Section I. DESCRIPTION AND USE OF OPERATOR’S CONTROLS AND INDICATORS
INSPECTING IDENTIFICATION MARKERS
Check for damaged or missing control panel identification markers. If damaged, replace identification markers as follows.
MAINTENANCE INSTRUCTIONS (cont)
PUSH TO START identification marker
MODE SELECTOR position identification marker MODE SELECTOR identification marker
OPERATING TEMPERATURE identification marker HOUR METER identification marker
HOT WATER ALARM identification marker STEAM ALARM identification marker
ELECTRICAL COMPONENT LOCATION identification marker
1 Remove identification markers (1 thru 12) from control panel assembly (13).
2 Remove four tapping screws (14) and open control panel assembly (13).
3 Remove identification markers (15 and 16).
4 Ensure surface is clean and dry before applying identification marker. Remove any dirt, grease, or adhesive from previous identification marker using denatured alcohol (item 23, appx E) and wiping rag (item 18, appx E).
5 If removed, install two new identification markers (15 and 16) as shown.
6 Close control panel assembly (13) and install four new tapping screws (14).
7 If removed, center new identification markers (1 thru 12) as shown and install.
THIS TASK COVERS:
a. Disassembly b. Inspection/repair c. Reassembly
INITIAL SETUP
Tools and Special Tools
General mechanic’s tool kit (item 2, appx B) Material/Parts
Antiseizing tape (item 24, appx E) Equipment Conditions
Wash hose assemblies removed (para 4-13)
NOTE
There are three wash hose assemblies. The following procedures are written for one wash hose assembly; repeat as necessary.
DISASSEMBLY
1 Loosen two hose clamps (1) and remove two hose nipples (2 and 3) from hose (4). Remove two hose clamps (1).
2 Remove pipe coupling (5) from hose nipple (3).
INSPECTION/REPAIR
1 Check for broken, damaged, or missing parts.
2 Repair is by replacement of damaged or unserviceable parts.
3 Hose is a manufactured item. Refer to appendix F.
1 Wrap threads of hose nipples with antiseizing tape (item 24, appx E).
2 Install pipe coupling (5) onto hose nipple (3).
3 Install two hose nipples (2 and 3) and two hose clamps (1) onto hose (4).
NOTE
Hose clamps must be tightened evenly or wash hose assembly will leak.
4 Tighten two hose clamps (1) evenly.
4-22. ENCLOSURE AND LIFT ASSEMBLY AND HOSE RACK ACCESS DOOR—
MAINTENANCE INSTRUCTIONS THIS TASK COVERS:
a. Disassembly b. Inspection/repair c. 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) Materials/Parts
Steam cleaner shut down and cooled (para 2-5) External cable and hoses removed
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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 right cover (5).
Remove eight capscrews (6) and top left cover (7).
Remove four tapping screws (8) and ac-cess cover (9).
Remove five capscrews (10), left front door assembly (11), and door hinge spacer (12).
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7
8
Remove self-locking nut (13), Iockwasher (14), chain assembly (15), flat washer (16), machine bolt (17), and flat washer (18) from left rear access door (19).
If damaged or illegible, remove six hex nuts (20), six Iockwashers (21), six capscrews (22), six flat washers (23), and technical instructions sheet (24) from left rear access door (19).
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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MAINTENANCE INSTRUCTIONS (cont)
NOTE
Left post assembly is direction and location sensitive; mark before removal.
12 Remove two capscrews (40), plain nut (41), Iockwasher (42), capscrew (43), and left post assem-bly (44).
13 Remove two cotter pins (45 and 46), flat washer (47), spring (48), flat washer (49), retaining band (50), and flat washer (51) from right rear access door (52) and steam cleaner lift assembly (3).
14 Remove eight capscrews (53), right rear access door (52), and rear door spacer (54) from steam cleaner lift assembly (3).
NOTE
Structural channel is direction and location sensitive; mark before removal.
