Tronair MALABAR 150-5 Installation and operating instructions

OPERATION & SERVICE MANUAL
Malabar International Phone: [phone] | 800-426-6301
1 Air Cargo Pkwy East Web: www.malabar.com
Swanton, OH 43558 Email: [email protected]
Model: 150-5
1 qt (.95 l) O-C Fluid
Gun Dispenser
10/2018 Rev. 01

REVISION DATE TEXT AFFECTED
01 10/2018 Original release

Model: 150-5
1 qt (.95 l) O-C Fluid Gun Dispenser
10/2018 | Rev. 01
TABLE OF CONTENTS PAGE
1.0 PRODUCT INFORMATION ..............................................................................................................................................4
1.1 DESCRIPTION....................................................................................................................................................4
1.2 MODEL & SERIAL NUMBER..............................................................................................................................4
1.3 MANUFACTURER..............................................................................................................................................4
1.4 SPECIFICATIONS..............................................................................................................................................4
2.0 SAFETY INFORMATION..................................................................................................................................................4
2.1 USAGE AND SAFETY INFORMATION..............................................................................................................4
3.0 PREPARATION PRIOR TO FIRST USE ..........................................................................................................................4
4.0 TRAINING.........................................................................................................................................................................5
4.1 TRAINING REQUIREMENTS.............................................................................................................................5
4.2 TRAINING PROGRAM .......................................................................................................................................5
4.3 OPERATOR TRAINING......................................................................................................................................5
5.0 OPERATION.....................................................................................................................................................................5
6.0 MAINTENANCE................................................................................................................................................................5
6.1 SERVICING ........................................................................................................................................................5
6.2 REPAIR AND REPLACEMENT ..........................................................................................................................5
7.0 PROVISION OF SPARES.................................................................................................................................................6
7.1 SOURCE OF SPARE PARTS.............................................................................................................................6
7.2 RECOMMENDED SPARE PARTS LISTS ..........................................................................................................6
8.0 IN SERVICE SUPPORT....................................................................................................................................................6
9.0 GUARANTEES/LIMITATION OF LIABILITY....................................................................................................................6

Model: 150-5
1 qt (.95 l) O-C Fluid Gun Dispenser
10/2018 | Rev. 01 Page | 4
This product can not be modified without the written approval of Tronair, Inc. Any modifications done without written approval
voids all warranties and releases Tronair, Inc., it suppliers, distributors, employees, or financial institutions from any liability
from consequences that may occur. Only Tronair OEM replacement parts shall be used.
CAUTION!
Aircraft manufacturer’s specifications and instructions must be followed. In the event of contradiction
between aircraft manufacturer’s specifications and Malabar’s, aircraft manufacturer’s will prevail.
1.0 PRODUCT INFORMATION
1.1 DESCRIPTION
The Malabar Model 150-5 is a one quart original container fluid gun dispenser used to service various commercial
aircraft. The O-C Fluid Gun Dispenser consists of a hand pump assembly, filter assembly and a fluid delivery hose with
a coupling .
1.2 MODEL & SERIAL NUMBER
Reference nameplate on unit
1.3 MANUFACTURER
Malabar International Telephone: [phone] or 800-426-6301
1 Air Cargo Pkwy East E-mail: [email protected]
Swanton, Ohio 43558 USA Website: www.malabar.com
1.4 SPECIFICATIONS
Fluid Engine and IDG Oil
Fluid Capacity 1 qt (.95 l)
Pump Outlet Pressure 80 psig (551 kg/sq cm)
Volume Per Stroke 2 cu in (33 cc)
Hose Length 74 in (1880 mm)
Net Weight (empty) 6.5 lbs (2.9 kg)
Filter Rating 3 micron nominal
2.0 SAFETY INFORMATION
2.1 USAGE AND SAFETY INFORMATION
To insure safe operations please read the following statements and understand their meaning. Also refer to your equipment
manufacturer’s manual for other important safety information. This manual contains safety precautions which are explained
below. Please read carefully.
WARNING!
Warning is used to indicate the presence of a hazard that can cause severe personal injury, death, and/or
substantial property damage if the Warning Notice is ignored.
CAUTION!
Caution is used to indicate the presence of a hazard, which will or can cause minor personal injury or property
damage is the Caution Notice is ignored.
3.0 PREPARATION PRIOR TO FIRST USE
1. Attach the hose assembly to the gun. Avoid over tightening the swivel nut.
2. The two latches attached to the clamp bars may require adjustment. Loosen the four screws, washers and self-
locking nuts and adjust latches to fit oil can before tightening screws.

