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TM 09211A-14&P

U.S. MARINE CORPS TECHNICAL MANUAL

OPERATION AND MAINTENANCE MANUAL FOR THE TRAY RATION HEATING SYSTEM

NSN 7310-01-295-7479

THIS PUBLICATION IS REQUIRED FOR OFFICIAL USE OR FOR ADMINISTRATIVE OR OPERATIONAL PURPOSES. DISTRIBUTION IS LIMITED TO U.S. GOVERNMENT AGENCIES ONLY. OTHER REQUESTS FOR THIS DOCUMENT MUST BE REFERRED TO: COMMANDANT OF THE MARINE CORPS (ARD) WASHINGTON, D.C. 20380-0001. DESTRUCTION NOTICE: FOR UNCLASSIFIED, LIMITED DOCUMENTS, DESTROY BY ANY METHOD THAT WILL PREVENT DISCLOSURE OF CONTENTS OR RECONSTRUCTION OF THE DOCUMENTS.

FOR OFFICIAL USE ONLY

NOVEMBER 2005 PCN 184 092110 00

TM 09211A-CD

DEPARTMENT OF THE NAVY Headquarters, U.S. Marine Corps Washington, DC 20380-0001 30 November 2005 1. This Electronic Technical Manual (ETM), authenticated for Marine Corps use and effective upon receipt, provides system operation and maintenance with illustrated parts listing for the Tray Ration Heating System (TRHS). 2. Submit notice of discrepancies or suggested changes on NAVMC 10772 to: Commander, Marine Corps Systems Command, Attn: Assistant Commander Acquisition and Logistics (LOG/TP), 814 Radford Boulevard, Suite 20343, Albany, Georgia 31704-0343.

BY DIRECTION OF THE COMMANDANT OF THE MARINE CORPS

OFFICIAL:

D. M. FITZGERALD Program Manager/Infantry Combat Equipment (ICE) (PMM-162) Marine Corps Systems Command DISTRIBUTION: PCN 173 092110 00

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TM 09211A-14&P DEPARTMENT OF THE NAVY Headquarters, U.S. Marine Corps Washington, DC 20380-0001 30 Nov 2005 1. This Technical Manual (TM), authenticated for Marine Corps use and effective upon receipt, provides system operation and maintenance with illustrated parts listing for the Tray Ration Heating System (TRHS).
2. 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. Identify deficiencies in TMs and notify appropriate TM sponsor by submission of NAVMC 10772 (Recommended Changes to Publications/Logistics-Maintenance Data Coding). The NAVMC 10772 may be submitted via the Internet using web site http://www.matcom.usmc.mil/home.htm, scrolling down to the NAVMC 10772 Tracking Program and following the instructions provided, or by Electronic mail to mbmatcommarlogbases@matcom.usmc.mil, or by mailing of paper copy NAVMC 10772 in an envelope addressed to Commander, Marine Corps Systems Command, Attn: Assistant Commander Acquisition and Logistics (LOG/TP), 814 Radford Boulevard, Suite 20343, Albany, Georgia 31704-0343. If submitting a paper copy NAVMC 10772; it should be submitted to the above address in ail cases except when the authentication sheet in the technical publication directs otherwise. 3. This supercedes TM 09211A-14&P dated 30 April 2002.

BY DIRECTION OF THE COMMANDANT OF THE MARINE CORPS

OFFICIAL:

D. M. FITZGERALD Program Manager/Infantry Combat Equipment (ICE) (PMM-162) Marine Corps Systems Command DISTRIBUTION: PCN 184 092110 00 1

TM 09211A-14&P RECORD OF CHANGES TITLE OR BRIEF DESCRIPTION

CHANGE NO.

DATE

ENTERED BY

TM 09211A-14&P TABLE OF CONTENTS Section/Paragraph CHAPTER 1. I GENERAL INFORMATION ................................................................ Introduction ............................................................................................ 1-1. Equipment Overview................................................................... Page 1-1 1-1 1-1

II

Equipment Description .......................................................................... 1-2. 1-3. 1-4. 1-5. Tray Ration Heater ...................................................................... Inverter Assembly ....................................................................... Serving Tables, Stowing Clamp and Brackets ........................... Collateral Equipment...................................................................

1-5 1-5 1-11 1-12 1-13 2-1 2-1 2-7 2-8

CHAPTER 2.

Set up and use ....................................................................................... 2-1. 2-2. 2-3. Installation of the TRHS in the HMMWV................................. Initial Checkout and Adjustment of the TRHS ......................... Relocation of the TRHS ..............................................................

CHAPTER 3. I

OPERATING INSTRUCTIONS ........................................................... Controls and Indicators .......................................................................... 3-1. Operational Controls and Indicators ..........................................

3-1 3-1 3-1 3-4 3-4 3-7 3-8 3-8 4-1 4-1 4-1

II

Operating Procedures ............................................................................. 3-2. 3-3. 3-4. 3-5. Operation Under Normal Conditions ......................................... TRHS Maximum Single Site Procedure..................................... TRHS Maximum Multi-Site Capability ..................................... TRHS Operation Under Cold/Unusual Conditions ...................

CHAPTER 4. I

SCHEDULED MAINTENANCE.......................................................... Introduction ............................................................................................ 4-1. General .........................................................................................

TABLE OF CONTENTS (Continued) Section/Paragraph II Tools and Equipment ............................................................................. 4-2. 4-3. III TRHS Tool Kit ............................................................................. 3rd and 4th Echelon Tools and Test Equipment ....................... Page 4-3 4-3 4-3 4-5

Scheduled Maintenance ......................................................................... 4-4. Operator Preventive Maintenance Checks and Services (PMCS) ..................................................................

4-5

CHAPTER 5.

OPERATING PRINCIPLES, TROUBLESHOOTING AND CORRECTIVE MAINTENANCE........................................................ Operating Principles ............................................................................... 5-1. 5-2. 5-3. 5-4. 5-5. General ......................................................................................... Airtronic Burner Operation ......................................................... TRHS Tank Electrical Control System....................................... Tray Ration Heater Safety Features............................................ Airtronic Burner Safety Features................................................

5-1 5-1 5-1 5-1 5-5 5-5 5-6 5-7 5-7 5-8 5-9 5-10 5-11 5-11 5-12 5-13 5-15 5-16 5-17 5-17 5-18 5-18 5-19 5-20 5-20

II

Troubleshooting Procedures .................................................................. 5-6. 5-7. 5-8. 5-8a. 5-9. 5-10. 5-11. 5-12. 5-13. 5-14. 5-15. 5-16. 5-17. 5-18. 5-19. 5-20. 5-21. Overview of the Burner Troubleshooting Concept ................... Setting Up the Burner on the Workbench.................................. Using the Airtronic Burner Test Box.......................................... Motor Bump (Turn) Test............................................................. Igniter Test (Spark) ...................................................................... Air Control Solenoid Test ........................................................... Setting Up for the Fuel Pump and Priming Test........................ Fuel Troubleshooting .................................................................. Verification of Proper Burner Operation (Test Firing) .............. Adjusting Burner Settings ........................................................... Shutting Down and Storing the Burner...................................... Burner Fuel System Problems .................................................... Troubleshooting Burner System Air Leaks................................ Checking the Output of the Air Compressor with a Gauge...... Checking the Fuel Pump with Gauges . Using the Bubble Test to Locate Air Leaks................................ Checking the Fuel Sump for Leaks ............................................

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TM 09211A-14&P TABLE OF CONTENTS (Continued) Section/Paragraph III Troubleshooting the Tank 6-1. 6-2. 6-3. 6-4. 6-5. 6-6. IV Testing the Wiring and the Electric Controls of the Tank......... Troubleshooting the Power Inverter........................................... TRHS Tank Fuel Filter Replacement.......................................... Fuel Can Filter Replacement....................................................... Airtronic Burner Compressor Air Filter Replacement . TRHS Lid Latch Adjustment Page 5-21 5-21 5-24 5-25 5-27 5-27 5-28 5-29 5-29 5-30 5-32 5-50 5-51 5-68

Disassembly, Repair and Reassembly Instructions . 7-1. 7-2. 7-3. 7-4. 7-5. 7-6. Airtronic Burner Removal Airtronic Burner Installation Airtronic Burner Disassembly (Field Stripping) ........................ Fuel Pump Membrane Replacement.......................................... Airtronic Burner Assembly ........................................................ Burner/Control Box Wiring Instructions ...................................

Tank Repair ........................................................................................ 8-1. 8-2. 8-3. 8-4. Tank Lid Removal and Lid-Stop Replacement ......................... Tank Drain Valve Replacement .................................................. Tank Skid and Shock Absorber Replacement ........................... Tank Push Pull Switch Light Bulb Replacement.......................

5-68 5-70 5-71 5-72 5-73 5-74 5-74 5-75 5-76 5-77 5-78 5-79 5-80 5-82 5-85

VI

Tank Repair Depot Level . ................................................................. 9-1. 9-2. 9-3. 9-4. 9-5. 9-6. 9-7. 9-8. 9-9. Tank Auto/Boil Switch Replacement ......................................... Tank Lid Gasket Replacement.................................................... Tank Push Pull Switch Replacement.......................................... Tank Power Fitting Replacement................................................ Tank Circuit Breaker/Reset Switch Replacement...................... Tank Tilt Switch Replacement .................................................... Tank Thermodisc Removal/Replacement .................................. Teflon Probe Removal/Replacement.......................................... Replacement Flange Mounting Procedures ...............................

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TABLE OF CONTENTS (Continued) Section/Paragraph CHAPTER 6. I REPAIR PARTS..................................................................................... Introduction ............................................................................................ 6-1. 6-2. II Overview ...................................................................................... Content......................................................................................... Page 6-1 6-1 6-1 6-1 6-1 6-1 6-1 6-1 6-1 6-1 6-2 6-2 6-2 6-2 6-3 6-3 6-3 6-3

Explanation of Columns and Cross Reference..................................... 6-3. 6-4. 6-5. 6-6. 6-7. 6-8. 6-9. 6-10. 6-11. 6-12. 6-13. 6-14. 6-15. Overview ...................................................................................... Item Numbers (Column 1).......................................................... Model (Column 2) ....................................................................... National Stock Number (Column 3) .......................................... Reference Designator (Column 4).............................................. Indenture Code (Column 5)........................................................ Item Identification (Column 6) ................................................... Unit of Measure (Column 7)....................................................... Quantity (Column 8) ................................................................... Source Maintenance Recoverability Code (Column 9)............. Item Number Cross Reference ................................................... National Stock Number Cross Reference .................................. Part Number Cross Reference ....................................................

III

Definitions and Application of Source, Maintenance and Recoverability Codes ...................................................................... 6-16. Source Codes............................................................................... 6-17. Maintenance Codes ..................................................................... 6-18. Recoverability Codes ..................................................................

6-3 6-3 6-6 6-7 6-8 6-19 6-21 6-23 6-25 A-1 B-1 C-1

IV V VI VII VIII

Repair Parts Listing ................................................................................ Item Number Cross Reference .............................................................. National Stock Number Cross Reference ............................................. Part Number Cross Reference ............................................................... Commercial and Government Entities ..................................................

APPENDIX A. COMPONENTS OF END ITEM LIST................................................. APPENDIX B. PACKING LIST FOR TRHS................................................................. APPENDIX C. POWER CONVERTER SCHEMATICS (Reference Only)................

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TM 09211A-14&P LIST OF TABLES Page 1-1. 1-2. 1-3. 1-4. 1-5. 1-6. 2-1. 2-2. 3-1. 4-1. 4-2. 4-3. 4-4. 5-1. 5-2. 6-1. 6-2. 6-3. 6-4. TRHS Equipment........................................................................................ TRH Tank Specifications ............................................................................ Airtronic Burner Specifications .................................................................. Fuel Supply System Specifications............................................................ TRH Electrical Control Box Specifications ............................................... Inverter Assembly Specifications............................................................... TRH Initial Checkout and Inspection Procedures..................................... Airtronic Burner Checkout and Adjustment Procedures.......................... Estimated Tray Pack Requirements ........................................................... TRHS Maintenance Responsibilities.......................................................... TRHS Tool Kit............................................................................................. TRH Maintenance Kit Components .......................................................... TRHS Operator PMCS Schedule ............................................................... Airtronic Burner Generation Identification................................................ Optimum Settings for Generations 1,2, and 3 Burners (Tank-Type-1).... Burner Assembly Parts (Generation 1) ...................................................... Burner Assembly Parts (Generation 2 and 3)............................................ Tank Assembly Parts ................................................................................. Electrical System Parts ............................................................................... 1-2 1-7 1-9 1-9 1-10 1-11 2-7 2-8 3-4 4-2 4-3 4-4 4-5 5-4 5-16 6-10 6-13 6-16 6-18

LIST OF FIGURES Page 1-1. 1-2. 1-3. 1-4. 1-5. 1-6. 1-7. 1-8. 1-9. 1-10. 1-11. 2-1. 2-2 2-3. 2-4. 2-5. 3-1. 3-2. 3-3. 3-4. 3-5. 3-6. 4-1. 5-1. 5-2. 5-3. 5-4. 5-5. 5-6. 6-1. 6-2. 6-3. 6-4. 6-5. 6-6. A-1. Installed TRHS, Top View.......................................................................... Installed TRHS, Tailgate View ................................................................... Tray Ration Heater ...................................................................................... TRH-End View of Tank with Airtronic Burner Cover.............................. Open TRH Tank with Removable Tray Pack Rack................................... Airtronic Burner, Parts Breakout................................................................ 5-Gllon Fuel Can.. TRH Electrical Control Box........................................................................ Inverter Assembly ....................................................................................... Serving Tables, Stowing Clamp and Brackets........................................... Side-Loading Pan Carriers .......................................................................... TRH Stabilizing Devices (Cargo Bed Rings/Tiedown Strap Positioning)........................................................................................ Installed TRHS, Top View... Securing the Fuel Can ................................................................................ Securing Tables in the HMMWV. Converter Assembly. Inverter Assembly TRH Electrical Control Box TRH End View of Tank with Airtronic Burner Cover Top View of Burner Proper Set-up of the Serving Line ............................................................. Serving Tables, Stowing Clamp and Brackets TRH Maintenance Kit ................................................................................. Babington Atomization Principle ............................................................... Airtronic Burner Fuel-Air Mixing Process................................................. TRH Electrical Control Box Schematic ..................................................... Upper Acess Panel Wiring Schematic........................................................ Airtronic Burner Sub-Assemblies .............................................................. Airtronic Burner Control Box Wiring Diagram......................................... Tray Ration Heating System....................................................................... Burner Assembly......................................................................................... Burner Assembly Generation 1 (Illustrated Breakdown).......................... Burner Assembly Generation 2 and 3 (Illustrated Breakdown) ............... Tank Assembly ........................................................................................... Electrical System ......................................................................................... Components of End Item List.................................................................... 1-3 1-4 1-5 1-6 1-6 1-8 1-10 1-11 1-12 1-13 1-14 2-2 2-3 2-3 2-4 2-5 3-1 3-2 3-3 3-4 3-6 3-7 4-3 5-1 5-2 5-5 5-4 5-51 5-68 6-8 6-8 6-9 6-12 6-14 6-17 A-1

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TM 09211A-14&P SAFETY SUMMARY The following WARNINGS and CAUTIONS appear on the page referenced and are listed here for emphasis. WARNING NEVER USE GASOLINE IN THE TRAY RATION HEATER (TRH). GASOLINE IS VOLATILE AND MAY EXPLODE, CAUSING DEATH, SERIOUS INJURY AND/OR SIGNIFICANT DAMAGE TO EQUIPMENT. USE ONLY DIESEL, DF-1, DF-2, DFA, KEROSENE OR JP-8. (Pages 1-9, 2-2, 2-6, 3-9) WARNING NEVER LEAVE TRHS UNATTENDED WHEN OPERATING IN THE BOIL MODE. WATER MAY BOIL OVER CAUSING PERSONAL INJURY AND/OR EQUIPMENT DAMAGE. (Page 1-7) WARNING DRAIN ALL WATER FROM TRH TANK BEFORE LIFTING THE TRH INTO A HMMWV OR REMOVING IT FROM THE VEHICLE. ATTEMPTING TO LIFT A TRH CONTAINING WATER CAN RESULT IN INJURIES FROM LIFTING STRAIN OR EQUIPMENT DROP. FOUR PERSONS ARE REQUIRED TO PROPERLY LIFT A DRAINED TRH. (Pages 2-1, 2-10) WARNING USE THE 90-DEGREE EXHAUST ELBOW OVER THE EXHAUST PIPE TO ANGLE HOT EXHAUST AWAY FROM PERSONNEL AND EQUIPMENT. (Page 2-1) WARNING DO NOT TURN POWER ON UNTIL PROCEDURE TO FILL HEATER TANK WITH WATER IS COMPLETE. (Page 2-5) WARNING TRH EXHAUST PIPE MAY BE HOT. DO NOT TOUCH. DO NOT PLACE OBJECTS IN FRONT OF THE EXHAUST. (Page 2-9)

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WARNING TRH TANK WATER MAY BE SCALDING AND COULD CAUSE SERIOUS INJURY. REMAIN CLEAR OF TANK WHILE DRAINING. (Page 2-9) WARNING DO NOT EXPOSE THE AIRTRONIC BURNER, TRH ELECTRICAL CONTROL BOX OR INVERTER TO RAIN OR WATER TO AVOID ELECTRICAL SHOCK. UNPLUG INVERTER AND TRH ELECTRICAL CONTROL BOX PRIOR TO SERVICING OR REPLACING SYSTEM COMPONENTS. (Page 2-10) WARNING BEFORE RESETTING THE INVERTER CIRCUIT BREAKER, MAKE SURE THE TRH RED, PULL-ON/PUSH-OFF SWITCH IS IN THE OFF POSITION. THE SWITCH SHOULD BE TURNED OFF TO PREVENT UNNECESSARY DISCHARGE OF THE HMMWV BATTERY WHEN THE TRH IS NOT IN USE. THIS WILL PREVENT INADVERTENT TURN-ON OF THE AIRTRONIC BURNER. (Page 3-1) WARNING THE TRAY RACK AND HEATED TRAY PACKS ARE HOT. WEAR PROTECTIVE GLOVES WHEN HANDLING HOT TRAY PACKS AND #10 CANS. EXERCISE CARE WHEN OPENING THE LID OF THE TRAY RATION HEATER.. PLACING HANDS INTO WATER, EVEN IF PROTECTED BY A GLOVE, COULD RESULT IN A SERIOUS INJURY. (Page 3-6) WARNING TO AVOID CONTAMINATION OF FOOD AND POSSIBLE INJURY TO PERSONNEL, DO NOT LUBRICATE TRH LID HINGES. (Page 4-6) WARNING USE THE BOIL MODE ONLY FOR SHORT PERIODS OF TIME. EXTENDED USE OF THE BOIL MODE PRODUCES EXCESSIVE STEAM THROUGH THE PRESSURE RELIEF HOLE IN THE BACK OF THE LID AND CAUSES EXCESSIVE PRESSURE TO ACCUMULATE IN THE CANNED FOOD. PERSONNEL CAN BE BURNED BY VENTED STEAM OR PRESSURIZED, SCALDING CAN CONTENTS. (Page 5-5)

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TM 09211A-14&P WARNING BEFORE REMOVING AIRTRONIC BURNER FROM THE TRH, MAKE SURE THE TRH RED, PULL-ON/PUSH-OFF SWITCH IS IN THE OFF POSITION AND THE TRH ELECTRICAL CONTROL BOX IS UNPLUGGED FROM POWER SOURCE TO PREVENT ELECTRICAL SHOCK AND INADVERTENT AIRTRONIC BURNER IGNITION. (Page 5-29) WARNING TO MAINTAIN WATER TEMPATURE AND REDUCE THE CHANCE OF WATER CONTAMINATION AND ACCIDENTAL BURNING, KEEP THE TANK TOP CLOSED EXCEPT WHEN LOADING AND UNLOADING TRAY PACKS. (Page 3-5) WARNING #10 CANS CAN BECOME PRESSURIZED, TO AVOID INJURY PUNCH A HOLE IN THE CENTER OF THE CAN PRIOR TO OPENING WITH THE CAN OPENER. (Page 3-6) WARNING DO NOT EVER USE THE BOIL MODE TO PREPARE MEALS. IT BYPASSES BUILT IN SAFETY FEATURES AND CAUSES PERSONNEL TO BE BURNED BY VENTED STEAM OR SCALDING CAN CONTENTS. (Page 5-6) CAUTION DO NOT PLUG IN A COMPUTER OR ANY OTHER POWER SENSITIVE DEVICE AS HIGH VOLTAGE COULD DAMAGE THAT PIECE OF EQUIPMENT. (Page 5-24) CAUTION DO NOT USE THE LID HANDLE AS A LIFTING DEVICE FOR THE TRH AS IT WILL RESULT IN EQUIPMENT DAMAGE. (Page 2-1) CAUTION MAKE SURE ALL SWITCHES ARE IN THE OFF POSITION. (Page 2-5)

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CAUTION OMISSION OF ANY PROCEDURE IN THE REMOVAL, PACKING, STORAGE OR TRANSPORTATION PROCESS COULD ADVERSELY AFFECT SYSTEM SAFETY AND/OR OPERATIONAL EFFECTIVENESS. (Page 2-9) CAUTION LIFT THE TRH WITH A FORKLIFT ONLY IF THE TRH IS ON A PALLET. PUNCTURE OF THE TRH WALL CAN DAMAGE THE TRH BEYOND REPAIR. (Page 2-10) CAUTION TO MAINTAIN WATER TEMPERATURE AND REDUCE THE CHANCE OF WATER CONTAMINATION AND ACCIDENTAL BURNING, KEEP THE TANK TOP CLOSED EXCEPT WHEN LOADING AND UNLOADING TRAY PACKS. (Page 3-2) CAUTION LID LOCKING LEVERS ARE ADJUSTABLE. EXCESSIVE FORCE IS NOT REQUIRED TO CLOSE THE LID. EQUIPMENT DAMAGE CAN RESULT IF LOCKING LEVERS ARE OUT OF ADJUSTMENT. THE LID SHOULD BE JUST TIGHT ENOUGH TO PREVENT WATER LEAKAGE AROUND THE LID GASKET. (Page 3-5) CAUTION WHEN OPERATING THE TRH IN COLD WEATHER, KEEP THE LID CLOSED AND LATCHED EXCEPT WHEN LOADING AND UNLOADING THE HEATER TANK WITH TRAY PACKS. OPENING THE TRH TANK WILL RESULT IN HEAT LOSS. (Page 3-5) CAUTION IF THE TRH IS EVER OPERATED WITH THE WATER LEVEL SENSOR BYPASSED, THE WATER LEVEL MUST BE MONITORED AT ALL TIMES TO PREVENT EQUIPMENT DAMAGE. (Page 5-52) CAUTION STAND DIRECTLY BEHIND THE BURNER WITH THE NOSE FACING AWAY FROM YOU. (Page 5-15)

TM 09211A-14&P CAUTION ONCE THE BURNER IGITES IMMEDIATELY REMOVE THE LADLE WITHOUTCONTACTING BURNER FLAME TUBE. (Page 5-16) CAUTION ALL THESE PROCEDURES TO ISOLATE THE INOPERATIVE CONTROLS IN THE TRHS PRIMARY ACCESS PANEL ARE CONDUCTED WITH POWER APPLIED. EXERCISE EXTREME CAUTION WHLE PERFORMING THESE STEPS. REMOVE ALL JEWELRY AND ALWAYS USE ONE HAND WHLE PROBING. THAT WILL PREVENT ELECTRICAL SHOCK FROM PASSING THROUGH THE HEART. (Page 5-22) CAUTION IF IT IS EVER DETERMINED BY THE COMMANDING OFFICER THAT IT IS NECESSARY TO OPERATE THE TRHS WHILE BYPASSING A SWITCH IN THE ELECTRICAL PANEL, YOU MUST TAG THAT PANEL AND ENSURE THAT YOU MONITOR WHATEVER SAFETY FEATURE IS BYPASSED. FOR EXAMPLE IF THE TRHS IS OPERATED WITH THE WATER LEVEL SENSOR BYPASSED, THE WATER LEVEL MUST BE MONITORED AT ALL TIMES TO PREVENT EQUIPMENT DAMAGE. (Page 5-23) CAUTION ALL ELECTRICAL PARTS AND CONNECTIONS WITH THE EXCEPTIONS OF THE IGNITION TRANSFORMER AND PRIMARY CONTROL CAN BE SPRAYED WITH ELECTRO-MOTIVE CLEANSER. (Page 5-32) CAUTION DO NOT ATTEMPT TO ADJUST (MOVE) IGNITOR POST WHEN ADJUSTING SPARK GAP, THIS WILL CAUSE IGNITOR POST TO BREAK OFF. ATTEMPT ALL ADJUSTMENTS ON THE IGNITOR ONLY. (Page 5-34) CAUTION DO NOT DAMAGE O-RING CONNECTIONS AT BOTH ENDS OF CROSSOVER TUBE. (Page 5-38)

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CAUTION MAKE SURE THE PISTON IS IN ITS FULLY EXTENDED POSITION AND GENTLY PLACE THE COMPRESSOR HEAD OVER THE PISTON CHECKING CAREFULLY TO ENSURE THE PISTON RING DOES NOT BECOME DISLODGED FROM THE PISTON. THE COMPRESSOR HEAD SHOULD SLIDE OVER THE PISTON RING WITHOUT SIGNIFICANT RESISTANCE. DO NOT FORCE IT! THE PISTON RING OR THE COMPRESSOR CYLINDER COULD BECOME DAMAGED . (Page 5-49,52) CAUTION DO NOT FORCE THE WHEEL BACK ON THE SHAFT, IF NECESSARY PLACE A BLOCK OF WOOD OVER THE BLOWER WHEEL AND GENTLY TAP IT. (Page 5-54) CAUTION IT IS VERY IMPORTANT TO USE THE RETAINING PINS. THE PINS PREVENT THE BURNER FROM BACKING OUT OF THE FIREBOX. (PAGE 5-86)

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TM 09211A-14&P CHAPTER 1 GENERAL INFORMATION Section I. INTRODUCTION 1-1. EQUIPMENT OVERVIEW

a. This manual describes operation and maintenance procedures for the Tray Ration Heating System (TRHS). The TRHS is comprised of a Tray Ration Heater (TRH) and associated collateral and support equipment that form a component of the Marine Corps Combat Field Feeding System. When installed on an M998 High-Mobility Multipurpose Wheeled Vehicle (HMMWV) the TRHS is a fully-mobile system with heat-on-the-move capability to feed 250 hot tray ration meals in remote areas or 500 meals in a ration day. The system also supports nonmobile feeding requirements. b. The TRH consists of a stainless steel hot-water tank and a multi-fuel, Airtronic Burner that operates from its own fuel source (5-gallon can). A thermodisc maintains water temperature between 180oF to 200oF (180oF 5oF is required for heating tray packs). The TRH will heat 18 tray packs to serving temperature in about 40 minutes. When installed on the HMMWV, the TRH uses vehicular electrical power. If the TRH is not HMMWV-mounted, it can be plugged into any 120 VAC, 60 Hz source. c. When not in use, the TRHS is stored in a Quadruple Container (QuadCon). The QuadCon is also used for transporting. d. The TRHS can be fully installed on a HMMWV without material handling equipment. Easily installed, ratchet-operated tiedown straps secure the TRH as well as beverage containers and side-loading pan carriers for transportation within the HMMWV. After filling the TRH with potable water and connecting the fuel and electrical power, the TRH is ready for operation. Every TRHS is equipped with support items, including serving tables, serving utensils, insulated beverage containers, side-loading pan carriers, can opener and spare burner maintenance. e. When the HMMWV arrives at the feeding location, serving tables and equipment are deployed and a serving line is established. Hot tray packs are taken from the heater or sideloading pan carriers, opened and served. As hot tray packs are taken from the heater, they are replaced with cold ones, which will then be ready to serve at the next feeding site. Disposable plates and utensils, packaged in the unitized tray ration box, are used to feed cafeteria-style meals. When serving is completed, tables and equipment are put back on the HMMWV and secured for travel. f. Table 1-1, Page 1-2 lists all equipment provided with the TRHS. Figure 1-1, Page 1-3 and Figure 1-2, Page 1-4 illustrate key components of the TRHS installed in a HMMWV.

