mc-70 truck-mounted blender om - 230744-02

JilinMC-70 Truck-MountedBlender Unit

Stewart & Stevenson Well Servicing Products10750 Telge RoadHouston, Texas 77095

SO# 230744-002MKT# 2704103

OEMOriginal Equipment Manufacturer

Operation and Maintenance Manual

230744-002/2704103

Front Matter© 2006 Stewart & Stevenson

i

RECORD OF REVISIONS

Property of:

Company:

Address:

City: State: Zip Code:

Revision Data

Check each revision received, and insert the revised and supplementary pages in your manual.Stewart & Stevenson assumes no liability for personal injury or equipment failure due to anyoperation performed without heed to manual revisions.

Date of original publication: November 2006

Revision Number Date Work Order

1

2

3

4

5

6

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COPYRIGHT NOTICE

This manual is copyrighted as an unpublished work.

This manual contains confidential and proprietary information of Stewart & Stevenson.

Neither this document, nor any information contained herein, may be reproduced or redistributedin any form whatsoever without the express, written consent of an authorized agent of Stewart &Stevenson.

Any attempt by any person other than an authorized agent of Stewart & Stevenson to alter thecontents of this manual in any way shall be construed as copyright infringement, punishable byall applicable laws.

All vendor literature contained in this manual is the copyrighted property of the respectivevendors, protected by the same laws governing this operation and maintenance manual.

© C o p y r i g h t 2006 b y S t e w a r t & S t e v e n s o n . A l l r i g h t s r e s e r v e d .

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ABOUT THIS MANUAL

This manual is not a textbook on mechanics, electronics, or hydraulics. Sufficient descriptivematerial and illustrations are included to enable the operator to understand the basic construc-tion and theory of operation of this equipment. The intent of this manual is to guide the operatorsand maintenance personnel in the proper use of the equipment. This manual is not a substitutefor properly trained personnel or common sense.

No liability, either expressed or implied, is given for any information contained herein. Thismanual is intended only as a guide, and not as a substitute for proper training by qualifiedpersonnel.

Stewart & Stevenson assumes no responsibility for improper use of equipment, improperlytrained personnel, improperly maintained equipment, or failure to follow normal safety precau-tions outlined here, in the vendor literature, or by properly trained personnel.

Use of this manual for any purpose other than for the safe and proper operation and mainte-nance of the equipment and all its components constitutes misuse, and is punishable by allapplicable laws.

If there is any discrepancy between information contained in this manual and the vendor litera-ture, the vendor literature is assumed correct. Stewart & Stevenson assumes no liability whatso-ever for any person who fails to follow the operation and safety procedures of the original equip-ment manufacturers.

Please read through this manual in its entirety before attempting to operate the equipment.Stewart & Stevenson assumes no liability for failure to do so.

This manual contains different sections, depending on the equipment purchased. All manualscontain an operation and maintenance section. Chapter 1 provides a description and specifica-tions of the unit and the components of the unit. Chapter 2 provides operation information andoperational procedures. Chapter 3 provides maintenance information. Chapter 4 contains draw-ings of the unit and components of the unit.

Most manuals have a manufacturer’s section containing information supplied by vendors ofStewart & Stevenson. If enough information is available on components with very large manuals,such as engines, transmissions, and so on; this section will be under separate cover as a PartsCatalog. Manufacturer’s literature is divided by numbered tabs. Components are arranged withprimary components first, if any, then alphabetically by manufacturer’s name. Tab numbers arecross-referenced on drawings if and where the respective component appears.

All information in this manual is based on the latest product information available at the time ofpublication. Direct any questions concerning the contents or format of this manual to:

Stewart & Stevenson10750 Telge Road

Houston, Texas 77095Phone: (281) 345-5100

Fax: (281) 345-1188

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UNIT IDENTIFICATION

To aid the technician in repair or service work on this unit, a Stewart & Stevenson identificationnameplate, similar to that shown below, is located on the frame of the equipment.

The serial number identification of each unit will appear on the nameplate (as shown above)along with the date of manufacture. The mailing address of Stewart & Stevenson, telephonenumber, telex number, and cable information are all located in the middle of the nameplate oneither side of the Stewart & Stevenson logo. This necessary information will ensure the cus-tomer a fast and accurate response to any parts and/or service request.

Please verify the serial number on the unit’s identification nameplate andENTER YOUR UNIT SERIAL NUMBER HERE:

If applicable,ENTER YOUR COMPANY IDENTIFICATION NUMBER HERE:

TECHNICAL ASSISTANCE

For parts or warranty assistance, wire, write, or call:

Stewart & Stevenson10750 Telge Rd.

Houston, Texas 77095

For Parts: 281-345-5100; ask for Parts Department.For Service: 281-345-5100; ask for Service Department.

Be sure to list the equipment model number, rating, specific nature of the problem, and thesuspected area of malfunction.

Do not use the Operator’s Manual to order parts. If parts or main-tenance are needed, please refer to the Parts Catalog or the ap-propriate component supplier.

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TABLE OF CONTENTSChapter/Section Page

Front Matter

Record of Revisions ................................................................................................................. iCopyright Notice ................................................................................................................... iiAbout This Manual .................................................................................................................. iiiUnit Identification .................................................................................................................. ivTechnical Assistance .............................................................................................................. ivTable of Contents ................................................................................................................... vSafety ................................................................................................................. vii

Safety Symbols ............................................................................................................... viiWarning Statements ........................................................................................................ viiiCautionary Statements ...................................................................................................... x

Chapter 1 Description and Specifications

1.1 Specifications and Capacities ................................................................................. 1-11.1.1 System Specifications and Capacities ........................................................ 1-11.1.2 Unit Dimensions .......................................................................................... 1-1

Chapter 2 Operation

2.1 Controls and Indicators ............................................................................................ 2-12.1.1 Typical Gauge and Control Panel ................................................................. 2-1

2.1.1.1 Liquid Chemical Controls ................................................................ 2-32.1.1.2 Dry Chemical Controls .................................................................... 2-72.1.1.3 Auger Controls ................................................................................ 2-92.1.1.4 Tub Controls ................................................................................... 2-112.1.1.5 Suction Controls ............................................................................ 2-132.1.1.6 Discharge Controls ....................................................................... 2-152.1.1.7 Hydraulic System Gauges............................................................. 2-172.1.1.8 Deck Engine Controls and Gauges ............................................... 2-192.1.1.9 AccuFrac™ and Electrical System Controls................................. 2-23

2.2 Inspections ............................................................................................................ 2-252.2.1 Before-Trip Inspection ................................................................................ 2-252.2.2 After-Trip Inspection ................................................................................... 2-252.2.3 Preoperation Inspection After Overhaul and Storage ................................. 2-262.2.4 Postoperation Inspection ........................................................................... 2-27

2.3 Operational Procedures ........................................................................................ 2-272.3.1 Preoperation Engine Test Run (Optional) .................................................. 2-272.3.2 Unit Startup ................................................................................................ 2-282.3.3 Normal Shutdown ...................................................................................... 2-282.3.4 Emergency Shutdown ............................................................................... 2-29

2.4 Starting Unit After Extended Storage/Major Overhaul ............................................. 2-292.4.1 Power Unit Assembly Preparation ............................................................. 2-29

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TABLE OF CONTENTS (Cont)Chapter/Section Page

Chapter 3 Maintenance

3.1 Nature of Maintenance ..............................................................................................3-1 3.1.1 Actions ..........................................................................................................3-1

3.2 Scheduled Maintenance ...........................................................................................3-23.3 Maintenance Instructions ..........................................................................................3-2

3.3.1 Daily Maintenance Instructions .....................................................................3-2 3.3.2 Weekly Maintenance Instructions .................................................................3-5 3.3.3 Scheduled Maintenance Instructions ............................................................3-5

3.4 Corrosion Check ....................................................................................................3-103.5 Servicing ................................................................................................................. 3-11

Chapter 4 Drawings

4.1 Drawings List ............................................................................................................4-1

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SAFETY

Due to the many hazards involved in the oilfield industry, operators of Stewart & Stevenson builtequipment should be familiar with all relevant safety regulations and precautions. Failure to followthe specific safety procedures outlined in this section, and warnings and cautions given in othersections, will result in equipment damage or failure, as well as personal injury or death. Pleaseread through the following safety procedures before attempting to operate the equipment.

