TM-9-4940-503-14-and-P

TM-9-4940-503-14-and-P
TM 9-4940-503-14&P
TECHNICAL MANUAL
OPERATOR, ORGANIZATIONAL, DIRECT SUPPORT
AND GENERAL SUPPORT MAINTENANCE
MANUAL INCLUDING REPAIR PARTS LIST
FOR
DEGREASER
MODEL AUC-81
(NSN 4940-00-356-9891)
HEADQUARTERS, DEPARTMENT OF THE ARMY
OCTOBER 1983
WARNINGS
THE FOLLOWING SUMMARY LIST IS ADAPTED FROM WARNINGS WITHIN THE
MANUAL. HOWEVER, ALL WARNINGS SHOULD BE OBSERVED AS NOTED IN
THE TEXT.
OBSERVE CUSTOMARY SAFETY PRECAUTIONS WHEN WORKING WITH HIGH
VOLTAGES AND DANGEROUS CHEMICALS.
BODILY INJURIES OR DEATH
COULD OCCUR IF SAFETY PRECAUTIONS ARE NOT FOLLOWED.
SODIUM HYDROXIDE CAN CAUSE SEVERE BURNS TO SKIN AND EYES. WEAR
GOGGLES OR FACE SHIELD WHEN HANDLING. AVOID DUST OR FUMES. KEEP
AWAY FROM FOOD PRODUCTS. IN CASE OF EYE OR SKIN CONTACT, FLUSH
IMMEDIATELY WITH PLENTIFUL AMOUNTS OF WATER FOR AT LEAST 15
MINUTES AND GET IMMEDIATE MEDICAL ATTENTION.
THE COVER MUST REMAIN CLOSED AT ALL TIMES WHILE THE IMPELLERS ARE
IN OPERATION. FOR SAFETY, IT IS RECOMMENDED THAT THE COVER BE KEPT
CLOSED AT ALL TIMES EXCEPT WHEN REQUIRED TO BE OPEN DURING FILL,
DRAIN, LOADING AND UNLOADING OPERATIONS OR WHEN THE TANK IS
EMPTY.
UNDER NO CIRCUMSTANCES SHOULD THE EQUIPMENT BE OPERATED WHILE
SAFETY SWITCHES OR DEVICES ARE DISCONNECTED.
THE SAFETY
EQUIPMENT IS DESIGNED TO FAIL SAFE. IN THE EVENT A SAFETY DEVICE
REQUIRES REPLACEMENT BECAUSE IT IS DEFECTIVE, REPLACE IT
IMMEDIATELY, NEVER WIRE AROUND IT.
MOTOR ROTATION IS CRITICAL FOR PROPER OPERATION.
TO AVOID
EXCESSIVE STRAIN ON IMPELLER AND SHAFT AND THEIR POSSIBLE FAILURE,
MOTOR MUST ROTATE COUNTERCLOCKWISE WHEN VIEWED FROM REAR OF
MOTOR. ROTATION MAY BE REVERSED BY CHANGING ANY TWO OF ITS
VOLTAGE SUPPLY LEADS.
WHEN A FLAME FAILURE IS EXPERIENCED, OR BURNER FAILS TO OPERATE
IMMEDIATELY WHEN THERMOSTAT IS SET AT DESIRED TEMPERATURE
ALWAYS DELAY ABOUT TEN OR ELEVEN MINUTES BEFORE ATTEMPTING A
RESTART IN ORDER TO ALLOW FUMES AND OIL SPILLAGE TO DISSIPATE.
OPEN CLEAN OUT DOOR AND CLEAN OUT MAJOR SPILLS.
THIS DEGREASE IF USED IN A CONFINED AREA SHALL BE PROVIDED WITH A
FORCED VENTILATION SYSTEM.
DRAIN FACILITIES INTO SEWAGE LINES MUST BE CERTIFIED AND APPROVED
TO RECEIVE THE ALKALI OR PETROLEUM SOLVENTS AS SEWAGE DISPOSAL
PLANTS MAY BE DAMAGED, OR CANNOT PROCESS THESE COMPOUNDS.
DRAINAGE INTO A STORM DRAIN, EARTH OR GRAVEL DRAINAGE AREAS MUST
BE DONE WITH CAUTION TO AVOID CONTAMINATION OF GROUND OR NEARBY
WATER SUPPLIES.
This manual contains copyright material.
TM 9-4940-503-14&P
Technical Manual
HEADQUARTERS
DEPARTMENT OF THE ARMY
Washington, DC, 13 October 1983
No. 9-4940-503-14&P
OPERATORS, ORGANIZATIONAL, DIRECT SUPPORT
AND GENERAL SUPPORT MAINTENANCE MANUAL
INCLUDING REPAIR PARTS LIST
FOR
DEGREASER
MODEL AUC-81
(NSN 4940-00-356-9891)
REPORTING OF ERRORS
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 2028-2, located
in the back of this manual direct to: Commander, US Army Armament Materiel
Readiness Command, ATTN: DRSAR-MAS, Rock Island, IL 61299. A reply will be
furnished directly to you.
NOTE
This manual is published for the purpose of identifying an authorized commercial
manual for the use of the personnel to whom this equipment is issued.
Manufactured By:
Alpha Ultrasonics & Electronics
P.O. Box 4361, 500 E. 6th St.
Panama City, FL 32401
Procured under Contract No. DAAA09-77-C-7012
This technical manual is an authentication of the manufacturers' commercial literature
and does not conform with the format and content specified in AR 310-3, Military
Publications. This technical manual does, however, contain available information that is
essential to the operation and maintenance of the equipment.
i
TM 9-4940-503-14&P
INSTRUCTIONS FOR REQUISITIONING PARTS
NOT IDENTIFIED BY NSN
When requisitioning parts not identified by National Stock Number, it is mandatory that the following information be
furnished the supply officer.
1 - Manufacturer's Federal Supply Code Number - 55735.
2 - Manufacturer's Part Number exactly as listed herein.
