TM-5-3740-211-14

TM-5-3740-211-14
TM 5-3740-211-14
TECHNICAL MANUAL
OPERATOR, ORGANIZATIONAL, DIRECT SUPPORT AND
GENERAL SUPPORT MAINTENANCE MANUAL
SPRAYER, INSECTICIDE, AIRCRAFT-MOUNTED: WITH PUMP
AGRINAUTICS MODEL NO. 30000
FSN 3740-470-9811
This reprint includes all changes in effect at the time
of publication; change 1
HEADQUARTERS, DEPARTMENT OF THE ARMY
21 DECEMBER 1971
WARNING
In-flight checkout of the spray system must be carried out in an area set aside for this purpose to prevent accidental injury
or contamination to personnel, animals, or vegetation. Never exceed an air speed of 120 knots with the spray system
installed in the aircraft.
If spray booms vibrate or misalign during flight, reduce speed slowly, land, and adjust tension of cables. If a leak develops
in flight within the sprayer system, apply pump brake at once and stop spraying. If fan blade is damaged in flight and
causes vibration, apply pump brake at once and stop spraying.
WARNING
Avoid splashing insecticide fluid onto skin or into eyes. Observe precautions for handling poisonous fluids by flushing
exposed areas with clean running water. Wash hands thoroughly with soap and water after handling and before eating or
smoking.
WARNING
Fuel and fuel vapors are explosive mixtures. Do not use near open flame. Wash hands after using, before smoking or
eating.
WARNING
Use cleaning solvent in well ventilated area. Avoid breathing of fumes and excessive contact with skin. Keep away from
open flame. Wash hands before eating or smoking.
SAFETY PRECAUTIONS AND EMERGENCY PROCEDURES
A.
Insecticide Sprayer
(1) Never exceed air speed of 120 knots.
(2) If booms noticeably vibrate or misalign during flight, reduce speed gradually, land and adjust tension of
cables.
(3) If a leak develops in flight within the aircraft, apply pump brake immediately and discontinue operation.
(4) If fan blade becomes damaged in flight and causes vibration, apply pump brake immediately
and discontinue operation.
(5) If spray does not stop when valve control has been actuated, apply pump brake as an alternate method of
control.
(6) Do not attempt to lift by booms or braces. Lift by designated handles only.
(7) Tank must be drained before installation or removal.
(8) In event of contamination by chemicals, wash with soap and water.
B.
Liquid Loading Pump
(1) To prevent burns, avoid touching muffler during operation.
(2) Do not fill fuel tank while engine is running. Set switch to OFF.
(3) To allow for fuel expansion, never fill fuel tank to top.
(4) When unscrewing fuel cap, keep face and eyes turned away from fuel tank. Fuel expands greatly when
heated and agitated, and may be discharged from tank when cap is removed.
TM 5-3740-211-14
C1
Change
No. 1
HEADQUARTERS
DEPARTMENT OF THE ARMY
Washington, DC, 30 November 1973
}
Operator, Organizational, Direct Support
and General Support Maintenance Manual
SPRAYER, INSECTICIDE, AIRCRAFT-MOUNTED:
WITH PUMP, AGRINAUTIES MODEL NO. 3000, FSN 3740-470-9811
Page 2-2. Caution is added preceding paragraph 2-4a.
TM 5374021114, 21 December 1971, is changed as
follows:
Page 15.
Paragraph 16d(2), is superseded as follows:
(2) Overall dimensions and weight. See figure
41 for reduced shipping dimensions.
Weight:
As shipped........................................
Flight weight ....................................
"Shipping Specifications:
Weight ..............................................
Cube .................................................
CAUTION
Aircraft maximum operating gross
weight is limited to 8500 pounds.
Maximum air speed is limited to 110
knots indicated air speed.
Page 23. Paragraph 27c, second sentence of Warn ing,
change "120 knots" to read "110 knots".
Subparagraph (4), add the following caution.
CAUTION
If pressure gage (21, fig. 4-10) fails to
register, apply brake (16, fig. 410).
Return to base, remove pump drain plug
(20, fig. 73) and spin pump until fluid
begins to flow. Takeoff and try again.
Page 3-2. Sections VI and VII are added as follows:
pounds
200
(approx)"
and substitute
1020 lbs.
250.5 cu. in".
Paragraph 1-6(13), line 2. Change model No.
"11/4 436TSE" to read "11/2 436RSE". Line 4 change
"1-1/4 in. line size" to read "1-1/2 in. line size".
Section VI. CALIBRATION INSTRUCTIONS
3-8.
GENERAL
label rates are practically invisible.
e. Have pilot practice flying a desired height
with a measured reference height (a building, pole, etc.)
unless he has previous experience with flying in creased
heights used in this type application.
f
Do not fly in winds over 8 m.p.h., or when
temperature inversions will prevent droplets from going
down.
g. Every formulation has its own flow rate affect
ing rate of application. Flow rate must be known; cutting
formulation with solvent or dilutent will change flow rate.
Mixing two formulations of known flow rate will not
necessarily result in arithmetical mean rate.
Information presented in this section is for guidance in
calibrating aircraft for the dispersal of insecticides.
Calibration of the aircraft spray equipment is very
important when applying insecticides because of the
volume applied per acre. These are specific instructions
based upon field experience. Calibration is very simple,
but is given in detail for inexperienced persons. General
safety precautions are: a. This system should be flushed
periodically to remove any trash, condensation or other
foreign matter. The system should be flushed after each
day of operation.
b. Follow label cautions carefully since
handling insecticides presents personal hazards.
Practice safety first.
c. Be aware of effects insecticides may have
on structural materials.
d. Do not be alarmed if you do not see spray
since
3-9.
SELECTION OF CONFIGURATION
The spray system configuration to be selected for any
given spray operation is based on the type of
1
spray, the application rate, the altitude of the air craft, the
speed of the aircraft, and the effective swath width.
Based upon these factors the nozzle con figurations can
be selected. Based on previous field experience Chart
Number 1 is offered as a plot of altitude vs. effective
swath width.
CHART 2. Weight and Conversion Factor
WEIGHT OF SOLUTION
Effective Swath Width
150’
200’
250’
Chart Number 2 is based on the weights of various
solutions with relation to water and conversion factors
that are applicable.
Acres per minute = 2 X Effective Swath Width X Speed
(Miler Per Hour)
1000
Chart 3. Acres 1 per Minute
ACRES PER MINUTE
SPEED
MPH
70
75
80
85
90
95
100
110
120
130
140
150
3-10.
CONVERSION
FACTOR
7.0 Ibs/ gallon
.84
1.09
8.0
"
"
.96
1.02
8.34 "
" -Water
1.00
1.00
9.0
"
"
1.08
96
10.0 "
"
1.20
.91
11.0 "
"
1.32
.87
12.0 "
"
1.44
.83
13.0 "
"
1.56
.80
14.0 "
"
1.68
.77
15.0 "
"
1.80
.75
16.0 "
"
1.92
.73
Chart Number 3 indicates the acres per minute covered
by an aircraft at various speeds and various effective
swath widths and is derived from the following formula:
CHART 1. Altitude vs. Swath Width
Altitude
75’
100’
150’
SPECIFIC
GRAVITY
KNOTS
60.9
65.3
69.6
73.9
78.3
82.6
87.0
95.7
104.4
113.1
121.7
130.4
50 ’SWATH
7.0
7.5
8.0
8.5
9.0
9.5
10.0
11.0
12.0
13.0
14.0
15.0
75’ ’SWATH
10.5
11.2
12.0
11.7
13.5
14.2
15.0
16.5
18.0
19.5
21.0
22.5
100’ SWATH
14.0
15.0
16.0
17.0
18.0
19.0
20.0
22.0
24.0
26.0
28.0
30.0
FLIGHT TEST CALIBRATION
200’ SWATH
28.0
30.0
32.0
34.0
36.0
38.0
40.0
44.0
48.0
52.0
56.0
60.0
300’ SWATH
42.0
45.0
48.0
51.0
54.0
57.0
60.0
66.0
72.0
78.0
84.0
90.0
500 ’SWATH
70.0
75.0
80.0
85.0
90.0
95.0
100.0
110.0
120.0
130.0
140.0
150.0
rate is the amount dispersed in gallons divided by the
time in minutes.
b. To derive the application rate, divide the
flow rate by the swath width and speed factors as follows:
Application Rate =
Flow Rate (gal/min)
(gal/acre)
002 X swath (ft) x speed (mph.
c. As noted above, increase windmill blade
angle position to decrease application rate or decrease
blade angle to increase application rate and repeat tests.
Increase or decrease number of nozzles to fulfill
requirements if blade angle does not remain within the
1.0 to 2.0 range.
The selection of nozzle configurations and windmill blade
pitch angle settings are preliminary in nature and a flight
test must be performed to refine the output performance
of the system with the liquid chemicals to be used before
initiating an operation. The procedure for adjusting the
flow is to increase the windmill blade angle to decrease
flow or to decrease the blade angle to increase flow to
that required. Retain blade angles between the 1.0 to 2.0
values and remove or add nozzles to fulfill further
adjustments that may be required. The pressure in the
system should be 40 p. s. i. when calibrating and
operating. Procedures for flight testing are noted as
follows:
3-11. CALCULATION PROCEDURES
Typical sprays required to effectively accomplish the
mission vary between 3 and 32 ounces of application per
acre, depending upon the insecticide formulation spray
being utilized. Where variations in flight height become
necessary, there will of course be a change in swath
width. To determine new nozzle configurations to meet
the new flow rate as a direct result of changes in swath
width and also forward
a. With a known liquid quantity in the tank, con
duct a spray test for a specific time period and determine
the amount of liquid dispersed.
The flow
2
speed, a calculation procedure is useful. The
follow ing is defined to establish the calculation
procedure:
a. Establish the rate of application required in
gallons per acre. For insecticide application 3 to 32
ounces per acre is required. Each gallon contains 128
ounces; therefore, the application rate varies between
3/128 to 32/128 gallons per acre. For purpose of this
calculation we will use 16 ounces per acre which is equal
to 16/128 gallons per acre.
b. Select an altitude at which the helicopter will
fly. For the purpose of this calculation we will use 100
feet of altitude which should give us an effective swath
width of 200’ as per information contained in Chart 1.
c. Select a speed at which the helicopter will
fly. Based on previous field experience, the normal
speeds used for helicopters spraying have been between
70 and 90 knots per hour, which is equivalent to 80.5 to
103.5 miles per hour. For purposes of this calculation we
will use 80 knots per hour which is equivalent to 92 miles
per hour.
d. Calculate work rate (acres/minute) as
follows:
Acres/minute =
1000
Acres/minute =
nozzle tips. With a Spraying System nozzle, at 40 p.s.i.,
move 3 places from left and place decimal. This will give
rate in gallons per minute using water, i.e.:
8001 nozzle tip = 0.1 g.p.m.
80015 nozzle tip = 0.15 g.p.m.
8002 nozzle tip = 0.2 g.p.m.
8003 nozzle tip = 0.3 g.p.m.
8004 nozzle tip = 0.4 g.p.m.
We will assume that the nozzle tip selected is an 8002,
so that the flow rate/nozzle using water would be 0.2
g.p.m. If we were to use an insecticide weighing 10
lbs/gallons, it would have a conversion factor of 0.91 as
per information contained in Chart 2, and there fore the
actual flow rate/nozzle using the concentrated solution
would be 0.2 x 0.91 or 0.182 g.p.m./ nozzle. Chart 4
provides these calculations.
g. Divide the required flow rate (4.6) by the flow
rate/nozzle (0.182), to determine the number of nozzles
required.
No. of nozzles required = 4.6 = 25.3 use 26
nozzles. (13 per boom)
0.182
h. Conduct a flight test to determine the actual
flow rate performance that exists.
i.
If the flow is too low, increase the pressure
in the system, or add additional nozzles, or increase the
size of the nozzle tips.
J
If the flow is too great, decrease pressure
in the system, or delete nozzles, or decrease the size of
the nozzle tips.
k. Final adjustments can be made after the
first chemical spray operations by the same procedures
outlined in steps (9) and (10).
I
Record all data on a spray lot sheet (a
sample of which is included as (Chart 5) to provide
information for new chemical flow charts to be
established from these date.
2X Swath Width X Speed (mph)
2 X 200 x 92 = 36.8
1000
Interpolation in Chart 3 at 92 miles per hour and 200 foot
swath indicates the correct answer to be 36.8
acres/minute.
e.
Determine the flow rate (g. p. m.) required
as follows:
Gallons/minute
Gallons/Minute =
gallons/acre X Acres/minute
16/128 X 36.8 = 4.6
f Select a nozzle tip to fit our nozzle. For purposes of
these calculations we will use Spraying System
Section VII. PILOTS INSTRUCTIONS
WARNING
Aircraft maximum operating
weight is limited to 8500 pounds.
WARNING
gross
Maximum air speed is limited to 110
knots indicated air speed.
3
Chart 4. Flow Per Nozzle in Gallons Per Minute When
The Weight of the Solution Is:
7.0 LBS./GALLON
System Pressure
Nozzle/Orifice
Tip/Dia.
8001=.026
80015 =.031
8002 =.035
8003 =.043
8004 =.052
20 PSI
25 PSI
30 PSI
40 PSI
50 PSI
60 PSI
.0763
.11445
.1526
.2289
.3052
.0872
.1308
.1744
.2616
.3488
.109
.1635
.218
.327
.436
.1199
.17985
.2398
.3597
.4795
.1308
.1962
.2616
.3924
.5232
8001 =.026
80015-.031
8002 =.035
8003 =.043
8004 =.052
.0714
.1071
.1428
.2142
.2856
.0816
.1224
.1632
.2448
.3264
.102
.153
.204
.306
.408
.1122
.1683
.2244
.3366
.4488
.1224
.1836
.2448
.3672
.4896
8001 =.026
80015 =.031
8002 =.035
8003 =.043
8004 =.052
.0672
.1008
.1344
.2016
.2688
.0768
.1152
.1536
.2304
.3072
.096
.144
.192
.288
.384
.1056
.1584
.2112
.3168
.4224
.1152
.1782
.2304
.3456
.4608
8001 = .026
80015= .031
8002 = .035
8003 = .043
8004 = .052
.0637
.09555
.1274
.1911
.2548
.0728
.1092
.1456
.2186
.2912
.091
.1365
.182
.273
.364
.1001
.15015
.2002
.3003
.4004
.1092
.1638
.2184
.3276
.4368
8001= .026
80015 = .031
8002 = .035
8003 = .043
8004 = .052
.0609
.09135
.1218
.1827
.2436
.0696
.1044
.1392
.2088
.2784
.087
.1305
.174
.261
.348
.0957
.14355
.1914
.2871
.3828
.1044
.1566
.2088
.3132
.4176
8001 = .026
80015 = .031
8002 = .035
8003 = .043
8004 = .052
.0581
.08715
.1162
.1743
.2324
.0664
.0996
.1328
.1992
.2656
.083
.1245
.166
.249
.332
.0913
.13695
.1826
.2739
.3652
.0996
.1494
.1992
.2988
.3984
8001 = .026
80015 = .031
8002 = .035
8003 = .043
8004 = .052
.056
.084
.112
.168
.224
.064
.096
.128
.192
.256
.080
.120
.160
.240
.320
.088
.132
.176
.264
.352
.096
.144
.192
.288
.384
8001 = .026
80015 = .031
8002 = .035
8003 = .043
8004 = .052
.0539
.08085
.1078
.1617
.2156
.0616
.0924
.1232
.1848
.2464
.077
.1155
.154
.231
.308
.0847
.12705
.1694
.2541
.3388
.0924
.1386
.1848
.2772
.3696
8001 = .026
80015 = .031
8002 = .035
8003 = .043
8004 = .052
.0525
.07875
.1050
.1575
.2100
.060
.090
.120
.180
.240
.075
.1125
.150
.225
.300
.0825
.12375
.1650
.2475
.3300
.090
.135
.180
.270
.360
8001 = .026
80015 = .031
8002 = .035
8003 = .043
8004 = .052
.0511
.07665
.1022
.1533
.2044
.0584
.0876
.1168
.1752
.2336
.0981
.14715
.1962
.2943
.3924
8.0 LBS./GALLON
.0918
.1377
.1836
.2754
.3672
9.0 LBS./GALLON
.0864
.1296
.1728
.2592
.3456
10.0 LBS./GALLON
.0819
.12285
.1638
.2457
.3276
11.0 LBS./GALLON
.0783
.11745
.1566
.2349
.3132
12.0 LBS./GALLON
.0747
.11205
.1494
.2241
.2988
13.0 LBS./GALLON
.072
.108
.144
.216
.288
14.0 LBS./GALLON
.0693
.10395
.1386
.2079
.2772
15.0 LBS./GALLON
.0675
.10125
.1350
.2025
.2700
16.o LBS./GALLON
.0657
.09855
.1314
.1971
.2628
.073
.1095
.146
.219
.292
.0803
.11045
.1606
.2409
.3212
.0876
.1314
.1752
.2628
.3504
4
Page 46.
follows:
Paragraph 43a(6) is changed to read as
brace (1) be attached in the uppermost position on the
tank support center brace (2). The control panel must be
in its innermost position in the control panel support (3).
Use short valve rod (10) and connect. between valve
lever (11) and lever on control valve (25, fig. 12). Refer
to paragraph 424, step e(3) for instructions on attaching
valve rod.
Page 4-15. Add the following to table 4-3.
(6) Control panel should always be placed in UH-1B
position (fig. 45) to assure that the helicopter console is
cleared. In some model helicopters the map case must
be removed to permit clearance of the control panel.
Installation
required
that
the
folding
10.
Table 4-3. Organizational troubleshooting chart
Malfunction
Probable, Cause
Corrective Action
Windmill pump fails to build up Pump requires priming.
Remove pump drain plug, spin pump
pressure.
until fluid flows and remove boom ends
until fluid flows.
5
By Order of the Secretary of the Army:
CREIGHTON W. ABRAMS
General, United States Army
Chief of Staff
Official:
VERNE L. BOWERS
Major General, United States Army
The Adjutant General
Distribution:
To be distributed in accordance with DA Form 1225A (qty rqr block No. 149) operator maintenance requirements
for Insect and Pest Control Equipment.
6
TM 5-3740-211-14
TECHNICAL MANUAL
No. 5-3740-211-14
HEADQUARTERS
DEPARTMENT OF THE ARMY
WASHINGTON, D.C., 21 December 1971
}
OPERATOR, ORGANIZATIONAL, DIRECT SUPPORT AND
GENERAL SUPPORT MAINTENANCE MANUAL
SPRAYER, INSECTICIDE, AIRCRAFT MOUNTED: WITH
PUMP, AGRINAUTICS MODEL NO. 30000
FSN 3740-470-9811
CHAPTER
Section
CHAPTER
Section
CHAPTER
Section
CHAPTER
Section
CHAPTER
Section
CHAPTER
Section
CHAPTER
Section
CHAPTER
Section
CHAPTER
Section
1.
I.
II.
2.
I.
II.
III.
IV.
3.
I.
II.
III.
IV.
V.
4.
I.
II.
III.
IV.
V.
VI.
VII.
VIII.
IX.
5.
I.
II.
III.
IV.
6.
I.
II.
7.
I.
II.
III.
8.
I.
II.
III.
9.
I.
II.
Paragraph
INTRODUCTION
General...................................................................................................... 1-1-1-3
Description and data ................................................................................. 1-4-1-6
OPERATING INSTRUCTIONS
Service upon receipt of materiel ............................................................... 2-1
Controls and instruments .......................................................................... 2-2, 2-3
Operation under usual conditions ............................................................. 2-4-2-7
Operation under unusual conditions ......................................................... 2-8, 2-9
OPERATOR’S MAINTENANCE INSTRUCTIONS
Basic issue items ...................................................................................... 3-1, 3-2
Lubrication instructions ............................................................................. 3-3
Preventive maintenance checks and services ......................................... 3-4, 3-5
Troubleshooting ........................................................................................ 3-6
Maintenance of aircraft-mounted insecticide sprayer ............................... 3-7
ORGANIZATIONAL MAINTENANCE INSTRUCTIONS
Service upon receipt of materiel ............................................................... 4-1-4-5
Movement to a new worksite .................................................................... 4-6, 4-7
Repair parts, special tools and equipment ................................................ 4-8-4-10
Preventive maintenance checks and services .......................................... 4-11, 4-12
Troubleshooting ........................................................................................ 4-13
Maintenance of tank, hoses, coupling, strainer, valves, and tubing ......... 4-14-4-19
Maintenance of boom spray system.......................................................... 4-20, 4-21
Maintenance of pump and brake assembly .............................................. 4-22, 4-23
Maintenance of control system ................................................................. 4-24
DIRECT SUPPORT AND GENERAL SUPPORT MAINTENANCE
INSTRUCTIONS
Repair parts, special tools and equipment ................................................ 5-1--5-3
Troubleshooting ........................................................................................ 5-4
General maintenance ............................................................................... 5-5-5-7
Removal and installation of major components......................................... 5-8-5-17
REPAIR OF BOOM SPRAY SYSTEM
Spray boom removal and disassembly ..................................................... 6-1-6-3
Cleaning, inspection, and assembly .......................................................... 6-4-6-6
REPAIR OF PUMP AND BRAKE ASSEMBLY
Synchromatic windmill assembly............................................................... 7-1-7-6
Brake assembly ........................................................................................ 7-7-7-10
Pump assembly ........................................................................................ 7-11-7-16
REPAIR OF VALVES, COUPLING, AND TANK
Flow control and bypass valves ................................................................ 8-1-8-5
Valved quick-disconnect coupling ............................................................ 8-6--8-8
Tank assembly ......................................................................................... 8-9-8-14
REPAIR OF TANK SUPPORT ASSEMBLY
Tank support assembly ............................................................................ 9-1-9-4
Tank straps, struts, and tiedown lugs ....................................................... 9-5-9-8
i
Page
1-1-1-1
1-1-1-5
2-1
2-2-2-2
2-2-2-3
2-5-2-5
3-1-3-1
3-1
3-1-3-1
3-1
3-1
4-1-4-11
4-1-4-14
4-15-4-15
4-15-4-15
4-15
4-16-4-22
4-22-4-23
4-23-4-24
4-25
5-1-5-1
5-1
5-1-5-2
5-2-5-6
6-1 6-1
6-4-6-4
7-1-7-3
7-3-7-5
7-5-7-8
8-1-8-4
8-5--8-5
8-5-8-6
9-1-9-2
9-2-9-2
Paragraph
Page
REPAIR OF MANUAL CONTROL PANEL
General...................................................................................................... 10-1
10-1
Removal and disassembly......................................................................... 10-2, 10-3
10-1-10-1
Cleaning, inspection, repair, and assembly............................................... 10-4
10-1
CHAPTER
MAINTENANCE OF LIQUID LOADING SYSTEM
Section
General ..................................................................................................... 11-1, 11-2
11-1-11-5
Operator’s maintenance instructions ......................................................... 11-3-11-5
11-5-11-5
Organizational maintenance instructions .................................................. 11-6-11-8
11-7-11-8
Direct support and general support maintenance instructions ................. 11-9
11-13
CHAPTER
ADMINISTRATIVE STORAGE AND INSTRUCTIONSFOR DESTRUCTION
OF MATERIEL TO PREVENT ENEMY USE
Section
I.
Administrative storage .............................................................................. 12-1
12-1
II.
Destruction of materiel to prevent enemy use .......................................... 12-2
12-1
APPENDIX A.
REFERENCES .........................................................................................
A-1
B.
MAINTENANCE ALLOCATION CHART ............................................................................ B-1, B-2
C.
BASIC ISSUE ITEMS LIST AND MAINTENANCE AND OPERATING
SUPPLIES .................................................................................................................. C-1, C-2
INDEX...........................................................................................................................................................I-1, I-2, I-3, I-4
CHAPTER
Section
10.
I.
II.
III.
11.
I.
II.
III.
IV.
12.
ii
LIST OF ILLUSTRATIONS
Number
1-1
1-2
1-3
4-1
4-2
4-3
4-4
4-5
4-6
4-7
4-8
4-9
4-10
6-1
7-1
7-2
7-3
8-1
8-2
11-1
11-2
11-3
11-4
11-5
11-6
11-7
11-8
11-9
11-10
11-11
11-12
11-13
11-14
11-15
11-16
11-17
11-18
11-19
11-20
11-21
11-22
11-23
Title
Page
Insecticide sprayer in UH-IB helicopter ..................................................................................
Insecticide sprayer - assembled view ....................................................................................
Insecticide sprayer system - block diagram ...........................................................................
Aircraft-mounted insecticide sprayer - shipping and storage .................................................
Insecticide sprayer -- installation details ................................................................................
UH-LB installation details .......................................................................................................
UH-D installation details .........................................................................................................
Alternate control panel positions ............................................................................................
Turnbuckle safetying diagram ................................................................................................
Insecticide spray nozzle .........................................................................................................
Blade angle pitch setting.........................................................................................................
Tank installation -- exploded view ..........................................................................................
Manual control panel -- exploded view ..................................................................................
Spray boom assembly - exploded view .................................................................................
Sychromatic windmill assembly -- exploded view ..................................................................
Brake assembly - exploded view ...........................................................................................
Pump assembly -- exploded view ..........................................................................................
Valve assembly -- exploded view ...........................................................................................
Valve quick-disconnect coupling ............................................................................................
Liquid loading system ............................................................................................................
Pump assembly .....................................................................................................................
Liquid loading system pump engine - wiring schematic .........................................................
Inlet strainer -- exploded view ................................................................................................
Fabrication of muffler cleaning tool ........................................................................................
Muffler cleaning ......................................................................................................................
Carburetor adjustment controls .............................................................................................
Fabrication of rotor locking tool ..............................................................................................
Fabrication of offset wrench ...................................................................................................
Fabrication of needle bearing assembly tool .........................................................................
Fabrication of bearing and seal tool .......................................................................................
Fabrication of seal assembling plug ......................................................................................
Fabrication of seal assembling sleeve ...................................................................................
Fabrication of piston pin removal tool .....................................................................................
Starter fan housing and ignition parts - exploded view ..........................................................
Using rotor locking tool to hold shaft ......................................................................................
Removal of magneto rotor .....................................................................................................
Starter finger and torsion spring position ...............................................................................
Carburetor chamber -- exploded view ...................................................................................
Engine -exploded view ...........................................................................................................
Carburetor assembly -- exploded view ..................................................................................
Pump assembly - exploded view ...........................................................................................
Ball shutoff valve -- exploded view .........................................................................................
iii
1-2
1-4
1-6
4-2
4-5
4-7
4-8
4-9
4-10
4-12
4-13
4-19
4-27
6-3
7-2
7-4
7-6
8-3
8-5
11-1
11-3
11-4
11-7
11-8
11-11
11-12
11-14
11-15
11-16
11-17
11-18
11-18
11-19
11-22
11-23
11-25
11-29
11-30
11-32
11-37
11-39
11-40
Number
3-1
3-2
4-1
4-2
4-3
5-1
11-1
11-2
11-3
11-4
11-5
11-6
11-7
LIST OF TABLES
Title
Operator’s Preventive Maintenance Checks and Services ...........................................................
Operator’s Troubleshooting Chart .................................................................................................
Nozzle Orifice Data .......................................................................................................................
Organizational Preventive Maintenance Checks and Services ....................................................
Organizational Troubleshooting Chart ..........................................................................................
Direct Support and General Support Troubleshooting Chart ........................................................
Operator’s Preventive Maintenance Checks and Services ...........................................................
Operator’s Troubleshooting Chart - Liquid Ioading System ..........................................................
Organizational Preventive Maintenance Checks and Services ....................................................
Organizational Troubleshooting Chart - Liquid Loading System ..................................................
Repair and Replacement Standards .............................................................................................
Fabricated Special Tools ..............................................................................................................
Direct Support and General Support Troubleshooting Chart - Liquid Loading System .................
iv
Page
3-2
3-2
4-12
4-15
4-15
5-1
11-5
11-6
11-9
11-9, 11-10
11-13
11-17
11-20
CHAPTER 1
INTRODUCTION
Section I. GENERAL
for this equipment, and the list of maintenance and
operating supplies required for initial opera tion.
1-1.
Scope
a. This manual provides instructions for opera
tion and maintenance of the Agrinautics Model 30000
aircraft mounted insecticide sprayer. Chapters 1 and 2
provide information and operating instructions. Chapters
3 through 5 provide main tenance instructions for
operator, organizational, and direct and general support
maintenance. Chapters 6 through 10 provide repair
information for direct support and general support
maintenance.
Chapter 11 provides maintenance
instructions for the liquid loading system. Chapter 12
provides administrative storage instructions and
instructions for destruction of materiel to prevent enemy
use.
b. Appendix A contains a list of publications
applicable to this equipment. Appendix B contains the
maintenance allocation chart. Appendix C contains the
basic
issue
items
list
(BIIL)
authorized
1-2. Forms and Records
Maintenance forms, records, and reports which are to be
used by maintenance personnel at all maintenance levels
are listed in and prescribed by TM 38-750.
1-3. Reporting of Errors
Report of errors, omissions, and recommendations for
improving this publication by the individual user is
encouraged. Reports should be submitted on DA Form
2028, (Recommended Changes to Publications) and
forwarded direct to Commanding General, U. S. Army
Mobility Equipment Command, ATTN: AMSMEMPP,
4300 Goodfellow Boulevard, St. Louis, Mo. 63120.
Section II. DESCRIPTION AND DATA
ed inside the helicopter on a support structure.
Insecticide from the tank assembly is pumped to the
spray booms by a windmill type pump con trolled by the
operator. The tank assembly and other insecticide
sprayer components are mounted on a skid to facilitate
moving and tiedown. Filling the tank assembly with
insecticide is accomplished by use of the liquid loading
system interconnected between the tank assembly and
external insecticide supply.
1-4.
Description
a.
General.
The aircraft mounted insecticide
sprayer with pump (fig. 1-1) consists of the insecticide
sprayer (fig. 1-2), liquid loading system (fig. 11-1), skid
(fig. 4-1), and Government furnished field chest (fig. 4-1).
The sprayer is designed for easy installation in a
helicopter. Two spray booms extending from the doors
on each side of the helicopter are used during operation
to spray insecticide from a tank assembly through
nozzles in the booms. The tank assembly is mount
1-1
Figure 1-1. Insecticide sprayer in UH-1B helicopter.
1-2
b. Insecticide Sprayer. The insecticide sprayer
(fig. 12) consists of a support structure, tank, windmill
driven pump, valves, spray booms and nozzles, and a
control system. Normally, the sprayer is not in the
helicopter,
but
is
maintained
ready for use. It can be installed in a helicopter by four
men in about 1 hour.
Note:
Initial loading, including uncrating,
inventory, assembly, and loading, may
require about 6 hours.
1-3
1.
2.
3.
4.
Tank assembly
Filler cap and strainer
Vent and overflow tube
Web safety strapUH-1B installation
(WB661-1-52N)
5.
6.
Tank strap assembly
Web safety strapUH-1D installation
(WB661-1-25N)
7.
8.
9.
10.
11.
12.
13.
14.
15.
Pump inlet tube
Center boom (with tee
strainer assembly)
Boom attaching nut
Boom tube
Boom support strut
Rear boom cable
Boom support cable
Nozzle assembly
Boom clamp
16.
17.
18.
19.
20.
21.
22.
23.
24.
Boom brace
Front boom cable
Pump and brake assembly
Sychromatic windmill
Pump strut
Pump cable
Web safety strap
(WB661-1-52-N)
Tank support
Bypass valve
Figure 1-2. Insecticide sprayer - assembled view.
1-4
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
Control valve
Manual control panel
Valve control lever
Pressure gage
Pump brake lever
Handle
Liquid level gage
Strap tiedown end fitting
Ground loading tube
Valved nipple (male)with dust cap
c. Liquid Loading System. The liquid loading
system (fig. 11-1) is used to load insecticide spray fluid
into the insecticide sprayer. It is made up of gasoline
operated pump with a pump inlet strainer, an outlet ball
valve, and three lengths of hose. The hoses and pump
inlet and outlet are provided with quick disconnect
couplings.
d
Skid. The entire insecticide sprayer and
liquid loading system is shipped attached to a skid (fig.
41). Included with each sprayer is a field chest holding
spare parts and tools. The skid and mounted parts are
contained in a specially de signed packing crate.
e. Field Chest. The field chest (fig. 4-1) is
Army supplied and is shipped with the insecticide
sprayer. It is used to store spare parts and tools for the
sprayer.
1-5.
Weight:
As shipped ...........................
Flight weight (empty) ...........
Size (without booms) ...........
Length (each boom) ............
Length (overall)31 ft, 5.56 in.
(3) Pump drive.
Type Operation ...................
Direct coupled, variable
pitch, air driven windmill
(4) Pump.
Type
Bearing
Centrifugal
Sealed
(5) Pump drive brake.
Type Operation
Manually operated
(6) Spray tank assembly.
Capacity............................... 195 gallons maximum
Weight ................................ Empty: 100 lb (approx)
Filled:
Determined by
density of fluid used
Size
................................ 62 in. (w) by 32 in. (dia)
Material ............................... Fiberglass
reinforced
polyester resin
(7) Valve control.
Type ................................ Lever, push-pull rod
Type ................................ operation
Manually
operated
(8) Control valve.
Type Ball rotor valve, operated manually
(9) Bypass valve.
Type ................................ Ball rotor valve
Type ................................ operationSet manually on
ground
(10) Spray boom.
Type ................................ Hollow aluminum
extrusions
Inside diameter .................... 1-5/16 in.
Outside diameter ................. 1% in.
(11) Nozzles.
Type ................................ Diaphragm tee-jet
Quantity (both booms) ......... As required (nominally, 60)
(12) Liquid loading system pump.
Manufacturer........................ Homelite
Model No ............................. XLS 1-3
Type ................................ Twocycle,
gasoline
powered, manually started,
self-priming
(13) Liquid loading system valve.
Manufacturer........................ Worcester
Model No ............................. 14-436T-SE
Type ................................ Manually operated ball
Size
1Y in. line size
(14) Valved couplers.
Manufacturer Snap-Tite, Inc.
Model No.
Female......................... AVKC24-24F (TEF)
Male............................. AVKN24-24F (TEF)
Type Double shutoff, quick-disconnect, ball lock,
manually operated (15) Insecticide sprayer system.
Refer to figure 1-3 block diagram.
Differences Between Models
The insecticide sprayer may be mounted on either the
UH1B or UH1D helicopters with slight changes in the
mounting procedure. Refer to paragraph 4-3, step a for
details.
1-6.
100 pounds
200 (approx)
10 ft (w) x4 ft (d) x38 ft (h:
11 ft, 7.78 in.
Identification and Tabulated Data
a. Identification.
The aircraft mounted
insecticide sprayer has two identification plates.
(1) Insecticide sprayer plate. Located on
the right front panel.
Specifies nomenclature,
manufacturer, model and serial numbers, and tank
capacity.
(2) Liquid loading system pump plate.
Located on the engine fan housing.
Specifies
nomenclature manufacturer, model and serial numbers,
and pump rating.
b. Instruction.
The
aircraft
mounted
insecticide sprayer has 10 instruction plates.
(1) Manual control plates. Eight instruction
plates are located on the manual control panel (26, fig.
12). They identify control positions of the control valve
and pump brake levers (27 and 29).
(2) Liquid loading system. Two instruction
plates are located on the liquid loading system pump:
switch ON/OFF plate (13, fig. 11-15), and a decal on the
pump outlet stating to prime pump before starting engine.
c. Tabulated Data.
(1) Aircraft mounted insecticide sprayer.
Manufacturer ....................... AGRINAUTICS
Model ................................ 30000
Serial number range............ 101 through 128
(2) Overall dimensions and weight. See
figure
4-1
for
reduced
shipping
dimensions.
1-5
Figure 1-3. Insecticide sprayer system - block diagram.
1-6
CHAPTER 2
OPERATING INSTRUCTIONS
Section I. SERVICE UPON RECEIPT OF MATERIEL
(1) Check strainer assembly (11), fluid
coupler and nipple (4 and 5), hoses (8), and ball valve (2)
for tightness and condition.
(2) Check fuel level of pump engine. Add
fuel if needed.
2-1.
Inspecting and Servicing the
Equipment
a. Insecticide Sprayer. Prior to each flight,
with the insecticide sprayer (fig. 1-2) installed in the
helicopter, perform the following preflight checks
specified by the Maintenance Allocation Chart (app. B):
WARNING
Fuel and fuel vapors are explosive
mixtures. Do not use near open
flame.
Wash hands after using,
before smoking or eating.
(1) Check all hoses for condition and
tightness.
(2) Check all fluid couplings for tightness.
(3) Check tank assembly (1) for damage,
leaks, and alignment.
(4) Check vent and overflow tube (3) for
condition and tightness.
(5) Check tank straps (4 or 6, and 22),
pump struts (20), and tiedown lugs (28, fig. 4-2) for
tightness.