Safety is everyone’s business and must be of primary concern. Knowing the guidelines coveredin this manual will help to provide for the safety of the individual, for the safety of the group, andfor the proper operation of equipment.

SAFETY SYMBOLS

Look for these symbols that point out items of importance to the safety of the individualand group.

Safety warnings MUST be followed. Failure to do so may result inSERIOUS INJURY or DEATH.

Safety cautions are very important. Failure to follow them may causeSERIOUS DAMAGE to the equipment.

NOTE: Is used to notify the operator of information that is IMPOR-TANT, but not hazard-related.

The safety warnings and cautions contained in this manual are typical, and are not the onlytypes of general precautions that should always be observed during all phases of operationand maintenance. Actions during any unusual circumstances should be dictated by commonsense.

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WARNING STATEMENTS

Operating personnel MUST be completely familiar with the con-trol/indicator definitions in this section before operation.

The Emergency Stop switch should ONLY be used under emer-gency conditions. Activating it can cause SERIOUS ENGINE DAM-AGE to occur.

Always use caution when inspecting equipment. Begin only whenthe equipment is shut down, isolated, and tagged “OUT OFSERVICE.” Any accidental or poorly timed operation can causeserious injury to personnel and/or damage to equipment.

Well service blenders are to be installed and operated in a hori-zontal position only. Operation of equipment on a slope could causeequipment failure due to improper oil flow, and/or improperly seal-ing valves.

All personnel should be located away from the blender while inoperation. Only trained personnel should be around the blender,especially during service or operation.

Use Emergency Stop switch for emergencies only. This will in-crease unit life. The blending unit must normally be taken off-lineslowly to allow all components to properly dissipate operationalheat.

This procedure is for emergency shutdown situations ONLY. Nor-mal unit shutdown should always be used under normal operatingsituations.

Attempting to run the blending unit before becoming familiar withthese instructions may result in serious damage to the engine anddeck unit.

Do not attempt to touch the compressor wheel for any reasonwhile the engine is running as this may result in personal injury.

Inadvertent starting could cause death or injury. Deactivate thestarting system power and air before performing the following in-spection.

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WARNING STATEMENTS (Cont)

The cooling system is under pressure and could cause severeinjury. Partially open the filler cap to relieve pressure before re-moving it completely.

Do not overfill the engine sump at any time or serious equipmentdamage can occur.

Do not overfill the hydraulic reservoir at any time or serious equip-ment damage can occur.

Never use diesel fuels as a cleaning agent as they are highly flam-mable and can cause equipment damage.

After draining and refilling the lube oil system, it is imperative thatthe strainer housing be filled with oil before starting the engine.Failure to do this may result in serious engine damage.

Do not overfill crankcase with lube oil or serious engine damagecould occur.

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CAUTIONARY STATEMENTSAllow engine to completely warm up to operational levels beforeattempting to pump.

Always allow power unit to cool down completely before shutdown.This will prolong engine life.

Never dry-fire engine after draining lubricating oil or when enginehas been in storage. Lubricating oil must be present in upper en-gine components prior to starting or serious damage could occur.

If preservative oil has been used in the engine for storage pur-poses, it must be drained prior to bringing the engine into ser-vice.

Do not overfill the lubricating system for any reason.

Observe camshaft bearings. If lube oil flows from camshaft bear-ings with turbo lube pump running and engine shut down, inspectturbo filter outlet check valve for proper operation.

Many leaks at fluid fittings are caused by loose fittings and can beeliminated by simply tightening the fittings. Tapered thread fittings(pipe fittings) must always have pipe sealant compound or Teflontape applied to their male threads before assembly.

If the operator has ANY QUESTIONS about the safe use or mainte-nance of the unit, ASK THE SUPERVISOR - NEVER GUESS -ALWAYS CHECK.

If the cooling system of a hot engine has been drained, do not fillthe system until the engine cools. A sudden change in tempera-ture may cause damage to the engine.

Use only specified lubricants. Refer to the vendor data in the PartsCatalog under separate cover.

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CAUTIONARY STATEMENTS (Cont)

Do not overtighten the filter body as leaking may occur.

Do not use fuel oil, kerosene, or gasoline as a solvent.

Any repairs or service (routine maintenance) performed on thepumps and engine should be performed by a trained service tech-nician who is qualified to work on this type of equipment. All suchservice and repairs must be supervised by qualified managementpersonnel and only Stewart & Stevenson (S&S) replacement partsshould be utilized.

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Chapter 1© 2006 Stewart & Stevenson

1-1

INTRO

CHAPTER 1DESCRIPTION AND SPECIFICATIONS

1.1 SPECIFICATIONS AND CAPACITIES

1.1.1 SYSTEM SPECIFICATIONS AND CAPACITIES

Unit Model MC-70, Truck-MountedFluid Rate @ 90 psi 70 bbl/min (11.1 m3/min)Proppant Input 22,000 lb/min (10,000 kg/min)Maximum Discharge Density 20 lb sand/gallon water (2400 kg/m3)Dry Chemical Rate 5.3 ft3/min (147 L/min)Liquid Chemical Rate 39 gal/min (150 L/min)Maximum Discharge Pressure 100 psi (0.7 mPa)Ambient Operating Temperature -40 oF to 122 oF (-40 oC to +50 oC)Total Fuel Capacity 158.5 gal (U.S.) (600 L)

1.1.2 UNIT DIMENSIONS

Length 466.249″ (11842.72 mm)Height 160.163″ (4068.15 mm)Gross Vehicle Weight 90,390 lb (41,000 kg)

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Chapter 1 © 2006 Stewart & Stevenson

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CHAPTER 2OPERATION

2.1 CONTROLS AND INDICATORS

This section contains instructions for safe and effective operation of the MC-70 Truck-MountedBlender.

Keeping Records Records should be kept of all operating parameters while the MC-70 unit isin use. These should include date, time, pressures, temperatures, and any repairs oradjustments made. Data should be recorded at hour intervals. This will ensure that adiscrepancy, such as a gradual drop in oil pressure, can be monitored and repaired beforedamage to the engine can occur. Notations of date, time, temperature, and pressures should bekept at each startup to record any change or degradation of performance.

Control Panels The following tables and illustrations are presented to help the operators andmaintenance personnel become familiar with the operating controls and indicators of theMC-70 Truck-Mounted Blender.