3 - Nomenclature exactly as listed herein, including dimensions,
if necessary.
4 - Manufacturer's Model Number - AUC-81.
5 - Manufacturer's Serial Number (End Item).
6 - Any other information such as Type, Frame Number, and Electrical Characteristics, if applicable.
7 - If DD Form 1348 is used, fill in all blocks except 4, 5, 6, and Remarks field in accordance with AR 725-50.
Complete Form as Follows:
(a)
In blocks 4, 5, 6, list manufacturer's Federal
Supply Code Number - 55735 followed by a colon and
manufacturer's Part Number for the repair part.
(b)
Complete Remarks field as follows:
Noun:
For:
Manufacturer:
(nomenclature or repair part)
NSN: 4940-00-356-9891
Alpha Ultrasonics & Electronics
P.O. Box 4361, 500 E. 6th St.
Panama City, FL 32401
Model: AUC-81
Serial:
(of end item)
Any other pertinent information such as Frame Number,
Type, Dimensions, etc.
ii
TM 9-4940-503-14&P
Section
I.
II.
III.
IV.
Para
Page
Description
Scope
General
Physical Characteristics
1-1
1-2
1-3
1-1
1-1
1-1
1-2
Operating Instructions
General
Initial Set-Up
Theory of Operation
Operating Instructions
Securing Equipment
Drain
Sediment Tank
Safety Devices
2-1
2-2
2-3
2-4
2-5
2-6
2-7
2-8
2-1
2-1
2-1
2-2
2-2
2-4
2-5
2-5
2-6
Maintenance, Repair & Troubleshooting
General
Maintenance
Electric Motors
Chain Drive
Control Panel
Oil Burner
Combustion Chamber
Shaft Bearing Housing
Long Term Storage
3-1
3-2
3-3
3-4
3-5
3-6
3-7
3-8
3-9
3-1
3-1
3-1
3-1
3-1
3-1
3-1
3-1
3-1
3-7
Parts List
General
Ordering Information
4-1
4-2
4-1
4-1
4-1
iii (iv/Blank)
TM 9-4940-503-14&P
SECTION I - DESCRIPTION
1-1. Scope. a. This manual contains the operating and maintenance procedures recommended for the AUC-81 model
stationary degreaser. The procedures consist of a description, installation and operating instruction, maintenance, repair
and troubleshooting instructions and a listing of replacement parts.
b. Before servicing and operating this equipment, the operator should be thoroughly familiar with this manual.
WARNING
OBSERVE CUSTOMARY SAFETY PRECAUTIONS WHEN WORKING WITH HIGH
VOLTAGES AND DANGEROUS CHEMICALS.
BODILY INJURIES OR DEATH
COULD OCCUR IF SAFETY PRECAUTIONS ARE NOT FOLLOWED.
1-2. General. a. The AUC-81 is a stationary, oil-fired, centrifugal impact type degreaser utilizing hot alkali (MIL-C-14460,
Type 1) or cold petroleum solvents (Federal Specification O-T-236) as the cleaning solution. The equipment is specifically
designed to meet the requirements of Size 2 degreasers described in Military Specification MIL-D-45099B(WC) and is
intended for use in engine repair and rebuild shops for the removal of grease, sludge, and other foreign materials from
vehicle engine parts and blocks. The cleaning action is effected by agitating a heated alkali solution or cold petroleum
solution over the object being cleaned thus removing deposits of sludge, oil, metal chips, buffing compounds, varnish and
paint from metal objects.
b. The degreaser tank is fabricated from steel of Standard number 10 gage and is reinforced with structural steel
where required. The cover is fabricated from steel of Standard gage number 16 and may be fully removed to allow for the
vertical insertion and removal of the work basket or any parts that are being cleaned. The tank rim is so constructed that
solution dripping from parts being removed will drain back into the tank. A safety step with a non-skid surface is provided
for the operator's use.
c. A sediment tank is located at the rear of the degreaser and the sediment can be removed while the tank is filled to
normal capacity. A steel heavy duty work basket is supplied with the AUC-81 and is capable of holding at least 2,000 lbs
of parts or engine blocks. Pad eyes are available on the basket to allow it to be lowered into the tank by chain fall. While
in the tank, the work basket rests on supports to hold it above the tank base.
d. An overflow and drain is designed so as to carry off excess solution before it can overflow the tank. A water
intake line with a shut off valve allows the operator to control the liquid level within the tank.
1-1
TM 9-4940-503-14&P
e. Two impellers, each driven by a five horsepower electric motor are installed to agitate the solution. The impellers
are fabricated of stainless steel and are located so that they do not interfere with the operation, loading or unloading of the
tank. A safety screen on each side of the degreaser protects the impellers from possible damage from the basket. The
shafts of the electric motors are connected to the impellers through a sprocket and chain drive. A bearing housing
prevents liquid leaking around the impeller shaft.
f. An oil burner, Model LC-134, is installed as the heating source to raise the solution to the proper working
temperature. Use fuel oil meeting Federal Specification W-F-815. It is a high pressure atomizing burner which furnishes
100% of the combustion air through the burner. Oil atomization is accomplished through pressure generated by a gear
type high-speed fuel pump assembled as a unit with an oil strainer and pressure regulating valve which is an integral part
of the burner. Injection of oil by pressure through the nozzle produces a very fine oil spray. Air is delivered by a multivane fan through a non-reverberating blower tube equipped with a diffuser and is intimately mixed with oil mist for efficient
combustion. A transformer energizing a spark gap provides the igniting source for the burner.
g. The combustion chamber/fire box is constructed from low carbon steel lined with fire brick refractory and
insulating material. A cleanout port is available for inspection and cleanout as necessary. An exhaust stack is installed
and should be vented to the outside atmosphere if the degreaser is installed in a confined area. Should repairs or
alterations be required in the combustion chamber, the tank may be unbolted and lifted free to give complete access to
the fire box/combustion chamber.
h. The temperature of the cleaning solution may be preselected and the temperature will then be maintained
automatically. An overtemp control will automatically shut off the oil burner should the liquid temperature exceed 225
degrees F. A thermometer is mounted near the control box in order that the operator may monitor the temperature of the
solution at all times.
i. The control panel is mounted on the side of the degreaser near the oil burner. This panel allows the operator to
maintain control of the various functions and operations of the equipment. A list of controls and safety devices is set forth
in the physical characteristics, paragraph 1-3.
