Stepp SRM Operation, Maintenance And Parts Manual

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Page 1

Rev. 12/2014

OPERATIONS/MAINTENANCE/PARTS

MANUAL

Diesel Burner Systems

12325 River Road North Branch MN 55056 ~ Phone: 651-674-4491 ~ Fax: 651-674-4221

www.steppmfg.com

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Warranty

Stepp Manufacturing Company Inc. hereby warrants to the original purchaser that products manufactured by Stepp Mfg. will be free from defects in material and workmanship for a period of one (1) year from the date of purchase.

Stepp Mfg., at its discretion, will provide for the repair or replacement of any part found upon examination by Stepp Mfg. to be defective, except as noted below. Such repair or replacement will be free of charge to the original purchaser for a period of one (1) year from the date of purchase, except as noted below.

No warranty is extended to cover:

•Product pump wear or damage caused by foreign objects.

•Routine maintenance, cleaning, and adjustments.

•Parts/components that have been altered, misused, or improperly adjusted or maintained.

•Transportation to and from the place of warranty repair.

•Removal of material from equipment.

The following items are covered solely by their manufactures warranty:

•Engines

•Hydraulic components

•Burners

•Pumps

•Tires

•Other component parts

The following items are covered by a pro-rata warranty:

•Hoses that carry heated materials.

•Heating elements for hoses and wands.

Disclaimer of further warranty:

Stepp Mfg. makes no warranty, expressed or implied, other than this warranty. The implied warranties of merchantability and fitness for particular purpose are hereby disclaimed. Repair or replacement of products or parts proving to be defective in material or workmanship shall be the exclusive remedy for breach of this warranty. Stepp Mfg shall not be liable for incidental or consequential damages including but not limited to: damages for inconvenience, rental or purchase of replacement equipment, for loss of profits, loss of material, or other loss resulting from breach of this warranty. Stepp Mfg reserves the right to incorporate any changes in design into its products without obligation to make such changes on products previously manufactured.

Please see Warranty section for more details.

Stepp Manufacturing Co., Inc.

12325 River Road

North Branch, MN 55056

P: 651-674-4491 F: 651-674-4221

www.steppmfg.com

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INTRODUCTION

SRM Recycler

Thank you for selecting Stepp highway maintenance equipment. We are confident you will be satisfied with the Stepp Recycler Mixer. Stepp Manufacturing is backed by over 70 years of experience in the design and manufacture of highway maintenance equipment. This experience, along with our innovative design and unique features, make the Stepp Recycler Mixer an indispensable piece of equipment for your road repairs.

In order to assure safe operation of this equipment, the operator must read and understand all operating procedures and safety notices contained in this manual. In addition, the operator must receive instruction on how to safely operate the Stepp Recycler Mixer. Contact the manufacturer if any questions arise or if you desire training for additional staff members.

Operating instructions, adjustments, and periodic maintenance procedures are given so you, the operator, can keep your unit working like new and expect many years of dependable service from it. Remember, any machine, regardless of design or type, will perform only in relation to the way it is operated and the maintenance it receives.

Read this manual carefully and observe all warnings and cautions. If you have any recommendations or comments regarding this manual, please send them to: Stepp Manufacturing Co. Inc., 12325 River Road, North Branch MN 550566225 or call 651-674-4491. All comments we receive are reviewed and may be incorporated into future manuals.

When ordering parts or making any inquiry about the Stepp Recycler Mixer, be sure to include the model and serial number found on the data plate attached to the frame.

WARNING Do not use the equipment unless the operator has read and understood the oper-

ating and safety instructions and has received proper training. Do not operate equipment unless all guards and safety devices are in place and functional.

WARNING Do not exceed safe operating temperature of asphalt or bituminous material.

Know the "Flash Point" temperature of the material being used and DO NOT exceed this temperature. The recommended operating temperature information is available from the material manufacturer. Exceeding the recommended temperature may cause equipment damage and serious injury or death.

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Dimensions (approx.)

Length.………………………………………………………………...……...……234 in. Width…………………………………..………………...……………………..…...99 in. Height……………………………………………………………..…….Operating 116 in. Weight…………………………………………………..…………………...…..5,350 lbs.

General

Fuel Tank Capacity……………………..……………………………..……... 60 Gallons

Preheat Hopper

Capacity……………………………………………………………………….….10 cu.ft. Opening Dimensions…………………………………………………………. …23"x 38"

Loading Conveyor

Belt………………………………………………………...…………... 16" Wide Cleated Hydraulic Motor…………………….….4.0 cu.in. Hydraulic Motor w\ Forward-Reverse

Mixing Chamber

Chamber Type………………………………...………………..Continuous Batch Mixing Mixing Style…………………………………..……………………….. Rotating Pugmill Liner Type……………………………………………………..….U-shaped, Replaceable

Combustion Chamber Liner Material……….....Replaceable ¼" Wear Resistant AR Steel

Insulation Type and Thickness…………………...….. 2" Fiberglass & Cerwool, 2" thick Pugmill Drive, Hyd Motor……………..5.75:1 Gear Reduction Driven by 18/9 ci 2 speed

Pugmill:

Pugmill Dimensions…………………………………………..Length 57" x Diameter 27" Shaft Size……………………………………………………………………...2½" Square Paddle Size………………………………..………………….……... Replaceable 4" x 5" Paddle Material………………….. Reversible, Replaceable, ¼" Wear Resistant AR Steel

Number of Paddles………..………………………………………………………........24

Mixing Chamber Heating System

Burner Type …………………………………..……………... Indirect Diesel, Forced Air Number of Burners……………………………...………………………………...Two (2) Fuel Type…………………………………………...……………………………… Diesel Manufacturer………………………………………...…………………………..Beckett® BTU Output ……………………………...up to 420,000 BTU each - 840,000 BTU Total

CONTINUED ON NEXT PAGE

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Kettle Pumping System

Pump Model……………………………………………………………….Viking HL32® Relief Valve ………………………………………………………...…….…. WPC Valve GPM Output Rating……………………………………………………………….20 gpm Pump Mounting……………………….………………………………..……...Submerged Pump Drive……………….…..Hydraulic, Reversible, Variable Speed with PLC Display

Engine

Manufacture………………………………..………………………………...…. Kubota® Model…………………………………..……………………..……………….. V1505EB Displacement…………………………..……………………...…………….81 cubic inch Number of Cylinders…..…………………………………………………………...…..(4) Horse Power…………………………..………………..…………………………35.1 HP Fuel Type……………………………….……………..…………………………….Diesel Cooling………………………………...……………….…………………………..Liquid

Hydraulic System

System Type………………………………………...…..Eaton 7000 Series Load Sensing Pump Displacement…………………..…………………………...Variable 0 to 1.9 cu.in.