Operating personnel MUST be completely familiar with the control/indicator definitions in this section before operation.

2.1.1 TYPICAL GAUGE AND CONTROL PANEL

Sections 2.1.1.1 through 2.1.1.9 describe the functions of a typical gauge and control panel.

Figure 2.1, Typical MC-70 Truck-Mounted Blender Gauge and Control Panel

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NOTE: Controls for the blender are arranged according to function. Eachfunctional group has a numbered illustration and a table of definitions onthe following pages.

Chemical Delivery System Controls The blender’s chemical delivery system utilizes threeliquid chemical delivery systems and two dry chemical delivery systems. The operator mayselect either manual or automatic control of each.

Figure 2.2, Typical Liquid Chemical Controls

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2.1.1.1 Liquid Chemical Controls (Refer to Figure 2.2)

1. LIQUID CHEM 1 Display - This digital display shows the rate at which liquidchemical is being delivered in liters per minute. The display is programmable toindicate rates in user preferred units.

2. Liquid Chemical 1 Delivery Rate Adjustment Control - This knob is used in manualmode to adjust delivery rates. In the automatic mode, delivery rates are controlledvia the AccuFracTM system.

3. Liquid Chemical 1 AUTO/MANUAL Control - This switch sets the mode forchemical delivery to AccuFracTM control or manual control.

4. Liquid Chemical 1 TOTAL Display - This digital display shows the total amount ofliquid chemical delivered. This display is programmable to indicate rate totals inuser preferred units.

5. Liquid Chemical 1 RESET Control - This switch is used to reset the TOTALdisplay to zero.





10. Liquid Chemical 2 RESET Control - This switch is used to reset the totalizer tozero for the total display for the liquid chemical system.


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15. Liquid Chemical 3 RESET Control - This switch is used to reset the totalizer tozero for the total display for the liquid chemical system.

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Figure 2.3, Typical Dry Chemical Controls

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2.1.1.2 Dry Chemical Controls (Refer to Figure 2.3)

1. DRY CHEM 1 Display - This digital display shows the rate at which dry chemicalis being delivered. This display is programmable to indicate rate in user preferredunits.

2. Dry Chemical 1 Delivery Rate Adjustment Control - This knob is used in manualmode to adjust delivery rates. In the automatic mode, delivery rates are controlledvia the AccuFracTM system.

3. Dry Chemical 1 AUTO/MANUAL Control - This switch sets the mode for chemi-cal delivery to AccuFracTM control or manual control.

4. Dry Chemical 1 TOTAL Display - This digital display shows the total amount ofdry chemical delivered. This display is programmable to indicate totals in userpreferred units.

5. Dry Chemical 1 RESET Control - This switch is used to reset the totalizer to zerofor the total display for the dry chemical system.

6. DRY CHEM 2 Display - This digital display shows the rate at which dry chemicalis being delivered. This display is programmable to indicate rate in user preferredunits.

7. Dry Chemical 2 Delivery Rate Adjustment Control - This knob is used in manualmode to adjust delivery rates. In the automatic mode, delivery rates are controlledvia the AccuFracTM system.

8. Dry Chemical 2 AUTO/MANUAL Control - This switch sets the mode for chemi-cal delivery to AccuFracTM control or manual control.

9. Dry Chemical 2 TOTAL Display - This digital display shows the total amount ofdry chemical delivered. This display is programmable to indicate totals in userpreferred units.

10. Dry Chemical 2 RESET Control - This switch is used to reset the totalizer to zerofor the total display for the dry chemical system.

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Figure 2.4, Typical Auger Controls

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2.1.1.3 Auger Controls (Refer to Figure 2.4)

The MC-70 Truck-Mounted Blender has two augers which can be manually or automaticallycontrolled.

1. AUGER 1 Display - This digital display shows the speed of the auger in revolu-tions per minute.

2. Auger 1 AUTO/MANUAL Control - This switch sets the auger delivery toAccuFracTM control or to manual control.

3. Auger 1 SPEED Control - This knob is used in manual mode to adjust the rotatingspeed of the auger.

4. AUGER 2 Display - This digital display shows the speed of the auger in revolu-tions per minute.

5. Auger 2 AUTO/MANUAL Control - This switch sets the auger delivery toAccuFracTM control or to manual control.

6. Auger 2 SPEED Control - This knob is used in manual mode to adjust the rotatingspeed of the auger.

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Figure 2.5, Typical TubControls

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2.1.1.4 Tub Controls (Refer to Figure 2.5)

1. AUTO/MANUAL Control - This switch sets the mode for tub fluid delivery toAccuFracTM control or to manual control. In manual mode, the suction PUMPSPEED control knob, in conjunction with the tub inlet valve, is used to manuallycontrol the fluid level. Refer to section 2.1.1.5.

NOTE: LEVEL TRIM Control has been incorporated into theAccuFracTM system. This control can be accessed from theAccuFracTM Title Screen by pressing the button sequence:

Density Control Hardware Setup Tub Level.

The Tub LEVEL TRIM Control is used in automatic mode to control thefluid level in the mixing tub. When the system is in automatic mode,the level is monitored and controlled by an automatic tub levelingsystem.

2. FORWARD/REVERSE ROTATION Control - This switch is used to select for-ward or reverse rotational direction of the mixing paddles.

3. PADDLE SPEED Control - This knob is used to adjust the rotational speed of themixing paddles.

4. DRAIN VALVE Control - This pneumatic switch is used to operate the drain valveto drain the tub contents.

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Figure 2.6, Typical Suction Controls

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2.1.1.5 Suction Controls (Refer to Figure 2.6)

1. BYPASS VALVE Control - This pneumatic control opens and closes the manifolddischarge valves to select which side of the truck will be the suction manifold andwhich will be the discharge manifold. Normally, the valve is closed, the suctionmanifold is on the passenger’s side, and the discharge manifold is on the driver’sside. When the valve is opened, the suction manifold is on the driver’s side, andthe discharge manifold is on the passenger’s side.

2. PUMP SPEED Control - This knob controls the speed of the suction pump.

3. SUCTION FLOW Display - This digital display shows the suction flow rate incubic meters per minute. The display is programmable to indicate rates in userpreferred units. (Refer to Section 2.1.1.4)

4. SUCTION TOTAL Display - This digital display shows the suction total in cubicmeters. The display is programmable to indicate totals in user preferred units.

5. RESET Control - This switch is used to reset the totalizer to zero for the suctiontotal display.

6. SUPPLY PRESSURE Gauge - This gauge indicates suction supply pressure.

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.

Figure 2.7, Typical Discharge Controls

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2.1.1.6 Discharge Controls (Refer to Figure 2.7)

1. CROSSOVER VALVE Control - This pneumatic control opens and closes thecrossover valve and the discharge centrifugal valve to bypass the tub when in theOPEN position.

2. PUMP SPEED Control - This knob controls the speed of the discharge pump.

3. DISCHARGE FLOW Display - This digital display shows the discharge flow ratein cubic meters per minute. The display is programmable to indicate rates in userpreferred units.

4. DISCHARGE TOTAL Display - This digital display shows the discharge total incubic meters. The display is programmable to indicate totals in user preferredunits.