1-3. Physical Characteristics.
a. Overall Dimensions: 58" H x 108" L x 65" W.
b. Tank Dimensions:
Overall: 60" L x 36" W x 36" D.
Sediment: 32" L x 18" W x 12" D.
1-2
TM 9-4940-503-14&P
c. Tank Capacity:
Overall: 336.6 gallons.
Sediment: 29.9 gallons.
d. Work Basket Dimensions: 42" L x 32" W x 27" D.
e. Work Basket Capacity: Minimum 2,000 lbs.
f. Tank Material: Manufacturers' Standard low carbon steel gage number 10.
g. Work Basket Material: Manufacturers' Standard low carbon steel angle.
h. Fire Box Material: Low carbon steel lined with fire brick refractory and insulating material with firebox deflectors,
oil burner tube, cleanout tube and exhaust manifold.
i. Firebox/Combustion Chamber Dimensions: 52" L x 28" W x 13½" D.
j. Electrical and Utility Requirements:
(1) 230 volts, 60 Hz, 3 phase power.
(2) Water inlet, 3/4" NPT.
(3) Suitable, approved drain facility for discharge of alkali (MIL-C-14460) or petroleum based solvents (Federal
Specification (O-T-236) either from the overflow or tank or both, 2" NPT.
(4) Suitable and approved exhaust fume vents from oil burner stack as required.
(5) Fuel source and inlet line, 3/8" copper tubing.
k. Oil Burner: Model LC-134, mounted with pump, strainer, pressure regulating valve, fan, and ignition transformer
assembled as an integral part of the burner assembly.
(1) Burner Capacity: 2.5 to 2.75 gallons of fuel per hour.
(2) Fuel Type: Number 2 grade fuel oil or lighter grades may be used.
(3) Burner Motor: 1/8 HP at 1725 RPM, 115 volt AC, single phase.
l. Impeller Motors: Five horsepower electric motors of the induction squirrel cage type with Class B insulation, a
continuous duty rating, and 1740 RPM. The motors are dual voltage 230/460 volts, and are initially wired for operation on
230 volts, 60 Hz, 3 phase.
1-3
TM 9-4940-503-14&P
m. Finish: All outside tank skin and the frame protected by a coat of primer followed by a coat of epoxy enamel.
n. Control Panel:
temperature control.
Houses circuit breakers; impeller motor control switches; thermometer; oil burner variable
o. Safety Devices and instruments: Circuit breakers including main power and individual circuit protection; overtemperature cutout switch; built-in oil burner safety features in accordance with UL Oil Burners 296; and a thermometer.-
1-4
TM 9-4940-503-14&P
SECTION II - OPERATING INSTRUCTIONS
2-1. General. This section contains the instructions for initial setup, operation with hot alkali solutions (MIL-C-14460),
operation with cold petroleum solvents (Federal Specification O-T-236), drain and sediment tank operation and a listing of
the various safety devices built into the equipment.
2-2. Initial Set-Up. The AUC-81 is packed in accordance with various military specifications and instructions. The
packing and parts inventory list along with the diagram should be removed from the waterproof packet and used in
conjunction with the instructions contained in this manual for set-up.
a. The AUC-81 while still in its crating materials should be placed near the desired location in order to avoid
excessive handling after unpacking. Required utility lines and facilities should already be in place.
b. Uncrate and remove all packing materials from the AUC-81.
c. Certain parts are packed in consolidated packs in the degreaser tank. These are:
(1) Sediment Tank.
(2) Basket.
(3) Step.
(4) Vent Pipe (stand pipe).
Unpack each item carefully and inspect it for completeness and damage. Check the parts against the packing list and the
parts diagram.
d. After unpacking the tank and consolidated packs, open the control panel and remove all cushioning materials and
protective tape from the thermometer, switches, circuit breakers, and so forth.
e. Utility lines and service requirements should have been prepositioned prior to receipt of the AUG-81. This
includes fuel tank and supply line; water fill line; 230 volts AC, 60 Hz, 3 phase electrical service; suitable drain and
overflow lines (2" NPT); and exhaust stack or venting in the event the degreaser is installed in a building or enclosed area.
f. Move the AUC-81 into the desired position.
CAUTION
THE AUC-81 SHOULD BE PLACED ON A LEVEL BASE. WHILE EXACT LEVELING
IS NOT REQUIRED, THE MACHINE SHOULD BE ROUGHLY LEVEL IN ORDER TO
AVOID SPILLAGE WHEN AGITATION IS IN PROCESS.
2-1
TM 9-4940-503-14&P
g. Electric Hook-Up. The AUC-81 is initially wired for operation on 230 volts, 60 Hz, 3 phase electrical service. The
control panel is wired completely and all required wires to various locations have been pulled and are in place in the
protected flexible or rigid electrical conduit. Bring power to the main circuit breaker. Ensure system is grounded to plant
ground system.
h. Fuel Oil Hook-Up. The fuel oil tank and fuel line should be installed in accordance with regulations of the National
Board of Fire Underwriters. The fuel line should be no less than 3/8" copper tubing for line lengths under 50 feet; and ½"
copper tubing for line lengths over 50 feet. Connect line to the oil filter inlet port (3/8"). To bleed air: if gravity system,
loosen the filter vent plug until there is a flow of oil from the plug.
i. Water Supply: A water supply line 3/4" NPT should be connected to the water inlet near the control box to
provide a source of fresh water.
j. Drains: A suitable drain facility should be connected to the drain outlet of the tank (2" NPT).
k. The sediment tank should be connected to the main drain piping using the pipe union furnished. Install the stand
pipe vent into the coupling located on the top of the sediment tank.
