TM 10-4930-204-13 Tank and Pump Unit Liquid Dispensing for Truck Mounting

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    TM 10-4930-204-13

    T E C H N I C A L M A N U A L

    OPERATORS, ORGANIZATIONAL AND DIRECT SUPPORT

    MAINTENANCE MANUAL

    TANK AND PUMP UNIT, LIQUID DISPENSING

    FOR TRUCK MOUNTING (UNITED MANUFACTURING

    AND ENGINEERING CORP. MODEL STYLE 1)

    (MODEL

    (MODEL

    N S N 4 9 3 0 - 0 0 - 5 4 2 - 2 8 0 0 ,

    2 5 1 9 ) N S N 4 9 3 0 - 0 0 - 9 8 7 - 8 5 7 6 ,

    2 9 3 8 ) N S N 4 9 3 0 - 0 0 - 0 7 8 - 4 9 3 9 ,

    (ORR

    (BOWSER INC. MODEL 36W50)

    N S N 4 9 3 0 - 0 0 - 0 7 8 - 4 9 3 8

    AND SEMBOWER INC. MODEL BL-100)

    N S N 4 9 3 0 - 0 0 - 9 2 6 - 3 6 9 2

    (ALTECH INC. MODEL 4000)

    N S N 4 9 3 0 - 0 0 - 9 2 6 - 3 5 8 1

    T h i s c o p y i s a r e p r i n t w h i c h i n c l u d e s c u r r e n t

    p a g e s f r o m C h a n g e s 1 t h r o u g h 7 .

    H E A D Q U A R T E R S , D E P A R T M E N T O F T H E A R M Y

    31 JULY 1980

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    TM 10-4930-204-13

    C 8

    CHANGE HEADQUARTERS

    DEPARTMENT OF THE ARMY

    NO. 8 WASHINGTON, D.C., 1 February 1994

    Operators, Organizational and Direct Support Maintenance Manual

    TANK AND PUMP UNIT, LIQUID DISPENSING

    FOR TRUCK MOUNTING (UNITED MANUFACTURING

    AND ENGINEERING CORP, MODEL STYLE 1)

    NSN 4930-00-542-2800,

    (MODEL 2519) NSN 4930-00-987-8576,

    (MODEL 2938) NSN 4930-00-078-4939,

    (BOWSER INC. MODEL 36W50)

    NSN 4930-00-078-4938

    (ORR AND SEMBOWER INC. MODEL BL-100)

    NSN 4930-00-926-3692

    (ALTECH INC. MODEL 4000)

    NSN 4930-00-926-3581

    DISTRIBUTION STATEMENT A: Approved for public release; distribution is unlimited.

    TM 10-4930-204-13, 31 July 1980, is changed as follows:

    1. Remove and insert pages as indicated below. New or changed text material is

    indicated by a vertical bar in the margin. An illustration change is indicated

    by a miniature pointing hand.

    Remove pages Insert pages

    i and ii i and ii

    2-5 and 2-6 2-5 and 2-6

    2-6.1/(2-6.2 blank) 2-6.1 and 2-6.2

    A-1 and A-2 A-1/(A-2 blank)

    2. Retain this sheet in front of manual for reference purposes.

    By Order of the Secretary of the Army:

    Official:

    MILTON H. HAMILTON

    Administrative Assistant to theSecretary of the Army

    GORDON R.SULLIVANGeneral, United States Army

    Chief of Staff

    06347

    DISTRIBUTION:

    To be distributed in accordance with DA Form 12-25-E, block no. 5109, require-

    mens for TM 10-4930-204-13.

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    TM 10-4930-204-13

    WARNING

    HIGH TENSION SPRING

    When hose reel is turned to remove hose, the recoil spring tension is increased. Before performing

    maintenance on the hose reel, carefully unwind reel to release spring tension.

    Do not disassemble spring housing assembly. The spring is under tension and can cause serious injury or

    death if disassembled improperly. Repair of spring housing assembly is by replacement only.

    WARNING

    FLAMMABLE FUEL

    DEATH or serious injury may result if personnel fail to observe safety precautions.

    Do not smoke or use open flame within 50 feet (15.24 meters) of the tank and pump unit.

    Be sure proper grounding procedures have been followed prior to operating the equipment.

    Do not refuel the GED pump assembly fuel can while the engine is operating; stop engine and allow to cool

    before refueling.

    If fuel is spilled, wash the area of spillage thoroughly with water.

    After refueling operation is completed, replace the filler cap securely before removing the nozzle bonding wire.

    WARNING

    Operation of this equipment presents a noise hazard to personnel in the area. The noise level exceeds theallowable limits for unprotected personnel. Wear ear muffs or earplugs which were fitted by a trained

    professional.

    WARNING

    All aircraft fuel must be dispensed through a filter/separator unit. It is mandatory that the performance offilter/separators on all aircraft refueling equipment be checked every 30 days through submission of samples

    taken from the effluent stream of the filters/separator.

    WARNING

    DEATH or SERIOUS INJURY may result if personnel fail to heed Safety Precautions for welding. Prior towelding, read welding instructions contained in Chapter 5, on repair of the Tank Assembly.

    If conditions require fuel tank repairs by welding or other methods involving heat or flame, be sure that all

    fumes are purged from the tank or fill tank with water before commencing the repair. If possible, tank should

    be filled with water prior to welding after being thoroughly purged of fumes. Applying heat or flame to a fuel

    tank containing residue may result in a violent explosion, causing injury or death to personnel.

    Personnel engaged in purging operations will not wear wool, nylon, silk, rayon, or other similar static elec-

    tricity generating clothing. Clean cotton clothing with no metal buttons or fittings will be worn. All contents

    will be removed from pockets.

    The tank being purged must have a static ground during all operations. Precautions should be taken with all

    tools and metal objects around the tank to ensure no spark will be made. Conduct a combustible vapor testreading prior to purging the tank using an acceptable explosive meter.

    Change 4 a

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    TM 10-4930-204-13

    Only competent personnel thoroughly instructed in the proper handling and reading of the explosive meter

    will conduct vapor tests. Conduct a combustible vapor test reading immediately after purging. Under no cir-

    cumstances will repair of the tank begin until declared safe by safety personnel. Discontinue all operationsif an electrical storm is threatening or in progress. Eliminate conditions that could cause explosions.

    WARNING

    Operate GED engine in a well ventilated location. Carbon monoxide is a deadly gas that is given off by a

    gasoline engine. It is odorless and tasteless. The first evidence of its presence is that the operator of the equip-ment will have a headache or suffer from a feeling of dizziness.

    WARNING

    Drycleaning solvent, P-D-680, used to clean parts is potentially dangerous to personnel and property. Avoidrepeated and prolonged skin contact. Do not use near open flame or excessive heat. Flash point of solvent

    is 100 degrees F to 138 degrees F (38 degrees C to 59 degrees C).

    WARNING

    Do not touch metal parts with bare skin during cold weather. The skin may stick to the metal.

    WARNING

    For the electric motor driven pumping assembly, disconnect power cable from vehicle slave receptacle beforereplacing or repairing motor or electrical components. When connecting power cable be sure remote ON-OFF

    Switch is in OFF position. Low voltage can cause Severe Shock or Death.

    WARNING

    Equipment must not be used for other than the intended purpose. Failure to heed this warning can causedamage to equipment and/or injury or death to personnel.

    WARNING

    Transportation or storage of liquid, other than petroleum products, is hazardous to personnel and can damagethe equipment.

