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TECHNICAL MANUAL
OPERATOR AND FIELD MAINTENANCE MANUAL
INCLUDING REPAIR PARTS AND SPECIAL TOOLS LIST
(RPSTL) FOR
TANK ASSEMBLY, FABRIC, COLLAPSIBLE,
210,000 U.S. GALLONS, FUEL
NSN 5430-01-571-5535 (Depot)and
NSN 5430-01-571-5512 (IPDS)
DISTRIBUTION STATEMENT A - Approved for public release: Distribution unlimited.
HEADQUARTERS, DEPARTMENT OF THE ARMY
JUNE 2010
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WARNING SUMMARY
GENERAL WARNING PRECAUTIONS
This warning summary contains general safety warnings and hazardous material warnings that must be understoodand applied during operation and maintenance of this equipment. Failure to observe these precautions could result in
serious injury or death to personnel. Also included are explanations of safety and hazardous materials icons used
within this technical manual.
SPECIFIC WARNING PRECAUTIONS
The tank is a permit required confined space. Do not enter to clean or for any other
reason. Sludge that accumulates in the bottom of the fuel tank gives off toxic and
explosive vapors. Inhaling these vapors is harmful to personnel. Death or serious injury
may occur if warning is not followed due to lack of oxygen.
Tank entry is restricted to authorized maintenance personnel only. Should tank condition
arise, which would require tank entry, notify your supervisor. Failure to heed this warning
can cause injury to personnel.
Do not smoke or bring open flame within 100 feet (30.48 meters) of tank. Death or serious
injury may occur if warning is not followed.
If fuel spil ls on or around a tank within the diked area, shutdown any nearby engine-driven
equipment. Do not resume operation until it has been determined that the vapor
concentrations are below the explosive range. Death or serious injury may occur if
warning is not followed.
All petroleum products contain additives that may be harmful to personnel and the
environment. All leaks must be corrected as soon as possible. Wash fuel or oil from skin
immediately. Remove and wash contaminated clothing immediately. Spills of fuel or oil
must be cleaned up in accordance with local area direction to prevent harm to personnel
or damage to the environment.
Fuel and fuel sludge can cause injury to skin and eyes. If fuel or sludge comes into contactwith eyes, flush eyes with water. For further information on first aid, refer to FM 21-11.
Serious injury may occur if warning is not followed.
Do not carry or store anything edible near tank. Food will absorb vapors. After leaving
area, wash before eating or smoking. Death or serious injury may occur if warning is not
followed.
Do not deploy the tank system on a slope greater than 1%. Personnel injury or
equipment damage may occur.
Do not locate tank system near electrical equipment, power generation or power
distribution equipment. Electrical shock, death or equipment damage may result (if the
tank ruptures).
The packaged tank is heavy. Sixteen personnel are required to deploy system. Always liftwith your legs, not your back. Failure to observe this warning may result in back injury.
Do not fill if the tank has trapped air. Filling the tank with fuel, if air is trapped in the tank
could cause tank rupture. Death or serious injury may occur if warning is not followed.
Use caution to ensure fingers are not caught or pinched in the valves cam-lock lever.
Serious injury may occur if warning is not followed.
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SPECIFIC WARNING PRECAUTIONS - Continued
Use caution when walking near the tank system. Valves and hoses can cause tripping.
Serious injury may occur if warning is not followed.
Use only approved cleaning chemicals. Personnel injury and equipment damage may
occur.
Do not use decontamination spray on personnel. It could cause personal injury.
Do not overfill the tank. Damage to the tank will occur if overfilled. Personnel injury and
equipment damage may occur.
Do not lift or move the tank if there is any fuel in the tank. Personal injury or damage to the
tank may occur.
List of Warnings found in Manual
CH 1:
None
CH 2:
WARNINGWARNING
Make certain that the berm ball valve is closed and locked after installing and draining the
berm. In the event of tank rupture, an open berm ball valve would permit fuel to drain from
the berm. Undetected fuel leakage can result in an explosion and cause death, severe
personal injury, and damage to equipment.
WARNINGWARNING
The lifting device must have a minimum lifting capacity of 10,000 lbs. Failure to heed this
warning can cause injury or death to personnel as well as damage to equipment.
WARNINGWARNING
Before fuel is introduced into the tank, verify that the drain ball valve handle is rotated fully
to the right (closed position), before fuel is introduced into the tank. Unobserved drainage
of fuel can result in an explosion or fire. Failure to heed this warning can cause death or
severe personal injury and damage to equipment.
WARNINGWARNING
Check that the drain valve is closed. The valve is closed when the handle is rotated fully in
the clockwise direction. Failure to close valve can cause loss of fuel and possible fire or
explosion with possible death or severe personal injury and damage to equipment.
WARNINGWARNING
Use caution to ensure fingers are not caught or pinched in the cam-lock levers. Serious
injury may occur if warning is not followed.
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SPECIFIC WARNING PRECAUTIONS - Continued
WARNINGWARNING
Check the placement of sandbags to see potential leak points in order to avoid fire hazard.Failure to check the positions of sandbags can cause serious injury or death by fire or
explosion.
WARNINGWARNING
Over time tanks can become weakened and rupture, thereby spilling fuel. Tanks that have
exceeded the minimum service life of 3 years should be monitored closely. Failure to heed
this warning can cause injury or death to personnel.
WARNINGWARNING
Ensure that all cam locks are in the proper locked position before filling the tank.
Improperly closed connections can cause leaks, which can cause serious injury or death
by fire or explosion.
WARNINGWARNING
Do not exceed maximum fill capacity. The fuel tank will burst if it is overfilled, causing
damage to the equipment. Failure to heed this warning can cause injury or death to
personnel.
WARNINGWARNING
Sludge that accumulates at the bottom of the tank gives off toxic and explosive vapors.
Inhaling these vapors can cause poisoning. When cleaning the fuel tanks, provide ample
ventilation to dissipate harmful fumes. Failure to heed this warning can cause injury or
death to personnel.
WARNINGWARNING
Always wear protective goggles, a breathing apparatus, and other protective gear when
cleaning the tank interior. Fuel vapors are toxic and can damage eyes, skin, and lungs.
Failure to heed this warning can cause injury or death to personnel.
WARNINGWARNING
Fuel vapors are extremely flammable. Exercise care to prevent sparks when working near
or in the tank. Death or severe personal injury can result if safety precautions are not
strictly observed.
WARNINGWARNING
Do not exceed maximum air pressure of 0.5 pounds per square inch. Failure to heed thiswarning can cause injury or death to personnel.
WARNINGWARNING
Personnel shall wear ear protection device when working near or around compressed air.
Failure to heed this warning can cause injury to personnel.
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SPECIFIC WARNING PRECAUTIONS - Continued
WARNINGWARNING
Do not use decontamination spray on personnel. It could cause personal injury.
CH 3:
None
CH 4:
WARNINGWARNING
When servicing this equipment, performing maintenance or disposing of materials such as
oil or fuel consult your unit/local hazardous waste disposal center or safety office for local
regulatory guidance. Failure to heed this warning can cause injury to personnel.
CH 5:
WARNINGWARNING
Improper cleaning methods and use of unauthorized cleaning liquids or solvents can injure
personnel and damage equipment. To prevent this, refer to TM 9-247 (Materials Used forCleaning, Preservation, Abrading and Cleaning Ordinance Material and Related Materials
Including Chemicals) for further instructions.
WARNINGWARNING
Dry cleaning solvent, A-A-59601, used to clean metal parts, is potentially dangerous to
personnel and property. It produces toxic and flammable fumes. Use only in well-
ventilated areas. Avoid repeated and prolonged skin contact. Do not use solvent near an
open flame or near excessive heat. The flash point of the solvent is 100F to 130F.
Failure to heed this warning can result in severe personal injury or death.
WARNINGWARNING
Always wear protective goggles, a breathing apparatus and other protective gear when
cleaning the tank. Fuel vapors are toxic and can damage eyes, skin and lungs.
WARNINGWARNING
Use care when packing the tank. The tank will be easily damaged by tools, packing box
nails, or other sharp objects. Personnel shall wear ear protection device when working
near or around compressed air. Failure to heed this warning can cause injury to
personnel.
WARNINGWARNING
Personnel shall wear ear protection device when working near or around compressed air.
Failure to heed this warning can cause injury to personnel.
CH 6:
None
CH 7:
None
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LIST OF EFFECTIVE WORK PACKAGES
NOTE: Zero in the Change No. column indicates an original page or work package.
Dates of issue for original and updated pages/work packages are:
Original . . . . . . . . . . . . . . 15 June 2010
TOTAL NUMBER OF PAGES FOR FRONT AND REAR MATTER IS 26 AND TOTAL
NUMBER OF WORK PACKAGES IS 37, CONSISTING OF THE FOLLOWING:
Page/WP No. Change No.
