TECHNICAL EXHIBIT 1 - MAFFS Maintenance Manual.pdf

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Modular Airborne Fire Fighting Systems (MAFFS) Coordination and Maintenance Services
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This document is a Technical Exhibit containing the Modular Airborne Fire Fighting Systems (MAFFS) Maintenance Manual.

The related federal contract opportunity is for Modular Airborne Fire Fighting Systems (2nd Generation) (MAFFS II) Sustainability, Maintenance, and Coordination Services. The Department of Agriculture, U.S. Forest Service has a requirement for professional mechanic services to inspect, maintain, repair, manage inventory, provide engineering support, training, and coordination activities to ensure the operational readiness of eight MAFFS II systems and associated ground equipment. The contract will be a firm-fixed price, indefinite-delivery, indefinite-quantity (IDIQ) with a base period of 12 months and four 12-month option periods. The anticipated period of performance is May 1, 2025 to April 30, 2030. This procurement is a total small business set-aside. Interested parties must submit quotes via email by the due date stated on the SF-1449 solicitation form.

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MAINTENANCE MANUAL

MAFFS

MODULAR AIRBORNE FIREFIGHTING SYSTEM

PART NUMBER 113000-301

Notice: Reproduction of the information or illustrations contained in this manual is not permitted without specific approval of the Assistant Director, Fire Operations, U.S. Forest Service

NOTICE: Reproduction for non-military or non US government use of the information or illustrations contained in this publication is not permitted without specific approval of the Assistant Director, Fire Operations U.S. Forest Service

D.4 - Technical Exhibit 1

15 APRIL 2016 A

The portion of the text affected by the changes is indicated by a vertical line in the outer margins of the page. Changes are indicated by shaded or screened areas, or by miniature pointing hands.

Dates of issue for original and changed pages are:

Original 0 1 MARCH 2014 Revision 1 15 APRIL 2016

TOTAL NUMBER OF PAGES IN THIS PUBLICATION IS 250 CONSISTING OF THE FOLLOWING

Page No. *Change No.

Page No. *Change No.

Page No. *Change No.

Title 0 A 0 i-vii 0 1-1 thru 1-2 0 2-1 thru 2-40 0 3-1 thru 3-2 0 4-1 thru 4-12 0 5-1 thru 5-14 0 6-1 thru 6-130 0 7-1 thru 7-8 0 8-1 thru 8-4 0 9-1 thru 9-2 0 10-1 thru 10-24 0

* Zero in this column indicates an original page.

B 15 APRIL 2016

This page intentionally left blank

15 APRIL 2016 i

Contents

CHAPTER 1 INTRODUCTION ..................................................................................................................................1-1

CHAPTER 2 SYSTEM DESCRIPTION .....................................................................................................................2-1

2.1. AIRBORNE FIRE FIGHTING SYSTEM (MAFFS) ..................................................................................... 2-1

2.2. MAFFS MAJOR ASSEMBLY DESCRIPTION........................................................................................... 2-3

2.2.1. Forward Pallet Description ..................................................................................................................... 2-3

2.2.2. Center Pallet Description........................................................................................................................ 2-5

2.2.3. Aft Pallet Description .............................................................................................................................. 2-7

2.2.4. Nozzle Assembly Description ................................................................................................................. 2-9

2.2.5. Paratroop Door Plug Description.......................................................................................................... 2-10

2.3. MAFFS FUNCTIONAL DESCRIPTION................................................................................................... 2-11

2.3.1. Electrical System .................................................................................................................................. 2-11

2.3.1.1. Power and Control Rack Assembly ................................................................................................ 2-11

2.3.1.1.1. Programmable Logic Controller Shelf......................................................................................... 2-13

2.3.1.1.2. Drop, E-Dump and Nozzle Control Shelf .................................................................................... 2-13

2.3.1.1.3. Power Distribution Drawer .......................................................................................................... 2-13

2.3.1.2. Cabin Control Box Assembly .......................................................................................................... 2-13

2.3.1.3. Foam Control Box Assembly .......................................................................................................... 2-13

2.3.1.4. Take Off Valve Box ........................................................................................................................ 2-13

2.3.1.5. Drop Pendant Assembly ................................................................................................................. 2-13

2.3.2. Air System Description ......................................................................................................................... 2-13

