35-22-02 Rev 2.pdf

B/E Aerospace, Inc. Commercial Aircraft Products Group 10800 Pflumm Road Lenexa, KS 66215 TEL: 913-338-9800 FAX: 913-469-4032 CAGE: 16827

35-22-02 2006/06/26

OXYGEN CYLINDER ASSEMBLY

PART NUMBER 176200 SERIES 176219 SERIES 176250 SERIES

COMPONENT MAINTENANCE MANUAL WITH

ILLUSTRATED PARTS LIST

B/E AEROSPACE COMPONENT MAINTENANCE MANUAL

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HIGHLIGHTS

TO: HOLDERS OF THE OXYGEN CYLINDER ASSEMBLY, PART NUMBERS 176200 SERIES, 176219 SERIES AND 176250 SERIES COMPONENT MAINTENANCE MANUAL, ATA NO. 35-22-02.

REVISION NO. 2 DATED 2006/06/26

TO: HOLDERS OF THE OXYGEN CYLINDER ASSEMBLY, PART NUMBER 176226 SERIES. INFORMATION ABOUT THE PART NUMBER 176226 SERIES HAS BEEN REMOVED AND PLACED IN A SEPARATE COMPONENT MAINTENANCE MANUAL, ATA NO. 35-22-18.

The main changes to the Component Maintenance Manual ATA No. 35-22-02 are listed below. Please destroy the affected manual and enter the appropriate Date Inserted on the RECORD OF REVISIONS Section of this revised copy.

MAIN CHANGES

1. Revised all front matter to describe this revision. 2. Revision bars have been placed in left page margins and bold-faced R placed in the left margin

of tables to show where information has been changed. 3. Corrected typographical errors throughout CMM. 4. Added a SUBJECT column to the Service Bulletin and the Service Information Letter Lists. 5. Incorporated the Service Information Letter 3500-98-21. Torque value information in Service

Information Letter has been superseded per engineering drawing revision. 6. Revised text throughout manual for parts and assemblies per revised engineering drawings. 7. Revised illustrations throughout manual for parts and assemblies per revised engineering

drawings. 8. Revised CLEANING Section, describing more cleaning materials. 9. Changed torque values and instructions related to torque values on assemblies per revised

engineering drawings. 10. Corrected and changed IPL and Numerical Index for parts and assemblies per revised

engineering drawings. 11. Removed all information about part number series 176226.


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THIS PAGE INTENTIONALLY LEFT BLANK.


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RECORD OF REVISIONS

REV NO. ISSUE DATE DATE INSERTED BY

REV NO. ISSUE DATE DATE INSERTED BY

New 2000/11/01 1 2003/06/27

R 2 2006/06/26


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RECORD OF TEMPORARY REVISIONS

TEMPORARY REV NO. PAGE NUMBER ISSUE DATE INSERT DATE BY DATE REMOVED BY


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SERVICE BULLETIN LIST

SB NUMBER CMM REVISION SUBJECT DATE INCORPORATED

SERVICE INFORMATION LETTER LIST

SIL NUMBER CMM REVISION SUBJECT DATE INCORPORATED

3500-98-21 2 Torque Value for Main Nut 2006/06/26


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LIST OF EFFECTIVE PAGES

SECTION TITLE PAGE DATE R Title 1 2006/06/26

R Highlights 1 2006/06/26 R

2 Blank

R Record of Revisions 1 2006/06/26 R

2 Blank

R Record of 1 2006/06/26 R Temporary Revisions 2 Blank

R Service Bulletin/ Service Information 1 2006/06/26

R Letter List 2 Blank

R List of 1 2006/06/26 R Effective Pages 2 Blank

R Table of 1 2006/06/26 R Contents 2 Blank

R Introduction 1 2006/06/26 R

2 Blank

R Description 1 2006/06/26 R and Operation 2 2006/06/26 R

3 2006/06/26 R

4 2006/06/26

R Testing and 1001 2006/06/26 R Fault Isolation 1002 2006/06/26 R

1003 2006/06/26 R

1004 Blank

R Disassembly 3001 2006/06/26 R

3002 Blank R

R Cleaning 4001 2006/06/26 R

4002 2006/06/26

R Check 5001 2006/06/26 R

5002 2006/06/26

R Repair 6001 2006/06/26 R

6002 2006/06/26

R Assembly (including 7001 2006/06/26 R Storage) 7002 2006/06/26 R

7003 2006/06/26 R

7004 Blank

SECTION TITLE PAGE DATE R Fits and 8001 2006/06/26 R Clearances 8002 Blank

R Special Tools, 9001 2006/06/26 R Fixtures and 9002 Blank R Equipment

R Illustrated Parts List 10001 2006/06/26 R

10002 2006/06/26 R

10003 2006/06/26 R

10004 2006/06/26 R

10005 2006/06/26 R

10006 2006/06/26 R

10007 2006/06/26 R

10008 2006/06/26 R

10009 2006/06/26 R

10010 2006/06/26


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TABLE OF CONTENTS

SUBJECT PAGE

Description and Operation ................................................................................................................................. 1 Testing and Fault Isolation........................................................................................................................... 1001 Schematic and Wiring Diagrams ................................................................................................................... N/A Disassembly................................................................................................................................................. 3001 Cleaning....................................................................................................................................................... 4001 Check............................................................................................................................................................5001 Repair ...........................................................................................................................................................6001 Assembly (Including Storage).......................................................................................................................7001 Fits and Clearances......................................................................................................................................8001 Special Tools, Fixtures and Equipment ........................................................................................................9001 Illustrated Parts List ................................................................................................................................... 10001


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INTRODUCTION

This manual has been prepared to fulfill the requirements of ATA 100/2200 for Component Maintenance Manuals.

All procedures established in this manual have been performed and verified acceptable by trained personnel at B/E Aerospace, Inc. A competent shop mechanic who is unfamiliar with these units should, with a minimum amount of effort and tools, be able to isolate the problems of a nonfunctional unit and restore it to service.

Procedures are provided for the full range of maintenance and include all the work functions that could or may be done to the unit throughout its entire service life.

A competent shop mechanic should use this manual first to test and isolate a faulty component. The mechanic should then go directly to the applicable manual subject to effect a repair in the specific problem area without disturbing other areas.

