (item 7, appx E).

Cleaning solvent vapors are toxic. Do not use solvent in a confined space. Avoid longperiods of breathing solvent vapors and/or contact with skin to avoid death or injury topersonnel.

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 antiseizingtape (item 24, appx E).

e. Be familiar with the warnings that are listed on the warning page located inside the front coverof this TM.

4-12 . TRAILER-MOUNTED STEAM CLEANER—MAINTENANCE INSTRUCTIONS

THIS TASK COVERS:

c .

a. Generator cable assembly removalb. Decal removal

Inspection/repaird. Decal installatione. Generator cable assembly installation

INITIAL SETUP

Tools and Special ToolsGeneral mechanic’s tool kit (item 2, appx B)

Equipment ConditionsGenerator set turned offSteam 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 removegenerator cable assembly (1).

4-20

DECAL REMOVAL

TM 9-4940-531-14

1

2

3

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

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

If necessary for replacement, remove fourblind 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

2

3

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

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

If removed, install four new identificationmarkers (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 generatorcable assembly (4) onto steam cleaner (5).

4-13 . STEAM CLEANER—MAINTENANCE INSTRUCTIONS

THIS TASK COVERS:

a. Disassemb ly b. Inspect ion/repair c. Reassembly

INITIAL SETUP


Material/PartsBlind 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 ConditionsEMERGENCY OFF switch in OFF position and external power cable disconnectedWater tank assembly drainedClean 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 andlabel all hoses prior to removal.

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

2 Remove sixteen blind rivets (5), output capacity identification plate (6), identification plate (7), andtwo 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 warningmarker (11) from chemical holder weldment (12).

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

5 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).

4-24

TM 9-4940-531-14

6

7

8

9

10

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

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

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.

Remove chemical bottle-to-metering valvehose (35) from liquid storage tank (36) anddrain hose into suitable container.

Remove webbing strap (37) and liquidstorage tank (36) from chemical holderweldment (12).

4-25

TM 9-4940-531-14


DISASSEMBLY (cont)

11

12

4-26

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

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

TM 9-4940-531-14

13 Remove hose clamp (43) and metering valve-to-water pump hose (39) from water pump assem-bly (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 oilburner.

15 Loosen filler opening cap (48) and, with suitable container in place, remove drain plug (49) todrain 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 CLEANER—MAINTENANCE

DISASSEMBLY (cont)

INSTRUCTIONS (cont)

16 Remove two hose clamps (50) and disconnect fuel shutoff-to-oil burner hose (51) and oil burnerto-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

19

20

21

22

23

Remove four hose clamps (54) and disconnect fuel shutoff-to-fuel tank hose (55), fuel tank-to-fuelshutoff 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).

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

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

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

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

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

4-29

TM 9-4940-531-14


DISASSEMBLY (cont)

24

25

26

27

28

29

4-30

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

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

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

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

Remove tiedown strap (80).

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

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

2

3

4

5

6

7

8

9

10

11

Check for damaged, broken, or missing parts.

Repair is by replacement of damaged or unserviceable parts.

Hoses are manufactured items, refer to appendix F.

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

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

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

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

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

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

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

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 (15and 16) with two hose clamps (17). Secure hoses to platform skid (18) with new tiedown strap(19).

4-33

TM 9-4940-531-14


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 assem-bly (26) onto pipe tee (21).

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

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

4 - 3 4

10

11

12

13

14

15

TM 9-4940-531-14

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

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

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

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

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

Install fuel shutoff-to-oil burner hose (45), fuel strainer-to-fuel shutoff hose (38), fuel tank-to-fuelshutoff hose (41), and fuel shutoff-to-fuel tank hose (42) onto fuel shutoff assembly (34) with fourhose 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 burnerassembly (48) with two hose clamps (49).

4-35

TM 9-4940-531-14


REASSEMBLY (cont)

18

19

4-36

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

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

TM 9-4940-531-14

20 Install lower control panel assembly (56) onto control box assembly (57) with three new tappingscrews (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 storagetank (63) onto chemical holder weldment(64).

23 Install chemical bottle-to-metering valvehose (59) onto liquid storage tank (63).

4-37

TM 9-4940-531-14


REASSEMBLY (cont)

24 Install elbow (65) onto FUEL PRESSURE gauge (66). Install FUEL PRESSURE gauge ontolower 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 tubingnut (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) intohose rack access door (81).

4-39

TM 9-4940-531-14


REASSEMBLY (cont)

27

28

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

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

4-40

TM 9-4940-531-14

29

30

31

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

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

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

4 - 4 1

TM 9-4940-531-14

4-14. OIL BURNER ASSEMBLY—MAINTENANCE INSTRUCTIONS

c .

THIS TASK COVERS:

a. Removal/disassemblyb. Inspect ion/repair

Reassembly/installationd. Fuel pressure adjustmente. Cad cell cleaning and adjustmentf. Cad cell test

g. Adjustment using smoke analyzer

INITIAL SETUP

Tools and Special ToolsGeneral mechanic’s tool kit (item 2Smoke test kit (item 3, appx B)

Material/PartsAntiseizing 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

appx B)

EMERGENCY OFF switch in OFF positionMain power to steam cleaner off

4-42

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-to-strainer hose (6).

4 - 4 3

TM 9-4940-531-14

4-14. OIL BURNER ASSEMBLY—MAINTENANCE INSTRUCTIONS (cont)

REMOVAL/DISASSEMBLY (cont)

4

5

6

NOTESome parts not shown for clarity.

Loosen two screws (7) and slide electro-magnet relay cover (8) to access wireconnections.

NOTEBe sure all wires are tagged andlabeled before removal.

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

Remove conduit connector locknut (13) anddisconnect conduit assembly no.from electromagnet relay (11).

209 (12)

7 Loosen tapping screw (14) and rotateretaining strap (15) to open power trans-former lid (16) to accesscapscrew (17).Close power transformer lid after access isobtained.

4-44

TM 9-4940-531-14

8

9

10

11

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

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

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

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

lNSPECTION/REPAIR


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


1

2

3

4

5

Some parts not shown for clarity.

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

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

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

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

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

4-46

6 Close power transformer lid (17) andsecure with retaining strap (18) and tappingscrew (19).

7 Position conduit assembly no. 209 (20) inelectromagnet relay (21) and secure withconduit connector locknut (22).

8 Install conduit splices (23) to connect fourwires no. 6, 3, 4, and 5 (24) to electromag-net relay (21).

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

TM 9-4940-531-14

4-47

TM 9-4940-531-14


REASSEMBLY/lNSTALLATION (cont)

10 Connect fuel shutoff-to-oil burner hose (27)and oil burner-to-strainer hose (28). Installtwo hose clamps (29).

11 Connect fuel pump-to-pressure gaugetubing assembly (30).

12 Open two fuel shutoff assembly valves (31).

FUEL PRESSURE ADJUSTMENT

1 With steam cleaner operating in steammode, FUEL PRESSURE gauge shouldread between 90 and 110 psi (621 and 758kPa).

2 If pressure is not within range in precedingstep, adjust pressure regulating screwinside nut (1) on fuel pump (2). Turnpressure regulating screw inside nut (1)clockwise to increase fuel pressure andcounterclockwise to decrease fuel pres-sure.

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TM 9-4940-531-14

CAD CELL CLEANING AND ADJUSTMENT

WARNINGTo avoid electrical shock, make sure main power to steam cleaner is off.

NOTEThe electromagnet relay is a safety control that senses flame through a cad cell. If cadcell does not sense flame, it will shut off oil burner assembly. Electromagnet relay is amanual reset control and will not come back on until operator depresses reset button.

1 Turn EMERGENCY OFF switch (1) to OFF.

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TM 9-4940-531 -14

4-14 . OIL BURNER ASSEMBLY-MAINTENANCE INSTRUCTIONS (cont )

CAD CELL CLEANING AND ADJUSTMENT (cont)

1

2

3

4

5

6

7

8

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

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.

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

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

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

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

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

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TM 9-4940-531-14

CAD CELL TEST

NOTETest cad cell if cleaning of the cad cellwindow fails to restore proper oil

1

2

3

4

5

6

7

8

burner operation.

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

Start steam cleaner (para 2-6).

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

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

Shut off steam cleaner and remove tempo-rary jumper.

With oil burner off, dark cell resistance withohmmeter connected to cad cell lead wiresshould be greater than 20,000 ohms.

Notify direct support maintenance if resis-tance does not meet specified require-ments.

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

ADJUSTMENT USING SMOKE ANALYZER

NOTESteam cleaner must be running atnormal operating temperature whensampling with smoke analyzer.

1 Adjust fuel pressure. Refer to fuel pressureadjustment on page 4-48.

2 Using smoke analyzer (1), check exhaust attop of coil unit assembly (2) for proper airand fuel mixture as follows.

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TM 9-4940-531-14


ADJUSTMENT USING SMOKE ANALYZER (cont)

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

4 Insert sampling tube into the exhauststack.

5 Pump smoke analyzer handle 10 full pumpstrokes.

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.

NOTEThe darker the spot, the more fuel isburning. To lighten the spot, increaseair flow.

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TM 9-4940-531-14

8 If air adjustment is required, loosen screw(7) on vaporizing oil burner (8) and rotateair louvers (9). Opening air louvers (9)provides increased primary air flow; closingair louvers (9) decreases air flow. Tightenscrew (7).

NOTEAir louvers must be fastened tightlyafter adjustment. Louvers can vibrateout of position if screws are not tight-ened sufficiently.

9 Repeat steps 1 thru 8 preceding to takeanother smoke sample. If oil burner as-sembly cannot be adjusted, notify directsupport maintenance.

4-15 . FUEL TANK ASSEMBLY—MAINTENANCE INSTRUCTIONS

THIS TASK COVERS:

a. Disassemb ly b. Inspect ion/repair c. R e a s s e m b l y

INITIAL SETUP

Tools and Special ToolsCrescent 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/PartsAntiseizing 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 ConditionsClean oil and diesel fuel containers availableFuel tank assembly drained (para 4-6)

4-53

TM 9-4940-531-14

4-15. FUEL TANK ASSEMBLY—MAINTENANCE INSTRUCTIONS (cont)

NOTERemove 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 pumpassembly (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 twoself-locking nuts (10), two capscrews (11), two plain nuts (12), two Iockwashers (13), twocapscrews (14), and front post assembly (15).

4 - 5 4

TM 9-4940-531-14

5

6

7

8

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

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

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

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

4-55

TM 9-4940-531-14


DISASSEMBLY (cont)

4-56

TM 9-4940-531-14

WARNINGTo 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) andwater pump assembly (2)

10 Remove hose clamp (32) and disconnect pump inlet-to-water pump hose (33) from pump inletassembly (31).

NOTEPipe union (34) and suction inlet assembly nonmetallic hose (35) cannot be replaced atthis level of maintenance.

11 Uncouple pipe union (34) and remove suction inlet nonmetallic hose assembly (35) with attachedpipe 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 bereplaced 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) andconduit 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) frompump inlet assembly (31).

15 Remove two conductor splices (48) and remove two wires no. 22 and 24 (42 and 43) from 1SOLsolenoid valve (49).

4-57

TM 9-4940-531-14


DISASSEMBLY (cont)

16 Remove three self-locking nuts (50), threecapscrews (51), and angle bracket (52)from saddle and fuel tank weldment (28).

17 Remove hose clamp (53), pump inlet-to-water pump hose (33), and grommet (54).

18 Remove six hose clamps (55) and three water pump-to-coil inlet hoses (56, 57, and 58) fromwater 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



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

2

3

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

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

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

4-59

TM 9-4940-531-14


REASSEMBLY (cont)

4 Install new grommet (11) into saddle and fuel tank weldment (4). Install pump inlet-to-waterpump 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) andthree new self-locking nuts (16).

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TM 9-4940-531-14

6

7

8

9

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

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

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

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). Installjunction box cover (29) and tighten two screws (30).

4-61

TM 9-4940-531-14


REASSEMBLY (cont)

10

11

12


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

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

Install nonmetallic hose (34) onto waterpump assembly (8) and pump inlet assem-bly (23) with two hose clamps (35).

13

14

15

16

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

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

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

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

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TM 9-4940-531-14

17 Install front post assembly (48) on enclosure and lift assembly (49) with two capscrews (50), twonew 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

19

20

21

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

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

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

Fill fuel tank; refer to paragraph 2-5.

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TM 9-4940-531-14

4 - 1 6 . V - B E L T — M A I N T E N A N C E I N S T R U C T I O N S

THIS TASK COVERS:

Belt replacement and adjustment

INITIAL SETUPTools and Special Tools

GeneraI mechanic’s tool kit (item 2, appx B)

Equipment ConditionEMERGENCY OFF switch in OFF position and external power cable disconnected

BELT REPLACEMENT AND ADJUSTMENT

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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.

NOTEV-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:

NOTEWater 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 assem-bly and water pump assembly pulleys are exactly aligned and that V-belts are tracking smoothly.

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TM 9-4940-531-14

4-17. WATER INLET ASSEMBLY—MAINTENANCE INSTRUCTIONS

THIS TASK COVERS:

a. Disassembly b. Inspection/repair c. Reassembly

INITIAL SETUP


Materials/PartsAntiseizing tape (item 24, appx E)

Equipment ConditionsWater inlet assembly removed (para 4-15)

DISASSEMBLY

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

2 Remove straight adapter (4) and pipeelbow (5) from angle bracket (3).

INSPECTION/REPAIR

1 Check for broken or damaged parts.

2 Repair is by replacement of damaged orunserviceable 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).

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TM 9-4940-531-14

4-18 . PUMP INLET ASSEMBLY—MAINTENANCE INSTRUCTIONS

THIS TASK COVERS:


INITIAL SETUP



Equipment ConditionsPump inlet assembly removed (para 4-15)

DISASSEMBLY

1

2

3

4

5

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

Remove hose clamp (7) and hose (8) fromsolenoid valve (9).

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

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

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

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TM 9-4940-531-14

4-18 . PUMP INLET ASSEMBLY-MAINTENANCE INSTRUCTIONS (cont )

INSPECTION/REPAlR



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

REASSEMBLY

1

2

3

4

5

6

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

Install two pipe nipples (1), pipe bushing

(2), pipe tee (3), pipe nipple (4), and pipeunion half (5) onto pipe tee (6).

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

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

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

Install pipe (13), reducer (14), and hosebarb (15) onto pipe union half (16). Couplepipe union.

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TM 9-4940-531-14

4-19. LOWER CONTROL PANEL ASSEMBLY AND CHEMICAL METERING VALVEASSEMBLY—MAINTENANCE INSTRUCTIONS

THIS TASK COVERS:


INITIAL SETUP


Materials/PartsAntiseizing tape (item 24, appx E)White enamel (item 26, appx E)

Equipment ConditionsLower control panel assembly removed and partially disassembled (para 4-13)

DISASSEMBLY

1

2

3

4

Loosen setscrew (1) and remove knob (2),two nuts (3), flat washer (4), and CHEMl-CAL METERING valve assembly (5) fromindicator panel (6).

If necessary for replacement, removecalibration plate (7).

If necessary for replacement, removeCHEMICAL METERING identificationmarker (8) and FUEL PRESSURE identifi-cation marker (9).

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

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TM 9-4940-531-14

4-19. LOWER CONTROL PANEL ASSEMBLY AND CHEMICAL METERING VALVEASSEMBLY-MAINTENANCE INSTRUCTIONS (cont )

INSPECTION/REPAIR



REASSEMBLY

1

2

3

4

5

6

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

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

If removed, install new CHEMICAL ME-TERING identification marker (4) and newFUEL PRESSURE identification marker (5)onto indicator panel (6).

If removed, install new calibration plate (7).Ensure calibration plate (7) is installed sozero mark is 60 degrees above its horizon-tal center line and to the left of hole centerline as shown.

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

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

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TM 9-4940-531-14

4-20. CONTROL PANEL ASSEMBLY AND ELECTRICAL COMPONENTS ASSEMBLY—MAINTENANCE INSTRUCTIONS

THIS TASK COVERS:

a. Replacing cartridge fuseb. Inspecting identification markersc. Replacing identification markers

INITIAL SETUP


Materials/PartsCartridge fuse (F09B250V6-1/4A)Denatured alcohol (item 2, appx E)Wiping rag (item 18, appx E)Tapping screw (4) (MS51861-46)

Equipment ConditionsSteam cleaner shut down (para 2-6) and power disconnected


REPLACING CARTRIDGE FUSE

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

2 Remove and discard cartridge fuse (3) frompower transformer (4). Install new cartridgefuse (3).

3 Close control panel assembly (2) and installfour new tapping screws (1).

INSPECTING IDENTIFICATION MARKERS

Check for damaged or missing control panelidentification markers. If damaged, replaceidentification markers as follows.

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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 markerMODE SELECTOR position identification markerMODE SELECTOR identification markerOPERATING TEMPERATURE identification markerHOUR METER identification markerHOT WATER ALARM identification markerSTEAM ALARM identification markerCIRCUIT BREAKER identification markerDRAIN LIGHT identification markerPOWER LIGHT identification markerDELlME LIGHT identification markerEMERGENCY OFF identification marker208 VOLTS identification markerELECTRICAL 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) andwiping 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.

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TM 9-4940-531-14

4-21 . WASH HOSE ASSEMBLY—MAINTENANCE INSTRUCTIONS

THIS TASK COVERS:


INITIAL SETUP


Material/PartsAntiseizing tape (item 24, appx E)

Equipment ConditionsWash hose assemblies removed (para 4-13)

NOTEThere are three wash hose assemblies. The following procedures are written for onewash hose assembly; repeat as necessary.

DISASSEMBLY

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

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

INSPECTION/REPAIR



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

4-74

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).

NOTEHose 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:


INITIAL SETUP


Materials/PartsBlind 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 ConditionsSteam cleaner shut down and cooled (para 2-5)External cable and hoses removed

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4-22. ENCLOSURE AND LIFT ASSEMBLY AND HOSE RACK ACCESS DOOR—

1

2

3

4

5

MAINTENANCE INSTRUCTIONS (cont)

DISASSEMBLY

Remove two tapping screws (1) and ex-haust flap (2) from steam cleaner lift as-sembly (3).

Remove twelve capscrews (4) and top rightcover (5).

Remove eight capscrews (6) and top leftcover (7).

Remove four tapping screws (8) and ac-cess cover (9).

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

4-76

6

7

8

TM 9-4940-531-14

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

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

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).—

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4-22. ENCLOSURE AND LIFT ASSEMBLY AND HOSE RACK ACCESS DOOR—MAINTENANCE INSTRUCTIONS (cont)

NOTELeft 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 assem-bly (44).

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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 steamcleaner lift assembly (3).

NOTEStructural 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).

NOTEEnsure 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


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

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).

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

Remove eight self-locking nuts (79), eight flat washers (80), eight machine screws (81), and two

18

19

20

21hasps (82) from hose rack cover (71).

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22 Remove 20 capscrews (83) and front panel (84) from steam cleaner lift assembly (3).

NOTEFront 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.



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), twonew 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).

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3

4

5

6

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

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

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

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 ninecapscrews (29).

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

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9

10

11

12

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).

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

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

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

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

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16 Install flat washer (62), retaining band (63), flat washer (64), spring (65), flat washer (66), and twonew 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 flatwashers (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).

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4-23. FACILITY POWER CABLE ASSEMBLY—MAINTENANCE INSTRUCTIONS

THIS TASK COVERS:

a. Inspection b. Disassembly c. Repair d. Reassembly

INITIAL SETUP

Tools and Special ToolsGeneral mechanic’s tooI kit (item 2, appx B)

Equipment ConditionsFacility power cable assembly removed (para 4-13)

INSPECTION


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

3 If electrical plug connectors are unserviceable, proceed to disassembly.

NOTEElectrical plug connector style may vary slightly.

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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 powercable (5). Remove three screws (13) and disconnect three wires (7) to remove power cable (5)from eletrical plug connector (14). Remove cover (12).

REPAIR


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) topower cable (5) with two screws (9).

3 Slide cover (4) onto power cable (5). Connect three wires (7) to electrical plug connector (8) asshown and secure with three screws (6).

4 Install cover (4) onto electrical plug connector (8) with three screws (3). Secure clamp (2) topower cable (5) with two screws (1).

4-24. OUTLET AND WATER DRAIN ASSEMBLY—MAINTENANCE INSTRUCTIONS

THIS TASK COVERS:

a. Disassemb ly b. Inspect ion/repair c. R e a s s e m b l y

INITIAL SETUP


Material/PartsAntiseizing tape (item 24, appx E)Self-locking nut (2) (MS51988-5)

Equipment ConditionsSteam cleaner shut down (para 2-6) and power disconnectedOil burner assembly removed (para 4-13)Thermocouple and attached parts removed (para 4-13)

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4-24. OUTLET AND WATER DRAIN ASSEMBLY—MAINTENANCE INSTRUCTIONS (cont)

1

2

3

NOTERemove parts only if damaged or if necessary for access to damaged items.

