SECTION V
MAINTENANCE INSTRUCTIONS
5. GENERAL. Maintenance of the FSU consists of periodic inspection, cleaning, service adjustment, minor repairs or replacement of parts and components, and lubrication. The procedures described in this section must be performed regularly and thoroughly, even though the FSU is operating satisfactorily. Through proper inspection, maintenance, and lubrication, equipment that is not continuous use is kept ready for operation when necessary, and the unit is maintained at peak performance levels for the maximum life of the equipment.
5.1 SERVICING HYDRAULIC RESERVOIR.
a. Open reservoir fill access door and remove reservoir filler cap.
b. Fill the reservoir to ¾ full. To allow for thermal
c. Install reservoir filler cap.
5.1.1 FUEL TANK SERVICE.
a. Locate draincock on bottom of tank. Drain any water or sediment, prior to starting the engine.
b. Close draincock & fill tank.
NOTE
Keep fuel tanks filled to reduce condensation which contaminates fuel.
5.2 SERVICING HYDRAULIC FILTERS. All HPS hydraulic system filters incorporate differential pressure switches to indicate when the filters need servicing. No service interval is recommended.
a. Open SUPPLY BYPASS valve (12, Figure 4-10 fully counterclockwise.
b. Replace supply (high) pressure filter (Figure 5-9) by unscrewing filter bowl (1) and removing old element (3). Install new element and install filter bowl.
c. Replace (low pressure filter (Figure 5-9) by removing twelve screws (1) and washers (2). Remove head (3), O-ring (4) and unscrew the retaining plug (5). Remove retainer (6) and element (7). Install new element. Install retainers, plug, and cover with O-ring, and retain with screws and washers.
5.3 ENGINE MAINTENANCE.
5.3.1 CHECKING ENGINE OIL LEVEL. To check the engine oil level, proceed as follows (see Figure 5-1).
a. Check oil level on dipstick (1).
b. Add lubrication oil as required to bring the oil level up to the dipstick MAX level.
Figure 5-1. Oil Level/Addition
5.3.2 SERVICING AIR FILTER (see Figure 5-2). The air cleaner should be checked and the filter replaced as required by the air filter indicator light on the instrument (5, Figure 4-1).
a. Loosen clamps (1). Remove lid (2) screws (3), and cover (4).
b. Install new filter, cover, screws, and lid.
Figure 5-2. Air Filter
LEGEND
Figure 5-3. Diesel Engine
5.3.3 CHANGING ENGINE OIL AND OIL FILTER. To change the engine oil and oil filter proceed as follows (see Figure 5-4).
a. Remove oil drain plug (1) and drain oil into a container.
b. Unscrew oil filter (2) using a strap (3).
c. Lightly lubricate filter gasket with oil install new filter and handtighten.
d. Install drain plug (1).
e. Remove dipstick and fill crankcase with 9.0 quarts of lubricating oil includes filter.
f. Check oil level near max. Return dipstick and push firmly to seat.
g. Start engine and check for oil leaks around crankcase drain plugs and engine oil filter.
Figure 5-4. Oil Filter/Change
5.3.4 SERVICING FUEL FILTERS. There are two fuel filters. A pre-filter (5, Figure 5-3). The pre-filter is on the outside of the engine. The main fuel filter (6) is located inside the engine.
a. To service the pre-filter (Figure 5-5) remove fuel line (1) from pre-filter (2). Have a suitable container to catch residual fuel.
b. Insert new pre-filter. Insure that arrow (3) is facing in the direction of flow (towards the main fuel filter).
Figure 5-5. Fuel Pre-Filter
c. To service the MAIN fuel filter.
1. (Figure 5-3) remove fuel filter cover (7) by removing 5 screws (8).
2. (Figure 5-6) with strap (1) remove filter (2) by turning to the left.
3. Lightly oil fuel filter lip gasket.
4. Install fuel filter and handtighten.
5. For an easier start prime the fuel filter with manual primer (1, Figure 5-6A).
Figure 5-6. Main Fuel Filter
Figure 5-6A. Manual Fuel Primer
5.4 BATTERY MAINTENANCE. The original battery sent with the FSU was maintenance free and those items in the checklist below that deal with electrolyte do not apply to this battery. For the regular non-maintenance free battery all the following items apply
When handling batteries, face shield or goggles, rubber gloves and apron shall be used. Failure to comply may result in injury to personnel.
a. Maintain electrolyte level approximately 3/8 inch over plates.
