OPERATOR MAINTENANCE ADVANCED AVIATION FORWARD AREA REFUELING SYSTEM MODEL M100A1 REPLACE UNISEX COUPLING FACE SEAL/DUST CAP SEAL
OPERATOR, UNIT, DIRECT SUPPORT AND GENERAL SUPPORT MAINTENANCE ADVANCED AVIATION FORWARD AREA REFUELING SYSTEM MODEL M100A1 GENERAL INFORMATION
DESTRUCTION OF MATERIEL TO PREVENT ENEMY USE
Quality of Material -815120019
CHAPTER 1 DESCRIPTION AND THEORY OF OPERATION FOR ADVANCED AVIATION FORWARD AREA REFUELING SYSTEM
EQUIPMENT DESCRIPTION AND DATA -815120023
LOCATION AND DESCRIPTION OF MAJOR COMPONENTS
Pump-Engine Module -815120025
Engine Module
Liquid Fuel Filter-Separator
Accessory Module -815120028
Fuel Delivery Equipment
Figure 5. Fuel Delivery Equipment
Figure 6. D-1 Nozzle Assembly
Figure 8. Oil/Fuel Servicing Nozzle
Figure 10. Single Two-Inch Unisex Coupling-Inlet Combinations
Figure 12. Valved Elbow Coupling
Auxiliary Pump Module
TRICON Containers
Fuel Spill Kit
Pressure Control -815120038
Table 1. Equipment Data
Table 1. Equipment Data (Continued) -815120040
Table 1. Equipment Data (Continued) -815120041
Table 1. Equipment Data (Continued) -815120042
Table 1. Equipment Data (Continued) -815120043
Table 1. Equipment Data (Continued) -815120044
Table 1. Equipment Data (Continued) -815120045
Table 1. Equipment Data (Continued) -815120046
THEORY OF OPERATION -815120047
PUMPING SUBSYSTEM
Figure 3. Liquid-Fuel Filter Separator
POWER SUBSYSTEM
ELECTRICAL SUBSYSTEM
Figure 5. Defueling Subsystem
CHAPTER 2 OPERATOR INSTRUCTIONS FOR ADVANCED AVIATION FORWARD AREA REFUELING SYSTEM
DESCRIPTION AND USE OF OPERATOR CONTROLS AND INDICATORS -815120055
Table 2. Electrical Connection Panel Controls and Connectors
Table 3. Pressure Control Controls
OPERATOR MAINTENANCE ADVANCED AVIATION FORWARD AREA REFUELING SYSTEM MODEL M100A1 OPERATOR'S PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) INTRODUCTION
LEAKAGE CRITERIA
OPERATOR MAINTENANCE ADVANCED AVIATION FORWARD AREA REFUELING SYSTEM MODEL M100A1 OPERATOR'S PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) PROCEDURES
Table 1. Operator's Preventive Maintenance Checks and Services for AAFARS
Table 1. Operator's Preventive Maintenance Checks and Services for AAFARS (Continued) -815120063
Table 1. Operator's Preventive Maintenance Checks and Services for AAFARS (Continued) -815120064
Table 1. Operator's Preventive Maintenance Checks and Services for AAFARS (Continued) -815120065
Table 1. Operator's Preventive Maintenance Checks and Services for AAFARS (Continued) -815120066
Table 1. Operator's Preventive Maintenance Checks and Services for AAFARS (Continued) -815120067
Table 1. Operator's Preventive Maintenance Checks and Services for AAFARS (Continued) -815120068
Table 1. Operator's Preventive Maintenance Checks and Services for AAFARS (Continued) -815120069
Table 1. Operator's Preventive Maintenance Checks and Services for AAFARS (Continued) -815120070
Table 1. Operator's Preventive Maintenance Checks and Services for AAFARS (Continued) -815120071
Table 1. Operator's Preventive Maintenance Checks and Services for AAFARS (Continued) -815120072
Table 1. Operator's Preventive Maintenance Checks and Services for AAFARS (Continued) -815120073
OPERATOR, UNIT, DIRECT SUPPORT AND GENERAL SUPPORT MAINTENANCE ADVANCED AVIATION FORWARD AREA REFUELING SYSTEM MODEL M100A1 OPERATION UNDER USUAL CONDITIONS
Figure 1. AAFARS Emplacement
SYSTEM ASSEMBLY AND PREPARATION FOR USE
Figure 2. Fuel Contamination Test Kit
Position fuel drums (figure 1, 2) on spill containment unit (1).
Figure 3. API Specific Gravity Determination
Figure 4. Pump-Engine Emplacement
Figure 5. 2" Unisex Non-Valved Coupling to 2" Male Camlock Adapter Assembly
Install engine module in pump-engine module.
Establish recirculation path.
Position one nozzle kit at each fueling point.
OPERATING PROCEDURES
Perform normal electric engine start.
Figure 6. Manual Engine Start
Verify that pump outlet hose pressurizes (hose expands).
Test for undissolved water in aviation fuel (AQUA GLO Test).
Figure 7. Fuel Contamination Test Kit
Figure 8. Undissolved Water Test
Sampling
Rating Procedure
Reporting
Figure 9. Particulate Fuel Contamination Test
Perform particulate contamination fuel test.
Periodically monitor condition of the fuel transfer pump discharge hose.
To change from use of a D-1 nozzle to a CCR nozzle during refueling operations:
Figure 10. Defueling Liquid Fuel Filter-Separator
Figure 11. Defueling System Fuel Hoses
Remove condensation from fuel lines.
With the fuel transfer pump
Defuel system fuel hoses.
NORMAL SYSTEM SHUTDOWN
PREPARATION FOR MOVEMENT
PREPARATION FOR MOVEMENT (Continued) -815120107
PREPARATION FOR MOVEMENT (Continued) -815120108
OPERATOR MAINTENANCE ADVANCED AVIATION FORWARD AREA REFUELING SYSTEM MODEL M100A1 SYSTEM COMPONENT REPLACEMENT
REPLACE ACCESSORY MODULE
REPLACE LIQUID FUEL FILTER-SEPARATOR
Illustration -815120112
OPERATOR, UNIT, DIRECT SUPPORT AND GENERAL SUPPORT MAINTENANCE ADVANCED AVIATION FORWARD AREA REFUELING SYSTEM MODEL M100A1 OPERATION UNDER UNUSUAL CONDITIONS
Engine Cold Start
OPERATION IN RAIN
STOWAGE AND DECAL/DATA PLATE GUIDE
Figure 2. Pump Engine Module Decals and Data Plates
Figure 3. Engine Module Decals and Data Plates
Figure 4. Accessory Module Data Plates (Sheet 1 of 3)
Figure 4. Accessory Module Data Plates (Sheet 2 of 3)
Figure 4. Accessory Module Data Plates (Sheet 3 of 3)
Figure 5. Accessory Module Decals
Figure 6. Auxiliary Pump Decals
Figure 7. Liquid Fuel Filter-Separator Decals and Data Plates
Figure 8. CCR Nozzle Decals and Data Plate
Figure 10. Decals Discharge Fitting Kit, P/N 532606-01-01
Figure 12. Decals Discharge Hose Kit, P/N 532607-01-01
Figure 14. Decals and Data Plates Drum Fitting Kit, P/N 532612-01-01
Figure 15. Decals Drum Fitting Kit, P/N 532612-01-02
Figure 17. Decals Discharge Hose Kit, P/N 532605-01-01
Figure 19. Decals Discharge Hose Kit, P/N 532603-01-01
Figure 21. Decals and Data Plates Fuel Test Kit, P/N 532636-01-01 (Sheet 1 of 2)
Figure 21. Decals Fuel Test Kit, P/N 532636-01-01 (Sheet 2 of 2)
Figure 22. Decals and Data Plates Manual Starter Kit, P/N 532801-01-01
Figure 23. Recirculation Manifold
