TM 5-4320-251-14

D E P A R T M E N T O F T H E A R M Y T E C H N I C A L M A N U A L

OPERATOR, ORGANIZATIONAL, DIRECT SUPPORT

AND GENERAL SUPPORT MAINTENANCE MANUAL

PUMP, RECIPROCATING, POWER DRIVEN

DIAPHRAGM, GAS ENGINE DRIVEN, WHEEL

MOUNTED, 100 GPM

THE GORMAN-RUPP COMPANY

MODEL 4D-2A016

F S N 4 3 2 0 - 4 0 7 - 2 5 8 2

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

M A R C H 1 9 7 1

Shut off the engine before filling the fuel tank. Take care to prevent spillinggasoline on a hot engine. The gasoline can ignite, causing severe injury ordeath to the operator.

If the fuel tank must be repaired by any method involving heat or flame,steam-clean the tank thoroughly to assure that all traces of gasoline areremoved before starting repairs. Failure to purge the tank of all traces of fuelfumes before applying heat or flame may result in a severe explosion.

W A R N I N G

The exhaust fumes from the engine contain carbon monoxide, a colorless,odorless, deadly poisonous gas. Do not operate this pump in an enclosed areaunless the exhaust gasses are piped to the outside of the enclosure.

TM 5-4320-251-14

TECHNICAL M A N U A L HEADQUARTERS,DEPARTMENT OF THE ARMY

No. 5-4320-251-14 WASHINGTON, D. C., 25 March 1971

OPERATOR, ORGANIZATIONAL, DIRECT SUPPORT,

AND GENERAL SUPPORT MAINTENANCE MANUAL

P U M P , R E C I P R O C A T I N G , P O W E R - D R I V E N ,

DIAPHRAGM, GAS-ENGINE-DRIVEN, WHEEL

MOUNTED, 100 GPM

THE GORMAN-RUPP CO. MODEL 4D-2A016

CHAPTER

Section

CHAPTER

Section

CHAPTER

Section

CHAPTER

Section

CHAPTER

Section

CHAPTER

CHAPTER

Section

1.I.

II.

2.I

II.III.IV.V.

3.I.

II.III.IV.V.

4.I.

II.III.IV.V.

VI.VII.

VIII.

5.I.

II.III.IV.

6.

7.

I.II.

FSN 4320-407-2582

Paragraph

INTRODUCTIONGeneral . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Description and data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OPERATING INSTRUCTIONSService upon receipt of material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Movement to a new worksite . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Operation under usual conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Operation under unusual conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OPERATOR’S MAINTENANCE INSTRUCTIONSBasic issue items . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Lubrication instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Preventive maintenance checks and services . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Maintenance of fuel strainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ORGANIZATIONAL MAINTENANCE INSTRUCTIONSService upon receipt of materiel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Repair parts, special tools, and equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Preventive maintenance checks and services (quarterly) . . . . . . . . . . . . . . . . . . . . . . . .Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Maintenance of fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Maintenance of pump suction and discharge assemblies . . . . . . . . . . . . . . . . . . . . . . . . .Maintenance of diaphragm and plunger assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Maintenance of wheels and axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-11-5

2-12-32-52-7

2-11

3-13-23-43-63-8

4-14-34-54-74-9

4-134-174-21

DIRECT SUPPORT AND GENERAL SUPPORT MAINTENANCE INSTRUCTIONSRepair parts, special tools, and equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3General maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5Removal and installation of major components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8

REPAIR OF RECIPROCATING PUMP GEAR CASE . . . . . . . . . . 6-1

ADMINISTRATIVE STORAGE AND INSTRUCTIONS FOR DESTRUCTION OFMATERIEL TO PREVENT ENEMY USE

Administrative storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1Destruction of materiel to prevent enemy use . . . . . . . . . . . . . . . . . . 7-2

Page

1-11-1

2-12-22-32-42-6

3-13-13-13-33-3

4-14-14-14-24-34-54-9

4-11

5-15-15-15-2

6-1

7-17-1

i

A P P E N D I X A REFERENCESB MAINTENANCE ALLOCATION CHARTC BASIC ISSUE ITEMS LIST

INDEX

Paragraph Page

A-1B-1C-1I-1

i i

C H A P T E R 1

I N T R O D U C T I O N

Sect ion I .

1-1. ScopeThis technical manual covers the operation andoperator’s maintenance, organizational main-tenance, and direct and general support main-tenance for Pump, Reciprocating, Power-Driven,Diaphragm, Gas-Engine-Driven, Wheel Mounted,100 GPM, Federal Stock No. 4320-407-2582,German-Rupp Model 4D-2A016, manufacturedby German-Rupp Company, Mansfield, Ohio.

1-2. Forms and RecordsMaintenance forms, records, and reports which areto be used by maintenance personnel at al lmaintenance levels are listedTM 38-750.

in and prescribed by

S e c t i o n I I . D E S C R I T I O N A N D D A T A

G E N E R A L

1-5. Descr ipt iona. Reciprocating Pump Model 4D-2A016 (fig.

1-1) is driven by an air-cooled, two-cylinder,Military Standard gasoline engine. The torque

1-3. Equipment Serviceabi l i ty Cr i ter iaNot Applicable.

1-4 . Repor t ing o f E r ro r s

Report of errors, omissions, and recommendationsfor improving this publication by the individualuser is encouraged. Reports should be submitted onD A F o r m 2 0 2 8 , R e c o m m e n d e d C h a n g e s t oPublications, and forwarded direct to CommandingGeneral, U.S. Army Mobility Equipment Com-mand, ATTN : A M S M E - M P P , 4 3 0 0 G o o d -fellow Blvd., St. Louis, Mo. 63120.

from the engine is transferred to the pump througha flexible coupling. The engine and pump arebolted to a two-wheeled steel trailer.

1-1

Figure 1-1. Reciprocating

b. T h e p u m p h a s o n e s u c t i o n p o r t a n d o n ed i s c h a r g e p o r t . T h e s e a r e t h r e a d e d t o r e c e i v esuction and discharge hoses, Thread size is 4-inch

npt male. Four 10-foot suction hoses are providedwith the pump. The pump is capable o f pumping100 gallons per minute at a total dynamic head of35 feet .

1-6. Differences between Models

This technical manual covers only Reciprocat ingP u m p M o d e l N o . 4 D - 2 A 0 1 6 , m a n u f a c t u r e d b yG e r m a n - R u p p C o m p a n y , M a n s f i e l d , O h i o . N oknown d i f ferences ex is t on the pumps procuredunder this model number .

1-7 . Identif ication and Tabulated Data

a. Ident i f i cat ion . The rec iprocat ing pump hasthree ident i f i cat ion p lates .

(1) Army data p late . The army data p late is

1-2

pump, left front view,

located on the coupling guard between the pump

and engine. It specifies the nomenclature, contractnumber , model number , manufacturer , capaci ty ,d imensions , weight , and cubage .

(2) Engine plate. The engine plate is locatedon the flywheel housing. It specifies the number of

cy l inders , d isp lacement , Federal Stock Number ,serial number, and model number. It lists the dateof manufacture , contract number , and appl icabletechnical manuals .

(3) Pump plate. The pump plate is located onthe gear case on the r ight s ide o f the pump. I tspec i f ies the manufacturer , model number , ser ia lnumber , and patent information.

b. Tabulated Data .

(1) Pump.

Manufacturer . . . . . . . . . . . . . . . . . German-Rupp CompanyModel . . . . . . . . . . . . . . . . . . . . . . . . 4D-2AO16

LIST OF ILLUSTRATIONS

Number

1-12-12-22-32-42-53-14-14-24-34-44-55-16-1

Title Page

Reciprocating pump, left front view . . . . . . . . 1-1Front view of reciprocating pump . . . . . . . . . . 2-2Engine fuel and ignition controls . . . . . . . . . . . . . . . . 2-3Fuel shutoff valve and related parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3Inlet temperature control and related parts . . . . . . . . 2-4Starting the pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5Fuel strainer service . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4Fuel tank, lines, and fittings, disassembly and reassembly . . . . . . . . . . . . . . . . 4-4Schematic diagram showing operation of reciprocating pump 4-6Suction and discharge assemblies, disassembly and reassembly . . . . . . . . . . 4-8Diaphragm and plunger, disassembly and reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10Wheels and axle, disassembly and reassembly . . . . . . . . . . . . . . . . . . . . . 4-12Major components of reciprocating pump . . . . . . . . . . . . . . . . . . . . . . 5-2Gear case assembly, disassembly and reassembly . . . . . . . . . . . . . . . . . . . . . 6-2

iii

Federal Stock Number 4 3 2 0 - 4 0 7 - 2 5 8 2Serial number range . . . . . . . . . 459804-459993Type . . . . . . . . . . . . . . . . . . . . . . . Reciprocating, diaphragm

typePumping medium . . . . . . . . . . . . WaterCapacity . . . . . . . . . . . . . . . . . ...100 gpm at 35 ft tdh at

3500 rpmMaximum rated driven speed 3600 rpmSuction port size . . . . . . . . . . . 4 in. npt maleDischarge port size . . . . . . . . 4 in. npt male

(2) E n g i n e .

Manufacturer . . . . . . . . . . . . . . . GFEModel . . . . . . . . . . . . . . . . . . . . . 2A016-3Federal Stock Number 2 8 0 5 - 0 7 2 - 4 8 7 1

(3) C o u p l i n g .

Manufacturer . . . . . . . . . Lovejoy Flexible Couplingc o .

Type . . . . . . . . . . . . . . . . . . . . FlexibleShaft size . . . . . . . . . . . . . . . . . . . ¾ inch diameter

(4) Overal l d imensions and weights .

PUMP BOXED (KD)Overall length . . . . . . . . . . . . . . . 59 in. 42 in.Overall width . . . . . . . . . . . . . . . . 43 in. 37 in.Overall height . . . . . . . . . . . . . ...32 in. 32 in.Overall weight . . . . . . . . . . . . . . .3l2lb 465 lbShipping volume . . . . . . . . . . . . . . 28.7 cu ftShipping weight . . . . . . . . . . . . . 465 lb

(5) H o s e ( b o x e d ) .

Length . . . . . . . . . . . . . . . . . . . . . .11 ft 0 in.Width . . . . . . . . . . . . . . . . . . . . . . 16 in.Height . . . . . . . . . . . . . . . . . . . . . .l6 in.Shipping Weight . . . . . . . . 380 lbShipping Volume . . . . . . . . . . . . .19.6 cu ft

1-3

CHAPTER 2

OPERATING INSTRUCTIONS

Section I. SERVICE UPON

2 - 1 . A s s e m b l i n g , I n s p e c t i o n , a n d S e r v i c i n gthe Equipment

a. Assembly. New pumps are shipped from thef a c t o r y w i t h t h e d i a p h r a g m r e m o v e d . N o t i f yo r g a n i z a t i o n a l m a i n t e n a n c e p e r s o n n e l f o r i n -stallation of the separately packed diaphragm.

b. Inspection. Inspect the pump assembly andhoses as fo l lows:

( 1 ) I n s p e c t t h e p u m p a s s e m b l y f o r c r a c k s ,dents, and other damage which may have occurredduring shipment .

