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TM-1-1740-204-13-and-P

1. 2 6 Preventive Maintenance Checks and Services PMCS 3 3 mt RET 1 10 Q DEG CMe y mco mms 1 3 mms 3 42 DISCODHECE OC GL u ss 3 42 R CI RSS A 1 Repair Parts and Special Tools List C 1 RetainiNO T 3 15 3 19 S Soe I lal ii 1 9 m 2 7 ana aqa 3 15 Shop Air Supply 1 4 TOC COULE u u mM MERO EMEND MEMMIUS 2 9 Storage and ohlipITIeFibss sies 3 43 4 17 T Tank Connector 8 3 13 Tank Connector Assembly 003 Figure 90 C 26 Tank Connector Assembly Inspect Filters Replacing Components 3 96 Tank Connector 3 35 INDEX 3 TM 1 1740 204 13 amp P ALPHABETICAL INDEX PAGE UF AMG ANS ec E UNE 3 37 Metentl ON cie 3 32 eund aq M e imm cT EUM EM EE EM MEM RM RN 1 4 Pilli Um MR Rc 3 14 UM se IO RN ERE C 27 FUINO HOSO A REDAN m E T
2. 3 3 4 3 GOImDOHenub ec UE e LUE 1 10 Confidence Test 2 10 Controls and gle fer 6 2 4 D FU 2 6 2 9 lt MATENE T TP 1 3 RE E uy E 1 4 e RR an 2 6 EMMONS IM Dal u IM IM dE C cuc 1 4 Equipment Improvement Recommendations 1 3 Expendable Durable Supplies and Material 5 D 2 Extreme Environmental sna asserens 2 14 F 3 38 mici Tem 3 23 c 3 23 INDEX 1 TM 1 1740 204 13 amp P ALPHABETICAL INDEX PAGE G Seal U 3 31 Rana M 3 37 Fland TrgckAssembplV FIGUE O E C 22 Rigi Pressure Charging OSC DU RUE IU
3. C 16 Low Pressure Relief E e T 3 15 M Maintenance Allocation Chart MAC B 3 Maintenance 3 1 Maintenance Insirielions uuu uuu k u un UD UP ODE 4 1 Maintenance Procedures 1 1 3 11 Ila Or GOMDONE AUS OE EE 1 6 Mission Capable 2 6 INDEX 2 TM 1 1740 204 13 amp P ALPHABETICAL INDEX PAGE N National Stock Number C 30 Nipple eee 3 37 Nitrogen Charging Directly from the Supply 2 11 Nitrogen Charging Using Booster nnne nennen nnns nna nnne nnns 2 12 No Nitrogen Flow to High Pressure Output Not Requiring Rooster Pump Operation 3 6 No Nitrogen Flow to High Pressure Output Requiring Booster Pump Operation 3 7 4 5 No Tire Inflation Low 3 5 O cl G 2 6 peralin OMGIU GINS uu OE mmm 1 4 PATINI IE TOC 2 11 P wig mci 3 37 Part Number C 31 Pneumatic Input Requirements 1 3 Pre Operation 2 2 Preventive Maintenance Checks and Services PMCS Operator
4. is to be used for troubleshooting difficulties associated with no high pressure output appearing at the High Pressure Output connector C5 of Figure 1 3 or at the high pressure fitting end of the high pressure charging hose Booster pump operation is not required is to be used for troubleshooting difficulties associated with booster pump operation Figures 1 3 and 1 4 for the function and location of the designated components 4 4 TM 1 1740 204 13 amp P 4 11 NO NITROGEN FLOW TO HIGH PRESSURE OUTPUT NOT REQUIRING BOOSTER PUMP OPERATION This flow chart is to be used for troubleshooting difficulties associated with no high pressure output appearing at the High Pressure Output connector C5 of Figure 1 3 or at the high pressure fitting end of the high pressure charging hose See Figures 1 3 and 1 4 the function and location of the designated components is G1 reading nitrogen pressure Is G3 reading nitrogen pressure Are tanks pressurized Replace with pressurized Inspect and if needed tanks per paragraphs 2 7 Is G4 reading nitrogen replace check valves in and 2 5 pressure the booster pump per paragraph 4 14 yes Open shut off 15 R2 adjusted for desired 2 valves V2 and V4 pressure Are cylinder valves open Replace G4 per Adiust R2 Replace G1 Open cylinder paragraph 3 17 l paragraph 3 16 valves 4 5 TM 1 1740 204 13 amp P 4 12 TROUBLESHOOTING PROCEDURE REQU
5. 012 2404 4 45 5602 4SP RV54 1 ASP 2BV 2501 LL 8 8SP 93639 11 F004SP F011SP PA011 PA015 B 37T C 015 F019SP 6500 6 6SP 010 007 009 B 50T C 005 018 524243 FOO3SP FO10SP F013SP F012SP F001SP FOO8SP FOO9SP 060 014 023 024 028 022 026 025 14 6 DESCRIPTION AND USABLE CODE UOC GROUP 01 FIGURE C 2 PANEL ASSY BOOSTER 004 Assy High Pressure Regulator see figure C 4 Clamp Base Cushion 1 4 Pipe Clamp Top Clamp Bolt 5 16 18 x 1 1 2 Tube Assy Assy High Pressure Shutoff see figure C 6 Bracket High Press Shut Off Washer Flat 1 4 grd 8 Bolt Hex 1 4 20 x 3 4 grd 8 Flatwasher 7 16 Tube Assy Fitting Flared Fitting Pipe Valve High Pressure Relief Vent Breather Fitting Plared Elbow Pump Booster Bolt Flat 3 8 16 x3 4 grd 8 Washer Flat 3 8 grd 8 Tube Assy Clamp Base Cushion 3 8 Tube Clamp Top Clamp Bolt 5 16 18x2 Fitting Flared Tube Assy Assy Low Pressure Filter see figure C 5 Tube Assy Cushion 1 2 Tube Clamp Assy Low Pressure Regulator see figure C 3 Cushion 1 2 Pipe Clamp Nameplate Top Assy Rivet Bolt Hex 5 16 18x1 2 grd 8 Washer Lock 5 16 grd 8 Nut Hex 3 8 16 grd 8 Washer Lock 3 8 grd 8 Bolt Hex 1 4 20 x 1 2 grd 8 Washer Lock 1 4 grd 8 Nut Hex 1 4 20 grd 8 Panel Steel Mtg w labels Panel Steel Mounting Label Regulated H
6. c Shop Air Regulator is an adjustable regulator that controls the shop air drive pressure for the gas booster pump Its output pressure range is 7 to 125 psi and is read on gauge G2 TM 1 1740 204 13 amp P G1 Tank Pressure Gauge This gauge indicates the pressure remaining in the nitrogen supply tanks The gauge is 2 1 2 inches in diameter and has a 3 000 psi scale and 2 1 2 full scale accuracy G2 Regulated Low Pressure Gauge This gauge indicates the output pressure of regulator R1 which is provided to connector C4 and to drive the booster pump The gauge is 2 1 2 inches in diameter and has a 300 psi scale and 196 full scale accuracy G3 Pump Outlet Pressure Gauge This gauge indicates the output pressure of the booster pump P The gauge is 2 1 2 inches in diameter and has a 5 000 psi scale and 2 1 2 full scale accuracy G4 Regulated High Pressure Gauge This gauge indicates the output pressure of regulator R2 that is being supplied to connector C5 The gauge is 2 1 2 inches in diameter and has a 5 000 psi scale and 1 full scale accuracy V1 Pump Drive Valve This valve turns on and shuts off the flow of shop air applied at connector C3 or nitrogen from the tanks to the booster pump P Turning the handle in line with the tubing turns the valve on for flow Turning the valve handle perpendicular to the tubing will shut off flow V2 High Pressure Vent Valve This vent valve when open vents the line pressure co
7. Paragraph 3 112 is to be used for troubleshooting difficulties associated with no high pressure output appearing at the High Pressure Output connector C5 or at the high pressure fitting end of the high pressure charging hose See Figures 1 3 and 1 4 for the function and location of the designated components 3 4 TM 1 1740 204 13 amp P 3 11 1 NO TIRE INFLATION LOW PRESSURES This flow chart is to be used for troubleshooting difficulties associated with low pressure operation such as tire inflation The nitrogen supply pressure is obtained from the Cart s C4 connector in this case 1 3 and 1 4 for the function and location of the designated components Is G1 reading nitrogen pressure and is greater than desired pressure E Is G2 reading the correct nitrogen pressure Are tanks pressurized Can R1 be adjusted so that G2 reads the correct pressure yes Are all hose connections made from cart to the tire valve Replace with pressurized tanks Check for hose or C4 blockage Replace C4 if needed Make connections Are cylinder valves open Adjust R1 to Y proper setting Replace using x Open cylinder valves paragraph 3 16 Replace R1 per paragraph 3 16 TM 1 1740 204 13 amp P 3 11 2 NO NITROGEN FLOW TO HIGH PRESSURE OUTPUT NOT REQUIRING BOOSTER PUMP OPERATION This flow chart is to be used for troubleshoot
8. 3N103iNVHOJH3d SNOT RECOMMENDED CHANGES TO EQUIPMENT TECHNICAL PUBLICATIONS SOMETHING WRONG WITH THIS PUBLICATION FROM PRINT YOUR UNIT S COMPLETE ADDRESS THEN JOT DOWN THE DOPE ABOUT IT ON THIS FORM CAREFULLYTEAR IT OUT FOLD IT AND DROP IT IN THE MAIL PUBLICATION NUMBER PUBLICATION DATE PUBLICATION TITLE TM 1 1740 204 13 amp P 31 December 1996 Truck Hand Nitrogen Servicing Cart BE EXACT PIN POINT WHERE IT IS IN THIS SPACE TELL WHAT IS WRONG WHAT SHOULD BE DONE ABOUT IT PARA FIGURE TABLE GRAPH O NO DATE SENT a a PRINTED NAME GRADE OR TITLE AND TELEPHONE NUMBER D A 20 28 2 ABE URSUS P S IF YOUR OUTFIT WANTS TO KNOW ABOUT YOUR RECOMMENDATION MAKE A CARBON COPY OF THIS DRSTS M verprint2 1 Nov 80 AND GIVE TO YOUR HEADQUARTERS REVERSE OF DA FORM 2028 2 Reverse of DRSTS M Overprint 2 1 Nov 80 FILL IN YOUR UNITS ADDRESS FOLD BACK DEPARTMENT OF THE ARMY OFFICIAL BUSINESS COMMANDER U S ARMY AVIATION AND TROOP COMMAND ATTN AMSAT I MP 4300 GOODFELLOW BOULEVARD ST LOUIS MO 63120 1798 rc 3N103iNVHOJH3d SNOT RECOMMENDED CHANGES TO EQUIPMENT TECHNICAL PUBLICATIONS SOMETHING WRONG WITH THIS PUBLICATION FROM PRINT YOUR UNIT S COMPLETE ADDRESS THEN JOT DOWN THE DOPE ABOUT IT ON THIS FORM CAREFULLYTEAR IT OUT FOLD IT AND DROP IT IN THE MAIL PUBLICATION NUMBER PUBLICATION DATE PUBLICATI
9. ASSEMBLY UCK TM 1 1740 204 13 amp P Figure C 7 HAND TRUCK ASSEMBLY CA033 2 of 2 C 23 1 ITEM NO OND Of 10 11 13 2 SMR CODE PBOFF PAOZZ PAOZZ XDFZZ PAOZZ PAOZZ PAOZZ PAOZZ PAOZZ PAOZZ PAOZZ PAOZZ 4 5 PART CAGE NUMBER 4G303 034 46303 CA053 4G303 F017SP 62081 2 25 1 9238 2 4G303 052 10054 524243 46303 0055 46303 F014SP 4G303 F015SP 4G303 F016SP 4G303 CA049 4G303 FOO6SP 4G303 050 END OF FIGURE C 24 TM 1 1740 204 13 amp P 6 DESCRIPTION AND USABLE ON CODE UOC GROUP 02 FIGURE 7 TRUCK ASSY HAND CA033 Chassis Hand Truck Assy Wheel and Tire see figure C 8 Jam Nut Dustcap Vinyl 2 25xl Nameplate Hand Truck Hivet Bolt Hex 2 13 x l grd 8 Flat Washer Washer Lock 1 2 grd 8 Machine Nut Spacer Strap Mounting Hex Bolt Strap Tank Retention 7 QTY OQ OO F 1 ITEM NO TM 1 1740 204 13 amp P Figure C 8 WHEEL AND TIRE ASSEMBLY 053 2 3 4 5 6 7 SMR PART CODE NSN CAGE NUMBER DESCRIPTION AND USABLE ON CODE UOC QTY GROUP 0201 FIGURE C8 WHEEL AND TIRE ASSY CA053 PAOOO 4G303 10 0059 Assy Wheel and Tire 1 PAOZZ 4G303 30 429 Seal Grease 1 PAOZZ 4G303 30 427 Bearing 2 PAOZZ 4G303 10 005 Tire 480 8 Highway Rib 1 PAOZZ 4G303 30 399W Wheel 8x3 75 white 1 PAOZZ 27783 413 Valve Stem 1 END OF FIGURE
10. C 25 TM 1 1740 204 13 amp P 6 Pd 2 lt A 4 Figure C 9 TANK CONNECTOR ASSEMBLY 003 1 2 3 4 5 6 7 ITEM SMR PART NO CODE NSN CAGE NUMBER DESCRIPTION AND USABLE ON CODE UOC QTY GROUP 03 FIGURE C o 1 CONNECTOR ASSY TANK 003 1 16166 615 3SF Nipple Connector CGA580 2 2 PAOZZ 16166 RO 11V O ring 2 3 PAOZZ 4730 01 300 3048 16166 692P Nut Hand Tight CGA580 2 4 PAOZZ 4G303 RA054 Assy Tank Hose 1 5 PAOZZ 1U339 5000 6 48P Coupling Reducing Pipe 1 6 PAOZZ 29771 CWIO025SS Valve Check High Pressure 1 7 PAOZZ 1U339 5605 6SP Tee Pipe 1 8 PAOZZ 4G303 055 Assy Panel Hose 1 END OF FIGURE C 26 ITEM 1 NO 2 3 SMR CODE NSN PAOZZ PAOZZ PAOZZ NJ TM 1 1740 204 13 amp P Figure C 10 TIRE FILLING HOSE HA056 4 5 PART CAGE NUMBER 4G303 056 60515 DM 341 60515 P 341B END OF FIGURE C 27 6 7 DESCRIPTION AND USABLE ON CODE UOC QTY GROUP 04 FIGURE C 10 FILLING HOSE TIRE 056 Hose Assembly 1 Socket Quick Disconnect 1 Nipple Quick Disconnect 1 TM 1 1740 204 13 amp P Figure C 11 WHIP HOSE 058 1 2 3 4 5 6 7 ITEM SMR PART NO CODE NSN CAGE NUMBER DESCRIPTION AND USABLE ON CODE UOC QTY GROUP 04 FIGURE C 11 HOSE WHIP HA058 1 PAOZZ 40303 058 Hose Assy Whip 1 2 PAOOO 27783 5784 Chuck High Pressure Inflating 1 3 PAOZZ 27783 2755 26 Washer C
11. Refer to the Repair Parts List for the figure to find the part number for the item number noted on the figure Refer to the Part Number Index to find the NSN if assigned b When National Stock Number or Part Number is known STEP 1 STEP 2 Using the Index of National Stock Numbers and Part Numbers find the pertinent National Stock Number or Part Number The NSN index is in National Item Identification Number NIIN sequence The part numbers in the Part Number Index are listed in ascending alphanumeric sequence Both indexes cross reference you to the illustration figure and Item Number of the item you are looking for After finding the figure and item number verify that the item is the one you are looking for then locate the item number in the repair parts list for the figure C 7 TM 1 1740 204 13 amp P SECTION Il Repair Parts List Figure C 1 HIGH PRESSURE NITROGEN SERVICING CART C 8 1 2 3 ITEM SMR NO CODE NSN QTY 1 PBOFF 2 PAOOO 3 PBOFF 4 PAOZZ 5 PAOZZ 6 PAOOO 7 8 PAOZZ 9 PAOZZ 4 CAGEC 4G303 4G303 4G303 4G303 61049 4G303 4G303 4G303 4G303 5 PART NUMBER CA033 004 57 9698935 058 056 F015SP FOO5SP 6 TM 1 1740 204 13 amp P 7 DESCRIPTION AND USABLE ON CODE Assy Hand Truck see figure C 7 Assy Tank Connector see figure C 9 Panel Assy Booster see figure C 2 Assy Hose High Pressure Va
12. 5 by gripping pipe tee 5 in a non marring vise d The tank hose assembly 6 and panel hose assembly 7 may be removed Use a wrench to disconnect the hose fittings from the tee Remove check valve 8 e Place a ratchet wrench with a 6 point 11 16 inch socket over the nipple 9 and turn it counterclockwise while holding the fitting of the tank hose assembly 6 with a wrench on the fitting hex f Remove hand nut 10 Remove O rings 11 GO TO NEXT PAGE 3 37 TM 1 1740 204 13 amp P 3 26 2 FILTER INSPECTION PROCEDURE Connectors 1 and 9 have a porous bronze filter on the threaded end After removing the connector inlets 1 and 9 tap the inlet s O ring end on a solid surface any particles or contaminants are visible replace the inlets with a new one 3 26 3 INSTALLATION a olip hand nut 10 over nipple connector 9 in the orientation as shown Apply Teflon tape D1 or sealant D2 to the threaded end of the nipple connector 9 Place a ratchet wrench with a 6 point 11 16 inch socket over the nipple connector 9 and turn it clockwise while holding the fitting of the tank hose assembly 6 with a wrench on its hex Slip hand nut 3 over nipple connector 1 in the orientation as shown Apply Teflon tape D1 or sealant D2 to the threaded end of the nipple connector 1 Place a ratchet wrench with a 6 point 11 16 inch socket over the nipple connector 1 and turn it clockwise while holding the reducing p
13. 5404 N 43 0SP C 4 11 FOO2SP C 2 10 5404 8 2 55 C 3 7 F003SP C 2 35 5406 8 4SP C 3 16 F004SP C 2 19 55044SP C 3 12 F005SP C 1 9 550445 4 10 FOO5SP C 7 7 5601 8 8SP C 3 19 FOO6SP C 7 12 5602 4SP C 2 14 F007SP C 2 9 5605 65 9 7 F008SP C 2 40 5605 8SP C 3 3 F009SP C 2 41 5652 8SP C 3 17 F010SP C 2 36 5784 C 11 2 F011SP C 2 20 615 3SF C 9 1 F012SP C 2 38 6500 4 4SP C 6 1 F013SP C 2 37 6500 6 6SP C 2 26 F014SP C 7 8 692P C 9 3 F015SP C 1 8 79550 5 1 C 2 68 F01 5SP C 7 9 89297 C 2 69 F016SP C 7 10 89780 C 2 56 F017SP C 7 3 90868 C 2 59 F018SP C 2 5 91417 016 1 C 2 71 F019SP C 2 25 91417 016 1 C 2 58 F020SP C 2 11 91417 019 C 2 57 F26 04FMO C 5 1 91451 2 C 2 80 FPNC 01 C 1 0 91462 C 2 79 003 C 1 2 91662 C 2 72 054 C 9 4 92124 06B18Z C 2 81 055 9 8 31 TM 1 1740 204 13 amp P PART NUMBER FIG ITEM PART NUMBER FIG ITEM 056 C 1 7 PA016 T C 2 4 HA056 A C 10 1 PA017 C 2 8 HAO57 C 1 4 018 C 2 33 058 C 1 6 019 C 2 50 058 C 11 1 020 C 2 51 524243 C 2 34 021 C 2 55 524243 7 6 022 C 2 47 NAR2500 NO2 C 3 14 PA023 C 2 44 P 341B C 10 3 024 2 45 341 C 3 13 025 C 2 49 004 C 1 3 026 C 2 48 005 C 2 31 027 C 2 53 006 C 2 1 028 C 2 46 007 C 2 28 029 C 2 54 008 C 2 7 2 52 9 2 29 060 C 2 42 010 C 2 27 RO 111V C 9 2 011 C 2 21 RV06 43 C 3 20 012 C 2 12 RV54 1 C 2 15 013 C 2 6 SR4K
14. Preventive Maintenance Checks PMCS IV ANM MI ete qooi oe Maintenance Procedures aaa Section VI Preparation for Storage or Shipment APPENDIX A TREFERENGES DEDE APPENDIX B MAINTENANCE ALLOCATION CHART B 1 APPENDIX C REPAIR PARTS AND SPECIAL TOOLS LIST RPSTL 1 C 1 APPENDIX D SUPPLIES AND MATERIALS LIST 1L 1 ALPHABEIISAL lis INDEX 1 TM 1 1740 204 13 amp P HOW TO USE THIS MANUAL 1 Take a few minutes to look through this manual We ve designed this manual so that it will be easy for you to find and perform the procedures you need 2 If the High Pressure Nitrogen Servicing Cart needs repair and you know what s wrong with it here s what you do a Turn to the alphabetical index and check for a paragraph on the component you want to remove and replace b Turn to the paragraph Under the paragraph title you ll find the tools materials and equipment condition needed to perform the procedure If there are no tools or materials needed it will also be noted there If there is no equipment condition needed to prepare the High Pressure Nitrogen Servicing Cart for the removal procedure it will
15. R1 and high pressure regulator R2 by turning the T handles counter clockwise until they spin freely 2 7 TM 1 1740 204 13 amp P NOTE The V1 shut off valve is closed when the handle is perpendicular to the direction of gas flow Close the shut off valve V1 and vent valves V2 and V3 and the shut off valve V4 on the high pressure charging hose Rotate the valve handles clockwise to seat the needle Unlock the adjustment knob of the shop air regulator R3 by pulling the knob out Turn the adjustment knob fully counter clockwise to set the regulator at its lowest setting Figure 2 2 Connecting Nitrogen Tanks 2 8 TM 1 1740 204 13 amp P 2 6 SETTING THE HIGH PRESSURE RELIEF VALVE See Fig 2 1 When new the high pressure relief valve is set at the maximum setting at 4 000 to 4 200 psi for normal use The high pressure relief valve may be set for relief at any pressure between 2 300 psi to 4 200 psi as required The following procedure may be used to set and verify the relief valve s performance and setting f CAUTION Do not set the high pressure relief valve for less than 2 300 psi since fully charged nitrogen tanks may be pressurized to that level Setup the cart pef paragraph 2 5 Open both nitrogen tank valves and pump drive valve V1 Adjust low pressure regulator R1 T handle clockwise slowly until the booster pump cycles and the pump outlet pressure gauge G3 reads 4000 psi Loosen t
16. Remove nut 2 and washer 3 from hose fitting 4 Hemove valve assembly 5 by disconnecting assembly from elbow 1 and mounting bracket 6 Hemove hose fitting 4 and elbow 6 from the body of the high pressure shutoff valve 7 INSTALLATION Using Teflon tape D1 or sealant D2 install hose fitting 4 and elbow 6 into the body of the high pressure shutoff valve 7 Position the assembly in the hole of mounting bracket 6 and loosely secure with nut 2 Mount the assembly by elbow 6 and tighten the flare nut on elbow 1 Tighten the nut 2 to secure the assembly to the mounting bracket 6 Perform leak check and confidence test procedure pe END OF TASK 3 25 TM 1 1740 204 13 amp P 3 21 TUBE ASSEMBLIES REPLACE TYPICAL PA009 THROUGH PA013 THIS TASK COVERS TYPICAL REMOVAL AND INSTALLATION PAO11 SHOWN Personnel Required 67 Series Tools Test and Support Equipment Tool Kit SC 5180 99 A01 NSN 5180 00 323 4692 Material parts Tube assemblies PA009 010 011 012 013 as required Equipment Conditions Shop air disconnected Cart depressurized and shutdown per GO TO NEXT PAGE 3 26 3 21 1 TM 1 1740 204 13 amp P REMOVAL WARNING Remove or disconnect nitrogen tanks before maintenance Never disconnect a pressurized line Loosen flare nuts 1 and 2 and fittings 3 at both ends of the tubing assembly so it can be removed If clamp assemblies are used to secure tubing