2.3.3. Hydraulic System.................................................................................................................................. 2-14

2.4. CONTROLS, INDICATORS AND CONNECTORS ................................................................................. 2-14

2.4.1. Forward Pallet Controls, Indicators and Connectors............................................................................ 2-14

2.4.1.1. Forward Pallet Electrical Controls, Indicators and Connectors ...................................................... 2-14

2.4.1.1.1. Power Distribution Panel Controls, Indicators and Connectors.................................................. 2-14

2.4.1.1.2. Dump, Drop and Nozzle Control Drawer Controls, Indicators arid Connectors ......................... 2-19

2.4.1.1.3. Programmable Logic Controller (PLC) Drawer Controls, Indicators and Connectors ................ 2-21

2.4.1.2. Forward Pallet Air Controls, Indicators and Connectors................................................................. 2-23

2.4.2. Center Pallet Controls, Indicators and Connectors .............................................................................. 2-24

2.4.2.1. Center Pallet Electrical Controls, indicators and Connectors......................................................... 2-24

2.4.2.2. Center Pallet Air Controls, Indicators and Connectors ................................................................... 2-26

2.4.2.3. Center Pallet Hydraulic Controls, Indicators and Connectors ........................................................ 2-28

2.4.3. Aft Pallet Controls, Indicators and Connectors..................................................................................... 2-28

2.4.3.1. Aft Pallet Electrical Controls, Indicators and Connectors ............................................................... 2-28

2.4.3.1.1. Take Off Vent Box Controls, Indicators and Connectors............................................................ 2-29

2.4.3.1.2. Cabin Control Unit Controls, Indicators and Connectors............................................................ 2-31

2.4.3.1.3. Foam Injection Control Box Controls, Indicators, and Connectors............................................. 2-33

2.4.3.1.4. Fill Control Box Controls, Indicators and Connectors................................................................. 2-34

2.4.3.1.5. Drop Pendant Controls, Indicators and Connectors ................................................................... 2-35

2.4.3.2. Aft Pallet Air Controls, Indicators and Connectors ......................................................................... 2-36

2.4.3.3. Aft Pallet Hydraulic Controls, Indicators and Connectors............................................................... 2-37

2.4.4. Nozzle Assembly Controls, Indicators and Connectors ....................................................................... 2-39

2.4.4.1. Nozzle Assembly Electrical and Hydraulic Controls, Indicators and Connectors........................... 2-39 CHAPTER 3 THEORY OF OPERATION ..................................................................................................................3-1

3.1. Theory of Operation ................................................................................................................................... 3-1 CHAPTER 4 TESTING AND FAULT ISOLATION....................................................................................................4-1

4.1. SYSTEM TESTING.................................................................................................................................... 4-1

4.1.1. System Tie Down.................................................................................................................................... 4-1

4.1.1.1. Trailer Tie Down................................................................................................................................ 4-1

4.1.1.2. MAFFS Tie Down.............................................................................................................................. 4-2

4.1.2. Test Preparation ..................................................................................................................................... 4-3

4.1.2.1. Mechanical Preparation .................................................................................................................... 4-3

4.1.2.2. System Configuration ....................................................................................................................... 4-5

4.1.3. System Test............................................................................................................................................ 4-6 ii 15 APRIL 2016

4.1.3.1. Emergency Backup Battery Test ...................................................................................................... 4-6

4.1.3.2. Functional Test ................................................................................................................................. 4-7

4.1.3.3. Drop Test .......................................................................................................................................... 4-9

4.1.3.4. High Pressure Reservoir Test........................................................................................................... 4-9

4.2. FAULT ISOLATION ................................................................................................................................. 4-10 CHAPTER 5 REPAIR......................................................................................................................................................5-1

5.1. GENERAL.................................................................................................................................................. 5-1

5.2. ELECTRICALSYSTEM REPAIR ............................................................................................................... 5-1

5.2.1. Electrical Cable Repair ........................................................................................................................... 5-1

5.3. AIR SYTEM REPAIR ................................................................................................................................. 5-5

5.3.1. Air Line Repair ........................................................................................................................................ 5-5

5.4. HYDRAULIC SYSTEM REPAIR................................................................................................................ 5-9

