TECHNICAL MANUAL. MAINTENANCE Volume 2 M081 ASPHALT MIXING PLANT NSN

Transcription

1 TECHNICAL MANUAL MAINTENANCE Volume 2 M081 ASPHALT MIXING PLANT NSN Manufactured by WRT Equipment Ltd rd Street East Saskatoon, Saskatchewan Canada S7K 3V1 Contract DAAE07-92-C-1191 DISTRIBUTION STATEMENT A: Approved for public release; distribution unlimited. HEADQUARTERS DEPARTMENT OF THE ARMY 1 NOVEMBER 1995

2 TECHNICAL MANUAL TM HEADQUARTERS, DEPARTMENT OF THE ARMY Washington, D.C. Unit, Direct Support and General Support Maintenance Manual for ASPHALT MIXING PLANT NSN November 1995 REPORTING OF ERRORS AND RECOMMENDING IMPROVEMENTS You can help improve this manual. If you find any mistakes or if you know of a way to improve the procedures, please let us know. Mail your letter, DA Form 2028 (Recommended changes to Publications and Blank Forms), or DA Form 20282, located in the back of this manual, direct to: Commander, US Army Tankautomotive and Armaments Command, ATTN: AMSTA-IM-MMAA, Warren MI A reply will be furnished to you. You may also provide DA Form information to TACOM via datafax or . TACOM s datafax number for AMSTA- IM-MMAA is: (810) and the address is: amsta-immmaa@cc.tacom.army.mil THIS MANUAL SET CONSISTS OF THE FOLLOWING: VOLUME 1 OPERATOR S MANUAL TM VOLUME 2 MAINTENANCE MANUAL TM VOLUME 3 MAINTENANCE MANUAL TM VOLUME 4 PARTS MANUAL TM P The Maintenance information for the Asphalt Mixing Plant (AMP) is contained in two volumes, TM AND TM Each volume contains a table of contents that covers both volumes and shows where volume 1 ends and volume 2 starts. make sure you have both volumes with you when performing maintenance. This maintenance manual is an Army authentication of a commercial manual. The manual is not formatted to Department of the Army specifications. This manual does contain the information needed to perform maintenance on the AMP. You will find some pages in this manual have two pages numbers, one in parenthesis. The page number contained in the parenthesis is the true page number that tracks with the table of contents. The page number not in the parenthesis is a page number that exists in the commercial vendor manual as it appears in commercial use. This commercial page number has been left on the page to maintain continuity with the internal page referencing of the commercial vendor sections. Refer to TB for any Warranty Issues. This TB takes precedence over all vendor warranty information that may appear in this manual. Approved for Public Release: Distribution is Unlimited. page i

3 TABLE OF CONTENTS VOLUME 1 - TM Cover Page Manual Set Listing i Table of Contents ii Appendix A - 1 List of Illustrations viii Safety Summary xii CHAPTER 1 GENERAL INFORMATION Paragraph Title Page Number 1-1 INTRODUCTION Tabulated Data Tools and Test Equipment 1-1 CHAPTER 2 PREPARATION FOR USE BY RECEIVING ACTIVITY Paragraph Title Page Number 2-1 General Lubrication Visual Inspection 2-2 page ii

4 CHAPTER 3 MAINTENANCE INSTRUCTIONS Paragraph Title Page Number 3-1 General Removal, Repair, and Replacement Control Van Burner Control Damper Control Asphalt Calibration Scale Weight Indicator Motor Control Center Variable Speed Drives Electrical Schematics Data Table Access Module Programmable Logic Controller Blending Controller Printer Environmental Control Unit Timers Trailer Suspension - Tandem Axle Trailer Air Brake System Trailer 5th Wheel Adapter Drum Mixer Burner and Blower Assembly Fuel System Pilot System Drum Drive Gear Reducer Shaft Coupling Chain Oiler Trunnions and Guide Wheels Drum Trunnion Alignment Drum Flights Drum Seals Asphalt/Fines Injection Pipes Pillow Block - Split Housing Sheaves and Bushings Trailer Suspension - Triple Axle page iii