Control type ………………………………………....…..Forward/Reverse Flow Control,

Electric Over Manual Operated, Expandable Manifold Cartridge Valve

Hydraulically Powered Hopper Agitator, Hopper Loading Doors,

Sub. Pumping System, and Loading Conveyor Reservoir Capacity……..………………………………………...…………….30 Gallons Filtration………………………….………………………………...………….10 Microns

Chassis

Number of Axles………………………..………………………………..………..Two (2) Axle Capacity…………………………..…………………………………..6000 lbs. each Tire Size…………………………...………………………………………..….225/75R15 Brake Type…………………….……….…..…..Electric Std (Hyd Optional), all 4 wheels Landing Gear Static Capacity………….…………………………………..8,000 lbs each Screw jack Quantity……...……………...………………………………………...One (1)

Hitch Type……………....3" Pintle Ring or 2 5/16” Ball Type adjustable from 24" to 31"

Frame Material………………………..........................2"x 6"x 3/16” Rectangular Tubing

Lighting………………………...……………………...……Approved w/ Breakaway Kit Recessed Grommeted Lights……………………………………………………Standard

Page 6

TABLE OF CONTENTS

Introduction 3

Warnings, Cautions, Notes 7

Operations 9

Maintenance 27

Trouble Shooting 37

Replacement Parts 45

Warranty Guide 101

Schematics 107

Hydraulic Oil MSDS 111

Tire Information Insert

Engine Manual Insert

IMPORTANT NOTICE!

This manual contains cautions and warnings that alert you to potential safety issues.

WARNING is used to inform you of conditions or operations that could cause serious injury or death.

CAUTION is used to inform you of conditions or operations that could cause damage to the equipment.

NOTE is used to provide you with additional information that may be helpful or useful for a particular situation.

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Before Starting or Operating this Machine

Understand and observe all the following Warnings, Cautions, and Notes.

WARNINGS

 This equipment contains mechanical and heating components that may cause serious injury or death if not

handled or maintained properly. All personnel must be properly trained in the operation and maintenance of this equipment.

 Before refueling, shut off the burners and allow all flames in the burner and pilot light to extinguish. Shut off

the engine.

 Check fuel lines, fuel line connections, and all other components for leaks. If any leaks are found, they must

be repaired before using the unit.

 Know the temperature required for the material being used, and do not exceed this temperature. Avoid over

heating, as this may cause equipment damage, personal injury, and/or death.

 Never load a tank with heated oil when moisture is present in the tank. Depending on the temperature of the

hot oil, the moisture may instantly boil causing hot oil to foam up and out of the tank causing severe burns.

 Do not operate the tack tank burner when the amount of material in the tank is less than 4" above the flues.

Allow 10 minutes cool-down time after the burner has been shut off before exposing the flues. Exposed flues will over-heat and cause an explosion and/or fire.

 The tack tank cover must be unlatched when operating the tack tank burner. This is to provide for emergen-

cy venting, in the event of a flash, to prevent the tank from exploding.

CAUTIONS

 Know the materials being used and know the proper handling, heating, application, clean-up, and storage

procedures. Not all materials are compatible with each other. Many materials have a very limited shelf life. Most materials require special handling procedures to prevent personal injury and/or equipment damage. Contact your material supplier and/or manufacturer for proper handling instructions. Equipment malfunction or damage due to improper handling or use of the materials is not covered by warranty.

 Do not exceed the maximum heating temperature or storage time as recommended by the material manu-

facturer. This may cause emulsion type materials to separate and become difficult or impossible to remove from the machine. Consult with the material manufacturer for recommendations.

 Over-agitation or circulation may cause emulsion type materials to separate and become difficult or impossi-

ble to remove from the machine. Consult with the material manufacturer for recommendations.

 Do not mix Anionic and Cationic materials together, as the materials attach to each other and will become

difficult or impossible to remove from the machine. If you are not sure consult your material supplier.

NOTES

 Become familiar with the Material Safety Data Sheet (MSDS) for the material being used in the machine and

take appropriate safety precautions. Wear the proper clothing and protective gear as recommended by the MSDS and your safety director.

 DO NOT use the equipment unless it is in good condition.

 In case of skin contact with hot materials, dip into cool, clean water immediately. Do not wipe the product,

as this will spread the burn.

 Consult the MSDS and contact your safety director for proper extinguishing of petroleum based fires.

 Carry a fire extinguisher(s) as recommended by your safety director.

 Notify your supervisor or the manufacturer if any questions arise concerning the operation of this equipment.

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Page 9

OPERATIONS

Page 10

OPERATIONS Basic Operation

WARNING: Before refueling, shut off the burners and the engine.

CAUTION: Be sure operators have been properly instructed in starting and op-

erating all equipment before beginning.

NOTE: See following pages for specific instructions on operating burners and

heating systems.

Pre-Trip Inspection

1. Check engine fluid levels & grease machine.

2. Check tire pressure.

3. Start conveyor check for wear & tracking.

4. Inspect unit for any physical damage.

5. Check pugmill for broken paddles and excessive wear.

6. Check that discharge door is operating properly.

7. Truck hook-up and lights .

Transporting

Trailer Hook-up

1. Connect trailer to towing vehicle a. Assure hitch is engaged properly. b. Attach safety chains to towing vehicle. c. Connect battery charging circuit to tow vehicle if required. (see illustration below) d. Connect electrical plug to towing vehicle. e. Connect breakaway cable to towing vehicle. f. Check operation of lights and brakes.

2. Secure trailer for transport a. Shut OFF the engine and burners. b. Shut OFF all fuel valves. c. Be sure the product temperature is not above the recommended operating temperature. d. Securely latch the tank cover.

WARNING: Prior to transporting, the driver of the tow vehicle must assure the

safety of the operation. The driver must also know, and assure, that the product temperature is within limits.

Page 11

OPERATIONS Basic Operation

1. Start engine (refer to engine operations).

2. Turn on control box power switch.

3. Load bituminous/asphalt material into kettle using the safety loading chute. Make sure no moisture is present in tank. Be sure to wear proper protective clothing. Flues must be completely covered with 4” or more of material to prevent equipment damage or personal injury. Turn burner-oil switch on. The red indicator light on the switch will turn green. Set tack oil SP (set point) thermostat to desired temperature using the up and down buttons on the controller. The tack oil thermostat will display the actual temperature (top reading) and SP (set point), or desired, temperature. Depending on the asphalt materials being used, set temperature to a lower setting to allow temperature to “creep” for initial heat up.

4. When material is hot enough to flow, set valves for circulation and engage product pump in "Pump" position (refer to pumping operations chart located on the rear of the pugmill). Start the loading conveyor.

5. Fill preheat hopper with recyclable asphalt material to a level even with the top edge. Piec- es must be small enough to pass through the trap doors. The equipment will provide better performance with smaller pieces. Start conveyor and load hopper with material. NOTE: Check hopper doors. Doors must be closed prior to loading.

6. Start pugmill burners, front and rear. Switch will turn green when on. CAUTION: Do not

use recycler timer for initial pugmill warm up. This could cause residue in hopper to catch fire. If hopper catches fire, dispense load of material into hopper to smother fire, turn the burners off, and allow the machine to cool down before re-firing. Burners will shut off at set point temperature (250°). Over heating may cause pugmill damage.

