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tm 55-1560-307-13&p technical manual operator

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1. Figure FO 1 ERFS Wiring Diagram FP 1 FP 2 Blank PUMP 1 RELAY K101 6731422 9731822 0731622 0730420 0730820 0702822 0702C22N 0702C22N C H P 0 56 1 PUHP 2 RELAY K102 TM 55 1560 307 13 amp P DASH DASH 0 wo me arm eno ew 2 fer wire no rye eno 1 Jero Q700C12 1 13 J1B A CB1 Q734C20N 1 48 P103 B E 0735 22 1 13 TB 1 Q701C12 0735822 1 23 K103 Q735C22 1 K103 Q702A22 4 Q735D22N 1 1DS3 Q702B22 3 X1 Q736A20 1 CB5 Q702C22N X2 0736820 1 K104 Q703A22 4 Q736C20N 1 P104 Q703B22 3 X1 Q737A22 1 TB 1 Q703C22N x2 B Q737822 1 K104 0704 22 4 0737 22 1 104 0704822 3 X1 Q737D22N 1 1054 Q704C22N 2 0 0705422 4 Q740A22 1 CB6 Q705B22 3 X1 Q740B22 1 S105 Q705C22N X2 Q740C22N 1 105 9740022 1 CB6 Q706A22 5 5 0740 22 1 CB6 0707422 5 Q741A22 1 Q708A22 5 Q741B22N 1 Q709A22 5 Q742A22 1 0710422 3 Q742B22N 1 Q711A22 6 Q710B22N C Q711B22N C Q700B12 Q700E12N Q701B12 Q701E12N Q721A20 Q722A22 Q722B22N Q722C22 Q723A22 Q723B22N Q723C22 Q724A22 Q724B22N Q724C22 Q725A22 Q725B22N Q725C22 Q726J22N Q730A20 Q730820 Q730C20N Q731A22 Q731B22 Q731C22 Q731D22N Q732A20 Q732BH20 Q732C20N 0733 22 0733822 0733 22 Q733D22N Q734A20 Q734B20
2. Weight Full Capacity System Installation Data Time to Install System Time to Remove System Change 2 Extended Range Fuel System ERFS TT 85SDSCC D 0007 2 Corpus Christi Army Depot DE 580 gal 60 inches 73 inches 52 inches 4 men 3 hours 4 men 3 hours 1 9 TM 55 1560 307 13 amp Section TECHNICAL PRINCIPLES OF OPERATION 1 13 OPERATIONS a Overall aircraft fuel management is the responsibility of the aircraft commander and is accomplished by utilizing the fuel management control panel and fuel quantity indicator in the cockpit b The ERFS has capabilities which enable the aircraft commander to select single or multiple tanks at his discretion The transfer of fuel from the 600 gallon tanks to replenish fuel in the aircraft s main fuel tanks is accomplished by the operator activating the FMCP switches This is a self contained pumping system which utilizes the aircraft s 28 dc UH and utility receptacles at station 260 1 14 OPERATING INSTRUCTIONS Operating instructions and use of operator controls and
3. Q722D22 Q723D22 Q724D22 Q725D22 Q726H22N MR C9 i NU 5 WHITE BLACK WHITE BLACK Q722E22 Q723E22 Q724E22 Q725E22 Q726A22N Q726B22N Q726C22N Q726D22N Q726E22N Q726F22N Q726G22N AO eo 101 gt gt gt 0 e M NN NN gt pea pb 2 fed nd ft ft ft ft ft ft od ft ded ud O pd k lt 2 0 2 22 2 2 00 0 NOTES FOR WIRE CHART 1 WIRE LENGTH TOLERANCE SHALL BE 0 10 INCHES EXCEPT AS NOTED 2 NUMBER IN TYPE COLUMN OF WIRE CHART INDICATES WIRE TYPE AS FOLLOWS 1 DENOTES WIRE PER M22759 43 2 DENOTES CABLE PER MIL C 3432 Figure FO 2 Wire Chart for Wiring Diagram FP 3 FP 4 Blank TM 55 1560 307 13 amp P TM 55 1560 307 13 amp TM 55 1560 307 13 amp P DRILL 0 500 85SDSCC D 0007 115 INSTALL NAS1329H6 200 NUT BLIND RIVET N S TANK ASSY REF 3REQD 4PLACES DRILL 0 500 INSTALL NAS1329H6 200 NUT BLIND RIVET F S 1 REQD 6 PLACES 2 5 AN4 7A BOLT 960 416 WASHER 2 REQ D MS21043L4 NUT 20 PLAGES 6 10 BOLT 535338 46 WASHER LOCK AN960PD616 WASHER 18 PLACES St e REF SCALE NONI E Ue A 90505
4. or arama CI NOTES 1 MARK PARTS PER MIL STS 180 2 TRANSFER HOLE LOCATIONS FROM 2 OR 3 ASSY ON TO 115 TANK ASSY AS SHOWN 3 TRANSFER HOLE LOCATIONS FROM 5 STRAP AND 7 ANGLE TO 11 1 589 CONVEYOR ROLLER AS SHOWN 4 11 1 589 CONVEYOR ROLLER NSN 3910 00 905 1303 HAS AN OVERALL LENGTH OF 117 0 INCHES THIS ITEM SHALL BE MODIFIED TO DIMENSIONS GIVEN BEFORE ITEMS 5 6 7 AND RELATED HARDWARE ARE INSTALLED amp 11 1 592 1 COUPLING ASSY WILL BE REMOVED AND NOT USED 5 ALL WELDS PER MIL W 8604 6 ALL WELD SYMBOLS PER AWS 2 4 79 Figure FO 3 Fabrication of Roller Assembly 90505 0093 Sheet 3 3 Change 2 FP 9 FP 10 Blank TM 55 1560 307 13 amp RECOMMENDED CHANGES TO EQUIPMENT TECHNICAL PUBLICATIONS SOMETHING WRONG WITH PUBLICATION FROM PRINT YOUR UNIT S COMPLETE ADDRESS THEN DOWN THE DOPE ABOUT IT ON THIS FORM CAREFULLY TEAR IT QUT FOLD IT AND DROP IT IN THE MAIL sss SENT IN THIS SPACE TELL WHAT IS WRONG AND WHAT SHOULD BE DONE ABOUT IT PRINTED NAME GRADE OR TITLE AND TELEPHONE NUMBER SIGN HERE DA M 2028 2 PREVIOUS EDITIONS P 5 IF YOUR OUTFIT WANTS TO KNOW ABOUT YOUR JUL 79 ARE OBSOLETE RECOMMENDATION MAKE A CARBON COPY OF THIS AND GIVE IT TO YOUR HEADQUARTERS Linear Measure 1 centimeter 10 millimeters 39 inch 1 decimeter 10 centimeters 3 94 inches 1 meter 10 decimeters 39 37
5. 127 REF 129 129 o 0 139 REF 129 REF 143 REF 9 143 REF BOTTOM ELEVATION Figure E 8 Fabrication of Box Assembly P N 85SDSCC D 0007 104 Sheet 3 of 3 E 13 TM 55 1560 307 13 amp TM 55 1560 307 13 amp 257 DIA HOLE 2 PLCS MATERIALS FABRICATE FROM 2024 73 AL ALLOY STOCK SIZE 1 X 1 1 4 X 4 IN FINISHES 1 TREAT ALUMINUM WITH CHEMICAL CONVERSION COATING PER MIL C 5541 CLASS 1A 2 APPLY EPOXY PRIMER PER MIL P 23377 3 PAINT WITH CARC ACFT GREEN COLOR NO 34031 FED STD 595 PER MIL C 46168 TOLERANCES X 0 0 20 Figure 9 Fabrication of Pump Riser P N 85SDSCC D 0007 138 2 3 4 5 7 8 9 TM 55 1560 307 13 amp P 3 P 8 d EO __ 1 2 21A HR 0700812 Q700E12N 32 0701812 El 110 HARNESS WIRING SCHEMATIC ITEMS FOR 110 HARNESS WIRE ELEC M22759 43 12 9 81349 20 IN IN 2 PLCS WIRE ELEC M22759 43 12 9 81349 6 IN IN 2 PLCS CONNECTOR MS3476W14 4S 96906 1 EA ADAPTER CABLE CLAMP M85049 51 1 14W 81349 1 EA RECEPTOR CONNECTOR MS3472W14 4P 96906 2 EA ADAPTER CABLE CLAMP M85049 52 1 14W 81349 2 EA TERMINAL LUG MS25036 96906 2 EA SLEEVE INSULATING IDENTIFYING M23053 5 107 9 81349 1 IN IN 3 PLCS STRAP TIEDOWN ELEC MS3367 1 0 96906 QTY AS REQD Figure E 10 Fabrication of Electrical Harness Assembly P N
6. WIRE CHART WIRE NO TYPE LG IN END 1 END 2 0722 22 1 P3A A Q723E22 1 168 B 5 0724522 1 1108 C 0725 22 1 48 D Q726A22N 1 72 6 8 563 Q726B22N 1 P5 B 593 Q726C22N 1 563 562 1 Q726D22N 12 P4 1 B 1562 Q726E22N 1 60 562 51 J 561 Q726F22N 1 12 B 59 0726G22N 561 E 1 WIRE PER MIL W 22759 43 22 9 WIRE LENGTH TOLERANCE 3 IN 0 IN PLUG MS3493 4 MODIFIED AS SHOWN SEE DETAIL B Figure E 3 Fabrication of Electrical Harness Assembly P N 85SDSCC D 0007 112 113 114 Sheet 2 of 3 E 5 DETAIL A DETAIL B TM 55 1560 307 13 amp P TM 55 1560 307 13 amp NE Tg NOTE 1 CONNECTIONS AT P1 WHITE WIRE TO NARROW PIN ON PLUG 1 BLACK WIRE TO WIDE PIN ON PLUG 1 2 CONNECTIONS AT P1A WHITE WIRE TO A PIN ON CONNECTOR 2 BLACK WIRE TO B PIN ON CONNECTOR 2 85SDSCC D C007 112 HARNESS ASSEMBLY NOTE 1 CONNECTIONS AT P2 WHITE WIRE TO NARROW PIN ON PLUG 1 BLACK WIRE TO WIDE PIN ON PLUG 1 2 2 CONNECTIONS AT P2A 3 WHITE WIRE TO A PIN ON CONNECTOR 2 BLACK WIRE TO B PIN ON CONNECTOR 2 ose SLEEVE 85SDSCC D 0007 114 HARNESS ASSEMBLY ITEMS FOR 112 AND 114 HARNESS CONNECTOR PLUG 7102 C 74545 1 EA CONNECTOR MS3476W14 4S 96906 1 EA ADAPTER M85049 52 1 14W 81349 1 E
7. Figure 3 11 Removal and Replacement of Dump Valve 3 31 3 22 FUEL FILTER Replace filter This task covers a Removal b Inspection c Installation INITIAL SETUP Tools Safety Wire Pliers Materials Parts Fuel Filter 42 Fig C Rag item 3 Appx Safety Wire 0 032 in Seal 41 43 Fig C 3j Appx C Equipment Conditions Refer to Figure 3 12 Tank must be grounded Tank cam lever dump valve closed Fuel hose from tank to manifold must be isolated using the hose couplings shutoff capability GENERAL SAFETY INSTRUCTIONS CAUTION Fuel will spill if the tank cam lever dump valve or hose couplings are not in closed position TM 55 1560 307 13 amp P REMOVAL 1 Remove safety wire from adapter 1 2 Pull lock tabs on adapter 1 outward 3 Disconnect adapter 1 from dump valve 2 and remove seal 3 screen 4 and seal 5 INSPECTION 1 Visually inspect screen 4 for cleanliness 2 Clean screen 4 with solvent item 16 Appx and blow dry 3 Replace screen 4 if damaged INSTALLATION 1 Install seal 5b into adapter 1 2 Install screen 4 and ensure that the screen flange is seated into grooved area of seal 5 3 Install seal 3 around screen 4 Ensure that seal 5 and 3 are properly seated in machined groove of adapter 1 4 Connect adapter 1 to dump valve 2 Secure lock tabs on adapter with safety wire 5 Check for l
8. INSPECTION 1 Inspect electrical wire harness for frayed insulation broken wires or loose pin to wire connection 2 Test float switch 9 replace if defective Refer to step 6 above ASSEMBLY INSTALLATION 1 Install packing 12 on float switch 9 and guide electrical wires through tubes 10 amp 11 2 Install nut 6 packing 8 plug 5 bracket 7 Do not tighten any of the nuts 6 onto plug 5 at this time 3 Solder wires to receptacle 4 pins and install screws 3 washers 2 and nuts 1 4 Seal areas with sealant item 15 DP 5 Install assembled components in tank and tighten tank plug 5 6 Adjust tube 10 to meet 2 5 inch clearance between float 9 and bottom of tank 7 Tighten nuts 6 after adjustment and seal center of tube 10 and entire area around plug 5 with sealant item 15 LAppx DJ TM 55 1560 307 13 amp Receptacle Tank Plug Bracket Packing Float Switch 7 8 9 Tube 11 Tube 12 Packing 10 Figure 3 13 Remove and Replace Fuel Float Assembly 3 35 TM 55 1560 307 13 amp P Section V PREPARATION FOR STORAGE OR SHIPMENT 3 24 SCOPE This section contains information and references of information pertaining to preservation storage and shipping 3 25 PRESERVATION The tank can be purged and preserved as follows WARNING e Ground aircraft and all equipment used in performing this operation Use appropriate clothing and glo
9. TO ACFT AFT MAIN P d TANK COUPLING L H OahON TM 55 1560 307 13 amp P Discharge Fuel Hose Quick Disconnect Coupling Quick Disconnect Coupling Suction Hose Quick Disconnect Coupling Tee Fitting 3 TO AFT MIN _____ s TANK COUPLING R H Figure 3 9 Removal of Suction and Discharge Fuel Hose 3 27 55 1560 307 13 amp REMOVAL 1 Disconnect discharge fuel hose 1 at FMCP quick disconnect coupling 2 2 Disconnect other end of hose at quick disconnect 3 to main tank coupling 3 Remove quick disconnect couplings 2 and 3 from hose to be replaced and set aside for installation on new hose 4 Disconnect suction hose 4 at quick disconnect coupling 5 at FMCP 5 Disconnect other end of hose at tee fitting 6 6 Remove couplings 5 from hose 4 INSPECTION 1 Visually inspect new hose for kinks and obvious damage to outer insulation 2 Inspect locknuts on new hose for thread damage and also damage to coupling fitting threads INSTALLATION 1 Install quick disconnect couplings 2 and 3 to both ends of hose 1 2 Route long hose under tank skid carefully and secure quick disconnect 3 to main tank coupling first then forward end to FMCP box coupling 2 3 Install quick disconnect couplings 5 on suction hose 4 4 Install other end of hose 4 to tee 6 5 Secure end with quick disconnect coupling to box coupling 3 28
10. cO gt O G N CROSS REFERENCE INDEXES FIGURE AND ITEM NUMBER INDEX NATIONAL STOCK NUMBER 5430 00 585 2529 4730 00 684 7446 4730 01 276 7564 4730 01 214 0996 4720 01 214 1001 4720 01 214 1003 4720 01 214 1002 4730 01 140 6760 4730 01 214 2913 4720 01 214 2914 4730 01 214 2910 4730 01 214 0994 4730 01 276 7564 4520 01 214 2915 5340 01 233 3063 1670 00 725 1437 5310 00 269 4040 5310 00 587 5559 5310 00 187 2399 5306 00 151 2626 4730 00 798 2966 5306 00 515 8064 4820 00 527 4333 5330 00 524 4375 12757 96906 96906 00624 00624 00624 00624 00624 78286 00624 12757 12757 12757 00624 00624 00624 00624 00624 15757 15757 15757 00624 00624 00624 00624 00624 00624 23755 23755 97403 96906 97403 96906 88044 88044 12757 12757 12757 12757 96906 12757 88044 88044 97499 96906 55 1560 307 13 amp PART NUMBER 85SDSCC D 0007 115 MS28741 24D 0160 MS24399D28 AE86844Z AE82111R AE706285 6 AE706285 3 AE706285 1 SS9609GZ1 810 114PS491 2 950234 16D 2300 85SDSCC D 0007 187 85SDSCC D 0007 113 390A 16D 0720 AE82567R AE706285 2 AE25010 011 85SDSCC D 0007 99 85SDSCC D 0007 192 85SDSCC D 0007 112 85SDSCC D 0007 114 AE82568R 000 9501 92 16D 0960 180 950248 16D 0360 AE85893M AE82155R AE706285 5 B D 1 0000R 0 234 HH 24 SP4212 1 13217E7080 MS51922 4
11. 5 MATERIALS FABRICATE FROM 2024 T3 AL ALLOY STOCK SIZE 0 063 X 7 00 X 33 50 IN TOLERANCES 0 1 XX 20 03 FINISHES 1 TREAT ALUMINUM WITH CHEMICAL CONVERSION 30 010 COATING PER MIL C 5541 CLASS 1 2 APPLY EPOXY PRIMER PER MIL P 23377 3 PAINT WITH CARC ACFT GREEN COLOR 34031 FED STD 595 PER MIL C 46168 Figure E 20 Fabrication of Bottom Panel P N 85SDSCC D 0007 130 E 25 TM 55 1560 307 13 amp 1 00 TYP 5 00 EP 4 40 0 098 DIA HOLE MATERIALS 0 063 2024 T3 AL ALLOY TOLERANCES X 20 1 FINISHES 1 TREAT ALUMINUM WITH CHEMICAL CONVERSION 0 03 COATING PER MIL C 5541 CLASS 1A XXX 0 005 2 APPLY EPOXY PRIMER PER MIL P 23377 3 PAINT WITH CARC ACFT GREEN COLOR NO 34031 FED STD 595 PER MIL C 46168 Figure E 21 Fabrication of Top Panel P N 8505 0007 131 E 26 TM 55 1560 307 13 amp MEI 63 si 13 000 13 EQ SPCS 18 500 375 DIA HOLE 1 062 DIA HOLE 15 R TYP 21 000 21 EQ SPCS 40 0 098 DIA HOLE 59 PLCS ee NE 198 4 PLCS MATERIALS 0 063 2024 73 AL ALLOY TOLERANCES X 0 1 FINISHES 1 TREAT ALUMINUM WITH CHEMICAL CONVERSION 20 03 COATING PER MIL C 5541 CLASS 1A XXX 0 005 2 APPLY EPOXY PRIMER PER MIL P 23377 3 PAINT WITH CARC ACFT GREEN COLOR NO
12. manifold tee at each tank Figure 2 5 e Install elbow fitting 3 to tank dump fitting Figure 2 5 Ensure camlock latch handles are either tie wrapped or safety wired to prevent them from opening f Connect No 1 tank low level warning light harness to tank Fiqure 2 4 g Route hoses 7 between tank skids towards aft tanks h Connect hoses 7 to FMCP lower couplings 5 i Connect fuel hose 4 from fitting 3 to manifold tee 8 Figure 2 5 NOTE TM 55 1560 307 13 amp Connect all system hose couplings to tee couplings and fittings as shown in Connect pump hoses 6 to coupling tee 9 k Using tiewraps item 17 D secure 2 inch manifold to floor as close as possible to the R H tank skid I Position inboard straps for No 2 tank prior to positioning No 2 tank Figure 2 6 NOTE As each tank is moved into position tighten straps on L H side of tank first Preposition all outboard straps for all tanks prior to tanks being moved into position m Position No 2 tank behind No 1 allowing space to connect hose from dump valve Figure 2 7 n Connect No 2 tank manifold hose assembly to dump valve and safety wire or tiewrap camlock handles and move tank forward into place Figure 2 7 o Position shoring under skids paragraph 2 6 b p Install grounding strap from No 1 tank to No 2 tank q Connect No 2 low level warning light harness to tank Install No 2 tank
13. operation Figure 2 23 i Turn pump switch 2 ON and hold until pump engages Figure 2 23 2 12 OPERATION The ERFS system is an auxiliary fuel system designed to supplement the aircraft standard fuel system Refer 224606 the following procedure for operating procedures 4 overrides the fuel NOTE e In order to maintain aircraft CG suggested tank burn sequence is 4 1 3 e After aircraft ground checks but prior to flight ensure positive fuel flow from ERFS to aircraft fuel system a Initiate fuel transfer when the aircraft s main fuel tanks have decreased 1000 pounds or sooner The ERFS is designed as an automatic system Once fuel 2 29 TM 55 1560 307 13 amp P transfer is initiated the pumps can be turned on and simply monitored One fuel pump per side is enough to meet the demands of the aircraft Two pumps per side are installed for redundancy and for faster fuel transfer if desired b Ensure tank cam lever for selected tank is open c Turn all pump switches 3 four each ON and 2 24 NOTE Do not use liquid level indicator for continuous fuel quantity readings during flight Use only as necessary Lock in place after use d Transfer fuel until low level warning lights 5 come on Figure 2 22 NOTE Preferred method of operation is to turn all pumps ON during fuel transfer Allow at least 10 second delay between each pump switch actuation 2 13 TURN OFF PROCEDURES Turn o
14. 0 0093 2 ROLLER ASSY 5 2 90SDSCC D 0093 3 ROLLER ASSY UH SHT 2 90SDSCC D 0093 1 INSTALLATION SE N SCALE NONE 90SDSCC D 0093 7 STRAP 3 PLACES SHT 3 90SDSCC D 0093 5 ANGLE 7 REF 2 PLACES SHT 3 90SDSCC D 0093 8 CONVEYOR ROLLER AN C D 0093 2 ROLLER ASSEMBLY SHN 2 D 0093 3 ROLLER ASSEMBLY OPP SCALE NONE 8 REF 90SDSCC D 0093 6 BRACE END SHT 3 VIEW SHT2 SCALE NONE Figure FO 3 Fabrication of Roller Assembly P N 90SDSCC D 0093 Sheet 1 of 3 Change 2 FP 5 FP 6 Blank TM 55 1560 307 13 amp 250 STK 1 500 3 SPCS 0 265 4PLCS 11 25 2 EQ SPCS 13 500 15 00 1 00 3 00 REF 0 406 3PLCS 90SDSCC D 0093 5 ANGLE SHT 2 MATERIAL AND10133 3002 6061 651 EXTAN FINISH NONE SCALE FULL 0 265 4PLCS 12 00 ss 625 STK 90SDSCC D 0093 7 STRAP SHT 2 MATERIAL 250 2024 T3 ALUM FINISH NONE SCALE HALF 7 90SDSCC D 0093 6 BRACE 5 2 MATERIAL 625 6061 76 ALUM WELD RELIEF FINISH SCALE FULL 06 45 2PLCS Figure FO 3 Fabrication of Roller Assembly P N 90SDSCC D 0093 Sheet 2 of 3 Change 2 FP 7 FP 8 Blank PART NUMBER 90SDSCC D0093 1 90SDSCC D 0093 2 90SDSCC D 0093 3 ER ANATA mur ha ANSA mo sur s ANSGOPDGIS 53550546 6210424 se10 00807 1475 NI
15. CHAPTER 3 PARAGRAPH 3 12 IF EITHER INDICATOR IS DAMAGED REMOVE TO PARAGRAPH 3 20 TO PARAGRAPH 3 20 3 2 TM 55 1560 307 13 amp TROUBLESHOOTING PROCEDURE NO 2 FUEL TRANSFER IS LESS THAN ENGINE FUEL CONSUMPTION NOTE ONE ERFS FUEL PUMP WILL NOT TRANSFER ENOUGH TO KEEP UP WITH BOTH AIRCRAFT ENGINES CHECK TO DETERMINE IF FUEL TANK IS EMPTY YES TNO MANUALLY SHUT OFF THE TANK CHECK FUEL MANIFOLD HOSE CAM LEVER AND SWITCH TO CONNECTIONS CONNECTION NEXT TANK IN BURN SEQUENCE CHECK OK YES NO CHECK FUEL PUMPS FOR ENSURE THAT FUEL OPERATION ACCORDING TO TRANSFER VALVE IS PROCEDURES NO 7 AND OPEN NO 8 3 3 TROUBLESHOOT FUEL MANAGEMENT ELECTRICAL CONSOLE INTERNAL TROUBLESHOOTING PROCEDURE NO 3 PANEL INDICATOR LIGHTS DO NOT ILLUMINATE DURING PRESS TO TEST CAUTION TO PREVENT POSSIBLE FIRE NEVER DO VOLTAGE CHECKS ON ANY RANGE EXTENSION SYSTEM COMPONENTS WITH ANY ACCESS COVERS OR SERVICING COVERS REMOVED AND FUEL IN TANKS WITH ALL UTILITY CIRCUIT BREAKERS ON NO 1 AND NO 2 POWER DISTRIBU TION PANEL PUSHED IN AND POWER CORDS CONNECTED CHECK FOR 28 VDC BETWEEN PINS A C OF CONNECTOR AND AIRFRAME GROUND SYSTEM 3 4 TROUBLESHOOT POWER CORDS AND OR DC POWER DISTRIBUTION TM 55 1560 307 13 amp TM 55 1560 307 13 amp TROUBLESHOOTING PROCEDURE NO 4 LOW LEVEL LIGHT DOES NOT ILLUMINATE WITH FUEL LEVEL LOW IN
16. TM 55 1560 307 13 amp P STA 280 300 320 340 3 360 ir 380 400 420 440 460 I 480 Figure 2 9 ERFS No 3 Tank Installation and Tiedown 2 12 TM 55 1560 307 13 amp 360 380 400 420 440 460 10 000 Lb Strap 480 5 000 Lb Strap 5 000 Lb Strap attaches to top T Take Up Fitting Looped Strap Figure 2 10 ERFS No 4 Tank Installation and Tiedown 2 13 TM 55 1560 307 13 amp 10 000 Lb Strap 5 000 Lb Strap 5 000 Lb Strap attaches to top Take Up Fitting Looped Strap Figure 2 11 ERFS Tank Installation and Secured 2 14 t Route hoses 7 between tank No 3 and tank No 4 and connect to the helicopter s respective fuel supply coupling u Install grounding strap to existing aircraft grounding point v Connect vent from tank to tank fitting and then to aircraft fitting TM 55 1560 307 13 amp P WARNING All vent lines must be connected from tank to tank and to aircraft overboard vent Aircraft overboard vent cap must be removed anytime ERFS is installed w Remove aircraft vent cap from top of fuselage x Check all hoses and couplings for proper installation Figure 2 12 HOSE COUPLINGS IN LOCKED AND FUE
17. Tiedown AR Adhesive 82C18 CN 70 5 GOVERNMENT PRINTING OFFICE 1992 654 029 65010 Change 1 D 2 APPENDIX E ILLUSTRATED LIST OF MANUFACTURED ITEMS E 1 INTRODUCTION This appendix includes complete instructions for making items authorized to be manufactured fabricated at organizational maintenance or Aviation Unit Maintenance if applicable a part number index in alphanumeric order is provided for cross referencing the part number of the item to be manufactured to the figure which covers fabrication criteria b Bulk material needed for manufacturing an item is listed by part number or specification number Refer to Figure 1 E 2 MANUFACTURED ITEMS PART NUMBER INDEX The index lists all part numbers of items illustrated in this appendix The part number of each manufactured item is referenced in Figure E 1 E 3 INSTRUCTIONAL CRITERIA Refer fo Figure 2 E 1 TM 55 1560 307 13 amp P Table E 1 PIN Index PART NUMBER MS2057P5 2150 MS28741 24D 0160 M83796 1K043E M83796 1K047A M83796 1K086A 000 950192 16D 0960 180 950248 16D 0360 85SDSCC D 0007 102 85SDSCC D 0007 104 85SDSCC D 0007 106 85SDSCC D 0007 110 85SDSCC D 0007 111 85SDSCC D 0007 112 85SDSCC D 0007 113 85SDSCC D 0007 114 85SDSCC D 0007 119 85SDSCC D 0007 120 85SDSCC D 0007 123 85SDSCC D 0007 125 85SDSCC D 0007 126 85SDSCC D 0007 127 85SDSCC D 0007 128 85SDSCC D 0007 129 85SDSCC D 0007 130 85SDSCC D 0007 131 85SDSCC D 0007 132
18. ensure all aircraft electrical switches are turned off Refer to FM 10 68 Table 3 1 Fuel Quantity Gallons and Pounds Decals Table 3 1 US POUNDS LEVEL GAL JP 4 JP 5 JP 8 1 90 585 612 603 2 100 650 680 670 3 115 747 782 770 4 130 845 884 871 5 145 942 986 971 6 160 1040 1088 1072 7 175 1137 1190 1172 8 190 1235 1292 1273 9 205 1332 1394 1373 10 220 1430 1496 1474 11 235 1527 1598 1574 12 255 1657 1734 1708 13 270 1755 1836 1809 14 285 1852 1938 1909 15 300 1950 2040 2010 16 320 2080 2176 2144 17 330 2145 2244 2211 18 345 2242 2346 2311 3 13 Fuel Quantity Gallons and Pounds Decals IND US POUNDS LEVEL JP 4 JP 5 8 19 335 2177 2278 2244 20 350 2275 2380 2345 21 365 2372 2482 2445 22 380 2470 2584 2546 23 400 2600 2720 2680 24 415 2697 2822 2780 25 430 2795 2924 2881 26 445 2892 3026 2981 27 460 2990 3128 3082 28 475 3087 3230 3182 29 490 3185 3332 3283 30 505 3282 3434 3383 31 520 3380 3536 3484 32 535 3477 3638 3584 33 550 3575 3740 3685 34 565 3672 3842 3785 35 575 3737 3910 3852 35 5 580 3770 3944 3886 WARNING e ELECTRICAL GROUNDING OF THE HELICOPTER Army regulations require the grou
