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CMM 35-21-93 Oxygen Cylinder

This document is a revision of a component maintenance manual. It provides filing instructions stating that the manual has been entirely re-issued due to modifications and extensive revisions, and operators should discard all previous copies. It also contains record pages tracking revisions and service bulletins related to cylinder and valve assembly parts.

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Ghaith Aldebsi

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100% found this document useful (1 vote)

3K views138 pages

CMM 35-21-93 Oxygen Cylinder

Uploaded by

Ghaith Aldebsi

We take content rights seriously. If you suspect this is your content, claim it here.

Available Formats

Download as PDF, TXT or read online on Scribd

Introduction
Description and Operation
Testing and Fault Isolation
Disassembly
Cleaning
Check
Repair
Assembly
Fits and Clearances
Storage
Rework

ZODIAC SERVICES

ZODIAC SERVICES
61, rue Pierre Curie
BP 1
78373 PLAISIR CEDEX
FRANCE
Phone international : + 33 1 61 34 23 23
Fax international : + 33 1 61 34 21 13
Web Site : www.services.zodiac.com

TO: HOLDERS OF COMPONENT MAINTENANCE MANUAL 35-21-93, PART NUMBER

897 SERIES

The Re-issue, dated JAN 24/12 is attached and covers all components held by every
operator

GENERAL :

DUE TO MODIFICATION, THE COMPONENT MAINTENANCE MANUAL 35-21-93

HAS BEEN ENTIRELY RE-ISSUED.

FILING INSTRUCTIONS :

DUE TO EXTENSIVE REVISION, THIS PUBLICATION HAS BEEN REPRINTED

AND REPLACES THE PREVIOUS ISSUE DATED OF NOVEMBER 18/08.
DISCARD ALL OTHER COPIES OF CMM 35-21-93
AVOX SYSTEMS
AIRCRAFT SYSTEMS

225 Erie Street

Lancaster NY 14086-9502 - USA
Phone: + 1 716 683 5100 - Fax: + 1 716 681 1089

(53655)

COMPONENT MAINTENANCE MANUAL

WITH
ILLUSTRATED PARTS LIST

CYLINDER AND VALVE ASSEMBLY

PART NUMBERS
89710015 89726022 89793015 89796015
89713015 89726050 89793050 89796077
89715050 89726077 89793077 89798015
89718015 89728040 89794015 89798022
89718050 89730050 89794040 89798050
89720050 89730077 89794050 89798077
89721022 89790022 89794077 89799015
89723015 89790050 89795050 89799050

Page: T-1

Initial Issue Date : JUL 15/92 35-21-93 Revision 3

JAN 24/12
The data and information contained herein are proprietary of AVOX Systems. Copy and distribution to a third party are strictly forbidden. Printed in United States
AVOX SYSTEMS
COMPONENT MAINTENANCE MANUAL
897 SERIES

© Copyright AVOX Systems Inc. 2012 All rights reserved

The data and information contained in this document are proprietary rights of AVOX
Systems. This document is given in confidence and may not be reproduced, stored in a
retrieval system, or transmitted to a third party, in any form or by any means, electronic,
mechanical, photocopying, or otherwise, without the prior written permission of AVOX
Systems.

Any unauthorized copy, distribution or utilization is illegal.

35-21-93 Page: T-2

RECORD OF REVISIONS

Revision Revision Date By Revision Revision Date By

Number Date Filed Number Date Filed

1 JUL 15/92 JUL 15/92 SCOTT

2 NOV 18/08 NOV 18/08 AVOX

3 JAN 24/12 JAN 24/12 ZS

35-21-93 Page RR-1

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35-21-93 Page RR-2

RECORD OF TEMPORARY REVISIONS

Temporary Issue Date Date Date Date

Revision Inserted/ Removed/ incorporated
Number Inserted by Removed by

35-21-93 Page RTR-1

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35-21-93 Page RTR-2

SERVICE BULLETIN LIST

Service Bulletin / Date

Issue Date Title
Revision Number Incorporated

SIL-35-03 / 0 19921113 ENHANCED ASSEMBLY TECHNIQUES FOR

METAL-TO-METAL VALVES

SIL-35-57 / 0 20061211 TEST DATA SHEET FOR P/N 897 SERIES

CYLINDER AND VALVE ASSEMBLY

SIL-35-59 / 0 20071015 ADDITION OF A LATENT LEAKAGE TEST

TO THE TESTING OF THE P/N 897 SERIES
CYLINDER AND VALVE ASSEMBLY

SIL-35-103 / 4 20091009 US GOVERNMENT FINAL RULE FOR THE

TRANSPORTATION OF CYLINDERS
CONTAINING COMPRESSED OXYGEN

SIL-35-115 / 1 20080801 US DOT SPECIAL PERMIT AND

TRANSPORT CANADA PERMITS CHANGE
HYDROSTATIC TEST INTERVAL FOR PN
897 SERIES CYLINDER AND VALVE
ASSEMBLY

SIL-35-125 / 2 20100222 CLARIFICATION OF LATENT LEAKAGE

TEST PROCEDURES IN AVOX SYSTEMS
MANUALS FOR PORTABLE CYLINDER
ASSEMBLIES, CYLINDER AND VALVE
ASSEMBLIES AND CYLINDER AND
REGULATOR ASSEMBLIES.

SIL-35-126 / 1 20100126 NEW US DEPARTMENT OF

TRANSPORTATION (US DOT) RULE
HM224B FOR AIR SHIPMENT OF
CHEMICAL OXYGEN GENERATORS AND
CYLINDER ASSEMBLIES THAT CONTAIN
COMPRESSED OXYGEN INTO AND WITHIN
THE US.

SIL-35-127 / 0 20100406 IMPORTANT INFORMATION REGARDING

CLEANING OF AVIATION OXYGEN
CYLINDER ASSEMBLIES.

SIL-35-130 / 0 20100615 IMPORTANT INFORMATION ABOUT LEAK

DETECTION FLUIDS AND PROCEDURES.

SIL-35-131 / 0 20100615 IMPORTANT INFORMATION REGARDING

OXYGEN COMPATIBLE LUBRICANTS.

35-21-93 Page SBL-1

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35-21-93 Page SBL-2

LIST OF EFFECTIVE PAGES

SUBJECT PAGE DATE SUBJECT PAGE DATE

Title Page T-1 R JAN 24/12 Testing And Fault 1012 JAN 24/12
T-2 BLANK Isolation 1013 R JAN 24/12
1014 JAN 24/12
Record of Revisions RR-1 R JAN 24/12 1015 R JAN 24/12
RR-2 BLANK 1016 R JAN 24/12
1017 JAN 24/12
Record of Temporary RTR-1 JAN 24/12 1018 JAN 24/12
Revisions RTR-2 BLANK 1019 R JAN 24/12
1020 BLANK
Service Bulletin List SBL-1 R JAN 24/12 1021 JAN 24/12
SBL-2 BLANK 1022 BLANK
1023 JAN 24/12
List of Effective Pages LEP-1 R JAN 24/12 1024 BLANK
LEP-2 R JAN 24/12
Disassembly 3001 R JAN 24/12
Table of Contents TOC-1 JAN 24/12 3002 JAN 24/12
TOC-2 BLANK 3003 JAN 24/12
TOC-3 JAN 24/12 3004 JAN 24/12
TOC-4 BLANK 3005 JAN 24/12
3006 R JAN 24/12
Introduction INTRO 1 JAN 24/12 3007 R JAN 24/12
INTRO 2 JAN 24/12 3008 BLANK
INTRO 3 R JAN 24/12
INTRO 4 R JAN 24/12 Cleaning 4001 R JAN 24/12
INTRO 5 JAN 24/12 4002 R JAN 24/12
INTRO 6 JAN 24/12 4003 R JAN 24/12
4004 BLANK
Description And 1 JAN 24/12
Operation 2 R JAN 24/12 Check 5001 R JAN 24/12
3 JAN 24/12 5002 R JAN 24/12
4 JAN 24/12 5003 R JAN 24/12
5 R JAN 24/12 5004 R JAN 24/12
6 JAN 24/12 5005 R JAN 24/12
5006 R JAN 24/12
Testing And Fault 1001 R JAN 24/12
Isolation 1002 JAN 24/12 Repair 6001 R JAN 24/12
1003 R JAN 24/12 6002 R JAN 24/12
1004 R JAN 24/12 6003 R JAN 24/12
1005 JAN 24/12 6004 BLANK
1006 JAN 24/12 6005 JAN 24/12
1007 R JAN 24/12 6006 JAN 24/12
1008 JAN 24/12
1009 JAN 24/12 Assembly 7001 JAN 24/12
1010 JAN 24/12 7002 R JAN 24/12
1011 JAN 24/12 7003 JAN 24/12

35-21-93 Page LEP-1

SUBJECT PAGE DATE SUBJECT PAGE DATE

Assembly 7004 R JAN 24/12 Detailed Parts List 10023 BLANK

7005 JAN 24/12 10001 10024 JAN 24/12
7006 JAN 24/12 10025 R JAN 24/12
7007 JAN 24/12 10026 R JAN 24/12
7008 R JAN 24/12 10027 R JAN 24/12
7009 R JAN 24/12 10028 R JAN 24/12
7010 R JAN 24/12 10029 R JAN 24/12
7011 JAN 24/12 10030 R JAN 24/12
7012 JAN 24/12 10031 R JAN 24/12
7013 JAN 24/12 10032 R JAN 24/12
7014 R JAN 24/12
7015 R JAN 24/12 Storage 15001 JAN 24/12
7016 BLANK 15002 R JAN 24/12
15003 JAN 24/12
Fits And Clearances 8001 R JAN 24/12 15004 JAN 24/12
8002 BLANK 15005 JAN 24/12
15006 BLANK
Special Tools, Fixtures, 9001 JAN 24/12
Equipment And 9002 R JAN 24/12
Consumables 9003 JAN 24/12
9004 R JAN 24/12
9005 JAN 24/12
9006 BLANK

Illustrated Parts List 10001 JAN 24/12

10001 10002 BLANK

Intro 10001 10003 JAN 24/12

10004 R JAN 24/12
10005 JAN 24/12
10006 BLANK

Vci 10001 10007 R JAN 24/12

10008 BLANK

Ni 10001 10009 R JAN 24/12

10010 R JAN 24/12
10011 R JAN 24/12
10012 R JAN 24/12
10013 R JAN 24/12
10014 BLANK

Detailed Parts List 10015 JAN 24/12

10001 10016 JAN 24/12
10017 R JAN 24/12
10018 JAN 24/12
10019 BLANK
10020 JAN 24/12
10021 R JAN 24/12
10022 JAN 24/12

35-21-93 Page LEP-2

TABLE OF CONTENTS

PAGE

DESCRIPTION AND OPERATION ..................................................................................................................... 1

TESTING AND FAULT ISOLATION .............................................................................................................. 1001

SCHEMATICS AND WIRING DIAGRAMS ............................................................................. NOT APPLICABLE

DISASSEMBLY.............................................................................................................................................. 3001

CLEANING..................................................................................................................................................... 4001

CHECK .......................................................................................................................................................... 5001

REPAIR .......................................................................................................................................................... 6001

ASSEMBLY.................................................................................................................................................... 7001

FITS AND CLEARANCES ............................................................................................................................. 8001

SPECIAL TOOLS, FIXTURES, EQUIPMENT AND CONSUMABLES.......................................................... 9001

ILLUSTRATED PARTS LIST ............................................................................................................. IPL 10001

SPECIAL PROCEDURES ...................................................................................................... NOT APPLICABLE

REMOVAL .............................................................................................................................. NOT APPLICABLE

INSTALLATION ...................................................................................................................... NOT APPLICABLE

SERVICING ............................................................................................................................ NOT APPLICABLE

STORAGE ................................................................................................................................................... 15001

REWORK ................................................................................................................................ NOT APPLICABLE

35-21-93 Page TOC-1

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35-21-93 Page TOC-2

TABLE OF FIGURES

PAGE

COMPONENT MAINTENANCE MANUAL:

FIGURE 1 897 SERIES CVA DIMENSIONS ............................................................................................3

FIGURE 2 VALVE ASSEMBLY (P/N 803361) ..........................................................................................4

FIGURE 3 VALVE ASSEMBLY (P/N 803345) ..........................................................................................5

FIGURE 4 TYPICAL INSTALLATION .......................................................................................................6

FIGURE 1001 INTERNAL LEAKAGE TEST OF OXYGEN VALVE P/N 803361 .....................................1005

FIGURE 1002 PRESSURE GAUGE ACCURACY TEST SETUP ............................................................1006

FIGURE 1003 OPEN/CLOSE TORQUE TEST .........................................................................................1009

FIGURE 1004 INTERNAL LEAKAGE TEST OF OXYGEN VALVE P/N 803345 .....................................1011

FIGURE 1005 PRESSURE GAUGE ACCURACY TEST SETUP ............................................................1012

FIGURE 1006 OPEN/CLOSE TORQUE TEST .........................................................................................1014

FIGURE 1007 FLOW TEST SETUP .........................................................................................................1015

FIGURE 9001 SPECIAL TOOLS, FIXTURES AND TEST EQUIPMENT (REFER TO TABLE 9001) ......9005

FIGURE 15001 CYLINDER TAG, SHIPPING (P/N 10015660) ................................................................15005

ILLUSTRATED PARTS LIST:

FIGURE 1 CYLINDER AND VALVE ASSEMBLY .............................................................................10016

FIGURE 1A CYLINDER AND VALVE ASSEMBLY .............................................................................10020

FIGURE 2 VALVE ASSEMBLY,SLOW OPENING ...........................................................................10024

FIGURE 3 BODY ASSY ....................................................................................................................10028

FIGURE 4 BODY AND GAUGE ASSY .............................................................................................10030

35-21-93 Page TOC-3

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35-21-93 Page TOC-4

INTRODUCTION

TASK 35-21-93-990-801-A01

1. CYLINDER AND VALVE ASSEMBLY - INTRODUCTION

A. Scope

(1) This manual establishes the user maintenance, overhaul and service procedures for the 897
Series Cylinder and Valve Assemblies (CVA's). This CMM includes these different
configurations of the CVA:

89710015 89726022 89793015 89796015

89713015 89726050 89793050 89796077
89715050 89726077 89793077 89798015
89718015 89728040 89794015 89798022
89718050 89730050 89794040 89798050
89720050 89730077 89794050 89798077
89721022 89790022 89794077 89799015
89723015 89790050 89795050 89799050

(2) This manual gives this information:

- Warnings, Cautions, and Notes to be obeyed while doing service on the CVA.

- The correct sequence of operations to be performed on the defined equipment.

- Specifications and a list of the tools, equipment, and materials for maintenance, check, test
and repair of the CVA.

B. Warnings, Cautions, and Notes

The Warnings, Cautions, and Notes call attention to important information.

(1) Warnings

(a) Warnings call attention to the use of materials, processes, methods, procedures or limits
which must be obeyed exactly to avoid personal injury or death.

(2) Cautions

(a) Cautions call attention to methods and procedures which must be obeyed to avoid damage
to the equipment.

(3) Notes

(a) Notes call attention to methods that make the job easier.

35-21-93 Page INTRO-1

C. General Recommendations
WARNING: FAILURE TO FOLLOW THE PROCEDURES IN THIS MANUAL OR ATTEMPTING TO
PERFORM ANY OF THE PROCEDURES IN THIS MANUAL UNLESS TRAINED IN
THE PROPER USE AND MAINTENANCE OF AVIATION OXYGEN EQUIPMENT,
MAY RESULT IN AN EXPLOSION, ILLNESS, SERIOUS PERSONAL INJURY, OR
DEATH.
(1) Read and understand all the information in this manual before performing any procedures on
the CVA. Perform all procedures in the sequence of operations given. Do not attempt to
perform any of the procedures in this manual unless you are trained and qualified in the proper
use and maintenance of aviation oxygen equipment. Maintenance personnel must know how to
avoid the hazards of maintaining aviation oxygen equipment and must comply with all
applicable government regulations.
WARNING: FAILURE TO CONTROL HIGH PRESSURE GASEOUS OXYGEN MAY RESULT IN
SERIOUS PERSONAL INJURY OR DEATH.
(2) High pressure oxygen is a hazardous material. When pressurized oxygen is discharged
intentionally or due to equipment failure, the released energy can be highly destructive if not
properly controlled. Do not perform any procedure on an unsecured, charged, cylinder
assembly. Also, while oxygen is not a flammable material, it will accelerate combustion and
must be considered a fire hazard. Refer to paragraph below.
WARNING: FAILURE TO HANDLE OXYGEN EQUIPMENT IN AN AREA CLEAN OF OIL,
GREASE, FLAMMABLE SOLVENTS, OR OTHER COMBUSTIBLE MATERIALS
INCLUDING DUST, LINT, AND FINE METAL PARTICLES OR FAILURE TO USE
CLEAN HANDS, GLOVES, TOOLS WHEN HANDLING OXYGEN EQUIPMENT MAY
RESULT IN FIRE OR EXPLOSION THAT MAY CAUSE SERIOUS PERSONAL
INJURY, OR DEATH.
(3) If oxygen equipment becomes contaminated with oil, grease, flammable solvents, or other
combustible materials, fire and explosion may occur. Also, many substances and materials that
do not normally burn in air, including dust, lint, and fine metal particles can ignite in the
presence of oxygen. Handle oxygen equipment only in a clean area and with clean hands,
gloves, and tools.
WARNING: FAILURE TO USE ONLY OXYGEN COMPATIBLE PRODUCTS, EQUIPMENT, AND
MATERIALS CAN RESULT IN A VIOLENT REACTION RESULTING IN FIRE OR
EXPLOSION THAT MAY CAUSE SERIOUS PERSONAL INJURY, OR DEATH.
(4) Many commonly used materials may react violently in the presence of high pressure oxygen.
Only equipment and materials known to be compatible with oxygen should be used. Do not
substitute other equipment or materials such as elastomeric o-rings, gaskets, seals, and metal
components, even if they look the same.
WARNING: FAILURE TO REFER TO AND FOLLOW APPLICABLE MANUFACTURER'S OR
SUPPLIER'S MATERIAL SAFETY DATA SHEET (MSDS) BEFORE USING
PRODUCTS SPECIFIED IN THIS MANUAL, MAY RESULT IN SERIOUS PERSONAL
INJURY, ILLNESS, OR DEATH.
(5) Some substances, such as cleaning materials used in this manual may be toxic under certain
conditions. Material Safety Data Sheets provide information on chemical makeup, properties,
and precautions for handling potentially hazardous substances, which may affect health risks,
storage, disposal, and other workplace safety factors.

35-21-93 Page INTRO-2

WARNING: FAILURE TO USE EYE PROTECTION AT ALL TIMES DURING SERVICE OR

OVERHAUL PROCEDURES DESCRIBED IN THIS MANUAL MAY CAUSE INJURY
TO THE EYES.
(6) Use eye protection at all times during all service or overhaul procedures.

D. Manufacturing

(1) The equipment is manufactured by:

AVOX SYSTEMS Inc.

225 Erie Street
Lancaster, NY 14086
USA
Phone : 716-683-5100
Fax: 716-681-1089

(2) Product Support

ZODIAC SERVICES AMERICAS

ZODIAC SERVICES EUROPE
4900 St. Joe Boulevard,
61 Rue Pierre CURIE
Building 200, Suite 400
BP 1
COLLEGE PARK, GA 30337
78373 PLAISIR CEDEX / FRANCE
USA
Phone : +33 1 61 34 23 23
Phone : +1 678 228 8153
Fax : +33 1 61 34 21 12
Fax : +1 800 994 7901

ZODIAC SERVICES ASIA

36, Loyang Drive
SINGAPORE 508949
Phone : +65 6546 9792
Fax : +65 6579 2231

(3) Spare Parts Sales

ZODIAC SERVICES EUROPE ZODIAC AEROSPACE U.K.

61 Rue Pierre CURIE Unit 9, Blackwell drive
BP 1 Spring Wood Industrial estate
78373 PLAISIR CEDEX / FRANCE BRAINTREE - ESSEX CM72QJ, ENGLAND
Phone : +33 1 61 34 23 23 Phone: 44 (0)-1376-329-194
Fax : +33 1 61 34 21 12 Fax: 44 (0)-1376-340-734

ZODIAC SERVICES AMERICAS ZODIAC SERVICES ASIA

4900 St. Joe Boulevard, 36, Loyang Drive
Building 200, Suite 400 SINGAPORE 508949
COLLEGE PARK, GA 30337 Phone : +65 6546 9792
USA Fax : +65 6579 2231
Phone : +1 678 228 8153
Fax : +1 800 994 7901

35-21-93 Page INTRO-3

IN-SERVICES MIDDLE EAST

Abu Dhabi International Airport
Cargo Village Area – P.O. Box No 106675
ABU DHABI - UNITED ARAB EMIRATES
Phone : + 971 2575 7088
Fax : + 971 2575 8482

E. Recommended Repair Facilities

EUROPE:
ZODIAC SERVICES EUROPE ZODIAC AEROSPACE UK
61 Rue Pierre CURIE Unit 9, Blackwell drive
BP 1 Spring Wood Industrial estate
78373 PLAISIR CEDEX / FRANCE BRAINTREE - ESSEX CM72QJ, ENGLAND
Phone : +33 1 61 34 23 23 Phone: 44 (0)-1376-329-194
Fax : +33 1 61 34 21 12 Fax: 44 (0)-1376-340-734
USA: ASIA:
ZODIAC SERVICES AMERICAS ZODIAC SERVICES ASIA
4900 St. Joe Boulevard, 36, Loyang Drive
Building 200, Suite 400 SINGAPORE 508949
COLLEGE PARK, GA 30337 Phone : +65 6579 2230
USA Phone : +1 678 228 8153 Fax : +65 6579 2231
Fax : +1 800 879 0411
MIDDLE EAST
IN-SERVICES MIDDLE EAST
Abu Dhabi International Airport
Cargo Village Area – P.O. Box No 106675
ABU DHABI - UNITED ARAB EMIRATES
Phone : + 971 2575 7088
Fax : + 971 2575 8482

F. Abbreviations

(1) The following is a list of abbreviations found in this manual.