7. Start pugmill mix paddles (2). NOTE: Make sure pugmill paddles are moving freely in both directions, forward and reverse positions.

8. Engage pugmill mix. Empty contents of the preheat hopper into the recycler mixing cham- ber using the hydraulic operated trap doors using the door open switch.

9. Set the recycler burner timer for desired heating time by using the up and down buttons next to the timer. The amount of mixing time and heat necessary will be determined through experience. Moisture and material quality varies and will vary the timer setting.

10. Set batch time. NOTE: Set initial batch time for 10 minutes. Normal batch times may vary

from anywhere between 8-16 minutes, with the first batch of the day taking longer due to heating the machine up. Press the “Cycle Start” button to start the batch timer and activate

the burners to the pugmill set point. If more time is needed, adjust time accordingly. Operator will need to dispense a small amount of material to test the temperature with a hand held infrared scanner. Burners will fire to the high level set point until additional time has elapsed. When burners are firing, watch the top stack for moisture dissipating. Batch will be very close to temperature once the steam has stopped and you are getting a clean exhaust. If exhaust starts to smoke or turn blue, the material is overheated or very close to being overheated. If blue smoke is present turn burner switches off and discharge material. CAUTION: Discharge material at 320-350°. If material is at temperature before time is

done, shut off the burner.

11. Adjust the damper on the exhaust stack according to heating needs. Closing the damper will retain more heat in the recycler’s mixing chamber. Opening the damper will allow raw aggregate to dry quicker.

Page 12

OPERATIONS Basic Operation

12. If necessary, add heated bituminous binding material to the recycler mixing chamber (refer to the plumbing operations chart). Here again, experience is the best indicator of how much to add. Start with 1/2-11/2 gallons of oil. Know the material being added and the flash point. We recommend that you use an AC type oil and add the oil in the first three minutes of the batch timer. The pump has an oil counter so you can meter the amount of material added. With the pump running in the “forward” position, move valve #2 to the “Mixer” position. The pump will run until the preset amount is reached. At that point, the pump will stop and the attention light will flash until valve #3 is returned to “Recirculate” position.

13. Reload preheat hopper while you wait for the mixing action to be completed. This will al- low for the next batch to be preheated, resulting in faster batch times.

14. Set the toggle switch to discharge in order to empty the mixed material onto the shovel platform for easy shoveling. Swinging the shovel platform up out of the way will allow the mixed material to empty directly on the ground. The switch has two settings: green for slow discharge, yellow for higher speed discharge. To engage high speed, press discharge twice.

15. Reload the next batch. Press “Cycle Start” button in order to start the next batch.

16. To shut down the machine shut off all burner switches. Empty the recycler mixing cham- ber.

WARNING: All flames (burners and pilot lights) must be extinguished before flushing opera-

tions begin to reduce the chance of fire and/or personal injury.

17. Flush the pump, wand, and plumbing to prevent a plugged system (refer to the plumbing operations chart). NOTE: Running a load of coarse rock through the unit will help remove

asphalt deposits.

18. Shut off the engine.

NOTES:

 Operator must have infrared heat gun to operate machine.

 Check “Set Points” on control panel.

 Never have burners on without material in pugmill, unless you are doing start up.

 Check material temperature at 8 minutes. Material temperatures will climb quickly once

moisture is out of material. Check every minute or two after that.

 Normal batch times vary from 6-18 minutes depending on moisture and material quality.

 Initial batch could take 2x’s longer, due to initial heat up of machine.

 1/2-1 1/2 gallons of oil additive is average for material.

 Allow cooling at end of the day. (Open hopper doors and run pugmill for 10 minutes in dis-

charge.)

Page 13

OPERATIONS Material Tips

Helpful Tips to Making Quality Recycled Materials

1. Have your millings tested for asphalt content. This will help you decide how much ad-

ditive you need. The average ton of asphalt top mix has 5-7% oil by weight. This translates into 100-125 pounds of asphalt added to virgin aggregate to make top mix. PG grade asphalts are approximately 7.5 pounds per gallon. So if you convert that to gallons there is approx. 13.3 gallons of asphalt in 100 pounds to make 1 ton of mix. 100/7.5= 13.3333. Most millings need 1/2-1% of new oil to give you a quality patch material. The SRM makes approximately a 1000 pound batch, so on average you need to add 1/2 gallon to 1 1/2 gallon or 3.75 pounds to 11.25 pounds of asphalt additive to make a quality mix.

2. Recycled materials have huge variables. Different asphalt contents, different moisture

contents, different aggregates, base material containments, and different size aggregates will all vary the batch times and material quality. Making your first batches in your SRM will take some experimenting. You will need to find the right recipe. Start with shorter batch times and check your material often on the first batch or two. Start with a little oil and add more as you need it. Once you come up with your recipe for the materials that you are using you should see consistent results. The next batches will be very similar and you should only have to make minor adjustments.

3. Keep materials dry. Moisture content is the number one cause for slow batch times. If

you can, keep your millings inside or covered. It takes more BTU to dissipate a gallon of water than it does to melt a gallon of asphalt. Moisture acts as a refractory in the material and can not be dispersed until turned to a gas (steam). High moisture content can double or triple batch times, so having dry millings is key to higher production.

4. Quality of materials. Using quality materials also aids in faster batch times. Materials

with large aggregates take longer to drive the heat into the stone. Contaminated materials with base also take longer to heat because of lack of oil in the materials. Materials with higher asphalt contents also heat up faster. The SRM does not care, it just may affect the heat up times.

5. The SRM is capable of making materials from virgin aggregates. You can make virgin

materials with the SRM, you just need more oil. Using the reference above, in #1, you can make your own custom mixes. Sand mixes, fine mixes, and mixes from virgin materials. Again, you will need to do some experimenting to get the right mix design. If making virgin mix, use the 5-7% to get you started (5-7gallons). Always start with a smaller amount of oil; you can always add more oil, but you can’t take it away. Different oils will also give you different results in materials.

6. Pre-made cold mix materials. You can use your SRM to warm your cold mix materials.

Use extreme caution when doing so. Most cold patch materials have a high content of cutter (solvent) in the oil. This makes the material soft and pliable, but also makes them very easy to catch on fire. If you are using the SRM to heat cold patch material, only fire the burner in 1-2 minute cycles and check the temperature very often to prevent the material from flashing.

Page 14

OPERATIONS Kettle Heating System

WARNING: The burners must be shut off when the product reaches a level approximately 4"

above the flues. Exposed flues will overheat causing an explosion in the tank. This will cause equipment damage and possible injury or death to personnel.

Before Igniting the Burner:

1. Know the materials being used. DO NOT exceed flash point or operating range tempera- tures.

2. Ensure the kettle is level and the heating flues are completely immersed in product to pre- vent damage to equipment or personal injury.