Model: 150-5
1 qt (.95 l) O-C Fluid Gun Dispenser
10/2018 | Rev. 01 Page | 5
4.0 TRAINING
4.1 TRAINING REQUIREMENTS
The employer of the operator is responsible for providing a training program sufficient for the safe operation of the unit.
4.2 TRAINING PROGRAM
The employer provided operator training program should cover safety procedures concerning use of the unit in and around the
intended aircraft at the intended aircraft servicing location.
4.3 OPERATOR TRAINING
The operator training should provide the required training for safe operation of the unit.
NOTE: Maintenance and Trouble Shooting are to be performed by a skilled and trained technician.
5.0 OPERATION
1. Slide piercer rod fully up and latch oil can to gun. Check the fluid specification and brand for compatibility with
the aircraft system.
2. Strike piercer handle firmly using palm of hand or rubber mallet to drive piercer through top of oil can. Assure
piercer is firmly placed in oil can.
CAUTION!
To prevent damage to the piercer rod or piercer handle, do not use any tool other than a rubber mallet.
3. Open the bleed screw on the sight gage (one turn only) and carefully pump the gun to prime and eliminate any
air bubbles. Close bleed screw.
CAUTION!
Air pumped in with oil may cause false level readings in aircraft systems as the air eventually bubbles off
and the level drops.
4. Remove dust plug from hose end coupling and connect hose end coupling to the aircraft service point.
5. Use full steady pump strokes when operating pump assembly during replenishing. Stop pumping oil when can
is empty or air bubbles are detected in sight gage. Reprime gun when changing cans.
6. When finished, disconnect the hose end coupling from the aircraft service point. Replace the dust plug and
store the gun in a dry dust free location.
7. When gun is stored, it is advisable to keep oil can latched to the gun to prevent contamination and oil mess.
6.0 MAINTENANCE
6.1 SERVICING
The frequency of filter change depends on operating conditions. Generally, changes should be made every 3-4
months or sooner if more than normal resistance is felt on the pumping stroke at low pressure. Refer to figure 1A,
item 43 to change filter element.
6.2 REPAIR AND REPLACEMENT
No definite time schedule can be established for the overhaul of the O-C fluid gun dispenser assembly for the
replacement of the various moving parts. The number of times the pump assembly is operated materially affects the
life of the working parts. The moving piston seals (figure 1A, item 20) and piercer rod seals (figure 1A, item 22) are
normally the first to wear. This is usually indicated by leakage of fluid past the piston rod (figure 1A, item 2) or the piercer
rod (figure 1A, item 12). It is advisable to change piston seals (figure 1A, item 20) and piercer rod seals (figure 1A, item
22) immediately if leakage is discovered. Regardless of apparent condition, replace all parts marked with ( ♦ ). A repair
parts kit (P/N 150-4PK) which contains all of the parts marked with ( ♦ ) is available and recommended to keep on hand at
your facility. Coat all o-rings with petroleum jelly prior to assembly. Clean all metal parts with solvent and dry with
compressed air. Lubricate all threads. Refer to sheet 6 for the complete list of parts contained in the repair parts kit.