ABBREV. DEFINITION of ITEM ABBREV. DEFINITION of ITEM

ADJ Adjustment CAD Cadmium
ALT Alternate cc cubic centimeter
ANPT Aeronautical National Taper Pipe Thread ccm cc per minute
APN AVOX Part Number CFR Code of Federal Regulations
ASSY Assembly CGA Compressed Gas Association
AR As Required CID Commercial Item Description
ATA Air Transport Association cm centimeter
BKDN Breakdown cm2 square centimeter
ºC Degrees Celsius CMM Component Maintenance Manual

35-21-93 Page INTRO-4

ABBREV. DEFINITION of ITEM ABBREV. DEFINITION of ITEM

CONFIG Configuration NP Not Procurable
CVA Cylinder and Valve Assembly NTPD Normal Temperature and Pressure Dry
CRES Corrosion Resistant Steel (760mm Hg, 70ºF (21,1ºC))
cu ft cubic feet O2 Oxygen
CYL Cylinder OD Outside Diameter
DET Detailed OPT Optional
DIA Diameter PARA Paragraph
DOT Department of Transportation Ph Hydrogen ion concentration
EFF Effectivity P/N Part Number
e.g. example given PRESS Pressure
ºF Degrees Fahrenheit psia pounds per square inch absolute
FAA Federal Aviation Administration (USA) psig Pounds per square inch gauge
FAR Federal Aviation Regulations (USA) PTFE polytetrafluoroethylene
FED STD Federal Standard REG Regulator
Fig or FIG Figure REPLD Replaced
ft feet REPLS Replaces
ft2 square feet REQ'D Required
gm grams RF Reference
Hg Mercury SB Service Bulletin
hr hour SIL Service Information Letter
ID Identification or Inside Diameter STPD Standard Temperature and Pressure Dry
(760 mmHg, 32°F (0°C))
i.e. that is
SUPSD Superseded
in inch
SUPSDS Supersedes
in.lb inch-pound
TC Transport Canada
in.oz inch-ounce
Te Transducer Exposure Temperature
IPL Illustrated Parts List
TEMP Temperature
kg kilogram
THD Thread
KPa KiloPascal
THK Thick
lbs pounds
thru through
LNG Long
TTL Total TYP or TypTypical
lpm liters per minute
TYP Typical
m meter
UNF United National Fine (Thread)
MAX Maximum
U.S. or US United States
mg milligram
USA United States of America
min minute
VAC Vacuum
MIN Minimum
VDC Volts Direct Current
ml milliliter
W/ or w/ With
mm millimeter
WC Water Column
MPa MegaPascal
W/O or w/o Without
MSDS Material Safety Data Sheet
Wt or wt Weight
N Newton
N/A Not Applicable
NHA Next Higher Assembly
N.m newton-meter
No. or NO. Number

35-21-93 Page INTRO-5

G. Verification

Testing and Fault Isolation ............................................................... : 19920515

Disassembly ..................................................................................... : 19920515

Assembly .......................................................................................... : 19920515

35-21-93 Page INTRO-6

DESCRIPTION AND OPERATION

TASK 35-21-93-870-801-A01

1. DESCRIPTION
A. General
(Refer to figure 1)(Refer to figure 2)(Refer to figure 3)(Refer to figure 4)
(1) This section describes the equipment that comprises the 897 Series Cylinder and Valve Assemblies.
Information regarding part numbers, operation and installation is also presented in this section.
B. Description
(1) The 897 Series Cylinder and Valve Assemblies are self-contained, unregulated, high- pressure oxygen
sources that supply aviation grade oxygen (per Military Specification MIL-PRF-2721 0, Type I) to crew
members and/or passengers.
(2) The 897 Series Cylinder and Valve Assemblies are compliant with Cylinder Rating DOT-SP 8162.
(3) Each assembly consists of a cylinder on which a manually operated ON/OFF valve is installed. One, or
more, units may be installed to supply the oxygen distribution system of an aircraft. The number and size
of cylinders selected will be determined by the oxygen volume requirements of the specific aircraft.
C. Part Number Identification
(1) The part number for each cylinder and valve assembly is an eight digit number as shown in Table 1. The
first three digits (897) indicate the series to which the cylinder and valve assembly belongs. The fourth
digit indicates the ON/OFF valve configuration employed on the unit (see Table 1, column 1). The fifth
digit indicates the safety outlet assembly that is installed on the valve assembly (see Table 1, column 4).
The seventh and eighth digits indicate the size of the cylinder supplied with the unit (see Table 1, column
7).

897 x x 0 x x
SERIES No.

CYLINDER
VALVE BODY ASSY VALVE SAFETY OUTLET ASSY (Refer to Table 3)
GAUGE
CONFIG P/N CONFIG P/N THREAD CONFIG P/N
(Y/N)
1 803361-01 Y 0 800844-00 .438-20 UNF-3A 22 21507-01
2 803361-02 N 1 801153-00 .500-20 UNJF-3B 40 21507-05
3 803361-03 Y 2 800843-00 .625-20 UN-3A 50 21507-02
9 803345-01 Y 3 22606-01 .438-20 UNF-3A 77 21507-03
4 800844-01 .500-20 UNEF-3A 15 21507-04
5 10722-00 1/8-ANPT
6 2814-00 N/A
7 - -
8 22608-01 .438-20 UNF-3A
9 22608-02 .500-20 UNF-3A

Table 1: CVA Part Number Configuration Matrix

35-21-93 Page 1
JAN 24/12
The data and information contained herein are proprietary of AVOX Systems. Copy and distribution to a third party are strictly forbidden. Printed in United States
AVOX SYSTEMS
COMPONENT MAINTENANCE MANUAL
897 SERIES

(2) A replacement Valve with mounted Safety Outlet Assembly (less Cylinder) may be ordered as
indicated in Table 2. Select the appropriate CONFIG numbers to complete the part number as
indicated.

803440 - x x
Basic P/N

VALVE VALVE SAFETY OUTLET ASSY

GAUGE WEIGHT WEIGHT

CONFIG P/N CONFIG P/N THREAD
(Y/N) lbs kg lbs kg
1 803361-01 Y 1.66 0,752 0 800844-00 .438-20 UNF-3A 0.19 0,086
2 803361-02 N 1.48 0,670 1 801153-00 .500-20 UNJF-3B 0.09 0,041
3 803361-03 Y 1.81 0,820 2 800843-00 .625-20 UN-3A 0.17 0,077
9 803345-01 Y 1.66 0,752 3 22606-01 .438-20 UNF-3A 0.17 0,077
4 800844-01 .500-20 UNEF-3A 0.19 0,086
5 10722-00 1/8-ANPT 0.16 0,072
6 2814-00 N/A 0.11 0,050
7 - - - -
8 22608-01 .438-20 UNF-3A 0.12 0,054
9 22608-02 .500-20 UNF-3A 0.13 0,059
Table 2: 803440 Series Oxygen Valve Assembly Part Numbering Matrix

(3) Table 3 shows the dimensions, capacity and weight of the cylinder.

NOMINAL DIMENSIONS CYLINDER CYLINDER WEIGHT CYLINDER WEIGHT *

CYLINDER in. (cm) CAPACITY (EMPTY) (CHARGED)
CONFIG. (Refer to (Refer to Fig. 1) lbs. (kg) lbs. (kg)
Table 1 for P/N) cu.ft
A B C MIN MAX MIN MAX
(liters)
5.1 19.6 23.70 22.8 3.3 4.0 5.2 5.9
22
(13,0) (49,8) (60,2) (646) (1,5) (1,8) (2,4) (2,7)
6.7 20.2 24.30 39.9 5.4 6.7 8.7 10.0
40
(17,0) (51,3) (61,7) (1130) (2,5) (3,0) (4,0) (4,5)
6.7 24.8 28.90 50.1 6.7 7.9 10.9 12.1
50
(17,0) (63,0) (73,4) (1419) (3,0) (3,6) (4,9) (5,5)
7.5 29.4 33.50 77.1 10.8 12.9 17.2 19.3
77
(19,1) (74,7) (85,1) (2183) (4,9) (5,9) (7,8) (8,8)
9.0 31.3 35.46 115.7 15.9 18.1 25.5 27.7
15
(22,9) (79,5) (90,1) (3276) (7,2) (8,2) (11,6) (12,6)
(*) Weights shown DO NOT include weight of valve assembly, or weight of safety outlet assembly (see Table 2).

Table 3: 897 Series CVA Cylinder Dimensions, Capacity, and Weight

35-21-93 Page 2
JAN 24/12
The data and information contained herein are proprietary of AVOX Systems. Copy and distribution to a third party are strictly forbidden. Printed in United States
AVOX SYSTEMS
COMPONENT MAINTENANCE MANUAL
897 SERIES

C MAX

B ±0.5

±0.1
A DIA.

Manufacturer's
Ident. Plate

897 Series CVA Dimensions

FIGURE 1/GRAPHIC 35-21-93-991-001-A01

TASK 35-21-93-870-802-A01

2. OPERATION

A. General

(1) Two basic styles of manually operated, slow opening valve assemblies are available for use
with the 897 Series Cylinder and Valve. The function of both valve styles is identical. Opening
either style valve allows high pressure (1850 psi /12,76 MPa) oxygen, from the cylinder, to flow
from the outlet port of the valve. Closing either style valve retains the pressurized oxygen in the
cylinder and lower portion of the valve body. Some of the available valve configurations are
equipped with pressure gauges to indicate oxygen pressure remaining in the cylinder.

(2) A number of safety outlet assemblies (see Table 2) are available for use with either of the two
valve styles. The safety outlet assemblies are mounted to the valve bodies, and are exposed to
pressure entering the inlet port of the valve. A disc, contained within the safety outlet assembly,
will rupture should the unit become over pressurized (2500 - 2775 psi / 17,24 - 19,13 MPa).

(3) The valve assemblies addressed in this document are simple ON and OFF type valves and are
not intended for regulating oxygen flow. During normal operation, the valve should be in only
one of two positions (opened or closed).

(4) The mechanics of operation for both valve styles differ, and shall be described separately.
Operational differences of the two valve styles are summarized in Table 4.

35-21-93 Page 3
JAN 24/12
The data and information contained herein are proprietary of AVOX Systems. Copy and distribution to a third party are strictly forbidden. Printed in United States
AVOX SYSTEMS
COMPONENT MAINTENANCE MANUAL
897 SERIES

B. Valve Assembly (P/N 803361)

(Refer to figure 2)
(1) The valve handle (6), is used to open and close the valve assembly. The handle is attached to
the upper end of the valve stem. The squared lower end of the valve stem passes through a
compression spring and engages a square hole on the top surface of the valve plug (2).
(2) Rotating the valve handle in a counterclockwise direction causes plug (2) to unthread and lift
from the valve seat assembly (3). Pressurized oxygen from the cylinder may now pass through
the opened valve seat orifice and exits the outlet port (5) of the valve body.
(3) The initial flow of oxygen is small, but increases as the plug is raised to enlarge the valve seat
orifice. The slowly increasing volume of oxygen that is output from the valve prevents the
downstream system from pressurizing too quickly and overheating. No significant increase in
oxygen flow is realized after the valve handle has been opened 3 full revolutions.
(4) Approximately 3-1/2 rotations of the handle are required to completely open the valve. At the
full open position, the top surface of the valve plug (2) just begins to compress the spring (8),
and the torque required to operate the valve handle immediately increases. DO NOT operate
the valve handle in the increased operating torque range.
(5) Proper operation will extend the service life of a valve and minimize the need for repairs. Open
and close the valve as indicated below.

OPEN Turn valve handle (6) in a counterclockwise direction to full open position
(approximately 3-1/2 turns); turn valve handle approximately 1/4 turn
clockwise. Forcing the valve handle beyond the full open position will not
increase the flow of oxygen, and may damage seals and/or packings within
the valve body.
CLOSE Turn valve handle (6) in a clockwise direction to stop oxygen flow. Forcing the
valve handle beyond the full closed position will deform the KEL-F seat
material of the plug assembly (3).

6 7

8
2

1. Inlet
4 3 2. Valve plug
3. Valve seat assembly
4. Safety Outlet Assembly
5. Valve Outlet
6. Valve Handle
1 7. Cylinder Pressure Gauge
8. Spring

Valve Assembly (P/N 803361)

FIGURE 2/GRAPHIC 35-21-93-991-002-A01

35-21-93 Page 4
JAN 24/12
The data and information contained herein are proprietary of AVOX Systems. Copy and distribution to a third party are strictly forbidden. Printed in United States
AVOX SYSTEMS
COMPONENT MAINTENANCE MANUAL
897 SERIES

C. Valve Assembly (P/N 803345)

(Refer to figure 3)
(1) This style valve assembly (body and gauge assy) is equipped with filter arrangements at both
the inlet (5) and outlet (6) ports of the valve body. The mechanics of operation for this valve
differ from other valves covered by this document, and are described below.
(2) A valve handle (1) is attached to the upper end of valve stem (2), and a tip and poppet
assembly (3) is attached to the lower end. Counterclockwise rotation of the valve handle, lifts
the tip and poppet assembly to open the orifice in the seat and filter assembly (4) to allow
passage of oxygen.
(3) Approximately 6-1/2 rotations of the valve handle are required to completely open the valve.
Clockwise rotation of the valve handle lowers the tip and poppet assembly to block the flow of
oxygen from the cylinder.
(4) The initial flow of oxygen is small but increases as the tip and poppet assembly is raised to
enlarge the seat and filter assembly orifice. The slowly increasing volume of oxygen that is
output from the valve prevents the downstream system from pressurizing too quickly and
overheating.
(5) Proper operation will extend the service life of a valve and minimize the need for repairs. Open
and close the valve as indicated below.

OPEN Turn valve handle (1) in a counterclockwise direction to full open position (approximately 6-
1/2 turns); turn valve handle approximately 1/4 turn clockwise. Forcing the valve handle
beyond the full open position will not increase the flow of oxygen, and may damage seals
and/or packings within the valve body.
CLOSE Turn valve handle (1) to a full clockwise position to stop oxygen flow.

2
1. Handle
2. Stem
3. Tip and poppet assembly
3 4. Seat and filter assembly
5. Inlet
6. Filter assembly (outlet)
7. Pressure Cap Assembly
4 6 7

Valve Assembly (P/N 803345)

FIGURE 3/GRAPHIC 35-21-93-991-003-A01

35-21-93 Page 5
JAN 24/12
The data and information contained herein are proprietary of AVOX Systems. Copy and distribution to a third party are strictly forbidden. Printed in United States
AVOX SYSTEMS
COMPONENT MAINTENANCE MANUAL
897 SERIES

VALVE ASSEMBLY
CHARACTERISTICS
803361 803345

Inlet Filter No Yes

Outlet Filter No Yes

Turns (Open/Close)
3-1/2 6-1/2
(Approximate)

OPEN/CLOSE Torque 15 in.lbs. 30 in.lbs.

(Maximum) (1,7 Nm) (3,4 Nm)

7 in.lbs. 7 in.lbs.
Operating Torque (Average)
(0,8 Nm) (0,8 Nm)

Table 4: Difference Data - Valve Characteristics

D. Installation

(Refer to figure 4)

(1) A typical installation of the 897 Series Cylinder and Valve Assemblies is presented in Figure 4.
1 6 5 7 8

1. Cylinder and Valve Assy (4 shown)

2. Pressure Regulator
3. Slow Opening Line Valve
4. Diluter Demand Regulators
5. Aneroid Operated Oxygen System Release Valve
6. Electrically Operated Oxygen System Release Valve
7. Automatic Constant Flow Pressure Regulator
8. Passenger Mask Compartment Doors
9. Check Valve
4 3 2 9

Typical Installation
FIGURE 4/GRAPHIC 35-21-93-991-004-A01

35-21-93 Page 6
JAN 24/12
The data and information contained herein are proprietary of AVOX Systems. Copy and distribution to a third party are strictly forbidden. Printed in United States
AVOX SYSTEMS
COMPONENT MAINTENANCE MANUAL
897 SERIES

TESTING AND FAULT ISOLATION

TASK 35-21-93-700-801-A01

1. CYLINDER AND VALVE ASSEMBLY-TESTING

A. General

(1) This section contains the testing and fault isolation procedures used to evaluate performance
of the 897 Series Cylinder and Valve Assemblies (CVA). Should the CVA need repair or
replacement parts installed, the CVA must pass the appropriate test requirements before the
unit is available for use. Also, when a CVA has been overhauled, all tests in this section must
be performed.

(2) Should a failure occur during test procedures, refer to the Troubleshooting Chart (Table 1004
and 1005) for fault isolation techniques.

(3) Facilities performing the tests shall hold a current, valid DOT Approval.

(4) Unless noted otherwise, the tests contained in this section apply to all 897 Series CVA’s. Tests
should be accomplished in a shop proper for repair of high pressure aviation oxygen
equipment with an environment maintained within the limits specified below.

Temperature .......................................................: 15 - 35°C (59 - 95°F)

Barometric Pressure ..........................................: 686 - 813 mm. Hg (27 - 32 in. Hg)

Relative Humidity ...............................................: 5 - 95 Percent

(5) Refer to the ILLUSTRATED PARTS LIST section of this manual for the item numbers given in
parenthesis.

NOTE: APN's with dash numbers of this form (-1, -2, -3, -4, -5, -6, -7, -8, 9) are identical to
APN's with dash nmbers of this form (-01, -02, -03, -04, -05, -06, -07, -08, 09).

WARNING: FAILURE TO USE ONLY PURE, TEST GAS (NOT OIL PUMPED) MAY CAUSE AN
EXPLOSION OR FIRE RESULTING IN SERIOUS PERSONAL INJURY OR DEATH.

(6) Oxygen contaminated with oil can ignite with explosive force. Do not, under any circumstances
use oil pumped test gas. Even a minute quantity of oil will cause contamination of the CVA and
test equipment.

WARNING: FAILURE TO FULLY DISCHARGE THE OXYGEN FROM THE CVA, COMPONENT
PARTS, OR TEST SETUP PRIOR TO DISASSEMBLY OF ANY PART MAY CAUSE
SERIOUS PERSONAL INJURY, OR DEATH.

(7) High pressure oxygen is a hazardous material. When pressurized oxygen is discharged
intentionally or due to equipment failure, the released energy can be highly destructive if not
properly controlled. Fully discharge the oxygen from the CVA, component parts, and test setup
prior to disassembly of any part.

WARNING: FAILURE TO REFER TO AND FOLLOW APPLICABLE MANUFACTURER'S OR

SUPPLIER'S MATERIAL SAFETY DATA SHEET (MSDS) BEFORE USING
CONSUMABLE TEST MATERIALS SPECIFIED IN THIS MANUAL, MAY RESULT IN
SERIOUS PERSONAL INJURY, ILLNESS, OR DEATH.

35-21-93 Page 1001

(8) Some consumable test materials used in this manual may be hazardous under certain
conditions. Material Safety Data Sheets provide information on chemical makeup, properties,
and precautions for handling potentially hazardous substances which may affect health risks,
storage, disposal, and other workplace safety factors.

B. Reference Documents

(1) A list of applicable reference documents is given in Table 1001.

DOCUMENT
DOCUMENT NAME ORDERING INFORMATION
NUMBER

MIL-PRF-27210 Performance Specification Superintendent of Documents

Oxygen, Aviator's Breathing, Liquid and Gas US Government Printing Office
Washington, DC 20402
A-A-59503 Federal Specification USA (VER765)
Nitrogen, Technical

MIL-PRF-25567 Military Specification

Leak Detection Compound,
Oxygen Systems

AIR 1059 Transfilling and Maintenance of Oxygen SAE International

Cylinders Warrendale PA 15096-001
USA (V0U583)

Table 1001: Reference Documents

C. Special Tools, Fixtures, and Test Equipment

(1) Special tools, fixtures, and test equipment required are given in Table 1002. Special tools,
fixtures, and test equipment must be cleaned for oxygen service before use. Unless otherwise
noted, one of each item listed is required. Equivalents may be substituted.

PART NUMBER MANUFACTURER

NOMENCLATURE
(or DESCRIPTION) (VENDOR CODE)
Pressure Gauge 1404 Series Ametek (US Gauge)
0 - 2000 psig (0 - 13,79 MPa) Feasterville, PA 19053
(Minimum accuracy ± 0.25% full scale) USA (V61349)

Test Gauge (Calibrated Gauge Component) 1409 Series

0-3000 psig (0 – 20,68 MPa)
Accuracy ±1.0% of span

Test Regulator 44-1100 Series Tescom Corp.