Figure 24. TRICON 1 Data Plate
Figure 25. TRICON 2 Decals and Data Plate
ON-VEHICLE EQUIPMENT LOADING PLAN
Figure 1. UH-60 Loading Arrangement (Sheet 2)
HMMWV WITH CARGO TRAILER LOADING PLAN
CH-47 HELICOPTER LOADING PLAN
5-TON CARGO TRUCK LOADING PLAN
CHAPTER 3 OPERATOR TROUBLESHOOTING FOR ADVANCED AVIATION FORWARD AREA REFUELING SYSTEM
OPERATOR MAINTENANCE ADVANCED AVIATION FORWARD AREA REFUELING SYSTEM MODEL M100A1 OPERATOR TROUBLESHOOTING PROCEDURES
Table 1. Operator Troubleshooting
Table 1. Operator Troubleshooting (Continued) -815120149
Table 1. Operator Troubleshooting (Continued) -815120150
CHAPTER 4 UNIT TROUBLESHOOTING FOR ADVANCED AVIATION FORWARD AREA REFUELING SYSTEM
UNIT MAINTENANCE ADVANCED AVIATION FORWARD AREA REFUELING SYSTEM MODEL M100A1 UNIT TROUBLESHOOTING PROCEDURES
ENGINE
FUEL TRANSFER PUMP
FILTER SEPARATOR
CONTROL BOX
System Electrical Schematic
FUEL DRUM -815120159
TRICON CONTAINER -815120160
PRESSURE CONTROL -815120161
CHAPTER 5 DIRECT SUPPORT TROUBLESHOOTING FOR ADVANCED AVIATION FORWARD AREA REFUELING SYSTEM
DIRECT SUPPORT MAINTENANCE ADVANCED AVIATION FORWARD AREA REFUELING SYSTEM MODEL M100A1 DIRECT SUPPORT TROUBLESHOOTING PROCEDURES
FUEL DRUM -815120166
TRICON CONTAINER -815120167
CHAPTER 6 OPERATOR MAINTENANCE FOR ADVANCED AVIATION FORWARD AREA REFUELING SYSTEM
OPERATOR MAINTENANCE ADVANCED AVIATION FORWARD AREA REFUELING SYSTEM MODEL M100A1 REPLACE UNISEX COUPLING FACE SEAL/DUST CAP SEAL
EMERGENCY REPAIR, FUEL DRUM CASING
Illustration -815120174
CHAPTER 7 UNIT MAINTENANCE FOR ADVANCED AVIATION FORWARD AREA REFUELING SYSTEM
UNIT MAINTENANCE ADVANCED AVIATION FORWARD AREA REFUELING SYSTEM MODEL M100A1 SERVICE UPON RECEIPT
PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) INTRODUCTION
GENERAL
Table 1. Unit Preventive Maintenance Checks and Services (PMCS) for AAFARS
Table 1. Unit Preventive Maintenance Checks and Services (PMCS) for AAFARS (Continued) -815120182
Table 1. Unit Preventive Maintenance Checks and Services (PMCS) for AAFARS (Continued) -815120183
Table 1. Unit Preventive Maintenance Checks and Services (PMCS) for AAFARS (Continued) -815120184
REPLACE ENGINE OIL FILTER
INSTALLATION -815120186
REPLACE ENGINE FUEL FILTER
INSTALLATION -815120188
REPLACE PUMPAGE OVER TEMPERATURE SENSOR/SENSOR CABLE (W103)
REMOVAL -815120190
REPLACE ENGINE AIR FILTER ELEMENT
REPLACE ENGINE AIR FILTER HOSE
REPLACE FUEL TRANSFER PUMP PN 8424/PN 60975-5 INLET QUICK DISCONNECT FITTING PACKING
INSTALLATION -815120196
INTRODUCTION TO FUEL DELIVERY EQUIPMENT MAINTENANCE
REPLACE TWO-INCH VALVED UNISEX COUPLING
INSTALLATION -815120200
REPLACE THREE-INCH UNISEX COUPLING
INSTALLATION -815120202
REPLACE UNISEX COUPLING DUST CAP
INSTALLATION -815120204
REPLACE UNISEX COUPLING BUMPER
REPLACE UNISEX COUPLING LUGS
INSTALLATION -815120208
REPLACE TWO-INCH NON-VALVED UNISEX COUPLING
INSTALLATION -815120210
REPAIR TWO-INCH NON-VALVED UNISEX COUPLING
ASSEMBLY -815120212
REPLACE FUEL TRANSFER PUMP PN 8424/PN 60975-5
INSTALLATION -815120214
REPLACE FUEL TRANSFER PUMP PN 8424 DISCHARGE HOUSING O-RING
INSTALLATION -815120216
REPLACE FUEL TRANSFER PUMP PN 8424 DISCHARGE VALVE
REPLACE ENGINE MODULE CARRYING HANDLE
REPLACE ENGINE MODULE PULLEY GUARD
REPLACE ENGINE MODULE ALIGNMENT BOLTS
REPLACE CABLE ASSEMBLY W101
INSTALLATION -815120226
INSTALLATION (Cont.)
REPLACE STARTER
REPLACE FUEL PUMP
INSTALLATION -815120232
ADJUST ENGINE INTAKE AND EXHAUST VALVES
Illustration -815120234
REPLACE FUEL INJECTOR NOZZLE
INSTALLATION -815120236
REPLACE EXHAUST MANIFOLD
REPLACE INTAKE MANIFOLD
INSTALLATION -815120240
REPLACE DECOMPRESSION ARM O-RING
INSTALLATION -815120242
REPLACE BATTERY
INSTALLATION -815120244
REPLACE CONTROL BOX
INSTALLATION -815120246
REPLACE BATTERY CABLE W202
INSTALLATION -815120248
REPAIR BATTERY CABLE
ASSEMBLY -815120250
INSTALLATION -815120251
REPLACE CONTROL CABLE W201
INSTALLATION -815120254
REPAIR BATTERY HOLDDOWN
Illustration -815120256
DATA PLATE REPLACEMENT (TYPICAL)
REPLACE FILTER VESSEL COVER O-RING
REMOVAL -815120260
INSTALLATION (Figure 1)
Figure 2. Filter Vessel Cover Torque Pattern
REPLACE COALESCER ELEMENTS AND SEPARATOR ELEMENT
Figure 1. Coalescer and Separator Elements Removal
WATER PUMP START SWITCH (DS2) REPLACEMENT REMOVAL, INSTALLATION
REPLACE DIFFERENTIAL PRESSURE GAUGE AND/OR INLET AND OUTLET LINES
INSTALLATION OF INLET AND OUTLET LINES
REMOVAL OF DIFFERENTIAL PRESSURE GAUGE
REPLACE SIGHT GAUGE COMPONENTS
INSTALLATION -815120272
REPLACE FILTER SEPARATOR MANUAL VENT VALVE
Illustration -815120274
REPLACE FILTER SEPARATOR GRAVITY DRAIN PLUG
INSTALLATION -815120276
REPAIR OF CONTROL BOX
REPLACE CONTROL PANEL LAMP ASSEMBLIES/PANEL LIGHTS
Illustration -815120280
REPLACE PANEL LIGHTS DIMMER POTENTIOMETER R1
INSTALLATION -815120282
REPAIR EMERGENCY STOP SWITCH (S4)
INSTALLATION -815120284
REPLACE CONTROL PANEL TOGGLE SWITCHES
Illustration -815120286
REPLACE CAPACITOR C1
Illustration -815120288
REPLACE CIRCUIT BREAKERS CB1 OR CB2
Illustration -815120290
REPLACE RELAY K1
REPLACE VOLTAGE REGULATOR
Illustration -815120294
REPLACE CONTROL BOX VOLTMETER
REPLACE AUXILIARY PUMP
INSTALLATION -815120298
CLEAN AND REPLACE AUXILIARY PUMP INLET COMPONENTS
Illustration -815120300
REPLACE AUXILIARY PUMP ROTOR VANES
ASSEMBLY -815120302
REPAIR AUXILIARY PUMP
PUMP ASSEMBLY
PUMP ASSEMBLY-Continued
REPAIR CCR NOZZLE ASSEMBLY -815120307
Illustration -815120308
INSPECTION -815120309
REPLACE CCR NOZZLE UNISEX COUPLING
INSTALLATION -815120312
REPAIR D1-NOZZLE TWO-INCH NON-VALVED UNISEX COUPLING
DISASSEMBLY AND INSPECTION
ASSEMBLY -815120315
REPLACE D1-NOZZLE BONDING CABLE ASSEMBLY
REPLACE D1-NOZZLE HANDLE ASSEMBLY
ASSEMBLY -815120320
REPLACE D1-NOZZLE HOSE END REGULATOR
REMOVAL -815120322
INSTALLATION -815120323
REPAIR FUEL DRUM ADAPTER ASSEMBLY
ASSEMBLY -815120326
REPAIR TOWING YOKE
ASSEMBLY -815120328
REPAIR PRESSURE CONTROL
Figure 1. Pressure Control Diaphragm Valve
STOP CYCLING VALVE ASSEMBLY REMOVAL AND DISASSEMBLY
STOP CYCLING VALVE ASSEMBLY CLEANING, REPAIR, REASSEMBLY AND INSTALLATION
STOP CYCLING VALVE ASSEMBLY CLEANING, REPAIR, REASSEMBLY AND INSTALLATION (Cont.)