5.4.1. Hydraulic Line (Flexible and Rigid) Repair ............................................................................................. 5-9

5.4.2. Hydraulic Component Repair ................................................................................................................. 5-9

5.5. CORROSION REPAIR ............................................................................................................................ 5-13

5.5.1. Light Corrosion. .................................................................................................................................... 5-13

5.5.2. Moderate Corrosion. ............................................................................................................................. 5-13

5.5.3. Severe Corrosion.................................................................................................................................. 5-13 CHAPTER 6 REMOVAL AND INSTALLATION .......................................................................................................6-1

6.1. INTRODUCTION ....................................................................................................................................... 6-1

6.1.1. Safety...................................................................................................................................................... 6-1

6.1.2. System Depressurization........................................................................................................................ 6-2

6.1.3. Torque Values ........................................................................................................................................ 6-2

6.2. REMOVAL AND INSTALLATION.............................................................................................................. 6-5

6.2.1. Forward Pallet Installation and Removal ................................................................................................ 6-5

6.2.1.1. Condensate Tank Assembly Removal and Installation .................................................................... 6-5

6.2.1.2. Filtration Assembly Canister Removal and Installation .................................................................... 6-7

6.2.1.3. Filtration Assembly Mounting Bracket Removal and Installation...................................................... 6-9

6.2.1.4. Hydrocarbon and Coalescing Filter Element Replacement............................................................ 6-11

6.2.1.5. Compressor Motor Belt and Belt Shroud Installation and Removal ............................................... 6-13

6.2.1.6. Compressor Motor Oil Replacement .............................................................................................. 6-15

6.2.1.7. Compressor Motor Clutch Shoe Replacement ............................................................................... 6-16

6.2.1.8. Power and Control Rack door and rear cover removal and installation: ........................................ 6-18

6.2.1.9. Air Compressor Removal and Installation ...................................................................................... 6-18

6.2.1.10. Power and Control Rack Removal and Installation ........................................................................ 6-20

6.2.1.11. Emergency Backup Battery Replacement...................................................................................... 6-22

6.2.2. Center Pallet Installation and Removal ............................................................................................... 6-23

6.2.2.1. Overboard Vent Valve (V3) Assembly Removal and Installation ................................................... 6-23

6.2.2.2. Rupture Disk Assembly (RD1) Removal and Installation ............................................................... 6-26

6.2.2.3. High Pressure Reservoir Manifold Block Removal and Installation ............................................... 6-28

6.2.2.4. High and Low Pressure Switches and Pressure Relief Valve Removal and Installation ............... 6-32

6.2.2.5. High Pressure Reservoir Output Manifold Removal and Installation ............................................. 6-34

6.2.2.6. Main Tank Float Assembly Removal and Installation..................................................................... 6-35

6.2.2.7. Arming Valve Assembly (V1/V2) Removal and Installation ............................................................ 6-37

6.2.2.8. Fisher Regulator Assembly (R1/R2) Removal and Installation ...................................................... 6-40

6.2.2.9. High Pressure Reservoir Tank (T1/T2) Removal and Installation .................................................. 6-42

6.2.2.10. Main Tank Inlet Manifold Removal and Installation ........................................................................ 6-44

6.2.2.11. J-Rail Assembly Removal and Installation ..................................................................................... 6-46

6.2.2.12. Left and Right J-Rails Removal and Installation............................................................................. 6-47

6.2.2.13. Center Pallet Bridge Removal and Installation ............................................................................... 6-48

6.2.3. Aft Pallet Installation and Removal....................................................................................................... 6-49

6.2.3.1. Loadmaster Chairs Removal and installation ................................................................................. 6-49

6.2.3.2. Seat Track Removal and Installation .............................................................................................. 6-51

6.2.3.3. Loadmaster Controls Removal and Installation.............................................................................. 6-52

6.2.3.4. Foam Tank (T3) Removal and Installation ..................................................................................... 6-55

6.2.3.4.1. Pressure Gauge (G3) Removal and Installation......................................................................... 6-57

6.2.3.4.2. Foam Tank Rupture Disk (R02) Removal and Installation ......................................................... 6-58

6.2.3.4.3. Three-Way Solenoid Valve (V15) Removal and Installation....................................................... 6-59

6.2.3.4.4. Foam inject Valve (V14) Removal and Installation..................................................................... 6-60