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    TM 10-4930-204-13

    TECHNICAL MANUAL HEADQUARTERS

    10-4930-204-13 DEPARTMENT OF THE ARMYWASHINGTON, D. C., 31 July 1980

    OPERATORS, ORGANIZATIONAL AND DIRECT SUPPORT MAINTENANCE MANUAL

    TANK AND PUMP UNIT, LIQUID DISPENSING FOR TRUCK MOUNTING (UNITED MANUFACTURING ANDENGINEERING CORP. MODEL STYLE 1)

    NSN 4930-00-542-2800,(MODEL 2519) NSN 4930-00-987-8576,(MODEL 2938) NSN 4930-00-078-4939,

    (BOWSER INC. MODEL 36W50)

    NSN 4930-00-078-4938

    (ORR AND SEMBOWER INC. MODEL BL-100)

    NSN 4930-00-926-3692

    (ALTECH INC. MODEL 4000)

    NSN 4930-00-926-3581

    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 2028-2 located

    in back of this manual direct to: Commander, US Army Aviation and Troop Command,

    ATTN: AMSATIMP, 4300 Goodfellow Blvd., St. Louis, MO 631 201798. A reply will be

    furnished to you.

    TABLE OF CONTENTSParagraph

    CHAPTER 1. INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    Section 1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

    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 theTank and Pump Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

    Section III. Operation Under

    DISTRIBUTION STATEMENT A:

    Unusual Conditions . . . . . . . . . . . . . . . . . . . . . . . . 2-10

    Approved for public release; distribution is unlimited

    Page1-1

    1-1

    1-1

    2-12-1

    2-8

    2-10

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    TM 10-4930-204-13

    CHAPTER 3.Section 1.

    Section Il.

    Section Ill.

    Section IV.

    CHAPTER 4.Section 1.

    Section Il.

    Section Ill.

    Section IV.Section V.

    Section VI.Section VII.

    Section Vlll.

    CHAPTER 5.Section I.

    Section Il.Section Ill.

    Section IV.Section V.

    APPENDIX A.APPENDIX B.

    APPENDIX C.APPENDIX D.

    APPENDIX E.

    APPENDIX F.

    Figure

    TABLE OF CONTENTS (Continued)

    Paragraph

    OPERATOR/CREW MAINTENANCE INSTRUCTIONS . . . . . . . . . . . .Lubrication Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    Preventive Maintenance Checks and Services (PMCS) . . . . . . . . . .

    Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    Maintenance Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    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 . . . . . . . . . . .

    DIRECT SUPPORT MAINTENANCE lNSTRUCTIONSRepair Parts, Special Tools and Equipment .

    . . . . . . . . . . . . . . .

    . . . . . . . . . . .

    . . . . . . . . . . . . . . . . .

    . . . . . . . . . . . .. . . . . . . . .

    Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .General Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Repair of Pumping Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Repair of Tank Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    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 . . . . . .

    LIST OF ILLUSTRATIONS

    Title

    3-1

    3-3

    3-5

    3-7

    4-1

    4-6

    4-8

    4-114-13

    4-15

    4-19

    4-34

    5-1

    5-45-6

    5-10

    5-25

    Page

    3-13-1

    3-1

    3-53-12

    4-1

    4-1

    4-6

    4-6

    4-7

    4-7

    4-12

    4-12

    4-59

    5-15-1

    5-15-2

    5-3

    5-36

    A-1

    B-1

    C-1D-1

    E-1

    F-1

    Page

    1-1. Tank and Pump Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-21-2. Model 2519 Pumping Assembly, Front and Rearview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

    1-3. Models 2938 and 36W50 Pumping Assembly, Front and Rear View . . . . . . . . . . . . . . . . . . . . . 1-41-4. Pumping and Engine Assembly, Three-Quarter View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

    1-4.1. Pump Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6.1

    1-5. Filter/Separator Flow Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-71-6. (Deleted)

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    4-224-23

    4-274-294-304-324-334-344-344-354-364-384-404-414-424-43

    4-45

    TM 10-4930-204-13

    LIST OF ILLUSTRATIONS (Continued)

    Figure

    2-1.

    2-2.

    2-3.

    2-4.

    2-5.2-6.

    2-7.

    2-8.

    2-9.

    2-10.

    3-1.

    3-1.

    3-2.

    3-3.

    3-3.3-4.

    3-4.1

    3-5.4-1.

    4-2.

    4-3.

    4-4.

    4-4.

    4-5.

    4-6.

    4-7.

    4-7.

    4-7.

    4-8.

    4-9.4-10.

    4-11.

    4-12.

    4-13.4-14.

    4-15.

    4-16.

    4-17.

    4-18.

    4-19.

    4-20.

    4-21.

    4-22.

    Title Page

    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 andInstallation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    2-1

    2-2

    2-3

    2-3

    2-42-42-6

    2-6.1

    2-8

    2-9

    3-2

    3-3

    3-4

    3-9

    3-93-13

    3-14

    3-154-3

    4-4

    4-5

    4-11

    4-11

    4-21

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    Figure

    4-23.4-24.4-25.4-25.1.

    4-25.2.4-25.3.4-25.4.4-25.5.4-25.6.4-25.7.4-25.7.4-25.8.4-26.4-27.4-28.4-29.4-30.4-30.4-31.5-1.5-2.5-3.5-4.5-5.5-6.5-7.5-8.5-9.5-10.5-10.1.5-10.2.

    5-11.5-12.5-12.5-13.5-14.5-15.5-16.

    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 InstallationCrankshaft, 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 . . . . . . .

    . . . .

    . . . .

    . . . .

    . . . .

    . . . .

    . . . .

    . . . .

    . . . .

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    . . . .

    . . . .

    . . . .

    Page

    4-464-474-48

    4-48.2

    4-48.44-48.54-48.64-48.64-48.74-48.9

    4-48.104-48.12

    4-504-524-544-564-584-594-60

    5-45-65-85-9

    5-115-135-145-165-205-21

    5-22.25-22.4

    5-245-265-275-295-315-335-38

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    CHAPTER 1INTRODUCTION

    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 andpump unit.

    1-2. MAINTENANCE FORMS AND RECORDS.

    DA forms and records used for equipment maintenance are explained in DA PAM 738-750. The Army

    Maintenance Management System (TAMMS).

    1-3. 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 deter-mined 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 modifica-tion work orders (MWOS) should be applied.

    c. Storage site selection. Inside storage is preferred for items selected for administrative storage. If inside storageis not available, trucks, vans, conex containers and other containers may be used.

    1-4. DESTRUCTION OF ARMY MATERIAL TO PREVENT ENEMY USE.

    For information on procedures for destruction of equipment to prevent enemy use, refer to TM 750-244-3.

    1-5. REPORTING EQUIPMENT IMPROVEMENT RECOMMENDATIONS (EIR).

    ElRs will be prepared on SF-368 Quality Deficiency Report. Instructions for preparing ElRs are provided in DA PAM

    738-750, The Army Maintenance Management System. ElRs should be mailed directly to Commander, Headquarters,U.S. Army Troop Support Command, ATTN: AMSTR-QX, 4300 Goodfellow Blvd., St. Louis, MO 63120-1798. A replywill 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 suchas 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 maintenanceparagraphs contain detailed descriptions of its components. (NOTE: Electric Motor Driven Pump requires SlaveReceptacle mounted at r ight rear side of cab).

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    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 exten-

    sion of the engine crankshaft. The pump is coupled to the engine by an intermediate coupler. Both pump and engineare mounted on a base plate to facilitate removal and use in auxiliary pumping operations.

    Figure 1-1. Tank and Pump Unit.

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

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    Figure 1-3. Models 2938 and 36W50 Pumping Assembly,Front and Rear View.

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    Figure 1-4. Pumping and Engine Assembly, Three-Quarter View.

