S6226-PD-MMO-010 Revision 1

TECHNICAL MANUAL

OPERATION AND MAINTENANCE MANUAL WITH ILLUSTRATED PARTS BREAKDOWN

ORGANIZATIONAL LEVEL

SELF-CONTAINED BREATHING APPARATUS BREATHING AIR CHARGING SYSTEM (SCBA BACS)

0910-LP-103-6441

DISTRIBUTION STATEMENT A. Approved for public release; distribution is unlimited.

PUBLISHED BY DIRECTION OF THE COMMANDER, NAVAL SEA SYSTEMS COMMAND

0 9 1 0 L P 1 0 3 6 4 4 1

S6226-PD-MMO-010 Revision 1

TECHNICAL MANUAL

OPERATION AND MAINTENANCE MANUAL WITH ILLUSTRATED PARTS BREAKDOWN

ORGANIZATIONAL LEVEL

SELF-CONTAINED BREATHING APPARATUS BREATHING AIR CHARGING SYSTEM (SCBA BACS)

0910-LP-103-6441

DISTRIBUTION STATEMENT A. Approved for public release; distribution is unlimited.

PUBLISHED BY DIRECTION OF THE COMMANDER, NAVAL SEA SYSTEMS COMMAND

28 AUGUST 2004

S6226-PD-MMO-010

INSERT LATEST CHANGE PAGES. DESTROY SUPERCEDED PAGES. NOTE: The portion of the text affected by the changes is indicated

by a vertical line in the outer margins of the page. Changes to illustrations are indicated by miniature pointing hands.

Dates of issue for original and changed pages are: Original .........0 ...................12 January 1998 Revision ........1 ....................28 August 2004

TOTAL NUMBER OF PAGES IN THIS PUBLICATION IS 121, CONSISTING OF THE FOLLOWING:

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LIST OF EFFECTIVE PAGES A Revision 1

*Zero in this column indicates an original page

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CHANGE NO. DATE TITLE OR BRIEF DESCRIPTION ENTERED BY

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TABLE OF CONTENTS

Section Page

LIST OF ILLUSTRATIONS ............................................................................................................................iv LIST OF TABLES ..............................................................................................................................................v FOREWORD.....................................................................................................................................................vii ABBREVIATIONS AND ACRONYMS..........................................................................................................ix SAFETY SUMMARY .......................................................................................................................................xi CHAPTER 1 INTRODUCTION AND SAFETY PRECAUTIONS.......................................................... 1-1

1.1 INTRODUCTION........................................................................................................................... 1-1 1.1.1 Purpose ................................................................................................................................ 1-1 1.1.2 Scope ................................................................................................................................... 1-1

1.2 SYSTEM DESCRIPTION .............................................................................................................. 1-1 1.3 SPECIFICATIONS ......................................................................................................................... 1-2 1.4 SAFETY PRECAUTIONS.............................................................................................................. 1-3

1.4.1 Standard Safety Precautions ................................................................................................ 1-4 1.4.2 General Safety Instructions ................................................................................................. 1-4 1.4.3 Warnings, Cautions, And Notes .......................................................................................... 1-4 1.4.4 Special Precautions.............................................................................................................. 1-4

1.5 EQUIPMENT AND ACCESSORIES SUPPLIED ......................................................................... 1-4 1.6 REFERENCE PUBLICATIONS NOT SUPPLIED........................................................................ 1-5 1.7 EQUIPMENT ACCEPTANCE....................................................................................................... 1-6

1.7.1 Inventory ............................................................................................................................. 1-6 1.7.2 Maintenance Verification .................................................................................................... 1-6 1.7.3 Inspection ............................................................................................................................ 1-6

1.8 INITIAL OPERATIONAL TEST................................................................................................... 1-6 1.9 STORAGE REQUIREMENTS....................................................................................................... 1-6

CHAPTER 2 OPERATION.......................................................................................................................... 2-1 2.1 INTRODUCTION........................................................................................................................... 2-1 2.2 CONTROLS AND INDICATORS ................................................................................................. 2-1 2.3 OPERATING PROCEDURES........................................................................................................ 2-6

2.3.1 Setup.................................................................................................................................... 2-6 2.3.2 Operation ............................................................................................................................. 2-7 2.3.3 Disassembly....................................................................................................................... 2-10 2.3.4 Emergency Operation........................................................................................................ 2-10

CHAPTER 3 FUNCTIONAL DESCRIPTION ........................................................................................... 3-1 3.1 INTRODUCTION........................................................................................................................... 3-1 3.2 DESCRIPTION ............................................................................................................................... 3-2

3.2.1 ABPA .................................................................................................................................. 3-2 3.2.1.1 Drive Air Inlet Pressure Gauge (AHP G201) ........................................................ 3-2 3.2.1.2 Drive Air Regulator (AHP-V201).......................................................................... 3-2 3.2.1.3 Regulated Air Pressure Gauge (ALP-G202).......................................................... 3-2

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TABLE OF CONTENTS (Continued)

Section Page

3.2.1.4 Drive Air Filter .......................................................................................................3-2 3.2.1.5 Drive Air Relief Valve (ALP-V202) ......................................................................3-2 3.2.1.6 Drive Air Bleed Valve (ALP-V204).......................................................................3-2 3.2.1.7 Drive Air Control Valve (ALP-V203)....................................................................3-2 3.2.1.8 Filtered Air Inlet Pressure Gauge (AHP-G204)......................................................3-3 3.2.1.9 Filtered Air Inlet Valve (AHP-V206) .....................................................................3-3 3.2.1.10 Booster Pump........................................................................................................3-3 3.2.1.11 Surge Tank............................................................................................................3-4 3.2.1.12 Filtered Air Relief Valve (AHP-V207).................................................................3-4 3.2.1.13 Pilot Switch (AHP-V205).....................................................................................3-4 3.2.1.14 In-Line Filter.........................................................................................................3-4 3.2.1.15 Filtered Air Outlet Pressure Gauge (AHP-G203) .................................................3-4

3.2.2 HPFA....................................................................................................................................3-4 3.2.2.1 Coalescor Filter.......................................................................................................3-4 3.2.2.2 Relief Valve (AHP-V304) ......................................................................................3-4 3.2.2.3 Check Valve (AHP-V303)......................................................................................3-4 3.2.2.4 Cartridge Holders....................................................................................................3-4 3.2.2.5 Manifold .................................................................................................................3-4 3.2.2.6 H2O/CO Indicator ...................................................................................................3-4 3.2.2.7 HPFA Indicator (AHP-G301) .................................................................................3-4 3.2.2.8 In-Line Filters .........................................................................................................3-4 3.2.2.9 Shutoff Valve (AHP-V301) ....................................................................................3-4 3.2.2.10 Bleed Valve (AHP-V302).....................................................................................3-5 3.2.2.11 Drain Valve (AHP-V305).....................................................................................3-5

3.2.3 Connecting Hose Assemblies...............................................................................................3-5 3.2.3.1 Drive Air Hose Assembly.......................................................................................3-6 3.2.3.2 Filtered Air Hose Assembly ...................................................................................3-6 3.2.3.3 Filtered Air Supply Hose Assembly .......................................................................3-6 3.2.3.4 Quick-Charge Wand ...............................................................................................3-6

CHAPTER 4 SCHEDULED MAINTENANCE ..........................................................................................4-1 4.1 INTRODUCTION............................................................................................................................4-1 4.2 SCOPE .............................................................................................................................................4-1 4.3 SAFETY REQUIREMENTS ...........................................................................................................4-1 4.4 MAINTENANCE CONCEPT .........................................................................................................4-1

4.4.1 Scheduled Maintenance........................................................................................................4-1 4.4.2 Unscheduled Maintenance ...................................................................................................4-2

4.5 PLANNED MAINTENANCE SYSTEM ........................................................................................4-2

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TABLE OF CONTENTS

Section Page

4.6 UNITED STATES NAVY MAINTENANCE AND MATERIAL MANAGEMENT SYSTEM

COVERAGE AND PROBLEM REPORTING .............................................................................. 4-2 4.7 GENERAL MAINTENANCE INSTRUCTIONS .......................................................................... 4-3

4.7.1 Equipment Disassembly and Parts Replacement................................................................. 4-3 4.7.1.1 Bagging Components............................................................................................. 4-3

4.7.2 General Cleaning Procedure................................................................................................ 4-4 4.7.3 Leak Detection .................................................................................................................... 4-4 4.7.4 Anti-seize Tape.................................................................................................................... 4-4 4.7.5 Lubricants............................................................................................................................ 4-4 4.7.6 O-Rings ............................................................................................................................... 4-4

4.7.6.1 O-Ring Removal .................................................................................................... 4-4 4.7.6.2 O-Ring Installation................................................................................................. 4-4

CHAPTER 5 TROUBLESHOOTING......................................................................................................... 5-1 5.1 INTRODUCTION........................................................................................................................... 5-1 5.2 GENERAL TROUBLESHOOTING INSTRUCTIONS................................................................. 5-1

CHAPTER 6 CORRECTIVE MAINTENANCE ....................................................................................... 6-1 6.1 INTRODUCTION........................................................................................................................... 6-1

6.1.1 Scope ................................................................................................................................... 6-1 6.1.2 Safety Requirements............................................................................................................ 6-1