0 - 2500 psig (0 - 17,24 MPa) Outlet Pressure 44-1114-24 Elkhorn, MN 55330-2491
USA (V5H642)

Flowmeters 1110 Series

(Minimum accuracy ± 2% full scale)

10,0 - 100 cu.cm/min 1110DC21CBGAA Brooks Instruments

Hatfield, PA 19440-3052
200 - 2000 l/m 1110DM41CBGAA USA (V4ZW64)

35-21-93 Page 1002

PART NUMBER MANUFACTURER

NOMENCLATURE
(or DESCRIPTION) (VENDOR CODE)
Valve Outlet Test Assembly

Nut – CGA 540 P/N 62 Western Enterprises

Avon Lake, OH 44012-2322
Nipple – CGA 540 x ¼ ANPT P/N 69 USA (V16166)

Valve Inlet Test Adapter APN 803213-S58-10 AVOX Systems

Lancaster, NY 14086-9502
USA (V53655)

Cap (0.903-14 NGO-RH n/a Local Vendor

Table 1002: Special Tools, Fixtures, and Test Equipment

D. Consumable Test Materials

(1) A list of consumable test materials is given in Table 1003. Equivalent materials may be
substituted. All flow rates specified are for oxygen test gas at NTPD.

MANUFACTURER)
MATERIAL DESCRIPTION
(VENDOR CODE)

Test Gas Oxygen (MIL-PRF-27210, Type 1) Local Vendor

Refer to NOTE 1 and NOTE 2

Leak Test Solution Sherlock Leak Detector Winton Products Co. Inc.
MIL-PRF-25567, Type 1 Charlotte, NC 28236
USA (V23316)

Rust Inhibiting Leak Test 5 cc of a base solution specified in NOTE Fisher Scientific
Solution 3, dissolved in one US gallon (3,79 liters) Pittsburgh, PA 15275
of water USA (V1KP78)

Masking Tape "Tape Dots" Bradymarker TM Masks Brady United States

3/8 in. dia. Milwaukee, WI 53201
Cat. No. 49237, Prod. No. CMC-3750 USA (V85480)

NOTE 1: Oxygen (MIL-PRF-27210, Type 1) is specified in the testing procedures in this section of
the manual. If water pumped nitrogen or water pumped air (specified in Note 2) is used for
the test gas, the applicable test parameters must have the appropriate density correction
factors calculated and used, and the test equipment must be calibrated for the test gas. (A
copy of specification MIL-PRF-27210 is available from: Standardization Documents Order
Desk, Building 4D, 700 Robbins Avenue, Philadelphia, PA 19111-5094 USA).

NOTE 2: Water pumped nitrogen per Federal Specification A-A-59503, Type I, Class I, Grade B. (A
copy of Specification A-A-59503 is available from: General Services Administration,
Business Service Center, Washington, DC USA.) Water pumped air, equivalent in purity
to: MIL-PRF-27210, Type I.

Base solution is comprised of the following: Sodium Chromate (160 grams) combined with
NOTE 3:
Glacial Acetic Acid (150 cc), dissolved in water (1840 cc).

Table 1003: Consumable Test Materials

35-21-93 Page 1003

E. Hydrostatic Testing of Cylinder

(1) Refer to Check section , Cylinder and valve Inspection. (refer to Subtask 35-21-93-210-004-
A01)

F. Cylinder and Valve Assembly fitted with Oxygen Valve P/N 803361 - Test Procedures (Applicable to
'Cylinder and Valve Assembly 8971xxxx / 8972xxxx / 8973xxxx')

WARNING: IN ALL PROCEDURES LISTED BELOW, OXYGEN IS SPECIFIED AS THE TEST

GAS. WATER PUMPED NITROGEN OR OIL-FREE AIR MAY BE SUBSTITUTED,
BUT TEST RESULTS MUST BE CONVERTED PRIOR TO BEING COMPARED WITH
TEST RESULTS SPECIFIED FOR OXYGEN. DO NOT, UNDER ANY
CIRCUMSTANCES, USE OIL PUMPED GAS AS THIS WILL CAUSE
CONTAMINATION OF THE VALVE AND TEST EQUIPMENT. OIL, EVEN IN MINUTE
QUANTITY, COMING IN CONTACT WITH OXYGEN MAY CAUSE AN EXPLOSION
OR FIRE.

NOTE: Refer to Table 1004 for troubleshooting chart and to Testing Table 1006.

Subtask 35-21-93-790-001-A01

(1) Internal Leakage Test

(a) Job Set-up

1 Set up test using Fig. 1001.

(b) Procedure

ACTION RESULT

1 Close valve by rotating handle (100,

IPL Fig.3) to full clockwise position.

2 Connect a 2000 psi (13,79 MPa)

oxygen source to the inlet of the valve
body (230, IPL Fig.3).

3 Completely submerge the valve in leak

test solution.

4 Apply pressurized oxygen (1850 +0/-

50 psi / 12,755 +0/-0,34 MPa) to the
inlet.

5 Check the valve for leakage for two Make sure that there are no signs of
minutes. leakage.

6 Discontinue supply of pressurized

oxygen to valve assembly.

35-21-93 Page 1004

CGA 540
Nut
Valve
Flowmeter
10-100 cu.cm/min

Valve Inlet Test Adapter

APN 803213-S58-10 CGA 540
Nipple
Pressure Gauge
0-2000 psig (0-13,78 MPa)

Test Gas

Test Regulator
0-2500 psig (0-17,24 MPa)

Internal Leakage Test of Oxygen Valve P/N 803361

FIGURE 1001/GRAPHIC 35-21-93-991-101-A01

Subtask 35-21-93-790-002-A01

(2) Gauge Accuracy Test

(a) Job Set-up

1 Set up test using Fig. 1002.

2 Rotate valve handle clockwise until valve is in the closed position.

(b) Procedure

ACTION RESULT
1 Slowly apply 500 psig (3,447 MPa)
pressure to the test system as
indicated on test system pressure
gauge.
2 Check accuracy of valve gauge to test Make sure that the difference between the
system pressure gauge. pressure measured on the valve gauge
and the pressure read on the test system
pressure gauge is less than ± 50 psi
(0,345 MPa).
3 Apply 1000 psig (6,895 MPa) pressure
to the test system as indicated on test
system pressure gauge.

35-21-93 Page 1005

ACTION RESULT
4 Check accuracy of valve gauge to test Make sure that the difference between the
system pressure gauge. pressure measured on the valve gauge
and the pressure read on the test system
pressure gauge is less than ± 50 psi
(0,345 MPa).
5 Apply 1500 psig (10,34 MPa) pressure
to the test system as indicated on test
system pressure gauge.
6 Check accuracy of valve gauge to test Make sure that the difference between the
system pressure gauge. pressure measured on the valve gauge
and the pressure read on the test system
pressure gauge is less than ± 50 psi
(0,345 MPa).
7 Apply 2000 psig (13,79 MPa) pressure
to the test system as indicated on test
system pressure gauge.
8 Check accuracy of valve gauge to test Make sure that the difference between the
system pressure gauge. pressure measured on the valve gauge
and the pressure read on the test system
pressure gauge is less than ± 50 psi
(0,345 MPa).
9 Reduce inlet pressure to 0 psig (0
MPa) and slowly discharge remaining
oxygen from valve.
10 A gauge which does not pass this test
must be replaced.

Oxygen
Valve

Valve Inlet Test Adapter

APN 803213-S58-10
Pressure Gauge
0-3000 psig (0-20,68 MPa)

Test Gas

Test Regulator
0-2500 psig (0-17,24 MPa)

Pressure Gauge Accuracy Test Setup

FIGURE 1002/GRAPHIC 35-21-93-991-102-A01

35-21-93 Page 1006

Subtask 35-21-93-790-004-A01

(3) External Leakage Test

(a) Job Set-up

1 Perform external leakage testing of the slow opening valve either per "Non-immersion
method" or "Immersion method" below.

(b) Non-immersion Method

ACTION RESULT

1 Install the outlet cap (Table 1002) on

the valve body (60 thru 60J, IPL Fig 1)
outlet.

2 Tighten cap assembly wrench tight.

3 Slowly rotate the valve handle (100,

IPL Fig. 3) counterclockwise
(approximately 3 complete turns) until
the valve is in the half-open position.

4 Brush the Leak Test Solution (Table Bubbles in the Leak Test Solution indicate
1003) on all areas of the valve where leakage. Not to exceed 5 cc/hr (3 bubbles
external leakage can occur and on the in 2 mins.).
mating threads between the valve and
the cylinder (70 thru 70D, IPL Fig 1).

5 Rotate the handle clockwise until valve

is in the closed position.

6 Slowly open and close the valve two

more times.

7 Rotate handle counterclockwise until

valve is in full-open position.

8 Repeat the three steps above with the Bubbles in the Leak Test Solution indicate
valve is in the full-open position. leakage. Not to exceed 5 cc/hr (3 bubbles
in 2 mins.).

9 Rotate the handle clockwise until the

valve is in the closed position.

10 Dry the CVA using clean, dry air that is

oil-free.

35-21-93 Page 1007

ACTION RESULT

11 Discharge oxygen from valve by slowly

removing the cap assembly from the
valve outlet

12 Re-install the cap assembly (Table

1002) on the valve body.

(c) Immersion Method

ACTION RESULT

1 Install the cap assembly (Table 1002)

on the valve body (60 thru 60J, IPL Fig
1).

2 With the valve approximately half There shall be no evidence of leakage

open, immerse the valve and cylinder when observed for 2 minutes : external
neck in a container of Rust Inhibiting leakage, if present, must not exceed 5
Leak Test Solution (Table 1003). cc/hr (0,083 cu.cm/min) (approximately 3
bubbles in 2 minutes).

3 Cycle the valve (from open to closed

to fully open) 2 times.

4 With the valve approximately half There shall be no evidence of leakage

5 Dry the CVA using clean, dry air that is

oil-free. Then close the valve.

Subtask 35-21-93-790-005-A01

(4) Open/Close Torque Test

(a) Job Set-up

1 Set up test using Fig.1003.

35-21-93 Page 1008

(b) Procedure

ACTION RESULT
1 Install suitable cap (Table 1002) on
external threads of valve body (60 thru
60J, IPL Fig 1) outlet.
2 Close valve by rotating handle (100,
IPL Fig 3) to full clockwise position.
3 Connect oxygen supply to valve inlet.
4 Apply pressurized oxygen (1850 +0/-
50 psi / 12,76 +0/-0,34 MPa) to valve.
5 Using a torque wrench, determine The force necessary to rotate the stem to
required torque to open/close valve. the open or closed position cannot
exceed 15 in.lbs (1,70 N.m) when the
valve is pressurized.

Valve

Valve Inlet Test Adapter

APN 803213-S58-10 Cap Outlet

Pressure Gauge
0-2000 psig (0-13,78 MPa)

Test Gas

Test Regulator
0-2500 psig (0-17,24 MPa)

Open/Close Torque Test

FIGURE 1003/GRAPHIC 35-21-93-991-103-A01

G. Cylinder and Valve Assembly fitted with Oxygen Valve P/N 803345 - Test Procedures (Applicable to
Cylinder and Valve Assembly 8979xxxx')

WARNING: IN ALL PROCEDURES LISTED BELOW, OXYGEN IS SPECIFIED AS THE TEST

35-21-93 Page 1009

NOTE: Refer to Table 1005 for troubleshooting chart and to Testing Table 1007.

Subtask 35-21-93-790-006-A01

(1) Internal Leakage Test

(a) Job Set-up

1 Set up test using Fig.1004.

(b) Procedure

ACTION RESULT

1 Open valve by rotating handle (80, IPL

Fig.4) to full counterclockwise position
(approximately 6-1/2 revolutions).

2 Using a torque wrench, close valve by

rotating handle in a clockwise
direction. Closing torque shall be 60
+5 in.lbs (6,8 +0,57 Nm).

3 Apply pressurized oxygen (1850 +0/- There shall be no evidence of leakage.

50 psi / 12,76 +0/-0,34 MPa) to valve.

4 Discontinue flow of pressurized

oxygen to valve.

5 Open test valve.

6 Using a torque wrench, close test

valve using a maximum torque of 30
in.lbs (3,4 Nm).

7 Attach flowmeter (10-100 cu.cm/min)

to valve outlet.

8 Apply pressurized oxygen (1850 +0/-

50 psi / 12,76 +0/-0,34 MPa) to valve.

9 Monitor flowmeter. Leakage shall not exceed 50 cu.cm/min.

35-21-93 Page 1010

CGA 540
Nut
Valve
Flowmeter
10-100 cu.cm/min

Valve Inlet Test Adapter

APN 803213-S58-10 CGA 540
Nipple
Pressure Gauge
0-2000 psig (0-13,78 MPa)

Test Gas

Test Regulator
0-2500 psig (0-17,24 MPa)

Internal Leakage Test of Oxygen Valve P/N 803345

FIGURE 1004/GRAPHIC 35-21-93-991-104-A01

Subtask 35-21-93-790-007-A01

(2) Gauge Accuracy Test

(a) Job Set-up

1 Set up test using Fig.1005.

2 Rotate valve handle clockwise until valve is in the closed position.

(b) Procedure

35-21-93 Page 1011

Oxygen
Valve

Valve Inlet Test Adapter

APN 803213-S58-10
Pressure Gauge
0-3000 psig (0-20,68 MPa)

Test Gas

Test Regulator
0-2500 psig (0-17,24 MPa)

Pressure Gauge Accuracy Test Setup

FIGURE 1005/GRAPHIC 35-21-93-991-105-A01

35-21-93 Page 1012

Subtask 35-21-93-790-008-A01

(3) External Leakage Test

NOTE: Before performing the test, cover the vent hole on the back of the valve body (60 thru
60F, IPL Fig 1A) with an adhesive "tape dot" (Table 1003). Pierce a small pin hole
through the tape dot into the vent hole area. The pin hole will not allow the leak test
solution to enter the vent hole, but will allow any leakage to escape (Dry test article
and remove the tape dot after completing the test).

(a) Job Set-up

1 Install the outlet cap (Table 1002) on the valve body (60 thru 60F, IPL Fig 1A) outlet.

NOTE: Use a syringe to inject leak test solution through the cap assembly vent
hole. This will displace the air inside of the cap and prevent a false
indication of leakage through the outlet.

(b) Procedure

ACTION RESULT

1 Open valve by rotating handle (80, IPL

Fig. 4), three full revolutions, in a
counterclockwise direction.

2 Connect oxygen supply to inlet of

valve body (350, IPL Fig. 4).

3 Submerge valve assembly in leak test

solution.

4 Apply pressurized oxygen (1850 +0/-

50 psi / 12,76 +0/-0,34 MPa) to valve.

5 Observe the valve for a period of two

minutes. If leakage is apparent, actual
leakage shall be determined.

6 Cycle the valve (from open to closed

to fully open) 2 times.

7 With the valve fully open, observe the Leakage shall not exceed 5 cu.cm/h
valve for a period of two minutes. If (0.083 cu.cm/min).
leakage is apparent, actual leakage
shall be determined.

8 Discontinue supply of pressurized

oxygen to valve assembly.

9 Remove cap from valve body outlet.

10 Remove "tape dot" from valve body

vent hole.

35-21-93 Page 1013

Subtask 35-21-93-790-009-A01

(4) Open/Close Torque Test

(a) Job Set-up

1 Set up test using Fig.1006.

(b) Procedure

ACTION RESULT

1 Install suitable cap (Table 1002) on

external threads of valve body (60 thru
60F, IPL Fig 1A) outlet.
2 Close valve by rotating handle (80, IPL
Fig 4) to full clockwise position.
3 Connect oxygen supply to valve inlet.
4 Apply pressurized oxygen (1850 +0/-
50 psi / 12,76 +0/-0,34 MPa) to valve.
5 Using a torque wrench, determine The force necessary to rotate the stem to
required torque to open/close valve. the open or closed position cannot
exceed 30 in.lbs (3,40 N.m) when the
valve is pressurized.
6 Repeat the preceding step 2 times to
verify.

Valve

Valve Inlet Test Adapter

APN 803213-S58-10 Cap Outlet

Pressure Gauge
0-2000 psig (0-13,78 MPa)

Test Gas

Test Regulator
0-2500 psig (0-17,24 MPa)

Open/Close Torque Test

FIGURE 1006/GRAPHIC 35-21-93-991-106-A01

35-21-93 Page 1014

Subtask 35-21-93-720-001-A01

(5) Flow Test

(a) Job Set-up

1 Install test valve as shown in Figure 1007.

(b) Procedure

ACTION RESULT

1 Open valve by rotating valve handle

(80, IPL Fig 4) to full counterclockwise
position.

2 Using flow control valve, adjust oxygen

flow until flowmeter (Table 1002)
indicates a flow of 1000 lpm NTPD.

3 Adjust the valve to provide 1250 +0, -

50 psig (8.62 +0, -0.34 MPa) to the
valve inlet test adapter.

4 Monitor outlet pressure gauge. Pressure drop through valve shall not
exceed 200 psi (1,38 MPa).

Pressure Gauge
0-2000 psig (0-13,78 MPa)

Oxygen Valve
Flowmeter
200-2000 L/min

Valve Inlet Test Adapter

APN 803213-S58-10
CGA 540 Flow Control
Pressure Gauge Nipple Valve
0-2000 psig (0-13,78 MPa) CGA 540
Nut
Test Gas

Test Regulator
0-2500 psig (0-17,24 MPa)

Flow Test Setup

FIGURE 1007/GRAPHIC 35-21-93-991-107-A01

35-21-93 Page 1015

Subtask 35-21-93-790-003-A01

(6) Latent Leakage Test

NOTE: The latent leak test is only done after a cylinder assembly has been repaired,
overhauled or been hydrostatically tested.
If a cylinder assembly has been trans-filled but not repaired, overhauled or
disassembled, then a latent leak test is not required.

(a) Job Set-up

1 Install the valve body assembly (60 thru 60J, IPL Fig 1) on the cylinder (70 thru 70D,
IPL Fig 1) (refer to Page Block 7001).

(b) Procedure

ACTION RESULT

1 Charge the CVA to 1800 - 1850 psig

(12,4 - 12,8 MPa) in accordance with
Reference Document, AIR1059
(refer to Table 1001).

2 Connect the calibrated gauge (Table

1002) to valve outlet.

3 Using the calibrated gauge, determine

the cylinder pressure in accordance
with Reference Document, AIR1059
(refer to Table 1001).

4 Disconnect the calibrated gauge from

valve outlet.

5 Install the outlet cap (Table 1002), and

set valve to the open position.

6 Store cylinder and valve assembly for

48 hours minimum.

7 Set the valve to the closed position

and remove the cap from the outlet.

8 Connect the calibrated gauge (Table Using the calibrated gauge, make sure
1002) to valve outlet. that the cylinder pressure is still in
accordance with Reference Document,
AIR1059 (refer to Table 1001).

35-21-93 Page 1016

TASK 35-21-93-810-801-A01

2. FAULT ISOLATION

A. Cylinder and Valve Assembly with Oxygen Valve P/N 803361

Refer to Table 1004 for troubleshooting problems, causes, and solutions.

FAULT PROBABLE CAUSE CORRECTION

Incorrect indication on pressure Faulty pressure gauge Replace pressure gauge

gauge (10, IPL Fig. 3) (10, IPL Fig. 3)

Leakage between valve body Loose gauge Torque screws (20, IPL Fig. 3)
(230, IPL Fig. 3) and pressure per Table 8001
gauge (10, IPL Fig. 3) (refer to Page Block 8001)

Faulty packing (50, IPL Fig. 3) Replace packing (50, IPL Fig. 3)

Leakage between valve body Loose plug (320, IPL Fig. 2) or Tighten plug (320, IPL Fig. 2) or
(230, IPL Fig. 3) and safety nut (80, 80A, 140, 220, 280, 380 nut (80, 80A, 140, 220, 280, 380
outlet assembly (10, 10A, 90, or 380A, IPL Fig 2) or 380A, IPL Fig 2), as required
150, 230, 330, 330A IPL,
Figure 2) Faulty gasket (20, 100, 160, 240, Replace gasket (20, 100, 160,
300 or 340, IPL Fig. 2) 240, 300 or 340, IPL Fig. 2)

Leakage through safety outlet Ruptured disc (30, 30A, 110, Replace disc (30, 30A, 110,
assembly (10, 10A, 90, 150, 110A, 170, 170A, 250, 250A, 110A, 170, 170A, 250, 250A,
230, 330, 330A IPL, Figure 2) 310, 310A, 350 or350A IPL Fig. 310, 310A, 350 or350A IPL Fig.
2) 2)

Leakage from valve outlet port Valve not closed Rotate handle (100, IPL Fig. 3) to
full clockwise position

Faulty plug (190, IPL Fig. 3) Replace plug (190, IPL Fig. 3)

Loose/faulty seat assembly Tighten seat assembly (200, IPL

(200, IPL Fig. 3) Fig. 3) per Table 8001
(refer to Page Block 8001), or
replace, as required

Leakage between stem assy Faulty stem assy (140, IPL Fig. Replace defective part
(140, IPL Fig. 3) and guide 3) or spring (170, IPL Fig. 3)
(120, IPL Fig. 3)
Faulty guide (120, IPL Fig. 3) Replace guide (120, IPL Fig. 3)

Leakage between valve body Loose retainer (110, IPL Fig. 3) Replace retainer (110, IPL Fig. 3)
(230, IPL Fig. 3) and retainer
(110, IPL Fig. 3) Faulty stem assy (140, IPL Fig. Replace defective part
3) or washer (130, IPL Fig. 3)

Damaged threads on retainer Replace defective part

(110, IPL Fig. 3), or body (230,
IPL Fig. 3)

35-21-93 Page 1017

FAULT PROBABLE CAUSE CORRECTION

Leakage between valve Loose valve assembly Tighten per Table 8001
assembly and cylinder (70 thru (refer to Page Block 8001)
70D, IPL Fig. 1) neck
Faulty boss seal (70A, IPL Fig. 3) Replace boss seal
(70A, IPL Fig. 3)

Damaged threads on valve body Replace valve body

(230, IPL Fig. 3) (230, IPL Fig. 3)

Damaged threads in cylinder Replace cylinder

(70 thru 70D, IPL Fig. 1) neck (70 thru 70D, IPL Fig. 1)

Table 1004: Troubleshooting Chart

B. Cylinder and Valve Assembly with Oxygen Valve P/N 803345

Refer to Table 1005 for troubleshooting problems, causes, and solutions.