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    d. Electric-Motor Driven Pump. The electric motor driven pump (fig. 1-4.1) is a self-priming unit with the im-peller mounted on the extended shaft of the electric motor. Both the pump and motor are mounted on a base plateto facilitate removal and use in auxiliary pumping operations.

    e. Engine. The engine (figs. 1-2 and 1-3) is a 1 -cylinder, 4-cycle, air cooled, hand cranked, Wisconsin gasoline

    engine, Model MBKND. A radio shielded magneto supplies the ignition spark, and a governor controls the engine

    speeds by varying throttle openings to suit pump loads. A gasoline tank of 1 gallon (3.875 liter) capacity is provided.

    f. Electric Motor. The electric motor is explosion-proof. The motor operates on 28 volts dc (direct current) and

    is rated at 1.5 hp (horsepower). The electric motor driven pump assembly requires two cables (Fig. 1-4.1).

    NOTE

    Electric Motor Driven Pump requires slave receptacle mounted

    at right rear side of cab.

    g. Filter/Separator. The filter/separator (figs. 1-2 and 1-3) is a vertical, 50 gpm unit designed for maximum

    operating pressure of 75 psi (pounds per square inch) (5.2725 kg/sq cm). Both solids and water (free and entrainedwater) are removed from the fuel through coalescing and filtering media of the elements inside the filter/separator,The filter/separator has four canisters and filter elements, two pressure gages, sight glass, and two drains. Solid

    contaminants are deposited in the elements. The emulsified or entrained water coalesces within the elements and

    settles to the deck plate where it is removed, periodically, through the upper drain, as free water. Clean product builds

    up in the shell, and is pumped to the hose reels. Refer to figure 1-5 for flow direction of the pumped product.

    1-7. IDENTIFICATION AND TABULATED DATA.

    a. Identification. The tank and pump unit pumping assembly has the following identification and instructionplates.

    (1) Tank and pump unit manufacturers plate. Located at the lower center of the front frame of the pumping

    assembly. It specifies the nomenclature, manufacturer, model number, serial number, specification number, con-

    tract number, date manufactured, weight empty, weight with 600 gallons (2271 liters) of gasoline, and weight with1200 gallons (4542 liters) of gasoline.

    (2) Pump manufacturers identification plate. Located at the left side of pump housing. It specifies make,

    model, serial number, and National Stock Number of the pump and engine assembly.

    (3) Electric motor pump assembly. Located on the pump end of the skid. It specifies the nomenclature,manufacturer, model, serial number and rating (see figure 1-4.1).

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    Figure 1-4.1. Pump Assembly (EMD).

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    Figure 1-5. Filter Separator Flow Chart.

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    NOTE

    Only those units authorized electric motor pumpingassemblies will requisition those support itemsrequired for maintenance of the electric-motoredpump assembly.

    (4) Engine manufacturers identification plate (all models).

    Located on the top front of the engine air shroud. It specifies theengine model number, specification number, horsepower rating, serialnumber, operating RPM and operating instructions.

    (5) Electric motor plate. Located on the unit. It speci-fies the nomenclature, manufacturer, serial number and rating.

    (6) Tank and pump unit operation data (all models), Locatedon lower left frame. It specifies pre-operation procedures, enginestarting and stopping instructions, and pumping instructions.

    (7) Tank identification plate. Located in upper center offront of tank. It specifies manufacturer, contract number, serial

    number, National Stock Number, date of manufacture, empty weight andnomenclature.

    b. Tabulated Data.

    (1) Approximate weight of tanks and dispensing unit:

    W/two empty tanks . . . . . . . . . . . . . . . . 1720 lb (780kg)W/600 U.S. gallons . . . . . . . . . . . . . . 5442 lb (2271 kg)W/1200 U.S. gallons of gasoline . . . . . . 9400 lb (4264 kg)

    NOTE

    100 U.S. gallons of gasoline weighs approximately640 lb (289 kg).

    (2) Engine.

    ModelRPM

    Date . . . . . . . . . . . . . . . . . . . . . . . .Type . . . . . . . . . . . . . . . . . . . . . . . . .Bore. . . . . . . . . . . . . . . . . . . . . . .Stroke. . . . . . . . . . . . . . . . . . . . . .

    Displacement . . . . . . . . . . . . . . . .Horsepower . . . . . . . . . . . . . . . . . .Lubrication . . . . . . . . . . . . . . . .Cooling. . . . . . . . . . . . . . . . . . . . .

    MBKND 1891830001829184.49

    4 Cycle2 7/8 in.2 3/4 in.

    17.8 cu in.4 - 49 @ 3000 rpmSplashAir

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    (3) Electric Motor.

    Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    Rated current (at 1.5 hp load) . . . . . . . . . . . . . . . . . . . . . . . .Rated Speed (with motor at 35C). . . . . . . . . . . . . . . . . . . .

    Operating Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    (4) Carburetor.

    Manufacturer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    (5) Spark plug.

    Manufacturer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    (6) Magneto.

    Manufacturer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    (7) Capacities.

    Engine fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    Engine air cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    Engine crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    (8) Adjustment data.

    Spark plug gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Magneto point gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    16.58 in. (42.1 1 cm)5.59 in. (14.46 cm)

    6.34 in. (16.10 cm)

    86.5 lb. (39.32 kg)

    24 Vdc

    55A3600 rpm

    3100 rpm

    Zenith Carburetor Company11193-A

    Float

    Auto-Lite Division, Ford Motor Co.

    MS51009-1

    Fairbanks Morse

    FMXDE/B7S1

    1 gal. (3.785 liters)

    1/8 qt (0.118 liter)

    1 qt (0.946 liter)

    0.30 in. (0.762 mm)

    0.015 in. (0.381 mm)

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    Tappet clearance:Intake valve . . . .Exhaust valve . . .

    . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.008 in. (0.203 mm)

    . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.014 in. (0.356 mm)

    (9) Nut and bolt torque data.

    Cylinder head bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-18ft-lb (1.9-2.5 m-kg)

    1-8. DIFFERENCES BETWEEN MODELS.

    This manual covers the United Manufacturing and Engineering Corporation Model Style 1,Model 2519, Model2938, Bowser Model 36W50 Orr and Sembower Model BL-100 and Altech Model 4000 Tank and Pump Units. Thedifferences in these five models are in the filter/separator, hose reels, pump and manifold. Where differences exist,each model is covered separately in the appropriate maintenance section of the manual. The canister screen andelements in the filter/separator are different on some models now in use; however, all future models will use the typeshown in this manual. Differences in manufacturing of repair parts for manhole assemblies and discharge valveassemblies will make it necessary to replace with parts manufactured for that particular tank. Models 2519 and Style1, Orr and Sembower and others, have no discharge line running from the filter/separator to the manifold and therefore,the manifold is used for suction only. ModeIs 2938 and 36W50 have a discharge line connecting the filter to themanifold which permits discharging from the manifold outlet as well as from the two reels. Model 2519 and Style 1discharge from the two reels only.

    Figure 1-6. (Deleted)

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    CHAPTER 2OPERATING INSTRUCTIONS

    SECTION I. OPERATING PROCEDURES

    2-1. GENERAL.

    a. The instructions in this section are published for the information and guidance of the personnel responsible

    for the operation of the tank and pump unit.

    b. The operator must know how to perform every operation of which the tank and pump unit is capable. This sec-

    tion gives instructions on starting, stopping, and operating details of the tank and pump unit. Since nearly every ap-

    plication presents a different problem, the operator may have to vary given procedures to fit the individual job.

    2-2. CONTROLS AND INSTRUMENTS.

    The purpose of the controls and instruments and the normal and maximum reading of the instruments are illustratedin figures 2-1 through 2-6.

    Figure 2-1. Pressure Gages and Sight Glass.

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    Figure 2-2.

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    Figure 2-4.

    TM 10-4930-204-13

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    Figure 2-6.

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    2-3. STARTING.

    a. Preparation for Starting:

    (1) Check suction hose connections between the tanks and the pumping assembly to ensure that they

    are properly locked into place.

    (2) Bonding and grounding procedures are as follows:

    DEATH or serious injury may result if proper grounding proceduresare not followed prior to operating the equipment.