(2 ) Inspect for loose or miss ing hardware .(3) Check for damaged threads on the suction

and discharge ports.(4) Using the starting rope, turn the engine

over with the ignition switch in the OFF position.The engine and pump shall turn freely without anybinding, s c r a p i n g , o r other signs o f f a u l t yoperat ion .

(5) If the pump had been in servicepreviously, turn the engine over as directed in (4)above and carefully check the diaphragm for cuts,tears, and leaks.

( 6 ) I n s e r t a h a n d i n t o t h e s u c t i o n a n ddischarge ports and check for free operation of thes u c t i o n a n d d i s c h a r g e v a l v e s . T h e v a l v e s m u s tmove freely and seal tightly.

(7) Inspect the hoses for cuts, collapsed walls,and dam aged threads on end fittings.

RECEIPT OF MATERIEL

( .8 ) Tighten any loose hardware . Report anyother dam age to the required authority.

c. Servic ing . Service the equipment as follows:

(1 ) Serv ice the engine as d irected in TM 5-2 8 0 5 - 2 5 7 - 1 4 .

( 2 ) L u b r i c a t e t h e p u m p a s d i r e c t e d i n t h ecurrent L .O.

( 3 ) P e r f o r m a l l t h e d a i l y p r e v e n t i v e m a i n -tenance checks and services indicated in table 3-1.

2 - 2 . I n s t a l l a t i o n

Instal l the rec iprocat ing pump as fo l lows:

a. Locate the pump on a level surface as close tothe liquid supply as possible.

b. B l o c k t h e w h e e l s o f t h e p u m p t r a i l e r t oprevent the pump from shifting during operation.

c. Connect the female end of the suction hose tothe suct ion port (3 , f ig . 2 -1 ) on the pump. Usethread sealant on all threaded connections. If morethan one length of hose is required, add additionallenghts to the end of the first hose attached to thep u m p .

Note: Use the shortest possible length of suction hose.Suction hose exceeding 20 feet will reduce the pump capacity.Under any circumstances, the suction lift of the pump must notexceed 25 feet. When the suction lift is greater than 5 feet, a 3-inch suction hose can be used in place of a 4-inch hose withoutany loss of efficiency. Use a suitable reducer. The 3-inch hosewill reduce priming time and will cause less surging duringoperation. Make sure the suction hose has rigid walls toprevent the hose from collapsing when suction is applied.

2-1

1. Accumulator cap 4. Drain plug2. Accumulator 5. Drawbar3. Suction port 6. Discharge port

Figure 2-1. Front view of reciprocating pump.

d. Install a strainer on the intake end of the (6 , f i g . 2 -1 ) o f the pump. The l eng th o f t h esuction hose. discharge hose shall not exceed 50 feet. A 4 - i n c h

Caution. A strainer must be used on the discharge hose must be used.end of the suction hose to prevent rocks and f. Make sure the end of the suction hose andother unbreakable material from being sucked strainer are completely submerged in the liquid toup into the pump. These could cause severe be pumped. Make sure the end of the dischargedamage to the pump. hose is free from any restrictions.

e. Connect a discharge hose to the discharge port

Sect ion I I . MOVEMENT TO A NEW WORKSITE

2-3. Dismantl ing for Movement suction hose. Disconnect the suction hose from the

Dismantle the pump for movement to a new suction port (3) of the pump.worksite as follows: d. Use a shipping dock or use wood planks as a

a. Remove the drain plug (4, fig. 2-1 ) to drain ramp to load the pump on the bed of a suitable

the fluid from the pump. truck to transport the pump. Grasp the drawbar (5)

2-2

b. Disconnect the discharge hose from the dis- when moving the pump, Secure the pump to the

charge port (6) . side of the truck to prevent it from shifting. Lay the

c. Disconnect the strainer from the end of the hoses on the bed of the truck.

Caution: The wheels and axle of the pump during road or highway movement of theare designed to move the pump into position at pump.the worksite and are not designed for use 2-4. Reinstallation after Movement

Refer to paragraph 2-2 for installation instructions.

Section III. CONTROLS

2-5. General

This section describes the various controls andprovides the operator / crew sufficient informationto insure proper operation of the reciprocatingpump.

2-6. ControlsThe controls necessary for operation of thereciprocal pump are illustrated in figures 2-2through 2-4, and described in table 2-1.

1. Throttle lever2. Ignition switch3. Choke lever

Figure .2-2. Engine fuel and ignition controls

1. Fuel tank2. Fuel shutoff valve3. Fuel strainer

Figure 2-3. Fuel shutoff valve and related parts.

2-3

Fig. &index no.

2-2 2

2-2 3

2-2 1

2-3 1

2-4 1

1. Inlet temperature control2. Reset button3. Air filter service indicator4. Air filter

Figure 2-4. Inlet temperature control and related parts.

Table 2-1. Controls

2-7. General

Ignition switch

Choke lever

Throttle lever

Fuel shutoff valve

Inlet temperaturecontrol

Operation and use

In the OFF (down) position, the ignition switch grounds the magneto,preventing the engine from running. In the RUN (UP) position, it allowsnormal starting and operation of the engine. Moving the switch to the OFFposition stops engine operation.

In the counterclockwise position, the choke lever supplies an extra-rich fuelmixture to the engine to facilitate starting and warmup. In the clockwiseposition, the choke lever provides a fuel mixture for normal operation afterwarmup.

The throttle lever controls engine speed within the operating range of thegovernor. Loosening the locking nut on the throttle lever releases the lever sothat it can be positioned as required. Tighten the nut to lock the adjustment.When moved to the far right, the lever is positioned for start and idle. Whenmoved to the far left, the lever is positioned for full governed speedoperation. Positioning the lever in intermediate positions will cause theengine to run at speeds proportional to the lever position.

Controls the flow of fuel from the fuel tank. Turn counterclockwise to open thevalve; clockwise to close it.

Controls temperature of inlet air to carburetor. Pull control out for operation intemperatures above 50° F. Push control in for operation in temperaturesbelow 25° F. Position control in midposition for operation in temperaturesbetween 25° and 50” F.

Section IV. OPERATION UNDER USUAL CONDITIONS

b. The operator must know how to perform

a. The instructions in this section are for the every operation of which the reciprocating pump is

information and guidance of personnel responsible capable. This section contains instructions on

for operation of the reciprocating pump. starting and stopping the reciprocating pump, on

2-4

operation of the reciprocating pump, and on 2-8. Startingcoordinating the basic motions to perform the a. Perform all before operation preventivespecific tasks for which the equipment is designed. maintenance checks and services (table 3-1).Since nearly every j ob presents a different b. Start the reciprocating pump as shown inproblem, the operator may have to vary given figure 2-5.procedures to fit the individual job.

Figure 2-5. Starting the pump.

2-5

2-9. Stopping

To stop the pump, shut down the engine by movingthe ignition switch (2, fig. 2-2 ) to the OFF (down)position. Close the fuel shutoff valve.

Note: If the engine and pump have been running underheavy load for an extended period of time, move the throttlecontrol level slowly to START & IDLE position, allowing theengine to run for several minutes at lower speeds to distributethe engine heat and prevent warping of the engine parts.

2-10. Operation

Operate the reciprocating pump under usualconditions as follows:

a. Make sure the strainer at the end of thesuction hose and the end of the suction hose arefully submerged. Make sure that the end of thedischarge hose is not restricted.

b. Start the engine (para 2-8). After warmup,operate the throttle control to full-speed operatingposition.

c. If the suction lift is less than 15 feet, pumppriming is normally not necessary. If the suction liftis greater than 15 feet, remove the accumulator ca(1, fig. 2-1 ) and pour two gallons of water into theaccumulator to prime the pump. Install the ac-cumulator cap and tighten securely, making surethe gasket is in place.

d. After running for a time, the pump will suckthe fluid up into the pump pot and will discharge itthrough the discharge hose. The time before theactual pumping operation begins depends upon theheight of the suction lift and the condition of thepump.

e. If the pump fails to start pumping after areasonable time, consult the troubleshooting chart(table 3-2) to diagnose and correct the trouble.

f. After pumping operation has started, adjustthe throttle lever (1, fig. 2-2) on the engine toprovide an operating speed that will give therequired pumping rate.

g. Clean the strainer from time to time toprevent obstructions from disrupting the pumpingoperations.

h. Check the fuel level from time to time and fillthe tank if necessary to prevent the engine fromrunning out of fuel.

Warning: Shut off the engine beforefilling the fuel tank. Take care to preventspilling gasoline on a hot engine. The gasolinecan ignite, causing severe injury or death tothe operator.

i. If the temperature changes markedly duringthe operating cycle, adjust the inlet temperaturecontrol to compensate for the change.

Section V. OPERATION UNDER UNUSUAL CONDITIONS

2-11. Operation in Extreme Cold (Below 0° F(—18° C) )

TO operate the pump in conditions of extreme cold,proceed as follows:

a. Keep the fuel tank filled when the unit is notin operation.

b. Service the fuel filter frequently to prevent icecrystals from clogging the filter element.

c. Refer to the current L.O. for the lubricantsrequired during operation in extreme cold.

d. Take care to allow the engine to reachoperating temperature before operating it at fullspeed.

e. Make sure the engine inlet temperaturecontrol (1, fig. 2-4) is pushed in all the way.

f. Drain the fluid from the pump and hosesimmediately upon shut-down. To drain the pump,remove the drain plug (4, fig. 2-1 ) in the diaphragmpot. Lift the suction hose from the fluid beingpumped and allow it to drain. Drain all fluid fromthe discharge hose.

Caution: Always drain the pump whenfreezing temperatures may be encountered.Solid ice in the pump will delay pumpoperation until it can be completely thawed,and freezing of the trapped fluid may result inthe cracking of the metal parts.

2-6

2-12. Operation in Extreme Heat

To operate the pump in extreme heat, proceed asfollows :

a. Do not run the engine faster than necessary topump water at the required rate.

b. Refer to the current L.O. for the lubricantsrequired during operation in extreme heat.

c. Protect the unit from direct sunlight. Provideshade for the unit whenever possible.

d. Make sure the engine inlet temperaturecontrol (1, fig. 2-4) is pulled out all the way.

e. Take special care to run the engine at a slowerspeed before shutdown to distribute the engine heatand minimize the possibility of warping the metallicparts.2-13. Operation in Dusty or Sandy Areas

N o t e t h e f o l l o w i n g w h e n o p e r a t i n g t h ereciprocating pump in dusty or sandy areas:

a. Use extreme caution to prevent the lubricantsfrom becoming contaminated with dust or sand.

b. Check the engine air filter service indicator(3, fig. 2-4) frequently and service the air cleanerwhen necessary.

c. Prevent dust and sand from entering the fuelsystem. Service the fuel strainer frequently toprevent dust and sand from accumulating in thefuel bowl.