3. The kettle cover must be unlatched to provide emergency venting in event of a flash.

4. Vent the kettle by opening the cover for five minutes prior to firing.

5. Load bituminous/asphalt material into kettle using the safety loading chute. CAUTION:

Make sure that no moisture is present in tank and make sure to wear proper protective clothing. Turn “burner-oil” switch on. When material is hot enough to flow, set valves for

circulation and engage product pump in "Pump" position (refer to pumping operations chart located on the rear of the pugmill).

WARNING: Failure to observe these instructions may cause damage to the equipment, per-

sonnel injury, or death.

Igniting the Burner:

1. Verify heating flues are completely covered with a minimum 4" of product.

2. Verify proper heating temperature, and set the SP (set point) thermostat to that tempera- ture.

3. Turn oil burner power switch ON and burner will ignite; a small flame indicator will appear. The red indicator light on the switch will turn green. Set “tack oil SP” (set point) thermostat to desired temperature using the up and down buttons on the controller. Tack oil thermostat will display actual temperature (top reading) and SP (set point), or desired, temperature. Depending on asphalt materials used, set temperature to a lower setting to allow temperature to “creep” for initial heat up.

4. Monitor product level in kettle and shut burner OFF when oil level is 4" above heating flues.

NOTE: If the "Lockout" message appears on the screen, it indicates a malfunction of the

burner. Verify fuel supply to the burner (proper fuel and no air bubbles in system) then reset the burner by setting power switch OFF then ON. If problem persists, consult a service technician. DO NOT reset burner more than two times, as excess fuel may accumulate in combustion chamber creating a fire hazard.

Shutting off the Burner:

1. Set thermostat to the lowest setting and allow a one minute cooling period.

2. Turn OFF burner oil switch on the control box.

3. Close and latch kettle cover.

4. Turn main power switch OFF.

Page 15

OPERATIONS Mixing Chamber Heating System

WARNING: It is the operators responsibility to set the proper temperature on the thermostats

as required for the operation.

Before Igniting the Burner:

1. Know the materials being used. DO NOT exceed flash point or operating range tempera- tures.

Igniting the Burner:

1. The SRM recycler chamber has two set point temperatures. One “higher firing” set point for heating up the mix, and one “stand-by” temperature setting that keeps the liner and materials at a given temperature. Pressing the “Cycle Start” button changes the max set point to the “higher firing” set point. These set points are set at 750°F for the “higher firing” set point, and 250°F for the “stand-by” set point. Both of these are adjustable from the setup screen, which is accessed by pressing the ADJUST MILL SET POINT button located on the upper right hand of the display. The temperatures displayed on the screen are the temperature readings of the pugmil liner, not the material temperature.

2. Turn ON front, rear, or both recycler burner power switch(s) as desired and burner(s) will ignite and a flame indicator will appear next to the front or rear on the recycler chamber display. The burner will fire until the standby temperature is reached. The switch will turn green when on. CAUTION: Do not use recycler timer for initial pugmill warm up. This

could cause residue in hopper to catch fire. If hopper catches fire, dispense load of material into hopper to smother fire, turn the burners off, and allow the machine to cool down before re-firing. Burner’s will shut off at set point temperature (250°). Over-

heating may cause pugmill damage.

3. Set batch time. NOTE: Set initial batch time for 10 minutes. Normal batch times may vary from anywhere between 8-16 minutes, with the first batch of the day taking longer due to heating the machine up. Press the “Cycle Start” button to start the batch timer and activate

done, shut off the burner.

NOTE: If the "Lockout" message appears on the screen, it indicates a malfunction of the

burner. Verify fuel supply to the burner (proper fuel and no air bubbles in system) then reset the burner by setting power switch OFF then ON. If problem persists consult a service technician. Do not reset burner more than 2 times as excess fuel may accumulate in combustion chamber creating a fire hazard.

Shutting off the Burner:

1. Turn OFF power switch(s) on the control box.

Page 16

OPERATIONS PLC Controller

Tack Oil: Shows SP (set point) and actual temperature of oil kettle.

Tack Oil SP (set point) Temperature Adjustment

Oil Pumped SP (set point) Gallon Adjustment

Meter Reset: Resets the oil pumped to zero

Valve Position: Refers to #3 recirc/mixer valve located above control box.

Recycler Chamber: Shows temperature of the recycler/mixing chamber. Does not show indicated material temperature.

Cycle Start: Resets the batch timer.

Burner Timer Adjustment: Top display batch time will not restart without pressing the cycle start button.

Oil Pumped: Displays actual gallons pumped and SP (set point), or desired, gallons pumped. 1/10 gallon increments.

Burner Timer: Top display batch time will not restart without pressing the cycle start button

All PLC Switching are latching switches. Press once to turn on and press second time to turn off. When switch is activated it will turn from red to green.

Conveyor Forward/ Reverse

Top Door Open/Close: Opens trap door

Oil Pump Forward

Burner ConPugmill Mix: Press once for activating mixer. Indicator will turn green when on.

trols: Turns

on oil burn-

er, front and

rear pugmill

burners.

Pugmill Discharge: Press once for discharge and twice for high speed

Oil Pump Reverse

Compactor Plate Carrier up/down

Optional Equipment

discharge.

Page 17

OPERATIONS Engine Starting

WARNING: Be sure all pre-start checks are complete prior to starting engine.

The SRM is equipped with a digital engine management system. This system will shut the engine down in case of an engine overheat or low oil pressure. It is also equipped with an hour meter, cold weather glow plug button, and a starting button.

1. Fill fuel tank.

2. Turn “Key Switch” clockwise to the “Start” position.

3. Press and hold Yellow glow plug button for 30-90 seconds.

4. Press Green button to start.

5. If engine does not start on first try, you must turn the “Key Switch” OFF and restart the starting sequence.

6. To shut engine down turn “Key Switch” counterclockwise.

NOTE: If engine will not turn over, check the emergency shutdown button located on the op-

erators control box.

Page 18

OPERATIONS Pumping System

WARNING:

DO NOT allow flushing solvent to enter hot oil tank or mixer. DO NOT allow the hot oil tank burner to operate with the product level less than 2 inches above the flues. Severe damage to equipment and possible serious injury will result! DO NOT flush through a heated wand.

Page 19

OPERATIONS Pumping System

Page 20

OPERATIONS WPC Valve

Hand Wand

Wand Pressure Control Valve (WPC Valve)

Operators must understand the proper operation of the WPC valve located on the top rear of the unit. The purpose of this valve is to direct the flow of product either back to the tank (during start-up to assist melting) or to the wand (during crack filling or pothole spraying operations).

Because of the properties of asphalt, no automatic relief valve is installed in the system. Therefore, the operator must adjust the WPC valve to a position midway between the valve stops. This will allow product to flow to the wand and also back to the tank at the same time, preventing excessive pressure from building up in the hose and wand.

Positioning of the WPC valve towards "Recirculate" will cause less flow and less pressure to the wand. Positioning of the WPC valve towards "Wand" will cause more flow and more pressure to the wand.

