TECHNICAL MANUAL OPERATOR S, ORGANIZATIONAL AND DIRECT SUPPORT MAINTENANCE MANUAL TANK AND PUMP UNIT, LIQUID DISPENSING

Transcription

1 TECHNICAL MANUAL OPERATOR S, ORGANIZATIONAL AND DIRECT SUPPORT MAINTENANCE MANUAL TANK AND PUMP UNIT, LIQUID DISPENSING FOR TRUCK MOUNTING (UNITED MANUFACTURING AND ENGINEERING CORP. MODEL STYLE 1) NSN , (MODEL (MODEL 2519) NSN , 2938) NSN , (BOWSER INC. MODEL 36W50) NSN (ORR AND SEMBOWER INC. MODEL BL-100) NSN (ALTECH INC. MODEL 4000) NSN This copy is a reprint which includes current pages from Changes 1 through 7. HEADQUARTERS, DEPARTMENT OF THE ARMY 31 JULY 1980

2 TECHNICAL MANUAL HEADQUARTERS DEPARTMENT OF THE ARMY WASHINGTON, D. C., 31 July 1980 OPERATOR S, ORGANIZATIONAL AND DIRECT SUPPORT MAINTENANCE MANUAL TANK AND PUMP UNIT, LIQUID DISPENSING FOR TRUCK MOUNTING (UNITED MANUFACTURING AND ENGINEERING CORP. MODEL STYLE 1) NSN , (MODEL 2519) NSN , (MODEL 2938) NSN , (BOWSER INC. MODEL 36W50) NSN (ORR AND SEMBOWER INC. MODEL BL-100) NSN (ALTECH INC. MODEL 4000) NSN REPORTING ERRORS AND RECOMMENDING IMPROVEMENTS You can help improve this manual. If you find any mistakes or if you know of a way to improve the procedures, please let us know. Mail your letter, DA Form 2028 (Recommended Changes to Publications and Blank Forms), or DA Form located in back of this manual direct to: Commander, US Army Aviation and Troop Command, ATTN: AMSAT I MP, 4300 Goodfellow Blvd., St. Louis, MO A reply will be furnished to you. TABLE OF CONTENTS Paragraph CHAPTER 1. INTRODUCTION.. Section 1. General Section Il. Description and Data. 1-6 CHAPTER 2. OPERATING INSTRUCTIONS... Section 1. Operating Procedures 2-1 Section Il. Operation of Auxiliary Equipment Used in Conjunction with the Tank and Pump Unit. 2-6 Section III. Operation Under Unusual Conditions DISTRIBUTION STATEMENT A: Approved for public release; distribution is unlimited Change 8 i

3 TABLE OF CONTENTS (Continued) Paragraph CHAPTER 3. Section 1. Section Il. Section Ill. Section IV. OPERATOR/CREW MAINTENANCE INSTRUCTIONS Lubrication Instructions... Preventive Maintenance Checks and Services (PMCS).. Troubleshooting. Maintenance Procedures CHAPTER 4. Section 1. Section Il. Section Ill. Section IV. Section V. Section VI. Section VII. Section Vlll. ORGANIZATIONAL MAINTENANCE INSTRUCTIONS Service Upon Receipt of Equipment. Movement to a New Worksite.. Repair Parts, Special Tools and Equipment... Preventive Maintenance Checks and Services (PMCS). Troubleshooting. Radio Interference Suppression.. Maintenance of Pumping Assembly... Maintenance of Tank Assembly CHAPTER 5. Section I. Section Il. Section Ill. Section IV. Section V. DIRECT SUPPORT MAINTENANCE lnstructions Repair Parts, Special Tools and Equipment.. Troubleshooting... General Maintenance Repair of Pumping Assembly.. Repair of Tank Assembly APPENDIX A. APPENDIX B. APPENDIX C. APPENDIX D. APPENDIX E. APPENDIX F. REFERENCES... COMPONENTS OF END ITEM LIST (COEIL)... ADDITIONAL AUTHORIZATION LIST (AAL) MAINTENANCE ALLOCATION CHART REPAIR PARTS AND SPECIAL TOOLS LIST (RPSTL)... EXPENDABLE/DURABLE SUPPLIES AND MATERIALS LIST.. A-1 B-1 C-1 D-1 E-1 F-1 LIST OF ILLUSTRATIONS Figure Title 1-1. Tank and Pump Unit Model 2519 Pumping Assembly, Front and Rearview Models 2938 and 36W50 Pumping Assembly, Front and Rear View Pumping and Engine Assembly, Three-Quarter View Pump Assembly Filter/Separator Flow Chart (Deleted) ii Change 4