FAULT PROBABLE CAUSE CORRECTION

Incorrect indication on pressure Faulty pressure gauge Replace pressure gauge

gauge (10, IPL Fig. 4) (10, IPL Fig. 4)

Leakage between valve body Loose gauge Torque screws (20, IPL Fig. 4)
(350, IPL Fig. 4) and pressure per Table 8001
gauge (10, IPL Fig. 4) (refer to Page Block 8001)

Faulty packing (50, IPL Fig. 4) Replace packing (50, IPL Fig. 4)

Leakage between valve body Loose plug (320, IPL Fig. 2) or Tighten plug (320, IPL Fig. 2) or
(350, IPL Fig. 4) and safety nut (80, 80A, 140, 220, 280, 380, nut (80, 80A, 140, 220, 280, 380,
outlet assembly (10, 10A, 90, or 380A, IPL Fig 2) or 380A, IPL Fig 2), as required
150, 230, 330, 330A IPL, Fig 2)
Faulty gasket (20, 100, 160, 240, Replace gasket (20, 100, 160,
300 or 340, IPL Fig. 2) 240, 300 or 340, IPL Fig. 2)

Leakage through safety outlet Ruptured disc (30, 30A, 110, Replace disc (30, 30A, 110,
assembly (10, 10A, 90, 150, 110A, 170, 170A, 250, 250A, 110A, 170, 170A, 250, 250A,
230, 330, 330A IPL, Fig 2) 310, 310A, 350 or 350A, IPL Fig. 310, 310A, 350 or 350A, IPL Fig.
2) 2)

Leakage (in excess of 50 Valve not closed Rotate handle (80, IPL Fig. 4)
cu.cm/min) from valve outlet to full clockwise position
port
Faulty tip and poppet assembly Replace tip and poppet assembly
(180, IPL Fig. 4) (180, IPL Fig. 4)

Loose/faulty seat and filter Tighten seat assembly and filter

assembly (200, IPL Fig. 4) (200, IPL Fig. 4) per Table 8001
(refer to Page Block 8001), or
replace, as required

35-21-93 Page 1018

FAULT PROBABLE CAUSE CORRECTION

Leakage through vent hole Seal (140A, IPL Fig. 4) is leaking Re-install place seal
or damaged (140A, IPL Fig. 4)

Faulty stem (170, IPL Fig. 4) Replace valve stem

(170, IPL Fig. 4)

Leakage between stem (170, Faulty seal (140A, IPL Fig. 4) Replace seal (140A, IPL Fig. 4)
IPL Fig. 4) and sleeve (120,
IPL Fig. 4) Faulty stem (170, IPL Fig. 4) Replace valve stem
(170, IPL Fig. 4)

Faulty washer (160, IPL Fig. 4) Replace washer (160, IPL Fig. 4)

Loose sleeve (120, IPL Fig. 4) Retorque sleeve (120, IPL Fig. 4)

Leakage between valve Loose valve assembly Tighten per Table 8001
assembly and cylinder (70 thru (refer to Page Block 8001)
70D, IPL Fig. 1A) neck
Faulty boss seal (340, IPL Fig.4) Replace boss seal
(340, IPL Fig. 4)

Damaged threads on valve body Replace valve body

(350, IPL Fig. 4) (350, IPL Fig. 4)

Damaged threads in cylinder (70 Replace cylinder

thru 70D, IPL Fig. 1A) neck (70 thru 70D, IPL Fig. 1A)

Table 1005: Troubleshooting Chart

35-21-93 Page 1019

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35-21-93 Page 1020

TESTED BY: DATE: PART NO:

INSPECTED BY: DATE: SERIAL NO:

Visual Inspection
Refer to the CMM CHECK section for cylinder service life and the hydrostatic test frequency requirements. Check the condition of cylinder
surfaces for heat or fire damage, dents, gouges, cracks, distortion, and/or thread damage.

PASS FAIL

Cylinder and Valve Assembly

Internal Leakage Test (refer to Subtask 35-21-93-790-001-A01)
Perform an internal leakage test.

Inlet pressure psig (MPa) No leakage allowed

1800 to 1850 (12,4 to 12,8) PASS FAIL

Pressure gauge accuracy test (refer to Subtask 35-21-93-790-002-A01)

Perform a pressure gauge accuracy test.

Observed Gauge Pressure

Inlet pressure psig (MPa)
actual ± 50 psig (0,345 MPa)

500 (3,447) to 2000 (13,79) PASS FAIL

Latent Leakage Test (refer to Subtask 35-21-93-790-003-A01)

Perform a latent leakage test.

Inlet pressure psig (MPa) No pressure change after 48 hour hold

Charge the CVA to 1800 - 1850 (12,4 - 12,8) PASS FAIL

External Leakage Test (refer to Subtask 35-21-93-790-004-A01)

Perform an external leakage test using "Non-immersion Method".

No bubbles allowed

PASS FAIL

Perform an external leakage test using "Immersion Method".

Inlet Pressure psig (MPa) 5 cu.cm/hour (0,083 cc/min) MAX

(3 bubbles max in 2 minutes)

1800 to 1850 (12,4 to 12,8) PASS FAIL

Open/Close Torque Test (refer to Subtask 35-21-93-790-005-A01)

Perform an open/close torque test three times.

Torque
Inlet pressure psig (MPa)
15 in.lbs (1,7 N.m) MAX Allowed

1800 to 1850 (12,4 to 12,8) PASS FAIL

Table 1006: TESTING TABLE FOR CVA WITH OXYGEN VALVE P/N 803361
(Applicable to Cylinder and Valve Assembly 8971xxxx / 8972xxxx / 8973xxxx)

35-21-93 Page 1021

THIS PAGE INTENTIONALLY LEFT BLANK

35-21-93 Page 1022

TESTED BY: DATE: PART NO:

INSPECTED BY: DATE: SERIAL NO:

PASS FAIL

Cylinder and Valve Assembly

Internal Leakage Test (refer to Subtask 35-21-93-790-006-A01)
Perform an internal leakage test.

Inlet pressure psig (MPa) 50 cu.cm/min MAX Allowed

1800 to 1850 (12,4 to 12,8) PASS FAIL

Pressure gauge accuracy test (refer to Subtask 35-21-93-790-007-A01)

Perform a pressure gauge accuracy test.

Observed Gauge Pressure

Inlet pressure psig (MPa)
actual ± 50 psig (0,345 MPa)

500 (3,447) to 2000 (13,79) PASS FAIL

External Leakage Test (refer to Subtask 35-21-93-790-008-A01)

Perform an external leakage test

5 cu.cm/hour (0,083 cc/min) MAX

Inlet Pressure psig (MPa)
(3 bubbles max in 2 minutes)

1800 to 1850 (12,4 to 12,8) PASS FAIL

Open/Close Torque Test (refer to Subtask 35-21-93-790-009-A01)

Perform an open/close torque test three times.

Torque
Inlet pressure psig (MPa)
30 in.lbs (3,4 N.m) MAX Allowed

1800 to 1850 (12,4 to 12,8) PASS FAIL

Flow Test (refer to Subtask 35-21-93-720-001-A01)

Perform a flow test.

Flow Observed Pressure Drop

Inlet pressure psig (MPa)
l/Min 200 psig MAX Allowed

1200 to 1250 (8,27 to 8,62) 1000 PASS FAIL

Table 1007: TESTING TABLE FOR CVA WITH OXYGEN VALVE P/N 803345

(Applicable to Cylinder and Valve Assembly 8979xxxx)

35-21-93 Page 1023

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35-21-93 Page 1024

DISASSEMBLY

TASK 35-21-93-000-801-A01

1. CYLINDER AND VALVE ASSEMBLY - DISASSEMBLY

A. General

(1) This section describes the equipment and procedures necessary to disassemble the 897
Series Cylinder and Valve Assemblies (CVA). Most repair procedures do not need complete
disassembly of the CVA. Disassemble units only to the level necessary, as determined in
TESTING AND FAULT ISOLATION section, to repair or replace components. Disassembly is
organized as follows:

Paragraph Description IPL Figure No.

1.C. Cylinder and Valve Assembly 1, 1A

1.D. Slow Opening Oxygen Valve Assembly 2

1.E. Slow Opening Valve Body Assembly 3

1.F. Valve Body and Gauge Assembly 4

(2) The instructions in this section apply to all 897 Series CVA’s unless noted otherwise. Refer to
the ILLUSTRATED PARTS LIST section of this manual for the item numbers given in
parentheses. Unless otherwise noted, all disassembly procedures requiring turning, twisting or
unthreading will be in the counterclockwise direction.

NOTE: Refer to the "EFFECT CODE" column of the Group Assembly Parts List for the parts
applicable to the part number valve assembly being disassembled. Disregard
instructions concerning parts that are not used on the valve being disassembled.

NOTE: APN's with dash numbers of this form (-1, -2, -3, -4, -5, -6, -7,-8, -9) are identical to
APN's with dash numbers of this form (-01, -02, -03, -04, -05, -06, -07, -08, -09).

WARNING: FAILURE TO FULLY DISCHARGE THE OXYGEN FROM THE CVA OR

COMPONENT PARTS PRIOR TO DISASSEMBLY OF ANY PART, OR FAILURE TO
SECURE THE CYLINDER, VALVE ASSEMBLY, AND DISCHARGE HOSE DURING
OXYGEN DISCHARGE MAY CAUSE SERIOUS PERSONAL INJURY OR DEATH.

(3) High pressure oxygen is a hazardous material. When pressurized oxygen is discharged
intentionally or due to equipment failure, the released energy can be highly destructive if not
properly controlled. Fully discharge the oxygen from the CVA and component parts, prior to
disassembly of any part. Secure the cylinder, valve assembly, and discharge hose during
oxygen discharge.

WARNING: FAILURE TO USE EYE PROTECTION AT ALL TIMES DURING DISASSEMBLY

PROCEDURES MAY CAUSE INJURY TO THE EYES.

(4) Use eye protection at all times during all disassembly procedures.

35-21-93 Page 3001

B. Special Tools, Fixtures and Equipment

(1) Special tools, fixtures, and equipment needed for disassembly of the CVA are listed below.
Special tools, fixtures, and equipment must be cleaned for oxygen service before use.
Equivalents may be substituted.

PART NUMBER MANUFACTURER

NOMENCLATURE
(or DESCRIPTION) (VENDOR CODE)

Tee wrench 10850-T91-1 AVOX Systems Inc.

Lancaster, NY 14086-9502
USA (V53655)

Wrench (for valve seat) 10850-T91-2 AVOX Systems Inc.

Lancaster, NY 14086-9502
USA (V53655)

Driver 10850-T91-3 AVOX Systems Inc.

Lancaster, NY 14086-9502
USA (V53655)

Driver 2786-S52-1 AVOX Systems Inc.

Lancaster, NY 14086-9502
USA (V53655)

Table 3001: Special Tools, Fixtures, and Equipment

C. Cylinder and Valve Assembly - Disassembly Procedure

Subtask 35-21-93-070-001-A01

(1) Removal of the Valve Assembly

WARNING: TOOLS USED FOR MAINTENANCE / SERVICE OF OXYGEN RELATED

EQUIPMENT SHALL BE CLEAN AND FREE OF CONTAMINANTS. ENSURE
THAT CYLINDER (70, IPL FIG. 1) OR (70, IPL FIG. 1A) IS COMPLETELY
DISCHARGED PRIOR TO REMOVING VALVE ASSEMBLY (60, IPL FIG. 1) OR
(60, IPL FIG. 1A) FROM UNIT.

WARNING: DO NOT APPLY WRENCH FORCE TO CYLINDER NECK. TO REMOVE VALVE

ASSEMBLY FROM CYLINDER NECK, HOLD THE CYLINDER IN A SUITABLE
PADDED DEVICE IN SUCH A MANNER AS TO NOT DAMAGE THE FILAMENT
OVERWRAP.

(Refer to IPL figure. 1)(Refer to IPL figure. 1A)

(a) Fully discharge the oxygen from the CVA.

(b) Unthread the valve assembly (60 to 60J, IPL Fig. 1) from the cylinder (70, IPL Fig. 1).
(Applicable to Cylinder and Valve Assembly 8971xxxx / 8972xxxx / 8973xxxx)

(c) Unthread the valve assembly (60 to 60F, IPL Fig. 1A) from the cylinder (70, IPL Fig. 1A).
(Applicable to Cylinder and Valve Assembly 8979xxxx)

35-21-93 Page 3002

D. Slow Opening Oxygen Valve Assembly - Disassembly Procedure

Subtask 35-21-93-070-002-A01 (APPLICABLE TO CYLINDER AND VALVE ASSEMBLY

8971XXXX / 8972XXXX / 8973XXXX)
(1) Removal and Disassembly of Safety Outlet Assembly
NOTE: DO NOT remove and disassemble safety relief assembly unless indicated by Testing
and Fault Isolation.
(Refer to IPL figure. 2)
(a) Removal of the safety outlet assembly (10) (Applicable to Oxygen Valve Assy 803440-10/-
20/-30)
1 Remove cap assembly (70) from nut (80) by removing screw (60).
2 Remove nut (80) from body assembly (390), (390A) or (390B).
3 Remove insert (50) from outlet port.
4 With the 10850-T91-3 driver or the 2786-S52-1 driver, remove retainer (40) from outlet
port.
5 Remove and discard disc (30) or (30A) and gasket (20).
(b) Removal of the safety outlet assembly (90) (Applicable to Oxygen Valve Assy 803440-21)
1 Remove nut (140) from body assembly (390A).
2 Remove insert (130) from outlet port.
3 With the 10850-T91-3 driver or the 2786-S52-1 driver, remove retainer (120) from
outlet port.
4 Remove and discard disc (110) or (110A) and gasket (100).
(c) Removal of the safety outlet assembly (150) (Applicable to Oxygen Valve Assy 803440-
13/-23)
1 Remove cap assembly (210) from nut (220) by removing screw (200).
2 Remove nut (220) from body assembly (390) or (390A).
3 Remove insert (190) from outlet port.
4 With the 10850-T91-3 driver or the 2786-S52-1 driver, remove retainer (180) from
outlet port.
5 Remove and discard disc (170) or (170A) and gasket (160).
(d) Removal of the safety outlet assembly (230) (Applicable to Oxygen Valve Assy 803440-15)
1 Remove nut (280) from body assembly (390).
2 Remove insert (270) from outlet port.
3 With the 10850-T91-3 driver or the 2786-S52-1 driver, remove retainer (260) from
outlet port.
4 Remove and discard disc (250) or (250A) and gasket (240).

35-21-93 Page 3003

(e) Removal of the safety plug (290) (Applicable to Oxygen Valve Assy 803440-26)

1 Remove plug (320) from body assembly (390A).

2 Remove and discard gasket (300) and disc (310) or (310A) from plug (320).

(f) Removal of the safety outlet assembly (330) (Applicable to Oxygen Valve Assy 803440-
18/-28)

1 Remove nut (380) from body assembly (390) or (390A).

2 Remove insert (370) from outlet port.

3 With the 10850-T91-3 driver or the 2786-S52-1 driver, remove retainer (360) from
outlet port.

4 Remove and discard disc (350) or (350A) and gasket (340).

Subtask 35-21-93-070-003-A01 (APPLICABLE TO CYLINDER AND VALVE ASSEMBLY

8979XXXX)

(2) Removal and Disassembly of Safety Outlet Assembly

NOTE: DO NOT remove and disassemble safety relief assembly unless indicated by Testing
and Fault Isolation.

(Refer to IPL figure. 2)

(a) Removal of the safety outlet assembly (10) (Applicable to Oxygen Valve Assy 803440-90)

1 Remove cap assembly (70) from nut (80) by removing screw (60).

2 Remove nut (80) from body and gauge assembly (400).

3 Remove insert (50) from outlet port.

4 With the 10850-T91-3 driver or the 2786-S52-1 driver, remove retainer (40) from outlet
port.

5 Remove and discard disc (30) or (30A) and gasket (20).

(b) Removal of the safety outlet assembly (10A) (Applicable to Oxygen Valve Assy 803440-94)

1 Remove cap assembly (70A) from nut (80A) by removing screw (60).

2 Remove nut (80A) from body and gauge assembly (400).

3 Remove insert (50) from outlet port.

4 With the 10850-T91-3 driver or the 2786-S52-1 driver, remove retainer (40) from outlet
port.

5 Remove and discard disc (30) or (30A) and gasket (20).

35-21-93 Page 3004

1 Remove cap assembly (210) from nut (220) by removing screw (200).

2 Remove nut (220) from body and gauge assembly (400).

3 Remove insert (190) from outlet port.

4 With the 10850-T91-3 driver or the 2786-S52-1 driver, remove retainer (180) from
outlet port.

5 Remove and discard disc (170) or (170A) and gasket (160).

(d) Removal of the safety outlet assembly (230) (Applicable to Oxygen Valve Assy 803440-95)

1 Remove nut (280) from body and gauge assembly (400).

2 Remove insert (270) from outlet port.

3 With the 10850-T91-3 driver or the 2786-S52-1 driver, remove retainer (260) from
outlet port.

4 Remove and discard disc (250) or (250A) and gasket (240).

(e) Removal of the safety plug (290) (Applicable to Oxygen Valve Assy 803440-96)

1 Remove plug (320) from body and gauge assembly (400).

2 Remove and discard gasket (300) and disc (310) or (310A) from plug (320).

(f) Removal of the safety outlet assembly (330) (Applicable to Oxygen Valve Assy 803440-98)

1 Remove nut (380) from body and gauge assembly (400).

2 Remove insert (370) from outlet port.

3 With the 10850-T91-3 driver or the 2786-S52-1 driver, remove retainer (360) from
outlet port.

4 Remove and discard disc (350) or (350A) and gasket (340).

(g) Removal of the safety outlet assembly (330A) (Applicable to Oxygen Valve Assy 803440-
99)

1 Remove nut (380A) from body and gauge assembly (400).

2 Remove insert (370) from outlet port.

3 With the 10850-T91-3 driver or the 2786-S52-1 driver, remove retainer (360) from
outlet port.

4 Remove and discard disc (350) or (350A) and gasket (340).

35-21-93 Page 3005

E. Slow Opening Valve Body Assembly - Disassembly Procedure (Applicable to 'Body Assy 803361-
01/-02/-03')

Subtask 35-21-93-070-004-A01

(1) Disassembly of Body Assembly

(Refer to IPL figure. 3)

(a) Remove pressure gauge (10) as follows: (Applicable to Body Assy 803361-01/-03)

1 Remove pressure gauge (10) from body and tube assembly (230) or (230B) by
removing two screws (20) and two lock washers (30).

2 Remove sleeve (60).

3 Remove and discard packing (50) and backup ring (40).

(b) Remove and discard boss seal (70A) from body and tube assembly (230), (230A) or
(230B).

(d) Remove identification plate (80) from handle (100).

(e) Remove packing retainer (110), stem guide (120) and washer (130) from body and tube
assembly.

(f) Remove stem assembly (140), thrust washers (150) and (160), spring (170) and washer
(180) from body and tube assembly.

(g) Using 10850-T91-1 tee wrench, remove plug (190) from body and tube assembly.

(h) Using 10850-T91-2 valve seat wrench, remove valve seat assembly (200) from body and
tube assembly.

(i) Remove pipe plug (210) from body and tube assembly (230A), as required. (Applicable to
Body Assy 803361-02 only)

(j) Remove gauge guard (220) from body and tube assembly (230B) by turning guard in
counterclockwise direction. (Applicable to Body Assy 803361-03 only)

F. Valve Body and Gauge Assembly - Disassembly Procedure (Applicable to 'Body and Gauge Assy
803345-01')

Subtask 35-21-93-070-005-A01

(1) Disassembly of Body Assembly

(Refer to IPL figure. 4)

(a) Remove pressure gauge (10) from body and tube assembly (350) by removing two screws
(20) and two lock washers (30).

35-21-93 Page 3006

(b) Remove and discard two backup rings (40), two preformed packings (50) and backup ring
(60).

(c) Remove identification plate (70) from handle (80).

(d) Remove handle (80) by removing nut (90) and retaining ring (100).

(e) Remove packing retainer (110) from body and tube assembly (350).

(f) Turn sleeve (120) in a counterclockwise direction to disengage threads from body and tube
assembly (350). Lift stem (170), with attached parts, from body.

(g) Remove sleeve (120), guide (130), reciprocating seal (140), seal retainer (150) and washer
(160) from stem (170).

(h) Remove tip and poppet assembly (180), ball (210) and bearing (220) from stem (170) by
removing spring pin (190).

(i) Remove seat and filter assembly (200) from body and tube assembly (350).

(j) Remove pressure cap assembly (230) from body and tube assembly (350) by removing
screw (240), socket (250) and spacer (260).

