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TRAINING SUPPORT PACKAGE (TSP) TSP Number 77W11F03 TSP Title Operate the 600-GPM Pump Task Number(s) / Title(s) 101-540-1048, OPERATE/PERFORM PMCS ON THE 600-GPM DIESEL WATER PUMP Effective Date 01 Oct 1999 Supersedes TSP(s) None TSP Users MOS 77W10 Water Treatment Specialist Proponent The proponent for this document is Quartermaster Center and School. Comments / Recommendations Send comments and recommendations directly to: Foreign Disclosure Restrictions This product has been reviewed by the product developers in coordination with the U. S. Army Combined Arms Support Command foreign disclosure authority. This product is releasable to military students from foreign countries on a case-by-case basis. DEPARTMENT OF THE ARMY TRAINING DIRECTORATE ATTN: ATCL-AQ 401First Street Suite 277 Ft. Lee, VA 23801-1511 1 PREFACE Purpose This Training Support Package provides the instructor with a standardized lesson plan for presenting instruction for: Task Number: 101-540-1048 Title: OPERATE/PERFORM PMCS ON THE 600-GPM DIESEL WATER PUMP Conditions: Given the requirement to operate the 600-GPM water pump, the soldier, as a member of a Tactical Water Distribution Team, must operate the 600-GPM pump. Wear MOPP 4 when operating and/or performing PMCS on the 600-GPM diesel water pump. Materials needed: a 600-GPM pump with an operational Tactical Water Distribution System (TWDS), a fire extinguisher, 15 gallons of fuel, 1 quart of oil, earplugs, TM 5-4320-303-10, and a pencil. Forms needed: DA Form 2404 and DA Form 1970. Standards: Perform before-, during-, and after-operation PMCS. Position the pump. Connect the pump. Operate the pump. Shut down the pump. Complete entries on DA Form 1970 for hours of operation and record on DA Form 2404 actions taken to correct deficiencies and shortcomings. Give the completed forms to immediate supervisor at the end of the shift. 2 This TSP Contains TABLE OF CONTENTS PAGE Preface ............................................................................................................................................. 2 Lesson Section I Administrative Data ..................................................................................... 4 Section II Introduction.................................................................................................. 7 Terminal Learning Objective - Operate the 600-GPM pump, perform PMCS, make appropriate entries on DA Form 2404 and correct any deficiencies, and observe environmental considerations. ...................................................................................... 7 Section III Presentation ................................................................................................ 9 Enabling Learning Objective A - Students will acquire knowledge on performing before-, during-, and afteroperations PMCS on the 600-GPM diesel water pump, completing entries on water reports, logs, and forms, and positioning and connecting the pumping assemblies. .......................... 9 Section IV Summary................................................................................................... 31 Section V Student Evaluation .................................................................................... 32 3 77W11F03 version TATS / Operate the 600-GPM Pump 01 Oct 1999 SECTION I. ADMINISTRATIVE DATA Course Number All Courses Including This Lesson 720-77W10 Task(s) Taught(*) or Supported 101-540-1048 (*) Reinforced Task(s) Task Number Task Title OPERATE/PERFORM PMCS ON THE 600-GPM DIESEL WATER PUMP Task Number 101-540-1066 101-540-1068 Academic Hours Course Title 77W10, WATER TREATMENT SPECIALIST, AIT COURSE Task Title MAINTAIN, ASSEMBLY/DISASSEMBLE THE TACTICAL WATER DISTRIBUTON SYSTEM (TWDS) HOSE LINE MAINTAIN, ASSEMBLE/DISASSEMBLE THE POTABLE WATER STORAGE/DISTRIBUTION SYSTEM (PWS/DS) The academic hours required to teach this TSP are as follows: IDT Hours/Methods Test Test Review Total Hours: Lesson Number 1.0 / Conference / Discussion .0 .0 1.0 Lesson Title Prerequisite Lesson(s) None Clearance Access Security Level: Unclassified Requirements: There are no clearance or access requirements for the lesson. 4 References Number Title Date TM 10-4320-30313 Operator's, Unit and Direct Support Maintenance Manual for Tactical Water Distribution Equipment System (TWDS) Set 10-Mile Segment, Models 06749-018381, 110-00-0000, 919 and 10 (NSN 4320-01122-3547)(4320-01168-0591)(4320-01168-0590) Pumping Assembly, Water, 600 GPM, Model 609-A (NSN 4320-01-184-7494), Pumping Assembly, Water, 600 GPM, Model 609-C (432001-261-6470) Pumping Assembly, Water, 600 GPM, Model US636HCCD-1 (4320-01-2016937)(This Item is Included on EM 0077) 30 Jun 1993 TM 10-4320-34410 Student Study Assignments Instructor Requirements 28 Feb 1994 None One primary instructor and one alternate per class if conference Additional Support Personnel Requirements None Equipment Required for Instruction Name Materials Required Additional Information Quantity None INSTRUCTOR MATERIALS: Training Support Package VGT (1-25) Lite Pro Projector Projector Video Data Viewing Screen STUDENT MATERIALS: Notepad 5 Expendable Pen/Pencil Trainee Guide Classroom, Training Area, and Range Requirements GENERAL INSTRUCTION BUILDING Ammunition Requirements Name Instructional Guidance NOTE: Before presenting this lesson, instructors must thoroughly prepare by studying this lesson and identified reference material. Student Qty Misc Qty None Ensure facilities and materials are ready prior to class time. Proponent Lesson Plan Approvals Name Mr. Harold A. Williams James Keener Rank GS-13 MAJOR 6 Position Chief, QM-PWD, TD Chief, WTD Date SECTION II. INTRODUCTION Method of Instruction: Conference / Discussion Instructor to Student Ratio is: 1:18 Time of Instruction: 0 hrs 5 mins Media: Group-paced Instruction Motivator The ability to operate the 600-GPM diesel water pump is necessary for the water treatment specialist to operate the TWDS hose line. NOTE: Show VGT 01. Terminal Learning Objective NOTE: Inform the students of the following Terminal Learning Objective requirements. At the completion of this lesson, you [the student] will: Action: Operate the 600-GPM pump, perform PMCS, make appropriate Conditions: Standards: Safety Requirements entries on DA Form 2404 and correct any deficiencies, and observe environmental considerations. Given classroom instruction, a student handout, and TM 10-4320303-13. In accordance with TM 10-4320-303-13. 