17. Temperature Exact 5 9 after subtracting 32 Celsius temperature To Muitipiy by newton meters 007062 inches 394 feet 3 280 yards 1 094 miles 621 square inches 155 square feet 10 764 square yards 1 196 square miles 386 acres 2 471 cubic feet 35 315 cubic yards 1 308 fluid ounces 034 pints 2 113 quarts 1 057 gallons 264 ounces 035 pounds 2 205 short tons 1 102 PIN 075266 000 This fine document Was brought to you by me Liberated Manuals free army and government manuals Why do I do it I am tired of sleazy CD ROM sellers who take publicly available information slap watermarks and other junk on it and sell it Those masters of search engine manipulation make sure that their sites that sell free information come up first in search engines They did not create it They did not even scan it Why should they get your money Why are not letting you give those free manuals to your friends I am setting this document FREE This document was made by the US Government and is NOT protected by Copyright Feel free to share republish sell and so on I am not asking you for donations fees or handouts If you can please provide a link to liberatedmanuals com so that free manuals come up first in search engines lt A HREF http www liberatedmanuals com gt Free Military and Government Manuals lt A gt Sincerely Igor Chudov http igor chudov com
18. The maintenance code entered in the fourth position tells whether or not the item is to be repaired and identifies the lowest maintenance level with the capability to do complete repair i e perform all authorized repair functions NOTE Some limited repair may be done on the item at a lower level of maintenance if authorized by the maintenance allocation Chart MAC and SMR codes The portion will contain one of the following maintenance codes C 3 TM 1 1740 204 13 amp P Application Explanation Organizational or aviation unit is the lowest level that can do complete repair or the item F Direct support or aviation intermediate is the lowest level that can do complete repair on the item General support is the lowest level that can do complete repair on the item opecialized repair activity designates the specialized repair activity is the lowest level that can do complete repair on the item Depot is the lowest level that can do complete repair on the item Non repairable No repair is authorized No repair is authorized No parts or special tools are authorized for the maintenance of a B coded item However the item may be reconditioned by adjusting lubricating etc at the user level 3 gt Recoverability Code Recoverability codes are assigned to items to indicate the composition action on unserviceable its The recoverability code is entered in the fifth position of the SMR Code as follows Application
19. 4 If the cart has been connected to contaminated shop air and performance has degraded replace the low pressure filter F1 2 13 EXTREME ENVIRONMENTAL MAINTENANCE a The High Pressure Nitrogen Servicing Cart is capable of the specified performance under the following conditions 1 Temperatures ranging from 20 degrees to 160 degrees 2 Relative humidity up to 100 percent 3 Exposure to salt fog 4 Exposure to sand and dust particles as encountered in desert areas 5 Storage at temperatures ranging from 65 to 160 degrees F b Exposure to salt Hose off salt frequently with fresh water Check for chipped paint and possible corrosion Touch up paint per TM 43 0139 Painting Operations Instructions for Field Use Use paint item 7 of 2 14 TM 1 1740 204 13 amp P CHAPTER 3 AVIATION UNIT MAINTENANCE AVUM MAINTENANCE INSTRUCTIONS CHAPTER CONTENTS REPAIR PARTS SPECIAL TOOLS TMDE AND SUPPORT EQUIPMENT SERVICE UPON RECEIPT Section PREVENTIVE MAINTENANCE CHECKS AND SERVICES PMCS ROUBLESHOOTING MAINTENANCE PROCEDURES Section PREPARATION FOR STORAGE OR SHIPMENT 3 1 GENERAL This chapter contains maintenance procedures that are the responsibility of the aviation unit maintenance technician as authorized by the Maintenance Allocation Chart MAC and Source Maintenance and Recoverability SMR coded items in the Repair Parts and Special Tools List RPSTL The maintenance
20. 6 to be secured in a vise Remove both elbows 7 and 8 INSTALLATION Disassemble the new filter by depressing sliding latch 4 and turning the bowl 3 Remove the bowl 3 Remove the filter element 5 by unscrewing it Secure the top of the filter housing 6 in a bench vise by clamping its top and bottom Install elbows 7 and 8 in the top of the filter housing 6 with Teflon tape D1 or sealant D2 Position the elbows so that the flare ports are vertically pointing upward as illustrated Mount this assembly to the flare fittings of 1 elbow and tubing 2 Tighten the flare nuts Install the filter element 5 and assemble the bowl 3 to the top of the filter housing 6 by turning the bowl 3 until latch 4 clicks Perform leak check and confidence test procedure pe END OF TASK 3 23 TM 1 1740 204 13 amp P 3 20 HIGH PRESSURE SHUTOFF VALVE REPLACE THIS TASK COVERS REMOVAL AND INSTALLATION Personnel Required 67 Series Tools Test and Support Equipment Tool Kit SC 5180 99 A01 NSN 5180 00 323 4692 Material parts High Press Shutoff Valve 9698935 Teflon tape D1 or Perma Lok LM012 D2 Equipment Conditions Shop air disconnected Cart depressurized and shutdown per GO TO NEXT PAGE 3 24 3 20 1 a o Dop 3 20 2 TM 1 1740 204 13 amp P REMOVAL WARNING Remove or disconnect nitrogen tanks before maintenance Never disconnect a pressurized line Loosen fitting on elbow 1
21. CONNECTOR O RINGS REPLACE Personnel Required 67 Series Tools Test and Support Equipment Tool Kit SC 5180 99 A01 NSN 5180 00 323 4692 Material parts O Ring RO 111V Equipment Conditions Shop air disconnected Cart depressurized and shutdown per paragraph 2 7 3 28 1 REMOVAL the O ring 1 off the groove of the nipple connector 2 with the thumb or a sharp object such as an awl Be careful not to nick the brass surfaces 3 28 2 INSTALLATION Roll the O ring 1 onto the groove of the nipple connector 2 using the thumb or finger Do not use any tools END OF TASK 3 41 TM 1 1740 204 13 amp P 3 29 TIRE FILLING HOSE REPAIR Personnel Required 67 Series Tools Test and Support Equipment Tool Kit SC 5180 99 A01 NSN 5180 00 323 4692 Material parts Hose Assembly 056 Quick Disconnect Socket DM 341 Quick Disconnect Nipple P 341B Equipment Conditions tire filling hose from cart d 3 27 1 DISASSEMBLY a Using two wrenches one at the hose fitting 1 and one at the hex of the quick disconnect socket 2 remove the Socket 2 from the hose fitting 1 b Using a wrench to hold the body of the quick disconnect nipple 3 and an open end wrench on the hose fitting 4 Remove the quick disconnect nipple 3 3 27 2 INSTALLATION a Using two wrenches one at the hose fitting 1 one at the hex of the quick disconnect socket 2 mate the Socket threads to the flare fitting
22. Explanation Z Non repairable Item When unserviceable condemn and dispose of item at the level of maintenance shown in the 3rd oosition of the SMR code Repairable Item When uneconomically repairable condemn and dispose of item at organizational or aviation unit level F Repairable Item When unserviceable condemn and dispose of item at the direct support level Repairable Item When uneconomically repairable condemn and dispose of item at general support level Repairable Item When beyond lower level repair capability return to depot Condemnation and disposal of item not authorized below depot level L Repairable Item Condemnation and disposal not authorized below specialized repair activity A Item requires special handling or condemnation procedures because of specific reasons e g precious metal content high dollar value critical material or hazardous material Refer to appropriate manuals directives for specific instructions Column 3 The national stock number for the item is listed in this column d CAGE Column 4 The commercial and Government Entity Code CAGE is a 5 digit alohanumeric code which is used to identify the manufacturer distributor or Government agency etc that supplies the item e PART NUMBER Column 5 Indicates the primary number used by the manufacturer C 4 TM 1 1740 204 13 amp P individual company firm corporation or Government activity which c
23. Filling Output Label Shop Air Inlet Label Regulated Low Pressure Pump Booster Subassy Check Valve Part of Kit p n 93651 O ring Part of Kit p n 93651 O ring Part of Kit p n 93651 Check Valve Body Nipple Male Elbow Male Nut 3 8 Tube Sleeve 3 8 Tube Fubing 3 8 304 Stnls Stl 049 Tee Female Run Tee Union Elbow Female O ring Part of Kit p n 93652 Poppet Outlet Check Valve Part of Kit p n 93652 Spring Outlet Check Valve Part of Kit p n 93652 O ring Part of Kit p n 93652 Spacer Tee Female Pipe Elbow Male Tubing 1 4 304 Stnls Stl 035 Sleeve 1 4 Nut l 4 Tube Elbow Female Gasket Air Valve Air Pilot Valve Hex Head Screw 1 4 20 x 2 1 2 Pipe Nipple Valve Air Pilot Repair Kit Inlet Check Valve Subassy lInlet Check Valve O ring O ring Repair Kit Outlet Check Valve Poppet Outlet Check Valve O ring Spring Outlet Check Valve O ring TM 1 1740 204 13 amp P 7 QTY N o N N lt o O fe L lt TM 1 1740 204 13 amp P Figure C 3 LOW PRESSURE REGULATOR ASSEMBLY 005 C 16 TM 1 1740 204 13 amp P 1 2 3 4 5 6 7 SMR PART NO CODE NSN CAGE NUMBER DESCRIPTION AND USABLE ON CODE UOC QTY GROUP 0101 REGULATOR ASSY LOW PRESSURE 005 1 PAOZZ 59165 4205T 3PP Filter High Pressure 1 2 PAOZZ 10339 5404 8 6
24. ability to adjust and to secure the tanks tightly Check that all booster panel and accessory components are accounted for and undamaged Check that the wire retainers for the regulator T handles are present and in good shape Replace all missing or broken parts Refer to Appendix C Repair Parts and Special Tools List RPSTL Check the hand truck for any broken welds and corrosion of painted surfaces Check tire for tread wear cuts and bruises Check the condition of the valve stem and core Check tire pressures and inflate to 60 psi if necessary Spin the tire by hand to check the condition of wheel bearings and freedom of wheel rotation Leak check and confidence test the cart per the procedure i Clean all components END OF TASK TM 1 1740 204 13 amp P 3 14 ACCESSORY INSPECTION Personnel Required 67 Series Material parts High Pressure Hose Tire Filling Hose Equipment Condition Disconnect hoses from the cart High Pressure Charging Hose 8 7 9 Tire Filling Hose 3 14 1 HIGH PRESSURE HOSE a Inspect the rubber hose sections 1 and 2 of the high pressure hose for nicks cuts and abrasions Examine the crimps at the hose ends Inspect high pressure fitting 3 and inflating chuck 4 for bent distorted parts or deformed screw threads c Inspect the washer 5 in the inflating chuck 4 for wear and nicks CAUTION DO NOT force tighten control valves damage will occur to the soft needle seat of the va
25. any other matter from falling into the tubing going to the booster pump This will cause booster pump failure Disconnect the Tank Connector Assembly 1 from the Booster Panel Assembly 2 at the High Pressure Filter 3 Disconnect the Tire Filling Hose 4 at the quick disconnect fitting and the High Pressure Hose Assembly 5 at the swivel fitting Remove both hoses from the chassis Remove the six bolts 6 and lock washers 7 that hold the Booster Panel Assembly 2 to the cart 8 Carefully lift the Booster Panel Assembly 2 tilting it sideways with the booster pump 9 side first until the panel assembly components clear the chassis 8 INSTALLATION Carefully lower the Booster Panel Assembly 2 between the frame rails tilting it so that the booster pump 9 side of the panel is lowered last Align the panel assembly holes against the chassis mounting nut holes Secure the panel to the chassis by inserting the mounting bolts 6 through lock washers 7 and into the six panel through holes and tightening the bolts Remove old Teflon tape or sealant from the pipe threads of the Tank Connector Assembly 1 at the High Pressure Filter 3 while observing the caution above Apply Teflon tape D1 or sealant D2 on the pipe threads Install and tighten the Tank Connector Assembly 1 at the High Pressure Filter 3 Connect the Tire Filling Hose 4 at the quick disconnect and the High Pressure Hose Assembly 5 Perform leak check an
26. ground clearance is 5 inches A MS 51336 lunette coupler for towing the cart is provided 16 inch pneumatic tires permit a maximum towing speed of 15 mph Booster Panel 2 The components of the booster are mounted on the booster panel assembly 2 that forms an integral and easily removable system The panel is attached to the hand truck by six mounting bolts The regulators are mounted near the top of the panel to provide ease of operation and good visibility of the gauges The booster pump system is mounted on the lower portion of the booster panel assembly Labels indicate the location of controls and purpose of the gauges Booster Pump 3 The booster pump 3 is a 30 1 compression ratio double acting single stage air driven pump with a rated system gas outlet pressure of 4000 psi and a maximum air drive operating pressure of 150 psi The pump is capable of continuous operation at gas outlet temperatures of up to 300 degrees F An air pilot valve integral to the booster pump will shut off the pump when the nitrogen supply pressure is below 300 psi Mufflers are mounted on the booster exhaust to provide noise attenuation during booster pump operation Regulators 4 and 5 Low pressure regulator 4 sets the pressure of the tire filling output from the nitrogen tanks for tire inflation or nitrogen gas to operate the booster pump The high pressure regulator 5 sets the pressure available at the high pressure output Tank Conne
27. not deform the seal c Check the tire pressures They should be inflated to 60 psi Align the cart spindle 5 with the grease seal 7 and inner wheel bearing 6 in the wheel assembly 3 before pushing it over the spindle 5 d Insert the outer wheel bearing 4 into the wheel hub and over the spindle Clean the grease from the threads e Place two drops of thread lock fluid on the spindle threads Hand tighten the jam nut 2 against the wheel bearing 4 Tighten jam nut 2 with an adjustable wrench an additional 1 4 to 1 2 of a flat f Place dust cap 1 over the wheel hub of the wheel assembly 3 END OF TASK 3 31 TM 1 1740 204 13 amp P 3 24 TANK RETENTION STRAP ASSEMBLY REPLACE THIS TASK COVERS REMOVAL AND INSTALLATION Personnel Required 67 Series Tools Test and Support Equipment Tool Kit SC 5180 99 A01 NSN 5180 00 323 4692 Material parts Tank Retention Strap Assy CA050 Equipment Conditions Shop air disconnected Cart depressurized and shutdown per 3 24 1 REMOVAL a Loosen bolt 1 and remove nut 2 lock washer 3 strap mounting spacer 4 and strap 5 b Loosen bolt 6 and remove washer 7 lock washer 8 nut 9 and strap 10 3 24 2 INSTALLATION a Install straps 5 and 10 ensuring the mating buckle end pieces are properly oriented and that the mounting bracket of both straps 5 10 are properly positioned as shown GO TO NEXT PAGE 3 32 TM 1 1740 204 13 amp P b Inst
28. procedures in this chapter are prepared in the form of summary and detailed procedures 3 2 MAINTENANCE OPERATIONS These instructions provide the proper technique and detailed procedures required to perform the maintenance operations Each maintenance operation provides step by step instructions in the order in which the work is most logically accomplished Any unusual or critical steps are covered in detail 3 1 TM 1 1740 204 13 amp P Section l Repair Parts Special Tools TMDE and Support Equipment SECTION CONTENTS TOOLS AND TEST EQUIPMENT LIST SPECIAL TOOLS TMDE AND SUPPORT EQUIPMENT REPAIR PARTS 3 3 TOOLS AND TEST EQUIPMENT LIST Tools and test equipment required for maintenance of the High Pressure Nitrogen Servicing Cart are identified in the Maintenance Allocation Chart Appendix B 3 4 SPECIAL TOOLS TMDE AND SUPPORT EQUIPMENT There are no special tools required for test or inspection procedures at the AVUM level 3 5 REPAIR PARTS Repair parts are listed in the Repair Parts and Special Tools List RPSTL in Appendix Q of this manual Section Service Upon Receipt 3 6 GENERAL a Visually check the exterior of the High Pressure Nitrogen Servicing Cart for apparent damage Check contents to assure that all components listed in APPENDIX C RPSTL of this manual are enclosed and undamaged b If the equipment has been damaged report the damage on SF 368 REPORT OF DISCREPANCIES Check the equipment against
29. the pneumatic assemblies of the panel while positioning moving and tilting the High Pressure Nitrogen Servicing Cart CAUTION Before disassembly of any Cart components relieve all air pressures in the affected section prior to disconnecting 2 2 TM 1 1740 204 13 amp P CAUTION DO NOT force tighten control valves damage will occur to the soft needle seat of the valve CAUTION Verify that shop air supplies are within the limits as specified in Pneumatic Input Requirements or damage may result TM 1 1740 204 13 amp P 2 3 CONTROLS AND INDICATORS 62 Figure 2 1 Controls and Indicators of the Booster Panel Assembly General Refer tg Figure 2 1 This section describes the various controls and indicators provided for the proper operation of the equipment These component designators correspond to those described in Figure 1 3 Schematic Diagram and Figure 1 4 Component Location Diagram a R1 Low Pressure Regulator H1 is an adjustable regulator used to control the output pressure from the nitrogen supply tanks to connector C4 and the nitrogen drive pressure to the booster pump system regulator has a rated outlet working pressure of 0 300 psi Its output pressure is read on gauge G2 b R2 High Pressure Regulator 2 is an adjustable regulator that controls the output pressure to connector C5 by regulating the output pressure available from the booster pump system The regulator has a 300 to 4500 psi delivery range