19. 00 432 9340 C 5 23 96906 M590725 115 5305 00 071 2071 C 3 28 96906 MS90728 109 5305 00 071 2066 C 3 53 81340 M5594 1 2 y C 8 5 07623 M6106 27 029 5945 01 114 1288 C 8 40 81349 M81714 28 20 C 8 29 81349 M83413 8 BO6BB 6150 01 201 1570 C 8 58 81349 M83796 IG200E 4720 01 H76 8433 C 3 92 81349 M83796 1K043E 7 11 81349 M83796 1K047A C 7 8 81349 M83796 1K086A 7 4 81349 85049 55 10 re C 8 20 81349 M85049 31 1 12W 5935 01 256 0252 C 8 53 81349 M85049 31 1 14W 5935 01 163 3224 C 8 66 PADZZ NAS1334A5S09 5340 00 077 2459 C 6 23 80205 NAS43DD3 128 C 4 8 80205 NAS43DD3 64 C 4 11 96906 NAS677 8 C 3 79 80205 NAS679 AO6W 5310 00 685 3622 C 3 73 79515 P4012E C 3 40 C 36 TM 55 1560 307 13 amp CROSS REFERENCE INDEXES PART NUMBER INDEX Cont Section IV NATIONAL STOCK FIG ITEM CAGE PART NUMBER NUMBER NO NO 79515 P402A C 3 34 79515 P403 C 3 39 79515 P404 C 3 37 79515 P414 3 35 79515 P425A C 3 36 79515 P431 C 3 38 79515 P432 C 3 33 TN QQW34R1201B 6145 00 191 8457 C 9 3 2375 SP4212 1 1670 00 725 1437 C 2 28 12757 559096 02 0060 C 6 22 78286 559609071810 C 3 8A 00624 000 950192 16D 0960 pr C 2 22 97484 122634 4730 01 312 9233 C 7 6 14555 110 6 E C 3 47 00624 114 5491 2 4730 01 140 6760 C 2 9 86831 1140 0161 1 6680 01 293 9095 C 3 65 86831 1140 0161 2 6680 01 293 9094 C 3 66 97403 13217 7080 C 3 1 97403 13217E7082 C 3 29 97403 13217E7084 5330 00 063 2506 C 3 30 97403 13217E7085 ET C 3 52 97403 13217 7086 53
20. 005 Figure E 12 Fabrication of Brace Strap Assembly P N 85SDSCC D 0007 102 E 17 TM 55 1560 307 13 amp 312 DIA 875 os STOCK 2 62 MATERIALS 0 063 TEFLON THICKNESS FINISHES NONE TOLERANCES 20 1 20 03 0 010 Figure E 13 Fabrication of Teflon Pad PIN 85SOSCC D 0007 143 E 18 TM 55 1560 307 13 amp 520253 2 2200 HINGE PIN 96906 HINGE HALF 96906 MS20257HP5 HINGE HALF MATERIALS FABRICATE HINGES FROM MS20257HP5 7200 72 IN LONG HINGE HALF CUT TWO PIECES TO LENGTH PER DRAWING DIMENSIONS FINISHES 1 REMOVE ALL BURRS AND SHARP EDGES 2 PRIME WITH EPOXY PRIMER PER MIL P 23377 PRIOR TO RIVETING IN PLACE 3 SECURE HINGE PIN BY PEENING A FLAT ON BOTH ENDS AFTER ASSEMBLY TOLERANCES ALL DIMENSIONS ARE IN INCHES 20 1 0 03 0 010 Figure 14 Fabrication Hinge 520257 2150 19 MATERIALS 0 25 X 2 00 X 2 00 6061 T6511 EXTR TOLERANCES X 40 1 FINISHES 1 TREAT ALUMINUM WITH CHEMICAL CONVERSION 20 03 COATING PER MIL C 5541 CLASS 1A 10 005 2 APPLY EPOXY PRIMER PER MIL P 23377 3 PAINT WITH CARC ACFT GREEN COLOR NO 34031 FED STD 595 PER MIL C 46168 23 50 12 250 29 000 25 250 7 500 7 375 4 1 250 3 750 2 000 1 25 2 000 EQ 58 ot 5 r4 193 DIA HOLE 2 PLCS 250 DIA HOLE 16 PLCS EQ MP se
21. 00624 AE25010 011 4730 01 214 2570 C 3 44 00624 AE706285 1 4720 01 214 1002 C 2 8 00624 AE706285 2 4720 01 214 2914 C 2 15 00624 AE706285 3 4720 01 214 1003 C 2 7 00624 AE706285 5 4720 01 214 2915 C 2 26 00624 AE706285 6 4720 01 214 1001 C 2 6 00624 AE82111R 4730 01 214 0996 C 2 5 00624 AE82155R C 2 25 00624 AE82567R 4730 01 214 2913 C 2 14 00624 AE82568R 4730 01 214 0994 C 2 21 00624 AE85861M 4730 01 276 7563 C 5 9 00624 AE85893M 4730 01 276 7564 C 2 24 00624 AE86844Z 4730 01 276 7564 C 2 4 88044 AN310C12 C 3 49 88044 4 20 5306 00 151 1416 5 3 88044 AN4 7A 5306 00 515 8064 C 3 13 88044 AN4 7A 5306 00 515 8064 C 3 58 88044 AN5 13A 5306 00 151 2626 C 3 6 88044 AN743 12 5340 00 598 8251 C 5 13 88044 AN743 12 5340 00 598 8251 C 6 5 88049 AN821 12D 4730 00 194 1046 C 7 3 88044 AN827 12D 4730 00 256 2310 C 7 5 88044 833 6 4730 00 231 3078 C 3 93 88044 AN960 PBL 5310 00 184 9200 C 3 74 88044 AN960 10L 5310 00 167 0834 C 4 7 88044 AN960 10L 5310 00 167 0834 C 8 50 88044 AN960 10L 5310 00 167 0834 C 8 67 88044 AN960C416L C 3 14 88044 AN960PD416 5310 00 187 2354 C 3 57 88044 AN960PD416 5310 00 187 2354 C 5 4 88044 AN960PD516 5310 00 187 2399 C 3 5 88044 AN960D6 5310 00 167 0738 C 5 5 88044 AN960D6 5310 00 167 0738 C 5 21 79515 A609 C 3 32 23755 B D 10000R O 5340 01 233 3063 C 2 27 214 HH 24 07623 IN4001 5961 00 257 6865 C 8 33 07623 IN4001 5961 00 257 6865 C 8 45 C 34 TM 55 1560 307 13 amp CROSS REFERENCE INDEXES PART NUM
22. 1560 307 13 amp P Recoverability Code D Reparable item When beyond lower level repair capability return to depot Condemnation and disposal of item not authorized below depot level Application Explanation L Reparable item Condemnation and disposal not authorized below specialized repair activity SRA 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 c COMMERCIAL AND GOVERNMENT ENTITY CAGE CODE Column A five position numeric or alphanumeric code used to associate a source manufacturer or controller to all reference and or part numbers d PART NUMBER Column Indicates the primary number used by the manufacturer individual company firm corporation or Government activity which controls the design and characteristics of the item by means or its engineering drawings specifications 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 e DESCRIPTION AND USABLE ON CODE Column This column includes the 1 The Federal item name and when required a minimum description to identify the item 2 The physical security classification of the item is indi
23. 18 2 21 and 2 22 2 21 and 2 22 3 34 1 3 34 2 D 1 and D 2 D 1 and D 2 2 Retain this sheet in front of manual for reference purposes 55 1560 307 13 amp C1 By Order of the Secretary of the Army GORDON R SULLIVAN Official General United States Army Chief of Staff Z A Cam LES MILTON H HAMILTON Administrative Assistant to the Secretary of the Army 00470 DISTRIBUTION To be distributed in accordance with DA Form 12 31 E block no 2735 10 amp CL maintenance requirements for TM 55 1560 307 13 amp TECHNICAL MANUAL No 55 1560 307 13 amp P TM 55 1560 307 13 amp HEADQUARTERS DEPARTMENT OF THE ARMY WASHINGTON D C 11 December 1990 OPERATOR AVIATION UNIT AND AVIATION INTERMEDIATE MAINTENANCE MANUAL WITH REPAIR PARTS AND SPECIAL TOOLS LIST FOR EXTENDED RANGE FUEL SYSTEM 600 GALLON TANKS NSN 1560 01 221 7600 REPORTING OF ERRORS AND RECOMMENDING IMPROVEMENTS You can help improve this manual If you find any mistake or if you know of a way to improve the procedure please let us know Mail your letter or DA Form 2028 Recommended Changes to Publications and Blank Forms directly to Commander U S Army Aviation Systems Command ATTN AMSAV MC 4300 Goodfellow Blvd St Louis MO 63120 1798 A reply will be furnished to you TABLE OF CONTENTS CHAPTER 1 INTRODUCTION Section Section Il Section CHAPTER 2 Section 1 Section IV Section Se
24. 19 96906 MS3106F125 3S 5935 01 148 4737 C 8 60 96906 MS3320 1 5925 00 224 7422 C 8 2 96906 MS3320 10 5925 00 431 3255 C 8 2 96906 MS3339 1 9 5340 00 849 7043 C 5 14 96906 MS3367 2 4 13 96906 MS3472L14 4P 5935 01 064 5841 C 3 76 96906 MS3472W 12 85 5935 01 170 9127 C 8 52 C 35 TM 55 1560 307 13 amp CROSS REFERENCE INDEXES PART NUMBER INDEX Cont Section IV NATIONAL STOCK FIG ITEM CAGE PART NUMBER NUMBER NO NO 96906 MS3472W 14 4P 5935 01 199 7154 C 8 65 96906 MS3472W 14 45 5935 01 176 4517 C 9 2 96906 MS3476W 14 5P 5935 01 108 4486 C 9 1 96906 MS3493 5 5935 00 572 5154 C 4 4 96906 MS35206 215 5305 00 889 2997 C 3 75 96906 MS35206 230 5305 00 889 3000 C 5 22 96906 MS35207 264 5305 00 989 7435 C 4 12 80205 MS35207 270 5305 00 995 3440 C 4 10 96906 MS35207 274 5305 00 958 0671 C 4 5 96906 MS35207 279 5305 00 993 2463 C 8 57 96906 MS35333 121 5310 00 905 5454 C 8 13 96906 MS35333 73 5310 00 543 5933 C 4 4 96906 MS35338 48 5310 00 584 5272 C 3 27 96906 MS35338 48 5310 00 584 5272 C 8 69 96906 MS35650 320 T C 4 6 96906 MS35707 262 5305 00 717 5467 C 8 49 96906 MS51105 464 De C 3 51 96906 MS51520B 12 4730 00 933 0816 C 5 8 96906 MS51524B 12 4730 00 054 7296 7 10 96906 5551524816 4730 00 798 2966 C 3 11 96906 MS51860 58 4730 01 093 8464 C 5 6 96906 MS51922 33 5310 00 225 6993 C 3 26 96906 MS51922 49 5310 00 269 4040 C 3 2 96906 MS5691 36 5310 00 899 6082 C 3 21 96906 MS90298 2 5935 00 432 9340 C 3 87 96906 MS90298 2 5935
25. 34031 FED STD 595 PER MIL C 46168 Figure E 22 Fabrication of Panel P N 85505 0007 132 E 27 TM 55 1560 307 13 amp 4 PLCS TYP 40 0 098 DIA HOLE 21 000 59 PLCS 21 EQ 5 5 1 062 DIA HOLE PUBS OLE 1 00 5 Tel 4 25 TYP 2 PLCS 39 15 R 13 EQ 5 5 13 000 gt t 1 69 75 63 he MATERIALS 0 063 2024 T3 AL ALLOY TOLERANCES X 0 1 FINISHES 1 TREAT ALUMINUM WITH CHEMICAL CONVERSION 0 03 COATING PER MIL C 5541 CLASS 1A 40 005 2 APPLY EPOXY PRIMER PER MIL P 23377 3 PAINT WITH CARC ACFT GREEN COLOR NO 34031 FED STD 595 PER MIL C 46168 Figure 23 Fabrication of Panel P N 855805 0007 133 E 28 TM 55 1560 307 13 amp APPENDIX F TORQUE LIMITS F 1 GENERAL Standard torque values are not called out for individual maintenance procedures in this manual Use the standard torque of Tables F 1 and F 2 F 2 TORQUE DEFINITIONS a Breakaway Torque Breakaway torque Table F 1 lis defined as minimum torque required to start the movement of a nut on or off a bolt with no axial load on the nut and with the bolt completely through the nut b Friction Torque Tare Drag Run on The torque required to overcome the internal friction between a self locking nut and bolt as the nut is being turned on the bolt but before the nut contacts the washer no axial load
26. 4 Remove clamps 5 5 Remove pump 6 6 Remove nipple 7 and discard packing NOTE Install new packing on nipple 7 All 4 pumps on the system can be removed using same procedure INSPECTION 1 Visually inspect new pump fittings for thread damage 2 Inspect thread on hose assembly 3 Inspect wire harness for damage and cannon plug threads before connecting harness plugs INSTALLATION 1 Install new packing on nipple fitting 7 and install fitting on pump 2 Install pump 6 3 Install clamps 5 4 Install nuts 4 3 and 2 and tighten 5 Connect electrical wire 1 6 Test system for leaks Refer to Chapter 2 paragraph 2 13 for pressure check 3 26 TM 55 1560 307 13 amp 3 19 SUCTION AND DISCHARGE HOSES REPLACE HOSE This task covers a Removal b Inspection Installation INITIAL SETUP Tools Bonney Wrenches Material Parts Fuel Hose 22 23 Fig C 2 Appx C Equipment Conditions Refer to Figure 3 9 All ERFS tank cam levers CLOSED All coupling valves CLOSED All electrical power OFF GENERAL SAFETY INSTRUCTIONS WARNING ELECTRICAL GROUNDING OF THE HELICOPTER Army regulations require the grounding of the helicopter when parked and during all fueling and defueling operations No electrical switches shall be operated except those necessary for servicing during fueling defueling No smoking or flame during all fueling and defueling operations
27. 4631 Pallets Controls or Indicators Function Ne Controls or Indicators Function Ne Operator Crew Preventive Main Checks and Services Fuel Quantity Gallons and Pounds 5 iii iv blank TM 55 1560 307 13 amp CHAPTER 1 INTRODUCTION Section I GENERAL INFORMATION 1 1 SCOPE This TM is to be used by operator and unit maintenance personnel in maintaining the extended range fuel system ERFS P N 85SDSCC D 0007 2 used on CH 47G D aircraft This system is used to supplement the aircraft standard fuel system for longer sustained flights and for refueling other aircraft 1 2 PURPOSE This ERFS manual provides instructions for installation operation maintenance troubleshooting and storage It also includes a repair parts and special tools list 1 3 FORMS RECORDS AND REPORTS Department of the Army forms and procedures used for equipment maintenance will be those prescribed by DA PAM 738 751 The Functional User s Manual for the Army Maintenance Management System Aviation TAMMS A In accordance with provisions of DA PAM 738 751 an entry should be made on DA Form 2408 13 when the ERFS is installed or removed This entry will make personnel aware of prescribed operational limits and aircraft center of gravity CG for weight and balance purposes 1 4 REPORTING EQUIPMENT IMPROVEMENT AND RECOMM
28. 5 14 5340 00 849 7043 96906 MS3339 1 9 C 5 15 12757 85SDSCC D 0007 110 C 5 16 12757 85SDSCC D 0007 196 C 5 17 12757 85SDSCC D 0007 178 5 18 E 12757 85SDSCC D 0007 177 C 5 19 ES 12757 85SDSCC D 0007 111 C 5 20 5310 00 857 5560 96906 MS21045L06 C 5 21 5310 00 167 0738 88044 AN960D6 C 5 22 5305 00 889 3000 96906 MS35206 230 C 5 23 5935 00 432 9340 96906 MS90298 2 C 6 1 12757 85SDSCC D 0007 183 C 6 12757 85SDSCC D 0007 191 C 6 3 12757 85SDSCC D 0007 193 C 6 4 ES 12757 85SDSCC D 0007 194 C 6 5 5340 00 598 8251 88044 AN743 12 C 6 6 12757 85SDSCC D 0007 143 C 6 7 12757 85SDSCC D 0007 201 C 6 8 96906 MS2057P5 2150 C 6 9 12757 85SDSCC D 0007 125 C 6 10 12757 85SDSCC D 0007 126 C 6 11 12757 85SDSCC D 0007 127 C 6 12 12757 85SDSCC D 0007 128 C 6 13 22 12757 85SDSCC D 0007 129 C 6 14 12757 85SDSCC D 0007 130 C 6 15 12757 85SDSCC D 0007 131 C 6 16 12757 85SDSCC D 0007 132 C 6 27 12757 85SDSCC D 0007 133 C 6 18 12757 85SDSCC D 0007 175 C 6 19 22 12757 85SDSCC D 0007 176 C 6 20 224 12757 85SDSCC D 0007 177 C 43 Section IV FIG z 2 62 62 62 62 62 62 62 62 62 62 62 62 62 62 62 62 62 62 62 62 62 62 62 62 62 62 62 62 62 62 62 62 62 62 62 62 62 62 62 62 62 lt gt CO CO CO CO 00 00 00 SN O O O O O gt CROSS REFERENCE INDEXES FIGURE AND ITEM NUMBER INDEX Cont NATI
29. 62 62 62 lt gt 4 O1 O1 00 00 amp O1 02 G O1 O gt 00 00 02 CO 55 1560 307 13 amp P Section IV NATIONAL STOCK NUMBER 5961 00 257 6865 5310 00 269 4040 5310 00 282 7832 5925 00 431 3255 5935 00 432 9340 5935 00 432 9340 5306 00 515 8064 5306 00 515 8064 5330 00 524 4375 4820 00 527 4333 5310 00 543 5933 5935 00 572 5154 5310 00 584 5272 5310 00 584 5272 5430 00 585 2529 5430 00 585 2529 5310 00 587 5559 5340 00 598 8251 5340 00 598 8251 6150 00 600 6259 4730 00 649 9100 5930 00 683 1629 4730 00 684 7446 5310 00 685 3622 5305 00 717 5467 1670 00 725 1437 5330 00 733 2208 5330 00 733 2208 5315 00 753 3895 5340 00 794 6956 4730 00 798 2966 5310 00 807 1467 5310 00 809 8533 1680 00 839 1756 5340 00 849 7043 5310 00 857 5557 5310 00 857 5560 5310 00 877 5797 5305 00 889 2997 5305 00 889 3000 5310 00 897 6145 5310 00 899 6082 5310 00 905 5454 4730 00 933 0816 5940 00 950 1610 5305 00 958 067 1 FIG z 2 62 62 62 62 62 62 62 62 62 62 62 62 62 62 62 62 62 62 62 62 62 62 62 62 62 62 62 62 62 62 62 62 62 62 62 62 62 62 62 62 62 62 62 lt gt O1 00 00 O1 Q O1 O gt 00 00 00 00 00 Q 00 G 00 00 00 G G G CROSS REFERENCE INDEXES NATIONAL STOCK NUM
30. 85SDSCC D 0007 110 E 15 TM 55 1560 307 13 amp 85505 0 0007 111 HARNESS ASSEMBLY ITEMS FOR 111 HARNESS ASSEMBLY 1 WIRE ELECTRICAL M22759 43 22 9 81349 20 Y 0722022 INCHES IN 5 PLACES 5 CONDUCTORS B 1 07230224 B 2 RECEPTOR CONNECTOR MS3472W14 5S 96906 1 EACH C 0724022 3 ADAPTER CABLE CLAMP M85049 52 1 14W 81349 1 EACH p L 0725022 D 4 CONNECTOR MS3476W12 8P 96906 1 EACH E 0726H22N E 5 ADAPTER CABLE CLAMP M85049 51 1 12W 81349 1 EACH 6 SLEEVE INSULATING IDENTIFYING M23053 5 107 9 81349 1 INCH IN 2 PLACES 7 STRAP TIEDOWN ELECTRICAL 53367 1 0 96906 QUANTITY 111 HARNESS WIRING SCHEMATIC AS REQUIRED Figure E 11 Fabrication of Electrical Harness Assembly PIN 85SDSCC D 0007 111 E 16 TM 55 1560 307 13 amp 375 DIA HOLE 2 PLCS 62 0 125 DIA HOLE C SINK 1009 X 0 125 DP N S 0 125 DIA HOLE HOLE 0 312 ne OLE 2 PLCS 6 PLCS TYP 9 63 28 R TYP 4 PLCS AJ5 40 1B 2 PLCS Ei 090 STOCK GP58 GROMMET TYP MATERIALS 0 090 2024 T3 AL ALLOY RIVET MS20426AD4 2 RECEPTACLE S5A 200 2 STUD 5 40 18 2 GROMMET GP5B 2 FINISHES 1 TREAT ALUMINUM WITH CHEMICAL CONVERSION COATING PER MIL C 5541 CLASS IA 2 APPLY EPOXY PRIMER PER MIL P 23377 3 PAINT WITH CARC ACFT GREEN COLOR NO 34031 FED STD 595 PER MIL C 46168 TOLERANCES 20 1 20 03 0
31. 85SDSCC D 0007 168 C 8 61 12757 85SDSCC D 0007 169 C 8 18 12757 85SDSCC D 0007 170 C 8 24 12757 85SDSCC D 0007 170 C 8 56 12757 85SDSCC D 0007 172 C 8 46 12757 85SDSCC D 0007 173 C 8 42 12757 85SDSCC D 0007 175 C 6 18 12757 85SDSCC D 0007 176 C 5 11 12757 85SDSCC D 0007 176 C 6 19 12757 85SDSCC D 0007 177 C 5 18 12757 85SDSCC D 0007 177 C 6 20 12757 85SDSCC D 0007 178 C 5 17 12757 85SDSCC D 0007 178 C 6 21 12757 85SDSCC D 0007 182 C 3 89 12757 85SDSCC D 0007 183 C 6 1 12757 85SDSCC D 0007 184 C 3 88 12757 85SDSCC D 0007 187 C 2 11 12757 85SDSCC D 0007 113 C 9 5 12757 85SDSCC D 0007 191 C 6 2 15757 85SDSCC D 0007 192 C 2 18 12757 85SDSCC D 0007 193 C 6 3 12757 85SDSCC D 0007 194 C 6 4 12757 85SDSCC D 0007 195 C 8 16 12757 85SDSCC D 0007 196 C 3 91 12757 85SDSCC D 0007 196 C 5 12 12757 85SDSCC D 0007 196 C 5 16 12757 85SDSCC D 0007 197 C 3 90 96906 85SDSCC D 0007 20 C 3 75 12757 85SDSCC D 0007 201 C 6 7 85SDSCC D 0007 29 C 3 80 12757 85SDSCC D 0007 9 C 3 72 00624 85SDSCC D 0007 99 C 2 17 12757 89SDSCC D 01 04 4 4730 01 325 3820 3 42 12757 89SDSCC D 0104 5 5330 01 331 0499 C 3 43 12757 89SDSCC D 0104 6 5330 01 330 6368 C 3 41 00624 916 265S 5340 01 H76 8483 C 5 10 12757 950234 16D 2300 C 2 10 Change 2 C 39 zm OG
32. Controls and Indicators nennen ERFS Fuel Management Electrical Control 2 ERFS Operating RTT Gravity Refueling ERFS 3 12 Pressure Refueling 9 Removal of ERFS System HOSeS a Installing ERFS System Tee Coupling n nennen nennen sse n ennt nennen nnns Tee Coupling Installatiom r av Removal and Replacement of ERFS Fuel Pressure Switch TM 55 1560 307 13 amp LIST OF ILLUSTRATIONS Cont Removal and Replacement of ERFS Fuel Pum PN Removal of Suction and Discharge Fuel Hose Removal and Replacement of Liquid Level Removal and Replacement of Dump Valye pp Remove and Replace Fuel Filter Remove and Replace Fuel Float Assembly pp ERFS Wiring Diagram n Wire Chart for Wiring Diagram Equipment Data MM CH 47C D Weight Balance Range Endurance Performance Data ERFS Components ERFS Tiedown Configurations W O 4631 Pallets ERFS Tiedown Strap Quantity Configurations with
33. ERFS TANK PRESS TO TEST LOW LEVEL LIGHT LIGHT CHECK OK YES NO DISCONNECT LOW LEVEL REPLACE LIGHT BULB SWITCH TANK CONNECTOR ON RESPECTIVE TANK PLACE JUMPER ACROSS PIN AND B LIGHT ON YES REPLACE LOW LEVEL CHECK FOR 28 V DC ACROSS LIGHT SWITCH PINS A B C D AND E OF RECEPTACLE J3A IS 28 V DC PRESENT YES NO REPAIR REPLACE LOW TROUBLESHOOT FUEL LEVEL SWITCH TANK MANAGEMENT CONTROL HARNESS PANEL WIRING 3 5 TM 55 1560 307 13 amp TROUBLESHOOTING PROCEDURE NO 5 PUMP DOES NOT RUN WHEN PUMP SWITCH IS HELD TO ON WITH PUMP SWITCH HELD TO ON CHECK FOR 28 V DC ACROSS PINS AND B OF FUEL PUMP CONNECTOR TROUBLESHOOT FUEL MANAGEMENT CONTROL PANEL INTERNAL WIRING REPLACE FUEL PUMP TM 55 1560 307 13 amp TROUBLESHOOTING PROCEDURE NO 6 PUMP SWITCH DOES NOT REMAIN ENGAGED WITH PUMP SWITCH HELD TO ON CHECK FOR SOUND OF PUMP OPERATING YES WITH SENSOR LEVEL GO TO TROUBLE ELECTRO OPTICAL OVER CHART NO 5 RIDE PLACED TO ON ENGAGE PUMP SWITCH YES NO DISCONNECT SENSOR CONNECTOR TROUBLESHOOT FUEL MANAGEMENT AND PLACE A JUMPER ACROSS CONTROL PANEL INTERNAL WIRING PINS 1 AND 2 ENGAGE PUMP SWITCH YES NO REPLACE SENSOR TROUBLESHOOT FUEL MANAGEMENT CONTROL PANEL INTERNAL WIRING 3 7 TROUBLESHOOTING PROCEDURE NO 7 PUMP AUTOMATIC SHUTOFF DOES NOT SHUT PUMP OFF WITH LOW
34. Elbow 900 Bulkhead Nipple Tube Bracket END OF FIGURE 2 1 4 4 4 4 4 4 TM 55 1560 307 13 amp 4 5 7 8 10 11 12 4 5 6 7 8 9 10 1 ig 2 w 4 5 7 8 10 13 Figure 4 Control Panel Assembly SECTION TM 55 1560 307 13 amp P ITEM SMR PART NO CODE CAGEC NUMBER DESCRIPTION AND USABLE ON CODES UOC QTY GROUP 03 Control Panel Assy Control Panel Assy 85SDSCC D 0007 99 85SDSCC D 0007 100 85SDSCC D 0007 101 85SDSCC D 0007 103 Elec Control Panel MS35333 73 Washer MS35207 274 MS35650 320 Nut Plain AN960 10L Washer NAS43DD3 128 MS21919WDG13 MS35207 270 NAS43DD3 64 Spacer MS35207 264 Sol EE EEE MS3367 Tie Strap Plastic 1 2 3 4 5 6 7 8 9 N oo oo END OF FIGURE TM 55 1560 307 13 amp H Figure C 5 Panel Assembly C 19 SECTION II TM 55 1560 307 13 amp P ITEM SMR PART NO CODE CAGEC NUMBER DESCRIPTION AND USABLE ON CODES UO C GROUP 0301 Control Panels Fig 5 Panel Assy 85SDSCC D 0007 100 B5SDSCC D 0007 104 Box Assy M F roflAppx B5SDSCC D 0007 138 Pump Riser M F ref Appx CD S S 5 N NN LS N 1 2 3 4 5 6 7 8 9 Coupling Half Clamp Quick
35. Entity CAGE in parenthesis followed by the part number e Unit of Measure U M Indicates the measure used in performing the actual maintenance function This measure is expressed by a two character alphabetical abbreviation e g in pr If the unit of measure differs from the unit of issue requisition the lowest unit of issue that will satisfy your requirements ITEM NO LEVEL 1 0 2 0 3 0 4 0 5 0 6 U 7 0 8 0 9 0 10 0 11 0 12 0 13 U 14 0 15 0 16 0 17 0 His 0 55 1560 307 13 amp Section 1 EXPENDABLE SUPPLIES AND MATERIALS LIST NSN 6830 00 935 1008 6830 00 682 6840 7920 00 205 3570 6850 00 270 5557 5930 00 108 1877 8010 00 935 7080 9130 11 500 0003 9130 11 500 0005 9130 01 031 5810 5330 00 612 2674 5330 00 524 4375 9150 00 273 2388 8010 00 131 6254 8030 00 152 0013 8030 01 025 1692 6850 00 285 8011 5930 00 984 6582 8040 01 129 2559 UNIT OF DESGRIPTION MEASURE Argon Gas MIL A 18455B AR Carbon Dioxide Type ll AR Grade B BB C 101B Cloth Rags DDD R 30 BD Condition Metal amp Rust Remover CN Type 11 MIL M10578 Cover Seal Tight Rubber TU Epoxy Primer MIL L 23377 GAL Fuel Turbine Grade JP 4 GAL Fuel Turbine Grade JP 5 GAL Fuel Turbine Grade JP 8 GAL Gasket BU Gasket BU Oil Lubricant MIL L 6081 GAL Grade 1010 Paint Carc MIL C 46168 GAL Seal Tight TU Sealing Compound Type Il CN Grade N MIL S8802E Solvent Dry Cleaning GAL P D 680 Strap
36. F Appx Panel Top M F ref Panel Left Hand M F r Panel Right Hand M F ref Cable Attaching Pin Quick Release Rivets END OF FIGURE C 22 4 4 2 2 1 2 4 4 4 1 1 N E gt TM 55 1560 307 13 amp Figure C 7 Pump Assembly C 23 SECTION TM 55 1560 307 13 amp P SMR ITEM CODE DESCRIPTION AND USABLE ON CODES UOC NO GROUP 0303 Fuel Pump Pump Assy 85SDSCC D 0007 101 3B7 6 2266 12 125 AN821 12D M83796 1K086A AN827 12D 172634 Adapter 2F2633 Sensor Level Electro Control M83796 1K047A 525171 15 MS51524B 12 M83796 1K043E N N N N END OF FIGURE C 24 TM 55 1560 307 13 amp Figure C 8 Electrical Control Panel Sheet 1 of 2 C 25 TM 55 1560 307 13 amp 18 19 6 8 59 mang KO amp Inns Eli ul 36 REOR Td KO CCC leg 37 38 58 55 49 4 2 57 sof 48 54 53 46 Figure C 8 Electrical Control Panel Sheet 2 of 2 C 26 SECTION II TM 55 1560 307 13 amp P SMR ITEM CODE DESCRIPTION AND USABLE ON CODES UOC NO GROUP 0304 Elec Control Panel Fig 8 Elec Control Panel Assy 85SDSCC D 0007 103 85SDSCC D 0007 105 Electrical Panel Assy MS3320 1 Circuit Breaker MS3320 10 Circuit Breaker MS24523 23 SWILDO IL 85SDSCC D 000
37. Final torque is the sum of the friction torque plus the applicable torque values from Table or friction torque plus torque from the applicable maintenance manual d Break loose torque is defined as the effort to break loose an axially loaded nut TM 55 1560 307 13 amp Table F 1 Breakaway Torque MINIMUM BREAKAWAY TORQUE FOR USED ALL METALLIC AND NONMETALLIC SELF LOCKING NUTS NUT SIZE MIN BREAKAWAY TORQUE IN LBS FINE THREAD 10 32 20 1 4 28 3 5 5 16 24 6 5 3 8 24 9 5 7 16 20 14 0 1 2 20 18 0 9 16 18 24 0 5 8 18 32 0 3 4 16 50 0 7 8 14 70 0 1 12 90 0 1 1 8 12 117 0 1 1 4 12 143 0 1 3 8 12 180 0 1 1 2 12 210 0 COARSE THREAD 4 40 NOTE 6 32 NOTE 8 32 NOTE 10 24 NOTE 1 4 20 NOTE 5 16 18 7 5 3 8 16 12 0 7 16 14 16 5 1 2 13 24 0 9 16 12 30 0 5 8 11 40 0 3 4 10 60 0 7 8 9 82 0 1 8 110 0 1 1 8 7 137 0 1 1 4 7 165 0 1 3 8 6 200 0 1 1 2 6 230 0 1 3 4 5 300 0 NOTE TEST NUT FOR MINIMUM BREAKAWAY TORQUE BY ATTEMPTING TO INSERT A MATCHING BOLT BY HAND REUSE ONLY THOSE NUTS THAT CANNOT BE TIGHTENED DOWN WITH FINGERS AFTER THE LOCKING ACTION ENGAGES BOLT OR STUD NUTS THAT DO NOT MEET THE MINIMUM BREAKAWAY TORQUE SHALL NOT BE USED F 2 Size and Thread NO 6 40 8 36 10 32 1 4 28 5 16 24 3 8 24 7 16 20 1 2 20 9 16 18 5 8 18 3 4 16 7 8 14 NO 6 32 NOTES Table F 2 Recommended Torque Values Fine Thread Plain amp Castellated Steel Hex Nuts Used with Bolts in Note 8 Tension Loadin
