Inland and Coastal Large Tug (LT) NSN 1925-01-509-7013 (EIC XAG)

*TM 55-1925-273-24&P-2
TECHNICAL MANUAL FIELD AND SUSTAINMENT MAINTENANCE MANUAL INCLUDING REPAIR PARTS AND SPECIAL TOOLS LIST FOR
INLAND AND COASTAL LARGE TUG (LT) NSN 1925-01-509-7013 (EIC XAG)
MG ANTHONY WAYNE
US ARMY LT - 803
18 17 16 15 14 13
15 14 13 12 11 10 9
*SUPERSEDURE NOTICE - This manual supersedes TM 55-1925-273-24&P-2, dated 30 November 2005, including all changes. DISTRIBUTION STATEMENT A - Approved for public release; distribution is unlimited.
HEADQUARTERS, DEPARTMENT OF THE ARMY 31 JANUARY 2013

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TM 55-1925-273-24&P-2
WARNING SUMMARY
This warning summary contains general safety warnings and hazardous materials warnings that must be understood and applied during operation and maintenance of this vessel and its equipment. Failure to observe these precautions could result in serious injury or death to personnel. Also included are explanations of safety and of hazardous materials used within the technical manual. FIRST AID DATA Although the 128 ft Large Tug is normally assigned a medic, first aid is still an important skill for all crewmembers. The ability to promptly administer first aid to another crewmember could mean the difference between life and death for that crewmember. First aid procedures for soldiers are contained in FM 4-25.11. EXPLANATION OF SAFETY WARNING ICONS
EAR PROTECTION - Headphones over ears show that noise level will harm ears.
ELECTRICAL - Electrical wire to arm with electricity symbol running through human body shows that shock hazard is present.
ELECTRICAL - Electrical wire to hand with electricity symbol running through hand shows that shock hazard is present.
FALLING PARTS - Arrow bouncing off human shoulder and head shows that falling parts present a danger to life or limb.
FLYING PARTICLES - Arrows bouncing off face shows that particles flying through the air will harm face.
FLYING PARTICLES - Arrows bouncing off face with face shield show that particles flying through the air will harm face.
HEAVY OBJECT - Human figure stooping over heavy object shows physical injury potential from improper lifting technique.
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WARNING SUMMARY - Continued

EXPLANATION OF SAFETY WARNING ICONS - Continued
HEAVY PARTS - Hand with heavy object on top shows that heavy parts can crush and harm.
HEAVY PARTS - Foot with heavy object on top shows that heavy parts can crush and harm.
HEAVY PARTS - Heavy object on human figure shows that heavy parts present a danger to life or limb.
HEAVY PARTS - Heavy object pinning human figure against wall shows that heavy, moving parts present a danger to life or limb.
HELMET PROTECTION - Arrow bouncing off head with helmet shows that falling parts present a danger.
HOT AREA - Hand over object radiating heat shows that part is hot and can burn.
LASER LIGHT - Laser light hazard symbol indicates extreme danger for eyes from laser beams and reflections.
MOVING PARTS - Human figure with arm caught between gears shows that the moving parts of the equipment present a danger to life or limb.
MOVING PARTS - Hand with fingers caught between gears shows that the moving parts of the equipment present a danger to life or limb.
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EXPLANATION OF SAFETY WARNING ICONS - Continued
MOVING PARTS - Hand with fingers caught between rollers shows that the moving parts of the equipment present a danger to life or limb.
SHARP OBJECT - Pointed object in hand shows that a sharp object presents a danger to limb.
SHARP OBJECT - Pointed object in hand shows that a sharp object presents a danger to limb.
SHARP OBJECT - Pointed object in foot shows that a sharp object presents a danger to limb.
SLICK FLOOR - Wavy line on floor with legs prone shows that slick floor presents a danger for falling.
GENERAL SAFETY WARNINGS DESCRIPTION
WARNING
CONFINED SPACE ENTRY Only properly trained personnel may enter confined spaces, or act as entry supervisors and/ or attendants for those working in confined spaces. Before entering into a confined space, the space must be cleared for entry and a Confined Space Entry Permit must be secured. All entry into confined spaces must be in accordance with the Organizational Confined Space Entry Standard Operating Procedure and FM 4-01.502. Entry into an uninspected confined space may result in death or serious injury to personnel.
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GENERAL SAFETY WARNINGS DESCRIPTION - Continued
WARNING
ELECTRICAL Replace or repair components only after the affected circuit has been secured, locked out, and tagged out IAW FM 4-01.502. Performing replacement or repair with the circuit energized may result in serious injury or death. Take great care when working around energized electrical equipment. Contact between unprotected body parts and electrical conductors can cause serious injury or death. Do not wear jewelry or other conductive items while servicing energized electrical equipment. Failure to comply with these precautions can cause serious injury or death.
WARNING
GALLEY NOISE HAZARD All crewmembers working in the galley area must wear Army Hearing Protection Devices (HPDs) and ensure that the galley doors remain closed. Failure to comply could result in injury.
WARNING
LIFTING OPERATIONS AND HEAVY LOADS All personnel in the vicinity of lifting operations should wear appropriate safety equipment including gloves, hard hat, and safety shoes. Death or serious injury can result from failure to heed this warning. Heavy loads can crush. Do not allow any body parts to come under the load or between the load and a stationary object. Death or serious injury can result. Heavy loads can crush. Use a minimum of two crewmembers to lift and hold heavy loads. Do not allow any body parts to come under the load or between the load and a stationary object. Failure to comply can result in serious injury or death.
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GENERAL SAFETY WARNINGS DESCRIPTION - Continued
WARNING
LOCKING HARDWARE Never reuse locking hardware. Reuse of locking hardware such as lockwashers, locking nuts, cotter pins, and lockwire can result in undetected loosening of fastening hardware causing catastrophic component failure resulting in death, injury, or damage to equipment. Ensure that all locking hardware is discarded upon removal and replaced with new.
WARNING
MACHINE GUN NOISE HAZARD During M2 caliber 0.50 weapons firing, all personnel standing outside on deck must wear Army Hearing Protection Devices (HPDs). Failure to comply with this warning could result in serious injury.
WARNING
PRESSURIZED LINES Hydraulic hoses and lines may be under pressure. Relieve pressure by operating the appropriate control valve, if possible. Loosen fittings on hose lines slowly. Allow oil to run around threads of fitting, releasing pressure before disconnecting fitting. Releasing pressurized oil suddenly may cause death or severe personal injury.
WARNING
ROTATING EQUIPMENT Use extreme caution when working around rotating components. Do not allow hands or tools to come in contact with the rotating components. Do not wear loose clothing, jewelry, or anything else which might become entangled in the rotating components. Failure to comply can result in death or serious injury.
WARNING
SAFETY HARNESS Ensure that a safety harness is worn when inspecting antennas. Failure to comply could result in injury or death.
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EXPLANATION OF HAZARDOUS MATERIALS ICONS AND DESCRIPTIONS
BIOLOGICAL - Abstract symbol bug shows that a material may contain bacteria or viruses that present a danger to life or health.
CHEMICAL - Drops of liquid on hand shows that the material will cause burns or irritation to human skin or tissue.
CRYOGENIC - Hand in block of ice shows that the material is extremely cold and can injure human skin or tissue.
EXPLOSION - Rapidly expanding symbol shows that the material may explode if subjected to high temperatures, sources of ignition, or high pressure.
EYE PROTECTION - Person with goggles shows that the material will injure the eyes.
FIRE - Flame shows that a material may ignite and cause burns.
POISON - Skull and crossbones shows that a material is poisonous or is a danger to life.
RADIATION - Three circular wedges shows that the material emits radioactive energy and can injure human tissue.
VAPOR - Human figure in a cloud shows that material vapors present a danger to life or health.
TM 55-1925-273-24&P-2

HAZARDOUS MATERIALS DESCRIPTIONS
WARNING
BATTERIES Batteries produce hydrogen gas. This gas is explosive. Keep the work area free of sparks, open flame, and excessive heat. Take care to prevent conductive metal tools from arcing between the positive and negative terminals. Failure to comply with these precautions can result in death or serious injury. Batteries are filled with a sulfuric acid based electrolyte. This electrolyte is extremely corrosive to human tissue and to many other materials. Chemical protective gloves, goggles, faceshield, and an apron must be worn at all times when batteries are being serviced. If electrolyte comes in contact with clothing or other material, wash the affected area with large volumes of fresh water. If electrolyte comes in contact with the skin, flush the area with large volumes of water. If the electrolyte comes in contact with the eyes, flush them with large volumes of water. Continue flushing the affected area until medical assistance arrives. Failure to comply can result in death or serious injury.
WARNING
CHLORINE AND BROMINE STORAGE AND HANDLING Chlorine and the Water Demineralizer Cartridge (NSN 4610-01-022-9970) which contains the chemical Bromine may not be stored together. Both chemicals, Chlorine and Bromine, must follow the Federal HAZCOM standard (29 CFR 1910.1200) along with the Material Safety Data Sheet (MSDS) for each chemical. Failure to comply could result in injury or death.
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HAZARDOUS MATERIALS DESCRIPTIONS - Continued
WARNING
DIESEL FUEL Fuel vapors are explosive. Fuel is flammable. Before fueling the tanks or transferring fuel, ensure that firefighting equipment is immediately available for use in case of fire emergency. Do not smoke or allow smoking, or any other open flame in the vicinity of the fueling operation. Wipe clean any fuel spillage and dispose of spilled fuel in accordance with the appropriate local regulations. A fueling watch supervisor shall be stationed to ensure compliance with fueling safety procedures. Failure to comply can result in death or serious injury. Avoid prolonged exposure of the skin to diesel fuel. Chemical protective gloves and goggles must be worn whenever handling diesel fuel or parts which are saturated with diesel fuel. Failure to comply can result in death or serious injury.
WARNING
GAYLORD VENTILATION AND FIRE SUPPRESSION SYSTEM In the event that the Gaylord Ventilation and Fire Suppression system is activated and exposure to the fire suppressant occurs, all personnel exposed should immediately wash out the eyes and shower to remove residual material. Failure to comply could result in injury or death.
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WARNING
HOT WORK AND GRINDING Removing components by means of grinding or cutting produces hot, flying particles. These particles can cause serious injury to personnel. These hot particles can also ignite fires in the work area and in adjacent spaces. During and after removal, the work area will be very hot. Wear protective goggles, gloves, and/or apron at all times during cutting and grinding operations. A fire watch must be posted whenever grinding or cutting operations re taking place. Failure to comply with this warning can result in serious injury or death to personnel. Grinding, needling, and chipping operations produce high velocity flying debris which can become lodged in the skin or in the eyes. Grinding, needling, and chipping in confined spaces can result in debris flying from unexpected directions. All personnel working in the area must wear protective eyewear, gloves, and long sleeves when performing grinding, needling and chipping operations. Failure to comply can result in death or serious injury to personnel. Removing components by means of wire brushing produces flying particles. These particles can cause serious injury to personnel. Protective goggles, gloves, and long sleeves must be worn at all times during wire brushing operations. Failure to comply with this warning can result in serious injury to personnel.
WARNING
WELDING Unprotected exposure to arc welding rays can cause serious eye damage and radiation burns to the skin. Never perform arc welding operations without using appropriate eye and skin protection. Failure to comply can result in death or serious injury.
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WARNING
OILS AND CLEANING SOLVENT Cleaning solvent is flammable and its vapor is potentially explosive. Do not use cleaning solvent in the vicinity of spark, open flame, or excessive heat. Do not use cleaning solvent in unventilated spaces. Failure to comply can result in death or serious injury. Do not allow hydraulic fluid, engine oil, or cleaning solvents to come in contact with unprotected skin or eyes. Prolonged skin contact can cause illness or injury. Eye contact can cause serious injury. Always wear chemical protective gloves and goggles when handling hydraulic fluid, engine oil, and cleaning solvents. Failure to comply can result in death or serious injury.
WARNING
RADIATION, RADIO ANTENNAS Inspecting antennas with the INSA, radars, transceivers and receiver-transmitters turned on presents a radiation hazard. Ensure all transceivers and receiver-transmitters are turned off prior to inspecting antennas. Ensure that the appropriate circuit breaker has been secured, locked out, and tagged out (WP 0008) in accordance with FM 4-01.502. Failure to comply could result in injury or death.
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WARNING
SEWAGE Sewage is a common mode of transmission for parasitic organisms that may have the capability of causing communicable diseases. Chemical protective gloves and a protective apron should be worn to help prevent contact with sewage. After coming in contact with sewage or contaminated equipment, be sure to clean yourself with a disinfectant soap. Avoid sewage contact with skin abrasions, punctures, cuts, and other open wounds. Wipe up and clean any spills and/or contaminated equipment using a disinfectant soap. Failure to comply can result in death or serious illness. Toxic and flammable vapors are generated in the sewage system. Provide ventilation from outside source. Avoid open flames and prolonged breathing of fumes. Failure to comply can result in death or serious injury.
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LIST OF EFFECTIVE PAGES/WORK PACKAGES

NOTE: This manual supersedes TM 55-1925-273-24&P-2, dated 30 November 2005, including all changes. Zero in the "Change No." column indicates an original page or work package. Date of issue for the original manual is: Original 31 January 2013
TOTAL NUMBER OF VOLUMES IS 3, TOTAL NUMBER OF PAGES FOR FRONT AND REAR MATTER IS 54 AND TOTAL NUMBER OF WORK PACKAGES IS 163, CONSISTING OF THE FOLLOWING: Page/WP No. VOLUME 2 Front Cover (2 pages) Warning Summary (12 pages) i-xxiv (24 pages) Chapter 5 Title Page WP 0083 (2 pages) WP 0084 (4 pages) WP 0085 (10 pages) WP 0086 (22 pages) WP 0087 (2 pages) WP 0088 (4 pages) WP 0089 (6 pages) WP 0090 (4 pages) WP 0091 (8 pages) WP 0092 (12 pages) WP 0093 (4 pages) WP 0094 (6 pages) WP 0095 (6 pages) WP 0096 (6 pages) WP 0097 (6 pages) WP 0098 (8 pages) WP 0099 (2 pages) WP 0100 (2 pages) WP 0101 (4 pages) WP 0102 (4 pages) WP 0103 (6 pages) WP 0104 (6 pages) WP 0105 (4 pages) WP 0106 (2 pages) WP 0107 (6 pages) WP 0108 (6 pages) WP 0109 (4 pages) WP 0110 (4 pages) WP 0111 (10 pages) WP 0112 (4 pages) WP 0113 (4 pages) WP 0114 (4 pages) WP 0115 (4 pages) WP 0116 (12 pages) Change No. Page/WP No. WP 0117 (8 pages) WP 0118 (6 pages) WP 0119 (6 pages) WP 0120 (4 pages) WP 0121 (10 pages) WP 0122 (4 pages) WP 0123 (6 pages) WP 0124 (8 pages) WP 0125 (6 pages) WP 0126 (16 pages) WP 0127 (8 pages) WP 0128 (20 pages) WP 0129 (4 pages) WP 0130 (4 pages) WP 0131 (4 pages) WP 0132 (4 pages) WP 0133 (4 pages) WP 0134 (4 pages) WP 0135 (4 pages) WP 0136 (4 pages) WP 0137 (4 pages) WP 0138 (6 pages) WP 0139 (4 pages) WP 0140 (4 pages) WP 0141 (4 pages) WP 0142 (6 pages) WP 0143 (4 pages) WP 0144 (6 pages) WP 0145 (4 pages) WP 0146 (4 pages) WP 0147 (4 pages) WP 0148 (4 pages) WP 0149 (4 pages) WP 0150 (4 pages) WP 0151 (4 pages) WP 0152 (6 pages) WP 0153 (4 pages) WP 0154 (8 pages) WP 0155 (10 pages) WP 0156 (8 pages) Change No. 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
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LIST OF EFFECTIVE PAGES/WORK PACKAGES - Continued

Page/WP No. WP 0157 (20 pages) WP 0158 (4 pages) WP 0159 (6 pages) WP 0160 (14 pages) WP 0161 (4 pages) WP 0162 (6 pages) WP 0163 (6 pages) WP 0164 (2 pages) WP 0165 (6 pages) WP 0166 (8 pages) WP 0167 (8 pages) WP 0168 (4 pages) WP 0169 (4 pages) WP 0170 (4 pages) WP 0171 (8 pages) WP 0172 (4 pages) WP 0173 (4 pages) WP 0174 (8 pages) WP 0175 (16 pages) WP 0176 (2 pages) WP 0177 (8 pages) WP 0178 (4 pages) WP 0179 (14 pages) WP 0180 (4 pages) WP 0181 (12 pages) WP 0182 (4 pages) WP 0183 (4 pages) WP 0184 (4 pages) WP 0185 (6 pages) WP 0186 (8 pages) WP 0187 (6 pages) WP 0188 (8 pages) WP 0189 (6 pages) WP 0190 (4 pages) WP 0191 (6 pages) WP 0192 (4 pages) WP 0193 (10 pages) WP 0194 (6 pages) WP 0195 (8 pages) WP 0196 (12 pages) WP 0197 (6 pages) WP 0198 (4 pages) WP 0199 (4 pages) WP 0200 (2 pages) WP 0201 (6 pages) Change No. 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 Page/WP No. WP 0202 (10 pages) WP 0203 (6 pages) WP 0204 (6 pages) WP 0205 (4 pages) WP 0206 (8 pages) WP 0207 (4 pages) WP 0208 (8 pages) WP 0209 (4 pages) WP 0210 (6 pages) WP 0211 (6 pages) WP 0212 (6 pages) WP 0213 (4 pages) WP 0214 (10 pages) WP 0215 (6 pages) WP 0216 (6 pages) WP 0217 (6 pages) WP 0218 (6 pages) WP 0219 (4 pages) WP 0220 (8 pages) WP 0221 (4 pages) WP 0222 (4 pages) WP 0223 (4 pages) WP 0224 (4 pages) WP 0225 (8 pages) WP 0226 (6 pages) WP 0227 (4 pages) WP 0228 (8 pages) WP 0229 (10 pages) WP 0230 (6 pages) WP 0231 (8 pages) WP 0232 (4 pages) WP 0233 (8 pages) WP 0234 (4 pages) WP 0235 (12 pages) WP 0236 (6 pages) WP 0237 (6 pages) WP 0238 (6 pages) WP 0239 (4 pages) WP 0240 (4 pages) WP 0241 (4 pages) WP 0242 (4 pages) WP 0243 (4 pages) WP 0244 (6 pages) WP 0245 (4 pages) Back Cover Change No. 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
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*TM 55-1925-273-24&P-2 HEADQUARTERS DEPARTMENT OF THE ARMY WASHINGTON, D.C., 31 JANUARY 2013
TECHNICAL MANUAL
FIELD AND SUSTAINMENT MAINTENANCE MANUAL INCLUDING REPAIR PARTS AND SPECIAL TOOLS LIST FOR
INLAND AND COASTAL LARGE TUG (LT) NSN 1925-01-509-7013 (EIC XAG)
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 TACOM Unique Logistics Support Applications (TULSA) Web site. The Internet address is https://tulsa.tacom.army.mil. Access to all applications requires CAC authentication, and you must complete the Access Request form the first time you use it. The DA Form 2028 is located under the TULSA Applications on the left-hand navigation bar. Fill out the form and click on SUBMIT. Using this form on the TULSA Web site will enable us to respond more quickly to your comments and to better manage the DA Form 2028 program. You may also mail, e-mail, or fax your comments or DA Form 2028 directly to the U.S. Army TACOM Life Cycle Management Command. The postal mail address is U.S. Army TACOM Life Cycle Management Command, ATTN: AMSTA-LCL-MPP/ TECH PUBS, MS 727, 6501 E. 11 Mile Road, Warren, MI 48397-5000. The e-mail address is tacomlcmc.daform2028@us.army.mil. The fax number is DSN 786-1856 or Commercial (586) 282-1856. A reply will be furnished to you.
*SUPERSEDURE NOTICE - This manual supersedes TM 55-1925-273-24&P-2, dated 30 November 2005, including all changes. DISTRIBUTION STATEMENT A - Approved for public release; distribution is unlimited.
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TABLE OF CONTENTS
Page No. WP Sequence No. Volume 2 Chapter 5 - FIELD MAINTENANCE INSTRUCTIONS FOR LT-800 SERIES SERVICE UPON RECEIPT............................................................................................................... WP 0083 HULL STRUCTURE SERVICE.......................................................................................................... WP 0084 Figure 1. Deck Drain.................................................................................................................... 0084-2 PILOTHOUSE REPLACE.................................................................................................................. WP 0085 Table 1. Windshield Wipers and Motors...................................................................................... 0085-2 Figure 1. Windshield Wiper Motor............................................................................................... 0085-2 Figure 2. Windshield Wiper Motor Junction Box.......................................................................... 0085-3 Figure 3. Windshield Wiper Components (Exploded View)......................................................... 0085-4 Table 2. Heater Switch Circuit Breakers...................................................................................... 0085-6 Figure 4. Heater Switch Bank...................................................................................................... 0085-7 Figure 5. Heater Switch............................................................................................................... 0085-8 PILOTHOUSE REPAIR...................................................................................................................... WP 0086 Figure 1. 120 V Exterior Emergency Lighting Panel No. 2.......................................................... 0086-2 Figure 2. Wiper Blade.................................................................................................................. 0086-3 Figure 3. Toggle Latch................................................................................................................. 0086-4 Figure 4. 01 & 02 Level Reheater 120 V Fuse Box No. 1............................................................ 0086-5 Figure 5. Pilothouse Wing Console (Starboard Shown, Port Opposite Hand)............................. 0086-6 Figure 6. Pilothouse Wing Console Thermostat.......................................................................... 0086-8 Figure 7. Pilothouse Wing Console Heater................................................................................ 0086-11 Figure 8. Navigator's Seat......................................................................................................... 0086-12 Figure 9. General Alarm and Emergency Lighting Distribution Panel....................................... 0086-13 Figure 10. Pilothouse Console Illumination Light....................................................................... 0086-14 Figure 11. Pilothouse Alarm Panel............................................................................................ 0086-16 Figure 12. Pilothouse Alarm Panel (Back Side)......................................................................... 0086-17 Figure 13. LED........................................................................................................................... 0086-17
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TABLE OF CONTENTS - Continued

Page No. WP Sequence No. Figure 14. Pilothouse Alarm Panel Pushbutton......................................................................... 0086-19 Figure 15. Pilothouse Alarm Panel Buzzer................................................................................ 0086-20 HYDRAULIC WATERTIGHT DOORS ADJUST................................................................................ WP 0087 Figure 1. Hydraulic Watertight Door............................................................................................ 0087-2 HYDRAULIC WATERTIGHT DOORS REPAIR................................................................................. WP 0088 Figure 1. Hydraulic Watertight Door............................................................................................ 0088-2 HYDRAULIC CYLINDER ASSEMBLY REPLACE............................................................................. WP 0089 Figure 1. Valve Assembly............................................................................................................ 0089-3 Figure 2. Hydraulic Cylinder........................................................................................................ 0089-5 HYDRAULIC CYLINDER ASSEMBLY REPAIR................................................................................ WP 0090 Figure 1. End View of Cylinder.................................................................................................... 0090-2 Figure 2. Cylinder Assembly........................................................................................................ 0090-3 CONTROL VALVE ASSEMBLY REPLACE....................................................................................... WP 0091 Figure 1. AMS 1 and AMS 2 Control Valve Assemblies.............................................................. 0091-3 Figure 2. Control Valve Assembly............................................................................................... 0091-4 Figure 3. Hydraulic Cylinder Vent................................................................................................ 0091-5 Figure 4. Control Valve Assembly Pressure Setting.................................................................... 0091-7 CONTROL VALVE ASSEMBLY REPAIR.......................................................................................... WP 0092 Figure 1. Remote Valve Assembly.............................................................................................. 0092-3 Figure 2. Single Check Valve...................................................................................................... 0092-5 Figure 3. Dual Relief Valve.......................................................................................................... 0092-7 Figure 4. Quad Check Valve........................................................................................................ 0092-9 Figure 5. Shuttle Valve.............................................................................................................. 0092-11 HAND PUMPS LOCAL/REMOTE REPLACE.................................................................................... WP 0093 Figure 1. Hydraulic Watertight Door System............................................................................... 0093-3 Figure 2. Hand Pump................................................................................................................... 0093-4 HAND PUMPS LOCAL/REMOTE REPAIR........................................................................................ WP 0094
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Page No. WP Sequence No. Figure 1. Local Hand Pump......................................................................................................... 0094-3 Figure 2. Remote Hand Pump..................................................................................................... 0094-4 WATERTIGHT DOORS REPAIR....................................................................................................... WP 0095 Figure 1. Watertight Door............................................................................................................ 0095-3 Figure 2. Watertight Door (Typical).............................................................................................. 0095-4 WATERTIGHT HATCHES REPAIR................................................................................................... WP 0096 Figure 1. Watertight Hatch........................................................................................................... 0096-2 Figure 2. Watertight Hatch........................................................................................................... 0096-4 WATERTIGHT SCUTTLES REPAIR................................................................................................. WP 0097 Figure 1. Watertight Scuttle......................................................................................................... 0097-3 Figure 2. Watertight Scuttle......................................................................................................... 0097-4 WATERTIGHT MANHOLES REPAIR................................................................................................ WP 0098 Figure 1. Manhole (Raised)......................................................................................................... 0098-3 Figure 2. Manhole (Flush)............................................................................................................ 0098-4 Figure 3. Raised Manhole Cover (Typical).................................................................................. 0098-5 Figure 4. Flush Manhole (Typical)............................................................................................... 0098-7 MAST SERVICE................................................................................................................................ WP 0099 MAST REPAIR................................................................................................................................... WP 0100 PORTLIGHT REPAIR........................................................................................................................ WP 0101 Figure 1. Window Cover and Glass Frame.................................................................................. 0101-2 ROTARY CLEAR-VIEW SCREEN REPLACE................................................................................... WP 0102 Figure 1. Clear-view Screen Control Box.................................................................................... 0102-2 Figure 2. Clear-view Screen........................................................................................................ 0102-3 ROTARY CLEAR-VIEW SCREEN REPAIR...................................................................................... WP 0103 Figure 1. Clear-view Screen Control Box.................................................................................... 0103-2 REDUCTION GEAR COOLING PUMP REPLACE............................................................................ WP 0104 Figure 1. Electrical Junction Box................................................................................................. 0104-2
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Page No. WP Sequence No. Figure 2. Reduction Gear Cooling Pump Assembly.................................................................... 0104-3 Figure 3. Reduction Gear Cooling Pump Assembly (Mounting Hardware)................................. 0104-4 REDUCTION GEAR COOLING PUMP REPAIR............................................................................... WP 0105 Figure 1. Reduction Gear Cooling Pump..................................................................................... 0105-3 PROPELLER INSPECT..................................................................................................................... WP 0106 KEEL COOLERS INSPECT............................................................................................................... WP 0107 Figure 1. Keel Cooler Piping........................................................................................................ 0107-3 FUEL SYSTEM VALVES REPLACE................................................................................................. WP 0108 Figure 1. Typical Threaded Ball Valve......................................................................................... 0108-3 Figure 2. Typical Two-Way Ball Valve......................................................................................... 0108-5 FUEL SYSTEM VALVES REPAIR..................................................................................................... WP 0109 Figure 1. Flanged Gate Valve...................................................................................................... 0109-3 FUEL OIL TRANSFER PUMP, PUMP END REPLACE..................................................................... WP 0110 Figure 1. Fuel Oil Transfer Pump................................................................................................ 0110-3 FUEL OIL TRANSFER PUMP, PUMP END REPAIR........................................................................ WP 0111 Figure 1. Fuel Oil Transfer Pump (Exploded View)..................................................................... 0111-4 Figure 2. Fuel Oil Transfer Pump................................................................................................ 0111-5 Figure 3. Rotor/Vane Orientation................................................................................................. 0111-6 Figure 4. Mechanical Seal........................................................................................................... 0111-7 Figure 5. Vane............................................................................................................................. 0111-8 FUEL OIL TRANSFER PUMP ELECTRIC MOTOR REPLACE........................................................ WP 0112 Figure 1. Electrical Junction Box................................................................................................. 0112-2 Figure 2. Coupling Guard............................................................................................................ 0112-3 Figure 3. Alignment of Pump Coupling Flange and Motor Coupling Flange................................ 0112-4 FUEL OIL FILTER/WATER SEPARATOR (ENGINES) SERVICE.................................................... WP 0113 Figure 1. Fuel Oil Filter/Water Separator..................................................................................... 0113-3 FUEL OIL FILTER/WATER SEPARATOR (ENGINES) REPAIR....................................................... WP 0114
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Page No. WP Sequence No. Figure 1. Fuel Oil Filter/Water Separator..................................................................................... 0114-3 ENGINE INTAKE/EXHAUST SYSTEM COMPONENTS REPLACE................................................. WP 0115 Figure 1. Air Box Drain Valve (Typical)........................................................................................ 0115-2 LUBE OIL SYSTEM VALVES REPLACE.......................................................................................... WP 0116 Figure 1. Typical Ball Valve (Flanged)......................................................................................... 0116-3 Figure 2. Typical Ball Valve (Threaded)...................................................................................... 0116-5 Figure 3. Typical Angle Hose Globe Valve (Flanged).................................................................. 0116-7 Figure 4. Typical Globe Stop Check Valve (Flanged).................................................................. 0116-9 Figure 5. Typical Swing Check Valve (Flanged)........................................................................ 0116-11 LUBE OIL SYSTEM VALVES REPAIR.............................................................................................. WP 0117 Figure 1. Flanged Ball Valve........................................................................................................ 0117-3 Figure 2. Flanged Globe Valve.................................................................................................... 0117-5 Figure 3. Flanged Check Valve................................................................................................... 0117-7 LUBE OIL TRANSFER PUMP REPLACE......................................................................................... WP 0118 Figure 1. Electrical Junction Box................................................................................................. 0118-2 Figure 2. Electric Motor................................................................................................................ 0118-3 Figure 3. Lube Oil Transfer Pump............................................................................................... 0118-4 Figure 4. Alignment of Pump Coupling Flange and Motor Coupling Flange................................ 0118-5 LUBE OIL TRANSFER PUMP REPAIR............................................................................................. WP 0119 Figure 1. Lube Oil Transfer Pump............................................................................................... 0119-3 PRELUBRICATION OIL PUMP, PUMP END REPLACE................................................................... WP 0120 Figure 1. Main Engine Prelubrication Pump................................................................................ 0120-3 PRELUBRICATION OIL PUMP, PUMP END REPAIR...................................................................... WP 0121 Figure 1. Main Engine Prelubrication Pump (Exploded View)..................................................... 0121-4 Figure 2. Mechanical Seal........................................................................................................... 0121-6 Figure 3. Locknut Adjustment...................................................................................................... 0121-8 PRELUBRICATION OIL PUMP ELECTRIC MOTOR REPLACE...................................................... WP 0122
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Page No. WP Sequence No. Figure 1. Electrical Junction Box................................................................................................. 0122-2 Figure 2. Electric Motor................................................................................................................ 0122-3 Figure 3. Alignment of Pump Coupling Flange and Motor Coupling Flange................................ 0122-4 ELECTRICAL POWER SYSTEM TEST............................................................................................ WP 0123 Table 1. Normal Power Interlocks................................................................................................ 0123-2 Figure 1. Main Switchboard......................................................................................................... 0123-3 Figure 2. Emergency Switchboard............................................................................................... 0123-4 Table 2. EDG Power Interlocks (No Feedback)........................................................................... 0123-4 Table 3. EDG Power, Interlocks (with Feedback)........................................................................ 0123-5 ELECTRICAL POWER SYSTEM ADJUST........................................................................................ WP 0124 Table 1. EDG Circuit Breaker Setting Information....................................................................... 0124-2 Figure 1. EDG Circuit Breaker Location...................................................................................... 0124-3 Table 2. SSDG 1 and SSDG 2 Circuit Breaker Setting Information............................................ 0124-4 Figure 2. SSDG 1 and SSDG 2 Circuit Breaker Location............................................................ 0124-5 Table 3. Shore Power Circuit Breaker Setting Information.......................................................... 0124-6 Figure 3. Shore Power Circuit Breaker Location......................................................................... 0124-7 ELECTRICAL POWER SYSTEM REPAIR........................................................................................ WP 0125 Figure 1. Shore Power Receptacle.............................................................................................. 0125-3 Figure 2. Shore Power Cable Connector..................................................................................... 0125-5 MAIN SWITCHBOARD REPLACE.................................................................................................... WP 0126 Figure 1. Main Switchboard Top Left Panel................................................................................. 0126-3 Figure 2. Main Switchboard Top Left Aft Panel (Rear)................................................................ 0126-5 Figure 3. Main Switchboard Middle Left Panel............................................................................ 0126-7 Figure 4. Main Switchboard Top Center Panel............................................................................ 0126-9 Figure 5. Main Switchboard, Top Center Panel (Rear).............................................................. 0126-11 Figure 6. Main Switchboard Bottom Center Panel..................................................................... 0126-15 MAIN SWITCHBOARD REPAIR........................................................................................................ WP 0127
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Page No. WP Sequence No. Figure 1. Main Switchboard......................................................................................................... 0127-3 Figure 2. Main Switchboard Back Panel Layout.......................................................................... 0127-5 EMERGENCY SWITCHBOARD REPAIR.......................................................................................... WP 0128 Figure 1. Emergency Switchboard Top Panel............................................................................. 0128-3 Figure 2. Emergency Switchboard Middle Panel......................................................................... 0128-7 Figure 3. Emergency Switchboard Back Panel Layout.............................................................. 0128-10 Figure 4. Emergency Switchboard............................................................................................. 0128-13 Figure 5. Bus Tie Circuit Breaker............................................................................................... 0128-14 Figure 6. Bus Tie Circuit Breaker Bus Bar and Wire Connections............................................ 0128-15 Figure 7. SSDG 1, SSDG 2, and EDG Circuit Breaker Front Panel (Typical)........................... 0128-17 Figure 8. EDG Circuit Breaker................................................................................................... 0128-18 DISTRIBUTION AND FUSE PANELS (TYPICAL) REPLACE........................................................... WP 0129 Figure 1. Load Center.................................................................................................................. 0129-2 LIGHTING FIXTURE JUNCTION BOX (TYPICAL) REPAIR............................................................. WP 0130 Figure 1. Junction Box Lighting................................................................................................... 0130-3 LIGHTING FIXTURE BRACKET (TYPICAL) REPAIR....................................................................... WP 0131 Figure 1. Lighting Fixture Bracket................................................................................................ 0131-3 RECESSED FLUORESCENT FIXTURE REPLACE......................................................................... WP 0132 Figure 1. Fluorescent Fixture (Recessed)................................................................................... 0132-2 SURFACE MOUNT FLUORESCENT LIGHT REPLACE................................................................... WP 0133 Figure 1. Fluorescent Light, Surface Mount................................................................................. 0133-2 WATERTIGHT INCANDESCENT EXPLOSION PROOF (TYPICAL) LIGHTING FIXTURE REPAIR.................................................................................................................................... WP 0134 Figure 1. Explosion Proof Lighting Fixture................................................................................... 0134-2 FLOODLIGHTS REPLACE................................................................................................................ WP 0135 Figure 1. Metal Halide Floodlight................................................................................................. 0135-3 FLOODLIGHTS REPAIR................................................................................................................... WP 0136 Figure 1. Metal Halide Floodlight................................................................................................. 0136-3
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0270 MOTOR CONTROLLER: REDUCTION GEAR COOLING PUMP; SEWAGE DISCHARGE PUMP 1 & 2; LUBE OIL TRANSFER PUMP; POTABLE WATER PUMP 1 & 2; GALLEY SUPPLY FAN; GALLEY EXHAUST FAN; SANITARY SPACE EXHAUST FAN; CREW MESS FAN COIL UNIT; 01, 02, 03 LEVELS FAN COIL UNIT; AIR COMPRESSOR 1 & 2; FUEL OIL TRANSFER PUMP; AFFF PUMP REPLACE.......................................................... WP 0137 0271 Figure 1. Motor Controller Type 1 (Typical) ..................................................................................0137-3
0272 MOTOR CONTROLLER: REDUCTION GEAR COOLING PUMP; SEWAGE DISCHARGE PUMP 1 & 2; LUBE OIL TRANSFER PUMP; POTABLE WATER PUMP 1 & 2; GALLEY SUPPLY FAN; GALLEY EXHAUST FAN; SANITARY SPACE EXHAUST FAN; CREW MESS FAN COIL UNIT; 01, 02, 03 LEVELS FAN COIL UNIT; AIR COMPRESSOR 1 & 2; FUEL OIL TRANSFER PUMP; AFFF PUMP REPAIR............................................................... WP 0138 0273 Figure 1. Motor Controller Type 1 (Typical) ..................................................................................0138-3
0274 MOTOR CONTROLLER: LUBE OIL PRIMING PUMP 1 & 2 REPLACE ........................................... WP 0139 0275 0276 Figure 1. Motor Controller Type 6 (Typical) ..................................................................................0139-2 Figure 2. Motor Controller Type 6 Cover Removed ...................................................................0139-3
0277 MOTOR CONTROLLER: LUBE OIL PRIMING PUMP 1 & 2 REPAIR................................................ WP 0140 0278 0279 Figure 1. Motor Controller Type 6 (Typical) ..................................................................................0140-2 Figure 2. Motor Controller Type 6 Cover Removed ...................................................................0140-3
0280 MOTOR CONTROLLER: AMS 1 & 2 SUPPLY FAN; BOATSWAINS STORE ROOM SUPPLY FAN; ARMS LOCKER EXHAUST FAN; ENGINE ROOM SUPPLY FAN 1 & 2; ENGINE ROOM EXHAUST FAN 1 & 2 REPLACE.................................................................................. WP 0141 0281 Figure 1. Motor Controller Type 2 (Typical) ..................................................................................0141-3
0282 MOTOR CONTROLLER: AMS 1 & 2 SUPPLY FAN; BOATSWAINS STORE ROOM SUPPLY FAN; ARMS LOCKER EXHAUST FAN; ENGINE ROOM SUPPLY FAN 1 & 2; ENGINE ROOM EXHAUST FAN 1 & 2 REPAIR...................................................................................... WP 0142 0283 Figure 1. Motor Controller Type 2 (Typical)...................................................................................0142-3
0284 MOTOR CONTROLLER: BILGE & BALLAST PUMP 1 & 2; FIRE & GENERAL SERVICE EMERGENCY PUMP #1 & #2 REPLACE ................................................................................ WP 0143 0285 Figure 1. Type 3 Motor Controller .................................................................................................0143-3
0286 MOTOR CONTROLLER: BILGE & BALLAST PUMP 1 & 2; FIRE & GENERAL SERVICE EMERGENCY PUMP #1 & #2 REPAIR ................................................................................... WP 0144 0287 Figure 1. Motor Controller Type 3 (Typical) ..................................................................................0144-3
0288 MOTOR CONTROLLER: HOT POTABLE WATER RECIRCULATING PUMP REPLACE................ WP 0145
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Page No. WP Sequence No. Figure 1. Type 4 Motor Controller................................................................................................ 0145-3 MOTOR CONTROLLER: HOT POTABLE WATER RECIRCULATING PUMP REPAIR................... WP 0146 Figure 1. Motor Controller Type 4................................................................................................ 0146-3 MOTOR CONTROLLER: WELD HOOD EXHAUST FAN REPLACE................................................ WP 0147 Figure 1. Motor Controller Type 5 (Typical)................................................................................. 0147-2 Figure 2. Interior of Motor Controller Type 5................................................................................ 0147-3 MOTOR CONTROLLER: WELD HOOD EXHAUST FAN REPAIR................................................... WP 0148 Figure 1. Motor Controller Type 5 (Typical)................................................................................. 0148-2 BATTERY POWER SUPPLY SYSTEM TEST................................................................................... WP 0149 Figure 1. Batteries and Refractometer......................................................................................... 0149-3 BATTERY POWER SUPPLY SYSTEM SERVICE............................................................................ WP 0150 Figure 1. Battery Bank Power Supply System............................................................................. 0150-4 BATTERY POWER SUPPLY SYSTEM REPLACE........................................................................... WP 0151 Figure 1. Battery.......................................................................................................................... 0151-2 Figure 2. Battery, Power Supply System..................................................................................... 0151-4 BATTERY POWER SUPPLY SYSTEM REPAIR............................................................................... WP 0152 Figure 1. Battery.......................................................................................................................... 0152-3 Figure 2. Battery Bank................................................................................................................. 0152-3 Figure 3. Battery Box Fan............................................................................................................ 0152-5 BATTERY CHARGER REPLACE...................................................................................................... WP 0153 Figure 1. Battery Charger............................................................................................................ 0153-2 Figure 2. Battery Charger Internal Components.......................................................................... 0153-3 BATTERY CHARGER REPAIR......................................................................................................... WP 0154 Figure 1. Battery Charger............................................................................................................ 0154-2 Figure 2. Battery Charger Internal Components.......................................................................... 0154-3 Figure 3. Typical Wire Terminal................................................................................................... 0154-5 Figure 4. Battery Charger............................................................................................................ 0154-7
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Page No. WP Sequence No. SEARCHLIGHTS SERVICE.............................................................................................................. WP 0155 Figure 1. Searchlight Lamp.......................................................................................................... 0155-3 Table 1. Lubrication Points (Refer to Figure 2)............................................................................ 0155-4 Figure 2. Searchlight.................................................................................................................... 0155-5 Figure 3. Searchlight.................................................................................................................... 0155-7 Figure 4. Lamp Starter................................................................................................................. 0155-8 SEARCHLIGHTS REPLACE............................................................................................................. WP 0156 Figure 1. 500 W Xenon Searchlight............................................................................................. 0156-3 Figure 2. 500 W Xenon Searchlight Rear Cover Removed......................................................... 0156-5 Figure 3. Searchlight Base Assembly.......................................................................................... 0156-7 SEARCHLIGHTS REPAIR................................................................................................................. WP 0157 Figure 1. Searchlight Lamp.......................................................................................................... 0157-3 Figure 2. 500 W Xenon Searchlight............................................................................................. 0157-4 Figure 3. Searchlight Side View................................................................................................... 0157-5 Figure 4. 500 W Xenon Searchlight Rear Cover Removed......................................................... 0157-6 Figure 5. Searchlight Base Assembly.......................................................................................... 0157-9 Figure 6. Searchlight Lamp Starter Assembly........................................................................... 0157-12 Figure 7. Searchlight Control Station......................................................................................... 0157-14 SEARCHLIGHT POWER SUPPLY TEST.......................................................................................... WP 0158 Figure 1. Exterior Searchlight Power Supply............................................................................... 0158-2 Figure 2. Interior Searchlight Power Supply................................................................................ 0158-3 SEARCHLIGHT POWER SUPPLY REPLACE.................................................................................. WP 0159 Figure 1. Searchlight Power Supply (External)............................................................................ 0159-3 Figure 2. Searchlight Power Supply (Internal)............................................................................. 0159-4 SEARCHLIGHT POWER SUPPLY REPAIR..................................................................................... WP 0160 Figure 1. Searchlight Power Supply............................................................................................ 0160-3 Figure 2. Searchlight Power Supply Internal Door Components................................................. 0160-4
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Page No. WP Sequence No. Figure 3. Searchlight Power Supply Internal Components.......................................................... 0160-9 NAVIGATION LIGHTS (RUNNING LIGHTS) REPLACE................................................................... WP 0161 Figure 1. Navigation Light (Single Lens)...................................................................................... 0161-3 NAVIGATION LIGHTS (RUNNING LIGHTS) REPAIR...................................................................... WP 0162 Figure 1. Navigation Light (Single Lens)...................................................................................... 0162-3 Figure 2. Navigation Light (Double Lens).................................................................................... 0162-5 YARDARM BLINKER LIGHT AND KEY REPLACE........................................................................... WP 0163 Figure 1. Yardarm Blinker Light................................................................................................... 0163-3 Figure 2. Yardarm Blinker Key..................................................................................................... 0163-4 Figure 3. Blinker Key Wiring........................................................................................................ 0163-5 YARDARM BLINKER LIGHT AND KEY REPAIR.............................................................................. WP 0164 Figure 1. Yardarm Light............................................................................................................... 0164-2 NAVIGATION LIGHTING PANEL REPLACE.................................................................................... WP 0165 Figure 1. Navigation Lighting Panel............................................................................................. 0165-3 Figure 2. Internal Components of the Navigation Lighting Panel................................................ 0165-4 NAVIGATION LIGHTING PANEL REPAIR........................................................................................ WP 0166 Figure 1. Navigation Lighting Panel............................................................................................. 0166-2 Figure 2. Navigation Lighting Panel............................................................................................. 0166-4 Figure 3. Navigation Lighting Panel (OPEN)............................................................................... 0166-5 GENERAL ALARM SYSTEM REPLACE........................................................................................... WP 0167 Figure 1. General Alarm Bell Assembly....................................................................................... 0167-3 Figure 2. Bell Assembly............................................................................................................... 0167-4 Figure 3. Contactor Switch Cover................................................................................................ 0167-6 Figure 4. Contactor Terminal....................................................................................................... 0167-7 ROTATING BEACON REPLACE....................................................................................................... WP 0168 Figure 1. General Alarm Rotating Beacon................................................................................... 0168-3 ROTATING BEACON REPAIR.......................................................................................................... WP 0169
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Page No. WP Sequence No. Figure 1. General Alarm Rotating Beacon................................................................................... 0169-3 BATTERY CHARGER REPLACE...................................................................................................... WP 0170 Table 1. Battery Charger Lock Out and Tag Out Guide.............................................................. 0170-1 Figure 1. Battery Charger............................................................................................................ 0170-2 Figure 2. Battery Charger Internal Components.......................................................................... 0170-3 BATTERY CHARGER REPAIR......................................................................................................... WP 0171 Figure 1. Typical Wire Terminal................................................................................................... 0171-2 Figure 2. Battery Charger............................................................................................................ 0171-4 Figure 3. Battery Charger Front Cover........................................................................................ 0171-6 Figure 4. Ammeter and Circuit Breaker....................................................................................... 0171-7 BATTERY BANK SERVICE............................................................................................................... WP 0172 Figure 1. Battery Bank Power Supply System............................................................................. 0172-4 BATTERY BANK REPLACE.............................................................................................................. WP 0173 Figure 1. Battery.......................................................................................................................... 0173-2 Figure 2. Battery Power Supply System...................................................................................... 0173-3 SIGNAL HORN REPLACE................................................................................................................. WP 0174 Figure 1. Signal Horn................................................................................................................... 0174-3 Figure 2. Signal Horn Power Supply............................................................................................ 0174-4 Figure 3. Oscillator....................................................................................................................... 0174-6 Figure 4. Timer............................................................................................................................ 0174-7 ALARM SYSTEM, ARMS STORAGE AND RADIO ROOM REPAIR................................................ WP 0175 Figure 1. Alarm Panel Components (Exterior View).................................................................... 0175-3 Figure 2. Alarm Panel Components (Internal View).................................................................... 0175-5 Figure 3. Thermostat Assembly................................................................................................... 0175-9 Figure 4. Arms Locker Water Switch Assembly......................................................................... 0175-11 Figure 5. Rotary Snap Switch Assembly................................................................................... 0175-12 Figure 6. Door Alarm Switch Assembly..................................................................................... 0175-13
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Page No. WP Sequence No. Figure 7. Alarm Panel Assembly............................................................................................... 0175-15 INTERIOR COMMUNICATIONS REPLACE...................................................................................... WP 0176 Figure 1. Public Address System Amplifier.................................................................................. 0176-2 INTERIOR COMMUNICATIONS REPAIR......................................................................................... WP 0177 Figure 1. Volume Control Box...................................................................................................... 0177-3 Figure 2. Interior/Exterior Loudspeaker Depiction (Typical)........................................................ 0177-5 Figure 3. Electrical Wiring Terminal Depiction (Typical).............................................................. 0177-7 SOUND POWERED TELEPHONES REPLACE................................................................................ WP 0178 Figure 1. Sound Powered Telephone - Handset (Typical)........................................................... 0178-2 Figure 2. Sound Powered Telephone - Headset-Chestset (Typical)........................................... 0178-3 SOUND POWERED TELEPHONES REPAIR................................................................................... WP 0179 Figure 1. Sound Powered Telephone MWT-246J....................................................................... 0179-2 Figure 2. Sound Powered Telephone SW-23J............................................................................ 0179-5 Figure 3. Sound Powered Telephone SWLR-243J...................................................................... 0179-7 Figure 4. Sound Powered Telephone SW-243J........................................................................ 0179-11 Figure 5. Sound Powered Telephone Wiring (Typical).............................................................. 0179-13 INTERCOMMUNICATION SYSTEM REPLACE................................................................................ WP 0180 Figure 1. Intercommunication Station (Typical)........................................................................... 0180-2 INTERCOMMUNICATION SYSTEM REPAIR................................................................................... WP 0181 Figure 1. Intercommunication Station (Front View)..................................................................... 0181-2 Figure 2. Intercommunication Station (Rear View)...................................................................... 0181-4 Figure 3. Intercommunication Station (Front View)..................................................................... 0181-6 Figure 4. Intercommunication Station (Top View Inside of Faceplate)........................................ 0181-9 Figure 5. Intercommunication Station (Bottom View)................................................................ 0181-11 ENGINE ORDER TELEGRAPH (EOT) REPLACE............................................................................ WP 0182 Figure 1. EOT Panel Removed.................................................................................................... 0182-3 ENGINE ORDER TELEGRAPH (EOT) REPAIR............................................................................... WP 0183
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Page No. WP Sequence No. Figure 1. Engine Order Telegraph (EOT) Panel Repair (Typical)................................................ 0183-3 TANK LEVEL INDICATOR (TLI) INSPECT....................................................................................... WP 0184 Figure 1. 11 Channel TLI Control Panel...................................................................................... 0184-3 Figure 2. 7 Channel TLI Control Panel........................................................................................ 0184-3 Figure 3. TLI Remote Indicator.................................................................................................... 0184-4 Figure 4. Control Module Circuit Card......................................................................................... 0184-4 TANK LEVEL INDICATOR (TLI) TEST.............................................................................................. WP 0185 Figure 1. 11 Channel TLI Control Panel...................................................................................... 0185-2 Figure 2. 7 Channel TLI Control Panel........................................................................................ 0185-3 Figure 3. TLI Remote Indicator.................................................................................................... 0185-3 Figure 4. Control Module Circuit Card......................................................................................... 0185-4 TANK LEVEL INDICATOR (TLI) ADJUST......................................................................................... WP 0186 Figure 1. 11 Channel TLI Control Panel...................................................................................... 0186-2 Figure 2. 7 Channel TLI Control Panel........................................................................................ 0186-3 Figure 3. TLI Remote Indicator.................................................................................................... 0186-4 Figure 4. Control Module Circuit Card......................................................................................... 0186-4 Figure 5. Float Simulator............................................................................................................. 0186-6 TANK LEVEL INDICATOR (TLI) CALIBRATE................................................................................... WP 0187 Figure 1. 11 Channel TLI Control Panel...................................................................................... 0187-2 Figure 2. 7 Channel TLI Control Panel........................................................................................ 0187-3 Figure 3. TLI Remote Receiver Module....................................................................................... 0187-3 Figure 4. Control Module Circuit Card......................................................................................... 0187-4 TANK LEVEL INDICATOR (TLI) REPLACE...................................................................................... WP 0188 Figure 1. Tank Level Indicator Panel........................................................................................... 0188-3 Figure 2. TLI Control Panel and Components............................................................................. 0188-4 Figure 3. Receiver Panel Interior................................................................................................. 0188-5 Figure 4. Panel Meter.................................................................................................................. 0188-6
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Page No. WP Sequence No. Figure 5. Alarm Horn Assembly................................................................................................... 0188-8 TANK LEVEL INDICATOR (TLI) REPAIR.......................................................................................... WP 0189 Figure 1. 120 V Emergency Distribution Panel No. 1.................................................................. 0189-2 Figure 2. TLI Control Panel and Components............................................................................. 0189-3 Figure 3. Control Panel Fuse Holder Assembly........................................................................... 0189-5 TLI FLUID LEVEL DETECTION DEVICES INSPECT....................................................................... WP 0190 Figure 1. Tank Level Indicator (TLI) Transmitter Mounting Brackets........................................... 0190-3 TLI FLUID LEVEL DETECTION DEVICES REPLACE...................................................................... WP 0191 Figure 1. TLI Transmitter Mounting Brackets and Transmitter.................................................... 0191-2 Figure 2. TLI Transmitter Mounting Bracket Top View................................................................ 0191-3 TLI TRANSMITTERS INSPECT........................................................................................................ WP 0192 Figure 1. TLI Indicator Transmitter.............................................................................................. 0192-3 TLI TRANSMITTERS REPLACE....................................................................................................... WP 0193 Figure 1. Connection Box (Typical)............................................................................................. 0193-2 Figure 2. TLI Transmitter Configuration and Components.......................................................... 0193-3 Figure 3. TLI Transmitter (Typical).............................................................................................. 0193-4 Figure 4. TLI Transmitter Mounts (Typical).................................................................................. 0193-5 Figure 5. Junction Box and Flange Mounted Transmitter (Typical)............................................. 0193-9 TLI CABLE ASSEMBLIES INSPECT................................................................................................. WP 0194 Figure 1. TLI Transmitter Configuration and Components.......................................................... 0194-3 Figure 2. Connection Box............................................................................................................ 0194-4 Figure 3. TLI Transmitter Tag...................................................................................................... 0194-5 TLI CABLE ASSEMBLIES REPLACE................................................................................................ WP 0195 Figure 1. Connection Box (Typical)............................................................................................. 0195-2 Figure 2. TLI Transmitter Configuration and Components (Typical)............................................ 0195-3 Figure 3. Cable Assembly Adapter and TLI Transmitter Connector (Typical)............................. 0195-4 Figure 4. TLI Transmitter Tag...................................................................................................... 0195-6
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Page No. WP Sequence No. DAY TANK HIGH LEVEL ALARM, ALARM PANEL REPAIR............................................................ WP 0196 Figure 1. Machinery DC Control Distribution Panel..................................................................... 0196-2 Figure 2. Day Tank High Level Alarm Panel................................................................................ 0196-3 Figure 3. Day Tank High Level Alarm Panel Components.......................................................... 0196-7 Figure 4. Relay Assembly............................................................................................................ 0196-9 Figure 5. Horn/Strobe Assembly................................................................................................ 0196-11 DAY TANK HIGH LEVEL ALARM LEVEL ALARM SENSOR REPLACE.......................................... WP 0197 Figure 1. Junction Box with Cover Removed............................................................................... 0197-3 Figure 2. Day Tank High Level Alarm Sensor Assembly............................................................. 0197-4 SEWAGE SYSTEM VALVES REPLACE........................................................................................... WP 0198 Figure 1. Flanged Scupper Gag Valve........................................................................................ 0198-3 SEWAGE SYSTEM VALVES REPAIR.............................................................................................. WP 0199 Figure 1. Ball Valve...................................................................................................................... 0199-3 SEWAGE DISCHARGE PUMP REPAIR........................................................................................... WP 0200 Figure 1. Sewage Discharge Pump............................................................................................. 0200-2 SEWAGE DISCHARGE PUMP, PUMP END REPLACE................................................................... WP 0201 Figure 1. Sewage Discharge Pump............................................................................................. 0201-3 Figure 2. Sewage Discharge Pump............................................................................................. 0201-4 SEWAGE DISCHARGE PUMP, PUMP END REPAIR...................................................................... WP 0202 Figure 1. Sewage Discharge Pump Assembly............................................................................ 0202-3 Figure 2. Impeller......................................................................................................................... 0202-4 Figure 3. Bearing Positioning....................................................................................................... 0202-7 Figure 4. Tightening the Impeller................................................................................................. 0202-8 Table 1. Impeller Clearance Settings........................................................................................... 0202-9 SEWAGE DISCHARGE PUMP ELECTRIC MOTOR REPLACE....................................................... WP 0203 Figure 1. Electrical Junction Box................................................................................................. 0203-2 Figure 2. Electric Motor................................................................................................................ 0203-3
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Page No. WP Sequence No. Figure 3. Alignment of Pump Coupling Flange and Motor Coupling Flange................................ 0203-4 SEWAGE DISCHARGE PUMP ELECTRONIC MOTOR REPAIR..................................................... WP 0204 Figure 1. Sewage Discharge Pump Electric Motor...................................................................... 0204-3 OILY BILGE SYSTEM PIPING STRAINER SERVICE...................................................................... WP 0205 Figure 1. Duplex Strainer............................................................................................................. 0205-3 OILY BILGE SYSTEM VALVES REPLACE....................................................................................... WP 0206 Figure 1. Flanged Angle Valve.................................................................................................... 0206-3 Figure 2. Flanged Globe Valve.................................................................................................... 0206-5 Figure 3. Threaded Valve (Typical)............................................................................................. 0206-6 OILY BILGE SYSTEM, OILY PUMP REPLACE................................................................................ WP 0207 Figure 1. Oily Bilge Pump............................................................................................................ 0207-3 OILY BILGE SYSTEM OILY BILGE PUMP REPAIR......................................................................... WP 0208 Figure 1. Alignment Marks........................................................................................................... 0208-2 Figure 2. Oily Bilge Pump............................................................................................................ 0208-4 Figure 3. Oily Bilge Pump............................................................................................................ 0208-6 BALLAST SYSTEM PIPING/STRAINER SERVICE.......................................................................... WP 0209 Figure 1. Duplex Strainer............................................................................................................. 0209-3 BALLAST SYSTEM VALVES REPLACE........................................................................................... WP 0210 Figure 1. Threaded Vertical Check Valve (Typical)..................................................................... 0210-2 Figure 2. Flanged Angle/Stop Check Valve................................................................................. 0210-3 Figure 3. Flanged Globe/Gate Valve........................................................................................... 0210-5 BALLAST SYSTEM VALVES REPAIR.............................................................................................. WP 0211 Figure 1. Threaded Ball Valve..................................................................................................... 0211-3 Figure 2. Flanged Stop Check Valve........................................................................................... 0211-5 Figure 3. Flanged Check Valve................................................................................................... 0211-6 BALLAST PUMP REPAIR.................................................................................................................. WP 0212 Figure 1. Ballast Pump Hardware................................................................................................ 0212-2
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Page No. WP Sequence No. Figure 2. Ballast Pump................................................................................................................ 0212-3 Figure 3. Strainer Hardware........................................................................................................ 0212-5 BALLAST PUMP, PUMP END REPLACE......................................................................................... WP 0213 Figure 1. Ballast Pump................................................................................................................ 0213-3 BALLAST PUMP, PUMP END REPAIR............................................................................................. WP 0214 Figure 1. Ballast Pump................................................................................................................ 0214-3 Figure 2. Impeller......................................................................................................................... 0214-4 Figure 3. Bearing Positioning....................................................................................................... 0214-7 Figure 4. Tightening The Impeller................................................................................................ 0214-8 Table 1. Impeller Clearance Settings........................................................................................... 0214-9 BALLAST PUMP ELECTRIC MOTOR REPLACE............................................................................. WP 0215 Figure 1. Electrical Junction Box................................................................................................. 0215-2 Figure 2. Electric Motor................................................................................................................ 0215-3 Figure 3. Alignment of Pump Coupling Flange and Motor Coupling Flange................................ 0215-4 BALLAST PUMP ELECTRIC MOTOR REPAIR................................................................................ WP 0216 Figure 1. Ballast Pump Electric Motor (Typical)........................................................................... 0216-3 POTABLE WATER SYSTEM VALVES REPLACE............................................................................ WP 0217 Figure 1. Threaded Hose Connection Valve................................................................................ 0217-2 Figure 2. Flanged Globe Valve.................................................................................................... 0217-4 Figure 3. Threaded Valve (Typical)............................................................................................. 0217-5 POTABLE WATER PUMP REPAIR................................................................................................... WP 0218 Figure 1. Electrical Junction Box (Typical)................................................................................... 0218-3 Figure 2. Electrical Wiring To The Controller Terminal (Typical)................................................. 0218-4 Figure 3. Potable Water Pump.................................................................................................... 0218-5 POTABLE WATER PUMP, PUMP END REPLACE.......................................................................... WP 0219 Figure 1. Potable Water Pump Assembly.................................................................................... 0219-2 POTABLE WATER PUMP, PUMP END REPAIR.............................................................................. WP 0220
xx
TM 55-1925-273-24&P-2

Page No. WP Sequence No. Figure 1. Potable Water Pump Disassembly............................................................................... 0220-3 Figure 2. Removing Old Threads................................................................................................. 0220-5 Figure 3. Tapping New Threads.................................................................................................. 0220-5 Figure 4. Installing the Insert....................................................................................................... 0220-6 Figure 5. Drive Down the Keys.................................................................................................... 0220-6 Figure 6. Typical Impeller Machining........................................................................................... 0220-8 POTABLE WATER PUMP ELECTRIC MOTOR REPLACE.............................................................. WP 0221 Figure 1. Potable Water Pump Motor and Junction Box.............................................................. 0221-2 Figure 2. Potable Water Pump, Fittings, and Fasteners.............................................................. 0221-3 HYDROPNEUMATIC TANK REPLACE............................................................................................. WP 0222 Figure 1. Hydropneumatic Tank.................................................................................................. 0222-3 HYDROPNEUMATIC TANK PRESSURE SWITCH REPLACE......................................................... WP 0223 Figure 1. Hydropneumatic Tank Pressure Switch....................................................................... 0223-3 PROPORTIONING BROMIDE FEEDER SYSTEM TEST................................................................. WP 0224 Figure 1. Brominator.................................................................................................................... 0224-2 Figure 2. Brominator Cartridge Change Indicator........................................................................ 0224-3 PROPORTIONING BROMIDE FEEDER REPLACE......................................................................... WP 0225 Figure 1. Cartridge Change Indicator/Brominator........................................................................ 0225-3 Figure 2. Brominator Feeder Assembly....................................................................................... 0225-4 Figure 3. Dual Feed Valve Assembly.......................................................................................... 0225-7 PROPORTIONING BROMIDE FEEDER SYSTEM REPAIR............................................................. WP 0226 Figure 1. Bypass Header Assembly............................................................................................ 0226-3 HOT WATER HEATER ADJUST....................................................................................................... WP 0227 Figure 1. Hot Water Heater.......................................................................................................... 0227-2 Figure 2. Water Heater Temperature Controls............................................................................ 0227-3 HOT WATER HEATER REPLACE.................................................................................................... WP 0228 Table 1. Hot Water Heater Lock Out and Tag Out Guide............................................................ 0228-2
xxi
TM 55-1925-273-24&P-2

Page No. WP Sequence No. Figure 1. Typical Water Heater.................................................................................................... 0228-4 Figure 2. Water Heater Vent Valve.............................................................................................. 0228-7 HOT WATER HEATER REPAIR........................................................................................................ WP 0229 Table 1. Hot Water Heater Lock Out and Tag Out Guide............................................................ 0229-2 Figure 1. Water Heater and Components.................................................................................... 0229-3 Figure 2. Heating Element Jumper Configuration........................................................................ 0229-5 Figure 3. Magnetic Contactor/Fuse Holder.................................................................................. 0229-7 HOT POTABLE WATER RECIRCULATION PUMP REPLACE........................................................ WP 0230 Figure 1. Electrical Junction Box................................................................................................. 0230-3 Figure 2. Hot Potable Water Recirculation Pump........................................................................ 0230-4 FIRE AND GENERAL SERVICE PUMP SERVICE........................................................................... WP 0231 Figure 1. Fire and General Service Pump................................................................................... 0231-3 Figure 2. Electric Motor................................................................................................................ 0231-5 Figure 3. Duplex Strainer............................................................................................................. 0231-6 FIRE AND GENERAL SERVICE PUMP ALIGNMENT...................................................................... WP 0232 Figure 1. Coupling Alignment...................................................................................................... 0232-2 FIRE AND GENERAL SERVICE PUMP REPAIR.............................................................................. WP 0233 Figure 1. Typical Junction Box..................................................................................................... 0233-3 Figure 2. Typical Wire Terminal................................................................................................... 0233-4 Figure 3. Fire and General Service Pump................................................................................... 0233-5 Figure 4. Flanged Globe Valve.................................................................................................... 0233-6 FIRE AND GENERAL SERVICE PUMP, PUMP END REPLACE..................................................... WP 0234 Figure 1. Fire and General Service Pump................................................................................... 0234-2 FIRE AND GENERAL SERVICE PUMP, PUMP END REPAIR......................................................... WP 0235 Figure 1. Fire and General Service Pump................................................................................... 0235-4 Figure 2. Shaft Key for Rotation.................................................................................................. 0235-5 Figure 3. Removing Old Threads................................................................................................. 0235-8
xxii
TM 55-1925-273-24&P-2

Page No. WP Sequence No. Figure 4. Tapping New Threads.................................................................................................. 0235-8 Figure 5. Installing the Insert....................................................................................................... 0235-8 Figure 6. Drive Down the Keys.................................................................................................... 0235-9 Figure 7. Impeller Machining..................................................................................................... 0235-11 FIRE AND GENERAL SERVICE PUMP ELECTRIC MOTOR REPLACE......................................... WP 0236 Figure 1. Typical Junction Box..................................................................................................... 0236-3 Figure 2. Fire and General Service Pump Motor......................................................................... 0236-4 FIRE AND GENERAL SERVICE PUMP ELECTRIC MOTOR REPAIR............................................ WP 0237 Figure 1. Fire and General Service Pump Electric Motor (Typical)............................................. 0237-3 WORK SHOP EQUIPMENT PRESS, DRILL REPLACE................................................................... WP 0238 Figure 1. Drill Press..................................................................................................................... 0238-3 Figure 2. Drill Press Components................................................................................................ 0238-5 WORK SHOP EQUIPMENT GRINDER, BENCH REPLACE............................................................ WP 0239 Figure 1. Workshop Machinery Junction Box.............................................................................. 0239-2 Figure 2. Bench Grinder.............................................................................................................. 0239-3 WORK SHOP EQUIPMENT MACHINE, ARC WELDER REPLACE................................................. WP 0240 Figure 1. Welder.......................................................................................................................... 0240-3 WORK SHOP EQUIPMENT MACHINE, ARC WELDING REPAIR................................................... WP 0241 Figure 1. Arc Welder.................................................................................................................... 0241-4 PORTABLE ELECTRIC PUMP REPAIR........................................................................................... WP 0242 Figure 1. Portable Pump (JABSCO Model 11810-Series)........................................................... 0242-2 ARMAMENTS INSTALLATION AMMUNITION LOCKER REPAIR................................................... WP 0243 Figure 1. Ammunition Locker Thermometer................................................................................ 0243-2 Figure 2. Ammunition Locker Gasket.......................................................................................... 0243-3 ARMAMENT INSTALLATIONS GUN MOUNTS SERVICE............................................................... WP 0244 Figure 1. Machine Gun Mount Upper Cradle............................................................................... 0244-2 Figure 2. Machine Gun Mount..................................................................................................... 0244-3
xxiii
TM 55-1925-273-24&P-2

Page No. WP Sequence No. Figure 3. Machine Gun Mount Lubrication Points........................................................................ 0244-5 TORQUE LIMITS............................................................................................................................... WP 0245 Figure 1. Measuring Bolt Sizes.................................................................................................... 0245-1 Figure 2. Bolt Grades................................................................................................................... 0245-1 Table 1. Torque Table 1.............................................................................................................. 0245-2 Figure 3. Torque Table 2............................................................................................................. 0245-4
xxiv
TM 55-1925-273-24&P-2
CHAPTER 5 FIELD MAINTENANCE INSTRUCTIONS FOR LT-800 SERIES
TM 55-1925-273-24&P-2 FIELD MAINTENANCE SERVICE UPON RECEIPT
0083
INITIAL SETUP: Tools and Special Tools N/A Materials/Parts N/A Personnel Required Chief Engineer (1) Cook (2) First Engineer (1) First Mate (1) Medic (1) Second Engineer (1) Second Mate (1) Third Engineer (1) Third Mate (1) Vessel Master (1) Personnel Required (cont.) Watercraft Engineer 88L (6) Watercraft Operator 88K (6) References DA Form 2404 DA PAM 750-8 TB 740-97-4 TM 55-1925-273-10 Volume 1, WP 0079 Volume 1, WP 0080 Volume 1, WP 0081 Volume 1, WP 0082 Equipment Condition N/A
SERVICE UPON RECEIPT OF MATERIEL The primary mission of the Inland and Coastal Large Tug (LT) consists of ocean and coastal towing as well as docking and undocking operations with large ocean vessels. The vessel's secondary mission is to perform general purpose harbor duties such as positioning floating cranes, etc. With this mission capability in mind, the LT may be located along any waterway sufficiently deep to support the vessel. The vessel may be located adjacent to a pier, barge, or other berthing, or may lie at anchor as port conditions dictate. The LT is completely self-sufficient with regard to electrical power. Two ship's service diesel generators and an emergency diesel generator supply all of the electrical needs of the vessel. The vessel's electrical needs may also be supplied by a shore power connection to a shore facility or to another vessel. The shore supply source must be 440 V AC, three phase. The LT is outfitted with a shore power cable to make this connection. The LT requires no shelter. When not in use, the vessel is moored alongside a pier, alongside another vessel, or is anchored. The services performed upon receipt of a new or used vessel are the responsibility of the receiving organization and will be performed by the crew and the issuing activity.
0083-1
03/15/2011 Rel(1.8) root(surwp) wpno(M00001)
TM 55-1925-273-24&P-2 SERVICE UPON RECEIPT OF MATERIEL - Continued
0083
WARNING
Before volatile materials are brought aboard, or the engines are started, ensure that firefighting equipment is immediately available for use in case of fire emergency. Failure to comply could endanger personnel and/or equipment. The crew and issuing activity will conduct a 100 percent inventory of the vessel and required components per the Basic Issue Items (BII) List (TM 55-1925-273-10), the Component of End Item (COEI) List (TM 55-1925-273-10), and On-board Spare Parts List (OBSL) (TM 55-1925-273-10). Any shortages will be listed and reported to the proper authority for corrective action. The crew will perform all of the operator Preventive Maintenance Checks and Services (PMCS) as listed in TM 55-1925-273-10 and all of the field PMCS as listed in (Volume 1, WP 0079) through (Volume 1, WP 0082) up to and including those done annually. All defects and shortages will be recorded on DA Form 2404 as per DA PAM 750-8. A vessel received from storage will be inspected as specified in the paragraph above. However, storage personnel will have performed the depreservation operation and outfitted and operated the vessel prior to the arrival of the crew. END OF TASK INSTALLATION INSTRUCTIONS If the LT has been in storage, or has been transported as deck cargo aboard a transport ship, perform the following procedures: 1. 2. 3. 4. 5. If preservation was performed on the vessel, depreservation is detailed in TB 740-97-4. Reactivation of the vessel after movement is detailed in TB 740-97-4. Open all vessel hatches, doors, windows, and portholes to ventilate the vessel interior. Fill the potable water tank with potable water from an approved source. Fill both fuel tanks with diesel fuel from an approved source.
Perform all operator and field PMCS up through and including the annual level. Operator PMCS procedures are contained in TM 55-1925-273-10. Field PMCS procedures are contained in (Volume 1, WP 0079) through (Volume 1, WP 0082). END OF TASK END OF WORK PACKAGE
0083-2
03/15/2011 Rel(1.8) root(surwp) wpno(M00001)
TM 55-1925-273-24&P-2 FIELD MAINTENANCE HULL STRUCTURE SERVICE
0084
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 3, WP 0344, Table 1, Item 27) Apron, Utility (Volume 3, WP 0344, Table 1, Item 1) Faceshield, Industrial (Volume 3, WP 0344, Table 1, Item 5) Gloves, Chemical and Oil Protective (Volume 3, WP 0344, Table 1, Item 8) Gloves, Leather (Volume 3, WP 0344, Table 1, Item 9) Tool Kit, Welder's (Volume 3, WP 0344, Table 1, Item 29) Materials/Parts N/A Personnel Required Entry Supervisor/Attendant (1) Personnel Required (cont.) Fire Watch As Required for Grinding IAW FM 4-01.502 Watercraft Engineer 88L (1) Watercraft Operator 88K (trained in confined space entry) (3) References FM 4-01.502 TB 55-1900-204-24 WP 0098 Volume 3, WP 0249 Volume 3, WP 0344 Equipment Condition Manhole removed for applicable void. (WP 0098) Voids must be prepared for confined space entry with Confined Space Entry Permit secured IAW FM 4-01.502.
0084-1
03/15/2011 Rel(1.8) root(maintwp) wpno(M00002)
TM 55-1925-273-24&P-2
0084
SERVICE DECK DRAINS 1. 2. 3. Use a stiff brush and fresh water to clean any debris from the deck drain (Figure 1, Item 1). If debris still clogs the deck drain grate (Figure 1, Item 1), remove the two screws (Figure 1, Item 2) and remove the deck drain grate. The deck drain grate may now be cleaned with a wire brush and fresh water. Install the deck drain grate (Figure 1, Item 1) and secure it with two screws (Figure 1, Item 2).
2
M1001T73
Figure 1. END OF TASK SERVICE VOIDS
Deck Drain.
WARNING
Entry into an uninspected/unprepared confined space may result in serious injury or death to personnel. Only properly trained personnel may enter confined spaces, or act as entry supervisors and/or attendants for those working in confined spaces. Before entering into a confined space, the space must be cleared for entry and a Confined Space Entry Permit must be secured. All entry into confined spaces must be in accordance with FM 4-01.502. Failure to comply with this warning can result in serious injury or death to personnel. 1. Visually inspect the voids for any damage or deterioration (hull pierced, rust, etc.). If minor damage or deterioration is noted, clean, prime, and paint as described in Steps (4) and (5). If more serious damage is detected, notify the maintenance supervisor. Check for signs of water, oil, or other signs of leakage into watertight compartments. If liquids are present in the compartment, notify the maintenance supervisor. Check for any unusual signs of stress to the structure. Stress can be detected by looking for cracks, broken welds, dented or bulging plating, and unexpected gaps in plating or frame members. Report any signs of unusual stress to the maintenance supervisor.
2. 3.
0084-2
TM 55-1925-273-24&P-2 SERVICE VOIDS - Continued
0084
WARNING
Cleaning components by means of grinding produces hot, flying particles. These particles can cause serious injury to personnel or ignite fires in the work area. Wear protective faceshield, gloves, and/or aprons at all times. A fire watch must be posted whenever grinding operations are taking place. Failure to comply with this warning can result in serious injury or death to personnel and damage to the vessel. 4. 5. 6. If minor damage such as rust and/or missing paint is found, thoroughly clean the damaged area to bare metal by grinding or wire brushing. After the area is cleaned, prime and paint as necessary IAW TB 55-1900-204-24. Install the manhole cover (WP 0098).
END OF TASK END OF WORK PACKAGE
0084-3/4 blank
TM 55-1925-273-24&P-2 FIELD MAINTENANCE PILOTHOUSE REPLACE
0085
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 3, WP 0344, Table 1, Item 27) Multimeter (Volume 3, WP 0344, Table 1, Item 15) Tool Kit, Electrical Repair (Volume 3, WP 0344, Table 1, Item 26) Materials/Parts N/A Personnel Required Watercraft Engineer 88L (2) References FM 4-01.502 References (cont.) Volume 3, WP 0250 Volume 3, WP 0344 Equipment Condition N/A
WARNING
Never reuse locking hardware. Reuse of locking hardware such as lockwashers, locking nuts, cotter pins, and lock wire can result in undetected loosening of fastening hardware causing catastrophic component failure resulting in death, injury, or damage to equipment. Ensure that all locking hardware is discarded upon removal and replaced with new.
0085-1
TM 55-1925-273-24&P-2
0085
WINDSHIELD WIPER BELT REMOVAL 1. 2. 3. Determine which windshield wiper belt will be replaced. At 120 V exterior emergency lighting panel No. 2, set to OFF, lock out, and tag out IAW FM 4-01.502 the corresponding circuit breaker shown in Table 1. Remove the four screws (Figure 1, Item 2) from the cover (Figure 1, Item 3) of the windshield wiper motor junction box (Figure 1, Item 1). Remove the cover (Figure 1, Item 3) from the windshield wiper motor junction box (Figure 1, Item 1). Table 1. Windshield Wipers and Motors. Windshield Wiper to Repair Forward Port and Starboard Circuit Breaker to Lock Out and Tag Out WINDSCREEN WIPERS. (PORT & STBD FWD). (LT 803 Only) WINDSCREEN WIPERS. (PORT & STARBOARD FORWARD) (All Other Vessels) Forward Starboard and Port WINDSCREEN WIPERS. (STARBOARD & PORT FWD). (LT 803 Only) WINDSCREEN WIPERS. (STARBOARD & PORT FORWARD) (All Other Vessels)
M1166T73
Figure 1. Windshield Wiper Motor.
0085-2
TM 55-1925-273-24&P-2 WINDSHIELD WIPER BELT REMOVAL - Continued
0085
WARNING
Replace or repair components only after the affected circuit has been secured, locked out, and tagged out IAW FM 4-01.502. Performing replacement with the circuit energized may result in injury. 4. Using a multimeter, check for voltage at the windshield wiper motor terminals (Figure 2, Item 1). If voltage is present, ensure that the correct circuit breakers have been secured, locked out, and tagged out IAW FM 4-01.502. If no voltage is present, continue with the procedure.
1
M1167T73
Figure 2. Windshield Wiper Motor Junction Box.
0085-3
TM 55-1925-273-24&P-2 WINDSHIELD WIPER BELT REMOVAL - Continued 5. 6. 7. 8. Loosen and remove the nut (Figure 3, Item 11) from the water line (Figure 3, Item 10). Remove the two bolts (Figure 3, Item 13) from the cover (Figure 3, Item 12) and remove the cover.
0085
Remove the two screws (Figure 3, Item 16) from the park switch (Figure 3, Item 15) and remove the park switch. Remove the three screws (Figure 3, Item 9) that secure the windshield wiper blade assembly (Figure 3, Item 14) to the carriage plate assembly (Figure 3, Item 8) and remove the windshield wiper blade assembly. Slide the carriage plate assembly (Figure 3, Item 8) toward the idler tension pulley (Figure 3, Item 6) and remove the belt (Figure 3, Item 7) from the drive shaft pulley assembly (Figure 3, Item 4). Remove the carriage plate assembly (Figure 3, Item 8) from the windshield wiper housing (Figure 3, Item 5). Remove the two nuts (Figure 3, Item 19) securing the clamp (Figure 3, Item 18) and remove the clamp from the idler pulley assembly (Figure 3, Item 17). Remove the belt (Figure 3, Item 7) from idler pulley assembly (Figure 3, Item 17).
9. 10. 11. 12.
5 1 2
3 4
17 18
19
10 11
16 12 15
14
M1168T73
13
Figure 3. END OF TASK
Windshield Wiper Components (Exploded View).
WINDSHIELD WIPER BELT INSTALLATION 1. 2. 3. Install the belt (Figure 3, Item 7) on the idler pulley assembly (Figure 3, Item 17). Install the clamp (Figure 3, Item 18) on the idler pulley assembly (Figure 3, Item 17) and secure the clamp (Figure 3, Item 18) with the two nuts (Figure 3, Item 19). Tighten the two nuts securely. Install the carriage plate assembly (Figure 3, Item 8) in the windshield wiper housing (Figure 3, Item 5).
0085-4
TM 55-1925-273-24&P-2 WINDSHIELD WIPER BELT INSTALLATION - Continued 4. 5.
0085
Slide the carriage plate assembly (Figure 3, Item 8) toward the idler tension pulley (Figure 3, Item 6) and install the belt (Figure 3, Item 7) on the drive shaft pulley assembly (Figure 3, Item 4). Install the windshield wiper blade assembly (Figure 3, Item 14) on the carriage plate assembly (Figure 3, Item 8). Install the three screws (Figure 3, Item 9) securing the windshield wiper blade assembly. Tighten the three screws securely. Install the park switch (Figure 3, Item 15) into the windshield wiper housing (Figure 3, Item 5) and secure it with the two screws (Figure 3, Item 16). Tighten the two screws securely. Install the cover (Figure 3, Item 12) on the windshield wiper housing (Figure 3, Item 5) and secure it with the two bolts (Figure 3, Item 13). Tighten the two bolts securely. Connect the nut (Figure 3, Item 11) to the water line (Figure 3, Item 10) and tighten the nut securely. Install the cover (Figure 1, Item 10) on the windshield wiper motor junction box (Figure 1, Item 13) and secure it with the four screws (Figure 1, Item 11). Perform the FOLLOW-ON MAINTENANCE procedure at the end of this work package.
6. 7. 8. 9. 10.
END OF TASK WINDSHIELD WIPER ASSEMBLY (MOTOR) REMOVAL 1. 2. Determine which windshield wiper assembly motor will be replaced. At the 120 V exterior lighting panel No. 2, set to OFF, lock out, and tag out IAW FM 4-01.502 the corresponding circuit breaker shown in Table 1. Remove the four screws (Figure 1, Item 2) from the cover (Figure 1, Item 3) of the windshield wiper motor junction box (Figure 1, Item 3).
WARNING
Replace or repair components only after the affected circuit has been secured, locked out, and tagged out IAW FM 4-01.502. Performing replacement with the circuit energized may result in injury. 3. Use a multimeter to check for voltage at the windshield wiper motor terminals (Figure 2, Item 1). If any voltage is present, ensure that the correct circuit breakers have been secured, locked out, and tagged out. If no voltage is present, continue with the procedure. Label and remove the wiring (Figure 2, Item 2) from the windshield wiper motor junction box (Figure 1, Item 1). Loosen the setscrew (Figure 3, Item 3) on the drive shaft pulley assembly (Figure 3, Item 4). Remove the four screws (Figure 3, Item 2) that secure the windshield wiper motor (Figure 3, Item 1) and remove the windshield wiper motor.
4. 5. 6.
END OF TASK WINDSHIELD WIPER ASSEMBLY (MOTOR) INSTALLATION 1. 2. Install the windshield wiper motor (Figure 3, Item 1) and secure it with the four screws (Figure 3, Item 2). Tighten the setscrew (Figure 3, Item 3) on the drive shaft pulley assembly (Figure 3, Item 4).
0085-5
TM 55-1925-273-24&P-2 WINDSHIELD WIPER ASSEMBLY (MOTOR) INSTALLATION - Continued 3.
0085
Connect the wiring (Figure 2, Item 2) in the windshield wiper motor junction box (Figure 1, Item 1) using the labels from Step (4) of WINDSHIELD WIPER ASSEMBLY (MOTOR) REMOVAL as a guide. Remove the labels. Install the cover (Figure 1, Item 3) on the windshield wiper motor junction box (Figure 1, Item 1) and secure it with the four screws (Figure 1, Item 2). Perform the FOLLOW-ON MAINTENANCE procedure at the end of this work package.
4. 5.
END OF TASK HEATER SWITCHES REMOVAL 1. Determine which heater switch will be replaced. At the 120 V pilothouse emergency distribution panel, set to OFF, lock out, and tag out IAW FM 4-01.502 the corresponding circuit breaker shown in Table 2. Table 2. Heater Switch Circuit Breakers. Heater Switch to Repair HEATER 1-PORT Circuit Breaker to Lock Out and Tag Out WINDSCREEN ELEMENTS. (FWD). (LT 803 Only) WINDSCREEN ELEMENTS. (FORWARD) (All Other Vessels) WINDSCREEN ELEMENTS. (FWD). (LT 803 Only) WINDSCREEN ELEMENTS. (FORWARD) (All Other Vessels) WINDSCREEN ELEMENTS. (FWD). (LT 803 Only) WINDSCREEN ELEMENTS. (FORWARD) (All Other Vessels) WINDSCREEN ELEMENTS. (FWD). (LT 803 Only) WINDSCREEN ELEMENTS. (FORWARD) (All Other Vessels) WINDSCREEN ELEMENTS. (FWD). (LT 803 Only) WINDSCREEN ELEMENTS. (FORWARD) (All Other Vessels) WINDSCREEN ELEMENTS. (AFT). WINDSCREEN ELEMENTS. (AFT). WINDSCREEN ELEMENTS. (AFT). WINDSCREEN ELEMENTS. (AFT).
HEATER 2-PORT
HEATER 2-FWD
HEATER 3-FWD
HEATER 4-FWD
HEATER 1-STBD HEATER 1-AFT HEATER 2-AFT HEATER 3-AFT
0085-6
TM 55-1925-273-24&P-2 HEATER SWITCHES REMOVAL - Continued 2.
0085
Remove the four screws (Figure 4, Item 1) from the front panel (Figure 4, Item 2) of the heater switch bank (Figure 4, Item 3).
WARNING
Replace or repair components only after the affected circuit has been secured, locked out, and tagged out IAW FM 4-01.502. Performing replacement with the circuit energized may result in injury. 3. Remove the front panel (Figure 4, Item 2), and use a multimeter to check for voltage on the switch contacts (Figure 5, Item 1) inside the heater switch bank (Figure 4, Item 3). If voltage is present, ensure that the correct circuit breakers have been secured, locked out, and tagged out IAW FM 4-01.502. If no voltage is present, continue with the procedure.
ON
ON
OFF HEATER 1-PORT HEATER 1-FWD HEATER 2-FWD HEATER 3-FWD HEATER 4-FWD HEATER 1-STBD HEATER 1-AFT HEATER 2-AFT
OFF HEATER 3-AFT
3
Figure 4. Heater Switch Bank.
M1169T73
0085-7
TM 55-1925-273-24&P-2 HEATER SWITCHES REMOVAL - Continued 4. 5. 6. Label and remove the wiring from the switch (Figure 5, Item 2). Remove the retaining nut (Figure 5, Item 4) securing the switch (Figure 5, Item 2) to the front panel (Figure 5, Item 3). Remove the switch (Figure 5, Item 2) from the front panel (Figure 5, Item 3).
0085
END OF TASK HEATER SWITCHES INSTALLATION 1. 2. 3. 4. Install the switch (Figure 5, Item 2) in the front panel (Figure 5, Item 3), and secure it with the retaining nut (Figure 5, Item 4). Install the wiring on the switch (Figure 5, Item 2) using the labels from Step (4) of HEATER SWITCHES REMOVAL as a guide. Remove the labels. Install the front panel (Figure 4, Item 2), and secure it with four screws (Figure 4, Item 1). Perform the FOLLOW-ON MAINTENANCE procedure at the end of this work package.
3 1 2 4
M1170T73
Heater Switch.
0085-8
TM 55-1925-273-24&P-2
0085
FOLLOW-ON MAINTENANCE 1. 2. 3. 4. Remove the lock outs and tag outs IAW FM 4-01.502. Set the applicable circuit breaker at the 120 V pilothouse emergency distribution panel or the 120 V exterior emergency lighting panel No. 2 to ON. Refer to Table 1 or 2. Operate the windshield wipers IAW TM 55-1925-273-10 and check for proper operation. Operate the heater switch IAW TM 55-1925-273-10 and check for proper operation.
0085-9/10 blank
TM 55-1925-273-24&P-2 FIELD MAINTENANCE PILOTHOUSE REPAIR
0086
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 3, WP 0344, Table 1, Item 27) Drill, Electric, Portable (Volume 3, WP 0344, Table 1, Item 4) Drill Set, Twist (Volume 3, WP 0344, Table 1, Item 2) Gloves, Leather (Volume 3, WP 0344, Table 1, Item 9) Goggles, Industrial (Volume 3, WP 0344, Table 1, Item 10) Multimeter (Volume 3, WP 0344, Table 1, Item 15) Riveter, Blind, Hand (Volume 3, WP 0344, Table 1, Item 19) Materials/Parts Compound, Silicone; Corrosion Inhibitor, 8 oz (Volume 3, WP 0343, Table 1, Item 46) Materials/Parts (cont.) Strap, Tiedown, Electrical Components (Volume 3, WP 0343, Table 1, Item 157) Tape, Insulation, Electrical; 1 in. (Volume 3, WP 0343, Table 1, Item 161) Personnel Required Watercraft Engineer 88L (2) References FM 4-01.502 TM 55-1925-273-10 Volume 3, WP 0250 Volume 3, WP 0343 Volume 3, WP 0344 Equipment Condition N/A
WARNING
0086-1
TM 55-1925-273-24&P-2
0086
WINDSHIELD WIPER BLADE REMOVAL
WARNING
Replace or repair components only after the affected circuit has been secured, locked out, and tagged out IAW FM 4-01.502. Performing replacement with the circuit energized may result in injury.
NOTE
This procedure is applicable to all of the wiper blades regardless of their position. 1. At 120 V exterior emergency lighting panel No. 2, set to OFF, lock out, and tag out IAW FM 4-01.502 the WINDSCREEN WIPERS (PORT & STARBOARD FWD) circuit breaker (LT 803 Only), or the WINDSCREEN WIPERS (PORT & STARBOARD FORWARD) circuit breaker (All Other Vessels) (Figure 1, Item 1) and the WINDSCREEN WIPERS (STARBOARD & PORT FWD) circuit breaker (LT 803 Only), or the WINDSCREEN WIPERS, (STARBOARD & PORT FORWARD) circuit breaker (All Other Vessels) (Figure 1, Item 2).
M1171T73
Figure 1. 2. 3.
120 V Exterior Emergency Lighting Panel No. 2.
Remove the three allen head screws (Figure 2, Item 6) and three locknuts (Figure 2, Item 1) from the blade attachment clip (Figure 2, Item 3). Remove the end cap (Figure 2, Item 4) from the windshield wiper blade assembly (Figure 2, Item 2).
0086-2
TM 55-1925-273-24&P-2 WINDSHIELD WIPER BLADE REMOVAL - Continued 4.
0086
Remove the windshield wiper blade (Figure 2, Item 5) and blade attachment clip (Figure 2, Item 3) from the windshield wiper blade assembly (Figure 2, Item 2).
1 6 5 3 4
Figure 2. END OF TASK WINDSHIELD WIPER BLADE INSTALLATION 1. Install the windshield wiper blade (Figure 2, Item 5) and blade attachment clip (Figure 2, Item 3) onto the windshield wiper blade assembly (Figure 2, Item 2) and secure it with three allen head screws (Figure 2, Item 6) and three locknuts (Figure 2, Item 1). Install the end cap (Figure 2, Item 4) onto the windshield wiper blade assembly (Figure 2, Item 2). At 120 V exterior emergency lighting panel No. 2, remove the lock outs, and tag outs IAW FM 4-01.502 and set to ON the WINDSCREEN WIPERS. (PORT & STARBOARD FWD). circuit breaker (LT 803 Only), or the WINDSCREEN WIPERS. (PORT & STARBOARD FORWARD) circuit breaker (All Other Vessels) (Figure 1, Item 1) and the WINDSCREEN WIPERS. (STARBOARD & PORT FWD). circuit breaker (LT 803 Only), or the WINDSCREEN WIPERS, (STARBOARD & PORT FORWARD) circuit breaker (All Other Vessels) (Figure 1, Item 2). Operate the windshield wipers IAW TM 55-1925-273-10 and check for proper operation. Return the windshield wipers to the desired readiness condition IAW TM 55-1925-273-10.
M1172T73
Wiper Blade.
2. 3.
4. 5.
END OF TASK
0086-3
TM 55-1925-273-24&P-2
0086
TOGGLE LATCH REMOVAL
WARNING
Drilling operations produce high velocity flying debris which can become lodged in skin or in the eyes. All personnel working in the area must wear protective eyewear, gloves, and long sleeves when performing grinding, needling, and chipping operations. Failure to comply with this warning can result in serious injury or death to personnel. 1. 2. Drill out the two rivets (Figure 3, Item 1) securing the top half of the toggle latch (Figure 3, Item 2). Remove the top half of the toggle latch. Drill out the two rivets (Figure 3, Item 3) securing the bottom half of the toggle latch (Figure 3, Item 4). Remove the bottom half of the toggle latch.
3 2
M1174T73
Toggle Latch.
0086-4
TM 55-1925-273-24&P-2
0086
TOGGLE LATCH INSTALLATION 1. 2. Position the bottom half of the toggle latch (Figure 3, Item 4) over the existing rivet holes and secure it with two rivets (Figure 3, Item 3). Position the top half of the toggle latch (Figure 3, Item 2) over the existing rivet holes and secure it with two rivets (Figure 3, Item 1).
END OF TASK PILOTHOUSE WING CONSOLE THERMOSTAT REMOVAL 1. At 01 & 02 level reheater 120 V fuse box No. 1, remove the PORT BRIDGE WING CONSOLE HEATER fuses (Figure 4, Item 2) and STARBOARD BRIDGE WING CONSOLE HEATER fuses (Figure 4, Item 1). Lock out and tag out IAW FM 4-01.502.
M1175T73
Figure 4.
01 & 02 Level Reheater 120 V Fuse Box No. 1.
0086-5
TM 55-1925-273-24&P-2 PILOTHOUSE WING CONSOLE THERMOSTAT REMOVAL - Continued 2. 3. Remove the 15 screws (Figure 5, Item 2) and the access plate (Figure 5, Item 3). Inspect the gasket (Figure 5, Item 1) for damage. Replace the gasket as required.
0086
M1176T73
Figure 5. Pilothouse Wing Console (Starboard Shown, Port Opposite Hand).
0086-6
TM 55-1925-273-24&P-2 PILOTHOUSE WING CONSOLE THERMOSTAT REMOVAL - Continued
0086
WARNING
Replace or repair components only after the affected circuit has been secured, locked out, and tagged out IAW FM 4-01.502. Performing replacement with the circuit energized may result in injury. 4. 5. Remove the two screws (Figure 6, Item 2) and the junction box cover (Figure 6, Item 3). Use a multimeter to check for available voltage at the thermostat wiring (Figure 6, Item 7). If voltage is present, ensure that the proper fuses are removed, locked out, and tagged out IAW FM 4-01.502. If no voltage is present, continue with the procedure. Label and disconnect the thermostat wiring (Figure 6, Item 7) inside the junction box (Figure 6, Item 1). Pull the thermostat wiring (Figure 6, Item 7) out of the junction box (Figure 6, Item 1). Remove the nut (Figure 6, Item 6) and remove the thermostat (Figure 6, Item 4) from its bracket (Figure 6, Item 5).
6. 7. 8.
0086-7
TM 55-1925-273-24&P-2 PILOTHOUSE WING CONSOLE THERMOSTAT REMOVAL - Continued
0086
7 3
6 5
M1177T73
Figure 6. Pilothouse Wing Console Thermostat. END OF TASK PILOTHOUSE WING CONSOLE THERMOSTAT INSTALLATION 1. 2. 3. Position the thermostat (Figure 6, Item 4) in its bracket (Figure 6, Item 5) and secure it with the nut (Figure 6, Item 6). Feed the thermostat wiring (Figure 6, Item 7) into the junction box (Figure 6, Item 1). Connect the thermostat wiring (Figure 6, Item 7) in the junction box (Figure 6, Item 1) using the labels from Step (6) of PILOTHOUSE WING CONSOLE THERMOSTAT REMOVAL as a guide. Insulate the wiring with electrical tape. Remove the labels. Install the junction box cover (Figure 6, Item 3) and secure it with two screws (Figure 6, Item 2).
4.
0086-8
TM 55-1925-273-24&P-2 PILOTHOUSE WING CONSOLE THERMOSTAT INSTALLATION - Continued 5. 6. 7. 8.
0086
If a gasket (Figure 5, Item 1) is required, fabricate one from bulk gasket material using the cover as a template. Apply a thin coat of silicone compound to the access plate (Figure 5, Item 3) side of the gasket (Figure 5, Item 1). Install the access plate (Figure 5, Item 3) and gasket (Figure 5, Item 1) and secure them with 15 screws (Figure 5, Item 2). Remove the lock outs and tag outs installed during Step (1) of the PILOTHOUSE WING CONSOLE THERMOSTAT REMOVAL procedure IAW FM 4-01.502. Install the fuses removed during Step (1) of the PILOTHOUSE WING CONSOLE THERMOSTAT REMOVAL procedure. If the ambient temperature is below 70F (21C), observe the console after one hour and note that the outer surfaces of the bridge wing are noticeably warm to the touch.
9. 10.
END OF TASK PILOTHOUSE WING CONSOLE HEATER REMOVAL 1. At 01 & 02 level reheater 120 V fuse box No. 1, remove the PORT BRIDGE WING CONSOLE HEATER fuses (Figure 4, Item 1) and STARBOARD BRIDGE WING CONSOLE HEATER fuses (Figure 4, Item 2). Lock out and tag out IAW FM 4-01.502. Remove the 15 screws (Figure 5, Item 2) and the access plate (Figure 5, Item 3). Inspect the gasket (Figure 5, Item 1) for damage. Replace the gasket as required.
2. 3.
0086-9
TM 55-1925-273-24&P-2 PILOTHOUSE WING CONSOLE HEATER REMOVAL - Continued
0086
WARNING
Replace or repair components only after the affected circuit has been secured, locked out, and tagged out IAW FM 4-01.502. Performing replacement with the circuit energized may result in injury. 4. Use a multimeter to check for available voltage at the heater wiring terminals (Figure 7, Item 7). If voltage is present, ensure that the proper fuses are removed, locked out, and tagged out IAW FM 4-01.502. If no voltage is present, continue with the procedure. Label and disconnect the heater wiring (Figure 7, Item 6) at the terminals (Figure 7, Item 7). Remove the two bolts (Figure 7, Item 1), two nuts (Figure 7, Item 4), two flat washers (Figure 7, Item 2), and two lockwashers (Figure 7, Item 3) that secure the heater element (Figure 7, Item 8) to its mounts (Figure 7, Item 5). Remove the heater element from its mounts.
5. 6.
END OF TASK PILOTHOUSE WING CONSOLE HEATER INSTALLATION 1. Position the heater element (Figure 7, Item 8) on its mounts (Figure 7, Item 5) and secure it with two bolts (Figure 7, Item 1), the two nuts (Figure 7, Item 4), two flat washers (Figure 7, Item 2), and two lockwashers (Figure 7, Item 3). Connect the heater wiring (Figure 7, Item 6) to the terminals (Figure 7, Item 7) using the labels from Step (5) of PILOTHOUSE WING CONSOLE HEATER REMOVAL as a guide. Remove the labels. If a gasket (Figure 5, Item 1) is required, fabricate one from bulk gasket material using the cover as a template. Apply a thin coat of silicone compound to the access plate (Figure 5, Item 3) side of the gasket (Figure 5, Item 1). Install the access plate (Figure 5, Item 3) and gasket (Figure 5, Item 1) and secure them with 15 screws (Figure 5, Item 2). Remove the lock outs and tag outs installed during Step (1) of the PILOTHOUSE WING CONSOLE HEATER REMOVAL procedure IAW FM 4-01.502. Install the fuses removed during Step (1) of the PILOTHOUSE WING CONSOLE HEATER REMOVAL procedure. If the ambient temperature is below 70F (21C), observe the console after one hour and note that the outer surfaces of the bridge wing are noticeably warm to the touch.
2. 3. 4. 5. 6. 7. 8.
0086-10
TM 55-1925-273-24&P-2 PILOTHOUSE WING CONSOLE HEATER INSTALLATION - Continued

