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Stepp SMT series Operation, Maintenance And Parts Manual

Lp or diesel burner systems mini trailer emulsion tanker
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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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  • 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 Engineering Dept., Stepp Manufacturing Co. Inc., 12325 River Road, North Branch MN. 55056-6225 or call 651-674-4491. When ordering parts or making any inquiry about the Stepp SMT 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 SMT Mini Tanker. The main ob- jective of this equipment is to heat, transport, store, and apply various asphalts and emulsions for crack filling, seal coating, and priming of road surfaces.
  • 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 SMT is equipped with spark ignition or 12 volt electronic thermostats and does not have its own battery charging system. (ie: 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 1. Loading Procedures: a. Check that the proper material is being used. b. The tank must be thoroughly cleaned if the material being loaded is not compatible with that already in the tank. Check with your material supplier for compatibility. c.
  • 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 Agitator Agitator operation is control by a hydraulic control valve. Move the lever from the center posi- tion to engage the agitator. The agitator may be operated in either forward or reverse direc- tion. Adjust the variable flow divider to obtain the desired agitator RPM. (20 RPM recommend- ed) Depending on the type of product used, the contents of the tank may need to be heated before agitator operation.
  • Page 15 OPERATIONS Shutdown Procedures The plumbing system must be sucked-back and flushed of material when operations are com- plete or the system will plug and cause difficulty the next time the equipment is used. See previous pages for material suck-back instructions and operational charts to assist in valve operational placement.
  • Page 16 PUMPING OPERATIONS UNLOAD Unload/Wand Valve (10) WAND PRODUCT Wand/Recirc Air In Wand/Recirc Valve (2) Valve (4) Valve TANK Tank Wand position to Valve PUMP flush wand—— Re-circulate position to flush re-circulating plumbing. Flush Drain (5) Valve (3) = 2 Port Valve FLUSH TANK = 3 Port Valve...
  • Page 17 PUMPING SYSTEM UPPER TANK VALVE (7) FLUSH VALVE (9) FLUSH VALVE (3) AIR IN VALVE (4) TANK VALVE (1)
  • Page 18 WAND/RECIRC VALVE (2) DRAIN (5) UNLOAD (10) WAND/RECIRC VALVE (6)
  • Page 20 SMT MINI TANKER MAINTENANCE SCHEDULE ITEM OPERATION TO PERFORM DAILY EVERY EVERY EVERY EVERY EVERY WEEK MONTH YEAR...
  • Page 21 SMT MINI TANKER MAINTENANCE RECORD DATE MAINTENANCE PERFORMED HOUR METER SERVICED BY All maintenance items must be performed according to the maintenance schedules All maintenance items must be performed according to the maintenance schedules and documented for warranty coverage to be effective. and documented for warranty coverage to be effective.

  • Page 22: Maintenance

    MAINTENANCE Diesel Burner Fuel Filter Replacement (burner) 1. Close fuel shut off 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 24: Troubleshooting