15 Remove two self-locking nuts (55), two capscrews (56), two plain nuts (57), two Iockwashers (58), two capscrews (59), and structural channel (60).
NOTE
Ensure all equipment is removed before removing hose rack access door.
16 Remove 22 capscrews (61) and hose rack access door (62).
17 Remove nine capscrews (63) and steam cleaner hose rack (64).
MAINTENANCE INSTRUCTIONS (cont)
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
21 hasps (82) from hose rack cover (71).
22 Remove 20 capscrews (83) and front panel (84) from steam cleaner lift assembly (3).
NOTE
Front post assembly is direction and location sensitive; mark before removal.
23 Remove two self-locking nuts (85), two capscrews (86), two plain nuts (87), two Iockwashers (88), two capscrews (89), and front post assembly (90).
INSPECTION/REPAIR
1 Inspect that components are free of burrs and sharp edges. File or smooth as necessary.
2 Check for broken, damaged, or missing parts.
3 Repair is by replacement of damaged or unserviceable parts.
4 Steam cleaner lift assembly is a repairable assembly. Notify direct support maintenance.
1 Install front post assembly (1) onto steam cleaner lift assembly (2) with two capscrews (3), two new Iockwashers (4), two plain nuts (5), two capscrews (6), and two new self-locking nuts (7).
2 Install front panel (8) with 20 capscrews (9).
MAINTENANCE INSTRUCTIONS (cont)
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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 eight machine 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 nine capscrews (29).
8 Install steam cleaner hose rack (28) and hose rack access door (30) with 22 capscrews (31).
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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 two new cotter pins (46 and 47) onto right rear access door (38) and steam cleaner lift assembly (2).
Install left post assembly (48) with capscrew (49), new Iockwasher (50), plain nut (51), and two capscrews (52).
MAINTENANCE INSTRUCTIONS (cont)
13 Install side mounting rail (53) and lower left panel (54) with 15 capscrews (55).
14 Install left rear panel (56), chain assembly (57), and flat washer (58) with nine capscrews (59).
15 Install left rear access door (60) onto steam cleaner lift assembly (2) with eight capscrews (61).
16 Install flat washer (62), retaining band (63), flat washer (64), spring (65), flat washer (66), and two new cotter pins (67 and 68) onto left rear access door (60) and steam cleaner lift assembly (2).
17 If removed, install new technical instructions sheet (69) onto left rear access door (60) with six flat washers (70), six capscrews (71), six new Iockwashers (72), and six hex nuts (73).
18 Install flat washer (74), machine bolt (75), flat washer (76), chain assembly (77), new lockwasher (78), and new self-locking nut (79) onto left rear access door (60).
19 Install door hinge spacer (80) and left front door assembly (81) onto steam cleaner lift assembly (2) with five capscrews (82).
20 Install access cover (83) with four new tapping screws (84).
21 Install top left cover (85) with eight capscrews (86).
22 Install top right cover (87) with twelve capscrews (88).
23 Install exhaust flap (89) with two new tapping screws (90).
THIS TASK COVERS:
a. Inspection b. Disassembly c. Repair d. Reassembly
INITIAL SETUP
Tools and Special Tools
General mechanic’s tooI kit (item 2, appx B) Equipment Conditions
Facility power cable assembly removed (para 4-13)
INSPECTION
1 Check for broken, damaged, or missing parts.
2 If cable is damaged, order new facility power cable assembly.
3 If electrical plug connectors are unserviceable, proceed to disassembly.
NOTE
Electrical plug connector style may vary slightly.
DISASSEMBLY
1 Remove two screws (1), clamp (2), and three screws (3). Slide cover (4) back onto power cable (5). Remove three screws (6) and disconnect three wires (7) from electrical plug connector (8).
Remove cover (4).
2 Remove two screws (9), clamp (10), and three screws (11). Slide cover(12) back onto power cable (5). Remove three screws (13) and disconnect three wires (7) to remove power cable (5) from eletrical plug connector (14). Remove cover (12).