1. No smoking in the classroom. 2. Keep aisles clear for hasty exits. 3. Identify and point out primary and alternate fire exits. 4. Observe all safety precautions. Risk Assessment Level Environmental Considerations Evaluation Low Army Regulation 200-1 delineates TRADOC responsibilities to integrate environmental requirements across DTLOMS and ensure all training procedures, materials, and doctrine include sound environmental practices and considerations. The Army's environmental vision is to be a national leader in environmental and natural resource stewardship for present and future generations as an integral part of all Army missions. This Training Support Package meets this standard. Refer students to the Student Evaluation Plan. 7 Instructional Lead-In The ability to operate the 600-GPM diesel water pump, in addition to knowledge of the TWDS components and their functions and the ability to lay out the TWDS hose line, is essential for the water treatment specialist to operate the TWDS. 8 SECTION III. PRESENTATION NOTE: Inform the students of the Enabling Learning Objective requirements. A. ENABLING LEARNING OBJECTIVE A 1. ACTION: Students will acquire knowledge on performing before-, during-, and afteroperations PMCS on the 600-GPM diesel water pump, completing entries on water reports, logs, and forms, and positioning and connecting the pumping assemblies. CONDITIONS: Given classroom instruction, a student handout, and TM 10-4320303-13. STANDARDS: In accordance with TM 10-4320-303-13. Learning Step / Activity 1. Discuss risk assessment and safety considerations. Method of Instruction: Instructor to Student Ratio: Time of Instruction: Media: Conference / Discussion 1:18 40 mins Group-paced Instruction NOTE: Show VGT 02. a. No smoking in the classroom. b. Keep aisles clear for hasty exits. c. Identify and point out primary and alternate fire exits. d. Observe all safety precautions. NOTE: Conduct a check on learning and summarize the learning activity. 2. Learning Step / Activity 2. Discuss characteristics and functions of the 600-GPM diesel water pump. Method of Instruction: Instructor to Student Ratio: Time of Instruction: Media: Conference / Discussion 1:18 0 hrs Group-paced Instruction NOTE: Show VGT 03 and 04. NOTE: Provide students with Student Handout #1. a. Characteristics. The Model 609-A Pumping Assembly is a diesel engine driven centrifugal pump mounted on a two wheel trailer. The 9 trailer has two tail lights that are controlled by the towing vehicle. The trailer is equipped with an inertia-actuated hydraulic brake system. It also has a manually operated park brake for each wheel. Control of each park brake is independent of the other. The trailer has two jacks at the rear and a tongue jack at the front. The jacks prevent the trailer from tipping when disconnected from the towing vehicle. b. Capabilities and features. 1) Output volume: 600 GPM at 350 ft. tdh. 2) Can be operated in manual mode, electric manual mode, and electric automatic mode. 3) Can be used as source pump or boost pump. NOTE: Show VGT 05. c. Functional description. 1) The pumping assembly has a centrifugal pump that is directconnected to the diesel engine by means of a flexible coupling. The pump speed (revolutions per minute [rpm]) is determined by the engine speed. When the pump is primed (filled with water), pump rotation creates centrifugal force that causes water to flow outward to the discharge outlet. The outward flow of water causes suction so that water is drawn into the pump through the suction inlet. The volume of water flow and the discharge pressure are related to the pump speed. Decreasing the engine speed, and thus the pump speed, will decrease the water discharge volume and pressure. If operating at less than maximum volume and pressure, increasing the engine speed will increase the pump output. The pumping assembly has controls that sense the suction and discharge pressures. When operated in an automatic mode, the controls adjust the engine speed as needed to regulate the pump output. 2) Source or lead pump. When operated as a source or lead pump, the pumping assembly draws water from a large source, such as a lake or stream or a storage facility that is supplied by wells, water purification units, or desalination operations. If operated singly as a source pump, the water is fed to another storage facility. If operated as a lead pump, the water is fed down line through a hose line or pipe line to a boost pump. 3) Boost pump. When operated as a boost pump, the pumping assembly draws water from a hose line or pipe line and feeds it down line to the next boost pump or to a storage facility. Operated manually during startup, it can then be switched to an automatic mode for sustained operation. In automatic mode, engine speed is regulated automatically. 4) Engine and control electrical system. The engine starter and engine controls are supplied with direct current (dc) electric power by the pumping assembly battery or batteries and engine alternator. 