The following abbreviations may be used in this manual:

ABBREVIATION MEANING ABBREVIATION MEANING

ASSY Assembly SPEC Specification ATA Air Transport

Association lb Pound

C Celsius lbf Pound-force CAGE Commercial and

Government Entity lbm Pound(s) Mass

CGA Compressed Gas Association

LG Long

cm Centimeter LP Low Pressure CMM Component

Maintenance Manual LPM Liter(s) per Minute, Flow

Rate cu ft Cubic Feet MAX. Maximum DIA Diameter MIL Military Standard DISC Disconnect mm Millimeter DOT Department of

Transportation Nm Newton Meter

EFF Effectivity NO. Number F Fahrenheit NTPD Normal Temperature

and Pressure, Dry FIG Figure PN Part Number HP High Pressure psi Pound(s) per Square

Inch IN. Inch psig Pound(s) per Square

Inch, Gauge Pressure IPL Illustrated Parts List QD Quick Disconnect kPag Kilopascal(s), Gauge,

Pressure RF Reference

RH Right-hand V Vendor


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DESCRIPTION AND OPERATION

1. General

A. The cylinder assembly consists of a twist ON/OFF pressure regulator mounted on a composite cylinder (refer to Figure 1). The fittings attached to the regulator provide a charging port, high pressure distribution port, a low pressure service port and a high pressure safety port. The cylinder assembly has a flow rate capacity sufficient to be used as the sole source of oxygen for both the crew and the passenger oxygen systems in an aircraft.

B. The cylinder consists of an aluminum liner fully wrapped with Kevlar fiber. The cylinder has been fully qualified for this application and has been granted DOT exemption DOT-E8162-1850. Hydrostatic testing is required every three years. Prior hydrostatic test dates may have been stamped in the metal of the cylinder neck or on a decal placed close to the neck and covered with a layer of clear epoxy paint.

Figure 1 (Sheet 1 of 2) Cylinder Assembly


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Figure 1 (Sheet 2 of 2) Cylinder Assembly


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2. Operation (refer to IPL Figure 1)

A. The cylinder assembly is charged through the charge valve (130). The cylinder pressure can be determined at any time by viewing the pressure gauge mounted on the regulator or by an external pressure gauge source.

B. The regulator (100) can be turned ON or OFF by rotating the control knob located on top of the regulator. With the knob in the ON position, the regulator provides downstream pressure of 414 to 552 kPag (60 to 80 psig) for flow rates up to 300 LPM. With the control knob in the OFF position, the regulator functions as a shutoff valve, confining high pressure to the cylinder. When the knob is turned to the OFF position, the downstream regulated line pressure is vented through the low pressure relief valve inside the regulator. The low pressure relief valve also vents downstream line pressure when it exceeds 620 to 690 kPag (90 to 100 psig) with the regulator turned ON.

NOTE: Refer to CMM 35-22-10 for regulator repair.

3. Leading Particulars

A. Leading Particulars for the cylinder assembly are listed in Table 1 and Table 2.

Table 1 Leading Particulars

ITEM CHARACTERISTIC

Cylinder Charge Pressure 12,755 kPag at 21C (1850 psig at 70F) Rupture Disc Burst Pressure 17,060 to 19,130 kPag (2575 to 2775 psig) at

21.1C (70F) Cylinder Rating DOT Exemption DOT-E8162-1850

Cylinder Thread 0.750-16 UNF -2B

Regulator Inlet Pressure 200 to 1850 psig

Regulator Outlet Pressure 60 to 80 psig

Regulator Flow Capacity 300 LPM-NTPD (minimum) Ambient Temperature Range -53.89 to 71.1C (-65 to 160F) Operating Temperature Range -40 to 60C (-40 to 140F) Operating Altitude Sea Level to 45,000 feet

Handle Torque Reqd to close 3-9 in-lb at 1850 psig at 70F

Regulator Ports and Threads

Low Pressure-1/8 NPT High Pressure-1/8 NPT Safety-0.625-18 UNF-2B

Charge Valve Thread 0.375-24 UNF-3A

High Pressure Fitting Assembly (Capillary) 0.562-18 UNF-2A


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Leading Particulars Table 2

Part No Assy Length (max)

Assy Diameter (max)

Mass (Fully Charged)

(max) Cylinder Volume

(max)

176200-22 62.18 cm (24.48 in) 13.00 cm (5.10 in) 3.56 kg (7.85 lb) 650 l (23.0 cu ft) 176200-40 62.96 cm (24.79 in) 17.00 cm (6.70 in) 5.88 kg (12.96 lb) 1125 l (39.8 cu ft) 176200-50 75.13 cm (29.58 in) 17.00 cm (6.70 in) 6.37 kg (14.04 lb) 1435 l (50.6 cu ft) 176200-77 86.82 cm (34.18 in) 19.00 cm (7.50 in) 9.67 kg (21.30 lb) 2205 l (77.9 cu ft) 176200-115 91.90 cm (36.18 in) 22.60 cm (8.90 in) 13.72 kg (30.23 lb) 3310 l (116.9 cu ft) 176219-50 75.43 cm (29.70 in) 17.00 cm (6.70 in) 6.41 kg (14.11 lb) 1435 l (50.6 cu ft) 176219-77 87.12 cm (34.30 in) 19.00 cm (7.50 in) 9.70 kg (21.37 lb) 2205 l (77.9 cu ft) 176219-115 92.20 cm (36.30 in) 22.90 cm (9.00 in) 13.76 kg (30.30 lb) 3310 l (116.9 cu ft) 176250-22 62.50 cm (24.60 in) 13.00 cm (5.10 in) 3.56 kg (7.86 lb) 650 l (23.0 cu ft) 176250-40 64.00 cm (25.20 in) 17.00 cm (6.70 in) 5.87 kg (13.00 lb) 1125 l (39.8 cu ft) 176250-50 75.40 cm (29.70 in) 17.00 cm (6.70 in) 6.37 kg (14.04 lb) 1435 l (50.6 cu ft) 176250-77 87.10 cm (34.29 in) 19.10 cm (7.50 in) 9.66 kg (21.30 lb) 2205 l (77.9 cu ft) 176250-115 92.20 cm (36.30 in) 22.60 cm (9.00 in) 13.72 kg (30.23 lb) 3310 l (116.9 cu ft)


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TESTING AND FAULT ISOLATION

1. General

A. The materials required for testing the cylinder assembly are listed in Table 1001.

NOTE: Equivalent substitutes may be used for listed items.

