TM-5-3895-371-24P Melter Asphalt Skid Mounted Hot Oil Circulating 750 GPH Chausse Model STMD-3000A Manual

CHAPTER   1 INTRODUCTION
1-2. Maintenance Forms and Records
Section II. DESCRIPTION AND DATA - TM-5-3895-371-24P_18
Figure, 1-1. Major Components and Their Locations (Sheet 2 of 3).
Figure 1-1. Major Components and Their Locations (Sheet 3 of 3)
a. Dimensions and Weight - Distributor and Truck.
f. Bituminous Pump Data.
CHAPTER 2 ORGANIZATIONAL   MAINTENANCE   INSTRUCTIONS
Section IV. PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) - TM-5-3895-371-24P_25
(5) Hoses and fluid lines
Table 2-1. ORGANIZATIONAL PREVENTIVE MAINTENANCE CHECKS AND SERVICES - TM-5-3895-371-24P_27
Table 2-1. ORGANIZATIONAL PREVENTIVE MAINTENANCE CHECKS AND SERVICES - TM-5-3895-371-24P_28
Section V. TROUBLESHOOTING - TM-5-3895-371-24P_29
Table 2-2. Troubleshooting.
Table 2-2. Troubleshooting (Continued}
Table 2-2.    Troubleshooting   (Continued)
Table 2-2. Troubleshooting   (Continued). - TM-5-3895-371-24P_33
Table 2-2. Troubleshooting   (Continued). - TM-5-3895-371-24P_34
Table 2-2. Troubleshooting   (Continued). - TM-5-3895-371-24P_35
Table 2-2. Troubleshooting   (Continued). - TM-5-3895-371-24P_36
Section VI. MAINTENANCE OF ELECTRICAL SYSTEM - TM-5-3895-371-24P_37
(19) For repair of blackout lamps
Figure 2-1. Remove/Install Loom Bumper and Marker Lamps (Sheet 1 of 2).
Figure 2- 1. Remove/lnstall Loom Bumper and Marker Lamps (Sheet 2 of 2)
b. Installation - TM-5-3895-371-24P_41
b. Installation -CONT
Figure   2-2. Bumper Terminal Board Wiring Connectors.
Figure 2-3. TA 075806 Body Wiring Harness Routing
b. Inspection and Repair of Harness
Section VII. MAINTENANCE OF STOWAGE BOX - TM-5-3895-371-24P_46
Section VIII. MAINTENANCE OF BELL
Figure 2-6. Disassemble/Assemble    Bell    Mechanism - TM-5-3895-371-24P_48
Figure 2-6. Disassemble/Assemble    Bell    Mechanism - TM-5-3895-371-24P_49
Figure 2-8. Disassemble/Assemble Hand Spray Gun
Section X. MAINTENANCE OF HYDRAULIC PUMP PROPELLER SHAFT - TM-5-3895-371-24P_51
Figure 2-9. Remove/Install Hydraulic Pump Propeller Shaft. - TM-5-3895-371-24P_52
c. Repair of Universal Joint
Section XI. MAINTENANCE OF HYDRAULIC PUMP CONTROL AND FRONT OVERRIDE CONTROL
Figure 2-11. Hydraulic Pump Controls (Sheet 2 of 2)
Section XII. MAINTENANCE OF HYDRAULIC TANK AND FILTER
Figure 2-12. Hydraulic Tank and Filter
b. Hydraulic Filter Disassembly
Section XIII. MAINTENANCE AND ROUTING OF HYDRAULIC LINES
b. Installation - TM-5-3895-371-24P_60
Figure 2-13. Maintenance and Routing of Hydraulic Lines
Section XIV. MAINTENANCE OF HYDRAULIC CONTROL BOX
d. Assembly.
Figure 2-14. Hydraulic Control Box (Sheet 1 of 2)
Figure 2-14. Hydraulic Control Box (Sheet 2 of 2)
Section XV. ROUTING OF CAB HYDRAULIC CONTROL BOX TO AIR CONTROL BOX HARNESS - TM-5-3895-371-24P_66
Figure 2-15. Routing of Cab Hydraulic Control Box to Air Control Box Harness
Section XVI. MAINTENANCE OF AIR CONTROL BOX
Figure 2-16. Disassemble/Reasemble Air Control Box.