2 - 1 4 . O p e r a t i o n u n d e r R a i n y o r H u m i dCondit ions

N o t e t h e f o l l o w i n g w h e n o p e r a t i n g t h ereciprocating pump in rainy or humid conditions:

a. Take care to prevent moisture from enteringthe fuel system. Keep the fuel tank filled when theunit is not in use to prevent moisture from con-densing in the fuel tank.

b. Service the fuel strainer frequently to preventmoisture from accumulating in the fuel bowl.

2-15. Operation at High AltitudesN o t e t h e f o l l o w i n g w h e n o p e r a t i n g t h e

reciprocating pump at high altitudes:a. The efficiency of internal combustion engines

decreases because of the reduced supply ofavailable oxygen necessary to burn the fuel in theengine. Keep the engine tuned up and running atthe greatest possible efficiency during high-altitudeoperation.

b. Because of the reduced atmospheric pressureat high altitudes, the pumping capacity of the pumpis reduced. Keep suction lifts as short as possible bylocating the pump as close to the fluid supply aspossible.

2-7

CHAPTER 3

OPERATOR’S MAINTENANCE INSTRUCTIONS

3-1. Basic IssueTools, equipment,

Section I. BASIC ISSSUE ITEMS

Items.and repair parts issued with or

authorized for the reciprocating pump are listed inthe Basic Issue Items List, Appendix B.

Section II. LUBRICATION INSTRUCTIONS

3-2. General Lubrication Informationa. Proper lubrication is the most important

single factor in a good preventive maintenanceplan. Follow lubrication instructions provided inthis section exactly to assure trouble-free, long-lifeoperation of the reciprocating pump.

b. The current L.O. provides detailed in-formation regarding the points of lubrication,lubrication interval and recommended lubricant.

3-3. Detailed Lubrication Informationa. General. Keep all lubricants in closed

containers and store in a clean, dry place away fromexternal heat. Allow no dust, dirt, or other foreign

material to mix with the lubricants. Keep alllubrication equipment clean and ready to use.

b. Cleaning. Keep all external parts notrequiring lubrication clean of lubricants. Beforelubricating the equipment, wipe all lubricationpoints free of dirt and grease. Clean all lubricationpoints after lubricating to prevent accumulation offoreign matter.

c. Points of Lubrication. Service the lubricationpoints of the pump at proper intervals as illustratedin the current L.O.

d. Engine Lubrication. Lubricate the engine asdirected in LO 5-2805-257-12.

Section III. PREVENTIVE MAINTENANCE CHECKS AND SERVICES

3-4. GeneralTo insure that the reciprocating pump is ready foroperation at all times, it must be inspectedsystematically so that defects may be discoveredand corrected before they result in serious damageor failure. The necessary preventive maintenancechecks and services to be performed are listed asdescribed in paragraph 3-5. The item numbersindicate the sequence of minimum inspectionrequirements. Defects discovered during operationof the unit will be noted for future correction to bemade as soon as operation has ceased. Stop

operation immediately if a deficiency is notedduring operation which would damage theequipment if operation were continued. Alldeficiencies and short-comings will be recordedtogether with the corrective action taken on DAForm 2404 at the earliest possible opportunity.

3-5. Preventive Maintenance Checks andServices

Refer to table 3-1 for a listing of operator’spreventive maintenance checks and services.Service the engine as directed in TM 5-2805-257-14.

3-1

Table 3-1.

figure 5-1.

Paragraph 3-9.

figure 4-1. P

aragraph 2-1b. P

aragraph 2-1b P

aragraph 2-1b P

aragraph 2-1b

3-2

Section IV. TROUBLESHOOTING

3-6. General corrective actions given in this chart do not correctThis section describes troubles which might occur the malfunction, report the t r o u b l e t oduring operation of the reciprocating pump, along organizational maintenance.with the probable causes and corrective actions 3-7. Operator / Crew Troubleshooting Chartrelating to the troubles. Only those malfunctions Refer to table 3-2 for troubleshooting which iswhich are within the maintenance scope of theoperator / crew are included in this chart. If the

allocated to the operator/ crew level of main-tenance.

Table 3-2. Troubleshooting Chart

Malfunction

1. Engine turns over but fails tostart.

2. Engine starts but then stops.

3. Engine starts but pump fails topump.

4. Pump output to low.

Probable cause

a. Fuel tank empty.b. Water in fuel.

c. Ignition switch in OFF position

a. Fuel filter clogged.b. Insufficient fuel supply.a. Suction hose or strainer clogged.b. Suction leak.c. Suction strainer and hose not fully

submerged.d. Suction lift too high.

e. Pump not primed (suction lifts 15to 25 feet).

f. Foreign material lodged undervalve.

g. Static discharge head too high.a. Suction hose or strainer clogged.b. Suction leak.c. Throttle lever not in full-speed

position.

d. Diameter of discharge hose toosmall.

e. Foreign material lodged undervalve.

f. High static discharge head.

Corrective action

a. Fill fuel tank.b. Drain fuel tank. Service

fuel strainer para 3-9). Refill tankwith fresh, uncontaminated fuel.

c. Operate switch to ON position (fig.2-2).

a. Service fuel strainer (para 3-9).b. Fill fuel tank.a. Clean hose or suction strainer.b. Tighten all suction connections.c. Submerge suction strainer and

hose.d. Reduce suction lift to less than 25

feet.e. Prime pump (para 2-10c).

f. Remove foreign material fromvalve.

g. Lower discharge bead.a. Clean suction hose or strainer.b. Tighten all suction connections.c. Operate throttle l e v e r s o

that engine operates at fullgoverned speed (fig. 2-2).

d. Use 4-inch discharge hose.

e. Remove foreign material fromvalve.

f. Lower discharge head.

Sect ion V. MAINTENANCE OF FUEL STRAINER

3-8. General release the fuel bowl (3). Remove the fuel bowl and

The fuel strainer is installed in the fuel system gasket. Empty the contents of the fuel bowl and

between the fuel tank and the engine carburetor. It wipe it clean with a lint-free cloth.

filters dirt, sand, and moisture from the fuel, c. If necessary, remove the fuel filter element (4)preventing these foreign materials from disrupting and clean it with an approved cleaning solvent.

the operation of the carburetor. Shake out excess solvent.

3-9. Fuel Strainer Serviced. Reassemble the fuel strainer parts and tighten

t h e b a i l n u t t o p o s i t i o n t h e f u e l b o w la. Close fuel shutoff valve (2, fig. 3-1).b. Loosen bail nut (5) and swing the bail (6) to

e. Open the fuel shutoff valve and check forleaks. Correct any leaks.

3-3

1. Fuel tank2. Fuel shutoff valve3. Fuel bowl4. Fuel filter element5. Bail nut6. Bail

Figure 3-1. Fuel strainer service

3-4

CHAPTER 4

ORGANIZATIONAL MAINTENANCE INSTRUCTIONS

Section I. SERVICE UPON RECEIPT OF MATERIEL

4-1. GeneralInspection and servicing of received equipment isdescribed in paragraph 2-1. New pumps areshipped from the factory with the diaphragmsremoved and packed separately. Organizationalmaintenance is normally responsible for theassembly of the diaphragms into the pumps prior toinstallation.

4-2. Diaphragm InstallationInstall the diaphragm in a new pump as follows:

a. With the ignition switch (2, fig. 2-2) in OFFposition, turn over the engine so that the diaphragmplunger is in the bottom position.

b. Remove the suction and discharge assemblies(para 4-14).

c. Remove the nuts (6, fig. 4-4) and lock washers(7) that secure the diaphragm pot (9) to thediaphragm ring (20); remove the diaphragm pot.

d. Remove the four nuts ( 10) that secure thelower diaphragm plate (11 ) to the upperdiaphragm plate (18); remove the lowerdiaphragm plate.

e. Make sure all parts are clean. If necessary,wire-brush the upper and lower diaphragm platesand rinse with water. Remove any sharp edges witha fine file or stone.

f. The natural configuration of the diaphragm isdish-shaped. Install the diaphragm on the upperdiaphragm plate (18) with the bottom of the dishtoward the floor. Aline the holes in the diaphragmwith the holes in the upper diaphragm plate andinstall the lower diaphragm plate (11). Secure withfour nuts (10). Tighten the nuts evenly andalternately to prevent diaphragm distortion.

g. Position the diaphragm pot (9) on the pump,taking care that the edges of the diaphragm areevenly spaced around the periphery of the pot anddiaphragm ring (20). Secure with nuts (6) and lockwashers (7). Tighten the nuts evenly and alter-nately to prevent diaphragm distortion.

h. Install the suction and discharge assemblies(para 4-16).

i. Turn over the engine and pump a number ofrevolutions to make sure all parts are free.

Section II. REPAIR PARTS, SPECIAL TOOLS, AND EQUIPMENT

4-3. Special Tools and Equipment 4-4. Maintenance Repair Parts

No special tools or equipment is required for Repair parts and equipment are listed andorganizational maintenance of the reciprocating illustrated in the repair parts and special tools listpump. covering organizational maintenance for this pump.

Refer to TM 5-4320-251-24P.

Section III. PREVENTIVE MAINTENANCE CHECKSA N D S E R V I C E S

4-5. GeneralThis section lists the preventive maintenancechecks and services which shall be performed on aquarterly basis by organizational maintenancepersonnel. It includes and expands upon thepreventive maintenance services performed dailyby operator/ crew and includes additional serviceswhich are allocated to organizational maintenance.

(QUARTERLY)

4-6. Preventive Maintenance Checks andServices

Refer to table 4-1 for a listing of the preventivemaintenance checks and services which areallocated to organizational maintenance. Servicethe engine as directed in TM 5-2805-257-14.

4-1

Sequencenumber

1

2

3

4

5

6

7

8

9

10

11

12

Table 4-1. Preventive Maintenance Checks and Services

Organizational Maintenance Category Quarterly Schedule

Item to beinspected

Fuel tank

Oil in pump gear case

Engine mounting

Fuel strainer

Fuel line and fittings

Pump rotation

Pump diaphragm

Suction and dischargeassembly

Plunger rod and bearings

Wheels and axle

Hoses

Water leaks

Procedures

Drain and refill tank if fuel is dirty orcontaminated. Replace fuel tank ifinterior is rusted or corroded, or iftank leaks or is severely dented.

Check for contamination. Make sureoil was changed at recommendedinterval.

Tighten loose hardware. Replacemissing hardware.

Check for dirt and water in bowl.Replace strainer if damaged.

Replace damaged fuel lines andfittings.

Use starting rope to check for freerotation. Determine cause ofbinding and repair or report todirect support maintenance.

Check for cracks, tears, holes, andleaks. Replace if damaged.

Remove valves and check for freemovement and for proper seating.Replace defective parts.

Replace parts if play is excessive, orparts are distorted or damaged.

Repair or replace damaged parts ifwheels fail to roll easily.

Replace hoses if cut, punctured, orabraded, or if fittings are damaged.

Tighten fittings and hardware tocorrect leaks. Replace gaskets ifnecessary.

Paragraphreference

See paragraphs 4-10 through 4-12 for fuel tank replacement.

See current L.O.

See figure 5-1.

See paragraph 3-9.

See paragraphs 4-10 through 4-12.

See paragraph 2-1 b ( 4).

See paragraphs 4-18 through 4-20.