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

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

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

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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



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4-24. OUTLET AND WATER DRAIN ASSEMBLY—MAINTENANCE INSTRUCTIONS (cont)

REASSEMBLY

1

2

3

4


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

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

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

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5 Install pipe union half (13) onto pipe nipple (14). Couple pipe union. Install pipe elbow (15) andstraight 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 supportassembly (21) with two machine bolts (22) and two new self-locking nuts (23).

4-25 . SUCTION HOSE ASSEMBLY—MAINTENANCE INSTRUCTIONS

THIS TASK COVERS:


INITIAL SETUP


Materials/PartsAntiseizing tape (item 24, appx E)Gasket (MS27030-2)

Equipment ConditionsSuction 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 inletstrainer (7).

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

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4-25. SUCTION HOSE ASSEMBLY—MAINTENANCE INSTRUCTIONS (cont)

INSPECTION/REPAIR

1

2

3

4

5

6

7

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

Inspect hose (3) for deterioration or damage.

If straight adapters or hoses areunserviceable, requisition new suction hoseassembly.

Check for broken, damaged, or missing parts.

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

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

Repair is by replacement of damaged orunserviceable 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 inletstrainer (4).

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

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4-26. GENERATOR POWER CABLE ASSEMBLY—MAINTENANCE INSTRUCTIONS

THIS TASK COVERS:

a. Inspection b. Disassembly c. Repair d. Reassembly

INITIAL SETUP


Materials/PartsSolder (item 21, appx E)

Equipment ConditionsGenerator power cable assembly removed (para 4-12)

INSPECTION


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.

NOTEElectrical 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).

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4-26 . GENERATOR POWER CABLE ASSEMBLY—MAINTENANCE INSTRUCTIONS(cont)

REPAIR


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

R E A S S E M B L Y

1

2

3

4

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

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

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

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

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4-27. FLAT BED TRAILER—MAINTENANCE INSTRUCTIONS

THIS TASK COVERS:

a. Removal of reflectors b. Inspection/repair c. Installation of reflectors

INITIAL SETUP


Materials/PartsSelf-locking nut (4) (MS17829-3C)Tapping screw (4) (MS51861-65)

NOTERefer to TM 9-2330-202-14&P for additional information on unit level maintenance ofthe trailer.

REMOVAL OF REFLECTORS

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

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

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4-27. FLAT BED TRAILER—MAINTENANCE INSTRUCTIONS (cont)

INSPECTION/REPAIR

1 Check for broken, damaged, or missingparts.


INSTALLATION OF REFLECTORS

1 Install two red indicating reflectors (1) ontoframe of trailer chassis (2) with four ma-chine screws (3) and four new self-lockingnuts (4).

2 Install two red indicating reflectors (5) ontofenders of trailer chassis (2) with four newtapping screws (6).

S e c t i o n V I . P R E P A R A T I O N F O R S T O R A G E O R S H I P M E N T

4 - 2 8 . G E N E R A L

Unit commanders are responsible for ensuring that all materiel issued or assigned to their command ismaintained in a serviceable condition and properly cared for, and that personnel under their commandcomply 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 timewhen:

(a) An organization lacks operating funds, personnel, other resources, or normal usage ofits organic materiel.

(b) Materiel which exceeds the capability of the owning organization to operate or maintainmust be retained by that organization for contingency or other cogent reasons.

(2) Installation or organization commanders may authorize the administrative storage of theirmateriel within guidance furnished by MACOM commanders and AR 750-1. The steam cleanershould 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.

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b. Scope. The requirements specified herein are necessary to maintain steam cleaner in adminis-trative 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 administra-tive storage should be capable of being readied to perform its mission within a 24-hour period or asotherwise may be prescribed by the approving authority. Before equipment is placed in administrativestorage, current maintenance services, shortcomings, and deficiencies should be corrected, and allmodification work orders (MWO’s) should be applied.

(2) Report equipment in administrative storage in Materiel Readiness and Unit Readinessreports as prescribed for all reportable equipment. See AR 220-1.

NOTETouchup painting will be in accordance with TM 43-0139.

(3) Records and reports to be maintained for equipment in administrative storage are thoseprescribed by DA PAM 738-750 for equipment in use.

(4) Ten percent variance is acceptable on time running hours used to determine maintenanceactions required.

d. Storage Site.

(1) Select the best available site for administrative storage. Separate stored equipment fromequipment in use. Conspicuously mark the area “Administrative Storage.”

(2) Covered space is preferred. When sufficient covered space for all steam cleaners to bestored 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 provideaccess for inspection, maintenance, and exercising. Anticipate removal or deployment problems andtake 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 takeadequate 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 majorpreventive maintenance service (monthly, quarterly, or semiannually).

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4-29. ADMINISTRATIVE STORAGE (cont)

g. Corrections of Shortcomings and Deficiencies. Correct all shortcomings and deficienciesprior 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.

CAUTIONDo not direct water or steam under pressure against air duct inlets/outlets, exhaustoutlets, unsealed electrical systems, or any exterior opening which will damage acomponent.

(2) Remove rust and damaged paint by scraping, wire brushing, sanding or buffing, and spotpainting as required.

(3) After cleaning and drying, immediately coat unpainted metal surfaces with an oil or greaseas appropriate.

(4) Sunlight, heat, moisture (humidity), and dirt tend to accelerate deterioration. Install allcovers authorized for the equipment. Close and secure all openings except those required for ventingand draining. Seal openings to prevent the entry of rain, snow, or dust. Place equipment and provideblocking or framing to allow for ventilation and water drainage.

NOTEAir circulation under draped covers reduces deterioration from moisture and heat.

j. Maintenance Services. After equipment has been placed in administrative storage, suspend allregularly 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 exami-nation of all equipment to observe any deficiencies that may have occurred. Inspect equipment inopen storage weekly and equipment in covered storage monthly. Immediately after any severe stormor environmental change, inspect all equipment. The following are examples of things to look forduring 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 thismanual or notify support maintenance.

(3) Corrosion or other deterioration.

(4) Missing or damaged parts.

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(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 otherwiseunsatisfactory condition due to deficiencies in preservation, packaging, marking, handling, loading, orstorage.

m. Rotation. To assure utilization of all assigned materiel, rotate items in accordance with anyrotational plan that will keep equipment in an operational condition and reduce maintenance effort.

n. Removal From Administrative Storage. Remove preservative materials. Perform the nextscheduled preventive maintenance service and prepare equipment for service.

o. Servicing. Resume the maintenance service schedule in effect at the commencement ofstorage 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 coolwith cold water running through coil unit assembly and steam cleaning gun until water is clear. TurnMODE SELECTOR switch to OFF.

(2) Turn water source off and allow system to drain until no water flows from steam cleaninggun. 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 threeplaces 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 compart-ment.

(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.

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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 cleaninggun. 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 threeplaces 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 compart-ment.

(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, and6, 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 withMIL-STD-129.

(2) Prepare all Army shipping documents in accordance with AR 725-50.

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C H A P T E R 5D I R E C T S U P P O R T M A I N T E N A N C E I N S T R U C T I O N S

CHAPTER INDEX

Paragraph

5-1.5-2.5-3.5-4.5-5.5-6.5-7.

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 SwitchTubing Assembly - Maintenance Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Coil Inlet-to-inlet Pressure Gauge Tubing Assembly, CoilOutlet-to-Outlet Pressure Gauge Tubing Assembly, and FuelPump-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 . . . . . . . . . . . . . . . . . . . . . .. . . .

Page

5-25-445-445-485-535-58

5-645-73

5-78

5-905-1005-102

5-1075-1105-1185-1235-1245-1265-1285-1295-137

5-1385-146

5-149

5-150

5-1515-1525-1545-156

5-1675-1705-1775-178

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TM 9-4940-531-14

S e c t i o n I . T R O U B L E S H O O T I N G

5-1 . 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 andremove power completely when performing maintenance on electrical components.

• To avoid electrical shock, use extreme caution when depressing S2 and S3 sensitiveswitches. 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. Defectivecomponents in the 220 VAC circuit will trip CB circuit breaker.

a. This table contains troubleshooting information for locating and correcting many of the operat-ing troubles which may develop in the steam cleaner. Perform the tests, inspections, and correctiveactions in the order they appear in the table.

b. This table cannot list all malfunctions that may occur, all the tests and inspections needed tofind the fault, or all the corrective actions needed to correct the fault. If the equipment malfunction isnot 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 malfunc-tions are listed in order of appearance within table 5-1, with a page number reference to the pagewhere a test or inspection and corrective action are provided.

MALFUNCTION INDEX


(Page)

STEAM CLEANER

POWER LIGHT does not come on when PUSH-TO-START button is pressed . . . . . . . . . . . . ..5-5POWER LIGHT comes on when PUSH-TO-START button is pressed and

then goes off when PUSH-TO-START button is released . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..5-9POWER LIGHT comes on but water pump motor will not start . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11

EMERGENCY OFF circuit breaker trips after a short operation time . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...5-13Cartridge fuse F1 blows repeatedly- cold mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..5-15Cartridge fuse F1 blows repeatedly- hot mode . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . .5-16Cartridge fuse F1 blows repeatedly- steam mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-17Water pump runs but there is low or no water output from nozzle . . . . . . . . . . . .. . . . . . . . . . . . ..5-19

5-2

TM 9-4940-531-14


(Page)

Water output is delivered but working pressure fluctuates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-25Water pump vibrates and/or is noisy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-26Steam cleaning gun emits dry (superheated) steam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-27Oil burner motor will not start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .5-28Oil burner has delayed ignition (noisy starts) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-31Oil burner motor runs but oil burner fails to ignite or goes out prematurely . . . . . . . . . . . . . . . . . . . . . 5-33OPERATING TEMPERATURE gauge indicates abnormal water temperature . . . . . . . . . . . . . ...5-35OUTLET PRESSURE gauge indicates low outlet pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-37OUTLET PRESSURE gauge indicates high outlet pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-38Water pump motor will not stop and water does not drain when MODE

SELECTOR switch is set to OFF position from COLD or HOT modes . . . . . . . . . . . . . . . . . . . . .. . . . . . . 5-39Blowdown 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

MALFUNCTIONTEST OR lNSPECTION

CORRECTIVE ACTION

STEAM CLEANER

5-4

TM 9-4940-531-14

Table 5-1. Direct Support Troubleshooting (cont)


CORRECTIVE ACTION

1. POWER LIGHT(1) DOES NOT COME ON WHEN PUSH-TO-START BUTTON (2) ISPRESSED.

NOTEIf steam cleaner starts and POWER LIGHT does not come on, replace 1LT indicatorlight (para 5-22).

Before performing any electrical checks, be sure to check the circuits first for any looseor broken wires.

Step 1. Check for incoming power.

Repeat procedures in table 3-1, malfunction 1, page 3-3.

NOTEWhen checking for voltage, make sure that S2 and S3 sensitive switches (3) and PUSHTO START button (2) are all depressed.

Step 2. Check operation of S2 and S3 sensitive switches (3). Check line terminals ofS1 EMERGENCY OFF switch (4) while depressing S2 and S3 sensitiveswitches. 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. Voltageshould measure approximately 104 VAC. If not, replace defectivesensitive switch (para 5-22).

(2) Check voltage from the back of power receptacle (5) wire 37white to ground and wire 38 black to 21 green (ground). Voltageshould measure approximately 104 VAC. If not, replace defectivepower receptacle (para 5-22), facility or generator power cableassembly (para 4-13 or 4-12), or power source.

5-5

TM 9-4940-531-14




CORRECTIVE ACTION


5 - 6

TM 9-4940-531-14



CORRECTIVE ACTION

1. POWER LIGHT DOES NOT COME ON WHEN PUSH-TO-START BUTTON ISPRESSED. (cont)

b. If there is incoming voltage:

(1) Turn S1 EMERGENCY OFF switch (4) ON. Check voltageacross the two load terminals. Voltage should measure approxi-mately 208 VAC. If not, replace S1 EMERGENCY OFF switch(para 5-22).

(2) Depress PB1 PUSH TO START button (2) and measurevoltage from terminals 1B to ground and 2B to ground. Voltageshould measure approximately 104 VAC. If not, replace PB1PUSH TO START switch (para 5-22).

(3) Check 1CR electromagnet relay (6). Measure voltage fromAUX terminals wire 51 black or 42 black to ground and 52 whiteor 44 white to ground. Voltage should measure approximately104 VAC. If not, replace 1CR electromagnet relay (para 5-22).

(4) Check T1 power transformer (7). Measure voltage fromterminals H1 to ground and H2 to ground. Measure voltage fromterminal X1 of T1 power transformer (7) to ground. Voltage shouldmeasure approximately 104 VAC. If not, replace T1 powertransformer (para 5-22).

5-7

TM 9-4940-531-14




CORRECTIVE ACTION


5 - 8

TM 9-4940-531-14



CORRECTIVE ACTION

2. POWER LIGHT (1) COMES ON WHEN PUSH-TO-START BUTTON (2) IS PRESSED ANDTHEN 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 PUSHTO 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




CORRECTIVE ACTION


5 - 1 0

TM 9-4940-531-14



CORRECTIVE ACTION

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

l

•

NOTEBefore performing any electrical checks, be sure to check the circuits first for any looseor broken wires.

When checking for voltage, make sure that S2 and S3 sensitive switches (3) and PB1PUSH 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




CORRECTIVE ACTION


5-12

TM 9-4940-531-14



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)



CORRECTIVE ACTION


5-14

TM 9-4940-531-14



CORRECTIVE ACTION

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

Step 1. Perform procedures in malfunction 4 above.


Step 2. After installing new F1 cartridge fuse (1), remove 8CR relay-switch (2) whileholding 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 solenoidvalve (5).

Replace defective component(s) (para 5-22, 4-18, 5-11, and 5-13)as required.

5-15

TM 9-4940-531-14




CORRECTIVE ACTION


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



Step 2. Check for shorts in 4CR relay-switch (2).

Replace 4CR relay-switch (para 5-22).

5-16

TM 9-4940-531-14



CORRECTIVE ACTION

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


NOTEBefore performing any electrical checks, be sure to check the circuits first for any loose orbroken 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 andfig. FO-3) as required.

5-17

TM 9-4940-531-14




CORRECTIVE ACTION


5-18

TM 9-4940-531-14


—


CORRECTIVE ACTION

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

CAUTIONTo prevent damage, do not operate water pump longer than 3 minutes without waterflowing.

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 5-gallon 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 flowfrom steam cleaning gun. If air bubbles are observed, check for air leakage atinput side of water pump (1).

Tighten any loose fittings and/or replace broken fittings (para 4-135-11).

Step 2. For pressurized water source only, check that 208 VAC is available at S4

and

liquid level switch (2) and 9SOL solenoid valve (3) (switch should be closedexcept when the float is at the top of its range).

Replace defective S4 liquid level switch, 9SOL solenoid valve, or anydefective wiring (para 5-17).

Step 3. Check that vent valve (4) is closed. Vent valve is defective if water comes outof elbow (5).

Replace defective vent valve (para 5-11).

Step 4. Check for leaks and cracks in plumbing components on inlet side of waterpump (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




CORRECTIVE ACTION


5-20

TM 9-4940-531-14



CORRECTIVE ACTION



Step 5. Measure voltage between TB1 terminal strip (8) terminal 8B (wire 1 red) and3CR relay-switch (9) terminal 6 (wire 2 white), to check operation of 5SOLsolenoid 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 of6SOL 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 notcorrect malfunction, replace defective regulating valve(s) (para 5-20)and readjust.

5-21

TM 9-4940-531-14

5-1 . TROUBLESHOOTING (cont)



CORRECTIVE ACTION

5-22


TM 9-4940-531-14



CORRECTIVE ACTION


Step 8. Check 1SOL solenoid valve (15), 3SOL solenoid valve (16), and 4SOL sole-noid 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 blowdownregulating valve (18).

If water is observed from blowdown drain, clean or replace blowdownregulating valve as necessary (para 5-13). Check 2SOL solenoidvalve (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




CORRECTIVE ACTION


5-24

TM 9-4940-531-14



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 looseor broken wires.

Step 1. Hydraulic accumulator (1) must function properly to prevent excessivepressure 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




CORRECTIVE ACTION


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



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


Table 5-1. Direct Suppport Troubleshooting (cont)


CORRECTIVE ACTION


5-28

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.


When checking for voltage, make sure that S2 and S3 sensitive switches (4) and PUSHTO START button (5) are all depressed.

TM 9-4940-531-14



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 Aand 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




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), turnoff power and check continuity of sections RS2 and RS3 of MODE SELEC-TOR 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 1and 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)


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




CORRECTIVE ACTION


5-32

TM 9-4940-531-14



CORRECTIVE ACTION

14. OIL BURNER MOTOR (1) RUNS BUT OIL BURNER (2) FAILS TO IGNITE OR GOES OUTPREMATURELY.

WARNINGInjury or death can occur as a result of explosion if excess fuel has accumulated inbottom 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 relaywill trip.

Before performing any electrical checks, be sure to check the circuits first for any looseor 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 orbroken insulators, or for eroded spark-gap conductors (para 5-14).

Adjust for correct sparkgap or replace defective electrodes (replaceboth electrodes, as a pair).


Step 3. Remove oil burner electromagnet relay (7) (para 5-14) and check for approxi-mately 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 lowor no fuel pressure:

a. Check 8SOL fuel solenoid valve (10) for continuity. If solenoidcoil 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




CORRECTIVE ACTION


14. OIL BURNER MOTOR RUNS BUT OIL BURNER FAILS TO IGNITE OR GOES OUTPREMATURELY. (cont)

Step 5. Check for 208 VAC between white and black wires from oil burner electro-magnet relay (7).

If there is no voltage: Check 2CR relay-switch (12), PS2 pressureswitch (13), and TC1 temperature control box (14) if in HOT mode; orcheck 2CR relay-switch (12), PS1 pressure switch (15), and TC1temperature control box (14) if in STEAM MODE (para 5-7 and 5-22).Replace defective component(s).

5-34

TM 9-4940-531-14



CORRECTIVE ACTION

15. OPERATING TEMPERATURE GAUGE (1) INDICATES ABNORMAL WATERTEMPERATURE.


Step 1. Turn MODE SELECTOR switch (2) to another mode and check OPERATINGTEMPERATURE 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 replacedefective thermocouple (para 4-13).

5-35

TM 9-4940-531-14




CORRECTIVE ACTION


15. OPERATING TEMPERATURE GAUGE INDICATES ABNORMAL WATER TEMPERA-TURE. (cont)

Step 3. Remove end of thermocouple probe (3) and place in container of boilingwater. Measure water temperature with thermometer and compare withOPERATING TEMPERATURE gauge (1) reading.

If temperatures differ by more than 15°F (8.3 °C), calibrate OPERAT-ING TEMPERATURE gauge (para 5-22) and test again. Replacedefective OPERATING TEMPERATURE gauge.

5-36

TM 9-4940-531-14



CORRECTIVE ACTION

16.

Step 4. If oil burner (4) is on and the HOT mode is selected and the temperature istoo 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 OUTLETPRESSURE 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




CORRECTIVE ACTION


17. OUTLET PRESSURE GAUGE (1) lNDICATES HIGH OUTLET PRESSURE.

Step 1. HOT or COLD mode: Check 500 psi (3448 kPa) regulating valve (2) forrestrictions 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



CORRECTIVE ACTION

18. WATER PUMP MOTOR (1) WILL NOT STOP AND WATER DOES NOT DRAIN WHENMODE SELECTOR SWITCH (2) IS SET TO OFF POSITION FROM COLD OR HOT MODES.


When checking for voltage, make sure that S2 and S3 sensitive switches (3) and PUSHTO START button (4) are all depressed.

Step 1. Check voltage across 1CR electromagnet relay (5).

If voltage does not measure approximately 208 VAC, replace defective1CR electromagnet relay (para 5-22).

5-39

TM 9-4940-531-14




CORRECTIVE ACTION


5-40

TM 9-4940-531-14



CORRECTIVE ACTION

18. WATER PUMP MOTOR WILL NOT STOP AND WATER DOES NOT DRAIN WHEN MODESELECTOR SWITCH IS SET TO OFF POSITION FROM COLD OR HOT MODES. (cont)

Step 2.

Step 3.

Step 4.

Check voltage across 8CR relay-switch (6), RS7 of MODE SELECTOR switch(2), 5CR relay-switch (7), and 7CR relay-switch (8).