Front Cover ..................................0Warning summary (4 pgs)........... 0i - xiii/xiv blank ............................. 0Chp 1 title page ............................0WP 0001 (4 pgs) .........................0WP 0002 (2 pgs) ..........................0WP 0003 (2 pgs) .........................0Chp 2 title page ............................0WP 0004 (4 pgs) ..........................0WP 0005 (28 pgs) .......................0WP 0006 (30 pgs) .......................0WP 0007 (6 pgs) ..........................0Chp 3 title page ............................0WP 0008 (2 pgs) ..........................0WP 0009 (2 pgs) ..........................0WP 0010 (6 pgs) ..........................0Chp 4 title page ............................0WP 0011 (4 pgs) ..........................0WP 0012 (16 pgs) ........................0WP 0013 (2 pgs) ..........................0WP 0014 (2 pgs) .........................0WP 0015 (2 pgs) ..........................0
WP 0016 (2 pgs) ..........................0Chp 5 title page ............................0
WP 0017 (4 pgs) ..........................0
WP 0018 (4 pgs) ..........................0WP 0019 (4 pgs) ..........................0WP 0020 (4 pgs) ..........................0WP 0021 (4 pgs) ..........................0WP 0022 (4 pgs) ..........................0WP 0023 (4 pgs) ..........................0WP 0024 (4 pgs) ..........................0WP 0025 (4 pgs) ..........................0WP 0026 (6 pgs) ..........................0Chp 6 title page ............................0WP 0027 (8 pgs) ..........................0
WP 0028 (24 pgs) ........................0WP 0029 (10 pgs) ........................0WP 0030 (2 pgs) ..........................0WP 0031 (4 pgs) ..........................0Chp 7 title page ............................0WP 0032 (2 pgs) ..........................0WP 0033 (6 pgs) ..........................0WP 0034 (6 pgs) ..........................0WP 0035 (4 pgs) ..........................0WP 0036 (2 pgs) ..........................0WP 0037 (2 pgs) ..........................0INDEX-1-INDEX-2........................0
Page/WP No. Change No.
A/B blank
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HEADQUARTERSDEPARTMENT OF THE ARMY
WASHINGTON, D.C., 15 JUNE 2010
TECHNICAL MANUAL
Operator and Field Maintenance ManualIncluding Repair Parts and Special Tools List
(RPSTL) for
TANK ASSEMBLY, FABRIC, COLLAPSIBLE, 210,000 U.S. GALLONS, FUEL
NSN 5430-01-571-5535 (Depot) and NSN 5430-01-571-5512 (IPDS)
REPORTING ERRORS AND RECOMMENDING IMPROVEMENTS
You can help improve this publication. If you find any errors, or if you would like to recommend any
improvements to the procedures in this publication, please let us know. The preferred method is to
submit your DA Form 2028 (Recommended Changes to Publications and Blank Forms) through the
Internet, on the Army Electronic Product Support (AEPS) website. The Internet address is https://
aeps.ria.army.mil. The DA Form 2028 is located under the Public Applications section in the AEPS
Public Home Page. Fill out the form and click on SUBMIT. Using this form on AEPS will enable us to
respond more quickly to your comments and better manage the DA Form 2028 program. You may also
mail, e-mail, or fax your comments or DA Form 2028 directly to: U.S. Army TACOM Life Cycle Manage -
ment Command, ATTN: AMSTA-LCL-MPP/TECH PUBS, 1 Rock Island Arsenal, Rock Island, IL 61299-
7630. The mail address is tacomlcmc.daform2028@us.army.mil. The fax number is DSN 793-0726 or
Commercial (309) 782-0726.
DISTRIBUTION STATEMENT A - Approved for public release. Distribution unlimited
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TABLE OF CONTENTS - Continued
Page No.
WP Sequence No.
Table 3. Items Inside Depot Collapsible Fuel Tank Crate #2 of 2..... WP 0005-8
Figure 7. Representative View of a Depot Collapsible Fuel Tank Crate #2 of 2.................................................................................................... WP 0005-8
Figure 8. Operating the Collapsible Fuel Tank Crate. ...................... WP 0005-9
Figure 9. Lifting the Berm Liner. ....................................................... WP 0005-10
Figure 10. Unrolling the Berm Liner. ................................................ WP 0005-10
Figure 11. Unfolding the Berm Liner................................................. WP 0005-11
Figure 12. Berm Liner Drain and Hose Assembly. ........................... WP 0005-13
Figure 13. Berm Liner Drain Assembly and Cushioning Material. ... WP 0005-13
Figure 14. Lifting the Collapsible Fuel Tank. .................................... WP 0005-15
Figure 15. Unrolling the Tank. .......................................................... WP 0005-16
Figure 16. Unfolding the Tank. ......................................................... WP 0005-17
Figure 17. Tank Drain and Hose Assembly. ..................................... WP 0005-18
Figure 18. Tank Vent Dust Cap. ....................................................... WP 0005-21
Figure 19. Vent Pipe Assembly. ....................................................... WP 0005-21
Figure 20. Fill/Discharge Elbow Assembly. ...................................... WP 0005-23
Figure 21. Fill/Discharge Hose and Valve Assembly........................ WP 0005-24
Figure 22. Elevated Connections for Easy Leak Detection.............. WP 0005-25
Table 4. Strapping Chart................................................................... WP 0005-27
Operation Under Usual Conditions - Retrieval............................................. WP 0006
Figure 1. Tank Drain and Hose Assembly. ....................................... WP 0006-2
Figure 2. Fill/Discharge Elbow Assembly. ........................................ WP 0006-3
Figure 3. Vent Pipe Assembly. ......................................................... WP 0006-4
Figure 4. Cushioning Material. ......................................................... WP 0006-5
Figure 5. Secure Cushioning Material.............................................. WP 0006-5
Figure 6. Vent Tank Assembly. ......................................................... WP 0006-6
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TABLE OF CONTENTS - Continued
Page No.
WP Sequence No.
Figure 7. Fill/Discharge Elbow Assembly. ........................................ WP 0006-7
Figure 8. Flat Tank. .......................................................................... WP 0006-8
Figure 9. First 7.5-Foot Fold............................................................. WP 0006-8
Figure 10. Folding the Edge to Center. ............................................ WP 0006-9
Figure 11. Half the Tank Folded. ...................................................... WP 0006-9
Figure 12. Final Folded Tank Configuration. .................................... WP 0006-10
Figure 13. Rolling the Tank. ............................................................. WP 0006-10
Figure 14. Tank Half-Rolled.............................................................. WP 0006-11
Figure 15. Secure Cushioning Material. ........................................... WP 0006-12
Figure 16. Rolled Tank. .................................................................... WP 0006-12
Figure 17. Lifting the Tank................................................................ WP 0006-13
Figure 18. Rolled Tank Ready for Crate. .......................................... WP 0006-13
Figure 19. Tank Dimensions............................................................. WP 0006-14
Figure 20. First Fold. ........................................................................ WP 0006-14
Figure 21. Second Fold.................................................................... WP 0006-15
Figure 22. Third Fold........................................................................ WP 0006-15Figure 23. Fourth Fold...................................................................... WP 0006-16
Figure 24. Roll the Sides.................................................................. WP 0006-16
Figure 25. Measure Folded Tank. .................................................... WP 0006-17
Table 1. Tank Accessories................................................................ WP 0006-18
Table 2. Tank Accessories................................................................ WP 0006-18
Figure 26. Layout Berm Liner........................................................... WP 0006-19
Figure 27. First 7.5 Foot Fold. .......................................................... WP 0006-20
Figure 28. Folding the Edge to Center. ............................................ WP 0006-20Figure 29. Folding the Edge to Center the Second Time................. WP 0006-21
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TABLE OF CONTENTS - Continued
Page No.
WP Sequence No.
Figure 30. Final Folded Liner Configuration..................................... WP 0006-21
Figure 31. Rolling the Berm Liner..................................................... WP 0006-22
Figure 32. Berm Liner Half-Rolled.................................................... WP 0006-22
Figure 33. Rolled Berm Liner. .......................................................... WP 0006-23
Figure 34. Lifting the Berm Liner. ..................................................... WP 0006-24
Figure 35. Rolled Berm Liner on Top of Tank (IPDS Only)............... WP 0006-24
Figure 36. Berm Liner Dimensions................................................... WP 0006-25
Figure 37. First Fold. ........................................................................ WP 0006-25
Figure 38. Second Fold.................................................................... WP 0006-26
Figure 39. Third Fold........................................................................ WP 0006-26
Figure 40. Fourth Fold...................................................................... WP 0006-27
Figure 41. Roll the Berm Liner. ........................................................ WP 0006-27
Figure 42. Finish the Folding............................................................ WP 0006-28
Figure 43. Measure the Folded Berm Liner...................................... WP 0006-28
Figure 44. Insert Berm Liner into Crate (Depot Only). ..................... WP 0006-29
Operation Under Unusual Conditions .......................................................... WP 0007Figure 1. Wood Plug Repair. ............................................................ WP 0007-4
Figure 2. Mechanical Clamp Repair. ................................................ WP 0007-5
Chapter 3 - Operator and Field Level Troubleshooting for Tank Assembly, Fabric, Collapsible,210,000 U.S. Gallons, Fuel
Operator and Field Level Troubleshooting Introduction ............................... WP 0008
Operator and Field Level Troubleshooting Index ......................................... WP 0009
Operator and Field Level Troubleshooting Procedure ................................. WP 0010
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TABLE OF CONTENTS - Continued
Page No.