Model: 150-5
1 qt (.95 l) O-C Fluid Gun Dispenser
10/2018 | Rev. 01 Page | 6
7.0 PROVISION OF SPARES
7.1 SOURCE OF SPARE PARTS
Spare parts may be obtained from the manufacturer:
Malabar International Telephone: [phone] or 800-426-6301
1 Air Cargo Pkwy East E-mail: [email protected]
Swanton, Ohio 43558 USA Website: www.malabar.com
7.2 RECOMMENDED SPARE PARTS LISTS
Reference the following page(s) for Replacement Parts and Kits available.
8.0 IN SERVICE SUPPORT
Contact Malabar, Inc. for technical services and information. See Section 1.3 Manufacturer.
9.0 GUARANTEES/LIMITATION OF LIABILITY
I. Seller warrants each new product of its manufacture to be free from defects in material or workmanship, under proper,
reasonable, and normal use and service.
II. The warranty period shall be as follows:
A. For Malabar equipment, with the exception of Tripod Jacks, the warranty period is one (1) year after date of
shipment.
B. For Malabar Tripod Jacks, the warranty period is three (3) years after date of shipment.
III. Where Buyer claims an alleged defect in material or workmanship and so advises Seller in writing within ten (10) days
after discovery thereof, then and in such event, Buyer shall return said equipment, transportation prepaid, to the Seller,
provided such return is timely and within the above-mentioned warranty period. This warranty and liability of the Seller
is expressly limited solely to replacement or repair of defective parts or goods, and return at Buyer’s expense to Buyer
after finding by Seller the product was defective prior to original shipment or, at the option of Seller, to providing refund
to Buyer of the purchase price for said product.
IV. It is further expressly understood and agreed that:
A. THERE IS NO WARRANTY, REPRESENTATION OF CONDITION OF ANY KIND, EXPRESS OR IMPLIED,
(INCLUDING NO WARRANTY OF MERCHANTABILITY OR OF FITNESS) EXCEPT THAT THE MATERIAL
SHALL BE OF THE QUALITY SPECIFIED IN APPLICABLE SPECIFICATIONS, AND NONE SHALL BE IMPLIED
BY LAW. Except as otherwise provided herein, quality shall be in accordance with Seller’s specifications. Final
determination of the material for the use contemplated by Buyer is the sole responsibility of Buyer and Seller shall
have no responsibility in connection with such suitability, and
B. Buyer’s sole and exclusive remedy shall be repair or replacement of defective parts or goods by the Seller. Should
the goods, in the judgment of Seller, preclude the remedying of the warranted defects by repair or replacement, the
Buyer’s sole and exclusive remedy shall be the refund of the purchase price, and
C. Seller shall not be liable for prospective profits or special, indirect or consequential damages, nor shall any
recovery of any kind against Seller be greater in amount than the purchase price of the specific material sold and
causing the alleged loss, damage or injury. Buyer assumes all risk and liability for loss, damage or injury to persons
or property of Buyer or others arising out of use or possession of any product or part sold hereunder, and
D. Seller shall in no way be deemed or held to be obligated, liable or accountable upon or for any guarantees or
warranties, express or implied, or created by statute or by operation of law or otherwise, in any manner of form
beyond its express agreement above set forth, and
E. No warranty herein shall apply to any product which shall have been repaired or altered, unless such alteration or
repair has been made by Seller or if, after return to and inspection by Seller, the product is found by Seller to have
been subject to misuse, negligence or accident, and
F. No warranty of any nature is made by Seller as to any component forming a part of the product sold and Buyer
shall receive only such warranties offered by such other manufacturer of such component, and
G. Seller does not assume nor does Seller authorize any other person to assume for it any other liability or make any
warranty in connection with the sale of its products.