(k) Remove lanyard cable assembly (270) from pressure cap assembly (230) by removing
screw (280), fastener (290) and washer (300).

(l) Remove nut (320) and nipple (310) from body and tube assembly (350).

(m) Remove filter assembly (330) from body and tube assembly (350) by turning filter assembly
in a counterclockwise direction.

(n) Remove and discard boss seal (340A) from body and tube assembly (350).

35-21-93 Page 3007

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35-21-93 Page 3008

CLEANING

TASK 35-21-93-100-801-A01

1. CYLINDER AND VALVE ASSEMBLY - CLEANING

A. General

(1) This section contains information about the equipment and the procedures for cleaning the 897
Series CVA. Before cleaning, the CVA shall be disassembled using procedures in the
DISASSEMBLY section.

NOTE: Unless otherwise noted, any use of an item number in this section includes all alpha
variants and dashed variants (i.e. items not illustrated) of that number. For example,
item (75) includes 75, -75, 75A, unless otherwise noted.

NOTE: APN's with dash numbers of this form (-1, -2, -3, -4, -5, -6, -7,-8, -9) are identical to
APN's with dash numbers of this form (-01, -02, -03, -04, -05, -06, -07, -08, -09).

WARNING: FAILURE TO USE EYE PROTECTION AT ALL TIMES DURING CLEANING

PROCEDURES MAY CAUSE INJURY TO THE EYES.

(2) Use eye protection at all times during all cleaning procedures.

WARNING: FAILURE TO REFER TO AND FOLLOW APPLICABLE MANUFACTURER'S OR

SUPPLIER'S MATERIAL SAFETY DATA SHEET (MSDS) BEFORE USING
CLEANING MATERIALS SPECIFIED IN THIS MANUAL, MAY RESULT IN SERIOUS
PERSONAL INJURY, ILLNESS, OR DEATH.

(3) Some cleaning materials used in this manual may be hazardous under certain conditions.
Material Safety Data Sheets provide information on chemical makeup, properties, and
precautions for handling potentially hazardous substances which may affect health risks,
storage, disposal, and other workplace safety factors.

WARNING: CONTAMINATION OF OXYGEN EQUIPMENT BY FAILING TO HANDLE OXYGEN

(4) If oxygen equipment becomes contaminated with oil, grease, flammable solvents, or other
combustible materials, fire and explosion may occur. Also, many substances and materials that
do not normally burn in air, including dust, lint, and fine metal particles can ignite in the
presence of oxygen. Handle oxygen equipment only in a clean area and with clean hands,
gloves, tools, or other means.

B. Reference Documents

(1) A list of applicable reference documents is given in Table 4001.

35-21-93 Page 4001

DOCUMENT NUMBER DOCUMENT NAME ORDERING INFORMATION

RR-C-901C General specification US Government Printing Office

Cylinders, Compressed Gas; Washington, DC 20402
High Pressure, Steel DOT 3AA and USA (VER765)
Aluminum Application

C-6 Standards for Visual Inspection of Compressed Gas Association, Inc.

Steel Compressed Gas Cylinders 4221 Walney Road, 5th floor
Chantilly, VA 20151-2923
C-6.2 Guidelines for Visual Inspection and Phone: 703-788-2700
Requalification of Fiber Reinforced Fax: 703-961-1831
High Pressure Cylinders Email: [email protected]
Website: www.cganet.com
C-8 Standard for Requalification of DOT
3HT, CTC 3HT, and TC 3H

C-10 Recommended Procedures for

Changes of Gas Service for
Compressed Gas Cylinders

G-4.1 Cleaning Equipment for Oxygen

Service

ARP1176 Oxygen System and Component Society of Automotive Engineers

Cleaning and Packaging Intl.
Warrendale, PA 19428-2959
USA (VOU583)

MIL-D-16791 Military Specification US Government Printing Office

Detergents, General Purpose, Washington, DC 20402
(Liquid, Non-ionic) USA (VER765)

Table 4001: Reference Documents

C. Special Tools, Fixtures, and Equipment

(1) A list of special tools, fixtures, and equipment recommended for cleaning of the 897 Series
CVA are shown in Table 4002. Special tools, fixtures, and equipment must be cleaned for
oxygen service before use. Equivalents may be substituted.

NOMENCLATURE MANUFACTURER (VENDOR CODE)

Protective Cap Local Vendor

Table 4002: Special Tools, Fixtures, and Equipment

Subtask 35-21-93-160-001-A01

D. Parts to be Discarded

(Refer to IPL figure. 2)(Refer to IPL figure. 3)(Refer to IPL figure. 4)

(1) Discard the following parts if removed during service. Do not clean these parts.

35-21-93 Page 4002

(a) Metallic parts

1 Do not clean used safety discs (30, 110, 170, 250, 310, 350, IPL Fig. 2), used filters
(330, IPL Fig. 4) or metal-boss seals (70, IPL Fig. 3) or (340, IPL Fig. 4). These items
must be replaced each time they are removed for disassembly.

(b) Non-metallic parts

1 Do not clean the used preformed packings (50, IPL Figs. 3) and backup rings (40, IPL
Figs. 3, 4; 60, IPL Fig. 4). These items must be replaced each time they are removed
for disassembly.

Subtask 35-21-93-140-001-A01

E. External Cleaning (See reference CGA G-4.1 in Table 4001)

(1) Seal the opening at the neck of the cylinder with a Protective Cap (Table 4002).

(2) Clean the cylinder.

(3) Rinse the outside of the cylinder with clean water.

(4) Dry the cylinder.

(5) Remove the protective cap from the cylinder opening.

Subtask 35-21-93-140-002-A01

F. Internal Cleaning

CAUTION: THE NECK AND THREADED AREA OF COMPOSITE CYLINDERS MUST NOT BE
CLEANED WITH ANY ABRASIVE ACTION OR ABRASIVE MATERIALS, INCLUDING
WIRE BRUSHES OR ABRASIVE PRODUCTS, OR DAMAGE TO SEALING
SURFACES OR THREADS MAY OCCUR.

(1) Refer to CGA pamphlet G-4.1 (Table 4001) for procedures to clean the inside of steel and
composite cylinders.

G. Metallic Parts

(1) Refer to ARP 1176 in Table 4001 for cleaning practices for metallic parts.

(2) Make sure that all metallic parts in direct contact with oxygen are cleaned to a cleanliness level
of category 1C per ARP 1176 (see Table 4001).

H. Non-Metallic Parts

(1) Refer to ARP 1176 in Table 4001 for the cleaning practices for non-metallic parts.

(2) Make sure that all non-metallic parts in direct contact with oxygen are cleaned to a cleanliness
level of category 1C per ARP 1176 (see Table 4001).

35-21-93 Page 4003

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35-21-93 Page 4004

CHECK

TASK 35-21-93-210-801-A01

1. CYLINDER AND VALVE ASSEMBLY - CHECK

A. General

(1) After disassembly and cleaning of any component, assembly or unit, examine each part before
assembly. If you are not sure that a part is serviceable, replace it. The instructions in this
section apply to all 897 Series CVA’s unless noted otherwise. Refer to the ILLUSTRATED
PARTS LIST section of this manual for the item numbers given in parentheses.

B. Reference Documents

(1) A list of applicable reference documents is given in Table 5001.

DOCUMENT NO. DOCUMENT NAME ORDERING INFORMATION

C-1 Methods of Hydrostatic Testing of Compressed Gas

Compressed Gas Cylinders Association, Inc.
4221 Walney Road, 5th
C-6.1 Standards for Visual Inspection of floor
High Pressure Aluminum Chantilly, VA 20151-2923
Compressed Gas Cylinders Phone: 703-788-2700
Fax: 703-961-1831
C-6.2 Guidelines for Visual Inspection and Email: [email protected]
Requalification of Fiber Reinforced Website: www.cganet.com
High Pressure Cylinders

C-10 Recommended Procedures for

Changes of Gas Service for
Compressed Gas Cylinders

DOT-SP-8162 Special Permit for Composite US Government Printing

Cylinder Office
Washington, DC 20402
49 CFR 107, Subpart Title 49, Code of Federal Regulations USA (VER765)
I
49 CFR 173.301
49 CFR 173.301a
49 CFR 173.302
49 CFR 173.302a
49 CFR 180.201
49 CFR 180.205
49 CFR 180.209
49 CFR 180.212
49 CFR 180.213
49 CFR 180.215

35-21-93 Page 5001

Table 5001: Reference Documents

C. Special Tools, Fixtures, and Equipment

(1) A list of special tools, fixtures, and equipment required to examine the 897 Series CVA’s is
given in Table 5002. If not specified, one of each is required. Tools, fixtures, and equipment
can be replaced with equivalent tools, fixtures, and equipment.

PART NUMBER MANUFACTURER

NOMENCLATURE
(or DESCRIPTION) (VENDOR CODE)

Bright Inspection Light IL-24 Titan Tool Supply Co. Inc.

Buffalo, NY 14216-1784
USA (V51679)

Table 5002: Special Tools, Fixtures, and Equipment

D. Overhaul

WARNING: FAILURE TO FOLLOW THE PROCEDURES IN THIS MANUAL OR ATTEMPTING TO

PERFORM ANY OF THE PROCEDURES IN THIS MANUAL UNLESS TRAINED IN
THE PROPER USE AND MAINTENANCE OF AVIATION OXYGEN EQUIPMENT,
MAY RESULT IN AN EXPLOSION, ILLNESS, SERIOUS PERSONAL INJURY, OR
DEATH.

Read and understand all the information in this manual before performing any
procedures on the CVA. Perform all procedures in the sequence of operations given.
Do not attempt to perform any of the procedures in this manual unless you are
trained and qualified in the proper use and maintenance of aviation oxygen
equipment. Maintenance personnel must know how to avoid the hazards of
maintaining aviation oxygen equipment and must comply with all applicable
government regulations.

Subtask 35-21-93-210-001-A01

(1) Overhaul Period

(a) Every five years (i.e., when every hydrostatic test of the cylinder is done) or more
frequently.

Subtask 35-21-93-210-002-A01

(2) Minimum Necessary Parts to Replace for an Overhaul

(a) At Overhaul, the following items should be discarded and replaced with new parts:

- Valve Seat Assembly, (200, IPL Fig. 3)

- Roll Pin (90 IPL Fig. 3)

- Thrust Washer (150, IPL Fig. 3)

35-21-93 Page 5002

- Thrust Washer (160, IPL Fig. 3)

- Safety Disc (30, 30A, 110, 110A, 170, 170A, 250, 250A, 310, 310A, 350, 350A, IPL Fig.
2)

- Gasket (20, 100, 160, 240, 300, 340, IPL Fig. 2)

- Preformed Packing (50, IPL Figs. 3, 4)

- Backup Ring (40, IPL Figs. 3, 4)

- Backup Ring (60, IPL Fig. 4)

- Sleeve (60, IPL Fig. 3)

- Stem Guide Washer (130, IPL Fig. 3)

- PTFE Washer (160, IPL Fig. 4)

- Boss Seal (70A, IPL Fig. 3; 340A, IPL Fig. 4)

- Seat with Filter (200, IPL Fig. 4)

- Filter Assembly (330, IPL Fig. 4)

- Ball Seal (-140, IPL Fig. 4)

NOTE: Ball Seal (-140, IPL Fig. 4) is not procurable. You must obtain Ball Seal
Replacement Kit (140A, IPL Fig. 4).

1 You must replace other parts if they are defective.

(b) During an overhaul of a CVA, the following items may require replacement due to damage
during disassembly or from rough handling. When removed or disassembled, the following
items should be discarded and replaced with new parts. These items are attached by
adhesive, and should not be reused. Reuse of these items may cause them to detach from
the CVA, creating potential for “foreign object damage.”

- Oxygen Identification Decal (20, IPL Figs. 1, 1A)

- Identification Plate (30, IPL Fig.1, 1A)

- Warning Label (40, IPL Figs. 1, 1A)

- Label (50, IPL Figs. 1, 1A)

- ID Plate (80, IPL Fig. 3,; 70, IPL Fig. 4)

35-21-93 Page 5003

Subtask 35-21-93-210-003-A01

(3) Functional Tests that are Necessary After an Overhaul

(a) You must do all the functional tests in the CMM after you do an overhaul on the 897 Series
CVA. You must follow all applicable procedures in this CMM when you do an overhaul.

E. Cylinder and Valve Inspection

Subtask 35-21-93-210-004-A01

(1) Cylinder Inspection

(a) General

1 Check of the surfaces and thread areas for signs of damage, contamination, galling,
burrs, corrosion or too much wear.

CAUTION: CVA MAY BE DAMAGED OR LEAK IF A PART THAT EITHER HAS, OR

HAS CAUSED TOO MUCH WEAR OR DAMAGE TO ADJACENT SEALING
SURFACES IS NOT REPLACED.

2 Check of the mating parts and sealing surfaces for scratches and other damage that
will cause leakage.

(b) Plates, Decals, Placards and Labels

1 Make sure that Oxygen Identification Decal (20, IPL Figs. 1, 1A); Identification Plate
(30, IPL Fig.1, 1A); Warning Label (40, IPL Figs. 1, 1A); Label (50, IPL Figs. 1, 1A); ID
Plate (80, IPL Fig. 3,; 70, IPL Fig. 4) can be read and are not damaged.

(c) Cylinder Assembly (70 thru -70D, IPL Figs. 1, 1A)

1 Table 5003 contains information about cylinder hydrostatic testing and cylinder
service-life requirements.

2 Cylinder inspection frequency or service life information given in Tables 5003 and
5004 is valid for the date of issue for this 897 Series CVA CMM.

a US DOT rule DOT-SP 8162 superseded US DOT rule DOT-E 8162. Rule DOT-
SP 8162 applies to all units manufactured after September 30, 2007.

b TC Permit SU 9209 applies to all affected units manufactured after February 5,

2007 with the mark TC-SU 9209 on the cylinder.

c TC Permit SU 4237 applies to all affected units with the mark TC-SU 4237 on the
cylinder.

d The maximum life limit of the cylinder remains the same at 15 years if the cylinder
passes all inspection criteria.

e The hydrostatic test interval changes (refer to Tables 5003 and 5004).

35-21-93 Page 5004

Transport
US DOT Subseque Cylinder Life Limit
Canada New Retest
Cylinder Last Retest nt retest (NOTE 1 and NOTE
Cylinder Interval
Markings interval 2)
Marking

Before July 1, 3 years after

5 years 15 years max.
2006 last retest
E 8162 SU 4237
5 years after
After July 1, 2006 5 years 15 years max.
last retest

5 years after
SP 8162 SU 4237 After July 1, 2006 5 years 15 years max.
last retest

5 years after
SP 8162 SU 9209 See NOTE 3 5 years 15 years max.
last retest

Note 1: Specific information contained in these columns is taken directly from documents listed
in Table 5001.
Note 2: Cylinder service-life begins at the initial hydrostatic test date of the cylinder.
Note 3: Permit SU 9209 applies to all affected units manufactured after February 5, 2007 with
the mark TC-SU 9209 on the cylinder.

Table 5003: Hydrostatic Test Interval (when offered for transport or import in or to the United States)

Transport Cylinder Life Limit

US DOT
Canada Subsequent retest (NOTE 1 and NOTE
Cylinder New Retest Interval
Cylinder interval 2)
Markings
Marking

E 8162 SU 4237 3 years after last retest 3 years 15 years max.

SP 8162 SU 4237 3 years after last retest 3 years 15 years max.

SP 8162 SU 9209 5 years after last retest 5 years 15 years max.

Table 5004: Hydrostatic Test Interval (when offered for transport or import in or to Canada)

3 Determine actual cylinder condition (e.g., serviceable, rejected, repairable or

condemned) by using the applicable references from Table 5001. All cylinder repairs
must be made before a hydrostatic test of the cylinder is performed. Any cylinder that
has been repaired (as required in the references in Table 5001) needs a hydrostatic
test before it is available for use.

35-21-93 Page 5005

4 Check composite cylinder as shown in Tables 5003 or 5004. Any cylinder that fails the
hydrostatic test must not be used (i.e., condemned).

a Look at the date of the last hydrostatic test of the cylinder. Hydrostatic test dates
will be shown on the cylinder neck or on a hydrostatic retest label. The cylinder
may have more than one hydrostatic retest label. The initial cylinder test date and
US DOT special permit number are shown on the manufacturer’s identification
plate found on the cylinder sidewall.

b Hydrostatic tests must be performed as noted in Tables 5003 or 5004 using

approved procedures by service locations having up-to-date United States
Department of Transportation approval. Additional hydrostatic tests may be
required in your country.

c The composite cylinder service-life is given in Tables 5003 or 5004.

d Do a check of the exterior of cylinders for twists or bends, cuts in the fiber over-
wrap, either heat or fire damage, contamination or other damage.

e Make sure that identification plates and warning labels can be read and are not
damaged.

f Do a check of the cylinder neck for cracks and distortion. Also check the cylinder
threads for damage and contamination.

NOTE: Make sure that the sealing surface between the valve assembly and
the cylinder does not have nicks, cuts or distortion. Leakage will
occur between the valve assembly and cylinder if this surface is
distorted or damaged.

g Put a Bright Inspection Light (Table 5002) inside the cylinder and do a check for
contamination and corroded surfaces.

h Make sure the inside of the cylinder does not have an odor.

Subtask 35-21-93-210-005-A01

(2) Valve Components

(a) Visually inspect all surfaces and threaded areas for evidence of damage, contamination,
galling, burrs, excessive wear and corrosion.

NOTE: Excessive wear shall be defined as any obvious deformation, or deterioration of

a part, which may render the unit inoperative or beyond operational limits.

(b) Visually inspect all packing sealing surfaces for scratches or other obvious damage that
may impair valve operation.

(c) Examine the pressure gauge (10, IPL Figs. 3, 4) for a damaged gauge case, gauge lens
and mounting ring, or pressure indicating pointer.

(d) Make sure all identification plates can be read and are not damaged.

35-21-93 Page 5006

REPAIR

TASK 35-21-93-300-801-A01

1. REPAIR NO.1 - CYLINDER AND VALVE ASSEMBLY - GENERAL INFORMATION

A. General

(1) This section gives the repair procedures that can be performed on the 897 Series CVA. Before
repair, components must be examined using procedures in the CHECK section of this manual.

(2) Do not repair the Valve Seat Assy , (200, IPL Fig. 3); Roll Pin (90 IPL Fig. 3); Thrust Washer
(150, IPL Fig. 3); Thrust Washer (160, IPL Fig. 3); Safety Disc (30, 30A, 110, 110A, 170, 170A,
250, 250A, 310, 310A, 350, 350A, IPL Fig. 3) Gasket (20, 100, 160, 240, 300, 340, IPL Fig. 3);
Preformed Packing (50, IPL Figs. 3, 4); Backup Ring (40, IPL Figs. 3, 4); Backup Ring (60, IPL
Fig. 4); Sleeve (60, IPL Fig. 3); Stem Guide Washer (130, IPL Fig. 3); Boss Seal (70A, IPL Fig.
3; 340A, IPL Fig. 4); Seat with Filter (200, IPL Fig. 4); Filter Assy (330, IPL Fig. 4); Ball Seal (-
140, IPL Fig. 4); These items must be replaced each time they are removed.

NOTE: Unless otherwise noted, any use of an item number in this section includes all alpha
variants and dashed variants (i.e., items not shown) of that number. For example,
item (75) includes 75, -75, -75A thru -75B, unless otherwise noted.

NOTE: APN's with dash numbers of this form (-1, -2, -3, -4, -5, -6, -7,-8, -9) are identical to
APN's with dash numbers of this form (-01, -02, -03, -04, -05, -06, -07, -08, -09).

B. Reference Documents

(1) A list of applicable reference documents is given in Table 6001.

DOCUMENT
DOCUMENT NAME ORDERING INFORMATION
NUMBER

FED STD-595 Colors Used in Government Superintendent of Documents

Procurement US Government Printing Office
Washington DC 20402
USA (VER765)

Table 6001: Reference Documents

C. Special Tools, Fixtures, and Equipment

(1) A list of special tools, fixtures and equipment necessary for repair is shown in Table 6002.
Special tools, fixtures and equipment must be cleaned for oxygen service before use. Unless
noted otherwise, one of each item is required. Equivalents may be substituted.

35-21-93 Page 6001

PART NUMBER MANUFACTURER

NOMENCLATURE
(or DESCRIPTION) (VENDOR CODE)

Bright Inspection Light IL-24 Titan Tool Supply Co. Inc.

Buffalo, NY 14216-1784
USA (V51679)

Spray Gun Model 19 Binks Manufacturing

Company
AMF Ohare, IL 60666-2887
USA (V07334)

Cylinder Hanger for Square Drive Plug Fitting Local Vendor

Painting Cylinder (Cross-drilled for hanger)
0.750 - 16UNF-2A Threads

Table 6002: Special Tools, Fixtures, and Equipment

D. Consumable Repair Materials

(1) A list of applicable consumable repair materials is given in Table 6003. Equivalent materials
may be substituted.

MANUFACTURER (VENDOR
MATERIAL DESCRIPTION
CODES)

Plastic Abrasive Pad Scotch-Brite pad 3M Abrasive Systems

(No. 2 Size) Division
P/N 10116NA St. Paul, MN 55144-1000
USA (V28124)

Catalyst R6120 A.P. Nonweiler Co.