4
0086
7 6
M1178T73
Pilothouse Wing Console Heater.
0086-11
TM 55-1925-273-24&P-2 NAVIGATOR'S SEAT REMOVAL
0086
WARNING
Before removing clamp, the navigators seat must be supported. Failure to comply could result in injury or death to personnel. 1. 2. 3. 4. Position one crewmember to hold the navigator's seat (Figure 8, Item 1). While holding the navigator's seat (Figure 8, Item 1), loosen the nut (Figure 8, Item 3) and remove the clamp (Figure 8, Item 10). Lift the navigator's seat (Figure 8, Item 1) and pedestal (Figure 8, Item 2) from the base (Figure 8, Item 9) as an assembly. Remove the four bolts (Figure 8, Item 4), four nuts (Figure 8, Item 7), four flat washers (Figure 8, Item 5), and four lockwashers (Figure 8, Item 6). Remove the base (Figure 8, Item 9) from the foundation (Figure 8, Item 8).
3 10 9 8
M1179T73
4 5 6 7
Navigator's Seat.
0086-12
TM 55-1925-273-24&P-2 NAVIGATOR'S SEAT INSTALLATION 1.
0086
Position the base (Figure 8, Item 9) on the foundation (Figure 8, Item 8) and secure it with the four bolts (Figure 8, Item 4), four nuts (Figure 8, Item 7), four flat washers (Figure 8, Item 5), and four lockwashers (Figure 8, Item 6). Position the navigator's seat (Figure 8, Item 1) and pedestal (Figure 8, Item 2) on the base (Figure 8, Item 9) as an assembly.
2.
NOTE
The seat and pedestal will swivel on the base until the clamp is tightened. Before fully tightening the clamp, ensure that the seat is positioned facing the desired direction. 3. While one crewmember supports the navigator's seat (Figure 8, Item 1), the second crewmember installs the clamp (Figure 8, Item 10) and tightens the nut (Figure 8, Item 3).
END OF TASK PILOTHOUSE CONSOLE ILLUMINATION LIGHT BULB REMOVAL 1. At the general alarm and emergency lighting distribution panel, set to OFF the STALK LIGHTS (Figure 9, Item 1) and PILOTHOUSE ILLUMINATION (Figure 9, Item 2) circuit breakers. Lock out and tag out IAW FM 4-01.502.
1
M1180T73
Figure 9. General Alarm and Emergency Lighting Distribution Panel.
WARNING
Replace or repair components only after the affected circuit has been secured, locked out, and tagged out IAW FM 4-01.502. Performing replacement with the circuit energized may result in injury. 2. Turn the ON/OFF switch (Figure 10, Item 1) past the OFF position until it clicks.
0086-13
TM 55-1925-273-24&P-2 PILOTHOUSE CONSOLE ILLUMINATION LIGHT BULB REMOVAL - Continued 3. 4.
0086
Pull the ON/OFF switch (Figure 10, Item 1) out of the pilothouse console illumination light (Figure 10, Item 9). Push IN slightly and turn the bulb (Figure 10, Item 10) approximately 1/8 turn counterclockwise. Remove the bulb.
1 2 3 4 5 6
ELC-24EP- 11
10 7
9
E.O.T POWER FAIL ALARM
ENGINE ORDER TELEGRAPH POWER FAILURE ALARM NORMAL POWER AVAILABLE POWER FAILURE ACKNOWLEDGE
M1181T73
Figure 10. Pilothouse Console Illumination Light. END OF TASK PILOTHOUSE CONSOLE ILLUMINATION LIGHT BULB INSTALLATION 1. 2. 3. 4. Position a bulb (Figure 10, Item 10) in the ON/OFF switch (Figure 10, Item 1), push it straight IN, and turn it approximately 1/8 turn clockwise to latch it. Position the ON/OFF switch (Figure 10, Item 1) in the pilothouse console illumination light assembly (Figure 10, Item 9) and turn it toward the ON position until it clicks into place. Remove the lock outs and tag outs installed during Step (1) of the PILOTHOUSE CONSOLE ILLUMINATION LIGHT BULB REMOVAL procedure IAW FM 4-01.502. Set to ON the circuit breakers set to OFF during Step (1) of the PILOTHOUSE CONSOLE ILLUMINATION LIGHT BULB REMOVAL procedure and return the unit to the desired readiness condition IAW TM 55-1925-273-10.
END OF TASK PILOTHOUSE CONSOLE ILLUMINATION LIGHT REMOVAL 1. At the general alarm and emergency lighting distribution panel, set to OFF the STALK LIGHTS
0086-14
TM 55-1925-273-24&P-2 PILOTHOUSE CONSOLE ILLUMINATION LIGHT REMOVAL - Continued
0086
(Figure 9, Item 1) and PILOTHOUSE ILLUMINATION (Figure 9, Item 2) circuit breakers. Lock out and tag out IAW FM 4-01.502.
WARNING
Replace or repair components only after the affected circuit has been secured, locked out, and tagged out IAW FM 4-01.502. Performing replacement with the circuit energized may result in injury. 2. Use a multimeter to check for available voltage at the pilothouse console illumination light wiring (Figure 10, Item 8) terminals on the terminal block (Figure 10, Item 7). If voltage is present, ensure that the proper circuit breakers are secured, locked out, and tagged out IAW FM 4-01.502. If no voltage is present, continue with the procedure. Label and disconnect the pilothouse console illumination light wiring (Figure 10, Item 8) terminals at the terminal block (Figure 10, Item 7). Press IN on the locking tab (Figure 10, Item 5) and slide the pilothouse console illumination light (Figure 10, Item 9) from its base (Figure 10, Item 6). Remove the four screws (Figure 10, Item 2), four lockwashers (Figure 10, Item 3), and four washers (Figure 10, Item 4) securing the base (Figure 10, Item 6) to the console. Remove the base.
3. 4. 5.
END OF TASK PILOTHOUSE CONSOLE ILLUMINATION LIGHT INSTALLATION 1. 2. 3. Position the base (Figure 10, Item 6) on the console and secure it with four screws (Figure 10, Item 2), four lockwashers (Figure 10, Item 3), and four washers (Figure 10, Item 4). Slide the pilothouse console illumination light (Figure 10, Item 9) into the base (Figure 10, Item 6) until the lock tab (Figure 10, Item 5) clicks and secures the pilothouse console illumination light. Connect the pilothouse console illumination light wiring (Figure 10, Item 8) terminals at the terminal block (Figure 10, Item 7) using the labels from Step (3) of PILOTHOUSE CONSOLE ILLUMINATION LIGHT REMOVAL as a guide. Remove the labels. Remove the lock outs and tag outs installed during Step (1) of PILOTHOUSE CONSOLE ILLUMINATION LIGHT REMOVAL procedure IAW FM 4-01.502. Set to ON the circuit breakers set to OFF during Step (1) of the PILOTHOUSE CONSOLE ILLUMINATION LIGHT REMOVAL procedure and return the unit to the desired readiness condition IAW TM 55-1925-273-10.
4.
5.
END OF TASK PILOTHOUSE ALARM PANEL LIGHT EMITTING DIODE (LED) REMOVAL 1. At the general alarm and emergency lighting panel, set to OFF the PILOTHOUSE ALARM PNL circuit breaker (Figure 9, Item 3). Lock out and tag out IAW FM 4-01.502.
0086-15
TM 55-1925-273-24&P-2 PILOTHOUSE ALARM PANEL LIGHT EMITTING DIODE (LED) REMOVAL - Continued 2.
0086
Remove the four screws (Figure 11, Item 2), four nylock nuts (Figure 11, Item 1), and four nylon washers (Figure 11, Item 3) that secure the pilothouse alarm panel (Figure 11, Item 4) to the port main console. Remove the pilothouse alarm panel from the port main console.
1
2 3
BILGE ALARM
GENERAL ALARM
PORT SHAFT ALLEY
PORT ENGINE ROOM
STBD ENGINE ROOM
STBD SHAFT ALLEY
DC CHARGER NEWAR
DC CHARGER 12V
DC CHARGER GMDSS
DC CHARGER GEN. ALARM
ACKNOWLEDGE
PRESS TO TEST
M1182T73
Figure 11.
Pilothouse Alarm Panel.
WARNING
Replace or repair components only after the affected circuit has been secured, locked out, and tagged out IAW FM 4-01.502. Performing replacement with the circuit energized may result in injury. 3. Use a multimeter to check for available voltage at the terminal block (Figure 12, Item 3). If voltage is present, ensure that the proper circuit breakers are secured, locked out, and tagged out IAW FM 4-01.502. If no voltage is present, continue with the procedure. Cut the wire ties (Figure 12, Item 1) from the wire harness (Figure 12, Item 2) as necessary to determine which wires lead to the defective LED. At the terminal block (Figure 12, Item 3), label and disconnect the wiring (Figure 12, Item 2) to the defective LED.
4. 5.
0086-16
TM 55-1925-273-24&P-2 PILOTHOUSE ALARM PANEL LIGHT EMITTING DIODE (LED) REMOVAL - Continued
0086
M1183T73
Figure 12. 6.
Pilothouse Alarm Panel (Back Side).
Remove the nut (Figure 13, Item 3) and star washer (Figure 13, Item 2) and remove the LED (Figure 13, Item 1) and its integral wiring from the pilothouse alarm panel (Figure 13, Item 4).
5
M1184T73
LED.
0086-17
TM 55-1925-273-24&P-2
0086
PILOTHOUSE ALARM PANEL LIGHT EMITTING DIODE (LED) INSTALLATION 1. 2. 3. Position the LED (Figure 13, Item 1) and its integral wiring in the pilothouse alarm panel (Figure 13, Item 4) and secure it with the nut (Figure 13, Item 3) and a star washer (Figure 13, Item 2). Crimp solderless connectors to the wiring (Figure 13, Item 5) to match the connectors used on the removed LED (Figure 13, Item 1). Connect the wiring (Figure 12, Item 2) at the terminal block (Figure 12, Item 3) using the labels from Step (5) of PILOTHOUSE ALARM PANEL LIGHT EMITTING DIODE (LED) REMOVAL as a guide and secure the wire harness (Figure 12, Item 2) using wire ties. Remove the labels. Position the pilothouse alarm panel (Figure 11, Item 4) on the port main console and secure it with four screws (Figure 11, Item 2), four nylock nuts (Figure 11, Item 1), and four nylon washers (Figure 11, Item 3). Remove the lock outs and tag outs installed in Step (1) of the PILOTHOUSE ALARM PANEL LIGHT EMITTING DIODE (LED) REMOVAL procedure IAW FM 4-01.502. Set to ON the PILOTHOUSE ALARM PNL circuit breaker (Figure 9, Item 3).
4. 5. 6.
END OF TASK PILOTHOUSE ALARM PANEL PUSHBUTTON REMOVAL 1. 2. At the general alarm and emergency lighting panel, set to OFF the PILOTHOUSE ALARM PNL circuit breaker (Figure 9, Item 3). Lock out and tag out IAW FM 4-01.502. Remove the four screws (Figure 11, Item 2), four nylock nuts (Figure 11, Item 1), and four nylon washers (Figure 11, Item 3) that secure the pilothouse alarm panel (Figure 11, Item 4) to the port main console. Remove the pilothouse alarm panel from the port main console.
WARNING
Replace or repair components only after the affected circuit has been secured, locked out, and tagged out IAW FM 4-01.502. Performing replacement with the circuit energized may result in injury. 3. Use a multimeter to check for available voltage at the terminal block (Figure 12, Item 3). If voltage is present, ensure that the proper circuit breakers are secured, locked out, and tagged out IAW FM 4-01.502. If no voltage is present, continue with the procedure. Loosen, but do not remove, the tension screw (Figure 14, Item 5). Label and disconnect the wiring (Figure 14, Item 4) from the pushbutton contact block (Figure 14, Item 3). Pull OUT on the locking tab (Figure 14, Item 2) and separate the pushbutton contact block (Figure 14, Item 3) from the operator (Figure 14, Item 6). Remove the operator from the pilothouse alarm panel (Figure 14, Item 1).
4. 5. 6.
0086-18
TM 55-1925-273-24&P-2 PILOTHOUSE ALARM PANEL PUSHBUTTON REMOVAL - Continued
0086
4
M1185T73
Pilothouse Alarm Panel Pushbutton.
PILOTHOUSE ALARM PANEL PUSHBUTTON INSTALLATION 1. 2. 3. 4. 5. 6. 7. Position the operator (Figure 14, Item 6) in the pilothouse alarm panel (Figure 14, Item 1). Place the pushbutton contact block (Figure 14, Item 3) over the operator (Figure 14, Item 6) and jiggle it into position. Push IN on the lock tab (Figure 14, Item 2) and secure the pushbutton contact block to the operator. Snug the tension screw (Figure 14, Item 5). Connect the wiring (Figure 14, Item 4) to the pushbutton contact block (Figure 14, Item 3) using the labels from Step (5) of PILOTHOUSE ALARM PANEL PUSHBUTTON REMOVAL as a guide. Remove the labels. Position the pilothouse alarm panel (Figure 11, Item 4) on the port main console and secure it with four screws (Figure 11, Item 2), four nylock nuts (Figure 11, Item 1), and four nylon washers (Figure 11, Item 3). Remove the lock outs and tag outs installed in Step (1) of the PILOTHOUSE ALARM PANEL PUSHBUTTON REMOVAL procedure IAW FM 4-01.502. Set to ON the PILOTHOUSE ALARM PNL circuit breaker (Figure 9, Item 3).
END OF TASK
0086-19
TM 55-1925-273-24&P-2
0086
PILOTHOUSE ALARM PANEL BUZZER REMOVAL 1. 2. At the general alarm and emergency lighting panel, set to OFF the PILOTHOUSE ALARM PNL circuit breaker (Figure 9, Item 3). Lock out and tag out IAW FM 4-01.502. Remove the four screws (Figure 11, Item 2), four nylock nuts (Figure 11, Item 1), and four nylon washers (Figure 11, Item 3) that secure the pilothouse alarm panel (Figure 11, Item 4) to the port main console. Remove the pilothouse alarm panel from the port main console.
WARNING
Replace or repair components only after the affected circuit has been secured, locked out, and tagged out IAW FM 4-01.502. Performing replacement with the circuit energized may result in injury. 3. Use a multimeter to check for available voltage at the terminal block (Figure 12, Item 3). If voltage is present, ensure that the proper circuit breakers are secured, locked out, and tagged out IAW FM 4-01.502. If no voltage is present, continue with the procedure. Label and disconnect the wiring (Figure 15, Item 2) at the terminals (Figure 15, Item 3). Unscrew the face ring (Figure 15, Item 1) and remove the buzzer (Figure 15, Item 4) from the pilothouse alarm panel (Figure 15, Item 5).
4. 5.
2
M1186T73
Figure 15. Pilothouse Alarm Panel Buzzer. END OF TASK
0086-20
TM 55-1925-273-24&P-2
0086
PILOTHOUSE ALARM PANEL BUZZER INSTALLATION 1. 2. 3. 4. 5. Position the buzzer (Figure 15, Item 4) in the pilothouse alarm panel (Figure 15, Item 5) and secure it with the face ring (Figure 15, Item 1). Connect the wiring (Figure 15, Item 2) to the terminals (Figure 15, Item 3) using the labels from Step (4) of PILOTHOUSE ALARM PANEL BUZZER REMOVAL as a guide. Remove the labels. Position the pilothouse alarm panel (Figure 11, Item 4) on the port main console and secure it with four screws (Figure 11, Item 2), four nylock nuts (Figure 11, Item 1), and four nylon washers (Figure 11, Item 3). Remove the lock outs and tag outs installed in Step (1) of the PILOTHOUSE ALARM PANEL BUZZER REMOVAL procedure IAW FM 4-01.502. Set to ON the PILOTHOUSE ALARM PNL circuit breaker (Figure 8, Item 3).
0086-21/22 blank
TM 55-1925-273-24&P-2 FIELD MAINTENANCE HYDRAULIC WATERTIGHT DOORS ADJUST
0087
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 3, WP 0344, Table 1, Item 27) Materials/Parts N/A Personnel Required Watercraft Engineer 88L (2) References FM 4-01.502 References (cont.) Volume 3, WP 0251 Volume 3, WP 0344 Equipment Condition Door(s) CLOSED and hand pumps locked out and tagged out IAW FM 4-01.502. Operational sound powered telephones.
0087-1
TM 55-1925-273-24&P-2
0087
ADJUST
NOTE
The clearance between the door and frame at all points along the sealing surface should be less than 0.003 in. (0.08 mm), but not close enough to cause the door to stick in the closed position when full power is applied for opening. 1. 2. Check the clearance with a 0.003 in. (0.08 mm) feeler gage. It should not pass through at any point along the sealing surface. If the door sticks or if the clearance is exceeded, adjust the clearance by turning the set bolts (Figure 1, Item 1) in or out to obtain the required clearance.
1
M1002T73
Figure 1. Hydraulic Watertight Door. END OF TASK FOLLOW-ON MAINTENANCE Remove the lock outs and tag outs IAW FM 4-01.502. END OF TASK END OF WORK PACKAGE
0087-2
TM 55-1925-273-24&P-2 FIELD MAINTENANCE HYDRAULIC WATERTIGHT DOORS REPAIR
0088
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 3, WP 0344, Table 1, Item 27) Faceshield, Industrial (Volume 3, WP 0344, Table 1, Item 5) Gloves, Leather (Volume 3, WP 0344, Table 1, Item 9) Gloves, Chemical and Oil Protective (Volume 3, WP 0344, Table 1, Item 8) Goggles, Industrial (Volume 3, WP 0344, Table 1, Item 10) Lubricating Gun, Hand (Volume 3, WP 0344, Table 1, Item 14) Tool Kit, Welder's (Volume 3, WP 0344, Table 1, Item 29) Torch Outfit, Welding (Volume 3, WP 0344, Table 1, Item 30) Materials/Parts Cleaning Compound, Solvent (Volume 3, WP 0343, Table 1, Item 37) Grease, Ball and Roller Bearing; 1.75 lb (Volume 3, WP 0343, Table 1, Item 74) Rag, Wiping (Volume 3, WP 0343, Table 1, Item 132) Personnel Required Watercraft Engineer 88L (2) Fire watch as required IAW FM 4-01.502 (if welding will be performed) References FM 4-01.502 TB 43-0144 TB 55-1900-204-24 Volume 3, WP 0251 Volume 3, WP 0343 Volume 3, WP 0344 Equipment Condition Vessel certified safe for HOTWORK IAW FM 4-01.502. (if welding will be performed). Door(s) OPEN and hand pumps locked out and tagged out IAW FM 4-01.502.
0088-1
TM 55-1925-273-24&P-2
0088
DISASSEMBLY 1. 2. 3. Remove the grease fitting (Figure 1, Item 7). Remove the hex nut (Figure 1, Item 6) and the metal guide (Figure 1, Item 5). Remove the washer (Figure 1, Item 4).
WARNING
Watertight doors are extremely heavy. Two crewmembers are required to raise and secure the door. Do not attempt to raise or lower the door without assistance. Failure to comply with this warning can result in serious injury or death. 4. 5. If removing a bottom roller, pry the door up and secure it in position. Slide the roller (Figure 1, Item 3) off the pin (Figure 1, Item 1).
M1187T73
Figure 1. Hydraulic Watertight Door. END OF TASK
0088-2
TM 55-1925-273-24&P-2 CLEAN AND INSPECT
0088
WARNING
Cleaning solvent is flammable and its vapor is potentially explosive. Do not use cleaning solvent in the vicinity of spark, open flame, or excessive heat. Do not use cleaning solvent in unventilated spaces. Always wear chemical protective gloves and goggles when handling hydraulic fluid, engine oil, and cleaning solvents. Failure to comply with this warning can result in serious injury or death. 1. 2. 3. Clean all metal parts with cleaning solvent and dry with clean wiping rags. Inspect the door roller for corrosion, pitting, deep scratches, or other damages that would prevent smooth operation. If the damage is found, the roller must be replaced. Clean the pin with cleaning solvent to remove all excess grease. Inspect the pin for corrosion, pitting, deep scratches, or other damage that would prevent smooth operation. If damage is found, notify the maintenance supervisor. Clean the old grease out of the 90 degree cavity (Figure 1, Item 2).
4.
END OF TASK REPAIR
WARNING
Grinding or cutting operations produce hot, flying particles. These particles can cause serious injury to personnel or ignite fires in the work area. Wear protective faceshield, gloves, and/or aprons at all times during cutting and grinding operations. A fire watch must be posted whenever cutting or grinding operations are taking place. Unprotected exposure to arc-welding rays can cause serious eye damage and radiation burns to the skin. Never perform arc-welding operations without using appropriate eye and skin protection. Failure to comply with this warning can result in serious injury or death to personnel and serious damage to the vessel.
CAUTION
Improper connection of ground leads can cause serious electrolytic and electronic damage to the vessel and its components. Always ensure that ground leads are connected IAW TB 55-1900-204-24.
NOTE
Inspect the door structure and sealing edges for corrosion and other damage that would prevent a proper seal. 1. If welding repairs are required, perform such repairs using the applicable design drawings and acceptable welding practices. All watercraft welding and repair must be accomplished as detailed in TB 55-1900-204-24.
0088-3
TM 55-1925-273-24&P-2 REPAIR - Continued 2.
0088
After the area has cooled, paint the affected area IAW TB 43-0144, taking care not to paint any threads.
END OF TASK ASSEMBLY 1. 2. 3. 4. Apply a liberal coating of grease to the inside of the door roller (Figure 1, Item 3) and to the pin (Figure 1, Item 1). Slide the door roller over the pin. Install the washer (Figure 1, Item 4). Install the metal guide (Figure 1, Item 5), hex nut (Figure 1, Item 6), and grease fitting (Figure 1, Item 7). Using a grease gun, apply grease to the grease fitting (Figure 1, Item 7) and throughly grease the door roller.
END OF TASK FOLLOW-ON MAINTENANCE Remove the lock outs and tag outs IAW FM 4-01.502. END OF TASK END OF WORK PACKAGE
0088-4
TM 55-1925-273-24&P-2 FIELD MAINTENANCE HYDRAULIC CYLINDER ASSEMBLY REPLACE
0089
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 3, WP 0344, Table 1, Item 27) Gloves, Chemical and Oil Protective (Volume 3, WP 0344, Table 1, Item 8) Goggles, Industrial (Volume 3, WP 0344, Table 1, Item 10) Suitable Drain Pan Materials/Parts Cleaning Compound, Solvent (Volume 3, WP 0343, Table 1, Item 37) Hydraulic Fluid, Fire Resistant (Volume 3, WP 0343, Table 1, Item 88) Rag, Wiping (Volume 3, WP 0343, Table 1, Item 132) Personnel Required Watercraft Engineer 88L (3) References FM 4-01.502 TM 55-1925-273-10 Volume 3, WP 0252 Volume 3, WP 0343 Volume 3, WP 0344 Equipment Condition Remote hand pump and local hand pumps locked out and tagged out IAW FM 4-01.502.
0089-1
TM 55-1925-273-24&P-2
0089
WARNING
Never reuse locking hardware. Reuse of locking hardware such as lockwashers, locking nuts, cotter pins, and lock wire can result in undetected loosening of fastening hardware causing catastrophic component failure resulting in death, injury, or damage to equipment. Ensure that all locking hardware is discarded upon removal and replaced with new. REMOVAL 1. CLOSE the remote valves (Figure 1, Items 1 and 2).
0089-2
TM 55-1925-273-24&P-2 REMOVAL - Continued
0089
CLOSE
M1188T73
Figure 1.
Valve Assembly.
0089-3
0089
WARNING
Do not allow hydraulic fluid, engine oil, or cleaning solvents to come in contact with unprotected skin or eyes. Prolonged skin contact can cause illness or injury. Eye contact can cause serious injury. Always wear chemical protective gloves and goggles when handling hydraulic fluid, engine oil, and cleaning solvents. Failure to follow these precautions can result in illness, serious injury, or death. 2. Position a suitable drain pan beneath the hydraulic cylinder (Figure 2, Item 6) that is to be removed.
WARNING
Hydraulic hoses and lines may be under pressure. Relieve pressure by operating the appropriate control valve, if possible. Loosen fittings on hoses and lines slowly. Allow oil to run around threads of fitting, releasing pressure before disconnecting fitting. Releasing pressurized oil suddenly may cause serious injury or death. 3. 4. 5. Loosen, but do not remove, the hydraulic lines (Figure 2, Item 2) on each end of the hydraulic cylinder (Figure 2, Item 6) to release pressure from the system. After all the pressure has been relieved, remove the hydraulic lines (Figure 2, Item 2) at the hydraulic cylinder (Figure 2, Item 6). Cover the hydraulic lines (Figure 2, Item 2) with clean wiping rags to prevent contamination.
WARNING
Cleaning solvent is flammable and its vapor is potentially explosive. Do not use cleaning solvent in the vicinity of spark, open flame, or excessive heat. Do not use cleaning solvent in unventilated spaces. Always wear chemical protective gloves and goggles when handling hydraulic fluid, engine oil, and cleaning solvents. Failure to comply with this warning can result in serious injury or death. 6. 7. Use wiping rags and cleaning solvent to clean up all hydraulic fluid immediately to prevent unsafe working conditions. Remove the rod nut (Figure 2, Item 1), and remove the hydraulic cylinder (Figure 2, Item 6) from the door.
0089-4
0089
WARNING
Heavy loads can crush. Use a minimum of two crewmembers to lift and hold heavy loads. Do not allow any body parts to come under the load or between the load and a stationary object. Failure to comply with this warning can result in serious injury or death. 8. 9. Using two crewmembers, hold the hydraulic cylinder (Figure 2, Item 1) while a third crewmember removes the cotter pins (Figure 2, Item 4) and anchor pin (Figure 2, Item 5). Remove the hydraulic cylinder (Figure 2, Item 6) from the cylinder mounting bracket (Figure 2, Item 3).
20 15 10 5 0
25 30 35
40 45 50 55 60
20 15 10 5 0
25 30 35
40 45 50 55 60
3
M1189T73
Hydraulic Cylinder.
0089-5
TM 55-1925-273-24&P-2 INSTALLATION
0089
WARNING
Heavy loads can crush. Use a minimum of two crewmembers to lift and hold heavy loads. Do not allow any body parts to come under the load or between the load and a stationary object. Failure to comply with this warning can result in serious injury or death. 1. 2. 3. 4. 5. Using two crewmembers, position the hydraulic cylinder (Figure 2, Item 6) in the cylinder mounting bracket (Figure 2, Item 3) and secure it in place with the anchor pin (Figure 2, Item 5). Install cotter pins (Figure 2, Item 4) to secure the anchor pin (Figure 2, Item 5) in place. Connect the hydraulic cylinder (Figure 2, Item 6) to the door, and install the rod nut (Figure 2, Item 1). Connect the hydraulic lines (Figure 2, Item 2). OPEN the remote valves (Figure 1, Items 1 and 2).
END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. 4. Fill the reservoir with clean hydraulic fluid to the proper level as indicated on the sight glass. Remove the lock outs and tag outs IAW FM 4-01.502. Cycle the door fully OPEN and fully CLOSED IAW TM 55-1925-273-10 four to five times to test the door and to release trapped air. Check for leaks and replenish the hydraulic oil as necessary. Return the equipment to the desired readiness condition.
0089-6
TM 55-1925-273-24&P-2 FIELD MAINTENANCE HYDRAULIC CYLINDER ASSEMBLY REPAIR
0090
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 3, WP 0344, Table 1, Item 27) Gloves, Chemical and Oil Protective (Volume 3, WP 0344, Table 1, Item 8) Goggles, Industrial (Volume 3, WP 0344, Table 1, Item 10) Suitable Drain Pan Materials/Parts Cleaning Compound, Solvent (Volume 3, WP 0343, Table 1, Item 37) Hydraulic Fluid, Fire Resistant (Volume 3, WP 0343, Table 1, Item 88) Rag, Wiping (Volume 3, WP 0343, Table 1, Item 132) Ring, Retaining (Snap Ring) (Volume 3, WP 0252, Figure 4, Item 7) Qty: 1 Cup, Bitan (Volume 3, WP 0252, Figure 4, Item 2) Qty: 1 O-ring (Volume 3, WP 0252, Figure 4, Item 3) Qty: 3 Materials/Parts (cont.) Packing, Preformed (Volume 3, WP 0252, Figure 4, Item 5) Qty: 1 Seal, Plain Encased (Volume 3, WP 0252, Figure 4, Item 6) Qty: 1 Spacer, Sleeve (Volume 3, WP 0252, Figure 4, Item 4) Qty: 1 Personnel Required Watercraft Engineer 88L (2) References WP 0089 Volume 3, WP 0252 Volume 3, WP 0343 Volume 3, WP 0344 Equipment Condition Hydraulic cylinder removed. (WP 0089)
0090-1
TM 55-1925-273-24&P-2
0090
WARNING
Never reuse locking hardware. Reuse of locking hardware such as lockwashers, locking nuts, cotter pins, and lock wire can result in undetected loosening of fastening hardware causing catastrophic component failure resulting in death, injury, or damage to equipment. Ensure that all locking hardware is discarded upon removal and replaced with new. DISASSEMBLY 1. Remove the snap ring (Figure 1, Item 1) that holds the rod (Figure 1, Item 2) in the cylinder (Figure 1, Item 3). Discard snap ring.
WARNING
Do not allow hydraulic fluid, engine oil, or cleaning solvents to come in contact with unprotected skin or eyes. Prolonged skin contact can cause illness or injury. Eye contact can cause serious injury. Always wear chemical protective gloves and goggles when handling hydraulic fluid, engine oil, and cleaning solvents. Failure to follow these precautions can result in illness, serious injury, or death. 2. 3. 4. 5. 6. Position the rod end of the cylinder (Figure 1, Item 3) over a suitable drain pan to catch any hydraulic fluid lost during removal of the rod (Figure 1, Item 2). Using two crewmembers, pull the rod (Figure 1, Item 2) out of the cylinder (Figure 1, Item 3). One crewmember must hold the cylinder while the other removes the rod. Remove the nut (Figure 2, Item 1) from the rod (Figure 2, Item 9). Remove the piston (Figure 2, Item 11) from the rod (Figure 2, Item 9). Remove and discard bitan cups (Figure 2, Item 2), O-rings (Figure 2, Item 3, 4, and 10), preformed packing (Figure 2, Item 6), plain seal (Figure 2, Item 7), and sleeve spacer (Figure 2, Item 5) from the piston (Figure 2, Item 11) and the rod (Figure 2, Item 9).
2 3
M1190T73
Figure 1. End View of Cylinder.
0090-2
TM 55-1925-273-24&P-2 DISASSEMBLY - Continued

1 2 3 2 4 5 6 7
0090
11
10
M1191T73
Figure 2. END OF TASK CLEAN AND INSPECT
Cylinder Assembly.
WARNING
Cleaning solvent is flammable and its vapor is potentially explosive. Do not use cleaning solvent in the vicinity of spark, open flame, or excessive heat. Do not use cleaning solvent in unventilated spaces. Failure to comply can result in serious injury or death. Do not allow hydraulic fluid, engine oil, or cleaning solvents to come in contact with unprotected skin or eyes. Prolonged skin contact can cause illness or injury. Eye contact can cause serious injury. Always wear chemical protective gloves and goggles when handling hydraulic fluid, engine oil, and cleaning solvents. Failure to follow these precautions can result in illness, serious injury, or death. 1. 2. 3. 4. Clean all metal parts with cleaning solvent and dry with clean wiping rags. Inspect the cylinder rod for corrosion, pitting, deep scratches, or other damage that would harm the plain seal and preformed packing. If damage is found, the entire cylinder assembly must be replaced. Use a light to examine the interior of the cylinder for corrosion, pitting, deep scratches, or other damage that would harm the plain seal and preformed packing. If damage is found, replace the entire cylinder assembly. Inspect the piston and sleeve spacer for corrosion, pitting, deep scratches, or other damage that would harm the O-rings. If damage is found, replace the piston or sleeve spacer.
END OF TASK
0090-3
TM 55-1925-273-24&P-2 ASSEMBLY
0090
WARNING
Do not allow hydraulic fluid, engine oil, or cleaning solvents to come in contact with unprotected skin or eyes. Prolonged skin contact can cause illness or injury. Eye contact can cause serious injury. Always wear chemical protective gloves and goggles when handling hydraulic fluid, engine oil, and cleaning solvents. Failure to follow these precautions can result in illness, serious injury, or death. 1. 2. 3. 4. 5. 6. 7. 8. Install an O-ring (Figure 2, Item 4), preformed packing (Figure 2, Item 6), and plain seal (Figure 2, Item 7) in the sleeve spacer (Figure 2, Item 5). Apply a liberal coating of clean hydraulic fluid to the preformed packing (Figure 2, Item 6), O-ring (Figure 2, Item 4), and plain seal (Figure 2, Item 7). Slide the sleeve spacer (Figure 2, Item 5) on the rod (Figure 2, Item 9), taking care not to damage the plain seal (Figure 2, Item 7). Install an O-ring (Figure 2, Item 10) on the rod (Figure 2, Item 9) and apply a liberal coating of hydraulic fluid to the O-ring. Install a O-ring (Figure 2, Item 3) and bitan cups (Figure 2, Item 2) on the piston (Figure 2, Item 11). Apply a liberal coating of clean hydraulic fluid to the O-ring (Figure 2, Item 3) and bitan cups (Figure 2, Item 2). Slide the piston (Figure 2, Item 11) onto the rod (Figure 1, Item 2) and secure it with the nut (Figure 2, Item 1). Carefully slide the rod (Figure 2, Item 9), piston (Figure 2, Item 11), and spacer assembly (Figure 2, Item 5) into the cylinder (Figure 2, Item 8), ensuring that the components previously installed are not twisted or damaged. Install a snap ring (Figure 1, Item 1) to secure the rod (Figure 1, Item 2) into the cylinder (Figure 1, Item 3).
9.
END OF TASK FOLLOW-ON MAINTENANACE Perform the HYDRAULIC WATERTIGHT DOORS HYDRAULIC CYLINDER REPLACE INSTALLATION procedure (WP 0089). END OF TASK END OF WORK PACKAGE
0090-4
TM 55-1925-273-24&P-2 FIELD MAINTENANCE CONTROL VALVE ASSEMBLY REPLACE
0091
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 3, WP 0344, Table 1, Item 27) Gage, Pressure, Dial Indicating (Volume 3, WP 0344, Table 1, Item 7) Gloves, Chemical and Oil Protective (Volume 3, WP 0344, Table 1, Item 8) Goggles, Industrial (Volume 3, WP 0344, Table 1, Item 10) Suitable Drain Pan Materials/Parts Hydraulic Fluid, Fire Resistant (Volume 3, WP 0343, Table 1, Item 88) Personnel Required Watercraft Engineer 88L (2) References FM 4-01.502 Volume 3, WP 0253 Volume 3, WP 0343 Volume 3, WP 0344 Equipment Condition N/A
0091-1
TM 55-1925-273-24&P-2
0091
REMOVAL 1. For AMS 1 control valve assembly replacement, CLOSE the cutoff valves (Figure 1, Item 5) at the AMS 1 hydraulic watertight door main deck passageway remote station (Figure 1, Item 1). Lock out and tag out IAW FM 4-01.502. For AMS 2 control valve assembly replacement, CLOSE the cutoff valves (Figure 1, Item 4) at the AMS 2 hydraulic watertight door vestibule remote station (Figure 1, Item 2). Lock out and tag out IAW FM 4-01.502.
2.
0091-2
0091
AMS 1 HYDRAULIC WATERTIGHT DOOR REMOTE, MAIN DECK PASSAGEWAY

Figure 1.
AMS 2 HYDRAULIC WATERTIGHT DOOR RESERVOIR, VESTIBULE

M1192T73
AMS 1 and AMS 2 Control Valve Assemblies.
0091-3
TM 55-1925-273-24&P-2 REMOVAL - Continued 3. Place a suitable drain pan beneath the work area.
0091
WARNING
Hydraulic hoses and lines may be under pressure. Relieve pressure by operating the appropriate control valve, if possible. Loosen fittings on hoses and lines slowly. Allow oil to run around threads of fitting, releasing pressure before disconnecting fitting. Releasing pressurized oil suddenly may cause serious injury or death.
CAUTION
Always use two wrenches when loosening hydraulic lines. Failure to use two wrenches can result in damage to the hydraulic lines or fittings. Always use the two wrench method. 4. 5. 6. 7. Label and remove the hydraulic lines (Figure 2, Items 1, 2, 3, 5, 6, 7, and 10). Allow any hydraulic fluid to drain into the suitable drain pan. Remove the four screws (Figure 2, Item 4) that secure the control valve assembly (Figure 2, Item 11) to its mounting bracket. Remove the control valve assembly (Figure 2, Item 11) from its mounting bracket.
2 1 3
4 11
4 5
10
6 7
M1193T73
Figure 2. Control Valve Assembly. END OF TASK
0091-4
TM 55-1925-273-24&P-2
0091
INSTALLATION 1. Position the control valve assembly (Figure 2, Item 11) in its mounting bracket and secure it with the four screws (Figure 2, Item 4).
CAUTION
Always use two wrenches when tightening hydraulic lines. Failure to use two wrenches can result in damage to the hydraulic lines or fittings. Always use the two wrench method. 2. 3. 4. 5. 6. Connect the hydraulic lines (Figure 2, Items 1, 2, 3, 5, 6, 7, and 10) to the control valve assembly (Figure 2, Item 11) using the labels from Step (4) of REMOVAL as a guide. Remove the labels. Remove the lock out and tag outs IAW FM 4-01.502. Remove the pipe plug (Figure 2, Item 9) from the control valve assembly (Figure 2, Item 11). OPEN the cutoff valves (Figure 1, Items 4 and 5) for the appropriate remote location, and install the pipe plug (Figure 2, Item 9) when hydraulic fluid is vented from the pipe plug opening. OPEN the vent (Figure 3, Item 2) on the mounting end of the cylinder.
1 2
M1194T73
Figure 3. 7. 8. 9.
Hydraulic Cylinder Vent.
Rotate the remote hand pump (Figure 1, Item 3) in the CLOSE direction until hydraulic fluid flows freely from the vent (Figure 3, Item 2). CLOSE the vent (Figure 3, Item 2) and continue to rotate the remote hand pump (Figure 1, Item 3) clockwise until the watertight door (Figure 3, Item 3) closes. OPEN the vent (Figure 3, Item 1) at the rod end of the cylinder (Figure 3, Item 4).
0091-5
TM 55-1925-273-24&P-2 INSTALLATION - Continued 10. 11. 12. 13. 14. 15. Operate the local hand pump in the OPEN direction until hydraulic fluid flows freely from the vent (Figure 3, Item 1). CLOSE the vent (Figure 3, Item 1) and continue to rotate the local hand pump until the watertight door (Figure 3, Item 3) is OPEN.
0091
Operate the watertight door through four to five complete OPEN/CLOSE cycles to bleed any remaining air from the system. Remove the pipe plug (Figure 2, Item 9) from the OPEN part of the control valve assembly (Figure 2, Item 11). Install a pressure gage in this opening. Remove the pipe plug (Figure 2, Item 8) from the CLOSE part of the control valve assembly (Figure 2, Item 11). Install a pressure gage in this opening. Turn the local hand pump until the door is fully CLOSED and the cylinder is deadheaded.
NOTE
Turn the crank handle against a deadheaded cylinder only while taking gage readings. Do not continue cranking the door after the gage reading has been observed. 16. 17. 18. 19. 20. Observe the reading on the pressure gage in the CLOSE piping (Figure 2, Item 8). The proper CLOSE relief pressure setting is 800 PSI (55 bar). If the CLOSE relief pressure is not wet at 800 PSI (55 bar), perform Steps (18) through (23). If the CLOSE relief pressure is set to 800 PSI (55 bar), proceed to Step (24). Remove the cap nut (Figure 4, Item 2) from the CLOSE relief valve cartridge. Loosen the jamnut (Figure 4, Item 6) on the CLOSE relief valve cartridge. If the CLOSE relief pressure is too high, turn the CLOSE adjusting screw (Figure 4, Item 1) counterclockwise until the proper relief pressure is attained. If the CLOSE relief pressure is too low, turn the adjusting screw clockwise until the proper relief pressure is attained. Hold the CLOSE adjusting screw (Figure 4, Item 1) stationary and tighten the jamnut (Figure 4, Item 6). Check the CLOSE relief pressure. If the proper relief pressure is noted, proceed to Step (23). If an incorrect CLOSE relief pressure is noted, repeat Steps (19) through (22). Install the cap nut (Figure 4, Item 2) on the CLOSE relief valve cartridge. Turn the local hand pump until the door is fully OPEN and the cylinder is deadheaded.
21. 22. 23. 24.
NOTE
Turn the crank handle against a deadheaded cylinder only while taking gage readings. Do not continue cranking the door after the gage reading has been observed. 25. 26. 27. 28. 29. Observe the reading on the pressure gage in the OPEN piping. The proper OPEN relief pressure setting is 800 PSI (55 bar). If the OPEN relief pressure is not set at 800 PSI (55 bar), perform Steps (27) through (32). If the OPEN relief pressure is set at 800 PSI (55 bar), proceed to Step (33). Remove the cap nut (Figure 4, Item 5) from the OPEN relief valve cartridge. Loosen the jamnut (Figure 4, Item 3) on the OPEN relief valve cartridge. If the OPEN relief pressure is too high, turn the OPEN adjusting screw (Figure 4, Item 4) counterclockwise until the proper relief pressure is attained. If the OPEN relief pressure is too low, turn the adjusting screw clockwise until the proper relief pressure is attained.
0091-6
TM 55-1925-273-24&P-2 INSTALLATION - Continued 30. 31. 32. 33. 34. Hold the OPEN adjusting screw (Figure 4, Item 4) stationary and tighten the jamnut (Figure 4, Item 3).
0091
Check the CLOSE relief pressure. If the proper relief pressure is noted, continue with the procedure. If an incorrect OPEN relief pressure is noted, repeat Steps (28) through (31). Install the cap nut (Figure 4, Item 2) on the OPEN relief valve cartridge. Remove the pressure gage and install the pipe plugs (Figure 2, Items 8 and 9). Return the hydraulic watertight door to the desired readiness condition.
CLOSE
OPEN
M1195T73
Figure 4. END OF TASK END OF WORK PACKAGE
Control Valve Assembly Pressure Setting.
0091-7/8 blank
TM 55-1925-273-24&P-2 FIELD MAINTENANCE CONTROL VALVE ASSEMBLY REPAIR
0092
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 3, WP 0344, Table 1, Item 27) Gloves, Chemical and Oil Protective (Volume 3, WP 0344, Table 1, Item 8) Goggles, Industrial (Volume 3, WP 0344, Table 1, Item 10) Suitable Drain Pan Materials/Parts Cloth, Abrasive (Crocus Cloth) (Volume 3, WP 0343, Table 1, Item 39) Hydraulic Fluid, Fire Resistant (Volume 3, WP 0343, Table 1, Item 88) Rag, Wiping (Volume 3, WP 0343, Table 1, Item 132) O-ring (Volume 3, WP 0253, Figure 5, Item 2) Qty: 3 O-ring (Volume 3, WP 0253, Figure 5, Item 3) Qty: 1 O-ring (Volume 3, WP 0253, Figure 5, Item 7) Qty: 3 Packing With Retainer (Volume 3, WP 0253, Figure 5, Item 8) Qty: 2 O-ring (Volume 3, WP 0253, Figure 5, Item 10) Qty: 1 Materials/Parts (cont.) O-ring (Volume 3, WP 0253, Figure 5, Item 12) Qty: 3 O-ring (Volume 3, WP 0253, Figure 5, Item 15) Qty: 3 O-ring (Volume 3, WP 0253, Figure 5, Item 18) Qty: 3 Personnel Required Watercraft Engineer 88L (1) References WP 0091 Volume 3, WP 0253 Volume 3, WP 0343 Volume 3, WP 0344 Equipment Condition Control valve assembly removed. (WP 0091)
0092-1
TM 55-1925-273-24&P-2
0092
CONTROL VALVE DISASSEMBLY 1. Match mark the control valve assembly (Figure 1, Item 1) top section (Figure 1, Item 4), middle section (Figure 1, Item 5), and bottom section (Figure 1, Item 6) to ensure that the control valve assembly is reassembled in the correct order and in the proper orientation.
CAUTION
Always use two wrenches when loosening hydraulic lines. Failure to use two wrenches can result in damage to the hydraulic lines or fittings. Always use the two wrench method. 2. Using two wrenches, remove the three nuts (Figure 1, Item 2) from the top section (Figure 1, Item 4) of the control valve assembly (Figure 1, Item 1) and the three nuts (Figure 1, Item 7) from the bottom section (Figure 1, Item 6) of the control assembly.
WARNING
Do not allow hydraulic fluid, engine oil, or cleaning solvents to come in contact with unprotected skin or eyes. Prolonged skin contact can cause illness or injury. Eye contact can cause serious injury. Always wear chemical protective gloves and goggles when handling hydraulic fluid, engine oil, and cleaning solvents. Failure to follow these precautions can result in illness, serious injury, or death. 3. 4. Position the control valve assembly (Figure 1, Item 1) over a suitable drain pan and remove the three bolts (Figure 1, Item 3) from the control valve assembly. Allow any hydraulic fluid to drain into the suitable drain pan. Separate the control valve assembly (Figure 1, Item 1) into its sections.
END OF TASK CONTROL VALVE INSPECT 1. 2. 3. Inspect all sealing surfaces for damage. Minor damage may be repaired using an abrasive cloth. Major damage requires replacement of the component. Inspect all springs for breakage or distortion. Replace the entire valve section if broken or distorted springs are discovered. Inspect all balls for corrosion, pitting, or other obvious damage. Replace the entire valve assembly if corrosion, pitting, or other obvious damage is discovered.
END OF TASK CONTROL VALVE ASSEMBLY 1. Assemble the bottom section (Figure 1, Item 6), the middle section (Figure 1, Item 5), and the top section (Figure 1, Item 4) of the control valve assembly (Figure 1, Item 1) using the match marks from Step (1) of CONTROL VALVE DISASSEMBLY as a guide. Install the three bolts (Figure 1, Item 3) in the control valve assembly (Figure 1, Item 1). Install the three nuts (Figure 1, Item 7) on the three bolts (Figure 1, Item 3) on the bottom section (Figure 1, Item 6) of the control valve assembly (Figure 1, Item 1). Do not tighten at this time.
2. 3.
0092-2
TM 55-1925-273-24&P-2 CONTROL VALVE ASSEMBLY - Continued 4. Install the three nuts (Figure 1, Item 2) on the three bolts (Figure 1, Item 3) on the top section (Figure 1, Item 4) of the control valve assembly (Figure 1, Item 1). Do not tighten at this time.
0092
CAUTION
Always use two wrenches when tightening hydraulic lines. Failure to use two wrenches can result in damage to the hydraulic lines or fittings. Always use the two wrench method. 5. Using two wrenches, tighten the three nuts (Figure 1, Item 2) on the top section (Figure 1, Item 4) and the three nuts (Figure 1, Item 7) on the bottom section (Figure 1, Item 6) of the control valve assembly (Figure 1, Item 1).
1
3 3 2 3
4 2 5 6
7 3
7
M1196T73
Remote Valve Assembly.
0092-3
TM 55-1925-273-24&P-2
0092
SINGLE CHECK VALVE DISASSEMBLY
WARNING
Do not allow hydraulic fluid, engine oil, or cleaning solvents to come in contact with unprotected skin or eyes. Prolonged skin contact can cause illness or injury. Eye contact can cause serious injury. Always wear chemical protective gloves and goggles when handling hydraulic fluid, engine oil, and cleaning solvents. Failure to follow these precautions can result in illness, serious injury, or death. 1. 2. 3. 4. Perform the CONTROL VALVE DISASSEMBLY procedure in this work package. Remove and discard O-rings (Figure 2, Items 2, 3, and 7). Remove the plug (Figure 2, Item 4), spring (Figure 2, Item 6), and check ball (Figure 2, Item 8) from the single check valve (Figure 2, Item 1). Remove and discard O-ring (Figure 2, Item 5) from the single check valve (Figure 2, Item 1).
END OF TASK SINGLE CHECK VALVE INSPECT 1. 2. 3. Inspect all sealing surfaces for damage. Minor damage may be repaired using an abrasive cloth. Major damage requires replacement of the component. Inspect all springs for breakage or distortion. Replace the entire valve section if broken or distorted springs are discovered. Inspect all balls for corrosion, pitting, or other obvious damage. Replace the entire valve assembly if corrosion, pitting, or other obvious damage is discovered.
END OF TASK SINGLE CHECK VALVE ASSEMBLY
WARNING
Do not allow hydraulic fluid, engine oil, or cleaning solvents to come in contact with unprotected skin or eyes. Prolonged skin contact can cause illness or injury. Eye contact can cause serious injury. Always wear chemical protective gloves and goggles when handling hydraulic fluid, engine oil, and cleaning solvents. Failure to follow these precautions can result in illness, serious injury, or death. 1. 2. 3. Seat the ball (Figure 2, Item 8) and spring (Figure 2, Item 6) in the single check valve (Figure 2, Item 1). Lubricate an O-ring (Figure 2, Item 5) with hydraulic fluid and install it in the single check valve (Figure 2, Item 1). Install the plug (Figure 2, Item 4) in the single check valve (Figure 2, Item 1).
0092-4
TM 55-1925-273-24&P-2 SINGLE CHECK VALVE ASSEMBLY - Continued 4. 5.
0092
Lubricate the O-rings (Figure 2, Items 2, 3, and 7) with hydraulic fluid and install them in the single check valve (Figure 2, Item 1). Perform the CONTROL VALVE ASSEMBLY procedure in this work package.
8
CLOSE OPEN
5
4
Single Check Valve.
M1197T73
0092-5
TM 55-1925-273-24&P-2
0092
SAFETY RELIEF VALVE DISASSEMBLY
WARNING
Do not allow hydraulic fluid, engine oil, or cleaning solvents to come in contact with unprotected skin or eyes. Prolonged skin contact can cause illness or injury. Eye contact can cause serious injury. Always wear chemical protective gloves and goggles when handling hydraulic fluid, engine oil, and cleaning solvents. Failure to follow these precautions can result in illness, serious injury, or death. 1. 2. 3. 4. 5. 6. Perform the CONTROL VALVE DISASSEMBLY procedure in this work package. Remove and discard O-rings (Figure 3, Items 9, 10, and 11). Remove the cap nut (Figure 3, Item 1) and the packing with retainer (Figure 3, Item 2). Discard packing with retainer. Remove the jamnut (Figure 3, Item 3) and set aside. Remove and discard packing with retainer (Figure 3, Item 4). Remove the plug (Figure 3, Item 5), spring (Figure 3, Item 6), and ball (Figure 3, Item 7) from the safety relief valve (Figure 3, Item 8) and set aside. Perform Steps (3) through (5) for the remaining side.
END OF TASK SAFETY RELIEF VALVE INSPECT 1. 2. 3. Inspect all sealing surfaces for damage. Minor damage may be repaired using an abrasive cloth. Major damage requires replacement of the component. Inspect all springs for breakage or distortion. Replace the entire valve section if broken or distorted springs are discovered. Inspect all balls for corrosion, pitting, or other obvious damage. Replace the entire valve assembly if corrosion, pitting, or other obvious damage is discovered.
END OF TASK SAFETY RELIEF VALVE ASSEMBLY 1. 2. 3. 4. Seat the ball (Figure 3, Item 7) and spring (Figure 3, Item 6) in the safety relief valve (Figure 3, Item 8). Install the plug (Figure 3, Item 5) in the safety relief valve (Figure 3, Item 8). Install packing with retainer (Figure 3, Item 4) and install the jamnut (Figure 3, Item 3). Install packing with retainer (Figure 3, Item 2) and install the cap nut (Figure 3, Item 1).
0092-6
TM 55-1925-273-24&P-2 SAFETY RELIEF VALVE ASSEMBLY - Continued
0092
WARNING
Do not allow hydraulic fluid, engine oil, or cleaning solvents to come in contact with unprotected skin or eyes. Prolonged skin contact can cause illness or injury. Eye contact can cause serious injury. Always wear chemical protective gloves and goggles when handling hydraulic fluid, engine oil, and cleaning solvents. Failure to follow these precautions can result in illness, serious injury, or death. 5. 6. Lubricate the O-rings (Figure 3, Items 9, 10, and 11) with hydraulic fluid and install them in the safety relief valve (Figure 3, Item 8). Perform the CONTROL VALVE ASSEMBLY procedure in this work package.
2 3 4 5 6
11
TANK 1
7 8
CLOSE OPEN
10
Figure 3. END OF TASK Dual Relief Valve.
M1198T73
0092-7
TM 55-1925-273-24&P-2
0092
CHECK VALVE DISASSEMBLY
WARNING
Do not allow hydraulic fluid, engine oil, or cleaning solvents to come in contact with unprotected skin or eyes. Prolonged skin contact can cause illness or injury. Eye contact can cause serious injury. Always wear chemical protective gloves and goggles when handling hydraulic fluid, engine oil, and cleaning solvents. Failure to follow these precautions can result in illness, serious injury, or death. 1. 2. 3. 4. 5. Perform the CONTROL VALVE DISASSEMBLY procedure in this work package. Remove and discard O-rings (Figure 4, Items 1, 6, and 7). Remove the plug (Figure 4, Item 3), spring (Figure 4, Item 2), and ball (Figure 4, Item 5) from the check valve (Figure 4, Item 8) and set aside. Remove and discard O-ring (Figure 4, Item 4) from the check valve (Figure 4, Item 8). Perform Steps (3) and (4) for the remaining assemblies.
END OF TASK CHECK VALVE INSPECT 1. 2. 3. Inspect all sealing surfaces for damage. Minor damage may be repaired using an abrasive cloth. Major damage requires replacement of the component. Inspect all springs for breakage or distortion. Replace the entire valve section if broken or distorted springs are discovered. Inspect all balls for corrosion, pitting, or other obvious damage. Replace the entire valve assembly if corrosion, pitting, or other obvious damage is discovered.
END OF TASK CHECK VALVE ASSEMBLY 1. Seat the ball (Figure 4, Item 5) and spring (Figure 4, Item 2) in the check valve (Figure 4, Item 8).
WARNING
Do not allow hydraulic fluid, engine oil, or cleaning solvents to come in contact with unprotected skin or eyes. Prolonged skin contact can cause illness or injury. Eye contact can cause serious injury. Always wear chemical protective gloves and goggles when handling hydraulic fluid, engine oil, and cleaning solvents. Failure to follow these precautions can result in illness, serious injury, or death. 2. 3. Lubricate an O-ring (Figure 4, Item 4) with hydraulic fluid and install it in the check valve (Figure 4, Item 8). Install the plug (Figure 4, Item 3) in the check valve (Figure 4, Item 8).
0092-8
TM 55-1925-273-24&P-2 CHECK VALVE ASSEMBLY - Continued 4. 5. 6. Perform Steps (1) through (3) for the remaining assemblies.
0092
Lubricate the O-rings (Figure 4, Items 1, 6, and 7) with hydraulic fluid and install them on the check valve (Figure 4, Item 8). Perform the CONTROL VALVE ASSEMBLY procedure in this work package.
1
2 3 4
TANK
OPEN CLOSE
M1199T73
Quad Check Valve.
0092-9
TM 55-1925-273-24&P-2
0092
SHUTTLE VALVE DISASSEMBLY
WARNING
Do not allow hydraulic fluid, engine oil, or cleaning solvents to come in contact with unprotected skin or eyes. Prolonged skin contact can cause illness or injury. Eye contact can cause serious injury. Always wear chemical protective gloves and goggles when handling hydraulic fluid, engine oil, and cleaning solvents. Failure to follow these precautions can result in illness, serious injury, or death. 1. 2. 3. 4. 5. 6. 7. 8. 9. Perform the CONTROL VALVE DISASSEMBLY procedure in this work package. Remove and discard O-rings (Figure 5, Items 8, 9, and 15). Remove the cap nut (Figure 5, Item 2) and O-ring (Figure 5, Item 3). Discard O-ring. Remove the jamnut (Figure 5, Item 4) and set aside. Remove and discard O-ring (Figure 5, Item 3). Remove O-ring (Figure 5, Item 1) from the needle valve (Figure 5, Item 5). Remove the plug (Figure 5, Item 6) from the shuttle valve (Figure 5, Item 14) and set aside. Remove O-ring (Figure 5, Item 7). Remove the plug (Figure 5, Item 13), spring (Figure 5, Item 11), and ball (Figure 5, Item 10) from the shuttle valve (Figure 5, Item 14). Remove O-ring (Figure 5, Item 12). Perform Steps (6) and (7) for the remaining assemblies.
END OF TASK SHUTTLE VALVE INSPECT 1. 2. 3. Inspect all sealing surfaces for damage. Minor damage may be repaired using an abrasive cloth. Major damage requires replacement of the component. Inspect all springs for breakage or distortion. Replace the entire valve section if broken or distorted springs are discovered. Inspect all balls for corrosion, pitting, or other obvious damage. Replace entire valve assembly if corrosion, pitting, or other obvious damage is discovered.
END OF TASK SHUTTLE VALVE ASSEMBLY 1. Seat the ball (Figure 5, Item 10) and spring (Figure 5, Item 11) in the shuttle valve (Figure 5, Item 14).
0092-10
TM 55-1925-273-24&P-2 SHUTTLE VALVE ASSEMBLY - Continued
0092
WARNING
Do not allow hydraulic fluid, engine oil, or cleaning solvents to come in contact with unprotected skin or eyes. Prolonged skin contact can cause illness or injury. Eye contact can cause serious injury. Always wear chemical protective gloves and goggles when handling hydraulic fluid, engine oil, and cleaning solvents. Failure to follow these precautions can result in illness, serious injury, or death. 2. 3. 4. 5. 6. 7. 8. 9. 10. Lubricate the O-ring (Figure 5, Item 12) with hydraulic fluid and install it on the plug (Figure 5, Item 13). Install the plug (Figure 5, Item 13) in the shuttle valve (Figure 5, Item 14). Lubricate the O-ring (Figure 5, Item 7) with hydraulic fluid and install it on the plug (Figure 5, Item 6). Install the plug (Figure 5, Item 6) in the shuttle valve (Figure 5, Item 14). Lubricate the O-ring (Figure 5, Item 1) with hydraulic fluid and install it on the needle valve (Figure 5, Item 5). Install an O-ring (Figure 5, Item 3) and the jamnut (Figure 5, Item 4) on the shuttle valve (Figure 5, Item 14). Install an O-ring (Figure 5, Item 3) and the cap nut (Figure 5, Item 2) on the shuttle valve (Figure 5, Item 14). Lubricate the O-rings (Figure 5, Items 8, 9, and 15) with hydraulic fluid and install them on the shuttle valve (Figure 5, Item 14). Perform the CONTROL VALVE ASSEMBLY procedure in this work package.
1 2 3 4 5 6 7
8
CLOSE OPEN
TANK
15
9 10 11
14
12 13
M1200T73
Shuttle Valve.
0092-11
TM 55-1925-273-24&P-2 FOLLOW-ON MAINTENANCE Install control valve assembly (WP 0091). END OF TASK END OF WORK PACKAGE
0092
0092-12
TM 55-1925-273-24&P-2 FIELD MAINTENANCE HAND PUMPS LOCAL/REMOTE REPLACE
0093
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 3, WP 0344, Table 1, Item 27) Gloves, Chemical and Oil Protective (Volume 3, WP 0344, Table 1, Item 8) Goggles, Industrial (Volume 3, WP 0344, Table 1, Item 10) Suitable Drain Pan Materials/Parts Hydraulic Fluid, Fire Resistant (Volume 3, WP 0343, Table 1, Item 88) Personnel Required Watercraft Engineer 88L (2) References FM 4-01.502 References (cont.) TM 55-1925-273-10 Volume 3, WP 0254 Volume 3, WP 0343 Volume 3, WP 0344 Equipment Condition Applicable hydraulic door secured and local and remote hand pumps locked out and tagged out IAW FM 4-01.502.
0093-1
TM 55-1925-273-24&P-2
0093
WARNING
Never reuse locking hardware. Reuse of locking hardware such as lockwashers, locking nuts, cotter pins, and lock wire can result in undetected loosening of fastening hardware causing catastrophic component failure resulting in death, injury, or damage to equipment. Ensure that all locking hardware is discarded upon removal and replaced with new. REMOVAL 1. 2. Place the suitable drain pan beneath the work area. CLOSE the remote valves (Figure 1, Items 1 and 4).
WARNING
Do not allow hydraulic fluid, engine oil, or cleaning solvents to come in contact with unprotected skin or eyes. Prolonged skin contact can cause illness or injury. Eye contact can cause serious injury. Always wear chemical protective gloves and goggles when handling hydraulic fluid, engine oil, and cleaning solvents. Failure to follow these precautions can result in illness, serious injury, or death. Hydraulic hoses and lines may be under pressure. Relieve pressure by operating the appropriate control valve, if possible. Loosen fittings on hoses and lines slowly. Allow oil to run around threads of fitting, releasing pressure before disconnecting fitting. Releasing pressurized oil suddenly may cause serious injury or death.
CAUTION
Always use two wrenches when loosening hydraulic lines. Failure to use two wrenches can result in damage to the hydraulic lines or fittings. Always use the two wrench method. 3. Label and remove the hydraulic lines (Figure 1, Item 2) from the pump (Figure 1, Item 3).
0093-2
0093
1 2
M1201T73
Figure 1. 4. 5.
Hydraulic Watertight Door System.
Remove the two taper pins (Figure 2, Item 4) from the hand crank (Figure 2, Item 5). Remove the hand crank. For the local pump, remove both hand cranks. Remove the six bolts (Figure 2, Item 1) and lockwashers (Figure 2, Item 2) from the pump (Figure 2, Item 3).
END OF TASK
0093-3
TM 55-1925-273-24&P-2
0093
INSTALLATION 1. 2. Install the pump (Figure 2, Item 3) and secure it with six lockwashers (Figure 2, Item 2) and six bolts (Figure 2, Item 1). Install the hand crank (Figure 2, Item 5) and secure it with the two taper pins (Figure 2, Item 4). For the local pump, install both hand cranks.
5 4
M1202T73
Figure 2.
Hand Pump.
CAUTION
Always use two wrenches when loosening hydraulic lines. Failure to use two wrenches can result in damage to the hydraulic lines or fittings. Always use the two wrench method. 3. Install the hydraulic lines (Figure 1, Item 2) on the pump (Figure 1, Item 3) using the labels from Step (4) of REMOVAL as a guide. Remove the labels.
END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. 4. Remove the lock outs and tag outs IAW FM 4-01.502. OPEN the remote valves. Using the hand pump, operate the door through three to four complete OPEN/CLOSE cycles IAW TM 55-1925-273-10 to ensure that all air is removed from the system. Return the equipment to the desired readiness condition.
0093-4
TM 55-1925-273-24&P-2 FIELD MAINTENANCE HAND PUMPS LOCAL/REMOTE REPAIR
0094
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 3, WP 0344, Table 1, Item 27) Gloves, Chemical and Oil Protective (Volume 3, WP 0344, Table 1, Item 8) Goggles, Industrial (Volume 3, WP 0344, Table 1, Item 10) Materials/Parts Cleaning Compound, Solvent (Volume 3, WP 0343, Table 1, Item 37) Rag, Wiping (Volume 3, WP 0343, Table 1, Item 132) Gasket (Snap Ring) (Volume 3, WP 0254, Figure 6, Item 2) Qty: 2 Retainer, Packing (Preformed Packing) (Volume 3, WP 0254, Figure 6, Item 3) Qty: 1 Gasket (Snap Ring) (Volume 3, WP 0254, Figure 6, Item 6) Qty: 2 Materials/Parts (cont.) Retainer, Packing (Preformed Packing) (Volume 3, WP 0254, Figure 6, Item 7) Qty: 1 Seal, Plain, Encased (End Cap Gasket) (Volume 3, WP 0254, Figure 6, Item 5) Qty: 1 Personnel Required Watercraft Engineer 88L (1) References WP 0093 Volume 3, WP 0254 Volume 3, WP 0343 Volume 3, WP 0344 Equipment Condition Hand pump removed. (WP 0093)
0094-1
TM 55-1925-273-24&P-2
0094
WARNING
Never reuse locking hardware. Reuse of locking hardware such as lockwashers, locking nuts, cotter pins, and lock wire can result in undetected loosening of fastening hardware causing catastrophic component failure resulting in death, injury, or damage to equipment. Ensure that all locking hardware is discarded upon removal and replaced with new. LOCAL PUMP DISASSEMBLY
WARNING
Do not allow hydraulic fluid, engine oil, or cleaning solvents to come in contact with unprotected skin or eyes. Prolonged skin contact can cause illness or injury. Eye contact can cause serious injury. Always wear chemical protective gloves and goggles when handling hydraulic fluid, engine oil, and cleaning solvents. Failure to follow these precautions can result in illness, serious injury, or death. 1. 2. 3. 4. 5. 6. 7. 8. Remove the screws (Figure 1, Item 1) holding the end cap (Figure 1, Item 2) to the pump. Remove the plain encased seal (Figure 1, Item 3) from the end cap (Figure 1, Item 2) and the collar (Figure 1, Item 12). Remove the rear shaft seal (Figure 1, Item 14), collar-retaining pin (Figure 1, Item 13), and the collar (Figure 1, Item 12). Remove the screws (Figure 1, Item 10) that hold the pump head to the body. Remove the snap ring (Figure 1, Item 11) and the rear bearing (Figure 1, Item 4). Discard snap ring and rear bearing. Remove and discard preformed packing (Figure 1, Item 8). Remove the snap ring (Figure 1, Item 7) and the front bearing (Figure 1, Item 9). Discard snap ring and front bearing. Remove the end cap gasket (Figure 1, Item 6) and rotor (Figure 1, Item 5). Discard end cap gasket.
END OF TASK CLEAN AND INSPECT
WARNING
Cleaning solvent is flammable and its vapor is potentially explosive. Do not use cleaning solvent in the vicinity of spark, open flame, or excessive heat. Do not use cleaning solvent in unventilated spaces. Always wear chemical protective gloves and goggles when handling hydraulic fluid, engine oil, and cleaning solvents. Failure to comply with this warning can result in serious injury or death. 1. Clean all metal parts with cleaning solvent and dry with clean wiping rags.
0094-2
TM 55-1925-273-24&P-2 CLEAN AND INSPECT - Continued 2.
0094
Inspect the bearings for corrosion, pitting, deep scratches, or other damage that would harm the seals and packing. If damage is found, the entire pump assembly must be replaced.
END OF TASK LOCAL PUMP ASSEMBLY 1. 2. 3. 4. 5. 6. 7. Install the rotor (Figure 1, Item 5) and an end cap gasket (Figure 1, Item 6). Install the front bearing (Figure 1, Item 9) and a snap ring (Figure 1, Item 7). Install preformed packing (Figure 1, Item 8). Install the rear bearing (Figure 1, Item 4) and a snap ring (Figure 1, Item 11). Assemble the pump head to the pump body and secure it with the screws (Figure 1, Item 10). Install the collar (Figure 1, Item 12), collar-retaining pin (Figure 1, Item 13), and rear shaft seal (Figure 1, Item 14). Install a plain encased seal (Figure 1, Item 3) and the end cap (Figure 1, Item 2). Secure the pump with the screws (Figure 1, Item 1).
14
13
12 11
Figure 1.
10
Local Hand Pump.
M1203T73
END OF TASK
0094-3
TM 55-1925-273-24&P-2
0094
REMOTE PUMP DISASSEMBLY
WARNING
Do not allow hydraulic fluid, engine oil, or cleaning solvents to come in contact with unprotected skin or eyes. Prolonged skin contact can cause illness or injury. Eye contact can cause serious injury. Always wear chemical protective gloves and goggles when handling hydraulic fluid, engine oil, and cleaning solvents. Failure to follow these precautions can result in illness, serious injury, or death. 1. 2. 3. 4. 5. 6. 7. Remove the screws (Figure 2, Item 12) that hold the end cap (Figure 2, Item 1) to the pump. Remove and discard end cap gasket (Figure 2, Item 2). Remove the collar-retaining pin (Figure 2, Item 11) and the collar (Figure 2, Item 10). Remove the screws (Figure 2, Item 9) that hold the pump head to the body. Remove and discard preformed packing (Figure 2, Item 7) from the shaft end of the pump. Remove the snap ring (Figure 2, Item 8) and the front shaft bearing (Figure 2, Item 6). Discard snap ring. Remove and discard preformed packing (Figure 2, Item 5), the rear bearing (Figure 2, Item 3), and rotor (Figure 2, Item 4).
2 3
12
11
10
9
Figure 2. Remote Hand Pump.
M1204T73
END OF TASK
0094-4
0094
WARNING
Cleaning solvent is flammable and its vapor is potentially explosive. Do not use cleaning solvent in the vicinity of spark, open flame, or excessive heat. Do not use cleaning solvent in unventilated spaces. Always wear chemical protective gloves and goggles when handling hydraulic fluid, engine oil, and cleaning solvents. Failure to comply with this warning can result in serious injury or death. 1. 2. Clean all metal parts with cleaning solvent and dry with clean wiping rags. Inspect the bearings for corrosion, pitting, deep scratches, or other damage that would harm the seals and packing. If damage is found, the entire pump assembly must be replaced.
END OF TASK REMOTE PUMP ASSEMBLY 1. 2. 3. 4. 5. 6. Install the rotor (Figure 2, Item 4), rear bearing (Figure 2, Item 3), and preformed packing (Figure 2, Item 5). Install the front shaft bearing (Figure 2, Item 6) and a snap ring (Figure 2, Item 8). Install a preformed packing (Figure 2, Item 7). Assemble the pump head to the body and secure with screws (Figure 2, Item 9). Install the collar (Figure 2, Item 10) and secure it with a collar-retaining pin (Figure 2, Item 11). Install the end cap gasket (Figure 2, Item 2) and end cap (Figure 2, Item 1). Secure the pump with screws (Figure 2, Item 12).
END OF TASK FOLLOW-ON MAINTENANCE Install hand pump (WP 0093). END OF TASK END OF WORK PACKAGE
0094-5/6 blank
TM 55-1925-273-24&P-2 FIELD MAINTENANCE WATERTIGHT DOORS REPAIR
0095
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 3, WP 0344, Table 1, Item 27) Faceshield, Industrial (Volume 3, WP 0344, Table 1, Item 5) Gloves, Leather (Volume 3, WP 0344, Table 1, Item 9) Tool Kit, Carpenter's (Volume 3, WP 0344, Table 1, Item 25) Tool Kit, Welder's (Volume 3, WP 0344, Table 1, Item 29) Torch Outfit, Welding (Volume 3, WP 0344, Table 1, Item 30) Materials/Parts Cement, Rubber (Volume 3, WP 0343, Table 1, Item 31) Grease, Ball and Roller Bearing; 1.75 lb (Volume 3, WP 0343, Table 1, Item 74) Setscrew (Packing Plunger) (Volume 3, WP 0255, Figure 7, Item 7) Qty: 1 Bushing, Sleeve (Volume 3, WP 0255, Figure 7, Item 10) Qty: 1 Gasket (Volume 3, WP 0337, Figure BULK, Item 5) Qty: 1 Personnel Required Watercraft Engineer 88L (One of these must be trained in confined space entry if void entry is required) (2) Personnel Required (cont.) Fire watch as required IAW FM 4-01.502 (if welding will be performed) (1) Entry Supervisor Attendant (if void entry is required) (1) References FM 4-01.502 TB 43-0144 TB 55-1900-204-24 Volume 3, WP 0255 Volume 3, WP 0337 Volume 3, WP 0343 Volume 3, WP 0344 Equipment Condition Vessel certified safe for HOT WORK IAW FM 4-01.502 (if welding will be performed). Voids must be prepared for confined space entry (if void entry is required) with Confined Space Entry Permit secured IAW FM 4-01.502.
0095-1
TM 55-1925-273-24&P-2
0095
WARNING
Entry into an uninspected/unprepared confined space may result in serious injury or death to personnel. Only properly trained personnel may enter confined spaces, or act as entry supervisors and/or attendants for those working in confined spaces. Before entering into a confined space, the space must be cleared for entry and a Confined Space Entry Permit must be secured. All entry into confined spaces must be in accordance with FM 4-01.502. Failure to comply with this warning can result in serious injury or death to personnel. DISASSEMBLY 1. 2. 3. 4. 5. 6. 7. 8. Remove the jamnut (Figure 1, Item 7) from the handle (Figure 1, Item 5). Remove the pin (Figure 1, Item 4) from the dog (Figure 1, Item 1) and the flanged bushing (Figure 1, Item 8). Remove the handle (Figure 1, Item 5) from the dog (Figure 1, Item 1). Remove the dog (Figure 1, Item 1) from the watertight door sleeve (Figure 1, Item 2). Remove the packing plunger (Figure 1, Item 6) from the watertight door sleeve (Figure 1, Item 2). Discard packing plunger. Remove the sleeve bushing (Figure 1, Item 9) from the watertight door sleeve (Figure 1, Item 2). Discard sleeve bushing. Remove the flanged bushing (Figure 1, Item 8) from the watertight door sleeve (Figure 1, Item 2). Remove the helical compression spring (Figure 1, Item 3) from the watertight door sleeve (Figure 1, Item 2).
0095-2
0095
9 2
3 8 4 5
7 6
M1205T73
Watertight Door.
0095-3
TM 55-1925-273-24&P-2 GASKET SEALING AREA REPAIR
0095
WARNING
Wire brushing operations can produce high velocity flying debris which can become lodged in the skin or in the eyes. Wire brushing in confined areas can result in debris flying from unexpected directions. All personnel working in the area must wear protective faceshield, gloves, and long sleeves when performing wire brushing operations. Failure to comply with this warning can result in serious injury or death to personnel. 1. 2. Use a scraper to remove the gasket (Figure 2, Item 1). Use a wire brush to clean the gasket channel thoroughly. All of the old gasket and adhesive must be removed and the channel cleaned to the bare metal.
M1206T73
Figure 2. Watertight Door (Typical).
0095-4
TM 55-1925-273-24&P-2 GASKET SEALING AREA REPAIR - Continued
0095
WARNING
Unprotected exposure to arc-welding rays can cause serious eye damage and radiation burns to the skin. Never perform arc-welding operations without using appropriate eye and skin protection.
CAUTION
Improper connection of ground leads can cause serious electrolytic and electronic damage to the vessel and its components. Always ensure that ground leads are connected as detailed in TB 55-1900-204-24. 3. If welding repairs are required, perform such repairs as detailed in the applicable design drawings and acceptable welding practices. All watercraft welding and repair must be accomplished as detailed in TB 55-1900-204-24. If a confined space must be entered in order to perform work or to post a fire watch, prepare the space for confined space entry and secure a Confined Space Entry Permit IAW FM 4-01.502. After the area has cooled, paint the affected area IAW TB 43-0144, taking care not to paint any threads.
4. 5.
END OF TASK GASKET REPLACE 1. On a flat surface, lay out clean, dry boards or other material to protect the deck. Roll out the gasket material.
NOTE
The gasket will shrink over time. If the gasket is cut too short, it will eventually leave a gap at the joint and destroy the watertight integrity of the door. Allow one extra inch for every 3 ft (91.4 cm) of channel. 2. Measure the gasket channel and cut the gasket.
NOTE
A 45 degree joint should be used at corners in closures with square corners. Elsewhere, square butt joints are preferable. Joints should not be located in the radius portions of closures. The number of gasket joints should be kept to a minimum (no more than four). Very short strips (less than 2 ft [61 cm]) should not be used. 3. 4. 5. Install the gasket (Figure 2, Item 1) in the door using rubber cement. Clean the knife-edge of the closure frame. Apply a chalk line completely around the knife-edge of the doorframe.
0095-5
TM 55-1925-273-24&P-2 GASKET REPLACE - Continued
0095
NOTE
When setting up dogs on watertight doors, the dog on the opposite side of the hinges should be set up first with sufficient pressure to hold the door. Two dogs should then be set up snugly on the hinge side. All the dogs then should be set up evenly to ensure a good bearing all around. 6. 7. 8. 9. Close and dog the door. Open the door and inspect the gasket. If the door is watertight, the gasket will show an unbroken chalk line. If the line is broken, notify the maintenance supervisor. Operate the door and check for smooth and positive dogging action.
END OF TASK ASSEMBLY 1. 2. 3. 4. 5. 6. 7. 8. Inspect the helical compression spring (Figure 1, Item 3) for cracks. Replace it if it is cracked. Apply a light coat of grease to the helical compression spring and install it in the watertight door sleeve (Figure 1, Item 2). Lubricate the flanged bushing (Figure 1, Item 8) with a light coat of grease and install it in the watertight door sleeve (Figure 1, Item 2). Lubricate a sleeve bushing (Figure 1, Item 9) with a light coat of grease and install it in the watertight door sleeve (Figure 1, Item 2). Install the packing plunger (Figure 1, Item 6) in the watertight door sleeve (Figure 1, Item 2). Install the dog (Figure 1, Item 1) in the watertight door sleeve (Figure 1, Item 2). Install the pin (Figure 1, Item 4) in the dog (Figure 1, Item 1) and the flanged bushing (Figure 1, Item 8). Install the handle (Figure 1, Item 5) on the dog (Figure 1, Item 1). Install the jamnut (Figure 1, Item 7) on the handle (Figure 1, Item 5).
END OF TASK FOLLOW-ON MAINTENANCE Remove the lock outs and tags outs IAW FM 4-01.502. END OF TASK END OF WORK PACKAGE
0095-6
TM 55-1925-273-24&P-2 FIELD MAINTENANCE WATERTIGHT HATCHES REPAIR
0096
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 3, WP 0344, Table 1, Item 27) Apron, Utility (Volume 3, WP 0344, Table 1, Item 1) Faceshield, Industrial (Volume 3, WP 0344, Table 1, Item 5) Lubricating Gun, Hand (Volume 3, WP 0344, Table 1, Item 14) Tool Kit, Carpenter's (Volume 3, WP 0344, Table 1, Item 25) Tool Kit, Welder's (Volume 3, WP 0344, Table 1, Item 29) Torch Outfit, Welding (Volume 3, WP 0344, Table 1, Item 30) Materials/Parts Cement, Rubber (Volume 3, WP 0343, Table 1, Item 31) Grease, Ball and Roller Bearing; 1.75 lb (Volume 3, WP 0343, Table 1, Item 74) Gasket (Volume 3, WP 0337, Figure BULK, Item 5) Qty: 1 Personnel Required Watercraft Engineer 88L (One of these must be trained in confined space entry if void entry is required) (2) Entry Supervisor/Attendant (if void entry is required) (1) References FM 4-01.502 TB 43-0144 TB 55-1900-204-24 Volume 3, WP 0337 Volume 3, WP 0343 Volume 3, WP 0344 Equipment Condition Vessel certified safe for HOTWORK IAW FM 4-01.502 (if welding will be performed). Voids must be prepared for confined space entry with Confined Space Entry Permit secured IAW FM 4-01.502 (if void entry is required).
0096-1
TM 55-1925-273-24&P-2
0096
WARNING
Entry into an uninspected/unprepared confined space may result in serious injury or death to personnel. Only properly trained personnel may enter confined spaces, or act as entry supervisors and/or attendants for those working in confined spaces. Before entering into a confined space, the space must be cleared for entry and a Confined Space Entry Permit must be secured. All entry into confined spaces must be in accordance with FM 4-01.502. Failure to comply with this warning can result in serious injury or death to personnel. REMOVAL 1. 2. 3. Remove the jamnut (Figure 1, Item 1) and dog/handle set (Figure 1, Item 2). Inspect the sleeve (Figure 1, Item 4) and bushings (Figure 1, Item 5) for wear or damage. Remove the sleeve (Figure 1, Item 4) and bushing (Figure 1, Item 5) if any damage or wear are noted.
2
M1207T73
Watertight Hatch.
0096-2
TM 55-1925-273-24&P-2
0096
HATCH SEALING AREA REPAIR 1. Minor repairs to the gasket sealing edge (Figure 2, Item 2) may be made by welding.
WARNING
Grinding or cutting operations produce hot, flying particles. These particles can cause serious injury to personnel or ignite fires in the work area. Wear protective faceshield, gloves, and/or aprons at all times during cutting and grinding operations. A fire watch must be posted whenever cutting or grinding operations are taking place. Failure to comply with this warning can result in serious injury or death to personnel. 2. Use a grinder to clean the work area to the bare metal.
WARNING
CAUTION
Improper connection of ground leads can cause serious electrolytic and electronic damage to the vessel and its components. Always ensure that ground leads are connected IAW TB 55-1900-204-24. 3. Use the welder to build up the damaged area to a level higher than the desired contour.
WARNING
Grinding or cutting operations produce hot, flying particles. These particles can cause serious injury to personnel or ignite fires in the work area. Wear protective faceshield, gloves, and/or aprons at all times during cutting and grinding operations. A fire watch must be posted whenever cutting or grinding operations are taking place. Failure to comply with this warning can result in serious injury or death to personnel. 4. 5. Use a grinder to return the gasket sealing edge (Figure 2, Item 2) to the proper contour. After the work area is cooled, test the seal of the gasket as detailed in the GASKET REPLACE procedure in this work package.
END OF TASK
0096-3
TM 55-1925-273-24&P-2
0096
GASKET REPLACE 1. On a flat surface, lay out clean, dry boards or other material to protect the deck. Roll out the gasket material.
NOTE
The gasket will shrink over time. If the gasket is cut too short, it will eventually leave a gap at the joint and destroy the watertight integrity of the door. Allow one extra inch for every 3 ft (91.4 cm) of channel. 2. Measure the gasket channel and cut the gasket.
NOTE
A 45 degree joint should be used at corners in closures with square corners. Elsewhere, square butt joints are preferable. Joints should not be located in the radius portions of closures. The number of gasket joints should be kept to a minimum (no more than 4). Very short strips (less that 2 ft [61 cm]) should not be used. 3. Install the gasket (Figure 2, Item 1) on the door using rubber cement.
2
M1208T73
Figure 2. 4. 5. Clean the knife edge of the closure frame.
Watertight Hatch.
Apply a chalk line completely around the knife edge of the doorframe.
NOTE
When setting up dogs on watertight doors, the dog on the opposite side of the hinges should be set up first with sufficient pressure to hold the door. Two dogs should then be set up snugly on the hinge side. All the dogs then should be set up evenly to ensure a good bearing all around. 6. 7. 8. 9. 10. Close and dog the door. Open the door and inspect the gasket. If the door is watertight, the gasket will show an unbroken chalk line. If the line is broken, notify the maintenance supervisor. Operate the door and check for smooth and positive dogging action. Touch up any damaged paint IAW TB 43-0144.
END OF TASK
0096-4
TM 55-1925-273-24&P-2 INSTALLATION 1. 2. 3. 4.
0096
If the sleeve (Figure 1, Item 4) and bushing (Figure 1, Item 5) are being replaced, install a sleeve and bushing in the watertight hatch. Install the dog/handle set (Figure 1, Item 2) in the watertight hatch and secure them with the jamnut (Figure 1, Item 1). Using a lubrication gun, lubricate the sleeve (Figure 1, Item 4) with grease at the grease fitting (Figure 1, Item 3). Operate the hatch and check for smooth and positive dogging action. If the dogging action is not smooth, repeat the procedure ensuring that the sleeve (Figure 1, Item 4) is receiving grease. If rough operation continues, notify the maintenance supervisor.
0096-5/6 blank
TM 55-1925-273-24&P-2 FIELD MAINTENANCE WATERTIGHT SCUTTLES REPAIR
0097
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 3, WP 0344, Table 1, Item 27) Faceshield, Industrial (Volume 3, WP 0344, Table 1, Item 5) Gloves, Leather (Volume 3, WP 0344, Table 1, Item 9) Tool Kit, Carpenter's (Volume 3, WP 0344, Table 1, Item 25) Tool Kit, Welder's (Volume 3, WP 0344, Table 1, Item 29) Torch Outfit, Welding (Volume 3, WP 0344, Table 1, Item 30) Materials/Parts Cement, Rubber (Volume 3, WP 0343, Table 1, Item 31) Gasket (Volume 3, WP 0337, Figure BULK, Item 5) Qty: 1 Personnel Required Watercraft Engineer 88L (2) References FM 4-01.502 TB 43-0144 TB 55-1900-204-24 Volume 3, WP 0257 Volume 3, WP 0337 Volume 3, WP 0343 Volume 3, WP 0344 Equipment Condition Vessel certified safe for HOT WORK IAW FM 4-01.502.
0097-1
TM 55-1925-273-24&P-2
0097
WARNING
Never reuse locking hardware. Reuse of locking hardware such as lockwashers, locking nuts, cotter pins, and lock wire can result in undetected loosening of fastening hardware causing catastrophic component failure resulting in death, injury, or damage to equipment. Ensure that all locking hardware is discarded upon removal and replaced with new. DISASSEMBLY 1. 2. 3. 4. 5. 6. Remove the two self-locking nuts (Figure 1, Item 6) and handwheel (Figure 1, Item 5) from the scuttle (Figure 1, Item 1). Remove all six cotter pins (Figure 1, Item 4) from the cylindrical pins (Figure 1, Item 2), then remove the cylindrical pins. Loosen the setscrews (Figure 1, Item 8) and remove the dog arms (Figure 1, Item 12) and guides (Figure 1, Item 9) from the scuttle. Remove the hex steel adjusters (Figure 1, Item 10) and springs (Figure 1, Item 11). Remove the grease fittings (Figure 1, Item 13). Remove the spider (Figure 1, Item 7) and shim (Figure 1, Item 3) from the scuttle.
0097-2
0097
13
12 11 10 9 8
7
Figure 1.
6
Watertight Scuttle.
M1210T73
0097-3
TM 55-1925-273-24&P-2 DISASSEMBLY - Continued 7. 8. 9. Remove the dog stud (Figure 2, Item 2). Remove the delrin bushings (Figure 2, Item 1) and preformed packing (Figure 2, Item 4). Use a scraper to remove the gasket (Figure 2, Item 6).
0097
WARNING
Removing components by means of wire brushing produces flying particles. These particles can cause serious injury to personnel. Wear protective faceshield, gloves, and long sleeves at all times during wire brushing operations. Failure to comply with this warning can result in serious injury to personnel. 10. Use a wire brush to clean the basket channel thoroughly. All of the old gasket and adhesive must be removed and the channel cleaned to the bare metal.
END OF TASK INSPECT 1. 2. 3. Inspect the gasket sealing edge (Figure 1, Item 5) for damage or deformity. Repair minor deformities as described in the REPAIR paragraph. Refer major deformities to the maintenance supervisor. Inspect the bushing (Figure 2, Item 1) and seals (Figure 2, Item 3) for wear or damage. Replace any worn or damaged components. Inspect the dog stud for wear or damage, taking special care to inspect the bushing and seal surfaces of the stud. Replace the stud if wear or damage is noted.
5 6
Figure 2. END OF TASK REPAIR 1. Minor repairs to the gasket sealing edge (Figure 2, Item 5) may be made by welding. Watertight Scuttle.
5
M1209T73
0097-4
TM 55-1925-273-24&P-2 REPAIR - Continued
0097
WARNING
Removing components by means of grinding or cutting produces hot, flying particles. These particles can cause serious injury to personnel. These hot particles can also ignite fires in the work area and in adjacent spaces. During and after removal, the work area will be very hot. Wear protective faceshield, gloves, and/or aprons at all times during cutting and grinding operations. A fire watch must be posted whenever cutting or grinding operations are taking place. Failure to comply can result in serious injury or death to personnel and serious damage to the vessel. 2. Use a grinder to clean the work area to the bare metal.
WARNING
CAUTION
Improper connection of ground leads can cause serious electrolytic and electronic damage to the vessel and its components. Always ensure that ground leads are connected as outlined in TB 55-1900-204-24. 3. Use the welder to build up the damaged area to a level higher than the desired contour.
WARNING
Removing components by means of grinding or cutting produces hot, flying particles. These particles can cause serious injury to personnel. These hot particles can also ignite fires in the work area and in adjacent spaces. During and after removal, the work area will be very hot. Wear protective faceshield, gloves, and/or aprons at all times during cutting and grinding operations. A fire watch must be posted whenever cutting or grinding operations are taking place. Failure to comply can result in serious injury or death to personnel and serious damage to the vessel. 4. 5. Use a grinder to return the gasket sealing edge to the proper contour. After the area has cooled, paint the affected area IAW TB 43-0144.
END OF TASK
0097-5
TM 55-1925-273-24&P-2 ASSEMBLY 1. Measure the required length around the scuttle for the gasket.
0097
NOTE
The gasket will shrink over time. If the gasket is cut too short, it will eventually leave a gap at the joint and destroy the watertight integrity of the scuttle. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. Add one additional inch and cut the gasket. Install the gasket (Figure 2, Item 6) on the scuttle using rubber cement. Ensure that it is seated well in the gasket channel. Install the shim (Figure 1, Item 3) and the spider (Figure 1, Item 7). Place the springs (Figure 1, Item 11) and hex steel adjusters (Figure 1, Item 10) in position. Install the grease fitting (Figure 1, Item 13). Install the guides (Figure 1, Item 9) with dog arms (Figure 1, Item 12) and tighten the setscrews (Figure 1, Item 8). Install the cylindrical pins(Figure 1, Item 2) in the dog arms. Secure the cylindrical pins using six cotter pins (Figure 1, Item 4). Install the handwheel (Figure 1, Item 5) and secure it with two self-locking nuts (Figure 1, Item 6). Operate the scuttle and check for smooth and positive dogging action. Clean the knife-edge of the closure frame. Apply a chalk line completely around the knife-edge of the scuttle. Close and dog the scuttle. Open the scuttle and examine the gasket. If the scuttle is watertight, the gasket will show an unbroken chalk line. If the line is broken, notify the maintenance supervisor. Operate the scuttle and check for smooth and positive dogging action. Touch up any damaged paint IAW TB 43-0144.
0097-6
TM 55-1925-273-24&P-2 FIELD MAINTENANCE WATERTIGHT MANHOLES REPAIR
0098
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 3, WP 0344, Table 1, Item 27) Faceshield, Industrial (Volume 3, WP 0344, Table 1, Item 5) Gloves, Chemical and Oil Protective (Volume 3, WP 0344, Table 1, Item 8) Gloves, Leather (Volume 3, WP 0344, Table 1, Item 9) Goggles, Industrial (Volume 3, WP 0344, Table 1, Item 10) Threading Set, Screw (Volume 3, WP 0344, Table 1, Item 24) Tool Kit, Carpenter's (Volume 3, WP 0344, Table 1, Item 25) Tool Kit, Welder's (Volume 3, WP 0344, Table 1, Item 29) Torch Outfit, Welding (Volume 3, WP 0344, Table 1, Item 30) Materials/Parts Gasket (Volume 3, WP 0337, Figure BULK, Item 3) Qty: 1 Personnel Required Watercraft Engineer 88L (One of these must be trained in confined space entry) (2) References FM 4-01.502 TB 43-0144 TB 55-1900-204-24 Volume 3, WP 0258 Volume 3, WP 0337 Volume 3, WP 0344 Equipment Condition Vessel certified safe for HOTWORK IAW FM 4-01.502 (if welding will be performed). Fire watch as required IAW FM 4-01.502. Voids must be prepared for confined space entry with confined space entry permit secured IAW FM 4-01.502.
0098-1
TM 55-1925-273-24&P-2
0098
WARNING
Entry into an uninspected/unprepared confined space may result in serious injury or death to personnel. Only properly trained personnel may enter confined spaces, or act as entry supervisors and/or attendants for those working in confined spaces. Before entering into a confined space, the space must be cleared for entry and a Confined Space Entry Permit must be secured. All entry into confined spaces must be in accordance with FM 4-01.502. Failure to comply with this warning can result in serious injury or death to personnel. MANHOLE (RAISED) REMOVAL 1. 2. 3. 4. Remove all nuts (Figure 1, Item 2) and washers (Figure 1, Item 3) from the studs (Figure 1, Item 4). Remove the manhole cover (Figure 1, Item 1) from the closure. Remove the gasket (Figure 1, Item 5) from the manhole cover. Thoroughly clean the gasket sealing area on the manhole cover and on the hull structure, using a scraper and/or wire brush.
END OF TASK MANHOLE (RAISED) INSPECT 1. Inspect the gasket sealing area for nicks, burrs, or deformities that would prevent the gasket from sealing properly.
WARNING
Removing components by means of grinding or cutting produces hot, flying particles. These particles can cause serious injury to personnel. These hot particles can also ignite fires in the work area and in adjacent spaces. During and after removal, the work area will be very hot. Wear protective faceshield, gloves, and/or aprons at all times during cutting and grinding operations. A fire watch must be posted whenever cutting or grinding operations are taking place. Failure to comply can result in serious injury or death to personnel and serious damage to the vessel. a. b. 2. Small defects may be corrected by grinding or filing. Larger defects may require welding repair. If this is the case, report the defect to the maintenance supervisor.
Inspect all studs for any thread damage and stability of mounting. Report any studs or threads that are damaged or insecurely mounted to the maintenance supervisor.
END OF TASK MANHOLE (RAISED) INSTALLATION 1. 2. 3. On a flat surface, lay out clean, dry boards or other material to protect the deck. Roll out the gasket material. Using the manhole as a template and a craftsman's knife, cut the gasket to match the manhole's dimensions.
0098-2
TM 55-1925-273-24&P-2 MANHOLE (RAISED) INSTALLATION - Continued 4. 5. 6. 7. Position the gasket (Figure 1, Item 5) over the studs (Figure 1, Item 4). Place the manhole cover (Figure 1, Item 1) on the closure. Secure the cover using washers (Figure 1, Item 3) and nuts (Figure 1, Item 2). After replacement is complete, touch up the paint on the affected areas IAW TB 43-0144.
1 2
0098
3 4
M1211T73
Manhole (Raised).
0098-3
TM 55-1925-273-24&P-2
0098
MANHOLE (FLUSH) REMOVAL 1. 2. 3. Remove the screws (Figure 2, Item 2) from the manhole cover (Figure 2, Item 1). Remove the manhole cover (Figure 2, Item 1) from the closure. Remove the gasket (Figure 2, Item 3) from the manhole cover.
END OF TASK MANHOLE (FLUSH) INSPECTION Inspect the flush manhole using the procedure detailed for the raised manhole. END OF TASK MANHOLE (FLUSH) INSTALLATION 1. 2. 3. 4. 5. 6. On a flat surface, lay out clean, dry boards or other material to protect the deck. Roll out the gasket material. Using the manhole as a template and a craftsman's knife, cut the gasket to match the manhole's dimensions. Install the gasket (Figure 2, Item 3) on the manhole cover (Figure 2, Item 1). Place the manhole cover (Figure 2, Item 1) on the closure. Install the screws (Figure 2, Item 2) on the manhole cover.
1 2 1
M1212T73
Manhole (Flush).
GASKET SEALING AREA REPAIR (RAISED MANHOLE) 1. Minor repairs to the gasket sealing edge (Figure 2, Item 3 and Figure 3, Item 1) may be made by welding.
0098-4
TM 55-1925-273-24&P-2 GASKET SEALING AREA REPAIR (RAISED MANHOLE) - Continued
0098
WARNING
Removing components by means of grinding or cutting produces hot, flying particles. These particles can cause serious injury to personnel. These hot particles can also ignite fires in the work area and in adjacent spaces. During and after removal, the work area will be very hot. Wear protective faceshield, gloves, and/or aprons at all times during cutting and grinding operations. A fire watch must be posted whenever cutting or grinding operations are taking place. Failure to comply can result in serious injury or death to personnel and serious damage to the vessel. 2. Use a grinder to clean the work area to the bare metal.
WARNING
CAUTION
Improper connection of ground leads can cause serious electrolytic and electronic damage to the vessel and its components. Always ensure that ground leads are connected as outlined IAW TB 55-1900-204-24. 3. 4. 5. 6. 7. Use the welder to build up the damaged area to a level higher than the desired contour. Use a grinder to return the gasket sealing edge (Figure 2, Item 3 and Figure 3, Item 1) to the proper contour. Repeat Steps (2) through (4) until a satisfactory sealing edge is obtained. When the repair is cool, touch up paint IAW TB 43-0144. When the paint is dry, return the equipment to the desired readiness condition.
1
M1213T73
Raised Manhole Cover (Typical).
0098-5
TM 55-1925-273-24&P-2
0098
STUD REPLACE (RAISED MANHOLE) 1. If welding repairs are required, perform such repairs as detailed in the applicable design drawings and acceptable welding practices. All watercraft welding and repair must be accomplished as outlined IAW TB 55-1900-204-24.
WARNING
Special precautions must be taken if cutting or welding operations will take place inside tanks or confined spaces. All confined space protocols and regulations must be strictly adhered to. Ventilation and/or respiratory protection must also be provided to control exposure to welding fumes. Failure to comply with this warning can result in serious injury or death to personnel. 2. If a confined space must be entered in order to perform work or to a post a fire watch, prepare the space for confined space entry and secure a Confined Space Entry Permit IAW FM 4-01.502.
WARNING
Removing components by means of grinding or cutting produces hot, flying particles. These particles can cause serious injury to personnel. These hot particles can also ignite fires in the work area and in adjacent spaces. During and after removal, the work area will be very hot. Wear protective faceshield, gloves, and/or aprons at all times during cutting and grinding operations. A fire watch must be posted whenever cutting or grinding operations are taking place. Failure to comply can result in serious injury or death to personnel and serious damage to the vessel. 3. 4. 5. 6. Using a cutting torch, remove the old stud (Figure 4, Item 1). Use a grinder to thoroughly clean the work area. Position the stud (Figure 4, Item 1) in place. Thread several nuts (Figure 4, Item 2) onto the stud (Figure 4, Item 1) to protect the threads.
WARNING
Unprotected exposure to arc-welding rays can cause serious eye damage and radiation burns to the skin. Never perform arc-welding operations without using appropriate eye and skin protection. 7. 8. 9. Weld the stud (Figure 4, Item 1) securely in place. After the area has cooled, apply paint IAW TB 43-0144, but do not paint the threads. When the paint is dry, return the equipment to the desired readiness condition.
END OF TASK
0098-6
TM 55-1925-273-24&P-2
0098
THREAD REPAIR (FLUSH MANHOLE) 1. If welding repairs are required, perform such repairs as detailed in the applicable design drawings and acceptable welding practices. All watercraft welding and repair must be accomplished as outlined in TB 55-1900-204-24. Select the correct size tap, and run the tap through the damaged threads. Install a bolt (Figure 4, Item 1) into the hole, and attempt to tighten it.
1
2. 3.
M1214T73
Figure 4. 4.
Flush Manhole (Typical).
If the fastener holds securely, remove the fastener and proceed to Step (6) of this procedure.
0098-7
TM 55-1925-273-24&P-2 THREAD REPAIR (FLUSH MANHOLE) - Continued 5. If the threads are stripped, complete the following:
0098
WARNING
Removing components by means of grinding or cutting produces hot, flying particles. These particles can cause serious injury to personnel. These hot particles can also ignite fires in the work area and in adjacent spaces. During and after removal, the work area will be very hot. Wear protective faceshield, gloves, and/or aprons at all times during cutting and grinding operations. A fire watch must be posted whenever cutting or grinding operations are taking place. Failure to comply can result in serious injury or death to personnel and serious damage to the vessel. a. Use a grinder, needle gun, and wire brush to clean the damaged area to the bare metal.
WARNING
CAUTION
Improper connection of ground leads can cause serious electrolytic and electronic damage to the vessel and its components. Always ensure that ground leads are connected IAW TB 55-1900-204-24. b. c. d. e. f. 6. 7. Use the arc welder to build up the damaged area to a level higher than the desired contour. Use a grinder to smooth the damaged area and return the surfaces to normal. Repeat Steps (a) through (c) until a satisfactory surface is obtained. Drill and tap the hole for the hatch fastener. Allow the repair area to cool.
Apply paint IAW TB 43-0144. When the paint is dry, return the equipment to the desired readiness condition.
0098-8
TM 55-1925-273-24&P-2 FIELD MAINTENANCE MAST SERVICE
0099
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 3, WP 0344, Table 1, Item 27) Faceshield, Industrial (Volume 3, WP 0344, Table 1, Item 5) Gloves, Leather (Volume 3, WP 0344, Table 1, Item 9) Tool Kit, Welder's (Volume 3, WP 0344, Table 1, Item 29) Materials/Parts N/A Personnel Required Watercraft Operator 88K (2) Fire Watch as Required for Grinding IAW FM 4-01.502 References FM 4-01.502 TB 55-1900-204-24 References (cont.) TM 55-5825-311-10 Volume 3, WP 0344 Equipment Condition Set to OFF the S BAND RADAR MOTOR circuit breaker, the X BAND RADAR MOTOR circuit breaker, and the RADAR DISTRIBUTION PANEL circuit breaker in the 120 V pilothouse emergency distribution panel (LT 803 Only), or the S BAND RADAR MOTOR, (R-RN-2001) circuit breaker, the X BAND RADAR MOTOR (R-RN-1001) circuit breaker, and the UPS FOR RADAR POWER DISTRIBUTION PANEL, (PILOTHOUSE) circuit breaker in the 120 V pilothouse emergency distribution panel (All Other Vessels). Lock out and tag out IAW FM 4.01-502. Set to OFF all communications equipment IAW TM 55-5825-311-10. Lock out and tag out IAW FM 4-01.502.
0099-1
TM 55-1925-273-24&P-2
0099
SERVICE
WARNING
Electromagnetic radiation from the radar and communications equipment has the potential for serious radiation burns. Lock out and tag out radar and communications equipment IAW FM 4-01.502. Failure to comply with this warning can result in serious injury or death to personnel. 1. Visually inspect the masts for any damage or deterioration (structure dented, rust, etc.). If minor damage or deterioration is noted, clean, prime and paint as described in Steps (4) and (5). If serious damage is discovered, notify the maintenance supervisor. Check that all antennas, lights, and other mounted hardware are solidly mounted to the mast's structures. If loose components are found, notify the maintenance supervisor. Check for any unusual signs of stress to the structure. Stress can be detected by looking for cracks, broken welds, dented or bulging piping, and unexpected gaps in welded joints. Report any signs of unusual stress to the maintenance supervisor.
2. 3.
WARNING
Removing components by means of wire brushing produces flying particles. These particles can cause serious injury to personnel. Wear protective faceshield, gloves, and long sleeves at all times during wire brushing operations. Failure to comply with this warning can result in serious injury to personnel. 4. 5. If minor damage such as rust and/or missing paint is found, thoroughly clean the damaged area to bare metal with a wire brush. After the area is cleaned, prime and paint as necessary IAW TB 55-1900-204-24.
0099-2
TM 55-1925-273-24&P-2 FIELD MAINTENANCE MAST REPAIR
0100
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 3, WP 0344, Table 1, Item 27) Faceshield, Industrial (Volume 3, WP 0344, Table 1, Item 5) Gloves, Leather (Volume 3, WP 0344, Table 1, Item 9) Tool Kit, Welder's (Volume 3, WP 0344, Table 1, Item 29) Materials/Parts N/A Personnel Required Fire Watch as Required IAW FM 4-01.502 Watercraft Operator 88K (1) References FM 4-01.502 TB 43-0144 Volume 3, WP 0344 Equipment Condition N/A
REPAIR
WARNING
Grinding, needling, and chipping operations can produce high velocity flying debris which can become lodged in the skin or in the eyes. Grinding, needling, and chipping in confined areas can result in debris flying from unexpected directions. All personnel working in the area must wear protective faceshield, gloves, and long sleeves when performing grinding, needling, and chipping operations. Failure to comply with this warning can result in serious injury or death to personnel.
NOTE
Repair the masts by cleaning and painting as necessary. If any structural damage or defect is detected, notify the maintenance supervisor. 1. 2. Prepare the area for repair by removing paint, rust, and contamination. This may be accomplished using a chipping hammer, wire brush, grinder, or needle gun depending upon the size of the affected area. Prime and paint the repaired area IAW TB 43-0144.
0100-1/2 blank
TM 55-1925-273-24&P-2 FIELD MAINTENANCE PORTLIGHT REPAIR
0101
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 3, WP 0344, Table 1, Item 27) Faceshield, Industrial (Volume 3, WP 0344, Table 1, Item 5) Gloves, Leather (Volume 3, WP 0344, Table 1, Item 9) Materials/Parts Rubber Strip (Volume 3, WP 0259, Figure 11, Item 4) Qty: 1 Personnel Required Watercraft Engineer 88L (2) References Volume 3, WP 0259 Volume 3, WP 0344 Equipment Condition N/A
0101-1
TM 55-1925-273-24&P-2
0101
NOTE
This work package details repair of the portholes found throughout the vessel's berthing areas. Replacement of pilothouse windows is accomplished at depot level. COVER AND GLASS FRAME REPLACE REMOVAL 1. 2. Loosen four bell nuts (Figure 1, Item 2) and undog the cover (Figure 1, Item 6). Remove two cotter pins (Figure 1, Item 7) from the hinge pin (Figure 1, Item 1).
CAUTION
Hold the cover and glass frame securely when the hinge pins are driven out. Both assemblies will come loose when the hinge pin is removed. Cover or glass breakage could result if the components are permitted to fall freely. 3. 4. Have one crewmember hold the cover (Figure 1, Item 6) and glass frame (Figure 1, Item 4) while the other crewmember removes the hinge pin (Figure 1, Item 1). Set aside the cover (Figure 1, Item 6) and glass frame (Figure 1, Item 4) if they will be installed later.
1
2 6
3 1
4 5
M1215T73
Figure 1. Window Cover and Glass Frame. END OF TASK
0101-2
TM 55-1925-273-24&P-2
0101
COVER AND GLASS FRAME REPLACE INSTALLATION 1. 2. Have one crewmember hold the cover (Figure 1, Item 6) and glass frame (Figure 1, Item 4) in position while the other crewmember installs the hinge pin (Figure 1, Item 1) to hold them in place. Install two cotter pins (Figure 1, Item 7) in the hinge pin (Figure 1, Item 1) to secure it in place.
END OF TASK RUBBER STRIP GASKET REPLACE REMOVAL 1. 2. Remove the cover and glass frame as described in the preceding procedure in this work package. Remove the rubber strip (Figure 1, Item 3) from the cover (Figure 1, Item 6) or from the frame (Figure 1, Item 5) as required.
WARNING
Removing components by means of wire brushing produces flying particles. These particles can cause serious injury to personnel. Wear protective faceshield, gloves, and long sleeves at all times during wire brushing operations. Failure to comply with this warning can result in serious injury to personnel. 3. Use a wire brush to thoroughly clean all of the old gasket material from the gasket channel. Clean the gasket channel to bare metal.
END OF TASK RUBBER STRIP GASKET REPLACE INSTALLATION 1. 2. 3. 4. 5. 6. Position the rubber strip (Figure 1, Item 3) in the channel of the cover (Figure 1, Item 6) and/or the frame (Figure 1, Item 5) ensuring that the rubber strip is pressed firmly into place throughout the entire channel. Clean the sealing edge of the glass frame (Figure 1, Item 4). Apply a chalk line completely around both sealing edges of the glass frame (Figure 1, Item 4). Close and dog the porthole. Open the porthole and inspect the rubber strip. If the porthole is watertight, the gaskets will show an unbroken chalk line. If the line is broken, notify the maintenance supervisor.
0101-3/4 blank
TM 55-1925-273-24&P-2 FIELD MAINTENANCE ROTARY CLEAR-VIEW SCREEN REPLACE
0102
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 3, WP 0344, Table 1, Item 27) Materials/Parts Rag, Wiping (Volume 3, WP 0343, Table 1, Item 132) Gasket (Volume 3, WP 0260, Figure 12, Item 3) Qty: 1 Personnel Required Watercraft Engineer 88L (2) References FM 4-01.502 References (cont.) TM 55-1925-273-10 Volume 3, WP 0260 Volume 3, WP 0343 Volume 3, WP 0344 Equipment Condition At 120 V exterior emergency lighting panel No. 2, set the ROTARY CLEAR-VIEW WIPER AND HEATER. circuit breaker (LT 803 Only), or the ROTARY CLEAR-VIEW WIPER AND HEATER, (FORWARD & AFT) circuit breaker (All Other Vessels) to OFF. Lock out and tag out IAW FM 4-01.502.
0102-1
TM 55-1925-273-24&P-2
0102
REMOVAL 1. Set the HEATER switch (Figure 1, Item 3) and the MOTOR switch (Figure 1, Item 2) on the clear-view screen control box (Figure 1, Item 1) to OFF.
CLEARVIEW SCREEN CONTROL BOX