1-1

TM 09211A-14&P Table 1-1. TRHS Equipment


ITEM Quadruple Container (Quadcon) 1 Tray Ration Heating System Heater Tank with Airtronic Burner Can, Fuel, Five-Gallon Holder, Fuel Can, Bracket Assembly Fuel Line/Filter with Quick Disconnect (12 1/2-ft) Fuel Can Adapter Kit Inverter Assembly Collateral Equipment Padlock (for Quadcon) Tables, Folding, Stainless Bracket, Table, Rear Bracket, Table, Forward Clamp, Table Tiedown Straps, TRH Fire Extinguisher, 5-lb Bracket, Fire Extinguisher Tool Box, Portable Screwdriver, Cross Tip (1/4-in) Screwdriver, Flat Tip (1/4-in) Key Set, Hexagonal (2 to 5 mm) Pliers, Slip Joint, 8-in Wrench, Adjustable, 8-in Hammer, Blacksmiths, 3-lb Pan Carriers, Side-Loading Beverage Dispenser, 5-gallon Tiedown Straps, Pan Carriers and Beverage Dispensers Gloves, Thermal (pr) Technical Manual Utensil Box, Portable Can Opener, Stainless Steel, Edlund S11, w/Knife Table Adapter, Can Opener Tin Snips Thermometers, Pocket Spoodle, 8-oz Spoon, Perforated, 11-in Spoodle, 4-oz Spoon, Serving, 11-in Spatula Tongs, 9-in Knife, Cooks Wire Whip, French, 12-in Insulated Tray Pack Holders w/ Lids High Temperature Drain Hose, 4-ft Tray Pack Handling Tool #10 Can Handling Tool Exhaust Elbow Strap Adapter
1

QTY 1 1 1 1 1 1 1 2 3 1 1 1 2 1 1 1 1 1 1 1 1 1 3 6 2 2 1 1 1 2 1 2 2 4 2 6 2 2 1 1 24 1 1 1 1 1

Government furnished equipment (Marine Corps end items only).

1-2

TM 09211A-14&P

Figure 1-1. Installed TRHS, Top View

1-3

TM 09211A-14&P

Figure 1-2. Installed TRHS, Tailgate View

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TM 09211A-14&P Section II. EQUIPMENT DESCRIPTION 1-2. TRAY RATION HEATER. The TRH is comprised of an Airtronic Burner, heater tank with removable tray-pack rack and stabilizing devices (ratchet-operated straps). The TRH electrical control box (with red, pull-on/push-off switch) includes such safety features as a circuit breaker, low-water sensor, thermodisc and mercury tilt switch (turns the Airtronic Burner off in the event of an excessive angle of operation). Each component of the TRH is illustrated in the following paragraphs. Functional component descriptions are provided as required. a. TRH Tank

(1) Figure 1-3, Page 1-5, Figure 1-4, and 1-5, Page 1-6 along with Table 1-1, Page 1-2 contain identification of TRH parts and other TRH components.

Figure 1-3. Tray Ration Heater

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TM 09211A-14&P

Figure 1-4. TRH-End View of Tank with Airtronic Burner Cover

Figure 1-5. Open TRH Tank with Removable Tray Pack Rack

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TM 09211A-14&P Table 1-2. TRH Tank Specifications


Dimensions (Approximate) Height ............................................................................................................ Length............................................................................................................ Width ............................................................................................................. Weights (Approximate) Empty ............................................................................................................ With Tray Rations and Water ......................................................................... Capacity...................................................................................................................... Construction Supported Stainless Steel. 2 insulation layer between interior and exterior walls. Top connected by hinges and held open by a lockable hinge arm. Top closed and fastened with two pullover latches. Drain valve (3/4-inch) at the bottom right corner, opposite the Airtronic Burner end of water tank.

25.5 inches 53.0 inches 23.0 inches

285 pounds 400 pounds 30 gallons

Drain

Tray Pack Capacity 18/25 (with/without rack)

(2) The TRH tank can withstand cross-country transportation while loaded with 18 tray packs, securely held in a welded wire rack, which is submerged in hot water. The tank is well insulated to reduce loss from heat generated by the Airtronic Burner, which is attached at one end. b. Airtronic Burner

(1) Table 1-3, page 1-9 contains Airtronic Burner data. Figure 1-6, page 1-8 contains front and top views of the Airtronic Burner as well as an internal side view. WARNING NEVER LEAVE TRHS UNATTENDED WHEN OPERATING IN THE BOIL MODE. WATER MAY BOIL OVER CAUSING PERSONAL INJURY AND/OR EQUIPMENT DAMAGE. (2) The Airtronic Burner is a thermostatically controlled heat source for the TRH tank. It can heat the tank water to 212oF, if in the boil (see WARNING above) vice auto mode. The Airtronic Burner is attached to the tank by two mounting pins that support it above the HMMWV cargo bed. It uses fuel from a 5-gallon can mounted in the HMMWV. The Airtronic Burner can burn continuously for 10 hours on 5 gallons of fuel if the firing rate is preset for .5 gallons of fuel per hour. 1-7

TM 09211A-14&P

SUCTION INLET PORT SOLENOID VALVE (AIR) SOLENOID VALVE (FUEL) ELECTRIC MOTOR OVERFLOW SAFETY FLOAT FUEL PUMP STARTING BUTTON, INLET VALVE OUTLET NIPPLE RETURN FUEL REGULATOR FUEL PRESSURE GAUGE CONNECTION FUEL VACUUM GAUGE CONNECTION COMPRESSOR COMPRESSOR PRESSURE GAUGE CONNECTION 14. FILTER

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13.

15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28.

REGULATOR MODULE FUEL FLOW CONTROL BLOWER WHEEL CONTROL BOX RESET BUTTON FUEL SUMP DRAINAGE PLUG COMBUSTION AIR CONTROL ATOMIZATION CHAMBER PUMP PRESSURE ADJUSTMENT SCREW FUEL FILTER FUEL POWER CORD FINGER PRIMING PORT

Figure 1-6. Airtronic Burner Parts Breakout

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Table 1-3. Airtronic Burner Specifications Dimensions (Approximate) Height ........................................................................................................... Length........................................................................................................... Width............................................................................................................

11.125 inches 11.5 inches 12.25 inches

Power Requirement.................................................................................................. 120 VAC, 60 Hz

WARNING NEVER USE GASOLINE IN THE TRAY RATION HEATER (TRH). GASOLINE IS VOLATILE AND MAY EXPLODE, CAUSING DEATH, SERIOUS INJURY AND/OR SIGNIFICANT DAMAGE TO EQUIPMENT. USE ONLY DIESEL, DF-1, DF-2, DFA, KEROSENE OR JP-8. c. Airtronic Burner Fuel Supply System. Table 1-4 contains pertinent fuel system data. The 5-gallon fuel supply, independent of the vehicle supply, is easily installed/deinstalled for use inside the HMMWV or for use in static situations. A quick-disconnect fitting on the fuel line permits separation of the fuel source from the Airtronic Burner without spilling fuel line contents (Figure 1-7, Page 1-10). Table 1-4. Fuel Supply System Specifications Tank Bracket Fuel Line Can, fuel, military, 5-gallon, plastic Stainless steel, with strap for mounting to vehicle Hose, 1/4-inch, fuel, 12 1/2-foot total (12-foot section plus 1/2-foot section; one transparent, in-line fuel filter; four, 1/4-inch hose clamps; and two, quick-disconnect fittings [Parker]) Fits fuel can for suction feed

Adapter Kit

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Figure 1-7. 5-Gallon Fuel Can

d. TRH Electrical Control Box. Table 1-5 contains pertinent power data; Figure 1-8 depicts the red pull-on/push-off switch and the auto/boil switch on the TRH electrical control box. The stainless steel, weatherproof, TRH electrical control box houses the external, red, pull-on/pushoff switch, which is the primary operating control for the TRH. The TRH electrical control box also contains the auto/boil switch, Amphenol plug, circuit breaker and internal safety controls (thermodisc, low water sensor and mercury tilt switch). Table 1-5. TRH Electrical Control Box Specifications Power Box Type Primary Control 120 VAC, 60 Hz Stainless steel Red, pull-on/push-off

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Figure 1-8. TRH Electrical Control Box 1-3. INVERTER ASSEMBLY

a. Table 1-6, Page 1-12 contains relevant electrical data; Figure 1-9, Page 1-12 shows a diagram of the inverter assembly.

CAUTION NEVER PLUG AN ADDITIONAL APPLIANCE INTO THE INVERTER RECEPTACLE THAT USES MORE THAN 150 WATTS OF POWER. b. The inverter assembly converts vehicular 24 VDC to 120 VAC, 60 Hz with quasisine wave. A NATO slave plug connects the inverter to the HMMWV 24 VDC receptacle, located under the passenger seat. The inverter contains an integral ground fault receptacle, from which a power cord to the control box energizes the system. A switch on the inverter allows current to flow from the HMMWV. A green LED inverter indicator illuminates when power from the HMMWV is flowing through the inverter. A red LED low battery warning indicator illuminates when the HMMWV battery power is low, at which time the engine should be started to recharge the batteries. The assembly is protected by a 5 amp circuit breaker.

1-11

TM 09211A-14&P Table 1-6. Inverter Assembly Specifications Inverter Input Output Dimensions Ground Fault Receptacle Output Cover Switch Circuit Breaker

24 VDC 120 VAC, 60 Hz 7 x 7 x 14 inches

120 VAC, 60 Hz, 300 watts Weatherproof Toggle 5 amp

Figure 1-9. Inverter Assembly

1-4. SERVING TABLES, STOWING CLAMP AND BRACKETS. Three folding metal tables are stowed in the HMMWV as shown in Figure 1-2, Page 1-4 and Figure 1-10, Page 1-13. Two brackets, which fit on the right hand seat, secure the collapsed tables and prevent movement forward and back. A clamp, also installed on the right hand seat and attached to the canvas support, secures and separates the tables.

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Figure 1-10. Serving Tables, Stowing Clamp and Brackets 1-5. COLLATERAL EQUIPMENT. The TRHS is equipped with collateral equipment as discussed below. a. Side-Loading Pan Carriers. Three stackable, side-loading pan carriers are used to store 24 hot tray packs, which are heated prior to arrival at a feeding site. The heated tray packs are fitted into insulated tray pack holders, with lids, then placed into the side-loading pan carriers. Combined with 18 tray packs in the heater and those heated on site, a single HMMWV is capable of delivering at least 250 hot meals to the field at one site. Figure 1-11, Page 1-14 illustrates the side-loading pan carriers.

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Figure 1-11. Side-Loading Pan Carriers b. Other Equipment. Other essential TRHS collateral equipment includes: fire extinguisher, toolbox, beverage dispensers and serving utensils. Table 1-1, Page 1-2 contains a complete listing of collateral equipment. Figure 1-2, Page 1-4 shows collateral equipment stowed aboard the HMMWV.

1-14

TM 09211A-14&P CHAPTER 2 INSTALLATION 2-1. INSTALLATION OF THE TRHS IN THE HMMWV. The TRHS can be easily and safely installed in a matter of minutes. All components can be installed without material handling equipment. The following paragraphs detail the installation of the TRH, the TRH fuel supply system and the inverter. a. Tray Ration Heater

WARNING DRAIN ALL WATER FROM TRH TANK BEFORE LIFTING THE TRH INTO A HMMWV OR REMOVING IT FROM THE VEHICLE. ATTEMPTING TO LIFT A TRH CONTAINING WATER CAN RESULT IN INJURIES FROM LIFTING STRAIN OR EQUIPMENT DROP. FOUR PERSONS ARE REQUIRED TO PROPERLY LIFT A DRAINED TRH. WARNING USE THE 90-DEGREE EXHAUST ELBOW OVER THE EXHAUST PIPE TO ANGLE HOT EXHAUST AWAY FROM PERSONNEL AND EQUIPMENT. CAUTION DO NOT USE THE LID HANDLE AS A LIFTING DEVICE FOR THE TRH AS IT WILL RESULT IN EQUIPMENT DAMAGE. (1) Step 1. Place HMMWV tailgate in down position. Position TRH (without water) so that the Airtronic Burner end will enter the HMMWV first. Using four-man lift, place the TRH by its side handles into the HMMWV, taking care to keep the TRH relatively level so fuel will not run out of the Airtronic Burner. The skids on the bottom of the TRH will fit into the grooves on the cargo bed of the HMMWV. It may be necessary to move the TRH slightly from side to side so that it aligns with the cargo bed corrugated grooves. Line up the TRH skid rings with the D-rings on the left side of the HMMWV cargo bed as illustrated in Figure 2-1, Page 2-3. (2) Step 2. Install the two tiedown straps by looping them through the D-rings attached to the HMMWV cargo bed and the TRH skid rings. Snug the TRH to the bed of the HMMWV using the strap ratchet, but DO NOT over tighten. (Note: TRH may have to be lifted in order to install tiedown straps through D-rings.)

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Bed Rings

Figure 2-1. TRH Stabilizing Devices (Cargo Bed Rings/Tiedown Strap Positioning) WARNING NEVER USE GASOLINE IN THE TRAY RATION HEATER (TRH). GASOLINE IS VOLATILE AND MAY EXPLODE, CAUSING DEATH, SERIOUS INJURY AND/OR SIGNIFICANT DAMAGE TO EQUIPMENT. USE ONLY DIESEL, DF-1, DF-2, DFA, KEROSENE OR JP-8. b. Fuel Can

(1) Step 1. Install the fuel can bracket directly behind the drivers seat. The fuel can must be positioned in the HMMWV as shown in Figure 2-2 on page 2-4.

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TM 09211A-14&P (2) Step 2. Place a fuel can, filled with appropriate fuel, (DO NOT fill can while in HMMWV) in the bracket and secure as shown in Figure 2-3, Page 2-5. Run the securing strap in back of the can and in back of the boards of the troop seat, go through fuel can handle. DO NOT run strap over the top of the can handles. Fasten the strap and tighten securely.

Figure 2-2 Installed TRHS, Top View (3) Step 3. After the fuel can is in place and secure, ensure plastic dip tube is attached to the fuel can cap and connect the Airtronic Burner fuel line to the can using the adapter. The Fuel Can Adapter Figure 2-3, Page 2-5, with flexible probe attached, screws onto the top of the fuel can. The male metal fitting on the fuel line snaps into the female fitting on the feed line of the fuel can adapter. The other end of the fuel line fits the fitting at the Airtronic Burner cover. The vent screw on top of the fuel can adapter must be opened slightly to vent the fuel can so that the fuel pump in the Airtronic Burner will draw fuel from the can properly. Ensure the fuel line connector clicks when attached to the fitting at the Airtronic Burner cover and fuel can. 2-3

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Figure 2-3. Securing the Fuel Can c. Table Brackets, Clamp and Tables

(1) Step 1. Install front and rear table brackets on the right hand seat of the HMMWV as shown in Figure 2-4. A square tubing guide on the bottom of each bracket fits between the wooden troop seat slats. The rear bracket (closest to the tailgate) is placed on the seat and moved back until it hits the seat frame. The front bracket is placed on the seat so that the tab on the side fits into the seat frame.

Figure 2-4. Securing Tables in the HMMWV

2-4

TM 09211A-14&P (2) Step 2. Install tables with legs facing inboard to prevent snagging of clothing or equipment (Figure 2-4, page 2-5). (3) Step 3. Install the table clamp assembly in the location shown in Figure 2-4, page 2-5. Fit the metal bracket end of the assembly around the top wooden back support of the seat. Place the upright part around the tubular support for the HMMWV canvas top. Insert the quick release pins behind the upright tubing to complete installation. d. Inverter Assembly CAUTION DO NOT TURN POWER ON UNTIL PROCEDURE TO FILL HEATER TANK WITH WATER IS COMPLETE. CAUTION MAKE SURE ALL SWITCHES ARE IN THE OFF POSITION. (1) Step 1. Fit the metal bracket with attached inverter assembly over the middle of the panel that runs behind the driver and passenger seats. The inverter box should remain inside the cab. (2) Step-2. Plug in the cable to HMMWV NATO receptacle under the front of the passenger seat Figure 2-2, Page 2-4. (3) Step 3. Plug in the cord from the TRH electrical control box to the inverter receptacle outlet to send power to the TRH. Ensure reset button on RFI receptacle has not been tripped. Turn on the Power switch located on the front of the inverter to allow flow of 120 VAC 60 HZ to the outlet on the receptacle as shown in Figure 2-5. The green LED indicator will illuminate if current is flowing through the inverter. If vehicle battery is low, a red indicator will light up on electrical control box. In that case, start vehicle to supply power to run TRHS.

Figure 2-5 Inverter Assembly 2-5

TM 09211A-14&P e. Side-Loading Pan Carriers. Stack the three side-loading pan carriers behind the TRH Figure 2-2, Page 2-4 and secure to HMMWV D-ring via ratchet-operated strap. It may be necessary to fasten the short strap adapter to a D-Ring and run the tiedown strap through the strap adapter as all HMMWVs are not configured the same. f. Beverage Containers. Mount the six, 5-gallon beverage containers on the troop seat next to the TRH Figure 2-2, Page 2-4 and secure to seat with a ratchet-operated strap slung over the containers and under the seat-support slats. g. Fire Extinguisher. Mount the fire extinguisher/bracket Figure 2-2, Page 2-4 to an upright troop-seat slat, behind the tables, by inserting the bracket quick-release pin behind the slat. h. Tool Box, Utensil Box and Maintenance Kit. Place these items on the deck of the HMMWV as shown in Figure 2-2, Page 2-4. 2-2. SERVICING NECESSARY FOR TRHS USE. Service requirements prior to system operation are limited to filling the TRH fuel can with an approved fuel and filling the TRH with potable water (after the TRH is installed on the HMMWV). Cleaning procedures are discussed in Chapter 4, Section III and Table 4-4. WARNING NEVER USE GASOLINE IN THE TRAY RATION HEATER (TRH). GASOLINE IS VOLATILE AND MAY EXPLODE, CAUSING DEATH, SERIOUS INJURY AND/OR SIGNIFICANT DAMAGE TO EQUIPMENT. USE ONLY DIESEL, DF-1, DF-2, DFA, KEROSENE OR JP-8. a. Fueling. Detach the fuel line from the fuel can via the quick disconnect. Unbuckle securing strap from fuel can and remove can from HMMWV before refilling to prevent any spillage inside the vehicle. Unscrew the adapter from the fuel can and refill. After filling, secure cap, replace full fuel can in bracket and secure with strap. Replace fuel cap with fuel adapter kit and reconnect the fuel line. Ensure fuel can is vented by loosening the vent screw on top of the adapter kit slightly. b. Water Tank Servicing. For mobile operations, fill the TRH with potable water to the top of the tray pack rack only after it is installed in the HMMWV. Ensure that the drain valve (spigot) is closed before filling by pushing the drain valve handle until perpendicular to the spigot. The empty tray pack rack, however, should remain in the tank during filling. An empty tank will require approximately 10 gallons of potable water if 18 tray ration packs are to be placed in the tank. To cook fewer than 18 tray ration packs, add sufficient water so that only 1 1/2 inches of the tray ration packs are exposed above the water line. If a water shortage is encountered, only enough water to cover the water-level sensor need be used. Additionally, if

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TM 09211A-14&P necessary to change water while the TRH is mounted in a HMMWV, a water hose may be connected to the drain hose and the tank backfilled after it is drained. 2-3. INITIAL CHECKOUT AND ADJUSTMENT OF THE TRHS. The system checkouts and inspection procedures in Table 2-1 and Airtronic Burner adjustment procedures in Table 2-2, Page 2-9 must be accomplished prior to operating the TRHS. Table 2-1. TRHS Initial Checkout and Inspection Procedures STEP 1 PROCEDURE Visually inspect to ensure that required personnel, tools, parts, publications, accessories and support equipment are on hand for mobile or non-mobile application of the TRHS, as required. Refer to Table 1-1, Page 1-2 for a complete listing of TRHS equipment. Inventory equipment for missing items and visually inspect equipment for serviceability. Install the TRHS in accordance with paragraph 2-1, Page 2-1 of this manual. Inspect all stabilizing devices (side braces, brackets and tiedown straps) to ensure that TRHS is ready for travel. Inspect shock mounts for cracks. Perform operational services outlined in paragraph 2-2, Page 2-6 pertaining to fueling and water tank servicing. Inspect fuel line for visible leakage at fuel can and Airtronic Burner attachment points, adapter kit, filter and at the quick disconnect. Ensure the pressure release valve located in the lid of the TRH is clean and free of obstruction. Keep inverter power switch in the OFF position to prevent battery discharge until TRH is ready for use. Shut off TRH at the red, pull-on/push-off switch assembly by pushing the switch to the OFF position. Ensure that inverter NATO slave plug is properly plugged into HMMWV outlet. Ensure that Airtronic Burner power cord is properly inserted into the side of the TRH electrical control box via the push and twist Amphenol connection and the other end plugged into inverter outlet. Inspect cable connection at the TRH electrical control box receptacle for tightness. Adjust Airtronic Burner settings in accordance with Table 2-2, Page 2-8. The TRH is ready for operational use.

2 3 4 5 6 7 8 9 10 11

12 13 14

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TM 09211A-14&P Table 2-2. Airtronic Burner Checkout and Adjustment Procedures STEP 1 2 3 4 5 PROCEDURE Ensure that the TRHS has been properly installed and serviced for operation. Refer to Table 2-1, Page 2-7 and Chapter 2. Visually inspect for exterior damage to the Airtronic Burner (dents, loose or missing screws and leaks). Inspect fuel line for secure connection to Airtronic Burner fuel pump at the suction inlet port. Refer to Figures 1-6, Page 1-8 for location. Power the TRH using the switch on the inverter. Start the Airtronic Burner by pulling the red, pull-on/push-off switch to the ON position. The Airtronic Burner should pre-purge for about 20 seconds, then ignite. After ignition, go to Step 8. If the Airtronic Burner does not ignite, push red, pullon/push-off to OFF and go to Steps 6 and 7. Locate the following adjustment mechanisms on the Airtronic Burner. Refer to Figure 1-6, Page -8: starting button inlet valve, finger priming port, solenoid valve (air), Airtronic Burner control box reset button, combustion air control knob and fuel flow control knob. Check Table 5-1, page 5-16 to verify that the combustion air setting and the fuel flow settings are correct for the version of burner you are checking out. Locate and depress the reset button on the Airtronic Burner control box. Next, simultaneously cover the finger priming port and starting button inlet valve; pull the red, pull-on/push-off switch to the ON position. Upon ignition go to Step 8. Repeat this fuel priming step up to to 3 times, if the Airtronic Burner does not ignite. (Observe transparent fuel filter to check for fuel flow.) If the Airtronic Burner still fails to ignite replace the burner and refer to the troubleshooting steps in Chapter 5. Allow the Airtronic Burner to run and observe exhaust gas. If exhaust gas is smoke free, go to Step 9. If exhaust is smoking, leave the burner running for 5 minutes, if after that time it continues to smoke, swap out the burner and refer to the troubleshooting procedures in Chapter 5. Allow Airtronic Burner to operate for five minutes while inserted in the tank and the Auto/Boil switch in the Boil position and observe overall functioning. If the Airtronic Burner shuts off automatically during the test period, refer to the troubleshooting procedures in Chapter 5.

2-4. RELOCATION OF THE TRHS. The TRHS is designed for full operation during transport in a HMMWV. The system is rugged and fully capable of on-the-move operation over variable terrain. Although the system is rugged, care must be taken when removing the system to safeguard personnel and the system itself. The following paragraphs outline removal of the TRHS and give general guidelines for storage of the system. a. TRHS Removal. Before removal, review Table 1-1, Page 1-2, Chapter 1 for familiarization with all system components.

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TM 09211A-14&P WARNING TRH EXHAUST PIPE MAY BE HOT. DO NOT TOUCH. DO NOT PLACE OBJECTS IN FRONT OF THE EXHAUST. CAUTION OMISSION OF ANY PROCEDURE IN THE REMOVAL, PACKING, STORAGE OR TRANSPORTATION PROCESS COULD ADVERSELY AFFECT SYSTEM SAFETY AND/OR OPERATIONAL EFFECTIVENESS. (1) Step 1. Turn off TRH at the red, pull-on/push-off switch by pushing to off position (red light on switch should go out). Next, turn off power to the TRH at the inverter toggle switch (green indicator light on inverter should go out). Unplug power cable from the HMMWV NATO plug under the passenger seat. Next, unplug both ends of the power cable that leads from the TRH electrical control box to the inverter receptacle. Coil the cable and store it in the plastic tool box. Lift and remove the inverter mounting bracket. Remove bracket and power cable from the HMMWV. WARNING TRH TANK WATER MAY BE SCALDING AND COULD CAUSE SERIOUS INJURY. REMAIN CLEAR OF TANK WHILE DRAINING. (2) Step 2. Park the HMMWV facing slightly uphill in an area where water drainage is permitted. Open tailgate. Attach the 4-foot drain hose to the drain valve. Open drain valve located at the rear of the water tank by pulling handle out completely until perpendicular to TRH tank and drain water from tank. (3) Step 3. Disconnect fuel line from the 5-gallon can to the Airtronic Burner by pulling on the diverging section of the female portion of the Parker fitting, which will cause the male end of the fitting to pop out (it is imperative to keep the male end of the Parker fitting free of dirt as well as to prevent dirt from entering the female portion of the Parker double shutoff fuel inlet system). Remove the fuel can from the HMMWV. Disconnect fuel line from fuel can by pulling the quick disconnect fitting between the adapter kit and the fuel line. Unscrew adapter kit from fuel can. Drain hose into fuel can (depress nipples on both end fittings simultaneously). Screw adapter kit back onto fuel can and close the vent screw on the adapter kit. Wipe fuel line clean and store in plastic tool box. (4) Step 4. Close and latch the TRH lid. If necessary adjust lid latches by adjusting the position of the retaining nuts on the latch with an adjustable wrench. The lid need only be tight enough to prevent water leakage. Open ratchet to loosen and remove the tiedown straps. Release ratchet tension by pulling on the spring-tensioned slide bar on the under side of the ratchet handle in the direction of the arrow, then fully open the mechanism until the slide bar engages in the tab slots. The strap can now be unwound from the ratchet spindle. Roll the straps neatly and place them in the toolbox for safekeeping.

