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Stepp SBF series Parts Manual

Lp or diesel burner systems bottom fired kettle
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Rev. 12/2014
OPERATIONS/MAINTENANCE/PARTS
MANUAL
LP or 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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Summary of Contents for Stepp SBF series

  • Page 1 Rev. 12/2014 OPERATIONS/MAINTENANCE/PARTS MANUAL LP or Diesel Burner Systems 12325 River Road North Branch MN 55056 ~ Phone: 651-674-4491 ~ Fax: 651-674-4221 www.steppmfg.com...
  • Page 2 (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 re- placement 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.

  • Page 3: Introduction

    Road, North Branch MN. 55056-6225 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 SBF, be sure to in- clude the model number and serial number found on the data plate attached to...

  • Page 4: Table Of Contents

    This manual explains the basic operations, maintenance, and use of the Stepp SBF Bot- tom Fired Kettle. The main objective of this equipment is to heat various bitumens and...
  • Page 5 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.

  • Page 8: Operations

    TRAILER Connect to 12 volt power on tow vehicle ISOLATOR Connection to the tow vehicles battery is required when the Stepp SBF is equipped with spark ignition or 12 volt electronic thermostats and does not have its own battery charging system. (i.e.: onboard engine or generator) The isolator will protect the battery on the trailer from discharging through the tow vehicles electrical system.
  • Page 9 OPERATIONS Loading WARNING: Be sure operators have been properly instructed in starting and operating equip- ment. 1. Check that the proper material is being used. 2. The tank must be thoroughly cleaned if the material being loaded is not compatible with that already in the tank.
  • Page 10 OPERATIONS LP Burner w/ Thermostat This system uses electrical sparks to ignite the pilot lights that, in turn, ignite the burners. If the pilot light goes out, the system will attempt a re-ignition. If the re-ignition is not successful, the gas supply will automatically be shut off and the system must be vented before resetting the system.
  • Page 11 OPERATIONS LP Burner w/ Baso Valve When equipped with a Baso Safety Valve, this system will shut off the gas supply to the burn- ers if the flame should go out for any reason. This system is not equipped with automatic tem- perature controls.
  • Page 12 OPERATIONS Diesel Burner This system incorporates a 12 volt burner and blower assembly and burns #2 diesel fuel. A 12 volt battery and charging circuit supplies power to the burner, blower motor, and thermo- stat. The charging circuit may consist of an engine driven alternator mounted on the unit, or a hook-up to the tow vehicle’s charging system.
  • Page 13 OPERATIONS Pumping System w/ Spray Wand An optional pump may be installed to pump material through a spray wand. The pump may be driven by a gas or diesel engine or by an electrical or hydraulic system. The plumbing must be purged of material when finished to prevent plumbing freeze-up. This is done by re- versing the pump to suck the material out of the wand.
  • Page 14 OPERATIONS Pumping System w/ Spray Wand CONT. 4. System Flush. (optional) Flushing solvent is pumped through the pump and wand to clean material from the system. WARNING: The burners must be extinguished prior to performing flushing operations. DO NOT allow flushing solvent to contaminate the contents of the main tank. a.
  • Page 15 OPERATIONS Pumping System w/ Wand & Spray Bar An optional pump may be installed to pump material through a wand and spray bar. The pump may be driven by a gas or diesel engine, or by an electrical or hydraulic system. The plumbing must be purged of material when finished to prevent plumbing freeze-up.
  • Page 16 OPERATIONS Pumping System w/ Wand & Spray Bar CONT. 5. System Flush. (optional) Flushing solvent is pumped through the pump, spray bar, and wand to clean material from the system. WARNING: The burners must be extinguished prior to performing flushing operations. DO NOT allow flushing solvent to contaminate the contents of the main tank.
  • Page 18 OPERATIONS Misc. Heated Hose & Wand (optional) CAUTION: DO NOT turn on the wand heat unless the hose is filled with material. Damage to equipment may result. The application wand and hose may be equipped with an optional electrical heating element. This heating element prevents the product from freezing in the hose and wand.
  • Page 20 SBF MAINTENANCE SCHEDULE ITEM OPERATION TO PERFORM DAILY EVERY EVERY EVERY EVERY EVERY WEEK MONTH YEAR Product Pump Adjust end clearances and packing as needed. Burner Orifice Clean and blow out with compressed air. Heating Flues Clean and inspect for leaks. Door Hinges Lubricate with high temperature grease.
  • Page 21 SBF MAINTENANCE RECORD DATE MAINTENANCE PERFORMED HOUR METER SERVICED BY All maintenance items must be performed according to the maintenance schedules and documented for warranty coverage to be effective.