(6) Check boom tubes (10, fig. 1-2), boom
support struts (11), braces (16), struts (20), and cables
(12, 13, and 17) for wear, damage, proper tension, and
tightness.
(7) Check all nozzles (14) to assure that
tips are clean and are properly aligned.
(8) Check attach fasteners for pump and
brake assembly (18), for tightness.
(9) Check blades of synchromatic windmill
(19) for proper angle setting, as called out in flight and
spray plan.
(10) Check handle of bypass valve (24) for
proper position as called out in flight and spray
plan.
CAUTION
Mix fuel in exact amounts. Use only
clean, fresh gasoline, and clean
mixing cans. Mix oil and fuel well
before pouring into fuel tank to
insure constant oil content.
(a) Thoroughly mix fuel in a clean fuel can,
using the following table as a guide:
Fuel Mixing Table
(1:16 ratio of OE-30 motor oil to regular gasoline)
Oil
% pint
1 pint
1 quart
Gasoline
1 gal
2 gal
4 gal
WARNING
Do not fill gas tank when engine is
running, as to do so might cause a
fire.
(b) Fill tank to within 1/, inch of top of filler neck.
Use a filler spout or funnel to prevent spillage. Replace
gas cap and wipe up any spilled fuel before starting
engine.
(3) Inspect engine and pump for general
condition. Inspect ignition cable for security.
(4) Check that ball valve (2), is in closed
position (handle across tube).
CAUTION
Before starting engine, be sure the
pump contains fluid (insecticide or
water).
(5) Remove pump filler cap (3, fig. 112)
and fill pump body with fluid through opening. Replace
cap and gasket.
Note:
Always replace filler cap and gasket after priming pump.
The pump cannot self-prime when dry. However, once
filled with fluid, the pump will retain fluid for automatic
priming and need not be refilled except if overturned or
drained.
(6) Start the pump engine and run for about 30 seconds
to test for proper operation. Stop engine after this test.
Refer to paragraph 2-5, step
b for engine starting and stopping.
Note:
Handle is closed in pull position, with
flow going back to pump.
(11) Check control valve (25) for operation
by using valve control lever (27). If faulty, check for
binding in fittings at end of connecting rod.
(12) Check that manual control panel (26) is
in proper position.
(13) Check fan brake in locked and
unlocked positions by using pump brake lever (29).
Note:
Fan should spin freely by hand when
unlocked.
(14) Listen to pump bearings when fan is
hand spun to assure freedom from friction.
b. Liquid Loading System (fig. 11-1). Prior to
using the liquid loading system to load fluid into the
insecticide sprayer, perform the following checks:
2-1
Section II. CONTROLS AND INSTRUMENTS
2-2.
General
This section describes the controls and instruments of
the insecticide sprayer and liquid loading system. It also
provides information needed to insure proper operation
of the equipment.
or to the pump when the control valve (25) is closed. It is
set prior to flight as stated in the flight and spray plan.
The valve is hand set to one of two positions, closed or
open. The handle position is marked on the valve
casting.
b. Liquid Loading System. The following controls
used in pump operation are mounted on the pump
engine (fig. 11-2):
(1) Starting rope grip. The starter grip (9) is
attached to a starting cord. Pulling the starter grip turns
the engine for starting.
(2) Choke button. The choke button (20) is used
when starting a cold engine. Pulling the choke button
partly out decreases air supply to the engine.
(3) Ignition ON/OFF switch.
The ignition
ON/OFF switch (24) must be ON for starting engine.
Placing switch to OFF stops engine.
(4) Throttle button. The throttle button (28) is
used to control gas flow to the engine. Pushing button in
causes engine to speed up. Pulling button out slows
engine speed.
(5) Pump outlet ball valve. The pump outlet ball
valve (2, fig. 11-1) is set by hand to block the pump
outlet port. It is used to control insecticide flow when
filling tank on insecticide sprayer. Closing this valve also
keeps fluid in the pump when test running the engine.
The valve is closed when the handle is across the tube.
2-3. Controls and Instruments
a. Insecticide Sprayer. The following controls and
instruments are installed on the insecticide sprayer for
use in flight operations.
(1) Manual control panel. A manual control panel
(26, fig. 1-2) is mounted on the front side of the tank
assembly, between the pilot and copilot seats. The
control panel contains a pump brake lever (29), a valve
control lever (27), and a pressure gage (28). The pump
brake lever is used to hold or free the windmill for
operation, as required. The valve control lever is used to
control flow of liquid to the spray booms. Instruction
plates showing the control positions are placed next to
both valve levers. The pressure gage, within a range of 8
to 100 psi in 2 psi steps, is mounted on top of the manual
control panel. The pressure gage reads insecticide fluid
pressure at the center of the spray booms.
(2) Bypass valve. A bypass valve (24, fig.1-2) is
installed partly beneath the tank, between and behind the
crew seats. The bypass valve is attached to the tank and
opens into the tank. It is used to direct spray fluid back
into
the
tank
Section III. OPERATION UNDER USUAL CONDITIONS
General
paragraph 34. Refer to paragraph 2-7 for operating
a
The instructions in this section are to inform
procedures.
and guide personnel operating the aircraft mounted
b. Liquid Loading System. Before starting the liquid
insecticide sprayer and liquid loading system.
loading system pump, perform the check list of
b.
The operator must know how to perform
Perform any preventive
paragraph 2-1, step b.
every operation of which the insecticide sprayer and
maintenance checks and services found necessary as
liquid loading system are capable. This section contains
listed in paragraph 11-4. Start the liquid loading system
instructions on starting, stopping, and operating the
pump as outlined in the following steps (fig. 11-2):
insecticide sprayer and liquid load ing system, and on
CAUTION
coordinating the basic motions to perform the specific
Before starting the engine for the first time after
tasks for which the equipment is designed. Since nearly
unpacking (refer to para 4-2, step b), remove spark plug
every job presents a different problem, the operator may
and turn engine over several times to prevent hydrostatic
have to vary given procedures to fit the individual job.
lock.
2-5.
Starting
(1) If engine is cold, loosen fuel filler cap (8). This will
a. Insecticide Sprayer. No specific preflight
relieve a vacuum which may have formed in a cold fuel
starting procedures are required for the insecticide
tank.
sprayer. However, the preflight check list of paragraph
(2) Set ignition switch (24) to ON.
21, step a must be performed. Per form any preventive
(3) If engine is cold, pull choke button (20) outward. If
maintenance checks and service functions found
engine is warm, little or no choking should be needed.
necessary
as
listed
in
2-4.
2-2
by performing the steps described in paragraph 25.
Load liquid into sprayer tank in the following manner (fig.
11-1):
WARNING
Insecticides are poisonous, and should be
handled with care. Avoid splashing fluid and
excessive contact and breathing of fumes.
Wash hands before smoking or eating, after
contact with insecticides.
CAUTION
r
(1) Place the liquid loading system on right
side of aircraft (pilot side). Place the spray fluid drums
within 10 feet of the pump.
CAUTION
Check contents of drum before
loading. Be sure contents are in
liquid state, and not clotted into
lumps. Do not mix water or waterbase fluids with oil-base fluids, as
mixing will cause the fluids to jell.
(2) Remove large cap from top of fluid
drum and place suction pipe (9, fig. 11-1) into drum.
(3) Check that ball valve (2) is in closed
position (handle across tube).
(4) Start pump engine and verify that
pump is primed. (Refer to paragraph 25, step b for
starting procedure, and paragraph 21, step b (5) for
pump priming procedure.)
Note:
A sign that pump is primed is slowdown or laboring of
engine.
(5) Remove dust caps from valved coupler
(4) and mating valved nipple (34, fig. 12)
on insecticide sprayer.
(6) Engage coupler halves, open ball valve
(2, fig. 11-1), and start filling sprayer tank. A sealing
valve in each coupler half opens upon engagement to
allow fluid to flow.
CAUTION
As tank fills, check for leaks. Shut
down filling operation at once if any
leaks are observed.
(7) Fill tank to desired level, as noted on
liquid level gage (31, fig. 1-2), or markers on ends of
tank. Do not fill above 195 gallons.
Note:
Tank end markings may not be the same if helicopter is
not parked on level pad. In this case, average readings
of both ends of tank.
(8) Stop fluid flow by turning ball valve (2,
fig. 11-1) so handle is across tube.
(4) Pull starter grip (9) upward with quick,
short pulls. Do not pull the starting rope out to the end or
allow it to snap back by itself. Hold the cord so it will
rewind properly on the pulley.
CAUTION
If you need to stop engine
prematurely, flip ignition switch to
OFF position.
(5) When engine fires, push choke button
halfway in. Continue to crank until engine starts. The
engine should start within one to five cranking attempts.
(6) If the engine does not start after
several cranking attempts, pull the choke button out and
try again.
(7) As the engine warms up, push choke
button slowly inward. Always operate the warm engine
with the choke all the way in.
(8) Tighten fuel filler cap after engine has
started.
Note:
Although the pump engine starts easily
at any throttle setting, including idle,
supply the engine with all the fuel it
wants for “cold starting.” After the pump
is running and has primed, you can set
the throttle to desired pump
ing speed by pulling throttle button (28)
outward.
2-6.
Stopping
a. Liquid Loading System. The liquid loading
system pump can be stopped after filling the insecticide
sprayer tank or when desired, by performing the
following steps (fig. 112):
(1) Pull pump engine throttle button (28)
out to slow engine speed.
(2) Place ignition ON/OFF switch (24) to
OFF to stop pump engine.
(3) Close pump outlet ball valve (2, fig. 11
1) to stop insecticide flow.
Valve is
closed when handle is across tube.
b. Insecticide Sprayer.
Operation of the
insecticide sprayer is stopped as follows (fig. 12):
(1) Place valve control lever (27) to
VALVE CLOSED position to stop spray operation.
(2) Place pump brake lever (29) to BRAKE
ON position to stop pump operation.
2-7.
Operation of Equipment
a. General.
Operation of the insecticide
sprayer and liquid loading system consists of loading, inflight checkout, in-flight operation, and post flight
operations. Adjustment of the windmill blade angle and
changes in nozzle parts are done at the organizational
level and are covered in paragraph 45, step b.
b. Loading Procedure. Prepare the insecticide
sprayer and liquid loading system for operation
2-3
CAUTION
Close input valve before detaching
hose from sprayer.
reading (as stated in flight plan). Observe nozzles for
proper operation and flow, and check for system leaks.
(5) After about 30 seconds, close valve control
lever (27).
(6) Check nozzles for drip, and again check
system for leaks.
(7) Repeat in-flight spray system checkout of
steps 3 through 6, above.
(8) Record any troubles noted for future action.
(9) Place pump brake lever (29) in BRAKE ON
position, or permit pump to run as stated in flight plan.
Note:
On successful completion of the in-flight
checkout, the spray system is ready for
operation.
d. In-flight Operation.
Conduct in-flight
operation as stated in flight plan. Observe safety
precautions listed on inside front cover of this manual.
Use the following steps and figure 12 as a guide:
(1) Prior to reaching spray area, place
pump brake lever (29) in BRAKE OFF position.
(2) At the desired point, move valve
control lever (27) to VALVE OPEN position.
(3) Conduct spray operation as stated in
flight plan.
(4) At the end swath (pass), move valve
control lever to VALVE CLOSED position to stop spray
operation.
(5) On completion of spray operation,
place brake control lever in BRAKE ON position to
prevent overheating of pump.
e. Post Flight Operation. At end of spray
mission, the following post flight operations must be
performed:
CAUTION
Be sure you drain any fluid still in
tank into a drum that contains the
same type fluid being used. Do not
mix oil-base fluids with water-base
fluids.
(1) Tank holds some spray fluid at end of
flight and must be drained. Use one length of hose from
liquid loading system to connect to valved nipple (34, fig.
1-2) of insecticide sprayer. Drain fluid from tank back into
fluid drum.
(2) Using the liquid loading system so that
it may be cleaned out also, fill the spray tank with water,
or non-corrosive mineral oil. Use water if spray fluid was
water-base; use mineral oil if spray fluid was oil-base.
(3) Fly helicopter to an area set aside for
dumping, and permit system to unload. Empty tank by
spraying in a manner like that described for normal
operation in paragraph 2-7, step d.
(9)
Detach hose from aircraft by releasing ball
holding ring (fig. 82) with one hand and pulling hose
away with other hand.
(10)
Replace dust caps on coupler halves.
Place hose end on top of barrel or other place to protect
from dirt. Replace cap on fluid drum.
CAUTION
Do not attempt to load insecticide
sprayer
before
mounting
and
securing sprayer in helicopter.
(11) A second method of filling the tank is
through the top filler cap on tank (2, fig. 1-2). A hand
pump or bucket and funnel may be used. In either case,
use care not to damage the filler neck or strainer, or
contaminate the helicopter.
c. In-flight Checkout. Prior to carrying out
actual spraying operations, conduct an in-flight checkout
of the sprayer system. Perform checkout as follows (fig.
1-2):
WARNING
In-flate checkout of the spray system
must be carried out in an area set
aside for this purpose to prevent
accidental injury or contamination to
personnel, animals, or vegetation.
Never exceed an air speed of 120
knots with the spray system installed
in the aircraft.
If spray booms vibrate or misalign
during flight, reduce speed slowly,
land, and adjust tension of cables (ref
para 43, steps a(7)(h) through a(7)(l)).
If a leak develops in flight within the
sprayer system, apply pump brake at
once and stop spraying.
If fan blade is damaged in flight and
causes vibration, apply pump brake at
once and stop spraying.
CAUTION
Do not allow pump to run without
fluid in actual operation.
(1) Subject to flight plan, pump brake lever
(29) may be released (BRAKE OFF position) soon after
takeoff. This will permit stirring or heating of fluid.
(2) When planned altitude and speed have
been reached and aircraft has arrived at test or
operational area, proceed with in-flight checkout.
(3) If pump brake has not yet been
released, release at this point. Place valve control lever
(27) to VALVE OPEN position and observe nozzles for
spray.
(4) Observe pressure gage (28) for proper
2-4
may also remove the plug from spray boom ends to
speed the flushing and draining.
(5) Clean and decontaminate the helicopter,
spray system, and liquid loading system as required.
(6) Leave both the control valve (25) and
bypass valve (24) in the middle (unlocked) position when
the system is not in use.
Note:
If desired for cleaning operation, remove
nylon plugs from end of spray booms
prior to flushing operations to speed up
the cleaning and flushing process.
(4) A second but less thorough method of
cleaning and flushing the spray system is to dump
cleaning fluid by gravity feed while aircraft is on ground.
Place valve control lever (27, fig. 12) in VALVE OPEN
position
for
this
operation.
You
Section IV. OPERATION UNDER UNUSUAL CONDITIONS
2-8.
General
sprayer system in cold weather may require warming the
spray fluid prior to spraying operations. To preheat the
fluid, place handle of bypass valve (24, fig. 12) in TANK
OPEN position to direct fluid back into tank. Place valve
control lever (27) in CLOSED position to direct fluid to
the bypass valve. Place the pump brake lever (29) in
BRAKE OFF position to permit fluid to circulate for
warming.
c. Operation in extreme heat. When using the
liquid loading system pump in extreme heat, observe the
following:
(1) Check the cooling fins on the engine
cylinder often to be sure they are clean and not
damaged.
(2) If possible, provide shade to protect
the unit from the direct rays of the sun.
d. Operation in dusty areas.
Using the
spraying system in dusty areas will require careful
inspection and cleaning procedures. Use the following
as a guide (refer also to preventive maintenance checks
and services, paragraph 34):
(1) Oily surfaces attract dust quite readily.
Therefore, since the insecticide spray in itself
may be an oil-base fluid, the spray nozzles and other
parts must be inspected and cleaned often.
(2) Keep outer portions of all equipment clean
to prevent dirt buildup.
(3) Inspect and repair all leaks and loose
connections promptly when leakage is noted.
(4) Inspect and clean filters and strainers often.
The liquid loading engine air filter may require weekly or
even daily cleaning.
CAUTION
Never run engine with a clogged air
filter or with air filter removed.
(5) Always use dust caps provided with
liquid loading system quick disconnect couplings. Never
drop hoses in dirt.
(6) Keep spray fluid, gasoline, and oil cans
covered to prevent dirt getting into these fluids.
(7) Use only clean gasoline and oil in
pump engine to prevent clogging of fuel filter wick.
e. Operation in salt water areas.
(1) Salt water and sea air are very
corrosive. If the equipment is used in a salt water area,
Use of the insecticide sprayer system under unusual
weather conditions depends much on the capabilities
and limitations of the aircraft with which it is used. Refer
to the documents which apply to UH1B and UH1D
helicopters for special procedures.
2-9.
Procedures
a. General. To insure proper operation, keep
the equipment clean and operate and maintain it as
instructed in this manual. The following additional steps
are provided for conditions under which the equipment
may be expected to operate:
b. Operation in freezing weather. Using the
system in freezing weather poses the problem of liquids
freezing in the pumps, containers, tank, lines, spray
booms, and nozzles. Generally, operations will not be
carried out when daytime temperatures are at such
extremes.
However, overnight freezing may be
encountered in areas where the equipment is required to
operate. It is best to allow the equipment to thaw out
naturally, without applying external heat. Thoroughly
draining the equipment and covering overnight will
reduce the effects of short term freezing weather. The
following steps will help protect the liquid loading pump
engine from freezing.
(1) Keep fuel tank of liquid loading pump
full at all times to prevent moisture buildup. Keep fuel
tank cap securely closed except just before starting,
when it is loosened to break a possible vacuum.
(2) Use winter grade gasoline in fuel
mixture for easier starting.
(3) Before starting engine, check to see if
pump is frozen. Pull starter cord just enough to see if
crankshaft will turn freely. If pump impeller is frozen fast,
heat the pump slowly, until the ice melts.
(4) Start the engine as described in
paragraph 25, step b. You may need to crank the engine
a few extra times to start. Use extra care to insure that
the engine warms up completely before pumping fluid.
(5) Operation in cold weather. Use of the
2-5
flush often with fresh water. Then wipe dry and protect
the finish by wiping with an oily rag. (2) Paint exposed
metallic surfaces if paint has been removed. Coat
exposed ferrous metal surfaces with a standard issue
rust-proofing material if available, or cover parts with a
light film of grease.
f
Operation at high altitudes.
(1) Operation of the insecticide sprayer at
high altitudes may require insecticide tank to be only
partially filled. Consult UH1B or UH1D manuals for
takeoff weight restrictions.
(2) Liquid loading system pump engine power
output will decrease at a rate of 31/2 percent for each
1000 foot increase in elevation. Pump output will
decrease accordingly as engine output decreases.
(3) Maintain maximum performance of
pump engine by following all service instructions
carefully. Be sure the air cleaner element is not clogged.
(4) Pump engine carburetor may require
readjustment for high altitude operation.
Refer to
paragraph 118, step f for instructions.
2-6
CHAPTER 3
OPERATOR’S MAINTENANCE INSTRUCTIONS
Section I. BASIC ISSUE ITEMS
3-1.
General
a. Tools, equipment, and repair parts issued
with or authorized for the aircraft-mounted insecticide
sprayer are listed in the basic issue items list, appendix
C.
b. Refer to chapter 11 for Operator’s
maintenance instructions for the liquid loading system.
3-2.
Repair Parts and Special Tools List
Refer to the Repair Parts and Special Tools List Manual,
TM 5-3740-211-24P for a complete list-ing and
illustrations of repair parts and special tools used with the
aircraft-mounted insecticide sprayer.
Section II. LUBRICATION INSTRUCTIONS
c. Insecticide Sprayer. Most components of
Detailed Lubrication Information
the insecticide sprayer are adequately lubricated at
a. General. Keep all lubricants in closed
assembly for the life of the system. Therefore, no
containers and store in a clean, dry place away from
scheduled lubrication periods have been established.
external heat. Allow no dust, dirt, or other foreign
d. Windmill Pump and Brake Assembly.
material to mix with the lubricants. Keep all lubrication
Lubrication of the windmill driven pump is accomplished
equipment clean and ready to use.
by the fluid being pumped.
b. Cleaning.
Keep all external parts not
CAUTION
requiring lubrication clean of lubricants.
Before
lubricating the equipment, wipe all lubrication points free
Never allow the pump to operate dry. If
of dirt and grease. Clean all lubrication points after
fluid is not being pumped, apply pump
lubricating to prevent accumulation of foreign matter.
brake.
3-3.
Section III. PREVENTIVE MAINTENANCE CHECKS AND SERVICES
operation of the unit for correction to be made as soon as
operation has ceased. Stop operation at once if a defect
is noted during operation which would damage the
equipment if operation is continued.
3-5.
Operator’s Preventive Maintenance Checks
and Services
Table 3-1 lists the operator’s preventive maintenance
checks and services and functions.
3-4.
General
Insure that the aircraft mounted insecticide sprayer
system is ready for use at all times. Inspect the
equipment following a regular plan so that defects may
be found and corrected before they result in serious
damage or failure. Perform the needed preventive
maintenance checks and services listed in paragraph 35.
Item numbers indicate the sequence of minimum
inspection requirements. Record any defects found
during
Section IV. TROUBLESHOOTING
serves only as a guide and does not preclude the
possibility of other troubles existing.
3-6.
Troubleshooting Chart
Table 3-2 lists the Operator’s troubleshooting activities
for
the
insecticide
sprayer.
The
chart
Section V. MAINTENANCE OF AIRCRAFT MOUNTED INSECTICIDE SPRAYER
a. Servicing. Service liquid loading system
3-7. General
pump engine by cleaning air filter, intake strainer, and
Maintenance duties of the operator/crew of the
exterior, and by filling the fuel tank with the proper fuel/oil
insecticide sprayer consist primarily of inspecting the
mixture.
equipment to determine its serviceability and keeping the
b. Cleaning.
Cleaning the equipment is
equipment clean. Discrepancies are logged for service
accomplishing by draining, flushing, and decontaminating
by higher level maintenance activities. Exceptions to this
the sprayer system, aircraft, and liquid load-ing system
procedure are as follows:
components promptly upon completion of spraying
operations.
3-1
Table 3-1. Operator’s Preventive Maintenance Checks and Services.
Item
No.
B
01
02
Daily Interval
D
Item to be inspected
Procedure
Reference
A
X
Insecticide sprayer
Pump assembly
Perform pre-light check
Do not allow to run dry
Insecticide sprayer
Perform post flight check
X
03
X
2-1
2-7c
3-3d
2-7e
1
B = before operation; D = during operation; A = after operation.
Table 3-2. Operator’s Troubleshooting Chart.
Malfunction
Probable cause
1. Booms noticeably vibrate or misalign in
flight
2. Leak develops in system during flight.
Cable tension out of adjustment.
3. Use of pump causes vibration.
Fan blade damaged, or pump
bearings faulty.
a. Loose connection or connector on
control valve.
Cancel mission; return to base (2-7d).
4. No response to start spray command.
b. Inlet or outlet couplings split.
5. No response to stop spray command.
6. Spray intermittent.
7. Spray uneven
Faulty fluid system components.
Loose connection or connector on
control valve.
a. Brake cable or cable connector
loose.
b. Faulty windmill drive on pump.
a. Contamination in spray nozzle.
b. Faulty pump.
c. Boom tee strainer clogged.
Corrective action
Land aircraft and adjust tension (43a (7)).
Apply pump brake; stop operations
(2-7d).
Apply pump brake; stop operations
(2-7d).
Cancel mission; return to base (27d).
Stop pump at once using pump
brake(2-7d).
See footnote at end of table.
See footnote at end of table.
See footnote at end of table.
See footnote at end of table.
See footnote at end of table.
For intermittent or uneven spray, record condition for service. Depending upon severity of condition, complete or
discontinue mission.
3-2
CHAPTER 4
ORGANIZATIONAL MAINTENANCE INSTRUCTIONS
Section I. SERVICE UPON RECEIPT OF MATERIAL
in the spray booms upon field assembly of the
Inspecting and Servicing the Equipment
equipment. Included on the skid are the liquid loading
a
General. Each aircraft mounted insecticide
system and a field chest containing tools and spare
sprayer is shipped and stored in a skid (fig. 41). The
parts.
sprayer and skid are enclosed within a ship ping crate.
b.
Uncrating and Inventory of Equipment (fig.
The insecticide sprayer is shipped fully assembled,
41). Uncrate the insecticide sprayer, liquid load ing
except with the spray booms, nozzles, and windmill fan
system, and field chest. Check for missing parts.
detached, as shown in figure 4-2. The spray nozzles are
to
be
installed
4-1.
4-1
Figure 4-1. Aircraft-mounted insecticide sprayer - shipping and storage.
4-2
(1) Remove shipping crate in sequence marked
on outside of the removable side panel of the crate (ref.
Military Specification MILS 52623 (ME)).
(2) Remove field chest (1). Count all parts
enclosed in chest and check against basic issue items
list (app C). Record any shortages noted. Use tools from
chest as needed for removal of remainder of equipment.
(3) Remove wing nuts and washers (2 and 3)
and liquid loading system pump (4).
(4) Remove liquid loading system hoses (5) and
suction pipe (6).
(5) Remove spray booms and cables (7) and
boom braces (8).
(6) Remove control valve rods (9), web straps
(10) holding control panel in place, and all small
components from skid frame.
(7) Detach quick release pins (11) and re move
skid frame (12) from skid base (13).
(8) Remove cotter pins from each of eight
tiedown lugs (15), and remove lock nuts and washers.
CAUTION
Four men are needed to lift tank
installation. Lift by handles only; do
not lift by braces or spray booms.
(9)
Remove
tank
installation
from
skid.
(10) Reattach all attachment hardware not part of the
insecticide sprayer to the skid. Retain shipping crate and
skid for later storage and re shipment use.
c. Initial Inspection and Servicing of Equipment. Prior to
installing insecticide sprayer into aircraft, perform all
inspections allocated to the Operator maintenance level.
Perform these inspections to insure that the equipment is
in operable condition. Perform the tasks listed in table 42.
4-2. Assembly
a. Assemble Insecticide Sprayer (fig. 42). The
insecticide sprayer is shipped partly disassembled. Prior
to initial installation of the insecticide sprayer into
helicopter (refer to P3), install nozzles and synchromatic
windmill assembly.
CAUTION
Spray boom tubes may be assembled
to tank installation for initial
assembly if desired. However, the
spray boom tubes must be removed
for installation of the insecticide
sprayer into the helicopter. Refer to
43 for installation procedures for
spray boom assemblies.
(1) Install nozzles (16) to boom tubes of spray boom
assemblies (19) as follows:
4-3
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
Lockwire, or turnbuckle
locking clip, MS21256
(Used for shipping
and storage only)
Nut, MS 21044C3
Washer, MS15795-808
Screw, MS51958-66
Shackle, wire-rope,
MS20115-5
Nut, MS21044C3
Washer, MS15795-808
Screw, MS51958-67
Nut, MS21044C3
Washer, MS15795-808
Screw, MS51958-67
Nut, MS21044C4
Washer, MS15795-810
Clevis bolt, AN24-18A
Boom support strut
Nozzle
17.
18.
19.
Nipple, SAE J530, fig. 1
Elbow, SAE J530, fig. 14
Spray boom assembly
(ref fig. 6-1)
20. Bolt, AN3-22A (3 requd)
21. Nut (1)
22. Washer (1)
23. Bolt (1)
24. Synchromatic windmill
assembly (ref fig. 6-1)
25. Cotter pin
26. Lock nut
27. Washer
28. Tiedown lug
29. Tank installation (ref fig.
4-9)
30. Cap, AN929-a4D(1)
31. Plug, AN806-24D(1)
32. Plug, SAE J531
4-4
Figure 4-2. Insecticide sprayer - installation details.
4-5
(a) Install elbow (18) in spray boom.
(b) Install nipple (17) into elbow.
(c) Attach nozzle (16) to nipple. Tighten
parts snug only.
Note:
Boom tubes have holes for 30 nozzles each.
If nozzles are not required for all holes,
use plug (32) in holes not used.
(c) Connect remaining hoses (8) together and
attach to ball valve (2), using appropriate couplers (4)
and nipples (5).
(2) Remove the warning tag attached to the
engine, which reads: "Caution: Prior to starting the
engine, the spark plug shall be removed and the engine
turned over several times to eliminate possibility of
hydrostatic lock.
CAUTION
Do not pull starter cord out to end, or let it
snap back by itself.
(3) Remove spark plug from engine. Using the
starting cord, turn the engine over several times.
(d) Position all nozzles so that spray orifices
face down and forward.
(2) Attach synchromatic windmill assembly (24) to
pump and brake assembly of tank installation (29) as
follows:
(a) Remove nut (21), washer (22), and bolt
(23) used to hold windmill assembly together for shipping
or storage.
CAUTION
Do not allow pump engine to run for more
than a few minutes without pumping fluid.
Refer to paragraph 2-1, steps b(4) and
b(5) for pump priming procedures.
(4) Install spark plug and start engine using steps
described in paragraph 2-5, step b.
Allow pump to
run for about 30 seconds.
CAUTION
Do not overtighten bolts when attaching
windmill fan to pump and brake
assembly.
(b) Attach windmill assembly to pump and
brake assembly using three bolts (20). Use a 3/8-inch
socket wrench to tighten the attachment bolts. Tighten
bolts snug only.
b. Assemble and Test Liquid Loading System.
Assemble the liquid loading system and test run the
pump engine using the following steps as a guide:
(1) Assemble the liquid loading system, using
figure 11-1 and the following steps as a guide.
(a) Remove dust plugs and caps from the
respective valved coupler (4) and valved nipple (5).
(b) Attach hose (8), connected to suction pipe
(9), to strainer assembly (11).
4-3. Installation
a. Install the insecticide sprayer into the UH-1B or
UH-1D helicopter, using figure 4-2 and the following
steps as a guide:
Note:
Installation is identical for UH-IB or UH-ID
helicopter models, except where noted.
(1) Remove tiedown lugs (28) from skid base
(13, fig. 4-1).
(2) Place tiedown lugs on studs in cargo deck
of the helicopter. See figure 4-3 (UH-1B) or figure 4-4
(UH-1D) to find correct stud locations.
4-6
Figure 4-3. UH-1B installation details.
4-7
Figure 4-4. UH-1D installation details.
Attach other end of strap to the lower, center cargo
rings attached to helicopter rear bulkhead. Cinch straps
down tight.
(b) UH-1D installation. Attach web safety
straps (22, fig. 1-2) between holes in upper channel on
front of tank support (23) and cargo rings in stud
locations as shown in figure 4-4. Attach web safety
straps (6, fig. 1-2) to cargo rings of cargo deck as shown
in figure 4-4. Run other end of strap through strap
tiedown fittings (32, fig. 1-2) on rear of tank installation,
and attach to tiedown rings of cargo deck as shown in
figure 4-4. Cinch straps down tight.
(6) Extend and adjust manual control panel (fig. 45). Control panel position depends upon helicopter model
into which insecticide sprayer is installed. The UH-1B
installation requires that folding brace (1) be attached in
the uppermost position on tank support center brace (2).
The control panel must be in its innermost position in
control panel support (3).
UH-1D installation requires
that folding brace be in lower position
CAUTION
Four men are required to load tank
installation into aircraft.
Do not attempt
to lift by booms or braces. Lift
by
designated handles only. Tank
installation must be secured to aircraft
prior to attaching spray booms.
(3) Place tank installation (29, fig. 4-2) into aircraft
with pump facing forward.
(4) Verify that tiedown lugs (28) are properly
placed. Secure lugs to tank support and tank support to
aircraft with washers (27), lock nuts (26), and cotter keys
(25).
(5) Attach and secure tiedown straps as follows:
(a) UH-1B installation. Attach web safety
straps (22, fig. 1-2) between holes in upper channel on
front of tank support (23) and cargo rings in stud
locations as shown in figure 4-3. Place web safety
straps (4, fig. 1-2) over tank. Attach one end to strap
tiedown end fittings (32) on front of tank installation.
4-8
and that control panel be in its outer position in control
panel support (shown in phantom on figure 4-5). Adjust
control panel position as follows:
(a) Remove nuts (4) and bolts (5) securing
control panel (6) into control panel support (3). Slide
control panel to alternate position (determined by
alternate bolt hole positions in panel and panel support).
Secure with bolts and nuts.
(b) Remove nuts (7) and bolts (8) securing
folding brace (1) to center support of tank support
structure. Move folding brace connecting bracket (9) to
1 Folding brace
2. Tank support center
brace
3. Control panel support
4. Nut, control panel
5. Bolt, control panel
6. Control panel
7. Wing nut, folding brace
alternate position (determined by alternate bolt hole
positions in center support). Secure with bolts and nuts.
(c) Place control panel in extended position.
Be sure tang of spring-loaded lock in folding brace
arm seats in slotted detent on other brace arm.
(d) Select correct valve rod (10) to go
between valve lever (11) and lever on control valve (25,
fig. 1-2). Short rod is used on UH-1B; long rod is used
on UH-1D. Refer to paragraph P24, step e(3) for
instructions on attaching valve rod.
8. Nut, folding brace
9. Folding brace connecting
bracket
10. Valve rod: (for UH-1B,
length 25 in. ) (for UH1D, length 38 in. )
11. Valve lever
Figure 4-5. Alternate control panel positions.
4-9
Note:
Front boom cable passes under pump
support strut on tank installation (29).
1. Insert wire-rope shackle (5) through loop
in end of cable assembly.
2. Secure wire-rope shackle to holes in
end of lower channel rail of tank installation (29) with
screw (4), washer (3), and nut (2).
(h Make sure rear boom cables have slack.
Tighten turnbuckle on inboard forward cable until tip
of boom is about 3 inches forward of boom centerline.
Then tighten turnbuckle on inboard rear cable to
adjust boom back to centerline position.
(i) Repeat the process of step (h) preceding
for outboard cables, except reduce boom deflection for
this step to 2 inches.
(j) Firmly tighten boom tube to boom center
section. Hold boom tube securely with strap wrench,
while tightening boom attaching nut.
(k) Check to see if boom tubes are straight.
If not, repeat preceding steps as required.
(l) Upon completion of cable adjustment, if
available, use MS 21256 lock clips to secure turnbuckles
or 0. 041-inch diameter stainless steel lockwire (1, fig.
4-2).
Attach lockwire per figure 4-6, in
accordance with MS 33540.
(7) Install spray boom assemblies to tank
installation, using figure 4-2 and the following steps as
guides:
(a) Remove cap (30) from end threads of
boom tube.
(b) Remove plug (31) from end of center
section boom on tank installation (29).
(c) Lightly lubricate threads on connector of
spray boom tube with suitable thread lubricate.
(d) Attach boom tube to center section boom
with nozzles aft. Tighten boom attaching nut handtight
only at this time.
(e) Attach boom support strut (15), with rivet
heads up, to inboard tube clamp of spray boom
assembly (19).
Secure with clevis bolt (14), washer
(13), and nut (12). Attach other end of strut to lower hole
in end bracket located at upper end of tank installation
(29). Secure with screw (11), washer (10), and nut (9).
(f) Attach upper boom cable of spray boom
assembly (19) to upper hole in tank end bracket of tank
installation (29). Secure with screw (8), washer (7), and
nut (6).
(g) Attach front and rear boom cables of
spray boom assembly (19) to tank installation as follows:
Figure 4-6. Turnbuckle safetying diagram.
(2) Remove spray boom assemblies as follows:
(a) Support spray boom assembly (19) to
prevent damage.
(b) Remove lockwire (1) or clips from all
turnbuckles. Loosen turnbuckles as needed to provide
cable slack.
Note:
Retain all attaching hardware by replacing in
attachment points from which removed.
(c) Remove nuts (2), washers (3), and
screws (4), retaining wire-rope shackles (5) to tank
installation (29). Remove wire-rope shackles from front
and rear boom cable assemblies of spray boom
assembly (19).
4-4. Removal from Helicopter
a. Usage of the insecticide sprayer is such that it
normally is removed from the helicopter immediately
after use. Removal consists of thoroughly flushing and
cleaning the system, as well as removal from the
helicopter. Use figure 4-2 and the following steps as
guides:
(1) Thoroughly drain and clean the tank and all
fluid lines as described in the post flight operation (ref
para. 2-7, step e). Flush the system thoroughly.
Use noncorrosive mineral oil following use of oilbase spray fluid. Use water following use of waterbase spray fluid. Use the liquid loading system for this
operation to clean that system at the same time.
4-10
(d) Remove nut (6), washer (7), and screw (8)
to detach upper boom cable of spray boom assembly
(19) from tank installation (29).
(e) Remove nut (9), washer (10) and screw
(11) to detach boom support strut (15) from tank
installation (29).
(f) Remove nut (12), washer (13), and clevis
bolt (14) to remove boom support strut (15) from spray
boom assembly (19).
Note:
Do not remove nozzles from spray booms
unless necessary.
(g) Remove nozzles (16), nipples (17), and
elbows (18) from spray boom assemblies (19) only if
required.