6.2.3.4.5. Foam System Pressure Regulator (R3) Removal and Installation............................................. 6-62

15 APRIL 2016 iii

6.2.3.4.6. Foam Tank Motor Controlled Throttle Valve (MCTV) (V4) Removal and Installation ................ 6-64

6.2.3.4.7. Foam Injection Ring Removal and Installation ........................................................................... 6-66

6.2.3.5. Hydraulic System Removal and Installation ................................................................................... 6-68

6.2.3.5.1. Hydraulic Accumulator (AC1) Removal and Installation............................................................. 6-68

6.2.3.5.2. Hydraulic Accumulator (AC2) Removal and installation ............................................................. 6-70

6.2.3.5.3. Hydraulic Accumulator (AC3) Removal and Installation............................................................. 6-73

6.2.3.5.4. Hydraulic Accumulator (AC4) Removal and Installation............................................................. 6-76

6.2.3.5.5. Hydraulic Pump Assembly removal and Installation................................................................... 6-78

6.2.3.5.6. E-Dump Low Pressure Switch (LSP2) Removal and Installation ............................................... 6-80

6.2.3.5.7. System Hydraulic Filter Assembly (FL1) Removal and Installation............................................ 6-82

6.2.3.5.8. Case Drain Hydraulic Filter Assembly (FL2) Removal and Installation...................................... 6-84

6.2.3.5.9. Check Valve (CV2) Removal and Installation............................................................................. 6-86

6.2.3.5.10. Check Valve (CV1) Removal and installation............................................................................. 6-88

6.2.3.5.11. E-Dump Jettison Bypass Valve (BV2) Removal and Installation ............................................... 6-90

6.2.3.5.12. Main Bypass Valve (BV1) Removal and Installation .................................................................. 6-92

6.2.3.5.13. E-Dump Isolation Valve (HV5) Removal and Installation ........................................................... 6-94

6.2.3.5.14. Isolation Valves and Pressure Switches Removal and Installation ............................................ 6-96

6.2.3.5.15. Hydraulic Reservoir Assembly Removal and Installation ........................................................... 6-99

6.2.3.5.16. Hydraulic Rack Removal and Installation ................................................................................. 6-101

6.2.3.5.17. Hydraulic Accumulator Pre-Charge .......................................................................................... 6-103

6.2.3.6. Aft Pallet Structural Components.................................................................................................. 6-103

6.2.3.6.1. Fill Pipe Assembly Removal and Installation ............................................................................ 6-103

6.2.3.7. Strobe Light Power Supply Assembly Installation and Removal.................................................. 6-105

6.2.3.8. Nozzle Assembly Seal Removal and Installation ......................................................................... 6-107

6.2.3.9. Pintle Removal and Installation .................................................................................................... 6-109

6.2.3.10. Hydraulic Actuator Assembly Removal and Installation ............................................................... 6-112

6.2.4. Nozzle Assembly Installation and Removal ...................................................................................... 6-114

6.2.4.1. Strobe Light Installation and Removal .......................................................................................... 6-114

6.2.4.2. FOD Protection Cover Installation and Removal.......................................................................... 6-116

6.2.5. Door Plug Assembly Installation and Removal ................................................................................. 6-118

6.2.5.1. Door Plug Seal Removal and Installation ..................................................................................... 6-118

6.2.6. Pressure Bellows Installation and Removal ....................................................................................... 6-120

6.2.7. Overboard vent Pipe Seal Removal and Installation.......................................................................... 6-120

6.3. CALIBRATION....................................................................................................................................... 6-122

6.3.1. Fisher Regulator (R1 and R2) Calibration .......................................................................................... 6-122

6.3.1.1. Test Setup..................................................................................................................................... 6-122

6.3.1.2. Calibration Procedure ................................................................................................................... 6-122

6.3.2. Pressure Switch Calibration ............................................................................................................... 6-123

6.3.2.1. Test Setup..................................................................................................................................... 6-123

6.3.2.2. Calibration Procedure ................................................................................................................... 6-124

6.3.3. Low Pressure Relief Valve (V6) Calibration ....................................................................................... 6-125

6.3.3.1. Test Setup..................................................................................................................................... 6-125

6.3.3.2. Calibration Procedure ................................................................................................................... 6-126

