Tech Manual TO 34Y1-125-41.pdf

TO 34Y1-125-41

TECHNICAL MANUAL

OPERATION AND MAINTENANCE INSTRUCTIONS

WITH

ILLUSTRATED PARTS BREAKDOWN

COMPRESSOR, RECIPROCATING,

POWER DRIVEN, AIR, DIESEL ENGINE,

15 CFM, 4,000 PSI

TYPE MC-11

MODEL 3MC-11

PART NUMBER 69718

NSN 4310-01-065-7232

DAVEY COMPRESSOR CO.

DIVISION OF KECO INDUSTRIES, INC.

16004

F09603-78-C-1825

FA8501-05-D-0002

DISCLOSURE NOTICE - This information is furnished upon the condition that it will not be released to another nation without the specific authority of the Department of the Air Force of the United States, that it will be used for military purposes only, that individual or corporate rights originating in the information, whether patented or not, will be respected, that the recipient will report promptly to the United States, any known or suspected compromise, and that the information will be provided substantially the same degree of security afforded it by the Department of Defense of the United States. Also, regardless of any other markings on the document, it will not be downgraded or declassified without written approval of the originating United States agency.

DISTRIBUTION STATEMENT C - Distribution authorized to U.S. Government Agencies and their contractors (Administrative or Operational Use) (1 April 2004). Other requests for this document shall be referred to 584 CBSS/GBHDE, Robins AFB, GA 31098. Questions concerning technical content shall be referred to 578 CBSS/GBLA.

WARNING - This document contains technical data whose export is restricted by the Arms Export Control Act (Title 22, U.S.C., Sec 2751, et seq.) or the Export Administration Act of 1979, as amended, Title 50, U.S.C., App. 2401 et seq. Violations of these export laws are subject to severe criminal penalties. Disseminate in accordance with provisions of DoD Directive 5230.25.

HANDLING AND DESTRUCTION NOTICE - Comply with distribution statement and destroy by any method that will prevent disclosure of contents or reconstruction of the document.

Published Under Authority of the Secretary of the Air Force

1 APRIL 2004 CHANGE 1 - 26 JUNE 2007

BASIC AND ALL CHANGES HAVE BEEN MERGED

TO MAKE THIS A COMPLETE PUBLICATION

5-96

Assemble hourmeter (26) to panel (50) from the front and assemble wire lead (25) to hourmeter (26) and stud.

Secure meter to panel with mounting bracket, lock washers, and nuts removed from the hourmeter studs.

f. Unscrew and remove two nuts and mounting brackets supplied with compressor oil pressure gauge (27).

Assemble the gauge through the front of panel (50).

Assemble the mounting brackets on gauge studs and secure with nuts removed from mounting studs.

g. Unscrew and remove two nuts. lock washers. and mounting bracket supplied with the ammeter (24).

Assemble ammeter (24) to panel (50) from the front and secure with mounting bracket, luck washers, and nuts removed from ammeter terminal studs.

h. Unscrew and remove nuts and mounting brackets, two each supplied with gauges (18, 19, 20, 21, 22 and 23).

Assemble these six gauges from the front of panel (50) mounting gauges as shown on panel (50). Secure each gauge to panel with mounting brackets and nuts removed from each gauge.

i. Unscrew and remove nuts and mounting brackets sup-plied with gauges (17, 28, 29 and 32). Assemble these four gauges from tire front of panel (50) mounting gauges as shown on panel (50). Secure each gauge to panel with mounting brackets and outs removed from each gauge.

j. Assemble the two panel lamps (11) to the front of panel

(50) and secure with lock washers (13) and jars nuts (12).

k. Assemble seven adaptors (10), one each of the seven gauges (17 through 23).

l. Assemble pipe tee (9) on back of engine oil pressure gauge (27) with oil pressure switch (8) on run of tee and tubing elbow (7) on rung facing away from panel (50).

m. Assemble pipe tee (6) branch on pressure gauge (28) with run of tee in horizontal position. Install reducing bushing (5), adaptor (4) and elbow (2) in run of tee (6) with elbow (2) in vertical position.

n. Install gauge protector (3) on gauge (29) with relief valve in the vertical position. Install tubing elbow (2) in end of tube protector with elbow in vertical position.