(h) Using a strap wrench to keep spray boom
assembly (19) from turning, unscrew boom attaching nut
to release spray boom from tank installation.
(i) Cap open ends of spray boom tubes with
caps (30). Plug open ends of center section boom on
tank installation with plugs (31).
Note:
Do not remove synchromatic windmill assembly
(24) from tank installation unless required.
(3) Remove three bolts (20), and remove
synchromatic windmill assembly (24) from pump and
brake assembly of tank installation.
Remove only if
required. If removed, secure hubs together using bolt
(23), washer (22), and nut (21).
(4) Retract manual control panel of tank
installation (29) using the following steps as a guide:
(a) Remove cotter pin, washer, and clevis pin
(10, 11, and 12, fig. 4-10), to detach valve rod (15), from
lever of control valve assembly (47,
fig. 4-9).
Leave attaching hardware in valve control lever.
Lay loose end of valve rod in drip pan beneath tank
installation.
(b) Firmly depress locking button on brace arm
of control panel, and push control panel to retracted
position.
(5) Detach web safety straps (4 or 6, and 22, fig.
1-2) from cargo rings in helicopter cargo
compartment (fig. 4-3 or 4-4).
(6) Remove cotter pins, lock nuts and washers
(25, 26, and 27, fig.
4-2) from all tiedown lugs (28).
procedures.
(7) Remove tank installation (29) and tiedown lugs
(28) from helicopter.
4-5. Equipment Conversion
a. Replace in Alternate Aircraft. The
insecticide
sprayer may be installed in either the UH-1B or UH-1D
helicopters with only slight modification required.
Installation details are described in 4-3.
Steps
required are:
(1) If not yet removed from helicopter,
remove insecticide sprayer (para 4-4).
(2) Attach tiedown lugs to helicopter cargo
deck.
Note:
UH-1B requires use of eight tiedown lugs.
UH-1D requires use of nine tiedown lugs.
When not in use, ninth tiedown lug is kept in
field chest (1, fig. 4-1).
(3) Install insecticide sprayer into helicopter
(refer to para 4-3).
b. Alteration of Spray Pattern. Alteration of the
spray pattern, as defined by flight and spray plans, may
call for alteration of the system in one or more of the
following ways:
WARNING
Avoid excessive contact with insecticide
spray fluid.
Avoid breathing fluid vapors.
Following contact with fluid and before
eating or smoking, wash hands with soap
and water.
CAUTION
Install nozzles and plugs handtight only.
Remove and reinstall
(1) Quantity of nozzles.
spray nozzles and plugs in threaded holes of spray boom
tubes as required. Refer to paragraph 4-2, step a(1) for
details.
(2) Orifice size. The size of orifice in each
individual nozzle may be changed as required by the
flight and spray plans. Use figure 4-7 and the following
steps as guides:
(a) Unscrew cap (1) from body assembly (8).
(b) Remove spray tip (2).
(c) Install new spray tip with orifice size
selected from those listed in table 4-1.
(d) Secure nozzle components with cap (1).
CAUTION
Four men are required to remove tank
installation from helicopter.
Lift
by
handles only, never by booms or braces.
Do not attempt to remove tank installation
with fluid remaining in tank.
Refer
to
paragraph 2-7, step e for tank draining
4-11
Table 4-1. Nozzle Orifice Data.
Capacity, gpm, and spray angle at:
Dash
No.
Spray
-1
-2
-3
-4
-5
Vendor
part No.
30399-7
30399-9
30399-11
30399-13
30399-15
Approx
equiv
orifice
dia
0. 026
0. 031
0. 035
0. 043
0. 052
20 PS
25 PS
Spray
30PS
Spray
40 PS
Spray
GPM
angle
GPM
angle
GPM
angle
0. 07
0. 11
0. 14
0. 21
0. 28
68
68
69
70
71
0. 08
0. 12
0. 16
0. 24
0. 32
71
71
72
73
74
0. 09
0. 13
0. 17
0. 26
0. 35
75
75
76
76
77
1.
2.
3.
4.
Cap
Spray tip
Strainer assembly
Retainer
5.
6.
7.
8.
50 PS
Spray
GPM
0. 10
0. 15
0. 20
0. 30
0. 40
angle
80
80
80
80
80
60 PSI
Spray
GPM
0. 11
0. 17
0. 23
0. 34
0. 45
angle
GPM
angle
82
82
82
82
81
0. 12
0. 18
0. 25
0. 37
0. 49
85
85
84
84
83
End cap assembly
Diaphragm
Secondary diaphragm
Body assembly
Figure 4-7. Insecticide spray nozzle.
(3) Windmill blade angle adjustment. Adjust
the blade angle of the synchromatic windmill assembly
(24, fig. 4-2) as called for in spray plan.
Use figure 48 and the following steps as guides:
CAUTION
Do not attempt to adjust blades beyond
position 1 on hub if you feel resistance
when turning adjusting nut.
Internal
damage to mechanism will result if you do
so when parts are binding.
4-12
(a) Turn adjusting nut (1) in center of cap hub
(2) clockwise to a setting less than the number you want.
The blade settings is determined when the root
edge of blade (3) matches the value marked on the cap
hub boss.
(b) Turn adjusting nut in counterclockwise
direction and stop at the exact setting. If you overshoot
the setting, return blades in clockwise direction to a value
less than the desired number then repeat
counterclockwise adjustment to the desired setting.
(c) The following list may be used to select
blade tip angles:
Actual tip angle
Pitch setting number
350
2 ½ pitch
300
2 pitch
1/2
250
1 pitch
200
1 pitch
(d) To feather the blades, turn the adjusting
nut until the blade root is in line with the letter F on the
hub.
1.
2.
3.
Adjusting nut
Cap hub
Blade
Figure 4-8. Blade angle pitch setting.
4-13
Section II. MOVEMENT TO A NEW WORKSITE
of hydrostatic lock. "
4-6. Dismantling for Movement
a. Insecticide Sprayer.
Dismantle
the
insecticide sprayer and prepare for packaging. Use
figure 4-2 and the following steps as guides:
(1) If insecticide sprayer is installed in
helicopter, remove from helicopter (para 4-4).
Note:
Disassemble components only as necessary for
packing in shipping container and to protect
parts from damage.
(2) Remove synchromatic windmill assembly
(24) from tank installation (29) as described in paragraph
4-4, step a(3).
b. Liquid Loading System. Prepare the liquid
loading system for reshipment using figure 11-1 and the
following steps as guides:
(1) Thoroughly flush the liquid loading
system.. Use noncorrosive mineral oil if spray fluid used
was oil-base, or water if spray fluid was water-base.
(2) Remove all hose connections at the
valved couplers and nipples (4 and 5), and cap all
openings with the dust plugs and caps attached to each
coupler half.
(3) Prepare the pump (1) engine for shipment
using the following steps as a guide:
(a) Start the engine then choke it until it
stops, to coat all internal parts of the engine with oilcontaining fuel.
Note:
Refer to paragraph 2-5, step b for starting instructions.
(b) Drain the fuel tank and pump cavity
by removing the caps and inverting the engine.
Replace caps after draining.
(c) Remove the spark plug from the
engine. Preserve the combustion chamber with Type P10, grade 2 preservative oil per Military Specification
MIL-L-21260. While rotating the engine crankshaft,
spray 1/4 ounce of preservative oil into the combustion
chamber through the spark plug hole. With
the
crankshaft stopped, spray 1/4 ounce of preservative oil
into the spark plug hole.
Coat the spark plug
threads with a light coating of the preservative oil, and
reinstall the spark plug. Attach a warning tag to the
engine reading as follows: "Caution
Prior to starting
the engine, the spark plug shall be removed and the
engine turned over several times to eliminate possibility
(d) Protect the finish by wiping the entire
unit clean.
If the unit has been exposed to salt water
or sea air atmosphere, wipe the unit with an oily rag.
c. Packaging.
Load the insecticide sprayer and
accessories on the skid, and package in the shipping
crate, using figure 4-1 and the following steps as guides:
(1) Load the tank installation on the skid base
and secure in position using the hardware supplied.
Attach skid frame and attach the spray booms,
cables, liquid loading pump, hoses, field chest, and other
accessories in the specified locations and in the manner
provided.
(2) Secure the cables to the booms with tape
per Federal Specification PPP-T-97, type II or III to
prevent movement.
(3) Place the hinged manual control panel in
its most inward position toward the tank (ref para 4-4,
step a(4)). Secure the control panel to the adjacent skid
frame members with web straps (10).
(4) Secure all other small components which
might move within the designated mounting location with
reinforced tape per Federal Specification PPP-T-97, type
II or III, to prevent movement.
(5) Preserve and package repair parts and
tools included with the sprayer system using the methods
of Military Specification MILP-116.
Package
each
part or group of similar parts in a paperboard or
fiberboard box. Place the packaged repair parts and
tools into the field chest (1, fig. 4-1).
Cushion or block
parts where required to prevent movement within the
chest.
(6) Install the insecticide sprayer and all
associated components and accessories, mounted on
the skid, into the shipping crate. Secure shipping crate
in accordance with figures 1 and 2 of Military
Specification MIL S-52623 (ME).
4-7. Reinstallation After Movement
The procedure for reinstalling the insecticide sprayer
after movement to a new worksite is identical to that for
installing new equipment (paras 4-1, 4-2, and 4-3).
4-14
Section III. REPAIR
PARTS, SPECIAL TOOLS AND EQUIPMENT
sprayer.
4-8. Tools and Equipment
Tools, equipment, and spare parts issued with or
4-10.
Maintenance Repair Parts
authorized for the aircraft mounted insecticide sprayer
are listed in the basic issue items list, appendix C.
Repair parts and equipment covering Organizational
maintenance for the insecticide sprayer are listed and
illustrated in TM 5-3740-211-24P.
4-9. Special Tools and Equipment
No special tools or equipment are required for
Organizational maintenance of the insecticide
Section IV. PREVENTIVE
MAINTENANCE CHECKS AND SERVICES
minimum inspection requirements.
4-11.
General
Insure that the aircraft-mounted insecticide sprayer is
ready for operation at all times. To do so you must
perform a systematic inspection so that defects may be
discovered and corrected before they result in serious
damage or failure. Perform the necessary preventive
maintenance checks and services described in 4-12.
The item numbers indicate the sequence of
4-12.
Organizational Maintenance Preventive
Maintenance Checks and Services
Table 4-2 lists Organizational maintenance level
preventive maintenance checks and service functions.
Table 4-2. Organizational Preventive Maintenance Checks and Services
Interval
Item
No.
Daily
B
01
02
D
A
W
X
X
03
05
M
Item to be inspected
X
X
Tee boom strainer
Hoses, couplings, tank
strainer, nozzles.
Pump brake cables and
controls.
Liquid loading system
strainer.
Windmill blades.
X
04
X
X
B - Before operation
D - During operation
X
Section V.
4-13.
Troubleshooting Chart
Table 4-3 is a tabulation of troubleshooting steps
assigned to Organizational maintenance level for the
AAfter operation
W-W
eekly
M - Monthly
Procedure
Remove strainer; clean or replace, if required.
Clean parts; replace as necessary.
Lubricate.
Clean; replace if required.
Check blade angle and condition; service and
replace as necessary.
TROUBLESHOOTING
insecticide sprayer. The chart serves only as a guide,
and does not mean that other troubles may not exist
Table 4-3. Organizational Troubleshooting Chart.
Malfunction
1. Booms
tiedown devices.
in flight.
2. Leak develops in sprayer system.
3. Use of pump causes.
4. No response to start spray command.
5.
6.
7.
8.
9.
Probable cause
Corrective action
noticeably vibrate or misalign
b. Cable tension out of adjustment.
Faulty fluid system components.
Fan blade damaged.
a. Loose connection on control valve.
b. Inlet or outlet couplings split.
No response to stop spray command. Loose connection on control valve.
Spray intermittent.
Brake cable or cable connector loose.
Spray uneven.
a. Contamination in spray nozzles.
b. Boom tee screen clogged.
Unable to adjust windmill blade pitch Internal mechanism damaged.
angle.
Incorrect pressure gage indication.
a. Gage damaged or out of calibration.
b. Pressure line loose or broken.
4-15
a.
Tank installation loose.
a.
b. Adjust cable tension as required.
Repair or replace faulty components.
Replace fan blade.
a. Adjust and secure connectors.
b. Replace any faulty couplings.
Adjust and secure connectors.
Adjust and secure cable.
a. Disassemble and clean nozzles.
b. Clean or replace screen.
Replace hub assembly.
a.
b.
Replace gage.
Repair or replace pressure line.
Secure all tank
Section VI. MAINTENANCE OF TANK, HOSES,
COUPLING, STRAINER, VALVES, AND TUBING
fittings for the following components are bonded within
4-14.
Tank Assembly
the tank at the respective openings:
a. General. The tank assembly (125, fig. 4-9) is a
(1) Top strainer and cap assemblies (116
200-gallon tank. It is molded from fiberglass reinforced
through 119).
polyester, and has two internal baffles. It is attached to
(2) Overflow tube a n d connector (61 through
the tank support assembly (133) by two strap assemblies
64, 111 and 112).
(123) and serves as the reservoir for the spray liquid.
(3) Liquid level gage (110).
Tank spray liquid quantity is displayed by a liquid level
(4) Bypass valve and gasket (52 and 51).
gage (110) and by markings on the ends of the tank.
(5) Sump and gasket (34 and 33).
The tank is translucent, allowing the fluid level within to
b. Maintenance Adjustment.
Maintenance and
be seen. The tank is normally filled from the bottom by
adjustment of the tank assembly consists primarily of
the liquid loading system.
However, it may be gravity
inspecting the tank for signs of leaks, security of
filled through an opening in the top. Brackets for
components, and for security of tiedown straps and lugs.
fastening boom support struts and cables are bonded to
the top ends of the tank.
Attachment
4-16
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
37.
38.
39.
40.
41.
42.
43.
44.
Cotter pin, MS24665-161
Washer, MS15795-810
Clevis pin, MS9464-14
Cotter pin, MS24665-151
Washer, MS15795-808
Pin, MS20392-2013
Fork
Pump link
Nut, AN316-6
Washer, MS27183-14
Cable assembly
Clamp, MS35842-13
Hose, 13216E5307-5
Hose, MS28741-20-0520
Elbow, MS20823-20D
Nut, MS21044C6
Washer, MS15795-814
Screw, MS35308-362
Pump and brake assembly (fig.
7-2 and 7-3)
Clamp, MS35842-13
Hose, 13216E5307-2
Clamp, MS35842-13
Hose, 13216E5307-3
Nut, 21044C4
Washer, MS15795-810
Screw, MS35308-319
Spacer
Pump inlet tube
Clamp, MS35842-13
Hose, 13216E5307-3
Screw, M551958-66
Washer, MS15795-808
Gasket
Sump
Dust cap
Valved nipple
Nut, 2104404
Washer, MS15795-810
Screw, MS35308-319
Spacer
Liquid loading tube
Hose assembly, MS2874120-0140
Nut, MS20365-1032
Washer, AN960-10
45.
46.
47.
48.
49.
50.
51.
52.
53.
54.
55.
56.
57.
58.
59.
60.
61.
62.
63.
64.
65.
66.
67.
68.
69.
70.
71.
72.
73.
74.
75.
76.
77.
78.
79.
80.
81.
82.
83.
84.
85.
86.
87.
88.
89.
Bolt, AN3-6A
Gasket
Control valve assembly
Lockwire
Bolt, AN3-H4A
Washer, AN960-10
Gasket
Bypass valve assembly
Nut
Screw, MS35308-307
Nut, MS21044C4
Washer, MS15795-810
Screw, MS35308-307
Manual control panel
(fig. 4-10)
Nut, MS21044C3
Bolt, MS51957-65
Clamp, MS21104-D24
Clamp, MS21104-D30
Clamp, MS35842-13
Plastic Tube (overflow)
Nut, MS2104464
Washer, MS15795-810
Screw, MS35308-309
Nut, MS2104464
Washer, MS15795-810
Screw, MS35308-309
Spacer
Upper clamp
Lower clamp
Drip pan
Elbow, MS20823-21D
Elbow, SAEJ514, fig. 6A
Plug
Cap
Gasket
Screen assembly
Center boom
Nut, MS21044C4
Washer, MS15795-808
Bolt, AN3C-1OA
Nut, MS21044C4
Washer, MS15795-808
Bolt, AN3C-1OA
Nut, MS21044C4
Washer, MS15795-808
4-18
90.
91.
92.
93.
94.
95.
96.
97.
98.
99.
100.
101.
102.
103.
104.
105.
106.
107.
108.
109.
110.
111.
112.
113.
114.
115.
116.
117.
118.
119.
120.
121.
122.
123.
124.
125.
126.
127.
128.
129.
130.
131.
132.
133.
Eye bolt, AN43B-C4A
Long pump strut
Nut, MS21044C3
Washer, MS15795-808
Bolt, AN3C-6A
Short pump strut
Nut, MS21046C4
Washer, AN970-4
Bushing, NAS-75-4-010
Eye bolt, AN43B-C1OA
Nut, MS21044C3
Washer, MS15795-308
Bolt, AN3C-1OA
Nut, MS21044C3
Washer, MS15795-808
Screw, MS51958-75
Bracket
Pump support assembly
Screw, MS21295-36
Handle
Liquid level gage
Adaptor, MS24522-34
Elbow, MS51952-8
Screw, MS51958-66
Washer, MS15795-808
Cap
Filler flange
Gasket
Filler
Strainer assembly
Nut, MS21044C4
Washer, MS15795-810
Screw, MS35308-320
Tank strap assembly
Cushion
Tank assembly
Nut, MS21044C4
Washer, MS15795-808
Strap end tiedown fittings, NAS1211B15
Nut, MS21044C3
Washer, MS15795-808
Screw, MS24693-C279
Tank clamp
Tank support assembly
Figure 4-9. Tank Installation 4-19
exploded view.
Figure 4-9. Tank Installation - exploded view.
4-20
Adjust fittings so that no kinks or twists exist.
(2) Low-pressure hoses.
Use tire soap to
lubricate inside ends of low-pressure hoses.
Place
hose clamps over hoses before installing. Slip ends of
hoses onto mating connections, and secure hose clamps
using a screwdriver only.
(3) Plastic overflow tube. Install
plastic
overflow tube (64, fig. 4-9) to tank installation as follows:
(a) Install end of plastic tube over
adaptor (111) at top of tank. Secure with hose clamp
(63).
(b) Route tube over back of tank and
around outside of tank support, to pump side of tank
installation.
(c) Fasten tube to center boom tube (81)
at approximately 2 inches inboard from boom tube
coupling nut. Wrap 3/4-inch black electrical tape, or
equivalent, around tubes at clamp locations.
Place
clamp (62) around center boom tube, and clamp (61)
around plastic tube.
(d) Secure ends of clamps together,
using bolt (60) and nut (59).
Note:
Insert screw through clamps from top.
4-15.
Hoses
a. General. Three high-pressure hoses and four
low-pressure hoses are used on the insecticide sprayer.
Refer to figure 4-9 and 4-10 for locations. The
high-pressure hoses (14 and 42, fig. 4-9, and 22, fig. 410) are attached by MS28741 medium pressure,
detachable end fittings. Low- pressure hoses (13, 21, 23,
and 30, fig. 4-9) are attached by low-pressure hose
clamps. A plastic tube is used as a tank vent and
overflow tube. The plastic tube (64) is secured to the
adaptor (111) with a low-pressure hose clamp. The
other end is attached to the center boom tube by a pair
of clamps (61 and 62).
b. Maintenance and Adjustment.
Inspect
hoses for condition and for security.
Adjust
highpressure hoses to remove any kinks or twists. To do
so, loosen hose end connections, or rotate mating
connectors or elbows as required.
Note:
Threaded connectors must be rotated in a tightening
direction only, as loosening may cause a leak. You
may find it necessary to remove connectors and apply
fresh teflon tape per Military Specification MIL-T-27730,
to stop a leak.
c. Removal.
(1) Remove
high-pressure
hoses
by
unscrewing end fittings from mating connections.
(2) Remove low-pressure hoses by loosening
hose clamps, and slipping hose ends from connections.
(3) Remove plastic overflow tube as follows
(fig. 4-9):
(a) Loosen hose clamp (63) and slip end
of tube (64) from adapter (111).
(b) Remove nuts (59) and bolts (60)
from clamps (61 and 62) securing tube to center boom
tube.
(c) Remove clamps and black tape
(placed around tubes beneath clamps) from both tubes.
d. Cleaning and Inspection.
Clean interior and
exterior portions of hoses and plastic tube to remove
spray fluid residue, dirt, and other foreign matter.
Clean threads of high-pressure hose connectors.
Inspect condition of hoses, connectors, and hose
clamps. Replace any hoses, connectors, or clamps
found not serviceable.
e. Installation. Install hoses in same position
from which removed.
Replace any components found
not serviceable.
Clean mating connectors before
installing to remove dirt, grease, tape, and other foreign
matter. Install hoses as follows:
(1) High-pressure hoses.
Apply a suitable lubricant to
threads prior to installation of high pressure hoses.
Mate the connectors carefully to avoid stripping
threads. Tighten connectors handtight only, using a
wrench.
4-16.
Valved Nipple and Dust Cap
a. General. One valved nipple (36, fig. 4-9)
with dust cap (35) is attached to the liquid loading tube
(41). It forms the male half of a quick disconnect
coupling used for connecting the ground liquid loading
tube hose for loading operations. When disconnected,
an internal valve closes, sealing off the liquid loading
tube and preventing the tank from draining. The
dust
cap (35) is attached to the valved nipple body by a steel
cable. The dust cap is used to protect the valved nipple
from dust and other contaminants which might cause the
valved nipple to leak.
b. Maintenance. Inspect the valved nipple and
dust cap for leaks. Clean the valved nipple and dust cap
to remove any foreign matter which may get caught in
the valve and cause leakage.
c. Removal. Unscrew the valved nipple from the
liquid loading tube using a wrench.
Do not remove
dust cap from valved nipple unless required for
replacement.
d. Installation. Clean the threads of liquid
loading tube. Wrap a thin layer of teflon tape per military
specification- MIL-T-27730 around pipe threads. Tighten
valved nipple to liquid loading tube with wrench.
4-17.
Strainer
a. General. A strainer assembly (119, fig.
9) is located at the top of the tank assembly (125)
4-21
4-
beneath the filler cap (115). Its use is to filter spray fluid
when the tank is loaded from the top.
b. Maintenance. Remove filler cap (115) and
inspect strainer and gaskets.
If strainer is dirty,
clogged, or damaged, or if gaskets are bad, remove
faulty parts for cleaning or replacement.
c. Removal (fig. 4-9). Remove six screws (113)
and washers (114), and filler flange (116) from top of
tank.
Remove gasket (117), filler (118), and strainer
assembly (119).
Detach cap chain from filler flange.
d. Cleaning, Inspection and Repair.
WARNING
Use air to maximum pressure of 25 psig.
Avoid splashing insecticide fluid onto skin
or into eyes.
Observe precautions for
handling poisonous fluids by flushing
exposed areas with clean running water.
Wash hands thoroughly with soap and
water after handling and before eating or
smoking.
If spray fluid used in
(1) Cleaning.
sprayer was water-base, clean the strainer by sloshing in
clear water. If spray fluid used was oil-base, slosh in
mineral oil. Use a stiff bristle brush, or low-pressure air
to dislodge particles which cling to wire mesh.
Inspect all parts of strainer
(2) Inspection.
and cap assemblies.
Check
for
condition
of
components, and replace defective or damaged parts.
(3) Repair. Repair or replace any part which
does not pass inspection.
Repair will consist mainly of
straightening filler metal components. Replace
torn
gaskets or filler.
e. Installation. Install strainer in tank, using figure
4-9 and the following steps as guides:
Note:
Line up all attachment holes as required when
installing parts.
(1) Place strainer assembly (119) in place,
open end up.
(2) Place filler (118) around outside edges of
strainer top flange.
(3) Place gasket (117) over strainer top
flange and filler.
(4) Place filler flange (116) over entire
assembly of parts.
(5) Secure parts with six washers (114) and
screws (113).
(6) Attach safety chain from cap (115) to filler
flange, and screw cap onto filler flange.
4-18.
Control Valve
a. General. The control valve assembly (47, fig.
4-9) is a hand lever-controlled, ball type gate valve. It
has three ports with connections to the pump outlet hose
(14), spray boom inlet hose (42), and bypass valve (52).
Its use is to control spray fluid flow during spraying
operations. It is controlled by the valve lever (17, fig. 410). When the valve lever is in the VALVE CLOSED
position, fluid is directed to the bypass valve. When in
the VALVE OPEN position, fluid is directed to the spray
booms.
b. Maintenance and Adjustment.
Inspect
valve and connections for condition and security of
attachment. Adjust flow control screw (40, fig. 8-1) for
back suction control.
To adjust, turn flow control
screw fully in to shut off back suction. Back screw off 2
to 21/2 turns for maximum back suction.
Set the valve
for maximum back suction.
Note:
The purpose of back suction is to draw fluid from
spray booms when the control valve is in closed
position. This prevents nozzles from dripping.
4-19.
Bypass Valve
a. General. The bypass valve (52, fig.
4-9) is
identical to the control valve (ref. para.
4-18),
except for the end ports (fig. 8-1).
The bypass valve
inlet port is attached to the control valve (47, fig. 4-9).
The flanged outlet port is attached to the bottom of
the tank assembly (125). The other outlet port is
attached by hose to the pump inlet tube (28).
The
bypass valve is set to either open or closed position prior
to flight. It is used to direct fluid from the control valve
back to the tank (closed position) or back through the
pump (open position).
b. Maintenance and Adjustment.
inspect
valve and connections for condition and security of
attachment. Flow control screw (40, fig.
8-1) should
be all the way in, as no back suction is required for the
bypass valve.
SECTION VII. MAINTENANCE OF BOOM SPRAY SYSTEM
attached to the top end of the tank assembly (fig.
42). Fore and aft motions of the spray boom are
restricted by front and rear boom cables (21 and 22, fig.
6-1). These cables are attached to the lower channel
rails of the tank support (fig. 4-2).
b. Maintenance and Adjustment.
4-20.
Spray Booms
a. General (fig. 6-1).
Two
spray
boom
assemblies are installed on the insecticide sprayer.
Each boom has threaded holes for 30 spray nozzles.
Vertical support of the spray boom is supplied by a boom
support strut (15, fig.
4-2) and boom support cable (4,
fig. 6-1). The strut and cable are attached to a bracket
4-22
(1) Adjust boom cables as described in
paragraph 4-3, step a(7).
(2) Replace nozzles as described in
paragraph 4-2, step a (1).
(3) Change nozzle orifice diameters by
replacing spray tips (as described in para 4-5, step
b (2)).
WARNING
Use air at maximum pressure of 25 psig.
Avoid splashing insecticide fluid onto skin or
into eyes. Observe precautions for handling
poisonous fluids by flushing exposed areas
with clean, running water.
Wash hands
thoroughly with soap and water after
handling and before eating or smoking.
(4) Disassemble, clean, and inspect nozzles using
figure 4-7 and the following steps as guides:
(a) Unscrew cap (1) from nozzle body
assembly (8).
(b) Remove spray tip (2), and strainer
assembly (3).
(c) Depress spring on nozzle body
assembly (8) and unscrew retainer (4).
(d) Remove end cap assembly (5),
secondary diaphragm (7), and diaphragm (6) from nozzle
body assembly (8).
(e) Clean parts by sloshing in clear,
running water (following use in water-base spray fluid) or
mineral oil (following use with oil-base spray fluid).
Use low-pressure air to blow contaminants from
parts.
(f) Inspect parts, and replace damaged
components.
(5) Assemble nozzles, using figure 4-7 and
the following steps as guides:
secondary diaphragm (7) and end cap assembly (5) on
nozzle body assembly (8), and secure with retainer (4),
handtight only.
Note:
Teflon diaphragm (7) goes against body rubber
diaphragm (6) against end cap assembly.
(b) Insert strainer assembly (3) and
spray tip (2) into nozzle body assembly (8), and secure
handtight with cap (1).
4-21.
Center Boom
is
a. General. Center boom (81, fig. 4-9)
located within tank support assembly (133), beneath the
tank assembly (125). Nuts on tube ends connect to
spray booms. Tubes are welded to the strainer body.
Large elbow (75) is connected to hose (42) from
control valve assembly (47). Small elbow (76) connects
hose to pressure gage on manual control panel (58).
The strainer body contains screen assembly
(80).
Spray flow is strained and divided to the
two spray booms in the strainer body.
b. Maintenance
(1) Inspect fluid connections, welded joints, cap (78), and
gasket (79) for leakage. (2) Remove and clean or
replace strainer and gasket, using figure 4-9 and the
following steps as guides:
(a) Remove strainer cap (78), gasket
(79), and screen assembly (80) from body or center
boom (81).
Note:
Square plug in center of tap normal) does not
need to be removed.
(b) Clean, inspect, and repair strainer
screen and gasket in the manner described in paragraph
4-17, step d.
(c) Replace screen assembly (80) in
body of center boom (81), and secure with gasket (79)
and cap (78).
CAUTION
Do not overtighten nozzle parts.
(a) Place rubber diaphragm (6), teflon
SECTION VIII. MAINTENANCE OF PUMP AND BRAKE ASSEMBLY
combining the two following steps:
4-22.
Pump Broke Cable
(1) Adjust jam nuts (9, fig. 4-9),
which
a. General. The pump brake cable assembly (11,
secure cable to bracket (106). Secure jam nuts firmly
fig. 4-9) is enclosed within a protective sheath over
after adjustment.
much of its length. The cable is attached to the brake
(2) Rotate handle of brake lever (16, fig. 4-10)
lever on the manual control panel (58) and is routed out
in direction required to tighten or loosen the cable.
to the pump and brake assembly (19). When actuating
c. Removal.
the brake lever, the cable applies or releases the pump
Note:
brake and thereby controls pump operation.
Observe routing and attachment points of brake
b. Maintenance and Adjustment.
Adjust
the
cable as an aid to assembly.
cable for proper tension. With brake on, linkage at brake
(1) Remove cotter pin, washer, and clevis
should be slightly slack, and the windmill must not be
free to turn. With brake off, windmill must be free to turn,
with no brake drag.
Adjustment may be made by
4-23
pin (1, 2, and 3, fig.
4-10) to release brake cable
from actuator of brake lever (16).
(2) Remove lower nut (4), washers (5), and
screw (6) from bracket of brake lever (16), to release
spacer (8) and cable housing clamp (9). Do not remove
cable housing clamp from cable unless necessary for
parts replacement.
(3) Loosen jam nuts (9, fig. 4-9)
securing
cable to bracket (106) on pump support assembly (107).
(4) Remove cotter pin (4), washer (5), and pin (6)
securing cable to pump link (8).
(5) Remove cable from tank installation.
CAUTION
Nylon blade failures have occurred in hot,
dry climates as a result of losing blade
flexibility caused by loss of their natural
moisture content.
Therefore, at 30-day
intervals, remove the blades from the hub
assembly and place in boiling water for 30
minutes. This action is mandatory in all
areas where humidity remains below 50
percent for extended periods of time.
(1) Remove blades from hub assembly as
.
described in steps c and d following
(2) Place blades in boiling water for 30
minutes to restore flexibility.
c. Removal (fig. 4-2).
Remove three bolts
(20) and remove synchromatic windmill assembly (24)
from brake drum (2, fig. 7-2).
d. Disassembly (fig. 7-1).
CAUTION
Use solvent in a well-ventilated area. Avoid
breathing of fumes and excessive solvent
contact with skin. Keep solvent away from
open flame. Wash hands before smoking or
eating.
d. Clcalilg and Inspection. Clean cable of all di)-rt
and other foreign matter by sloshing in cleaning solvent,
Federal Specification P-D-680.
Inspect cable for wear
or damage.
e. Installation. Install pump brake cable on tank
installation by routing in manner noted during removal.
Uise figure 4-9 and the following steps as guides:
(1) Route cable over pump support assembly
(107) and through tank support assembly (133) beneath
the tank. End of cable with jam nuts on sheath goes
toward pump.
(2) Attach cable end to pump link (8).
Secule with pin (6), washer (5), and cotter pin (4).
(3) Connect cable end to actuator of brake
lever (16, fig. 4-10), using clevis pin (3), washer (2).
and cotter pin (1).
(4) Secure cable housing clamp (9) and
spacer (8) to bracket of brake lever (16), using screw (6),
washers (5), and nut (4).
(5) Secure brake cable to bracket (106, fig.
41-), using two washers (10) and jam nuts (9).
(6) Adjust cable as described in step b,
preceding.
4-23.
CAUTION
Do not disassemble cap hub assembly (1).
(1) Lift cap hub assembly (1) from base hub
(3).
(2) Remove blades (2) from base hub.
installation details for use during reassembly.
(3) Remove actuator (4) from adjusting
screw (8).
e. Cleaning, Inspection, and Repair. Clean and
inspect all parts of the synchromatic windmill assembly as follows:
(1) Inspect all metal parts for nicks,
scratches, corrosion, or other damage.
Polish
out
minor defects using aluminum oxide abrasive cloth per
Federal Specification P-C-451 for aluminum parts.
Use crocus cloth per Federal Specification P-C-458
for steel parts.
(2) Inspect all threaded parts for crossed or
otherwise damaged threads and for damaged tool
surfaces.
(3) Inspect blades for cracks, breaks, and
stiffness.
Note:
Blades should be quite flexible. Check
for
stiffness by doubling blade tip over toward hub.
You should be able to bend blade tip over
to almost touch itself.
(4) Replace all parts not meeting inspection
requirements. Restore blade flexibility by placing blade in
boiling water for 30 minutes, as in step b, preceding.
f.
Assembly. Reassemble synchromatic windmill
assembly using figure 7-1 and the following steps as
guides:
(1) Lightly oil bearing surfaces of base hub
(3) with oil per Federal Specification VV-L-820.
Synchromatic Windmill Assembly
a. General. The synchromatic windmill assembly
(24, fig. 4-2) is attached to and drives the airborne pump.
It consists of six adjustable, molded nylon blades
mounted within two hub halves which contain an
adjustment mechanism (fig. 7-1). Blade angles are set
by turning the adjusting nut in the center of the windmill
hub. The synchromatic windmill assembly is turned by
the slipstream while the helicopter is in forward flight.
b. Maintenance and Adjustment.
Check
blades for condition.
4-24
Note:
If synchromatic windmill assembly is not being installed
on pump, secure parts together with bolt, washer, and
nut (23, 22, and 21, fig. 4-2)
placed
through
one
mounting hole.
g. Installation. Install the synchromatic windmill
assembly on the pump brake drum.
CAUTION
Do not overtighten bolts. Blade adjustment may be
restricted, and undue stresses may be applied to
hub assemblies.
(1) Place synchromatic windmill assembly
against pump brake drum (2, fig. 7-2).
(2) Align holes and secure to brake drum with
three new bolts (20, fig. 4-2).
(2) Install actuator (4) onto adjusting screw
(8), with raised surface toward adjusting nut (6). Screw
actuator onto adjusting nut until spoke ends are in line
with lower surface of cap hub (9).
Note:
Approximately 34 inches of thread will protrude
through the actuator.
(3) Install hubs of blades (2) into cap hub (9) with
the retaining shoulder slots (10) of the blade hubs
inserted over the spokes of the actuator (4).
The
blade hub retaining shoulder (11) should be fully seated
in the cap hub bearing slots.
(4) With cap hub index aligned with base hub
index, install base hub (3) onto cap hub assembly (1).
Section IX. MAINTENA NCE OF CONTROL SYSTEM
4-24.
Manual Control Panel
a. General. The manual control panel (fig.
410) with its attached components, comprises most of the
control system. Maintenance procedures for the pump
brake cable are covered in paragraph 4-22. The control
panel is attached to the tank support by hinges and a
folding brace. This permits folding the control panel for
installation and shipping.
The control panel may be
adjusted for installation into either the UH-1B or UH-1D
helicopters (refer to para 4-3).
Major components of
the control panel include brake lever (16), valve lever
(17), valve rod (15), pressure gage (21), and brake cable
assembly (11, fig. 4-9).
b. Maintenance and Adjustment.
(1) Inspect the manual control panel and its
components for security of attachment.
(2) Adjust brake cable assembly (21, fig. 9)
for proper tension as described in para 4- 22.
(3) Adjust linkage of valve lever (17, fig. 110), valve rod (15), and control lever of control valve
assembly (47, fig. 4-9). Refer to paragraph
5-9, steps b(6) through b(9) for adjustment details.
(4) Inspect pressure gage (21, fig.
4-10)
for condition and security of attachment.
Replace
gage if glass is broken, or if needle is bent or not at zero
with no pressure applied. Tighten coupling (18) to
secure pressure gage in position, facing aft.
(5) Inspect instruction plates (26) for condition
and security of attachment. Replace if missing, loose,
or if they cannot be read.
c. Disassembly. Remove components of control
panel assembly as follows (fig.