VOLTS
HEATER ON
IMPORTANT TURN HEATER ON 20-30 MINUTES BEFORE STARTING MOTOR
MOTOR ON
OFF
OFF
3
Figure 1. 2.
2
M1216T73
Clear-view Screen Control Box.
Remove the connector (Figure 2, Item 8) from the junction box (Figure 2, Item 1).
CAUTION
A minimum of two personnel are needed when removing the clear-view screen from the window. The second person is needed outside to prevent the rotary assembly from falling during disassembly. Failure to comply with this caution can cause damage to the rotary assembly. 3. Remove the twelve screws (Figure 2, Item 5), twelve washers (Figure 2, Item 6), the retaining ring (Figure 2, Item 7), the gasket (Figure 2, Item 3), and the rotary assembly (Figure 2, Item 4) from window (Figure 2, Item 2). Discard gasket.
0102-2
0102
2 3 1 8 7 6 5
M1218T73
Figure 2. END OF TASK INSTALLATION 1. 2.
Clear-view Screen.
Thoroughly clean the window (Figure 2, Item 2) with clean wiping rags and clean water. Verify that there are no cracks or damage. Install a gasket (Figure 2, Item 3), the rotary assembly (Figure 2, Item 4), and the retaining ring (Figure 2, Item 7). Secure them with the twelve screws (Figure 2, Item 5) and twelve washers (Figure 2, Item 6). Install the connector (Figure 2, Item 8) on the junction box (Figure 2, Item 1).
3.
END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. 4. 5. Remove the lock outs and tag outs IAW FM 4-01.502. Set the circuit breaker to ON. Operate the clear-view screen under usual conditions IAW TM 55-1925-273-10. Verify that the window spins and heats properly. Return the equipment to the desired readiness condition.
0102-3/4 blank
TM 55-1925-273-24&P-2 FIELD MAINTENANCE ROTARY CLEAR-VIEW SCREEN REPAIR
0103
INITIAL SETUP: Tools and Special Tools Multimeter (Volume 3, WP 0344, Table 1, Item 15) Tool Kit, Electrical Repair (Volume 3, WP 0344, Table 1, Item 26) Materials/Parts Rag, Wiping (Volume 3, WP 0343, Table 1, Item 132) Personnel Required Watercraft Engineer 88L (2) References FM 4-01.502 References (cont.) TM 55-1925-273-10 Volume 3, WP 0260 Volume 3, WP 0343 Volume 3, WP 0344 Equipment Condition At 120 V exterior emergency lighting panel No. 2, set the ROTARY CLEAR-VIEW WIPER AND HEATER. circuit breaker (LT 803 Only), or the ROTARY CLEAR-VIEW WIPER AND HEATER, (FORWARD & AFT) circuit breaker (All Other Vessels) to OFF. Lock out and tag out IAW FM 4-01.502.
0103-1
TM 55-1925-273-24&P-2
0103
CONTROL BOX LAMP REMOVAL 1. 2. Remove the protective lens cover (Figure 1, Item 12). Remove the lamp (Figure 1, Item 11).
1 1
16 2 3 CLEARVIEW SCREEN CONTROL BOX

VOLTS
13
14
15 4 5 6 5
12
HEATER ON
IMPORTANT TURN HEATER ON 20-30 MINUTES BEFORE STARTING MOTOR
MOTOR ON
4 11 10
OFF
OFF
7 9
Figure 1. END OF TASK CONTROL BOX LAMP INSTALLATION 1. 2. 3. Install the lamp (Figure 1, Item 11). Install the protective lens cover (Figure 1, Item 12) finger tight. Perform the FOLLOW-ON MAINTENANCE procedure at the end of this work package.
M1217T73
Clear-view Screen Control Box.
END OF TASK CONTROL BOX FUSE REMOVAL 1. 2. Remove the fuse holder (Figure 1, Item 13). Remove the fuse (Figure 1, Item 14) from the fuse holder (Figure 1, Item 13).
END OF TASK
0103-2
TM 55-1925-273-24&P-2
0103
CONTROL BOX FUSE INSTALLATION 1. 2. 3. Install the fuse (Figure 1, Item 14) in the fuse holder (Figure 1, Item 13). Install the fuse holder (Figure 1, Item 13) with the installed fuse (Figure 1, Item 14) in the control box (Figure 1, Item 16). Perform the FOLLOW-ON MAINTENANCE procedure at the end of this work package.
END OF TASK LAMP HOUSING REMOVAL 1. 2. Perform the CONTROL BOX LAMP REMOVAL procedure in this work package. Loosen the captive screw (Figure 1, Item 1), and open the control box (Figure 1, Item 16).
WARNING
Replace or repair components only after the affected circuit has been secured, locked out, and tagged out IAW FM 4-01.502. Performing replacement with the circuit energized may result in injury. 3. Use a multimeter to check for the presence of voltage at the fuse holder assembly terminals (Figure 1, Item 3). If voltage is present, verify that the correct circuit breaker is set to OFF, locked out, and tagged out IAW FM 4-01.502. If no voltage is present, proceed with the procedure. Label and remove the wiring (Figure 1, Item 4) from the lamp assembly terminals (Figure 1, Item 5). Remove the retaining nut (Figure 1, Item 10) and remove the lamp housing assembly (Figure 1, Item 6) from the control box (Figure 1, Item 16).
4. 5.
END OF TASK LAMP HOUSING INSTALLATION 1. 2. 3. 4. 5. Install the lamp housing assembly (Figure 1, Item 6) in the control box (Figure 1, Item 16) and secure it with the retaining nut (Figure 1, Item 10). Install the wiring (Figure 1, Item 4) on the lamp assembly terminals (Figure 1, Item 5) using the labels from Step (4) of LAMP HOUSING REMOVAL as a guide. Remove the labels. Close the control box (Figure 1, Item 16) and secure it with the captive screw (Figure 1, Item 1). Perform the CONTROL BOX LAMP INSTALLATION procedure in this work package. Perform the FOLLOW-ON MAINTENANCE procedure at the end of this work package.
END OF TASK
0103-3
TM 55-1925-273-24&P-2
0103
FUSE HOLDER ASSEMBLY REMOVAL 1. 2. Perform the CONTROL BOX FUSE REMOVAL procedure in this work package. Loosen the captive screw (Figure 1, Item 1) and open the control box (Figure 1, Item 16).
WARNING
Replace or repair components only after the affected circuit has been secured, locked out, and tagged out IAW FM 4-01.502. Performing replacement with the circuit energized may result in injury. 3. Use a multimeter to check for the presence of voltage at the fuse holder assembly terminals (Figure 1, Item 3). If voltage is present, verify that the correct circuit breaker is set to OFF, locked out, and tagged out IAW FM 4-01.502. If no voltage is present, proceed with the procedure. Label and remove the wiring (Figure 1, Item 4) from the fuse holder assembly (Figure 1, Item 2) from the control box (Figure 1, Item 16).
4.
END OF TASK FUSE HOLDER ASSEMBLY INSTALLATION 1. 2. 3. 4. 5. Install the fuse holder assembly (Figure 1, Item 2) in the control box (Figure 1, Item 16) and secure it with the retaining nut (Figure 1, Item 15). Install the wiring (Figure 1, Item 4) on the fuse holder assembly terminals (Figure 1, Item 3) using the labels from Step (4) of FUSE HOLDER ASSEMBLY REMOVAL as a guide. Remove the labels. Close the control box (Figure 1, Item 16) and secure it with the captive screw (Figure 1, Item 1). Perform the CONTROL BOX FUSE INSTALLATION procedure in this work package. Perform the FOLLOW-ON MAINTENANCE procedure at the end of this work package.
END OF TASK
0103-4
TM 55-1925-273-24&P-2
0103
TOGGLE SWITCH REMOVAL 1. Loosen the captive screw (Figure 1, Item 1), and open the control box (Figure 1, Item 16).
WARNING
Replace or repair components only after the affected circuit has been secured, locked out, and tagged out IAW FM 4-01.502. Performing replacement with the circuit energized may result in injury. 2. Use a multimeter to check for the presence of voltage at the fuse holder assembly terminals (Figure 1, Item 3). If voltage is present, verify that the correct circuit breaker is set to OFF, locked out, and tagged out IAW FM 4-01.502. If no voltage is present, proceed with the procedure. Label and remove the wiring (Figure 1, Item 4) from the toggle switch terminals (Figure 1, Item 7). Remove the retaining nut (Figure 1, Item 8) and remove the toggle switch (Figure 1, Item 9) from the control box (Figure 1, Item 16).
3. 4.
END OF TASK TOGGLE SWITCH INSTALLATION 1. 2. 3. 4. Install the toggle switch (Figure 1, Item 9) in the control box (Figure 1, Item 16), and secure it with the retaining nut (Figure 1, Item 8). Install the wiring (Figure 1, Item 4) on the toggle switch terminals (Figure 1, Item 7) using the labels from Step (3) of TOGGLE SWITCH REMOVAL as a guide. Remove the labels. Close the control box (Figure 1, Item 16) and secure it with the captive screw (Figure 1, Item 1). Perform the FOLLOW-ON MAINTENANCE procedure at the end of this work package.
END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. 4. 5. Remove the lock outs and tag outs IAW FM 4-01.502. Set the circuit breaker to ON. Operate the clear-view screen under usual conditions IAW TM 55-1925-273-10. Verify that the window spins and heats properly. Return the equipment to the desired readiness condition.
0103-5/6 blank
TM 55-1925-273-24&P-2 FIELD MAINTENANCE REDUCTION GEAR COOLING PUMP REPLACE
0104
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 3, WP 0344, Table 1, Item 27) Gloves, Chemical and Oil Protective (Volume 3, WP 0344, Table 1, Item 8) Gloves, Leather (Volume 3, WP 0344, Table 1, Item 9) Goggles, Industrial (Volume 3, WP 0344, Table 1, Item 10) Multimeter (Volume 3, WP 0344, Table 1, Item 15) Suitable Drain Pan Materials/Parts Tape, Antiseizing; 1/2 in. (Volume 3, WP 0343, Table 1, Item 158) Personnel Required Watercraft Engineer 88L (2) References FM 4-01.502 References (cont.) TM 55-1925-273-10 Volume 3, WP 0261 Volume 3, WP 0343 Volume 3, WP 0344 Equipment Condition Set to OFF the FRESH WATER PUMP No. 1, (REDUCTION GEAR). or the FRESH WATER PUMP No. 2, (REDUCTION GEAR). circuit breaker in 440 V power panel No. 1. Lock out and tag out IAW FM 4-01.502. CLOSE valves FWC-13, F.W. FR. RED. GEAR No. 1 TO KEEL CLR and FWC-15, F.W. FR. KEEL CLR TO RED. GEAR No. 1 or FWC-14, F.W. FR. RED. GEAR No. 2 TO KEEL CLR and FWC-16, F.W. FR. KEEL CLR TO RED. GEAR No. 2. Lock out and tag out IAW FM 4-01.502.
0104-1
TM 55-1925-273-24&P-2
0104
WARNING
Never reuse locking hardware. Reuse of locking hardware such as lockwashers, locking nuts, cotter pins, and lock wire can result in undetected loosening of fastening hardware causing catastrophic component failure resulting in death, injury, or damage to equipment. Ensure that all locking hardware is discarded upon removal and replaced with new. REMOVAL 1. 2. Remove the four screws (Figure 1, Item 1) that secure the junction box cover (Figure 1, Item 3). Remove the junction box cover (Figure 1, Item 3) from the junction box (Figure 1, Item 2).
WARNING
Replace or repair components only after the affected circuit has been secured, locked out, and tagged out IAW FM 4-01.502. Performing replacement with the circuit energized may result in injury. 3. Use a multimeter to check for voltage at the wiring in the junction box (Figure 1, Item 2). If voltage is present, check that the proper circuit breaker is set to OFF, locked out, and tagged out IAW FM 4-01.502. If no voltage is present, continue with the procedure. Label and remove the wiring in the junction box (Figure 1, Item 2).
4.
M1008T73
Figure 1.
Electrical Junction Box.
0104-2
TM 55-1925-273-24&P-2 REMOVAL - Continued 5. 6. 7. Place a suitable drain pan under the reduction gear cooling pump (Figure 2, Item 2). Disconnect the tubing (Figure 2, Item 7) from the discharge pressure cutoff valve (Figure 2, Item 1). Remove the insulation from the elbow joint (Figure 2, Item 5).
0104
WARNING
Do not allow used antifreeze to come in contact with unprotected skin or eyes. Prolonged skin contact can cause illness or injury. Eye contact can cause serious injury. Always wear chemical protective gloves and goggles when handling antifreeze. Failure to comply with this warning can result in illness, serious injury, or death. Always wear heavy leather gloves when handling hot components. Handling hot components with bare hands or skin may result in severe burns. Failure to comply with this warning can result in serious injury or death.
CAUTION
Never attempt to disconnect unions with only one wrench. Damage to the vessel's standing piping or to the pump's piping could occur. Always use two wrenches. 8. 9. 10. Loosen, but do not disconnect, the union (Figure 2, Item 4) connecting the elbow joint (Figure 2, Item 5) to the reduction gear cooling pump (Figure 2, Item 2). Permit water from the union (Figure 2, Item 4) to drain into the suitable drain pan. After the coolant stops draining, disconnect the union. Disconnect the union (Figure 2, Item 6) at the reduction gear cooling pump outlet (Figure 2, Item 3).
7 5
6
M1009T73
Figure 2. Reduction Gear Cooling Pump Assembly.
0104-3
TM 55-1925-273-24&P-2 REMOVAL - Continued 11. 12. Remove bolts (Figure 3, Item 1), lockwashers (Figure 3, Item 2), and flat washers (Figure 3, Item 3).
0104
Place the pump on a secure workstation and remove the elbows (Figure 2, Items 3 and 5) from the pump. Retain the elbows for installation on the replacement pump.
2 3
M1010T73
Figure 3. END OF TASK INSTALLATION 1.
Reduction Gear Cooling Pump Assembly (Mounting Hardware).
Thoroughly clean the pipe threads on the elbows (Figure 2, Items 3 and 5) of all old sealant.
CAUTION
Although antiseizing tape is necessary on the elbow joint pipe threads, none will be allowed or necessary on the union threads. Leakage will result from applying antiseizing tape to union threads. 2. 3. Apply antiseizing tape onto the threaded end of the elbow joint (Figure 2, Item 5). Do not apply sealant tape to the unions (Figure 2, Items 4 and 6) or their threads. Install the elbow joints (Figure 2, Items 3 and 5) into the pump (Figure 2, Item 2) and tighten the elbow joints. After the elbow joints are tightened, they must be aligned to mate with the cooling piping at the pump's foundation.
0104-4
TM 55-1925-273-24&P-2 INSTALLATION - Continued 4. 5.
0104
Position the reduction gear cooling pump on the foundation, install the bolts (Figure 3, Item 1) with lockwashers (Figure 3, Item 2) and flat washers (Figure 3, Item 3). Do not tighten the bolts at this time. Connect the unions (Figure 2, Items 4 and 6) onto the vessel's existing piping. Minor reorientation of the elbows (Figure 2, Items 3 and 5) may be necessary to properly align the unions.
CAUTION
Never attempt to connect unions with only one wrench. Damage to the vessel's standing piping or to the pump's piping could occur. Always use two wrenches. 6. 7. 8. Tighten the unions (Figure 2, Items 4 and 6) securely. Tighten the bolts (Figure 3, Item 1) to secure the pump to the foundation. Clean all the old antiseizing tape off of the threads of the discharge pressure cutoff valve (Figure 2, Item 1). Apply antiseizing tape to the tubing connection (Figure 2, Item 7) threads and connect the tubing to the discharge pressure cutoff valve (Figure 2, Item 1). Connect the wiring in the junction box (Figure 1, Item 2) using the labels from Step (4) of REMOVAL as a guide. Remove the labels. Install the junction box cover (Figure 1, Item 3) and secure it in place with the four screws (Figure 1, Item 1).
9. 10.
END OF TASK FOLLOW-ON MAINTANANCE 1. 2. 3. Remove the lock outs and tag outs IAW FM 4-01.502. Operate the reduction gear cooling pump under normal conditions IAW TM 55-1925-273-10 and check for leaks and proper operation. Return the equipment to the desired readiness condition.
0104-5/6 blank
TM 55-1925-273-24&P-2 FIELD MAINTENANCE REDUCTION GEAR COOLING PUMP REPAIR
0105
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 3, WP 0344, Table 1, Item 27) Faceshield, Industrial (Volume 3, WP 0344, Table 1, Item 5) Gloves, Chemical and Oil Protective (Volume 3, WP 0344, Table 1, Item 8) Materials/Parts Cleaning Compound, Solvent (Volume 3, WP 0343, Table 1, Item 37) Grease, Ball and Roller Bearing; 1.75 lb (Volume 3, WP 0343, Table 1, Item 74) Rag, Wiping (Volume 3, WP 0343, Table 1, Item 132) Parts Kit, Seal Replace (Volume 3, WP 0336, Figure KITS, Item 1) Personnel Required Watercraft Engineer 88L (1) References FM 4-01.502 References (cont.) TM 55-1925-273-10 WP 0104 Volume 3, WP 0261 Volume 3, WP 0336 Volume 3, WP 0343 Volume 3, WP 0344 Equipment Condition Reduction gear cooling pump removed. (WP 0104)
0105-1
TM 55-1925-273-24&P-2
0105
WARNING
Never reuse locking hardware. Reuse of locking hardware such as lockwashers, locking nuts, cotter pins, and lock wire can result in undetected loosening of fastening hardware causing catastrophic component failure resulting in death, injury, or damage to equipment. Ensure that all locking hardware is discarded upon removal and replaced with new. DISASSEMBLY
WARNING
Cleaning solvent is flammable and its vapor is potentially explosive. Do not use cleaning solvent in the vicinity of spark, open flame, or excessive heat. Do not use cleaning solvent in unventilated spaces. Always wear chemical protective gloves and goggles when handling hydraulic fluid, engine oil, and cleaning solvents. Failure to comply with this warning can result in serious injury or death.
NOTE
Disassemble the reduction gear cooling pump only as far as required to perform the maintenance work needed. 1. 2. Drain the reduction gear cooling pump. Flush with clean water if necessary. Using cleaning solvent, clean exterior surfaces of the unit. Inspect all component parts for unusual wear or damage, and replace as required.
WARNING
Cleaning solvent is flammable and its vapor is potentially explosive. Do not use cleaning solvent in the vicinity of spark, open flame, or excessive heat. Do not use cleaning solvent in unventilated spaces. Always wear chemical protective gloves and goggles when handling hydraulic fluid, engine oil, and cleaning solvents. Failure to comply with this warning can result in serious injury or death. 3. 4. 5. 6. 7. 8. 9. Remove the drain plugs (Figure 1, Item 5) from the volute (Figure 1, Item 14). Remove the capscrews (Figure 1, Item 17) securing the backplate (Figure 1, Item 3) to the volute (Figure 1, Item 14). Separate the volute from the backplate. Remove the gasket (Figure 1, Item 15) from the volute (Figure 1, Item 14). Discard gasket. Remove the front plate wear ring (Figure 1, Item 7) from the volute (Figure 1, Item 14). Discard front plate wear ring. Remove the impeller screw (Figure 1, Item 10) and the impeller washer (Figure 1, Item 9). Remove the impeller (Figure 1, Item 6) from the shaft (Figure 1, Item 11). Remove the key (Figure 1, Item 8) from the impeller. Remove the capscrews (Figure 1, Item 18) securing the backplate (Figure 1, Item 3) to the bracket (Figure 1, Item 19). Separate the backplate from the bracket.
0105-2
TM 55-1925-273-24&P-2 DISASSEMBLY - Continued 10. 11. 12. 13. 14. 15. Remove the gasket (Figure 1, Item 16) from the backplate (Figure 1, Item 3). Discard gasket.
0105
Remove the rear case wear ring (Figure 1, Item 4) from the backplate (Figure 1, Item 3). Discard rear case wear ring. Remove the snap ring (Figure 1, Item 12) from the shaft (Figure 1, Item 11). Discard snap ring. Remove the shaft seal assembly (Figure 1, Item 1) from shaft (Figure 1, Item 11). Discard shaft seal assembly. Remove the sleeve (Figure 1, Item 13) from the shaft (Figure 1, Item 11). Remove the stuffing box plug (Figure 1, Item 2) from the bracket (Figure 1, Item 19).
1 2 3 4
5 6 7 8 9 10
11 12 13 14 5 19 18 17 16 15
M2002T73
Reduction Gear Cooling Pump.
0105-3
TM 55-1925-273-24&P-2
0105
ASSEMBLY
WARNING
Cleaning solvent is flammable and its vapor is potentially explosive. Do not use cleaning solvent in the vicinity of spark, open flame, or excessive heat. Do not use cleaning solvent in unventilated spaces. Always wear chemical protective gloves and goggles when handling hydraulic fluid, engine oil, and cleaning solvents. Failure to comply with this warning can result in serious injury or death. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. Using cleaning solvent, clean the disassembled parts of the unit before assembly. Install the stuffing box plug (Figure 1, Item 2) in the bracket (Figure 1, Item 19). Install the shaft sleeve (Figure 1, Item 13) over the shaft (Figure 1, Item 11). Install the shaft seal assembly (Figure 1, Item 1) on the shaft (Figure 1, Item 11). Install a snap ring (Figure 1, Item 12) on the shaft (Figure 1, Item 11). Install the rear case wear ring (Figure 1, Item 4) on the backplate (Figure 1, Item 3). Install the gasket (Figure 1, Item 16) on the backplate (Figure 1, Item 3). Install the backplate (Figure 1, Item 3) on the bracket (Figure 1, Item 19). Install the capscrews (Figure 1, Item 18) in the backplate. Tighten the capscrews. Install the key (Figure 1, Item 8) in the impeller (Figure 1, Item 6). Install the impeller (Figure 1, Item 6) on the shaft (Figure 1, Item 11). Install the impeller washer (Figure 1, Item 9) and the impeller screw (Figure 1, Item 10) to secure the impeller. Tighten the impeller screw. Install the front plate wear ring (Figure 1, Item 7) on the volute (Figure 1, Item 14). Install the gasket (Figure 1, Item 15) on the volute (Figure 1, Item 14). Lower the volute over the backplate (Figure 1, Item 3). Install the capscrews (Figure 1, Item 17) securing the volute (Figure 1, Item 14) to the bracket (Figure 1, Item 19). Tighten the capscrews. Install the drain plugs (Figure 1, Item 5) in the volute (Figure 1, Item 14). Tighten the drain plugs.
END OF TASK FOLLOW-ON MAINTENANCE Install the reduction gear cooling pump (WP 0104). END OF TASK END OF WORK PACKAGE
0105-4
TM 55-1925-273-24&P-2 FIELD MAINTENANCE PROPELLER INSPECT
0106
INITIAL SETUP: Tools and Special Tools Flashlight (Volume 3, WP 0344, Table 1, Item 6) Gloves, Leather (Volume 3, WP 0344, Table 1, Item 9) Materials/Parts N/A Personnel Required Watercraft Engineer 88L (2) Qualified Divers and Attendants (ATTP 3-34.84) (1) References ATTP 3-34.84 FM 4-01.502 TM 55-1925-273-10 Volume 3, WP 0344 Equipment Condition Vessel is moored and on shore power. (TM 55-1925-273-10) Set the anchor windlass brakes. (TM 55-1925-273-10) Pelican hooks securing the anchor chains. At the emergency switchboard, set the STEERING GEAR PUMP #1 circuit breaker to OFF; set the FIRE PUMP #1 circuit breaker to OFF; set the BILGE PUMP #1 circuit breaker to OFF; set the CENT HYD SYS circuit breaker to OFF. Lock out and tag out IAW FM 4-01.502. At the main switchboard, set the BILGE PUMP NO. 2 circuit breaker to OFF; set the FIRE PUMP NO. 2 circuit breaker to OFF; set the STEERING GEAR PUMP #2 circuit breaker to OFF. Lock out and tag out IAW FM 4-01.502. At 440 V power panel NO. 1, set the SEWAGE DISCHARGE PUMP NO. 1 circuit breaker (LT 803 Only), or the LVP FOR STARBOARD SEWAGE DISCHARGE PUMP NO. 1 circuit breaker (All Other Vessels) to OFF; set the SEWAGE DISCHARGE PUMP NO. 2 circuit breaker (LT 803 Only), or the LVP FOR PORT SEWAGE DISCHARGE PUMP NO. 2 circuit breaker (All Other Vessels) to OFF. Lock out and tag out IAW FM 4-01.502. Equipment Condition (cont.) At 440 V power panel NO. 4, set the MSD DISCHARGE PUMP AND BLOWER circuit breaker (LT 803 Only), or the CONTROLLER FOR MSD DISCHARGE PUMP AND BLOWER circuit breaker (All Other Vessels) to OFF. Lock out and tag out IAW FM 4-01.502. At 120 V distribution panel NO. 4, set the OILY WATER SEPARATOR circuit breaker to OFF. Lock out and tag out IAW FM 4-01.502. At 120 V pilothouse emergency distribution panel, set the SPEED LOG 85 ELECTRONICS UNIT circuit breaker to OFF; set the SONAR DIGITAL AN/SQN. (ECHO SOUNDER DISPLAY) circuit breaker (LT 803 Only), or the GDS 101 ECHO SOUNDER DISPLAY circuit breaker (All Other Vessels) to OFF. Lock out and tag out IAW FM 4-01.502. At the SSDG 1 engine control panel push IN the emergency stop pushbutton. Lock out and tag out IAW FM 4-01.502. CLOSE valves CA-5 STG AIR TO BOW THRUSTER ENG; CA-6 STG AIR TO PMP DR ENG; CA-7 STG AIR TO DSL ENG; CA-8 STG AIR TO ME NO. 2; CA-9 STG AIR TO ME #1; CA-22 SEA CHEST BLWT.; and CA-23 SEA CHEST BLWT. Lock out and tag out IAW FM 4-01.502.
0106-1
TM 55-1925-273-24&P-2
0106
NOTE
Inspection of the propellers and the bow thruster must be performed by a team of qualified divers. INSPECT
WARNING
Do not pump from or discharge to the sea while diving operations are in progress. Do not rotate screws, cycle rudders, or perform any other operation that might injure the divers. Do not operate the fathometer or any other underwater electrical devices. Failure to comply with this warning can result in serious injury or death to the divers. 1. 2. 3. Inspect the propellers and the bow thruster for signs of obvious damage such as dings, nicks, deformation, or entangled materials. Report any damage to the maintenance supervisor. Inspect the propellers and the bow thruster for security of mounting. Report any loose mounting to the maintenance supervisor. Inspect the propellers and the bow thruster for contamination by marine growth. If contamination is found, report the contamination to the maintenance supervisor who will determine the most effective cleaning method.
END OF TASK FOLLOW-ON MAINTENANCE 1. 2. Remove the lock outs and tags outs IAW FM 4-01.502. Return the vessel to the desired operating condition IAW TM 55-1925-273-10.
0106-2
TM 55-1925-273-24&P-2 FIELD MAINTENANCE KEEL COOLERS INSPECT
0107
INITIAL SETUP: Tools and Special Tools Flashlight (Volume 3, WP 0344, Table 1, Item 6) Gloves, Leather (Volume 3, WP 0344, Table 1, Item 9) Materials/Parts Rag, Wiping (Volume 3, WP 0343, Table 1, Item 132) Personnel Required Crewmember any MOS trained in Confined Space Entry (1) Confined Space Entry Supervisor/Attendant (1) Watercraft Engineer 88L (1) Qualified Divers and Attendents (ATTP 3-34.84) References ATTP 3-34.84 FM 4-01.502 TM 55-1925-273-10 Volume 3, WP 0343 Volume 3, WP 0344 Equipment Condition Vessel operating on shore power. Confined Space Entry Permit secured IAW FM 4-01.502 for both port and starboard shaft alleys. CLOSE valves CA-8 STG AIR TO ME #2, CA-9 STG AIR TO ME #1, FO-21 F.O. SPLY TO S.S.D.G. No. 1, and FO-22 F.O. SPLY to S. Set the anchor windlass brakes (TM 55-1925-273-10). Pelican hooks securing the anchor chains. At the emergency switchboard, set the STEERING GEAR PUMP #1 circuit breaker to OFF; set the FIRE PUMP #1 circuit breaker to OFF; set the BILGE PUMP #1 circuit breaker to OFF; set the Equipment Condition (cont.) CENT HYD SYS circuit breaker to OFF. Lock out and tag out IAW FM 4-01.502. At the main switchboard, set the BILGE PUMP NO. 2 circuit breaker to OFF; set the FIRE PUMP NO. 2 circuit breaker to OFF; set the STEERING GEAR PUMP #2 circuit breaker to OFF. Lock out and tag out IAW FM 4-01.502. At 440 V power panel No. 1, set the SEWAGE DISCHARGE PUMP No. 1 circuit breaker (LT 803 Only), or the LVP FOR STARBOARD SEWAGE DISCHARGE PUMP No. 1 circuit breaker (All Other Vessels) to OFF; set the SEWAGE DISCHARGE PUMP No. 2 circuit breaker (LT 803 Only), or the LVP FOR PORT SEWAGE DISCHARGE PUMP No. 2 circuit breaker (All Other Vessels) to OFF. Lock out and tag out IAW FM 4-01.502. At 440 V power panel No. 4, set the MSD DISCHARGE PUMP AND BLOWER circuit breaker (LT 803 Only), or the CONTROLLER FOR MSD DISCHARGE PUMP AND BLOWER circuit breaker (All Other Vessels) to OFF. Lock out and tag out IAW FM 4-01.502. At 120 V distribution panel No. 4, set the OILY WATER SEPARATOR circuit breaker to OFF. Lock out and tag out IAW FM 4-01.502. At 120 V pilothouse emergency distribution panel, set the SPEED LOG 85 ELECTRONICS UNIT circuit breaker to OFF; set the SONAR DIGITAL AN/SQN. (ECHO SOUNDER DISPLAY) circuit breaker (LT 803 Only), or the GDS 101 ECHO SOUNDER DISPLAY circuit breaker (All Other Vessels) to OFF. Lock out and tag out IAW FM 4-01.502. At the SSDG 1 engine control panel push IN the emergency stop pushbutton. Lock out and tag out IAW FM 4-01.502. CLOSE valves CA-5 STG AIR TO BOW THRUSTER ENG; CA-6 STG AIR TO PMP DR ENG; CA-7 STG AIR TO DSL ENG; CA-8 STG AIR TO ME #2; CA-9 STG AIR TO ME #1; CA-22 SEA CHEST BLWT.; and CA-23 SEA CHEST BLWT. Lock out and tag out IAW FM 4-01.502.
0107-1
TM 55-1925-273-24&P-2
0107
KEEL COOLERS INSPECT
WARNING
Entry into an uninspected confined space may result in death or serious injury to personnel. Only properly trained personnel may enter confined spaces, or act as entry supervisors and/or attendants for those working in cofined spaces. Before entering into a confined space, the space must be cleared for entry and a Confined Space Entry Permit must be secured. All entry into confined spaces must be in accordance with FM 4-01.502. Failure to comply with this warning can result in serious injury or death to personnel. The keel coolers work area can be very hot. Wear protective gloves. Failure to comply with this warning can result in personal injury or death. 1. 2. 3. Enter into the port shaft alley and, using a flashlight, visually inspect around the PORT side main engine keel cooler piping (Figure 1, Item 1) and valves, checking for obvious wear, rust, or coolant leakage. Inspect the coolant piping extending between the PORT side keel cooler piping (Figure 1, Item 1) and the main engine 2 (Figure 1, Item 4) for obvious wear, rust, or coolant leakage. Repeat Steps (1) and (2) for the STARBOARD keel cooler piping (Figure 1, Item 8) inspection, entering the starboard shaft alley and inspect from the STARBOARD keel cooler piping to the main engine 1 (Figure 1, Item 5). Perform the FOLLOW-ON MAINTENANCE procedure at the end of this work package.
4.
0107-2
TM 55-1925-273-24&P-2 KEEL COOLERS INSPECT - Continued
0107
FWC-4
KEEL COOLER KEEL COOLER
FWC-2
KEEL COOLER FWC-16
FWC-12 KEEL COOLER
FWC-10
SSDG 2
FWC FWC -14 -24
12 RED GEAR 2 MAIN ENGINE 2 ENGINE ROOM
11 AMS 2 10
RED GEAR 1
FWC-23 FWC-13
SEA CHEST MAIN ENGINE 1
FWC-3
KEEL COOLER KEEL COOLER
5
FWC-15 KEEL COOLER
FWC-1
KEEL COOLER FWC-11
FWC-9
SSDG 1
8
7
Keel Cooler Piping.
6
M1219T73
0107-3
TM 55-1925-273-24&P-2
0107
SHIP'S SERVICE DIESEL GENERATOR (SSDG) KEEL COOLERS INSPECT
WARNING
Work area can be very hot. Wear protective leather gloves. Failure to comply with this warning can result in personal injury or death. 1. 2. 3. 4. 5. Enter into the bilge and, using a flashlight, visually inspect around the PORT side SSDG keel cooler piping (Figure 1, Item 2) and valves checking for obvious wear, rust, or coolant leakage. Inspect the coolant piping extending between the PORT side keel cooler (Figure 1, Item 2) and SSDG 2 (Figure 1, Item 3). Enter into the bilge and, using a flashlight, visually inspect around the STARBOARD side SSDG keel cooler piping (Figure 1, Item 7) and valves checking for obvious wear, rust, or coolant leakage. Inspect the coolant piping extending between the STARBOARD side keel cooler (Figure 1, Item 7) to SSDG 1 (Figure 1, Item 6). Perform the FOLLOW-ON MAINTENANCE procedure at the end of this work package.
END OF TASK REDUCTION GEAR KEEL COOLERS INSPECT 1. 2. 3. 4. 5. Enter into the bilge and, using a flashlight, visually inspect around the PORT side reduction gear keel cooler piping (Figure 1, Item 12) and valves, checking for obvious wear, rust, or coolant leakage. Inspect the coolant piping extending between the PORT side keel cooler (Figure 1, Item 12) and reduction gear 2 (Figure 1, Item 11). Enter into the bilge and, using a flashlight, visually inspect around the STARBOARD side reduction gear keel cooler piping (Figure 1, Item 9) and valves, checking for obvious wear, rust, or coolant leakage. Inspect the coolant piping extending between the STARBOARD side keel cooler (Figure 1, Item 9) and the reduction gear 1 (Figure 1, Item 10). Perform the FOLLOW-ON MAINTENANCE procedure at the end of this work package.
END OF TASK
0107-4
TM 55-1925-273-24&P-2
0107
EXTERIOR COMPONENTS INSPECT
WARNING
Do not pump from or discharge to the sea while diving operations are in progress. Do not rotate screws, cycle rudders, or perform any other operation that might injure the divers. Do not operate the fathometer or any other underwater electrical devices. Failure to comply with this warning can result in serious injury or death to the divers.
NOTE
Inspection of the keel cooler components must be performed by a team of qualified divers. 1. 2. 3. Inspect all six keel coolers for signs of external damage or leakage. Report any damage to the maintenance supervisor. Inspect all six keel coolers for security of mounting. Report any loose mounting to the maintenance supervisor. Inspect all six keel coolers for contamination by sand, mud, paint, or marine growth. If contamination is found, report the contamination to the maintenance supervisor who will determine the most effective cleaning method.
END OF TASK FOLLOW-ON MAINTENANCE 1. 2. Remove the lock outs and tag outs IAW FM 4-01.502. Return the vessel to the desired operating condition IAW TM 55-1925-273-10.
0107-5/6 blank
TM 55-1925-273-24&P-2 FIELD MAINTENANCE FUEL SYSTEM VALVES REPLACE
0108
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 3, WP 0344, Table 1, Item 27) Faceshield, Industrial (Volume 3, WP 0344, Table 1, Item 5) Gloves, Chemical and Oil Protective (Volume 3, WP 0344, Table 1, Item 8) Goggles, Industrial (Volume 3, WP 0344, Table 1, Item 10) Suitable Drain Pan Materials/Parts Cleaning Compound, Solvent (Volume 3, WP 0343, Table 1, Item 37) Tape, Antiseizing; 1/2 in. (Volume 3, WP 0343, Table 1, Item 158) Gasket (Volume 3, WP 0262, Figure 14, Item 5) Qty: 2 Personnel Required Watercraft Engineer 88L (2) References FM 4-01.502 TM 55-1925-273-10 Volume 3, WP 0262 Volume 3, WP 0343 Volume 3, WP 0344 Equipment Condition CLOSE all valves upstream and downstream of the affected valve. Lock out and tag out IAW FM 4-01.502.
0108-1
TM 55-1925-273-24&P-2
0108
WARNING
Never reuse locking hardware. Reuse of locking hardware such as lockwashers, locking nuts, cotter pins, and lock wire can result in undetected loosening of fastening hardware causing catastrophic component failure resulting in death, injury, or damage to equipment. Ensure that all locking hardware is discarded upon removal and replaced with new. THREADED BALL VALVE REMOVAL
WARNING
Diesel fuel is flammable and diesel fuel vapors can be explosive. Ensure all work is performed in a well ventilated area. Keep sparks, open flame, and excessive heat away from the work area. Do not smoke or allow smoking, or any other flame in the vicinity of fuel sounding operations. Wipe clean any fuel spillage and dispose of spilled fuel and fuel-soaked rags in accordance with the appropriate local regulations. Avoid prolonged exposure of the skin to diesel fuel. Protective nitrile gloves and chemical protective goggles must be worn whenever handling diesel fuel or parts which are saturated with diesel fuel. Failure to comply with this warning can result in serious injury or death to personnel. 1. 2. 3. 4. Place a suitable drain pan under the ball valve (Figure 1, Item 3) and the fuel oil filter/water separator assembly (Figure 1, Item 1). Unscrew the swivel connector (Figure 1, Item 4) from the fuel oil filter/water separator assembly (Figure 1, Item 1). Unscrew the ball valve (Figure 1, Item 3) from the fuel manifold (Figure 1, Item 2). Cap the fuel manifold (Figure 1, Item 2) opening to prevent contamination of the fuel system.
END OF TASK THREADED BALL VALVE INSTALLATION
WARNING
Removing components by means of wire brushing produces flying particles. These particles can cause serious injury to personnel. Wear protective faceshield, gloves, and long sleeves at all times during wire brushing operations. Failure to comply with this warning can result in serious injury to personnel. Do not allow cleaning solvents to come in contact with unprotected skin or eyes. Prolonged skin contact can cause illness or injury. Eye contact can cause serious injury. Always wear chemical protective gloves and goggles when handling hydraulic fluid, engine oil, and cleaning solvents. Failure to follow these precautions can result in illness or serious injury.
0108-2
TM 55-1925-273-24&P-2 THREADED BALL VALVE INSTALLATION - Continued 1. 2. 3. 4. 5. 6. 7.
0108
Clean the male threads of the fuel manifold (Figure 1, Item 2) connector using cleaning solvent and a wire brush. Clean the applicable male threads of the swivel connector (Figure 1, Item 4) using cleaning solvent and a wire brush. Clean the female threads of ball valve (Figure 1, Item 3) using cleaning solvent and a wire brush. Apply antiseizing tape to the male threads of the fuel manifold (Figure 1, Item 2). Install the ball valve (Figure 1, Item 3) onto the fuel manifold (Figure 1, Item 2). Install the swivel connector (Figure 1, Item 4) into the ball valve (Figure 1, Item 3). Perform the FOLLOW-ON MAINTENANCE procedure at the end of this work package.
4 3
2
M1025T73
Typical Threaded Ball Valve.
0108-3
TM 55-1925-273-24&P-2
0108
TYPICAL TWO-WAY BALL VALVE (FLANGED) REMOVAL
WARNING
Diesel fuel is flammable and diesel fuel vapors can be explosive. Ensure all work is performed in a well ventilated area. Keep sparks, open flame, and excessive heat away from the work area. Do not smoke or allow smoking, or any other flame in the vicinity of fuel sounding operations. Wipe clean any fuel spillage and dispose of spilled fuel and fuel-soaked rags in accordance with the appropriate local regulations. Avoid prolonged exposure of the skin to diesel fuel. Protective nitrile gloves and chemical protective goggles must be worn whenever handling diesel fuel or parts which are saturated with diesel fuel. Failure to comply with this warning can result in serious injury or death to personnel.
CAUTION
Valves can trap pressurized media in the cavity. This pressure can remain even after the valve has been removed from the line. Partially open the valve to make sure there is no pressure to or in the valve before removing any bolts. 1. 2. 3. 4. 5. 6. Place a suitable drain pan under two-way ball valve (Figure 2, Item 1). Slowly loosen the bolts (Figure 2, Item 7) on one end of two-way ball valve (Figure 2, Item 1) and break the seal between two-way ball valve and the vessel's piping. After the fuel oil drains from two-way ball valve (Figure 2, Item 1), remove all the bolts (Figure 2, Item 7) and the nuts (Figure 2, Item 5). Remove the bolts (Figure 2, Item 3) and the nuts (Figure 2, Item 2) from the opposite side of the two-way ball valve (Figure 2, Item 1). Lift the two-way ball valve (Figure 2, Item 1) clear of vessel's piping. Remove and discard gaskets (Figure 2, Items 4 and 6) from the ends of two-way ball valve (Figure 2, Item 1) and the vessel's piping.
END OF TASK
0108-4
TM 55-1925-273-24&P-2 TYPICAL TWO-WAY BALL VALVE (FLANGED) INSTALLATION
0108
WARNING
Removing components by means of wire brushing produces flying particles. These particles can cause serious injury to personnel. Wear protective faceshield, gloves, and long sleeves at all times during wire brushing operations. Failure to comply with this warning can result in serious injury to personnel. Do not allow cleaning solvents to come in contact with unprotected skin or eyes. Prolonged skin contact can cause illness or injury. Eye contact can cause serious injury. Always wear chemical protective gloves and goggles when handling hydraulic fluid, engine oil, and cleaning solvents. Failure to follow these precautions can result in illness or serious injury. 1. 2. 3. 4. Clean the flanges of two-way ball valve (Figure 2, Item 1) and vessel's piping using cleaning solvent and a wire brush. Install the two-way ball valve (Figure 2, Item 1) and gaskets (Figure 2, Items 4 and 6) in the vessel's piping. Install the bolts (Figure 2, Items 3 and 7) and nuts (Figure 2, Items 2 and 5) to secure the two-way ball valve (Figure 2, Item 1). Tighten the bolts. Perform the FOLLOW-ON MAINTENANCE procedure at the end of this work package.
2 3
M1026T73
Typical Two-Way Ball Valve.
0108-5
TM 55-1925-273-24&P-2 FOLLOW-ON MAINTENANCE 1. 2. 3. 4. Remove the lock outs and tag outs IAW FM 4-01.502. Test operate the fuel oil transfer system under usual conditions IAW TM 55-1925-273-10. Observe the valve and connections, checking for leakage. Return the equipment to the desired readiness condition.
0108
0108-6
TM 55-1925-273-24&P-2 FIELD MAINTENANCE FUEL SYSTEM VALVES REPAIR
0109
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 3, WP 0344, Table 1, Item 27) Gloves, Chemical and Oil Protective (Volume 3, WP 0344, Table 1, Item 8) Goggles, Industrial (Volume 3, WP 0344, Table 1, Item 10) Materials/Parts Gasket (Volume 3, WP 0262, Figure 14, Item 5) Qty: 1 Packing Material (Volume 3, WP 0262, Figure 14, Item 26) Qty: 1 Personnel Required Watercraft Engineer 88L (1) References FM 4-01.502 WP 0108 Volume 3, WP 0262 Volume 3, WP 0344 Equipment Condition Fuel system valve removed. (WP 0108)
0109-1
TM 55-1925-273-24&P-2
0109
FLANGED GATE VALVE DISASSEMBLY
WARNING
Diesel fuel is flammable and diesel fuel vapors can be explosive. Ensure all work is performed in a well ventilated area. Keep sparks, open flame, and excessive heat away from the work area. Do not smoke or allow smoking, or any other flame in the vicinity of fuel sounding operations. Wipe clean any fuel spillage and dispose of spilled fuel and fuel-soaked rags in accordance with the appropriate local regulations. Avoid prolonged exposure of the skin to diesel fuel. Protective nitrile gloves and chemical protective goggles must be worn whenever handling diesel fuel or parts which are saturated with diesel fuel. Failure to comply with this warning can result in serious injury or death to personnel. 1. 2. 3. 4. 5. Remove the nut (Figure 1, Item 1) and the flat washer (Figure 1, Item 2) from the valve (Figure 1, Item 7). Remove the handle (Figure 1, Item 3) from the valve (Figure 1, Item 7). Remove the gland nut (Figure 1, Item 4) from the valve (Figure 1, Item 7). Remove the gasket (Figure 1, Item 5) from the valve (Figure 1, Item 7). Discard gasket. Remove the packing (Figure 1, Item 6) from the valve (Figure 1, Item 7). Discard packing.
END OF TASK FLANGED GATE VALVE ASSEMBLY
WARNING
Diesel fuel is flammable and diesel fuel vapors can be explosive. Ensure all work is performed in a well ventilated area. Keep sparks, open flame, and excessive heat away from the work area. Do not smoke or allow smoking, or any other flame in the vicinity of fuel sounding operations. Wipe clean any fuel spillage and dispose of spilled fuel and fuel-soaked rags in accordance with the appropriate local regulations. Avoid prolonged exposure of the skin to diesel fuel. Protective nitrile gloves and chemical protective goggles must be worn whenever handling diesel fuel or parts which are saturated with diesel fuel. Failure to comply with this warning can result in serious injury or death to personnel. 1. 2. 3. 4. Install the packing (Figure 1, Item 6) in the valve (Figure 1, Item 7). Install the gasket (Figure 1, Item 5) in the valve (Figure 1, Item 7). Install the gland nut (Figure 1, Item 4) on the valve (Figure 1, Item 7). Install the handle (Figure 1, Item 3) on the valve (Figure 1, Item 7), and secure it with the nut (Figure 1, Item 1) and the flat washer (Figure 1, Item 2).
0109-2
TM 55-1925-273-24&P-2 FLANGED GATE VALVE ASSEMBLY - Continued
0109
2 3 4 5 6
M1027T73
Figure 1. END OF TASK FOLLOW-ON MAINTENANCE
Flanged Gate Valve.
Perform the APPLICABLE VALVE REPLACEMENT procedure (WP 0108). END OF TASK END OF WORK PACKAGE
0109-3/4 blank
TM 55-1925-273-24&P-2 FIELD MAINTENANCE FUEL OIL TRANSFER PUMP, PUMP END REPLACE
0110
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 3, WP 0344, Table 1, Item 27) Gloves, Chemical and Oil Protective (Volume 3, WP 0344, Table 1, Item 8) Goggles, Industrial (Volume 3, WP 0344, Table 1, Item 10) Suitable Drain Pan Materials/Parts Tape, Antiseizing; 1/2 in. (Volume 3, WP 0343, Table 1, Item 158) Personnel Required Watercraft Engineer 88L (2) References FM 4.01-502 References (cont.) TM 55-1925-273-10 WP 0112 Volume 3, WP 0263 Volume 3, WP 0343 Volume 3, WP 0344 Equipment Condition CLOSE valves FO-6, C.O.V.-F.O. XFER PMP No. 1 SUCTION, FO-7, C.O.V.-F.O. XFER PMP No. 2 SUCTION, FO-8, C.O.V.-F.O. XFER PMP No. 1 DISCHARGE, and FO-9, C.O.V.-F.O. XFER PMP No. 2 DISCHARGE. Lock out and tag out IAW FM 4.01-502.
0110-1
TM 55-1925-273-24&P-2
0110
WARNING
Never reuse locking hardware. Reuse of locking hardware such as lockwashers, locking nuts, cotter pins, and lock wire can result in undetected loosening of fastening hardware causing catastrophic component failure resulting in death, injury, or damage to equipment. Ensure that all locking hardware is discarded upon removal and replaced with new. REMOVAL
WARNING
Diesel fuel is flammable and diesel fuel vapors can be explosive. Ensure all work is performed in a well ventilated area. Keep sparks, open flame, and excessive heat away from the work area. Do not smoke or allow smoking, or any other flame in the vicinity of fuel sounding operations. Wipe clean any fuel spillage and dispose of spilled fuel and fuel-soaked rags in accordance with the appropriate local regulations. Avoid prolonged exposure of the skin to diesel fuel. Protective nitrile gloves and chemical protective goggles must be worn whenever handling diesel fuel or parts which are saturated with diesel fuel. Failure to comply with this warning can result in serious injury or death to personnel. 1. Place a suitable drain pan under the fuel oil transfer pump.
CAUTION
Fuel oil hoses and lines may be under pressure. Loosen fittings on hose lines slowly. Allow fuel oil to run around threads of fitting, releasing pressure before disconnecting fittings. Releasing pressurized fuel oil suddenly may cause severe personal injury. 2. 3. Slowly loosen the pressure gage piping (Figure 1, Item 3) to relieve pressure from the fuel oil transfer pump (Figure 1, Item 7). Allow any fuel oil to drain into the suitable drain pan. After all pressure has been released, remove the pressure gage piping (Figure 1, Item 3) from the fuel oil transfer pump (Figure 1, Item 7).
CAUTION
Never attempt to disconnect union connections with only one wrench. Damage to the vessel's standing piping or to the pump's piping could occur. Always use two wrenches. 4. 5. 6. Disconnect the fuel oil piping at the fuel oil transfer pump (Figure 1, Item 7) inlet and outlet unions (Figure 1, Items 1 and 11). Remove the four bolts (Figure 1, Item 4), four nuts (Figure 1, Item 9), four flat washers (Figure 1, Item 6), and four lockwashers (Figure 1, Item 10) securing the fuel oil transfer pump (Figure 1, Item 7) to its foundation. Remove the fuel oil transfer pump (Figure 1, Item 7) from its foundation.
NOTE
Observe the positioning of the elbows before removing them from the unit. Refer to Figure 1. 7. Remove the inlet (Figure 1, Item 8) and outlet elbows (Figure 1, Item 2) and discharge pressure fittings (Figure 1, Item 5) from the applicable sides of the fuel oil transfer pump (Figure 1, Item 7). Retain the fittings for installation on the new or repaired pump.
0110-2
0110
4 5 6 7 8
11 10 9
Figure 1. END OF TASK INSTALLATION 1. Apply antiseizing tape on the pipe threads of the inlet (Figure 1, Item 8) and outlet elbows (Figure 1, Item 2), and discharge pressure fittings (Figure 1, Item 5). Install the elbows and discharge fittings on the fuel oil transfer pump (Figure 1, Item 7). Position the fuel oil transfer pump (Figure 1, Item 7) on its foundation. Install the four bolts (Figure 1, Item 4), four nuts (Figure 1, Item 9), four flat washers (Figure 1, Item 6), and four lockwashers (Figure 1, Item 10) in the fuel oil transfer pump (Figure 1, Item 7). Do not tighten the bolts at this time. Fuel Oil Transfer Pump.
M1028T73
2. 3.
CAUTION
Never attempt to connect union connections with only one wrench. Damage to the vessel's standing piping or to the pump's piping could occur. Always use two wrenches. 4. 5. 6. Connect and tighten the unions (Figure 1, Items 1 and 11) on the fuel oil transfer pump (Figure 1, Item 7). Tighten the four bolts (Figure 1, Item 4) securing the fuel oil transfer pump (Figure 1, Item 7) to its foundation. Connect the discharge pressure gage piping (Figure 1, Item 3) to fuel oil transfer pump (Figure 1, Item 7) and tighten the piping connection.
END OF TASK
0110-3
TM 55-1925-273-24&P-2
0110
FOLLOW-ON MAINTENANCE 1. 2. 3. 4. Align pump per FUEL OIL TRANSFER PUMP ELECTRIC MOTOR REPLACE motor installation procedure (WP 0112). Remove the lock outs and tag outs IAW FM 4-01.502. Operate the fuel oil transfer pump under usual conditions IAW TM 55-1925-273-10, checking for leaks and proper operation. Return the fuel oil transfer pump to the desired readiness condition.
0110-4
TM 55-1925-273-24&P-2 FIELD MAINTENANCE FUEL OIL TRANSFER PUMP, PUMP END REPAIR
0111
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 3, WP 0344, Table 1, Item 27) Gloves, Chemical and Oil Protective (Volume 3, WP 0344, Table 1, Item 8) Goggles, Industrial (Volume 3, WP 0344, Table 1, Item 10) Locknut, Tool Bearing (Volume 3, WP 0344, Table 1, Item 13) Wrench, Torque, 0-250 lb-ft (0-339 Nm) (Volume 3, WP 0344, Table 1, Item 33) Materials/Parts Cleaning Compound, Solvent (Volume 3, WP 0343, Table 1, Item 37) Grease, Ball and Roller Bearing; 1.75 lb (Volume 3, WP 0343, Table 1, Item 74) Maintenance Kit, Rotary Pump (Volume 3, WP 0336, Figure KITS, Item 2) Personnel Required Watercraft Engineer 88L (1) References TM 55-1925-273-10 WP 0110 Volume 3, WP 0263 Volume 3, WP 0336 Volume 3, WP 0343 Volume 3, WP 0344 Equipment Condition Fuel oil transfer pump removed. (WP 0110)
0111-1
TM 55-1925-273-24&P-2
0111
WARNING
Never reuse locking hardware. Reuse of locking hardware such as lockwashers, locking nuts, cotter pins, and lock wire can result in undetected loosening of fastening hardware causing catastrophic component failure resulting in death, injury, or damage to equipment. Ensure that all locking hardware is discarded upon removal and replaced with new. DISASSEMBLY 1. Remove the relief valve cap (Figure 1, Item 25) from the cover (Figure 1, Item 21).
WARNING
Loosen jamnut slowly. Removing the jamnut suddenly may cause severe personal injury from spring pressure. 2. Loosen the jamnut (Figure 1, Item 23) and remove the adjusting screw (Figure 1, Item 24) and the O-ring (Figure 1, Item 22). Discard O-ring.
WARNING
Do not allow hydraulic fluid, engine oil, or cleaning solvents to come in contact with unprotected skin or eyes. Prolonged skin contact can cause illness or injury. Eye contact can cause serious injury. Always wear chemical protective gloves and goggles when handling hydraulic fluid, engine oil, and cleaning solvents. Failure to follow these precautions can result in illness, serious injury, or death. 3. 4. 5. 6. 7. 8. 9. 10. Remove the cover (Figure 1, Item 21) from the casing (Figure 1, Item 26). Remove the O-ring (Figure 1, Item 20) from the cover (Figure 1, Item 21). Discard O-ring. Remove the washer (Figure 1, Item 19), the spring (Figure 1, Item 18), and the valve (Figure 1, Item 17) from the casing (Figure 1, Item 26). Remove the woodruff key (Figure 1, Item 42) from the rotor and shaft assembly (Figure 1, Item 43). Remove the grease fitting (Figure 1, Item 36) from the inboard bearing cover (Figure 1, Item 34). Remove the grease fitting relief (Figure 1, Item 33) from the inboard bearing cover (Figure 1, Item 34). Remove the capscrews (Figure 1, Item 35) from the inboard bearing cover (Figure 1, Item 34). Slide the inboard bearing cover (Figure 1, Item 34), inboard bearing cover gasket (Figure 1, Item 31), and the grease seal (Figure 1, Item 32) off the rotor and shaft assembly (Figure 1, Item 43). Discard bearing cover gasket and grease seal. Remove the capscrews (Figure 1, Item 37) from the inboard head (Figure 1, Item 27) and slide the head off the rotor and shaft assembly (Figure 1, Item 43). Remove the bearing lockwasher (Figure 1, Item 29) and the bearing locknut (Figure 1, Item 30) using a locknut tool. Discard bearing lockwasher. Remove the grease fitting (Figure 1, Item 12) from the outboard bearing cover (Figure 1, Item 11). Remove the grease fitting relief (Figure 1, Item 14) from the outboard bearing cover (Figure 1, Item 11). Remove the capscrews (Figure 1, Item 13) from the outboard bearing cover (Figure 1, Item 11).
11. 12. 13. 14. 15.
0111-2
TM 55-1925-273-24&P-2 DISASSEMBLY - Continued 16.
0111
Slide the outboard bearing cover (Figure 1, Item 11) and the outboard bearing cover gasket (Figure 1, Item 10) off the rotor and shaft assembly (Figure 1, Item 43). Discard outboard bearing cover gasket. Remove the capscrews (Figure 1, Item 16) from the outboard head (Figure 1, Item 7) and slide the outboard head off the rotor and shaft assembly (Figure 1, Item 43). Remove the lockwasher (Figure 1, Item 8) and the bearing locknut (Figure 1, Item 9) from the rotor and shaft assembly (Figure 1, Item 43) using a locknut wrench. Discard lockwasher. Remove the ball bearing (Figure 1, Item 28) from the inboard head (Figure 1, Item 27). Remove the ball bearing (Figure 1, Item 15) from the outboard head (Figure 1, Item 7). Remove the mechanical seal (Figure 1, Item 41) from the rotor and shaft assembly (Figure 1, Item 43). Remove the remaining mechanical seal (Figure 1, Item 6) from the opposite side of the pump. Carefully remove the disc (Figure 1, Item 40) and the head O-ring (Figure 1, Item 39). Discard head O-ring. Carefully remove the disc (Figure 1, Item 5) and the head O-ring (Figure 1, Item 4). Discard head O-ring. Remove the rotor and shaft assembly (Figure 1, Item 43) from the casing (Figure 1, Item 26) with one hand cupped underneath the assembly to keep the vanes (Figure 1, Item 1) and the push rods (Figure 1, Item 44) from falling out. Remove the vanes (Figure 1, Item 1) and the push rods (Figure 1, Item 44) from the rotor and shaft assembly (Figure 1, Item 43). Remove the liner (Figure 1, Item 38) from the casing (Figure 1, Item 26). Remove the gage plug (Figure 1, Item 3) and the liner setscrew (Figure 1, Item 2) from the casing (Figure 1, Item 26).
17. 18. 19. 20. 21. 22. 23. 24. 25.
26. 27. 28.
0111-3
0111
12 11 10 9 8 7 6 5 4 1 2 44 43 42 41
OUTBOARD SIDE
13 3 15 16 14
17 18 19 20 40 39 21 22 23 24 38 37 36 35 26 25
27 28 29 34 32 33
Figure 1. END OF TASK Fuel Oil Transfer Pump (Exploded View).
30 31
INBOARD SIDE
M1029T73
0111-4
0111
WARNING
Cleaning solvent is flammable and its vapor is potentially explosive. Do not use cleaning solvent in the vicinity of spark, open flame, or excessive heat. Do not use cleaning solvent in unventilated spaces. Always wear chemical protective gloves and goggles when handling hydraulic fluid, engine oil, and cleaning solvents. Failure to comply with this warning can result in serious injury or death. 1. 2. Using cleaning solvent, clean all the removed parts. Check for burrs on the liner (Figure 1, Item 35), the rotor and shaft assembly (Figure 1, Item 43), the casing (Figure 1, Item 26), and all other removed parts. Inspect all component parts for unusual wear or damage, and replace as required.
END OF TASK ASSEMBLY 1. Install the liner (Figure 1, Item 38) into the casing (Figure 1, Item 26).
NOTE
The word "INTAKE" cast on the liner must face the intake port of the pump casing. 2. 3. 4. Align the liner (Figure 1, Item 38) keyway with the liner setscrew (Figure 1, Item 2) bore that extends down into the casing (Figure 1, Item 26) and slide the liner in the casing. Uniformly tap the outer edge of the liner (Figure 1, Item 38) with a rubber mallet to fully insert into the casing (Figure 1, Item 26). Install the setscrew (Figure 1, Item 2) and gage plug (Figure 1, Item 3). Place the disc (Figure 1, Item 5) against the liner (Figure 1, Item 38) with the seal cavity outward and disc relief hole located as shown in Figure 2.
INTAKE
DISCHARGE
45 RELIEF HOLE POSITION

Figure 2. Fuel Oil Transfer Pump.
M1030T73
0111-5
TM 55-1925-273-24&P-2 ASSEMBLY - Continued 5. 6.
0111
Without installing the head O-ring (Figure 1, Item 4), temporarily attach the outboard head (Figure 1, Item 7) and the bearing (Figure 1, Item 30) in the casing (Figure 1, Item 26). Install and hand tighten two capscrews (Figure 1, Item 16), 180 degrees apart. The outboard head (Figure 1, Item 7) will be used to hold and align the rotor and shaft assembly (Figure 1, Item 43) while the inboard side of the pump is being assembled.
NOTE
Use care when handling the rotor and shaft assembly while installing the vanes and push rods. 7. Insert the vanes (Figure 1, Item 1) in the bottom two rotor slots with the relief grooves facing in the direction of pump rotation and the rounded edges outward. Refer to Figure 3.
ROUNDED EDGE OUT
RELIEF GROOVES FACE IN DIRECTION OF ROTATION
M1031T73
Figure 3. 8. 9. 10. 11. 12.
Rotor/Vane Orientation.
Hold the vanes (Figure 1, Item 1) in place while installing the push rods (Figure 1, Item 44) in the rotor and shaft assembly (Figure 1, Item 43). Install the rotor and shaft assembly (Figure 1, Item 43) in the casing (Figure 1, Item 26) and install the remaining two vanes (Figure 1, Item 1) in the rotor. Install an inboard head O-ring (Figure 1, Item 39) on the disc (Figure 1, Item 40). Install the disc (Figure 1, Item 40) with the seal cavity facing outward on the inboard side of the pump. The disc relief hole should be located as shown in Figure 2. Install the mechanical seal (Figure 1, Item 41) on the rotor shaft assembly (Figure 1, Item 43) as illustrated in Figure 4.
0111-6
TM 55-1925-273-24&P-2 ASSEMBLY - Continued
0111
M1032T73
Figure 4. 13. 14.
Mechanical Seal.
Install the inboard head (Figure 1, Item 27) on the rotor and shaft assembly (Figure 1, Item 43). Position the inboard head (Figure 1, Item 27) with the small weep hole towards the bottom of the pump. Install and uniformly tighten the capscrews (Figure 1, Item 40) 90 degrees apart. Torque the capscrews to 30 lb-ft (41 Nm). Hand pack the ball bearing (Figure 1, Item 28) with grease.
15.
NOTE
The bearing balls should face outward, with the grease shield inward. The bearing must be fully and squarely seated in the head. 16. 17. 18. 19. 20. Install the bearing (Figure 1, Item 28) in the inboard head (Figure 1, Item 27). Turn the casing (Figure 1, Item 26) around and remove the outboard head (Figure 1, Item 7). Install an outboard head O-ring (Figure 1, Item 4) on the disc (Figure 1, Item 5). Install the disc (Figure 1, Item 5) on the rotor and shaft assembly (Figure 1, Item 43). Install the mechanical seal (Figure 1, Item 6) on the rotor and shaft assembly (Figure 1, Item 43) as illustrated in Figure 4.
NOTE
The bearing balls should face outward, with the grease shield inward. The bearing must be fully and squarely seated in the head. 21. 22. 23. Hand pack the bearing (Figure 1, Item 15) with grease and install it in the outboard head (Figure 1, Item 7). Install the outboard head (Figure 1, Item 7) on the casing (Figure 1, Item 26). Lightly tap the rims of the inboard head (Figure 1, Item 27) and the outboard head (Figure 1, Item 7) with a soft-faced mallet into the correct position until the rotor and shaft assembly (Figure 1, Item 43) does not turn freely. Install the remaining capscrews (Figure 1, Items 16 and 37) to secure the inboard head (Figure 1, Item 27) and the outboard head (Figure 1, Item 7). Uniformly torque the capscrews to 30 lb-ft (41 Nm).
24.
0111-7
0111
CAUTION
It is important that the bearing locknuts and bearing lockwashers are installed and adjusted properly. Over tightening locknuts can cause bearing failure or a broken lockwasher tang. Loose locknuts will allow the rotor on the shaft and rotor assembly to shift against the discs causing premature wear.
NOTE
Ensure the inner tang "A" of the bearing lockwasher is located in the slot of the shaft and rotor assembly threads, bending the bearing lockwasher slightly, if necessary. 25. On the inboard end of the shaft and rotor assembly (Figure 1, Item 43), install a bearing lockwasher (Figure 1, Item 35) with the tangs facing outwards and the bearing locknut (Figure 1, Item 30) with the tapered end inward. On the outboard end of the shaft and rotor assembly (Figure 1, Item 43), install a bearing lockwasher (Figure 1, Item 8) with the tangs facing outwards and the bearing locknut (Figure 1, Item 9) with the tapered end inward.
26.
CAUTION
Do not over tighten, bend, or shear the lockwasher inner tang. 27. 28. 29. 30. Using the locknut tool, tighten both bearing locknuts (Figure 1, Items 9 and 30) to ensure that the bearings (Figure 1, Items 15 and 28) are bottomed in the outboard and inboard head's (Figure 1, Items 7 and 27) recess. Using the locknut tool, loosen both bearing locknuts (Figure 1, Items 9 and 30) one complete turn. Using the locknut tool, tighten the bearing locknut (Figure 1, Item 30) until a slight drag is felt when turning the shaft and rotor assembly (Figure 1, Item 43) by hand. Using the locknut tool, back off the bearing locknut (Figure 1, Item 30) the width of one lockwasher tang "B" (Figure 5). Secure the bearing locknut by bending the closest aligned bearing lockwasher tang into the slot in the bearing locknut. The pump should turn freely when rotated by hand.
2 STOPS EQUALS 1 TANG. WIDTH
SE
_ A
TI G
HT
1 STOP EQUALS .001 IN. (.025 MM) ROTOR MOVEMENT
LO O
Figure 5.
0111-8
EN
Vane.
M1033T73
TM 55-1925-273-24&P-2 ASSEMBLY - Continued 31. 32. 33. 34.
0111
Tighten the bearing locknut (Figure 1, Item 9) by hand until it is snug against the bearing (Figure 1, Item 15). Using the locknut tool, tighten the bearing locknut (Figure 1, Item 9) the width of one lockwasher tang. Refer to Figure 5. Using the locknut tool, tighten the bearing locknut (Figure 1, Item 9) just past the desired tang, then back off the locknut to align the tang with the locknut slot. Refer to Figure 5. Secure the bearing locknut (Figure 1, Item 9) by bending the aligned bearing lockwasher (Figure 1, Item 8) tang into the slot in the bearing locknut (Figure 1, Item 9). The assembly should continue to turn freely when rotated by hand. Check the adjustment by grasping the bearing locknut (Figure 1, Item 9) and the bearing lockwasher (Figure 1, Item 8) and rotating them back and forth. If this cannot be accomplished, one or both bearing locknuts (Figure 1, Item 9 or 27) are too tight. Alternately loosen the bearing locknuts one stop at a time 0.001 in. (0.0254 mm) (Figure 5) until the correct adjustment is achieved. Grease the outside diameter of the grease seal (Figure 1, Item 32) with grease and install it in the inboard bearing cover (Figure 1, Item 34) with the lip of the grease seal inward (towards the pump). Install a bearing cover gasket (Figure 1, Item 31) on the inboard head (Figure 1, Item 27). Install the inboard bearing cover (Figure 1, Item 34) on the inboard head (Figure 1, Item 27). Install a bearing cover gasket (Figure 1, Item 10) on the outboard head (Figure 1, Item 7). Install the outboard bearing cover (Figure 1, Item 11) on the outboard head (Figure 1, Item 7). Install and torque the capscrews (Figure 1, Item 35) to 30 lb-ft (41 Nm). Install and torque the capscrews (Figure 1, Item 13) to 30 lb-ft (41 Nm). Install the grease fitting (Figure 1, Item 12) in the outboard bearing cover (Figure 1, Item 11). Install the grease fitting relief (Figure 1, Item 14) in the outboard bearing cover (Figure 1, Item 11). Install the grease fitting (Figure 1, Item 36) in the inboard bearing cover (Figure 1, Item 34). Install the grease fitting relief (Figure 1, Item 33) in the inboard bearing cover (Figure 1, Item 34). Install the valve (Figure 1, Item 17), the spring (Figure 1, Item 18), and the washer (Figure 1, Item 19) in the casing (Figure 1, Item 26). Install an O-ring (Figure 1, Item 20) on the cover (Figure 1, Item 21). Install the cover (Figure 1, Item 21) on the casing (Figure 1, Item 26). Install the adjusting screw (Figure 1, Item 14), jamnut (Figure 1, Item 23), and an O-ring (Figure 1, Item 22) in the cover (Figure 1, Item 21). Install the relief valve cap (Figure 1, Item 25) on the cover (Figure 1, Item 21).
35.
36. 37. 38. 39. 40. 41. 42. 43. 44. 45. 46. 47. 48. 49. 50. 51.
END OF TASK
0111-9
TM 55-1925-273-24&P-2
0111
FOLLOW-ON MAINTENANCE 1. 2. Install the fuel oil transfer pump (WP 0110). Operate the fuel oil transfer pump under usual conditions IAW TM 55-1925-273-10 and check for proper operation. If the fuel oil transfer pump discharge pressure requires adjustment, loosen the jamnut (Figure 1, Item 23) and turn the adjusting screw (Figure 1, Item 24) clockwise to increase discharge pressure or counterclockwise to decrease discharge pressure. Return the fuel oil transfer pump to the desired readiness condition.
3.
0111-10
TM 55-1925-273-24&P-2 FIELD MAINTENANCE FUEL OIL TRANSFER PUMP ELECTRIC MOTOR REPLACE
0112
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 3, WP 0344, Table 1, Item 27) Multimeter (Volume 3, WP 0344, Table 1, Item 15) Materials/Parts N/A Personnel Required Watercraft Engineer 88L (2) References FM 4-01-502 TM 55-1925-273-10 References (cont.) Volume 3, WP 0264 Volume 3, WP 0344 Equipment Condition For fuel oil transfer pump 2, set to OFF the FUEL OIL TRANSFER PUMP No. 2. circuit breaker (LT 803 Only), or the LVP FOR FUEL OIL TRANSFER PUMP No. 2. circuit breaker (All Other Vessels) in 440 V power panel No. 1. Lock out and tag out IAW FM 4-01.502. For fuel oil transfer pump 1, set to OFF the FUEL OIL XFER PUMP No. 1. circuit breaker on the emergency switchboard. Lock out and tag out IAW FM 4-01.502.
0112-1
TM 55-1925-273-24&P-2
0112
WARNING
NOTE
Electrical junction boxes may vary in size, shape, and mounting position of the box on the motor frame. Electrical junction box covers may vary in number and placement of screws holding the cover in place. 1. 2. Remove the four screws (Figure 1, Item 1) holding the electrical junction box cover (Figure 1, Item 2). Remove the electrical junction box cover (Figure 1, Item 2).
2 1
M1034T73
Figure 1.
WARNING
Replace or repair components only after the affected circuit has been secured, locked out, and tagged out IAW FM 4-01.502. Performing replacement with the circuit energized may result in injury. 3. Using a multimeter, check for voltage at the wiring terminals. If voltage is present, ensure that the proper circuit breaker is set to OFF, locked out, and tagged out IAW FM 4.01-502. If no voltage is present, continue with the procedure.
0112-2
TM 55-1925-273-24&P-2 REMOVAL - Continued 4. 5. 6. 7. 8. 9. 10. 11. Label and disconnect the electrical wiring. Remove the two bolts (Figure 2, Item 5), two lockwashers (Figure 2, Item 6), and two flat washers (Figure 2, Item 7) from coupling guard (Figure 2, Item 8). Discard lockwashers. Remove the coupling guard (Figure 2, Item 8). Loosen the motor coupling flange setscrew (Figure 2, Item 3). Slide the motor coupling flange (Figure 2, Item 4) towards the motor (Figure 2, Item 2). Remove the four bolts (Figure 2, Item 1), four lockwashers (Figure 2, Item 12), and four flat washers (Figure 2, Item 11). Discard lockwashers. Remove the motor (Figure 2, Item 2) from the foundation (Figure 2, Item 10). Slide the motor coupling flange (Figure 2, Item 4) off the motor shaft (Figure 2, Item 9).
0112
5
3 2
6 7 8
1 4
12 11
10 9
M2003T73
Figure 2. END OF TASK INSTALLATION 1. 2. 3.
Coupling Guard.
Slide the motor coupling flange (Figure 2, Item 4) onto the motor shaft (Figure 2, Item 9) with the flat end towards the motor (Figure 2, Item 2) housing. Position the motor (Figure 2, Item 2) on the foundation (Figure 2, Item 10) with the mounting holes aligned. Install four bolts (Figure 2, Item 1), four lockwashers (Figure 2, Item 12), and four flat washers (Figure 2, Item 11). Do not tighten at this time.
0112-3
TM 55-1925-273-24&P-2 INSTALLATION - Continued 4. 5. 6. Align the pump coupling flange and the motor coupling flange together leaving approximately 0.016 in. (0.41 mm) space between the ends of both flanges. Refer to Figure 3. Check the alignment between the pump coupling flange and the motor coupling flange.
0112
The maximum angular offset shall be 1 degree and maximum parallel offset shall be 0.015 in. (0.381 mm). Refer to Figure 3.
STRAIGHT EDGE PUMP COUPLING FLANGE MOTOR COUPLING FLANGE
OPTIMUM GAP BETWEEN FLANGES 0.016 IN. (0.41 MM) 1 MAXIMUM ANGULAR OFFSET
PUMP
0.015 IN. (0.381 MM) MAXIMUM PARALLEL OFFSET
MOTOR PUMP COUPLING FLANGE MOTOR COUPLING FLANGE