6.2 GENERAL MAINTENANCE INFORMATION ........................................................................... 6-1 6.2.1 Maintenance Parts ............................................................................................................... 6-2 6.2.2 Related Maintenance ........................................................................................................... 6-2

6.3 TEST EQUIPMENT AND TOOLS................................................................................................ 6-2 6.4 MATERIALS REQUIRED ............................................................................................................. 6-3 6.5 GENERAL MAINTENANCE PROCEDURES ............................................................................. 6-3

6.5.1 System Tightness Test......................................................................................................... 6-3 6.5.1.1 ABPA Tightness Test ............................................................................................ 6-3 6.5.1.2 HPFA Tightness Test ............................................................................................. 6-4

6.6 ABPA CORRECTIVE MAINTENANCE ...................................................................................... 6-5 6.6.1 Booster Pump Removal and Installation ............................................................................. 6-5 6.6.2 Drive Air Regulator (AHP-V201) Removal and Installation.............................................. 6-9 6.6.3 Drive Air Relief Valve (ALP-V202) Removal and Installation........................................ 6-13 6.6.4 Drive Air Control Valve (ALP-V203) Removal and Installation ..................................... 6-15 6.6.5 Drive Air Bleed Valve (ALP-V204) Removal and Installation ........................................ 6-17 6.6.6 Pilot Switch (AHP-V205) Removal and Installation ........................................................ 6-19 6.6.7 Filtered Air Inlet Valve (AHP-V206) Removal and Installation....................................... 6-21 6.6.8 Surge Tank and Filtered Air Relief Valve (AHP-V207) Removal and Installation.......... 6-24

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TABLE OF CONTENTS

Section Page

6.6.9 Drive Air Inlet Pressure Gauge (AHP-G201), Regulated Air Pressure Gauge (AHP-G202),

and Filtered Air Inlet Pressure Gauge (AHP-G204) Removal and Installation.................6-26 6.6.10 Filtered Air Outlet Pressure Gauge (AHP-G203) Removal and Installation ...................6-28 6.6.11 Drive Air Filter Removal and Installation........................................................................6-30 6.6.12 In-Line Filter Removal and Installation ...........................................................................6-31 6.6.13 Spooler Valve Assembly Removal and Installation.........................................................6-32

6.7 HPFA Corrective Maintenance ......................................................................................................6-36 6.7.1 Bleeding HPFA ..................................................................................................................6-37 6.7.2 Filter Removal and Installation ..........................................................................................6-37 6.7.3 Shut Off Valve (AHP-V301) Removal and Installation.....................................................6-38 6.7.4 Check Valve (AHP-V303) Removal and Installation ........................................................6-40 6.7.5 Drain Valve (AHP-V305) Removal and Installation .........................................................6-41

CHAPTER 7 ILLUSTRATED PARTS BREAKDOWN ............................................................................7-1 7.1 INTRODUCTION............................................................................................................................7-1 7.2 PARTS LISTS AND ILLUSTRATIONS ........................................................................................7-1 7.3 LIST OF MANUFACTURERS .......................................................................................................7-1

APPENDIX A OPERATIONAL CHECKLISTS .......................................................................................A-1 A-1 INTRODUCTION..........................................................................................................................A-1 A-2 CHECKLISTS PROVIDED ..........................................................................................................A-1

LIST OF ILLUSTRATIONS

Figure Page

1-1 SCBA BACS ............................................................................................................................... 1-2 2-1 Air Booster Pump Assembly (ABPA) Controls and Indicators .................................................. 2-2 2-2 High-Pressure Filter Assembly (HPFA) Controls and Indicators ............................................... 2-3 2-3 Filtered Air Supply Hose Assembly (H-103) Controls and Indicators........................................ 2-4 2-4 Inlet/Outlet Connection Points..................................................................................................... 2-5 3-1 SCBA BACS Functional Schematic and Flow Diagram............................................................. 3-1 3-2 Air Booster Pump Assembly (ABPA)......................................................................................... 3-3 3-3 High Pressure Filter Assembly (HPFA) ...................................................................................... 3-5 6-1 Booster Pump............................................................................................................................... 6-8 6-2 Drive Air Regulator (AHP-V201) ............................................................................................. 6-10 6-3 Drive Air Relief Valve (ALP-V202) ......................................................................................... 6-14 6-4 Drive Air Control Valve (ALP-V203)....................................................................................... 6-15 6-5 Drive Air Bleed Valve (ALP-V204).......................................................................................... 6-18 6-6 Pilot Switch (AHP-V205).......................................................................................................... 6-19 6-7 Filtered Air Inlet Valve (AHP-V206)........................................................................................ 6-22

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LIST OF ILLUSTRATIONS (Continued)

Figure Page

6-8 Surge Tank with Filtered Air Relief Valve (AHP-V207).......................................................... 6-25 6-9 Drive Air Inlet Gauge (AHP-G201), Regulated Air Pressure Gauge (ALP-G202), and Filtered

Air Inlet Pressure Gauge (AHP-G204) ..................................................................................... 6-27 6-10 Filtered Air Outlet Pressure Gauge (AHP-G203).................................................................... 6-29 6-11 Drive Air Filter ........................................................................................................................ 6-30 6-12 In-Line Filter............................................................................................................................ 6-32 6-13 Tube Assembly ........................................................................................................................ 6-33 6-14 Banjo Fitting Hex Nut ............................................................................................................. 6-34 6-15 Spooler Valve Assembly ......................................................................................................... 6-34 6-16 Spooler Valve Installation and Removal Tool ........................................................................ 6-35 6-17 Spooler Valve Sleeve............................................................................................................... 6-35 6-18 Filter......................................................................................................................................... 6-38 6-19 Shutoff Valve (AHP-V301)..................................................................................................... 6-39 6-20 Check Valve (AHP-V303)....................................................................................................... 6-41 6-21 Drain Valve (AHP-V305)........................................................................................................ 6-42 7-1 ABPA (Sheet 1 of 4)..................................................................................................................... 7-2 7-2 HPFA (Sheet 1 of 2) .................................................................................................................... 7-9

LIST OF TABLES

Table Page

1-1 SCBA BACS Specifications........................................................................................................ 1-3 1-2 Equipment and Accessories Supplied.......................................................................................... 1-5 1-3 Reference Publications Not Supplied .......................................................................................... 1-5 4-1 SCBA BACS Planned Maintenance System............................................................................... 4-2 5-1 ABPA Troubleshooting Guidelines............................................................................................. 5-1 5-2 HPFA Troubleshooting Guidelines ............................................................................................. 5-4 6-1 Tools Required ............................................................................................................................ 6-2 6-2 Materials Required ...................................................................................................................... 6-3 7-1 ABPA Parts List .......................................................................................................................... 7-6 7-2 HPFA Parts List......................................................................................................................... 7-11 7-3 Drive Air Hose Assembly Parts List ......................................................................................... 7-13 7-4 Filtered Air Hose Assembly Parts List ...................................................................................... 7-14 7-5 Filtered Air Supply Hose Assembly Parts List.......................................................................... 7-15 7-6 List of Manufacturers ................................................................................................................ 7-16 A-1 Setup Checklist .......................................................................................................................... A-3 A-2 Operation Checklist ................................................................................................................... A-5 A-3 Disassembly Checklist............................................................................................................... A-9 A-4 Emergency Operation Checklist .............................................................................................. A-11

ii

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FOREWORD

This technical manual contains procedures for operation and maintenance of the Self-Contained Breathing Apparatus Breathing Air Charging System (SCBA BACS). The information in this manual is presented in seven chapters and one appendix, as follows:

Chapter 1 Introduction and Safety Precautions Chapter 2 Operation Chapter 3 Functional Description Chapter 4 Scheduled Maintenance Chapter 5 Troubleshooting Chapter 6 Corrective Maintenance Chapter 7 Illustrated Parts Breakdown Appendix A Operational Checklists

Ships, training activities, supply points, depots, Naval Shipyards, and Supervisors of Shipbuilding are requested to arrange for the maximum practical use and evaluation of Naval Sea Systems Command (NAVSEA) technical manuals. The In-Service Engineering Agent (ISEA) may be contacted at Commanding Officer, Naval Surface Warfare Center Panama City, Attn: Code E53, 110 Vernon Avenue, Panama City, FL 32407.

All errors, omissions, discrepancies, and suggestions for improvement to NAVSEA technical manuals shall be forwarded to: Naval System Data Support Activity (NSDSA), Code 5E30, Port Hueneme Division, Naval Surface Warfare Center.

Technical Manual Deficiency/Evaluation Report (TMDER) (formally form NAVSEA 4160/1) can now be accessed, completed, and transmitted electronically to NSDSA. To access this form from the Internet, enter:

http://nsdsa.phdnswc.navy.mil/

At the Home Page, click on the TMDER icon. Complete the form and transmit as directed. All comments shall be thoroughly investigated and originators will be advised of action resulting from those comments.