APN 50761-03 Oshkosh, WI 54903-1007
USA
Paint (2 part catalyzed urethane) 4285K123 Fax: 920-231-8085
Green (No. 14187 per FED-STD-
595)

Table 6003: Consumable Repair Materials

E. List of Repair Procedures

(1) Limit repairs to the procedures given below:

- Cleaning (refer to Page Block 4001).

- Removal of unwanted sharp edges.

- Thread repair.

35-21-93 Page 6002

- Replacement of cracked, bent, broken, scratched, or otherwise damaged components.

- Replacement of Valve Seat Assembly , (200, IPL Fig. 3); Roll Pin (90 IPL Fig. 3); Thrust
Washer (150, IPL Fig. 3); Thrust Washer (160, IPL Fig. 3); Safety Disc (30, 30A, 110, 110A,
170, 170A, 250, 250A, 310, 310A, 350, 350A, IPL Fig. 3); Gasket (20, 100, 160, 240, 300,
340, IPL Fig. 3); Preformed Packing (50, IPL Figs. 3, 4); Backup Ring (40, IPL Figs. 3, 4);
Backup Ring (60, IPL Fig. 4); Sleeve (60, IPL Fig. 3); Stem Guide Washer (130, IPL Fig. 3);
Boss Seal (70A, IPL Fig. 3; 340A, IPL Fig. 4); Seat with Filter (200, IPL Fig. 4); Filter Assy
(330, IPL Fig. 4); Ball Seal (-140, IPL Fig. 4); These items must be replaced each time they
are removed.

- Application of paint to steel cylinder.

(2) If there are signs of internal corrosion or contamination in the cylinder, do not attempt to repair.
Have the cylinder properly inspected/hydrostatically tested by a DOT authorized repair facility.

35-21-93 Page 6003

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35-21-93 Page 6004

TASK 35-21-93-380-801-A01

2. REPAIR 02 - CYLINDER PAINT APPLICATION

A. Reason for the Job

(1) Paint must be applied only to the exterior surface of the cylinder. This should be limited to small
spot repairs only.

(2) The hydrostatic retest labels and permanently affixed cylinder manufacturer's identification
label must remain visible and readable after the paint application.

WARNING: FAILURE TO REFER TO AND FOLLOW APPLICABLE MANUFACTURER'S OR

SUPPLIER'S MATERIAL SAFETY DATA SHEET (MSDS) BEFORE USING PRIMER,
PAINT, OR CATALYSTS, OR FAILURE TO SEEK EMERGENCY MEDICAL AID, MAY
RESULT IN SERIOUS PERSONAL INJURY, ILLNESS, OR DEATH.

Primer, paint and catalysts may be hazardous under certain conditions. Material Safety Data
Sheets provide information on chemical makeup, properties, and precautions for handling
potentially hazardous substances which may affect health risks, storage, disposal, and other
workplace safety factors. If you suspect that you have been exposed to a toxic level of any of
these substances, seek immediate medical aid.

B. Procedure

Subtask 35-21-93-350-001-A01

(1) Pre-painting Preparation

CAUTION: THE COMPOSITE CYLINDER OVER-WRAP OR REINFORCING FIBERS, MUST

NOT BE ABRADED DURING THE PRE-PAINTING PREPARATION OR
PERMANENT CYLINDER DAMAGE MAY RESULT.

(a) Cylinders (70 thru -70D, IPL Figs. , 1A) that require spot repair or full repainting should be
lightly sanded with a Plastic Abrasive Pad (Table 6003) only enough to roughen the
surface without abrading through the existing paint layer.

(b) Refer to Paragraph 1.E. in the CLEANING section and clean the exterior surface of the
cylinder to remove contamination.

(c) Remove the Oxygen Identification Decal (20, IPL Figs.1, 1A), Identification Plate (30, IPL
Figs. 1, 1A), Warning Label (40, IPL Figs. 1, 1A), and Label (50 IPL Figs. 1, 1A) or install
masking tape over them to protect from paint over spray. Do not remove any hydrostatic
retest labels from the cylinder. Hydrostatic retest labels and the cylinder manufacturer’s
identification label on composite cylinders must be covered with masking tape before
painting.

35-21-93 Page 6005

Subtask 35-21-93-380-002-A01

(2) Paint Application

(a) Thread the Cylinder Hanger (0.750 - 16 UNF-2A Threads, Table 6002) into the cylinder.

(b) Mix the Green Paint (No. 14187, Table 6003) and Catalyst (Table 6003) using the
instructions supplied by the manufacturer.

(c) Filter the catalyzed paint and spray the paint on the cylinder surface with a Spray Gun
(Table 6002) using the instructions supplied by the manufacturer.

(d) Dry the cylinder for 60 - 90 minutes at approximately 70°F (21°C) or 25 - 30 minutes at 100
- 125°F (38 - 52°C) in air.

(e) Allow the paint to cool and stabilize for 24 hours before placing the cylinder into service.

(f) If Identification Decal (20, IPL Figs.1, 1A), Identification Plate (30, IPL Figs. 1, 1A), Warning
Label (40, IPL Figs. 1, 1A), and Label (50 IPL Figs. 1, 1A) were removed from the cylinder
before the paint application process, they must be replaced. Refer to the ASSEMBLY
section for the proper location and application of these items.

35-21-93 Page 6006

ASSEMBLY

TASK 35-21-93-400-801-A01

1. CYLINDER AND VALVE ASSEMBLY - ASSEMBLY

A. General

(1) This section describes the equipment and procedures necessary for assembly of the 897
Series Cylinder and Valve Assembly (CVA). All components of the CVA must be cleaned and
checked in accordance with the previous sections of this manual. Assembly is organized as
follows:

Paragraph Description IPL Figure No.

Cylinder and Valve Assembly fitted with
1.F. Oxygen Valve P/N 803361 - Assembly 1, 2, 3
Procedure
Cylinder and Valve Assembly fitted with Body
1.G. and Gauge Assembly P/N 803345 - 1A, 2, 4
Assembly Procedure
1.H. CVA Charging Procedure -

WARNING: CONTAMINATION OF OXYGEN EQUIPMENT BY FAILING TO HANDLE OXYGEN

EQUIPMENT IN AN AREA CLEAN OF OIL, GREASE, FLAMMABLE SOLVENTS, OR
OTHER COMBUSTIBLE MATERIALS INCLUDING DUST, LINT, AND FINE METAL
PARTICLES; CONTAMINATION FROM FAILING TO USE CLEAN HANDS, GLOVES,
TOOLS; OR CONTAMINATION BY ANY OTHER MEANS, WHEN HANDLING
OXYGEN EQUIPMENT, MAY RESULT IN FIRE OR EXPLOSION THAT MAY CAUSE
SERIOUS PERSONAL INJURY OR DEATH.
If oxygen equipment becomes contaminated with oil, grease, flammable solvents, or other
combustible materials, fire and explosion may occur. Also, many substances and materials that
do not normally burn in air, including dust, lint, and fine metal particles can ignite in the
presence of oxygen. Handle oxygen equipment only in a clean area and with clean hands,
gloves, and tools.
WARNING: FAILURE TO USE ONLY OXYGEN COMPATIBLE PRODUCTS, EQUIPMENT, AND
MATERIALS CAN BRING ABOUT A VIOLENT REACTION RESULTING IN FIRE OR
EXPLOSION THAT MAY CAUSE SERIOUS PERSONAL INJURY OR DEATH.
Many commonly used materials may react violently in the presence of high pressure oxygen.
Only equipment and materials known to be compatible with oxygen should be used. Do not
substitute other equipment or materials such as elastomeric o-rings, gaskets, seals, and metal
components, even if they look the same.
WARNING: FAILURE TO USE EYE PROTECTION AT ALL TIMES DURING ASSEMBLY
PROCEDURES MAY CAUSE INJURY TO THE EYES.
Use eye protection at all times during all assembly procedures.

35-21-93 Page 7001

NOTE: APN's with dash numbers of this form (-1, -2, -3, -4, -5, -6, -7,-8, -9) are identical to
APN's with dash numbers of this form (-01, -02, -03, -04, -05, -06, -07, -08, -09).

B. Reference Documents

(1) A list of applicable reference documents is given in Table 7001.

ORDERING
DOCUMENT NUMBER DOCUMENT NAME
INFORMATION
S-1.1 Pressure Relief Device Standards Compressed Gas
Part 1 - Cylinders for Compressed Association Inc.
Gases Arlington, VA 22202-4102
USA (V01701)
AIR1059 Transfilling and Maintenance of SAE International
Oxygen Cylinders Warrendale, PA 15096-
0001
USA (V0U583)
CID A-A-58092 Commercial Item Description US Government Printing
Tape Antiseize, Office
Polytetrafluoroethylene Washington, DC 20402
USA (VER765)
NASM33540 Safety Wiring and Cotter Pinning,
General Practices for
MIL-PRF-25567 Military Specification, Oxygen
Aviator's Breathing, Liquid and Gas

Table 7001: Reference Documents

C. Special Tools, Fixtures, and Equipment

(1) Special tools, fixtures, and equipment needed for assembly of the CVA’s are shown in Table
7002. Special tools, fixtures, and equipment can be replaced with equivalent tools, fixtures, and
equipment.

PART NUMBER MANUFACTURER

NOMENCLATURE
(or DESCRIPTION) (VENDOR CODE)
Pneumatic Bench Vise Model BV-101-P Getz Fire Equipment Co.
P/N 58634 Peoria, IL 61602-1711
USA (V58013)
Tee Wrench 10850-T91-1 AVOX Systems
Lancaster, NY 14086-9502
Valve Seat Wrench 10850-T91-2 USA (V53655)
Driver 10850-T91-3
Driver 2786-S52-1
Filler assembly 5020-01

35-21-93 Page 7002

PART NUMBER MANUFACTURER

NOMENCLATURE
(or DESCRIPTION) (VENDOR CODE)
Torque Wrench Commercially Available Local Vendor

Table 7002: Special Tools, Fixtures, and Equipment

D. Consumable Materials

(1) A list of consumable assembly materials is shown in Table 7003. Reference documents shown
in Table 7001 contain important information for some materials specified. Materials can be
replaced with equivalent materials, except for the Oxygen and Oxygen Compatible Lubricant.

MANUFACTURER
MATERIAL DESCRIPTION
(VENDOR CODES)

Oxygen MIL-PRF-27210, Type I Local Vendor

1850 psig (12,8 MPa)
minimum pressure

Oxygen Compatible Krytox®* 240 AC E.I. du Pont de Nemours

Lubricant APN 50527-00 & Co. Inc.
Wilmington, DE 19898
USA (V23037)

Loctite Loctite Threadlock Grade A Loctite Corp.

Newington, CT 06111-1411
USA (V05972)

Thread Sealing Tape 0.250 PTFE Ribbon Tape Local Vendor

in. (0,535 cm) wide CID A-A-58092, size I
APN 50011-00

Lockwire MS20995C20 Local Vendor

APN 13603-00 (V96906)

Lubricant Molykote®** No. 106 Dow Corning Corp.

Midland, MI 48686-0997
USA (V71984)

Torque Paint F-900 Torque Seal Organic Products

F-1000 Irving, TX 75017
Torque Sentry USA (V01195)

* Krytox is a Registered Trademark of E.I. du Pont de Nemours & Co. Inc.

** Molykote is a Registered Trademark of Dow Corning Corporation.

Table 7003: Consumable Materials

E. Pre-Assembly Information

(1) All components that are to be used in the assembly of the 897 Series CVA must be cleaned
and checked in accordance with the preceding sections of this manual. Also, all components
must pass the required tests in the TESTING AND FAULT ISOLATION section.

35-21-93 Page 7003

(2) Unless otherwise noted, all packings, seals and o-rings shall be lubricated with a thin film of
Krytox 240 AC Lubricant, prior to installation.

(3) Refer to Table 7002 (Special Tools, Fixtures and Equipment) and Table 7003 (Consumable
Materials) as required.

F. Cylinder and Valve Assembly fitted with Oxygen Valve P/N 803361 - Assembly Procedure
(Applicable to 'Cylinder and Valve Assembly 8971xxxx / 8972xxxx /8973xxxx')

NOTE: Not all assembly procedures are required for each valve configuration. Refer to the "EFF
CODE" column of the Illustrated Parts List to determine components used on valve
configuration being assembled.

NOTE: APN's with dash numbers of this form (-1, -2, -3, -4, -5, -6, -7,-8, -9) are identical to APN's
with dash numbers of this form (-01, -02, -03, -04, -05, -06, -07, -08, -09).

Subtask 35-21-93-440-001-A01

(1) Assembly of Body Assembly

(Refer to IPL figure. 3)

(a) Install the gauge guard (220) (Applicable to Valve Body Assy 803361-03 only)

1 Thread gauge guard (220) on front of body and tube assembly (230).

(b) Install the pipe plug (210) (Applicable to Valve Body Assy 803361-02 only)

1 Apply 1-1/2 turns of PTFE Thread Sealing Tape to threads of pipe plug (210).

NOTE: Tape shall be applied in accordance with MIL-T-27730, and shall not extend
beyond first thread of plug.

2 Trim off excess tape, as required.

3 Install pipe plug in port located on front face of body and tube assembly (230).

(d) Torque valve seat assembly (200) to the value given in FITS AND CLEARANCES
(refer to Page Block 8001).

(e) Using 10850-T91-1 tee-wrench, install plug (190) in body and tube assembly (230).

NOTE: If threads of plug (190) are uncoated, or coating has been worn off, apply thin
film of Molykote No. 106 lubricant to threads. Bake plug for one hour at 260°F
(126°C).

(f) lnstall washer (180) in body and tube assembly (230). Washer shall lie flat on top of plug
(190).

(g) Install spring (170) in body and tube assembly (230).

35-21-93 Page 7004

(h) Apply thin film of Krytox 240 AC Oxygen Lubricant to thrust washers (150) and (160). First
install metallic thrust washer (160) then install non-metallic thrust washer (150) into body
and tube assembly (230). Washers shall lie flat on top surface of spring (170).

(i) Apply thin film of Krytox 240 AC Oxygen Lubricant to gasket surface of stem assembly
(140). With gasket surface facing upward, install stem assembly in body and tube
assembly. Rotate shaft of stem assembly as required, to engage lower end of stem into
plug (190) opening.

(j) Apply thin film of Krytox 240 AC Oxygen Lubricant to washer (130). Install washer over
shaft of stem assembly (140). Washer shall lie flat against gasket surface of stem
assembly.

(k) With stepped diameter of stem guide (120) facing downward, install stem guide on shaft of
stem assembly (140).

(l) lnstall retainer (110) on shaft of stem assembly (140). Carefully thread retainer in body and
tube assembly (230). Torque retainer (110) to the value given in FITS AND CLEARANCES
(refer to Page Block 8001).

(m) lnstall identification plate (80) on handle (100).

(n) lnstall handle (100) on stem assembly (140). Secure handle to stem with roll pin (90).

(o) Install pressure gauge (10) on body and tube assembly (230) as follows: (Applicable to
Valve Body Assy 803361-01/-03)

1 Apply thin film of Krytox 240 AC Oxygen Lubricant to sleeve (60), packing (50) and
backup ring (40).

2 lnstall above items in hole on face of body and tube assembly (230). Refer to IPL
Figure 3 for sequence of installation.

3 lnstall stem of pressure gauge (10) in hole on face of body and tube assembly (230)

4 Secure gauge (10) to body and tube assembly (230) with two screws (20) and two
lockwashers (30). Torque screws (20) to the value given in FITS AND CLEARANCES
(refer to Page Block 8001).

(p) Install safety plug/outlet (refer to Subtask 35-21-93-440-002-A01)

Subtask 35-21-93-440-002-A01

(2) Safety Plug/Outlet Installation

(Refer to IPL figure. 2)

(a) Install safety outlet assembly (10) as follows: (Applicable to Slow Opening Valve 803440-
10/-20/-30)

1 With identification number, on face of safety disc (30) or (30A), facing away from the
assembler, install disc in recess of retainer (40).

35-21-93 Page 7005

2 Apply thin film of Krytox 240 AC Oxygen Lubricant to gasket (20).

3 Install gasket (20) in retainer (40).

4 Using 10850-T91-3 driver or 2786-S52-1 driver, install retainer (40) in safety outlet
port of body assembly (390), (390A) or (390B), or body and gauge assembly (400).

5 Torque retainer (40) to the value given in FITS AND CLEARANCES

(refer to Page Block 8001).

6 Install insert (50) in nut (80).

7 Install nut (80) in safety outlet port of body assembly (390), (390A) or (390B).

8 Install cap assembly (70) on nut (80).

9 Secure cap assembly (70) to nut (80) with screw (60).

(b) Install safety outlet assembly (90) as follows: (Applicable to Slow Opening Valve 803440-
21)

1 With identification number, on face of safety disc (110) or (110A), facing away from
the assembler, install disc in recess of retainer (120).

2 Apply thin film of Krytox 240 AC Oxygen Lubricant to gasket (100).

3 Install gasket (100) in retainer (120).

4 Using 10850-T91-3 driver or 2786-S52-1 driver, install retainer (120) in safety outlet
port of body assembly (390A).

5 Torque retainer (120) to the value given in FITS AND CLEARANCES

(refer to Page Block 8001).

6 Install insert (130) in nut (140).

7 Install safety outlet assembly (90) in safety outlet port of body assembly (390A).

1 With identification number, on face of safety disc (170) or (170A), facing away from
the assembler, install disc in recess of retainer (180).

2 Apply thin film of Krytox 240 AC Oxygen Lubricant to gasket (160).

3 Install gasket (160) in retainer (180).

4 Using 10850-T91-3 driver or 2786-S52-1 driver, install retainer (180) in safety outlet
port of body assembly (390) or (390A).

5 Torque retainer (180) to the value given in FITS AND CLEARANCES

(refer to Page Block 8001).

6 Install insert (190) in nut (220).

35-21-93 Page 7006

7 Install nut (220) in safety outlet port of body assembly (390) or (390A), or body and
gauge assembly (400).

8 Install cap assembly (210) on nut (220).

9 Secure cap assembly (210) to nut (220) with screw (200).

(d) Install safety outlet assembly (230) as follows: (Applicable to Slow Opening Valve 803440-
15)

1 With identification number, on face of safety disc (250) or (250A), facing away from
the assembler, install disc in recess of retainer (260).

2 Apply thin film of Krytox 240 AC Oxygen Lubricant to gasket (240).

3 lnstall gasket (240) in retainer (260).

4 Using 10850-T91-3 driver or 2786-S52-1 driver, install retainer (260) in safety outlet
port of body assembly (390) or body and gauge assembly (400).

5 Torque retainer (260) to the value given in FITS AND CLEARANCES

(refer to Page Block 8001).

6 Install insert (270) in nut (280).

7 Install safety outlet assembly (230) in safety outlet port of body assembly (390).

(e) Install safety plug assembly (290) as follows: (Applicable to Slow Opening Valve 803440-
26)

1 With identification number on face of safety disc (310) facing toward the assembler,
install safety disc in plug (320).

2 Apply thin film of Krytox 240 AC Oxygen Lubricant to gasket (300).

3 Install gasket in plug (320).

4 Apply thin film of Krytox 240 AC Oxygen Lubricant to face of safety outlet port of body
assembly (390A).

5 Install plug (320) on body.

6 Torque plug (320) to the value given in FITS AND CLEARANCES

(refer to Page Block 8001).

(f) Install safety outlet assembly (330) as follows: (Applicable to Slow Opening Valve 803440-
18/-28)

1 With identification number, on face of safety disc (350) or (350A), facing away from
the assembler, install disc in recess of retainer (360).

2 Apply thin film of Krytox 240 AC Oxygen Lubricant to gasket (340).

35-21-93 Page 7007

3 *install gasket (340) in retainer (360).

4 Using 10850-T91-3 driver or 2786-S52-1 driver, install retainer (360) in safety outlet
port of body assembly (390) or (390A).

5 Torque retainer (360) to the value given in FITS AND CLEARANCES

(refer to Page Block 8001).

6 Install insert (370) in nut (380).

7 Install safety outlet assembly (330) in safety outlet port of body assembly (390) or
(390A) or body and gauge assembly (400).

Subtask 35-21-93-440-003-A01

(3) Testing

(Refer to IPL figure. 3)

(a) Test assembled slow opening oxygen valve assembly in accordance with Testing
(refer to TASK 35-21-93-700-801-A01).

(b) Lockwire retainer (110) to body and tube assembly (230) in accordance with MS33540.

Subtask 35-21-93-440-004-A01

(4) Installation of the Valve Assembly on the Cylinder

WARNING: PRIOR TO INSTALLING VALVE ASSEMBLY ON CYLINDER, ENSURE THAT

VALVE ASSEMBLY HAS BEEN TESTED IN ACCORDANCE WITH THE
TESTING AND FAULT ISOLATION SECTION OF THIS DOCUMENT.

CAUTION: DO NOT APPLY WRENCH FORCE TO CYLINDER NECK. INSTALL CYLINDER

IN A SUITABLE PADDED HOLDING DEVICE IN SUCH A MANNER AS TO NOT
DAMAGE THE FILAMENT OVERWRAP.

(Refer to IPL figure. 1) and (Refer to IPL figure. 3)

(a) Apply thin film of Krytox 240 AC Oxygen Lubricant to boss seal (70A, IPL Fig. 3). Install
seal on inlet port of body (230, IPL Fig. 3).

(b) CAREFULLY thread inlet port of Oxygen valve assembly (60 thru 60J, IPL Fig. 1) into neck
of cylinder (70, IPL Fig. 1).