The WPC valve should never be positioned fully to the “Wand” position, unless the wand control valve located on the wand is fully open, or for flushing operations to ensure that flush solvent will not enter the tank. Excess flow and pressure to the wand may cause damage to the hose and system, and possibly result in personal injury.

Observing unusual flexing in the wand hose should alert the operator that excess pressure is being applied to the wand hose. Considering factors such as temperature of product, desired amount of flow and varied operating conditions will assist the operator in selecting the proper position of the WPC valve. The WPC valve must be left in the “Recirculate” position when the unit is shut down.

CAUTION: The WPC valve should never be positioned fully to the “Wand” position, unless the

wand control valve located on the wand is fully open, or for flushing operations to ensure that flush solvent will not enter the tank. Excess flow and pressure to the wand may cause damage to the hose and system, and possibly result in personal injury.

Page 21

OPERATIONS Heated Hose

Heated Hose & Wand (optional)

The application hose and wand are equipped with internal heating elements. The elements are powered by the 24 volt alternator run by the engine. This heating element prevents the product from freezing in the hose and wand. The electric wand heat control should be turned on 20 to 30 minutes before trying to pump material through the hose and wand. This will allow time for the material to re-liquefy in the hose.

It is recommended that you circulate the product back to the tank through the wand circulating flange provided in the hood. This is to assure proper flow and temperature of the material going though the wand. Depending upon the volume of the material going through the wand and the outside temperature, it may not be necessary to run the heated wand all the time. Once flow is established through the wand and circulating back to tank, it is recommended that the electric heating element be used only as required to maintain flow. This will help to extend the life of the heating elements. If the flow is not adequate to maintain temperature in the hose and wand, freeze up may occur. If this happens, simply turn the electric heating element on, and allow time for the material to re-melt. No clean up is required with the electric wand; just shut the machine off as the product can be re-melted by activating the Wand Heat Control. No additional flushing is required.

CAUTION: Do not activate the Electric Wand Heat unless the hose and wand have product in

them. Absence of product will cause the element to overheat and destroy the hose, possibly causing serious injury.

Overnight Heater (optional)

This feature will decrease start up time by maintaining the product from 150° to 200° F, depending on ambient temperature. The system consists of a heating element submerged in the product. Set the thermostat to the desired temperature and plug the heater in. The heater requires 110V, 15 AMP service. The extension cord used must be the outdoor heavy duty type, grounded, and rated for 1500 watt service.

CAUTION: If overnight heaters are used, make sure to vent the kettle by opening the cover

for five minutes before firing the diesel burner. Failure to do so may result in a FLASH of the asphalt vapors.

NOTE: The heater is screwed into the rear of the kettle. To install a heater, or to replace A

heater, follow these steps:

1. Be sure all the asphalt product is drained from the tank. The tank may need to be heated and then drained if it contains frozen asphalt.

2. When the unit has cooled to ambient temperature remove the heater and replace with the new heater.

3. Replace cord if needed.

Page 22

OPERATIONS Wand

Application with Twist-Valve Wand

1. Position the WPC valve midway between the wand and recirculate position.

2. Close the wand flow control valve (located on the wand handle) and remove wand from the recirculating flange.

3. Set product pump to "Pump" position, then open the wand flow control valve to apply prod- uct to the road surface.

4. Adjust the WPC valve as necessary, being careful not to over pressurize the wand and hose assembly.

5. Monitor the level in the tank and add product as necessary.

Page 23

OPERATIONS Pumping System

WARNING: The Stepp SRM requires special shut down procedures that must be followed to

maximize safety and equipment performance. The procedures will assure that the hose and wand always have product in them to avoid an over-heated element. (Do Not suck the product back out of the wand and hose assembly) No hose cleanup is necessary as the product in the hose is re-melted at the next start up with the wand and hose heating element.

Standard Shutdown Procedures for Units With Heated Hose

1. Turn OFF the wand heat control switch.

2. Move the WPC valve to the "Recirculate" position.

3. Turn oil pump switch to reverse position for two minutes, then turn oil pump switch to off. This will draw the product out of the pump, plumbing, and WPC valve.

4. Reduce engine RPM and allow to run at idle for a minimum of two minutes.

5. Shut OFF the engine.

6. Securely latch all covers.

CAUTION: Do not reverse the pump with the WPC valve in the "Wand" position as this would

suck the product out of the wand and hose assembly. The hose and wand must contain product to absorb the heat from the heating elements to avoid equipment damage. Only reverse the pump when the WPC valve is in the "Re-circulate" position. No hose cleanup is necessary with this system.

Page 24

OPERATIONS Pumping System

Standard Shut Down Procedures for Units With Non-Heated Hose

WARNING: The Stepp SRM requires special shut down procedures that must be followed to

maximize safety and equipment performance.

CAUTION: Set pump to OFF or neutral before adjusting valves.

1. Turn oil pump switch to OFF position. Red indicator light will come on.

2. Move the WPC valve to the "Wand" position and open the wand handle.

3. Turn oil pump switch to reverse position for two minutes, then turn oil pump switch to OFF. This will draw the product out of the pump, wand, plumbing, and WPC valve.

4. Set valves to flush system according to the pump chart.

5. Set WPC valve to “Full Wand” position. Failure to set this in “Full Wand” position will allow flushing solvent to enter the product tank. Insert wand into the recirculating flush tank to recover flush solvent. Turn oil pump switch to “Pump/Forward” position and flush the plumbing thoroughly for 2-3 minutes.

6. Turn oil pump switch to “Neutral/Off” position.

7. Move the WPC valve to the "Wand" position and open the wand handle.

8. Turn oil pump switch to “Reverse” position for two minutes, then turn oil pump switch to OFF. This will draw the product out of the pump, wand, plumbing, and WPC valve. This will return the flush solvent to the flush tank. Operators may choose to leave the flushing solvent in the lines overnight to assure that the lines are clean. Operator must follow the suck back flush solvent before changing valves to spray asphalt or you may contaminate the product tank with flushing solvent.

9. Reduce engine RPM and allow to run at idle for a minimum of two minutes.

10. Shut OFF the engine.

11. Securely latch all covers.

NOTE: All plumbing operations that were used must be flushed or lines will be frozen with as-

phalt. Refer to the pump operations chart.

Page 25

OPERATIONS Helpful Hints

1. It is recommended that the product be drawn down to 1/4 capacity or less prior to shutdown. This will decrease the start up time the next time the machine is used. How-

ever if you are certain the equipment will be used the next day (no chance of rain, etc.), leave the unit about ½ to ¾ full, then plug in the optional overnight heaters. This will help retain heat for a faster start up the following day.

2. Do not heat or reheat any product for a length of time more than that recommended by the product manufacture. This is typically 16 hours or two heating cycles. Check with your product manufacture for recommendations specific to your material.

3. The valve at the end of the wand is not heated by the heating element. Although heat transfer from the wand will normally be enough, by inserting the wand into the recirculating flange, additional heat from the kettle will aid in heating the valve.