Check

Check

If voltage does not measure approximately 110 VAC, replace defectivecomponent(s) (para 5-22).

voltage across 3SOL and 4SOL solenoid valves (9 and 10).

If voltage does not measure approximately 115 VAC, replace defectivesolenoid valves(s) (para 5-9 and 5-11).

that blowdown regulating valve (11) opens.

Clean and/or replace blowdown regulating valve (para 5-13).

5-41

TM 9-4940-531-14




CORRECTIVE ACTION


5-42

TM 9-4940-531-14



CORRECTIVE ACTION

19. BLOWDOWN CYCLE MALFUNCTIONS.


Step 1. If steam cleaner does not enter blowdown cycle when shut down fromSTEAM 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 defectivecomponent(s) (para 5-13 and 5-22).

Step 2. If water does not resume flow and oil burner does not stop after 127seconds, 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 onbeyond 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 . G E N E R A L M A I N T E N A N C E

Refer to general maintenance instructions on page 4-19.

5-3 . TRAILER-MOUNTED STEAM CLEANER—MAINTENANCE INSTRUCTIONS

THIS TASK COVERS:


INITIAL SETUP

Tools and Special ToolsGeneral mechanic’s tool kit (item 2, appx B)Electric repair shop equipment (item 1, appx B)

Materials/PartsRubber strip (2) (11024796)Self-locking nut (4) (MS51922-33)Tapping screw (4) (MS51861-65)

Personnel Required: (2)

ReferencesTM 9-6115-615-34

Equipment ConditionsGenerator set turned off (TM 9-6115-515-12)Leveling support jack and rear stabilizer kit lowered into positionGenerator power cable assembly removed (para 4-12)External hose assemblies disconnectedSuitable lifting device and lifting straps available

5-44

TM 9-4940-531-14

1 Remove four tapping screws (1) and two amber indicating reflectors (2) from generator set(3).

WARNINGGenerator 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 (619.16kg) wet, 1185 lb (537.52 kg) dry. Toavoid injury, do not attempt to liftsteam cleaner without proper equip-ment.

5 Attach suitable lifting device (4) to steamcleaner lifting ring (14) using lifting strap(6).

NOTETo remove steam cleaner with skidfrom flat bed trailer, perform step 6.To remove enclosure and lift assem-bly, refer to paragraph 5-4.

6 Remove four machine bolts (15) and fourflat washers (16). Lift steam cleaner (17)away from flat bed trailer (11).

INSPECTION/REPAIR



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.

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TM 9-4940-531-14

REASSEMBLY

1

2

3

4

5

6

7

Position leveling support jack (1) and rearstabilizer kit (2) to level flatbed trailer (3).

Attach suitable lifting device (4) to steamcleaner lifting ring (5) with lifting strap (6).Position steam cleaner (7) on flat bed trailer(3).

Secure steam cleaner (7) to flat bed trailer(3) with four flat washers (8) and fourmachine bolts (9).

Install generator platform (10) and two newrubber strips (11) onto flat bed trailer (3).

Attach suitable lifting device (4) to genera-tor set lifting eye (12) with lifting strap (6).Position generator set (13) on generatorplatform (10).

Secure generator set (13) to flat bed trailer(3) with four flat washers (14), fourcapscrews (15), four flat washers (16), andfour new self-locking nuts (17).

Install two amber indicating reflectors (18and 19) onto generator set (13) with fournew tapping screws (20) as follows:

a.

b.

Locate amber indicating reflector (18)on right panel (21) 7 in. (1 7.78 cm) frombase and 8 in. (20.32 cm) from frontpanel of generator set. If generator sethas been replaced, drill two holes at0.228 +0.006 -0.001 in. (0.58 +0.015-0.003 cm).

Locate amber indicating reflector (19)on left panel (22) 6 in. (15.24 cm) frombase and 7 in. (1 7.78 cm) from frontpanel. If generator set has been re-placed, drill two holes at 0.228 +0.006-0.001 in. (0.58 +0.015 -0.003 cm).

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TM 9-4940-531-14

5-4. STEAM CLEANER (ENCLOSURE AND LIFT ASSEMBLY)—MAINTENANCEINSTRUCTIONS

THIS TASK COVERS:

a. Removal of enclosure and lift assemblyb. Inspect ion/repairc. Installation of enclosure and lift assembly

INITIAL SETUP


Materials/PartsLockwasher (14)(MS35338-46)Self-locking nut (4)(MS51988-5)Self-locking nut (4)(MS51988-7)

Personnel Required: (2)

Equipment ConditionsLifting strap and suitable lifting device availableSteam cleaner shut down (para 2-6)External power cable and hoses removedHoses removed from hose rackLeft 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

NOTEIllustrations show the steam cleanerremoved from the trailer. This proce-dure can be performed when steamcleaner is installed on the trailer.

1 Attach suitable lifting device (1) to enclo-sure and lift assembly lifting ring (2) withlifting strap (3).

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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) ontosaddle and fuel tank weldment (12).

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TM 9-4940-531-14

5-4. STEAM CLEANER (ENCLOSURE AND LIFT ASSEMBLY)—MAINTENANCEINSTRUCTIONS (cont)

4 Remove four self-locking nuts (13) and four capscrews (14) holding structural channel (8) andfront post assembly (15)onto platform skid (16).

5 Remove 12 nuts (17), 12 Iockwashers (18), and 12 machine screws (19) holding enclosure andlift assembly (20) onto platform skid (16). Remove two self-locking nuts (21) and two machinescrews (22) from left rear of steam cleaner. Remove two self-locking nuts (23) and two machinebolts (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


2 Enclosure and lift assembly is a repairable assembly, refer to paragraph 4-22.


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TM 9-4940-531-14

INSTALLATION OF ENCLOSURE AND LIFT ASSEMBLY

1

2

3

4

Ensure hose rack

Using suitable lifting

NOTEaccess door (1) is closed and secured with chain assembly (2).

device (3), position enclosure and lift assembly (4) on platform skid (5).

Secure enclosure and lift assembly (4) onto platform skid (5) with 12 machine screws (6), 12 newIockwashers (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.

install enclosure and lift assembly (4) onto platform skid (5) with 23 capscrews (13).

Install front post assembly (14) and structural channel (15) onto platform skid (5) with fourcapscrews (16) and four new self-locking nuts (17).

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TM 9-4940-531-14

5-4. STEAM CLEANER (ENCLOSURE AND LIFT ASSEMBLY)—MAINTENANCEINSTRUCTIONS (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 partsonto structural channel (15) with two capscrews (24), two new Iockwashers (23), and two nuts(22).

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TM 9-4940-531-14

7 Detach lifting device (3) and lifting strap(26) from enclosure and lift assembly liftingring (27).

5-5 . STEAM CLEANER (PRESSURE GAUGE ASSEMBLY)-MAINTENANCEINSTRUCTIONS

THIS TASK COVERS:

a. Removal/disassembly of pressure gauge assemblyb. Inspection/repairc. Reassembly/installation of pressure gauge assembly

INITIAL SETUP


Materials/PartsLockwasher (5) (MS35338-46)

Equipment ConditionsSteam cleaner shut down (para 2-6)

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5-5. STEAM CLEANER (PRESSURE GAUGE ASSEMBLY)-MAINTENANCEINSTRUCTIONS (cont)

REMOVAL/DISASSEMBLY OF PRESSURE GAUGE ASSEMBLY

WARNING

1

2

3

To avoid injury to personnel, ensure that INLET and OUTLET PRESSURE gaugesshow no pressure before beginning maintenance.

Disconnect coil inlet-to-inlet pressure gauge tubing assembly (1) and pipe bushing (2) fromINLET PRESSURE gauge (3).

Disconnect coil outlet-to-outlet pressure gauge tubing assembly (4) and pipe bushing (5) fromOUTLET PRESSURE gauge (6).

Remove three nuts (7), three Iockwashers (8), three capscrews (9), two flat washers (10), gaugeupper clamp (11), gauge lower clamp (12), and diaphram support bracket (13) from control boxassembly (14).

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TM 9-4940-531-14

4 Remove two nuts (15), bracket (16), andbracket (17).

5 Remove two nuts (18), bracket (19), andbracket (17).

INLET PRESSURE gauge (3) from gauge support

OUTLET PRESSURE gauge (6) from gauge support

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



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TM 94940-531-14

5-5 . STEAM CLEANER (PRESSURE GAUGE ASSEMBLY)—MAINTENANCEINSTRUCTIONS (cont)

REASSEMBLY/lNSTALLATION OF PRESSURE GAUGE ASSEMBLY

1 Remove two nuts (1), two Iockwashers (2), and two capscrews (3) from enclosure and lift assem-bly (4). Install gauge support bracket (5) onto enclosure and lift assembly (4) with twocapscrews (3), two new Iockwashers (2), and two nuts (1).

2 Install OUTLET PRESSURE gauge (6) onto gauge support bracket (5) with bracket (7) and twonuts (8).

3 Install INLET PRESSURE gauge (9) onto gauge support bracket (5) with bracket (10) and twonuts (11).

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4 Install diaphram support bracket (12), gauge lower clamp (13), and gauge upper clamp (14) ontocontrol box assembly (15) with two flat washers (16), three capscrews (17), three newIockwashers (18), and three nuts (19). Do not tighten hardware.

5 Connect pipe bushing (20) and coil outlet-to-outlet pressure gauge tubing assembly (21) toOUTLET PRESSURE gauge (6).

6 Connect pipe bushing (22) and coil inlet-to-inlet pressure gauge tubing assembly (23) to INLETPRESSURE gauge (9).

7 Install OUTLET PRESSURE gauge (6) and INLET PRESSURE gauge (9) onto diaphram supportbracket (12). Tighten three capscrews (17).

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5-6 . STEAM CLEANER (CONTROL BOX ASSEMBLY)-MAINTENANCE INSTRUCTIONS

THIS TASK COVERS:

a. Removal of control box assemblyb. Inspection/repairc. Installation of control box assembly

INITIAL SETUP


Materials/PartsTapping screw (MS51869-23) (6)Tapping screw (MS51861-46) (4)

Equipment ConditionsSteam cleaner shut down (para 2-6) and power source removedLower control panel assembly removed (para 4-13)Left rear access door and left rear panel removed (para 4-22)

REMOVAL OF CONTROL BOX ASSEMBLY


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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 temperaturecontrol box (5). Reinstall two screws (3).

3 For access to wire terminals and conduit assemblies, remove relay-switches (6) as needed.

NOTEl 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 wirenumbers 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.201202203204205206207208211

Wire no. Callout no.1 , 21 5 , 1 6 , 1 7 , 1 8 , 1 9 , 2 09, 5028, 29, 8723, 26, 121, 12330, 3191 ,13958, 81, 13612, 13

789101112131415

5 Remove nine conduit connectorfrom control box assembly (2).

locknuts (16) and disconnect nine conduit assemblies (7 thru 15)

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5-6 . STEAM CLEANER (CONTROL BOX ASSEMBLY)—MAINTENANCEINSTRUCTIONS (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) fromsaddle and fuel tank weldment (19). Remove four tapping screws (20) and control box assembly(2).

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INSPECTIONREPAIR



3 Control box assembly is a repairable assembly.

INSTALLATION OF CONTROL BOX ASSEMBLY

Refer to paragraph 5-22.

1 Install control box assembly (1) onto saddle and fuel tank weldment (2) with four new tappingscrews (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.

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5-6 . STEAM CLEANER (CONTROL BOX ASSEMBLY)—MAINTENANCEINSTRUCTIONS (cont)

INSTALLATION OF CONTROL BOX ASSEMBLY (cont)

NOTERefer to schematic on FO-1 for conduit/wire connections. The listed conduit and wirenumbers 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 con-nector locknuts (16).

4 Connect 26 wires entering control box assembly (1) through the following conduit assemblies:

Conduit no.201202203204205206207208211

5-62

Wire no.1 , 21 5 , 1 6 , 1 7 , 1 8 , 1 9 , 2 09, 5028, 29, 8723, 26, 121, 12330,3191 ,13958, 81, 13612,13

Callout no.789101112131415

TM 9-4940-531-14


5 Reinstall relay-switches (6).

6 Remove two screws (17) from TC1 temperature control box (18). Connect two thermocoupleprobe 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).

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5-7. STEAM CLEANER (PS1 , PS2, AND PS3 PRESSURE SWITCHES)-MAINTENANCEINSTRUCTIONS

THIS TASK COVERS:

a. Removal of PS1, PS2, and PS3 pressure switchesb. Inspection/repairc. Installation of PS1, PS2, and PS3 pressure switches

INITIAL SETUP


Materials/PartsSelf-locking nut (9) (MS51988-3)

Equipment ConditionsSteam cleaner shut down (para 2-6) and power source removed

REMOVAL OF PS1, PS2, AND PS3 PRESSURE SWITCHES


5 - 6 4

TM 9-4940-531-14

WARNINGTo avoid injury to personnel, ensure that INLET and OUTLET PRESSURE gaugesshow no pressure before beginning maintenance.

NOTEBe sure all wires, conduits, and tubing are labeled before removal.

1 Disconnect coil inlet-to-differential pressure switch tubing assembly (1), coil outlet-to-differentialpressure switch tubing assembly (2), and two pipe bushings (3) from PS3 differential pressureswitch (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) anddisconnect conduit assembly no. 212 (13).

5 Disconnect conduit connector locknut (14). Remove conduit assembly no.212 (13) and conduitconnector 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).

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5-7. STEAM CLEANER (PS1, PS2, AND PS3 PRESSURE SWITCHES)—MAINTENANCEINSTRUCTIONS (cont )

REMOVAL OF PS1, PS2, AND PS3 PRESSURE SWITCHES (cont)

7

8

9

10

5-66

Remove four screws (18) and cover (19) from PS2 pressure switch (20).

Disconnect two wires no. 19 and 20 (21 and 22). Remove conduit connector locknut (23) anddisconnect conduit assembly no. 213 (24).

Loosen conduit connector locknut (25). Remove conduit assembly no. 213 (24) and conduitconnector locknut (25) from 301 junction box (7).

Disconnect coil outlet-to-pressure switch tubing assembly (26) from pipe tee (27).

11

12

13

14

15

16

17

TM 9-4940-531-14

Remove two self-locking nuts (28), two machine screws (29), and PS2 pressure switch (20) fromswitch plate assembly (17).

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).

Remove four screws (34) and cover (35) from PS1 pressure switch (33).

Disconnect two wires no. 17 and 18 (36 and 37).

Remove conduit connector locknut (38). Disconnect conduit assembly no. 202 (39) from 301junction box (7).

Remove electrical locknut (40), 301 junction box (7), and electrical locknut (41) from PS1 pres-sure switch (33).

Remove pipe nipple (42), two self-locking nuts (43), two machine screws (44), and PS1 pressureswitch (33) from switch plate assembly (17).

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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), andswitch plate assembly (17) from coil unit assembly (49) and coil inlet control assembly (50).

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lNSPECTION/REPAIR



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) withtwo capscrews (4), two new self-locking nuts (5), capscrew (6), and new self-locking nut (7).

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INSTALLATION OF PS1, PS2, AND PS3 PRESSURE SWITCHES (cont)

2

3

4

5

6

5-70

Install pipe nipple (8) into PS1 pressure switch (9). Secure 301 junction box (10) to PS1 pressureswitch (9) with electrical locknut (11) and electrical locknut (12).

Connect conduit assembly no. 202 (13) to 301 junction box (10) with conduit connector locknut(14).

Install PS1 pressure switch (9) onto switch plate assembly (1) with two machine screws (15) andtwo new self-locking nuts (16).

Connect two wires no. 17 and 18 (17 and 18) to PS1 pressure switch (9).

Install cover (19) onto PS1 pressure switch (9) with four screws (20).

TM 9-4940-531-14

7 Install two pipe bushings (21), pipe nipple (22), pipe tee (23), and pressure switch-to-pressureswitch tubing assembly (24) onto PS1 and PS2 pressure switches (9 and 25).

8 Install PS2 pressuretwo new self-locking

switch (25) onto switch plate assembly (1) with two machine SCrews (26) andnuts (27). —

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) toPS2 pressure switch (25).

11 Install cover (34) onto PS2 pressure switch (25) with four screws (35).

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INSTALLATION OF PS1, PS2, AND PS3 PRESSURE SWITCHES (cont)

12

13

14

15

Install PS3 differential pressure switch (36) onto switch plate assembly (1) with two machinescrews (37) and two new self-locking nuts (38).

Connect conduit assembly no. 212 (39) to PS3 differential pressure switch (36) and 301 junctionbox (10) with two conduit connector locknuts (40 and 41). Connect two wires no. 10 and 15 (42and 43) to PS3 differential switch (36).

Install cover (44) onto PS3 differential pressure switch (36) with four screws (45)

Install cover (46) onto 301 junction box (10) with two machine screws (47).

16 Install two pipe bushings (48) into PS3differential pressure switch (36). Connectcoil outlet-to-differential pressure switchtubing assembly (49) and coil inlet-to-differential pressure switch tubing assembly(50).

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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 ToolsCrescent 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/PartsConductor splice (2) (M7928/5-4)Conductor splice (2) (11024917)

Equipment ConditionsSteam cleaner shut down (para 2-6) and power source removedFront panel removed (para 4-22)Hose removed (para 4-13)

NOTEBe sure wires are tagged and labeledbefore removal.

REMOVAL OF COIL INLET ASSEMBLY

1 Loosen two screws (1) and remove cover(2) from 303 junction box (3).

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5-8 . STEAM CLEANER (COIL INLET ASSEMBLY)—MAINTENANCEINSTRUCTIONS (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

4

5

Remove conduit connector locknut (7) and disconnect conduit assembly no. 216 (8) from 303junction box (3).

Disconnect conduit assembly no. 216 (8) from 3SOL solenoid valve (9).

Remove two conductor splices (10) and two wires no. 23 and 26 (5 and 6).

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6

7

8

9

Disconnect coil inlet-to-differential pressure switch tubing assembly (11) and coil inlet-to-inletpressure gauge tubing assembly (12) from coil inlet assembly (13).

Uncouple pipe union (14). Remove coil inlet hose assembly (15) from coil inlet assembly (13)and coil inlet control assembly pipe reducer (16).

Uncouple pipe union (17) and remove coil inlet assembly (13) from pipe nipple (18).

Remove halves of two pipe unions (14 and 17) from coil inlet hose assembly (15) and pipe nipple(18).

INSPECTION/REPAIR



3 Coil inlet assembly is a repairable assembly. Refer to paragraph 5-11.

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5-8 . STEAM CLEANER (COIL INLET ASSEMBLY)—MAINTENANCEINSTRUCTIONS (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 pres-sure 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 coilinlet hose assembly (4) to coil inlet assembly (5). Couple pipe union (2).

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5 Connect two wires no. 23 and 26 (9 and 10) to 3SOL solenoid valve (11) with two new conductorsplices (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).

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5-9. STEAM CLEANER (COIL OUTLET ASSEMBLY AND OUTLET AND WATER DRAINASSEMBLY)- -MAINTENANCE INSTRUCTIONS

THIS TASK COVERS:

a. Removal of coil outlet assembly and outlet and water drain assemblyb. Disassembly of outlet and water drain assemblyc. Inspection/repaird. Reassembly of outlet and water drain assemblye. Installation of coil outlet assembly and outlet and water drain assembly

INITIAL SETUP


Materials/PartsConductor 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 ConditionsSteam cleaner shut down (para 2-6) and power source removedHoses removed (para 4-13)Outlet and water drain assembly partially disassembled (para 4-24)Top left cover removed (para 4-22)

WARNINGTo avoid injury to personnel, ensure that INLET and OUTLET PRESSURE gaugesshow no pressure before beginning maintenance.

NOTEBe sure wires are tagged and labeled before removal.

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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-pressureswitch tubing assembly (2), and coil outlet-to-outlet pressure gauge tubing assembly (3) from coiloutlet assembly (4).

2 Uncouple pipe union (5). Remove coil inlet control-to-blowdown hose assembly (6) from coil inletcontrol assembly (7) and blowdown assembly (8). Remove halves of pipe union (5) from coil inletcontrol-to-blowdown hose assembly (6) and coil inlet control assembly (7).

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5-9. STEAM CLEANER (COIL OUTLET ASSEMBLY AND OUTLET AND WATER DRAINASSEMBLY)—MAINTENANCE INSTRUCTIONS (cont)

REMOVAL OF COIL OUTLET ASSEMBLY AND OUT LET AND WATER DRAIN ASSEMBLY (cont)

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TM 9-4940-531-14

3

4

5

6

7

8

Disconnect two wires no. 91 and 139 from control box assembly (9).

