SFN-20240111A Replace center pop-up

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TICO Document #: SFN-20240111A (formerly TES 151)

Description of Procedure: Replace components used for the center pop-up with components used for the forward pop-up, which will make it consistent with current production of bomb carts.

Units Affected: Bombcarts manufactured prior to March 2014 converted from the wedge pop-up design to the pin design.

Parts Required: CENTER POP-UP CONVERSION FIELD KIT 550075 (QTY 1 )

Planned Labor: 4 hours

Instructions:

  1. Park the vehicle on a flat surface, apply a parking brake, and chock wheels. If your company utilizes a “Lock Out, Tag Out” policy, you should employ it during this procedure.

  2. Release all pressure from air system by releasing the drain valve.

  3. Disconnect the service and emergency air lines from the control valve that run down the left side of the frame and through the pop-up brackets.

  4. Pull air lines all the way through the center pop-up brackets.

  5. Remove the two grommets from the left-hand side pop-up brackets and discard.

  1. Remove eight 5/8”-11 x 2½” bolts, nuts, and washers securing the center pop-up assembly to the spacer plate, four on each side of the unit.

  2. If desired, pop-up pins may be removed from housing first by removing two 5/8”-11 x 2” bolts securing each tube cover plate on the bottom of the housing.

    Warning: Loaded spring inside of tube. To avoid injury, use caution when removing bolts.

  3. Discard assembly and hardware.

  1. Remove eight 5/8”-11 x 2½” bolts, nuts, and washers securing the spacer plates to the bombcart frame brackets, four on each side of the unit.

  2. Discard plates and hardware.

  1. Remove center pop-up frame brackets (P/N 5225), two on each side of the unit. Grind any residual weld smooth.

  2. Discard brackets.

  1. Prepare weld area by removing any paint and debris from area which may cause impurities in weld.

  1. Position brackets using dimensions shown and tack into place.

  1. Weld ¼” fillet to front and rear edges of center pop-up frame brackets (P/N 5228).

  2. Apply rust-inhibitive primer to all bare metal surfaces and welds. Paint primed surfaces.

  1. Using two 5/8”-11 x 2” bolts, nuts, and washers, install the longer leg of pop-up bracket (P/N 52328) to the pop-up housing (P/N 52315).

  2. Bolts should be finger-tight so pop-ups can be adjusted later.

  3. Repeat for the other three pop-up brackets.

  1. Using twelve 5/8”-11 x 2” bolts, nuts, and washers install the pop-up housing and brackets to the frame brackets (P/N 5228).

  2. Adjust housing fore/aft and left/right as needed.

  3. Torque all bolts to 170 ft-lb.

  1. Slide a new polyurethane ring (P/N 52324) over the top of the new pin (P/N 520454) and down onto the sleeve.

  2. Using a new spring (P/N 52009), place one end over the spring guide welded to the cover plate (P/N 52320).

  3. Insert the assembled pin into the left-hand housing tube, leaving the spring guide still exposed.

  4. Insert the free end of the spring onto the spring guide on the bottom of the pin and use to push the pin up the tube.

  1. Secure cover plate (P/N 52320) to pop-up housing using two 5/8”-11 x 2” bolts, nuts, and washers.

  2. Torque bolts to 170 ft-lb.

  3. Repeat process for the right-hand side.

  1. Add one grommet (P/N 90678) to the top hole on each of the left-hand side pop-up brackets.

  2. Route loose airlines through pop-up brackets and through any additional tab or cross member.

  3. Reconnect air lines to the control valve.

  1. Remove “Lock Out, Tag Out” plaque.

  1. Return vehicle to service.