See paragraphs 4-14 through 4-16 for parts replacement.

See paragraphs 4-18 through 4-20.

See paragraphs 4-22 through 424.

See paragraph 2-1 b (7).

Section IV. TROUBLESHOOTING

4-7. G e n e r a l malfunction, report the trouble to direct supportThis section describes troubles which might occur maintenance. Refer to TM 5-2805-257-14- forduring operation of the reciprocating pump, along troubles that relate solely to the engine.with the probable causes and corrective actions 4-8. Organizational M a i n t e n a n c e T r o u -relating to the troubles. Only those malfunctions bleshooting Chart.which are within the scope of organizational Refer to table 4-2 for troubleshooting which ismaintenance are included in this chart. If corrective allocated to the organizational level of main-actions given in this chart do not correct the tenance.

Table 4-2. Organizational Maintenance Troubleshooting Chart

Malfunction

1. Engine fails to start

2. Engine starts but pump fails topump.

3. Pump fails to produce ratedoutput.

Probable cause

a. Fuel line clogged.b. Fuel filter element clogged.a. Defective suction or discharge

valve.b. Defective diaphragm.

c. Cracked diaphragm pot.

a. Suction or discharge valve notseating properly.

Corrective action

a. Clear or replace fuel line.b. Replace fuel filter element.a. Replace defective valve (para 4-14

through 4-1 6).b. Replace diaphragm (para 4-18

through 4-20 ).c. Replace diaphragm pot (para 4-18

through 4-20 ).a. Repair or replace valve (para 4-14

through 4-1 6).

4-2

Table 4-2. Organizational Maintenance Troubleshooting Chart—Continued

M a l f u n c t i o n

4. Pump is noisy

5. Wheels fail to turn or turn withdifficulty.

P r o b a b l e c a u s e

b. Slight leak in diaphragm.

c. Cracked diaphragm pot.

a. Plunger bearing defective.

b. Plunger spring length too long,allowing plunger to strike pot.

c. Debris caught in diaphragm pot.a. Wheel defective.b. Axle bent.

Corrective action

b. R e p l a c e d i a p h r a g m ( p a r a 4 - 1 8through 4-20 ).

c. Replace diaphragm pot (para 4-18through 4-20 ).

a. Replace plunger bearings (para 4-18 through 4-20).

b. Adjust spring length (para 4-20).

c. Clean pot of debris.a. Replace wheel.b. Straighten or replace axle (para 4-

22 through 4-24).

Section V. MAINTENANCE OF FUEL SYSTEM

4-9. Description 4-10. DisassemblyThe fuel system consists of the fuel tank, fuel Disassemble the fuel tank, lines, fittings, and fuelstrainer with shutoff valve, and the fuel lines and strainer in the sequence shown in figure 4-1. Drainfittings. The fuel tank is mounted with straps which the fuel tank prior to removing it from thesecure it to brackets that are bolted to the pump equipment. Unless chain or cap is damagedassembly. val of permanently secured cap is unnecessary.

4-3

Figure 4-1. Fuel tank, lines, and fittings, disassembly and reassembly.

4-4

KEY to fig. 4-1:1. Tube nut2. Copper tube3. Adapter4. Elbow5. Fuel strainer6. Nipple7. Cap screw8. Nut9. Leek washer

10. Flat washer

11. Fuel tank strap12. Fuel tank cap13. Chain14. Fuel tank15. Cap screw16. Flat washer17. Lower fuel tank bracket18. Cap screw19. Lock washer20. Lifting bail21. Upper fuel tank bracket

4-11. Cleaning and Inspectiona. Clean all parts with an approved cleaning

solvent. Flush the fuel line with solvent and blow itout with clean, filtered compressed air.

Warning: The fuel tank is normallyreplaced if damaged. However, if expediencyrequires that the fuel tank be repaired by anymethod involving heat or flame, steam-cleanthe tank thoroughly to assure that all traces ofgasoline are removed before starting repairs.Failure to purge the tank of all traces of fuelfumes before applying heat or flame may resultin a severe explosion.

b. Inspect the fuel tank for cracks, leaks, and

severe dents. Make sure the cap and chain arepresent and are in good condition,

c. Inspect the fuel strainer for a cracked bowl orbody, damaged threads, and distorted bowl bail.Make sure the bowl glass is clear so that the fuel isvisible in the bowl. Check the fuel shutoff valve onthe fuel strainer. Make sure it operates freely andeffectively.

d. Inspect the fuel line for cracks, dents,damaged tube nuts, clogging, and other damage;replace the fuel line.

e. Inspect the fuel tank straps for cracks,distortion, and other damage; replace damagedstraps:

f. Inspect all other parts for cracks, distortion,and damaged threads; replace damaged parts.

4-12. Reassemblya. Reassemble the fuel system as shown in figure

4-1.b. After reassembly, fill the fuel tank with fuel,

making sure the fuel shutoff valve on the fuelstrainer is open. Check the entire fuel system forleaks. Correct any leaks before restoring the unit toservice.

Section VI. MAINTENANCE OF PUMP SUCTION ANDDISCHARGE ASSEMBLIES

4-13. Description relieve the vacuum caused by the diaphragm as it isa. The pump suction assembly is mounted on pulled upward (A, fig. 4-2 ). It prevents reverse

one side of the diaphragm pot to control the fluid movement of the water as the diaphragm is pushedmovement at the inlet side of the pump. It consists downward, since the check valve is pushed tightlymainly of a check valve mounted in a housing. This against its seat, presenting the water from escapingcheck valve allows water to flow into the pump to from the suction port (B, fig. 4-2).

4-5

Figure 4-2. Schematic diagram showing operation of reciprocating pump.

b. The pump discharge assembly is mounted on pot (B, fig. 4-2 ). It closes to prevent dischargedthe side of the diaphragm opposite the suction water from returning to the diaphragm pot on theassembly. It controls the fluid movement at the upward stroke of the diaphragm (A, fig. 4-2).outlet side of the pump. It consists mainly of a c. An accumulator is mounted on the suctioncheck valve mounted in a housing. This check valve check valve housing. This accumulator reduces theallows water to flow out of the pump as the surging of the fluid as the pump diaphragmdiaphragm is forced downward into the diaphragm changes stroke direction. At the end of the intake

4-6

part of the pump cycle, a column of fluid in the the accumulator minimizes the rocking of the pumpsuction line is in movement toward the pump. As and lines resulting from the starting and stopping ofthe diaphragm reverses its stroke, the column of the fluid column.fluid is suddenly stopped. This would normally 4-14. Disassemblyresult in a surge in the suction line. This surge isminimized because the shock is absorbed by the

a. Disassemble the discharge assembly as shownin figure 4-3, items 1 through 17.

cushion of air in the accumulator. In this manner,

4-7

Figure 4-3.

4-8

KEY to fig. 4-3:1. Discharge nipple2. Nut3. Washer4. Discharge elbow5. Gasket6. Screw7. Check valve seat8. Screw9. Lock washer

10. Valve weight11. Valve weight12. Valve flap13. Stud14. Nut15. Flat washer16. Discharge flange17. Gasket18. Stud

19. Suction nipple20. Accumulator cap21. Gasket22. Nut23. Flat washer24. Accumulator25. FILL HERE TO PRIME label26. SUCTION label27. Gasket28. Cap screw29. Lock washer30. Check valve seat31. Machine screw32. Lock washer33. Valve weight34. Valve weight35. Valve flap36. Stud

b. Disassemble the accumulator and suctionassembly as shown in figure 4-3, items 19 through35.

c. Do not remove the studs (36) from thediaphragm pot unless they are damaged andrequire replacement.

4-15. Cleaning and Inspectiona. Clean the rubber parts by wiping with a clean

dry cloth.

b. Clean all remaining parts with an approvedcleaning solvent; dry thoroughly.

c. Inspect the suction and discharge valve flapsfor cracks, deterioration, brittleness, and otherimperfections which could result in valve leakage.Replace damaged valve flaps.

d. Inspect the check valve seats for cracks,distortion, and damage to the valve seating area.Remove small nicks with a fine file or stone.Replace a damaged seat.

e. Inspect the accumulator for cracks, distortion,dam aged threads, and damaged gasket surfaces;replace a damaged accumulator.

f. Inspect all other parts for cracks, distortion,and damaged threads; replace damaged parts.

4-16. Reassemblya. Reassemble the accumulator and suction

assembly as shown in figure 4-3, items 19 through35.

Note. Take care when assembling the discharge andsuction assemblies. Make sure the valve flaps (12 and 35) arecentered on the valve seats (7 and 30 ) and that the flaps arefree from distortion and puckering when the related parts areassembled and secured into place.

b. Reassemble the discharge assembly as shownin figure 4-3, items 1 through 17.

Section VII. MAINTENANCE OF DIAPHRAGM AND PLUNGER ASSEMBLY

4-17. Descriptiona. The diaphragm is a tough, flexible rubber ring

which is mounted between the diaphragm pot andthe diaphragm ring which is secured to the frame.The center of the diaphragm is secured to theplunger assembly which forces the center of thediaphragm into and out of the diaphragm pot. Onthe upward stroke, a partial vacuum is createdbetween the diaphragm and the pot. This suckswater through the suction valve and into the pot.On the downward stroke, the suction valve closesand the water in the pot is forced out through thedischarge valve. In this manner water is trans-ferred, under pressure, from the suction to thedischarge side of the pump to cause the requiredpumping action.

b. The plunger assembly is powered by thecrankshaft of the pump gear case. The bearing

housing and bearing assembly mounted at the topof the plunger assembly is also mounted on the endof the crankshaft so that it rotates with the shaft.This imparts an up-and-down reciprocating motionto the plunger assembly. On the upward stroke, theplunger rod pulls the upper diaphragm plate andthe diaphragm up. On the downward stroke, theheavy plunger spring pushes the diaphragm platedownward. By spring-loading the downwardstroke, damage to the pump will be minimized ifrocks or other debris is pulled into the pump duringoperation.

4-18. Disassemblya. Remove the suction and discharge assembly

(para 4-14).b. Disassemble the diaphragm and plunger

assembly following the sequence shown in figure 4-4.

4-9

Figure 4-4. Diaphragm and plunger, disassembly and reassembly.

4-10

KEY to fig. 4-4.

1. Plug 14 Plunger nut2. Nut 15. Spring3. Lock washer 16. Spring washer4. U-bolt 1 i. Lubrication fitting5. Drawbar 18. Upper diaphragm plate6. Nut 19. Cap screw7. Leek washer 20. Diaphragm ring8. Ribbed bolt 21. Protective cap9. Diaphragm pot 22. Retaining ring

10. Nut 23. Retaining ring11. Lower diaphragm plate 24. Roller bearing12. Diaphragm 25. Lubrication fitting13. Plunger rod 26. Bearing housing

c. To remove the bearing housing (26) andbearing (24), pry out the protective cap (21) toprovide access to the parts. Remove the retainingring (22), and pull the assembled bearing andhousing from the end of the crankshaft with abearing puller.

d. Remove the retaining ring (23) and slip thebearing (24) from the housing (26).