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ABBREVIATIONS AND ACRONYMS

3-M Maintenance and Material Management

ABPA Air Booster Pump Assembly AHP Air High Pressure ALP Air Low Pressure Ao Operational Availability

BACS Breathing Air Charging System

CAGE Commercial and Government Entity CGA Compressed Gas Association CIN Course Identification Number CO Carbon Monoxide

FEDLOG Federal Logistics Record

H2O Water HP High Pressure HPFA High-Pressure Filter Assembly

IPB Illustrated Parts Breakdown ISEA In-Service Engineering Agent

MDS Maintenance Data Sheet METCAL Metrology and Calibration MIL-STD Military Standard MIP Maintenance Index Page MRC Maintenance Requirement Card MS Military Specification

NAVOSH Navy Occupational Safety and Health NAVSEA Naval Sea Systems Command NID Non-ionic Detergent NSDSA Naval System Data Support Activity NSN National Stock Number

OPNAV Office of the Chief of Naval Operations OPNAVINST Office of the Chief of Naval Operations Instruction

PMS Planned Maintenance System

QD Quick Disconnect

SAE Society of Automotive Engineers SCBA Self-Contained Breathing Apparatus SCBA BACS Self-Contained Breathing Apparatus Breathing Air Charging System SCFM Standard Cubic Feet Per Minute STEP Shipboard Training Enhancement Program

TMDER Technical Manual Deficiency/Evaluation Report TSP Trisodium Phosphate

USN United States Navy

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SAFETY SUMMARY

1. GENERAL SAFETY NOTICES.

The general safety notices supplement specific warnings and cautions appearing in this manual. All general safety notices and specific warnings and cautions must be understood and applied during all Self-Contained Breathing Apparatus Breathing Air Charging System (SCBA BACS) operation and maintenance functions. Should situations arise that are not covered in the general or specific safety notices, the commanding officer, or other authority, will issue orders as deemed necessary to cover the specific situation. In addition, refer to Office of the Chief of Naval Operations Instruction (OPNAVINST) 5100.19, Navy Occupational Safety and Health (NAVOSH) Program Manual for Forces Afloat, Vol I/II/III or OPNAVINST 5100.23, Navy Occupational Safety and Health (NAVOSH) Program Manual for any situation not covered in the general or specific safety notices.

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CHAPTER 1 INTRODUCTION AND SAFETY PRECAUTIONS

1.1 INTRODUCTION.

1.1.1 Purpose. This manual contains technical information necessary to install, operate, troubleshoot, and maintains the Self-Contained Breathing Apparatus Breathing Air Charging System (SCBA BACS), hereinafter referred to as BACS (Figure 1-1). Reference to additional publications is given if auxiliary manuals exist or if lengthy procedures are required.

1.1.2 Scope. Information in this manual is presented in seven chapters and one appendix as follows:

Chapter 1, Introduction and Safety Precautions, introduces safety considerations; presents a system description and specifications; reference data and publications; lists of equipment, accessories, and documents supplied with each system; equipment acceptance procedures; initial operational test procedures; and storage requirements.

Chapter 2, Operation, provides a description of SCBA controls and indicators and detailed instructions on BACS setup, operating, and disassembly procedures. This chapter also provides BACS emergency shutdown procedures.

Chapter 3, Functional Description, provides a detailed description of the function of each major component of the BACS.

Chapter 4, Scheduled Maintenance, provides information required to perform scheduled and general maintenance procedures on the BACS.

Chapter 5, Troubleshooting, provides tables to isolate BACS equipment malfunctions and direct the user to related maintenance procedures.

Chapter 6, Corrective Maintenance, provides procedures required to perform corrective maintenance on the BACS.

Chapter 7, Illustrated Parts Breakdown, provides illustrated parts breakdown for major components of the BACS.

Appendix A, Operational Checklists, provides reproducible copies of checklists for BACS setup, operating, disassembly, and emergency procedures.

1.2 SYSTEM DESCRIPTION.

The BACS (Figure 1-1) is used to recharge SCBA cylinder assemblies with breathing quality air (Grade D as defined by Compressed Gas Association [CGA] publication G-7.1). High Pressure Filter Assemblies (HPFAs) are hard mounted to the ships bulkheads at various locations throughout the ship. The Air Booster Pump Assembly (ABPA) and connecting hose assemblies are portable and can be moved from one HPFA filter station to another. Personnel should become familiar with the shipboard location of all system components. Refer to Chapter 3 for a complete functional description of the system.

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1-2

1.3 SPECIFICATIONS.

Table 1-1 lists the specifications for the BACS.

Figure 1-1. SCBA BACS.

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Table 1-1. SCBA BACS Specifications.

Equipment Specifications

SCBA BACS Specifications o Setup Time: 15 minutes o Operational Availability (AO): 90%

Subassemblies o High-Pressure Filter Assembly (HPFA) o Air Booster Pump Assembly (ABPA) o Connecting Hose Assemblies

High-Pressure Filter Assembly

Specifications o Dimensions: 9.0 in. x 11.0 in. x 28.0 in. (LxWxH) o Weight: 68 lb o Bulkhead-mounted aluminum housing o Filter cartridge duration: maximum usage life 6 months (shelf life 18 months) o Produces Grade D air IAW CGA G-7.1 o High Pressure (HP) air requirements: 2,000 - 3,000 psig o Maximum flow rate: 60 scfm (filtered air only) o Maximum operating pressure: 3,000 psig o Relief valve (AHP-V304) setting: 3,300 psig

Air Booster Pump Assembly

Specifications o Dimensions: 33.5 in. x 14.4 in. x 22.5 in. (LxWxH) o Weight: 108 lb o Portable aluminum frame o HP air requirements: 2,000 - 3,000 psig o Boosts filtered HPFA air to 4,500 psig o Filtered air relief valve (AHP-V207) setting: 5,300 psig o Nominal drive air pressure: 125 psig o Drive air relief valve (ALP-V202) setting: 150 psig

Connecting Hose Assemblies

Specifications o Drive Air/Filtered Air Hose Assemblies nominal operating pressure:

3,000 psig o Filtered Air Supply Hose Assembly nominal operating pressure: 4,500 psig o Thermoplastic hose

Components o Drive Air Hose Assembly (H-101) o Filtered Air Hose Assembly (H-102) o Filtered Air Supply Hose Assembly (H-103)

1.4 SAFETY PRECAUTIONS.

Personnel using the BACS (Figure 1-1) shall observe the safety precautions specified in this technical manual. Personnel must understand the potential hazards associated with the BACS before operating or performing maintenance on the equipment. The following safety guidelines apply to operation and maintenance procedures in general and do not appear elsewhere in this publication, except by reference. Personnel must understand and comply with these guidelines during operation and maintenance of the BACS. The Safety Summary includes a comprehensive list of warnings and cautions that affect the system.

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1-4

1.4.1 Standard Safety Precautions. The BACS shall be used only after personnel have been properly instructed and have completed the BACS Shipboard Training Enhancement Program (STEP) operation training course. Personnel must u nd limitations. Personnel should

complete the BACS STEP maintenance training course.

P oroughly y practices the potential hazards associated w before operat on the equipment.

1.4.2 General Safety Instruc

se the equipment IAW instructions, labels, aalso

ersonneith the BACS

l must be th familiar with all safeting o e

and understandr p rforming maintenance

tions. Standard operational and maintenance safety precautions contained in the following documents apply

Forces afloat must compl erations (OPNAVINST) 5100.19, tional S NAVOSH) Program Manual for Forces Afloat, Vol I/II/III

Shore activities must com INST 5100.23, Navy Occupational Safety and Health (NAVOSH) Program Man

1.4.3 Warnings, Cautions, A

to the SCBA BACS:

y with Office of the Chief of Naval OpNavy Occupa afety and Health (

ply with OPNAVual.

nd Notes.

The warnings, cautions, and notes st be followed to prevent hazards to personnel and damage warnings, cautions, and notes a the text of i

appearing throughout this technical manual mu to equipment. The following notations define

s they are used in th s manual:

WARNING

Warnings highl dure, practice, condit result in injury

ight an essential operating or maintenance proceictly observed, couldion, or statement, which, if not str

to, or death of, personnel.

CAUTION

Cautions refer re, practice, condition, o ich, if not strictly observed, could result in damage to, or d ssion effectiveness, or long-term health

NOTE

an operating or maintenance procedure, practice, condition, or statement that is essential, but not of a known hazardous

to an operating or maintenance procedur statement, wh

estruction of, equipment, loss of mi hazards to personnel.

Notes refer to

nature.

1.4.4 Special Precautions. The warnings, cautions, and notes appearing throughout this technicamust be followed to prevent hazards to personnel and damage to equipment.

1.5

l manual

EQUIPMENT AND ACCESSORIES SUPPLIED.

Table 1-2 provides a listing of the equipment and accessories that are supplied with each BACS.

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Part Number (PN)

Table 1-2. Equipment and Accessories Supplied.

Qty Item Reference Number or

1 EACH SCBA BACS Components: o High Pressure Filter Assembly (HPFA)1

1

PN 53

o Air Booster Pump Assembly (ABPA)

o 3)1

711ASSY7245941 PN 53711ASSY7245940

PN 53711ASSY7245948-1

o Drive Air Hose Assembly (H-101)1 o Filtered Air Hose Assembly (H-102)1

Filtered Air Supply Hose Assembly (H-10

PN 53711ASSY7245944-2 PN 53711ASSY7245944-1

o Quick-Charge Wand1 PN 200150-03 REF

Apparatus Breathing Air Charging System (SCBA BACS) Planned Maintenance System (PMS) for Self-Contained Breathing MIP 5519/018

1 C

o Strap Wrench PN 53711-7245957 PN 54325A22

EA H Special Tools: o Spanner Wrench2

3

1 Quantity is ship class dependent. 2 One per HPFA. 3 One per ship system. 1.6 REFERENCE PUBLICATIONS NOT SUPPLIED.

Table 1-3 lists reference publications that are not supplied with each BACS.

lication Number Application

Table 1-3 Reference Publications Not Supplied.

