Section I. DESCRIPTION AND USE OF OPERATOR’S CONTROLS AND INDICATORS
GENERATOR CABLE ASSEMBLY INSTALLATION
Connect three generator cable wires (1) to terminal block (2) on generator set (3). Install generator cable assembly (4) onto steam cleaner (5).
4-13. STEAM CLEANER—MAINTENANCE INSTRUCTIONS THIS TASK COVERS:
a. D i s a s s e m b l y b. I n s p e c t i o n / r e p a i r c . R e a s s e m b l y INITIAL SETUP
Tools and Special Tools
General mechanic’s tool kit (item 2, appx B) Material/Parts
Blind rivet (16) (M24243/1-B402) Self-locking nut (3) (MS17828-06C) Self-locking nut (2) (MS51922-1) Self-locking nut (MS51988-3) Self-locking nut (MS51988-5) Tapping screw (4) (MS51850-85) Tapping screw (3) (MS51869-23) Tiedown strap (MS3367-6-0) Equipment Conditions
EMERGENCY OFF switch in OFF position and external power cable disconnected Water tank assembly drained
Clean diesel fuel container available
Remove parts only if damaged or if necessary for access to damaged items. Tag and label all hoses prior to removal.
1 Remove four hearing caution markers (1), two moving parts warning markers (2), and diesel fuel warning marker (3) from enclosure and lift assembly (4).
2 Remove sixteen blind rivets (5), output capacity identification plate (6), identification plate (7), and two weight and dimension plates (8) from enclosure and lift assembly (4).
DISASSEMBLY (cont)
3 Remove fuel decal (9) from top of fuel tank assembly (10). Remove high temperature warning marker (11) from chemical holder weldment (12).
4 Remove two identification markers (13 and 14) from pressure gauge assembly (15).
5 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).
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) from elbow (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 valve hose (35) from liquid storage tank (36) and drain hose into suitable container.
Remove webbing strap (37) and liquid storage tank (36) from chemical holder weldment (12).
DISASSEMBLY (cont)
11
12
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 chemichemi-cal bottle-to-metering valve hose (35).
Remove three tapping screws (41) and lower control panel assembly (28) from control box as-sembly (42).
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 oil burner.
15 Loosen filler opening cap (48) and, with suitable container in place, remove drain plug (49) to drain fuel from fuel tank assembly (10). Reinstall drain plug (49) and tighten filler opening cap (48).
DISASSEMBLY (cont)
16 Remove two hose clamps (50) and disconnect fuel shutoff-to-oil burner hose (51) and oil burner to-fuel strainer hose (52) from oil burner assembly (53).
17 Remove fuel pump-to-pressure gauge tubing assembly (30).
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19
20
21
22 23
Remove four hose clamps (54) and disconnect fuel shutoff-to-fuel tank hose (55), fuel tank-to-fuel shutoff hose (56), fuel strainer-to-fuel shutoff hose (57), and fuel shutoff-to-oil burner hose (51) from fuel shutoff assembly (58). Remove fuel shutoff-to-oil burner hose (51).
Remove two hose clamps (59), fuel shutoff-to-fuel tank hose (55), and fuel tank-to-fuel shutoff hose (56) from fuel tank assembly (10).
Remove two hose clamps (60), oil burner-to-fuel strainer hose (52), and fuel strainer-to-fuel shutoff hose (57) from fuel strainer assembly (61).
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).
DISASSEMBLY (cont)
24
2 5
26
2 7 2 8 29
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) from steam outlet support assembly (73).
Remove chain assembly (72), pipe coupling (74), pipe elbow (75), pipe nipple (76), and pipe bushing (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).
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).
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).
3 Install drain hose (7) onto blowdown assembly solenoid valve (8) with hose clamp (9).
4 Install drain hose (10) onto outlet and water drain assembly (11) with hose clamp (12).
5 Install two coil outlet hoses (13 and 14) onto two coil outlet assembly fluid regulating valves (15 and 16) with two hose clamps (17). Secure hoses to platform skid (18) with new tiedown strap (19).
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) and new self-locking nut (29).
9 Connect thermocouple probe (30) to pipe-to-tube straight adapter (31). Install pipe-to-tube straight adapter (31) onto pipe bushing (22).
10 11 12
13
14
15
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-locking nuts (37).
Install fuel strainer-to-fuel shutoff hose (38) and oil burner-to-fuel strainer hose (39) onto fuel strainer assembly (32) with two hose clamps (40).
Install fuel tank-to-fuel shutoff hose (41) and fuel shutoff-to-fuel tank hose (42) onto fuel tank assembly (43) with two hose clamps (44).