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TM 09211A-14&P WARNING DRAIN ALL WATER FROM TRH TANK BEFORE LIFTING THE TRH INTO A HMMWV OR REMOVING IT FROM THE VEHICLE. ATTEMPTING TO LIFT TRH CONTAINING WATER CAN RESULT IN INJURIES FROM LIFTING STRAIN OR EQUIPMENT DROP. FOUR PERSONS ARE REQUIRED TO PROPERLY LIFT A DRAINED TRH. (5) Step 5. Using the two built-in lift handles and one lift bar, raise and slide the fully drained TRH out of the HMMWV. DO NOT use lid handle for this purpose. Refer to Figure 1-3. Maintain the TRH relatively level when removing from the HMMWV to prevent fuel from running out of the Airtronic Burner into the fire box. Note: If fuel does enter the fire box, this does not create a safety hazard-the system will merely smoke when next started until the fuel burns out of the fire box. (6) Step 6. Lift top clamp and remove tables from HMMWV. Detach fasteners from metal upright and remove top clamp. Remove table brackets from seat. (7) Step 7. Check equipment list Table 1-1, Page 1-2 and remove remaining components of the TRHS. b. Packing and Storing the TRHS. Follow established procedures when packing the TRH and TRHS accessories for storage. The TRHS can operate in diverse environments. Accordingly, most enclosed storage facilities are adequate for storage of the system. Initial checkout and adjustment procedures contained in paragraph 2-3, Page 2-8 should be followed prior to placing the TRHS in service after any period of storage. When not in use, the TRHS should be stored in the Quadcon provided. The TRHS should never be left unprotected outdoors. WARNING DO NOT EXPOSE THE AIRTRONIC BURNER, TRH ELECTRICAL CONTROL BOX OR INVERTER TO RAIN OR WATER TO AVOID ELECTRICAL SHOCK. UNPLUG INVERTER AND TRH ELECTRICAL CONTROL BOX PRIOR TO SERVICING OR REPLACING SYSTEM COMPONENTS. c. Transportation of the TRHS. The TRHS can be transported overland without restriction, provided it is properly secured in a HMMWV or within a Quadcon. CAUTION LIFT THE TRH WITH A FORKLIFT ONLY IF THE TRH IS ON A PALLET. PUNCTURE OF THE TRH WALL CAN DAMAGE THE TRH BEYOND REPAIR

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TM 09211A-14&P CHAPTER 3 OPERATING INSTRUCTIONS Section I. CONTROLS AND INDICATORS This section provides operators and maintenance technicians with descriptions and illustrations of TRHS controls and indicators and discusses system operating procedures. 3-1. OPERATIONAL CONTROLS AND INDICATORS. Operator controls and indicators are designed for ease of operation and monitoring. 1. Inverter Circuit Breaker. The inverter circuit breaker is located on the receptacle box of the inverter. Figure 3-1 illustrates the location of the controls and indicators on the inverter. When the inverter is on and functioning properly, a green LED indicator illuminates to indicate DC power is flowing to the inverter. The inverter on-off switch enables the flow of 120 VAC 60 Hz power from the inverter to the TRH electrical control box. WARNING BEFORE RESETTING THE INVERTER CIRCUIT BREAKER, MAKE SURE THE TRH RED, PULL-ON/PUSH-OFF SWITCH IS IN THE OFF POSITION (PUSHED IN). THIS WILL PREVENT INADVERTENT TURN-ON OF THE AIRTRONIC BURNER. NOTE THE INVERTER CIRCUIT BREAKER SHOULD BE TURNED OFF TO PREVENT UNNECESSARY DISCHARGE OF THE HMMWV BATTERY WHEN THE TRH IS NOT IN USE.

Figure 3-1 Inverter Assembly

3-1

TM 09211A-14&P 2. Red, Pull-On/Push-off Switch. This control is located on the TRH electrical control box as shown in Figure 3-2. As the principal control on the TRHS, the pull on/push off style switch regulates the flow of electricity through a circuit breaker, to the TRH electrical control box, thermodisc and automatic safety sensors located within the TRH electrical control box. A schematic of the wiring and electrical flow is illustrated in Section 6-1, Figure 6-1-1, page 5-21.

Figure 3-2 TRH Electrical Control Box

3. Circuit Breaker. This control is located on the Airtronic Burner control box attached to the Airtronic Burner as shown in Figure 3-2. In the event of automatic system shutdown because of improper flame or lack of fuel, this button must be reset before power can be restored to the Airtronic Burner following corrective action. If automatic shutdown occurs, wait 2 minutes before pressing the reset button. A waiting period is necessary to cool the bimetallic relay. Reset should restore power to the Airtronic Burner.

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Figure 3-3. TRH-End View of Tank with Airtronic Burner Cover

4. Combustion Air Control. This knob is located on the top right of the Airtronic Burner, just behind the Airtronic Burner control box shown as Item 1 in Figure 3-4, Page 3-4 Top View of Burner, page 3-3. The knob has a center-positioned set screw, which, when tightened, prevents movement of the knob setting. The screw must be loosened before knob setting is changed. The combustion air setting should according to Table 5-1, Page 5-16 for best results on the Generation of burner you are currently using. 5. Fuel Flow Control. This screw adjustment is located on top of the Airtronic Burner, just to the left of the Airtronic Burner control box, shown as Item 2 in Figure 3-4, Page 3-4 Top View of Burner. This screw regulates the flow of fuel to the combustion (atomization) chamber of the Airtronic Burner. By regulating the flow of fuel, this adjustment further controls heat output. The fuel flow setting should be set according to Table 5-1, Page 5-16 for best results on the Generation of burner you are currently using.

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Figure 3-4 Top View of Burner

Section II. OPERATING PROCEDURES The TRHS is designed to operate within a wide range of climatic and physical conditions to meet the needs of personnel in the field. This section provides a step-by-step procedure for utilizing the TRHS after it is properly installed and serviced. System installation and checkouts should be accomplished in accordance with Chapter 2. Rations and disposable mess gear loaded in the HMMWV with the TRHS are from unitized, tray-ration modules. Each module provides about 50 meals. 3-2. OPERATION UNDER NORMAL CONDITIONS. Under normal conditions, no special servicing procedures or preventive maintenance activities need be accomplished. In general, this procedure would involve heating tray packs as well as #10 cans of food in the TRH, setting up of a serving line, serving the food and cleaning and stowing equipment and food items. The following steps are a guide to using the TRHS. 3-2-1 Set-Up Serving Line 1. Step 1. Establish whether the meals will be cooked in or out of the HMMWV. If the meals are to be cooked while the TRHS is in the back of the HMMWV, do not load with water until the TRHS is mounted in the HMMWV. 2. Step 2. Load TRH with tray packs and/or #10 cans (remove tray pack rack, if necessary) issued for feeding. 3. Step 3. To initiate operation, fill TRH with water such that 1 1/2 inches of tray packs are exposed or water level is approximately 2 inches from the top. 4. Step 4. Close TRH lid and secure latches.

3-4

TM 09211A-14&P WARNING TO MAINTAIN WATER TEMPERATURE AND REDUCE THE CHANCE OF WATER CONTAMINATION AND ACCIDENTAL BURNING, KEEP THE TANK TOP CLOSED EXCEPT WHEN LOADING AND UNLOADING TRAY PACKS. CAUTION LID LOCKING LEVERS ARE ADJUSTABLE. EXCESSIVE FORCE IS NOT REQUIRED TO CLOSE THE LID. EQUIPMENT DAMAGE CAN RESULT IF LOCKING LEVERS ARE OUT OF ADJUSTMENT. THE LID SHOULD BE JUST TIGHT ENOUGH TO PREVENT WATER LEAKAGE AROUND THE LID GASKET.

5. Step 5. Ensure auto/boil switch on TRH electrical control box is in the auto position. 6. Step 6. Ensure inverter switch is turned ON. 7. Step 7. Check that the vent on the fuel can adapter is open. 8. Step 8. Pull the red, pull-on/push-off switch to the ON position. 9. Step 9. Observe TRH for 5 minutes to ensure Airtronic Burner is functioning properly. 10. Step 10. Allow tray packs to heat to 180oF for a minimum of 40 minutes before removing to serve or place into side-loading pan carriers. 11. Step 11. Set up serving line. a. Set up tables by lifting the table clamp, removing tables from the HMMWV and assembling as shown in Figure 3-5, page 3-6. b. Install the stainless steel Edlund can opener in a mounting bushing, which must be placed in the opening on a table end (the shank on the stainless Edlund is smaller than the shank on the regular Edlund, for which the hole in the table is sized). Place the following items on the tables: disposable mess gear, beverage containers and supplements.

3-5

TM 09211A-14&P

Figure 3-5 Proper Set-up of the Serving Line WARNING THE TRAY RACK AND HEATED TRAY PACKS ARE HOT. WEAR PROTECTIVE GLOVES WHEN HANDLING HOT TRAY PACKS AND #10 CANS. PLACING HANDS INTO WATER, EVEN IF PROTECTED BY A GLOVE, COULD RESULT IN A SERIOUS INJURY. WARNING #10 CANS CAN BECOME PRESSURIZED, TO AVOID INJURY PUNCH A HOLE IN THE CENTER OF THE CAN PRIOR TO OPENING WITH THE CAN OPENER 12. Step 12. Remove tray packs from TRH tank first (replace with cold tray packs and close tank lid), then load side-loading pan carriers. Open tray packs and place on the serving line. 3-2-2. Tear Down Serving Line 1. Step 1. Clean tables and discard open tray packs and disposable mess gear. Repack can opener, beverage containers, cleaned serving utensils and remaining food supplements in the HMMWV. 2. Step 2. Fold table legs and place tables in their brackets in HMMWV. Place tables in the brackets so folded legs of each table are facing each other as shown in Figure 3-6, Page 3-7. Lock tables in place using the table clamp.

3-6

TM 09211A-14&P

Figure 3-6. Serving Tables, Stowing Clamp and Brackets

3-3.

TRHS MAXIMUM SINGLE SITE PROCEDURE. The TRHS can be used to feed 250 hot meals at one site in 90 minutes. This time period is adequate to set-up, serve and clean up.

1. Step 1. Heat first load of tray packs in preparation for the mission. Allow approximately 40 minutes for this activity. Place preheated tray packs in the insulated, side-loading pan carriers as shown in Figure 1-11, Chapter 1, Page 1-14. 2. Step 2. Place cold tray packs in the TRH tank and proceed to the feeding site. Allow about 40 minutes for these tray packs to heat before serving. 3. Step 3. After arrival at the feeding site, set up the serving line. Comply with the following serving procedures:

3-7

TM 09211A-14&P

a. First, serve hot tray packs brought to the site in the TRH tank. b. Second, place remaining cold tray packs in the TRH tank and serve the preheated tray packs in the side-loading pan carriers. c. Third, serve the remaining tray packs contained in the TRH tank. 3-4. TRHS MAXIMUM MULTI-SITE CAPABILITY.

1. The TRHS is capable of providing 500 meals to three or more sites within a ration day. The TRH fuel capacity is sufficient for at least 10 hours of continuous heater operation. The contents of 16 unitized tray ration modules can be loaded into the HMMWV at the beginning of the ration day and will require subsequent replenishment. 2. Operators must follow the pre-heating procedures listed in paragraph 3-3 so that hot meals are ready to serve at each site. At each site, operators must set up serving line, clean up tables and utensils (using hot soapy water) and stow TRHS equipment in the HMMWV for movement to a subsequent site. 3-5. TRHS OPERATION UNDER COLD/UNUSUAL CONDITIONS NOTE WHEN OPERATING THE TRH IN COLD WEATHER, KEEP THE LID CLOSED AND LATCHED EXCEPT WHEN LOADING AND UNLOADING THE HEATER TANK WITH TRAY PACKS. OPENING THE TRH TANK WILL RESULT IN HEAT LOSS. 1. General. The TRHS is designed to operate effectively in cold weather down to 25oF. The following precautions must be followed during cold weather/unusual conditions to prevent equipment damage and ensure overall system effectiveness. 2. TRH Use From 0oF to 32oF. If the TRHS is used once every 24 hours, no restrictions or special requirements apply when operating within this temperature range. The insulated tank and latched tank lid will maintain water temperature above 32oF. a. Operators must ensure that the tank lid gasket is sealing properly and preventing unnecessary heat loss from the tank. Operators are also advised to monitor tank water temperature, using the tank-mounted pocket thermometer, during periods when the TRH is not in use. b. If the TRH is used less than once every 24 hours, the tank should be drained after each use and then refilled as required when operating between 0oF to 32oF.

3-8

TM 09211A-14&P WARNING NEVER USE GASOLINE IN THE TRAY RATION HEATER (TRH). GASOLINE IS VOLATILE AND MAY EXPLODE, CAUSING DEATH, SERIOUS INJURY AND/OR SIGNIFICANT DAMAGE TO EQUIPMENT. USE ONLY DIESEL, DF-1, DF-2, DFA, KEROSENE OR JP-8. NOTE THESE PROCEDURES MUST BE ACCOMPLISHED PRIOR TO ENTERING ARCTIC CONDITIONS. USE THE AIR-ACTIVATED HEATERS IN THE MAINTENANCE KIT TO LOOSEN SOLENOIDS AND/OR VALVES, IF REQUIRED. 3. TRH Use from 25oF to 0oF. Special precautions must be taken when operating in this temperature range. Prior to operating the Airtronic Burner below 0oF, run the Airtronic Burner using Diesel Fuel Artic (DFA) for five minutes to purge the fuel line and fuel sump of non-arctic fuel. No further adjustments are required. Burn JP-8 or arctic diesel (DFA). 4. High Altitude. No adjustment to the Airtronic Burner is required at high altitudes. 5. Inclement Weather. When the canvas cover to the HMMWV is in use due to inclement weather, slide the 90-degree exhaust elbow (Figure A-2) over the exhaust pipe to angle hot exhaust away from the canvas cover.

3-9

TM 09211A-14&P CHAPTER 4 SCHEDULED MAINTENANCE INTRODUCTION 4-1. GENERAL

1. The purpose of this chapter is to prescribe the maintenance required for the TRHS. The general maintenance concept adopted for the TRHS combines all first and second-echelon organizational level maintenance. Operator maintenance will be done by Food Service Technicians (MOS 3381) of the using unit. Food Service Technicians (MOS 3381) will perform third and limited fourth-echelon maintenance (intermediate maintenance), under the supervision of the Staff Non-Commissioned Officer-in-Charge (SNCOIC). Troubleshooting and corrective maintenance presented later in this manual are based on manufacturer maintenance procedures. 2. This chapter illustrates the TRHS maintenance concept, operator responsibilities, third and limited fourth-echelon maintenance (intermediate maintenance) responsibilities. Illustrations in chapter 5 also support TRH Airtronic Burner maintenance. Chapter 6 contains exploded views of parts and components of the Airtronic Burner to illustrate parts location and National Stock Numbers (NSN) for ordering parts for repair. 3. Maintenance information is divided into two parts that correspond with organizational (first and second-echelon) and intermediate (third and fourth-echelon) maintenance. Fifth-echelon maintenance does not apply to the TRHS. Table 4-1 lists specific operator and maintenance technician responsibilities for replacement of TRHS components. Organizational level maintenance responsibilities include preventive maintenance checks and services and Airtronic Burner swap out and simple replacements. Intermediate maintenance responsibilities include troubleshooting and repair by piece-part replacement. The spare Airtronic Burner in the maintenance kit will be installed prior to shipping the failed Airtronic Burner to the FSSG. The failed Airtronic Burner will be placed in the maintenance kit and both will be shipped to the FSSG for 3rd and 4th echelon maintenance. NOTE WHEN THE REPAIRED AIRTRONIC BURNER AND MAINTENANCE KIT ARE RETURNED, THE USING UNIT WILL INVENTORY THE MAINTENANCE KIT AND REPLACE ANY MISSING PARTS WITH USING UNIT O&MMC FUNDS.

4-1

TM 09211A-14&P Table 4-1. TRHS Maintenance Responsibilities MAINTENANCE LEVEL ORGANIZATIONAL (1st/2nd Echelon) REPLACEMENT ASSEMBLY, COMPONENT, PART 1. Replace in-line fuel filter 2. Replace fuel hose/clamps 3. Replace Airtronic Burner (swap-out) 4. Replace TRH red pull-on/push-off switch peanut bulb 5. Adjust TRH lid latches 6. Replace TRH lid assembly 7. Replace shock mount 8. Replace Airtronic Burner control box 9. Replace TRH electrical control box components 10. Replace atomizing chamber 11. Replace photo cell/light socket 12. Skids and bushings 1. Replace Airtronic Burner components: a. Ignition transformer b. Electric motor and compressor c. Fuel pump and coupling d. Compressor head e. Piston ring and 0-ring f. Compressor filter g. Solenoid air valve h. Solenoid fuel valve i. Overflow safety device Repair TRH Structural Components1 a. Hinges b. Latches c. Handles d. Brackets Replace water level sensor Replace thermodisc Replace lid gasket

INTERMEDIATE (3rd Echelon)

(4th Echelon)

2.

3. 4. 5.

Structural repair via welding may be appropriate for incidental repair of these items. Reparability of stainless steel components is a matter of professional judgment of qualified maintenance technicians.

4-2

TM 09211A-14&P Section II. TOOLS AND EQUIPMENT 4-2. TRHS TOOL KIT. A limited number of tools are issued with the TRHS tool kit to support maintenance activities in the field. Table 4-2 lists these tools. Table 4-2. TRHS Tool Kit ITEM Tool Box, Portable Screwdriver, Cross Tip Screwdriver, Flat Tip Hex Wrench, Metric (2-5 mm) Pliers, Slip Joint Wrench, Adjustable QUANTITY/UNIT OF ISSUE 1 each 1 each 1 each 1 set 1 each 1 each

4-3. 3RD AND 4TH ECHELON TOOLS AND TEST EQUIPMENT. 1. A TRHS maintenance kit (encased in a 14 cubic stainless steel box with assembly tray), with test equipment and spare parts, is issued with each TRHS, as shown in Figure 4-1. Components of the maintenance kit are listed in Table 4-3, page 4-4.

Figure 4-1. TRHS Maintenance Kit

4-3

TM 09211A-14&P Table 4-3. TRHS Maintenance Kit Components ITEM Maintenance Kit Box & Assembly Tray Technical Manual: TM 09211A-14&P/1 Airtronic Burner (spare) Atomizing Chamber Assembly Fuel Pump Airtronic Burner Control Box Electronic Troubleshooting Test Box Test Box Adapter2 Burner Test Power Cord Photo Cell Photo Cell Light Socket Photo Cell Power Cord Spare Ignitor Ignition Transformer Assorted Gaskets and O-Rings Fuel Pump Pressure Gauge with Extension Fuel Pump Vacuum Gauge with Extension Compressor Pressure Gauge Nylon Pump Coupling Compressor Air Filter Small Tool Kit 10 mm Wrench (Open/Box) 11 mm Wrench (Open/Box) 5/8-Inch Wrench (Open/Box) 1/8-Inch Flat-Tip Screwdriver 3/16-Inch Flat-Tip Screwdriver Hose Clamps, Cotter Pins and Clips Fuel Filter QUANTITY 1 each 1 each 1 each 1 each 1 each 1 each 1 each 1 each 1 each 1 each 1 each 1 each 1 each 1 each 1 set 1 each 1 each 1 each 1 each 1 each 1 set 1 each 1 each 1 each 1 each 1 each 1 each 1 each

Maintenance Kits with TRHS serial numbers 1-28 only. Maintenance kits delivered with TRHS serial numbers 29 or higher have a test box with integral adapter built in.

4-4

TM 09211A-14&P Section III. SCHEDULED MAINTENANCE 4-4. OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS)

1. The key to TRHS maintenance is the thorough performance of preventive maintenance checks and services. The TRHS requires minimal first and second-echelon preventive maintenance (PM). Table 4-4 contains a PMCS chart, which lists task descriptions/schedule with four specific PM intervals to maintain system readiness. The as necessary (AN) requirement means the task may be performed more frequently, if needed. For example, changing TRH tank water is scheduled for weekly (W), AN. This means the water must be changed weekly, but must be changed more frequently if food or other foreign-matter have contaminated the tank. Table 4-4. TRHS Operator PMCS Schedule
MAINTENANCE SCHEDULE MANDATORY INTERVALS D W

STEP

MAINTENANCE TASK DESCRIPTION A U

A N

TRH Water Tank a. Check water tank in TRH for leaks. b. Check water level and fill. c. Drain water from TRH, clean and refill. d. Check straps and brackets for tightness. e. Clean exterior/interior of TRH. f. Inspect lid latches for serviceability. g. Inspect lid gasket for serviceability. h. Inspect tiedown straps for fraying/wear. i. Inspect strap ratchets for serviceability. j. Check tray pack rack for broken welds. TRH Fuel System a. Check fuel level and fill. b. Inspect fuel line for leaks. c. Check fuel can bracket/tiedown for tightness. d. Inspect fuel filter for serviceability. e. Drain fuel hose. TRH Electrical System a. Inspect inverter plugs/connections. b. Inspect NATO slave plug connection. Airtronic Burner a. Inspect Airtronic Burner for leaks. b. Check screw on control box for tightness (snug only, do not over tighten).

X X X X X X X X X X X X

X X X X X X X X X

LEGEND: AU = After Use; D = Daily; W = Weekly; AN = As Needed

4-5

TM 09211A-14&P Table 4-4. TRHS Operator PMCS Schedule (Continued) MAINTENANCE SCHEDULE MANDATORY INTERVALS A D W A U N X X X X X X X X X X X X X X X X

STEP

MAINTENANCE TASK DESCRIPTION

c.

Observe Airtronic Burner exhaust for smoke and/or fuel mist. d. Check air and fuel solenoid plugs for tightness. Table and Table Securing Devices a. Clean table tops. b. Lubricate table hinges. c. Lubricate clamp hinges. d. Adjust clamp hinges. e. Tighten nuts. Serving Utensils, Nonexpendable a. Inventory items. b. Inspect and sanitize can opener. c. Reorder components as necessary. d. Inspect cleanliness of utensils. Visual and Functional Checks a. Beverage containers. b. Side-loading pan carriers. c. Rain cover kit.

X X X

LEGEND: AU = After Use; D = Daily; W = Weekly; AN = As Needed.

WARNING TO AVOID CONTAMINATION OF FOOD AND POSSIBLE INJURY TO PERSONNEL, DO NOT LUBRICATE TRH LID HINGES. 4-4.1 TRHS Tank Preventive Maintenance. The tray ration heater tank contains no moving parts. Preventive maintenance; therefore, is limited to daily cleaning and a periodic inspection of structural integrity. Daily cleaning will prevent the build up of lime and scale deposits which can interfere with the proper functioning of the low water sensor. 1. Clean exterior of TRH tank with warm water. 2. Clean interior of tank periodically with Scotch Brite to remove mineral deposits (rinse thoroughly).

4-6

TM 09211A-14&P 3. Lubricate table hinges and strap ratchets with WD-40. 4. Clean serving utensils, tray pack handling tool, #10 can handling tool, beverage containers, side-loading pan carriers and insulated tray pack holders/lids with hot, soapy water and rinse thoroughly with clean, hot water. 5. Keep tools dry and coat occasionally with a thin film of WD-40 to prevent rust. 6. Clean folding table tops with hot, soapy water, rinse with clean water and dry. Wipe dirt from all brackets, clamps and straps. 4-4.2. TRHS Burner Preventive Maintenance 1. The Airtronic burner has moving parts and it produces fire to create heat. The fuel used to produce the flame also acts as a lubricant to keep the pump in good working condition. For this reason, the best form of preventive maintenance for the burner is frequent operation. 2. A burner used every day will experience fewer maintenance problems than one used infrequently and stored for long periods of time between uses. The user should plan to fire the equipment on a routine schedule, even during those times when no feeding requirement exists. 3. As a general rule, maintenance kit burners and any burner in warehouse storage should be exercised at least quarterly. 4. Check all wiring connections and ensure the photocell is properly mounted. 5. If burners are to be stored for any length of time, they should be drained of fuel prior to be being boxed or shipped. 6. Keeping the exterior of the burner free of dirt and accumulated residues will minimize the potential for cross-contamination by the operator.

4-7

TM 09211A-14&P CHAPTER 5 OPERATING PRINCIPLES, TROUBLESHOOTING AND CORRECTIVE MAINTENANCE Section I. OPERATING PRINCIPLES 5-1. GENERAL. This section contains, a description and discussion of the mechanical and electrical operating principles of the TRHS. 5-2. AIRTRONIC BURNER OPERATION

1. The Airtronic Burner employs a unique fuel-atomization technique to achieve highefficiency, reliable, smokeless operation. The atomization principle is shown in Figure 5-1. Fuel is supplied to the exterior surface of a hollow convex atomizer; fuel spreads out and covers the entire atomizing surface with a continuous thin film. The atomizer surface contains a small, lasercut hole. As compressed air escapes through this small orifice, it ruptures the portion of the thin film that flows over the exterior surface of the atomizer. This creates a continual dispersion of liquid particles that are as much as 10 times smaller in diameter than those produced by a conventional, burner. The portion of the fuel not turned into a fine mist by-the escaping air drains into a sump, where it is re-circulated back to the fuel supply system. This makes the Airtronic Burner insensitive to contamination, even if the fuel contains water, dirt or other particulate matter.

Figure 5-1. Babington Atomization Principle 2. The Airtronic Burner has two atomizers mounted in the atomizing chamber, as shown in Figure 5-2. The amount of fuel being converted into a mist is controlled by the Fuel Flow

5-1

TM 09211A-14&P Control screw, this regulates the thickness of fuel covering the atomizers, the thicker the coating of fuel, the more mist is made. The two sprays (mist) converge in the flame tube to create a swirling flame with excellent combustion stability. 3. A blower fan that is controlled by the Combustion Air Control knob provides the combustion air. This air mixes with the fuel mist to provide the additional air required for complete burning of the fuel. It is important to maintain a proper balance of fuel mist and this combustion air for proper operation. 4. Ignition is achieved with a compact, low-energy, solid-state ignition transformer that is located inside the Airtronic Burner housing. 5. Safety devices are incorporated into the burner by the use of a Primary Control Box(PCB). The PCB uses information collected from an attached photocell to determine if the burner is performing properly. The PCB controls startup and automatically stops the burner if any of the following cases occur; failure to start properly, flame failure while running, or problems with the control system on the burner.

Figure 5-2. Airtronic Burner Fuel Air Mixing Process

6. While all the Airtronic burners operate the same, there are three generations of these burners in use. To properly adjust and order replacement parts you need to be able to identify the types. 5-2

TM 09211A-14&P

Generation 1 Burner

Gen 1 Flow Control (Compatible w/Gen 2

Generation 2 Burner

Generation 2 Burner (Cont.)