38. INITIAL SETUP Tools Bonney Wrench Drift Hammer 3 4 in Box End Wrench Materials Parts Dump Valve 31 Fig Appx C Flashlight explosion proof Gaskets 30 Fig C 3 Equipment Conditions Refer to Figure 3 11 Tank must be empty and separate from other tanks Tank access cover removed Tank grounded Tank must be purged Refer to Chapter 3 paragraph 3 25 3 30 TM 55 1560 307 13 amp P GENERAL SAFETY INSTRUCTIONS WARNING Injury to personnel and equip ment may occur if the purging maintenance procedure above is not performed The fuel vapor and air mixture in the tank can cause a violent explosion setoff by sparks from tools being dropped in tank REMOVAL 1 Remove dust cover 1 2 Remove nuts 2 and washers 3 3 Remove bolts 4 and flange 5 4 Remove gaskets 6 5 Remove pin 7 and lever 8 6 Remove setscrew 9 and block 10 7 Slide rod 11 yoke 12 and rod 13 down through support 14 8 Disconnect dump valve 15 from rod 13 INSPECTION 1 Visually inspect all hardware removed 2 Inspect dump valve and disassemble as shown in INSTALLATION 1 Install in reverse order of removal 2 Check for leaks after completion of work Gg 2 ED 7 TM 55 1560 307 13 amp Dust Cover Nuts Washer Bolts Flange Gasket Pin Lever Setscrew 10 Block 11 Rod 12 Yoke 13 Rod 14 Support Dump Valve
39. addition the following procedures shall be followed 1 The 600 gallon fuel tank and all of its components stored inside the storage container shall be preserved in accordance with paragraph 3 25 above 2 The 600 gallon tank and storage container shall be inspected for bare metal and treated accordingly to prevent corrosion 3 Outside storage is complete when tank and storage container is preserved 3 37 TM 55 1560 307 13 amp P b For administrative storage instructions refer to AR 750 1 Army Material Maintenance Concepts and Policy and TM 740 90 1 Maintenance of Supplies and Equipment 3 27 SHIPPING The ERFS 600 gallon fuel tanks and its components can be shipped after complete purging of the fuel tanks Shipping and storage container P N 9329 100 P N 9329 200 will be used and a list of all items in containers provided The following procedures will be complied with prior to shipping a Drain all fuel from tank Refer to paragraph 3 14 b Connect static ground receptacle on fuel tank cable into ground WARNING In addition to these procedures follow all procedures for purging fuel tanks given in TM 55 1500 204 25 1 c All residual fuel must be removed and may require removal of fuel tank access cover plate d Insert defuel nozzle directly into tank and defuel residual fuel e Remove forward filter cap f Connect a one quarter inch ID flexible hose to an inert gas supply such as Argon i
40. inches 1 dekameter 10 meters 32 8 feet 1 hectometer 10 dekameters 328 08 feet 1 kilometer 10 hectometers 3 280 8 feet Weights 1 centigram 10 milligrams 15 grain 1 decigram 10 centigrams 1 54 grains 1 gram 10 decigram 035 ounce 1 decagram 10 grams 35 ounce 1 hectogram 10 decagrams 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 The Metric System and Equivalents Liquid Measure 1 centiliter 10 milliters 34 fl ounce 1 deciliter 10 centiliters 3 38 fl ounces 1 liter 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 dekameter are 100 sq meters 1 076 4 sq feet 1 sq hectometer hectare 100 sq dekameters 2 47 acres 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 change To inches centimeters feet meters yards meters miles kilometers square inches
41. maintenance codes are entered in the third and fourth positions of the SMR Code as follows a The maintenance code entered in the third position tells you the lowest maintenance level authorized to remove replace and use an item The TM 55 1560 307 13 amp P Items with these codes are not to be requested requisitioned individually The parts that make up the assembled item must be requisitioned or fabricated and assembled at the level of maint enance indicated by the source code If the 3rd position code of the SMR code authorizes you to replace the item but the source code indicates the items are assembled at a higher level order the item from the higher level of maintenance maintenance code entered in the third position will indicate authorization to one of the following levels of maintenance Code Application Explanation C Crew or operator maintenance done within organizational or aviation unit maintenance O Organizational or aviation unit category can remove replace and use the item F Direct support or aviation intermediate level can remove replace and use the item H General support level can remove replace and use the item L Specialized repair activity can remove replace and use the item D item Depot level can remove replace and use the b The maintenance code entered in the fourth position tells whether or not the item is to be repaired and identifies the lowest maintenance level
42. 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 A HREFzhttp www liberatedmanuals com Free Military and Government Manuals lt A gt Sincerely Igor Chudov http igor chudov com
43. tanks will be filled to 580 gallons when in use The tanks are secured using 5K and 10K pound cargo strap assemblies The fuel management control panel FMCP is housed in an aluminum constructed box and is mounted on the most forward tank TM 55 1560 307 13 amp P NOTE TIEDOWN STRAPS OMITTED FOR CLARITY 1 Tank 600 Gallon 7 Tiedown Assy 2 Float Assy 8 Poppet Drain Cock 3 Hoisting Eyes 9 Fuel Filler Assy 4 Cam Lever 10 Liquid Level Indicator 5 Receptacle Ground 11 Cover Access 6 Dump Valve Fitting 12 Fitting Vent Figure 1 1 Extended Range Fuel System Sheet 1 of 5 1 2 19 4 Panel Assy Hose Assy Suction Hose Assy Discharge Coupling Half Quick TM 55 1560 307 13 amp P 14 17 Hose Assy 18 Coupling Half Identical Tee 19 Tee Assy 4 required 20 Hose Assy Vent Figure 1 1 Extended Range Fuel System Sheet 2 of 5 1 3 TM 55 1560 307 13 amp 21 Hose Assy 25 Adapter 22 Hose Assy 3 required 26 Hose Assy 23 Elbow Assy 3 required 27 Coupling Half Quick 24 Hose Assy 2 required 2 required Figure 1 1 Extended Range Fuel System Sheet 3 of 5 1 4 28 29 30 Hose 2 required 37 Coupling Half 38 4 required 39 32 33 Tee Tube 2 required 34 Pin Quick Release 35 4 required 36 Pump 4 required Electrical Control Panel TM 55 1560 307 13 amp Hose 2 required Hose 4 required Sensor Level Electro Optica
44. tiedown straps Figure 2 6 s Continue procedure until remaining tanks are installed and tied down per Figures 2 9 2 10 2 11 TM 55 1560 307 13 amp LOW LEVEL WARNING LIGHT HARNESS GROUND WIRE gt TO L H RECEPTACLE GROUND WIRE POWER CABLES TO ACFT FMCP ASSY RECEPTACLE Figure 2 4 Fuel Management Control Panel Installation 2 8 TM 55 1560 307 13 amp 1 FMCP Box 2 Fuel Manifold 3 Fuel Fitting 4 Hose Assy 5 Coupling Half 4 ea 6 Hose Assy Suction 7 Hose Assy Tank Feed Lines 8 Tee Fitting Manifold 6 9 Coupling gt 10 Hose Assy Sp 007 S UG 74 e gt lt Figure 2 5 Fuel Pumping System and Plumbing 2 9 TM 55 1560 307 13 amp STA 220 240 260 280 300 320 10 000 Lb Strap ____ _ 5 000 Lb Strap 340 5 000 Lb Strap attaches to top 360 i F Take Up Fitting 380 Looped Strap 400 DUMP VALVE Figure 2 7 Manifold Hose and Fitting Installation 2 10 TM 55 1560 307 13 amp REDUCER D MODEL HOSE ASSY FOR D LOW LEVEL WARNING LIGHT HARNESS VENT HOSE PUSH COUPLINGS TOGETHER VALVES IN CLOSED POSITION AND TWIST CLOCKWISE Figure 2 8 Manifold and Hose Couplings Installation 2 11 10 000 Lb ON ee Nel CN 5 000 Lb 5 000 Lb attaches Strap Strap Strap to top T Take Up Fitting Looped Strap
45. 1 LOGIG TREE OVERBOARD PRESSURE FILL PURGE REDUNDANT SHORING SPLASH FILL TIEWRAPS flexible hoses TRIP UNI SEX TM 55 1560 307 13 amp P GLOSSARY Cont A diagram of troubleshooting procedures Discharge or venting of fluids or gases including necessary plumbing connections to the outside of aircraft Filling of fuel tanks through a sealed plumbing system using controlled fuel pressure or venting Emptying of fuel in liquid and gas form from fuel system tanks and lines Excess or duplication of a feature Plywood sheets used for cargo floor decking Filling of fuel tanks through an open fuel fill assembly Plastic bands used to secure electrical cable bundles or Automatic opening of an electrical circuit breaker causing disconnection of the circuit from power source due to faults or electrical overload Complete interchangeable hose coupling fittings that have no unique male or female end fittings GLOS 2 TM 55 1560 307 13 amp ALPHABETICAL INDEX Subject Para A Assembly and Preparation for for Use 2 16 B C Checking Unpacked Equipment 3 5 CH 47G D Weight Balance Range Endurance Performance Data T 1 2 Common Tools and Equipment 3 1 Controls and Indicators Function 2 9 T 2 4 D Destruction of Army Material to Prevent Enemy Use 1 5 Dump Valve 3 21 E Emergency Procedures 2 22 Equipment Characteristics Capabilities and Features 1 10 Equipment Configuration 1 9 Equipme
46. 10 0 28 5 402 422 442 462 10 000 Lb Strap 5 000 Lb Strap 5 000 Lb Strap attaches to top T Take Up Fitting Strap Figure 2 16 Four Tanks with Pallets 2 21 TM 55 1560 307 13 amp 160 10 0 k 28 5 4 200 268 5 10 000 Lb Strap 5 000 Lb Strap 5 000 Lb Strap attaches to top Take Up Fitting Looped Strap Figure 2 17 One Tank with One Pallet Change 1 2 22 224 244 260 264 268 5 273 293 264 313 273 VIEM A 333 353 10 000 Lb Strap 5 000 Lb Strap 3 3 t 377 5 5 000 Lb Strap 382 attaches to top Take Up Fitting 402 TM 55 1560 307 13 amp STA 204 0 0 28 5 4 Looped Strap Figure 2 18 Two Tanks with Pallets 2 23 320 VIEW 377 5 10 000 Lb Strap 5 000 16 Strap 5 000 Lb Strap attaches to top Take Up Fitting Looped Strap Figure 2 19 Three Tanks with Pallets 2 24 TM 55 1560 307 13 amp P 28 5 4 10 000 Lb Strap 5 000 Lb Strap 5 000 Lb Strap attaches to top Take Up Fitting Looped Strap 377 5 __ 380 440 486 373 382 402 422 442 462 482 Figure 2 20 Four Tanks with Pallets 2 25 TM 55 1560 307 13 amp P TM 55 1560 307 13 amp Section IV OPERATING INSTRUCTIONS
47. 12 1 GROUP 01 Sys Installation Fuel Tank Extended Range Fuel Sys 85SDSCC D0007 2 ERFS Tank Assy Hose Assy M F ref Appx Coupling Half Tee Assy Hose tte ie Hose ASSy iinan Hose eee ee es Quick Disconnect Hose Decking M F ref Appx E Harness Assy M F re Hose Coupling Half 900 Hose ASSY nire ets Control Panel Assy Ground Strap Electrical Harness Assy M F ref DD Electrical Harness Assy M F ref bet uve dv de and Elbow ASSy Hose Assy M F ref Appx Hose Assy M F rdf Appx E Coupling Half Cap Coupling Hose ASSy idees Strap Webbing Strap Webbing END OF FIGURE oo om Co TM 55 1560 307 13 amp Figure C 3 ERFS Tank Sheet 1 of 2 C 12 TM 55 1560 307 13 amp Figure ERFS Tank Sheet 2 of 2 C 13 SECTION TM 55 1560 307 13 amp P ITEM SMR PART NO CODE CAGEC NUMBER DESCRIPTION AND USABLE ON CODES UOC QTY 13217E7080 551922 49 5 14 365 16 52104515 AN960PD516 AN5 13A 85SDSCC D 0007 123 85SDSCC D 0007 119 SS9609GZ1810 85SDSCC D 0007 120 8
48. 16 W 3 8 Deep MATERIAL 75 PLYWOOD 17105 MATER SEAL WATERPROOFING FORMULA GROOVE WIDTH 0 1875 IN DEPTH 0 3750 IN Figure 2 Fabrication of Decking PIN 855505 0007 187 E 3 11 12 IN 4 PLCS ITEMS FOR GROUND STRAP HARNESS GROUND STRAP WIRE QQW343R12018 81349 BULK 540 IN SPLICE CONDUCTOR M83519 2 9 66114 4 EA PLUG ASSEMBLY MS3493 5 96906 TYPICAL IN 5 PLACES PLUG CONNECTOR 85SDSCC D 0007 190 12757 1 FABRICATE PER DETAIL A FIG E 3 SHEET 2 OF 3 INSULATION SLEEVE SHRINKABLE RNF 100 3 16 IN BLACK 06090 BULK 540 IN USE ON GROUND HARNESS ONLY ITEMS FOR LOW LEVEL WARNING HARNESS CONNECTOR MS3476W14 45 96906 TYPICAL IN 4 PLACES CONNECTOR MS3476W14 5P 96906 1 EA ADAPTER M85049 52 1 14W 81349 1 EA WIRING SEE WIRE CHART FIG E 3 SHEET 2 OF 3 INSULATION SLEEVE SHRINKABLE RNF 100 1 4 IN BLACK 12 06090 USE ON LOW LEVEL WARNING HARNESS ONLY INSULATION SLEEVE SHRINKABLE RNF 100 3 18 IN BLACK 06090 USE TO COMBINE AND BIND THE GROUND STRAP AND LOW LEVEL WARNING HARNESS TOGETHER CRIMP ELEC SPLICE PERMANENT M81824 1 2 81349 3 EA Figure E 3 Fabrication of Electrical Harness Assembly P N 85SDSCC 0 0007 112 113 114 Sheet 1 of 3 E 4 TM 55 1560 307 13 amp SEE DETAIL m O gt 4 gt m 0726 22 Q726E22N Q726C22N P3A 5 N lt
49. 2 18 OPERATING PROCEDURE Refer td Chapter paragraph 2 12 2 19 OPERATION OF AUXILIARY EQUIPMENT The ERFS electrical power supply is provided by an external APU generator the aircraft APU or the aircraft s main generators with the engines running 2 20 OPERATING INSTRUCTIONS ON DECALS AND INSTRUCTION PLATES Refer to Figure 2 24 TM 55 1560 307 13 amp Section VII OPERATION UNDER UNUSUAL CONDITIONS 2 21 OPERATION IN UNUSUAL WEATHER The ERFS system can be installed and operated in climatic conditions that are acceptable to aircraft operations WARNING Installing the non crashworthy ERFS increases the potential for thermal injuries during a crash sequence Therefore the number of personnel on board the aircraft will be kept to the minimum required to perform the required mission Additionally all personnel are required to be seated with a lap belt during flight 2 22 EMERGENCY PROCEDURES The ERFS is a system designed with redundant capabilities to ensure system reliability in flight a In the event of an inflight fuel leak due to a manifold seal malfunction the dust cover seal can be used to replace the manifold seal b Leaks in the ERFS fuel manifold system can be isolated by using the coupling shutoff characteristics c Failure of pumps If both pumps feeding one side of the aircraft fail pumps 1 and 2 use these procedures 1 Place the override switch in the ON position 2 If pumps 1 and 2
50. 2 62 62 62 62 62 62 62 62 62 62 62 62 62 62 62 62 62 62 62 62 62 62 62 62 62 62 62 62 62 62 62 62 62 62 62 62 62 lt gt O gt O gt O O O Q O Q O amp amp amp 0 00000000000 TM 55 1560 307 13 amp P Section IV NATIONAL STOCK NUMBER FIG z 9 62 62 62 62 62 62 62 62 62 62 62 62 62 62 62 62 62 62 62 62 62 62 62 62 62 62 62 62 62 62 62 62 62 62 62 62 62 62 62 62 62 62 lt gt CO CO 00 CO 00 00 00 4 O O O O O O O O gt CROSS REFERENCE INDEXES NATIONAL STOCK NUMBER INDEX ITEM NO C 32 NATIONAL STOCK NUMBER 5310 00 003 9415 5305 00 052 9329 4730 00 054 7296 5330 00 063 2506 5305 00 071 2066 5305 00 071 2071 5340 00 077 2459 5320 00 117 6937 5940 00 143 4775 5306 00 151 1416 5306 00 151 2626 5310 00 159 6209 5310 00 167 0738 5310 00 167 0738 5310 00 167 0834 5310 00 167 0834 5310 00 167 0834 5310 00 184 9200 5310 00 187 2354 5310 00 187 2354 5310 00 187 2399 6145 00 191 8457 4730 00 194 1046 5940 00 204 8966 5925 00 224 7422 5310 00 225 6993 4730 00 231 3078 5940 00 247 0524 5330 00 248 3846 5330 00 251 8839 4730 00 256 2310 5961 00 257 6865 FIG z 2 62 62 62 62 62 62 62 62 62 62 62 62 62 62 62 62 62 62 62 62 62 62 62 62 62 62 62 62 62 62 62 62 62 62 62 62 62 62 62
51. 28 ZN MAR po 0701 12 10 Oc 0704422 9704A22 PUMP 3 cr tt zi B FU Md Tris RELAY K 03 B 5 5 8 6852 22 8 S u aoz 55 5 5 lt gt 10 OC 0705422 55 P102 0736A20 IT JUHPER ASSY 0735822 58 1 0740422 5 0735C22 pda s 4 lt gt 0734420 D L 0734820 o7azczon E6 Ru or 100228 TEE Ik P 0 66 2 P O 0741822N P70 GG 1 07 42822N 0704822 O 510 07046224 i 0709422 w V P O 65 1 6 0708422 H 1 XFER 07428220 2 NOTES OVERRIDE 0742422 07 10422 pave ph 1 HARNESS FABRICATION AND WIRING INSTALLATION SHALL BE FR MIL V 5085 1 0741822N 0707422 PUMP 4 0741422 7 RELAY KJO4 2 EQUIPMENT INSTALLATION PER NIL E 3080 I 3 SYMBOL INDICATES 525036 1 TERM i 0740822 07065422 INAL LUG 0740C22N SS 5 4 SYHBA SEI INDICQTES 81824 1 PERMANENT SPLICE BR 3 5 USE STANDARD SLEEVE P N TMS 1 2 1 5 060801 85 5 OR FAUNA ERT TO IDENTIFY HARNESS ENDS Linc Ed nS ilr E I 2 Pump 12 Swr lt H 55 55 1 H 0 3 66 2 As e Fl Q711822N 0736C20N r aj B 970422 66 1 3 4 3 Me 0705 22 SwTcH 55 gmoazzN 07108228 P O 66 1 5 2
52. 3 20 MAINTENANCE OF ERFS COMPONENTS LIQUID LEVEL INDICATOR LEVEL INDICATOR REPLACE LIQUID This task covers a Removal b Inspection c Installation INITIAL SETUP Tools 1 5 16 Crow Foot Material Parts Adhesive item 14 Appx D Liquid Level Indicator 61 62 Flashlight explosion proof Equipment Conditions Refer to Figure 3 10 ERFS tank must be empty and separate from other tanks Tank access cover removed Tank grounded Tank must be purged Refer to Chapter paragraph 3 25 GENERAL SAFETY INSTRUCTIONS WARNING Injury to personnel and equipment may occur if the purging maintenance procedure above is not performed The fuel vapor and air mixture in the tank can cause a violent explosion setoff by sparks from tools being dropped in tank REMOVAL I Remove retainer 1 and float 2 2 Remove nut 3 and washer 4 3 Remove tube 5 TM 55 1560 307 13 amp P Retainer Float Nut Washer Tube 02 Figure 3 10 Removal and Replacement of Liquid Level Indicator 3 29 INSPECTION 1 Visually inspect threads on new indicator tube 2 Check threads on nut 3 3 Ensure that new indicator tube has packing installed on upper groove INSTALLATION 1 Install tube 5 2 Install washer 4 and nut 3 and tighten nut 3 Install float 2 and retainer 1 3 21 DUMP VALVE Replace dump valve This task covers a Removal b Inspection c Installation
53. 40 00 794 6956 C 3 23 97403 13217 7087 5314 01 137 4739 C 3 20 97403 13217 7088 4930 01 017 3637 C 3 24 97403 13217 7089 5341 01 173 7592 C 3 25 97403 13217 7090 5330 00 733 2208 C 3 19 97403 13217E7092 C 3 55 97403 13217 7096 4020 01 150 2927 C 3 31 00624 180 950248 16D 0360 M C 2 23 97484 2F2633 6680 01 H77 0066 C 7 7 XDOZZ 205 030 493 1 1680 00 839 1756 C 6 24 205 060 613 3 2915 00 968 6363 C 3 83 79499 205 063 604 1 1560 01 078 5647 C 3 62 97499 214 066 005 1 4820 00 527 4333 C 3 15 96906 214 066 015 1 5330 00 524 4375 C 3 16 00624 2266 12 125 4730 01 117 5649 7 2 00624 3 7 6 1680 01 238 8159 C 7 1 00624 390A 16D 0720 C 2 13 97403 5 14 365 16 C 3 3 97403 5 14 365 52 1 4930 01 041 6870 C 3 18 85SDSCC D 0007 10 C 3 81 12757 85SDSCC D 0007 100 C 4 1 12757 85SDSCC D 0007 101 C 4 2 12757 85SDSCC D 0007 102 C 8 4 12757 85SDSCC D 0007 103 C 4 3 C 37 TM 55 1560 307 13 amp CROSS REFERENCE INDEXES PART NUMBER INDEX Cont Section IV NATIONAL STOCK FIG ITEM CAGE PART NUMBER NUMBER NO NO 12757 85SDSCC D 0007 104 C 5 1 12757 85SDSCC D 0007 105 C 8 1 12757 85SDSCC D 0007 106 C 3 10 12757 85SDSCC D 0007 110 C 5 15 12757 85SDSCC D 0007 111 C 5 19 15757 85SDSCC D 0007 112 C 2 19 12757 85SDSCC D 0007 113 C 2 12 15757 85SDSCC D 0007 114 C 2 20 12757 85SDSCC D 0007 116 C 3 64 12757 85SDSCC D 0007 117 C 3 86 12757 85SDSCC D 0007 118 C 3 12 12757 85SDSCC D 0007 119 C 3 8 12757 85SDSCC D 0007 119 C 3 59 12757 85SDSCC
54. 57 81349 88044 96906 12757 12757 12757 12757 96906 96906 96906 88044 80205 96906 80205 80205 55 1560 307 13 amp PART NUMBER 205 063 604 1 MS29513 114 85SDSCC D 0007 116 1140 0161 1 1140 0161 2 MS21083C 4 85SDSCC D 0007 9 NAS679 AO6W AN960 PBL MS35206 215 MS3472L14 4P MS24400 D5 85SDSCC D 0007 20 NAS677 8 85SDSCC D 0007 29 85SDSCC D 0007 10 MS28772 6 205 060 613 3 85SDSCC D 0007 117 MS90298 2 85SDSCC D 0007 184 85SDSCC D 0007 182 85SDSCC D 0007 197 85SDSCC D 0007 196 M83796 1G200E 833 6 524392 6 85SDSCC D 0007 124 85SDSCC D 0007 100 85SDSCC D 0007 101 85SDSCC D 0007 103 MS35333 73 MS35207 274 MS35650 320 AN960 10L NAS43DD3 128 MS21919WDG13 MS35207 270 NAS43DD3 64 TM 55 1560 307 13 amp CROSS REFERENCE INDEXES FIGURE AND ITEM NUMBER INDEX Cont Section IV FIG ITEM NATIONAL STOCK NO NO NUMBER CAGE PART NUMBER C 4 12 5305 00 989 7435 96906 MS35207 264 C 4 13 m 96906 MS3367 C 5 1 m 12757 85SDSCC D 0007 104 C 5 12757 85SDSCC D 0007 138 C 5 3 5306 00 151 1416 88044 AN4 20A C 5 4 5310 00 187 2354 88044 AN960PD416 C 5 5 5310 00 167 0738 88044 AN960D6 C 5 6 4730 01 093 8464 96906 MS51860 58 C 5 7 5330 00 251 8839 96906 MS28778 12 C 5 8 4730 00 933 0816 96906 MS51520B 12 C 5 9 4730 01 276 7563 00624 AE85861M C 5 10 5340 01 H76 8483 00624 916 2655 5 11 2 12757 85SDSCC D 0007 176 5 12 2 12757 85SDSCC D 0007 196 C 5 13 5340 00 598 8251 88044 AN743 12 C
55. 5SDSCC D 0007 106 MS51524B16 85SDSCC d 0007 118 AN4 7A AN960C416L MS16562 256 5 14 365 52 1 13217E7090 13217 7087 55691 36 29513 112 13217 7 086 13217 7088 13217 7089 MS51922 33 MS35338 48 MS90725 115 13217E7082 13217E7084 13217E7096 GROUP 02 Tank Assy ERFS Tank 85SDSCC D 0007 115 Nut Self Locking He Loop Drag Nut Self Locking Washer Flat Bolt Machine Cover M F 6061 TA Alum 0 375 X 15 00 X 19 25 ref Appx Fuel Filler Cap M F P N 55960609 re DD Cap Filler Opening Gasket M F MIL R 8855D Class 1 GR60 ref Appx E Fitting Bolt Machine Washer Flat Rollover Vent Valve Pin Spring Lever Cam Adapter Rod Cam Lever Rod Cam Lever Upper Packing Preformed Base Cam Lever Yoke Adjusting Valve Rod Lower Operating Not Plain Hex Washer Lock Valve Mtg Screw Cap Hex Ring gua Gasket Valve Valve Dispensing Nut Eye ua aaa hana kaa Setscrew Plunger Spring Stem Plunger Retainer PIG Nut Plunger Disc PH HOH N SECTION II TM 55 1560 307 13 amp P ITEM SMR PART NO CODE CAGEC NUMBER DESCRIPTION AND USABLE ON CODES UOC QTY P4012E Body Valve 89SDSCC D 01 04 6 89SDSCC D 0104 4 Screen As
56. 65 5935 01 199 7154 96906 MS3472W 14 4P C 8 66 5935 01 163 3224 81349 M85049 31 1 14W C 8 67 5310 00 167 0834 88044 AN960 10L C 8 68 5310 00 807 1467 96906 MS21042 3 C 8 69 5310 00 584 5272 96906 MS35338 48 C 9 1 5935 01 108 4486 96906 MS3476W 14 5P C 9 2 5935 01 176 4517 96906 MS3476W 14 45 C 9 3 6145 00 191 8457 a QQW34R1201B C 9 4 5935 00 572 5154 AA MS3493 5 C 9 5 T 12757 85SDSCC D 0007 190 C 45 C 46 Blank TM 55 1560 307 13 amp APPENDIX D EXPENDABLE 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 ERFS 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 COLUMNS Number This number is assigned to the entry in the listing and is referenced in the narrative Instructions to identify the material e g Use cleaning compound item 5 Appendix D b Level This column identifies the lowest level of maintenance that requires the listed item C Operator Crew U Organizational Maintenance D 1 c National Stock Number This is the National Stock Number assigned to the item use it to request requisition the item d Description Indicates the Federal item name and if required a description to identify the item The last line for each item indicates the Commercial and Government
