Book Book

To: Holders of CRJ900 Slide Reservoir and Valve Inflation Assembly
(P/N 65359-101) Manufactured by Air Cruisers; Component Maintenance

Manual 25-65-42.
Revision No. 5, Dated 04 Dec 2018
HIGHLIGHTS
Revision No. 5 of Component Maintenance Manual 25-65-42 reflects pages which

have been revised, added, or deleted. The revisions are outlined below. Please
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discard the manual now in your possession, replace with the attached revised
manual, and enter your initials for Revision No. 5 dated 04 Dec 2018 to the
Record of Revisions.
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CHAPTER/SECTION
AND PAGE NUMBER
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DESCRIPTION OF CHANGE
TITLE PAGE
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T-1 Updated revision, date, and copyright year.
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RECORD OF REVISIONS
RR-1 Added listing for Revision “5”.
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LIST OF EFFECTIVE PAGES

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LEP-1 through LEP-3 Updated to reflect this revision.

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INTRODUCTION
INTRO-1 Table of contents updated for this revision.
INTRO-8, INTRO-9 Paragraph 7: “Air Cruisers Maintenance Tasks”
was “Air Cruisers Maintenance Recommenda-
tions” (reference current Air Cruisers guide-
lines).
Paragraph 7.A and NOTEs: Newly added (Ref.
current Air Cruisers guidelines).
Table INTRO-1: Updated to add title and table
number, and to identify Standard Maintenance
Tasks (Ref. current Air Cruisers guidelines).
HIGHLIGHTS
25-65-42 Page 1 of 2
CHAPTER/SECTION
DESCRIPTION OF CHANGE
AND PAGE NUMBER
INTRODUCTION (Cont’d)
INTRO-10 Paragraph 7.B entirety, NOTE and Table
INTRO-2: Newly added to identify Extended
Maintenance tasks (Ref. current Air Cruisers
guidelines).
CHECK
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502 Third NOTE: Newly added (Ref. current Air
Cruisers guidelines).
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505 Paragraph 4: “(Tables 502 and 503)” was “(Table
502)” (Ref. current Air Cruisers guidelines).
Table 502: Revised to split off Table 503 for
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Extended Maintenance checks (Ref. current Air
Cruisers guidelines).
506, 507 Table 503: Newly added (Ref. current Air Cruis-
21
ers guidelines).
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HIGHLIGHTS
25-65-42 Page 2 of 2
CRJ900 SLIDE
RESERVOIR AND VALVE ASSEMBLY
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MANUFACTURED BY AIR CRUISERS
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(DOING BUSINESS AS ZODIAC AERO EVACUATION SYSTEMS)
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P/N 65359-101
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COMPONENT MAINTENANCE MANUAL

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WITH
ILLUSTRATED PARTS LIST
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The end item product(s)/commodity(s) described in the Component Maintenance Manual

(CMM) is controlled for export under the jurisdiction of the United States Department of Com-
merce, Bureau of Industry and Security Export Administration Regulation (EAR). Zodiac Aero
Evacuation Systems (ZAES) believes the proper Export Control Classification Number (ECCN)
for the described product is 9A991. This CMM is also subject to the EAR. ZAES believes the
proper ECCN for this CMM is 9E991. An export license may be required before this technology
(CMM) is used for development, production, or use by foreign persons from specific coun-
tries. The user of this technology (CMM) has the individual responsibility to abide by all U.S.
export laws and regulations.
ORIGINAL ISSUE: 02 JUN 2003

REVISION NO. 5 DATE: 04 DEC 2018
Zodiac Aero Evacuation Systems, Copyright 2018
T-1
25-65-42
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65359
RECORD OF REVISIONS
RETAIN THIS RECORD IN THE FRONT OF THE MANUAL. ON

RECEIPT OF A REVISION, INSERT THE REVISED PAGES INTO
THE MANUAL, ENTER THE DATE INSERTED, AND YOUR INITIALS.
REVISION REVISION ENGINEER WRITERS DATE

INITIALS
22
NO. DATE INITIALS INITIALS INSERTED
Original 02 Jun 2003 EHS FXC
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Issue
1 23 May 2005 JOD DV
2 18 Sep 2015 SMY
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3 13 Apr 2016 MKT JCG
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4 14 Jul 2017 ABU MJS

5 04 Dec 2018 ABU JCG
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65359
TEMPORARY REVISION RECORD
DATE INSERTED REMOVED

TEMP. ISSUE
INCORPORATED
REV. NO. DATE
INTO CMM DATE BY DATE BY
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TR-1
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65359
SERVICE BULLETIN RECORD
SERVICE BULLETIN / DATE

ISSUE DATE TITLE
REVISION NUMBER INCORPORATED
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SB-1
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65359
SERVICE INFORMATION LETTER RECORD
SERVICE
INFORMATION DATE
ISSUE DATE SUBJECT
LETTER / REVISION INCORPORATED
NUMBER
25-102 / R26 31 Jan 2014 18 Sep 2015 Authorized Repair/Service Facilities
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25-179 / R4 25 Nov 2005 18 Sep 2015 Availability of Pre-Coined Replace-
ment Ball Seats for Carleton Infla-
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tion Valves
25-181 / R11 12 Apr 2013 18 Sep 2015 Implementation of New Valve/Reg-

ulator Reservoir Fitting
25-196 / R2 25 Nov 2005

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18 Sep 2015 Inflation Valve Assembly Supersed-
ing Pulley Assembly
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25-212 / R1 04 Sep 2007 18 Sep 2015 O-Ring Installation Tool Kit
25-222 / R3 04 Nov 2011 18 Sep 2015 Methodology of Serial Numbers

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25-244 03 Aug 2009 18 Sep 2015 Change of Address
25-260 / R1 27 Jan 2012 18 Sep 2015 Gas Specification Recommenda-

tions
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25-279 / R1 18 Jan 2013 18 Sep 2015 Lubrication of Inflation Valve

Assembly O-Rings and Related
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Parts
25-302 / R1 14 Feb 2014 18 Sep 2015 Low Gas Pressure in Reservoir and
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Valve Assemblies
25-341 02 Oct 2015 14 Jul 2017 New Composite Valve/Regulator

Pulley Assembly
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LIST OF EFFECTIVE PAGES SECTION PAGE DATE

SECTION PAGE DATE
Description and 3 18 Sep 15
Title Page T-1 04 Dec 18 Operation (Cont’d) 4 18 Sep 15
5 14 Jul 17
Record of Revisions RR-1 04 Dec 18 6 Blank
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Temporary Revision TR-1 18 Sep 15 Testing and 101 14 Jul 17
Record Fault Isolation 102 18 Sep 15
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103 14 Jul 17
Service Bulletin SB-1 18 Sep 15 104 14 Jul 17
Record 105 18 Sep 15
-06 106 18 Sep 15
Service Information SIL-1 14 Jul 17 107 18 Sep 15
Letter Record 108 14 Jul 17
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109 18 Sep 15
List of LEP-1 04 Dec 18 110 18 Sep 15
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Effective Pages LEP-2 04 Dec 18 111 14 Jul 17

LEP-3 04 Dec 18 112 14 Jul 17
LEP-4 Blank 113 14 Jul 17
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114 14 Jul 17
Table of Contents T/C-1 18 Sep 15 115 18 Sep 15
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116 18 Sep 15
Introduction INTRO-1 04 Dec 18 117 18 Sep 15
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INTRO-2 18 Sep 15 118 Blank

INTRO-3 18 Sep 15
INTRO-4 18 Sep 15 Disassembly 301 18 Sep 15
INTRO-5 14 Jul 17 302 18 Sep 15
INTRO-6 18 Sep 15 303 14 Jul 17
INTRO-7 18 Sep 15 304 18 Sep 15
INTRO-8 04 Dec 18 305 18 Sep 15
INTRO-9 04 Dec 18 306 18 Sep 15
INTRO-10 04 Dec 18 307 18 Sep 15
308 14 Jul 17
Description and 1 18 Sep 15 309 14 Jul 17
Operation 2 14 Jul 17 310 18 Sep 15
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65359
SECTION PAGE DATE SECTION PAGE DATE
Disassembly (Cont’d) 311 18 Sep 15 Assembly (Cont’d) 710 14 Jul 17

312 18 Sep 15 711 18 Sep 15
712 18 Sep 15
Cleaning 401 18 Sep 15 713 18 Sep 15
402 18 Sep 15 714 18 Sep 15
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403 18 Sep 15 715 18 Sep 15
404 18 Sep 15 716 18 Sep 15
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405 18 Sep 15 717 18 Sep 15
406 Blank 718 18 Sep 15
719 18 Sep 15
Check 501 18 Sep 15
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502 04 Dec 18 721 18 Sep 15
503 18 Sep 15 722 14 Jul 17
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504 14 Jul 17 723 18 Sep 15

505 04 Dec 18 724 18 Sep 15
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506 04 Dec 18 725 18 Sep 15

507 04 Dec 18 726 14 Jul 17
508 Blank 727 14 Jul 17
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728 18 Sep 15
Repair 601 18 Sep 15 729 14 Jul 17
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602 18 Sep 15 730 18 Sep 15

603 18 Sep 15
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604 18 Sep 15 Fits and Clearances 801 18 Sep 15

802 14 Jul 17
Assembly 701 18 Sep 15 803 14 Jul 17
702 18 Sep 15 804 Blank
703 18 Sep 15
704 14 Jul 17 Special Tools, 901 18 Sep 15
705 14 Jul 17 Fixtures, and 902 14 Jul 17
706 14 Jul 17 Equipment 903 18 Sep 15
707 14 Jul 17 904 14 Jul 17
708 14 Jul 17 905 18 Sep 15
709 14 Jul 17 906 18 Sep 15
907 18 Sep 15
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65359
SECTION PAGE DATE
Special Tools, 908 18 Sep 15

Fixtures, and 909 18 Sep 15
Equipment (Cont’d) 910 Blank
Illustrated Parts List 1001 18 Sep 15
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1002 18 Sep 15
1003 18 Sep 15
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1004 18 Sep 15
1005 18 Sep 15
1006 18 Sep 15
1007 14 Jul 17
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1008 14 Jul 17
1009 14 Jul 17
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1010 14 Jul 17
1011 18 Sep 15
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1012 18 Sep 15
1013 18 Sep 15
1014 18 Sep 15
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1015 18 Sep 15
1016 14 Jul 17
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1018 14 Jul 17
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1019 14 Jul 17
1020 14 Jul 17
LEP-3, 04 Dec 2018

25-65-42 LEP-4, Blank
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65359
TABLE OF CONTENTS
Page
INTRODUCTION INTRO-1
DESCRIPTION AND OPERATION 1
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TESTING AND FAULT ISOLATION 101
DISASSEMBLY 301
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CLEANING 401
CHECK -06 501
REPAIR 601
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ASSEMBLY 701
FITS AND CLEARANCES 801

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SPECIAL TOOLS, FIXTURES, AND EQUIPMENT 901
ILLUSTRATED PARTS LIST 1001

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T/C-1
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65359
TABLE OF CONTENTS
INTRODUCTION
Page
1. General Information INTRO-2
2. Document Distribution INTRO-3
3. Qualification Dates INTRO-3
22
4. Abbreviations and Symbols INTRO-4
5. Listing of Authorized Service Centers INTRO-7
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6. Identifying Revised Material INTRO-7
7. Summary of Air Cruisers Maintenance Tasks INTRO-8
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INTRO-1
25-65-42 04 Dec 2018
65359
1. General Information
A. This manual provides Description and Operation, Disassembly,

Assembly, Repair, and Testing Instructions for approved mechanics,
and an Illustrated Parts List for the Reservoir and Valve/Regulator
Assembly used on the CRJ900 Slide Emergency Evacuation Systems.
The equipment is manufactured by Air Cruisers, 1747 State Route 34,
Wall Township, NJ 07727-3935, United States of America - CAGE
Code 70167.
22
B. To facilitate use of this manual, data that is particular to a specific con-
figuration(s) is presented separately by subsection within each major
-20
section of the manual. The Table of Contents at the beginning of the
manual tabulates all major sections. A more detailed Table of Contents
is provided at the beginning of each section.
-06
C. Throughout the manual pay particular attention to the WARNINGS,
CAUTIONS, and NOTES; their intentions are as follows:
21
WARNING: TO CALL ATTENTION TO METHODS AND PROCE-
DURES WHICH MUST BE FOLLOWED PRECISELY TO
AVOID INJURY TO PERSONS.
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CAUTION: TO CALL ATTENTION TO METHODS AND PROCE-

DURES WHICH MUST BE FOLLOWED TO AVOID DAM-
AGE TO EQUIPMENT.
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NOTE: To call attention to methods which make the job easier.

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D. Pages INTRO-4 through INTRO-6 consist of a list of Abbreviations and

Symbols used throughout this manual.
E. Comments, suggestions, or improvements to this document, including
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those of an editorial nature, can be sent to:
Zodiac Aero Evacuation Systems

Technical Publications Department
1747 State Route 34, Wall Township, NJ 07727-3935
Tel. (732) 681-3527, Fax. (732) 681-9163
E-mail: ZAESTechPubs@zodiacaerospace.com
www.zodiacaerospace.com
INTRO-2
25-65-42 18 Sep 2015
65359
2. Document Distribution
A. Copies of non restricted Component Maintenance Manuals (CMM),

Service Bulletins (SB), Service Information Letters (SIL), and Folding
Procedures are available on the Technical Publications Index (TPI)
through Zodiac Services website:
http://tpi.services.zodiacaerospace.com/technical/tpi
The documents will be in PDF format and can be read on-line or down-
loaded at the customer's convenience.
22
To subscribe for this service, contact Zodiac Services using link:
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http://tpi.services.zodiacaerospace.com/subscribe/form
For additional information, please visit:
www.services.zodiacaerospace.com
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3. Qualification Dates
21
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VERIFICATION DATE
Testing and Fault Isolation 02 Jun 2003

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Disassembly 02 Jun 2003

Assembly 02 Jun 2003
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A. Listed below is a cross reference tabulation between the Emergency

Evacuation Systems and the Reservoir and Valve Assembly.
RESERVOIR
EVACUATION
FOLDING AND VALVE EVACUATION
SLIDE
PROCEDURE ASSEMBLY SLIDE CMM
P/N
P/N
65250-101 P-12214 65359-101 25-66-28
INTRO-3
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65359
4. Abbreviations and Symbols
AD Airworthiness Directive
AR As Required
Assy. Assembly
Approx. Approximate
@ At
BKDN Breakdown
22
cc Cubic Centimeters
CFE Customer Furnished Equipment
CFM Customer Furnished Material
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CFR Code of Federal Regulations
CGA Compressed Gas Association
CL
cm
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Centerline
Centimeter
CMM Component Maintenance Manual
21
Cont’d Continued
CO2 Carbon Dioxide
Csk. Countersunk
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Cu. Ft. Cubic Feet

Cu. In. Cubic Inch
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DCR Document Change Request

Dia. Diameter
DOT Department of Transportation
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ECN Engineering Change Notice

EFF Effectivity
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ELT Emergency Locator Transmitter

etc. Etcetera
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C Degrees Centigrade
o
F Degrees Fahrenheit
FAA Federal Aviation Administration
FAR Federal Aviation Regulation
FIG. Figure
Ft. Feet, Foot
Ft. Lb. Foot Pounds
g Gram
Hg Mercury
ICC Interstate Commerce Commission
INTRO-4
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65359
I. D. Inside Diameter
In. Inch
In. Hg Inches of Mercury
In. Lb. Inch Pounds
IPL Illustrated Parts List
kg Kilograms
kg/sec Kilograms per Second
Lb. Pound or Pounds
22
Lb./Sec Pounds per Second
L. H. Left Hand
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L. S. Left Side
m Meter
Max. Maximum
mb Millibar
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MEK Methyl Ethyl Ketone
Min. Minimum
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MIL STD Military Standard
mm Millimeter
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MS Military Standard
N Newton
N/A Not Applicable
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N/cm2 Newtons per Square Centimeter

N-m Newton-Meter
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NAS National Aircraft Standard

NHA Next Higher Assembly
NO. Number
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NP Not Procurable
O. D. Outside Diameter
P/N Part Number
Para. Paragraph
PERM Permanent
Post Subsequent to
Pre Prior to
psig Pounds per Square Inch Gage
QTY Quantity
R Revised
Rd. Hd. Round Head
REE Rejection Elastic Expansion
INTRO-5
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65359
REV Revision
RF or REF. Reference
R. H. Right Hand
R. S. Right Side
S. B. (SB) Service Bulletin
SCFM Standard Cubic Feet per Minute
Sec. Seconds
S. I. L. (SIL) Service Information Letter
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S/N Serial Number
SRB Survival Radio Beacon
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Subs Subsequent
Supsd Superseded
Supsds Supersedes
Temp. Rev. or T. R.
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Temporary Revision
TSO Technical Standard Order
Ty. Type
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TYP. Typical
V Vendor
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*** Denotes end of Attaching Hardware