WP Sequence No.
Chapter 4 - Operator and Field Level Preventative Maintenance Checks and Services for TankAssembly, Fabric, Collapsible, 210,000 U.S. Gallons, Fuel
Operators Preventative Maintenance Checks and Services (PMCS) Introduction............................................................................................................... WP 0011
Operators Preventative Maintenance Checks and Services (PMCS) ......... WP 0012
Figure 1. 210K Tank Item Numbers for PMCS................................. WP 0012-4
Table 1. Preventative Maintenance Checks and Services. .............. WP 0012-5
Operator Maintenance Procedures.............................................................. WP 0013
Fill/Discharge Gate Valve, Hose Assembly Coupling, and Dust Cap Gasket Replacement............................................................................................................... WP 0014
Figure 1. Fill/Discharge Gate Valve.................................................. WP 0014-2
Vent Fitting Assembly Coupling and Dust Cap Gasket Replacement.......... WP 0015
Figure 1. Vent Fitting Assembly........................................................ WP 0015-2
Fill/Discharge Assembly Elbow and Dust Cap Gasket Replacement .......... WP 0016
Figure 1. Fill/Discharge Assembly. ................................................... WP 0016-2
Chapter 5 - Field Maintenance Instructions for Tank Assembly, Fabric, Collapsible,210,000 U.S. Gallons, Fuel
Field Maintenance Introduction ................................................................... WP 0017
Service Upon Receipt .................................................................................. WP 0018
Figure 1. Emergency Field Repair Kit Inspection. ............................ WP 0018-2
Figure 2. Consumable/Overpack Kit Inspection. .............................. WP 0018-3
Figure 3. Berm Liner Emergency/Consumable Repair Kit ............... WP 0018-4
Fill/Discharge Hose Assembly - 12-Feet Long Service and Replacement .. WP 0019
Figure 1. Fill/Discharge Hose Assembly........................................... WP 0019-2
Tank or Berm Liner Drain Ball Valve Service, Replacement, Repair .......... WP 0020
Figure 1. Drain Ball Valve Assembly. ............................................... WP 0020-2
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TABLE OF CONTENTS - Continued
Page No.
WP Sequence No.
Tank or Berm Liner Drain Hose (With Dome) Service and Replacement ... WP 0021
Figure 1. Drain Hose Assembly (with Dome). .................................. WP 0021-2
Tank or Berm Liner Drain Hose Service and Replacement ......................... WP 0022
Figure 1. Drain Hose Assembly........................................................ WP 0022-2
Vent Assembly Service and Replacement ................................................... WP 0023
Figure 1. Vent Fitting Assembly........................................................ WP 0023-2
Fill/Discharge Assembly (With Manway) Service and Repair ..................... WP 0024
Figure 1. Fill/Discharge Assembly (with Manway). .......................... WP 0024-2
Preparation for Storage or Shipment ........................................................... WP 0025
Torque Limits................................................................................................ WP 0026
Table 1. 11 ft-lbs Torque Increment Chart. ....................................... WP 0026-1
Table 2. 40 ft-lbs Torque Increment Chart. ....................................... WP 0026-2
Figure 1. Torque Patterns................................................................. WP 0026-3
Table 3. Torque Limits - SAE Standard Fasteners............................ WP 0026-4
Table 4. Torque Limits - Metric Fasteners. ....................................... WP 0026-5
Chapter 6 - Parts Information for Tank Assembly, Fabric, Collapsible, 210,000 U.S.Gallons, Fuel
Repair Parts and Special Tools List (RPSTL) Introduction........................... WP 0027
Table 1. SMR Code Explanation. ................................................... WP 0027-2
Repair Parts and Special Tools List (RPSTL)............................................... WP 0028
Figure 1. Tank Assembly, Fabric, Collapsible, 210,000 U.S. Gallons, Fuel.................................................................................................... WP 0028-2
Figure 2. 210K Tank and Drain Assembly. ....................................... WP 0028-4
Figure 3. Berm Liner Assembly (Sheet 1 of 2). ................................ WP 0028-7
Figure 3. Berm Liner Assembly (Sheet 2 of 2). ................................ WP 0028-8
Figure 4. Drain Hose Assembly - Fuel 2 Inches X 20 Feet. ............. WP 0028-10
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TABLE OF CONTENTS - Continued
Page No.
WP Sequence No.
Figure 5. Drain Hose Assembly - 10-Foot and 20-Foot. .................. WP 0028-12
Figure 6. Drain Valve Assembly. ...................................................... WP 0028-14
Figure 7. Fill/Discharge Hose Assembly........................................... WP 0028-16
Figure 8. Vent Assembly, Double, W/Flame Arrestor and Pipe........ WP 0028-18
Figure 9. 6-Inch Valve Assembly...................................................... WP 0028-20
Figure 10. Berm Liner Drain Assembly............................................. WP 0028-22
Repair Kits.................................................................................................... WP 0029
Figure 11. Consumable/Overpack Kit............................................... WP 0029-2
Figure 12. Emergency Field Repair Kit. ........................................... WP 0029-4
Figure 13. Permanent Repair Kit...................................................... WP 0029-6
Figure 14. Berm Liner Emergency/Consumable Repair Kit. ............ WP 0029-8
National Stock Number Index ...................................................................... WP 0030
Part Number Index....................................................................................... WP 0031
Chapter 7 - Supporting Information for Tank Assembly, Fabric, Collapsible, 210,000 U.S. Gallons,Fuel
References................................................................................................... WP 0032
Maintenance Allocation Chart Introduction .................................................. WP 0033
Maintenance Allocation Chart (MAC)........................................................... WP 0034
Table 1. MAC for Tank Assembly, Fabric, Collapsible, 210,000 U.S. Gallons, Fuel................................................................................................... WP 0034-1
Table 2. Tools and Test Equipment for 210K Tank ........................... WP 0034-5
Table 3. Remarks for 210K Tank ...................................................... WP 0034-6
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TABLE OF CONTENTS - Continued
Page No.
WP Sequence No.
Components of End Item (COEI) and Basic Issue Items (BII) List............... WP 0035
Figure 1. Components of End Item. ................................................. WP 0035-2
Table 1. Components of End Item List. ............................................ WP 0035-3
Expendable and Durable Items List ............................................................ WP 0036
Table 1. Expendable and Durable Items List.................................... WP 0036-2
Mandatory Replacement Parts List ............................................................. WP 0037
Table 1. Mandatory Replacement Parts ........................................... WP 0037-1
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HOW TO USE THIS MANUAL
INTRODUCTION
1. This Operator and Field Maintenance Manual for Tank Assembly, Fabric, Collapsible, 210,000 U.S. Gallons,
Fuel contains general information, operating instructions, maintenance procedures, Operator Preventative
Maintenance Checks and Services (PMCS), and an illustrated Repair Parts and Special Tools List (RPSTL) for
the tank assembly. It is divided into seven chapters.
2. This manual is written in work package format:
a. Work packages are grouped in chapters as in a conventional Technical Manual. Chapters divide the manual
into major categories of information (e.g., Description and Theory of Operation, Operator Instructions, etc.).
b. Each chapter is divided into work packages, which are identified by a 4-digit number (e.g., 0001,
0002, etc.) located at the upper right-hand corner of each page. The work package (WP) page number (e.g.0001-1, 0001-2, etc.) is located at, and centered on, the bottom of each page.
c. The first four digits of the work package number are the work package sequence number, the fifth and sixth
digits indicate the change status of the WP (00 indicates an original WP). If a Change Package is issued for
this manual, added work packages use the 5th and 6th digits of their number to indicate new material. For
instance, work packages inserted between WP 0001 00 and WP 0002 00 are numbered WP 0001 01,
WP 0001 02, etc.
d. Supporting Information WPs at the rear of the manual serve the same function and contain the same
information as appendices in older manuals.
Figures and Tables
Figures and tables in WPs are numbered and titled. The figures and tables are sequentially numbered within
the WP. In a Repair and Special Tools List (RPSTL) WP, figures are numbered sequentially within the
chapter.
3. Read through this manual to become familiar with its organization and contents before attempting to operate or
maintain the equipment.
CONTENTS OF THIS MANUAL
1. A Warning Summary is located at the beginning of this manual. Become familiar with these warnings before
operating or maintaining the equipment.
2. AList of Effective Pages/Work Packages is located in the front of the manual. It lists the change status of each
section and work package in the manual.
3. A Table of Contents is located in the front of the manual. It lists all chapters and work packages in this
publication. If you cannot find what you are looking for in the Table of Contents, refer to the alphabetical Index
at the back of the manual.
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CONTENTS OF THIS MANUAL - Continued
4. Chapter 1,Description and Theory of Operation provides general information about the equipment, identifies the
major components and systems, and describes how the components and systems work. It also contains a
discussion of General Safety Instructions.