Generation 3 Burner

Generation 3 (Sump w/Removable Foot Assembly) Sump is also compatible with Generation 2 Burner

5-3

TM 09211A-14&P

Generation 3 Burner (Flat Cam) Table 5-1 Airtronic Burner Generation Identification

Burner Configuration

Babington Part No

Production Date 1995-1997

Primary Configuration Changes Stainless Steel bolt-on mounting saddle Rectangular upper fan housing Small fuel sump Molded, die cast mounting saddle Same rectangular upper fan housing as Generation 1 Large fuel sump Same molded, die cast mounting saddle Curved upper fan housing USMC insignia etched into upper fan housing (cosmetic change only) Flat cam flow control module assembly

Generation 1

BEMO 110-1

Serial Numbers: 1-800 Jan 1998 Dec 1998

Generation 2

BAMO 110-1 Serial Numbers: 800-1000

Generation 3

BAMO 110-2

1999 - Present

5-4

TM 09211A-14&P 5-3. TRHS TANK ELECTRICAL CONTROL SYSTEM. The TRHS electrical system uses 120 VAC, 60 Hz, single-phase current, such as that provided by a standard U.S. electrical wall outlet. An inverter converts 24 VDC from the HMMWV NATO slave outlet to 120 VAC, 60 Hz. The Airtronic Burner maintains the TRHS tank water temperature thermostatically within a 180oF to 200oF (50F) range. The electrical system automatically shuts off the Airtronic Burner in the event of low water level, tilt or accidental tip over. These built-in safety features are discussed in further detail in this chapter. Figure 5-4 on page 5-6 shows a schematic diagram of the TRHS electrical control box circuitry.

. Figure 5-3. TRHS Electrical Control Box Schematic 5-4. TRAY RATION HEATER TANK SAFETY FEATURES. Both the TRHS and the Airtronic Burner each have their own unique safety features. The below listed components break the power supply to the Airtronic Burner as shown schematically in Figure 5-4. They must be functional before the Airtronic Burner will ignite. 1. Circuit breaker on the TRHS electrical control box (opposite the red, pull-on/push-off switch). 2. Mercury tilt switch to shut down the Airtronic Burner in the case of accidental tip over or excessive tilt.

5-5

TM 09211A-14&P 3. Water-level sensor to ensure that the Airtronic Burner will not fire without sufficient water in the TRHS tank. a. Thermodisc to regulate water temperature. b. Red, pull-on/push-off switch and auto/boil switch. WARNING DO NOT EVER USE THE BOIL MODE TO PREPARE MEALS. IT BYPASSES BUILT IN SAFETY FEATURES AND CAUSES PERSONNEL TO BE BURNED BY VENTED STEAM OR SCALDING CAN CONTENTS. 5-5. AIRTRONIC BURNER SAFETY FEATURES. When the TRHS safety parameters listed in paragraph 5-4, Page 5-4 are functional, the Airtronic Burner will operate under its own safety and control features, as listed below. 1. The Airtronic Burner photocell must see dark prior to light-off. This ensures it is properly installed in the TRHS, without light leakage. 2. During startup, the Airtronic Burner photocell must see light to establish proof-of-flame within 10 seconds or the Airtronic Burner control box will go into lockout. 3. After proof-of-flame is established, the ignition spark will turn off. This increases ignitor and ignition transformer life. 4. Airtronic Burner control constantly monitors flame to confirm proof-of-flame. 5. In the unlikely event the Airtronic Burner flames out for any reason, it will automatically relight within 10 seconds. 6. If proof-of-flame is not re-established after 10 seconds during re-light trial, the Airtronic Burner control goes into lockout. 7. The fuel level in the Airtronic Burner sump is constantly monitored; if the level rises too high for any reason, the overflow safety float will shut off the inlet fuel solenoid until the fuel level recedes to proper operating level. 8. Should the Airtronic Burner go into lockout, it must be manually reset by pushing the button on the back of the Airtronic Burner control box. This button has a red light indicator for lockout. After a two-minute wait, reset the Airtronic Burner control box by depressing the button and the red light will go out.

5-6

TM 09211A-14&P Section II. TROUBLESHOOTING 5-6. OVERVIEW OF THE BURNER TROUBLESHOOTING CONCEPT 1. To identify problems with the burner, follow the information provided in these troubleshooting steps. 2. The Triangle of Combustion is necessary to ensure proper operation of the burner. a. Fuel (The Diesel /JP8 Turned into a fog) b. Air (The blower motor & Compressor) c. Spark (The ignition electrode (Spark Plug) 3. The method to determine the Triangle of Combustion is a Step-by-step process to make sure that the burner has Fuel, Air, & Spark. It is also necessary to make sure that the photocell, which provides data to the Control Box is installed correctly and working. 4. The function of the Control Box (CB): a. The Control Box (CB) is there to ensure equipment and personnel safety. 1. If the burner is not lighting properly, it turns the burner off. 2. It is designed to ensure that a waiting period of at least 2 minutes occurs before you attempt to reignite the burner. 3. It keeps the TRHS burner from filling up with fuel after the fire blows out. b. Proper operation of the Control Box. 1. The following must occur before the CB will allow the burner to fire. a). The combustion chamber should be free of any fire. b). The CB allows the burner to attempt to fire for 10 seconds. If the burner has not ignited during this time it trips the re-set button and shuts down the burner. c. The detection of fire is accomplished by the photocell. 1. The photocell is designed to see light or detect when no light is available in the combustion chamber. 2. It then sends a signal to the CB as to whether light is present. 3. See Section 5-8 on page 5-11 for Photocell troubleshooting procedures.

5-7

TM 09211A-14&P 5-7 . SETTING UP THE BURNER ON THE WORKBENCH 1. Items needed: (See Figure 5-7-1) a. TRHS Table b. Fire Extinguisher c. Fuel Can with hose d. Power Test cord e. Test-Control Box f. TRHS Tool Kit g. Sheet Pan h. Burners to test i. Cleaning Gear

Figure 5-7-1 2. Establish the workbench outside or in a well-ventilated location. 3. Use the following steps to set up the workbench: a. Set the Burner on the bench inside the sheet pan. (This catches any spilled fuel.) b. Remove the Control Box from the Burner. c. Attach fuel line from the 5-gallon can (use the hose clamp). d. Place Test-Control Box on burner (Ensure all switches are in the OFF position, depressed to the left, toward the fuel line)

Figure 5-7-2

e. Connect Power Test Cord (See Figure 5-7-2)

5-8

TM 09211A-14&P 5-8. USING THE AIRTRONIC BURNER TEST BOX CAUTION THE TEST-BOX, WAS NEVER MEANT TO REPLACE THE CONTROL MODULE FOR OPERATION OF THE TRHS (COOKING). UTILIZING THE TEST BOX BYPASSES ALL THE BUILTIN SAFETY FEATURES OF THE TRHS AND RENDERS IT UNSAFE TO OPERATE. 1. There are several types of test boxes in use at this time, however all use the same markings on the switches.

Generation 1

Generation 2 and 3 (Fuses)

Generation 4

2. The TB also verifies whether or not the photocell is working properly.

5-9

TM 09211A-14&P 3. Photo Cell Test a. Face the front (nose) of the burner toward a good light source. b. Place hand over end of burner combustion chamber (Repeat). Figure 5-8-1. c. Watch the lights (LED) Bar Type LED on the TB. d. Ensure the LED bar goes up and down. Go /No-Go TB: It should Change from Bottom to the top LED (Light). Figure 5-8-1 e. The Generation 2,3 red LED will light when the nose of the burner is facing a light source. It will go out when the nose is covered or blocked from the light. f. The Generation 4 TBs have a different LED labeled FLAME. The FLAME LED will light when the nose of the burner is facing a light source. It will go out when the nose is covered or blocked from the light. 4. If the Photo Cell Test fails, check the following: a. Improperly installed. (The photocell is facing the rear of the burner instead of looking into the combustion chamber). b. The photocell has been pulled apart or is not properly inserted into the side of the burner. c. Wires pulled off the photocell connecter or connector is not fully seated. d. Photo Cell pulled apart 5-8A. MOTOR BUMP (TURN) TEST. 1. Briefly turn on the Motor switch ( 2. The Blower will start running. 3. Listen for any weird noises. (Fan Blade hitting housing, Motor not turning freely) 4. Turn motor off 5. If any problems were noted turn to Section 7.3 and replace the blower motor. ) on the Test-Box (looks like a Whistle or a hair dryer)

5-10

TM 09211A-14&P 5-9. IGNITER TEST (SPARK) 1. Turn on the Ignition Transformer switch ( ) on the Test-Box (Looks like two circles with bull horns on top) 2. You should hear a sizzle sound. 3. Look in the Combustion chamber for a Blue spark. (Figure 5-9-1) 4. Turn off Ignition Transformer switch. 5. If you do not see a spark refer to Section 7-1 to replace the igniter in the atomizing chamber. Figure 5-9-1 5-10. AIR CONTROL SOLENOID TEST 1. Turn on the Air Control Solenoid switch (ACS) may be labeled 1 or 2 depends on test Box) 2. You should hear a loud click. 3. Pick up your screwdriver 4. Locate the ACS on the side of the motor under the air compressor. 5. Hold the screwdriver very close to the end of the ACS, you should feel the screwdriver vibrating in your hand, this means the solenoid (its an electromagnet) has power running through it. (Figure 5-10-1), (Figure 5-10-2, Page 5-12 Close-up) 6. If the ACS is working, turn off the switch on the Test Box. 7. If the ACS is not working verify whether or not the cables on the Fuel/Air Control Solenoid are switched (Flipped). a. If you cant feel any vibrations, on the ACS put your screwdriver next to the fuel control solenoid located on the fuel pump. (Figure 5-10-3, Page 5-12) b. If you feel vibrations here (the fuel solenoid), it means the cables to the two solenoids have been switched (Flipped). (Looks like a brick with a bowtie on it,

Figure 5-10-1

5-11

TM 09211A-14&P c. Pull the cables off the solenoids and switch them so the ACS is the one that vibrates the screwdriver.

Figure 5-10-2 5-11. SETTING UP FOR THE FUEL PUMP AND PRIMING TEST

Figure 5-10-3

1. Remove the two screws holding the top of the fuel tower on. (Figure 5-11-1) 2. Remove the top of the fuel tower and the metal plate inside. 3. Check the gasket for any epoxy (glue) residue and clean it off. This will keep the gasket from properly sealing. a. Make sure the rubber O-ring is seated in the hole at the front of the tower and not stuck to the bottom of the plate you removed from the tower. Figure 5-11-1 3. Fuel Pump Priming a. With the fuel can and power cord attached, turn on the Motor switch ( Box (looks like a Whistle or a hair dryer)

) on the Test-

b. Place your thumb over the vent hole and press in the stud on the side of the fuel pump. This causes the pump to pull fuel at a faster rate of speed. (See Figure 5-11-2, Page 5-13) 4. Verify whether or not the burner is getting fuel.

5-12

TM 09211A-14&P a. Watch the fuel tower, it will look like its blowing bubbles, then it will start making smaller bubbles, when the fuel starts to foam, turn off the motor. (The air has been purged from the fuel lines and filled the fuel sump up.) (See Figure 5-11-3) b. If you do not get the desired results continue on to Step 5-12.

Figure 5-11-2 5-12. FUEL TROUBLE SHOOTING

Figure 5-11-3

1. Remove the Fuel Can Cap and check Fuel Can Dipstick or drawtube for the following: a. Bent or Kinked dipstick b. Dipstick connecter leaking air c. Bent and kinked fuel connecter hose d. Quick disconnect seating fully e. Fuel Filter f. Fuel filter hose clamps g. Section 5-16, page 5-17 discusses further fuel problems that may be identified once the burner is operating.

5-13

TM 09211A-14&P 2. Once Fuel problem is identified and corrected place reassemble the fuel tower. a. Replace the metal plate inside the fuel tower. b. Do not screw on the tower top, holding the tower top in place insert a flat tip screwdriver into the fuel adjustment screw, turn the screw left and right of a turn, this allows the screw cam to seat with the screw in the top of the tower. Figure 5-12-1 c. Put the screws back in and adjust. d. Place the screws in the top of the fuel tower and screw in by hand, do not tighten them yet

Figure 5-12-1

e. The arrow on the fuel screw should be set between 1 and 1.5 kg/hr. If the serial number on the burner is higher than 799 set it to read between 7 and 10. f. Tighten the screws on the fuel tower top by alternating between the 2 screws to ensure a good seal on the gasket. (Do not over tighten)

Generation 1 Fuel Tower

Flat Cam Fuel Control Tower (Generations 2 and 3)

5-14

TM 09211A-14&P 5-13 VERIFICATION OF PROPER BURNER OPERATION (TEST FIRING THE BURNER) 1. Remove the power source from the burner. 2. Install the Control-Box on the Burner, screw in the retaining screw. (Do not over tighten) (See Figure 5-13-1) 3. Press the re-set switch on the control box. 4. Lighting the Burner with a Control Box installed to verify proper operation of the burner. a. Get a 56-Dipper or an 8oz ladle to cover the nose of the burner, so the photocell does not detect light and send a signal to the CB that a fire already exist. (See Figure 5-13-2) Figure 5-13-1 b. Dont jam the bottom of the Dipper or ladle on to the end of the nose of the burner, leave space for the air to escape; you are just blocking the light from the end of the tube.

Figure 5-13-2 8. To start it up, connect the power test.

Figure 5-13-3

CAUTION STAND DIRECTLY BEHIND THE BURNER WITH THE NOSE FACING AWAY FROM YOU

5-15

TM 09211A-14&P CAUTION ONCE THE BURNER IGNITES IMMEDIATELY REMOVE THE LADLE WITHOUT CONTACTING BURNER FLAME TUBE. a. The Motor should start running; you will hear the spark kick in and 15 seconds later you will hear the Air solenoid Click and you should have fire, remove the dipper or ladle. (See Figure 5-13-3, Page 5-15) b. Let it run for 15 minutes, this will ensure that the Burner has had a chance to burn all the fuel out of the sump and refill it. If the Burner runs for 15 minutes without shutting down, which is a good indication that the Burner will operate properly once it is inserted into the TRHS. 5-14. ADJUSTING THE BURNER SETTINGS Table 5-2 Optimum Settings for Generations 1,2 and 3 Burners (Tank Type-1) Property Fuel Flow Control Combustion Air Control Compressor Air Pressure Fuel Pump Pressure Fuel Pump Vacuum Generation 1 Setting 1.0 to 1.5 9 20 to 27 psi .48 to .65 bars (7.09.5 psi) -.15 to -.35 bars (4.5-10.0 psi) Generation 2 Setting (Ser #799+) Between 7 and 10 Between 9 and 10 20 to 27 psi .48 to .65 bars (7.09.5 psi) -.15 to -.35 bars (4.510.0 psi) Generation 3 Setting (Flat Cam) Between M & H on the Arc Between 9 and 10 20 to 27 psi .48 to .65 bars (7.09.5 psi) -.15 to -.35 bars (4.5-10.0 psi)

1. The arrow on the fuel screw should be set between 1 and 1.5 kg/hr on burners with serial numbers 798 or below. New burners with serial numbers higher than 799 are set between 7 and 10. 2. If the Air knob is hard to turn loosen the screw on the air knob, turning it counter-clockwise about two turns. 3. While the burner is running, set the airflow. a. Rotating the Air knob observe the flame and length of the two tongs of flame that are coming out of the burner. (See Fig.5-14-1) b. Adjust them to be the same length. The dial should point between 9 and 10. Tighten screw. Figure 5-14-1

5-16

TM 09211A-14&P 5-15. SHUTTING DOWN AND STORING THE BURNER. 1.Remove the power cord from the top of the burner. 2.Let the burner cool down. 3.Remove the fuel line from the burner. 4.If storing the burner in the spare parts box, drain the fuel from the fuel sump, by removing the drain plug. (See Figure 5-15-1)

Figure 5-15-1 5-16. BURNER FUEL SYSTEM PROBLEMS 1. Burner is not making Fog or is Spitting Fuel while trying to ignite. a. To troubleshoot this it is necessary to have an understanding about how the fuel is atomized (turned into a fog). b. The atomizing chamber is made up of two (2) stainless steel atomizer (Bullet Heads) that are fuel fed by a liquid inlet valve (faucet) hanging over each of them. c. Fuel comes out of the liquid inlet valve and runs over the outside of the atomizer (Bullet Heads). While the fuel is being fed, compressed air is pumped through the small hole in the middle of the atomizer. This air grabs the fuel and sprays it out as a fine mist or fog. e. Taking the fuel and breaking it down into a fine mist makes the fuel very easy to burn. 2. After getting familiar with the Atomization principal, start troubleshooting possible fuel problems. 3. If you have not already purged the system of air, refer to Section 5-11 on Page 5-12 Setting up for the Fuel Pump and Priming Test. Use this procedure to ensure that there is no air in the Burner system. 4. If you purge the system and are still having fuel problems (fireflies or fuel spitting out of the flame tube (nose) of the burner, continue on to Section 5-17 and make sure that enough air is getting through the atomizer (Bullet Heads). 5-17

TM 09211A-14&P 5-17. TROUBLESHOOTING BURNER SYSTEM AIR LEAKS. 1. If your symptoms are fireflies or fuel spitting out of the end (nose) of the burner, the problem could be an air leak. 2. The problem could be that the compressed air going through the Bullet Heads does not have a high enough pressure form a fine mist and ignite. 3. The first test to perform is the Wiggle Test. a. Grab the stainless steel airline hose about an inch away from the end fitting and wiggle it, if it moves its not sealed. (See Fig. 5-17-1)

Figure 5-17-1

1) Before you tighten the fitting ensure that it is not cross-threaded by turning the fitting counter-clockwise until it is free from the Burner body. 2) Check the threads and make sure they have not been stripped or cross-threaded. If it is stripped or cross-threaded replace the airline. 3) If the threads on the burner body are cross-threaded, refer to Section 7.1 on page and replace the Air Control Solenoid. 4) If there is no cross-threading on the fitting or the Burner body, tighten down the fitting till the wiggle goes away. b. After ensuring the fittings are all tight proceed to Section 5-18 to check air pressure with a gauge. 5-18. CHECKING THE OUTPUT OF THE AIR COMPRESSOR WITH A GAUGE. 1. Place the Airtronic Burner and install test box. 2. Remove brass fitting from compressor cylinder with a 4 mm hex key. 3. Install the compressor pressure gauge (shortest of three gauges) in the head of the compressor and screw in compressor pressure gauge with 9/16 wrench about two turns. (See Figure 5-18-1, Page 5-19) 4. Turn on the Motor switch ( ) on the Test-Box (looks like a Whistle or a hair dryer). While the motor is running the Gauge should read about 2 PSI.

5-18

TM 09211A-14&P 5. While the blower is operating Turn on the Air Control Solenoid switch (ACS) (Looks like a brick with a bowtie on it, may be labeled 1 or 2 depends on test Box), the Gauge should read between 20-32 PSI. (25-27 PSI is preferred) a. A pressure reading above 32 PSI indicates a partially clogged orifice. (The greater the pressure the greater the clog. If the pressure reading is above 32 PSI refer to Section 7-3 to replace the Atomizing Chamber. b. Pressure reading below 20 psi indicates poor compressor performance. Refer to Section 7-3 and service the compressor by replacing the piston ring and o-ring assembly. If compressor pressure remains too low, refer to Section 7-3 and replace the compressor cylinder. The inner walls of a faulty compressor will show signs of uneven wear. 5-19 CHECKING THE FUEL PUMP WITH GAUGES 1. Remove the metal screws in the fuel pump pressure gauge ports with a 5 mm hex key. 2. Gently screw the fuel pump vacuum and pressure gauges into the ports with an adjustable wrench about two turns. (Figure 5-19-1, Page 5-22) 3. Verify fuel pump malfunction by connecting the fuel pump pressure gauge (positively graduated) and the fuel pump vacuum gauge (negatively graduated) (both found in the maintenance kit) to proper ports. a. Both of these gauges are mounted on 1 1/2-inch coupling extensions. b. Fuel pump pressure should read between .48 and .65 bars and fuel pump vacuum should read between -.15 and -.35 bars (4.5-10.0 psi)

Figure 5-18-1

Figure 5-19-1

c. Fuel pump vacuum lower than -.36 bars may indicate a kinked fuel line, non-vented fuel can, and/or clogged fuel filter. e. If these are not evident and fuel pump pressure is out of tolerance, refer to Section 7-1 and replace the fuel pump. Removal of fuel sump will make fuel pump replacement easier. Drain the fuel sump first by opening the fuel sump drainage plug.

5-19

TM 09211A-14&P 5-20 USING THE BUBBLE TEST TO LOCATE AIR LEAKS 1. To perform this test get a spray bottle of soapy water, turn the motor and the air control solenoid on, spray the air fittings with the soapy water and look for bubbles. (See Fig. 5-20-1) a. If any of the fittings bubble or foam this indicates you have an air leak. b. No Bubbles usually indicates there is no leak at that fitting. 1) Most fuel leaks come from three places. a) The gasket that goes under the top of the fuel tower. b) The gasket around the fuel sump. c) The O-rings on the cross connecting fuel tube that runs between the fuel pump and the fuel sump.

Figure 5-20-1 2) Checking the fuel tower for leaks:

a) Shine a flashlight around the top seal of the fuel tower, if it is leaking you will be able to see the fuel running down the side of the fuel tower. 3) If the tower is leaking open the top of the fuel tower and check the gasket. When checking or replacing the gasket ensure that excessive adhesive (glue) is removed in order for the top to seal properly. 5-21. CHECKING THE FUEL SUMP FOR LEAKS: 1. Ensure that all four (4) retaining screws are properly tightened. If they are properly tightened and the sump continues to leak then drain the fuel remove the sump and replace the gasket. 2. When checking or replacing the gasket ensure that excessive adhesive is removed in order for the top to seal properly. 3. Ensure that the drain plug is properly tightened and that the Washer with O-ring is in good condition. 4. Check the O-rings on the cross connection tubes to make sure they are flexible (not brittle) and do not have any nicks or tears. 5. Discard and replace any bad O-rings. 6. When reconnecting the cross connection tubes after replacing the O-rings use a lubricant on the O-rings to ensure that they are not destroyed when you tighten the fitting.

5-20

TM 09211A-14&P SECTION III. TROUBLESHOOTING THE TANK 6-1. TESTING THE WIRING AND ELECTRIC CONTROLS OF THE TANK NOTE THE TRHS ELECTRICAL CONTROL BOX (UPPER ACCESS PANEL) IS ILLUSTRATED SCHEMATICALLY BELOW FOR FURTHER REFERENCE. (FIGURE 6-1-1) THIS SCHEMATIC IS ALSO ATTACHED TO THE INSIDE OF THE PRIMARY CONTROL ACCESS PANEL FOR FIELD REFERENCE.

Figure 5-4 Electrical Control Box Wiring Schematic 1. If the Tray Ration Heater (TRHS) does not start when the red push-pull On/Off switch is pulled to on. 2. Check to be certain the power cord is plugged into a live receptacle. 3. If you verify that the Power cord is plugged into a known good source and the TRHS still does not operate, proceed to the next step. 4. Remove the cover to the TRHS primary access panel to expose the operating controls (See Figure 6-1-2, Page 5-22) 5. Push the Auto/Boil switch to the Auto position

5-21

TM 09211A-14&P 6. Fabricate an insulated jumper wire to perform these checks; wire must be 16/18 gauge stranded wire and 12 long with an insulated probe (alligator clips) at each end

Figure 6-1-2 NOTE EACH OF THESE CONTROLS OR CIRCUIT BREAKERS, ON/OFF SWITCH, TILT SWITCH, WATER LEVEL SWITCH, HIGH TEMPERATURE (AUTO/BOIL) SWITCH AND THERMOSTAT (THERMODISC) ARE WIRED IN SERIES AND ALL MUST BE FUNCTIONING FOR THE TRHS TO OPERATE SAFELY. NOTE THE PROCEDURE LISTED ON THE FOLLOWING PAGE WILL DETERMINE AND ISOLATE THE INOPERATIVE CONTROL INSIDE THE ELECTRICAL PANEL THAT IS PREVENTING THE TRHS FROM OPERATING. CAUTION ALL THESE PROCEDURES TO ISOLATE THE INOPERATIVE CONTROLS IN THE TRHS PRIMARY ACCESS PANEL ARE CONDUCTED WITH POWER APPLIED. EXERCISE EXTREME CAUTION WHILE PERFORMING THESE STEPS. REMOVE ALL JEWELRY AND ALWAYS USE ONE HAND WHILE PROBING. THAT WILL PREVENT ELECTRICAL SHOCK FROM PASSING THROUGH THE HEART. NOTE ALWAYS USE THE RIGHT SIDE OF THE TERMINAL BLOCK TO PLACE YOUR JUMPERS. (SEE FIGURE 6-1-3, PAGE 5-23)

5-22

TM 09211A-14&P NOTE ENSURE THAT THE TRHS IS FILLED WITH COLD WATER (COVERING THE LOW WATER SENSOR PROBE) DURING THIS TEST PROCEDURE. CAUTION IF IT IS EVER DETERMINED BY THE COMMANDING OFFICER THAT IT IS NECESSARY TO OPERATE THE TRHS WHILE BYPASSING A SWITCH IN THE ELECTRICAL PANEL YOU MUST TAG THE PANEL AND ENSURE THAT YOU MONITOR WHATEVER SAFETY FEATURE IS BYPASSED. FOR EXAMPLE IF THE TRHS IS OPERATED WITH THE WATER LEVEL SENSOR BYPASSED, THE WATER LEVEL MUST BE MONITORED AT ALL TIMES TO PREVENT EQUIPMENT DAMAGE. 7. To isolate the Main Circuit Breaker (Reset Button) touch one insulated probe to Terminal #2 of the Terminal strip, and touch the other probe to Terminal strip screw #3. If the TRHS operates refer to Section 9.5 Tank Circuit Breaker Replacement and replace circuit breaker. 8. To isolate the push-pull On/Off switch touch one insulated probe to Terminal #2 of terminal strip and touch the other insulated probe to terminal strip screw #4. This removes the switch from the operating circuit; if the TRHS operates refer to Section 9.3 Tank Push-Pull Switch Replacement and replace On/Off switch. Figure 6-1-3 9. To isolate the tilt switch touch one insulated probe to Terminal strip screw #2 and touch the other insulated probe to Terminal strip screw #5. If the TRHS operates refer to Section 9.6 Tank Tilt Switch Replacement and replace the tilt switch. 10. To isolate the water level sensor touch one insulated probe to Terminal strip screw #2, and touch the other insulated probe to Terminal strip screw #6. If the TRHS operates refer to Section 9.7 Tank Low-Water Sensor Control Replacement and replace water level sensor control. 11. To isolate the Thermodisc touch one insulated probe to Terminal strip screw #2, and touch the other insulated probe to terminal block screw #7. If the TRHS operates refer to Section 9.8 Thermo-disc Replacement and replace the Thermodisc.