35-21-93 Page 7008

G. Cylinder and Valve Assembly fitted with Body and Gauge Assembly P/N 803345 - Assembly
Procedure (Applicable to 'Cylinder and Valve Assembly 8979xxxx')

Subtask 35-21-93-440-005-A01

(1) Assembly of Body and Gauge Assembly

(Refer to IPL figure. 4)

(a) lnstall filter assembly (330) in outlet port of body and tube assembly (350). Torque filter
assembly (330) to the value given in FITS AND CLEARANCES (refer to Page Block 8001).

(b) Install seat and filter assembly (200) in body and tube assembly (350). Torque seat and
filter assembly (200) to the value given in FITS AND CLEARANCES
(refer to Page Block 8001).

(c) Install bearing (220) in cavity on underside of stem (170). Smooth side of bearing shall face
outward. Ensure bearing is completely seated in stem recess.

(d) Apply thin film of Krytox 240 AC Oxygen Lubricant to ball (210); install ball in cavity on
underside of stem (170).

(e) lnstall tip and poppet assembly (180) in cavity on underside of stem (170). Secure tip and
poppet assembly to stem with spring pin (190A).

(f) lnstall washer (160) in top of body and tube assembly (350).

(g) Apply thin film of Krytox 240 AC Oxygen Lubricant to body threads of stem (170). Using
seal replacement kit (part number 801581-00), and instructions supplied with the kit, install
reciprocating seal (140A) on stem (170).

NOTE: The seal replacement kit is supplied with the reciprocating seal (140A) installed
inside tapered holder. Kit installation tools are intended as single usage items
and should be discarded after seal is installed.

(h) With small diameter of guide (130) facing downward, install guide on stem (170).

(i) With tip and poppet (180) portion of stem subassembly facing downward, install stem in top
of body and tube assembly (350).

(j) With wrench fits of sleeve (120) facing upward, install sleeve in body and tube assembly
(350). Rotate stem (170) in a counterclockwise direction to ensure that the valve is in the
"open" position. Torque sleeve (120) into body and tube assembly (350) to the value given
in FITS AND CLEARANCES (refer to Page Block 8001). Torque to sleeve (120) once
again to the value given in FITS AND CLEARANCES (refer to Page Block 8001).

NOTE: The torque that is applied to sleeve (120) is an in-line torque value. If a crowfoot
adapter is used, the torque value must be adjusted accordingly to compensate
for the difference in the moment arm when applying the torque.

NOTE: After initial torque is applied to sleeve (120), the sleeve has shown a tendency to
slightly loosen and therefore does not maintain the initially applied torque.
Reapplying the torque value a second time overcomes this problem.

35-21-93 Page 7009

(k) Install packing retainer (110) onto body and tube assembly (350). Verify that stem (170) is
rotated to full counterclockwise ("open") position; torque packing retainer (110) to the
maximum value given in FITS AND CLEARANCES (refer to Page Block 8001).

(l) Lockwire the retainer (110) to the body and tube assembly (350) per applicable instructions
of MS-33540.

(m) lnstall pressure cap assembly (230) on outlet port of body and tube assembly (350) as
follows:

1 Install rounded end of nipple (310) in outlet port of body and tube assembly (350).
Secure nipple in body with union nut (320). Torque union nut (320) to the value given
in FITS AND CLEARANCES (refer to Page Block 8001).

2 Position large diameter of spacer washer (300) against exposed face of nipple (310),
and align clearance hole of washer with tapped hole in nipple.

3 Slip one looped end of lanyard cable assembly (270) over hub of spacer washer
(300).

4 Apply thin film of Loctite Grade A Threadlock to threads of screw (280).

5 Position large diameter of stud fastener (290) against exposed surface of spacer
washer (300). Secure space washer in position with screw (280).

6 Slip spacer (260) through remaining looped end of lanyard cable assembly (270).

7 Apply thin film of Loctite Grade A Threadlock to the threads of screw (240).

8 Secure free end of lanyard cable assembly (270) to rear of body and tube assembly
(350) with socket fastener (250) and screw (240).

(n) lnstall pressure gauge (10) on body and tube assembly (350) as follows:

1 Install two backup rings (40), two packings (50) and one backup ring (60) on shaft of
pressure gauge (10).

NOTE: See IPL Figure 4 for proper installation sequence of components on shaft of
pressure gauge (10).

2 lnstall stem of pressure gauge (10) in hole on face of body and tube assembly (350).

3 Secure gauge (10) to body and tube assembly (350) with two screws (20) and two
lock washers (30). Torque screws (20) to the value given in FITS AND CLEARANCES
(refer to Page Block 8001).

(o) Install safety plug/outlet (refer to Subtask 35-21-93-440-003-A01)

Subtask 35-21-93-440-006-A01

(2) Safety Plug/Outlet Installation

(Refer to IPL figure. 2)

35-21-93 Page 7010

(a) Install safety outlet assembly (10) as follows: (Applicable to Slow Opening Valve 803440-
90)

1 With identification number, on face of safety disc (30) or (30A), facing away from the
assembler, install disc in recess of retainer (40).

2 Apply thin film of Krytox 240 AC Oxygen Lubricant to gasket (20).

3 Install gasket (20) in retainer (40).

4 Using 10850-T91-3 driver or 2786-S52-1 driver, install retainer (40) in safety outlet
port of body and gauge assembly (400).

5 Torque retainer (40) to the value given in FITS AND CLEARANCES

(refer to Page Block 8001).

6 Install insert (50) in nut (80).

7 Install nut (80) in safety outlet port of body and gauge assembly (400).

8 Install cap assembly (70) on nut (80).

9 Secure cap assembly (70) to nut (80) with screw (60).

(b) Install safety outlet assembly (10A) as follows: (Applicable to Slow Opening Valve 803440-
94)

1 With identification number, on face of safety disc (30) or (30A), facing away from the
assembler, install disc in recess of retainer (40).

2 Apply thin film of Krytox 240 AC Oxygen Lubricant to gasket (20).

3 Install gasket (20) in retainer (40).

4 Using 10850-T91-3 driver or 2786-S52-1 driver, install retainer (40) in safety outlet
port of body and gauge assembly (400).

5 Torque retainer (40) to the value given in FITS AND CLEARANCES

(refer to Page Block 8001).

6 Install insert (50) in nut (80A).

7 Install nut (80A) in safety outlet port of body and gauge assembly (400).

8 Install cap assembly (70A) on nut (80A).

9 Secure cap assembly (70A) to nut (80A) with screw (60).

1 With identification number, on face of safety disc (170) or (170A), facing away from
the assembler, install disc in recess of retainer (180).

35-21-93 Page 7011

2 Apply thin film of Krytox 240 AC Oxygen Lubricant to gasket (160).

3 Install gasket (160) in retainer (180).

4 Using 10850-T91-3 driver or 2786-S52-1 driver, install retainer (180) in safety outlet
port of body and gauge assembly (400).

5 Torque retainer (180) to the value given in FITS AND CLEARANCES

(refer to Page Block 8001).

6 Install insert (190) in nut (220).

7 Install nut (220) in safety outlet port of body assembly (390) or (390A), or body and
gauge assembly (400).

8 Install cap assembly (210) on nut (220).

9 Secure cap assembly (210) to nut (220) with screw (200).

(d) Install safety outlet assembly (230) as follows: (Applicable to Slow Opening Valve 803440-
95)

1 With identification number, on face of safety disc (250) or (250A), facing away from
the assembler, install disc in recess of retainer (260).

2 Apply thin film of Krytox 240 AC Oxygen Lubricant to gasket (240).

3 lnstall gasket (240) in retainer (260).

4 Using 10850-T91-3 driver or 2786-S52-1 driver, install retainer (260) in safety outlet
port of body and gauge assembly (400).

5 Torque retainer (260) to the value given in FITS AND CLEARANCES

(refer to Page Block 8001).

6 lnstall insert (270) in nut (280).

7 lnstall safety outlet assembly (230) in safety outlet port of body and gauge assembly
(400).

(e) Install safety plug assembly (290) as follows: (Applicable to Slow Opening Valve 803440-
96)

1 With identification number on face of safety disc (310) facing toward the assembler,
install safety disc in plug (320).

2 Apply thin film of Krytox 240 AC Oxygen Lubricant to gasket (300).

3 lnstall gasket in plug (320).

4 Apply thin film of Krytox 240 AC Oxygen Lubricant to face of safety outlet port of body
and gauge assembly (400).

35-21-93 Page 7012

5 lnstall plug (320) on body.

6 Torque plug (320) to the value given in FITS AND CLEARANCES

(refer to Page Block 8001).

(f) Install safety outlet assembly (330) as follows: (Applicable to Slow Opening Valve 803440-
98)

1 With identification number, on face of safety disc (350) or (350A), facing away from
the assembler, install disc in recess of retainer (360).

2 Apply thin film of Krytox 240 AC Oxygen Lubricant to gasket (340).

3 lnstall gasket (340) in retainer (360).

4 Using 10850-T91-3 driver or 2786-S52-1 driver, install retainer (360) in safety outlet
port of body and gauge assembly (400).

5 Torque retainer (360) to the value given in FITS AND CLEARANCES

(refer to Page Block 8001).

6 lnstall insert (370) in nut (380).

7 lnstall safety outlet assembly (330) in safety outlet port of body and gauge assembly
(400).

(g) Install safety outlet assembly (330A) as follows: (Applicable to Slow Opening Valve
803440-99)

1 With identification number, on face of safety disc (350) or (350A), facing away from
the assembler, install disc in recess of retainer (360).

2 Apply thin film of Krytox 240 AC Oxygen Lubricant to gasket (340).

3 lnstall gasket (340) in retainer (360).

4 Using 10850-T91-3 driver or 2786-S52-1 driver, install retainer (360) in safety outlet
port of body and gauge assembly (400).

5 Torque retainer (360) to the value given in FITS AND CLEARANCES

(refer to Page Block 8001).

6 lnstall insert (370) in nut (380A).

7 lnstall safety outlet assembly (330A) in safety outlet port of body and gauge assembly
(400).

Subtask 35-21-93-440-007-A01

(3) Testing

(Refer to IPL figure. 4)

35-21-93 Page 7013

(a) Test assembled slow opening oxygen valve assembly in accordance with Testing
(refer to TASK 35-21-93-700-801-A01).

Subtask 35-21-93-440-008-A01

(4) Installation of Handle on Oxygen Valve.

(Refer to IPL figure. 4)

(a) Lockwire retainer (110) to body and tube assembly (350) in accordance with MS33540.

(b) Apply thin film of Loctite Grade A Threadlock to threads on end of stem (170).

(c) lnstall handle (80) on stem (170).

(d) Secure handle (80) in position with retaining ring (100) and nut (90).

(e) lnstall identification plate (70) on handle (80).

(f) Apply dab of torque paint to head of screws (20) that secure gauge (10) to body and tube
assembly (350).

Subtask 35-21-93-440-009-A01

(5) Installation of the Valve Assembly on the Cylinder

WARNING: PRIOR TO INSTALLING VALVE ASSEMBLY ON CYLINDER, ENSURE THAT

VALVE ASSEMBLY HAS BEEN TESTED IN ACCORDANCE WITH THE
TESTING AND FAULT ISOLATION SECTION OF THIS DOCUMENT.

CAUTION: DO NOT APPLY WRENCH FORCE TO CYLINDER NECK. INSTALL CYLINDER

IN A SUITABLE PADDED HOLDING DEVICE IN SUCH A MANNER AS TO NOT
DAMAGE THE FILAMENT OVERWRAP.

(Refer to IPL figure. 1A)

(Refer to IPL figure. 4)

(a) Apply thin film of Krytox 240 AC Oxygen Lubricant to boss seal (340, IPL Fig. 4). Install
seal on inlet port of body (350, IPL Fig. 4).

(b) CAREFULLY thread inlet port of Oxygen valve assembly (60 thru 60F, IPL Fig. 1A) into
neck of cylinder (70, IPL Fig. 1A).

(c) Torque valve assembly (60 thru 60F, IPL Fig. 1A) to the value given in FITS AND
CLEARANCES (refer to Page Block 8001).

H. CVA Charging Procedure

Subtask 35-21-93-610-001-A01

(1) CVA Charging Setup

(a) Remove nut (320)of filler valve.

(b) Attach the APN 5020-01 filler assembly to fill valve assembly.

35-21-93 Page 7014

Subtask 35-21-93-610-002-A01

(2) Charge the CVA

(a) In order to charge the CVA, the oxygen valve assembly must be set in the "ON" position.

(b) For correct charging procedure refer to Reference Document (Table 7001).

Subtask 35-21-93-610-003-A01

(3) Disconnect the CVA

WARNING: FAILURE TO SECURE THE CVA DURING OXYGEN DISCHARGE OR FAILURE

TO FULLY DISCHARGE THE OXYGEN FROM THE CVA CHARGING SETUP
PRIOR TO DISASSEMBLY OF ANY PART FROM THE CVA CHARGING SETUP,
MAY CAUSE SERIOUS PERSONAL INJURY OR DEATH.

(a) High pressure oxygen is a hazardous material. When pressurized oxygen is discharged
intentionally or due to equipment failure, the released energy can be highly destructive if
not properly controlled. Secure the CVA and fully discharge the oxygen from the CVA
charging setup prior to disassembly of any part of the CVA charging setup.

(b) Perform the CVA Latent Leakage Test (refer to Subtask 35-21-93-790-003-a01) and
External Leakage Test (refer to Subtask 35-21-93-790-004-a01) described in the TESTING
AND FAULT ISOLATION section of this manual. (Applicable to Cylinder and Valve
Assembly 8971xxxx / 8972xxxx /8973xxxx)

(c) Perform the CVA External Leakage Test (refer to Subtask 35-21-93-790-008-a01)
described in the TESTING AND FAULT ISOLATION section of this manual. (Applicable to
Cylinder and Valve Assembly 8979xxxx)

35-21-93 Page 7015

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35-21-93 Page 7016

FITS AND CLEARANCES

TASK 35-21-93-992-801-A01

1. CYLINDER AND VALVE ASSEMBLY - FITS AND CLEARANCES

A. General

(1) Torque values, critical to the assembly and operation of the 897 Series CVA, are listed in Table
8001.

(2) Refer to the ILLUSTRATED PARTS LIST section of this manual for the item numbers given.

NOTE: APN's with dash numbers of this form (-1, -2, -3, -4, -5, -6, -7,-8, -9) are identical to
APN's with dash numbers of this form (-01, -02, -03, -04, -05, -06, -07, -08, -09).

IPL REFERENCE TORQUE VALUES

NOMENCLATURE
Fig. No. ITEM No. in.lbs ft.lbs N.m

1 60 to 60J Valve Assembly - 50 to 70 67,8 to 94,9

1A 60 to 60F Valve Assembly - 50 to 70 67,8 to 94,9

350 or 375
2 320 Plug - 39,5 or 42,3
See NOTE

40, 120, 180, 350 or 375

2 Retainer - 39,5 or 42,3
260, 360 See NOTE

80, 80A, 140,

2 220, 280, 380, Safety Outlet Nut 300 - 33.9
380A

3 20 Screw 12 - 1,4

3 110 Retainer 300 - 33,9

3 200 Valve Seat Assy 140 - 15,8

4 20 Screw 12 - 1,4

4 110 Packing Retainer 100 - 11,3

4 120 Sleeve 160 - 18,1

4 200 Seat and Filter Assy 300 - 33,9

4 320 Union Nut 350 to 400 - 39,5 to 45,2

4 330 Filter Assy 45 to 60 - 5,1 to 6,8

NOTE: Torque plug or retainer to 350 in.lbs (39,5 N.m) when installing disc P/N 10003742 (silver).
Torque plug or retainer to 375 in.lbs (42,3 N.m) when installing disc P/N 10006001 (bronze).

Table 8001: Torque Values

35-21-93 Page 8001

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35-21-93 Page 8002

SPECIAL TOOLS, FIXTURES, EQUIPMENT AND CONSUMABLES

TASK 35-21-93-940-801-A01

1. CYLINDER AND VALVE ASSEMBLY - SPECIAL TOOLS, FIXTURES, AND EQUIPMENT

A. General

(1) This section contains a complete listing of all Special Tools, Fixtures, Equipment, (Table 9001)
and Consumable Materials (Table 9002) used throughout this CMM.

B. Special Tools, Fixtures, And Equipment

(Refer to figure 9001)

(1) Special tools, fixtures, and equipment required for disassembly, assembly, testing, cleaning,
checking or repair of the CVA are presented in Table 9001. Special tool required for
disassembly and assembly of the 6350 Series CVA is shown in Figure 9001. Tools and
equipment used in this manual, not listed in Table 9001, are standard oxygen shop tools or
equipment. Special tools, fixtures, and equipment must be cleaned for oxygen service before
use. Equivalents may be substituted for the listed items.

PART NUMBER MANUFACTURER

NOMENCLATURE
(or DESCRIPTION) (VENDOR CODE)

Pressure Gauge 0 - 2000 psig 1404 Series Ametek (US Gauge)

(0 - 13,79 MPa) (Minimum Feasterville, PA 19053
accuracy ± 0.25% full scale) USA (V61349)

Test Gauge (Calibrated Gauge 1409 Series

Component)
0-3000 psig (0 – 20,68 MPa)
Accuracy ±1.0% of span

Test Regulator 0 - 2500 psig 44-1100 Series Tescom Corp.

(0 - 17,24 MPa) Outlet Pressure 44-1114-24 Elkhorn, MN 55330-2491
USA (V5H642)

Flowmeters (Minimum accuracy 1110 Series Brooks Instruments

± 2% full scale) Hatfield, PA 19440-3052
USA (V4ZW64)
10,0 - 100 cu.cm/min 1110DC21CBGAA

200 - 2000 l/m 1110DM41CBGAA

Valve Outlet Test Assembly Western Enterprises

Avon Lake, OH 44012-
Nut – CGA 540 P/N 62 2322
USA (V16166)
Nipple – CGA 540 x ¼ ANPT P/N 69

35-21-93 Page 9001

PART NUMBER MANUFACTURER

NOMENCLATURE
(or DESCRIPTION) (VENDOR CODE)

Valve Inlet Test Adapter APN 803213-S58-10 AVOX Systems

Lancaster, NY 14086-9502
Tee wrench (Item 1 - Fig 9001) 10850-T91-1 USA (V53655)

Wrench (Item 2 - Fig 9001) 10850-T91-2

Driver (Item 3 - Fig 9001) 2786-S52-1

Driver (Item 4 - Fig 9001) 10850-T91-3

Filler assembly 5020-01

Cap (0.903-14 NGO-RH n/a Local Vendor

Pneumatic Bench Vise Model BV-101-P Getz Fire Equipment

P/N 58634 Peoria, IL 61602-1711
USA (V58013)

Protective Cap Alliance Plastics Inc.

Erie, PA 16510-3045
1.188 in. (3,018 cm) ID C234 (APN 33492-029) USA (V34669)

1.125 in. (2,858 cm) ID C336 (APN 33492-027)

1.250 in. (3,175 cm) ID C340 (APN 33492-032)

Liquid/Vapor Degreaser System Baron Blakeslee Enviro Tech International

MSR-216LE Melrose Park, IL 60160
USA (0S8S8)

Ultrasonic Cleaning System TH-1418-9 Mass Technology

PO Box 795-T
East Moline, IL 61244-795
USA
Fax: 309-755-1121

Stainless Steel Tubing 0.250 in. (6,35 mm) OD x Local Vendor

0.035 in. (0,889 mm) Wall
or
0.375 in. (9,53 mm) OD x
0.035 in. (0,889 mm) Wall

Soft Bristle Brush No specific Local Vendor

Bright Inspection Light IL-24 Titan Tool and Supply Co.

Buffalo, NY 14216-1784
USA (V51679)

Torque Wrench No specific Local vendor

Table 9001: Special Tools, Fixtures, and Equipment

35-21-93 Page 9002

C. Consumable Materials

(1) A list of consumable materials required for testing and fault isolation, cleaning, repair and
assembly of CVA are shown in Table 9002. Equivalent materials may be substituted, except for
Oxygen Compatible Lubricant and Oxygen (when used in Cylinder Charging Procedures in the
ASSEMBLY section of this manual (refer to Page Block 7001).

(2) Also, Oxygen (MIL-PRF-27210, Type I) is the Test Gas specified in the TESTING AND FAULT
ISOLATION section of this manual (refer to Page Block 1001). Water pumped Nitrogen (A-A-
59503) or Air (equivalent in purity to MIL-PRF-27210, Type I) may be substituted for Oxygen
only when used as the Test Gas.

MANUFACTURER
MATERIAL PART NUMBER (or DESCRIPTION)
(VENDOR CODE)

Test Gas 1850 psig Oxygen (MIL-PRF-27210, Type I) Local Vendor

(12,76 MPa) min press (See NOTE 1 and NOTE 2)

Non-ionic Detergent Non-ionic Detergent Local vendor

(MIL-D-16791, Type I)

Leak Test Solution Sherlock Leak Detector Winton Products Co. Inc.
MIL-PRF-25567, Type 1 Charlotte, NC 28236
USA (V23316)

Rust Inhibiting Leak 5 cc of a base solution specified in Fisher Scientific

Test Solution NOTE 3, dissolved in one gallon Pittsburgh, PA 15275
(3,79 liters) of water. USA (V1KP78)

Flushing Agent Lenium ®* GS Petroferm Inc.