5. RESET Control - This switch is used to reset the totalizer to zero for the dis-charge total display.

6. DISCHARGE PRESSURE Gauge - This gauge indicates discharge pressure.

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Figure 2.8, Typical Hydraulic System Gauges

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2.1.1.7 Hydraulic System Gauges (Refer to Figure 2.8)

1. AUGER 1 HYDRAULIC PRESSURE Gauge- This gauge measures and dis-plays the hydraulic pressure to the hydraulic motor for auger number 1. Maximumpressure is 6000 psi.

2. AUGER 2 HYDRAULIC PRESSURE Gauge - This gauge measures and dis-plays the hydraulic pressure to the hydraulic motor for auger number 2. Maximumpressure is 6000 psi.

3. SUCTION CENTRIFUGAL HYDRAULIC PRESSURE Gauge - This gaugemeasures and displays the hydraulic pressure to the hydraulic motor for the slurrysuction pump. Maximum pressure is 6000 psi.

4. DISCHARGE CENTRIFUGAL HYDRAULIC PRESSURE Gauge - This gaugemeasures and displays the hydraulic pressure to the hydraulic motor for thesupply pump. Maximum pressure is 6000 psi.

5. OPEN LOOP 1 PRESSURE Gauge- This gauge measures and displays thehydraulic pressure to the hydraulic systems in open loop 1, which includes theauger cylinders and the liquid chemical hydraulic motors. Normal pressure is2000 psi.

6. OPEN LOOP 2 PRESSURE Gauge- This gauge measures and displays thehydraulic pressure to the hydraulic systems in open loop 2, which includes thehydraulic cooling fan motor and the dry chemical hydraulic motors. Normalpressure is 3000 psi.

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Figure 2.9, Typical Deck Engine Controls and Gauges

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2.1.1.8 Deck Engine Controls and Gauges (Refer to Figure 2.9)

1. DIAGNOSTIC MODULE Interface - This interface allows the operator to scrollthrough readings of various engine parameters, such as engine hours, coolanttemperature, oil pressure, voltage, fuel rate, % load, etc.

NOTE: Engine parameters monitored through the diagnostic modulevary from engine to engine.

2. CHECK ENGINE Indicator Light- This light illuminates to indicate that the engineneeds maintenance or service.

3. WARNING Indicator Light - This light illuminates to indicate the engine must beserviced as quickly as possible.

4. START Switch - This momentary toggle switch starts the engine.

5. NORMAL KILL Switch - This switch is used to control normal shutdown of theengine.

6. EMERGENCY STOP Switch - This switch is used to stop the engine underemergency conditions ONLY.

The Emergency Stop switch should ONLY be used under emer-gency conditions. Activating it can cause SERIOUS ENGINE DAM-AGE to occur.

7. ENGINE OIL PRESSURE Gauge - This gauge measures and displays theengine oil pressure.

8. Engine RPM Tachometer - This gauge measures and displays the engine speedin revolutions per minute.

9. THROTTLE Control - This knob is used to control the engine speed and ismonitored by the engine control system.

10. ENGINE WATER TEMP Gauge - This gauge measures and displays the enginecoolant temperature.

11. VOLTS - This gauge measures and displays system voltage.

12. PUMPBOX OIL TEMPERATURE Gauge - This gauge measures and displaysthe oil temperature in the hydraulic pump gear box located behind the engine.

13. FUEL LEVEL Gauge - This gauge measures and displays the deck engine fuellevel.

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14. SYSTEM AIR PRESSURE Gauge - This gauge measures and displays thesystem air pressure tub drain valve, the discharge system crossover valve, andthe suction system bypass valve.

15. HYDRAULIC TEMP Gauge - This gauge measures and displays the hydraulicsystem temperature in the sump.

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Figure 2.10, Typcial AccuFracTM and Electrical System Controls

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2.1.1.9 AccuFracTM and Electrical System Controls (Refer to Figure 2.10)

1. AccuFracTM Control - This switch is used to control the power to the AccuFracTM

blender control system.

2. PANEL POWER Control - This switch is used to control the power to the controlpanel and instruments.

3. FAN Control - This switch overides Hydraulic Fluid and Coolant Temptemperature switches to power the hydraulic cooler fan at any time.

4. AccuFracTM Display - This user friendly AccuFracTM graphical interface controlpanel is used for operator input to the AccuFracTM Automatic Control System.For more details, refer to the Stewart & Stevenson AccuFracTM AutomatedBlender Control User’s Guide in the MC-70 Truck-Mounted Blender PartsCatalog.

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2.2 INSPECTIONS

NOTE: Refer to Chapter 3 for details on inspection procedures.

2.2.1 BEFORE-TRIP INSPECTION

Perform the following inspections before moving the truck-mounted Blender:

1. Check the work lights.

2. Check the chassis for any damage.

3. Check for loose or damaged components.

4. Check the hoses, connections, and field iron inventory.

5. Check all auxiliary support connections (pneumatic and electrical).

6. Check all fluid levels and fill them if necessary. These include:

• Engine oil• Coolant• Hydraulic reservoir oil• Fuel tank

2.2.2 AFTER-TRIP INSPECTION

Always use caution when inspecting equipment. Begin only when theequipment is shut down, isolated, and tagged “OUT OF SERVICE.” Anyaccidental or poorly timed operation can cause serious injury to person-nel and/or damage to equipment.

Perform the following inspections after moving the truck-mounted Blender, prior to operating:

1. Check for oil leaks.

2. Check for coolant leaks.

3. Check the radiator core.

4. Check for damaged hoses.

5. Check for loose or damaged components.

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6. Check for inadequately stowed gear.

7. Check the hydraulic system.

8. Check and replenish the engine oil as required.

9. Check and replenish the engine coolant as required.

10. Check and replenish the hydraulic fluid as required.

11. Check and replenish the diesel fuel as required.

2.2.3 PREOPERATION INSPECTION AFTER OVERHAUL AND STORAGE

Well service blenders are to be installed and operated in a hori-zontal position only. Operating the equipment on a slope couldcause equipment failure due to improper oil flow, and/or improp-erly sealing valves.

All personnel should be located away from the blender while it isin operation. Only trained personnel should be around the blender,especially during service or operation.

Verify the following before operating the unit:

1. All the belts are tight.

2. All the guards are in place.

3. All the driveline bolts are torqued.

4. All the drivelines and bearings are greased.

5. The fluid oil tank suction valves are open.

6. The fluid tank bypass valves are closed.

7. The fuel tank crossover and suction valves are open.

8. The hydraulic pump suction valves are open.

9. The Emergency Kill switch on the control panel has been released.

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2.2.4 POSTOPERATION INSPECTION

1. Verify that the Emergency Stop switch on the control panel is used to lockout thepower unit to prevent accidental starting during inspection. Then, tag the unit‘Out of Service.’

2. Check for oil leaks, coolant leaks, damaged hoses, and loose or damagedcomponents.

3. Check and replenish the engine oil and coolant, and the hydraulic fluid as re-quired.

4. Inspect the belts, bolting, and electrical connections and tighten them as required.

5. Inspect and grease all drivelines and bearings as required.

6. Close the fluid oil tank suction valves.

7. Open the fluid tank bypass valves.

8. Close the fuel tank crossover and suction valves.

2.3 OPERATIONAL PROCEDURES

2.3.1 PREOPERATION ENGINE TEST RUN (OPTIONAL)

1. Verify that the preoperation inspection is complete.

2. Set the hydraulic pumps to neutral.

3. Clear the area and start the power unit.

4. The engine will accelerate for Rapid Engine Warmup and then move to idle.

5. With the unit at idle, perform a walk-around visual inspection to check for leaks,loose items, and operating fluid levels.