6.3.3.3. Foam System Regulator (R3) Calibration..................................................................................... 6-127

6.3.3.3.1. Test Setup................................................................................................................................. 6-127

6.3.3.3.2. Calibration Procedure ............................................................................................................... 6-127

6.3.3.4. Motor Controlled Throttle Valve (V4) (MCTV) .............................................................................. 6-128

6.3.4. Pintle Calibration................................................................................................................................. 6-129

6.3.4.1. Test Setup..................................................................................................................................... 6-129

6.3.4.2. Calibration Procedure ................................................................................................................... 6-129 CHAPTER 7 PLACARD AND MARKINGS...............................................................................................................7-1

7.1. INTRODUCTION ....................................................................................................................................... 7-1

7.2. FORWARD PALLET .................................................................................................................................. 7-1

7.3. CENTER PALLET AREA........................................................................................................................... 7-3

7.3.1. Nozzle Support Struts............................................................................................................................. 7-3

7.3.2. Main Tank Markings ............................................................................................................................... 7-4

7.4. AFT PALLET AREA................................................................................................................................... 7-5

7.4.1. Hydraulic Reservoir Tank ....................................................................................................................... 7-5

7.5. NOZZLE ASSEMBLY ................................................................................................................................ 7-6

7.6. PARATROOP DOOR-PLUG ASSEMBLY................................................................................................. 7-7 CHAPTER 8 SUPPORT EQUIPMENT......................................................................................................................8-1 iv 15 APRIL 2016

8.1. INTRODUCTION ....................................................................................................................................... 8-1

8.2. SPECIAL TOOLS....................................................................................................................................... 8-1

8.3. SUPPORT EQUIPMENT ........................................................................................................................... 8-2

8.3.1. MAFFS Trailer ........................................................................................................................................ 8-2

8.3.2. Nozzle Assembly Lift-and-Transport Dolly ............................................................................................. 8-3 CHAPTER 9 STORAGE ............................................................................................................................................9-1

9.1. INTRODUCTION ....................................................................................................................................... 9-1

9.2. SHORT TERM STORAGE ........................................................................................................................ 9-1

9.2.1. Nozzle Assembly Storage Preparation................................................................................................... 9-1 CHAPTER 10 INSPECTION AND MAINTENANCE CHECKLISTS.......................................................................10-1

10.1. INTRODUCTION ..................................................................................................................................... 10-1

10.2. THE INSPECTION PROCESS ................................................................................................................ 10-1

10.2.1. Inspection Areas Defined ..................................................................................................................... 10-1

10.3. INSPECTIONS REQUIRED .................................................................................................................... 10-2

10.3.1. MAFFS General Inspection .................................................................................................................. 10-2

10.3.2. Forward Pallet Detailed inspection ....................................................................................................... 10-3

10.3.3. Center Pallet Detailed Inspection ......................................................................................................... 10-4

10.3.4. Aft Pallet Detailed Inspection................................................................................................................ 10-5

10.3.5. Nozzle Assembly Detailed Inspection .................................................................................................. 10-7

10.3.6. Overboard Vent Detailed Inspection..................................................................................................... 10-7

10.3.7. Door Plug Assembly Inspection............................................................................................................ 10-7

10.4. CORROSION INSPECTION.................................................................................................................... 10-8

10.4.1. MAFFS Material Types......................................................................................................................... 10-8

10.4.1.1. Stainless Steel Materials ................................................................................................................ 10-8

10.4.2. Corrosion Prevention and Control ........................................................................................................ 10-8

10.4.3. Corrosion Inspection Locations ............................................................................................................ 10-8

10.5. High Pressure Test and Tank Inspection............................................................................................... 10-10

10.6. Pre-Season Checklist ............................................................................................................................ 10-11

10.7. Pre-Loading Checklist............................................................................................................................ 10-16

10.8. Post-Flight Checklist .............................................................................................................................. 10-17

10.9. Post-Season and Pre-Storage Checklist ............................................................................................... 10-22 APPENDIX A FOAM TANK WEIGHT REDUCTION...............................................................................................A-1

APPENDIX B C-130-J CONVERSION.....................................................................................................................B-1

APPENDIX C BONDING MAFFS EQUIPMENT ......................................................................................................C-1