30. the Description column heading Usable on codes are shown in the Description Column justified left on the first line applicable item description of the usable on codes used in the RPSTL are Code Used On N A N A FABRICATION INSTRUCTIONS Bulk materials required to manufacture items are listed in the Bulk Materials functional Group of the RPSTL Part number of bulk materials are also referenced in the description column of the line item entry for the item to be manufactured fabricated ASSEMBLY INSTRUCTION N A KITS Line item entries for repair parts kits appear in a group in Section INDEX NUMBERS Items which are the work BULK in the figure column will have an index number shown in the item number column This index number is a cross reference between the National Stock Number Part Number Index and the bulk material list in Section II ASSOCIATED PUBLICATIONS N A C 6 TM 1 1740 204 13 amp P 6 HOW TO LOCATE REPAIR PARTS a When National Stock Number or Part Number is not known STEP 1 STEP 2 STEP 3 STEP 4 STEP 5 Using the table of contents determine the assembly group or subassembly group to which the item belongs This is necessary since figures are prepared for assembly and subassembly groups and lists are divided into the same groups Find the figure covering the assembly group or subassembly group to which the item belongs Identify the item on the figure and note the item number
31. the packing slip to see if the shipment is complete Report any discrepancies accordance with the instructions of DA PMA 738 751 3 2 TM 1 1740 204 13 amp P Section Ill Preventive Maintenance Checks PMCS SECTION CONTENTS GENERAL CLEANING SETUP CONFIDENCE AND LEAK TESTS 3 7 GENERAL Preventive maintenance of the High Pressure Nitrogen Servicing Cart is covered by the following paragraphs as well as the warnings cautions and Notes in Chapter 2 and PMCS information listed in Table 2 1 These if followed assure that the equipment will be used in the proper manner No lubrication is required for the Booster Pump Any required lubrication internally to the pump is provided during pump rebuild 3 8 CLEANING a Keep equipment free of dirt and grease Place a protective cover over the booster panel and tank connectors when not in use b In salt water environment hose cart off frequently with water Cover tank connectors and connector ports with plastic bags to prevent entry of contaminants C Use a soft cloth dampened with a solution of mild soap and water or isopropyl alcohol for cleaning 3 9 SETUP CONFIDENCE AND LEAK TESTS Visually inspect the High Pressure Nitrogen Servicing Cart accessories indicators and shut off valves Refer to the following paragraphs for the applicable procedures PARA BEFORE YOU OPERATE SETUP SETTING THE HIGH PRESSURE RELIEF VALVE 2 6 SHUTDOWN PROCEDURE LEAK CHECK AND CONFIDE
32. vent relief valve 4 200 psi perlparagraph 2 6 6 mos Paint item 7 of Visually inspect for corrosion chipping and worn areas Treat corrosion and touch up per 43 0139 2 5 SETUP CAUTION Nitrogen tanks must be secured tightly to the hand truck s saddles Loose or unsecured tank retention straps will allow the tanks to shift during towing This could damage the tank connectors hoses or tow vehicle CAUTION The maximum safe towing speed for the High Pressure Nitrogen Servicing Cart is 15 miles per hour Do not exceed this speed To set up the cart follow these procedures a Verify that the high pressure charging hose is connected to the high pressure output port labeled HIGH PRESSURE SHUT OFF b Place one or two pressurized 230 cu ft nitrogen tanks into the saddles of the hand truck Roll each tank into its saddle Adjust the upper and lower pairs of tank retention straps until they hold the tanks securely c Refer tb Figure 2 2 Inspect the O ring at the end of the nipple connector 1 for cuts and bruises Connect each tank to its connector by inserting the nipple connector 1 into the tank connector port 2 fully seating the connector 1 and turning the knurled hand nut 3 until it is hand tight d Leave the tank valve s completely closed until ready for use Refer t Figure 2 1 Before any test or operation of the unit verify that the following controls are properly set Back off both low pressure regulator
33. washers 8 at four places The booster pump can then be removed from the booster panel Hemove high pressure relief valve 9 and T fitting 10 assembly with an adjustable wrench Remove the elbows 11 and 12 from the booster pump 13 INSTALLATION Install elbow fitting 11 on the booster pump 13 but do not tighten the flare fitting yet Using Teflon tape D1 or sealant D2 install elbow fitting 12 and T fitting 10 on the booster pump 13 and orient as shown in the illustration Using Teflon tape D1 or sealant D2 install high pressure relief valve 9 to T fitting 10 and orient as shown in the illustration Mount booster pump to booster panel using four each of bolt 5 flat washer 6 nut 7 and lock washers 8 Apply a drop of thread lock fluid D3 to the mounting bolts 5 before assembling nuts 7 Connect supply and output line flare fittings 1 and 2 and tighten Tighten the flare nuts of elbow fitting 11 Reconnect the flare fittings in the pressure sense line to the air pilot valve at 3 and 4 Perform leak check and confidence test procedure pe END OF TASK 3 29 TM 1 1740 204 13 amp P 3 23 WHEEL ASSEMBLY REPLACE AND REPAIR THIS TASK COVERS REMOVAL AND INSTALLATION Personnel Required 67 Series Tools Test and Support Equipment Tool Kit SC 5180 99 A01 NSN 5180 00 323 4692 Shop Set SC 4920 99 890 1 1 2 in Adj Wrench NSN 5120 00 264 3796 Brush Wood Block Material parts
34. weighs approximately 100 16 This requires a two man lift to remove from the cart chassis Protect the hands from being pinched with gloves WARNING Always confirm that the pressure produced by the High Pressure Nitrogen Servicing Cart does not exceed the servicing pressures specified in the applicable aircraft technical manuals WARNING Verify the correct tire inflation pressure in the aircraft manual before inflating a TM 1 1740 204 13 amp P WARNING Use nitrogen from approved nitrogen tanks only for the supply gas If shop air is used as the supply in a high pressure system an explosion could occur WARNING Depressurize and shut down the high pressure nitrogen servicing cart prior to any repair action including the tightening of fittings WARNING Check the direction of the arrow stamped on the check valve before replacement An incorrectly installed check valve may cause the connector hose to whip violently when used with only one tank of nitrogen and possibly cause serious injury to the operator WARNING Inspect all four check valves Remove and inspect only one check valve at a time on the booster pump to ensure proper reassembly Improper assembly of the check valves or the swapping of the inlet and outlet check valves can cause very high pressures to be trapped in the booster pump These pressures can be released suddenly and unexpectedly with any subsequent disassembly CAUTION Use only a 6 point 11 16 inch socket to remov
35. 13 amp P Mount the entire assembly 11 in a non marring vise Using an adjustable wrench tighten and orient the quick disconnect assembly 18 and the shop air regulator 17 in the correct orientation Using Teflon tape D1 or sealant 02 install low pressure relief valve 10 This reassembles the shop air regulator assembly 11 Mount the low pressure regulator 9 by the rear forged hex part of the valve body in a vise with non marring jaws Slip the end of retaining wire 16 with the large loop over the stem of gauge 14 Using Teflon tape 01 or sealant D2 install gauges 14 and 15 onto the regulator 9 using open end wrenches Expand the eyelets of the small loop retainer of retainer wire 16 with a pair of needle nose pliers Place the smaller loop retainer over the channel of the low pressure regulator 9 T handle Loop the wire loop over the eyelets of the retainer then close the eyelets with a pair of needle nose pliers Install the T assembly with the High Pressure Filter 2 onto regulator 9 pipe fittings using Teflon tape DI or sealant D2 Spin tighten and orient the assembly 11 on the low pressure regulator 9 Using Teflon tape D1 or sealant D2 install low pressure relief valve 10 Secure this assembly to the booster panel by using tube clamp assemblies 7 and 8 and bolts 5 and 6 Tighten the flare fittings of tubing assemblies 3 and 4 Install Tank Connector Assembly 1 to High Pressure Fil
36. 2 C Refer to the inset illustration for the inlet check valve Carefully remove the O ring 3 from the groove in the check valve body 2 Remove check valve assembly 4 d Remove the flat O ring 5 from inside the check valve cavity of the pump body 6 e Examine all rubber parts for contamination nicks cuts and abrasions necessary replace all components with repair kit components Refer td Appendix Q RPSTL for kit part numbers NOTE Complete the installation of this check valve before proceeding with the inspection of the next one f Press O ring 3 with fingers into the groove of the check valve body 2 Insert the O ring 5 into the check valve cavity of the pump body 6 Position check valve 4 in the check valve body 2 Thread the check valve body 2 into the pump body 6 tighten and orient assembly as illustrated g Reassemble the flare fittings of tubing 1 and tighten GO TO NEXT PAGE 4 8 TM 1 1740 204 13 amp P 4 14 2 LOWER INLET CHECK VALVE a Loosen the flare fittings of tubing 1 and remove the tubing b Loosen the bolts of bracket assemblies 2 and 3 Loosen the lower flare fitting of tubing 4 and the flare fitting of elbow 5 Remove elbow 5 from T fitting 6 C With an adjustable wrench remove the lower inlet check valve body 7 with T fitting 6 attached d Refer to the inset illustration for the inlet check valve Carefully remove the O ring 8 from the groo
37. 2 ABE URSUS P S IF YOUR OUTFIT WANTS TO KNOW ABOUT YOUR RECOMMENDATION MAKE A CARBON COPY OF THIS DRSTS M verprint2 1 Nov 80 AND GIVE TO YOUR HEADQUARTERS REVERSE OF DA FORM 2028 2 Reverse of DRSTS M Overprint 2 1 Nov 80 FILL IN YOUR UNITS ADDRESS FOLD BACK DEPARTMENT OF THE ARMY OFFICIAL BUSINESS COMMANDER U S ARMY AVIATION AND TROOP COMMAND ATTN AMSAT I MP 4300 GOODFELLOW BOULEVARD ST LOUIS MO 63120 1798 rc 3N103iNVHOJH3d SNOT The Metric System and Equivalents Linear Measure 1 centimeter 10 millimeters 39 inch 1 decimeter 10 centimeters 3 94 inches 1 meter 10 decimeters 39 37 inches 1 dekameter 10 meters 32 8 feet 1 hectometer 10 dekameters 328 08 feet 1 kilometer 10 hectometers 3 280 8 feet centigram 10 milligrains 15 grain 1 decigram 10 centigrams 1 54 grains gram 10 decigram 035 ounce 1 dekagram 10 grams 35 ounce 1 hectogram 10 dekagrams 3 52 ounces 1 kilogram 10 hectograms 2 2 pounds 1 quintal 100 kilograms 220 46 pounds 1 metric ton 10 quintals 1 1 short tons To change inches feet yards miles square inches square feet square yards square miles acres cubic feet cubic yards fluid ounces pints quarts gallons ounces pounds short tons pound feet pound inches Liquid Bearers 1 centiliter 10 milliters 34 fl ounce 1 deciliter 10 centiliters 3 38 fl ounces
38. 250 VIC 079 C 4 6 014 C 2 43 SR700E 500 VIC 0 C 3 10 015 C 2 22 TUBING 1 4 C 2 75 015 C 2 24 TUBING 3 8 C 2 64 016 C 2 2 VMH2 A9 1 2 C 3 21 C 32 TM 1 1740 204 13 amp P APPENDIX D EXPENDABLE DURABLE SUPPLIES AND MATERIALS LIST SECTION I Introduction D 1 SCOPE This appendix lists expendable supplies and materials you will need to operate and maintain the High Pressure Nitrogen Servicing Cart These items are authorized to you by CTA 50 970 Expendable Items Except Medical Class V Repair Parts and Heraldic Items D 2 EXPLANATION OF CO1UMNS a Column 1 Item Number This number is assigned to the entry in the listing b Column 2 Level This column identifies the lowest level of maintenance that requires the listed it C Operator Crew O Organizational Maintenance F Direct Support Maintenance H General Support Maintenance c Column 3 National Stock Number This is the National Stock number assigned to the item use it to request or requisition the item d Column 4 Description Indicates the Federal item name and if required a description to identify the item The last line for each parentheses followed by the part number e Column 5 Unit of Measure U M Indicates the measure used in performing the actual maintenance function This measure is expressed by a two character alphabetical abbreviations e g ea in pr If the unit of measure differs from the unit of issue requisiti
39. 323 4692 Six point socket 11 16 inch x 3 8 sq drive NSN 5120 01 335 0320 Vise Material parts Refer to RPSTL for component part numbers Teflon tape 01 or Perma Lok LM012 02 Equipment Conditions Shop air disconnected Cart depressurized and shutdown per GO TO NEXT PAGE 3 36 TM 1 1740 204 13 amp P 3 26 1 REMOVAL To remove a component of the tank connector assembly use the following disassembly procedures WARNING Remove or disconnect nitrogen tanks before maintenance Never disconnect a pressurized line WARNING Check the direction of the arrow stamped on the check valve An incorrectly installed check valve may cause the connector hose to whip violently when used with only one tank of nitrogen and possibly cause serious injury to the operator CAUTION Use only a 6 point 11 16 inch socket to remove the nipple connector of the tank connector assembly An open end wrench or 12 point socket will deform and damage this part NOTE Carefully remove old Teflon tape or sealant Do not allow Teflon tape or dried sealant particles to fall into the components a Place a ratchet wrench with a 6 point 11 16 inch socket over the nipple connector 1 and turn it counter clockwise while holding the reducing pipe coupling 2 with an adjustable wrench on its hex b Remove hand nut 3 Remove coupling 2 from check valve 4 by using a box wrench and an adjustable wrench on the hexes c Remove check valve 4 from pipe tee
40. 4 4SP Fitting Flared Elbow 1 5 PAOZZ 99862 CL 51 KA 8 00 16 9R Wire Retention 1 6 PAOOO 63026 SR4K 250 VIC 0797 Regulator High Pressure 1 0232 7 PAOZZ 63026 0750 0049 T Handle Regulator 1 8 PAOZZ 1U339 2404 4 4SP Fitting Flared 1 9 PAOZZ 10339 5404 4 45 Nipple Pipe 1 10 PAOZZ 1U339 5504 4SP Elbow Pipe 1 11 PAOZZ 1U339 5404 N 4 3 0SP Nipple Pipe 1 12 PAOZZ 61049 9698935 Valve High Press Shut Off 1 13 PAOZZ OB8K7 ASP 2BV Vent Breather 1 END OF FIGURE C 19 1 ITEM NO 2 SMR CODE PAOZZ PAOZZ 3 NSN TM 1 1740 204 13 amp P Figure 5 LOW PRESSURE FILTER ASSEMBLY 007 4 5 6 PART CAGE NUMBER DESCRIPTION AND USABLE ON CODE UOC GROUP 0103 FIGURE C 5 FILTER ASSY LOW PRESSURE PA007 98963 F26 04 FMO Filter Low Pressure 1U339 2501 8 8SP Fitting Flared Elbow END OF FIGURE C 20 7 QTY 1 2 SMR NO CODE PAOZZ PAOZZ PAOZZ PAOZZ PAOZZ G N TM 1 1740 204 13 amp P Figure C 6 HIGH PRESSURE SHUT OFF ASSEMBLY 008 3 NSN 4 5 PART CAGE NUMBER 1U339 6500 4 4SP 1U339 2501 4 4SP 61049 9698935 1U339 2706 4 4SP 1U339 0306 4SP END OF FIGURE C 21 6 7 DESCRIPTION AND USABLE ON CODE UOC QTY GROUP 0104 SHUTOFF ASSY HIGH PRESSURE PA008 Fitting Swivel Nut Tube Fitting Flared Elbow Valve High Press Shut Off Fitting Flared Bulkhead Nut Bulkhead Fitting CA033 1 of 2
41. CRIPTION OF MAJOR COMPONENTS 1 6 FUNCTION The High Pressure Nitrogen Servicing Cart is a two wheeled unit which includes a 30 1 booster pump tank carriage hose rack and hoses suitable for use in aircraft flight line servicing of accumulators struts and tires The cart is towable to a maximum speed of 15 mph 1 7 PNEUMATIC INPUT REQUIREMENTS The High Pressure Nitrogen Servicing Cart is capable of operation in two different pneumatic input modes One or two 230 cu ft size nitrogen tanks can be used to supply the nitrogen gas in the low regulated pressure mode the high pressure mode either the tank supplied nitrogen gas or shop air can be used to operate the booster pump system to generate high nitrogen gas pressures 1 3 TM 1 1740 204 13 amp P TANK SUPPLY Gas Supply Containers Uses one or two 230 std cu ft nitrogen tanks nominally 9 inch diameter and 50 inches in length NSN 6830 01 028 9402 2 000 to 2 500 psi Gas Connector Compressed Gas Association CGA 580 SHOP AIR SUPPLY Shop Air Coupling 1 4 quick disconnect socket coupler compliant with MIL C 4109 Shop Air Requirements 90 psi minimum and 150 psi maximum with a minimum flow rate of 40 cfm 1 8 EQUIPMENT DATA TABLE 1 1 Equipment Data Cart Dimensions x 36 0 inches NENNEN Width 32 5 inches 60 0 inches 152 4 cm with hoses 1 but without tanks 241 Ib 109 3 icu with full tanks and ho
42. Components Leak check Performance Check Re bend Cart Tubing Weld and Paint Cart B 6 TM 1 1740 204 13 amp P APPENDIX C REPAIR PARTS AND SPECIAL TOOLS LIST SECTION I Introduction C 1 SCOPE This RPSTL lists and authorizes spares and repair parts special tools special test measurement and diagnostic equipment TMDE and other special support equipment required for performance of AVIM AVUM maintenance of the high pressure nitrogen servicing cart It authorizes the requisitioning issue and disposition of spares repair parts and special tools as indicated by the source maintenance and recoverability SMR codes C 2 GENERAL In addition to Section Introduction this Repair Parts and special Tools List is divided into the following sections a Section Repair Parts List A list of spares and repair parts authorized by the RPSTL for use in the performance of removed for replacement of the authorized parts Parts lists are composed of functional groups in the ascending alphanumeric sequence with the parts in each group listed in ascending item number sequence b Section Ill Special Tools List a list of special tools special TMDE and other special support equipment authorized by this RPSTL as indicated by Basis of Issue information in DESCHIPTION AND USABLE ON CODE column for the performance of maintenance C Section IV National Stock Number and Part Number Index A list in National Item Identification Num
43. DE and other special support equipment When density of equipment s supported exceeds density spread indicated in the basis of issue the total authorization is increased proportionately The statement END OF FIGURE appears just below the last item description in Column 5 for given figure in both Section and Section lll g QTY Column 7 The QTY quantity per figure column indicated the quantity of the item used in the breakout shown on the illustration figure which is prepared for a functional group sub function group or an assembly A V appearing in this column in lieu of a quantity indicated that the quantity is variable and the quantity may vary from application to application C 4 EXPLANATION OF COLUMNS SECTION IV a NATIONAL STOCK NUMBER NSN INDEX 1 STOCK NUMBER COLUMN this column lists the NSN by National Identification Number NIIN sequence The NIIN consists of the last nine digits of the NSN Example 5305 01 674 1467 NIIN When using this column to locate an item ignore the first 4 digits of the NSN However the complete NSN should be used when ordering items by stock number C 5 b TM 1 1740 204 13 amp P 2 FIG Column this column lists the number of the figure where the item is identified located the figures are in numerical order in Section and Section 3 ITEM Column The item number identifies the item associated with the figure listed the adjacent FIG column Thi