General Cleaning Solvent Fernandina Beach,
(n-Propyl Bromide) FL 32034
USA (V0WUA8)

Oxygen Compatible Krytox ** 240 AC E.I. du Pont de Nemours

Lubricant APN 50527-00 & Co. Inc.
Wilmington, DE 19898
USA (V23037)

Precision Cleaner HFE-71DE 3M Performance Materials

(Azeotrope of Perfluorobutyl Methyl Division
Ether) St. Paul, MN 55133-3900
USA (V0U817)

Loctite Loctite Threadlock Grade A Loctite Corp.

Newington,
CT 06111-1411
USA (V05972)

Lockwire MS20995C20 Local Vendor

APN 13603-00 (V96906)

35-21-93 Page 9003

MANUFACTURER
MATERIAL PART NUMBER (or DESCRIPTION)
(VENDOR CODE)

Thread Sealing Tape PTFE Ribbon Tape Local Vendor

0.250 in. (CID A-A-58092, size 1)
(6,35 cm wide) APN 500011-00

Torque Paint F-900 Torque Seal Organic Products

F-1000 Irving, TX 75017
Torque Sentry USA (V01195)
APN 50564-00

Lubricant Molykote ®*** No. 106 Dow Corning Corp.

Midland, MI 48686-0997
USA (V71984)

Oxygen MIL-PRF-27210, Type I Local Vendor

1850 psig (12,8 MPa)
minimum pressure

* Lenium is a registered trademark of Petroferm Inc.

** Krytox is a registered trademark of E.I. du Pont de Nemours & Co. Inc.

*** Molykote is a registered trademark of Dow Corning Corp.

NOTE 1: Oxygen (MIL-PRF-27210, Type I) is specified in the TESTING AND FAULT ISOLATION section of the
CMM (refer to Page Block 1001). If water pumped nitrogen or water pumped air (specified in Note 2) is
used for the test gas, the applicable test parameters must have the appropriate density correction
factors calculated and used, and the test equipment must be calibrated for the test gas. (A copy of
specification MIL-PRF-27210 is available from: Standardization Documents Order Desk, Building 4D,
700 Robbins Avenue, Philadelphia, PA 19111-5094 USA.)

NOTE 2: Water pumped nitrogen per Federal Specification A-A-59503, Type I, Class I, Grade B. (A copy of
Specification A-A-59503 is available from: General Services Administration, Business Service Center,
Washington, DC USA.) Water pumped air, equivalent in purity to: MIL-PRF-27210, Type I.

NOTE 3: Base solution is comprised of the following: Sodium Chromate (160 grams) combined with Glacial
Acetic Acid (150 cc), dissolved in water (1840 cc).

Table 9002: Consumable Materials

35-21-93 Page 9004

1 2

3 4

Special Tools, Fixtures and Test Equipment (Refer to Table 9001)

FIGURE 9001/GRAPHIC 35-21-93-991-901-A01

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35-21-93 IPL Page 10001

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35-21-93 IPL Page 10002

ILLUSTRATED PARTS LIST

TASK 35-21-93-990-802-A01

1. INTRODUCTION

This Illustrated Parts List section shows the illustrations and the authorized replacement parts for
the 897 Series Stationary Cylinder and Valve Assembly (CVA).

A. How To Use This Section

(1) If you do not know the part number you need:

(a) Find the part in the applicable figure.

(b) Note the ITEM number used for the part.

(2) If you know the part number, refer to the figure to be sure that the part illustration is the same
as the part that you need.

B. Description of the Numerical Index

(1) The Numerical index is used to locate parts in the unit when only the part number is known.
The Numerical Index is a cross-reference of numbers that include:

- Airline Stock number, Figure No., Item No., and the number of parts required.

- The character-sort-order for part numbers is: dashes first, letters A thru Z second, and then
numbers 0 thru 9.

C. Description of the Illustrated Parts List Entries

The section describes the information found in the Illustrated Parts List (IPL).

(1) FIG. ITEM

(a) Items not Illustrated

Items that are not shown in the figure have a dash in front of the item number.

(b) Alpha Variant Item Numbers

Alpha variants that are A-Z (except I and O) added after the item number show
configuration differences in items, optional parts, parts that have had product
improvement, or added items.

35-21-93 INTRO Page 10003

(2) PART NUMBER

(a) The numbers in this column are the part numbers that AVOX gives to an item, the original
part number for an item that is from a vendor, or a common specification number (e.g., MIL
specification number) that is used for reference of an item. If a part number that AVOX
gives an item is different than the vendor part number or the common specification number,
the vendor part number or the common specification number is shown in the PART
NUMBER column and the AVOX part number (APN) is shown in the NOMENCLATURE
column for user convenience.

NOTE: APN's with dash numbers of this form (-1, -2, -3, -4, -5, -6, -7,-8, -9) are identical
to APN's with dash numbers of this form (-01, -02, -03, -04, -05, -06, -07, -08, -
09).

CVA P/N 897 x x 0 x x

SERIES No.

VALVE BODY ASSY VALVE OUTLET ASSY CYLINDER

GAUGE
CONFIG P/N CONFIG P/N CONFIG P/N
(Y/N)
1 803361-01 Y 0 800844-00 22 21507-01
2 803361-02 N 1 801153-00 40 21507-05
3 803361-03 Y 2 800843-00 50 21507-02
9 803345-01 Y 3 22606-01 77 21507-03
4 800844-01 15 21507-04
5 10722-00
6 2814-00
7 -
8 22608-01
9 22608-02

VALVE P/N 803440 - x x

Table 10001: CVA and Valve Part Number Configuration Matrix

(3) AIRLINE STOCK NUMBER

(a) This column has space available for a number, up to eleven characters in length, given by
the airline.

(4) NOMENCLATURE

This column has the description of the part and may contain the following:

(a) Abbreviations

1 The abbreviations in this column in the table are shown in the List of Abbreviations in
the INTRODUCTION section of this manual (refer to Page Block 0000).

35-21-93 INTRO Page 10004

(b) Level of Indenture

This information shows the relationship of one part to another. An example is shown:

123 (Assembly Number)

• Subassembly Top No.

• Attaching Parts for the Subassembly Top No. or Assembly Item ***

• Assembly Item

•• Sub-Subassembly Top Number

•• Attaching Parts for the Sub-Subassembly Top No. or Subassembly Item

***

•• Subassembly Item

NOTE: The three asterisks are used to separate the attaching parts of one Item from the
following Item.

(5) Vendor Codes

(a) The following is a list of the vendors that supply items in this section of the manual. All
items, including standard parts, vendor supplied parts, and those parts that do not specify
a vendor code, are available from the sources listed in the INTRODUCTION section of this
manual.

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  
  
  
  
  
  
  
  
  
  
  
  
  


  
  
  
  
  
  
  
  
  
  
  
  
  
   

   

  
  
  
  
  
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  
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  
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  
  
  
  
  
  
  
  
  
  
  
  
  
  
  
  
  
  
  
  
  
  
  
  
  
  
  
  
  
 
 
  
  
  
  
   
  
  
  
  
  
  
  
  
  
  
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  
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   
  
  
  


  
  
  
  
  
   
   
  
  
  
  
   

  
  
 

   
   
  
  
  
  
  
  
  
  
  
  
  
  
  
  
  
  
  
  
  
  
  
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  
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  
  
  
  
  
  
  
  
  
  
  
  
  
  
  
  
  
  
  
  
  
  
  
  
  
  
  
  
  
  
  
  
  
  
  
  
  
  
  
  
  
  
  
  
  
  
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  
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  
  
  
  
  
  
  
  
  
  
  
  
  
  
  
  
  
  
  
  
  
  
  
  
  
  
  
  
  
  
  
  
  
  
  
  
  
  
  
  
  
  
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- ITEM NOT ILLUSTRATED

35-21-93 NI Page 10013

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

35-21-93 NI Page 10014



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


35-21-93 Page 10016

   

     
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 
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   
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   
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

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

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     
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   
 
 
 

 
  
  
 


 
  
  
 

 
  
  
 

 
  
  
 

 
  
 
 
 
   
   

   
 
 
 
   
   

   
 
 
 
   
   

   
 
 
 
   
   

   
 
 
 

 
 
 
 
 
 


  
 
 
 
 


 
 
 
 
 
 


  
 
 
 
 


 
 
 
 
 
 


 
 
 
 
 
 


 
 
 
 
 
 


  
 
 
 
 


 
 
 
 
 
 


  
 
 
 
 


 
 
 
 
 
 
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      
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   
  
   
    
 
   

 
   
 
 
   
   
 
   
 
 
   
   
      
      
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      
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      
      
      
      
      
      
      
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      
      
      
      
      
      
      
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      
      
      
      
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      
      
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35-21-93 Page 10022

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

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


35-21-93 Page 10024

   

     
  
   

 
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 
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 
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 
 
 
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   
 
  
 
 
 
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 
  
 
 
 
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   
 
  
 
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 
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   
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  
 
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   

   
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   
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   
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   
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   
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   
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   
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   
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   
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   
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   
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
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  
 
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 
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 
 
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 
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
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 
 
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
 
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 
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 
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 

 
   
 
 

   
   
   
   
   
   

   
 
 
 

 
  
 
 
 

 
  
 
 
 

 
  
 
 
 

 
  
 
 
 

 
  
 
 
 

 
  
 
 
 

 
  
 
 
 

 
  
  
 

   
   
   
   
   
   

   
 
 
 

 
  
 
 
 

 
  
 
 
 

 
  
 
 
 

 
  
 
 
 

 
  
 
 
 

 
  
  
 


 
 
 
 
 
 


 
 
 
 
 
 


 
 
 
 
 
 


  
 
 
 
 


 
 
 
 
 
 


 
 
 
 
 
 


  
 
 
 
 


 
 
 
 
 
 

      


- ITEM NOT ILLUSTRATED

35-21-93 Page 10026

   
     
    
 
   

 
  
 
 
 

   
   
   
   
   
   
 
  
 
 
 

 
  
 
 
 

 
  
 
 
 

 
  
 
 
 
 
  
 
 
 
 
   
 
 
 
   
   
 
  
 
 
 
   
   
 
  
 
 
 
   
   

 
  
 
 
 
   
 
  
      
      
      
      
      
      
      
      
      
      
      
      
      
      
      
      
      
      
      
      
      
      
      
      
      
      
      
      
      
      


- ITEM NOT ILLUSTRATED

35-21-93 Page 10027

90
100

110

120

130

140

150

160

170

180

190
20 30 200
220

230
40
50
60
10

70A

210
CROSS SECTION
 (ITEM 70A)





35-21-93 Page 10028

JAN 24/12 R
The data and information contained herein are proprietary of AVOX Systems. Copy and distribution to a third party are strictly forbidden. Printed in United States
AVOX SYSTEMS
COMPONENT MAINTENANCE MANUAL
897 SERIES

   

     
  
   

 

 
  
 
 
 
   
   
 
  
 
 
 
   
   
 
  
 
 
 
   
   

 
  
 
 
 
   
   
   
   
   
   
 
   
 
 
 
   
   

 
  
 
 
 
   
   
   
   

 
  
 
 
 

 
  
 
 
 
   
   
   
   

 
  
 
 
 

 
  
   


   
  
 


 
  
  
 

 
  
  
 

 
  
  
 

 
  
  
 

 
  
  
 

 
  
  
 

 
  
  
 

 
  
  
 

 
  
  
 

 
  
  
 

 
  
  
 

 
  
  
 

 
  
  
 

 
 
 
 
 
 


 
 
 
 
 
 


 
 
 
 
 
 


  
 
 
 
 


  
 
 
 
 

      
      
      
      
      
      
      


- ITEM NOT ILLUSTRATED

35-21-93 Page 10029

140A 90

CROSS SECTION 150 80

(ITEM 140A)
160 100

170 110
190
220 120

210 130

180

200

20 30

280
240 290
270
250A 300
320
260 310
330 230

50 10
350
40
340A 60
40

CROSS SECTION
(ITEM 340A)






35-21-93 Page 10030

   

     
  
   

 

 
  
  
 
   
   
 
   
  
 
   
   
   
   
   
   

 
  
  
 
   
   

 
  
  
 
   
   
   
   

 
  
  
 

 
  
  
 
   
   
   
   

 
  
  
 

 
  
  
 

 
  
  
 
   
   

 
  
  
 
   
   

 
  
  
 

 
  
  
 

 
  
  
 

 
  
  
 

 
  
  
 

   
  
 

 
  
  
 

 
  
  
 
   
   
   
   

 
  
  
 

 
  
  
 
   
   

 
  
  
 

 
 
 
 
 
 


  
 
 
 
 


 
 
 
 
 
 


 
 
 
 
 
 


 
 
 
 
 
 


 
 
 
 
 
 


 
 
 
 
 
 


 
 
 
 
 
 

      
      
      
      


- ITEM NOT ILLUSTRATED

35-21-93 Page 10031

   
  
   
    
 
   


 
   
 
 
   
   
   
   
   
   

 
   
 
 
 
   
 
 

 
  
  
 

 
  
  
 
   
   

 
   
 
 
   
   
   
   

 
   
 
 
   
   
   
   

 
  
  
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
 
  
  
 

 
  
  
 

 
  
  
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
 
  
   


   
  
 


 
  
  
 
      
      
      
      
      
      
      
      
      
      
      
      
      
      
      
      
      
      
      
      
      
      
      
      
      


- ITEM NOT ILLUSTRATED

35-21-93 Page 10032

STORAGE

TASK 35-21-93-500-801-A01

1. CYLINDER AND VALVE ASSEMBLY - STORAGE

A. General

(1) This section contains information on storage (including transportation) requirements for the 897
Series CVA’s.

B. Procedure

Subtask 35-21-93-550-001-A01

(1) Storage

(a) Make sure the CVA is safety wired in the "OFF" position before being placed in storage or
transported. Refer to the ASSEMBLY section in this manual for instructions on how to
safety wire the CVA in the "OFF" position.

(b) A CVA must be stored and transported with a minimum amount of oxygen pressure to
prevent contamination from entering. A minimum of 150 psig (1,034 MPa) pressure is
recommended. A CVA even when it contains a minimum amount of oxygen pressure, must
still be stored and transported under all applicable regulations.

(c) A CVA that is completely depleted of oxygen pressure must be assumed to be

contaminated. Refer to CLEANING section in this manual and clean the CVA.

(d) Make sure all protective caps, plugs, and covers are installed.

(e) Place the CVA in a clean polyethylene bag and seal it to protect the CVA from dust and
dirt.

(f) Store the CVA in a cool area, away from sources of high heat and humidity.

(g) Refer to the applicable aircraft maintenance manual for procedures to reinstall the CVA
onto the aircraft. Make sure the safety wire securing the CVA in the "OFF" position is
removed when reinstallation of the CVA onto the aircraft is complete.

Subtask 35-21-93-510-001-A01

(2) Transportation

(a) General

1 The United States Department of Transportation (DOT) Code of Federal Regulations

(CFR) provides rules affecting shipments of compressed oxygen cylinders by ground
(motor freight) passenger carrying aircraft and cargo aircraft. These regulations are
specified in 49 CFR Parts 171, 172 and 175.

35-21-93 Page 15001

2 The specified number and size of cylinders to be shipped, certain packaging

requirements (Air Transport Association of America (ATA) Specification No. 300),
hazardous materials descriptions and proper shipping names (Oxygen, compressed),
as well as hazardous materials identification numbers (UN1072 for Oxygen,
compressed) are identified.

3 Additional requirements and regulations (e.g., Transport Canada) for transport of

oxygen cylinders may apply in other countries.

(a) Reference Documents

1 Table 15001 contains a list of applicable reference documents for the transportation
and packing of compressed oxygen cylinders aboard aircraft. The information in Table
15001 was accurate on the revision date of this manual.

ORDERING
DOCUMENT NUMBER DOCUMENT NAME
INFORMATION

Federal Register - Part V; Vol. 64; Hazardous Materials: Chemical US Government Printing
No. 160 US Department of Oxidizers and Compressed Office
Transportation (Research and Oxygen Aboard Aircraft; Final Rule Washington, DC 20402
Special Programs Administration) USA (VER765)

49 CFR Part 171 General Information, Regulations

and Definitions

49 CFR Part 172 Hazardous Materials Table,

Special Provisions, Hazardous
Materials Communications,
Emergency Response Information
and Training Requirements

49 CFR Part 175 Carriage by Aircraft

49 CFR Part 177 Carriage by Public Highway

ATA Specification No. 300 Packaging of Airline Supplies Air Transport Association of
America
Washington, DC 20004-1707
USA

DOT-SP 8162 Special Permit For Composite US Government Printing

Cylinder Office
Washington, DC 20402
USA (VER765)

Table 15001: Reference Documents

35-21-93 Page 15002

Subtask 35-21-93-530-001-A01

(3) Packaging

(a) US DOT HM224B requirements

1 All cylinders charged with compressed oxygen gas greater than 25.9 psig at 68° F
(20° C) that are offered for air shipment within or into the US must comply with US
DOT HM224B packaging requirements.

2 Cylinders charged to less than 25.9 psig at 68° F (20° C) are considered empty by the
DOT and may be air shipped without HM224B compliant packaging.

WARNING: THE PACKING FOR SHIPMENT AND OFFERING FOR SHIPMENT OF ANY
CHARGED COMPRESSED OXYGEN GAS CYLINDERS SHALL BE DONE
ONLY BY THOSE FACILITIES AUTHORIZED AND THOSE PERSONNEL
TRAINED TO HANDLE AND PACKAGE HAZARDOUS MATERIAL.
PERSONNEL ALSO NEED TO BE EXPERIENCED AND
KNOWLEDGEABLE IN HANDLING AVIATION OXYGEN EQUIPMENT.
FAILURE TO COMPLY MAY RESULT IN INJURY OR DEATH.

3 Cylinders charged greater than 25.9 psig at 68° F (20° C) may be transported by:.

a Surface transport by ship or truck in conventional packaging.

b Air transport in boxes compliant with HM224B in non-passenger aircraft.

Approved boxes are listed in Table 15002.

CYLINDER CAPACITY
AVOX SYSTEMS P/N ZODIAC SERVICES P/N
cu ft (liters)

82009-22 VPS-308E 22 (623)

82009-76 VPS-302E 76.5 (2,166)

82009-115 VPS-301E 115 (3,256)

Table 15002: AVOX Systems P/Ns of US DOT Compliant Reusable Shipping

Boxes for Compressed Oxygen Cylinders

(b) New US DOT HM224B compliant Procedures

1 Package securely in a box that is compliant with HM224B (a list of compliant boxes is
shown in Table 15002).

2 This package may be offered for air shipment on any aircraft or surface vehicle (Air
carriers may restrict the shipment of charged cylinders in HM224B compliant boxes,
e.g., they may limit the quantities carried).

3 HM224B compliant boxes are available for sale. AVOX and Zodiac Services will
provide the option to return of any HM224B boxes used for shipping of AVOX oxygen

35-21-93 Page 15003

cylinder assemblies. The purchase price of the box less a handling fee will be credited
provided box is returned in good, usable condition. The Return Material Authorization
Number must be included on the Return Material Authorization Form. The Return
Material Authorization Number must be provided by AVOX or Zodiac Services before
material is returned.

1 Bleed the cylinder down to less than 25.9 psig at 68° F (20° C).

2 Close the cylinder valve.

3 Affix the shipping tag (P/N 10015660; see Figure 15001) securely to the neck of the
cylinder.

4 Package in standard corrugated shipping boxes with appropriate dunnage to protect

and hold the cylinder assembly in place.

5 Affix an “EMPTY CYLINDER” label to the outside of the box.

6 Cylinders satisfying (c).1 thru (c).4 can be offered for shipment to any destination by
air or surface.

WARNING: CYLINDER ASSEMBLIES MUST BE FULLY CHARGED BEFORE PLACING

INTO SERVICE. FAILURE TO FULLY CHARGE A CYLINDER BEFORE
PLACING IN SERVICE MAY RESULT IN INJURY OR DEATH.

7 After arrival at destination

a Charge the cylinder assembly to full operating pressure before placing into
service.

b Remove the shipping tag (P/N 10015660; see Figure 15001) from the neck of the
cylinder.

c Verify that the cylinder is charged to full operating pressure.

d Check the cylinder assembly for leaks.

e Issue an EASA Form 1 or equivalent as required.

f Add statement to block 13 on the EASA Form 1 or equivalent stating that service
was performed in accordance with the CMM.

g Add in block 12 of the EASA Form 1 or equivalent “Inspected/Tested.”

h Sign on the right side in block 20.

i Install in aircraft or place in stores ready for service.

j Re-package if unit is being forwarded (outside US only).

35-21-93 Page 15004

-WARNING-
THIS CYLINDER ASSEMBLY
CONTAINS LESS THAN 25 PSIG
OXYGEN PER MIL-PRF-27210
FOR AIR TRANSPORT PURPOSES.
(REF.;49 CFR 173.115(B)(1))
CHARGE FULLY AND
REMOVE THIS LABEL
BEFORE PLACING IN
SERVICE. FAILURE TO
FULLY CHARGE CYLINDER
BEFORE PLACING IN SERVICE
MAY RESULT IN INJURY
OR DEATH.

Cylinder Tag, Shipping (P/N 10015660)

FIGURE 15001/GRAPHIC 35-21-93-991-1501-A01

35-21-93 Page 15005

THIS PAGE INTENTIONALLY LEFT BLANK

35-21-93 Page 15006

JAN 24/12
The data and information contained herein are proprietary of AVOX Systems. Copy and distribution to a third party are strictly forbidden. Printed in United States

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