Connect regulator pressure low range gauge-to-high range gauge tube (1) between the elbow (2) on gauge

(28) and elbow (2) in tee (6).

o. Install bushing (31) and adaptor (30) on gauge (32).

Connect high-flow pressure gauge (32) to hose bleed valve tube assembly and large receiver pressure gauge

(17) to isolation valve tube assembly.

5.6.22 Air Cooler Subassembly. (See Figure 7-28.) The

following paragraphs contain disassembly, cleaning, inspec-tion, repair or replacement, and assembly instructions for the air cooler subassembly.

5.6.22.1 Disassembly. Disassemble air cooler subassembly

only to the extent necessary to replace or repair a defective part or parts. Disassembly. To disassemble the air cooler sub-assembly proceed as follows:

a. Unscrew and remove first stage safety valve assembly (Figure 7-28, 1), reducing bushing (2), tubing elbow (3), tubing adaptor (4), tubing snubber (5), reducing bushing (6), pipe cross (7). pipe nipple (8), and pipe elbow (9).

Remove tubing adaptor (10).

b. Unscrew and remove fourth stage safety valve assembly (11). Remove tubing elbow (12), tubing adaptor (13), tubing snubber (14), reducing bushing (15). pipe cross 116), pipe elbow (17). and tubing adaptor (18).

c. From the opposite side of the cooler assembly, unscrew and remove the third stage safety valve assembly (19).

Remove tubing adaptor (20), tubing snubber (21).

reducing bushing (22), tubing elbow (23), pipe cross (24), and pipe elbow (25).

d. Unscrew and remove the second stage safety valve assembly (26), adaptor (27), tubing adaptor (28), tubing snubber (29), reducing bushing (30), pipe cross (31), nipple (33), and tubing elbows (34 and 35).

e. Remove six machine screws (37) and remove fan shroud (36) from air cooler assembly (38).

NOTE

Refer to CLEANING, INSPECTION, and REPAIR or REPLACEMENT to determine if further disassemble of air cooler (37) is necessary.

5.6.22.2 Cleaning. This paragraph contains cleaning

instruction for the air cooler subassembly.

5-97

Proper precautions must be exercised to protect per-sonnel. Stand clear of all tubing openings. After cleaning, drain air cooler, and dry with low pressure compressed air (maximum 30 PSIG [207 kPa]).

a. Clean outside and inside surfaces of the air cooler and tubing assemblies with compressed air, pressurized hot water and detergent or steam.

b. Clean the pressure snubbers (5, 14, 21, and 30), proceed as follows:

Provide adequate ventilation when using MIL-PRF- 680A, isopropyl alcohol, aliphatic naphtha, trichloro-ethane, and methyl ethyl ketone. Avoid prolonged breathing of vapors and minimize skin contact.

(1) Clean with MIL-PRF-680A, solvent.

(2) After cleaning dry with low pressure compressed air

(30 PSI).

5.6.22.3 Inspection. Upon disassembly and cleaning, each

part shall be inspected. After a part has been accepted as usable by inspection, the part shall be retained for repair and assembly of the air cooler subassembly. All parts which do not meet minimum acceptable standards shall be repaired or replaced with a like serviceable item. Visually inspect all parts for the following:

a. Hexagon nuts for stripped or damaged threads.

b. Screws for stripped or damaged threads.

c. Threaded parts (fittings, etc.) for stripped or damaged threads.

d. Test safety valves. Connect valve to be tested to a gauged and, regulated 4,300 PSIG (27,580 kPa) air or nitrogen source (see Figure 5-38).

Keep unprotected parts of body away from valve opening during test.

NOTE

Hydrostatic tester may be used in lieu of nitrogen or air pressure source.

(1) Starting with zero pressure increase pressure to valve operating pressure.

(2) If safety valve relieves pressure prior to or after specified pressure, replace safety valve.

e. Screw a steel pipe plug into first stage outlet opening.