44. DESCRIPTION AND USE OF OPERATOR CONTROLS AND INDICATORS PREVENTIVE MAINTENANCE CHECKS AND SERVICES PMCS Section lll OPERATIONS UNDER USUAL CONDITIONS OPERATIONS UNDER UNUSUAL CONDITIONS Section l Description and Use of Operator s Controls and Indicators SECTION CONTENTS GENERAL PRE OPERATION PROCEDURES CONTROLS AND INDICATORS TM 1 1740 204 13 amp P TM 1 1740 204 13 amp P 2 1 GENERAL This chapter contains instructions for operating the High Pressure Nitrogen Servicing Cart Operating personnel should be familiar with inflation of tires accumulators and struts 2 2 PRE OPERATION PROCEDURES Review the following warning and cautions before operating the equipment WARNING PRESSURIZED AIR OR GAS CAN CAUSE SEVERE INJURY OR DEATH IF MISUSED Read and understand these and manufacturers operating instructions prior to operating the cart WARNING Do not remove tamper with or in any way disable installed pressure relief valves WARNING Always wear safety glasses WARNING Always confirm that the pressure produced by the High Pressure Nitrogen Servicing Cart does not exceed the servicing pressures specified in the applicable aircraft technical manuals WARNING Use nitrogen from approved nitrogen tanks only for the supply gas If shop air is used as the supply in a high pressure system an explosion could occur CAUTION Do not stand on any tubing or pneumatic assemblies or place any pressure on any of
45. EPLACE TM 1 1740 204 13 amp P THIS TASK COVERS REMOVAL AND INSTALLATION Personnel Required Tools Test and Support Equipment Material parts Equipment Conditions 67 Series Tool Kit SC 5180 99 A01 NSN 5180 00 323 4692 Pipe Wrench NSN 5120 00 277 1485 or Vise Grip NSN 5120 00 494 191 1 Air Pilot Valve 93622 Air Valve Gasket 91462 Teflon tape 01 or Perma Lok LM012 02 Shop air disconnected Cart depressurized and shutdown per GO TO NEXT PAGE 4 15 4 15 1 1 1740 204 13 amp REMOVAL In order to remove and replace the air pilot valve 1 the air valve assembly 2 must be removed Removal and replacement of the air valve assembly 2 will require the replacement of the air valve gasket 3 a b 4 15 2 Loosen the flare fittings of tubing 4 and 5 and remove Remove the air valve assembly 2 along with the air pilot valve 1 by removing the four bolts 6 Remove air valve gasket 3 and discard Grip the air valve assembly 2 in a non marring vise Remove the air pilot valve 1 by pivoting it about the pipe nipple and bushing assembly 7 Remove the elbows 8 and 9 from the air pilot valve 1 Remove the nipple and bushing assembly 7 from the air pilot valve 2 and remove the filter screen 10 Inspect the filter screen 10 for contaminants and clean if necessary INSTALLATION Insert the filter screen 10 into the air valve assembly 2 Grip th
46. ERATIONS TOOLS AND TEST EQUIPMENT LIST SPECIAL TOOLS TMDE AND SUPPORT EQUIPMENT REPAIR PARTS 4 1 GENERAL This chapter contains maintenance procedures that are the responsibility of the Aviation Intermediate Maintenance AVIM technician as authorized by the Maintenance Allocation Chart MAC and Source Maintenance and Recoverability SMR coded items in the Repair Parts and Special Tools List RPSTL The maintenance procedures in this chapter are prepared in the form of summary and detailed procedures TM 1 1740 204 13 amp P 4 2 MAINTENANCE OPERATIONS These instructions provide the proper technique and detailed procedures required to perform the maintenance operations Each maintenance operation provides step by step instructions in the order in which the work is most logically accomplished Any unusual or critical steps are covered in detail 4 3 TOOLS AND TEST EQUIPMENT LIST Tools and test equipment required for maintenance of the High Pressure Nitrogen Servicing Cart are identified in the Maintenance Allocation Chart Appendix 4 4 SPECIAL TOOLS TMDE AND SUPPORT EQUIPMENT There are no special tools required for test or inspection procedures at the AVIM level 4 5 REPAIR PARTS Repair parts are listed in the Repair Parts and Special Tools List RPSTL irl Appendix Q of this manual Section Il Service Upon Receipt 4 6 GENERAL a Visually check the exterior of the High Pressure Nitrogen Servicing Cart for appa
47. IRING BOOSTER PUMP OPERATION This flow chart is to be used in troubleshooting difficulties with booster pump operation Figures 1 3 and 1 4 for the function and location of the designated components Perform confidence test per paragraph 2 8 is the booster pump cycling Is SV2 venting or any fitting or hose leaking yes no Is G1 greater than 350 psi Readjust or replace SV2 high pressure relief valve Bia ip si ue with paragraph 2 6 Tighten ull tanks per t loose fittings paragraphs 2 7 2 5 Turn R2 handle full CW Are G3 and G4 gauge readings Does hun be 50 psi the same m yen mo yes Inspect and if needed replace the Raise pressure by adjusting check valves in booster pump Replace regulator Is V1 open R1 if pressure does not rise paragraph 4 14 Otherwise R2 paragraph 3 17 to 50 psi replace R1 per replace the pump per paragraph paragraph 3 16 3 22 yes no Inpsect and needed replace the air pilot valve on booster pump per paragraph 4 15 Otherwise replace the pump per paragraph 3 22 4 6 TM 1 1740 204 13 amp P Section V Maintenance Procedures SECTION CONTENTS PARA PAGE MAINTENANCE PROCEDURES GENERAL BOOSTER PUMP CHECK VALVES INSPECTION AND REPAIR BOOSTER PUMP AIR PILOT VALVE REPLACE 4 15 4 15 4 13 MAINTENANCE PROCEDURES GENERAL WARNING Remove or disconnect nitrogen t
48. NCE TEST PROCEDURE 2 8 3 3 TM 1 1740 204 13 amp P Section IV Troubleshooting SECTION CONTENTS GENERAL TROUBLESHOOTING PROCEDURES NOT REQUIRING BOOSTER PUMP OPERATION TROUBLESHOOTING PROCEDURE REQUIRING BOOSTER PUMP OPERATION CART INSPECTION ACCESSORY INSPECTION 3 10 GENERAL WARNING Remove or disconnect nitrogen tanks before maintenance Never disconnect a pressurized line Possible failures of the High Pressure Nitrogen Servicing Cart as well as probable cause and corrective action are shown in the following troubleshooting flow charts Corrective actions as shown in the following troubleshooting flow charts are described in the applicable removal installation paragraphs in the text of this manual Troubleshooting flow charts are grouped into two categories Paragraph 3 11 covers the case where booster pump oaragraph 3 12 operation is not used and covers troubleshooting for the case where the booster pump is required for operation 3 11 TROUBLESHOOTING PROCEDURES NOT REQUIRING BOOSTER PUMP OPERATION Paragraphs 3 11 1 No Tire Inflation Low Pressures and 3 11 2 No Nitrogen Flow to High Pressure Output show troubleshooting flow charts for the cases where booster pump operation is not required Paragraph 3 1111 is to be used for troubleshooting difficulties associated with low pressure operation such as tire inflation The nitrogen supply pressure is obtained from the Cart s C4 connector in this case
49. OGEN CHARGING DIRECTLY FROM THE SUPPLY TANKS NITROGEN CHARGING USING BOOSTER PUMP 2 9 OPERATING PROCEDURES The cart can be configured to provide nitrogen for pressurizing tires accumulators and struts directly from the nitrogen tank when tank pressure is adequate or by increasing the nitrogen supply pressure with the booster pump The booster pump can be driven by the supply nitrogen or by compressed air when available WARNING Always confirm that the pressure produced by the High Pressure Nitrogen Servicing Cart does not exceed the servicing pressures specified in the applicable aircraft technical manuals WARNING Verify the correct tire inflation pressure in the aircraft manual before inflating CAUTION Do not exceed 30 inch pounds of torque when connecting high pressure inflation chuck to any charging fitting 2 10 NITROGEN CHARGING DIRECTLY FROM THE SUPPLY TANKS See a High Pressure Servicing 1 Setup the cart paragraph 2 5 Use one or two tanks with adequate pressure to complete the charging procedure for the given accumulator or strut 2 Slowly open valve s located on the nitrogen tanks 3 Check tank pressure on the tank pressure gauge G1 to make sure that tank pressure is higher than the required servicing pressure per the applicable aircraft manual 2 11 TM 1 1740 204 13 amp P NOTE If tank pressure is not adequate for the task nitrogen charging can be accomplished using the booster pum
50. ON TITLE TM 1 1740 204 13 amp P 31 December 1996 Truck Hand Nitrogen Servicing Cart BE EXACT PIN POINT WHERE IT IS IN THIS SPACE TELL WHAT IS WRONG WHAT SHOULD BE DONE ABOUT IT PARA FIGURE TABLE GRAPH O NO DATE SENT a a PRINTED NAME GRADE OR TITLE AND TELEPHONE NUMBER D A 20 28 2 ABE URSUS P S IF YOUR OUTFIT WANTS TO KNOW ABOUT YOUR RECOMMENDATION MAKE A CARBON COPY OF THIS DRSTS M verprint2 1 Nov 80 AND GIVE TO YOUR HEADQUARTERS REVERSE OF DA FORM 2028 2 Reverse of DRSTS M Overprint 2 1 Nov 80 FILL IN YOUR UNITS ADDRESS FOLD BACK DEPARTMENT OF THE ARMY OFFICIAL BUSINESS COMMANDER U S ARMY AVIATION AND TROOP COMMAND ATTN AMSAT I MP 4300 GOODFELLOW BOULEVARD ST LOUIS MO 63120 1798 rc 3N103iNVHOJH3d SNOT RECOMMENDED CHANGES TO EQUIPMENT TECHNICAL PUBLICATIONS SOMETHING WRONG WITH THIS PUBLICATION FROM PRINT YOUR UNIT S COMPLETE ADDRESS THEN JOT DOWN THE DOPE ABOUT IT ON THIS FORM CAREFULLYTEAR IT OUT FOLD IT AND DROP IT IN THE MAIL PUBLICATION NUMBER PUBLICATION DATE PUBLICATION TITLE TM 1 1740 204 13 amp P 31 December 1996 Truck Hand Nitrogen Servicing Cart BE EXACT PIN POINT WHERE IT IS IN THIS SPACE TELL WHAT IS WRONG WHAT SHOULD BE DONE ABOUT IT PARA FIGURE TABLE GRAPH O NO DATE SENT a a PRINTED NAME GRADE OR TITLE AND TELEPHONE NUMBER D A 20 28
51. RE ass 3 39 RON uuu ua 3 15 3 35 High Pressure Nitrogen Servicing Cart FPNC 01 Figure 1 C 8 RION Pressure HMM M LINE 3 18 High Pressure Regulator Assembly 006 Figure 4 C 18 Pressa VaN G 3 29 High Pressure Relief Valve 3 20 High Pressure Relief Valve 2 9 High Pressure Shut Off Assembly 008 Figure C 6 C221 miis ee Pressure Sh toll uuu 3 40 High Pressure Shutoff Valve 3 24 HOSE ONF OSSU ASSY PEE o C tttm 3 14 FIOW 10 Use Iris RES iii 3 40 3 8 Inspection 3 9 Inspection In Line Filters T T 3 36 J 3 31 L Leak mt 2 10 Low FPress re FINOP E o Tn 3 22 Low Pressure Filter Assembly 007 Figure 5 C 20 LOW Pressure u nam 3 15 Low Pressure Regulator 3 14 Low Pressure Regulator Assembly 005 Figure 3
52. SP Nipple Reducing Pipe 1 3 PAOZZ 10339 5605 8SP Tee Pipe 1 4 PAOZZ 10339 2404 6 85 Fitting Flared 1 5 PAOOO 61049 9767150 Gauge Tank Pressure 1 6 PAOZZ 61049 534 307 Cap Fill 1 7 PAOZZ 1U339 5404 N 8 2 5SP Nipple Pipe 2 8 PAOZZ 99862 CL 51 KA 8 00 16 9R Wire Retention 1 9 PAOZZ 59018 123 007 21 Gauge Regulated Low Press 1 10 PAOOO 63026 SR700E 500 VIC 0797 Regulator Low Pressure 1 0233 11 PAOZZ 63026 0750 0007 T Handle Regulator 1 12 PAOZZ 1U339 5504 4SP Elbow Pipe 1 13 PAOZZ 60515 P 341B Nipple Quick Disconnect 1 14 PAOZZ 55470 NAR2500 N02 Regulator Shop Air 1 15 PAOZZ 29771 020552 Valve Low Pressure Check 1 16 PAOZZ 10339 5406 8 45 Bushing Hex Pipe 2 17 PAOZZ 1U339 5652 8SP Cross Pipe 1 18 PAOZZ 60515 DM 341 Socket Quick Disconnect 1 19 PAOZZ 1U339 5601 8 8 8SP Tee Male Run Pipe 1 20 PAOZZ 91816 06 43 Valve Low Pressure Safety 1 21 PAOZZ 60515 VMH2 A9 1 2 Valve Shut Off Ball 1 22 PAOZZ 10339 2404 8 8SP Fitting Flared Str 1 END OF FIGURE C 17 TM 1 1740 204 13 amp P Figure C 4 HIGH PRESSURE REGULATOR ASSEMBLY 006 C 18 TM 1 1740 204 13 amp P 1 2 3 4 5 6 7 SMR PART NO CODE NSN CAGE NUMBER DESCRIPTION AND USABLE ON CODE UOC QTY GROUP 0102 FIGURE 4 REGULATOR ASSY HIGH PRESSURE 006 1 PAOZZ 59018 123NID15A21 X Gauge Regulated High Pressure 1 2 PAOOO 61049 9767169 Gauge Booster Output Pressure 1 3 PAOZZ 61049 534 307 Cap Fill 1 4 PAOZZ 10339 2501 LL
53. States Army Chief of Staff To be distributed in accordance with Form 12 31 E block no 3636 requirements for TM 1 1740 204 13 amp P Tum GOVERNKIENT PRINTING OFFICE 1887 54 02480112 RECOMMENDED CHANGES TO EQUIPMENT TECHNICAL PUBLICATIONS THEN JOT DOWN THE DOPE ABOUT IT ON THIS FORM CAREFULLYTEAR IT OUT FOLD AND DROP IT IN THE MAIL SOMETHING WRONG WITH THIS PUBLICATION FROM PRINT YOUR UNIT S COMPLETE ADDRESS DOE Jt Janaadweed MO 63108 DATE SENT 22 August 1992 PUBLICATION NUMBER PUBLICATION DATE PUBLICATION TITLE TM 1 1520 250 10 15 June 1992 Operator s manual MH60K Helicopter BE EXACT WHERE IT ISI IN THIS SPACE TELL WHAT IS WRONG AND WHAT SHOULD BE DONE ABOUT IT PAGE PARA FIGURE TABLE NO GRAPH NO NO 6 2 1 PRINTED NAME GRADE OR TITLE AND TELEPHONE NUMBER JOHN DOE PFC 268 317 7111 FORM PREVIOUS EDITIONS DA 1 JUL 79 2028 2 ARE OBSOLETE DRSTS M verprint2 1 Nov BO SIGN HERE JOHN DOE P S IF YOUR OUTFIT WANTS TO KNOW ABOUT YOUR RECOMMENDATION MAKE A CARBON COPY OF THIS AND GIVE TO YOUR HEADQUARTERS mw REVERSE OF DA FORM 2028 2 Reverse of DRSTS M Overprint 2 1 Nov 80 FILL IN YOUR UNITS ADDRESS FOLD BACK DEPARTMENT OF THE ARMY OFFICIAL BUSINESS COMMANDER U S ARMY AVIATION AND TROOP COMMAND ATTN AMSAT I MP 4300 GOODFELLOW BOULEVARD ST LOUIS MO 63120 1798 rc
54. TION STATEMENT A Approved for public release distribution unlimited TABLE OF CONTENTS Page Warning and First Aid Data Page CRAPTER PITI O PIP TON m S S 1 1 Garne Mi es us ISIS III EE E A E EETA Section ll Equipment Description and Section Ill Technical Principles of Operation 9 9 CHAPTER 2 OPERATING INSTRUCTIONS nn nn tent sts 2 1 Description and Use of Operator s Controls and Indicators Preventive Maintenance Checks and Services PMCS Operations under Usual Conditions nnn Operations under Unusual TM 1 1740 204 13 amp P CHAPTER 3 AVIATION UNIT MAINTENANCE MAINTENANCE INSTRUCTIONS 3 1 CHAPTER 4 AVIATION INTERMEDIATE MAINTENANCE MAINTENANCE NO TRUC D 4 1 Section ll Section lll Repair Parts Special Tools TMDE and Support Service DDOHn s s isdem Eid Eb NU pain m Preventive Maintenance Checks 5 Repair Parts Special Tools TMDE and Support RN TO
55. TM 1 1740 204 13 amp P TECHNICAL MANUAL OPERATOR S AVIATION UNIT AND INTERMEDIATE MAINTENANCE MANUAL INCLUDING REPAIR PARTS AND SPECIAL TOOLS LIST FOR TRUCK HAND HIGH PRESSURE NITROGEN SERVICING CART P N FPNC 01 NSN 1740 01 327 6831 DISTRIBUTION STATEMENT A Approved for public release distribution unlimited Headquarters Department of the Army 31 December 1996 TM 1 1740 204 13 amp P WARNINGs and CAUTIONs Page A WARNING denotes a hazard A WARNING highlights a procedure practice etc which if not correctly followed could result in personnel injury or loss of life Do not proceed beyond a WARNING until the indicated conditions are fully understood and met A CAUTION denotes a hazard It calls attention to an operating procedure practice or the like which if not correctly performed or adhered to could result in damage to or destruction of part of or all of the product Do not proceed beyond a CAUTION until the indicated conditions are fully understood and met WARNING PRESSURIZED AIR OR GAS CAN CAUSE SEVERE INJURY OR DEATH IF MISUSED Read and understand these and manufacturer s operating instructions prior to operating the cart WARNING Do not remove tamper with or in any way disable installed pressure relief valves WARNING Always wear safety glasses WARNING Remove or disconnect nitrogen tanks before maintenance Never disconnect a pressurized line WARNING The booster panel assembly
56. V2 7 0 Booster Pump Low Pressure Regulator High Pressure Regulator Shop Air Regulator Tank Pressure Regulated Low Pressure Gauge Pump Outlet Pressure Gauge Regulated High Pressure Gauge Relief Valve Low Pressure Relief Valve High pressure Pump Drive Valve High Pressure Vent V3 CV E D No V3 v4 CV2 F1 F2 H1 H2 C1 C2 C3 C4 C5 C6 1 9 55 NITROGEN TANK HIGH PRESSURE CHARGING HOSE High Pressure Shut Off Valve High Pressure Shut Off Valve Tank Check Valve Shop Air Check Valve Tank Check Valve Low Pressure Filter High Pressure Filter Hoses Tank Connectors Shop Air Inlet Tire Filling Output High Pressure Output Figure 1 3 Schematic Diagram of High Pressure Nitrogen Servicing Cart TM 1 1740 204 13 amp P Refer to Figure 1 3 Schematic of the High Pressure Nitrogen Servicing Cart for the following discussion of the principles of operation The corresponding physical location of the designated component is shown i Figure 1 4 Component Location Diagram for the High Pressure Nitrogen Servicing Cart Nitrogen gas is supplied by one or two 230 cu ft tanks via connectors C1 and C2 Nitrogen gas flows to the system from the tanks via flexible hoses H1 H2 and filter F2 There are also porous bronze filters located in the nipple connectors C1 and C2 Nitrogen from the tanks pass TM 1 1740 204 13 amp P through the check valves CV1 an
57. W Are G3 and G4 gauge readings the same Does gauge G2 read 50 psi minimum R1 If pressure does not rise to 50 psi replace R1 per paragraph 3 16 Replace regulator x Raise pressure by adjusting R2 paragraph 3 17 Refer to AVIM for replacement of check valves Otherwise replace the pump per paragraph 3 22 Refer to AVIM for replacement of check valves Otherwise replace the pump per paragraph 3 22 3 7 TM 1 1740 204 13 amp P 3 13 CART INSPECTION Personnel Required 67 Series Material parts High Pressure Nitrogen Servicing Cart FPNC 01 Nitrogen tanks 1 or 2 230 cu ft NSN 6830 01 028 9402 Equipment Condition Cart in upright position a Shut off the valves of both nitrogen tanks Shut down the cart and bleed the booster pump system per shutdown procedure of paragraph 2 7 Disconnect both tank connectors from the tanks by turning hand nut counterclockwise Remove nipple connector from the tank fitting Examine the O ring on the nipple connector as shown in the Figure 2 2 and described paragraph 2 5 c Inspect the items described in Preventive Maintenance Checks and Services PMCS Table 2 1 Check all hoses and rigid tubing Check entire cart for bent broken or corroded fittings and components Examine the nipple connector of both tank connectors for nicks and flat spots Examine the webbing of the tank retention straps for cuts and abrasions Check the buckles for