- Denotes Item Not Illustrated
 Denotes Intentionally Left Blank
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INTRO-6
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65359
5. Listing of Authorized Service Centers
For a complete list of authorized service centers refer to S. I. L. 25-102.
6. Identifying Revised Material
NOTE: A revision to a page is defined as any change to the printed

matter that existed previously.
22
A. Revisions, additions, and deletions shall be identified by a vertical
black line along the left hand margin of the page opposite only that por-
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tion of the printed matter that has changed.
B. A black line in the left hand margin opposite the page number and date,
will indicate that the text was unchanged but the material was relocated
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to a different page.
C. For the detailed parts listing an individual code letter “R”, instead of a
21
vertical black line, shall be used on each line to identify revisions.
D. Each page of a complete manual change is assigned the new revision
date.
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INTRO-7
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65359
7. Summary of Air Cruisers Maintenance Tasks
A. Standard Maintenance for Reservoir and Valve Assemblies

NOTE: The first maintenance shall be performed 3 years from the
evacuation system’s date of manufacture. Subsequent mainte-
nance shall be performed 3 years from the prior maintenance
date.
NOTE: Instructions detailed herein serve as a general guideline for
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reservoir requalification (i.e. Visual Inspection, Hydrostatic
Testing, etc.). All inspection and testing shall be performed in
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accordance with the applicable governing DOT Regulations by
DOT-Approved Facilities.
(1). Standard Maintenance includes the following tests and inspec-
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tions (if applicable to system):.
RECOMMENDATION REFERENCE
21
(a). Verify incorporation of all out- Refer to Introduction section
standing Airworthiness Direc- (Para. 2) of CMM 25-65-42
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tives, recommended Service for technical publication index

Bulletins, and Service Information and document sources.
Letters. Consult owner/operator
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regarding incorporation of
optional Service Bulletins.
(b). Reservoir
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1. Reservoir Requalifica- See Testing section of CMM

tion 25-65-42.
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2. Visual Check See Check section of CMM

25-65-42.
(c). Valve/Regulator Assembly
25-65-42.
2. Valve/Regulator See Testing section of CMM
Assembly Leakage Test 25-65-42.
3. Inflation Valve Pull Force See Testing section of CMM
Test 25-65-42.
STANDARD MAINTENANCE FOR RESERVOIR AND VALVE ASSEMBLIES
TABLE INTRO-1 (SHEET 1 OF 2)
INTRO-8
25-65-42 04 Dec 2018
65359
RECOMMENDATION REFERENCE
(d). Reservoir and Valve
Assembly
25-65-42.
2. Reservoir and Valve See Testing section of CMM
Assembly Leakage Test 25-65-42.
22
STANDARD MAINTENANCE FOR RESERVOIR AND VALVE ASSEMBLIES
TABLE INTRO-1 (SHEET 2 OF 2)
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INTRO-9
25-65-42 04 Dec 2018
65359
B. Extended Maintenance for Aged Valve/Regulator Assemblies

NOTE: These tasks may be performed within 1 year either before or
after the 15 year service mark to align with evacuation system
maintenance schedules.
(1). Perform the following at 15 year intervals from date of manufac-
ture of the valve assembly, in addition to the Standard Reservoir
and Valve Assembly Maintenance.
22
TASK REFERENCE
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(a). Fully disassemble and See Disassembly and Check sec-
inspect valve/regulator tions of CMM 25-65-42.
assembly. -06
(b). Replace all O-rings. See Disassembly and Assembly
sections of CMM 25-65-42.
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(c). Regulator Calibration. See Testing section of CMM

25-65-42.
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EXTENDED MAINTENANCE FOR AGED VALVE/REGULATOR ASSEMBLIES

TABLE INTRO-2
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INTRO-10
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65359
TABLE OF CONTENTS
DESCRIPTION AND OPERATION
Page
1. Leading Particulars 2
2. Description and Operation 4
3. Operation 5
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Page 1
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1. Leading Particulars
ITEM DESCRIPTION/VALUE
Reservoir Composite Fiber/Resin Composite over an

(DOT-SP 11194-3295) Aluminum Liner
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Nominal Pressure 3000 psig (2068 N/cm2)
at 70°F (21.1°C)
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Volume Capacity 145 Cu. In. (2.4 liters)
Valve/Regulator Assembly Ball-Type Valve, Piston Regulator
Regulated Pressure
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550 ± 50 psig (379.2 ± 34.5 N/cm2)
Rupture Disc Relief Device 4500-4950 psig (3103-3413 N/cm2)
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Fusible Plug Thermal Relief Device 174° ± 5°F (78.9° ± 2.8°C)

Pressure Gage Temperature-Compensated
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Direct Reading Type

Refer to Air Cruisers Component Maintenance Manual 25-66-28 for maintenance
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of the Evacuation System(s) used with the subject Reservoir and Valve/Regulator
Assembly. An Evacuation System Applicability Index is listed in the Introduction
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section.
LEADING PARTICULARS
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TABLE 1
Page 2
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65359
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PRESSURE
GAGE
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RESERVOIR
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VALVE/REGULATOR
ASSEMBLY
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INFLATION
CABLE
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LOCK PIN
RESERVOIR AND VALVE/REGULATOR ASSEMBLY

FIGURE 1
Page 3
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65359
2. Description and Operation
WARNING: TO PREVENT DAMAGE TO EQUIPMENT AND INJURY

TO PERSONNEL, HANDLE THE RESERVOIR AND
VALVE ASSEMBLY WITH EXTREME CARE SINCE IT
CONTAINS A HIGH PRESSURE STORED GAS.
WHEN A PROVISION FOR A SAFETY PIN IS PROVIDED

MAKE SURE THAT THE PIN IS FULLY ENGAGED INTO
22
THE VALVE PRIOR TO LIFTING/CARRYING A
CHARGED RESERVOIR AND VALVE ASSEMBLY. FAIL-
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URE TO DO SO MAY RESULT IN ACCIDENTAL DIS-
CHARGE OF STORED GAS.
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TO ENSURE INTEGRITY OF ASSEMBLED COMPO-
NENTS AND PREVENT DAMAGE TO EQUIPMENT AND
INJURY TO PERSONNEL, NEVER MOVE, CARRY, OR
21
REPOSITION A RESERVOIR AND VALVE ASSEMBLY
BY THE VALVE AND/OR COMPONENTS THEREOF.
WHEN CARRYING A RESERVOIR AND VALVE ASSEM-
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BLY, SUPPORT THE RESERVOIR USING BOTH ARMS.

DO NOT GRASP OR PULL THE CABLE INSERTED IN
THE VALVE. MAKE SURE CABLE IS NOT SUBJECT TO
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ENTANGLEMENT ON ANY ADJACENT OBJECT.

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CHARGED RESERVOIR SHOULD BE TRANSPORTED

IN A CART OR OTHER SIMILAR DEVICE TO PREVENT
DAMAGE TO EQUIPMENT AND INJURY TO PERSON-
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NEL.
NOTE: See Figure 1 for typical Reservoir and Valve/Regulator Assem-
bly configuration.
A. The inflation system consists of reservoir and valve/regulator assem-
bly, connected by a hose, to the inflatable. The reservoir is a composite
structure consisting of a seamless aluminum liner reinforced with over-
lapping carbon filaments bonded with epoxy resin. The reservoir
capacity is listed in Table 1.
Page 4
25-65-42 18 Sep 2015
65359
B. The reservoir and valve/regulator assembly contains a gas mixture of

30% CO2 and 70% N2 by weight at a pressure of 3000 psig at 70°F
(2068 N/cm2 at 21.1°C). The valve/regulator has a “ball-type” valve
section, which retains the gas charge, then provides full flow to the reg-
ulator when opened. The regulator maintains full discharge pressure
throughout the inflation cycle. Installed in the body of the valve are two
devices to relieve excessive pressure. One is a frangible “rupture” disc
which limits pressure during charging operations and the other is a
22
temperature sensitive fusible plug which relieves pressure build-up due
to a cabin fire.
-20
C. The valve incorporates a direct reading temperature-compensated
pressure gage which indicates the status of the gas charge. The gage
simplifies pre-flight pressure checks, since it is not necessary to deter-
-06
mine ambient temperature. When the reservoir and valve/regulator
assembly is fully charged, the pressure pointer will be within the limits
of the green “GO” band. The “GO” band moves as a function of temper-
21
ature. The pressure pointer moves in relation to the pressure in the res-
ervoir.
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3. Operation
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A. The reservoir and valve/regulator assembly is a functional component of

the Evacuation Systems. For operating characteristics, refer to the
Description and Operation section of the appropriate Air Cruisers Com-
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ponent Maintenance Manual listed in the Introduction section.

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Page 5, 14 Jul 2017

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65359
TABLE OF CONTENTS
TESTING AND FAULT ISOLATION
Page
1. Test Equipment/Materials 102
2. Testing and Fault Isolation 105
3. Valve/Regulator Assembly Leakage Test 105
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4. Valve/Regulator Assembly Pull Force Test 106
5. Regulator Calibration 107
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6. Reservoir and Valve/Regulator Assembly Leakage Test 111
7. Hydrostatic Test Procedure 112
8. Fault Isolation
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Page 101
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65359
1. Test Equipment/Materials (Table 101)
NOTE: Drawings of equipment/tools manufactured by Air Cruisers are

available from Air Cruisers upon request.
NOTE: Equivalent substitutes may be used for items when marked
with the following symbol .
22
ITEM/DESCRIPTION QUANTITY SOURCE USE
Krylon Spray Coating As Krylon Decal/stencil protec-
-20
Acrylic No. 1306  Required Products Group tant.
V4KNS6
Two Part, 5 Minute Epoxy As Commercially Decal adhesive/pro-
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Resin Required Available tectant.
Devcon 5  or
(Shelf life of 3 years) Air Cruisers
21
V70167
Borescope or Flexible Fiber- 1 Lenox Instru- Used to visually
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Optic Light Source  ment Co. inspect reservoir inte-

FLS 150 V35733 or rior.
Commercially
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Available
Retest Label As Air Cruisers Reservoir requalifica-
int
60140-101 Required V70167 tion decal.

Adapter - For Hydrostatic 1 Air Cruisers Attaches reservoir to
Pr
Testing V70167 hydrostatic test equip-

C19848-3 ment.
Vise, Chain Link Type 1 Air Cruisers Immobilizes reservoir
65455-101  V70167 and valve assembly
during assembly/
maintenance/testing.
TESTING EQUIPMENT/MATERIALS
TABLE 101 (SHEET 1 OF 3)
Page 102
25-65-42 18 Sep 2015
65359

Neoprene Strap 1 Commercially Protects reservoir
28 x 4 x 1/8 In. Available while immobilized in
(711.2 x 101.6 x 3.2 mm) vise.
Durometer #80-85 
Hydrostatic Test Equipment 1 Hydro-Test Hydrostatically tests
500-HP-18S-M Products reservoirs.
22
(or test equipment per V56043 or
49 CFR 180.205(g)) Commercially
Available
-20
Dow Corning Molykote 55 As Dow Corning External O-ring lubri-
(Air Cruisers P/N DC-55M) Required Corporation cant.
-06 V5D028,
Air Cruisers
V70167, or
21
Commercially
Available
Kit, O-Ring Tools 1 Air Cruisers Protects O-rings from
on
67189-1  V70167 threaded fittings dur-

ing installation.
ed
High Pressure Chuck 1 Air Cruisers Mounting apparatus

TO3840 V70167 for valve/regulator
assembly/testing.
int
Tool - Charging Adapter to 1 Air Cruisers Filler valve adapter for

Filler Valve (with O-ring which V70167 reservoir and valve
Pr
conforms to NAS1611-008) assembly charging.

B19285-1
Leak Test Solution As Commercially Determines leakage
MIL-PRF-25567 Type I Required Available of reservoir and valve
assemblies.
Soft Bristle Brush  1 Commercially Applies leak test solu-
Available tion.
Page 103
25-65-42 14 Jul 2017
65359

Force Gage, 1 Commercially Determines valve
Push/Pull Gage Available actuating pull force.
0-50 Lb. (0-22.7 kg) with 0.5
Lb. (0.2 kg) graduations 
Calibration Fixture 1 Air Cruisers Mounting apparatus
65011-101 V70167 for valve regulator cal-
22
ibration.
Safety Plug 1 Commercially Seals valve outlet port
-20
(Valve Outlet Port) Available to prohibit leakage,
AN814-10 or AS5169-10 damage, and contami-
nation.
Torque Seal (Green) As
-06 Organic Sealant applied to
F-900 or equivalent ** Required Products Co. torqued fittings.
V01195,
21
Air Cruisers
V70167, or
Commercially
on
Available
Sealant, Tamper Proof (White) As 3M Co. V04963, Sealant applied to
ed
Scotch Seal 1252 ** Required Air Cruisers torqued fittings.

V70167, or
Commercially
int
Available
Screwdriver, Offset, Slotted 1 McMaster-Carr Arms valve/regulator
Pr
36585A91 * Supply Co. assemblies fitted with

V2V507 composite pulley.
Screwdriver, Standard, Slot- 1 Commercially Arms valve/regulator
ted (¼ In., 45°) * Available assemblies fitted with
composite pulley.
* Alternatives
** Alternatives
Page 104
25-65-42 14 Jul 2017
65359
2. Testing and Fault Isolation
WARNING: USE EYE, FACE, AND EAR PROTECTION WHEN

USING HIGH PRESSURE AIR TO PROTECT PERSON-
NEL FROM POSSIBLE INJURY.
A. A valve/regulator assembly pull force test must be performed after
each system deployment and prior to return to service.
B. A reservoir and valve/regulator assembly leakage test must be per-
22
formed each time the assembly is recharged. Leakage test can be per-
formed in conjunction with pull force test sequence.
-20
C. Reservoir Requalification and Service Life Requirements
(1). A hydrostatic test must be conducted per the requirements of the
U. S. DOT special permit or specification.
-06
(2). Service Life is per the requirements of the U.S. DOT special per-
mit or specification.
21
(3). See Check section, Table 501.
on
3. Valve/Regulator Assembly Leakage Test

WARNING: ENSURE THAT VALVE OUTLET PORT IS OPEN (NOT
ed
PLUGGED) AND VALVE IS IN THE CLOSED POSITION

(PULLEY STOP PIN ALIGNED WITH BLACK ARROW)
TO PREVENT EQUIPMENT DAMAGE AND/OR INJURY
int
TO PERSONNEL.
Pr
TO PERSONNEL, EXERCISE EXTREME CARE WHEN

HANDLING CHARGED VALVE/REGULATOR ASSEM-
BLY.
A. Lubricate O-ring (80, IPL Figure 1) with Molykote 55 (Table 101) and
install on reservoir fitting of valve/regulator assembly (60, IPL Figure 1)
using appropriate O-ring tool from kit (Table 101).
B. Install valve/regulator assembly on high pressure chuck (Table 101).
Torque per Table 801.
C. Attach charging adapter tool (Table 101) to filler valve (160, 160A, IPL
Figure 2), then attach charging apparatus supply line to charging
adapter tool.
Page 105
25-65-42 18 Sep 2015
65359
D. Apply pressure to valve/regulator assembly through the charging

adapter tool (Table 101) until the indicator pointer aligns with the black
index dot on gage face. Turn outer nut on filler valve counter-clockwise
to open and clockwise to close.
E. Remove valve/regulator assembly from charging apparatus and let
valve sit undisturbed for 12 hours.
F. After 12 hours, inspect gage. No pressure drop as indicated by gage
reading permissible.
22
CAUTION: DO NOT SUBMERGE PRESSURE GAGE DURING
LEAKAGE TEST.
-20
G. If pressure loss is detected, immerse valve/regulator in water, deep
enough to include all threaded connections and inspect for leaks,
escaping air bubbles. -06
NOTE: If leaks are not detected on valve/regulator, apply leak test
solution (Table 101) with brush (Table 101) over entire gage.
21
NOTE: If the valve/regulator leaks, discharge gas, disassemble, check
all sealing areas to determine cause, reassemble and retest.
H. Remove the valve/regulator assembly with high pressure chuck from
on
the water and dry with compressed air.

ed
4. Valve/Regulator Assembly Pull Force Test

int
NOTE: If valve/regulator assembly is attached to high pressure chuck

and pressurized (i.e. following leakage test), proceed to Para-
graph 4.E.
Pr
WARNING: POINT VALVE OUTLET PORT IN A SAFE DIRECTION

TO PREVENT INJURY TO PERSONNEL.
A. Lubricate O-ring (80, IPL Figure 1) with Molykote 55 (Table 101) and
install on reservoir fitting of valve/regulator assembly (60, IPL Figure 1)
using appropriate O-ring tool from kit (Table 101).
B. Install valve/regulator assembly on high pressure chuck (Table 101).
Torque per Table 801.
C. Attach charging adapter tool (Table 101) to filler valve (160, 160A, IPL
Figure 2), then attach charging apparatus supply line to charging
adapter tool.
Page 106
25-65-42 18 Sep 2015
65359
D. Apply pressure to valve/regulator assembly through the charging

adapter tool (Table 101) until the indicator pointer aligns with the black
index dot on gage face. Turn outer nut on filler valve counter-clockwise
to open and clockwise to close.
E. Attach a calibrated push/pull gage (Table 101) to the valve release
cable (20, IPL Figure 1). Slowly apply force parallel to the valve regula-
tor section centerline to discharge the pressure.
F. The force required to activate (discharge) the valve/regulator shall not
22
exceed 10 Lb. (4.5 kg).
NOTE: If the force is not as specified, disassemble, inspect and deter-
-20
mine cause prior to assembly and final calibration of regulator.
G. Remove valve/regulator assembly from high pressure chuck and thor-
oughly dry the valve with compressed air.
-06
21
5. Regulator Calibration (Figures 101 and 102)
A. Install valve/regulator to be calibrated on reservoir per Paragraph 8 of

the Assembly section, and pressurize assembly per Paragraph 9 of the
on
Assembly section.
NOTE: For regulator calibration only, reservoir may be pressurized
ed
with straight nitrogen in lieu of a CO2 and N2 mixture. Pressur-

ize while observing pressure gage. The movable green “GO”
band, at room temperature, is nearly centered with respect to
int
the black dot index on the gage face perimeter. Fill reservoir
until the pressure reading indicator pointer is centered in the
Pr
green “GO” band.