    (a) Bonding is the process that equalizes the charge on two unlike objects such as an aircraft and

    a refueling nozzle. It is done in order to prevent arcing, in the presence of flammable vapors, as the two objectsare joined.

    1 Extend the grounding cable from the ground reel assembly so the plug (if present) can beinserted into the vehicle receptacle. Otherwise, attach one of the grounding clips to a bare metal surface of thereceiving vehicle. Attach the remaining clip to the grounding rod. Bond beforethe dust cap or gas tank cap isremoved to prevent a spark occurring when fuel vapor is present. Do not disconnect the bond until refueling iscomplete and the gas tank cap and nozzle dust cap are replaced.

    (b) Grounding of equipment is a means to provide a conductive path into the ground so a static

    charge isnt trapped on the surface of the equipment where it could discharge as a spark.

    1 Insert the grounding rod into the soil to the required depth (refer to table 2-1). Drive therod into the soil to reach below the permanent ground moisture level.

    2 If the top of the rod is level with the surrounding surface, scoop out an area around thetop to allow attachment of the ground dips to the rod. Attach the clip from the grounding wheel to the exposedportion of the grounding rod. The refueler and vehicle are now grounded and the refueling process may begin.

    Table 2-1. Required Depths for Ground Rods

    Type of Soil Depth of Ground Rod

    Coarse ground, cohesionless sands and gravels 6 feet

    Inorganic day, claying gravels, gravel-sand- 4 feet

    day, claying sands, sandy clay, gravelly clay,and silty day

    Silty gravel, gravel-sand-silt, silty sand, sand, 3 feetsilt, peat, muck, and swamp soil

    (c) Methods of Grounding. There is no quick or easy way to test the adequacy of a ground. Thetesting procedures (See FM 10-68 Appendix E) are complex and the equipment is bulky and expensive;

    therefore, several levels or methods of grounding and bonding are required to meet the various operationalneeds of the Army. The three methods/levels are listed in order of preference.

    1 Method 1: equipment is grounded to a rod or rods that have measured resistance toground equal to or less than 10,000 ohms. Ground the refueling system to this tested ground rod. Bond thenozzle to the vehicle aircraft. This method is required, unless conditions, as described below, prevent its use.This method is the only standard of grounding acceptable, without authorization, at any fixed airfield orrefueling point. It is the safest method.

    2 Method 2: If equipment is not available to test resistance to ground, use method 2.

    Method 2 uses an untested ground - a grounding system based on the knowledge that damp earth will acceptand drain off an electrical charge. Use method 2 when the location, tactical situation, or type of operationmakes it impossible to test ground rods. Ground equipment to a rod or rods driven a specific depth into theground depending on the type of soil at the site (see table 2-1). The depth to which the reds must be driven is

    determined by the normal depth of permanent ground moisture in the various types of soils. The commander ofthe operating unit must authorize the use of method 2. This method is less desirable. Employ method 2 whenimpossible to use method 1.

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    Death or serious injury may occur if proper bonding procedures arenot followed. While using method 3, an object with a differentelectrical potential (any object that is not part of the bondedsystem) should not come into contact with the bonded equipmentwhen a flammable vapor-air mixture maybe present.

    3 Method 3: When the climate, terrain, or tactical condition makes it impossible to secure asatisfactory ground rod, requirements to ground the fuel dispenser (system or refueler) may be waived;however, the requirement to bond the fuel dispenser to the aircraft/vehicle may not be waived underany circumstances. Method 3 relies on bonding alone. Bonding is made between the aircraft/vehicle and therefueling system or refueler along with the nozzle and the aircraft/vehicle. A contact between an unbendedobject and the system could produce a spark that could set off an explosion or fire. Method 3 procedures areauthorized by the commander of the unit one organizational level above the operating unit. This is the leastdesirable method since it involves bonding only.

    (3) Maintain a minimum distance of 25 feet (7.62 meters) between the vehicles being refueled.

    (4) Open only filler plug of tank being filled. Do not attempt to refuel two vehicles at the same timeunless the tank and pump unit operator has an assistant who can constantly monitor the second nozzle.

    (5) Open the hand valves on the sight glass assembly (fig. 2-1) and allow the sight glass to fill. if the

    glass does not fill, open the petcock on the lower valve to release the air. Close the petcock when the sightglass is full.

    (6) Check the sight glass for presence of water and drain when necessary.

    NOTE

    A petcock is located at the bottom of the left side of the filter/separator on Models 2938 and 36W50. A pipe plug drain is locatedin the same position on Models 2519 Style 1 Orr and SembowerModels and must be removed to drain water.

    (7) Attach the nozzle grounding cable clamp/bayonet connector to the vehicle to be refueled.

    (8) Normally, the pump will automatically prime itself when the tanks are full by means of gravity flow.

    (9) To prepare to start electric motor driven pumping assembly, connect intervehicular power cable,with adapter (if needed), to vehicle receptacle and junction box receptacle J2 (fig. 1-4.1). Then connectON-OFF switch cable to junction box receptacle J1.

    Do not remove the priming cap when the tanks are full to check forpump prime, as this will result in a fuel spill. Entrapped air will bereleased through the dispensing nozzle when the nozzle is initiallyopened at the beginning of the dispensing cycle.

    Check that all camlock couplings are closed before and duringpumping operations. Couplings opening because of vibration willresult in a fuel spill. Repair or replace defective couplings.

    b. Starting Procedures for Engine. Refer to figure 2-7 and start the engine in accordance with theprocedures.

    2-6 Change 8

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    Figure 2-7. Starting Engine.

    Change 8 2-6.1

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    Figure 2-8.

    TM 10-4930-204-13

    c. Starting Electric Motor Driven Pumping Assembly

    (1) Adjust truck hand throttle for proper engine RPM (approximately 1000 RPMs) to maintain adequate chrate during pumping operation.

    (2) Turn ON-OFF switch to ON position. Refer to Figure 2-8.

    NOTEContinuous operation of the motor for more than 30 minutes will

    cause the thermo protector to activate. The motor will then shut

    Figure 2-8.1. ON-OFF Switch.

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    2-4. OPERATION.

    The tank and pump unit is intended for use in dispensing all types of automotive, aviation, diesel and burner fuels.Only one type of fuel should be carried in and dispensed from the unit at one time. Since the pumping assembly ishighly adaptable, dispensing with the tank and pump unit may be done in various ways to meet different situations

    in the field. Most of the differences between the models covered in this manual have no direct effect on the basic

    operational function.

    2-5. STOPPING.

    a. Stopping Procedures for Engine. Refer to figure 2-9 and stop the engine in accordance with the procedures.

    b. Stopping Procedure for Electric Motor Driven Pumping Assembly.

    (1)

    2-8).

    (2)

    To stop the electric motor driven pumping assembly, turn the remote pump switch to its OFF position (fig.

    Reduce hand throttle setting to idle.

    c. When moving to a new location:

    (1) Disconnect ON-OFF switch cable from junction box receptacle J1. (figure 1-4.1)

    (2) Disconnect intervehicular power cable from vehicle receptacle and junction box receptacle J2.

    Change 4 2-7

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    Figure 2-9. Stopping Engine.

    SECTION II. OPERATION OF AUXILIARY EQUIPMENT USED IN CONJUNCTIONWITH THE TANK AND PUMP UNIT

    2-6. GENERAL.

    This section contains information on the fire extinguishers andthe volumetric meter. The carbon dioxide type fire extinguisher (para2-7) is a nonshatterable, hand type extinguisher. The meter is a vol-

    umetric, positive displacement, liquid measuring device, used when re-fueling aircraft or any vehicle which requires a specific measurementof the product. It is equipped with a five-figure reset counter anda nonsetback totalizer that registers to 9,999,999 gallons.

    2-7. FIRE EXTINGUISHER (CARBON DIOXIDE TYPE).

    a.suitable

    2-8

    Description. The carbon dioxide type fire extinguisher isfor electrical and flammable liquid fires.

