TM-5-3895-354-14-P Heater Hot Oil Trailer Mounted Model 200 STM77 Manual

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TM-5-3895-354-14-P

TECHNICAL MANUAL
WARNING
HEATER, HOT OIIL, TRAIILER MOUNTED
Distribution
HEATER, HOT OIIL, TRAIILER MOUNTED
Table of Contents
Part 1 Operation Maintenance and Repiar Parts for Heater, Hot Oil Trailer Mounted Model 200 STM77
SAFETY PRECAUTIONS
STORAGE DATA
TABLE OF CONTENTS
TABLE OF CONTENTS - CONTINUED
TABLE OF CONTENTS - CONTINUED
TABLE OF CONTENTS - CONTINUED
TABLE OF CONTENTS - CONTINUED
TABLE OF CONTENTS - CONTINUED
LIST OF ILLUSTRATIONS
LIST OF ILLUSTRATIONS CONTINUED
LIST OF ILLUSTRATIONS CONTINUED
Chapter 1 Introduction
Section B. DESCRIPTION AND DATA
Figure 1. HOT OIL HEATER, LEFT FRONT THREE-QUARTER VIEW WITH SHIPPING DIMENSIONS
Figure 2. HOT OIL HEATER, LEFT REAR, THREE-QUARTER VIEW
Tabulated Data
Burner
Program Controller
Pressure Gauge, Fuel
Pump Switch
Tires (Trailer)
Section C. NORMAL INSTRUMENT READING AND GAUGES
Figure 3. AIR-HYDRAULIC TRAILER
NOMENCLATURE FOR FIGURE 3
Figure 4. TRAILER WIRING DIAGRAM, 12 & 24 VOLT
Figure 5. HOT OIL HEATER WIRING DIAGRAM, 230 VOLT
CHAPTER 2 OPERATION Section A. SERVICE UPON RECEIPT OF EQUIPMENT
Figure 6. TRAILER UNLOADING BY CRANE
Inspecting and Servicing the Equipment
Figure 8. PACKED ITEMS, TOOL BOX.
Figure 9. ASSEMBLY OF HEAT TRANSFER HOSE & UNIONS, HOT OIL HEATER TO GEVERNMENT USER
Figure 10. ASSEMBLY-GROUND RODS
Figure 11. BURNER SWITCH AND CIRCULATING PUMP PUSHBUTTON, ELECTRICAL CONNECTIONS.
Figure 12. REAR GROUNDING CONNECTION.
Preparation for Operation
Section B. OPERATION OF EQUIPMENT
Figure 13. DUAL FUEL STRAINER VALVE OPERATION.
FIGURE 14. MANUAL TRANSFER OIL VALVES (GATE VALVES)
Starting
Stopping.
Operation in Dusty or Sandy Areas
Unloading the System
Figure 15 SYSTEM UNLOADING DIAGRAM
Section C. OPERATION OF AUXILIARY MATERIAL USED IN CONJUNCTION WITH THE EQUIPMENT
Reflectors
Chapter 3 Section A. OPERATOR MAINTENANCE
FIGURE 16 LUBRICATION ORDER HEATER, HOT OIL, TRLR, MTD.
Section B. HOT FLUID SYSTEM
Cleaning and Inspection
Figure 17. CIRCULATING PUMP AND MOTOR MOUNTING HARDWARE
Figure 18. CIRCULATING PUMP AND MOTOR COUPLING
Figure 19. Circulating Pump Assembly
Figure 20. CIRCULATING PUMP GEAR REDUCTION ASSEMBLY
Hot Fluid Strainers
Figure 22. HOT FLUID STRAINER
Figure 23. VALVES, LINES AND FITTINGS
Hot Oil Relief Valve
Figure 24. RELIEF VALVE
Vent Pipe Assembly
Section C. ELECTRICAL SYSTEMS
Figure 26. MARKER & CLEARANCE LAMPS
Fuse Block
Figure 28. CONTROL BOX EQUIPMENT
Cleaning and Inspection
Figure 29. FLAME PROGRAM CONTROLLER
Figure 30. TEMPERATURE CONTROL.
Circulating Pump Motor Starter Overload Heaters
Figure 31. TEMPERATURE CONTROL MOUNTING.
Figure 33. CIRCULATING PUMP MOTOR STARTER ENCLOSURE.
Pressuretrol
Figure 34. PRESSURETROL
Low Fluid Level Cutoff (Low Level Control)
Figure 35. LOW LEVEL CONTROL MOUNTING.
Figure 36. LOW LEVEL CONTROL
Figure 37. HIGH TEMPERATURE CONTROL
Ultraviolet (UV) Scanner
Figure 38. ULTRAVIOLET (U.V.) CELL.
Figure 39. IGNITION SYSTEM
Figure 40. CONTROL SWITCHES.
Figure 41. BLOWER MOTOR STARTER RESET PUSHBUTTON.
Section D. BURNER DRAWER ASSEMBLY, NOZZLE, AND ELECTRODES
Figure 42. ELECTRODE ADJUSTMENT AND DETAIL ASSEMBLY
Figure 43. AIR DAMPER LINKAGE
Nomenclature for Figure 44
Burner Electrode Adjustment
Figure 45. REAR VIEWER ASSEMBLY.