B. Place charged reservoir and valve/regulator assembly in the calibrating
fixture (Table 101). Remove outlet port plug and O-ring. Install hose
and tighten connections (Table 801).
WARNING: POINT VALVE OUTLET IN A SAFE DIRECTION TO
PREVENT INJURY TO PERSONNEL.
Page 107
25-65-42 18 Sep 2015
65359
NOTE: Properly adjusted valve/regulators should perform as follows:
As reservoir discharges, an immediate initial pressure rise to

the regulator system pressure of 200 - 300 psig (137.9 - 206.8
N/cm2) should occur, followed by continuing rise of pressure to
460 ± 50 psig (317.2 ± 34.5 N/cm2) and then decrease to 0
psig as the reservoir is exhausted. See Figure 102 for “typical”
regulation discharge curve.
22
C. Check reservoir pressure by observing gage, gage pointer must be in
the green “GO” band. Remove lock pin assembly (40, IPL Figure 1).
-20
For valve/regulator assemblies fitted with an aluminum pulley (30, 30A,
IPL Figure 2), insert a 3/16 In. hex key (Allen) wrench into the socket at
the center of the pulley. For valve/regulator assemblies fitted with a
-06
composite pulley (30B, IPL Figure 2), insert a standard or offset slotted
screwdriver (Table 101) into the slot at the center of the pulley. Rapidly
rotate in the opposite direction of the arming label (valve open position)
21
to discharge reservoir pressure. Carefully note peak pressure rise.
D. If the observed initial pressure rise is not within limits, turn the adjusting
screw (320, IPL Figure 2) to the right to increase, to the left to decrease
on
pressure using a 3/16 hex key (Allen) wrench; approximately 1/10 turn
for every 20 psig (13.8 N/cm2) of change required. Recharge the reser-
voir and repeat the above procedure until proper adjustment is
ed
obtained.
E. Apply torque seal (Table 101) or tamper proof sealant (Table 101) to
int
adjusting screw/plug.
F. Press fit flanged bushing (310, IPL Figure 2) into hex socket of regula-
Pr
tor adjusting screw.
Page 108
25-65-42 14 Jul 2017
BAFFLE
BAFFLE SUPPORT
FIXTURE
PRESSURE
SINGLE CHANNEL TRANSDUCER
FLATBED RECORDER
Pr
CONDUCTOR
CABLE ASSEMBLY ASPIRATOR
TEST LEAD ASSEMBLY
int
ed
POWER SUPPLY
ASSEMBLY on
HOSE ASSEMBLY
65359
21
FIGURE 101
RESERVOIR AND
25-65-42
VALVE ASSEMBLY
-06
O-RING
-20
CHAIN VISE 22
CALIBRATION FIXTURE-RESERVOIR ASSEMBLY

NEOPRENE
STRAP
RESERVOIR
SUPPORT
18 Sep 2015
Page 109
65359
22
-20
REGULATED PRESSURE
-06
460 ± 50
21
300
200
on
ed
0
0
int
TIME (SECONDS)
Pr
REGULATED DISCHARGE CHARACTERISTIC

FIGURE 102
Page 110
25-65-42 18 Sep 2015
65359
6. Reservoir and Valve/Regulator Assembly Leakage Test
CAUTION: DO NOT SUBMERGE PRESSURE GAGE.

A. Submerge reservoir and valve/regulator assembly for five minutes in
water deep enough to include all threaded connections for the following
components; bottle threaded connection, rupture disc threaded con-
nection, pressure gage fitting threaded connection (lock nut), but do
not submerge the pressure gage housing; no leakage (indicated by
escaping bubbles) is permitted. Dry thoroughly with compressed air. If
22
leakage occurs, discharge reservoir per the instructions in the Disas-
sembly section and determine cause.
-20
B. Check gage for leakage. Use a soft bristle brush to apply leak test solu-
tion (Table 101) around gage face and around base of gage head. No
leakage is permitted. Replace gage if it leaks.
-06
CAUTION: ENSURE HIGH PRESSURE CAP IS INSTALLED ON
FILLER VALVE.
21
C. If not previously done, remove charging line and adapter. Install the
high pressure cap on filler valve.
on
D. Install tube (90, IPL Figure 1) on the filler valve cap.

WARNING: DO NOT REMOVE THE LOCK PIN, TO PREVENT ACCI-
DENTAL DISCHARGE OF PRESSURIZED GAS.
ed
WARNING: DO NOT REMOVE THE PLUG FROM OUTLET PORT

UNTIL THE RESERVOIR IS INSTALLED IN ITS SLING
int
ON THE SLIDE AND THE HOSE ASSEMBLY IS CON-

NECTED. THIS WILL PREVENT INJURY TO PERSON-
NEL RESULTING FROM THE ACCIDENTAL
Pr
DISCHARGE OF PRESSURIZED GAS.
Page 111
25-65-42 14 Jul 2017
65359
7. Hydrostatic Test Procedure
NOTE: Refer to 49 CFR 180.201 through 180.215 Qualification, main-

tenance, and use of reservoirs, the applicable DOT special
permit or specification as identified on the reservoir and the
Check section for hydrostatic testing and visual checking
acceptable criteria.
CAUTION: ENSURE RESERVOIR THREADS ARE FREE OF FOR-
EIGN OBJECTS OR CONTAMINATION.
22
A. Perform visual inspection per applicable DOT/CGA guidelines.
-20
B. Record reservoir information, DOT numbers on hydrostatic data sheet
(Figure 103).
WARNING: RESERVOIR MUST BE WRAPPED WITH NEOPRENE
-06
STRAP (TABLE 101) PRIOR TO CLAMPING IN VISE TO
PREVENT DAMAGE TO EQUIPMENT OR INJURY TO
PERSONNEL.
21
C. Immobilize the reservoir vertically in a vise, chain link type (Table 101).
CAUTION: USE ONLY CLEAN WATER TO HYDROSTATICALLY
on
TEST THE RESERVOIR.

D. Fill reservoir to the top with clean water.
E. Purge the reservoir to remove entrapped air.
ed
F. Install adapter (Table 101) and O-ring (40, 40A, IPL Figure 1; 40, IPL
Figure 2) into the reservoir.
int
G. Remove the reservoir from the chain vise.

H. Install the reservoir in hydrostatic test equipment (Table 101).
Pr
I. Slowly close and clamp the lid on the hydrostatic test equipment, do
not trap air by slamming, and clamp the lid shut.
J. “Top off” water level in reservoir until all the air bubbles in the reservoir
are released.
K. “Top off” water level in the hydrostatic test equipment until a bubble-
free clear flow is observed.
CAUTION: WATER LEVEL IN BURETTE MUST BE STABLE PRIOR
TO PRESSURIZING THE RESERVOIR.
L. Stabilize water level in burette.
Page 112
25-65-42 14 Jul 2017
65359
M. Slowly apply pre-test pressure to stabilize the reservoir and test equip-
ment. The pre-test pressure shall be in accordance with the specific
reservoir special permit. If one is not prescribed, the value shall be 85-
90% of the test pressure.
N. Assure the system is leak free, release the pressure and re-zero the
burette.
CAUTION: WATER LEVEL IN BURETTE MUST BE STABLE PRIOR
TO PRESSURIZING THE RESERVOIR.
22
NOTE: Refer to reservoir DOT specification or special permit for test
pressure requirement.
-20
O. Slowly apply hydrostatic pressure to the reservoir UNTIL TEST PRES-
SURE IS REACHED.
P. -06
Maintain hydrostatic pressure per the applicable DOT special permit or
specification as identified on the reservoir.
Q. Record total reservoir expansion.
21
R. Turn off hydrostatic test equipment, and open the toggle valve located
in the pressure line to bleed off hydrostatic pressure from the reservoir.
on
NOTE: Composite reservoirs compared with steel reservoirs require

more time to return to shape after removal of pressure.
S. Wait 60 seconds minimum or longer for water level in the burette to sta-
ed
bilize, then read and record permanent expansion. (For composite res-
ervoirs, hold time at zero pressure may be extended (6) six minutes or
int
longer, to allow for complete contraction.)

NOTE: When using computer controlled test equipment make sure
Pr
that the 60 second minimum wait period is entered into the

software. Failure to do so may result in a false permanent
expansion reading, because composite reservoirs do not
immediately return to their original shape like metal reservoirs.
T. Record permanent reservoir expansion.
U. Calculate and record elastic expansion. Record marked REE if applica-
ble.
V. Calculate and record the percent permanent expansion.
W. Maximum expansion (permanent and/or elastic as applicable) shall not
exceed the requirements specified in the applicable DOT special per-
mit or specification as identified on the reservoir. See Check section.
X. Accept or condemn reservoir as applicable.
Page 113
25-65-42 14 Jul 2017
65359
CAUTION: ENSURE THAT ALL MOISTURE IS REMOVED FROM

THE RESERVOIR.
CAUTION: ENSURE RESERVOIR THREADS ARE FREE OF FOR-
EIGN OBJECTS OR CONTAMINATION.
Y. Remove excess moisture from the reservoir with compressed air.
Z. Place the reservoir valve end, open end, face down in an environment
of 125°F ± 5°F (51.7°C ± 2.8°C) for a time period of 30 minutes mini-
mum.
22
WARNING: FOR CARBON FIBER REINFORCED ALUMINUM LINED
-20
RESERVOIRS, DO NOT STAMP ON THE RESERVOIR
NECK, THE IDENTIFICATION LABEL, NOR ANY
OTHER LOCATION ON THE COMPOSITE OVERWRAP.
DOING SO WILL RESULT IN FIBER DAMAGE AND
-06
SUBSEQUENT INJURY TO PERSONNEL.
AA. Mark reservoirs according to their applicable DOT special permit or
21
specification. When none apply, reference CGA pamphlets for marking
month and year of re-test
(1). For carbon reservoirs it is mandatory to affix retest label near the
on
original test date as detailed below. This method is an alternate

for all other composite reservoir types.
ed
(a). Clean the surface, where the label (Table 101) is to be

attached, with ammoniated water (“Windex” or equivalent).
int
(b). Dry surface using compressed air before applying label.

(c). Mark the month, year, and retester’s identification number on
label using either a typewriter or permanent marker.
Pr
(d). Overcoat the label with a thin coat of Krylon spray (Table 101).
(e). Peel label from the paper backing and apply label to the reser-
voir surface near the original test date.
(f). Overcoat label with two part clear epoxy (Table 101) and cure
per the manufacturers instructions.
Page 114
25-65-42 14 Jul 2017
65359
22
-20
-06
21
on
ed
int
Pr
HYDROSTATIC TEST DATA SHEET

FIGURE 103
Page 115
25-65-42 18 Sep 2015
65359
8. Fault Isolation (Table 102)
TEST
FAULT POSSIBLE CAUSE TO CORRECT
STEP
3.A Reservoir and Valve Leakage from valve/regula- Use leak test solution to
through Assembly Low Pressure tor assembly to reservoir prove leakage. Discharge
3.H, connection. reservoir and valve/regula-
22
6.A tor assembly per Disassem-
through bly section. Tighten fitting
-20
6.D and/or replace O-ring (80,
IPL Figure 1). Re-charge
per Assembly section. Re-
test per Testing and Fault
-06 Isolation section.
Leakage at filler valve port, Use leak test solution to

thermal/fusible plug port, or prove leakage. Discharge
21
rupture/burst disc port. reservoir and valve/regula-
tor assembly per Disassem-
bly section. Tighten fitting
on
and/or replace O-ring (150,

180, IPL Figure 2). Re-
charge per Assembly sec-
ed
tion. Re-test per Testing

and Fault Isolation section.
Discharge leakage: con- Discharge reservoir and

int
tamination (hair or dust valve/regulator assembly

particles) between ball and per Disassembly section.
seat. Deformed seat. Disassemble valve/regula-
Pr
tor assembly and check ball

and seat for contamination
or deformation. Clean and/
or replace ball (250, IPL
Figure 2) and seat (360A,
IPL Figure 2). Re-assem-
ble and re-charge per
Assembly section. Re-test
per Testing and Fault Isola-
tion section.
FAULT ISOLATION
Page 116
25-65-42 18 Sep 2015
65359
TEST
FAULT POSSIBLE CAUSE TO CORRECT
STEP
3.A Reservoir and Valve Shaft discharge. Discharge reservoir and

through Assembly Low Pressure valve/regulator assembly,
3.H, (Cont’d) and disassemble valve/reg-
6.A ulator assembly, per Disas-
through sembly section. Replace
6.D shaft O-ring (280, IPL Fig-
22
(Cont’d) ure 2) and back-up ring
(270, IPL Figure 2). Re-
assemble and re-charge
-20
per Assembly section. Re-
test per Testing and Fault
Isolation section.
port.
-06
Leakage at gage assembly Tighten gage assembly
(see Table 801) or replace
Teflon Tape (Table 701).
Re-test per Testing and
21
Fault Isolation section. If
testing proves leakage,
replace gage assembly.
on
4.A High Pull Force Inflation cable assembly Disassemble valve/regula-

through Above 10 Lb. (4.5 kg). does not move freely and/ tor assembly per Disassem-
4.G or is restricted. Pulley and/ bly section. Inspect for
ed
or pulley housing restric- restrictions and replace pul-

tion. ley (30, 30A, 30B, IPL Fig-
int
ure 2) as necessary. Re-

assemble valve/regulator
assembly per Assembly
Pr
section. Re-test per Testing

and Fault Isolation section.
5.A Low Regulator Pressure Regulator out of adjust- Check assembly of regula-
through ment. tor assembly per Assembly
5.F section.
FAULT ISOLATION
Page 117, 18 Sep 2015

25-65-42 Page 118, Blank
Pr
int
ed
on
21
-06
-20
22
65359
TABLE OF CONTENTS
DISASSEMBLY
Page
1. Disassembly Materials/Tools 302
2. General Information 303
3. Removal from Evacuation Slide System 303
22
4. Discharge Reservoir and Valve/Regulator Assembly 304
5. Disassembly of Valve/Regulator Assembly 308
-20
-06
21
on
ed
int
Pr
Page 301
25-65-42 18 Sep 2015
65359
1. Disassembly Materials/Tools (Table 301)

with the following symbol 
22
Vise, Chain Link Type  1 Commercially Immobilizes reservoir
-20
Available and valve assembly
or Air Cruisers during assembly/main-
P/N 65455-101
-06 tenance/testing.
Neoprene Strap 1 Commercially Protects reservoir
21
(711.2 x 101.6 x 3.2 mm) vise.
on
Adapter -Torque Wrench 1 Air Cruisers Used with breaker bar

(Reservoir Fitting to V70167 to disengage valve
Reservoir) from reservoir.
ed
B19586-3
int

nation.
Pr
Socket - Rupture Disc 1 Air Cruisers Installs/removes rup-

60586-1 V70167 ture/burst disk.
Socket - Fusible Plug 1 Air Cruisers Installs/removes fus-
60593-1 V70167 ible/thermal plug.
DISASSEMBLY MATERIALS/TOOLS
TABLE 301
Page 302
25-65-42 18 Sep 2015
65359
A. Decision to disassemble generally should be based on presence of

leaks, visible damage, or functional discrepancies discovered in perfor-
mance of procedures outlined in Check or Testing and Fault Isolation
sections. Disassemble only to the extent necessary to complete local
repair or replacement. Complete disassembly of all components cov-
ered in this section is neither necessary nor recommended.
CAUTION: USE ONLY BRASS OR PLASTIC TOOLS TO REMOVE
22
THE O-RINGS, TOOLS NOT MADE OF BRASS OR
PLASTIC CAN SCRATCH THE O-RING GROOVES,
-20
CAUSING LEAKAGE AND POSSIBLE CORROSION.
NOTE: A small bead of green or white torque marker may have been
applied to the connected joint between specific components.
-06
This torque marker is used in some cases to identify joints that
have been torqued per specific requirements. The marker sub-
sequently provides an indication that the joint has not loosened
21
or been adjusted after inspection during the manufacturing/

assembly process. This marker is not required during field
on
maintenance (unless otherwise instructed per documented

Testing or Assembly criteria).
B. When disassembly is necessary, replace all O-rings and gaskets.
ed
Replacement of other items should be guided by sound examination

criteria, see Check section.
int
3. Removal from Evacuation Slide System
WARNING: VERIFY THAT VALVE LOCK PIN IS INSTALLED INTO

Pr
THE VALVE PULLEY HOUSING TO DISARM THE RES-

ERVOIR AND VALVE/REGULATOR ASSEMBLY AND
PREVENT ACCIDENTAL DISCHARGE OF PRESSUR-
IZED GAS.
WARNING: WHEN HOSE IS DISCONNECTED FROM VALVE/REGU-
LATOR ASSEMBLY INSTALL SAFETY PLUG (TABLE
301) IN VALVE OUTLET PORT TO PREVENT INJURY
TO PERSONNEL RESULTING FROM THE ACCIDEN-
TAL DISCHARGE OF PRESSURIZED GAS.
A. Remove the reservoir and valve/regulator assembly from the evacua-
tion system in accordance with instructions in the appropriate Compo-
nent Maintenance Manual listed in the Introduction section.
Page 303
25-65-42 14 Jul 2017
65359
4. Discharge Reservoir and Valve/Regulator Assembly (Figures 301 and 302)

(IPL Figure 1)
NOTE: If reservoir was discharged during a functional test of the evac-

uation system proceed to Paragraph 4F.
WARNING: TO PREVENT INJURY TO PERSONNEL, ENSURE ALL
PERSONNEL AND LOOSE OBJECTS ARE OUT OF
RANGE OF THE DISCHARGING GAS. ENSURE THAT
PLUG (TABLE 301) IS INSTALLED IN VALVE OUTLET
22
PORT.
-20
A. Install plug (Table 301) in valve outlet port, hand tight.
B. Wrap reservoir with neoprene strap (Table 301).
C. Immobilize the reservoir in a vise, chain link type (Table 301).
-06
D. Remove the tube (90) and high pressure cap (170, IPL Figure 2) from
the end of the filler valve.
21
E. Discharge the reservoir by opening the filler valve (160, 160A, IPL Fig-
ure 2) using two 3/4 In. open end wrenches.
F. Check the gage pressure reading and the filler valve for residual vapor
on
discharge before continuing.

ed
int
Pr
Page 304
25-65-42 18 Sep 2015
65359
22
RESERVOIR
-20
NEOPRENE
STRAP
-06
21
VALVE/
REGULATOR
on
LOCK PIN
ed
int
CHAIN VISE
Pr
SAFETY PLUG
TUBE
HIGH
PRESSURE CAP
DISCHARGE THE RESERVOIR AND VALVE/REGULATOR

FIGURE 301
Page 305
25-65-42 18 Sep 2015
65359
G. Remove pressure gage (10).