58. Wheel and tire assy CA053 Thread lock fluid Loctite 241 03 Lithium Bearing Grease D4 Kerosene D5 Shop Towels D6 Equipment Conditions Any position except towing position GO TO NEXT PAGE 3 30 TM 1 1740 204 13 amp P REMOVAL a Pull off the dust cap 1 With an adjustable wrench remove jam nut 2 b Pull wheel assembly 3 part way out and note that the outer bearing 4 is loose Remove this bearing and wrap in a shop towel D6 to prevent the contamination of wheel bearing grease c Then remove the wheel assembly 3 entirely from the axle spindle 5 The inner bearing 6 is retained by the grease seal 7 d The wheel bearings 4 and 6 require periodic maintenance depending on severity of use Remove the inner bearing 6 by removing and discarding the grease seal 7 INSTALLATION CAUTION Make sure grease seals and bearings are in good condition before reassembly a Clean the wheel bearings 4 and 6 of old grease using kerosene D5 and kerosene soaked brush Dry wheel bearings with shop towels and repack the wheel bearings with lithium based grease D4 b Lay the wheel and tire assembly flat on the ground with the inner hub facing up Reassemble inner wheel bearing 6 by placing it into wheel hub and securing it with a new grease seal 6 Tap the grease seal 6 into the wheel hub using a block of wood and a hammer Position the block of wood over the seal so that tapping with the hammer does
59. all bolt 1 through strap 5 mounting bracket spacer 4 through the chassis with lock washer 3 and nut 2 c Install bolt 6 through strap 10 mounting bracket through the chassis with lock washer 8 and nut 9 END OF TASK 3 33 TM 1 1740 204 13 amp P 3 25 TANK CONNECTOR ASSEMBLY AND HIGH PRESSURE FILTER INSPECT AND REPLACE THIS TASK COVERS REMOVAL INSPECTION OF THE FILTERS AND INSTALLATION Personnel Required 67 Series Tools Test and Support Equipment Tool Kit SC 5180 99 A01 NSN 5180 00 323 4692 Material parts Tank Connector Assy 003 High Pressure Filter 4205T 3PP Teflon tape D1 or Perma Lok LM012 02 Equipment Conditions Shop air disconnected Cart depressurized and shutdown per GO TO NEXT PAGE 3 34 TM 1 1740 204 13 amp P 3 25 1 REMOVAL WARNING Remove or disconnect nitrogen tanks before maintenance Never disconnect a pressurized line CAUTION When removing or tightening a fitting to the high pressure filter hold the filter body hex with a wrench adjacent the fitting Tightening the filter across its body may stress the filter housing and cause leaks to develop Extreme caution should be used to prevent contaminants such as old Teflon tape sealant dirt or any other matter from falling into the tubing going to the booster pump This will cause booster pump failure a Verify that the valves on both nitrogen supply tanks are shut off Remove both connectors 1 and 2 of the tank conne
60. ance is required removal and replacement of a part or assembly is indicated Removal procedures are given only to the extent necessary to repair or replace authorized parts Removal of the booster panel assembly from the hand truck is generally not necessary to remove and replace components Most of the components are accessible with the panel on the cart 3 11 TM 1 1740 204 13 amp P 3 15 BOOSTER PANEL ASSEMBLY REPLACE THIS TASK COVERS REMOVAL AND INSTALLATION Personnel Required 67 Series 2 Tools Test and Support Equipment Tool Kit SC 5180 99 A01 NSN 5180 00 323 4692 Gloves Material parts Booster Panel Assy 004 Teflon Tape D1 or Perma Lok LMO12 02 Equipment Conditions Shop air disconnected Cart depressurized and shutdown per Nitrogen tanks disconnected and removed Cart in horizontal position booster panel side up GO TO NEXT PAGE 3 12 3 15 1 3 15 2 C d TM 1 1740 204 13 amp P REMOVAL WARNING The booster panel assembly weighs approximately 100 Ib This requires two man lift to remove from the cart chassis Protect the hands from being pinched with gloves CAUTION When removing or tightening a fitting to the high pressure filter hold the filter body hex with a wrench adjacent the fitting Tightening the filter across its body may stress the filter housing and cause leaks to develop Extreme caution should be used to prevent contaminants such as old Teflon tape sealant dirt or
61. and tighten the hose fitting b Install the hose by using an open end wrench on the hose end fitting 4 and another one at the quick disconnect nipple 3 Mate and tighten both together END OF TASK 3 42 TM 1 1740 204 13 amp P Section Preparation for Storage or Shipment SECTION CONTENTS PARA PAGE PREPARATION FOR STORAGE 3 43 PREPARATION FOR SHIPMENT 3 34 3 43 3 33 PREPARATION FOR STORAGE The High Pressure Nitrogen Servicing Cart may be stored using normal procedures Instructions are provided in TM 1 1500 204 23 Series Manuals 1 through 10 Carts may NOT be stored with nitrogen tanks strapped to the cart There are no in storage maintenance or inspection procedures required for storage less than 12 months 3 34 PREPARATION FOR SHIPMENT Carts may NOT be shipped with nitrogen tanks strapped to the cart Preservation and packaging shall be level A or Level B in accordance with MIL STD 2073 1 or Level C in accordance with MIL STD 1190 3 43 3 44 blank TM 1 1740 204 13 amp P CHAPTER 4 AVIATION INTERMEDIATE MAINTENANCE AVIM MAINTENANCE INSTRUCTIONS CHAPTER CONTENTS REPAIR PARTS SPECIAL TOOLS TMDE AND SUPPORT EQUIPMENT SERVICE UPON RECEIPT Section PREVENTIVE MAINTENANCE CHECKS PMCS Section IV ITROUBLESHOOTING MAINTENANCE PROCEDURES Section VI PREPARATION FOR STORAGE OR SHIPMENT Section Repair Parts Special Tools TMDE and Support Equipment SECTION CONTENTS GENERAL MAINTENANCE OP
62. anks before maintenance Never disconnect a pressurized line When maintenance is required removal and replacement of a part or assembly is indicated Removal procedures are given only to the extent necessary to repair or replace authorized parts most cases removal of the pump panel from the hand truck is not necessary because most of the components are accessible with the panel on the cart 4 14 BOOSTER PUMP CHECK VALVES INSPECTION AND REPAIR THIS TASK COVERS REMOVAL REPAIR AND INSTALLATION Personnel Required 67 Series Tool Kit SC 5180 99 01 NSN 5180 00 323 Tools Test and Support Equipment 4692 Inlet Check Valve Repair Kit 93651 Outlet Check Valve Repair Kit 93652 Teflon tape 01 or Perma Lok LM012 02 Material parts Equipment Conditions Shop air disconnected Cart depressurized shutdown per WARNING Inspect all four check valves Remove and inspect only one check valve at a time on the booster pump to ensure proper reassembly Improper assembly of the check valves or the swapping of the inlet and outlet check valves can cause very high pressures to be trapped in the booster pump These pressures can be released suddenly and unexpectedly with any subsequent disassembly GO TO NEXT PAGE 4 7 TM 1 1740 204 13 amp P 4 14 1 UPPER INLET CHECK VALVE a Loosen the flare nuts of tubing 1 and remove the tubing b With an adjustable wrench remove the upper inlet check valve body
63. be noted c To remove the bad component perform the removal procedure To install the new component perform the installation procedure Perform the leak check and confidence test procedure The High Pressure Nitrogen Servicing Cart should now be ready to operate 3 If the High Pressure Nitrogen Servicing Cart needs repair and you don t know what is wrong with it go to the troubleshooting procedures Troubleshooting procedures will direct you to the appropriate paragraph to repair your unit Repair Parts and Special Tools List RPSTL will show component relationships provide part number information and show a illustration of the various components of the cart iii iv blank TM 1 1740 204 13 amp P CHAPTER 1 INTRODUCTION CHAPTER CONTENTS GENERAL INFORMATION Section ll EQUIPMENT DESCRIPTION AND DATA Section lll PRINCIPLES OF OPERATION Section l General Information SECTION CONTENTS PARA SCOPE MAINTENANCE FORMS RECORDS AND REPORTS ADMINISTRATIVE STORAGE 1 4 REPORTING EQUIPMENT IMPROVEMENT RECOMMENDATIONS EIRS 1 5 DESTRUCTION OF ARMY MATERIEL TO PREVENT ENEMY USE 1 1 TM 1 1740 204 13 amp P 1 1 SCOPE This manual contains operation maintenance and illustrated parts breakdown and repair parts list for the Hand Truck High Pressure Nitrogen Servicing Cart Part Number FPNC 01 illustrated 1 1 The High Pressure Nitrogen Servicing Cart is a mobile self contained piece of field support e
64. ber NIIN sequence of all National stock numbered items appearing in the listing followed by a list in alohanumeric sequence of all part numbers appearing in the listings National stock numbers and part numbers are all cross referenced to each illustration figure and item number appearance TM 1 1740 204 13 amp P EXPLANATION OF COLUMNS SECTIONS II AND III a ITEM NO Column 1 Indicates the number used to identify items called out in the illustration b SMR CODE Column 2 The Source Maintenance and Recoverability SMR code is a 5position code containing supply requisitioning information maintenance category authorization criteria and disposition instruction as shown in the following breakout Source Maintenance Recoverability Code Code Code PA m x Who can install Who can do complete replace or use repair on the item the item How you get it Who determines disposition action on an unserviceable item Complete Repair maintenance capacity capability and authority to perform all corrective maintenance tasks on the Repair function in a use user environment in order to restore serviceability to a failed item 1 Source Code The source code tells you how to get an item needed for maintenance repair or overhaul of an end item equipment Explanations of source codes follows Explanation otocked items use the applicable NSN to request requisition items with these source
65. codes They are authorized to the category indicated by the code entered in the 3rd position of the SMR code NOTE Items coded PC are subject to deterioration ltems with these codes are not to be requested requisitioned individually They are part of a kit which is authorized to the maintenance category indicated in the 3rd position of the SMR code The complete kit must be requisitioned and applied KO made at Org AVUM level ltems with these codes are not to be requested requisitioned MF made at DS AVIM level individually They must be made from bulk material which is MH made at GS level identified by part number in the DESCRIPTION AND USABLE ML made at Specialized ON CODE UOC column and listed in the Bulk Material group Repair Activity SRA of the repair parts list in this RPSTL If the item is authorized to MD made at Depot you by the 3rd position of the SMR code but the source code indicates it is made at a higher level order the item from the higher level of maintenance TM 1 1740 204 13 amp P Explanation assembled at Org AVUM Items with those codes are not to be requested requisitioned level individually The parts that make up the assembled item must assembled at DS AVIM be requisitioned or fabricated at the level of maintenance level indicated by the source code If the 3rd position authorizes you assembled at GS level to replace the item but the source code indicated the item is assembled by SRA a
66. condition 2 AVIM Aviation Intermediate Maintenance AVIM provides mobile responsive onestop maintenance support Authorized maintenance includes replacement and repair of module components and end items which can be accomplished efficiently with available skills tools and equipment inspects troubleshoots tests diagnoses repairs adjusts calibrates and aligns system modules and components e Column 5 Tools and Equipment Column 5 specifies by code those common tool sets not individual tools and special tools TMDE and support equipment required to perform the designated function f Column 6 Remarks This column shall when applicable contain a letter code in alphabetic order which shall be keyed to the remarks contained in Section IV B 2 TM 1 1740 204 13 amp P SECTION Il Maintenance Allocation Chart 2 COMPONENT ASSEMBLY Servicing Cart High Pressure Nitrogen Panel Assy Booster Regulator Low Pressure Regulator High Pressure Relief Valve High Pressure Regulator Shop Air Filter Low Pressure Shutoff High Pressure Tube Assembly Pump Booster check valve pilot valve Valve Check for High Pressure Nitrogen Servicing Cart 3 4 5 MAINTENANCE CATEGORY MAINTENANCE TOOLS AND FUNCTION EQUIPMENT REMARKS Inspect Service Test Repair Repair Inspect Replace Repair Inspect Test Replace Inspect Test Replace Inspect Service Replace Insp
67. ctor Assembly 6 The tank connector assembly provides the means to connect one or two nitrogen tanks to the high pressure nitrogen servicing cart In line check valves prevent nitrogen from escaping when only one tank is used Accessories 7 and 8 A 30 foot 1 4 inch high pressure charging hose assembly 7 consisting of 27 feet of hose followed by a soft seat needle shut off valve followed by a 3 foot length of hose terminated with a high pressure 5000 psi inflating chuck is supplied The high pressure hose outer rubber jacket is perforated to prevent ballooning A 20 foot low pressure 1 4 inch tire filling hose 8 is supplied with a 1 4 inch quick disconnect coupling socket that mates with a quick disconnect coupling plug 1 7 TM 1 1740 204 13 amp P g High Pressure Relief Valve 9 The adjustable high pressure relief valve 9 has a range of 2 000 psi to 4 000 psi It is provided to limit the high pressures generated in the booster pump system and has a mechanical stop limiting the maximum pressure to 4 200 psi h Low Pressure Filter 10 The low pressure filter 10 separates water and particulate contaminants from the shop air source and has an automatic mechanical drain to remove the contaminants from the filter bowl TM 1 1740 204 13 amp P SECTION Ill Principles of Operation 1 10 PRINCIPLES OF OPERATION R1 R2 R3 G1 G2 G3 G4 SV1 SV2 V1 V2 C H1 NITROGEN TANK C1 SHOP C35 C
68. ctor assembly 3 from the nitrogen supply tanks Use the filter body hex adjacent the fitting for loosening b Disconnect the tank connector assembly 3 from the booster panel 4 at the high pressure filter 5 by loosening the fitting and removing the entire assembly c Remove the high pressure filter 5 with a wrench and observing the caution regarding the use of the hex on the filter adjacent the fitting 3 25 2 FILTER INSPECTION PROCEDURE After removing high pressure filter 5 tap the inlet end on a solid surface If any particles or contaminants are visible replace the filter with a new one 3 25 3 INSTALLATION a Using Teflon tape 01 or sealant 02 install high pressure filter 5 while observing the caution note The direction of the arrow on the filter MUST be pointed toward the booster pump Using Teflon tape D1 or sealant D2 install the tank connector assembly 3 to the high pressure filter 5 Use the filter body hex adjacent the fitting for tightening Connect the two tank connectors 1 and 2 to the nitrogen supply tanks b c Perform leak check and confidence test procedure pe END OF TASK 3 35 TM 1 1740 204 13 amp 3 26 TANK CONNECTOR ASSEMBLY INSPECT FILTERS REPLACING COMPONENTS THIS TASK COVERS REMOVAL AND INSTALLATION OF NIPPLES HOSES AND FITTINGS AND INSPECTION OF THE IN LINE FILTERS Personnel Required 67 Series Tools Test and Support Equipment Tool Kit SC 5180 99 A01 NSN 5180 00
69. d CV2 One or two nitrogen tanks may be used with the operation of the servicing cart The check valves prevent nitrogen gas from escaping if only one tank is connected Gauge G1 monitors nitrogen supply pressure available from the tanks Low pressure regulator R1 allows the user to adjust the available pressure to the desired pressure as measured by gauge G2 This regulated nitrogen is available at the 1 4 inch quick disconnect coupler C4 This output is typically used for inflating tires A maximum of 160 psi working pressure is available at this output This same pressure can be used to drive booster pump P via pump drive valve V1 The pump is a double acting single stage air or gas driven booster pump with a compression ratio of 30 1 The booster pump is capable of continuous operation at outlet temperatures of up to 300 degrees F and the booster system can provide a 4000 psi maximum working pressure output at connector C5 for charging aircraft struts and accumulators The pump drive pressure can be supplied either from the tank source or shop air Shop air is connected to the system via quick disconnect coupler This pressure is used for driving pump P and is adjustable with the use of R3 located under the label designated Shop Air Inlet Check valve CV2 prevents nitrogen from escaping via quick disconnect coupler C3 An air pilot valve integral with pump P monitors the tank supply pressure and will shut off the pump driv
70. d confidence test procedure pe END OF TASK TM 1 1740 204 13 amp P 3 16 LOW PRESSURE AND SHOP AIR REGULATOR REPLACE THIS TASK COVERS REMOVAL AND INSTALLATION Personnel Required 67 Series Tools Test and Support Equipment Tool Kit SC 5180 99 A01 NSN 5180 00 323 4692 Pipe Wrench NSN 5120 00 277 1485 Workbench vise Material parts Low Press Reg SR700E 500 VIC 0797 0233 Shop Air Reg NAR2500 NO2 Teflon Tape D1 or Perma Lok LMO12 D2 Equipment Conditions Shop air disconnected Cart depressurized and shutdown per Nitrogen tanks and accessory hoses disconnected and removed GO TO NEXT PAGE 3 14 3 16 1 3 16 2 TM 1 1740 204 13 amp P REMOVAL WARNING Remove or disconnect nitrogen tanks before maintenance Never disconnect a pressurized line CAUTION When removing or tightening a fitting to the high pressure filter hold the filter body hex with a wrench adjacent the fitting Tightening the filter across its body may stress the filter housing and cause leaks to develop Extreme caution should be used to prevent contaminants such as old Teflon tape sealant dirt or any other matter from falling into the tubing going to the booster pump This will cause booster pump failure Remove the Tank Connector Assembly 1 at the High Pressure Filter 2 Loosen tubing flare nuts at 3 and 4 Remove bolts 5 and 6 and the tube clamp assemblies 7 and 8 Disconnect the flare fittings at 3 and 4 and rem
71. e air valve assembly 2 in a non marring vise Apply Teflon tape D1 or sealant D2 on the threads of pipe fittings 7 8 and 9 Thread the pipe nipple and bushing assembly 7 onto the inlet of the air valve assembly 2 Attach the air pilot valve 1 by pivoting it about the pipe nipple and bushing assembly 7 Align the air pilot valve 1 in the orientation as shown in the illustration Thread tighten and position elbows 8 and 9 as shown in the illustration Position a new gasket 3 between the air valve assembly 2 and the body of the booster pump 11 Fasten the assembly to the pump 11 with four bolts 6 Align and tighten the flare fittings of tubing 4 first and then 5 Align elbows 8 and 9 if necessary This completes the removal and replacement of the booster pump air pilot valve Perform leak check and confidence test procedure pe END OF TASK TM 1 1740 204 13 amp P Section VI Preparation for Storage or Shipment SECTION CONTENTS PREPARATION FOR STORAGE PREPARATION FOR SHIPMENT 4 16 PREPARATION FOR STORAGE The High Pressure Nitrogen Servicing Cart may be stored using normal procedures Instructions are provided in TM 1 1500 204 23 Series Carts may NOT be stored with nitrogen tanks strapped to the cart There are no in storage maintenance or inspection procedures required for storage of less than 12 months 4 17 PREPARATION FOR SHIPMENT Carts may NOT be shipped with nitrogen tanks strapped