2-3. Theory of Operation. a. The AUC-81 is a stationary, high velocity centrifugal impact type degreaser utilizing hot
alkali or cold petroleum solvents, as the cleaning solution. An oil burner provides a source of heat to raise the alkali
solution (MIL-C-14460) to the proper operating temperature between 190 and 200 degrees F. Two thousand or more
pounds can be loaded in the work basket and lowered into the solution. The cover is then placed on the tank and the
impeller motors energized.
b. The impellers create high velocity, turbulent flow of the liquid into and around the items to be cleaned flushing and
removing heavy deposits of sludge, oil, metal chips, buffing compounds, varnish, paint, etc. from the object.
c. Operating temperature for the hot alkali solution (MIL-C14460) is maintained automatically on less than 3.00
gallons of oil per hour. Various safety and regulating devices are installed to ensure safety of operation.
2-4. Operating Instructions. The following instructions are for operating the AUC-81 using a HOT ALKALI SOLUTION
(MIL-C-14460):
a. Check the tank drain valve to ensure that the valve is in the CLOSED position. Sediment tank valve in the OPEN
position. Check to be sure sediment drain plug and vent stand pipe are in place. Remove the work basket from the tank.
2-2
TM 9-4940-503-14&P
b. Ensure all electrical equipment is OFF by placing the master circuit breaker in the OFF position.
thermostat at the OFF position.
Position
c. OPEN the water intake valve and begin filling the tank with water. After the liquid level in the tank has risen a few
inches, sodium hydroxide base corrosive removing compound conforming to Military Specification MIL-C-14460, Type I,
may be added to the water per local instructions as to the desired concentration or as specified in the Military
Specification. Under no circumstances should the concentration exceed that specified in the MIL-SPEC.
WARNING
SODIUM HYDROXIDE CAN CAUSE SEVERE BURNS TO SKIN AND EYES. WEAR
GOGGLES OR FACE SHIELD WHEN HANDLING. AVOID DUST OR FUMES. KEEP
AWAY FROM FOOD PRODUCTS. IN CASE OF EYE OR SKIN CONTACT, FLUSH
IMMEDIATELY WITH PLENTIFUL AMOUNTS OF WATER FOR AT LEAST 15
MINUTES AND GET IMMEDIATE MEDICAL ATTENTION.
WARNING
THIS DEGREASER IF USED IN A CONFINED AREA SHALL BE PROVIDED WITH A
FORCED VENTILATION SYSTEM.
d. Continue to fill the degreaser tank with water until reaching a level about 2" below the overflow drain outlets.
e. Turn the master circuit breaker to the ON position.
f. Set the temperature control on the thermostat to the desired setting, that is between 190 and 200 degrees F. It is
suggested that the control be set at 200 degrees initially. Thereafter, the temperature will be maintained at the selected
temperature automatically plus or minus 10 degrees. The oil burner should begin operation a few seconds after the
thermostat is moved beyond the water temperature in the tank.
g. The AUC-81 requires about 2 1/2 to 3 hours to raise the temperature of the tank liquid solution from 70 degrees
ambient to 200 degrees F.
h. While the solution is heating, load the work basket with the items or item requiring degreasing.
CAUTION
LOAD THE WORK BASKET SO THAT THE SOLUTION MAY REACH ALL
SURFACES AND CREVICES AND FREELY CIRCULATE THROUGH HOLES,
CYLINDERS, ETC.
2-3
TM 9-4940-503-14&P
i. When the temperature has reached 200 degrees F as indicated by the temperature gage, raise the cover, position
the work basket over the tank, and lower it CAREFULLY into the solution. Replace the cover immediately.
NOTE
THE TEMPERATURE OF THE SOLUTION WILL DROP IMMEDIATELY AFTER THE
WORK BASKET IS LOWERED INTO THE SOLUTION.
THE TEMPERATURE
SHOULD RISE TO 200 DEGREES PLUS OR MINUS FIVE DEGREES WITHIN TEN
MINUTES.
j. After the temperature has stabilized at 200 degrees F or the selected temperature, energize the impeller motors
by depressing the electric motor START buttons. The electric motors may be operated singly to obtain a certain level or
direction of agitation; or operated together to obtain maximum agitation.
WARNING
THE COVER MUST REMAIN CLOSED AT ALL TIMES WHILE THE IMPELLERS ARE
IN OPERATION. FOR SAFETY, IT IS RECOMMENDED THAT THE COVER BE KEPT
CLOSED AT ALL TIMES EXCEPT WHEN REQUIRED TO BE OPEN DURING FILL,
DRAIN, LOADING AND UNLOADING OPERATIONS OR WHEN THE TANK IS
EMPTY.
k. When the desired degree of cleanliness has been reached, depress impeller motor switches to the OFF position,
raise the cover, remove the work basket allowing liquid to drain into the tank, and then remove the contents. Reload the
work basket and continue in accordance with subparagraph h above.
NOTE
THE LENGTH OF TIME REQUIRED TO DEGREASE AND CLEAN METAL ITEMS
VARIES ACCORDING TO THE DEGREE OF SOILAGE PRESENT; THE SIZE OF THE
OBJECT; THE COMPLEXITY OF THE OBJECT; TYPE OF METAL AND SO FORTH.
IT IS SUGGESTED THAT THE ITEMS BE INSPECTED AT INTERVALS FOR
CLEANLINESS.
2-5. Securing Equipment. Upon completion of the cleaning operations the liquid may be left in the tank for use in the next
scheduled cleaning period. To secure the machine for short time periods, i.e., a week or less, place the cover on the tank;
place all electrical equipment in the OFF position; place master circuit breaker in the OFF position; ensure that the
sediment tank drain valve remains in the OPEN position.