Table 1001 Test Equipment and Materials

NOMENCLATURE PART/SPEC NO. SOURCE (CAGE) Leak Detector Fluid MIL-L-25567, Type 1 Commercially Available

Clear Epoxy Paint Stock No. 14200 Devcon Corp. (V16059)

Any of the following gases can be used for testing: (1) Oxygen per MIL-O-27210, Type 1 (2) Water-pumped nitrogen per MIL-N-6011 (3) Water-pumped air equal in dryness to MIL-N-6011 specifications

2. Procedures

A. Cylinder Assembly Test (refer to IPL Fig 1)

(1) Charge cylinder assembly (1) to 12,755 kPag (1850 psig). Refer to ASSEMBLY Section for charging procedures.

(2) Check the neck area and all fitting connections for leaks with leak detector fluid (refer to Table 1001).

NOTE: If leakage is detected, do not attempt to tighten any high pressure connections while the cylinder (80) is charged. Empty the cylinder to zero pressure before proceeding with necessary repairs. Refer to DISASSEMBLY Section for instructions on emptying the cylinder.

B. Cylinder Test (refer to IPL Fig 1) WARNING: IF LEAKAGE IS DETECTED, DO NOT ATTEMPT TO TIGHTEN ANY HIGH-

PRESSURE CONNECTIONS WHILE THE OXYGEN CYLINDER ASSEMBLY (1) IS CHARGED. COMPLETELY DISCHARGE THE OXYGEN CYLINDER ASSEMBLY (1) TO ZERO PRESSURE BEFORE PROCEEDING WITH ANY REPAIRS. REFER TO THE DISASSEMBLY SECTION IN THIS MANUAL FOR INSTRUCTIONS ABOUT EMPTYING THE OXYGEN CYLINDER ASSEMBLY (1).

(1) Inspect the composite cylinder (80) using the procedure outlined in CHECK.

(2) Determine the date of the last hydrostatic test. If the composite cylinder (80) does not need a hydrostatic test, proceed to paragraph C, Fittings Test.


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NOTE: To comply with Department of Transportation Regulations, Title 49, DOT-E8162-1850, oxygen cylinders must be hydrostatically tested every three years and are no longer authorized after 15 years.

NOTE: Inspection and requalification of DOT exemption cylinders must be performed by a facility holding a current retester's identification number issued by the Research and Special Programs Administration of the DOT. The retest facility must also comply with other administrative DOT requirements in order to retest exemption cylinders.

NOTE: The hydrostatic test procedure must meet the requirements of the Code of Federal Regulations, Title 49 and DOT-E8162-1850.

(3) Inspect the cylinder (80) using the procedure outlined in the CHECK Section.

C. Fittings Test (refer to IPL Fig 1) WARNING: TESTING PARTS AND ASSEMBLIES WITH HIGH PRESSURE OXYGEN CAN BE

HAZARDOUS. VERIFY ALL FITTINGS ARE TIGHTLY ATTACHED BEFORE APPLYING HIGH PRESSURE. ALL PARTS, INCLUDING NEW PARTS, MUST BE CLEAN. GIVE SPECIAL ATTENTION TO HYDROCARBON RESIDUES BECAUSE THEY CAN IGNITE EASILY IN THE PRESENCE OF HIGH PRESSURE GASEOUS OXYGEN.

NOTE: These tests are more easily performed if the fittings are removed from the regulator assembly (100).

(1) Verify the function of the charge valve assembly (200).

(a) Remove the cap from the charge valve (200) and attach the normally capped end to a low pressure (700 kPag/100 psig) source. Slowly increase the supply pressure. The charge valve should open at a pressure of 552 kPag (80 psig) or less.

(b) Recap the charge valve (200). Attach a high pressure line to the pipe thread. Apply a pressure of 12,755 kPag (1850 psig). Use leak detector fluid to check the capped end for leakage. Replace applicable cap assembly (240) or the valve core (230) if leakage is observed (see REPAIR Section).

(2) Verify the function of the connector assembly (110).

(a) Attach a low pressure (700 kPag/100 psig) source to the female end of the connector assembly (110). Slowly increase the pressure while monitoring the flow rate at the pipe thread end. The connector assembly (110) should open at a pressure of 552 kPag (80 psig) or less. Detach the low pressure source from the fitting.

(b) Attach a high pressure line to the pipe thread end of the body (150). Apply a pressure of 12,755 kPag (1850 psig). Use leak detector fluid to check the open end for leakage. If leakage is observed, replace the valve core (140) (see REPAIR Section).

(3) Verify the safety fitting assembly (260) is leak free. Apply 12,755 kPag (1850 psig) to the regulator (100) inlet and apply leak detector fluid around the safety fitting thread. Draw a film across the threaded end. Replace the unit if leakage is observed or if the threaded end is damaged.


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3. Fault Isolation (refer to IPL Fig 1)

A. Table 1002 lists the probable causes for faults observed during usage.

Table 1002 Fault Isolation

FAULT PROBABLE CAUSE REMEDY

Cylinder (80) fails hydrostatic test

Prior over pressurization Replace cylinder.

Outlet pressure increases at zero flow condition

Main seat and/or O-ring of regulator (100) leakage

See CMM 35-22-10 for replacement.

Leakage through top of regulator (100) when regulator is ON

Relief valve malfunction or O-ring of regulator (100) leakage


Leakage when regulator (100) is OFF

Main seat or O ring of regulator (100) leakage


Outlet pressure out of range Adjust nut of regulator (100) out of position

See CMM 35-22-10 for adjustment.

Leakage at main nut of regulator

Main nut of regulator (100) not secured or damaged diaphragm

See CMM 35-22-10 for replacement procedures.