Remove conduit connector locknut (10) and disconnect conduit assembly no. 207 (11) fromcontrol box assembly (9).

Remove conduit assembly no. 207 (11), two conductor splices (12), and two wires no. 91 and139 (13 and 14) from S5 flow switch (15).

Disconnect two wires no. 12 and 13 from control box assembly (9).

Remove conduit connector locknut (16) and disconnect conduit assembly no. 211 (17) fromcontrol box assembly (9).

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.control box assembly (9).

208 (23) from

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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).

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14 Disconnect conduit assembly no. 217 (34) from 7SOL solenoid valve (35). Remove two conduc-tor 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 twowires no. 58 and 136 (29 and 31).

16 Remove 304 junction box (26) with attached 4SOL solenoid valve (32).

17

18

19

Remove two self-locking nuts (39) and U-bolt (40) holding blowdown assembly (8) to fuel shutoffbracket (41).

Uncouple pipe union (42) from coil unit assembly (43). Remove halves of pipe union (42) fromcoil unit assembly (43) and coil outlet assembly (4).

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).

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REMOVAL OF COIL OUTLET ASSEMBLYAND OUTLET AND WATER DRAINASSEMBLY (cont)

20 Remove two nuts (51), two lockwashers(52), U-bolt (53), pipe support (54), and coiloutlet assembly (4) from steam outletsupport assembly (49).

DISASSEMBLY OF OUTLET AND WATERDRAIN ASSEMBLY

1 Remove electrical conduit locknut (1) and304 junction box (2) from pipe nipple (3).

2 Remove electrical conduit locknut (4) andpipe nipple (3) from 4SOL solenoid valve(5).

INSPECTION/REPAIR


2 Coil outlet assembly is a repairable assem-bly, refer to paragraph 5-12.


REASSEMBLY OF OUTLET AND WATERDRAIN ASSEMBLY

1 Install pipe nipple (1) and electrical conduitlocknut (2) onto 4SOL solenoid valve (3).

2 Install 304 junction box (4) and electricalconduit locknut (5) onto pipe nipple (1).

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INSTALLATION OF COIL OUTLET ASSEMBLY

1 Install coil outlet assembly (1) onto steamoutlet support assembly (2) with pipesupport (3), U-bolt (4), two new lock-washers (5), and two nuts (6).

AND OUTLET AND WATER DRAIN ASSEMBLY

2 Install steam outlet support assembly (2) with attached parts onto coil unit assembly (7) andplatform 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 coiloutlet 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 self-Iocking nuts (18).

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INSTALLATION OF COIL OUTLET ASSEMBLY AND OUTLET AND WATER DRAINASSEMBLY (cont)

5 - 8 6

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 conduc-tor 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 twonew 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 connectorlocknut (36).

11 Connect three wires no. 58, 59, and 136 to control box assembly (35).

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INSTALLATION OF COIL OUTLET ASSEMBLY AND OUTLET AND WATER DRAINASSEMBLY (cont)

12

13

Connect two wires no. 12 and 13 (37 and 38) to 2SOL solenoid valve (39) with two new conduc-tor splices (40). Install conduit assembly no. 211 (41).

Install conduit assembly no. 211 (41) onto control box assembly (35) with conduit connectorIocknut (42).

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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 conductorsplices (46). Connect conduit assembly no. 207 (47).

16 Install conduit assembly no. 207 (47) onto control box assembly (35) with conduit connectorlocknut (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 coilinlet control assembly (51). Install coil inlet control-to-blowdown hose assembly (50) ontoblowdown 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 switchtubing assembly (53), and coil outlet-to-differential pressure switch tubing assembly (54) to coiloutlet assembly (1).

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5-10. STEAM CLEANER (FUEL TANK ASSEMBLY AND COIL UNIT ASSEMBLY)-MAINTENANCE INSTRUCTIONS

THIS TASK COVERS:

a. Removal of fuel tank assembly and coil unit assemblyb. Inspect ion/repairc. Installation of fuel tank assembly and coil unit assembly

INITIAL SETUP


Materials/PartsConductor 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 ConditionsSteam cleaner shut down (para 2-6) and power source removedOil 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)

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NOTEBe sure wires are tagged and labeled before removal.

REMOVAL OF FUEL TANK ASSEMBLY AND COIL UNIT ASSEMBLY

1

2

3

4

Loosen two screws (1) and remove cover (2) from 303 junction box (3).

Remove two conductor splices (4) and disconnect two wires no. 122 and 123 (5 and 6) from S4liquid level switch (7). Loosen conduit connector locknut (8) and disconnect conduit assemblyno. 215 (9).

Remove conduit assembly no. 215 (9) from 9SOL solenoid valve (10). Remove two conductorsplices (11) and disconnect two wires no. 121 and 122 (12 and 5).

Remove two conduit connector locknuts (8 and 13), conduit assembly no. 205 (14), and fourwires no. 23, 26, 121, and 123 (15, 16, 12 and 6).

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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).

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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 302junction box (29).

10 Remove conduit assembly no. 214 (37) from FS1 flow switch (38). Remove two conductorsplices (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 threewires no. 28, 29 and 87 (32, 33, and 40) from 302 junction box (29).

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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 tankassembly (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 recessedwashers (54), and coil unit assembly (50) from platform skid (47).

INSPECTION/REPAIR



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.

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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).

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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 conductorsplices (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 twonew conductor splices (25 and 26).

8 Install cover (27) onto 302 junction box(18) with two machine screws (28).

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9 Connect two wires no. 9 and 50 (29 and 30) to 6SOL solenoid valve (31) with two new conductorsplices (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 conduc-tor splices (37). Connect conduit assembly no. 201 (38).

5 - 9 7

TM 9-4940-531-14


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 con-ductor splices (42). Connect conduitassembly (no. 215 (43).

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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 wiresno. 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).

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5-11. COIL INLET ASSEMBLY—MAINTENANCE INSTRUCTIONS

THIS TASK COVERS


INITIAL SETUP



Equipment ConditionsCoil inlet assembly removed (para 5-8)Coil inlet hose removed (para 4-13)

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TM 9-4940-531-14

DISASSEMBLY

1

2

3

4

5

6

7

8

Remove pipe elbow (1), pipe nipple (2), and pipe elbow (3) from pipe nipple (4).

Remove check valve (5) and two pipe nipples (4 and 6).

Uncouple pipe union (7).

Remove pipe bushing (8), pipe union half (9), pipe nipple (10), pipe union half (11), and pipenipple (12) from pipe tee (13).

Remove pipe union half (14), pipe nipple (15), pipe union half (16), pipe tee (17), and two pipenipples (18 and 19).

Uncouple pipe union (20).

Remove pipe tee (21), pipe nipple (22), pipe bushing (23), pipe tee (24), pipe nipple (25), pipeunion half (26), and pipe nippIe (27) from pipe elbow (28).

Remove pipe union half (29), pipe bushing (30), pipe nipple (31), pipe nipple (32), and straightadapter (33) from solenoid valve (34).

lNSPECTION/REPAIR



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 unionhalf (29) onto solenoid valve (34).

3 Install pipe union half (26), pipe nipple (27), pipe elbow (28), pipe nipple (25), pipe tee (24), pipebushing (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 (14and 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).

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5-12. COIL OUTLET ASSEMBLY—MAINTENANCE INSTRUCTIONS

THIS TASK COVERS:

a. Disassemblyb. Inspect ion/repairc . Reassemblyd. Adjustment of pressure regulating valves

INITIAL SETUP



Equipment ConditionsCoil outlet assembly removed (para 5-9)Hose assemblies removed (para 4-13)

DISASSEMBLY

1 Remove blowdown assembly (1) from pipe adapter (2).

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CAUTION

2

To prevent damage to equipment, do not tamper with pressure settings of regulatingvalves. If adjustment is necessary, refer to adjustment procedure below.

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) regulat ing 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) from400 psi (2758 kPa) regulating valve (23).

6 Remove pipe union half (24) and pipe nipple (25) from pipe tee (26).

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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 pipetee (32) from pipe adapter (2).

INSPECTION/REPAIR



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) ontopipe tee (1).

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TM 9-4940-531-14

4

5

6

7

8

9

Install pipe nipple (13) and pipe union half (14) onto pipe tee (5)

CAUTIONTo prevent damage to equipment, do not tamper with pressure settings on regulatingvalves. If adjustment is necessary, refer to adjustment procedure below.

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), pipenipple (22), pipe elbow (23), and pipe union half (24) onto 400 psi (2738 kPa) regulating valve(19).

Couple pipe union (25).

Install pipe nipple (26) and pipe union half(27) onto pipe tee (3).

Install pipe elbow (28), straight adapter(29), and pipe plug (30) onto 600 psi (4137kPa) regulating valve (31). Install pipenipple (32) and pipe union half (33) onto600 psi (4137 kPa) regulating valve (31).

Couple pipe union (34).

5-105

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5-12. COIL OUTLET ASSEMBLY—MAINTENANCE INSTRUCTIONS (cont)

REASSEMBLY (cont)

10 Install blowdown assembly (35) onto pipeadapter (7).

ADJUSTMENT OF PRESSURE REGULATING VALVES

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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 regulatingvalve or if OUTLET PRESSURE gauge (1) displays reading above normal pressurelimits (para 2-6).

2 After initial startup procedure (para 2-5), install appropriate nozzle for mode selected and securecleaning 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-MAINTENANCEINSTRUCTIONS

THIS TASK COVERS:

a. Disassembly b. Inspection/cleaning/repair c. Reassembly

INITIAL SETUP


Materials/PartsAntiseizing tape (item 24, appx E)Gasket (1 1025019)

Equipment ConditionsBlowdown assembly removed (para 5-12)Drain hose and clamp removed (para 4-13)

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5-13. BLOWDOWN ASSEMBLY AND VALVE AND SWITCH ASSEMBLY—MAINTENANCEINSTRUCTIONS (cont)

1

2

3

4

5

6

7

Remove pipe elbow (1), drain pipe (2), and pipe elbow (3) from valve and switch assembly (4).

Remove straight adapter (5) from 2SOL solenoid valve (6).

Uncouple pipe union (7) and remove 2SOL solenoid valve (6) with attached parts.

Remove pipe elbow (8), pipe union half (9), two pipe nipples (10 and 11), and two bushing adapt-ers (12 and 13) from 2SOL solenoid valve (6).

Remove pipe union half (14) and pipe nipple (15) from S5 flow switch (16).

Remove S5 flow switch (16) and straight pin (17) from fluid regulating valve (18).

Remove fluid regulating valve (18), ball (19), valve seat (20), and gasket (21) from metal pipeassembly (22).

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lNSPECTION/CLEANING/REPAIR


2 Separate fluid regulating valve and remove any foreign matter. Rinse components andreassemble fluid regulating valve.


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 pipeassembly (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 pipeunion 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).

NOTEPipe 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).

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5-14. ATOMIZING VAPORIZING OIL BURNER—MAINTENANCE INSTRUCTIONS

THIS TASK COVERS:

a. Disassemblyb. Inspection/repairc. Reassemblyd. Electrode adjustment and replacement

INITIAL SETUP


Materials/PartsAntiseizing tape (item 24, appx E)Tapping screw (3) (MS51851-106)Tapping screw (2) (MS51869-15)

Equipment ConditionsAtomizing vaporizing oil burner removed (para 4-14)Steam cleaner assembled and operational to perform electrode adjustment

and replacement

DISASSEMBLY

1

2

3

NOTEBe sure all wires are tagged andlabeled before removal.

Remove two screws (1) and disconnect twowires (2) from terminals F and F of electro-magnet relay (3). Remove two screws (4)and disconnect wire no. 49 (5) from termi-nals T and T. Reinstall four screws (1 and4).

Remove tapping screw (6) and retainingstrap (7) from blower housing (8).

Swing power transformer (9) open andremove thermal resistor (10) which housescad cell (11).

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4

5

6

7

8

9

10

Loosen two screws (12) and separateelectromagnet relay (3).

Remove conductor splice (13) and discon-nect orange wire (14).

Remove top half (15) of electromagnetrelay.

Remove two tapping screws (16) andelectromagnet relay junction box (17).

Remove two tapping screws (18) andpower transformer (9).

Disconnect fuel solenoid valve-to-oil burnerconduit (19) from blower housing (8).

If necessary for replacement of electrodesand/or oil burner nozzle, remove fuel pump-to-oil burner tubing assembly (20) and nut(21), loosen screw (22), slide plate (23),and remove burner assembly (24). Re-move two electrodes (25 and 26) and oilburner nozzle (27) from burner assembly(24).

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5-14. ATOMIZING VAPORIZING OIL BURNER—MAINTENANCE INSTRUCTIONS (cont)

DISASSEMBLY (cont)

11 Remove feed-through bolt (28), 8SOLsolenoid valve (29), and washer (30) fromfuel 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).

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INSPECTION/REPAIR



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).

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5-14. ATOMIZING VAPORIZING OIL BURNER—MAINTENANCE

REASSEMBLY (cont)

5 Install washer (11) and 8SOL solenoidvalve (12) onto fuel pump (9) with feed-through bolt (13).

6

7

If removed, install oil burner nozzle (14)and two electrodes (15 and 16) onto burnerassembly (17). Check electrode dimen-sions; refer to steps 6 and 7 of electrodeadjustment and replacement procedure.

Install burner assembly (17), adjust plate(18), tighten screw (19), and install nut (20).Install fuel pump-to-oil burner tubing as-sembly (21).

8

9

10

Connect fuel solenoid valve-to-oil burnerconduit (22) onto blower housing (5).

Install power transformer (23) with two newtapping screws (24).

Install electromagnet relay junction box (25)with two new tapping screws (26).

5-114

INSTRUCTIONS (cont)

TM 9-4940-531-14

11

12

13

14

15

Connect orange wire (27) from electromag-net relay (28) and red wire (29) from 8SOLsolenoid valve (12) with conductor splice(30).

Position top half (31) of electromagnet relay(28) onto junction box (25) and secure withtwo screws (32).

Secure bracket of thermal resistor (33) ontopower transformer (23).

Close power transformer (23). Installretaining strap (34) onto blower housing(35) with new tapping screw (36).

Remove four screws (37 and 38). Connectwire no. 49 (39) onto terminals T and T ofelectromagnet relay (28) with two screws(37). Connect two wires (37) onto termi-nals F and F with two screws (38).

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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 fuelfrom draining.

3 Remove tapping screw (3) and move retaining strap (4). Swing power transformer (5) back onthe hinges, exposing burner assembly (6).

4 Remove nut (7). Loosen screw (8), slide plate (9), and remove burner assembly (6).

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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 appropriatedirection 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). Adjustnew 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).

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1

2

3

Uncouple pipe union (1) and removenonmetallic hose assembly (2) from waterpump assembly (3) and coil inlet controlassembly (4). Remove pipe union (1)halves from nonmetallic hose assembly (2)and water pump assembly (3).

Remove four capscrews (5) and coil inletcontrol assembly (4) from saddle and fueltank weldment (6).

Remove four self-locking nuts (7), two V-belts (8), and motor assembly (9).

4 Remove two hose clamps (10) and nonmetallic hose (11) from water pump assembly (3) and oild r a i n a s s e m b l y ( 1 2 ) .

5 Remove two self-locking nuts (13), two machine bolts (14), and oil drain assembly (12) fromsaddle and fuel tank weldment (6).

6 Remove four self-locking nuts (15) and water pump assembly (3).

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DISASSEMBLY (cont)

7

8

9

10

11

Remove self-locking nut (16), two capscrews (17), and lift water tank assembly (18) from saddleand fuel tank weldment (6).

Remove hose clamp (19) and disconnect suction inlet-to-water tank hose (20) from straight pipeadapter (21). Remove water tank assembly (18).

Remove suction inlet assembly (22).

Remove two self-locking nuts (23), two capscrews (24), pipe coupling (25), straight pipe adapter(21), and elbow (26).

Remove two straight adapters (27) and two pipe elbows (28).

INSPECTION/REPAIR

1 Inspect for broken, damaged, or missing parts.


3 The suction inlet assembly is a repairable assembly, refer to paragraph 5-16

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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

2

3

4

5

6


Install two pipe elbows (1) and two straight adapters (2) onto saddle and fuel tank weldment (3).

Install elbow (4) and straight adapter (5) on pipe coupling (6). Install pipe coupling (6) with twocapscrews (7) and two new self-locking nuts (8).

Install suction inlet assembly (9).

Position water tank assembly (10) on saddle and fuel tank weldment (3). Install suction inlet-to-water tank hose (11) onto straight pipe adapter (5) with hose clamp (12).

Install water tank assembly (10) onto saddle and fuel tank weldment (3) with two capscrews (13)and new self-locking nut (14).

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REASSEMBLY (cont)

7

8

9

10

11

12

Install water pump assembly (15) with four new self-locking nuts (16).

Install oil drain assembly (17) with two machine bolts (18) and two new self-locking nuts (19).

Install nonmetallic hose (20) onto oil drain assembly (17) and water pump assembly (15) with twohose clamps (21).

Install motor assembly (22) and two V-belts(23) and secure with four new self-lockingnuts (24).

Install coil inlet control assembly (25) withfour capscrews (26).

Install pipe union (27) halves onto waterpump assembly (15) and nonmetallic hoseassembly (28). Couple pipe union (27).Install nonmetallic hose assembly (28) ontocoil inlet control assembly (25).

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5-16 . SUCTION INLET ASSEMBLY—MAINTENANCE INSTRUCTIONS

THIS TASK COVERS:


INITIAL SETUP



Equipment ConditionsSuction 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 pipeunion (5) halves from pipe nipple (6) andhose 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



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 onpipe 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).

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5-17 . WATER TANK ASSEMBLY—MAINTENANCE INSTRUCTIONS

THIS TASK COVERS:


INITIAL SETUP



Equipment ConditionsWater 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 watertank (5).

5 Remove strainer element (18) from water tank (5).

INSPECTION/CLEANING/REPAIR


2 Clean strainer element by tapping gently on a hard surface and/or rinsing in clean water.


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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-watertank hose (2) onto straight adapter (3) with hose clamp (1).

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5-18 . WATER PUMP ASSEMBLY—MAINTENANCE INSTRUCTIONS

THIS TASK COVERS:


INITIAL SETUP

Tools and Special ToolsCrescent 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/PartsAntiseizing tape (item 24, appx E)Gasket (MS27030-2)

ReferencesTM 9-4940-531-24P

Equipment ConditionsWater pump assembly removed (para 5-15)

1

2

3

4

5

6

7

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 unionhalf (10).

Remove two straight adapters (11), two pipe elbows (12), pipe union half (13), and pipe nipple(14) from reciprocating pump (15).

Remove hose elbow (16), pipe union half (17), pipe nipple (18), tee (19), and pipe nipple (20)from pipe tee (21).

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).

Remove two screws (28) and cap (29) from pulley (30).

Remove pulley (30) and machine key (31) from reciprocating pump (15).

Remove two pipe plugs (32) from reciprocating pump (15).

INSPECTION/REPAIR



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 (aninstruction sheet is included).

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TM 9-4940-531-14

REASSEMBLY

1

2

3

4

5

6

7

8


Install two pipe plugs (32) onto reciprocating pump (15).

Install pulley (30) and machine key (31) on reciprocating pump (15).

Install cap (29) onto pulley (30) with two screws (28).

Install pipe nipple (27), pipe elbow (26), nipple (25), pipe tee (21), male coupler (24), new gasket(23), and coupler cap (22).

Install pipe nipple (20), tee (19), pipe nipple (18), pipe union half (17), and hose elbow (16) onpipe tee (21).

Install pipe nipple (14), pipe union half (13), two pipe elbows (12), and two straight adapters (11)on reciprocating pump (15).

Installelbow

pipe nipple (9), pipe tee (8), pipe nipple (7), pipe tee (6), pipe nipple (5), pipe tee (4), pipe(3), and four straight adapters (2) onto pipe union half (10). Couple pipe union (1).

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5-19 . MOTOR ASSEMBLY—MAINTENANCE INSTRUCTIONS

THIS TASK COVERS:


INITIAL SETUP

Tools and Special ToolsGeneral mechanic’s tool kit (item 2, appx B)Electric repair shop equipment (item 1, appx B)Pulley puller (item 1, appx B)

Materials/PartsWiping rag (item 18, appx E)

Equipment ConditionsMotor assembly removed (para 5-15)

DISASSEMBLY

Loosen setscrew (1) and remove pulley (2) andmachine key (3) from motor (4).

INSPECTION/CLEANING/REPAIR


2 Remove all surface dirt with clean wipingrag (item 18, appx B).


REASSEMBLY

Install machine key (3) and pulley (2) on motor(4). Tighten setscrew (1).