2-4
TM 9-4940-503-14&P
NOTE
IT IS SUGGESTED THAT SLUDGE AND SEDIMENT BE REMOVED FROM THE
SEDIMENT TANK PRIOR TO THE NEXT SCHEDULED DEGREASING OPERATIONS.
SEE SECTION 2-7 FOR THESE PROCEDURES.
2-6. Drain. To drain the degreaser:
a. Place all electrical switches in the OFF position.
b. OPEN the sediment tank drain valve.
c. OPEN the tank drain valve to the fully OPENED position.
d. When the tank has been completely emptied, use a stream of water from a hose to wash or flush out any residue
clinging to the sides, tank supports or bottom.
e. When completely drained and flushed, CLOSE the tank drain valve.
CAUTION
DRAIN FACILITIES INTO SEWAGE LINES MUST BE CERTIFIED AND APPROVED
TO RECEIVE ALKALI OR PETROLEUM SOLVENTS.
2-7. Sediment Tank. The AUC-81 has a sediment settling tank with a means for removal of settled sludge and sediment.
Removal can be accomplished when the degreaser tank is filled to normal capacity with a minimum loss of solvent. To
remove sediment from the sediment tank while the degreaser tank is filled to normal capacity:
a. CLOSE the sediment tank valve.
b. Remove the sediment tank bottom drain plug; remove the stand pipe.
c. After the solution has drained from the sediment tank, rod the debris and sludge out and flush completely with a
hot water flush through the stand pipe coupling.
d. When clean out is completed, replace the bottom plug and replace the stand pipe.
e. OPEN sediment tank valve.
f. Continue with degreasing process or other operation. Check tank liquid level and refill as necessary.
2-5
TM 9-4940-503-14&P
NOTE
IT IS RECOMMENDED THAT THE SEDIMENT TANK BE CLEANED AT REGULAR
INTERVALS AND ALWAYS CLEANED WHENEVER THE MAIN TANK IS DRAINED
COMPLETELY.
2-8. Safety Devices.
a. General. The AUC-81 has been equipped with several safety devices in order to protect the operator, the
equipment, and the surrounding environment.
WARNING
TINDER NO CIRCUMSTANCES SHOULD THE EQUIPMENT BE OPERATED WHILE
SAFETY SWITCHES OR DEVICES ARE DISCONNECTED.
THE SAFETY
EQUIPMENT IS DESIGNED TO FAIL SAFE. IN THE EVENT A SAFETY DEVICE
REQUIRES REPLACEMENT BECAUSE IT IS DEFECTIVE, REPLACE IT
IMMEDIATELY, NEVER WIRE AROUND IT.
b. Safety Equipment.
(1) Main circuit breaker. The main circuit breaker controls all electrical power for the AUC-81. If the breaker
trips, it signifies that an electrical component or wiring has developed trouble. Correct the trouble before continuing
operations.
(2) Secondary circuit breakers. Each impeller motor is protected by overload heaters. The oil burner has its
own circuit breaker protection.
(3) Overtemperature cutout switch. This switch is wired in series with the oil burner control and is normally
closed allowing the burner to operate. A situation wherein the temperature of the tank liquid rises to or above 225
degrees F will cause the over-temp cutout switch to open and interrupt the electrical power to the oil burner causing it to
cease firing.
(4) Oil burner safety controls. The oil burner is an extremely reliable equipment and has built-in safety devices
conforming to the Underwriters Laboratories' standards for oil burner operation which will automatically shut off the fuel
supply in the event of a flame failure. A stack mounted relay control is a further protection device to ensure fuel cutoff if
the burner ignition system fails to ignite the fuel mixture when the thermostat is activated or in the event of flame failure.
2-6
TM 9-4940-503-14&P
WARNING
DRAIN FACILITIES INTO SEWAGE LINES MUST BE CERTIFIED AND APPROVED
TO RECEIVE THE ALKALI OR PETROLEUM SOLVENTS AS SEWAGE DISPOSAL
PLANTS MAY BE DAMAGED, OR CANNOT PROCESS THESE COMPOUNDS.
DRAINAGE INTO A STORM DRAIN, EARTH OR GRAVEL DRAINAGE AREAS MUST
BE DONE WITH CAUTION TO AVOID CONTAMINATION OF GROUND OR NEARBY
WATER SUPPLIES.
WARNING
MOTOR ROTATION IS CRITICAL FOR PROPER OPERATION.
TO AVOID
EXCESSIVE STRAIN ON IMPELLER AND SHAFT AND THEIR POSSIBLE FAILURE,
MOTOR MUST ROTATE COUNTERCLOCKWISE WHEN VIEWED FROM REAR OF
MOTOR. ROTATION MAY BE REVERSED BY CHANGING ANY TWO OF ITS
VOLTAGE SUPPLY LEADS.
CAUTION
THE FOREGOING INSTRUCTIONS COMPLETE THE INITIAL SET-UP OF THE AUC81 DEGREASER AND IT IS NOW READY TO OPERATE. IT IS SUGGESTED THAT A
REVIEW OF THE PROCEDURES BE CONDUCTED AND EACH ITEM CHECKED TO
ENSURE THAT THE PROCEDURES HAVE BEEN FOLLOWED AND THAT THE
EQUIPMENT IS WIRED AND MECHANICALLY ASSEMBLED CORRECTLY.
CAUTION
THE OIL PUMP WILL CONTINUE OPERATING FOR A SHORT TIME AFTER A
FLAME OR STARTING IGNITION FAILURE; OR A CUTOFF OCCURS DUE TO
STACK SWITCH RELAY CONTROL OPERATION. IN THIS EVENT FOLLOW THE
PROCEDURES CONTAINED IN THE TROUBLESHOOTING SECTION OF THIS
MANUAL.
2-7 (2-8/Blank)
TM 9-4940-503-14&P
SECTION III - MAINTENANCE, REPAIR AND TROUBLESHOOTING
3-1. General. The AUC-81 is a relatively simple machine designed for rugged, long, virtually trouble-free operation.