4-19. Cleaning and Inspection

a. Clean the bearing by placing it in a wirebasket and immersing it into a container of ap-proved cleaning solvent. Agitate it thoroughly. Ifnecessary to dislodge caked or hardened grease,strike the flat of the bearing aginst a soft woodenblock. When the bearing is clean, blow it dry withfiltered compressed air. Do not allow bearing tospin. Dip it in light engine oil and wrap it in lint-free paper to protect it from dust and dirt.

b. Wash the diaphragm with water and wipedry.

c. Clean all remaining parts with approvedcleaning solvent; dry thoroughly.

d. Inspect the bearing for rough, catching, andbinding operation, excessive looseness betweenballs and races, scoring, and other damage; replacea damaged bearing.

e. Inspect the diaphragm for wear, cracks,brittleness, deterioration, damage to seating sur-faces, cuts, bruises, and signs of leaking; replace adam aged diaphragm.

f. Inspect the diaphragm pot and diaphragmring for cracks, distortion, and damaged threads.Clean up sl ightly damaged threads. Replacedamaged parts.

g. Inspect the lower diaphragm plate and upperdiaphragm plate for cracks and distortion. Inspectthe studs on the upper diaphragm plate forlooseness and for damaged threads. Replacedamaged parts.

h. Inspect the plunger spring for cracks,distortion, and compression. Free length of thespring should be 8¼ inch. Replace a damagedspring.

i. Inspect the plunger rod for distortion andworn or damaged threads. Replace if damaged.

j. Inspect the bearing housing for cracks,distortion, worn or damaged threads, and wornbearing seating surfaces. Replace a damagedbearing housing.

k. Check the end of the crankshaft of the pumpgear case. If the bearing surface is damaged or ifthe end of the crankshaft is distorted or misalined,report the condition to direct support maintenance.

4 - 2 0 . R e a s s e m b l y

a. Reassemble the diaphragm and plungerassembly as shown in figure 4-4.

b. Pack the roller bearing( 24) with grease andslip it into the bearing housing (26) until it is fullyseated. Be sure to press against the outer race of thebearing only. Secure the bearing with a retainingring (23).

c. Drive the assembled bearing and housing ontothe end of the crankshaft. Secure by installing theretaining ring (22).

d. After the diaphragm ring (20) is installed onthe frame, position the upper diaphragm plate (18),spring washer (16), plunger spring (15), andplunger nut (14) on the plunger rod (13). Duringassembly, lubricate the lower end of the plunger rodwith grease. Tighten the plunger nut onto the rod sothat the spring is compressed to a length of 8 +1 / 32 inch.

e. Turn the assembled plunger and spring intothe threaded bore of the bearing housing (26) onthe crankshaft. Tighten the plunger nut (14)against the bearing housing to lock the parts. Takecare not to disrupt the length adjustment of thespring.

f. Install the diaphragm on the pump as directedin paragraph 4-2.

g. Refer to current lubrication order andlubricate all lube fittings.

Section VIII. MAINTENANCE OF WHEELS AND AXLE

4-21. Description 4-22. Disassembly

The pump wheels are mounted on a one-piece, a. Lift the pump assembly and place blockinground, bar-stock axle which, in turn, is mounted on under the pump frame so that the pump wheels justthe pump frame with U-bolts. The wheels have clear the ground.semi-pneumatic tires. Each wheel, tire, and bearing b. Disassemble the wheels and axle from theunit is treated only as a complete assembly and pump assembly as shown in figure 4-5.should not be disassembled for maintenance orrepair. 4-11

1. Nut 6. Engine guard 11. Nut

2. Lock washer 7. Cotter pin 12. Look washer

3. U-bolt 8. Washer 13. U-bolt

4. Clamp 9. Wheel 14. Axle

5. Hose 10. Lube fitting 15. Base

Figure 4-5. Wheels and axle, disassembly and reassembly.

4-23. Cleaning and Inspectiona. Clean the wheel and tire assembly with a cloth

dampened lightly with an approved cleaningsolvent.

b. Clean all remaining parts with cleaningsolvent; dry thoroughly.

c. Inspect the wheel and tire assembly for wear,cuts, and damage to the tire, distortion of the wheel,and rough, binding, or catching operation of thewheel bearing. Replace a damaged wheel and tireassembly.

d. Inspect the axle for wear or scoring of thewheel mounting surfaces, for misalinement, and forcracks. Replace a damaged axle.

4-24. Reassemblya. Reassemble the wheels and axle as shown in

figure 4-5.b. Remove the blocking from under the pump

frame. Lubricate the wheels as indicated in thecurrent lubrication order. Check that the pumpwheels roll freely and easily. Correct anydeficiencies.

4-12

CHAPTER 5

DIRECT SUPPORT AND GENERAL SUPPORT

MAINTENANCE INSTRUCTIONS

Section I. REPAIR PARTS, SPECIAL TOOLS, AND EQUIPMENT

5-1. Special Tools and Equipment 5-2. Maintenance Repair PartsNo special tools and equipment are required for the Repair parts and equipment are listed anddirect support and general support maintenance of illustrated in the repair parts and special tools listthe reciprocating pump. covering direct support and general support

maintenance for this pump. Refer to TM 5-4320-251-24P.

Section II. TROUBLESHOOTING

5-3. General scope of organizational maintenance and

This section describes troubles which might occur operator / crew maintenance, refer to the ap-during operation of the reciprocating pump, along plicable chapters of this publication.with the probable causes and corrective actions 5-4. Direct Support and General Supportrelating to the troubles. Only those functions which Maintenance Troubleshootingare solely within scope of direct support and general Refer to table 5-1 for troubleshooting which issupport maintenance are listed. Fortroubleshooting procedures which are within the

allocated to the direct support and general supportlevels of maintenance.

Table 5-1. Direct Support and General Support Maintenance Troubleshooting

Malfunction Probable cause Corrective action

1.

2.

3.

4.

5.

Engine seised, binds or scrapeswhen turned over.

Pump seized, binds or scrapeswhen turned over.

Pump is noisy or vibrates ex-cessively during operation.

Pump heats up during operation.

Engine labors excessively to drive

Engine requires overhaul.

a. Defective bearing in gear case.

b. Defective gears in gear case.

Defective gears or bearings.

Defective bearings.

a. Pump and engine misalined.

Replace engine.

a. Repair or overhaul gear case (para6-2 through 6-4).

b. Repair or overhaul gear case (para6-2 through 6-4).

Replace defective gears of bearings(para 6-2 through 6-4).

Replace defective bearings (para 6-2 through 6-4).

a. Aline pump and engine (para 5-9).pump. b. Bearings seizing in gear case. b. Replace defective bearings (para

6-2 through 6-4 ).

Section III. GENERAL MAINTENANCE

5-5. General 5-6. CleanlinessThis section describes general maintenance a. Take care to assure that the workplace ispractices which must be considered when per- clean before starting to disassemble the gear case.forming direct support and general support b. Steam-clean the exterior of the gear casemaintenance on the reciprocating pump. Follow the before starting disassembly to prevent the dirt frominstructions contained herein to help assure the entering the bearings.success of the repairs or overhaul. c. If compressed air is used to clean the parts,

5-1

make sure the compressed air is free from dirt and fresh cleaning solvent. Agitate the bearings in thecontaminants. solvent to remove all traces of old lubricant.

d. Protect disassembled parts from blowing sand b. After the bearings are cleaned, dry them withand dust which could later cause rapid wear of the clean, filtered compressed air. Take care to preventgears and bearings. spinning the bearings with the compressed air jet.

5-7. Care of Bearings c. Dip the cleaned bearings in clean engine oil

a. Clean bearings by placing them in a wireand immediately wrap them in lint-free paper to

basket and immersing them into a container ofprevent the entry of dust and dirt.

Section IV. REMOVAL AND INSTALLATION OF MAJOR COMPONENTS

5-8. Removal c. Disassemble the diaphragm and plungera. Disassemble the fuel system components from assembly from the pump (para 4-18).

the pump (para 4-10). d. Remove the cap screws (1, fig. 5-1), nuts (2),b. Disassemble the suction and discharge and lock washers (3) that secure the coupling guard

assemblies (para 4-14). (4) to the frame: remove the coupling guard.

Figure 5-1. Major components of reciprocating pump.

5-2

KEY to fig. 5-’: 13. Cap screw1. Cap screw 14. Flat washer2. Nut3. Lock washer4. Coupling guard5. Pump gear case6. Damper spider7. Setscrew8. Coupling half9. Key

10. Setscrew11. Coupling half12. Key

15. Nut16. Lock washer17. Flat washer18. Shim19. Shim20. Shim21. Cap screw22. Lock washer23. Engine mounting bracket24. Engine mounting bracket25. Engine

e. The pump gear case mounting hardware wasremoved when the diaphragm ring of thediaphragm and plunger assembly was removed.Pull straight out on the pump gear case to removeit. This will free the damper spider (6) of thecoupling.

f. Remove the coupling halves (8 and 11) andkeys (9 and 12) from the gear case and engineshaft.

g. Remove the cap screws (13), flat washers(14), nuts (15), lock washers (16), and flat washers(17 ) that secure the engine mounting brackets (23and 24) to the frame; lift the assembled engine andmounting brackets from the frame.

h. Remove the cap screws ( 21 ) and lock washers(22) that secure the engine mounting brackets (23and 24) to the engine (25) ; remove the brackets.

5-9. Installation

a. Position the assembled pump gear case (5, fig.5-1) on the pump frame. Position the diaphragmring (21, fig. 4-4) on the pump frame. Secure bothparts to the frame with four cap screws (20).

b. Install the keys (9 and 12, fig. 5-1) and thecoupling halves (8 and 11 ) on the shafts of the gearcase and engine; secure with setscrews ( 7 and 10).

c. Install the engine mounting brackets (23 and24) on the engine (25) with cap screws (21) andlock washers (22).

d. Install the damper spider (6) on the gear casecoupling half (8).

e. Position the engine (25) with assembledmounting brackets (23 and 24) on the pump frame.Slide it toward the pump gear case, checking thealinement of the engine coupling half (11) with thedamper spider (6) on the gear case coupling half(8). If necessary, add shims (18, 19, and 20)between the engine mounting brackets and pumpframe if necessary to bring the parts into alinement.Make sure the centerline of the gear case inputshaft is alined with the centerline of the engine shaftand secure the engine mounting brackets (23 and24) to the pump frame with cap screws (13), flatwashers ( 14), nuts (15), lock washers ( 16), and flatwashers ( 17).

f. R o t a t e t h e e n g i n e cranksha f t s evera lrevolutions to check that no binding exists betweenthe engine and pump gear case.

g. Install the coupling guard (4) over the pumpcoupling.

h. Install the diaphragm and plunger assemblyon the pump (para 4-20).

i. Install the suction and discharge assemblies onthe pump (para 4-16).

j. Install the fuel system components on thepump (para 4-12).