To prevent battery damage, keep soda solution out of cells. Damage to battery could occur.
b. Keep top of battery clean. When necessary, wash with a baking soda and water solution and rinse with fresh water.
c. Inspect cables, clamps and holddown bracket for corrosion. Clean and replace damaged parts. Apply coat of petrolatum.
d. Specific gravity of a fully charged battery should be 1.275 to 1.285. Charge battery if specific gravity goes below 1.150. Check electrical system if battery becomes discharged repeatedly.
5.5 SERVICING DRIVE BELTS. Too much tension on belts may damage bearings of the driven part. A loose belt will slip and wear out.
5.5.1 REPLACING/ADJUSTING ALTERNATOR BELT. Adjust belt tension so that the belt slack is approximately ½ inch (see Figure 5-7).
Figure 5-7. Belt Tension
5.5.2 COOLING FAN BELT. The cooling fan belt (10, Figure 5-8A) is automatically adjusted by the engine hydraulic belt tensioner (11).
5.5.3 REPLACING COOING FAN BELT.
a. (Figure 5-8A) loosen alternator (1) and remove alternator belt (2).
b. Loosen setscrew (14) and remove pulley (4).
c. Remove fan guard adapter (8) by removing six screws (9).
d. Remove fan guard (6) by removing four screws (7).
e. (Figure 5-8B) remove one screw (11) from pulley (5) and shaft (3). Push in belt tensioner (12), which rotates lever (13) up. Insert screw that was removed into hole beneath lever (13) to hold lever in place, which in turns holds tensioner in.
f. Remove belt (10) and remove remaining bolts (11) from pulley (5) and shaft (3). Remove pulley.
g. (Figure 5-8C) install belt (10) over pulley while pulley is remove. With one screw (11) secure pulley and shaft into position without centering on hub.
h. (Figure 5-8) install a large screwdriver between tensioner (12) and belt pulley. Press screwdriver down until pulley slides onto the centering hub. Insert and tighten remaining bolts (11) to pulley and shaft.
i. (Figure 5-8B) remove screw (11) that was holding lever (13) up and screw in to pulley (5) and shaft.
j. (Figure 5-8A) install fan guard (6) and secure with four socket head screws (7). Install fan guard adapter (8) and secure with six screws.
k. Put alternator belt (2) on alternator (1), adjust and tighten.
5.6 BLEEDING THE FUEL SYSTEM. The engine has automatic bleeding at the injection pump.
5.8 SUBMERSIBLE PUMP (see Figure 5-10).
5.8.1 REMOVAL. Remove submersible pump from its compartment and disconnect all hoses if they are connected.
5.8.2 DISASSEMBLY.
a. Remove quick-disconnects (1) and (2), swivel connectors 93) and elbows (4) from hydraulic motor (8).
b. Remove camloc (29), elbow (28), nipple (27) and reducer (26) from housing (18).
c. Remove strainer (25) by disengaging camloc (24) from camloc (23). Remove camloc (24), reducer (22), and nipple (21) from strainer.
d. Remove camloc (23), reducer (22) and nipple (21) from housing (18).
e. Remove handle (5) by removing two screws (6) and washers (7).
f. Disconnect adapter plate (11) from housing (18) by removing 4 remaining screws (12), washers (13) and lift plate out from housing.
g. The impeller (17) is now exposed and can be replaced by removing nut (19). Remove impeller by sliding it down the hydraulic motor shaft.
h. Remove and replace shim (16) and retaining ring (15) if the impeller was separated from the hydraulic motor in step (g) above.
i. Remove gasket (14).
j. Remove hydraulic motor (8) from plate (11) by removing four screws (9) and washers (10). Remove gasket (31). Disassembly is now complete.
5.8.3 CLEANING. Wash pump in cleaning solvent. Air dry or dry with compressed air 30 PSI or less.
5.8.4 INSPECTION/REPAIR. Check all parts for signs of wear and damage such as grooves, scrapes, nicks, or impact washers. Any damaged parts must be replaced.