4-10):
(1) Levers. Remove cotter pin (1), washer
(2), and clevis pin (3) which attach brake cable assembly
(11, fig. 4-9) or valve rod (15, fig. 4-10) to lever (16 or
17). Remove nuts (4), washers (5), and screws (6) and
spacers (7 and/or 8) which secure lever (16 or 17) to
control bracket (27).
Remove assembly (and cable
clamp housing (9) if removing brake lever (16).
Note:
Do not attempt to disassemble levers.
4-25
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
Cotter pin, MS34665-151
Washer, MS16795-810
Clevis pin, MS9464-14
Nut, MS16228-2
Washer, MS15795-812
Screw, MS35307-341
Spacer
Spacer
Cable housing clamp
Cotter pin, MS34665-161
Washer, MS15795-810
Clevis pin, MS9464-14
Lever clevis, 13216E5413-2
Lever clevis, 13216E4313-1
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
4-26
Valve rod: (for UH-1B, 25
in. ) (for UH-1D, 36 in. )
Brake lever
Valve lever
Coupling
Washer
Washer, rubber
Gage
Hose assembly
Nut
Screw, MS35308-307
Support
Instruction plate
Control bracket
Figure 4-10. Manual control panel - exploded view.
4-27
(2) Valve rod (fig. 4-10).
Remove
cotter
pin (1), washer (2), and clevis pin (3) which attach valve
rod (15) to valve lever (17). Remove cotter pin, washer,
and clevis pin (10, 11, and 12) to detach valve rod from
lever of control valve (47, fig.
4-9).
Remove
valve rod, and remove lever devises (13 and 14, fig. 410) from ends of valve rod.
CAUTION
If pressure gage is not immediately replaced
on pressure hose, cap or tape hose end to
prevent entry of dirt or other foreign matter.
(3) Pressure gage (fig.
4-10).
Detach
hose assembly (22) from coupling (18) then remove
coupling from gage (21). Remove washers (19 and 20)
and pressure gage. Cap end of pressure gage and hose
to prevent dirt entry.
d. Cleaning, Inspection, and Repair. Thoroughly
clean all components of the control system to remove
dirt, corrosion, or other foreign matter. Inspect each
component and its attaching hardware for damage.
Discard components not considered usable.
e. Installation. Install components on manual
control panel as follows (fig. 4-10):
Note:
Control valve lever has longer handle and slots in
sides (4. 5 inches) than brake lever.
(1) Brake lever (fig.
4-10).
Place brake
lever (16) in position on control panel. Line up holes,
and place spacer (7) between sides of brake
lever bracket in upper position.
Place spacer (8) and
cable housing clamp (9) attached to brake cable in lower
position. Secure parts with screws
(6), washers (5), and nuts (4).
Attach brake
cable end to actuator of brake lever with clevis pin (3),
washer (2), and cotter pin (1).
(2) Valve lever (fig. 4-10). Place valve lever
(17) in position on manual control panel.
Line
up
holes, and place spacers (7) between sides of valve
lever bracket. Secure parts with screws (6), washers (5),
and nuts (4). Attach lever clevis (13) of valve rod (15) to
actuator of valve lever with clevis pin (3), washer (2), and
cotter pin (1).
(3) Valve rod (fig. 4-10).
Screw
lever
clevises (13 and 14) onto each end of valve rod (15).
Attach clevis at curved end of valve rod to control valve
(47, fig. 4-9) using clevis pin, washer, and cotter pin (12,
11, and 10, fig. 4-10). Connect opposite end of valve rod
to valve lever (17) as described in step (2), preceding.
urn valve handle as required to adjust control valve for
proper operation. Refer to 5-9, steps b (6) through b (9)
for details of adjustment.
(4) Pressure gage (fig.
4-10).
Place
washer (20) on threaded fitting of gage (21).
Insert
gage threaded fitting through square hole on ton of
manual control panel. Place washers (20 and 19) on
threaded portion of gage. Wrap threads of gage with
Teflon tape per Military Specification MIL-T-27730.
Secure coupling (18) to gage (21), and hose (22) to
coupling.
4-28
CHAPTER 5
DIRECT SUPPORT AND GENERAL SUPPORT
MAINTENANCE INSTRUCTION’S
Section I. REPAIR PARTS, SPECIAL TOOLS AND EQUIPMENT
maintenance of the insecticide sprayer.
5-1. Tools and Equipment
Tools, equipment, and spare parts issued with or
5-3. Maintenance Repair Parts
authorized for the aircraft-mounted insecticide
sprayer are listed in the basic issue items list,
Repair parts and equipment covering Direct Supappendix C.
port and General Support maintenance levels for
the insecticide sprayer are listed and illustrated
5-2. Special Tools and Equipment
in TM 5-3740-211-24P.
No special tools or equipment are required for
Section II. TROUBLESHOOTING
insecticide sprayer.
The chart serves only as a guide
and does not preclude the chance that other troubles
exist.
5-4. Toubleshooting Chart
Table 5-1 lists troubleshooting steps for Direct Support
and General Support maintenance level for the
Section III. GENERAL MAINTENANCE
removal of hoses, use procedures given in paragraph 415, step c.
When installation calls for attachment of
hoses, use procedures given in paragraph 4-15, steps d
and e.
Clean all threaded connectors thoroughly.
Use MIL-T-27730 teflon tape on all pipe threads.
Use suitable thread lubricant on all tube fittings.
Use tire soap on inside diameter of low-pressure
hoses to aid in installation.
5-5. Removal of Components
Removal of major components, as described in section
IV following, often requires removal of components
authorized for removal by organizational maintenance
level.
When procedures are lacking for removal of
parts, refer to pertinent paragraphs of chapter 4.
5-6. Hose Removal and Installation
Whenever removal of major components calls for
Table 5-1. Direct Support and General Support Troubleshooting Chart.
Malfunction
Probable cause
Corrective action
1.
Tank support damaged.
Combat damage or improper handling.
2.
Leaks in tank.
3.
Couplings leak.
4.
Leak develops in system installed in
aircraft.
Use of pump causes vibration.
Pump leaks through weep holes.
No response to spray command.
a. Holes or cracks.
b. Severe damage or faulty seals.
a. Foreign particles present.
b. Faulty seals
Faulty fluid system components.
Repair or replace damaged components
(9-1/9-4).
a. Repair tank (8-12).
b. Replace tank (8-9/8-14).
a. Clean couplings.
b. Replace coupling (8-6/8-8).
Repair or replace faulty components.
Pump bearings faulty.
Seals faulty
a. Faulty control valve.
Replace pump bearings (7-11/7-16).
Replace seals (7-11/7-16).
a. Replace or repair control valve (8-1/8-5).
b.
Pump brake sticks.
b.
Faulty control valve.
a.
Pump brake sticks.
b.
5.
6.
7.
8.
No response to stop spray command. a.
b.
9.
Spray intermittent.
Faulty synchromatic windmill pump drive.
10. Spray uneven.
Faulty pump.
11. Unable to adjust windmill blade angle. Synchromatic windmill internal mechanism damaged.
5-1
Replace brake cable (4-22) or repair pump brake (77/7-10).
Remove and repair control valve (8-1/8-5).
Replace brake cable (4-22) or remove and repair
pump brake (7-7/7-10).
Remove and repair pump and brake assembly and
windmill assembly as required (7-2/7-16).
Remove and repair pump (7-11/7-16).
Remove and repair synchromatic windmill
assembly (7-2/7-6).
5-7. Drip Pan Removal
c. Installation of Drip Pan.
Install drip pan
beneath tank using figure 4-9 and the following steps as
guides:
(1) Line up all mounting holes of drip pan (74)
with mating holes in lower channel of tank support
assembly (133).
CAUTION
Spacers (27, 40, and 71) are placed with
in tank support channel at each
attachment hole used for securing drip
pan, tube flanges, and tube clamps to
tank support. When inserting bolts, be
sure bolt passes through spacers.
Insert screw head from inside of tank
support with washers and nuts on
outside of tank support.
(2) Insert spacers (27, 40, and 71) within
channel and in line with mounting holes.
(3) Insert screws (26 and 39) from inside drip
pan, through the following components: lower channel of
tank support assembly (133); spacers (27 and 40); lower
holes in mounting flanges of liquid loading tube (41), and
pump inlet tube (28).
Secure
components
with
washers (25 and 38) and nuts (24 and 37).
(4) Insert screws (70), from inside drip pan,
through the following components; lower channel of tank
assembly (133); spacers (71), and lower tube clamp
(73). Secure components with washers (69) and nuts
(68).
When working on components located beneath the tank,
you may find it convenient to remove the drip pan (74,
fig. 4-9). This will provide you with easy access to
components.
WARNING
A minimum of two men are required to tilt
the tank installation. Always block the
tank installation to prevent its falling.
CAUTION
Lift tank installation by handles, never by
booms or braces.
a
Tilting Tank Installation. Carefully tilt the tank
installation backward unless it rests on the back frame of
the tank support. Place blocking material of sufficient
size and strength beneath the tank support frame to hold
tank installation in tilted position.
b. Removal of Drip Pan. Remove drip pan (74)
from tank installation as follows, using figure 4-9 and the
following steps as guides:
(1) Remove lower nuts (24, 37, and 68),
washers (25, 38, and 69), screws (26, 39, and 70) and
spacers (27, 40, and 71) that secure drip pan to tank
support assembly (133).
Note:
Attaching hardware also secures bottom
portions of tube flanges of pump inlet tube
(28), liquid loading tube (41), and tube lower
clamps (73) to tank support assembly.
(2) Remove
drip
pan.
Section IV.
REMOVAL AND INSTALLATION OF MAJOR COMPONENTS
in position.
5-8. Pump and Brake Assembly
a. Removal.
(1) If synchromatic windmill assembly (24, fig.
4-2) is not removed from pump and brake assembly (19,
fig. 4-9), remove as instructed in paragraph 4-23, step c.
Disconnect inlet and outlet hoses (13 and 14) from pump
and brake assembly as instructed in paragraph 4-15.
(2) Disconnect brake cable assembly (11, fig.
4-9) by removing cotter pin (1), washer (2), and
clevis pin (3). Disengage pump link (8) from brake
actuation lever of pump and brake assembly (19).
Disconnect outlet hose (14) and inlet hose (13) from
pump and brake assembly.
(3) Remove pump and brake assembly from
pump support assembly (107) using figure 4-9 and the
following steps as guides:
(a) Remove two bottom nuts (16),
washers (17), and screws (18).
(b) Loosen and back off two upper nuts
(96) as required to permit slipping pump and brake
assembly from pump support assembly (107). Do not
remove nuts as they secure the pump support assembly
(c) Remove pump and brake assembly
from pump support assembly.
(4) Remove elbow (15) from outlet port of
pump and brake assembly.
b. Installation.
(1) Attach pump and brake assembly (19) to
pump support assembly (114) using figure 4-9 and the
following steps as guides:
(a) Loosen nuts (96) at top of pump
support assembly enough to permit slipping foot of pump
and brake assembly (19) over bushings (98).
(b) Slip upper slots in foot of pump and
brake assembly over bushings.
(c) Insert screws (18) through lower
holes in pump support assembly (107) and through slots
in foot of pump and brake assembly. Place
washers
(17) and nuts (16) over screws.
(d) Secure all upper and lower nuts (96
and 16).
5-2
(2) Install elbow (15) in outlet port of pump
and brake assembly after wrapping threads with Teflon
tape per MILT-27730. Attach high pressure hose (14) as
instructed in paragraph 5-6. Orient elbow to provide the
least possible amount of bending, kinking, or twisting of
the hose.
(3) Attach inlet hose (13) to inlet port of pump
and brake assembly, and secure with hose clamps (12).
(4) Connect brake cable assembly (11) by
attaching the pump link (8) to the brake actuation lever.
Use clevis pin (3), washer (2), and cotter pin (1) to
secure parts.
valve lever is in VALVE OPEN position.
If
further
adjustment is required, repeat portions of steps 5, 6, and
7, preceding, as required.
(9) When lever is properly adjusted,
disconnect valve rod (15, fig. 4-10) from lever. Secure
attaching parts to lever. Lay end of valve rod in drip pan,
and fold control panel to its retracted position.
Note:
Control panel must be in retracted position
before loading sprayer into helicopter.
5-10.
Liquid Loading Tube
Note:
To gain access to components, consider
tilting tank installation and removing drip pan
(para 5-7).
a. Removal. Remove liquid loading tube from tank
installation using figure 4-9, and the following steps as
guides:
(1) Loosen hose clamps (29) and hose (30)
connecting liquid loading tube (41) to sump (34).
(2) Remove four nuts (37), washers (38),
screws (39) and spacers (40) securing liquid loading
tube to tank support assembly (133).
(3) Remove liquid loading tube.
(4) If required, remove valved nipple (36) with
dust cap (35) from liquid loading tube.
b. Installation. Install liquid loading tube to tank
installation using figure 4-9 and the following steps as
guides:
(1) Place liquid loading tube (41) into position
through opening in tank support assembly (133) under
tank assembly (125).
(2) Using procedure of paragraph 4-15, step
e (2) for installing low-pressure hoses, insert end of liquid
loading tube into low-pressure hose (30) attached to
sump (34). Secure with hose clamps (29).
Note:
if drip pan was removed, replace drip pan as
instructed in paragraph 5-7, step c.
(3) Line up attachment holes in mounting
flange of liquid loading tube with holes in lower channel
of tank support assembly (133). Place spacers (40)
between sides of tank support channels and in line with
mounting holes. Insert screws (39) through drip pan,
channel, spacers, and mounting flange of liquid loading
tube. Secure with washers (38) and nuts (37).
5-9. Control Valve Assembly
Note:
To gain access to components, consider
tilting tank installation and remove drip pan
(para 5-7).
a. Removal.
Remove control valve assembly
(47, fig. 4-9) as follows:
(1) Remove cotter pin, washer, and clevis pin
(10, 11, and 12, fig. 4-10), securing valve rod (15) to
control lever of valve assembly.
(2) Unscrew end fittings of high-pressure
hoses (14 and 42, fig. 4-9) from valve connectors.
(3) Remove nuts (43), washers (44), and
bolts (45) attaching control valve assembly to bypass
valve assembly (52).
(4) Remove control valve assembly and
gasket (46) from sprayer system.
b. Installation. Install control valve assembly as
follows:
(1) Place gasket (46) on flange of bypass
valve assembly (72). Attach control valve assembly to
bypass valve assembly, and secure with bolts (45),
washers (44), and nuts (43).
(2) Attach high-pressure hoses (14 and 42) to
control valve assembly (ref para 5-6).
(3) Place manual control panel (58) in
extended position.
(4) Turn handle of valve lever (17, fig.
410) all the way in (clockwise).
(5) Place valve control lever in closed
position. Loosen nut (1, fig. 8-1) to loosen lever (4) on
shaft of valve ball (38).
(6) With valve lever (17, fig.
4-10)
on
control panel in VALVE CLOSED position, connect valve
rod (15) to valve lever (4, fig. 8-1). Turn lever as needed
to properly align parts. Secure lever clevis (14, fig. 410) on valve rod to valve lever with clevis pin, washer,
and cotter pin (12, 11, and 10, fig.
4-10).
(7) Secure nut (1, fig. 8-1) on lever (4).
(8) Test valve for actuation and proper adjustment by
actuating valve lever (17, fig. 4-10) several times.
Valve must be in closed position when valve lever is
in VALVE CLOSED position, and in open position when
5-11.
Pump Inlet Tube
Note:
To gain access to components, consider
tilting tank installation and removing drip pan
(para 5-7).
a. Removal. Remove pump inlet tube from tank
installation using figure 4-9, and the following steps as
guides:
5-3
(1) Loosen hose clamp (12) and remove
pump inlet hose (13) from outlet end of pump inlet tube
(28).
(2) Loosen hose clamps (20) and hose (21)
connected between bypass valve assembly (32) and wye
stub of pump inlet tube (28).
(3) Loosen hose clamps (22) and hose (23)
connected between sump (34) and inlet end of pump
inlet tube (28).
(4) Remove four nuts (24), washers (25),
screws (26), and spacers (27) securing pump inlet tube
to tank support assembly (133). (5) Remove pump inlet
tube.
b. Installation. Install the pump inlet tube to
tank installation using figure 4-9 and the following steps
as guides:
(1) Place pump inlet tube (28) into position
through opening in tank support assembly (133) under
tank assembly (125).
Curved end of tube goes
outboard, facing up and forward.
(2) Use procedure of paragraph 4-15, step e
(2) to install low-pressure hoses. Insert inlet end of
pump inlet tube into hose (23) connected to sump (34).
Secure hose with tube clamps (22). Insert wye stub tube
end of pump inlet tube into hose (21) connected to
bypass valve (52). Secure with hose clamps (20).
Note:
If drip pan was removed, replace drip pan as
instructed in para 5-7, step c.
(3) Line up attachment holes in mounting
flange of pump inlet tube with holes in lower channel of
tank support assembly (133).
Place spacers (27)
between sides of tank support channels, in line with
mounting holes. Insert screws (26) through dip pan,
channel, spacers, and mounting flange of pump inlet
tube. Secure with washers (25) and nuts (24).
(4) Use procedure of 4-15, step e (2) to install
low-pressure hoses.
Slip pump inlet hose (13) over
outlet end of pump inlet tube.
Secure with hose
clamp (12).
remove six bolts (49) and washers (50) that
secure bypass valve assembly to tank connector.
(4) Loosen hose clamps (20) and remove
low-pressure hose (21) from bypass valve assembly
outlet port.
(5) Remove bypass valve assembly and
gasket (51) from tank connector.
b. Installation. Install bypass valve assembly (52,
fig. 4-9) as follows:
(1) Using procedure of paragraph 4-15, step
e (2) for installing low-pressure hoses, install hose (21)
to bypass valve outlet port. Secure with hose clamp
(20).
(2) Install bypass valve assembly as
instructed in paragraph 8-13, step a(3).
(3) Install pump inlet tube (28) to tank
installation as instructed in paragraph 5-11, step b.
(4) Install control valve assembly (47, fig. 49) as instructed in paragraph 5-9, step b.
(5) If drip pan was removed, replace drip pan
as instructed in paragraph 5-7, step c.
5-13.
Center Boom Assembly
Note:
To gain access to components, consider tilting tank and
removing drip pan (ref para 5-7).
a. Removal.
Remove center boom (81, fig.
4-9) using the following steps as guides:
(1) Remove overflow tube (64) from tank
installation as described in paragraph 4-15, step c(3).
(2) Remove liquid loading tube (41) from tank
installation as described in para 5-10. Do not remove
valved nipple (36) with dust cap (35) unless necessary
for replacement.
(3) Disconnect hoses to control valve
assembly (47) and pressure gage (21, fig. 4-10).
(4) Remove nuts (65, fig. 4-9),
washers
(66), and screws (67) which secure upper clamp (72)
and lower clamp (73) together at each end of the tank
support assembly (133).
(5) Remove nuts (68), washers (69), screws
(70), and spacers (71) securing upper and lower clamps
to tank support.
Remove upper and lower clamps.
(6) Remove center boom (81) from tank
installation through the opening in right-hand side of tank
support (looking forward).
Note position of center
boom as an aid during installation.
(7) Remove elbows (75 and 76) from body of
center boom.
(8) Remove cap (78), gasket (79), and screen
assembly (80) from body.
Do not remove plug (77)
from cap unless it needs to be replaced.
b. Installation. Install center boom in tank
installation, using figure 4-9 and the following steps as
guides:
5-12.
Bypass Valve Assembly
a. Removal. Remove bypass valve assembly (52,
fig. 4-9) as follows:
Note:
Refer to paragraph 8-11, step c for instructions for
removal of bypass valve assembly with tank assembly
(125) removed from tank support (133).
To
gain
access to components with tank assembly installed to
tank support, consider tilting tank installation and
removing drip pan (para 5-7).
(1) Remove control valve (para 5-9, step a).
(2) Remove pump inlet tube (28) as
instructed in paragraph 5-11, step a.
(3) Remove and discard lockwire (48) and
5-4
(1) Install screen assembly (80) in body of
center boom (81), and secure with gasket (79) and cap
(78).
(2) Wrap threads of elbow (75) with teflon
tape per Military Specification MIL-T-27730.
Install
elbow into body of center boom.
(3) With liquid loading tube (41) removed
from tank installation, insert end of center boom through
opening at bottom of tank support assembly (133).
with teflon tape per Military Specification MIL-T-27730.
(2) Tilt tank to permit vertical installation of
liquid level gage. Insert float end of gage into tank, and
carefully attach gage to its mounting flange.
Turn
gage in a clockwise direction to attach.
(3) Make final adjustment of gage to place "1/2" mark at
top.
5-15.
Sump
Note:
To gain access to components, consider tilting
tank installation and removing drip pan (ref para
5-7).
a. Removal.
Remove sump (34, fig. 4-9)
from bottom of tank, using figure 4-9 and the following
steps as guides:
(1) Loosen clamps (29 and 22), and remove
hoses (30 and 23) connecting sump to liquid loading
tube (41) and pump inlet tube (28).
Remove
hoses per instructions of paragraph 4-15, step
c(2).
(2) Remove 12 screws (31) and washers
(32) securing sum to bottom of tank.
(3) Remove sump and gasket (33) from
tank.
b. Installation. Install sump (34) to tank, using figure 4-9 and the following steps as guides:
(1) Coat new gasket (33) and screws (31)
with Tite-seal gasket and joint compound, part
no. T3504 or equivalent.
(Non-hardening sealant
may be used on gasket surfaces).
(2) Place gasket (33) on flange of sump
(34) with mounting holes aligned.
(3) Place sump into position under tank,
with end ports pointing toward ends of tank.
(4) Attach sump to tank with 12 washers
(32) and screws (31). Secure screws handtight.
(5) Reconnect hoses (30 and 23) to liquid
loading tube (41) and pump inlet tube (28). Install hoses per instructions of paragraph 4-15,
step e(2).
Secure hoses with clamps (29 and 22).
5-16.
Tank Assembly
a. Removal. Remove tank assembly from tank
installation using the following steps as guides:
(1) Remove liquid loading tube (41, fig. 4-9)
from tank installation as instructed in paragraph 5-10,
step a.
(2) Remove pump inlet tube (28) from tank
installation as instructed in paragraph 5-11, step a.
(3) Loosen hose clamps (20) and hose (21)
at outlet port of bypass valve assembly (52).
(4) Remove cotter pin (10, fig. 4-10),
washer (11), and clevis pin (12) securing valve rod
Note:
Insert tube so that cap of screen assembly faces aft and
pressure sensing hole in screen assembly body is up.
(4) Position body of center boom midway
between ends of tank support assembly.
Install upper
clamps (72) to tank support channels using spacers (71),
screws (70), washers (69), and nuts (68).
(5) Attach lower clamps (73) to upper clamps
with center boom tubes between clamps halves. In stall
screws (67) with heads up, washers (66), and nuts (65)
to hold clamps together. Do not secure tightly at this
time.
(6) Attach hose assembly (42) from control
valve to large elbow and secure (ref para 5-6). Adjust
hose and elbow (75) as required to remove any kinks or
twists.
(7) Install liquid loading tube (41) and secure
(para 5-10, step b).
(8) Adjust center boom to position screen
assembly body midway between tank support ends.
Rotate center boom as required to eliminate any kinks in
hose assembly (42) to control valve. Secure nuts (65) to
secure upper and lower clamps.
Note:
If drip pan is removed, delay final adjustment of
center boom until drip pan is replaced (ref para
5-7).
(9) Wrap threads of elbow (76) with teflon
tape per Military Specification MIL-T-27730. Install
elbow into screen assembly body.
Attach hose from
pressure gage on manual control panel (58).
(10) Install overflow tube (64) to tank
installation and secure as described in paragraph 4-15,
step e(3).
5-14.
Liquid Level Gage
a. Removal.
Tilt tank for vertical removal of
liquid level gage to avoid baffles and damage to
mechanism. Remove liquid level gage (110, fig. 4-9)
from tank assembly by unscrewing gage in
counterclockwise direction. Use care not to damage
gage or its attached float.
b. Installation. Install liquid level gage to tank
assembly using figure 4-9 and the following steps as
guides:
(1) Cover threads of liquid level gage (110)
5-5
(15) to control lever of control valve assembly (47, fig. 49).
(5) Unscrew end fittings of high-pressure
hoses (14 and 42) from connectors of control valve
assembly (47).
(6) Remove overflow tube (64) from tank
installation as described in paragraph 4-15, step c(3).
(7) Remove nuts (120), washers (121), and
screws (122) securing tank strap assemblies (123) to
tank clamps (132). Remove tank strap assemblies and
upper cushions (124).
(5) Connect overflow tube (64) to tank
installation and secure as described in para 4-15, step
e(3).
(6) Install hose (21) between outlet port of
bypass valve (52) and wye stub of pump inlet tube (28
Secure with hose clamps (20) (ref para 5-6).
(7) Attach high-pressure hoses (14 and 42) to
control valve assembly (ref para 5-6).
(8) Install pump inlet tube (28) as instructed in
paragraph 5-11, step b.
(9) Install liquid loading tube (41) as
instructed in paragraph 5-10, step b.
(10) Attach valve rod (15, fig.
4-10)
to
control valve assembly (47, fig. 4-9) and adjust as
described in 5-9, steps b(6) through b (9).
(11) Tighten nuts (120) attaching tank (123) to
tank clamps (132).
5-17.
Manual Control Panel
a. Removal. Remove manual control panel (58,
fig. 4-9) from tank support assembly (133), using figure
4-10 and the following steps as guides:
(1) Remove cotter pins (1), washers (2), and
clevis pins (3) from brake and valve levers
(16 and 17) to disconnect brake cable assembly
(11, fig. 4-9) and valve rod (15, fig.
4-10) from lever
actuators. Remove lower nut (4), washers (5), and screw
(6) from bracket of brake lever (16).
Remove spacer
(8) and brake cable assembly (11, fig. 4-9).
Remove
cable housing clamp (9, fig. 4-10) from brake cable
assembly if necessary for replacement.
(2) Detach hose assembly (22) from pressure
gage (21) by unscrewing pressure gage line from
coupling (18). Leave coupling attached to pressure gage
to retain parts in position.
Cap pressure gage horse
assembly to prevent dirt entry.
(3) Remove two nuts (53, fig.
4-9)
and
screws (54) retaining folding brace of manual control
panel (58) to center brace of tank support assembly
(133).
(4) Remove nuts (55), washers (56), and
screws (57) securing manual control panel hinge to tank
support assembly (133).
Remove manual control
panel from tank support assembly.
(5) Do not remove components from manual
control panel unless necessary. Refer to paragraph 424, step c for instructions.
b. Installation. Install manual control panel on
tank support assembly using figure 4-9 and the following
steps as guides:
(1) Attach hinge of manual control panel (58)
to tank support assembly (133), using screws (57)
washers (56), and nuts (55).
CAUTION
A minimum of two men are required to
remove tank assembly from tank support
assembly.
(8) Carefully lift tank assembly (125) from
tank support assembly (133).
Remove
cushions
(124) from cradle channels of tank support assembly
only if they are damaged and need to be replaced.
These are cemented in.
(9) Remove components from tank assembly
only if required. Refer to paragraph 8-11 for instructions.
b. Installation. Install tank assembly in tank
support using figure 4-9 and the following steps as
guides:
(1) Check condition of felt cushion (124) on
cradle channels of tank support assembly (133).
Replace with new cushions if necessary, as instructed in
paragraph 9-8, step c(3).
(2) Replace any components removed from
tank as instructed in paragraph 8-13.
CAUTION
A minimum of two men are required to lift the tank
assembly.
Exercise care in placing tank assembly
in tank support assembly.
(3) Carefully lift tank assembly (125) and
install in tank support assembly (133). Liquid level gage
(110) faces forward. Center tank sump between tank
support cradle channels.
Rotate tank as required to
place sump directly on bottom.
Note:
Leave tank strap assemblies loose so that tank may be
rotated for alignment of connections.
(4) Attach tank assembly (125) loosely to tank
support assembly (133) with tank strap assemblies
(123). Place upper half of cushions (124) beneath tank
straps, and connect tank straps to tank clamps (132)
with screws (122).
Attach with washers (121) and nuts (120).
Note:
At least two threads of screws (122) must
show through attaching nut (120)
5-6
(2) Attach folding brace of manual control
panel to center brace of tank support assembly, using
screws (54) and nuts (53).
coupling (18).
(4) Attach brake cable assembly (11, fig. 4-9)
to brake lever (16, fig. 4-10) and valve rod (15) to valve
lever (17). Place clevis pins (3) through slots in lever
sides, connecting cable and lever clevis (13) to actuation
arm of lever. Place washers (2) over clevis pins, and
secure with cotter pins (1).
Note:
Folding braces may be attached to either the
upper or lower pair of holes in tank support
center brace. Use upper holes for UH-1B
installation, and lower holes for UH-1D
installation (ref para 4-3).
(5) Reattach cable housing clamp (9) and
spacer (8) to brake lever position on control panel using
screw (6), washers (5) and nut (4).
(3) Attach hose assembly (22, fig. 4-10) to
5-7
CHAPTER 6
REPAIR OF BOOM SPRAY SYSTEM
Section I. SPRAY BOOM REMOVAL AND DISASSEMBLY
a. Remove nozzles (16, fig. 4-2), nipples (17),
elbows (18), and plugs (32) from spray boom assembly
(19).
Two spray boom assemblies are attached to the tank
b. Disconnect cable assemblies from outboard
installation (fig. 4-2).
Each spray boom assembly
tube clamps, and remove tube clamps using figure 6-1
consists of a boom tube with nozzles evenly spaced
and the following steps as guides:
along the length of the tube. Cables and braces
(1) Remove nut (1), washer (2), and bolt (3),
attached to the boom provide support. The boom tubes
and remove upper boom support cable (4) from top tube
are connected to the center boom of the tank installation
clamp half (12).
with tube type fittings. Direct Support and General
(2) Remove nuts (5) and washers (6) from
Support maintenance of the boom spray system is
short bolts (7) on top tube clamp half (12). Remove bolts
described in this chapter.
(7) to release ends of long front and rear boom cables
(21 and 22) from top tube clamp half.
6-2. Removal
(3) Remove four nuts (8) and washers (9)
from long bolts (10) holding top and bottom tube clamp
Remove spray boom assemblies from tank installation
halves (12 and 13) together.
as described in paragraph 4-4, step a(2).
(4) Remove bolts, links (11), top and bottom
clamp
halves,
and two ring halves (14) from boom tube
6-3. Disassembly
(32).
Disassemble spray boom assemblies using the following
steps as guides:
6-1. General
6-1
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
Nut, MS21044C4
Washer, MS15795.810
Clevis bolt, AN24-18A
Boom support cable
Nut, MS21044C3
Washer, MS15795-808
Clevis bolt, AN23-14A
Nut, MS21044C3
Washer, MS1579&-808
Clevis bolt, AN3-22A
Link
Tube clamp
Bottom tube clamp
Half ring
Nut, MS21044C3
Washer, MS15795-808
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
6-2
Bolt, AN3C-1OA
Nut, MS21044C3
Washer, MS15795-808
Clevis bolt, AN23-14A
Front boom cable
Rear boom cable
Nut, MS21044C3
Washer, MS15795-808
Clevis bolt, AN3-22A
Boom brace
Link
Tube clamp
Bottom tube clamp
Half ring
Plug
Boom tube
Figure 6-1. Spray boom assembly – exploded view.
6-3
c. Remove nuts (15), washers (16) and bolts (17)
from slotted ends of boom brace (26), and remove cable
from slots.
d. Disconnect cable assemblies from inboard
tube clamps, and remove tube clamps using figure 6-1
and the following steps as guides:
(1) If boom support strut (15, fig. 4-2) is not
yet removed, remove per instructions of paragraph 4-4,
step a (2) (f).
(2) Remove nuts (18, fig. 6-1) and washers
(19) from short bolts (20) on top tube clamp half (28).
Remove bolts (20) to release ends of short cables of
front and rear boom cables (21 and 22) from top tube
clamp half.
(3) Remove four nuts (23) and washers (24)
from long bolts (25) securing boom brace (26) and
holding top and bottom tube clamp halves (28 and 29)
together. Remove bolts (25), boom brace (26), links
(27), top and bottom tube clamps halves, and two ring
halves (30) from boom tube (32).
e. Remove plug (31) from end of boom tube (32).
Section II. CLEANING, INSPECTION, AND ASSEMBLY
(2) Place top tube clamp half (12 or 28) over
ring half on top of tube, and bottom tube clamp half (13
or 29) over ring half on bottom side of tube.
(3) Place four long bolts (10 or 25) through
tube clamp halves from top side. The bolts on outboard
side of tube clamps go through one hole of links (11 or
27).
(4) On inboard tube clamps only, install boom
brace (26) under bottom tube clamp half (29).
6-4. Cleaning
Clean boom tubes thoroughly to remove buildup of
spray fluid, dirt, and other contaminants. Clean threads
of all nozzle attachment holes, and of tube end fittings.
Clean threads of nipples, elbows, and nozzles. Clean
nozzles as described in paragraph 4-20, step b (4).
6-5. Inspection
Note
Inspect all components of the spray boom
assembly. Check all threaded parts for crossed or
otherwise damaged threads. Check boom tubes (32, fig.
6-1) and tube clamp halves (12, 13, 28 and 29) for
cracks, bends, or distortion. Check cables (4, 21, and
22) for damage, fraying, or corrosion. Check cable ends
and slots in boom brace (26) for damage. Discard any
parts which are not usable.
Long arm of boom brace faces forward
(5) Secure components with washers (9 or
24) and nuts (8 or 23).
e. Attach front and rear boom cable assemblies
(21 and 22) to upper tube clamp halves (12 and 28)
noting the following:
(1) Overall length of front boom cable (21) is
about 1 inch longer than length of rear boom cable (22).
(2) Place long boom cable in slots in boom
brace (26). Hold in place by inserting bolts (17) from top
down, and secure with washers (16) and nuts (15).
(3) Attach long and short boom cables to
outer holes in upper tube clamp halves (12 or 28) Insert
short bolts (7 or 20) from top down, and secure with
washers (6 or 19) and nuts (5 or 18). On forward side of
each top tube clamp (12 and 28). The bolts pass through
links (11 or 27).
f.
Attach upper boom support cable (4) to
outboard tube clamp upper half (12). Use bolt (3),
washer (2), and nut (1) to secure.
6-6. Assembly
Assemble the spray boom assemblies using figure
6-1 and the following steps as guides:
a. Assemble nozzles (16, fig. 4-2) as described in
paragraph 4-20, step b (5).
b. Install nozzles into boom tube as described in
paragraph 4-2, step a (1).
c. Install plug (31, fig. 6-1), into end of boom tube
(32).
d. Attach tube clamp assemblies to boom tube.
Locate tube clamp assemblies between 18th and 19th,
and between 4th and 5th nozzles from outboard (plug)
end of boom tube. Using the following steps as a guide:
(1) Place ring halves (14 or 30) on top and
bottom of tube.
6-4
CHAPTER 7
REPAIR OF PUMP AND BRAKE ASSEMBLY
Section I. SYNCHROMATIC WINDMILL ASSEMBLY
Note installation details for use during reassembly.
c. Remove actuator (4) from adjusting screw (8),
noting its position for use during reassembly.
7-1. General
The synchromatic windmill assembly (fig. 7-1) is a
six-blade, adjustable pitch fan which is attached directly
to the pump and brake assembly (19, fig. 4-9). The
windmill assembly is operated by the airstream as the
helicopter moves forward in flight. It provides the power
required to pump insecticide spray fluid from the tank to
the spray nozzles.
Note:
For normal maintenance do not remove
roll pin and nut from adjusting screw.
d. Using a drift punch and a hammer, drive roll
pin (5) from adjusting nut (6) and adjusting screw (8).
7-2. Removal
e. Carefully note details of adjusting nut and
screw in cap hub for use during reassembly. Adjusting
screw must be free to turn in hub, but must have no play
or looseness. You may find it helpful to apply light
lubricating oil or penetrating oil to the adjusting screw to
free it in the hub. Before removing adjusting nut,
determine how far you must turn the nut to tighten it.
Record this information for later use. Then remove the
adjusting nut (6), washers (7), and adjusting screw.
Remove the synchromatic windmill assembly from
the pump and brake assembly by removing the three
attachment bolts (20, fig. 4-2).
7-3. Disassembly
Disassemble the synchromatic windmill assembly
using figure 7-1 and the following steps as guides:
a.
b.
Lift cap hub assembly (1) from base hub (3).
Remove blades (2) from base hub or cap.
7-1
1.
2.
3.
4.
5.
6.
Cap hub assembly
Blade
Base hub
Actuator
Roll pin
Adjusting nut
7.
8.
9.
10.
11.
Washer
Adjusting screw
Cap hub
Retaining Shoulder slots
Blade hub retaining
shoulder
Figure 7-1. Synchromatic windmill assembly-- exploded view.