M1037T73
Figure 3. Alignment of Pump Coupling Flange and Motor Coupling Flange. 7. 8. 9. 10. 11. Tighten the motor coupling flange setscrew (Figure 2, Item 3). Tighten the four bolts (Figure 2, Item 1). Install the coupling guard (Figure 2, Item 8) and secure it with two bolts (Figure 2, Item 5), two lockwashers (Figure 2, Item 6), and two flat washers (Figure 2, Item 7). Connect the electrical wiring using the labels from Step (4) of REMOVAL as a guide. Remove the labels. Install the electrical junction box cover (Figure 1, Item 2) and secure it with the four screws (Figure 1, Item 1).
END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. Remove the lock outs and tag outs IAW FM 4-01.502. Operate the fuel oil transfer pump under usual conditions IAW TM 55-1925-273-10 and check for proper operation. Return the fuel oil transfer pump to the desired readiness condition.
0112-4
TM 55-1925-273-24&P-2 FIELD MAINTENANCE FUEL OIL FILTER/WATER SEPARATOR (ENGINES) SERVICE
0113
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 3, WP 0344, Table 1, Item 27) Gloves, Chemical and Oil Protective (Volume 3, WP 0344, Table 1, Item 8) Goggles, Industrial (Volume 3, WP 0344, Table 1, Item 10) Suitable Drain Pan Materials/Parts Cleaning Compound, Solvent (Volume 3, WP 0343, Table 1, Item 37) Rag, Wiping (Volume 3, WP 0343, Table 1, Item 132) Tape, Antiseizing; 1/2 in. (Volume 3, WP 0343, Table 1, Item 158) Packing, Preformed (O-ring) (Volume 3, WP 0265, Figure 17, Item 3) Qty: 1 Gasket (Volume 3, WP 0265, Figure 17, Item 5) Qty: 2 Materials/Parts (cont.) Filter Element, Fluid (Volume 3, WP 0265, Figure 17, Item 6) Qty: 1 O-ring (Volume 3, WP 0265, Figure 17, Item 10) Qty: 1 Personnel Required Watercraft Engineer 88L (1) References FM 4-01.502 Volume 3, WP 0265 Volume 3, WP 0343 Volume 3, WP 0344 Equipment Condition Affected fuel oil filter/water separator isolated from the fuel oil system, locked out, and tagged out IAW FM 4-01.502.
0113-1
TM 55-1925-273-24&P-2
0113
SERVICE
WARNING
Diesel fuel is flammable and diesel fuel vapors can be explosive. Ensure all work is performed in a well ventilated area. Keep sparks, open flame, and excessive heat away from the work area. Do not smoke or allow smoking, or any other flame in the vicinity of fuel sounding operations. Wipe clean any fuel spillage and dispose of spilled fuel and fuel-soaked rags in accordance with the appropriate local regulations. Avoid prolonged exposure of the skin to diesel fuel. Protective nitrile gloves and chemical protective goggles must be worn whenever handling diesel fuel or parts which are saturated with diesel fuel. Failure to comply with this warning can result in serious injury or death to personnel. 1. 2. 3. 4. 5. 6. 7. Position a suitable drain pan beneath the fuel oil filter/water separator. Remove the tee handle (Figure 1, Item 2) and the O-ring (Figure 1, Item 3) from the cover (Figure 1, Item 4). Discard O-ring. Remove the cover (Figure 1, Item 4) and the gasket (Figure 1, Item 1). Discard gasket. Grasp the molded handle on top of the filter element (Figure 1, Item 11) and remove the filter element from the body (Figure 1, Item 10) by slowly twisting and pulling upward. Remove the drain valve (Figure 1, Item 8) and O-ring (Figure 1, Item 7) from the bowl (Figure 1, Item 5). Discard O-ring. Flush the body (Figure 1, Item 10) and bowl (Figure 1, Item 5) with clean diesel fuel. If contamination is still present in the bowl (Figure 1, Item 5) after flushing, remove the bowl retainer screws (Figure 1, Item 9), and remove the retaining ring (Figure 1, Item 6) and gasket (Figure 1, Item 1) from the body (Figure 1, Item 10). Discard gasket.
WARNING
Do not allow hydraulic fluid, engine oil, or cleaning solvents to come in contact with unprotected skin or eyes. Prolonged skin contact can cause illness or injury. Eye contact can cause serious injury. Always wear chemical protective gloves and goggles when handling hydraulic fluid, engine oil, and cleaning solvents. Failure to follow these precautions can result in illness, serious injury, or death. 8. 9. 10. 11. 12. 13. Remove the bowl (Figure 1, Item 5) and clean it with cleaning solvent. Dry the bowl with clean wiping rags. Install a gasket (Figure 1, Item 1) on the bowl (Figure 1, Item 5). Position the bowl (Figure 1, Item 5) on the body (Figure 1, Item 10) and secure the bowl to the body with the retaining ring (Figure 1, Item 6) and retainer screws (Figure 1, Item 9). Replace the drain valve (Figure 1, Item 8) using an O-ring (Figure 1, Item 7). Install a filter element (Figure 1, Item 11) into the body (Figure 1, Item 10) using a twisting, downward motion. Prime the fuel oil filter/water separator by filling it with clean diesel fuel.
0113-2
TM 55-1925-273-24&P-2 SERVICE - Continued 14. 15. 16. 17. Install a gasket (Figure 1, Item 1) on the cover (Figure 1, Item 4). Install the cover (Figure 1, Item 4) on the body (Figure 1, Item 10). Install the O-ring (Figure 1, Item 3) in the cover (Figure 1, Item 4). Install the tee handle (Figure 1, Item 2) into the cover (Figure 1, Item 4).
0113
3 11 4
1 10 5
6 7 8
9
Figure 1. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. Remove the lock outs and tag outs IAW FM 4-01.502.
M1038T73
Fuel Oil Filter/Water Separator.
Place the fuel oil filter/water separator back online and check for fuel leaks. Return the fuel oil filter/water separator to the desired readiness condition.
0113-3/4 blank
TM 55-1925-273-24&P-2 FIELD MAINTENANCE FUEL OIL FILTER/WATER SEPARATOR (ENGINES) REPAIR
0114
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 3, WP 0344, Table 1, Item 27) Gloves, Chemical and Oil Protective (Volume 3, WP 0344, Table 1, Item 8) Goggles, Industrial (Volume 3, WP 0344, Table 1, Item 10) Suitable Drain Pan Materials/Parts Cleaning Compound, Solvent (Volume 3, WP 0343, Table 1, Item 37) Rag, Wiping (Volume 3, WP 0343, Table 1, Item 132) Tape, Antiseizing; 1/2 in. (Volume 3, WP 0343, Table 1, Item 158) Packing, Preformed (O-ring) (Volume 3, WP 0265, Figure 17, Item 3) Qty: 1 Gasket (Volume 3, WP 0265, Figure 17, Item 5) Qty: 2 Materials/Parts (cont.) Filter Element, Fluid (Volume 3, WP 0265, Figure 17, Item 6) Qty: 1 O-ring (Volume 3, WP 0265, Figure 17, Item 10) Qty: 1 Personnel Required Watercraft Engineer 88L (1) References FM 4-01.502 TM 55-1925-273-10 Volume 3, WP 0265 Volume 3, WP 0343 Volume 3, WP 0344 Equipment Condition Affected fuel oil filter/water separator isolated from the fuel oil system, locked out, and tagged out IAW FM 4-01.502.
0114-1
TM 55-1925-273-24&P-2
0114
DISASSEMBLY
WARNING
Diesel fuel is flammable and diesel fuel vapors can be explosive. Ensure all work is performed in a well ventilated area. Keep sparks, open flame, and excessive heat away from the work area. Do not smoke or allow smoking, or any other flame in the vicinity of fuel sounding operations. Wipe clean any fuel spillage and dispose of spilled fuel and fuel-soaked rags in accordance with the appropriate local regulations. Avoid prolonged exposure of the skin to diesel fuel. Protective nitrile gloves and chemical protective goggles must be worn whenever handling diesel fuel or parts which are saturated with diesel fuel. Failure to comply with this warning can result in serious injury or death to personnel. 1. 2. 3. 4. 5. 6. Position a suitable drain pan beneath the fuel oil filter/water separator. Remove the tee handle (Figure 1, Item 2) and the O-ring (Figure 1, Item 3) from the cover (Figure 1, Item 4). Discard O-ring. Remove the cover (Figure 1, Item 4) and the gasket (Figure 1, Item 1). Discard gasket. Grasp the molded handle on top of the filter element (Figure 1, Item 11) and remove the filter element from the body (Figure 1, Item 10) by slowly twisting and pulling upward. Remove the drain valve (Figure 1, Item 8) and O-ring (Figure 1, Item 7) from the bowl (Figure 1, Item 5). Discard O-ring. Remove the bowl retainer screws (Figure 1, Item 9) and the retaining ring (Figure 1, Item 6), bowl (Figure 1, Item 5), and gasket (Figure 1, Item 1) from the body (Figure 1, Item 10). Discard gasket.
END OF TASK INSPECT 1. Inspect the bowl (Figure 1, Item 5) and the cover (Figure 1, Item 4) for any obvious damage such as scratches, cracks, or deformations that could prevent proper mating of sealing surfaces that permit fuel leakage. Replace any defective parts. Inspect the bowl (Figure 1, Item 5) and the cover (Figure 1, Item 4) O-ring grooves for distortion, burrs, or corrosion, which might damage O-rings during installation, operation, or could prevent proper mating of sealing surfaces that permit fuel leakage. Replace any defective parts.
2.
END OF TASK ASSEMBLY 1. 2. 3. 4. Install a gasket (Figure 1, Item 1) on the bowl (Figure 1, Item 5). Secure the bowl to the body (Figure 1, Item 10) with the retaining ring (Figure 1, Item 6) and retainer screws (Figure 1, Item 9). Replace the drain valve (Figure 1, Item 8) using an O-ring (Figure 1, Item 7). Install a filter element (Figure 1, Item 11) into the body (Figure 1, Item 10) using a twisting, downward motion. Prime the fuel oil filter/water separator by filling it with clean diesel fuel.
0114-2
TM 55-1925-273-24&P-2 ASSEMBLY - Continued 5. 6. 7. Install the cover (Figure 1, Item 4) with a gasket (Figure 1, Item 1) on the body (Figure 1, Item 10). Install the O-ring (Figure 1, Item 3) in the cover (Figure 1, Item 4). Install the tee handle (Figure 1, Item 2).
1 2
0114
3 11 4
1 10 5
6 7 8
M1039T73
Figure 1. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. 4.
Fuel Oil Filter/Water Separator.
Remove the lock outs and tag outs IAW FM 4-01.502. Operate the fuel oil transfer system under usual conditions IAW TM 55-1925-273-10. Check the fuel oil filter/water separator for leaks and proper operation. Return the equipment to the desired readiness condition.
0114-3/4 blank
TM 55-1925-273-24&P-2 FIELD MAINTENANCE ENGINE INTAKE/EXHAUST SYSTEM COMPONENTS REPLACE
0115
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 3, WP 0344, Table 1, Item 27) Faceshield, Industrial (Volume 3, WP 0344, Table 1, Item 5) Gloves, Chemical and Oil Protective (Volume 3, WP 0344, Table 1, Item 8) Gloves, Leather (Volume 3, WP 0344, Table 1, Item 9) Goggles, Industrial (Volume 3, WP 0344, Table 1, Item 10) Suitable Drain Pan Materials/Parts Cleaning Compound, Solvent (Volume 3, WP 0343, Table 1, Item 37) Tape, Antiseizing; 1/2 in. (Volume 3, WP 0343, Table 1, Item 158) Personnel Required Watercraft Engineer 88L (2) References FM 4-01.502 References (cont.) MIL-STD-769 S9086-VH-STM-010/CH-635 Volume 3, WP 0266 Volume 3, WP 0343 Volume 3, WP 0344 Equipment Condition For starboard main engine, CLOSE valve CA-9, STG AIR TO ME #1. Lock out and tag out IAW FM 4-01.502. For port engine, CLOSE valve CA-8, STG AIR TO ME #2. Lock out and tag out IAW FM 4-01.502.
0115-1
TM 55-1925-273-24&P-2
0115
AIR BOX DRAIN VALVE REMOVAL 1. 2. 3. Place a suitable drain pan under the air box drain valve (Figure 1, Item 2). Remove the lower drain pipe (Figure 1, Item 3) from the air box drain valve (Figure 1, Item 2). Remove the air box drain valve (Figure 1, Item 2) from the upper drain pipe (Figure 1, Item 1).
M1390T73
Figure 1. Air Box Drain Valve (Typical). END OF TASK
0115-2
TM 55-1925-273-24&P-2
0115
AIR BOX DRAIN VALVE INSTALLATION
WARNING
Wire brushing operations can produce high velocity flying debris which can become lodged in the skin or in the eyes. Wire brushing in confined areas can result in debris flying from unexpected directions. All personnel working in the area must wear protective faceshield, gloves, and long sleeves when performing wire brushing operations. Failure to comply with this warning can result in serious injury or death to personnel. 1. Using a wire brush, clean the remnants of antiseizing tape from the male thread connections of both the upper drain pipe (Figure 1, Item 1) and the lower drain pipe (Figure 1, Item 3).
WARNING
Cleaning solvent is flammable and its vapor is potentially explosive. Do not use cleaning solvent in the vicinity of spark, open flame, or excessive heat. Do not use cleaning solvent in unventilated spaces. Always wear chemical protective gloves and goggles when handling hydraulic fluid, engine oil, and cleaning solvents. Failure to comply with this warning can result in serious injury or death. 2. 3. 4. 5. 6. Apply antiseizing tape to the male pipe threads of the upper drain pipe (Figure 1, Item 1). Install the air box drain valve (Figure 1, Item 2) onto the upper drain pipe (Figure 1, Item 1). Apply antiseizing tape to the male pipe threads of the lower drain pipe (Figure 1, Item 3). Install the lower drain pipe (Figure 1, Item 3) into the air box drain valve (Figure 1, Item 2). Perform the FOLLOW-ON MAINTENANCE procedure at the end of this work package.
END OF TASK
0115-3
TM 55-1925-273-24&P-2
0115
INSULATION REPLACE
WARNING
Insulation is a skin and eye irritant. Wear goggles to protect eyes. Wearing loose-fitting, long-sleeved, and long-legged clothing is recommended to prevent skin irritation. Wearing gloves is also recommended. Skin irritation cannot occur if there is no direct contact between insulation and skin. Failure to comply with this warning can result in serious injury or death. Always wear heavy leather gloves when handling hot engine components. Handling hot engine components with bare hands or skin may result in severe burns. Failure to comply with this warning can result in serious injury or death. 1. 2. Refer to MIL-STD-769 and S9086-VH-STM-010/CH-635 for repair and replacement of insulation. All insulation replacement must be conducted IAW these publications. Perform the FOLLOW-ON MAINTENANCE procedure at the end of this work package.
END OF TASK FOLLOW-ON MAINTENANCE 1. Remove the lock outs and tag outs IAW FM 4-01.502.
WARNING
Use protective goggles, faceshield, and necessary precautions to avoid personal injury. Ensure the valve is in the OPEN position before applying any fluid pressure. Sudden pressurization may rupture the new valve. Failure to comply with this warning can result is serious injury or death. 2. 3. Operate the affected main engine IAW TM 55-1925-273-10. Cycle air box drain valve from CLOSED to OPEN several times while observing connections for leakage. Ensure that the air box drains when the valve is OPEN. There shall be no leakage when the air box drain valve is CLOSED.
0115-4
TM 55-1925-273-24&P-2 FIELD MAINTENANCE LUBE OIL SYSTEM VALVES REPLACE
0116
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 3, WP 0344, Table 1, Item 27) Faceshield, Industrial (Volume 3, WP 0344, Table 1, Item 5) Gloves, Chemical and Oil Protective (Volume 3, WP 0344, Table 1, Item 8) Goggles, Industrial (Volume 3, WP 0344, Table 1, Item 10) Suitable Drain Pan Materials/Parts Cleaning Compound, Solvent (Volume 3, WP 0343, Table 1, Item 37) Rag, Wiping (Volume 3, WP 0343, Table 1, Item 132) Tape, Antiseizing; 1/2 in. (Volume 3, WP 0343, Table 1, Item 158) Personnel Required Watercraft Engineer 88L (2) References FM 4-01.502 MIL-STD-769 S9086-VH-STM-010/CH-635 References (cont.) TM 55-1925-273-10 Volume 3, WP 0267 Volume 3, WP 0343 Volume 3, WP 0344 Equipment Condition Set to OFF the LUBE OIL TRANSFER PUMP. circuit breaker (LT 803 Only), or the LVP FOR LUBE OIL TRANSFER PUMP circuit breaker (All Other Vessels) in 440 V power panel No. 1. Lock out and tag out IAW FM 4-01.502. Set to OFF the MAIN ENGINE LUBE OIL PRIMING PUMP No. 1 or the MAIN ENGINE LUBE OIL PRIMING PUMP No. 2. circuit breaker (LT 803 Only), or the CONTROLLER FOR STARBOARD MAIN ENGINE LUBE OIL PRIMING PUMP No. 1 circuit breaker, or the CONTROLLER FOR PORT MAIN ENGINE LUBE OIL PRIMING PUMP No. 2 circuit breaker (All Other Vessels) in 440 V power panel No. 1. Lock out and tag out IAW FM 4-01.502. CLOSE all affected valves upstream and downstream of the valve being replaced. Lock out and tag out IAW FM 4-01.502.
0116-1
TM 55-1925-273-24&P-2
0116
WARNING
NOTE
The valve replacement procedures in this work package are for typical valves used in the lube oil system. Actual removal and installation of the valves in this work package may differ slightly from the procedures as written. TYPICAL 1 IN. BALL VALVE (FLANGE) REMOVAL 1. Place a suitable drain pan under the ball valve (Figure 1, Item 3).
WARNING
Do not allow hydraulic fluid, engine oil, or cleaning solvents to come in contact with unprotected skin or eyes. Prolonged skin contact can cause illness or injury. Eye contact can cause serious injury. Always wear chemical protective gloves and goggles when handling hydraulic fluid, engine oil, and cleaning solvents. Failure to follow these precautions can result in illness, serious injury, or death. Hydraulic hoses and lines may be under pressure. Relieve pressure by operating the appropriate control valve, if possible. Loosen fittings on hoses and lines slowly. Allow oil to run around threads of fitting, releasing pressure before disconnecting fitting. Releasing pressurized oil suddenly may cause serious injury or death. 2. 3. 4. 5. 6. 7. Slowly loosen the four bolts (Figure 1, Item 4), and allow any pressure to vent and fluid to drain into the suitable drain pan. Remove the four bolts (Figure 1, Item 4) and the four nuts (Figure 1, Item 1). Remove gasket (Figure 1, Item 2). Loosen and remove the four bolts (Figure 1, Item 7) and the four nuts (Figure 1, Item 5) on the opposite side of the ball valve (Figure 1, Item 3). Remove the ball valve (Figure 1, Item 3) from the vessel's piping. Remove gasket (Figure 1, Item 6).
END OF TASK
0116-2
TM 55-1925-273-24&P-2
0116
TYPICAL 1 IN. BALL VALVE (FLANGE) INSTALLATION
WARNING
Removing components by means of wire brushing produces flying particles. These particles can cause serious injury to personnel. Wear protective faceshield, gloves, and long sleeves at all times during wire brushing operations. Failure to comply with this warning can result in serious injury to personnel. Do not allow cleaning solvents to come in contact with unprotected skin or eyes. Prolonged skin contact can cause illness or injury. Eye contact can cause serious injury. Always wear chemical protective gloves and goggles when handling hydraulic fluid, engine oil, and cleaning solvents. Failure to follow these precautions can result in illness or serious injury. 1. 2. 3. 4. 5. 6. Using a wire brush and cleaning solvent, clean the flange surfaces of the valve (Figure 1, Item 3) and the vessel's piping. Position the ball valve (Figure 1, Item 3) between the vessel's piping. Install the gaskets (Figure 1, Items 2 and 6) between the ball valve (Figure 1, Item 3) and the vessel's piping. Install the four bolts (Figure 1, Item 4) and four nuts (Figure 1, Item 1) to secure the ball valve (Figure 1, Item 3) to the vessel's piping. Tighten the bolts. Install the four bolts (Figure 1, Item 7) and four nuts (Figure 1, Item 5) to secure the opposite side of the ball valve (Figure 1, Item 3) to the vessel's piping. Tighten the bolts. Perform the FOLLOW-ON MAINTENANCE procedure at the end of this work package.
1 2 3 4
M1011T73
Typical Ball Valve (Flanged).
0116-3
TM 55-1925-273-24&P-2
0116
TYPICAL BALL VALVE (THREADED) REMOVAL 1. Place a suitable drain pan under the ball valve (Figure 2, Item 1).
WARNING
Do not allow hydraulic fluid, engine oil, or cleaning solvents to come in contact with unprotected skin or eyes. Prolonged skin contact can cause illness or injury. Eye contact can cause serious injury. Always wear chemical protective gloves and goggles when handling hydraulic fluid, engine oil, and cleaning solvents. Failure to follow these precautions can result in illness, serious injury, or death. Hydraulic hoses and lines may be under pressure. Relieve pressure by operating the appropriate control valve, if possible. Loosen fittings on hoses and lines slowly. Allow oil to run around threads of fitting, releasing pressure before disconnecting fitting. Releasing pressurized oil suddenly may cause serious injury or death.
CAUTION
Never attempt to disconnect unions with only one wrench. Damage to the vessel's piping or to the valve's piping could occur. Always use two wrenches. 2. 3. 4. 5. Slowly loosen, but do not disconnect, the union (Figure 2, Item 2) connecting the vessel's piping to the ball valve (Figure 2, Item 1). Permit any pressure to vent and any fluid to drain from the union (Figure 2, Item 2) into the suitable drain pan. After the lube oil stops draining, disconnect the union. Disconnect the opposite end of the ball valve (Figure 2, Item 1) and remove it from the vessel's piping. Remove the nipple (Figure 2, Item 3) from the ball valve (Figure 2, Item 1).
END OF TASK TYPICAL BALL VALVE (THREADED) INSTALLATION
WARNING
0116-4
TM 55-1925-273-24&P-2 TYPICAL BALL VALVE (THREADED) INSTALLATION - Continued 1. 2. 3.
0116
Using a wire brush and cleaning solvent, clean the female threaded end of the ball valve (Figure 2, Item 1) and the male threaded end of the vessel's piping. Using a wire brush and cleaning solvent, clean the male threaded end of the nipple (Figure 2, Item 3). Apply antiseizing tape to the male threaded end of the nipple (Figure 2, Item 3) and install the nipple into the ball valve (Figure 2, Item 1).
CAUTION
Although antiseizing tape is necessary on the valve's connection pipe threads, none will be allowed or necessary on the union threads. Leakage will result from applying antiseizing tape to union threads. 4. 5. 6. Apply antiseizing tape to the male threaded end of the vessel's piping. Do not apply antiseizing tape to the union (Figure 2, Item 2) or its threads. Install the ball valve (Figure 2, Item 1) in the vessel's piping. Connect the union (Figure 2, Item 2) onto the vessel's piping.
CAUTION
Never attempt to connect unions with only one wrench. Damage to the vessel's piping or to the valve's piping could occur. Always use two wrenches. 7. 8. Tighten the union (Figure 2, Item 2) securely. Perform the FOLLOW-ON MAINTENANCE procedure at the end of this work package.
M1012T73
Typical Ball Valve (Threaded).
0116-5
TM 55-1925-273-24&P-2 TYPICAL ANGLE HOSE GLOBE VALVE (FLANGED) REMOVAL 1. Place a suitable drain pan under the valve cap (Figure 3, Item 2).
0116
WARNING
Do not allow hydraulic fluid, engine oil, or cleaning solvents to come in contact with unprotected skin or eyes. Prolonged skin contact can cause illness or injury. Eye contact can cause serious injury. Always wear chemical protective gloves and goggles when handling hydraulic fluid, engine oil, and cleaning solvents. Failure to follow these precautions can result in illness, serious injury, or death. Hydraulic hoses and lines may be under pressure. Relieve pressure by operating the appropriate control valve, if possible. Loosen fittings on hoses and lines slowly. Allow oil to run around threads of fitting, releasing pressure before disconnecting fitting. Releasing pressurized oil suddenly may cause serious injury or death. 2. 3. 4. 5. Remove the valve cap (Figure 3, Item 2) and slowly OPEN the valve (Figure 3, Item 1). Permit any pressure to vent and any fluid to drain from the valve into the suitable drain pan. Remove the four bolts (Figure 3, Item 5) and four nuts (Figure 3, Item 4) that secure the valve (Figure 3, Item 1). Remove the valve (Figure 3, Item 1) from the vessel's piping. Remove gasket (Figure 3, Item 3).
END OF TASK TYPICAL ANGLE HOSE GLOBE VALVE (FLANGED) INSPECT 1. 2. Inspect the connecting flange for corrosion, deformation, and scoring. Inspect the valve cap (Figure 3, Item 2) threads for corrosion, deformation, and scoring.
END OF TASK TYPICAL ANGLE HOSE GLOBE VALVE (FLANGED) INSTALLATION
WARNING
0116-6
TM 55-1925-273-24&P-2 TYPICAL ANGLE HOSE GLOBE VALVE (FLANGED) INSTALLATION - Continued 1. 2. 3. 4. Using a wire brush and cleaning solvent, clean the piping flange of the vessel's piping. Install gasket (Figure 3, Item 3) onto the piping flange of the vessel's piping.
0116
Install the valve (Figure 3, Item 1) onto the flange on the vessel's piping, and secure it with the four bolts (Figure 3, Item 5) and the four nuts (Figure 3, Item 4). Perform the FOLLOW-ON MAINTENANCE procedure at the end of this work package.
1 2
M1013T73
Typical Angle Hose Globe Valve (Flanged).
0116-7
TM 55-1925-273-24&P-2
0116
TYPICAL GLOBE STOP CHECK VALVE REMOVAL 1. Place a suitable drain pan under the valve (Figure 4, Item 2).
CAUTION
Loose-fitting, long-sleeved, and long-legged clothing is recommended to prevent irritation from exposure to insulation. Gloves are also recommended. Skin irritation can occur if the skin contacts insulation. 2. 3. 4. Slide the insulation sleeves (Figure 4, Items 1 and 3) off and away from the mounting flanges. Partially OPEN the valve (Figure 4, Item 2) to equalize any pressure on both sides of the valve. Note the direction of flow on the valve (Figure 4, Item 2) and the vessel's piping.
WARNING
Do not allow hydraulic fluid, engine oil, or cleaning solvents to come in contact with unprotected skin or eyes. Prolonged skin contact can cause illness or injury. Eye contact can cause serious injury. Always wear chemical protective gloves and goggles when handling hydraulic fluid, engine oil, and cleaning solvents. Failure to follow these precautions can result in illness, serious injury, or death. Hydraulic hoses and lines may be under pressure. Relieve pressure by operating the appropriate control valve, if possible. Loosen fittings on hoses and lines slowly. Allow oil to run around threads of fitting, releasing pressure before disconnecting fitting. Releasing pressurized oil suddenly may cause serious injury or death. 5. 6. 7. 8. 9. 10. Slowly loosen the four bolts (Figure 4, Item 9) and nuts (Figure 4, Item 8). Permit any pressure to vent and any fluid to drain from the valve into the suitable drain pan. After the fluid drains from the valve (Figure 4, Item 2), remove the four bolts (Figure 4, Item 9) and four nuts (Figure 4, Item 8) that secure the valve. Remove gasket (Figure 4, Item 4). Loosen and remove the four bolts (Figure 4, Item 6) and nuts (Figure 4, Item 7). Remove the valve (Figure 4, Item 2) from the vessel's piping. Remove gasket (Figure 4, Item 5).
END OF TASK TYPICAL GLOBE STOP CHECK VALVE INSPECT 1. 2. 3. Inspect the connecting flange for corrosion, deformation, and scoring. Inspect the insulation sleeves (Figure 4, Items 1 and 3) for any rips, tears, or obvious damage. Refer to MIL-STD-769 and S9086-VH-STM-010/CH-635 for repair and replacement of insulation.
END OF TASK
0116-8
TM 55-1925-273-24&P-2 TYPICAL GLOBE STOP CHECK VALVE INSTALLATION
0116
WARNING
Removing components by means of wire brushing produces flying particles. These particles can cause serious injury to personnel. Wear protective faceshield, gloves, and long sleeves at all times during wire brushing operations. Failure to comply with this warning can result in serious injury to personnel. Do not allow cleaning solvents to come in contact with unprotected skin or eyes. Prolonged skin contact can cause illness or injury. Eye contact can cause serious injury. Always wear chemical protective gloves and goggles when handling hydraulic fluid, engine oil, and cleaning solvents. Failure to follow these precautions can result in illness or serious injury. 1. Using a wire brush and cleaning solvent, clean the piping flange of the vessel's piping.
CAUTION
During installation, verify the correct direction of flow. Failure to comply with this caution can result in pump failure. 2. 3. 4. Install the gaskets (Figure 4, Items 4 and 5) onto the piping flanges of the vessel. Place the valve (Figure 4, Item 2) in the vessel's piping using the direction of flow notes from Step (4) of TYPICAL GLOBE STOP CHECK VALVE REMOVAL as a guide. Secure the valve (Figure 4, Item 2) to the vessel's piping with bolts (Figure 4, Items 6 and 9) and nuts (Figure 4, Items 7 and 8).
CAUTION
Loose-fitting, long-sleeved, and long-legged clothing is recommended to prevent irritation from exposure to insulation. Gloves are also recommended. Skin irritation can occur if the skin contacts insulation. 5. 6. Install the insulation sleeves (Figure 4, Items 1 and 3) over the valve's (Figure 4, Item 2) flanges. Perform the FOLLOW-ON MAINTENANCE procedure at the end of this work package.
1 2 4 5
9 8 7 6
M1014T73
Typical Globe Stop Check Valve (Flanged).
0116-9
TM 55-1925-273-24&P-2
0116
TYPICAL SWING CHECK VALVE (FLANGED) REMOVAL 1. 2. Place a suitable drain pan under the valve (Figure 5, Item 1). Note the direction of flow on the valve (Figure 5, Item 1) and the vessel's piping.
WARNING
Do not allow hydraulic fluid, engine oil, or cleaning solvents to come in contact with unprotected skin or eyes. Prolonged skin contact can cause illness or injury. Eye contact can cause serious injury. Always wear chemical protective gloves and goggles when handling hydraulic fluid, engine oil, and cleaning solvents. Failure to follow these precautions can result in illness, serious injury, or death. Hydraulic hoses and lines may be under pressure. Relieve pressure by operating the appropriate control valve, if possible. Loosen fittings on hoses and lines slowly. Allow oil to run around threads of fitting, releasing pressure before disconnecting fitting. Releasing pressurized oil suddenly may cause serious injury or death. 3. 4. 5. 6. 7. 8. Slowly loosen the four bolts (Figure 5, Item 6) and nuts (Figure 5, Item 5). Permit any pressure to vent and any fluid to drain from the valve into the suitable drain pan. After the fluid drains from the valve (Figure 5, Item 1) remove the four bolts (Figure 5, Item 6) and four nuts (Figure 5, Item 3). Remove gasket (Figure 5, Item 7). Remove the four bolts (Figure 5, Item 4) and four nuts (Figure 5, Item 3) from the opposite side of the valve (Figure 5, Item 1). Remove the valve (Figure 5, Item 1) from the vessel's piping. Remove gasket (Figure 5, Item 2).
END OF TASK TYPICAL SWING CHECK VALVE (FLANGED) INSTALLATION
WARNING
0116-10
TM 55-1925-273-24&P-2 TYPICAL SWING CHECK VALVE (FLANGED) INSTALLATION - Continued 1. 2.
0116
Using a wire brush and cleaning solvent, clean the flange surfaces of the valve (Figure 5, Item 1) and the vessel's piping. Install the gaskets (Figure 5, Items 2 and 7) between the valve (Figure 5, Item 1) and the vessel's piping.
CAUTION
During installation, verify the correct direction of flow. Failure to comply with this caution can result in pump failure. 3. 4. 5. 6. Place the valve (Figure 5, Item 1) in the vessel's piping using the direction of flow notes from Step (2) of TYPICAL SWING CHECK VALVE (FLANGED) REMOVAL as a guide. Secure the valve (Figure 5, Item 1) to the vessel's piping with the four bolts (Figure 5, Item 6) and four nuts (Figure 5, Item 5). Install the four bolts (Figure 5, Item 4) and four nuts (Figure 5, Item 3) to secure the opposite side of the valve (Figure 5, Item 1) to the vessel's piping. Perform the FOLLOW-ON MAINTENANCE procedure at the end of this work package.
3
M1015T73
Figure 5. Typical Swing Check Valve (Flanged). END OF TASK
0116-11
TM 55-1925-273-24&P-2
0116
FOLLOW-ON MAINTENANCE 1. 2. 3. 4. Remove the lock outs and tag outs IAW FM 4-01.502. Operate the lube oil system under usual conditions IAW TM 55-1925-273-10. Check for leaks and for proper operation of the lube oil system. Return the equipment to the desired readiness condition.
0116-12
TM 55-1925-273-24&P-2 FIELD MAINTENANCE LUBE OIL SYSTEM VALVES REPAIR
0117
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 3, WP 0344, Table 1, Item 27) Materials/Parts Rag, Wiping (Volume 3, WP 0343, Table 1, Item 132) Gasket, Spiral Wound (Volume 3, WP 0267, Figure 19, Item 20) Qty: 1 Disk, Valve (Volume 3, WP 0267, Figure 19, Item 21) Qty: 1 O-ring (Volume 3, WP 0267, Figure 19, Item 19) Qty: 1 Personnel Required Watercraft Engineer 88L (1) References WP 0116 Volume 3, WP 0267 Volume 3, WP 0343 Volume 3, WP 0344 Equipment Condition Lube oil system valve removed. (WP 0116)
0117-1
TM 55-1925-273-24&P-2
0117
WARNING
NOTE
The valve replacement procedures in this work package are for typical valves used in the lube oil system. Actual removal and installation of the valves in this work package may differ slightly from the procedures as written. TYPICAL FLANGED BALL VALVE DISASSEMBLY
WARNING
Do not allow hydraulic fluid, engine oil, or cleaning solvents to come in contact with unprotected skin or eyes. Prolonged skin contact can cause illness or injury. Eye contact can cause serious injury. Always wear chemical protective gloves and goggles when handling hydraulic fluid, engine oil, and cleaning solvents. Failure to follow these precautions can result in illness, serious injury, or death. 1. 2. 3. 4. 5. 6. 7. 8. Remove the nut (Figure 1, Item 1) and the handle (Figure 1, Item 2) from the valve body (Figure 1, Item 12). Remove the gland nut (Figure 1, Item 3) from the valve body (Figure 1, Item 12). Remove the gland nut packing (Figure 1, Item 4) from the valve body (Figure 1, Item 12). Remove the valve stem (Figure 1, Item 5) from the valve body (Figure 1, Item 12). Remove the valve stem packing (Figure 1, Item 6) from the valve body (Figure 1, Item 12). Remove the retainer (Figure 1, Item 11) from the valve body (Figure 1, Item 12). Remove the gasket (Figure 1, Item 10) from the valve body (Figure 1, Item 12). Remove the valve seat (Figure 1, Item 9), the ball (Figure 1, Item 8), and the valve seat (Figure 1, Item 7) from the valve body (Figure 1, Item 12).
END OF TASK TYPICAL FLANGED BALL VALVE ASSEMBLY 1. 2. 3. 4. 5. 6. Inspect all valve components for wear and damage. Clean the parts of the valve (Figure 1, Item 1) using clean wiping rags and water. Install valve seat (Figure 1, Item 7), ball (Figure 1, Item 8), valve seat (Figure 1, Item 9), and gasket (Figure 1, Item 10) in the valve body (Figure 1, Item 12). Secure them with the retainer (Figure 1, Item 11). Install valve stem packing (Figure 1, Item 6) in the valve body (Figure 1, Item 12). Install valve stem (Figure 1, Item 5) in the valve body (Figure 1, Item 12). Install gland nut packing (Figure 1, Item 4) in the valve body (Figure 1, Item 12). Secure it with gland nut (Figure 1, Item 3).
0117-2
TM 55-1925-273-24&P-2 TYPICAL FLANGED BALL VALVE ASSEMBLY - Continued 7. 8. Install handle (Figure 1, Item 2) on the valve stem (Figure 1, Item 5). Secure it with the nut (Figure 1, Item 1). Perform the FOLLOW-ON MAINTENANCE at the end of this work package.
0117
3 4
7 8 9 10 11 12
M1016T73
Flanged Ball Valve.
0117-3
TM 55-1925-273-24&P-2
0117
TYPICAL FLANGED GLOBE VALVE DISASSEMBLY
WARNING
Do not allow hydraulic fluid, engine oil, or cleaning solvents to come in contact with unprotected skin or eyes. Prolonged skin contact can cause illness or injury. Eye contact can cause serious injury. Always wear chemical protective gloves and goggles when handling hydraulic fluid, engine oil, and cleaning solvents. Failure to follow these precautions can result in illness, serious injury, or death. 1. 2. 3. 4. 5. Remove the nut (Figure 2, Item 1) and hand wheel (Figure 2, Item 11) from the valve stem (Figure 2, Item 2). Remove the four bolts (Figure 2, Item 9) and four nuts (Figure 2, Item 8). Remove the bonnet (Figure 2, Item 3) from the valve body (Figure 2, Item 7). Remove gasket (Figure 2, Item 5). Remove the spiral-wound gasket (Figure 2, Item 6) and the disk (Figure 2, Item 10) from the valve body (Figure 2, Item 7). Discard spiral-wound gasket and disk. Remove the O-ring (Figure 2, Item 4) from the bonnet (Figure 2, Item 3). Discard O-ring.
END OF TASK TYPICAL FLANGED GLOBE VALVE ASSEMBLY 1. 2. 3. 4. 5. 6. 7. 8. Inspect all valve components for wear and damage. Clean the parts of the valve (Figure 1, Item 1) using clean wiping rags and water. Install O-ring (Figure 2, Item 4) and secure it in the bonnet (Figure 2, Item 3). Install disk (Figure 2, Item 10) and spiral-wound gasket (Figure 2, Item 6) in the valve body (Figure 2, Item 7). Install gasket (Figure 2, Item 5) between the valve body (Figure 2, Item 7) and the bonnet (Figure 2, Item 3). Install bonnet (Figure 2, Item 3) and secure it to the valve body with the four bolts (Figure 2, Item 9) and four nuts (Figure 2, Item 8). Install hand wheel (Figure 2, Item 11) on the valve stem (Figure 2, Item 2) and secure it with the nut (Figure 2, Item 1). Perform the FOLLOW-ON MAINTENANCE procedure at the end of this work package.
0117-4
TM 55-1925-273-24&P-2 TYPICAL FLANGED GLOBE VALVE ASSEMBLY - Continued
0117
1 11
10 9
2 3
4 5 6
7
M1017T73
Flanged Globe Valve.
0117-5
TM 55-1925-273-24&P-2
0117
TYPICAL FLANGED CHECK VALVE DISASSEMBLY
WARNING
Do not allow hydraulic fluid, engine oil, or cleaning solvents to come in contact with unprotected skin or eyes. Prolonged skin contact can cause illness or injury. Eye contact can cause serious injury. Always wear chemical protective gloves and goggles when handling hydraulic fluid, engine oil, and cleaning solvents. Failure to follow these precautions can result in illness, serious injury, or death. 1. 2. 3. 4. Remove the nuts (Figure 3, Item 1) and bolts (Figure 3, Item 5), and remove the cover (Figure 3, Item 2) from the valve body (Figure 3, Item 7). Remove the gasket (Figure 3, Item 8) from the cover (Figure 3, Item 2). Remove the valve hinge pin (Figure 3, Item 3), and valve seat (Figure 3, Item 6). Remove the plug (Figure 3, Item 4) from the valve body (Figure 3, Item 7).
END OF TASK TYPICAL FLANGED CHECK VALVE ASSEMBLY 1. 2. 3. 4. 5. 6. Inspect all valve components for wear and damage. Clean the parts of the valve (Figure 3, Item 7) using clean wiping rags and water. Install valve seat (Figure 3, Item 6) and secure it inside the valve body (Figure 3, Item 7) with the valve hinge pin (Figure 3, Item 3). Install gasket (Figure 3, Item 8) on the cover (Figure 3, Item 2) and secure it to the valve body (Figure 3, Item 7) with the nuts (Figure 3, Item 1) and bolts (Figure 3, Item 5). Install plug (Figure 3, Item 4) in the valve body (Figure 3, Item 7). Perform the FOLLOW-ON MAINTENANCE at the end of this work package.
0117-6
TM 55-1925-273-24&P-2 TYPICAL FLANGED CHECK VALVE ASSEMBLY - Continued
0117
3 5
4 5
7
Figure 3. END OF TASK FOLLOW-ON MAINTENANCE Flanged Check Valve.
M1018T73
Perform the applicable VALVE REPLACEMENT INSTALLATION procedure (WP 0116). END OF TASK END OF WORK PACKAGE
0117-7/8 blank
TM 55-1925-273-24&P-2 FIELD MAINTENANCE LUBE OIL TRANSFER PUMP REPLACE
0118
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 3, WP 0344, Table 1, Item 27) Gloves, Chemical and Oil Protective (Volume 3, WP 0344, Table 1, Item 8) Goggles, Industrial (Volume 3, WP 0344, Table 1, Item 10) Multimeter (Volume 3, WP 0344, Table 1, Item 15) Suitable Drain Pan Materials/Parts Tape, Antiseizing; 1/2 in. (Volume 3, WP 0343, Table 1, Item 158) Personnel Required Watercraft Engineer 88L (2) References FM 4-01.502 References (cont.) TM 55-1925-273-10 Volume 3, WP 0268 Volume 3, WP 0343 Volume 3, WP 0344 Equipment Condition Set to OFF the LUBE OIL TRANSFER PUMP circuit breaker (LT 803 Only), or the LVP FOR LUBE OIL TRANSFER PUMP circuit breaker (All Other Vessels) in 440 V power panel No. 1. Lock out and tag out IAW FM 4-01.502.
0118-1
TM 55-1925-273-24&P-2
0118
WARNING
NOTE
Electrical junction boxes may vary in size, shape, and mounting position of the box on the motor frame. Electrical junction box covers may vary in number and placement of screws holding the cover in place. 1. 2. Remove the four screws (Figure 1, Item 1) holding the electrical junction box cover (Figure 1, Item 2). Remove the electrical junction box cover (Figure 1, Item 2).
WARNING
Replace or repair components only after the affected circuit has been secured, locked out, and tagged out IAW FM 4-01.502. Performing replacement with the circuit energized may result in injury. 3. Using a multimeter, check for voltage at the wiring terminals. If voltage is present, ensure that the proper motor controller is set to OFF, locked out, and tagged out IAW FM 4-01.502. If no voltage is present, continue with the procedure.
M1019T73
Figure 1.
0118-2
TM 55-1925-273-24&P-2 REMOVAL - Continued 4. 5. 6. 7. 8. 9. 10. 11. Label and disconnect the electrical wiring.
0118
Remove the two bolts (Figure 2, Item 5), the two lockwashers (Figure 2, Item 6), and the two flat washers (Figure 2, Item 7) from the coupling guard (Figure 2, Item 8). Discard lockwashers. Remove the coupling guard (Figure 2, Item 8). Loosen the motor coupling flange setscrew (Figure 2, Item 3). Slide the motor coupling flange (Figure 2, Item 4) towards the motor (Figure 2, Item 2). Remove the four bolts (Figure 2, Item 1), the four lockwashers (Figure 2, Item 12), and the four flat washers (Figure 2, Item 11). Discard lockwashers. Remove the motor (Figure 2, Item 2) from the foundation (Figure 2, Item 10). Slide the motor coupling flange (Figure 2, Item 4) off the motor shaft (Figure 2, Item 9).
3 2
5 6 7 8
1 4 12 11
10 9
M2004T73
Figure 2.
Electric Motor.
0118-3
TM 55-1925-273-24&P-2 REMOVAL - Continued 12. Place a suitable drain pan under the lube oil transfer pump (Figure 3, Item 5).
0118
WARNING
Hydraulic hoses and lines may be under pressure. Relieve pressure by operating the appropriate control valve, if possible. Loosen fittings on hoses and lines slowly. Allow oil to run around threads of fitting, releasing pressure before disconnecting fitting. Releasing pressurized oil suddenly may cause serious injury or death. 13. 14. Slowly loosen the pressure gage piping (Figure 3, Item 2) to relieve pressure from the lube oil transfer pump (Figure 3, Item 5). Allow any lube oil to drain into the suitable drain pan. After all pressure has been released, remove the pressure gage piping (Figure 3, Item 2) from the lube oil transfer pump (Figure 3, Item 5).
CAUTION
Never attempt to disconnect union connections with only one wrench. Damage to the vessel's piping or to the pump's piping could occur. Always use two wrenches. 15. 16. Loosen and disconnect the lube oil piping at the lube oil transfer pump (Figure 3, Item 5) inlet union (Figure 3, Item 3) and the outlet union (Figure 3, Item 6). Remove the two bolts (Figure 3, Item 1), the two lockwashers (Figure 3, Item 8), and the two flat washers (Figure 3, Item 7) securing the lube oil transfer pump (Figure 3, Item 5) to the foundation (Figure 3, Item 4). Discard lockwashers. Remove the lube oil transfer pump (Figure 3, Item 5) from the foundation (Figure 3, Item 4).
1
17.
8 7 6
2 3
4
M1022T73
Figure 3. Lube Oil Transfer Pump. END OF TASK
0118-4
TM 55-1925-273-24&P-2 INSTALLATION 1. 2. Position the lube oil transfer pump (Figure 3, Item 5) on the foundation (Figure 3, Item 4). Install the two bolts (Figure 3, Item 1), two lockwashers (Figure 3, Item 8), and two flat washers (Figure 3, Item 7) in the lube oil transfer pump (Figure 3, Item 5). Do not tighten the bolts at this time.
0118
CAUTION
Never attempt to connect union connections with only one wrench. Damage to the vessel's piping or to the pump's piping could occur. Always use two wrenches. 3. 4. 5. 6. 7. 8. 9. 10. 11. Connect and tighten the inlet and outlet unions (Figure 3, Items 3 and 6) on the lube oil transfer pump (Figure 3, Item 5). Tighten the bolts (Figure 3, Item 1) securing the lube oil transfer pump (Figure 3, Item 5) to the foundation (Figure 3, Item 4). Apply antiseizing tape to the pipe threads of the pressure gage piping. Connect the pressure gage piping (Figure 3, Item 2) to lube oil transfer pump (Figure 3, Item 5) and tighten the piping connection. Slide the motor coupling flange (Figure 2, Item 4) onto the motor shaft (Figure 2, Item 9) with the flat end towards the motor (Figure 2, Item 2) housing. Positon the motor (Figure 2, Item 2) on the foundation (Figure 2, Item 10) with the mounting holes aligned. Install the four bolts (Figure 2, Item 1), four lockwashers (Figure 2, Item 12), and the four flat washers (Figure 2, Item 11). Do not tighten at this time. Align the pump coupling flange (Figure 4, Item 1) and the motor coupling flange (Figure 4, Item 2) together leaving approximately 0.016 in. (0.41 mm) space between the ends of both flanges. Refer to Figure 4. Check the alignment between the pump coupling flange (Figure 4, Item 1) and the motor coupling flange (Figure 4, Item 2). The maximum angular offset shall be 1 degree and maximum parallel offset shall be 0.015 in. (0.381 mm). Refer to Figure 4.
STRAIGHT EDGE OPTIMUM GAP BETWEEN FLANGES 0.016 IN. (0.41 MM) 1 MAXIMUM ANGULAR OFFSET
PUMP
MOTOR 1 2
M1023T73
Figure 4. Alignment of Pump Coupling Flange and Motor Coupling Flange. 12. 13. Tighten the motor coupling flange setscrew (Figure 2, Item 3). Tighten the four bolts (Figure 2, Item 1).
0118-5
TM 55-1925-273-24&P-2 INSTALLATION - Continued 14. 15. 16.
0118
Install the coupling guard (Figure 2, Item 4) and secure it with the two bolts (Figure 2, Item 1), two lockwashers (Figure 2, Item 2), and the two flat washers (Figure 2, Item 3). Tighten the bolts. Connect the electrical wiring using the labels from Step (4) of REMOVAL as a guide. Remove the labels. Install the electrical junction box cover (Figure 1, Item 1) and secure it with the four screws (Figure 1, Item 2). Tighten the screws.
END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. Remove the lock outs and tag outs IAW FM 4-01.502. Operate the lube oil transfer pump under usual conditions IAW TM 55-1925-273-10 and check for proper operation. Return the lube oil transfer pump to the desired readiness condition.
0118-6
TM 55-1925-273-24&P-2 FIELD MAINTENANCE LUBE OIL TRANSFER PUMP REPAIR
0119
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 3, WP 0344, Table 1, Item 27) Gloves, Chemical and Oil Protective (Volume 3, WP 0344, Table 1, Item 8) Goggles, Industrial (Volume 3, WP 0344, Table 1, Item 10) Locknut, Tool Bearing (Volume 3, WP 0344, Table 1, Item 13) Lubricating Gun, Hand (Volume 3, WP 0344, Table 1, Item 14) Wrench, Torque, 0-250 lb-ft (0-339 Nm) (Volume 3, WP 0344, Table 1, Item 33) Materials/Parts Cleaning Compound, Solvent (Volume 3, WP 0343, Table 1, Item 37) Grease, Ball and Roller Bearing; 1.75 lb (Volume 3, WP 0343, Table 1, Item 74) Lubricating Oil, Engine; OE/HDO-10, 5 gal (Volume 3, WP 0343, Table 1, Item 102) Packing, Preformed (O-ring) (Volume 3, WP 0268, Figure 20, Item 15) Qty: 1 Seal (Grease) (Volume 3, WP 0268, Figure 20, Item 5) Qty: 1 Bearing, Ball, Annular (Volume 3, WP 0268, Figure 20, Item 7) Qty: 1 Gasket (Volume 3, WP 0268, Figure 20, Item 12) Qty: 1 Materials/Parts (cont.) O-ring (Volume 3, WP 0268, Figure 20, Item 9) Qty: 1 Vane, Pump, Rotary (Volume 3, WP 0268, Figure 20, Item 10) Qty: 4 Personnel Required Watercraft Engineer 88L (1) References TM 55-1925-273-10 WP 0118 Volume 3, WP 0268 Volume 3, WP 0343 Volume 3, WP 0344 Equipment Condition Lube oil transfer pump removed. (WP 0118)
0119-1
TM 55-1925-273-24&P-2
0119
DISASSEMBLY 1. Loosen the locknut (Figure 1, Item 29) and remove the adjusting screw (Figure 1, Item 30) from the cover (Figure 1, Item 28).
WARNING
The cover is under spring pressure. Use appropriate eye and safety protection during disassembly of the lube oil transfer pump. Failure to comply with this warning can result in severe personal injury or death. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. Remove the cover (Figure 1, Item 28) and O-ring (Figure 1, Item 27). Discard O-ring. Remove the spring guide (Figure 1, Item 26) and preformed packing (spring) (Figure 1, Item 25). Remove the disc and valve (Figure 1, Item 24) from the pump body (Figure 1, Item 23). Remove the grease fitting (Figure 1, Item 32) from the mounting bracket (Figure 1, Item 2). Remove the grease fitting relief (Figure 1, Item 3) from the mounting bracket (Figure 1, Item 2). Remove the four capscrews (Figure 1, Item 1) from the mounting bracket (Figure 1, Item 2). Slide the mounting bracket (Figure 1, Item 2) and the grease seal (Figure 1, Item 4) off the rotor and shaft assembly (Figure 1, Item 22). Discard grease seal. Remove the lockwasher (Figure 1, Item 6) and the bearing locknut (Figure 1, Item 5) from the rotor and shaft assembly (Figure 1, Item 22) using the lockout tool. Do not discard lockwasher and bearing locknut. Remove the ball bearing (Figure 1, Item 7) from the pump body (Figure 1, Item 23). Discard ball bearing. Remove the mechanical seal (Figure 1, Item 31) from the rotor and shaft assembly (Figure 1, Item 22). Remove the grease fitting (Figure 1, Item 17) from the bearing cover (Figure 1, Item 18). Remove the grease fitting relief (Figure 1, Item 20) from the bearing cover (Figure 1, Item 18). Remove the four capscrews (Figure 1, Item 19) from the bearing cover (Figure 1, Item 18) and slide the bearing cover and the gasket (Figure 1, Item 16) off the rotor and shaft assembly (Figure 1, Item 22). Discard gasket. Remove the shaft key (Figure 1, Item 9) from the rotor and shaft assembly (Figure 1, Item 22). Remove the lockwasher (Figure 1, Item 14) and the bearing locknut (Figure 1, Item 15) from the rotor and shaft assembly (Figure 1, Item 22) using the lockout tool. Do not discard lockwasher and bearing locknut. Remove the ball bearing (Figure 1, Item 13) from the head (Figure 1, Item 11). Remove the mechanical seal (Figure 1, Item 12) from the head (Figure 1, Item 11). Remove the four capscrews (Figure 1, Item 21) from the head (Figure 1, Item 11) and remove the head from the pump body (Figure 1, Item 23). Remove the O-ring (Figure 1, Item 8) from the head (Figure 1, Item 11). Discard O-ring. Remove the rotor and shaft assembly (Figure 1, Item 22) from the pump body (Figure 1, Item 23). Remove the vanes (Figure 1, Item 10) from the rotor and shaft assembly (Figure 1, Item 22). Discard vanes.
0119-2
0119
1 2 3 45 6
32 8 9 10 11 31 30 29 24 23 22 21 12 13 14 15 16 17 18 19 25 26 27 28
20
Figure 1. END OF TASK CLEAN AND INSPECT Lube Oil Transfer Pump.
M1024T73
WARNING
Cleaning solvent is flammable and its vapor is potentially explosive. Do not use cleaning solvent in the vicinity of spark, open flame, or excessive heat. Do not use cleaning solvent in unventilated spaces. Always wear chemical protective gloves and goggles when handling hydraulic fluid, engine oil, and cleaning solvents. Failure to comply with this warning can result in serious injury or death. 1. Using cleaning solvent, clean all the removed parts. Check for any burrs on the rotor and shaft assembly, the pump body, and all other removed parts. Inspect all component parts for unusual wear or damage and replace as required. Allow all parts to air dry prior to assembly.
2.
END OF TASK
0119-3
TM 55-1925-273-24&P-2
0119
ASSEMBLY 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. Install vanes (Figure 1, Item 10) in the rotor and shaft assembly (Figure 1, Item 22). Lubricate the rotor and shaft assembly (Figure 1, Item 22) with engine lubricating oil and install it in the pump body (Figure 1, Item 23). Lubricate an O-ring (Figure 1, Item 8) with engine lubricating oil and install it on the head (Figure 1, Item 11). Install head (Figure 1, Item 11) on the pump body (Figure 1, Item 23) and secure it with the four capscrews (Figure 1, Item 21). Install the mechanical seal (Figure 1, Item 12) in the head (Figure 1, Item 11). Install a ball bearing (Figure 1, Item 13) in the head (Figure 1, Item 11). Install the lockwasher (Figure 1, Item 14) and the bearing locknut (Figure 1, Item 15) on the rotor and shaft assembly (Figure 1, Item 22) using the lockout tool. Install the shaft key (Figure 1, Item 9) on the rotor and shaft assembly (Figure 1, Item 22). Install a gasket (Figure 1, Item 16) on the bearing cover (Figure 1, Item 18) and slide the bearing cover on the rotor and shaft assembly (Figure 1, Item 22). Secure the bearing cover (Figure 1, Item 18) to the head (Figure 1, Item 11) with the four capscrews (Figure 1, Item 19). Install the grease fitting relief (Figure 1, Item 20) in the bearing cover (Figure 1, Item 18). Install the grease fitting (Figure 1, Item 17) in the bearing cover (Figure 1, Item 18). Install the mechanical seal (Figure 1, Item 31) on the rotor and shaft assembly (Figure 1, Item 22). Install a ball bearing (Figure 1, Item 7) in the pump body (Figure 1, Item 23). Install the lockwasher (Figure 1, Item 6) and the bearing locknut (Figure 1, Item 5) on the rotor and shaft assembly (Figure 1, Item 22) using the lockout tool. Install a grease seal (Figure 1, Item 4) in the mounting bracket (Figure 1, Item 2) and slide the mounting bracket on the rotor and shaft assembly (Figure 1, Item 22). Secure the mounting bracket (Figure 1, Item 2) to the pump body (Figure 1, Item 23) with the four capscrews (Figure 1, Item 1). Install the grease fitting relief (Figure 1, Item 3) in the mounting bracket (Figure 1, Item 2). Install the grease fitting (Figure 1, Item 32) in the mounting bracket (Figure 1, Item 2). Install the disc and valve (Figure 1, Item 24) in the pump body (Figure 1, Item 23). Install the spring guide (Figure 1, Item 26) and preformed packing (spring) (Figure 1, Item 25) in the pump body (Figure 1, Item 23). Install an O-ring (Figure 1, Item 27) on the cover (Figure 1, Item 28) and install the cover in the pump body (Figure 1, Item 23). Install the adjusting screw (Figure 1, Item 30) in the cover (Figure 1, Item 28). Do not tighten the locknut (Figure 1, Item 28) at this time. Using a lubricating gun, lubricate the lube oil transfer pump bearings at the grease fittings (Figure 1, Items 17 and 32) with grease until the grease comes out of the grease fitting relief (Figure 1, Items 3 and 20). Install the lube oil transfer pump (WP 0118). Operate the lube oil transfer pump under usual conditions IAW TM 55-1925-273-10.
25. 26.
0119-4
TM 55-1925-273-24&P-2 ASSEMBLY - Continued 27. To adjust the discharge pressure: a. b. c. Loosen the locknut (Figure 1, Item 30).
0119
With the pump running, turn the adjusting screw (Figure 1, Item 29) clockwise to increase pressure or counterclockwise to decrease pressure until the desired pressure is attained. Tighten the locknut (Figure 1, Item 30).
END OF TASK FOLLOW-ON MAINTENANCE Install lube oil transfer pump (WP 0118). END OF TASK END OF WORK PACKAGE
0119-5/6 blank
TM 55-1925-273-24&P-2 FIELD MAINTENANCE PRELUBRICATION OIL PUMP, PUMP END REPLACE
0120
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 3, WP 0344, Table 1, Item 27) Gloves, Chemical and Oil Protective (Volume 3, WP 0344, Table 1, Item 8) Goggles, Industrial (Volume 3, WP 0344, Table 1, Item 10) Suitable Drain Pan Materials/Parts Compound, Sealing; Gray (Volume 3, WP 0343, Table 1, Item 42) Personnel Required Watercraft Engineer 88L (1) References FM 4-01.502 References (cont.) WP 0122 Volume 3, WP 0269 Volume 3, WP 0343 Volume 3, WP 0344 Equipment Condition CLOSE valve LO-47 C.O.V. PRELUBE PMP. DISCH or valve LO-48 C.O.V. PMP. DISCH. Lock out and tag out IAW FM 4-01.502.
0120-1
TM 55-1925-273-24&P-2
0120
WARNING
Never reuse locking hardware. Reuse of locking hardware such as lockwashers, locking nuts, cotter pins, and lock wire can result in undetected loosening of fastening hardware causing catastrophic component failure resulting in death, injury, or damage to equipment. Ensure that all locking hardware is discarded upon removal and replaced with new. REMOVAL 1. Position a suitable drain pan beneath the pressure gage plug (Figure 1, Item 4).
WARNING
Oil hoses and lines may be under pressure. Relieve pressure by operating the appropriate control valve, if possible. Loosen fittings on hoses and lines slowly. Allow oil to run around threads of fitting, releasing pressure before disconnecting fitting. Releasing pressurized oil suddenly may cause severe personal injury. Do not allow hydraulic fluid, engine oil, or cleaning solvents to come in contact with unprotected skin or eyes. Prolonged skin contact can cause illness or injury. Eye contact can cause serious injury. Always wear chemical protective gloves and goggles when handling hydraulic fluid, engine oil, and cleaning solvents. Failure to follow these precautions can result in illness, serious injury, or death. 2. Slowly OPEN the pressure gage plug (Figure 1, Item 4) to relieve pressure from the main engine prelubrication pump (Figure 1, Item 7). Allow the lube oil to drain into the suitable drain pan.
CAUTION
Never disconnect piping unions with only one wrench. Damage to the vessel's piping or to the pump's piping could occur. Always use the two wrench method. 3. 4. Using the two wrench method, disconnect the inlet union (Figure 1, Item 5) and the outlet union (Figure 1, Item 2) from the vessel's piping. Remove the two bolts (Figure 1, Item 1) and two lockwashers (Figure 1, Item 8) that secure the main engine prelubrication pump (Figure 1, Item 7) to the foundation, and remove the main prelubrication pump (Figure 1, Item 7). Discard lockwashers. Remove the outlet piping elbow (Figure 1, Item 3) and the inlet piping elbow (Figure 1, Item 6) from the main engine prelubrication pump (Figure 1, Item 7).
5.
0120-2

1 8 2 3 4 5 6
0120
7
M1003T73
Figure 1. END OF TASK INSTALLATION 1. 2.
Main Engine Prelubrication Pump.
Install the outlet piping elbow (Figure 1, Item 3) and the inlet piping elbow (Figure 1, Item 6) on the main engine prelubrication pump (Figure 1, Item 7). Install the main engine prelubrication pump (Figure 1, Item 7) on the foundation, and secure it with the two bolts (Figure 1, Item 1) and two lockwashers (Figure 1, Item 8). Do not tighten the bolts at this time.
CAUTION
Never connect piping unions with only one wrench. Damage to the vessel's piping or to the pump's piping could occur. Always use the two wrench method. 3. 4. Using the two wrench method, install the inlet union (Figure 1, Item 5) and the outlet union (Figure 1, Item 2) to the vessel's piping. Tighten the bolts (Figure 1, Item 1) to secure the main engine prelubrication pump (Figure 1, Item 7) to the foundation.
END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. 4. Align pump per PRELUBRICATION OIL PUMP ELECTRIC MOTOR REPLACE MOTOR INSTALLATION procedure (WP 0122). Remove the lock outs and tag outs IAW FM 4-01.502. Operate the prelubrication oil pump under usual conditions IAW TM 55-1925-273-10, checking for leaks and proper operation. Return the prelubrication oil pump to the desired readiness condition.
0120-3/4 blank
TM 55-1925-273-24&P-2 FIELD MAINTENANCE PRELUBRICATION OIL PUMP, PUMP END REPAIR
0121
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 3, WP 0344, Table 1, Item 27) Gloves, Chemical and Oil Protective (Volume 3, WP 0344, Table 1, Item 8) Goggles, Industrial (Volume 3, WP 0344, Table 1, Item 10) Locknut, Tool Bearing (Volume 3, WP 0344, Table 1, Item 13) Suitable Drain Pan Wrench, Torque, 0-250 lb-ft (0-339 Nm) (Volume 3, WP 0344, Table 1, Item 33) Materials/Parts Cleaning Compound, Solvent (Volume 3, WP 0343, Table 1, Item 37) Grease, Ball and Roller Bearing; 1.75 lb (Volume 3, WP 0343, Table 1, Item 74) Isopropyl Alcohol, Technical (Volume 3, WP 0343, Table 1, Item 91) Lubricating Oil, Engine; OE/HDO-30, 1 qt (Volume 3, WP 0343, Table 1, Item 102) Rag, Wiping (Volume 3, WP 0343, Table 1, Item 132) Tape, Antiseizing; 1/2 in. (Volume 3, WP 0343, Table 1, Item 158) Packing, Preformed (O-ring) (Volume 3, WP 0269, Figure 21, Item 13) Qty: 1 Materials/Parts (cont.) Seal (Grease) (Volume 3, WP 0269, Figure 21, Item 3) Qty: 1 Lockwasher, Bearing (Volume 3, WP 0269, Figure 21, Item 4) Qty: 2 Seal, Mechanical (Volume 3, WP 0269, Figure 21, Item 9) Qty: 2 O-ring (Volume 3, WP 0269, Figure 21, Item 7) Qty: 1 Personnel Required Watercraft Engineer 88L (2) References TM 55-1925-273-10 WP 0120 WP 0122 Volume 3, WP 0269 Volume 3, WP 0343 Volume 3, WP 0344 Equipment Condition Main engine prelubrication pump removed. (WP 0120)
0121-1
TM 55-1925-273-24&P-2
0121
WARNING
Never reuse locking hardware. Reuse of locking hardware such as lockwashers, locking nuts, cotter pins, and lock wire can result in undetected loosening of fastening hardware causing catastrophic component failure resulting in death, injury, or damage to equipment. Ensure that all locking hardware is discarded upon removal and replaced with new. Do not allow hydraulic fluid, engine oil, fuels, or cleaning solvents to come in contact with unprotected skin or eyes. Prolonged skin contact can cause illness or injury. Eye contact can cause serious injury. Always wear chemical protective gloves and goggles when handling hydraulic fluid, engine oil, fuels, and cleaning solvents. Failure to follow these precautions can result in illness, serious injury, or death. Diesel fuel is flammable and diesel fuel vapors can be explosive. Ensure all work is performed in a well ventilated area. Keep sparks, open flame, and excessive heat away from the work area. Do not smoke or allow smoking, or any other flame in the vicinity of fuel sounding operations. Wipe clean any fuel spillage and dispose of spilled fuel and fuel-soaked rags in accordance with the appropriate local regulations.
NOTE
Ensure exterior of pump is clean and free of damage before disassembly. If required, use cleaning solvent to clean exterior surfaces of the main engine prelubrication pump. Disassemble the main engine prelubrication pump only to the level necessary to correct the obvious problem. DISASSEMBLY 1. Loosen the locknut (Figure 1, Item 32) and remove the adjusting screw (Figure 1, Item 31) from the jamnut (Figure 1, Item 30).
WARNING
The cover is under spring pressure. Use appropriate eye and safety protection during disassembly. Failure to comply with this warning can result in severe personal injury. 2. 3. 4. 5. 6. Remove the jamnut (Figure 1, Item 30) and O-ring (Figure 1, Item 29). Discard O-ring. Remove the spring guide (Figure 1, Item 28) and spring (Figure 1, Item 27). Remove the disc and valve (Figure 1, Item 26) from the pump body (Figure 1, Item 25) cavity. Remove the grease fitting (Figure 1, Item 34) from the mounting bracket (Figure 1, Item 2). Remove the grease fitting relief (Figure 1, Item 3) from the mounting bracket (Figure 1, Item 2).
0121-2
TM 55-1925-273-24&P-2 DISASSEMBLY - Continued 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. Remove the four capscrews (Figure 1, Item 1) from the mounting bracket (Figure 1, Item 2).
0121
Remove the mounting bracket (Figure 1, Item 2) and the grease seal (Figure 1, Item 4) from the rotor and shaft assembly (Figure 1, Item 24). Discard grease seal. Remove the lockwasher (Figure 1, Item 6) and bearing locknut (Figure 1, Item 5) from the rotor and shaft assembly (Figure 1, Item 24). Discard lockwasher. Remove the bearing (Figure 1, Item 7) from the pump body (Figure 1, Item 25). Remove the mechanical seal (Figure 1, Item 33) from the rotor and shaft assembly (Figure 1, Item 24). Discard mechanical seal. Remove the grease fitting (Figure 1, Item 19) from the bearing cover (Figure 1, Item 20). Remove the grease fitting relief (Figure 1, Item 22) from the bearing cover (Figure 1, Item 20). Remove the four capscrews (Figure 1, Item 21) from the bearing cover (Figure 1, Item 20) and remove the bearing cover and the gasket (Figure 1, Item 18) from the rotor and shaft assembly (Figure 1, Item 24). Remove the shaft key (Figure 1, Item 11) from the rotor and shaft assembly (Figure 1, Item 24). Remove the lockwasher (Figure 1, Item 16). Using a locknut tool, remove the bearing locknut (Figure 1, Item 17) from the rotor and shaft assembly (Figure 1, Item 24). Discard lockwasher. Remove the bearing (Figure 1, Item 15) from the head (Figure 1, Item 13). Remove the mechanical seal (Figure 1, Item 14) from the head (Figure 1, Item 13). Discard mechanical seal. Remove the four capscrews (Figure 1, Item 23) from the head (Figure 1, Item 13) and carefully slide the head off the rotor and shaft assembly (Figure 1, Item 24). Remove the O-ring (Figure 1, Item 10) from the head (Figure 1, Item 13). Discard O-ring. Gently remove the rotor and shaft assembly (Figure 1, Item 24) from the pump body (Figure 1, Item 25), with one hand cupped underneath the assembly to keep the vanes (Figure 1, Item 12) from falling out. Remove the four vanes (Figure 1, Item 12) from the rotor and shaft assembly (Figure 1, Item 24). Remove the two 1/4 in. gage plugs (Figure 1, Item 8) from the pump body (Figure 1, Item 25). Remove the 3/4 in. gage plug (Figure 1, Item 9) from the pump body (Figure 1, Item 25).
0121-3
0121
OUTBOARD SIDE OF PUMP
19
20
18
11
12
13
14
15
16
17
10
INBOARD SIDE OF PUMP
26
33
27
25
24
28
29
32
34
31
30
23
M1220T73
Main Engine Prelubrication Pump (Exploded View).
0121-4
22
21
0121
WARNING
Cleaning solvent is flammable and its vapor is potentially explosive. Do not use cleaning solvent in the vicinity of spark, open flame, or excessive heat. Do not use cleaning solvent in unventilated spaces. Always wear chemical protective gloves and goggles when handling hydraulic fluid, engine oil, and cleaning solvents. Failure to comply with this warning can result in serious injury or death. Using cleaning solvent, clean all the removed parts. Check for any burrs on the rotor and shaft assembly (Figure 1, Item 12), the pump body (Figure 1, Item 25), and all other removed parts. Inspect all component parts for unusual wear or damage. END OF TASK ASSEMBLY
NOTE
Reassemble the INBOARD side of the pump first. Position the pump cylinder with the INTAKE port and relief valve to the right. 1. 2. 3. Apply a small amount of engine lubrication oil in the mechanical seal (Figure 2, Item 1) and bearing recess of the pump body (Figure 1, Item 25) before installing the mechanical seal. Insert the seal jacket assembly (Figure 2, Item 2) into the seal recess of the pump body (Figure 1, Item 25) with the drive tangs of the jacket facing inward. With the polished face facing outward, align the notches of the rotating seal face (Figure 2, Item 4) with the jacket assembly (Figure 2, Item 2), and install the rotating seal face and rotating O-ring (Figure 2, Item 3) into the jacket assembly. Thoroughly clean the rotating seal face (Figure 2, Item 4) with clean wiping rags and isopropyl alcohol. Install the seal backup ring (Figure 2, Item 5) into the seal recess of the pump body (Figure 1, Item 25). Thoroughly clean the polished face of the stationary seat (Figure 2, Item 7) with a clean wiping rag and isopropyl alcohol. Align the stationary seat (Figure 2, Item 7) and the O-ring (Figure 2, Item 6) and insert it into the seal recess with the polished face inward to mate with the rotating seal face (Figure 2, Item 4).
4. 5. 6. 7.
0121-5
0121
2 1 3 4 5 6 7
M1221T73
Figure 2. 8.
Mechanical Seal.
Hand pack the bearing (Figure 1, Item 7) with grease.
NOTE
The balls in the bearing should face outward, with the grease shield inward. The bearing must be fully and squarely seated against the mechanical seal during installation. 9. Install the bearing (Figure 1, Item 7) into the pump body (Figure 1, Item 25) recessed cavity.
NOTE
Use care when handling the rotor and shaft assembly and installing the vanes. 10. 11. 12. 13. Install the rotor and shaft assembly (Figure 1, Item 24) into the pump body (Figure 1, Item 25) and through the mechanical seal (Figure 2, Item 1). Rotate the rotor and shaft assembly (Figure 1, Item 24) to engage the drive tangs of the mechanical seal (Figure 1, Item 33) into the rotor and shaft assembly. Apply 2 to 3 drops of engine lubrication oil on the vanes (Figure 1, Item 12) and insert the vanes into the slots on the rotor and shaft assembly (Figure 1, Item 24). Install the shaft key (Figure 1, Item 11) in the rotor and shaft assembly (Figure 1, Item 24).
0121-6
0121
CAUTION
It is important that the bearing locknuts and bearing lockwashers are installed and adjusted properly. Over tightening locknuts can cause bearing failure or broken lockwasher tang. Loose locknuts will allow the rotor on the shaft and rotor assembly to slip gradually.
NOTE
Ensure that the inner tang of the bearing lockwasher is located in the slot in the shaft and rotor assembly threads. Bend the bearing lockwasher slightly, if necessary. 14. 15. 16. 17. 18. Install a lockwasher (Figure 1, Item 6) with the tangs outward. Install the locknut (Figure 1, Item 5) with the tapered end facing inward. Using a locknut tool, tighten the locknut (Figure 1, Item 5) to pull the rotor and shaft assembly's (Figure 1, Item 24) rotor flat against the back wall of the pump body (Figure 1, Item 25). Repeat Steps (1) through (9) to install the mechanical seal (Figure 1, Item 14) into the head (Figure 1, Item 13). Apply a small amount of engine lubrication oil to the head (Figure 1, Item 13) O-ring groove on the inside face of the head. Install an O-ring (Figure 1, Item 10) into the groove.
NOTE
Use care not to damage the mechanical seal when installing the head onto the cylinder. 19. Apply a small amount of engine lubrication oil on the exposed end of the rotor and shaft assembly (Figure 1, Item 24) and install the head over the rotor shaft assembly and against the head (Figure 1, Item 13). Rotate the head (Figure 1, Item 13) to engage the drive tangs of the mechanical seal (Figure 1, Item 14) jacket assembly (Figure 2, Item 2) with slots in the rotor of the rotor and shaft assembly (Figure 1, Item 24). Install the four capscrews (Figure 1, Item 23) hand tight at this time.
20. 21.
CAUTION
It is important that the bearing locknuts and bearing lockwashers are installed and adjusted properly. Overtightening locknuts can cause bearing failure or a broken lockwasher tang. Loose locknuts will allow the rotor on the shaft and rotor assembly to shift causing premature wear.
NOTE
Ensure that the inner tang "A" of the bearing lockwasher is located in the slot in the shaft and rotor assembly threads, bending the bearing lockwasher slightly, if necessary. 22. 23. Install a lockwasher (Figure 1, Item 16) with the tangs outward. Install the locknut (Figure 1, Item 17) with the tapered end facing inward. Using a locknut tool, tighten the locknut (Figure 1, Item 17) to pull the head (Figure 1, Item 13) up against the pump body (Figure 1, Item 25).
CAUTION
Do not overtighten, bend, or shear the lockwasher inner tang. Equipment damage could occur if the lockwasher is damaged.
0121-7
0121
Using the pump's coupling half, hold the rotor shaft assembly's end and tighten the outboard locknut with a locknut tool to pull the head (Figure 1, Item 13) against the pump body (Figure 1, Item 25). Tighten both bearing locknuts (Figure 1, Items 5 and 17) to ensure that the bearings (Figure 1, Items 7 and 15) are bottomed in the head (Figure 1, Item 13) and the pump's body (Figure 1, Item 25) recess. Loosen both bearing locknuts (Figure 1, Items 5 and 17) one complete turn. Tighten bearing locknut (Figure 1, Item 5) until a slight shaft and rotor assembly (Figure 1, Item 24) drag is felt when turning the shaft by hand. Back off the bearing locknut (Figure 1, Item 5) the width of one lockwasher tang "B" (Figure 3). Secure the bearing locknut by bending the closest aligned bearing lockwasher tang into the slot in the bearing locknut. The pump should turn freely when rotated by hand. Tighten the bearing locknut (Figure 1, Item 17) by hand until it is snug against the bearing (Figure 1, Item 15). Using a locknut tool, tighten the bearing locknut (Figure 1, Item 17) the width of one lockwasher tang "B" (Figure 3). Tighten bearing locknut (Figure 1, Item 17) just past the desired tang, then back off the locknut to align the tang with the lockout slot as shown in Figure 3.
B 2 STOPS EQUALS 1 TANG. WIDTH
26. 27. 28.
29. 30. 31.
N SE
LO O
_ A
TIG
Figure 3. Locknut Adjustment. 32. 33. Secure the bearing locknut (Figure 1, Item 17) by bending the aligned bearing lockwasher (Figure 1, Item 16) tang into the slot in the bearing locknut. The assembly should continue to turn freely when rotated by hand. Check adjustment by grasping the bearing locknut (Figure 1, Item 17) and the bearing lockwasher (Figure 1, Item 16) with fingers and rotate back and forth. If this cannot be accomplished, one or both bearing locknuts (Figure 1, Item 5 or 17) are too tight. Alternately loosen bearing locknuts one stop at a time until the pump shaft rotates freely by hand. Grease the outside diameter of the grease seal (Figure 1, Item 4) and install it on the mounting bracket (Figure 1, Item 2) with the lip of the grease seal inward (towards the pump). Install a bearing cover gasket (Figure 1, Item 18) into the head (Figure 1, Item 13) recess.
H
TE
1 STOP EQUALS .001 IN. (.025 MM) ROTOR MOVEMENT
M1222T73
34. 35.
0121-8
0121
NOTE
The bearing cover must be installed with the grease fitting facing up. 36. 37. 38. 39. 40. 41. 42. 43. 44. 45. 46. 47. 48. Install the bearing cover (Figure 1, Item 20) on the head (Figure 1, Item 13) and secure it with the four capscrews (Figure 1, Item 21) securing the bearing cover (Figure 1, Item 20). Torque the capscrews 15 lb-ft (20 Nm). Install the grease fitting (Figure 1, Item 19) into the bearing cover (Figure 1, Item 20). Install the grease fitting relief (Figure 1, Item 22) into the bearing cover (Figure 1, Item 20). Install the grease fitting (Figure 1, Item 34) into the mounting bracket (Figure 1, Item 2). Install the grease fitting relief (Figure 1, Item 3) into the mounting bracket (Figure 1, Item 2). Apply grease to the outer diameter of a grease seal and install the grease seal into the mounting bracket (Figure 1, Item 2) with the lip facing inward. Install the mounting bracket (Figure 1, Item 2) onto the pump body (Figure 1, Item 25) and secure it with the four capscrews (Figure 1, Item 1). Install the valve and disc (Figure 1, Item 26), the spring (Figure 1, Item 27), and the spring guide (Figure 1, Item 28) in the pump body (Figure 1, Item 25). Install the 3/4 in. gage plug (Figure 1, Item 9). Install the two 1/4 in. gage plugs (Figure 1, Item 8). Install an O-ring (Figure 1, Item 29) on the jamnut (Figure 1, Item 30). Install the jamnut (Figure 1, Item 30) into the pump body (Figure 1, Item 25). Install the adjusting screw (Figure 1, Item 31) and locknut (Figure 1, Item 32) in the jamnut (Figure 1, Item 30).
END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. 4. Install the pump (WP 0120) and the electric motor (WP 0122). Operate the prelube pump under usual conditions IAW TM 55-1925-273-10 to ensure proper operation. Priming should occur within one minute. Observe that prelube oil discharge from the engine bearings is within expected parameters IAW TM 55-1925-273-10. If the discharge pressure is not acceptable, adjust the pressure by: a. b. c. d. 5. Loosening the locknut. Adjusting the adjusting screw. With the pump running, turn the adjusting screw clockwise (increases pressure) or counterclockwise (decreases pressure) until the desired discharge pressure is attained. Tightening the locknut.
Return the equipment to the desired readiness condition IAW TM 55-1925-273-10.
0121-9/10 blank
TM 55-1925-273-24&P-2 FIELD MAINTENANCE PRELUBRICATION OIL PUMP ELECTRIC MOTOR REPLACE
0122
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 3, WP 0344, Table 1, Item 27) Multimeter (Volume 3, WP 0344, Table 1, Item 15) Materials/Parts N/A Personnel Required Watercraft Engineer 88L (2) References FM 4-01.502 TM 55-1925-273-10 References (cont.) Volume 3, WP 0270 Volume 3, WP 0344 Equipment Condition Set to OFF the MAIN ENGINE LUBE OIL PRIMING PUMP No. 1 circuit breaker or the MAIN ENGINE LUBE OIL PRIMING PUMP No. 2 circuit breaker (LT 803 Only), or the CONTROLLER FOR STARBOARD MAIN ENGINE LUBE OIL PRIMING PUMP No. 1 circuit breaker or the CONTROLLER FOR PORT MAIN ENGINE LUBE OIL PRIMING PUMP No. 2 circuit breaker (All Other Vessels) in 440 V power panel No. 1. Lock out and tag out IAW FM 4-01.502.
WARNING
0122-1
TM 55-1925-273-24&P-2
0122
REMOVAL
NOTE
Electrical junction boxes may vary in size, shape, and mounting position of the box on the motor frame. Electrical junction box covers may vary in number and placement of screws holding the cover in place. 1. 2. Remove the four screws (Figure 1, Item 2) holding the electrical junction box cover (top) (Figure 1, Item 2). Remove the electrical junction box cover (top) (Figure 1, Item 1).
WARNING
Replace or repair components only after the affected circuit has been secured, locked out, and tagged out IAW FM 4-01.502. Performing replacement with the circuit energized may result in injury. 3. Using a multimeter, check for voltage at the wiring terminals. If voltage is present, ensure that the proper circuit breaker is secured, locked out, and tagged out IAW FM 4.01-502. If no voltage is present, continue with the procedure.
M1004T73
Figure 1. 4. 5. 6. 7. Label and remove the wiring.
Remove the two bolts (Figure 2, Item 5), two lockwashers (Figure 2, Item 6), and the two flat washers (Figure 2, Item 7) from the coupling guard (Figure 2, Item 8). Discard lockwashers. Remove the coupling guard (Figure 2, Item 8). Loosen the motor coupling flange setscrew (Figure 2, Item 3).
0122-2
TM 55-1925-273-24&P-2 REMOVAL - Continued 8. 9. 10. 11. Slide the motor coupling flange (Figure 2, Item 4) towards the motor (Figure 2, Item 2).
0122
Remove the four bolts (Figure 2, Item 1), four lockwashers (Figure 2, Item 12), and the four flat washers (Figure 2, Item 11). Discard lockwashers. Remove the motor (Figure 2, Item 2) from the foundation (Figure 2, Item 10). Slide the motor coupling flange (Figure 2, Item 4) off the motor shaft (Figure 2, Item 9).
5
3 2
6 7 8
1 4
12 11
10 9
M2005T73
Figure 2. END OF TASK INSTALLATION 1. 2. 3. 4. 5. 6.
Electric Motor.
Slide the motor coupling flange (Figure 2, Item 4) onto the motor shaft (Figure 2, Item 5) with the flat end towards the motor (Figure 2, Item 2) housing. Position the motor (Figure 2, Item 2) on the foundation (Figure 2, Item 10) with the mounting holes aligned. Install the four bolts (Figure 2, Item 1), four lockwashers (Figure 2, Item 12), and the four flat washers (Figure 2, Item 11). Do not tighten at this time. Align the pump coupling flange (Figure 3, Item 1) and the motor coupling flange (Figure 3, Item 2) together leaving approximately 0.016 in. (0.41 mm) space between the ends of both flanges. Refer to Figure 3. Check the alignment between the pump coupling flange (Figure 3, Item 1) and the motor coupling flange (Figure 3, Item 2). The maximum angular offset shall be 1 degree and maximum parallel offset shall be 0.015 in. (0.381 mm). Refer to Figure 3.
0122-3
TM 55-1925-273-24&P-2 INSTALLATION - Continued
0122
2 STRAIGHT EDGE
PUMP
MOTOR 1 2
M1007T73
Figure 3. Alignment of Pump Coupling Flange and Motor Coupling Flange. 7. 8. 9. 10. 11. Tighten the motor coupling flange setscrew (Figure 2, Item 3). Tighten the four bolts (Figure 2, Item 1). Install the coupling guard (Figure 2, Item 8) and secure it with the two bolts (Figure 2, Item 5), two lockwashers (Figure 2, Item 6), and the two flat washers (Figure 2, Item 7). Tighten the bolts. Install the wiring using the labels from Step (4) of REMOVAL as a guide. Remove the labels. Install the electrical junction box cover (top) (Figure 1, Item 1) and secure it with the four screws (Figure 1, Item 2).
END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. Remove the lock outs and tag outs IAW FM 4-01.502. Operate the main engine prelubrication pump under usual conditions IAW TM 55-1925-273-10 and check for proper operation. Return the main engine prelubrication pump to the desired readiness condition.
0122-4
TM 55-1925-273-24&P-2 FIELD MAINTENANCE ELECTRICAL POWER SYSTEM TEST
0123
INITIAL SETUP: Tools and Special Tools N/A Materials/Parts N/A Personnel Required Watercraft Engineer 88L (2) References TM 55-1925-273-10 Volume 3, WP 0271 Equipment Condition N/A
NOTE
The interlock system incorporated into the switchboards is designed to prevent damage by allowing power from only one source to be supplied to the electrical circuits at the same time. Perform this procedure to test that the interlocks in the electrical power distribution system are working properly.
0123-1
TM 55-1925-273-24&P-2
0123
TEST NORMAL POWER INTERLOCKS 1. Ensure that the following conditions exist prior to the testing of the electrical power interlock system: a. b. c. 2. 3. The main switchboard is powered by Ship's Service Diesel Generator (SSDG) 1, SSDG 2, or shore power IAW TM 55-1925-273-10. Set the BUS TIE CKT. BKR. (Figure 1, Item 4) on the lower center panel of the main switchboard to OFF. Set the BUS TIE BKR FEEDBACK switch (Figure 2, Item 2) on the top panel of the emergency switchboard to NORMAL.
Test that the following interlock conditions operate as listed in Table 1. If any of the interlocks fail to operate correctly, notify the maintenance supervisor. Table 1. Circuit Breaker CLOSED GEN. 1 CKT BKR (Figure 1, Item 2) GEN. 2 CKT BKR (Figure 1, Item 6) Normal Power Interlocks. Cannot Close SHORE POWER Circuit Breaker (Figure 1, Item 1) SHORE POWER Circuit Breaker (Figure 1, Item 1) GEN. 1 CKT BKR (Figure 1, Item 2) GEN. 2 CKT BKR (Figure 1, Item 6) EMG GENERATOR CIRCUIT BREAKER (Figure 2, Item 1) EMG. GEN. SWBD BUS TIE #2 (Figure 1, Item 5) EMG. GEN. SWBD BUS TIE #1 (Figure 1, Item 3)
SHORE POWER Circuit Breaker (Figure 1, Item 1) SHORE POWER Circuit Breaker (Figure 1, Item 1) BUS TIE CKT. BKR. (Figure 1, Item 4) EMG. GEN. SWBD BUS TIE #1 (Figure 1, Item 3) EMG. GEN. SWBD BUS TIE #2 (Figure 1, Item 5)
0123-2
TM 55-1925-273-24&P-2 TEST NORMAL POWER INTERLOCKS - Continued

1
0123
6 5
M2001T73
Figure 1.
Main Switchboard.
0123-3
TM 55-1925-273-24&P-2 TEST NORMAL POWER INTERLOCKS - Continued
0123
M1223T73
Emergency Switchboard.
TEST EMERGENCY DIESEL GENERATOR (EDG) POWER INTERLOCKS (NO FEEDBACK) 1. Ensure that the following circuit breaker/switches are set as indicated prior to the testing of the electrical power interlock system. a. b. 2. 3. EDG is running IAW TM 55-1925-273-10. Set the BUS TIE BKR FEEDBACK switch (Figure 2, Item 2) on the top panel of the emergency switchboard to NORMAL.
Test that the following interlock condition operates as listed in Table 2. If any of the interlocks fail to operate correctly, notify the maintenance supervisor. Table 2. EDG Power Interlocks (No Feedback). Circuit Breaker CLOSED EMG GENERATOR CIRCUIT BREAKER (Figure 2, Item 1) Cannot Close BUS TIE CKT. BKR. (Figure 1, Item 4)
END OF TASK
0123-4
TM 55-1925-273-24&P-2
0123
TEST EDG POWER INTERLOCKS (WITH FEEDBACK) 1. Ensure that the following circuit breaker/switches are set as indicated prior to the testing of the electrical power interlock system: a. b. 2. 3. EDG is running IAW TM 55-1925-273-10. Set the BUS TIE BKR FEEDBACK switch (Figure 2, Item 2) switch on the top panel of the emergency switchboard to FEEDBACK.
Test that the following interlock conditions operate as listed in Table 3. If any of the interlocks fail to operate correctly, notify the maintenance supervisor. Table 3. EDG Power, Interlocks (with Feedback). Cannot Close GEN. 1 CKT BKR (Figure 1, Item 2)
Circuit Breaker CLOSED EMG GENERATOR CIRCUIT BREAKER (Figure 2, Item 1) & BUS TIE CKT. BKR. (Figure 1, Item 4) EMG GENERATOR CIRCUIT BREAKER (Figure 2, Item 1) & BUS TIE CKT. BKR. (Figure 1, Item 4) EMG GENERATOR CIRCUIT BREAKER (Figure 2, Item 1) & BUS TIE CKT. BKR. (Figure 1, Item 4) END OF TASK END OF WORK PACKAGE
GEN. 2 CKT BKR (Figure 1, Item 6)
SHORE POWER Circuit Breaker (Figure 1, Item 1)
0123-5/6 blank
TM 55-1925-273-24&P-2 FIELD MAINTENANCE ELECTRICAL POWER SYSTEM ADJUST
0124
INITIAL SETUP: Tools and Special Tools Tool Kit, Electrical Repair (Volume 3, WP 0344, Table 1, Item 26) Materials/Parts N/A Personnel Required Watercraft Engineer 88L (2) References WP 0126 References (cont.) WP 0128 WP 0129 Volume 3, WP 0271 Volume 3, WP 0344 Equipment Condition N/A
0124-1
TM 55-1925-273-24&P-2
0124
EDG CIRCUIT BREAKER ADJUST 1. Refer to (WP 0128) for REMOVAL and INSTALLATION procedures for the emergency diesel generator (EDG) circuit breaker (Figure 1, Item 1).
WARNING
Take great care when working around energized electrical equipment. Contact between unprotected body parts and electrical conductors can cause serious injury or death. Do not wear jewelry or other conductive items while servicing energized electrical equipment. Failure to comply with these precautions can cause serious injury or death. 2. After installation, refer to Table 1 for voltage adjustments and trip settings. Table 1. Manufacturer/Type SQUARE D Type MP0841 EDG Circuit Breaker Setting Information. Adjustment/Settings Trip Settings: 1R on Long Time 1M on Inst Time
0124-2
TM 55-1925-273-24&P-2 EDG CIRCUIT BREAKER ADJUST - Continued
0124
GENERATOR 1 CIRCUIT BREAKER 3P 450V 500AT
EMERGENCY SWITCHBOARD
M1384T73
EDG Circuit Breaker Location.
0124-3
TM 55-1925-273-24&P-2
0124
SSDG 1/SSDG 2 CIRCUIT BREAKER ADJUST 1. Refer to (WP 0128) for REMOVAL and INSTALLATION procedures for the Ship's Service Diesel Generator 1 (SSDG 1) circuit breaker (Figure 2, Item 1) and/or SSDG 2 circuit breaker (Figure 2, Item 2).
WARNING
Take great care when working around energized electrical equipment. Contact between unprotected body parts and electrical conductors can cause serious injury or death. Do not wear jewelry or other conductive items while servicing energized electrical equipment. Failure to comply with these precautions can cause serious injury or death. 2. After installation, refer to Table 2 for voltage adjustments and trip settings. Table 2. Manufacturer/Type MASTERPACT Type MP08 N1 CURRENT .4-1: Set on .63 SSDG 1 and SSDG 2 Circuit Breaker Setting Information. Adjustment/Settings Trip Settings: SHORT TIME P/U 2-10: Set on 6 SHORT TIME DELAY 0-.3: Set on .1
0124-4
TM 55-1925-273-24&P-2 SSDG 1/SSDG 2 CIRCUIT BREAKER ADJUST - Continued
0124
MAIN SWITCHBOARD 2
M1385T73
SSDG 1 and SSDG 2 Circuit Breaker Location.
0124-5
TM 55-1925-273-24&P-2
0124
SHORE POWER CIRCUIT BREAKER ADJUST 1. Refer to (WP 0126) for REMOVAL and INSTALLATION procedures for the shore power circuit breaker located on the main switchboard (Figure 3, Item 1).
WARNING
Take great care when working around energized electrical equipment. Contact between unprotected body parts and electrical conductors can cause serious injury or death. Do not wear jewelry or other conductive items while servicing energized electrical equipment. Failure to comply with these precautions can cause serious injury or death. 2. After installation of the applicable circuit breaker, refer to Table 3 for voltage adjustments and trip settings. Table 3. Manufacturer/Type MERLIN GERLIN Type CJ400N INST 400A Shore Power Circuit Breaker Setting Information. Adjustment/Settings Trip Settings: MAGNETIC 2.5-10: SET ON 10
0124-6
TM 55-1925-273-24&P-2 SHORE POWER CIRCUIT BREAKER ADJUST - Continued
0124
SHORE POWER CIRCUIT BREAKER 3P 450 V 400 AT
AUX MACH SPACE NO 2 PWR PNL NO 5 3P 450 V 150 AT
CEN T HYD SYS POWER UNIT NO 1 & 2 3P 450 V 200 AT
SPARE 3P 450 V 90 AT
BILGE PUMP NO 2 3P 450 V 30 AT
LUBE OIL PURIFIER 3P 450 V 20 AT
HOT POTABLE WTR HTR NO 2 3P 450 V 20 AT
MAIN DECK PWR PNL NO 3 3P 450 V 100 AT
ENGINE ROOM PWR PNL NO 1 3P 450 V 100 AT
ENGINE ROOM EXHAUST FAN NO 1 3P 450 V 30 AT
FIRE PUMP NO 2 3P 450 V 6 AT
BUS TIE CIRCUIT BREAKER 3P 450 V 400 AT
1-25 KVA XFMR 440 V/220-110 V 3P 450 V 60 AT
A.F.F.F. PUMP 3P 450 V 40 AT
M1386T73
Shore Power Circuit Breaker Location.
0124-7/8 blank
TM 55-1925-273-24&P-2 FIELD MAINTENANCE ELECTRICAL POWER SYSTEM REPAIR
0125
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 3, WP 0344, Table 1, Item 27) Multimeter (Volume 3, WP 0344, Table 1, Item 15) Tool Kit, Electrical Repair (Volume 3, WP 0344, Table 1, Item 26) Materials/Parts N/A Personnel Required Watercraft Engineer 88L (2) References FM 4.01-502 References (cont.) TM 55-1925-273-10 Volume 3, WP 0271 Volume 3, WP 0344 Equipment Condition Set to OFF the SHORE POWER circuit breaker on the main switchboard (middle center panel). Lock out and tag out IAW FM 4.01-502. Shore power, if applicable, secured, locked out, and tagged out IAW FM 4.01-502.
WARNING
0125-1
TM 55-1925-273-24&P-2
0125
SHORE POWER RECEPTACLE REMOVAL
WARNING
Replace or repair components only after the affected circuit has been secured, locked out, and tagged out IAW FM 4-01.502. Performing replacement with the circuit energized may result in injury. 1. Use a multimeter to check for voltage at the applicable terminals (Figure 1, Item 5). If voltage is present, ensure that the appropriate circuit breakers have been set to OFF, locked out, and tagged out IAW FM 4.01-502. If no voltage is present, continue with the procedure. Remove the four screws (Figure 1, Item 6), four lockwashers (Figure 1, Item 7), and four flat washers (Figure 1, Item 8) that secure the shore power receptacle (Figure 1, Item 4) to the junction box (Figure 1, Item 1) mounted on the bulkhead of the vessel. Discard lockwashers. Label and disconnect the wiring (Figure 1, Item 2) from the terminal connection (Figure 1, Item 3). Remove the shore power receptacle (Figure 1, Item 4) from the junction box (Figure 1, Item 1).
2.
3. 4.
END OF TASK SHORE POWER RECEPTACLE INSTALLATION 1. 2. Install the shore power receptacle (Figure 1, Item 4) on the junction box (Figure 1, Item 1). Install the electrical wiring (Figure 1, Item 2) to the appropriate terminal connection (Figure 1, Item 3) using the labels from Step (3) of SHORE POWER RECEPTACLE REMOVAL as a guide. Remove the labels.
NOTE
Lockwashers are supplied with the shore power receptacle. 3. 4. Install the four screws (Figure 1, Item 6), four lockwashers (Figure 1, Item 7), and four flat washers (Figure 1, Item 8) that secure the receptacle to the junction box (Figure 1, Item 1). Perform the FOLLOW-ON MAINTENANCE procedure at the end of this work package.
0125-2
TM 55-1925-273-24&P-2 SHORE POWER RECEPTACLE INSTALLATION - Continued
0125
1 2 3
8 7 4
M1040T73
Shore Power Receptacle.
0125-3
TM 55-1925-273-24&P-2
0125
SHORE POWER CABLE CONNECTOR REMOVAL 1. 2. 3. Loosen the strain relief clamp (Figure 2, Item 11) by loosening the two screws (Figure 2, Item 2) that secure the strain relief clamp to the shore cable (Figure 2, Item 1). Remove the three screws (Figure 2, Item 10) securing the strain relief clamp housing (Figure 2, Item 3). Remove the four screws (Figure 2, Item 4), four lockwashers (Figure 2, Item 5), and four flat washers (Figure 2, Item 6) and slide the assembly down the shore power cable (Figure 2, Item 1) far enough to gain access to the wiring. Discard lockwashers. Label and disconnect the wiring (Figure 2, Item 9) from the terminals (Figure 2, Item 8). Remove the connector (Figure 2, Item 7) from the shore power cable (Figure 2, Item 1).
4. 5.
END OF TASK SHORE POWER CABLE CONNECTOR INSTALLATION 1. 2. 3. 4. 5. 6. 7. Install the shore power cable (Figure 2, Item 1) through the strain relief clamp (Figure 2, Item 11), the strain relief clamp housing (Figure 2, Item 3), and into the connector (Figure 2, Item 7). Install the wiring (Figure 2, Item 9) to the terminals (Figure 2, Item 8) using the labels from Step (4) of SHORE POWER CABLE CONNECTOR REMOVAL as a guide. Remove the labels. Install the four screws (Figure 2, Item 4), four lockwashers (Figure 2, Item 5), and four flat washers (Figure 2, Item 6) securing the connector (Figure 2, Item 7) to the shore power cable (Figure 2, Item 1). Slide the strain relief clamp housing (Figure 2, Item 3) down to the connector (Figure 2, Item 7). Install the three screws (Figure 2, Item 10) securing the strain relief clamp housing (Figure 2, Item 3) to the connector (Figure 2, Item 7). Tighten the three screws evenly around the strain relief clamp housing. Secure the strain relief clamp (Figure 2, Item 11) to the power cable (Figure 2, Item 1) by tightening the two screws (Figure 2, Item 2). Perform the FOLLOW-ON MAINTENANCE procedure at the end of this work package.
0125-4
TM 55-1925-273-24&P-2 SHORE POWER CABLE CONNECTOR INSTALLATION - Continued

1
0125
10
11 2
9 8 3 7
6 5
4
M1041T73
Figure 2. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3.
Shore Power Cable Connector.
Remove the lock outs and tag outs IAW FM 4.01-502. Perform Operation Under Usual Conditions: CONNECT TO THE SHORE POWER procedure IAW TM 55-1925-273-10 and check for proper operation of the shore power receptacle. Return the shore power receptacle to the desired readiness condition.
0125-5/6 blank
TM 55-1925-273-24&P-2 FIELD MAINTENANCE MAIN SWITCHBOARD REPLACE
0126
INITIAL SETUP: Tools and Special Tools Multimeter (Volume 3, WP 0344, Table 1, Item 15) Tool Kit, Electrical Repair (Volume 3, WP 0344, Table 1, Item 26) Materials/Parts N/A Personnel Required Watercraft Engineer 88L (2) References FM 4-01.502 TM 55-1925-273-10 Volume 3, WP 0272 Volume 3, WP 0344 Equipment Condition Set to OFF the GEN. 2 CKT BKR. circuit breaker on the main switchboard (upper left panel). Lock out and tag out IAW FM 4-01.502. Equipment Condition (cont.) Set to OFF the GEN. 1 CKT BKR. circuit breaker on the main switchboard (upper right panel). Lock out and tag out IAW FM 4-01.502. Set to OFF the BUS TIE circuit breaker on the main switchboard (lower center panel). Lock out and tag out IAW FM 4-01.502. Set to OFF the SHORE POWER circuit breaker on the main switchboard (middle center panel). Lock out and tag out IAW FM 4-01.502. Set to OFF the EMG. GEN. SWBD. BUS TIE #2 circuit breaker on the main switchboard (lower left panel). Lock out and tag out IAW FM 4-01.502. Set to OFF all circuit breakers located on the top left panel of the main switchboard. CLOSE valve FO-21, F.O. SPLY TO S.S.D.G. No. 1. Lock out and tag out IAW FM 4-01.502. CLOSE valve FO-22, F.O. SPLY TO S.S.D.G. No. 2. Lock out and tag out IAW FM 4-01.502. CLOSE valve FO-32, F.O. SPLY TO ENG (Emergency Diesel Generator). Lock out and tag out IAW FM 4-01.502. External light source available for work areas.
0126-1
TM 55-1925-273-24&P-2
0126
TOP LEFT AND RIGHT PANELS LAMP REMOVAL
WARNING
Replace or repair components only after the affected circuit has been secured, locked out, and tagged out IAW FM 4-01.502. Performing replacement with the circuit energized may result in injury. 1. 2. Remove the indicator lens cover (Figure 1, Item 5) from the main switchboard panel (Figure 1, Item 1). Remove the incandescent lamp (Figure 1, Item 6) from the main switchboard panel (Figure 1, Item 1).
END OF TASK TOP LEFT AND RIGHT PANELS LAMP INSTALLATION 1. 2. 3. Install the incandescent lamp (Figure 1, Item 6) in the main switchboard panel (Figure 1, Item 1). Install the lens cover (Figure 1, Item 5) on the main switchboard panel (Figure 1, Item 1). Perform the FOLLOW-ON MAINTENANCE procedure at the end of this work package.
END OF TASK ACCESS TO TOP LEFT AND RIGHT INNER PANEL
WARNING
Replace or repair components only after the affected circuit has been secured, locked out, and tagged out IAW FM 4-01.502. Performing replacement with the circuit energized may result in injury. 1. 2. Loosen the captive screws (Figure 1, Item 3) on the main switchboard panel (Figure 1, Item 1). Open the main switchboard panel (Figure 1, Item 1).
0126-2
TM 55-1925-273-24&P-2 ACCESS TO TOP LEFT AND RIGHT INNER PANEL - Continued
0126
300 400 200 500 100 600 AC

VOLTS
300 400 200 500 100 800 AC

AMPERES
60 58 56
HERTZ
200 62 64 66 100 300 400

AC KILOWATTS
5, 6
BUS GEN 2 AMMETER ADJ 3 1 GEN 2 GOVERNOR RAISE LOWER GOVERNOR RAISE GEN 2 POWER AVAILABLE SHORE POWER AVAILABLE VOLT ADJ 1-2 2-3 3-1 2 LOWER
1-2 2-3
7 5, 6
GEN 2 CKT BKR CLOSED
10
3-1
GEN 2 AUTO VOLT RHEO
8
GEN 2 CKT BKR OPEN CLOSED
M1042T73
Main Switchboard Top Left Panel.
0126-3
TM 55-1925-273-24&P-2 TOP LEFT AND RIGHT PANELS SWITCH REMOVAL 1. Perform the ACCESS TO TOP LEFT AND RIGHT INNER PANEL procedure in this work package.
0126
WARNING
Replace or repair components only after the affected circuit has been secured, locked out, and tagged out IAW FM 4-01.502. Performing replacement with the circuit energized may result in injury. 2. Use a multimeter to check for voltage at the applicable governor toggle switch (Figure 1, Item 7), circuit breaker switch (Figure 1, Item 8), and/or the applicable select switch (Figure 1, Items 9 and 10) to be replaced. If voltage is present, ensure that the appropriate circuit breakers and engine fuel oil valves have been secured, locked out, and tagged out IAW FM 4-01.502. If no voltage is present, continue with the procedure. Label and disconnect the wiring to the applicable select switch (Figure 2, Items 2 and 3), circuit breaker switch (Figure 2, Item 4), and/or governor toggle switch (Figure 2, Item 5) that is required to be replaced. Remove the knob(s) and the mounting hardware from the applicable circuit breaker switch that is being replaced. Remove the applicable circuit breaker switch from the main switchboard panel (Figure 1, Item 1).
3. 4. 5.
END OF TASK TOP LEFT AND RIGHT PANELS SWITCH INSTALLATION 1. Install the replacement select switch (Figure 1, Items 9 and 10), the circuit breaker switch (Figure 1, Item 8), and/or the governor toggle switch (Figure 1, Item 7) through the rear of the main switchboard panel (Figure 1, Item 1). Install the mounting hardware on the replacement select switches (Figure 2, Items 2 and 3), the circuit breaker switch (Figure 2, Item 4), and/or the toggle switch (Figure 2, Item 5). Install the wiring to the appropriate switch using labels from Step (3) of TOP LEFT AND RIGHT PANELS SWITCH REMOVAL as a guide. Remove the labels. Perform the SECURING TOP LEFT AND RIGHT INNER PANEL procedure in this work package. Perform the FOLLOW-ON MAINTENANCE procedure at the end of this work package.
2. 3. 4. 5.
0126-4
TM 55-1925-273-24&P-2 TOP LEFT AND RIGHT PANELS SWITCH INSTALLATION - Continued

1
0126
5 3
M1043T73
Main Switchboard Top Left Aft Panel (Rear).
TOP LEFT AND RIGHT PANELS METER REMOVAL 1. Peform the ACCESS TO TOP LEFT AND RIGHT INNER PANEL procedure in this work package.
WARNING
Replace or repair components only after the affected circuit has been secured, locked out, and tagged out IAW FM 4-01.502. Performing replacement with the circuit energized may result in injury. 2. Use a multimeter to check for voltage at the applicable meter (Figure 1, Item 2). If voltage is present, ensure that the appropriate circuit breakers and engine fuel oil valves have been secured, locked out, and tagged out IAW FM 4-01.502. If no voltage is present, continue with the procedure.
0126-5
TM 55-1925-273-24&P-2 TOP LEFT AND RIGHT PANELS METER REMOVAL - Continued 3. 4. 5. 6. Remove the four screws (Figure 1, Item 4) from the applicable meter (Figure 1, Item 2).
0126
Label and disconnect the electrical wiring to the applicable meter (Figure 2, Item 1) that is being replaced. Remove any associated hardware from the applicable meter(s) being replaced. Remove the meter(s) from the main switchboard panel (Figure 1, Item 1).
END OF TASK TOP LEFT AND RIGHT PANELS METER INSTALLATION 1. 2. 3. 4. 5. 6. Install the meter(s) (Figure 1, Item 2) through the rear of the main switchboard panel (Figure 1, Item 1). Install the four screws (Figure 1, Item 4) in the meter (Figure 1, Item 2). Install any associated mounting hardware on the meter (Figure 1, Item 2). Connect the electrical wiring to the meter (Figure 2, Item 1) using the labels from Step (4) of TOP LEFT AND RIGHT PANELS METER REMOVAL as a guide. Remove the labels. Perform the SECURING THE TOP LEFT AND RIGHT INNER PANEL procedure in this work package. Perform the FOLLOW-ON MAINTENANCE procedure at the end of this work package.
END OF TASK SECURING THE TOP LEFT AND RIGHT INNER PANEL 1. 2. Close the main switchboard panel (Figure 1, Item 1). Secure the main switchboard panel by tightening the captive screws (Figure 1, Item 3).
END OF TASK MIDDLE LEFT AND RIGHT PANELS CIRCUIT BREAKER REMOVAL
NOTE
The circuit breaker may have internally mounted and/or factory installed accessories. 1. 2. Loosen the captive screws (Figure 3, Item 2) on the door panel (Figure 3, Item 4). Remove the door panel (Figure 3, Item 4) using the handrail (Figure 3, Item 1).
WARNING
Replace or repair components only after the affected circuit has been secured, locked out, and tagged out IAW FM 4-01.502. Performing replacement with the circuit energized may result in injury. 3. Use a multimeter to check for voltage at the applicable circuit breaker (Figure 3, Item 5). If voltage is present, ensure that the appropriate circuit breakers and engine fuel oil valves have been secured, locked out, and tagged out IAW FM 4.01-502. If no voltage is present, continue with the procedure. Loosen the associated screws from the circuit breaker (Figure 3, Item 5).
4.
0126-6
TM 55-1925-273-24&P-2 MIDDLE LEFT AND RIGHT PANELS CIRCUIT BREAKER REMOVAL - Continued 5. Remove the circuit breaker (Figure 3, Item 5) from the main switchboard (Figure 3, Item 3 ).
0126
EMG GEN SWBD BUS TIE 2 3P 450 V 125 AT N/A
ENG RM SUPPLY FAN 2 3P 450 V 40 AT
GALLEY 440 V PWR PNL 2 3P 450 V 125 AT
ENG RM EXH FAN 2 3P 450 V 30 AT
M1044T73
Figure 3. Main Switchboard Middle Left Panel. END OF TASK
0126-7
TM 55-1925-273-24&P-2
0126
MIDDLE LEFT AND RIGHT PANELS CIRCUIT BREAKER INSTALLATION 1. 2. 3. 4. 5. Install the circuit breaker (Figure 3, Item 5) in the main switchboard (Figure 3, Item 3). Tighten the associated screws on the circuit breaker (Figure 3, Item 5). Install the door panel (Figure 3, Item 4) using the handrail (Figure 3, Item 1) on the main switchboard (Figure 3, Item 3). Tighten the captive screws (Figure 3, Item 2). Perform the FOLLOW-ON MAINTENANCE procedure in this work package.
END OF TASK ACCESS TO TOP CENTER INNER PANEL
WARNING
Replace or repair components only after the affected circuit has been secured, locked out, and tagged out IAW FM 4-01.502. Performing replacement with the circuit energized may result in injury. 1. 2. Loosen the captive screws (Figure 4, Item 7) on the door panel (Figure 4, Item 10). Open the door panel (Figure 4, Item 10).
END OF TASK TOP CENTER PANEL SYNC LIGHT REMOVAL 1. 2. Remove the sync light and lens cover (Figure 4, Item 5) from the door panel (Figure 4, Item 10). Remove the lamp (Figure 4, Item 6) from the door panel (Figure 4, Item 10).
END OF TASK TOP CENTER PANEL SYNC LIGHT INSTALLATION 1. 2. 3. Install the lamp (Figure 4, Item 6) in the door panel (Figure 4, Item 10). Install the sync light and lens cover (Figure 4, Item 5) on the door panel (Figure 4, Item 10). Perform the FOLLOW-ON MAINTENANCE procedure in this work package.
0126-8
TM 55-1925-273-24&P-2 TOP CENTER PANEL SYNC LIGHT INSTALLATION - Continued

3 1, 2 4 5, 6 4 5, 6 4 3
0126
7
SHORE POWER FREQUENCY
300 400 200 500 100 AC 800

VOLTS
BUS TIE CKT BKR CLOSED
SYNCHRONIZING GEN 2 GEN 1 INC INC
8
SHORE POWER
VOLT METER OFF
21
12
A PHASE
B PHASE
C PHASE
A PHASE
B PHASE
C PHASE
2S BUS GND DETECT PUSH TO TEST LAMPS

1 2 3
1S BUS GND DETECT PUSH TO TEST LAMPS
1, 2
PHASE SEQUENCE INCORRECT 321 CORRECT 123
1, 2 10 7
9 1, 2
1, 2
M1045T73
Figure 4. Main Switchboard Top Center Panel. END OF TASK 0126-9
TM 55-1925-273-24&P-2 TOP CENTER PANEL LAMP REMOVAL 1. 2. Remove the indicator lens cover (Figure 4, Item 1) from the door panel (Figure 4, Item 10). Remove the incandescent lamp (Figure 4, Item 2) from the door panel (Figure 4, Item 10).
0126
END OF TASK TOP CENTER PANEL LAMP INSTALLATION 1. 2. 3. Install the incandescent lamp (Figure 4, Item 2) in the door panel (Figure 4, Item 10). Install the indicator lens cover (Figure 4, Item 1) on the door panel (Figure 4, Item 10). Perform the FOLLOW-ON MAINTENANCE procedure in this work package.
END OF TASK TOP CENTER PANEL PUSHBUTTON REMOVAL 1. Perform the ACCESS TO TOP CENTER INNER PANEL procedure in this work package.
WARNING
Replace or repair components only after the affected circuit has been secured, locked out, and tagged out IAW FM 4-01.502. Performing replacement with the circuit energized may result in injury. 2. Use a multimeter to check for voltage at the applicable pushbutton(s) (Figure 4, Item 9). If voltage is present, ensure that the proper circuit breakers and engine fuel oil valves have been secured, locked out, and tagged out IAW FM 4-01.502. If no voltage is present, continue with the procedure. Remove any associated hardware from the applicable pushbutton(s) (Figure 4, Item 9). Label and disconnect the electrical wiring to the pushbutton (Figure 5, Item 3). Remove the pushbutton (Figure 5, Item 3) from the door panel (Figure 4, Item 10).
3. 4. 5.
END OF TASK TOP CENTER PANEL PUSHBUTTON INSTALLATION 1. 2. 3. 4. 5. Install the pushbutton(s) (Figure 5, Item 3) in the door panel (Figure 4, Item 10). Install the associated hardware for the pushbutton (Figure 5, Item 3). Connect the electrical wiring to the pushbutton (Figure 5, Item 3) using the labels from Step (4) of TOP CENTER PANEL PUSHBUTTON REMOVAL as a guide. Remove the labels. Perform the SECURING THE TOP CENTER INNER PANEL procedure in this work package. Perform the FOLLOW-ON MAINTENANCE procedure in this work package.
0126-10
TM 55-1925-273-24&P-2 TOP CENTER PANEL PUSHBUTTON INSTALLATION - Continued