72. e pressure when the nitrogen supply pressure is below 300 psi The filter Fl separates water and particulate contaminants from the shop air source and has an automatic mechanical drain to remove the contaminants from the filter bowl The high pressure filter F2 prevents extremely fine particulate matter and contaminates from entering the booster system Gauge G3 allows the user to monitor pump output pressure and high pressure regulator R2 permits the user to adjust the high pressure output at connector C5 The adjustable regulated pressure output is measured by gauge G4 Valve V3 is the shut off valve for the high pressure output Valve V4 is part of the high pressure charging hose and is used to control the application of high pressure nitrogen High pressure vent V2 exhausts excess nitrogen during the adjustment of high pressure regulator R2 and is used to bleed the entire booster pump system Relief valves SV1 and SV2 limit the low and high pressure in the system respectively to safe levels in the case of misapplication of air sources or malfunction of the system The low pressure relief valve SV1 is set to crack at 175 psi to limit pneumatic pressures applied to the system and to prevent tire blow outs SV2 is provided to limit the high pressures generated in the booster pump system and has a mechanical stop limiting the maximum pressure to 4 200 psi 1 11 1 12 blank CHAPTER 2 OPERATING INSTRUCTIONS CHAPTER CONTENTS
73. e the nipple connector of the tank connector assembly An open end wrench or 12 point socket will deform and damage this part CAUTION Nitrogen tanks must be secured tightly to the hand truck s saddles Loose or unsecured tank retention straps will allow the tanks to shift during towing This could damage the tank connectors hoses or tow vehicle CAUTION The maximum safe towing speed for the High Pressure Nitrogen Servicing Cart is 15 miles per hour Do not exceed this speed TM 1 1740 204 13 amp P CAUTION Do not stand on any tubing or pneumatic assemblies or place any pressure on any of the pneumatic assemblies of the panel while positioning moving and tilting the High Pressure Nitrogen Servicing Cart CAUTION Use of an air line lubricator of any kind is not recommended Lubricating oil leaking into the compressor chamber may cause pump valve damage CAUTION Before disassembly of any Cart components relieve all air pressures in the affected section prior to disconnecting CAUTION When removing or tightening a fitting to the high pressure filter hold the filter body hex with a wrench adjacent the fitting Tightening the filter across its body may stress the filter housing and cause leaks to develop Extreme caution should be used to prevent contaminants such as old Teflon tape sealant dirt or any other matter from falling into the tubing going to the booster pump This will cause booster pump failure CAUTION DO NOT force tigh
74. ect Test Replace Inspect Replace Inspect Replace Inspect Replace Inspect Replace Repair Inspect Replace Repair B 3 TM 1 1740 204 13 amp P SECTION Il Maintenance Allocation Chart for High Pressure Nitrogen Servicing Cart Cont 2 3 4 5 6 MAINTENANCE CATEGORY COMPONENT MAINTENANCE TOOLS AND ASSEMBLY FUNCTION EQUIPMENT REMARKS Pilot Valve Air Inspect Replace Truck Assy Hand Inspect Repair Repair Wheel Assy Inspect Service Replace Repair Strap Tank Retention Inspect Replace Connector Assy Tank Inspect Replace Repair Nipple Inspect Service Replace Repair Hose Assy Whip Inspect Repair Chuck Inflating Inspect Replace Repair Hose Tire Filling Inspect Repair Coupler Quick Inspect Disconnect Replace B 4 TM 1 1740 204 13 amp P SECTION 11 Tools and Test Equipment Requirements NATIONAL REFERENCE MAINTENANCE NOMENCLATURE STOCK TOOL SET CODE CATEGORY NUMBER NUMBER Tool Kit Aircraft 5180 00 323 4692 SC 5180 99 A01 Mechanic s General 10 Pipe Wrench or 5120 00 277 1485 or SC 4920 99 B90 Vise Grip 5120 00 494 191 1 6 point socket 11 16 x 5120 01 335 0320 or 3 8 sq drive std length 5120 01 335 0328 or long length TM 1 1740 204 13 amp P SECTION IV MAC Reference Code and Remarks Reference Code MAINTENANCE ALLOCATION CODE Visual inspection only Preventive Maintenance Checks and Services PMCS
75. ee spinning The shop air regulator R3 may be left set where it is If the nitrogen tanks are to be removed unbuckle the upper and lower tank retention straps of the tank to be removed Carefully pull the tank out of its saddle and roll the tank away from the cart Repeat with the second tank if used 2 9 TM 1 1740 204 13 amp P 2 8 LEAK CHECK AND CONFIDENCE TEST PROCEDURE SeelFig 2 1 WARNING Depressurize and shut down the high pressure nitrogen servicing cart paragraph 2 7 prior to any repair action including the tightening of fittings Setup the cart pef paragraph 2 5 Remove tire filling hose assembly from hose cleats Place the quick disconnect plug end of the tire filling hose assembly into the connector C4 labeled TIRE FILLING OUTPUT Couple the quick disconnect socket side to the connector C3 labeled SHOP AIR INLET Slowly open valve s located on the nitrogen tanks The tank pressure gauge G1 and pump outlet pressure gauge G3 on both regulator assemblies will show the tank pressure Slowly turn low pressure regulator R1 T handle clockwise until the regulated low pressure gauge G2 reads 150 psi Slowly turn the high pressure regulator R2 T handle fully clockwise Hemove the high pressure charging hose from hose cleats Open the high pressure shutoff valve V3 NOTE The high pressure charging hose assembly consists of two hose assemblies connected by a shut off valve The system is now press
76. es Open the shut off valve V4 in the high pressure servicing hose Depressurize and shut down the system pe paragraph 2 7 Disconnect the inflating chuck C6 from the inlet port of the aircraft component 2 13 TM 1 1740 204 13 amp P Section IV Operations under Unusual Conditions SECTION CONTENTS UNUSUAL CONDITIONS EXTREME ENVIRONMENTAL MAINTENANCE 2 12 UNUSUAL CONDITIONS a Towing The cart may be towed by a tow vehicle at a maximum speed of 15 miles per hour to any location on good roads The cart has a clearance of five inches if towed over rough terrain b Extremes of heat and cold The cart is designed to operate in temperatures ranging from 20 degrees F to 160 degrees F c Other unusual conditions 1 When operating the cart in extreme conditions of snow ice rain mud dust salt air or similar conditions do everything possible to prevent foreign material from entering the nitrogen tank connector nipples This may clog in line filters and cause reduced booster pump performance 2 After operation in extreme conditions thoroughly clean and dry the cart and its accessories Perform the filter inspection procedures Connector Assembly Inspect and Replace and 3 26 Tank Connector Assembly Inspecting and Replacing Components Replace the tank connector nipples and the high pressure filter F2 if necessary 3 Frequent over the road service or submersion requires wheel bearing maintenance
77. he locknut on the knob of the high pressure relief valve SV2 and turn the knob counterclockwise Relief valve SV2 will exhaust Continue turning the knob counterclockwise until the pump outlet pressure gauge G3 reads at the desired setting Tighten locknut to secure the knob position Turn the low pressure regulator R1 T handle fully counterclockwise until regulated low pressure gauge G2 reads zero Depressurize and shut down the system pe 2 7 SHUTDOWN PROCEDURE See Fig 2 1 To depressurize the High Pressure Nitrogen Servicing Cart and shutdown the system perform the following steps a b Close the valves on the nitrogen tanks If the regulated high pressure gauge G4 reads zero psi rotate the high pressure regulator R2 T handle clockwise until G4 reads 300 psi minimum If high pressure gauge G4 already reads pressure above 300 psi do not adjust the regulator Open the high pressure vent valve V2 to bleed off the high pressure When pressure is bled off do not turn high pressure regulator R2 handle at this time Turn low pressure regulator R1 handle clockwise until handle is free spinning The regulated low pressure gauge G2 will still show some pressure Open pump drive valve V1 to exhaust this pressure through the booster pump exhaust The system is depressurized Turn the valves V1 V2 and V3 clockwise to shut off valves and turn the high pressure regulator R2 T handle counterclockwise until handle is fr
78. he lower outlet check valve GO TO NEXT PAGE 4 12 TM 1 1740 204 13 amp P 4 14 4 LOWER OUTLET CHECK VALVE NOTE Tubing 1 has already been removed from the inspection of the upper outlet check valve a With an adjustable wrench remove the lower outlet check valve body 2 from the pump body 3 b Refer to the inset illustration for the outlet check valve Carefully remove the spacer 4 spring 5 and the check valve poppet 6 Parts may remain in the pump 3 Carefully remove the O ring 7 from the groove in the check valve body 2 Remove the O ring 8 from the end of the check valve poppet 6 d Examine all rubber parts for contamination nicks cuts and abrasions Examine the spring If necessary replace all components with repair kit components Refer 1 Appendix RPSTL for kit numbers GO TO NEXT PAGE 4 13 TM 1 1740 204 13 amp P Assemble the check valve parts 4 through 8 as shown in the outlet check valve illustration Press O ring 8 with fingers into the groove of the check valve body 2 The spacer 4 slides into the cavity of the check valve body 2 Thread the check valve assembly into the pump body 3 tighten and orient as illustrated Align and tighten the flare fittings of tubing 1 This completes the inspection and repair of the booster pump check valves Perform leak check and confidence test procedure pe END OF TASK 4 14 4 15 BOOSTER PUMP AIR PILOT VALVE R
79. igh Pressure Label Pump Outlet Pressure Label Tank Pressure Label High Press Regulator Label High Press Shut Off Label High Press Relief Vlve TM 1 1740 204 13 amp P 7 QTY ANAN T BR PR SS aS ll es F gt ROA oo 1 ITEM NO 2 SMR CODE PAOZZ PAOZZ PAOZZ PAOZZ PAOZZ PAOZZ PBOLL PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAOZZ PAOZZ 3 NSN 4 PART CAGE NUMBER 4G303 019 46303 020 46303 030 46303 027 46303 029 46303 21 86768 93639 11 86768 89780 86768 91417 019 86768 91417 016 1 86768 90868 86768 93644 86768 93645 2 10339 318 65 1U339 319 65 86768 30455 3 8 86768 93647 86768 93648 86768 93646 2 86768 79550 5 1 86768 89297 86768 5 216 63 86768 91417 016 1 86768 91662 86768 93649 86768 93645 1 86768 30455 1 4 1U339 319 45 10339 318 45 86768 93646 1 86768 91462 86768 93622 86768 92124 06B18Z 86768 1 2FF B 86768 93622 86768 93651 86768 93652 END OF FIGURE 5 C 15 6 DESCRIPTION AND USABLE ON CODE UOC GROUP 01 FIGURE C 2 PANEL ASSY BOOSTER PA004 Label High Pressure Vent Label Low Pressure Regulator Label Pump Drive Valve Label Tire
80. ing difficulties associated with no high pressure output appearing at the High Pressure Output connector C5 or at the high pressure fitting end of the high pressure charging hose See Figures 1 3 1 4 the function and location of the designated components 5 G1 reading nitrogen pressure ne Is G3 reading nitrogen pressure Are tanks pressurized Replace with pressurized E Refer to AVIM for the tanks per paragraphs 2 7 Is G4 reading nitrogen inspection and and 2 5 pressure replacement of booster pump check valves Open shut off valves V2 and V4 Is R2 adjusted for desired pressure Adjust R2 3 6 Are cylinder valves open Replace G4 per paragraph 3 17 Replace G1 using paragraph 3 16 Open cylinder valves TM 1 1740 204 13 amp P 3 12 TROUBLESHOOTING PROCEDURE REQUIRING BOOSTER PUMP OPERATION This flow chart is to be used in troubleshooting difficulties with booster pump operation See Figures 1 3 and 1 4 for the function and location of the designated components Perform confidence test paragraph 2 8 s the booster pump cycling Is SV2 venting or any fitting or hose leaking is G1 greater than 350 psi or replace SV2 high pressure relief valve per paragraph 2 6 Tighten loose fittings Replace tanks with full tanks per paragraphs 2 7 2 5 Turn R2 handle full C
81. ipe coupling 2 with a wrench on the fitting hex Grip pipe tee 5 in a non marring vise and using Teflon tape D1 or sealant D2 assemble check valve 4 along with items 1 through 3 as shown by using a wrench on the hex of reducing pipe coupling 2 Using Teflon tape D1 or sealant D2 connect the tank hose assembly 6 and panel hose assembly 7 end fittings to the pipe tee 5 Using your fingers roll the O rings 11 over the nipple connectors 1 and 9 until they are retained by the groove on the inlet Perform leak check and confidence test procedure pe END OF TASK 3 38 TM 1 1740 204 13 amp P 3 27 HIGH PRESSURE CHARGING HOSE REPAIR Personnel Required Tools Test and Support Equipment Material parts Equipment Conditions 67 Series Tool Kit SC 5180 99 A01 NSN 5180 00 323 4692 Washer 2755 26 Refer to RPSTL for other part numbers Teflon tape D1 or Perma Lok LM012 D2 High Pressure Charging Hose disconnected from cart CAUTION Do not exceed 30 inch pounds of torque when connecting high pressure inflation chuck to any charging fitting NOTE A replacement copper washer is available to replace the fiber washer Its part number is found in the RPSTL Appendix C GO TO NEXT PAGE 3 39 3 27 1 a 3 27 3 1 1740 204 13 amp P REMOVAL Using two wrenches one at the whip hose fitting 1 and one at the hex of the inflating chuck 2 remove the inf
82. isconnect nitrogen tanks before maintenance Never disconnect a pressurized line Depressurize and shut down the system pe Hemove vent breather 1 using an open end wrench Grip the body of the high pressure relief valve 2 with an adjustable wrench Turn body counterclockwise so that the pipe threads back out of fitting 3 INSTALLATION Using Teflon tape D1 or sealant D2 install the high pressure relief valve 2 by gripping the body of the valve with an adjustable wrench and turning clockwise until seated in fitting 3 Install vent breather 1 using the open end wrench END OF TASK 3 21 TM 1 1740 204 13 amp P 3 19 LOW PRESSURE FILTER REPLACE THIS TASK COVERS REMOVAL AND INSTALLATION Personnel Required 67 Series Tools Test and Support Equipment Tool Kit SC 5180 99 A01 NSN 5180 00 323 4692 Pipe Wrench NSN 5120 00 277 1485 Work Bench vise Material parts Low Pressure Filter F26 04 FMO Teflon tape D1 or Perma Lok LM012 02 Equipment Conditions Shop air disconnected Cart depressurized and shutdown per GO TO NEXT PAGE 3 22 3 19 1 TM 1 1740 204 13 amp P REMOVAL WARNING Remove or disconnect nitrogen tanks before maintenance Never disconnect a pressurized line Loosen and disconnect the flare fittings at the elbows 1 and 2 Remove bowl 3 by sliding latch 4 down and rotating bowl Discard the bowl Unscrew the filter element 5 and discard This permits the top of the filter housing
83. ith a solution of mild soap and water or isopropyl alcohol for cleaning TM 1 1740 204 13 amp P 4 9 SETUP CONFIDENCE AND LEAK TESTS Visually inspect the High Pressure Nitrogen Servicing Cart accessories indicators and shut off valves Refer to the tasks in Chapter 2 jor applicable procedures Refer to the following paragraphs for the applicable procedures PARA BEFORE YOU OPERATE SETUP 2 5 SETTING THE HIGH PRESSURE RELIEF VALVE SHUTDOWN PROCEDURE 2 7 LEAK CHECK AND CONFIDENCE TEST PROCEDURE 2 8 Section IV Troubleshooting SECTION CONTENTS GENERAL NO NITROGEN FLOW TO HIGH PRESSURE OUTPUT NOT REQUIRING BOOSTER PUMP OPERATION TROUBLESHOOTING PROCEDURE REQUIRING BOOSTER PUMP OPERATION 4 10 GENERAL Possible failures of the High Pressure Nitrogen Servicing Cart as well as probable cause and corrective action are shown in the following troubleshooting flow charts Corrective actions as shown in the following troubleshooting flow charts are described in the applicable removal installation paragraphs in the text of this manual In this chapter troubleshooting flow charts are grouped into two Paragraph 4 11 overs the case of high pressure operation where booster pump operation is not used and paragraph 4 12 covers troubleshooting for the case where the booster pump is required for operation The low pressure operation troubleshooting procedure is described in No Tire Inflation Low
84. lating chuck 2 from the hose fitting Using an adjustable wrench to hold the body of the high pressure shutoff valve 3 and an open end wrench on the end fitting of the whip hose 4 remove the whip hose Remove the high pressure hose 5 by using an open end wrench on the end fitting WASHER INSPECTION AND REPLACEMENT see inset illustration Remove snap ring 6 with a small flat blade screw driver Lift the hex shell 7 off Remove collet halves 8 Remove the threaded washer housing 9 that holds the washer 10 against the chuck body 11 Inspect the washer 10 for nicks and wear Replace the washer 10 if necessary Reassemble by placing the washer 10 between the threaded washer housing 9 and the chuck body 11 Install the two collet halves 8 Slip the hex shell 7 over the collet halves 8 and secure with the snap ring 6 INSTALLATION Using two wrenches one at the whip hose fitting 1 one at the hex of the inflating chuck 2 mate the chuck threads to the flare fitting and tighten the hose flare fitting Using Teflon tape D1 or sealant D2 install the whip hose 4 to the high pressure shutoff valve 3 Using Teflon tape D1 or sealant D2 install the high pressure hose 5 to the high pressure shutoff valve 3 Install inflating chuck 2 to the whip hose fitting 1 Perform leak check and confidence test procedure pet paragraph 2 8 END OF TASK 3 40 TM 1 1740 204 13 amp P 3 28 TANK