5 3-16 Trailer Air Brake System Trailer 5th Wheel Adapter Hydraulic Leveling System Surge Bin Batcher Slat Conveyor Slat Conveyor Drive Slat Conveyor Gear Reducer Shaft Coupling Pneumatic System Air Compressor Air Cylinder Hydraulic Pump Drive Hydraulic System Telescoping Cylinder Hydraulic Cylinder Bin Heating System Bin Gates Electrical Panel Tail Shaft Bearing Trailer Suspension - Triple Axle Trailer Air Brake System Trailer 5th Wheel Adapter Hydraulic Leveling System VOLUME 2 - TM Baghouse Griffin Baghouse Exhaust Blower Drive Exhaust Blower Exhaust Louver Exhaust Inlet Assembly Air Cylinder Gear Reducers, Screw Conveyors Fines Blower Assembly Fines Blower page iv

6 Pneumatic System Air Compressor Screw Conveyor Drives Screw Conveyor Motor Mounts Sheaves and Bushings Trailer Suspension - Tandem Axle Trailer Air Brake System Trailer 5th Wheel Adapter Hydraulic Leveling System Dedrummer/Melter Asphalt Piping System Heat Transfer Fluid System Fuel System Fuel Tank Fuel Pump Drive Shaft Coupling Hydraulic System Drum Lift Hoist Chain Hoist Trolley Chain Hoist Fuel Pump Trailer Air Brake System Trailer 5th Wheel Adapter Hydraulic Leveling System Asphalt Tanker Hot Oil Heater Heat Transfer Fluid System Fuel System Asphalt Metering Pump Assembly Asphalt Metering Pump Drive Shaft Coupling Asphalt Metering Pump Asphalt Meter Asphalt Metering and Transfer Systems Divert Assembly Air Cylinder Pneumatic System page v

7 Asphalt Transfer Pump Drive Calibration Tank/System Gear Reducer Sheaves and Bushings Trailer Suspension - Tandem Axle Trailer Air Brake System Trailer 5th Wheel Adapter Hydraulic Leveling System Feed Conveyor Screen Deck Conveyor Head Pulley Conveyor Assembly Conveyor Belt, Idler Pulleys and Adjustments Belt Scale, Speed Sensor Hydraulic System Gear Reducer, Conveyor Screen Adjustment Conveyor Drive Sheaves and Bushings Belt Fasteners Hydraulic Cylinder Trailer Suspensions - Single Axle Trailer Air Brake System Trailer 5th Wheel Adapter Four Bin Feeder Belt Feeder Drives Gear Reducer Feed Gate Feeder Flow Switch Belt Feeder Bin Vibrators Gathering Conveyor Gathering Conveyor Drive Shaft Coupling Conveyor Belt, Idler Pulleys and Adjustments Hydraulic System Sheaves and Bushings page vi

8 Hydraulic Cylinder Belt Fasteners Trailer Suspensions - Tandem Axle Trailer Air Brake System Trailer 5th Wheel Adapter Hydraulic Leveling System Dolly Trailer Suspensions - Tandem Axle Trailer Air Brake System Generator Trailer Trailer Suspensions - Tandem Axle Trailer Air Brake System Trailer 5th Wheel Adapter Hydraulic Power Pack Pump Drive Hydraulic System Shaft Coupling Trailer Suspensions Trailer Suspensions - Single Axle Trailer Suspensions - Tandem Axle Trailer Suspensions - Triple Axle Trailer Air Brakes Trailer Air Brake System Brake Adjustment Mechanical Release th Wheel Adapter Hydraulic Leveling System Hydraulic Cylinder page vii