Figure 46. DAMPER CYLINDER MOUNTING
Installation
Burner Oil Valves
Section E. FUEL SYSTEM
Figure 48. FUEL PUMP MOUNTING
Figure 49. Fuel Supply Pump Assembly
Fuel Oil Strainers
Figure 50. FUEL OIL PUMP ADJUSTMENTS
Figure 52. FUEL STRAINER MOUNTING
Section F. BRAKES, LINES AND FITTINGS, WHEELS AND RIMS, MAINTENANCE INSTRUCTIONS
Figure 53. AIR TANK & RELAY VALVE MOUNTING
Figure 54. AIR TANK & RELAY VALVE
Removal
Figure 55. WHEEL ASSEMBLY
Figure 57. SPRINGS & SHOCKS
Axle
Figure 58. AXLE.
Figure 59. POWER CLUSTER MOUNTING.
Section G. HOSE CARRIERS, TOOLBOX, NOSE BOX, MUD GUARDS, AND CABLE REEL
Tool Box (Above Hose Carrier)
Figure 62. TOOL BOX MOUNTING HARDWARE
Figure 63. NOSE BOX MOUNTING HARDWARE
Cable Reel
Mud Guards
Section H. GAUGES
Fuel Oil Pressure Gauge
Figure 67. GAUGES, FRONT
Figure 68. Gauges , Rear
CHAPTER 4 TROUBLESHOOTING
Scope
Section B. HOT FLUID SYSTEM
CIRCULATING PUMP CAPACITY IS LOW
Section C. ELECTRICAL
BLOWER MOTOR WILL NOT START (continued)
ULTRAVIOLET (UV) CELL FAILS TO OPERATE
Section D. BURNER
BURNER EXHAUST SMOKY
Section E. FUEL SYSTEM
CHAPTER 5 ORGANIZATIONAL, DIRECT SUPPORT AND GENERAL SUPPORT MAINTENANCE REPAIR PARTS AND SPECIAL TOOLS LIST
Source Code
Recoverability Code
Explanation of Columns (Section IV)
Special Information
Figure 1. CLEARANCE LIGHTS
GROUP:06 ELECTRICAL
Figure 2. COMBINATION TURN, STOP AND TAIL LIGHTS
GROUP:0609 LIGHTS
Figure 3. AXLE.
GROUP:11 REAR AXLE
Figure 4. BRAKES.
GROUP:12 BRAKES
Figure 5. AIR/HYDRAULIC BRAKE ASSEMBLY
GROUP:1208 HYDRAULIC BRAKE SYSTEM
Figure 6. WHEEL ASSEMBLY.
GROUP:13 WHEELS AND TRACKS
Figure 7. SIDEMOUNT BRACKETS.
GROUP:16 SPRINGS AND SHOCK ABSORBERS
Figure 8. SNUBBER AND SHOCK ABSORBER.
GROUP:1604 SHOCK ABSORBERS
Figure 9. POWER CABLE ASSEMBLY AND POWER CABLE ADAPTER
GROUP:22 ACCESSORY ITEMS
Figure 10. GROUND ASSEMBLY RODS.
GROUP:22 BODY ACCESSORY ITEMS
Figure 11. CIRCULATING PUMP MOTOR,
GROUP:40 ELECTRIC MOTORS AND GENERATORS
Figure 12. CIRCULATING PUMP MOTOR STARTER.
GROUP:4006 STARTING AND PROTECTIVE DEVICES
Figure 13. BLOWER MOTOR STARTER.
GROUP:4006 STARTING AND PROTECTIVE DEVICES
Figure 14. CONTROL BOX EQUIPMENT
GROUP:42 ELECTRICAL EQUIPMENT
Figure 15. LOW LEVEL CONTROL.
GROUP:4202 ELECTRICAL CONTROLS
Figure 16. TEMPERATURE CONTROL.
GROUP:4202 ELECTRICAL CONTROLS
Figure 17. HIGH TEMPERATURE CONTROL.
GROUP:4206 THERMOSTATIC, AUTOMATIC AND MANUAL CONTROL DEVICES
Figure 18. ULTRAVIOLET (UV) SCANNER.
GROUP:4206 THERMOSTATIC, AUTOMATIC AND MANUAL CONTROL DEVICES
Figure 19. PRESSURETROL.
GROUP:47 GAGES (NONELECTRICAL), WEIGHING AND MEASURING DEVICES
Figure 20. MISCELLANEOUS GAGES.
GROUP:4702 GAGES, MOUNTINGS, LINES AND FITTINGS
Figure 21. LIQUID LEVEL SIGHT GAGE.
GROUP:4702 GAGES, MOUNTINGS, LINES AND FITTINGS
Figure 22. CIRCULATING PUMP ASSEMBLY.
GROUP:55 PUMPS
Figure 23. GEAR REDUCTION ASSEMBLY.
GROUP:5507 PUMP DRIVE
Figure 24. CIRCULATING PUMP AND MOTOR COUPLING.