5-3

CHAPTER 6

REPAIR OF RECIPROCATING PUMP GEAR CASE

6-1. Description

a. The pump gear case provides the torquemultiplication and speed reduction necessary todrive the pump plunger at the rate of speednecessary for efficient operation. The coupling half,which is driven by the engine, is mounted on theinput shaft of the pump and drives the gear case atengine speed. This input shaft has integral pinionteeth which engage the internal gear to provide aninitial speed reduction of 8.083:1.

b. The internal gear is pressed onto and drives apinion shaft. This pinion shaft is roller bearingmounted in the housing and drives a spur gear.This engagement provides the second speedreduction, this one having a 7.56:1 ratio. The spur

gear is keyed to the ball-bearing-mountedcrankshaft which drives the pump plunger anddiaphragm assembly. The total speed reductionthrough the gear case is approximately 61:1. If theengine is operating at 3000 rpm, the pump plungerwill cycle approximately 49 times per minute.

c. The gear case in which the shafts and gearsare installed is sealed and contains gear oil to keepthe parts lubricated. The lubrication fitting on thelower side of the case regulates the level of lubricantwhich can be poured into the case.

6-2. Disassemblya. Disassemble the gear case following the

sequence shown in figure 6-1.

6-1

Figure 6-1.

6-2

KEY to fig. 6-1:

1. Pipe plug2. Shoulder bolt3. Cap screw4. Cap screw5. Shoulder bolt6. Nut7. Lock washer8. Gasket9. Washer

10. Spur gear11. Key12. Retaining ring13. Crankshaft14. Retaining ring15. Ball bearing16. Washer17. Internal gear18. Spur gearshaft

19. Expansion plug20. Sleeve bearing21. Roller bearing22. Gear housing23. Cap screw24. Lock washer25. Eccentric gasket26. Retaining ring27. Ball bearing28. Spacer29. Input shaft30. Grease seal31. Eccentric housing32. Expansion plug33. Sleeve bearing34. R oiler bearing35. Lubrication cup36. Ball bearing37. Gear housing cover

b. Remove the pipe plug (1) to drain the gear oilfrom the gear case prior to disassembly.

c. After removing the cap screws (3 and 4).shoulder bolts (2) and (5), nuts (6), and lockwashers (7), screw a 5/8-11 x 3-inch fully threadedbolt in the threaded bore in the gear housing cover(37) opposite the crank end of the crankshaft.Continue to turn the screw until the gear housingcover with its assembled parts is freed from the gearhousing (22). Remove the gasket (8).

d. Use a conventional gear puller having two 5/8 -1 l-inch puller screws to pull the spur gear (10)from the crankshaft (13) ; remove the key (11).

e. Remove the retaining ring (12) and press thecrankshaft (13) from the gear housing (22) .Remove the retaining ring ( 14) and press the ballbearing (15) from its seat in the gear housing.

f. Do not press the gearshaft (18) from theinternal gear (17) unless either part is damaged andrequires replacement.

g. If the sleeve bearing (20) or roller bearing(21) requires replacement, pierce the expansionplug (19) with a sharp punch and pry the plug fromthe gear housing. Use a driver with a slightlysmaller outside diameter than the needle bearingand press the sleeve bearing and roller bearing fromthe gear housing.

h. After removing the eccentric housing (31)containing the input shaft assembly, remove theretaining ring (26 ) and press the assembled inputshaft (29), bearings (27eccentric housing.

i. Press the bearingsthe input shaft (29).

j. Pry the gease sea

and spacer (28 ) from the

27) and spacer (28) from

(30) from the eccentrichousing (31 ).

k. If the sleeve bearing (33) and roller bearing(34) in the gear housing cover are damaged, use asharp punch to pierce the expansion plug (32) inthe cover and pry out the plug. Press the sleeve

bearing and roller bearing from the gear housingcover.

l. If the ball bearing (36) seated in the gearh o u s i n g c o v e r i s d a m a g e d a n d r e q u i r e sreplacement, use an internal puller to pull it fromthe cover.

6-3. Cleaning and Inspection

a. Discard and replace expansion plugs, oil seals,and gaskets.

b. Clean the bearings as directed in paragraph 5-7.

c. Clean all remaining parts with an approvedcleaning solvent. Use a fiber-bristled brush ifnecessary to remove caked or hardened lubricantsfrom the gear teeth or other parts.

d. Inspect the gears for chipped, cracked, ormissing gear teeth, distortion, worn bores, andother damage; replace damaged gears.

e. Inspect the input shaft and pinion shaft formisalinement, damaged gear teeth, and scored orworn bearing mounting surfaces; replace damagedparts.

f. I n s p e c t t h e c r a n k s h a f t f o r c r a c k s ,misalinement, damaged retaining ring seat, worn ordamaged keyway, and damaged bearing mountingseats; replace a damaged crankshaft.

g. Inspect the gear housing and gear housingcover for cracks, distortion, damaged gasketsurfaces, damaged threads, and worn or scoredbearing seats. Check that oil passages to rollerbearing seats are open. Remove burrs and nickswith a fine file or stone. Replace ‘a damaged gearhousing or cover.

6-4. Reassembly

a. Reassemble the pump gear case as shown infigure 6-1.

b. When installing the ball bearing (36) in thegear housing cover (37), press only against theouter race of the bearing. Make sure the bearing isfully seated in the cover.

c. Press the roller bearing (34) and the sleevebearing (33) into the bearing bore of the gearhousing cover (37). Make sure that the shoulder ofthe sleeve bearing is fully seated against the cover.

d. When assembling the input shaft (29) andbearing (27 ), press the one bearing tightly againstthe side of the pinion teeth. Secure the bearing inplace with Loctite bearing mount (manufacturedby Loctite Corporation, Newington, Connecticut,as Part Number 18771-035). Install the spacer(28 ) and press on the second bearing. Seal it inplace with Loctite bearing mount. Make sure thefirst bearing is rigidly against the pinion teeth andthat the second bearing holds the spacer tightlybetween the bearings. Allow the Loctite bearingmount to cure for 15 minutes to 4 hours beforeassembling the parts into the bearing housing (31).

6-3

e. After the assembled input shaft and bearingsare pressed into the eccentric housing (31), securethem in place with the retaining ring (26). Press theseal (30 ) into the seal seat on the eccentric housing,taking care to prevent the shaft keyway fromcutting the inner lip,

Note: Do not install the assembled input shaft and ec-centric housing on the gear housing cover until the gearhousing cover is installed on the gear housing.

f. If the gearshaft (18) was removed from theinternal gear (17 ), press the gear onto the shaftuntil the hub on the inside of the gear is snugagainst the pinion teeth of the shaft.

g. Press the roller bearing, (21) and the sleevebearing (20) in the gear housing (22) so that theshoulder of the sleeve bearing is seated tightlyagainst the housing.

h. Press the ball bearing (15) onto thecrankshaft (13 ); secure with a retaining ring (12).Press the assembled bearing and crankshaft intoposition in the bore of the gear housing. Use theretaining ring ( 14) to position the parts in thehousing.

i. Install the key (11) in the keyway of thecrankshaft and press the spur gear (10 ) onto thecrankshaft Until it is seated against the shaftshoulder.

j. Position the gear housing on the bench withthe flange facing upward. Position the assembledinternal gear (17 ) and gearshaft ( 18) in place onthe gear housing. Install the washers ( 9 and 16) onthe ends of their respective shafts.

k. Place the gasket (8) on the gear housingflange. Position the gear housing cover withassembled parts over the gear housing so that theends of the shafts engage their respective bearings.Use a plastic mallet to drive the gear housing coverinto place.

l. Secure the gear housing cover to the gearhousing with cap screws (3 and 4), shoulder bolts(2 and 5), nuts (6), and lock washers (7). Installthe shoulder bolts (2 and 5 ) first and tighten themevenly and alternately until they are snug, makingsure the shafts and the internal gears rotate freelywithout gear lash. Install the cap screws (3 and 4),lock washers (7), and nuts (6) and tighten themevenly and alternately. After all hardware istightened, check again to assure that the shaftsrotate freely.

m. Position the assembled input shaft (29),eccentric housing (31 ), and gasket (25) on the gearhousing cover. The thicker part of the eccentrichousing marked TOP must be up when the pumpgear case is in the upright position. This willprovide proper engagement between the pinion ofthe input shaft and the internal gear. Secure theeccentric housing with cap screws (23 ) and lockwashers (24). Tighten the, cap screws evenly andalternately to prevent distorting the housing.

n. Position the expansion plugs (19 and 32) intheir respective bores with the convex side outward.Strike the convex side sharply with a hammer toexpand each plug into place.

o. Install the gear case on the pump (para 5-9).

6-4

CHAPTER 7

ADMINISTRATIVE STORAGE AND INSTRUCTIONS FOR

DESTRUCTION OF MATERIEL TO PREVENT ENEMY USE

Section I. ADMINISTRATIVE STORAGE

7-1. Administrative Storage shall be in accordance with TM 740-90-1.

Administrative storage for the reciprocating pump

Section Il. DESTRUCTION OF MATERIEL TO PREVENT ENEMY USE

7-2. Destruction of Materiel to Prevent Enemy For procedures regarding destruction of equipmentUse to prevent enemy use, refer to TM 750-244-3.

7-1

APPENDIX A

REFERENCES

A-1. Fire Protection

TB 5-4200-200-10

A-2. Lubrication

LO 5-2805-257-12C9100-ILFSC Group 91

A-3. Painting

TM 9-213

A-4. Radio Interference Suppression

TM 11-483

A-5. Maintenance

TM 5-2805-257-14TM 5-2805-257-14PTB ENG 347

TM 9-207

TM 38-750

A-6. Shipment and Storage

TB 740-93-2

TM 740-90-1TM 38-230

Hand portable fire extinguishers approved forArmy users.

Engine, Gasoline 3 HP, Military Standard Model2A016-3.

Fuels, oils, lubricants and waxes.

Painting instructions for field use.

Radio Interference Suppression.

Engine, Gasoline, 3 HP, Military Standard Model2A016-3, FSN 2805-072-4871.

Winterization Techniques for Engineer Equip-ment.

Operating and Maintenance of Army Materiel inExtreme Cold Weather (0° to–65° F).

The Army Maintenance Management System.

Preservation of USAMECOM MechanicalEquipment for Shipment and Storage.

Administrative Storage of Equipment.Preservation, Packaging and Packing of Military

Supplies and Equipment.

A-1

APPENDIX B

MAINTENANCE ALLOCATION CHART

Section I. INTRODUCTION

B-1. Generala. This section provides a general explanation of

all maintenance and repair functions authorized atvarious maintenance levels.

b. Section II designates overall responsibility forthe performance of maintenance functions on theidentified end item or component. The im-plementation of the maintenance functions uponthe end item or component will be consistent withthe assigned maintenance functions.

c. Section III lists the special tools and testequipment required for each maintenance functionas referenced from Section II. (Not Applicable)

d. Section IV contains supplemental in-structions, explanatory notes and / or illustrationsrequired for a particular maintenance function.