APPENDIX D HIGH PRESSURE TANK PRESSURE TEST ...................................................................................D-1

15 APRIL 2016 v

List of Figures Figure Title ....................................................................................................................................................... Page

Figure 2-1 MAFFS..................................................................................................................................................... 2-2 Figure 2-2 Forward Pallet Components .................................................................................................................... 2-4 Figure 2-3 Center Pallet Components ...................................................................................................................... 2-6 Figure 2-4 Aft Pallet Components ............................................................................................................................. 2-8 Figure 2-5 Nozzle Assembly Components................................................................................................................ 2-9 Figure 2-6 Paratroop Door Plug Components ........................................................................................................ 2-10 Figure 2-7 Power and Control Rack Assembly Components ................................................................................. 2-12 Figure 2-8 Power Distribution Front Panel Electrical Controls, Indicators and Connectors (Sheet 1 of 2) ............ 2-16 Figure 2-9 Power Distribution Rear Panel Electrical Controls, Indicators and Connectors .................................... 2-18 Figure 2-10 Dump, Drop and Nozzle Control Front Panel Electrical Controls, Indicators and Connectors ........... 2-20 Figure 2-11 PLC Drawer Front Panel Controls, Indicators and Connectors........................................................... 2-22 Figure 2-12 Forward Pallet Air Controls and Indicators.......................................................................................... 2-23 Figure 2-13 Center Pallet Electrical Controls, Indicators, and Connectors ............................................................ 2-25 Figure 2-14 Center Pallet Controls, Indicators and Connectors ............................................................................. 2-27 Figure 2-15 Main Tank Float Assembly Removal and installation.......................................................................... 2-29 Figure 2-16 Vent Valve Box Controls, Indicators and Connectors ......................................................................... 2-30 Figure 2-17 Cabin Control Unit Operators Controls, Indicators and Connectors ................................................... 2-32 Figure 2-18 Foam Injection Control Box Operators Controls, Indicators and Connectors ..................................... 2-33 Figure 2-19 Fill Control Box Controls, Indicators and Connectors.......................................................................... 2-34 Figure 2-20 Drop Pendant Controls, Indicators and Connectors............................................................................ 2-35 Figure 2-21 Aft Pallet Air Controls, Indicators and Connectors .............................................................................. 2-36 Figure 2-22 Aft Pallet Operators Hydraulic Controls, Indicators and Connectors .................................................. 2-38 Figure 2-23 Nozzle Assembly Electrical and Hydraulic Controls, Indicators, and Connectors .............................. 2-40 Figure 4-1 Trailer Tie down ....................................................................................................................................... 4-1 Figure 4-2 MAFFS Tie down ..................................................................................................................................... 4-2 Figure 4-3 MAFFS Ground Test Safety Corridor ...................................................................................................... 4-4 Figure 4-4 Drop, E-Dump, and Nozzle Control Drawer ............................................................................................ 4-6 Figure 5-1 Electrical Schematic ................................................................................................................................ 5-3 Figure 5-2 Air System Schematic.............................................................................................................................. 5-7 Figure 5-3 Hydraulic System Schematic................................................................................................................. 5-11 Figure 5-4 Corrosion Depth Example ..................................................................................................................... 5-13 Figure 6-1 Condensate Tank Assembly Removal and Installation ........................................................................... 6-6 Figure 6-2 Filtration Assembly Canister Removal and Installation ........................................................................... 6-8 Figure 6-3 Filtration Assembly Mounting Bracket Removal and Installation .......................................................... 6-10 Figure 6-4 Hydrocarbon and Coalescing Filter Element Replacement................................................................... 6-12 Figure 6-5 Compressor Motor V-Belt and Shroud Installation and Removal.......................................................... 6-14 Figure 6-6 Compressor Motor Oil Replacement Details ......................................................................................... 6-15 Figure 6-7 Compressor Motor Clutch Shoe Replacement Details.......................................................................... 6-17 Figure 6-8 Air Compressor Removal and Installation ............................................................................................. 6-19 Figure 6-9 Power and Control Rack Assembly Removal and Installation .............................................................. 6-21 Figure 6-10 Emergency Battery Installation and Removal ..................................................................................... 6-22 Figure 6-11 Overboard Vent Valve (V3) Assembly Removal and Installation ........................................................ 6-25 Figure 6-12 Rupture Disk Assembly (RD1) Removal and Installation .................................................................... 6-27 Figure 6-13 High Pressure Reservoir Manifold Block............................................................................................. 6-30 Figure 6-14 High Pressure Reservoir Manifold Block Removal and Installation .................................................... 6-31 Figure 6-15 High and Low Pressure Switches and Pressure Relief Valve Removal and Installation .................... 6-33 Figure 6-16 High Pressure Reservoir Output Manifold Removal and Installation .................................................. 6-34 Figure 6-17 Main Tank Float Assembly Removal and installation.......................................................................... 6-36 Figure 6-18 Arming Valve Assembly (V1/V2) Removal and Installation................................................................. 6-39 Figure 6-19 Fisher Regulator Assembly (R1/R2) Removal and Installation ........................................................... 6-41 Figure 6-20 High Pressure Tank Assembly Removal and Installation.................................................................... 6-43 Figure 6-21 Inlet Manifold Removal and Installation............................................................................................... 6-45 Figure 6-22 J-Rail Assembly Removal and Installation .......................................................................................... 6-46 Figure 6-23 Left and Right J-Rail Removal and Installation ................................................................................... 6-47 Figure 6-24 Center Pallet Bridge Removal and Installation.................................................................................... 6-48 Figure 6-25 Loadmaster Chair Removal and Installation ....................................................................................... 6-50 vi 15 APRIL 2016