7-2
disassembly (para 7-3, step e, preceding). Check to see
that at this position, adjusting screw is free to turn with no
play or looseness in the cap hub (9). If holes in adjusting
nut and adjusting screw line up, insert a new roll pin (5).
If holes do not align, drill new hole 0.062 in. diameter in a
location that will miss existing hole.
(b) If a new adjusting nut only is
required, turn the nut down on the adjusting screw, and
then back off slightly, as noted in step (a), preceding.
Check to see that adjusting screw is free to turn with no
play or looseness. If hole in nut does not line up with
hole in adjusting screw, drill a new hole through the
adjusting screw. Use the hole in the adjusting nut as a
guide, and drill hole of same size as in nut (0.062 inch
diameter). Secure nut with new roll pin (5).
(c) If a new adjusting screw is required,
find position of adjusting nut on adjusting screw as
described in step (b), preceding. After determining
correct position, drill hole through adjusting screw in line
with hole in nut. Secure nut with new roll pin (5)).
b. Complete assembly of synchromatic windmill
assembly as instructed in paragraph 4-23, step. f.
CAUTION
Do not try to turn blade angle when
resistance to adjustment is noted.
Internal damage to mechanism will
result if parts are binding.
c. Check blade adjustment mechanism
for
operation. Turn adjusting nut (6) to adjust blade angle to
maximum positions. Blade must be adjustable from
position "I" to position "F" as noted on figure 4-8 without
evidence of sticking or binding. If adjustment cannot be
made freely, do not try to force the blade adjustment.
Remove the cap hub assembly (1, fig. 7-1) and turn the
actuator in the desired direction. Replace cap assembly
and again test adjustment. Repeat this procedure until
full adjustment of the blade angle can be made.
7-4. Cleaning, Inspection, and Repair
Clean all parts thoroughly to remove buildup of spray
residue and dirt. Inspect and repair the synchromatic
windmill assembly as described in paragraph 4-23, step
e, with the following additional steps:
a. Check condition of threads on adjusting screw
(8), adjusting nut (6), and actuator (4).
b. Check base and cap hubs (3 and 9) carefully
for cracks, distortion, and for condition of blade hub
bearing surfaces. Smooth out any rough areas which
might affect blade adjustment.
Note:
Base and cup hubs are shipped as a
matched set. If either needs to be
replaced, replace both with a matched
set.
c. Place blades (2) in boiling water for 30 minutes to restore flexibility.
7-5. Assembly
Assemble the synchromatic windmill assembly using
figure 7-1 and the following steps as guides:
a. Assemble cap hub assembly (1) as follows:
(1) Lightly lubricate threads of adjusting screw
(8) with instrument grease per Military Specification MIG-23827.
(2) Place washer (7) over short end of
adjusting screw.
(3) Place short end of adjusting screw
through cap hub (9) and install second washer (7) over
adjusting screw.
CAUTION
Position of adjusting nut on adjusting
screw is critical. Adjusting screw
must be free to turn in cap hub, but
must not have excessive play or
looseness.
(4) Attach adjusting nut (6) to adjusting screw
(8), using one of the following steps, as applicable:
(a) If reusing both the adjusting nut and
adjusting screw, turn adjusting screw down until it is just
tight. Then back off by the amount noted during
7-6. Installation
Attach the synchromatic windmill fan assembly to the
pump brake drum as described in paragraph 4-23, step
g.
Section II. BRAKE ASSEMBLY
the brake shoes are returned to their normal position by
the brake springs (5, fig. 7-2). This action allows the
synchromatic windmill assembly and pump to operate.
7-7. General
The brake assembly (fig. 7-2) is attached directly to the
spray fluid pump assembly (8). The brake assembly
consists of a pair of brake shoes (4) contained inside a
brake drum (2). Actuation of the brake arm by the brake
lever (16, fig. 410) causes the brake shoes to expand
against the brake drum.
This action stops the
synchromatic windmill assembly from turning, thereby
stopping the pump. When the brake lever is released,
7-8. Removal
a. Remove the synchromatic windmill assembly
from brake drum by removing three attachment bolts (20,
fig. 42).
7-3
b. Remove the brake assembly from the pump
assembly using figure 7-2 and the following steps as
guides:
Note:
Brake assembly may be removed from
pump with pump installed on tank
installation. For instructions on removal
1.
2.
3.
4.
5.
of pump from tank installation, refer to
paragraph 5-8, step a.
(1) Using a pair of snap ring pliers, remove
snap ring (1) from end of pump shaft.
CAUTION
Do not beat on end of shaft.
Snap ring
Brake drum
Woodruff key
Brake shoe
Brake spring
6.
7.
Socket screw, flat head
1/4-20 x 1/2
Brake back plate assembly
8.
Pump assembly (fig. 7-3)
Figure 7-2. Brake assembly - exploded view.
(2) With brake in off position, remove brake
drum (2). Attach a gear puller to any two of the four
5/16-24 thread mounting holes in the brake drum. Using
a wrench, tighten gear puller bolt against the end of
pump shaft until drum slips off pump shaft.
(3) Remove woodruff key (3) from recess in
shaft. (Not required if brake only is to be removed.)
(4) Remove brake springs (5) and carefully
remove brake shoes (4) from brake back plate assembly
(7).
7-4
(5) Using a pair of snap ring pliers, remove
second snap ring (1) from pump shaft. (Not required if
brake only is to be removed.)
(6) Using an allen wrench, remove three
screws (6). Discard screws.
Note:
Observe position of back plate to pump
for use during reassembly. Suggest
marking location of brake actuation on
pump body with grease pencil.
(7) Remove brake back plate assembly (7)
from pump assembly (8).
considered too thin to last until next regular overhaul.
(3) Replace springs if kinked, bent, or
damaged.
(4) Replace brake back plate assembly if bent
or if actuation arm is bent or will not operate smoothly.
7-10.
Assembly
Assemble brake assembly to pump assembly using
figure 7-2 and the following steps as guides:
a. Using three new screws (6) and an allen
wrench, attach brake back plate assembly (7) to pump
assembly (8). Position back plate assembly such that
actuation arm is in line with the word AGAVENCO on
pump body (between pump foot and outlet port). Secure
screws handtight.
b. Place brake shoes (4) ) together with the flat
ends facing each other. Holding brake shoes together,
install brake shoes to stud on back plate assembly. Fit
flat ends of brake shoes on each side of actuation arm
shaft of brake plate assembly. Install brake springs (5) to
secure brake shoes in position on back plate assembly.
c. Using snap ring pliers, install snap ring (1) in
inner groove of pump shaft.
d. Insert woodruff key (3) into recess in pump
shaft.
e. Install brake drum (2) over pump shaft,
woodruff key, and brake shoes.
f.
Test fit of brake drum by spinning brake drum
with brake shoes in relaxed position. If any brake drag
occurs, operate brake by hand and rotate brake drum by
hand. Relieve pressure on brake lever and continue to
rotate brake drum. If brake still drags remove brake
drum and lightly file brake shoe lining to remove any high
spots. Replace brake drum and again check for
rotational freedom. Repeat these steps as required until
brake drum spins freely with no evidence of drag.
g. Secure brake assembly with snap ring (1) in
outer groove of pump shaft.
7-9. Cleaning, Inspection, and Repair
WARNING
Avoid breathing dust found within
brake assembly. Material worn off
brake lining may be injurious to
lungs.
a. Clean brake drum, shoes, and back plate
assembly carefully to remove dust. Do not clean brake
linings with oil-base cleaning fluids.
b. Inspect condition of all components, and
replace any part not found to be usable. Make the
following specific checks:
(1) Check interior of brake drum for
scratches, grooves, or distortion.
(2) Check brake shoes for condition of lining.
Thickness of lining should be 1/16 inch minimum.
(3) Check springs for condition and tension.
(4) Check brake back plate for flatness and
for condition of actuation arm. Arm should rotate freely
in back plate.
c. Repair or replace components as required,
noting the following:
(1) Remove light scratches from interior of
brake drum by smoothing out with crocus cloth per
Federal Specification P-C-451. Polish in direction of
drum rotation only, never across drum.
(2) Replace brake shoes if lining is
Section III. PUMP ASSEMBLY
7-11.
as described in paragraph 5-8, step a. Remove brake
assembly as described in paragraph 7-8, step b.
General
The pump portion of the pump and brake assembly (19,
fig. 4-9) is a centrifugal type, driven by the synchromatic
windmill assembly. Pump speed depends upon the
windmill fan blade angle and helicopter forward flight
speed. The pump is stopped and started by the brake
lever (16, fig. 4-10) on the manual control panel.
7-13.
Disassembly
Disassemble pump assembly using figure 7-3 and the
following steps as guides:
a. Remove screws (1) and washers (2) securing
inlet (3) to case (21). Remove inlet and gasket (4). (Not
required unless gasket is leaking.)
7-12.
Removal
Remove pump and brake assembly from tank installation
7-5
b. Remove screws (5) and washers (6) securing
body (19) to case (21). Remove body and attached parts
(8 through 19) and gasket (7) from case.
c. Remove bolt (8) and lock washer (9) from
impeller shaft (18). Discard bolt. Insert a 3/8-16 coarsethread bolt into the center hole of the impeller (12).
Threaded end of bolt must be at least 1.0 inch long.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
Tighten this bolt against the shaft end (18) to remove
impeller. Remove bolt from impeller.
d. Using two flat blade screwdrivers, pry the
stationary seal (10) from the impeller. Discard seal.
Pressure should be applied evenly to both sides of seal
to prevent damage to impeller.
e. Remove pin (11) from slot in impeller hub.
Screw
Washer, AN960-416
Inlet
Gasket
Screw
Washer, AN960-516
Gasket
Bolt
Washer, Lock
Stationary seal
Pin
Impeller
13.
14.
15.
Main seal
Snap ring
Shaft and bearing assembly
16.
17.
18.
19.
20.
21.
22.
Snap ring
Bearing
Shaft
Body
Plug Y%-27
Case
Identification plate
Figure 7-3. Pump assembly - exploded view.
7-6
f.
Using two flat blade screwdrivers, pry main
seal (13) from pump body. Use the two recesses in
pump body at edges of seal for this purpose. Discard
seal. Pressure should be applied evenly to both sides of
seal to prevent damage to pump body. Blocking under
screwdriver will increase leverage.
Note:
At this point in disassembly, check
condition of bearings to determine if
further disassembly is necessary. If
further disassembly is necessary,
continue with succeeding steps. If not,
go to paragraph 7-15, step g, to
reassemble pump assembly.
g. Using snap ring pliers, remove snap rings (14)
from both ends of shaft (18) within body hub.
CAUTION
Do not hammer shaft and bearings
from body as damage to shaft and
body will result.
h. Using an arbor press and a large socket or a
piece of pipe, press shaft and bearing assembly (15)
from body.
i.
Remove snap rings (16) from shaft.
j.
Using arbor press and large socket or piece of
pipe, press bearings (17) off shaft. Discard bearings.
k. Remove plugs (20)) from case, to complete
disassembly of pump assembly.
l.
If necessary for replacement, remove
identification plate (22) from body (19).
(2) Check body (19) and case (21) carefully
for cracks or damage.
(3) Check bearing surfaces within hub of
body (19). This surface must be free of scratches, nicks,
and burrs.
(4) Check all threaded parts for crossed or
otherwise damaged threads.
(5) Check condition of all gaskets. Discard
broken or cracked gaskets.
c. Repair or replace parts of pump assembly as
required, noting the following:
(1) Replace bolt (8), seal assembly (10 and
13), and bearings (17) at overhaul, regardless of their
apparent condition.
Note:
Seal assembly (10 and 13) on original
unit contains viton rubber components.
Replacement seals contain Teflon
components.
Therefore, on first
overhaul of unit, the replacement seal
may look different than the seal being
replaced.
(2) Remove minor scratches from sealing
surface of impeller (12) and from interior of body (19)
hub. Use crocus cloth, Federal Specification P-C-451.
Polish in direction of part rotation only, never cross
sealing or bearing areas. Reclean parts per step a,
preceding, after repair.
7-14.
Assemble the pump assembly using figure 7-3 and the
following steps as guides:
a. Using snap ring pliers, insert snap ring (14) in
groove within body (19) hub on side toward impeller.
CAUTION
Use care when installing bearings not
to allow them to cock to one side.
Scoring of bearing surface in hub and
preloading of bearings may result.
b. Using an arbor press and a piece of pipe,
press one new bearing (17) into body hub. Insert from
brake side of hub and press carefully down against snap
ring. Use care not to press against bearing surfaces.
c. Using snap ring pliers, install two snap rings
(16) into grooves on shaft (18) away from woodruff key
recess.
d. Install shaft (18) in body hub and press into
bearing using an arbor press. Press in carefully, until
snap ring on shaft contacts bearing.
e. Using arbor press and a large socket or piece
of pipe, press remaining bearing (17) onto shaft. Press
carefully down against snap ring on shaft. Use care not
to press against bearing surfaces.
f.
Using snap ring pliers, install second snap ring
(14) into groove in body hub.
g. Using arbor press and a large socket or piece
of pipe, carefully press new main seal (13) into
7-15.
Cleaning, Inspection, and Repair
WARNING
Use cleaning solvent in wellventilated area. Avoid breathing of
fumes and excessive contact with
skin. Keep away from open flame.
Wash hands before eating or
smoking.
CAUTION
Do not use wire brush or other
materials which might scratch metal
surface on sealing surface of impeller
or on bearing surface within body
hub.
a. Clean all portions of the pump assembly
thoroughly to remove buildup of spray fluid residue, dirt,
lubricants, and sealants. Use cleaning solvent per
Federal Specification P-D-680 to remove oily
substances.
A stiff wire brush may be used on
nonsealing areas such as the impeller face and body
casting to remove caked material.
b. Inspect condition of all components and
replace any parts not found to be usable. Make the
following specific checks:
(1) Check sealing surface within impeller hub
(12, fig. 7-3). This surface must be clean and smooth for
assembly.
7-7
Assembly
k. Insert impeller (12) over end of pump shaft. Be
careful not to allow sealant to come in contact with
mating surfaces of seal assembly (10 and 13).
l.
Secure impeller (12) to pump shaft (18) with
lock washer (9) and new bolt (8). Check impeller for
freedom of rotation.
m. Attach body (19) and gasket (7) to case (21)
using washers (6) and screws (5). Place body such that
word AGAVENCO goes between pump foot and outlet
port.
n. Install gasket (4) and inlet (3) to case (21)
using washers (2) and screws (1).
o. Install two plugs (20) into threaded holes in
case (21).
p. If identification plate (22) was removed.
transfer all information from old plate to new plate.
Remove adhesive backing from new plate and install in
approximate position shown in figure 7-3.
body (19). Press enclosed end of seal into body hub
until flange on seal is seated in hub. Use care not to
press against sealing surface.
Note:
Upon original seal installation at factory,
seal assembly (10 and 13) was
lubricated with John Crane plastic lead
seal No. 2. However, replacement seals
are pre-lubed (as noted by blue color)
and, therefore, do not require lubrication
upon installation.
h. Install new stationary seal (10) in impeller (12).
Be sure seating surface in impeller is smooth and clean.
Apply a light coating of oil per Federal Specification VVL-820 to seating surface of impeller and to rubber
packing on seal. Install seal so that polished surface will
make contact with black surface of main seal (13). Do
not allow oil to get on sealing surface of seals.
i.
Install pin (11) into slot in impeller (12) hub.
j.
Apply sealant (Tite-seal T-3504), or equivalent
to screw threaded end of pump shaft (18).
7-16.
Installation
Attach the pump and brake assembly to the pump
support assembly as described in paragraph 5-8, step b.
7-8
CHAPTER 8
REPAIR OF VALVES, COUPLING, AND TANK
Section I. FLOW CONTROL AND BYPASS VALVES
9) as instructed in paragraph 5-12, step a. If tank
8-1. General
assembly (125) is removed from tank support assembly
Two valves (fig. 8-1), which are identical in design and
(133), remove bypass valve as instructed in paragraph 8function except for end fittings, are used in the
11, step c.
insecticide sprayer. They are manually operated, ball
type, flow control valves containing a back pressure
bleed passage. The valves are used to control flow of
8-3. Disassembly
insecticide fluids within the sprayer system.
Back
pressure is controlled by an adjustable screw.
Disassemble the control valve or bypass valve using
figure 81 and the following steps as guides:
8-2. Removal
Note:
a. Remove the control valve assembly (47, fig. 4Discard removed parts that are to be
9) as instructed in paragraph 5-9, step a.
replaced from overhaul kit.
b. Remove the bypass valve assembly(52, fig. 4-
8-1
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
Nut
Washer
Bolt
Lever
Bolt
Washer
Fitting
Fitting (45° elbow)
Flange
*Gasket
*O-ring
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
*Seat
Bolt
Washer
Fitting
Fitting
*Gasket
*O-ring
*Seat
Bolt
Washer
Cap (7517)
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
*Parts contained in overhaul kit PN K7520-1
8-2
*Gasket
*O-ring
*Seat
Bolt
Washer
*Bearing
Cap
*Gasket
Bolt
Washer
*Bearing
34.
35.
36.
37.
38.
39.
40.
41.
Shaft end cap
*Gasket
*Quad ring
*Thrust washer
Ball
*O-ring
Flow control screw
Body
Figure 8-1. Valve assembly - exploded view.
8-3
a. Remove nut (1), washer (2), and bolt (3)
holding lever (4) to shaft of ball (38). Remove lever,
noting its position relative to ball position in valve for aid
during assembly.
b. Remove four bolts (5) and washers (6).
Remove fitting (7) from bypass valve, or fitting and flange
(8 and 9) from control valve.
c. Remove gasket (10) and seat (12) from body
(41); remove O-rings (11) from seat.
d. Remove four bolts (13) and washers (14).
Remove fitting (15) from bypass valve, or fitting (16) from
control valve.
e. Remove gasket (17) and seat (19) from body
(41); remove O-rings (18) from seat.
f.
Remove four bolts (20) and washers (21), and
remove cap (22), gasket (23), and seat (25) from body
(41). Remove O-rings (24) from seat.
g. Remove four bolts (26) and washers (27), and
remove can (29) and gasket (30) from body (41); remove
bearing (28) from cap.
h. Remove four bolts (31) and washers (32), and
remove shaft end cap (34) and gasket (35) from body
(41). Remove bearing (33) and quad rings (36) from
shaft end cap.
i.
Remove ball (38) from body (41); remove
thrust washer (37) from shaft of ball.
l.
Remove flow control screw (40) from body
(41); remove O-rings (39) from flow control screw.
k. Discard all kitted Darts (noted on key to fig. 81). These parts shall be replaced by new parts from the
overhaul kit at assembly.
a. Place new O-ring (39) on flow control screw
(40). Grease O-ring and insert flow control screw into
body (41). For bypass valve tighten flow control screw
down tight against seat. For control valve, tighten flow
control screw down against seat, and then back off about
3/4 turn.
b. Assemble new bearing (28) in cap (29). Attach
gasket (30) and cap (29) to body (41). Secure with four
washers (27) and bolts (26). Refer to figure 8-1 for
proper location of parts.
c. Install ball (38) with short shaft into bearing
(28) in cap (29) installed in body (41) in step b,
preceding.
d. Place thrust washer (37) over long shaft of ball
(38).
e. Install quad rings (36) and bearing (33) into
shaft end cap (34).
f.
Grease quad rings and long end of shaft on
ball (38).
g. Attach gasket (35) and shaft end cap (34) to
body (41) over long shaft of ball (38). Secure with four
washers (32) and bolts (31). Check ball for freedom of
movement.
h. Place one each new O-ring (24, 18, and 11) in
groove closest to concave sealing surface of three new
seats (25, 19, and 12). Grease O-rings and slide seats
into the three ports of body (41).
i.
Place one each new O-ring (24, 18, and 11) in
exposed groove of seats (25, 19, and 12).
j.
To reassemble bypass valve, place new
gaskets (23, 17, and 10) under cap (22) and fittings (15
and 7). Refer to figure 8-1 for proper locations of parts.
Secure parts to body (41) using four washers (21, 14,
and 6) and bolts (20, 13, and 5) at each location.
k. To reassemble control valve, place new
gaskets (23, 17, and 10) under cap (22), fittings (16), and
flange (9). Slip flange (9) over fitting (8). Refer to figure
8-1 for proper locations of these parts. Secure parts to
body (41) using four washers (21, 14, and 6) and bolts
(20, 13, and 5) at each location.
Note:
Bolts (5) securing flange (9) and elbow
fitting (8) may be left slightly loose.
Fitting is rotated on final assembly to
insecticide sprayer and is secured when
proper location is determined.
l.
Place lever (4) over exposed end of long shaft
of ball (38).
Secure in same position noted on
disassembly with bolt (3), washer (2), and nut (1).
m. Check valve for freedom of movement.
8-4. Cleaning, Inspection, and Repair
Thoroughly clean and inspect all reusable parts of the
valve as follows:
a. Inspect all metal parts for nicks, scratches,
cracks, or other damage. Polish out minor defects using
crocus cloth, Federal Specification P-C-458 for steel
parts and aluminum oxide abrasive cloth, Federal
Specification P-C-451 for aluminum parts.
b. Inspect all threaded parts for crossed or
otherwise damaged threads.
c. Inspect surfaces of ball (38) for condition.
8-5. Assembly
Reassemble the valve in accordance with the following
steps, using new parts from overhaul kit for those parts
noted in the key to figure 8-1. Assembly of the bypass
valve (52, fig. 4-9) and control valve assembly (47) is
identical except where noted.
8-4
Section II. VALVED QUICK-DISCONNECT COUPLING
balls in the valved coupler half which engage in a groove
on the valved nipple half. The balls are retained in place
by a sleeve on the valved coupler half. Sliding the sleeve
away releases the balls, allowing the coupling halves to
disengage. When disconnected, springs within each
coupling half return the respective poppets to the closed
position. A dust cap and dust cover are attached to the
valved nipple and valved coupler, respectively, by steel
cables. The dust cap and cover are used to cover the
open ends of the coupler to protect them from dirt,
grease, and other contaminants.
8-6. General
A valved nipple (36, fig. 4-9) is attached to the liquid
loading tube (41). The valved nipple (fig. 8-2) contains a
poppet which is spring-loaded closed against a seat
within the body. The valved nipple forms the male half of
a quick-disconnect coupling. A valved coupler forms the
female half of the quick-disconnect coupling and is part
of the liquid loading system (ch. 11). When the coupling
halves are mated, valves within each half of the coupling
force each other open. The coupling is held together by
Figure 8-2. Valved quick-disconnect coupling.
following specific checks:
(1) Check threaded parts for crossed or
otherwise damaged threads.
(2) Check condition of teflon seals on valve
assemblies for cuts or contamination with foreign
particles.
(3) Check seating surfaces within nipple and
coupler for nicks, scratches, or other damage.
c. Discard valved nipple or coupler if either is
found not to be usable.
8-7. Removal
Remove the valved nipple from ground loading tube of
the insecticide sprayer as described in paragraph P16,
step c.
8-8. Cleaning and Inspection
a. Clean all parts of the valved quick-disconnect
coupling thoroughly to remove spray fluid residue, dirt,
lubricants, and other contaminants.
b. Inspect condition of all parts.
Make the
Section III. TANK ASSEMBLY
internal baffles provided for strength and to reduce
sloshing of fluid within the tank during flight. The tank is
translucent with fluid level markings on each end. A fluid
level gage is mounted on the front side. Fluid level within
the tank can be seen through the tank material. In
addition, connectors for components attached to the tank
are permanently attached.
8-9. General
The tank assembly (125, fig. 4-9) consists of a
cylindrical, molded fiberglass tank with attachment
fittings for components connected to the tank. The tank
has a 200-gallon capacity and is a molded fiberglass
reinforced polyester resin structure. It contains two
8-5
8-10.
all fractured areas. Large holes should be backed up by
a flat piece of wood, paperboard, or similar while
applying material. Cover entire patch with epoxy and
allow to cure. The size and nature of damage may
indicate the need for additional layers of patching
material.
Removal
Remove tank assembly from tank support assembly
(133, fig. 4-9) as instructed in paragraph 5-16, step a.
8-11.
Disassembly
8-13.
Remove components attached to tank assembly using
figure 4-9 and the following steps as guides:
a. Remove top fill cap and strainer components
(115 through 119) as instructed in paragraph 4-17, step
c.
b. Unscrew elbow (112) from tank connector, and
adaptor (111) from elbow.
c. Remove bypass valve assembly (52) from tank
connector by cutting and discarding lockwire (48) and
removing six bolts (49) and washers (50). Remove
bypass valve and gasket (51).
d. Remove sump (34) from tank as instructed in
paragraph 5-15, step a.
e. Remove liquid level gage (110) from tank
connector as instructed in paragraph 5-14, step a.
8-12.
Assembly
a. Assemble the tank assembly using figure 4-9
and the following steps as guides:
(1) Install liquid level gage (110) in tank as
instructed in paragraph 5-14, step b.
(2) Install sump (34) to opening in bottom of
tank as instructed in paragraph 5-15, step b.
(3) Install bypass valve in opening in bottom
front of tank as follows:
(a) Coat new gasket (51) and bolts (49)
with Tite-seal gasket and joint sealing compound, part
No. T3504 or equivalent.
(b) Place gasket (51) on flange of
bypass valve (52) with mounting holes aligned.
(c) Place valve into position, with valve
mounting flange mating with connector flange. Align
mounting holes so that valve end ports are canted to
approximately 5 o’clock/11 o’clock position as viewed
from front of tank. Be sure flow direction arrow on valve
points toward end of tank.
(d) Attach valve to connector flange with
six washers (50) and bolts (49). Secure bolts tight, and
then lockwire per MS33540. Lockwire three bolts on
each side together, with breaking point in line with flow
control screw on valve (40, fig. 8-1).
(4) Wrap male threads of elbow (112) and
pipe to hose adaptor (111) with teflon tape, Military
Specification MILT-27730. Install elbow (112) into tank
connector, and pipe to hose adapter (111) into elbow.
(5) Install top fill strainer assembly and cap
(115 through 119) as instructed in paragraph 4-17, step
e.
Cleaning, Inspection, and Repair
a. Clean tank thoroughly to remove buildup of
spray fluid residue and other foreign matter. Clean all
threaded parts and connectors.
b. Inspect tank for damage, cracks, and holes.
Determine extent of damage and if tank can be repaired.
If damage is too severe, replace tank.
Inspect
attachment fittings and connectors for security and
condition of threads.
c. Repair minor cracks, holes, or other leaks by
pushing epoxy resin through opening and permit it to
cure for the required time. Follow directions on epoxy
container carefully when preparing and using the
material. Tank areas to be repaired must be prepared by
thorough cleaning and roughening of the surface.
Generally, this may be done by sandpapering. Sharp
edges should be beveled to insure secure bonding. All
surfaces to be bonded must be kept free of dirt, oil,
grime and fingerprints.
d. Repair of larger damage requires use of a
reinforced patch of glass or linen cloth on top of
previously applied epoxy. Coverage must extend beyond
8-14.
Installation
Install tank assembly into tank support assembly (133)
as instructed in paragraph 5-16, step b.
8-6
CHAPTER 9
REPAIR OF TANK SUPPORT ASSEMBLY
Section I. TANK SUPPORT ASSEMBLY
g. If tiedown lugs (28, fig. 4-2) are attached to
tank support assembly, remove tiedown lugs using figure
4-2 and the following steps, as required:
(1) Remove cotter pin (25), if in place.
(2) Remove lock nut (26) and washers (27).
(3) Remove tiedown lug (28).
9-1. General
The tank support assembly (133, fig. 4-9) consists
primarily of aluminum alloy channel rail. connected
together by aluminum alloy sheet. It is assembled by
riveting and welding. The tank sup port provides the
base to which the remainder o! the insecticide sprayer is
mounted. It also provides the means for attaching the
sprayer to the helicopter.
9-3. Cleaning, Inspection, and Repair
a. Cleaning.
Clean all portions of the tank
support assembly to remove spray residue, dirt, rust, or
other foreign matter.
b. Inspection. Inspect all portions of the tank
support assembly for damage that might impair
operation of the insecticide sprayer. Check condition of
all threaded parts, and all attachment or mounting holes.
Check security of rivets and weldments. Mark any areas
found or suspected of being faulty or in need of repair.
Inspect security of attachment and condition of felt
cushions (124, fig. 4-9) on inside of cradle channels.
c. Repair. Repair tank support assembly only as
required, noting the following:
(1) Repair channel rails and sheet metal
portions by straightening, patching, or replacing any parts
found to be faulty. Remove parts by drilling out rivets or
cutting weldments as required. Cut new pieces to size,
using removed parts as a pattern. Drill new rivet holes in
exact locations, and deburr holes. Locate parts into
position, with all joints tight against one and other. Rivet
parts in place per Military Standard MILSTD-403. Check
to see that all rivets are securely installed.
(2) Perform any welding required per Military
Specification MIL-W-45205, Class B.
(3) Replace felt cushion (124, fig. 4-9) on
cradle channel if missing, torn, or badly worn. Center
cushion on channel and attach to channel with glue.
Allow glue to set before installing tank.
(4) On completion of repair operations,
reclean tank support assembly thoroughly to remove any
dirt or oil. Treat metal per Military Specification MIL-C5541 and paint per Military Specification MILC-22751C,
color gray, No. 26231. Corrosion resistant steel parts will
require pretreatment per Military Specification MIL-C8514.
(5) Paint area around nine mounting holes in
tank support base used for UH-1D installation (fig. 4-4).
Use red color No. 31136 per Federal Standard FEDSTD-595.
9-2. Disassembly
a. Remove parts from the tank support assembly
per instructions in chapter 5.
b. Remove pump support assembly (107, fig 4-9)
from tank support assembly (133) using figure 4-9 and
the following steps as guides:
(1) Remove pump struts (91 and 95) as
follows:
(a) Remove nuts (82), washers (83), and
bolts (84) securing pump struts to eyebolts (99) in flange
of pump support assembly (107).
(b) Remove nut (85), washer (86), and
bolt (87) securing long pump strut (91) to eyebolt (90).
Remove long pump strut.
(c) Remove nut (88), washer (89), and
eyebolt (90) from rear upper channel rail of tank support
assembly (133).
(d) Remove nut (92), washer (93), and
bolt (94) securing short pump strut (95) to complete
removal of short pump strut.
(e) Remove nuts (96), washers (97),
bushings (98), and eyebolts (99) from flange of pump
support assembly (107).
(2) Complete removal of pump support
assembly (107) from tank support assembly (133) by
removing nuts (100), washers (101) and bolts (102).
c. Remove bracket (106) from pump support
assembly (107) by removing nuts (103), washers (104),
and screws (105).
d. Remove eight handles (109) from bottom tank
support rails by removing screws (108).
e. Remove four stray end tiedown fittings (128)
from upper tank support rails by removing nuts (126) and
washers (127).
f.
Remove four tank clamps (132) from tank
support cradle channels by removing nuts (129),
washers (130), and screws (131)).
9-1
pump support assembly (107). Install bushings (98),
washers (97), and nuts (96) on pump side of flange. Do
not secure nuts at this time.
(7) Check position and alignment of all parts,
then secure all nuts (100, 96, 92, 88, 85, and 82).
c. Attach eight handles (109) to tank support
bottom rails using screws (108) to secure handles in
place.
d. Attach two strap end tiedown fittings (128) to
each upper rail on front and rear of tank support
assembly (133). On front rail, fittings go on top of rail; on
rear rail, fittings go on bottom of rail. Secure in place
with washers (127) and nuts (126).
e. Attach four tank clamps (132) to ends of tank
support cradle channels. Strap ends go inside channel,
with clamp facing outward. Secure with screws (131),
washers (130), and nuts (129). Insert screws from inside
of channel rings.
f.
If desired to install tiedown lugs (28, fig. 4-2) to
tank support base, place one washer (27) over lug, and
install tiedown lug body from underneath frame. Place
second washer (27) over lug, and secure lug to tank
support frame with nut (26). Secure parts of tiedown lug
in place with cotter pin (25).
9-4. Assembly
a. Attach bracket (106, fig. 49) to pump support
assembly (107) using screws (105), washers (104), and
nuts (103).
b. Attach pump support assembly to tank support
assembly using figure 4-9 and the following steps as
guides:
(1) Install short pump strut (95), to upper
channel rail on front of tank support assembly (133).
Attach with bolt (94), washer (93), and nut (92). Do not
secure nut at this time.
(2) Install eyebolt (90) through hole in upper
channel on rear of tank support assembly. Insert eyebolt
from front side of channel. Place washer (89) and nut
(88) on eyebolt. Do not secure nut at this time.
(3) Attach long pump strut (91), to eyebolt
(90). Attach with bolt (87), washer (86), and nut (85). Do
not secure nut at this time.
(4) Attach eyebolts (99) to remaining ends of
pump struts (91 and 95). Attach with bolts (84), washers
(83), and nuts (82). Do not secure nuts at this time.
(5) Attach pump support assembly (107) to
lower front rail of tank support assembly (133). Attach
with bolts (102), placed from inside channel, washers
(101), and nuts (100). Do not secure nuts at this time.
(6) Insert eyebolts (99) on ends of pump
support struts (91 and 95) through top holes of flange of
Section II. TANK STRAPS, STRUT, AND TIEDOWN LUGS
threaded parts, attachment holes, and rivets for general
condition.
c. Repair components as found necessary by
removing dents from struts (91 and 95, fig. 4-9), and
replacing rivets in strap assemblies (123), tank clamps
(132), and struts. Replace rivets by drilling out old rivets
and replacing with exact duplicate or with next larger size
if required. Install rivets per Military Standard MIL-STD403.
9-5. General
Two tank strap assemblies (123, fig. 4-9) are used to
secure the tank assembly (125) to the tank clamps (132).
Pump struts (91 and 95) are used to support the pump
support assembly (107). Tiedown lugs (28, fig. 4-2) are
used to secure the insecticide sprayer to the helicopter
cargo deck (fig. 4-3 or 4-4) or to the skid frame (fig. 4-1).
9-6. Removal
9-8. Installation
a. Remove tank strap assemblies (123, fig. 4-9)
as instructed in paragraph 5-16, step a (7).
b. Remove tank clamps (132) as instructed in
paragraph 9-2, step f.
c. Remove pump struts (91 and 95) as instructed
in paragraph 9-2, step b (1).
d. Remove tiedown lugs (28, fig. 4-2) as
instructed in paragraph 9-2, step g.
a. Attach tank clamps (132, fig. 4-9) to tank
support assembly (133) as instructed in paragraph 9-4,
step e.
b. Attach tank strap assemblies (123) to secure
tank assembly (125) to tank support assembly (133) as
instructed in paragraph 5-16, step b (4).
c. Attach pump struts (91 and 95) to tank support
assembly (133) as instructed in paragraph 9-4, step b.
d. Attach tiedown lugs (28, fig. 4-2) to tank
support base if required, as instructed in paragraph 9-4,
step f.
9-7. Cleaning, Inspection, and Repair
a. Clean all parts thoroughly to remove buildup of
spray residue, dirt, and grease.
b. Inspect parts for serviceability. Check all
9-2
CHAPTER 10
REPAIR OF MANUAL CONTROL PANEL
Section I. GENERAL
10-1.
control bracket is attached to the support and may be
adjusted to two positions as required for installation into
the UH-1B or UH-1D helicopters (para 4-3).
Introduction
The manual control panel (fig. 4-10) primarily consists of
a support (25) and a control bracket (27). The support is
hinged at the bottom and contains a folding brace. The
Section II. REMOVAL AND DISASSEMBLY
10-2.
control panel as instructed in paragraph 4-24, step c.
b. Remove control bracket (27, fig. 4-10) from
support (25) by removing nuts (23) and screws (24).
Removal
Remove the manual control panel from tank installation
as instructed in paragraph 5-17, step a.
10-3.
a.
Disassembly
Disassemble components from the manual
Section III. CLEANING, INSPECTION, REPAIR, AND ASSEMBLY
10-4.
d. Drill new holes to exactly match holes in mating
parts.
e. Assemble parts using rivets, cherry lock bolts,
or by welding, to match original assembly.
f.
Install rivets in accordance with Military
Standard MIL-STD-403.
g. Perform welding in accordance with Military
Specification MIL-W-6858.
h. Reclean assembly after repair to remove burrs,
chipped paint, dirt, and oil.
i.
Treat bare metal surfaces in accordance with
Military Specification MIL-T-704, and paint in accordance
with Military Specification MILP-22806, using gray paint
no. 26231.
10-7.
Assembly
Cleaning
Clean all portions of the manual control panel to remove
spray residue, dirt, rust, or other foreign matter.
10-5.
Inspection
Inspect all portions of the manual control panel for
damage that might impair operation of the insecticide
sprayer. Check for the following specific items:
a. Bent, broken, or loose components.
b. All rivets, cherry lock bolts, and weldments for
security.
c. Operation and security of hinge and folding
brace.
d. Fit of control bracket (27, fig. 4-10) in support
(25).