5.8.5 ASSEMBLY.
a. Install gasket (31), hydraulic motor (8) on plate (11) and secure with four screws (9) and washers (10).
b. Install gasket (14), retainer ring (15), shim (16) and impeller (17) in plate (11) and secure impeller with nut (19).
c. Install the impeller/plate into housing (18). Secure plate to housing with four screws (12) and washers (13).
d. Install handle (5) on plate and secure with two remaining screws (6) and washers (7).
e. Install camloc (23), reducer (22) and nipple (21) on housing (18).
f. Install camloc (24), reducer (22) and nipple (21) on strainer (25). Engage camloc (23) and (24) to secure strainer to pump.
g. Install camloc (29), elbow (28), nipples (26) on housing (18).
h. Install elbow (4), swivel connector (3) and quick disconnects (1) and (2) on hydraulic motor.
i. Install plug (20).
j. Assembly is now complete.
5.8.6 TEST. The pump may be tested dry using the FSU provided the dry test does exceed 2 minutes. During the dry test listen for scraping or rubbing noises.
5.9 CLEANING. Clean metal parts of FSU with cleaning solvent P-D-680 Type III. Dry with low-pressure compressed air or a clean, lint-free cloth. Clean outlet ports and hose fittings by washing in solvent. Allow solvent to evaporate before connections are made. Wipe electrical parts with a cloth.
5.10 PAINT. To touch up or repaint FSU, refer to TO 35-1-3.
LEGEND:
Figure 5-8. Cooling Belt Removal
Figure 5-10. Submersible Pump (Sheet 1 of 2)
Figure & Index No. |
Part Number |
CAGE |
Description 1 2 3 4 5 6 7 |
Units Per Assy |
SMR Code |
| 5-10 | 95470-210 | 56529 |
SUBMERSIBLE PUMP | 1 |
PAFFF |
1 |
24278-100 | 2N386 |
|
1 |
PAFZZ |
2 |
24277-900 | 2N386 |
|
1 |
PAFZZ |
3 |
AH04224 | 0E6D6 |
|
2 |
PAFZZ |
4 |
AN914-6J | 88044 |
|
1 |
PAFZZ |
5 |
30017 | 76122 |
|
1 |
PAFZZ |
6 |
21291 | 76122 |
|
2 |
PAFZZ |
7 |
21266 | 76122 |
|
2 |
PAFZZ |
8 |
25435 | 76122 |
|
1 |
PAFZZ |
9 |
21251 | 76122 |
|
4 |
PAFZZ |
10 |
21238 | 76122 |
|
4 |
PAFZZ |
11 |
25176 | 76122 |
|
1 |
PAFZZ |
12 |
21251 | 76122 |
|
4 |
PAFZZ |
13 |
21266 | 76122 |
|
4 |
PAFZZ |
14 |
21216 | 76122 |
|
1 |
PAFZZ |
15 |
25004 | 76122 |
|
1 |
PAFZZ |
16 |
22304 | 76122 |
|
1 |
PAFZZ |
17 |
30019 | 76122 |
|
1 |
PAFZZ |
18 |
21202 | 76122 |
|
1 |
PAFZZ |
19 |
22655 | 76122 |
|
1 |
PAFZZ |
20 |
21267 | 76122 |
|
1 |
PAFZZ |
21 |
MS51872-172 | 96906 |
|
2 |
PAFZZ |
22 |
MS14315-31 | 96906 |
|
2 |
PAFZZ |
23 |
AD300 | 24269 |
|
1 |
PAFZZ |
24 |
300A | 24269 |
|
1 |
PAFZZ |
25 |
30018 | 76122 |
|
1 |
PAFZZ |
*26 |
COMM | - |
|
1 |
PAFZZ |
*27 |
COMM | - |
|
1 |
PAFZZ |
*28 |
COMM | - |
|
1 |
PAFZZ |
29 |
300F | 24269 |
|
1 |
PAFZZ |
30 |
AH300 | 24269 |
|
1 |
PAFZZ |
31 |
24009 | 76122 |
|
1 |
PAFZZ |
32 |
95470-209 | 56529 |
|
1 |
PAFZZ |
33 |
MS35214-44 | 96906 |
|
3 |
PAFZZ |
34 |
MS35333-106 | 96906 |
|
3 |
PAFZZ |
35 |
MSS35649-286 | 96906 |
|
3 |
PAFZZ |
36 |
AN914 | 88044 |
|
1 |
PAFZZ |
| * Supplied by distributor Simmons Pump Co.
9950 Bell Ranch Dr., Suite 101, Santa Fe Springs, CA 900670-2686 |
5.11 TROUBLESHOOTING. Testing consists of a functional check of the test stand. Perform the functional check in accordance with engine start procedures. In event of abnormal operation Table 5-1 provides a quick checklist of possible troubles, their possible cause and suggested remedy. The section has four parts.