Figure 2-17. Air Control Box Piping Diagram
Figure 2-18. Air Control Box Wiring Connections
d. Installation of 12-Volt Solenoid Valve.
Section XVII. MAINTENANCE AND ROUTING OF AIR LINES
Figure 2-19. Maintenance and Routing of Air Lines. - TM-5-3895-371-24P_74
b. Installation - TM-5-3895-371-24P_75
Section XVIII. MAINTENANCE OF SPRAY BAR CONTROL CYLINDERS
Figure 2-20. Remove/lnstall Bar Shifting Control Cylinder.
b. Installation of Bar Shifting Control Cylinder
Figure 2-21. Remove/Install Bottom Bar On-Off Cylinder
Figure 2-22. Remove/Install Top Bar On-Off Cylinder.
g. Removal of Bar Turn-Up Cylinders
Figure 2-23. Removal of Bar Turn-Up Cylinders
Section XIX. MAINTENANCE OF BITUMETER WHEEL ASSEMBLY
Figure 2-24. Main Air Valve and Bituminous Supply Tank Petcock
Figure 2-25.    Remove/Install Bitumeter Wheel Solenoid Valve and Air Chamber
b. Installation of Bitumeter Wheel Solenoid Valve and Air Chamber.
e. Installation of Bitumeter Wheel, Tire, and Bearings
Figure 2-26. Remove/lnstall Bitumter Wheel, Tire and Bearing
Section XX. MAINTENANCE OF BITUMETER AIR CONTROL RESERVOIR
Section XXI. MAINTENANCE OF PUMP TACHOMETER AND RECORDING BITUMETER
Figure 2-28. Remove/lnstall Pump Tachometer, Recording Bitumeter, and Cables
Section   XXII.   MAINTENANCE   OF   HYDRAULIC   MOTOR   UNIVERSAL   DRIVE
Figure 2-29. Remove/Install Pump Universal Drive
Section XXIII. MAINTENANCE OF BURNER FUEL TANK
Figure 2-30. Remove/lnstall Burner Fuel Tank
Section XXIV. MAINTENANCE OF EXTERNAL SMOKE STACKS
Figure 2-31. Remove/Install Smoke Stacks
Section XXV. MAINTENANCE OF QUADRANT
Figure 2-32. Remove/Install Quadrant.
c. Disassembly
Figure   2-33.   Disassemble/Reassemble   Quadrant
Section XXVI. VACU-FLO, INTAKE, AND CONTROL VALVES MAINTENANCE
Figure 2-34. Valves - Intake, Vacu-Flo and Control.
Figure 2-35. Remove/install Intake Valves.
Section XXVII. MAINTENANCE OF FILLING LINE
Figure   2-36. Remove/Install   Filling   Line   and   Strainer
Section XVIII. MAINTENANCE OF TRANSFER VALVES
Figure 2-37. Remove/lnstall Transfer Valve.
Section XXIX. MAINTENANCE OF CONTROL VALVE
Figure   2-38. Control   Valve   Maintenance
Section XXX. MAINTENANCE OF MANHOLE COVER - TM-5-3895-371-24P_111
Figure   2-40. Disassemble/Assemble    Manhole    Cover.
d. Installation.
Section XXXI. MAINTENANCE OF BLOWER ASSEMBLY - TM-5-3895-371-24P_114
b. Removal of Blower Motor Control Valve.
Figure   2-42. Disassemble/Reassemble Blower Assembly (Sheet 1 of 2)
Figure   2-42. Disassemble/Reassemble Blow Assembly (Sheet 2 of 2).
Figure 2-43. Remove/Install Fuel Pump From Blower End Cap
e. Repair of Fuel Pump.
Figure   2-44. Fuel Pump
9. Disassembly of Burner Blower Drive Motor.
Figure 2-47. Remove/Install   Top   Case   Bearings.
Figure   2-49. Remove/Install Lower Case Plate and Seal.
Figure   2-52. Remove/Install Lower Case Seal
i. Reassembly of Burner Blower Drive Motor
Section XXXII. MAINTENANCE OF PORTABLE BURNER
Figure 2-53. Portable Burner.