10-6.
a. Place control bracket (27, fig. 1-10) into
position on support (25). Secure with four screws (24),
and nuts (23). Nuts go on outside of frame.
b. Install levers (16 and 17), valve rod (15), and
pressure gage (21) to manual control panel as instructed
in 4-24, step e.
Repair
Repair the control support components as found
necessary, using the following as a guide:
a. Remove and replace damaged sheet metal
components as required.
b. Drill out rivets or cut away cherry lock bolts with
a hammer and chisel.
c. Fabricate replacement parts using removed
components as patterns.
10-8.
Installation
Install manual control panel to tank installation as
instructed in 5-17, step b.
10-1
CHAPTER 11
MAINTENANCE OF LIQUID LOADING SYSTEM
Section I. GENERAL
11-1.
loading system is shipped with each insecticide sprayer.
Attached to the pump inlet port is a 12-foot length of
hose and a suction pipe. Attached to the pump outlet
port is a ball type shutoff valve and two 12-foot lengths of
hose. Quick-disconnect couplings are used to connect
the hoses to other components of the liquid loading
system and to the insecticide sprayer for loading
insecticide spray fluid.
Introduction
a. The liquid loading system is shown in figure 111. The system consists of an engine driven pump (1), a
pump inlet strainer assembly (11), a shutoff ball valve
(2), and three hoses (8). The liquid loading system is
used to pump liquid insecticide fluid from storage drums
into the aircraft-mounted insecticide sprayer. The liquid
loading system is part of the sprayer system. One liquid
1. Pump
2. Ball valve
3. Nipple
4. Valved coupler
5. Valved nipple
6. Hose clamp
7. Adaptor
8. Hose
9. Pipe
10. Elbow
11. Strainer assembly
Figure 11-1. Liquid loading system.
b. The major component of the liquid loading
system is the pump. Refer to figure 11-2 for details and
important features of the pump.
11-1
1. Suction nipple
2. Discharge nipple
3. Pump filler cap and
gasket
4. Carrying grip
5. Fuel line
6. Air filter cover nut
7. Air filter cover
8. Fuel filler cap
9. Starter grip
10. Fan housing
11. Pump base
12. Fuel line connecting
elbow
13. Bearing housing
14. Back plate
15. Pump wear plate
16. Pump body
17. Pump drain plug and
gasket
18. Muffler strap clamping
screw
19. Muffler
20. Choke button
21. Exhaust manifold
22. Spark plug
23. Nameplate
24. Ignition ON/OFF switch
28. Throttle button
11-2
25. Carburetor main (HI)
mixture adjustment
screw
26. Carburetor idle (LO)
mixture adjustment
screw
27. Spare for drain or
filler plug
Figure 11-2. Pump assembly.
11-3
c. Refer to paragraph 11-1 for a general
description of the liquid loading system. Figure 11-3 is a
wiring schematic of the pump engine. Tabulated data for
the liquid loading system is as follows:
(1) Liquid loading system pump engine.
Manufacturer .............................Homelite
Type............................................Air-cooled
Number of cylinders ...................1
Stroke cycle ...............................2
Fuel ............................................Gasoline and oil, mixed
Fuel tank capacity ......................18 ounces liquid
Piston displacement ..................3.3 cubic inches
Bore ...........................................13/4 inches
Stroke ........................................13/8 inches
Compression ratio .....................8:1
Air cleaner .................................Dry type
Ignition system ...........................Magneto
Type of lubrication .....................Oil mixed with fuel
Governor ....................................Air-vane type
(2) Pump.
Manufacturer .............................Homelite
Type ...........................................Self-priming, centrifugal
Rated speed (no load) ...............6400 -- 6600 rpm
Drive ..........................................Direct
(3) Engine accessories.
(a) Carburetor.
Manufacturer .............................Tillotson
Model .........................................HS40A
Type ...........................................Diaphragm with integral
fuel pump
(b) Ignition system.
Type............................................Magneto
Manufacturer of magneto ...........Wico
Model..........................................FW-2782-C
(c) Spark plug.
Manufacturer .............................. Champion
Type ........................................... XEJ-12
Size ............................................ 14 millimeters
(d) Adjustment data.
Spark plug gap ........................... 0.023-0.028 inch
Magneto breaker point gap ........ 0.015 inch
(e) Torque data.
Spark plug .................................. 250-300 lb-in.
No. 8 Spinlock screws ............... 6 lb-in. min
No. 10 Spinlock screws ............. 50 lb-in. min
No. 12 Spinlock screws ............. 80 lb-in. min
No. 4-40 ordinary screws ........... 4 3/4 lb-in. min
No. 6-32 ordinary screws ........... 8 3/4 lb-in. min
No. 8-32 ordinary screws .......... 18 lb-in. min
No. 10-24 ordinary screws ........ 23 lb-in. min
No. 10-32 ordinary screws ........ 32 lb-in. min
(4) Quick-disconnect couplings.
Manufacturer ............................. Snap-Tite, Inc.
Type .......................................... Double shut-off
coupling: valved
nipple and valved
coupler
Size ............................................ 1 1/2 inch
Material ...................................... Brass
Seals .......................................... Teflon
Working pressure ....................... 270 psig
Force to connect (at no
pressure ................................ 37 pounds
(5) Ball shutoff valve.
Manufacturer .............................. Worcester Valve Co.,
Inc.
Part Number............................... 1 1/4-436T-SE
Type ........................................... Manually operated, ball
shutoff
Size ............................................ 1 1/4 inch
Figure 11-3. Liquid loading system pump engine - wiring schematic.
11-4
11-2.
section IV covers direct support/general support level
maintenance.
Note:
Operating instructions for the liquid
loading system are included with
operating instructions for the insecticide
sprayer system (ch. 2).
Scope
This chapter provides separate sections covering
maintenance activities or the liquid loading system.
Section I provides introduction, description and data, and
scope; section II covers operator’s maintenance; section
III covers organizational level maintenance; and
Section II. OPERATOR’S MAINTENANCE INSTRUCTIONS
11-3.
is ready for use at all times. Inspect the equipment
thoroughly so that defects may be found and fixed before
they result in serious damage or failure. Perform
necessary preventive maintenance checks and services
listed in step b, following. Item numbers indicate the
sequence of minimum inspection requirements. Record
any defects noted during use of the equipment for repair
to be made as soon as possible. Stop pump right away
if a trouble is noted during pumping which would damage
the equipment if pumping were continued.
b. Operator’s Preventive Maintenance Checks
and Services. Table 11-1 lists the operator’s preventive
maintenance checks and services.
c. Troubleshooting Chart. Table 11-2 contains a
list of the operator’s troubleshooting tasks for the liquid
loading system. The chart serves only as a guide and
does not mean that other troubles may not exist.
Troubles beyond the scope of the operator/crew are
contained in tables 11-4 and 11-7.
General
a. Basic Issue Items. Tools, equipment, and
repair parts issued with or authorized for the liquid
loading system are listed in the basic issue items list,
appendix C.
b. Repair Parts and Special Tools List. Refer to
Repair Parts and Special Tools List Manual, TM 5-3740211-24P, for a complete listing and illustrations of repair
parts and special tools used in conjunction with the
aircraft-mounted insecticide sprayer.
c. Lubrication Instructions.
(1) General. Keep all lubricants and fuel in
closed containers and store in a clean, dry place away
from external heat. Allow no dust, dirt, or other foreign
material to mix with the lubricants. Keep all lubrication
equipment clean and ready to use.
(2) Cleaning. Keep all external parts not
requiring lubrication clean of lubricants and dirt.
(3) Liquid loading system engine. Lubrication
of the liquid loading system engine is accomplished
through the addition of oil into the gasoline supply (para
2-1, step b(2).
(4) Liquid loading system pump. Lubrication
of the liquid loading system pump is accomplished by the
fluid being pumped (para 21, step b (5).
11-4.
a.
Preventive
Services
Maintenance
Checks
11-5.
Maintenance of Liquid Loading System
a. General. Instructions in this paragraph are
published to inform and guide the operator in maintaining
the liquid loading system.
b. Air Cleaner Element Service.
(1) Clean the air cleaner element (3, fig. 1119) as often as necessary to maintain engine power.
Under very dusty operating conditions, the air cleaner
element may require weekly or even daily cleanings.
Never operate the engine without the air cleaner
element.
and
General. Insure that the liquid loading system
Table 11-1. Operator’s Preventive Maintenance Checks and Services.
Interval
Item
No.
Daily
B
01
02
03
04
05
06
07
D
A
50
100
X
X
X
X
X
X
X
X
X
X
X
B - Before operation
A - After operation
D - During operation
50 - After 50 hours operation
100 - After 100 hours operation
Item to be inspected
Procedure
Engine
Air cleaner element
Air cleaner element
Fuel lines
Fuel level
Pump assembly strainer
Pump assembly strainer
11-5
Inspect for condition
Remove and clean
Replace
Check for damage
Keep tank full
Clean and decontaminate
Remove and clean
11-5, step b
11-5, step b
11-5, step c
11-5, step d
Table 11-2. Operator’s Troubleshooting Chart - Liquid Loading System.
Malfunction
Probable cause
Corrective action
1. Engine will not start.
a.
b.
c.
d.
e.
Ignition switch not at ON position.
Low fuel level.
Choke or throttle not set properly.
Gas cap vent plugged.
Vacuum in gas tank.
a.
b.
c.
d.
e.
Place ignition switch to ON position.
Fill tank with fresh fuel/oil mixture.
Adjust choke or throttle as required.
Loosen cap or clean vent.
Loosen cap.
2. Engine not running properly.
a.
b.
c.
d.
Low fuel level.
Gas cap vent plugged.
Air filter dirty.
Choked engine.
a.
b.
c.
d.
Fill tank with fresh fuel/oil mixture.
Loosen cap or clean vent.
Clean air filter.
Push choke in.
3. Pump not pumping.
a. Pump not primed.
b. Loose intake line connections.
c. Pump plugged with contaminant.
a. Fill pump with water.
b. Tighten intake line connections.
c. Stop engine; drain pump and fill with clear, clean
d. Inlet strainer clogged.
e. Input valve closed (handle across tube).
f. Supply fluid depleted.
g. Pump defective.
d. Clean strainer.
e. Open inlet valve.
f. Change supply drums.
g. Refer to organizational maintenance level.
water.
e. Throttle Rod Friction. If throttle rod (28, fig. 1119) slips or "walks" during engine operation, tighten as
follows:
(1) Position ignition switch at OFF to stop
engine.
(2) Tighten two screws (34) as required to
increase friction of throttle rod clamp (29).
(3) Resume normal operation.
f.
Pump Priming. Since the fluid being pumped
lubricates the pump and keeps it cool, make sure the
pump contains water or the pumped fluid at all times
while running. Refer to paragraph 2-1, step b (5) for
pump priming procedure.
g. Inlet Strainer, Hoses, and Couplings.
WARNING
Insecticide
spray
fluids
are
poisonous and should be handled
with care. Avoid splashing fluid or
prolonged contact or breathing of
fumes. Wash hands before smoking
or
eating,
after
contact
with
insecticide fluid.
Prior to operating the equipment, inspect the inlet
strainer, hoses, and couplings for condition and
serviceability.
(1) Strainer. Loosen the screw assembly (2,
fig. 11-4) on strainer body (7). Remove cap (4), O-ring
(5), and screen (6). Clean the screen by sloshing in
clean, running water. Inspect the O-ring, and replace if
defective.
(2) Hoses. Inspect the hose assemblies for
breaks, cracks, or loose connections. Replace any hose
assembly found to be defective.
(3) Valved couplers. Inspect valved coup-
(2) Clean the air cleaner element as follows
(fig. 11-19):
(a) Loosen captive nut (1) and remove
air cleaner element cover (2). Do not remove nut from
cover.
CAUTION
Use care not to allow loose dirt or
dust particles to fall into carburetor
chamber.
(b) Before removing air cleaner element
(3), remove all loose dirt or dust particles. Then remove
air cleaner element.
(c) Slosh the element in clean solvent
(not fuel mix), and dry thoroughly before use. If cleaning
with solvent is not possible, clean the element by tapping
against a flat surface or by blowing out dust or dirt with
an air hose.
(d) Replace element after 100 hours of
operation or when it appears clogged and cleaning will
not restore engine power.
(e) Install air cleaner element, and
secure in position with air cleaner element cover and
captive nut.
c. Fuel Line. Inspect the fuel line (5 fig. 11-2)
prior to use, and while engine is running. Observe for
fuel leakage caused by cracked hose or loose
connections. Stop pump right away if a leak occurs.
Secure loose connections prior to restarting.
d. Fuel Mixture and Level. Check fuel level prior
to starting pump engine, and fill upon completion of
operations to prevent moisture condensation in fuel tank.
Fill tank as instructed in paragraph 2-1, step b. Insure
that proper fuel mixture is used to prevent engine
malfunctions.
11-6
lers and nipples (4 and 5, fig. 11-1) for condition and
cleanliness. Internal sealing valves must be closed when
coupling halves are separated. Make sure coupling
halves are fully engaged and locked when connected.
Keep dust caps or dust plugs in place when couplers are
separated. Remove any
1. Cotter pin
2. Screw assembly
foreign particles which may cause leakage past sealing
valves.
h. Ignition Cable. Check ignition cable prior to
starting engine to insure that connections are tight and
that insulation is not cracked or shorted out.
3. Yoke
4. Cap
5. O-ring
6. Screen
7. Body
Figure 11-4. Inlet strainer - exploded view.
Section III. ORGANIZATIONAL MAINTENANCE INSTURCTIONS
special tool required for organizational maintenance
personnel for maintenance of the liquid loading system is
a muffler cleaning tool. This tool can be fabricated as
shown in figure 11-5. The tool is used to clean out
clogged perforations of the muffler as described in
paragraph 11-8c.
11-6.
Repair Parts, Special Tools, and Equipment
a. Tools and Equipment. Tools, equipment, and
spare parts issued with or authorized for the liquid
loading system are listed in the basic issue items list,
appendix C.
b. Special Tools and Equipment. The only
11-7
Figure 11-5. Fabrication of muffler cleaning tool.
c. Maintenance Repair Parts.
Repair parts and
equipment covering organizational maintenance for the
liquid loading system are listed and illustrated in TM 53740-211-24P.
from rear end of spark plug while pulling
starter handle (this may require two
men) If sparks do not jump, the trouble
is in the electrical system. (Report this
condition to direct support maintenance.)
If sparks jump, replace spark plug. If
this does not correct the problem, the
trouble is in the fuel system. Check fuel
lines, fuel tank, and carburetor.
11-7.
Preventive Maintenance Checks and
Services
a. General. Insure that the liquid loading system is
ready for operation at all times. Inspect the equipment
systematically so that defects may be discovered and
corrected before they result in serious damage or failure.
Perform necessary preventive maintenance checks and
services listed in step b, following. Item numbers
indicate the sequence of minimum inspection
requirements.
b. Organizational Preventive Maintenance Checks
Table 11-3 lists the preventive
and Services.
maintenance checks and services applicable to
organizational maintenance.
c. Troubleshooting Chart. Table 11-4 contains a
tabulation of troubleshooting activities pertinent to
organizational maintenance. The chart serves only as a
guide and does not preclude the possibility of other
troubles existing.
Note:
A quick check of pump condition for
troubleshooting
purposes
is
to
disconnect shielded ignition cable from
spark plug and hold end of the cable
approximately ¼/4 inch
11-8.
Maintenance of Liquid Loading System
a. General. Instructions in this paragraph are to
inform and guide organizational maintenance personnel
in maintaining the liquid loading system.
b. Spark Plug Service.
(1) A fouled or dirty spark plug which has
caused trouble will often prove serviceable after it has
been thoroughly cleaned, washed, and properly gapped.
CAUTION
When setting spark plug gap be sure
not to damage electrodes or
insulator.
(2) Service spark plug as follows:
(a) Carefully unscrew spark plug (HItension) lead (43, 11-15) from end of spark plug (41, fig.
11-20) using a 3/4-inch open end wrench.
(b) Using a 13/16-inch deep socket
wrench, remove the spark plug and gasket (41 and 42).
11-8
Table 11-3. Organizational Preventive Maintenance Checks and Services.
Item
No.
01
02
03
04
05
06
07
08
09
10
50
Interval (hours)
100
500
X
X
X
X
X
X
X
X
X
X
Item to be inspected
Procedure
Spark plug
Spark plug
Cylinder fins
Cylinder exhaust port
Exhaust manifold
Muffler
Fuel lines
Magneto breaker points
Cylinder chamber and piston dome
Condenser and breaker points
Clean and regap
Replace
Clean cylinder fins
Clean
Clean
Clean
Repair if damaged
Clean and regap
Remove and clean
Change points and set gap
Table 11-4. Organizational Troubleshooting Chart - Liquid Loading System.
Malfunction
1. Engine fails to start or starts with difficulty.
Probable cause
a. Ignition switch not set correctly.
b. No fuel in tank.
c. Excessive carbon on spark plug.
d. Spark plug gap incorrect.
e. Muffler clogged.
f. Exhaust manifold or cylinder exhaust
port clogged.
g. Air cleaner element clogged.
h. Water or dirt in fuel tank.
i. Engine needs choking.
j. Fuel tank cap valve clogged.
2. Engine overheats or lacks power.
a. Incorrect fuel mixture.
b. Choke open.
c. Carburetor improperly adjusted.
d. Muffler, exhaust manifold, or cylinder
exhaust port clogged.
e. Cylinder fins clogged.
f. Inadequate ventilation.
g. Engine or pump parts binding.
h. Air leak in fuel line.
i. Ruptured fuel pump diaphragm.
j. Spark plug fouled.
3. Engine misfires.
a. Choke open.
b. Carburetor improperly adjusted.
c. Spark plug fouled.
4. Excessive smoke from muffler.
d. Ignition cable, ignition coil, or breaker
points defective.
a. Excessive oil in fuel mixture.
b. Carburetor set too rich.
11-9
Corrective action
a. Set ignition to ON.
b. Fill fuel tank.
c. Clean or replace spark plug (11-8b).
d. Regap spark plug (11-8b).
e. Clean muffler (11-8c).
f. Clean exhaust manifold and cylinder
exhaust port (11-8d).
g. Clean or replace air cleaner element
(11-5b (2)).
h. Drain, clean, and refill fuel tank with
correct fuel mixture.
i. Pull choke button out and restart.
j. Remove cap and restart; if engine runs
better, replace fuel tank cap.
a. Drain, clean, and refill tank with correct fuel mixture.
b. Push in choke button fully to close
choke.
c. Adjust carburetor.
d. Clean muffler (11-8c) exhaust manifold, and cylinder exhaust port (118d).
e. Clean cylinder fins.
f. Provide adequate cooling air flow.
g. Perform overhaul (report this condition
to direct support maintenance).
h. Inspect and replace fuel line if
required.
i. Disassemble carburetor and correct
trouble.
j. Clean and regap or replace spark plug
(11-8b).
a. Push in choke button fully to close
choke.
b. Adust carburetor (11-8f).
c. Clean and regap or replace spark plug
(11-8b).
d. Replace defective parts.
a. Drain fuel tank and fill with correct
fuel mixture.
b. Adjust carburetor (11-8f).
Table 11-4. Organizational Troubleshooting Chart - Liquid Loading System (Continued).
Malfunction
5. No fluid being pumped.
6. Restricted fluid flow.
Probable cause
Corrective action
a. Ball valve closed.
b. Pump not primed.
c. Inlet strainer clogged.
a. Open ball valve.
b. Prime pump.
c. Remove and clean or replace strainer
screen (11-5b).
d. Fluid source empty or inlet pipe clogged. d. Check fluid source for cause.
e. Leaks in suction hose or couplings.
e. Inspect and repair or replace hose or
couplings.
f. Pump faulty.
f. Repair pump (report to direct support
maintenance).
a. Inlet strainer clogged.
a. Remove and clean or replace strainer
screen (11-5b).
b. Fluid source low or inlet pipe clogged.
b. Check fluid source for cause.
c. Leaks in suction hose or couplings.
c. Inspect and repair or replace hose or
couplings.
d. Pump faulty or engine not up to speed
d. Repair pump (report to direct support
or power.
maintenance).
(c) Inspect the spark plug and clean or
replace as necessary. Replace spark plug and gasket
after 100 hours of operation or if cleaning and regapping
the plug does not return it to serviceable condition.
(d) Clean the spark plug by wire-brushing and
by digging out carbon around the insulator with a sharp
instrument.
(e) Using a 0.035-inch feeler gage, set the
spark plug gap.
(f) Place gasket (42, fig. 11-20) over spark
plug threads, and install spark plug. Tighten spark plug
to a torque of 250 to 300 lb-in. using a 13/16-inch deep
socket and torque wrench.
(g) Replace spark plug lead (43, fig. 11-15)
using a 3/4-inch open end wrench over end terminal of
spark plug. Make sure plug lead is fully installed and that
no dirt is trapped in spark
plug when installing. Check to see that terminal end of
ignition wire (43) is fully inserted in spark plug boot.
c. Muffler Service.
(1) Loosen screw of muffler strap (21, fig. 1122). Remove muffler strap from muffler (20) and muffler
bracket (22).
(2) Loosen locknut on inlet of muffler (20) and
unscrew muffler from exhaust manifold (40, fig. 11-20).
(3) Using a scriber or the fabricated muffler
cleaning tool (fig. 11-5), clean out all of the perforations
of the muffler by inserting the tool into each end and
picking out carbon deposits (fig. 11-6).
Note:
It is necessary to clean from both ends
because of the solid baffle in the center
of the muffler.
11-10
Figure 11-6. Muffler cleaning.
(4) Before installing the muffler, clean the
exhaust manifold and cylinder exhaust port (ref step d,
following).
(5) Replace muffler by screwing muffler (20,
fig. 11-22) into exhaust manifold (40, fig. 11-20) and
securing locknut on muffler inlet threads. Place muffler
strap (21, fig. 11-22) over muffler and over muffler
bracket (22). Secure strap adjusting screw to retain
muffler snugly in place.
d. Cylinder Exhaust Port and Exhaust Manifold
Service.
(1) Remove muffler as instructed in c, steps 1
and 2, preceding.
(2) Remove the two screws (37, fig. 11-20),
and remove exhaust manifold (40) from cylinder (43).
(3) Put piston and pin (34) to top dead center
position to cover the cylinder ports so that dirt or dust
cannot fall inside.
(4) Using a wooden or plastic scraper, carefully remove the carbon deposits from the cylinder
exhaust port. Be careful not to scratch the piston or
damage the chamfered edges of the cylinder exhaust
port. Clean the cylinder fins and blow out all loose
particles from the exhaust manifold and cylinder exhaust
port before reinstalling the exhaust manifold and muffler.
(5) Attach exhaust manifold (40) to the
cylinder (43) using screws (37). Install muffler
11-11
(20, fig. 11-22)
to exhaust manifold as instructed in
step c (5), preceding.
e. Fuel Line Replacement. If replacement of the
flexible fuel line (19, fig. 11-20) is required, heat ends of
the new fuel line in a pot of boiling water until they are
soft. While soft, stretch ends over the fitting as required.
This softening is required only on new fuel lines. Once
they are stretched, they will retain their shape.
f. Carburetor Adjustment (fig. 11-7).
(3) Push the throttle button (4) all the way in.
Start engine and pump water at open discharge. When
engine is fully warmed up, adjust the main mixture
adjustment needle for the highest pumping speed
obtainable. Then, open the needle 1/8 turn more.
CAUTION
The screws holding the governed
speed adjust clamp (2) should never
be loosened, except by direct support
or general support personnel with
proper test equipment available.
(4) Pull the throttle button (4) all the way out,
and adjust the idle mixture adjustment needle (7) for the
smoothest and highest speed obtain-able. If this speed
is either too high or too low, adjust speed by means of
the idle speed adjustment screw (1).
Note:
Before changing the carburetor mixture
adjustments, be sure the tank is full of
clean, fresh, properly mixed fuel. Then
clean the air filter, and leave the filter
and cover off until the carburetor has
been adjusted.
Note:
Because main and idle mixture
adjustment needles are interdependent,
some readjustment under full load
conditions may be necessary.
(5) Recheck adjustments under full load
conditions as in steps (2), (3), and (4), preceding. Be
sure settings are correct before reinstalling the air filter
and cover.
(6) Reinstall air cleaner filter element and
cover as instructed in paragraph 11-5, step b (2) (e).
g. Removal and Replacement of Hoses, Couplings,
Strainer, and Ball Valve (fig. 11-1).
(1) All threaded connections of the pump (1),
hoses (8), couplers (4), strainer assembly (11), ball valve
(2), and valved nipples (5), use pipe threads. Removal
and replacement procedures are therefore identical for
each. To remove, use a pipe wrench, strap wrench, or
vise to hold one part, while unscrewing the mating part
with a second wrench.
(2) Disconnect mated valved couplers by
pulling back the retaining ring of the female half of the
coupler, and pull the coupling halves apart.
(3) Clean threads of all components before
reattaching. Remove all dirt, spray fluid residue, tape, or
lubricants.
(4) Apply a new layer of Teflon tape per
Military Specification MILT-27730, to pipe threads before
reattaching.
(5) Connect mating parts and screw down
fairly snug. Since pipe threads are tapered, it is not
necessary to overtighten them. However, do not back
threads off from their tightest position, as a leak may
occur.
1. Idle speed adjustment
5. Throttle rod adjustment
screw
screws
2. Governed speed adjust- 6. Main mixture adjustment
ment clamp and screws
needle (HI)
3. Choke button
7. Idle mixture adjustment
4. Throttle button
needle (LO)
Figure 11-7. Carburetor adjustment controls.
(1) Remove and clean the air cleaner element
as instructed in paragraph 11-5, step b (2).
CAUTION
Use care when adjusting needles not
to jam needles in their orifices.
(2) Very gently turn the idle mixture
adjustment needle (7), and the main mixture adjustment
needle (6) until they just close against their seats. Then
open both needles one turn from the gently closed
position.
11-12
Section IV. DIRECT SUPPORT AND GENERAL SUPPORT
MAINTENANCE INSTRUCTIONS
plies normally available to using organizations.
b. Repair and Replacement Standards. Table 11-5
lists
manufacturer’s
sizes,
tolerances,
desired
clearances, and maximum allowable wear and
clearances pertaining to the liquid loading system pump
engine.
11-9.
General
a. Scope. These instructions are published for the
use of direct support and general support maintenance
personnel maintaining the liquid loading system. They
provide information on the maintenance of the equipment
which is beyond the scope of tools, equipment,
personnel, or sup-
Table 11-5. Repair and Replacement Standards
Manufacturer’s
dimensions and
tolerances in
inches
Component
Crankshaft:
Needle bearing journals
Connecting rod roller journal
Connecting rod needle bearing journal
Minimum
0.6245
0.5565
0.5615
Desired
clearance
Maximum
Minimum
Maximum
0.6250
0.5570
0.5625
0.0005
0.0010
---------------
Maximum allowable
wear and clearance
0.0005
0.0005
0.0010
for direct and general support maintenance personnel
performing major overhaul work on the liquid loading
system pump. Tools listed in table 11-6 are not available
for issue, .but can be fabricated by qualified maintenance
personnel for expedient repair by utilization.
11-10.
Special Tools and Equipment
a. Special Tools and Equipment. No special tools
and equipment are required.
b. Specially Designed Tools and Equipment. The
specially designed tools listed in table 11-6 and
illustrated in figures 11-8 through 11-14 are
11-13
Figure 11-8. Fabrication of rotor locking tool.
11-14
Figure 11-9. Fabrication of offset wrench.
11-15
Figure 11-10. Fabrication of needle bearing assembly tool.
11-16
Figure 11-11. Fabrication of bearing and seal tool.
Table 11-6. Fabricated Special Tools
Reference
Figure
Number
Paragraph
Rotor locking tool
11-8
11-12c, 11-12d
Offset wrench
Needle bearing assembly tool
11-9
11-10
11-13d
11-13d
Bearing and seal tool
11-11
11-13d, 11-13f
Seal assembling plug
11-12
11-13d, 11-13f
Seal assembling sleeve
11-13
11-12c, 11-13d
Piston pin removal tool
11-14
11-13d
Item
11-17
Use
Hold magneto rotor when removing or installing rotor shaft nut or pump impeller.
Remove and install cylinder nuts.
Remove and install needle bearing in connecting rod (piston end)
Remove needle bearing and seal from
crank-case; remove and install needle
and seal in pump bearing housing, and
install needle bearing in crankcase and
pump bearing housing.
Install seals in crankcase, and pump bearing
housing.
Protect seal when installing crankshaft into
crankcase.
Remove piston pin from piston.
Figure 11-12. Fabrication of seal assembling plug.
Figure 11-13. Fabrication of seal assembling sleeve.
11-18
Figure 11-14. Fabrication of piston pin removal tool.
11-11.
Troubleshooting
Table 11-7 contains a tabulation of troubleshooting
activities pertinent to direct support and general support
maintenance. The chart serves only as a guide, and
does not preclude the possibility of other troubles
existing.
11-12.
Removal
and
Installation
of
Major
Components
a. General. The major components which make up
the liquid loading system pump, and which can be easily
removed as major components, are the starter fan
housing, pump, ignition parts, and carburetor.
Note:
The crankshaft, connecting rod, and
piston removal and installation are
covered in paragraph 11-13d.
11-19
Table 11-7. Direct Support and General Support Troubleshooting Chart Liquid Loading System
Malfunction
1. Engine fails to start or starts with difficulty.
Probable cause
a. Breaker points defective or improperly
gapped.
b. Condenser defective.
c. Carburetor dirty or defective.
d. Starter binding or defective
e. Spark plug overheated (indicated by
burned electrode; insulator tip light
gray or chalk white).
f. Spark plug: wet, fouled indication; insulator tip black, damp oily film over
firing end; carbon layer over entire
nose.
g. Spark plug: oxide fouled indication
(electrode covered with ash-like deposits).
2. Engine lacks power.
a.
b.
c.
d.
Piston rings worn.
Cylinder worn or scored.
Damaged bearings.
Carburetor dirty.
e. Parts binding.
3. Engine speed erratic or pump output
erratic.
4. Ball valve leaking or will not shut off.
5. Couplers leaking or will not engage or
disengage.
f. Damaged or leaking crankcase.
a. Parts binding or worn in pump.
b. Intermittent magneto coil failure.
Worn or damaged parts.
Worn or damaged parts.
b. Starter Fan Housing.
(1) Removal (fig. 11-15).
(a) Using a thin-walled 5/16-inch socket wrench or a
large screwdriver, remove four housing screws (1 and 2).
(b) Lift the starter fan housing and attached parts (3
through 14) out far enough to clear the end tabs of the
left and right legs (2 and 5, fig. 11-22). Continue to lift
the starter fan housing out far enough to permit
disconnecting the ignition switch electrical lead (11, fig.
11-15) at the ignition coil (50). Pull the lead straight off
the terminal.
(c) Remove starter fan housing assembly from
pump engine.
(2) Installation.
(a) Position the starter fan housing assembly (3)
with attached parts close enough to the engine so that
the ignition switch lead may be
Corrective action
a. Regap or replace breaker points (1113b).
b. Replace condenser (11-13b).
c. Clean or replace defective carburetor
parts (11-12c).
d. Check and correct trouble (11-13a).
e. Check for:
1. Clogged muffler (11-&), or
exhaust port or exhaust
manifold (11-8d).
2. Air leak in fuel line (11-5c).
3. Ruptured fuel pump diaphragm
in carburetor (11-13e).
f. Check for incorrect carburetor adjustment (11-8f); air cleaner element
clogged (11-5b); wrong fuel mix
11-5d); faulty ignition parts (11-12d
and 11-13b).
g. Check for excessive combustion
chamber deposits (11-13d);
Clogged muffler (11-8c); clogged
cylinder exhaust port
or manifold (11-8d); use of nonrecommended oil, or to much oil in
fuel mix (11-5d).
a. Replace piston rings (11-13d).
b. Replace cylinder (11-13d).
c. Replace bearings (11-13d).
d. Clean or replace defective carburetor
parts (11-13e).
e. Check and replace damaged parts (1113d).
f. Check and correct trouble (11-13d).
a. Check and replace damaged parts (1112c and 11-13f).
b. Replace magneto coil (11-12d).
Check and replace damaged parts
(11-13g).
Check and replace damaged parts (1118g).
connected to the ignition coil (50). Slide the quickdisconnect terminal (10) straight onto the coil (50) tab.
(b) Hold the starter fan housing assembly in place
with one hand. Pull the starter handle
(5) out a short distance with the other hand
until the starter fingers engage properly and the fan
housing seats against the engine.
CAUTION
Starter fan housing must seat all
around to avoid breaking of housing
or starter fingers when screws are
installed and tightened.
(c) Install and tighten the four screws (1 and 2).
Note that lower two screws also secure tabs of right and
left legs (5 and 2, fig. 11-22) to fan housing. Note also
that the one shorter screw (5/8-in. long) is to be
installed in the upper centrally located screw hole.
11-20
1. Screw, hex hd,
12-24 x 5/8
2. Screw, hex hd, 12-24 x
1-11/16 in. (3 reqd)
3. Starter fan housing
assembly
4. Rope retaining insert
5. Starter handle
6. Rope bushing
7. Starter post bushing
8. Starter rope
9. Quick-disconnect
terminal
10. Quick-disconnect
terminal
11. Electrical lead
12. Nut, hex, 15/32-32
13. Plate
14. Toggle switch
15. Inner spring shield
16. Recoil spring
17. Outer spring shield
18. Spring lock bushing
19. Spring lock
20. Starter pulley and cup
assembly
21. Screw. hex hd,
10-32 x M in.
22. Washer, flat. No. 10
23. Nut, hex, 5/16-24
24. Washer, lock, 5/16 in.
25. Washer, flat, 5/16 in.
26. Shouldered stud
(2 reqd)
27. Starter finger (2 reqd)
28. Washer, flat (2 reqd)
29. Torsion spring (2 reqd)
30. Magneto rotor
31. Breaker box cover
32. Breaker box cover gasket
33. Breaker box cover spring
34. Assembled washer and
screw
35. Nut, hex, No. 6-312
36. Washer, lock, No. 6
37. Terminal block
38. Terminal stud
39. Hairpin clip
40. Washer (1 or 2 as reqd)
41. Breaker arm group
42. Fixed contact
43. Shielded ignition cable
(HI-tension lead)
44. Captive screw
45. Condenser clamp
46. Condenser
47. Felt cam wiper
48. Coil ground screw
49. Coil wedge
50. Ignition coil
51. Screw, hex hd, 12-24 x 5/8
in. (3 reqd)
52. Stator plate
53. Felt seal
54. Gasket
11-21
Figure 11-15. Starter fan housing and ignition parts - exploded view.
11-22
c. Pump.
(1) Removal.
(a) Remove starter fan housing assembly (3,
fig. 11-15) as described in step b(l), preceding.
(b) Remove four screws (34 and 35, fig. 1122) and lock washers (36) holding pump to the vibration
mounts (32) on the pump base (31).
(c) Disconnect muffler bracket (22) from
pump housing (29) by removing two screws (24) and
lock washers (23).
(d) Remove four screws (26) securing pump
housing (29) to impeller housing (12). Tap pump
housing carefully with a soft mallet to break it loose from
the impeller housing. Remove pump housing, two large
gaskets (18), one small gasket (25), and the wear plate
(19) from impeller housing.
(e) Connect the fabricated rotor locking tool
(fig. 11-8) to the magneto rotor as shown in figure 11-16.
Use two nuts on shouldered studs
(26, fig. 11-15) to secure tool to rotor.
(f) Use the rotor locking tool to prevent the
crankshaft from turning. If the impeller (17, fig. 11-22) is
stuck and cannot be turned loose, tap it with a light
weight plastic or leather mallet to break it loose, then
spin impeller off the shaft.
(g) Remove impeller, seal assembly (16), and
shims (15) from end of crankshaft.
Note:
Determine the number and thickness of
shims (15) re-moved as an aid to
reassembly.
(h) Remove four screws (14) and sealing
washers (13) securing impeller housing (12) to bearing
housing (7). Remove impeller housing.
(i) Remove slinger (11) from crankshaft.
(j) Remove five screws
(10)
securing
bearing housing (7) to crankcase (22, fig. 11-20).
Remove bearing housing (7, fig. 11-22), which carries
seal (9) and needle bearing (8). Remove gasket (6).
Refer to paragraph 11-31f for instructions for removal of
bearing and seal from bearing housing.
Figure 11-16. Using rotor locking tool to hold shaft.
11-23
(2) Installation.
(i) Secure muffler bracket (22) to pump
housing (29) with two lockwashers (23) and screws (24).
(j) Secure engine and pump to
vibration mounts (32) on pump base (31). Place a
snubbing washer (33) between each engine and pump
foot and the vibration mounts. Secure with screws (34
and 35).