5. Chapter 2,Operator Instructions identify operating controls and indicators and explain how to use them. This
chapter covers all equipment operating procedures. It also contains information on transport of Tank Assembly,
Fabric, Collapsible, 210,000 U.S. Gallons, Fuel assembly.
6. Chapter 3, Operator and Field Level Troubleshooting describes operator troubleshooting procedures to locate
and correct malfunctions of the equipment. Included in this chapter is an Operator Troubleshooting Symptom
Index. If the equipment malfunctions, this index should always be consulted to locate the appropriate
troubleshooting procedure.
7. Chapter 4, Operator and Field Level Preventative Maintenance Checks and Services include preventative
maintenance and lubrication as well as operator maintenance procedures for the equipment.
8. Chapter 5, Field Maintenance Instructions explain how to maintain and repair the equipment at the Field
Maintenance level. Major areas covered are field PMCS and miscellaneous maintenance tasks.
9. Chapter 6, Parts Information contains the following: Repair Parts and Special Tools List (RPSTL), National
Stock Number (NSN) Index, and Part Number Index.
10. Chapter 7, Supporting Information contains the following: References, Maintenance Allocation Chart (MAC),
Components of End Item (COEI), Basic Issue Items (BII) List, and Expendable and Durable Items List.
11. An alphabeticalIndex is located at the back of this manual.
FEATURES OF THIS MANUAL
1. Warnings, Cautions, Notes, Subject headings and other important information are highlighted in BOLD print as
a visual aid.
WARNINGWARNING
A WARNING indicates a hazard, which may result in injury or death to personnel.
CAUTIONCAUTION
A CAUTION is a reminder of safety practices or directs attention to usage practices that
may result in damage to equipment.
NOTE
A NOTE is a statement containing information that will make the procedures easier to
perform.
2. Statements and words of particular interest may be printed in CAPITAL LETTERS to create emphasis.
xii
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FEATURES OF THIS MANUAL - Continued
3. Within a procedural step, reference may be made to another chapter or work package in this manual or to another
manual. These references indicate where you should look for more complete information.
a. If you are told: Prepare for storage or shipment (WP 0012 00), go to WP 0012 00 in this manual for
instructions on how to prepare the equipment for storage or shipment.
b. If you are told: Detailed decontamination procedures can be found in: FM 3-11.5, go to WP 0032 00,
References, for complete information on referenced technical manuals.
4. Illustrations are placed after or as close to the procedural steps to which they apply. Item callouts are placed on
the art as text or numbers.
xiii/xiv blank
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TM 10-5430-269-13&P 0001
0001-1
OPERATOR AND FIELD MAINTENANCE
TANK ASSEMBLY, FABRIC, COLLAPSIBLE, 210,000 U.S. GALLONS, FUEL
NSN 5430-01-571-5535 and NSN 5430-01-571-5512GENERAL INFORMATION
SCOPE
This technical manual contains instructions for operations, checks and corrective maintenance for the Tank
Assembly, Fabric, Collapsible 210,000 U.S. Gallons, Fuel.
Type of Manual: Operator and Field Maintenance.
Model Number and Equipment Name:
8600000764, Tank Assembly, Fabric, Collapsible, 210,000 U.S. Gallons, Fuel (IPDS)
8600000761, Tank Assembly, Fabric, Collapsible, 210,000 U.S. Gallons, Fuel (Depot)
Purpose of Equipment: The tanks are containers designed to store military specification fuels. The tanks will
be used to store fuel as part of a bulk fuel terminal. Fuel will be available for use in a quick response deployment
operation.
MAINTENANCE FORMS, RECORDS, AND REPORTS
Department of the Army forms and procedures used for equipment maintenance will be those prescribed by (as
applicable) DA PAM 750-8, The Army Maintenance Management System (TAMMS) Users Manual or
AR 700-138, Army Logistics Readiness and Sustainability.
REPORTING EQUIPMENT IMPROVEMENT RECOMMENDATIONS (EIR)
If your Tank Assembly, Fabric, Collapsible, 210,000 U.S. Gallons, Fuel needs improvement, let us know. Send us an
EIR. You, the user, are the only one who can tell us what you dont like about your equipment. Let us know why you
dont like the design or performance. If you have Internet access, the easiest and fastest way to report problems or
suggestions is to go to https://aeps.ria.army.mil/aepspublic.cfm (scroll down and choose the Submit Quality
Deficiency Report bar). The Internet form lets you choose to submit an Equipment Improvement Recommendation
(EIR), a Product Quality Deficiency Report (PQDR or a Warranty Claim Action (WCA). You may also submit your
information using an SF 368 (Product Quality Deficiency Report). You can send your SF 368 via e-mail, regular
mail, or facsimile using the addresses/facsimile numbers specified in DA PAM 750-8, The Army Maintenance
Management System (TAMMS) Users Manual. We will send you a reply.
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TM 10-5430-269-13&P 0001
0001-2
CORROSION PREVENTION AND CONTROL (CPC)
Corrosion Prevention and Control (CPC) of Army materiel is a continuing concern. It is important that any corrosion
problems with this be reported so that the problem can be corrected and improvements can be made to prevent the
problem in future items.
Corrosion specifically occurs with metals. It is an electrochemical process that causes the degradation of metals. It is
commonly caused by exposure to moisture, acids, bases, or salts. An example is the rusting of iron. Corrosion
damage in metals can be seen, depending on the metal, as tarnishing, pitting, fogging, surface residue, and/or
cracking.
Plastics, composites, and rubbers can also degrade. Degradation is caused by thermal (heat), oxidation (oxygen),
solvation (solvents), or photolytic (light, typically UV) processes. The most common exposures are excessive heat or
light. Damage from these processes will appear as cracking, softening, swelling, and/or breaking.
SF Form 368, Product Quality Deficiency Reportshould be submitted to the address specified in DA PAM 750-8, The
Army Maintenance Management System (TAMMS) Users Manual.
DESTRUCTION OF ARMY MATERIAL TO PREVENT ENEMY USE
Destruction of Army material to prevent enemy use shall be in accordance with TM 750-244-3, Procedures for
Destruction of Equipment to Prevent Enemy Use.
PREPARATION FOR STORAGE OR SHIPMENT
Refer to WP 0025 to prepare the Tank Assembly, Fabric, Collapsible, 210,000 U.S. Gallons, Fuel for storage and
shipment.
NOMENCLATURE CROSS-REFERENCE LIST
LIST OF ABBREVIATIONS/ACRONYMS
Common Name Official Name
Tank Tank Assembly, Fabric, Collapsible, 210,000 U.S. Gallons, Fuel
BII Basic Issue Item
BOI Basis of Issue
COEI Component of End Item
CPC Corrosion Prevention Control
DS2 Decontamination Solution (Ready to Use)
EIR Equipment Improvement Recommendation
EPA Environmental Protection Agency
FT Feet
FT-LB Foot Pound
IAW In Accordance With
IN Inch
IPDS Inland Petroleum Distribution System
MAC Maintenance Allocation Chart
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0001-3/4 blank
LIST OF ABBREVIATIONS/ACRONYMS - Continued
SAFETY, CARE, AND HANDLING
Always observe Warnings, Cautions, and Notes in the manual. They appear before appropriate procedures. Be sure
you read and understand each of the Warnings, Cautions, and Notes. Failure to observe them may cause damage to
yourself, others, or equipment.
END OF WORK PACKAGE
MTOE Modified Table of Organization and Equipment
NSN National Stock Number P/N Part Number
PMCS Preventative Maintenance Checks and Services
RPSTL Repair Parts and Special Tools List
SMR Source, Maintenance and Recoverability
SOP Standard Operating Procedure
TAMMS The Army Maintenance Management System
TOE Table of Organization and Equipment
UOC Usable On Code
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0008 00-4
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0002-1
0002
OPERATOR AND FIELD MAINTENANCE
TANK ASSEMBLY, FABRIC, COLLAPSIBLE, 210,000 U.S. GALLONS, FUEL
NSN 5430-01-571-5535 and NSN 5430-01-571-5512EQUIPMENT DESCRIPTION AND DATA
EQUIPMENT CHARACTERISTICS, CAPABILITIES, AND FEATURES
Characteristics, capabilities, and features of the Tank Assembly, Fabric, Collapsible, 210,000 U.S. Gallons, Fuel,
assemblies include:
Characteristics, Capabilities and Features:
Fabric, collapsible tank with cam-lock fittings.
Residual fuel can be drained from the tank by use of the low profile drains located on the bottom of the tank. Internal air pressure is vented through vent assembly.
Berm liner assembly with drain hose and valve assemblies.
Setup: Sixteen personnel in 2 hours.
LOCATION AND DESCRIPTION OF MAJOR COMPONENTS
Refer to WP 0004.
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0002-2
0002
EQUIPMENT DATATable 1. Leading Particulars.
Item Characteristic
Dimensions, outside:
(Packaged IPDS)
Height 84 in.
Width 61.5 in.
Length 192.75 in.