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    b. Operation. Remove the fire extinguisher from its location;break the seal, operate the control valve, and direct the stream atbase of flame.

    2-8. METERING KIT.

    A metering kit, NSN 4930-01-108-9568, is available for use with pumping assemblies on an"as required" basis(fig. 2-10).

    Figure 2-10. Metering Kit.

    2-9. METER REGISTER OPERATION.

    To reset indicating wheels to zero, push in and turn reset knobon right side of register.

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    CAUTION

    Do not start delivery unless shutter is in full open position. Ifnumbers on indicating wheels are not in full view, resetting

    operation has not been completed; in which case, turn reset

    knob until shutter disappears and reset knob returns to its nor-

    mal position. Adjustments or repairs will be accomplished by

    direct support maintenance personnel.

    SECTION Ill. OPERATION UNDER UNUSUAL CONDITIONS

    2-10. OPERATION IN EXTREME COLD (0 DEGREES F TO -25 DEGREES F) (18 DEGREES C TO -32

    DEGREES C).

    a. Fuel System.

    WARNING

    Always provide a metal-to-metal contact between the fuel tankfiller neck and the nozzle in order to avoid the possibility ofreleasing a static spark.

    (1) Remove snow and ice from the fuel tank filler cap. Fill the tank with clean, dry fuel,

    WARNING

    Do not touch metal parts with bare hands in extremely coldweather.

    (2) Lubricate the unit in accordance with the cold weather instructions specified in the current lubrication order.

    (3) Clean the fuel filter bowl daily.

    (4) Start the pumping unit in accordance with the instructions on the engine air shroud and as specified in

    figure 2-7.

    b. Carrier. When using the electric motor driven pumping assembly, the efficiency of batteries for electric motor

    operation decreases greatly as the temperature decreases. Operate the engine of the transporting vehicle at approx-

    imately 1000 RPMs when operating the electric motor driven pump to ensure full pump output.

    c. Electric Motor. Take special precautions to protect equipment in frigid climates or during cold periods. Use

    care in handling cables and wire insulation. These items become hard and brittle and are easily damaged. Avoid

    sharp bends or unnecessary loops in cables and wires.

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    2-11. OPERATION IN EXTREME HEAT.

    a. General. Accumulated dirt on engine reduces radiation of heat. Keep the unit clean to avoid overheating.

    b. Cooling System.

    (1) Keep the engine cooling fans clean.

    (2) Keep all exposed cylinder blocks and flywheel surfaces of the engine clean.

    (3) Remove all obstructions to the flow of air across the engine.

    c. Lubrication. Refer to the current lubrication order (fig. 3-1).

    d. Electric Motor. Hot, dry periods subject connectors, receptacles, and binding posts to damage from dust and

    dirt. If possible, operate electric motor in the shade. Do not remove front panel or chassis components unless re-.quired. Make more frequent PMCS.

    2-12. OPERATION AT HIGH ALTITUDES..

    The unit is designed to operate at 8000 feet (2438.4 meters) above sea level without special adjustments. However,

    at higher altitudes, the carburetor may require adjustment. Refer to figure 4-19 for adjustment procedures.

    2-13. OPERATION IN DUSTY OR SANDY AREAS.

    a. Protection. Take advantage of natural barriers that will afford some protection against blowing sand and dust,

    or if necessary, erect artificial barriers.

    b. Air Cleaner. Service the air cleaner frequently. Refer to figure 3-2 for servicing procedures.

    c. Filter/Separator Element. Service the filter/separator frequently. Refer to figure 3-5 for servicing procedures.

    d. Cleaning. Keep the tanks, and areas around the discharge valve and controls free from sand and dust.

    CAUTIONEnsure all open parts of the tank and pump unit are protected

    from moisture.

    2-14. OPERATION UNDER RAINY OR HUMID CONDITIONS.

    When the unit is outside and not operating, protect it with a canvas or other waterproof cover. Remove the cover

    during dry periods to allow the unit to dry out. Keep the fuel tank full to prevent the forming of condensate. Give special

    care to keeping all components free from moisture. Clean and paint all surfaces not otherwise protected.

    Change 4 2-11

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    2-15. OPERATION IN SALT WATER AREAS.

    Salt water corrodes metal. If unpainted equipment parts are ex-posed to salt water, clean them thoroughly with fresh water and permitthe unit to dry thoroughly.

    2-12

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    CHA P T E R 3

    OP E R A T OR / C RE W MA I N T E N A NC E I N S T R UC T I ON S

    SECTION I. LUBRICATION INSTRUCTIONS

    3-1. GENERAL LUBRICATION INFORMATION.

    a. This section contains a reproduction of the lubrication

    order, and lubrication instructions which are supplemental to and notspecifically covered in the lubrication order.

    b. The lubrication order shown in figure 3-1 is an exact repro-duction of the approved lubrication order for the United Manufacturingand Engineering Corporation Models Style 1, 2519, 2938 and BowserInc., Model 36W50 Orr and Sembower Model BL-100 and Altech, Model 4000

    . tank and pump unit. For the current lubrication order, refer to DAPam 310-4 (Military Publications).

    3-2. DETAILED LUBRICATION INFORMATION..

    a. General. Keep all lubricants in a clean, dry place away from

    external heat. Allow no dirt, dust, water, or other foreign materialof any kind to mix with the lubricants. Keep all lubrication equip-ment clean and ready to use.

    b. Cleaning of Components to be Lubricated. Before lubricatingthe equipment, wipe all lubrication points free of dirt and grease.Clean all lubrication points after lubricating to prevent the accumu-lation of foreign matter.

    c. Points of Lubrication. Service the lubrication points atproper intervals as illustrated in figure 3-1.

    d. Operation Immediately After Lubrication. Operate the engine

    immediately after lubrication. Inspect connections which might showoil leakage. If the crankcase oil has been changed, it will be neces-sary to operate the engine for 5 minutes before checking the oillevel. Add oil if necessary.

    e. Air Cleaner Service. Refer to figure 3-2 and service the aircleaner.

    SECTION II. PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS)

    3-3. GENERAL.

    To ensure that the tank and pump unit is ready for operation at

    all times, it must be inspected systematically so that defects may bediscovered and corrected before they result in serious damage or fail-ure. The necessary preventive maintenance checks and services are

    3-1

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    Figure 3-1. Lubrication Order (Sheet 1 of 2)

    3-2

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    Figure 3-1. Lubrication Order (Sheet 2 of 2)

    3-3

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    Figure 3-2. Servicing Air Cleaner.

    3-4

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    listed in table 3-1. Defects discovered during operation of the sys-tern shall be noted for future correction to be made as soon as opera-tion has ceased. Stop operation immediately if a deficiency is notedduring operation, which would damage the equipment if operation werecontinued. All deficiencies and shortcomings will be recorded to-gether with the corrective action taken on DA Form 2404 (EquipmentInspection and Maintenance Worksheet) at the earliest possibleopportunity.

    a. Before you operate. Always keep in mind the CAUTIONS andWARNINGS. Perform your before (B) PMCS.

    b. While you operate. Always keep in mind the CAUTIONS andWARNINGS. Perform your during (D) PMCS.

    c. After you operate. Be sure to perform your after (A) PMCS.

    d. If you equipment fails to operate. Troubleshoot with properequipment. Report any deficiencies using the proper forms. Refer toTM 38-750.

    3-4. OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES.

    The preventive maintenance checks and services to be performed atthe operator level of maintenance are listed and defined in table 3-1.It should be noted that the Item Number column shown in the table isused as a source of item numbers for the TM Number column on DA Form2404, Equipment Inspection and Maintenance Worksheet, in recordingresults of PMCS. Included with the table is a pictorial view of therequired inspection sequence (fig. 3-3).