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5-20. COIL INLET CONTROL ASSEMBLY—MAINTENANCE INSTRUCTIONS

THIS TASK COVERS:

a. Disassemblyb. Inspection/repairc. Reassemblyd. Adjustment of pressure regulating valves

INITIAL SETUP


Materials/PartsAntiseizing tape (item 24, appx E)Lockwasher (6) (MS35338-44)Tapping screw (4) (MS51861-65)

Equipment ConditionsCoil inlet control assembly removed (para 5-15)

MakeNOTE

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 bush-ing (9) from pipe tee (10).

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5-20. COIL INLET CONTROL ASSEMBLY—MAINTENANCE INSTRUCTIONS (cont)

DISASSEMBLY (cont)

3

4

5

6

7

Remove pipe tee (10), pipe nipple (11), andhydraulic accumulator (12) from pipe cross(13).

Remove pipe reducer (14), pipe nipple (15),flow switch (16), pipe nipple (17), and pipebushing (18) from pipe cross (13).

Remove two nuts (19), two Iockwashers(20), U-bolt (21), and pipe support (22) fromplumbing support assembly (23).

Remove pipe cross (13), pipe nipple (24),pipe elbow (25), and check valve (26) frompipe nipple (27).

Uncouple pipe union (28) from pipe nipple(29). Remove pipe union (28) halves frompipe nipple (29) and pipe nipple (30).Remove pipe nipple (30), solenoid valve(31), pipe nipple (32), and pipe elbow (33)from straight adapter (34).

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CAUTIONTo prevent damage to equipment, donot tamper with pressure settings ofregulating valves. If adjustment isnecessary, refer to adjustment proce-dure below.

8 Uncouple pipe union (35). Remove pipeunion (35) halves from two pipe nipples (36and 37). Remove pipe nipple (36), straightadapter (38), pipe elbow (39), pipe elbow(40), pipe nipple (41), pipe elbow (42), andpipe nipple (43) from 500 psi (3448 kPa)regulating valve (44).

9

10

Remove two hex nuts (45), twoIockwashers (46), U-bolt plate (47), U-bolt(48), and pipe support (49).

Uncouple pipe union (50). Remove pipeunion (50) halves from pipe nipple (51) andpipe elbow (52). Remove pipe nipple (51),solenoid valve (53), pipe nipple (54), pipeplug (55), straight adapter (56), pipe elbow(57), and pipe nipple (58) from 300 psi(2069 kPa) regulating valve (59).

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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), pipenipple (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



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TM 9-4940-531-14

1

2

3

4

5

6


Install two support plates (1) onto plumbing support assembly (2) with four new tapping screws(3).

Install two pipe nipples (4 and 5) onto pipe tee (6). Install two pipe nipples (7 and 8) and pipetee (6) onto pipe cross (9).

Secure pipe cross (9) onto plumbing support assembly (2) with U-bolt plate (10), U-bolt (11), twonew Iockwashers (12), and two hex nuts (13).

Install pipe elbow (14), pipe bushing (15), pipe nipple (16), vent valve (17), pipe nipple (18), pipeelbow (19), pipe nipple (20), and pipe elbow (21) onto pipe cross (9).

Install pipe nipple (22) and pipe elbow (23) onto pipe cross (9).

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REASSEMBLY (cont)

7

8

9

CAUTIONTo prevent damage to equipment, donot tamper with pressure settings ofregulating valves. If adjustment isnecessary, refer to adjustment proce-dure below.

Install pipe union (24) halves onto pipenipple (25) and pipe elbow (23). Assemblepipe nipple (25), solenoid valve (26), pipenipple (27), 300 psi (2069 kPa) regulatingvalve (28), pipe plug (29), pipe nipple (30),pipe elbow (31), and straight adapter (32).Couple pipe union (24).

Secure solenoid valve (26) and 300 psi(2069 kPa) regulating valve (28) ontoplumbing support assembly (2) with U-boltplate (33), pipe support (34), U-bolt (35),two new Iockwashers (36), and two hexnuts (37).

Install pipe union (38) halves onto two pipenipples (8 and 39). Assemble pipe nipple(39), 500 psi (3448 kPa) regulating valve(40), pipe nipple (41), pipe elbow (42), pipenipple (43), pipe elbow (44), pipe elbow(45), and straight adapter (46). Couplepipe union (38).

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TM 9-4940-531-14

10

11

12

13

14

15

16

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). Couplepipe union (47).

Install check valve (53), pipe elbow (54), pipe nipple (55), and pipe cross (56) onto pipe nipple (5).

Secure solenoid valve (49) onto plumbing support assembly (2) with pipe support (57), U-bolt(58), two new Iockwashers (59), and two nuts (60).

Install pipe bushing (61), pipe nipple (62), flow switch (63), pipe nipple (64), and pipe reducer (65)onto pipe cross (56).

Install hydraulic accumulator (66), pipe nipple (67).

Install pipe bushing (69), pipe coupling(70), pipe elbow (71), pipe bushing (72),and pressure switch (73) onto pipe tee (68).

Install junction box (74) onto pressureswitch (73) with two electrical locknuts (75).If removed, install cover (76) with twomachine screws (77).

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ADJUSTMENT OF PRESSURE REGULATING VALVES

1 Install coil inlet control assembly (para 5-15) and fuel tank assembly (para 5-10).

NOTEl This procedure requires two people.

l Preform this procedure only after replacing a defective coil inlet control assemblyregulating valve or if INLET PRESSURE gauge (1) displays reading above normalpressure limits (para 2-6).

2 After initial startup procedure (para 2-5), install appropriate nozzle for mode selected and securecleaning 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).

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5-21. OIL DRAIN ASSEMBLY —MAINTENANCE INSTRUCTIONS

THIS TASK COVERS:


INITIAL SETUP



Equipment ConditionsOil drain assembly removed (para 5-15)

DISASSEMBLY

Remove straight adapter (1) and pipe bushing (2) from oil drain bracket assembly (3).

INSPECTION/REPAIR



REASSEMBLY


2 Install pipe bushing (2) and straight adapter (1) to oil drain bracket assembly (3).

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5-22. CONTROL BOX ASSEMBLY, UPPER CONTROL PANEL ASSEMBLY, ANDELECTRICAL COMPONENTS ASSEMBLY—MAINTENANCE INSTRUCTIONS

THIS TASK COVERS:

a. Disassemblyb. Inspect ion/repairc. Reassemblyd. Calibration of OPERATING TEMPERATURE indicator

INITIAL SETUP


Materials/PartsGrommet (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 ConditionsControl box assembly removed (para 5-6)Upper control panel assembly partially disassembled (para 4-20)Accurate thermometer available for calibration procedure

DISASSEMBLY

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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 temperaturecontrol 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

NOTEThe 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 WATERALARM, 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).

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5-22. CONTROL BOX ASSEMBLY, UPPER CONTROL PANEL ASSEMBLY, ANDELECTRICAL COMPONENTS ASSEMBLY—MAINTENANCE INSTRUCTIONS (cont)

DISASSEMBLY (cont)

14

15

16

17

18

19

20

Remove four nuts (32) and four machine screws (33), tag and disconnect wires, and removeelectromagnet relay (34) from control box weldment (10).

Tag and disconnect wires. Remove ten screws (35) and two terminal jumpers (36) from terminalboard (37). Reinstall ten screws. Remove four tapping screws (38) and terminal board (37).

Tag and disconnect wires. Remove two self-locking nuts (39), two flat washers (40), two ma-chine screws (41), two flat washers (42), and two sensitive switches (43).

Tag and disconnect wires. Remove five screws (44) and terminal jumper (45) from terminalboard (46). Reinstall five screws. Remove four tapping screws (47) and terminal board (46).

Tag and disconnect wires. Remove two tapping screws (48) and receptacle connector (49).

Remove grommet (50).

Remove four nuts (51), four Iockwashers (52), four capscrews (53), electrical components assem-bly (54), and four panel mounting spacers (55).

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21 Tag and disconnect wires. Remove sixteentapping screws (56) and eight relay-switches (57) from mounting panel (58).

22 Tag and disconnect wires. Remove fourtapping screws (59) and two delay lines(60).

23 Tag and disconnect wires. Remove twonuts (61), two Iockwashers (62), twocapscrews (63), and power transformer (64)from mounting panel (58).

INSPECTION/REPAIR


2 Check for faulty or burnt wiring.


1 Install power transformer (1) onto mountingpanel (2) with two capscrews (3), two newIockwashers (4), and two nuts (5). Connectwires.

2 Install two delay lines (6) with four newtapping screws (7). Connect wires.

3 Install eight relay-switches (8) with sixteennew tapping screws (9). Connect wires.

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4

5

6

7

8

9

10

Install electrical components assembly (10) onto control boxweldment (11) with four panelmounting spacers (12), four capscrews (13), four new Iockwashers (14), and four nuts (15).

Install new grommet (16).

Install receptacle connector (17) with two new tapping screws (18). Connect wires.

Install terminal board (19) with four new tapping screws (20). Remove five screws (21). Installterminal jumper (22) onto terminal board (19) with five screws. Connect wires.

Install two sensitive switches (23) with two flat washers (24), two machine screws (25), two flatwashers (26), and two new self-locking nuts (27). Connect wires.

Install terminal board (28) with four new tapping screws (29). Remove ten screws (30). Installtwo terminal jumpers (31) onto terminal board (28) with ten screws. Connect wires.

Connect wires and install electromagnet relay (32) onto control box weldment (11) with fourmachine screws (33) and four nuts (34).

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TM 9-4940-531-14

11

12

13

14

15

16

17

Install HOUR METER (35) onto control panel (36) with three screws (37) and three nuts (38).

Install OPERATING TEMPERATURE indicator (39) with three screws (40) and three nuts (41).

Install MODE SELECTOR rotary switch (42) with washer (43) and nut (44).

Install nut (45) and PUSH TO START push switch (46). Install nut (47) and tighten nut (45).

Install nut (48) and CIRCUIT BREAKER (49). Install plug nut (50) and tighten nut (48).

Install EMERGENCY OFF circuit breaker (51) and switch guard (52) with four machine screws(53).

Install DELlME LIGHT, POWER LIGHT, DRAIN LIGHT, HOT WATER ALARM, and STEAMALARM indicator lights (54) with five spring clips (55).

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REASSEMBLY (cont)

18

19

20

21

22

23

5-144

Install upper control panel assembly (56) onto control box weldment (11) with four new tappingscrews (57).

Connect all wires to components of upper control panel assembly (56).

Install access door (58) with five new tapping screws (59).

Install temperature control box (60) onto access door (58) with four flat washers (61), fourcapscrews (62), and four new self-locking nuts (63).

Connect all wires to temperature control box (60).

If removed, close upper control panel assembly (56) and install four new tapping screws (64).

TM 9-4940-531-14

CALIBRATION OF OPERATING TEMPERATURE INDICATOR

NOTEThermocouple wire length is important to OPERATING TEMPERATURE indicatoraccuracy. 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).

WARNINGTo avoid personal injury, be sure no pressure registers on INLET and OUTLET PRES-SURE gauges (1 and 2) before disconnecting temperature probe.

2 Disconnect temperature probe (3) from outlet and water drain assembly (4). Place temperatureprobe 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 ambi-ent temperature.

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5-23. STEAM CLEANER LIFT ASSEMBLY—MAINTENANCE INSTRUCTIONS

THIS TASK COVERS:


INITIAL SETUP


Materials/PartsLockwasher (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), andright latch support (9).

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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).

i n s p e c t i o n / R E P A I R


2 Inspect components for burrs and sharp edges. Remove any burrs or sharp edges.


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5-23. STEAM CLEANER LIFT ASSEMBLY

REASSEMBLY

1 Install two front and rear top angles (1) andtwo left and right top angles (2) onto fourcorner post assemblies (3 and 4) with 16machine screws (5), 16 new Iockwashers(6), and 16 nuts (7).

2

3

Install right latch support (8) and left latchsupport (9) with four machine screws (10),four new Iockwashers (11), and four nuts(12).

Install lifting assembly tube (13) with fourmachine screws (14), four new Iockwashers(15), and four nuts (16).

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5-24. COIL OUTLET-TO-PRESSURE SWITCH TUBING ASSEMBLY AND PRESSURESWITCH-TO-PRESSURE SWITCH TUBING ASSEMBLY—MAINTENANCEINSTRUCTIONS

THIS TASK COVERS:


INITIAL SETUP


Equipment ConditionsCoil outlet-to-pressure switch tubing assembly (para 5-7 and 5-9) and/or pressure switch-to-

pressure switch tubing assembly removed (para 5-7)

DISASSEMBLY

1

2

NOTEThis procedure is written for one tubingassembly, but applies to both coiloutlet-to-pressure switch and pressureswitch-to-pressure switch tubing assem-blies. Repeat as needed.

Remove two straight adapters (1).

If necessary for replacement of parts, cuttubing (2) and remove two tube coupling nuts (3).

INSPECTION/REPAIR



3 Tubing is cut to a length of 19 in. (48.26 cm) for coil outlet-to-pressure switch tubing assemblyand 6 in. (15.24 cm) for pressure switch-to-pressure switch tubing assembly. If tubing is short-ened, 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).

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5-25. COIL OUTLET-TO-DIFFERENTIAL PRESSURE SWITCH TUBING ASSEMBLY ANDCOIL INLET-TO-DIFFERENTIAL PRESSURE SWITCH TUBING ASSEMBLY—MAINTENANCE INSTRUCTIONS

THIS TASK COVERS:


INITIAL SETUP


Equipment ConditionsCoil outlet-to-differential pressure switch tubing assembly (para 5-7 and 5-9) and/or coil inlet-

to-differential pressure switch tubing assembly removed (para 5-7 and 5-8)

DISASSEMBLY

NOTEThis procedure is written for onetubing assembly, but applies to bothcoil outlet-to-differential pressureswitch and coil inlet-to-differentialpressure switch 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).

lNSPECTION/REPAIR



3 Tubing is cut to a length of 19 in. (48.26 cm) for coil outlet-to-differential pressure switch tubingassembly and 24.5 in. (62.23 cm) for coil inlet-to-differential pressure switch tubing assembly. Iftubing is shortened, discard and replace with new tubing. Refer to appendix F.

REASSEMBLY



3 Couple straight adapter (1) and male pipe-to-tube elbow (2) to two tube coupling nuts (4).

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TM 9-4940-531-14

5-26. 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

THIS TASK COVERS:


INITIAL SETUP


Equipment ConditionsCoil 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 gaugetubing assembly removed (para 4-14 and 5-5)

DISASSEMBLY

This procedure is written for onetubing assembly, but applies to coilinlet-to-inlet pressure gauge coiloutlet-to-outlet pressure gauge, andfuel pump-to-pressure gauge tubingassemblies. 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



3 Tubing is cut to a length of 23.5 in. (59.69 cm) for coil inlet-to-inlet pressure gauge tubing assem-bly, 12 in. (30.48 cm) for coil outlet-to-outlet pressure gauge tubing assembly, and 36 in. (91.44cm) for fuel pump-to-pressure gauge tubing assembly. If tubing is shortened, discard and re-place with new tubing. Refer to appendix F.

REASSEMBLY



3 Couple straight adapter (1) and male pipe-to-tube elbow (2) to two tube coupling nuts (4).

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TM 9-4940-531-14

5-27 . FUEL STRAINER ASSEMBLY—MAINTENANCE INSTRUCTIONS

THIS TASK COVERS:


INITIAL SETUP


Materials/PartsAntiseizing tape (item 24, appx E)Gasket (MS51091-4)Wiping rag (item 18, appx E)

Equipment ConditionsFuel strainer assembly removed (para 4-13)

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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).

NOTENut (9) and washer (10) are components of pipe coupling (8), and cannot be requisi-tioned 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).

NOTESediment bowl (15) is a component of the sediment strainer (4) and cannot be requisi-tioned individually.

4 Remove sediment bowl (15), strainer element (16), and gasket (17).

lNSPECTION/CLEANING/REPAIR


2 Wipe off strainer element and sediment bowl with a clean wiping rag (item 18, appx E).


REASSEMBLY

1

2

3

4

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

Install new gasket (17), strainer element (16), and sediment bowl (15) onto sediment strainer (4).

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).

Install pipe elbow (13), pipe nipple (14), sediment strainer (4), pipe nipple (3), pipe elbow (2), andstraight adapter (1) onto pipe nipple (12).

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5-28 . FUEL SHUTOFF ASSEMBLY—MAINTENANCE INSTRUCTIONS

THIS TASKS COVERS:


INITIAL SETUP


Material/PartsAntiseizing tape (item 24, appx E)

Equipment ConditionsFuel shutoff assembly removed (para 4-13)All hoses and hose clamps removed (para 4-13)

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DISASSEMBLY

1 Remove four straight adapters (1) from two adapter bushings (2) and two pipe elbows (3).

NOTENuts and washers are components of adapter bushings and cannot be requisitionedindividually.

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



REASSEMBLY


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).

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TM 9-4940-531-14

5-29. COIL UNIT ASSEMBLY—MAINTENANCE INSTRUCTIONS

THIS TASK COVERS:

a. Disassemblyb. Inspection/repairc. Reassemblyd. Cleaning/deliming

INITIAL SETUP


Materials/PartsFire-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 ConditionsCoil unit assembly removed (para 5-10) to perform disassembly/reassemblyTwo suitable 5-gal. (18.9-1) plastic containers available for cleaning/delimingSteam 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 outercover 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

6 If necessary for replacement of parts, remove four tapping screws (11) and

coil (2).

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).

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TM 9-4940-531-14

5-29. COIL UNIT ASSEMBLY—MAINTENANCE INSTRUCTIONS (cont)

INSPECTION/REPAIR



1 If either insulation blanket(1) or outer cover assembly (2) was replaced, install fire-resistantadhesive (item 1, appx E) in 0.50 x 6.00-in. (1.27 x 15.24-cm) long strips to inside surface ofouter 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 firepot (3).

3 Install outer cover assembly (2) over assembled parts and secure with eight new tapping screws(7).

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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 securewith 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 organizationhaving jurisdiction to establish policies and procedures regarding industrial toxicology and envi-ronmental impact of the deliming chemicals.

2 Chemical deliming should be done only after the blowdown procedure has failed to reduce thedifference in coil inlet and outlet pressure to less than 70 psi (483 kPa) or when the DELlMELIGHT illuminates. Tests have shown that regular blowdown greatly increases the intervalsbetween chemical deliming. Mineral deposits in the coil unit assembly and coil outlet fittings arethe result of the effects of heat on undissolved solids in the water used. These deposits must beperiodically 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 compo-nent location before proceeding with deliming procedure.

4 Prior to deliming procedure, read and follow all warnings, first aid procedures, cautions, andnotes.

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TM 9-4940-531-14


CLEANING/DELIMING (cont)

5-160

WARNINGInhibited coil descaling (deliming) powder contains sulfamic acid and is a poison and acorrosive chemical. When working with acids always pour acid into water, neverwater into acid.

Sulfamic acid and sodium hydroxide should not be handled unless the user is properlyclothed, including rubber boots, rubber apron, rubber gloves, and a full face shield. Allprotective clothing must be kept on until deliming solution is neutralized and work site iscleaned up. Rubber gloves must be thoroughly washed prior to removal and should bethe 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 insevere or possibly fatal injury to personnel.

Do not handle sulfamic acid or sodium hydroxide bare-handed. Moisture in the skin willactivate the chemical, causing severe irritation or burns.

Operations must be performed in a well-ventilated area. Carbon dioxide vapors arereleased during this procedure. Injury to personnel may result if proper ventilation isnot provided.

Personnel should not eat, drink, or smoke in the immediate work area during thedeliming operation.

FIRST AID PROCEDURES

Sulfamic acid, sodium hydroxide, and their solutions can cause severe irritation orburns to eyes and skin.

In cases of eye contact, immediately flush the eyes with plenty of water for at least 15minutes. Call a physician.

In cases of skin contact, immediately flush area with plenty of water for at least 15minutes 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 largeamounts of water. DO NOT induce vomiting. Call a physician.

Read the Material Safety Data Sheet packed with the sulfamic acid and sodium hydrox-ide containers before use.

CAUTIONOnly authorized personnel who have read and who understand this procedure shouldbe permitted to perform the cleaning/deliming function.

Excess amounts of sulfamic acid can cause serious damage to water pump.

Adhere closely to directions.

TM 9-4940-531-14

5

6

7

8

9

10

11

Close CHEMICAL METERING valve (1) and valve (2) to water tank.

Fill 5 gal. (18.9 l) or larger plastic container (3) with clean water:

Clean suction hose assembly (4) (para 3-6).

Install suction hose assembly (4) onto water pump assembly (5).