57. 6D 0960 1 Hose Assy 950234 16D 2300 2 Hose Assy 950004 16D 0720 2 4 Hose Assy AE706285 1 4720 01 214 1002 1 Hose Assy AE706285 2 4720 01 214 2914 3 Hose Assy AE706285 3 4720 01 214 1003 2 Hose Assy AE706285 5 4720 01 214 2915 1 2 1 NOMENCLATURE Hose Assy Hose Assy Hose Assy Identical Tee Hose Assy Panel Assy FMCP Plywood Deck Shoring Pump Assy Quick Disconnect Reducer Tube Strap Webbing Strap Webbing Wrench Wrench Wrench Wrench Wrench Table 2 1 ERFS Components Cont TM 55 1560 307 13 amp PART NUMBER NSN QTY AE706285 6 4720 01 214 1001 1 528741 240 0160 1 390A 16D 0720 4 180 950248 16D 0360 85SDSCC D 0007 100 1 85SDSCC D 0007 187 8 85SDSCC D 0007 101 4 114 5491 2 4730 01 140 6760 2 MS24399D28 4730 01 262 8293 1 SP4212 1 1670 00 725 1437 38 B D 10000 R 0 234 HH 24 5340 01 233 3063 8 1232 5120 00 203 4812 1 1248 5120 00 203 4804 1 1244 5120 00 203 4806 1 1240 5120 00 203 4808 1 1252 5120 00 203 4802 1 Section INSPECTING THE EQUIPMENT 2 4 INSPECTION Inspect the ERFS components as follows CAUTION A daily visual inspection shall be made of the subject installation to ensure that no progressive structural deterioration is occurring that there is no loss of security and that no damage to the host helicopter tank fittings tiedown straps etc exist Any occurrence of the preceding shall be corrected prior to further flight operations a Initial Instal
58. 7 102 Brace Strap Assy M F ref Appx E M5594 1 2 Switch Mag 85 0 0 0007 163 85SDSCC D 0007 162 MS25224 1 ere esl Tire Een MS25041 11 Light Indicator 85SDSCC D 6007 164 85SDSCC D 0007 165 MS25082B21 MS35333 121 85 0 0 0007 166 85SDSCC D 0007 167 85SDSCC D 0007 195 85SDSCC D 0007 174 85SDSCC D 0007 169 MS3106A100SL 3S M85049 55 10A Clamp Backshell 90 MS25036 156 asa 85SDSCC D 0007 153 85SDSCC D 0007 155 85SDSCC D 0007 170 85SDSCC D 0007 161 MS25226 2 3 Link Terminal 518029 153 Cover Assy Terminal 85 0 0 0007 159 M81714 28 20 Module Ground MS27212 1 20 Terminal Cover 518029 156 Cover Assy Terminal 85SDSCC D 0007 160 IN4001 85SDSCC D 0007 157 MS25036 102 85SDSCC D 0007 162 85SDSCC D 0007 163 85SDSCC D 0007 164 85SDSCC D 0007 158 M6106 27 029 1 2 4 1 1 4 1 1 5 8 1 1 1 1 1 1 1 1 1 2 2 6 1 1 1 1 1 1 1 2 1 1 1 8 1 2 1 1 1 1 1 C 27 SECTION TM 55 1560 307 13 amp P SMR ITEM CODE DESCRIPTION AND USABLE ON CODES UOC 85SDSCC D 0007 156 85SDSCC D 0007 173 85SDSCC D 0007 154 MS27743 5 85SDSCC D 0007 152 85SDSCC D 0007 172 IN4001 85SDSCC D 0007 151 MS35707 262 AN960 10L MS21044 N3 MS3472W12 8S Receptacle M85049 31 1 12W Backsh
59. 85SDSCC D 0007 133 85SDSCC D 0007 138 85SDSCC D 0007 143 85SDSCC D 0007 187 85SDSCC D 0007 20 950234 16D 2300 FIGURE NUMBER mimm fk 1 N mimm 0300 ojoj ajo No NINDIN N I o TM 55 1560 307 13 amp P FITTING SEATING SURFACE 240 DEGREE ROTATION EXAMPLE OF FITTING ORIENTATION ROTATION ALWAYS TAKEN COUNTER CLOCKWISE CCW Lg DEPT TENES WU gg e JO emm rem NIE M83796 1K047A 4720 00 555 3499 4730 one rH 1957 MEER pe M83796 1K043E 4720 00 555 3499 4730 og 541 1957 4730 00 238 5338 M83796 1K086A 4720 00 555 3499 4730 581 957 FAE 8 3 4 NOTES 1 FABRICATE NONMETALLIC HOSE ASSEMBLIES USING MATERIALS AND DIMENSIONS LISTED 2 ALL HOSE ASSEMBLIES SHALL BE FABRICATED IN ACCORDANCE WITH INSTRUCTIONS CONTAINED IN TM 55 1500 204 25 1 AND TB 750 125 3 OVERALL HOSE LENGTH L IS MEASURED FROM FACE OF EACH END FITTING S SEATING SURFACE IN INSTANCES WHERE 45 or 902 ELBOW FITTING IS USED THE INTERSECTION POINT OF FITTING SEATING SURFACE LINE AND THE BEND AXIS IS USED AS HOSE LENGTH REFERENCE POINT 4 ALL DIMENSIONS ARE IN INCHES Figure E 1 Fabrication of Hose Assemblies E 2 TM 55 1560 307 13 amp 2 75 STOCK GROVE 3
60. 9 5 14 365 16 MS21 045L5 AN960PD516 AN5 13A 85SDSCC D 0007 123 85SDSCC D 0007 119 85SDSCC D 0007 120 85SDSCC D 0007 106 MS51524B16 85SDSCC D 0007 118 AN4 7A AN960C416L 214 066 005 1 214 066 015 1 70 5 GOVERNMENT PRINTING OFFICE 1993 755 02 80380 zm OG CO CO CO CO CO CO CO CO CO CROSS REFERENCE INDEXES FIGURE AND ITEM NUMBER INDEX Cont NATIONAL STOCK NUMBER 5315 00 753 3895 4930 01 041 6870 5330 00 733 2208 5314 01 137 4739 5310 00 899 6082 5330 00 733 2208 5340 00 794 6956 4930 01 017 3637 5341 01 173 7592 5310 00 225 6993 5310 00 584 5272 5305 00 071 2071 5330 00 063 2506 4020 01 150 2927 4730 01 214 2570 4730 00 649 9100 5310 00 809 8533 5305 00 071 2066 5310 00 003 9415 5310 00 857 5557 5310 00 187 2354 5306 00 515 8064 5305 00 052 9329 5310 00 159 6209 96906 97403 97403 97403 96906 96906 97403 97403 97403 96906 96906 96906 97403 97403 97403 79515 79515 79515 79515 79515 79515 79515 79515 79515 12757 12757 12757 00624 96906 96906 14555 96906 88044 96906 96906 97403 96906 96906 97403 96906 88044 88044 12757 96906 96906 TM 55 1560 307 13 amp PART NUMBER M
61. A CABLE POWER CO 02HLF 2 12 0625 81349 LENGTH AS FOLLOWS FOR 112 HARNESS 276 0 286 0 INCHES FOR 114 HARNESS 180 0 190 0 INCHES 5 SLEEVE INSULATING IDENTIFYING M23053 5 109 9 81349 1 INCH PER SLEEVE Figure E 3 Fabrication of Electrical Harness Assembly P N 85SDSCC D 0007 112 113 114 Sheet 3 of 3 E 6 TM 55 1560 307 13 amp 50 REF PS i 271 291 DIA 8 HOLES in EQUALLY SPACED 005 DIA T M ER u 3 796 85SDSCC D 0007 123 COVER MAKE FROM 3 8 X 15 X 19 1 4 5061 76 ALUM QQ A 250 11 85505 0 0007 120 GASKET MAKE FROM 1 8 X 15 X 19 1 4 SYN RUBBER MIL R 6855 CLASS I GR 60 255 EQ SPACED 073 TYP i L s LETT Ri 22 30 323 333 DIA 20 PLCS THRU COVER AND GASKET TYP IN EACH QUADRANT SEE BOLT PATTERN TABLE 005 DIA 1 010 DIA I 7 990 i amp ELLIPSE C 20 HOLE BOLT PATTERN ELLIPSE B INNER EDGE OF GASKET SEE ELLIPSE TABLE 4 880 DIA B C ELLIPSE A OUTER B _ EDGE OF COVER AND GASKET SEE ELLIPSE TABLE MATERIALS FABRICATE FROM 2024 T3 AL ALLOY STOCK SIZE 0 063 X 7 00 X 33 50 IN FINISHES ELLIPSE A 18 750 B 15 750 11 500 17 750 13 500 1 TREAT ALUMINUM WITH CHEMICAL CONVERSION 4 3235 COATING PER MIL C 5541 CLASS 1 5 6900 2 APPLY EPOXY PRIMER PER MIL P 23377 6 4883 3 PAINT WITH CARC ACFT GREEN COLOR 0 0000 6 7500 NO 34031 FED STD 595 PER MIL
62. AVIM b Less Than Company Size Aviation Units Aviation elements organic to brigade group battalion headquarters and detachment size units are normally small and have less than ten aircraft assigned Maintenance tasks performed by these units will be those which can be accomplished by the aircraft crew chief or assigned aircraft repairman and will normally be limited preventive maintenance inspections servicing spot painting stop drilling application of nonstress patches minor adjustments module component fault diagnosis and replacement of selected modules components Repair functions will normally be accomplished by the supporting AVIM unit 2 AVIM provides mobile responsive one stop maintenance support Maintenance functions which are not conducive to sustaining air mobility will be assigned to depot maintenance AVIM may perform all maintenance functions authorized to be done at AVUM Repair of equipment for return to user will emphasize support operational readiness requirements Authorized maintenance includes replacement and repair of modules components and end items which can be accomplished efficiently with available skills tools and equipment AVIM established the Direct Exchange DX program for AVUM units by repairing selected items for return to stock when such repairs cannot be accomplished at the AVUM level The AVIM level inspects troubleshoots performs diagnostic tests repairs adjust calibrates
63. BER INDEX Cont ITEM NO C 33 NATIONAL STOCK NUMBER 2915 00 968 6363 5305 00 989 7435 5305 00 993 2463 5305 00 995 3440 4720 01 H76 8433 5340 01 H76 8483 6680 01 H77 0066 5945 01 011 1318 4930 01 017 3637 4930 01 041 6870 5935 01 064 5841 1560 01 078 5647 4730 01 093 8464 5935 01 108 4486 5945 01 114 1288 4730 01 117 5649 5314 01 137 4739 4730 01 140 6760 5935 01 148 4737 4020 01 150 2927 5935 01 163 3224 5935 01 170 9127 5341 01 173 7592 5935 01 176 4517 5935 01 199 7154 6150 01 201 1570 4730 01 214 0994 4730 01 214 0996 4720 01 214 1001 4720 01 214 1002 4720 01 214 1003 4730 01 214 2570 4730 01 214 2910 4730 01 214 2913 4720 01 214 2914 4720 01 214 2915 5340 01 233 3063 1680 01 238 8159 5935 01 256 0252 4730 01 276 7563 4730 01 276 7564 4730 01 276 7564 6680 01 293 9094 6680 01 293 9095 4730 01 312 9233 FIG z 62 62 62 62 62 62 62 62 62 62 62 62 62 62 62 62 62 62 62 62 62 62 62 62 62 62 62 62 62 62 62 62 62 62 62 62 62 62 Ke Ke Keke LIO IO IO IO G IO 00 00 00 00 00 G 02 G 00 55 1560 307 13 amp TM 55 1560 307 13 amp CROSS REFERENCE INDEXES PART NUMBER INDEX Cont Section IV NATIONAL STOCK FIG ITEM CAGE PART NUMBER NUMBER NO NO C 3 84 ni C 3 85 86831 C 3 67 86831 C 3 68 86831 C 3 70 86831 C 3 71 00624 AE25010 011 4730 01 214 2910 C 2 16
64. BER INDEX Cont Section IV NATIONAL STOCK FIG ITEM CAGE PART NUMBER NUMBER NO NO 96906 MS122032 5310 00 159 6209 C 3 61 96906 MS16562 256 5315 00 753 3895 3 17 96906 516996 21 5305 00 052 9329 3 60 96906 518029 153 C 8 27 96906 518029 156 5940 00 247 0524 8 31 PAOZZ MS20426AD3 5320 00 117 6937 C 6 25 96906 MS2057P5 2150 8 C 6 8 96906 MS21042 3 5310 00 807 1467 C 8 68 96906 MS21044 N3 5310 00 877 5797 C 8 51 96906 MS21045L06 5310 00 857 5560 C 5 20 96906 MS21045L4 5310 00 857 5557 C 3 56 96906 MS21045L5 5310 00 587 5559 C 3 4 86831 MS21083C 4 5310 00 897 6145 C 3 69 96906 MS21919WDG13 C 4 9 96906 MS24392 6 8 94 96906 MS24399D28 4730 00 684 7446 2 3 96906 MS24400 D5 5310 00 282 7832 C 3 77 96906 MS24523 23 5930 00 683 1629 C 8 3 96906 MS24665 289 m C 3 48 96906 MS25036 102 5940 00 204 8966 C 8 35 96906 MS25036 156 5940 00 143 4775 C 8 21 96906 MS25041 11 C 8 9 96906 MS25082B21 C 8 12 96906 MS25171 1S 7 9 96906 MS25224 1 C 8 8 96906 MS25226 2 3 6150 00 600 6259 C 8 26 96906 MS27028 11 4730 00 649 9100 C 3 45 96906 MS27030 6 T C 3 46 96906 MS27183 18 5310 00 003 9415 C 3 54 96906 MS27183 23 5310 00 809 8533 C 3 50 96906 MS27212 1 20 5940 00 950 1610 C 8 30 96906 MS27743 5 5945 01 011 1318 C 8 44 96906 MS28741 24D 0160 2 2 96906 MS28772 6 C 3 82 96906 MS28778 12 5330 00 251 8839 C 5 7 96906 MS29513 112 5330 00 733 2208 C 3 22 96906 MS29513 114 5330 00 248 3846 C 3 63 96906 MS3106A10SL 3S T C 8
65. C 46168 Figure E 4 Fabrication of Gasket amp Cover PIN 85SDSCC D 0007 120 amp 123 E 7 TM 55 1560 307 13 amp P SEE DETAIL A BELOW 85505 0 0007 119 FUEL FILLER ASSEMBLY MAKE FROM P N SS9609 CAGE 78286 REMOVE NUMERALS 181 BY GRINDING PAINT THE REWORKED WITH RED PAINT CAP DETACHABLE PART OF FUEL FILLER ASSEMBLY FLANGE PART OF FUEL FILLER ATTACHED ERFS TANK 1 4 LANDYARD POLYURETHANE P MS27380 DETAIL Figure E 5 Fabrication of Fuel Filler Cap PIN 85SDSCC D 0007 119 E 8 TM 55 1560 307 13 amp 8 0 1 8 DRILL EXISTING HOLES 2 EA OUT TO 0 257 DIA 1 CAP ASSEMBLY AN926A16 2 BRACKET AN743 12 3 SMAGING SLEEVE 551844 62 4 WIRE ROPE FLEXIBLE MIL W 83420 TYPE II COMP A 1 16 NOM DIA X 16 LONG Figure E 6 Fabrication of Dust Cap PIN 85SDSCC D 0007 106 E 9 TM 55 1560 307 13 amp P 50 125 DIA 4 PLCS 2 38 453 DIA 13 R 500 DIA d MATERIAL 2024 3 AL ALLOY X 0 040 THICK FINISH 1 TREAT ALUMINUM WITH CHEMICAL CONVERSION COATING PER MIL C 5541 CLASS 1A 2 APPLY EPOXY PRIMER PER MIL P 23377 3 PAINT WITH CARC ACFT GREEN COLOR NO 34031 FED STD 595 PER MIL C 46168 Figure E 7 Fabrication of Bracket P N 85SDSCC D 0007 20 E 10 TM 55 1560 307 13 amp RIVET 4 PLCS 205 030 493 1 HANDLE 2 REQD RIVET 4 PLCS CAUTION ter mv 7183 REF i h DISCONNECT POWER BEFOR
66. Coupler Latch Dea Bracket Support Plate Mounting Plastic Elec Harness Assy M F ref Appx E I ea peace be drea re e re Elec Harness Assy M F ref Appx E Nut uuu M END OF FIGURE C 20 TM 55 1560 307 13 amp Figure C 6 Panel Box Assembly C 21 SECTION II 1 2 ITEM SMR NO CODE 3 4 NUMBER 85SDSCC D 0007 183 85 0 0 0007 191 85SDSCC D 0007 193 85SDSCC D 0007 194 AN743 12 85SDSCC D 0007 143 85SDSCC D 0007 201 MS2057P5 2150 85SDSCC D 0007 125 85SDSCC D 0007 126 85SDSCC D 0007 127 85SDSCC D 0007 128 85SDSCC D 0007 129 85SDSCC D 0007 130 85SDSCC D 0007 131 85SDSCC D 0007 132 85SDSCC D 0007 133 85SDSCC D 0007 175 85SDSCC D 0007 176 85SDSCC D 0007 177 85SDSCC D 0007 178 59096 B02HH0060 NAS1334A5809 205 030 493 1 MS20426AD3 5 TM 55 1560 307 13 amp P DESCRIPTION AND USABLE ON CODES UOC GROUP 0302 Panel Box Panel Box Assy 85SDSCC D 0007 104 Bracket Support Pad Teflon M F ref Appx Hinge Strap M F E Panel Back M F ref Appx Door M F re Appx E Doubler Panel Bottom M
67. D Helicopter Cargo Transport pU 2567 _ 0722022 0722022 H 0722 22 i I 0723c22 0723022 8 H 02322 0724C22 4724022 0724E22 _ 0725 22 0725622 D 0725E22 07262228 0725H22N 0728622N 4725 22 0726C22N NO PUMP r 3 TANK 2 A TANK l tx P3B J3A P3 5 LOV LEVEL 5 LN LEVEL LOV LEVEL T LEVEL eget 8 1051 oS f 51 5 1 FUEL PUMP BE En En 13 1 3 2 J ER 55 BM Pio 55 55 55 amp 07228208 07248229 cce PS 5 ri P O 65 2 He 12121 95 8E ul 0731422 855 E TR 07395422 P101 ES 0737422 0735422 55 A lt P fm os i 1 em T 25 vi si se 0706422 1 2 TANK 3 TANK 4 dde LOV LEVEL LOV LEVEL LOV LEVEL Lov LEVEL 12419 871925 SWITCH SWITCH SWITCH SWITCH E EE pfo E re ces ST j P O 65 2 OFF PANEL POWER FIA PIB 1 d Pl IIZ HARMESS 110 KARMESS 103 ASSY 7 0 i 0555 22 ud Ej 0700812 0700612 Y ND 3 PUMP BLK B z 1053 ecd FUEL UHP NO 2 PANEL lt gt POWER c s P2 114 MARESS 130 HARNESS 5
68. D 0007 120 C 3 9 12757 85SDSCC D 0007 123 C 3 7 12757 85SDSCC D 0007 124 C 3 95 12757 85SDSCC D 0007 125 C 6 9 12757 85SDSCC D 0007 126 C 6 10 12757 85SDSCC D 0007 127 C 6 11 12757 85SDSCC D 0007 128 C 6 12 12757 85SDSCC D 0007 129 C 6 13 12757 85SDSCC D 0007 130 C 6 14 12757 85SDSCC D 0007 131 C 6 15 12757 85SDSCC D 0007 132 C 6 16 12757 85SDSCC D 0007 133 C 6 17 12757 85SDSCC D 0007 138 C 5 2 12757 85SDSCC D 0007 143 C 6 6 12757 85SDSCC D 0007 145 C 8 59 12757 85SDSCC D 0007 146 C 8 62 12757 85SDSCC D 0007 147 C 8 63 12757 85SDSCC D 0007 148 C 8 54 12757 85SDSCC D 0007 149 C 8 64 12757 85SDSCC D 0007 150 C 8 55 12757 85SDSCC D 0007 151 C 8 48 12757 85SDSCC D 0007 152 C 8 45 12757 85SDSCC D 0007 153 C 8 22 12757 85SDSCC D 0007 154 C 8 43 12757 85SDSCC D 0007 155 C 8 23 12757 85SDSCC D 0007 156 C 8 41 12757 85SDSCC D 0007 157 C 8 34 12757 85SDSCC D 0007 158 C 8 39 12757 85SDSCC D 0007 159 C 8 28 12757 85SDSCC D 0007 160 C 8 32 12757 85SDSCC D 0007 161 C 8 25 12757 85SDSCC D 0007 162 C 8 7 C 38 TM 55 1560 307 13 amp CROSS REFERENCE INDEXES PART NUMBER INDEX Cont Section IV NATIONAL STOCK FIG ITEM CAGE PART NUMBER NUMBER NO NO 12757 85SDSCC D 0007 162 C 8 36 12757 85SDSCC D 0007 163 C 8 6 12757 85SDSCC D 0007 163 C 8 37 12757 85SDSCC D 0007 164 C 8 10 12757 85SDSCC D 0007 164 C 8 38 12757 85SDSCC D 0007 165 C 8 11 12757 85SDSCC D 0007 166 C 8 14 12757 85SDSCC D 0007 167 C 8 15 12757 85SDSCC D 0007 174 C 8 17 12757
69. E PERFORMING REPAIRS OR MAINTENANCE M520257P5 2150 HINGE STRAP 2 PLCS 1 18 REF 5 1 191 REF 7 15129 REF REF 176 REF as EX 130 o REF 1 00 0 010 7130 FG TYP 128 REF 130 REF FRONT ELEVATION Figure E 8 Fabrication of Box Assembly PIN 85SDSCC D 0007 104 Sheet 1 of 3 E 11 S d 132 REF Wi 126 REF ae aae IL 143 T 127 REF 128 REF 139 Gig p den need teen mil nm ae an fn od l h aka 128 ECI on pl 129 REF 201 REF LEFT SIDE ELEVATION SS9096B02HH0060 CABLE ASSEMBLY 1 REQD QUICK REL 4 PLCS 1 35 2 PLCS 75 12 i REE 55 1560 307 13 amp NAS1334A5S 9 PIN AN743 12 BRACKET 1 REQD INST 129 REF 4 PLCS U 143 REF 4 PLCS 12744 139 REF REF 133 REF 194 REF 8446 REF 24 PLCS 129 REF MS20426AD3 RIVET 4 REQD 4 PLCS SIS 201 REF 127 REF 130 REF RIGHT SIDE ELEVATION Figure E 8 Fabrication of Box Assembly P N 85SDSCC D 0007 104 Sheet 2 of 3 205 030 493 1 MDG 2 126 REF AJ5 40 1B STUD 126 REF GP58 GROMMET TYP TOP ELEVATION 126 REF 126 REF P kn n TV el jr tee en Eg 5 0 128 130 REF 128 Key 132 REF 7 CARO gt
70. E OF END ITEMS Helicopter Extended Range Fuel System ERFS P N 85SDSCC D 0007 2 TOOL GROUP COMPONENT MAINTENANCE MAINTENANCE CATEGORY AND NUMBER ASSEMBLY FUNCTION AVUM avim DEPOT EQUIPMENT Fuel Drain Inspect Replace Fuel Valve Inspect Fuel Quantity Inspect Replace Fuel Filter Inspect Replace 5 CONTROL PANEL ASSY Control Panels Inspect Replace Repair Panel Box Inspect Replace Fuel Pump Inspect Replace Elec Control Panel Inspect Replace Wiring Harness Assy Inspect Replace Sensor Level Inspect Electro Optical Replace TM 55 1560 307 13 amp P Section Il Use of Maintenance Allocation Chart Cont MAINTENANCE ALLOCATION CHART NOMENCLATURE OF END ITEMS Helicopter Extended Range Fuel System ERFS P N 85SDSCC D 0007 2 1 2 3 4 5 6 TOOLS GROUP COMPONENT MAINTENANCE MAINTENANCE CATEGORY AND NUMBER ASSEMBLY FUNCTION AVUM AVIM DEPOT EQUIPMENT REMARKS Lines and Fitting Inspect Assys Replace Quick Release Pins Inspect Replace RESTRAINT ASSY Tiedown Assys Inspect Replace Tiedown Straps Inspect Replace Section Ill Tool and Test Equipment Requirements HELICOPTER EXTENDED RANGE FUEL SYSTEM ERFS TOOL OR TEST EQUIPMENT MAINTENANCE NATIONAL NATO TOOL REFERENCE CODE CATEGORY NOMENCLATURE STOCK NUMBER NUMBER AVIM AVUM Tool Kit 5180 00 323 4195 SC518099CLA06 Electrical Repairer AVIM AVUM T
71. ENDATIONS EIRs EIRs will be prepared using SF Form 368 Quality Deficiency Report Instructions for preparing EIRs are provided in DA PAM 738 751 Functional Users Manual for the Army Maintenance System Aviation TAMMS A EIRs should be mailed to Commander U S Army Aviation Systems Command ATTN AMSAV QF 4300 Goodfellow Blvd St Louis MO 63120 1978 A reply will be furnished directly to you 1 5 DESTRUCTION OF ARMY MATERIEL PREVENT ENEMY USE For destruction of Army material to prevent enemy use refer to TM 750 244 1 5 Procedures for the Destruction of Aircraft Associated Equipment to Prevent Enemy Use 1 6 QUALITY ASSURANCE QUALITY CONTROL QA QC Qualified personnel shall inspect completed work for full compliance with technical requirements of instructions Inspection shall be in accordance with an approved prescribed inspection system to be determined at work site Section EQUIPMENT DESCRIPTION AND DATA 1 7 PHYSICAL DESCRIPTION The ERFS provides aircraft mission flexibility by extending aircraft range and by providing forward area refueling source The ERFS is mounted on the left hand side of the aircraft between stations 190 and 450 depending on aircraft CG requirements The ERFS is a modular interconnectable system composed of up to four 600 gallon NON CRASHW ORTHY metal tanks four electrically operated 1 1 fuel pumps a vent system associated wiring plumbing and mounting hardware Figure 1 1 The
72. ERFS System Hoses F 3 4 J K L Location and Description of Major Components 1 11 M Maintenance of ERFS Tank Components 3 12 Maintenance of ERFS Components Replace Any Fuel Hose 3 15 Maintenance of ERFS Components Replace Liquid Level Indicator 3 20 Maintenance of ERFS Components Replace Tee Coupling 3 16 Maintenance of FMCP Components Replace Fuel Sensor Level Electro Optical 3 17 Maintenance of ERFS Components Replace Fuel Pump 3 18 Maintenance Procedures 3 10 Manifold and Hose Couplings F 2 8 Manifold Hose and Fitting Installation F 2 7 INDEX 2 Subject Para N One Tank of Four with Pallet F 2 13 One Tank with One Pallet F 2 17 Operating Instructions 1 14 Operating Instructions on Decals and Instruction Plates 2 20 Operating Procedure 2 18 Operation 2 12 Operation of Auxiliary Equipment 2 20 Operations 1 13 Operator Crew Preventive Main Checks and Services T 2 6 Operation in Unusual Weather 2 21 P Performance Data 1 15 Physical Description 1 7 PMCS Procedures 2 15 Preflight Inspection 2 10 Preservation 3 25 Pressure Refueling 3 13 F 3 2 Purpose 1 2 Q Quality Assurance Quality Control QA QG 1 6 TM 55 1560 307 13 amp ALPHABETICAL INDEX Cont Subject Para R Removal and Replacement of Dump Valve F 3 11 Removal and Replacement of ERFS Fuel Sensor Level Electro Optical F 3 7 Removal and Replacement of Liquid Level Indicator F 3 10 Removal
73. Extended Range Fuel System Block Diagram pp ERFS Tank Loading with Forklift sss Installation and Tiedown 8 ERFS No 1 Tank Installation and Tiedown ppp Fuel Management Control Panel Fuel Pumping System and PIumbing ERFS 2 Tank Installation and Tiedown pp Manifold Hose and Fitting Installatiom Manifold and Hose Couplings ERFS No Tank Installation and Tiedown ERFS 4 Tank Installation and ERFS Tank Installation and Secured 2 12 System Couplings Installation One Tank of Four with Pallets Two Tanks of Four with Pallets a Three Tanks of Four with 8 n enne 1 Four Tanks with Pallets One Tank with One Pallet Two Tanks with Pallets nnne enne Three Tanks with Pallets a Four Tanks with Pallets ERFS Controls and Indicators FMCP
74. L FLOW POSITION HOSE COUPLINGS IN UNLOCKED NO FLOW POSITION Figure 2 12 System Couplings Installation 2 7 SYSTEM INSTALLATION WITH HELICOPTER INTERNAL CARGO SYSTEM HICHS AND 463L PALLETS NOTE e Tanks cannot be loaded on aircraft while attached to 4631 pallet If HICHS is installed the aircraft ferry fuel connection must have been raised above the heater buffer panel e Aircraft CG will vary with HICHS installed a Up to three 463L pallets are used for a four tank installation in accordance with TM 55 1680 358 12 amp P b The No 1 tank will be loaded on the most forward 463L pallet 2 16 TM 55 1560 307 13 amp P c Installation sequence shall be the same as described AEE except for use of tiedown configurations For _installation of tiedown strap assemblies refer to Table 2 3 Installation sequence shall be as shown in the figures listed below One tank of four w pallet Fig 2 13 Two tanks of four w pallets Fig 2 14 Three tanks of four w pallets Fig 2 15 Four tanks w pallets Fig 2 16 One tank w one PLE Two tanks w pallets Fig 2 18 Three tanks w pallets Fig 2 19 Four tanks w palletsj Fig 2 20 d Place plywood shoring between pallet and tank skid and position edge of right hand skid 28 5 inches to the left of pallet Front top leading edge of tank will be lined up with station 200 TM 55 1560 307 13 amp P Table 2 3 ERFS Tiedown Strap Quantity Configurations with 463L Palle
75. LEVEL FUEL IN TANKS DISCONNECT SENSOR LEVEL ELECTRO OPTICAL CONNECTOR DOES PUMP STOP RUNNING REPLACE FUEL SENSOR LEVEL ELECTRO OPTICAL 3 8 TROUBLESHOOT FUEL MANAGEMENT CONTROL PANEL INTERNAL WIRING TM 55 1560 307 13 amp TM 55 1560 307 13 amp TROUBLESHOOTING PROCEDURE NO 8 LOW LEVEL LIGHT STAYS ILLUMINATED WITH FUEL IN TANK DISCONNECT P3A ON FMCP DOES LOW LEVEL LIGHT REMAIN ILLUMINATED NO TROUBLESHOOT FUEL MANAGEMENT CHECK FOR CONTINUITY BETWEEN CONTROL PANEL INTERNAL WIRING PINS A AND B OF TANK LOW LEVEL SWITCH RECEPTACLE YES REPLACE TANK LOW LEVEL SWITCH REPAIR REPLACE LOW LEVEL SWITCH TANK HARNESS TM 55 1560 307 13 amp TROUBLESHOOTING PROCEDURE NO 9 PUMP LIGHT DOES NOT ILLUMINATE WITH PUMP SWITCH ENGAGED PRESS TO TEST PUMP LIGHT REPLACE BULB TROUBLESHOOT FUEL MANAGEMENT CONTROL PANEL INTERNAL WIRING 3 10 TM 55 1560 307 13 amp P Section IV SERVICE MAINTENANCE PROCEDURES 3 10 MAINTENANCE PROCEDURES The AVUM procedures include servicing inspecting and replacing the ERFS tanks FMCP ECP hose assemblies pressure switches and fuel pumps 3 11 SERVICE The 600 gallon tanks will be serviced with JP 4 5 8 fuel as required Utilize splash fill or pressure refueling techniques and CAUTION e Assure tank filler caps are free of sand and any other foreign matter e Check each tank internally for foreign ob