1
0126
M1046T73
Figure 5. Main Switchboard, Top Center Panel (Rear). END OF TASK
0126-11
TM 55-1925-273-24&P-2
0126
TOP CENTER PANEL SWITCH REMOVAL 1. Perform the ACCESS TO TOP CENTER INNER PANEL procedure in this work package.
WARNING
Replace or repair components only after the affected circuit has been secured, locked out, and tagged out IAW FM 4-01.502. Performing replacement with the circuit energized may result in injury. 2. Use a multimeter to check for voltage at the applicable switch (Figure 4, Item 8). If voltage is present, ensure that the appropriate circuit breakers and engine fuel oil valves have been secured, locked out, and tagged out IAW FM 4-01.502. If no voltage is present, continue with the procedure. Label and disconnect the electrical wiring to the applicable switch (Figure 5, Item 2). Remove the knob(s) and the associated hardware from the applicable switch (Figure 4, Item 8). Remove the switch (Figure 4, Item 8) from the door panel (Figure 4, Item 10).
3. 4. 5.
END OF TASK TOP CENTER PANEL SWITCH INSTALLATION 1. 2. 3. 4. 5. Install the switch (Figure 5, Item 2) through the rear of the door panel (Figure 4, Item 10). Install the associated hardware on the switch (Figure 4, Item 8). Connect the electrical wiring to the switch (Figure 5, Item 2) using the labels from Step (3) of TOP CENTER PANEL SWITCH REMOVAL as a guide. Remove the labels. Perform the SECURING THE TOP CENTER INNER PANEL procedure in this work package. Perform the FOLLOW-ON MAINTENANCE procedure in this work package.
END OF TASK
0126-12
TM 55-1925-273-24&P-2
0126
TOP CENTER PANEL METER REMOVAL 1. Perform the ACCESS TO THE TOP CENTER INNER PANEL procedure in this work package.
WARNING
Replace or repair components only after the affected circuit has been secured, locked out, and tagged out IAW FM 4-01.502. Performing replacement with the circuit energized may result in injury. 2. Use a multimeter to check for voltage at the applicable meter (Figure 4, Item 4) to be replaced. If voltage is present, ensure that the appropriate circuit breakers and engine fuel oil valves have been secured, locked out, and tagged out IAW FM 4-01.502. If no voltage is present, continue with this procedure. Remove the four screws (Figure 4, Item 3) from the meter (Figure 4, Item 4). Label and disconnect the electrical wiring from the meter (Figure 5, Item 1). Remove any associated hardware attached from the meter (Figure 5, Item 1). Remove the meter (Figure 5, Item 1) from the door panel (Figure 4, Item 10).
3. 4. 5. 6.
END OF TASK TOP CENTER PANEL METER INSTALLATION 1. 2. 3. 4. 5. Install the meter (Figure 5, Item 1) through the rear of the door panel (Figure 4, Item 10). Install the associated hardware on the meter (Figure 5, Item 1). Connect the electrical wiring to the meter (Figure 5, Item 1) using the labels from Step (4) of TOP CENTER PANEL METER REMOVAL as a guide. Remove the labels. Perform the SECURING THE TOP INNER PANEL procedure in this work package. Perform the FOLLOW-ON MAINTENANCE procedure in this work package.
END OF TASK SECURING THE TOP CENTER INNER PANEL 1. 2. Close the door panel (Figure 4, Item 10). Secure the top inner panel by tightening the captive screws (Figure 4, Item 7).
END OF TASK
0126-13
TM 55-1925-273-24&P-2
0126
BOTTOM CENTER PANEL CIRCUIT BREAKERS REPLACEMENT
WARNING
NOTE
Procedures for the repair of the circuit breakers are basically the same as those described in the MIDDLE LEFT AND RIGHT PANELS procedure in this work package and illustrated by Figure 3. For configuration variance of the circuit breakers (Figure 6, Item 1), see Figure 6. Procedures for the removal and installation of the circuit breakers are basically the same as those described in the MIDDLE LEFT AND RIGHT PANELS procedure in this work package and illustrated by Figure 3. For configuration variance of the circuit breakers (Figure 6, Item 1), see Figure 6.
0126-14
TM 55-1925-273-24&P-2 BOTTOM CENTER PANEL CIRCUIT BREAKERS REPLACEMENT - Continued
0126
SHORE POWER CIRCUIT BREAKER 3P 450 V 400 AT
CEN T HYD SYS POWER UNIT NO 1 & 2 3P 450 V 200 AT
BILGE PUMP NO 2 3P 450 V 30 AT
LUBE OIL PURIFIER 3P 450 V 20 AT
MAIN DECK PWR PNL NO 3 3P 450 V 100 AT
ENGINE ROOM PWR PNL NO 1 3P 450 V 100 AT
ENGINE ROOM EXHAUST FAN NO 1 3P 450 V 30 AT
FIRE PUMP NO 2 3P 450 V 6 AT
BUS TIE CIRCUIT BREAKER 3P 450 V 400 AT
1-25 KVA XFMR 440 V/220-110 V 3P 450 V 60 AT
A.F.F.F. PUMP 3P 450 V 40 AT
M1047T73
Main Switchboard Bottom Center Panel.
0126-15
TM 55-1925-273-24&P-2
0126
FOLLOW-ON MAINTENANCE 1. 2. 3. Remove the lock outs and tag outs IAW FM 4-01.502. Perform the Under Usual Conditions: PREPARATION FOR USE AND POWER GENERATION IAW TM 55-1925-273-10 and verify proper operation of the main switchboard. Return the main switchboard to the desired readiness condition.
0126-16
TM 55-1925-273-24&P-2 FIELD MAINTENANCE MAIN SWITCHBOARD REPAIR
0127
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 3, WP 0344, Table 1, Item 27) Multimeter (Volume 3, WP 0344, Table 1, Item 15) Tool Kit, Electrical Repair (Volume 3, WP 0344, Table 1, Item 26) Materials/Parts N/A Personnel Required Watercraft Engineer 88L (2) References FM 4-01.502 References (cont.) TM 55-1925-273-10 Volume 3, WP 0272 Volume 3, WP 0343 Volume 3, WP 0344 Equipment Condition CLOSE valves FO-21, F.O. SPLY TO S.S.D.G. NO 1; FO-22, F.O. SPLY TO S.S.D.G NO. 2; and FO-32, F.O. SPLY TO ENG. Lock out and tag out IAW FM 4-01.502. Set to OFF the SHORE PWR. RCPT. circuit breaker on the main switchboard. Lock out and tag out IAW FM 4-01.502. External lighting for the work area.
0127-1
TM 55-1925-273-24&P-2
0127
MAIN SWITCHBOARD ACCESS PANEL DISASSEMBLY 1. 2. Loosen the captive screws (Figure 1, Item 2) on the desired panel (Figure 1, Items 3, 4, 5, 6, 7, 8, and 9). Remove/OPEN the desired panel (Figure 1, Items 3, 4, 5, 6, 7, 8, and 9) from/on the main switchboard (Figure 1, Item 1).
END OF TASK MAIN SWITCHBOARD ACCESS PANEL ASSEMBLY 1. 2. 3. Install/CLOSE the desired panel (Figure 1, Items 3, 4, 5, 6, 7, 8, and 9) on the main switchboard (Figure 1, Item 1). Tighten the captive screws (Figure 1, Item 2) on the desired panel (Figure 1, Items 3, 4, 5, 6, 7, 8, and 9). Perform the FOLLOW-ON MAINTENANCE procedure at the end of this package.
0127-2
TM 55-1925-273-24&P-2 MAIN SWITCHBOARD ACCESS PANEL ASSEMBLY - Continued
0127
4 9 2 2 8 2 2 2 2
M1224T73
Main Switchboard.
0127-3
TM 55-1925-273-24&P-2
0127
FUSE REMOVAL 1. Perform the MAIN SWITCHBOARD ACCESS PANEL DISASSEMBLY procedure in this work package.
WARNING
Replace or repair components only after the affected circuit has been secured, locked out, and tagged out IAW FM 4-01.502. Performing replacement with the circuit energized may result in injury. 2. Use a multimeter to check for voltage at the fuse(s) (Figure 2, Item 1) to be replaced. If voltage is present, ensure that the appropriate fuel oil valves have been secured, locked out, and tagged out IAW FM 4-01.502. If no voltage is present, continue with this procedure. Using a fuse puller, remove the applicable fuse(s) (Figure 2, Item 1) from the fuse holder(s).
3.
END OF TASK FUSE INSTALLATION 1. 2. Using a fuse puller, install the applicable fuse(s) (Figure 2, Item 1) in the fuse holder(s). Perform the MAIN SWITCHBOARD ACCESS PANEL ASSEMBLY procedure in this work package.
END OF TASK RELAY REMOVAL 1. Perform the MAIN SWITCHBOARD ACCESS PANEL DISASSEMBLY procedure in this work package.
WARNING
Replace or repair components only after the affected circuit has been secured, locked out, and tagged out IAW FM 4-01.502. Performing replacement with the circuit energized may result in injury. 2. Use a multimeter to check for voltage at the relay(s) (Figure 2, Item 2) to be replaced. If voltage is present, ensure that the proper fuel oil valves have been secured, locked out, and tagged out IAW FM 4-01.502. If no voltage is present, continue with this procedure. Label and disconnect the wiring attached to the applicable relay (Figure 2, Item 2). Remove the relay from the relay from the main switchboard (Figure 1, Item 1).
3. 4.
0127-4
TM 55-1925-273-24&P-2 RELAY REMOVAL - Continued

1 2 3 FUSES
RELAY RELAY
0127
2
TRANSFORMER TRANSFORMER TRANSFORMER
RELAY
GENERATOR 2 SECTION BACK PANEL LAYOUT 1 FUSES

TRANSFORMER TRANSFORMER TRANSFORMER TRANSFORMER
2
RELAY
TRANSFORMER TRANSFORMER TRANSFORMER TRANSFORMER TRANSFORMER TRANSFORMER
RELAY
SYNCHRONIZING SECTION BACK PANEL LAYOUT 2 1 FUSES 3

RELAY
RELAY
3 2
RELAY
TRANSFORMER
TRANSFORMER
TRANSFORMER
GENERATOR 1 SECTION BACK PANEL LAYOUT
M1225T73
Figure 2. Main Switchboard Back Panel Layout. END OF TASK
0127-5
TM 55-1925-273-24&P-2 RELAY INSTALLATION 1. 2. 3. Install the applicable relay(s) (Figure 2, Item 2) in the main switchboard (Figure 1, Item 1).
0127
Connect the wiring to the relay (Figure 2, Item 2) using the labels from Step (3) of RELAY REMOVAL as a guide. Remove the labels. Perform the MAIN SWITCHBOARD ACCESS PANEL ASSEMBLY procedure in this work package.
END OF TASK TRANSFORMER REMOVAL 1. Perform the MAIN SWITCHBOARD ACCESS PANEL DISASSEMBLY procedure in this work package.
WARNING
Replace or repair components only after the affected circuit has been secured, locked out, and tagged out IAW FM 4-01.502. Performing replacement with the circuit energized may result in injury. 2. Use a multimeter to check for voltage at the transformer(s) (Figure 2, Item 3) to be replaced. If voltage is present, ensure the proper fuel oil valve has been secured, locked out, and tagged out IAW FM 4-01.502. If no voltage is present, continue with this procedure. Label and disconnect the wiring to the applicable transformer (Figure 2, Item 3). Remove the associated mounting hardware from the transformer (Figure 2, Item 3). Remove the transformer (Figure 2, Item 3) from the main switchboard (Figure 1, Item 1).
3. 4. 5.
END OF TASK TRANSFORMER INSTALLATION 1. 2. 3. Install the applicable transformer(s) (Figure 2, Item 3) in the main switchboard (Figure 1, Item 1) and secure it with the associated mounting hardware. Connect the wiring to the transformer (Figure 2, Item 3) using the labels from Step (3) of TRANSFORMER REMOVAL as a guide. Remove the labels. Close and secure the main switchboard door panels.
END OF TASK
0127-6
TM 55-1925-273-24&P-2
0127
FOLLOW-ON MAINTENANCE 1. 2. 3. 4. Remove the lock outs and tag outs IAW FM 4-01.502. Perform Operation Under Usual Conditions: PREPARATION FOR USE IAW TM 55-1925-273-10. Perform Operation Under Usual Conditions: POWER GENERATION IAW TM 55-1925-273-10 and check for proper operation. Return the main switchboard to the desired readiness condition.
0127-7/8 blank
TM 55-1925-273-24&P-2 FIELD MAINTENANCE EMERGENCY SWITCHBOARD REPAIR
0128
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 3, WP 0344, Table 1, Item 27) Gloves, Leather (Volume 3, WP 0344, Table 1, Item 9) Helmet, Safety (Volume 3, WP 0344, Table 1, Item 11) Multimeter (Volume 3, WP 0344, Table 1, Item 15) Tool Kit, Electrical Repair (Volume 3, WP 0344, Table 1, Item 26) Materials/Parts N/A Personnel Required Watercraft Engineer 88L (2) References FM 4-01.502 References (cont.) TM 55-1925-273-10 WP 0154 Volume 3, WP 0273 Volume 3, WP 0343 Volume 3, WP 0344 Equipment Condition CLOSE valves FO-21, F.O. SPLY TO S.S.D.G. No. 1; FO-22, F.O. SPLY TO S.S.D.G. No. 2; and FO-32, F.O. SPLY TO ENG. Lock out and tag out IAW FM 4-01.502. Shore power receptacle locked out and tagged out IAW FM 4-01.502. External lighting source available for work areas.
0128-1
TM 55-1925-273-24&P-2
0128
ACCESS TO TOP INNER PANEL
WARNING
Replace or repair components only after the affected circuit has been secured, locked out, and tagged out IAW FM 4-01.502. Performing replacement with the circuit energized may result in injury. 1. 2. Loosen the emergency switchboard door panel captive screws (Figure 1, Item 3). Open the emergency switchboard door panel (Figure 1, Item 4).
END OF TASK TOP PANEL LAMP REMOVAL 1. 2. Remove the indicator lens cover (Figure 1, Item 5) from the emergency switchboard door panel (Figure 1, Item 4). Remove the incandescent lamp (Figure 1, Item 6) from the emergency switchboard door panel (Figure 1, Item 4).
END OF TASK TOP PANEL LAMP INSTALLATION 1. 2. 3. 4. Install the incandescent lamp (Figure 1, Item 6) in the emergency switchboard door panel (Figure 1, Item 4). Install the indicator lens cover (Figure 1, Item 5) on the emergency switchboard door panel (Figure 1, Item 4). Perform the SECURE THE TOP INNER PANEL procedure in this work package. Perform the FOLLOW-ON MAINTENANCE procedure at the end of this work package.
0128-2
TM 55-1925-273-24&P-2 TOP PANEL LAMP INSTALLATION - Continued

1 2 3
0128
4
300 400 200 500
100 150 50 200 AC 0 AMPERES
60 58 56 62 64
100 600 AC 0 VOLTS
50 HERTZ66
EMG GENERATOR POWER AVAILABLE VOLT METER OFF 3-1 1-2 AMMETER OFF
5, 6
EMG GENERATOR AUTO VOLT RHEO
8 9 5, 6
EMG GENERATOR CIRCUIT BREAKER OPEN
EMG GENERATOR CIRCUIT BREAKER CLOSED
EMG GENERATOR CIRCUIT BREAKER OPEN CLOSED
MAIN SWBD BUS TIE CIRCUIT BREAKER OPEN
MAIN SWBD BUS TIE CIRCUIT BREAKER CLOSED
BUS TIE BKR SET FOR FEEDBACK
A PHASE
B PHASE
C PHASE
EMG CONTROL SW MAN OFF STBY
BUS TIE BKR FEEDBACK SW NORMAL FEEDBACK
7
EMG GEN BUS GND DET PUSH TO TEST LAMPS
5, 6
3 7
M1226T73
Emergency Switchboard Top Panel.
0128-3
TM 55-1925-273-24&P-2 TOP PANEL PUSHBUTTON REMOVAL 1. Perform the ACCESS TO TOP INNER PANEL procedure in this work package.
0128
WARNING
Replace or repair components only after the affected circuit has been secured, locked out, and tagged out IAW FM 4-01.502. Performing replacement with the circuit energized may result in injury. 2. Use a multimeter to check for voltage at the pushbutton(s) (Figure 1, Item 7). If voltage is present, ensure that the proper engine fuel oil valves have been secured, locked out, and tagged out IAW FM 4-01.502. If no voltage is present, continue with the procedure. Remove any associated hardware from the pushbutton(s) (Figure 1, Item 7). Label and disconnect the electrical wiring to the pushbutton(s) (Figure 1, Item 7). Remove the pushbutton (Figure 1, Item 7) from the emergency switchboard door panel (Figure 1, Item 4).
3. 4. 5.
END OF TASK TOP PANEL PUSHBUTTON INSTALLATION 1. 2. 3. 4. 5. Install the pushbutton(s) (Figure 1, Item 7) in the rear of the emergency switchboard door panel (Figure 1, Item 4). Install the associated hardware on the pushbuttons(s) (Figure 1, Item 7). Connect the electrical wiring to the pushbuttons(s) (Figure 1, Item 7) using the labels from Step (4) of TOP PANEL PUSHBUTTON REMOVAL as a guide. Remove the labels. Perform the SECURE THE TOP INNER PANEL procedure in this work package. Perform the FOLLOW-ON MAINTENANCE procedure at the end of this work package.
END OF TASK
0128-4
TM 55-1925-273-24&P-2
0128
TOP PANEL SWITCH REMOVAL 1. Perform the ACCESS TO TOP INNER PANEL procedure at the beginning of this work package.
WARNING
Replace or repair components only after the affected circuit has been secured, locked out, and tagged out IAW FM 4-01.502. Performing replacement with the circuit energized may result in injury. 2. Use a multimeter to check for voltage at the select switch (Figure 1, Item 8). If voltage is present, ensure that the proper engine fuel oil valves have been secured, locked out, and tagged out IAW FM 4-01.502. If no voltage is present, continue with the procedure. Label and disconnect the electrical wiring to the select switch (Figure 1, Item 8). Remove the knob (Figure 1, Item 9) and the associated hardware from the select switch (Figure 1, Item 8). Remove the select switch (Figure 1, Item 8) from the emergency switchboard door panel (Figure 1, Item 4).
3. 4. 5.
END OF TASK TOP PANEL SWITCH INSTALLATION 1. 2. 3. 4. 5. Install the select switch (Figure 1, Item 8) through the rear of the emergency switchboard door panel (Figure 1, Item 4). Install the associated hardware and the knob (Figure 1, Item 9) on the select switch (Figure 1, Item 8). Connect the electrical wiring to the select switch (Figure 1, Item 8) using the labels from Step (3) of TOP PANEL SWITCH REMOVAL as a guide. Remove the labels. Perform the SECURE THE TOP INNER PANEL procedure in this work package. Perform the FOLLOW-ON MAINTENANCE procedure at the end of this work package.
END OF TASK
0128-5
TM 55-1925-273-24&P-2
0128
TOP PANEL METER REMOVAL 1. Perform the ACCESS TO TOP INNER PANEL procedure in this work package.
WARNING
Replace or repair components only after the affected circuit has been secured, locked out, and tagged out IAW FM 4-01.502. Performing replacement with the circuit energized may result in injury. 2. Use a multimeter to check for voltage at the meter (Figure 1, Item 2). If voltage is present, ensure that the proper engine fuel oil valves have been secured, locked out, and tagged out IAW FM 4-01.502. If no voltage is present, continue with procedure. Remove the four screws (Figure 1, Item 1) from the applicable meter (Figure 1, Item 2). Label and disconnect the electrical wiring to the meter (Figure 1, Item 2). Remove any associated hardware attached to the meter (Figure 1, Item 2). Remove the meter (Figure 1, Item 2) from the emergency switchboard door panel (Figure 1, Item 4).
3. 4. 5. 6.
END OF TASK TOP PANEL METER INSTALLATION 1. 2. 3. 4. 5. 6. Install the meter (Figure 1, Item 2) through the rear of the emergency switchboard door panel (Figure 1, Item 4). Install the four screws (Figure 1, Item 1) on the meter (Figure 1, Item 2). Install the associated hardware on the meter (Figure 1, Item 2). Connect the electrical wiring to the meter (Figure 1, Item 2) using the labels from Step (4) of TOP PANEL METER REMOVAL as a guide. Remove the labels. Perform the SECURE THE TOP INNER PANEL procedure in this work package. Perform the FOLLOW-ON MAINTENANCE procedure at the end of this work package.
END OF TASK SECURE THE TOP INNER PANEL 1. 2. Close the emergency switchboard door panel (Figure 1, Item 4). Secure the top inner panel by tightening the captive screws (Figure 1, Item 3).
END OF TASK
0128-6
TM 55-1925-273-24&P-2
0128
ACCESS TO MIDDLE INNER PANEL
WARNING
Replace or repair components only after the affected circuit has been secured, locked out, and tagged out IAW FM 4-01.502. Performing replacement with the circuit energized may result in injury. 1. 2. 3. Loosen the emergency switchboard door panel captive screws (Figure 2, Item 3). Remove the emergency switchboard door panel (Figure 2, Item 7) using the handrail (Figure 2, Item 1). Store the emergency switchboard door panel (Figure 2, Item 7) in a safe place.
1 2 3 2
2 7 6 5
3P 450V 30AT BILGE PUMP 1 3P 450V 30AT FUEL OIL XFER PUMP 3P 450V 15AT MAIN SWBD BUS TIE CIRCUIT BREAKER SPARE 3P 450V AC 300A INST STEERING GEAR PUMP 1 3P 450V 300A INST FIRE PUMP 1 450V 60AT 3-10 KVA 1-10 XFMRS 3P 450V 50AT
M1227T73
Emergency Switchboard Middle Panel.
0128-7
TM 55-1925-273-24&P-2
0128
MIDDLE PANEL CIRCUIT BREAKER REMOVAL
NOTE
The circuit breaker may have internally mounted and/or factory installed accessories. 1. Perform the ACCESS TO MIDDLE INNER PANEL procedure in this work package.
WARNING
Replace or repair components only after the affected circuit has been secured, locked out, and tagged out IAW FM 4-01.502. Performing replacement with the circuit energized may result in injury. 2. Use a multimeter to check for voltage at the circuit breaker (Figure 1, Item 7). If voltage is present, ensure that the proper engine fuel oil valves have been secured, locked out, and tagged out IAW FM 4-01.502. If no voltage is present, continue with the procedure. Remove the screws (Figure 2, Item 5) from the circuit breaker (Figure 2, Item 6). Remove the circuit breaker (Figure 2, Item 6) from the emergency switchboard (Figure 2, Item 4).
3. 4.
END OF TASK MIDDLE PANEL CIRCUIT BREAKER INSTALLATION 1. 2. 3. 4. Install the circuit breaker (Figure 2, Item 6) in the emergency switchboard (Figure 2, Item 4). Install the screws (Figure 2, Item 5) in the circuit breaker (Figure 2, Item 6). Perform the SECURE THE MIDDLE INNER PANEL procedure in this work package. Perform the FOLLOW-ON MAINTENANCE procedure at the end of this work package.
END OF TASK MIDDLE PANEL SWITCH REMOVAL 1. Perform the ACCESS TO MIDDLE INNER PANEL procedure in this work package.
WARNING
Replace or repair components only after the affected circuit has been secured, locked out, and tagged out IAW FM 4-01.502. Performing replacement with the circuit energized may result in injury. 2. Use a multimeter to check for voltage at the circuit breaker switch (Figure 2, Item 2). If voltage is present, ensure that the proper engine fuel oil valves have been secured, locked out, and tagged out IAW FM 4-01.502. If no voltage is present, continue with the procedure.
0128-8
TM 55-1925-273-24&P-2 MIDDLE PANEL SWITCH REMOVAL - Continued 3. 4. 5. Label and disconnect the electrical wiring to the applicable circuit breaker switch (Figure 2, Item 2). If applicable, remove any associated hardware from the circuit breaker switch (Figure 2, Item 2). Remove the applicable circuit breaker switch (Figure 2, Item 2) from the emergency switchboard (Figure 2, Item 4).
0128
END OF TASK MIDDLE PANEL SWITCH INSTALLATION 1. 2. 3. 4. 5. Install the replacement circuit breaker switch (Figure 2, Item 2) through the emergency switchboard (Figure 2, Item 4). Install the associated hardware on the circuit breaker switch (Figure 2, Item 2). Connect the electrical wiring to the circuit breaker switch (Figure 2, Item 2) using the labels from Step (3) of MIDDLE PANEL SWITCH REMOVAL as a guide. Remove the labels. Perform the SECURE THE MIDDLE PANEL procedure in this work package. Perform the FOLLOW-ON MAINTENANCE procedure at the end of this work package.
END OF TASK SECURE THE MIDDLE INNER PANEL 1. 2. Install the emergency switchboard door panel (Figure 2, Item 7) using the handrail (Figure 2, Item 1). Install the emergency switchboard door panel captive screws (Figure 2, Item 3).
END OF TASK ACCESS TO EMERGENCY SWITCHBOARD BACK PANEL Access to the back panel is gained by going through the front panel of the emergency switchboard. Perform the ACCESS TO MIDDLE INNER PANEL procedure or the ACCESS TO TOP INNER PANEL procedure in this work package. END OF TASK
0128-9
TM 55-1925-273-24&P-2
0128
BACK PANEL FUSE REMOVAL 1. Perform the ACCESS TO EMERGENCY SWITCHBOARD BACK PANEL procedure in this work package.
WARNING
Replace or repair components only after the affected circuit has been secured, locked out, and tagged out IAW FM 4-01.502. Performing replacement with the circuit energized may result in injury. 2. Use a multimeter to check for voltage at the fuse(s) (Figure 3, Item 1). If voltage is present, ensure that the proper engine fuel oil valves have been secured, locked out, and tagged out IAW FM 4-01.502. If no voltage is present, continue with the procedure. Using a fuse puller, remove the fuse(s) (Figure 3, Item 1) from the fuse holder(s).
1 2
3.
FUSES RELAY RELAY RELAY RELAY RELAY
TRANSFORMER
TRANSFORMER
TRANSFORMER
4
TRANSFORMER
TRANSFORMER
M1228T73
Emergency Switchboard Back Panel Layout.
0128-10
TM 55-1925-273-24&P-2
0128
BACK PANEL FUSE INSTALLATION 1. 2. 3. Using a fuse puller, install the fuse(s) (Figure 3, Item 1) in the fuse holder(s). Perform the SECURE THE EMERGENCY SWITCHBOARD BACK PANEL procedure in this work package. Perform the FOLLOW-ON MAINTENANCE procedure at the end of this work package.
END OF TASK BACK PANEL RELAY REMOVAL 1. Perform the ACCESS TO EMERGENCY SWITCHBOARD BACK PANEL procedure in this work package.
WARNING
Replace or repair components only after the affected circuit has been secured, locked out, and tagged out IAW FM 4-01.502. Performing replacement with the circuit energized may result in injury. 2. Use a multimeter to check for voltage at the relay(s) (Figure 3, Item 2). If voltage is present, ensure that the proper engine fuel oil valves have been secured, locked out, and tagged out IAW FM 4-01.502. If no voltage is present, continue with the procedure. Label and disconnect the electrical wiring attached to the relay (Figure 3, Item 2). Remove the relay (Figure 3, Item 2) from the emergency switchboard (Figure 3, Item 3).
3. 4.
END OF TASK BACK PANEL RELAY INSTALLATION 1. 2. 3. 4. Install the relay(s) (Figure 3, Item 2) in the emergency switchboard (Figure 3, Item 3). Connect the electrical wiring to the relay (Figure 3, Item 2) using the labels from Step (3) of BACK PANEL RELAY REMOVAL as a guide. Remove the labels. Perform the SECURE THE EMERGENCY SWITCHBOARD BACK PANEL procedure in this work package. Perform the FOLLOW-ON MAINTENANCE procedure at the end of this work package.
END OF TASK
0128-11
TM 55-1925-273-24&P-2
0128
BACK PANEL TRANSFORMER REMOVAL 1. Perform the ACCESS TO EMERGENCY SWITCHBOARD BACK PANEL procedure in this work package.
WARNING
Replace or repair components only after the affected circuit has been secured, locked out, and tagged out IAW FM 4-01.502. Performing replacement with the circuit energized may result in injury. 2. Use a multimeter to check for voltage at the transformer (Figure 3, Item 4). If voltage is present, ensure that the proper engine fuel oil valves have been secured, locked out, and tagged out IAW FM 4-01.502. If no voltage is present, continue with the procedure. Label and disconnect the electrical wiring to the transformer (Figure 3, Item 4). Remove the associated mounting hardware from the transformer (Figure 3, Item 4). Remove the transformer (Figure 3, Item 4) from the emergency switchboard (Figure 3, Item 3).
3. 4. 5.
END OF TASK BACK PANEL TRANSFORMER INSTALLATION 1. 2. 3. 4. Install the transformer (Figure 3, Item 4) with the associated mounting hardware in the emergency switchboard (Figure 3, Item 3). Connect the electrical wiring to the transformer (Figure 3, Item 4) using the labels from Step (3) of BACK PANEL TRANSFORMER REMOVAL as a guide. Remove the labels. Perform the SECURE THE EMERGENCY SWITCHBOARD BACK PANEL procedure in this work package. Perform the FOLLOW-ON MAINTENANCE procedure at the end of this work package.
END OF TASK SECURE THE EMERGENCY SWITCHBOARD BACK PANEL Perform the SECURE THE MIDDLE INNER PANEL procedure or the SECURE THE TOP INNER PANEL procedure in this work package. END OF TASK
0128-12
TM 55-1925-273-24&P-2
0128
BUS TIE CIRCUIT BREAKER REMOVAL
WARNING
Replace or repair components only after the affected circuit has been secured, locked out, and tagged out IAW FM 4-01.502. Performing replacement with the circuit energized may result in injury. 1. 2. Loosen the four captive screws (Figure 4, Item 1) and remove the door panel (Figure 4, Item 2) from the emergency switchboard (Figure 4, Item 3). Use a multimeter to check for voltage at the bus tie circuit breaker assembly (Figure 5, Item 4). If no voltage is present, ensure that the proper fuel oil valves have been secured, locked out, and tagged out IAW FM 4-01.502. If no voltage is present, continue with procedure. Remove the three bolts (Figure 6, Item 1), the six flat washers (Figure 6, Item 2), and the three nuts (Figure 6, Item 3) from the bus terminals (Figure 6, Item 9). Label and remove the wiring (Figure 6, Item 4) from the bus terminals (Figure 6, Item 9). Remove the five bolts (Figure 6, Item 5), the 10 flat washers (Figure 6, Item 6), and the five nuts (Figure 6, Item 7) from the bus bar (Figure 6, Item 8). Remove the two bolts (Figure 5, Item 1), the four flat washers (Figure 5, Item 2), and the two nuts (Figure 5, Item 3) from the bus tie circuit breaker assembly (Figure 5, Item 4). Remove the bus tie circuit breaker assembly (Figure 5, Item 4) from the emergency switchboard (Figure 4, Item 3).
3. 4. 5. 6. 7.
1 1 2 3
M1387T73
Figure 4.
Emergency Switchboard.
0128-13
TM 55-1925-273-24&P-2 BUS TIE CIRCUIT BREAKER REMOVAL - Continued
0128
M1229T73
Figure 5. Bus Tie Circuit Breaker.
0128-14
TM 55-1925-273-24&P-2 BUS TIE CIRCUIT BREAKER REMOVAL - Continued

1 1
0128
2 3
2 3 1
4 4 2 3
4 9 4
6 7
8 4 5 5 6 7 6 8 7
M1230T73
Bus Tie Circuit Breaker Bus Bar and Wire Connections.
0128-15
TM 55-1925-273-24&P-2
0128
BUS TIE CIRCUIT BREAKER INSTALLATION 1. 2. 3. 4. Install the bus tie breaker assembly (Figure 5, Item 4) in the emergency switchboard (Figure 4, Item 3). Install the two bolts (Figure 5, Item 1), the four flat washers (Figure 5, Item 2), and the two nuts (Figure 5, Item 3) in the bus tie circuit breaker assembly (Figure 5, Item 4). Install the five bolts (Figure 6, Item 5), the 10 flat washers (Figure 6, Item 6), and the five nuts (Figure 6, Item 7) in the bus bar (Figure 6, Item 8). Connect the wiring (Figure 6, Item 4) to the bus terminals (Figure 6, Item 9) using the labels from Step (4) of BUS TIE CIRCUIT BREAKER REMOVAL as a guide and secure it with the three bolts (Figure 6, Item 1), the six flat washers (Figure 6, Item 2), and three nuts (Figure 6, Item 3). Remove the labels. Install the door panel (Figure 4, Item 2) on the emergency switchboard (Figure 4, Item 3). Tighten the four captive screws (Figure 4, Item 1) on the door panel (Figure 4, Item 2). Remove the lock out and tag outs IAW FM 4-01.502. Perform Operation Under Usual Conditions: PREPARATION FOR USE IAW TM 55-1925-273-10. Perform Operation Under Usual Conditions: POWER GENERATION IAW TM 55-1925-273-10 and check for proper operation of the bus tie circuit breaker assembly. Return the emergency switchboard to the desired readiness condition.
5. 6. 7. 8. 9. 10.
END OF TASK EMERGENCY DIESEL GENERATOR (EDG) CIRCUIT BREAKER REMOVAL
WARNING
NOTE
The procedure for replacement of the Ship's Service Diesel Generator (SDDG) 1 and SDDG 2 circuit breaker is the same as this procedure. The only difference is that the SSDG 1 and SSDG 2 circuit breakers are located in the main switchboard. 1. 2. 3. 4. 5. 6. Loosen the captive screws (Figure 7, Item 1) on the door panel (Figure 7, Item 2). Remove the door panel (Figure 7, Item 2) from the emergency switchboard (Figure 7, Item 3). Press the OFF switch (Figure 8, Item 1) on the circuit breaker face. Remove the crank (Figure 8, Item 3) from the storage slot (Figure 8, Item 6). Insert the crank (Figure 8, Item 3) into the cranking slot (Figure 8, Item 4). Turn the crank (Figure 8, Item 3) until the dial (Figure 8, Item 5) indicates DISCONNECTED. Remove the crank from the slot (Figure 8, Item 4).
0128-16
TM 55-1925-273-24&P-2 EMERGENCY DIESEL GENERATOR (EDG) CIRCUIT BREAKER REMOVAL - Continued
0128
NOTE
The circuit breaker is track mounted. 7. Grasp the latches (Figure 8, Item 2) firmly and pull the circuit breaker (Figure 8, Item 7) forward until the tracks are fully extended.
WARNING
Two personnel are required to lift the circuit breaker from the emergency switchboard. Personnel should wear hard hats, safety shoes, and heavy gloves when lifting the circuit breaker. Failure to comply with this warning can result in serious injury or death. 8. Remove the circuit breaker (Figure 8, Item 7) by lifting the circuit breaker straight up from the tracks.
1 2
EMERGENCY SWITCHBOARD
M1231T73
Figure 7. SSDG 1, SSDG 2, and EDG Circuit Breaker Front Panel (Typical).
0128-17
TM 55-1925-273-24&P-2 EMERGENCY DIESEL GENERATOR (EDG) CIRCUIT BREAKER REMOVAL - Continued

1
0128
push OFF
push ON
OFF
DISCHARGED
CONNECTED TEST DISCONNECTED
M1232T73
EDG Circuit Breaker.
0128-18
TM 55-1925-273-24&P-2
0128
EMERGENCY DIESEL GENERATOR (EDG) CIRCUIT BREAKER INSTALLATION
WARNING
Two personnel are required to lift the circuit breaker from the emergency switchboard. Personnel should wear hard hats, safety shoes, and heavy gloves when lifting the circuit breaker. Failure to comply with this warning can result in serious injury or death. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. Position the circuit breaker (Figure 8, Item 7) on the tracks. Grasp the latches (Figure 8, Item 2) and manually push the tracks in until they reach the track stop position. Insert the crank (Figure 8, Item 3) into the cranking slot (Figure 8, Item 4). Turn the crank (Figure 8, Item 3) until the circuit breaker (Figure 8, Item 7) is completely seated and the dial (Figure 8, Item 5) indicates CONNECTED. Continue turning the crank (Figure 8, Item 3) until two clicking sounds are heard, indicating the circuit breaker (Figure 8, Item 2) is locked in the connected position. Remove the crank (Figure 8, Item 3) and stow in storage slot (Figure 8, Item 6). Install the door panel (Figure 7, Item 2). Secure the door panel (Figure 7, Item 2) by tightening the captive screws (Figure 7, Item 1). Remove the lock outs and tag outs IAW FM 4-01.502. Perform Operation Under Usual Conditions: PREPARATION FOR USE IAW TM 55-1925-273-10. Perform Operation Under Usual Conditions: POWER GENERATION IAW TM 55-1925-273-10 and check for proper operation of the emergency switchboard. Return the emergency switchboard to the desired readiness condition.
END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. Remove the lock outs and tag outs IAW FM 4.01-502. Perform Operation Under Usual Conditions: PREPARATION FOR USE IAW TM 55-1925-273-10 and Operation Under Usual Conditions: POWER GENERATION IAW TM 55-1925-273-10. Return the emergency generator to the desired readiness condition.
0128-19/20 blank
TM 55-1925-273-24&P-2 FIELD MAINTENANCE DISTRIBUTION AND FUSE PANELS (TYPICAL) REPLACE
0129
INITIAL SETUP: Tools and Special Tools Multimeter (Volume 3, WP 0344, Table 1, Item 15) Tool Kit, Electrical Repair (Volume 3, WP 0344, Table 1, Item 26) Materials/Parts N/A Personnel Required Watercraft Engineer 88L (2) References FM 4-01.502 References (cont.) TM 55-1925-273-10 Volume 3, WP 0274 Volume 3, WP 0343 Volume 3, WP 0344 Equipment Condition Set to OFF the appropriate power panel circuit breaker on the main switchboard. Lock out and tag out IAW FM 4-01.502.
WARNING
WARNING
CAUTION
Exercise care when removing the face panel and door to prevent damage of the ground detection cable. Failure to comply with this caution may result in damage to the power panel.
NOTE
The power distribution panel replacement procedure is for all power distribution panels.
0129-1
TM 55-1925-273-24&P-2
0129
ACCESS INNER LOAD CENTER DISASSEMBLY 1. 2. 3. Press the key latch (Figure 1, Item 8) and open the door (Figure 1, Item 1). Loosen the screws (Figure 1, Item 2) and remove the face panel (Figure 1, Item 7). Remove the screws (Figure 1, Item 5) from the inner panel (Figure 1, Item 6). Remove the inner panel.
WARNING
Replace or repair components only after the affected circuit has been secured, locked out, and tagged out IAW FM 4-01.502. Performing replacement with the circuit energized may result in injury. 4. Use a multimeter to check for voltage at the fuses (Figure 1, Item 3). If voltage is present, ensure that the proper circuit breaker is set to OFF, locked out, and tagged out IAW FM 4-01.502. If no voltage is present, continue with the procedure.
1 2 3
9 8 10 4
10 2 6 7
M1233T73
Figure 1. END OF TASK FUSE REMOVAL 1. 2.
Load Center.
Perform the ACCESS INNER LOAD CENTER DISASSEMBLY procedure in this work package. Remove the fuse(s) (Figure 1, Item 3) with a fuse puller.
END OF TASK
0129-2
TM 55-1925-273-24&P-2 FUSE INSTALLATION 1. 2. Install the fuse(s) (Figure 1, Item 3) with a fuse puller. Perform the ACCESS INNER LOAD CENTER ASSEMBLY procedure in this work package.
0129
END OF TASK PLUG-IN CIRCUIT BREAKER REMOVAL 1. 2. Perform the ACCESS INNER LOAD CENTER DISASSEMBLY procedure in this work package. Remove the applicable plug-in circuit breaker(s) (Figure 1, Item 9) by pushing in on the end of the circuit breaker nearest the center of the panel and pulling out in an arcing motion on the other end of the circuit breaker.
END OF TASK PLUG-IN CIRCUIT BREAKER INSTALLATION 1. 2. Install the circuit breaker (Figure 1, Item 9) by positioning one end of the circuit breaker under the D-lip and pushing the other end in an arcing motion until it snaps into place. Perform the ACCESS INNER LOAD CENTER ASSEMBLY procedure in this work package.
END OF TASK STANDARD CIRCUIT BREAKER REMOVAL 1. 2. 3. Perform the ACCESS INNER LOAD CENTER DISASSEMBLY procedure in this work package. Label and remove wiring from circuit breaker. Remove the screws (Figure 1, Item 10) and remove the applicable circuit breaker (Figure 1, Item 4).
END OF TASK STANDARD CIRCUIT BREAKER INSTALLATION 1. 2. 3. Install the circuit breaker (Figure 1, Item 4) and secure it with the screws (Figure 1, Item 10) or relief clamps. Connect wiring to circuit breakers IAW labels. Remove labels. Perform the ACCESS INNER LOAD CENTER ASSEMBLY procedure in this work package.
END OF TASK ACCESS INNER LOAD CENTER ASSEMBLY 1. 2. Install the inner panel (Figure 1, Item 6) and secure it with the screws (Figure 1, Item 5). Install the face panel (Figure 1, Item 7) and secure it with the screws (Figure 1, Item 2).
END OF TASK
0129-3
TM 55-1925-273-24&P-2
0129
FOLLOW-ON MAINTENANCE 1. 2. 3. 4. 5. Remove the lock outs and tag outs IAW FM 4-01.502. Set the circuit breaker to ON. Test operate all affected circuit breakers and the applicable equipment under usual conditions IAW TM 55-1925-273-10. Close the door (Figure 1, Item 1) and secure it with the key latch (Figure 1, Item 8). Return the equipment to the desired readiness condition.
0129-4
TM 55-1925-273-24&P-2 FIELD MAINTENANCE LIGHTING FIXTURE JUNCTION BOX (TYPICAL) REPAIR
0130
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 3, WP 0344, Table 1, Item 27) Tool Kit, Electrical Repair (Volume 3, WP 0344, Table 1, Item 26) Materials/Parts N/A Personnel Required Watercraft Engineer 88K (2) References FM 4-01.502 References (cont.) Volume 3, WP 0275 Volume 3, WP 0344 Equipment Condition On associated lighting panel, set the circuit breaker(s) to OFF. Lock out and tag out IAW FM 4-01.502.
0130-1
TM 55-1925-273-24&P-2
0130
LAMP REMOVAL
WARNING
Replace or repair components only after the affected circuit has been secured, locked out, and tagged out IAW FM 4-01.502. Performing replacement with the circuit energized may result in injury. 1. 2. 3. Remove the guard (Figure 1, Item 2) from the fixture. Remove the globe (Figure 1, Item 3) from the fixture. Remove the lamp (Figure 1, Item 1) from the lamp socket.
END OF TASK LAMP INSTALLATION 1. 2. 3. Install the lamp (Figure 1, Item 1) in the lamp socket hand tight. Install the globe (Figure 1, Item 3) in the fixture hand tight. Install the guard (Figure 1, Item 2) in the fixture hand tight.
0130-2
TM 55-1925-273-24&P-2 LAMP INSTALLATION - Continued
0130
M1048T73
Junction Box Lighting.
Remove the lock outs and tag outs IAW FM 4-01.502. Set the associated circuit breaker(s) to ON. Perform a functional test by turning the light ON and OFF to ensure that the light operates properly. Return the equipment to the desired readiness condition.
0130-3/4 blank
TM 55-1925-273-24&P-2 FIELD MAINTENANCE LIGHTING FIXTURE BRACKET (TYPICAL) REPAIR
0131
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 3, WP 0344, Table 1, Item 27) Tool Kit, Electrical Repair (Volume 3, WP 0344, Table 1, Item 26) Materials/Parts N/A Personnel Required Watercraft Engineer 88K (2) References FM 4-01.502 References (cont.) Volume 3, WP 0276 Volume 3, WP 0344 Equipment Condition Set the circuit breaker(s) to OFF at the applicable lighting panel. Lock out and tag out IAW FM 4-01.502.
0131-1
TM 55-1925-273-24&P-2
0131
LAMP REMOVAL
WARNING
Replace or repair components only after the affected circuit has been secured, locked out, and tagged out IAW FM 4-01.502. Performing replacement with the circuit energized may result in injury. 1. 2. 3. Remove the guard (Figure 1, Item 2). Remove the globe (Figure 1, Item 1). Remove the lamp (Figure 1, Item 3).
END OF TASK LAMP INSTALLATION 1. 2. 3. Install the lamp (Figure 1, Item 3) in the lamp socket hand tight. Install the globe (Figure 1, Item 1) in the fixture hand tight. Install the guard (Figure 1, Item 2) in the fixture hand tight.
0131-2
0131
M1049T73
Lighting Fixture Bracket.
Remove the lock outs and tag outs IAW FM 4-01.502. Set appropriate circuit breaker(s) to ON. Perform a functional test by turning the light ON and OFF to ensure proper operation. Return the equipment to the desired readiness condition.
0131-3/4 blank
TM 55-1925-273-24&P-2 FIELD MAINTENANCE RECESSED FLUORESCENT FIXTURE REPLACE
0132
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 3, WP 0344, Table 1, Item 27) Materials/Parts N/A Personnel Required Watercraft Engineer 88K (2) References FM 4-01.502 References (cont.) Volume 3, WP 0277 Volume 3, WP 0344 Equipment Condition Set the circuit breaker(s) to OFF at the applicable lighting panel. Lock out and tag out IAW FM 4-01.502.
0132-1
TM 55-1925-273-24&P-2
0132
LAMP REMOVAL
WARNING
Replace or repair components only after the affected circuit has been secured, locked out, and tagged out IAW FM 4-01.502. Performing replacement with the circuit energized may result in injury. 1. 2. Loosen the captive-knurled screws (Figure 1, Item 1) and remove the diffuser (Figure 1, Item 2). Remove the fluorescent lamps (Figure 1, Item 3) from the fixture.
END OF TASK LAMP INSTALLATION 1. 2. Install the fluorescent lamps (Figure 1, Item 3) in the fixture. Install the diffuser (Figure 1, Item 2) in the fixture and secure it with the captive screws (Figure 1, Item 1).
3
Figure 1. Fluorescent Fixture (Recessed). END OF TASK
M1050T73
0132-2
TM 55-1925-273-24&P-2
0132
FOLLOW-ON MAINTENANCE 1. 2. 3. 4. Remove the lock outs and tag outs IAW FM 4-01.502. Set the applicable circuit breaker(s) to ON. Perform a functional test by turning the light ON and OFF to ensure that the light operates properly. Return the equipment to the desired readiness condition.
0132-3/4 blank
TM 55-1925-273-24&P-2 FIELD MAINTENANCE SURFACE MOUNT FLUORESCENT LIGHT REPLACE
0133
INITIAL SETUP: Tools and Special Tools Tool Kit, Electrical Repair (Volume 3, WP 0344, Table 1, Item 26) Materials/Parts N/A Personnel Required Watercraft Engineer 88K (2) References FM 4-01.502 References (cont.) Volume 3, WP 0278 Volume 3, WP 0344 Equipment Condition Set to OFF the circuit breakers on the applicable lighting panel. Lock out and tag out IAW FM 4-01.502.
0133-1
TM 55-1925-273-24&P-2
0133
LAMP REMOVAL
WARNING
Replace or repair components only after the affected circuit has been secured, locked out, and tagged out IAW FM 4-01.502. Performing replacement with the circuit energized may result in injury. 1. 2. 3. Release the latches (Figure 1, Item 1) that secure the diffuser (Figure 1, Item 2). Remove the diffuser (Figure 1, Item 2). Remove the fluorescent lamps (Figure 1, Item 3) from the fixture.
END OF TASK LAMP INSTALLATION 1. 2. Install the fluorescent lamps (Figure 1, Item 3) in the fixture. Install the diffuser (Figure 1, Item 2) in the fixture and secure it with the latches (Figure 1, Item 1).
M1051T73
Fluorescent Light, Surface Mount.
0133-2
TM 55-1925-273-24&P-2
0133
FOLLOW-ON MAINTENANCE 1. 2. 3. 4. Remove the lock outs and tag outs IAW FM 4-01.502. Set the associated circuit breaker(s) to ON. Perform a functional test by turning the light ON and OFF. Return the equipment to the desired readiness condition.
0133-3/4 blank
TM 55-1925-273-24&P-2 FIELD MAINTENANCE WATERTIGHT INCANDESCENT EXPLOSION PROOF (TYPICAL) LIGHTING FIXTURE REPAIR
0134
INITIAL SETUP: Tools and Special Tools Tool Kit, Electrical Repair (Volume 3, WP 0344, Table 1, Item 26) Materials/Parts N/A Personnel Required Watercraft Engineer 88K (2) References FM 4-01.502 References (cont.) Volume 3, WP 0279 Volume 3, WP 0344 Equipment Condition Set to OFF the circuit breaker(s) on the applicable lighting panel. Lock out and tag out IAW FM 4-01.502.
0134-1
TM 55-1925-273-24&P-2
0134
LAMP REMOVAL
WARNING
Replace or repair components only after the affected circuit has been secured, locked out, and tagged out IAW FM 4-01.502. Performing replacement with the circuit energized may result in injury. 1. 2. 3. Remove the screws (Figure 1, Item 5) and remove the guard (Figure 1, Item 2) from the lighting fixture (Figure 1, Item 1). Remove the globe (Figure 1, Item 3) from the lighting fixture (Figure 1, Item 1). Remove the lamp (Figure 1, Item 4) from the lamp socket (Figure 1, Item 6).
END OF TASK LAMP INSTALLATION 1. 2. 3. Install the lamp (Figure 1, Item 4) into the lamp socket (Figure 1, Item 6) hand tight. Install the globe (Figure 1, Item 3) until hand tight. Install the guard (Figure 1, Item 2) and secure it with the screw (Figure 1, Item 5).
1
2 6 3
5 4
M1052T73
Explosion Proof Lighting Fixture.
0134-2
TM 55-1925-273-24&P-2 FOLLOW-ON MAINTENANCE 1. 2. 3. 4. Remove the lock outs and tag outs IAW FM 4-01.502. Set the applicable circuit breaker(s) to ON. Perform a functional test by turning the light ON and OFF. Return the equipment to the desired readiness condition.
0134
0134-3/4 blank
TM 55-1925-273-24&P-2 FIELD MAINTENANCE FLOODLIGHTS REPLACE
0135
INITIAL SETUP: Tools and Special Tools Multimeter (Volume 3, WP 0344, Table 1, Item 15) Tool Kit, Electrical Repair (Volume 3, WP 0344, Table 1, Item 26) Materials/Parts N/A Personnel Required Watercraft Engineer 88K (2) References FM 4-01.502 References (cont.) Volume 3, WP 0280 Volume 3, WP 0344 Equipment Condition At 120 V exterior emergency lighting panel No. 2 set the applicable floodlight circuit breaker to OFF. Lock out and tag out IAW FM 4-01.502.
0135-1
TM 55-1925-273-24&P-2
0135
WARNING
Never reuse locking hardware. Reuse of locking hardware such as lockwashers, locking nuts, cotter pins, and lock wire can result in undetected loosening of fastening hardware causing catastrophic component failure resulting in death, injury, or damage to equipment. Ensure that all locking hardware is discarded upon removal and replaced with new. LAMP REMOVAL
WARNING
Replace or repair components only after the affected circuit has been secured, locked out, and tagged out IAW FM 4-01.502. Performing replacement with the circuit energized may result in injury. 1. 2. 3. 4. 5. Remove the cover from the floodlight junction box. Use a multimeter to check the wiring leads for available voltage. If voltage is present, ensure that the proper circuit breaker is secured, locked out, and tagged out. If no voltage is present, continue with the procedure. Label and disconnect the electrical wiring at the floodlight junction box. Remove the mounting bolts (Figure 1, Item 2), nuts (Figure 1, Item 5), flat washers (Figure 1, Item 3), and lockwashers (Figure 1, Item 4). Discard lockwashers. Remove the floodlight (Figure 1, Item 1) from the foundation.
END OF TASK LAMP INSTALLATION 1. 2. 3. Position the floodlight (Figure 1, Item 1) on the foundation. Secure the floodlight (Figure 1, Item 1) to the foundation with the mounting bolts (Figure 1, Item 2), nuts (Figure 1, Item 5), washers (Figure 1, Item 3), and lockwashers (Figure 1, Item 4). Connect electrical wiring using the labels from Step (3) of REMOVAL as a guide. Remove the labels.
0135-2
0135
2 3
4 5
M1053T73
Metal Halide Floodlight.
Remove the lock outs and tag outs IAW FM 4-01.502. Set the applicable floodlight circuit breaker to ON. Perform a functional test by turning the light ON and OFF to ensure proper operation. Return the equipment to the desired readiness condition.
0135-3/4 blank
TM 55-1925-273-24&P-2 FIELD MAINTENANCE FLOODLIGHTS REPAIR
0136
INITIAL SETUP: Tools and Special Tools Multimeter (Volume 3, WP 0344, Table 1, Item 15) Tool Kit, Electrical Repair (Volume 3, WP 0344, Table 1, Item 26) Materials/Parts N/A Personnel Required Watercraft Engineer 88K (2) References FM 4-01.502 References (cont.) TM 55-1925-273-10 Volume 3, WP 0280 Volume 3, WP 0344 Equipment Condition Set to OFF the associated floodlight circuit breaker at 120 V exterior emergency lighting panel No. 2. Lock out and tag out IAW FM 4-01.502.
0136-1
TM 55-1925-273-24&P-2
0136
WARNING
Replace or repair components only after the affected circuit has been secured, locked out, and tagged out IAW FM 4-01.502. Performing replacement with the circuit energized may result in injury. LAMP REMOVAL 1. 2. 3. Remove the nuts (Figure 1, Item 3) that secure the access plate (Figure 1, Item 2). Remove the access plate (Figure 1, Item 2). Remove the lamp (Figure 1, Item 1) from the fixture.
END OF TASK LAMP INSTALLATION 1. 2. 3. Install the lamp (Figure 1, Item 1) in the fixture. Install the access plate (Figure 1, Item 2) and secure it with the nuts (Figure 1, Item 3). Perform the FOLLOW-ON MAINTENANCE procedure at the end of this work package.
END OF TASK LENS REMOVAL 1. 2. Remove the nuts (Figure 1, Item 7). Remove the lens frame (Figure 1, Item 4), lens (Figure 1, Item 5), and gasket (Figure 1, Item 6).
END OF TASK LENS INSTALLATION 1. 2. 3. Install gasket (Figure 1, Item 6), lens (Figure 1, Item 5), and lens frame (Figure 1, Item 4). Secure the lens frame to the housing with the nuts (Figure 1, Item 7). Perform the FOLLOW-ON MAINTENANCE procedure at the end of this work package.
0136-2
TM 55-1925-273-24&P-2 LENS INSTALLATION - Continued
0136
2 1
6 5 4
Figure 1. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. 4. Remove the lock outs and tag outs IAW FM 4-01.502. Set the associated floodlight circuit breaker to ON. Test operate the floodlights IAW TM 55-1925-273-10. Return the equipment to the desired readiness condition. Metal Halide Floodlight.
M1054T73
0136-3/4 blank
TM 55-1925-273-24&P-2
0137
FIELD MAINTENANCE MOTOR CONTROLLER: REDUCTION GEAR COOLING PUMP; SEWAGE DISCHARGE PUMP 1 & 2; LUBE OIL TRANSFER PUMP; POTABLE WATER PUMP 1 & 2; GALLEY SUPPLY FAN; GALLEY EXHAUST FAN; SANITARY SPACE EXHAUST FAN; CREW MESS FAN COIL UNIT; 01, 02, 03 LEVELS FAN COIL UNIT; AIR COMPRESSOR 1 & 2; FUEL OIL TRANSFER PUMP; AFFF PUMP REPLACE
INITIAL SETUP: Tools and Special Tools Multimeter (Volume 3, WP 0344, Table 1, Item 15) Tool Kit, Electrical Repair (Volume 3, WP 0344, Table 1, Item 26) Materials/Parts N/A Personnel Required Watercraft Engineer 88L (2) References FM 4-01.502 References (cont.) TM 55-1925-273-10 Volume 3, WP 0281 Volume 3, WP 0344 Equipment Condition Set to OFF the applicable motor controller circuit breaker. Lock out and tag out IAW FM 4-01.502.
0137-1
TM 55-1925-273-24&P-2
0137
WARNING
Never reuse locking hardware. Reuse of locking hardware such as lockwashers, locking nuts, cotter pins, and lock wire can result in undetected loosening of fastening hardware causing catastrophic component failure resulting in death, injury, or damage to equipment. Ensure that all locking hardware is discarded upon removal and replaced with new. MOTOR CONTROLLER (TYPICAL) REMOVAL
NOTE
The switch handle must be OFF to open the door. 1. 2. 3. Set to OFF the switch handle (Figure 1, Item 11). Loosen the motor controller door screw (Figure 1, Item 1). Turn the handle (Figure 1, Item 13) to open the door (Figure 1, Item 10).
WARNING
Replace or repair components only after the affected circuit has been secured, locked out, and tagged out IAW FM 4-01.502. Performing replacement with the circuit energized may result in injury. 4. Use a multimeter to check for available voltage at the motor controller terminals (Figure 1, Item 8). If voltage is present, ensure that the appropriate circuit breakers have been secured, locked out, and tagged out. If no voltage is present, continue with this procedure. Label and remove the wiring (Figure 1, Item 6) by loosening the screws (Figure 1, Item 12) located on the terminals (Figure 1, Item 8). Loosen the strain relief clamps (Figure 1, Item 7) and pull the wiring (Figure 1, Item 6) from the motor controller (Figure 1, Item 9). Remove the four nuts (Figure 1, Item 2), lockwashers (Figure 1, Item 3), and the four flat washers (Figure 1, Item 4) from the studs (Figure 1, Item 5). Discard lockwashers. Remove the motor controller (Figure 1, Item 9) from the studs (Figure 1, Item 5).
5.
6. 7.
0137-2
TM 55-1925-273-24&P-2 MOTOR CONTROLLER (TYPICAL) REMOVAL - Continued
0137
7 1 6 6 8
ON
ON
11
12
OFF OFF
13
POWER AVAILABLE
POWER AVAILABLE
MOTOR RUN
MOTOR RUN
START STOP
START STOP
RESET
10
Figure 1. END OF TASK Motor Controller Type 1 (Typical).
M1234T73
0137-3
TM 55-1925-273-24&P-2 MOTOR CONTROLLER (TYPICAL) INSTALLATION 1. 2. 3. 4. 5. 6. 7. Install the motor controller (Figure 1, Item 9) on the studs (Figure 1, Item 5). Install the four nuts (Figure 1, Item 2), four lockwashers (Figure 1, Item 3), and the four flat washers (Figure 1, Item 4) on the studs (Figure 1, Item 5).
0137
Route the wiring (Figure 1, Item 6) into the motor controller (Figure 1, Item 9) and secure it in place with the strain relief clamps (Figure 1, Item 7). Connect the wiring (Figure 1, Item 6) to the motor controller (Figure 1, Item 9) by tightening the screws located on the terminals (Figure 1, Item 8) using the labels from Step (5) of REMOVAL as a guide. Remove the labels. Close and secure the door (Figure 1, Item 10) by turning the handle (Figure 1, Item 13). Tighten the door by turning the motor controller door screw (Figure 1, Item 1). Set to ON the switch handle (Figure 1, Item 11).
END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. 4. Remove the lock outs and tag outs IAW FM 4-01.502. Set to ON the applicable circuit breaker. Perform operation under usual conditions IAW TM 55-1925-273-10 for the applicable system and check for proper operation. Return the motor controller to the desired readiness condition.
0137-4
TM 55-1925-273-24&P-2
0138
FIELD MAINTENANCE MOTOR CONTROLLER: REDUCTION GEAR COOLING PUMP; SEWAGE DISCHARGE PUMP 1 & 2; LUBE OIL TRANSFER PUMP; POTABLE WATER PUMP 1 & 2; GALLEY SUPPLY FAN; GALLEY EXHAUST FAN; SANITARY SPACE EXHAUST FAN; CREW MESS FAN COIL UNIT; 01, 02, 03 LEVELS FAN COIL UNIT; AIR COMPRESSOR 1 & 2; FUEL OIL TRANSFER PUMP; AFFF PUMP REPAIR
INITIAL SETUP: Tools and Special Tools Multimeter (Volume 3, WP 0344, Table 1, Item 15) Tool Kit, Electrical Repair (Volume 3, WP 0344, Table 1, Item 26) Materials/Parts N/A Personnel Required Watercraft Engineer 88L (2) References FM 4-01.502 References (cont.) TM 55-1925-273-10 Volume 3, WP 0281 Volume 3, WP 0344 Equipment Condition Set the applicable circuit breaker to OFF. Lock out and tag out IAW FM 4-01.502.
0138-1
TM 55-1925-273-24&P-2
0138
LAMP REMOVAL
WARNING
Replace or repair components only after the affected circuit has been secured, locked out, and tagged out IAW FM 4-01.502. Performing replacement with the circuit energized may result in injury. 1. 2. Remove the lens cover (Figure 1, Item 4). Remove the lamps from the indicators.
END OF TASK LAMP INSTALLATION 1. 2. Install lamps and lens covers (Figure 1, Item 4). Perform the FOLLOW-ON MAINTENANCE procedure at the end of this work package.
END OF TASK ACCESS TO INNER MOTOR CONTROLLER
NOTE
The switch handle must be set to OFF to open the door. 1. 2. 3. Set the switch handle (Figure 1, Item 3) to OFF. Loosen the motor controller door screw (Figure 1, Item 1). Turn the handle (Figure 1, Item 8) to open the door (Figure 1, Item 7).
0138-2
TM 55-1925-273-24&P-2 ACCESS TO INNER MOTOR CONTROLLER - Continued
0138
ON
ON
3 9
OFF
OFF
10
POWER
AVAILABLE
MOTOR RUN
4 5
POWER
AVAILABLE
MOTOR RUN
START STOP
START
11
STOP
RESET
12 7
6
M1055T73
0138-3
TM 55-1925-273-24&P-2
0138
FUSE REMOVAL 1. Perform the ACCESS TO INNER MOTOR CONTROLLER procedure in this work package.
WARNING
Replace or repair components only after the affected circuit has been secured, locked out, and tagged out IAW FM 4-01.502. Performing replacement with the circuit energized may result in injury. 2. Use a multimeter to check for voltage at the fuses (Figure 1, Items 5 and 10). If voltage is present, ensure that the proper circuit breakers have been set to OFF, locked out, and tagged out IAW FM 4.01-502. If no voltage is present, continue with the procedure. Remove the cartridge fuses (Figure 1, Item 10) and/or the slo-blo fuse (Figure 1, Item 5) using a fuse puller.
3.
END OF TASK FUSE INSTALLATION 1. 2. 3. Install the cartridge fuses (Figure 1, Item 10) and/or the slo-blo fuse (Figure 1, Item 5) using a fuse puller. Perform the SECURE THE MOTOR CONTROLLER procedure in this work package. Perform the FOLLOW-ON MAINTENANCE procedure at the end of this work package.
END OF TASK MOTOR STARTER REMOVAL 1. Perform the ACCESS TO INNER MOTOR CONTROLLER procedure in this work package.
WARNING
Replace or repair components only after the affected circuit has been secured, locked out, and tagged out IAW FM 4-01.502. Performing replacement with the circuit energized may result in injury. 2. Use a multimeter to check for voltage at the fuses (Figure 1, Items 5 and 10). If voltage is present, ensure that the proper circuit breakers have been set to OFF, locked out, and tagged out IAW FM 4.01-502. If no voltage is present, continue with the procedure. Label and disconnect the electrical wiring attached to the motor starter (Figure 1, Item 6). Remove the screws (Figure 1, Item 12) that secure the motor starter (Figure 1, Item 6) to the motor controller back plate (Figure 1, Item 2).
3. 4.
0138-4
TM 55-1925-273-24&P-2 MOTOR STARTER REMOVAL - Continued 5. Remove the motor starter (Figure 1, Item 6).
0138
END OF TASK MOTOR STARTER INSTALLATION 1. 2. 3. 4. Install the motor starter (Figure 1, Item 6) on the motor controller back plate (Figure 1, Item 2) and secure it with the screws (Figure 1, Item 12). Connect the electrical wiring to the motor starter (Figure 1, Item 6) using the labels from Step (3) of MOTOR STARTER REMOVAL as a guide. Remove the labels. Perform the SECURE THE MOTOR CONTROLLER procedure in this work package. Perform the FOLLOW-ON MAINTENANCE procedure at the end of this work package.
END OF TASK TRANSFORMER REMOVAL 1. Perform the ACCESS TO INNER MOTOR CONTROLLER procedure in this work package.
WARNING
Replace or repair components only after the affected circuit has been secured, locked out, and tagged out IAW FM 4-01.502. Performing replacement with the circuit energized may result in injury. 2. Use a multimeter to check for voltage at the fuses (Figure 1, Items 5 and 10). If voltage is present, ensure that the proper circuit breakers have been set to OFF, locked out, and tagged out IAW FM 4.01-502. If no voltage is present, continue with the procedure. Label and disconnect the electrical wiring attached to the transformer (Figure 1, Item 11). Remove the screws (Figure 1, Item 9) holding the transformer (Figure 1, Item 11) to the motor controller back plate (Figure 1, Item 2). Remove the transformer (Figure 1, Item 11).
3. 4. 5.
END OF TASK TRANSFORMER INSTALLATION 1. 2. 3. 4. Install the transformer (Figure 1, Item 11) on the motor controller back plate (Figure 1, Item 2) and secure it with the screws (Figure 1, Item 9). Connect the electrical wiring to the transformer (Figure 1, Item 11) using the labels from Step (3) of TRANSFORMER REMOVAL as a guide. Perform the SECURE THE MOTOR CONTROLLER procedure in this work package. Perform the FOLLOW-ON MAINTENANCE procedure at the end of this work package.
END OF TASK
0138-5
TM 55-1925-273-24&P-2
0138
SECURE THE MOTOR CONTROLLER 1. 2. 3. Close the motor controller door (Figure 1, Item 7) and tighten the handle (Figure 1, Item 8). Secure the door by tightening the door screw (Figure 1, Item 1). Set the switch handle (Figure 1, Item 3) to ON.
END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. 4. 5. Remove the lock outs and tag outs IAW FM 4.01-502. Set the applicable circuit breaker(s) to ON. Operate the motor controller for the affected system IAW TM 55-1925-273-10. Verify proper operation of the motor controller. Return the equipment to the desired readiness condition.
0138-6
TM 55-1925-273-24&P-2 FIELD MAINTENANCE MOTOR CONTROLLER: LUBE OIL PRIMING PUMP 1 & 2 REPLACE
0139
INITIAL SETUP: Tools and Special Tools Multimeter (Volume 3, WP 0344, Table 1, Item 15) Tool Kit, Electrical Repair (Volume 3, WP 0344, Table 1, Item 26) Materials/Parts N/A Personnel Required Watercraft Engineer 88L (2) References FM 4-01.502 TM 55-1925-273-10 References (cont.) Volume 3, WP 0282 Volume 3, WP 0344 Equipment Condition Set to OFF the MAIN ENGINE LUBE OIL PRIMING PUMP No. 1, or the MAIN ENGINE LUBE OIL PRIMING PUMP No. 2. circuit breakers (LT 803 Only), or the CONTROLLER FOR STARBOARD MAIN ENGINE LUBE OIL PRIMING PUMP No. 1, or the CONTROLLER FOR PORT MAIN ENGINE LUBE OIL PRIMING PUMP No. 2 circuit breakers (All Other Vessels) at 440 V power panel No. 1. Lock out and tag out IAW FM 4-01.502.
WARNING
0139-1
TM 55-1925-273-24&P-2
0139
MOTOR CONTROLLER REMOVAL 1. Remove the screw (Figure 1, Item 3) and then remove the front cover (Figure 1, Item 2) from the motor controller (Figure 1, Item 1).
3
M1388T73
Figure 1. Motor Controller Type 6 (Typical).
WARNING
Replace or repair components only after the affected circuit has been secured, locked out, and tagged out IAW FM 4-01.502. Performing replacement with the circuit energized may result in injury. 2. Use a multimeter to check for voltage at the motor controller terminals (Figure 2, Item 1). If voltage is present, ensure that the appropriate circuit breakers have been secured, locked out, and tagged out IAW FM 4-01.502. If no voltage is present, continue with this procedure. Label and remove the wiring (Figure 2, Item 6) by loosening the screws located on the terminals (Figure 2, Item 1).
3.
0139-2
TM 55-1925-273-24&P-2 MOTOR CONTROLLER REMOVAL - Continued 4. 5.
0139
Remove the electrical connector (Figure 2, Item 7) from the motor controller (Figure 2, Item 8) and remove the wiring (Figure 2, Item 6). Remove the two screws (Figure 2, Item 5), two flat washers (Figure 2, Item 4), two lockwashers (Figure 2, Item 3), and two nuts (Figure 2, Item 2) that secure the motor controller (Figure 2, Item 8) to its foundation. Discard lockwashers. Remove the motor controller (Figure 2, Item 8) from its foundation.
6.
2 1
5 8
7
M1235T73
Figure 2. Motor Controller Type 6 Cover Removed. END OF TASK MOTOR CONTROLLER INSTALLATION 1. Install the motor controller (Figure 2, Item 8) on its foundation and secure it with the two screws (Figure 2, Item 5), two flat washers (Figure 2, Item 4), two lockwashers (Figure 2, Item 3), and two nuts (Figure 2, Item 2). Install the wiring (Figure 2, Item 6) in the motor controller (Figure 2, Item 8) and install the electrical connector (Figure 2, Item 7). Connect the wiring (Figure 2, Item 6) to the terminal screws (Figure 2, Item 1) using the labels from Step (3) of MOTOR CONTROLLER REMOVAL as a guide. Remove the labels.
2. 3.
0139-3
TM 55-1925-273-24&P-2 MOTOR CONTROLLER INSTALLATION - Continued 4.
0139
Install the front cover (Figure 1, Item 2) on the motor controller (Figure 1, Item 1) and secure it with the screw (Figure 1, Item 3).
END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. Remove the lock outs and tag outs IAW FM 4-01.502. Operate the lube oil priming pump while operating the main propulsion system under usual conditions IAW TM 55-1925-273-10 and check for proper operation. Return the lube oil priming pump motor controller to the desired readiness condition.
0139-4
TM 55-1925-273-24&P-2 FIELD MAINTENANCE MOTOR CONTROLLER: LUBE OIL PRIMING PUMP 1 & 2 REPAIR
0140
INITIAL SETUP: Tools and Special Tools Multimeter (Volume 3, WP 0344, Table 1, Item 15) Tool Kit, Electrical Repair (Volume 3, WP 0344, Table 1, Item 26) Materials/Parts N/A Personnel Required Watercraft Engineer 88L (2) References FM 4.01-502 TB 43-0218 TM 55-1925-273-10 References (cont.) Volume 3, WP 0282 Volume 3, WP 0344 Equipment Condition Set to OFF the MAIN ENGINE LUBE OIL PRIMING PUMP No. 1 circuit breaker, or the MAIN ENGINE LUBE OIL PRIMING PUMP No. 2. circuit breaker at 440 V power panel No. 1 (LT 803 Only), or set to OFF the CONTROLLER FOR STARBOARD MAIN ENGINE LUBE OIL PRIMING PUMP No. 1 circuit breaker, or the CONTROLLER FOR PORT MAIN ENGINE LUBE OIL PRIMING PUMP No. 2 circuit breaker at 440 V power panel No. 1 (All Other Vessels). Lock out and tag out IAW FM 4.01-502.
WARNING
0140-1
TM 55-1925-273-24&P-2
0140
CONTACTOR ASSEMBLY REMOVAL 1. Remove the screw (Figure 1, Item 1) and then remove the front cover (Figure 1, Item 2) from the motor controller.
WARNING
Replace or repair components only after the affected circuit has been secured, locked out, and tagged out IAW FM 4-01.502. Performing replacement with the circuit energized may result in injury. 2. Use a multimeter to check for voltage at the contactor terminals (Figure 2, Item 7). If no voltage is present, ensure that the proper circuit breaker has been set to OFF, locked out, and tagged out IAW FM 4.01-502. If no voltage is present, continue with the procedure. Label and disconnect the wiring (Figure 2, Item 6). Remove the two screws (Figure 2, Item 1), two flat washers (Figure 2, Item 2), two lockwashers (Figure 2, Item 4), and two nuts (Figure 2, Item 5). Discard lockwashers. Remove the contactor assembly (Figure 2, Item 3) from the motor controller.
3. 4. 5.
START STOP RESET
2
M1056T73
0140-2
TM 55-1925-273-24&P-2 CONTACTOR ASSEMBLY REMOVAL - Continued

1 2 3 4 5
0140
6 START 1 7 STOP RESET
4 5
M1057T73
Figure 2. Motor Controller Type 6 Cover Removed. END OF TASK
0140-3
TM 55-1925-273-24&P-2
0140
CONTACTOR ASSEMBLY INSTALLATION 1. Install the contactor assembly (Figure 2, Item 3) in the motor controller and secure it with the two screws (Figure 2, Item 1), two flat washers (Figure 2, Item 2), two lockwashers (Figure 2, Item 4), and two nuts (Figure 2, Item 5). Install the wiring (Figure 2, Item 6) using the labels from Step (3) of CONTACTOR ASSEMBLY REMOVAL as a guide. Remove the labels. Install the front cover (Figure 1, Item 2) and secure it with the screw (Figure 1, Item 1).
2. 3.
END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. 4. Remove lock outs and tag outs IAW FM 4.01-502. Set the appropriate circuit breaker to ON. Operate the motor controller for the affected system IAW TM-55-1925-273-10, ensuring proper operation. Return the equipment to the desired readiness condition.
0140-4
TM 55-1925-273-24&P-2
0141
FIELD MAINTENANCE MOTOR CONTROLLER: AMS 1 & 2 SUPPLY FAN; BOATSWAIN'S STORE ROOM SUPPLY FAN; ARMS LOCKER EXHAUST FAN; ENGINE ROOM SUPPLY FAN 1 & 2; ENGINE ROOM EXHAUST FAN 1 & 2 REPLACE
0141-1
TM 55-1925-273-24&P-2
0141
WARNING
NOTE
The switch handle must be OFF to open the door. 1. 2. Set to OFF the switch handle (Figure 1, Item 8). Loosen the motor controller door screw (Figure 1, Item 1) and turn the handle (Figure 1, Item 12) to open the door (Figure 1, Item 11).
WARNING
Replace or repair components only after the affected circuit has been secured, locked out, and tagged out IAW FM 4-01.502. Performing replacement with the circuit energized may result in injury. 3. Use a multimeter to check for voltage at the motor controller terminals (Figure 1, Item 3). If voltage is present, ensure that the correct circuit breakers are secured, locked out, and tagged out IAW FM 4-01.502. If no voltage is present, continue with the procedure. Label and remove the wiring (Figure 1, Item 10) from the motor controller terminals (Figure 1, Item 3). Loosen the strain relief clamps (Figure 1, Item 9) and remove the wiring (Figure 1, Item 10) from the motor controller. Remove the four nuts (Figure 1, Item 4), the four lockwashers (Figure 1, Item 5), and four flat washers (Figure 1, Item 6) from the studs (Figure 1, Item 7). Discard lockwashers. Remove the motor controller (Figure 1, Item 2) from the studs (Figure 1, Item 7).
4. 5. 6. 7.
0141-2
0141
ON ON
8 8
OFF
12
OFF
POWER AVAILABLE POWER AVAILABLE
SLOW FAST FAST SLOW
FAST SLOW RESET RESET FAST SLOW
STOP STOP
11 10
9
M1236T73
0141-3
TM 55-1925-273-24&P-2 MOTOR CONTROLLER (TYPICAL) INSTALLATION 1. 2. 3. 4. 5.
0141
Position the motor controller (Figure 1, Item 2) on the studs (Figure 1, Item 7), and secure it with the four nuts (Figure 1, Item 4), four lockwashers (Figure 1, Item 5), and four flat washers (Figure 1, Item 6). Route the wiring (Figure 1, Item 10) through the strain relief clamps (Figure 1, Item 9) and into the motor controller (Figure 1, Item 2). Connect the wiring (Figure 1, Item 10) to the terminals (Figure 1, Item 3) using the labels from Step (4) of MOTOR CONTROLLER (TYPICAL) REMOVAL as a guide. Remove the labels. Tighten the strain relief clamps (Figure 1, Item 9). Close the door (Figure 1, Item 11), and secure it by turning the handle (Figure 1, Item 12) and tightening the motor controller door screw (Figure 1, Item 1).
END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. 4. 5. Remove the lock outs and tag outs IAW FM 4-01.502. Set to ON the applicable circuit breaker. Set to ON the switch handle. Operate the applicable system under usual conditions IAW TM 55-1925-273-10 and check for proper operation. Return the system to the desired readiness condition.
0141-4
TM 55-1925-273-24&P-2
0142
FIELD MAINTENANCE MOTOR CONTROLLER: AMS 1 & 2 SUPPLY FAN; BOATSWAIN'S STORE ROOM SUPPLY FAN; ARMS LOCKER EXHAUST FAN; ENGINE ROOM SUPPLY FAN 1 & 2; ENGINE ROOM EXHAUST FAN 1 & 2 REPAIR
0142-1
TM 55-1925-273-24&P-2
0142
LAMP REMOVAL
WARNING
END OF TASK LAMP INSTALLATION 1. 2. Install the lamps and lens cover (Figure 1, Item 7). Perform the FOLLOW-ON MAINTENANCE procedure at the end of the work package.
NOTE
The switch handle must be set to OFF to open the door. 1. 2. 3. Set the switch handle (Figure 1, Item 5) to OFF. Loosen the motor controller door screw (Figure 1, Item 1). Turn the handle (Figure 1, Item 10) and open the door (Figure 1, Item 9).
0142-2
TM 55-1925-273-24&P-2 ACCESS TO INNER MOTOR CONTROLLER - Continued
0142
ON ON
5 5
OFF OFF
10 6
8
POWER
AVAILABLE
POWER
7
FAST SLOW
AVAILABLE
7
FAST SLOW
FAST SLOW RESET RESET
11
FAST SLOW
STOP STOP
8
M1058T73
0142-3
TM 55-1925-273-24&P-2
0142
FUSE REMOVAL 1. Perform the ACCESS TO INNER MOTOR CONTROLLER procedure in this work package.
WARNING
Replace or repair components only after the affected circuit has been secured, locked out, and tagged out IAW FM 4-01.502. Performing replacement with the circuit energized may result in injury. 2. Use a multimeter to check for voltage at the fuses (Figure 1, Item 2). If voltage is present, ensure that the proper circuit breakers have been set to OFF, locked out, and tagged out IAW FM 4-01.502. If no voltage is present, continue with the procedure. Remove the cartridge fuse(s) (Figure 1, Item 2) with a fuse puller.
3.
END OF TASK FUSE INSTALLATION 1. 2. 3. Install the cartridge fuse(s) (Figure 1, Item 2) with a fuse puller. Perform the SECURE THE MOTOR CONTROLLER procedure in this work package. Perform the FOLLOW-ON MAINTENANCE procedure at the end of this work package.
END OF TASK MOTOR STARTER REMOVAL 1. Perform the ACCESS TO INNER MOTOR CONTROL procedure in this work package.
WARNING
Replace or repair components only after the affected circuit has been secured, locked out, and tagged out IAW FM 4-01.502. Performing replacement with the circuit energized may result in injury. 2. Use a multimeter to check for voltage at the fuses (Figure 1, Item 2). If voltage is present, ensure that the proper circuit breakers have been set to OFF, locked out, and tagged out IAW FM 4-01.502. If no voltage is present, continue with the procedure. Label and disconnect the electrical wiring attached to the motor starter (Figure 1, Item 11). Remove the screws (Figure 1, Item 8) that secure the motor starter (Figure 1, Item 11) to the motor controller back plate (Figure 1, Item 6).
3. 4.
0142-4
TM 55-1925-273-24&P-2 MOTOR STARTER REMOVAL - Continued 5. Remove the motor starter (Figure 1, Item 11).
0142
END OF TASK MOTOR STARTER INSTALLATION 1. 2. 3. 4. Install the motor starter (Figure 1, Item 11) on the motor controller back plate (Figure 1, Item 6) and secure it with the screws (Figure 1, Item 8). Connect the electrical wiring to the motor starter (Figure 1, Item 11) using the labels from Step (3) of MOTOR STARTER REMOVAL as a guide. Remove the labels. Perform the SECURE THE MOTOR CONTROLLER procedure in this work package. Perform the FOLLOW-ON MAINTENANCE procedure at the end of this work package.
END OF TASK TRANSFORMER REMOVAL 1. Perform the ACCESS TO INNER MOTOR CONTROL procedure in this work package.
WARNING
Replace or repair components only after the affected circuit has been secured, locked out, and tagged out IAW FM 4-01.502. Performing replacement with the circuit energized may result in injury. 2. Use a multimeter to check for voltage at the fuses (Figure 1, Item 2). If voltage is present, ensure that the proper circuit breakers have been set to OFF, locked out, and tagged out IAW FM 4-01.502. If no voltage is present, continue with the procedure. Label and disconnect electrical wiring attached to the transformer (Figure 1, Item 3). Remove the screws (Figure 1, Item 4) that secure the transformer (Figure 1, Item 3) to the motor controller back plate (Figure 1, Item 6). Remove the transformer (Figure 1, Item 3).
3. 4. 5.
END OF TASK TRANSFORMER INSTALLATION 1. 2. 3. 4. Install the transformer (Figure 1, Item 3) on the motor controller back plate (Figure 1, Item 6) and secure it with the screws (Figure 1, Item 4). Connect the electrical wiring to the transformer (Figure 1, Item 3) using the labels from Step (3) of TRANSFORMER REMOVAL as a guide. Remove the labels. Perform the SECURE THE MOTOR CONTROLLER procedure in this work package. Perform the FOLLOW-ON MAINTENANCE procedure at the end of this work package.
END OF TASK
0142-5
TM 55-1925-273-24&P-2 SECURE THE MOTOR CONTROLLER 1. 2. 3. Close the motor controller door (Figure 1, Item 9) and tighten the handle (Figure 1, Item 10). Secure the door by tightening the door screw (Figure 1, Item 1). Set the switch handle (Figure 1, Item 5) to ON.
0142
END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. 4. 5. Remove the lock outs and tag outs IAW FM 4-01.502. Set the applicable circuit breaker to ON. Operate the motor controller for the affected system IAW TM 55-1925-273-10. Verify proper operation of the motor controller. Return the equipment to the desired readiness condition.
0142-6
TM 55-1925-273-24&P-2
0143
FIELD MAINTENANCE MOTOR CONTROLLER: BILGE & BALLAST PUMP 1 & 2; FIRE & GENERAL SERVICE EMERGENCY PUMP #1 & # 2 REPLACE
0143-1
TM 55-1925-273-24&P-2
0143
WARNING
NOTE
The switch handle must be OFF to open the door. 1. 2. Set to OFF the switch handle (Figure 1, Item 8). Loosen the motor controller door screw (Figure 1, Item 1) and turn the handle (Figure 1, Item 12) to open the door (Figure 1, Item 11).
WARNING
Replace or repair components only after the affected circuit has been secured, locked out, and tagged out IAW FM 4-01.502. Performing replacement with the circuit energized may result in injury. 3. Use a multimeter to check for voltage at the motor controller terminals (Figure 1, Item 3). If voltage is present, ensure that the correct circuit breakers are secured, locked out, and tagged out IAW FM 4-01.502. If no voltage is present, continue with the procedure. Label and remove the wiring (Figure 1, Item 2) from the motor controller terminals (Figure 1, Item 3). Loosen the strain relief clamps (Figure 1, Item 9), and remove the wiring (Figure 1, Item 10). Remove the four nuts (Figure 1, Item 4), the four lockwashers (Figure 1, Item 5), and the four flat washers (Figure 1, Item 6) from the studs (Figure 1, Item 7). Discard lockwashers. Remove the motor controller (Figure 1, Item 2) from the studs (Figure 1, Item 7).
4. 5. 6. 7.
0143-2

4 5 6 7
0143
ON
ON
OFF
12
OFF
POWER AVAILABLE
POWER AVAILABLE
MOTOR RUN
MOTOR RUN
START STOP
START STOP
MAN
AUTO
MAN
AUTO
RESET
11 9 10
M1237T73
Type 3 Motor Controller.
0143-3
TM 55-1925-273-24&P-2 MOTOR CONTROLLER (TYPICAL) INSTALLATION 1. 2. 3. 4. 5.
0143
Position the motor controller (Figure 1, Item 2) on the studs (Figure 1, Item 7), and secure it with the four flat washers (Figure 1, Item 6), four lockwashers (Figure 1, Item 5), and four nuts (Figure 1, Item 4). Route the wiring (Figure 1, Item 10) through the strain relief clamps and into the motor controller (Figure 1, Item 2). Connect the wiring (Figure 1, Item 10) to the terminals (Figure 1, Item 3) using the labels from Step (4) of MOTOR CONTROLLER (TYPICAL) REMOVAL as a guide. Tighten the strain relief clamps (Figure 1, Item 9). Close the door (Figure 1, Item 11) and secure it by turning the handle (Figure 1, Item 12) and tightening the motor controller door screw (Figure 1, Item 1).
END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. 4. 5. Remove the lock outs and tag outs IAW FM 4-01.502. Set to ON the applicable circuit breaker. Set to ON the switch handle. Operate the applicable system under usual conditions IAW TM 55-1925-273-10 and check for proper operation. Return the system to the desired readiness conditions.
0143-4
TM 55-1925-273-24&P-2
0144
FIELD MAINTENANCE MOTOR CONTROLLER: BILGE & BALLAST PUMP 1 & 2; FIRE & GENERAL SERVICE EMERGENCY PUMP #1 & #2 REPAIR
0144-1
TM 55-1925-273-24&P-2
0144
LAMP REMOVAL
WARNING
END OF TASK LAMP INSTALLATION 1. 2. Install the lamps and lens cover (Figure 1, Item 4). Perform the FOLLOW-ON MAINTENANCE procedure at the end of the work package.
NOTE
The switch handle must be set to OFF to open the door. 1. 2. 3. Set the switch handle (Figure 1, Item 3) to OFF. Loosen the motor controller door screw (Figure 1, Item 1). Turn the handle (Figure 1, Item 8) and open the door (Figure 1, Item 7).
END OF TASK FUSE REMOVAL 1. Perform the ACCESS TO INNER MOTOR CONTROLLER procedure in this work package.
WARNING
Replace or repair components only after the affected circuit has been secured, locked out, and tagged out IAW FM 4-01.502. Performing replacement with the circuit energized may result in injury. 2. Use a multimeter to check for voltage at the fuses (Figure 1, Items 10 and 11). If voltage is present, ensure that the proper circuit breakers have been set to OFF, locked out, and tagged out IAW FM 4-01.502. If no voltage is present, continue with the procedure.
0144-2
TM 55-1925-273-24&P-2 FUSE REMOVAL - Continued 3.
0144
Remove the cartridge fuse(s) (Figure 1, Item 10) and/or slo-blo fuse (Figure 1, Item 11) using a fuse puller.
ON
ON
OFF
OFF
10
POWER AVAILABLE MOTOR RUN POWER AVAILABLE MOTOR RUN
4 11
START STOP
START STOP
12
RESET
5 8 7
6
Figure 1. END OF TASK FUSE INSTALLATION 1. 2. 3.
M1059T73
Motor Controller Type 3 (Typical).
Install the cartridge fuse(s) (Figure 1, Item 10) and/or slo-blo fuse (Figure 1, Item 11) using a fuse puller. Perform the SECURE THE MOTOR CONTROLLER procedure in this work package. Perform the FOLLOW-ON MAINTENANCE procedure at the end of this work package.
END OF TASK MOTOR STARTER REMOVAL 1. Perform the ACCESS TO INNER MOTOR CONTROL procedure in this work package.
0144-3
TM 55-1925-273-24&P-2 MOTOR STARTER REMOVAL - Continued
0144
WARNING
Replace or repair components only after the affected circuit has been secured, locked out, and tagged out IAW FM 4-01.502. Performing replacement with the circuit energized may result in injury. 2. Use a multimeter to check for voltage at the fuses (Figure 1, Items 10 and 11). If voltage is present, ensure that the proper circuit breakers have been set to OFF, locked out, and tagged out IAW FM 4-01.502. If no voltage is present, continue with the procedure. Label and disconnect the electrical wiring attached to the motor starter (Figure 1, Item 6). Remove the screws (Figure 1, Item 5) that secure the motor starter (Figure 1, Item 6) to the motor controller back plate (Figure 1, Item 2). Remove the motor starter (Figure 1, Item 6).
3. 4. 5.
END OF TASK MOTOR STARTER INSTALLATION 1. 2. 3. 4. Install the motor starter (Figure 1, Item 6) on the motor controller back plate (Figure 1, Item 2) and secure it with the applicable screws (Figure 1, Item 5). Connect the electrical wiring to the motor starter (Figure 1, Item 6) using the labels from Step (3) of MOTOR STARTER REMOVAL as a guide. Remove the labels. Perform the SECURE THE MOTOR CONTROLLER procedure in this work package. Perform the FOLLOW-ON MAINTENANCE procedure at the end of this work package.
END OF TASK
0144-4
TM 55-1925-273-24&P-2
0144
TRANSFORMER REMOVAL 1. Perform the ACCESS TO INNER MOTOR CONTROL procedure in this work package.
WARNING
Replace or repair components only after the affected circuit has been secured, locked out, and tagged out IAW FM 4-01.502. Performing replacement with the circuit energized may result in injury. 2. Use a multimeter to check for voltage at the fuses (Figure 1, Items 10 and 11). If voltage is present, ensure that the proper circuit breakers have been set to OFF, locked out, and tagged out IAW FM 4-01.502. If no voltage is present, continue with the procedure. Label and disconnect electrical wiring attached to the transformer (Figure 1, Item 12). Remove the screws (Figure 1, Item 9) that secure the transformer (Figure 1, Item 12) to the motor controller back plate (Figure 1, Item 2). Remove the transformer (Figure 1, Item 12).
3. 4. 5.
END OF TASK TRANSFORMER INSTALLATION 1. 2. 3. 4. Install the transformer (Figure 1, Item 12) on the motor controller back plate (Figure 1, Item 2) and secure it with the screws (Figure 1, Item 9). Connect the electrical wiring to the transformer (Figure 1, Item 12) using the labels from Step (3) of TRANSFORMER REMOVAL as a guide. Remove the labels. Perform the SECURE THE MOTOR CONTROLLER procedure in this work package. Perform the FOLLOW-ON MAINTENANCE procedure at the end of this work package.
END OF TASK SECURE THE MOTOR CONTROLLER 1. 2. 3. Close the motor controller door (Figure 1, Item 7) and turn the handle (Figure 1, Item 8). Secure the door by tightening the door screw (Figure 1, Item 1). Set the switch handle (Figure 1, Item 3) to ON.
END OF TASK
0144-5
TM 55-1925-273-24&P-2
0144
FOLLOW-ON MAINTENANCE 1. 2. 3. 4. 5. Remove the lock outs and tag outs IAW FM 4-01.502. Set the applicable circuit breaker to ON. Operate the motor controller for the affected system IAW TM 55-1925-273-10. Verify proper operation of the motor controller. Return the equipment to the desired readiness condition.
0144-6
TM 55-1925-273-24&P-2 FIELD MAINTENANCE MOTOR CONTROLLER: HOT POTABLE WATER RECIRCULATING PUMP REPLACE
0145
INITIAL SETUP: Tools and Special Tools Multimeter (Volume 3, WP 0344, Table 1, Item 15) Tool Kit, Electrical Repair (Volume 3, WP 0344, Table 1, Item 26) Materials/Parts N/A Personnel Required Watercraft Engineer 88L (2) References FM 4-01.502 References (cont.) TM 55-1925-273-10 Volume 3, WP 0285 Volume 3, WP 0344 Equipment Condition Set to OFF the HOT POTABLE WATER RECIRCULATING PUMP circuit breaker (LT 803 Only), or the LVP FOR HOT POTABLE WATER RECIRCULATING PUMP circuit breaker (All Other Vessels) at 440 V power panel No. 4. Lock out and tag out IAW FM 4-01.502.
0145-1
TM 55-1925-273-24&P-2
0145
WARNING
Never reuse locking hardware. Reuse of locking hardware such as lockwashers, locking nuts, cotter pins, and lock wire can result in undetected loosening of fastening hardware causing catastrophic component failure resulting in death, injury, or damage to equipment. Ensure that all locking hardware is discarded upon removal and replaced with new. MOTOR CONTROLLER REMOVAL 1. 2. Loosen the four screws (Figure 1, Item 1) until the clamps (Figure 1, Item 2) clear the lip of the door (Figure 1, Item 3). Open the door (Figure 1, Item 3).
WARNING
Replace or repair components only after the affected circuit has been secured, locked out, and tagged out IAW FM 4-01.502. Performing replacement with the circuit energized may result in injury. 3. Use a multimeter to check for voltage at the motor controller terminals (Figure 1, Item 5). If voltage is present, ensure that the correct circuit breakers are secured, locked out, and tagged out IAW FM 4-01.502. If no voltage is present, continue with the procedure. Label and remove the wiring (Figure 1, Item 6) from the motor controller terminals (Figure 1, Item 5). Loosen the strain relief clamp (Figure 1, Item 7) and remove the wiring (Figure 1, Item 6) from the motor controller (Figure 1, Item 4). Remove the four bolts (Figure 1, Item 8), the four nuts (Figure 1, Item 11), the four lockwashers (Figure 1, Item 10), and the eight flat washers (Figure 1, Item 9). Discard lockwashers. Remove the motor controller (Figure 1, Item 4) from its foundation.
4. 5. 6. 7.
0145-2
TM 55-1925-273-24&P-2 MOTOR CONTROLLER REMOVAL - Continued