FILL CYCLING VALVE ASSEMBLY REMOVAL AND DISASSEMBLY
FILL CYCLING VALVE ASSEMBLY REMOVAL AND DISASSEMBLY (cont.)
PILOT VALVE TESTING
Figure 3. Pressure Control Testing
PILOT VALVE REMOVAL AND DISASSEMBLY (Refer to figure 4.)
Figure 5. Adjusting Pilot Valve Shut Off Pressure
PILOT VALVE CLEANING, INSPECTION AND REPAIR (Refer to figure 4.)
VENTURI REMOVAL AND DISASSEMBLY (Refer to figure 4.)
VENTURI ASSEMBLY AND INSTALLATION (Refer to figure 4.)
FEMALE COUPLING HALF REPLACEMENT (Refer to figure 2.)
MALE COUPLING HALF REPAIR (Refer to figure 2.)
REPLACE TRICON DOCUMENT HOLDER
INSTALLATION -815120346
REPLACE TRICON SEAL SET
INSTALLATION -815120348
INSTALLATION-Continued -815120349
INSTALLATION-Continued -815120350
INSTALLATION-Continued -815120351
INSTALLATION-Continued -815120352
REPLACE SPRING STARTER END CAP
INSTALLATION -815120354
PREPARATION FOR STORAGE OR SHIPMENT
PUMP-ENGINE MODULE -815120356
Preparation for Use After Storage/Shipment
ACCESSORY MODULE -815120358
AUXILIARY PUMP
FUEL DRUMS
SPECIAL INSTRUCTIONS FOR ADMINISTRATIVE STORAGE
ILLUSTRATED LIST OF MANUFACTURED ITEMS -815120363
Figure 1. Clamp, Grounding
Figure 2. Tube, Inlet, Filter-Separator
Figure 3. Tube, Outlet, Filter-Separator
Figure 4. TRICON 1
Figure 5. TRICON 2
CHAPTER 8 DIRECT SUPPORT MAINTENANCE FOR ADVANCED AVIATION FORWARD AREA REFUELING SYSTEM
DIRECT SUPPORT MAINTENANCE ADVANCED AVIATION FORWARD AREA REFUELING SYSTEM MODEL M100A1 REPLACE FUEL TRANSFER PUMP PN 60975-5 OUTLET FLAPPER VALVE/O-RINGS
Illustration -815120372
INSTALLATION -815120373
REPLACE FUEL TRANSFER PUMP PN 60975-5 INPUT SEALS
INSTALLATION
REPAIR FUEL TRANSFER PUMP PN 60975-5 ROTARY VANE PUMP
Illustration -815120378
ASSEMBLY -815120379
REPLACE FUEL TRANSFER PUMP PN 8424 INLET O-RING
INSTALLATION -815120382
REPLACE FUEL TRANSFER PUMP PN 8424 SHAFT SEAL ASSEMBLY/O-RINGS
REMOVAL -815120384
INSTALLATION -815120385
INSTALLATION - Continued
REPLACE FUEL TRANSFER PUMP PN 8424 VANE PUMP HOUSING O-RINGS
INSTALLATION -815120388
REPAIR OF FUEL TRANSFER PUMP PN 8424 ROTARY VANE PUMP
INSTALLATION -815120390
REPLACE FUEL TRANSFER PUMP PN 8424 IMPELLER-SHAFT ASSEMBLY
INSTALLATION -815120392
REPAIR THREE-INCH VALVED UNISEX COUPLING
DISASSEMBLY -815120394
INSPECTION -815120395
ASSEMBLY
REPAIR TWO-INCH VALVED UNISEX COUPLING
INSPECTION -815120398
ASSEMBLY -815120399
REPAIR CCR NOZZLE ASSEMBLY -815120401
DISASSEMBLY -815120402
DISASSEMBLY-Continued -815120403
DISASSEMBLY-Continued -815120404
DISASSEMBLY-Continued -815120405
DISASSEMBLY-Continued -815120406
DISASSEMBLY-Continued -815120407
INSPECTION -815120408
ASSEMBLY -815120409
ASSEMBLY-Continued -815120410
ASSEMBLY-Continued -815120411
ASSEMBLY-Continued -815120412
ASSEMBLY-Continued -815120413
ASSEMBLY-Continued -815120414
REPAIR D1-NOZZLE BODY ASSEMBLY
DISASSEMBLY -815120416
DISASSEMBLY-Continued -815120417
INSPECTION -815120418
ASSEMBLY -815120419
ASSEMBLY-Continued -815120420
REPAIR D1 NOZZLE HOSE END REGULATOR
DISASSEMBLY-
ASSEMBLY -815120423
ASSEMBLY (Cont.)
REPAIR FUEL DRUM ASSEMBLY
INSPECTION -815120426
ASSEMBLY -815120427
OPERATOR, UNIT, DIRECT SUPPORT AND GENERAL SUPPORT MAINTENANCE ADVANCED AVIATION FORWARD AREA REFUELING SYSTEM MODEL M100A1 MAINTENANCE TORQUE LIMITS
HEX NUT STRENGTH IDENTIFICATION
STANDARD TORQUE VALUES - ENGLISH SYSTEM
STANDARD TORQUE VALUES - ENGLISH SYSTEM (cont.)
DIRECT SUPPORT MAINTENANCE ADVANCED AVIATION FORWARD AREA REFUELING SYSTEM MODEL M100A1 WIRING DIAGRAMS
Figure 1. Control Panel Wiring Diagram (Sheet 1 of 2)
Figure 1. Control Panel Wiring Diagram (Sheet 2 of 2)
Figure 2. Cable Assembly W101 Wiring Diagram (Engine Wiring Harness)
Figure 3. Cable Assembly W102 Wiring Diagram (Engine Starter Cable)
Figure 4. Cable Assembly W103 Wiring Diagram (Pumpage Overtemperature Cable)
Figure 5. Cable Assembly W201 Wiring Diagram (Accessory Module Control Cable)
Figure 6. Cable Assembly W202 Wiring Diagram (Battery Power Cable)
CHAPTER 9 GENERAL SUPPORT MAINTENANCE FOR ADVANCED AVIATION FORWARD AREA REFUELING SYSTEM
GENERAL SUPPORT MAINTENANCE ADVANCED AVIATION FORWARD AREA REFUELING SYSTEM MODEL M100A1 ENGINE OVERHAUL INTRODUCTION
REMOVE ENGINE FROM ENGINE MODULE
Illustration -815120446
REMOVE ENGINE FROM ENGINE MODULE (cont.)
ENGINE DISASSEMBLY
REMOVE INTAKE MANIFOLD (Refer to figure 2.)