REPAIR
Repair is by replacement of damaged or unserviceable parts.
REASSEMBLY
1 Slide cover (12) onto power cable (5). Connect three wires (7) to electrical plug connector 14) as shown and secure with three screws (13).
2 Install cover (12) onto electrical plug connector (14) with three screws (11). Secure clamp (10) to power cable (5) with two screws (9).
3 Slide cover (4) onto power cable (5). Connect three wires (7) to electrical plug connector (8) as shown and secure with three screws (6).
4 Install cover (4) onto electrical plug connector (8) with three screws (3). Secure clamp (2) to power cable (5) with two screws (1).
4-24. OUTLET AND WATER DRAIN ASSEMBLY—MAINTENANCE INSTRUCTIONS THIS TASK COVERS:
a. D i s a s s e m b l y b. 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
Crescent wrench, 12-in. (item 1, appx B) Crescent wrench, 14-in. (item 1, appx B) General mechanic’s tool kit (item 2, appx B) Material/Parts
Antiseizing tape (item 24, appx E) Self-locking nut (2) (MS51988-5) Equipment Conditions
Steam cleaner shut down (para 2-6) and power disconnected Oil burner assembly removed (para 4-13)
Thermocouple and attached parts removed (para 4-13)
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2
3
NOTE
Remove 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) and release 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 pipe elbow (10) from 3SOL solenoid valve (8).
Uncouple pipe union (11). Remove pipe union half from pipe nipple (12).
4 Remove pipe union half (13), pipe nipple (14), pipe elbow (15), and pipe nipple (16) from pipe tee (17).
5 Remove mounting bracket (18), pipe nipple (19), pipe elbow (20), and pipe nipple (21).
6 Remove pipe tee (17), pipe bushing (22), and pipe nipple (23) from 3SOL solenoid valve (8).
INSPECTION/REPAIR
1 Check for broken, damaged, or missing parts.
2 Repair is by replacement of damaged or unserviceable parts.
REASSEMBLY
1 2 3 4
Wrap all pipe threads with antiseizing tape (item 24, appx E).
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).
5 Install pipe union half (13) onto pipe nipple (14). Couple pipe union. Install pipe elbow (15) and straight adapter (16) onto 3SOL solenoid valve (4).
6 Install drain hose (17) onto 3SOL solendoid valve (4) with hose clamp (18).
7 Secure outlet and water drain assembly (19) and chain assembly (20) onto steam outlet support assembly (21) with two machine bolts (22) and two new self-locking nuts (23).
4-25. SUCTION HOSE ASSEMBLY—MAINTENANCE INSTRUCTIONS THIS TASK COVERS:
a. Disassembly b. Inspection/repair c. Reassembly
INITIAL SETUP
Tools and Special Tools
General mechanic’s tool kit (item 2, appx B) Materials/Parts
Antiseizing tape (item 24, appx E) Gasket (MS27030-2)
Equipment Conditions
Suction hose assembly removed (para 4-13)
DISASSEMBLY
1 Remove foot valve (1) and bushing (2) from straight adapter (3).
2 Remove quick coupler plug with chain (4), gasket (5), and female quick coupler (6) from inlet strainer (7).
3 Remove inlet strainer (7), nipple (8), bushing (9), and 45-degree elbow (10) from straight adapter (11).
INSPECTION/REPAIR
Check straight adapters (1 and 2) for damaged threads, burrs, and sharp edges.
Inspect hose (3) for deterioration or damage.
If straight adapters or hoses are
unserviceable, requisition new suction hose assembly.
Check for broken, damaged, or missing parts.
Inspect foot valve for debris. Clean as needed (para 3-6).
Disassemble and inspect inlet strainer for debris. Clean as needed (para 3-6).
Repair is by replacement of damaged or unserviceable parts.
REASSEMBLY