2 1 3 4 5
0145
PO AV WER AIL AB LE MO TO RR UN
STA
RT
STO
P/R ES ET
START
STOP RESET
1 6
11
10
M1244T73
Type 4 Motor Controller.
0145-3
TM 55-1925-273-24&P-2
0145
MOTOR CONTROLLER INSTALLATION 1. Position the motor controller (Figure 1, Item 4) on its foundation, and secure it with the four bolts (Figure 1, Item 8), four nuts (Figure 1, Item 11), four lockwashers (Figure 1, Item 10), and eight flat washers (Figure 1, Item 9). Route the wiring (Figure 1, Item 6) through the strain relief clamp (Figure 1, Item 7) and into the motor controller (Figure 1, Item 4). Connect the wiring (Figure 1, Item 6) to the terminals (Figure 1, Item 5) using the labels from Step (4) of MOTOR CONTROLLER REMOVAL as a guide. Remove the labels. Tighten the strain relief clamp (Figure 1, Item 7). Close the door (Figure 1, Item 3), and secure it with the four clamps (Figure 1, Item 2) and four screws (Figure 1, Item 1).
2. 3. 4. 5.
END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. Remove the lock outs and tag outs IAW FM 4-01.502. Operate the potable water system under usual conditions IAW TM 55-1925-273-10 and check for proper operation. Return the potable water system to the desired readiness condition.
0145-4
TM 55-1925-273-24&P-2 FIELD MAINTENANCE MOTOR CONTROLLER: HOT POTABLE WATER RECIRCULATING PUMP REPAIR
0146
INITIAL SETUP: Tools and Special Tools Multimeter (Volume 3, WP 0344, Table 1, Item 15) Tool Kit, Electrical Repair (Volume 3, WP 0344, Table 1, Item 26) Materials/Parts N/A Personnel Required Watercraft Engineer 88L (2) References FM 4-01.502 References (cont.) TM 55-1925-273-10 Volume 3, WP 0285 Volume 3, WP 0344 Equipment Condition Set to OFF the HOT POTABLE WATER RECIRCULATING PUMP. circuit breaker (LT 803 Only), or the LVP FOR HOT POTABLE WATER RECIRCULATING PUMP circuit breaker (All Other Vessels) at 440 V power panel No. 4. Lock out and tag out IAW FM 4.01-502.
0146-1
TM 55-1925-273-24&P-2
0146
LAMP REPLACE
WARNING
Replace or repair components only after the affected circuit has been secured, locked out, and tagged out IAW FM 4-01.502. Performing replacement with the circuit energized may result in injury. 1. 2. 3. 4. Remove the lens cover (Figure 1, Item 7). Remove the lamps from the indicators. Install the lamp and lens covers (Figure 1, Item 7). Perform the FOLLOW-ON MAINTENANCE procedure at the end of this work package.
END OF TASK STARTER ASSEMBLY REMOVAL 1. 2. Loosen the screws (Figure 1, Item 1) until the clamps (Figure 1, Item 2) clear the lip of the motor controller door (Figure 1, Item 3). Open the motor controller door (Figure 1, Item 3).
WARNING
Replace or repair components only after the affected circuit has been secured, locked out, and tagged out IAW FM 4-01.502. Performing replacement with the circuit energized may result in injury. 3. Use a multimeter to check for voltage at the motor starter (Figure 1, Item 4). If voltage is present, ensure that the proper circuit breaker has been set to OFF, locked out, and tagged out IAW FM 4-01.502. If no voltage is present, continue with the procedure. Label and remove the electrical wiring from the motor starter (Figure 1, Item 4). Remove the four screws (Figure 1, Item 5) that secure the motor starter (Figure 1, Item 4) to the motor controller back plate (Figure 1, Item 6). Remove the motor starter (Figure 1, Item 4) from the motor controller.
4. 5. 6.
END OF TASK
0146-2
TM 55-1925-273-24&P-2
0146
STARTER ASSEMBLY INSTALLATION 1. 2. 3. 4. Install the motor starter (Figure 1, Item 4) on the motor controller back plate (Figure 1, Item 6) and secure it with the four screws (Figure 1, Item 5). Connect the electrical wiring to the motor starter (Figure 1, Item 4) using labels from Step (4) of STARTER ASSEMBLY REMOVAL as a guide. Remove the labels. Close the motor controller door (Figure 1, Item 3) and secure it with the clamps (Figure 1, Item 2). Tighten the door screws (Figure 1, Item 1).
POW AVA ER ILA BLE MOT OR R UN
START STO P STA RT
STOP RESET
6
Figure 1. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. 4. 5. Remove the lock outs and tag outs IAW FM 4-01.502. Set the circuit breaker to ON. Operate the motor controller for the affected system IAW TM 55-1925-273-10. Verify proper operation of the motor controller. Return the equipment to the desired readiness condition. Motor Controller Type 4.
5
M1060T73
0146-3/4 blank
TM 55-1925-273-24&P-2 FIELD MAINTENANCE MOTOR CONTROLLER: WELD HOOD EXHAUST FAN REPLACE
0147
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 3, WP 0344, Table 1, Item 27) Multimeter (Volume 3, WP 0344, Table 1, Item 15) Tool Kit, Electrical Repair (Volume 3, WP 0344, Table 1, Item 26) Materials/Parts N/A Personnel Required Watercraft Engineer 88L (2) References FM 4-01.502 References (cont.) TM 55-1925-273-10 Volume 3, WP 0286 Volume 3, WP 0344 Equipment Condition Set to OFF the WORKSHOP EXHAUST FAN E02-16-1. circuit breaker at 120 V distribution panel No. 4. Lock out and tag out IAW FM 4-01.502.
0147-1
TM 55-1925-273-24&P-2
0147
WARNING
Never reuse locking hardware. Reuse of locking hardware such as lockwashers, locking nuts, cotter pins, and lock wire can result in undetected loosening of fastening hardware causing catastrophic component failure resulting in death, injury, or damage to equipment. Ensure that all locking hardware is discarded upon removal and replaced with new. MOTOR CONTROLLER REMOVAL 1. 2. Loosen the four screws (Figure 1, Item 1) until the clamps (Figure 1, Item 2) clear the lip of the door (Figure 1, Item 3). OPEN the motor controller door (Figure 1, Item 3).
ON
1
OFF
M1245T73
WARNING
Replace or repair components only after the affected circuit has been secured, locked out, and tagged out IAW FM 4-01.502. Performing replacement with the circuit energized may result in injury. 3. Use a multimeter to check for voltage at the motor controller terminals (Figure 2, Item 1). If voltage is present, ensure that the proper circuit breakers have been secured, locked out, and tagged out IAW FM 4-01.502. If no voltage is present, continue with the procedure. Label and remove the wiring (Figure 2, Item 2) from the terminal screws (Figure 2, Item 1). Loosen the strain relief clamps (Figure 2, Item 8) and remove the wiring (Figure 2, Item 2) from the motor controller (Figure 2, Item 3).
4. 5.
0147-2
TM 55-1925-273-24&P-2 MOTOR CONTROLLER REMOVAL - Continued 6.
0147
Remove the four bolts (Figure 2, Item 7), four flat washers (Figure 2, Item 6), four lockwashers (Figure 2, Item 5), and four nuts (Figure 2, Item 4) from the motor controller (Figure 2, Item 3). Discard lockwashers. Remove the motor controller (Figure 2, Item 3) from its foundation.
7.
7
5
M1246T73
Interior of Motor Controller Type 5.
0147-3
TM 55-1925-273-24&P-2
0147
MOTOR CONTROLLER INSTALLATION 1. 2. 3. 4. Position the motor controller (Figure 2, Item 3) on its foundation. Secure the motor controller (Figure 2, Item 3) with the four bolts (Figure 2, Item 7), four flat washers (Figure 2, Item 6), four lockwashers (Figure 2, Item 5), and four nuts (Figure 2, Item 4). Route the wiring (Figure 2, Item 2) into the motor controller (Figure 2, Item 3) and secure it in place with the strain relief clamps (Figure 2, Item 8). Connect the wiring (Figure 2, Item 2) to the motor controller (Figure 2, Item 3) using the labels from Step (4) of MOTOR CONTROLLER REMOVAL as a guide. Tighten the terminal screws (Figure 2, Item 1) and remove the labels. CLOSE the door (Figure 1, Item 3). Rotate the clamp (Figure 1, Item 2) until it is over the lip of the door (Figure 1, Item 3). Tighten the door screws (Figure 1, Item 1).
5. 6. 7.
END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. Remove the lock outs and tag outs IAW FM 4-01.502. Operate the Heating, Ventilation, Air Conditioning, and Refrigeration (HVACR) systems under usual conditions IAW TM 55-1925-273-10 and check for proper operation of the workshop exhaust fan. Return the workshop motor controller to the desired readiness condition.
0147-4
TM 55-1925-273-24&P-2 FIELD MAINTENANCE MOTOR CONTROLLER: WELD HOOD EXHAUST FAN REPAIR
0148
INITIAL SETUP: Tools and Special Tools Multimeter (Volume 3, WP 0344, Table 1, Item 15) Tool Kit, Electrical Repair (Volume 3, WP 0344, Table 1, Item 26) Materials/Parts N/A Personnel Required Watercraft Engineer 88L (2) References FM 4-01.502 References (cont.) TM 55-1925-273-10 Volume 3, WP 0286 Volume 3, WP 0344 Equipment Condition Set to OFF the WORKSHOP EXHAUST FAN EO2-16-1. circuit breaker at 120 V distribution panel No. 4. Lock out and tag out IAW FM 4-01.502.
0148-1
TM 55-1925-273-24&P-2
0148
MOTOR STARTER REMOVAL 1. 2. Loosen the screws (Figure 1, Item 1) until the clamps (Figure 1, Item 2) clear the lip of the door (Figure 1, Item 3). Open the motor controller door (Figure 1, Item 3).
WARNING
Replace or repair components only after the affected circuit has been secured, locked out, and tagged out IAW FM 4-01.502. Performing replacement with the circuit energized may result in injury. 3. Use a multimeter to check for voltage at the motor starter (Figure 1, Item 5). If voltage is present, ensure that the proper circuit breaker has been set to OFF, locked out, and tagged out IAW FM 4-01.502. If no voltage is present, continue with the procedure. Label and disconnect the electrical wiring attached to the motor starter (Figure 1, Item 5). Remove the screws (Figure 1, Item 4) holding the motor starter (Figure 1, Item 5) to the motor controller door (Figure 1, Item 3). Remove the motor starter (Figure 1, Item 5) from the motor controller.
1 2 3 4
4. 5. 6.
ON
1
OF F
M1061T73
Figure 1. Motor Controller Type 5 (Typical). END OF TASK
0148-2
TM 55-1925-273-24&P-2 MOTOR STARTER INSTALLATION 1. 2. 3. 4.
0148
Install the motor starter (Figure 1, Item 5) on the motor controller door (Figure 1, Item 3) and secure it with the screws (Figure 1, Item 4). Connect the electrical wiring to the motor starter (Figure 1, Item 5) using the labels from Step (4) of MOTOR STARTER REMOVAL as a guide. Remove the labels. Close the motor controller door (Figure 1, Item 3) and rotate the clamp (Figure 1, Item 2) until it is over the lip of the door. Secure the motor controller door (Figure 1, Item 3) by tightening the door screws (Figure 1, Item 1).
END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. 4. 5. Remove the lock outs and tag outs IAW FM 4-01.502. Set the circuit breaker to ON. Operate the motor controller for the affected system IAW TM 55-1925-273-10. Ensure that the system starts and stops properly. Return the equipment to the desired readiness condition.
0148-3/4 blank
TM 55-1925-273-24&P-2 FIELD MAINTENANCE BATTERY POWER SUPPLY SYSTEM TEST
0149
INITIAL SETUP: Tools and Special Tools Apron, Utility (Volume 3, WP 0344, Table 1, Item 1) Faceshield, Industrial (Volume 3, WP 0344, Table 1, Item 5) Gloves, Chemical and Oil Protective (Volume 3, WP 0344, Table 1, Item 8) Goggles, Industrial (Volume 3, WP 0344, Table 1, Item 10) Refractometer (Volume 3, WP 0344, Table 1, Item 18) Tool Kit, Electrical Repair (Volume 3, WP 0344, Table 1, Item 26) Materials/Parts Distilled Water, Technical (Volume 3, WP 0343, Table 1, Item 61) Rag, Wiping (Volume 3, WP 0343, Table 1, Item 132) Personnel Required Watercraft Engineer 88L (2) References FM 4-01.502 Volume 3, WP 0287 Volume 3, WP 0343 Volume 3, WP 0344 Equipment Condition Set to OFF the switch for the applicable battery charger.
0149-1
TM 55-1925-273-24&P-2
0149
BATTERY TEST
WARNING
Batteries produce hydrogen gas. This gas is explosive. Keep work area free of sparks, open flame, and excessive heat. Take care to prevent conductive metal tools from arcing between positive and negative terminals. Failure to comply with these precautions can result in serious injury or death. Batteries are filled with a sulfuric acid-based electrolyte. This electrolyte is extremely corrosive to human tissue and many other materials. Chemical protective nitrile gloves, chemical protective goggles, faceshield, and a chemical protective apron must be worn at all times when batteries are being serviced. If electrolyte comes in contact with clothing or other material, wash the affected area with large volumes of fresh water. If electrolyte comes in contact with the skin or eyes, flush the area with large volumes of water. Continue flushing the affected areas until medical assistance arrives. Failure to comply with these precautions can result in serious injury or death. 1. Remove the battery filler caps (Figure 1, Item 1) from the battery (Figure 1, Item 2) and check the liquid level of each battery cell. The liquid level should be at the bottom of the split ring on each cell.
NOTE
To get an accurate reading, the liquid of the battery cell should be at normal height when the battery is tested. Any water added to the battery should be thoroughly mixed with the electrolyte by charging the battery before testing. If the battery is dry, and a field charge is not permitted, replace defective battery. 2. 3. 4. 5. If necessary, add distilled water to the battery (Figure 1, Item 2) and bring each cell to its normal level. Charge the battery to mix the water with the existing electrolyte. Set to ON the switch for the applicable battery charger, and charge the battery so that the water mixes with the existing electrolyte. After charging, set to OFF the switch for the applicable battery charger, and insert the refractometer into a cell of the battery. Use the battery dipstick (Figure 1, Item 7) located on the bottom of the refractometer (Figure 1, Item 5) to obtain a sample of the electrolyte by placing the battery dipstick approximately 1/2 in. into the electrolyte of the cell being tested. Remove the battery dipstick (Figure 1, Item 7) from the battery cell and touch it to the measuring prism (Figure 1, Item 3), allowing a few drops of electrolyte to roll onto the measuring prism from the battery dipstick. Close the sample cover (Figure 1, Item 4) of the refractometer (Figure 1, Item 5).
6. 7.
NOTE
The refractometer, when viewed through the eyeguard, contains two measuring scales. The scale on the right measures engine coolant. The scale on the left measures the battery charge and specific gravity. These scales are not visible until a sample is placed on the measuring prism and the sample cover is closed. 8. Point the refractometer (Figure 1, Item 5) at any light source and view the battery charge/specific gravity scale through the eyeguard (Figure 1, Item 6).
0149-2
TM 55-1925-273-24&P-2 BATTERY TEST - Continued 9.
0149
Record the electrolyte specific gravity reading of the cell tested. Use a wiping rag to thoroughly clean the measuring prism (Figure 1, Item 3) and sample cover (Figure 1, Item 4) between each of the electrolyte samples. Perform Steps (5) through (9) for each of the remaining battery cells. A fully charged battery (Figure 1, Item 2) should have a specific gravity reading of 1.260 to 1.270. If the specific gravity reading is below 1.225, charge the battery. After charging, again check each cell of the battery (Figure 1, Item 2) as described in this work package. Each cell must be within 0.025 specific gravity of all the other cells. If a greater difference exists between two cells, the battery is defective. After using the refractometer (Figure 1, Item 5), flush with clean, clear water. Install the battery caps (Figure 1, Item 1).
1 6 4 2 3 5
10. 11. 12.
13. 14.
M1062T73
Batteries and Refractometer.
0149-3/4 blank
TM 55-1925-273-24&P-2 FIELD MAINTENANCE BATTERY POWER SUPPLY SYSTEM SERVICE
0150
INITIAL SETUP: Tools and Special Tools Apron, Utility (Volume 3, WP 0344, Table 1, Item 1) Faceshield, Industrial (Volume 3, WP 0344, Table 1, Item 5) Gloves, Chemical and Oil Protective (Volume 3, WP 0344, Table 1, Item 8) Goggles, Industrial (Volume 3, WP 0344, Table 1, Item 10) Tool Kit, Electrical Repair (Volume 3, WP 0344, Table 1, Item 26) Materials/Parts Distilled Water, Technical (Volume 3, WP 0343, Table 1, Item 61) Petrolatum, Technical (Volume 3, WP 0343, Table 1, Item 126) Rag, Wiping (Volume 3, WP 0343, Table 1, Item 132) Sodium Bicarbonate, Technical (Volume 3, WP 0343, Table 1, Item 150) Personnel Required Watercraft Engineer 88L (2) References FM 4-01.502 WP 0149 Volume 3, WP 0287 Volume 3, WP 0343 Volume 3, WP 0344 Equipment Condition Set to OFF the applicable battery charger circuit breaker. Lock out and tag out IAW FM 4-01.502.
0150-1
TM 55-1925-273-24&P-2
0150
BATTERY SERVICE
WARNING
Batteries produce hydrogen gas. This gas is explosive. Keep work area free of sparks, open flame, and excessive heat. Take care to prevent conductive metal tools from arcing between positive and negative terminals. Failure to comply with these precautions can result in serious injury or death. Batteries are filled with a sulfuric acid-based electrolyte. This electrolyte is extremely corrosive to human tissue and many other materials. Chemical protective nitrile gloves, chemical protective goggles, faceshield, and a chemical protective apron must be worn at all times when batteries are being serviced. If electrolyte comes in contact with clothing or other material, wash the affected area with large volumes of fresh water. If electrolyte comes in contact with the skin or eyes, flush the area with large volumes of water. Continue flushing the affected areas until medical assistance arrives. Failure to comply with these precautions can result in serious injury or death.
NOTE
Whenever working with batteries, the negative cable must be disconnected first, the positive cable next, and the interconnecting cable (if installed) last. When connecting the batteries, the interconnecting cable (if installed) must be connected first, the positive cable next, and the negative cable last. 1. 2. 3. Label and remove the negative battery cable (Figure 1, Item 5) from the battery post connectors (Figure 1, Item 1). Label and remove the positive battery cable (Figure 1, Item 2) from the battery post connectors (Figure 1, Item 1). Label and remove the interconnecting cable (Figure 1, Item 3) from the battery post connectors (Figure 1, Item 1).
CAUTION
Do not apply any prying or twisting force to the battery posts. Doing so can cause the posts to break internally, permanently disabling the battery. If the battery post connectors are difficult to remove from the battery posts, spread the battery post connectors to loosen them before attempting to remove them from the batteries. 4. Remove the battery post connectors (Figure 1, Item 1) from the batteries (Figure 1, Item 7) taking care not to apply any prying or twisting force to the battery posts (Figure 1, Item 4). If the battery post connectors are difficult to remove from the battery posts, spread the battery post connectors to loosen them before attempting to remove them from the batteries.
0150-2
TM 55-1925-273-24&P-2 BATTERY SERVICE - Continued
0150
WARNING
Removing components by means of wire brushing produces flying particles. These particles can cause serious injury to personnel. Wear protective faceshield, gloves, and long sleeves at all times during wire brushing operations. Failure to comply with this warning can result in serious injury to personnel. 5. 6. Use a wire brush to remove all deposits from the battery posts (Figure 1, Item 4), battery post connectors (Figure 1, Item 1), and battery cable ends (Figure 1, Items 2, 3, and 5). Inspect the battery posts (Figure 1, Item 4), battery post connectors (Figure 1, Item 2), and battery cable ends (Figure 1, Items 2, 3, and 5) for damage. Replace any battery with posts damaged to the extent that the battery post connectors will not fit securely, and replace damaged battery post connectors and/or battery cables. Prepare a 50/50 mix of technical sodium bicarbonate and water. Scrub the battery tops, battery cable ends (Figure 1, Items 2, 3, and 5), and the battery post connectors (Figure 1, Item 1) with mixture. Rinse the cleaned areas with fresh water, and remove any water and debris with clean wiping rags. Remove the battery caps (Figure 1, Item 6) and check the electrolyte level in each cell. The level should be to the bottom of the split ring. If any cells are low, add technical distilled water to bring the cells to the proper level. Install the battery caps (Figure 1, Item 6). Install the battery terminal connectors (Figure 1, Item 1) onto the battery posts (Figure 1, Item 4) and tighten them snugly. Install the interconnecting cables (Figure 1, Item 3) on both batteries. Install the positive cables (Figure 1, Item 2) on both batteries. Install the negative cables (Figure 1, Item 5) on both batteries. Apply a thin coating of technical petrolatum to the exposed portions of the battery posts (Figure 1, Item 4), battery terminal connectors (Figure 1, Item 1), and battery cable ends (Figure 1, Items 2, 3, and 5).
7. 8. 9.
10. 11. 12. 13. 14. 15.
0150-3
TM 55-1925-273-24&P-2 BATTERY SERVICE - Continued
0150
1 3 2 1
5 1 4 4
6 7 6
Figure 1. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. Remove the lock outs and tag outs IAW FM 4-01.502. Test the battery and battery charger (WP 0149). Return the equipment to the desired readiness condition. Battery Bank Power Supply System.
M1063T73
0150-4
TM 55-1925-273-24&P-2 FIELD MAINTENANCE BATTERY POWER SUPPLY SYSTEM REPLACE
0151
INITIAL SETUP: Tools and Special Tools Apron, Utility (Volume 3, WP 0344, Table 1, Item 1) Faceshield, Industrial (Volume 3, WP 0344, Table 1, Item 5) Gloves, Chemical and Oil Protective (Volume 3, WP 0344, Table 1, Item 8) Goggles, Industrial (Volume 3, WP 0344, Table 1, Item 10) Tool Kit, Electrical Repair (Volume 3, WP 0344, Table 1, Item 26) Materials/Parts Battery, Storage; 6 V (Volume 3, WP 0343, Table 1, Item 9) Personnel Required Watercraft Engineer 88L (2) References FM 4-01.502 WP 0149 Volume 3, WP 0287 Volume 3, WP 0343 Volume 3, WP 0344 Equipment Condition Set to OFF the applicable circuit breaker. Lock out and tag out IAW FM 4-01.502.
0151-1
TM 55-1925-273-24&P-2
0151
BATTERY REMOVAL
WARNING
Batteries produce hydrogen gas. This gas is explosive. Keep work area free of sparks, open flame, and excessive heat. Take care to prevent conductive metal tools from arcing between positive and negative terminals. Failure to comply with these precautions can result in serious injury or death. Batteries are filled with a sulfuric acid-based electrolyte. This electrolyte is extremely corrosive to human tissue and many other materials. Chemical protective nitrile gloves, chemical protective goggles, faceshield, and a chemical protective apron must be worn at all times when batteries are being serviced. If electrolyte comes in contact with clothing or other material, wash the affected area with large volumes of fresh water. If electrolyte comes in contact with the skin or eyes, flush the area with large volumes of water. Continue flushing the affected areas until medical assistance arrives. Failure to comply with these precautions can result in serious injury or death. 1. 2. 3. Remove the hex nut and flat washer (Figure 1, Item 3) from the J-bolt (Figure 1, Item 4). Remove the battery hold down (Figure 1, Item 1). Remove the wood spacer bar (Figure 1, Item 2).
M1064T73
Figure 1. 4. 5. 6.
Battery.
Label and remove the negative battery cable (Figure 2, Item 2) from the battery bank. Label and remove the positive battery cable (Figure 2, Item 4) from the battery bank. Label and remove the connector battery cable (Figure 2, Item 3) from the battery bank.
0151-2
TM 55-1925-273-24&P-2 BATTERY REMOVAL - Continued
0151
CAUTION
Do not apply any prying or twisting force to the battery posts. Doing so can cause the posts to break internally, permanently disabling the battery. If the battery post connectors are difficult to remove from the battery posts, spread the battery post connectors to loosen them before attempting to remove them from the batteries. 7. Remove the battery post connectors (Figure 2, Item 1) from the batteries (Figure 2, Item 6), taking care not to apply any prying or twisting force to the battery posts (Figure 2, Item 5). If the battery post connectors are difficult to remove from the battery posts, spread the battery post connectors to loosen them before attempting to remove them from the batteries. Remove the batteries (Figure 2, Item 6) from the compartment.
8.
END OF TASK BATTERY INSTALLATION
WARNING
CAUTION
Ensure that there are no foreign objects, such as loose nuts, on the bottom of the battery box. The battery could be damaged if placed on foreign objects. 1. 2. 3. 4. 5. Place the batteries (Figure 2, Item 6) into the battery compartment. Install the battery post connectors (Figure 2, Item 1) on the battery posts (Figure 2, Item 5). Install the connector battery cable (Figure 2, Item 3) on the batteries (Figure 2, Item 6) using the labels from Step (6) of BATTERY REMOVAL as a guide. Remove the labels. Install the positive battery cable (Figure 2, Item 4) on the batteries (Figure 2, Item 6) using the labels from Step (5) of BATTERY REMOVAL as a guide. Remove the labels. Install the negative battery cable (Figure 2, Item 2) on the batteries (Figure 2, Item 6) using the labels from Step (4) of BATTERY REMOVAL as a guide. Remove the labels.
0151-3
TM 55-1925-273-24&P-2 BATTERY INSTALLATION - Continued

1 3 2 1 4
0151
1 5
M1065T73
Figure 2. Battery, Power Supply System. 6. 7. Install the wood spacer bar (Figure 1, Item 2). Install the battery hold down (Figure 1, Item 1) and secure it with the J-bolts (Figure 1, Item 4), washers, and nuts (Figure 1, Item 3).
END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. Remove the lock outs and tag outs IAW FM 4-01.502. Set to ON the applicable circuit breaker and test the battery charger and battery. Return the equipment to the desired readiness condition.
0151-4
TM 55-1925-273-24&P-2 FIELD MAINTENANCE BATTERY POWER SUPPLY SYSTEM REPAIR
0152
INITIAL SETUP: Tools and Special Tools Apron, Utility (Volume 3, WP 0344, Table 1, Item 1) Faceshield, Industrial (Volume 3, WP 0344, Table 1, Item 5) Gloves, Chemical and Oil Protective (Volume 3, WP 0344, Table 1, Item 8) Goggles, Industrial (Volume 3, WP 0344, Table 1, Item 10) Tool Kit, Electrical Repair (Volume 3, WP 0344, Table 1, Item 26) Materials/Parts N/A Personnel Required Watercraft Engineer 88L (2) References FM 4-01.502 TM 55-1925-273-10 WP 0149 Volume 3, WP 0287 Volume 3, WP 0344 Equipment Condition N/A
WARNING
0152-1
TM 55-1925-273-24&P-2
0152
BATTERY REMOVAL
WARNING
Batteries produce hydrogen gas. This gas is explosive. Keep work area free of sparks, open flame, and excessive heat. Take care to prevent conductive metal tools from arcing between positive and negative terminals. Failure to comply with these precautions can result in serious injury or death. Batteries are filled with a sulfuric acid-based electrolyte. This electrolyte is extremely corrosive to human tissue and many other materials. Chemical protective nitrile gloves, chemical protective goggles, faceshield, and a chemical protective apron must be worn at all times when batteries are being serviced. If electrolyte comes in contact with clothing or other material, wash the affected area with large volumes of fresh water. If electrolyte comes in contact with the skin or eyes, flush the area with large volumes of water. Continue flushing the affected areas until medical assistance arrives. Failure to comply with these precautions can result in serious injury or death. 1. 2. 3. 4. Set to OFF the applicable battery charger circuit breaker. Lock out and tag out IAW FM 4-01.502. Remove the hex nut and flat washer (Figure 1, Item 1) from the J-bolt (Figure 1, Item 4). Remove the battery hold down (Figure 1, Item 2). Remove the wood spacer (Figure 1, Item 3).
NOTE
A typical battery bank consists of two 12 V DC batteries connected in series to produce 24 V DC. Proper labeling when removing battery leads will ensure that the battery is connected correctly during installation. 5. 6. Label and remove the negative battery cable (Figure 2, Item 2) from the battery bank (Figure 2, Item 5). Label and remove the positive battery cable (Figure 2, Item 4) from the battery bank (Figure 2, Item 5).
CAUTION
Do not apply any prying or twisting force to the battery posts. Doing so can cause the posts to break internally, permanently disabling the battery. If the battery post connectors are difficult to remove from the battery posts, spread the battery post connectors to loosen them before attempting to remove them from the batteries. 7. Remove the battery post connectors (Figure 2, Item 1) from the battery bank (Figure 2, Item 5), taking care not to apply any prying or twisting force to the battery posts (Figure 2, Item 6). If the battery post connectors are difficult to remove from the battery posts, spread the battery post connectors to loosen them before attempting to remove them from the battery bank. Label and remove the battery connector battery cable (Figure 2, Item 3) from the battery bank (Figure 2, Item 5).
8.
0152-2
TM 55-1925-273-24&P-2 BATTERY REMOVAL - Continued

1 2 3 1
0152
M1066T73
Figure 1.
3 2 1
Battery.
4
5
M1067T73
Battery Bank.
0152-3
TM 55-1925-273-24&P-2
0152
BATTERY INSTALLATION 1. 2. 3. 4. 5. 6. Install the battery post connectors (Figure 2, Item 1) on the battery posts (Figure 2, Item 6). Install the connector battery cable (Figure 2, Item 3) on the battery bank (Figure 2, Item 5) using the labels from Step (8) of BATTERY REMOVAL as a guide. Remove the labels. Install the positive battery cable (Figure 2, Item 4) to the battery bank (Figure 2, Item 5) using the labels from Step (6) of BATTERY REMOVAL as a guide. Remove the labels. Install the negative battery cable (Figure 2, Item 2) to the battery bank (Figure 2, Item 5) using the labels from Step (5) of BATTERY REMOVAL as a guide. Remove the labels. Install the wood spacer (Figure 1, Item 3). Install the battery hold down (Figure 1, Item 2) and secure it with the J-bolts (Figure 1, Item 4), washers, and nuts (Figure 1, Item 1).
END OF TASK BATTERY BOX EXHAUST FAN (01 LEVEL FAN ROOM) REMOVAL 1. 2. Set to OFF the 60 A FUSED DISCONNECT SWITCH located on the forward bulkhead of the 01 level fan room. Lock out and tag out IAW FM 4-01.502. Remove the two screws (Figure 3, Item 9) and junction box cover (Figure 3, Item 8).
WARNING
Replace or repair components only after the affected circuit has been secured, locked out, and tagged out IAW FM 4-01.502. Performing replacement with the circuit energized may result in injury. 3. Use a multimeter to check for available voltage at the wiring terminals (Figure 3, Item 7) inside the junction box (Figure 3, Item 6). If voltage is present, ensure that the proper switch is secured, locked out, and tagged out IAW FM 4-01.502. If no voltage is present, continue with the procedure. Label and disconnect the wiring (Figure 3, Item 10) from the wiring terminals (Figure 3, Item 7) inside the junction box (Figure 3, Item 6). Loosen the hose clamps (Figure 3, Item 12) and remove the flexible hoses (Figure 3, Item 11) from the inlet (Figure 3, Item 1) and discharge (Figure 3, Item 13) flanges. Remove the four bolts (Figure 3, Item 2), four nuts (Figure 3, Item 5), eight flat washers (Figure 3, Item 3), and four lockwashers (Figure 3, Item 4). Discard lockwashers. Remove the fan.
4. 5. 6.
END OF TASK
0152-4
TM 55-1925-273-24&P-2
0152
BATTERY BOX EXHAUST FAN (01 LEVEL FAN ROOM) INSTALLATION 1. 2. 3. Position the fan and secure it with four bolts (Figure 3, Item 2), four nuts (Figure 3, Item 5), eight flat washers (Figure 3, Item 3), and four lockwashers (Figure 3, Item 4). Attach the flexible hoses (Figure 3, Item 11) to the inlet (Figure 3, Item 1) and discharge (Figure 3, Item 13) flanges and secure them with the hose clamps (Figure 3, Item 12). Connect the wiring (Figure 3, Item 10) to the terminals (Figure 3, Item 7) inside the junction box (Figure 3, Item 6) using the labels from Step (4) of BATTERY BOX EXHAUST FAN (01 LEVEL FAN ROOM) REMOVAL as a guide. Remove the labels. Install the junction box cover (Figure 3, Item 8) and secure it with two screws (Figure 3, Item 9).
4.
3 4 5
6 7 8
11
12 13 12 10 9
11
M1068T73
Battery Box Fan.
0152-5
TM 55-1925-273-24&P-2 FOLLOW-ON MAINTENANCE 1. 2. 3. 4. Remove the lock outs and tag outs IAW FM 4-01.502. Set to ON the applicable battery charger circuit breaker. Test the battery charger and battery (WP 0149). Return the equipment to the desired readiness condition.
0152
0152-6
TM 55-1925-273-24&P-2 FIELD MAINTENANCE BATTERY CHARGER REPLACE
0153
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 3, WP 0344, Table 1, Item 27) Multimeter (Volume 3, WP 0344, Table 1, Item 15) Materials/Parts N/A Personnel Required Watercraft Engineer 88L (3) References FM 4-01.502 TM 55-1925-273-10 References (cont.) Volume 3, WP 0288 Volume 3, WP 0343 Volume 3, WP 0344 Equipment Condition Set to OFF the applicable battery charger circuit breaker. Lock out and tag out IAW FM 4-01.502. Remove the positive and negative battery cables from the applicable battery bank. Lock out and tag out IAW FM 4-01.502.
0153-1
TM 55-1925-273-24&P-2
0153
BATTERY CHARGER REMOVAL 1. 2. Remove the screw (Figure 1, Item 3) from the battery charger door (Figure 1, Item 1). OPEN the battery charger door (Figure 1, Item 1).
2
Figure 1. Battery Charger.
M1238T73
WARNING
Replace or repair components only after the affected circuit has been secured, locked out, and tagged out IAW FM 4-01.502. Performing replacement with the circuit energized may result in injury. 3. Use a multimeter to check for available Alternating Current (AC) voltage at the fuse(s) (Figure 2, Item 3). If AC voltage is present, ensure that the proper circuit breaker(s) have been secured, locked out, and tagged out IAW FM 4-01.502. If no voltage is present, continue with the procedure. Use a multimeter to check for Direct Current (DC) voltage at the DC fuse(s) (Figure 2, Item 2). If DC voltage is present, ensure that the positive and negative battery cables are removed from the applicable battery bank and are locked out and tagged out IAW FM 4-01.502. If no DC voltage is present, continue with the procedure. Label and remove the wiring (Figure 2, Item 1) from the DC fuse terminals (Figure 2, Item 7). Label and remove the wiring (Figure 2, Item 5) from the AC terminals (Figure 2, Item 4).
4.
5. 6.
0153-2
TM 55-1925-273-24&P-2 BATTERY CHARGER REMOVAL - Continued 7. Remove the wiring (Figure 2, Items 1 and 5) from the battery charger (Figure 2, Item 6).
0153
WARNING
Heavy loads can crush. Do not allow any body parts to come under the load or between the load and a stationary object. Failure to comply with this warning can result in serious injury or death. 8. 9. While two crewmembers hold the battery charger (Figure 2, Item 6), have a third crewmember remove the two bolts (Figure 1, Item 2) that secure the battery charger to the bulkhead. Remove the battery charger (Figure 2, Item 6) from the bulkhead.
5 4 6
M1239T73
Battery Charger Internal Components.
0153-3
TM 55-1925-273-24&P-2 BATTERY CHARGER INSTALLATION
0153
WARNING
Heavy loads can crush. Do not allow any body parts to come under the load or between the load and a stationary object. Failure to comply with this warning can result in serious injury or death. 1. 2. 3. 4. 5. Using two crewmembers, position the battery charger (Figure 2, Item 6) on the bulkhead while a third crewmember installs the two bolts (Figure 2, Item 2) that secure the battery charger to the bulkhead. Install the wiring (Figure 2, Items 1 and 5) in the battery charger (Figure 2, Item 6). Connect the wiring (Figure 2, Item 5) to the AC terminals (Figure 2, Item 4) using the labels from Step (6) of BATTERY CHARGER REMOVAL as a guide. Remove the labels. Connect the wiring (Figure 2, Item 1) to the DC fuse terminals (Figure 2, Item 7) using the labels from Step (5) of BATTERY CHARGER REMOVAL as a guide. Remove the labels. CLOSE the battery charger door (Figure 1, Item 1) and secure it with the screw (Figure 1, Item 3).
END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. 4. 5. Remove the lock outs and tag outs IAW FM 4-01.502 from the battery cables. Connect the battery cables to the battery bank IAW TM 55-1925-273-10. Remove the remaining lock outs and tag outs IAW FM 4-01.502. Set the applicable circuit breaker to ON and check the battery charger for proper operation. Return the battery charger to the desired readiness condition.
0153-4
TM 55-1925-273-24&P-2 FIELD MAINTENANCE BATTERY CHARGER REPAIR
0154
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 3, WP 0344, Table 1, Item 27) Multimeter (Volume 3, WP 0344, Table 1, Item 15) Materials/Parts N/A Personnel Required Watercraft Engineer 88L (2) References FM 4-01.502 References (cont.) TC 55-509-1 TM 55-1925-273-10 WP 0149 Volume 3, WP 0288 Volume 3, WP 0344 Equipment Condition Set to OFF the applicable battery charger circuit breaker. Lock out and tag out IAW FM 4-01.502. Remove the positive and negative battery cables from the applicable battery bank. Lock out and tag out IAW FM 4-01.502.
0154-1
TM 55-1925-273-24&P-2
0154
AMMETER REMOVAL 1. 2. Remove the screw (Figure 1, Item 2) from the battery charger door (Figure 1, Item 1). OPEN the battery charger door (Figure 1, Item 1).
2
Figure 1. Battery Charger.
M1240T73
WARNING
Replace or repair components only after the affected circuit has been secured, locked out, and tagged out IAW FM 4-01.502. Performing replacement with the circuit energized may result in injury. 3. Use a multimeter to check for Alternating Current (AC) voltage at the fuse(s) (Figure 2, Item 2). If AC voltage is present, ensure that the proper circuit breaker(s) have been set to OFF, locked out, and tagged out IAW FM 4-01.502. If no voltage is present, continue with the procedure. Use a multimeter to check for voltage at the Direct Current (DC) fuse(s) (Figure 2, Item 1). If DC voltage is present, ensure that the positive and negative battery cables are removed from the applicable battery bank and are locked out and tagged out IAW FM 4-01.502. If no DC voltage is present, continue with the procedure. Remove the two nuts (Figure 2, Item 7) and two flat washers (Figure 2, Item 6) from the ammeter terminals (Figure 2, Item 11). Label and remove the wiring (Figure 2, Item 5) from the ammeter terminals (Figure 2, Item 11). Remove the two nuts (Figure 2, Item 8) and two flat washers (Figure 2, Item 9) from the ammeter mounting studs (Figure 2, Item 4). Remove the ammeter (Figure 2, Item 10) from the battery charger door (Figure 2, Item 3).
4.
5. 6. 7. 8.
0154-2
TM 55-1925-273-24&P-2 AMMETER REMOVAL - Continued

1 2
0154
8 9
10
11
4 3
M1241T73
Figure 2. END OF TASK AMMETER INSTALLATION 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.
Install the ammeter (Figure 2, Item 10) in the battery charger door (Figure 2, Item 3). Install the two nuts (Figure 2, Item 8) and two flat washers (Figure 2, Item 9) on the ammeter mounting studs (Figure 2, Item 4). Connect the wiring (Figure 2, Item 5) to the ammeter terminals (Figure 2, Item 11) using the labels from Step (6) of AMMETER REMOVAL as a guide. Remove the labels. Install the two nuts (Figure 2, Item 7) and two flat washers (Figure 2, Item 6) on the ammeter terminals (Figure 2, Item 11). CLOSE the battery charger door (Figure 1, Item 1). Install the screw (Figure 1, Item 2) in the battery charger door (Figure 1, Item 1). Remove the lock outs and tag outs IAW FM 4-01.502 from the battery cables. Connect the battery cables to the battery bank IAW TM 55-1925-273-10. Remove the remaining lock outs and tag outs IAW FM 4-01.502. Set the applicable circuit breaker to ON and check the battery charger for proper operation. Return the battery charger to the desired readiness condition.
END OF TASK
0154-3
TM 55-1925-273-24&P-2 WIRING (TYPICAL) REPAIR
0154
Proper repair of wiring consists of replacement of the damaged wiring. When an electrical casualty requires expedient repairs, the repair may be made by splicing. Splicing is authorized for repair of damaged cables and wiring harnesses if most of the wiring is in good useable electrical condition. The cable or wiring harness must be replaced in its entirety at the most opportune time. For proper splicing methods, refer to TC 55-509-1. END OF TASK WIRING (TYPICAL) DISASSEMBLY
WARNING
Replace or repair components only after the affected circuit has been secured, locked out, and tagged out IAW FM 4-01.502. Performing replacement with the circuit energized may result in injury. 1. Use a multimeter to check for voltage at the wire terminals (Figure 3, Item 4). If voltage is present, ensure that the proper circuit breakers are set to OFF, locked out, and tagged out IAW FM 4-01.502. If no voltage is present, continue with the procedure. Remove any covers or interference that restricts access to the wires being removed. Label all wiring to be removed, and make a sketch of the work area to permit proper assembly. Remove all nuts (Figure 3, Item 2) that secure the wire terminals (Figure 3, Item 4) to the post (Figure 3, Item 1), and remove the wire (Figure 3, Item 3). Follow the wire (Figure 3, Item 3) to the opposite end, freeing it from the vessel's structure as required. Remove the nuts (Figure 3, Item 2) that secure the wire terminals (Figure 3, Item 4) to the post (Figure 3, Item 1), and remove the wire (Figure 3, Item 3) at the opposite end. Perform Steps (1) through (6) for any other wires that require removal.
2. 3. 4. 5. 6. 7.
0154-4
TM 55-1925-273-24&P-2 WIRING (TYPICAL) DISASSEMBLY - Continued
0154
1 2 3
M1242T73
Figure 3. END OF TASK WIRING (TYPICAL) ASSEMBLY 1. 2. 3. 4. 5. 6.
Typical Wire Terminal.
Determine the wires to be connected by referring to the sketches and labels from Step (3) of WIRING (TYPICAL) DISASSEMBLY as guides. Install the wires (Figure 3, Item 3) along the same path as the old wires, and secure them in the same manner as the old wiring assembly. Install the nuts (Figure 3, Item 2) that secure the wire terminals (Figure 3, Item 4) to the post (Figure 3, Item 1) at both ends of the wire. Remove any remaining labels. Install any covering or interference removed during the WIRING (TYPICAL) DISASSEMBLY procedure. Perform the FOLLOW-ON MAINTENANCE procedure at the end of this work package.
END OF TASK
0154-5
TM 55-1925-273-24&P-2
0154
AC FUSE REMOVAL 1. Loosen the captive screw (Figure 4, Item 1) and OPEN the battery charger door (Figure 4, Item 8).
WARNING
Replace or repair components only after the affected circuit has been secured, locked out, and tagged out IAW FM 4-01.502. Performing replacement with the circuit energized may result in injury. 2. Use a multimeter to check for voltage at the AC fuses (Figure 4, Item 2). If voltage is present, ensure that the proper circuit breakers are set to OFF, locked out, and tagged out IAW FM 4-01.502. If no voltage is present, continue with the procedure. Remove the AC fuses (Figure 4, Item 2) using a fuse puller.
3.
END OF TASK AC FUSE INSTALLATION 1. 2. 3. Install the AC fuses (Figure 4, Item 2) using a fuse puller. CLOSE the battery charger door (Figure 4, Item 8) and secure it with the captive screw (Figure 4, Item 1). Perform the FOLLOW-ON MAINTENANCE procedure at the end of this work package.
END OF TASK DC FUSE REMOVAL 1. Loosen the captive screw (Figure 4, Item 1) and OPEN the battery charger door (Figure 4, Item 8).
WARNING
Replace or repair components only after the affected circuit has been secured, locked out, and tagged out IAW FM 4-01.502. Performing replacement with the circuit energized may result in injury. 2. Use a multimeter to check for voltage at the DC fuses (Figure 4, Item 7). If voltage is present, ensure that the proper circuit breakers are set to OFF, locked out, and tagged out IAW FM 4-01.502. If no voltage is present, continue with the procedure. Remove the nut (Figure 4, Item 3) and flat washer (Figure 4, Item 4), and remove the wire terminal (Figure 4, Item 5) from the post (Figure 4, Item 6). Remove the DC fuse (Figure 4, Item 7) from the post (Figure 4, Item 6).
3. 4.
0154-6
TM 55-1925-273-24&P-2 DC FUSE REMOVAL - Continued
0154
SWITC H
3 4 5
M1243T73
Battery Charger.
0154-7
TM 55-1925-273-24&P-2 DC FUSE INSTALLATION 1. 2. 3.
0154
Install the DC fuse (Figure 4, Item 7) and the wire terminal (Figure 4, Item 5) on the post (Figure 4, Item 6) and secure them with the nut (Figure 4, Item 3) and flat washer (Figure 4, Item 4). CLOSE the battery charger door (Figure 4, Item 8) and secure it with the captive screw (Figure 4, Item 1). Perform the FOLLOW-ON MAINTENANCE procedure at the end of this work package.
END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. 4. Remove the lock outs and tag outs IAW FM 4-01.502. Set the circuit breaker to ON. Test the battery and battery charger (WP 0149). Return the battery charger to the desired readiness condition.
0154-8
TM 55-1925-273-24&P-2 FIELD MAINTENANCE SEARCHLIGHTS SERVICE
0155
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 3, WP 0344, Table 1, Item 27) Gloves, Leather (Volume 3, WP 0344, Table 1, Item 9) Goggles, Industrial (Volume 3, WP 0344, Table 1, Item 10) Suitable Rubber Ink Eraser Tool Kit, Electrical Repair (Volume 3, WP 0344, Table 1, Item 26) Wrench, Lamp, Searchlight (Volume 3, WP 0344, Table 1, Item 32) Materials/Parts Rag, Wiping (Volume 3, WP 0343, Table 1, Item 132) Personnel Required Watercraft Engineer 88L (2) References FM 4-01.502 Volume 3, WP 0289 Volume 3, WP 0343 Volume 3, WP 0344 Equipment Condition N/A
0155-1
TM 55-1925-273-24&P-2
0155
SEARCHLIGHT SERVICE
WARNING
High pressures exist inside the lamp, especially when hot. The lamp could explode. Protect eyes and wear gloves when handling the lamp. Failure to comply with this warning can result in severe injury, blindness, or death.
CAUTION
Handle the lamp only in its protective cover. Premature lamp failure may result from handling the lamp with bare hands. 1. At the 120 V pilothouse emergency distribution panel set the PORT SEARCHLIGHT POWER SUPPLY or STARBOARD SEARCHLIGHT POWER SUPPLY circuit breaker to OFF. Lock out and tag out IAW FM 4-01.502. Release the latch (Figure 1, Item 5) that secures the glass cover (Figure 1, Item 6) and open the cover. With a water-dampened, clean wiping rag, wipe down the reflector (Figure 1, Item 4). If the reflector becomes exceptionally tarnished, it can be cleaned with a good quality silver polish. Spray the glass cover (Figure 1, Item 6) with commercial glass cleaner and wipe it dry with a clean wiping rag. Close the glass cover (Figure 1, Item 6) and secure it with the latch (Figure 1, Item 5). Perform the FOLLOW-ON MAINTENANCE procedure at the end of this work package.
2. 3. 4. 5. 6. 7.
0155-2
TM 55-1925-273-24&P-2 SEARCHLIGHT SERVICE - Continued
0155
3 2 1 6 4 5
M1247T73
Searchlight Lamp.
0155-3
TM 55-1925-273-24&P-2
0155
SEARCHLIGHT LUBRICATION Approximately once every 3 months or more frequently as required, lubricate the points as indicated in Table 1. Table 1. Location Fitting at top of arms for trunnion bearings (Figure 2, Item 1) Fitting at edge of rotating base (Figure 2, Item 2) for bearing balls Lubrication Points (Refer to Figure 2). Lubricant/Quantity Approx. 1-2 applications from a standard grease gun Approx. 1-2 applications from a standard grease gun
0155-4
TM 55-1925-273-24&P-2 SEARCHLIGHT LUBRICATION - Continued
0155
1 1
M1248T73
Searchlight.
0155-5
TM 55-1925-273-24&P-2
0155
SEARCHLIGHT ALIGNMENT
WARNING
Avoid direct or reflected radiation from the lamp. Do not stand close in front of the searchlight. Cover the glass when the lamp is lit. Failure to comply with this warning can result in injury or death. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Turn the searchlight ON and shine the beam on a vertical flat surface approximately 20-50 ft from the searchlight. Rotate the focus knob (Figure 1, Item 3) until the beam is as sharp and concentrated as possible. Remove the rear cover (Figure 1, Item 1) by releasing the toggle clamps (Figure 1, Item 2). Adjust the clamp screws (Figure 3, Item 2) so that the horizontal disk wheel (Figure 3, Item 1) and the vertical alignment disk wheel (Figure 3, Item 3) are free to turn. Do not loosen so much that the lamp support sags. Rotate the horizontal disk wheel (Figure 3, Item 1) until a bright spot is centered horizontally in the beam. Rotate the vertical alignment wheel (Figure 3, Item 3) until the bright spot is centered vertically in the beam. Tighten the clamp screws (Figure 3, Item 2) to hold the alignment. Rotate the focus knob (Figure 1, Item 3) to check the appearance of the beam at various focus settings. Circular areas in the beam should be essentially concentric. Install the rear cover (Figure 1, Item 1) and secure it with the toggle clamps (Figure 1, Item 2). Return the equipment to the desired readiness condition.
0155-6
TM 55-1925-273-24&P-2 SEARCHLIGHT ALIGNMENT - Continued

1
0155
2 3
M1249T73
Searchlight.
0155-7
TM 55-1925-273-24&P-2
0155
SPARK GAP ADJUSTMENT 1. At the 120 V pilothouse emergency distribution panel set the PORT SEARCHLIGHT POWER SUPPLY or STARBOARD SEARCHLIGHT POWER SUPPLY circuit breaker to OFF. Lock out and tag out IAW FM 4-01.502. Clean the spark gap contacts (Figure 4, Item 1) with a rubber ink eraser. Loosen the jamnut (Figure 4, Item 2). Adjust the bolt (Figure 4, Item 3) until the proper measurement is reached. Use a feeler gage to ensure that the gap is between 0.030 0.005 in. (0.76 0.13 mm). Tighten the jamnut (Figure 4, Item 2). Measure the gap again to make sure it has not shifted. Perform the FOLLOW-ON MAINTENANCE procedure at the end of this work package.
2. 3. 4. 5. 6. 7.
3 2
M1250T73
Lamp Starter.
0155-8
TM 55-1925-273-24&P-2
0155
FOLLOW-ON MAINTENANCE 1. 2. 3. 4. Remove the lock outs and tag outs IAW FM 4-01.502. Set the circuit breaker to ON. Test operate the searchlight to verify proper operation. Perform the SEARCHLIGHT ALIGNMENT and SEARCHLIGHT LUBRICATION procedures in this work package if needed. Return the equipment to the desired readiness condition.
0155-9/10 blank
TM 55-1925-273-24&P-2 FIELD MAINTENANCE SEARCHLIGHTS REPLACE
0156
INITIAL SETUP: Tools and Special Tools Multimeter (Volume 3, WP 0344, Table 1, Item 15) Tool Kit, Electrical Repair (Volume 3, WP 0344, Table 1, Item 26) Materials/Parts Lockwasher (Volume 3, WP 0289, Figure 41, Item 6) Qty: 8 Lockwasher (Volume 3, WP 0289, Figure 41, Item 130) Qty: 2 Lockwasher (Volume 3, WP 0289, Figure 41, Item 134) Qty: 3 Lockwasher (Volume 3, WP 0289, Figure 41, Item 71) Qty: 8 Gasket (Volume 3, WP 0289, Figure 41, Item 72) Qty: 1 Lockwasher (Volume 3, WP 0289, Figure 41, Item 80) Qty: 3 Personnel Required Watercraft Engineer 88L (3) References FM 4-01.502 WP 0155 Volume 3, WP 0289 Volume 3, WP 0344 Equipment Condition Set to OFF the PORT SEARCH LIGHT POWER SUPPLY. circuit breaker or the STARBOARD SEARCH LIGHT POWER SUPPLY. circuit breaker on the 120 V pilothouse emergency distribution panel. Lock out and tag out IAW FM 4-01.502.
0156-1
TM 55-1925-273-24&P-2
0156
WARNING
Never reuse locking hardware. Reuse of locking hardware such as lockwashers, locking nuts, cotter pins, and lock wire can result in undetected loosening of fastening hardware causing catastrophic component failure resulting in death, injury, or damage to equipment. Ensure that all locking hardware is discarded upon removal and replaced with new. DRUM ASSEMBLY REMOVAL 1. 2. Remove the eight screws (Figure 1, Item 7) and eight lockwashers (Figure 1, Item 6) from the rear cover (Figure 1, Item 4) of the drum assembly (Figure 1, Item 5). Discard lockwashers. Remove the rear cover (Figure 1, Item 4) from the drum assembly (Figure 1, Item 5).
WARNING
Replace or repair components only after the affected circuit has been secured, locked out, and tagged out IAW FM 4-01.502. Performing replacement with the circuit energized may result in injury. 3. Use a multimeter to check for voltage at the terminal block (Figure 2, Item 1). If voltage is present, ensure that the proper circuit breaker is secured, locked out, and tagged out IAW FM 4-01.502. If no voltage is present, continue with the procedure. Label and remove the wiring (Figure 2, Item 5) from the terminal block (Figure 2, Item 1). Loosen the stuffing tube (Figure 2, Item 3) and packing assembly (Figure 2, Item 4). Remove the wiring (Figure 2, Item 5) from the drum assembly (Figure 2, Item 2). Remove the two nuts (Figure 1, Item 11) and four flat washers (Figure 1, Item 12) from the rack bracket (Figure 1, Item 13).
4. 5. 6. 7.
CAUTION
Two crewmembers are required to maintain positive control of the drum assembly during removal from the arm assembly. Failure to comply with this caution will result in damage to the drum assembly. 8. 9. Remove the two bolts (Figure 1, Item 1), two flat washers (Figure 1, Item 2), and two lockwashers (Figure 1, Item 3) from the arm assembly (Figure 1, Item 14). Discard lockwashers. Remove the drum assembly (Figure 1, Item 5) from the arm assembly (Figure 1, Item 14).
0156-2
TM 55-1925-273-24&P-2 DRUM ASSEMBLY REMOVAL - Continued
0156
2 3 4 5
6 7 14
13 12 11 8 9
10
M1251T73
500 W Xenon Searchlight.
0156-3
TM 55-1925-273-24&P-2
0156
DRUM ASSEMBLY INSTALLATION
CAUTION
Two crewmembers are required to maintain positive control of the drum assembly during removal from the arm assembly. Failure to comply with this caution will result in damage to the drum assembly. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. Install the drum assembly (Figure 1, Item 5) on the arm assembly (Figure 1, Item 14). Install the two bolts (Figure 1, Item 1), two flat washers (Figure 1, Item 2), and two lockwashers (Figure 1, Item 3) in the arm assembly (Figure 1, Item 14). Install the two nuts (Figure 1, Item 11) and four flat washers (Figure 1, Item 12) in the rack bracket (Figure 1, Item 13). Install the wiring (Figure 2, Item 5) in the drum assembly (Figure 2, Item 2). Tighten the stuffing tube (Figure 2, Item 3) and packing assembly (Figure 2, Item 4). Connect the wiring (Figure 2, Item 5) to the terminal block (Figure 2, Item 1). Install the rear cover (Figure 1, Item 4) on the drum assembly (Figure 1, Item 5). Install the eight screws (Figure 1, Item 7) and eight lockwashers (Figure 1, Item 6) in the rear cover (Figure 1, Item 4) of the drum assembly (Figure 1, Item 5). Remove the lock outs and tag outs IAW FM 4-01.502. Lubricate the searchlight, align the searchlight, and verify the spark gap adjustment (WP 0155). Return the searchlight to the desired readiness condition.
END OF TASK ARM ASSEMBLY REMOVAL 1. 2. 3. Perform the DRUM ASSEMBLY REMOVAL procedure in this work package. Remove the three bolts (Figure 1, Item 8) and three lockwashers (Figure 1, Item 9) from the arm assembly (Figure 1, Item 14). Discard lockwashers. Remove the arm assembly (Figure 1, Item 14) from the base assembly (Figure 1, Item 10).
END OF TASK ARM ASSEMBLY INSTALLATION 1. 2. 3. Install the arm assembly (Figure 1, Item 14) on the base assembly (Figure 1, Item 10). Install the three bolts (Figure 1, Item 8) and three lockwashers (Figure 1, Item 9) in the arm assembly (Figure 1, Item 14). Perform the DRUM ASSEMBLY INSTALLATION procedure in this work package.
0156-4
TM 55-1925-273-24&P-2 ARM ASSEMBLY INSTALLATION - Continued
0156
4 3
2
M1252T73
Figure 2. 500 W Xenon Searchlight Rear Cover Removed. END OF TASK
0156-5
TM 55-1925-273-24&P-2
0156
BASE ASSEMBLY REMOVAL 1. 2. 3. 4. Perform the ARM ASSEMBLY REMOVAL procedure in this work package. Remove the eight screws (Figure 3, Item 2) and eight lockwashers (Figure 3, Item 3) from the upper base assembly (Figure 3, Item 1). Discard lockwashers. Remove the upper base assembly (Figure 3, Item 1) from the lower base assembly (Figure 3, Item 5). Remove the gasket (Figure 3, Item 4) from the lower base assembly (Figure 3, Item 5). Discard gasket.
WARNING
Replace or repair components only after the affected circuit has been secured, locked out, and tagged out IAW FM 4-01.502. Performing replacement with the circuit energized may result in injury. 5. Use a multimeter to check for voltage at the terminal block (Figure 3, Item 9). If voltage is present, ensure that the proper circuit breaker is secured, locked out, and tagged out IAW FM 4-01.502. If no voltage is present, continue with the procedure. Label and remove the wiring (Figure 3, Item 10) from the terminal block (Figure 3, Item 9). Loosen the stuffing tube (Figure 3, Item 11) and packing assembly (Figure 3, Item 12). Remove the wiring (Figure 3, Item 10) from the lower base assembly (Figure 3, Item 5). Remove the three nuts (Figure 3, Item 8) and three lockwashers (Figure 3, Item 7) from the studs (Figure 3, Item 6). Discard lockwashers.
6. 7. 8. 9.
CAUTION
Two crewmembers are required to maintain positive control of the drum assembly during removal from the arm assembly. Failure to comply with this caution will result in damage to the drum assembly. 10. Remove the lower base assembly (Figure 3, Item 5) from its foundation.
0156-6
TM 55-1925-273-24&P-2 BASE ASSEMBLY REMOVAL - Continued
0156
2 3
12 11 10
6 7 8
5 9 10
M1253T73
Searchlight Base Assembly.
0156-7
TM 55-1925-273-24&P-2 BASE ASSEMBLY INSTALLATION
0156
CAUTION
Two crewmembers are required to maintain positive control of the drum assembly during removal from the arm assembly. Failure to comply with this caution will result in damage to the drum assembly. 1. 2. 3. 4. 5. 6. 7. 8. 9. Install the lower base assembly (Figure 3, Item 5) on its foundation. Install the three nuts (Figure 3, Item 8) and three lockwashers (Figure 3, Item 7) on the studs (Figure 3, Item 6). Install the wiring (Figure 3, Item 10) in the lower base assembly (Figure 3, Item 5). Tighten the stuffing tube (Figure 3, Item 11) and packing assembly (Figure 3, Item 12). Connect the wiring (Figure 3, Item 10) to the terminal block (Figure 3, Item 9) using the labels from Step (6) of REMOVAL as a guide. Remove the labels. Install a gasket (Figure 3, Item 4) on the lower base assembly (Figure 3, Item 5). Install the upper base assembly (Figure 3, Item 1) on the lower base assembly (Figure 3, Item 5). Install the eight screws (Figure 3, Item 2) and eight lockwashers (Figure 3, Item 3) in the upper base assembly (Figure 3, Item 1). Perform the ARM ASSEMBLY INSTALLATION procedure in this work package.
END OF TASK FOLLOW-ON MAINTENANCE Remove the lock outs and tag outs IAW FM 4-01.502. END OF TASK END OF WORK PACKAGE
0156-8
TM 55-1925-273-24&P-2 FIELD MAINTENANCE SEARCHLIGHTS REPAIR
0157
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 3, WP 0344, Table 1, Item 27) Gloves, Leather (Volume 3, WP 0344, Table 1, Item 9) Goggles, Industrial (Volume 3, WP 0344, Table 1, Item 10) Multimeter (Volume 3, WP 0344, Table 1, Item 15) Suitable Rubber Ink Eraser Tool Kit, Electrical Repair (Volume 3, WP 0344, Table 1, Item 26) Wrench, Lamp, Searchlight (Volume 3, WP 0344, Table 1, Item 32) Materials/Parts Rag, Wiping (Volume 3, WP 0343, Table 1, Item 132) Lockwasher (Volume 3, WP 0289, Figure 41, Item 6) Qty: 8 Gasket (Volume 3, WP 0289, Figure 41, Item 72) Qty: 1 Lockwasher (Volume 3, WP 0289, Figure 41, Item 94) Qty: 4 Lockwasher (Volume 3, WP 0289, Figure 41, Item 107) Qty: 2 Lockwasher (Volume 3, WP 0289, Figure 41, Item 111) Qty: 1 Materials/Parts (cont.) Lockwasher (Volume 3, WP 0289, Figure 41, Item 142) Qty: 2 Lockwasher (Volume 3, WP 0289, Figure 41, Item 139) Qty: 1 Personnel Required Watercraft Engineer 88L (2) References FM 4-01.502 WP 0156 WP 0158 Volume 3, WP 0289 Volume 3, WP 0343 Volume 3, WP 0344 Equipment Condition N/A
0157-1
TM 55-1925-273-24&P-2
0157
LAMP REMOVAL 1. At the 120 V pilothouse emergency distribution panel set the PORT SEARCHLIGHT POWER SUPPLY or STARBOARD SEARCHLIGHT POWER SUPPLY circuit breaker to OFF. Lock out and tag out IAW FM 4-01.502. Release the latch (Figure 1, Item 3) that secures the glass cover (Figure 1, Item 4), and open the cover. Loosen, but do not remove, the two clamp screws (Figure 1, Item 5). Remove the insulator assembly (Figure 1, Item 6) from the ring assembly (Figure 1, Item 8) and gently let it dangle on the end of the positive wire lead (Figure 1, Item 7). Insert the lamp wrench (Figure 1, Item 9) slots over the drive pins (Figure 1, Item 1) on the lamp (Figure 1, Item 2).
2. 3. 4. 5.
WARNING
CAUTION
Handle the lamp only in its protective cover. Premature lamp failure may result from handling the lamp with bare hands. 6. 7. Remove the lamp (Figure 1, Item 2) from the enclosure. Install a protective cover on the lamp (Figure 1, Item 2).
END OF TASK LAMP INSTALLATION
WARNING
CAUTION
Handle the lamp only in its protective cover. Premature lamp failure may result from handling the lamp with bare hands. 1. 2. 3. Install the lamp (Figure 1, Item 2) using the lamp wrench (Figure 1, Item 9). Install the insulator assembly (Figure 1, Item 6) and secure it to the ring assembly (Figure 1, Item 8) with the clamp screws (Figure 1, Item 5). Close the glass cover (Figure 1, Item 4) and secure it with the latch (Figure 1, Item 3).
0157-2
TM 55-1925-273-24&P-2 LAMP INSTALLATION - Continued 4. Perform the FOLLOW-ON MAINTENANCE procedure at the end of this work package.
3 1 2
0157
5 6
7 8
M1254T73
Searchlight Lamp.
0157-3
TM 55-1925-273-24&P-2
0157
LAMP STARTER ASSEMBLY REMOVAL
WARNING
Never reuse locking hardware. Reuse of locking hardware such as lockwashers, locking nuts, cotter pins, and lock wire can result in undetected loosening of fastening hardware causing catastrophic component failure resulting in death, injury, or damage to equipment. Ensure that all locking hardware is discarded upon removal and replaced with new. 1. 2. Remove the eight screws (Figure 2, Item 4) and eight lockwashers (Figure 2, Item 5) from the rear cover (Figure 2, Item 2) of the drum assembly (Figure 2, Item 3). Discard lockwashers. Remove the rear cover (Figure 2, Item 2) from the drum assembly (Figure 2, Item 3).
1 2 3
5 4 7
M1389T73
Figure 2. 500 W Xenon Searchlight.
0157-4
TM 55-1925-273-24&P-2 LAMP STARTER ASSEMBLY REMOVAL - Continued 3. 4. Loosen the four screws (Figure 3, Item 2) on the safety cover (Figure 3, Item 3). Remove the safety cover (Figure 3, Item 3) from the drum assembly (Figure 3, Item 1).
1
0157
2 3 2
M1255T73
Figure 3.
Searchlight Side View.
WARNING
Replace or repair components only after the affected circuit has been secured, locked out, and tagged out IAW FM 4-01.502. Performing replacement with the circuit energized may result in injury. 5. Use a multimeter to check for voltage at the terminal block (Figure 4, Item 1). If voltage is present, ensure that the proper circuit breaker is secured, locked out, and tagged out IAW FM 4-01.502. If no voltage is present, continue with the procedure. Label and remove the plug and cord assembly (Figure 4, Item 7) from the fan (Figure 4, Item 2).
6.
0157-5
TM 55-1925-273-24&P-2 LAMP STARTER ASSEMBLY REMOVAL - Continued 7. 8. 9. 10. 11. 12. 13. Remove the four screws (Figure 4, Item 4) and four lockwashers (Figure 4, Item 3) from the fan (Figure 4, Item 2). Discard lockwashers. Remove the fan (Figure 4, Item 2) from the drum assembly (Figure 4, Item 8). Label and remove the lamp wire (Figure 4, Item 5) from the starter assembly (Figure 4, Item 6). Label and remove the negative wire (Figure 4, Item 11) from the starter assembly (Figure 4, Item 6).
0157
Label and remove the wiring (Figure 4, Item 12) from the terminal block (Figure 4, Item 13) on the starter assembly (Figure 4, Item 6). Remove the four self-locking screws (Figure 4, Item 10) and four flat washers (Figure 4, Item 9). Discard self-locking screws. Remove the starter assembly (Figure 4, Item 6) from the drum assembly (Figure 4, Item 8).
2 3 1 4
7 13 8 9 12 11 10
M1256T73
Figure 4. 500 W Xenon Searchlight Rear Cover Removed. END OF TASK
0157-6
TM 55-1925-273-24&P-2
0157
LAMP STARTER ASSEMBLY INSTALLATION 1. 2. 3. Install the starter assembly (Figure 4, Item 6) in the drum assembly (Figure 4, Item 8). Install four self-locking screws (Figure 4, Item 10) and four flat washers (Figure 4, Item 9). Connect the wiring (Figure 4, Item 12) to the terminal block (Figure 4, Item 13) on the starter assembly (Figure 4, Item 6) using the labels from Step (11) of LAMP STARTER ASSEMBLY REMOVAL as a guide. Remove the labels. Connect the negative wire (Figure 4, Item 11) to the starter assembly (Figure 4, Item 6) using the labels from Step (10) of LAMP STARTER ASSEMBLY REMOVAL as a guide. Remove the labels. Connect the lamp wire (Figure 4, Item 5) to the starter assembly (Figure 4, Item 6) using the labels from Step (9) of LAMP STARTER ASSEMBLY REMOVAL as a guide. Remove the labels. Install the fan (Figure 4, Item 2) in the drum assembly (Figure 4, Item 8). Install the four screws (Figure 4, Item 4) and four lockwashers (Figure 4, Item 3) in the fan (Figure 4, Item 2). Connect the plug and cord assembly (Figure 4, Item 7) to the fan (Figure 4, Item 2) using the labels from Step (6) of LAMP STARTER ASSEMBLY REMOVAL as a guide. Remove the labels. Install the safety cover (Figure 3, Item 3) in the drum assembly (Figure 3, Item 1). Tighten the four screws (Figure 3, Item 2) on the safety cover (Figure 3, Item 3). Install the rear cover (Figure 2, Item 2) on the drum assembly (Figure 2, Item 3). Install the eight screws (Figure 2, Item 4) and eight lockwashers (Figure 2, Item 5) in the rear cover (Figure 2, Item 4) of the drum assembly (Figure 2, Item 3). Perform the FOLLOW-ON MAINTENANCE procedure at the end of this work package.
4. 5. 6. 7. 8. 9. 10. 11. 12. 13.
END OF TASK
0157-7
TM 55-1925-273-24&P-2
0157
MOTOR (UP AND DOWN/LEFT AND RIGHT) REMOVAL 1. 2. 3. 4. 5. Remove the drum assembly (Figure 2, Item 3) from the arm assembly (Figure 2, Item 1) (WP 0156). Remove the arm assembly (Figure 2, Item 1) from the upper base assembly (Figure 2, Item 6) (WP 0156). Remove the eight screws (Figure 5, Item 3) and eight lockwashers (Figure 5, Item 4) from the upper base assembly (Figure 5, Item 2). Remove the upper base assembly (Figure 5, Item 2) from the lower base assembly (Figure 5, Item 6). Remove the gasket (Figure 5, Item 5) from the lower base assembly (Figure 5, Item 6). Discard gasket.
WARNING
Replace or repair components only after the affected circuit has been secured, locked out, and tagged out IAW FM 4-01.502. Performing replacement with the circuit energized may result in injury. 6. Use a multimeter to check for voltage at the terminal block (Figure 5, Item 19). If voltage is present, ensure that the proper circuit breaker is secured, locked out, and tagged out IAW FM 4-01.502. If no voltage is present, continue with the procedure. Label and remove the motor (up and down/left and right) wiring (Figure 5, Item 18) from the terminal block (Figure 5, Item 19). Remove the four screws (Figure 5, Item 15) and four lockwashers (Figure 5, Item 16) from the motor (up and down/left and right) (Figure 5, Item 17). Discard lockwashers. Remove the motor (up and down/left and right) (Figure 5, Item 17) from the lower base assembly (Figure 5, Item 6).
7. 8. 9.
0157-8
TM 55-1925-273-24&P-2 MOTOR (UP AND DOWN/LEFT AND RIGHT) REMOVAL - Continued

1
0157
2 3 4 5
6 14 13 12 11 10 9
8 15 16
17
18
19
16
15
18
17
M1257T73
Searchlight Base Assembly.
0157-9
TM 55-1925-273-24&P-2 MOTOR (UP AND DOWN/LEFT AND RIGHT) INSTALLATION 1. 2. 3. Install the motor (up and down/left and right) (Figure 5, Item 17) in the lower base assembly (Figure 5, Item 6). Install the four screws (Figure 5, Item 15) and four lockwashers (Figure 5, Item 16) in the motor (up and down/left and right) (Figure 5, Item 17).
0157
Connect motor (up and down/left and right) wiring (Figure 5, Item 18) to the terminal block (Figure 5, Item 19) using the labels from Step (7) of MOTOR (UP AND DOWN/LEFT AND RIGHT) REMOVAL as a guide. Remove the labels. Install a gasket (Figure 5, Item 5) on the lower base assembly (Figure 5, Item 6). Install the upper base assembly (Figure 5, Item 2) on the lower base assembly (Figure 5, Item 6). Install the eight screws (Figure 5, Item 3) and eight lockwashers (Figure 5, Item 4) in the upper base assembly (Figure 5, Item 2). Install the arm assembly (Figure 2, Item 1) on the upper base assembly (Figure 2, Item 6) (WP 0156). Install the drum assembly (Figure 2, Item 3) on the arm assembly (Figure 2, Item 1) (WP 0156). Attach a spring scale to the arm assembly (Figure 2, Item 1) if the right and left motor and/or clutch were replaced. Attach the spring scale to the elevation rack (Figure 2, Item 7) if the up and down motor and/or clutch were replaced. Pull on the spring and measure the resistance required to move the searchlight. a. b. A force of 20 to 25 lbs (9.1 to 11.3 kg) is required for the up and down clutch. A force of 15 to 20 lbs (6.8 to 9.1 kg) is required for the right and left clutch.
4. 5. 6. 7. 8. 9.
10.
11.
If the force required to slip the clutch is not within the required range, perform Steps (1) through (5) of MOTOR (UP AND DOWN/LEFT AND RIGHT) REMOVAL and adjust the nut (Figure 5, Item 7). Tighten the nut to increase the force required; loosen the nut to decrease the force required. Perform Steps (4) through (11) of MOTOR (UP AND DOWN/LEFT AND RIGHT) INSTALLATION until the force required to move the searchlight is within the tolerances outlined in Step (10) of MOTOR (UP AND DOWN/ LEFT AND RIGHT) INSTALLATION. Perform the FOLLOW-ON MAINTENANCE procedure at the end of this work package.
12.
13.
END OF TASK CLUTCH (UP AND DOWN/LEFT AND RIGHT) REMOVAL 1. 2. 3. 4. 5. 6. 7. Perform the MOTOR (UP AND DOWN/LEFT AND RIGHT) REMOVAL procedure in this work package. Remove the self-locking nut (Figure 5, Item 7) from the shaft (Figure 5, Item 1). Discard self-locking nut. Remove the flat washer (Figure 5, Item 8) and spring (Figure 5, Item 9) from the shaft (Figure 5, Item 1). Remove the woodruff key (Figure 5, Item 10) from the shaft (Figure 5, Item 1). Remove the lower clutch plate (Figure 5, Item 11) from the shaft (Figure 5, Item 1). Remove the setscrew (Figure 5, Item 14) from the upper clutch plate (Figure 5, Item 13). Remove the upper clutch plate (Figure 5, Item 13) and worm gear (Figure 5, Item 12) from the shaft (Figure 5, Item 1).
END OF TASK
0157-10
TM 55-1925-273-24&P-2 CLUTCH (UP AND DOWN/LEFT AND RIGHT) INSTALLATION 1. 2. 3. 4. 5. 6. 7. Install the upper clutch plate (Figure 5, Item 13) and worm gear (Figure 5, Item 12) on the shaft (Figure 5, Item 1). Install the setscrew (Figure 5, Item 14) in the upper clutch plate (Figure 5, Item 13). Install the lower clutch plate (Figure 5, Item 11) on the shaft (Figure 5, Item 1). Install the woodruff key (Figure 5, Item 10) in the shaft (Figure 5, Item 1). Install the flat washer (Figure 5, Item 8) and spring (Figure 5, Item 9) on the shaft (Figure 5, Item 1). Install a self-locking nut (Figure 5, Item 7) on the shaft (Figure 5, Item 1).
0157
Perform the MOTOR (UP AND DOWN/LEFT AND RIGHT) INSTALLATION procedure at the end of this work package.
END OF TASK TRANSFORMER REMOVAL 1. 2. 3. 4. Perform the LAMP STARTER ASSEMBLY REMOVAL procedure in this work package. Remove the two screws (Figure 6, Item 1), two lockwashers (Figure 6, Item 2), and two nuts (Figure 6, Item 3) from the lamp starter assembly (Figure 6, Item 4). Discard lockwashers. Remove the screw (Figure 6, Item 9) and lockwasher (Figure 6, Item 8) from the connector (Figure 6, Item 7). Discard lockwasher. Remove the RF transformer (Figure 6, Item 5) and the high voltage transformer (Figure 6, Item 6) from the lamp starter assembly (Figure 6, Item 4).
END OF TASK TRANSFORMER INSTALLATION 1. 2. 3. 4. Install the RF transformer (Figure 6, Item 5) and the high voltage transformer (Figure 6, Item 6) in the lamp starter assembly (Figure 6, Item 4). Install the screw (Figure 6, Item 9) and lockwasher (Figure 6, Item 8) in the connector (Figure 6, Item 7). Install the two screws (Figure 6, Item 1), two lockwashers (Figure 6, Item 2), and two nuts (Figure 6, Item 3) in the lamp starter assembly (Figure 6, Item 4). Perform the LAMP STARTER ASSEMBLY INSTALLATION procedure in this work package.
0157-11
TM 55-1925-273-24&P-2 TRANSFORMER INSTALLATION - Continued
0157
2 3 2 1
4 5
7 9 8
3 7
5 1 3 2 3 2 6
1
Figure 6. END OF TASK JOYSTICK CONTROLLER REMOVAL 1. 2. Searchlight Lamp Starter Assembly.
M1258T73
Remove the four screws (Figure 7, Item 7) from the cover plate (Figure 7, Item 8) of the control station (Figure 7, Item 22). Remove the cover plate (Figure 7, Item 8) from the control station (Figure 7, Item 22).
0157-12
TM 55-1925-273-24&P-2 JOYSTICK CONTROLLER REMOVAL - Continued
0157
WARNING
Replace or repair components only after the affected circuit has been secured, locked out, and tagged out IAW FM 4-01.502. Performing replacement with the circuit energized may result in injury. 3. Use a multimeter to check for voltage at the terminal block (Figure 7, Item 26). If voltage is present, ensure that the proper circuit breaker is secured, locked out, and tagged out IAW FM 4-01.502. If no voltage is present, continue with the procedure. Label and remove the wiring (Figure 7, Item 25) of the joystick controller (Figure 7, Item 27) from the terminal block (Figure 7, Item 26). Remove the nut (Figure 7, Item 16) from the joystick (Figure 7, Item 27). Remove the joystick controller (Figure 7, Item 27) from the cover plate (Figure 7, Item 8).
4. 5. 6.
0157-13
TM 55-1925-273-24&P-2 JOYSTICK CONTROLLER REMOVAL - Continued
0157
7 2 3 1 4 6 5
UP
80
100
9
0
10
90
14 15
SPEED
10
13
20
70
LEFT DOWN
RIGHT
30
40
OFF ON START BEAM FOCUS

START
STANDBY OFF
17 16
18 20 19 21 22 11
27 26
1 2 3 4 5 6 7 8 9 10
25
Figure 7. END OF TASK JOYSTICK CONTROLLER INSTALLATION 1. 2. 3.
24
23
Searchlight Control Station.
Install the joystick controller (Figure 7, Item 27) in the cover plate (Figure 7, Item 8). Install the nut (Figure 7, Item 16) on the joystick controller (Figure 7, Item 27). Connect the wiring (Figure 7, Item 25) of the joystick controller (Figure 7, Item 27) to the terminal block (Figure 7, Item 26) using the labels from Step (4) of JOYSTICK CONTROLLER REMOVAL as a guide. Remove the labels. Install the cover plate (Figure 7, Item 8) on the control station (Figure 7, Item 22). Install the four screws (Figure 7, Item 7) in the cover plate (Figure 7, Item 8) of the control station (Figure 7, Item 22). Perform the FOLLOW-ON MAINTENANCE procedure at the end of this work package.
4. 5. 6.
END OF TASK
0157-14
50
60
12
M1259T73
TM 55-1925-273-24&P-2 RECTIFIER DIODE IN SEARCHLIGHT CONTROL PANEL REMOVAL 1. 2. Remove the four screws (Figure 7, Item 7) from the cover plate (Figure 7, Item 8) of the control station (Figure 7, Item 22). Remove the cover plate (Figure 7, Item 8) from the control station (Figure 7, Item 22).
0157
WARNING
Replace or repair components only after the affected circuit has been secured, locked out, and tagged out IAW FM 4-01.502. Performing replacement with the circuit energized may result in injury. 3. Use a multimeter to check for voltage at the terminal block (Figure 7, Item 26). If voltage is present, ensure that the proper circuit breaker is secured, locked out, and tagged out IAW FM 4-01.502. If no voltage is present, continue with the procedure. Label and remove the wiring (Figure 7, Item 5) from the rectifier diode (Figure 7, Item 6). Remove the two screws (Figure 7, Item 2) and two lockwashers (Figure 7, Item 3) from the terminal block (Figure 7, Item 1). Discard lockwashers. Remove the terminal block (Figure 7, Item 1), spacer (Figure 7, Item 4), and rectifier diode (Figure 7, Item 6) from the control station (Figure 7, Item 22).
4. 5. 6.
END OF TASK RECTIFIER DIODE IN SEARCHLIGHT CONTROL PANEL INSTALLATION 1. 2. 3. 4. 5. 6. Install the terminal block (Figure 7, Item 1), spacer (Figure 7, Item 4), and rectifier diode (Figure 7, Item 6) in the control station (Figure 7, Item 22). Install the two screws (Figure 7, Item 2) and two lockwashers (Figure 7, Item 3) in the terminal block (Figure 7, Item 1). Connect the wiring (Figure 7, Item 5) to the rectifier diode (Figure 7, Item 6) using the labels from Step (4) of RECTIFIER DIODE IN SEARCHLIGHT CONTROL PANEL REMOVAL as a guide. Remove the labels. Install the cover plate (Figure 7, Item 8) on the control station (Figure 7, Item 22). Install the four screws (Figure 7, Item 7) in the cover plate (Figure 7, Item 8) of the control station (Figure 7, Item 22). Perform the FOLLOW-ON MAINTENANCE procedure at the end of this work package.
END OF TASK
0157-15
TM 55-1925-273-24&P-2
0157
CONTROL PANEL ADJUSTABLE TRANSFORMER REMOVAL 1. 2. Remove the four screws (Figure 7, Item 7) from the cover plate (Figure 7, Item 8) of the control station (Figure 7, Item 22). Remove the cover plate (Figure 7, Item 8) from the control station (Figure 7, Item 22).
WARNING
Replace or repair components only after the affected circuit has been secured, locked out, and tagged out IAW FM 4-01.502. Performing replacement with the circuit energized may result in injury. 3. Use a multimeter to check for voltage at the terminal block (Figure 7, Item 26). If voltage is present, ensure that the proper circuit breaker is secured, locked out, and tagged out IAW FM 4-01.502. If no voltage is present, continue with the procedure. Label and remove the wiring (Figure 7, Item 10) from the transformer (Figure 7, Item 9). Remove the setscrew (Figure 7, Item 15) from the knob (Figure 7, Item 11). Remove the knob (Figure 7, Item 11) from the shaft (Figure 7, Item 14). Remove the nut (Figure 7, Item 12) and lockwasher (Figure 7, Item 13) from the shaft (Figure 7, Item 14). Discard lockwasher. Remove the transformer (Figure 7, Item 9) from the cover plate (Figure 7, Item 8).
4. 5. 6. 7. 8.
END OF TASK CONTROL PANEL ADJUSTABLE TRANSFORMER INSTALLATION 1. 2. 3. 4. 5. 6. 7. 8. Install the transformer (Figure 7, Item 9) in the cover plate (Figure 7, Item 8). Install the nut (Figure 7, Item 12) and lockwasher (Figure 7, Item 13) on the shaft (Figure 7, Item 14). Install the knob (Figure 7, Item 11) on the shaft (Figure 7, Item 14). Install the setscrew (Figure 7, Item 15) in the knob (Figure 7, Item 11). Connect the wiring (Figure 7, Item 10) to the transformer (Figure 7, Item 9) using the labels from Step (4) of CONTROL PANEL ADJUSTABLE TRANSFORMER REMOVAL as a guide. Remove the labels. Install the cover plate (Figure 7, Item 8) on the control station (Figure 7, Item 22). Install the four screws (Figure 7, Item 7) in the cover plate (Figure 7, Item 8) of the control station (Figure 7, Item 3). Perform the FOLLOW-ON MAINTENANCE procedure at the end of this work package.
END OF TASK
0157-16
TM 55-1925-273-24&P-2
0157
CONTROL PANEL SELECTOR SWITCH REMOVAL 1. 2. Remove the four screws (Figure 7, Item 7) from the cover plate (Figure 7, Item 8) of the control station (Figure 7, Item 22). Remove the cover plate (Figure 7, Item 8) from the control station (Figure 7, Item 22).
WARNING
Replace or repair components only after the affected circuit has been secured, locked out, and tagged out IAW FM 4-01.502. Performing replacement with the circuit energized may result in injury. 3. Use a multimeter to check for voltage at the terminal block (Figure 7, Item 26). If voltage is present, ensure that the proper circuit breaker is secured, locked out, and tagged out IAW FM 4-01.502. If no voltage is present, continue with the procedure. Label and remove the wiring (Figure 7, Item 23) from the selector switch (Figure 7, Item 21). Remove the nut (Figure 7, Item 20) from the selector switch (Figure 7, Item 21). Remove the selector switch (Figure 7, Item 21) from the cover plate (Figure 7, Item 8).
4. 5. 6.
END OF TASK CONTROL PANEL SELECTOR SWITCH INSTALLATION 1. 2. 3. 4. 5. 6. Install the selector switch (Figure 7, Item 21) in the cover plate (Figure 7, Item 8). Install the nut (Figure 7, Item 20) on the selector switch (Figure 7, Item 21). Connect the wiring (Figure 7, Item 23) to the selector switch (Figure 7, Item 21) using the labels from Step (4) of CONTROL PANEL SELECTOR SWITCH REMOVAL as a guide. Remove the labels. Install the cover plate (Figure 7, Item 8) on the control station (Figure 7, Item 22). Install the four screws (Figure 7, Item 7) in the cover plate (Figure 7, Item 8) of the control station (Figure 7, Item 22). Perform the FOLLOW-ON MAINTENANCE procedure at the end of this work package.
END OF TASK
0157-17
TM 55-1925-273-24&P-2
0157
CONTROL PANEL TOGGLE SWITCH REMOVAL 1. 2. Remove the four screws (Figure 7, Item 7) from the cover plate (Figure 7, Item 8) of the control station (Figure 7, Item 22). Remove the cover plate (Figure 7, Item 8) from the control station (Figure 7, Item 22).
WARNING
Replace or repair components only after the affected circuit has been secured, locked out, and tagged out IAW FM 4-01.502. Performing replacement with the circuit energized may result in injury. 3. Use a multimeter to check for voltage at the terminal block (Figure 7, Item 26). If voltage is present, ensure that the proper circuit breaker is secured, locked out, and tagged out IAW FM 4-01.502. If no voltage is present, continue with the procedure. Label and remove the wiring (Figure 7, Item 24) from the toggle switch (Figure 7, Item 19). Remove the nut (Figure 7, Item 17) and lockwasher (Figure 7, Item 18) from the toggle switch (Figure 7, Item 19). Discard lockwasher. Remove the toggle switch (Figure 7, Item 19) from the cover plate (Figure 7, Item 8).
4. 5. 6.
END OF TASK CONTROL PANEL TOGGLE SWITCH INSTALLATION 1. 2. 3. 4. 5. 6. Install the toggle switch (Figure 7, Item 19) in the cover plate (Figure 7, Item 8). Install the nut (Figure 7, Item 17) and lockwasher (Figure 7, Item 18) on the toggle switch (Figure 7, Item 19). Connect the wiring (Figure 7, Item 24) to the toggle switch (Figure 7, Item 19) using the labels from Step (4) of CONTROL PANEL TOGGLE SWITCH REMOVAL as a guide. Remove the labels. Install the cover plate (Figure 7, Item 8) on the control station (Figure 7, Item 22). Install the four screws (Figure 7, Item 7) in the cover plate (Figure 7, Item 8) of the control station (Figure 7, Item 22). Perform the FOLLOW-ON MAINTENANCE procedure at the end of this work package.
END OF TASK
0157-18
TM 55-1925-273-24&P-2
0157
FOLLOW-ON MAINTENANCE 1. 2. 3. 4. Remove the lock outs and tag outs IAW FM 4-01.502. Lubricate the searchlight, align the searchlight, and verify the spark gap adjustment (WP 0155). Perform the SEARCHLIGHT POWER SUPPLY TEST procedure (WP 0158). Return the searchlight to desired readiness condition.
0157-19/20 blank
TM 55-1925-273-24&P-2 FIELD MAINTENANCE SEARCHLIGHT POWER SUPPLY TEST
0158
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 3, WP 0344, Table 1, Item 27) Materials/Parts N/A Personnel Required Watercraft Engineer 88L (1) References Volume 3, WP 0290 Volume 3, WP 0344 Equipment Condition N/A
0158-1
TM 55-1925-273-24&P-2
0158
SEARCHLIGHT POWER SUPPLY TEST 1. On the front door (Figure 1, Item 3) of the power supply (Figure 1, Item 2), read the lamp current displayed on the ammeter (Figure 1, Item 1). The current should read approximately 30 A.
1
2 3
M1260T73
Figure 1.
Exterior Searchlight Power Supply.
0158-2
TM 55-1925-273-24&P-2 SEARCHLIGHT POWER SUPPLY TEST - Continued 2. 3.
0158
If the lamp current is low, turn the lamp and the disconnect switch to OFF. Move the transformer primary connection (Figure 2, Item 1) to a higher number. If the lamp current is high, turn the lamp and the disconnect switch to OFF. Move the transformer primary connection (Figure 2, Item 1) to a lower number.
+ -
M1261T73
Interior Searchlight Power Supply.
0158-3/4 blank
TM 55-1925-273-24&P-2 FIELD MAINTENANCE SEARCHLIGHT POWER SUPPLY REPLACE
0159
INITIAL SETUP: Tools and Special Tools Multimeter (Volume 3, WP 0344, Table 1, Item 15) Tool Kit, Electrical Repair (Volume 3, WP 0344, Table 1, Item 26) Materials/Parts N/A Personnel Required Watercraft Engineer 88L (2) References FM 4-01.502 References (cont.) WP 0158 Volume 3, WP 0290 Volume 3, WP 0344 Equipment Condition Set to OFF the PORT SEARCHLIGHT POWER SUPPLY or the STARBOARD SEARCHLIGHT POWER SUPPLY circuit breaker on the 120 V pilothouse emergency distribution panel. Lock out and tag out IAW FM 4-01.502.
0159-1
TM 55-1925-273-24&P-2
0159
SEARCHLIGHT POWER SUPPLY REMOVAL 1. 2. Loosen the two captive screws (Figure 1, Item 2) on the door (Figure 1, Item 1) of the power supply (Figure 1, Item 3). Open the door (Figure 1, Item 1) of the power supply (Figure 1, Item 3).
WARNING
Replace or repair components only after the affected circuit has been secured, locked out, and tagged out IAW FM 4-01.502. Performing replacement with the circuit energized may result in injury. 3. Use a multimeter to check for voltage at the terminal blocks (Figure 2, Item 7). If voltage is present, ensure that the proper circuit breaker is secured, locked out, and tagged out IAW FM 4-01.502. If no voltage is present, continue with the procedure. Label and remove the wiring (Figure 2, Item 1) from terminal block (Figure 2, Item 5). Remove the wiring (Figure 2, Item 1) from the power supply (Figure 1, Item 3). Remove the two nuts (Figure 2, Item 2) and the two flat washers (Figure 2, Item 3) from the two studs (Figure 2, Item 4). Remove the power supply (Figure 2, Item 6) from the two studs (Figure 2, Item 4).
4. 5. 6. 7.
0159-2
TM 55-1925-273-24&P-2 SEARCHLIGHT POWER SUPPLY REMOVAL - Continued
0159
M1262T73
Figure 1. Searchlight Power Supply (External).
0159-3
TM 55-1925-273-24&P-2 SEARCHLIGHT POWER SUPPLY REMOVAL - Continued
0159
4 5 6
TB1
GND
7
TB2 TB3
TB4
M1263T73
Searchlight Power Supply (Internal).
0159-4
TM 55-1925-273-24&P-2 SEARCHLIGHT POWER SUPPLY INSTALLATION 1. 2. 3. 4.
0159
Position the power supply (Figure 2, Item 6) on the two studs (Figure 2, Item 4) and secure it with the two nuts (Figure 2, Item 2) and the two flat washers (Figure 2, Item 3). Install the wiring (Figure 2, Item 1) in the power supply (Figure 1, Item 3). Connect the wiring (Figure 2, Item 1) to terminal block 1 (Figure 2, Item 5) using the labels from Step (4) of SEARCHLIGHT POWER SUPPLY REMOVAL as a guide. Remove the labels. Close the door (Figure 1, Item 1) to the power supply (Figure 1, Item 3) and secure it with the two captive screws (Figure 1, Item 2).
END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. 4. Remove the lock outs and tag outs IAW FM 4-01.502. Set to ON the PORT SEARCHLIGHT POWER SUPPLY or the STARBOARD SEARCHLIGHT POWER SUPPLY circuit breaker on the 120 V pilothouse emergency distribution panel. Perform the SEARCHLIGHT POWER SUPPLY TEST procedure (WP 0158) and check for proper operation of the searchlight power supply. Return the searchlight power supply to the desired readiness condition.
0159-5/6 blank
TM 55-1925-273-24&P-2 FIELD MAINTENANCE SEARCHLIGHT POWER SUPPLY REPAIR
0160
INITIAL SETUP: Tools and Special Tools Multimeter (Volume 3, WP 0344, Table 1, Item 15) Tool Kit, Electrical Repair (Volume 3, WP 0344, Table 1, Item 26) Materials/Parts N/A Personnel Required Watercraft Engineer 88L (2) References FM 4-01.502 References (cont.) WP 0158 Volume 3, WP 0290 Volume 3, WP 0344 Equipment Condition Set to OFF the PORT SEARCHLIGHT POWER SUPPLY or the STARBOARD SEARCHLIGHT POWER SUPPLY circuit breaker on the 120 V pilothouse emergency distribution panel. Lock out and tag out IAW FM 4.01-502.
0160-1
TM 55-1925-273-24&P-2
0160
WARNING
Never reuse locking hardware. Reuse of locking hardware such as lockwashers, locking nuts, cotter pins, and lock wire can result in undetected loosening of fastening hardware causing catastrophic component failure resulting in death, injury, or damage to equipment. Ensure that all locking hardware is discarded upon removal and replaced with new. ELAPSED TIME INDICATOR REMOVAL 1. 2. Loosen the two captive screws (Figure 1, Item 1) on the door (Figure 1, Item 3) of the power supply (Figure 1, Item 2). OPEN the door (Figure 1, Item 3) of the power supply (Figure 1, Item 2).
WARNING
Replace or repair components only after the affected circuit has been secured, locked out, and tagged out IAW FM 4-01.502. Performing replacement with the circuit energized may result in injury. 3. Use a multimeter to check for voltage at the terminal blocks (Figure 2, Item 8). If voltage is present, ensure that the proper circuit breaker is secured, locked out, and tagged out IAW FM 4.01-502. If no voltage is present, continue with the procedure. Label and remove the wiring of the Elapsed Time Indicator (ETI) (Figure 2, Item 18) from terminal block 5 (Figure 2, Item 9). Remove the three screws (Figure 2, Item 1), the three lockwashers (Figure 2, Item 2), and the three nuts (Figure 2, Item 3) from the ETI (Figure 2, Item 18). Discard lockwashers. Remove the ETI (Figure 2, Item 18) from the door (Figure 1, Item 3) of the power supply (Figure 1, Item 2).
4. 5. 6.
0160-2
TM 55-1925-273-24&P-2 ELAPSED TIME INDICATOR REMOVAL - Continued
0160
2 3
M1264T73
Figure 1.
Searchlight Power Supply.
0160-3
TM 55-1925-273-24&P-2 ELAPSED TIME INDICATOR REMOVAL - Continued

4 1 2 3 5 6
0160
TB5
18 17
16
+ -
15
14
13
12
11
10
M1265T73
Searchlight Power Supply Internal Door Components.
0160-4
TM 55-1925-273-24&P-2 ELAPSED TIME INDICATOR INSTALLATION 1. 2. 3. 4. 5. 6. Install the ETI (Figure 2, Item 18) in the door (Figure 1, Item 3) of the power supply (Figure 1, Item 2). Install the three screws (Figure 2, Item 1), three lockwashers (Figure 2, Item 2), and the three nuts (Figure 2, Item 3) in the ETI (Figure 2, Item 18).
0160
Connect the wiring of the ETI (Figure 2, Item 18) to terminal block 5 (Figure 2, Item 9) using the labels from Step (4) of ELAPSED TIME INDICATOR REMOVAL as a guide. Remove the labels. CLOSE the door (Figure 1, Item 3) on the power supply (Figure 1, Item 2). Tighten the two captive screws (Figure 1, Item 1) in the door (Figure 1, Item 3). Perform the FOLLOW-ON MAINTENANCE procedure at the end of this work package.
END OF TASK R2 RELAY REMOVAL 1. 2. Loosen the two captive screws (Figure 1, Item 1) on the door (Figure 1, Item 3) of the power supply (Figure 1, Item 2). OPEN the door (Figure 1, Item 3) of the power supply (Figure 1, Item 2).
WARNING
Replace or repair components only after the affected circuit has been secured, locked out, and tagged out IAW FM 4-01.502. Performing replacement with the circuit energized may result in injury. 3. Use a multimeter to check for voltage at the terminal blocks (Figure 2, Item 8). If voltage is present, ensure that the proper circuit breaker is secured, locked out, and tagged out IAW FM 4.01-502. If no voltage is present, continue with the procedure. Label and remove the wiring of the R2 relay (Figure 2, Item 17) from terminal block 5 (Figure 2, Item 9). Remove the two screws (Figure 2, Item 15), two lockwashers (Figure 2, Item 14), and two nuts (Figure 2, Item 13) from the R2 relay (Figure 2, Item 17). Discard lockwashers. Remove the R2 relay (Figure 2, Item 17) from the door (Figure 1, Item 3) of the power supply (Figure 1, Item 2).
4. 5. 6.
END OF TASK R2 RELAY INSTALLATION 1. 2. 3. 4. 5. Install the R2 relay (Figure 2, Item 17) in the door (Figure 1, Item 3) of the power supply (Figure 1, Item 2). Install the two screws (Figure 2, Item 15), two lockwashers (Figure 2, Item 13), and two nuts (Figure 2, Item 13) in the R2 relay (Figure 2, Item 17). Connect the wiring of the R2 relay (Figure 2, Item 17) to terminal block 5 (Figure 2, Item 9) using the labels from Step (4) of R2 RELAY REMOVAL as a guide. Remove the labels. CLOSE the door (Figure 1, Item 3) on the power supply (Figure 1, Item 2). Tighten the two captive screws (Figure 1, Item 1) in the door (Figure 1, Item 3).
0160-5
TM 55-1925-273-24&P-2 R2 RELAY INSTALLATION - Continued 6. Perform the FOLLOW-ON MAINTENANCE procedure at the end of this work package.
0160
END OF TASK AMMETER REMOVAL 1. 2. Loosen the two captive screws (Figure 1, Item 1) on the door (Figure 1, Item 3) of the power supply (Figure 1, Item 2). OPEN the door (Figure 1, Item 3) of the power supply (Figure 1, Item 2).
WARNING
Replace or repair components only after the affected circuit has been secured, locked out, and tagged out IAW FM 4-01.502. Performing replacement with the circuit energized may result in injury. 3. Use a multimeter to check for voltage at the terminal blocks (Figure 2, Item 8). If voltage is present, ensure that the proper circuit breaker is secured, locked out, and tagged out IAW FM 4.01-502. If no voltage is present, continue with the procedure. Label and remove the wiring from the ammeter (Figure 2, Item 7). Remove the three screws (Figure 2, Item 4), three lockwashers (Figure 2, Item 5), and three nuts (Figure 2, Item 6) from the ammeter (Figure 2, Item 7). Discard lockwashers. Remove the ammeter (Figure 2, Item 7) from the door (Figure 1, Item 3) of the power supply (Figure 1, Item 2).
4. 5. 6.
END OF TASK AMMETER INSTALLATION 1. 2. 3. 4. 5. 6. Install the ammeter (Figure 2, Item 7) in the door (Figure 1, Item 3) of the power supply (Figure 1, Item 2). Install the three screws (Figure 2, Item 4), three lockwashers (Figure 2, Item 5), and three nuts (Figure 2, Item 6) in the ammeter (Figure 2, Item 7). Connect the wiring to the ammeter (Figure 2, Item 7) using the labels from Step (4) of AMMETER REMOVAL as a guide. Remove the labels. CLOSE the door (Figure 1, Item 3) on the power supply (Figure 1, Item 2). Tighten the two captive screws (Figure 1, Item 1) in the door (Figure 1, Item 3). Perform the FOLLOW-ON MAINTENANCE procedure at the end of this work package.
END OF TASK
0160-6
TM 55-1925-273-24&P-2
0160
FAN REMOVAL 1. 2. Loosen the two captive screws (Figure 1, Item 1) on the door (Figure 1, Item 3) of the power supply (Figure 1, Item 2). OPEN the door (Figure 1, Item 3) of the power supply (Figure 1, Item 2).
WARNING
Replace or repair components only after the affected circuit has been secured, locked out, and tagged out IAW FM 4-01.502. Performing replacement with the circuit energized may result in injury. 3. Use a multimeter to check for voltage at the terminal blocks (Figure 2, Item 8). If voltage is present, ensure that the proper circuit breaker is secured, locked out, and tagged out IAW FM 4.01-502. If no voltage is present, continue with the procedure. Label and remove the wiring of the fan (Figure 2, Item 16) from terminal block 5 (Figure 2, Item 9). Remove the four screws (Figure 2, Item 12), four lockwashers (Figure 2, Item 11), and four nuts (Figure 2, Item 10) from the fan (Figure 2, Item 16). Discard lockwashers. Remove the fan (Figure 2, Item 16) from the door (Figure 1, Item 3) of the power supply (Figure 1, Item 2).
4. 5. 6.
END OF TASK FAN INSTALLATION 1. 2. 3. 4. 5. 6. Install the fan (Figure 2, Item 16) in the door (Figure 1, Item 3) of the power supply (Figure 1, Item 2). Install the four screws (Figure 2, Item 12), four lockwashers (Figure 2, Item 11), and four nuts (Figure 2, Item 10) in the fan (Figure 2, Item 16). Connect the wiring of the fan (Figure 2, Item 16) to terminal block 5 (Figure 2, Item 9) using the labels from Step (4) of FAN REMOVAL as a guide. Remove the labels. CLOSE the door (Figure 1, Item 3) on the power supply (Figure 1, Item 2). Tighten the two captive screws (Figure 1, Item 1) in the door (Figure 1, Item 3). Perform the FOLLOW-ON MAINTENANCE procedure at the end of this work package.
END OF TASK
0160-7
TM 55-1925-273-24&P-2
0160
RESISTOR ASSEMBLY REMOVAL 1. 2. Loosen the two captive screws (Figure 1, Item 1) on the door (Figure 1, Item 3) of the power supply (Figure 1, Item 2). OPEN the door (Figure 1, Item 3) of the power supply (Figure 1, Item 2).
WARNING
Replace or repair components only after the affected circuit has been secured, locked out, and tagged out IAW FM 4-01.502. Performing replacement with the circuit energized may result in injury. 3. Use a multimeter to check for voltage at terminal block 1 (Figure 3, Item 1). If voltage is present, ensure that the proper circuit breaker is secured, locked out, and tagged out IAW FM 4.01-502. If no voltage is present, continue with the procedure. Remove the two screws (Figure 3, Item 17) from the resistor assembly (Figure 3, Item 16). Remove the resistor assembly (Figure 3, Item 16) from the capacitor (Figure 3, Item 18).
4. 5.
END OF TASK RESISTOR ASSEMBLY INSTALLATION 1. 2. 3. 4. 5. Install the resistor assembly (Figure 3, Item 16) on the capacitor (Figure 3, Item 18). Install the two screws (Figure 3, Item 17) in the resistor assembly (Figure 3, Item 16). CLOSE the door (Figure 1, Item 3) on the power supply (Figure 1, Item 2). Tighten the two captive screws (Figure 1, Item 1) in the door (Figure 1, Item 3). Perform the FOLLOW-ON MAINTENANCE procedure at the end of this work package.
0160-8
TM 55-1925-273-24&P-2 RESISTOR ASSEMBLY INSTALLATION - Continued