Figure 2. Intake Manifold Removal
REMOVE AND CLEAN OIL PAN. (Refer to figure 3.)
REMOVE ENGINE SHROUD, CYLINDER CASING AND GATES. (Refer to figure 4.)
Figure 4. Shroud, Cylinder Casing and Gates Removal
REMOVE STARTER (Refer to figure 5)
REMOVE FLYWHEEL/ALTERNATOR ROTOR AND STATOR. (Refer to figure 6.)
Figure 6. Flywheel and Alternator Removal
REMOVE FUEL FLOW SOLEOID. (Refer to figure 7.)
REMOVE VALVE COVERS (Refer to figure 8.)
REMOVE DECOMPRESSION LEVER. (Refer to figure 9.)
REMOVE INJECTION PUMP. (Refer to figures 10 and 11.)
Figure 10. Fuel System Components Removal
Figure 11. Injection Pump Removal
REMOVE FUEL PUMP (Refer to figure 12.)
REMOVE FUEL INJECTORS. (Refer to figure 13.)
REMOVE CYLINDER HEAD AND CYLINDER (Refer to figures 14 and 15.)
Figure 14. Cylinder Head Removal
Figure 15. Cylinder Removal
REMOVE PISTON AND RINGS. (Refer to figure 16.)
REMOVE AND CHECK OIL PUMP. (Refer to figure 17.)
Figure 17. Oil Pump Removal
REMOVE TIMING (PULLEY END) COVER. (Refer to figure 18.)
REMOVE GOVERNOR ASSEMBLY AND SPEED CONTROL (Refer to figures 19 and 20.)
Figure 19. Governor Removal
REMOVE CAMSHAFT AND VALVE TAPPETS. (Refer to figure 21.)
REMOVE REAR CRANKSHAFT SUPPORT. (Refer to figure 22.)
REMOVE CRANKSHAFT GEAR, CRANKSHAFT AND BEARINGS. (Refer to figure 23.)
Figure 23. Crankshaft Gear, Crankshaft and Bearings Removal
REMOVE OIL PRESSURE RELIEF VALVE. (Refer to figure 24.)
DISASSEMBLE CYLINDER HEAD. (Refer to figure 25.)
Figure 25. Cylinder Head Disassembly
ENGINE ASSEMBLY
Figure 1. Crankshaft Assembly Installation
Figure 2. Front Crankshaft Bearing Installation
Figure 3. Rear Crankshaft Support Installation
INSTALL OIL PRESSURE RELIEF VALVE (Refer to Figure 4.)
INSTALL PISTON RINGS (Refer to Figure 5)
Figure 5. Piston Ring Installation
CHECK CYLINDER (Refer to Figure 6.)
INSTALL PISTON ASSEMBLY AND CYLINDER (Refer to Figure 7.)
Figure 7. Piston Assembly Installation
INSTALL CAMSHAFT (Refer to Figures 8 and 9.)
Figure 9. Camshaft and Tappet Installation
INSTALL GOVERNOR ASSEMBLY AND SPEED CONTROL (Refer to Figures 10 and 11)
INSTALL GOVERNOR ASSEMBLY AND SPEED CONTROL (Refer to Figures 10 and 11) (cont.)
Figure 10. Governor and Speed Control Installation
INSTALL OIL PUMP (Refer to Figure 12.)
INSTALL TIMING (PULLEY END) COVER (Refer to Figure 13.)
CHECK PISTON PROTRUSION (Refer to Figure 14.)
ASSEMBLE CYLINDER HEAD (Refer to Figure 15)
ASSEMBLE CYLINDER HEAD (Refer to Figure 15) (Cont.)
Figure 15. Cylinder Head Repair and Assembly
INSTALL CYLINDER HEAD (Refer to Figures 16, 17, 18 and 19.)
Figure 16. Pushrod Measurement
Figure 18. Cylinder Head Installation
Figure 19. Cylinder Head Alignment
INSTALL FLYWHEEL/ALTERNATOR ROTOR AND STATOR (Refer to Figure 20.)
Figure 20. Flywheel/Alternator Installation
INSTALL INTAKE MANIFOLD (Refer to Figure 21.)
INSTALL EXHAUST MANIFOLD (Refer to Figure 22.)
INSTALL INJECTION PUMP (Refer to Figure 23.)
Figure 23. Install Injection Pump
INSTALL FUEL INJECTOR (Refer to Figure 24.)
Figure 24. Fuel Injector Installation
INSTALL FUEL PUMP (Refer to Figure 25.)
INSTALL VALVE COVERS (Refer to Figure 26.)
INSTALL DECOMPRESSION LEVER (Refer to Figure 27.)
INSTALL FUEL FLOW SOLENOID (Refer to Figure 28.)
Figure 28. Fuel Flow Solenoid Installation
INSTALL OIL PAN (Refer to Figure 29.)
Figure 29. Oil Pan Installation
INSTALL STARTER (Refer to Figure 30.)
INSTALL GATES, SHROUD AND OIL COOLER (Refer to Figure 31.)
Figure 31. Shroud, Gates and Oil Cooler Installation
INSTALL FLEXIBLE COUPLING ADAPTER AND GUARD TO ENGINE (Refer to Figure 32.)
INSTALL ENGINE IN ENGINE MODULE (Refer to Figure 33.)
Figure 33. Installation of Engine in Engine Module
ADJUST FUEL INJECTION PUMP. (Refer to Figure 34.)
Figure 34. Fuel Injection Pump Timing Adjustment
ADJUST ENGINE INTAKE AND EXHAUST VALVES (Refer to Figure 35.)
Figure 35. Valve Adjustment
INSTALL CASING (Refer to Figure 36.)