GROUP:5511 COUPLINGS
Figure 25. HOT FLUID STRAINER.
GROUP :5513 FLUID LINES
Figure 26.2" GATE VALVE (F/S).
GROUP:5513 FLUID LINES
Figure 27.1 1/2" GATE VALVE (F/S).
GROUP:5513 FLUID LINES
Figure 28. HOT OIL RELIEF VALVE.
GROUP:5513 FLUID LINES
Figure 29.1/4" NEEDLE VALVE (BAR STOCK).
GROUP:5513 FLUID LINES
Figure 30. HOT OIL STRAINER PIPING .
GROUP:5513 FLUID LINES
Figure 31. MISCELLANEOUS PIPING.
FIGURE 31. MISCELLANEOUS PIPING.
Figure 32. HOUSING.
GROUP:60 BURNERS
Figure 33. FUEL OIL STRAINER PIPING .
GROUP:6004 FUEL SYSTEP
Figure 34. FUEL PUMP- EXPLODED VIEW.
GROUP:6004 FUEL SYSTEM
Figure 35. FUEL OIL STRAINER.
GROUP:6004 FUEL PUMP
Figure 36. BURNER ASSEMBLY.
GROUP:6005 BURNER ASSEMBLY
Figure 37. ELECTRODE ADJUSTMENT AND DETAIL ASSEMBLY.
GROUP:6005 BURNER ASSEMBLY
Figure 38. EXHAUST STACK
GROUP:6010 EXHAUST SYSTEM
NATIONAL STOCK NUMBER INDEX
NATIONAL STOCK NUMBER INDEX
PART NUMBER INDEX
PART NUMBER INDEX
PART NUMBER INDEX
PART NUMBER INDEX
PART NUMBER INDEX
PART NUMBER INDEX
PART NUMBER INDEX
PART NUMBER INDEX
PART NUMBER INDEX
PART NUMBER INDEX
FIGURE AND ITEM NUMBER INDEX
FIGURE AND ITEM NUMBER INDEX
FIGURE AND ITEM NUMBER INDEX
FIGURE AND ITEM NUMBER INDEX
FIGURE AND ITEM NUMBER INDEX
FIGURE AND ITEM NUMBER INDEX
FIGURE AND ITEM NUMBER INDEX
FIGURE AND ITEM NUMBER INDEX
FIGURE AND ITEM NUMBER INDEX
FIGURE AND ITEM NUMBER INDEX
FIGURE AND ITEM NUMBER INDEX
INDEX
INDEX
INDEX
INDEX
INDEX
INDEX
INDEX
Part II Supplemental Operating, Maintenance and Repair Parts Instruction for Heater, Hot Oil, Trailer Mounted
TABLE OF CONTENTS
Section I General
Personnel and Training.
Section II MAINTENANCE
Maintenance Expenditure Limits
SECTION III REPAIR PARTS SUPPLY
Requisitioning Repair Parts
APPENDIX A EQUIPMENT PUBLICATIONS
APPENDIX B BASIC ISSUE ITEMS LIST
ITEMS TROOP INSTALLED OR AUTHORIZED LIST
APPENDIX C MAINTENANCE ALLOCATION CHART
Overhaul
Section II. MAINTENANCE ALLOCATION CHART 2, 100, 000 BTU/HR
Section II. MAINTENANCE ALLOCATION CHART
Section II. MAINTENANCE ALLOCATION CHART 2, 100, 000 BTU/HR
Section II. MAINTENANCE ALLOCATION CHART 2, 100, 000 BTU/HR
Section II. MAINTENANCE ALLOCATION CHART 2, 100, 000 BTU/HR
SECTION III TOOL AND TEST EQUIPMENT REQUIREMENTS
SECTION III TOOL AND TEST EQUIPMENT REQUIREMENTS
APPENDIX D INITIAL RECOMMENDATION PRESCRIBED LOAD LIST (PLL) AUTHORIZED STOCKAGE LIST (ASL)
APPENDIX E MAINTENANCE AND OPERATING SUPPLY LIST
APPENDIX F PREVENTIVE MAINTENANCE CHECKS AND SERVICES
PREVENTIVE MAINTENANCE CHECKS AND SERVICES
Operator/Crew Preventive Maintenance Checks and Services
Operator/Crew Preventive Maintenance Checks and Services
Operator/Crew Preventive Maintenance Checks and Services
Operator/Crew Preventive Maintenance Checks and Services
APPENDIX G SAMPLE FORMAT - DA FORM 2765 PART NUMBER REQUEST
APPENDIX H SAMPLE FORMAT - MILSTRIP REQUISITION(NSN)
APPENDIX I SAMPLE FORMAT - MILSTRIP REQUISITION (NON-NSN)
SAMPLE FORMAT - MILSTRIP REQUISITION (NON-NSN)
APPENDI X J SAMPLE FORMAT - MILSTRIP REQUISITION
INSTRUCTIONS
Distribution
THE METRIC SYSTEM AND EQUIVALENTS
Recommended Chages to Equipment Technical Publications
TM-5-3895-354-14-P
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