TM 10-4610-232-34
Table 2-1. Direct Support Troubleshooting Guide (Continued)
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
3.
4.
5.
6.
7.
High pressure pump oil has water in it (looks milky).
Step 1. Replace pony rod oil seals.
Refer to para. 2-78.
Step 2.
Operate unit and check that plunger packing is not leaking excessively.
Replace packing if necessary (para. 2-78). Replace plunger, if worn (para. 2-78).
High pressure pump discharge pressure will not go to 900 psig.
Step 1.
Check high pressure control valve needle for wear.
Replace stem and needle if worn (para. 2-17).
Step 2.
Check high pressure gauge for accuracy.
Refer to pressure gauge troubleshooting (malfunction 3).
Step 3.
Check feed low pressure switch for operation.
Refer to feed low pressure switch troubleshooting (malfunction 16).
High pressure pump and piping pulsating or vibrating moderate to severe. Pump may be making sharp hammering
sounds (also, see pressure gauge troubleshooting, malfunction 4).
Step 1.
Check high pressure pump inlet and outlet valve discs and springs. Replace any valve discs that show radial
or circumferential cracks, pitting other than normal surface wear, nicks, gouges, elongated center holes, and
a chalky feeling/appearance when scratched with a fingernail (para. 2-78).
Replace any broken valve springs (para. 2-78).
Step 2.
Check high pressure pump inlet and outlet valveseats. Usually a visual inspection without removing the seats
is sufficient to reveal seat problems. Only remove the seats if a closer examination is required.
Replace any seats that show pitting other than normal surface wear, nicks or gouges (para. 2-78)
Step 3.
Replace the pulsation dampener if high pressure pump repairs or inspections have not fixed the problem. It
only affects high pressure fluctuations and will have no effect on low pressure suction side fluctuations which
are controlled by the media filter and cartridge filter air blankets. Refer to those troubleshooting symptoms
and also backwash air solenoid leaking problems for continued low pressure fluctuations.
Refer to para. 2-75 for pulsation dampener replacement.
High pressure pump starts but shuts down on feed high pressure.
Step 1.
Check that feed water is flowing out of the waste hoses with the raw water and boost pump running. If water is
not flowing, check back through the system and find where the water is being stopped. Check for frozen
hoses if operating in freezing conditions.
Repair as necessary.
Step 2.
Check feed high pressure switch for accuracy.
Refer to feed high pressure switch troubleshooting (malfunction 1).
Step 3.
Check high pressure gauge for accuracy.
Refer to pressure gauge troubleshooting (malfunction 3).
High pressure pump is started but generator loads down. Overload circuit breakers may open.
WARNING
Do not operate the high pressure pump until water flows freely out of the waste hoses.
NOTE
If water flows freely from the waste hose go to step 3.
Step 1. Check for plugged high pressure lines and hoses on the high pressure pump skid. (Possibly frozen if
operating in freezing conditions).
Change 2
2-11