Model: 150-5
1 qt (.95 l) O-C Fluid Gun Dispenser
10/2018 | Rev. 01 Page | 7
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Model: 150-5
1 qt (.95 l) O-C Fluid Gun Dispenser
10/2018 | Rev. 01 Page | 8
Parts List –Figure 1A
When ordering replacement parts/kits, please specify model, serial number and color of your unit.
PART OF REPAIR PARTS KIT

Model: 150-5
1 qt (.95 l) O-C Fluid Gun Dispenser
10/2018 | Rev. 01 Page | 9
Parts List –Figure 1A
When ordering replacement parts/kits, please specify model, serial number and color of your unit.
Item
Part Number
Description
Qty
1
*1744493-1
PUMP BODY MACHINE
1
2
1744405
PISTON ROD
1
4
1744407
CLAMP BAR
2
5
174459
BEARING BOLT ASSEMBLY
1
6
174411
PISTON
1
7
174412
ADAPTER FITTING
1
8
174413
VALVE POPPET
1
9
174414
POPPET GUIDE
1
10
174415
CAN SEAL
1
11
174416
PIERCER HANDLE
1
12
174460
PIERCER ROD
1
13
174461
PIERCER
1
19
55925-019
O-RING
1
20
55925-112
O-RING
2
21
55925-120
O-RING
1
22
55925-114
O-RING
2
23
326-009
BHCS, 1/4-20 x 1" LG
1
24
326-010
BHCS, 1/4-20 x 5/8 LG
4
25
326-020
BHCS, 10-24 x 1/2 LG
4
26
355-025
HEX LOCKNUT, 10-24
4
27
363-001
SPLIT LOCKWASHER, 1/4
4
29
410-017
BRONZE BEARING
1
30
495-035
SPRING
1
31
495-036
SPRING
1
33
412-002
BALL, CHROME, 5/16 DIA
1
36
380-004
RETAINING RING, PUSH ON
1
37
55926-100
RETAINING RING, PUSH ON
1
39
362-045
FLAT WASHER, #10
4
40
369-002
NYLON FLAT WASHER
1
41
491-056
LATCH
2
43
481-005
FILTER ELEMENT
1

Model: 150-5
1 qt (.95 l) O-C Fluid Gun Dispenser
10/2018 | Rev. 01 Page | 10
Parts List –Figure 1B
When ordering replacement parts/kits, please specify model, serial number and color of your unit.
Item
Part Number
Description
Qty
3
1744406
HANDLE
1
14
174419
BLEED SCREW
1
15
174420
SPRING SUPPORT
1
16
174421
PLACARD
1
17
174467
PLACARD, ENGINE AND IDG OIL
1
18
174468
PLACARD, ENGINE AND IDG OIL
1
28
721-004
CONNECTOR, 3/8 37° x 1/4 MPT
1
32
495-037
SPRING
1
34
412-004
BALL, CHROME, 1/4 DIA
1
35
380-005
RETAINING RING, PUSH ON
1
38
393-004
DRIVE SCREW, #2 x 3/16 LG
8
42
174445
HOSE ASSEMBLY
1
44
491-027
CABLE, .048 DIA x 6" LG
1
45
491-028
SLEEVE CRIMP
2
46
55925-904
O-RING
1
47
174425
SIGHT GAGE
1
48
PF55817
FEMALE ELBOW ASSEMBLY
1
49
736-013
COUPLING
1
50
PF55987
DUST PLUG
1
PART OF REPAIR PARTS KIT

Model: 150-5
1 qt (.95 l) O-C Fluid Gun Dispenser
10/2018 | Rev. 01 Page | 11
Parts List –150-4PK Repair Parts Kit
When ordering replacement parts/kits, please specify model, serial number and color of your unit.
Part Number
Description
Qty
174445
HOSE ASSEMBLY
1
481-005
FILTER ELEMENT
1
174415
CAN SEAL
1
55925-904
O-RING
1
55925-114
O-RING
2
55925-120
O-RING
1
55925-112
O-RING
2
55925-019
O-RING
1
495-035
SPRING
1
495-036
SPRING
1
495-037
SPRING
1
412-002
BALL, CHROME, 5/16 DIA
1
412-004
BALL, CHROME, 1/4 DIA
1
380-005
RETAINING RING, PUSH ON
1
380-004
RETAINING RING, PUSH ON
1
150-4PKDOC
REPAIR PARTS KIT LIST
1