B-2. Explanation of Columns in Section IIa. Group Number, Column (l). The functional

group is a numerical group set up on a functionalbasis. The applicable functional grouping indexes(obtained from TB 750-93-l, Functional GroupingCodes ) are listed on the MAC in the appropriatenumerical sequence. These indexes are normally setup in accordance with their function and proximityto each other.

b. Functional Group, Column (2). This columncontains a brief description of the components ofeach functional group.

c. Maintenance Functions; Column (3). Thiscolumn lists the various maintenance functions (Athrough K ) and indicates the lowest maintenancecategory authorized to perform these functions.The symbol designations for various maintenancecategories are as follows:

C — Operator or crewO — Organizational maintenanceF — Direct support maintenanceH — General support maintenanceD — Depot maintenance

The maintenance functions are defined as follows:

A – Inspect. To determine serviceability ofan item by comparing its physical,mechanical, and electrical characteristicswith established standards.

B — Test. To verify serviceability and todetect electrical or mechanical failure byuse of test equipment.

C —

D —

E —

F —

G —

H —

I —

J –

K —

Service. To clean, to preserve, to charge,to paint, and to add fuel, lubricants,cooling agents, and air.Adjust. To rectify to the extent necessaryto bring into proper operating range.Align. To adjust specified variableelements of an item to bring to optimumperformance.Calibrate. To determine the correctionsto be made in the readings of instrumentsor test equipment used in precisemeasurement. Consists of the com-parisons of two instruments, one ofwhich is a certified standard of knownaccuracy, to detect and adjust anydiscrepancy in the accuracy of the in-strument being compared with thecertified standard.Install. To set up for use in anoperational environment such as anemplacement, site, or vehicle.Replace. To replace unserviceable itemswith serviceable assemblies, sub-assemblies, or parts.Repair. To restore an item to serviceablecondition. This includes, but is notl imited to , inspect ion , c leaning ,preserving, adjusting, replacing, welding,riveting, and strengthening.Overhaul. To restore an item to acompletely serviceable condition asprescribed by maintenance serviceabilitystandards using the Inspect and RepairOnly as Necessary (IROAN) technique.Rebuild. To restore an item to a standardas nearly as possible to original or newcondition in appearance, performance,and life expectancy. This is accomplishedthrough complete disassembly of theitem, inspection of all parts of com-ponents, repair or replacement of wornor unserviceable elements (items) usingoriginal manufacturing tolerances andspecifications, and subsequent re-assembly of the item.

d. Tools and Equipment, Columncolumn is provided for referencing bvspecial tools and test equipment,

(4). Thiscode the

(sec. III)

B-1

required to perform the maintenance functions(sec. II). (Not Applicable)

e. Remarks, Column (5). This column isprovided for referencing by code the remarks (sec.IV) pertinent to the maintenance functions.

B-3. Explanation of Columns in Section IIIa. Reference Code. This column consists of a

number and a letter separated by a dash. Thenumber references the T&TE requirements columnon the MAC. The letter represents the specificmaintenance function the item is to be used with.The letter is representative of columns A through Kon the MAC,

b. Maintenance Category. This column showsthe lowest level of maintenance authorized to usethe special tool or test equipment.

c. Nomenclature. This column lists the name oridentification of the tool or test equipment.

d. Tool Number. This column lists themanufacturer’s code and part number, or FederalStock Number of tools and test equipment.

B-4. Explanation of Columns in Section IVa. Reference Code. This column consists of two

letters separated by a dash, both of which arereferences to Section II. The first letter referencescolumn 5 and the second letter references amaintenance function, column 3, A through K.

b. Remarks. This column lists informationpertinent to the maintenance function beingperformed, as indicated on the MAC, Section II.

Section II. MAINTENANCE ALLOCATION CHART

B-2

Section III. SPECIAL TOOL AND SPECIAL TEST EQUIPMENT REQUIREMENTS

Reference Maintenance Toolcode category Nomenclature number

Not Applicable

Section IV. REMARKS

Referencecode Remarks

A — F Refer to TM 5-2805-257-14 and TM 5-2805-257-24P forA — J ENGINE maintenance and repair.

I

B-3

APPENDIX C

BASIC ISSUE ITEMS LIST

Section I. INTRODUCTION

C-1. Scope

This appendix lists items which accompany thereciprocating pump or are required for installation,operation, or operator’s maintenance.

C-2. GeneralThis Basic Issue Items List is divided into thefollowing sections:

a. Basic Issue Items—Section II. A list of itemswhich accompany the reciprocating pump and arerequired by the operator / crew for installation,operation, or maintenance.

b. Maintenance and Operating Supplies—Section III. A listing of maintenance and operatingsupplies required for initial operation.

C-3. Explanation of Columns

The following provides an explanation of columnsin the tabular list of Basic Issue Items, Section II.

a. Source, Maintenance, and RecoverabilityCodes (SMR), Column (l).

(1) Source code indicates the selection statusand source for the listed item. Source codes are:

Code Explanation

P Repair parts which are stocked in or suppliedfrom the GSA / DSA, or Army supply systemand authorized for use at indicated maintenancecategories.

(2) Maintenance code indicates the lowestcategory of maintenance authorized to install thelisted item. The maintenance level code is:

Code Explanation

C Operator / crew

(3) Recoverabi l i ty code indicates whetherunserviceable items should be returned for recoveryor salvage. Items not coded are expendable.

b. Federal Stock Number, Column (2). Thiscolumn indicates the Federal stock numberassigned to the item and will be used forrequisitioning purposes.

c. Description, Column (3). This column in-dicates the Federal item name and any additionaldescription of the item required. A part number orother reference number is followed by the ap-p l i cab l e f i ve -d ig i t Federa l supp ly c ode f o rmanufacturers in parentheses.

d. Unit of Measure (U/M), Column (4). A two-character alphabetic abbreviation indicating theamount or quantity of the item upon which theallowances are based, e.g., ft, ea, pr, etc.

e. Quantity Incorporated in Unit, Column(5). This column indicates the quantity of the item

used in the reciprocating pump.j. Quantity Furnished with Equipment, Column

(6). This column indicates the quantity of an anitem furnished with the equipment.

g. Illustration, Column (7). This column isdivided as follows:

(1) Figure Number, Column (7)(a). I n -dicates the figure number of the illustration inwhich the item is shown.

(2) Item number, Column (7) (b). Indicatesthe callout number used to reference the item in theillustration.C-4. Explanation of Columns in the Tabular

List of Maintenance and OperatingSupplies— Section III

a. Component Application, Column (l). Thiscolumn identifies the component application ofeach maintenance or operating supply item.

b. Federal Stock Number, Column (2). Thiscolumn indicates the Federal stock numberassigned to the item and will be used forrequisitioning purposes.

c. Description, Column (3). This column in-dicates the item name and brief description.

d. Quantity Required for Initial Operation,Column (4). This column indicates the quantity of

each maintenance or operating supply i temrequired for initial operation of the equipment.

e. Quantity Required for 8 Hours Operation,Column (5). This column indicates the estimated

quantities required for an average 8 hours ofoperation.

f. Notes, Column (6). This column indicatesinformative notes keyed to data appearing in apreceding column.

C-5. Federal Supply Code for Manufacturers

Code Manufacturer

97403 Army Engineer Research and DevelopmentLaboratories, Fort Belvoir, Va.

C-1

PC

PC

PC

7520-559-9618

4210-555-8837

2990-972-7950

Section II. BASIC ISSUE ITEMS

Case, Maintenance and Operational Manual, MIL-E-11743 DEPARTMENT OF THE ARMY

Lubrication Order:LO 5-2805-257-12

DEPARTMENT OF THE ARMYTechnical Manuals:

TM 5-2805-257-14TM 5-4320-251-14

Extinguisher Fire monobromobriflouromathanecharged, hand type w / bracket 2¾ lbs. MIL-E-52031

Rope, Starting (9786E12) (97403)

EA

EA

EAEAEA

EA 1

1

1

11

1

C-2

Section III.

C-3

I N D E X

Page

4-94-64-94-97-15-3

C-1B-1A-11-2

2-1

4-124-114-114-12

3-15-2

4-94-12

4-114-94-56-3

4-114-9

4-123-15-1

5-35-22-3

1-2

4-64-11

4-94-64-36-14-91-14-5

4-11

7-1

4-114-94-95-3

4-115-21-2

Paragraph

Accumulator:Cleaning and inspection . . . . . . . . . . . . . 4-15Description . . . . . . . . . . . . . . . . . . . . . . . . . 4-13cDisassembly . . . . . . . . . . . . . . . . . . . . . . 4-14bReassembly . . . . . . . . . . . . . . . . . . . . . . . . 4-16a

Administrative storage . . . . . . . . . . . . . . . . . 7-1Alinement . . . . . . . . . . . . . . . . . . . . . . . . 5-8eAppendixes:

Basic issue items list . . . . . . . . . . . . . . . .Maintenance allocation chart . . . . . . .References . . . . . . . . . . . . . . . . . . . . . . .

Army data plate . . . . . . . . . . . . . . . . . . . . . . 1-7a(l)Assembly up receipt

of materiel . . . . . . . . . . . . . . . . . . . . .Axle and wheel assembly:

Cleaning and inspection . . . . . . . . . . . . . .Description . . . . . . . . . . . . . . . . . . . . . . . . .Disassembly . . . . . . . . . . . . . . . . . . . . . . .Reassembly . . . . . . . . . . . . . . . . . . . . . . .

Basic issue items . . . . . . . . . . . . . . . . . . . . .Bearing care . . . . . . . . . . . . . . . . . . . . . . . . . .Cleaning and inspection:

Accumulator . . . . . . . . . . . . . . . . . . . . . . . .Axle and wheel assembly . . . . . . . . .Diaphragm and plunger

assembly . . . . . . . . . . . . . . . . . . . . . . . . .Discharge assembly . . . . . . . . . . . . . .Fuel system . . . . . . . . . . . . . . . . . . . . . . .Gear case . . . . . . . . . . . . . . . . . . . . . . . . .Plunger assembly . . . . . . . . . . . . . . . . . . .Suction assembly . . . . . . . . . . . . . . . . . .Wheel and axle assembly . . . . . . . . . . .

Cleaning prior to lubrication . . . . . . . . . . .Cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . .Components, major:

Installation of . . . . . . . . . . . . . . . . . . . . .Removal of . . . . . . . . . . . . . . . . . . . . . . .

Controls . . . . . . . . . . . . . . . . . . . . . . . . . . .Coupling:

Tabulated data . . . . . . . . . . . . . . . . . . . . 1-76(3)

2-1a

4-234-214-224-24

3-15-7

4-154-23

4-194-154-11

6-34-194-154-233-3b

5-6

5-95-82-6

Description:Accumulator . . . . . . . . . . . . . . . . . . . . . . . .Axle and wheel assembly . . . . . . . . . . . .Diaphragm and plunger

assembly . . . . . . . . . . . . . . . . . . . . . . . . .Discharge assembly . . . . . . . . . . . . . . . . . .Fuel system . . . . . . . . . . . . . . . . . . . . . . . .Gear case . . . . . . . . . . . . . . . . . . . . . . . . . .Plunger assembly . . . . . . . . . . . . . . . . . .Reciprocating pump . . . . . . . . . . . . . . . . .Suction assembly . . . . . . . . . . . . . . . . . .Wheel and axle assembly . . . . . . . . . .

Destruction of materielto prevent enemy use...... . . . . . . . . . .