With steam cleaner in normal operating mode and power off, remove nozzle from steam cleaninggun (6) and tie trigger (7) so water will flow. Put suction end of suction hose assembly (4) andspray end of steam cleaning gun (6) into plastic container (3) so water will recirculate.

Turn MODE SELECTOR switch (8) to COLD. Operate steam cleaner (9) on COLD long enoughto clear out all soap solution and loose scale (5 minutes minimum).

Shut down steam cleaner (9) and empty water from plastic container (3).

5-161

TM 9-4940-531-14



5-162

TM 9-4940-531-14

12

13

14

15

16

17

18

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 allowsteam cleaner to produce steam with the cleaning solution circulating, as injury topersonnel may result from fumes or hot acid splash.

Sulfamic acid is a poisonous and corrosive chemical.

NOTECarbon dioxide is released as long as scale and sulfamic acid are present. After scaleis completely dissolved, gases cease to form.

Pour 2 lb (1 kg) of sulfamic acid (item 23, appx E) into plastic container (3). Place suction end ofsuction hose assembly (4) and spray end of steam cleaning gun (6) into plastic container (3), asin step 9, and allow solution to circulate. To clean nozzles, place them in a separate container ofthe deliming solution. After 30 minutes, turn off steam cleaner (9) and check solution strengthusing red litmus paper (item 25, appx E). Dip test litmus paper into solution. If a reddish color ispresent, the solution is strong enough to remove the scale. If the litmus paper turns blue, thesolution is spent. Repeat litmus paper test, adding 2 lb (1 kg) of sulfamic acid at 30-minuteintervals until the solution tests a reddish color on the litmus paper. During this procedure, turnMODE SELECTOR switch (8) to HEAT just long enough for the steam cleaning gun (6) to feelwarm but not hot. It may be necessary to stop steam cleaner (9) from time to time to pumpexcess solution into another container to avoid overflowing plastic container. This excess solu-tion must be subsequently neutralized, using sodium hydroxide mixture as follows.

WARNINGSodium hydroxide is a poisonous and corrosive chemical.

Before draining the solution from steam cleaner (9), it must be neutralized. Turn on steamcleaner and add sodium hydroxide (item 20, appx E) in 1-oz (28-g) increments. Using red litmuspaper (item 25, appx E), dip litmus paper into the solution and wait until the solution just begins tochange from red to blue. When this change occurs, the solution is neutralized. It then can beflushed into a sanitary sewer with equal parts of water.

Stop steam cleaner and remove end of steam cleaning gun (6) from plastic container and placedischarge 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 solutioninto a sanitary or storm water system.

Turn on either pressurized or nonpressurized water supply to steam cleaner (9). Operate onCOLD and flush water through steam cleaner for 5 minutes.

Any areas that may have been splashed with acid solution should be flushed with water.

Clean water tank strainer and water inlet fittings in accordance with equipment manual operatinginstructions.

5-163

TM 9-4940-531-14



19

20

Install pressure tip or steam nozzle (10) on steam cleaning gun (6).

Press PUSH TO START switch (11) and check INLET PRESSURE gauge (12) with OUTLETPRESSURE gauge (13). If pressure differential is more than 70 psi (483 kPa), the heating coil ofthe coil unit assembly (14) may need a second treatment.

5-164

TM 9-4940-531-14

21 If a second treatment fails to reduce thepressure differential as specified, theheating coil (15) may need to be removed(p 5-157) and soaked in a solution ofsulfamic acid as follows:

NOTEEnsure EMERGENCY OFF switch is in off position and CHEMICAL METERING valveis closed.

a. Following disassembly procedure above, remove heating coil (15) from coil unit assembly andsoak in a solution of 5.0 lb (2.3 kg) of sulfamic acid (item 23, appx E) added to 10 gal. (38 l) ofwater. Enough solution should be mixed in a suitable plastic container (16) to cover theheating coil completely. Check the solution by using red litmus paper (item 25, appx E). Diplitmus paper into the solution. If a reddish color is present, the solution is strong enough toremove scale. If the litmus paper turns a blue color, the solution is spent. Allow the heatingcoil (15) to soak between 3 to 5 hours. This will allow the solution to work its way throughoutthe heating coil (15). Periodically check the solution strength with litmus paper (item 25, appxE). 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 litmuspaper tests a reddish color.

b. Before draining the solution from the heating coil container, it must be neutralized as speci-fied 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



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 posi-tion.

24 Install nozzle (10) in steam cleaning gun (6). Steam cleaner (9) is now ready for normal opera-tion.

5-166

TM 9-4940-531-14

5-30. CONNECTION DIAGRAM, WIRE ASSEMBLY, AND CONDUIT ASSEMBLY—MAINTENANCE INSTRUCTIONS

THIS TASK COVERS:

a. Inspection/repair of wire assembly PN 11024261b. Inspection/repair if wire assembly PN 11025004c . Inspection/repair of conduit assembly

INITIAL SETUP


Equipment ConditionsWire 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

NOTEProcedure is written for one wire assembly. Repeat as needed for all wire assemblies.



3 Wire assembly is a manufactured item, refer to appendix F. Cut wire to length and add terminallugs as specified.

4 Strip 0.50 in. (1.27 cm) from ends of wire (1), position and crimp new terminal lugs (2 and 3) asapplicable.

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

NOTEProcedure is written for one wire assembly. Repeat as needed for other wire assembly.



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

NOTEProcedure is written for one conduit assembly. Repeat as needed for all conduit as-semblies. Electrical box connectors will vary, but repair procedures remain the same.


5-168

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

NOTEElectrical box connectors are only replaceable as a whole, their component partscannot be requisitioned.

Check conductor locknuts and seals for damage.

TM 9-4940-531-14

Remove box connector housing (1) from back nut (2) and slide back nut (2) onto flexible metalconduit (3). Remove conduit sleeve insert (4) from flexible metal conduit (3).

Remove back nut (2) and check bushing (5) for damage.

Remove box connector housing (6) from back nut (7) and slide back nut (7) onto flexible metalconduit (3). Remove conduit sleeve insert (8) from flexible metal conduit (3).

Remove back nut (7) and check bushing (9) for damage.


Conduit assemblies are manufactured items, refer to appendix F. Cut flexible metal conduit tolength specified.

Install bushing (9) into back nut (7).

Slide back nut (7) onto flexible metal conduit (3). Install conduit sleeve insert (8) onto flexiblemetal conduit (3).

Install connector housing (6) onto back nut (7).

Install bushing (5) into back nut (2).

Slide back nut (2) onto flexible metal conduit (3). Install conduit sleeve insert (4) onto flexiblemetal conduit (3).

Install connector housing (1) onto back nut (2).

Install wire assemblies in conduit assemblies in accordance with schematics on pages FP-3 thruFP-5.

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:


INITIAL SETUP


Materials/PartsCotter 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)

ReferencesTM 9-2330-202-14&PTM 9-4940-531-24P

Equipment ConditionsHandbrake engagedMaster 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

TM 9-4940-531-14

DISASSEMBLY

1

2

3

4

5

Support front and rear of flat bed trailer. If brake lines require replacement, bleed and drain linesin accordance with TM 9-2330-202-14&P.

Remove two tapping screws (1), two loop clamps (2), and brake line tube assembly (3) fromtrailer chassis (4).

Remove three self-locking nuts (5), three machine screws (6), three loop clamps (7), and brakeline tube assembly (8).

Remove nonmetallic hose assembly (9).

Remove front brake line tube assembly (10).

5-171

TM 9-4940-531-14


DISASSEMBLY (cont)

6 Remove eight hex nuts (11), eight Iockwashers (12), eight capscrews (13), and two vehicularfenders (14).

NOTEHardware and bracket in steps 7 and 8 are component parts of rear stabilizer kit andcannot 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 lockingarm (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



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 per-formed by general support maintenance. If the trailer chassis requires replacement, notify gen-eral support maintenance.

5-173

TM 9-4940-531-14


REASSEMBLY

1

2

3

4

5

6

screws (7).

Install drawbar locking arm (8), locking pin assembly (9), headed straight pin (10), and new cotterpin (11).

Install leveling-support jack (12), headless grooved pin (13), and two new retaining rings (14).

NOTENo paint is permitted on threads or inside diameter of tube.

Support front and rear of flat bed trailer.

Install new self-locking nut (1), hook bolt (2), and new self-locking nut (3) onto trailer chassis (4).

If removed, install three loop clamps (5), three new tapping screws (6), and four new tapping

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), andeight hex nuts (30).

NOTEBrake lines will need to be bent as needed at installation. The minimum inside bendradius is 0.50 in. (1.27 cm).

5-175

TM 9-4940-531-14


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), andthree 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:


INITIAL SETUP


Materials/PartsSelf-locking nut (MS51922-17)

ReferencesTM9-4940-531-24P

Equipment ConditionsLeveling-support jack removed (para 5-31)

DISASSEMBLY

1 Remove four hex nuts (1), four capscrews(2), and wheel (3) from inner housingassembly (4).

2 Remove self-locking nut (5), capscrew (6),and inner housing assembly (4) from upperjack assembly (7).

INSPECTION/REPAIR


2 If upper jack assembly or inner housingassembly is damaged, replace entireleveling-support jack (TM 9-4940-531-24P).


REASSEMBLY

1 Install inner housing assembly (4) onto upper jack assembly (7) with capscrew (6) and new self-Iocking 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.

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TM 9-4940-531-14

5-33. BRAKE LINE TUBE ASSEMBLY—MAINTENANCE INSTRUCTIONS

THIS TASK COVERS:

a. Serv iceb. Disassemblyc. Inspection/repaird. Reassembly

INITIAL SETUP


Equipment ConditionsBrake line tube assembly removed (para 5-31)

SERVICE

If brake lines are leaking, tighten connections. Ifthey continue to leak after being tightened,perform procedure below.

NOTEThis procedure is written for one brakeline tube assembly, but applies to allbrake line tube assemblies. Repeat asneeded.

DISASSEMBLY

If brake line tubing (1) is damaged, but coupling (2) and two tube nuts (3) are serviceable, cut brakeline tubing (1) and remove components.

INSPECTION/REPAIR


2 Brake line tubing is a manufactured item, refer to appendix F.


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).

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TM 9-4940-531-14

C H A P T E R 6G E N E R A L S U P P O R T M A I N T E N A N C E I N S T R U C T I O N S

CHAPTER INDEX

Paragraph Page

6-1. General Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .6-2. M116A2 Trailer Chassis Modification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . .

6-1. GENERAL MAINTENANCE

Refer to general maintenance instructions in paragraph 4-11.

6-2 . M116A2 TRAILER CHASSIS MODIFICATION

6-16-1

THIS TASK COVERS:

Modification of M116A2 trailer chassis

INITIAL SETUP


Materials/PartsBlack paint (item 4, appx E)Brown paint (item 5, appx E)Green paint (item 6, appx E)Support blocks available

ReferencesMIL-C-53072MIL-STD-171TM9-237TM9-2330-202-14&P

Equipment ConditionsM116A2 trailer chassis and all modification parts receivedMaster 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. Whilewelding 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 TM9-2330-202-14&P.

NOTEEnsure 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


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

12

13

Weld four threaded plates (13) to trailer chassis (1).

Weld right front main sill reinforcement (14) and left front main sill reinforcement (15) to trailerchassis (1).

Weld two top sill reinforcements (16) and two bottom sill reinforcements (17) to trailer chassis (1).

6 - 5

TM 9-4940-531-14


MODIFICATION OF M116A2 TRAILER CHASSIS (cont)

14

15

16

17

6-6

Weld two rear main sill reinforcements (18) to trailer chassis (1) as shown.

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).

Drill four holes 0.250±0.005 in. (0.635±0.01 3 cm) in trailer chassis (1) (View L-L).

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).

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 9-2330-202-14&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 brakefluid 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

TM 5-6115-615-12

A P P E N D I X AR E F E R E N C E S

A - 1 . T E C H N I C A L M A N U A L S

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Operator and Organizational MaintenanceManual: Generator Set, Diesel Engine Driven, andSingle Phase 120/240 Volts AC and 28 Volts DCDoD 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 28VDC;(6115-150-0367)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Organizational, Direct Support, and GeneralTM 5-6115-615-24P

TM 5-6115-615-34 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Support Repair Parts and Special Tools List;Generator Set, Diesel Engine Driven, Tactical,Skid Mounted, 3Kw, 3 Phase 120/240 Volts ACand 28 Volts DC: DoD Model MEP-016B; ClassUtility; Mode 60 Hz; (NSN 6115-01-150-4140);DoD Model-021 B; Class Utility; Mode 400 Hz;(6115-01-151-8126); Model MEP-026B; ClassUtility; Mode 28 VDC; (6115-01-150-0367)

Intermediate (Field) (Direct and General Support)

TM 9-237

Maintenance Manual; Generator Set Diesel EngineDriven, Tactical Skid Mounted, 3 Kw, 3 Phase120/208 and Single Phase 120/240 Volts AC and28 Volts DC; DoD Model MEP-016B; Class Utility;Mode 60 Hz (NSN 6115-01-150-4140); DoD ModelMEP-021B; Class Utility; Mode 400 Hz (6115-01-150-8126); DoD Model MEP-026B; Class Utility;Mode 28 VDC; (6115-01-150-0367)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Operator’s Manual for Welding Theory and Appli-cation

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Operator’s, Organizational, Direct Support andGeneral Support Maintenance Manual IncludingRepair Parts and Special Tools List for Trailer,Cargo: 3/4-Ton, 2-Wheel, M101 (NSN 2330-00-738-9509), 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 (2330-01-101-8434)

TM 9-2330-202-14&P

A-1

TM 9-4940-531-14

A-1 . TECHNICAL MANUALS (cont )

TM 9-4940-531-24 P . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . .Unit, Direct Support, and General Support Mainte- nance Repair Parts and Special Tools List forCleaner, 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 Fed-eral Supply Classifications 1000, 1005, 1010,1015, 1020, 1025, 1030, 1055, 1090 and 1095 toPrevent Enemy Use

A-2 . FORMS

DA Form 2028 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . Recommended Changes to Publications and BlankForms

DA Form 2028-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Recommended Changes to Equipment TechnicalPublications

DA Form 2404 . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . .Equipment Inspection and MaintenanceWorksheet

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

A- A-55057 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Panels, Wood/Wood Based; Construction andDecorative

AR 220-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Unit Status Reporting

AR 725-50 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Requisitioning, Receipt, and Issue System

AR 735-5 . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . Policies and Procedures for Property Account-ability

AR 750-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Army Materiel Maintenance Policy and RetailMaintenance Operations

ASTMB75 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Standard Specification for Seamless Copper Tube

A-2

TM 9-4940-531-14

CTA 8-100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Army Medical Department Expendable/DurableItems

CTA 50-970 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Expendable/Durable Items (Except: Medical, ClassV, Repair Parts and Heraldic Items)

DA PAM 738-750 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Functional Users Manual for The Army Mainte-nance 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) SystemApplication Procedures and Quality ControlInspection

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 WiringDevices 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, SemitrailerMounted

SC 5180-90-CL-N26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tool Kit, General Mechanic’s, Automotive

A-3/(A-4 blank)

TM 9-4940-531-14

A P P E N D I X BM A I N T E N A N C E A L L O C A T I O N C H A R T ( M A C )

S E C T I O N l . I N T R O D U C T I O N

B-1. THE ARMY MAINTENANCE SYSTEM MAC

a. This introduction (section l) provides a general explanation of all maintenance and repairfunctions authorized at various maintenance levels under the standard Army Maintenance Systemconcept.

b. The Maintenance Allocation Chart (MAC) in section II designates overall authority and respon-sibility for the performance of maintenance functions on the identified end item or component. Theapplication of the maintenance functions to the end item or component will be consistent with thecapacities and capabilities of the designated maintenance levels, which are shown on the MAC incolumn (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) requiredfor each maintenance function as referenced from section Il.

d. Section IV contains supplemental instructions and explanatory notes for a particular mainte-nance function.

B-2. MAINTENANCE FUNCTIONS. Maintenance functions are limited to and defined as follows:

a. Inspect. To determine the serviceability of an item by comparing its physical, mechanical,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 electricalcharacteristics 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.

d. Adjust. To maintain or regulate, within prescribed limits, by bringing into proper position, or bysetting the operating characteristics to specified parameters.

B-1

TM 9-4940-531-14

B-2 . MAINTENANCE FUNCTIONS (cont )

e. Align. To adjust specified variable elements of an item to bring about optimum or desiredperformance.

f. Calibrate. To determine and cause corrections to be made or to be adjusted on instrumentsor test, measuring, and diagnostic equipment used in precision measurement. Consists of compari-sons of two instruments, one of which is a certified standard of known accuracy, to detect and adjustany discrepancy in the accuracy of the instrument being compared.

g. Remove/lnstall. To remove and install the same item when required to perform service orother maintenance functions. Install may be the act of emplacing, seating, or fixing into position aspare, repair part, or module (component or assembly) in a manner to allow the proper functioning ofan equipment or system.

h. Replace. To remove an unserviceable item and install a serviceable counterpart in its place.Replace is authorized by the MAC and assigned maintenance level is shown as the 3d position codeof the SMR code.

i. Repair. The application of maintenance services’ including fault location/troubleshooting2,removal/installation, and disassembly/assembly3 procedures, and maintenance actions4 to identifytroubles and restore serviceability to an item by correcting specific damage, fault, malfunction, orfailure in a part, subassembly, module (component or assembly), end item, or system.

j. Overhaul. That maintenance effort (service/action) prescribed to restore an item to a com-pletely serviceable/operational condition as required by maintenance standards in appropriate techni-cal publications (i.e., DMWR). Overhaul is normally the highest degree of maintenance performed bythe Army. Overhaul does not normally return an item to like new condition.

k. Rebuild. Consists of those services/actions necessary for the restoration of unserviceableequipment to a like new condition in accordance with original manufacturing standards. Rebuild is thehighest degree of materiel maintenance applied to Army equipment. The rebuild operation includesthe act of returning to zero those age measurements (e.g., hours/miles) considered in classifying Armyequipment/components.

1Services-Inspect, test, service, adjust, align, calibrate, and/or replace.

2Fault location/troubleshooting—The process of investigating and detecting the cause of equipmentmalfunctioning; the act of isolating a fault within a system or unit under test (UUT).

3Disassembly/assembly—The step-by-step breakdown (taking apart) of a spare/functional groupcoded item to the level of its least component, that is assigned an SMR code for the level of mainte-nance under consideration (i.e., identified as maintenance significant).

4Actions—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 ofwhich is to identify maintenance significant components, assemblies, subassemblies, and moduleswith 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 itemlisted 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 toperform each function listed in column 3, by indicating work time required (expressed as man-hours inwhole hours or decimals) in the appropriate subcolumn. This work-time figure represents the activetime required to perform that maintenance function at the indicated level of maintenance. If thenumber or complexity of the tasks within the listed maintenance function varies at different mainte-nance levels, appropriate work-time figures are to be shown for each level. The work-time figurerepresents the average time required to restore an item (assembly, subassembly, component, mod-ule, end item, or system) to a serviceable condition under typical field operating conditions. This timeincludes preparation time (including any necessary disassembly/assembly time), troubleshooting/faultlocation time, and quality assurance time in addition to the time required to perform the specific tasksidentified for the maintenance functions authorized in the maintenance allocation chart. The symboldesignations for the various maintenance levels are as follows:

C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Operator or crew maintenanceO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Unit maintenanceF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Direct support maintenanceL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Specialized Repair Activity (SRA)5

H . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .General support maintenanceD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Depot maintenance

e. Column 5, Tools and Test Equipment Reference Code. Column 5 specifies, by code, thosecommon tool sets (not individual tools), common TMDE, and special tools, special TMDE, and specialsupport equipment required to perform the designated function. Codes are keyed to tools and testequipment in section Ill.

f. Column 6, Remarks. When applicable, this column contains a letter code, in alphabeticalorder, which is keyed to the remarks contained in section IV.

5This maintenance level is not included in section II, column (4) of the Maintenance AllocationChart. Functions to this level of maintenance are identified by a work-time figure in the H column ofsection II, column (4), and an associated reference code is used in the Remarks column (6). Thiscode 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 acode used in the MAC, section II, column 5.

b. Column 2, Maintenance Level. The lowest level of maintenance authorized to use the tool ortest 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.

e. Column 5, Tool Number. The manufacturer’s part number, modelnumber, model number, or type number.