OVERHAUL FUEL TRANSFER PUMP PN 60975-7
DISASSEMBLY -815120536
Illustration -815120537
ASSEMBLY -815120538
ASSEMBLY Continued -815120539
ASSEMBLY Continued -815120540
CHAPTER 10 SUPPORTING INFORMATION FOR ADVANCED AVIATION FORWARD AREA REFUELING SYSTEM
OPERATOR, UNIT, DIRECT SUPPORT AND GENERAL SUPPORT MAINTENANCE ADVANCED AVIATION FORWARD AREA REFUELING SYSTEM MODEL M100A1 SUPPORTING INFORMATION REFERENCES
Regulations
SUPPORTING INFORMATION MAINTENANCE ALLOCATION CHART (MAC) INTRODUCTION
Explanation of Columns in the MAC
Explanation of Columns in the Tools and Test Equipment Requirements -815120547
SUPPORTING INFORMATION MAINTENANCE ALLOCATION CHART
Table 1. MAC for AAFARS M100A1
Table 1. MAC for AAFARS M100A1 (Continued) -815120551
Table 1. MAC for AAFARS M100A1 (Continued) -815120552
Table 1. MAC for AAFARS M100A1 (Continued) -815120553
Table 1. MAC for AAFARS M100A1 (Continued) -815120554
Table 1. MAC for AAFARS M100A1 (Continued) -815120555
Table 2. Tools and Test Equipment For AAFARS
SUPPORTING INFORMATION COMPONENTS OF END ITEM (COEI) AND BASIC ISSUE ITEM (BII) LISTS
Illsutration
Table 1. Components of End Item List
Table 2. Basic Issue Item List
SUPPORTING INFORMATION ADDITIONAL AUTHORIZATION LIST
SUPPORTING INFORMATION EXPENDABLE AND DURABLE ITEMS LIST
Table 1. Expendable and Durable Items List
SUPPORTING INFORMATION MANDATORY REPLACEMENT PARTS LIST
Table 1. Mandatory Replacement Parts List
Table 1. Mandatory Replacement Parts List (Continued) -815120567
Table 1. Mandatory Replacement Parts List (Continued) -815120568
Table 1. Mandatory Replacement Parts List (Continued) -815120569
SUPPORTING INFORMATION GLOSSARY
The Metric System and Equivalents
TM-10-4930-351-14 Advanced Aviation Forward Area Refueling System (AAFARS) Model M1001A1 Manual
OPERATOR, UNIT, DIRECT SUPPORT AND GENERAL SUPPORT MAINTENANCE ADVANCED AVIATION FORWARD AREA REFUELING SYSTEM MODEL M100A1 GENERAL INFORMATION
DESTRUCTION OF MATERIEL TO PREVENT ENEMY USE
Quality of Material -815120019
CHAPTER 1 DESCRIPTION AND THEORY OF OPERATION FOR ADVANCED AVIATION FORWARD AREA REFUELING SYSTEM
EQUIPMENT DESCRIPTION AND DATA -815120023
LOCATION AND DESCRIPTION OF MAJOR COMPONENTS
Pump-Engine Module -815120025
Engine Module
Liquid Fuel Filter-Separator
Accessory Module -815120028
Fuel Delivery Equipment
Figure 5. Fuel Delivery Equipment
Figure 6. D-1 Nozzle Assembly
Figure 8. Oil/Fuel Servicing Nozzle
Figure 10. Single Two-Inch Unisex Coupling-Inlet Combinations
Figure 12. Valved Elbow Coupling
Auxiliary Pump Module
TRICON Containers
Fuel Spill Kit
Pressure Control -815120038
Table 1. Equipment Data
Table 1. Equipment Data (Continued) -815120040
Table 1. Equipment Data (Continued) -815120041
Table 1. Equipment Data (Continued) -815120042
Table 1. Equipment Data (Continued) -815120043
Table 1. Equipment Data (Continued) -815120044
Table 1. Equipment Data (Continued) -815120045
Table 1. Equipment Data (Continued) -815120046
THEORY OF OPERATION -815120047
PUMPING SUBSYSTEM
Figure 3. Liquid-Fuel Filter Separator
POWER SUBSYSTEM
ELECTRICAL SUBSYSTEM
Figure 5. Defueling Subsystem
CHAPTER 2 OPERATOR INSTRUCTIONS FOR ADVANCED AVIATION FORWARD AREA REFUELING SYSTEM
DESCRIPTION AND USE OF OPERATOR CONTROLS AND INDICATORS -815120055
Table 2. Electrical Connection Panel Controls and Connectors
Table 3. Pressure Control Controls
OPERATOR MAINTENANCE ADVANCED AVIATION FORWARD AREA REFUELING SYSTEM MODEL M100A1 OPERATOR'S PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) INTRODUCTION
LEAKAGE CRITERIA
OPERATOR MAINTENANCE ADVANCED AVIATION FORWARD AREA REFUELING SYSTEM MODEL M100A1 OPERATOR'S PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) PROCEDURES
Table 1. Operator's Preventive Maintenance Checks and Services for AAFARS
Table 1. Operator's Preventive Maintenance Checks and Services for AAFARS (Continued) -815120063
Table 1. Operator's Preventive Maintenance Checks and Services for AAFARS (Continued) -815120064
Table 1. Operator's Preventive Maintenance Checks and Services for AAFARS (Continued) -815120065
Table 1. Operator's Preventive Maintenance Checks and Services for AAFARS (Continued) -815120066
Table 1. Operator's Preventive Maintenance Checks and Services for AAFARS (Continued) -815120067
Table 1. Operator's Preventive Maintenance Checks and Services for AAFARS (Continued) -815120068
Table 1. Operator's Preventive Maintenance Checks and Services for AAFARS (Continued) -815120069
Table 1. Operator's Preventive Maintenance Checks and Services for AAFARS (Continued) -815120070
Table 1. Operator's Preventive Maintenance Checks and Services for AAFARS (Continued) -815120071
Table 1. Operator's Preventive Maintenance Checks and Services for AAFARS (Continued) -815120072
Table 1. Operator's Preventive Maintenance Checks and Services for AAFARS (Continued) -815120073
OPERATOR, UNIT, DIRECT SUPPORT AND GENERAL SUPPORT MAINTENANCE ADVANCED AVIATION FORWARD AREA REFUELING SYSTEM MODEL M100A1 OPERATION UNDER USUAL CONDITIONS
Figure 1. AAFARS Emplacement
SYSTEM ASSEMBLY AND PREPARATION FOR USE
Figure 2. Fuel Contamination Test Kit
Position fuel drums (figure 1, 2) on spill containment unit (1).
Figure 3. API Specific Gravity Determination
Figure 4. Pump-Engine Emplacement
Figure 5. 2" Unisex Non-Valved Coupling to 2" Male Camlock Adapter Assembly
Install engine module in pump-engine module.
Establish recirculation path.
Position one nozzle kit at each fueling point.
OPERATING PROCEDURES
Perform normal electric engine start.
Figure 6. Manual Engine Start
Verify that pump outlet hose pressurizes (hose expands).
Test for undissolved water in aviation fuel (AQUA GLO Test).
Figure 7. Fuel Contamination Test Kit
Figure 8. Undissolved Water Test
Sampling
Rating Procedure
Reporting
Figure 9. Particulate Fuel Contamination Test
Perform particulate contamination fuel test.
Periodically monitor condition of the fuel transfer pump discharge hose.
To change from use of a D-1 nozzle to a CCR nozzle during refueling operations:
Figure 10. Defueling Liquid Fuel Filter-Separator
Figure 11. Defueling System Fuel Hoses
Remove condensation from fuel lines.
With the fuel transfer pump
Defuel system fuel hoses.
NORMAL SYSTEM SHUTDOWN
PREPARATION FOR MOVEMENT
PREPARATION FOR MOVEMENT (Continued) -815120107
PREPARATION FOR MOVEMENT (Continued) -815120108
OPERATOR MAINTENANCE ADVANCED AVIATION FORWARD AREA REFUELING SYSTEM MODEL M100A1 SYSTEM COMPONENT REPLACEMENT
REPLACE ACCESSORY MODULE
REPLACE LIQUID FUEL FILTER-SEPARATOR
Illustration -815120112
OPERATOR, UNIT, DIRECT SUPPORT AND GENERAL SUPPORT MAINTENANCE ADVANCED AVIATION FORWARD AREA REFUELING SYSTEM MODEL M100A1 OPERATION UNDER UNUSUAL CONDITIONS
Engine Cold Start
OPERATION IN RAIN
STOWAGE AND DECAL/DATA PLATE GUIDE
Figure 2. Pump Engine Module Decals and Data Plates
Figure 3. Engine Module Decals and Data Plates
Figure 4. Accessory Module Data Plates (Sheet 1 of 3)
Figure 4. Accessory Module Data Plates (Sheet 2 of 3)