6. Set the engine at 950 rpm and monitor the engine for anything unusual (knocks,smoke, etc.).

7. Set engine at maximum speed of 2100 rpm and monitor the engine for anythingunusual (knocks, smoke, etc.).

8. Check all pressure and temperature gauges for proper operating setpoints.

9. Set the hydraulics to the required pressures.

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10. Operate the unit with the control panel and monitor for correct speed.

11. Shut down the unit.

12. Check all fluid levels and fill them if necessary. These include:

• Engine oil• Coolant• Hydraulic reservoir oil• Fuel

13. Perform a postoperation inspection.

14. Once the test run is complete and all proper hookups have been carried out,implement the blending operation.

2.3.2 UNIT STARTUP

1. Verify that the preoperation inspection is complete.

2. With the unit not running, turn power to the control panel to the ON position.

3. Start the engine. The engine will increase immediately to 900 rpm and maintainthat speed until Rapid Warmup is complete. The engine speed will then decreaseto 650 rpm (idle).

4. Increase the engine speed to 2100 rpm and monitor the engine for operationalparameters.

5. Monitor the unit for the specified rates and pressures.

Allow the engine to warm up to operational levels before attempt-ing to pump.

6. Perform the unit shutdown procedure.


2.3.3 NORMAL SHUTDOWN

Use Emergency Stop switch for emergencies only. This will in-crease unit life. The Blender must normally be taken off-line slowlyto allow all components to properly dissipate operational heat.

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2-29

1. Use the Throttle Control Knob to reduce the engine speed.

2. Allow the power unit to cool down for approximately ten minutes at idle speed.

Always allow power unit to cool down completely before shutdown.This will prolong engine life.

3. Use the STOP switch on the control panel. The engine moves to idle and shut-down after a preset cool-down period.


2.3.4 EMERGENCY SHUTDOWN

This procedure is for emergency shutdown situations ONLY. Nor-mal unit shutdown should always be used under normal operatingsituations.

1. In an emergency situation, use the Emergency Stop switch on the control panel.The air inlet cuts off the air supply, which immediately shuts down the power unit.


2.4 STARTING UNIT AFTER EXTENDED STORAGE/MAJOR OVERHAUL

2.4.1 POWER UNIT ASSEMBLY PREPARATION

Before starting the power unit for the first time, carefully read and follow these instructions.Follow these procedural steps when starting the Blender after extended transportation or storageor a major overhaul of one or all of the major components in the system.

Attempting to run the Blender before becoming familiar with theseinstructions may result in serious damage to the engine and deckunit.

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Cooling System

1. Verify that all of the drain cocks or plugs in the cooling system are installed and/orclosed properly. The unit is shipped with drain plugs installed.

2. Open the cooling system vents, if they are available. Refer to the vendor data inthe MC-70 Truck-Mounted Blender Parts Catalog.

3. Loosen the vents at the top of the thermostat housing.

4. Remove the filler cap and fill the cooling system with fluids recommended in thevendor data in the MC-70 Truck-Mounted Blender Parts Catalog. When thesystem is cold, keep the liquid level of the coolant on the centerline of the levelgauge located on the top fluid-expansion tank of the radiator.

5. Close the vents, if used, after filling the cooling system.

Lubricating System

1. The lubricating oil film on the rotating parts and bearings of a new orremanufactured engine, or one that has been in storage, may be insufficient forproper lubrication when the engine is started for the first time.

2. Check the engine lubricating crankcase for the proper level and fill it, if necessary,with the recommended grade of lubricating oil. Refer to the vendor data in theMC-70 Truck-Mounted Blender Parts Catalog. Use the following methods toprelubricate a dry engine:

a. Ensure proper lubrication of upper engine components by cranking theengine over with the emergency air flap closed or with the fuel solenoiddisconnected. Upon indication of lubricating oil pressure, reset the emer-gency air flap or fuel solenoid valve.

b. For engines that have been in extended storage or are being started forthe first time, bar the engine over by hand, making sure the engine rotatesfreely. Refer to the vendor data in the MC-70 Truck-Mounted BlenderParts Catalog for this procedure.

Then, disable the fuel and/or air system by manually tripping emergencyair flap closed, or by disconnecting fuel solenoid, and cranking the engineover. Upon indication of lubricating oil pressure, reset the emergency airflap or fuel solenoid valve.

Never dry-fire the engine after draining lubricating oil or when the enginehas been in storage. Lubricating oil must be present in upper enginecomponents prior to starting or serious damage could occur.

3. Remove and check the dipstick and add sufficient oil, if necessary, to bring the oillevel to the full mark on the dipstick.

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If preservative oil has been used in the engine for storage pur-poses, it must be drained prior to bringing the engine into ser-vice.

Do not overfill the lubricating system for any reason.

4. Drain preservative oil from engine crankcase, if used. Reinstall and tighten thedrain plug. Fill the crankcase to the proper level with the recommended grade oflubricating oil. Refer to the vendor data in the MC-70 Truck-Mounted BlenderParts Catalog. Install new lubricating oil filter elements and gaskets. Refer to thevendor data in the MC-70 Truck-Mounted Blender Parts Catalog.

Turbocharger

1. After installing a rebuilt or new turbocharger, it is very important that all movingparts of the turbocharger center housing be lubricated as follows before startingfor the first time:

a. Clean the area and disconnect the oil inlet (supply line at the bearingcenter) housing.

b. Fill the bearing housing cavity with clean engine oil. Turn the rotatingassembly by hand to coat all of the internal surfaces with oil.

c. Add additional clean engine oil to completely fill the bearing housing cavityand reinstall the oil line. Clean off any spilled oil.

Do not attempt to touch the compressor wheel for any reason while theengine is running, as this may result in personal injury.

Air Filters

1. Check for a good seal on all gaskets, especially the dust cup assembly.

Fuel System

1. Fill the fuel tank with the proper fuel, as specified in the vendor data in the MC-70Truck-Mounted Blender Parts Catalog. If the unit is equipped with a fuel valve, itmust be opened.

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To ensure prompt filling, fill the fuel system at the primary filters.Prime the filter between the fuel pump and the injectors by re-moving the plug in the top of the filter cover and slowly filling thefilter with fuel. If there is a non-return valve in the fuel suctioncircuit, filling the primary fuel filters will prime the unit from thevalve to the low-pressure pump. Refer to the vendor data in theMC-70 Truck-Mounted Blender Parts Catalog for details.

Lubrication Fittings

1. Fill all grease cups and lubricate all the fittings with a grease as specified in thevendor data in the MC-70 Truck-Mounted Blender Parts Catalog.

Inadvertent starting could cause death or injury. Deactivate thestarting system power and air before performing the following in-spection.

2. Check the fluid level in the hydraulic reservoir. Replenish the fluid through the filland filter assembly as required to restore to full level. Use only the approvedhydraulic fluids. Also, refer to the Sauer Danfoss vendor data in theMC-70 Truck-Mounted Blender Parts Catalog.

3. Check the coolant level in the radiator. The coolant level should read FULL in sightgauge. Replenish the coolant as needed. Refer to the vendor data in theMC-70 Truck-Mounted Blender Parts Catalog.