H. Remove lock pin assembly (40).
I. Remove cable guide assembly (30) from the valve.
J. Pull the valve release cable (20) from within the valve pulley housing.
NOTE: If disassembly of the valve/regulator assembly is to follow,
loosen, but do not remove, all external fittings.
K. Remove the valve/regulator assembly (60) from the reservoir (70)
22
using a torque wrench adapter (Table 301) with a 1/2 In. drive breaker
bar. Discard O-ring (80).
-20
L. Remove safety plug (Table 301) from outlet port.
-06
21
on
ed
int
Pr
Page 306
25-65-42 18 Sep 2015
65359
22
PRESSURE
GAGE
-20
-06 VALVE/
REGULATOR
ASSEMBLY
21
O-RING
RESERVOIR
on
ed
PLUG
LOCK PIN
int
Pr
CABLE GUIDE
VALVE RELEASE
CABLE
RESERVOIR AND VALVE/REGULATOR DISASSEMBLY

FIGURE 302
Page 307
25-65-42 18 Sep 2015
65359
5. Disassembly of Valve/Regulator Assembly (Figures 303 through 305)

(IPL Figure 2)
NOTE: Bearing bushing (70) and pulley bearing (100) are installed on
valve/regulator assemblies fitted with an aluminum pulley (30,
30A) only.
A. Use a small screwdriver to unseat the retaining ring (10) from the valve
body (370). Turn valve over so that the cover plate (20, 20A), pulley
(30A, 30B) with coupling pin (40) and pawl assembly (50) fall out of the
22
pulley housing. Remove bearing bushing (70) from cover plate.
-20
B. Do not remove the coupling pin (40) from the pulley unless damage,
wear, and/or misalignment are evident.
C. Remove the pawl (50) and pawl spring (90) from the pawl pin/screw
-06
(60). Remove the pulley bearing (100) from the pulley housing.
D. Use a suitable hex key (Allen) wrench to remove socket head screws
(110) from the cable adapter (120). Remove the cable adapter (120)
21
from the pulley housing.
E. Use rupture disc socket (Table 301) to remove the rupture disc (130)
on
from the valve body.

F. Use fusible plug socket (Table 301) to remove the fusible plug (140)
from the valve body. Remove O-ring (150).
ed
G. Remove the high pressure cap (170) from the end of the filler valve
(160), if not previously done.
int
H. Use a 3/4 In. open end wrench to remove the filler valve (160) from
valve body. Remove O-ring (180).
Pr
I. Using a suitable open end wrench remove the gage fitting (190) and
O-ring (200) from the valve body.
WARNING: BALL GUIDE SPRING (230) IS UNDER COMPRESSION,
USE EYE AND FACE PROTECTION TO PROTECT PER-
SONNEL FROM POSSIBLE INJURY.
J. Remove the bottle fitting (210A, 210B), O-ring (220), ball guide spring
(230) and the ball guide (240, 240A) from the valve body.
K. Tilt the valve body to the side and flow ball (250) will fall through the
bottle fitting port.
Page 308
25-65-42 14 Jul 2017
65359
L. Push down gently on the shaft (260) with its back-up ring (270), O-ring
(280), shims (290), and thrust bearing (300). All will disengage from
the valve body and fall through the bottle fitting port. Remove back-up
ring, O-ring, shims, and thrust bearing from shaft.
M. Remove flanged bushing (310) from end of adjusting screw.
WARNING: REGULATOR SPRING (330) IS UNDER COMPRES-
SION, USE EYE AND FACE PROTECTION TO PRO-
TECT PERSONNEL FROM POSSIBLE INJURY.
22
NOTE: Heat may be necessary to aid in the removal of the adjusting
screw (320). Apply heat to the housing at the adjusting screw
-20
location with a heat gun or other non flaming device. The
approximate temperature necessary at the joint is 200°F to
300°F (93°C to 149°C) for a period of 5 to 10 minutes. After
-06
exposure to heat, all “soft” goods such as O-rings and back-up
rings should be replaced.
N. Use a 3/16 In. hex key (Allen) wrench to remove the adjusting screw
21
(320) from the regulator assembly. Remove regulator spring (330).

O. Push the piston (340) and O-ring (350) out of the regulator section.
on
NOTE: It is not necessary to remove the ball seat, unless damaged or

deformed.
ed
CAUTION: DO NOT PUSH THE SHARP POINTED INSTRUMENT

THROUGH THE TEFLON SEAT.
int
P. Visually inspect the ball seat (360, 360A) for damage. Remove, if nec-
essary, by using a sharp pointed instrument via the filler valve opening
in the body to pry the ball seat from the valve body.
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Page 309
25-65-42 14 Jul 2017
65359
22
A
-20
-06
21
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B B
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VALVE/REGULATOR
ASSEMBLY
A
VALVE/REGULATOR ASSEMBLY
FIGURE 303
Page 310
25-65-42 18 Sep 2015
65359
BEARING BUSHING*
COUPLING PIN PULLEY
22
COVER PLATE
RETAINING RING
-20
BACK-UP RING
PULLEY
BEARING* O-RING
SHAFT
-06
THRUST
21
BEARING
RUPTURE DISC
on
FUSIBLE PLUG
FILLER VALVE
WITH CAP
ed
SHIM
FLOW BALL
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GAGE FITTING
O-RING
Pr
SECTION A-A
* VALVE/REGULATOR ASSEMBLIES
FITTED WITH AN ALUMINUM PULLEY
FIGURE 304
Page 311
25-65-42 18 Sep 2015
65359
FILLER VALVE
WITH CAP
22
BALL GUIDE
-20
FLOW BALL
BOTTLE FITTING -06

PISTON
21
O-RING
on
SPRING
SPRING
ed
O-RING
O-RING
int
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FLANGED BUSHING
ADJUSTING
SCREW
SECTION B-B
FIGURE 305
Page 312
25-65-42 18 Sep 2015
65359
TABLE OF CONTENTS
CLEANING
Page
1. Cleaning Materials/Tools 402
3. Reservoir Exterior 403
22
4. Valve/Regulator Assembly 404
5. Pressure Gage 404
-20
6. Valve Release Cable 404
7. Lock Pin Assembly 405
-06
21
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Page 401
25-65-42 18 Sep 2015
65359
1. Cleaning Materials/Tools (Table 401)

with the following symbol 
22
Cleaning Solution As Commercial Moderate cleaning of
Moderate Duty: Required Standard surfaces.
-20
MIL-PRF-87937 Type II or
Type IV
Cleaning Solution
Heavy Duty:
As
Required
-06
Commercially Heavy duty cleaning
Available of surfaces.
Isopropyl Alcohol
21
((CH3)2CHOH)
or Butyl Acetate (C6H12O2)
or Acetone (CH3COCH3)
on
Cleaning Solvent for Metal As Commercial Cleaning of metal

Parts: Required Standard surfaces.
ed
MIL-PRF-680
or
Clear Mineral Spirits 
int
Stiff Bristle Brush  1 Commercially Application of solu-

Available tions/solvents.
Pr
Soft Bristle Brush  1 Commercially Application of solu-

Available tions/solvents.
CLEANING MATERIALS/TOOLS
TABLE 401
Page 402
25-65-42 18 Sep 2015
65359
WARNING: WHEN USING SOLVENTS, CEMENTS, OR OTHER

CHEMICAL BASED PRODUCTS, REFER TO THE
APPLICABLE MATERIAL SAFETY DATA SHEET
(MSDS) FOR SPECIFIC GUIDELINES ON PROPER
PERSONAL PROTECTIVE EQUIPMENT, STORAGE,
HANDLING, AND VENTILATION REQUIREMENTS TO
PREVENT SICKNESS OR INJURY OF PERSONNEL.
22
-20
WARNING: TO PREVENT POSSIBLE INJURY, ENSURE AIR NOZ-
ZLE AND VALVE OPENINGS ARE POSITIONED AWAY
-06
FROM BODY OR OTHER PERSONNEL AND ENSURE A
30 PSIG (20.7 N/cm2), OR LESS, AIR NOZZLE IS
21
ATTACHED TO AIR HOSE.
A. Observe all shop safety precautions and practices. As applicable, parts
should be dried using an oil and moisture free compressed air source
on
which is filtered through a 20-micron filter.

ed
3. Reservoir Exterior
A. Normal soiled conditions (i.e. dirt, non-petroleum based stains) may be

int
removed by wiping with a soft, dry cloth. If the condition persists,

dampen cloth in clean water and wipe dry.
Pr
B. Minor petroleum based contaminants may be removed using a clean

cloth dampened with a mixture of cleaning solution (Table 401) and
water, rinsing with damp cloth, and drying with compressed air.
C. For heavier concentrations of contaminants, a clean cloth dampened in
isopropyl alcohol (Table 401) should be wiped over the affected area.
If necessary, Butyl Acetate (Table 401) or Acetone (Table 401) may be
used in further attempts to remove more stubborn contaminants.
Page 403
25-65-42 18 Sep 2015
65359
4. Valve/Regulator Assembly
A. For removal of light to moderate concentrations of dust and dirt, use

cleaning solution (Table 401).
(1). Apply solution with a soft bristle brush or clean cloth.
(2). Thoroughly rinse with clean water and blow dry with compressed
air.
B. For removal of heavy concentrations of dirt and grease, use cleaning
22
solvent (Table 401).
(1). Apply cleaning solvent with a clean cloth.
-20
(2). Blow dry with compressed air.
5. Pressure Gage
-06
CAUTION: DO NOT IMMERSE PRESSURE GAGE IN CLEANING
21
SOLUTION.
A. Clean exterior surfaces of pressure gage using cloth dampened with a
on
mixture of cleaning solution (Table 401) and water.

B. Wipe with cloth dampened in clean water.
C. Blow dry with compressed air.
ed
int
6. Valve Release Cable
A. For removal of light to moderate concentrations of dust and dirt, use a

Pr

air.
CAUTION: DO NOT ALLOW SOLVENT TO CONTACT WARNING
FLAG ASSEMBLY OTHERWISE STENCILING MAY BE
REMOVED.
(1). Apply cleaning solvent with a clean cloth.
(2). Blow dry with compressed air.
Page 404
25-65-42 18 Sep 2015
65359
7. Lock Pin Assembly
A. For removal of light to moderate concentrations of dust and dirt, use a

air.
CAUTION: DO NOT ALLOW SOLVENT TO CONTACT WARNING
22
FLAG ASSEMBLY OTHERWISE STENCILING MAY BE
REMOVED.
-20
(1). Clean lock pin assembly using cleaning solvent (Table 401).
-06
(2). Apply solvent with a clean soft cloth or bristle brush for local
areas of oil, dust, or dirt.
21
(3). Immediately remove excess solvent with a cloth and dry using
compressed air.
on
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Page 405, 18 Sep 2015

25-65-42 Page 406, Blank
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21
-06
-20
22
65359
TABLE OF CONTENTS
CHECK
Page
1. System Check 502
2. Leakage Check 502
3. Visual Check: Reservoir and Inflation Assembly Components 503
22
4. Visual Check: Valve/Regulator Assembly 505
-20
-06
21
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Page 501
25-65-42 18 Sep 2015
65359
1. System Check
NOTE: Refer to Table 501 for visual check guidelines of the reservoir
and inflation assembly components.
NOTE: Refer to Table 502 for visual check guidelines of the valve/reg-
ulator and components.
NOTE: Refer to Table 503 for additional valve/regulator assembly
visual inspection checks during 15 year Extended Mainte-
22
nance System checks.
NOTE: When the disposition is replace refer to the Disassembly sec-
-20
tion for the disassembly of the component and to the Assembly
section for the assembly of the component.
A. The work area must be clean and well lighted.
-06
B. The check can be made without the aid of special optical devices,
unless otherwise indicated herein.
21
2. Leakage Check
on
CAUTION: DO NOT IMMERSE PRESSURE GAGE.

A. Check pressure gage (10, IPL Figure 1). If the indicator pointer is to the
ed
left of the movable portion of the green “GO” band, immerse reservoir
and valve/regulator assembly (except the pressure gage) in water.
Check for leaks particularly between the reservoir and valve/regulator
int
assembly and at all valve porting surfaces. Attach a tag indicating loca-
tion of leak(s).
Pr
Discharge reservoir assembly and disassemble in accordance with the

Disassembly section. Inspect and reassemble in accordance with the
Assembly section.
B. If the indicator pointer is within the limits of the movable portion of the
green “GO” band the unit is suitable for service use with no additional
charge necessary. Acceptable pressure exists if any portion of the indi-
cator pointer overlaps the green “GO” band.
C. Perform hydrostatic pressure test on the reservoir in accordance with
the Testing and Fault Isolation section.
Page 502
25-65-42 04 Dec 2018
65359
3. Visual Check: Reservoir and Inflation Assembly Components (Table 501)
COMPONENT CONDITION DISPOSITION
Reservoir
NOTE: Examine in accordance with 49 CFR 180.201 through 180.215

Qualification, maintenance and use of reservoirs, the applicable
22
DOT special permit or specification as identified on the reservoir,
the guidelines CGA C6.2 1988 or subsequent, and this Check sec-
-20
tion for hydrostatic testing (reservoir requalification due date) and
visual checking criteria.
-06
NOTE: Reservoirs shall be requalified in accordance with applicable DOT
requirements.
21
Check the reservoir manu- Remove from service if reser-
facture date on reservoir voir age exceeds service life
label. set in applicable DOT special
on
permit or specification as iden-

tified on the reservoir.
CAUTION: DO NOT MACHINE, FILE, SAND, GRIND, OR BURNISH THE

ed
O-RING SEAT OR BOSS FACE OF THE THREADED PORT.

int
Reservoir Threaded
Port
Pr
NOTE: Inspect interior of reservoir using a borescope or flexible light.

Interior inspection requirements are found in 49 CFR 180.201
through 180.215, CGA C-6 and C-6.1 [3] and [4].
Pressure Gage Stripped and/or damaged Replace pressure gage.

threads, damaged case,
cracked, or broken glass, or
water damage; none permis-
sible.
VISUAL CHECK: RESERVOIR AND INFLATION ASSEMBLY COMPONENTS

Page 503
25-65-42 18 Sep 2015
65359
Valve Release Cable Fraying, corrosion, or kinks Replace valve release cable.
which would impair function.
Inspect ball ends for uniform
spherical shape and integ-
rity. No defects permissible.
22
Lock Pin Assembly Check for secure attachment If attachment is not secure,
of pin and warning flag. replace lock pin assembly.
-20
Pin deformed. Replace lock pin assembly.
Warning Flag Printed instructions not legi- Replace.