Weight 9,300 pounds (max weight)
(Package 1 Depot) One Tank, Vent Pipe Assembly, Type III Repair Kit ATPD-2263, four 6-in. Dust
Caps, one Center Cap, two Lifting Slings
Height 45.937 5 in.
Width 84 in.
Length 1 14 in.
Weight 5,3 20 pounds
(Package 2 Depot) One Berm liner, two lifting slings, one hose (2-in. x 10 ft. M-QD), one hose (2-in. x
20 ft. C&E Cap & Plug), two hoses (2-in. X 20 ft.) and Drain Assembly, four hoses
(6-in. x 12 ft.), four Gate Valve Assemblies (6-in.), two elbows (female/female),
two elbows (female/male), two Drain Valve Assemblies (2-in.), one Cunsumable/
Overpack Kit, one Berm Overpack Kit, one Berm Emergency Repair Kit
Height 32.187 5 in.
Width 84 in.
Length 1 14 in.Weight 4,1 72 pounds
(Deployed)
Height at 100% capacity 5 ft. 8 in.
Length Not more than 75 ft.
Width Not more than 75 ft.
(Berm Liner)
Length 115 ft. +/- 3 in.
Width 115 ft. min, 120 ft. 2 in. nom
EnvironmentalRequirements:
Temperature:
Operating -25 to 140 F
Storage -25 to 160 F
Fuel Storage Capacity: 210,000 Gallons
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0003-1/2 blank
0003
OPERATOR AND FIELD MAINTENANCE
TANK ASSEMBLY, FABRIC, COLLAPSIBLE, 210,000 U.S. GALLONS, FUEL
NSN 5430-01-571-5535 and NSN 5430-01-571-5512THEORY OF OPERATION
Refer to WP 0004.
END OF WORK PACKAGE
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CHAPTER 2
OPERATOR INSTRUCTIONS
FOR
TANK ASSEMBLY, FABRIC, COLLAPSIBLE,
210,000 U.S. GALLONS, FUEL
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0004-1
0004
OPERATOR AND FIELD MAINTENANCE
TANK ASSEMBLY, FABRIC, COLLAPSIBLE, 210,000 U.S. GALLONS, FUEL
NSN 5430-01-571-5535 and NSN 5430-01-571-5512GENERAL INFORMATION
GENERAL
This section lists major components, controls, and indicators, and describes their function within the tank assembly.
DESCRIPTION AND USE OF MAJOR COMPONENTS
Description and use of major components, including controls and indicators, are contained in Table 1 and shown in
Figure 1.
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0004-2
0004
DESCRIPTION AND USE OF MAJOR COMPONENTS - Continued
Figure 1. Major Components.
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0004-3
0004
DESCRIPTION AND USE OF MAJOR COMPONENTS - Continued
Table 1. Major Components, Controls, and Indicators.
KeyComponent, Control or
IndicatorFunction
1 210K Tank Provides means to store fuel.
2 Tank Fill/Discharge Fitting With
Male Cam-Type Coupling
Provides means to add or remove fuel from tank. Accessed by
removing dust cap, which is held in place with four cam-lock
levers.
3 Elbow with Cam-Type Connections Used with tank Fill/Discharge fittings, hose, valve
assemblies to add or remove fuel for tank.
4 Fill/Discharge Hose Assembly Used with tank Fill/Discharge fittings and valve assembly for
addition or removal of fuel.
5 Fill/Discharge Valve Assembly Used with Fill/Discharge hose assembly for addition orremoval of fuel.
6 Tank Vent Tube Fitting with Male
Cam-Type Coupling
Provides means for connecting Vent Tube Assembly.
7 Vent Tube Assembly Vent Tube Assembly allows any trapped air in tank to be
vented when tank is being filled. Assembly is fitted with a
flame arrestor that provides protection against water or
airborne contamination of stored fuel.
8 Emergency Field Repair Kit * Repair kit contains all items needed to perform emergency
repair of cuts and punctures in tank fabric. Repair kit items are
stored in repair kit bag. Also included with repair kit is a
laminated instruction sheet, detailing fabric repair.
9 Tank Drain Fittings Tank is shipped with blind flanges installed on four drain
fittings. When needed, blind flange is removed and dome drain
fitting and drain hose assembly installed.
10 Drain Hose Assemblies 20-ft When attached to tank and drain valve assembly, provides a
means to drain tank.
11 Drain Valve Assembly Attaches to drain hose for draining 210K tank.
12 Berm Liner Provides protection from fuel spills.
13 Berm Liner Drain Fittings Berm liner is shipped with blind flanges installed on two drain
fittings. When needed, blind flange is removed and dome drain
fitting and drain hose assembly installed.
14 Berm Liner Drain Hose Assembly
20-ft
When attached to berm liner and drain valve assembly,
provides a means to drain berm liner.
15 Berm Liner Drain Valve Assemblies Attaches to drain hose for draining berm liner.
16 Consumable Items Overpack Kit * Overpack kit contains Technical Manual, strapping chart, and
replacement fasteners.
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0004-4
0004
DESCRIPTION AND USE OF MAJOR COMPONENTS - Continued
Table 1. Major Components, Controls, and Indicators. - Continued
* NOT ILLUSTRATED.
Figure 2 through Figure 5 are provided as guides for identifying cam lock closed and open positions.
END OF TASK
END OF WORK PACKAGE
17 Sling Used for lifting tank and berm liner from crate.
Figure 2. Cam Locks Closed Position. Figure 3. Cam Locks Open Position.
Figure 4. Cam Locks Closed Position. Figure 5. Cam Locks Open Position.
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0005-2
0005
ASSEMBLY AND PREPARATION FOR USE
Construction of Berm
WARNINGWARNING
Make certain that the berm ball valve is closed and locked after installing and draining the
berm. In the event of tank rupture, an open berm ball valve would permit fuel to drain from
the berm. Undetected fuel leakage can result in an explosion and cause death, severe
personal injury, and damage to equipment.
CAUTIONCAUTION
Damage to tank may occur if chosen site is not free of sharp objects (rocks, sticks, glass,
etc.), and center of leveled area should not exceed 9.0-inches below ground level. Retain
a slight incline for draining surface water. Safety berms must have capacities of not less
than one and one-half times that of the tank capacities. Failure to construct a secure
safety berm may result in catastrophic damage.
NOTE
A minimum of 21.0-foot working clearance is necessary between the side of the tank and
the berm on all four sides. When a single berm is used to contain more than one tank,
maintain a 10.0-foot space between tanks. The installation site should have less than a
1-inch or 20-inch rise in 100 feet in order to prevent creeping of the tank. The site must not
be subject to flooding or high water.
If possible, provide a 4.0-inch thick sand bottom for all collapsible fuel storage tanks. To
provide a berm drain for all collapsible fuel storage tanks, place a 2.0-inch pipe with a ball
valve through the bottom of the discharge end of the berm in order to provide a means of
draining accumulated water. Position the drain assembly at the lowest point of the slope to
aid in draining water or sludge. The ball valve should be normally closed, and opened onlyto drain water from the bermed area.
1. Clear and level an area so there is at least a 21-foot wide perimeter around empty flat tank (Figure 1
and Figure 2).
2. Erect a 5-foot high berm around outside of sloped area. Protect berm walls against erosion with sod or
stone (Figure 3).
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0005-3
0005
ASSEMBLY AND PREPARATION FOR USE - Continued
Figure 1. Berm Construction.
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0005-4
0005
ASSEMBLY AND PREPARATION FOR USE - Continued
Berm Cross-Section
Figure 2. Berm Cross-Section.
Typical Berm Cross-Section of Liquid Level in Relation
to the Position of the Collapsible Fabric Fuel Tank.
Surface Water Drain
Figure 3. Slope Towards One End by 1 Degree.
END OF TASK
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0005-5
0005
UNPACKING THE EQUIPMENT
Tank is packaged in a container designed for shipment. The base of the container is constructed as a shipping pallet to
be handled with a forklift. After unloading, unpack as follows:
1. Position packaged tank (Figure 4) on an approved site near point of installation.
Figure 4. Cross-section View of an IPDS Collapsible Fuel Tank Crate #1 of 1 Crate.
CAUTIONCAUTION
Remove all protruding nails and other objects before attempting to remove the tank from
the container. Failure to heed this caution can result in tearing the tank.
2. Know contents of shipping container by reviewing packing slip.
NOTE
There are three different types of collapsible fuel tank crates:
1. IPDS Collapsible Fuel Tank Crate, qty 1 of 1
2. Depot Berm Liner Crate, qty 1 of 2
3. Depot Collapsible Fuel Tank Crate, qty 2 of 2
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0005-6
0005
UNPACKING THE EQUIPMENT - Continued
NOTE
The installation steps outlined in this section apply to the IPDS Collapsible Fuel TankCrate (Figure 5) and its contents (Table 1).
Figure 5. A Typical IPDS Collapsible Fuel Tank Crate.
Table 1. Items Inside IPDS Collapsible Fuel Tank Crate #1 of 1.