Figure   2-54. Disassemble/Reassemble    Portable    Burner.
Section XXXIII. MAINTENANCE OF SPRAY BAR DISTRIBUTING LINES
Hinge section ball joints
Figure 2-55. Remove/Install Spray Bar Distributing Lines and Component Parts (Sheet 1 of 2).
Figure   2-55. Remove/Install Spray Bar Distributing Lines and Component Parts (Sheet 2 of 2)
Section XXXIV. MAINTENANCE OF SPRAY BAR - TM-5-3895-371-24P_133
Figure   2-56. Remove/Install Spray Bar Lines and Component Parts
(1) Remove left carry arm assembly
Figure 2-57. Remove/Install   End   Tube   Assembly
Figure   2-58. Remove/Install Bearing Balls
(3) Remove flip valves
Figure 2-59. Remove/Install Flip Valves.
Figure   2-60. Disconnect/Connect   Swivel   Toggle   Rods
Figure   2-61. Remove/Install    Spay    Nozzles
C. Reassembly.
Section   XXXV. MAINTENANCE OF LOW PRESSURE BURNER ASSEMBLY
b. Installation - TM-5-3895-371-24P_144
CHAPTER 3 DIRECT SUPPORT AND GENERAL SUPPORT MAINTENANCE INSTRUCTIONS
Table 3-1. Direct Support and General Support Troubleshooting
Table 3-1.    Direct Support and General Support Troubleshooting (Continued)
Section IV. REPAIR OF HYDRAULIC PUMP
Figure 3-2.    Hydraulic Motor Pressure Adjustment.
Figure 3-3. Remove/Install Hydraulic Pump
f. General Instructions (Before Disassembly of Hydraulic Pump)
Figure 3-4. Hydraulic Pump Sectional Drawing (Sheet 1 of 2) - TM-5-3895-371-24P_153
Figure 3-4.   Hydraulic Pump Sectional Drawing (Sheet 2 of 2)
Figure 3-5. Charge Pump Upper Valve Plate
Figure 3-7. Charge Pump Lower Valve Plate
h. Disassemble Override Control.
Figure 3-10.    Override    Control.
Figure 3-11.   Cam Actuator Arm and Valve Sleeve
Figure 3-13. Control Valve Spool with Valve Sleeve.
Figure 3-14. Cylinder Cover with Transfer Tube. - TM-5-3895-371-24P_161
Figure 3-16.   Control Housing Cover
Figure 3-18.    Removing   Housing
Figure 3-19. Marking Number 1 Piston
(7) Examine the block assembly
Figure 3-21. Block Rework Specifications
Figure 3-22. Return Plate Disassembly.
Figure 3-23. Removing Cam Reaction P/ate.
Figure 3-24. Removing Flange Square Ring.
Figure 3-26. Removing Shaft Assembly.
i. Assemble Hydraulic Pump
Figure 3-28. Installing Pump Shaft Assembly
Figure 3-29.    Installing Shaft Seal Retainer
igure 3-30. Cam Reaction to Wear Plate
Figure 3-32. Inspecting Piston Shoe
Figure 3-34. Three Groove and Two Groove Pistons.
Figure   3-35.   Inspecting   Piston   Body.
Figure 3-37. Return Plate Assembly
Figure 3-38. Rotating Group Assembly
Figure 3-39. Positioning Rotating Group. - TM-5-3895-371-24P_180
Figure   3-40.   Positioning   Pump   Housing.
Figure 3-41. Inspecting Trunnions
Figure 3-43. Inspecting Pump Cover.
Figure 3-44. Pump Cow Rework specifications.
Figure 3-45. Installing Pump Cover. - TM-5-3895-371-24P_185
Figure 3-47. Inspecting Outer Rotor. - TM-5-3895-371-24P_186
Figure 3-49. Checking Charge Pump Clearance
Figure 3-51. Charge Pump Cover.
k. Assemble Override Control.
Figure 3-53. Cylinder with Servo Plunger
Figure 3-55.    Valve Sleeve in Piston.