Figure 4. Accessory Module Data Plates (Sheet 3 of 3)
Figure 5. Accessory Module Decals
Figure 6. Auxiliary Pump Decals
Figure 7. Liquid Fuel Filter-Separator Decals and Data Plates
Figure 8. CCR Nozzle Decals and Data Plate
Figure 10. Decals Discharge Fitting Kit, P/N 532606-01-01
Figure 12. Decals Discharge Hose Kit, P/N 532607-01-01
Figure 14. Decals and Data Plates Drum Fitting Kit, P/N 532612-01-01
Figure 15. Decals Drum Fitting Kit, P/N 532612-01-02
Figure 17. Decals Discharge Hose Kit, P/N 532605-01-01
Figure 19. Decals Discharge Hose Kit, P/N 532603-01-01
Figure 21. Decals and Data Plates Fuel Test Kit, P/N 532636-01-01 (Sheet 1 of 2)
Figure 21. Decals Fuel Test Kit, P/N 532636-01-01 (Sheet 2 of 2)
Figure 22. Decals and Data Plates Manual Starter Kit, P/N 532801-01-01
Figure 23. Recirculation Manifold
Figure 24. TRICON 1 Data Plate
Figure 25. TRICON 2 Decals and Data Plate
ON-VEHICLE EQUIPMENT LOADING PLAN
Figure 1. UH-60 Loading Arrangement (Sheet 2)
HMMWV WITH CARGO TRAILER LOADING PLAN
CH-47 HELICOPTER LOADING PLAN
5-TON CARGO TRUCK LOADING PLAN
CHAPTER 3 OPERATOR TROUBLESHOOTING FOR ADVANCED AVIATION FORWARD AREA REFUELING SYSTEM
OPERATOR MAINTENANCE ADVANCED AVIATION FORWARD AREA REFUELING SYSTEM MODEL M100A1 OPERATOR TROUBLESHOOTING PROCEDURES
Table 1. Operator Troubleshooting
Table 1. Operator Troubleshooting (Continued) -815120149
Table 1. Operator Troubleshooting (Continued) -815120150
CHAPTER 4 UNIT TROUBLESHOOTING FOR ADVANCED AVIATION FORWARD AREA REFUELING SYSTEM
UNIT MAINTENANCE ADVANCED AVIATION FORWARD AREA REFUELING SYSTEM MODEL M100A1 UNIT TROUBLESHOOTING PROCEDURES
ENGINE
FUEL TRANSFER PUMP
FILTER SEPARATOR
CONTROL BOX
System Electrical Schematic
FUEL DRUM -815120159
TRICON CONTAINER -815120160
PRESSURE CONTROL -815120161
CHAPTER 5 DIRECT SUPPORT TROUBLESHOOTING FOR ADVANCED AVIATION FORWARD AREA REFUELING SYSTEM
DIRECT SUPPORT MAINTENANCE ADVANCED AVIATION FORWARD AREA REFUELING SYSTEM MODEL M100A1 DIRECT SUPPORT TROUBLESHOOTING PROCEDURES
FUEL DRUM -815120166
TRICON CONTAINER -815120167
CHAPTER 6 OPERATOR MAINTENANCE FOR ADVANCED AVIATION FORWARD AREA REFUELING SYSTEM
OPERATOR MAINTENANCE ADVANCED AVIATION FORWARD AREA REFUELING SYSTEM MODEL M100A1 REPLACE UNISEX COUPLING FACE SEAL/DUST CAP SEAL
EMERGENCY REPAIR, FUEL DRUM CASING
Illustration -815120174
CHAPTER 7 UNIT MAINTENANCE FOR ADVANCED AVIATION FORWARD AREA REFUELING SYSTEM
UNIT MAINTENANCE ADVANCED AVIATION FORWARD AREA REFUELING SYSTEM MODEL M100A1 SERVICE UPON RECEIPT
PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) INTRODUCTION
GENERAL
Table 1. Unit Preventive Maintenance Checks and Services (PMCS) for AAFARS
Table 1. Unit Preventive Maintenance Checks and Services (PMCS) for AAFARS (Continued) -815120182
Table 1. Unit Preventive Maintenance Checks and Services (PMCS) for AAFARS (Continued) -815120183
Table 1. Unit Preventive Maintenance Checks and Services (PMCS) for AAFARS (Continued) -815120184
REPLACE ENGINE OIL FILTER
INSTALLATION -815120186
REPLACE ENGINE FUEL FILTER
INSTALLATION -815120188
REPLACE PUMPAGE OVER TEMPERATURE SENSOR/SENSOR CABLE (W103)
REMOVAL -815120190
REPLACE ENGINE AIR FILTER ELEMENT
REPLACE ENGINE AIR FILTER HOSE
REPLACE FUEL TRANSFER PUMP PN 8424/PN 60975-5 INLET QUICK DISCONNECT FITTING PACKING
INSTALLATION -815120196
INTRODUCTION TO FUEL DELIVERY EQUIPMENT MAINTENANCE
REPLACE TWO-INCH VALVED UNISEX COUPLING
INSTALLATION -815120200
REPLACE THREE-INCH UNISEX COUPLING
INSTALLATION -815120202
REPLACE UNISEX COUPLING DUST CAP
INSTALLATION -815120204
REPLACE UNISEX COUPLING BUMPER
REPLACE UNISEX COUPLING LUGS
INSTALLATION -815120208
REPLACE TWO-INCH NON-VALVED UNISEX COUPLING
INSTALLATION -815120210
REPAIR TWO-INCH NON-VALVED UNISEX COUPLING
ASSEMBLY -815120212
REPLACE FUEL TRANSFER PUMP PN 8424/PN 60975-5
INSTALLATION -815120214
REPLACE FUEL TRANSFER PUMP PN 8424 DISCHARGE HOUSING O-RING
INSTALLATION -815120216
REPLACE FUEL TRANSFER PUMP PN 8424 DISCHARGE VALVE
REPLACE ENGINE MODULE CARRYING HANDLE
REPLACE ENGINE MODULE PULLEY GUARD
REPLACE ENGINE MODULE ALIGNMENT BOLTS
REPLACE CABLE ASSEMBLY W101
INSTALLATION -815120226
INSTALLATION (Cont.)
REPLACE STARTER
REPLACE FUEL PUMP
INSTALLATION -815120232
ADJUST ENGINE INTAKE AND EXHAUST VALVES
Illustration -815120234
REPLACE FUEL INJECTOR NOZZLE
INSTALLATION -815120236
REPLACE EXHAUST MANIFOLD
REPLACE INTAKE MANIFOLD
INSTALLATION -815120240
REPLACE DECOMPRESSION ARM O-RING
INSTALLATION -815120242
REPLACE BATTERY
INSTALLATION -815120244
REPLACE CONTROL BOX
INSTALLATION -815120246
REPLACE BATTERY CABLE W202
INSTALLATION -815120248
REPAIR BATTERY CABLE
ASSEMBLY -815120250
INSTALLATION -815120251
REPLACE CONTROL CABLE W201
INSTALLATION -815120254
REPAIR BATTERY HOLDDOWN
Illustration -815120256
DATA PLATE REPLACEMENT (TYPICAL)
REPLACE FILTER VESSEL COVER O-RING
REMOVAL -815120260
INSTALLATION (Figure 1)
Figure 2. Filter Vessel Cover Torque Pattern
REPLACE COALESCER ELEMENTS AND SEPARATOR ELEMENT
Figure 1. Coalescer and Separator Elements Removal
WATER PUMP START SWITCH (DS2) REPLACEMENT REMOVAL, INSTALLATION
REPLACE DIFFERENTIAL PRESSURE GAUGE AND/OR INLET AND OUTLET LINES
INSTALLATION OF INLET AND OUTLET LINES
REMOVAL OF DIFFERENTIAL PRESSURE GAUGE
REPLACE SIGHT GAUGE COMPONENTS
INSTALLATION -815120272
REPLACE FILTER SEPARATOR MANUAL VENT VALVE
Illustration -815120274
REPLACE FILTER SEPARATOR GRAVITY DRAIN PLUG
INSTALLATION -815120276
REPAIR OF CONTROL BOX
REPLACE CONTROL PANEL LAMP ASSEMBLIES/PANEL LIGHTS
Illustration -815120280
REPLACE PANEL LIGHTS DIMMER POTENTIOMETER R1
INSTALLATION -815120282
REPAIR EMERGENCY STOP SWITCH (S4)
INSTALLATION -815120284
REPLACE CONTROL PANEL TOGGLE SWITCHES
Illustration -815120286
REPLACE CAPACITOR C1
Illustration -815120288
REPLACE CIRCUIT BREAKERS CB1 OR CB2
Illustration -815120290
REPLACE RELAY K1
REPLACE VOLTAGE REGULATOR
Illustration -815120294
REPLACE CONTROL BOX VOLTMETER
REPLACE AUXILIARY PUMP
INSTALLATION -815120298
CLEAN AND REPLACE AUXILIARY PUMP INLET COMPONENTS
Illustration -815120300
REPLACE AUXILIARY PUMP ROTOR VANES
ASSEMBLY -815120302
REPAIR AUXILIARY PUMP
PUMP ASSEMBLY
PUMP ASSEMBLY-Continued
REPAIR CCR NOZZLE ASSEMBLY -815120307
Illustration -815120308
INSPECTION -815120309
REPLACE CCR NOZZLE UNISEX COUPLING
INSTALLATION -815120312
REPAIR D1-NOZZLE TWO-INCH NON-VALVED UNISEX COUPLING
DISASSEMBLY AND INSPECTION
ASSEMBLY -815120315
REPLACE D1-NOZZLE BONDING CABLE ASSEMBLY
REPLACE D1-NOZZLE HANDLE ASSEMBLY
ASSEMBLY -815120320
REPLACE D1-NOZZLE HOSE END REGULATOR
REMOVAL -815120322
INSTALLATION -815120323
REPAIR FUEL DRUM ADAPTER ASSEMBLY
ASSEMBLY -815120326
REPAIR TOWING YOKE
ASSEMBLY -815120328
REPAIR PRESSURE CONTROL
Figure 1. Pressure Control Diaphragm Valve
STOP CYCLING VALVE ASSEMBLY REMOVAL AND DISASSEMBLY
STOP CYCLING VALVE ASSEMBLY CLEANING, REPAIR, REASSEMBLY AND INSTALLATION
STOP CYCLING VALVE ASSEMBLY CLEANING, REPAIR, REASSEMBLY AND INSTALLATION (Cont.)