5-23

TM 09211A-14&P 12. To isolate the Auto/Boil switch touch one insulated probe to Terminal strip screw #2, and touch the other insulated probe to terminal strip screw #7. If TRHS operates refer to Section 9.1 Tank Auto/Boil Switch Replacement and replace the high temperature (Auto/Boil) switch. 6-2. TROUBLESHOOTING THE POWER INVERTER 1. Make sure that the NATO Slave plug is properly connected to the HMMWV. 2. Ensure that the Power Switch is in the on position. 3. Press the reset button on the RFI receptacle. 4. Ensure that the Green LED indicator is lit. If the Red LED indicator is lit start the HMMWV, it indicates that the vehicle battery is low. Start the vehicle to supply the proper power to the Power Inverter allowing the proper power to the TRHS. CAUTION DO NOT PLUG IN A COMPUTER OR ANY OTHER POWER SENSITIVE DEVICE AS HIGH VOLTAGE COULD DAMAGE THAT PIECE OF EQUIPMENT 5. If the TRHS is still not working properly verify that power is available at the RFI receptacle by plugging in a known good 110 volt device, i.e. radio, shaver, etc. If the device you plug in is working properly, then the problem exists at the TRHS. 6. If the device that you plug into the RFI receptacle is not working, try it on another good power source to verify whether or not it is operational. If the device works on another power source, you Power Inverter is probably bad, find another Power Inverter or another known good source of power, i.e. a generator or a good 110 VAC commercial power source. 7. Evacuate the bad Power Inverter to a Higher Echelon of Maintenance.

5-24

TM 09211A-14&P 6-3. TRHS TANK FUEL FILTER REPLACEMENT 1. Push the Tray Ration Heater red, pull-on/push-off switch to the OFF position. (Figure 6-3-1) 2. Ensure Tray Ration Heater is not connected to any power source to prevent electrical shock and inadvertent Airtronic Burner ignition. 3. Lift Airtronic Burner cover and tap to the right until off its hinges. (Figure 6-3-2) 4. Remove fuel line connection by loosening the attached hose clamp, (Figure 6-3-3) and female power cord plug by loosening the integral screw. (Fig. 6-3-4, Page 5-26)

Figure 6-3-1

Figure 6-3-2

Figure 6-3-3

5-25

TM 09211A-14&P

Figure 6-3-4

Figure 6-3-5

5. Remove the hitch-pins, and slide the burner straight out from the TRHS. (Figure 6-3-5) NOTE: USE RAGS TO COLLECT EXCESS FUEL TO PREVENT SPILLAGE. 6. Pull fuel lines from both sides of filter. 7. Plug fuel lines into ends of new filter, ensuring that arrow on fuel filter points in direction of fuel flow (From side wall toward Airtronic Burner). 8. Check the hose clamps for serviceability and tighten on both sides of the fuel filter with a 3/16 flat-tip screwdriver. (Figure 6-3-6)

Figure 6-3-6 5-26

TM 09211A-14&P 6-4. TRHS FUEL CAN FILTER REPLACEMENT 1. Loosen hose clamps on both sides of the filter. Pull fuel lines off of the filter. 2. Make sure that hose clamps are in place to easily slide in place once you connect the hoses to the filter. 3. Plug fuel lines into ends of new filter, ensuring that arrow on fuel filter points in direction of fuel flow (From gas can toward TRHS). 4. Tighten hose clamps on both sides of the fuel filter with a 3/16 flat-tip screwdriver. Figure 6-4-1

6-5.

AIRTRONIC BURNER COMPRESSOR AIR FILTER REPLACEMENT

1. Refer to Section 7.1 and remove the air compressor from the burner. 2. Then remove air compressor filter plug with 4 mm hex key. (Figure 6-5-1) 3. Remove small compressor air filter with long-nose pliers. (Figure 6-5-2) 4. Replace old air filter with new filter (if needed) with long-nose pliers. (Figure 6-5-2) 5. Replace filter plug with 4 mm hex key. (Figure 6-5-1)

Figure 6-5-1

Figure 6-5-2

5-27

TM 09211A-14&P 6-6. TRHS LID LATCH ADJUSTMENT 1. Release lid latches by pulling handles up. 2. Adjust lid latches by adjusting position of upper and lower retaining nuts on latch with 3/8 adjustable wrench(s). The more thread showing, the looser the latch. (Figure 6-6-1) Do not adjust to the point where excessive force is needed to close the lid. The lid need only be tight enough to compress the lid gasket and prevent water leakage. Do not over tighten.

Figure 6-6-1

Figure 6-6-1

5-28

TM 09211A-14&P VII. DISASSEMBLY, REPAIR & REASSEMBLY INSTRUCTIONS WARNING BEFORE REMOVING AIRTRONIC BURNER FROM THE TRHS, MAKE SURE THE TRHS RED, PULL-ON/PUSH-OFF SWITCH IS IN THE OFF POSITION AND THE TRHS ELECTRICAL CONTROL BOX IS UNPLUGGED FROM A POWER SOURCE TO PREVENT ELECTRICAL SHOCK AND INADVERTENT AIRTRONIC BURNER IGNITION. 7-1. AIRTRONIC BURNER REMOVAL 1. Push the Tray Ration Heater red, pull-on/push-off switch to the OFF position. (Figure 7-1-1) 2. Ensure Tray Ration Heater is not connected to any power source to prevent electrical shock and inadvertent Airtronic Burner ignition. 3. Lift Airtronic Burner cover and tap to the right until off its hinges. (Figure 7-1-2) 4. Remove fuel line connection by loosening the attached hose clamp, (Figure 7-1-3) and female power cord plug by loosening the integral screw. (Figure 7-1-4, page 5-31) Figure 7-1-1 5. Remove the hitch-pins, and slide the burner straight out from the TRHS. (Figure 7-1-5, Page 530)

Figure 7-1-2

Figure 7-1-3

5-29

TM 09211A-14&P

Figure 7-1-4 7-2. AIRTRONIC BURNER INSTALLATION

Figure 7-1-5

NOTE DO NOT TILT AIRTRONIC BURNER EXCESSIVELY FORWARD TOWARD FLAME TUBE TO PREVENT FUEL FROM SPILLING OUT OF THE ATOMIZING CHAMBER AND INTO THE FLAME TUBE. 1. Slide Airtronic Burner onto the saddle pins and install the retaining hitch-pins from saddle pins on both sides of Airtronic Burner. (Figure 7-2-1) 2. Install fuel line on suction inlet port and tighten fuel clamp. (Figure 7-2-2, Page 5-31) 3. Insert female power cord plug into top of Airtronic Burner control box base and secure it by tightening the screw that is integral to the power plug. (Figure 7-2-3, Page 5-31) 4. Align Airtronic Burner cover with hinges and tap to left to install and swing down to cover burner(Figure 7-2-4, Page 5-31)

Figure 7-2-1

5-30

TM 09211A-14&P

Figure 7-2-2

Figure 7-2-3

Figure 7-2-4

5-31

TM 09211A-14&P 7.3 AIRTRONIC BURNER DISASSEMBLY (FIELD STRIPPING) This section provides a step-by-step procedure for complete disassembly of the Airtronic burner. Complete disassembly is only required when it is necessary to replace a known bad part, it should never be used to guess at parts replacement. Understanding how to disassemble the burner will provide a greater understanding of the parts relationships. This will also enable the user to more quickly replace individual components when it becomes necessary. One practical reason for complete disassembly is post-deployment maintenance. Given the sandy, windswept environments of many of todays battlefields and the high salt environment of ocean transport, a complete field strip and cleaning of the burner can be beneficial. Cleaning the burner post-op can prevent burner failure in future operations. CAUTION ALL ELECTRICAL PARTS AND CONNECTIONS, WITH THE EXCEPTIONS OF THE IGNITION TRANSFORMER AND PRIMARY CONTROL CAN BE SPRAYED WITH ELECTRO-MOTIVE CLEANSER. Once disassembly is complete, all non-electrical parts can be soaked in hot, soapy water and thoroughly scrubbed clean. Non-electrical parts should be rinsed and allowed to air dry before reassembly. Disassembly Steps: 1. Unscrew control box retaining screw with 3/16 flat-tip screwdriver and remove control box (Fig. 7-3-1). 2. Drain fuel sump by unscrewing fuel sump drainage plug with 5mm hex key and allowing fuel to thoroughly drain into an appropriate container. Replace drain plug when drained. (Fig. 7-3-2).

Fig. 7-3-1

Fig. 7-3-2

5-32

TM 09211A-14&P 3. Remove the front flange of the lower fan housing by removing the three or four screws with a 3/16 flat-tip screwdriver to expose the atomizing chamber. It is not necessary to remove the air tube/flame tube assembly. (Figs. 7-3-3)

Fig. 7-3-3

Fig. 7-3-4

Fig. 7-3-5 NOTE: DO NOT ALLOW DIRT TO CONTAMINATE THE AIR PASSAGES OF THE ATOMIZING CHAMBER. WHEN THE ATOMIZING CHAMBER IS REMOVED, THREE MACHINED HOLES IN THE LOWER FAN HOUSING (CONTAINING CAPTURED O-RINGS) WILL BE EXPOSED. THESE PASSAGEWAYS, FROM TOP TO BOTTOM, DELIVER: FUEL TO THE FEED TUBES WITHIN THE ATOMIZING CHAMBER; COMPRESSED AIR TO THE BULLET-SHAPED ATOMIZERS; AND EXCESS, UNSPRAYED FUEL BACK TO THE INTERNAL FUEL SUMP FOR RECIRCULATION. 4. Removal and installation of the atomizing chamber does not require tools. Remove the atomizing chamber by pulling directly out. (Fig. 7-3-4). Once removed, use the 3/16 flat-tip screwdriver to pry the ignitor cable spade connector from the ignition transformer. (Fig. 7-3-5)

5-33

TM 09211A-14&P

Fig. 7-3-6

Fig. 7-3-6a

a. To remove and replace the ignitor loosen the ignitor retaining screw with a 2.5 mm hex key wrench. (Fig. 7-3-6) b. Slide the ignitor out of the front of the Atomizing Chamber and replace the new ignitor back through the front of the Atomizing Chamber. (Fig. 7-3-6a) CAUTION DO NOT ATTEMPT TO ADJUST (MOVE) IGNITOR POST WHEN ADJUSTING SPARK GAP, THIS WILL CAUSE IGNITOR POST TO BREAK OFF. ATTEMPT ALL ADJUSTMENTS ON THE IGNITOR ONLY c. Align the tip of the ignitor with the tip of the ignitor post, tighten the ignitor retaining screw with the 2.5 mm hex key.

Fig. 7-3-6b

Fig. 7-3-7

5-34

TM 09211A-14&P 5. To ensure that fuel and air passages remain clean, install the red plastic "o-ring" plug into the three holes. This plug will also allow servicing the Airtronic burner upside down with minimum fuel leakage (Fig. 7-3-7). 6. Place protective, rubber caps of a plastic tube over the air and fuel connections at the back of the atomizing chamber to prevent dirt intrusion. (Fig. 7-3-8) 7. Place atomizing chamber in protective container to prevent dirt intrusion. (Fig. 7-3-9)

Fig. 7-3-8

Fig. 7-3-9

8. Turn Airtronic Burner upside down and disconnect primer port tubing at base of fuel pump (Fig. 7-3-10). 9. Remove primer port t from base of air solenoid with the adjustable (9/16) wrench. (Fig. 7-3-11)

Fig. 7-3-10

Fig. 7-3-11

5-35

TM 09211A-14&P 10. Remove air solenoid coil retaining nut with the adjustable (16mm) wrench. (Fig. 7-3-12) 11. Remove air solenoid coil from valve body. (Fig. 7-3-13)

Fig. 7-3-12 12. Unplug air solenoid coil from power cable. (Fig. 7-3-14)

Fig. 7-3-13

13. Unscrew hex nuts on opposite ends of metal airline that leads from the air compressor using an 11mm (7/16) wrench. (Fig. 7-3-15)

Fig. 7-3-14

Fig. 7-3-15

5-36

TM 09211A-14&P 14. Remove the metal airline and set in a clean place. (Fig. 7-3-16) 15. Unscrew both metal fuel line hex-nut connections with 11mm wrench. (Fig. 7-3-17)

Fig. 7-3-16 16. Remove the metal fuel line and set in a clean place. (Fig. 7-3-18)

Fig. 7-3-17

17. Remove four or six screws (new burner) that hold the fuel sump to the lower fan housing using a 3/16 flat-tip screwdriver. (Fig. 7-3-19)

Fig. 7-3-18

Fig. 7-3-19

5-37

TM 09211A-14&P 18. Slowly slide sump horizontally away from the pump to disengage the fuel crossover tube from the sump pump, taking care not to damage overflow safety device. Remove the fuel sump and crossover tube. CAUTION: DO NOT DAMAGE O-RING CONNECTIONS AT BOTH ENDS OF CROSSOVER TUBE.

Fig. 7-3-20 19. Disconnect fuel solenoid power cable from fuel solenoid coil. (Fig. 7-3-21) 20. If necessary, detach coil from pump by either removing 13mm nut (new burner) or copper retaining clip (old burner) with pliers. (Fig. 7-3-22)

Fig. 7-3-21

Fig. 7-3-22

21. Disconnect all wires from the Airtronic Burner control box base with 1/8 flat-tip screwdriver. (Figs. 7-3-23 & 7-3-24) When rewiring the burner, follow the wiring instructions illustrated in section 7.6.1. 5-38

TM 09211A-14&P

Fig. 7-3-23

Fig. 7-3-24

22. Pull control box wires through access hole in bottom of control box. (Fig. 7-3-25) 23. Pull photocell (proof-of-flame sensor) from socket (Fig. 7-3-26).

Fig. 7-3-25

Fig. 7-3-26

5-39

TM 09211A-14&P 24. Remove the two 10mm hex nuts, which hold the motor mounts to the upper fan housing, from their posts. Remove the entire power pack (consisting of the motor, compressor, fuel pump, and blower wheel) (Fig. 7-3-27). 25. Using 3/16 flat-tip screwdriver, remove two screws holding photocell base (Fig. 7-3-28).

Fig. 7-3-27

Fig. 7-3-28

26. Using 3/16 flat-tip screwdriver, remove two screws holding control box base to lower fan housing (Fig. 7-3-29, Page 5-41). 27. Remove control box base. (Fig. 7-3-30, Page 5-41)

5-40

TM 09211A-14&P

Fig. 7-3-29

Fig. 7-3-30

28. With Adjustable wrench (18mm), remove overflow safety float switch retaining nut. (Fig. 7-3-31) 29. Remove overflow safety device. (Fig. 7-3-32)

Fig. 7-3-31

Fig. 7-3-32

5-41

TM 09211A-14&P 30. Disconnect spade connections from ignition transformer (pry off with 1/8 flat-tip screwdriver if necessary) (Fig. 7-3-33). 31. Unscrew ignition transformer retaining screw with 3/16 flat-tip screwdriver (old burner) or removing retaining nut with Adjustable (5/16) wrench (new burner) (Fig. 7-3-34). 32. Remove ignition transformer, power cable, and ground wire from lower fan housing. (Fig. 7-3-35)

Fig. 7-3-33

Fig. 7-3-34

Fig. 7-3-35

5-42

TM 09211A-14&P 33. With 3/16 flat-tip screwdriver, remove four screws that retain upper fan housing to intermediate motor mounting plate (two screws on both sides). (Figs. 7-3-36 & 7-3-37)

Fig. 7-3-36

Fig. 7-3-37

34. Separate upper fan housing and intermediate motor mounting plate. (Fig. 7-3-38) 35. If necessary use a 3/16 flat-tip screwdriver to remove blower control knob retaining screw (Fig. 7-3-39).

Fig. 7-3-38

Fig. 7-3-39

5-43

TM 09211A-14&P 36. If necessary remove blower control knob (Fig. 7-3-40). 37. If necessary remove blower control knob printed index (Fig. 7-3-41).

Fig. 7-3-40

Fig. 7-3-41

38. If necessary, remove blower-regulating scroll from upper fan housing. (Fig. 7-3-42) 39. If necessary, remove air inlet cover retaining screws using 3/16 flat-tip screwdriver (Fig. 7-3-42).

Fig. 7-3-42

Fig. 7-3-43

5-44

TM 09211A-14&P 40. Remove air inlet cover (Fig. 7-3-44) 41. If it is necessary to remove the cover from the flow control module, use a 3/16 flat-tip screwdriver to remove the two screws holding it in place (Fig. 7-3-45).

Fig. 7-3-44

Fig. 7-3-45

42. Remove flow control module cover. (Fig. 7-3-46) 43. Push fuel-regulating cam out of flow control module cover. (Fig. 7-3-47)

Fig. 7-3-46

Fig. 7-3-47

5-45

TM 09211A-14&P 44. Lift out flow control module insert (do not misplace small o-ring seal between insert and lower fan housing). (Fig. 7-3-48) 45. With 4mm hex key, loosen three pump retaining screws that secure the pump assembly. (Fig. 7-3-49)

Fig. 7-3-48 46. Lift out pump assembly. (Fig. 7-3-50)

Fig. 7-3-49

47. If necessary remove the nylon pump coupling from pump shaft. Otherwise just leave it attached so it doesnt get lost (Fig. 7-3-51)

Fig. 7-3-50

Fig. 7-3-51

5-46

TM 09211A-14&P 48. If necessary, remove fuel solenoid body with the Adjustable (16mm) wrench. (Fig. 7-3-52) 49. Using 2mm hex key, loosen blower wheel retaining set screw (note access hole in blower wheel). (Fig. 7-3-53)

Fig. 7-3-52

Fig. 7-3-53

50. If necessary, remove blower wheel (use two flat-tip screwdrivers on opposite sides to gently pry wheel from shaft). (Fig. 7-3-54) 51. Remove air compressor filter plug with 4mm hex key. (Fig. 7-3-55)

Fig. 7-3-54

Fig. 7-3-55

5-47

TM 09211A-14&P 52. Remove small compressor air filter by pulling lightly with needle-nose pliers. (Fig. 7-3-56) 53. Loosen and remove air solenoid body with Adjustable (24mm) wrench. (Fig. 7-3-57)

Fig. 7-3-56

Fig. 7-3-57

54. Using 4mm hex key, remove two compressor head mounting screws. (Fig. 7-3-58)

Fig. 7-3-58 55. Remove compressor head and shim (if so equipped). (Fig. 7-3-59, page 5-49) 56. Using seal pick to remove compressor piston ring to expose compressor piston o-ring. (Fig. 7-3-60, page 5-49)

5-48

TM 09211A-14&P

Fig. 7-3-59

Fig. 7-3-60

57. Remove piston o-ring using seal pick. (Fig. 7-3-60 and 7-3-61) Set them aside. (Fig. 7-3-62)

Fig. 7-3-61

Fig. 7-3-62

NOTE WHEN CHANGING PISTON RING DUE TO LOW COMPRESSOR AIR PRESSURE, GO AHEAD AND CHANGEO-RING WITH THE PISTON RING (BE CAREFUL NOT TO DAMAGE PISTON RING OR O-RING). WHEN REASSEMBLING O-RING AND PISTON RING, INSERT O-RING FIRST, FOLLOWED BY THE PISTON RING. CAUTION MAKE SURE THE PISTON IS IN ITS FULLY EXTENDED POSITION AND GENTLY PLACE THE COMPRESSOR HEAD OVER THE PISTON CHECKING CAREFULLY TO ENSURE THE PISTON RING DOES NOT BECOME DISLODGED FROM THE PISTON. THE COMPRESSOR HEAD SHOULD SLIDE OVER THE PISTON RING WITHOUT SIGNIFICANT RESISTANCE. DO NOT FORCE IT! THE PISTON RING OR THE COMPRESSOR CYLINDER COULD BECOME DAMAGED.

5-49

TM 09211A-14&P 7-4. FUEL PUMP MEMBRANE REPLACEMENT 1. Completely drain burner of all fuel as illustrated in paragraph 5-15-4, Figure 5-15-1, page 519. Flip burner upside down and remove the priming port airline. 2. Loosen the four lower pump access plate 3 mm HEX nuts or Phillips screws (Figure 7-4-1), and remove the access plate. (Figure 7-4-2) 3. Gently lift out the pump membrane being careful not to loose the small coil tension spring and retaining collar secured to the bottom side. (Figure 74-3) Set the small coil tension spring and retaining collar to the side.

Fig. 7-4-1

4. Install the replacement membrane using the collar and spring from the old membrane. Seat the collar on the new diaphragm by gently pulling the tip until the collar snaps into place. Re-secure the pump access plate. (Fig. 7-4-2)

Fig.7-4-2

Fig. 7-4-3

Fig. 7-4-4

5-50

TM 09211A-14&P 7-5. AIRTRONIC BURNER ASSEMBLY 1. The Airtronic Burner is constructed in a modular design for ease of assembly and disassembly and to aid in troubleshooting and maintenance procedures. This modular design is illustrated in Figure 7-5-1; knowledge of this will assist in the assembly of the Airtronic Burner. The basic modules that make up the Airtronic Burner are comprised of the sub-assemblies listed below: Burner Housing Assembly: ...................................Blower inlet cover, upper blower housing, lower housing, immediate motor mounting plate, and front flange Power Pack Assembly: ..........................................Motor, blower wheel, compressor, and fuel pump Atomizing & Combustion Assembly: ..................Atomizing chamber, flame tube, and air tube Ignition & Control Assembly:...............................Ignition transformer, ignitor, control box base and control box Fuel Re-circulating Assembly: ..............................Fuel pump, overflow safety device & fuel crossover tube 2. These sub-assemblies will be re-assembled in the same order as the appropriate steps and photographs in this chapter. The basic modules can then be assembled as shown in Figure 7-5-1 to complete final assembly of the Airtronic Burner.

Fig. 5-5 Airtronic Burner Sub-Assemblies 5-51

TM 09211A-14&P

Fig. 7-5-2

Fig. 7-5-3

Fig. 7-5-4

Fig. 7-5-4a

CAUTION MAKE SURE THE PISTON IS IN ITS FULLY EXTENDED POSITION AND GENTLY PLACE THE COMPRESSOR HEAD OVER THE PISTON CHECKING CAREFULLY TO ENSURE THE PISTON RING DOES NOT BECOME DISLODGED FROM THE PISTON. THE COMPRESSOR HEAD SHOULD SLIDE OVER THE PISTON RING WITHOUT SIGNIFICANT RESISTANCE. DO NOT FORCE IT! THE PISTON RING OR THE COMPRESSOR CYLINDER COULD BECOME DAMAGED. 3. Replace piston o-ring using seal pick, do not tear or damage the piston o-ring. (Fig. 7-5-2, 7-5-3) 4. Replace compressor Piston Ring. 5. Replace the Compressor Head (Fig. 7-5-4) and Shim (if so equipped). (Fig. 7-5-4a) 6. Using 4mm hex key, replace two compressor head mounting screws. (Fig. 7-5-5)

5-52

TM 09211A-14&P 7. Replace small compressor air filter by pushing lightly with needle-nose pliers. (Fig. 7-5-6) 8. Replace and tighten air solenoid body with adjustable (24mm) wrench, Do not over tighten. (Fig. 7-5-7)

Fig. 7-5-5

Fig. 7-5-6

Fig. 7-5-7

5-53

TM 09211A-14&P 9. Replace air compressor filter plug with 4mm hex key. (Fig. 7-5-8) NOTE: IF IT IS NECESSARY TO REPLACE THE BLOWER WHEEL, BACK OUT THE 2MM HEX SCREW UNTIL THE BLOWER WHEEL SLIPS OFF THE SHAFT BUT NOT SO LOOSE THAT THE SCREW WILL FALL OUT BEFORE YOU TIGHTEN IT. CAUTION: DO NOT FORCE THE WHEEL BACK ON THE SHAFT, IF NECESSARY PLACE A BLOCK OF WOOD OVER THE BLOWER WHEEL AND GENTLY TAP IT. 10. Replace the blower wheel by placing it back over the shaft. Ensuring that the screw will tighten against the flat spot on the shaft. (Fig. 7-5-9) NOTE: AFTER REPLACING THE BLOWER WHEEL SPIN IT WITH YOUR HAND TO ESURE THAT IT IS NOT RUBBING AGAINST THE MOTOR BODY. IF IT IS RUBBING YOU CAN ADJUST IT BY LOOSENING THE RETAINING SET SCREW AND LIFTING SLIGHTLY WHILE TIGHTENING THE SCREW.

Fig. 7-5-8

Fig. 7-5-9

11. Using 2mm hex key, tighten blower wheel retaining set screw (note access hole in blower wheel). (Fig. 7-5-10)

5-54

TM 09211A-14&P 12. Replace fuel solenoid body and tighten with the Adjustable (16mm) wrench. (Fig. 7-5-11)

Fig. 7-5-10

Fig. 7-5-11

13. If it was removed, replace nylon pump coupling on pump shaft. Ensure that the flat side of the shaft coordinates with the slot on the pump coupling. (Fig. 7-3-12) 14. Replace Pump assembly onto Pump Shaft ensuring that the nylon teeth line up with the Pump Assembly (Fig. 7-5-13). If necessary rotate the blower fan until pump assemble slides all the way against the motor. Align the corner of the Pump assembly to the right of the primer port connection with the Air Solenoid Body (Fig. 7-3-13a).

Fig. 7-5-12

Fig. 7-5-13

Fig. 7-5-13a

5-55

TM 09211A-14&P

Fig. 7-5-14

Fig. 7-5-15

15. With 4mm hex key, tighten three pump retaining screws. (Fig. 7-5-14) 16. Replace flow control module insert (Insure small o-ring seal is between insert and lower fan housing). (Fig. 7-5-15)

Fig. 7-5-16

Fig. 7-5-17

17. Insert fuel-regulating cam back into flow control module cover. (Fig. 7-5-16) 18. Replace flow control module cover. (Fig. 7-5-17)

5-56

TM 09211A-14&P

Fig. 7-5-18

Fig. 7-5-19

19. Using 3/16 flat-tip screwdriver replace and tighten the two screws to secure the flow control module cover (Fig. 7-5-18). 20. Replace air inlet cover (Fig. 7-5-19)

Fig. 7-5-20

Fig. 7-5-21

21. Replace and tighten the air inlet cover retaining screws using 3/16 flat-tip screwdriver (Fig. 75-20). 22. Replace blower-regulating scroll into upper fan housing. (Fig. 7-5-21)

5-57

TM 09211A-14&P

Fig. 7-5-22

Fig. 7-5-23

23. Replace blower control knob printed index (Fig. 7-5-22). 24. Replace blower control knob (Fig. 7-5-23).

Fig. 7-5-24

Fig. 7-5-25

25. Using 3/16 flat-tip screwdriver, tighten blower control knob retaining screw (Fig. 7-5-24). 26. Place intermediate motor mounting plate back on upper fan housing. (Fig. 7-5-25)

5-58

TM 09211A-14&P

Fig. 7-5-26

Fig. 7-5-27

27. With 3/16 flat-tip screwdriver, replace four screws that retain upper fan housing to intermediate motor mounting plate (two screws on both sides). (Figs. 7-5-26 & 7-5-27)

Fig. 7-5-28

Fig. 7-5-29

28. Replace ignition transformer, power cable, and ground wire into lower fan housing. (Fig. 7-5-28) 29. Tighten ignition transformer retaining screw with 3/16 flat-tip screwdriver (old burner) or retaining nut with Adjustable (5/16) wrench (new burner) (Fig. 7-5-29).