Figure 3-56. Control Valve Spool with Cam Follower. - TM-5-3895-371-24P_192
Figure 3-57. Cam Actuator Arm and Cam Follower
Section V. REPAIR OF HYDRAULIC MOTOR
Figure 3-58.   Remove/Install Hydraulic Motor (Sheet 1 of 2)
Figure 3-58.   Remove/Install Hydraulic Motor (Sheet 2 of 2)
Figure 3-59.    Tachometer  Drive -  Hydraulic.
d. General Instructions
Figure 3-60. Motor - Hydraulic (Sheet 1 of 2)
Figure 3-60.   Motor - Hydraulic (Sheet 2 of 2)
Figure 3-61. Removing Low Pressure Relief Valve.
Figure 3-63. Marking Across Cover-Housing Parting Line.
Figure   3-65.   Removing   Housing   Capscrews
Figure   3-66.   Removing   Housing
Figure 3-68. Removing Cylinder Block
Figure 3-69. Inspecting Cylinder Block
Figure 3-71. Removing Pistons and Return Plate
Figure 3-72. Removing Pistons and Return Plate
Figure 3-74. Removing Shaft Seal Retainer Capscrews.
Figure 3-76. Removing Motor Shaft Assembly
Figure 3-77. Installing Motor Shaft Assembly
Figure 3-79. Inspecting Cam Wear Plate.
Figure   3-81.   Inspecting   Piston
Figure 3-83. Inspecting Piston Body. - TM-5-3895-371-24P_214
Figure 3-84. Three Groove and Two Groove Pistons
Figure 3-86. Installing Pistons and Return Plate.
Figure 3-87. lnstalling Return Plate Clips. - TM-5-3895-371-24P_217
Figure 3-88. Installing Block Assembly. - TM-5-3895-371-24P_218
Figure 3-89. Installing Housing. - TM-5-3895-371-24P_219
Figure   3-90.   Inspecting   Motor   Cover.
Figure   3-92.   Installing   Motor   Cover
Figure 3-94. Installing Low Pressure Relief Valve
Figure 3-95. Installing High Pressure Relief Valve Body.
Figure 3-97. High Pressure Relief Valve and Pilot.
Figure 3-99. High Pressure Relief Valve.
g. Install Motor.
Section VI. REPLACE ASPHALT PUMP - TM-5-3895-371-24P_227
Figure 3-101. Disconnect/Connect Control Linkage and Manifold. - TM-5-3895-371-24P_228
Figure   3-102.   Remove/Install   Covers.
Figure   3-103. Remove/Install    Asphalt    Pump
Section VII. REPAIR OF COMBUSTION CHAMBER
Figure 3-104. Remove/Install Combustion Chamber Components
Section VIII. REPAIR OF ASPHALT TANK AND HOSES
Figure 3-105. Remove/Install Tank Forward Support Braces. - TM-5-3895-371-24P_234
Figure 3-106. Remove/Install Hose Brace.
Figure 3-108. Remove/Install Tank Rear Support Braces. - TM-5-3895-371-24P_236
Figure 3-109. Disconnect/connect Control Linkage and Manifold.
Figure 3-110. Disconnect/Connect Micro Switch and Cables. - TM-5-3895-371-24P_238
Figure 3-111. Remove/Install Low Pressure Burner Assembly, - TM-5-3895-371-24P_239
Figure 3-112. Remove/Install Manifold.
Figure 3-113. Remove/Install Asphalt Pump
(35) Remove control valve.
Figure 3-114. Disconnect/Connect Electrical Cable.
Figure 3-115. Support Tank with Sling and Hoist
(8) Install air supply tank
3-10. Asphalt Hose
c. Repair of Adapter and Fittings
Figure 3-116. Asphalt Hoses (Metal) and Connectors
CHAPTER   4 REPAIR OF PLATFORMS AND WALKWAYS
Figure 4-1. Remove/Install Guard Rail - TM-5-3895-371-24P_251
Figure 4-2. Remove/Install Platform.
Figure 4-3. Disconnect/Connect Manifold. - TM-5-3895-371-24P_253
Figure 4-4. Disconnect/Connect Control Linkage. - TM-5-3895-371-24P_254
Figure 4-5.   Remove/Install Air Control Box Components.