9 CHAPTER 4 TROUBLE SHOOTING AND PMCS Paragraph Title Page Number 4-1 General Commercial Trouble Shooting Information Production Trouble Shooting Control Van/Controls Asphalt Display (Screen) Motor Controls Temperature Device Control Panel Programmable Logic Controller (PLC) Blending Controller Surge Bin Aggregate Feed Baghouse Burner Control System Interlocks Control Logic Charts Unit Preventive Maintenance Checks and Service 4-38 APPENDIX Appendix Title Page Number A REFERENCES A - 1 A-1 Scope A - 1 A-2 Department of the Army Pamphlets A - 1 A-3 Forms A - 1 A-4 Field Manuals A - 1 A-5 Technical Bulletins A - 2 A-6 Technical Manuals A - 2 A-7 Other Publications A - 2 B MAINTENANCE ALLOCATION CONCEPT B - 1 page viii

10 LIST OF ILLUSTRATIONS Figure Title Page Number 3-1 Control Van Components Fuel System Pilot System Drum Drive Chain Oiler Trunnions and Guide Wheels Drum Trunnion Alignment Drum Flights Drum Seals Injection Pipes Batcher Slat Conveyor Slat Conveyor Slinging Idler and Sprocket Spacing Slat Conveyor Drive Drive Slinging Pneumatic System Air Cylinder Hydraulic Pump Drive Hydraulic System Telescoping Cylinder Hydraulic Cylinder Bin Heating System Bin Gates Exhaust Blower Drive Exhaust Blower Exhaust Louver Exhaust Inlet Assembly Air Cylinder Fines Blower Assembly Pneumatic System Screw Conveyor Drives Asphalt Piping System Heat Transfer Fluid System Fuel System Fuel Tank Fuel Pump Drive Hydraulic System Drum Lift Hoist Heat Transfer Fluid System page ix

11 3-41 Fuel System Asphalt Metering Pump Assembly Asphalt Metering Pump Fittings Asphalt Metering Pump Drive Asphalt Metering and Transfer Systems Divert Assembly Air Cylinder Pneumatic System Asphalt Transfer Pump Drive Calibration Tank/System Screen Deck Conveyor Head Pulley Conveyor Assembly Belt Training Hydraulic System Conveyor Drive Hydraulic Cylinder Belt Feeder Drive Feed Gate Feeder Flow Switch Feeder Flow Switch Position Belt Feeder Bin Vibrators Gathering Conveyor Tail Section Gathering Conveyor Fold Section Gathering Conveyor Head Section Gathering Conveyor Drive Hydraulic System Hydraulic Cylinder Pump Drive Hydraulic System Trailer Axle Assembly Trailer Electrical System 12V - 24V Trailer Electrical System 12V - 24V Trailer Electrical System 12V - 24V Trailer Electrical System 12V - 24V Trailer Electrical System 12V - 24V Trailer Electrical System 12V - 24V Trailer Electrical System 12V - 24V Trailer Air Brake System Trailer Air Brake System Trailer Air Brake System Trailer Air Brake System page x

12 3-84 Trailer Air Brake System Trailer Air Brake System th Wheel Adapter Hydraulic Leveling System Hydraulic Leveling System Hydraulic Cylinder Start Up Control MCC Power to Motor Control Asphalt Metering Pump Baghouse Motor Controls Feed Motor Controls Batcher Control Baghouse Exhaust Shutter Motor Alarms Motor Alarm Silence Reset Asphalt Metering Pump Auto Reset Alarms Alarm Silence/Reset 4-37 page xi