10 5) Trailer lights. The trailer lights are supplied with 24 volts dc through an electrical cable connected to the towing vehicle. NOTE: Show VGT 06. 6) Trailer hydraulic brake system. The pumping assembly trailer is equipped with an inertial hydraulic brake system. The inertial hydraulic brake system automatically applied the brakes when the vehicle slows or stops or when the trailer accidentally uncouples from the towing vehicle. The brake system includes a drawbar ring or lunette, a hydraulic brake actuator, a master cylinder, a breakaway lever and chain, brake lines, wheel cylinders, brake shoes, and brake drums. a) Lunette. The lunette attaches to the towing vehicle. It is connected to the hydraulic brake actuator, which controls the master cylinder. When the towing vehicle moves forward, the lunette is pulled and the brakes are released. When the towing vehicle slows down, the trailer pushes the lunette against the towing vehicle, which causes the brakes to be applied. b) Hydraulic brake actuator. The hydraulic brake actuator connects the drawbar ring/lunette to the master cylinder. It transmits mechanical motion from the drawbar ring/lunette to the master cylinder. c) Master cylinder. The master cylinder receives mechanical motion from the hydraulic brake actuator and from the breakaway lever. It changes the mechanical motion into hydraulic pressure. The hydraulic pressure is transmitted through the brake lines. d) Breakaway lever and chain. The breakaway chain is attached to the breakaway lever and to the towing vehicle. It will pull the breakaway lever up if the trailer accidentally uncouples from the towing vehicle. When the breakaway lever is pulled up, it transmits mechanical motion to the master cylinder and applies brakes. e) Brake lines and wheel cylinders. The brake lines transmit hydraulic pressure from the master cylinder to the wheel cylinders. When pressurized, the wheel cylinders engage the brake shoes. f) Brake shoes and drums. When wheel cylinder pressure causes the brake shoes to be engaged, the brake shoes press against the brake drums. This causes friction that slows and stops the trailer. The brake shoes disengage from contact with the brake drums when the pressure is released. 11 NOTE: Conduct a check on learning and summarize the learning activity. 3. Learning Step / Activity 3. Discuss performing before-, during-, and after-operations PMCS. Method of Instruction: Instructor to Student Ratio: Time of Instruction: Media: Conference / Discussion 1:18 0 hrs Group-paced Instruction NOTE: Show VGT 07. NOTE: Provide students with Student Handout #2 and #3. a. Before-operations PMCS. 1) Exterior--Leaks. a) Inspect ground for evidence of leaks. b) If leaks are present, notify unit maintenance. c) Equipment is not fully mission capable if any evidence of leaks is present. 2) Trailer chassis. a) Frame. (1) Inspect all frame seam welds for damage. (2) If weld is damaged, notify unit maintenance. (3) Equipment is not fully mission capable if weld is damaged. b) Axle and springs. (1) Check for damage. (2) If damaged, notify unit maintenance. (3) Equipment is not fully mission capable if axle or spring is damaged. c) Lunette. (1) Check for damage. (2) If damaged, notify unit maintenance. (3) Equipment is not fully mission capable if lunette is damaged. d) Park brake levers. (1) Check that levers on both sides of trailer are locked. 12 (2) Check for proper adjustment. Adjust as needed. (3) Equipment is not fully mission capable if park brake(s) is damaged or inoperable. e) Rear jacks. (1) Check rear jacks for damage. Check that rear jacks are secured and operable. If required, operate rear jacks to level trailer. (2) If rear jack is damaged or not operable, notify unit maintenance. (3) Equipment is not fully mission capable if rear jack is damaged or not operable. f) Tongue jack. (1) Check tongue jack, supports, and welds for damage. If damaged, notify unit maintenance. (2) Check that jack is secured and jack is operable. If needed, operate tripod jack to level trailer. If not operable, notify unit maintenance. (3) Equipment is not fully mission capable if tongue jack is inoperable or tripod is damaged. g) Safety/breakaway chains and intervehicular cable. (1) Check for damaged/broken chains. (2) Check intervehicular cable for damaged connector and broken pins. (3) If chain is damaged or broken or intervehicular cable is damaged or has broken pin(s), notify unit maintenance. (4) Equipment is not fully mission capable if chain is damaged or broken or intervehicular cable is damaged or has broken pin(s). NOTE: Show VGT 08. 3) Hood and panels. a) Check that hood and panels are secure. b) Check hood and side panel hinges and fasteners for damage. c) If damaged, notify unit maintenance. 4) Radiator. 13 a) Remove radiator cap and check coolant level. Fluid should be visible in radiator reservoir. Add coolant as required to raise coolant level into radiator filler neck. Install radiator cap. b) Check radiator exterior for damaged and blocked passages. If radiator is damaged or air passages are blocked, notify unit maintenance. c) Equipment is not fully mission capable if coolant level is low, radiator is damaged, or air passages are blocked. 5) Engine. a) Fuel lines. (1) Inspect lines for damage and leaks. (2) If line is damaged or leaking, notify unit maintenance. (3) Equipment is not fully mission capable if Class I, II, or III leak is present or fuel line is damaged. b) Oil lines. (1) Inspect lines for damage and leaks. (2) If line is damaged or leaking, notify unit maintenance. (3) Equipment is not fully mission capable if Class III leak is present or oil line is damaged. c) Oil dipstick. (1) Check level. If oil is at or below ADD mark on dipstick, remove cap from oil filler neck. Add oil as required to FULL mark on dipstick. Reference LO 10-4320-344-12. Install cap after adding oil. (2) Equipment is not fully mission capable if oil level is below ADD mark on dipstick or dipstick is missing. d) Primary fuel filter. (1) Open valve bottom and drain water and sediment. Close valve when fuel starts coming through outlet. (2) Equipment is not fully mission capable if Class I, II, or III leak is present or filters are cracked or damaged. e) Cooling system hoses. (1) Inspect for cracks, damage, and leaks. (2) Check for loose hose clamps. 