# Presentation: 692622

## Unit 5Bench Testing, Maintenance, and Troubleshooting

## Objectives

- Trainee to be proficient with
- Helitorch bench testing
- Helitorch/Mixing System maintenance and troubleshooting

## Slide 3

## Helitorch Bench Testing

**Prior to helitorch operation, a bench test will be conducted**

## Helitorch Bench Testing

**Helitorch should be empty**
**Have a 40-B:C fire extinguisher available**
**Make sure switches are off and propane bottle is installed**
**Connect 24 volt power source to helitorch with the 9 pin test adapter **
**With the pump switch off, turn on the igniter switch, check for spark and if applicable, propane ignition**

## Helitorch Bench Test cont.

**Check the propane pressure and adjust if needed**
**After testing (if needed) let the tip and ignition parts cool**
**Remove clay bailey 2” cam lock from the drum**
**With the ignition switch off turn on the pump switch**
**You should feel air being sucked into the drum**

**Notes:**
This is one method of bench testing pump, another example (for the Simplex 5400) is outlined in Instructor syllabus

## Helitorch Bench Test cont.

**Do not run pump dry for more than a few seconds**
**Turn Switches off and unhook power source**
**Reinstall vent hose cap**
**Remove 9 pin adapter **
**Check suspension cables, wire ties, bolts, nuts, connectors, and drum tie down straps for tightness and serviceability **

## General Helitorch Maintenance

**Properly service and store the helitorch to maintain dependability**
**Flush system with diesel or Jet A and pump dry prior to storage**
**Do not store Helitorch with gel or fuel remaining in plumbing**
**Remove propane bottle and install empty cylinder**
**Keep internal components free of dirt and debris**
**Replace hoses when no longer flexible/cracked**

## Slide 9

## Helitorch Maintenance cont.

**Disassemble torch tip and clean**
**Check electrical cable**
**Service & repair dry break coupler**
**Check motor brushes periodically (simplex)**
**Keep components clean & free of moisture**
**Reference helitorch inspection checklist (IAIG APP B)**
**Store in a sheltered, clean, dry area**
**Apply service tag after maintenance performed with name, date, repairs needed if any**

## Slide 11

## General Mixing System Maintenance

**Batchmixers that meet MC306 or DOT 406 design specs must comply with DOT regs**
**Annual visual inspection by DOT certified Inspector**
**Hydrostatic pressure test every 5 years by a DOT certified inspector**
**Maintain trailer brakes, wheel bearings, electrical system, engine oil, air filter, spark arrestor, and general integrity of the unit**

## Mixing System Maintenance cont.

**Pump tank empty of gelled fuel, use non-ferrous paddle/scraper if necessary**
**Clean with diesel or Jet A and flush all hoses**
**Prevent rust/paint as needed**
**Purge entire system**
**Keep mixing system clean and store in dry place**
**Maintain a log of all maintenance performed**

## Drum & Associated Hardware Maintenance

**Keep drum purged of gel/fuel **
**Paint as need to prevent rust **
**Store in clean, dry environment**
**Keep dry break valve clean of dirt & debris**
**Clay & Bailey, Site Glasses, Cam-Locks free of gel residue- CLEAN WITH SOLVENT**

## Slide 15

## Slide 16

## Vapor Hose Maintenance

**Store hoses in dry location away from sunlight**
**Keep cam-lock caps on during storage**
**Perform continuity test prior to use**
**Replace brittle/cracked hoses **

## Slide 18

## Helitorch Troubleshooting(Handout)

**Circuit breakers on helicopter stay tripped open**
** ****Check polarity of plug between  helicopter and torch**
** ****Check for electrical shorts in wiring**
** ****Check motor for short**

**Notes:**
Instructor Hand out “Helitorch troubleshooting List” to students (Instructor Syllabus Unit 5 pages 5 & 6)

## Slide 20

## Helitorch Troubleshooting cont.

** ****Check pump for drag or obstruction**
** ****Check gel thickness**
** ****Check motor bearings**
**Check polarity of plug to Helicopter or Helitorch (Do not hook suspension cable to cargo hook) **

## Slide 22

## Slide 23

**No spark from igniter**
** ****Check igniter switch**
** ****Check electrical connection from   helicopter**
**Check vibrator**
** ****Check coil**

## Slide 25

## Helitorch Troubleshooting cont.

**Check coil wire**
**Check wire connection on igniter rod**
**Check igniter rod gap**
**Check polarity of plug to helicopter**
**Trace electrical wiring system and continuity **

**Propane does not light (if applicable)**
**Check propane quantity and gage pressure**
**Check that solenoid valve is opening**
**Check for plugged propane torch orifice **
**Replace propane bottle with another**
**Insure propane torch tip slit is in line with the arcing rod**

**No gel being pumped**
**Check pump switch**
**Make sure valves are open**
**Check pump for obstructions**
**Check hose for obstructions**
**Check thickness of gel**
**Check motor and drive belt**

**Pump turns backwards (clockwise)**
**Helicopter or 9 pin plug on the helitorch are wired backwards, polarity is wrong.  Check the helitorch first**
**Gel leaks out of discharge nozzle valve.**
**Spring is weak or O-rings are bad**
**Gel leaks from pump shaft  (Simplex 5400)**
**Replace pump shaft seal or replace pump**

## Do it by the numbers!