FILL CYCLING VALVE ASSEMBLY REMOVAL AND DISASSEMBLY
FILL CYCLING VALVE ASSEMBLY REMOVAL AND DISASSEMBLY (cont.)
PILOT VALVE TESTING
Figure 3. Pressure Control Testing
PILOT VALVE REMOVAL AND DISASSEMBLY (Refer to figure 4.)
Figure 5. Adjusting Pilot Valve Shut Off Pressure
PILOT VALVE CLEANING, INSPECTION AND REPAIR (Refer to figure 4.)
VENTURI REMOVAL AND DISASSEMBLY (Refer to figure 4.)
VENTURI ASSEMBLY AND INSTALLATION (Refer to figure 4.)
FEMALE COUPLING HALF REPLACEMENT (Refer to figure 2.)
MALE COUPLING HALF REPAIR (Refer to figure 2.)
REPLACE TRICON DOCUMENT HOLDER
INSTALLATION -815120346
REPLACE TRICON SEAL SET
INSTALLATION -815120348
INSTALLATION-Continued -815120349
INSTALLATION-Continued -815120350
INSTALLATION-Continued -815120351
INSTALLATION-Continued -815120352
REPLACE SPRING STARTER END CAP
INSTALLATION -815120354
PREPARATION FOR STORAGE OR SHIPMENT
PUMP-ENGINE MODULE -815120356
Preparation for Use After Storage/Shipment
ACCESSORY MODULE -815120358
AUXILIARY PUMP
FUEL DRUMS
SPECIAL INSTRUCTIONS FOR ADMINISTRATIVE STORAGE
ILLUSTRATED LIST OF MANUFACTURED ITEMS -815120363
Figure 1. Clamp, Grounding
Figure 2. Tube, Inlet, Filter-Separator
Figure 3. Tube, Outlet, Filter-Separator
Figure 4. TRICON 1
Figure 5. TRICON 2
CHAPTER 8 DIRECT SUPPORT MAINTENANCE FOR ADVANCED AVIATION FORWARD AREA REFUELING SYSTEM
DIRECT SUPPORT MAINTENANCE ADVANCED AVIATION FORWARD AREA REFUELING SYSTEM MODEL M100A1 REPLACE FUEL TRANSFER PUMP PN 60975-5 OUTLET FLAPPER VALVE/O-RINGS
Illustration -815120372
INSTALLATION -815120373
REPLACE FUEL TRANSFER PUMP PN 60975-5 INPUT SEALS
INSTALLATION
REPAIR FUEL TRANSFER PUMP PN 60975-5 ROTARY VANE PUMP
Illustration -815120378
ASSEMBLY -815120379
REPLACE FUEL TRANSFER PUMP PN 8424 INLET O-RING
INSTALLATION -815120382
REPLACE FUEL TRANSFER PUMP PN 8424 SHAFT SEAL ASSEMBLY/O-RINGS
REMOVAL -815120384
INSTALLATION -815120385
INSTALLATION - Continued
REPLACE FUEL TRANSFER PUMP PN 8424 VANE PUMP HOUSING O-RINGS
INSTALLATION -815120388
REPAIR OF FUEL TRANSFER PUMP PN 8424 ROTARY VANE PUMP
INSTALLATION -815120390
REPLACE FUEL TRANSFER PUMP PN 8424 IMPELLER-SHAFT ASSEMBLY
INSTALLATION -815120392
REPAIR THREE-INCH VALVED UNISEX COUPLING
DISASSEMBLY -815120394
INSPECTION -815120395
ASSEMBLY
REPAIR TWO-INCH VALVED UNISEX COUPLING
INSPECTION -815120398
ASSEMBLY -815120399
REPAIR CCR NOZZLE ASSEMBLY -815120401
DISASSEMBLY -815120402
DISASSEMBLY-Continued -815120403
DISASSEMBLY-Continued -815120404
DISASSEMBLY-Continued -815120405
DISASSEMBLY-Continued -815120406
DISASSEMBLY-Continued -815120407
INSPECTION -815120408
ASSEMBLY -815120409
ASSEMBLY-Continued -815120410
ASSEMBLY-Continued -815120411
ASSEMBLY-Continued -815120412
ASSEMBLY-Continued -815120413
ASSEMBLY-Continued -815120414
REPAIR D1-NOZZLE BODY ASSEMBLY
DISASSEMBLY -815120416
DISASSEMBLY-Continued -815120417
INSPECTION -815120418
ASSEMBLY -815120419
ASSEMBLY-Continued -815120420
REPAIR D1 NOZZLE HOSE END REGULATOR
DISASSEMBLY-
ASSEMBLY -815120423
ASSEMBLY (Cont.)
REPAIR FUEL DRUM ASSEMBLY
INSPECTION -815120426
ASSEMBLY -815120427
OPERATOR, UNIT, DIRECT SUPPORT AND GENERAL SUPPORT MAINTENANCE ADVANCED AVIATION FORWARD AREA REFUELING SYSTEM MODEL M100A1 MAINTENANCE TORQUE LIMITS
HEX NUT STRENGTH IDENTIFICATION
STANDARD TORQUE VALUES - ENGLISH SYSTEM
STANDARD TORQUE VALUES - ENGLISH SYSTEM (cont.)
DIRECT SUPPORT MAINTENANCE ADVANCED AVIATION FORWARD AREA REFUELING SYSTEM MODEL M100A1 WIRING DIAGRAMS
Figure 1. Control Panel Wiring Diagram (Sheet 1 of 2)
Figure 1. Control Panel Wiring Diagram (Sheet 2 of 2)
Figure 2. Cable Assembly W101 Wiring Diagram (Engine Wiring Harness)
Figure 3. Cable Assembly W102 Wiring Diagram (Engine Starter Cable)
Figure 4. Cable Assembly W103 Wiring Diagram (Pumpage Overtemperature Cable)
Figure 5. Cable Assembly W201 Wiring Diagram (Accessory Module Control Cable)
Figure 6. Cable Assembly W202 Wiring Diagram (Battery Power Cable)
CHAPTER 9 GENERAL SUPPORT MAINTENANCE FOR ADVANCED AVIATION FORWARD AREA REFUELING SYSTEM
GENERAL SUPPORT MAINTENANCE ADVANCED AVIATION FORWARD AREA REFUELING SYSTEM MODEL M100A1 ENGINE OVERHAUL INTRODUCTION
REMOVE ENGINE FROM ENGINE MODULE
Illustration -815120446
REMOVE ENGINE FROM ENGINE MODULE (cont.)
ENGINE DISASSEMBLY
REMOVE INTAKE MANIFOLD (Refer to figure 2.)
Figure 2. Intake Manifold Removal
REMOVE AND CLEAN OIL PAN. (Refer to figure 3.)