5-59

TM 09211A-14&P

Fig. 7-5-30

Fig. 7-5-30a

30. Re-connect wire spades to the ignition transformer. (Fig. 7-5-30). Blue wire on the top left terminal and red wire on the second terminal (Fig. 7-5-30a)

Fig. 7-5-31 31. Replace overflow safety device. (Fig. 7-5-31)

Fig. 7-5-32

32. With Adjustable (18mm) wrench, tighten overflow safety float switch retaining nut. (Fig. 7-5-32)

5-60

TM 09211A-14&P

Fig. 7-5-33 33. Replace control box base. (Fig. 7-5-33)

Fig. 7-5-34

34. Using 3/16 flat-tip screwdriver, replace two screws holding control box base to lower fan housing (Fig. 7-5-34).

Fig. 7-5-34 35. Using 3/16 flat-tip screwdriver, replace two screws holding photocell base (Fig. 7-5-34). 36. Replace the entire power pack (consisting of the motor, compressor, fuel pump, and blower wheel). Replace the two 10mm hex nuts, which hold the motor mounts to the upper fan housing. (Fig. 7-5-35).

Fig. 7-5-35

5-61

TM 09211A-14&P

Fig. 7-5-36

Fig. 7-5-37

37. Insert photocell (proof-of-flame sensor) back into socket (Fig. 7-5-36). 38. Place all the control wires back into the control box access hole in bottom of control box. (Fig. 7-5-37)

Fig. 7-5-39 45. Re-connect all wires from the Main Power (Brown/Blue wires), as you replace the component to be wired, i.e. when you place the Air Control Solenoid in place route the wires behind the motor and attach to the Burner Control Box. (Figs. 7-5-38 & 7-5-39) When rewiring the burner follow the wiring instructions illustrated in the Burner/Control Box Wiring Instructions in section 7.6.

Fig. 7-5-38

5-62

TM 09211A-14&P

Fig. 7-5-39

Fig. 7-5-40

39. Place coil on pump and secure by both replacing and tightening the 13mm nut (new burner) or copper retaining clip (old burner) with pliers. (Fig. 7-5-39) Connect the wires to the Burner Control Box. (Section 7.6) 40. If you disconnected the fuel solenoid power cable from fuel solenoid coil replace it. (Fig. 7-5-40) Connect the fuel solenoid wires to the Burner Control Box. (Section 7.6)

Fig. 7-5-39

Fig. 7-5-40

41. Replace the fuel sump and crossover tube. Slowly slide sump horizontally toward the pump to engage the fuel crossover tube to the sump pump, taking care not to damage overflow safety device. (Fig. 7-5-39) 5-63

TM 09211A-14&P 42. Check the fuel sump gasket to ensure it is flexible, not torn and has no epoxy (glue) residue on it. Replace the four or six screws (new burner) that hold the fuel sump to the lower fan housing and tighten using a 3/16 flat-tip screwdriver alternating screws to ensure uniform seal. (75-40, Page 5-63)

Fig. 7-5-41

Fig. 7-5-42

43. Replace the metal fuel line and tighten both metal fuel line hex-nut connections by hand first then with the 11mm wrench, be careful not to cross-thread the connection (Fig. 7-5-41) 44. Replace the metal airline and tighten both airline hex-nut connections by hand first then with 11mm wrench. (Fig. 7-5-42)

5-64

TM 09211A-14&P

Fig. 7-5-43

Fig. 7-5-44

45. Plug air solenoid coil into power cable. (Fig. 7-5-43) 46. Replace air solenoid coil onto valve body and tighten air solenoid coil retaining nut with 16mm wrench. (Fig. 7-5-44,)

Fig. 7-5-45

Fig. 7-5-46

47. Replace primer port t onto the base of the air solenoid and tighten with the Adjustable (9/16) wrench. (Fig. 7-5-45) 48. Re-connect primer port tubing to the base of the fuel pump (Fig. 7-5-46).

5-65

TM 09211A-14&P

Fig. 7-5-47

Fig. 7-5-48

49. Remove the red plastic "o-ring" plug from the front of the burner to allow for the attachment of the Atomizing Chamber. (Fig. 7-5-47) 50. Remove the protective, rubber caps from the air and fuel connections at the back of the atomizing chamber. (Fig. 7-5-48)

Fig. 7-5-49

Fig. 7-5-50

51. Re-connect the ignitor cable spade connector from the atomizing chamber to the ignition transformer. Removal and installation of the atomizing chamber does not require tools. Replace the atomizing chamber by inserting the tubing into the appropriate slots by hand. (Fig. 7-5-49 & 7-5-50).

5-66

TM 09211A-14&P

Fig. 7-5-51

Fig. 7-5-52

52. Replace the front face plate of the lower fan housing by replacing and tightening the three or four screws with a 3/16 flat-tip screwdriver to expose the atomizing chamber. If the air tube/flame tube assembly was removed replace it prior to placing front flange back on the lower housing.(Figs. 7-5-51 & 7-5-52)

Fig. 7-5-53 Fig. 7-5-54 53. Ensure that the fuel sump drainage plug is in place and tightened with a 5mm hex key. (Fig. 7-5-53). 54. Replace the control box and tightened retaining screw with 3/16 flat-tip screwdriver. (Fig. 7-5-54).

5-67

TM 09211A-14&P 7-6. BURNER/CONTROL BOX BASE WIRING INSTRUCTIONS

Fig. 5-6. AIRTRONIC BURNER ELECTRICAL WIRING DIAGRAM.

NOTE THE TWO PHOTOCELL (BROWN AND BLUE) WIRES CAN BE INTERCHANGED

5-68

TM 09211A-14&P NOTE FIRST CONNECTING THE PHOTOCELL WIRES TO TERMINALS #1 AND #2, ALL REMAINING BLUE (NEUTRAL) WIRE TO TERMINAL #8, AND THE GROUND WIRES TO GROUND TERMINALS GREATLY SIMPLIFIES THE WIRING PROCESS. UNDERSTANDING THE CONCEPT OF POWER FLOWING THROUGH THE FLOAT SWITCH TO THE FUEL SOLENOID AND CONNECTING ONE OF THE FLOAT SWITCH WIRES AND FUEL SOLENOID POWER CABLES TO LOWER TERMINAL A, THEN ALL THE REMAINING BROWN (POWER) WIRES CAN BE CONNECTED BY SIMPLY REFERENCING THE WIRING SCHEMATIC ON THE UNDERSIDE OF THE CONTROL BOX. 1. Connect the two photocell wires (brown and blue) to upper terminals (#1 and #2) respectively. 2. Connect all the ground (green/yellow) wires from main power, motor, air solenoid, and fuel solenoid to the three lower ground terminals. 3. Connect all the neutral (blue) wires from the main power, motor, air solenoid, fuel solenoid, and ignition transformer to the #8 terminals. NOTE: it is generally best to connect the main power neutral to the upper #8 terminal; however, it makes no practical difference since these terminals are all internally connected. 4. Connect either wire on the float switch and the brown wire of the fuel solenoid to lower terminal A. NOTE: terminal A is essentially a wire nut used to connect of the control box. The effect of this wiring is to allow power to flow through the float switch (when fuel sump level is normal) to fuel solenoid when power is supplied to the motor. If the fuel sump level is too high, power will not be supplied to the fuel solenoid. 5. Connect the brown ignition transformer wire to upper terminal #3. 6. Connect the brown motor wire and the remaining float-switch wire to upper terminal #4. 7. Connect the air solenoid brown wire to upper terminal #5. 8. Connect the main power brown wire to upper terminal #9. NOTE UPPER TERMINALS #6 AND #7 ARE NOT USED.

5-69

TM 09211A-14&P SECTION V. TANK REPAIR 8-1. TANK LID REMOVAL AND LID-STOP REPLACEMENT 1. Raise lid and latch. 2. Remove retaining safety hitch-pin from lid stop pin. (Figure 8-1-1) 3. Hold lid upright and pull lid stop pin out of the lid stop. (Figure 8-1-1) 4. Remove lid stop from lid assembly bracket. (Figure 8-1-2) 5. Tap lid toward Airtronic Burner (use soft rubber mallet, if necessary) until lid separates from Tray Ration Heater. (Figure 8-1-3) 6. Replace components and reinstall in reverse order. Fig. 8-1-1

Fig 8-1-2

Fig. 8-1-3

5-70

TM 09211A-14&P 8-2. TANK DRAIN VALVE REPLACEMENT NOTE: THE DRAIN VALVE CAN EASILY BECOME SEIZED BECAUSE OF THE VARYING TEMPATURES FOR WHICH THE TRHS OPERATES. IT MAY BE NECESSARY TO INITIALLY BREAK THE VALVE FREE BY USING A PAIR OF VISE GRIPS OR A PLUMBERS WRENCH 1. Remove drain valve by placing the Adjustable wrench across the flats of the drain valve and rotate counter clockwise. (Figure 8-2-1)

2. Replace the drain valve using Teflon tape, or plumbers thread sealant to insure a leak proof seal. Start threading the valve by hand to ensure no cross threading. Tighten the valve with the Adjustable wrench until handle of valve is on top, but do not over tighten.

Fig. 8-2-1

5-71

TM 09211A-14&P 8-3. TANK SKID AND SHOCK ABSORBER REPLACEMENT

Fig. 8-3-1 1. Disconnect power and fuel lines. 2. Remove Airtronic Burner and cover.

Fig. 8-3-2

3. Using 4-man lift, turn Tray Ration Heater over or onto its side, elevating the skid/shock requiring replacement. 4. Remove four shock mounting nuts with 1/2 wrench (lower) and 9/16 wrench (upper). (Figure 16) 5. Remove four retaining screws in bottom with #3 cross-tip screwdriver. (Figure 17) 6. Install in reverse order.

5-72

TM 09211A-14&P 8-4. TANK PUSH PULL SWITCH LIGHT BULB REPLACEMENT 1. Unscrew red, translucent control knob. (Figure 8-4-1) 2. Push and twist peanut bulb with thumb and forefinger 1/8 turn clockwise or until bulb pops out. 3. Insert new peanut bulb into socket and push and turn until seated. 4. Screw on red, translucent pull-on/push-off control knob.

Fig. 8-4-1

5-73

TM 09211A-14&P IX. DEPOT LEVEL REPAIRS 9-1. TANK AUTO/BOIL SWITCH REPLACEMENT 1. Remove primary Tray Ration Heater access control cover panel by removing retaining screws with 1/4 cross-tip screwdriver. 2. Remove auto/boil switch retaining nut with 5/8 wrench. (Figure 9-1-1) 3. Remove auto/boil switch from control box. 4. Remove screws from two wire eyelet connectors using 3/16 flat-tip screwdriver. 5. Replace the Auto/Boil switch; reconnect wires and replace four retaining nuts. 6. Replace primary control panel access cover.

Fig. 9-1-1

5-74

TM 09211A-14&P 9-2. TANK LID GASKET REPLACEMENT 1. Remove lid from Tray Ration Heater and place top down. (Figure 9-2-1) NOTE PLACE FOLDED BLANKET OR SOFT CLOTH UNDERNEATH LID TO PREVENT SCRATCHES. 2. Using electric drill with 3/ 16 bit, drill out the 24 rivets that hold the four gasket flanges in place. (Figure 9-2-1) If Phillips head screws are used to secure the Gasket flanges to the lid, remove the screws, using a #2 Phillips head screwdriver. 3. Remove old lid gasket and replace with new lid gasket. 4. Adjust lid gasket flanges around new lid gasket and align holes in flanges with holes in lid. 5. Secure lid gasket flanges with 24 pop rivets. (If equipped) Replace the screws with a #2 Phillips head screwdriver. 6. Reinstall lid on the Tray Ration Heater by aligning the hinges and tapping the lid with a rubber mallet toward the exhaust end of the TRHS. (Figure 9-2-2)

Fig. 9-2-1

Fig. 9-2-2

5-75

TM 09211A-14&P 9-3. TANK PUSH-PULL SWITCH REPLACEMENT 1. Remove primary Tray Ration Heater access control panel cover by removing retaining screws with 3/16 cross-tip screwdriver. 2. Remove on/off switch retaining nut with a 1 3/8 wrench. (Figure 9-3-1) 3. Remove on/off switch from control box. 4. Unscrew two wires from eyelet connectors using 3/16 flat-tip screwdriver. 4. Replace switch, reconnect wires, and reinstall access control panel cover.

Fig. 9-3-1

5-76

TM 09211A-14&P 9-4. TANK POWER FITTING REPLACEMENT 1. Remove primary Tray Ration Heater access control panel cover by removing retaining screws with 1/4 cross-tip screwdriver. 2. Remove four screws using #1 cross-tip screwdriver. (Figure 9-4-1) 3. Remove two wires from spade fittings, one wire at a time placing them on the proper spade fitting of the new Tray Ration Heater Amphenol main power fitting. 4. Replace the Amphenol main power fitting, connect wires, and replace four retaining screws. 5. Replace primary access control panel cover.

Fig. 9-4-1

5-77

TM 09211A-14&P 9-5. TANK CIRCUIT BREAKER/RESET SWITCH REPLACEMENT 1. Remove primary Tray Ration Heater access control panel cover by removing retaining screws with 3/16 cross-tip screwdriver. 2. Remove 5 amp circuit breaker/reset switch retaining nut with the Adjustable (5/8) wrench. (Figure 9-5-1) 3. Remove circuit breaker. 4. Remove spade connectors from circuit breaker. 5. Replace the circuit breaker, reconnect wires, and reinstall retaining nut. 6. Replace primary control panel access cover.

Fig. 9-5-1

5-78

TM 09211A-14&P 9-6. TANK TILT SWITCH REPLACEMENT 1. Remove primary Tray Ration Heater access control panel cover by removing retaining screws with 1/4 cross-tip screwdriver. 2. Remove two tilt switch-mounting nuts from angled platform using 3/8 wrench. (Figure 9-6-1) 3. Disconnect tilt switch wires from terminal block. 4. Remove tilt switch. 5. Replace the tilt switch, reconnect wires, and reinstall mounting nuts. 6. Replace primary control panel access cover.

Fig. 9-6-1

5-79

TM 09211A-14&P 9-7. THERMODISC REMOVAL/REPLACEMENT 1. Remove secondary access panel cover plate, located below TRH main stainless control box, by removing four 10-24 stainless screws. (Figure 9-7-1) 2. Remove the foam insulation from inside the access control panel and set to the side. Inside secondary access panel, locate the Thermodisc (left) and Teflon water level sensor probe (right). Use 5/16 nut driver, or socket driver, to unscrew 2 lock nuts from threaded studs on the Thermodisc Mounting Bracket. Loosen Thermodisc mounting flange from threaded studs and remove it with your fingers. Figure 9-7-2)

Figure 9-7-1

Figure 9-7-2

5-80

TM 09211A-14&P

Figure 9-7-3 3. Cut wire leads, approximately 2 inches in length, from Thermodisc. Discard bad Thermodisc and leave hanging wire leads for reconnection later. (Figure 9-7-3) 4. Mount new Thermodisc so that it sits in the same position as the bad Thermodisc. Align holes in the mounting flange over the threaded weld studs and push the Thermodisc into place so it is flush against the TRH tank wall. Secure Thermodisc into place with 5/16 nylon lock nuts. 5. Using wire nuts connect the Thermodisc wires back to the wire leads in the tank observing color codes (red to red and blue to blue). (Figure 9-7-4). Replace the foam insulation and the primary control panel access cover by replacing the retaining screws and tightening with a 3/16 flat-tip screwdriver. .

Figure 9-7-4

5-81

TM 09211A-14&P 9-8. TEFLON PROBE ASSEMBLY REMOVAL/REPLACEMENT

Figure 9-8-1 1. Remove secondary access panel cover plate, located below TRH main stainless control box, by removing four 10-24 stainless screws with a 3/16 flat-tip screwdriver (Figure 9-8-1) 2. Remove rubber boot protector from probe assembly (if a boot is covering the probe) NOTE THE TEFLON PROBE (WHITE) IS SEATED INSIDE A STAINLESS STEEL SLEEVE (WHICH IS WELDED TO THE INNER WALL OF THE TRH TANK). (FIGURE 9-8-2) 3. Remove the stainless steel 10-24 screw from the wire lead (eye loop connector) on the probe with a 3/16 flat-tip screwdriver. (Figure 9-8-3)

Figure 9-8-2

Figure 9-8-3

5-82

TM 09211A-14&P 4.The Teflon probe is secured inside the stainless sleeve via an o-ring seal and a #4-40 stainless setscrew. Using a 2.5 mm Allen Wrench loosen the #4-40 setscrew to allow removal of the Teflon probe. (Figure 9-8-4)

Figure 9-8-4 5. Using the blunt end of the 3/16 Flat Tip screwdriver, take the Teflon probe out of its stainless steel sleeve by pressing from inside the tank outward toward the secondary access panel. (Figure 9-8-5) 6. Re-insert the replacement Teflon probe assembly back into stainless sleeve (make sure set screw is backed-out of Teflon probe assembly). Also, ensure o-ring seal is present on Teflon probe assy. (if not, probe will leak water) (Figure 9-8-6)

Figure 9-8-5

Figure 9-8-6

5-83

TM 09211A-14&P

Figure 9-8-7

Figure 9-8-8

7. Tighten set screw in place with a 2.5 mm Allen/Hex wrench (Figure 9-8-7) 8. Apply silicone caulking to top of screw head and connector for insulation. Reconnect and tighten the eye loop connector lead back onto the Teflon probe with a 3/16 Flat Head screwdriver. (Figure 9-8-8) 9. Re-cover probe with rubber boot (if the Teflon probe was previously covered with a rubber boot). Re-place blanket insulation back into secondary access panel and cover Thermodisc and Probe Assy. 10. Replace the Secondary Access covering by ensuring that the black rubber cover plate gasket is between the stainless steel cover plate and the Tray Ration Heater Tank. Tighten stainless steel cover plate with four (4) 10-24 stainless screws.

5-84

TM 09211A-14&P 9.9 REPLACEMENT FLANGE MOUNTING PROCEDURES.

Figure 9-9-1 Flange Replacement Parts

1. Ensure all components for the Replacement Flange Mounting Kit, Part Number 8747105 are available. (Figure 9-9-1) The kit consists of: Stainless Flange; Red Gasket P/N 8263K144G; White Gasket; Brass Hex Nuts; and Stainless Steel Washers. 2. Remove Burner compartment lid. (Figure 9-9-2) 3. Disconnect Power, fuel lines and remove burner from the TRHS in accordance with 7-1. AIRTRONIC BURNER REMOVAL, Page 5-29. 4. Using the adjustable wrench from the maintenance kit, remove the two retaining nuts from the flange plate by rotating them in a counter clockwise motion

Figure 9-9-2

5. Remove and discard, nuts, washers, and the aluminum flange from the TRH (old). (Figure 9-9-3 and Figure 9-9-4, Page 5-86) 6. Inspect the flange-mounting surface of the Tank, to ensure it is clean and free of damage.

5-85

TM 09211A-14&P

Figure 9-9-3

Figure 9-9-4

7. Assemble the replacement flange by sliding the white fibrous gasket over the cone up to the mounting ears; ensure that it is sitting flush with the outer rim of the new flange. (Figure 9-9-5) 8. Insert the new flange into the tank; cone first, and slide the ears over the protruding bolt studs. Center the flange between the studs. (Figure 9-9-6)

Figure 9-9-5

Figure 9-9-6

5-86

TM 09211A-14&P 9. Place one of the provided brass washers on each stud. (Figure 9-9-8)

Figure 9-9-8

Figure 9-9-9

10. Place one of the provided brass nuts on each stud; turn clockwise, and hand tighten to seat the new flange. Ensure that the flange is centered between the studs and is even with the mounting surface (Dont put it in offset or crooked) (Figure 9-9-8) 11. Take the adjustable wrench, tighten the two nuts, being careful not to over tighten. (The Flange nuts are considered tight enough when you cannot turn the 6-inch adjustable wrench easily with two fingers at the end of the wrench handle.) (Figure 9-9-9)

Figure 9-9-10

Figure 9-9-11

12. Remove the red high temperature gaskets from the modification kit, place one over the air tube of the burner from the TRH Tank, and slide down flush against the burner body. Do the same for the spare burner in the maintenance kit. Store the third gasket with the repair parts in the maintenance kit box. (Figure 9-9-10 and Figure 9-9-11)

5-87

TM 09211A-14&P

Figure 9-9-12

Figure 9-9-13

13. Take the burner now equipped with the Red high temp gasket, and slide it into the tank. Align the mounting rods with the appropriate holes in the burner housing and slide forward. (If you encounter binding; it doesnt slide in easily, stop and go to the 9.1.1 PROBLEM SOLVING section on page 5-89.) NOTE THE NEW GASKET IS FLEXIBLE; YOU WILL HAVE TO PRESS THE BURNER IN SLIGHTLY TO INSERT THE RETAINING PINS IN THE MOUNTING RODS ON THE TANK. CAUTION IT IS VERY IMPORTANT TO USE THE RETAINING PINS. THE PINS PREVENT THE BURNER FROM BACKING OUT OF THE FIREBOX. 14. After inserting the retaining pins, connect the fuel line and power cord in accordance with section 7-2. AIRTRONIC BURNER INSTALLATION, Page 5-30.

5-88

TM 09211A-14&P 9.1.1 PROBLEM SOLVING 1. The replacement flange was designed to work with Type-1 tanks as originally constructed. Warping of the internal sheet metal from extreme heat and mishandling of the Tank in its past, may require repositioning of flange on the studs to allow the insertion of the Airtronic burner. 9.1.2 REPOSITIONING OF FLANGE 1. Using the wrench turn the two brass nuts counter clock wise to loosen them, then hand tighten them to just barely snug. (This should allow the new flange to move around on the mounting rods.) 2. Insert the burner and shift it from left to right, up and down till it seats all the way in. 3. Carefully remove the burner making sure not to disturb the positioning of the flange. 4. Take the adjustable wrench, tighten the two nuts, being careful not to over tighten. (The Flange nuts are considered tight enough when you cannot turn the 6-inch adjustable wrench easily with two fingers at the end of the wrench handle.)

5-89

TM 09211A-14&P CHAPTER 6 REPAIR PARTS Section I. INTRODUCTION 6-1. OVERVIEW. This chapter contains a list of all parts required to maintain and support this equipment. It furnishes complete data, including items used in conjunction with and furnished as part of, or with, the equipment, to enable the user to perform required maintenance and supply support of the equipment described herein. 6-2. CONTENT. This chapter furnishes explanations and application of the information contained in the Repair Parts Listing, defines Source Maintenance Recoverability (SMR) codes; and lists applicable Commercial and Government Entities identification. Section II. EXPLANATION OF COLUMNS AND CROSS REFERENCE 6-3. OVERVIEW. This listing comprises the main part of the Repair Parts Listing (RPL). It is arranged in columns, which show national stock numbers, item identification, and other data necessary to maintain this equipment in an operative condition. Illustrations are placed either before, or in close proximity to, the component or assembly. The items are arranged in top down breakdown sequence within the major combination. 6-4. ITEM NUMBERS (COLUMN 1). This column specifies item numbers assigned in numerical sequence and in the order that each item appears in the RPL. The item numbers are provided for reference purposes. 6-5. MODEL (COLUMN 2). This column indicates by an alphabetical code the specific application of repair parts, components, or assemblies when more than one model of an assembly, component, or equipment is contained in this publication. The absence of the code indicates that only one version of the item (assembly, component, or equipment) is covered by this RPL. 6-6. NATIONAL STOCK NUMBER (COLUMN 3). This column furnishes National Stock Numbers (NSNs) assigned to those centrally managed items required for support of the equipment. When they have been assigned, NSNs will be used in all supply operations, from original purchase to final disposal of the item. Absence of an NSN indicates the item is not normally stocked as a repair part, as indicated by the source code portion of the SMR codes. 6-7. REFERENCE DESIGNATOR (COLUMN 4). This column contains alphabetical and/or numerical designators for referencing an individual repair part to an illustration.

6-1

TM 09211A-14&P 6-8. INDENTURE CODE (COLUMN 5). This column contains the Indenture Code Letter, which indicates the relationship of a line item to the end item or to the preceding component, assembly, or subassembly. Visual indentation of the line item is not shown; however, the Indenture Code Letter will enable the user of the RPL to interpret the relationship of the line item with its next higher assembly. a. Normally, the Indenture Code Letters indicate the following relationship: Code Relationship A B End item Component; attaching parts for component or detail parts of the end item not contained in a component Assembly; attaching parts for assembly or detail parts of component not contained in a component Subassembly; attaching parts for subassembly or detail parts of assembly not contained in subassembly Detail parts of subassembly And so forth

E F

6-9. ITEM IDENTIFICATION (COLUMN 6). This column contains the item name and description of the repair part. When the items comprise a kit or set, a complete list of the components will be given in alphabetical order immediately following the item, under the heading Consist of, abbreviated (C/O). 6-10. UNIT OF MEASURE (COLUMN 7). This column indicates the measure of quantity. 6-11. QUANTITY (COLUMN 8). This column is divided into sub-columns (A) and (B) and indicates the following: (A) The quantity of a maintenance or a non-maintenance part used in a specific application within the end item. (B) The consolidated quantity of a maintenance part used in an end item.

6-2

TM 09211A-14&P 6-12. SOURCE, MAINTENANCE AND RECOVERABILITY CODE (COLUMN 9). This column contains a series of alphabetic letters, which denote the uniform source, maintenance and recoverability coding structure. This Code is assigned to items subordinate to or associated with an end item, i.e., spares, repair parts and support equipment. The uniform code format is composed of three parts consisting of a two (2) position Source Code, a two (2) position Maintenance Code and a one (1) position Recoverability Code. The code provides the user with information on each item relative to (1) the method of obtaining the item; for example, by requisition, fabrication or salvage; (2) the lowest maintenance echelon authorized to remove, replace and use the item and the lowest echelon capable to perform complete repair; and (3) disposition action on unserviceable items. 6-13. ITEM NUMBER CROSS-REFERENCE. Section V consists of a cross-reference from RPL item numbers to part numbers, manufacturers code numbers and NSNs. 6-14. NATIONAL STOCK NUMBER CROSS-REFERENCE. Section VI consists of a cross-reference from NSNs to manufacturers code numbers, part numbers and RPL item numbers. 6-15. PART NUMBER CROSS-REFERENCE. Section VII consists of a cross-reference from part numbers to manufacturers code numbers, NSNs and RPL item numbers. Section III. DEFINITIONS AND APPLICATION OF SOURCE, MAINTENANCE AND RECOVERABILITY CODES 6-16. SOURCE CODES. Source codes are assigned to support items and indicate the manner of acquiring the support item. Source codes are entered in the first and second position of the uniform SMR code format. a. Series A: Assemble, Complete Assembly Not Stocked

Code A entered in the first position of the source code applies to items that are not procured as assemblies but are assembled within the Marine Corps prior to installation. The code entered in the second position designates the lowest echelon authorized to assemble the item. All the parts used in the assembly will be P coded. Code Application/Explanation AO AF AH AD Assemble at organizational maintenance level 2nd echelon. Assemble at intermediate level 3rd echelon. Assemble at intermediate level 4th echelon. Assemble at depot maintenance level 5th echelon.