Assembly ble. -06
Cable Guide Tube Cracks that impair function. Replace.
21
Cable Guide Nut Cracks, cross threading and Replace.
stripping.
on
VISUAL CHECK: RESERVOIR AND INFLATION ASSEMBLY COMPONENTS

ed
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Page 504
25-65-42 14 Jul 2017
65359
4. Visual Check: Valve/Regulator Assembly (Tables 502 and 503)
Valve/Regulator Perform an external leak- If leakage occurs, replace

age test. discrepant components.
22
Valve Body Cracks and dents which Replace.
impair function or reas-
-20
sembly; none permissible.
Cover Plate Damage, marking illegibil- Replace.

ity; none permissible.
-06
External Threads Minor thread damage (not If leakage occurs, replace
involving the loss of a valve/regulator.
21
complete thread). Per-
form an external leakage
test.
on
Major thread damage Replace valve/regulator.

(involving the loss of one
ed
thread or more).
int
All Other Valve Parts Imperfections which would Replace.

impair function or affect
reassembly and/or reten-
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tion, particularly mating

surfaces and threads;
none permissible.
VISUAL CHECK: VALVE/REGULATOR ASSEMBLY

TABLE 502
Page 505
25-65-42 04 Dec 2018
65359
Adjustment Screw Thread damage. Replace.
Piston Sealing ring groove, dents Replace.

or scratches; none per-
missible.
22
Spring Corrosion. Replace.
-20
Cover Assembly Damage, marking illegibil- Replace.
ity; none permissible.
-06
Loose, detached, or dam- Repair or replace. See
aged pulley bearing Repair section.
(bearing should be
21
bonded to bottom side of
cover assembly plate).
on
Pulley Cable ball recess wear, Replace.

pin and key slot wear;
none permissible.
ed
CAUTION: THESE PARTS ARE CRITICAL REGARDING AIR LEAK-

int
AGE.
NOTE: Ball seat deformation, flattening, consequent to sealing forces

Pr
applied at ball interface is normal and not reason for replace-

ment.
Ball, Ball Seat, Seat Eccentric with recess in Replace.

Recess in Body body, nicks, scratches,
other surface discontinuity.
15 YEAR VALVE/REGULATOR ASSEMBLY INSPECTION

Page 506
25-65-42 04 Dec 2018
65359
CAUTION: THESE PARTS ARE CRITICAL REGARDING AIR

LEAKAGE.
Shaft Slot spread open (dis- Replace.

torted), surfaces
scratched; none permissi-
22
ble.
Shaft Bearing Corrosion, retainer distor- Replace.
-20
tion, balls missing; none
permissible.
Housing
-06
Thread damage, cracks Replace.
and surface scratches;
none permissible.
21
NOTE: Ensure new guide ball B14243-3 is used with new reservoir fit-
tings B45265-3.
on
Valve/Regulator Reser- Ensure new fitting is Replace.

voir Fitting installed per S.I.L. 25-181.
ed
All Other Valve Parts Imperfections which would Replace.

impair function or affect
int
reassembly and/or reten-

tion, particularly mating
Pr
surfaces and threads;

none permissible.
15 YEAR VALVE/REGULATOR ASSEMBLY INSPECTION

Page 507, 04 Dec 2018

25-65-42 Page 508, Blank
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on
21
-06
-20
22
65359
TABLE OF CONTENTS
REPAIR
Page
1. Repair Materials 602
3. Reservoir Repair 603
22
4. Valve Regulator Repair 604
-20
-06
21
on
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Page 601
25-65-42 18 Sep 2015
65359
1. Repair Materials (Table 601)

22
Two Part, 5 Minute Epoxy As Commercially Exterior reservoir
Resin Required Available repair.
-20
Devcon 5  or
(Shelf life of 3 years) Air Cruisers
V70167
Stencil Ink, White As
-06
Sherwin- System Identification.
“Sprayon”  Required Williams Co.
Sprayon
21
Products Div.
V5N004
on
REPAIR MATERIALS
TABLE 601
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Page 602
25-65-42 18 Sep 2015
65359
A. Decision to disassemble for repair is based on presence of leaks, visi-

ble damage, or functional discrepancies discovered in performance of
procedures outlined in Check or Testing and Fault Isolation sections.
Disassemble only to the extent necessary to complete local repair or
replacement. Complete disassembly of all components is neither nec-
essary nor recommended.
B. When disassembly is necessary, replace all O-rings and gaskets.
22
Replacement of other items should be guided by sound examination
criteria, See Check section.
-20
3. Reservoir Repair -06
21
on

ed

int
NOTE: Refer to 49 CFR 180.205 through 180.215 and the applicable

DOT special permit to determine if repair of observed damage
Pr
is authorized and to ensure repair is performed properly.

WARNING: IN NO CASE SHALL A RESERVOIR WHICH HAS BEEN
EXPOSED TO FIRE OR HAS FAILED A HYDROSTATIC
TEST BE REPAIRED. SUCH RESERVOIRS ARE TO BE
CONDEMNED TO PREVENT SUBSEQUENT EQUIP-
MENT DAMAGE AND INJURY TO PERSONNEL
A. Repair exterior area(s) with two part epoxy resin (Table 601) following
epoxy manufacturer’s directions.
B. Perform hydrostatic test per Testing section after any external repair of
the reservoir.
C. If stencil inked lettering becomes obliterated re-stencil using stencil ink
(Table 601). Allow to dry thoroughly.
Page 603
25-65-42 18 Sep 2015
65359
4. Valve Regulator Repair
A. Replace parts that are damaged. (See Check, Disassembly, and

Assembly sections for instructions).
B. For repairs that are required which are not addressed in this document,
call or consult your Zodiac Services Representative for repair and/or
replacement.
22
-20
-06
21
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Page 604
25-65-42 18 Sep 2015
65359
TABLE OF CONTENTS
ASSEMBLY
Page
1. Assembly Materials 702
2. Assembly Equipment 703
3. Assembly Tools 704
22
4. Preparatory Safety Instructions 705
5. Valve/Regulator Assembly 705
-20
A. Assemble Sub-Assemblies 705
B. Assemble Valve/Regulator Section 707
-06
C. Valve/Regulator Section Final Assembly 709
D. Valve/Regulator Leakage Test 709
21
E. Assemble Regulator Section 710
6. Valve/Regulator Assembly Pull Force Test 712
on
7. Regulator Calibration 712

8. Assemble Reservoir and Valve/Regulator Assembly 712
ed
9. Charge Reservoir and Valve/Regulator Assembly 718

10. Reservoir and Valve/Regulator Assembly Leakage Test 730
int
11. Storage Instructions 730

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Page 701
25-65-42 18 Sep 2015
65359
1. Assembly Materials (Table 701)

22
Braycote Micronic As Castrol Internal O-ring lubri-
-20
No. 601 EF * Required Industrial cant.
NA Inc.
V1ZDW6
E.I. Dupont As
-06 E. I. Dupont Exterior O-ring lubri-
Krytox 240AZ * Required V43S57 cant.
21
Dow Corning Molykote 55 * As Dow Corning External O-ring lubri-
(Air Cruisers P/N DC-55M) Required Corporation cant.
V5D028,
on
Air Cruisers
V70167, or
Commercially
ed
Available
Lubricant As McGee Component lubricant.
int
McLube 1720L Required Industries, Inc.

V04672
Pr
Nickel Coated Teflon Tape As Air Cruisers Prevents leakage from

M12243 Required V70167 pipe threaded fittings.
Loctite 242, Loctite 243, As Loctite Sealant applied to
(Removable Threadlocker) Required Corporation screw threads.
or equivalent to V05972 or
MIL-S-46163 Type II Grade N Commercially
Adhesive Available
* Alternatives for external O-ring lubrication only (reference S.I.L. 25-279).
ASSEMBLY MATERIALS
TABLE 701
Page 702
25-65-42 18 Sep 2015
65359
2. Assembly Equipment (Table 702)


22
Vise, Chain Link Type  1 Commercially Immobilizes reservoir
-20
Available and valve assembly
or Air Cruisers during assembly/
P/N 65455-101 maintenance/testing.
Neoprene Strap 1
-06 Commercially Protects reservoir
(711.2 x 101.6 x 3.2 mm) vise.
21
on

nation.
ed
O-Ring (Safety Plug) 1 Air Cruisers Used with safety plug

B14056-910 V70167 to seal valve outlet
int
port to prohibit leak-

age, damage, and
Pr
contamination.
Adapter -Torque Wrench 1 Air Cruisers Used with torque
(Bottle Fitting to Reservoir) V70167 wrench for valve to
B19586-3 reservoir installation.
Master Gage/Adapter 1 Air Cruisers Calibrated pressure
Assembly V70167 readings of reservoir
65425-101 (or equivalent and valve assembly.
gage per 49 CFR 180.205) 
ASSEMBLY EQUIPMENT
TABLE 702
Page 703
25-65-42 18 Sep 2015
65359
3. Assembly Tools (Table 703)

22
Tool Kit- Regulator Adjusting 1 Air Cruisers Adjusts screw in order
-20
Plug to Body V70167 to regulate gas flow
TA03318 from valve assembly.
Filler Valve (with O-ring which
-06 V70167 reservoir and valve
conforms to NAS1611-008) assembly charging.
B19285-1
21
67189-1  V70167 threaded fittings dur-
ing installation.
on

60586-1 V70167 ture/burst disk.
ed

60593-1 V70167 ible/thermal plug.
int

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V2V507 composite pulley.

composite pulley.
* Alternatives
ASSEMBLY TOOLS
TABLE 703
Page 704
25-65-42 14 Jul 2017
65359
4. Preparatory Safety Instructions

22
-20
WARNING: RESERVOIR MUST BE WRAPPED WITH NEOPRENE
STRAP (TABLE 701) PRIOR TO CLAMPING IN VISE TO
-06
PREVENT DAMAGE TO EQUIPMENT OR INJURY TO
PERSONNEL.
21
CAUTION: PRIOR TO INSTALLATION, ENSURE COMPONENT
THREADS ARE FREE OF FOREIGN OBJECTS OR
CONTAMINATION.
on
5. Valve/Regulator Assembly (IPL Figure 2)

ed
A. Assemble Sub-Assemblies
int
CAUTION: DO NOT APPLY PETROLEUM BASED COMPOUNDS TO

O-RINGS.
Pr
CAUTION: USE OF RECOMMENDED O-RING INSTALLATION

TOOLS (TABLE 703) IS ESSENTIAL TO RESERVOIR
AND VALVE PERFORMANCE AND AIR RETENTION
CAPABILITIES.
CAUTION: BRAYCOTE MICRONIC 601EF IS THE ONLY
APPROVED LUBRICANT FOR INTERNAL VALVE COM-
PONENTS.
(1). Liberally coat all external O-rings (150, 180, 200, 220) with a thin
film of Braycote Micronic 601EF, Krytox 240AZ, or Molykote 55
(Table 701).
Page 705
25-65-42 14 Jul 2017
65359
(2). Liberally coat thrust bearing (300), ball seat (360, 360A), flow ball
(250), ball guide (240, 240A), ball spring (230), pawl spring (90),
shaft (260), and shaft O-ring (280) with a thin film of Braycote
Micronic 601EF (Table 701) such that the lubricant can be plainly
seen on all surfaces.
(3). Install O-ring (280) onto shaft (260) using appropriate O-ring tool
from kit (Table 703).
(4). Install back-up ring (270) onto shaft.
22
(5). Lubricate each shim (290) and fill bearing cage of thrust bearing
(300) with Braycote Micronic 601EF (Table 701). Install shim,
-20
thrust bearing (bearing cage face down), shim onto shaft.
CAUTION: ENSURE COUPLING PIN IS NOT DEFORMED OR
SCRATCHED. -06
(6). Press coupling pin (40) into pulley (30A, 30B). Examine to ensure
pin is scratch free and not deformed.
21
CAUTION: DO NOT DAMAGE SEAT DURING INSTALLATION.
NOTE: When the ball seat is installed in the valve body the coined
on
edge, which is identified with black marks, should face toward

the flow ball.
(7). Place a new flow ball seat (360, 360A) in valve body (370). The
ed
coined edge, which is identified with black marks, will face toward
the flow ball.
int
CAUTION: THE PISTON O-RING SHOULD BE INSTALLED ONTO A

CLEAN, DRY, UNLUBRICATED PISTON.
Pr
(8). Coat piston O-ring (350) with an even, light film of Braycote
Micronic 601EF (Table 701), so as to cover the O-ring. Install O-
ring (350) on piston (340) using appropriate O-ring tool (Table
703) and position in groove.
NOTE: Bearing bushing (70) is installed on valve/regulator assemblies
fitted with an aluminum pulley (30, 30A) only.
(9). Install bearing bushing (70) in cover plate (20) with flange on
inside (non-printed side).
(10). Install O-ring (150) on fusible plug (140) using appropriate O-ring
tool from kit (Table 703).
(11). Install O-ring (200) on gage adapter fitting (190) using appropri-
ate O-ring tool from kit (Table 703).
Page 706
25-65-42 14 Jul 2017
65359
(12). Install O-ring (220) on bottle fitting (210A, 210B) using appropri-
ate O-ring tool (Table 703).
(13). Install O-ring (180) on filler valve (160) using appropriate O-ring
tool (Table 703).
(14). Coat first 3 or 4 threads of socket head screws (110) with a small
amount of Loctite 242, Loctite 243, or adhesive per MIL-S-46163
(Table 701).
(15). Install cable adapter (120) onto valve body with socket head
22
screws (110), tighten to 20-30 In. Lb. (2.3-3.4 N-m).
-20
NOTE: Allow 2-3 hours for adhesive to set.
B. Assemble Valve/Regulator Section
(1). For valve/regulator assemblies fitted with an aluminum pulley
-06
(30,30A) only, coat edges of pulley, pawl (50), pawl pivot pin (60),
and inside wall, all around, of pulley housing with thread lubricant
McLube 1720L (Table 701).
21
CAUTION: ENSURE TANGS OF SHAFT ARE PARALLEL (NOT

SPREAD) AND THAT COUPLING PIN IS NOT
on
SCRATCHED OR DEFORMED.
(2). Insert shaft (260) with O-rings, shims, and thrust bearing in valve
body (370) through the gage fitting port. Push the cylindrical por-
ed
tion of the shaft (260) through the center hole at top of valve body.
Press in firmly with a finger; ensure shaft rotates freely.
int
NOTE: Pulley bearing (100) is installed on valve/regulator assemblies

fitted with an aluminum pulley (30, 30A) only.
Pr
(3). Coat the surfaces of the pulley bearing (100) and bearing bonded
to cover plate (20, 20A) with Braycote Micronic (Table 701) and
install pulley bearing (100) by aligning hole in bearing over bush-
ing safety pin (pawl pivot pin).
NOTE: Support shaft from below to avoid dislodging shaft from valve
body.
(4). Install pulley (30A, 30B) into pulley housing by aligning coupling
pin (40) on underside of pulley with slot in shaft (260).
NOTE: Notch on pawl should contact ratchet notches in pulley.
(5). Place pawl spring (90) in hole of pawl (50). Install pawl (50) by
aligning through hole over the pawl pivot pin so spring (90) is
lodged between the wall of the pulley housing and the pawl.
Page 707
25-65-42 14 Jul 2017
65359
NOTE: Tab of cover plate should be in cut out of pulley housing wall.
Pulley stop pin should protrude through curved slot in cover
plate.
(6). Place cover plate assembly (20, 20A) on pulley housing section
of valve.
(7). Install retaining ring (10) into annular groove in pulley housing to
retain cover plate.
(8). Depress the pawl (50) with a 1/8 In. diameter punch through the
22
hole in the pulley housing at decal (380). For valve/regulator
assemblies fitted with an aluminum pulley (30, 30A), insert a 3/16
-20
In. hex key (Allen) wrench into the socket at the center of the pul-
ley. For valve/regulator assemblies fitted with a composite pulley
(30B), insert a standard or offset slotted screwdriver (Table 703)
-06
into the slot at the center of the pulley. Turn pulley until the pulley
stop pin is adjacent to the black triangular index mark (closed
position) on the cover plate. This will locate shaft tang in position
21
to engage slot in flow ball.
(9). Insert flow ball (250) into valve body through the gage fitting port.
on
Align slot in the flow ball (250) with paddle end of the shaft. Solid
face down (over seat) with the small bore facing the filler valve.
(10). Install ball guide (240, 240A) through gage fitting port so cham-
ed
fered side of guide is against the flow ball (250).

(11). Install ball guide spring (230) into counterbore of ball guide and
int
hold into position.

(12). Install bottle fitting (210A, 210B) with O-ring (220) using an open
Pr
end wrench. Tighten per Table 801. Ensure ball guide spring
(230) is centered in gage fitting recess.
(13). Install gage fitting (190) with O-ring (200). Using an open end
wrench tighten per Table 801.
Page 708
25-65-42 14 Jul 2017
65359
C. Valve/Regulator Section Final Assembly

(1). Install rupture disc (130) and tighten per Table 801, using socket
(Table 703) and torque wrench.
(2). Install the fusible plug (140) with O-ring (150) and tighten per
Table 801, using socket (Table 703) and torque wrench.
(3). Install the filler valve (160) with O-ring (180) and tighten per Table
801, using Torque wrench and 3/4 In. crowsfoot.
22
(4). Install pressure gage (10, IPL Figure 1) into the gage fitting per
Paragraph 8.F.
-20
(5). Ensure valve is in the open position. Install ball end of valve
release cable (20, IPL Figure 1) into pulley and cable adapter
(120) until it is pulled into pulley housing.
-06
(6). Depress the pawl (50) with a 1/8 In. diameter punch through hole
in wall of pulley housing at decal (380). For valve/regulator
assemblies fitted with an aluminum pulley (30, 30A), insert a 3/16
21
In. hex key (Allen) wrench into the socket at the center of the pul-
ley. For valve/regulator assemblies fitted with a composite pulley
(30B), insert a standard or offset slotted screwdriver (Table 703)
on
into the slot at the center of the pulley. Turn pulley until the pulley
stop pin is adjacent to the black triangular index mark (closed
position) on the cover plate. Install lock pin assembly (40, IPL Fig-
ed
ure 1) into valve.