14 (3) If hose is cracked, damaged, or leaks or clamp is loose, notify unit maintenance. (4) Equipment is not fully mission capable if Class III leak is present, hose is cracked or damaged, or hose clamp is loose. WARNING: Fumes from battery acid may cause explosion, which could result in personal injury. Keep sparks and open flame away from battery. Battery electrolyte contains sulfuric acid, which can cause severe burn. Handle batteries with care. If electrolyte should contact skin or clothing, rinse immediately with clean water. f) Battery box and cover--Check for damage. If damaged, notify unit maintenance. g) Battery and cables. (1) Remove cover. Check cables for corrosion, loose connections, and damage. Clean corrosion and tighten connections as required. (2) Check battery for cracks. (3) Remove battery caps and check fluid level. If fluid level is low, notify unit maintenance. Install battery caps and battery box cover. (4) Equipment is not fully mission capable if battery is cracked, fluid level is low, or battery cables are damaged. NOTE: Show VGT 09. h) Fan belt. (1) Check belt for wear and damage. (2) Check for 1/2-in. deflection at center of belt, between water pump and alternator. (3) If belt is worn, damaged, or not properly adjusted, notify unit maintenance. (4) Equipment is not fully mission capable if belt is worn, damaged, or not properly adjusted. i) Wiring harness. (1) Check for loose or damaged connections. (2) If connection is loose or damaged, notify unit maintenance. (3) Equipment is not fully mission capable if wiring is damaged to extent that pumping assembly does not operate. 15 j) Muffler. (1) Check for damage and loose clamps. (2) Tighten loose clamps. (3) If muffler is damaged, notify unit maintenance. (4) Equipment is not fully mission capable if muffler is damaged. k) Air cleaner. (1) Check for damage. (2) Check for and tighten loose clamps. (3) Check if service indicator is red. (4) If air cleaner is damaged or if service indicator is red, notify unit maintenance. (5) Equipment is not fully mission capable if air cleaner is damaged or service indicator is red. 6) Control panel. a) Enclosure. (1) Check control panel box and cover for damage. (2) Check for damaged hinge or fastener. (3) If box, cover, hinge, or fastener is damaged, notify unit maintenance. b) Gauges and meters. (1) Check gauge and meter faces for cracked or broken glass. (2) If glass is cracked or broken, notify unit maintenance. (3) Equipment is not fully mission capable if glass is cracked or broken. c) Controls. (1) Check controls for free movement. If control binds, notify unit maintenance. (2) Equipment is not fully mission capable if control binds. NOTE: Show VGT 10. 7) Pump assembly. 16 a) Pump casing. (1) Check for damage and leaks. (2) If pump is damaged or leaking, notify unit maintenance. (3) Equipment is not fully mission capable if Class III leak is present or pump is damaged. b) Hoses and fittings. (1) Check hoses and fittings for damage and leaks. (2) If hose or fitting is damaged or leaking, notify unit maintenance. (3) Equipment is not fully mission capable if Class III leak is present or hose or fitting is damaged. WARNING: To prevent fire or explosion and possible personal injury or death, keep open flame and sparks away from fuel tank. 8) Fuel tank and gauge. a) Check fuel tank for cracks, damage, or leaks. b) Check fuel level indication on fuel gauge. If fuel is needed, remove fuel tank cap and add fuel. Install cap after adding fuel. c) Equipment is not fully mission capable if Class I, II, or III leak is present or fuel tank is cracked or damaged. NOTE: Show VGT 11. b. During-operations PMCS. 1) Exterior--Leaks. a) Inspect ground for evidence of leaks. b) If leaks are present, notify unit maintenance. c) Equipment is not fully mission capable if there is any evidence of leaks. 2) Engine. a) Fuel lines. (1) Inspect lines for damage and leaks. (2) If line is damaged or leaking, notify unit maintenance. 17 (3) Equipment is not fully mission capable if Class I, II, or III leak is present or fuel line is damaged. b) Oil lines. (1) Inspect lines for damage and leaks. (2) If line is damaged or leaking, notify unit maintenance. (3) Equipment is not fully mission capable if Class III leak is present or oil line is damaged. c) Muffler. (1) Listen for excessive noise. (2) If muffler makes excessive noise, notify unit maintenance. d) Air cleaner. (1) Check if service indicator is red. If red, notify unit maintenance. (2) Equipment is not fully mission capable if air cleaner service indicator is red. 3) Control panel gauges and meters. a) Check gauge and meter faces for cracked or broken glass. b) If glass is cracked or broken, notify unit maintenance. c) Equipment is not fully mission capable if glass is cracked or broken. NOTE: Show VGT 12. 4) Pump assembly. a) Pump casing. (1) Check for leaks. (2) If pump is leaking, notify unit maintenance. (3) Equipment is not fully mission capable if Class III leak is present. b) Hoses and fittings. (1) Check hoses and fittings for leaks. (2) If hose or fitting is leaking, notify unit maintenance. (3) Equipment is not fully mission capable if Class III leak is present. 