(k) Remove the fabricated rotor locking
tool from the magneto rotor (30, fig. 11-15).
(l) Replace
starter
fan
housing
assembly (3) as described in step b(2), preceding.
d. Ignition Parts.
(1) Removal.
(a) Remove the starter fan housing
assembly (3, fig. 11-15) as described in step b(1), preceding.
(b) Connect the fabricated rotor locking
tool (fig. 11-8) to the magneto rotor in the manner shown
in figure 11-16.
Use two nuts to secure tool to
shouldered studs in rotor.
(c) With rotor blocked, move starter
fingers (27, fig. 11-15) aside. Use a 1/2-inch socket
wrench through the hole in the rotor locking tool to
loosen the rotor nut (23). Remove rotor nut (23),
lockwasher (24), and flat washer (25). Screw the rotor
nut (23) part way back onto the end of the crankshaft to
protect the thread during removal of the rotor. Remove
and reposition the rotor locking tool so the jackscrew of
the tool is centered over the shaft and lock nut as shown
in figure 11-17. Turn the jackscrew down until rotor pops
free of crankshaft taper. Remove all tools, fastenings,
and rotor.
(d) Disconnect the high-tension lead
(43, fig. 11-15) from the spark plug (41, fig. 11-20).
Remove the spark plug and gasket (42) from cylinder
(43).
(e) Remove three screws (51, fig. 1115) which hold the stator Plate (52) to the crankcase and
cylinder (22 and 43, fig. 11-20).
(f) Remove the complete coil, stator
plate, and attached parts. Remove the felt seal (53, fig.
11-15) and gasket (54) from between the stator plate and
the crankcase. Do not lose the rotor key which should
be in the slot in the crankshaft.
Note:
When reassembling pump, use all new
seals and gaskets.
(a) If engine parts are to be
disassembled, do not reassemble pump to engine until
engine is completely reassembled.
(b) If needle bearing (8, fig. 11-22) and
seal (9) were removed from bearing housing (7), insert
new bearing and seal as instructed in paragraph 11-13,
step f(3).
(c) Make sure needle thrust bearing
(27, fig. 11-20) and thrust bearing race (26) are in place
on crankshaft (29). Place fabricated seal assembling
sleeve (fig. 11-13) over end of crank-shaft. Lubricate
seal assembling sleeve, seal (9, fig. 11-22) and needle
bearing (8)., Place crank-case gasket (6) in place, and
assemble bearing housing to crankshaft and crankcase
(22, fig. 11-20).
CAUTION
Be sure screws used to secure
bearing housing to crankcase are
9/16-inch long (not 1/2 or 5/8-inch
long). Screw length is critical.
(d) Using new screws (10, fig. 11-22),
clean screw threads and apply Locktite to threads before
installing screws. Tighten the screws alternately, and
remove seal assembling sleeve from crankshaft.
(e) Attach impeller housing (12) to
bearing housing (7) using four new sealing washers (13)
and screws (14).
(f) Install shims (15) as necessary to
provide minimum clearance between impeller (17) and
wear plate (19) without causing impeller (17) to rub
against wear plate.
(g) Install new seal assembly (16), and
then install impeller (17). While installing impeller, hold
magneto rotor of engine (30, fig. 11-15) with rotor
locking tool (fig. 11-8) as shown in figure 11-16.
(h) Carefully place one new gasket (18,
fig. 11-22) into sealing groove of impeller housing (12).
Carefully place new gaskets (18 and 25) into sealing
grooves in pump housing (29). Secure impeller housing,
wear plate (19), and pump housing together with four
screws (26).
11-24
Figure 11-17. Removal of magnets rotor.
(2) Installation.
(a) Position gasket (54, fig. 11-15)
against crankcase (22, fig. 11-20), and felt seal (53, fig.
11-15) on crankshaft.
(b) Secure stator plate (52) to cylinder
(43, fig. 11-20) and crankcase with three screws (51, fig.
11-15). Before tightening fully, rotate the stator plate
clockwise as far as possible to eliminate any play.
(c) Place gasket (42, fig. 11-20) on
spark plug (41). Install spark plug in cylinder (43), and
attach high-tension lead (43, fig. 11-15).
(d) Make sure the Woodruff key is
installed in the crankcase keyway. Line up the keyway in
the magneto rotor (30) with the key and start the rotor
onto the shaft. Push the rotor as far as possible by
hand, so as to engage the tap-
ered end of the shaft.
(e) Install the flat washer (25), lock
washer (24), and nut (23) on the crankshaft.
(f) Secure the fabricated rotor locking
tool to the magneto rotor as shown in figure 11-16.
Tighten the nut (23, fig. 11-15), to secure magneto rotor
(30), with a 1/2-inch socket wrench.
(g) Remove rotor locking tool.
(h) Install starter fan housing assembly
(3) as described in step b (2), preceding.
e. Carburetor Chamber Group.
(1) Removal.
(a) Turn captive nut (1, fig. 11-19)
counterclockwise and remove the air cleaner element
cover (2), air cleaner element (3), and the mounting stud
gasket (6).
(b) Remove one cotter pin (13) and un11-25
hook the choke rod (14) from the carburetor choke shaft
and lever (24, fig. 11-21). Pull choke rod out of
carburetor chamber (38, fig. 11-19) far enough to clear
carburetor, but do not remove completely.
(c) Remove cotter pin (13) from
governor link (20) and disengage governor link from
carburetor throttle shaft and lever (33, fig. 1-21).
(d) Disconnect governor spring (15, fig.
11-19) from throttle shaft and lever (33, fig. 11-21). Do
not remove throttle rod clamp (29, fig. 11-19) from
carburetor chamber (38).
(e) Remove two screws (7) and
lockwashers (8) which hold the cover mounting bracket
(9) and carburetor assembly (32) to the carburetor
chamber (38). Remove cover mounting bracket.
(f) Angle or tilt the carburetor from side
to side as necessary to remove it. Disconnect the fuel
line from the fuel pump inlet fitting on the carburetor by
working it off. With a twisting motion, lift the carburetor
up on the fuel intake side and lift it out. Remove the
carburetor spacer (31) and two gaskets (30).
(g) Remove the fuel line and rubber
grommet (33) from carburetor chamber.
(h) Remove five screws (37), four inside
carburetor chamber and one outside at the bottom of the
chamber. While lifting the carburetor chamber off the
engine, free the high-tension lead (43, fig. 11-15) from
the clip in the underside of the carburetor chamber.
(2) Installation.
(a) Position the carburetor chamber (38,
fig. 11-19) on the engine. Push high-tension lead (43,
fig. 11-15) into retaining clip located on the underside of
the carburetor chamber.
(b) Install rubber grommet (33, fig. 1119) into carburetor chamber (38), and start fuel line
through grommet and into carburetor chamber.
(c) Using five screws (37), secure
chamber to engine with four screws, and to fuel tank (at
bottom) with the remaining screw.
(d) Angling the carburetor (32) as
necessary to place it in position with the adjustment
needles fitted through the "LO-HI" grommet (36), push
the fuel line onto the carburetor inlet.
(e) Assemble one carburetor gasket
(30), carburetor spacer (31), another carburetor gasket
(30), the carburetor (32), and the cover mounting bracket
(9) to the carburetor chamber. Use two lockwashers (8),
and two screws (7) to fasten components. Do not tighten
securely at this time.
(f) Install end of governor link (20) into
throttle shaft and lever (33, fig. 11-21). Place through
hole nearest unflanged end of throttle lever. Secure with
cotter pin (13, fig. 11-19).
(g) Hook end of choke rod (14) to the
end hole on the carburetor choke shaft and lever (24, fig.
11-21). Secure with cotter pin (13, fig. 11-19).
Note:
Be sure that choke has been assembled in
such a manner that nothing interferes with
its operation.
(h) Check alignment of the carburetor,
gaskets, and spacer. Tighten the screws (7) to se-cure
carburetor to carburetor chamber.
(i) Install mounting stud gasket (6) over
cover mounting bracket (9). Install air cleaner element
(3 )and air cleaner element cover (2). Secure with
captive nut (1).
11-13.
Speciaic Repair Instructions
a. Repair of Starter Fan Housing.
(1) Disassembly.
(a) Refer to 11-12, step b (1) for
instructions on removing starter fan housing assembly
(3, fig. 11-15) from engine.
(b) Place starter fan housing on a
bench. Pull the starter rope (8) out to the end. Hold the
starter pulley and cup assembly (20) so it cannot rewind,
then pry the rope knot from the pulley. Let the pulley
rewind slowly to relieve excess tension.
WARNING
The recoil spring (16) is still coiled
under tension inside starter fan
housing. Use care to protect the
hands and face at this point of
disassembly because the spring can
inflect injury if it flies loose.
(c) Hold the starter pulley and use a
5/32-inch Allen wrench to remove screw (21), and
retaining washer (22).
(d) Peer through the knot hole in the
pulley while rotating pulley clockwise until you see that
the inner loop of the recoil spring (16) is disengaged from
the notch in the pulley hub. Care-fully lift the pulley
straight off without disturbing the spring. Remove spring
lock bushing (18), spring lock (19), and starter post
bushing (7).
(e) To remove the recoil spring, hold the
fan housing, open and down, over a flat work surface.
Slap the starter fan housing squarely and sharply down
on the work surface to dislodge the recoil spring without
its uncoiling.
(f) If starter rope (8) is to be replaced,
pry rope retaining insert (4) out of starter handle (5). Cut
rope near the insert, and remove the remaining knot end
from the insert.
Note:
Do not remove starter rope (8) or rope
bushing (6) from starter fan housing (3)
unless necessary for replacement.
11-26
(g) Remove ground electrical lead (11)
with terminals from tab on toggle switch (14). Unscrew
nut (12) and remove toggle switch (14) and ON-OFF
plate (13).
(2) Cleaning, inspection, and repair.
CAUTION
Use solvent in a well-ventilated area.
Avoid breathing of fumes and
excessive contact with skin. Keep
solvent away from open flame. Wash
hands before smoking or eating.
(a) Clean all nonelectrical parts with
cleaning solvent, Federal Specification P-D-680, or
equivalent. Dry parts thoroughly. Apply a film of light oil
to all exposed ferrous metal parts as a corrosion
preventive.
(b) Inspect all threaded parts for
crossed or otherwise damaged threads.
(c) Inspect bearing surfaces and
bushings for condition.
(d) Inspect starter rope for worn or
frayed condition. Replace if condition is doubtful.
(3) Assembly (fig. 11-15).
(a) If rope bushing (6) was removed
from starter fan housing (3), insert new bushing.
(b) Lay starter fan housing down so the
spring retainer pin is at the 10 o’clock position. Position
recoil spring (16) so the outer loop is over the pin and
pointing to your left. Push recoil spring down into fan
housing.
(c) Place starter post bushing (7) and
spring lock bushing (18) over starter post in fan housing.
(d) Place spring lock (19) over end of
starter cup shaft on pulley (20), with tang of spring lock
facing in counterclockwise direction when looking at
pulley from side with rope knot hole (fig. 11-15).
(e) Slide pulley assembly onto starter
post bushing (7). Turn pulley clockwise until it en-gages
the recoil spring. Secure pulley on the starter post in the
starter fan housing with washer (22) and cap screw (21)
using a 5/32-inch Allen wrench.
(f) If a new starter rope is used, thread
rope through the hole in starter fan housing. Insert one
end of starter rope through starter handle (5), and rope
retaining insert (4). Tie a knot in the end of the rope, and
harden the knot with liquid cement or by heating. Pull
knot tight against inner edge of rope retaining insert, and
fit insert into starter handle. Tie and harden a knot in the
other end of the rope.
(g) Preload the starter with eight
clockwise turns of the pulley. While holding pulley under
eight turns tension, slide rope into the pulley
key slot so the knot engages in the key hole. Then let
pulley rewind. It will have two turns pretension left when
starter handle is drawn up to fan housing.
(h) If ON-OFF plate (13) was removed,
install it at ignition switch opening in starter fan housing
(3). Install ignition toggle switch (14) and secure with
attaching nut (12). Secure one terminal (9) of electrical
lead (11) to switch tab.
CAUTION
Starter fan housing must seat all
around to avoid breaking housing or
starter fingers when screws are
installed and tightened. Use only the
proper length screws.
(i) Refer to paragraph 11-12, step b(2)
for instructions for installing starter fan housing
assembly.
b. Repair of Ignition Parts.
(1) Disassembly (fig. 11-15.)
(a) Remove ignition parts from engine
as instructed in paragraph 11-12, step d(l).
(b) If necessary for parts replacement,
unscrew two shouldered studs (26), and remove starter
fingers (27), flat washers (28), and torsion springs (29)
from magneto roto (30).
Note:
Carefully note position of starter fingers
and springs as an aid to reassembly.
(c) Remove breaker box cover (31),
cover gasket (32), and cover spring (33).
(d) Remove nut (35), and washer (36)
from end of terminal stud (38). Remove black (primary)
lead of ignition coil (50) and con-denser (46) lead from
terminal stud.
(e) Remove assembled washer and
screw (34). Pull entire point set (37 through 42) from
breaker box on stator plate (52).
(f) Remove terminal stud (38) and
terminal block (37) from spring of breaker arm group
(41).
(g) Remove hairpin clip (39) and point
washer (40), and separate fixed contact (42) from
breaker arm group (41).
(h) Remove
captive
screw
(44),
condenser clamp (45), and condenser (46) from stator
plate (52).
(i) Remove coil ground screw (48) and
ground (white) lead of ignition coil (50) from stator plate
(52). Slide ignition coil (50) and coil wedge (49) from
armature of stator plate (52).
(j) If necessary for replacement,
unscrew high-tension lead (43) from ignition coil.
(k) Remove felt seal (53) from side wall
of breaker box portion of stator plate (52).
(2) Cleaning, inspection, and repair.
11-27
(f) Place entire point set (37 through
42) into breaker box of stator plate (52). Start the
terminal block (37) into position in the slot of the stator
plate breaker box and at the same time en-gage the
breaker arm pivot pin in the hole in the floor of the box.
Secure the fixed contact (42) to the breaker box with the
assembled washer and screw (34). Hook the primary
(black) lead of the ignition coil (50) through the lead
guide in the floor of the breaker box. Wrap the
condenser lead twice around the coil primary lead. Insert
terminal stud (38) through spring of breaker arm group
(41) and through terminal block (37). Put primary lead
on terminal stud, and slip the con-denser (46) lead over
the primary coil lead. Push terminal block (37) all the
way down in the slot and secure with the terminal washer
(36) and nut (35).
(g) Set contact point gap at this point.
Note:
The proper contact point setting is 0.015
inch. For emergency repairs, the cover
of a paper match book, which is usually
about 0.015-inch (1/64-inch) thick may
be used as a feeler gage; however, for
setting the gap accurately, without fear
of scratching the points, a plastic feeler
gage should be used.
(h) Rotate the engine crankshaft in a
counterclockwise manner until the breaking edge of the
actuating cam is 1/8 inch beyond the breaker arm cam
follower. This is the highest point of the cam. Loosen
the assembled washer and screw (34), and move the
fixed contact (42) as necessary to set the gap. Check by
moving the feeler gage between the points. When the
gap is 0.015 inch, you should feel a slight, steady,
smooth friction as you move the gage. After tightening
the assembled washer and screw (34), check the gap
again to see that it is still 0.015 inch. Readjust if
necessary.
(i) Place cover gasket (32) and breaker
box cover (31) in place, and secure with cover spring
(33).
(j) Install the torsion springs (29), flat
washers (28), and starter fingers (27) to magneto rotor
(30) with shouldered studs (26). Be sure that the torsion
springs are so located between two vanes of the rotor
that the springs will be parallel to the flat edges of the
starter fingers when the fingers are touching the rotor nut
(23) (fig. 11-18). The fingers should have no more
spring tension than is necessary to hold them against the
rotor nut.
(k) Complete assembly of ignition parts
to engine as instructed in paragraph 11-12, step d(2).
CAUTION
Use solvent in a well-ventilated area.
Avoid breathing of fumes and
excessive contact with skin. Keep
solvent away from open flame. Wash
hands before smoking or eating.
(a) Clean all nonelectrical parts with
cleaning solvent, Federal Specification P-D-680, or
equivalent. Dry parts thoroughly. Apply a film of light oil
to all exposed ferrous metal parts (except magneto,
points, and electrical contacts) as a corrosion preventive.
(b) Discard breaker point set (39
through 42), condenser (46), and felt seal (53).
(c) Inspect all threaded parts for
crossed or otherwise damaged threads.
(d) Inspect high-tension lead (43) and
ignition coil (50 )for damaged leads, cracked insulation,
or other damage. Replace if damaged.
(e) Inspect magneto rotor (30) for
cracks or other visible damage. Be sure the rotor
keyway and the rotor taper show no wear or damage
which could result in a loose or off-center assembly. The
rotor must be in perfect shape with no cracks or broken
fins.
(f) Inspect starter fingers (27) and
torsion springs (29). Worn or broken starter fingers or
bent springs should be replaced.
(3) Assembly.
(a) Install a new prelubricated felt seal
(53) in the wiper on side wall of breaker box on stator
plate (52).
(b) If high-tension lead (43) was
removed from ignition coil (50), screw end of hightension lead into ignition coil.
(c) Slide coil wedge (49) into center of
ignition coil (50). Slide ignition coil onto armature of
stator plate (52) until tang of coil wedge engages end of
armature. Secure coil wedge and coil ground lead
(white) to armature with screw (48).
(d) Attach new condenser (46) to stator
plate (52) with condenser clamp (45). Secure with
captive screw (44).
(e) Insert post of new fixed contact (42)
through new breaker arm group (41), and secure with
washer (40) and hairpin clip (39).
CAUTION
When installing the breaker arm
group, do not bend the tension
spring more than necessary to fit the
points in place. A change in tension
may cause a bouncing motion, which
in turn causes improper contact.
11-28
(b) If necessary for replacement,
remove instruction plate (5), retaining ring (4), and
captive nut (1) from air cleaner element cover (2).
(c) Remove felt plug (10) from
carburetor chamber subassembly (38).
(d) Remove choke button (11) from end
of choke rod (14). Remove choke rod and rubber
grommet (12) from carburetor chamber.
(e) Remove governor link (20) from air
vane governor (19). Remove two screws (18), and air
vane governor (19) from beneath carburetor chamber.
(f) Remove and discard two screws
(21) securing reed assembly (22 through 24) to
carburetor chamber. Remove reed stop (22), reed
spring (23), and reed (24).
(g) Remove governor spring (15) from
throttle return spring clamp (17). Remove screw (16),
and throttle return spring clamp (17).
(h) Remove two throttle rod friction adjust screws (34) and springs (35) from outside of
carburetor chamber (38). Remove throttle rod clamp
(29) and washers (26).
(i) Remove setscrew (25) from throttle
rod collar (27). Slide throttle rod (28) from throttle rod
collar, and from carburetor chamber. Remove throttle
rod collar from carburetor chamber.
(j) Remove rubber grommet (36) from
carburetor chamber.
Figure 11-18. Starter finger and torsion spring position.
c. Repair of Carburetor Chamber.
Note:
This paragraph contains complete repair
instructions for the carburetor chamber,
but not for the carburetor assembly.
Refer to paragraph 11-13, step e, for
carburetor assembly repair instructions.
(1) Disassembly (fig. 11-19).
(a) Remove carburetor chamber group
from engine as instructed in paragraph 11-12, step e(1).
11-29
1. Captive nut
2. Air cleaner element
cover
3. Air cleaner element
4. Retaining ring
5. Instruction plate
6. Gasket
7. Screw, hex hd. 10-32 x
2 1/4 in. (2 reqd)
8. Washer, lock no. 10 (2
reqd)
9. Cover mounting bracket
10. Felt plug
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
Choke button
Rubber grommet
Cotter pin
Choke rod
Governor spring
Screw, pan hd 8 32 x
1/4 in. (2 reqd)
Throttle return spring
clamp
Screw, pan hd, 4-40 x
3/16 in. (2 reqd)
Air vane governor
Governor link
21. Screw, pan hd, 4-40 x
3/16 in. (2 reqd)
22. Reed stop
23. Reed spring
24. Reed
25. Setscrew, 4-40 x 1/8 in.
26. Washer, flat, no. 8 (2
reqd)
27. Throttle rod collar
28. Throttle rod
29. Throttle rod clamp
30. Carburetor gasket (2
reqd)
Figure 11-19. Carburetor chamber - exploded view.
11-30
31.
32.
33.
34.
35.
36.
37.
38.
Carburetor spacer
Carburetor assembly
Rubber grommet
Screw, pan hd, 8-32
x 3/8 in. (2 reqd)
Spring (2 reqd)
Rubber grommet
Screw, hex hd, 12-24 x
7/8 in. (5 reqd)
Carburetor chamber
subassembly
(2) Inspection and repair (fig. 11-19).
(a) Inspect all parts for visible damage,
and replace those parts which do not meet minimum
inspection requirements.
(b) Inspect reed (24) to be sure it is not
cracked, warped, or ragged.
(c) Inspect the surface of carburetor
chamber (38) on which the reed seats. There must be
no gouges or wear indicated.
(d) Inspect all threaded parts for
crossed or otherwise damaged threads.
(e) Inspect
condition
of
rubber
grommets (12, 33, and 36) and felt plug (10).
(f) Inspect air cleaner element (3) and
gasket bonded to air cleaner element. If either gasket or
element is damaged, discard and install new air cleaner
element.
(g) Inspect condition of fuel line.
Replace if it is damaged or considered doubtful.
(3) Assembly (fig. 11-19).
(a) Insert grommet (36) into carburetor
chamber (38).
(b) Insert throttle rod (28) into
carburetor chamber and through throttle rod collar (27).
Secure with setscrew (25).
(c) Place springs (35) on two screws
(34). Insert screws into holes in side of carburetor
chamber. Place a washer (26) over each screw, and
attach screws to throttle rod clamp (29). Place throttle
rod clamp with holes down, and concave surface
adjacent to throttle rod (28). Tighten screws only as
required to keep throttle rod from slipping during pump
operation.
(d) Place throttle return spring clamp
(17) in position. Use the marks left by previous screw
heads to locate proper position of clamp. Secure with
two screws (16).
(e) Hook short end of governor spring
(15) in hole in tab of throttle return spring clamp (17).
Hook long end of governor spring (15) in second hole
from unflanged end of throttle shaft and lever (33, fig.
11-21).
(f) Install air vance governor (19, fig.
11-19) to bottom of carburetor chamber (38). Se-cure
with screws (18). Slip end of governor link (20 )through
hole in bottom of carburetor chamber. Fasten governor
link (20) to air vance governor (19).
(g) Install reed (24), reed spring (23),
and reed stop (22) to carburetor chamber with two
screws (21). Be sure the reed components are perfectly
centered on the valve face before tightening screws.
(h) Install grommet (12) in carburetor
chamber (38). Slide choke rod (14) into carbure-
tor chamber. Screw choke button (11) on choke rod.
(i) If removed, install instruction plate
(5) in underside of air cleaner element cover (2). Place
captive nut (1) through air cleaner element cover (2) and
secure with retaining ring (4).
(j) Install carburetor assembly (32) in
carburetor chamber as instructed in paragraph 11-12,
step e(2).
d. Repair of Engine (fig. 11-20).
(1) Disassembly.
(a) Remove starter fan housing as
instructed in paragraph 11-12, step b (1).
(b) Remove muffler as instructed in
para-graph 11-8, steps c(1) and c(2).
(c) Remove pump as instructed in
paragraph 11-12, step c(1).
(d) Remove ignition assembly as
instructed in paragraph 11-12, step d(1).
(e) Remove carburetor chamber group
as instructed in paragraph 11-12, step e(1).
(f) Remove two screws (37), and
remove manifold (40).
(g) Using a thin walled, 7/16-inch offset
wrench (fig. 11-9), remove the two innermost cylinder
nuts (39, fig. 11-20) and lock washers (38). Using a
7/16-inch deep socket with a short extension, remove the
remaining two cylinder nuts (39) and lockwashers (38).
(h) Grasp the cylinder (43) firmly and lift
it straight off the piston and pin (34). Pack rags around
the piston to prevent damage.
(i) Remove crankcase gasket (21) from
crankcase (22).
Do not remove studs (25) from
crankcase unless replacement is necessary.
(j) Use a 9/64-inch Allen wrench to
loosen socket head screws (32). Discard the screws.
Remove both halves of connecting rod (30) and all 28
needle rollers (33).
(k) Using fabricated needle bearing
assembly tool (fig. 11-10), press needle bearing (31, fig.
11-20) out of connecting rod (30).
(l) Using a pair of retaining ring pliers,
remove retaining ring (35) from piston and pin (34).
CAUTION
Do not press piston pin removal tool
too far into piston or the spirol pin
will shear off.
(m) Insert fabricated piston pin removal
tool (fig. 11-14) past the spirol pin in piston (34, fig. 1120). Press or tap out piston pin.
(n) Starting from the top of the piston
(34), carefully expand piston rings (36) to clear the
piston, and remove them.
11-31
(o) Slide crankshaft (29) straight out of
crankcase (22). Remove thrust bearing race (26) and
needle thrust bearing (27) from each end of the
crankshaft. Remove rotor key (28).
(p) Using fabricated bearing and seal
tool (fig. 11-11), remove needle bearing (24, fig. 11-20)
and seal (23) from crankcase (22). Insert the longer
shouldered end of the tool from inside the crankcase and
press the parts out.
(q) Remove fuel filter cap (8) and fuel
cap gasket (9) from fuel and oil tank (6).
(r) Remove three screws (7) and
remove fuel oil tank (6) from crankcase (22).
1.
2.
3.
4.
5.
6.
7.
Fuel tank cover
Drain and filler cap
Gasket
Felt Washer
Pipe plug
Fuel and oil tank
Screw, shoulder, 1/4-20 x
3/4 (3 reqd)
8. Fuel filler cap
9. Gasket
10. Decal
11. Nut, lock, 10-32
12. Washer, flat, No. 10
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
(s) Remove flexible fuel line (19) from
fuel line elbow (20), and remove fuel line elbow from fuel
and oil tank.
(t) Remove all 16 cover-to-tank screws
(18). Remove cover (1) from fuel and oil tank (6).
(u) Remove nut (11), flat washer (12),
spring (13), wick washer (14), felt washer (4), gasket
(15) and fuel pickup wick (16) from wick stud (17).
Remove wick stud from fuel tank cover (1).
(v) Do not remove pipe plug (5), or
drain and filler cap (2) and gasket (3) unless necessary
for replacement.
Spring
Wick washer
Gasket
Fuel pickup wick
Wick stud
Screw, rd hd, No. 6 x 1/2
(16 reqd)
24. Bearing
25. Stud (4 reqd)
26. Thrust bearing race
(2 reqd)
27. Needle thrust bearing
2 reqd)
28. Rotor key
33.
34.
35.
36.
37.
Flexible fuel line
Fuel line elbow
Crankcase gasket
Crankcase
Seal
29.
30.
31.
32.
39.
40.
41.
42.
43.
Crankshaft
Connecting rod
Bearing
Screw, socket, 8-36 x 1/2
(2 reqd)
Figure 11-20. Engine - exploded view.
11-32
38.
Rollers - set of 28
Piston and pin
Retaining ring
Piston ring (2 reqd)
Screw, hex hd, 12-24 x
3/4 (2 reqd)
Washer, lock, 1/4 (4
reqd)
Nut, 1/4-28 (4 reqd)
Manifold
Spark plug
Gasket
Cylinder
(2) Inspection and repair (fig. 11-20).
(a) Discard socket head screws (32), 28
needle rollers (33), and retaining ring (35) each time they
are removed.
(b) Discard seal (23) whenever it is removed from crankcase (22). Discard fuel pickup wick
(16) whenever it is removed from fuel and oil tank (6).
(c) Inspect and clean or replace spark
plug (41) as required. Reset gap to 0.035 inch.
(d) Clean and inspect cylinder (43) for
worn chrome plating. Replace if more than three of the
cooling fins are cracked or broken off or if cylinder walls
are badly worn or scored.
(e) Inspect cylinder (43), crankshaft
(29), and crankcase (22) for cracks, porous spots, and
scored sealing surfaces.
(f) Inspect needle bearings (24, and 31)
by trying to separate the needles at one end. If the
needles can be separated more than the width of one
needle, replace the bearing.
CAUTION
Do not clean varnish-like deposits
from piston skirt or side walls of
cylinder (43). Use extreme care so as
not to scratch polished chrome
surfaces.
(g) Scrape heavy deposits from the top
of piston (34) and clean by carefully wire-brushing only
the dome area.
(h) Using the butt end of a discarded
piston ring, carefully clean piston ring grooves in piston
(34). Wash the piston in an approved cleaning solvent.
(i) Inspect piston rings (36) for wear.
Replace if they are scored, have excessively round wear
pattern, or have machining marks worn away.
(3) Assembly.
(a) Assemble fuel and oil tank.
1. Install wick stud (17) into fuel tank
cover (1). Place new fuel pickup wick (16) over stud.
Secure with gasket (15), felt washer (4), wick washer,
(14), spring (13), flat washer (12), and nut (11).
2. Apply cement (Homelite part
number 22788, or equivalent; no known service
specification) to the sealing surfaces of the tank and
cover.
3. Lay out fingers of fuel pickup wick
in the fuel and oil tank while installing the cover. Secure
fuel tank cover (1) to fuel and oil tank (6) using 16
screws (18).
4. Install pipe plug (5) and drain and
filler cap (2) and gasket (3), if they were re-moved.
5. Screw fuel line elbow (20) into fuel
tank cover (1). Slip end of flexible fuel line (19) over fuel
line elbow.
Note:
If a new fuel line is being installed, place
end of fuel line in boiling water until soft.
Then install. Once stretched, the fuel
line may be reinstated without further
heating.
(b) Assemble engine.
1. Using fabricated bearing and seal
tool (fig. 11-11), install needle bearing (24, fig. 11-20) in
crankcase (22). Use the shorter shouldered end of the
tool (from the interior of the crankcase), pressing against
the lettered side of the needle bearing only.
2. Using a new seal (23), greased to
protect it from damage, place the seal on the long end of
fabricated seal assembling plug (fig. 11-12), with the
open end of the seal facing the needle bearing (24, fig.
11-20). Install the seal from the outer surface of
crankcase.
3. Install thrust bearing (27) and
bearing race (26) on each side of the crankshaft (29).
4. Making sure the rotor key (28) is
not in place, install fabricated seal assembling sleeve
(fig. 11-13) with beveled end out onto the key end of
crankshaft.
Lubricate the sleeve and end of the
crankshaft to prevent damage.
5. Carefully insert crankshaft (29, fig.
11-20) into crankcase (22). Remove seal assembling
sleeve and install it on the opposite end of the
crankshaft. Lubricate the sleeve and shaft as in step 4,
preceding. Install rotor key (28) in key-way of crankshaft
(29).
CAUTION
Be sure screws used to secure
bearing housing to crankcase are
9/16-inch long (not 1/2-inch or 5/8inch long). Screw length is critical.
6. Place bearing housing (7, fig. 1122) in position. Secure with five new screws (10),
prepared by cleaning threads and applying a coat of
sealant (Locktite screw-lock), to threads. Tighten screws
alternately.
Remove seal assembling sleeve from
crankshaft after assembly.
7. Using fabricated needle bearing
assembly tool (fig. 11-10), install needle bearing (31, fig.
11-20) into connecting rod (30). Press bearing only on
lettered side.
8. Carefully install piston rings (36) on
piston (34). Open ends of piston rings must be adjacent
to piston ring locating pin.
Note:
Piston ring retaining pin is permanently
installed in piston. It may be seen at top
edge of piston, and extends through
both piston ring grooves.
9. Insert connecting rod (30) into
piston (34).Start blunt end of piston pin through
11-33
piston from same side as piston ring locating pin (ref
step 8, preceding). Insert a rod of approximately 3/16inch diameter into the open end of the piston pin, and
press or tap pin into position flush against the spirol pin
(located in piston pin bore in piston).
10. Using a pair of retaining ring pliers,
install a new retaining ring (35) into groove in piston. Be
sure the square edge of. the ring faces outward. Rotate
the ring to be sure it is installed properly. Align the open
end of the ring parallel with the connecting rod (either up
or down).
CAUTION
When installed in the engine, piston
must be oriented so that open end of
piston rings, and open end of piston
pin are on side toward starter
assembly. Match marks on mating
flanges
of
upper
and
lower
connecting rod halves must be in
alignment.
11. Using bearing grease or beeswax
to lay out the rollers (33) lay out two strips, each of 14
new rollers. Stick on strip into each of the connecting
rod (30) halves. Determine the direction in which the
piston (34) must be placed in the engine (open ends of
piston rings and open end of piston pin toward starter
assembly side of the engine). Align the match marks on
the connecting rod (30) halves.
12. Place the lower half of the
connecting rod into position in the crankcase under the
crankshaft (29) journal. Hold these parts in place with a
strip of metal or wire bent beneath the lower half of the
connecting rod. Lower the upper half of the connecting
rod into position in crank-case (22). Use two new socket
head screws (32) to fasten the halves of the connecting
rod together. Before securing the screws completely, be
sure none of the rollers are out of place. Tighten screws
(32) with a 9/64-inch Allen wrench to 60 inch-pounds
torque. Rotate crankshaft to see that bearing works
smoothly.
13. Place the crankcase gasket (21) on
the crankcase studs. Be sure the holes in the gasket are
aligned with the mounting holes in the fuel intake section
of the casting.
14. If a piston ring compressor is not
available, make one out of a tin can or strip of metal bent
to the outside diameter of the piston (34)
Squirt oil into
the cylinder (43) and oil the piston. Compress the piston
rings with the piston ring compressor, and push the
cylinder straight down onto the piston. When both rings
have started into the cylinder, see that the cylinder
exhaust ports are on the pump side of the crank-
case. Remove piston ring compressor, and secure
cylinder (43) and gasket (21) to crankcase with four
lockwashers (38) and cylinder nuts (39). Tighten nuts
alternately with the fabricated off-set wrench (fig. 11-9).
e. Repair of Carburetor (fig. 11-21).
(1) Disassembly.
(a) Remove carburetor from engine as
instructed in paragraph 11-12, step e(1).
(b) Remove four screws (1) and lockwashers (2) from the pump cover (3). Lift the fuel pump
cover, gasket (4), and pump diaphragm (5) from the
carburetor body (35). Re-move the inlet screen (6) by
picking it out care-fully with a sharp pointed instrument.
(c) Remove four screws (7) and lockwashers (8) from the diaphragm cover (9), and lift off the
diaphragm cover, the diaphragm (10), and the
diaphragm gasket (11).
(d) Remove the fulcrum pin retaining
screw (12), the fulcrum pin (13), inlet valve control lever
(14), control lever comparison spring (15), and the inlet
needle (16).
Note:
During servicing be very careful not to
stretch the control lever compression
spring. It is made to a predetermined
length by the manufacturer.
(e) If necessary, remove expansion
plug (17) (ref step (2) (c), following). Remove plug (18)
with screen (19) and retaining ring (20) from body (35).
(f) Remove screw (28) and lockwasher
(29) from throttle shaft and lever (33). Remove throttle
shutter (31) from throttle shaft and lever (33).
(g) Remove screw (28) and lockwasher
(29) from throttle shaft clip (30). Remove throttle shaft
clip and spring pin (32) from throttle shaft and lever (33),
and pull throttle shaft from the body (35).
(h) Close the choke and tap the large
center section of the choke shutter (25) just above the
top of the shaft to bend it back in line with the remainder
of the shutter. Open the choke, and pull the shutter out
of the slot in the choke shaft and lever (24) with pliers.
While pulling the choke shaft out, hold a hand over the
rear of the body (35) to catch the choke friction ball
bearing (26) and spring (27). These parts are installed
inside of barrel opposite choke lever and are ejected
when the shaft is removed.
(i) Remove the main and idle
adjustment screws (21 and 22), springs (23), and
connector elbow (34) from body (35).
11-34
1. Screw, fil hd, 6-32 x %
in. (4 reqd)
2. Washer, lock, No. 6
(4 reqd)
3. Pump cover
4. Fuel pump gasket
5. Fuel pump diaphragm
6. Screen
7. Screw, round hd, 4-40
x 1/4 in. (4 reqd)
8. Washer, lock, No. 4
(4 reqd)
9. Diaphragm cover
10. Diaphragm
11. Diaphragm gasket
12. Screw, thread cutting,
4-40 x 5/16 in.
13. Fulcrum pin
14. Inlet valve control lever
15. Compression spring
16. Inlet needle
17. Expansion plug
18. Plug
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
11-36
Screen
Retaining ring
Main adjustment screw
Idle adjustment screw
Compression spring
(2 reqd)
Choke shaft and lever
Choke shutter
Ball bearing
Compression spring
Screw, round hd, 4-40
x 3/16 in. (2 reqd)
29. Washer, lock, No. 4
(2 reqd)
30. Throttle shaft clip
31. Throttle shutter
32. Spring pin
33. Throttle shaft and lever
34. Connector elbow
35. Body
Figure 11-21. Carburetor assembly - exploded view.