Minimum preventative maintenance and repair is required, and troubleshooting requirements are also simple and at a
minimum.
3-2. Maintenance. Little or no preventative maintenance other than oiling is necessary.
3-3. Electric Motors. All electrical motors are of the sealed bearing type and require no lubrication.
3-4. Chain Drive. The chain drive should be lubricated prior to operation with a good grade commercial chain drive
lubricator, e.g., MIL-C-14460. It is suggested that the chain drive be checked for alignment of the sprockets and removal
of accumulated dirt and grime from the teeth every four months.
3-5. Control Panel. Once a year the accumulated dust and dirt should be blown away from switches and other control
panel components using a low pressure air source.
3-6. Oil Burner. Once a year the oil burner should be examined by a qualified oil burner repairman and the burner
nozzle, diffuser, spark setting, pump operation, etc., inspected and adjusted as necessary to maintain an efficient flame
pattern in accordance with the vendor's instructions.
3-7. Combustion Chamber. After three years of operation it is recommended that the tank be unbolted from the
combustion chamber and raised sufficiently to allow inspection, and if needed, to clean out the entire firebox area.
3-8. Shaft Bearing Housing. The shaft bearing housing houses the impeller shaft, with the necessary bearing races,
seals and retaining rings. The shaft housing should be disassembled and the grease renewed every six to eight months
of use. To inspect the bearing races and to renew the grease, follow the instructions below (see diagram in the
appendices).
a. Disconnect the main power source to the degreaser and place a warning placard on the circuit panel.
b. Drain the main tank completely.
c. Using an Allen type wrench, loosen the impeller set screw and remove the impeller blade from the shaft (3/16"
Allen head wrench required).
d. Loosen the electrical motor mounting bolts and slacken the drive chain. Remove the chain.
3-1
TM 9-4940-503-14&P
e. Using an Allen type wrench, loosen the sprocket set screw and remove the sprocket from the shaft (1/8" Allen
head wrench required).
f. Remove the seal part number 14 from the housing.
g. Using a pair of snap ring pliers. compress the retainer ring part number 19 and remove. Now slip the entire shaft
out (bearings will slip out on the shaft).
h. Remove seal part number 15.
i. Inspect all pieces and parts for abnormal wear.
j. Wipe and clean all pieces and parts as well as the shaft housing of old grease.
k. Replenish the bearing races with new grease.
l. Replace seal part number 15 into housing. Note: Always replace with a new seal.
m. Insert the shaft with greased bearings into housing and through seal number 15.
n. Reinstall snap retainer ring part number 19.
o. Reinstall front seal part number 14 (use new seal).
p. Using a grease gun, pump 12 to 15 pumps of grease into the cartridge (bearing housing) (see part number 44,
Alemite fitting).
q. Reinstall impeller on the shaft and tighten the alien set screw securely.
r. Reinstall the sprocket part number 7 on the shaft. Do not tighten the Allen head set screw at this time.
s. Using a straight edge line up the rear sides of the shaft sprocket, part number 7, and the motor sprocket, part
number 6. When aligned, tighten the Allen head set screw of the shaft sprocket securely.
t. Reinstall the chain.
u. Retighten the motor mounting bolts securely.
3-2
TM 9-4940-503-14&P
Recommended Lubrication or Maintenance
ITEM
PERIOD
MATERIAL OR METHOD
1. Chain Drive
4 month intervals
Clean sprocket teeth and lubricate with
chain drive lubricant.
2. Control Panel
1 year interval
Blow dust & dirt away from contacts with
low pressure air.
3. Oil Burner
1 year interval
Inspect and adjust as necessary.
4. Combustion Chamber
3 year interval
Unbolt and raise tank to inspect. Clean
as required.
5. Bearing Housing
6 months
See instructions, para 3-8.
3-3
TM 9-4940-503-14&P
Troubleshooting
WHAT HAPPENED
PROBABLE CAUSE
WHAT TO DO
Circuit Breakers on,
unit fails to operate.
Main electrical source
is OFF or breaker
tripped at source.
Check main power source, reset or
restore main power.
Main and secondary
breakers on, thermostat
set at desired temperature
burner fails to operate.
1. No fuel oil.
1. Check main oil supply for oil and
proper fuel number.
2. Liquid temperature
above the desired temperature.
2. Operate thermostat beyond
temperature desired.
3. Liquid temperature
above overtemperature
limit of 225°F; Cal-Stat
switch has interrupted
electrical power to the
burner.
3. Wait until temperature falls below
225°F.
4. Burner component
failure.
4. If the foregoing items are not the
source of trouble, then there is a
possibility that the burner lower, fuel
pump, and/or ignition transformer have
failed. Test each component separately
and replace as necessary in accordance
with the vendor's instructions.
Blow fuse or open
breaker.
Reset breaker.
Open circuit in winding
or starting switch.
Evidenced by a humming sound from
motor when switch is closed. Check
for loose connections.
Mechanical failure
Check bearings.
Short circuited
stator.
Indicated by breaker tripping
continuously. Replace motor.
Overload tripped.
Press reset button.
Motor fails to start.
3-4
TM 9-4940-503-14&P
Troubleshooting--Continued
WHAT HAPPENED
PROBABLE CAUSE
WHAT TO DO
Motor stalls.
Low line voltage.
Check AC line and correct if possible.
Motor runs and then
dies down.
Loss of line voltage.
Check AC line and correct if possible.
Stator shorts when
motor warms up.
Replace motor.
Motor overloaded.
Check water level in the tank
(2" below safety screen).
Three phase motor may
have one phase open,
overload tripped.
Check power source depress reset
button.
Line voltage too
high or too low.
Check power source.
Worn bearings.
Replace.
Sprockets misaligned.
Realign sprockets.
Mounting bolts loose.
Tighten mounting bolts.
Worn bearings.
Replace bearings and seals.
Fan rubbing cover.
Remove interference.
Motor mounting bolts
loose.
Tighten motor mounting bolts.
Chain badly worn.
Replace chain.