B-5. EXPLANATION OF COLUMNS IN REMARKS, SECTION IV

a. Column 1, Remarks Code. The code recorded in column 6,

b. Column 2, Remarks. This column lists information pertinentbeing performed as indicated in the MAC, section Il.

section Il.

to the maintenance function

S e c t i o n I l . M A I N T E N A N C E A L L O C A T I O N C H A R T F O R S T E A M C L E A N E R

(1)

GroupNumber

00

01

0101

0102

DirectSupport Depot

B-4

(2)

Component/Assembly

Steam Cleaner,Trailer Mounted(11024645)

Steam Cleaner(11024000)

Inlet Assembly,Coil(11024109)

Outlet Assembly,Coil(11024170)

(3)

MaintenanceFunction

InspectServiceReplaceRepair

InspectServiceReplaceRepair

InspectServiceRepair

InspectServiceAdjustRepair

Unit

C

0.50.5

0.10.5

O

0.30.7

3.0

0.30.7

1.5

0.1

0.5

0.1

0.8

(4)Maintenance

F

0.52.0

0.5

0.54.0

0.10.51.5

0.10.10.52.0

LevelGeneralSupport

D

(5)

Tools andEquipmentRef Code

1,2

1,2

1,2

1,21,2

(6)

RemarksCodeH

TM 9-4940-531-14

MAINTENANCE ALLOCATION CHART FOR STEAM CLEANER (cont)

(1)

GroupNumber

010201

01020101

0103

010301

0104

010401

010402

010403

010404

(2)Maintenance Level

DepotComponent/

Assembly H

BlowdownAssembly(11024956)

Valve and SwitchAssembly(11024941)

Oil BurnerAssembly(11024215)

Burner, Oil,Vaporizing,Atomizing(11024220)

Fuel TankAssembly(11024222)

Inlet Assembly,Suction(11024018)

Tank Assembly,Water(11024130)

Pump Assembly(11024146)

Inlet Assembly,Water(11024185)

(3)

MaintenanceFunction




InspectTestServiceAdjustReplaceRepair


InspectRepair



InspectRepair

Unit

C

0.1

0.1

0.1

0.10.2

0.1

0.1

0.10.4

0.1

O

0.1

0.10.20.30.8

0.1

0.20.30.5

0.10.20.12.0

0.10.5

0.10.4

0.11.0

(4)

DirectSupport

F

0.20.52.0

0.10.50.9

0.50.1

0.5

2.5

0.5

12.0

0.12.5

0.30.53.0

0.3

2.5

GeneralSupport

D

(5)


1,2

1,2

32

3

1,2

21,2

1,2

1,2

1,2

2

(6)

RemarksCode

B-5

TM 9-4940-531-14


(1)

GroupNumber

010405

010406

010407

010408

0105

010501

0106

010601

010602

0107


Component/Assembly

Inlet Assembly,Pump(11024195)

Motor Assembly(11024208)

H

Control Assembly,Coil Inlet(11024584)

Drain Assembly,Oil(11024872)

Lower ControlPanel Assembly(11024303)

Valve Assembly,Metering(11024304)

Control BoxAssembly(11024370)

Control PanelAssembly(11024322)

ElectricalComponentsAssembly(11024363)

Hose Assembly,Wash(11024408)

(3)

MaintenanceFunction

InspectRepair



InspectRepair

InspectRepair

InspectRepair

InspectRepair

InspectServiceCalibrateRepair

InspectRepair

InspectRemove/InstallRepair

Unit

C

0.1

0.1

0.1

0.1

0.1

0.10.2

0.10.5

O

0.21.3

0.5

0.11.5

0.11.5

0.1

0.1

1.0

0.1

1.2

(4)

DirectSupport

F

0.1

2.5

0.10.50.51.5

0.11.5

0.83.8

0.8

0.22.2

0.52.0

GeneralSupport Depot

D

(5)


2

1,2

1,21,2

1,2

2

2

1,2

1,21,2

1,2

2

(6)

RemarksCode

B-6

TM 9-4940-531-14


(1)

GroupNumber

0108

010801

010802

0109

0110

0111

0112

0113


GeneralSupportComponent/

Assembly

Enclosure andLift Assembly(11024520)

Door, Access(Hose Rack)(11024412)

Lift Assembly,Steam Cleaner(11024481)

Cable Assembly,Special Purpose,Electrical(Facility Power)(11024763)

Tubing Assembly(Coil Outlet-to-Pressure Switch)(11024820-1)

Tubing Assembly(Coil Outlet-to-DifferentialPressure Switch)(11024820-2)

Tubing Assembly(Coil Inlet-to-InletPressure Gauge)(11024820-3)

Tubing Assembly(Coil lnlet-to-differentialPressure Switch)11024820-4)

(3)

MaintenanceFunction


InspectReplaceRepair

InspectRepair

InspectReplaceRepair

InspectRepair

InspectRepair

InspectRepair

InspectRepair

Unit

C

0.1

0.1

0.1

0.1

0.1

0.1

0.1

O

0.10.82.0

0.10.5

1 .0

0.10.11.0

(4)

Direct,Support

F

0.1

2.6

0.12.0

0.11.2

0.11.2

0.11.2

0.11.2

Depot

DH

(5)


1,2

2

1,2

2

1,2

1,2

1,2

1,2

(6)

Remark:Code

B - 7

TM 9-4940-531-14


(1)

GroupNumber

0114

0115

0116

0117

0118

0119

0120

0121

B-8


GeneralSupport

Component/Assembly

Tubing Assembly(Coil Outlet-to-Outlet PressureGauge)(11024820-5)

Tubing Assembly(Pressure Switch-to-Pressure Switch)(11024820-6)

Tubing Assembly(Fuel Pump-to-Pressure Gauge)(11024820-7)

Outlet and WaterDrain Assembly(11024848)

Strainer Assembly,Fuel(11024870)

Shutoff Assembly,Fuel(11024886)

Coil UnitAssembly(11024903)

Diagram,Connection(11024915)

(3)

MaintenanceFunction

InspectRepair

InspectRepair



InspectServiceRemove/InstallRepair


InspectReplaceServiceRepair

Unit

C

0.1

0.1

0.1

0.1

0.10.5

0.1

O

0.6

0.10.31.5

0.8

0.10.5

0.5

0.1

(4)

DirectSupport

F

0.11.2

0.11.2

0.1

1.2

0.10.30.6

0.1

1.2

0.1

1.5

0.22.02.03.0

Depot

D

(5)


1,2

1,2

1,2

1,2

1,2

1,2

1,2

(6)

RemarksCode

A

TM 9-4940-531-14


B - 9

TM 9-4940-531-14


(1) (2) (3) (4) (5) (6)Maintenance Level

Unit Depot RemarksGroup Component/ Maintenance

Number Assembly Function C O F H D Ref Code Code

0404 Tube Assembly, Inspect 0.1 0.2Brake Line Repair 1.5 1 ,2(11024822-2)

0405 Tube Assembly, Inspect 0.1 0.2Brake Line Repair 1.5 1,2(11024822-3)

05 Generator Set, Replace 1.0 1,2 DDiesel (MEP-701A)

S e c t i o n I l l . T O O L S A N D T E S T E Q U I P M E N T F O R S T E A M C L E A N E R

TOOL OR TESTEQUIPMENT MAINTENANCE NATIONALREF CODE LEVEL NOMENCLATURE STOCK NUMBER 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

S e c t i o n I V . R E M A R K S F O R S T E A M C L E A N E R

REMARKSCODE 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.

D i r e c tSupport

GeneralSupport

Tools andEquipment

B-10

TM 9-4940-531-14

A P P E N D I X CC O M P O N E N T S O F E N D I T E M ( C O E I )A N D B A S I C I S S U E I T E M S ( B l l ) L I S T S

S e c t i o n I . I N T R O D U C T I O N

C - 1 . S C O P E

This appendix lists components of the end item and basic issue items for the steam cleaner to helpyou inventory the items required for safe and efficient operation of the equipment.

C - 2 . G E N E R A L

The Components of End Item (COEI) and Basic Issue Items (BII) Lists are divided into the followingsections:

a. Section II. Components of End Item. This listing is for information purposes only, and is notauthority to requisition replacements. These items are part of the steam cleaner. As part of the enditem, these items must be with the end item whenever it is issued or transferred between propertyaccounts. Items of COEI are removed and separately packaged for transportation or shipment onlywhen 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 cleanerin operation, operate it, and to do emergency repairs. Although shipped separately packaged, Bllmust be with the steam cleaner during operation and when it is transferred between property ac-counts. This list is your authority to request/requisition them for replacement based on authorizationof 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 forrequisitioning purposes.

c. Column (3) - Description and Usable On Code. Identifies the Federal item name (in all capitalletters) followed by a minimum description when needed. The last line below the description is theContractor 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 Num-ber shown in column two.

e. Column (5) - Qty Rqd. Indicates the quantity required.

C - 1

TM 9-4940-531-14

S e c t i o n I I . C O M P O N E N T S O F E N D I T E M

(1)Illus

Number

1

2

3

4

5

C-2

(2)National Stock

Number

6150-01-283-4354

6150-01-283-4355

4730-01-275-8091

2910-01-285-3087

2910-01-281-1663

(3)Description andUsableOnCode

ELECTRICAL SPECIAL PURPOSE(FACILITY POWER) CABLE ASSEMBLY(59678) 11024763

ELECTRICAL SPECIAL PURPOSEPOWER(GENERATOR POWER)CABLE ASSEMBLY(59678) 11024764

EMULSION FLUID SPRAY NOZZLE(59678) 11024391

EMULSION LARGE FAN NOZZLE(59678) 11024401

EMULSION SMALL FAN NOZZLE(59678) 11024396

(4)

U / I

EA

EA

EA

EA

EA

(5)QtyRqd

1

1

1

1

1

TM 9-4940-531-14

COMPONENTS OF END ITEM (cont)

(1)Illus

Number

6

7

8

9

10

11

(2)National Stock

Number

4730-01-276-6629

4210-00-555-8837

2330-01-283-4357

4730-01-275-8090

6115-01-234-5966

4720-00-203-3912

(3)Description andUsable On Code

EMULSION HI PRESSURE (FOGGER)NOZZLE(59678) 11024393

FIRE EXTINGUISHER WITH BRACKET(81349) MIL-E-52031

FLAT BED TRAILER(59678) 11024780

FLUID-EMULSION SPRAY NOZZLE(59678) 11024388

GENERATOR SET(30554) MEP-701A

NONMETALLIC (PRESSURIZEDWATER) HOSE ASSEMBLY(31348) L-H-520

(4)

U/ l

EA

EA

EA

EA

EA

EA

(5)QtyRqd

1

1

1

1

1

1

C-3

TM 9-4940-531-14

COMPONENTS OF END ITEM (cont)

(1) (2) (3) (4) (5)Illus National Stock Description and Qty

Number Number Usable On Code U/l Rqd

12 4940-01-275-2556 STEAM CLEANER EA 1(59678) 11024000

13 4940-01-279-1810 STEAM CLEANING GUN EA 1

(59678) 11024235

14 NA SUCTION HOSE ASSEMBLY EA 1(59678) 11024270

15 NA WASH HOSE ASSEMBLY EA 3(59678) 11024408

C-4

TM 9-4940-531-14

S e c t i o n I l l . B A S I C I S S U E I T E M S

(1) (2) (3) (4) (5)Illus National Stock Description Qty

Number Number and Usable on Code U/l Rqd

1 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

C-5/(C-6 blank)

TM 9-4940-531-14

A P P E N D I X D

A D D I T I O N A L A U T H O R I Z A T I O N L I S T ( A A L )


D-1 . SCOPE

This appendix lists additional items that you are authorized for the support of the steam cleaner.

D - 2 . G E N E R A L

This list identifies items that do not have to accompany the steam cleaner and that do not have to beturned in with it. These items are authorized to you by CTA, MTOE, TDA, or JTA.

D-3. EXPLANATION OF L ISTING

National Stock Numbers, description, and quantities are provided to help you identify and request theadditional items you require to support this equipment.

S e c t i o n I l . A D D I T I O N A L A U T H O R I Z A T I O N L I S T

(1) (2) (3) (4)

National DescriptionStock Used Qty

Number CAGEC & Part Number On Code U/M 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

A P P E N D I X E

E X P E N D A B L E A N D D U R A B L E I T E M S L I S T


E-1 . SCOPE

This appendix lists expendable and durable items you will need to maintain the steam cleaner. Thislisting is for informational purposes only and is not authority to requisition the listed items. Theseitems 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 isreferenced in the narrative instructions to identify the material (e.g., “Use cleaning compound, item 7,appx E.”).

b. Column (2) - Level. This column identifies the lowest level of maintenance that requiresthe listed item.

C - Operator/CrewO - Unit MaintenanceF - Direct Support MaintenanceH - General Support Maintenance

c. Column (3) - National Stock Number. This is the National stock number assigned to theitem; use it to request or requisition the item.

d. Column (4) - Description. Indicates the Federal item name and, if required, a descriptionto 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 inperforming the actual maintenance function. This measure is expressed by a two-character alphabeti-cal abbreviation (e.g., ea, in., pr). If the unit of measure differs from the unit of issue, requisition thelowest unit of issue that will satisfy your requirements.

E-1

TM 9-4940-531-14

S e c t i o n I l . E X P E N D A B L E A N D D U R A B L E I T E M S L I S T

(1)

ItemNumber

1

2

3

4

5

6

7

8

9

10

11

12

13

(2)

Level

F

O

C

O

O

O

C

O

0

C

C

C

C

(3)National

StockNumber

8040-00-273-8707

6810-00-201-0906

6135-00-835-7210

8010-01-141-2419

8010-01-160-6744

8010-01-160-6741

6850-00-753-4998

4020-00-240-2154

4940-01-154-8269

9140-00-286-5286

9140-00-286-5294

8415-00-268-7859

6240-00-155-8675

(4)

Description

ADHESIVE, FIRERESISTANT(81349) MiL-A-3316

ALCOHOL, DENATURED,grade III16-fl oz (0.48-l) bottle(81348) O-E-760

BATTERY, DRY,D-size, 1.5 V(81349) BA-3030/U

CARC, BLACK(37030) MIL-C-46168

CARC, BROWN, NO. 383(30051) MIL-C-46168

CARC, GREEN, NO. 383(34094) MIL-C-46168

CLEANING COMPOUND,HIGH PRESSURE CLEANER(81348) MIL-C-22542

CORD, FIBROUS,500-yd(457-m)spool(81349) MIL-C-5040

DESOOTER, RED DEVIL(94774) 1002-1-05

DIESELFUEL,grade 1(81348) DF1Wl

DIESELFUEL,grade 2(81348) DF2Wl

GLOVES, GAUNTLET(81348) KK-G-486

LAMP, INCANDESCENT, 3V(81348) W-L-001 11/36

(5)

U/M/U/l

CN

BT

PG

Q T

QT

QT

GL

YD

PT

GL

GL

PR

EA

E-2

TM 9-4940-531-14

EXPENDABLE AND DURABLE ITEMS LIST (cont)

(1)

ItemNumber

14

15

16

17

18

19

20

21

22

23

(2)

Level

C

C

O

O

C

O

F

O

C

F

(3)National

StockNumber

9150-00-402-4478

9150-00-889-3522

6695-01-059-9973

6640-00-663-0832

7920-00-205-1711

6695-01-059-9475

6810-00-270-8177

3439-00-003-8601

6850-00-281-1985

6850-01-174-9548

(4)

Description

LUBRICATING OIL, ENGINE,low temperature (arctic)(81349) MIL-L-46167

LUBRICATING OIL,SEMIFLUID(LSA) 40z (118.3ml)(81349) MIL-L-46000

PAPER, FILTER(05083) 21-0019

PAPER, LENS(81348) NNN-P-40

RAG, WIPING(80244) DDD-R-30

SMOKE SCALE(05083) 21-0018

SODIUM HYDROXIDE,TECHNICAL(81348) O-S-598

SOLDER, LEAD-TIN ALLOY,1-lb (0.45-kg) can(81348) SN-50, SN-60

SOLVENT, DRY CLEANINGliquid, white, 140 degreeflash point (SD-2)(58536) A-A-7118-oz (236.6-ml) can

SULFAMIC ACID,10-lb (4.54-kg) can(81348) P-S-120

(5)

U/M/U/I

Q T

BT

PG

SH

EA

EA

O Z

LB

CN

LB

E-3

TM 9-4940-531-14

EXPENDABLE AND DURABLE ITEMS LIST (cont)

(1)

ItemNumber

24

25

26

(2)

Level

O

F

O

(3)National

StockNumber

8030-00-889-3535

6630-00-226-0920

8010-00-664-7653

(4)

Description

TAPE, ANTISEIZING(81349) MIL-T-27730

TEST PAPER AND COLORCHART, HYDROGEN ANDION(81348) OP94

WHITE ENAMEL,1-qt (0.95-1) can(81348) TT-E-489

(5)

U/M/U/I

EA

EA

Q T

E - 4

TM 9-4940-531-14

A P P E N D I X F

I L L U S T R A T E D L I S T O F M A N U F A C T U R E D I T E M S

F-1 . INTRODUCTION

a. This appendix includes complete instructions for making items authorized to be manufacturedor fabricated at unit or direct support maintenance level.

b. A part number index in alphanumeric order is provided for cross-referencing the part number ofthe 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 specificationnumber in a tabular list on the illustration.

F-2 . MANUFACTURED ITEMS PART NUMBER INDEX

Part Number Figure Number

M16878 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .M23053/2-109-OX.75 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11024136 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11024254 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11024261 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11024410 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11024415 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11024665 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11024727 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11024795 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11024831 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11024846 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11024849 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11024882 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11024913 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

F-4F-1F-2F-3F-4F-5F-6F-7F-8F-9F-10F-11F-12F-13F-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. DIMENSIONS SHOWN ARE IN INCHES (CENTIMETERS).2. 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.


NOTES:


PROCEDURE:

FABRICATE FROM RUBBER HOSE, 0.250 (0.635) I.D., GRADE 3, CLASS 1, IAW ZZ-H-601 , NSN4720-00-230-6477.

F-2

TM 9-4940-531-14

Figure F-4.

NOTES:

1. LENGTHS LISTED ARE IN INCHES

Wire Assembly 11024261.

(CENTIMETERS).2. 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)

3. FOR IDENTIFICATION OF ITEMS IN FROM AND TO COLUMNS, SEE FO-2AND FO-3.

PROCEDURES:

1. FABRICATE FROM ELECTRICAL WIRE:PN M16878/1BJE2, NSN 6145-00-754-8082PN M16878/1BJE9, NSN 6145-00-643-0650PN M16878/1BJE0, NSN 6145-00-822-1427PN M16878/1BJE4, NSN 6145-00-542-6573PN M16878/1BJE5, NSN 6145-00-822-1425PN M16878/1BJE6, NSN 6145-00-822-1424PN M16878/3BLE0, NSN 6145-00-727-0244PN M16878/3BLE9, NSN 6145-00-643-0643

2. CUT TO LENGTH SPECIFIED IAW MIL-STD-339(AT) SECTION 1200.3. INSTALL TERMINALS IAW MIL-T-7928.

Wire Assembly Chart

WIRE ASSYPART NO.

11024261-111024261-211024261-311024’261-411024261-511024261-611024261-711024261-811024261-911024261-1011024261-11

WIREPART NO. COLOR

REDWHITEWHITEBLACKYELLOWREDBLACKWHITEBLACKRED

LEFTTERMINAL

110249141102491411024914

11024914: 11022304-21102491411024914110249141102491411024914

WIRELENGTH

30 (76)30 (76)72 (183)72 (183)78 (198)60(152)10 (25)36 (91)24 (61)71 (180)

RIGHTTERMINAL

STRIPPED .50 (1.27)STRIPPED .50 (1.27)STRIPPED .50 (1.27jSTRIPPED .50 (1.27)STRIPPED .50 (1.27)STRIPPED .50 (1.27)1102491411024914STRIPPED .50 (1.27)11024914

FROM TO

F-3

TM 9-4940-531 -14


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 ILLUSTRATIONS (cont)

Figure F-5.

NOTES:

Nonmetallic those 11024470.


PROCEDURE:

FABRICATE FROM NONMETALLIC HOSE, PN 232MB2IN, NSN 4720-00-146-0449.


NOTES:

DIMENSIONS SHOWN ARE IN INCHES (CENTIMETERS).2. TOLERANCES ARE +/-0.12 (0.30).

1.

PROCEDURE:

FABRICATE FROM 0.25 (0.64) I.D. RUBBER HOSE, GRADE I, CLASS I, IAW ZZ-H-601 , NSN4720-00-230-6477.

F-6

TM 9-4940-531-14

Figure F-7. Tubing 11024665.