Install fuel shutoff-to-oil burner hose (45), fuel strainer-to-fuel shutoff hose (38), fuel tank-to-fuel shutoff hose (41), and fuel shutoff-to-fuel tank hose (42) onto fuel shutoff assembly (34) with four hose clamps (46).
16 Install fuel pump-o-pressure gauge tubing assembly (47) onto oil burner assembly (48).
17 Install oil burner-to-fuel strainer hose (39) and fuel shutoff-to-oil burner hose (45) onto oil burner assembly (48) with two hose clamps (49).
REASSEMBLY (cont)
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19
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 fire extinguisher (55) on bracket.
20 Install lower control panel assembly (56) onto control box assembly (57) with three new tapping screws (58).
21 Install chemical bottle-to-metering valve hose (59) and metering valve-to-water pump hose (50) onto metering valve assembly (60) with two hose clamps (61).
22 Install webbing strap (62) and liquid storage tank (63) onto chemical holder weldment (64).
23 Install chemical bottle-to-metering valve hose (59) onto liquid storage tank (63).
REASSEMBLY (cont)
24 Install elbow (65) onto FUEL PRESSURE gauge (66). Install FUEL PRESSURE gauge onto lower control panel assembly (56) with three machine screws (67) and three new self-locking nuts (68). Connect fuel pump-to-pressure gauge tubing assembly (47) to elbow (65). Tighten tubing nut (69).
25 Close lower control panel assembly (56) and install new self-locking nut (70).
26 Place spray nozzle (71), high pressure nozzle (72), small fan nozzle (73), large fan nozzle (74), wide spray nozzle (75), pressurized water hose assembly (76), three wash hose assemblies (77), suction hose assembly (78), facility power cable assembly (79), and steam cleaning gun (80) into hose rack access door (81).
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 warning marker (86) onto chemical holder weldment (64).
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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 hearing caution markers (94) onto enclosure and lift assembly (90).
To fill fuel tank assembly, refer to paragraph 2-5.
c .
THIS TASK COVERS:
a. Removal/disassembly b . I n s p e c t i o n / r e p a i r
Reassembly/installation d . Fuel pressure adjustment
e. Cad cell cleaning and adjustment f. Cad cell test
g . Adjustment using smoke analyzer INITIAL SETUP
Tools and Special Tools
General mechanic’s tool kit (item 2 Smoke test kit (item 3, appx B) Material/Parts
Antiseizing tape (item 24, appx E) Filter paper (item 16, appx E) Gasket (11024877)
Lens paper (item 17, appx E) Self-locking nut (3) (MS51988-7) Smoke chart (item 19, appx E) Personnel Required: 2
Equipment Conditions
appx B)
EMERGENCY OFF switch in OFF position Main power to steam cleaner off
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).
REMOVAL/DISASSEMBLY (cont)
4
5
6
NOTE
Some parts not shown for clarity.
Loosen two screws (7) and slide electro-magnet relay cover (8) to access wire connections.
NOTE
Be sure all wires are tagged and labeled before removal.
Remove five conduit splices (9) and discon-nect four wires no. 5, 4, 3, and 6 (10) entering electromagnet relay (11) from conduit assembly no. 209 (12).
Remove conduit connector locknut (13) and disconnect conduit assembly no.
from electromagnet relay (11).
209 (12)
7 Loosen tapping screw (14) and rotate retaining strap (15) to open power trans-former lid (16) to accesscapscrew (17).
Close power transformer lid after access is obtained.
8
9 10 11
Remove three self-locking nuts (1 8), three capscrews (17), three flat washers (19), oil burner assembly (3), and gasket (20) from coil unit assembly (21).
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
1 Check for broken, damaged, or missing parts.
2 Repair is by replacement of damaged or unserviceable parts
3 Atomizing vaporizing oil burner is a repairable assembly, notify direct support maintenance.
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) into pipe 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) with three flat washers (14), three capscrews (15), and three new self-locking nuts (16). Open power transformer lid (17) as needed to gain access for capsrew (15).
6 Close power transformer lid (17) and secure with retaining strap (18) and tapping screw (19).
7 Position conduit assembly no. 209 (20) in electromagnet relay (21) and secure with conduit connector locknut (22).
8 Install conduit splices (23) to connect four wires no. 6, 3, 4, and 5 (24) to electromag-net relay (21).
9 Slide electromagnet relay cover (25) into position and tighten two screws (26).
REASSEMBLY/lNSTALLATION (cont)
10 Connect fuel shutoff-to-oil burner hose (27) and oil burner-to-strainer hose (28). Install two hose clamps (29).
11 Connect fuel pump-to-pressure gauge tubing assembly (30).
12 Open two fuel shutoff assembly valves (31).