ITEM QUANTITY
Hoses Four 6-inch fill/discharge hose assemblies
Four 2-inch berm liner drain hose assemblies
Valves and Elbows Four 6-inch gate valve assemblies
Four 6-inch elbows
Two 2-inch drain valves
One vent tube assembly
SlingsConsolidation box containing accessories and
Emergency repair items.
One each
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0005-7
0005
UNPACKING THE EQUIPMENT - Continued
NOTE
When unpacking a Depot type crate (Figure 6) and its contents (Table 2), the individualberm liner assembly procedures should be followed as needed.
Figure 6. Representative View of a Depot Berm Liner Crate #1 of 2.
NOTE
When unpacking collapsible fuel tank (Figure 7) and its contents (Table 3), assembly
procedures should be followed as needed.
3. Check contents for overpack kit and emergency repair kit (WP 0029).
Table 2. Items Inside Depot Berm Liner Crate #1 of 2.
ITEM QUANTITY
Hoses Four 2-inch berm liner drain hose assemblies
Four 6-inch fill/discharge hose assemblies
Valves and Elbows Two 2-inch drain valves
Four 6-inch gate valve assemblies
Four 6-inch elbows
Slings
Berm Liner Consumable Overpack Kit One
Tank Consumable Overpack Kit One
Berm Liner Emergency/Consumable Repair Kit One
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0005-8
0005
UNPACKING THE EQUIPMENT - Continued
Figure 7. Representative View of a Depot Collapsible Fuel Tank Crate #2 of 2.
UNPACKING THE IPDS EQUIPMENT - INSTALLATION OF THE BERM LINER
1. Carefully open IPDS Collapsible Fuel Tank Crate by removing bolts (Figure 8, Item 4) from bottom edge ofcrate shell (Figure 8, Item 2). Lift crate shell off crate skids (Figure 8, Item 3) and remove drain fitting hoses and
fill/discharge hoses from top of tank (Figure 8, Item 1) and berm liner (not shown).
WARNINGWARNING
The lifting device must have a minimum lifting capacity of 10,000 lbs. Failure to heed this
warning can cause injury or death to personnel as well as damage to equipment.
NOTE
If a berm liner is being replaced, package the unserviceable berm liner in the empty
container in the same manner that the new berm liner was packaged.
2. Locate lifting straps (Figure 9, Item 2) around berm liner (Figure 9, Item 1). Carefully insert fork lift forks(10,000-lb. capacity) through loops of lifting straps.
Table 3. Items Inside Depot Collapsible Fuel Tank Crate #2 of 2.
ITEM QUANTITY
Valves and Elbows One Vent Tube Assembly
Slings
Tank Emergency Repair Kit One
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0005-9
0005
UNPACKING THE IPDS EQUIPMENT - INSTALLATION OF THE BERM LINER - Continued
Figure 8. Operating the Collapsible Fuel Tank Crate.
3. Transport berm liner (Figure 9, Item 1) to center of desired installation site.4. Remove three ratchet straps and secure for packaging.
5. Unwrap berm liner from packaging material, unroll one-half of berm liner (Figure 10) along length of
installation site, unroll other half of berm liner in opposite direction along length of installation site.
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0005-10
0005
UNPACKING THE IPDS EQUIPMENT - INSTALLATION OF THE BERM LINER - Continued
Figure 9. Lifting the Berm Liner.
Figure 10. Unrolling the Berm Liner.
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0005-11
0005
UNPACKING THE IPDS EQUIPMENT - INSTALLATION OF THE BERM LINER - Continued
6. Berm liner is folded symmetrically about its center line. Unfold one side (Figure 11) to expose sides of berm
liner.
NOTE
Half of the berm liner remains folded to prevent damage by running over it with the lifting
device during tank installation.
7. Grasp berm liner and pull towards and over side of berm (Figure 11).
Figure 11. Unfolding the Berm Liner.
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0005-12
0005
UNPACKING THE IPDS EQUIPMENT - INSTALLATION OF THE BERM LINER - Continued
8. Locate 2-inch drain ball valves. Remove cushioning from ends of all hoses.
NOTE
Save all cushioning and packing material for reuse when berm liner is put back into
storage.
The packaging material the berm liner was wrapped in, as well as the lifting sling, will
remain spread flat under the berm liner.
Repair items (sealing clamps, plugs, gaskets) are packaged in a bag and should be
placed in a secure storage area until needed.
END OF TASK
REMOVAL OF BERM LINER DRAIN ASSEMBLY FLANGE AND INSTALLATION
OF DRAIN HOSE ASSEMBLY
WARNINGWARNING
Before fuel is introduced into the tank, verify that the drain ball valve handle is rotated fully
to the right (closed position). Unobserved drainage of fuel can result in an explosion or
fire. Failure to heed this warning can cause death or severe personal injury and damage to
equipment.
NOTE
There are drains on bottom of two diagonal corners of the berm liner.
1. Lift and fold over each corner as required to expose berm liner drain flange assembly underneath.
2. Remove O-ring (Figure 12, Item 12) and drain assembly blind flange (Figure 12, Item 11) by removing eight
1/4-inch cap screws (Figure 12, Item 8) and washers (Figure 12, Item 9) from berm liner (Figure 12, Item 13).
Discard O-ring (Figure 12, Item 12).
3. Locate 20-foot drain hose assembly with drain dome fitting (Figure 12, Item 10).
4. Inspect hose and drain fittings for cleanliness before assembly. Clean debris as necessary.
5. Position drain dome fitting (Figure 12, Item 10) where blind flange (Figure 12, Item 11) was removed. Rotate
drain dome fitting such that attached drain hose (Figure 12, Item 14) extends in proper direction away from
center of berm liner.
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0005-13
0005
REMOVAL OF BERM LINER DRAIN ASSEMBLY FLANGE AND INSTALLATION OF DRAIN HOSE
ASSEMBLY - Continued
Figure 12. Berm Liner Drain and Hose Assembly.
6. Place original cushioning material (Figure 13) between drain dome fitting and ground.
Figure 13. Berm Liner Drain Assembly and Cushioning Material.
7. Install new O-ring (Figure 12, Item 12).
8. Secure dome fitting (Figure 12, Item 10) with eight 1/4-inch cap screws (Figure 12, Item 8) and
washers (Figure 12, Item 9).
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0005-14
0005
REMOVAL OF BERM LINER DRAIN ASSEMBLY FLANGE AND INSTALLATION OF DRAIN HOSE
ASSEMBLY - Continued
9. Torque eight 1/4-inch cap screws (Figure 12, Item 8) to 11 ft-lbs. See WP 0026.
10. Save drain assembly blind flange (Figure 12, Item 11) for reuse in redeployment.
11. Locate drain ball valve assembly (Figure 12, Item 2).
WARNINGWARNING
Check that the drain valve is closed. The valve is closed when the handle is rotated fully in
the clockwise direction. Failure to close valve can cause loss of fuel and possible fire or
explosion with possible death or severe personal injury and damage to equipment.
Use caution to ensure fingers are not caught or pinched in the cam-lock levers. Serious
injury may occur if warning is not followed.
12. Move cam-lock levers on hose assembly dust cap (Figure 12, Item 7) to outward position and remove dust cap
from end of hose.
13. Move cam-lock levers on valve assembly (Figure 12, Item 15) to outward position and remove dust
plug (Figure 12, Item 6) from valve assembly.
14. Inspect hose and valve fittings for cleanliness before assembly. Clean debris as necessary.
15. Insert hose assembly (Figure 12, Item 14) into valve assembly (Figure 12, Item 2).
16. Close cam locks.
17. Rotate ball valve lever (Figure 12, Item 1) to closed position.
18. Locate other 20-foot drain hose assembly with male and female cam-lock fittings (Figure 12, Item 3).
19. Move cam-lock levers on hose assembly dust plug (Figure 12, Item 5) to outward position and remove dust plug
from end of hose.
20. Move cam-lock levers on hose assembly dust cap (Figure 12, Item 4) to outward position and remove dust cap
from end of hose.
21. Inspect hose and valve fittings for cleanliness before assembly. Clean debris as necessary.
22. Insert hose assembly (Figure 12, Item 3) onto valve assembly (Figure 12, Item 2).
23. Close cam locks.
END OF TASK
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0005-15
0005
UNPACKING THE EQUIPMENT - INSTALLATION OF THE FUEL TANK
WARNINGWARNING
The lifting device must have a minimum lifting capacity of 10,000 lbs. Failure to heed thiswarning can cause injury or death to personnel as well as damage to equipment.
1. Locate lifting straps (Figure 14, Item 2) around tank (Figure 14, Item 1). Carefully insert fork lift
forks (10,000-lb. capacity) through loops of lifting straps (Figure 14, Item 2).
Figure 14. Lifting the Collapsible Fuel Tank.
2. Transport tank (Figure 14, Item 1) to center of desired installation site.
3. Remove three ratchet straps and secure for packaging.
CAUTIONCAUTION
Ratchet straps must not be left under the tank because the buckles can tear the tank.
Failure to heed this caution can cause tank rupture.