  • Page 22: Maintenance

    MAINTENANCE Engine Oil & Filter Change 1. Run engine until operating temperature is reached, then shut OFF engine. 2. Place drain pan under oil drain hose. 3. Open oil drain valve and drain oil from the engine. 4. Close the oil drain valve. 5.
  • Page 23 MAINTENANCE Hydraulic System Maintenance Filter Change 1. Position drain pan under filter. 2. Remove oil filter. 3. Lubricate gasket of new filter with hydraulic oil. 4. Install new filter, hand tighten only. 5. Start unit and check for leaks. 6. Shut down unit, then check hydraulic oil level. Hydraulic Oil Change 1.
  • Page 24 MAINTENANCE Burner Fuel Filter Replacement (burner) 1. Close fuel shutoff valve located at the fuel tank. 2. Remove the nut securing the canister to the fuel filter body. 3. Remove the canister and the filter element. 4. Replace the element with a new one. 5.

  • Page 26: Troubleshooting

    TROUBLE SHOOTING Hydraulic System POSSIBLE CAUSE Items to Check /Service Plugged Strainer Screen Service strainer screen LACK OF PERFORMANCE Hydraulic Filter Plugged Replace hydraulic oil filter Collapsed Suction Hose Replace suction hose and ser- vice strainer screen Air Leak in Suction Hose Replace hose.
  • Page 27 TROUBLE SHOOTING Product Delivery POSSIBLE CAUSE Items to Check /Service Product in Tank not Melted Allow more time for product to PRODUCT PUMP melt. DOES NOT TURN Foreign Material Jamming Product Pump Remove foreign material from product pump Pump Motor not Functioning Refer to “Hydraulic System”...
  • Page 28 TROUBLE SHOOTING Product Pump Lack of flow from wand. Check for rotation No Rotation Engage pump control Refer to hydraulic Little or no of product pump. and observe engine system trouble change in RPM. shooting. Rotation Definite RPM drop Check that the pump control is in Check that the product CAUTION:...
  • Page 29 TROUBLE SHOOTING Electric Wand & Hose 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 for an open resister or open wires Start engine, with wand 9 volts or less from battery to alternator, or a short-...
  • Page 30 Test the Primary control- condition, turn main power ler function, replace if switch “off” then “on” again to Check the photo faulty. Contact Stepp reset the system. electric eye for a Mfg. if this does not cor- Check to see if : dirty lens and prop- rect problem.
  • Page 31 TROUBLE SHOOTING Diesel Burner Component Test 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 wir- ing schematics for wire identification. 1.
  • Page 32 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;...
  • Page 33 TROUBLE SHOOTING LP Burner Spark Ignition Pilot won't ignite Pilot ignites & then goes out. (flame not sensed causing control to lock out) Turn power switch ON and check for sparks at electrodes Check for sufficient flame to at pilot light. be sensed.
  • Page 34 TROUBLE SHOOTING LP Burner Fuel Valve Solenoid The fuel solenoid valve needs to be removed to perform this test. 12 volts applied to the fuel solenoid valve activates an electromagnet that pulls the valve open. With no power applied, a spring pushes the valve closed.
  • Page 35 TROUBLE SHOOTING Fenwal Ignition Tests Fenwal Ignition Control The Ignition Controller can be tested for proper operation using an automotive type 12 volt battery as a power source. A propane torch, and a 12 volt test light will also be needed. Do not use a digital volt/ohm meter, as it may give false readings for these tests.