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DISASSEMBLY

1. General

A. Cylinder and Fittings Disassembly (refer to IPL Figure 1 and CMM 35-22-10) WARNING: THE OXYGEN CYLINDER ASSEMBLY MUST BE COMPLETELY DISCHARGED

PRIOR TO REMOVAL OF ANY COMPONENTS. DO NOT VENT THE CYLINDER PRESSURE IN AN AREA WHERE THERE IS ANY HYDRAULIC FLUID, FUEL, ELECTRICAL EQUIPMENT, OR CONTAMINANTS. VENT THE CYLINDER IN A WELL VENTILATED AREA.

(1) Do not remove cylinder nameplate. Contact B/E Aerospace if nameplate is missing or if text is not readable.

(2) Attach to the low pressure outlet of the regulator (100) a needle valve or other flow restriction device that can limit the regulator flow rate to 200 LPM during bleed down.

(3) Turn the regulator knob to the ON position to bleed down the cylinder assembly (1).

(4) Continue to draw flow from the regulator (100) until no flow can be heard or felt at the flow restricter. Rotate knob to the OFF position.

WARNING: DO NOT DISASSEMBLE THE CYLINDER ASSEMBLY IN THE PRESENCE OF HYDROCARBONS SUCH AS FUELS OR OILS. CONDUCT DISASSEMBLY, REPAIR, AND OVERHAUL IN THE CLEANEST AREA POSSIBLE. USE ONLY CLEAN TOOLS FREE OF ALL OILS AND CONTAMINANTS.

(5) Use a wrench or torque machine to remove the regulator (100) from the cylinder (80).

(6) Remove and discard the O-ring (90) from around the regulator (100) threads. (7) Do not remove the charge valve assembly (200), connector assembly (110), or safety fitting

assembly (260) from the regulator (100) unless parts must be replaced, cleaned, or tested.

NOTE: Do not further disassemble the above items at this time. See REPAIR Section, for replacement parts and instructions for the fittings.

(8) Do not remove the plug (190) from the regulator (100) unless it needs to be replaced.


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CLEANING

1. General

A. The materials required for cleaning all cylinder assembly parts are listed in Table 4001.


Table 4001 Cleaning Materials

NOMENCLATURE PART OR SPEC NO. SOURCE (CAGE) Cleaner Correct cleaner for oxygen

service per CGA G-4.1 Cleaning Equipment for Oxygen Service (www.cganet.com), ASTM G-127-95 Standard Guide for the Selection of Cleaning Agents for Oxygen Systems (American Society for Testing (610) 832-9585)

Commercially Available Cleaner Correct for Oxygen Service

Navy Oxygen Cleaner (NOC)

(ASTM G72) (Mil-Std-13300) Octagon Process, Inc.

Degreaser Isopropyl Alcohol Commercially Available

Air Dryer Model SCD-8 Galiso Corp. (V26220) Nitrogen DOT Specification Class 1,

AA59503 Commercially Available

Inspection Light None Commercially Available

2. Cleaning Procedures

A. Cylinder Assembly (refer to IPL Figure 1) WARNING: ALL PARTS, INCLUDING NEW PARTS, MUST BE CLEANED BEFORE

ASSEMBLY. GIVE SPECIAL ATTENTION TO HYDROCARBON RESIDUES BECAUSE THEY CAN IGNITE EASILY IN THE PRESENCE OF HIGH PRESSURE, GASEOUS OXYGEN. USE ONLY FRESH CLEANING AGENTS BECAUSE CONTAMINATED CLEANING AGENTS CAN LEAVE DEPOSITS OF FOREIGN MATERIALS AFTER EVAPORATING.

(1) The composite cylinder (80) must be inspected (refer to CHECK Section) and hydrostatically tested (if required) before it is cleaned.

CAUTION: THE MATERIALS USED TO CLEAN CYLINDERS AND REGULATORS CAN BE HARMFUL TO THE EYES AND SKIN. WEAR EYE PROTECTION AND GLOVES WHEN CLEANING CYLINDER ASSEMBLY PARTS.

(2) Clean the composite cylinder (80) using the following procedure:


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(a) Prepare a cleaning solution (refer to Table 4001) (1 part cleaner to 4 parts water). Refer to the manufacturers label for mixing instructions for the Navy Oxygen Cleaner.

(b) Fill the composite cylinder (80) 1/3 to 1/2 full with the cleaning solution, and agitate for 30 seconds.

(c) Pour out the solution, and then flush the composite cylinder (80) with hot (65C, 150F), flowing water.

(d) Dry the composite cylinder (80) with a Galiso Model SCD-8 air dryer, or equivalent, at 65C (150F) for a maximum of three minutes or until the interior is completely dry.

(e) Using an inspection light (refer to Table 4001), inspect the interior of the composite cylinder (80) for corrosion or cracks, and verify that all contaminants have been removed.

(f) Clean the exterior surface of the composite cylinder (80) by wiping it with a clean, lint-free cloth that has been moistened with a solution of cleaner or NOC. Rinse the composite cylinder (80) by wiping it with a cloth that is moistened with water only.

(g) Touch-up paint may be used to cover minor scrapes or damage on the composite cylinders (80) exterior surface (see CHECK Section).

B. Regulator and Fittings Cleaning (refer to IPL Figure 1)

(1) The oxygen pressure regulator (110) must be inspected (refer to CHECK Section) and disassembled before it is cleaned.

(2) Clean all metal regulator parts with clean isopropyl alcohol. Blow the parts dry with dry, filtered, oil-free air. Make sure parts are fully dry.

(3) Clean the plug (190), safety fitting assembly (260) parts, and fitting (180) using clean isopropyl alcohol. Blow the parts dry with dry, filtered, oil-free air. Make sure parts are fully dry.

(4) Clean the external surfaces of the connector (110), fitting (180), charge valve (200), and oxygen pressure regulator (100) with clean isopropyl alcohol. Blow the parts dry with dry, filtered, oil-free air. Make sure parts are fully dry.

(5) Clean O-rings (90, 160) using clean isopropyl alcohol. Blow the O-rings (90, 160) dry with dry, filtered, oil-free air. Make sure parts are fully dry.