4. Check the available air pressure.

5. Check the fuel level in the tank by observing the level gauge on the tank.

The engine should be blown down and cranked over two complete revolu-tions with the cylinder test valves open before starting. If any fluid dis-charge is observed from any cylinder, find the cause and make the neces-sary repairs. This practice should apply particularly to engines that areapproaching a scheduled overhaul after several years of service, or thathave had a history of water or fuel leaks.

6. Open the cylinder test valves, set them to the minimum fuel position, and crankthe engine over two revolutions. Observe the engine for leakage from the testvalves. Close the test valves.

Observe the camshaft bearings. If lube oil flows from the camshaftbearings with the turbo lube pump running and the engine shutdown, inspect the turbo filter outlet check valve for proper opera-tion.

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Many leaks at fluid fittings are caused by loose fittings and can beeliminated by simply tightening the fittings. Tapered thread fittings(pipe fittings) must always have pipe sealant compound or Teflontape applied to their male threads before assembly.

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3-1230744-002/2704103

© 2006 Stewart & Stevenson

CHAPTER 3MAINTENANCE

If the operator has ANY QUESTIONS about the safe use or mainte-nance of the unit, ASK THE SUPERVISOR - NEVER GUESS -ALWAYS CHECK.

3.1 NATURE OF MAINTENANCE

Awareness Maintenance demands operator awareness of the unit’s operation. Awarenessdemands consciousness of abnormalities such as unusual knocks or smoke. Awareness alsodemands knowing the unit’s capabilities and perceiving the its service needs.

Promptly Corrected Regardless of the method and manner of detection, the potential failureshould be promptly corrected in order to reduce the likelihood of a shutdown or a breakdown.The corrective actions taken, or the service rendered, constitute maintenance.

3.1.1 ACTIONS

The nature of maintenance calls for actions which will reduce the need for major repair work.These actions can be performed at an operator level, and can usually be categorized into(1) maintenance, (2) treating for corrosion, and (3) servicing.

Maintenance The operational level maintenance described in this manual is primarily the actionof checking, adjusting and testing for the proper operation and set points (calibrating), tighteningloose components and determining operational readiness of the unit’s systems. Maintenance isalso maintaining the proper amounts (levels) of lubricating grease, oil, coolant, fuel, etc., andcleaning filtration systems and/or changing filters.

Treating for Corrosion This necessary, ongoing process consists of thorough cleaning,lubrication, and assurance of protective finish integrity. Units transported to locations where highhumidity or high temperatures are prevalent require extra awareness.

Servicing Servicing the unit is performing major repair work, such as replacing a gasket orseal, replacing piping, troubleshooting systems, etc. An example of major electrical repair work isrepairing/ changing wiring, troubleshooting systems, etc. Major repair work can be accomplishedby service-level personnel and by use of the OEM manuals in the MC-70 Truck-MountedBlender Parts Catalog.

NOTE: While performing service on equipment, refer to the specificequipment service manuals supplied in the MC-70 Truck-MountedBlender Parts Catalog.

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3.2 SCHEDULED MAINTENANCE

General Instructions Engine and hydraulic pump fluids and lubricants should be checkedbefore and after each operation. Refill or replace as necessary. Fluid capacities are approximatebased on manufacturer’s data. Capacities on individual units may vary due to custom changes.Filters should always be changed with the fluids they protect to ensure long equipmentlife and dependability.

Visually inspect all fittings and hoses before and after each operation. Tighten any loose fittings,and replace any worn hoses. This will ensure the longevity and dependability of the unit.

Perform maintenance on items daily, weekly, or when the hour meter registers the recom-mended scheduled hours of operation.

3.3 MAINTENANCE INSTRUCTIONS

3.3.1 DAILY MAINTENANCE INSTRUCTIONS

Daily maintenance is operational level service to the unit. These maintenance procedures arepart of the before and after operation checklists and operating procedures in Chapter 2.

NOTE: While performing service on equipment, always secureequipment on level ground and tag unit, ‘Out of Service.’

Preoperation Maintenance Tasks

Check the Deck Connections

1. Check the pneumatic and hydraulic quick-disconnects on the deck assembly.

2. Verify that all hose connect locks are in place and secure.

3. Verify that all control panel electrical interconnections are in place and secure.

4. Proceed with maintenance or return the unit to service.

Check the Deck Lights And Battery System

1. Check all lights for proper electrical connection and proper positioning aftertransport.

2. Verify that the batteries are in place and connections are secure.

3. Verify that all control panel electrical interconnections are in place and secure.


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Check That All Guards In Place

1. Check all guards of the deck assembly, including the engine driveline, and radiatorguards for secure and proper positioning after transport.

2. Verify that all bolting and nuts are in place.


Check Hoses And Connections

1. Check all hoses and hose connections for damage and replace as necessary.


Postoperation Maintenance Tasks

Check the Fuel System

1. Check all fuel hoses and connections of the deck assembly, including the tankconnections to the fuel filter assembly and the tank interconnections, for secureand proper positioning after transport.

2. Look for any signs of leaks or seepage around connections.

3. Verify the fuel level with fuel tank sight gauge. Fill as required.

4. Check the fuel tank isolation valves for proper positioning.


Check the Cooling System

1. Check all coolant hoses and connections for secure and proper positioning afterbeing operated. Make a visual check for cooling system leaks. Look for any signsof leaks or seepage around connections.

2. Allow the system to cool down before opening the filler cap.

The cooling system is under pressure and could cause severeinjury. Partially open the filler cap to relieve pressure before re-moving it completely.

If the cooling system of a hot engine has been drained, do not fillthe system until the engine cools. A sudden change in tempera-ture may cause damage to the engine.

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3. Verify the coolant level with liquid level sight gauge on the radiator assembly. Fillas required.

4. Inspect the radiator core for damage or blockage from dirt and/or debris. Check itby shining a backlight through coil. A dirty or damaged coil will not allow much lightthrough the fin assembly. Clean the core as required.


Check the Engine Oil Level

1. Check the engine oil level with the sump-mounted dip stick. A dipstick extendsfrom the side of the oil pan into the oil pan sump.

2. The dipstick should show a level between LOW and FULL. The oil level with theengine stopped should be above the FULL mark.

3. Verify that the oil level is at the FULL mark.

4. Fill as required with proper lubricating oils.

Do not overfill the engine sump at any time or serious equipmentdamage can occur.

Use only specified lubricants. Refer to the vendor data in theMC-70 Truck-Mounted Blender Parts Catalog.

Check the Air System

1. Check the air intake filters for any large debris in the assembly prefilter.

2. Brush or wipe the assembly clean of dust.

3. Check the air restriction filter at the sleeve of the intake assembly.

Do not operate the power unit with a dirty air intake system or seriousequipment damage can occur.


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3.3.2 WEEKLY MAINTENANCE INSTRUCTIONS

Check the Hydraulic Fluid Level

1. Check the hydraulic fluid level with the reservoir-mounted indicator gauge.

2. Verify that the oil level is at the FULL mark.

3. Fill as required with proper hydraulic fluids.

Do not overfill the hydraulic reservoir at any time or serious equip-ment damage can occur.

Use only specified lubricants.


Clean the Unit

1. Verify that all electrical connections are secured properly.

2. Spray down the unit with water and brush off dirt and debris. Carefully clean upany corrosive material accumulating on the piping, auger trays, hoppers, andhydraulic manifolds.