Publication Title PubBACS Shipboard Training Enhancement Program (STEP) Operational

Course Identification Number 5-0008

Computer-based training (CIN) A49

BACS STEP Maintenance CIN A495-0039 Computer-based training Cleaning of Ship t cleaning board Compressed Air Systems Military Standard

(MIL-STD-1622) Componen

Commodity Spe and testing fiberglass cylinders

cification for Air CGA G-7.1 Inspecting

Metrology and Calibration (METCAL) Program 4734.1A Calibration and maintenance of gauges

NAVSEA

Navy OccupatioProgram Manua

nd ce safety

nal Safety and Health (NAVOSH) l

OPNAVINST 5100.23 Operation amaintenan

Navy Occupatio and Health (NAVOSH) OPNAVINST 5100.19 Operation and nal SafetyProgram Manual for Forces Afloat, Vol I/II/III maintenance safety

Self-Contained Breathing Apparatus Scott Air-Pak 4.5

S6220-EN-MMO-010 Operation and maintenance manual

Ships Maintenance and Material Management OPNAV(3-M) Manual

INST 4790.4 (Series) Failure analysis reporting

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EQUIPMENT ACCEP1.7 TANCE.

Upon receipt, BACS components must be inventoried and inspected. The equipment will not be ready for imm e operational use; shipboard installation is required.

1. n r

ediat

7.1 Inve to y. To ensure receipt of all items, conduct a visual inventory f all components IAW Table 1-2. The shipment in the sh Verify all serial numbers co g lists.

1.7.2 Maintena

o should be compared with the packing lists included ipping documentation. rrespond with the accompanying packin

nce Verification. Examine the maintenance records acco , Maintenance Req rify that requ e has been performed. if any, before operating the equipm

1.7.3 Inspe

mpanying shipments (e.g.uirement Cards [(MRCs)] and logbooks) to ve ired scheduled maintenanc Perform omitted MRCs, ent.

ction. Carefully remove each item from its packing container. Perform a thorough inspection, no di d by the packing and manufacturing process. Inspect for completeness of assemblies, faulty cracks, corrosion, and deterioration. Check the ABPA and HPFA for damage to the alu d control panel, and inspect the unit to ens trols and

on.

TIONAL TEST

ting any screpancies cause workmanship, dirt, minum frames an ure that all con

indicators are in good operating conditi

1.8 INITIAL OPERA .

a. Install filter cartridges and indicator elements IAW MIP 5519/018.

3.1.

rocedures paragraph 2.3.2.

d. Perform system tig

e. Disass IAW procedures described in paragraph 2.3.3.

1

b. Set up the BACS IAW procedures in paragraph 2.

c. Using an SCBA cylinder, conduct operational test IAW operating p

htness test IAW paragraph 6.5.1.

emble the BACS

.9 STORAGE REQUIREMENTS.

The BACS is a breathing supply support system; co e handled and storB repar ng-term storageLay-up SCBA Breathing Air Charging System. Gen rage precautions are listed as follows:

peratures higher than F (48.8C) or lower t

ight; s rubber compo

en

co en stored.

mponents must b ed with care. If the ACS will not be used for 90 days or longer, p e the system for lo

eral long-term sto IAW MRC LU-1,

Do not store components in tem 120 han 0F (-17C). Do not store components in direct sunl sunlight deteriorate nents. Ensure components are dry and clean wh stored. Ensure flexible parts are not subjected to ntinuous distortion wh Ensure storage area is well-ventilated.

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Revision 1 2-1

CHAPTER 2

2.1 INTRODUCTION

OPERATION

.

A description and illustration of the controls and indicators of the Self-Contained Breathing Apparatus

mergency operation procedures. Checklists for these procedures are provided in Appendix A.

This chapter contains the following information:

Breathing Air Charging System (SCBA BACS); hereinafter referred to as BACS.

Operational use procedures providing setup, operation, disassembly, and e

2.2 CONTROLS AND INDICATORS.

Controls and indicators for the Air Booster Pump Assembly (ABPA), the High Pressure Filter Assemb(HPFA), and the Filtered Air Supply Hose A

ly ssembly (H-103) are illustrated in Figures 2-1 through 2-3. The

following information is provided for each illustration:

Number identifies corresponding callout Nomenclature item name Function provides brief description of function of item Normal Operating Condition describes position of item during operational use or identifies

g hose assemblies.

maximum psig reading.

Figure 2-4 illustrates the connection points for correct attachment of the connectin

S6226-PD-MMO-010

2-2

No. Nomenclature Function Normal Operating Condition 1 Filtered Air Outlet Pressure Gauge

(AHP-G203) Indicates charging air pressure 4,500 psig

2 Filtered Air Inlet Pressure Gauge (AHP-G204)

Indicates pressure from the HPFA 3,000 psig

3 Drive Air Bleed Valve (ALP-V204)

Releases remaining drive air when charging is complete

Closed

4 Regulated Air Pressure Gauge (ALP-G202)

Indicates reduced drive air pressure after drive air has been regulated

125 psig

5 Drive Air Inlet Pressure Gauge (AHP-G201)

Indicates drive air pressure from HPFA 3,000 psig

6 Filtered Air Inlet Valve (AHP-V206)

Controls high-pressure filtered air from HPFA Open

7 Drive Air Control Valve (ALP-V203)

Controls drive air flow to booster pump from HPFA

Open

8 Drive Air Regulator (AHP-V201)

Regulates drive air pressure from HPFA 125 psig

Figure 2-1. Air Booster Pump Assembly (ABPA) Controls and Indicators.

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Revision 1 2-3

No. Nomenclature Function Normal Operating Condition 1 HPFA Indicator (AHP-G301) Indicates air pressure in cartridge holders and

manifold block 3,000 psig

2 Shutoff Valve (AHP-V301) Stops air flow to ABPA Open 3 Bleed Valve (AHP-V302) Bleeds air pressure in HPFA Closed 4 Drain Valve (AHP-V305) Drains moisture from coalescor Closed 5 H2O/CO Indicator Indicates presence of water (H2O) or carbon

monoxide (CO) in breathing air Blue (H2O) and yellow (CO)

6 Relief Valve (AHP-V304) Protects HPFA from over-pressurization Closed

Figure 2-2. High-Pressure Filter Assembly (HPFA) Controls and Indicators.

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2-4

No. Nom perating Condition enclature Function Normal O

1 Shutoff Knob, Hose Isolation Va(AHP-V101, A

lve HP-V102)*

ssembly (H-103) Shutoff for Filtered Air Supply Hose A Closed

2 Bleed Handle, Hose Isol(AHP-V101, A

ation Valve HP-V102)* Supply Hose Assembly (H-103)

Bleeds filtered air supply from Filtered Air Closed

* B A 2 refer to the

Fig s.

oth HP-V101 and AHP-V10 Hose Isolation Valve.

ure 2-3. Filtered Air Supply Hose Assembly (H-103) Controls and Indicator

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Revision 1 2-5

Figu ts.

re 2-4. Inlet/Outlet Connection Poin

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2-6

3 OPERATING PROCEDURES2. .

ragraphs 2.3.1 through 2.3.4 address the following procedures: setup, operation, disassembly, and ergency operations. Appendix A provides corresponding checklists to be copied and used as needed.

2.3.1 Setup

Paem

. The Setup Checklist (Table A-1) should be completed when the following procedures are performed.

a. Move ABPA within 5 to 7 feet of HPFA.

b. Ensure ship high-pressure (HP) air system valve is closed.

WARNING

A color change from blue to pink in the H2O/CO indicator reveals high moisture content; a color change from yellow to brown indicates a high CO content. Any color change requires replacement of filter cartridges and indicator elements to avoid serious injury or death to personnel.

c. Check HPFA H2O/CO indicator for appropriate colors.

d. Ensure HPFA shutoff valve (AHP-V301) and drain valve (AHP-V305) are closed.

WARNING

Before opening bleed valves, ensure all personnel stand clear to avoid serious injury or death from flying debris. Operator shall announce BLEEDING DOWN to warn nearby personnel. Operator must wear protective eyewear and hearing protection to prevent personal injury.

e. Open HPFA bleed valve (AHP-V302). Bleed pressure; close valve.

CAUTION

Ensure hoses are routed to avoid equipment damage.

f ve PA ir inlet att

g ere d AB ed air inlet es, and atta

ose Assembly (H-103) to ABPA filtered air supply.

i. Ensure Filtered Air Supply Hose Assembly (H-103) hose isolation valves (AHP-V101/AHP-V102) sh

. Remove dust caps, connect driquick-disconnect sockets, and

air hose assembly (H-101) to HPFA and ABach snap shackles to eye nuts.

drive a

. Remove dust caps, connect filtquick-disconnect nippl

d air hose assembly (H-102) to HPFA anch snap shackles to eye nuts.