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CHECK

1. General

A. The equipment and materials required for checking the cylinder assembly are listed in Table 5001.

Table 5001 Check Equipment and Materials

NOMENCLATURE PART/SPEC NO. SOURCE (CAGE) Depth Gauge None Commercially Available

Inspection Light None Commercially Available

2. Check Procedures

A. Cylinder Check (refer to IPL Fig 1)

(1) Check the cylinder (80) exterior for abrasions, dents, chipped paint, de-lamination, and cuts or scratches. Any cuts and scratches that are deeper than .127 mm (0.005 inch) as measured with the depth gauge need further evaluation. Refer to REPAIR Section for additional information.

(2) Check the exterior surface for evidence of fire damage and structural damage affecting the cylinder envelope shape. Refer to REPAIR Section for disposition of damaged cylinders (80).

(3) Determine the most recent hydrostatic test date. The date may be stamped in the metal of the cylinder (80) neck, or it may be on a decal attached to the composite surface in the area of the neck. The cylinder must be hydrostatically tested every three years for DOT-E8162-1850 composite type cylinders.

(4) Inspect the neck, threads, and O-ring gland sealing surface for nicks, cracks, cuts, and damage.

(5) Inspect cylinder (80) interior with inspection light for corrosion and damage. Corrosion will appear as a roughened and discolored area with a white deposit sometimes associated with pitting. If corrosion is present, return the cylinder to the manufacturer for removal of corrosion. Cylinders with visible dents on the interior must be condemned.

B. Regulator Check (refer to IPL Fig 1)

(1) Inspect the pressure regulator body threads for damage and contamination.

(2) Verify the regulator knob is intact and operating properly. Turn the knob to the ON and OFF positions and verify the detent poppet is seating correctly. The detent poppet will make a "click" sound as it seats.

(3) If the regulator assembly satisfies the functional requirements of the TESTING AND FAULT ISOLATION Section, it is not necessary to disassemble the regulator for overhaul. If the regulator must be disassembled for repair or overhaul (refer to CMM 35-22-10).


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C. Fittings Check (refer to IPL Fig 1)

(1) Examine the fitting (180) and the plug (190) for damage to the threads and to the coupling inlet.

(2) Check the charge valve (200) for damaged threads. Verify the cap retention cord is intact and unfrayed. Examine the sealing surfaces on the connector assembly (110) and cap plug (120) for scratches and other damage.


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REPAIR

1. General

A. The equipment and materials required for repair of the cylinder assembly are listed in Table 6001. Equivalent substitutes may be used for listed items.

Table 6001 Repair Equipment and Materials

NOMENCLATURE PART/SPEC NO. SOURCE (CAGE) Epoxy Coating, Clear Stock No. 14200 Devcon Corp. (V16059) Polyurethane Coating, Green, per Federal Standard 595 Shade 14187

PN 1270432-7 Structural Composites Ind. (V58943)

Tool, Valve Core Removal PN 970530 B/E Aerospace, Inc. (V16827)

2. Repair Procedures

A. Cylinder Repair (refer to IPL Fig 1)

CAUTION: PAINT REMOVAL FOR REPAIR IS NOT RECOMMENDED. VERIFY THE SUITABILITY OF ANY PROPOSED PAINT REMOVAL PROCEDURE WITH THE CYLINDER MANUFACTURER. ABRASIVE OR MECHANICAL PAINT REMOVAL IS PROHIBITED.

NOTE: Most of the damage assessment and repair criteria listed below were obtained from a well illustrated and comprehensive discussion of fiber wrapped composite cylinder inspection and repair procedures presented in a pamphlet offered by the Compressed Gas Association (CGA). The pamphlet is identified with the number CGA C-6.2-1982, and is entitled "Guidelines for Visual Inspection & Requalification of Fiber Reinforced High Pressure Cylinders." It is available from the Compressed Gas Association, Arlington, VA, CAGE 01701.

(1) Cylinder (80) repair is limited to epoxy coating and/or touch-up painting of minor abrasions, chipped paint, and cuts or scratches.

(2) Minor abrasions can be repaired, unless the damage is deep and groups of fibers are exposed. Abrasions with isolated groups of fibers exposed or flat spots with depth less than 0.254 mm (0.010 inch) must be epoxy coated to avoid water entrapment.

(3) Cuts or scratches less than 0.127 mm (0.005 inch) deep and less than 25.4 mm (1.0 inch) long are repairable. For repair, cuts must be coated with a room temperature curing epoxy.

(4) Bruises and delaminations may also be repaired. Fibers that are exposed, cut, and delaminated must be repaired with a room temperature curing epoxy coating.

(5) Every repaired cylinder (80) must pass a hydrostatic test after it is repaired. Cylinders which evidence flaw growth or cut propagation after a hydrostatic test or which fail hydrostatic test, must be condemned.


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(6) Any cylinder (80) with evidence of fire damage or with visible dents on the interior surface cannot be repaired and must be condemned and removed from service.

B. Fittings Repair (refer to IPL Figure 1). (1) Replace a leaking valve core (230) in a charge valve assembly (200) as follows:

(a) Remove the valve core (230) using the valve core removal tool (PN 970530).

(b) Insert a new valve core (230) into the charge valve body (220) and tighten using a torque of 0.34 to 0.45 Nm (3 to 4 in-lbf).

(2) Replace a leaking valve core (140) in a connector fitting assembly (110) as follows:

(a) Remove the valve core (140) using the valve core removal tool (PN 970530). (b) Insert a new valve core (140) into the charge valve body (150) and tighten using a torque

of 0.34 to 0.45 Nm (3 to 4 in-lbf).

(3) To replace parts in a leaking safety fitting assembly (260) remove all parts of the assembly then replace the washer (290A) and rupture disc (300). Reassemble by following the instructions in ASSEMBLY Section.


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ASSEMBLY (INCLUDING STORAGE) 1. General

A. Make sure parts are clean for oxygen service before assembly and complete assemblies are clean after assembly (refer to document SAE ARP 1176, Oxygen System and Component Cleaning and Packaging).

B. This section provides assembly instructions for the component.

2. Assembly Equipment and Materials

The materials required for assembly are listed in Table 7001.