Figure 4-6. Disconnect/Connect Terminal Strip Wires. - TM-5-3895-371-24P_256
Figure   4-7.   Disconnect/Connect   Fender   and   Step
Figure   4-8.   Disconnect/Connect   Override   Cable.
Figure 4-9. Displace/Mount Auxiliary Hoses
Figure 4-11.    Remove/Install   Platform   Attaching   Parts
4-2.   Installation
Section II. REPAIR OF SIDE WALKWAYS - TM-5-3895-371-24P_262
Figure 4-12.   Passenger Side and Drivers Walkway (Sheet 1 of 2)
Figure 4-12. Passenger Side and Drivers Walkway (Sheet 2 of 2)
4-6. Install Drivers Side Walkway.
Figure 4-13.    Rear Wheel Splash Guard.
4-9. Remove Tool Box
Figure 4-14.    Tool Box.
CHAPTER   5 REPAIR OF SPRAY BAR SUBFRAME
Figure 5-2. Remove/Install Platform
Figure 5-3.    Remove/Install Left Side Platform and Step
Figure 5-4. Disassemble/Assemble Sub frame (Sheet 1 of 2).
Figure 5-4.    Disassemble/Assemble   Subframe   (Sheet 2 of 2).
Figure 5-5. Remove/Install Raising Bar Spring.
5-2. Reassembly
CHAPTER   6 6-1.   Removal. REPAIR OF HYDRAULIC TANK
6-2. General Repair
CHAPTER 7 REPAIR OF SPRAY BAR AIR CYLINDERS
7-4. Reassembly of Turn Up and On-Off Control Cylinders
Figure 7-2. Disassemble/Assemble Bar On-Off Cylinder
h. Install new leather seal
CHAPTER 8 REPAIR OF BITUMETER AIR CHAMBER
Figure   8-1.    Disassemble/Reassemble   Bitumeter   Air   Chamber.
CHAPTER   9 REPAIR OF ASPHALT PUMP
Figure 9-1.    Disassemble/Reassemble    Asphalt    Pump
9-2. Clean and Inspect.
CHAPTER   10 REPAIR OF LOW PRESSURE BURNER ASSEMBLY
Figure 10-1. Disassemble/Reassemble Low Pressure Burner Assembly.
CHAPTER 11 REPAIR OF BURNER FUEL TANK
11-1. Removal of Fuel Gage
CHAPTER 12 REPAIR OF ASPHALT TANK GAGE
Figure 12-1. Disassemble/Assemble Asphalt Tank Gage (Sheet 2 of 2)
12-2. Disassembly
12-5. Installation of Gage.
12-6. Discharge Header Strainer
APPENDIX A REFERENCES - TM-5-3895-371-24P_300
REFERENCES --cont - TM-5-3895-371-24P_301
REFERENCES --cont - TM-5-3895-371-24P_302
APPENDIX B MAINTENANCE   ALLOCATION   CHART
B-3. Explanation of Columns in the MAC, Section II
B-4   Explanation of Columns in Tool and Test Equipment Requirements, Section III.
Section II -ASSIGNMENT OF MAINTENANCE FUNCTIONSSection II -ASSIGNMENT OF MAINTENANCE FUNCTIONS
ASSIGNMENT OF MAINTENANCE FUNCTIONS. --cont - TM-5-3895-371-24P_308
ASSIGNMENT OF MAINTENANCE FUNCTIONS. --cont - TM-5-3895-371-24P_309
ASSIGNMENT OF MAINTENANCE FUNCTIONS. --cont - TM-5-3895-371-24P_310
ASSIGNMENT OF MAINTENANCE FUNCTIONS. --cont - TM-5-3895-371-24P_311
ASSIGNMENT OF MAINTENANCE FUNCTIONS. --cont - TM-5-3895-371-24P_312
Section Ill. TOOL AND TEST EQUIPMENT REQUIREMENTS
APPENDIX D EXPENDABLE SUPPLIES AND MATERIALS LIST
Section II. EXPENDABLE SUPPLIES AND MATERIALS LIST
APPENDIX E ILLUSTRATED LIST OF MANUFACTURED ITEMS
Section II. PART NUMBER INDEX
Section III. ILLUSTRATED MANUFACTURING INSTRUCTIONS
Figure E-2. Nylon Tubing and Fittings

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