Figure 6-26 Seat Track Removal and Installation................................................................................................... 6-51 Figure 6-27 Loadmaster Controls Removal and Installation................................................................................... 6-54 Figure 6-28 Foam Tank (T3) Removal and Installation .......................................................................................... 6-56 Figure 6-29 Pressure Gauge (G3) Removal and Installation.................................................................................. 6-57 Figure 6-30 Rupture Disk (RD2) Removal and Installation..................................................................................... 6-58 Figure 6-31 3-Way Solenoid Valve (V15) Removal and Installation....................................................................... 6-59 Figure 6-32 Foam Inject Valve (V14) Removal and Installation ............................................................................. 6-61 Figure 6-33 Foam System Pressure Regulator (R3) Removal and Installation...................................................... 6-63 Figure 6-34 Foam Tank Motor Controlled Throttle Valve Removal and Installation............................................... 6-65 Figure 6-35 Foam Injection Ring Removal and Installation .................................................................................... 6-67 Figure 6-36 Hydraulic Accumulator (AC1) Removal and Installation...................................................................... 6-69 Figure 6-37 Hydraulic Accumulator (AC2) Removal and Installation...................................................................... 6-72 Figure 6-38 Hydraulic Accumulator (AC3) Removal and Installation...................................................................... 6-75 Figure 6-39 Hydraulic Accumulator (AC4) Removal and Installation...................................................................... 6-77 Figure 6-40 Hydraulic Pump Removal and Installation........................................................................................... 6-79 Figure 6-41 E-Dump Low Pressure Switch (LSP2) Removal and Installation........................................................ 6-81 Figure 6-42 System Hydraulic Filter Assembly (FLA) Removal and Installation .................................................... 6-83 Figure 6-43 Case Drain Hydraulic Filter Assembly (FL2) Removal and Installation............................................... 6-85 Figure 6-44 Check Valve (CV2) Removal and Installation ..................................................................................... 6-87 Figure 6-45 Check Valve (CV1) Removal and Installation ..................................................................................... 6-89 Figure 6-46 E-Dump Bypass Valve (BV2) Removal and Installation...................................................................... 6-91 Figure 6-47 Main Bypass Valve (BV1) Removal and Installation ........................................................................... 6-93 Figure 6-48 E-Dump Isolation Valve (HV5) Removal and Installation .................................................................... 6-95 Figure 6-49 Isolation Valves and Pressure Switches Removal and Installation (Sheet 1 of 2).............................. 6-97 Figure 6-50 Hydraulic Reservoir Assembly Removal and Installation .................................................................. 6-100 Figure 6-51 Hydraulic Rack Removal and Installation .......................................................................................... 6-102 Figure 6-52 Fill Pipe Assembly Removal and Installation..................................................................................... 6-104 Figure 6-53 Strobe Light Power Supply Installation and Removal ....................................................................... 6-106 Figure 6-54 Nozzle Seal Removal and Installation ............................................................................................... 6-108 Figure 6-55 Pintle Removal and Installation (Sheet 1 of 2) .................................................................................. 6-110 Figure 6-56 Hydraulic Actuator Assembly Removal and installation .................................................................... 6-113 Figure 6-57 Strobe Light Installation and Removal............................................................................................... 6-115 Figure 6-58 FOD Protection Cover Installation and Removal............................................................................... 6-117 Figure 6-59 Door Plug Seal Removal and installation .......................................................................................... 6-119 Figure 6-60 Overboard vent Pipe Seal Removal and Installation......................................................................... 6-121 Figure 6-61 Fisher Regulator Calibration Test Setup ........................................................................................... 6-122 Figure 6-62 Pressure Switch Calibration Setup.................................................................................................... 6-123 Figure 6-63 Pressure Relief Valve Test Setup...................................................................................................... 6-125 Figure 6-64 Foam System Regulator (R3) calibration Test Setup........................................................................ 6-127 Figure 6-65 Motor Controlled Throttle Valve (MCTV) ........................................................................................... 6-128 Figure 7-1 Electrical Control Box Hazard Markings .................................................................................................. 7-1 Figure 7-2 Resistive Soft Start Warning Label.......................................................................................................... 7-2 Figure 7-3 Nozzle Support Strut Markings................................................................................................................ 7-3 Figure 7-4 Main Tank Markings ................................................................................................................................ 7-4 Figure 7-5 Hydraulic Reservoir Markings.................................................................................................................. 7-5 Figure 7-6 Nozzle Assembly Markings ..................................................................................................................... 7-6 Figure 7-7 Paratroop Door-Plug Markings ................................................................................................................ 7-7 Figure 8-1 MAFFS Transport Trailer ......................................................................................................................... 8-2 Figure 8-2 Nozzle Assembly Lifting-and-Transport Dolly ......................................................................................... 8-3 Figure 9-1 S-Duct and Nozzle Assembly Storage .................................................................................................... 9-1