    Test the Primary control- condition, turn main power ler function, replace if Check the photo switch “off” then “on” again to faulty. Contact Stepp electric eye for a reset the system. Mfg. if this does not cor- dirty lens and prop- Check to see if : rect problem.
  • Page 25 Diesel Burner Adjustments 1. Bleed all air from fuel system through bleeder screw. electrode 5/32” See Fig. 4 (burner motor must be running). 2. Check and adjust igniter electrodes as shown in Fig. 1. 3. Verify dimensional adjustments. The “Z” in dimen- nozzle sion is set to 1 1/8’...
  • Page 26 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 wir- ing schematics for wire identification. 1.
  • Page 27 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 28 TROUBLE SHOOTING Sensor Test The temperature sensor can be tested with a digital ohm meter. Using the chart below you can determine if the sensor is functioning properly.
  • Page 30 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 ....... A10008105-004 Air Tube ......................509070 Photo electric eye (under ignition transformer) -With Connectors ..................
  • Page 31 REPLACEMENT PARTS Controls ITEM DESCRIPTION PART# Thermostat, Watlow 0-550°, EZ 12V P10003540 Sensor, RTD Watlow 0-550° A10001017 Switch– SPDT Toggle ON/OFF P10002869 Light– Call For Heat 12V P10000181 20 Amp Breaker P10000179 Volt Meter P10000184 Overnight Heat ITEM DESCRIPTION PART# Heater 240v 3KW 2”...
  • Page 32 REPLACEMENT PARTS Filters ITEM QTY DESCRIPTION Z482 Oil Filter, Kabota 508054 Fuel Filter Element, Kabota 508055 Air Filter Element, Kabota 508053 Fuel Filter Element, General 509078 Hydraulic Filter, Zinga 510025 Service Kit, 400 hr. Includes 4 of item 1, 508061 1 each of items 2 through 4, and 2 of item 5.
  • Page 33 REPLACEMENT PARTS Twist Spray Wand ITEM DESCRIPTION PART # Wand assembly complete, steel 204004-5...
  • Page 34 REPLACEMENT PARTS Brakes & Axles ITEM DESCRIPTION PART# Magnet, electric brake (1 required for each wheel) .........Give Serial # Brake Shoe Set (1 set required for each wheel) ..........Give Serial # Brake Drum and Hub assembly (1 required for each wheel) ......Give Serial # Leaf Spring assembly (1 required for each wheel) ..........Give Serial # Complete replacement axle assemblies are available and include brakes, hubs, and springs.
  • Page 35 REPLACEMENT PARTS Heating System Repair Kit 12V Diesel or Propane Heating System Repair Kit These Kits are designed to eliminate down-time by organizing into one handy package the parts, troubleshooting procedures, and test tools, needed to complete virtually any repair of the Diesel or Propane burner systems and the electronic thermostats. The Kit includes a comprehensive troubleshooting and repair guide, test instruments, and all the common (and some not-so-common) parts to complete most repairs.
  • Page 36 REPLACEMENT PARTS Ortec Hose ITEM QTY DESCRIPTION PART # Hose, yellow ortec, 15 ft. 523038 Note: Illustrations are for parts identification only. Illustrations may not represent actual parts. Lighting ITEM DESCRIPTION PART # Clearance LED– Red P10002891 Clearance LED– Amber P10002894 4”...

  • Page 37: Parts

    Description– ENGINE PACKAGE PART # OIL - AMCO 300 15W 40W 603004 FUEL GAGE P10000150 FUEL PUMP - 12V DC P10000156 3’ HOSE - 5/16" FUEL LINE P10001239 HOUR METER P10002722 Z482 STRD ENGINE W/LIGHTS P10003760-001 Quantity Description PART # VALVE - HYD MANL 3POS 1500PSI 510005A HYD PUMP - 0.66 CU IN EATON...
  • Page 38 REPLACEMENT PARTS HL32 Product Pump ITEM DESCRIPTION PART# Pump, complete with relief valve..............515006 Pump, complete without relief valve, with steel rotor .... 515063 (OJK-50, 75, 120) Pump, complete without relief valve, with standard rotor ......515005 Packing seal, shaft ................... 515019 Bushing, bracket .....................
  • Page 39 REPLACEMENT PARTS Valves ITEM DESCRIPTION PART # 2 Port Valve, Brass, 1/4" ................. P10000155 2 Port Valve, Brass, 1/2" ................. P10008268 2 Port Valve, Brass, 3/4" ................. P10001772 2 Port Valve, Brass, 1" ..................517018 2 Port Valve, Brass, 1 1/2" ................P10008125 2 Port Valve, Brass, 2"...

  • Page 40: 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 41: Warranty Guide

    Consumer Warranty Guide 12325 River Road, North Branch, MN 55056~ Phone: 651-674-4491~ Fax: 651-674-4221 www.steppmfg.com...
  • Page 42 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 43 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 44 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 45 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 48 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 49 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 50 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 51 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 52 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 53 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 54 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 55 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 60 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 61 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 62 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 63 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 64 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 65 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 66 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 67 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 68 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 69 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.