4. Overnight heating elements normally should not be used for more than 48 hours. Check the product manufacturers recommendations for the material’s maximum "pot life". The overnight heater will maintain approximately 200º F after temperatures have stabilized.

5. If the engine quits for any reason, move the WPC valve to the recirculate position, then attempt to resolve the problem and restart the engine as soon as possible. The proper shut down procedures must be followed before the product hardens in the exterior plumbing. If the product hardens in exterior plumbing, use heat to re-liquefy the product to re-establish flow.

6. Avoid excessive pulling, bending, and twisting of the wand hose. This may cause the service life of the hose and heating elements to be greatly reduced.

Page 26

Page 27

MAINTENANCE

Page 28

MAINTENANCE Product Pump

The pump used for hot oil pumping is a gear type pump.

Fig. 1

Shaft rotation will determine which port is suction and which is discharge. A look at the Fig.1 will show how the fluid will flow through the pump. As the gears come out of mesh (A), liquid is drawn into the suction port. As the gears come into mesh (B), the liquid is forced out the discharge port. Reversing the rotation reverses the flow through the pump.

NOTE: An easy way to determine which port is suction or dis-

charge is to note the shaft rotation and remember that the fluid takes the "long way" around the pump to get from the suction port to the discharge port.

NOTE: The idler pin, which is offset on the pump head, should be positioned toward, and an

equal distance, between the suction and discharge ports.

End Clearance Adjustment

The head to rotor clearances (B, in Fig.1) should be checked every 100 hours of operation or when pump performance decreases noticeably. If adjustment is necessary the pump will need to be disassembled.

1. Measure end clearance by moving pump shaft in and out, clearance should be .005" to .007"

2. Clearances are adjusted by adding or removing head gaskets (C) of various thicknesses.

NOTE: Be careful not to adjust clearances too tight as the pump may "bind" at high operating

temperatures due to expansion.

Packing Adjustment

The pump shaft packing should be adjusted after the first 50 hours of operation, then every 100 hours or when leakage increases noticeably. Note: A "small" amount of leakage is required to lubricate the packing. The pump DOES NOT need to be disassembled for this adjustment.

1. Tighten the 2 packing gland nuts (A) equally, 1/4 turn at a time, to decrease excess leak age.

NOTE: A small amount of leakage is required to lubricate the packing.

Fig. 2

Page 29

MAINTENANCE Hot Asphalt Hose Replacement

CAUTION: Do not remove hose without first removing the heating element or damage to

heating element will result.

Hose Removal:

1. Remove heating element from hose (refer to heating element removal procedures).

2. Disconnect all electrical connections from hose.

3. Separate the hose from the wand at the quick coupling.

4. Remove the quick coupling from the hose and save for reuse on the new hose.

5. Unscrew the hose from the cross fitting at the end of the boom assembly.

6. Gently pull the hose off the unit, being careful not to damage the heating element.

Hose Installation:

1. Screw the hose fitting into the cross fitting at the end of the boom assembly and tighten securely.

2. Screw the quick coupling to the other end of the hose and tighten securely.

3. Reconnect all electrical connections to hose.

4. Reinstall heating element into hose, but do not reconnect electrical connector at this time.

NOTE: The heating element will protrude about 10" from the end of the hose.

5. Gently heat the end of the wand with a propane torch. This will soften the material in the wand for easy insertion of the protruding hose heating element (see next step).

6. Connect the hose to the wand at the quick coupling. Use gentle pressure to insert the pro- truding hose heating element into the wand. CAUTION: Do not apply power to the hose

heating element in an empty hose or damage to the hose will result.

7. Bring material in tank up to operating temperature (refer to operating instructions).

8. Verify hose heating element is disconnected.

9. Activate wand and boom heat for 20 minutes.

10. Pump material through wand until flowing freely (refer to operating instructions).

11. Stop pump. Connect hose heating element connector. The hose is now full of material and the unit can be returned to service.

Page 30

MAINTENANCE Hose Heating Element Replacement

(Functioning Element)

Hose Heating Element Removal:

These instructions assume the heating element is functioning properly. If the heating element does not function, refer to the instructions on the following pages.

NOTE: If the hose is damaged, skip steps 1 through 3, activate wand heat for 15 minutes,

then begin at step 4.

1. Start the engine and the burner and allow the product to reach operating temperature. Activate wand heat switch. Begin circulation of material through the wand into the recirculating flange when temperatures permit. When product is circulating freely proceed to step two.

2. Turn OFF the electric wand heat. Then with wand valve open, and the wand pressure con- trol valve in the "Wand" position, reverse the pump for two minutes to clear the hose, wand, and boom of material.

3. Shut OFF the burner and the engine.

4. Disconnect the hose heating element connector at the end of the boom.

NOTE: The following steps must be accomplished with all components warm.

5. Remove the compression fitting that holds the hose heating element at the top of the cross

fitting on the end of the boom.

6. Gently pull the heating element from the cross fitting and the hose.

WARNING: The heating element will be HOT, wear protective clothing, leather welding

gloves, and safety gear.

CAUTION: Do not pull on the wires to remove the heating element or damage to the element

may result.

Page 31

MAINTENANCE Hose Heating Element Replacement

(Functioning Element)

Hose Heating Element Installation:

1. Remove wand from hose at quick coupling.

2. Lay the hose out as straight as possible.

3. Install new compression fitting into cross fitting.

NOTE: If hose DOES NOT contain material proceed with step 4. If hose CONTAINS material,

replace step 4 with steps A & B listed below.

4. Insert heating element into compression fitting and hose. About 10" of the heating ele- ment will protrude out the other end of the hose. Tighten compression fitting.

5. Insert protruding element into wand and reattach wand to hose at quick coupling. (Gently heat wand with propane torch to ease installation if needed.)

6. Reconnect all electrical connections.

CAUTION: Do not apply power the hose heating element in an empty hose or damage to the

hose will result.

7. Bring material in tank up to operating temperature. (refer to operating instructions) and ac- tivate wand heat.

8. Pump material through wand until flowing freely. (refer to operating instructions) The hose is now full of material and the unit can be returned to service.

Steps A & B

A. Connect one lead of the heating element to the large terminal of the 24V alternator, and

the other lead to a good chassis ground. Use 10 gage (minimum) jumper wires.

B. Start the engine, as the heating element heats, insert it into the hose. Start and stop the

engine, or disconnect the jumper wires, as needed to regulate the heat of the element. Use only enough heat to soften the material and allow the element to be pushed into the hose. (About 10" of the heating element will protrude out the other end of the hose) Tighten compression fitting.

Proceed to step 5 above.

WARNING: The heating element will be HOT; wear protective clothing, leather welding

gloves, and safety gear.

Page 32

MAINTENANCE Hose Heating Element Replacement

(Non-Functioning Element)

Hose Heating Element Removal and Installation:

These instructions assume the heating element is damaged and NOT functioning. If the heating element functions properly, refer to the instructions on the previous page. The element may be damaged during removal, rendering it useless.