REMOVE ENGINE SHROUD, CYLINDER CASING AND GATES. (Refer to figure 4.)
Figure 4. Shroud, Cylinder Casing and Gates Removal
REMOVE STARTER (Refer to figure 5)
REMOVE FLYWHEEL/ALTERNATOR ROTOR AND STATOR. (Refer to figure 6.)
Figure 6. Flywheel and Alternator Removal
REMOVE FUEL FLOW SOLEOID. (Refer to figure 7.)
REMOVE VALVE COVERS (Refer to figure 8.)
REMOVE DECOMPRESSION LEVER. (Refer to figure 9.)
REMOVE INJECTION PUMP. (Refer to figures 10 and 11.)
Figure 10. Fuel System Components Removal
Figure 11. Injection Pump Removal
REMOVE FUEL PUMP (Refer to figure 12.)
REMOVE FUEL INJECTORS. (Refer to figure 13.)
REMOVE CYLINDER HEAD AND CYLINDER (Refer to figures 14 and 15.)
Figure 14. Cylinder Head Removal
Figure 15. Cylinder Removal
REMOVE PISTON AND RINGS. (Refer to figure 16.)
REMOVE AND CHECK OIL PUMP. (Refer to figure 17.)
Figure 17. Oil Pump Removal
REMOVE TIMING (PULLEY END) COVER. (Refer to figure 18.)
REMOVE GOVERNOR ASSEMBLY AND SPEED CONTROL (Refer to figures 19 and 20.)
Figure 19. Governor Removal
REMOVE CAMSHAFT AND VALVE TAPPETS. (Refer to figure 21.)
REMOVE REAR CRANKSHAFT SUPPORT. (Refer to figure 22.)
REMOVE CRANKSHAFT GEAR, CRANKSHAFT AND BEARINGS. (Refer to figure 23.)
Figure 23. Crankshaft Gear, Crankshaft and Bearings Removal
REMOVE OIL PRESSURE RELIEF VALVE. (Refer to figure 24.)
DISASSEMBLE CYLINDER HEAD. (Refer to figure 25.)
Figure 25. Cylinder Head Disassembly
ENGINE ASSEMBLY
Figure 1. Crankshaft Assembly Installation
Figure 2. Front Crankshaft Bearing Installation
Figure 3. Rear Crankshaft Support Installation
INSTALL OIL PRESSURE RELIEF VALVE (Refer to Figure 4.)
INSTALL PISTON RINGS (Refer to Figure 5)
Figure 5. Piston Ring Installation
CHECK CYLINDER (Refer to Figure 6.)
INSTALL PISTON ASSEMBLY AND CYLINDER (Refer to Figure 7.)
Figure 7. Piston Assembly Installation
INSTALL CAMSHAFT (Refer to Figures 8 and 9.)
Figure 9. Camshaft and Tappet Installation
INSTALL GOVERNOR ASSEMBLY AND SPEED CONTROL (Refer to Figures 10 and 11)
INSTALL GOVERNOR ASSEMBLY AND SPEED CONTROL (Refer to Figures 10 and 11) (cont.)
Figure 10. Governor and Speed Control Installation
INSTALL OIL PUMP (Refer to Figure 12.)
INSTALL TIMING (PULLEY END) COVER (Refer to Figure 13.)
CHECK PISTON PROTRUSION (Refer to Figure 14.)
ASSEMBLE CYLINDER HEAD (Refer to Figure 15)
ASSEMBLE CYLINDER HEAD (Refer to Figure 15) (Cont.)
Figure 15. Cylinder Head Repair and Assembly
INSTALL CYLINDER HEAD (Refer to Figures 16, 17, 18 and 19.)
Figure 16. Pushrod Measurement
Figure 18. Cylinder Head Installation
Figure 19. Cylinder Head Alignment
INSTALL FLYWHEEL/ALTERNATOR ROTOR AND STATOR (Refer to Figure 20.)
Figure 20. Flywheel/Alternator Installation
INSTALL INTAKE MANIFOLD (Refer to Figure 21.)
INSTALL EXHAUST MANIFOLD (Refer to Figure 22.)
INSTALL INJECTION PUMP (Refer to Figure 23.)
Figure 23. Install Injection Pump
INSTALL FUEL INJECTOR (Refer to Figure 24.)
Figure 24. Fuel Injector Installation
INSTALL FUEL PUMP (Refer to Figure 25.)
INSTALL VALVE COVERS (Refer to Figure 26.)
INSTALL DECOMPRESSION LEVER (Refer to Figure 27.)
INSTALL FUEL FLOW SOLENOID (Refer to Figure 28.)
Figure 28. Fuel Flow Solenoid Installation
INSTALL OIL PAN (Refer to Figure 29.)
Figure 29. Oil Pan Installation
INSTALL STARTER (Refer to Figure 30.)
INSTALL GATES, SHROUD AND OIL COOLER (Refer to Figure 31.)
Figure 31. Shroud, Gates and Oil Cooler Installation
INSTALL FLEXIBLE COUPLING ADAPTER AND GUARD TO ENGINE (Refer to Figure 32.)
INSTALL ENGINE IN ENGINE MODULE (Refer to Figure 33.)
Figure 33. Installation of Engine in Engine Module
ADJUST FUEL INJECTION PUMP. (Refer to Figure 34.)
Figure 34. Fuel Injection Pump Timing Adjustment
ADJUST ENGINE INTAKE AND EXHAUST VALVES (Refer to Figure 35.)
Figure 35. Valve Adjustment
INSTALL CASING (Refer to Figure 36.)
OVERHAUL FUEL TRANSFER PUMP PN 60975-7
DISASSEMBLY -815120536
Illustration -815120537
ASSEMBLY -815120538
ASSEMBLY Continued -815120539
ASSEMBLY Continued -815120540
CHAPTER 10 SUPPORTING INFORMATION FOR ADVANCED AVIATION FORWARD AREA REFUELING SYSTEM
OPERATOR, UNIT, DIRECT SUPPORT AND GENERAL SUPPORT MAINTENANCE ADVANCED AVIATION FORWARD AREA REFUELING SYSTEM MODEL M100A1 SUPPORTING INFORMATION REFERENCES
Regulations
SUPPORTING INFORMATION MAINTENANCE ALLOCATION CHART (MAC) INTRODUCTION
Explanation of Columns in the MAC
Explanation of Columns in the Tools and Test Equipment Requirements -815120547
SUPPORTING INFORMATION MAINTENANCE ALLOCATION CHART
Table 1. MAC for AAFARS M100A1
Table 1. MAC for AAFARS M100A1 (Continued) -815120551
Table 1. MAC for AAFARS M100A1 (Continued) -815120552
Table 1. MAC for AAFARS M100A1 (Continued) -815120553
Table 1. MAC for AAFARS M100A1 (Continued) -815120554
Table 1. MAC for AAFARS M100A1 (Continued) -815120555
Table 2. Tools and Test Equipment For AAFARS
SUPPORTING INFORMATION COMPONENTS OF END ITEM (COEI) AND BASIC ISSUE ITEM (BII) LISTS
Illsutration
Table 1. Components of End Item List
Table 2. Basic Issue Item List
SUPPORTING INFORMATION ADDITIONAL AUTHORIZATION LIST
SUPPORTING INFORMATION EXPENDABLE AND DURABLE ITEMS LIST
Table 1. Expendable and Durable Items List
SUPPORTING INFORMATION MANDATORY REPLACEMENT PARTS LIST
Table 1. Mandatory Replacement Parts List
Table 1. Mandatory Replacement Parts List (Continued) -815120567
Table 1. Mandatory Replacement Parts List (Continued) -815120568
Table 1. Mandatory Replacement Parts List (Continued) -815120569
SUPPORTING INFORMATION GLOSSARY
The Metric System and Equivalents
TM-10-4930-351-14 Advanced Aviation Forward Area Refueling System (AAFARS) Model M1001A1 Manual