Never use diesel fuels as a cleaning agent as they are highly flam-mable and can cause equipment damage and serious injury to per-sonnel.

3. If required, use a noncorrosive industrial strength cleanser mixed in a 50/50 ratiowith clean water to remove buildup.

4. Wipe down all exposed controls, indicators, and the gauge panel.

3.3.3 SCHEDULED MAINTENANCE INSTRUCTIONS

Scheduled maintenance intervals are determined by the OEM of the equipment and should befollowed as required by the OEM service manuals supplied in the MC-70 Truck-Mounted BlenderParts Catalog.

Replace the Air Cleaner Elements

1. Remove the air inlet outer housing from the air intake assembly.

2. Remove the dirty element from the inner housing.

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3. Clean the housing and remove any debris around the element gasket.

4. Insert a new element into the housing. Ensure that the element is properly seatedagainst the housing gasket assembly.

5. Replace the outer housing cover and tighten it by hand only.

Replace the Engine Oil and Filters

After draining and refilling the lube oil system, it is imperative thatthe strainer housing be filled with oil before starting the engine.Failure to do this may result in serious engine damage.

Hot Oil and hot components can cause personal injury. Do not al-low hot oil or components to contact the skin.

1. Drain the oil while it is still warm to remove suspended debris. Allow 20 minutesfor all oil to drain from the galleys and oil pan.

2. Remove the spin-on filters using a strap wrench and a 1/2″ drive socket wrenchand extension. Dispose of the used oil and filters in an environmentallyresponsible manner. Clean the adapter with a clean, lint-free cloth. Fill the newfilters with clean lubricating oil, and lightly coat the filter gaskets with the same oil.

3. Start the new filters on the adapter and tighten by hand until the gaskets touch themounting adapter head. Tighten the filters an additional two-thirds turn by hand.

4. Add oil as required to bring the level to the FULL mark on the dipstick.

5. Start and run the engine for a short period and check for leaks. Stop the engine.After 20 minutes and recheck the oil level on the dipstick. Add oil as required tobring the level to the proper mark on the dipstick.

Do not overfill crankcase with lube oil or serious engine damagecould occur.

Use only specified lubricants. Refer to the vendor data in theMC-70 Truck-Mounted Blender Parts Catalog.

Replace the Fuel Filters

The frequency of water draining or element replacement is determined by thecontamination level of the fuel being used. The fuel filter/water separator allows theoperator to isolate one filter at a time for servicing while the engine is in operation.

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1. With the engine shut down, place a suitable container under the fuel filters. Turnthe handle on the fuel shutoff valve to the closed position.

2. Using a suitable band type filter wrench, remove the primary and secondary fuelfilters. Dispose of the filters in an environmentally responsible manner.

3. Fill the new filters with clean fuel oil and lightly coat the gaskets with clean fuel oil.

4. Thread the new filters onto the adapters until they make full contact with thegasket and no side movement is evident. Then, rotate them an additional one-halfturn BY HAND. Open the fuel shutoff valve.

5. Start the engine and check for leaks.

6. Correct any leaks with the engine off.

Fuel leaked or spilled onto hot surfaces or electrical componentscan cause a fire. To reduce the chance of possible injury, turn thestart switch off when changing fuel filters or water separator ele-ments. Clean up fuel spills immediately.

Do not overtighten the filter body as leaking may occur.

Clean the Pneumatic System Strainer

The pneumatic system components should be checked periodically for loose con-nections and/or corrosion. Repair or replace them when necessary.

1. The air line lubricator is the only component of the pneumatic system whichrequires scheduled maintenance.

2. The lubricator in the air line to the starting motors should be checked regularly foroil, refilled, and adjusted when necessary.

3. Oil is added to the lubricator through a filler cone at the top of the bowl on thelubricator.

4. Use of a clean, high quality grade of an SAE No. 10 oil is recommended forambient temperatures between 60-120 °F (16-49 °C).

5. Inspect the pneumatic exhaust for excessive oil as air is moving through system.

6. Adjust the needle valve on the lubricator assembly to permit only one or two dropsof oil per second when the air is moving. The adjustment ratio is approximatelytwo drops of oil per turn of the needle valve.

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7. Reinspect the exhaust.

8. The strainer in the air line should be checked and cleaned of any debris regularly.If the strainer becomes clogged prematurely, check the air tanks and connectionsfor possible leaks.

Check the Fuel Tank

1. Open the drain at the bottom of the fuel oil day tank to drain off any waterand sediment.

2. Ambient temperature changes can cause condensation in partially filled fuel oiltanks. Water accumulation can be controlled by keeping the fuel tank filled and, ifrequired, using fuel additives as recommended in the vendor data in theMC-70 Truck-Mounted Blender Parts Catalog.

3. Microbe growth can be eliminated with commercially available biocides. Refer tothe vendor data in the MC-70 Truck-Mounted Blender Parts Catalog.

NOTE: Keep the fuel tank filled to reduce condensation. Select theproper grade of fuel oil as specified in the vendor data in theMC-70 Truck-Mounted Blender Parts Catalog.

Check the Coolant System

Take a sample of the coolant at least every 500 hours of operating time or threemonths, whichever occurs first, and have a complete analysis run to determineneeded additives.

Flushing and Refilling the Radiator

1. Clean the cooling system every 4000 hours, or two years, of operational service.

2. With the engine cool, drain the previous solution from the engine and radiator.Dispose the solution in an environmentally responsible manner.

3. Use a good radiator cleaning solution designated as an inner coil cleaner/flushingagent and use in accordance with the instructions on the container.

4. After the cleaning operation and with the engine cool, fill the cooling system withsoft water and run the engine for 15 minutes. Stop the engine and allow it to cool.

5. With the engine cool, drain the cleaner residue from the cooling system.

6. Refill the system with the required coolant. Refer to the vendor data in theMC-70 Truck-Mounted Blender Parts Catalog for the required coolant.

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Radiator Inspection

1. Inspect the exterior of the radiator core every 700 hours and, if necessary, clean itwith a quality grease solvent that is designated for use as a coil cleaner.

2. Direct the solvent through the fin assembly in the opposite direction of the normalair flow.

3. Dry the core with compressed air in the same manner.

Do not use fuel oil, kerosene, or gasoline as a solvent.

4. Service personnel should be aware that periodic cleaning intervals will depend onthe individual unit’s operating conditions and ambient environment and shouldadjust the cleaning /maintenance regimen accordingly. In certain types of service,deposits will form more rapidly than others. Heavy deposits will cause anincrease in the pressure drop through the heat exchanger and a decrease in thecooling effect. Cleaning intervals can be shortened or lengthened depending onthe characteristics of the site, once the personnel have established the optimumtime frame.

Inspect the Fan Bearings

1. If the fan bearing hub assembly is provided with a grease fitting, use a hand-heldgrease packing gun and lubricate the bearings with one shot of Texaco PremiumRB grease or an equivalent lithium base multipurpose grease every 700 hours ofoperational service or 2 to 3 months of service.

2. The operating temperature of the bearing may indicate how much lubrication isrequired. Normal temperature of the bearing may range from “cool to warm to thetouch,” to the point of “too hot to touch for more than a few seconds” dependingon the bearing size and speed and the surrounding ambient conditions.