18 WARNING: Hot refueling of pumping assembly while it is operating poses a safety hazard and should not be attempted. Hot engine surfaces and sparks produced from the engine and control circuitry are possible sources of ignition. Severe personal injury or death and/or damage to the equipment may result. c) Fuel tank and gauge. (1) Check fuel tank for cracks, damage, or leaks. (2) Check fuel level indication on fuel gauge. If fuel is required, stop engine and allow to cool. Then remove fuel tank cap and add fuel. Install cap after adding fuel. (3) Equipment is not fully mission capable if Class I, II, or III leak is present or fuel tank is cracked or damaged. NOTE: Show VGT 13. c. After-operations PMCS. 1) Exterior--Leaks. a) Inspect ground for evidence of leaks. b) If leaks are present, notify unit maintenance. c) Equipment is not fully mission capable if any evidence of leaks is present on the ground. 2) Engine. a) Fuel lines. (1) Inspect lines for damage and leaks. (2) If line is damaged or leaking, notify unit maintenance. (3) Equipment is not fully mission capable if Class I, II, or III leak is present or fuel line is damaged. b) Oil lines. (1) Inspect lines for damage and leaks. (2) If line is damaged or leaking, notify unit maintenance. (3) Equipment is not fully mission capable if Class III leak is present or oil line is damaged. c) Oil dipstick. (1) Check level. If oil is at or below ADD mark on dipstick, remove cap from oil filler neck. Add oil as required to 19 FULL mark on dipstick. Reference LO 10-4320-344-12. Install cap after adding oil. (2) Equipment is not fully mission capable if oil level is below ADD mark on dipstick or dipstick is missing. d) Primary fuel filter. (1) Open valve bottom and drain water and sediment. Close valve when fuel starts coming through outlet. (2) Equipment is not fully mission capable if Class I, II, or III leak is present or filters are cracked or damaged. e) Cooling system hoses. (1) Inspect for leaks or damage. (2) If hose leaks or is damaged, notify unit maintenance. (3) Equipment is not fully mission capable if Class III leak is present or hose is damaged. f) Air cleaner. (1) Check if service indicator is red. If red, notify unit maintenance. (2) Equipment is not fully mission capable if air cleaner service indicator is red. NOTE: Show VGT 14. 3) Control panel. a) Gauges and meters. (1) Check gauge and meter faces for cracked or broken glass. (2) If glass is cracked or broken, notify unit maintenance. (3) Equipment is not fully mission capable if glass is cracked or broken. b) Controls. (1) Check controls for free movement. If control binds, notify unit maintenance. (2) Equipment is not fully mission capable if control binds. WARNING: To prevent fire or explosion and possible personal injury, keep open flame and sparks away from fuel tank. CAUTION: To prevent condensation, fill tank after operation. 20 4) Fuel tank and gauge. a) Check fuel tank for cracks, damage, and leaks. b) Check fuel level indication on fuel gauge. If fuel is required, remove fuel tank cap and add fuel. Install cap after adding fuel. c) Equipment is not fully mission capable if Class I, II, or III leak is present or fuel tank is cracked or damaged. 5) Trailer chassis--Safety/breakaway chains and intervehicular cable. a) Check for damaged/broken safety and breakaway chains. b) Check intervehicular cable for damaged connector and broken pins. c) If chain is damaged or broken or intervehicular cable connector is damaged or has broken pin(s), notify unit maintenance. d) Equipment is not fully mission capable if chain is damaged or broken or intervehicular cable connector is damaged or has broken pin(s). d. Log all actions/deficiencies on DA Form 2404. e. Give form to supervisor at the end of the shift. NOTE: Conduct a check on learning and summarize the learning activity. 4. Learning Step / Activity 4. Discuss positioning and connecting the pumping assemblies. Method of Instruction: Instructor to Student Ratio: Time of Instruction: Media: Conference / Discussion 1:18 0 hrs Group-paced Instruction NOTE: Show VGT 15. a. Site location. 1) Site requirements will be based on the needs of the system in which the pumping assembly is to be used. The pumping assemblies are components of a Tactical Water Distribution Equipment System (TWDS). When used as a source pumping station, the site location will be determined by the location of the water source. When used as boost pumping station(s), the spacing and location(s) will be determined by the configuration of the line (hose line or pipe line) to which the pumping assembly is connected. For all requirements, the site should be as level as possible and must be capable of being traversed by the vehicle used to tow the pumping assembly. 21 2) Select a level site not more than 25 feet above the water supply. a) Clean and clear the site. b) Ensure the surface is firm. 3) Position pump as close as possible to source, making sure there is enough room on all sides to operate and ventilate the unit. NOTE: Show VGT 16. b. Assembly and preparation of pumping assemblies. 1) Use a suitable vehicle to tow pumping assembly to the installation site. 2) Place park brake lever(s) (5) in lock position. 3) Disconnect intervehicular cable (6) from mating receptacle (2) on tow vehicle (7). NOTE: Tongue jack may be equipped with a double-posted front jack or a front tripod. If equipped with a front tripod, go to step 5). NOTE: Show VGT 17. 4) If equipped with a double-posted front jack, perform the following: a) Disconnect double-posted front jack (6) from travel position by removing pin (2) and sliding post (4 or 5) from sleeve (3). b) Slip upper post (4) over sleeve (3) on front right side of trailer (7). c) Turn double-posted front jack (6) to vertical position. Align holes in post (4) and sleeve (3). Insert pin (2) through holes. d) Use turncrank (1) to lower jack (6). Jack trailer (7) to position where trailer lunette can be released from pintle hook (8) on tow vehicle (7). NOTE: Show VGT 18. 