  • Page 38: Replacement Parts

    REPLACEMENT PARTS Diesel Burner ITEM DESCRIPTION PART# Burner assembly w/ Primary Control (less fuel retention head and nozzle)..A10008215 Burner assembly, complete w/ fuel retention head and nozzle ....... A10008105 Air Tube ......................509070 Photo electric eye (under ignition transformer) -With Connectors ..................
  • Page 39 REPLACEMENT PARTS LP Burner ITEM DESCRIPTION PART# Orifice, main burner call Burner assembly call Pilot light, spark ignition 901101 Ignition electrode & flame sensor assy. P10005738 Low voltage cable assembly P10005737 Ignition control box P10005719 High voltage cable assembly P10005736 Orifice, pilot light, .035 P10005718 LP Solenoid valve assembly, 12V...
  • Page 40 REPLACEMENT PARTS Spray Wand ITEM DESCRIPTION PART # Wand Assembly Complete, Steel (Includes Item 1-4) A10008187 2 Port Valve, Brass, 3/4” 517012 Coupling 3/4 to 1/4 513809 Veejet Nozzle, H1/4W-9508 520060 Hose 1/2 x25’ Yellow Ortec 523006 Note: Illustrations are for parts identification only. Illustrations may not represent actual parts.
  • Page 41 REPLACEMENT PARTS Controls ITEM DESCRIPTION PART# Thermostat, Watlow 0-550°, (12volt) P10003540 Sensor, RTD Watlow 0-550°, (12volt) A10001017 Switch– SPST Toggle ON/OFF P10000180 Light– Call For Heat 12V P10000181 Volt Meter P10000184 20 Amp Breaker P10000179 ** Not Shown...
  • Page 42 REPLACEMENT PARTS Product Pump Drive Line ITEM DESCRIPTION PART # Motor, Hydraulic Call Woodruff Key, ¼" × 1" Call Chain Hub, 4016 x5/8 Bore P10004555-001 Coupling Chain, 4016 P10004556 Chain Hub, 4016 x 3/4 Bore P10004555-002 Drive Key, 3/16" x 1 1/2"L Call Product Pump (refer to parts break-down page) P10004373...
  • Page 43 REPLACEMENT PARTS Product Pump ITEM DESCRIPTION PART# HL32 Pump L/RV P10004373 Note: Illustrations are for parts identification only. Illustrations may not represent actual parts. Items without part num- bers are available by giving the part description and the serial number of the equipment.
  • Page 44 REPLACEMENT PARTS Valves ITEM DESCRIPTION PART # 2 Port Valve, 1/2" 517005 2 Port Valve, 1" 517018 2 Port Valve, 1 1/2" P10008125 2 Port Valve, 2" 517014 3 Port Valve, 1/4” 517023 3 Port Valve, 1" P10004391 3 Port Valve, 1 1/2" P10004387 Note: Illustrations are for parts identification only.

  • Page 45: Nhtsa Reporting Safety Defects

    If you believe that your vehicle has a defect in which could cause a crash or could cause injury or death, you should imme- diately inform the National Highway Traffic Safety Administration (NHTSA) in addition to notifying STEPP MANUFAC- TURING CO., INC..