Pressurize air cooler with low pressure air (30 PSIG [207 kPa] maximum) at first stage inlet opening.

Immerse cooler first stage in water. Inspect for any leaks.

f. Remove pipe plug and air source from first stage.

Repeat step e. for second, third, and fourth stages of air cooler.

g. Refer to REPAIR OR REPLACEMENT to repair leaks in the air cooler.

5.6.22.4 Repair or Replacement. The following para-

graph contains information necessary to repair and replace worn or defective parts prior to assembly. Clean up minor thread damage to threaded connections. The repair and replacement procedure for the air cooler subassembly is as follows:

a. Replace all threaded parts having worn, stripped, or damaged threads.

b. Replace damaged or defective fittings.

c. Replace damaged or defective safety valve/s.

d. Straighten bent or dented shroud assembly. Weld any cracks or breaks.

e. Repair air cooler, if leaking, as follows:

(1) Using an oxy-acetylene torch, carefully solder fitting (40, 41, 42, 44 and/or 45) from one end of the defec-tive tube and elbow (42) from the other end.

1st stage valve 80 PSIG (552 kPa)

2nd stage valve 240 PSIG (1,655 kPa)

3rd stage valve 1,500 PSIG (10,343 kPa)

4th stage valve 4,300 PSIG (26,196 kPa)

5-98

(2) Manufacture extraction tool by using a four inch long 0.375 inch diameter (102 mm long, 9.525 mm diameter) solid steel rod. Solder a three inch (7.63

mm) piece of same material for t-handle. Insert tool into exposed elbow end, flared end of the defective tube, work the defective tube loose from the cooling fins.

(3) Rotate the tool installed in step (2), but do not exert extreme torque that will deform tube. If tube will not work loose, use a blade type screw driver or other flat tool to work each cooling fin gently back and forth to relieve any oxide or corrosion. Spray the tube around the fins with silicone lubricant (NSN 9150-00-823-7860).

(4) Manufacture a new tube section and have one end swaged to proper size for resoldering elbow.

NOTE

Use a piece of asbestos cloth or other heat shield to protect surrounding fittings from direct flame. Small pin holes can develop in the solder joints of existing fittings if they are not protected.

(5) Ensure ends of new tube, original fittings, and all unsoldered areas are clean. Insert new tube through cooler. Use silver solder and flux, resolder new tube and original fittings back into place.

(6) After soldering is finished, test the cooler, with low pressure -air and water, refer to INSPECTION to determine if any leaks are present. If leaks are present, resolder where necessary. Check the cooling stages to the proper pressure for each with water or hydraulic pressure. If hydraulic pressure is used, be sure the tubes are purged of hydraulic fluid before repainting and reuse.

5.6.22.5 Assembly. To assemble the air cooler subassem-

bly, proceed as follows:

a. Attach fan shroud (Figure 7-28, 36) to the air cooler assembly (38) with six cap screws (37).

b. Assemble pipe nipple (33), pipe cross (32), pipe corns (31), reducing bushing (30), tubing snubber (29), tubing adaptor (28), and adaptor (27). Install second stage valve assembly (26) in pipe cross (32). Assemble pipe nipple (33) to air cooler assembly (38).

c. Assemble pipe elbow (25), pipe cross (24), tubing elbow (23), reducing bushing (22), tubing snubber (21), and tubing adaptor (20). Assemble pipe elbow (25) to air cooler assembly (38) third stage inlet. Install third stage safety valve assembly (19) in pipe cross (24).

d. On the opposite side of cooler, assemble pipe elbow (17), pipe moss (16), reducing bushing (15), tubing snubber (14), tubing adaptor (13), and tubing elbow (12). Install fourth stage safety valve assembly (11) in pipe cross (16). Assemble pipe elbow (17) to air cooler assembly (38) fourth stage inlet.

e. Assemble elbow (9), dose nipple (8), pipe cross (7), reducing bushing (4), tubing snubber (5), tubing adaptor (6), tubing elbow (3) and reducing bushing (2). Assem-ble pipe elbow (9) to air oil cooler (38) first stage inlet.