5) If trailer is equipped with front tripod, perform the following: a) Use turncrank (2) of tripod jack (1) to lower tripod (4). b) Raise trailer (3) to position where lunette (5) can be released from pintle hook on tow vehicle. 6) Disconnect safety chains and breakaway chain from tow vehicle. NOTE: Show VGT 19. 22 7) Reposition rear jacks from travel position to operating position as follows: a) For each jack (4) remove pin (1) that secures jack (4) in travel position. b) Swing jack (4) down to vertical position. Align holes in post (3) and sleeve (5). Insert pin (1) through holes. 8) Use turncranks (2) to lower jacks (4) until trailer (6) is secured in level position. NOTE: Show VGT 20. c. Unpacking--Model 609-A is shipped with a protective plywood cap. The protective plywood cap will have been removed by unit maintenance as part of the service upon receipt of material. If depreservation was needed, it will have been performed by unit maintenance. d. Installation of pumping assemblies--The suction port and discharge ports have a groove for connection to a grooved pipe coupling. Before operation, the suction and discharge ports must be connected to a hose line or pipe line. 1) Connect a hard-rubber hose to the suction inlet. 2) Connect a collapsible hose and check valve to the discharge outlet. e. Initial adjustments, checks, and self-test. CAUTION: Do not operate pump unless casing is filled with water to level of suction port. Operating a dry pump will cause overheating and damage unit. 1) The pumping assembly must be primed before initial startup. Once primed, repriming is not needed unless the pump loses prime because of a leak, hose line or pipe line break, or disconnection for maintenance. If the pumping assembly is to be operated as a standalone unit or source pump, manually prime the pump by filling it with water through the pump fill plug or priming port cap. If the pumping assembly is to be operated as a boost pump, it will receive priming water from the up line pump; but trapped air must be released through the discharge elbow. NOTE: Show VGT 21. 2) Priming of lead pump. a) Remove fill plug (1) or priming port cap (2). b) Fill pump casing (3) with water to bottom of fill plug hole. c) Install fill plug (1) or priming port cap (2). NOTE: Show VGT 22. 23 3) Priming of boost pump. CAUTION: Trapped air can cause hose line to collapse. Trapped air could cause pressure at down line pumping station(s) to fall below required suction pressure. To prevent damage to pump, vent air from hose line/pipe line. a) Turn petcock (2) on pump discharge elbow (1) until fully open. b) Notify operator of up line pumping station to begin pump operation. c) Listen for air escaping from petcock (2). d) Watch for start of water flow from petcock outlet (3). Close petcock (2) when water begins to flow from petcock outlet (3). NOTE: Conduct a check on learning and summarize the learning activity. 5. Learning Step / Activity 5. Discuss operating the 600-GPM diesel water pump. Method of Instruction: Instructor to Student Ratio: Time of Instruction: Media: Conference / Discussion 1:18 0 hrs Group-paced Instruction NOTE: Show VGT 23. NOTE: Provide students with Student Handout #4 and #5. a. The pumping assembly is capable of three modes of operation: manual, electric manual, and electric automatic. Use manual or electric manual mode for startup. Electric automatic mode may be used for sustained operation after startup. NOTE: Show VGT 24. b. Manual mode. Before starting Model 609-A, make sure that the pump has been primed. Start, operate, and shut down the pump as follows: 1) Perform before-operations PMCS. 2) Pull out MODE SWITCH (4) to unlock and set to MANUAL THROTTLE position. 3) Turn MANUAL THROTTLE (6) clockwise until it is fully in. 4) Turn FUEL RACK handle (7) counterclockwise to UNLOCK position. Pull handle fully out and turn clockwise to LOCK position. WARNING: To avoid hearing loss, hearing protection must be worn by personnel standing within 50 feet of operating pumping assembly. 24 CAUTION: To prevent damage to starter, allow 3 minutes between start attempts. NOTE: Engine alarm will sound if engine does not start within 30 seconds after ENGINE SWITCH is set to START position. 5) Push ENGINE SWITCH (5) to START position and hold for no more than 30 seconds or until engine starts. When engine starts, release ENGINE SWITCH (5). Engine will run at idle speed (1,000 revolutions per minute [rpm]). If engine alarm sounds: a) Set ENGINE SWITCH (5) to OFF position. b) Reset engine alarm by pushing ENGINE ALARM reset button (2). c) Wait 3 minutes, then repeat step 5). WARNING: If pump fails to take suction, pump can overheat. Overheated pump can cause severe burns. 6) Turn MANUAL THROTTLE (6) counterclockwise until pump takes suction, as indicated by pressure reading on PUMP SUCTION gauge (3) or decrease in engine speed as indicated on ENGINE TACHOMETER/HOURMETER (10). If pump fails to take suction after 3 minutes, shut down engine by setting ENGINE SWITCH (5) to off position. Notify unit maintenance. CAUTION: Down line pumping assemblies can be damaged if suction pressure falls below 10 pounds per square inch (psi). Any pumping assemblies may be damaged if discharge pressure rises above 150 psi. NOTE: Suction and discharge pressures will vary depending on operating conditions and engine speed. 