4 Figure LIST OF ILLUSTRATIONS (Continued) Title Pressure Gages and Sight Glass. Three-Way Valve (Models 2938 and 36W50) Engine Choke Lever and lgnition Switch... Governor Speed Control Lever.. Tank Dipstick, Drain Valve, and Discharge Valve Lever... Electric Motor Driven Pumping Assembly.. Starting Engine... ON-OFF Switch.. Stopping Engine.. Metering Kit. Lubrication Order (Sheet 1of 2).. Lubrication Order (Sheet 2 of 2).. Servicing Air Cleaner.. Operator/Crew Preventive Maintenance Sequence of Checks and Services (Sheet 1of 2)... Operator/Crew Preventive Maintenance Sequence of Checks and Services (Sheet 2 of 2)... Servicing Fuel Strainer. Pump Assembly Cables Servicing Filter/Separator.. Blocking Instructions.. Tank and Pump Unit Vertical Tiedown Strap Assembly... Tank and Pump Unit Vertical Tiedown Strap Assembly installed Organizational Preventive Maintenance Sequence of Checks and Services (Sheet 1of 2) Organizational Preventive Maintenance Sequence of Checks and Services (Sheet 2 of 2) (Deleted) Hose, Nozzles, and Bonding Wire, Removal and installation... Pump and Engine, Removal and installation (Sheet 1of 3) Pump and Engine, Removal and installation (Sheet 2 of 3) Pump and Engine, Removal and Installation (Sheet 2 of 3) (Deleted). Conversion of Gasoline Engine Driven Pumping Assembly to Electric Motor Driven Pumping Assembly.. Starter Pulley, Air Shroud, and lgnition Switch Bracket, Removal and installation.. Flywheel, Removal and installation... ignition Cable, Sparkplug, Ground Cable and ignition Switch, Removal and installation. Magneto, Removal and installation... Magneto Points Replacement... Magneto Drive Gear, Removal and Installation.. Timing the Magneto... Fuel Tank, Bracket, Fuel Strainer, and Shutoff Valve, Removal and Installation Air Cleaner, Bracket, and Carburetor, Removal and installation Carburetor Service Carburetor Adjustment. Governor Controls, Removal and Installation... Governor Controls Adjustment... Crankcase Breather, Exhaust Muffler and Elbow, Fill and Drain Plugs, Removal and Installation Change 4 iii

5 Figure LIST OF ILLUSTRATIONS (Continued) Title Cylinder Head, Removal and lnstallation.. Cylinder Head Bolts Tightening Sequence Tappet Cover Plate, Removal, Installation, and Clearance Measurement Pump and Electric Motor Assembly.. ON-OFF Switch Cable Test for Continuity Connector Assembly.. Lug Terminal Removal and Replacement. Conduit Assembly Junction Box Assembly (Sheet 1 of 2) Junction Box AssembIy (Sheet 2 of 2) K-l Relay Test... Filter/Separator, Removal and lnstailation. Filter/Separator,Gages and Valves, Removal and installation. Manifold and Three-Way Valve, Removal and installation Ground Reel and Clips, Removal and installation... Hose Reels, Hose Rollers and Spring Housing, Removal and installation (Sheet 1 of 2). Hose Reels, Hose Rollers and Spring Housing, Removal and installation (Sheet 2 of 2). Servicing Tank Assembly.. Magneto, Disassembly and Reassembly.. Valves, Removal, Disassembly, Reassembly and installation.. Engine Base and Oil Pump, Removal and installation... Engine Base and Oil Pump, Disassembly and Reassembly... Pistons and Connecting Rod, Removal, Disassembly, Reassembly and Installation Crankshaft, Removal and installation Crankshaft, Disassembly and Reassembly Camshaft and Governor, Removal, Disassembly, Reassembly and installation Centrifugal Pump, Disassembly and Reassembly... Centrifugal Pump, Seal and lmpeller Installation... Centrifugal Pump and Check Valve.. Adapter Shaft Seal Assembly :.. Filter/Separator, Disassembly and Reassembly Ground Reel and Cable, Disassembly and Reassembly (Sheet loft)... Ground Reel and Cable, Disassembly and Reassembly (Sheet 2 of 2)... Nozzle, Disassembly and Reassembly... Hose Reels, Disassembly and Reassembly (All Models Except 36W50). Hose Reel, Disassembly and Reassembly (Model 36W50) Manhole Assembly, Removal, Disassembly, Reassembly, and installation iv Change 4