76. LL ERFS tank cam levers CLOSED All tee and system coupling valves CLOSED TM 55 1560 307 13 amp HOSE COUPLINGS IN UNLOCK POSITION ROTATE COUPLINGS TO SEPARATE Figure 3 3 Removal of ERFS System Hoses 3 17 TM 55 1560 307 13 amp VALVES IN CLOSED LUGS AND GROOVES ALIGNED POSITION PUSH COUPLINGS TOGETHER AND TWIST CLOCKWISE LEVER CLOSED POSITION LEVER OPEN POSITION Figure 3 4 Installing ERFS System Hoses 3 18 GENERAL SAFETY INSTRUCTIONS WARNING ELECTRICAL GROUNDING OF THE HELICOPTER Army regulations require the grounding of the helicopter when parked and during all fueling and defueling operations No electrical switches shall be operated except those necessary for servicing during fueling and defueling No smoking or flame during all fueling defueling operations CAUTION Do not move coupling levers to open position with hose or tee couplings while couplings are disconnected NOTE e Hose and tee coupling lock levers have to be in closed position when disconnected e Couplings will not unlock if levers are not moved from closed position REMOVAL 1 Place clean rags item 3 Appx D under hose connections 2 Remove fuel hose a Unlock hose couplings b Twist hose couplings counterclockwise at both attaching ends Remove hose INSPECTION Refer to POL manual for hose inspection a Visually inspect new hose for kinks damaged 3 19 TM 55 1560 307 13 amp
77. ONAL STOCK NUMBER 5340 00 077 2459 1680 00 839 1756 5320 00 117 6937 1680 01 238 8159 4730 01 117 5649 4730 00 194 1046 4730 00 256 2310 4730 01 312 9233 6680 01 H77 0066 4730 00 054 7296 5925 00 224 7422 5925 00 431 3255 5930 00 683 1629 5310 00 905 5454 5940 00 143 4775 6150 00 600 6259 C 44 CAGE 12757 78286 80205 97499 96906 00624 00624 88049 81349 88044 97484 97484 81349 96906 96906 81349 12757 96906 96906 96906 12757 81340 12757 12757 96906 96906 12757 12757 96906 96906 12757 12757 12757 12757 12757 96906 81349 96906 12757 12757 12757 12757 96906 96906 12757 TM 55 1560 307 13 amp PART NUMBER 85SDSCC D 0007 178 559096 02 0060 NAS1334A5S09 205 030 493 1 MS20426AD3 3B7 6 2266 12 125 AN821 12D M83796 1K086A AN827 12D 122634 2F2633 M83796 1K047A 525171 15 551524 12 M83796 1K043E 85SDSCC D 0007 105 MS3320 1 MS3320 10 524523 23 85SDSCC D 0007 102 M5594 1 2 85SDSCC D 0007 163 85SDSCC D 0007 162 525224 1 525041 11 85505 0 0007 164 85SDSCC D 0007 165 525082 21 MS35333 121 85SDSCC D 0007 166 85SDSCC D 0007 167 85SDSCC D 0007 195 85SDSCC D 0007 174 85SDSCC D 0007 169 53106 10051 35 M85049 55 10A 525036 156 85SDSCC D 0007 153 85SDSCC D 0007 155 85SDSCC D 0007 170 85SDSCC D 0007 161 MS25226 2 3 18029 1 3 85SDSCC D 0007 159 TM 55 1560 307 13 amp CROSS REFERENCE INDEXES FIGURE AND ITEM NUMBER INDEX C
78. P couplings and other obvious damage b Replace fuel hose if above conditions are found INSTALLATION NOTE After hose is installed ensure that coupling levers are open 1 Unlock hose couplings by turning lock levers to closed position 2 Align lugs with grooves 3 Push hose couplings together and twist clockwise Move levers to open position 3 16 MAINTENANCE OF ERFS COMPONENTS REPLACE TEE COUPLING This task covers a Removal b Inspection c Installation INITIAL SETUP Tools None Materials Parts Tee Assembly 5 Fig 2 Appx C Equipment Conditions Refer to Figures 3 5 and 3 6 All ERFS tank cam levers CLOSED All tee and system coupling valves CLOSED Suction hose assembly 14 coupling closed Refer to Figure 1 1 TM 55 1560 307 13 amp TEE COUPLING HOSE AND COUPLING HOSE AND COUPLING Figure 3 5 Tee Coupling Removal 3 20 TM 55 1560 307 13 amp P NOTE Adhesive 18 Appx D may be used lieu of sealant item 15 Appx D in the above application Cure time of sealant item 15 Appx D is 72 hours Cure time of adhesive item 18 is 24 hours Due to cost adhesive item 18 Appx D should only be used when circumstances dictate the need for a shorter cure time Change 1 3 34 1 3 34 2 Blank TM 55 1560 307 13 amp TEE COUPLING HOSE AND COUPLING HOSE AND COUPLING PUSH COUPLINGS TOGETHER AND TWIST TO ASSEMBLE Figure 3 6 Tee Coup
79. S16562 256 5 14 365 52 1 13217E7090 13217E7087 MS5691 36 MS29513 112 13217E7086 13217E7088 13217E7089 MS51922 33 MS35338 48 MS90725 115 13217E7082 13217E7084 13217E7096 A609 P432 P402A P414 P425A P404 P431 P403 P4012E 85SDSCC D 0104 6 85SDSCC D 0104 4 85SDSCC D 0104 5 AE25010 011 MS27028 11 MS27030 6 110 6 MS24665 289 AN310C12 MS27183 23 MS51105 464 13217E7085 MS90728 109 MS27183 18 13217E7092 MS21045L4 AN960PD416 AN4 7A 85SDSCC D 0007 119 MS16996 21 MS122032 Section IV FIG z 62 62 62 62 62 62 62 62 62 62 62 62 62 62 62 62 62 62 62 62 62 62 62 62 62 62 62 62 62 62 62 62 62 62 62 62 62 62 62 62 62 lt gt gt G Q 02 02 02 0 Q 00 00 00 00 02 G G G 00 00 00 00 O CROSS REFERENCE INDEXES FIGURE AND ITEM NUMBER INDEX Cont NATIONAL STOCK NUMBER 1560 01 078 5647 5330 00 248 3846 6680 01 293 9095 6680 01 293 9094 5310 00 897 6145 5310 00 685 3622 5310 00 184 9200 5305 00 889 2997 5935 01 064 5841 5310 00 282 7832 2915 00 968 6363 5935 00 432 9340 4720 01 H76 8433 4730 00 231 3078 5310 00 543 5933 5305 00 958 0671 5310 00 167 0834 5305 00 995 3440 79499 96906 12757 86831 86831 86831 86831 86831 86831 86831 12757 80205 88044 96906 96906 96906 96906 96906 96906 12757 96906 12757 12757 12757 127
80. TEMENT A Approved for public release distribution is unlimited TM 55 1560 307 13 amp P 11 December 1990 is changed as follows 1 Remove and insert pages as indicated below New or changed text material is indicated by a vertical bar in the margin An illustration change is indicated by a miniature pointing hand Remove pages Insert pages 1 7 through 1 10 C 15 and C 16 C 39 and C 40 blank through FP 10 blank 2 Retain this sheet in front of manual for reference purposes By Order of the Secretary of the Army Official Z Ham LES MILTON H HAMILTON Administrative Assistant to the Secretary of the Army 05170 DISTRIBUTION TM 55 1560 307 13 amp P C2 GORDON R SULLIVAN General United States Army Chief of Staff be distributed in accordance with DA Form 12 31 E block no 2735 requirements for TM 55 1560 307 13 amp P TM 55 1560 307 13 amp C1 CHANGE HEADQUARTERS DEPARTMENT OF THE ARMY NO 1 WASHINGTON 31 December 1991 OPERATOR AVIATION UNIT AND AVIATION INTERMEDIATE MAINTENANCE MANUAL WITH REPAIR PARTS AND SPECIAL TOOLS LIST EXTENDED RANGE FUEL SYSTEM ARMY MODEL CH 47 HELICOPTER TM 55 1560 307 13 amp P 11 December 1990 is changed as follows 1 Remove and insert pages as indicated below New or changed text material is indicated by a vertical bar in the margin An illustration change is indicated by a miniature pointing hand Remove pages Insert pages 2 17 and 2 18 2 17 and 2
81. TM 55 1560 307 13 amp TECHNICAL MANUAL OPERATOR AVIATION UNIT AND AVIATION INTERMEDIATE MAINTENANCE MANUAL WITH REPAIR PARTS AND SPECIAL TOOLS LIST EXTENDED RANGE FUEL SYSTEM ARMY MODEL CH 47 HELICOPTER C HAPTER 1 INTRODUCTION INSTALLATION AND OPERATING INSTRUCTIONS MAINTENANCE INSTRUCTIONS MAINTENANCE ALLOCATION CHART MAINTENANCE REPAIR PARTS AND SPECIAL TOOL LIST EXPENDABLE SUPPLIES AND MATERIALS LIST ILLUSTRATED LIST OF MANUFACTURED ITEMS PART NUMBER 85SDSCC D 0007 2 Y gm oll m o gt 2 gt lt n NATIONAL STOCK NUMBER 1560 01 221 7600 NDEX Approved for public release distribution is unlimited Headquarters Department of the Army 11 December 1990 TM 55 1560 307 13 amp P WARNINGS AND FIRST AID DATA For artificial respiration and other first aid data refer to FM 21 11 Personnel performing instructions involving operations procedures and practices which are included in this technical manual shall observe the following instructions Disregard of these warnings and precautionary information can cause serious injury death or an aborted mission WARNING An operating or maintenance procedure practice etc which if not correctly followed could result in personnel injury or loss of life CAUTION An operating or maintenance procedure practice etc which if not strictly observed could result in damage to or destruction of equipment NOTE An oper
82. WARNING Smoking not permitted anytime on military aircraft CAUTION FMCP pumping system will not be operated without fuel in the 600 gallon tanks or with tank cam lever in the CLOSED position NOTE System fuel pumps are self priming 2 8 SCOPE Operating instructions are provided in this section for the ERFS and description on how to use operator controls and indicators is also provided Included in this section are the preventive maintenance checks and services PMCS procedures and instructions for operation of the ERFS under usual and unusual conditions 2 9 CONTROLS AND INDICATORS The controls and indicators for the ERFS and FMCP are illustrated and described ir Figure 2 21 Table 2 4 and Figure 2 Table 2 5 Figure index numbers key each control and indicator to the pertinent information in the tables 2 10 PREFLIGHT INSPECTION In addition to the preflight inspection procedures defined in TM 55 1520 240 10 perform the applicable checks and services listed on the PMCS Table 2 6 prior to applying electrical power for system operation CAUTION fuel sample is required before the first flight of the day and after each refueling 2 26 NOTE To avoid tripping system circuit breakers do not turn on any two pump switches at once 2 Allow at least 10 second delay between each pump switch actuation a Check all fuel manifold lines electrical lines grounding cables and vent
83. and alines aircraft system modules components AVIM units will have capability to determine the serviceability of specified modules components removed prior to the expiration of the time between overhaul TBO or finite life Module component disassembly and repair will support the DX program and will normally be limited to tasks requiring cleaning and the replacement of seals fittings and items of common hardware Airframe repair and fabrication of parts will be limited to those maintenance tasks which can be performed with available tools and test equipment Unserviceable repairable TM 55 1560 307 13 amp P modules components and end items which are beyond the capability of AVIM to repair will be evacuated to Depot Maintenance AVIM will perform aircraft weight and balance inspections and other special inspections which exceed AVUM capability Provides quick response maintenance support including aircraft recovery and air evacuation on the job training and technical assistance through the use of mobile maintenance contact teams Maintains authorized operational readiness float aircraft Provides collection and classification services for serviceable unserviceable material Operates a cannibalization activity in accordance with AR 750 50 The aircraft maintenance company within the maintenance battalion of a division will perform AVIM functions consistent with air mobility requirements and conservation of personnel and equipment resourc
84. annot be reduced Refer to paragraph 2 8 for installation of system with pallets Install the ERFS tanks and system components as follows WARNING Use a one ton or larger forklift Damage of equipment or injury of personnel may occur if a ground guide for forklift operations is not used Refer to Figure 2 1 Tank must be loaded to be within the CG limits of the aircraft NOTE The installation sequence described covers a four tank installation The helicopter may be operated with one to four tanks depending on mission needs provided tank installation and fuel transfer management are such that aircraft CG be maintained within limits In addition the tiedown configuration is depicted for a four tank installation when no other loads are being carried If less than four tanks are being used the tanks may be moved forward or aft depending on internal external loads and main taining CG The number of tiedowns per tank as shown in Table 2 2 will not be reduced 2 4 a Ground aircraft b Position No I tank at station 190 butt line eleven left Tilt tank and position wood shoring under skids Align groove of shoring to aircraft extrusion rail c Tie down No 1 tank as shown i Use Table 2 2 to select the straps required WARNING Chains will not be used to tie down the ERFS NOTE No more than 1 2 twist allowed on tiedown strap Minimum 1 1 2 wraps required rachet drum of ti
85. are still inoperative turn them OFF Continue pumping operations with pumps 3 and 4 until all ferry fuel is transferred Since fuel is only being pumped to one side of the aircraft fuel management via the cross feed method will be required 3 Repeat procedure in same manner if pumps 3 and 4 were to fail d If pump switch fails to stay ON in flight check to see that the FMCP pump circuit breaker is in and turn the override switch on If the pump switch still fails to stay ON turn the effected pump OFF If all pump switches fail abort mission 2 35 2 36 Blank TM 55 1560 307 13 amp CHAPTER 3 MAINTENANCE INSTRUCTIONS Section I REPAIR PARTS SPECIAL TOOLS TMDE AND SUPPORT EQUIPMENT 3 1 COMMON TOOLS AND EQUIPMENT For authorized common tools and equipment refer to the modified table of organization and equipment MTOE applicable to your unit 3 2 SPECIAL TOOLS TMDE AND SUPPORT EQUIPMENT a When special tools TMDE and or support equipment are required they will be listed in the repair parts and special tools list RPSTL Appx C b Refer td Appx E fabricated items 3 3 REPAIR PARTS Repair parts are listed and illustrated in Appx C NOTE Order any decal you need using CAGE and P N listed in TM 55 1560 307 13 amp P Order on a DD Form 1348 6 from RIC B16 Section II SERVICE UPON RECEIPT 3 4 UNPACKING Refer td Chapter 2 paragraph 2 3 5 CHECKING UNPACKED EQUIPMENT Insp
86. assembly item entry or reference is made to an applicable figure d KITS Line item entries for repair parts kits appear a group in Section e INDEX NUMBERS Items which have the word BULK in the figure column will have an index number shown in the item number column This index number is cross reference between National Stock ERU Number Index and the bulk material list in Section ll f ASSOCIATED PUBLICATIONS Not applicable C 6 HOW TO LOCATE REPAIR PARTS a WHEN NATIONAL STOCK NUMBER OR PART NUMBER IS NOT KNOWN 1 First 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 groups and subassembly groups and listings are divided into the same groups 2 Second Find the figure covering the assembly group or subassembly group to which the item belongs 3 Third Identify the item on the figure and use the figure and item number index to find the NSN b WHEN NATIONAL STOCK NUMBER OR PART NUMBER IS KNOWN TM 55 1560 307 13 amp P 1 First Using the national stock number or the part number index find the pertinent national stock number or part number The NSN index is in National Item Identification Number NIIN sequence see 4 1 1 The part numbers in the part number index are listed in ascending alphanumeric sequence see 4 b Both indexes cross reference you to the illus
87. ating or maintenance procedure condition etc which is essential to highlight WARNING When using JP 4 JP 5 and JP 8 fuel use the following precautions Aircraft overboard vent cap must be removed anytime ERFS is installed Fuel is highly flammable Do not use near welding areas open flames or on very hot surfaces Use only with adequate ventilation Avoid prolonged or repeated contact with skin Prolonged contact may cause drying and irritation of skin Remove saturated clothing immediately Do not smoke when handling fuel Do not take internally Store in approved metal safety containers WARNING The Extended Range Fuel System is airworthy when installed operated and maintained as described in this manual However with this configuration fuel leakage into the cabin is possible and a catastrophic incident is possible in the event of hard landing or accident Even when properly installed this system is not capable of satisfying the 8 G crashworthiness requirement occupied areas of the helicopter taken as a whole TM 55 1560 307 13 amp TM 55 1560 307 13 amp P C2 CHANGE HEADQUARTERS DEPARTMENT OF THE ARMY NO 2 WASHINGTON D C 31 AUGUST 1993 OPERATOR AVIATION UNIT AND AVIATION INTERMEDIATE MAINTENANCE MANUAL WITH REPAIR PARTS AND SPECIAL TOOLS LIST EXTENDED RANGE FUEL SYSTEM ARMY MODEL CH 47 HELICOPTER P N 85SDSCC D 0007 2 NSN 1560 01 221 7600 DISTRIBUTION STA
88. cated by the parenthetical entry e g Phy Sec 1 C Confidential Phy Sec S Secret Phy Sec CI T Top Secret No parts of the extended range fuel system have a physical security classification 3 Items that are included in kits and sets are listed below the name of the kit or set 4 Spare repair parts that make up an assembled item are listed immediately following the assembled item line entry 5 Part numbers for bulk materials are referenced in this column in the line item entry for the item to be manufactured fabricated 69 When the item is not used with all serial numbers of the same model the effective serial numbers are shown on the last line s of the description before UOC 7 The usable on code when applicable see paragraph C 5 Special information 8 In the Special Tools List section the basis of issue BOI appears as the last line s in the entry for each special tool special TMDE and other special support equipment When density of equipments supported exceeds density spread indicated in the basis of issue the total authorization is increased proportionately 9 The statement END OF FIGURE appears just below the last item description in Column 5 for a given figure in both Section and Section III f QTY Column The QTY quantity per figure column indicates the quantity of the item used in the breakout shown on the illustration figure which is prepared for a functional gro
89. cs 2 EQ 2 250 5PCS 13 tQ 13 000 specs 20 625 7 tQ 22 50 7 250 spcs 4 PLES 18 250 19 000 III FF Figure E 15 Fabrication of Back Panel P N 85SDSCC D 0007 125 E 20 TM 55 1560 307 13 amp P TM 55 1560 307 13 amp Ne di EEE EEE MN ET 09 e 098 DIA HOLE 21 UN 4 lt 20 000 20 EQ 5 MATERIALS FABRICATE FROM 2024 T3 AL ALLOY STOCK SIZE 0 063 X 13 00 X 22 5 IN FINISHES 1 TREAT ALUMINUM WITH CHEMICAL CONVERSION COATING PER MIL C 5541 CLASS 1A 2 APPLY EPOXY PRIMER PER MIL P 23377 3 PAINT WITH CARC ACFT GREEN COLOR NO 34031 FED STD 595 PER MIL C 46168 TOLERANCES 0 1 20 03 0 010 Figure E 16 Fabrication of Door P N 85SDSCC D 0007 126 E 21 TM 55 1560 307 13 amp 19 R 125 75 SH i 5 Bis tn 4 2 DEET re 7 I DIA 50 1 750 PILOT HOLES 2 EQ 5 5 26 PLCS MATERIALS 0 063 2024 73 AL ALLOY FINISHES 1 TREAT ALUMINUM WITH CHEMICAL CONVERSION COATING PER MIL C 5541 CLASS 1A 2 APPLY EPOXY PRIMER PER MIL P 23377 3 PAINT WITH CARC ACFT GREEN COLOR NO 34031 FED STD 595 PER MIL C 46168 TOLERANCES 0 1 0 03 0 005 Figure E 17 Fabrication of Doubl
90. ction Section CHAPTER 3 Section Section Il Section lll Section IV Section V Page General aS Leda no Taboo cod 1 1 Equipment Description and Data a 1 1 Technical Principles of 1 10 INSTALLATION AND OPERATING INSTRUCTIONS Service Upon Receipt of Equipment Inspecting the Equipment ERFS Installation Operating Instructions Preventive Maintenance Checks and Services PMCS Operation Under Usual Conditions nnns Operation Under Unusual Conditions MAINTENANCE INSTRUCTIONS Repair Parts Special Tools TMDE and Support Equipment Service Upon Troubleshooting eerte ree eet eee eee te e ke pe OE Service Maintenance Procedures enn nnn nnn nnn nnns nnn nnns Preparation for Storage or Shipment TM 55 1560 307 13 amp P TABLE OF CONTENTS Cont 25 uum a n ____6_ 6 _ _ Maintenance Allocation Chart 4 APPENDIX C Repair Parts and Special Tools List Expendable Supplies and Material List eee tenete tnnt tette tnnc Illustrated List of Manufactured LIST OF ILLUSTRATIONS Figure Page 1 1 Extended Range Fuel System Sheet 1 of 5
91. e Section I SERVICE UPON RECEIPT OF EQUIPMENT 2 2 UNPACKING AND INSPECTION The 600 gallon Commander AVSCOM ATTN AMSAV QF 4300 tanks will be delivered enclosed in suitable shipping Goodfellow Blvd St Louis MO 63120 1798 crates containers FMCP fittings hoses and other associated equipment required for complete assembly b Check to ensure that each item listed in Table 2 will be packaged separately been received a Upon receipt inspect the ERFS tanks for 2 3 EQUIPMENT FURNISHED Table 2 1 lists all obvious damage incurred during shipment Damage of major components and items furnished for the ERFS tanks and other equipment should be reported on SF installation Appendix C contains a parts list which will 361 Discrepancy in Shipment Report Mail form to be helpful in identifying all components Table 2 1 ERFS Components NOMENCLATURE PART NUMBER NSN QTY Adapter AE25010 011 4730 01 214 2910 4 Coupling Half AE85893M 4730 01 276 7564 4 Coupling Half AE86844Z 4730 01 H76 9177 1 Coupling Half AE82568R 4730 01 214 0994 1 Quick Disconnect Coupling Half 90 AE82567R 4730 01 214 2913 3 Quick Disconnect Coupling Half AE85861M 4730 01 214 4765 4 Quick Disconnect Coupling Tee AE82111R 4730 01 214 0996 4 Elec Harness Assy 85SDSCC D 0007 112 na 1 Elec Harness Assy 85SDSCC D 0007 113 1 Elec Harness Assy 85SDSCC D 0007 114 1 ERFS Tank Assy 85SDSCC D 0007 115 4 Ground Strap 85SDSCC D 0007 192 1 Hose Assy 000 950192 1
92. eaks TM 55 1560 307 13 amp Adapter Dump Valve Seal Screen Seal AN Figure 3 12 Remove and Replace Fuel Filter 3 33 3 23 FUEL FLOAT ASSEMBLY Replace This task covers a Removal b Inspection c Installation INITIAL SETUP Tools 3 4 and 1 4 in Wrench 24 in Adjustable Wrench Putty Knife Steel Measuring Tape Materials Parts Packing Preformed 79 80 Fig C 3 Appx C Float Switch 83 Fig 2 Appx Sealant 15 Appx D MIL S 8802E 3 Type II Class B 2 Equipment Conditions Refer to Figure 3 13 Tank must be empty and separate from other tanks Tank access cover removed Tank grounded Tank must be purged Refer to Chapter paragraph 3 25 GENERAL SAFETY INSTRUCTIONS WARNING Injury to personnel and equipment may occur if the purging maintenance procedure above is not performed The fuel vapor and air mixture in the tank can cause a violent explosion setoff by sparks from tools being dropped in tank REMOVAL 1 Remove sealant with putty knife 2 Remove tank plug 5 using adjustable wrench 3 34 TM 55 1560 307 13 amp P Refer to 3 Disassemble on workbench 4 Remove nuts 1 washers 2 screws 3 from receptacle 4 5 Remove nuts 6 bracket 7 and packing 8 6 If defective replace float switch 9 as follows a Unsolder wires from receptacle 4 b Remove float switch from tubes 10 amp 11 and remove packing 12