2
0160
3 1 4 5 6
TB1
GND
7 23 8
TB2
TB3
10 22 11
TB4
+ -
21
20
19
18 17
16 15
14
13
M1266T73
12
Figure 3. Searchlight Power Supply Internal Components. END OF TASK
0160-9
TM 55-1925-273-24&P-2 CAPACITOR REMOVAL 1. 2. 3. 4. Perform the RESISTOR ASSEMBLY REMOVAL procedure in this work package. Label and remove the wiring from the capacitor (Figure 3, Item 18). Remove the three screws (Figure 3, Item 21), three lockwashers (Figure 3, Item 20), and three clamps (Figure 3, Item 19) from the capacitor (Figure 3, Item 18). Discard lockwashers. Remove the capacitor (Figure 3, Item 18) from the power supply (Figure 3, Item 5).
0160
END OF TASK CAPACITOR INSTALLATION 1. 2. 3. 4. Install the capacitor (Figure 3, Item 18) in the power supply (Figure 3, Item 5). Install the three clamps (Figure 3, Item 19), three lockwashers (Figure 3, Item 20), and three screws (Figure 3, Item 21) on the capacitor (Figure 3, Item 18). Connect the wiring to the capacitor (Figure 3, Item 18) using the labels from Step (2) of CAPACITOR REMOVAL as a guide. Remove the labels. Perform the RESISTOR ASSEMBLY INSTALLATION procedure in the work package.
END OF TASK TRANSFORMER ASSEMBLY REMOVAL 1. 2. Loosen the two captive screws (Figure 1, Item 1) on the door (Figure 1, Item 3) of the power supply (Figure 1, Item 2). OPEN the door (Figure 1, Item 3) of the power supply (Figure 1, Item 2).
WARNING
Replace or repair components only after the affected circuit has been secured, locked out, and tagged out IAW FM 4-01.502. Performing replacement with the circuit energized may result in injury. 3. Use a multimeter to check for voltage at terminal block 1 (Figure 3, Item 1). If voltage is present, ensure that the proper circuit breaker is secured, locked out, and tagged out IAW FM 4.01-502. If no voltage is present, continue with the procedure. Label and remove the wiring on the transformer assembly (Figure 3, Item 15) from terminal block 3 (Figure 3, Item 10) and terminal block 4 (Figure 3, Item 11). Remove the four capscrews (Figure 3, Item 12), four flat washers (Figure 3, Item 13), and four lockwashers (Figure 3, Item 14) from the transformer assembly (Figure 3, Item 15). Discard lockwashers. Remove the transformer assembly (Figure 3, Item 15) from the power supply (Figure 3, Item 5).
4. 5. 6.
END OF TASK
0160-10
TM 55-1925-273-24&P-2 TRANSFORMER ASSEMBLY INSTALLATION 1. 2. 3. Install the transformer assembly (Figure 3, Item 15) in the power supply (Figure 3, Item 5).
0160
Install the four capscrews (Figure 3, Item 12), four flat washers (Figure 3, Item 13), and four lockwashers (Figure 3, Item 14) in the transformer assembly (Figure 3, Item 15). Connect the wiring of the transformer assembly (Figure 3, Item 15) to terminal block 3 (Figure 3, Item 10) and terminal block 4 (Figure 3, Item 11) using the labels from Step 4 of TRANSFORMER ASSEMBLY REMOVAL as a guide. Remove the labels. CLOSE the door (Figure 1, Item 3) on the power supply (Figure 1, Item 2). Tighten the two captive screws (Figure 1, Item 1) in the door (Figure 1, Item 3). Perform the FOLLOW-ON MAINTENANCE procedure at the end of this work package.
4. 5. 6.
END OF TASK FUSE REMOVAL 1. 2. Loosen the captive screws (Figure 1, Item 1) in the door (Figure 1, Item 3) of the power supply (Figure 1, Item 2). OPEN the door (Figure 1, Item 3) of the power supply (Figure 1, Item 2).
WARNING
Replace or repair components only after the affected circuit has been secured, locked out, and tagged out IAW FM 4-01.502. Performing replacement with the circuit energized may result in injury. 3. Use a multimeter to check for voltage at terminal block 1 (Figure 3, Item 1). If voltage is present, ensure that the proper circuit breaker is secured, locked out, and tagged out IAW FM 4.01-502. If no voltage is present, continue with the procedure. Using a fuse puller, remove the fuse (Figure 3, Item 22) from the fuse block (Figure 3, Item 23).
4.
END OF TASK FUSE INSTALLATION 1. 2. 3. 4. Using a fuse puller, install the fuse (Figure 3, Item 22) in the fuse block (Figure 3, Item 23). CLOSE the door (Figure 1, Item 3) on the power supply (Figure 1, Item 2). Tighten the two captive screws (Figure 1, Item 1) in the door (Figure 1, Item 3). Perform the FOLLOW-ON MAINTENANCE procedure at the end of this work package.
END OF TASK
0160-11
TM 55-1925-273-24&P-2
0160
FUSIBLE SWITCH REMOVAL 1. 2. Loosen the two captive screws (Figure 1, Item 1) in the door (Figure 1, Item 3) of the power supply (Figure 1, Item 2). OPEN the door (Figure 1, Item 3) of the power supply (Figure 1, Item 2).
WARNING
Replace or repair components only after the affected circuit has been secured, locked out, and tagged out IAW FM 4-01.502. Performing replacement with the circuit energized may result in injury. 3. Use a multimeter to check for voltage at terminal block 1 (Figure 3, Item 1). If voltage is present, ensure that the proper circuit breaker is secured, locked out, and tagged out IAW FM 4.01-502. If no voltage is present, continue with the procedure. Label and remove the wiring from the fuse kit (Figure 3, Item 6). Remove the three screws (Figure 3, Item 8) and three lockwashers (Figure 3, Item 9) from the fusible disconnect switch (Figure 3, Item 7). Discard lockwashers. Remove the fuse kit (Figure 3, Item 6) from the fusible disconnect switch (Figure 3, Item 7). Remove the fusible disconnect switch (Figure 3, Item 7) from the power supply (Figure 3, Item 5).
4. 5. 6. 7.
END OF TASK FUSIBLE SWITCH INSTALLATION 1. 2. 3. 4. 5. 6. 7. Install the fuse kit (Figure 3, Item 6) on the fusible disconnect switch (Figure 3, Item 7). Install the fusible disconnect switch (Figure 3, Item 7) in the power supply (Figure 3, Item 5). Install the three screws (Figure 3, Item 8) and three lockwashers (Figure 1, Item 9) in the fusible disconnect switch (Figure 3, Item 7). Connect the wiring to the fuse kit (Figure 3, Item 6) using the labels from Step (4) of FUSIBLE SWITCH REMOVAL as a guide. Remove the labels. CLOSE the door (Figure 1, Item 3) on the power supply (Figure 1, Item 2). Tighten the two captive screws (Figure 1, Item 1) in the door (Figure 1, Item 3). Perform the FOLLOW-ON MAINTENANCE procedure at the end of this work package.
END OF TASK R1 RELAY REMOVAL 1. 2. Loosen the captive screws (Figure 1, Item 1) in the door (Figure 1, Item 3) of the power supply (Figure 1, Item 2). OPEN the door (Figure 1, Item 3) of the power supply (Figure 1, Item 2).
0160-12
TM 55-1925-273-24&P-2 R1 RELAY REMOVAL - Continued
0160
WARNING
Replace or repair components only after the affected circuit has been secured, locked out, and tagged out IAW FM 4-01.502. Performing replacement with the circuit energized may result in injury. 3. Use a multimeter to check for voltage at terminal block 1 (Figure 3, Item 1). If voltage is present, ensure that the proper circuit breaker is secured, locked out, and tagged out IAW FM 4.01-502. If no voltage is present, continue with the procedure. Label and remove the wiring from the R1 relay (Figure 3, Item 4). Remove the two screws (Figure 3, Item 2) and two lockwashers (Figure 3, Item 3) from the R1 relay (Figure 3, Item 4). Discard lockwashers.
4. 5.
END OF TASK R1 RELAY INSTALLATION 1. 2. 3. 4. 5. 6. Install the R1 relay (Figure 3, Item 4) in the power supply (Figure 3, Item 5). Install the two screws (Figure 3, Item 2) and two lockwashers (Figure 3, Item 3) in the R1 relay (Figure 3, Item 4). Connect the wiring to the R1 relay (Figure 3, Item 4) using the labels from Step (4) of R1 RELAY REMOVAL as a guide. Remove the labels. CLOSE the door (Figure 1, Item 3) on the power supply (Figure 1, Item 2). Tighten the two captive screws (Figure 1, Item 1) in the door (Figure 1, Item 3). Perform the FOLLOW-ON MAINTENANCE procedure at the end of this work package.
END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. 4. Remove the lock outs and tag outs IAW FM 4.01-502. Set to ON the PORT SEARCHLIGHT POWER SUPPLY or the STARBOARD SEARCHLIGHT POWER SUPPLY circuit breaker on the 120 V pilothouse emergency distribution panel. Perform the SEARCHLIGHT POWER SUPPLY TEST procedure (WP 0158) and check for proper operation of the searchlight power supply. Return the searchlight power supply to the desired readiness condition.
0160-13/14 blank
TM 55-1925-273-24&P-2 FIELD MAINTENANCE NAVIGATION LIGHTS (RUNNING LIGHTS) REPLACE
0161
INITIAL SETUP: Tools and Special Tools Multimeter (Volume 3, WP 0344, Table 1, Item 15) Tool Kit, Electrical Repair (Volume 3, WP 0344, Table 1, Item 26) Materials/Parts Gasket (Volume 3, WP 0291, Figure 43, Item 2) Qty: 1 Personnel Required Watercraft Engineer 88L (2) References FM 4-01.502 References (cont.) Volume 3, WP 0291 Volume 3, WP 0344 Equipment Condition Set to OFF the PILOTHOUSE EMERGENCY DISTRIBUTION PANEL. circuit breaker at the 120 V emergency load center distribution panel; set to OFF the PORT SEARCH LIGHT. circuit breaker, or STARBOARD SEARCH LIGHT. circuit breaker at the navigation lighting panel. Lock out and tag out IAW FM 4-01.502.
0161-1
TM 55-1925-273-24&P-2
0161
WARNING
Never reuse locking hardware. Reuse of locking hardware such as lockwashers, locking nuts, cotter pins, and lock wire can result in undetected loosening of fastening hardware causing catastrophic component failure resulting in death, injury, or damage to equipment. Ensure that all locking hardware is discarded upon removal and replaced with new. SINGLE LENS/DOUBLE LENS LIGHT FIXTURES REMOVAL
NOTE
Single lens navigation lights are structurally identical, but differ in the color of the lens. Double lens navigation lights are also structurally identical, but differ in lens color. This procedure is applicable to the four single lens and the four double lens navigation lights on the vessel. 1. 2. 3. 4. Loosen the setscrew (Figure 1, Item 2) and remove the lid (Figure 1, Item 1) and gasket (Figure 1, Item 3). Discard gasket. Remove the clamp (Figure 1, Item 5). Remove the lens (Figure 1, Item 4). Remove the lamp (Figure 1, Item 6) from the socket (Figure 1, Item 7).
WARNING
Replace or repair components only after the affected circuit has been secured, locked out, and tagged out IAW FM 4-01.502. Performing replacement with the circuit energized may result in injury. 5. Use a multimeter to check for voltage at the lamp socket (Figure 1, Item 7). If voltage is present, ensure that the proper circuit breaker is set to OFF, locked out, and tagged out IAW FM 4-01.502. If no voltage is present, continue with the procedure. Label and remove the wiring (Figure 1, Item 12). Remove the four nuts (Figure 1, Item 11), four lockwashers (Figure 1, Item 10), four bolts (Figure 1, Item 8), and four flat washers (Figure 1, Item 9) that secure the light fixture (Figure 1, Item 13). Discard lockwashers. Remove the light fixture (Figure 1, Item 13) from its foundation.
6. 7. 8.
END OF TASK SINGLE LENS/DOUBLE LENS LIGHT FIXTURES INSTALLATION 1. Install the light fixture (Figure 1, Item 13) on its foundation and secure it with the four bolts (Figure 1, Item 8), four flat washers (Figure 1, Item 9), four lockwashers (Figure 1, Item 10), and four nuts (Figure 1, Item 11). Install the wiring (Figure 1, Item 12) to the light fixture (Figure 1, Item 13) using the labels from Step (6) of SINGLE LENS/DOUBLE LENS LIGHT FIXTURES REMOVAL as a guide. Remove the labels. Install the lamp (Figure 1, Item 6) in the socket (Figure 1, Item 7) hand tight. Install the lens (Figure 1, Item 4) and secure it with the clamp (Figure 1, Item 5).
2. 3. 4.
0161-2
TM 55-1925-273-24&P-2 SINGLE LENS/DOUBLE LENS LIGHT FIXTURES INSTALLATION - Continued 5. Install gasket (Figure 1, Item 3) and the lid (Figure 1, Item 1), securing them with the setscrew (Figure 1, Item 2).
1
0161
3 4 5
7 8
10 11
13
12
M1069T73
Navigation Light (Single Lens).
0161-3
TM 55-1925-273-24&P-2
0161
FOLLOW-ON MAINTENANCE 1. 2. 3. 4. Remove the lock outs and tag outs IAW FM 4-01.502. Set the circuit breaker to ON. Perform a functional test by turning the light ON and OFF to ensure proper operation. Return the equipment to the desired readiness condition.
0161-4
TM 55-1925-273-24&P-2 FIELD MAINTENANCE NAVIGATION LIGHTS (RUNNING LIGHTS) REPAIR
0162
INITIAL SETUP: Tools and Special Tools Tool Kit, Electrical Repair (Volume 3, WP 0344, Table 1, Item 26) Materials/Parts Gasket (Volume 3, WP 0291, Figure 43, Item 2) Qty: 1 Gasket (Volume 3, WP 0291, Figure 43, Item 18) Qty: 1 Personnel Required Watercraft Engineer 88L (2) References FM 4-01.502 References (cont.) Volume 3, WP 0291 Volume 3, WP 0344 Equipment Condition Set to OFF the NAVIGATION LIGHTING PANEL. circuit breaker at the 120 V emergency load center distribution panel. Lock out and tag out IAW FM 4-01.502.
0162-1
TM 55-1925-273-24&P-2
0162
SINGLE LENS LAMP BULBS AND/OR LENSES REMOVAL
WARNING
NOTE
Single lens navigation lights are structurally identical, but differ in the color of the lens. This procedure is applicable to the four single lens navigation lights on the vessel. Use the correct replacement color when replacing a lens. 1. 2. 3. 4. Loosen the setscrew (Figure 1, Item 2) and remove the lid (Figure 1, Item 1) and gasket (Figure 1, Item 3). Discard gasket. Remove the clamp (Figure 1, Item 5). Remove the lens (Figure 1, Item 4). Remove the lamp (Figure 1, Item 6) from the socket (Figure 1, Item 7).
END OF TASK SINGLE LENS LAMP BULBS AND/OR LENSES INSTALLATION 1. 2. 3. 4. Install the lamp (Figure 1, Item 6) in the socket (Figure 1, Item 7). Install the lens (Figure 1, Item 4) and secure it with the clamp (Figure 1, Item 5). Install a gasket (Figure 1, Item 3) and the lid (Figure 1, Item 1), securing them with the setscrew (Figure 1, Item 2). Perform the FOLLOW-ON MAINTENANCE procedure at the end of this work package.
0162-2
TM 55-1925-273-24&P-2 SINGLE LENS LAMP BULBS AND/OR LENSES INSTALLATION - Continued
0162
3 4
5 6
M1070T73
Navigation Light (Single Lens).
0162-3
TM 55-1925-273-24&P-2
0162
DOUBLE LENS LAMP BULBS AND/OR LENSES REMOVAL
NOTE
Double lens navigation lights are structurally identical, but differ in the color of the lens. This procedure is applicable to the four double lens navigation lights on the vessel. Use the correct replacement color when replacing a lens. 1. 2. 3. 4. 5. 6. 7. Loosen the setscrew (Figure 2, Item 2) and remove the lid (Figure 2, Item 1) and gasket (Figure 2, Item 12). Discard gasket. Remove the upper clamp (Figure 2, Item 9). Remove the upper lens (Figure 2, Item 10) and the screen (Figure 2, Item 11). Remove the upper lamp (Figure 2, Item 3) from the upper socket (Figure 2, Item 4). Remove the lower clamp (Figure 2, Item 6). Remove the lower lens (Figure 2, Item 5). Remove the lower lamp (Figure 2, Item 7) from the lower socket (Figure 2, Item 8).
END OF TASK DOUBLE LENS LAMP BULBS AND/OR LENSES INSTALLATION 1. 2. 3. 4. 5. 6. Install the lamp (Figure 2, Item 7) into the socket (Figure 2, Item 8). Install the lower lens (Figure 2, Item 5) and secure it with the lower clamp (Figure 2, Item 6). Install the upper lamp (Figure 2, Item 3) in the upper socket (Figure 2, Item 4). Install the upper lens (Figure 2, Item 10) and screen (Figure 2, Item 11), securing them with the clamp (Figure 2, Item 9). Install a gasket (Figure 2, Item 12) and the lid (Figure 2, Item 1), securing them with the setscrew (Figure 2, Item 2). Perform the FOLLOW-ON MAINTENANCE procedure at the end of this work package.
0162-4
TM 55-1925-273-24&P-2 DOUBLE LENS LAMP BULBS AND/OR LENSES INSTALLATION - Continued

1 2 11 12 3
0162
5 6
10 9 9 8 7
M1071T73
Navigation Light (Double Lens).
Remove the lock outs and tag outs IAW FM 4-01.502. Set the circuit breaker to ON. Perform a functional test by turning the light(s) ON and OFF to ensure proper operation. Return the equipment to the desired readiness condition.
0162-5/6 blank
TM 55-1925-273-24&P-2 FIELD MAINTENANCE YARDARM BLINKER LIGHT AND KEY REPLACE
0163
INITIAL SETUP: Tools and Special Tools Multimeter (Volume 3, WP 0344, Table 1, Item 15) Tool Kit, Electrical Repair (Volume 3, WP 0344, Table 1, Item 26) Materials/Parts N/A Personnel Required Watercraft Engineer 88L (2) References FM 4-01.502 References (cont.) Volume 3, WP 0292 Volume 3, WP 0344 Equipment Condition Set to OFF the NAVIGATION LIGHTING PANEL circuit breaker at the 120 V emergency load center distribution panel. Lock out and tag out IAW FM 4-01.502.
0163-1
TM 55-1925-273-24&P-2
0163
WARNING
Never reuse locking hardware. Reuse of locking hardware such as lockwashers, locking nuts, cotter pins, and lock wire can result in undetected loosening of fastening hardware causing catastrophic component failure resulting in death, injury, or damage to equipment. Ensure that all locking hardware is discarded upon removal and replaced with new. YARDARM LIGHT REMOVAL 1. 2. Remove the bolts (Figure 1, Item 3), retaining ring (Figure 1, Item 4), and lens (Figure 1, Item 1) from the existing light. Remove the bulb (Figure 1, Item 2) from the socket.
WARNING
Replace or repair components only after the affected circuit has been secured, locked out, and tagged out IAW FM 4-01.502. Performing replacement with the circuit energized may result in injury. 3. 4. 5. 6. Use a multimeter to check for voltage at the light. If voltage is present, ensure that the proper breaker is set to OFF, locked out, and tagged out IAW FM 4-01.502. If no voltage is available, continue with the procedure. Label and remove the wiring (Figure 1, Item 9) from the existing light. Remove the two bolts (Figure 1, Item 5), two nuts (Figure 1, Item 8), two flat washers (Figure 1, Item 6), and two lockwashers (Figure 1, Item 7) that secure the light to its foundation. Discard lockwashers. Remove the light from its foundation.
END OF TASK YARDARM LIGHT INSTALLATION 1. 2. 3. 4. 5. Install the light on its foundation and secure it with the two bolts (Figure 1, Item 5), two flat washers (Figure 1, Item 6), two lockwashers (Figure 1, Item 7), and two nuts (Figure 1, Item 8). Install the wiring (Figure 1, Item 9) inside the light using the labels from Step (4) of YARDARM LIGHT REMOVAL as a guide. Remove the labels. Install the lamp (Figure 1, Item 2). Install the lens (Figure 1, Item 1) and retaining ring (Figure 1, Item 4), securing them with the bolts (Figure 1, Item 3). Perform the FOLLOW-ON MAINTENANCE procedure at the end of this work package.
0163-2
TM 55-1925-273-24&P-2 YARDARM LIGHT INSTALLATION - Continued
0163
3 4
5 6
7 9
M1072T73
8
Figure 1. Yardarm Blinker Light.
END OF TASK
0163-3
TM 55-1925-273-24&P-2
0163
YARDARM BLINKER KEY REMOVAL 1. 2. Remove the four screws (Figure 2, Item 2) that secure the cover (Figure 2, Item 3) to the base (Figure 2, Item 4). Remove the cover (Figure 2, Item 3) to expose the terminals for the switch (Figure 2, Item 1).
2 3 4
8 7
Figure 2. Yardarm Blinker Key.
M1073T73
WARNING
Replace or repair components only after the affected circuit has been secured, locked out, and tagged out IAW FM 4-01.502. Performing replacement with the circuit energized may result in injury. 3. Use a multimeter to check for voltage at the switch contacts (Figure 3, Item 1). If voltage is present, ensure that the proper circuit breaker is set to OFF, locked out, and tagged out IAW FM 4-01.502. If no voltage is present, continue with the procedure. Label and remove the wiring (Figure 3, Item 3) from the switch terminals (Figure 3, Item 1) and from the light terminals (Figure 3, Item 2). Loosen the strain relief (Figure 3, Item 5) and remove the wiring (Figure 3, Item 3) from the base (Figure 3, Item 4).
4. 5.
0163-4
TM 55-1925-273-24&P-2 YARDARM BLINKER KEY REMOVAL - Continued
0163
3 5
Figure 3. 6.
4
Blinker Key Wiring.
M1074T73
Remove the two bolts (Figure 2, Item 5), two nuts (Figure 2, Item 7), two flat washers (Figure 2, Item 6), and two lockwashers (Figure 2, Item 8) that secure the base (Figure 2, Item 4) to its foundation. Discard lockwashers. Remove the base (Figure 2, Item 4).
7.
END OF TASK YARDARM BLINKER KEY INSTALLATION 1. Install the blinker key base (Figure 2, Item 4) on its foundation and secure it with the two bolts (Figure 2, Item 5), two flat washers (Figure 2, Item 6), two lockwashers (Figure 2, Item 8), and two nuts (Figure 2, Item 7). Install the wiring (Figure 3, Item 3) through the base (Figure 3, Item 4) and tighten the strain relief (Figure 3, Item 5). Install the wiring (Figure 3, Item 3) to the switch terminals (Figure 3, Item 1) and to the light terminals (Figure 3, Item 2) using the labels from Step (4) of YARDARM BLINKER KEY REMOVAL as a guide. Remove the labels. Install the cover (Figure 2, Item 3) on the base (Figure 2, Item 4) and secure it with the four screws (Figure 2, Item 2). Perform the FOLLOW-ON MAINTENANCE procedure at the end of this work package.
2. 3.
4. 5.
END OF TASK
0163-5
TM 55-1925-273-24&P-2 FOLLOW-ON MAINTENANCE 1. 2. 3. 4. Remove the lock outs and tag outs IAW FM 4-01.502. Set the circuit breaker to ON. Test operate the light by turning it ON and cycling the blinker switch ON and OFF. Return the equipment to the desired readiness condition.
0163
0163-6
TM 55-1925-273-24&P-2 FIELD MAINTENANCE YARDARM BLINKER LIGHT AND KEY REPAIR
0164
INITIAL SETUP: Tools and Special Tools Tool Kit, Electrical Repair (Volume 3, WP 0344, Table 1, Item 26) Materials/Parts Gasket (Volume 3, WP 0292, Figure 44, Item 5) Qty: 1 Personnel Required Watercraft Engineer 88L (2) References FM 4-01.502 References (cont.) Volume 3, WP 0292 Volume 3, WP 0343 Volume 3, WP 0344 Equipment Condition At the 120 V emergency load center distribution panel, set the NAVIGATION LIGHTING PANEL. circuit breaker to OFF. Lock out and tag out IAW FM 4.01-502.
0164-1
TM 55-1925-273-24&P-2
0164
YARDARM LAMP AND/OR LENS REMOVAL 1. 2. 3. Remove the four screws (Figure 1, Item 5), retaining ring (Figure 1, Item 4), and lens (Figure 1, Item 1). Remove and discard gasket (Figure 1, Item 3). Remove the lamp (Figure 1, Item 2) from the lamp socket.
4 3
M1075T73
Figure 1. END OF TASK YARDARM LAMP AND/OR LENS INSTALLATION 1. 2.
Yardarm Light.
Install the lamp (Figure 1, Item 2) in the lamp socket hand tight. Install the gasket (Figure 1, Item 3), lens (Figure 1, Item 1), and retaining ring (Figure 1, Item 4) and secure them with the four screws (Figure 1, Item 5).
END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. 4. Remove the lock outs and tag outs IAW FM 4-01.502. Set the circuit breaker to ON. Perform the functional test by turning the light ON and OFF to ensure proper operation. Return the equipment to the desired readiness condition.
0164-2
TM 55-1925-273-24&P-2 FIELD MAINTENANCE NAVIGATION LIGHTING PANEL REPLACE
0165
INITIAL SETUP: Tools and Special Tools Multimeter (Volume 3, WP 0344, Table 1, Item 15) Tool Kit, Electrical Repair (Volume 3, WP 0344, Table 1, Item 26) Materials/Parts N/A Personnel Required Watercraft Engineer 88L (2) References FM 4-01.502 References (cont.) Volume 3, WP 0293 Volume 3, WP 0344 Equipment Condition Set to OFF the NAVIGATION LIGHTING PANEL circuit breaker on the 120 V emergency load center distribution panel. Lock out and tag out IAW FM 4-01.502.
0165-1
TM 55-1925-273-24&P-2
0165
WARNING
Hydraulic hoses and lines may be under pressure. Relieve pressure by operating the appropriate control valve, if possible. Loosen fittings on hoses and lines slowly. Allow oil to run around threads of fitting, releasing pressure before disconnecting fitting. Releasing pressurized oil suddenly may cause serious injury or death. REMOVAL 1. 2. Loosen the two captive screws (Figure 1, Item 4) securing the clamps (Figure 1, Item 3) on the navigation lighting panel door (Figure 1, Item 2). Rotate the clamps (Figure 1, Item 3) off the lip of the navigation lighting panel door (Figure 1, Item 2) and OPEN the door.
WARNING
Replace or repair components only after the affected circuit has been secured, locked out, and tagged out IAW FM 4-01.502. Performing replacement with the circuit energized may result in injury. 3. Use a multimeter to check for voltage at terminal block 1 (Figure 2, Item 6). If voltage is present, ensure that the proper circuit breaker is set to OFF, locked out, and tagged out IAW FM 4-01.502. If no voltage is present, continue with the procedure. Label and remove the wiring (Figure 2, Item 8) from the input side of the terminal block 1 (Figure 2, Item 6). Loosen the two screws (Figure 2, Item 7) on the strain relief clamps (Figure 2, Item 9) and remove the wiring (Figure 2, Item 8) from the navigation lighting panel (Figure 2, Item 1). Remove the four bolts (Figure 2, Item 5), four flat washers (Figure 2, Item 4), four lockwashers (Figure 2, Item 3), and four nuts (Figure 2, Item 2) from the navigation lighting panel (Figure 2, Item 1). Discard lockwashers. Remove the navigation lighting panel (Figure 2, Item 1) from the bulkhead.
4. 5. 6.
7.
0165-2

1
0165
SECONDARY
OFF
PRIMARY
LIGHTS 3A MAX ALARM POWER PORT STARBOARD MASTHEAD STERN UPPER TOW/ REST. ABILITY TO MANEUVER LOWER TOW AFT TOW /UPPER AFT TOW /LOWER ANCHOR
EMERGENCY REPAIR PLUG IN USE
BLINKER
NUC
TEST
REST. ABILITY TO MANEUVER
NAVIGATION LIGHTING PANEL ELC-1EP-NLP
DIMMER
M1267T73
Figure 1.
Navigation Lighting Panel.
0165-3
0165
1 5 4 3 2 6
8
Figure 2. Internal Components of the Navigation Lighting Panel. END OF TASK
M1268T73
0165-4
TM 55-1925-273-24&P-2
0165
INSTALLATION 1. Install the navigation lighting panel (Figure 2, Item 1) on the bulkhead and secure it with the four bolts (Figure 2, Item 5), four flat washers (Figure 2, Item 4), four lockwashers (Figure 2, Item 3), and four nuts (Figure 2, Item 2). Install the wiring (Figure 2, Item 8) through the strain relief clamps (Figure 2, Item 9) and in the navigation lighting panel (Figure 2, Item 1). Connect the wiring (Figure 2, Item 8) to the input side of terminal block 1 (Figure 2, Item 6) using the labels from Step (4) of REMOVAL as a guide. Remove the labels. Tighten the two screws (Figure 2, Item 7) on the strain relief clamps (Figure 2, Item 9). CLOSE the navigation lighting panel door (Figure 1, Item 2). Install the clamps (Figure 1, Item 3) over the lip of the navigation lighting panel door (Figure 1, Item 2) and secure them with the two captive screws (Figure 1, Item 4).
2. 3. 4. 5.
END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. 4. Remove the lock outs and tag outs IAW FM 4-01.502. Set to ON the NAVIGATION LIGHTING PANEL circuit breaker on the 120 V emergency load center distribution panel. Set to ON all ON/OFF toggle switches on the navigation lighting panel and verify that all navigation lights illuminate. Return the navigation lighting panel to the desired readiness condition.
0165-5/6 blank
TM 55-1925-273-24&P-2 FIELD MAINTENANCE NAVIGATION LIGHTING PANEL REPAIR
0166
INITIAL SETUP: Tools and Special Tools Multimeter (Volume 3, WP 0344, Table 1, Item 15) Tool Kit, Electrical Repair (Volume 3, WP 0344, Table 1, Item 26) Materials/Parts N/A Personnel Required Watercraft Engineer 88L (2) References FM 4-01.502 References (cont.) Volume 3, WP 0293 Volume 3, WP 0344 Equipment Condition Set to OFF the NAVIGATION LIGHTING PANEL. circuit breaker at the 120 V emergency load center distribution panel. Lock out and tag out IAW FM 4-01.502.
0166-1
TM 55-1925-273-24&P-2
0166
NAVIGATION LIGHTING PANEL BULB REMOVAL
WARNING
Replace or repair components only after the affected circuit has been secured, locked out, and tagged out IAW FM 4-01.502. Performing replacement with the circuit energized may result in injury. 1. 2. Remove the locking ring (Figure 1, Item 5) and the indicator lens (Figure 1, Item 4) from the light. Remove the lamp (Figure 1, Item 3) from the socket.
5 4
3 2 1
M1270T73
Figure 1. Navigation Lighting Panel. END OF TASK NAVIGATION LIGHTING PANEL BULB INSTALLATION 1. 2. 3. Install the lamp (Figure 1, Item 3) in the socket finger tight. Install the indicator lens (Figure 1, Item 4) and secure it with the locking ring (Figure 1, Item 5). Perform the FOLLOW-ON MAINTENANCE procedure at the end of this work package.
END OF TASK FUSE REMOVAL 1. 2. Remove the fuse holder cap (Figure 1, Item 2) from the panel. Remove the fuse from the fuse holder cap (Figure 1, Item 2).
END OF TASK
0166-2
TM 55-1925-273-24&P-2 FUSE INSTALLATION 1. 2. 3. Install the fuse in the fuse holder cap (Figure 1, Item 2). Install the fuse holder cap (Figure 1, Item 2) and fuse into the fuse holder (Figure 1, Item 1). Perform the FOLLOW-ON MAINTENANCE procedure at the end of this work package.
0166
END OF TASK LAMP ASSEMBLY REMOVAL
WARNING
Never reuse locking hardware. Reuse of locking hardware such as lockwashers, locking nuts, cotter pins, and lock wire can result in undetected loosening of fastening hardware causing catastrophic component failure resulting in death, injury, or damage to equipment. Ensure that all locking hardware is discarded upon removal and replaced with new. 1. 2. Loosen the two captive screws (Figure 2, Item 6) securing the clamps (Figure 2, Item 5) on the navigation lighting panel door (Figure 2, Item 4). Rotate the clamps (Figure 2, Item 5) off the lip of the navigation lighting panel door (Figure 2, Item 4) and OPEN the door.
WARNING
Replace or repair components only after the affected circuit has been secured, locked out, and tagged out IAW FM 4-01.502. Performing replacement with the circuit energized may result in injury. 3. Use a multimeter to check for voltage at the terminal block 1 (Figure 3, Item 8). If voltage is present, ensure that the proper circuit breaker is set to OFF, locked out, and tagged out IAW FM 4-01.502. If no voltage is present, continue with the procedure. Label and remove the wiring (Figure 3, Item 3) from the lamp assembly (Figure 3, Item 2). Remove the nut (Figure 2, Item 3) from the lens (Figure 2, Item 2). Remove the lens (Figure 2, Item 2) from the lamp assembly (Figure 3, Item 2). Remove the nut (Figure 3, Item 1) from the lamp assembly (Figure 3, Item 2). Remove the lamp assembly (Figure 3, Item 2) from the navigation lighting panel door (Figure 3, Item 7).
4. 5. 6. 7. 8.
0166-3
TM 55-1925-273-24&P-2 LAMP ASSEMBLY REMOVAL - Continued

1
0166
2
SECONDARY OFF PRIMARY LIGHTS 3A MAX POWER PORT STARBOARD MASTHEAD STERN UPPER TOW/ REST. ABILITY TO MANEUVER LOWER TOW AFT TOW /UPPER AFT TOW /LOWER ANCHOR
BLINKER
ALARM
EMERGENCY REPAIR PLUG IN USE
NUC
TEST
NAVIGATION LIGHTING PANEL ELC-1EP-NLP
REST. ABILITY TO MANEUVER
DIMMER
M1271T73
Figure 2. Navigation Lighting Panel.
0166-4
TM 55-1925-273-24&P-2 LAMP ASSEMBLY REMOVAL - Continued

1 2 3 4 5 6
0166
7 8
11
9 10
M1272T73
Figure 3. END OF TASK LAMP ASSEMBLY INSTALLATION 1. 2.
Navigation Lighting Panel (OPEN).
Install the lamp assembly (Figure 3, Item 2) in the navigation lighting panel door (Figure 3, Item 7). Install the nut (Figure 3, Item 1) on the lamp assembly (Figure 3, Item 2). 0166-5
TM 55-1925-273-24&P-2 LAMP ASSEMBLY INSTALLATION - Continued 3. 4. 5. 6. 7. 8. Install the lens (Figure 2, Item 2) on the lamp assembly (Figure 3, Item 2). Install the nut (Figure 2, Item 3) on the lens (Figure 2, Item 2).
0166
Connect the wiring (Figure 3, Item 3) to the lamp assembly (Figure 3, Item 2) using labels from Step (4) of LAMP ASSEMBLY REMOVAL as a guide. Remove the labels. CLOSE the navigation lighting panel door (Figure 2, Item 4). Install the clamps (Figure 2, Item 5) on the lip of the navigation lighting panel door (Figure 2, Item 4) and tighten the two captive screws (Figure 2, Item 6). Perform the FOLLOW-ON MAINTENANCE procedure at the end of this work package.
END OF TASK FUSE ASSEMBLY REMOVAL 1. 2. Loosen the two captive screws (Figure 2, Item 6) securing the clamps (Figure 2, Item 5) on the navigation lighting panel door (Figure 2, Item 4). Rotate the clamps (Figure 2, Item 5) off the lip of the navigation lighting panel door (Figure 2, Item 4) and OPEN the door.
WARNING
Replace or repair components only after the affected circuit has been secured, locked out, and tagged out IAW FM 4-01.502. Performing replacement with the circuit energized may result in injury. 3. Use a multimeter to check for voltage at the terminal block 1 (Figure 3, Item 8). If voltage is present, ensure that the proper circuit breaker is set to OFF, locked out, and tagged out IAW FM 4-01.502. If no voltage is present, continue with the procedure. Label and remove the wiring (Figure 3, Item 6) from the fuse assembly (Figure 3, Item 5). Remove the nut (Figure 3, Item 4) from the fuse assembly (Figure 3, Item 5). Remove the fuse assembly (Figure 3, Item 5) from the navigation lighting panel door (Figure 3, Item 7).
4. 5. 6.
END OF TASK FUSE ASSEMBLY INSTALLATION 1. 2. 3. 4. Install the fuse assembly (Figure 2, Item 5) in the navigation lighting panel door (Figure 3, Item 7) and secure it with the nut (Figure 3, Item 4). Connect the wiring (Figure 3, Item 6) to the fuse assembly (Figure 3, Item 5) using the labels from Step (4) of FUSE ASSEMBLY REMOVAL as a guide. Remove the labels. CLOSE the navigation lighting panel door (Figure 2, Item 4). Install the clamps (Figure 2, Item 5) on the lip of the navigation lighting panel door (Figure 2, Item 4) and tighten the two captive screws (Figure 2, Item 6).
0166-6
TM 55-1925-273-24&P-2 FUSE ASSEMBLY INSTALLATION - Continued 5. Perform the FOLLOW-ON MAINTENANCE procedure at the end of this work package.
0166
END OF TASK TOGGLE SWITCH ASSEMBLY REMOVAL 1. 2. Loosen the two captive screws (Figure 2, Item 6) securing the clamps (Figure 2, Item 5) on the navigation lighting panel door (Figure 2, Item 4). Rotate the clamps (Figure 2, Item 5) off the lip of the navigation lighting panel door (Figure 2, Item 4) and OPEN the door.
WARNING
Replace or repair components only after the affected circuit has been secured, locked out, and tagged out IAW FM 4-01.502. Performing replacement with the circuit energized may result in injury. 3. Use a multimeter to check for voltage at the terminal block 1 (Figure 3, Item 8). If voltage is present, ensure that the proper circuit breaker is set to OFF, locked out, and tagged out IAW FM 4-01.502. If no voltage is present, continue with the procedure. Label and remove the wiring (Figure 3, Item 10) from the toggle switch assembly (Figure 3, Item 11). Remove the nut (Figure 3, Item 9) from the navigation lighting panel door (Figure 3, Item 7). Remove the toggle switch assembly (Figure 2, Item 11) from the navigation lighting panel door (Figure 3, Item 7).
4. 5. 6.
END OF TASK TOGGLE SWITCH ASSEMBLY INSTALLATION 1. 2. 3. 4. 5. Install the toggle switch assembly (Figure 3, Item 11) in the navigation lighting panel door (Figure 3, Item 7) and secure it with the nut (Figure 3, Item 9). Connect the wiring (Figure 3, Item 10) to the toggle switch assembly (Figure 3, Item 11) using the labels from Step (4) of TOGGLE SWITCH ASSEMBLY REMOVAL as a guide. Remove the labels. CLOSE the navigation lighting panel door (Figure 2, Item 2). Install the clamps (Figure 2, Item 3) on the lip of the navigation lighting panel door (Figure 2, Item 2) and tighten the two captive screws (Figure 2, Item 8). Perform the FOLLOW-ON MAINTENANCE procedure at the end of this work package.
END OF TASK
0166-7
TM 55-1925-273-24&P-2
0166
FOLLOW-ON MAINTENANCE 1. 2. 3. 4. Remove the lock outs and tag outs IAW FM 4-01.502. Set to ON the NAVIGATION LIGHTING PANEL. circuit breaker on the 120 V emergency load center distribution panel. Set to ON all ON/OFF toggle switches (Figure 2, Item 1) on the navigation lighting panel door (Figure 2, Item 4) and verify that all navigation lights illuminate. Return the navigation lighting panel to the desired readiness condition.
0166-8
TM 55-1925-273-24&P-2 FIELD MAINTENANCE GENERAL ALARM SYSTEM REPLACE
0167
INITIAL SETUP: Tools and Special Tools Multimeter (Volume 3, WP 0344, Table 1, Item 15) Tool Kit, Electrical Repair (Volume 3, WP 0344, Table 1, Item 26) Materials/Parts N/A Personnel Required Watercraft Engineer 88L (2) References FM 4-01.502 Volume 3, WP 0255 Volume 3, WP 0344 Equipment Condition Set to OFF the GENERAL ALARM BATTERY CHARGER circuit breaker (LT 803 Only), or the GENERAL ALARM D.C. POWER PANEL BATTERY CHARGER circuit breaker (All Other Vessels) at 120 V emergency load center distribution panel. Lock out and tag out IAW FM 4-01.502. Equipment Condition (cont.) Set to OFF the applicable compartment alarm switch at the general alarm feeder distribution panel. Lock out and tag out IAW FM 4-01.502. Set to OFF the ENGINE ROOM EMERGENCY LIGHTS. (PORT). circuit breaker, or the ENGINE ROOM EMERGENCY LIGHTS. (STBD). circuit breaker (LT 803 Only), ENGINE ROOM EMERGENCY LIGHTS, (STBD) & SOUND POWER TELEPHONE HORN circuit breaker (All Other Vessels), or the BOW THRUSTER & AMS No. 1 EMERGENCY LIGHTS. circuit breaker, or the AMS No. 2 EMERGENCY LIGHTS. circuit breaker at 120 V emergency distribution panel No. 1. Lock out and tag out IAW FM 4-01.502.
0167-1
TM 55-1925-273-24&P-2
0167
BELL ASSEMBLY REMOVAL 1. 2. 3. Remove the bolt (Figure 1, Item 1) and flat washer (Figure 1, Item 2) that secure the gong (Figure 1, Item 3) to the bell actuator assembly cover (Figure 1, Item 7). Remove the gong from the bell actuator assembly cover. Remove the six retaining screws (Figure 1, Item 4) that secure the bell actuator assembly cover (Figure 1, Item 7). Remove the bell actuator assembly cover from the bell actuator assembly. Turn the bell actuator assembly cover (Figure 1, Item 7) over to reveal the internal electrical components (Figure 2, Item 2).
WARNING
Replace or repair components only after the affected circuit has been secured, locked out, and tagged out IAW FM 4-01.502. Performing replacement with the circuit energized may result in injury. 4. Use a multimeter to check for voltage at the terminals (Figure 2, Item 1). If voltage is present, ensure that the proper circuit breaker is set to OFF, locked out, and tagged out IAW FM 4-01.502. If no voltage is present, continue with the procedure. Label and remove the wiring from the terminals (Figure 2, Item 1) of the bell actuator assembly cover (Figure 1, Item 7). Label and remove all wiring from the bell actuator assembly. Remove the four bolts (Figure 1, Item 6) and four washers (Figure 1, Item 5) that secure the bell actuator assembly to the bulkhead. Remove the bell actuator assembly from the bulkhead.
5. 6. 7.
0167-2
TM 55-1925-273-24&P-2 BELL ASSEMBLY REMOVAL - Continued

1 2 3
0167
5 7 6
M1084T73
Figure 1.
General Alarm Bell Assembly.
0167-3
TM 55-1925-273-24&P-2 BELL ASSEMBLY REMOVAL - Continued
0167
M1085T73
Figure 2. END OF TASK BELL ASSEMBLY INSTALLATION 1. 2. 3. 4. 5.
Bell Assembly.
Install the bell actuator assembly to the bulkhead, securing it in place with the four bolts (Figure 1, Item 6) and four washers (Figure 1, Item 5). Install the wiring using the labels from Steps (5) and (6) of BELL ASSEMBLY REMOVAL as a guide. Remove the labels. Install the bell actuator assembly cover (Figure 1, Item 7), securing it to the bell actuator assembly with the six retaining screws (Figure 1, Item 4). Install the gong (Figure 1, Item 3) on the bell actuator assembly cover (Figure 1, Item 7), securing it with the bolt (Figure 1, Item 1) and flat washer (Figure 1, Item 2). Perform the FOLLOW-ON MAINTENANCE procedure at the end of this work package.
END OF TASK
0167-4
TM 55-1925-273-24&P-2 CONTACTOR SWITCH ASSEMBLY REMOVAL 1. 2.
0167
Remove the four screws (Figure 3, Item 2) that secure the contactor switch cover (Figure 3, Item 3). Remove the contactor switch cover. Turn the contactor switch cover (Figure 3, Item 3) over to reveal the internal electrical components (Figure 4, Item 2).
WARNING
Replace or repair components only after the affected circuit has been secured, locked out, and tagged out IAW FM 4-01.502. Performing replacement with the circuit energized may result in injury. 3. Use a multimeter to check for voltage at the terminals (Figure 4, Item 1). If voltage is present, ensure that the proper circuit breaker is set to OFF, locked out, and tagged out IAW FM 4-01.502. If no voltage is present, continue with the procedure. Label and remove the wiring from the terminals (Figure 4, Item 1) on the contactor switch. Label and remove all wiring from the contactor switch assembly (Figure 4). Remove the four screws (Figure 3, Item 1) that secure the contactor switch assembly (Figure 4) to the bulkhead. Remove the contactor switch assembly from the bulkhead.
4. 5. 6.
0167-5
TM 55-1925-273-24&P-2 CONTACTOR SWITCH ASSEMBLY REMOVAL - Continued

1
0167
3 1
M1086T73
Figure 3. Contactor Switch Cover.
0167-6
TM 55-1925-273-24&P-2 CONTACTOR SWITCH ASSEMBLY REMOVAL - Continued
0167
1
Figure 4. END OF TASK CONTACTOR SWITCH ASSEMBLY INSTALLATION 1. 2. 3. 4. Contactor Terminal.
M1087T73
Install the contactor switch assembly (Figure 4) to the bulkhead, securing it with the four screws (Figure 3, Item 1). Install the wiring using the labels from Steps (4) and (5) of CONTACTOR SWITCH ASSEMBLY REMOVAL as a guide. Remove the labels. Install the contactor switch cover (Figure 3, Item 3), securing it with the four screws (Figure 3, Item 2). Perform the FOLLOW-ON MAINTENANCE procedure at the end of this work package.
END OF TASK
0167-7
TM 55-1925-273-24&P-2
0167
FOLLOW-ON MAINTENANCE 1. 2. 3. 4. Remove the lock outs and tag outs IAW FM 4-01.502. Set the circuit breakers to ON. Test the general alarm, ensuring proper operation of the general alarm system. Return equipment to the desired readiness condition.
0167-8
TM 55-1925-273-24&P-2 FIELD MAINTENANCE ROTATING BEACON REPLACE
0168
INITIAL SETUP: Tools and Special Tools Multimeter (Volume 3, WP 0344, Table 1, Item 15) Tool Kit, Electrical Repair (Volume 3, WP 0344, Table 1, Item 26) Materials/Parts Gasket (Volume 3, WP 0295, Figure 47, Item 4) Qty: 1 Personnel Required Watercraft Engineer 88L (2) References FM 4-01.502 Volume 3, WP 0295 Volume 3, WP 0343 Volume 3, WP 0344 Equipment Condition Set to OFF the GENERAL ALARM BATTERY CHARGER. circuit breaker (LT 803 Only), or the GENERAL ALARM D.C. POWER PANEL BATTERY CHARGER circuit breaker (All Other Vessels) at 120 V emergency load center distribution panel. Lock out and tag out IAW FM 4-01.502. Equipment Condition (cont.) Set to OFF the applicable compartment alarm swich at the general alarm feeder distribution panel. Lock out and tag out IAW FM 4-01.502. Set to OFF the ENGINE ROOM EMERGENCY LIGHTS (PORT). circuit breaker, or ENGINE ROOM EMERGENCY LIGHTS. (STBD). circuit breaker (LT 803 Only), or the ENGINE ROOM EMERGENCY LIGHTS, (STARBOARD) & SOUND POWER TELEPHONE HORN circuit breaker (All Other Vessels), or BOW THRUSTER & AMS No.1 EMERGENCY LIGHTS. circuit breaker, or AMS No. 2. EMERGENCY LIGHTS. circuit breaker to OFF at 120 V emergency distribution panel No. 1. Lock out and tag out IAW FM 4-01.502.
0168-1
TM 55-1925-273-24&P-2
0168
REMOVAL 1. 2. 3. 4. Loosen the locking screw (Figure 1, Item 11) just enough to allow removal of the clamp ring (Figure 1, Item 8). Remove the clamp ring (Figure 1, Item 8) by sliding it over the bottom of the dome (Figure 1, Item 10). Remove the dome (Figure 1, Item 10) from the base (Figure 1, Item 4). Remove and discard gasket (Figure 1, Item 9).
WARNING
Replace or repair components only after the affected circuit has been secured, locked out, and tagged out IAW FM 4-01.502. Performing replacement with the circuit energized may result in injury. 5. Use a multimeter to check for voltage at the connection points under the wire nuts (Figure 1, Item 13). If voltage is present, ensure that the proper circuit breaker is set to OFF, locked out, and tagged out IAW FM 4-01.502. If no voltage is present, continue with the procedure. Label and disconnect the wiring (Figure 1, Item 6). Remove the four retaining screws (Figure 1, Item 7) that secure the roto-beam assembly (Figure 1, Item 12). Remove it from the base plate (Figure 1, Item 5). Remove the base plate (Figure 1, Item 5) to gain access to the inside of the base (Figure 1, Item 4) of the beacon. Label and remove the wiring (Figure 1, Item 1) inside the base (Figure 1, Item 4). Remove the bolts (Figure 1, Item 3) and washers (Figure 1, Item 2) that secure the base (Figure 1, Item 4) to the mounting bracket.
6. 7. 8. 9. 10.
END OF TASK INSTALLATION 1. 2. 3. 4. 5. 6. 7. Secure the base (Figure 1, Item 4) of the beacon to the mounting bracket with the bolts (Figure 1, Item 3) and washers (Figure 1, Item 2). Install the wiring (Figure 1, Item 1) inside the base (Figure 1, Item 4) of the beacon using the labels from Step (9) of REMOVAL as a guide. Remove the labels. Install the base plate (Figure 1, Item 5). Install the roto-beam assembly (Figure 1, Item 12) securing it with the four retaining screws (Figure 1, Item 7). Install the wiring (Figure 1, Item 6) using the labels from Step (6) of REMOVAL as a guide. Remove the labels. Place a gasket (Figure 1, Item 9) in the recessed ridge on top of the open end of the dome (Figure 1, Item 10). Place the open end of the dome (Figure 1, Item 10) in contact with the base (Figure 1, Item 4), and install the clamp ring (Figure 1, Item 8) over the junctions where the base (Figure 1, Item 4) and dome (Figure 1, Item 10) meet.
0168-2
TM 55-1925-273-24&P-2 INSTALLATION - Continued 8. Tighten the locking screw (Figure 1, Item 11) to secure the clamp ring (Figure 1, Item 8) until the dome (Figure 1, Item 10) is securely fastened in place on the base (Figure 1, Item 4).
0168
1 2 3
4 13 5
6 12 7
8 11 9
10
M1088T73
General Alarm Rotating Beacon.
0168-3
TM 55-1925-273-24&P-2
0168
FOLLOW-ON MAINTENANCE 1. 2. 3. 4. Remove the lock outs and tag outs IAW FM 4-01.502. Set the circuit breakers to ON. Test the general alarm system, ensuring proper operation of the rotating beacon. Return the equipment to the desired readiness condition.
0168-4
TM 55-1925-273-24&P-2 FIELD MAINTENANCE ROTATING BEACON REPAIR
0169
INITIAL SETUP: Tools and Special Tools Multimeter (Volume 3, WP 0344, Table 1, Item 15) Tool Kit, Electrical Repair (Volume 3, WP 0344, Table 1, Item 26) Materials/Parts Gasket (Volume 3, WP 0295, Figure 47, Item 4) Qty: 1 Personnel Required Watercraft Engineer 88L (2) References FM 4-01.502 Volume 3, WP 0295 Volume 3, WP 0344 Equipment Condition Set to OFF the GENERAL ALARM BATTERY CHARGER. (LT 803 Only), or the GENERAL ALARM D.C. POWER PANEL BATTERY CHARGER circuit breaker (All Other Vessels) at 120 V emergency load center distribution panel. Lock out and tag out IAW FM 4-01.502. Equipment Condition (cont.) Set to OFF the applicable compartment alarm switch at the general alarm feeder distribution panel. Lock out and tag out IAW FM 4-01.502. Set to OFF the ENGINE ROOM EMERGENCY LIGHTS. (PORT). circuit breaker, or ENGINE ROOM EMERGENCY LIGHTS. (STBD). circuit breaker (LT 803 Only), or the ENGINE ROOM EMERGENCY LIGHTS, (STBD) & SOUND POWER TELEPHONE HORN circuit breaker (All Other Vessels), or BOW THRUSTER & AMS No. 1. EMERGENCY LIGHTS. circuit breaker, or AMS No. 2. EMERGENCY LIGHTS. circuit breaker at 120 V emergency distribution panel No. 1. Lock out and tag out IAW FM 4-01.502.
0169-1
TM 55-1925-273-24&P-2
0169
DOME REMOVAL 1. 2. 3. 4. Loosen the locking screw (Figure 1, Item 6) just enough to allow removal of the clamp ring (Figure 1, Item 3). Remove the clamp ring (Figure 1, Item 3) by sliding it over the bottom of the dome (Figure 1, Item 5). Remove the dome (Figure 1, Item 5) from the base (Figure 1, Item 2) of the beacon. Remove and discard gasket (Figure 1, Item 4).
END OF TASK DOME INSTALLATION 1. 2. 3. 4. 5. Place a gasket (Figure 1, Item 4) in the recessed ridge on top of the open end of the dome (Figure 1, Item 5). Install the dome (Figure 1, Item 5) by inserting the open end on the base (Figure 1, Item 2). Install the clamp ring (Figure 1, Item 3) over the recessed junctions where the base (Figure 1, Item 2) and dome (Figure 1, Item 5) meet. Tighten the locking screw (Figure 1, Item 6) until the dome (Figure 1, Item 5) is securely fastened in place on the base (Figure 1, Item 2). Perform the FOLLOW-ON MAINTENANCE procedure at the end of this work package.
END OF TASK LAMP REMOVAL 1. Perform the DOME REPLACE REMOVAL procedure in this work package.
WARNING
Replace or repair components only after the affected circuit has been secured, locked out, and tagged out IAW FM 4-01.502. Performing replacement with the circuit energized may result in injury. 2. Use a multimeter to check for voltage at the connection points under the wire nuts (Figure 1, Item 1). If voltage is present, ensure that the proper circuit breaker is set to OFF, and locked out and tagged out IAW FM 4-01.502. If no voltage is present, continue with the procedure. Rotate the lamp (Figure 1, Item 7) 1/4 of a turn counterclockwise, and remove it from the lamp holder.
3.
END OF TASK LAMP INSTALLATION 1. 2. 3. Install the lamp (Figure 1, Item 7) in the lamp holder, and rotate it 1/4 of a turn clockwise to secure it in place. Perform the DOME REPLACE INSTALLATION procedure in this work package. Perform the FOLLOW-ON MAINTENANCE procedure at the end of this work package.
0169-2
0169
7 3
4 6
M1089T73
General Alarm Rotating Beacon.
Remove the lock outs and tag outs IAW FM 4-01.502. Set the circuit breakers to ON. Test the general alarm system, ensuring proper operation of the rotating beacon. Return the equipment to the desired readiness condition.
0169-3/4 blank
TM 55-1925-273-24&P-2 FIELD MAINTENANCE BATTERY CHARGER REPLACE
0170
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 3, WP 0344, Table 1, Item 27) Multimeter (Volume 3, WP 0344, Table 1, Item 15) Materials/Parts N/A Personnel Required Watercraft Engineer 88L (3) References FM 4-01.502 References (cont.) TM 55-1925-273-10 Volume 3, WP 0296 Volume 3, WP 0344 Equipment Condition Negative battery cable for the applicable battery disconnected and insulated from the negative battery terminal IAW FM 4-01.502.
REMOVAL 1. Set to OFF the specific breaker for the applicable battery charger as detailed in Table 1. Lock out and tag out IAW FM 4-01.502. Table 1. Battery Charger Lock Out and Tag Out Guide. Battery Charger ROWPU EDG Specific Breaker ROWPU BATTERY CHARGER. EMERGENCY DIESEL GENERATOR SET BATTERY CHARGER. SSDG No. 1 BATTERY CHARGER. GMDSS BATTERY CHARGER. (LT 803 Only) GMDSS DC POWER BATTERY CHARGER. (All Other Vessels) Distribution Panel 120 V Distribution Panel No. 4 120 V Emergency Load Center Distribution Panel 120 V Emergency Distribution Panel No. 1 120 V Elex Distribution Panel
SSDG No. 1 GMDSS
0170-1
TM 55-1925-273-24&P-2 REMOVAL - Continued 2. Remove the screw (Figure 1, Item 3) and OPEN the battery charger door (Figure 1, Item 1).
1
0170
M1273T73
Figure 1.
Battery Charger.
WARNING
Replace or repair components only after the affected circuit has been secured, locked out, and tagged out IAW FM 4-01.502. Performing replacement with the circuit energized may result in injury. 3. Use a multimeter to check for available Alternating Current (AC) voltage at the fuse(s) (Figure 2, Item 3). If AC voltage is present, ensure that the proper circuit breaker(s) have been secured, locked out, and tagged out IAW FM 4-01.502. If no voltage is present, continue with the procedure. Use a multimeter to check for Direct Current (DC) voltage at the DC fuse(s) (Figure 2, Item 2). If DC voltage is present, ensure that the positive and negative battery cables are removed from the applicable battery bank and are locked out and tagged out IAW FM 4-01.502. If no DC voltage is present, continue with the procedure. Label and remove the wiring (Figure 2, Item 1) from the DC fuse terminals (Figure 2, Item 7). Label and remove the wiring (Figure 2, Item 5) from the AC terminals (Figure 2, Item 4). Remove the wiring (Figure 2, Items 1 and 5) from the battery charger (Figure 2, Item 6).
4.
5. 6. 7.
0170-2
0170
WARNING
Heavy loads can crush. Do not allow any body parts to come under the load or between the load and a stationary object. Failure to comply with this warning can result in serious injury or death. 8. 9. While two crewmembers hold the battery charger (Figure 2, Item 6), have a third crewmember remove the two bolts (Figure 1, Item 2) that secure the battery charger to the bulkhead. Remove the battery charger (Figure 2, Item 6) from the bulkhead.
7 1 2 3 4 5
6
M1274T73
0170-3
0170
WARNING
Heavy loads can crush. Do not allow any body parts to come under the load or between the load and a stationary object. Failure to comply with this warning can result in serious injury or death. 1. 2. 3. 4. 5. Using two crewmembers, position the battery charger (Figure 2, Item 6) on the bulkhead while a third crewmember installs the two bolts (Figure 1, Item 2) that secure the battery charger to the bulkhead. Install the wiring (Figure 2, Items 1 and 5) in the battery charger (Figure 2, Item 6). Connect the wiring (Figure 2, Item 5) to the AC terminals (Figure 2, Item 4) using the labels from Step (6) of REMOVAL as a guide. Remove the labels. Connect the wiring (Figure 2, Item 1) to the DC fuse terminals (Figure 2, Item 7) using the labels from Step (5) of REMOVAL as a guide. Remove the labels. CLOSE the battery charger door (Figure 1, Item 1) and secure it with the screw (Figure 1, Item 3).
END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. 4. 5. Remove the lock outs and tag outs IAW FM 4-01.502 from the battery cables. Connect the battery cables to the battery bank IAW TM 55-1925-273-10. Remove the remaining lock outs and tag outs IAW FM 4-01.502. Set the applicable circuit breaker to ON and check the battery charger for proper operation. Return the battery charger to the desired readiness condition.
0170-4
TM 55-1925-273-24&P-2 FIELD MAINTENANCE BATTERY CHARGER REPAIR
0171
INITIAL SETUP: Tools and Special Tools Multimeter (Volume 3, WP 0344, Table 1, Item 15) Tool Kit, Electrical Repair (Volume 3, WP 0344, Table 1, Item 26) Materials/Parts N/A Personnel Required Watercraft Engineer 88L (2) References FM 4-01.502 References (cont.) TC 55-509-1 TM 55-1925-273-10 WP 0149 Volume 3, WP 0296 Volume 3, WP 0343 Volume 3, WP 0344 Equipment Condition Set to OFF the applicable battery charger circuit breaker. Lock out and tag out IAW FM 4-01.502. Disconnect, lock out, and tag out IAW FM 4-01.502 the negative battery cable for the affected battery bank.
WIRING (TYPICAL) REPAIR Proper repair of wiring consists of replacement of the damaged wiring. When an electrical casualty requires expedient repairs, the repair may be made by splicing. Splicing is authorized for repair of damaged cables and wiring harnesses if most of the wiring is in good useable electrical condition. The cable or wiring harness must be replaced in its entirety at the most opportune time. For proper splicing methods, refer to TC 55-509-1. END OF TASK
0171-1
TM 55-1925-273-24&P-2
0171
WIRING (TYPICAL) DISASSEMBLY
WARNING
Replace or repair components only after the affected circuit has been secured, locked out, and tagged out IAW FM 4-01.502. Performing replacement with the circuit energized may result in injury. 1. Use a multimeter to check for voltage at the wire terminals (Figure 1, Item 4). If voltage is present, ensure that the proper circuit breakers are set to OFF, locked out, and tagged out IAW FM 4-01.502. If no voltage is present, continue with the procedure. Remove any covers or interference that restrict access to the wires being removed. Label all wiring to be removed, and make a sketch of the work area to permit proper assembly. Remove the nuts (Figure 1, Item 2) that secure the wire terminals (Figure 1, Item 4) to the post (Figure 1, Item 1), and remove the wire (Figure 1, Item 3). Follow the wire (Figure 1, Item 3) to the opposite end, freeing it from the vessel's structure as required. Remove the nuts (Figure 1, Item 2) that secure the wire terminals (Figure 1, Item 4) to the post (Figure 1, Item 1), and remove the wire (Figure 1, Item 3) at the opposite end. Perform Steps (1) through (6) for any other wires that require removal.
2. 3. 4. 5. 6. 7.
1 2 4 3
M1275T73
0171-2
TM 55-1925-273-24&P-2
0171
WIRING (TYPICAL) ASSEMBLY 1. 2. 3. 4. 5. 6. Determine the wires to be connected by referring to the sketches and labels from Step (3) of WIRING (TYPICAL) DISASSEMBLY as guides. Install the wires (Figure 1, Item 3) along the same path as the old wires, and secure them in the same manner as the old wiring assembly. Install the nuts (Figure 1, Item 2) that secure the wire terminals (Figure 1, Item 4) to the post (Figure 1, Item 1) at both ends of the wire. Remove any remaining labels. Install any covering or interference removed during the WIRING (TYPICAL) DISASSEMBLY procedure. Perform the FOLLOW-ON MAINTENANCE procedure at the end of this work package.
END OF TASK AC FUSE REMOVAL 1. Loosen the captive screw (Figure 2, Item 1) and OPEN the battery charger door (Figure 2, Item 2).
WARNING
Replace or repair components only after the affected circuit has been secured, locked out, and tagged out IAW FM 4-01.502. Performing replacement with the circuit energized may result in injury. 2. Use a multimeter to check for voltage at the Alternating Current (AC) fuses (Figure 2, Item 3). If voltage is present, ensure that the proper circuit breakers are set to OFF, locked out, and tagged out IAW FM 4-01.502. If no voltage is present, continue with the procedure. Remove the AC fuses (Figure 2, Item 3) using a fuse puller.
3.
END OF TASK AC FUSE INSTALLATION 1. 2. 3. Install the AC fuses (Figure 2, Item 3) using a fuse puller. CLOSE the battery charger door (Figure 2, Item 2) and secure it with the captive screw (Figure 2, Item 1). Perform the FOLLOW-ON MAINTENANCE at the end of this work package.
0171-3
TM 55-1925-273-24&P-2 AC FUSE INSTALLATION - Continued
0171
1 2
7 6
M1276T73
Battery Charger.
0171-4
TM 55-1925-273-24&P-2 DC FUSE REMOVAL 1. Loosen the captive screw (Figure 2, Item 1) and OPEN the battery charger door (Figure 2, Item 2).
0171
WARNING
Replace or repair components only after the affected circuit has been secured, locked out, and tagged out IAW FM 4-01.502. Performing replacement with the circuit energized may result in injury. 2. Use a multimeter to check for voltage at the AC fuses (Figure 2, Item 3). If voltage is present, ensure that the proper circuit breakers are set to OFF, locked out, and tagged out IAW FM 4-01.502. If no voltage is present, continue with the procedure. Remove the nut (Figure 2, Item 4) and flat washer (Figure 2, Item 5), and remove the wire terminal (Figure 2, Item 7) from the post (Figure 2, Item 6). Remove the Direct Current (DC) fuse (Figure 2, Item 8) from the post (Figure 2, Item 6).
3. 4.
END OF TASK DC FUSE INSTALLATION 1. 2. 3. Install the DC fuse (Figure 2, Item 8) and the wire terminal (Figure 2, Item 7) on the post (Figure 2, Item 6) and secure them with the nut (Figure 2, Item 4) and flat washer (Figure 2, Item 5). CLOSE the battery charger door (Figure 2, Item 2) and secure it with the captive screw (Figure 2, Item 1). Perform the FOLLOW-ON MAINTENANCE procedure in this work package.
END OF TASK AMMETER REMOVAL
WARNING
Replace or repair components only after the affected circuit has been secured, locked out, and tagged out IAW FM 4-01.502. Performing replacement with the circuit energized may result in injury. Take great care when working around energized electrical equipment. Contact between unprotected body parts and electrical conductors can cause serious injury or death. Do not wear jewelry or other conductive items while servicing energized electrical equipment. Failure to comply with these precautions can cause serious injury or death. 1. Open the front panel of the battery charger by loosening the screw (Figure 3, Item 1).
0171-5
TM 55-1925-273-24&P-2 AMMETER REMOVAL - Continued
0171
M1277T73
Figure 3. Battery Charger Front Cover. 2. Use a multimeter to ensure that no voltage is available to the ammeter's wiring (Figure 4, Item 10). If voltage is noted, ensure that the power supply is locked out and tagged out IAW FM 4-01.502. If no voltage is noted, continue with the procedure. Label and disconnect the electrical leads (Figure 4, Item 10) from the ammeter (Figure 4, Item 4). Remove the two machine screws (Figure 4, Item 1), lockwashers (Figure 4, Item 2), and nuts (Figure 4, Item 3). Discard lockwashers. Remove the ammeter (Figure 4, Item 4) from the front cover.
3. 4. 5.
END OF TASK AMMETER INSTALLATION 1. 2. Position the ammeter (Figure 4, Item 4) in the cover and secure it with the two screws (Figure 4, Item 1), lockwashers (Figure 4, Item 2), and nuts (Figure 4, Item 3). Connect the electrical leads (Figure 4, Item 10) to the ammeter (Figure 4, Item 4) and remove the labels.
0171-6
TM 55-1925-273-24&P-2 AMMETER INSTALLATION - Continued

1 2 3
0171
10
7, 8, 9
M1278T73
Figure 4. 3. 4.
Ammeter and Circuit Breaker.
Close the front panel and secure with the screw (Figure 3, Item 1). Perform the FOLLOW-ON MAINTENANCE procedure at the end of this work package.
END OF TASK
0171-7
TM 55-1925-273-24&P-2
0171
CIRCUIT BREAKER REMOVAL
WARNING
Replace or repair components only after the affected circuit has been secured, locked out, and tagged out IAW FM 4-01.502. Performing replacement with the circuit energized may result in injury. 1. 2. Open the front panel of the battery charger by loosening the captive screw (Figure 3, Item 1). Use a multimeter to ensure that no voltage is available to the circuit breaker (Figure 4, Item 5). If voltage is noted, ensure that the power supply is locked out and tagged out IAW FM 4-01.502. If no voltage is noted, continue with the procedure. Label and disconnect the electrical leads (Figure 4, Item 6) to the circuit breaker (Figure 4, Item 5). Remove the two machine screws (Figure 4, Item 7), nuts (Figure 4, Item 8), and lockwashers (Figure 4, Item 9). Discard lockwashers. Remove the circuit breaker (Figure 4, Item 5) from the front cover.
3. 4. 5.
END OF TASK CIRCUIT BREAKER INSTALLATION 1. 2. 3. 4. Position the circuit breaker (Figure 4, Item 5) in the cover and secure it with the two screws (Figure 4, Item 7), nuts (Figure 4, Item 8), and lockwashers (Figure 4, Item 9). Connect the electrical leads (Figure 4, Item 6) to the circuit breaker (Figure 4, Item 5) and remove the labels. Close the front panel and secure it with the captive screw (Figure 3, Item 1). Perform the FOLLOW-ON MAINTENANCE at the end of this work package.
END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. 4. 5. Connect the negative cable on the battery bank. Remove the lock outs and tag outs IAW FM 4-01.502. Set the battery charger circuit breaker to ON. Verify that the battery charger functions correctly. Return the equipment to the desired readiness condition.
0171-8
TM 55-1925-273-24&P-2 FIELD MAINTENANCE BATTERY BANK SERVICE
0172
INITIAL SETUP: Tools and Special Tools Apron, Utility (Volume 3, WP 0344, Table 1, Item 1) Faceshield, Industrial (Volume 3, WP 0344, Table 1, Item 5) Gloves, Chemical and Oil Protective (Volume 3, WP 0344, Table 1, Item 8) Goggles, Industrial (Volume 3, WP 0344, Table 1, Item 10) Tool Kit, Electrical Repair (Volume 3, WP 0344, Table 1, Item 26) Materials/Parts Distilled Water, Technical (Volume 3, WP 0343, Table 1, Item 61) Petrolatum, Technical (Volume 3, WP 0343, Table 1, Item 126) Rag, Wiping (Volume 3, WP 0343, Table 1, Item 132) Sodium Bicarbonate, Technical (Volume 3, WP 0343, Table 1, Item 150) Personnel Required Watercraft Engineer 88L (2) References FM 4-01.502 WP 0149 Volume 3, WP 0297 Volume 3, WP 0343 Volume 3, WP 0344 Equipment Condition Set to OFF the applicable battery charger circuit breaker. Lock out and tag out IAW FM 4-01.502.
0172-1
TM 55-1925-273-24&P-2
0172
SERVICE
WARNING
NOTE
Whenever working with batteries, the negative cable must be disconnected first, the positive cable next, and the interconnecting cable (if installed) last. When connecting the batteries, the interconnecting cable (if installed) must be connected first, the positive cable next, and the negative cable last. 1. 2. 3. Label and remove the negative battery cable (Figure 1, Item 5) from the battery post connectors (Figure 1, Item 1). Label and remove the positive battery cable (Figure 1, Item 2) from the battery post connectors (Figure 1, Item 1). Label and remove the interconnecting cable (Figure 1, Item 3) from the battery post connectors (Figure 1, Item 1).
CAUTION
Do not apply any prying or twisting force to the battery posts. Doing so can cause the posts to break internally, permanently disabling the battery. If the battery post connectors are difficult to remove from the battery posts, spread the battery post connectors to loosen them before attempting to remove them from the batteries. 4. Remove the battery post connectors (Figure 1, Item 1) from the batteries (Figure 1, Item 7) taking care not to apply any prying or twisting force to the battery posts (Figure 1, Item 4). If the battery post connectors are difficult to remove from the battery posts, spread the battery post connectors to loosen them before attempting to remove them from the batteries.
0172-2
TM 55-1925-273-24&P-2 SERVICE - Continued
0172
WARNING
Removing components by means of wire brushing produces flying particles. These particles can cause serious injury to personnel. Wear protective faceshield, gloves, and long sleeves at all times during wire brushing operations. Failure to comply with this warning can result in serious injury to personnel. 5. 6. Use a wire brush to remove all deposits from the battery posts (Figure 1, Item 4), battery post connectors (Figure 1, Item 1), and battery cable ends (Figure 1, Items 2, 3, and 5). Inspect the battery posts (Figure 1, Item 4), battery post connectors (Figure 1, Item 1), and battery cable ends (Figure 1, Items 2, 3, and 5) for damage. Replace any battery with posts damaged to the extent that the battery post connectors will not fit securely, and replace damaged battery post connectors and/or battery cables. Prepare a 50/50 mix of technical sodium bicarbonate and water. Scrub the battery tops, battery cable ends (Figure 1, Items 2, 3, and 5) and the battery post connectors (Figure 1, Item 1) with the mixture. Rinse the cleaned areas with fresh water, and remove any water and debris with clean wiping rags. Remove the battery caps (Figure 1, Item 6) and check the electrolyte level in each cell. The level should be at the bottom of the split ring. If any cells are low, add technical distilled water to bring the cells to the proper level. Install the battery caps (Figure 1, Item 6). Install the battery terminal connectors (Figure 1, Item 1) onto the battery posts (Figure 1, Item 4) and tighten them snugly. Install the interconnecting cables (Figure 1, Item 3) on both batteries (Figure 1, Item 7). Install the positive cables (Figure 1, Item 2) on both batteries (Figure 1, Item 7). Install the negative cables (Figure 1, Item 5) on both batteries (Figure 1, Item 7). Apply a thin coating of technical petrolatum to the exposed portions of the battery posts (Figure 1, Item 4), battery terminal connectors (Figure 1, Item 1), and battery cable ends (Figure 1, Items 2, 3, and 5).
7. 8. 9.
10. 11. 12. 13. 14. 15.
0172-3
0172
1 3 2
1 4 1
7
M1090T73
Battery Bank Power Supply System.
Remove the lock outs and tag outs IAW FM 4-01.502. Test the battery and battery charger (WP 0149). Return the equipment to the desired readiness condition.
0172-4
TM 55-1925-273-24&P-2 FIELD MAINTENANCE BATTERY BANK REPLACE
0173
INITIAL SETUP: Tools and Special Tools Apron, Utility (Volume 3, WP 0344, Table 1, Item 1) Faceshield, Industrial (Volume 3, WP 0344, Table 1, Item 5) Gloves, Chemical and Oil Protective (Volume 3, WP 0344, Table 1, Item 8) Goggles, Industrial (Volume 3, WP 0344, Table 1, Item 10) Tool Kit, Electrical Repair (Volume 3, WP 0344, Table 1, Item 26) Materials/Parts Battery, Storage; 6 V (Volume 3, WP 0343, Table 1, Item 9) Personnel Required Watercraft Engineer 88L (2) References FM 4-01.502 Volume 3, WP 0297 Volume 3, WP 0343 Volume 3, WP 0344 Equipment Condition Set to OFF the applicable circuit breaker. Lock out and tag out IAW FM 4-01.502.
0173-1
TM 55-1925-273-24&P-2
0173
REMOVAL
WARNING
Batteries produce hydrogen gas. This gas is explosive. Keep work area free of sparks, open flame, and excessive heat. Take care to prevent conductive metal tools from arcing between positive and negative terminals. Failure to comply with these precautions can result in serious injury or death. Batteries are filled with a sulfuric acid-based electrolyte. This electrolyte is extremely corrosive to human tissue and many other materials. Chemical protective nitrile gloves, chemical protective goggles, faceshield, and a chemical protective apron must be worn at all times when batteries are being serviced. If electrolyte comes in contact with clothing or other material, wash the affected area with large volumes of fresh water. If electrolyte comes in contact with the skin or eyes, flush the area with large volumes of water. Continue flushing the affected areas until medical assistance arrives. Failure to comply with these precautions can result in serious injury or death. 1. 2. 3. Remove the hex nut and flat washer (Figure 1, Item 3) from the J-bolt (Figure 1, Item 4). Remove the battery hold down (Figure 1, Item 1). Remove the wood spacer bar (Figure 1, Item 2).
2 3
M1091T73
Figure 1. 4. 5.
Battery.
Label and remove the negative battery cable (Figure 2, Item 2) from the battery bank. Label and remove the positive battery cable (Figure 2, Item 4) from the battery bank.
0173-2
TM 55-1925-273-24&P-2 REMOVAL - Continued 6. Label and remove the connector battery cable (Figure 2, Item 3) from the battery bank.
0173
CAUTION
Do not apply any prying or twisting force to the battery posts. Doing so can cause the posts to break internally, permanently disabling the battery. If the battery post connectors are difficult to remove from the battery posts, spread the battery post connectors to loosen them before attempting to remove them from the batteries. 7. Remove the battery post connectors (Figure 2, Item 1) from the batteries (Figure 2, Item 6), taking care not to apply any prying or twisting force to the battery posts (Figure 2, Item 5). If the battery post connectors are difficult to remove from the battery posts, spread the battery post connectors to loosen them before attempting to remove them from the batteries. Remove the batteries (Figure 2, Item 6) from the compartment.
1 3 2 4
8.
1 5 1 5
6
M1092T73
Battery Power Supply System.
0173-3
0173
WARNING
CAUTION
Ensure that there are no foreign objects, such as loose nuts, on the bottom of the battery box. The battery could be damaged if placed on foreign objects. 1. 2. 3. 4. 5. 6. 7. Place the batteries (Figure 2, Item 6) into the battery compartment. Install the battery post connectors (Figure 2, Item 1) on the battery posts (Figure 2, Item 5). Install the connector battery cable (Figure 2, Item 3) on the batteries (Figure 2, Item 6) using the labels from Step (6) of REMOVAL as a guide. Remove the labels. Install the positive battery cable (Figure 2, Item 4) on the batteries (Figure 2, Item 6) using the labels from Step (5) of REMOVAL as a guide. Remove the labels. Install the negative battery cable (Figure 2, Item 2) on the batteries (Figure 2, Item 6) using the labels from Step (4) of REMOVAL as a guide. Remove the labels. Install the wood spacer (Figure 1, Item 2). Install the battery hold down (Figure 1, Item 1) and secure it with the J-bolts (Figure 1, Item 4), washers, and nuts (Figure 1, Item 3).
END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. Remove the lock outs and tag outs IAW FM 4-01.502. Set to ON the applicable circuit breaker and test the battery charger and battery. Return the equipment to the desired readiness condition.
0173-4
TM 55-1925-273-24&P-2 FIELD MAINTENANCE SIGNAL HORN REPLACE
0174
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 3, WP 0344, Table 1, Item 27) Multimeter (Volume 3, WP 0344, Table 1, Item 15) Materials/Parts N/A Personnel Required Watercraft Engineer 88L (2) References FM 4-01.502 References (cont.) Volume 3, WP 0298 Volume 3, WP 0344 Equipment Condition At 120 V elex distribution panel, set the FOG HORN. circuit breaker to OFF. Lock out and tag out IAW FM 4-01.502.
0174-1
TM 55-1925-273-24&P-2
0174
WARNING
Never reuse locking hardware. Reuse of locking hardware such as lockwashers, locking nuts, cotter pins, and lock wire can result in undetected loosening of fastening hardware causing catastrophic component failure resulting in death, injury, or damage to equipment. Ensure that all locking hardware is discarded upon removal and replaced with new. HORN REMOVAL 1. 2. Remove the housing top cover (Figure 1, Item 1) by removing the capscrews (Figure 1, Item 2), washers, (Figure 1, Item 3), and self-locking nuts (Figure 1, Item 4). Discard self-locking nuts. Loosen the gland nut (Figure 1, Item 6) to relieve tension on the wiring (Figure 1, Item 5).
WARNING
Replace or repair components only after the affected circuit has been secured, locked out, and tagged out IAW FM 4-01.502. Performing replacement with the circuit energized may result in injury. 3. Use a multimeter to check for the presence of voltage at the wiring (Figure 1, Item 5). If voltage is present, verify that the correct circuit breaker is set to OFF, locked out, and tagged out IAW FM 4-01.502. If no voltage is present, continue with the procedure. Label and remove the wiring (Figure 1, Item 5). Remove the two bolts (Figure 1, Item 10), two lockwashers (Figure 1, Item 9), and two nuts (Figure 1, Item 8) that secure the horn assembly (Figure 1, Item 7). Remove the horn assembly (Figure 1, Item 7) from its foundation.
4. 5. 6.
0174-2
TM 55-1925-273-24&P-2 HORN REMOVAL - Continued
0174
5 2 3
9 10 8
Figure 1. END OF TASK HORN INSTALLATION 1. 2. 3. 4. Install the horn assembly (Figure 1, Item 7) and secure it with the two bolts (Figure 1, Item 10), two lockwashers (Figure 1, Item 9), and two nuts (Figure 1, Item 8). Connect the wiring (Figure 1, Item 5) using the labels from Step (4) of HORN REMOVAL as a guide. Remove the labels. Install the housing top cover (Figure 1, Item 1) and secure it with the capscrews (Figure 1, Item 2), washers (Figure 1, Item 3), and self-locking nuts (Figure 1, Item 4). Perform the FOLLOW-ON MAINTENANCE at the end of this work package. Signal Horn.
7
M1093T73
END OF TASK
0174-3
TM 55-1925-273-24&P-2 POWER SUPPLY REMOVAL 1.
0174
Remove the four bolts (Figure 2, Item 1) that secure the cover (Figure 2, Item 4) to the power supply. Remove the cover.
WARNING
Replace or repair components only after the affected circuit has been secured, locked out, and tagged out IAW FM 4-01.502. Performing replacement with the circuit energized may result in injury. 2. Use a multimeter to check for the presence of voltage at the terminal board (Figure 2, Item 3). If voltage is present, verify that the correct circuit breaker is set to OFF, locked out, and tagged out IAW FM 4-01.502. If no voltage is present, continue with the procedure. Label and remove the wiring from the terminal board (Figure 2, Item 3). Remove the four screws (Figure 2, Item 2) and remove the power supply from the bulkhead.
1 2
3. 4.
A.C.
SHIPS WHISTLE POWER SUPPLY 120/240 V. 50/60 HZ. INPUT 24 V. DC OUTPUT WARNING CONTROL VOLTAGE MAY BE PRESENT INSIDE ENCLOSURE - DISCONNECT POWER BEFORE SERVICING
+ A.C.
L N EE + -
M1094T73
Signal Horn Power Supply.
0174-4
TM 55-1925-273-24&P-2 POWER SUPPLY INSTALLATION 1. 2. 3. 4. Install the power supply on the bulkhead and secure it with the four screws (Figure 2, Item 2).
0174
Install the wiring at the terminal board (Figure 2, Item 3) using the labels from Step (3) of POWER SUPPLY REMOVAL as a guide. Remove the labels. Install the cover (Figure 2, Item 4) and secure it with the screws (Figure 2, Item 1). Perform the FOLLOW-ON MAINTENANCE at the end of this work package.
END OF TASK OSCILLATOR REMOVAL 1. Remove the four screws (Figure 3, Item 2) that secure the cover (Figure 3, Item 1) to the oscillator. Remove the cover.
WARNING
Replace or repair components only after the affected circuit has been secured, locked out, and tagged out IAW FM 4-01.502. Performing replacement with the circuit energized may result in injury. 2. Use a multimeter to check for the presence of voltage at the terminal board (Figure 3, Item 3). If voltage is present, verify that the correct circuit breaker is set to OFF, locked out, and tagged out IAW FM 4-01.502. If no voltage is present, continue with the procedure. Label and remove the wiring from the terminal board (Figure 3, Item 3). Remove the four screws (Figure 3, Item 4) and remove the oscillator.
3. 4.
0174-5
TM 55-1925-273-24&P-2 OSCILLATOR REMOVAL - Continued

1 2 3 4
0174
BL
BL
BK
PT128-002 OSCILLATOR BOARD
WH
WH
BK
WH WH
BK
Figure 3. END OF TASK OSCILLATOR INSTALLATION 1. 2. 3. 4.
M1095T73
Oscillator.
Install the oscillator and secure it with four screws (Figure 3, Item 4). Install the wiring to the terminal board (Figure 3, Item 3) using the labels from Step (3) of OSCILLATOR REMOVAL as a guide. Remove the labels. Install the cover (Figure 3, Item 1) and secure it with the four screws (Figure 3, Item 2). Perform the FOLLOW-ON MAINTENANCE at the end of this work package.
END OF TASK
0174-6
TM 55-1925-273-24&P-2
0174
TIMER REMOVAL 1. Remove the four screws (Figure 4, Item 1) that secure the cover (Figure 4, Item 4) to the timer.
WARNING
Replace or repair components only after the affected circuit has been secured, locked out, and tagged out IAW FM 4-01.502. Performing replacement with the circuit energized may result in injury. 2. Use a multimeter to check for the presence of voltage at the terminal board (Figure 4, Item 3). If voltage is present, verify that the correct circuit breaker is set to OFF, locked out, and tagged out IAW FM 4-01.502. If no voltage is present, continue with the procedure. Label and disconnect the wiring from the terminal board (Figure 4, Item 3). Remove the four screws (Figure 4, Item 2) and remove the timer from the bulkhead.
1 2
3. 4.
WARNING
CONTROL VOLTAGE MAY BE PRESENT INSIDE ENCLOSURE - DISCONNECT POWER BEFORE SERVICING
+
E E N L
M1096T73
Timer.
0174-7
TM 55-1925-273-24&P-2
0174
TIMER INSTALLATION 1. 2. 3. 4. Install the timer on the bulkhead and secure it with the four screws (Figure 4, Item 2). Install the wiring to the terminal board (Figure 4, Item 3) using the labels from Step (3) of TIMER REMOVAL as a guide. Remove the labels. Install the cover (Figure 4, Item 4) and secure it with the four screws (Figure 4, Item 1). Perform the FOLLOW-ON MAINTENANCE at the end of this work package.
END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. 4. Remove the lock outs and tag outs IAW FM 4-01.502. Set the circuit breaker to ON. Test operate the signal horn to check it for proper operation. Return the equipment to the desired readiness condition.
0174-8
TM 55-1925-273-24&P-2 FIELD MAINTENANCE ALARM SYSTEM, ARMS STORAGE AND RADIO ROOM REPAIR
0175
INITIAL SETUP: Tools and Special Tools Multimeter (Volume 3, WP 0344, Table 1, Item 15) Tool Kit, Electrical Repair (Volume 3, WP 0344, Table 1, Item 26) Materials/Parts N/A Personnel Required Watercraft Engineer 88L (2) References FM 4-01.502 References (cont.) Volume 3, WP 0299 Volume 3, WP 0343 Volume 3, WP 0344 Equipment Condition Set to OFF the ALARM SWITCHBOARD. (HIGH TEMPERATURE & SPRINKLER). circuit breaker at 120 V main deck 01 & 02 emergency lighting panel No. 1. Lock out and tag out IAW FM 4-01.502.
0175-1
TM 55-1925-273-24&P-2
0175
ALARM INDICATOR BULBS (SQUARE LENS) REMOVAL 1. 2. Remove the square protective lens cover (Figure 1, Item 1). Remove the lamp (Figure 1, Item 3).
END OF TASK ALARM INDICATOR BULBS (SQUARE LENS) INSTALLATION 1. 2. 3. Install the lamp (Figure 1, Item 3) finger tight. Install the protective lens cover (Figure 1, Item 1). Perform the FOLLOW-ON MAINTENANCE procedure at the end of this work package.
END OF TASK FUSE REMOVAL 1. 2. Remove the fuse holder (Figure 1, Item 5) from the panel. Remove the fuse (Figure 1, Item 4) from the fuse holder (Figure 1, Item 5).
END OF TASK FUSE INSTALLATION 1. 2. 3. Install the fuse (Figure 1, Item 4) in the fuse holder (Figure 1, Item 5). Install the fuse holder (Figure 1, Item 5) in the panel. Perform the FOLLOW-ON MAINTENANCE procedure at the end of this work package.
0175-2
TM 55-1925-273-24&P-2 FUSE INSTALLATION - Continued

1
ALARM SWBD EL1-EL-K
0175
2 1
ARMS CONT RM WTR LVL
ARMS CONT RM HI TEMP
RADIO RM DOOR OPEN
FAN RM DOOR OPEN
FUSES A/C D/C
LA
RM A C
P OW E R
PUSH ON/OFF
LA
R M TE
HOLD FOR 3 SECONDS TO TEST
T
S
7 6
M1077T73
Alarm Panel Components (Exterior View).
0175-3
TM 55-1925-273-24&P-2 ALARM PANEL SWITCH/INDICATOR BULB (ROUND LENS) REMOVAL 1. 2. Remove the protective lens cover (Figure 1, Item 7). Remove the lamp (Figure 1, Item 6) from the panel.
0175
END OF TASK ALARM PANEL SWITCH/INDICATOR BULB (ROUND LENS) INSTALLATION 1. 2. 3. Install the lamp (Figure 1, Item 6) finger tight. Install the protective lens cover (Figure 1, Item 7) on the panel. Perform the FOLLOW-ON MAINTENANCE procedure at the end of this work package.
END OF TASK ALARM INDICATOR LAMP ASSEMBLY (SQUARE LENS) REMOVAL 1. 2. Perform the ALARM INDICATOR BULBS (SQUARE LENS) REMOVAL procedure in this work package. Loosen the two clamping screws (Figure 1, Item 2) and open the front panel.
WARNING
Replace or repair components only after the affected circuit has been secured, locked out, and tagged out IAW FM 4-01.502. Performing replacement with the circuit energized may result in injury. 3. Use a multimeter to check for voltage at the fuse holders (Figure 2, Item 7). If voltage is present, ensure that the proper circuit breaker is set to OFF, locked out, and tagged out IAW FM 4-01.502. If no voltage is present, continue with the procedure. Label and remove the wiring (Figure 2, Item 10) from the lamp assembly (Figure 2, Item 1) at the terminals (Figure 2, Item 2). Remove the retaining screws (Figure 2, Item 3) that secure the lamp assembly (Figure 2, Item 1). Remove the lamp assembly from the alarm panel.
4. 5.
0175-4
TM 55-1925-273-24&P-2 ALARM INDICATOR LAMP ASSEMBLY (SQUARE LENS) REMOVAL - Continued

1
0175
3 2 3 3 10
7 8 9 8
M1078T73
Alarm Panel Components (Internal View).
ALARM INDICATOR LAMP ASSEMBLY (SQUARE LENS) INSTALLATION 1. 2. 3. 4. Install the lamp assembly (Figure 2, Item 1) in the alarm panel, securing it with the retaining screws (Figure 2, Item 3). Install the wiring (Figure 2, Item 10) using the labels from Step (4) of ALARM INDICATOR LAMP ASSEMBLY (SQUARE LENS) REMOVAL as a guide. Remove the labels. Close the front panel and tighten the clamping screws (Figure 1, Item 2). Perform the ALARM INDICATOR BULBS (SQUARE LENS) INSTALLATION procedure in this work package.
END OF TASK
0175-5
TM 55-1925-273-24&P-2 FUSE HOLDER ASSEMBLY REMOVAL 1. 2. Perform the FUSE REMOVAL procedure in this work package. Loosen the clamping screws (Figure 1, Item 2) and open the front panel.
0175
WARNING
Replace or repair components only after the affected circuit has been secured, locked out, and tagged out IAW FM 4-01.502. Performing replacement with the circuit energized may result in injury. 3. Use a multimeter to check for voltage at the fuse holders (Figure 2, Item 7). If voltage is present, ensure that the proper circuit breaker is set to OFF, locked out, and tagged out IAW FM 4-01.502. If no voltage is present, continue with the procedure. Label and remove the wiring from the terminals of the fuse holder assembly (Figure 2, Item 8) to be removed. Remove the retaining nut (Figure 2, Item 9) that secures the fuse holder assembly (Figure 2, Item 8), and remove it from the alarm panel.
4. 5.
END OF TASK FUSE HOLDER ASSEMBLY INSTALLATION 1. 2. 3. 4. Install the fuse holder assembly (Figure 2, Item 8) in the alarm panel, and secure it with the retaining nut (Figure 2, Item 9). Install the wiring to the fuse holder assembly (Figure 2, Item 8) using the labels from Step (4) of FUSE HOLDER ASSEMBLY REMOVAL as a guide. Remove the labels. Close the front panel and tighten the clamping screws (Figure 1, Item 2). Perform the FUSE INSTALLATION procedure in this work package.
END OF TASK ALARM PANEL SWITCH/INDICATOR ASSEMBLY (ROUND LENS) REMOVAL 1. 2. Perform the ALARM PANEL SWITCH/INDICATOR ASSEMBLY (ROUND LENS) REMOVAL procedure in this work package. Loosen the two clamping screws (Figure 1, Item 2) and open the front panel.
WARNING
0175-6
TM 55-1925-273-24&P-2 ALARM PANEL SWITCH/INDICATOR ASSEMBLY (ROUND LENS) REMOVAL - Continued 3.
0175
Use a multimeter to check for voltage at the fuse holders (Figure 2, Item 7). If voltage is present, ensure that the proper circuit breaker is set to OFF, locked out, and tagged out IAW FM 4-01.502. If no voltage is present, continue with the procedure. Label and remove the wiring from the terminals (Figure 2, Item 6) of the alarm panel switch/indicator assembly. Remove the retaining screws (Figure 2, Item 4). Remove the alarm panel switch/indicator assembly from the alarm panel.
4. 5.
END OF TASK ALARM PANEL SWITCH/INDICATOR ASSEMBLY (ROUND LENS) INSTALLATION 1. 2. 3. 4. Install the alarm panel switch/indicator assembly in the alarm panel, and secure it with the retaining screws (Figure 2, Item 4). Install the wiring to the alarm panel switch/indicator assembly using the labels from Step (4) of ALARM PANEL SWITCH/INDICATOR ASSEMBLY (ROUND LENS) REMOVAL as a guide. Remove the labels. Close the front panel and tighten the clamping screws (Figure 1, Item 2). Perform the ALARM PANEL SWITCH/INDICATOR ASSEMBLY (ROUND LENS) INSTALLATION procedure in this work package.
END OF TASK AUDIBLE ALARM BUZZER ASSEMBLY REMOVAL 1. Loosen the clamping screws (Figure 1, Item 2) and open the front panel.
WARNING
Replace or repair components only after the affected circuit has been secured, locked out, and tagged out IAW FM 4-01.502. Performing replacement with the circuit energized may result in injury. 2. Use a multimeter to check for voltage at the fuse holders (Figure 2, Item 7). If voltage is present, ensure that the proper circuit breaker is set to OFF, locked out, and tagged out IAW FM 4-01.502. If no voltage is present, continue with the procedure. Label and remove the wiring from the terminals (Figure 2, Item 5) of the audible alarm buzzer. Remove the knurled retaining ring (Figure 1, Item 8). Remove the audible alarm buzzer (Figure 2, Item 5) from the alarm panel.
3. 4.
END OF TASK
0175-7
TM 55-1925-273-24&P-2
0175
AUDIBLE ALARM BUZZER ASSEMBLY INSTALLATION 1. 2. 3. 4. Install the audible alarm buzzer (Figure 2, Item 5) in the alarm panel and secure it with the knurled retaining ring (Figure 1, Item 8). Install the wiring to the audible alarm buzzer (Figure 2, Item 5) using the labels from Step (3) of AUDIBLE ALARM BUZZER ASSEMBLY REMOVAL as a guide. Remove the labels. Close the front panel and tighten the clamping screws (Figure 1, Item 2). Perform the FOLLOW-ON MAINTENANCE procedure at the end of this work pacakge.
END OF TASK THERMOSTAT ASSEMBLY (ARMS LOCKER) REMOVAL 1. Remove the four screws (Figure 3, Item 6) that secure the thermostat cover (Figure 3, Item 1). Remove the thermostat cover.
WARNING
Replace or repair components only after the affected circuit has been secured, locked out, and tagged out IAW FM 4-01.502. Performing replacement with the circuit energized may result in injury. 2. Use a multimeter to check for voltage at the thermostat terminals (Figure 3, Item 5). If voltage is present, ensure that the proper circuit breaker is set to OFF, locked out, and tagged out IAW FM 4-01.502. If no voltage is present, continue with the procedure. Label and remove the wiring from the terminal (Figure 3, Item 5) of the thermostat. Remove the two screws (Figure 3, Item 2) that secure the thermostat assembly to the mounting bracket (Figure 3, Item 4). Remove the electrical conduit (Figure 3, Item 3) and wires (Figure 3, Item 5) from the thermostat assembly.
3. 4. 5.
0175-8
TM 55-1925-273-24&P-2 THERMOSTAT ASSEMBLY (ARMS LOCKER) REMOVAL - Continued
0175
2 1
2 6
6
M1079T73
Thermostat Assembly.
THERMOSTAT ASSEMBLY (ARMS LOCKER) INSTALLATION 1. 2. 3. 4. 5. Install the wiring (Figure 3, Item 5) in the thermostat, securing it with the conduit retaining nut (Figure 3, Item 3). Install the thermostat switch assembly on the mounting bracket (Figure 3, Item 4) and secure it with the two screws (Figure 3, Item 2). Install the wiring to the terminals (Figure 3, Item 5) of the thermostat using the labels from Step (3) of THERMOSTAT ASSEMBLY (ARMS LOCKER) REMOVAL as a guide. Remove the labels. Install the thermostat cover (Figure 3, Item 1), and secure it with the four screws (Figure 3, Item 6). Perform the FOLLOW-ON MAINTENANCE procedure at the end of this work package.
END OF TASK
0175-9
TM 55-1925-273-24&P-2 ARMS LOCKER SPRINKLER WATER SWITCH ASSEMBLY REMOVAL 1. 2. 3. CLOSE valve FM-52, FM TO ARMS CONT RM. Lock out and tag out IAW FM 4-01.502.
0175
Remove the three nuts (Figure 4, Item 7) that secure the arms locker sprinkler water switch back plate assembly (Figure 4, Item 6). Separate the arms locker water switch back plate assembly (Figure 4, Item 6) from the arms locker sprinkler water switch mounting plate (Figure 4, Item 5) to reveal the arms locker sprinkler water switch terminals.
WARNING
Replace or repair components only after the affected circuit has been secured, locked out, and tagged out IAW FM 4-01.502. Performing replacement with the circuit energized may result in injury. 4. Use a multimeter to check for voltage at the exposed terminals of the arms locker sprinkler water switch (Figure 4, Item 4). If voltage is present, ensure that the proper circuit breaker is set to OFF, locked out, and tagged out IAW FM 4-01.502. If no voltage is present, continue with the procedure. Label and remove the wiring from the terminals connected to the arms locker sprinkler water switch (Figure 4, Item 4). Remove the four bolts and nuts (Figure 4, Item 3) that secure the arms locker sprinkler water switch (Figure 4, Item 4) to the fire main (Figure 4, Item 1). Remove the arms locker sprinkler water switch (Figure 4, Item 4) and gasket (Figure 4, Item 2).
5. 6. 7.
0175-10
TM 55-1925-273-24&P-2 ARMS LOCKER SPRINKLER WATER SWITCH ASSEMBLY REMOVAL - Continued