NOTE
Before the tank installation continues, the folded half of the berm liner must be unfoldedand extended across the installation site and over the berm.
4. Unwrap tank from packaging material, unroll one-half of tank (Figure 15) along length of installation site, unroll
other half of tank (Figure 15) in opposite direction along length of installation site.
5. Tank is folded symmetrically about its center line. Unfold each side of tank.
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0005
UNPACKING THE EQUIPMENT - INSTALLATION OF THE FUEL TANK - Continued
Figure 15. Unrolling the Tank.
6. Pull folded sides of tank toward berm walls (Figure 16).
7. Locate all 6-inch fill/discharge valves, 2-inch drain ball valves, and vent assembly. Remove cushioning material
from ends of all hoses.
CAUTIONCAUTION
Use caution when operating sharp, cutting objects near, on or around the tank. Failure to
heed this caution can result in tearing the tank.
8. Remove cushioning material from all fill/discharge and vent fitting assemblies by cutting tape that secures
material in place.
9. Retighten all fill/discharge, vent, and drain fittings on tank to 11 ft-lbs (WP 0026).
NOTE
Save all cushioning and packing material for reuse when tank is put back into storage.
The packaging material the tank was wrapped in, as well as the lifting sling, will remain
spread flat under the collapsible fuel tank.
Repair items (sealing clamps, plugs, gaskets) are packaged in a bag and should be
placed in a secure storage area until needed.
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0005
UNPACKING THE EQUIPMENT - INSTALLATION OF THE FUEL TANK - Continued
Figure 16. Unfolding the Tank.
END OF TASK
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0005-19
0005
REMOVAL OF FUEL TANK DRAIN ASSEMBLY FLANGE AND INSTALLATION OF DRAIN HOSE
ASSEMBLY - Continued
7. Install new O-ring (Figure 17, Item 12).
8. Secure dome fitting (Figure 17, Item 10) with eight 1/4-inch cap screws (Figure 17, Item 8) and
washers (Figure 17, Item 9).
9. Torque 1/4-inch cap screws (Figure 17, Item 8) to 11 ft-lbs. See (WP 0026).
10. Save drain assembly blind flange for reuse in redeployment.
11. Locate drain ball valve assembly (Figure 17, Item 2).
WARNINGWARNING
Check that the drain valve is closed. The valve is closed when the handle is rotated fully inthe clockwise direction. Failure to close valve can cause loss of fuel and possible fire or
explosion with possible death or severe personal injury and damage to equipment.
Use caution to ensure fingers are not caught or pinched in the valves cam-lock levers.
Serious injury may occur if warning is not followed.
12. Move cam-lock levers on hose assembly dust cap (Figure 17, Item 7) to outward position and remove dust cap
from end of hose.
13. Move cam-lock levers on valve assembly (Figure 17, Item 15) to outward position and remove dust
plug (Figure 17, Item 6) from valve assembly.
14. Inspect hose and valve fittings for cleanliness before assembly. Clean debris as necessary.
15. Insert hose assembly (Figure 17, Item 14) into valve assembly (Figure 17, Item 2).
16. Close cam locks.
17. Rotate ball valve lever (Figure 17, Item 1) to closed position.
18. Locate 10-foot drain hose assembly (Figure 17, Item 3) with male and female cam-lock fittings.
19. Move cam-lock levers on hose assembly dust plug (Figure 17, Item 5) to outward position and remove dust plug
from end of hose.
20. Move cam-lock levers on hose assembly dust cap (Figure 17, Item 4) to outward position and remove dust cap
from end of hose.
21. Inspect hose and valve fittings for cleanliness before assembly. Clean debris as necessary.
22. Insert hose assembly (Figure 17, Item 3) onto valve assembly (Figure 17, Item 2).
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0005
REMOVAL OF FUEL TANK DRAIN ASSEMBLY FLANGE AND INSTALLATION OF DRAIN HOSE
ASSEMBLY - Continued
23. Close cam locks.
END OF TASK
INSTALLATION OF VENT PIPE ASSEMBLY
CAUTIONCAUTION
Prior to installing the fuel tanks, check all coupling gaskets and sealing surfaces to ensure
they are in place and serviceable. Failure to heed this caution can damage the equipment.
NOTE
Dust cap is chain-attached to prevent loss.
1. Remove dust cap (Figure 18, Item 1) by pulling cam-lock levers (Figure 18, Item 2) outward and lifting up on
dust cap.
NOTE
Normally the vent pipe and female coupling half are received pre-assembled.
2. Inspect all vent components for cleanliness before assembly. Clean debris as necessary.
3. Check that vent (Figure 19, Item 1) is installed tightly on vent pipe (Figure 19, Item 2).
4. Insert new gasket (Figure 19, Item 5) and female coupling (Figure 19, Item 6) over flanged
adapter (Figure 19, Item 4), with cam-lock levers (Figure 19, Item 3) in outward position.
5. Press cam-lock levers (Figure 19, Item 3) upward, and inward, to lock vent pipe (Figure 19, Item 2) into
operating position.
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0005
INSTALLATION OF VENT PIPE ASSEMBLY - Continued
Figure 18. Tank Vent Dust Cap.
Figure 19. Vent Pipe Assembly.
END OF TASK
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0005-22
0005
INSTALLATION OF FILL/DISCHARGE ELBOW ASSEMBLY
NOTE
The dust cap is attached to the flanged adapter to prevent it from being lost. Thefill/discharge elbow on the discharge end requires a female/male elbow; whereas, the
fill/discharge elbow used on the intake end requires a female/female elbow.
1. Remove dust cap (Figure 20, Item 2) from flanged adapter (Figure 20, Item 3) by pulling cam-lock
levers (Figure 20, Item 1) outward and lifting up on dust cap.
2. Inspect elbow (Figure 20, Item 6) for cleanliness. Clean debris as necessary.
3. Check that gasket (Figure 20, Item 4) is in place and properly seated.
4. Position female end of elbow (Figure 20, Item 6) over flanged adapter (Figure 20, Item 3) with cam-lock
levers (Figure 20, Item 5) in outward position.
5. Rotate elbow (Figure 20, Item 6) so that open end points in required direction.
NOTE
Cam-lock levers must be pushed inward to lock and pulled outward to unlock the elbow.
6. Lift cam-lock levers (Figure 20, Item 5) and lock elbow (Figure 20, Item 6) in place.
7. Install dust cap (Figure 20, Item 2) on open end of elbow (Figure 20, Item 6) and lock in place.
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0005
IINSTALLATION OF FILL/DISCHARGE ELBOW ASSEMBLY - Continued
Figure 20. Fill/Discharge Elbow Assembly.
END OF TASK
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0005
INSTALLATION OF FILL/DISCHARGE HOSE ASSEMLY AND FILL/DISCHARGE VALVE ASSEMBLY -
Continued
10. Gate valve (Figure 21, Item 6) is fully closed by rotating hand-wheel (Figure 21, Item 5) to right and
backing off one-quarter turn.
END OF TASK
INITIAL ADJUSTMENTS AND ROUTINE CHECKS
NOTE
If the tank is cut or punctured during any phase of operation, refer to WP 0007 for
emergency repair procedures.
1. Position filled sandbag(s) (Figure 22, Item 1) under hose (Figure 22, Item 3) near fill/discharge
elbow (Figure 22, Item 4). This support will reduce stress on tank fitting, gasket in hose coupling, and
coupling of fill/discharge elbow.
Figure 22. Elevated Connections for Easy Leak Detection.
WARNINGWARNING
Check the placement of sandbags to see potential leak points in order to avoid fire hazard.
Failure to check the positions of sandbags can cause serious injury or death by fire or
explosion.
2. Position other sandbags (Figure 22, Item 1) or wood blocks on ground near hose connections so that faulty or
leaking connection is easier to see, and fire hazard can be avoided.
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0005
INITIAL ADJUSTMENTS AND ROUTINE CHECKS - Continued.
3. Inspect tank to verify elevated connection setup for easy leak detection.
4. Check drain ball valve (not shown) to verify closed position.
5. Check fill/discharge gate valve (Figure 22, Item 2) to verify closed position.
END OF TASK
FILLING THE TANK
WARNINGWARNING
Over time tanks can become weakened and rupture, thereby spilling fuel. Tanks that have
exceeded the minimum service life of 3 years should be monitored closely. Failure to heed
this warning can cause injury or death to personnel.
Ensure that all cam locks are in the proper locked position before filling the tank.
Improperly closed connections can cause leaks, which can cause serious injury or death
by fire or explosion.
CAUTIONCAUTION
Persons operating the fuel tank must periodically check the dates on the data plates to
verify that the tank is safe for use. Each tank has a three-year service life beginning on
the date when it is first filled. Shelf storage life is twelve years from the date of
manufacture. Failure to heed this caution can cause tank rupture.
1. After performing adjustments and routine checks, attach fuel source to fill/discharge gate
valve (Figure 22, Item 2).
2. Open gate valve (Figure 22, Item 2).
WARNINGWARNING
Do not exceed maximum fill capacity. The fuel tank will burst if it is overfilled, causing
damage to the equipment. Failure to heed this warning can cause injury or death to
personnel.