PA filter

h. Remove dust caps and connect Filtered Air Supply H

utoff knobs and bleed handles are closed.

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3.2 Operation2. . The Operation Checklist (Table A-2) should be completed when the following procedures med.

WARNING

are perfor

Before operating the BACS, ensure that a gas sample has been taken within the last three months IAW Maintenance Requirements Cards (MRC) Q-1 to ensure that Grade D air quality, as defined by CGA G-7.1, is being produced to avoid serious injury or death to personnel.

a. Ensure ABPA drive air regulator (AHP-V201) is fully unloaded by rotating counterclockwise.

b. Ensure ABPA drive air control valve (ALP-V203), drive air bleed valve (ALP-V204), and filtered air inlet valve (AHP-206) are closed.

c. Slowly open ship HP air system supply valve.

d. Turn HPFA shutoff valve (AHP-V301) fully counterclockwise, then back off valve 1/4 turn.

e. Adjust ABPA drive air regulator (AHP-V201) until regulated air pressure gauge (ALP-G202) reads 125 5 psig.

NOTE

The system can be configured to charge the following: (1) one or two SCBA cylinders, (2) one or two quick-charge wands, or (3) one SCBA cylinder and one quick-charge wand.

f. Attach Filtered Air Supply Hose Assembly (H-103) to SCBA cylinder assembly(ies) and/or quick-charge wand(s) supplied with SCBAs.

WARNING

Do not refill any SCBA cylinder assembly that is damaged. Failures to inspect, depressurize, and remove a damaged SCBA cylinder assembly may result in serious injury or death to personnel.

g. Prior to charging an SCBA cylinder assembly, inspect entire SCBA or SCBA cylinder assembly for evidence of exposure to chemicals, high temperature, impact damage, or worn components.

NOTE

If quick-charge wands are used, proceed to step s.

h. Open SCBA cylinder(s) valve fully by rotating counterclockwise, then back off valve 1/4 turn.

Filtered air outlet pressure gauge (AHP-G203) will indicate SCBA cylinder pressure.

NOTE

S6226-PD-MMO-010

2-8

se Assembly (H-103) hose isolation valves (AHP-V101/AHP-V102) shutoff knobs for each SCBA cylinder assembly connected.

essure gauge (AHP-G204) are equal, open drive air control valve (ALP-V203) four to six complete turns.

NOTE

inutes to vent moisture during charging evolution.

l. When air booster pump stops or SCBA dual-reading pressure indicator reads approximately 4,500 psig, close Filtered Air Supply Hose Assembly (H-103) hose isolation valves (AHP-101/ AHP

i. Open Filtered Air Supply Ho

j. Open ABPA filtered air inlet valve (AHP-V206).

k. When readings on ABPA filtered air outlet pressure gauge (AHP-G203) and filtered air inlet pr

Open HPFA drain valve (AHP-V305) approximately every 15 m

-V102) shutoff knob(s).

WARNING

Before opening bleed valves, ensure all personnel stand clear to avoid serious injury or death from flying debris. Operator shall announceBLEEDING DOWN to warn nearby personnel. Operator must wear

protective eyewear and hearing protection to prevent personal injury.

m. Close each SCBA cylinder valve fully; y Hose Assembly (H-103) hose isolation valves (AHP-V101/AHP-V102) bleed handle(s) to bleed air between each SCBA cylinder assem bleed handl

n. Disco er assembly. If mission is complete, proceed to step y. If not, continue with next step.

o. Attach Filtered Air Supply Hose Assembly (H-103) to SCBA cylinder assembly.

p. Open each SCBA cylinder valve fully, k off valve 1/4 turn.

q. Open Filtered A HP-V101/AHP-V102) shutoff knob(s) for each SCBA cylinder assembly connected.

r. plete, proceed to step y.

open Filtered Air Suppl

bly and the corresponding hose isolation valve (AHP-V101/AHP-V102). Closee(s).

nnect Filtered Air Supply Hose Assembly (H-103) from each SCBA cylind

and then bac

ir Supply Hose Assembly (H-103) hose isolation valves (A

As needed, repeat procedure beginning with step l. When mission is com

CAUTION

Ensure hoses are routed to avoid equipment damage.

s. Open Filtered Air Supply Hose Assembly (H-103) hose isolation valves (AHP-V101/AHP-V102)

t. Open ABPA filtered air inlet valve (AHP-V206).

shutoff knob(s) for each quick-charge wand connected in step f.

S6226-PD-MMO-010

Revision 1 2-9

ure gauge (AHP-G204) are equal, open drive air control valve (ALP-V203) four to six complete turns counterclockwise.

v. Connect a quick-charge wand to each

w. As each SCBA is filled, di

x. Repe

y. Close

u. When readings on ABPA filtered air outlet pressure gauge (AHP-G203) and filtered air inlet press

SCBA.

sconnect quick-charge wand.

at steps v and w as needed. When mission is complete, proceed to step y.

ship HP air system valve.

WARNING

Before opening bleed valves, ensure all personnel stand clear to avoid ebris. Operator shall announce

BLEEDING DOWN to warn nearby personnel. Operator must wear

ated air pressure gauge (ALP-G202) and drive air inlet pressure gauge (AHP-G201) should read zero.

z. Slow 204). Bleed drive

aa. Close HPFA shutoff valve (AHP-V301).

WARNING

serious injury or death from flying d

protective eyewear and hearing protection to prevent personal injury.

NOTE

ABPA regul

ly open HPFA drain valve (AHP-V305) and ABPA drive air bleed valve (ALP-V air circuit. Close valves (AHP-V305 and ALP-V204).

Before opening bleed valves, rsonnel stand clear to avoid serious injury or death from flying debris. Operator shall announce

NOTE

bb. Depressurize system IAW one of the foll

(1) SCBA cylinder assembly charging configuration

(a) Connect Filtered Air Supply Hose Assembly (H 103) to each SCBA cylinder assembly and open Filtered Air Supply Hose Assembly (H-103) hose isolation valves

(b) Bleed system using Filtered Air Supply Hose Assembly (H-103) hose isolation valves (AHP-V101/AHP-V102) bleed handle(s).

ensure all pe

BLEEDING DOWN to warn nearby personnel. Operator must wear protective eyewear and hearing protection to prevent personal injury.

ABPA filtered air outlet pressure gauge (AHP-G203) and filtered air inlet pressure gauge (AHP-G204) should read zero.

owing:

(AHP-V101/AHP-V102) shutoff knob(s).

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2-10

bleed handle(s).

e Assembly (H-103) from SCBA cylinder assembly.

(a) Bleed system using Filtered Air Supply Hose Assembly (H-103) hose isolation valves (AHP-V101/AHP-V

s ob(s) and bleed handle(s).

cc. valve (AHP-V206) and drive air control valve (ALP-V203) fully clockwise.

dd. Back off ABPA drive air regulator (AH spring tension is released. The BACS is now in STANDBY condition.

2.3.3 Disasse

(c) Close Filtered Air Supply Hose Assembly (H-103) hose isolation valves (AHP-V101/AHP-V102) shutoff knob(s) and

(d) Disconnect Filtered Air Supply Hos

(2) Quick-charge configuration

102) bleed handle(s).

(b) Close Filtered Air Supply Hose Assembly (H-103) hose isolation valve(AHP-V101/AHP-V102) shutoff kn

(c) Remove quick-charge wand from Filtered Air Supply Hose Assembly (H-103).

Rotate ABPA filtered air inlet

P-V201) until

mbly. The Disassembly Checklist (Table A-3) should be completed when the ferformed.

nnect drive air hose assembly (H-101) and filtered air hose assembly (H-10

ollowing procedures are p

a. Disco 2) from HPFA and

b.

c. FA and ABPA drive air and filtered air connection points.

ABPA. Cap hose assemblies.

Disconnect Filtered Air Supply Hose Assembly (H-103) from ABPA. Cap hose assembly.

Cap all HP

d. Perform scheduled maintenance, as required.

e. Stow hose assemblies and ABPA IAW ship procedures.

2.3.4 Emergency Operation. Emergency operation procedures shall be followBACS not operate in a normal manner. An Emergency Operation Checklist (Table

ed immediately should the A-4) should be completed.

a. Immediately close ship HP air system valve.

b. Refer to Chapter 5, Troubleshooting, for fault isolation procedures.

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Revision 1 3-1

.1 I

CHAPTER 3 FUNCTIONAL DESCRIPTION

3 NTRODUCTION.

This chapter defines the functions of the major equipment groups for the Self-Contained Breathing Apparatus Breathing Air Charging System (SCBA BACS). A description of how the equipment operates is also

Figure 3-1. SCBA BACS Functional Schematic and Flow Diagram.

FILTERIN-LINE

FILTERIN-LINE

H-103

H-101

HP AIR GAUGE

included. Figure 3-1 provides a functional schematic and flow diagram of the system.

