Attachment_A_RTCH_accumulator_recharge_SOW_3_Aug_16.pdf

SCOPE OF WORK

(SOW)

FOR THE

RTCH ACCUMULATOR CHECK AND

RECHARGE

1. Description:

a. This contract is to provide accumulator test for the correct nitrogen fill pressure which is 1300 pounds per square inch (PSI), (procedure beginning on page 2), and recharge service if necessary (procedure beginning on page 6, for the RTCH RT-240 program.

i. The contractor shall be responsible for testing the nitrogen fill pressure, which is 1300 PSI and recharging all break accumulators that pass initial testing and are below 1300 PSI for the RTCH program.

ii. If the unit is non-rechargeable due to damage and/or the unit already meets the required 1300 PSI, the contractor shall contact the COR within 24 hours of discovery, place tape on the unit and write “BAD” for damaged units, and “Requalified” for units that are received that do not require recharge on the tape. Contractor shall not attempt to recharge the unit.

The contractor shall only invoice for work complete (testing) only for units deemed non-rechargeable and/or units that successfully tested at the required PSI level of 1300.

iii. The contractor shall be responsible to provide a secured facility to test and recharge the accumulators. Contractor shall crate in the box received all accumulators serviced under this SOW to Condition Code “A” standards IAW this SOW and applicable Technical Manual identified for return to the Red River Army Depot (RRAD). Contractor’s facility must be within 100 miles from the depot. All hired subcontractors performing work must be within 100 miles. RRAD transportation will deliver and pick up the accumulators at the vendors’ facility five days after delivery.

b. Unit of measure is EACH. Each UNIT consists of six individual accumulators.

c. RRAD will deliver units to contractor facility once a month. The COR will notify the contractor not less than 3 calendar days prior to delivery of units.

d. Turn-around time per unit shall be 5 business days from date of receipt of unit.

e. RRAD will pick up units once a week. COR will notify the contractor 24 hours prior to pick-up.

2. Technical References:

Technical Data:

Contractor is responsible for following the procedures provided in TM 10-3930-675-23-2 work package 0155.

Definitions:

1) Condition Code “A” (CCA): Serviceable/Issuable without qualifications, new, used, repaired or reconditioned material that is serviceable and issuable without limitations or restrictions.

Administrative Requirements:

1) All completed Condition Code “A” accumulators will be placed in the original pallet box for return back to RRAD.

2) Contractor shall refer any questions or issues electronically in writing to the Contracting Officer Representative or Contracting Officer.

3) Any deviations from this SOW will require approval from the Contracting Officer in writing.

3. Work Procedures:

TM 10-3930-675-23-2 0155

FIELD MAINTENANCE

BRAKE AND STEERING ACCUMULATOR SERVICE

INITIAL SETUP:

Tools and Special Tools

1. Tool Kit, General Mechanics (WP 0277, Table 1, Item 85)

2. Adapter, 3/8 in. Female to 1/2 in. Male (WP 0277, Table 1, Item 2)

3. Charging and Testing Unit, Nitrogen (WP 0277, Table 1, Item 15)

4. Goggles, Industrial (WP 0277, Table 1, Item 34)

5. Kit, Nitrogen Charging (WP 0277, Table 1, Item 46)

6. Screwdriver Attachment, Hex 3/8 in. (WP 0277, Table 1, Item 64)

Materials/Parts

1. Cylinder, Compressed Gas, Nitrogen (WP 0276, Table 1, Item 14)

2. Detergent General Purpose Liquid (WP 0276, Table 1, Item 15)

3. Rag, Wiping (WP 0276, Table 1, Item 50)

Equipment Condition

1. Accumulators and valve removed (WP 0154)

2. Steering hydraulic system pressure relieved, if checking pre-charge pressure on vehicle steering (WP 0204)

CHECKING BRAKE ACCUMULATOR PRE-CHARGE PRESSURE WARNING

• The brake accumulators are under extreme pressure (1300 psi (90 bar)).

• Do NOT loosen the plug from the end of the brake accumulator more than 1/4 turn.

• If plug is removed from the brake accumulator while under pressure it may result in damage to equipment or injury or death to personnel.

NOTE: Each brake accumulator is checked for pre-charge separately.

1. Remove cap (Figure 1, Item 2) from valve end of brake accumulator (Figure 1, Item 2).

To prevent damage to the brake accumulator charging tool, loosen plug

1/8 turn before installing the brake accumulator charging tool. Failure to follow this caution may result in equipment damage.

2. Clean threads (Figure 2, Item 2) and 0-ring flat surface (Figure 2, Item 4) of brake accumulator.

3. Loosen plug (Figure 2, Item 3) 1 /8 turn on brake accumulator (Figure 2, Item 1).

NOTE: Before installing the brake accumulator charging gauge on the brake accumulator, ensure the 0-ring (Figure 3, Item 2) is fitted correctly in the groove of the brake accumulator charging gauge.