Install valve assembly (1) in bushing (2).

f. Install elbows (34 and 35) in air cooler assembly (38) second stage and first stage outlets. Assemble tubing adaptors (10 and 18) air cooler (38) fourth stage and first stage inlets.

NOTE

Paragraph 5.6.23, Paragraph 5.6.23.1, Paragraph 5.6.23.2, Paragraph 5.6.23.3, Paragraph 5.6.23.4 and Paragraph 5.6.23.5 apply only to air compressors with serial numbers prior to 943270.

5.6.23 Air Pressure Regulator Subassembly. (See Fig-

ure 7-29.) The following paragraphs contain disassembly, cleaning, inspection, repair or replacement, and assembly instructions for the air pressure regulator subassembly.

5.6.23.1 Disassembly. Disassemble air pressure regulator

subassembly only to the extent necessary to replace or repair a defective part or parts. To disassemble the air pressure regula-tor subassembly, proceed as follows:

a. Remove plug button (Figure 7-29, 1), handle nut (3), and lever handle (2).

b. Remove three screws (5), lock washers (6) and the iden-tification plate (4).

c. Remove four cap screws (8). Hold valve bonnet (7) with cam shaft (17) pointing downward and separate bonnet

(7) from body (83). Remove two O-rings (9).

d. Push cam shaft (17) out of bonnet (7) with light pressure applied to handle (2) end of shaft.

e. Remove the limit plate (10), cam operator assembly (11), bonnet washer (14), valve cam (15), pivot pin (16), cam shaft (17), and bonnet washer (18), Remove the

7-58

Figure 7-28. Air Cooler Subassembly

7-59

FIGURE &

INDEX/

SHEET NO.

PART

NUMBER CAGE

DESCRIPTION

1 2 3 4 5 6 7

UNITS

PER

ASSY

USABLE

ON

CODE

SMR

CODE

7-28 81937 COOLER SUBASSY, Air (See Figure 7-25, 88 for

NHA.)

REF

1 48-80-1/4NPT . VALVE, Safety, 1 stg, 80 PSI Davey SPEC CONT

DWG 29771)

1 PAFZZ

2 81791 24617 . BUSHING, Rdcr, 3/8 NPT x 1/4NPT 3 MS51815-38 96906 . ELBOW, Male, 90 deg, 3/8 NPT x 1/2 tube . . . . . . . . . . 1 PAFZZ 4 PF101-6-2 . BUSHING, Rdcr, 3/8 NPT x 1/8 NPT (Davey

SPEC CONT DWG 61019)

5 12S1-8NPT 99752 . SNUBBER, Pressure (Davey SPEC CONT DWG 28784)

1 PAFZZ

6 MS51819-31 . ADAPTER, Straight, 1/8 NPT x 1/8 tube. . . . . . . . . . . . . 1 PAFZZ 7 81792 24617 . CROSS, Pipe, 3/8 NPT 8 MS51953-49 96906 . NIPPLE, Pipe, close, 3/8 NPT . . . . . . . . . . . . . . . . . . . . 1 PAFZZ 9 MS39203-3 96906 . ELBOW, Pipe, street, 3/8 NPT . . . . . . . . . . . . . . . . . . . . 1 PAFZZ 10 MS51819-37 96906 . ADAPTER, Straight, 1/4 MFT x 3/8 tube. . . . . . . . . . . . . 1 PAFZZ 11 65363 . VALVE, Safety, 4 stg, 4300 PSI . . . . . . . . . . . . . . . . . . . 1 PAFZZ 12 MS51815-36 96906 . ELBOW, Male, 90 deg, 1/4 NPT x 3/8 tube . . . . . . . . . . 1 PAFZZ 13 MS51819-31 96906 . ADAPTER, Straight, 1/8 MPT x 1/8 tube . . . . . . . . . . . . 1 PAFZZ 14 12S1-8NPT 99752 . SNUBBER, Pressure (Davey SPEC CONT DWG

28784)

1 PAFZZ

15 PF101-4-2 98660 . BUSHING, Rdcr, 1/4 NPT x 1/8 NPT (Davey

SPEC CONT DWG 65980)