MANIFOLD

PUMPBOOSTER

SWITCHPILOTFILTER

DRIVE AIR

H-102

SYSTEM VALVEHP AIR

AIR BOOSTER PUMP ASSEMBLY

HIGH PRESSURE FILTER ASSEMBLY

P

AHP-V301

AHP-G301INDICATOR

AHP-V302

DESICCANTFILTER

AHP-V303

AHP-V305

AHP-V304

SHIP'S AIR IN

HOPCALITE/DESICCANT/

CHARCOAL FILTER

AHP-G201 ALP-G202ALP-V204

REG

AHP-V201 ALP-V203

AHP-V205

ALP-V202

AHP-V206

AHP-G204

TAN

KSU

RG

E

AHP-G203

P

EXTERNAL PILOT AIR INLET

AHP-V207

DRIVE AIR INLET

DRIVEAIR INLET

FILTERAIR INLET

CHARGEQUICK

WAND

FILTERAIR SUPPLY

S6226-PD-MMO-010

3-2

.2 DESCRIPTIO3 N.

The BACS is used by shipboard damage control and firefighting personnel as a means to charge SCBAs to a ressure of 4,500 ps t

(CGA) G-7.1). The BACS can be used for charging SCBA cylinder assemblies or for quick-charging SCBA. The BACS is comprised of three subassemblies: the Air Booster Pump Assembly (ABPA), the High Pressure

m the ship high-pressure air system. The ship high-pressure air system is hard-piped into the bulkhead-mounted HPFA,

assemblies. The filtered mblies via a Filtered Air Supply Hose Assembly (H-102). The unfiltered high-pressure air from the HPFA is used to operate the booster pump.

3.2.1 ABPA

p i wi h breathing quality air (Grade D as defined by the Compressed Gas Association

Filter Assembly (HPFA), and connecting hose assemblies. The BACS receives high-pressure air fro

where it is divided into filtered and unfiltered air and then routed to the ABPA via two high-pressure hoseair is used to charge SCBA or SCBA cylinder asse

. The ABP ular frame. The frame supports a control panel and is shielded by protective front and back covers. The ABPA receives both

e ABPA via a quick disconnect (QD), passes by a gauge, and flows through a shutoff valve, where airflow into

4,500 psig (1) to the sensing port of a pilot switch (AHP-V205),

SCBA cyl essure relief valve is attached to the surge tank and is used to prevent

red d passes through a filter into a cross before taking three paths: (1) to the pilot

circuit; an hat controls booster pump speed. Figure 3-2 illustrates and lists ompo

A is a two-man portable system housed within an aluminum tub

high-pressure filtered air and high-pressure drive (unfiltered) air from the HPFA. The filtered air enters th

the booster pump is controlled. The air enters the booster pump, where the air pressure is increased to . The high-pressure air then takes three paths:

which controls the flow of drive air to the booster pump; (2) to a surge tank, which serves to absorb high-pressure fluctuations during operation; and (3) through an in-line filter, past a high pressure gauge, and into the

inder assembly. A high-prover-pressurization of the filtered air circuit. The drive air enters the ABPA via a QD, passes a high-pressure gauge, and flows through a regulator, where pressure is reduced to 125 5 psig. The reduced air is monitoby a low-pressure gauge answitch (AHP-V205), which automatically stops the flow of drive air to the booster pump when the filtered air pressure reaches 4,500 psig; (2) to a relief valve (AHP-V304) that prevents over-pressurization of the drive air

d (3) past a flow control valve tc nents of the ABPA

3.2.1.1 Drive Air Inlet Pressure Gauge (AHP-G201). The drive air Inlet P0 to 5,000 psig pressure gauge that displays regulator inlet pressure from the HPFA.

ressure Indicator is a

3.2.1.2 Drive Air Regulator (AHP-V201). The drive air regulator reduces the ship high-pressure air stemsy to 125 5 psig.

3.2.1.3 Regulated Air Pressure Gauge (ALP-G202). The Regulated Air Pressure Indicator is a 0 to 200 psig pressure gauge that displays the reduced air pressure reading after the drive air pressure is regulated.

3.2.1.4 Drive Air Filter. The drive air filter removes an automatic drain valve (AHP-V305).

moisture and debris from drive air. This filter also has

3.2.1.5 Drive Air Relief Valve (ALP-V202). The drive air relief valve is located between the drive air gulator (AHP-V201) and booster pump and actuates if drive air exceeds 150 psig.

2.1.6 Drive Air Bleed Valve (ALP-V204)

re

3. . The drive air bleed valve is used to release remaining drive air to the atmosphere after charging is complete.

3.2.1.7 Drive Air Control Valve (ALP-V203). The Drive Air Control Valve is a needle valve that controls the flow of drive air to the booster pump. The more the drive air valve is opened, the faster the booster pump will operate.

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Revision 1 3-3

Number Nomenclature Number Nomenclature 1 Filtered Air Outlet Pressure Gauge 9 Booster Pump 2 Drive Air Relief Valve 10 Drive Air Regulator 3 In-Line Filter 11 Drive Air Filter 4 Filtered Air Inlet Pressure Gauge 12 Drive Air Control Valve 5 Drive Air Bleed Valve 13 Surge Tank 6 Filtered Air Inlet Valve 14 Filtered Air Relief valve 7 Regulated Air Pressure Gauge 15 Pilot Switch 8 Drive Air Inlet Pressure Gauge

Figure 3-2. Air Booster Pump Assembly (ABPA).

3.2.1.8 Filtered Air Inlet Pressure Gauge (AHP-G204). The Filtered Air Inlet Pressure Gauge is a 0 to 5,000 psig pressure gauge that indicates the filtered air pressure from the HPFA.

3.2.1.9 Filtered Air Inlet Valve (AHP-V206). The Filtered Air Inlet Valve is a needle valve that is used to control filtered air flow through the booster pump to the SCBA cylinder assemblies.

3.2.1.10 Booster Pump. The booster pump, powered by low pressure drive air, is used to compress air filtered by the HPFA to 4,500 psig.

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3-4

3.2.1.11 Surge Tank. The surge tank provides a volume to absorb high pressure fluctuations.

3.2.1.12 Filtered Air Relief Valve (AHP-V207). The Filtered Air Relief Valve is a relief valve that is located on the surge tank, and actuates if air pressure exceeds 5,300 psig.

3.2.1.13 Pilot Switch (AHP-V205). The pilot switch senses when the booster pump discharge pressure reaches 4,500 psig and shuts off the drive air supply.

3.2.1.14 In-Line Filter. The in-line filter removes particulates from booster pump discharge prior to entering the quick-charge wands.

3.2.1.15 Filtered Air Outlet Pressure Gauge (AHP-G203). The Filtered Air Outlet Pressure Gauge is a 0 to 6,000 psig pressure gauge that indicates charging air pressure.

3.2.2 HPFA. The HPFA is bulkhead-mounted and hard-piped into the ship high-pressure service line via abulkhead union in the top back center of the HPFA. Air flows through the bulkhead fitting to a tee that directsthe air to either (1) the drive air quick disconnect nipple and in-line filter ready for discharge to the ABP(2) to the HPFA filters. Air directed to the HPFA filters first passes through a coalescor filter, through a check valve, and then to the two cartridge holders. The first cartridge holder houses a desiccant cartridge for moisture removal. The second cartridge holder houses a cartridge that contains a desiccant for moisture removal, as well as a catalyst for conversion of carbon monoxide (CO) to carbon dioxide (CO

A or

al

ts

2), and charcofor odor removal. From the cartridge holders, the air enters the manifold, which directs the air to an H2O/CO indicator housing and a pressure gauge. The air then passes through a micronic filter to a shutoff valve and a quick disconnect socket, and is ready for discharge to the ABPA. Figure 3-3 illustrates and lists componenof the HPFA.

3.2.2.1 Coalescor Filter. The coalescor filter removes moisture from air supplied by the ship high-pressure air system.

3.2.2.2 Relief Valve (AHP-V304). The relief valve actuates if pressure in the filter assembly exceed3,300 psig.

s

3.2.2.3 Check Valve (AHP-V303). The check valve ensures a one-way flow of air from the ship high-pressure air system to the cartridge holders.

3.2.2.4 Cartridge Holders. The two cartridge holders are identical, but hold different filter cartridges. The first, located on the right side of the assembly (labeled TOWER 1) holds a desiccant cartridge for moisture removal; the second, located on the left side of the assembly (labeled TOWER 2) holds a composite filter

3.2.2.5 Manifold

element containing a desiccant, a catalyst for conversion of CO to CO2, and charcoal for odor removal.

. The manifold houses the H2O/CO indicator, HPFA gauge (AHP-G301), in-line filter,

3.2.2.6 H

shutoff valve (AHP-V301), and bleed valve (AHP-V302).

2O/CO Indicator. The H2O/ CO indicator is located downstream of the cartridge holders and

3.2.2.7 HPFA Indicator (AHP-G301)

indicates the presence of water and carbon monoxide in breathing air.

. The HPFA Indicator is a 0 to 5,000 psig pressure indicator that displays filtered air pressure in the HPFA.

3.2.2.8 In-Line Filters. The first in-line filter removes particulates from the drive air before it is discharged to the ABPA and the second removes any remaining particulates from the filtered air.