7) Monitor suction pressure on PUMP SUCTION gauge (3). Also monitor discharge pressure on PUMP DISCHARGE gauge (1). If suction pressure falls below 10 psi on any down line pumping assemblies or discharge pressure rises above 150 psi on all pumping assemblies, reduce engine speed to regain proper pressure as follows: a) Turn MANUAL THROTTLE (6) clockwise to decrease engine speed. Decrease engine speed until reading on PUMP SUCTION gauge (3) and reading on PUMP DISCHARGE gauge (1) are within proper pressures. b) If required, reduce engine speed to idle (1,000 rpm on ENGINE TACHOMETER/HOURMETER [10]) until problem is corrected. 8) If required, use MANUAL THROTTLE (6) to control pump output by adjusting engine speed. Pump output is related to discharge pressure. Observe PUMP DISCHARGE gauge (1) and use MANUAL THROTTLE (6) to adjust engine speed. Turn MANUAL 25 THROTTLE (6) counterclockwise to increase speed and discharge pressure. Turn it clockwise to decrease speed and discharge pressure. 9) Perform during-operations PMCS. CAUTION: Engine can be damaged if engine operating temperature rises above 220 degrees F (104 degrees C) or oil pressure falls below 10 psi (69 kPa). NOTE: Engine alarm will sound if engine operating temperature rises above 220 degrees F (104 degrees C) or oil pressure falls below 10 psi (69 kPa). 10) If engine alarm (2) sounds: a) Check ENGINE COOLANT TEMPERATURE gauge (8) and ENGINE LUBE OIL PRESSURE gauge (9). If engine temperature or oil pressure is not within proper limits, shut down engine (step 11 below). b) Reset engine alarm by pushing ENGINE ALARM reset button (2). c) Notify unit maintenance. CAUTION: To prevent damage to engine, DO NOT shut down engine suddenly from full-load running. 11) To stop engine, turn MANUAL THROTTLE (6) clockwise to fully in position. Let engine idle for 2 or 3 minutes. Push engine switch (5) left to OFF position. Engine will shut down. 12) Turn FUEL RACK handle (7) counterclockwise and release. 13) Perform after-operations PMCS. c. Electric manual mode. Before starting pumping assembly 609-A, make sure that the pump has been primed. Start, operate, and shut down pump as follows: 1) Perform before-operations PMCS. 2) Turn PRESSURE REGULATOR SWITCH (8) counterclockwise to START position. 3) Turn ELECTRIC SPEED CONTROL (6) counterclockwise to IDLE position. 4) Pull out MODE SWITCH (4) and set to PRESSURE REGULATOR (NORMAL) position. 5) Turn MANUAL THROTTLE (7) clockwise until it is fully in. 6) Turn FUEL RACK handle (9) left to UNLOCK position. Push handle fully in and turn right to LOCK position. 26 WARNING: To avoid hearing loss, hearing protection must be worn by personnel standing within 50 feet of operating pumping assembly. CAUTION: To prevent damage to starter, allow 3 minutes between start attempts. NOTE: Engine alarm will sound if engine does not start within 30 seconds after ENGINE SWITCH is set to START position. 7) Push ENGINE SWITCH (5) right to START position and hold for no more than 30 seconds or until engine starts. When engine starts, release ENGINE SWITCH (5). Engine will run at idle speed (1,000 rpm). If engine alarm sounds: a) Set ENGINE SWITCH (5) to OFF position. b) Reset engine alarm by pushing ENGINE ALARM reset button (2). c) Wait 3 minutes, then repeat step 7). 8) Turn MANUAL THROTTLE (7) counterclockwise until it is fully out. 9) Set PRESSURE REGULATOR SWITCH (8) to ELECTRIC position. WARNING: If pump fails to take suction, pump can overheat. Overheated pump can cause severe burns. 10) Turn ELECTRIC SPEED CONTROL (6) clockwise until pump takes suction, as indicated by pressure reading on PUMP SUCTION gauge (3) or decrease in engine speed as indicated on ENGINE TACHOMETER/HOURMETER (12). If pump fails to take suction after 3 minutes, shut down engine (step 15). Notify unit maintenance. CAUTION: Down line pumping assemblies can be damaged if suction pressure falls below 10 psi. Any pumping assembly may be damaged if discharge pressure rises above 150 psi. NOTE: Suction and discharge pressures will vary depending on operating conditions and engine speed. 11) Monitor suction pressure on PUMP SUCTION gauge (3). Also, monitor discharge pressure on PUMP DISCHARGE gauge (1). If suction pressure falls below 10 psi or discharge pressure rises above 150 psi, reduce engine speed to regain proper pressure as follows: a) Turn ELECTRIC SPEED CONTROL (6) counterclockwise to decrease engine speed. Decrease engine speed until reading on PUMP SUCTION gauge (3) or reading on PUMP DISCHARGE gauge (1) are within proper pressures. b) If required, reduce engine speed to idle (1,000 rpm on ENGINE TACHOMETER/HOURMETER [10]) until problem is corrected. 27 12) If required, use ELECTRIC SPEED CONTROL (6) to control pump output by adjusting engine speed. Pump output is related to discharge pressure. Observe PUMP DISCHARGE gauge (1) and use ELECTRIC SPEED CONTROL (6) to adjust engine speed. Turn ELECTRIC SPEED CONTROL (6) clockwise to increase speed and discharge pressure. Turn ELECTRIC SPEED CONTROL (6) counterclockwise to decrease speed and discharge pressure. 13) Perform during-operations PMCS. CAUTION: Engine can be damaged if engine operating temperature rises above 220 degrees F (104 degrees C) or oil pressure falls below 10 psi (69 kPa). NOTE: Engine alarm will sound if engine operating temperature rises above 220 degrees F (104 degrees C) or oil pressure falls below 10 psi (69 kPa). 14) If engine alarm (2) sounds: a) Check ENGINE COOLANT TEMPERATURE gauge (10) and ENGINE LUBE OIL PRESSURE gauge (11). If engine temperature or oil pressure is not within proper limits, shut down engine (step 15 below). b) Reset engine alarm by pushing ENGINE ALARM reset button (2). c) Notify unit maintenance. CAUTION: To prevent damage to engine, DO NOT shut down engine suddenly from full-load running. 15) To stop engine, turn ELECTRIC SPEED CONTROL (6) counterclockwise to idle position. Let engine idle for 2 or 3 minutes. Push ENGINE SWITCH (5) to OFF position. Engine will shut down. 16) Turn FUEL RACK handle (7) counterclockwise and release. 