15 APRIL 2016 vii

List of Tables Table Title......................................................................................................................................................... Page

Table 2-1 Power Distribution Front Panel Electrical Controls, Indicators and Connectors..................................... 2-15 Table 2-2 Power Distribution Rear Panel Electrical Controls, Indicators and Connectors ..................................... 2-18 Table 2-3 Dump, Drop and Nozzle Control Electrical Controls, Indicators and Connectors .................................. 2-19 Table 2-4 PLC Drawer Front Panel Controls, Indicators and Connectors .............................................................. 2-21 Table 2-5 Forward Pallet Air Controls and Indicators ............................................................................................. 2-23 Table 2-6 Center Pallet Electrical Connector.......................................................................................................... 2-24 Table 2-7 Center Pallet Air Controls, Indicators and Connectors ........................................................................... 2-26 Table 2-8 Vent Valve Box Controls, Indicators and Connectors............................................................................. 2-29 Table 2-9 Cabin Control Unit Operators Controls, Indicators and Connectors....................................................... 2-31 Table 2-10 Foam Injection Control Box Operators Controls, Indicators and Connectors....................................... 2-33 Table 2-11 Fill Control Box Controls, Indicators and Connectors........................................................................... 2-34 Table 2-12 Drop Pendant Controls, indicators and Connectors ............................................................................. 2-35 Table 2-13 Aft Pallet Air Controls, Indicators and Connectors ............................................................................... 2-36 Table 2-14 Aft Pallet Operators Hydraulic Controls, Indicators and Connectors.................................................... 2-37 Table 2-15 Nozzle Assembly Electrical and Hydraulic Controls, Indicators, and Connectors................................ 2-39 Table 4-1 Initial Switch Positions for Pressure Testing............................................................................................. 4-5 Table 4-2 Initial Manual Valve Positions for Pressure Testing ................................................................................. 4-5 Table 4-3 Initial Pressure Gauge Readings for Pressure Testing ............................................................................ 4-6 Table 4-4 Electrical System Fault isolation ............................................................................................................. 4-10 Table 6-1 Hydraulic/Air Line Torque Values .............................................................................................................

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File details come from the government source that posted it. Updated .