2.2.9 Shutoff Valve (AHP-V301)3. . The shutoff valve controls filtered air flow to the ABPA.

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Revision 1 3-5

umb um ture N er Nomenclature N ber Nomencla1 7 Relief Valve Drain Valve 2 8 HPFA Indicator Coalescor Filter 3 9 alve Drain Check V4 10 Cartridge Holder Bleed Valve 5 Shutoff Valve 11 Manifold 6 H2O/CO Indicator 12 In-Line Filter

Figure 3-3. High Pressure Filter Assembly (HPFA).

3.2.2.10 Bleed Valve (AHP-V302). The bleed valve is used to release air from the filter assembly prior to changing filter cartridges.

3.2.2.11 Drain Valve (AHP-V305). The drain valve is used to periodically remove oil and moisture that

blies

has fallen to the bottom of the coalescor filter housing.

3.2.3 Connecting Hose Assem .

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3-6

3.2.3.1 Drive Air Hose Assembly. The Drive Air Hose Assembly (H-101) connects the HPFA drive air outlet QD to the ABPA drive air inlet QD.

3.2.3.2 Filtered Air Hose Assembly. The Filtered Air Hose Assembly (H-102) connects the HPFA filtered air outlet QD to the ABPA filtered air inlet QD.

3.2.3.3 Filtered Air Supply Hose Assembly. The Filtered Air Supply Hose Assembly (H-103) connects to the ABPA using a CGA 347 nipple with hand-tight nut. The Filtered Air Supply Hose Assembly (H-103)

SCBA cylinder and/or quick charge.

consists of two branches, each containing a combination bleed and shutoff valve. This design allows twopossible charging configurations

3.2.3.4 Quick-Charge Wand. The Quick-Charge Wand is purchased from the SCBA manufacturer and allows a quick-charge operation when connected to the Filtered Air Supply Hose Assembly (H-103).

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Revision 1 4-1

CHAPTER 4 SCHEDULED MAINTENANCE

WARNING

Omission or negligent performance of prescribed maintenance procedures for this equipment could result in equipment failure and serious injury or death to personnel.

4.1 INTRODUCTION.

Proper scheduling and performance of preventive maintenance actions reduces equipment failures and ensures efficient performance of the Self-Contained Breathing Apparatus Breathing Air Charging System (SCBA BACS), hereinafter referred to as BACS. This chapter outlines safety requirements, defines the maintenance concept, references the BACS Planned Maintenance System (PMS), discusses reporting requirements, and provides general maintenance instructions relating to both scheduled and unscheduled (corrective) maintenance actions.

4.2 SCOPE.

The preventive maintenance requirements for the BACS are addressed in this chapter to assist supervisors and maintenance personnel in planning, scheduling, and documenting maintenance actions. The information in this chapter supplements the BACS PMS (paragraph 4.5) and is presented in the following sequence:

Safety Requirements Maintenance Concept Planned Maintenance System United States Navy (USN) Maintenance and Material Management (3-M) System Coverage and

Problem Reporting

General Maintenance 4.3 SAFETY EQU

Instructions

R IREMENTS.

Maintenance personnel shall read and thoroughly understan e sa contained in this manual and the approp te M quirement Card (MRC) contained in the SC MS before performing an ain CS. Forces afloat should al th Office of the Chief of

val Operations Instructi Navy Occupation (NAVOSH) ogram Manual for Force OPNAVINST 5100.23, vy Occupational Safety and Health (NAVOSH) Program Manual.

d th fety precautions BA BACS Pria aintenance Re

y m tenance on the BAon (OPNAVINST) 5100.19,

so comply wial Safety and HealthNa

Pr s Afloat, Vol I/II/III. Shore activities should comply withNa

4.4 MAINTENANCE CONCEPT.

The BACS maintenance concept is based on the Navy PMS, which classifies maintenance into two categoriesscheduled and unscheduled.

:

4.4.1 Scheduled Maintenance. Scheduled maintenance primarily ireliable system operation and includes actions such as in

nvolves actions required to ensure spection, cleaning, lubrication, leak testing, and

S6226-PD-MMO-010

4-2

es located in Chapter 2 of this manual.

operational testing. Scheduled maintenance requirements are provided in the BACS PMS (paragraph 4.5) andare also integrated in the operating procedur

4.4.2 Unscheduled Maintenance. Unscheduled (corrective) maintenance includes actions required tlocate equipment faults and to correct failures or perform

o ance degradations. Unscheduled maintenance actions

that include troubleshooting and parts replacements are performed by maintenance technicians who are adequately trained in the appropriate service requirements. Unscheduled maintenance is covered in Chapter 5, Troubleshooting, and in Chapter 6, Corrective Maintenance.

4.5 PLANNED MAINTENANCE SYSTEM.

Table 4-1 lists the nine MRCs that govern the SCBA BACS PMS. The MRCs are indexed and referenced onMaintenance Index Page (MIP) 5519/018, SCBA BACS. MIP 5519/018 provides a summary of the

maintenance actions found on the MRCs, along with periodicity codes, personnel requirements, man-hours, d any related maintenance.

Table 4-1. SCBA BACS Planned Maintenance System.

Periodicity MRC Description

an

Q-1 Analyze Charging System Air Quality Q-2 Test Operate Air Booster Pump Assembly (ABPA) S-1 Replace High-Pressure Filter Assembly (HPFA) Tower Cartridges and HPFA H2O/CO Indicator

Elements A-1 Replace Air Booster Pump Assembly (ABPA) Drive Air Filter and Seal A-2 Replace High-Pressure Filter Assembly (HPFA) Coalescor Element A-3 Inspect Teflon, Thermoplastic, and Metal Hoses, End Fittings, and Supports

18M-1 Remove ABPA Pressure Gauge(s), deliver to IMA for calibration, install calibrated ABPA Pressure Gauge(s), and Test for Leaks

36M-1 Test Set Pressure of Drive Air Relief Valve (ALP-V202); Remove and Deliver Valve(s) to IMA for Testing

R-1 Inspect SCBA BACS 4.6 UNITED STATES NAVY MAINTENANCE AND MATERIAL MANAGEMENT SYSTEM COVERAGE AND PROBLEM REPORTING.

The provisions of the OPNAVINST 4790.4 series, Ships Maintenance and Material Management (3-M) Manual, apply to the SCBA BACS. Accordingly, any problems or need for corrective maintenance arising from performance of the maintenance actions contained in the SCBA BACS MRCs should be properly reported using Office of the Chief of Naval Operations (OPNAV) Form 4790/2K to ensure timely and accurate Maintenance Data System (MDS) documentation of SCBA BACS performance in the Fleet. In addition to Fleet requirements, MDS input from Fleet units is used by the In-Service Engineering Agent (ISEA) to identify and correct problems within the system itself or the related documentation and provisioning, including Coordinated Shipboard Allowance List support. The ISEA may be contacted at Commanding Officer, Naval Surface Warfare Center Panama City, Attn: Code E53, 110 Vernon Avenue, Panama City, FL 32407.

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Revision 1 4-3

4.7 GENERAL MAINTENANCE INSTRUCTIONS.

WARNING

If in doubt about the serviceabilitimmediately. Use only approved maintenance parts. Component failure

he HPFA, ensure high pressure air source is turned off and all pressure has been bled from the system.

exposure to escaping high pressure gas may result in serious injury or death to personnel.

OT LOOSEN OR TIGHTEN FITTINGS WHILE SYSTEM IS UNDER PRESSURE. Failure to comply could result in damage to

nd serious injury or death to personnel.

y of a part, repair or replace it

during operations may result in serious injury or death to personnel.

Before performing maintenance on t

Accidental

Do not use trisodium phosphate (TSP) for cleaning HPFA or ABPA aluminum components. Use may result in equipment failure and serious injury or death to personnel.

DO N

equipment a

4.7.1 Equipment Disassembly and Parts Replacement. Disassemble equipment only as necessary for each scheduled maintenance procedure. Ensure proper tag-out procedures are performed prior to conducting maintenance. Use only approved BACS replacement components. Ensure all replacement components have been cleaned IAW MIL-STD-1622, Cleaning of Shipboard Compressed Air Systems.

4.7.1.1 Bagging Components. To maintain cleanliness of system, replace all dust caps and bag all exp d orming maintenance.

WARNING

ose components while perf

Cleanliness is imperative in handling and maintaining the SCBA BACS. st be kept free of oil, grease, rust, or other

within an assembly could result in d serious injury or death to personnel.

All tools and parts mucontamination. Foreign substances equipment failure an

WARNING

Do not use TSP for cleaning HPFA or ABPA aluminum components. Use may result in equipment failure and serious injury or death to personnel.

S6226-PD-MMO-010

4-4

4.7.2 General Cleaning Procedure. Clean is defined as free of all loose scale, rust, grit, filings, dirt, oil, grease, and other foreign substances when viewed by the unaided eye. It is vitally important to keep the work area and parts clean during maintenance of breathing air systems and equipment. To avoid introducing

esh

4.7.3 Leak Detection

contaminants or foreign particles into joints or connections that need to be opened for maintenance, clean the affected parts with a soft bristle brush and cleaning solution prepared by mixing 1 teaspoon of MIL-D-16791, Type 1 non-ionic detergent (NID) to 1 gallon of warm, fresh water. Rinse the cleaned parts with clean, frwater and wipe dry with a clean cloth or air dry.