A functioning hose heating element is slid into the hose alongside the non-functioning element. As the material in the hose is heated with the new element, the old element can be pulled from the hose.

1. Remove wand from hose at quick coupling. About 10" of the hose heating element pro- trudes out of the hose and into the wand. Gently heat wand with propane torch to ease separation if needed.

2. Disconnect the hose heating element connector at the end of the boom.

3. Remove the compression fitting nut that holds the hose heating element at the top of the cross fitting on the end of the boom. Then, remove the complete compression fitting.

4. Pull the element out and to the side far enough to allow a new element to be slid in along- side the old element.

5. Connect one lead of the new element to the large terminal of the 24V alternator, and the other lead to a good chassis ground. Use 10 gage (minimum) jumper wires.

6. Start the engine, as the heating element heats, insert it into the hose along side the old element. Start and stop the engine, or disconnect the jumper wires, as needed to regulate the heat of the element. Use only enough heat to soften the material and allow the element to be pushed into the hose.

7. Pull the old heating element from the cross fitting and the hose.

8. Secure new heating element in compression fitting, then reconnect electrical connector.

9. Insert protruding hose element into wand and reattach wand to hose at quick coupling. (Gently heat wand with propane torch to ease installation if needed.)

WARNING: The heating element will be HOT, wear protective clothing, leather welding

gloves, and safety gear.

Page 33

MAINTENANCE Wand & Boom Heating

Element Replacement

Wand or Boom Heating Element Removal and Installation:

These instructions assume the heating element is damaged and not functioning. The element may be damaged during removal rendering it useless.

A functioning heating element is slid into the wand or boom along side the non-functioning element. As the material is heated with the new element, the old element can be pulled from the wand or boom.

1. Remove wand from hose at quick coupling. About 10" of the hose heating element pro- trudes out the hose and into the wand. Gently heat wand with propane torch to ease separation if needed.

2. Remove the compression fitting nut that holds the heating element in the wand or boom, then remove the complete compression fitting.

3. Pull the element out and to the side far enough to allow a new element to be slid in along side the old element.

4. Connect one lead of the new element to the large terminal of the 24V alternator, and the other lead to a good chassis ground. Use 10 gage (minimum) jumper wires.

5. Start the engine, as the heating element heats, insert it along side the old element. Start and stop the engine, or disconnect the jumper wires, as needed to regulate the heat of the element. Use only enough heat to soften the material and allow the element to be pushed into the wand or boom.

6. Pull the old heating element from the wand or boom.

7. Secure new heating element in compression fitting, then reconnect electrical connector.

WARNING: The heating element will be HOT, wear protective clothing, leather welding

gloves, and safety gear.

NOTE: An alternate method is to remove all insulation from the wand or boom., then heat as

needed with a torch to soften the material allowing removal and installation of the heating element.

Page 34

MAINTENANCE Pugmill Mixer

The SRM has many high torque moving parts. As a weekly inspection, we suggest that the operators check for loose fittings and loose bolts. Outlined below are some that need to be checked periodically due to the torque and vibration that the unit incurs.

1. Check for tightness of the motor and gear box assembly (#1). Because of the torque re- quired to mix the materials, this needs to be checked weekly.

2. Check grease bearing daily (#2). There is a bearing on each end of the pugmill and on each end of the conveyor.

3. Check top discharge door for proper operation (#3).

4. Visually inspect pugmill mixer blades for proper clearance and wear (#4).

Page 35

MAINTENANCE Conveyor

The conveyor needs to be inspected daily for wear, and to make sure that the belt is tracking properly. As the belts are used, they will stretch, requiring tightening.

1. Check grease bearings daily (#1).

2. Check belt tension and tracking (#2). To adjust tracking, you must first loosen the 4 nuts on the bearing. Do not loosen too much, you need a little tension on the nuts. Loosen the jam nut on the tension bolt and tighten or loosen the bolt tensioner the direction that you need the belt to go. Re-tighten the bearing bolts and lock jam nut down. NOTE: Make all adjustments with the conveyor in the off position. Once you make the adjustments, start the conveyor to check tracking.

Page 36

Page 37

TROUBLESHOOTING

Page 38

TROUBLE SHOOTING Hydraulic System

LACK OF PERFORMANCE

HYDRAULIC MOTORS DO NOT TURN OR TURN SLOWLY

UNUSAL NOISES

POSSIBLE CAUSE

Items to Check /Service

Plugged Strainer Screen Service strainer screen

Hydraulic Filter Plugged Replace hydraulic oil filter

Collapsed Suction Hose Replace suction hose and

service strainer screen

Air Leak in Suction Hose Replace hose

Low Fluid Level Fill reservoir to proper level

Over Heated Hydraulic Fluid Clean oil cooler fins with

pressurized water

Worn Pump or Hydraulic Motor Adjust, rebuild, or replace as

necessary

Crushed Hydraulic Lines Replace line

Engine at Idle Speed engine up

Product in Tank not Melted Allow for more time for prod-

uct to melt

Foreign Material Jamming Agitator Remove foreign material

from agitator

Foreign Material Jamming Product Pump

Flow Controls on Valve Need to be

Remove foreign material from product pump

Adjusted

Also see “Lack of Performance”

Low Hydraulic Fluid Fill reservoir to proper level

Air Leak in Suction Hose Replace hose

Damaged Pump or Hydraulic Motors Repair or replace as neces-

sary

EXCESSIVE OIL LEAKS FROM PUMP OR

Bad Shaft or Shaft Seal Replace as necessary

Loose Fittings Tighten fittings

HYDRAULIC MOTOR SHAFT

Page 39

TROUBLE SHOOTING Product Delivery

PRODUCT PUMP DOES NOT TURN

LACK OF FLOW FROM WAND

POSSIBLE CAUSE

Product in Tank not Melted Allow more time for product

Foreign Material Jamming Product Pump

Pump Motor not Functioning Refer to “Hydraulic System”

Product Temperature too Cold Heat product to manufactur-

Product Froze in Wand & Hose Allow additional time for

Non-functioning Heat Element in Hose

WPC Valve not Positioned Correctly Refer to operating instruc-

Items to Check /Service

to melt

Remove foreign material from product pump

Trouble Shooting

ers recommended temperature

heating element to melt product in hose

Refer to “Electric Wand & Hose” Trouble Shooting

tions for WPC Valve position

WPC Valve and External Plumbing Froze

Worn Product Pump Adjust or repair product

Heat to re-melt product

pump as necessary

Page 40

TROUBLE SHOOTING Product Pump

Lack of flow from

wand.

Check for rotation

of product pump.

Rotation

Check that the

pump control is in

the “Pump”

position and not

“Reverse”.

Check for loose

pump pick-up

tube and that tube

is in product

No Rotation

Engage pump control

and observe engine

Definite RPM drop

Check that the product

is at working Temperature.

Electric wand & hose

heat on. Allow 30 to 40

minutes to heat.