16 PF41-4 98660 . CROSS, Pipe, 1/4 NPT (Davey SPEC CONT

DWG 65170)

1 PAFZZ

17 PF20-4 98660 . ELBOW, Male, 90 deg, 1/4 NPT (Davey SPEC

CONT DWG 65644)

1 PAFZZ

18 MS51819-37 96906 . ADAPTER, Straight, 1/4 MPT x 3/8 tube . . . . . . . . . . . . 1 PAFZZ 19 230N1500-1/4NPT 34494 . VALVE, Safety, 3 stg, 1,500 PSI Davey SPEC

CONT DWG 28121)

1 PAFZZ

20 MS51819-31 96906 . ADAPTER, Straight, 1/8 MPT x 1/8 tube . . . . . . . . . . . . 1 PAFZZ 21 12S1-8NPT 99752 . SNUBBER, Pressure (Davey SPEC CONT

DWG 28784)

1 PAFZZ

22 PF101-4-2 96906 . BUSHING, Rdcr, 1/4 NPT x 1/8 NPT 23 MS51815-36 98660 . ELBOW, Male, 90 deg, 1/4 NPT x 3/8 tube

(Davey SPEC CONT DWG 65980)

1 PAFZZ

24 PF41-4 98660 . CROSS, Pipe, 1/4 NPT (Davey SPEC CONT

DWG 65170)

1 PAFZZ

25 PF20-4 98660 . ELBOW, Male 90 deg, 1/4 NPT (Davey SPEC

CONT DWG 65644)

1 PAFZZ

26 48-240-1/4NPT 34494 . VALVE, Safety, 2 Stg, 240 PSI (Davey SPEC

CONT DWG 27315)

1 PAFZZ

27 G5205X6 79470 . ADAPTER, Straight, 1/4 MPT x 3/8 JIC (Davey

SPEC CONT DWG 23670)

28 MS51819-31 96906 . ADAPTER, Straight, 1/8 MPT x 1/8 tube . . . . . . . . . . . . 1 PAFZZ 29 12S1-8NPT 99752 . SNUBBER, Pressure (Davey SPEC CONT DWG

28784)

1 PAFZZ

30 PF101-4-2 98660 . BUSHING, Rdcr, 1/4 NPT x 1/8 NPT Davey

SPEC CONT DWG 65980)

I

31 G3759X4 79470 . TEE, Street, 1/4 NPT (Davey SPEC CONT DWG 41024)

32 PF31-4 98660 . TEE, Pipe, female, 1/4 NPT (Davey SPEC

CONT DWG 65609)

1 PAFZZ

33 PF10-4 98660 . NIPPLE, Pipe, close, 1/4 NPT (Davey SPEC

CONT DWG 65610)

1 PAFZZ

34 MS51815-38 96906 . ELBOW, Male, 90 deg, 3/8 NPT x 1/2 tube . . . . . . . . . . 1 PAFZZ

7-60

7-28 35 MS51815-36 96906 . ELBOW, Male, 90 deg, 1/4 NPT x 3/8 tube . . . . . . . . . . 1 PAFZZ 36 65192 . SHROUD, Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 PAFZZ 37 9414204 24617 . SCREW. Mach, serr flg hd, 1/4 - 20 NC x 3/8 in lg (AP)

6 PAFZZ

38 65376 . COOLER, Air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 PAFLD 39 98008 67049 . . U-BEND, Copper . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 PAFZZ 40 147670 67049 . . U-BEND, Copper . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 PAFZZ 41 15032 67049 . . U-BEND, Copper . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 PAFZZ 42 109741 67049 . . ELBOW, 90 Deg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 PAFZZ 43 112987 67049 . . U-BEND, SST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 PAFZZ 44 279990 67049 . . U-BEND, SST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 PAFZZ 45 112988 67049 . . U-BEND, SST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 PAFZZ

FIGURE &

INDEX/

SHEET NO.

PART

NUMBER CAGE

DESCRIPTION

1 2 3 4 5 6 7

UNITS

PER

ASSY

USABLE

ON

CODE

SMR

CODE