6-3

TM 09211A-14&P b. Series K: Items Of A Kit, Not Purchased Separately Code Application/Explanation KD An item of depot overhaul/repair kit and not purchased separately. Depot kit defined as a kit that provides items required at the time of overhaul or repair. An item of a maintenance kit and not purchased separately. Maintenance kit defined as a kit that provides an item that can be replaced at organizational or intermediate levels of maintenance. Items included in both a depot overhaul/repair kit and a maintenance kit.

KF

KB c.

Series M: Manufacture, Parts Not Procured

Code M entered in the first position of the source code applies to items that are not procured but are capable of being fabricated or manufactured within the Marine Corps. These items have relatively low usage and will generally be fabricated or manufactured only as required for immediate repair or replacement. The code entered in the second position designates the lowest echelon authorized to manufacture or fabricate the item. Units will requisition the bulk materiel under the NSNs and the quantities indicated to effect the fabrication or manufacture of the item. Code Application/Explanation MO MF MH MD d. Manufacture or fabricate at organizational maintenance level 2nd echelon. Manufacture or fabricate at intermediate level 3rd echelon. Manufacture or fabricate at intermediate level 4th echelon. Manufacture or fabricate at depot maintenance level 5th echelon.

Series P: Parts Procured, Supply System Stock Code Application/Explanation PA Applied to items procured for the Marine Corps supply system for anticipated or known usage. Applied to items for which no usage is anticipated, but procured for the Marine Corps supply system in limited quantity for issuing purposes.

PB

6-4

TM 09211A-14&P PC Applied to items procured for the Marine Corps supply system, which would be coded PA except that they are deteriorative in nature. Support item, excluding support equipment, procured for initial issue or outfitting and stocked only for subsequent or additional initial issues or outfittings. Not subject to automatic replenishment. Support equipment procured and stocked for initial issue or outfitting to specified maintenance repair activities. Support equipment which will not be stocked but which will be centrally procured on demand. To provide for the sustained support for the life of the equipment. It is applied to an item peculiar to the equipment, which because of probable discontinuance or shutdown of production facilities would prove uneconomical to reproduce at a later time. Applied to items not maintained in the supply system; replacement of these parts is neither practical or economical. Support of the end equipment will be effected by replacing the next higher assembly. Applied to items not procured for stock, but may be acquired for use through salvage. Activities requiring such items will attempt to obtain them from salvage, if not obtainable from salvage, all efforts to manufacture or assemble the item should be exhausted prior to requisitioning. Such items will be requisitioned through normal supply channels citing manufacturers code and part number with supporting justification. Applied to installation drawing, diagram, instruction sheet or field service drawing identified by a manufacturers part number.

PD

PE

PF

PG

XA

XB

XC

6-5

TM 09211A-14&P 6-17. MAINTENANCE CODES. Maintenance codes are assigned to indicate the levels of maintenance authorized to use and repair the support item. The maintenance codes are entered in the third and fourth position of the uniform SMR code format. a. Use (Third Position). The maintenance code entered in the third position will indicate the lowest maintenance level authorized to remove, replace, and use the support item. The maintenance code entered in the third position will indicate one of the following levels of maintenance: Code Application/Explanation O F H D Organizational lst and 2nd echelon Intermediate 3rd echelon Intermediate 4th echelon Depot 5th echelon

b. Repair (Fourth Position). The maintenance code entered in the fourth position indicates whether the item is to be repaired and identifies the lowest maintenance level with the capability to perform complete repair. The decision to code the support item for repair at the indicated maintenance levels requires that all maintenance capability (remove, replace, repair, assemble and test) for the support items be provided to that level. This does not preclude some repair, which may be accomplished at a lower level of maintenance. Code Application/Explanation O F H D L Z B Organizational lst and 2nd echelon Intermediate 3rd echelon Intermediate 4th echelon Depot 5th echelon Repair restricted to designated Specialized Repair Activity. Non-reparable. No repair is authorized. No repair is authorized. The item may be reconditioned by adjusting, lubricating, etc., at the user level. No parts or special tools are procured for the maintenance of this item.

6-6

TM 09211A-14&P 6-18. RECOVERABILITY CODES. Recoverability codes are assigned to support items to indicate the disposition action on unserviceable items. The recoverability code is entered in the fifth position of the uniform SMR code format. Code Application/Explanation Z Nonreparable item. When unserviceable, condemn and dispose of at the maintenance level indicated in position 3. Reparable item. When uneconomically reparable, condemn and dispose of at organizational level. Reparable item. When uneconomically reparable, condemn and dispose of at intermediate level 3rd echelon. Reparable item. When uneconomically reparable, condemn and dispose of at intermediate level 4th echelon. Reparable item. When beyond lower level of repair capability, return to depot. Condemnation and disposal not authorized below depot level. Reparable item. Repair, condemnation and disposal not authorized below depot specialized repair activity level. Item requires special handling or condemnation procedures because of specific reasons (i.e., precious metal content, high dollar value, critical material or hazardous material). Refer to appropriate manuals/directives for specific instructions.

6-7

TM 09211A-14&P Section IV. REPAIR PARTS LISTING

Figure 6-1. Tray Ration Heating System

Figure 6-2 Burner Assembly

6-8

TM 09211A-14&P

Figure 6-3 Burner Assembly Generation 1 (Illustrated Breakdown)

6-9

TM 09211A-14&P

ITEM NO

NATIONAL STOCK NUMBER

REF IND DESIGN FIG-KEY

ITEM IDENTIFICATION

UNIT OF MEAS

QUANTITY

SMR CODE

1 2

7310-01-295-7479 7310-01-442-8340
4140-01-492-6734 7310-01-493-1801 4540-01-493-1729 4710-01-492-9160 7310-01-493-1765 5340-01-533-4450 6150-01-533-4483 6150-01-492-8211 6150-01-533-4465 7310-01-492-9271 5330-01-533-4274 5340-01-492-6700 5305-01-493-2282 7310-01-492-9267 4520-01-492-6662 7310-01-493-1726 5331-01-492-6618 5930-01-492-9140 5330-01-492-6716 7310-01-492-6728 2910-01-442-2875 4320-01-533-4444 4710-01-492-9150 5330-01-492-6629 4810-01-533-4207 3010-01-492-8203 6105-01-442-6342 4140-01-492-6709

6-1 6-2

3 4 5 6 7 8 9 10

11
12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30

6-3-001 6-3-002 6-3-003 6-3-03a 6-3-004 6-3-005 6-3-006 6-3-007 6-3-008 6-3-009 6-3-010 6-3-011 6-3-011a 6-3-012 6-3-013 6-3-014 6-3-015 6-3-016 6-3-017 6-3-018 6-3-019 6-3-020 6-3-021 6-3-022 6-3-023 6-3-024 6-3-025 6-3-026

A TRAY RATION HEATING SYSTEM A BURNER ASSEMBLY, GASOLINE FIELD RANGE OUTFIT (GEN 1) REPAIR PARTS B UPPER FAN HOUSING B BLOWER AIR SHUTTER B PRIMARY CONTROL BOX DIAGNOSTIC TEST BOX 15 MIN S/O B BASE, CONTROL BOX B SIDE PANEL, CONTROL BOX, BASE B CABLE, MOTOR CONNECTION B CABLE, SOLENOID B CABLE, PHOTO CELL B C C C C C C C C C C B C C D C C B C AIR TUBE/FLAME TUBE ASSY GASKET, BURNER HI-TEMP SILICON MOUNTING PLATE AND GASKET SCREW W/RUBBERBUSH ATOMIZING CHAMBER ASSY IGNITION ELECTRODE TRANSFORMER/RETAINER O-RING SET, LOWER HOUSING ASSY OVERFLOW SAFETY SWITCH GASKET FUEL SUMP FUEL SUMP PUMP, FUEL, ELECT SILICONE MEMBRANE, PUMP FUEL CROSSOVER O-RINGS FUEL SOLENOID BODY AND COIL COUPLING, SHAFT FUEL MOTOR, ALT CURRENT BLOWER WHEEL

EA EA

(A) (B) PER PER APPL EQUIP 1 1 PAFZZ 1 1 PAFZZ

EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA SE EA EA EA EA EA EA EA EA EA EA EA

1 1 1 1 1 1 1 1 1 1 1 1 3 1 1 1 1 1 1 1 1 1 1 2 1 1 1 1

1 1 1 1 1 1 1 1 1 1 1 1 3 1 1 1 1 1 1 1 1 1 1 2 1 1 1 1

PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ XBFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ

Table 6-3 Burner Assembly Parts (Generation 1)

6-10

TM 09211A-14&P

ITEM NO

NATIONAL STOCK NUMBER

REF IND DESIGN FIG-KEY

ITEM IDENTIFICATION

UNIT OF MEAS

QUANTITY

SMR CODE

31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46

4810-01-533-2068 4730-01-533-8368 4310-01-492-8190 5365-01-492-9147 4310-01-492-8182 4720-01-533-4407 5980-01-493-1761 4140-01-492-6683 4140-01-533-2053 5340-01-492-6739 4710-01-492-8200 4710-01-492-9160 4530-01-492-6719 5331-01-533-4279 5330-01-492-6717

6-3-027 6-3-028 6-3-029 6-3-030 6-3-031 6-3-032 6-3-033 6-3-034 6-3-035 6-4-035a 6-3-036 6-3-037 6-3-038 6-3-039 6-3-040 6-3-041

C C D D C C C C C C C C C C D D

COMPRESSOR HEAD AIR SOLENOID BODY AND COIL PRIMER PORT BRASS FITTING COMPRESSOR AIR FILTER AIR FILTER PLUG O-RING / PISTON RING PRIMER PORT TUBING 1/8" PHOTO CELL SENSOR W/ ADAPTER LOWER FAN HOUSING (GEN 1) LOWER FAN HOUSING (GEN 2&3) MOUNT PLATE LOWER HOUSING FUEL LINE ALUMINUM COMPRESSOR AIR LINE FUEL FLOW CONTROL O-RING, FLOW CONTROL GASKET, FLOW CONTROL

EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA

(A) (B) PER PER APPL EQUIP 1 1 PAFZZ 1 1 PAFZZ 1 1 PAFZZ 1 1 PAFZZ 1 1 XBFZZ 1 1 PAFZZ 1 1 PAFZZ 1 1 PAFZZ 1 1 PAFZZ 1 1 PAFZZ 1 1 PAFZZ 1 1 PAFZZ 1 1 PAFZZ 1 1 PAFZZ 1 1 PAFZZ 1 1 PAFZZ

Table 6-3-1 Burner Assembly Parts (Generation 1) (Cont)

6-11

TM 09211A-14&P

Figure 6-4 Burner Assembly Generation 2 and 3 (Illustrated Breakdown)

6-12

TM 09211A-14&P

ITEM NO

NATIONAL STOCK NUMBER

REF IND DESIGN FIG-KEY

ITEM IDENTIFICATION

UNIT OF MEAS

QUANTITY (A) (B) PER PER APPL EQUIP 1 1 1 1

SMR CODE

7310-01-442-8340

6-4 6-4

A BURNER ASSEMBLY, GASOLINE FIELD RANGE OUTFIT (GEN 2) A BURNER ASSEMBLY,

EA EA

PAFZZ PAFZZ

GASOLINE FIELD RANGE OUTFIT (GEN 3)


3a 21a 21b 22a 40 4140-01-533-2038 4140-01-533-4472 NSN TBA 7310-01-533-2095 4140-01-533-2053 6-4-001 6-4-017 6-4-017a 6-4-018a 6-4-035 B UPPER FAN HOUSING (Gen 2 & 3) C GASKET FUEL SUMP (Gen 2) C GASKET (O-RING) FUEL SUMP (Gen 3) C FUEL SUMP (Gen 2 & 3) C LOWER FAN HOUSING (GEN 2 & 3) EA EA EA EA EA 1 1 1 1 1 1 1 1 1 1 PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ

NOTE: The items listed in this table are just the items that are different from Generation 1 Airtronic Burners, all other parts are interchangeable between all Generations of Burners .

Table 6-4 Burner Assembly Parts Generation 2 and 3

6-13

TM 09211A-14&P

Figure 6-5. Tank Assembly (1 of 3)

Figure 6-5. Tank Assembly (2 of 3)

6-14

TM 09211A-14&P

Figure 6-5. Tank Assembly (3 of 3)

6-15

TM 09211A-14&P

ITE M NO

2 M O D E L

8 QUANTITY (A) (B) PER PER APPL EQUI P 1 1 2 4 8 8 4 1 1 1 4 1 1 1 1 22 1 1 1 2 1 1 1 2 4 8 8 4 1 1 1 4 1 1 1 1 22 1 1 1 2 1

NATIONAL STOCK NUMBER

REF DESIG N FIGKEY

I N D

ITEM IDENTIFICATION

UNIT OF MEAS

SMR CODE

TANK ASSEMBLY 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 7310-01-493-2193 7310-01-493-1832 5342-01-443-9361 5305-01-493-2214 5310-01-493-2243 5306-01-463-2101 4820-01-131-9521 4730-01-233-8396 7310-01-493-2628 5305-01-493-2489 5340-01-493-2154 7310-01-493-2195 5330-01-493-2202 5330-01-493-2198 5305-01-493-2487 5315-01-493-2189 5340-01-493-2184 7310-01-492-9254 5315-01-128-6802 4730-00-904-4986 6-5-001 6-5-002 6-5-003 6-5-004 6-5-005 6-5-006 6-5-007 6-5-008 6-5-009 6-5-010 6-5-011 6-5-012 6-5-013 6-5-014 6-5-015 6-5-016 6-5-017 6-5-018 6-5-019 6-5-020 C C C C C C C C C C C C C C C C C C C C TANK ASSEMBLY SKID SHOCK MOUNT SCREW, 5/16-18 X 1 SS ESNA LOCKNUT SCREW, 3/8-16 X 1 DRAIN VALVE ADAPTER, BRASS EXHAUST END SCREW, #10-32 COVER, BURNER LID GASKET RETAINER SCREW PIN, LID STOP STOP LID RACK, TRAY PACK PIN, LOCK STL, 0.015 DIA, 2.060 IN LG COUPLING HALF, QUICK DISCONNECT, COPPER, 2.500 IN LG COUPLING HALF, QUICK DISCONNECT ACCESS PANEL, SECON ACCESS PANEL, SECON

EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA

PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAOZZ PAOZZ PAOZZ PAOZZ PAOZZ PAFZZ PAOZZ PAOZZ PAOZZ PAOZZ PAOZZ PAOZZ PAOZZ PAOZZ

67 68 69

4730-01-380-6025 5340-01-493-1845 5305-01-493-2488

6-5-021 6-5-022 6-5-023

C C C

EA EA EA

1 1 14

1 1 14

PAOZZ PAOZZ PAOZZ

Table 6-5 Tank Assembly Parts

6-16

TM 09211A-14&P

Figure 6-6. Electrical System

6-17

TM 09211A-14&P
1 2 3 M O D NATIONAL E STOCK L NUMBER 4 5 6 7 8 QUANTITY (A) (B) PER PER APP EQUI L P 9

ITEM NO

REF DESIGN FIGKEY

I N D

ITEM IDENTIFICATION

UNIT OF MEAS

SMR CODE

ELECTRICAL SYSTEM 70 71 72 73 5340-01-493-2135 5930-01-268-2186 5999-01-442-7643 5925-00-283-6048 6-6-001 6-6-002 6-6-003 6-6-004 C C C C COVER, ELECTRICAL BOX SWITCH LIGHT-SWITCH, PUSH-PULL, 120.0 V CIRCUIT BREAKER, PLASTIC, EXTERNAL, 0.958 IN LG CONNECTOR, RECEPTICAL ELECTRICAL, EXTERNAL COVER, ELECTRICAL CONNECTOR POWER CORD PLUG, POWER INLET PLUG, ELECTRICAL TERMINAL BLOCK LIQUID LEVEL SWITCH INSERT, PROBE PROBE, MARTRON SENSOR MERCURY TILT SWITCH RESISTOR, THERMAL EA EA EA EA 1 1 1 1 1 1 1 1 PAOZZ PAOZZ PAOZZ PAOZZ

74 75 76 77 78 79 80 81 82 83 84

5935-00-197-6556 5935-01-195-2337 7360-01-514-1432 5935-00-148-8190 5935-01-108-8437 5940-00-458-0060 5930-01-492-9245 4730-01-492-9241 7310-01-493-2287 5930-01-492-7272 5905-01-443-9038

6-6-005 6-6-006 6-6-007 6-6-008 6-6-009 6-6-010 6-6-011 6-6-012 6-6-013 6-6-014 6-6-015

C C C C C C C C C C C

EA EA EA EA EA EA EA EA EA EA EA

1 1 1 1 1 1 1 1 1 1 1

1 1 1 1 1 1 1 1 1 1 1

PAOZZ PAOZZ XBFZZ PAFZZ PAFZZ PAOZZ PAOZZ PAOZZ PAOZZ PAOZZ PAOZZ

Table 6-6 Electrical System Parts

6-18

TM 09211A-14&P Section V. ITEM NUMBER CROSS REFERENCE


ITEM NO 1 2 3 3a 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 18a 19 20 21 21a 21b 22 22a 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 PART NO MFG CODE 04AL0 04AL0 04AL0 04AL0 04AL0 04AL0 04AL0 04AL0 04AL0 04AL0 04AL0 04AL0 04AL0 04AL0 04AL0 04AL0 04AL0 04AL0 04AL0 04AL0 04AL0 04AL0 04AL0 04AL0 04AL0 04AL0 04AL0 04AL0 04AL0 04AL0 04AL0 04AL0 04AL0 04AL0 04AL0 04AL0 04AL0 04AL0 04AL0 04AL0 04AL0 04AL0 04AL0 04AL0 04AL0 NATIONAL STOCK NUMBER 7310-01-295-7479 7310-01-442-8340 4140-01-492-6734 4140-01-533-2038 7310-01-493-1801 4540-01-493-1729 6625-01-533-8244 7310-01-493-1765 5340-01-533-4450 6150-01-533-4483 6150-01-492-8211 6150-01-533-4465 7310-01-492-9271 5330-01-533-4274 5340-01-492-6700 5305-01-493-2282 7310-01-492-9267 4520-01-492-6662 7310-01-493-1726 7310-01-533-2095 5331-01-492-6618 5930-01-492-9140 5330-01-492-6716 4140-01-533-4472 NSN TBA 7310-01-492-6728 7310-01-533-2095 2910-01-442-2875 4320-01-533-4444 4710-01-492-9150 5330-01-492-6629 4810-01-533-4207 3010-01-492-8203 6105-01-442-6342 4140-01-492-6709 NSN TBA 4810-01-533-2068 4730-01-533-8368 4310-01-492-8190 5365-01-492-9147 4310-01-492-8182 4720-01-533-4407 5980-01-493-1761 4140-01-492-6683 4140-01-533-2053

TRH-0100 B42000-95-0001 B42000-95-0020 B42000-98-0020 B42000-95-0021 B42000-95-0017 B42000-95-0050 B42000-95-0016 B42000-95-0016S B42000-98-0002C B42000-95-0014 B42000-95-0018C B42000-95-0035 8623K144G B42000-95-0031 B42000-95-0040 B42000-95-0027 B42000-95-0028 B42000-95-0029 B42005-05-0025 B42000-95-0039 B42000-95-0037 B42000-95-0042 B42000-98-0042 B42000-04-0042 B42000-95-0025 B42005-04-0025 B42000-95-0010 B42000-95-0010M B42000-95-0026 B42000-95-0046 B42000-95-0013 B42000-95-0011 B42000-95-0002 B42000-95-0038 B42000-95-0003 B42000-95-0006 1005309 B42000-95-0005 B42000-95-0044 B42000-95-0004 AAA00007 B42000-95-0018 B42000-95-0023 B42000-98-0023

6-19

TM 09211A-14&P
Section V. ITEM NUMBER CROSS REFERENCE (Cont.) ITEM NO 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 PART NO MFG CODE 04AL0 04AL0 04AL0 04AL0 04AL0 04AL0 04AL0 04AL0 0TS30 39428 39428 25795 25795 25795 04AL0 04AL0 04AL0 04AL0 04AL0 04AL0 04AL0 04AL0 04AL0 04AL0 39428 2570 2570 04AL0 04AL0 04AL0 17479 01121 77342 77820 96906 04AL0 74545 77820 01121 04AL0 04AL0 04AL0 0JW91 50157 NATIONAL STOCK NUMBER 5340-01-492-6739 4710-01-492-8200 4710-01-492-9160 4530-01-492-6719 5331-01-533-4279 5330-01-492-6717 7310-01-493-2193 7310-01-493-1832 5342-01-443-9361 5305-01-493-2214 5310-01-493-2243 5306-01-463-2101 4820-01-131-9521 4730-01-233-8396 7310-01-493-2628 5305-01-493-2489 5340-01-493-2154 7310-01-493-2195 5330-01-493-2202 5330-01-493-2198 5305-01-493-2487 5315-01-493-2189 5340-01-493-2184 7310-01-492-9254 5315-01-128-6802 4730-00-904-4986 4730-01-380-6025 5340-01-493-1845 5305-01-493-2488 5340-01-493-2135 5930-01-268-2186 5999-01-442-7643 5925-00-283-6048 5935-00-197-6556 5935-01-195-2337 7360-01-514-1432 5935-00-148-8190 5935-01-108-8437 5940-00-458-0060 5930-01-492-9245 4730-01-492-9241 7310-01-493-2287 5930-01-492-7272 5905-01-443-9038

B42000-95-0022 B42005-04-0007 B42000-95-0009 B42000-95-0024 9263K238 B42000-95-0041 TRH2050 TRH914 4C979 9221OA583 91839A127 4P313 5X716 4X072 TRH907 S10-32RC TRH1260 TRH2020 TRH1225 TRH1226 S8-32FC TRH928D TRH928A TRH931 92391AO54 B-QC4-BI-400 B-QC4-D-4HC TRH908A S8-32RS TRH120B 2X464 800H-FRXTQI0RD4 W58-XBIA4A-5 PT02E-12-3S MS3181-12CA 16/3SOJ/SOW 8215C PT06P-12-3P 1492-F1 16-01 TRH1313 TRH1314 TOS-12C-LI 60T21X-1236G

6-20

TM 09211A-14&P Section VI. NATIONAL STOCK NUMBER CROSS REFERENCE


NATIONAL STOCK NUMBER NSN TBA NSN TBA 2910-01-442-2875 3010-01-492-8203 4140-01-492-6683 4140-01-492-6709 4140-01-492-6734 4140-01-533-2038 4140-01-533-2053 4140-01-533-4472 4310-01-492-8182 4310-01-492-8190 4320-01-533-4444 4520-01-492-6662 4530-01-492-6719 4540-01-493-1729 4710-01-492-8200 4710-01-492-9150 4710-01-492-9160 4720-01-533-4407 4730-00-904-4986 4730-01-233-8396 4730-01-380-6025 4730-01-492-9241 4730-01-533-8368 4810-01-533-2068 4810-01-533-4207 4820-01-131-9521 5305-01-493-2214 5305-01-493-2282 5305-01-493-2487 5305-01-493-2488 5305-01-493-2489 5306-01-463-2101 5310-01-493-2243 5315-01-128-6802 5315-01-493-2189 5330-01-492-6629 5330-01-492-6716 5330-01-492-6717 5330-01-493-2198 5330-01-493-2202 5330-01-533-4274 MFG CODE 04AL0 04AL0 04AL0 04AL0 04AL0 04AL0 04AL0 04AL0 04AL0 04AL0 04AL0 04AL0 04AL0 04AL0 04AL0 04AL0 04AL0 04AL0 04AL0 04AL0 02570 25795 02570 04AL0 04AL0 04AL0 04AL0 25795 39428 04AL0 04AL0 04AL0 04AL0 25795 39428 39428 04AL0 04AL0 04AL0 04AL0 04AL0 04AL0 04AL0

PART NO. B42000-04-0042 B42000-95-0003 B42000-95-0010 B42000-95-0011 B42000-95-0023 B42000-95-0038 B42000-95-0020 B42000-98-0020 B42000-98-0023 B42000-98-0042 B42000-95-0004 B42000-95-0005 B42000-95-0010M B42000-95-0028 B42000-95-0024 B42000-95-0017 B42005-04-0007 B42000-95-0026 B42000-95-0009 AAA00007 B-QC4-BI-400 4X072 B-QC4-D-4HC TRH1313 1005309 B42005-04-0006 B42005-04-0013 5X716 9221OA583 B42000-95-0040 S8-32FC S8-32RS S10-32RC 4P313 91839A127 92391AO54 TRH928D B42000-95-0046 B42000-95-0042 B42000-95-0041 TRH1226 TRH1225 8263K144G

ITEM NO. 21b 31 23 28 39 30 3 3a 39a 21a 36 34 24 17 44 5 42 25 43 37 66 54 67 81 33 32 27 53 50 15 61 69 56 52 51 65 62 26 21 46 60 59 13

6-21

TM 09211A-14&P
Section VI. NATIONAL STOCK NUMBER CROSS REFERENCE (Cont.) NATIONAL STOCK NUMBER 5331-01-533-4279 5331-01-492-6618 5340-01-492-6700 5340-01-492-6739 5340-01-493-1845 5340-01-493-2135 5340-01-493-2154 5340-01-493-2184 5340-01-533-4450 5342-01-443-9361 5365-01-492-9147 5905-01-443-9038 5925-00-283-6048 5930-01-268-2186 5930-01-492-7272 5930-01-492-9140 5930-01-492-9245 5935-00-148-8190 5935-00-197-6556 5935-01-108-8437 5935-01-195-2337 5940-00-458-0060 5980-01-493-1761 5999-01-442-7643 6105-01-442-6342 6150-01-492-8211 6150-01-533-4465 6150-01-533-4483 6625-01-533-8244 7310-01-295-7479 7310-01-442-8340 7310-01-492-6728 7310-01-492-9254 7310-01-492-9267 7310-01-492-9271 7310-01-493-1726 7310-01-493-1765 7310-01-493-1801 7310-01-493-1832 7310-01-493-2193 7310-01-493-2195 7310-01-493-2287 7310-01-493-2628 7310-01-533-2095 7310-01-492-9254 7360-01-514-1432 MFG CODE 04AL0 04AL0 04AL0 04AL0 04AL0 04AL0 04AL0 04AL0 04AL0 0TS30 04AL0 50157 77342 17479 0JW91 04AL0 04AL0 74545 77820 77820 96906 01121 04AL0 01121 04AL0 04AL0 04AL0 04AL0 04Al0 04AL0 04AL0 04AL0 04AL0 04AL0 04AL0 04AL0 04AL0 04AL0 04AL0 04AL0 04AL0 04AL0 04AL0 04AL0 04AL0 04AL0

PART NO. 9263K238 B42000-95-0039 B42000-95-0031 B42000-95-0022 TRH908A TRH120B TRH1260 TRH928A B42000-95-0016S 4C979 95-0044 60T21X-1236G W58-XBIA4A-5 2X464 TOS-12C-LI B42000-95-0037 16-01 8215C PT02E-12-3S PT06P-12-3P MS3181-12CA 1492-F1 B42000-95-0018 800H-FRXTQI0RD4 B42000-95-0002 B42000-95-0014 B42000-95-0018C B42000-98-0002C B42000-95-0050 TRH-0100 B42000-95-0001 B42000-95-0025 TRH931 B42000-95-0027 B42000-95-0035 B42000-95-0029 B42000-95-0016 B42000-95-0021 TRH914 TRH2050 TRH2020 TRH1314 TRH907 B42005-04-0025 TRH931

16/3SOJ/SOW

ITEM NO 45 19 14 41 68 70 57 63 8 49 35 84 73 71 83 20 80 77 74 78 75 79 38 72 29 10 11 9 6 1 2 22 64 16 12 18 7 4 48 47 58 82 55 18a 64 76

6-22

TM 09211A-14&P
Section VII. PART NUMBER CROSS REFERENCE

PART NO. 1005309 1492-F1 16/3SOJ/SOW 16-01 2X464 4C979 4P313 4X072 5X716 60T21X-1236G 800H-FRXTQI0RD4 8215C 8263K144G 91839A127 9221OA583 92391AO54 9263K238 95-044 AAA00007
B-QC4-BI-400 B-QC4-D-4HC

NATIONAL MFG CODE STOCK NUMBER 04AL0 4730-01-533-8368 01121 5940-00-458-0060 04AL0 7360-01-514-1732 04AL0 5930-01-492-9245 17479 5930-01-268-2186 0TS30 5342-01-443-9361 25795 5306-01-463-2101 25795 4730-01-233-8396 25795 4820-01-131-9521 50157 5905-01-443-9038 01121 5999-01-442-7643 74545 5935-00-148-8190 04AL0 5330-01-533-4274 39428 5310-01-493-2243 39428 5305-01-493-2214 39428 5315-01-128-6802 04AL0 5331-01-533-4279 04AL0 5365-01-492-9147 04AL0 4720-01-533-4407
02570 02570 4730-00-904-4986 4730-01-380-6025

ITEM NO. 33 79 76 80 71 49 52 54 53 84 72 77 13 51 50 65 45 35 37
66 67

B42000-04-0042 B42000-95-0001 B42000-95-0002 B42000-95-0003 B42000-95-0004 B42000-95-0005 B42000-95-0010 B42000-95-0010M B42000-95-0011 B42000-95-0014 B42000-95-0016 B42000-95-0016S B42000-95-0017 B42000-95-0018 B42000-95-0018C B42000-95-0020 B42000-95-0021 B42000-95-0022 B42000-95-0023

04AL0 04AL0 04AL0 04AL0 04AL0 04AL0 04AL0 04AL0 04AL0 04AL0 04AL0 04AL0 04AL0 04AL0 04AL0 04AL0 04AL0 04AL0 04AL0

NSN TBA 7310-01-442-8340 6105-01-442-6342 NSN TBA 4310-01-492-8182 4310-01-492-8190 2910-01-442-2875 4320-01-533-4444 3010-01-492-8203 6150-01-492-8211 7310-01-493-1765 5340-01-533-4450 4540-01-493-1729 5980-01-493-1761 6150-01-533-4465 4140-01-492-6734 7310-01-493-1801 5340-01-492-6739 4140-01-492-6683

21b 2 29 31 36 34 23 24 28 10 7 8 5 38 11 3 4 41 39

6-23

TM 09211A-14&P
Section VII. PART NUMBER CROSS REFERENCE (Cont.)