Wand & hose hot

Position WPC valve toward

Little or no change in RPM

“Wand” position and observe

RPM.

CAUTION: Product repeatedly heated beyond

Little or no heat in wand or hose

engine RPM’s.

Little or no change in RPM

manufacturer’s recommended heating cycles

will harden and be difficult or impossible to

remove from machine.

Refer to hydraulic

system trouble

Shooting.

Refer to electric wand &

hose troubleshooting.

Definite RPM drop

Check pump packing for

excessive leakage.

No Excessive Leakage

Adjust pump end clear-

ance per Mfg.

Excessive Leakage

Lack of flow from wand

instructions.

Normal flow from wand

Adjust packing per Mfg.

instructions.

Rebuild or replace as

necessary.

Normal flow from wand

System functioning properly;

return unit to service.

Indicates a plugged/

frozen wand or

hose; allow addi-

tional time for heat-

ing elements to

work. Also check for a plugged valve or nozzle at the end of the wand, or fro-

zen plumbing next

to WPC valve. Heat

if necessary.

Page 41

TROUBLE SHOOTING Electric Wand

No heat, or low heat in wand

or hose.

With engine OFF,

Check for loose pulleys and

loose or missing belts on

24 volt alternator.

Check for a dead battery, then check

Start engine, with wand

switch OFF check voltage at

battery terminal of 24 volt

alternator.

9 volts or less

for an open resister or open wires

from battery to alternator, or a short-

ed wire between the alternator and control panel switch and alternator

and battery

24 to 28

volts

With engine running, turn

wand switch ON, check volt-

age at battery terminal of 24

volt alternator.

24 to 28

volts

Check heating elements for

an "open" condition. Check

for faulty switch. Check for

broken wires or loose connections from alternator to

switch, and switch to heating

elements.

12 to 14 volts

9 volts or less

Check for "short" between switch and heating

elements. Alternately disconnect the wires to

the hose and wand heating elements, when the

voltage goes to 24 - 28 volts you have located

Repair or replace alternator

the "shorted" circuit.

Check element resistance as follows:

15' hose element: .4 to 1.0 W. 20' hose element: .5 to 1.2 W. Wand element: .9 to 1.6 W.

Repair or replace as necessary.

Page 42

TROUBLE SHOOTING Diesel Burner

No heat or lack

of heat.

Is “Call For

Heat” Light on?

Verify low level shut-down is not

activated on units

equipped.

Verify 12.6 volts

min. at burner and

charging circuit works properly.

Verify the burner

is burning.

Check that the power switch is “on”, the circuit breaker is not tripped and that the

Is the thermostat set to the

desired temperature?

Is there any showing on

the temperature display?

Replace Thermo-

stat if burner and

“call for heat” light

do not function.

Check “Call

for Heat” light bulb

condition.

engine is running.

Does the digital tem-

perature read out

jump all around or

show “1” on the left

side of the display, or

show an obviously

inaccurate reading?

Is thermostat calibrated

correctly?

Set thermostat to material manu-

factures recommendations.

Check for power on the #3 ter-

minal of the thermostat.

Check for damaged or incor-

rect wiring. Check that ribbon

cable is connected correctly

between thermostat and LCD

Display.

A “1” indicated the temper-

ature sensor is disconnected

or faulty. An inaccurate or

jumping display indicates the

temperature sensor may be

wet or shorted to the ground.

Dry off and/or replace sen-

sor.

Check for proper burner adjustments. Verify proper fuel and no contamina-

tion. Check for obstructions in combus-

tion chamber, flues, and exhaust stack.

The burner is in a “lock out”

condition, turn main power

switch “off” then “on” again to

reset the system.

Check to see if :

Burner stays burning

Burner lights but goes out

Burner does not light at all

This may have been an isolated incident

caused by unknown factors.

Calibrate thermostat ac-

Test the Primary control-

Check the photo

electric eye for a

dirty lens and prop-

er function.

Verify fuel supply to burner, check con-

dition of fuel pump drive coupling,

bleed system. Check electrode condi-

tion and adjustment. Check function of

Ignition Transformer.

ler function, replace if

faulty. Contact Stepp

Mfg. if this does not cor-

cording to instructions

rect problem.

651-674-4491

Page 43

TROUBLE SHOOTING Diesel Burner Component

Primary Controller Burner MTD/Hard Wired

NOTE: The primary controller can be bench tested for proper operation us-

ing an automotive type, 12 volt battery as a power source. Refer to the wiring schematics for wire identification.

1. Remove controller from burner. Mark all wires for proper reassembly.

2. Using two test lights, or volt meters, connect one to the blue wire, and one to the white/ orange wire of the controller. Connect the black leads of your test instruments to the negative (-) terminal of the battery.

3. Connect the black wire from the controller to the negative (-) terminal of the battery.

4. Connect the red, white/red, and the white wires together, then connect these three wires to battery (+) terminal. Both test instruments should show voltage for approximately 15 seconds. After 15 seconds, the controller should "lock out" and no voltage will be present.

5. Repeat step #4, only this time connect the two yellow wires from the controller together

three seconds after applying power to the three wires of the controller. (This simulates the controller receiving a "flame" signal from the photo electric eye). The white/orange wire should show voltage as long as the controller is hooked to the battery. The blue wire should only show voltage for about 15 seconds. Replace the controller if it fails any of these tests.

RED To Main power Switch WHITE To Thermostat WHITE/RED Not Used YELLOW To Photo Electric Eye YELLOW To Photo Electric Eye ORANGE To Fuel Valve and Blower Motor BLUE To Igniter Transformer

A10008216

PRIMARY CONTROLLER

BLACK To Ground

Page 44

TROUBLE SHOOTING Diesel Burner

Photo Electric Eye

NOTE: The Photo Electric Eye can be bench tested for proper oper-

ation using an ohm meter. Assure the lens of the Photo Electric Eye is clean prior to testing.

1. Block off all light to the Photo Electric Eye. Test across the leads with your ohm meter; you should get an infinite resistance reading (a lot of resistance).

2. Point the Photo Electric Eye at a light source, the brighter the light, the less resistance your ohm meter will show. CAUTION: Replace the Photo Electric Eye if it does not re-

spond in this way.

Fuel Valve

NOTE: The Fuel Valve can be bench tested for proper operation using an automotive type 12

volt battery as a power source.

1. Disconnect the two leads and remove the fuel lines from the fuel valve.

2. The valve should be closed when no power is available.

3. Apply 12 volts to the two leads and the valve should open. CAUTION: Replace the fuel valve if it does not respond in this way.

Ignition Transformer

WARNING: Shock hazard, high voltage up to 20,000 volts.

1. Assure that 12 volts is being supplied to the transformer during the ignition cycle. (Refer to the Primary Controller tests.)

2. Check electrode condition and adjustment. Replace or adjust as necessary. CAUTION:

Replace ignition transformer if unit won't produce sparks.

Ignition Transformer

Fuel Valve

Page 45

REPLACEMENT PARTS

Page 46