Table 7001 Assembly Equipment and Materials

NOMENCLATURE PART OR SPEC NO. SOURCE (CAGE) Isopropyl Alcohol NA Commercially Available

Thread-seal Tape (1/2 inch) 820561 B/E Aerospace, Inc. (V16827) Leak Check Tool 970631 B/E Aerospace, Inc. (V16827) Leak Detector Fluid MIL-L-25567 Type 1 Commercially Available

Fluorinated Grease DuPont Krytox 240 AZ E. I. du Pont de Nemours and Company, Inc. (V31708)

Glyptal, Red 820773-00 B/E Aerospace, Inc. (V16827) Grease, Halocarbon Series 25-5S 820729 Halocarbon Products, Inc. (V07644)

B/E Aerospace, Inc. (V16827) Lockwire (installed after assembly) Fits holes in fasteners and fittings on the regulator

300900-32 MS20995-C32

B/E Aerospace, Inc. (V16827) Commercially Available

CAUTION: CHECK TO MAKE SURE THERE IS NO THREAD-SEAL TAPE ON THE FIRST TWO THREADS FROM THE OPENING OF A FITTING.

3. Assembly Procedure

A. Fittings Assembly (refer to IPL Fig 1)

(1) If applicable, assemble the safety fitting assembly (260) as follows (refer to IPL Fig 1).

(a) Place the washer (290A), with the larger diameter leading, into the regulator body safety port.

(b) Place the rupture disc (300), with dome side trailing, on top of the washer (290A) in the safety port.


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(c) Hold the safety fitting (270) with the smaller thread down and place the small end of the retainer (280) inside the fitting.

(d) Screw the fitting assembly (260) into the regulator body safety port and torque to the torque value specified in Table 8001.

(e) Apply Teflon tape to the pipe threads of the connector assembly (110), the fitting (180), the plug (190), and the charge valve (210). Screw the fittings into the regulator assembly (100) ports and tighten to the torque values listed in Table 8001.

B. Cylinder Assembly (refer to IPL Fig 1)

(1) Lubricate the O-ring (90) sparingly with Krytox 240AZ and carefully slip it over the regulator (100) threads.

(2) Purge the cylinder (80) with a stream of oxygen to drive out any foreign matter and to purge the cylinder contents with oxygen.

(3) Install the regulator (100) into the neck of the composite cylinder (80) and tighten to the torque listed in Table 8001.

(4) Contact B/E Aerospace if cylinder nameplate is missing or text is not readable. (5) Test the cylinder assembly (1) as specified in TESTING AND FAULT ISOLATION Section.

(6) Attach lockwire as required to prevent movement of calibrated assemblies.

NOTE: Do not cross wires over each another when attaching lockwire from one fitting to another fitting.

NOTE: Do not attach lockwire from any other fitting to the safety fitting (260). Attach lockwire from the safety fitting (260) to the nearest brass fitting.

NOTE: Do not attach lockwire from any fitting to an aluminum fitting.

NOTE: Install lockwire on the main nut of the regulator to prevent the nut from loosening.

(7) Install dust caps on all ports or fittings as required.

(8) Attach lockwire as required to prevent movement of the knob on the regulator (110A, 100B, 100C) and to prevent accidental discharge of the composite cylinder (80A, 80B, 80C, 80D, 80E).

C. Storage (refer to IPL Fig 1)

(1) Verify the knob is in the full OFF position.

(2) Charge the cylinder assembly (1) to a minimum of 1380 kPag (200 psig) with oxygen prior to placing it in storage. Pressure less than 200 psi may allow oxygen to escape over time with new regulators, due to the kel-F seat and poppet not being fully seated.

(3) Wrap the regulator (100) in a polyethylene plastic bag to prevent dust accumulation. Do not use preservative coatings of any type on any part of the cylinder assembly.


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(4) For prolonged storage, wrap the entire cylinder assembly (1) in a polyethylene plastic bag or place it in a cardboard container.

(5) Store the cylinder assembly (1) in a clean, dry location. D. Cylinder Inspection and Charging

(1) Inspection Preparation

(a) Check fittings on cascade, cylinder and outside filler valve for contamination. Clean as necessary to prevent contaminants from entering oxygen system.

(b) Check cylinder service life and hydrostatic test date to insure cylinder is in compliance with DOT standards.

NOTE: Cylinders that do not have a DOT designation cannot be charged.

NOTE: If the cylinder has less than 20 psig pressure, the valve must be removed and the cylinder inspected and cleaned by an authorized FAA approved facility.

(2) Cylinder Charging

NOTE: Use only aviation breathing oxygen, MIL-O-27210.

(a) Check overboard discharge indicator before charging to insure safety fitting has not discharged.

(b) Attach connector from oxygen supply source to cylinder assembly filler valve. WARNING: NEVER OPEN A VALVE SUDDENLY THAT IS CONNECTED TO A HIGH

PRESSURE OXYGEN SOURCE AS ADIABATIC COMPRESSION COULD HAPPEN, RESULTING IN AN OXYGEN FIRE.

(c) Slowly open valve of oxygen supply source. (d) Monitor gauge of oxygen supply source and fill cylinder at a rate no greater than 300 psig

per minute.

(e) Monitor cylinder gas temperature to insure cylinder wall temperature does not exceed 25F above initial cylinder wall temperature during filling.

(f) Overfill cylinder to pressure relative to cylinder wall temperature rise equation of 3.28 psi per degree F.

(g) Allow temperature to stabilize for at least one hour, then check pressure and adjust as necessary to reach service pressure.