    SECTION III. TROUBLESHOOTING

    3-5. GENERAL.

    a. This section contains troubleshooting information for locat-ing and correcting most of the operating troubles which may develop inthe tank and pump unit. Each malfunction for an individual component,unit, or system is followed by a list of tests or inspections whichwill help to determine corrective actions to take.

    b. This manual cannot list all malfunctions that may occur, nor. all tests or inspections and corrective actions. If a malfunction is

    not listed or is not corrected by listed corrective actions, notifyyour supervisor.

    c. Table 3-2 lists the common malfunctions which you may findduring the operation or maintenance of the tank and pump unit or its

    components. Perform the tests/inspections and corrective actions inthe order listed.

    3-5

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    Table 3-1. Operator Preventive

    NOTE: Within designated interval, these checks are to be

    B-BeforeD-During

    AAfterWWeekly

    ItemNo.

    1

    2

    3

    Interval Item to beInspected

    Hose and

    N ozz l e s

    G r o u n d i n g

    T e r m i n a l s

    F i l t e r /

    S e p a r a t o r

    Maintenance Checks

    performed in the order listed.

    and Services

    MMonthlyC-Combat Operability Check

    Procedures

    Check for and have repairedor adjusted as necessary

    C h e c k h o s e s f o r l e a k s ,

    c r a c k s , a n d w o r n a r e a s .

    C h e c k n o z z l e s f o r d i s t o r -

    t i o n , c o r r o s i o n a n d l e a k s

    ( f i g . 3 - 3 ) . C h e c k s c r e e n

    i n n o z z l e .

    C h e c k f o r w o r n , f r a y e d ,

    o r c o r r o d e d c a b l e a n d

    c l i p s ( f i g . 3 - 3 ) .

    C h e c k f o r l e a k s , c r a c k s

    o r o t h e r d a m a g e . C h e c k

    f o r l e a k i n g , c r a c k e d o r

    d i r t y s i g h t g l a s s . C l e a n

    d i r t y s i g h t g l a s s . O p e n

    d r a i n c o c k a n d d r a i n w a -

    t e r , d a i l y b e f o r e o p e r a -

    t i o n s , a f t e r o p e r a t i o n s ,

    a n d d u r i n g o p e r a t i o n s a s

    r e q u i r e d . O b s e r v e p r e s -

    s u r e g a g e s d u r i n g o p e r a -

    t i o n . R e p l a c e f i l t e r e l e -

    m e r i t s a n d d o m e g a s k e t

    w h e n d i s c h a r g e g a g e ( u p -

    p e r ) h a s p r e s s u r e r e a d i n g

    o f 20 p s i l e s s t han i n l e t

    g a g e ( l o w e r ) w i t h e n g i n e

    a t f u l l t h r o t t l e a n d b o t h

    n o z z l e s o p e n . C h e c k t a n k

    c o v e r , c o u p l i n g h a l v e s ,

    c a n i s t e r s a n d r e t a i n e r f o r

    d a m a g e a n d r e p l a c e a sn e c e s s a r y ( f i g . 3 - 5 ) .

    For Readiness Reporting,Equipment is Not Ready/Available If:

    Evidence of fuel

    l e ak a ge . N oz zl es ar e

    inoperat ive or leaking

    f ue l .

    Broken cable or clamp

    which would not allow

    proper ground.

    Evidence of leakage.

    3 - 6 Change 2

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    Table 3-1. Operator Preventive Maintenance Checks and Services (Cont)

    NOTE: Within designated interval, these checks are to be performed in the order listed.

    BBefore

    D-During

    AAfter MMonthly

    WWeekly C-Combat Operability Check

    Change 5 3-7

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    Table 3-1. OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES (Cont)

    NOTE: Within designated interval, these checks are to be performed in the order listed.

    B-BeforeD-During

    ItemNo.

    Interval

    3-8 Change 5

    A-After M-MonthlyW-Weekly C-Combat Operability Check

    Item to beInspected

    Tank and PumpUnit

    IntervehiclePower Cable(EMD)

    ON-OFF SwitchCable Assembly(EMD)

    ProceduresCheck for and have repaired

    or adjusted as necessary

    Deleted.

    Check entire system for fuelleakage.

    NOTE: During operation ob-

    serve for any unusualnoise or vibration.

    For Readiness Reporting,Equipment is Not Ready/Available If:

    Evidence of leakage,

    Check cable assembly and con-nectors for damage.

    Check switch for proper opera-tion. Check cable and connectorfor damage.

    Excessively damaged cableor connectors which couldcause electrical spark, orcreate an unserviceablecondition.

    Damaged cable assemblywhich could cause elec-trical spark.

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    Figure 3-3. Operator/Crew Preventive Maintenance Sequence of Checksand Services (Sheet 1 of 2).

    Figure 3-3. Operator/Crew Preventive Maintenance Sequence of Checksand Services (Sheet 2 of 2).

    3-9

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    Table 3-2. Operator Troubleshooting

    MALFUNCTIONTEST OR INSPECTION

    CORRECTIVE ACTION

    ENGINE

    1. ENGINE FAILS TO START.

    Step 1.

    Step 2.

    Step 3.

    Step 4.

    Check ignition switch for RUN position.

    Position ignition switch to RUN.

    Check for empty fuel tank.

    Refill fuel tank if empty or low.

    Check for closed fuel shutoff valve.

    Open fuel shutoff valve (fig. 2-4).

    Check for dirty or clogged air cleaner.

    Service air cleaner (fig. 3-2).

    2. ENGINE MISSES, OPERATES ERRATICALLY, OR LOSES POWER.

    Check for closed or partially closed choke.

    Fully open choke (fig. 2-3).

    3. ENGINE OVERHEATS OR KNOCKS.

    Check for poor ventilation across engine.

    Provide proper engine ventilation.

    4. ENGINE EXHAUST SMOKE EXCESSIVE.

    Step. 1. Check for closed or partially closed choke.

    Fully open choke (fig. 2-3).

    3-10

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    Table 3-2. Operator Troubleshooting (Cont)

    MALFUNCTIONTEST OR INSPECTION

    CORRECTIVE ACTION

    4. ENGINE EXHAUST SMOKE EXCESSIVE (cont)

    Step 2. Check for dirty or clogged air cleaner.

    Service air cleaner (fig. 3-2).

    ELECTRIC MOTOR

    5. ELECTRIC MOTOR WILL NOT OPERATE.

    Check vehicle power supply.

    -If batteries are discharged, contact OrganizationalMaintenance.

    PUMP

    6. PUMP FAILS TO OPERATE.

    WARNING

    Do not remove priming cap if tanks are full, as this will resultin fuel spill.

    Check to assure pump is primed. Remove priming port cap and check forevidence of fuel.

    Prime pump by filling tank and ensuring gravity action fills pumpchamber.

    7. PUMP FAILS TO PUMP PRODUCT.

    Step 1. Check that tank dispensing valve is open.

    -If pump does not prime, contact Organizational Maintenance.

    Step 2. Check ON-OFF switch connection.

    -Connect cable properly to connector J1.

    Step 3. Check to see that intervehicle cable is connected properly.

    -Connect cable and adapter to vehicle receptacle and connectorJ2.

    8. PUMP WILL NOT PUMP FUEL AT RATED CAPACITY.

    Step 1. Check for low pump engine speed,

    -Adjust engine speed. (GED)Change 4 3-11

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    Table 3-2, Operator Troubleshooting (Cont)

    MALFUNCTION

    TEST OR INSPECTIONCORRECTIVE ACTION

    Step 2. Check truck engine R. P. M. for proper charge rate. (EMD)

    Adjust engine R.P.M. to approximately 1000 R.P.M.

    Step 3. Check level in 600 gallon fuel tanks,

    Fill tanks if emply.

    Step 4. Check that tank cam lever is fully open.

    Open cam lever.

    FILTER/SEPARATOR

    9. PRODUCT DISCHARGE IS NOT CLEAN.

    Step 1, Inspect for loose canister (para. 3-9).