93. ect the ERFS for obvious damage or shortages incurred during packing or shipment Damage or shortages should be reported on a SF 361 Discrepancy in Shipment Report 3 6 TOOLS TEST EQUIPMENT AND MATERIALS REQUIRED FOR INSTALLATION Refer to maintenance allocation chart MAC Appx B 3 7 INSTALLATION INSTRUCTIONS Refer to Chapter 2 Section for installation of the ERFS and system components Section TROUBLESHOOTING 3 8 SCOPE This section contains troubleshooting information for locating correcting most malfunctions which may develop with the ERFS Each malfunction is presented in logic tree format and the tests inspections and corrective actions should be performed in the order as listed If a malfunction is not listed or cannot be corrected by the corrective actions listed consult with next higher level of maintenance 3 1 3 9 ERFS TROUBLESHOOTING Perform operational procedures applicable to the fuel tanks in to determine malfunction symptom prior to performing the troubleshooting procedure Correct malfunctions using the troubleshooting procedures on the following pages Refer to Figures FO 1 and 2 wiring diagram and wire chart TM 55 1560 307 13 amp TROUBLESHOOTING PROCEDURE NO 1 TANK LIQUID LEVEL INDICATOR READING INCORRECT CHECK TANK FOR FUEL LEVEL THROUGH FILL PORT IS TANK FULL YES NO CHECK LIQUID LEVEL PERFORM REFUEL PROCEDURE INDICATORS FOR DAMAGE
94. ectrical cannon plug and on new switch INSTALLATION Install new sensor level electro optical a Connect electrical cannon plug 1 to sensor level electro optical 2 b Clean up any spilled fuel and check system for proper operation Perform maintenance operational check 3 24 TM 55 1560 307 13 amp P 3 18 MAINTENANCE OF FMCP COMPONENTS REPLACE FUEL PUMP This task covers a Removal b Inspection c Installation INITIAL SETUP Tools Bonney Wrenches Material Parts Fuel Pump 1 Fig C 7 Appx C Packing Equipment Conditions Refer Figure 3 8 All ERFS tank cam levers CLOSED All tee and system coupling valves CLOSED Suction hose assembly 14 coupling closed All electrical power OFF Refer to Figure 1 1 GENERAL SAFETY INSTRUCTIONS WARNING ELECTRICAL GROUNDING OF THE HELICOPTER Army regulations require the grounding of the helicopter when parked and during all fueling and defueling operations No electrical switches shall be operated except those necessary for servicing during fueling and defueling No smoking or flame during all fueling and defueling operations TM 55 1560 307 13 amp P g 7 Harness Nut Nut Nut Clamps Pump Figure 3 8 Removal and Replacement of ERFS Fuel Pump eI 3 25 REMOVAL 1 Disconnect electrical harness 1 2 Loosen nuts 2 and 3 3 Loosen nut 4
95. ed requisitioned individually They must be made from bulk material which is identified by the part number in the DESCRIPTION AND USABLE ON CODE UOG column and listed in the Bulk Material group of the repair parts list in this RPSTL If the item is authorized to you by the 3rd position code of the SMR code but the source code indicated it is made at a higher level order the item from the higher level of maintenance 2 Code Explanation AO Assembled by org AVUM Level AF Assembled by DS AVIM Level AH Assembled by GS Category AL Assembled by SRA AD Assembled by Depot XA 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 from salvage order it using the CAGE and part number given XC Installation drawing diagram instruction sheet field service drawing that is identified by manufacturer s part number XD Item is not stocked Order an XD coded item through normal supply channels using the CAGE and part number given if no NSN is available 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 750 1 2 Maintenance Code Maintenance code tells you the level s of maintenance authorized to USE and REPAIR support items The
96. ed along with the item National stock number NSN and if applicable the tool number to aid in identifying the tool device 3Disassemble assemble encompasses the step by step taking apart or breakdown of a spare functional group coded item to the level of its least componency identified as maintenance significant i e assigned an SMR code for the category of maintenance under consideration 4 actions welding grinding riveting straightening facing remachining and or resurfacing TM 55 1560 307 13 amp P Section Il Use of Maintenance Allocation Chart MAINTENANCE ALLOCATION CHART OMENCLATURE OF END ITEMS Helicopter Extended Range Fuel System ERFS P N 85SDSCC D 0007 2 1 2 3 4 5 6 TOOLS GROUP COMPONENT MAINTENANCE MAINTENAN A OB AND NUMBER ASSEMBLY FUNCTION AVUM AVIM DEPOT EQUIPMENT REMARKS SYSTEM INSTALLATION Fuel Tank Install Service Test Repair Mount Assemblies Inspect Replace Line amp Fitting Assys Inspect Replace Hose Assys Inspect Replace Coupling and Inspect Adapter Assys Replace Wiring Harness Assys Inspect Replace Repair TANK ASSY Access Door amp Gasket Inspect Replace Lines amp Fitting Assys Inspect Replace Wiring Harness Assys Inspect Replace Repair Liquid Level Inspect Indicators Replace Fuel Filler Assy Inspect Replace TM 55 1560 307 13 amp P Section Use of Maintenance Allocation Chart Cont MAINTENANCE ALLOCATION CHART OMENCLATUR
97. edown strap Figure 2 2 Installation and Tiedown Straps TM 55 1560 307 13 amp STA 140 160 180 200 220 240 260 280 300 320 10 000 Lb Strap 5 000 Lb Strap Pr 5 000 Lb Strap attaches to top i Take Up Fitting e Looped Strap Figure 2 3 ERFS No 1 Tank Installation and Tiedown 2 5 TM 55 1560 307 13 amp Table 2 2 ERFS Tiedown Configurations W O 463L Pallet D lt gt 79 5 000 Lb 10 000 Lb w Ao 5 000 Lb 28 10 000 Lb 6 34 5 000 Lb 20 10 000 Lb 4 24 5 000 Lb 12 10 000 Lb 2 14 10 000 Lb Strap 5 000 Lb Strap 5 000 Lb Strap attaches to top i Take Up Fitting Looped Strap 1 Install FMCP to forward end of No 1 tank at mounting brackets 2 Connect power cables to bottom receptacles of FMCP Long power cable should connect to R H side of aircraft receptacle Route both cables under tanks 1 and 2 with long cable installed over fuel manifold Connect cables to top 15 amp utility receptacles and R H side at station 260 NOTE Install dust caps to each other after securing all tee and hose couplings d Assemble fuel manifold 2 inch position to R H side of cabin floor 1 Fuel manifold assembly consists of attaching tee fitting 8 to coupling assembly 9 and hose assembly 10 Figure 2 5 2 Secure all four hoses to its respective
98. eld Use Other Publications AR 420 90 Fire Prevention and Protection AR 55 38 Reporting of Transportation Discrepancies in Shipments AR 700 58 Packaging Improvement Report AR 70 38 Research Development Test and Evaluation of Materials for Extreme Climatic Conditions DA PAM 310 13 Military Publications Posting and Filing DA PAM 738 751 Functional User s Manual for the Army Maintenance Management System Aviation TAMMS A FM 10 68 Aircraft Refueling FM 10 69 Petroleum Supply Point Equipment and Operations 21 11 First Aid For Soldiers 43 180 Calibration Requirements for the Maintenance of Army Materiel 55 1500 204 25 1 General Aircraft Maintenance Manual TM 55 1520 240 10 Operator s Manual TM 55 1520 240 23 Aviation Unit and Aviation Intermediate Maintenance Manual TM 55 1680 358 128 Helicopter Internal Cargo Handling System TM 750 244 1 5 Procedures for the Destruction of Aviation Ground Support Equipment FSC 4920 to Prevent Enemy Use A 1 A 2 Blank TM 55 1560 307 13 amp APPENDIX B MAINTENANCE ALLOCATION CHART Section l INTRODUCTION B 1 MAINTENANCE ALLOCATION CHART a This Maintenance Allocation Chart MAC assigns maintenance functi
99. ell 85SDSCC D 0007 148 85SDSCC D 0007 150 85SDSCC D 0007 170 MS35207 279 M83413 8 BO6BB 85SDSCC D 0007 145 MS3106F125 3S 85SDSCC D 0007 168 85SDSCC D 0007 146 85SDSCC D 0007 147 85SDSCC D 0007 149 MS3472W14 4P Receptacle M85049 31 1 14W Backshell AN960 10L 521042 3 Locknut MS35338 48 Washer Lock U U A ine be A hit DOD 0 END OF FIGURE C 28 TM 55 1560 307 13 amp Figure C 9 Harness Assembly C 29 SECTION II SMR TM 55 1560 307 13 amp P ITEM CODE NO DESCRIPTION AND USABLE ON CODES UOC GROUP 0305 Wiring Harness Assy Fig C 9 Harness Assy 85SDSCC D 0007 113 Harness Assy M F rel Appx MS3476W 14 5P Connector MS3476W 14 45 Connector QQW34R1201B 53493 5 Plug Assembly 85SDSCC D 0007 190 Connector M F ref Appx END OF FIGURE C 30 Section IV NATIONAL STOCK NUMBER FIG z 62 62 62 62 62 62 62 62 62 62 62 62 62 62 62 62 62 62 62 62 62 62 62 62 62 62 62 62 62 62 62 62 62 62 62 62 62 62 62 62 62 lt gt 02 02 00 G G 02 G 2 02 00 00 00 00 G G 02 G 2 02 00 00 00 00 G G 02 G PS P IO IO P IO rS CROSS REFERENCE INDEXES NATIONAL STOCK NUMBER INDEX ITEM NO C 31 NATIONAL STOCK NUMBER FIG z 2 62 62 62 6
100. er P N 85SDSCC D 0007 127 E 22 TM 55 1560 307 I3 amp P 40 DIA 06 STOCK 6 PLCS 3 00 2 00 2 EQ SPCS MATERIALS 0 063 2024 73 AL ALLOY FINISHES 1 TREAT ALUMINUM WITH CHEMICAL CONVERSION COATING PER MIL C 5541 CLASS 1A 2 APPLY EPOXY PRIMER PER MIL P 23377 3 PAINT WITH CARC ACFT GREEN COLOR NO 34031 FED STD 595 PER MIL C 46168 TOLERANCES 20 1 20 03 0 005 Figure E 18 Fabrication of Gusset P N 85SDSCC D 0007 128 E 23 TM 55 1560 307 13 amp 125 DIA HOLE 6 PLCS 25 R 250 1 40 0 098 D 4 PLCS 2 00 MATERIALS 0 25 X 2 00 X 2 00 6061 T6511 EXTR FINISHES 1 TREAT ALUMINUM WITH CHEMICAL CONVERSION COATING PER MIL C 5541 CLASS 1A 2 APPLY EPOXY PRIMER PER MIL P 23377 3 PAINT WITH CARC ACFT GREEN COLOR NO 34031 FED STD 595 PER MIL C 46168 TOLERANCES 20 1 0 0 20 0 Figure E 19 Fabrication of Mount P N 85SDSCC D 0007 129 E 24 TM 55 1560 307 13 amp 16 000 16 EQ SPCS 1 35 23 000 156 D 8 PLCS REMOVED AND I ROTATED VIEW 193 D 4 PLCS 1 031 1 38 021 515 Jas SM pure EE EE CRM E a 1 031 5 00 NN 515 33 50 V 1 062 DIA HOLE 1 000 DIAHOLE 1 062 19 R Pkt DIA 1375 DIA HOLE 6 PLCS D E TYP ij cq e c KM I uu UM E ORA 4 75 45 2 000 2 EQ
101. es Additional intermediate maintenance support will be provided by the supporting nondivisional AVIM unit B 2 USE OF THE MAINTENANCE ALLOCATION CHART SECTION II a The maintenance allocation chart assigns maintenance functions to the lowest category of maintenance based on past experience and the following considerations 1 Skills available 2 Work time required 3 Tools and test equipment required and or available b Only the lowest category of maintenance authorized to perform a maintenance function is indicated If the lowest maintenance category cannot perform all tasks of any single maintenance function e g test repair then the higher maintenance level s that can accomplish additional tasks will also be indicated A maintenance function assigned to maintenance category will automatically be authorized to be performed at any higher maintenance category d A maintenance function that cannot be performed at the assigned category of maintenance for any reason may be evacuated to the next higher maintenance category Higher maintenance categories will perform the maintenance functions of lower maintenance categories when required or directed by the commander that has the authority to direct such tasking e The assignment of a maintenance function will not be construed as authorization to carry the related repair parts or spares in stock Information to requisition or otherwise secure the necessary re
102. essure hose 6 to adapter 6 Refueling sequence Tank 4 3 2 1 rear to forward due to a 2 degree nose up attitude of the aircraft NOTE After all tanks are filled do not open all 4 tank cam levers at the same time Fuel will seek its own level and could cause tanks 3 and 4 to overfill This could cause a fuel spill 7 Ensure tank cam lever on tank to be filled is opened and closed on other tanks lsolate other tanks by closing the quick disconnect coupling on hose connected from cam lever to manifold TEE 8 Start pressure refueling at no greater than 35 psi truck delivery pressure and 150 gallons per minute maximum 9 With an explosion proof flashlight carefully watch fuel level and stop refueling when level is up to top of fuel filler port 10 Close tank cam lever and proceed to the next tank to be filled 11 Close either side of hose coupling to isolate filled tank before filling next tank TM 55 1560 307 13 amp 1 Fuel Hose Ground Wire 2 Tank Receptacle 3 Hose 4 Fuel Filler Port Cap 5 Pressure Refueling Adapter 6 D 1 Pressure Hose FUELING VEHICLE GROUNDED pu gt gt GROUNDING Hooo MEDI Y LII Tid WIRE lr Sal zr ol 9 Ni M c U mS NX SR CH47 GROUNDING POINT Figure 3 2 Pressure Refueling 3 15 12 Repeat steps 7 thru 12 for each tank 13 Disconnect D 1 pressure refueling hose 6 from mani
103. ff system operation as follows a Turn all pump switches 3 four each OFF Figure 2 22 b Close cam lever 8 Figure 2 21 TM 55 1560 307 13 amp 1 2 3 4 Indicator Lights press test Pump switches Low Level Warning Lights Auto Transfer Pump Override Switch Circuit Breakers AUTO XFER PUMP SWITCH OVERRIDE 3 5 OPERATING INSTRUCTIONS FOR 600 GALLON EXTENDED RANGE FUEL SYSTEM lt INSTALL FUEL MANIFOLD AND VENTS AS REQUIRED 2 ENSURE GROUNDING CABLES ARE INSTALLED 3 CONNECT ELECTRICAL PLUGS INTO UTILITY RECEPTACLES 4 SERVICE FUEL TANKS AS REQUIRED S OPEN ONE 600 GALLON DUMP VALVE NORMAL TANK BURN SEQUENCE 4 1 3 2 6 TURN ON PUMP 1 AND HOLD UNTIL PUMP REMAINS ON PUMP 2 MAY BE TURNED ON TO INCREASE FUEL TRANSFER 7 TURN ON PUMP 3 AND HOLD UNTIL PUMP REMAINS ON PUMP 4 MAY BE TURNED ON TO INCREASE FUEL TRANSFER B FUEL TRANSFER MAY BE MONITORED FUEL QUANTITY INDICATORS MOUNTED IN TANK 9 LOW LEVEL LIGHT WILL ILLUMINATE WHEN TANK IS EMPTY PUMPS WILL SHUT OFF AUTOMATICALLY CLOSE DUMP VALVE AFTER FUEL EXHAUSTION Figure 2 24 ERFS Operating Instructions 2 30 TM 55 1560 307 13 amp Section V PREVENTIVE MAINTENANCE CHECKS AND SERVICES PMCS 2 14 SCOPE The ERFS requires some preventive maintenance checks and services Once the system is installed on t
104. fold hose 3 and wipe up any fuel that may have dripped 14 Disconnect grounding wire 1 from tank receptacle 2 15 Secure fuel truck and aircraft 3 14 SUCTION DEFUELING This task covers a Grounding procedures b Defueling ERFS tanks INITIAL SETUP Tools Flashlight explosion proof Materials Parts Fuel JP 4 5 8 items 7 8 9 Appx D Refueling Truck Refueling Adapter Nozzle P N AE82605R Equipment Conditions Same as gravity refueling Refer to Figure 3 2 DEFUELING 1 Ground helicopter as required 2 Connect fuel hose ground wire 1 to tank ground receptacle 2 3 Remove dust cap from coupling assembly on hose 3 4 Remove fuel filler port 4 cap 3 16 TM 55 1560 307 13 amp P 5 Install adapter 5 to manifold hose 3 and connect fuel truck hose 6 to adapter 6 Open all tank and hose cam levers for tanks to be defueled 7 With an explosion proof flashlight monitor fuel level until tank is empty 8 Secure tank and proceed to next tank as required 9 After defueling all tanks disconnect defueling hose 6 and ground wire 1 10 Reinstall dust cap on manifold hose 3 11 Secure fuel truck and helicopter 3 15 MAINTENANCE OF ERFS COMPONENTS REPLACE ANY SYSTEM FUEL HOSE This task covers a Removal b Inspection c Installation INITIAL SETUP Tools None Materials Parts Fuel Hose 6 7 8 15 Equipment Conditions Refer to Figures 3 3 and 3 4 A
105. g Average 10 2 11 2 480 690 800 1000 1100 1300 2300 2500 2500 3000 Coarse Thread 1150 1600 2200 3000 TM 55 1560 307 13 amp Thin Plain amp Castellated Steel Hex Nuts Used with Bolts in Note 8 Shear Loading Average 9 5 10 5 1300 1500 1500 1800 1300 1800 1 THE ABOVE TORQUE LOADS MAY BE USED FOR ALL CADMIUM PLATED STEEL NUTS OF THE FINE OR COARSE THREAD SERIES WHICH HAVE APPROXIMATELY EQUAL NUMBER OF THREADS AND EQUAL BEARING AREAS 2 TORQUE VALUES ARE IN INCH POUNDS 3 TORQUE VALUES ARE NOMINAL AND MAY NOT AGREE WITH SPECIFIC AIRCRAFT OR ENGINE MAINTENANCE MANUALS TORQUE VALUES CITED IN SPECIFIC MANUALS ARE CORRECT FOR INDIVIDUAL APPLICATION 4 SIZE REFERS TO BOLT SHANK DIAMETER OR INSIDE DIAMETER OF NUT AND THREAD INDICATES NUMBER OF THREADS PER INCH VALUE IN TENSION LOADING 8 TORQUE VALUES ARE APPLICABLE TO SELF LOCKING NUTS AS WELL REFERENCE TABLE F 1 F 3 F 4 Blank TORQUE VALUES ARE DERIVED FROM OIL FREE CADMIUM PLATED THREADS ALL TORQUE VALUES ARE BASED ON USE OF 125 KSI BOLTS AVERAGE TORQUE VALUES IN SHEAR LOADING ARE APPROXIMATELY 6096 OF AVERAGE TORQUE APU BONNEY WRENCH CAM LEVER CAMLOCK COUPLING VALVES CRASHWORTHY CUT LINE ECP OPTICAL ERFS EXTRUSION FARE FLASH POINT FMCP HICHS KINK LOCKNUT TM 55 1560 307 13 amp GLOSSARY Auxiliary power unit A small turbine powered combination electrical generator a
106. he aircraft it will be treated as part of the aircraft PMCS are normally visual inspections of the fuel tanks fuel system hoses fittings and the FMCP The FMCP checks consist of checking lights switches and pumps Table 2 6 WARNING Installing the non crashworthy ERFS increases the potential for thermal injuries during a crash sequence Therefore the number of personnel on board the aircraft will be kept to the minimum required to perform the required mission Additionally all personnel are required to be seated with 2 31 a lap belt during flight 2 15 PMCS PROCEDURES Inspections and services required to be performed are listed Table 2 a Before operations perform your before B PMCS b After operation be sure to perform your after A PMCS lf your equipment fails to operate troubleshoot as elc Sr il Enter deficiencies or discrepancies on proper forms as per DA PAM 738 751 TAMMS A ITEM NO TM 55 1560 307 13 amp Table 2 6 Operator Crew Preventive Maintenance Checks and Services B BEFORE A AFTER W WEEKLY ITEMS TO BE INSPECTED Fuel Filter 600 Gallon Tanks Fuel Sample Hoses Fittings Tiedown Bonding Jumpers amp Electrical Harnesses PROCEDURES CHECK FOR AND HAVE REPAIRED OR CORRECTED AS NECESSARY NOTE Within designated interval these checks are to be performed in the order listed Ensure that fuel filter is installed Inspect filter and clea
107. id level indicators and fuel sample drain provide better means for servicing the system l Mounting angle brackets provide easy installation of FMCP and interchangeability from tank to tank m Tank access covers are fabricated with spillproof rollover vent valve 1 7 TM 55 1560 307 13 amp VENT LINES Fo e 0 enl em eh om CAM LEVER L H MAIN TANK TANK 4 TANK TANK 2 TANK 1 3 FERRY CONNECTION FARE FUEL TRANSFER CONNECTION ENE GD R H MAIN TANK Pace FERRY N CONNECTION FUEL MANAGEMENT CONTROL PANEL TRANSFER FMCP PUMP Figure 1 2 Extended Range Fuel System Block Diagram n Fuel manifold is equipped with unisex dry break couplings o System is equipped with vent lines which will fit either CH 47D model aircraft p Fuel transfer pump system can operate with an external APU generator the aircraf s APU or the aircraft s main generators engines have to be running when using main generators TM 55 1560 307 13 amp P q Tanks may be configured with separate roller assemblies when internal cargo handling system highs is not installed on aircraft 1 11 LOCATION AND DESCRIPTION OF MAJOR COMPONENTS Refer td Figure 1 1 1 12 EQUIPMENT DATA For equipment data refer to Table 1 1 Table 1 1 Equipment Data System Nomenclature Part Number ae Manut ctur r as a uA Tank four each Weight Empty
108. indicators can be found in Chapter 2 1 15 PERFORMANCE DATA Refer tq Table 1 2 1 16 SAFETY CARE AND HANDLING Warnings and cautions are stated as applicable throughout this manual 1 17 SAFETY HAZARDS Installation of the ERFS increases the exposure of the aircraft and crew to fire hazards However if personnel use reasonable caution and safety practices as prescribed in this manual the ERFS is an airworthy system Table 1 2 CH 47D Weight Balance Range Endurance Performance Data WEIGHTS CONFIGURATION POUNDS STATION MOMENTS 1000 ENDURANCE RANGE HRS CH 47D ERFS performance factors with zero wind factor and standard day Fuel Tank 1 511 3 230 0 Fuel Tank 2 511 3 290 0 Fuel Tank 3 511 3 350 0 Fuel Tank 4 511 3 410 0 FMCP 48 190 Vent Lines 15 320 Pump Discharge Lines 20 290 Feed Lines Manifold 70 290 FARE EQUIP 800 502 2 pumps 2 filter 2 fuel cans Helicopter Internal 878 379 9 Cargo Handling System HICHS 3 463L Pallets 870 323 290 Ibs ea 1 10 117 6 148 3 178 9 209 6 TM 55 1560 307 13 amp CHAPTER 2 INSTALLATION AND OPERATING INSTRUCTIONS 2 1 SCOPE Installation and operating instructions for maintenance checks and services PMCS procedures the ERFS are provided in this chapter A description on and instructions for operation of the system under usual how to use operator controls and indicators is also and unusual conditions provided This chapter includes the preventiv
109. its place Replace is authorized by the MAC and is shown as the 3d position code of the SMR code i Repair The application of maintenance services including fault location troubleshooting2 removal installation and disassembly assembly procedures3 and maintenance actions4 to identify troubles and restore serviceability to an item by correcting specific damage fault malfunction or failure in a part subassembly module component or assembly end item or system j Overhaul That maintenance effort service action prescribed to restore an item to a completely serviceable operational condition as required by maintenance standards in appropriate technical publications i DMWR Overhaul is normally the highest degree of maintenance performed by the Army Overhaul does not normally return an item to like new condition k Rebuild Consists of those services actions necessary for the restoration of unserviceable equipment to a like new condition in accordance with original manufacturing standards Rebuild is the highest degree of materiel maintenance applied to Army equipment The rebuild operation includes the act of returning to zero those age measurements hours miles etc considered in classifying army equipment components 1Services inspect test service adjust aline calibrate and or replace 2Fault locate troubleshoot the process of investigating and detecting the cause of equipment malfunctioning