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FITS AND CLEARANCES

1. General (refer to IPL Fig 1)

A. Torque values to be used for assembly of the cylinder assembly are listed in Table 8001.

B. First apply minimum torque. If leakage occurs, apply additional torque. Do not exceed maximum torque.

Table 8001 Assembly Torque Values

TORQUE VALUES ITEM

Nm in-lbf

Safety Fitting Assembly (260) 43.4 to 46 384 to 408 (33 1 ft-lbf) Regulator (100) to Cylinder ( 80) 88 to 102 780-900 (65-75 ft-lbf) Plug (190) 6.78 to 16.95 60 to 150 (NPT Thread) Charge Valve Assy (200) 6.78 to 16.95 60 to 150 (NPT Thread) Charge Valve Cap Assy (240) 3.39 to 5.65 30 to 50 Connector Assy (110) 6.78 to 16.95 60 to 150 (NPT Thread) Fitting (180) 6.78 to 16.95 60 to 150 (NPT Thread)


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SPECIAL TOOLS, FIXTURES AND EQUIPMENT

1. General

A. The special tools and fixtures required for maintenance of the oxygen cylinder assembly are listed in Table 9001.


Table 9001 Special Tools and Fixtures

NOMENCLATURE PART/SPEC NO SOURCE (CAGE) Leak Detection Machine Type H-25 Yokogawa of America

(V60336) Air Dryer Model SCD-8 Galiso Corp. (V26220) Valve Core Removal Tool PN 970530 B/E Aerospace, Inc. (V16827)

B. Rough depictions of the special tools manufactured by B/E Aerospace, Inc. are shown in Figure 9001. Most of the illustrations are not at full scale and show only the forms of the tools so they can be readily identified.

Figure 9001 Special Tools

Valve Core Removal Tool PN 970530


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ILLUSTRATED PARTS LIST

1. Introduction

The ILLUSTRATED PARTS LIST is intended for use in provisioning, storing, and issuing replaceable parts for the component, and in identification of new and reclaimed parts.

2. Vendors Parts

Vendors parts used in the unit and which are not altered by B/E Aerospace, Inc are listed in the Detailed Parts List by the vendor's part number, vendor's description of the part, and vendor's code listed in parentheses following the description. Vendors' code symbols used in this publication are taken from the CAGE Cataloging Handbook, and consist of the applicable code symbol preceded by the Letter "V". Following is a numerically arranged list of vendor codes used in this publication.

VENDOR CODE (CAGE) ADDRESS V16059 Devcon Corp

30 Endicott Street Danvers, MA 01923

V16827 B/E Aerospace Inc 10800 Pflumm Road Lenexa, KS 66215

V17875 Eaton Corp 2564 Durham Road PO Box 241 Roxboro, NC 27573

V26220 Galiso Corp. 22 Ponderosa Court Montrose, CO 81401

V58943 Structural Composites Industries 325 Enterprise Place Pomona, CA 91768

V60336 Yokogawa of America 2 Dart Road Newnan, GA 30265

V70292 Sherwood Selpac Corp. 120 Church St. Lockport, NY 14094

V88044 Aeronautical Standards Group Dept. of the Navy and Air Force


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3. Use of the ILLUSTRATED PARTS LIST

A. When the part number is known:

Turn to the Numerical Index and locate the part number. Figure and item number on the illustration where the part appears are listed in the column to the right of the part number. Turn to the illustration and locate the item number. The corresponding item number in the accompanying Detailed Parts List will give part number, description, assembly relationship, quantity required for that particular application, and whether or not the part appears in the illustrations.

B. When the part number is not known:

Look through the figures and identify the part by appearance. Note the figure number and the item number. The corresponding Fig-Item number in the Detailed Parts List shows the part number, description, assembly relationship, effectivity code, and the number of units per assembly.

4. Material Arrangement

A. Numerical Index

The Numerical Index is an alphanumeric listing of all the part numbers in the Detailed Parts List. Each part number is listed together with its corresponding item number, ILLUSTRATED PARTS LIST figure number, and the total required number of units per assembly. The Fig-Item number is composed of two parts. To the left of the dash is the figure number. It is the number of the figure in the ILLUSTRATED PARTS LIST that shows the part. To the right of the dash is the item number. It is the number that identifies a part in a figure.

B. Illustrations

The ILLUSTRATED PARTS LIST illustrations interrelate to the Numerical Index and the Detailed Parts List. The separate illustrations pictorially describe recommended disassembly/assembly sequence and support the DISASSEMBLY and ASSEMBLY Sections as well as the Numerical Index and the Detailed Parts List of this manual.

C. Detailed Parts List

(1) Fig-Item The Detailed Parts List is arranged numerically by item numbers. These are the same item numbers listed in the Numerical Index. In the Detailed Parts List, the figure number portion of the Fig-Item number is listed only once per column. Immediately below a figure number are the item numbers that appear on that figure. A dash in front of an item number means the corresponding part is not shown in that or any other figure. Each item number is listed together with its corresponding part number, nomenclature (description, assembly relationship), effectivity code, and units per assembly.

(2) Part Number

The part number column contains the original manufacturer's part number. When standard parts are used, the standard part number is listed in this column. When B/E Aerospace, Inc. is not the original manufacturer the vendor's part number is shown in the part number column, and the CAGE vendor number and equivalent B/E Aerospace, Inc. part number are given in the nomenclature column.


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(3) Airline part number

This column is left blank for airline internal use.

(4) Nomenclature (a) Indenture System

The indenture system shows the relationship of parts and assemblies to next higher assemblies or installations, as follows:

123456789 Unit (Product which this manual describes) . Detail parts for assembly into the unit . Subassemblies . Attaching parts for subassemblies

. . Detail parts for subassemblies

. . Sub-subassemblies

. . Attaching parts for sub-subassemblies

. . . Detailed parts for sub-subassemblies

(b) Attaching Parts Attaching parts are captioned ATTACHING PARTS and are listed immediately following the parts attached. The *** symbol follows the last item of the attaching parts group.

(c) Vendor Code

Parts manufactured by companies other than B/E Aerospace, Inc. are identified by an appropriate vendors CAGE code following the nomenclature, and are preceded by the letter "V." Standard parts such as AN, MS, etc., are not identified by a vendor code.

(5) Eff Code

When two or more units (main assemblies) are listed in the same ILLUSTRATED PARTS LIST, a code letter ("A", "B", "C", etc.) is assigned to each main unit. All subcomponents that are peculiar to a particular unit are identified by the same effectivity code letter as the unit. If parts are common to all units, the effectivity code column is left blank. The coding used in the ILLUSTRATED PARTS LIST in this manual is as follows:


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ASSEMBLY PN IPL FIGURE NO. EFF CODE

176250-22 1 A 176250-40 1 B 176250-50 1 C 176250-77 1 D 176250-115 1 E 176200-22 1 F 176200-40 1 G 176200-50 1 H 176200-77 1 J 176200-115 1 K 176219-50 1 L 176219-77 1 M 176219-115 1 N

(6) Units per assembly Quantities specified in the "UNITS PER ASSY" column are the total number of each part required per assembly or subassembly and are not necessarily the total used per the complete unit.