17) Perform after-operations PMCS. d. Electric automatic mode. Start, operate, and shut down Model 609-A as follows: CAUTION: During startup, all pumping assemblies should be operated in manual or electric manual modes. 1) Perform before-operations PMCS. 2) Turn PRESSURE REGULATOR SWITCH counterclockwise to START position. 3) Turn ELECTRIC SPEED CONTROL counterclockwise to IDLE position. 28 4) Pull out MODE SWITCH and set to PRESSURE REGULATOR (NORMAL) position. 5) Turn MANUAL THROTTLE clockwise until it is fully in. 6) Turn FUEL RACK handle left to UNLOCK position. Push handle fully in and turn right to LOCK position. WARNING: To avoid hearing loss, hearing protection must be worn by personnel standing within 50 feet of operating pumping assembly. CAUTION: To prevent damage to starter, allow 3 minutes between start attempts. NOTE: Engine alarm will sound if engine does not start within 30 seconds after ENGINE SWITCH is set to START position. 7) Push ENGINE SWITCH right to START position and hold for no more than 30 seconds or until engine starts. When engine starts, release ENGINE SWITCH. Engine will run at idle speed (1,000 rpm). If engine alarm sounds: a) Set ENGINE SWITCH to OFF position. b) Reset engine alarm by pushing ENGINE ALARM reset button. c) Wait 3 minutes, then repeat step 7). 8) Turn MANUAL THROTTLE counterclockwise until it is fully out. 9) Set PRESSURE REGULATOR SWITCH to ELECTRIC position. WARNING: If pump fails to take suction, pump can overheat. Overheated pump can cause severe burns. 10) Turn ELECTRIC SPEED CONTROL clockwise until pump takes suction, as indicated by pressure reading on PUMP SUCTION gauge or decrease in engine speed as indicated on ENGINE TACHOMETER/HOURMETER. If pump fails to take suction after 3 minutes, shut down engine (step 14). Notify unit maintenance. 11) Turn PRESSURE REGULATOR SWITCH (4) clockwise to AUTO position. Engine speed is now automatically controlled by the pressure regulator. The pressure regulator provides 150 psi discharge pressure at suction pressures of 20 to 120 psi. 12) Perform during-operations PMCS. CAUTION: Engine can be damaged if engine operating temperature rises above 220 degrees F (104 degrees C) or oil pressure falls below 10 psi (69 kPa). NOTE: Engine alarm will sound if engine operating temperature rises above 220 degrees F (104 degrees C) or oil pressure falls below 10 psi (69 kPa). 29 13) If engine alarm sounds: a) Check ENGINE COOLANT TEMPERATURE gauge (5) and ENGINE LUBE OIL PRESSURE gauge (6). If engine temperature or oil pressure is not within proper limits, shut down engine (step 14). b) Reset engine alarm by pushing ENGINE ALARM reset button (1). c) Notify unit maintenance. CAUTION: To prevent damage to engine, DO NOT shut down engine suddenly from full-load running. 14) To stop engine, turn ELECTRIC SPEED CONTROL (3) counterclockwise to idle position. Let engine idle for 2 or 3 minutes. Push ENGINE SWITCH (2) to OFF position. Engine will shut down. 15) Perform after-operations PMCS. NOTE: Conduct a check on learning and summarize the learning activity. CHECK ON LEARNING: Conduct a check on learning and summarize the ELO. 30 SECTION IV. SUMMARY Method of Instruction: Conference / Discussion Instructor to Student Ratio is: 1:18 Time of Instruction: 0 hrs 5 mins Media: Group-paced Instruction Review / Summarize Lesson NOTE: Show VGT 25. The following key points were discussed within the lesson unit: a. Characteristics And Functions Of The 600-GPM Diesel Water Pump b. Before-, During-, And After-Operations PMCS c. Positioning And Connecting The Pumping Assemblies d. Operating The 600-GPM Diesel Water Pump Check on Learning Determine if the students have learned the material presented by soliciting student questions and explanations. Ask the students questions and correct misunderstandings. 1) What is the function of the master cylinder of the 600-GPM diesel water pump trailer hydraulic brake system? (The master cylinder receives mechanical motion from the hydraulic brake actuator and from the breakaway lever. It changes the mechanical motion into hydraulic pressure. The hydraulic pressure is transmitted through the brake lines.) 2) What components of the trailer chassis should be checked or inspected during before-operations PMCS on the 600-GPM diesel water pump? (Frame, axles and springs, lunette, park brake levers, rear jacks, tongue jack, safety/breakaway chains, and intervehicular cable.) 3) What components of the engine should be checked or inspected during before-operations PMCS on the 600-GPM diesel water pump? (Fuel lines, oil lines, oil dipstick, primary fuel filter, cooling system hoses, battery box and cover, battery and cables, fan belt, wiring harness, muffler, and air cleaner.) 4) What are the site requirements for the 600-GPM diesel water pump? (The site should be level, clean, clear, firm, as close as possible to the source with enough room on all sides to operate and ventilate the unit, and not more than 25 feet above the water supply.) 31 SECTION V. STUDENT EVALUATION NOTE: Describe how the student must demonstrate accomplishment of the TLO standard. Refer student to the Student Evaluation Plan. Testing Requirements The student must score a "GO" for each item on the "GO/NO GO" checklist to receive a "GO" for the practical exercise. The student must meet the requirements of this lesson by achieving a passing score on the End of Annex Examination. NOTE: Rapid, immediate feedback is essential to effective learning. Schedule and provide feedback on the evaluation and any information to help answer students' questions about the test. Provide remedial training as needed. Feedback Requirement 32