3. Unusually high temperatures accompanied by excessive leakage of greaseindicates too much grease. High temperature with no grease showing at theseals, particularly if the bearing seems noisy, usually indicates too little grease.Normal temperature and a slight indication of grease at the seals indicatesproper lubrication levels.

4. Every 2500 hours of operational service, clean, inspect, and repack the fanbearing hub assembly with the above recommended multipurpose grease.

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Inspect the Intake and Exhaust

1. Inspect the mountings, intake, and exhaust ducting and connections for tightnessand possible leaks.

2. Check the oil inlet and outlet lines for leaks and corrosion causing restrictions tothe oil flow.

3. Check for unusual noises or vibrations and, if excessive, remove the turbochargerassembly and correct the cause (starting with the gaskets).

NOTE: It is not recommended or practical to attempt any recondition-ing of the turbocharger in the field. It is recommended that it be re-turned for service. However, if this is not possible, refer to the vendordata in the MC-70 Truck-Mounted Blender Parts Catalog.

Check the Control System

1. With the DC potential disconnected, the control cabinet and panels should beblown out with air and/or wiped clean inside and out.

2. A light coat of a corrosion-preventive spray solution is recommended onunpainted/untreated surfaces. A nonoil base cleaner/lubricant spray isrecommended as an oil base spray will eventually fog the glass covers on thegauges/indicators, making them unreadable.

3. Inspect for any loose components, terminal screws, and soldered connections.This inspection is especially beneficial for the deck-mounted local control panelsand electrical enclosures, which are constantly exposed to vibration from theengine.

4. Inspect the vibration absorbing neoprene panel and cabinet mounts for elasticityand resiliency. If they are hardened or cracked, replace them immediately.

3.4 CORROSION CHECK

Treating for corrosion before it becomes a problem is a necessary, ongoing process. A weeklyinspection for corrosion damage consists of thoroughly cleaning and preserving or lubricating allexposed metal surfaces. The Blender is sealed with several coats of industrial sealant paint, but

Chapter 3

3-11230744-002/2704103


this protective shell can break down at vibration sensitive areas or places exposed to extremeheat for long periods of operation. Inspection for signs of rust should always be conducted andongoing during the course of routing maintenance procedures.

When the unit is not in service, every precaution should be taken to prevent corrosion.

3.5 SERVICING

Any repairs or service (routine maintenance) performed on thepumps and engine should be performed by a trained service tech-nician who is qualified to work on this type of equipment. All suchservice and repairs must be supervised by qualified managementpersonnel and only Stewart & Stevenson replacement parts shouldbe utilized.

Servicing the unit is performing major repair work such as replacing a major component and/orseals, replacing piping, troubleshooting systems, etc. An example of major electrical repair workis repairing/changing wiring, troubleshooting systems, etc.

Major repair work can be accomplished by service-level personnel and by use of the OEMmanuals in the MC-70 Truck-Mounted Blender Parts Catalog.

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JilinMC-70 Truck-MountedBlender Unit

Stewart & Stevenson Well Servicing Products10750 Telge RoadHouston, Texas 77095

SO# 230744-002MKT# 2704103

OEMOriginal Equipment Manufacturer

Parts Catalog

230744-002/2704103


i

RECORD OF REVISIONS

Property of:

Company:

Address:

City: State: Zip Code:

Revision Data

Check each revision received, and insert the revised and supplementary pages in your manual.Stewart & Stevenson assumes no liability for personal injury or equipment failure due to anyoperation performed without heed to manual revisions.

Date of original publication: November 2006

Revision Number Date Brief Description

1

2

3

4

5

6

230744-002/2704103


ii

COPYRIGHT NOTICE

This manual is copyrighted as an unpublished work.

This manual contains the confidential and proprietary information of Stewart & Stevenson.

Neither this document, nor any information contained herein may be reproduced, or redistributedin any form whatsoever without the express, written consent of an authorized agent of Stewart &Stevenson.

Any attempt by any person other than an authorized agent of Stewart & Stevenson. to alter thecontents of this manual in any way shall be construed as copyright infringement, punishable byall applicable laws.

All vendor literature contained in this manual is the copyrighted property of the respectivevendors, protected by the same laws governing this operation and maintenance manual.

© C o p y r i g h t 2006 b y St e w a r t & St e v e n s o n . A l l r i g h t s r e s e r v e d .

230744-002/2704103


iii

ABOUT THIS MANUAL

This manual is intended as a Parts Catalog for referencing the OEM vendor manuals and/orcatalogs for in-depth service procedures and parts listings. This manual is not intended as anoperation or maintenance manual. The intent of this manual is to guide the service personnel inthe proper repair and/or service for the various components and assemblies of the equipment asmanufactured by Stewart & Stevenson.

No liability, either express or implied, is given for any information contained herein. This manualis intended only as a guide, and not as a substitute for proper training by qualified personnel.

Stewart & Stevenson assumes no responsibility for improper use of equipment, improperlytrained personnel, improperly maintained equipment, or failure to follow normal safety precau-tions outlined in the vendor literature, or by properly trained personnel.

Use of this manual for any purpose other than for the safe and proper maintenance of the equip-ment and all its components constitutes misuse, and is punishable by all applicable laws.

If there is any discrepancy between information contained in the operator’s manual and thevendor literature, the vendor literature is assumed correct. Stewart & Stevenson assumes noliability whatsoever for any person who fails to follow the operation and safety procedures of theoriginal equipment manufacturers.

Please read through this manual in its entirety before attempting to service the equipment.Stewart & Stevenson assumes no liability for failure to do so.

OEM manufacturer’s literature is divided by numbered tabs. Components are arranged withprimary components first, if any, then alphabetically by manufacturer’s name. Some tabs containmore than one set of vendor data sheets and/or manuals for that particular vendor. Thesedifferent sets of data are listed with separate descriptions and separated by blank blue sheets foryour convenience.

All information in this manual is based on the latest production information available at the time ofpublication. Direct any questions concerning the contents or format of this manual to:

Stewart & Stevenson10750 Telge Road

Houston, Texas 77095Phone: (281) 345-5100

Fax: (281) 345-1188

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iv

UNIT IDENTIFICATION

To aid the technician in repair or service work on this unit, a Stewart & Stevenson identificationnameplate, similar to that shown below, is located on the frame of the equipment.

The serial number identification of each unit will appear on the nameplate (as shown above)along with the date of manufacture. The mailing address of Stewart & Stevenson, telephonenumber, telex number, and cable information are all located in the middle of the nameplate oneither side of the Stewart & Stevenson logo. This necessary information will ensure the cus-tomer a fast and accurate response to any parts and/or service request.

Please verify the serial number on the unit’s identification nameplate andENTER YOUR UNIT SERIAL NUMBER HERE:

If applicable,ENTER YOUR COMPANY IDENTIFICATION NUMBER HERE:

TECHNICAL ASSISTANCE

For parts or warranty assistance, wire, write, or call:

Stewart & Stevenson10750 Telge Rd.

Houston, Texas 77095

For Parts: 281-345-5100; ask for Parts Department.For Service: 281-345-5100; ask for Service Department.

Be sure to list the equipment model number, rating, specific nature of the problem, and thesuspected area of malfunction.

Do not use the Operator’s Manual to order parts. If parts or main-tenance are needed, please refer to the Parts Catalog or the ap-propriate component supplier.

mc-70 truck-mounted blender om - 230744-02

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