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IPL Figure 1 Oxygen Cylinder Assembly


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- ITEM NOT ILLUSTRATED

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FIG ITEM

PART NUMBER AIRLINE PART NO. NOMENCLATURE

1 2 3 4 5 6 7 EFF

CODE UNITS PER

ASSY

1- -1A 176250-22 CYLINDER ASSY, OXYGEN A RF

-1B 176250-40 CYLINDER ASSY, OXYGEN B RF

-1C 176250-50 CYLINDER ASSY, OXYGEN C RF

-1D 176250-77 CYLINDER ASSY, OXYGEN D RF

-1E 176250-115 CYLINDER ASSY, OXYGEN E RF

-1F 176200-22 CYLINDER ASSY, OXYGEN F RF

-1G 176200-40 CYLINDER ASSY, OXYGEN G RF

-1H 176200-50 CYLINDER ASSY, OXYGEN H RF

-1J 176200-77 CYLINDER ASSY, OXYGEN J RF

-1K 176200-115 CYLINDER ASSY, OXYGEN K RF

-1L 176219-50 CYLINDER ASSY, OXYGEN L RF

-1M 176219-77 CYLINDER ASSY, OXYGEN M RF

-1N 176219-115 CYLINDER ASSY, OXYGEN N RF

80A 1270152-1 . CYLINDER, COMPOSITE (B/E AEROSPACE PART NUMBER 176700-22)(V58943)

AF 1

-80B 1207452 . CYLINDER, COMPOSITE (B/E AEROSPACE PART NUMBER 176700-40)(V58943)

BG 1

R -80C 1270152-2 . CYLINDER, COMPOSITE (B/E AEROSPACE PART NUMBER 176700-50)(V58943)

CHL 1

R -80D 1270152-3 . CYLINDER, COMPOSITE (B/E AEROSPACE PART NUMBER 176700-77)(V58943)

DJM 1

R -80E 1270152-4 . CYLINDER, COMPOSITE (B/E AEROSPACE PART NUMBER 176700-115)(V58943)

EKN 1

90 632049 . O-RING 1

R 100A 172270-01 . REGULATOR ASSY (REFER TO CMM 35-22-10)

ABCDE 1

R -100B 172200-00 . REGULATOR ASSY (REFER TO CMM 35-22-10)

FGHJK 1

R -100C 172200-01 . REGULATOR ASSY (REFER TO CMM 35-22-10)

LMN 1

110 170042-00 . CONNECTOR ASSY 1

R 120 839245-10 . . CAP PLUG 1


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- ITEM NOT ILLUSTRATED

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FIG ITEM

PART NUMBER AIRLINE PART NO. NOMENCLATURE

1 2 3 4 5 6 7 EFF

CODE UNITS PER

ASSY

1- 130 170040 . . VALVE, OXYGEN CHARGE 1

R 140 302-DV . . . CORE, VALVE (B/E AEROSPACE PART NUMBER 179000-00)(V17875)

1

R 150 500009 . . . BODY, CHARGE VALVE 1

160 632007-11 . . O-RING 1

R 170 500033 . . ADAPTOR 1

180 500921-52 . FITTING 1

R -190 AN962C2 . PLUG (B/E AEROSPACE PART NUMBER 500910) (V88044) (SUPSD BY ITEM 190A)

R 190A 500910 . PLUG (SUPSDS ITEM 190) 1 R 200 170041 . VALVE ASSY, CHARGE 1

R 210 170040 . . VALVE, OXYGEN CHARGE 1

R 220 500009-00 . . . BODY, CHARGE VALVE 1

R -230 302-DV . . . VALVE CORE (B/E AEROSPACE PART NUMBER 179000-00) (V17875)

1

240 270024 . . CAP ASSY 1

250 838100 . . RING 1

260 170912-04 . FITTING ASSY, SAFETY 1

270 500014 . . FITTING 1

280 500017 . . RETAINER 1

R -290 1410 . . WASHER (B/E AEROSPACE PART NUMBER 800014) (V70292) (SUPSD BY ITEM 290A)

R 290A 800014 . . WASHER (SUPSDS ITEM 290) 1 R -300 800078 . . DISC, RUPTURE 1

R -310 820584 . DUST CAP LMN 1

R -320 511041 . CAP ASSY LMN 1

-330 300900-32 . LOCKWIRE LMN AR


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NUMERICAL INDEX

PART NO. AIRLINE

PART NO. IPL

FIG-ITEM TTL REQ

R AN962C2 1-190 SUPSD

1207452 1-80B 1

1270152-1 1-80A 1

1270152-2 1-80C 1

1270152-3 1-80D 1

1270152-4 1-80E 1

R 1410 1-290 SUPSD

R 170040 1-130 1

R 1-210 1

R 170041 1-200 1

R 170042-00 1-110 1

170912-04 1-260 1

172200-00 1-100B 1

172200-01 1-100C 1

172270-01 1-100A 1

176200-22 1-1F RF

176200-40 1-1G RF

176200-50 1-1H RF

176200-77 1-1J RF

176200-115 1-1K RF

176219-50 1-1L RF

176219-77 1-1M RF

176219-115 1-1N RF

176250-22 1-1A RF

176250-40 1-1B RF

176250-50 1-1C RF

176250-77 1-1D RF

176250-115 1-1E RF

R 179000-00 1-140 RF

R 1-230 RF

270024 1-240 1

300900-32 1-330 AR

R 302-DV 1-140 1

R 1-230 1

R 500009 1-150 1

R 1-220 1

500014 1-270 1


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NUMERICAL INDEX

PART NO. AIRLINE

PART NO. IPL

FIG-ITEM TTL REQ

500017 1-280 1

R 500033 1-170 1

500910 1-190A 1

500921-52 1-180 1

511041 1-320 1

632007-11 1-160 1

632049 1-90 1

800014 1-290A 1

800078 1-300 1

820584 1-310 1

838100 1-250 1

839245-10 1-120 1

Documents

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