4. Install brake accumulator charging gauge (Figure 3, Item 1) on brake accumulator (Figure 3, Item 3).

5. Close bleeder valve (Figure 3, Item 5) on brake accumulator charging gauge

(Figure 3, Item 1).

6. Open plug (Figure 3, Item 4) on brake accumulator (Figure 3, Item 3) until pressure reading is obtained on brake accumulator charging gauge (Figure 3, Item 1 ).

7. Pressure should be 1300 psi (90 bar).

If pressure is under 1300 psi (90 bar), perform Brake Accumulator Charging in this work package.

If pressure is over 1300 psi (90 bar), bleed off excess pressure using bleeder valve (Figure 3, Item 5) on brake accumulator charging gauge (Figure 3, Item 1 ).

8. Close plug (Figure 3, Item 4) on brake accumulator (Figure 3, Item 3). Tighten plug to 221 in-lb (25 N∙m).

9. Open bleeder valve (Figure 3, Item 5) on brake accumulator charging gauge

(Figure 3, Item 1 ).

10. Remove brake accumulator charging gauge (Figure 3, Item 1) from brake accumulator (Figure 3, Item 3).

11. Tighten plug (Figure 4, Item 2) on brake accumulator (Figure 4, Item 1) to 266 in-lb (30 N∙m).

12. Soak plug (Figure 4, Item 2) with soapy water to check for leaks.

13. Install cap (Figure 5, Item 1) on brake accumulator (Figure 5, Item 2).

BRAKE ACCUMULATOR CHARGING:

• The brake accumulators are under extreme pressure (1300 psi (90 bar)).

• Do NOT loosen the plug from the end of the brake accumulator more than 1/4 turn.

• If plug is removed from the brake accumulator while under pressure it may result in damage to equipment or injury or death to personnel.

NOTE: New brake accumulators are not shipped charged. Brake accumulators must be charged prior to installation on machine. Each brake accumulator is charged separately.

1. If needed, install brake accumulator charging kit adapters (Figure 6, Item 1) on nitrogen source.

2. Install brake accumulator charging kit hose (Figure 7, Item 2) on brake accumulator charging kit adapters (Figure 7, Item 1 ).

3. Install brake accumulator charging kit hose (Figure 8, Item 2) on brake accumulator charging gauge (Figure 8, Item 1 ).

4. Remove cap (Figure 9, Item 1) from brake accumulator (Figure 9, Item 2).

CAUTION: To prevent damage to the brake accumulator charging tool, loosen plug 1/8 turn before installing the brake accumulator charging tool. Failure to follow this caution may result in equipment damage. NOTE: Clean threads (Figure 10, Item 2) and 0-ring flat surface (Figure 10, Item 4) of brake accumulator.

5. Loosen plug (Figure 10, Item 3) 1/8 turn on brake accumulator (Figure 10, Item 1).

NOTE: Before installing the brake accumulator charging gauge on the brake accumulator, ensure the 0-ring (Figure 11, Item 3) is fitted correctly in the groove of the brake accumulator charging gauge.

6. Install brake accumulator charging gauge (Figure 11, Item 1) on brake accumulator (Figure 11, Item 4 ).

7. Close bleeder valve (Figure 11, Item 2) on brake accumulator charging gauge

(Figure 11, Item 1 ).

8. Open plug (Figure 11, Item 5) on brake accumulator (Figure 11, Item 4 ).

NOTE: Open nitrogen source valve slightly until nitrogen flows in to brake accumulator. At intervals, close the nitrogen source valve and read the current pressure.

9. Open valve (Figure 12, Item 1) on nitrogen source to charge brake accumulator (Figure 12, Item 2).

NOTE: Once the pressure of 1300 psi (90 bar) has been reached, close the nitrogen source valve and wait for the temperature to stabilize in the brake accumulator.

10. Charge brake accumulator (Figure 12, Item 2) to 1300 psi (90 bar).

11. Close valve (Figure 12, Item 1) on nitrogen source.

NOTE: Excessive pressure can be released by opening the bleeder screw on the brake accumulator charging gauge.

12. Close plug (Figure 13, Item 3) on brake accumulator (Figure 13, Item 1).

Tighten plug to 221 in-lb (25 N∙m).

13. Open bleeder valve (Figure 13, Item 4) on brake accumulator charging gauge

(Figure 13, Item 2).

14. Remove brake accumulator charging gauge (Figure 13, Item 2) from brake accumulator (Figure 13, Item 1 ).

15. Tighten plug (Figure 14, Item 2) on brake accumulator (Figure 14, Item 1) to 266 in-lb (30 N ∙m).

16. Soak plug (Figure 14, Item 2) with soapy water to check for leaks.

17. Install cap (Figure 15, Item 1) on brake accumulator (Figure 15, Item 2).

18. Remove hose (Figure 16, Item 2) from brake accumulator charging gauge (Figure 16, Item 1).

19. Remove hose (Figure 17, Item 2) from adapters (Figure 17, Item 1).

20. Remove adapters (Figure 18, Item 1) from nitrogen source.