Excessive chain slack.
Take up slack.
Material build-up in
sprockets tooth
pockets.
Clean sprocket teeth.
Sprocket misalignment.
Check alignment and correct.
Inadequate lubrication
Lubricate with chain drive lubricant.
Chain or sprockets
worn badly.
Replace chain or sprocket are
necessary.
Drive misalignment.
Realign drive.
Motor overheats
and trip overloads.
Motor vibrates.
Excessive motor noise.
Chain climbs sprocket.
Excessive drive noise.
Excessive wear on
sprocket teeth.
3-5
TM 9-4940-503-14&P
Troubleshooting--Continued
WHAT HAPPENED
PROBABLE CAUSE
WHAT TO DO
Chain breakage.
Inadequate lubrication
Lubricate with chain drive lubricant.
Material build-up in
sprocket tooth pockets.
Clean sprocket teeth.
Drive misalignment.
Realign sprockets.
Badly worn sprockets.
Replace sprockets.
Chain gets stiff.
Inadequate lubrication.
Lubricate.
Non-symmetrical wear
on sprockets.
Shaft not parallel
or in same plane.
Check alignment.
Excessive vibration.
Broken or missing
roller.
Replace chain.
Bearing housing leaks.
Seals damage.
Replace seals.
Flame fails to ignite
when thermostat set
at desired temperature.
Out of oil.
Check fuel supply, wait ten
minutes before restarting
burner. Reset red button
on stack switch.
Spark gap too wide
for ignition voltage.
Have repairman reset gap.
.
Ignition transformer
failure or short.
Replace transformer.
See vendor handbook.
WARNING
WHEN A FLAME FAILURE IS EXPERIENCED OR BURNER FAILS TO OPERATE
IMMEDIATELY WHEN THERMOSTAT IS SET AT DESIRED TEMPERATURE,
ALWAYS DELAY ABOUT TEN OR ELEVEN MINUTES BEFORE ATTEMPTING A
RESTART IN ORDER TO ALLOW FUMES AND OIL SPILLAGE TO DISSIPATE.
OPEN CLEANOUT DOOR AND CLEAN OUT MAJOR SPILLS.
3-6
TM 9-4940-503-14&P
3-9. Long Term Storage. If it is planned that the degreaser will not be used for a long period of time, it should be
prepared for storage by:
a. Draining all fluids from the tank.
b. Flushing and draining the sediment tank.
c. Follow the procedures listed in MILSPEC MIL-D-45099B(WC) as pertains to preserving the inside tank walls from
rust or other damage.
3-7 (3-8/Blank)
TM 9-4940-503-14&P
SECTION IV - PARTS LIST
4-1. General. This section contains a listing of replacement parts for the AUC-81 degreaser. The parts are listed alphanumerically by part numbers and the listing includes:
a. Part number.
b. Description of part.
c. Quantity required.
4-2. Ordering Information. To order replacement parts specify the following information for each part:
a. Part number.
b. Description.
4-1
TM 9-4940-503-14&P
Figure 1 - AUC-81, Front Elevation
Part
Number
4
6
8
10
11
12
20
*24
*25
28
31
32
32
33
4-2
Description
Qty
Motor, 5HP, 230/460V
2
60HZ, 3Ph, 1,800 RPM,
3N264
Sprocket No. 40 Chain,
2
1-1/8" bore, 40B14
Motor Starter, Size 1
2
with 14A O.L. HTR,
Class 8536
Exhaust Stack 8"
1
Stack Double Wall
8" Double Wall, Gas
Control Panel,
1
3/8" Tube, Brass
Oil Burner, Complete
1
3.0 GPH, LC-134
Safety Control (Stack
1
Switch) 2E299
ASBESTOS Tape, 2" wide 20'
Impeller Guard,
2
100547-1
Solenoid Valve 3/8",
1
115V, 60HZ, 8262B208
Cover, R.H., 100552-1
1
Cover, L.H., 100552-2
1
Cover, L.H., 100552-2
1
Hinge, 3" Heavy Duty
4
Part
Number
34
35
Description
Screw, 10/32
Nut, 10/32
Qty
8
8
*38
40
Wiring Assembly, 100549
3 1/2" Dial, 50-300 Deg.,
F., 4" Stem, Figure 100
1
1
41
1
42
Elbow, 8" Dia., 8"
Double Wall, Gas Vent
Exhaust Stack Ext.,
43
Union 3/8" Pipe to
2
45
46
3/8" Copper Tubing
Union 1/4" Pipe to
3/8" Tube, Brass
4'
2
47
48
49
Nut, 10/32
Screw, 10/32
Chain, Cover Stop
20" Long
4
4
2
53
*54
Motor Supports, 10053-4
Platform Step, 100553-1
1
1
*Not Shown
1
TM 9-4940-503-14&P
Figure 2 - AUC-81. Top View
Part
Number
Description
Qty
27
30
Schedule 40 Pipe, 1"
Piping Assembly,
100546
4'
1
*38
Wiring Assembly,
100549
1
50
Lifting Eye, 3/8"
bolt, 8890Y14
4
Part
Number
Description
Qty
51
52
Basket, 100553-2
Rack, 100553-3
1
1
*54
Platform, 100553-1
1
*Not Shown
4-3
TM 9-4940-503-14&P
Figure 3 - AUC-81, Right End View
Part
Number
Description
Qty
Part
Number
Description
Qty
1
Fire Box, 100548
1
26
Oil Filter, 1A-25A
1
2
Boil Tank, 100547
1
29
3/4" Gate Valve,
Brass Water Inlet
1
3
Sediment Tank, 100551
1
30
Piping Assembly, 100546
1
9
No. 40 Chain, 1/2" pitch 8'
36
Bolt Hex Hd, 3/8-16xl
32
Overtemp Switch Calstat,
1E2B2
1
21
22
Lockwasher, Split
type, 3/8"
32
37
Chain Guard, 100553-5
2
*38
Wiring Assembly, 100549
1
23
Nut, Hex, 3/8"
32
39
Skid Assembly, 100544
1
*24
ASBESTOS TAPE, 2" wide 20’
*25
Impeller Guard,
100547-1
*Not Shown
4-4
2
TM 9-4940-503-14&P
Figure 4 - AUC-81, Bearing Housing Assembly
Part
Number
5
Description
Qty
10 x 10 Propeller
1" Bore, 1/8" x 1/4"
Keyway Stainless
Steel
2
Sprocket No. 40
Chain, 7/8" Bore,
40B25
2
13
Shaft, 100460
2
14
Seal, 10158
2
15
Seal, 8870
2
7
Part
Number
Description
Qty
16
Bearing, SK10
2
17
Bearing, R-14
2
18
Retaining Ring,
N5000-187
2
19
Retaining Ring,
N5000-200
2
43
Union 3/8" Pipe to
3/8" Tube, Brass
2
44
1/8" NPT Grease Fitting
2
*Not Shown
4-5
TM 9-4940-503-14&P
4-6
TM 9-4940-503-14&P
By Order of the Secretary of the Army:
Official:
ROBERT M. JOYCE
Major General, United States Army
The Adjutant General
Distribution:
To be distributed in accordance with Special List.