13 WARNING The following procedures must be followed when performing maintenance on the AMP. Failure to do so may result in injury or death. - Use of ear protection for all plant personnel working outside the control van. - Use of all safety devices and guards provided with the plant. - Personnel must wear the following protective items at all times. Coveralls (not loose fitting) Safety glasses with side shields Insulated gloves - non-asbestos Hard hat Safety shoes - Routine maintenance procedures must be followed at all times. Maintain all equipment in good operating condition. This includes but is not limited to; Fuel lines Asphalt lines Hot oil heating lines Hydraulic lines Electric cables and connectors Air lines - Restrict entry to all confined spaces except for authorized and scheduled maintenance inspections. Establish a confined space entry SOP IAW DHEW (NIOSH) Publication No (provided with AMP) when maintenance requires work in a confined space. This SOP must be coordinated with your local medical (preventive medicine) authority. Prior to entry, test for fumes and make provisions for adequate ventilation. Never work alone. Always use the buddy system when working in confined spaces. - Do not operate equipment in an enclosed area unless all exhaust fumes are safely vented away from the work area. - Army field manual (FM) must be followed if the AMP is operated in conditions that expose its operators and maintainers to heat stress conditions. - USE COMMON SENSE NOTE You must be aware of and avoid the following potential hazards when operating and maintaining the AMP. Recommendations are included to provide the necessary information so these hazards can be avoid. page xiv

14 II. HAZARDS AND RECOMMENDATIONS 1. Control Van Table 1-1 Hazards and Recommendations High voltage All electrical switch-gear are Operate and maintain in electrical located in this unit and all accordance with all safety power cables are attached to procedures. Do not perform the power source in the van. repair work without a qualified electrician. The trailer air brake system is Maintain system in good Compressed air comprised of air lines, tanks operating condition. Release and valves which activate the air pressure prior to repairing trailer brakes. the system. 2. Four Bin Feeder Noise Aggregate materiels loaded Use of ear protection. into the four bin feeder by a front end loader may cause intermittent noise levels exceeding 85 dba. Operating V-Belt drives and moving Use of guards during machinery conveyor belts. operation. Operator should not wear loose fitting clothing. High voltage Power cables. Avoid contact when energized. electrical Maintain in good condition. Use cable supports provided. Do not perform repair work without a qualified electrician. Fluids under Hydraulic cylinders, lines and Maintain lines in good pressure valves. operating condition. Wear protective clothing while operating the plant. (gloves, hat) page xv

15 Compressed air The trailer air brake system is Maintain system in good comprised of air lines, tanks operating condition. Release and valves which activate the air pressure prior to repairing trailer brakes. the system. 3. Feed Conveyor Operating Vibrating screen and moving Use of guards during machinery conveyor belt. operation. Operator should not wear loose fitting clothing. Noise Aggregate materiels Use of ear protection. discharged onto the screen may cause steady noise levels exceeding 85 dba. High voltage Power cables. Avoid contact when energized. electrical Maintain in good condition. Use cable supports provided. Do not perform repair work without a qualified electrician. Fluids under Hydraulic cylinders, lines and Maintain lines in good pressure valves. operating condition. Wear protective clothing while operating the plant. (gloves, hat) Compressed air The trailer air brake system is Maintain system in good comprised of air lines, tanks operating condition. Release and valves which activate the air pressure prior to repairing trailer brakes. the system. 4. Drum Mixer Noise Aggregate materiels Use of ear protection. discharged into the feed chute may cause steady noise levels exceeding 85 dba. page xvi

16 Operating machinery The drum is chain driven. Use of guards during operation. Operator should not wear loose fitting clothing. High voltage Power cables. Avoid contact when energized. electrical Maintain in good condition. Use cable supports provided. Do not perform repair work without a qualified electrician. Fluids under Diesel fuel lines, asphalt pump Maintain lines in good pressure and lines. Hydraulic cylinders, operating condition. Wear lines and valves. protective clothing while operating the plant. (gloves, hat) Compressed air The trailer air brake system is Maintain system in good comprised of air lines, tanks operating condition. Release and valves which activate the air pressure prior to repairing trailer brakes. the system. High temperature The burner creates Wear protective clothing while temperatures to 800 F. The operating the plant. (gloves, drum, asphalt aggregate mixtures being discharged and hat, work boots) exhaust gases will become hot (approximately 300 F). Fumes Asphalt hot mix is discharged Avoid inhaling fumes and from the drum mixer. operating equipment in a confined area. Flammable and The burner is a diesel fired Inspect and maintain burner combustible unit. Liquid asphalt. safety systems as per materiels manuals. Operate equipment with trained personnel. page xvii