NOTE: Ensure lock pin assembly is fully engaged into the housing pul-
int
ley.
(7). Pull on the valve release cable. If it moves, the lock pin is not fully
Pr
engaged.
NOTE: Installation of the inflation cable guide and nut are accom-
plished during applicable folding procedure of the evacuation
system.
(8). Coil and tape excess cable to the reservoir.
D. Valve/Regulator Leakage Test
(1). See Testing and Fault Isolation section.
Page 709
25-65-42 14 Jul 2017
65359
E. Assemble Regulator Section

NOTE: Valve/regulator assembly must be recalibrated after regulator
section has been reassembled, see Paragraph 6, Regulator
Calibration.
CAUTION: THE OUTSIDE OF THE PISTON ALONG WITH THE PIS-
TON BORE SHOULD BE CLEAN AND DRY AND
SHOULD NOT BE LUBRICATED.
(1). Place piston (340) with O-ring (350) in regulator port. Install pis-
22
ton into regulator port as far as it will go.
-20
NOTE: Ensure that the regulator spring is totally recessed into the
adjusting plug body during threading procedure.
(2). Lubricate regulator spring (330) with Braycote Micronic 601EF
(Table 701). -06
(3). Insert regulator spring (330) into the counterbore of the piston
inside the regulator port.
21
NOTE: When adhesive has been applied to the threads of adjusting

screw, calibration and final setting should be performed within
on
approximately six hours. Otherwise, adhesive should be omit-

ted and applied at the time of calibration.
(4). Coat adjusting screw (320) with a thin film of Loctite 242, Loctite
ed
243, or adhesive per MIL-S-46163 (Table 701).

(5). Install adjusting screw (320) using a 3/16 In. hex key (Allen)
int
wrench and the appropriate adjusting tool from kit TA03318

(Table 703) as a predetermined depth gage. Approximate depth
of adjusting screw is 0.031 In. (0.787 mm).
Pr
Page 710
25-65-42 14 Jul 2017
65359
REGULATOR SECTION
22
ADJUSTING
-20
SCREW
O-RING
PISTON
-06
21
SPRING
on
ed
0.031 In. (0.787 mm)

int
Pr
ADJUSTING SCREW
REGULATOR SECTION
FIGURE 701
Page 711
25-65-42 18 Sep 2015
65359
6. Valve/Regulator Assembly Pull Force Test
A. See Testing and Fault Isolation section.
7. Regulator Calibration
22
8. Assemble Reservoir and Valve/Regulator Assembly (Figures 702 through 705)
-20
(IPL Figure 1)
A. Coat O-ring (80) with a thin film of Molykote 55 (Table 701) and install
on valve-to-reservoir connection using appropriate O-ring tool from kit
-06
(Table 703).
B. Coat first three threads of valve bottle fitting with Molykote 55 (Table
21
702).
C. Wrap the reservoir (70) with a neoprene strap (Table 702) prior to
clamping in vise. Immobilize the reservoir in a vise, chain link type
on
(Table 701).
ed
int
Pr
Page 712
25-65-42 18 Sep 2015
65359
22
-20
RESERVOIR
-06
21
O-RING
on
ed
COAT FIRST
int
THREE THREADS
Pr
VALVE/REGULATOR
ASSEMBLY OF RESERVOIR AND VALVE/REGULATOR

FIGURE 702
Page 713
25-65-42 18 Sep 2015
65359
D. Install the valve assembly on to the reservoir and tighten to the value
given in Table 801 using torque wrench adapter (Table 703) and torque
wrench.
22
RESERVOIR
-20
-06 NEOPRENE
STRAP
21
on
ed
int
Pr
VALVE/
REGULATOR
TORQUE WRENCH
CHAIN VISE WITH ADAPTER
ASSEMBLY OF RESERVOIR AND VALVE/REGULATOR

FIGURE 703
Page 714
25-65-42 18 Sep 2015
65359
E. Inspect the pressure gage to verify that, at room temperature - approx-

imately 70°F (21.1°C) - the movable green “GO” band is nearly cen-
tered with respect to the black dot index on the gage face perimeter.
The indicator pointer should be on left edge of red band. If accuracy is
suspect, refer to Paragraph 9.E, pressure gage calibration check.
22
-20
MOVABLE GREEN
“GO” BAND
-06 BLACK INDEX
RED BAND MARK
21
on
ed
INDICATOR
int
GREEN GO
POINT RED NO-GO
P
R E
E V
S
SUR LE
Pr
E PRESSURE
GAGE FACE
PRESSURE GAGE FACE

(ROOM TEMPERATURE)
FIGURE 704
Page 715
25-65-42 18 Sep 2015
65359
F. Pressure gage installation (IPL Figure 1)

(1). Apply nickel coated Teflon tape, M12243 (Table 701), on gage
threads as follows:
(a). Thoroughly clean and degrease male and female threads
assuring the removal of all previously applied anti-seize com-
pound or tape.
CAUTION: IN NO CASE WILL THE TAPE BE PERMITTED TO
EXTEND BEYOND THE FIRST THREAD.
22
NOTE: Apply tension on tape while wrapping.
-20
(b). Wrap tape tightly in direction of the thread spiral of the male
pipe thread beginning with the first thread.
(c). Using care not to contaminate tape, encircle the threads and
-06
join together with a very slight overlap, not more than half of
the tape width.
21
(d). Press tightly on tape. Cut tape using scissors. Ensure tape is
tight and remains at the first thread of fitting. Loose ends are
not permitted. Pipe thread is now ready for joining.
on
(e). If removal of Teflon tape is necessary, hold valve at such an

angle as to ensure that any loose Teflon tape fragments cannot
fall into valve or adjacent components.
ed
(2). Install pressure gage (10) into the valve body, hand tight.
(3). Turn pressure gage 2 to 3 turns beyond hand tight to position/ori-
int
ent gage face as shown in view “A-A”.

Pr
Page 716
25-65-42 18 Sep 2015
65359
22
PRESSURE GAGE
FACE
-20
GREEN GO
RED NO-GO
P
R E
E V
S
SUR
E LE
-06
FILLER
VALVE
21
A
VIEW “A-A”
on
A PRESSURE
GAGE
ed
GAGE THREADS
int
GAGE ADAPTER
FITTING
Pr
FILLER VALVE
PRESSURE GAGE INSTALLATION

FIGURE 705
Page 717
25-65-42 18 Sep 2015
65359
9. Charge Reservoir and Valve/Regulator Assembly (IPL Figure 1)
WARNING: ENSURE THE RESERVOIR AND VALVE/REGULATOR

ASSEMBLY IS EMPTY. EXCESSIVE CHARGING MAY
LEAD TO EQUIPMENT DAMAGE AND/OR INJURY TO
PERSONNEL.
A. Install safety plug (Figure 706)
(1). Wrap the reservoir with a neoprene strap (Table 702).
22
(2). Immobilize the reservoir and valve/regulator assembly in a vise,
chain link type (Table 702).
-20
(3). Install safety plug (Table 702) in outlet port of valve/regulator until
O-ring contacts valve port.
(4). Remove the lock pin. -06
21
on
ed
int
Pr
Page 718
25-65-42 18 Sep 2015
65359
22
RESERVOIR
-20
NEOPRENE
STRAP
-06
21
VALVE/
REGULATOR
on
ed
LOCK PIN
int
Pr
CHAIN VISE
SAFETY PLUG
INSTALL SAFETY PLUG AND O-RING

FIGURE 706
Page 719
25-65-42 18 Sep 2015
65359
B. Arm valve/regulator (Figure 707)

(1). Rotate reservoir in chain vise until pulley housing is facing up.
(2). For valve/regulator assemblies fitted with an aluminum pulley (30,
30A, IPL Figure 2), insert a 3/16 In. hex key (Allen) wrench into
the socket at the center of the pulley. For valve/regulator assem-
blies fitted with a composite pulley (30B, IPL Figure 2), insert a
standard or offset slotted screwdriver (Table 703) into the slot at
the center of the pulley. Slowly rotate pulley until stop pin is at
22
opposite end of its arc of motion.
(3). Insert ball end of valve release cable (20) through the cable
-20
adapter port into the recess in the pulley.
(4). Depress ratchet pawl through hole in pulley housing using 1/8 In.
diameter punch and rotate pulley to the left to stop (mark). The
-06
cable will be pulled approximately 3 In. (76 mm) into the valve.
NOTE: Installation of the cable guide assembly is accomplished dur-
21
ing folding procedure of the evacuation slide.
WARNING: ENSURE LOCK PIN IS FULLY ENGAGED INTO THE
HOUSING PULLEY TO PREVENT ACCIDENTAL DIS-
on
CHARGE OF PRESSURIZED GAS.

(5). Install lock pin assembly (40) into valve.
ed
(6). Gently pull on valve release cable. If it moves the lock pin is not
fully engaged.
int
(7). Coil and tape excess cable to the reservoir.

Pr
Page 720
25-65-42 14 Jul 2017
65359
VALVE/REGULATOR ASSEMBLIES VALVE/REGULATOR ASSEMBLIES

FITTED WITH ALUMINUM PULLEY FITTED WITH COMPOSITE PULLEY
DIRECTION
OF TURN
HEX KEY SCREWDRIVER
22
(SOCKET) (SLOT)
-20
-06 LOCK PIN
LOCK PIN
21
SHOULDER
CABLE
on
ADAPTER
ed
int
TAPE
Pr
STOP PIN
VALVE/REGULATOR
RESERVOIR
VALVE
RELEASE CABLE
ARM VALVE/REGULATOR ASSEMBLY

FIGURE 707
Page 721
25-65-42 18 Sep 2015
65359
C. Charge with CO2 (Figure 708)

(1). Remove reservoir and valve from chain vise.
(2). Place the reservoir and valve on scale and note tare weight.
(3). Remove the high pressure cap from the filler valve and attach the
charging line and adapter (Table 703) to the filler valve.
NOTE: Use a compressor equipped with a 20-micron filter and a mois-
ture and oil separator.
22
CAUTION: RATE OF CHARGE IS NOT TO EXCEED 0.05 LB./SEC-
OND.
-20
(4). With the charging line secured to the filler valve, loosen the valve
nut 2 1/4 turns and pressurize the reservoir with CO2 to the
charge weight specified in Table 704.
-06
(5). Check reservoir and valve/regulator weight for CO2 charge. If
excessive, disconnect the charging line and bleed to proper
21
weight by slowly loosening the filler valve nut, then retighten nut.
on
CO2 N2 ALLOWABLE
RESERVOIR AND ALLOWABLE
CHARGE CHARGE TOTAL N2 ABOVE
VALVE/REGULATOR CO2 AND N2
-0.00 LB. MINIMUM WEIGHT MINIMUM
ed
ASSEMBLY BLEED OFF

+0.02 LB. WEIGHT WEIGHT
int
65359-101 0.44 Lb. 1.06 Lb. 1.5 Lb. 0.10 Lb. 0.10 Lb.
(0.19 kg) (0.48 kg) (0.68 kg) (0.04 kg (0.04 kg)
Pr
CHARGE VALUES
TABLE 704
Page 722
25-65-42 14 Jul 2017
65359
RESERVOIR CHOCKS
BONDED TO SCALE
22
(TYPICAL 4 PLACES) RESERVOIR AND
VALVE/REGULATOR
-20
-06 LOCK PIN
21
on
ed
int
Pr
HIGH PRESSURE FILLER VALVE

CAP WITH ADAPTER
SCALE
CHARGING LINE
CHARGE RESERVOIR AND VALVE/REGULATOR

FIGURE 708
Page 723
25-65-42 18 Sep 2015
65359
D. Charge with Nitrogen (Table 704)

(1). Attach the nitrogen charging line and adapter (Table 703) to the
filler valve. Open filler valve using two 3/4 In. wrenches.
CAUTION: DO NOT EXCEED THE NITROGEN CHARGE SPECI-
FIED IN TABLE 704.
CAUTION: RATE OF CHARGE IS NOT TO EXCEED 50 psig (34.5
N/cm2) PER SECOND.
22
NOTE: Use a compressor equipped with a 20-micron filter and a mois-
ture and oil separator.
-20
(2). Pressurize the reservoir and valve/regulator with nitrogen to the
minimum weight specified in Table 704.
NOTE: To reduce time required to charge the reservoir and valve/reg-
-06
ulator, reservoir may be immersed in water (Figure 709) during
charging as follows.
21
CAUTION: DO NOT SUBMERGE THE VALVE/REGULATOR OR
PRESSURE GAGE.
(a). Immerse reservoir in tank, see Figure 709.
on
(b). Pressurize the reservoir and valve/regulator as noted in Table

704.
ed
(3). After charging close the filler valve using two 3/4 In. wrenches
(Table 703) and remove charging line and adapter.
int
NOTE: Allowable bleed off is not to exceed the weight specified in

Table 704.
Pr
(4). If the charge weight is excessive, bleed to proper weight using

two 3/4 In. open end wrenches.
Page 724
25-65-42 18 Sep 2015
65359
22
PERSONNEL
-20
PROTECTIVE SHIELD
-06
SUPPORT AROUND NECK
OF IMMERSED RESERVOIR
21
CHARGING LINE
(NITROGEN)
on
ed
int
COOLING WATER
Pr
WATER IMMERSION TANK FOR RESERVOIR CHARGING

FIGURE 709
Page 725
25-65-42 18 Sep 2015
65359
E. Pressure gage calibration check (Figure 710; Tables 705 and 706)
(1). Allow the charged reservoir assembly to stabilize at normal room
ambient temperature of 70°F (21.1°C) for a minimum of six hours.
(2). Wrap the reservoir with a neoprene strap (Table 702) prior to
clamping in vise. Immobilize the reservoir in a vise, chain link type
(Table 702).
NOTE: Use a pressure indicating device, master gage/adapter assem-
bly (Table 702), in accordance with 49 CFR 180.205.
22
(3). If ambient temperate is not 70°F (21.1°C), correct the pressure
-20
gage reading to determine the pressure reading which would
result at 70°F (21.1°C), see Table 705 or 706.
(4). If corrected pressure reading (after initial charge to minimum
-06
weights) is below 2950 psig (2034 N/cm2), add nitrogen, not more
than specified in Table 704, to bring the pressure up to a mini-
mum of 2950 psig (2034 N/cm2). If the pressure remains less
21
than 2950 psig (2034 N/cm2) after addition of N2, discharge the
reservoir and recharge per Paragraphs 9.A through 9.D.
on
(5). In no case shall this pressure exceed the marked service pres-
sure on the reservoir.
The pressure is measured as follows:
ed
(a). Attach master gage/adapter assembly, 65425-101 (Table 702),

to filling port on valve.
int
CAUTION: ENSURE CONNECTIONS ARE TIGHT PRIOR TO PRO-

CEEDING.
Pr
(b). Slowly loosen the filler valve nut until gage readout has stabi-
lized.
(c). Record reading and tighten the filler valve nut.
(d). Slowly crack open master gage/adapter assembly to bleed off
gas in gage.
(e). Remove master gage/adapter assembly.
Page 726
25-65-42 14 Jul 2017
65359
NOTE: Transient pressure excursions outside of the green “GO” band,

of up to on-half of the band width are acceptable (either on the
low side or the high side).
(6). System gage check - If the pressure reading results in the indica-
tor pointer of the pressure gage being below the green “GO”
band, accuracy of the gage is suspect. Verify that gas charge
weights are correct. If charge is correct, discharge the cylinder
and replace the gage. Recharge cylinder per Paragraphs 9.A
22
through 9.D. The indicator pointer may rest above the green “GO”
band provided the above charges are verified.
-20
(7). To close filler valve, secure the inner nut of the filler valve with a
3/4 In. wrench, and torque the outer nut with a 3/4 In. crowsfoot
and torque wrench per Table 801.
F.
-06
Perform the Leakage Test per Paragraph 10.
21
on
MOVABLE GREEN
“GO” BAND
BLACK MARK
INDEX
ed
RED BAND
int
Pr
GREEN GO
RED NO-GO INDICATOR POINTER
P
PRESSURE R E
ES V PREFERRED POSITION
GAGE FACE SUR LE
E AFTER CHARGING
PRESSURE GAGE FACE