JOHN A. WICKHAM, JR.
General, United States Army
Chief of Staff
THE METRIC SYSTEM AND EQUIVALENTS
LINEAR MEASURE
SQUARE MEASURE
1 Centimeter = 10 Millimeters = 0.01 Meters = 0.3937 Inches
1 Meter = 100 Centimeters = 1000 Millimeters = 39.37 Inches
1 Kilometer = 1000 Meters = 0.621 Miles
1 Sq Centimeter = 100 Sq. Millimeters = 0.155 Sq Inches
1 Sq. Meter = 10,000 Sq Centimeters = 10.76 Sq Feet
1 Sq Kilometer = 1,000,000 Sq Meters = 0.386 Sq Miles
WEIGHTS
CUBIC MEASURE
1 Gram = 0 001 Kilograms = 1000 Milligrams = 0.035 Ounces
1 Kilogram = 1000 Grams = 2.2 Lb
1 Metric Ton = 1000 Kilograms = 1 Megagram = 1.1 Short Tons
1 Cu Centimeter = 1000 Cu Millimeters = 0 06 Cu Inches
1 Cu Meter= 1,000,000 Cu Centimeters = 35 31 Cu. Feet
LIQUID MEASURE
TEMPERATURE
5/9 (°F - 32) = °C
212° Fahrenheit is equivalent to 100° Celsius
90° Fahrenheit is equivalent to 32 2° Celsius
32° Fahrenheit is equivalent to 0° Celsius
9/5 °C + 32 = °F
1 Milliliter = 0.001 Liters = 0.0338 Fluid Ounces
1 Liter = 1000 Milliliters = 33.82 Fluid Ounces
APPROXIMATE CONVERSION FACTORS
TO CHANGE
TO
MULTIPLY BY
Inches ............................................................Centimeters ..................................................................2.540
Feet................................................................Meters ...........................................................................0.305
Yards .............................................................Meters ...........................................................................0.914
Miles ..............................................................Kilometers ....................................................................1.609
Square Inches ..............................................Square Centimeters ....................................................6.451
Square Feet .................................................Square Meters .............................................................0.093
Square Yards ...............................................Square Meters .............................................................0.836
Square Miles ...............................................Square Kilometers ......................................................2.590
Acres .............................................................Square Hectometers ...................................................0.405
Cubic Feet....................................................Cubic Meters................................................................0.028
Cubic Yards ..................................................Cubic Meters................................................................0.765
Fluid...............................................................Ounces Milliliters ........................................................29.573
Pints ..............................................................Liters ..............................................................................0.473
Quarts ...........................................................Liters ..............................................................................0.946
Quarts. ..........................................................Liters ..............................................................................0.946
Gallons ..........................................................Liters ..............................................................................3.785
Ounces ..........................................................Grams ...........................................................................28.349
Pounds ..........................................................Kilograms......................................................................0.45
Short Tons....................................................Metric Tons...................................................................0.0907
Pound-Feet...................................................Newton-Meters ............................................................1.356
Pounds per Square .....................................Inch Kilopascals ..........................................................6.895
Miles per Gallon ..........................................Kilometers per Liter.....................................................0.425
Miles per Hour .............................................Kilometers per Hour....................................................1.609
TO CHANGE
TO
MULTIPLY BY
Centimeters ..................................................Inches ............................................................................0.394
Meters ...........................................................Feet................................................................................3.280
Meters ...........................................................Yards .............................................................................1.094
Meters ...........................................................Yards .............................................................................1.094
Kilometers ....................................................Miles ..............................................................................0.621
Square Centimeters ....................................Square Inches ..............................................................0 155
Square Meters .............................................Square Feet . ...............................................................10.764
Square Meters ............................................Square Yards ...............................................................1.195
Square Kilometers ......................................Square Miles ................................................................0.386
Square Hectometers ...................................Acres .............................................................................2.471
Cubic Meters................................................Cubic Feet....................................................................35.315
Cubic Meters................................................Cubic Yards ..................................................................1.308
Milliliters Fluid ..............................................Ounces ..........................................................................0.034
Liters ..............................................................Pints ..............................................................................2.113
Liters ..............................................................Quarts ...........................................................................1.057
Liters ..............................................................Gallons .........................................................................0.264
Grams ...........................................................Ounces ..........................................................................0.035
Kilograms......................................................Pounds ..........................................................................2 205
Metric Tons...................................................Short Tons....................................................................1.102
Newton-Meters ............................................Pound-Feet...................................................................0.738
Kilopascals ...................................................Pounds per Square Inch ............................................0.145
Kilometers per Liter.....................................Miles per Gallon ..........................................................2.354
Kilometers per Hour....................................Miles per Hour .............................................................0.621
TA089991
PIN: 054217-000
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