17 Confined space Repairs to the drum mixer will Check drum for fumes prior to require work inside the drum. entry. Use a fan for fresh air circulation. Use motor control lock out device prior to entering the drum. Maintenance work may only be performed after proper safety procedures have been met. 5. Surge Bin Noise Intermittent noise levels Use of ear protection. exceeding 85 dba may be caused by: the drag slat conveyor elevating asphalt hot mix to the batcher; air compressor; exhausting air from air cylinders; and asphalt being discharged from the batcher to the bin or from the bin into trucks. Operating The air compressor is belt Use of guards during machinery driven. The drag slat operation. Operator should conveyor is a chain with steel not wear loose fitting clothing. attached to it. The chain runs on sprockets. The conveyor drive is chain driven. High voltage Power cables. Avoid contract when electrical energized. Maintain in good condition. Use cable supports provided. Do not perform repair work without a qualified electrician. page xviii

18 Fluids under Hydraulic cylinders, lines and Maintain lines in good pressure valves. operating condition. Wear protective clothing while operating the plant. (gloves, hat) Compressed air An air compressor is mounted Maintain system in good on this unit and provides air at operating condition. Release 125 psi to the gate cylinders. air pressure prior to repairing An air tank is part of the the system. compressor. The trailer air brake system is comprised of air lines, tanks and valves which activate the trailer brakes. High temperature Asphalt aggregate mixtures Wear protective clothing while being discharged and exhaust operating the plant. (gloves, gases will become hot (approximately F) hat) Fumes Asphalt hot mix is discharged Avoid inhaling fumes and from the slat conveyor. operating equipment in a confined area. 6. Baghouse Noise Steady noise levels exceeding Use of ear protection. 85 dba may be caused by: the air compressor, rotary exhaust fan and blower. Operating The air compressor is belt Use of guards during machinery driven. The exhaust fan is operation. Operator should belt driven. not wear loose fitting clothing. page xix

19 High voltage Power cables. electrical Avoid contact when energized. Maintain in good condition. Use cable supports provided. Do not perform repair work without a qualified electrician. Fluids under Hydraulic cylinders, lines and Maintain lines in good pressure valves. operating condition. Wear protective clothing while operating the plant. (gloves, hat) Compressed air An air compressor is mounted Maintain system in good on this unit and provides air at operating condition. Release 95 psi. An air tank is part of air pressure prior to repairing the compressor. The trailer air the system. brake system is comprised of air lines, tanks and valves which activate the trailer brakes. High temperature The air drawn from the drum Wear protective clothing while into the baghouse is operating the plant. (gloves, approximately 3000 F. hat) Fumes The air drawn from the drum Avoid inhaling fumes and mixer may contain diesel operating equipment in a and/or asphalt fumes. confined area. Confined space Restrict entry 7. Generator Trailer Noise Steady noise levels exceeding Use of ear protection. 85 dba may be caused by the generators. page xx

20 High voltage Produced by this equipment. Avoid contact when energized. electrical Maintain in good condition. Use cable supports provided. Do not perform repair work without a qualified electrician. Fluids under Diesel lines and coolant Maintain lines in good pressure hoses. operating condition. Wear protective clothing while operating the plant. (gloves, hat) Compressed air The trailer air brake system is Maintain system in good comprised of air lines, tanks operating condition. Release and valves which activate the air pressure prior to repairing trailer brakes. the system. High temperature Operation will generate heat. Wear protective clothing while operating the plant. (gloves, hat) Fumes Diesel exhaust may cause Avoid inhaling fumes and nausea or headaches. operating equipment in a confined area. Flammable and The generators are diesel Inspect and maintain combustible engine powered units. generators as per manuals. materiel 8. Dedrummer/Melter High temperature Hot oil is used to melt the Wear protective clothing while asphalt. operating the plant (gloves, hat). Operating A electric chain hoist is Use of guards during machinery operated to raise and position operation. Operator should drums. not wear loose fitting clothing. page xxi