PART NO. B42000-95-0024 B42000-95-0025 B42000-95-0026 B42000-95-0027 B42000-95-0028 B42000-95-0029 B42000-95-0031 B42000-95-0035 B42000-95-0036 B42000-95-0037 B42000-95-0038 B42000-95-0039 B42000-95-0040 B42000-95-0041 B42000-95-0046 B42000-95-0050 B42000-98-0002C B42000-98-0020 B42000-98-0023 B42000-98-0042 B42005-04-0006 B42005-04-0007 B42005-04-0013 B42005-04-0025 MS3181-12CA PT02E-12-3S PT06P-12-3P S10-32RC S8-32FC S8-32RS TOS-12C-LI TRH0100 TRH120B TRH1225 TRH1226 TRH1260 TRH1313 TRH1314

MFG CODE 04AL0 04AL0 04AL0 04AL0 04AL0 04AL0 04AL0 04AL0 04AL0 04AL0 04AL0 04AL0 04AL0 04AL0 04AL0 04AL0 04AL0 04AL0 04AL0 04AL0 04AL0 04AL0 04AL0 04AL0 96906 77820 77820 04AL0 04AL0 04AL0 0JW91 04AL0 04AL0 04AL0 04AL0 04AL0 04AL0 04AL0

NATIONAL ITEM NO. STOCK NUMBER 4530-01-492-6719 44 7310-01-492-6728 22 4710-01-492-9150 25 7310-01-492-9267 16 4520-01-492-6662 17 7310-01-493-1726 18 5340-01-492-6700 14 7310-01-492-9271 12 5340-01-492-6647 40 5930-01-492-9140 20 4140-01-492-6709 30 5331-01-492-6618 19 5305-01-493-2282 15 5330-01-492-6717 46 5330-01-492-6629 26 6625-01-533-8244 6 6150-01-533-4483 9* 4140-01-533-2038 3a 4140-01-533-2053 39a 4140-01-533-4472 21a 4810-01-533-2068 32 4710-01-492-8200 42 4810-01-533-4207 27 7310-01-533-2095 18a 5935-01-195-2337 75 5935-00-197-6556 74 5935-01-108-8437 78 5305-01-493-2489 56 5305-01-493-2487 61 5305-01-493-2488 69 5930-01-492-7272 83 7310-01-295-7479 1 5340-01-493-2135 70 5330-01-493-2202 59 5330-01-493-2198 60 5340-01-493-2154 57 4730-01-492-9241 81 7310-01-493-2287 82

6-24

TM 09211A-14&P TRH2020 TRH2050 TRH907 TRH908A TRH914 TRH928A TRH928D TRH931 W58-XBIA4A-5 04AL0 04AL0 04AL0 04AL0 04AL0 04AL0 04AL0 04AL0 77342 7310-01-493-2195 7310-01-493-2193 7310-01-493-2628 5340-01-493-1845 7310-01-493-1832 5340-01-493-2184 5315-01-493-2189 7310-01-492-9254 5925-00-283-6048 58 47 55 68 48 63 62 64 73

6-25

TM 09211A-14&P Section VIII. COMMERCIAL AND GOVERNMENT ENTITIES


CODE S4462 MANUFACTURER SATRONIC AG BAHNSTR 102 REGENSDORF CH-8105 SWITZERLAND GRAINGER DIVISION OF W W GRAINGER INC 2261 RINGWOOD AVENUE SAN JOSE CA 95131 MCMASTER-CARR SUPPLY CO 9630 NORWALD BLVD SANTA FE SPRINGS CA 90670-2932 CODE 17479 MANUFACTURER HONEYWELL INC COMMERCIAL DIV 5025 BRADENTON AVE SUITE A DUBLIN OH 43017 MCMASTER-CARR. SUPPLY CO, 600 COUNTY LINE ROAD ELMHURST IL 60126

OC9M4

39428

OE328

50157

THERM-O-DISC INC SUB OF EMERSON ELECTRIC CO 1918 PORT CITY BLVD MUSKEGON MI 49443 POTTER AND BRUMFIELD INC A SIE MENS CO 200 S RICHARD CREEK DR PRINCETON IN 47671-0001 MILITARY STANDARDS PROMULGATED BY MILITARY DEPARTMENTS UNDER AUTHORITY OF DEFENSE STANDARDIZATION MANUAL 4120,3-M

01121

ALLEN-BRADLEY CO 1201 S 2ND STREET MILWAUKEE WI 53204

77342

02571

CRAWFORD FITTING CO 29500 SOLON ROAD SOLON OH 44139-3449

96906

04AL0

BABINGTON ENTERPRISES 1113 INGLESIDE AVE MCLEAN VA 22101

6-26

TM 09211A-14&P APPENDIX A COMPONENTS OF END ITEM LIST COMPONENT PARTS Item 1 NSN/Part No. 8115-01-354-0797 Qty. 1 Description Container, Quadruple (Quadcon) [weatherproof, flame retardant, dimensionally standard, reusable cargo container for transport and storage of organizational property and consumable supplies] (Figure A-1) Tray Ration Heater [Heater tank with lid, stainless steel, skid mounted, with aluminica-silica insulated fire box and electrical control box] (Figure 1-3) Airtronic Burner [(Includes primary control box) Babington Enterprises] Can, Fuel, 5-Gallon (Plastic, tan, with screw on, tethered cap) (Figure 2-2) Holder, Fuel Can, Bracket Assembly (Figure 2-2) Fuel Line with Quick Disconnect [c/o: valve coupling, female [NSN 4730-01-493-2207]; 12 1/2 fuel line hose, 1/4 inside diameter, in 12 section and 6 section [McMaster-Carr P/N 54605K12]; transparent fuel filter [Bosch P/N 71936); male nipple, 1/4 hose to 1/4 MNPT [NSN 4730-01-231-9692]; male shutoff [Parker P/N BH2-61Y]; and four 1/4 hose clamps [McMasterCarr P/N 5321K14] (Babington Enterprises)] (Figure 2-2) Fuel Can Adapter (Figure A-1) Inverter Assembly [c/o: 6 untethered 24 VDC to 120 VAC 300 watt inverter with integral, two-plug covered ground fault interrupter, 5 amp circuit breaker, on-off toggle switch, bracket and LED indicator lights (Dimensions Unlimited, Inc P/N DUI-24/300]; and NATO slave plug (2510-00-567-0128)] (Babington Enterprises) (Figure 1-8)

7310-01-295-7479

7310-01-442-8340

7240-01-337-5269

5 6

2590-00-473-6331 4720-01-493-1830

1 1

7 8

7240-21-911-8834 6130-01-493-1830

1 1

A-1

TM 09211A-14&P COLLATERAL EQUIPMENT Item NSN/Part No. Qty. 9 5340-00-817-4657 2

Description Padlock, Keyed [High security, precision 4-pin tumbler mechanism. Laminated steel case is rust proofed for extended wear. Two brass keys. Fits Quadcon. (Master Lock)] (Figure A-1) Tables, Stainless Steel [Folding legs; military green] (Figure 1-9) Bracket, Table, Rear [Babington -Enterprises] (Figure 1-9) Bracket, Table, Forward [Babington Enterprises] (Figure 1-9) Clamp, Table [Babington Enterprises] (Figure 1-9) Tiedown Straps, Tray Ration Heater [Comet Enterprises] (Figure 1-3) Storage Bag, Rain Cover Kit [Comet Enterprises] Canvas, Foul Weather, Rain Cover Kit [Comet Enterprises] Poles, Tent, 8 Extendable, Military Green [Babington Enterprises] Stays, Tent, Rain Cover Kit [Comet Enterprises] Tent Pins, Rain Cover Kit [Comet Enterprises] Fire Extinguisher, with Mounting Bracket [Red, hand, dry chemical (Walter Kidde); 2-A, 10-B:C.] (Figure A-1) Heavy duty steel strap bracket [Babington Enterprises)] (Figure A-1) Tool Box, Portable [General-use tool box for carrying all hand tools] Zoom Technologies (856) 767-8840 x-28 P/N TB-1 (Figure A-1)

10

7105-01-250-0086

11

5340-01-492-6746

12

5340-01-492-6747

13 14

5340-01-492-6748 5340-01-493-2511

1 2

15 16

7310-01-493-2621 7310-01-493-2622

1 1

17

7310-01-493-2633

18 19 20

7310-01-493-2625 8340-00-823-7451 4210-00-165-4703

4 4 1

21

5340-01-493-2502

22

0000-00-000-0000

A-2

TM 09211A-14&P Item 23 NSN/Part No. 5210-00-234-8913 Qty. 1 Description Screwdriver, cross Tip [Steel blade is securely attached in transparent plastic handle with comfortable grip. Phillips-type point. Heat treated blade with smooth, bright finish and corrosion-preventive coating. Has straight, round shank and a rounded handle end. Has a No. 2 point size tip, a 1/4 diameter, 4 long exposed blade and a 7/8 diameter handle. Size is approximately 7 1/2 long overall.] (Figure A-1) Screwdriver, Flat Tip [Steel blade is securely attached in transparent plastic handle with comfortable grip. Heat treated with smooth, bright finish and corrosionpreventive coating. Has straight, round shank and a rounded handle end. Has a 1/4 wide tip, a 10 long exposed blade and a 1 diameter handle. Size is approximately 13 2/3 long overall.] (Figure A-1) Key Set, Socket Head Screw [L-shaped wrenches for tightening and loosening hexagonal-socket screw products have two working ends and are made of tempered steel. Measures 2, 3, 4 and 5 mm wide across flats (Esco 67-220, 67-230, 67-240 and 67-250). (Fab-X)] (Figure A-1) Pliers, slip-joint [Angled nose pliers are approximately 8 long and have multiple tongue-and-groove adjustments. With bolt and nut joint; does not have cutter. Straight jaws, grooved grinning surfaces. Made of strong, forged steel with chrome plating. Minimum work capacity is 1 3/16, jaw is 7/8 long; has four adjustment positions. (Figure A-1) Wrench, Adjustable [Heavy-duty, hardened steel with bright chrome or nickel-plated finish for tightening both square and hexagonal-head nuts and bolts. Has an open end rack and worm adjustment. Head is angled at 22 1/2o. Consists of a frame (fixed jaw and handle) and a movable jaw and adjusting work. Jaw capacity is 15/16. Size is 7 1/2 to 8 1/2 long.] (Figure A-1)

24

5120-00-227-7334

25

5120-01-495-8208

26

5120-00-181-6819

27

5120-00-240-5328

A-3

TM 09211A-14&P Item 28 NSN/Part No. 5102-00-242-3915 Qty 1 Description Hammer (Peen), Blacksmiths/Engineers, 3-Pound [Short- Handled for driving tent pins. Handle length is approximately 16. Heavy-Duty hammer has forged steel head with corrosion preventive coating. Has an octagonal face on one end of the head and a cross peen on the other end. End of the peen is rounded and smooth. Cross peen is at a right angle to the handle axis.] (Figure A-1) Pan Carriers, Side-Loading [Cambro] (Figure A-1) P/N 200 MPC Beverage Containers, 5-gallon [Cambro] (Figure A1) Tiedown Straps, Beverage Containers/Pan Carriers [Comet Enterprises] (Figure 1) Gloves, Pro Chem, pr [Fabric lined, 12-gauntlet, reinforced neoprene coating (Magla Edmont).] (Figure A-1) Technical Manual TRHS (Figure A-1) Utensil Box, Portable [General-use tool box for carrying all food service utensils, including can opener. 8.5 Wide, 8.75 Height, 20 Long. P/N TB1 Zoom Technologies (856) 767-8840 x-28 (CAGE00000).] (Figure A-1) Tray Pack Handling Tool [CAGE 81337 Natick] (Figure A-1) Can Opener, Edlund S-11, Stainless Steel [Manual can opener opens any size can, up to and including #10 round, 7 square and oblong. Easily cleaned and sanitized. Table mounted, hand crank-operated on opener. Furnished with three additional cutting wheels and feed wheels. Modified shaft, without table bracket, (Edlund). P/N AA52206-4BB ] (Figure A-1) Can Opener, Knife [Edlund P/N K004] (Figure A-1)

29 30 31

7330-01-234-2163 7320-01-093-7371 5340-01-493-2508

3 6 2

32

8415-01-511-4637

33 34

PCN 18409211000 0000-00-000-0000

1 1

35 36

7330-01-234-2164 7330-01-411-9789

1 1

37

7330-01-234-2204

A-4

TM 09211A-14&P Item 38 NSN/Part No. 5110-00-273-0128 Qty. 1 Description Tin Snips [Aviation, cutting length, approximately 10 long overall. Compound lever action for easy repetitive cutting. Blades are drop forged alloy steel and finely serrated to prevent slipping. Snips have cushion-grip handle and safety latch. Cutting capacity for cold rolled steel is 22 gauge.] (Figure A-1) Thermometer, Pocket [0o to 220oF, accuracy 2o. External recalibration adjustment. Hermetically sealed. 304 stainless steel construction with polycarbonate window 5 stem length with high visibility dial layout. Protective polyethylene clip-sheath (Ashcroft).] P/N 10FT50R0/220 (Figure 1-5) #10 Can Handling Tool [Babington Enterprises] (Figure A-1) Spoodle, 8 oz [13 5/16 long (Vollrath). P/N 61182] (Figure A-1) Spoon, Perforated [Stainless steel, 11 long, has eyelet in handle for hanging. Bowl measures 3 1/2 x 2 1/2 x 9/16. Slotted bowl has 6 to 10 slots and is ideal for mixing.] (Figure A-1)
Spoodle, 4 oz (12 11/16 long [(Vollrath) P/N 61172.] (Figure A1)

39

6685-00-444-6500

40

7310-01-385-6263

41

7330-01-474-0779

42

7340-00-205-1421

43

7340-01-534-0610

44

7340-00-240-7079

Spoon, Serving [Stainless steel, 11 long, has eyelet in handle for hanging. Bowl measures 3 1/2 x 2 1/2 x 9/16. (Figure A-1) Spatula [Has hole in handle for hanging. Conforms to NSF standards. Solid, flexible blade is straight offset and measures 7 1/2 long and 3 wide. Comes with a plastic handle. Measures 14 long overall.] (Figure A-1) Tongs [Tweezer-style, 9-long, one-piece tongs are made of seamless stainless steel. The tips are scooped and have saw tooth edges. Springs into open position when released. Conforms to NSF standards.] (Figure A-1)

45

7330-00-634-1995

46

7330-00-616-0998

A-5

TM 09211A-14&P Item 47 NSN/Part No. 7340-00-488-7950 Qty. 1 Description Knife, Cooks [Stamped, stainless steel blade measures 10 long. Has plastic or aluminum handle that is used best for cooking and general preparing of foods. Approximately 14 1/2 long overall.) (Figure A-1) Wire Whip [Stainless steel, French-style whisk. Has seven to eight bow wires, firmly attached to the inside of the handle. Conforms to NSF standards. Made of .090 wire. Size 2 1/2 diameter, 12 long.] (Figure A-2) Insulated Tray Holder with Lid [Cambro P/N KRN-1113] (Figure A-2) Hose, Drain, High Temperature [Black, 4 long, 3/4 diameter, female connectors (Melard).] P/N 1508 CAGE 14674 (Figure A-2) Can Opener Adapter, Table Bushing [Adapts stainless Edlund can opener to stainless table (Babington Enterprises).] (Figure A-2) Exhaust Elbow [Directs TRH exhaust downward in event HMMWV canvas cover is used in back of vehicle (Babington Enterprises).] (Figure A-2) Strap Adapter [Adapts tiedown strap to HMMWV D-ring, if necessary (Comet Enterprises).] (Figure A-2)

48

7330-00-205-3336

49

7310-01-533-8713

24

50

5310-01-024-9057

51

7310-01-493-2491

52

4520-01-493-1836

53

5340-01-493-2523

A-6

TM 09211A-14&P

Figure A-1. Component Parts/Collateral Equipment

A-7

TM 09211A-14&P

Figure A-2. Collateral Equipment

A-8

TM 09211A

Appendix B

Packing List for TRHS Maint Kit Box


NSN Item PCN 184 092110 00 TECHNICAL MANUAL (On top of tray) Qty 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 SET 2 4 2 2 1 SET 2 3 1 1 SET 1 1 1 1 1 1 1 1 1 Babington Part No

Stored in Tray
7310-01-492-9267 2910-01-442-2875 4540-01-493-1729 6625-01-533-8244 Part of Photocell Kit 5980-01-493-1661 6150-01-533-4465 4520-01-492-6662 7310-01-493-1726 4330-01-533-8771 7330-01-234-2204 6685-01-533-8374 + (4730-01-533-8371) 6685-01-533-8686 6685-01-533-8374 3010-01-492-8203 4310-01-492-8190 5331-01-492-6618 5331-01-492-6629 5331-01-533-4279 NEED 5315-01-128-6802 4730-00-908-3195 4010-01-533-4957 ATOMIZING CHAMBER FUEL PUMP AIRTRONIC BURNER CONTROL BOX ELECTRONIC TROUBLESHOOTING TEST BOX PHOTO CELL SOCKET PHOTO CELL Kit PHOTO CELL POWER CORD IGNITER IGNITION TRANSFORMER FUEL FILTER CAN OPENER, KNIFE FUEL PUMP PRESSURE GAUGE+(Adapter Screwed on) FUEL PUMP VACUUM GAUGE W/ADAPTER COMPRESSOR PRESSURE GAUGE NYLON PUMP COUPLER COMPRESSOR AIR FILTER Bag of ASSORTED GASKETS & O-RINGS O-RING, 4.3mm, Atmz Chamber Air & Fuel O-RING, 2.4mm X 8.3MM, Crossover Tube O-RING, 13mm, Firing Rate Knob &Atmz Chamber O-RING, 4.1mm, Flow Control Module BAG of HOSE CLAMPS, COTTER PINS & CLIPS Cotter Pin, 18-8 stainless steel hairpin, 3/8"-7/16" Hose clamp, 7/32" to 5/8" dia range 304 Stainless Steel Nylon-Coated Lanyard Loop End SMALL TOOL KIT 10MM WRENCH (OPEN/BOX) 11MM WRENCH (OPEN/BOX) 5/8 WRENCH (OPEN/B0X) 1/8-INCH FLAT TIP SCREWDRIVER 3/16 INCH FLAT TIP SCREWDRIVER Tools SCREWDRIVER, CROSS TIP, NO. 2 SCREWDRIVER, FLAT TIP 1/4 TIP KEY SET SOCKET HEAD SCREW KEY SOCKET HEAD SCREW 2mm B42000-95-0027 B42000-95-0010 B42000-95-0017 B42000-95-0050 B42000-95-0018B B42000-95-0018 B42000-95-0018C B42000-95-0028 B42000-95-0029 7330-01-234-2204 (Gauge 3846K34) (Adapter 5078K25) 3846K34-C 3846K34 B42000-95-0011 B42000-95-0005 9263K212 9263K221 9263K238 9263K135 92391A054 5321K14 COL30345T7-304 MK-AT MKAT10 MKAT11 MKAT58 MKAT18 MKAT316 5210-00-234-8913 5120-00-293-0314 D-1918 set

5120-01-177-7258 5120-01-349-1477 5120-00-228-9508 5120-00-236-2140 5120-00-236-2127 5210-00-234-8913 5120-00-227-7334 5120-00-432-2196

B-1

TM 09211A-14&P

Maint Kit Box (Cont)


NSN Item KEY SOCKET HEAD SCREW 3mm KEY SOCKET HEAD SCREW 4mm KEY SOCKET HEAD SCREW 5mm PLIERS, SLIP JOINT WRENCH, ADJUSTABLE, 8" INCH Qty 1 1 1 1 1 1 1 1 1 Babington Part No

5120-00-181-6819 5120-00-240-5328 7310-01-442-8340 6150-01-492-9196 7360-01-514-1432 4720-01-493-1830 5310-01-024-9057

5120-00-278-0351 5120-00-240-5328 B42000-95-0001 B42000-95-0019 16/3so/SW TRH-FLA-001 18014

Bottom of Box
AIRTRONIC BURNER (SPARE) W/CONTROL BOX BURNER TEST POWER CORD TRHS TANK POWER CORD FUEL LINE W /QUICK DISCONNECT HOSE, DRAIN, HIGH TEMP

Utensil Box
7330-01-234-2164 7330-01-411-9789 5110-00-273-0128 6685-00-444-6500 7310-01-385-6263 7330-01-474-0779 7340-00-205-1421 73330-01-474-0779 7340-00-240-7079 7330-00-634-1995 7330-00-616-0998 7340-00-223-7771 7330-00-815-1458 7310-01-493-2491 TRAY PACK HANDLING TOOL CAN OPENER, STAINLESS STEEL TIN SNIPES THERMOMETER POCKET #10 CAN HANDLING TOOL SPOODLE, 8 OZ SPOON, PERFORATED SPOODLE, 4OZ SPOON, SERVING SPATULA, 71/2 INCH BLADE TONGS,9" INCH KNIFE, COOKS, 10 INCH BLADE WIRE WHIP, 12 INCH CAN OPENER ADAPTER, TABLE BUSHING 1 1 1 2 1 2 4 2 6 2 2 1 1 2 HMV300 S-11 5110-00-273-0128 10FT50R0/220 HMV303A 61182 7340-00-205-1421 61172 7340-00-240-7079 7330-00-634-1995 7330-00-616-0998 7340-00-488-7950 7330-00-205-3336 HMV400

Small Tool Box


5120-00-242-3915 5340-01-493-2508 5340-01-493-2523 5340-01-493-2511 8415-01-511-4637 HAMMER, BLACKSMITH, 3 LB TIE DOWN STRAPS, BEVERAGE CONTAINERS STRAP ADAPTER TIE DOWN STRAPS TRAY RATION GLOVES, THERMAL PROTECTIVE 2 1 2 2 PR CE-TDB-001 5340-01-493-2523 CD-TD-001 New Gloves NSN

B-2

TM 09211A

Appendix B

QuadCon
7310-01-493-2192 7240-01-337-5269 NEED 5340-01-493-2511 7240-21-911-8834 6130-01-493-1792 7105-01-250-0086 5340-01-492-6746 5340-01-492-6747 5340-01-492-6748 4210-00-165-4703 7330-01-234-2163 7320-01-093-7371 HEATER TANK, RACK, & BURNER CAN, FUEL, 5 GALLON HOLDER, FUEL CAN FUEL CAN TIE DOWN STRAP FUEL CAN ADAPTER KIT INVERTER ASSEMBLY TABLES, STAINLESS STEEL BRACKET, TABLE REAR BRACKET, TABLE FORWARD CLAMP, TABLE FIRE EXTINGUISHER W/MOUNTING BRACKET PAN CARRIERS, SIDE LOADING, with Insulated Trays BEVERAGE CONTAINER, 5 GALLON Maint Kit Box Utensil Box Small Tool Box 1 1 1 1 1 1 3 1 1 1 1 3 6 1 1 1 TRH-2050 7240-01-337-5269 HMVFCB CE-TD-001 7240-21-911-8834 24/300 7105-01-250-0086 HMV105 HMV100 HMV110-A HMV117/466288 (D-1924 Fire Ex only) 200MPC 7320-01-093-7371 Packing List in Lid of Box Packing List in Lid of Box Packing List in Lid of Box

B-3

Appendix C Power Converter Schematics (Reference Only)

C-1

Appendix C Power Converter Schematics (Reference Only)

C-2

Appendix C Power Converter Schematics (Reference Only)

C-3