110. jects sand and water and remove as appropriate Ensure the inspection includes the dump valve opening located at the bottom front of each tank Hoses and pump board must be opened and inspected for foreign material or damage prior to being installed e Inspect fuel filter for foreign material damage and serviceability Upon first fueling of each tank use the splash fill method with 25 to 50 gallons of fuel in both the forward and aft fill caps and be sure to wash all sides of the tank Obtain fuel sample from each tank If fuel is found contaminated defuel tank clean and refill again as described above Repeat until an acceptable fuel sample is obtained then fill the tank to the desired level 3 12 MAINTENANCE COMPONENTS OF ERFS TANK GRAVITY REFUELING This task covers a Grounding procedures b Fuel servicing tanks INITIAL SETUP Tools Flashlight explosion proof Personnel required 4 MOS 67U Materials Parts Fuel JP 4 5 8 items 7 8 9 Appx D Equipment Conditions Refer to Figure 3 1 Aircraft shutdown and all electrical power off Refueling vehicle parked minimum of 10 feet from helicopter Helicopter on level ground parked at least 50 feet from any structure Helicopter grounded Fuel vehicle grounded Fuel tank grounded to aircraft REFUELING 1 Connect hose grounding lead 1 to tank ground receptacle 2 2 Remove filler port cap 3 3 Ensure
111. l 2 required Nipple 4 required Elbow Tube 2 required Cross 2 required Figure 1 1 Extended Range Fuel System Sheet 4 of 5 1 5 TM 55 1560 307 13 amp 40 Electrical Harness Assy 4 required 41 Ground Harness Assy 42 Electrical Harness Assy 2 required Figure 1 1 Extended Range Fuel System Sheet 5 of 5 1 6 WARNING Installing the non crashworthy ERFS increases the potential for fires during a crash The number of personnel on board the aircraft will be kept to the minimum required to perform the required mission Additionally all personnel are required to be seated with a lap belt during flight 1 8 FUNCTIONAL DESCRIPTION An over all description of the ERFS is provided in the following paragraphs brief functional description of the ERFS components and information on operational status is also provided The ERFS is illustrated in functional block diagram a The operation of each tank is independent of the others when used in multiples greater than one The ERFS system combined with the FMCP allows any one tank in a multiple installation to feed the aircraft s main fuel tanks without the need to manually disconnect or connect the feed lines b After the ERFS tanks are installed on the aircraft the system is treated as part of the aircraft 1 9 FMCP FUNCTIONAL DESCRIPTION The fuel management control panel houses the fuel pumps utilized in fuel transfer operations Selective fuel ma
112. lation The ERFS will be inspected after initial installation in the aircraft 2 2 b When system components have been out of service for a period of 7 days or more c When maintenance has been preformed on any part or component of the system to correct a malfunction d When the ERFS tank system has been purged in accordance with instructions provided in Chapter 3 Section VJ para 3 25 pf this manual e Before each flight check system in accordance with the PMCS Table 2 6 f Immediately after fueling system inspect for leaks Figure 2 1 ERFS Tank Loading with Forklift 2 3 TM 55 1560 307 13 amp P TM 55 1560 307 13 amp P Section Ill ERFS INSTALLATION 2 5 INSTALLATION The ERFS will require four persons and approximately three hours for installation The tanks can be installed on aircraft with or without the helicopter internal cargo handling system HICHS if aircraft has been modified standard tool kit NSN 5180 00 323 4692 will be needed for installation of the system System kit will include four bonney wrenches For ERFS tiedown configurations refer 2 2 2 6 ERFS INSTALLATION PROCEDURES The following tiedown configurations are typical installation of one to four tanks installed Depending on loading configurations the tanks position can be moved forward or aft depending on mission needs however the helicopter CG must be maintained within limits and the number of tiedowns c
113. lines to ensure that they are properly secured and connected b Check for chafing of fuel manifold lines and tiedown straps c Ensure tank tiedown straps are secured d Ensure ERFS tanks are properly fueled 580 gallons maximum per tank e Take fuel sample from each tank 2 11 TURN ON PROCEDURES To turn system ON use the following procedures a To apply power to the ERFS the APU or engines must be operating The FMCP electrical power cords connect to electrical receptacles on the LH RH side of the aircraft at station 260 b Open appropriate tank cam valves levers dump c Power ON Perform power ON checks prior to system operation Figure 2 23 d Ensure the indicator lights 1 are operative by press to test method Lights should be ON when pumps are in operation Figure 2 23 e Each toggle switch 2 activates its respective pump when in ON position and shuts pumps off when in OFF position Figure 2 23 TM 55 1560 307 13 amp Figure 2 21 ERFS Controls and Indicators Table 2 4 Controls and Indicators Function KEY CONTROL OR INDICATOR FUNCTION an be removed to gain access to tank to Access Cover make repairs L Activates low level warning light 3 Control Panel land breakers 3 Control Panel and breakers Indicate fuel quantity in tank 6 jHoistingEyes Used to hoist tank 11 8 Tank Lever d
114. ling Installation 3 21 GENERAL SAFETY INSTRUCTIONS WARNING ELECTRICAL GROUNDING OF THE HELICOPTER Army regulations require the grounding of the helicopter when parked and during all fueling and defueling operations No electrical switches shall be operated except those necessary for servicing during fueling and defueling No smoking or flame during all fueling and defueling operations CAUTION Do move coupling levers to opened position with hose or tee couplings while couplings are disconnected NOTE e Hose and tee coupling lock levers have to be in closed position when disconnected Couplings will not unlock if lock levers are not moved from closed position REMOVAL 1 Place clean rags item 3 Appx D under hose to tee connections 2 Remove tee coupling a Unlock hose couplings at hose to be disconnected first b Twist hose coupling counterclockwise to remove from tee coupling 3 Remove all hoses attached to tee coupling in the same manner and remove tee fitting INSPECTION 1 Visually inspect new tee coupling for obvious damage 3 22 TM 55 1560 307 13 amp P 2 Replace tee coupling if above conditions are found INSTALLATION NOTE After tee is installed ensure that coupling levers are open 1 Close hose couplings by levers to UNLOCK position to close valves turning 2 Twist hose coupling clockwise on to tee coupling and turn levers to open position 3 Secure all ho
115. ment agency etc that supplies the item 2 PART NUMBER Column Indicates the primary number used by the manufacturer individual firm corporation or Government activity which controls the design and characteristics of the item by means of its engineering drawings specifications standards 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 FIG 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 c FIGURE AND ITEM NUMBER INDEX 1 FIG Column This column lists the number of the figure where the item is identified located in Section II And 2 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 3 STOCK NUMBER Column lists the NSN for the item 4 CAGE Column The Commercial and Government Entity CAGE is 5 digit numeric code used to identify the manufacturer distributor or Government agency etc that supplies the item This column TM 55 1560 307 13 amp P 5 PART NUMBER Column Indicates the primary number used by the man
116. n thoroughly Filled to capacity of 580 gallons Check capacity indicated by liquid level indicators Check security of filler port cap access door and vent valve Drain fuel sample from each tank to check for contaminants Inspect for security leaks damage Check for antichaffing pads installation security and condition Ensure that straps are securing tanks to cabin floor as required Inspect for security proper installation to tanks and damage 2 32 EQUIPMENT IS NOT READY AVAILABLE IF Fuel samples show any kind of contamination Loose connections fuel leaks are evident Anti chaffing pads need to be replaced or installed or if chaffing of lines has occurred 10 11 12 13 14 TM 55 1560 307 13 amp Table 2 6 Operator Crew Preventive Maintenance Checks and Services B BEFORE ITEMS TO BE INSPECTED FMCP Panel Power Cords Panel Lamps Fuel Pumps Pump Switches Override Switch Function Vent Lines Cam Lever PROCEDURES CHECK FOR AND HAVE REPAIRED OR CORRECTED EQUIPMENT IS NOT AS NECESSARY READY AVAILABLE IF Installed properly on Breakers switches No 1 tank all lamps are not circuit breakers in operating properly pump and override switches OFF Plugged into proper utility receptacle Aircraft electrical power turned ON press to test lamps Turn No 1 pump ON ensure that the ON light illuminates and that pump is ru
117. nagement is incorporated to enable the operator to operate either single or multiple pumps and tanks at his discretion Electrical power is furnished by the existing aircraft power receptacles located at station 260 1 10 EQUIPMENT CHARACTERISTICS CAPABI LITIES AND FEATURES a The ERFS transports with ease due to the design of the skid mounts and hoisting eye Change 2 TM 55 1550 307 13 amp b The ERFS provides 2320 gallons of usable fuel for extended range missions c The ERFS can be installed operated removed transported handled and stored in all climatic conditions compatible with the CH 47D and MH 47D helicopters d The ERFS tanks are capable of being stored five years without deterioration provided the tanks are sealed e Fuel quantity can be accurately monitored in flight within four percent of the actual quantity using the liquid level indicators f The system can also be defueled using standard equipment g The ERFS has redundant fuel feed capability in all pump tank combinations h ERFS Servicing The system tanks can be filled by gravity splash fill System is capable of accepting all types of aviation fuel to include JP 4 5 and 8 i The ERFS can be used as a fare system providing 2320 gallons of fuel for refueling other aircraft j The ERFS can be installed and used in a one tank or multiple tank configuration as the mission requires k Accessibility to fuel filler port liqu
118. nd hydraulic pump permanently installed in the aircraft A thin head open end wrench with only one opening and short tapered handle Normally used on hose and tube fittings A manually operated lever located on top of extended range fuel system ERFS fuel tank linked mechanically to operate fuel dump valve located at bottom of tank A type of quick release latch or fastener Spring loaded discs built into hose couplings which close automatically when couplings are separated thus preventing fuel spillage Fuel is field captive in the lines The design of an aircraft s fuel system to sustain crash damage with fuel leakage A line or mark on hose fittings used as a guide in establishing length bulk hose Electrical control panel A design principle used by the ERFS low fuel pressure sensing system Absence of fuel in pump lines causes a change in light pattern detected by optical sensor which is translated into an electrical output Extended range fuel system A metal strip or bar formed with a consistent cross section during manufacturing Forward air refueling equipment Lowest temperature at which liquid will give off sufficient vapor to ignite upon application of flame or spark Fuel management control panel Helicopter internal cargo handling system An undesirable crimp twist or sharp bend in a hose causing restriction of fluid or gas flow The internally threaded end fitting of a hose or piece of rigid tubing GLOS
119. nding of the helicopter when parked and during all fueling and defueling operations No electrical switches shall be operated except those necessary for servicing during fueling and defueling Fueler must exercise caution during fueling If fuel is spilled inside the aircraft removal of cabin floor panels may be required aircraft purged with clean water and allowed to air dry All spilled fuel must be removed prior to continuing operation See TM 55 1520 240 23 for additional instructions para 2 204 3 13 PRESSURE REFUELING This task covers a Grounding procedures b Refueling ERFS tanks INITIAL SETUP Tools Flashlight explosion proof Materials Parts JP 4 5 8 items 7 8 9 D Refueling Truck Refueling Adapter Nozzle P N AE82605R Equipment Conditions Same as gravity refueling Refer tol Figure 3 2 1 Ground the helicopter as required CAUTION No aircraft electrical power or auxiliary power unit is required when pressure fueling or defueling 2 Connect fuel hose ground wire 1 to tank receptacle 3 14 55 1560 307 13 amp 3 Remove dust cap from coupling assembly on hose 3 WARNING The ERFS vents must be open during refueling and defueling operations The ERFS tanks cannot be exposed to internal pressure of over 5 psi or failure will occur 4 Remove fuel filler port 4 cap 5 Install pressure refueling adapter 5 to manifold hose 3 and install fuel truck D 1 pr
120. nning Check that each pump Switches do not engage switch remains engaged and remain engaged after pressure switch has verified pump operation on all pumps Turn all pumps OFF Turn override switch Override switch is ON momentarily turn inoperative or will on any one pump not hold on detent Pump should be operative if pump is not operative override switch is defective Check for obvious damage and security to aircraft vent system Open valve on each tank one tank individually 2 33 TM 55 1560 307 13 amp P Table 2 6 Operator Crew Preventive Maintenance Checks and Services B BEFORE A AFTER ITEMS TO BE INSPECTED Low Level Warning Light Circuit Breakers PROCEDURES CHECK FOR AND HAVE REPAIRED OR CORRECTED AS NECESSARY Check entire system for fuel leaks Each line individually EQUIPMENT IS NOT READY AVAILABLE IF Any fuel leaks are evident Close all cam levers after leak check Electrical connection Press to test warning light All breakers in with power on Section VI OPERATION UNDER USUAL CONDITIONS 2 16 a Refer tq Section l for unpack aging b Refer td Section Illlfor assembly and installation instructions c Refer to Section Use of Controls and Indicators and Power ON OFF Procedures for electrical power application ASSEMBLY AND PREPARATION FOR USE 2 17 INITIAL ADJUSTMENTS DAILY CHECKS AND SELF TEST Refer to PMCS 2 34
121. nt Data 1 12 Equipment Furnished 2 3 ERFS Components T 2 1 ERFS Control and Indicators F 2 21 ERFS Fuel Management Electrical Control Panel ECP F 2 23 ERFS Installation Procedures 2 6 ERFS No 1 Tank Installation and Tiedown F 2 3 ERFS No 2 Tank Installation and Tiedown F 2 6 INDEX 1 Subject Para E Cont ERFS No 3 Tank Installation and Tiedown F 2 9 ERFS No 4 Tank Installation and Tiedown F 2 10 ERFS Operating Instructions F 2 24 ERFS Tank Installation and Secured F 2 11 ERFS Tank Loading with Forklift F 2 1 ERFS Tiedown Configurations W O 463L Pallet T 2 2 ERFS Tiedown Strap Configurations with 463L Pallets T 2 3 ERFS Troubleshooting 3 9 Extended Range Fuel System F 1 1 Extended Range Fuel System Block Diagram F 1 24 F FMCP Controls and Indicators F 2 22 FMCP Functional Description 1 9 Forms Records and Reports 1 3 Four Tanks with Pallets F 2 16 F 2 20 Fuel Filter 3 22 Fuel Float Assembly 3 23 Fuel Management Control Panel Installation F 2 4 Fuel Pumping System and Plumbing F 2 5 Fuel Quantity Gallons and Pounds Decal T 3 1 Functional Description 1 8 G Gravity Refueling ERFS Tanks F 3 1 TM 55 1560 307 13 amp ALPHABETICAL INDEX Cont Subject Para H Initial Adjustments Daily Checks and Self Test 2 17 Inspection 2 4 Inspection Unpacking and 2 2 Installation 2 5 Installation and Tiedown Straps F 2 2 Installation Instructions 3 7 Installing
122. of ERFS System Hoses F 3 3 Removal of Suction and Discharge Fuel Hose F 3 9 Remove and Replace ERFS Fuel Pump F 3 8 Remove and Replace Fuel Filter F 3 12 Remove and Replace Fuel Float Assembly F 3 13 Repair Parts 3 3 Reporting Equipment Improvement and Recommendations 1 4 S Safety Hazards 1 17 Safety Care and Handling 1 16 Service 3 11 Shipping 3 27 Special Tools TMDE and Support Equipment 3 2 Storage 3 26 Suction and Discharge Hoses 3 19 Suction Defueling 3 14 System Couplings Installation F 2 12 System Installation with Helicopter Internal Cargo System HICHS and 463L Pallets 2 7 Subject Para T Tee Coupling Installation F 3 6 Tee Coupling Removal F 3 5 Three Tanks with Pallets F 2 15 Three Tanks with Pallets F 2 19 Tools Test Equipment and Materials Required for Installation 3 6 Troubleshooting ERFS 3 9 Turn Off Procedures 2 13 Turn On Procedures 2 11 Two Tanks of Four with Pallets F 2 14 Two Tanks with Pallets F 2 18 U Unpacking 3 4 Unpacking and Inspection 2 2 V W Wire Chart FO 2 Wiring Diagram FO 1 XYZ INDEX 3 INDEX 4 TM 55 1560 307 13 amp By Order of the Secretary of the Army CARL E VUONO General United States Army Chief of Staff Official THOMAS F SIKORA Brigadier General United States Army The Adjutant General DISTRIBUTION To be distributed in accordance with DA Form 12 31 AVUM and AVIM Maintenance requirements for CH 47
123. ons in accordance with the Three Levels of Maintenance concept for Army Aviation These maintenance levels categories Aviation Unit Maintenance AVUM Aviation Intermediate Maintenance AVIM and Depot Maintenance are depicted on the MAC as AVUM which corresponds to an 0 Code in the Repair Parts and Special Tools List RPSTL AVIM which corresponds to an F Code in the Repair Parts and Special Tools List RPSTL DEPOT which corresponds to a D Code in the Repair Parts and Special Tools List RPSTL b The maintenance to be performed below depot and in the field is described as follows 1 activities will be staffed and equipped to perform high frequency On Aircraft maintenance tasks required to retain or return aircraft systems to a serviceable condition The maintenance capability of the AVUM will be governed by the MAC and limited by the amount and complexity of ground support equipment GSE facilities required authorized manning strength and critical skills available The range and quantity of authorized spare modules components will be consistent with the mobility requirements dictated by the air mobility concept Assignments of maintenance tasks to divisional company size aviation units will consider the overall maintenance capability of the division the requirement to conserve personnel and equipment resources and air mobility requirements a Company size aviation units Perform those tasks which con
124. ont Section IV FIG ITEM NATIONAL STOCK NO NO NUMBER CAGE PART NUMBER C 8 29 81349 81714 28 20 C 8 30 5940 00 950 1610 96906 MS27212 1 20 C 8 31 5940 00 247 0524 96906 518029 156 C 8 32 12757 85SDSCC D 0007 160 C 8 33 5961 00 257 6865 07623 IN4001 C 8 34 SS 12757 85SDSCC D 0007 157 C 8 35 5940 00 204 8966 96906 MS25036 102 C 8 36 og 12757 85SDSCC D 0007 162 C 8 37 224 12757 85SDSCC D 0007 163 C 8 38 2 4 12757 85SDSCC D 0007 164 C 8 39 E 12757 85SDSCC D 0007 158 C 8 40 5945 01 114 1288 07623 M6106 27 029 C 8 41 12757 85SDSCC D 0007 156 C 8 42 pe 12757 85SDSCC D 0007 173 C 8 43 E 12757 85SDSCC D 0007 154 C 8 44 5945 01 011 1318 96906 MS27743 5 C 8 45 e 12757 85SDSCC D 0007 152 C 8 46 2 12757 85SDSCC D 0007 172 C 8 47 5961 00 257 6865 07623 IN4001 C 8 48 eM 12757 85SDSCC D 0007 151 C 8 49 5305 00 717 5467 96906 MS35707 262 C 8 50 5310 00 167 0834 88044 AN960 1OL C 8 51 5310 00 877 5797 96906 MS21044 N3 C 8 52 5935 01 170 9127 96906 MS3472W 12 85 C 8 53 5935 01 256 0252 81349 M85049 31 1 12W C 8 54 12757 85SDSCC D 0007 148 C 8 55 12757 85SDSCC D 0007 150 C 8 56 m 12757 85SDSCC D 0007 170 C 8 57 5305 00 993 2463 12757 MS35207 279 C 8 58 6150 01 201 1570 81349 M83413 8 B06BB C 8 59 12757 85SDSCC D 0007 145 C 8 60 5935 01 148 4737 96906 MS3106F125 3S C 8 61 12757 85SDSCC D 0007 168 C 8 62 222 12757 85SDSCC D 0007 146 C 8 63 DE 12757 85SDSCC D 0007 147 C 8 64 E 12757 85SDSCC D 0007 149 C 8
125. ool Kit 5180 00 323 4692 SC518099CLAO1HR Aircraft Mechanic AVUM Wrench 5120 00 203 4812 5120 00 203 4804 5120 00 203 4806 5120 00 203 4808 5120 00 203 4802 B 7 B 8 Blank TM 55 1560 307 13 amp P APPENDIX C OPERATOR AVIATION UNIT AND AVIATION INTERMEDIATE MAINTENANCE REPAIR PARTS AND SPECIAL TOOLS LIST Section I INTRODUCTION C 1 SCOPE This repair parts and special tools list 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 AVUM and AVIM maintenance of the Extended Range Fuel System It authorizes the requisitioning issue and disposition of spares repair parts and special tools as indicated by source maintenance and recoverability SMR codes C 2 GENERAL In addition to Section 1 Introduction this repair parts and special tools list is divided into the following sections a Section Repair Parts List list of spares and repair parts authorized by this RPSTL for use in the performance of maintenance The list also includes parts which must be removed for replacement of the authorized parts Parts lists are composed of functional groups in ascending alphanumeric sequence Bulk materials are listed by item name recae part kits are listed separately in their own function group within Section Repair parts for reparable special tools are also listed in thi
126. pair parts will be as specified in the associated repair parts and special tools list RPSTL f Normally there will be no deviation from the assigned level of maintenance In cases of operational necessity maintenance functions assigned to maintenance level may on a one time basis and at the request of the lower maintenance level be specifically authorized by the maintenance officer of the level of maintenance to which the function is assigned The special tools equipment etc required by the lower level of maintenance to perform this function will be furnished by the maintenance level to which the function is assigned This transfer of a maintenance function to a lower maintenance level does not relieve the higher maintenance level of the responsibility for the function The higher level of maintenance will provide technical supervision and inspection of the function being performed at the lower level g Changes to the maintenance allocation chart will be based on continuing evaluation and analysis by responsible technical personnel and on reports received from field activities TM 55 1560 307 13 amp P B 3 MAINTENANCE FUNCTIONS Maintenance functions will be limited to and defined as follows a Inspect To determine the serviceability of an by comparing its physical mechanical and or electrical characteristics with established standards through examination e g by sight sound or feel b Test To verify