FIGURE 710
Page 727
25-65-42 14 Jul 2017
65359
Degree 0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9
60 120 119 118 116 115 114 113 112 110 109
61 108 107 106 104 103 102 101 99.6 98.4 97.2
62 96 94.8 93.6 92.4 91.2 90 88.8 87.6 86.4 85.2
63 84 82.8 81.6 80.4 79.2 78 76.8 75.6 74.4 73.2
64 72 70.8 69.6 68.4 67.2 66 64.8 63.6 62.4 61.2
65 60 58.8 57.6 56.4 55.2 54 52.8 51.6 50.4 49.2
22
66 48 46.8 45.6 44.4 43.2 42 40.8 39.6 38.4 37.2
67 36 34.8 33.6 32.4 31.2 30 28.8 27.6 26.4 25.2
-20
68 24 22.8 21.6 20.4 19.2 18 16.8 15.6 14.4 13.2
69 12 10.8 9.6 8.4 7.2 6 4.8 3.6 2.4 1.2
70 0 -1.2 -2.4 -3.6 -4.8 -6 -7.2 -8.4 -9.6 -11
71
72
-12
-24
-13
-25
-14
-26
-16
-28
-06
-17
-29
-18
-30
-19
-31
-20
-32
-22
-34
-23
-35
73 -36 -37 -38 -40 -41 -42 -43 -44 -46 -47
21
74 -48 -49 -50 -52 -53 -54 -55 -56 -58 -59
75 -60 -61 -62 -64 -65 -66 -67 -68 -70 -71
76 -72 -73 -74 -76 -77 -78 -79 -80 -82 -83
on
77 -84 -85 -86 -88 -89 -90 -91 -92 -94 -95
78 -96 -97 -98 -100 -101 -102 -103 -104 -106 -107
79 -108 -109 -110 -112 -113 -114 -115 -116 -118 -119
ed
80 -120 -121 -122 -124 -125 -126 -127 -128 -130 -131
81 -132 -133 -134 -136 -137 -138 -139 -140 -142 -143
int
82 -144 -145 -146 -148 -149 -150 -151 -152 -154 -155
83 -156 -157 -158 -160 -161 -162 -163 -164 -166 -167
84 -168 -169 -170 -172 -173 -174 -175 -176 -178 -179
Pr
85 -180 -181 -182 -184 -185 -186 -187 -188 -190 -191
RESERVOIR PRESSURE CORRECTION CHART FOR 70°F
Instruction for calculating corrected pressure value:

1) Obtain temperature reading from thermometer.
2) Look up reservoir pressure correction value in the chart for temperature reading.
3) Add or subtract the value from the chart to or from the gage’s pressure reading.
Example:
1) Temperature from thermometer = 71.5°F
2) Value in chart for 71.5°F = -18 PSI
3) Pressure reading from gage = 3000 PSI
Corrected Pressure for 70°F = 3000 PSI - 18 PSI = 2982 PSI
TABLE 705
Page 728
25-65-42 18 Sep 2015
65359
Degree Degree N/cm2

F C
60 15.6 83
61 16.1 74
62 16.7 66
63 17.2 58
64 17.8 50
22
65 18.3 41
66 18.9 33
-20
67 19.4 25
68 20.0 17
69 20.6 8
70
71
21.1
21.7
-06 0
-8
72 22.2 -17
21
73 22.8 -25
74 23.3 -33
75 23.9 -41
on
76 24.4 -50
77 25.0 -58
78 25.6 -66
ed
79 26.1 -74
80 26.7 -83
int
81 27.2 -91
82 27.8 -99
83 28.3 -108
Pr
84 28.9 -116
85 29.4 -124
RESERVOIR PRESSURE CORRECTION CHART FOR 21.1°C
Instruction for calculating corrected pressure value:

1) Obtain temperature reading from thermometer.
2) Look up reservoir pressure correction value in the chart for temperature reading.
3) Add or subtract the value from the chart to or from the gage’s pressure reading.
Example:
1) Temperature from thermometer = 22.8°C
2) Value in chart for 22.8°C = -25 N/cm2
3) Pressure reading from gage = 2,068 N/cm2
Corrected Pressure for 21.1°C = 2,068 N/cm2 - 25 N/cm2 = 2,043 N/cm2
TABLE 706
Page 729
25-65-42 14 Jul 2017
65359
10. Reservoir and Valve/Regulator Assembly Leakage Test (IPL Figure 1)
11. Storage Instructions

TO PERSONNEL, HANDLE THE RESERVOIR/VALVE
22
ASSEMBLY WITH EXTREME CARE SINCE IT CON-
TAINS HIGH PRESSURE STORED GAS.
-20
A. Store reservoir assembly in clean protective container.
B. Permissible storage temperature extremes for extended periods are
-40° to + 160°F (-40° to +71.1°C). However, it is desirable to maintain
-06
assembly at normal room conditions, temperatures of 75° ± 15°F
(23.9° ± 8.3°C).
21
NOTE: Storage outside of allowable conditions may activate pressure
relief devices (Frangible Discs and/or Fusible Plugs if so
equipped).
on
C. A periodic check of the reservoir and valve assembly pressure is rec-

ommended particularly when equipment is subjected to extremes of
permissible storage conditions.
ed
D. Handling should be minimized. Exercise reasonable care and precau-

tions necessary for treatment of high-pressure gas storage equipment.
int
E. Individual components should be protected by suitable dust and mois-

ture free packing such as polyethylene bags.
Pr
F. For shipment, pack the reservoir and valve assembly in protective con-
tainer suitably marked in accordance with best commercial shipping
practices. Observe all Department of Transportation (DOT, U. S. A.)
requirements for shipment of charged reservoirs.
Page 730
25-65-42 18 Sep 2015
65359
TABLE OF CONTENTS
FITS AND CLEARANCES
Page
1. Torque Wrench Instructions 802
2. Torque Limits 802
22
-20
-06
21
on
ed
int
Pr
Page 801
25-65-42 18 Sep 2015
65359
1. Torque Wrench Instructions
CAUTION: DO NOT EXCEED TORQUE VALUE NOTED. IF MAXI-

MUM TORQUE IS EXCEEDED, THREAD COULD BE
DAMAGED AND/OR SEALING SURFACES DISTORTED.
A. Torque wrenches must be calibrated at frequent intervals using weights
and a measured lever arm to preclude inaccuracies due to mishandling
or considerable usage. Do not check one wrench against another.
22
2. Torque Limits
-20
ITEM/DESCRIPTION
-06 TORQUE TORQUE
MINIMUM MAXIMUM
Valve/Regulator to Reservoir 264 In. Lb. 276 In. Lb.
21
22 Ft. Lb. 23 Ft. Lb.

(29.8 N-m) (31.2 N-m)
on
Bottle Fitting 528 In. Lb. 624 In. Lb.

44 Ft. Lb. 52 Ft. Lb.
(59.7 N-m) (70.5 N-m)
ed
Outlet Port Plug Hand tight.

int
Fusible Plug 120 In. Lb. 144 In. Lb.

10.0 Ft. Lb. 12.0 Ft. Lb.
(13.6 N-m) (16.3 N-m)
Pr
Rupture Disc 180 In. Lb. 204 In. Lb.

15.0 Ft. Lb. 17.0 Ft. Lb.
(20.3 N-m) (23.0 N-m)
Filler Valve (Installation) 120 In. Lb. 144 In. Lb.
10.0 Ft. Lb. 12.0 Ft. Lb.
(13.6 N-m) (16.3 N-m)
Filler Valve (Closure) 80 In. Lb. 100 In. Lb.
6.7 Ft. Lb. 8.3 Ft. Lb.
(9.0 N-m) (11.3 N-m)
TORQUE LIMITS
Page 802
25-65-42 14 Jul 2017
65359
TORQUE TORQUE
ITEM/DESCRIPTION
MINIMUM MAXIMUM
Pressure Gage Fitting 180 In. Lb. 204 In. Lb.
15.0 Ft. Lb. 17.0 Ft. Lb.
(20.3 N-m) (23.0 N-m)
Hose to Valve/Regulator 180 In. Lb. 300 In. Lb.
15 Ft. Lb. 25.0 Ft. Lb.
22
(20.3 N-m) (33.9 N-m)
High Pressure Chuck to Valve/Regulator 456 In. Lb. 492 In. Lb.
-20
38 Ft. Lb. 41 Ft. Lb.
(51.5 N-m) (55.6 N-m)
TORQUE LIMITS
-06
21
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Page 803, 14 Jul 2017

25-65-42 Page 804, Blank
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21
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-20
22
65359
TABLE OF CONTENTS
SPECIAL TOOLS, FIXTURES, AND EQUIPMENT
Page
2. Special Tools, Fixtures, and Equipment 902
22
3. Special Tools, Fixtures, and Equipment Illustrated 905
-20
-06
21
on
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Page 901
25-65-42 18 Sep 2015
65359
A. The tools, fixtures, and equipment listed in Table 901 and shown in Fig-
ures 901 through 905 are recommended for use during Test Opera-
tions, Disassembly, Cleaning, Repairs, and Assembly.
2. Special Tools, Fixtures, and Equipment (Table 901)
22
-20
with the following symbol .
-06
Borescope or Flexible Fiber- 1 Lenox Instru- Used to visually inspect
21
Optic Light Source  ment Co. reservoir interior. (Test-

FLS 150 V35733 or ing)
on
Commercially
Available
Adapter - For Hydrostatic 1 Air Cruisers Attaches reservoir to
ed
Testing V70167 hydrostatic test equip-

C19848-3 ment. (Testing)
int
Vise, Chain Link Type 1 Air Cruisers Immobilizes reservoir

65455-101  V70167 and valve assembly
during assembly/main-
Pr
tenance/testing. (Test-
ing, Disassembly,
Assembly)
Neoprene Strap 1 Commercially Protects reservoir while
28 x 4 x 1/8 In. Available immobilized in vise.
(711.2 x 101.6 x 3.2 mm) (Testing, Disassembly,
Durometer #80-85  Assembly)
Page 902
25-65-42 14 Jul 2017
65359

Hydrostatic Test Equipment 1 Hydro-Test Hydrostatically tests
500-HP-18S-M Products reservoirs. (Testing)
(or test equipment per V56043 or
49 CFR 180.205(g)) Commercially
Available
67189-1 
22
V70167 threaded fittings during
installation. (Testing,
Assembly)
-20
High Pressure Chuck 1 Air Cruisers Mounting apparatus for
TO3840 V70167 valve/regulator assem-
-06 bly/testing. (Testing)
Filler Valve (with O-ring V70167 reservoir and valve
21
which conforms to NAS1611- assembly charging.
008) (Testing, Assembly)
B19285-1
on
Soft Bristle Brush  1 Commercially Applies leak test solu-

Available tion. (Testing)
ed
Force Gage, 1 Commercially Determines valve actu-

Push/Pull Gage Available ating pull force. (Test-
int
0-50 Lb. (0-22.7 kg) with 0.5 ing)

Lb. (0.2 kg) graduations 
Pr
Calibration Fixture 1 Air Cruisers Mounting apparatus for

65011-101 V70167 valve regulator calibra-
tion. (Testing)
nation. (Testing, Disas-
sembly, Assembly)
Page 903
25-65-42 18 Sep 2015
65359

V2V507 composite pulley. (Test-
ing, Assembly)
22
composite pulley. (Test-
ing, Assembly)
-20
Adapter -Torque Wrench 1 Air Cruisers Used with breaker bar
(Reservoir Fitting to Reser- V70167 to disengage valve
voir) from reservoir. (Disas-
B19586-3 -06 sembly, Assembly)
60586-1 V70167 ture/burst disk. (Disas-
21
sembly, Assembly)
on
60593-1 V70167 ible/thermal plug. (Dis-

assembly, Assembly)
Stiff Bristle Brush  1 Commercially Application of solutions/
ed
Available solvents. (Cleaning)

Soft Bristle Brush  1 Commercially Application of solutions/
int
Available solvents. (Cleaning)

Master Gage/Adapter 1 Air Cruisers Calibrated pressure
Pr
Assembly V70167 readings of reservoir

65425-101 (or equivalent and valve assembly.
gage per 49 CFR 180.205)  (Assembly)
Tool Kit- Regulator Adjusting 1 Air Cruisers Adjusts screw in order
Plug to Body V70167 to regulate gas flow
TA03318 from valve assembly.
(Assembly)
* Alternatives
Page 904
25-65-42 14 Jul 2017
65359
3. Special Tools, Fixtures, and Equipment Illustrated
TORQUE WRENCH
ADAPTER (B19586-3)
22
-20
-06
21
CHARGING ADAPTER
on
(B19285-1)
ed
int
FORCE GAGE
Pr
(PUSH/PULL)
SPECIAL TOOLS, FIXTURES, AND EQUIPMENT ILLUSTRATED

FIGURE 901
Page 905
25-65-42 18 Sep 2015
65359
22
-20
-06
21
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CHAIN VISE
Pr

FIGURE 902
Page 906
25-65-42 18 Sep 2015
65359
NEOPRENE STRAP
22
-20
-06
21
MASTERGAGE/ADAPTER
(65425-101)
on
ed
int
Pr
SAFETY PLUG
(VALVE OUTLET PORT)
(AN 814-10 OR AS5169-10)

FIGURE 903
Page 907
25-65-42 18 Sep 2015
65359
22
-20
HIGH PRESSURE
CHUCK (TO3840)
-06
21
O-RING TOOL
(TYP.)
on
ed
int
Pr
HYDROSTATIC TEST
ADAPTER (C19848-3)

FIGURE 904
Page 908
25-65-42 18 Sep 2015
BAFFLE
BAFFLE
SUPPORT
FIXTURE
ASPIRATOR
ASSEMBLY
Pr
int
CABLE, 4 CONDUCTOR,
RECORDER
ed
24 GA. SHIELDED
(2 CHANNEL) PRESSURE
TRANSDUCER
on
65359
HOSE ASSEMBLY
21
FIGURE 905
25-65-42
-06
O-RING
-20
RESERVOIR AND
VALVE ASSEMBLY
22
CHAIN VISE
NEOPRENE
STRAP

RESERVOIR
SUPPORT
Page 910, Blank

Page 909, 18 Sep 2015
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21
-06
-20
22
65359
TABLE OF CONTENTS
ILLUSTRATED PARTS LIST
Page
1. General 1002
2. Material Arrangement 1002
3. How to Use the Parts List 1004
22
4. List of Abbreviations/Symbols/Terms/Definitions 1005
5. Vendor Codes 1007
-20
6. Numerical Index 1008
7. Detailed Parts List 1008
-06
21
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Page 1001
25-65-42 18 Sep 2015
65359
1. General
This illustrated parts list (IPL) contains the complete listing of all replaceable parts
of the inflation system.
2. Material Arrangement
This IPL is comprised of the following sections.
22
A. Introduction
The introduction contains all the information necessary for the use of
-20
this IPL. It also contains a list of abbreviations used in the detailed
parts list, and a list of manufacturer codes, names, and addresses.
B. Numerical Index -06
This section has a list of all part numbers in the detailed parts list in
alpha-numerical sequence with cross-reference to the IPL Fig./Item
21
numbers as well as the quantity.
Sequence as follows:
on
(1). Letters A through Z (“O” to be considered zero).

(2). Numerals 0 through 9.
ed
C. Detailed Parts List

The detailed parts list illustrates all parts attached by means other than
int
riveting, sewing, or cementing. Parts attached by these means are

included when the next higher assembly is replaced.
(1). Column FIG/ITEM
Pr
The first number in the first line of a page indicates the number of
the first figure illustrating the part. The second number indicates
the item number by which the part is identifiable on the illustra-
tion. A dash (-) placed before the item number indicates that the
part is not illustrated.
(2). Column PART NUMBER
The part number column contains the original manufacturer part
number. When standard parts are used, the standard part num-
ber is listed in this column.
(3). Column AIRLINE PART NUMBER
This column is left blank for airline use.
Page 1002
25-65-42 18 Sep 2015
65359
(4). Column NOMENCLATURE

(a). Indenture System
The indenture system shows the relationship of parts and
assemblies to next higher assemblies or installations, as fol-
lows:
1234567
22
Assembly or installation assembly (RF) number
Attaching parts for assembly or installation
-20
.Detail parts for assembly
Sub-assembly -06
Attaching parts for sub assembly
21
..Detailed parts for sub-assembly
Sub-sub-assembly
Attaching parts for sub-sub-assembly
on
...Detailed parts for sub-sub-assembly

ed
(b). Attaching Parts

Attaching parts are captioned ATTACHING PARTS and are
int
listed immediately following the parts attached. The *** symbol

follows the last item of the attaching parts group.
Pr
(c). Vendor Code

Parts manufactured by companies other than Air Cruisers are
identified by an appropriate vendor code following the nomen-
clature. Vendor codes are in accordance with current issues of
Federal Supply Codes for Manufacturers Catalog handbooks
H4-1, H4-2, and H4-3, and are preceded by the letter “V”.
Standard parts such as AN, MS, etc. are not identified by ven-
dor code.
Page 1003
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65359
(5). Column EFF CODE

The Effectivity Code Column establishes part relationships with
units or assemblies which are essentially the same but have
minor deviations. These units or assemblies are assigned refer-
ence letters such as A, B, C, etc. Parts which are not common to
all configurations but are associated with one or more of the
coded lead items carry the letter or letters assigned to the lead
item with which it is associated. Where a part is common to all
22
lead items, the effectivity column is left blank.
(6). Column UNITS PER ASSEMBLY
-20
This column contains the quantity of a specific catalog sequence
numbered part required in the build sequence of only one (where
more than one exists), next higher sub-sub-assembly, sub-
-06
assembly, assembly or installation level as applicable. For bulk
items, the letters “AR” are inserted in the quantity column to indi-
cate “as required”. Where items are listed for reference purposes,
21
“RF” is inserted.
on
3. How to Use the Parts List
A. The part number is known

ed
(1). Find the part number in the Numerical Index. Note the Figure and
item number.
int
(2). Turn to the Figure.