85. lliter 10 deciliters 33 81 fl ounces 1 dekaliter 10 liters 2 64 gallons 1 hectoliter 10 dekaliters 26 42 gallons 1 kiloliter 10 hectoliters 264 18 gallons Square Measure 1 sq centimeter 100 sq millimeters 155 sq inch 1 sq decimeter 100 sq centimeters 15 5 sq inches 1 sq meter centare 100 sq decimeters 10 76 sq feet 1 sq dekarnecer are 100 sq meters 1 076 4 sq feet 1 sq hectomever hectare 100 sq dekameters 2 47 acre 1 sq kilometer 100 sq hectometers 386 sq mile Cubic Measure 1 cu centimeter 1000 cu millimeters 06 cu inch 1 cu decimeter 1000 cu centimeters 61 02 cu inches 1 cu meter 1000 cu decimeters 35 31 cu feet Approximate Conversion Factors To centimeters meters meters kilometers square centimeters square meters square meters square kilometers square hectometers cubic meters cubic meters milliliters liters liters liters grams kilograms metric tons newton meters newton meters F Fahrenheit temperature Maitiply by 2 540 305 914 1 609 8 451 093 836 2 590 405 028 765 29 573 473 946 3 185 28 349 454 907 1 356 11296 change ounce inches centimeters meters meters kilometers square centimeters square meters square meters square kilometers square hectometers cubic meters cubic meters milliliters liters liters liters grams kilograms metric tons
86. lve d Inspect high pressure shutoff valve 6 for smooth operation and freedom from corrosion GO TO NEXT PAGE TM 1 1740 204 13 amp P 3 14 2 TIRE FILLING HOSE Inspect the rubber hose section 7 of the tire filling hose for nicks cuts and abrasions Examine the crimps at the hose ends Examine both coupler 8 and plug 9 end of the quick disconnect fittings for wear b c Push the male quick disconnect plug 9 into the tire filling output connector item C4 of Figure 2 1 of the cart oaragraph 2 10 0 Listen for leaks Apply 90 psi of pressure using the tire servicing procedure of END OF TASK TM 1 1740 204 13 amp P Section V Maintenance Procedures SECTION CONTENTS PARA PAGE BOOSTER PANEL ASSY REPLACE LOW PRESSURE REGULATOR REPLACE 3 16 3 14 HIGH PRESSURE REGULATOR REPLACE HIGH PRESSURE RELIEF VALVE REPLACE 3 18 3 20 LOW PRESSURE FILTER REPLACE HIGH PRESSURE SHUTOFF VALVE REPLACE 3 20 3 24 TUBE ASSEMBLIES REPLACE BOOSTER PUMP REPLACE 3 22 3 28 WHEEL ASSEMBLY REPLACE C yx TANK RETENTION STRAP ASSY REPLACE 3 24 3 32 TANK CONNECTOR ASSY AND HIGH PRESSURE FILTER REPLACE TANK CONNECTOR ASSY INSP FILTERS REPLACE COMPONENTS 3 26 3 36 HIGH PRESSURE CHARGING HOSE REPAIR TANK CONNECTOR O RINGS REPLACE 3 28 3 41 TIRE FILLING HOSE REPAIR 3 29 3 42 WARNING Remove or disconnect nitrogen tanks before maintenance Never disconnect a pressurized line When mainten
87. lve High Press Shut Off Hose Assy Whip see figure C 10 Hose Assy Tire Filling see figure C 10 Washer Lock 1 2 grd 8 Bolt Hex 1 2 13 x l grd 8 END OF FIGURE TM 1 1740 204 13 amp P Figure 2 BOOSTER PANEL ASSEMBLY 004 1 of 4 C 10 TM 1 1740 204 13 amp P TOP VIEW FRONT VIEW Figure 2 BOOSTER PANEL ASSEMBLY 004 2 of 4 TM 1 1740 204 13 amp P Figure 2 BOOSTER PANEL ASSEMBLY 004 3 of 4 C 12 TM 1 1740 204 13 amp P Figure 2 BOOSTER PANEL ASSEMBLY 004 4 of 4 C 13 1 ITEM NO 2 SMR CODE PAOOO PAOZZ PAOZZ PAOZZ PAOZZ PAOZZ PAOOO PAOZZ PAOZZ PAOZZ PAOZZ PAOZZ PAOZZ PAOZZ PAOZZ PAOZZ PAOZZ PBOLL PAOZZ PAOZZ PAOZZ PAOZZ PAOZZ PAOZZ PAOZZ PAOZZ PAOZZ PAOOO PADZZ PAOZZ PAOOO PAOZZ XDFZZ PAOZZ PAOZZ PAOZZ PAOZZ PAOZZ PAOZZ PAOZZ PAOZZ XDOZZ XDOZZ PAOZZ PAOZZ PAOZZ PAOZZ PAOZZ PAOZZ 4 CAGE 4G303 4G303 61028 4G303 4G303 4G303 4G303 4G303 40303 46303 46303 46303 10339 10339 91816 OB8K7 1U339 86768 4G303 40303 46303 46303 61028 46303 40303 10339 46303 46303 46303 61028 46303 61028 46303 10054 46303 46303 46303 46303 46303 46303 46303 46303 46303 40303 46303 46303 46303 46303 40303 5 NUMBER 006 016 25 016 F018SP 013 008 017 F007SP 0025 F020SP
88. m 3 42 TT 3 31 Tools and Test Equipment Requirements B 5 TOUR IE SOOM MGs LUI Pos 3 4 Miis ma awia 4 4 Troubleshooting Procedure Not Requiring Booster Pump Operation 3 4 Troubleshooting Procedure Requiring Booster Pump 4 6 3 26 V OH 3 21 WN ATTA S 25502 a Washer Inspection and 3 40 Li OJ ll aaa a HB 1 4 Wheel and Tire Assembly CA053 Figure 8 a nnn nnne C 25 Wheel Assembly Replace and 3 30 B SERERE E E 3 31 D teat ot lt 3 40 Whip Hose 058 Figure C 11 C 28 INDEX 4 By Order of the Secretary of the Army Official B ZZ JOEL B HUDSON Administrative Assistam to the Secretary of Amy 13143 DISTRIBUTION TM 1 1740 204 13 amp P DENNIS J REIMER General United
89. mponent or assembly end item or system Calibrate to determine and cause corrections to be made or to be adjusted on instruments or test measuring and diagnostic equipment used in precession measurement Consists of comparisons of two instruments one of which is a certified standard of known accuracy to detect and adjust any discrepancy in the accuracy of the instrument being compared Test to verify serviceability by measuring the mechanical pneumatic hydraulic or electrical characteristics of an item and comparing those characteristics with prescribed standards TM 1 1740 204 13 amp P B 3 EXPLANATION OF COLUMNS IN THE MAC SECTION II a Column 1 Group Number Column 1 lists functional group code numbers the purpose of which is to identify maintenance significant components assemblies subassemblies and modules with the next higher assembly End item group number shall be 00 b Column 2 Component Assembly Column 2 contains the names of components assemblies subassemblies and modules for which maintenance is authorized C Column 3 Maintenance Function Column 3 lists the functions to be performed on the item listed in Column 2 For detailed explanation of these functions see paragraph B 2 d Column 4 Maintenance Category 1 AVUM Aviation Unit Maintenance AVUM activities will be staffed and equipped to perform high frequency On Equipment maintenance tasks required to retain or return equipment to a serviceable
90. ntained between regulator R2 and shut off valve V3 This is a soft needle seat valve and is actuated by turning the handle clockwise to shut the valve and counter clockwise to open the valve V3 High Pressure Shut Off Valve This valve turns on and shuts off the regulated high pressure output from the high pressure regulator R2 to connector C5 V4 High Pressure Shut Off Valve This valve turns and shuts the regulated high pressure output at the high pressure charging hose connector C6 It is used to control the flow when actually charging an aircraft accumulator or strut SV2 High Pressure Relief Valve The adjustable high pressure relief valve has a range of 2 000 psi to 4 000 psi It is provided to limit the high pressures generated in the booster pump system and has a mechanical stop limiting the maximum pressure to 4 200 psi 2 5 TM 1 1740 204 13 amp P Section Preventive Maintenance Checks and Services PMCS SECTION CONTENTS BEFORE YOU OPERATE SETUP SETTING THE HIGH PRESSURE RELIEF VALVE SHUTDOWN PROCEDURE LEAK CHECK AND CONFIDENCE TEST PROCEDURE 2 4 BEFORE YOU OPERATE Always keep in mind caution and warning Review those in the front of this manual Handle the High Pressure Nitrogen Servicing Cart like you would any other high pressure pneumatic equipment See Table 2 1 for normal preventive maintenance checks and services NOTE Within the designated interval these checks are to be pe
91. on the lowest unit of issue that will satisfy your requirements D 1 TM 1 1740 204 13 amp P EXPENDABLE DURABLE SUPPLIES AND MATERIALS LIST 1 3 4 S Unit of Item National Measure Number Stock Number Description U M Teflon Pipe Thread Tape Anaerobic Sealant Perma Lok LM012 Thread Locker Loctite 271 Grease Lithium wheel bearing Kerosene Shop Towels Paint Touch Up MIL C 46168 383 Green Soap Solution Glycerin O O O O O O F OO D 2 TM 1 1740 204 13 amp P ALPHABETICAL INDEX PAGE A Air Valve ASSY 4 16 Berre Em 2 6 Booster Panel Assembly PA004 Figure 2 C 10 RCD desi san UR RUNE CU ahua UM Utque 3 12 IDoostel T UID 3 28 Booster Pump Air Pilot Valve Replace 4 15 Booster Pump Check Valves Inspection and Repair 4 7 C CONS u Check Valve 4 8 cial i ue u u u gt LL ee 4 9 Check Valve Upper 4 11 Check valve eii uu u l DER 4 13 Check Valve Tank Connector Assy 9 3 37 Clamp Assemblies EM ee E E E 3 27 Same
92. ontrols the design and characteristics of the item by means of its engineering drawings specification standards and inspection requirements to identify an item or range of items NOTE When you use an NSN to requisition an item the item you receive may have a different part number from the part ordered f DESCRIPTION AND USABLE ON CODE UOC Column 6 This column includes the following information 1 2 9 The Federal item name and when required a minimum description to identify the item The physical security classification of the item is indicated by the parenthetical entry insert applicable physical security classification abbreviation e g Phy Sec C1 C confidential phy Sec Ca S Secret Phy Sec C1 T Top Secret Items that are included in kits and sets are listed below the name of the kit or set Spare repair parts that make up an assembled item are listed immediately following the assembled item line entry Part numbers for bulk materials are referenced in this column in the line item entry for the item to be manufactured fabricated When the item is not used with all serial numbers of the same model the effective serial numbers are shown on the last line of the description before UOC The usable on code when applicable see paragraph C 5 Special Information In the Special Tools List section the basis of the issue BOI appears as the last line s in the entry for each special tools special TM
93. opper 1 replacement for fiber washer END OF FIGURE C 28 TM 1 1740 204 13 amp P SECTION Ill Special Tools List NOT APPLICABLE C 29 TM 1 1740 204 13 amp P SECTION IV National Stock Number and Part Number Index CROSS REFERENCE INDEXES NATIONAL STOCK NUMBER INDEX C 30 TM 1 1740 204 13 amp P PART NUMBER INDEX PART NUMBER FIG ITEM PART NUMBER FIG ITEM 0306 4SP C 6 5 93622 C 2 83 0750 0049 4 7 93639 11 C 2 18 0750 7 C 3 11 93644 C 2 60 1 2FF B C 2 82 93645 1 C 2 74 10 005 8 4 93645 2 2 61 10 0059 8 1 93646 1 2 78 123NID07A21 X C 3 9 93646 2 C 2 67 123NID15A21 X C 4 1 93647 2 65 2 25 1 9238 2 7 4 93648 2 66 2404 4 45 2 13 93649 2 73 2404 4 45 4 6 9698935 C 1 5 24046 85 C 3 4 9698935 C4 12 2404 68 SP C 3 22 9698935 C 6 3 2501 4 4SP C 6 2 9767150 C 3 5 2501 8 8SP C 5 2 9767169 4 2 2501 LL 4 4SP C 4 4 A 25P C C 2 3 2501 LL 8 8SP C 2 17 ASP 2BV C 2 16 2706 4 4SP C 6 4 ASP 2BV C 4 13 2755 26 C 11 3 B 37T C C 2 23 30 399W C 8 5 B 50P C C 2 30 30 427 C 8 3 B 50T C C 2 32 30 429 C 8 2 CA033 C i 1 318 4SP C 2 77 CA034 C 7 1 318 6SP C 2 62 CA049 C 7 11 319 4SP C 2 76 CA050 C 7 13 319 6SP C 2 63 CA052 C 7 5 413 C 8 5 CA053 C 7 2 4205 C 3 1 CL 51 KA 8 00 16 9R C 3 8 5 216 63 C 2 70 CL 51 KA 8 00 16 9R 4 5 5 645 C 9 5 020552 C 3 15 534307 C 3 6 02555 9 6 534307 4 3 DM 341 C 10 2 5404 4 45 4 9 DM 341 C 3 18 54048 65 C 3 2 F001 SP C 2 39
94. oppet 10 These items could remain in the pump GO TO NEXT PAGE 4 11 TM 1 1740 204 13 amp P f Carefully remove the O ring 11 from the groove in the check valve body 5 Remove the O ring 12 from the end of the check valve poppet 10 g Examine all rubber parts for contamination nicks cuts abrasions Examine the spring necessary replace all components with repair kit components Refer t Appendix RPSTL for kit part numbers NOTE Complete the installation of this check valve before proceeding with the inspection of the next one h Assemble the check valve parts 8 through 12 as shown in the outlet check valve illustration Press O ring 12 onto the groove of check valve poppet 10 Press O ring 11 with fingers into the groove of the check valve body 5 The spacer 8 slides into the cavity of the check valve body 5 Insert these parts into the pump body 7 as shown Pivot the combination tee and coupler assembly 6 with the check valve body 5 attached Tighten and orient as illustrated j Insert flare fitting 4 with Teflon tape D1 or sealant D2 into the tee and coupler assembly 6 and tighten k Reconnect tubing 2 and tighten the flare fittings of tubing 2 Leave tubing 3 off for the lower check valve inspection in paragraph 4 144 l Reinstall the high pressure relief valve 1 with Teflon tape D1 or sealant D2 and orient as shown m Continue with the inspection of t
95. ove the regulator assembly NOTE To remove the shop air regulator 17 only go to step g otherwise proceed With the regulator 9 mounted by the rear forged hex part of the valve body in a vise with non marring jaws remove low pressure relief valve 10 Remove the assembly 11 using a pipe wrench on the nipple 12 using care not to damage threads Hemove the tee subassembly with the High Pressure Filter 2 using a pipe wrench on nipple 13 using care not to damage threads Hemove the gauges 14 and 15 from the regulator assembly using open ended wrenches retaining wire 16 from the regulator 9 T handle Expand the eyelets of the retainer on the T handle with a pair of needle nose pliers so that the wire loop can be removed from the retainer then slip the retainer off the T handle This completes the removal of the low pressure regulator To remove the shop air regulator 17 mount the assembly 11 in a non marring vise by the T and using a adjustable wrench remove the quick disconnect assembly 18 by the elbow Unscrew the shop air regulator 17 from the check valve 19 INSTALLATION If the shop air regulator 17 was removed assemble using Teflon tape D1 or sealant D2 but do not tighten the quick disconnect assembly 18 to the shop air regulator 17 Assemble this subassembly to the pipe threads of check valve 19 using Teflon tape D1 or sealant D2 GO TO NEXT PAGE 3 15 TM 1 1740 204
96. p by proceeding td paragraph 2 11 Otherwise replace supply tank s Adjust the high pressure regulator R2 to the required servicing pressure measured on gauge G4 Then open high pressure shut off valve V3 Connect the inflating chuck C6 of the charging hose assembly to the inlet port of the aircraft component to be serviced Do not over torque the inflating chuck C6 Refer to applicable aircraft manuals for charging procedures Open the shut off valve V4 in the high pressure servicing hose Depressurize and shut down the system pef paragraph 2 7 Leave the shutoff valve V4 in the high pressure charging hose open to vent the line Remove the inflating chuck C6 from the inlet port of the aircraft component b Tire Servicing Setup the cart per paragraph 2 5 Use one or two tanks with adequate pressure to complete the charging procedure for the tire Connect the tire filling hose from the tire filling output C4 to the tire using the appropriate inflating chuck Slowly open valve s located on the nitrogen tank s Verify the specified tire pressure per the applicable aircraft manual Adjust the T handle of the low pressure regulator R1 pressure as indicated on gauge G2 to the specified tire pressure Depressurize and shut down the system pef paragraph 2 7 2 11 NITROGEN CHARGING USING BOOSTER PUMP Sed Fig 2 1 a High pressure servicing using nitrogen to drive the booster pump 1 2 Setup the cart pef
97. paragraph 2 5 Use one or two tanks with adequate pressure to complete the charging procedure for the given accumulator or strut Slowly open valve s located on the nitrogen tank s NOTE Replace tank s if pressure is below 350 psi or if it will be reduced to 350 psi during the charging operation 3 4 Read tank pressure on regulator G1 Open the booster shutoff valve V1 Raise the pressure by slowly adjusting the low pressure regulator R1 until the indicated pressure on the pump outlet pressure gauge 2 12 TM 1 1740 204 13 amp P G3 is 3800 psi Reduce the pump drive by turning low pressure regulator R1 T handle counter clockwise if the safety relief valve SV2 starts to exhaust Adjust the high pressure regulator R2 until the required servicing pressure as shown on gauge G4 is attained Open high pressure shut off valve V3 Connect the inflating chuck of the charging hose assembly to the inlet port of the vessel to be serviced Do not over torque the inflating chuck C6 Refer to applicable aircraft manuals for charging procedures Open the shut off valve V4 in the high pressure servicing hose Depressurize and shut down the system pef paragraph 2 7 Leave the shutoff valve V4 in the high pressure charging hose open to vent the line Remove the inflating chuck C6 from the inlet port of the aircraft component b High pressure servicing using shop air to drive the booster pump 1 2 Setup
98. quipment suitable for use in aircraft flight line servicing of accumulators struts and tires The servicing cart is capable of supplying a regulated 160 psi maximum working pressure output for filling aircraft tires booster system is capable of providing a regulated 4000 psi maximum working pressure output for charging aircraft struts and accumulators Figure 1 1 Hand Truck High Pressure Nitrogen Servicing Cart 1 2 TM 1 1740 204 13 amp P 1 2 MAINTENANCE FORMS RECORDS AND REPORTS Department of the Army forms and procedures used for equipment maintenance will be those prescribed by DA PAM 738 751 Functional User s Manual for The Army Maintenance Management System Aviation TAMMS A 1 3 DESTRUCTION OF ARMY MATERIEL TO PREVENT ENEMY USE Refer to TM 750 244 1 4 Procedures for Destruction of Aviation Ground Support Equipment to Prevent Enemy Use 1 4 ADMINISTRATIVE STORAGE Storage and shipment instructions are provided in Chapter 4 1 5 REPORTING EQUIPMENT IMPROVEMENT RECOMMENDATIONS EIRs As a primary user of this equipment your ideas to improve its design or function are valuable If your equipment needs improvement let us know Send us an EIR Put it on an SF 368 Quality Deficiency Report Mail it to US Army Aviation and Troop Command ATTN AMSAT I MDO Will send you a reply Section Equipment Description and Data SECTION CONTENTS FUNCTION PNEUMATIC INPUT REQUIREMENTS EQUIPMENT DATA LOCATION AND DES
99. ral explanation of all maintenance and repair functions authorized at various maintenance categories The Maintenance Allocation Chart MAC in Section II designates overall authority and responsibility for the performance of maintenance functions of the identified end item or component The application of the maintenance functions to the end item or component will be consistent with the capacities and capabilities of the designated maintenance categories Section Ill lists the tools and test equipment both special tools and common tool sets required for each maintenance function as referenced from Section ll Section IV contains supplemental instructions and explanatory notes for a particular maintenance function MAINTENANCE FUNCTIONS a Inspect to determine the serviceability of an item by comparing its physical mechanical and or electrical characteristics with established standards through examination e g by sight sound or feel Replace to remove an unserviceable item and install a serviceable counterpart in its place Replace is authorized by the MAC and is shown as the 3rd position code for the SMR code Repair the application of maintenance services including fault location troubleshooting removal installation and disassembly assembly procedures and maintenance actions to identify troubles and restore serviceability to an item by correcting specific damage fault malfunction or failure in a part subassembly module co