127. s section b Section Special Tools List list of special tools special TMDE and other special support equipment authorized by this RPSTL for the performance of maintenance c Section Cross Reference Indexes list in National Item Identification Number NIIN sequence of all National Stock Numbers NSN appearing in the listings followed by a separate list in alphanumeric C 1 sequence of all part numbers appearing in the listings National stock numbers and part numbers are cross referenced to each illustration figure and item number appearance The figure and item number index lists figure and item numbers in alphanumeric sequence and cross references NSN CAGE and part numbers C 3 EXPLANATION OF COLUMNS Sections I and m a ITEM NO Column Indicates the number used to identify items called out in the illustration b SMR CODE Column The Source Maintenance and Recoverability SMR code is a 5 position code containing supply requisitioning information maintenance category authorization criteria and disposition instruction as shown in the following breakout 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 XA Do not requisition an XA coded item Order its next higher assembly Also refer to the NOTE below XB If an XB item is not available from salvage order it
128. serviceability by measuring the mechanical pneumatic hydraulic electrical characteristics of item comparing those characteristics with prescribed standards c Service Operations required periodically to keep an item in proper operating condition i e to clean includes decontaminate when required to preserve to drain to paint or to replenish fuel lubricants chemical fluids or gases d Adjust To maintain or regulate within prescribed limits by bringing into proper or exact position or by setting the operating characteristics specified parameters e Aline To adjust specified variable elements of an item to bring about optimum or desired performance f Calibrate To determine and cause corrections to be made or to be adjusted on instruments or test measuring and diagnostic equipments used in precision 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 g Remove Install To remove and install the same item when required to perform service or other maintenance functions Install may be the act of emplacing seating or fixing into position a spare repair part or module component or assembly in a manner to allow the proper functioning of an equipment or system h Replace To remove an unserviceable item and install a serviceable counterpart in
129. ses attached to tee 3 17 MAINTENANCE OF FMCP COMPONENTS REPLACE FUEL SENSOR LEVEL ELECTRO OPTICAL This task covers a Removal b Inspection c Installation INITIAL SETUP Tools Bonney Wrenches Material Parts Sensor Level Electro Optical 7 Fig 7 Appx Equipment Conditions Refer to Figure 3 7 ERFS tank cam lever CLOSED Suction hose assembly coupling closed Refer to Figure 1 1 14 All electrical power OFF All FMCP switches OFF TM 55 1560 307 13 amp P 6 4 a ESI t C oM FE 1 Elec Cannon Plug 2 Sensor Level Electro Optical TFT 3 Adapter Figure 3 7 Removal and Replacement of ERFS Fuel Sensor Level Electro Optical GENERAL SAFETY INSTRUCTIONS WARNING ELECTRICAL GROUNDING OF THE HELICOPTER Army regulations require the grounding of the helicopter when parked and during all fueling and defueling operations No electrical switches shall be operated except those necessary for servicing during fueling and defueling No smoking or flame during all fueling and defueling operations REMOVAL 1 Disconnect electrical plug 1 from sensor level electro optical 2 2 Remove sensor level electro optical 2 from adapter 3 INSPECTION 1 Visually inspect threads on adapter 3 and new sensor level electro optical 2 2 Check threads on el
130. sist primarily of preventive maintenance and maintenance repair and replacement functions associated with sustaining a high level of aircraft operational readiness Perform maintenance inspections and servicing to include preflight daily intermediate periodic or phased and special inspections as authorized by the MAC or higher headquarters ldentify the cause of equipment system malfunctions using applicable technical manual troubleshooting instructions built in test equipment BITE installed aircraft instruments or test measurement and diagnostic equipment TMDE Replace worn or damaged modules components that do not require complex adjustments or system alinement and which can be removed installed with available skills tools and ground support equipment Perform operational and continuity checks and make minor repairs to the electrical system Inspect service and make operational capacity and pressure checks to hydraulic systems Perform servicing functional adjustments and minor repair replacement to the flight control propulsion power train and fuel systems Accomplish air frame repair that does not require extensive disassembly jigging or alinement The manufacture of air frame parts will be limited to those items which can be fabricated with tools and equipment found in current air mobile tool and shop sets Evacuate unserviceable modules components and end items beyond the repair capability of AVUM to the supporting
131. square feet square yards square centimeters square meters square meters square miles square kilometers acres square hectometers cubic feet cubic meters cubic yards cubic meters fluid ounces milliliters pints liters quarts liters gallons liters ounces grams pounds kilograms short tons metric tons pound feet Newton meters pound inches Newton meters Fahrenheit temperature Multiply by To change To Multiply by 2 540 ounce inches Newton meters 007062 305 centimeters inches 394 914 meters feet 3 280 1 609 meters yards 1 094 6 451 kilometers miles 621 093 square centimeters square inches 155 836 square meters square feet 10 764 2 590 square meters square yards 1 196 405 square kilometers square miles 386 028 square hectometers acres 2 471 765 cubic meters cubic feet 35 315 29 573 cubic meters cubic yards 1 308 473 milliliters fluid ounces 034 946 liters pints 2 113 3 785 liters quarts 1 057 28 349 liters gallons 264 454 grams ounces 035 907 kilograms pounds 2 205 1 356 metric tons short tons 1 102 11296 Temperature Exact 5 9 after Celsius subtracting 32 temperature PIN 046218 002 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
132. sy 89SDSCC D 01 04 5 AE25010 011 Adapter Female Cam Lock MS27028 11 Cap Dust MS27030 6 Gasket Cap 110 6 Chain with Ring MS24665 289 Pin Cotter AN310C12 Nut Castellated Hex 527183 23 551105 464 13217 7085 590728 109 527183 18 13217 7092 MS21045L4 AN960PD416 AN4 7A 85SDSCC D 0007 119 Fuel Filler Cap M F SS9609 ref Appx E MS16996 21 MS122032 Washer Lock 205 063 604 1 Cock Poppet Drain MS29513 114 Packing Preformed 85SDSCC D 0007 116 Mount Block Assy 1140 0161 1 Liquid Level Indicator short 1140 0161 2 Liquid Level Indicator long Retainer Float MS21083G 4 Inner Stick Assy 85SDSCC D 0007 9 Float Assy NAS679 A06W AN960 PBL Washer MS35206 215 MS3472L1 4 4P Receptacle MS24400 D5 Nut 85SDSCC D 0007 20 Bracket M F 2024T3 Alloy ref Appx E NAS677 8 Packing Preformed 85SDSCC D 0007 29 85SDSCC D 0007 10 MS28772 6 Packing Preformed 205 060 613 3 Float Switch N pep P OO F OO O OO O PE HH KR 85SDSCC D 0007 117 Bracket Mount Change 2 C 15 SECTION TM 55 1560 307 13 amp P ITEM SMR PART NO CODE CAGEC NUMBER DESCRIPTION AND USABLE ON CODES UOC QTY PAFZZ 96906 XAOZZ 81349 PAOZZ 88044 590298 2 85SDSCC D 0007 184 85SDSCC D 0007 182 85SDSCC D 0007 197 85SDSCC D 0007 196 M83796 1G200E AN833 6 MS24392 6 85SDSCC D 0007 124
133. tem 1 Appx D Carbon Dioxide item 2 Appx D or filtered clean shop air g Put the open end of the hose into the tank and secure in place h Purge tank for 2 hours at 30 psi i Turn off inert gas supply Reinstall access cover plate and filler cap and allow tank to set for 3 hours j Test fuel tank with a combustible gas indicator for presence of fuel vapor If an unsafe condition exists repeat purging k Preserve fuel tank by coating all interior surfaces with lubricating oil item 12 ox DJ MIL L 6081 grade 1010 Attach tag to filler information printed on it cap with the following 3 38 TM 55 1560 307 13 amp P THIS FUEL TANK HAS BEEN PURGED ACCORDANCE WITH TM 55 1560 307 13 amp P AND IS GAS FREE REMOVE THIS TAG UPON FILLING TANK WITH FUEL Date Signature A 1 A 2 A 3 A 4 TM 55 1560 307 13 amp APPENDIX A REFERENCES Dictionaries of Terms and Abbreviations AR 310 25 Dictionary of United States Army Terms AR 310 50 Authorized Abbreviations and Brevity Codes Publication Index DA 25 30 Consolidated Index of Army Publications and Blank Forms Logistics and Storage TM 473 200 1 Storage and Materials Handling Maintenance of Supplies and Equipment AR 750 1 Army Material Maintenance Concepts and Policies TM 43 0139 Painting Operations Instructions for Fi
134. that the tank cam lever dump valve is closed TM 55 1560 307 13 amp FUELING VEHICLE GROUNDED E GROUND ING WIRE a KOVE TA GROUNDING POINT 3 FUEL FILLER 4 FUEL HOSE AND NOZZLE 21 GROUND WIRE 2 GROUND RECEPTACLE Figure 3 1 Gravity Refueling ERFS Tanks 3 12 4 Insert hose nozzle 4 into filler port Fill tank to proper level NOTE e No aircraft electrical power required to fuel ERFS tanks Fill tanks to 580 gallons and check fuel quantity level indicators Refer to Table 3 1 fuel quantity gallons and pounds decals 5 Remove nozzle 4 from filler port 6 Install filler port cap 3 and secure 7 Disconnect ground lead 1 from tank receptacle 2 TM 55 1560 307 13 amp P WARNING e Observe all cautions and warnings posted on tanks when refueling the ERFS Minimum personnel will be present during refueling operations Ensure ERFS and aircraft vents and cargo and troop doors are open before refueling starts Adequate fire fighting equipment will be readily available per unit SOP FUELING DEFUELING When refueling ERFS or operating a forward area refueling system FARE the vehicle used to service or is being serviced will be parked a minimum of 20 feet from the helicopter e Before refueling and defueling ERFS the fuel truck must be grounded to ground and aircraft During defueling operations and or fare operations
135. the act of isolating a fault within a system or unit under test UUT TM 55 1560 307 13 amp P B 4 FUNCTIONAL GROUPS Section Il Columns 1 and 2 The functional group shown Section TI under columns 1 and J 2 identify maintenance significant components assemblies and subassemblies with next higher assembly B 5 MAINTENANCE FUNCTION Column 3 Column 3 lists the functions to be performed on the items listed in column 2 B 6 MAINTENANCE CATEGORIES AND WORK TIMES Section Column 4 maintenance categories levels AVUM AVIM and DEPOT are listed on the Maintenance Allocation Chart with individual columns that include the work times for maintenance functions at each maintenance level Work time presentations such as 0 1 indicate the average time it requires a maintenance level to perform a specified maintenance function If a work time has not been established the columnar presentation shall indicate Maintenance levels higher than the level of maintenance indicated are authorized to perform the indicated function B 7 TOOLS AND TEST EQUIPMENT Section Column 5 and Section tool sets not individual tools special tools test and support equipment required to perform maintenance functions are listed alphabetically irj Section with a reference number to permit crossreferencing to column 5 in the MAC In addition the maintenance category authorized to use the device is list
136. ting oil item De help reduce the flash point of the empty fuel tank 4 Remove residual fuel in tank Flush the bottom of tank thoroughly with the oil 5 Close dump valve on tank after it is drained and fill with lubricating oil item 12 Appx D Allow oil to remain in fuel cell for 24 hours 6 Drain lubricating oil and let tank stand for 2 to 3 hours and then test with a combustible gas indicator for presence of fuel vapors If an unsafe condition exists reflush tank with fresh oil until a safe reading is obtained 7 Attach tag to the fuel filler cap with information stating that the tank has been preserved with oil item 12 Appx D and that no flushing is required when depreserving tank NOTE In order to allow tank to breathe when stored do not secure vent fitting caps tightly 8 Apply corrosion preventive compound item 4 Appx D to metal fittings and exposed bare metal areas 9 Remove tank from aircraft and store in an approved tank storage site 10 11 secured Install vent dust cap and tank opening cap Ensure fuel filler port caps are installed and 12 Ensure fuel quantity sticks are down locked and secured This prevents water from entering storage tube 3 26 STORAGE a The ERFS tanks and components should be stored outside in a secure location The tank and storage con tainer should be grounded due to con taining fuel vapors in a residual form In
137. tration figure and item number of the item you are looking for 2 Second Turn to 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 ABBREVIATIONS Abbreviations must be applicable to specific RPSTL and not listed in MIL STD 12 Abbreviations Explanation cd or zn pltd cadmium or zinc plated MOD Model opng opening NIIN National Item Identification Number consists of the last 9 digits of the NSN RPSTL Repair Parts and Special Tools List TM 55 1560 307 13 amp ERS TANK ASSY SEE VIEW MANIFOLD COUPLINGS AND ADAPTORS CONTROL PANEL ASSY SUCTION AND PUMPING SYSTEM Figure C 1 Extended Range Fuel System C 8 TM 55 1560 307 13 amp Figure C 2 Extended Range Fuel System Sheet 1 of 2 TM 55 1560 307 13 amp Figure C 2 Extended Range Fuel system Sheet 2 of 2 C 10 SECTION TM 55 1560 307 13 amp P ITEM SMR PART NO CODE CAGEC NUMBER DESCRIPTION AND USABLE ON CODES UOC QTY Q N 85SDSCC D 0007 115 MS28741 24D 0160 MS24399D28 AE86844Z AE82111R AE706285 6 AE706285 3 AE706285 1 114PS491 2 950234 16D 2300 85SDSCC D 0007 187 85SDSCC D 0007 113 390A 16D 0720 85SDSCC D 0007 99 85SDSCC D 0007 192 85SDSCC D 0007 112 85SDSCC D 0007 114 AE82568R 000 950192 16D 0960 180 950248 16D 0360 AE706285 5 B D 10000R 0 234 HH 24 SP42
138. ts STRAP QTY 5 000 Lb 38 10 000 Lb 8 46 5 000 Lb 28 10 000 Lb 6 34 5 000 Lb 20 10 000 Lb 4 MD Ai j TANK 5 10 5 10K 5 000 Lb 16 RET GE 1 18 10 000 Lb Strap 5 000 Lb Strap 5 000 Lb Strap attaches to top T Take Up Fitting e Looped Strap Change 2 17 TM 55 1560 307 13 amp STA 410 0 F 28 5 4 164 200 244 268 5 T 293 313 10 000 Lb Strap 5 000 Lb Strap 333 eo pe 5 000 Lb Strap attaches to top 353 F Take Up Fitting Looped Strap 373 Figure 2 13 One Tank of Four with Pallet 2 18 TM 55 1560 307 13 amp STA 204 410 0 28 5 224 244 260 273 293 313 VIEW 333 353 373 377 5 10 000 Lb Strap eT 222222 5 000 Lb Strap 5 000 Lb Strap uas attaches to top T T Take Up Fitting Looped Strap Figure 2 14 Two Tanks of Four with Pallets 2 19 TM 55 1560 307 13 amp P 10 0 28 5 STA 293 313 320 333 373 382 353 373 382 402 422 10 000 Lb Strap 442 _____ 5 000 Lb Strap 5 000 Lb Strap attaches to top 462 T F Take Up Fitting e Looped Strap Figure 2 15 Three Tanks of Four with Pallets 2 20 TM 55 1560 307 13 amp STA m 1
139. ufacturer individual firm 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 C 5 SPECIAL INFORMATION subparagraphs as applicable Use the following a USABLE ON CODE The usable on code appears in the lower left corner of the Description column heading Usable on codes are shown as in the Description Column justified left on the first line applicable item description nomenclature Uncoded items are applicable to all models Identification of the usable on codes used in the RPSTL are Code Used On PAA Model M114 PAB Model M114A 114 These codes and model numbers are examples only FABRICATION INSTRUCTIONS Bulk materials required to manufacture items are listed in the Bulk Material Functional group of this RPSTL Part numbers for bulk materials are also referenced in the description column of the line item entry for the item to be manufactured fabricated Detailed fabrication instructions for item source codes to be manufactured or fabricated are found in TM 55 1560 307 138 c ASSEMBLY INSTRUCTION Detailed assembly instructions for items source coded to be assembled from component spare repair parts are found in TM 55 1560 307 13 amp P Items that make up the assembly are listed immediately following the
140. ump valve Opens and closes fuel dispensing valve 9 Assembly Used to secure tank to cargo floor 2 27 TM 55 1560 307 13 amp Si n LS E Figure 2 22 Controls and Indicators CONTROL OR INDICATOR FUNCTION Electrical Control Houses electrical operation switches breakers and pumps Panel ECP Pump Override Switch malfunction Activates or shuts pumps with switch on on or 3 Pump Switches 4 each off position FR Controls low levet lights pump switches and Circuit Breakers 6 each Tights and override switch 5 Low Level Warning Light Iliuminates when fuel quantity is low 6 Pumps 4 each Transfer fuel from 600 gallon tanks Shuts off pumps automatically when fuel pressure 7 Electro Optical is below 1 5 pounds Fuel Inlet Coupling Admits fuel into system 9 Fuel Outlet Coupling Discharges fuel to aircraft tanks Table 2 5 Controls or Indicators Function 2 28 f Fuel low level light indicators 3 Check to test operation press and test the four lights Low level light will illuminate when fuel quantity in each tank is one minute from being empty Figure 2 The override switch g pressure switches Figure 2 23 h System circuit breakers 5 will trip if indicator lights pumps or override switch malfunctions All circuit breakers must be pushed in prior to system
141. up subfunctional group or an assembly A V appearing in this column in lieu of a quantity indicates 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 Item Identification Number NIIN sequence The NIIN consists of the last nine digits NSN of the NSN i 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 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 Il and Section lll 3 ITEM Column The item number identifies the item associated with the figure listed in the adjacent FIG column This item is also identified by the NSN listed on the same line b PART NUMBER INDEX Part numbers in this index are listed by part number in ascending alphanumeric sequence i e vertical arrangement of letter and number combination which places the first letter or digit of each group in order A through Z followed by the numbers 0 through 9 and each following letter or digit in like order 1 CAGE Column The Commercial and Government Entity CAGE is a 5 digit numeric code used to identify the manufacturer distributor or Govern
142. using the CAGE and part number given XC Installation drawing diagram instruction sheet field service drawing that is identified by manufacturer s part number TM 55 1560 307 13 amp Source Maintenance Recoverability Code Code Code XX 1 two XX X positions How you get an item 3d position 4th position Who determined disposition action on an unserviceable Who can install Who can do the item replace or use complete the item Repair see note on the item Complete Repair Maintenance capacity capability and authority to perform all corrective maintenance tasks of the Repair function in a use user environment in order to restore serviceability to a failed item Code MO Made at org AVUM Level MF Made at DS AVIM Level MH Made at GS Level ML Made at Spe cialized Repair Act SRA MD Made at Depot Explanation Stocked items use the applicable NSN to request requisition items with these source codes They are authorized to the category indicated by the code entered in the 3rd position of the SMR code Items coded PC are subject to deterioration Items with these codes are not to be requested re quisitioned individually They are part of a kit which is authorized to the maintenance category in dicated in the 3rd position of the SMR code The complete kit must be requisitioned and applied Explanation Items with these codes are not to be request
143. ves and goggles e Drain fuel tank Do not allow tank to remain empty overnight after fuel is drained a Electrical Harnesses Tiedown Straps and Vent Lines 1 Remove electrical wire harness and store inside storage container provided for system components 2 Remove tiedown straps and roll up and store inside storage container 3 b Fuel Management Control Panel FMCP 1 2 Empty residual fuel from by opening both pump inlet and outlet manifold lines Remove as much fuel as possible 3 4 Wipe up any fuel that may have spilled on or inside the FMCP and secure Remove vent lines from tanks and store Remove FMCP from 600 gallon tank Install pump inlet and outlet dust covers 3 36 5 Install FMCP inside storage container using quick release pins C Fuel Manifold Transfer Lines 1 aircraft 2 Open and drain residual fuel from each line tee and elbow fittings into an approved fuel storage container This is done to prevent over expansion of fuel lines due to normal heating cooling which will result in damage to hoses during storage 3 Place dust caps on each line tee and elbow after draining residual fuel and store inside storage container Remove all fuel manifold transfer lines from d 600 Gallon Tank 1 Defuel tank into aircraft s main tank or into defueling truck as required Refer ta paragraph 3 14 2 3 Pour approximately 5 gallons of lubrica
144. 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 This position will contain one of the following maintenance codes Code Application Explanation O Organizational or aviation unit is the lowest level that can do complete repair of the item F Direct support or aviation intermediate is the lowest level that can do complete repair of the item H General support is the lowest level that can do complete repair of the item L Specialized repair activity designate the specialized repair activity is the lowest level that can do complete repair of the item D Depot is the lowest level that can do complete repair of the item Z Nonreparable No repair is authorized B 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 Recoverability Code Recoverability codes are assigned to items to indicate the disposition action on unserviceable items The recoverability code is entered in the fifth position of the SMR Code as follows Recoverability Application Explanation Code H Reparable item When uneconomically reparable condemn and dispose of the item at the general support level TM 55

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