Diaphragm and plungerassembly:Cleaning and inspection . . . . . . . . . . . . .Description . . . . . . . . . . . . . . . . . . . . . . . .Disassembly . . . . . . . . . . . . . . . . . . . . . . .Installation on pump . . . . . . . . . . . . . . .Reassembly . . . . . . . . . . . . . . . . . . . . . . . .Removal from pump . . . . . . . . . . . . . . . .

Differences between models . . . . . . . .

4-13c4-21

4-17a4-13b

4-96-1

4-17b1-5

4-13a4-21

7-2

4-194-17a4-18b

5-9h4-205-8c

1-6

Paragraph

Dimensions and weights . . . . . . . . . . . . 1-7b(4)Disassembly:

Accumulator . . . . . . . . . . . . . . . .Axle and wheel assembly . . . . . .Diaphragm and plunger

assembly . . . . . . . . . . . . . . . . . . . . . .Discharge assembly . . . . . . . . . . . . . . .Fuel system . . . . . . . . . . . . . . . . . . . . . . .Gear case . . . . . . . . . . . . . . . . . . . . . . . . .Plunger assembly. . . . . . . . . . . . . . . . . . . Suction assembly . . . . . . . . . . . . . . . . . . . .Wheel and axle assembly . . . . . . . . . .

Discharge assembly:Cleaning and inspection . . . . .Description . . . . . . . . . . . . . . . . . . . . . . .Disassembly . . . . . . . . . . . . . . . . . . . . . . .Installation on pump . . . . . . . . . . . . . . . .Reassembly . . . . . . . . . . . . . . . . . . . . . . .Removal from pump . . . . . . . . . . . . . . . .

Dismantling for movement . . . . . . . . . . . . .

Engine:Installation on pump . . . . . . . . . . . . .

4-14b4-22

4-18b4-14a

4-106-2

4-18b4-14b4-22

4-154-13b4-14a

5-9i4-16b

5-8b2-3

5-9ePlate . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7a(2)Removal from pump . . . . . . . . . . . . . . . . 5-8gTabulated data . . . . . . . . . . . . . . . . . . . . l-7b(2)

Equipment serviceabilitycriteria . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Forms and records . . . . . . . . . . . . . . . . . . . .Fuel strainer service . . . . . . . . . . . . . . . . . . .Fuel system:

Cleaning and inspection . . . . . . . . . . .Description . . . . . . . . . . . . . . . . . . . . . . . . .Disassembly . . . . . . . . . . . . . . . . . . . . . . . .Installation on pump . . . . . . . . . . . . . . .Reassembly . . . . . . . . . . . . . . . . . . . . . . . .Removal from pump . . . . . . . . . . . . . . . .

Gear case:Cleaning and inspection . . . . . . . . . . . . .Description . . . . . . . . . . . . . . . . . . . . . . . . .Disassembly . . . . . . . . . . . . . . . . . . . . . . . .Installation on pump . . . . . . . . . . . . . . . .Reassembly . . . . . . . . . . . . . . . . . . . . . . . . .Removal from pump . . . . . . . . . . . . . . . .

Hose:

1-3

1-23-9

4-114-9

4-105-9j4-125-8a

6-36-16-2

5-9a6-4

5-8e

Tabulated data . . . . . . . . . . . . . . . . . . . . . 1-7b(5)

Identification and tabulateddata . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Inspection upon receiptof materiel . . . . . . . . . . . . . . . . . . . . . . . . .

Installation:Diaphragm . . . . . . . . . . . . . . . . . . . . . . . . .Of major components . . . . . . . . . . . . . . .Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installation on pump:Diaphragm and plunger

assembly . . . . . . . . . . . . . . . . . . . . . . . . .Discharge assembly . . . . . . . . . . . . . . . . . .Engine . . . . . . . . . . . . . . . . . . . . . . . . . . .Fuel system . . . . . . . . . . . . . . . . . . . . . . .Gear case . . . . . . . . . . . . . . . . . . . . . . . . . .Plunger assembly . . . . . . . . . . . . . . . . . .Suction assembly . . . . . . . . . . . . . . . . . . . .

1-7

2-1b

4-25-82-2

5-9h5-9i5-9e5-9j5-9a5-9 h5-9i

1-3

4-94-11

4-94-74-36-14-94-9

4-11

4-94-64-75-34-95-22-2

5-31-25-31-3

1-1

1-13-3

4-54-34-35-34-55-2

6-36-16-15-36-35-3

1-3

1-2

2-1

4-15-22-1

5-35-35-35-35-35-35-3

I-1

Paragraph

Lubrication:Detailed information . . . . . 3-3Engine . . . . . . . . . . . . . . . . . . . . . . . 3-3 dGeneral information . . . . . . . . . 3-2Points . . . . . . . . . . . . . . . . . . . . . . . . 3-3cUpon receipt of

materiel. . . . . . . . . . . . . . . . . . . . 2-1c(2)

Operation:At high altitudes . . . . . . . . . . . . . . . . . 2-15General . . . . . . . . . . . . . . . . . . . . . . . 2-7In dusty or sandy areas . . . . . . . . 2-13In extreme cold . . . . . . . . . . . . . . . . . . . . . 2-11In extreme heat . . . . . . . . . . . . . . . 2-12Under rainy or

humid conditions . . . . . . . . . . . . . 2-14U n d e r u s u a l c o n d i t i o n s . . . . 2-10

Plates, identification:Army data . . . . . . . . . . . . . . . . . . . . . . . . 1-7a(l)Engine . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7a(2)Plump . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7a(3)

Plunger assembly:C l e a n i n g a n d i n s p e c t i o nDescription . . . . . . . . . . . . . . . . . .Disassembly . . . . . . . . . . . . . . . . . . .Installation on pump . . . . . . . . . . . . . .Reassembly . . . . . . . . . . . . . . . . . . . . . . . .Removal from pump . . . . . . . . . . . . . . .

Preventive maintenance checksand services:O p e r a t o r ’ s m a i n t e n a n c eOrganizational maintenance . . . . .

Reassembly:Accumulator . . . . . . . . . . . . . . . . . . .A x l e a n d w h e e l a s s e m b l yDiaphragm and plunger

assembly . . . . . . . . . . . . . . . . . . . . .Discharge assembly, . . . . . . . . . . . . . .Fuel system . . . . . . . . . . . . . . . . . .Gear case . . . . . . . . . . . . . . . . . . . . . .Phunger assembl y . . . . . . . . . . . . . . .Suction assembly . . . . . . . . . . . . . . . . .Wheel and axle assembly . . . . . . . .

Records and forms . . . . . . . . . . . . . . . . . . . .R e i n s t a l l a t i o n a f t e r m o v e m e n tRemoval from pump:

Diaphragm and plungerassembly . . . . . . . . . . . . . . . . . . . . . . .

4-194-l7a4-18b

5-9h4-205-8 C

3-54-6

4-16a4-24

4-204-16b

4-126-4

4-204-16a4-24

1-22-4

5-8c

Page

3-13-13-13-1

2-1

2-72-42-62-62-6

2-72-6

1-21-21-2

4-114-94-95-3

4-115-2

3-14-1

4-94-12

4-114-94-56-3

4-114-9

4-121-12-3

5-2

Discharge assembly . . . . . . . . . . . . . . . .Engine . . . . . . . . . . . . . . . . . . . . . . . .Fuel system . . . . . . . . . . . . . . . . . . . .Gear case . . . . . . . . . . . . . . . . . . . .Plunger assembly . . . . . . . . . . . . . . . .Suction assembly . . . . . . . . . . . . . . . . . . . . .

Repair parts, . . . . . . . . . . . . . . . . . . . . . . . . . .Reporting of errors . . . . . . . . . . . . . . . . . . . . .

Scope. . . . . . . . . . . . . . . . . . . . . . . .

Fuel strainer. . . . . . . . . . . . . . . . . Upon receipt of materiel. . . . . . . . . .

Special tools and equipment. . . . . . . . .

Starting the pump . . . . . . . . . . . . . . .Stopping the pump . . . . . . . . . . . . . . . . . . .Storage, adminiatrative . . . . . .Suction assembly:

Cleaning and inspection . . . .Description . . . . . . . . . . . . . . . . . . . . .Disassembly . . . . . . . . . . . . . . . . . . . .Installation on pump . . . . . . . . . .Reassembly . . . . . . . . . . . . . . . . . . . .Removal from pump . . . . . . . . . . . . . .

Tabulated data:Coupling . . . . . . . . . . . . . . . . . . . . . . . .Engine . . . . . . . . . . . . . . . . . . . . . . . . .Hose . . . . . . . . . . . . . . . . . . . . . . . . . .Overall dimensions and

weights . . . . . . . . . . . . . . . . .Pump . . . . . . . . . . . . . . . . . . . . . . . .

Troubleshooting:Direct support and

general support . . . . . . . . . . . . . . . .Operator’s maintenance .Organizational maintenance . . . . . .

Weights and dimensions. . . . . . .Wheel and axle assembly:

C l e a n i n g a n d i n s p e c t i o nDescription . . . . . . . . . . . . . . . . . . . . . . . .Disassembly . . . . . . . . . . . . . . . .Reassembly . . . . . . . . . . . . . . . . . . . . .

Paragraph

5-8 b5-8g5-8a5-8e5-8c5-8b

4-41-4

1-1

3-92-1c4-14-35-12-82-97-1

4-154-13a4-14b

5-9i4-16a5-8b

1-7b(3)1-7b(2)1-7b(5)

1-7b(4)1-7b(l)

5-43-74-8

1-7b(4)

4-234-214-224-24

Page

5-25-35-25-35-25-24-11-1

1-1

3-32-14-14-15-12-52-67-1

4-94-54-95-34-95-2

1-31-31-3

1-31-2

5-13-34-2

1-3

4-124-114-114-12

I -2

By Order of the Secretary of the Army:

Official:

W. C . WESTMORELAND,General, United States Army,Chief of Staff.

K E N N E T H G . W I C K H A M ,Major General, United States Army,The Adjutant General.

D i s t r i b u t i o n :To be distributed in accordance with DA Form 12-25, Sec I (qty rqr Block No.242), Organizational maintenance requirements for Pumps, Centrifugal: FreshW a t e r .

TM 5-4320-251-14

This fine document...

Was brought to you by me:

Liberated Manuals -- free army and government manuals

Why do I do it? I am tired of sleazy CD-ROM sellers, who take publicly available information, slap “watermarks” and other junk on it, and sell it. Those masters of search engine manipulation make sure that their sites that sell free information, come up first in search engines. They did not create it... They did not even scan it... Why should they get your money? Why are not letting you give those free manuals to your friends?

I am setting this document FREE. This document was made by the US Government and is NOT protected by Copyright. Feel free to share, republish, sell and so on.

I am not asking you for donations, fees or handouts. If you can, please provide a link to liberatedmanuals.com, so that free manuals come up first in search engines:

<A HREF=http://www.liberatedmanuals.com/>Free Military and Government Manuals</A>

– SincerelyIgor Chudovhttp://igor.chudov.com/

– Chicago Machinery Movers