100. remove bolts 4 and clamp assemblies consisting of clamp cover 5 and tube cushion 6 to permit removal of the tubing assembly INSTALLATION Position tubing assembly with flare nuts 1 and 2 loosely tightened to its mating fittings Secure tubing assembly to the Booster Panel by sandwiching the tubing between tube cushions 6 and 7 and securing with clamp cover 5 and bolts 4 Tighten flare nuts 1 and 2 securely Perform leak check and confidence test procedure pe END OF TASK 3 27 TM 1 1740 204 13 amp P 3 22 BOOSTER PUMP REPLACE THIS TASK COVERS REMOVAL AND INSTALLATION Personnel Required 67 Series Tools Test and Support Equipment Tool Kit SC 5180 99 A01 NSN 5180 00 323 4692 Material parts Booster Pump 93639 11 Teflon tape D1 or Perma Lok LM012 D2 Thread lock fluid Loctite 241 D3 Equipment Conditions Shop air disconnected Cart depressurized and shutdown per paragraph 2 7 Place cart in horizontal position with booster pump on top 8 _ z GO TO NEXT PAGE 3 28 3 22 1 3 22 2 TM 1 1740 204 13 amp P REMOVAL WARNING Remove or disconnect nitrogen tanks before maintenance Never disconnect a pressurized line Loosen and disconnect the flare fittings in the supply and output lines at 1 and 2 Loosen and disconnect the flare fittings in the pressure sense line to the air pilot valve at 3 and 4 Loosen and remove bolts 5 flat washer 6 nuts 7 and lock
101. rent damage Check contents to assure that all components listed in APPENDIX C RPSTL of this manual are enclosed and undamaged b If the equipment has been damaged report the damage on SF 368 REPORT OF DISCREPANCIES Check the equipment against the packing slip to see if the shipment is complete Report any discrepancies in accordance with the instructions of DA PAM 738751 TM 1 1740 204 13 amp P Section Preventive Maintenance Checks and Services PMCS SECTION CONTENTS GENERAL CLEANING SETUP CONFIDENCE AND LEAK TESTS 4 7 GENERAL Preventive maintenance of the High Pressure Nitrogen Servicing Cart is covered by the following paragraphs as well as the Warnings Cautions and Notes in Chapter 2 and PMCS information listed in Table 2 1 These if followed assure that the equipment will be used in the proper manner CAUTION Use of an air line lubricator of any kind is not recommended Lubricating oil leaking into the compressor chamber may cause pump valve damage No lubrication is required for the booster pump Any required lubrication internally to the pump is provided during pump rebuild 4 8 CLEANING a Keep equipment free of dirt and grease Place protective cover over tester operator panel and tank connectors when not in use b In salt water environment hose cart off frequently with water Cover tank connectors and ports with plastic bags to prevent entry of contaminants C Use a soft cloth dampened w
102. rformed in the order listed TABLE 2 1 Preventive Maintenance Checks and Services Item to be Not Fully Interval Checked or Procedure Mission Capable Serviced if NEN new tank nipple connector soap solution item 8 of Appendix D missing or dry after connecting to tanks Visually inspect Cut leaking 3 6 mos Automatic Remove filter bowl and inspect for Binding or frozen mechanical less than 1 4 in Level of water Fill bowl full of water drain in low bowl with water and verify valve or contaminants oressure filter drains water down to 1 4 in Level 6 mos Wheel assembly Visually inspect tire valve stem and Tire is flat has wheel Check tire pressure cuts bruises inflate to 60 psi Wheel is bent 5 6 mos Wheel bearing Hemove wheel assembly from axle No grease water grease to examine bearings Clean and in bearings repack as necessary Gauge damping fluid in Inspect gauge face plate with gauges G1 or G3 see glycerin item 9 Appendix D blow out plugs to within 1 4 in From plate TM 1 1740 204 13 amp P TABLE 2 1 Preventive Maintenance Checks and Services Cont d Item Item to be Not Fully No Interval Checked or Procedure Mission Capable Serviced if 6 mos Leaks Leak check by pressurizing system with MERECE valves shut off Soap bubble test paragraph 2 8 6 mos High pressure qum that d EE vents at no higher than Relief valve does not
103. s item is also identified by the NSN listed on the same line PART NUMBER INDEX Part numbers in this index are listed by part number in ascending alphanumeric sequence 1 vertical arrangement of letter and number combination which places the first letter of digit of each group in order through Z followed by the numbers 0 through 9 and each following letter or digit in like order 1 CAGE Column Commercial and Government Entity Code CAGE is a 5 digit alohanumeric code used to identify the manufacturer distributor or Government agency etc that supplies the item 2 PART NUMBER Column Indicates the primary number used by the manufacturer individual form corporation or Government activity which controls the design and characteristics of the item by means of its engineering drawings specifications standards and inspection requirements to identify an item or range of items 3 STOCK NUMBER Column This column lists the NSN for the associated part number and manufacturer identified in the PART NUMBER and CAGE columns to the left 4 FIGURE Column This column lists the number of the figure where the item is identified located in Section II and lll 5 ITEM Column The item number is that number assigned to the item as it appears in the figure referenced in the adjacent figure number column SPECIAL INFORMATION Use the following subparagraphs as applicable USABLE ON CODE The usable on code appears in the lower left comer of
104. ses 501 Ib 227 3 The High Pressure Nitrogen Servicing Cart is capable of the specified performance under the following environmental conditions Temperatures ranging from 20 degrees to 160 degrees F Relative humidity up to 100 percent Exposure to salt fog Exposure to sand and dust particles as encountered in desert areas otorage at temperatures ranging from 65 to 160 degrees F ooo O p 1 4 1 5 blank TM 1 1740 204 13 amp P 1 9 LOCATION AND DESCRIPTION OF MAJOR COMPONENTS LEGEND 1 Hand Truck 6 Tank Connector Assembly 2 Booster Panel 7 High Pressure Charging Hose 3 Booster Pump 8 Tire Filling Hose 4 Low Pressure Regulator Assembly 9 High Pressure Relief Valve 5 High Pressure Regulator Assembly 10 Low Pressure Filter Figure 1 2 Major Components of the High Pressure Nitrogen Servicing Cart 1 6 TM 1 1740 204 13 amp P a Hand truck 1 The hand truck 1 is fabricated of tubular steel Its wrap around construction provides tip over protection for the booster system and tanks Retention means for two standard 230 cu ft nitrogen tanks is provided Means for attaching the booster panel and cleats for separately storing the tire filling and high pressure hose are provided The frame and axle locations provide for easy handling and tipping from the vertical to towing position When the cart is in the towing position the coupler is 20 inches above the pavement and the
105. ssembled at a higher level order the item from the higher level of maintenance Do not requisition an XA coded item Order its next higher assembly Also refer to the NOTE below If an XB item is not available for salvage order it using the CAGE and part number given Installation drawing diagram instruction sheet field service drawing that is identified by manufacturers part number NOTE Cannibalization or controlled exchange when authorized may be used as a source of supply for items with the above source codes except for those source coded XA or those aircraft support items restricted by requirements of AR 700 42 2 Maintenance Code maintenance code tells you the level s of maintenance authorized to USE and REPAIR support items The maintenance codes are entered in the third and fourth positions of the SMR Code as follows a he maintenance code entered in the third position tells you the lowest maintenance level authorized to remove replace and use an item The maintenance code entered in the third position will indicate authorization to one of the following levels of maintenance aviation unit maintenance Gods use the item F Direct support or aviation intermediate level can remove replace or use the item General support level can remove replace or use item Specialized repair activity can remove replace or use the item DQ 3 x BDepotlevel remove replace or use the item b
106. ten control valves damage will occur to the soft needle seat of the valve CAUTION Verify that shop air supplies are within the limits as specified in paragraph 1 7 Pneumatic Input Requirements or damage may result CAUTION Make sure grease seals and bearings are in good condition before reassembly CAUTION Do not set the high pressure relief valve for less than 2 300 psi since fully charged nitrogen tanks may be pressurized to that level TM 1 1740 204 13 amp P CAUTION Do not exceed 30 inch pounds of torque when connecting high pressure inflation chuck to any charging fitting TM 1 1740 204 13 amp P TECHNICAL MANUAL Headquarters No 1 1740 204 13 amp P Department of the Army Washington DC 31 December 1996 TECHNICAL MANUAL OPERATOR S AVIATION UNIT AND INTERMEDIATE MAINTENANCE MANUAL INCLUDING REPAIR PARTS AND SPECIAL TOOLS LIST FOR TRUCK HAND HIGH PRESSURE NITROGEN SERVICING CART P N FPNC 01 NSN 1740 01 327 6831 REPORTING OF ERRORS AND RECOMMENDING IMPROVEMENTS You can help improve this manual If you find any mistakes or if you know way to improve the procedures please let us know Mail your letter DA Form 2028 recommended Changes to Publications and Blank Forms or DA Form 2028 2 located in the back of this manual directly to Commander US Army Aviation and Troop Command ATTN AMSAT I MP 4300 Goodfellow Boulevard St Louis MO 63120 1798 A reply will be furnished to you DISTRIBU
107. ter 2 h Perform leak check and confidence test procedure per paragraph 2 8 END OF TASK 3 16 3 17 blank TM 1 1740 204 13 amp P 3 17 HIGH PRESSURE REGULATOR REPLACE THIS TASK COVERS REMOVAL AND INSTALLATION Personnel Required 67 Series Tools Test and Support Equipment Tool Kit SC 5180 99 A01 NSN 5180 00 323 4692 Pipe Wrench NSN 5120 00 277 1485 Workbench and Vise Material parts High Press Reg SR4K 250 VIC 0797 0232 Teflon tape 01 or Perma Lok LM012 02 Equipment Conditions Shop air disconnected Cart depressurized and shutdown per Nitrogen tanks and accessory hoses disconnected and removed 3 17 1 REMOVAL WARNING Remove or disconnect nitrogen tanks before maintenance Never disconnect a pressurized line GO TO NEXT PAGE 3 18 TM 1 1740 204 13 amp P Loosen flare nuts 1 and 2 bolts 3 4 and the tube clamp assemblies 5 6 Remove the high pressure regulator assembly 7 from booster panel 8 Hemove gauges 9 and 10 from the regulator 11 Remove the subassembly 12 from the regulator 11 The body of the regulator 11 may be clamped in a non marring vise lengthwise to remove fittings Hemove retaining wire 13 from the regulator 11 T handle as follows Expand the eyelets of the retainer on the T handle with a pair of needle nose pliers so that the wire loop can be removed from the retainer then slip the retainer off the T handle Remove elbow 14 and fit
108. the cart paragraph 2 5 Use one or two tanks with adequate pressure to complete the charging procedure for the given accumulator or strut Connect shop air or a portable air compressor to the shop air inlet C3 Make sure that the shop air is connected upstream from any air line lubricator Verify that the low pressure regulator R1 has its T handle turned fully counter clockwise since nitrogen will not be used to drive the booster pump P Slowly open valve s located on the nitrogen tank s Read tank pressure on regulator G1 Replace tank if pressure is below 350 psi or if it will be reduced to 390 psi during the charging operation Open the booster shutoff valve V1 Raise the booster pump drive pressure by slowly adjusting the shop air regulator R3 until the indicated pressure on the pump outlet pressure gauge G3 is 3800 psi Reduce if SV2 starts to exhaust NOTE The shop air supply may be inadequate to charge the pump outlet pressure to 3800 psi If it is insufficient to boost the output pressure to complete the task use the booster pump procedure in paragraph 2 111a Adjust the high pressure regulator R2 until the required servicing pressure as shown on gauge G4 is attained Open high pressure shut off valve V3 Connect the inflating chuck of the charging hose assembly to the inlet port of the vessel to be serviced Do not over torque the inflating chuck Refer to applicable aircraft manuals for charging procedur
109. ting 15 INSTALLATION Using Teflon tape D1 or sealant D2 for pipe threads install subassembly 12 elbow 14 and fitting 15 onto the body of the high pressure regulator 11 Expand the eyelets of the small loop retainer of retainer wire 13 with a pair of needle nose pliers Place the smaller loop retainer over the channel of the regulator 11 T handle Loop the wire loop over the eyelets of the retainer then close the eyelets with a pair of needle nose pliers Slip one end of retaining wire 13 over the stem of gauge 9 Using Teflon tape D1 or sealant 02 assemble gauges 9 and 10 to the body of the regulator 11 Secure the regulator assembly to the booster panel with tube clamps 5 and 6 and bolts 3 and 4 while aligning the flare fittings at 1 and 2 Tighten the flare nuts 1 and 2 Perform leak check and confidence check procedure per paragraph 2 8 END OF TASK 3 19 TM 1 1740 204 13 amp P 3 18 HIGH PRESSURE RELIEF VALVE REPLACE THIS TASK COVERS REMOVAL AND INSTALLATION Personnel Required 67 Series Tools Test and Support Equipment Tool Kit SC 5180 99 A01 NSN 5180 00 323 4692 Adjustable Wrench NSN 5120 00 264 3796 Material parts High Press Relief Valve RV54 1 Teflon tape 01 or Perma Lok LM012 02 Equipment Conditions Shop air disconnected Cart depressurized and shutdown per GO TO NEXT PAGE 3 20 3 18 1 TM 1 1740 204 13 amp P REMOVAL WARNING Remove or d
110. to the cart Preservation and packaging shall be level A or Level B in accordance with MIL STD 2073 1 or Level C in accordance with MIL STD 1190 4 17 4 18 blank TM 1 1740 204 13 amp P APPENDIX A REFERENCES A 1 DICTIONARIES OF TERMS AND ABBREVIATIONS 310 25 Dictionary of United States Army Terms AR 310 50 Authorized Abbreviations and Brevity Codes A 2 PUBLICATION INDEXES DA PAM 25 30 Consolidated Index of Army Publications and Blank Forms A 3 LOGISTICS AND STORAGE TM 1 1500 204 23 Series 1 through 10 TM 743 200 1 otorage and Materials Handling 4 MAINTENANCE OF SUPPLIES AND EQUIPMENT AR 750 1 Army Material Maintenance Concepts and Policies DA PAM 738 751 Functional User s Manual for The Army Maintenance Management System Aviation TM 43 0139 Painting Operations Instructions for Field Use A 5 OTHER PUBLICATIONS AR 420 90 Fire Prevention and Protection AR 55 38 Reporting of Transportation Discrepancies in Shipments AR 700 58 Packaging Improvement Report DA PAM 310 13 Posting and Filing Publications FM 21 11 First Aid for Soldier TB 43 180 Calibration Requirements for the Maintenance of Materiel TM 750 244 1 4 Procedures for the Destruction of Aviation Ground Support Equipment FSC 1740 to Prevent Enemy Use A 1 A2 blank B 1 B 2 TM 1 1740 204 13 amp P APPENDIX B MAINTENANCE ALLOCATION CHART SECTION I Introduction GENERAL a d This section provides a gene
111. urized with nitrogen tank pressure Soap bubble test all pressure connections If leaks are found depressurize and shut down the high pressure nitrogen cart using the procedure of paragraph 2 Refer to the applicable maintenance procedure in Chapters 3 or 4 If no leaks are found continue Turn the T handle of the low pressure regulator R1 counter clockwise until it spins freely Disconnect the tire filling hose from the mating connectors C3 and C4 Open the pump drive valve Vl Slowly turn the T handle of the low pressure regulator R1 clockwise until the booster pump cycles and charges the pump outlet pressure gauge G3 to read approx 3750 psi Do not charge the pump output pressure higher than 3900 psi or the high pressure relief valve SV2 may open The system is now pressurized with booster pump output pressure Soap bubble test all pressure connections with soap solution D8 If leaks are found depressurize and shut down the high pressure nitrogen cart using the procedure of paragraph 2 7 Tighten loose fittings and reapply Teflon tape or sealant on pipe threads as required If a component leaks refer to the applicable maintenance procedure in Chapters 3 or 4 for replacement If no leaks are found depressurize and shut down the system per This concludes the leak check and confidence test procedure 2 10 TM 1 1740 204 13 amp P Section Operations under Usual Conditions SECTION CONTENTS OPERATING PROCEDURES NITR
112. ve in the check valve body 7 Remove check valve assembly 9 e Remove the flat O ring 10 from inside the check valve cavity of the pump body 11 f Examine all rubber parts for contamination nicks cuts and abrasions If necessary replace all components with repair kit components Refer td Appendix RPSTL for kit part numbers GO TO NEXT PAGE 4 9 TM 1 1740 204 13 amp P NOTE Complete the installation of this check valve before proceeding with the inspection of the next one Press O ring 8 with fingers into the groove of the check valve body 7 Insert the O ring 10 into the check valve cavity of the pump body 11 Position check valve 9 in the check valve body 7 Thread the check valve body 7 with T fitting 6 attached into the pump body 11 tighten and orient as illustrated Install elbow fitting 3 and tighten flare nuts Tighten the bolts of the bracket assembly 5 and 6 if necessary Install tubing 1 and tighten the flare fittings GO TO NEXT PAGE TM 1 1740 204 13 amp P 4 14 3 UPPER OUTLET CHECK VALVE a Remove the high pressure relief valve 1 b Loosen flare fittings of tubing 2 and 3 and remove tubing 3 C Remove flare fitting 4 d Remove the upper outlet check valve body 5 with tee and coupler assembly 6 attached from the pump body 7 e Refer to the inset illustration of the outlet check valve Carefully remove the spacer 8 spring 9 and the check valve p

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