Trouble |
Probable Cause |
Corrective Action |
Starting Procedure Troubles |
||
| Ignition switch ON: panel lights not lit or dimly lit | Weak battery | Recharge battery/check electrolyte. |
| Dead battery | Replace battery. | |
| Loose cables/dirty posts | Clean and tighten. | |
| Fuse blown/faulty | Replace fuse. | |
| Engine will not crank | Low battery voltage | Recharge battery if a light load test indicates low or no voltage. Replace battery if it is damaged or will not hold a charge. |
| Defective START switch or ignition switch | Replace. | |
| Loose wiring connections to starter | Perform a wiring check of the starter circuit. Tighten loose connections. | |
| Internal seizure | With a socket wrench attached to the crankshaft pulley bolt, hand crank the engine at least one complete revolution. If engine cannot be rotated a complete revolution, internal damage is indicated. Replace engine | |
| Engine cranks but does not start
No fuel to engine |
No fuel in tank | Check fuel level/fill. |
| Clogged fuel filter | Replace. | |
| Fuel feed pump defective | Replace (TO 38G1-108-3). | |
| Fuel injection pressure too low | Remove, clean and adjust. If not adjustable replace (TO 38G1-108-3). | |
| Fuel to engine | Improper fuel injection timing | Adjust timing (TO 38G1-108-3). |
| Fuel injection pump defective | Remove and test all defective replace (TO 38G1-108-3). |
|
| Glow plug malfunction | Replace defective glow plugs (TO 33G1-108-3). | |
| Low cranking speed | Improper lubricating oil viscosity | Drain oil and refill with specified grade and weight. |
| Low battery output | Check battery in accordance with the corrective action for "low battery voltage", above. | |
| Loose starter connections or faulty starter | Tighten the starter connections. Inspect the starter commutator and brushes for wear. Replace the brushes if badly worn. Replace starter TO 38G1-108-3). | |
Table 5-1. Troubleshooting (cont’d)
Trouble |
Probable Cause |
Corrective Action |
Diesel Engine Problems |
||
| Engine starts but stalls as soon as START switch is released | Idle speed too low | Adjust. |
| Abnormal engine operation, lack of power | Improper engine adjustment (tune up) and fuel injection pump timing | Perform an engine tune up (TO 38G1-108-3). Check the fuel injection pump timing. An improperly adjusted fuel injection pump will result in loss of power due to the valves and injectors being actuated at the wrong point of the operating cycle. |
| Insufficient fuel | Fill tank. | |
| Insufficient air | Check for damaged or dirty air cleaner. Clean or replace. | |
| Abnormal engine operation, engine noise | Defective alternator | Worn bearing. Replace alternator (TO 38G1-108-3). |
| Valves out of adjustment | Adjust valve clearance (TO 38G1-108-3). | |
| Rocker arm damaged | Inspect rocker arm. If damaged replace (TO 38G1-108-3). | |
| High lubricating oil consumption, external leaks | Gasket or oil seal leaks | Replace gaskets and seals as necessary. |
| Blocked air intake | Remove any blockage/replace air filter. | |
| Low oil pressure | Low oil level | Check oil level on dipstick. Add oil as necessary. |
| Incorrect lubricating oil viscosity | Drain oil and refill with oil of specified grade and weight. Change oil filter. | |
| Exhaust shows black or gray | Blocked air intake system | Remove blockage, check air filter. |
| Defective fuel injection | Test injection, replace defective ones (TO 38G1-108-3). | |
| Improper fuel injection pump timing | Adjust fuel injection pump timing (TO 38G1-108-3). | |
| Defective injection pump | Repair or replace (TO 38G1-108-3). | |
| Exhaust shows blue smoke | Blocked air intake system | Remove blockage, check air filter. |
| Defective intake or exhaust valves or valve guides | Repair or replace defective components. If not defective replace engine. | |
Table 5-1. Troubleshooting (cont’d)
Trouble |
Probable Cause |
Corrective Action |
Diesel Engine Problems |
||
| Battery does not charge | Loose alternator drive belts | Adjust drive belt tension. |
| Alternator malfunction | Check alternator output 12 Volt 50 Amp. Replace if defective. | |