6 CHAPTER 1 INTRODUCTION SECTION 1. GENERAL 1-1. SCOPE. This manual is for use in operating and maintaining the tank and pump unit powered by a four hp gasoline engine or electric motor. It includes instructions for operator, organizational and direct support maintenance of the tank and pump unit MAINTENANCE FORMS AND RECORDS. DA forms and records used for equipment maintenance are explained in DA PAM The Army Maintenance Management System (TAMMS) ADMINISTRATIVE STORAGE. a. Placement of equipment in administrative storage should be for short periods of time when a shortage of maintenance effort exists. Items should be in mission readiness within 24 hours or within the time factors as determined by the directing authority. During the storage period appropriate maintenance records will be kept. b. Before placing equipment in administrative storage, current maintenance services and equipment serviceable criteria (ESC) evaluations should be completed, shortcomings and deficiencies should be corrected, and all modification work orders (MWO S) should be applied. c. Storage site selection. Inside storage is preferred for items selected for administrative storage. If inside storage is not available, trucks, vans, conex containers and other containers may be used DESTRUCTION OF ARMY MATERIAL TO PREVENT ENEMY USE. For information on procedures for destruction of equipment to prevent enemy use, refer to TM REPORTING EQUIPMENT IMPROVEMENT RECOMMENDATIONS (EIR). ElR s will be prepared on SF-368 Quality Deficiency Report. Instructions for preparing ElR s are provided in DA PAM , The Army Maintenance Management System. ElR s should be mailed directly to Commander, Headquarters, U.S. Army Troop Support Command, ATTN: AMSTR-QX, 4300 Goodfellow Blvd., St. Louis, MO A reply will be furnished directly to you. SECTION Il. DESCRIPTION AND DATA 1-6. DESCRIPTION. a. General. The tank and pump unit (figures 1-1 and 1-2) consists of a 50 gpm (189 liters per minute) pumping assembly, two 600-gallon (2271-liter) tanks and related items. It is designed for use with 5-ton Cargo Trucks such as M-54, M-55, M813A1, M814, M923, M924, M925 and M926. When installed in a cargo truck, the tank and pump unit is used in the field as a bulk carrier and dispenser. It carries 1200 gallons (4542 liters). The purpose of the tank and pump unit is to convert a general purpose military cargo vehicle into the bulk refueler. The maintenance paragraphs contain detailed descriptions of its components. (NOTE: Electric Motor Driven Pump requires Slave Receptacle mounted at right rear side of cab). Change 4 1-1

7 b. Pump Unit. The pump unit of the tank and pump unit includes the pump, engine, filter/separator, reels and other related items of equipment. Refer to figures 1-2 and 1-3 for views of different models. c. Engine Driven Pump. The pump (figure 1-4) is a self-priming unit, with the impeller screwed on the extension of the engine crankshaft. The pump is coupled to the engine by an intermediate coupler. Both pump and engine are mounted on a base plate to facilitate removal and use in auxiliary pumping operations. Figure 1-1. Tank and Pump Unit. 1-2 Change 4

8 Figure 1-2. Model 2519 Pumping Assembly, Front and Rear View. 1-3