    Tighten canister (para. 3-9).

    Step 2. Inspect inside of shell for signs of dirt.

    Clean inside of shell (para. 3-9).

    Step 3. Product discharge still not within acceptable limits.

    Replace filter separator elements, After replacement, retest

    nozzle sample, and if the fuel is still not within acceptable limits,notify your supervisor.

    10. NO PRODUCT APPEARS IN SIGHT GLASS.

    Step 1. Check for closed upper and lower valves.

    11. AM

    3-12

    Open valves.

    Step 2. Air is suspected of being present in sight glass.

    Open petcock to release air.

    RECEPTION IS POOR.

    Step 1. Turn off EMD unit to see if quality of communication receptionimproves.

    Change 5

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    Table 3-2. Operator Troubleshooting (Cont)

    MALFUNCTIONTEST OR INSPECTION

    CORRECTIVE ACTION

    If quality improves, notify Organizational Maintenance totest further.

    Step 2. Replace EMD unit, if necessary.

    3-6. Deleted.

    SECTION IV. MAINTENANCE PROCEDURES

    3-7. GENERAL.

    The instructions in this section are published for the information and guidance of the operator inmaintaining the tank and pump unit.

    3-12.1/(3-12.2 blank)

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    Figure 3-4. Servicing Fuel Strainer.

    3-8.1. PUMP ASSEMBLY (EMD)

    Disconnect intervehicle power cable before maintaining orreplacing component parts.

    a. The electric motor requires an intervehicular power cable.

    (1) Unplug and inspect intervehicle power cable (figure 3-4.1) for damaged or corroded connectors.

    (2) Clean connectors to obtain a good connection at J2 connector at Junction Box and connector and adapterat the vehicle receptacle.

    (3) Replace cable assembly if damaged.

    b. The electric motor is controlled by an ON-OFF switch cable.

    (1) Inspect ON-OFF switch cable (figure 3-4.1) for damage or corroded connectors, damaged or frayed cable,or damaged switch.

    Change 4 3-13

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    (2) If cable or switch is damaged, replace cable assembly.

    (3) Remove connector from J1 receptacle. Clean connectors to obtain a good connection at J1 connector atJunction Box. If connector is damaged, notify Organizational Maintenance for replacement.

    Figure 3-4.1. Pump Assembly Cables.

    3-9. FILTER/SEPARATOR SERVICE.

    Refer to figure 3-5 for procedures to service the filter/separator.

    3-10. TANK, LIFTING EYE, DRAG LOOPS AND GASKETS.

    a. Inspect the fuel tanks, lifting eyes, drag loops, and gaskets for any damage or defects.

    b. Report any damaged or defective part to organizational maintenance for replacement and to direct support

    maintenance for repairs.

    3-14

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    Figure 3-5.

    TM 10-4930-204-13

    Change 4 3-15/(3-16 Blank)

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    CHAPTER 4

    ORGANIZATIONAL MAINTENANCE INSTRUCTIONS

    4-1.

    a.

    b.

    SECTION I. SERVICE UPON RECEIPT OF EQUIPMENT

    UNLOADING EQUIPMENT.

    Remove all blocking and tiedown straps securing tank and pump unit to carrier.

    Remove tank and pump unit from carrier with a forklift or other suitable device with a lifting capacity of notless than 2000 Ibs (907 kg). If slings are used, exercise care in placing them around the unit to ensure proper balanceof the load to minimize the danger of the load slipping or damaging the equipment.

    4-2. UNPACKING EQUIPMENT.

    a. General. Move the unit to the installation site before removing the containers. Remove the containers andshipping skids from the pumping unit and tanks.

    b. Depreservation. Prior to placing the unit in operation, accomplish depreservation in accordance with instruc-

    tions outlined in DA Form 2258, (Depreservation Guide of Engineer Equipment).

    4-3. INSPECTING AND SERVICING EQUIPMENT.

    a. Inspection.

    (1) Inspect identification plates for positive identification of equipment.

    (2) Make a thorough inspection of pumping assembly and tanks for damage which may have occurred duringshipment.

    (3) Check equipment against packing list to make certain all items are accounted for and in serviceablecondition.

    (4) Inspect components for loose or missing mounting hardware and loose connections.

    (5) Ensure that all moving engine parts are operating properly.

    (6) Inspect engine unit for signs of damage, paying particular attention to gages and ground leads. inspectpumping unit reels for damage.

    b. Servicing.

    (1) Lubricate tank and pump unit in accordance with figure 3-1.

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    (2) Perform preventive maintenance checks and services (table 4-1).

    4-4. TYPICAL INSTALLATION OR SETTING-UP INSTRUCTIONS.

    a. General. DELETED.

    b .

    (1) Lower tailgate of truck and remove tarpaulin, bows, and racks with seats. Install tank and pump unit andappropriate blocking.

    NOTE

    Do not smoke or use open flame within 50 feet of refueling point orvehicle.

    (2) Secure tanks and pumping assembly to sides of truck with tiedown assemblies. Raise tailgate and

    secure it.

    c. A list of maintenance and operating supplies required for initial operationcontained in Appendix F.

    d. Tank Vertical Tiedown.

    of the tank and pump unit is

    (1) Refer to figure 4-2 for identification of the tiedown strap assemblies.

    (2) To unlock or release the ratchet, press the release in the ratchet handle. Hold the release; pull thehandle down until the side cams engage, and push the static ratchet locks Up from the ratchet dogs; this allows the

    center ratchet spool to rotate in either direction.

    (3) To aid in unrolling the nylon strap, turn the ratchet hook opening down on a flat surface; press down inthe center of the ratchet while pulling the strap away from the ratchet.

    (4) Refer to figure 4-3 and place the tiedown straps over the tank ends. Attach the brackets to the sides of

    the truck, connect the strap end and the ratchet to the brackets. Move the ratchet handle up and down until the strapis tight. Push the ratchet handle to the lock position.

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    Figure 4-1. Blocking Instructions. DELETED.

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    Figure 4-2. Tank and Pump Unit Vertical Tiedown Strap Assembly.

    e. Pump Unit Tiedown Strap Assembly.

    (1) Refer to figure 4-2 for identification of the tiedown strap assembly.

    (2) Refer to figure 4-3 and hook the loose bracket over the top of the reel frame (the long side with the holeout and down). Hook the bracket attached to the strap end beneath the rear truck from 8 to 10 inches (20 to 25 cm)right of center.

    (3) Pace the strap end up through the space between the tailgate and the truck body. Insert the strap end, rearto front, through the slot in the center of the ratchet spool, Pull the slack through the ratchet spool by the strap end.

    (4) Unlock the ratchet; move the ratchet handle in an up-and-down motion until the strap is tight; push the rat-chet handle to its closed position.

    (5) Raise the tailgate.

    4-5. EQUIPMENT CONVERSION.

    Refer to paragraph 4-23 for procedures to replace the gasoline engine driven pump with an electric motor drivenpumping assembly.

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    Figure 4-3. Tank and Pump Unit Vertical Tiedown Strap AssemblyInstalled.

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    SECTION II. MOVEMENT TO A NEW WORKSITE

    4-6. DISMANTLING FOR MOVEMENT.

    a. Short Distance Movement.

    NOTE

    Tanks should be emptied prior to being removedfrom truck and tanks must be disconnected frommanifold (pump unit).

    (1) Remove tank and pump unit from truck withother suitable device.

    (2) Move tank and pump unitor vehicle. Provide suitable blockingequipment from shifting.

    a forklift or

    to new worksite with forkliftand tiedowns to prevent

    b. Long Distance Movement.