| Loose charging circuit connection | Tighten/repair or replace. | |
| Dead battery/dead cell | Replace battery. | |
Fault Indicators and Troubles |
||
| ALTERNATOR indicator lights | Inoperable/belt loose | Replace/re-tension belt. |
| ENGINE OIL PRESSURE indicator light | Low oil pressure | (See diesel engine problems). |
| AIR FILTER indicator light | Clogged air filter | Replace. |
| OIL ENGINE TEMP indicator light | Defective oil pump | Replace |
| Oil filter clogged | Replace | |
Hydraulic Operating Troubles |
||
| Hydraulic pump fails to deliver sufficient volume | Insufficient engine speed | Adjust THROTTLE control handle for a TACHOURMETER reading of 2000 RPM. |
| Incorrect setting of pump volume control | Correct settng. | |
| PRESSURE BYPASS VALVE open | Close PRESSURE BYPASS VALVE. | |
| Incorrect setting of HIGH PRESSURE RELIEF VALVE or COMPENSATOR CONTROL | Correct setting. | |
| Hydraulic pump fails to compensate | Improper adjustment of COMPENSATOR CONTROL | Correct setting. |
| Inoperative COMPENSATOR CONTROL | Replace COMPENSATOR CONTROL valve. | |
Table 5-1. Troubleshooting (cont’d)
Trouble |
Probable Cause |
Corrective Action |
Hydraulic Operating Troubles |
||
| Test stand fails to deliver sufficient pressure | HIGH PRESSURE RELIEF VALVE improperly set | Correct setting. |
| HIGH PRESSURE RELIEF VALVE malfunctioning | Replace defective valve. | |
| Incorrect COMPENSATOR CONTROL setting | Correct setting. | |
| PRESSURE BYPASS VALE open or leaking | Close if open; replace if leaking. | |
| Damaged or worn out hydraulic pump | Repair or replace. | |
| System pressure too high | HIGH PRESSURE RELIEF VALVE improperly adjusted | Correct setting. |
| Incorrect setting of COMPENSATOR CONTROL | Correct setting. | |
| HIGH PRESSURE RELIEF VALVE inoperative | Replace. | |
| COMPENSATOR inoperative | Repair or replace. | |
| GAGE PRESSURE shutoff valve | Check fully open. | |
| PRESSURE GAGE faulty | Replace. | |
| HIGH PRESSURE CHECK valve | Clean or replace. | |
| Pump excessive noise | Pump incorrectly being started or stopped under load | Follow pre-start and shutdown check list completely. |
| Fluid low level | Fill oil tank min ¾ full. | |
| Air entering system | Check all connections for tightness. | |
| Fluid too cold/viscosity too high | Allow to warm up. | |
| Pump is turning but not pumping (pressure less than 1000 PSI) | Defective hydraulic power unit | Check hydraulic power unit with submersible pump disconnected to ensure power unit is functioning properly. |
| Lack of liquid in pump | Pump inlet obstructed; clear debris from inlet or strainer. | |
| Pump not submerged; submerged pump to the oil-fill plug on bearing housing. | ||
| Ensure vent screw (if fitted) is not plugged. | ||
| Air trapped in pump volute | Lower pump into liquid while operating. | |
| Lay pump on side with discharge in 12 O’clock position to allow air to escape. | ||
| Hydraulic motor worn | Replace motor. | |
| Excessive wear on impeller | Replace worn parts. | |
Table 5-1. Troubleshooting (cont’d)
Trouble |
Probable Cause |
Corrective Action |
Hydraulic Operating Troubles |
||
| Pump not pumping and not turning (pressure more than 1000 PSI) | Hydraulic motor or bearing seized | Replace hydraulic motor or bearings. |
| Impeller jammed | Remove top cover and free/replace impeller. | |
| Pump is turning but not pumping (pressure more than 1000 PSI) | Discharge head too high | Lower discharge head. |
| Discharge hose kinked or plugged | Clear hose obstruction | |
Table 5-2. Preventive Maintenance Schedule
JOB |
INTERVAL (IN RUNNING HOURS) |
||||
Once after break-in (25 hours) |
Before each use |
Each 250 hours |
Each 500 hours |
Each 1000 hours |
|
| Change oil filter | · |
· |
|||
| Change fuel filter* | · |
||||
| Change engine oil | · |
· |
· |
||
| Check tension V-belts | · |
||||
| Check pre-filter | |||||
| Change pre-filter | · |
||||
| Check oil level in engine | · |
||||
| Check air cleaner (replace w/fault light) | · |
||||
| Check battery and cable connections | · |
||||
* Replace earlier if outside conditions require it