  • Page 47: Warranty Guide

    Consumer Warranty Guide 12325 River Road, North Branch, MN 55056~ Phone: 651-674-4491~ Fax: 651-674-4221 www.steppmfg.com...
  • Page 48 If you do not have the facilities, or the technicians, to perform the repair, the unit can be brought to a local repair facility. In either case, Stepp Manufacturing MUST be contacted and authorize the warranty repair PRI- OR to any work being performed.
  • Page 49 Stepp Manufacturing Co., Inc. hereby warrants, to the original purchaser of new equipment, that products manufactured by Stepp Manufacturing will be free from defects in material and workmanship for a period of one (1) year from the date of purchase from Stepp Manufacturing.
  • Page 50 The pro-rated adjustment is based on the total number of months elapsed since the purchase date of the new equipment from Stepp Manufacturing. This rate is then applied to the one-half (0.5) hour labor rate and the current suggested retail price of the proper replacement heated asphalt hose or heating element supplied by Stepp Manufacturing.
  • Page 51 All parts returned must be tagged with the warranty authorization number and a copy of this claim. Retain all parts until credit is received from the factory. When requested, return the parts, along with this claim, to: Stepp Manufacturing Co., Inc. Attn: Warranty Department...
  • Page 54 Watlow 12v Series PM Temperature Controller Operators Programming Sequence for 12 volt devices. PN EZ-ZONE– P1003540 This programming sequence is taken from the manufacturers programming manual for this con- troller and reduced to eliminate the non-essential entries. Please follow the entries carefully and if any questions arise because of misunderstanding the instructions, see your supervisor or call the factory for clarification.
  • Page 55 Watlow Series PM-12 volt controller Sample Display Illustrations This display shows a typical temperature selection by the operator.  Upper display shows actual product temperature in red color.  Lower display shows operator desired maximum temp setting in green col- ...
  • Page 56 Watlow Series PM-12volt Temperature Controller Operators Programming Sequence for 12 volt devices This programming sequence is taken from the manufacturers programming manual for this controller and con- densed to eliminate the non-essential entries for ease of setup. Please follow the entries carefully and if any questions arise because of misunderstanding the instructions, please call the manufacturer for clarification.
  • Page 57 Watlow Series PM-12volt Temperature Controller Operators Programming Sequence for 12 volt devices Home Menu: Procedure for programming the Series PM-12 volt Watlow Control. Step 1: Connect all wires to Watlow control including RTD (temp sensor). Step 2: Connect power to Watlow controller. Step 3: Enter the Setup menu.
  • Page 58 Step 7: Press either the up or down key to select the Loop submenu. LOOP will be in the upper display and SEt will be in the lower display. If this is shown, press the advance key to enter the Loop submenu.
  • Page 59 Step 11: Use the up or down keys to select the global submenu gLbL will be in the upper dis play and SEt will be in the lower display. Press the advance key to enter the global menu. Parameter Value Description 11-1 display units...
  • Page 60 Parameter Value Description 18-3 id.5 75 degree F. Idle set point Advance key 18-4 h.hy 3.0 degree F. Heat hysteresis Advance key reads 3 on display 18-5 o.SP 0.0% Open loop set point Advance key Step 19: Pressing the advance key at parameter o.SP will advance you back to parameter C.r7 Press the infinity key...
  • Page 61 Step 28: Repeat steps 26 and 27 for display values of 4 through 2, changing each parameter to nonE. Note: The upper display will show the previous value you changed. You must increment this value from 4 through 20! Step 29: When all 20 parameters are set, press the infinity key once to return you to the main...
  • Page 68 MATERIAL SAFETY DATA SHEET SECTION 1 PRODUCT AND COMPANY IDENTIFICATION PRODUCT Product Name: UNIVIS N 32 Product Description: Base Oil and Additives Product Code: 8259 Intended Use: Hydraulic fluid COMPANY IDENTIFICATION Supplier: Canada Imperial Oil Limited, An Affliate of Exxon Mobil Corporation P.O.
  • Page 69 SECTION 4 FIRST AID MEASURES INHALATION Remove from further exposure. For those providing assistance, avoid exposure to yourself or others. Use adequate respiratory protection. If respiratory irritation, dizziness, nausea, or unconsciousness oc- curs, seek immediate medical assistance. If breathing has stopped, assist ventilation with a mechanical device or use mouth-to-mouth resuscitation.
  • Page 70 SECTION 6 ACCIDENTAL RELEASE MEASURES NOTIFICATION PROCEDURES In the event of a spill or accidental release, notify relevant authorities in accordance with all applicable regulations. U.S. regulations require reporting releases of this material to the environment which exceed the reportable quantity or oil spills which could reach any waterway including intermittent dry creeks. The National Response Center can be reached at (800)424-8802.
  • Page 71 PERSONAL PROTECTION Personal protective equipment selections vary based on potential exposure conditions such as applica- tions, handling practices, concentration and ventilation. Information on the selection of protective equipment for use with this material, as provided below, is based upon intended, normal usage. Respiratory Protection: If engineering controls do not maintain airborne contaminant concentrations at a level which is adequate to protect worker health, an approved respirator may be appropriate.
  • Page 72 OTHER INFORMATION Freezing Point: N/D Melting Point: N/A Pour Point: -48°C (-54°F) DMSO Extract (mineral oil only), IP-346: < 3 %wt SECTION 10 STABILITY AND REACTIVITY STABILITY: Material is stable under normal conditions. CONDITIONS TO AVOID: Excessive heat. High energy sources of ignition. MATERIALS TO AVOID: Strong oxidizers HAZARDOUS DECOMPOSITION PRODUCTS: Material does not decompose at ambient temperatures.
  • Page 73 SECTION 12 ECOLOGICAL INFORMATION The information given is based on data available for the material, the components of the material, and similar materials. ECOTOXICITY Material -- Not expected to be harmful to aquatic organisms. MOBILITY Base oil component -- Low solubility and floats and is expected to migrate from water to the land. Ex- pected to partition to sediment and wastewater solids.
  • Page 74 SECTION 14 TRANSPORT INFORMATION LAND (DOT) : Not Regulated for Land Transport LAND (TDG) : Not Regulated for Land Transport SEA (IMDG) : Not Regulated for Sea Transport according to IMDG-Code AIR (IATA) : Not Regulated for Air Transport SECTION 15 REGULATORY INFORMATION OSHA HAZARD COMMUNICATION STANDARD: When used for its intended purposes, this material is not classified as hazardous in accordance with OSHA 29 CFR 1910.1200.
  • Page 75 SECTION 16 OTHER INFORMATION N/D = Not determined, N/A = Not applicable THIS SAFETY DATA SHEET CONTAINS THE FOLLOWING REVISIONS: No revision information is available. ---------------------------------------------------------------------------------------------------------------------------------------- ------------- ---------------------------------------------------------------------------------------------------------------------------------------- ------------- The information and recommendations contained herein are, to the best of ExxonMobil's knowledge and belief, accurate and reliable as of the date issued.