. The use of MIL-L-25567D, Type I leak-detection compound is preferred for leak hat were broken for maintenance. The NID solution

mentioned in paragraph 4.7.2 may also be used for leak testing if necessary. testing all SCBA BACS air system connections t

4.7.4 Anti-seize Tape. The use of MIL-T-27730 anti-seize tape is required for all BACS pipe thretaping applications. Apply tape as follows:

ad

Thoroughly clean male and female threads assuring the removal of all previously applied anti-seize tape. Do not allow f any taped fittings.

ale pipe thread beginning hird thread.

ing ca le the threads twice. e anti-

4.7.5

tape particles to enter lines or valves during disassembly o

Wrap tape in spiral direction of m with second or tUs re not to contaminate the tape, encirc

Us seize tape on pipe threads only.

Lubricants. Only MIL-S-8660 lubricant is authorized. Apply lubricants sparingly.

4.7.6 ings O-R . inspected for damage and replaced if necess

CAUTION

Exposed O-rings that are not required to be removed shall be ary.

To avoid damage to O-ring groove, remove O-rings only using fingers or the appropriate tool from an O-ring extractor kit.

4.7.6.1 O-Ring Removal. If an O-ring cannot be removed with fingers, use an O-ring installation and removal tool. Scratching the O-ring groove may cause leakage or premature seal failure. Unless otherwise directed, all removed O-rings shall be cut and discarded.

4.7.6.2 O-Ring Installation. Strict cleanliness and proper lubrication are essential during O-ring installation. Ensure new O-rings are of the proper size and material. To ensure correct installation, observethe following:

Visually inspect new O-rings for deformities or compression set, hardening, or brittleness, nicks orcuts, pits or blisters, or any other signs of damage. Cut and discard damaged O-rings and obtain new O-rings for replacement.

Ensure parts are clean throughout the replacement procedure. Dirt, chips, or foreign particles in

O-ring grooves can cause leakage or damage to O-rings.

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Revision 1 4-5/(4-6 blank)

Lubricate O-rings before assembly. Use only approved lubricants for O-rings. Apply lubricant sparingly; excess lubricant can foul other

Do not needed for proper i

Ensure ent of large O-rings with rel

Do not ble, support, cone, or

When re or exposed. During installation of face seal O-rings, When re ment.

Rotating g of seals.

components.

overstretch O-rings during replacement. To avoid O-ring damage, stretch only asnstallation.

O-rings are not twisted in groove as twisting occurs easily during replacematively small cross-sectional diameters.

force O-rings over corners, threads, splines, ports, or other sharp edges. Use thim other device to prevent O-rings from contacting sharp edges of parts.

assembling SAE/MS straight-thread connections, ensure O-rings are not pinched

ensure O-rings are properly aligned.

assembling components, apply closing force to produce straight, longitudinal move or twisting movements should be avoided to prevent bunching, cutting, or tearin

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Revision 1 5-1

CHAPTER 5

5.1 INTRODUCTION

TROUBLESHOOTING

.

This chapter contains the troubleshootisource of equipment ction or performance degradation in the Self-Contained Breathing Apparatus Bre i

5.2 GENE IONS

ng procedures and data necessary to assist personnel in locating the malfun

ath ng Air Charging System (SCBA BACS).

RAL TROUBLESHOOTING INSTRUCT .

Trou leThis ma spections, or corrective acti notif t

Tab ctive actions for Air Boo rReferenapplicab

Table 5-1. ABPA Troubleshooting Guidelines.

Symptom Possible Cause(s) Fault Locating Procedure Corrective Action(s)

b shooting is based on locating potential faults in the equipment and taking timely corrective action. nual cannot possibly list all malfunctions that may occur nor all causes, tests, in

ons that may apply. If a malfunction is not listed or is not remedied by the suggested corrective action(s), y he supervisor.

les 5-1 and 5-2 list symptoms, possible causes, fault locating procedures, and correste Pump Assembly (ABPA) and High-Pressure Filter Assembly (HPFA) malfunctions and failures.

ces to additional maintenance procedures located elsewhere in this manual are included where le.

a. Ship high-pressure air

system valve(s) closed.

a. Ensure high-pressure air is available to HPFA and ABPA.

a. If no pressure indicated, ensure correct execution of setup and operating procedures in paragraphs 2.3.1 and 2.3.2 have been followed correctly.

1. Drive air inlet pressure gauge (AHP-G201) not operational.

b. Drive air inlet pressure gauge (AHP-G201) failed.

b. Compare drive air inlet pressure gauge (AHP-G201) to high-pressure air gauge on bulkhead.

b. Replace gauge IAW paragraph 6.6.9.

a. Ship high-pressure air system valve(s) closed.

a. Check drive air inlet pressure gauge (AHP-G201) reading.

a. If no pressure indicated, ensure correct execution of setup and operating procedures in paragraphs 2.3.1 and 2.3.2 have been followed correctly.

b. Regulated air pressure gauge (ALP-G202) failed.

b. Open drive air bleed valve (ALP-V204).

b. If air escapes from (ALP-V204), replace regulated air pressure gauge (ALP-G202) IAW paragraph 6.6.9.

2. Regulated air pressure gauge (ALP-G202) not operational.

c. Drive air regulator failed.

c. Determine if regulator control knob rotates freely.

c. If regulator control knob rotates freely, adjust regulator control knob IAW paragraph 6.6.2.d. If regulator control knob does not rotate freely, replace drive air regulator IAW paragraph 6.6.2.

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5-2 Revision 1

Table 5-1. ABPA Troubleshooting Guidelines Continued.

Symptom Possible Cause(s) Fault Locating Procedure Corrective Action(s) a. No high-pressure

filtered air. a. Ensure HPFA shutoff

valve (AHP-V301) is open.

a. If closed, open HPFA shutoff valve (AHP-V301). If open, proceed to Table 5-2.

3. Filtered air inlet pressure gauge (AHP-G204) not operational. b. Filtered air inlet

pressure gauge (AHP-G204) failed.

b. Compare filtered air inlet pressure gauge (AHP-G204) to drive air inlet pressure gauge (AHP-G201).

b. Replace filtered air inlet pressure gauge (AHP-G204) IAW paragraph 6.6.9.

a. Insufficient drive air pressure.

a. Ensure drive air pressure on regulated air pressure gauge (ALP-G202) reads at least 125 psig.

a. Adjust drive air regulator (AHP-V201) until regulated air pressure gauge (ALP-G202) reads 125 psi.

b. Clogged drive air filter.

b. Ensure source pressure is above 2,000 psig, but drive air regulator (AHP-V201) is 125 5 psig.

b. Replace filter element IAW MRC A-1.

c. Clogged in-line filter. c. Ensure filtered air high pressure relief valve (AHP-V207) is not venting.

c. Replace in-line filter IAW paragraph 6.6.12.

d. Pilot switch (AHP-V205) set incorrectly.

d. Observe if pump continuously stalls at the same pressure.

d. Adjust pilot switch (AHP-V205) IAW paragraph 6.6.6.b.

e. Low or loss of high-pressure air.

e. Check ship high-pressure air system pressure. Ensure high-pressure air system pressure is between 2,000 and 3,000 psig.

e. Recharge ship high-pressure air system.

f. Interior pump friction. f. Perform functional test IAW MRC Q-2R.

f. If pump fails functional test, replace IAW paragraph 6.6.1.

g. Excess moisture in drive air path.

g. Open HPFA drain valve (AHP-V305) to check for excessive moisture discharge.

g. If no pressure indicated, ensure correct execution of setup and operating procedures in paragraphs 2.3.1 and 2.3.2.

h. Faulty spooler valve assembly.

h1. Ensure head of spooler valve assembly does not protrude beyond the banjo fitting.

h2. If the head of the spooler valve assembly is positioned near the banjo fitting opening, press the head to ensure valve moves freely.

h. Replace spooler valve assembly IAW paragraph 6.6.13.

4. Pump stalls at less than 4,500 psig or becomes sluggish.

i. Low or loss of ship high-pressure air system.

i. Check high-pressure air gauge upstream of HPFA.

i. Restart ship high-pressure air compressors.

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Revision 1 5-3

Table 5-1. ABPA Tro delines Continued.

Possible Cause(s) Fault Locating Procedure Corrective Action(s)

ubleshooting Gui

Symptom

5. Pump runs a. Bleed handle on hose a. Listen for escaping air. a. Close bleed handle as continuously. isolation valve open. necessary.

b. Insufficient high-pressure air.

b. Ensure filtered air inlet b. If filtered air inlet pressupressure gauge (AHP-G204) reads at least

re gauge (AHP-G204) does not read at least 2,000 psi, proceed to Table 5-2. 2,000 psi.

c. Clogged in-line filter. c. Ensure filtered air high c. Replace in-line filter IAW pressure relief valve (AHP-V207) is not venting.

paragraph 6.6.12.

d. Filtered air high-pressure relief valve

d. Observe pressure on filtered air outlet

d. Reset filtered air high pressure relief valve

(AHP-V207) set incorrectly.

pressure gauge (AHP-G203) should relieve at 5,300 psig and reseat at 4,900 psig.

(AHP-V207) IAW MRC 36M-1.

e. Filtered air high-p(AHP-V207) leaking.

e. Listen for air leakage. e. Replace filtered air high pressure relief valve (AHP-V2