3. Activate fuel source. Table 4 provides approximate height-to-volume ratios.
4. Deactivate fuel source.
5. Close gate valve (Figure 22, Item 2) when tank is full.
6. Disconnect fuel source from gate valve (Figure 22, Item 2), if necessary.
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0005
FILLING THE TANK - Continued
END OF TASK
Table 4. Strapping Chart.
Height (in.) Volume (gal).
0.125 386
0.250 776
0.500 1544
0.750 2316
1 3,088
2 6,176
3 9,264
4 12,352
5 15,440
6 18,528
7 21,6168 24,704
9 27,792
10 30,800
11 33,968
12 37,056
13 40,144
14 43,232
15 46,320
16 49,408
17 52,496
18 55,58419 58,672
20 61,760
21 64,848
22 67,936
23 71,024
24 74,112
25 77,200
26 80,288
27 83,376
28 86,464
29 89,55230 92,640
31 95,728
32 98,816
33 101,904
34 104,992
35 108,080
36 111,168
37 114,256
38 117,344
39 120,432
40 123,520
41 126,608
42 129,696
43 132,78444 135,872
45 138,960
46 142,048
47 145,136
48 148,224
49 151,312
50 154,400
51 157,488
52 160,576
53 163,664
54 166,75255 169,840
56 172,928
57 176,016
58 179,104
59 182,192
60 185,280
61 188,368
62 191,456
63 194,544
64 197,632
65 200,72066 203,808
67 206,896
68 210,000
Table 4. Strapping Chart.
Height (in.) Volume (gal).
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0005
DRAINING THE TANK
NOTE
Use the female/male discharge elbow for this operation.
1. Attach emptying source to gate valve (Figure 22, Item 2).
2. Open gate valve (Figure 22, Item 2).
3. Activate emptying source.
4. Close gate valve (Figure 22, Item 2) when tank is empty by rotating handle clockwise.
5. Deactivate emptying source.
6. Disconnect emptying source from gate valve (Figure 22, Item 2).
7. Disconnect fill/discharge hose from elbow.
8. Squeeze excess fuel from tank by rolling ends of tank towards drain fitting (not shown).
9. Open drain fitting ball valve to allow fuel to drain from tank (not shown).
WARNINGWARNING
Sludge that accumulates at the bottom of the tank gives off toxic and explosive vapors.
Inhaling these vapors can cause poisoning. When cleaning the fuel tanks, provide ample
ventilation to dissipate harmful fumes. Failure to heed this warning can cause injury or
death to personnel.
Always wear protective goggles, a breathing apparatus, and other protective gear when
cleaning the tank interior. Fuel vapors are toxic and can damage eyes, skin, and lungs.
Failure to heed this warning can cause injury or death to personnel.
Fuel vapors are extremely flammable. Exercise care to prevent sparks when working near
the tank. Death or severe injury can result if safety precautions are not strictly observed.
The tank is a permit required confined space. Do not enter to clean or for any other
reason. Sludge that accumulates in the bottom of the fuel tank gives off toxic and
explosive vapors. Inhaling these vapors is harmful to personnel. Death or serious injury
may occur if warning is not followed due to lack of exygen.
10. Clean tank of residual sludge that accumulates at bottom of storage tank and dispose of sludge in compliance
with EPA and local regulations.
END OF TASK
END OF WORK PACKAGE
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0006-1
0006
OPERATOR AND FIELD MAINTENANCE
TANK ASSEMBLY, FABRIC, COLLAPSIBLE, 210,000 U.S. GALLONS, FUEL
NSN 5430-01-571-5535 and NSN 5430-01-571-5512OPERATION UNDER USUAL CONDITIONS - RETRIEVAL
PREPARATION FOR MOVEMENT
WARNINGWARNING
Do not exceed maximum air pressure of 0.5 pounds per square inch. Failure to heed this
warning can cause injury or death to personnel.
Personnel shall wear ear protection device when working near or around compressed air.
Failure to heed this warning can cause injury to personnel.
1. Dry out tank by purging with air pressure. Use maximum line pressure of 0.5 pounds per square inch.
INITIAL SETUP:
Tools and Special Tools Equipment Condition
Tool Kit, General Mechanics
(WP 0034, Table 2, Item 2)
Tank Drained
(WP 0005)
Torque Wrench(WP 0034, Table 2, Item 3) References
Ear Plugs
(WP 0036, Table 1, Item 4)
MIL-STD-129
WP 0005
WP 0026
WP 0036
Materials/Parts Personnel Required
Brush, Scrub
(WP 0036, Table 1, Item 1)
25
Dry Cleaning Solvent
(WP 0036, Table 1, Item 3)
Goggles, Industrial
(WP 0036, Table 1, Item 6) Mandatory Replacement Parts
Rags, Wiping
(WP 0036, Table 1, Item 8)
O-ring, 4-inch
(WP 0037, Table 1, Item 2)
Tape
(WP 0036, Table 1, Item 10)
Gasket, 2-inch
(WP 0037, Table 1, Item 4) (2)
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0006-2
0006
PREPARATION FOR MOVEMENT - Continued
a. Insert air hose through fill/discharge adapter, placing wiping rags (WP 0036, Table 1, Item 8) around air
hose at fitting to prevent air from escaping.
b. Apply compressed air into tank until tank expands to 3 feet in height.
c. Remove dust cap from vent fitting to allow air to vent from tank for 30 minutes.
d. Deactivate compressed air source and remove air hose and rags.
2. Remove drain hose assembly from drain fitting and install drain blind flange.
a. Locate 20-foot drain hose assembly with drain dome fitting (Figure 1, Item 10).
Figure 1. Tank Drain and Hose Assembly.
b. Remove drain dome fitting by removing eight 1/4-inch cap screws (Figure 1, Item 8) and
washers (Figure 1, Item 9).
c. Position O-ring (Figure 1, Item 12) and blind flange (Figure 1, Item 11) where drain dome fitting was
removed.
d. Secure O-ring (Figure 1, Item 12) and blind flange (Figure 1, Item 11) with eight 1/4-inch capscrews (Figure 1, Item 8) and washers (Figure 1, Item 9). Torque cap screws to 11 ft-lbs. See WP 0026.
3. Remove fill/discharge elbows from fill/discharge adapters.
a. Locate fill/discharge assemblies located on top of tank.
b. Remove each fill/discharge elbow assembly (Figure 2, Item 6) by releasing cam lock (Figure 2, Item 5).
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0006
PREPARATION FOR MOVEMENT - Continued
c. Secure dust cap (Figure 2, Item 2) on fill/discharge assembly (Figure 2, Item 3).
d. Wrap original cushioning material around fill/discharge fitting and secure in place with
tape (WP 0036, Table 1, Item 10).
Figure 2. Fill/Discharge Elbow Assembly.
e. Repeat steps 3b through 3d for other fill/discharge assemblies.
4. Remove vent pipe assembly from flanged adapter and install dust cap.
a. Locate vent fitting assembly in center of top of tank.
b. Remove upper portion of vent fitting assembly (Figure 3, Item 1) by releasing cam lock (Figure 3, Item 3).
c. Wrap upper portion with original cushioning material.
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0006-4
0006
PREPARATION FOR MOVEMENT - Continued
d. Do not secure dust plug on vent fitting assembly at this time, as it may be necessary to vent air from tank as
it is being rolled.
5. Secure original cushioning material to each tank fitting with tape (WP 0036, Table 1, Item 10) to protect tank
fabric from metal parts.
Figure 3. Vent Pipe Assembly.
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0006-5
0006
PREPARATION FOR MOVEMENT - Continued
6. Align original cushioning material with position of unlocked cams on dust cap (Figure 4).
Figure 4. Cushioning Material.
7. Pull tape until snug without overtightening (Figure 5).
8. Repeat for remaining three tank fittings.
Figure 5. Secure Cushioning Material.
9. Brush off any stones or debris clinging to tank.
END OF TASK
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0006-6
0006
PREPARATION FOR FOLDING TANK
1. Ensure tank is completely empty.
a. Lift up corners of tank where drain hose is attached and flip over to expose drain fitting.
b. Disconnect drain dome fitting and install drain blind flange.
c. Lay corner back so that tank is flat.
2. Remove vent fitting assembly.
a. Locate vent fitting assembly (Figure 6, Item 1) in center of top of tank.
b. Remove upper portion of vent fitting assembly (Figure 6, Item 1) by releasing cam lock (Figure 6, Item 3).
c. Wrap upper portion with original cushioning material.
Figure 6. Vent Tank Assembly.
d. Do not secure dust cap on vent fitting assembly at this time, as it may be necessary to vent air from tank as
it is being rolled.
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0006-7
0006
PREPARATION FOR FOLDING TANK - Continued
3. Remove air from inside tank and remove fill/discharge assembly elbows.
a. Locate fill/discharge elbow assemblies (Figure 7) located on top of tank.
b. Remove each fill/discharge elbow assembly (Figure 7, Item 6) by releasing cam lock (Figure 7,