    (1) Provide a suitable container for tanks and pump unit.Each tank and each pump unit should have a separate container tofacilitate handling during long distance moves. Wood is particularlyvaluable as a container material because of its high strength-weightratio, which compares favorably with mild steel. Tests and experiencehave shown that the strength of a wooden container depends largelyupon the type of wood used in its construction. The durability of woodand its ability to withstand shock and impact stresses are importantproperties in the selection of wood for containers. The quality ofwood members for containers and pallets is set forth in MIL-STD-731,Quality of Wood Members for Containers and Pallets.

    (2) Provide suitable blocking and tiedowns to prevent theunit from shifting during transport.

    4-7. REINSTALLATION AFTER MOVEMENT.

    Reinstall tanks and pump unit after movement to a new worksite asoutlined in paragraph 4-4.

    SECTION III. REPAIR PARTS, SPECIAL TOOLS AND EQUIPMENT

    4-8. SPECIAL TOOLS AND EQUIPMENT.

    No special tools or equipment are required by organizationalmaintenance personnel for the maintenance of the tank and pump unit.

    4-9. MAINTENANCE REPAIR PARTS.

    Repair parts and equipment are listed and illustrated in therepair parts and special tools list covering organizationalmaintenance in TM 10-4930-204-34P.

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    4-10. FABRICATED TOOLS AND EQUIPMENT.

    No fabrication of special tools and equipment is necessary for maintenance of the tank and pump unit.

    SECTION IV. PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS)

    4-11. GENERAL.

    To ensure that the equipment is ready for operation at all times, it must be inspected systematically so that defects

    may be discovered and corrected before they result in serious damage or failure. The necessary preventivemaintenance checks and services are listed in table 4-1. Defects discovered during operation of the system shall

    be noted for future correction to be made as soon as operation has ceased. Stop operation immediately if a deficiencyis noted during operation, which would damage the equipment if operation were continued. All deficiencies and short-

    comings will be recorded together with the corrective action taken DA Form 2404 (Equipment Inspection andMaintenance Worksheet) at the earliest possible opportunity.

    4-12. QUARTERLY AND MONTHLY PREVENTIVE MAINTENANCE SERVICES.

    a. This paragraph contains an illustrated tabulated listing of preventive maintenance services which must be per-formed by organizational maintenance personnel at quarterly or monthly intervals. A quarterly interval is equal to

    3 calendar months, or 250 hours of operation, whichever occurs first.

    b. The item numbers are listed consecutively and indicate the sequence of minimum requirements and the itemnumber column is used as a source of item numbers for the TM number column on DA Form 2402, Equipment In-spection and Maintenance Worksheet. Refer to table 4-1 for quarterly or monthly preventive maintenance services.

    Included with the table is a pictorial view of the required inspection sequence (fig. 4-4).

    4-13. GENERAL.

    SECTION V. TROUBLESHOOTING

    a. This section contains troubleshooting information for locating and correcting most of the operating troubles

    which may develop in the tank and pump unit. Each malfunction for an individual component, unit, or system is follow-

    ed by a list of tests or inspections which will help to determine corrective actions to take.

    b. This manual cannot list all malfunctions that may occur, nor all tests or inspections and corrective actions.If a malfunction is not listed or is not corrected by listed corrective actions, notify your supervisor.

    c. The table lists the common malfunctions which you may find during the operation or maintenance of the tank

    and pump unit or its components. Perform the tests/inspections and corrective actions in the order listed.

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    Table 4-1. Organizational Preventive Maintenance Checks and Services

    Item

    No.

    1

    2

    3

    4

    5

    Item

    To Be

    Inspected

    Hoses, Nozzles,and Reels

    Grounding Cable

    and Reels

    Filter/Separator

    Magnets

    Spark Plug

    Quarterly Schedule

    Procedures

    Check for and have Repaired,

    Replaced, Adjusted as necessary

    Check hoses for leaks, breaks, crackcuts and worn areas. Replace leaking,worn, or damaged hose. Check nozzlesfor distortion, corrosion and leaks.Clean or replace distorted, corroded,or leaking nozzles. Check reels foralignment and ease of operation. Checkscreen in refueling nozzle, (para. 4 -20)

    Check cable for worn, frayed or cor -

    roded condition. Check reel for easeof operation. Replace worn, frayed,or corroded cable and clips, (para. 4-29).

    Check for leaks, cracks, or otherdamage. Check for leaking, crackedor dirty sight glass. Remove andclean a dirty sight glass. Replacewashers to correct leaking condition.Replace cracked or broken sight glassDrain water as required. Observe

    pressure gages during operation. Re-place filter elements and dome gasketwhen discharge gage (upper) has pres-sure reading of 20 psi less than ingage (lower) with engine at full throttleand both nozzles open (para. 4-27).

    Replace pitted or burned magnetopoints. Proper gap adjustment is0.015 inch (0. 038 cm).(Check adjust-ment every 500 hours.)(para. 4-2).

    Replace spark plugs that have crackedinsulators and burned electrodes,Clean and set spark plug gaps for0.030 inch (0.076 cm). Replace leadswhich are frayed or broken. Clean andtighten lead connections, (fig. 4-11).

    For Readiness Reporting,

    Equipment is Not Ready/

    Available If:

    Evidence of fuelleakage. Nozzlesare inoperative orleaking fuel.

    Broken cable or

    clamp which wouldnot allow a properground.

    Evidence of leakage.

    Defective magnets.

    Faulty ignitioncircuit.

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    Table 4-1. Organizational Preventive Maintenance Checks and ServicesQuarterly Schedule - (Cont)

    Procedures Equipment willItem Item to be Check for and have repaired be reported NotNo. Inspected or adjusted as necessary Ready (Red) if:

    6 Fuel Tank Add fuel as required. Tighten loose Leakage of fuel is

    mounting. Replace leaking fuel tank. present.

    Replace defective cap gasket. Clean

    cap vent, (para. 4 -24).

    7 Fuel Filter Tighten thumb nut if gasket is leaking.Clean screen, (para. 4-24).

    8 Oil Level Plug Check that oil level is at second threadof oil plug hole. Add oil as required.Refer to current L.O. (fig. 3-l).

    9 Fire Extinguish- Inspect for broken seal . Check hose Missing or dischargee r for wear and deterioration. Check for cylinder.

    broken nozzles. Weigh the fire ex-

    tinguisher (CO2) and subtract from

    this weight, the empty weight (stamped

    on the valve body). If the resulting netweight (stamped on the extinguisher)has decreased 10% or more, the cyl-inder should be replaced or recharged.Forward extinguisher to next higher

    level of maintenance if weighing capa-

    bility does not exist.

    10 Outlet Strainer Check screen for dirt or damage. Damaged strainer

    Screen Clean or replace a dirty or damaged screen.s c r e e n .

    11 Discharge Valve Check control lever for binding or Evidence of leakage.and Control damage. Check valve for leaks. Re-

    L e v e r place damaged control lever. Tighten

    or replace a leaking valve.

    12 Air Vent Check vent assembly for dirt or dam- Damaged air vent.

    A s s e m b l y age. Clean or replace a dirty ordamaged vent assembly.

    No te OPERATION During operation observe for any un-

    1 TEST usual noise or vibration.

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    Item

    No.

    Note

    2

    Table 4-1. Organizational Preventive Maintenance Checks and Services

    Item to beInspected

    ADJUSTMENT

    Quarterly Schedule - (Cont)

    ProceduresCheck for and have repaired

    or adjusted as necessary

    Make all necessary adjustments dur -ing operational test.

    Equipment willbe reported NotReady (Red) if:

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    ItemNo.

    1

    2

    4

    5

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    Table 4-1. Organizational Preventive Maintenance Checks and Services

    Monthly Schedule-Continued

    Item

    To BeInspected

    Procedures

    Check for and have Repaired, For Readiness Reporting,

    Replaced, Adjusted as Equipment is Not Ready/

    Necessary Available If:

    WARNING

    Disconnect intervehicle cable from vehicle before maintaining or replacing elec-

    trical com