11-37
(2) Cleaning, inspection, and repair.
(a) Soak the carburetor body (35) and all parts
to be retained in the rebuilt assembly, except
diaphragms and gaskets, in carburetor cleaning solvent.
Blow all passages clean with an air hose. Clean the
small hole running from the spring cavity within the
carburetor body to the venturi with a 0.010-inch diameter
wire.
(b) Inspect all parts of the carburetor for
serviceability. Make the following specific checks: 1.
Inspect fuel pump diaphragm (5) and diaphragm (10) for
breaks or punctures. Replace if damaged.
2.
Inspect all threaded parts for crossed or
otherwise damaged threads.
(c) In extreme cases of clogged channels and
discharge ports, it may be necessary to remove
expansion plug (17). If required, drill a 1/16-inch hole
through the plug just deep enough to break through the
plug. Carefully pry out the plug and discard. Clean
channels and discharge ports. Install a new plug by
placing the plug in well, convex side out. Flatten with a
tool slightly larger than the plug.
(3) Assembly.
(a) Place spring (23) over main and idle
adjustment screws (21 and 22). Install adjustment
screws into body (35), in positions shown in figure 11-21.
(b) Insert choke friction spring (27) and ball
bearing (26) in spring cavity inside barrel.
Hold these parts in place while sliding the
choke shaft and lever (24) into the body (35). Slide
choke shutter (25) into slot in choke shaft and lever.
(c) Slide throttle shaft and lever (33) into body
(35). Secure with spring pin (32). Place throttle shaft
clip (30) over end of throttle shaft and lever and secure
with lockwasher (29) and screw (28).
(d) Slide throttle shutter (31) into slot in throttle
shaft and lever (33) and secure with lockwasher (29) and
screw (28).
(e) Turn body over, and install inlet needle (16)
and control lever compressor spring (15) into their
respective positions in body (35).
Place inlet valve control lever (14) into position, and slide
fulcrum pin (13) through holes in inlet valve control lever
and body. Secure components in place with screw (12).
Be sure that spring rests in the well of body and is
located on the dimple of the control lever.
If diaphragm end of lever is low, pry it up. If
lever is high, depress diaphragm end and push
on inlet needle for proper adjustment.
(f) Install diaphragm gasket (11), diaphragm
(10), and diaphragm cover (9) on bottom of body. Be
sure to align parts properly with pins cast in body.
Secure with lockwashers (8) and screws (7). Tighten
screws evenly.
(g) Insert inlet screen (6) into well in top of
body (35).
(h) Install fuel pump diaphragm (5), fuel pump
gasket (4), and pump cover (3) on top of body. Be sure
to align parts properly with pins cast in body. Secure
with lockwashers (2) and screws (1). Tighten screws
evenly.
f. Repair of Pump (fig. 11-22).
(1) Disassembly.
(a) Remove pump from engine as instructed in
paragraph 11-12, step c(1).
(b) Using fabricated bearing and seal tool (fig.
11-11), press both the needle bearing (8, fig. 11-12) and
seal (9) from bearing housing (7). Press from outside of
bearing housing.
(c) Remove drain and filler caps (27) and
gaskets (28) from pump housing (29).
(d) Using a strap wrench to prevent damage to
threads, remove inlet fitting (30) from pump housing (29).
(2) Inspection and repair.
(a) Inspect all parts for damage and
serviceability Replace any parts considered doubtful.
(b) Check all threaded parts for crossed or
otherwise damaged threads.
(c) Check all seals and gaskets for breaks,
cracks, elasticity, and shape. Replace any defective
parts.
(d) Check condition of needle bearing (8).
Try to separate the needles in the bearing. If
needles have flat spots, or can be separated more than
the width of one of the needles in the caged assembly,
replace the bearing.
(e) Replace seal (9) each time it is removed
from bearing housing (7).
(f) Check all castings for evidence of breaks,
cracks, porosity, scored sealing surfaces, and for
stripped, enlarged, or cross-threaded screw holes.
Replace unserviceable castings.
Note:
The valve control lever is properly set when
flush with the floor of the diaphragm chamber.
11-38
1. Screw, hex hd, 12-24 x
1-11/16 (2 reqd)
2. Left leg
3. Screw, hex hd, 12-24 x %
%7
4. Screw, hex hd, 12-24 x
5. Right leg
6. Gasket
7. Bearing housing
8. Needle bearing
9. Seal
10. Screw, hex hd, 12-24 x
9/16 (5 reqd)
11. Slinger
12. Impeller housing
13. Sealing washer (4 reqd)
14. Screw, pan hd, 12-24 x
% (4 reqd)
15. Shim (as reqd)
16. Seal assembly
17. Impeller
18. Gasket, 6-%s in. ID
(2 reqd)
19. Wear plate
20. Muffler
21. Muffler strap with screw
22. Muffler bracket
23. Lock washer (2 reqd)
24. Screw, hex hd, 1-20 x
% (2 reqd)
25. Gasket
26. Screw, hex hd, %-20 x
% (4 reqd)
27. Drain and filler cap
(2 reqd)
28. Gasket (2 reqd)
29. Pump housing
30. Fitting, 1-% in
31. Pump base
32. Vibration mount (4 reqd)
33. Snubbing washer (8 reqd)
34. Screw, Y4-20 x 1-24
2 reqd)
35. Screw, Y4-20 x 1 (2 reqd)
36. Lock washer, 1Y in.
(4 reqd)
37. Nut, %-20 (2 reqd)
38. Screw, flat hd, No. 10
(16 reqd)
39. Lock washer, No. 10
(16 reqd)
40. Nut, hex No. 10 (16 reqd)
Figure 11-22. Pump assembly - exploded view.
(3) Assembly.
(a) Install inlet fitting (30) in pump housing
(29). Use Military Specification MILT27730 teflon tape
on pipe threads.
(b) Install gaskets (28), and drain and filler
caps (27) in pump housing (29).
(c) Using the short shoulder end of fabricated
bearing and seal tool (fig. 11-11), press bearing (8, fig.
11-22) into bearing housing (7).
Press against lettered end of bearing only,
from outside of bearing housing.
(d) Using a new seal (9), greased to protect it
from damage, place the seal on the long .
end of fabricated seal assembling plug (fig. 1112), with
the open end of the seal facing the needle bearing Install
the seal from the interior of the bearing housing.
(e) Complete installation of pump assembly as
instructed in paragraph 11-12, step c(2).
g. Repair of Ball Shutoff Valve.
(1) Disassembly (fig. 11-23).
(a) Remove two nuts (1) and handle (2) from
stem (12).
(b) Remove bell washer (3), follower (4), and
stem seal (5) from stem (12).
(c) Remove four nuts (6) and four bolts
11-39
(7) attaching valve ends (8) from body (14).
(d) Remove two body seals (9) and two seats
(10) from body (14).
.
1.
2.
3.
4.
Nut (2 reqd)
Handle
Bell washer
Follower
5.
6.
7.
8.
Stem seal
Nut (4 reqd)
Bolt (4 reqd)
Valve end (2 reqd)
(e) Remove ball (11) and stem (12) with thrust
bearing (13) from body. Separate stem and thrust
bearing.
9. Body seal (2 reqd)
10. Seat (2 reqd)
11. Ball
12. stem
13. Thrust bearing
14. Body
Figure 11-23. Ball shutoff valve -- exploded view.
(2) Cleaning and inspection.
(a) Each time ball valve is disassembled for
repair, discard stem seal (5), body seals (9), two seats
(10), and thrust bearing (13). Replace with new items.
(b) Clean all portions of the ball valve
thoroughly to remove spray fluid residue, dirt, lubricants,
and contaminants.
(c) Inspect condition of all parts, and replace
any part not considered serviceable. Make the following
specific checks: 1. Check threaded parts for crossed or
otherwise damaged threads.
.
2. Check condition of all parts to ensure proper
function.
(3) Repair and assembly (fig. 11-23).
(a) Repair of the ball valve consists of replacing
any parts not considered serviceable. Assemble the ball
valve using figure 11-23 and the following steps as a
guide:
1. Install thrust bearing (13) on stem
(12). Insert threaded end of stem into body (14) and
through mating hole. Hold stem in position and insert
ball (11) into valve body. Align slot on ball to engage
stem (12).
11-40
2. Place new seats (10 )in valve body so
that concave surfaces are against ball (11).
3. Install new body seals (9) in body and
against seats (10).
4. Hold installed parts in position in body
while placing valve ends (8) on two sides of body.
5. Secure assembled valve parts with
four bolts (7), through valve ends (8) and body (14), and
nuts (6).
6. Place new stem seal (5), follower
.
(4), and bell washer (3) over stem. Seat stem seal by
pressing on parts. Secure parts in place with one nut
(1). Tighten snugly.
7. Place valve handle (2) over stem.
With ball in open position (hole in-line with valve ports),
handle must point toward valve ends (8).
Secure handle with second nut (1). Tighten snugly.
(b) Test valve for actuation by opening and
closing handle.
Valve shall operate smoothly and
positively.
11-41
CHAPTER 12
ADMINISTRATIVE STORAGE AND INSTRUCTIONS FOR DESTRUCTION
OF MATERIEL TO PREVENT ENEMY USE
Section I. ADMINISTRATIVE STORAGE
Refer to technical manual TM 740-90-1 for information regarding administrative storage applicable to the aircraft-mounted
insecticide sprayer.
Section II. DESTRUCTION OF MATERIEL TO PREVENT ENEMY USE
Refer to technical manual TM 750-244-3, dated 23 September 1969, for instructions regarding destruction of Army
materiel to prevent enemy use.
12-1
APPENDIX A
REFERENCES
A-1. Painting
TM 9-213
A-2. Radio Suppression
TM 11-483
A-3. Maintenance
TM 38-750
TM 5-3740-211-24P
A-4. Shipment and Storage
TB 740-97-2
for Shipment and Storage
TM 740-90-1
A-5. Destruction to Prevent Enemy Use
TM 750-244-3
Painting instructions for Field Use
Radio Interference Suppression
The Army Maintenance Management Systems
Repair Parts and Special Tools List
Preservation of USAMEC Mechanical Equipment
Administrative Storage of Equipment
Procedures for Destruction of Equipment to Prevent
Enemy Use
A-1
APPENDIX B
MAINTENANCE ALLOCATION CHART
Section I. INTRODUCTION
B TEST: Verify serviceability and detect incipient electrical or
mechanical failure by measuring the mechanical or electrical
characteristics of the item and comparing those characteristics
with authorized standards. Tests will be made commensurate
with test procedures and with calibrated tools and/or test
equipment referenced in the MAC.
C SERVICE: Operations required periodically to keep the item
in proper operating condition, i.e., to clean, preserve, drain,
paint, and replenish fuel, lubricants, hydraulic, and deicing
fluids, or compressed air supplies.
D ADJUST: Regulate periodically to prevent malfunction.
Adjustments will be made commensurate with adjustment
procedures and associated equipment specifications.
E ALIGN: Adjust two or more components of an electrical or
mechanical system so that their functions are properly
synchronized or adjusted.
F CALIBRATE: Determine, check, or rectify the graduation of
an instrument, weapon, or weapons system or components of
a weapons system.
GINSTALL: To set up for use in an operational environment
such as an emplacement, site, or vehicle.
H REPLACE: Substitute serviceable components, assemblies,
and subassemblies for unserviceable counterparts or remove
and install the same item when required for the performance of
other maintenance operations.
I REPAIR: Restore to a serviceable condition by replacing
unserviceable parts or by any other action required using
available tools, equipment, and skills-to include welding,
grinding, riveting, straightening, adjusting, and facing.
J OVERHAUL: Restore an item to a completely serviceable
condition (as prescribed by serviceability standards developed
and published by the commodity commands) by employing
techniques of "Inspect and Repair Only as Necessary"
(IROAN). Maximum use of diagnostic and test equipment is
combined with minimum disassembly during overhaul.
"Overhaul" may be assigned to any level of maintenance
except organizational, provided the time, tools, equipment,
repair parts authorization, and technical skills are available at
that level.
Normally, overhaul as applied to end items, is limited to depot
maintenance level.
K REBUILD. Restore to a condition comparable to new by
disassembling to determine the condition of each component
part and reassembling using serviceable, rebuilt, or new
assemblies, subassemblies, and parts.
B-1. General
a. Section I provides a general explanation of all
maintenance and repair functions authorized at various
maintenance levels.
b. Section II designates overall responsibility for the
performance of maintenance operations on the identified
end item or component. The implementation of the
maintenance tasks upon the end item or component will
be consistent with the assigned maintenance operations.
c. Section III-special tool and test equipment
requirements, (not applicable) and Section IVsupplemental instructions, explanatory notes, and/or
illustrations required for a particular maintenance
function, are not required for the aircraft-mounted
insecticide sprayer.
B-2. Explanation of Columns in Section II
a. Group Number. The functional group is a
numerical group set up on a functional basis. The
applicable functional grouping indexes (obtained from TB
750-93-1 Functional Grouping Codes) are listed on the
MAC in the appropriate numerical sequence. These
indexes are normally set up in accordance with their
function and proximity to each other.
b. Assembly Group. This column contains a brief
description of the components of each functional group.
c. Maintenance Functions. This column lists the
various maintenance operations ("A" through "K") and
indicates the lowest maintenance level authorized to
perform these operations. The symbol designations for
the various maintenance levels are as follows:
C - Operator or crew
0 - Organizational maintenance
F - Direct support maintenance
H - General support maintenance
d.
Tools and Equipment, and Remarks.
These
columns, numbered (4) and (5), are provided for
referencing the Special Tool and Test Equipment
Requirements (sec. III) and Remarks (sec. IV) that may
be associated with maintenance operations (sec. II).
The Maintenance operations are defined as follows:
A - INSPECT: Verify serviceability and detect incipient
electrical or mechanical failure by close visual examination.
.
B-1
SECTION II. MAINTENANCE ALLOCATION CHART
(1)
(2)
Functional Group
(3)
Maintenance functions
(4)
(5)
Tools and Remarks
equipment
A
01
02
03
04
05
06
B
C
D
E
F
G
H
I
J K
FRAME ASSEMBLY
Tank Support ...............................................C..... ...... ...... ........ ...... ....... ..... ..... ..... F .. F
Tank Straps, Cables, Struts
& Tiedown Lugs............................................C..... ...... ..... O ...... ...... ....... ..... ..... ..... O ... F
TANK, HOSES, COUPLINGS
AND STRAINERS
Tank .............................................................C..... ..... O .... ........ ...... ....... ..... ..... ..... F.... F
Hoses ..........................................................C..... ...... ...... ........ ...... ....... ..... ..... ..... O ... F
Couplings .....................................................C..... ...... ...... ........ ...... ....... ..... ..... ..... O ... F
Strainers ........................................................ ...... ..... O .... ........ ...... ....... ..... ..... ..... O
Valves............................................................ ...... ..... O .... ........ ...... ....... ..... ..... ..... F.... F
BOOM SPRAY SYSTEM
Spray Booms ................................................C..... ...... ..... O ...... ...... ....... ..... ....O..... ..... F
Nozzles ........................................................C..... ...... ...... ........ ...... ....... ..... ..... ..... O
Tee Boom ..................................................... ...... ...... ...... ........ ...... ....... ..... ..... ..... F
Tee Boom Strainer .....................................O..... ..... O .... ........ ...... ....... ..... ..... ..... F
PUMP ASSEMBLY
Pump.........................................................C..... ...... ...... ........ ...... ....... ..... ..... ..... F .. F
Impeller ...................................................... ...... ...... ...... ........ ...... ....... ..... ..... ..... F
Bearings ................................................... ...... ...... ...... ........ ...... ....... ..... ..... ..... F
Shafts ....................................................... ...... ...... ...... ........ ...... ....... ..... ..... ..... F
Brake Assy .................................................... ...... ...... ...... ........ ...... ....... ..... ..... ..... F
Drum, Brake............................................... ...... ...... ...... ........ ...... ....... ..... ..... ...... ..... F
Shoe, Brake ............................................... ...... ...... ...... ........ ...... ....... ..... ..... ..... F
Cable Brake ............................................... ...... ...... ..... O ...... ...... ....... ..... ..... ..... O
Windmill Assy ............................................... ...... ...... ...... ........ ...... ....... ..... ..... ..... O ... O
Blade, Propeller . .....................................C..... ...... ..... O ...... ...... ....... ..... ..... ..... O
Hub & Actuator .......................................... ...... ...... ...... ........ ...... ....... ..... ..... ..... O .. F
CONTROL SYSTEM
Support Assy ................................................. ...... ...... ..... O ...... ...... ....... ..... ..... ..... F.... F
Levers............................................................ ...... ...... ..... O ...... ...... ....... ..... ..... ..... O
Rods, Connecting ......................................... ...... ...... ..... O ...... ...... ....... ..... ..... ..... O
Gage, Pressure ........................................... ...... ...... ...... ........ ...... ....... ..... ..... .... O
Plates, Instruction .......................................... ...... ...... ...... ........ ...... ....... ..... ..... ..... O
GROUND LOADING UNIT
Engine Assy ................................................C..... ..... C ... O ...... ...... ....... ..... ....O.... F.... H
.. Head, Gaskets & Valves ........................... ...... ...... ...... ........ ...... ....... ..... ..... ..... F
Pistons, Rings & Crankshaft ..................... F ..... ...... ...... ........ ...... ....... ..... ..... ..... F
Point, Set, Ignition ................................... F ..... ...... ..... F....... ...... ....... ..... ..... ..... F
Plug, Spark ...............................................O..... ...... ..... O ...... ...... ....... ..... ..... ..... O
Cable, Ignition . ........................................ .C .... ...... ...... ........ ...... ....... ..... ..... ..... F
Carburetor ................................................ ...... ..... O ... O ...... ...... ....... ..... ..... ..... F
Starter, Recoil .......................................... ...... ...... ..... F....... ...... ....... ..... ..... ..... F.... F
Pump Assembly ...........................................C..... ...... ...... ........ ...... ....... ..... ....O.... F
Impeller .................................................... ...... ...... ..... F....... ...... ....... ..... ..... ..... F
Bearing & Shaft .......................................... ...... ...... ...... ........ ...... ....... ..... ..... ..... F
Seals & Gaskets ........................................ ...... ...... ...... ........ ...... ....... ..... ..... ..... F
Hose, Couplings and
Strainers ........................................................ C. .... ...... ...... ........ ...... ....... ..... ....O.... F
B-2
APPENDIX C
BASIC ISSUE ITEMS LIST AND MAINTENANCE ANID OPERATING SUPPLIES
Section I. INTRODUCTION
C-1. Scope
This appendix lists items which accompany the aircraftmounted insecticide sprayer or are required for
installation, operation, or maintenance.
Section II lists the accessories, tools and publications
required for the maintenance and operation, initially
issued or authorized with the equipment.
Section III lists the maintenance and operating supplies
required for initial operation.
Code
Explanation
T
Applied to high dollar value recoverable parts which are
subject to special handling and are issued on an exchange
basis. Such repair parts are normally repaired or overhauled
at depot maintenance activities.
U
Applied to repair parts specifically selected for salvage by
reclamation units because of precious metal content, critical
materials, high dollar value reusable casings and castings, etc.
C-2. Explanation of Columns
The following provides an explanation of columns
in the tabular list in section II:
a. Source, Maintenance, and Recoverability Codes
(Column (1)).
(1) Source code, column la, indicates the
selection status and source for the listed item.
Source Codes are:
c. Description (col. 3)). Indicates the Federal Item
Name and any additional description required. A fivedigit manufacturer’s or other service code is shown in
parentheses followed by the manufacturer’s part number.
Repair parts quantities included in kits, sets, and
assemblies that differ from the actual quantity used in the
specific item are listed in parentheses following the
repair part name.
d. Unit of Issue (col. (4)). Indicates the unit used
as a basis for issue, e.g., ea, pr, ft, yd, etc.
e. Quantity Authorized (col. (5)). Indicates the
total quantity of an item required to be on hand and
necessary for operation and maintenance of the
equipment. Items to be requisitioned as required are
indicated by an asterisk.
f. Illustration (col. (6)).
(1) Figure number, column 6a, indicates the
figure number of the illustration in which the item is
shown.
(2) Item number, column 6b, indicates the
callout number used to reference the item in the
illustration.
C-3. Explanation of Columns Contained in Section III
a. Item. This column contains numerical sequence
item numbers assigned to each component application
to facilitate reference.
b. Component Application. This column identifies
the component application of each maintenance or
operating supply item.
c. Federal Stock Number. The Federal Stock
Number will be shown in this column and will be used for
requisitioning purposes.
d. Description. The item and a brief description are
shown.
e. Quantity Required for Initial Operation. This column
lists the quantity of each mainte-
b. Federal Stock Number (col. (2)). Indicates the
Federal Stock Number for the item.
Code
Explanation
P
Applies to repair parts which are stocked in or
supplied from the GSA/DSA Army supply system,
and authorized for use at indicated maintenance
categories.
M Applied to repair parts which are not procured or
stocked but are to be manufactured at indicated
maintenance categories.
X2 Applied to repair parts which are not stocked. The
indicated maintenance category requiring such
repair parts will attempt to obtain them through
cannibalization.
If not obtainable through
cannibalization, such repair parts will be
requisitioned with supporting justification through
normal supply channels.
(2) Maintenance code, column lb, indicates the
lowest category of maintenance authorized to install the
listed item. The maintenance level codes are:
Code
Explanation
C Operator or crew
O Organizational maintenance
F
Direct support maintenance
H General support maintenance
(3) Recoverability code, column 1c, indicates
whether unserviceable items should be returned for
recovery or salvage. Items not coded are expendable
Recoverability codes are:
Code
Explanation
R Applied to repair parts and assemblies which are
economically repairable at DSU and GSU activities
and are normally furnished by supply on an
exchange basis.
.
C-1
nance or operating supply item required for initial
operation of the equipment.
f. Quantity Required for 8 Hours Operation.
Quantities listed represent the estimated requirements
for an average eight hours of operation.
.
C-4. Federal Supply Code/Manufacturer
Federal Supply Code
Manufacturer
22065
Agrinautics
29201
Homelite Division of Textron, Inc.
78357
Snap-Tite, Inc.
98991
Worcester Valve Co., Inc.
Section II. BASIC ISSUE ITEMS LIST
(1)
Source codes
(a)
Source
(b)
Main
tenance
(c)
Recover
ability
(2)
(3)
Federal
stock
number
Description
(4)
(5)
(6)
Illustration
(a)
(b)
Figure Item
Item
Unit of
Issue
Quantity
Auth
Group 31 -- Basic Issue Items, Manufacturer
installed 3100 -- Basic Issue Items
Manufacturer or depot installed
Group 312 -- Basic Issue Items, Manufacturer
installed 3100 -- Basic Issue Items
Manufacturer or depot installed
None
Group 32 - Basic Issue Items, Troop Installed
3200 - Basic Issue Items
Troop installed or authorized
None
Section III. MAINTENANCE AND OPERATING SUPPLIES
Item
(1)
Component
Application
0101-Crankcase
Federal
stock
number
Description
Oil Lubricating
1 qt. can as follows: OE30 (sae-30)
Quantity
required
for
initial
operation
Notes
(1) includes quantity
1/4 pint
0306-Fuel Tank
Fuel, gasoline
Bulk as follows
Gasoline: 91A
Quantity
required
for
8-hours
operation
18 ounces
of oil
to be mixed with fuel
system as follow: ¼
pint or (4) oz. To 1 gal.
Of gasoline. See FSC
C9100-IL addition data
for requisitioning
procedures
9131-160-11818
(2) tank capacity
Average fuel
consumption is 1/100
gal. Per hour of
continuous operation
C-2
INDEX
Paragraph
A
Administrative storage ............................................................................................................................................
Alteration of spray pattern........................................................................................................................................
Applicable publications .............................................................................................................................................
Assembly procedures (see specific component)
B
Ball shutoff valve ......................................................................................................................................................
Basic issue items......................................................................................................................................................
Boom, center
Maintenance ......................................................................................................................................................
Removal and installation...................................................................................................................................
Boom, spray
Maintenance and adjustment ............................................................................................................................
Removal..............................................................................................................................................................
Disassembly .......................................................................................................................................................
Cleaning..............................................................................................................................................................
Inspection ...........................................................................................................................................................
Assembly ............................................................................................................................................................
Brake assembly
Removal..............................................................................................................................................................
Cleaning, inspection, repair.................................................................................................................................
Assembly ............................................................................................................................................................
Brake cable, pump ...................................................................................................................................................
Bypass valve
Maintenance and adjustment ............................................................................................................................
Removal..............................................................................................................................................................
Disassembly .....................................................................................................................................................
Cleaning, inspection, repair.................................................................................................................................
Assembly ............................................................................................................................................................
C
Cable, pump brake ...................................................................................................................................................
Carburetor chamber group .......................................................................................................................................
Carburetor repair ......................................................................................................................................................
Center boom
Maintenance ......................................................................................................................................................
Removal and installation ...................................................................................................................................
Cleaning ...............................................................................................................................................................
Components, removal of
Insecticide sprayer ..............................................................................................................................................
Liquid loading system.........................................................................................................................................
Control panel
Maintenance and adjustment ..........................................................................................................................
Removal..............................................................................................................................................................
Disassembly .......................................................................................................................................................
Cleaning..............................................................................................................................................................
Inspection ...........................................................................................................................................................
Assembly ............................................................................................................................................................
Installation...........................................................................................................................................................
Controls and instruments..........................................................................................................................................
Control valve
Maintenance and adjustment ...........................................................................................................................
Removal and installation ...................................................................................................................................
Conversion of equipment .........................................................................................................................................
D
Description .............................................................................................................................................................
Destruction to prevent enemy use .........................................................................................................................
Differences between models.....................................................................................................................................
Dismantling for movement ........................................................................................................................................
Drip pan ...............................................................................................................................................................
Dust cap ...............................................................................................................................................................
E
Engine repair ............................................................................................................................................................
Equipment conversion .............................................................................................................................................
I-1
Page
12-1
A-5
A-1
12-1
A-1
A-1
11-12
3-1, C1
11-19
3-1, C-1
4-21
5-13
4-23
5-4
4-20
6-2
6-3
6-4
6-5
6-6
4-22
6-1
6-1
6-4
6-4
6-4
7-8
7-9
7-10
4-22
7-3
7-5
7-5
4-23
4-19
5-18,8-2
8-3
84
8-5
4-22
5-4, 8-1
8-1
8-4
8-4
4-22
11-12
11-13
4-23
11-25
11-29
4-21
6-13
3-7
4-23
5-4
31
5-5
11-12
5-1
11-19
4-24
517,10-2
4-24,103
4-24,10-4
4-24,10- 5
10-7
5-17,10-8
2-3
4-25
5-6,10-1
4-25,10-1
4-28,10-1
4-28,10-1
10-1
5-6,10-1
2-2
4-18
5-9
4-5
4-22
5-3
4-11
1-4
12-2
1-5
4-6
5-7
4-16
1-1
12-1
1-5
414
5-2
4-21
11-12
4-5
11-19
4-11
Paragraph
Page
F
Flow control valve
Removal.............................................................................................................................................................. 8-2
Disassembly ....................................................................................................................................................... 8-3
Cleaning, inspection, repair................................................................................................................................. 8-4
Assembly ............................................................................................................................................................ 8-5
Forms and records .................................................................................................................................................. 1-2
G
Gage, liquid level ...................................................................................................................................................... 5-14
H
Hoses, insecticide sprayer........................................................................................................................................ 4-15, 5-6
I
Identification and tabulated data ............................................................................................................................... 1-6
Ignition parts, liquid loading system .......................................................................................................................... 11-12, 11-13
In flight checkout....................................................................................................................................................... 2-7
Insecticide sprayer
Assembly ............................................................................................................................................................ 4-2
Installation........................................................................................................................................................... 4-3
Removal from helicopter ..................................................................................................................................... 4-4
Inspecting and servicing the equipment
Operator.............................................................................................................................................................. 2-1
Organizational..................................................................................................................................................... 4-1
L
Liquid level gage....................................................................................................................................................... 5-14
Liquid loading system
Assembly ............................................................................................................................................................ 4-2
Operator maintenance ........................................................................................................................................ 11-5
Organizational maintenance................................................................................................................................ 11-8
Liquid loading tube................................................................................................................................................... 5-10
Loading procedure.................................................................................................................................................... 2-7
Lubrication
Insecticide sprayer .............................................................................................................................................. 3-3
Liquid loading system.......................................................................................................................................... 11-3
M
Maintenance allocation chart ................................................................................................................................... B-1
Manual control panel ............................................................................................................................................... 4-24
Movement to a new worksite
Dismantling ......................................................................................................................................................... 4-6
Reinstallation ...................................................................................................................................................... 4-7
O
Operation under unusual conditions
General ............................................................................................................................................................... 2-8
Procedures in cold weather................................................................................................................................ 2-9
Procedures in dusty areas .................................................................................................................................. 2-9
Procedures in extreme heat ................................................................................................................................ 2-9
Procedures in freezing weather........................................................................................................................... 2-9
Procedures in high altitudes................................................................................................................................ 2-9
Procedures in salt water areas............................................................................................................................ 2-9
Operation under usual conditions
General ...............................................................................................................................................................
Starting ............................................................................................................................................................... 2-5
Operation ............................................................................................................................................................ 2-7
Stopping.............................................................................................................................................................. 2-6
Post flight operation ............................................................................................................................................ 2-7
P
Preventive maintenance checks and services
Insecticide sprayer
Operator.............................................................................................................................................................. 3-5
Organizational..................................................................................................................................................... 4-12
Liquid loading system
Operator.............................................................................................................................................................. 11-4
Organizational..................................................................................................................................................... 11-7
Pump and brake assembly ...................................................................................................................................... 5-8
Pump assembly
Removal.............................................................................................................................................................. 5-8, 7-12
Disassembly ....................................................................................................................................................... 7-13
I-2
8-1
8-1
8-4
8-4
1-1
5-5
4-21, 5-1
1-5
11-24
2-4
4-3
4-6
4-10
2-1
4-1
5-5
4-6
11-5
11-8
5-3
2-3
3-1
11-5
B-1
4-25
4-14
4-14
2-5
2-5
2-5
2-5
2-5
2-5
2-5
2-4
2-2
2-3
2-3
2-4
2-2
3-1
4-15
11-5
11-8
5-2
5-2, 7-5
7-5
Paragraph
P - Continued
Cleaning, inspection, repair.................................................................................................................................
Assembly ............................................................................................................................................................
Installation...........................................................................................................................................................
Pump brake cable.....................................................................................................................................................
Pump inlet tube........................................................................................................................................................
Pump, liquid loading system .....................................................................................................................................
R
Reinstallation after movement .................................................................................................................................
Removal of components
Insecticide sprayer .............................................................................................................................................
Liquid loading system.........................................................................................................................................
Removal from helicopter 4-4 4-10
Repair and replacement standards...........................................................................................................................
Repair parts and special tools list ............................................................................................................................
Reporting of errors....................................................................................................................................................
Reporting of errors....................................................................................................................................................
S
Scope
...............................................................................................................................................................
Service upon receipt of materiel
Operator..............................................................................................................................................................
Organizational.....................................................................................................................................................
Special tools and equipment
Insecticide sprayer .............................................................................................................................................
Liquid loading system..........................................................................................................................................
Spray boom
Maintenance and adjustment ..............................................................................................................................
Removal..............................................................................................................................................................
Disassembly .......................................................................................................................................................
Cleaning..............................................................................................................................................................
Inspection ...........................................................................................................................................................
Assembly ............................................................................................................................................................
Spray pattern, alteration ...........................................................................................................................................
Starter fan housing repair .........................................................................................................................................
Starting the equipment..............................................................................................................................................
Stopping the equipment............................................................................................................................................
Strainer
...............................................................................................................................................................
Sump
...............................................................................................................................................................
Synchromatic windmill assembly
Maintenance and adjustment ..............................................................................................................................
Removal..............................................................................................................................................................
Disassembly .......................................................................................................................................................
Cleaning, inspection, repair.................................................................................................................................
Assembly ............................................................................................................................................................
Installation...........................................................................................................................................................
T
Tabulated data
Insecticide sprayer ..............................................................................................................................................
Liquid loading system.........................................................................................................................................
Tank assembly
Maintenance and adjustment ..............................................................................................................................
Removal..............................................................................................................................................................
Disassembly .......................................................................................................................................................
Cleaning, inspection, repair.................................................................................................................................
Assembly ............................................................................................................................................................
Installation...........................................................................................................................................................
Tank straps, struts and tiedown lugs
Removal..............................................................................................................................................................
Cleaning, inspection, repair.................................................................................................................................
Installation...........................................................................................................................................................
Tank support assembly
Disassembly .......................................................................................................................................................
Cleaning, inspection, repair.................................................................................................................................
Installation...........................................................................................................................................................
Tools and equipment ..............................................................................................................................................
Troubleshooting chart
Insecticide sprayer
Operator........................................................................................................................................................
I-3
Page
7-14
7-15
5.8, 7-16
4-22
5-11
11-12
7-7
7-7
5-2, 7-8
4-23
5-3
11-23
4-7
4-14
5-5
11-12
5-1
11-19
11-9
3-2
1-3
1-3
11-13
3-1
1-1
1-1
1-1
1-1
3-1
4-1
3-1
4-1
4-9, -2
11-6 ,11-10
4-15, 5-1
11-7, 11-13
4-20
6-2
6-3
6-4
6-5
6-6
4-5
1 11-13
2-5
2-6
4-17
5-15
4-22
6-1
6-1
6-4
6-4
6-4
4-11
11-26
2-2
2-3
4-21
5-5
4-23
7-2
7-3
7-4
7-5
7-6
4-24
7-1
7-1
7-3
7-3
7-3
1-6
11-1
1-5
11-1
4-14
5-16, 8-10
8-11
8-12
8-13
5-16, 8-14
4-16
5-5, 8-6
86
8-6
8-6
5-6, 8-6
9-6
9-7
9-8
9-2
9-2
9-2
9-2
9-3
9-4
4-8, 5-1
9-1
9-1
9-2
4-15, 5-1
3-6
3-1
Paragraph Page
T - Continued
Organizational.....................................................................................................................................................
Direct and general support..................................................................................................................................
Liquid loading system
Operator..............................................................................................................................................................
Organizational.....................................................................................................................................................
Direct and general support..................................................................................................................................
Tube, liquid loading...................................................................................................................................................
Tube, pump inlet......................................................................................................................................................
V
Valve, ball shutoff .....................................................................................................................................................
Valve, bypass
Maintenance and adjustment ..............................................................................................................................
Removal..............................................................................................................................................................
Disassembly .......................................................................................................................................................
Cleaning, inspection, repair.................................................................................................................................
Assembly ............................................................................................................................................................
Valve, control
Maintenance and adjustment ..............................................................................................................................
Removal and installation.....................................................................................................................................
Valved nipple ............................................................................................................................................................
Valved quick-disconnect coupling
General ...............................................................................................................................................................
Removal..............................................................................................................................................................
Cleaning and inspection......................................................................................................................................
Valves, fuel control and bypass
Removal..............................................................................................................................................................
Disassembly .......................................................................................................................................................
Cleaning, inspection, repair.................................................................................................................................
Assembly ............................................................................................................................................................
W
Windmill assembly, synchromatic
Adjustment of blade angle...................................................................................................................................
Maintenance and adjustment ..............................................................................................................................
Removal..............................................................................................................................................................
Disassembly .......................................................................................................................................................
Cleaning, inspection, repair.................................................................................................................................
Assembly ............................................................................................................................................................
Installation...........................................................................................................................................................
I-4
4-13
5-4
4-15
5-1
11-4
11-7
11-11
5-10
5-11
11-5
11-8
11-19
5-3
5-3
11-12
11-9
4-19
5-12, 8-2
8-3
8-4
8-5
4-22
5-4, 8-1
8-1
8-4
8-4
4-18
5-9
4-16
4-22
5-3
4-21
8-7
8-8
8-6
8-5
8-5
8-2
8-3
8-4
8-5
8-1
8-1
8-4
8-4
4-5
4-23
7-2
7-1
7-4
7-5
7-6
4-12
4-24
7-1
73
7-3
7-3
7-3
8-5
By Order of the Secretary of the Army:
Official:
VERNE L. BOWERS
Major General, United States Army,
The Adjutant General.
W. C. WESTMORELAND,
General, United States Army,
Chief of Staff.
Distribution:
To be distributed in accordance with DA Form 12-25A, (qty rqr block No. 149) Operator maintenance requirements
for Insect and Pest Control Equipment.
U.S. GOVERNMENT PRINTING OFFICE : 1985 0 - 461-202 (20237)
THE METRIC SYSTEM AND EQUIVALENTS
PIN: 005452-001
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