(3). Locate the part on the illustration and in the parts list by item
Pr
number.
B. The part number is unknown
(1). Refer to the applicable Figure and look for the illustration of the
part.
(2). Note the item number.
(3). Turn to the applicable parts list and refer to the corresponding
item number.
Page 1004
25-65-42 18 Sep 2015
65359
4. List of Abbreviations/Symbols/Terms/Definitions
A. Abbreviations, Symbols
The following abbreviations/symbols are the more commonly used in
this IPL. This list is to be used in conjunction with the Glossary of
Abbreviations and Symbols, Introduction section.
22
AR As Required NO. Number
ASSY. Assembly NP Not Procurable
-20
BKDN Breakdown R Revised
CMM Component RF.
-06 Reference
Maintenance Manual
EFF. Effectivity R.H. Right Hand
21
FIG. Figure R.S. Right Side
IPL Illustrated Parts List SUBS Subsequent
on
L.H. Left Hand *** End of Attaching Hardware

L.S. Left Side - Item Not Illustrated
ed
NHA Next Higher Assembly  Denotes Intentionally Left

Blank
int
Pr
Page 1005
25-65-42 18 Sep 2015
65359
B. Interchangeability Terms, Abbreviations, and Definitions
TERM ABBREVIATION DEFINITION
Superseded SUPSD BY The part is superseded by and is one-way inter-

by changeable with the item number shown (old
part number can be used as replacement only
22
where old part number was installed).
Supersedes SUPSDS The part supersedes and is one-way inter-
-20
changeable with the item number shown (new
part number is acceptable replacement for old or
new part number).
Service SB PRE
-06
Identifies when a service bulletin (SB) has an
Bulletins SB POST effect on a part. PRE shows the condition of the
part before the work in the service bulletin is
21
done; POST shows the condition after the work

is done.
on
Alternate ALT The part agrees with all functional and structural
specifications, but the external dimensions, con-
nection installation, and/or mounting provisions
ed
are different. Rework or possible changes can

be necessary.
int
Replaced by REPLD The part is replaced and is two-way interchange-

able with the item number shown (old part num-
Pr
ber can replace either old or new part number

when removed).
Replaces REPLS The part replaces and is two-way interchange-
able with the item number shown (new part num-
ber is acceptable replacement for old or new
part number).
Page 1006
25-65-42 18 Sep 2015
65359
5. Vendor Codes
Table 1001 lists the CAGE code for vendors whose code appears in all
chapters of the CMM and also listed in the Nomenclature Column of
the Detailed Parts List. Absence of a vendor code following a part num-
ber in the Detailed Parts List identifies an Air Cruisers part.
22
CODE NAME/ADDRESS
V70167 Air Cruisers
-20
1747 State Route 34
Wall Township, NJ 07727-3935 USA
V4KNS6
-06
Krylon Products Group
101 West Prospect Avenue
21
Cleveland, OH 44115-1093 USA
V35733 Lenox Instrument Company, Incorporated
265 Andrews Road
on
Trevose, PA 19053-3427 USA

V56043 Hydro-Test Products, Incorporated
ed
85 Hudson Road
Stow, MA 01775-1254 USA
int
V43S57 E. I. Dupont De Nemours and Company

Dupont Performance Lubricants
4301 Lancaster Pike BMP 23/2324
Pr
Wilmington, DE 19805-1521 USA

V5D028 Dow Corning Corporation
3901 S. Saginaw Road
Midland, MI 48640-5670 USA
V1ZDW6 Castrol Industrial, N.A. Incorporated
149 South Grant Street
North Aurora, IL 60542-1603 USA
VENDOR INFORMATION
Page 1007
25-65-42 14 Jul 2017
65359
CODE NAME/ADDRESS
V2V507 McMaster-Carr Supply Company
200 New Canton Way
Robbinsville, NJ 08691-2343 USA
V5N004 Sherwin-Williams Company,
Sprayon Products Division
3818 Coronado Street
22
Anaheim, CA 92807-1620 USA
V05972 Loctite Corporation
-20
1001 Henkel Way
Rocky Hill, CT 06067-3582 USA
V01195 Organic Products Company
-06
1963 East Irving Boulevard
Irving, TX 75060-4555 USA
21
V04963 3M Company
3M Center
Saint Paul, MN 55144-1001 USA
on
VENDOR INFORMATION
ed
int
Pr
6. Numerical Index
A. Numerical index listed on pages 1009 through 1010.
7. Detailed Parts List
A. Detailed parts listed on pages 1012 through 1020.
Page 1008
25-65-42 14 Jul 2017
65359
AIRLINE IPL TOTAL

PART NUMBER ITEM
PART NUMBER FIGURE REQUIRED
B13966-1 2 250 1
B13968-1 2 10 1
B13969-1 2 300 1
B13975-1 2 290 2
B13976-1 2 20A 1
22
B13977-1 2 100 2
B13978-1 2 70 1
-20
B13979-1 2 260 1
B13984-3 2 140 1
B14052-1 2 120 1
B14056-008
B14056-015
-06 2
2
280
180
1
1
B14056-112 2 350 1
21
B14056-906 2 150 1
B14056-908 2 200 1
B14056-910 1 80 1
on
B14056-914 2 220 1
B14242-1 2 370 1
B14243-1 2 240 1
ed
SUPSD BY B14243-3
B14243-3 2 240A 1
SUPSDS B14243-1
int
B14245-1 2 90 1
B14246-1 2 360 1
Pr
B14247-1 2 230 1
B14250-1 2 340 1
B14251-1 2 330 1
B14252-1 2 320 1
B14253-1 2 60 1
B14256-1 2 210 1
SUPSD BY B45265-1
B14268-1 2 130 1
B14422-1 2 50 1
B14427-1 2 190 1
B14428-1 2 380 1
B14482-1 2 80 1
B14485-1 2 400 1
Page 1009
25-65-42 14 Jul 2017
65359
AIRLINE IPL TOTAL

PART NUMBER ITEM
PART NUMBER FIGURE REQUIRED
B14487-1 2 390 1
B14490-1 2 20 1
B15373-1 2 30 1
SUPSD BY B42013-1
B19007-1 2 310 1
B42013-1 2 30A 1
22
SUPSDS B15373-1
SUPSD BY B55396-1
B42099SP5 2 360A 1
-20
B45265-1 2 210A 1
SUPSDS B14256-1
SUPSD BY B45265-3 -06
B45265-3 2 210B 1
SUPSDS B45265-1
B55396-1 2 30B 1
21
SUPSDS B42013-1
C17849-107 1 10 1
on
C19784-101 1 50 1
D17961-103 1 40 1
D18306-101 1 60 1
ed
2 1 RF
MS20813-1 2 170 1
1000-0030-8 2 280 1
int
1000-0030-15 2 180 1
1000-0030-112 2 350 1
Pr
1000-0030-906 2 150 1
1000-0030-908 2 200 1
1000-0030-914 2 220 1
1002-0030-008 2 270 1
1003-0005-293 2 40 1
1005-0009-093 2 110 2
1054-0001-002 2 160 1
15A17168-1 1 90 1
64534-1 1 70 1
65359-101 1 1 RF
65400-101 1 20 1
65405-101 1 30 1
Page 1010
25-65-42 14 Jul 2017
65359
22
-20
-06
21
on
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ed
int
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Page 1011
25-65-42 18 Sep 2015
65359
22
10
-20
-06
60
21
on
80
70
90
ed
20
int
40
30
Pr
50
RESERVOIR AND VALVE/REGULATOR ASSEMBLY

IPL FIGURE 1
Page 1012
25-65-42 18 Sep 2015
65359
UNITS
FIG. AIRLINE NOMENCLATURE EFF.
PART NUMBER PER
ITEM PART NO. 1234567 CODE
ASSY.
1
-1 65359-101 Reservoir and Valve RF
22
Assembly
(See CMM 25-66-28 for
-20
NHA)
10 C17849-107 .Pressure Gage, 1
(Temperature Compen-
-06
sated)
20 65400-101 .Cable, Valve Release 1
21
30 65405-101 .Cable Guide Assembly 1
40 D17961-103 .Lock Pin Assembly 1
on
50 C19784-101 ..Warning Flag Assembly 1

60 D18306-101 .Valve/Regulator 1
ed
Assembly
(See IPL Figure 2 for
int
BKDN)
70 64534-1 .Reservoir 1
Pr
(DOT-SP 11194-3295)
(145 Cu. In.) (2.4 liters)
80 B14056-910 .O-Ring 1
90 15A17168-1 .Tube 1
- Item Not Illustrated
Page 1013
25-65-42 18 Sep 2015
65359
22
-20
-06
21
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Page 1014
25-65-42 18 Sep 2015
65359
400
390
10
90
50
70
1
22
310
60
-20
30A 330
20
40 -06 340 320
100
21
350
120 80
130
on
140
210B
ed
110 150
180 250
230
int
160, 160A
370 360,
360A
270 380
Pr
220
170 280 240A
290 300
190
260
200
(WITH ALUMINUM PULLEY)
IPL FIGURE 2 (SHEET 1 OF 2)
Page 1015
25-65-42 18 Sep 2015
65359
400
390
10
90
50
22
1
310
60
-20
30B 330
20A
40
-06 340 320
21
350
120 80
130
on
140
210B
ed
110 150
180 250
int
230
160, 160A
370 360,
360A
Pr
270 380 220

170 280 240A
290 300
190
260
200
(WITH COMPOSITE PULLEY)
IPL FIGURE 2 (SHEET 2 OF 2)
Page 1016
25-65-42 14 Jul 2017
65359
UNITS
PART NUMBER PER
ASSY.
2
1 D18306-101 Valve/Regulator Assembly RF
22
(See IPL Figure 1 for NHA)
10 B13968-1 .Ring, Retaining 1
-20
20 B14490-1 .Plate, Cover 1
Used with Items 30 or 30A
only)
-06
20A B13976-1 .Plate, Cover 1
Used with Item 30B only)
21
-30 B15373-1 .Pulley Assembly 1
(Aluminum) (Supsd by Item
30A)
on
30A B42013-1 .Pulley Assembly 1

(Aluminum) (Supsds Item
ed
30) (Supsd by Item 30B)

30B B55396-1 .Pulley Assembly 1
int
(Composite) (Supsds Item

30A)
40 1003-0005-293 ..Pin, Coupling 1
Pr
50 B14422-1 .Pawl, Machining 1

60 B14253-1 .Pin, Pawl 1
70 B13978-1 .Bearing, Bushing 1
(Used with Items 30 and
30A only)
80 B14482-1 .Bushing, Safety Pin 1
90 B14245-1 .Spring, Pawl 1
Page 1017
25-65-42 14 Jul 2017
65359
UNITS
PART NUMBER PER
ASSY.
2
100 B13977-1 .Bearing, Pulley 1
(Used with Items 30 and
30A only)
22
110 1005-0009-093 .Screw, Socket Head, Cap 2
120 B14052-1 .Adapter, Cable 1
-20
130 B14268-1 .Rupture Disc 1
140 B13984-3 .Fusible Plug
-06 1
150 B14056-906 .O-Ring, Fusible Plug 1
(1000-0030-906)
21
160 1054-0001-002 .Valve, Filler 1
160A MS28889-2 .Valve, Filler 1
on
(ALT to Item 160)

170 MS20813-1 ..Cap, High Pressure 1
ed
180 B14056-015 .O-Ring, Filler Valve 1

(1000-0030-15)
int
190 B14427-1 .Gage Fitting 1

200 B14056-908 .O-Ring, Gage Fitting 1
(1000-0030-908)
Pr
-210 B14256-1 .Fitting, Bottle 1

(Supsd by Item 210A)
- B45265-1 .Fitting, Bottle 1
210A (Supsds Item 210)
(Supsd by Item 210B)
210B B45265-3 .Fitting, Bottle 1
(Supsds Item 210A)
220 B14056-914 .O-Ring, Bottle Fitting 1
(1000-0030-914)
Page 1018
25-65-42 14 Jul 2017
65359
UNITS
PART NUMBER PER
ASSY.
2
230 B14247-1 .Spring, Ball Guide 1
-240 B14243-1 .Guide, Ball 1
(Supsd by Item 240A)
22
240A B14243-3 .Guide, Ball 1
(Supsds Item 240)
-20
250 B13966-1 .Ball, Flow 1
260 B13979-1 .Shaft
-06 1
270 1002-0030-008 .Ring, Back-Up 1
280 B14056-008 .O-Ring, Shaft 1
21
(1000-0030-8)
290 B13975-1 .Shim 2
on
300 B13969-1 .Bearing, Thrust 1

310 B19007-1 .Flanged Bushing 1
ed
320 B14252-1 .Screw, Adjusting 1

330 B14251-1 .Spring, Regulator 1
int
340 B14250-1 .Piston 1

350 B14056-112 .O-Ring, Piston 1
Pr
(1000-0030-112)
360 B14246-1 .Seat, Ball 1
(For field replacement
use Item 360A)
360A B42099SP5 .Seat, Ball 1
(Field replacement for
Item 360) (True P/N is
B42099SP-5)
Page 1019
25-65-42 14 Jul 2017
65359
UNITS
PART NUMBER PER
ASSY.
2
370 B14242-1 .Body 1
380 B14428-1 .Label, Pawl Reset 1
22
390 B14487-1 .Label 1
400 B14485-1 .Label, Arming 1
-20
-06
21
on
ed
int
Pr
Page 1020
25-65-42 14 Jul 2017

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To: Holders of CRJ900 Slide Reservoir and Valve Inflation Assembly

(P/N 65359-101) Manufactured by Air Cruisers; Component Maintenance

Revision No. 5 of Component Maintenance Manual 25-65-42 reflects pages which

LIST OF EFFECTIVE PAGES

LEP-1 through LEP-3 Updated to reflect this revision.

COMPONENT MAINTENANCE MANUAL

The end item product(s)/commodity(s) described in the Component Maintenance Manual

ORIGINAL ISSUE: 02 JUN 2003

RETAIN THIS RECORD IN THE FRONT OF THE MANUAL. ON

REVISION REVISION ENGINEER WRITERS DATE

Original 02 Jun 2003 EHS FXC

4 14 Jul 2017 ABU MJS

TEMPORARY REVISION RECORD

DATE INSERTED REMOVED

SERVICE BULLETIN RECORD

SERVICE BULLETIN / DATE

SERVICE INFORMATION LETTER RECORD

25-102 / R26 31 Jan 2014 18 Sep 2015 Authorized Repair/Service Facilities

25-181 / R11 12 Apr 2013 18 Sep 2015 Implementation of New Valve/Reg-

25-196 / R2 25 Nov 2005

25-222 / R3 04 Nov 2011 18 Sep 2015 Methodology of Serial Numbers

25-244 03 Aug 2009 18 Sep 2015 Change of Address

25-260 / R1 27 Jan 2012 18 Sep 2015 Gas Specification Recommenda-

25-279 / R1 18 Jan 2013 18 Sep 2015 Lubrication of Inflation Valve

25-341 02 Oct 2015 14 Jul 2017 New Composite Valve/Regulator

LIST OF EFFECTIVE PAGES SECTION PAGE DATE

Effective Pages LEP-2 04 Dec 18 111 14 Jul 17

INTRO-2 18 Sep 15 118 Blank

SECTION PAGE DATE SECTION PAGE DATE

Disassembly (Cont’d) 311 18 Sep 15 Assembly (Cont’d) 710 14 Jul 17

504 14 Jul 17 723 18 Sep 15

506 04 Dec 18 725 18 Sep 15

602 18 Sep 15 730 18 Sep 15

604 18 Sep 15 Fits and Clearances 801 18 Sep 15

SECTION PAGE DATE

Special Tools, 908 18 Sep 15

Illustrated Parts List 1001 18 Sep 15

LEP-3, 04 Dec 2018

DESCRIPTION AND OPERATION 1

CHECK -06 501

FITS AND CLEARANCES 801

SPECIAL TOOLS, FIXTURES, AND EQUIPMENT 901

ILLUSTRATED PARTS LIST 1001

A. This manual provides Description and Operation, Disassembly,

CAUTION: TO CALL ATTENTION TO METHODS AND PROCE-

NOTE: To call attention to methods which make the job easier.

D. Pages INTRO-4 through INTRO-6 consist of a list of Abbreviations and

those of an editorial nature, can be sent to:

Zodiac Aero Evacuation Systems

A. Copies of non restricted Component Maintenance Manuals (CMM),

Testing and Fault Isolation 02 Jun 2003

Disassembly 02 Jun 2003

A. Listed below is a cross reference tabulation between the Emergency

65250-101 P-12214 65359-101 25-66-28

4. Abbreviations and Symbols

Cu. Ft. Cubic Feet

DCR Document Change Request

ECN Engineering Change Notice

ELT Emergency Locator Transmitter

N/cm2 Newtons per Square Centimeter

NAS National Aircraft Standard

*** Denotes end of Attaching Hardware