NOTES:

1. DIMENSIONS SHOWN ARE IN INCHES.2. TOLERANCES ARE +/-0.12 (0.30).

PROCEDURES:

1. FABRICATE FROM 0.25 O.D. COPPER TUBING, 0.032 WALL, SEAMLESS, TEMPER H58,IAW ASTMB75, NSN 4710-00-277-5525.

2. REMOVE BURRS AND BREAK ALL SHARP EDGES.

F-7

TM 9-4940-531-14



NOTES:


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:


PROCEDURES:

1. FABRICATE FROM 0.62 (1.57) THICK PLYWOOD, GROUP A, TYPE I, GRADE 1, IAWNN-P-530, NSN 5530-00-129-2121.

2. USE WOOD PRESERVATIVE TREATMENT 25.3 IAW MlL-STD-171.3. 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


Figure F-10. Brakeline Tubing 11024831.

NOTES:


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:


PROCEDURES:

1. 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.

F-10

TM 9-4940-531-14


NOTES:


PROCEDURE:

FABRICATE FROM 0.250 (0.635) I.D. RUBBER HOSE, TYPE I, IAW MIL-H-13444, NSN 4720-00-005-5008.

F-1 1

TM 9-4940-531-14


Figure F-13. Conduit Assembly 11024913.

NOTES:

1. DIMENSIONS SHOWN2. LENGTH TOLERANCE

PROCEDURES:

ARE IN INCHES (CENTIMETERS).ON FLEXIBLE CONDUIT IS +0.12 (0.30).

1. FABRICATE FROM FLEXIBLE METAL CONDUIT (11024882) PN 47002, NSN 5975-00-983-5239 CUT TO LENGTH SPECIFIED.

2. INSTALL CONNECTORS IAW MIL-T-7928.

LENGTH PART NO. PART NO. PART NO., ASSY NO. A B C D FROM TO

11024913-1 15.0 (38.1) 11024885 11024883 11024882-1 CONT BOX 5 SOL

11024913-2 12.0 (30.0) 11024883 11024883 11024882-2 CONT BOX 301 JCT BOX

11024913-3 19.0 (48.3) 11024885 11024883 11024882-3 CONT BOX 6 SOL

11024913-4 13.0 (33.0) 11024885 11024883 11024882-4 CONT BOX 302 JCT BOX

11024913-5 21.0 (53.3) 11024885 11024883 11024882-5 CONT BOX 303 JCT BOX S4

11024913-6 13.5 (34.3) 11024883 11024883 11024882-6 CONT BOX 1 MOT

11024913-7 20.0 (50.8) 11024883 11024883 11024882-7 CONT BOX S5

11024913-8 36.0 (91.4) 11024883 11024883 11024882-8 CONT BOX 304 JCT BOX

11024913-9 34.0 (86.4) 11024883 11024833 11024882-9 CONT BOX BURNER

11024913-11 9.0 (22.9) 11024885 11024883 11024882-11 CONT BOX 2 SOL

11024913-14 14.0 (35.6) 11024883 11024885 11024882-14 302, JCT BOX FS1

11024913-15 9.0 (22.9) 11024885 11024883 11024882-15 9 SOL 303 JCT BOX S4

11024913-16 8.0 (20.3) 11024883 11024885 11024882-16 3 SOL 303 JCT BOX S4

11024913-17 8.0 (20.3) 11024885 11024885 11024882-17 304, JCT BOX 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

A L P H A B E T I C A L I N D E X

Subject

A

Additional authorization list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Administrative storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Atomizing vaporizing oil burner—maintenance instructions:Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Electrode adjustment and replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .inspection/repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

B

Basic issue items . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Blowdown assembly and valve and switch assembly—maintenanceinstructions:

Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Inspection/cleaning/repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Brake line tube assembly—maintenance instructions:Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Inspection/repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

C

Cable assembly, facility power—maintenance instructions:Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Page

D-1

1-2

C-5

D-1 D-1 D-1

4-96 4-96 4-96

5-1105-1165-1135-113

C - 5 C - 5 C - 5

5-1085-1095-109

5-1785-1785-1785-178

4-874-864-874-87

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INDEX1

TM 9-4940-531-14

S u b j e c t Page

C

Cable assembly, generator power—maintenance instructions:Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-93

Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-93

Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-94

Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-94

Checking unpacked equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cleaning agents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10

Coil inlet assembly—maintenance instructions:Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...Inspection/repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Coil inlet control assembly-maintenance instructions:Adjustment of pressure regulating valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Inspection/repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Coil outlet assembly—maintenance instructions:Adjustment of pressure regulating valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Inspection/repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-3

5-1015-1015-101

5-1365-1295-1325-133

5-1065-1025-1045-104

Coil unit assembly—maintenance instructions:Cleaning/deliming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-159

Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-157

Inspection/repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-158

Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-158

Common tools and equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 1-4 1-4 1-4

Components of end item and basic issue items . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-1 C-1 C-1 C-1

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*** Direct Support**** General Support

INDEX 2

TM 9-4940-531-14

Subject Page

Connection diagram, wire assembly, and conduit assembly-maintenanceinstructions:

Inspection/repair of conduit assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Inspection/repair of wire assembly PN 11024261 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Inspection/repair of wire assembly PN 11025004 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Control box assembly, upper control panel assembly, and electricalcomponents assembly—maintenance instructions:

Calibration of operating temperature indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Inspection/repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Control panel assembly and electrical components assembly—maintenance instructions

Inspecting identification markers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Replacing cartridge fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Replacing identification markers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Controls and indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Corrosion Prevention and Control (CPC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

D

Decals and instruction plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Deliming of coil unit assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Desooting of coil unit assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Destruction of Army materiel to prevent enemy use.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

E

5-1695-1675-168

5-1455-1385-1415-141

4-714-714-72

2-1 2-1 2-1 2-1

1-4 1-4 1-4 1-4

2-38

5-159

4-8

1-2 1-2 1-2 1-2

Electrical components assembly, control box assembly, and upper control panel assembly (SeeControl box assembly, upper control panel assembly, and electrical components assembly.)

l C r e w- U n i t“ Direct Support

**** General Support

INDEX 3

TM 9-4940-531-14

Subject

E

Enclosure and lift assembly and hose rack access door—maintenanceinstructions:

Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Inspection/repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . .Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Equipment characteristics, capabilities, and features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Equipment data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..

Equipment description and data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Expendable and durable items list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

F

Facility power cable assembly—maintenance instructions:Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Reassembly . . . . . . . . . . . . . . . . . . . . ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Flat bed trailer—maintenance instructions:Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Inspection/repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Installation of reflectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Removal of reflectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel shutoff assembly—maintenance instructions:Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Inspection/repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel strainer assembly—maintenance instructions:Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Inspection/cleaning/repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Page

1-4

1-10

1-4

E-1

3-193-18

3-19

4-764-814-81

1 - 4 1 - 4

1-10 1-10

1 - 4 1 - 4

E-1 E-1

4-874-864-874-87

5-1714-96 5-1734-96

5-1744-95

5-1555-1555-155

5-1535-1535-153

1-4

1-10

1-4

E-1

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INDEX 4

TM 9-4940-531-14

Subject

Fuel tank assembly—maintenance instructions:Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Inspection/repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

G

General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

General maintenance instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Generator power cable assembly—maintenance instructions:Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

H

Page

4-54 5-1194-59 5-1204-59 5-121

1-2 1-2 1-2 1-2

4-19 5-44 6-1

4-934-934-944-94

Hose rack access door and enclosure and lift assembly (See Enclosure and lift assembly and hoserack access door.)

I

Illustrated list of manufactured items . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-1

Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installation instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

J

Jack, leveling support (See leveling support jack.)

F-1 F-1 F-1

4-3

4-5

l C r e w ** Unit

*** Direct Support **** General Support

INDEX 5

TM 9-4940-531-14

Subject

L

Page

Leakage definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11 4-6

Leveling support jack—maintenance instructions:Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-177


Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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—maintenanceinstructions:

Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-69

Inspection/repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-70

Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-70

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 andmetering valve assembly.)

Motor assembly—maintenance instructions:Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-128

Inspection/cleaning/repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-128

Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-128

Ml16A2 trailer chassis modification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

N

Nomenclature cross-reference list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 1-3 1-3 1-3

l C r e w* * U n i t


INDEX 6

TM 9-4940-531-14

Subject

O

Page

Oil burner assembly—maintenance instructions:Adjustment using smoke analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-51Cad cell cleaning and adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-49Cad cell test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-51Fuel pressure adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-48Inspection/repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-45Reassembly/installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-46Removal/disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-43

Oil burner, atomizing vaporizing (See Atomizing vaporizing oil burner.)

Oil drain assembly—maintenance instructions:Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-137Inspection/repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-137Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-137

Operating procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-31In cold weather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-41In dirt, dust, mud, or sandy conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-41In hot or humid conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-41In wet weather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-41

Outlet and water drain assembly—maintenance instructions:Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-88 5-84Inspection/repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-89 5-84Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-67Inspection/repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-68Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-68

l C r e w“ U n i t‘* Direct Support


INDEX 7

TM 9-4940-531-14

Subject Page

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 DiagnosticEquipment (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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23


Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-32

Steam cleaner (coil inlet assembly)—maintenance instructions:Inspection/repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-75

Installation of coil inlet assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-76

Removal of coil inlet assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-73

Steam cleaner (coil outlet assembly and outlet and water drain assembly)—maintenance instructions:

Disassembly of outlet and water drain assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-84


Installation of coil outlet assembly and outlet and water drain assembly . . 5-85

Reassembly of outlet and water drain assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-84

Removal of coil outlet assembly and outlet and water drain assembly . . . . . 5-79



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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Steam cleaner (enclosure and lift assembly)—maintenance instructions:Inspection/repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Installation of enclosure and lift assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Removal of enclosure and lift assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Steam cleaner (pressure gauge assembly)—maintenance instructions:Inspection/repair.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Reassembly/installation of pressure gauge assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Removal/disassembly of pressure gauge assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Steam cleaner lift assembly:Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Inspection/repair.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Steam cleaner nozzles—maintenance instructions:Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17

Steam cleaner, trailer mounted (See trailer-mounted steam cleaner.)

5-615-615-58

5-505-515-48

5-945-955-91

5-555-565-54

5-695-695-64

5-1465-1475-148

l C r e w“ U n i t


INDEX 9

TM 9-4940-531-14

Subject Page

S

Suction hose assembly—maintenance instructions:Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-91


Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-92

Suction inlet assembly—maintenance instructions:Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-123


Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-164-214-21

5-454-21 5-46

4-224-205-47

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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-1785-1505-1515-1505-1515-1495-1515-149

* C r e w** Unit‘“ Direct Support


TM 9-4940-531-14

Subject

U

Page

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 switchassembly.)

W

Warranty information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 1-2 1-2 1-2

Wash hose assembly—maintenance instructions:Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-74


Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-75

Water inlet assembly—maintenance instructions:Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-66

inspection/repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-66

Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-66

Water pump assembly—maintenance instructions:Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-126inspection/repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-126

Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-127

Water tank assembly—maintenance instructions:Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-124

Inspection/cleaning/repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-124

Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-125

Wire assembly, conduit assembly, and connection diagram (See connection diagram, wire assembly,and conduit assembly.)


*** Direct Support**** Genera l Support

INDEX 11 /(lNDEX 12 blank)

By Order of the Secretary of the Army:

GORDON R. SULLIVANGeneral, United States Army

Chief of Staff

Offcial:

MILTON H. HAMILTONAdministrative Assistant to the

Secretary of the Army06962

DISTRIBUTION: TO be distributed in accordance with DA Form 12-25-E, block 5402requirements 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).

DATE

Date you filled out this form.

TO: (Forward to proponent of publication or form) (Include ZIP Code) AMSTA-LC-LMPP / TECH PUBS, TACOM-RI 1 Rock Island Arsenal Rock Island, IL 61299-7630

FROM: (Activity and location) (Include ZIP Code)

Your mailing address

PART I – ALL PUBLICATIONS (EXCEPT RPSTL AND SC/SM) AND BLANK FORMS PUBLICATION/FORM NUMBER DATE Title Operator & Support Maint Manual for CleanerTM 9-4940-531-14 01 Aug 94 Steam, High Pressure, Hot & Cold, Trailer Mounted ITEMNO.

PAGENO.

PARA-GRAPH

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FIGURENO.

TABLENO.

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

Your Name

TELEPHONE EXCHANGE/AUTOVON, PLUS EXTENSION Signature

Your Signature

DA FORM 2028, FEB 74 REPLACES DA FORM 2028, 1 DEC 68, WHICH WILL BE USED. USAPPC V3.00

TO: (Forward direct to addressee listed in publication) AMSTA-LC-LMPP / TECH PUBS, TACOM-RI 1 Rock Island ArsenalRock Island, IL 61299-7630


Your address DATEDate you filled out this form

PART II – REPAIR PARTS AND SPECIAL TOOL LISTS AND SUPPLY CATALOGS/SUPPLY MANUALS PUBLICATION NUMBER DATE TITLE Operator & Support Maint Manual for Cleaner

PAGENO.

COLMNO.

LINENO.

NATIONAL STOCK NUMBER

REFERENCENO.

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ITEMNO.

TOTAL NO.OF MAJOR

ITEMSSUPPORTED

RECOMMENDED ACTION

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

SAMPLE

TM 9-4940-531-14 01 Aug 94 Steam, high Pressure, Hot & Cold, Trailer Mounted




DATE

AMSTA-LC-LMPP / TECH PUBS, TACOM-RI 1 Rock Island ArsenalRock Island, IL 61299-7630


PART I – ALL PUBLICATIONS (EXCEPT RPSTL AND SC/SM) AND BLANK FORMS PUBLICATION/FORM NUMBER DATE TITLE Operator & Support Maint Manual for Cleaner

TM 9-4940-531-14 01 Aug 94 Steam, High Pressure, Hot & Cold, Trailer Mounted

ITEMNO.

PAGENO.

PARA-GRAPH

LINENO. *

FIGURENO.

TABLENO.


*Reference to line numbers within the paragraph or subparagraph.

TYPED NAME, GRADE OR TITLE TELEPHONE EXCHANGE/AUTOVON, PLUS EXTENSION

SIGNATURE


TO: (Forward to proponent of publication or form)(Include ZIP Code)

TO: (Forward direct to addressee listed in publication) AMSTA-LC-LMPP / TECH PUBS, TACOM-RI 1 Rock Island ArsenalRock Island, IL 61299-7630

FROM: (Activity and location) (Include ZIP Code) DATE

PART II – REPAIR PARTS AND SPECIAL TOOL LISTS AND SUPPLY CATALOGS/SUPPLY MANUALS

PUBLICATION NUMBER DATE TITLE Operator & Support Maint Manual for Cleaner

PAGENO.

COLMNO.

LINENO.


REFERENCENO.

FIGURENO.

ITEMNO.

TOTAL NO.OF MAJOR

ITEMSSUPPORTED

RECOMMENDED ACTION


TYPED NAME, GRADE OR TITLE TELEPHONE EXCHANGE/AUTOVON, PLUS EXTENSION SIGNATURE

USAPPC V3.00

TM 9-4940-531-14 01 Aug 94 Steam, High Pressure, Hot & Cold, Trailer Mounted




DATE

TO: (Forward to proponent of publication or form) (Include ZIP Code) AMSTA-LC-LMPP / TECH PUBS, TACOM-RI 1 Rock Island Arsenal Rock Island, IL 61299-7630


PUBLICATION/FORM NUMBER DATE TITLE Operator & Support Maint Manual for Cleaner TM 9-4940-531-14 01 Aug 94 Steam, High Pressure, Hot & Cold, Trailer Mounted

ITEM NO.

PAGENO.

PARA-GRAPH

LINE NO. *

FIGURENO.

TABLENO.


*Reference to line numbers within the paragraph or subparagraph.

TYPED NAME, GRADE OR TITLE TELEPHONE EXCHANGE/AUTOVON, PLUS EXTENSION

SIGNATURE


TO: (Forward direct to addressee listed in publication) AMSTA-LC-LMPP / TECH PUBS, TACOM-RI1 Rock Island ArsenalRock Island, IL 61299-7630

FROM: (Activity and location) (Include ZIP Code) DATE

PART II – REPAIR PARTS AND SPECIAL TOOL LISTS AND SUPPLY CATALOGS/SUPPLY MANUALS

PUBLICATION NUMBER DATE TITLE Operator&Support Maint Manual for Cleaner TM 9-4940-531-14 01 Aug 94 Steam, High Pressure, Hot & Cold, Trailer Mounted

PAGENO.

COLMNO.

LINENO.


REFERENCENO.

FIGURENO.

ITEMNO.

TOTAL NO.OF MAJOR

ITEMSSUPPORTED

RECOMMENDED ACTION


TYPED NAME, GRADE OR TITLE 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 Sq Centimeter = 100 Sq Millimeters = 0.155 Sq Inches1 Meter = 100 Centimeters = 1000 Millimeters = 39.37 Inches 1 Sq Meter = 10,000 Sq Centimeters = 10.76 Sq Feet1 Kilometer = 1000 Meters = 0.621 Miles 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 Cu Centimeter = 1000 Cu Millimeters = 0.06 Cu Inches1 Kilogram = 1000 Grams = 2.2 Lb 1 Cu Meter = 1,000,000 Cu Centimeters = 35.31 Cu Feet1 Metric Ton = 1000 Kilograms = 1 Megagram = 1.1 Short Tons

LIQUID MEASURE TEMPERATURE

1 Milliliter = 0.001 Liters = 0.0338 Fluid Ounces 5/9 (oF -- 32) = oC1 Liter = 1000 Milliliters = 33.82 Fluid Ounces 212o Fahrenheit is equivalent to 100o Celsius

90o Fahrenheit is equivalent to 32.2o Celsius32o Fahrenheit is equivalent to 0o Celsius9/5 Co + 32) = Fo

APPROXIMATE CONVERSION FACTORS

TO CHANGE TO MULTIPLY BY

Inches Centimeters 2.540. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Feet Meters 0.305. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Yards Meters 0.914. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Miles Kilometers 1.609. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Square Inches Square Centimeters 6.451. . . . . . . . . . . . . . . . . . . . . . . .Square Feet Square Meters 0.093. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Square Yards Square Meters 0.836. . . . . . . . . . . . . . . . . . . . . . . . . . . . .Square Miles Square Kilometers 2.590. . . . . . . . . . . . . . . . . . . . . . . . . .Acres Square Hectometers 0.405. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Cubic Feet Cubic Meters 0.028. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Cubic Yards Cubic Meters 0.765. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Fluid Ounces Milliliters 29.573. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Pints Liters 0.473. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Quarts Liters 0.946. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Gallons Liters 3.785. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Ounces Grams 28.349. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Pounds Kilograms 0.454. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Short Tons Metric Tons 0.907. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Pound--Feet Newton--Meters 1.356. . . . . . . . . . . . . . . . . . . . . . . . . . . . .Pounds per Square Inch Kilopascals 6.895. . . . . . . . . . . . . . . . . . . . . .Miles per Gallon Kilometers per Liter 0.425. . . . . . . . . . . . . . . . . . . . . .Miles per Hour Kilometers per Hour 1.609. . . . . . . . . . . . . . . . . . . . . . . .

TO CHANGE TO MULTIPLY BY

Centimeters Inches 0.394. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Meters Feet 3.280. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Meters Yards 1.094. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Kilometers Miles 0.621. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Square Centimeters Square Inches 0.155. . . . . . . . . . . . . . . . . . . . . . .Square Meters Square Feet 10.764. . . . . . . . . . . . . . . . . . . . . . . . . . . . .Square Meters Square Yards 1.196. . . . . . . . . . . . . . . . . . . . . . . . . . . . .Square Kilometers Square Miles 0.386. . . . . . . . . . . . . . . . . . . . . . . . . .Square Hectometers Acres 2.471. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Cubic Meters Cubic Feet 35.315. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Cubic Meters Cubic Yards 1.308. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Milliliters Fluid Ounces 0.034. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Liters Pints 2.113. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Liters Quarts 1.057. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Liters Gallons 0.264. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Grams Ounces 0.035. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Kilograms Pounds 2.205. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Metric Tons Short Tons 1.102. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Newton--Meters Pound--Feet 0.738. . . . . . . . . . . . . . . . . . . . . . . . . . . . .Kilopascals Pounds per Square Inch 0.145. . . . . . . . . . . . . . . . . . . . . .Kilometers per Liter Miles per Gallon 2.354. . . . . . . . . . . . . . . . . . . . . .Kilometers per Hour Miles per Hour 0.621. . . . . . . . . . . . . . . . . . . . . . .

PIN: 072808-000

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TM 9-4940-531-14 TECHNICAL MANUAL OPERATOR ... - NSN …€¦ · (NSN 4940-01-025-9856) (EIC: ... or fax your comments or DA Form 2028 directly to the U.S. Army TACOM Life Cycle Management