2 3 4
0175
1 5 6
7
M1080T73
Figure 4. Arms Locker Water Switch Assembly. END OF TASK ARMS LOCKER SPRINKLER WATER SWITCH ASSEMBLY INSTALLATION 1. 2. Install the arms locker sprinkler water switch (Figure 4, Item 4) with gasket (Figure 4, Item 2), securing them with the four bolts (Figure 4, Item 3). Install the wiring to the terminals of the arms locker sprinkler water switch (Figure 4, Item 4) using the labels from Step (5) of ARMS LOCKER SPRINKLER WATER SWITCH ASSEMBLY REMOVAL as a guide. Remove the labels. Install the arms locker sprinkler water switch back plate assembly with the cover (Figure 4, Item 6), and secure it with the three bolts (Figure 4, Item 7). Remove the lock outs and tag outs IAW FM 4-01.502. OPEN valve FM-52, FM TO ARMS CONT RM. Check for leaks at the gasket (Figure 4, Item 2).
3. 4. 5. 6.
END OF TASK
0175-11
TM 55-1925-273-24&P-2
0175
REPLACE ROTARY SNAP SWITCH ASSEMBLY REMOVAL 1. Remove the four screws (Figure 5, Item 2) and remove the rotary snap switch cover (Figure 5, Item 3).
WARNING
Replace or repair components only after the affected circuit has been secured, locked out, and tagged out IAW FM 4-01.502. Performing replacement with the circuit energized may result in injury. 2. Use a multimeter to check for voltage at the terminals inside the rotary snap switch (Figure 5, Item 1). If voltage is present, ensure that the proper circuit breaker is set to OFF, locked out, and tagged out IAW FM 4-01.502. If no voltage is present, continue with the procedure. Label and remove the wiring from the rotary snap swich (Figure 5, Item 1). Remove the three screws (Figure 5, Item 4) that secure the rotary snap switch (Figure 5, Item 1) to the bulkhead mounting bracket. Remove the rotary snap switch assembly (Figure 5, Item 1) from its bulkhead mounting bracket.
1 2
3. 4. 5.
M1081T73
Rotary Snap Switch Assembly.
REPLACE ROTARY SNAP SWITCH ASSEMBLY INSTALLATION 1. 2. 3. Install the rotary snap switch (Figure 5, Item 1) on the bulkhead mounting bracket, securing it with the three screws (Figure 5, Item 4). Install the wiring to the rotary snap switch (Figure 5, Item 1) using the labels from Step (3) of REPLACE ROTARY SNAP SWITCH ASSEMBLY REMOVAL as a guide. Remove the labels. Install the rotary snap switch cover (Figure 5, Item 3), securing it with the four screws (Figure 5, Item 2).
0175-12
TM 55-1925-273-24&P-2 REPLACE ROTARY SNAP SWITCH ASSEMBLY INSTALLATION - Continued 4. Perform the FOLLOW-ON MAINTENANCE procedure at the end of this work package.
0175
END OF TASK REPLACE DOOR ALARM SWITCH ASSEMBLY REMOVAL 1. Remove the three screws (Figure 6, Item 4) and remove the door alarm switch cover (Figure 6, Item 1).
WARNING
Replace or repair components only after the affected circuit has been secured, locked out, and tagged out IAW FM 4-01.502. Performing replacement with the circuit energized may result in injury. 2. Use a multimeter to check for voltage at the terminals inside the door alarm switch (Figure 6, Item 2). If voltage is present, ensure that the proper circuit breaker is set to OFF, locked out, and tagged out IAW FM 4-01.502. If no voltage is present, continue with the procedure. Label and remove the wiring from the door alarm switch (Figure 6, Item 2). Remove the three nuts (Figure 6, Item 3) that secure the door alarm to the bulkhead. Remove the door alarm switch from the bulkhead.
3. 4. 5.
1 2
4
M1082T73
Door Alarm Switch Assembly.
0175-13
TM 55-1925-273-24&P-2
0175
REPLACE DOOR ALARM SWITCH ASSEMBLY INSTALLATION 1. 2. 3. 4. Install the door alarm switch (Figure 6, Item 2) on the bulkhead studs, securing it with the three nuts (Figure 6, Item 3). Install the door alarm switch (Figure 6, Item 2) wiring using the labels from Step (3) of REPLACE DOOR ALARM SWITCH ASSEMBLY REMOVAL as a guide. Remove the labels. Install the door alarm switch cover (Figure 6, Item 1), securing it with the three screws (Figure 6, Item 4). Perform the FOLLOW-ON MAINTENANCE procedure at the end of this work package.
END OF TASK REPLACE ALARM PANEL ASSEMBLY REMOVAL 1. Loosen the two clamping screws (Figure 1, Item 2) and open the front panel.
WARNING
Replace or repair components only after the affected circuit has been secured, locked out, and tagged out IAW FM 4-01.502. Performing replacement with the circuit energized may result in injury. 2. Use a multimeter to check for voltage at the connection points on the back of all fuse holders (Figure 2, Item 7) and terminal boards (Figure 7, Items 1, 2, 3, 6, 7, and 8). If voltage is present, ensure that the proper circuit breaker is set to OFF, locked out, and tagged out IAW FM 4-01.502. If no voltage is present, continue with the procedure. Label and remove the wiring from the terminals that are part of the cables that penetrate the alarm panel. Remove the wiring and cables from the alarm panel. Remove the four bolts (Figure 7, Item 5) and four flat washers (Figure 7, Item 4). Remove the alarm panel from the bulkhead. >
3. 4.
END OF TASK REPLACE ALARM PANEL ASSEMBLY INSTALLATION 1. 2. Install the alarm panel, securing it to bulkhead with the four bolts (Figure 7, Item 5) and four flat washers (Figure 7, Item 4). Install the cables and connect the wiring to the terminal boards (Figure 7, Items 1, 2, 3, 6, 7, and 8) using the labels from Step (3) of REPLACE DOOR ALARM SWITCH ASSEMBLY REMOVAL as a guide. Remove the labels. Close the front panel and tighten the clamping screws (Figure 1, Item 2). Perform the FOLLOW-ON MAINTENANCE procedure at the end of this work package.
3. 4.
0175-14
TM 55-1925-273-24&P-2 REPLACE ALARM PANEL ASSEMBLY INSTALLATION - Continued
0175
4 8 5
M1083T73
Alarm Panel Assembly.
0175-15
TM 55-1925-273-24&P-2
0175
FOLLOW-ON MAINTENANCE 1. 2. 3. 4. Remove the lock outs and tag outs IAW FM 4-01.502. Set the circuit breaker to ON. Test each alarm circuit, ensuring the proper operation of each of the alarms on the alarm panel. Return the equipment to the desired readiness condition.
0175-16
TM 55-1925-273-24&P-2 FIELD MAINTENANCE INTERIOR COMMUNICATIONS REPLACE
0176
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 3, WP 0344, Table 1, Item 27) Tool Kit, Electrical Repair (Volume 3, WP 0344, Table 1, Item 26) Materials/Parts N/A Personnel Required Watercraft Engineer 88L (2) References TM 55-1925-273-10 References (cont.) Volume 3, WP 0300 Volume 3, WP 0344 Equipment Condition N/A
0176-1
TM 55-1925-273-24&P-2
0176
PUBLIC ADDRESS SYSTEM AMPLIFIER REMOVAL 1. 2. 3. 4. 5. On the front panel assembly (Figure 1, Item 2) of the amplifier (Figure 1, Item 1), set the ON/OFF power switch (Figure 1, Item 3) to OFF. Unplug the power cord from the outlet. Label and remove all wires attached to the amplifier (Figure 1, Item 1). Remove any associated mounting hardware securing the amplifier (Figure 1, Item 1). Remove the public address system amplifier (Figure 1, Item 1).
3
M1076T73
Figure 1. Public Address System Amplifier. END OF TASK PUBLIC ADDRESS SYSTEM AMPLIFIER INSTALLATION 1. 2. 3. 4. Install the amplifier (Figure 1, Item 1) and secure it with the mounting hardware. Install the wiring to the amplifier (Figure 1, Item 1) using the labels from Step (3) of PUBLIC ADDRESS SYSTEM AMPLIFIER REMOVAL as a guide. Remove the labels. Set the ON/OFF switch (Figure 1, Item 3) to ON. Check that the public address system operates properly IAW TM 55-1925-273-10.
0176-2
TM 55-1925-273-24&P-2 FIELD MAINTENANCE INTERIOR COMMUNICATIONS REPAIR
0177
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 3, WP 0344, Table 1, Item 27) Multimeter (Volume 3, WP 0344, Table 1, Item 15) Tool Kit, Electrical Repair (Volume 3, WP 0344, Table 1, Item 26) Materials/Parts N/A Personnel Required Watercraft Engineer 88L (2) References FM 4-01.502 References (cont.) TC 55-509-1 TM 55-1925-273-10 Volume 3, WP 0300 Volume 3, WP 0343 Volume 3, WP 0344 Equipment Condition Set to OFF the P.A. SYSTEM circuit breaker at the 120 V elex distribution panel. Lock out and tag out IAW FM 4-01.502.
0177-1
TM 55-1925-273-24&P-2
0177
VOLUME CONTROL BOX REMOVAL 1. Remove the two screws (Figure 1, Item 1) from the volume control box face plate (Figure 1, Item 2).
WARNING
Replace or repair components only after the affected circuit has been secured, locked out, and tagged out IAW FM 4-01.502. Performing replacement with the circuit energized may result in injury. 2. 3. Remove the volume control box face plate (Figure 1, Item 2) from the volume control box (Figure 1, Item 5). Use a multimeter to check for voltage at the wiring terminals (Figure 1, Item 3). If voltage is present, ensure that the appropriate circuit breakers have been set to OFF, locked out, and tagged out IAW FM 4-01.502. If no voltage is present, continue with the procedure. Label and remove the wiring (Figure 1, Item 4) from the volume control box face plate (Figure 1, Item 2).
4.
END OF TASK VOLUME CONTROL BOX INSTALLATION 1. 2. Connect electrical wiring (Figure 1, Item 4) to the volume control box face plate (Figure 1, Item 2) using the labels from Step (4) of VOLUME CONTROL BOX REMOVAL as a guide. Remove the labels. Install the volume control box face plate (Figure 1, Item 2) on the volume control box (Figure 1, Item 5) and secure it with the two screws (Figure 1, Item 1).
0177-2
TM 55-1925-273-24&P-2 VOLUME CONTROL BOX INSTALLATION - Continued
0177
3 4 4
M1279T73
Volume Control Box.
0177-3
TM 55-1925-273-24&P-2
0177
LOUDSPEAKER REMOVAL
WARNING
Never reuse locking hardware. Reuse of locking hardware such as lockwashers, locking nuts, cotter pins, and lock wire can result in undetected loosening of fastening hardware causing catastrophic component failure resulting in death, injury, or damage to equipment. Ensure that all locking hardware is discarded upon removal and replaced with new. 1. Remove the screws (Figure 2, Item 2) that secure the cover (Figure 2, Item 4) to the loudspeaker (Figure 2, Item 9).
WARNING
Replace or repair components only after the affected circuit has been secured, locked out, and tagged out IAW FM 4-01.502. Performing replacement with the circuit energized may result in injury. 2. Using a multimeter, check for voltage at the terminals (Figure 2, Item 1). If voltage is present, ensure that the proper circuit breaker is set to OFF, locked out, and tagged out IAW FM 4-01.502. If no voltage is present, continue with the procedure. Label and remove the electrical wiring (Figure 2, Item 3) from the terminals (Figure 2, Item 1). Remove the bolts (Figure 2, Item 8), nuts (Figure 2, Item 5), lockwashers (Figure 2, Item 6), and flat washers (Figure 2, Item 7) that secure the loudspeaker (Figure 2, Item 9) to the bulkhead. Remove the loudspeaker and discard lockwashers.
3. 4.
END OF TASK LOUDSPEAKER INSTALLATION 1. 2. 3. 4. Install the loudspeaker (Figure 2, Item 9) on the bulkhead and secure it with the bolts (Figure 2, Item 8), nuts (Figure 2, Item 5), lockwashers (Figure 2, Item 6), and flat washers (Figure 2, Item 7). Install the electrical wiring (Figure 2, Item 3) to the terminals (Figure 2, Item 1) using the labels from Step (3) of LOUDSPEAKER REMOVAL as a guide. Remove the labels. Install the cover (Figure 2, Item 4) on the loudspeaker (Figure 2, Item 9) and secure it with the screws (Figure 2, Item 2). Perform the FOLLOW-ON MAINTENANCE procedure at the end of the work package.
0177-4
TM 55-1925-273-24&P-2 LOUDSPEAKER INSTALLATION - Continued
0177
4 1 2 1 3
5 6 7 8 1
9 1 2
1 2 3 4 5
8 7
8 7 4 3
6 5
M1280T73
Figure 2. Interior/Exterior Loudspeaker Depiction (Typical). END OF TASK WIRING (TYPICAL) REPAIR Proper repair of wiring consists of replacement of the damaged wiring. When an electrical casualty requires expedient repairs, the repair may be made by splicing. Splicing is authorized for repair of damaged cables and wiring harnesses if most of the wiring is in good useable electrical condition. The cable or wiring harness must be replaced in its entirety at the most opportune time. For proper splicing methods, refer to TC 55-509-1. END OF TASK
0177-5
TM 55-1925-273-24&P-2 WIRING (TYPICAL) DISASSEMBLY
0177
WARNING
Replace or repair components only after the affected circuit has been secured, locked out, and tagged out IAW FM 4-01.502. Performing replacement with the circuit energized may result in injury. 1. Use a multimeter to check for voltage at the wire terminals (Figure 3, Item 3). If voltage is present, ensure that the proper circuit breakers are set to OFF, locked out, and tagged out IAW FM 4-01.502. If no voltage is present, continue with the procedure. Remove any covers or interference that restrict access to the wires being removed. Label all wiring to be removed, and make a sketch of the work area to permit proper assembly. Remove the nuts (Figure 3, Item 2) that secure the wire terminals (Figure 3, Item 3) to the post (Figure 3, Item 1), and remove the wire (Figure 3, Item 4). Follow the wire (Figure 3, Item 4) to the opposite end, freeing it from the vessel's structure as required. Remove the nuts (Figure 3, Item 2) that secure the wire terminals (Figure 3, Item 3) to the post (Figure 3, Item 1), and remove the wire (Figure 3, Item 4) at the opposite end. Perform Steps (1) through (6) for any other wires (Figure 3, Item 4) that require removal.
2. 3. 4. 5. 6. 7.
END OF TASK WIRING (TYPICAL) ASSEMBLY 1. 2. 3. 4. 5. 6. Determine the wires to be connected by referring to the sketches and labels from Step (3) of WIRING (TYPICAL) DISASSEMBLY as guides. Install the wires (Figure 3, Item 4) along the same path as the old wires, and secure them in the same manner as the old wiring assembly. Install the nuts (Figure 3, Item 2) that secure the wire terminals (Figure 3, Item 3) to the post (Figure 3, Item 1) at both ends of the wire (Figure 3, Item 4). Remove any remaining labels. Install any covering or interference removed during the WIRING (TYPICAL) DISASSEMBLY procedure. Perform the FOLLOW-ON MAINTENANCE procedure at the end of this work package.
0177-6
TM 55-1925-273-24&P-2 WIRING (TYPICAL) ASSEMBLY - Continued

1
0177
M1281T73
Figure 3. Electrical Wiring Terminal Depiction (Typical). END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. Remove the lock outs and tag outs IAW FM 4-01.502. Operate the intercommunication and sound powered telephone systems under usual conditions IAW TM 55-1925-273-10 and check for proper operation of the public address system. Return the interior communications system to the desired readiness condition.
0177-7/8 blank
TM 55-1925-273-24&P-2 FIELD MAINTENANCE SOUND POWERED TELEPHONES REPLACE
0178
INITIAL SETUP: Tools and Special Tools Tool Kit, Electrical Repair (Volume 3, WP 0344, Table 1, Item 26) Materials/Parts N/A Personnel Required Watercraft Engineer 88L (1) References Volume 3, WP 0301 Volume 3, WP 0344 Equipment Condition N/A
0178-1
TM 55-1925-273-24&P-2
0178
HANDSET REMOVAL
NOTE
The sound powered telephone system consists of similar sound powered telephones that contain identical handsets and headset-chestsets. The following procedures describe removal and installation procedures for both types of sound powered telephones. 1. 2. 3. 4. 5. 6. Remove the handset (Figure 1, Item 6) and disconnect the telephone cord nut (Figure 1, Item 5). Remove the four screws (Figure 1, Item 2) from the front panel (Figure 1, Item 1) of the telephone assembly (Figure 1, Item 3). Remove the front panel (Figure 1, Item 1) from the telephone assembly (Figure 1, Item 3). Label and remove the wiring (Figure 1, Item 7) from the telephone assembly (Figure 1, Item 3). Remove the four screws (Figure 1, Item 4) that secure the telephone assembly (Figure 1, Item 3) to the bulkhead. Remove the telephone assembly (Figure 1, Item 3) from the bulkhead.
1 2
6 4
7 5
M1282T73
Figure 1. END OF TASK HANDSET INSTALLATION 1. 2. 3. 4. 5.
Sound Powered Telephone - Handset (Typical).
Position the telephone assembly (Figure 1, Item 3) on the bulkhead. Secure the telephone assembly (Figure 1, Item 3) to the bulkhead with the four screws (Figure 1, Item 4). Connect the wiring (Figure 1, Item 7) using the labels from Step (4) of HANDSET REMOVAL as a guide. Remove the labels. Install the front panel (Figure 1, Item 1) on the telephone assembly (Figure 1, Item 3) and secure it with the four screws (Figure 1, Item 2). Connect the telephone cord by securing with the telephone cord nut (Figure 1, Item 5).
0178-2
TM 55-1925-273-24&P-2 HANDSET INSTALLATION - Continued 6. 7. Replace the handset (Figure 1, Item 6). Perform the FOLLOW-ON MAINTENANCE procedure at the end of this work package.
0178
END OF TASK HEADSET-CHESTSET REMOVAL 1. 2. Remove the headset-chestset (Figure 2, Item 1) by disconnecting the plug (Figure 2, Item 4) from the receptacle (Figure 2, Item 3) on the jack box (Figure 2, Item 2). Check the receptacle (Figure 2, Item 3) for moisture. If moisture is present, allow it to air dry.
2 1
M1283T73
Figure 2. Sound Powered Telephone - Headset-Chestset (Typical). END OF TASK HEADSET-CHESTSET INSTALLATION 1. 2. Connect the headset-chestset assembly (Figure 2, Item 1) to the jack box (Figure 2, Item 2) by pushing the plug (Figure 2, Item 4) into the receptacle (Figure 2, Item 3). Perform the FOLLOW-ON MAINTENANCE procedure at the end of this work package.
END OF TASK
0178-3
TM 55-1925-273-24&P-2 FOLLOW-ON MAINTENANCE 1. 2.
0178
Ensure that the sound powered telephone system operates properly by allowing other sound powered stations to transmit and receive voice communications to and from the replaced station. Return the equipment to the desired readiness condition.
0178-4
TM 55-1925-273-24&P-2 FIELD MAINTENANCE SOUND POWERED TELEPHONES REPAIR
0179
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 3, WP 0344, Table 1, Item 27) Multimeter (Volume 3, WP 0344, Table 1, Item 15) Tool Kit, Electrical Repair (Volume 3, WP 0344, Table 1, Item 26) Materials/Parts Cement, Rubber (Volume 3, WP 0343, Table 1, Item 31) Personnel Required Watercraft Engineer 88L (1) References FM 4-01.502 References (cont.) TC 55-509-1 TM 55-1925-273-10 WP 0178 Volume 3, WP 0301 Volume 3, WP 0343 Volume 3, WP 0344 Equipment Condition Sound powered telephone removed. (WP 0178)
NOTE
This work package contains the repair procedures for the MWT-246J, SW-23J, SWLR-23J, and the SW-243J sound powered telephones.
0179-1
TM 55-1925-273-24&P-2
0179
MWT-246J GASKET REMOVAL 1. 2. Loosen the T-handle (Figure 1, Item 2) and OPEN the cover (Figure 1, Item 3) of the handset box (Figure 1, Item 1). Remove the gasket (Figure 1, Item 4) from the telephone handset box (Figure 1, Item 1).
10
9 5 8 6 7
M1284T73
Figure 1. Sound Powered Telephone MWT-246J. END OF TASK MWT-246J GASKET INSTALLATION 1. 2. Install the gasket (Figure 1, Item 4) in the telephone handset box (Figure 1, Item 1) and secure it with rubber cement. CLOSE the cover (Figure 1, Item 3) of the handset box (Figure 1, Item 1) and tighten the T-handle (Figure 1, Item 2).
END OF TASK
0179-2
TM 55-1925-273-24&P-2 MWT-246J HAND RINGING GENERATOR REMOVAL 1. 2. 3. 4. 5. 6. 7. Loosen the T-handle (Figure 1, Item 2) and OPEN the cover (Figure 1, Item 3) of the handset box (Figure 1, Item 1). Remove the five screws (Figure 1, Item 10) from the mounting plate (Figure 1, Item 9). Remove the mounting plate (Figure 1, Item 9) from the handset box (Figure 1, Item 1). Label and remove the wiring (Figure 1, Item 5) from the hand ringing generator (Figure 1, Item 6).
0179
Remove the manual control handle (Figure 1, Item 8) from the hand ringing generator (Figure 1, Item 6) by turning it counterclockwise. Remove the four screws (Figure 1, Item 7) from the hand ringing generator (Figure 1, Item 6). Remove the hand ringing generator (Figure 1, Item 6) from the handset box (Figure 1, Item 1).
END OF TASK MWT-246J HAND RINGING GENERATOR INSTALLATION 1. 2. 3. 4. 5. 6. 7. Install the hand ringing generator (Figure 1, Item 6) in the handset box (Figure 1, Item 1). Install the four screws (Figure 1, Item 7) in the hand ringing generator (Figure 1, Item 6). Install the manual control handle (Figure 1, Item 8) on the hand ringing generator (Figure 1, Item 6). Connect the wiring (Figure 1, Item 5) to the hand ringing generator (Figure 1, Item 6) using the labels from Step (4) of MWT-246J HAND RINGING GENERATOR REMOVAL as a guide. Remove the labels. Install the mounting plate (Figure 1, Item 9) on the handset box (Figure 1, Item 1). Install the five screws (Figure 1, Item 10) in the mounting plate (Figure 1, Item 9). CLOSE the cover (Figure 1, Item 3) of the handset box (Figure 1, Item 1) and tighten the T-handle (Figure 1, Item 2).
END OF TASK MWT-246J MANUAL CONTROL HANDLE REMOVAL 1. 2. Loosen the T-handle (Figure 1, Item 2) and OPEN the cover (Figure 1, Item 3) of the handset box (Figure 1, Item 1). Remove the manual control handle (Figure 1, Item 8) from the hand ringing generator (Figure 1, Item 6) by turning it counterclockwise.
END OF TASK MWT-246J MANUAL CONTROL HANDLE INSTALLATION 1. 2. Install the manual control handle (Figure 1, Item 8) on the hand ringing generator (Figure 1, Item 6). CLOSE the cover (Figure 1, Item 3) of the handset box (Figure 1, Item 1) and tighten the T-handle (Figure 1, Item 2).
END OF TASK
0179-3
TM 55-1925-273-24&P-2 SW-23J GASKET REMOVAL 1. 2. 3.
0179
Remove the four screws (Figure 2, Item 1) from the cover (Figure 2, Item 2) of the SW-23J telephone junction box (Figure 2, Item 3). Remove the cover (Figure 2, Item 2) from the SW-23J telephone junction box (Figure 2, Item 3). Remove the gasket (Figure 2, Item 4) from the SW-23J telephone junction box (Figure 2, Item 3).
END OF TASK SW-23J GASKET INSTALLATION 1. 2. 3. Install the gasket (Figure 2, Item 4) on the SW-23J telephone junction box (Figure 2, Item 3). Install the cover (Figure 2, Item 2) on the SW-23J telephone junction box (Figure 2, Item 3). Install the four screws (Figure 2, Item 1) in the cover (Figure 2, Item 2) of the SW-23J telephone junction box (Figure 2, Item 3).
END OF TASK SW-23J RINGING GENERATOR REMOVAL 1. 2. 3. 4. 5. 6. Remove the four screws (Figure 2, Item 1) from the cover (Figure 2, Item 2) of the SW-23J telephone junction box (Figure 2, Item 3). Remove the cover (Figure 2, Item 2) from the SW-23J telephone junction box (Figure 2, Item 3). Remove the manual control handle (Figure 2, Item 10) from the hand ringing generator (Figure 2, Item 11) by turning it counterclockwise. Label and remove the wiring (Figure 2, Item 8) of the hand ringing generator (Figure 2, Item 11) from the terminal board (Figure 2, Item 9). Remove the two screws (Figure 2, Item 12) from the hand ringing generator (Figure 2, Item 11). Remove the hand ringing generator (Figure 2, Item 11) from the SW-23J telephone junction box (Figure 2, Item 3).
END OF TASK SW-23J RINGING GENERATOR INSTALLATION 1. 2. 3. 4. Install the hand ringing generator (Figure 2, Item 11) in the SW-23J telephone junction box (Figure 2, Item 3). Install the two screws (Figure 2, Item 12) in the hand ringing generator (Figure 2, Item 11). Install the manual control handle (Figure 2, Item 10) on the hand ringing generator (Figure 2, Item 11). Connect the wiring (Figure 2, Item 8) of the hand ringing generator (Figure 2, Item 11) to the terminal board (Figure 2, Item 9) using the labels from Step (4) of SW-23J RINGING GENERATOR REMOVAL as a guide. Remove the labels. Install the cover (Figure 2, Item 2) on the SW-23J telephone junction box (Figure 2, Item 3). Install the four screws (Figure 2, Item 1) in the cover (Figure 2, Item 2) of the SW-23J telephone junction box (Figure 2, Item 3).
5. 6.
END OF TASK
0179-4
TM 55-1925-273-24&P-2 SW-23J MANUAL CONTROL HANDLE REMOVAL 1. 2. 3.
0179
Remove the four screws (Figure 2, Item 1) from the cover (Figure 2, Item 2) of the SW-23J telephone junction box (Figure 2, Item 3). Remove the cover (Figure 2, Item 2) from the SW-23J telephone junction box (Figure 2, Item 3). Remove the manual control handle (Figure 2, Item 10) from the hand ringing generator (Figure 2, Item 11) by turning it counterclockwise.
END OF TASK SW-23J MANUAL CONTROL HANDLE INSTALLATION 1. 2. 3. Install the manual control handle (Figure 2, Item 10) on the hand ringing generator (Figure 2, Item 11). Install the cover (Figure 2, Item 2) on the SW-23J telephone junction box (Figure 2, Item 3). Install the four screws (Figure 2, Item 1) in the cover (Figure 2, Item 2) of the SW-23J telephone junction box (Figure 2, Item 3).
1 2
4 8
9 7 6 5
1 2 3 4 5 6 7 8 C T T
10
11 12
M1285T73
Figure 2. Sound Powered Telephone SW-23J. END OF TASK
0179-5
TM 55-1925-273-24&P-2 SW-23J ELECTRIC BELL REMOVAL 1. 2. 3. 4. 5.
0179
Remove the four screws (Figure 2, Item 1) from the cover (Figure 2, Item 2) of the SW-23J telephone junction box (Figure 2, Item 3). Remove the cover (Figure 2, Item 2) from the SW-23J telephone junction box (Figure 2, Item 3). Label and remove the wiring (Figure 2, Item 7) of the electric bell (Figure 2, Item 5) from the terminal board (Figure 2, Item 9). Remove the screw (Figure 2, Item 6) that secures the electric bell (Figure 2, Item 5) to the SW-23J telephone junction box (Figure 2, Item 3). Remove the electric bell (Figure 2, Item 5) from the SW-23J junction box (Figure 2, Item 3).
END OF TASK SW-23J ELECTRIC BELL INSTALLATION 1. 2. 3. Install the electric bell (Figure 2, Item 5) in the SW-23J junction box (Figure 2, Item 3). Install the screw (Figure 2, Item 6) that secures the electric bell (Figure 2, Item 5) in the SW-23J telephone junction box (Figure 2, Item 3). Connect the wiring (Figure 2, Item 7) of the electric bell (Figure 2, Item 5) to the terminal board (Figure 2, Item 9) using the labels from Step (3) of SW-23J ELECTRIC BELL REMOVAL as a guide. Remove the labels. Install the cover (Figure 2, Item 2) on the SW-23J telephone junction box (Figure 2, Item 3). Install the four screws (Figure 2, Item 1) in the cover (Figure 2, Item 2) of the SW-23J telephone junction box (Figure 2, Item 3).
4. 5.
END OF TASK SWLR-243J GASKET REMOVAL 1. 2. 3. Remove the four screws (Figure 3, Item 1) from the SWLR-243J telephone cover (Figure 3, Item 2). Remove the SWLR-243J telephone cover (Figure 3, Item 2) from the SWLR-243J telephone junction box (Figure 3, Item 3). Remove the gasket (Figure 3, Item 4) from the SWLR-243J telephone junction box (Figure 3, Item 3).
0179-6
TM 55-1925-273-24&P-2 SWLR-243J GASKET REMOVAL - Continued
0179
1 2
4 5 13 6 12 11 16 17 18 19 7 8
14 15
10
9
Figure 3. Sound Powered Telephone SWLR-243J. END OF TASK
M1286T73
0179-7
TM 55-1925-273-24&P-2
0179
SWLR-243J GASKET INSTALLATION 1. 2. 3. Install the gasket (Figure 3, Item 4) on the SWLR-243J telephone junction box (Figure 3, Item 3). Install the SWLR-243J telephone cover (Figure 3, Item 2) on the SWLR-243J telephone junction box (Figure 3, Item 3). Install the four screws (Figure 3, Item 1) in the SWLR-243J telephone cover (Figure 3, Item 2).
END OF TASK SWLR-243J LIGHT ASSEMBLY LAMP REMOVAL 1. 2. Remove the lens (Figure 3, Item 8) from the SWLR-243J light assembly (Figure 3, Item 6). Remove the lamp (Figure 3, Item 7) from the SWLR-243J light assembly (Figure 3, Item 6).
END OF TASK SWLR-243J LIGHT ASSEMBLY LAMP INSTALLATION 1. 2. Install the lamp (Figure 3, Item 7) in the SWLR-243J light assembly (Figure 3, Item 6). Install the lens (Figure 3, Item 8) on the SWLR-243J light assembly (Figure 3, Item 6).
END OF TASK SWLR-243J HOOK SWITCH REMOVAL 1. 2. 3. 4. 5. Remove the four screws (Figure 3, Item 1) from the SWLR-243J telephone cover (Figure 3, Item 2). Remove the SWLR-243J telephone cover (Figure 3, Item 2) from the SWLR-243J telephone junction box (Figure 3, Item 3). Label and remove the wiring (Figure 3, Item 9) of the hook switch (Figure 3, Item 18) from the terminal board (Figure 3, Item 10). Remove the two screws (Figure 3, Item 15) from the hook switch (Figure 3, Item 18). Remove the hook switch (Figure 3, Item 18) from the SWLR-243J telephone cover (Figure 3, Item 2).
END OF TASK SWLR-243J HOOK SWITCH INSTALLATION 1. 2. 3. Install the hook switch (Figure 3, Item 18) on the SWLR-243J telephone cover (Figure 3, Item 2). Install the two screws (Figure 3, Item 15) in the hook switch (Figure 3, Item 18). Connect the wiring (Figure 3, Item 9) of the hook switch (Figure 3, Item 18) to the terminal board (Figure 3, Item 10) using the labels from Step (3) of SWLR-243J HOOK SWITCH REMOVAL as a guide. Remove the labels. Install the SWLR-243J telephone cover (Figure 3, Item 2) on the SWLR-243J telephone junction box (Figure 3, Item 3). Install the four screws (Figure 3, Item 1) in the SWLR-243J telephone cover (Figure 3, Item 2).
4. 5.
END OF TASK
0179-8
TM 55-1925-273-24&P-2 SWLR-243J RELAY REMOVAL 1. 2. 3. 4. 5. Remove the four screws (Figure 3, Item 1) from the SWLR-243J telephone cover (Figure 3, Item 2).
0179
Remove the SWLR-243J telephone cover (Figure 3, Item 2) from the SWLR-243J telephone junction box (Figure 3, Item 3). Label and remove the wiring (Figure 3, Item 12) of the relay (Figure 3, Item 19) from the terminal board (Figure 3, Item 5). Remove the four screws (Figure 3, Item 11) from the relay (Figure 3, Item 19). Remove the relay (Figure 3, Item 19) from the SWLR-243J telephone junction box (Figure 3, Item 3).
END OF TASK SWLR-243J RELAY INSTALLATION 1. 2. 3. 4. 5. Install the relay (Figure 3, Item 19) on the SWLR-243J telephone junction box (Figure 3, Item 3). Install the four screws (Figure 3, Item 11) in the relay (Figure 3, Item 19). Connect the wiring (Figure 3, Item 12) of the relay (Figure 3, Item 19) to the terminal board (Figure 3, Item 5). Install the SWLR-243J telephone cover (Figure 3, Item 2) on the SWLR-243J telephone junction box (Figure 3, Item 3). Install the four screws (Figure 3, Item 1) in the SWLR-243J telephone cover (Figure 3, Item 2).
END OF TASK SWLR-243J HAND RINGING GENERATOR REMOVAL 1. 2. 3. 4. 5. 6. Remove the four screws (Figure 3, Item 1) from the SWLR-243J telephone cover (Figure 3, Item 2). Remove the SWLR-243J telephone cover (Figure 3, Item 2) from the SWLR-243J telephone junction box (Figure 3, Item 3). Label and remove the wiring (Figure 3, Item 13) of the hand ringing generator (Figure 3, Item 16) from the terminal board (Figure 3, Item 5). Remove the manual control handle (Figure 3, Item 17) from the hand ringing generator (Figure 3, Item 16) by turning it counterclockwise. Remove the four screws (Figure 3, Item 14) from the hand ringing generator (Figure 3, Item 16). Remove the hand ringing generator (Figure 3, Item 16) from the SWLR-243J telephone junction box (Figure 3, Item 3).
END OF TASK SWLR-243J HAND RINGING GENERATOR INSTALLATION 1. 2. 3. 4. Install the hand ringing generator (Figure 3, Item 16) in the SWLR-243J telephone junction box (Figure 3, Item 3). Install the four screws (Figure 3, Item 14) in the hand ringing generator (Figure 3, Item 16). Install the manual control handle (Figure 3, Item 17) on the hand ringing generator (Figure 3, Item 16). Connect the wiring (Figure 3, Item 13) of the hand ringing generator (Figure 3, Item 16) to the terminal board (Figure 3, Item 5) using the labels from Step (3) of SWLR-243J HAND RINGING GENERATOR REMOVAL as a guide. Remove the labels.
0179-9
TM 55-1925-273-24&P-2 SWLR-243J HAND RINGING GENERATOR INSTALLATION - Continued 5. 6. Install the SWLR-243J telephone cover (Figure 3, Item 2) on the SWLR-243J telephone junction box (Figure 3, Item 3). Install the four screws (Figure 3, Item 1) in the SWLR-243J telephone cover (Figure 3, Item 2).
0179
END OF TASK SWLR-243J MANUAL CONTROL HANDLE REMOVAL 1. 2. 3. Remove the four screws (Figure 3, Item 1) from the SWLR-243J telephone cover (Figure 3, Item 2). Remove the SWLR-243J telephone cover (Figure 3, Item 2) from the SWLR-243J telephone junction box (Figure 3, Item 3). Remove the manual control handle (Figure 3, Item 17) from the hand ringing generator (Figure 3, Item 16) by turning it counterclockwise.
END OF TASK SWLR-243J MANUAL CONTROL HANDLE INSTALLATION 1. 2. 3. Install the manual control handle (Figure 3, Item 17) on the hand ringing generator (Figure 3, Item 16). Install the SWLR-243J telephone cover (Figure 3, Item 2) on the SWLR-243J telephone junction box (Figure 3, Item 3). Install the four screws (Figure 3, Item 1) in the SWLR-243J telephone cover (Figure 3, Item 2).
END OF TASK SW-243J GASKET REMOVAL 1. 2. 3. Remove the four screws (Figure 4, Item 1) of the SW-234J telephone cover (Figure 4, Item 2) from the SW-243J telephone junction box (Figure 4, Item 3). Remove the SW-243J telephone cover (Figure 4, Item 2) from the SW-243J telephone junction box (Figure 4, Item 3). Remove the gasket (Figure 4, Item 4) from the SW-243J telephone junction box (Figure 4, Item 3).
END OF TASK SW-243J GASKET INSTALLATION 1. 2. 3. Install the gasket (Figure 4, Item 4) on the SW-243J telephone junction box (Figure 4, Item 3). Install the SW-243J telephone cover (Figure 4, Item 2) on the SW-243J telephone junction box (Figure 4, Item 3). Install the four screws (Figure 4, Item 1) of the SW-243J telephone cover (Figure 4, Item 2) in the SW-243J telephone junction box (Figure 4, Item 3).
0179-10
TM 55-1925-273-24&P-2 SW-243J GASKET INSTALLATION - Continued

1 2
0179
4 5 6
9 7 8
M1287T73
Sound Powered Telephone SW-243J.
SW-243J HAND RINGING GENERATOR REMOVAL 1. 2. 3. 4. 5. Remove the four screws (Figure 4, Item 1) of the SW-243J telephone cover (Figure 4, Item 2) from the SW-243J telephone junction box (Figure 4, Item 3). Remove the SW-243J telephone cover (Figure 4, Item 2) from the SW-243J telephone junction box (Figure 4, Item 3). Label and remove the wiring (Figure 4, Item 5) of the hand ringing generator (Figure 4, Item 7) from the terminal board (Figure 4, Item 9). Remove the manual control handle (Figure 4, Item 8) from the hand ringing generator (Figure 4, Item 7) by turning it counterclockwise. Remove the four screws (Figure 4, Item 6) from the hand ringing generator (Figure 4, Item 7).
0179-11
TM 55-1925-273-24&P-2 SW-243J HAND RINGING GENERATOR REMOVAL - Continued 6. Remove the hand ringing generator (Figure 4, Item 7) from the SW-243J telephone junction box (Figure 4, Item 3).
0179
END OF TASK SW-243J HAND RINGING GENERATOR INSTALLATION 1. 2. 3. 4. 5. 6. Install the hand ringing generator (Figure 4, Item 7) in the SW-243J telephone junction box (Figure 4, Item 3). Install the four screws (Figure 4, Item 6) in the hand ringing generator (Figure 4, Item 7). Install the manual control handle (Figure 4, Item 8) on the hand ringing generator (Figure 4, Item 7). Connect the wiring (Figure 4, Item 5) of the hand ringing generator (Figure 4, Item 7) to the terminal board (Figure 4, Item 9). Install the SW-243J telephone cover (Figure 4, Item 2) on the SW-243J telephone junction box (Figure 4, Item 3). Install the four screws (Figure 4, Item 1) of the SW-243J telephone cover (Figure 4, Item 2) in the SW-243J telephone junction box (Figure 4, Item 3).
END OF TASK SW-243J MANUAL CONTROL HANDLE REMOVAL 1. 2. 3. Remove the four screws (Figure 4, Item 1) of the SW-243J telephone cover (Figure 4, Item 2) from the SW-243J telephone junction box (Figure 4, Item 3). Remove the SW-243J telephone cover (Figure 4, Item 2) from the SW-243J telephone junction box (Figure 4, Item 3). Remove the manual control handle (Figure 4, Item 8) from the hand ringing generator (Figure 4, Item 7) by turning it counterclockwise.
END OF TASK SW-243J MANUAL CONTROL HANDLE INSTALLATION 1. 2. 3. Install the manual control handle (Figure 4, Item 8) on the hand ringing generator (Figure 4, Item 7). Install the SW-243J telephone cover (Figure 4, Item 2) on the SW-243J telephone junction box (Figure 4, Item 3). Install the four screws (Figure 4, Item 1) of the SW-243J telephone cover (Figure 4, Item 2) in the SW-243J telephone junction box (Figure 4, Item 3).
END OF TASK
0179-12
TM 55-1925-273-24&P-2 ELECTRICAL WIRING (TYPICAL) REMOVAL
0179
NOTE
Proper repair of the electrical wiring consists of replacement of the damaged wiring. When an electrical casualty requires expedient repairs, repair may be made by splicing. Splicing is authorized for repair of damaged cables if the remainder of the cable is in good mechanical and electrical condition. The cable must be replaced in its entirety at the most opportune time. Proper splicing methods should be performed as detailed in TC 55-509-1. 1. 2. 3. 4. Remove the four screws (Figure 5, Item 1) from the telephone cover (Figure 5, Item 2) of the telephone junction box (Figure 5, Item 3). Remove the telephone cover (Figure 5, Item 2) from the telephone junction box (Figure 5, Item 3). Label and remove the wiring (Figure 5, Item 4) from the terminal board (Figure 5, Item 5). Follow the wiring (Figure 5, Item 4) to its opposite end and remove it from its equipment.
1 2
5
1 2 3 4 5 6 7 8 C T T
4 4
M1288T73
Figure 5. Sound Powered Telephone Wiring (Typical). END OF TASK ELECTRICAL WIRING (TYPICAL) INSTALLATION 1. 2. 3. 4. Install wiring (Figure 5, Item 4) or splice the existing wiring IAW TC 55-509-1 and connect it to the equipment. Route the electrical wiring assembly along the same path as the old electrical wiring assembly, securing it in the same manner as the old wiring assembly. Connect the wiring (Figure 5, Item 4) to the terminal board (Figure 5, Item 5) using the labels from Step (3) of ELECTRICAL WIRING (TYPICAL) REMOVAL as a guide. Remove the labels. Install the telephone cover (Figure 5, Item 2) on the telephone junction box (Figure 5, Item 3).
0179-13
TM 55-1925-273-24&P-2 ELECTRICAL WIRING (TYPICAL) INSTALLATION - Continued 5.
0179
Install the four screws (Figure 5, Item 1) in the telephone cover (Figure 5, Item 2) of the telephone junction box (Figure 5, Item 3).
END OF TASK FOLLOW-ON MAINTENANCE Install sound powered telephone (WP 0178). END OF TASK END OF WORK PACKAGE
0179-14
TM 55-1925-273-24&P-2 FIELD MAINTENANCE INTERCOMMUNICATION SYSTEM REPLACE
0180
INITIAL SETUP: Tools and Special Tools Tool Kit, Electrical Repair (Volume 3, WP 0344, Table 1, Item 26) Materials/Parts N/A Personnel Required Watercraft Engineer 88L (2) References FM 4-01.502 References (cont.) TM 55-1925-273-10 Volume 3, WP 0302 Volume 3, WP 0344 Equipment Condition Set to OFF the INTERCOM SYSTEM. circuit breaker on the 120 V pilothouse emergency distribution panel. Lock out and tag out IAW FM 4-01.502.
0180-1
TM 55-1925-273-24&P-2
0180
REMOVAL
WARNING
NOTE
The intercommunication system consists of a 20-station system that is a party-line type voice communication system. The following describes the removal and installation instructions for a typical intercommunication unit. 1. 2. Remove the four screws (Figure 1, Item 3) that attach the intercommunication station (Figure 1, Item 2) to the housing (Figure 1, Item 1). Grasp the two handles (Figure 1, Item 4) and pull straight out until the intercommunication station (Figure 1, Item 2) is removed from the housing (Figure 1, Item 1).
1 2 3
OPERATING INSTRUCTIONS REL CALL BUSY
B
PRESS TO RELEASE
C
PRESS TO RELEASE
VOLUME OFF
DIMMER B
4
MIC OR HANDS FREE MAL HANDSET PRESS TO TALK
M1289T73
Intercommunication Station (Typical).
0180-2
TM 55-1925-273-24&P-2
0180
INSTALLATION 1. 2. Install the intercommunication station (Figure 1, Item 2) in the housing (Figure 1, Item 1) using the two handles (Figure 1, Item 4). Secure the intercommunication station (Figure 1, Item 2) to the housing (Figure 1, Item 1) with the four screws (Figure 1, Item 3).
END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. Remove the lock outs and tag outs IAW FM 4-01.502. Operate the intercommunications system under usual conditions IAW TM 55-1925-273-10. Return the intercommunication station to the desired readiness condition.
0180-3/4 blank
TM 55-1925-273-24&P-2 FIELD MAINTENANCE INTERCOMMUNICATION SYSTEM REPAIR
0181
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 3, WP 0344, Table 1, Item 27) Tool Kit, Electrical Repair (Volume 3, WP 0344, Table 1, Item 26) Materials/Parts N/A Personnel Required Watercraft Engineer 88L (1) References FM 4-01.502 References (cont.) TM 55-1925-273-10 WP 0180 Volume 3, WP 0302 Volume 3, WP 0344 Equipment Condition Intercommunication station removed. (WP 0180)
0181-1
TM 55-1925-273-24&P-2
0181
WARNING
Never reuse locking hardware. Reuse of locking hardware such as lockwashers, locking nuts, cotter pins, and lock wire can result in undetected loosening of fastening hardware causing catastrophic component failure resulting in death, injury, or damage to equipment. Ensure that all locking hardware is discarded upon removal and replaced with new. INDICATOR REMOVAL
NOTE
The intercommunication system consists of a 20-station system that is a party-line type voice communication system. The following describes the repair procedures for a typical intercommunication unit that has been removed from the system (WP 0180). The repair procedures consist of component removal and installation instructions. 1. 2. 3. 4. Remove the REL (release) indicator (Figure 1, Item 1), the incandescent lamp (Figure 1, Item 2), and the lamp lens gasket (Figure 1, Item 3) from the lamp holder (Figure 1, Item 4). Remove the CALL indicator (Figure 1, Item 5), the incandescent lamp (Figure 1, Item 6), and the lamp lens gasket (Figure 1, Item 7) from the lamp holder (Figure 1, Item 8). Remove the BUSY indicator (Figure 1, Item 9), the incandescent lamp (Figure 1, Item 10), and the lamp lens gasket (Figure 1, Item 11) from the lamp holder (Figure 1, Item 12). Remove the edge light lens (Figure 1, Item 19), the incandescent lamp (Figure 1, Item 20), and the edge light lamp gasket (Figure 1, Item 21) from the lamp holder (Figure 1, Item 22).
1, 2, 3, 4 5, 6, 7, 8 9, 10, 11, 12
OPERATING INSTRUCTIONS REL CALL BUSY
19, 20, 21, 22
PRESS TO RELEASE
17, 18
PRESS TO RELEASE
VOLUME OFF
DIMMER B
13
MIC OR
HANDS FREE
14
MAL HANDSET PRESS TO TALK
15, 16
M1290T73
Figure 1. Intercommunication Station (Front View). END OF TASK
0181-2
TM 55-1925-273-24&P-2
0181
INDICATOR INSTALLATION 1. 2. 3. 4. 5. Install the edge light lamp gasket (Figure 1, Item 21) over the lamp holder (Figure 1, Item 22), and install the incandescent lamp (Figure 1, Item 20) and the edge light lens (Figure 1, Item 19). Install the lamp lens gasket (Figure 1, Item 11) over the lamp holder (Figure 1, Item 12), and install the incandescent lamp (Figure 1, Item 10) and the BUSY indicator (Figure 1, Item 9). Install the lamp lens gasket (Figure 1, Item 7) over the lamp holder (Figure 1, Item 8), and install the incandescent lamp (Figure 1, Item 6) and the CALL indicator (Figure 1, Item 5). Install the lamp lens gasket (Figure 1, Item 3) over the lamp holder (Figure 1, Item 4), and install the incandescent lamp (Figure 1, Item 2) and the REL (release) indicator (Figure 1, Item 1). Perform the FOLLOW-ON MAINTENANCE procedure at the end of this work package.
END OF TASK FRONT PANEL SWITCH-HARDWARE REMOVAL 1. 2. 3. Remove the setscrew (Figure 1, Item 14) and the DIMMER switch knob (Figure 1, Item 13). Remove the setscrew (Figure 1, Item 15) and the HANDS FREE/NORMAL/PRESS TO TALK switch knob (Figure 1, Item 16). Remove the setscrew (Figure 1, Item 17) and the VOLUME switch knob (Figure 1, Item 18).
END OF TASK FRONT PANEL SWITCH-HARDWARE INSTALLATION 1. 2. 3. 4. Install the VOLUME switch knob (Figure 1, Item 18) and secure with the setscrew (Figure 1, Item 17). Install the HANDS FREE/NORMAL/PRESS TO TALK switch knob (Figure 1, Item 16) and secure with the setscrew (Figure 1, Item 15). Install the DIMMER switch knob (Figure 1, Item 13) and secure with the setscrew (Figure 1, Item 14). Perform the FOLLOW-ON MAINTENANCE procedure at the end of this work package.
END OF TASK
0181-3
TM 55-1925-273-24&P-2
0181
FUSE REMOVAL 1. 2. Remove the time lag fuse (Figure 2, Item 9) from the fuse holder (Figure 2, Item 10) using a fuse puller. Remove the normal fuse (Figure 2, Item 8) from the fuse holder (Figure 2, Item 10) using a fuse puller.
10 9 2
A3
7
M1291T73
Intercommunication Station (Rear View).
0181-4
TM 55-1925-273-24&P-2
0181
FUSE INSTALLATION
CAUTION
Ensure that the fuses being installed are the same voltage and amperage rating as the ones removed. Damage to the equipment could occur if incorrect fuses are installed. 1. 2. 3. Install the time lag fuse (Figure 2, Item 9) in the fuse holder (Figure 2, Item 10) using a fuse puller. Install the normal fuse (Figure 2, Item 8) in the fuse holder (Figure 2, Item 10) using a fuse puller. Perform the FOLLOW-ON MAINTENANCE procedure at the end of this work package.
END OF TASK AMPLIFIER & POWER SUPPLY BOARD CIRCUIT CARD ASSEMBLY REMOVAL 1. Remove the four screws (Figure 2, Item 4), four flat washers (Figure 2, Item 7), four lockwashers (Figure 2, Item 6), and four nuts (Figure 2, Item 5) from the amplifier and power circuit card assembly (Figure 2, Item 3) in the intercommunication station (Figure 2, Item 1). Discard lockwashers. Label and remove the wiring (Figure 2, Item 2) from the amplifier and power supply board circuit card assembly (Figure 2, Item 3). Remove the amplifier and power supply board circuit card assembly (Figure 2, Item 3).
2. 3.
END OF TASK AMPLIFIER & POWER SUPPLY BOARD CIRCUIT CARD ASSEMBLY INSTALLATION 1. 2. Install the amplifier and power supply board circuit card assembly (Figure 2, Item 3) in the intercommunication station (Figure 2, Item 1). Connect the wiring (Figure 2, Item 2) to the amplifier and power supply board circuit card assembly (Figure 2, Item 3) using the labels from Step (2) of AMPLIFIER & POWER SUPPLY BOARD CIRCUIT CARD ASSEMBLY REMOVAL as a guide. Remove the labels. Secure the amplifier and power supply board circuit card assembly (Figure 2, Item 3) with the four screws (Figure 2, Item 4), four flat washers (Figure 2, Item 7), four lockwashers (Figure 2, Item 6), and four nuts (Figure 2, Item 5). Perform the FOLLOW-ON MAINTENANCE procedure at the end of this work package.
3.
4.
END OF TASK
0181-5
TM 55-1925-273-24&P-2
0181
STATION SELECTOR ASSEMBLY REMOVAL 1. 2. 3. 4. Remove the two screws (Figure 3, Item 9) from the faceplate (Figure 3, Item 6) of the intercommunication station (Figure 3, Item 1). OPEN the faceplate (Figure 3, Item 6). Label and remove the wiring (Figure 3, Item 8) from the station selector assembly (Figure 3, Item 7). Remove the two screws (Figure 3, Item 3), two flat washers (Figure 3, Item 5), two lockwashers (Figure 3, Item 4), and two nuts (Figure 3, Item 2) from the station selector assembly (Figure 3, Item 7). Discard lockwashers.
1 4 8 8 2 3 5
7 9 4 5
6 FRONT VIEW
Figure 3. Intercommunication Station (Front View). END OF TASK
M1292T73
0181-6
TM 55-1925-273-24&P-2
0181
STATION SELECTOR ASSEMBLY INSTALLATION 1. 2. 3. 4. 5. 6. Install the station selector assembly (Figure 3, Item 7) in the intercommunication station. Install the two screws (Figure 3, Item 3), two flat washers (Figure 3, Item 5), two lockwashers (Figure 3, Item 4), and two nuts (Figure 3, Item 2) on the station selector assembly (Figure 3, Item 7). Connect the wiring (Figure 3, Item 8) to the station selector assembly (Figure 3, Item 7) using the labels from Step (3) of STATION SELECTOR ASSEMBLY REMOVAL as a guide. Remove the labels. CLOSE the faceplate (Figure 3, Item 6). Install the two screws (Figure 3, Item 9) in the faceplate (Figure 3, Item 6) of the intercommunication station (Figure 3, Item 1). Perform the FOLLOW-ON MAINTENANCE procedure at the end of this work package.
END OF TASK
0181-7
TM 55-1925-273-24&P-2
0181
RESISTOR BOARD CIRCUIT CARD ASSEMBLY REMOVAL 1. 2. 3. Remove the two screws (Figure 3, Item 9) from the faceplate (Figure 3, Item 6) of the intercommunication station (Figure 3, Item 1). OPEN the faceplate (Figure 3, Item 6). Remove the two screws (Figure 4, Item 4), two flat washers (Figure 4, Item 3), two lockwashers (Figure 4, Item 2), and two spacers (Figure 4, Item 1) from the resistor board circuit card assembly (Figure 4, Item 5). Discard lockwashers. Remove the resistor board circuit card assembly (Figure 4, Item 5) from the inside of the faceplate (Figure 4, Item 11).
4.
0181-8
TM 55-1925-273-24&P-2 RESISTOR BOARD CIRCUIT CARD ASSEMBLY REMOVAL - Continued
0181
DS4 XDS4
S25
DS1 XDS1
DS2 XDS2
11
DS3 XDS3
S27
DS5 XDS5
TOP VIEW 12
S26
LS1
E1
J1
5 13
10
6
M1377T73
Intercommunication Station (Top View Inside of Faceplate).
0181-9
TM 55-1925-273-24&P-2
0181
RESISTOR BOARD CIRCUIT CARD ASSEMBLY INSTALLATION 1. 2. Install the resistor board circuit card assembly (Figure 4, Item 5) in the inside of the faceplate (Figure 4, Item 11). Install the two screws (Figure 4, Item 4), two flat washers (Figure 4, Item 3), two lockwashers (Figure 4, Item 2), and two spacers (Figure 4, Item 1) in the resistor board circuit card assembly (Figure 4, Item 5). CLOSE the faceplate (Figure 3, Item 6). Install the two screws (Figure 3, Item 9) in the faceplate (Figure 3, Item 6) of the intercommunication station (Figure 3, Item 1). Perform the FOLLOW-ON MAINTENANCE procedure at the end of this work package.
3. 4. 5.
END OF TASK RELAY BOARD CIRCUIT CARD ASSEMBLY REMOVAL 1. Remove the three screws (Figure 5, Item 3), three flat washers (Figure 5, Item 4), three lockwashers (Figure 5, Item 5), retainer (Figure 5, Item 2), and three spacers (Figure 5, Item 6) from the relay board circuit card assembly (Figure 5, Item 1). Discard lockwashers. Remove the relay board circuit card assembly (Figure 5, Item 1) from the bottom of the intercommunication station (Figure 5, Item 7).
2.
0181-10
TM 55-1925-273-24&P-2 RELAY BOARD CIRCUIT CARD ASSEMBLY REMOVAL - Continued

1
0181
T1
A
T2
BOTTOM VIEW 7
6 5 4 3 2
M1293T73
Figure 5. Intercommunication Station (Bottom View). END OF TASK RELAY BOARD CIRCUIT CARD ASSEMBLY INSTALLATION 1. 2. Install the relay board circuit card assembly (Figure 5, Item 1) in the intercommunication station (Figure 5, Item 7). Install the three screws (Figure 5, Item 3), three flat washers (Figure 5, Item 4), three lockwashers (Figure 5, Item 5), retainer (Figure 5, Item 2), and three spacers (Figure 5, Item 6) in the relay board circuit card assembly (Figure 5, Item 1). Perform the FOLLOW-ON MAINTENANCE procedure at the end of this work package.
3.
END OF TASK SWITCH REMOVAL 1. 2. 3. Remove the setscrew (Figure 4, Item 10) from the knob (Figure 4, Item 9). Remove the knob (Figure 4, Item 9) from the switch shaft (Figure 4, Item 6). Remove the nut (Figure 4, Item 7) and lockwasher (Figure 4, Item 8) from the switch shaft (Figure 4, Item 6). Discard lockwasher.
0181-11
TM 55-1925-273-24&P-2 SWITCH REMOVAL - Continued 4. 5. 6. 7.
0181
Remove the two screws (Figure 3, Item 9) from the faceplate (Figure 3, Item 6) of the intercommunication station (Figure 3, Item 1). OPEN the faceplate (Figure 3, Item 6). Label and remove the wiring (Figure 4, Item 12) from the switch (Figure 4, Item 13). Remove the switch (Figure 4, Item 13) from the rear of the faceplate (Figure 4, Item 11).
END OF TASK SWITCH INSTALLATION 1. 2. 3. 4. 5. 6. 7. 8. Install the switch (Figure 4, Item 13) in the rear of the faceplate (Figure 4, Item 11). Connect the wiring (Figure 4, Item 12) to the switch (Figure 4, Item 13) using the labels from Step (6) of SWITCH REMOVAL as a guide. Remove the labels. CLOSE the faceplate (Figure 3, Item 6). Install the two screws (Figure 3, Item 9) in the faceplate (Figure 3, Item 6) of the intercommunication station (Figure 3, Item 1). Install the nut (Figure 4, Item 7) and lockwasher (Figure 4, Item 8) on the switch shaft (Figure 4, Item 6). Install the knob (Figure 4, Item 9) on the switch shaft (Figure 4, Item 6). Install the setscrew (Figure 4, Item 10) in the knob (Figure 4, Item 9). Perform the FOLLOW-ON MAINTENANCE procedure at the end of this work package.
END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. Install the intercommunication station (WP 0180). Operate the intercommunication system under usual conditions and check for proper operation IAW TM 55-1925-273-10. Return the equipment to the desired readiness condition.
0181-12
TM 55-1925-273-24&P-2 FIELD MAINTENANCE ENGINE ORDER TELEGRAPH (EOT) REPLACE
0182
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 3, WP 0344, Table 1, Item 27) Multimeter (Volume 3, WP 0344, Table 1, Item 15) Materials/Parts N/A Personnel Required Watercraft Engineer 88L (2) References FM 4-01.502 References (cont.) TC 55-509-1 TM 55-1925-273-10 Volume 3, WP 0303 Volume 3, WP 0344 Equipment Condition Set to OFF the E.O.T. SYSTEM. circuit breaker at the 120 V emergency distribution panel No. 1. Lock out and tag out IAW FM 4-01.502.
0182-1
TM 55-1925-273-24&P-2
0182
WARNING
NOTE
This procedure is applicable to both the Enclosed Operating Station (EOS) and pilothouse Engine Order Telegraph (EOT) units. 1. Remove the four screws (Figure 1, Item 5), four flat washers (Figure 1, Item 4), four lockwashers (Figure 1, Item 3), and four nuts (Figure 1, Item 2), and remove the EOT panel (Figure 1, Item 1) from the console. Discard lockwashers.
WARNING
Replace or repair components only after the affected circuit has been secured, locked out, and tagged out IAW FM 4-01.502. Performing replacement with the circuit energized may result in injury. 2. Use a multimeter to check for voltage at the terminal board (Figure 1, Item 6). If voltage is present, ensure that the proper circuit breaker is set to OFF, locked out, and tagged out IAW FM 4-01.502. If no voltage is present, continue with this procedure. Label and remove the wires from the terminal board (Figure 1, Item 6).
3.
END OF TASK INSTALLATION 1. 2. Install the wires on the terminal board (Figure 1, Item 6) using the labels from Step (3) of REMOVAL as a guide. Discard labels. Install the EOT panel (Figure 1, Item 1) in the console. Secure it with the four screws (Figure 1, Item 5), four flat washers (Figure 1, Item 4), four lockwashers (Figure 1, Item 3), and four nuts (Figure 1, Item 2).
0182-2

1
0182
PORT
STOP
STARBOARD
STOP
1/4
HA
LF
E ST RN
HA
E AH A D
LF
3/4
HA LF
STERN
1/4
LF HA
E AH A D
1/4
3/4
1/4
3/4
3/4
FU
LL
LL
LL FU
ENG
RA IN E O RD E R T ELEG
PH
ENG
DIMMER 1
EOT Panel Removed.
0182-3
A
IN E O R D E R T E L E G
FU
FU LL
RA
PH
M1294T73
TM 55-1925-273-24&P-2
0182
FOLLOW-ON MAINTENANCE 1. 2. 3. 4. Remove the lock outs and tag outs IAW FM 4-01.502. Set the circuit breaker to ON. Test operate the EOT IAW TM 55-1925-273-10. Return the equipment to the desired readiness condition.
0182-4
TM 55-1925-273-24&P-2 FIELD MAINTENANCE ENGINE ORDER TELEGRAPH (EOT) REPAIR
0183
INITIAL SETUP: Tools and Special Tools Tool Kit, Electrical Repair (Volume 3, WP 0344, Table 1, Item 26) Materials/Parts N/A Personnel Required Watercraft Engineer 88L (2) References FM 4-01.502 References (cont.) TM 55-1925-273-10 WP 0182 Volume 3, WP 0303 Volume 3, WP 0344 Equipment Condition Engine Order Telegraph (EOT) panel removed. (WP 0182)
0183-1
TM 55-1925-273-24&P-2
0183
WARNING
NOTE
This procedure is applicable to both the Enclosed Operating Station (EOS) and pilothouse Engine Order Telegraph (EOT) units. ROTARY SWITCH REMOVAL 1. 2. 3. 4. Remove the screw (Figure 1, Item 1) and the switch knob (Figure 1, Item 2) from the EOT panel (Figure 1, Item 3). Label and disconnect the electrical wiring (Figure 1, Item 4) from the applicable rotary switch (Figure 1, Item 9) to be replaced. Tilt the panel (Figure 1, Item 3) up and remove the four mounting screws (Figure 1, Item 8), four flat washers (Figure 1, Item 7), four lockwashers (Figure 1, Item 6), and four nuts (Figure 1, Item 5). Discard lockwashers. Remove the applicable rotary switch (Figure 1, Item 9) from the panel (Figure 1, Item 3).
END OF TASK ROTARY SWITCH INSTALLATION 1. Tilt the panel (Figure 1, Item 3) up and install the applicable rotary switch (Figure 1, Item 9) using the four mounting screws (Figure 1, Item 8), four flat washers (Figure 1, Item 7), four lockwashers (Figure 1, Item 6), and four nuts (Figure 1, Item 5). Tighten the four mounting screws (Figure 1, Item 8). Connect the electrical wiring (Figure 1, Item 4) to the rotary switch (Figure 1, Item 9). Position the switch knob (Figure 1, Item 2) on the shaft of the rotary switch (Figure 1, Item 9) and secure with the screw (Figure 1, Item 1).
2. 3.
0183-2
TM 55-1925-273-24&P-2 ROTARY SWITCH INSTALLATION - Continued
0183
PORT
STARBOARD
STOP
1/4
STOP
LF HA
HA LF
STER N
HA
LF
E ST RN
1/4
1/4
1/4
LF HA
E AH AD
E AH A D
3/4
LL FU
3/4
FU LL
3/4
FU LL
3/4
FU LL
EN
G IN E
O R D ER TE LE G R
AP
ENG
DIMMER
Engine Order Telegraph (EOT) Panel Repair (Typical).
0183-3
A
IN E O R D E R T E L E G
RA
PH
M1295T73
TM 55-1925-273-24&P-2
0183
FOLLOW-ON MAINTENANCE 1. 2. Install the EOT panel (WP 0182). Operate the EOT IAW TM 55-1925-273-10 and ensure that the panel operates properly.
0183-4
TM 55-1925-273-24&P-2 FIELD MAINTENANCE TANK LEVEL INDICATOR (TLI) INSPECT
0184
INITIAL SETUP: Tools and Special Tools Tool Kit, Electrical Repair (Volume 3, WP 0344, Table 1, Item 26) Materials/Parts N/A Personnel Required Watercraft Engineer 88L (2) References TM 55-1925-273-10 References (cont.) Volume 3, WP 0304 Volume 3, WP 0344 Equipment Condition TLI system operating under usual conditions IAW TM 55-1925-273-10.
0184-1
TM 55-1925-273-24&P-2
0184
INSPECT
WARNING
Take great care when working around energized electrical equipment. Contact between unprotected body parts and electrical conductors can cause serious injury or death. Do not wear jewelry or other conductive items while servicing energized electrical equipment. Failure to comply with these precautions can cause serious injury or death. 1. 2. Place the POWER ON/OFF switch (Figures 1 and 2, Item 3) on the Tank Level Indicator (TLI) control panel in the Enclosed Operating Station (EOS) to OFF. Verify that the fluid meters on the control panel (Figures 1 and 2, Item 1) and at the remote indicator panel (Figure 3, Item 1) deflects to zero.
WARNING
Replace or repair components only after the affected circuit has been secured, locked out, and tagged out IAW FM 4-01.502. Performing replacement with the circuit energized may result in injury. 3. 4. 5. 6. Loosen the captive screws (Figure 1 or 2, Item 3), and OPEN the front panel of TLI control panel that contains the faulty indication. Place the POWER ON/OFF switch (Figures 1 and 2, Item 2) on the control panel to ON. Verify that the POWER lamp (Figures 1 and 2, Item 4) illuminates. Locate, press, and hold the CALIBRATE pushbutton switch (Figure 4, Item 1) on the suspect control module in the TLI control panel. While the CALIBRATE pushbutton switch (Figure 4, Item 1) is pressed, verify that the selected control panel fluid level meter (Figures 1 and 2, Item 1) and the associated remote indicator panel fluid level meter (Figure 3, Item 1) deflects to the full-scale position. If the fluid meters do not fully deflect, notify the maintenance supervisor. Release the selected CALIBRATE pushbutton switch (Figure 4, Item 1). At the TLI control panels, place the POWER ON/OFF switch (Figures 1 and 2, Item 1) to OFF. CLOSE and secure the TLI control panel front covers (Figure 1 and 2, Item 3).
7. 8. 9. 10.
0184-2
TM 55-1925-273-24&P-2
0184
3
PANEL CONTROL
4
M1378T73
Figure 1.
11 Channel TLI Control Panel.
3
PANEL CONTROL
M1296T73
Figure 2.
0184-3
TM 55-1925-273-24&P-2
0184
M1297T73
Figure 3.
TLI Remote Indicator.
RP3 CR2 C4 R18 R19 Q5 CR22 Q2 R8 R8 Q6 R16 R7 Q1 R10 R14 R15 CR21 R6 CR1 C2 R4 R5
RP2 S1 R3 R2 C1
RP1
R7 R1 R20
Q7 Q3 R11 CR6 R13 R12 C3 CR4 K1 R23 R22 C3 CR8 Q4 R21
Q8 CR18
K2
M1298T73
Figure 4. Control Module Circuit Card. END OF TASK END OF WORK PACKAGE
0184-4
TM 55-1925-273-24&P-2 FIELD MAINTENANCE TANK LEVEL INDICATOR (TLI) TEST
0185
0185-1
TM 55-1925-273-24&P-2
0185
TEST 1. 2. Set the ON/OFF switch (Figures 1 and 2, Item 3) on the Tank Level Indicators (TLI) control panel in the Enclosed Operating Station (EOS) to OFF. Verify that the fluid meters on the control panel (Figures 1 and 2, Item 1) and at the remote indicator panel (Figure 3, Item 1) deflects to zero.
1 2
3
PANEL CONTROL
M1097T73
Figure 1. 11 Channel TLI Control Panel.
0185-2
TM 55-1925-273-24&P-2 TEST - Continued

1 2
0185
3
PANEL CONTROL
M1098T73
Figure 2.
M1099T73
Figure 3.
0185-3
TM 55-1925-273-24&P-2 TEST - Continued
0185
WARNING
Take great care when working around energized electrical equipment. Contact between unprotected body parts and electrical conductors can cause serious injury or death. Do not wear jewelry or other conductive items while servicing energized electrical equipment. Failure to comply with these precautions can cause serious injury or death. 3. 4. 5. 6. Loosen the captive screws (Figure 1 or 2, Item 2), and open the front panel of the TLI control panel. Set the ON-OFF switch (Figures 1 and 2, Item 3) on the control panel to ON. Verify that the POWER lamp (Figures 1 and 2, Item 4) illuminates. To test each level indicator circuit in turn, press and hold the CALIBRATE pushbutton switch (Figure 4, Item 1) on each control module in the TLI control panel one at a time. While the CALIBRATE pushbutton switch (Figure 4, Item 1) is pressed, verify that the selected control panel fluid level meter (Figures 1 and 2, Item 1) and the associated remote indicator panel fluid level meter (Figure 3, Item 1) deflects to the full-scale position.
RP3 CR2 C4 R18 R19 Q5 CR22 R16 Q2 R8 R8 Q6 R7 Q1 R10 R14 R15 CR21 R6 CR1 C2 R4 R5
RP2 S1 R3 R2 C1
RP1
R7 R1 R20
Q3 R11 CR6 R13 R12 C3 CR4 K1
Q4
Q7 R21
Q8 CR18 R23 R22 C3 CR8 K2
M1100T73
Figure 4. Control Module Circuit Card.
0185-4
TM 55-1925-273-24&P-2 TEST - Continued 7. 8. 9. 10. 11. If the fluid meters do not fully deflect, notify the maintenance supervisor. Release the selected CALIBRATE pushbutton switch (Figure 4, Item 1). At the TLI control panels, place the POWER ON/OFF switch (Figure 1 or 2, Item 3) to OFF.
0185
Close the front panel and tighten the captive screws (Figure 1 or 2, Item 2) on the TLI control panel front cover. Return the equipment to the desired readiness condition.
0185-5/6 blank
TM 55-1925-273-24&P-2 FIELD MAINTENANCE TANK LEVEL INDICATOR (TLI) ADJUST
0186
0186-1
TM 55-1925-273-24&P-2
0186
SELF CALIBRATION 1. Set to OFF the ON/OFF switches (Figure 1, Item 5 and Figure 2, Item 3) on the Tank Level Indicator (TLI) control panels in the Enclosed Operating Station (EOS), and verify that the POWER lamps (Figures 1 and 2, Item 2) are out. Verify that all fluid meters on the control panels (Figure 1, Item 6 and Figure 2, Item 4) and remote indicator panels (Figure 3, Item 1) deflect to 0.
1 2 3 2 3 4
2.
PANEL CONTROL
5 6 7
M1101T73
0186-2
TM 55-1925-273-24&P-2 SELF CALIBRATION - Continued
0186
PANEL CONTROL
3 4
M1102T73
Figure 2.
WARNING
Take great care when working around energized electrical equipment. Contact between unprotected body parts and electrical conductors can cause serious injury or death. Do not wear jewelry or other conductive items while servicing energized electrical equipment. Failure to comply with these precautions can cause serious injury or death. 3. 4. Loosen the captive screws (Figure 1, Item 4 or Figure 2, Item 2) and open the front panel of the TLI control panel. Set to ON the ON-OFF switches (Figure 1, Item 5 and Figure 2, Item 3) on the control panel. Verify that the POWER lamp (Figure 1, Item 6 and Figure 2, Item 4) illuminates.
NOTE
Test only one fluid level indicator at a time. 5. To test each level indicator circuit in turn, press and hold the CALIBRATE pushbutton switch (Figure 4, Item 1) on each control module in the TLI.
0186-3
TM 55-1925-273-24&P-2 SELF CALIBRATION - Continued 6.
0186
While the CALIBRATE pushbutton switch (Figure 4, Item 1) is pressed, verify that the selected control panel fluid level meter (Figures 1 and 2, Item 1) and the associated remote indicator panel fluid level meter (Figure 3, Item 1) deflect to the full-scale position.
1
M1103T73
Figure 3.

1
RP3 CR2 C4 R14 R15 CR22 Q2 R8 R8 Q6 R16 R7 Q1 R10 CR21 R6 CR1 C2 R4 R5
RP2 R3 R2 C1 S1
RP1
R18 R19 Q5
R7 R1 R20
Q3 CR6
Q4 R11 R13 R12 C3 CR4
Q7 R21 R23 R22 C3 CR8
Q8 CR18
K1
K2
M1104T73
0186-4
TM 55-1925-273-24&P-2 SELF CALIBRATION - Continued
0186
NOTE
The port and starboard day tanks are the only tanks that contain functional high and low level alarm circuits on the TLI system. 7. If the control module containing the CALIBRATE pushbutton switch (Figure 4, Item 1) being pressed contains a high-alarm circuit, verify that the ALARM horn sounds (Figure 1, Item 7) and the associated HIGH ALARM lamp illuminates (Figure 1, Item 2) when the fluid level meter (Figure 1, Item 1) is at full defection. Release the selected CALIBRATE pushbutton switch (Figure 4, Item 1). At the TLI control panels, set to OFF the POWER ON/OFF switch (Figure 1, Item 5 or Figure 2, Item 3). Close the front panel and tighten the captive screws (Figure 1, Item 4 or Figure 2, Item 2) on the TLI control panel front cover. Return the TLI control panel to the desired readiness condition.
8. 9. 10. 11.
END OF TASK PERFORM FLOAT SIMULATOR TEST 1. 2. Set to OFF the ON/OFF switches (Figure 1, Item 5 and Figure 2, Item 3) on the Tank Level Indicator (TLI) control panels in the EOS, and verify that the POWER lamps (Figure 1, Item 6 and Figure 2, Item 4) are out. Verify that all fluid meters on the control panels (Figures 1 and 2, Item 1) and remote indicator panels (Figure 3, Item 1) deflect to 0.
WARNING
Take great care when working around energized electrical equipment. Contact between unprotected body parts and electrical conductors can cause serious injury or death. Do not wear jewelry or other conductive items while servicing energized electrical equipment. Failure to comply with these precautions can cause serious injury or death. 3. Loosen the captive screws (Figure 1, Item 4 or Figure 2, Item 2) and open the front panel of the TLI control panel.
NOTE
This test is designed to be performed on all fluid level indicators one at a time. 4. 5. 6. Label and remove the wiring from terminals 1, 2, and 3 (Figure 5, Item 2) of the selected TLI control module in the control panel. Label and remove the float simulator cable from the FLOAT CONTROL INDICATOR simulator bracket (Figure 5, Item 3). Connect the float simulator cable to the terminals (Figure 5, Item 2) associated with the selected control module as follows: a. b. c. Red lead to terminal 1. Black lead to terminal 2. Green lead to terminal 3.
0186-5
TM 55-1925-273-24&P-2 PERFORM FLOAT SIMULATOR TEST - Continued
0186
M1105T73
Figure 5. 7. 8.
Float Simulator.
Set to ON the ON-OFF switch (Figure 1, Item 5 and Figure 2, Item 3) on the control panel. Observe fluid level meter deflection (Figures 1 and 2, Item 1) at the selected receiver module and verify that the deflection on the receiver module (Figure 3, Item 1) matches and follows the deflection on the control module. Adjust the FLOAT SIMULATOR control (Figure 5, Item 1) to bring the deflection on the selected TLI control panel indicator (Figures 1 and 2, Item 3) to 25% of its rated capacity.
9.
NOTE
The port and starboard day tanks are the only tanks that contain functional high and low level alarm circuits to the TLI system. 10. Verify that selected remote indicator panel indicator (Figure 3, Item 1) follows the control panel indicator (Figures 1 and 2, Item 1). For day tank meters, verify that the LOW ALARM lamp (Figure 1, Item 3) illuminates and the ALARM horn (Figure 1, Item 7) on the TLI control panel sounds. Adjust the FLOAT SIMULATOR control (Figure 5, Item 1) to bring the deflection on the selected TLI control panel indicator (Figures 1 and 2, Item 1) to 50% of its rated capacity. Verify that the selected remote indicator panel indicator (Figure 3, Item 1) follows the control panel indicator (Figures 1 and 2, Item 1). For day tank meters, verify that the LOW ALARM lamp (Figure 1, Item 3) goes out and the ALARM horn (Figure 1, Item 2) goes silent. Adjust the FLOAT SIMULATOR control (Figure 5, Item 1) to bring the deflection on the selected TLI control panel indicator (Figures 1 and 2, Item 1) to 95% of its rated capacity. Verify that selected remote indicator panel indicator (Figure 4, Item 1) follows the control panel indicator. For day tanks meters, verify that the HIGH ALARM (Figure 1, Item 2) lamp illuminates steadily and the ALARM horn (Figure 1, Item 7) on the TLI control panel sounds. Adjust the FLOAT SIMULATOR control (Figure 5, Item 1) to bring the deflection on the selected TLI control panel indicator (Figures 1 and 2, Item 1) to 50% of its rated capacity.
11. 12.
13.
14. 15.
0186-6
TM 55-1925-273-24&P-2 PERFORM FLOAT SIMULATOR TEST - Continued 16.
0186
Verify that selected remote indicator panel indicator (Figure 4, Item 1) follows the control panel indicator (Figures 1 and 2, Item 1). For day tank meters, verify that the HIGH ALARM (Figure 1, Item 2) lamp goes out and the ALARM horn (Figure 1, Item 7) goes silent. Set to OFF the ON-OFF switch (Figure 1, Item 5 and Figure 2, Item 3). Remove the float simulator cable from the control module terminals (Figure 5, Item 2). Connect the wiring to terminals 1, 2, and 3 (Figure 5, Item 2) using the labels from Step (4) as a guide. Remove the labels. Connect the float simulator cable to the FLOAT CONTROL INDICATOR simulator bracket (Figure 5, Item 3) using the labels from Step (5) as a guide. Remove the labels. Close the TLI control panel front cover and tighten the captive screws (Figure 1, Item 4 and Figure 2, Item 2). Return the equipment to the desired readiness condition.
17. 18. 19. 20. 21. 22.
0186-7/8 blank
TM 55-1925-273-24&P-2 FIELD MAINTENANCE TANK LEVEL INDICATOR (TLI) CALIBRATE
0187
INITIAL SETUP: Tools and Special Tools Tool Kit, Electrical Repair (Volume 3, WP 0344, Table 1, Item 26) Materials/Parts N/A Personnel Required Watercraft Engineer 88L (2) References TM 55-1925-273-10 References (cont.) Volume 3, WP 0304 Volume 3, WP 0344 Equipment Condition Tank Level Indicator (TLI) system operating under usual conditions IAW TM 55-1925-273-10.
0187-1
TM 55-1925-273-24&P-2
0187
CALIBRATION 1. 2. 3. Set to OFF the ON-OFF switch (Figure 1, Item 4 and Figure 2, Item 3) on the TLI control panels in the Enclosed Operating Station (EOS). Verify that the POWER lamp (Figure 1, Item 5 and Figure 2, Item 4) is out. Verify that all fluid meters on the control panels (Figure 1, Item 1) and at the remote receiver modules (Figure 3, Item 1) deflect to 0. Set to ON the ON-OFF switch (Figure 1, Item 4 and Figure 2, Item 3) on each control panel. Verify that the POWER lamp (Figure 1, Item 5 and Figure 2, Item 4) illuminates.
WARNING
Take great care when working around energized electrical equipment. Contact between unprotected body parts and electrical conductors can cause serious injury or death. Do not wear jewelry or other conductive items while servicing energized electrical equipment. Failure to comply with these precautions can cause serious injury or death. 4. Loosen the captive screws (Figure 1, Item 3 and Figure 2, Item 2) and open the front panel of the TLI control panel.
1 2 3
4
PANEL CONTROL
5
M1299T73
0187-2
TM 55-1925-273-24&P-2 CALIBRATION - Continued

1 2
0187
3
PANEL CONTROL
4
M1300T73
Figure 2. 5. 6.
Locate, press, and hold the CALIBRATE pushbutton switch (Figure 4, Item 1) on each control module in the receiver panel, in turn. While a CALIBRATE pushbutton switch (Figure 4, Item 1) is pressed, verify that the selected control panel fluid level meter (Figures 1 and 2, Item 1) and the associated remote fluid level meter (Figure 3, Item 1) deflect to the full-scale position.
1
M1301T73
Figure 3.
TLI Remote Receiver Module.
0187-3
0187
RP3 CR2 C4 R14 R15 CR22 R16 Q2 R8 R8 Q6 R7 Q1 R10 CR21 R6 CR1 C2 R4 R5
RP2 R3 R2 C1
S1
RP1
R18 R19
Q5
R7 R1 R20
Q3 CR6
Q4 R11 R13 R12 C3 CR4
Q7 R21 R23 R22 C3 CR8
Q8 CR18
K1
K2
M1302T73
0187-4
0187
NOTE
The port and starboard day tanks are the only tanks that contain functional high and low level alarm circuits on the TLI system. 7. If the control module containing the CALIBRATE pushbutton being pressed contains a high level alarm circuit, verify that the alarm horn (Figure 1, Item 6) sounds and the associated HIGH ALARM lamp (Figure 1, Item 2) illuminates when the CALIBRATE pushbutton switch (Figure 4, Item 1) is pressed. Release the selected CALIBRATE pushbutton switch (Figure 4, Item 1). Close the TLI control panel front cover and tighten the captive screws (Figure 1, Item 3 and Figure 2, Item 2).
8. 9.
NOTE
TLI transmitters may not be field repaired or calibrated. Return the TLI transmitter to the Original Equipment Manufacturer (OEM) for repair, calibration, or adjustment. Contact Gems Sensors Inc., One Cowles Road, Plainville, CT 06062-1198 to make arrangements for returning the TLI transmitter(s). 10. Return the equipment to the desired readiness condition.
0187-5/6 blank
TM 55-1925-273-24&P-2 FIELD MAINTENANCE TANK LEVEL INDICATOR (TLI) REPLACE
0188
INITIAL SETUP: Tools and Special Tools Multimeter (Volume 3, WP 0344, Table 1, Item 15) Tool Kit, Electrical Repair (Volume 3, WP 0344, Table 1, Item 26) Materials/Parts N/A Personnel Required Watercraft Engineer 88L (2) References FM 4-01.502 References (cont.) TM 55-1925-273-10 Volume 3, WP 0304 Volume 3, WP 0344 WP 0187 Equipment Condition Set to OFF the TLI SYSTEM. circuit breaker at 120 V emergency distribution panel No. 1. Lock out and tag out IAW FM 4-01.502.
0188-1
TM 55-1925-273-24&P-2
0188
POWER INDICATOR BULB REMOVAL 1. 2. Remove the protective lens cover (Figure 1, Item 1). Remove the bulb (Figure 1, Item 2).
END OF TASK POWER INDICATOR BULB INSTALLATION 1. 2. Install the bulb (Figure 1, Item 2) finger tight. Install the protective lens cover (Figure 1, Item 1) finger tight.
END OF TASK LOW ALARM AND HIGH ALARM INDICATOR BULBS REMOVAL 1. 2. Remove the protective lens cover (Figure 1, Item 3). Remove the bulb (Figure 1, Item 4).
END OF TASK LOW ALARM AND HIGH ALARM INDICATOR BULBS INSTALLATION 1. 2. Install the bulb (Figure 1, Item 4) finger tight. Install the protective lens cover (Figure 1, Item 3) finger tight.
0188-2
TM 55-1925-273-24&P-2 LOW ALARM AND HIGH ALARM INDICATOR BULBS INSTALLATION - Continued
1
0188
PANEL CONTROL
M1303T73
Tank Level Indicator Panel.
0188-3
TM 55-1925-273-24&P-2
0188
CONTROL MODULE REMOVAL
WARNING
Never reuse locking hardware. Reuse of locking hardware such as lockwashers, locking nuts, cotter pins, and lock wire can result in undetected loosening of fastening hardware causing catastrophic component failure resulting in death, injury, or damage to equipment. Ensure that all locking hardware is discarded upon removal and replaced with new. 1. 2. Set to OFF the POWER ON/OFF switch (Figure 2, Item 2) on the Tank Level Indicator (TLI) control panel in the Enclosed Operating Station (EOS). Loosen the captive screws (Figure 2, Item 1) and open the front panel.
WARNING
Replace or repair components only after the affected circuit has been secured, locked out, and tagged out IAW FM 4-01.502. Performing replacement with the circuit energized may result in injury. 3. Use a multimeter to check for voltage at the POWER ON/OFF switch (Figure 2, Item 2). If voltage is present, ensure that the proper circuit breaker is set to OFF, locked out, and tagged out IAW FM 4-01.502. If no voltage is present, continue with the procedure.
2
PANEL CONTROL
M1304T73
Figure 2. TLI Control Panel and Components. 4. 5. 6. Loosen the two retaining screws that secure the retaining bar (Figure 3, Item 1). Remove the retaining bar (Figure 3, Item 1). Remove the control module (Figure 3, Item 2) from the card rack.
0188-4
TM 55-1925-273-24&P-2 CONTROL MODULE REMOVAL - Continued
0188
M1305T73
Figure 3. END OF TASK CONTROL MODULE INSTALLATION 1. 2. 3.
Receiver Panel Interior.
Install the control module (Figure 3, Item 2) in the appropriate slot of the card rack, pushing straight inward until the card is firmly seated. Install the retaining bar (Figure 3, Item 1) and secure it with the retaining screws (Figure 2, Item 1). Perform the FOLLOW-ON MAINTENANCE procedure at the end of this work package.
END OF TASK
0188-5
TM 55-1925-273-24&P-2
0188
PANEL METER REMOVAL 1. 2. Set to OFF the POWER ON/OFF switch (Figure 2, Item 2) on the TLI control panel in the EOS. Loosen the captive screws (Figure 2, Item 1) and open the front panel.
WARNING
Replace or repair components only after the affected circuit has been secured, locked out, and tagged out IAW FM 4-01.502. Performing replacement with the circuit energized may result in injury. 3. Use a multimeter to check for voltage at the POWER ON/OFF switch (Figure 2, Item 2). If voltage is present, ensure that the proper circuit breaker is set to OFF, locked out, and tagged out IAW FM 4-01.502. If no voltage is present, continue with the procedure. CLOSE the TLI control panel door and tighten the captive screws (Figure 2, Item 1). Remove the four screws (Figure 4, Item 4) and four lockwashers (Figure 4, Item 3). Discard lockwashers. Remove the face frame (Figure 4, Item 2). Remove the four screws (Figure 4, Item 5) from the panel meter (Figure 4, Item 1). Remove the panel meter (Figure 4, Item 1) from its mount and disconnect the cable from the faulty panel meter.
1
4. 5. 6. 7. 8.
5 2
3 4
M1306T73
Panel Meter.
0188-6
TM 55-1925-273-24&P-2 PANEL METER INSTALLATION 1. 2. 3. 4. 5. Connect the panel meter cable and insert the panel meter (Figure 4, Item 1) in the control panel. Install the four screws (Figure 4, Item 5) in the panel meter (Figure 4, Item 1).
0188
Install the face frame (Figure 4, Item 2) over the panel meter (Figure 4, Item 1), securing it with the four screws (Figure 4, Item 4) and four lockwashers (Figure 4, Item 3). Set to ON the POWER ON/OFF switch (Figure 2, Item 2) at the TLI control panel in the EOS. Perform the FOLLOW-ON MAINTENANCE procedure at the end of this work package.
END OF TASK ALARM HORN REMOVAL 1. Loosen the captive screws (Figure 2, Item 1) and open the front panel.
WARNING
Replace or repair components only after the affected circuit has been secured, locked out, and tagged out IAW FM 4-01.502. Performing replacement with the circuit energized may result in injury. 2. Use a multimeter to check for voltage at the POWER ON/OFF switch (Figure 2, Item 2). If voltage is present, ensure that the proper circuit breaker is set to OFF, locked out, and tagged out IAW FM 4-01.502. If no voltage is present, continue with the procedure. Label and remove the wiring (Figure 5, Item 3) from the terminals (Figure 5, Item 4) of the alarm horn assembly (Figure 5, Item 2). Loosen the retaining nut (Figure 5, Item 5) and remove the alarm horn assembly (Figure 5, Item 2) from the alarm panel (Figure 5, Item 1).
3. 4.
0188-7
TM 55-1925-273-24&P-2 ALARM HORN REMOVAL - Continued

2 1
0188
5 4 3
PANEL CONTROL
M1307T73
Figure 5. END OF TASK ALARM HORN INSTALLATION 1. 2. 3. 4.
Alarm Horn Assembly.
Install the horn assembly (Figure 5, Item 2) in the alarm panel (Figure 5, Item 1) and secure it with the retaining nut (Figure 5, Item 5). Connect the wires (Figure 5, Item 3) to the terminals (Figure 5, Item 4) of the alarm horn assembly (Figure 5, Item 2) using the labels from Step (3) of REMOVAL as a guide. Remove the labels. Close the front panel and tighten the captive screws (Figure 2, Item 1). Perform the FOLLOW-ON MAINTENANCE at the end of this work package.
END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. 4. Remove the lock outs and tag outs IAW FM 4-01.502. Operate the TLI system under usual conditions IAW TM 55-1925-273-10. Perform the TANK LEVEL INDICATOR CALIBRATE procedure for the replaced equipment. Return the equipment to the desired readiness condition.
0188-8
TM 55-1925-273-24&P-2 FIELD MAINTENANCE TANK LEVEL INDICATOR (TLI) REPAIR
0189
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 3, WP 0344, Table 1, Item 27) Multimeter (Volume 3, WP 0344, Table 1, Item 15) Tool Kit, Electrical Repair (Volume 3, WP 0344, Table 1, Item 26) Materials/Parts N/A Personnel Required Watercraft Engineer 88L (2) References FM 4-01.502 References (cont.) TM 55-1925-273-10 Volume 3, WP 0304 Volume 3, WP 0343 Volume 3, WP 0344 Equipment Condition N/A
0189-1
TM 55-1925-273-24&P-2
0189
TLI POWER INDICATOR LAMP ASSEMBLY REMOVAL 1. Set to OFF the TLI SYSTEM. circuit breaker (Figure 1, Item 1) at 120 V emergency distribution panel No. 1. Lock out and tag out IAW FM 4-01.502.
1
M1308T73
Figure 1. 2. 3. 4.
120 V Emergency Distribution Panel No. 1.
Remove the protective lens cover (Figure 2, Item 12). Remove the bulb (Figure 2, Item 11). Loosen the nine captive screws (Figure 2, Item 10) and open the Tank Level Indicator (TLI) control panel (Figure 2, Item 9).
WARNING
Replace or repair components only after the affected circuit has been secured, locked out, and tagged out IAW FM 4-01.502. Performing replacement with the circuit energized may result in injury. 5. Use a multimeter to check for voltage at the terminals (Figure 2, Item 5) of the switch assembly (Figure 2, Item 6). If voltage is present, ensure that the correct circuit breaker is set to OFF, locked out, and tagged out IAW FM 4-01.502. If no voltage is present, continue with the procedure. Label and remove the wires (Figure 2, Item 3) from the terminals (Figure 2, Item 2) of the lamp assembly (Figure 2, Item 13). Remove the retaining nut (Figure 2, Item 1) and remove the lamp assembly (Figure 2, Item 13) from the TLI control panel (Figure 2, Item 9).
6. 7.
0189-2
TM 55-1925-273-24&P-2 TLI POWER INDICATOR LAMP ASSEMBLY REMOVAL - Continued

1
0189
12 11 10 2
3 9 4 13
M1309T73
TLI Control Panel and Components.
TLI POWER INDICATOR LAMP ASSEMBLY INSTALLATION 1. 2. Install the lamp assembly (Figure 2, Item 13) in the TLI control panel (Figure 2, Item 9) and secure it with the retaining nut (Figure 2, Item 1). Install the wires (Figure 2, Item 3) to the terminals (Figure 2, Item 2) of the lamp assembly (Figure 2, Item 13) using the labels from Step (6) of TLI POWER INDICATOR LAMP ASSEMBLY REMOVAL as a guide. Remove the labels. Close the TLI control panel (Figure 2, Item 9) and secure it with the nine captive screws (Figure 2, Item 10). Install the bulb (Figure 2, Item 11) finger tight. Install the protective lens cover (Figure 2, Item 12) finger tight. Remove the lock outs and tag outs IAW FM 4-01.502. Set the circuit breaker to ON. Operate the TLI system under usual conditions IAW TM 55-1925-273-10 and check for proper operation.
3. 4. 5. 6. 7. 8.
0189-3
TM 55-1925-273-24&P-2 TLI POWER INDICATOR LAMP ASSEMBLY INSTALLATION - Continued 9. Return the equipment to the desired readiness condition.
0189
END OF TASK TLI CONTROL PANEL SWITCH REMOVAL 1. 2. Set to OFF the TLI SYSTEM. circuit breaker (Figure 1, Item 1) at 120 V emergency distribution panel No. 1. Lock out and tag out IAW FM 4-01.502. Loosen the nine captive screws (Figure 2, Item 10) and open the TLI control panel (Figure 2, Item 9).
WARNING
Replace or repair components only after the affected circuit has been secured, locked out, and tagged out IAW FM 4-01.502. Performing replacement with the circuit energized may result in injury. 3. Use a multimeter to check for voltage at the terminals (Figure 2, Item 5) of the switch assembly (Figure 2, Item 6). If voltage is present, ensure that the correct circuit breaker is set to OFF, locked out, and tagged out IAW FM 4-01.502. If no voltage is present, continue with the procedure. Label and remove the wires (Figure 2, Item 4) from the terminals (Figure 2, Item 5) of the switch assembly (Figure 2, Item 6). Remove the retaining nut (Figure 2, Item 7), and remove the switch assembly (Figure 2, Item 6) from the TLI control panel (Figure 2, Item 9).
4. 5.
END OF TASK TLI CONTROL PANEL SWITCH INSTALLATION 1. 2. 3. 4. 5. 6. 7. Install the switch assembly (Figure 2, Item 6) in the TLI control panel (Figure 2, Item 9) and secure it with the retaining nut (Figure 2, Item 7). Install the wires (Figure 2, Item 4) to the terminals (Figure 2, Item 5) of the switch assembly (Figure 2, Item 6) using the labels from Step (4) of TLI CONTROL PANEL SWITCH REMOVAL as a guide. Remove the labels. Close the TLI control panel (Figure 2, Item 9) and secure it with the nine captive screws (Figure 2, Item 10). Remove the lock outs and tag outs IAW FM 4-01.502. Set the circuit breaker to ON. Operate the TLI system under usual conditions IAW TM 55-1925-273-10 and check for proper operation. Return the equipment to the desired readiness condition.
END OF TASK
0189-4
TM 55-1925-273-24&P-2
0189
TLI CONTROL PANEL FUSE REMOVAL 1. 2. 3. Set to OFF the TLI SYSTEM. circuit breaker (Figure 1, Item 1) at 120 V emergency distribution panel No. 1. Lock out and tag out IAW FM 4-01.502. Remove the fuse holder (Figure 2, Item 8) from the TLI control panel (Figure 2, Item 9). Remove the fuse (Figure 3, Item 2) from the fuse holder (Figure 3, Item 1).
END OF TASK TLI CONTROL PANEL FUSE INSTALLATION 1. 2. Install the fuse (Figure 3, Item 2) in the fuse holder (Figure 3, Item 1). Install the fuse holder (Figure 2, Item 8) with the fuse (Figure 3, Item 2) in the TLI control panel (Figure 2, Item 9) finger tight.
FUSE
M1310T73
Figure 3. 3. 4. 5. 6. Set the circuit breaker to ON.
Control Panel Fuse Holder Assembly.
Remove the lock outs and tag outs IAW FM 4-01.502. Operate the TLI system under usual conditions IAW TM 55-1925-273-10 and check for proper operation. Return the equipment to the desired readiness condition.
END OF TASK TLI CONTROL PANEL FUSE HOLDER ASSEMBLY REMOVAL 1. 2. 3. Set to OFF the TLI SYSTEM. circuit breaker (Figure 1, Item 1) at 120 V emergency distribution panel No. 1. Lock out and tag out IAW FM 4-01.502. Perform the TLI CONTROL PANEL FUSE REPLACE REMOVAL procedure in this work package. Loosen the nine captive screws (Figure 2, Item 10) and open the control panel (Figure 2, Item 9).
0189-5
TM 55-1925-273-24&P-2 TLI CONTROL PANEL FUSE HOLDER ASSEMBLY REMOVAL - Continued
0189
WARNING
Replace or repair components only after the affected circuit has been secured, locked out, and tagged out IAW FM 4-01.502. Performing replacement with the circuit energized may result in injury. 4. Use a multimeter to check for voltage at the terminals (Figure 3, Item 6) of the fuse holder assembly (Figure 3, Item 4). If voltage is present, ensure that the correct circuit breaker is set to OFF, locked out, and tagged out IAW FM 4-01.502. If no voltage is present, continue with the procedure. Label and remove the wires (Figure 3, Item 5) from the terminals (Figure 3, Item 6) of the fuse holder assembly (Figure 3, Item 4). Remove the retaining nut (Figure 3, Item 3), and remove the fuse holder assembly (Figure 3, Item 4) from the TLI control panel (Figure 2, Item 9).
5. 6.
END OF TASK TLI CONTROL PANEL FUSE HOLDER ASSEMBLY INSTALLATION 1. 2. 3. 4. Install the fuse holder assembly (Figure 3, Item 4) in the TLI control panel (Figure 2, Item 9) and secure it with the retaining nut (Figure 3, Item 3). Install the wires (Figure 3, Item 5) to the fuse holder assembly (Figure 3, Item 4) using the labels from Step (5) of TLI CONTROL PANEL FUSE HOLDER ASSEMBLY REMOVAL as a guide. Remove the labels. Close the TLI control panel (Figure 2, Item 9) and secure it with the nine captive screws (Figure 2, Item 10). Perform the TLI CONTROL PANEL FUSE INSTALLATION procedure in this work package.
0189-6
TM 55-1925-273-24&P-2 FIELD MAINTENANCE TLI FLUID LEVEL DETECTION DEVICES INSPECT
0190
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 3, WP 0344, Table 1, Item 27) Gloves, Leather (Volume 3, WP 0344, Table 1, Item 9) Goggles, Industrial (Volume 3, WP 0344, Table 1, Item 10) Materials/Parts N/A Personnel Required Watercraft Engineer 88L (One of these must be trained in confined space entry) (2) Entry Supervisor/Attendant (1) References FM 4-01.502 References (cont.) Organizational Confined Space Entry SOP WP 0098 Volume 3, WP 0305 Volume 3, WP 0344 Equipment Condition Set to OFF the TLI SYSTEM circuit breaker in 120 V emergency distribution panel No. 1. Lock out and tag out IAW FM 4-01.502. Manhole cover removed. (WP 0098) Tanks prepared for confined space entry with Confined Space Entry Permit secured IAW Organizational Confined Space Entry SOP and FM 4-01.502.
0190-1
TM 55-1925-273-24&P-2
0190
INSPECT TRANSMITTER MOUNTING BRACKETS
WARNING
Entry into an uninspected/unprepared confined space may result in serious injury or death to personnel. Only properly trained personnel may enter confined spaces, or act as entry supervisors and/or attendants for those working in confined spaces. Before entering into a confined space, the space must be cleared for entry and a Confined Space Entry Permit must be secured. All entry into confined spaces must be in accordance with FM 4-01.502. Failure to comply with this warning can result in serious injury or death to personnel. 1. Enter the tank and locate the transmitter mounting brackets (Figure 1, Item 3).
WARNING
Wire brushing operations can produce high velocity flying debris which can become lodged in the skin or in the eyes. Wire brushing in confined areas can result in debris flying from unexpected directions. All personnel working in the area must wear protective faceshield, gloves, and long sleeves when performing wire brushing operations. Failure to comply with this warning can result in serious injury or death to personnel. 2. 3. 4. 5. 6. If necessary, use a wire brush to scrape away any foreign matter from the mounting bracket welds (Figure 1, Item 4). Verify that no corrosion or damage is present on the mounting brackets (Figure 1, Item 3). Check for loose or missing attaching hardware on mounting brackets (Figure 1, Item 3), and replace and tighten any missing hardware (Figure 1, Item 1) as necessary. Look for cracks, breaks, physical damage, or other noticeable defects. Ensure that the mounting brackets (Figure 1, Item 3) are holding the transmitter(s) (Figure 1, Item 2) firmly in place.
0190-2
TM 55-1925-273-24&P-2 INSPECT TRANSMITTER MOUNTING BRACKETS - Continued
0190
1 2
M1311T73
Figure 1. Tank Level Indicator (TLI) Transmitter Mounting Brackets. 7. 8. Exit the tank and install the manhole cover (WP 0098). Remove the lock outs and tag outs IAW FM 4-01.502 and return equipment to the desired readiness condition.
0190-3/4 blank
TM 55-1925-273-24&P-2 FIELD MAINTENANCE TLI FLUID LEVEL DETECTION DEVICES REPLACE
0191
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 3, WP 0344, Table 1, Item 27) Faceshield, Industrial (Volume 3, WP 0344, Table 1, Item 5) Gloves, Leather (Volume 3, WP 0344, Table 1, Item 9) Goggles, Industrial (Volume 3, WP 0344, Table 1, Item 10) Sander, Disc, Pneumatic, Portable (Volume 3, WP 0344, Table 1, Item 20) Tool Kit, Welder's (Volume 3, WP 0344, Table 1, Item 29) Torch Outfit, Welding (Volume 3, WP 0344, Table 1, Item 30) Materials/Parts N/A Personnel Required Watercraft Engineer 88L (One must be trained in confined space entry) (2) Supervisor/Attendant (1) Fire Watch as Required IAW FM 4-01.502 References FM 4-01.502 References (cont.) Organizational Confined Space Entry SOP TB 43-0144 TM 55-1900-204-24 TM 55-1925-273-10 WP 0098 Volume 3, WP 0305 Volume 3, WP 0343 Volume 3, WP 0344 Equipment Condition Set to OFF the TLI SYSTEM. circuit breaker at 120 V emergency distribution panel No. 1. Lock out and tag out IAW FM 4-01.502. Manhole cover removed. (WP 0098) Tanks certified safe for hotwork IAW FM 4-01.502. Tanks prepared for confined space entry with Confined Space Entry Permit secured in accordance with Organizational Confined Space Entry SOP and FM 4-01.502.
0191-1
TM 55-1925-273-24&P-2
0191
WARNING
Never reuse locking hardware. Reuse of locking hardware such as lockwashers, locking nuts, cotter pins, and lock wire can result in undetected loosening of fastening hardware causing catastrophic component failure resulting in death, injury, or damage to equipment. Ensure that all locking hardware is discarded upon removal and replaced with new. TRANSMITTER MOUNTING BRACKETS REPLACE
WARNING
Entry into an uninspected/unprepared confined space may result in serious injury or death to personnel. Only properly trained personnel may enter confined spaces, or act as entry supervisors and/or attendants for those working in confined spaces. Before entering into a confined space, the space must be cleared for entry and a Confined Space Entry Permit must be secured. All entry into confined spaces must be in accordance with FM 4-01.502. Failure to comply with this warning can result in serious injury or death to personnel. 1. Enter the tank and locate the faulty Tank Level Indicator (TLI) transmitter mounting brackets (Figure 1, Item 8).
7 6 2
3 8
5 6 7
M1312T73
Figure 1.
TLI Transmitter Mounting Brackets and Transmitter.
0191-2
TM 55-1925-273-24&P-2 TRANSMITTER MOUNTING BRACKETS REPLACE - Continued
0191
WARNING
Removing components by means of wire brushing produces flying particles. These particles can cause serious injury to personnel. Wear protective faceshield, gloves, and long sleeves at all times during wire brushing operations. Failure to comply with this warning can result in serious injury to personnel. 2. Use a wire brush to scrape away any foreign matter from the mounting bracket welds (Figure 2, Item 1), the mounting bracket assembly (Figure 1, Item 4), bolts (Figure 1, Item 1), flat washers (Figure 1, Item 7), lockwashers (Figure 1, Item 6), and locknuts (Figure 1, Item 5).
1
M1313T73
Figure 2.
TLI Transmitter Mounting Bracket Top View.
CAUTION
Care must be taken when removing TLI transmitters from their mounts. Excessive shock and vibration can damage components. 3. 4. 5. Remove the upper and lower bolts (Figure 1, Item 1), flat washers (Figure 1, Item 7), lockwashers (Figure 1, Item 6), and locknuts (Figure 1, Item 5). Discard lockwashers and locknuts. Inspect the bolts (Figure 1, Item 1) and flat washers (Figure 1, Item 7) for wear and/or damage. Replace the bolts and flat washers if they are worn and/or damaged. Place a protective cover over the TLI transmitter (Figure 1, Item 2) to prevent damage from flying debris.
0191-3
TM 55-1925-273-24&P-2 TRANSMITTER MOUNTING BRACKETS REPLACE - Continued
0191
WARNING
Removing components by means of grinding or cutting produces hot, flying particles. These particles can cause serious injury to personnel. These hot particles can also ignite fires in the work area and in adjacent spaces. During and after removal, the work area will be very hot. Wear protective faceshield, gloves, and/or aprons at all times during cutting and grinding operations. A fire watch must be posted whenever cutting or grinding operations are taking place. Failure to comply can result in serious injury or death to personnel and serious damage to the vessel. 6. Use a grinder (sander) to clean the work area around the faulty mounting bracket (Figure 1, Item 8 and Figure 2, Item 1) to the bare metal.
WARNING
NOTE
Improper connection of ground leads can cause serious electrolytic and electronic damage to the vessel and its components. Always ensure that ground leads are connected IAW TB 55-1900-204-24. 7. 8. Post fire watches as necessary on both sides of the bulkhead where hotwork is to take place. Weld the mounting bracket (Figure 1, Item 8) to the bulkhead in accordance with the applicable construction drawings and welding practices detailed in TB 55-1900-204-24.
WARNING
Removing components by means of wire brushing produces flying particles. These particles can cause serious injury to personnel. Wear protective faceshield, gloves, and long sleeves at all times during wire brushing operations. Failure to comply with this warning can result in serious injury to personnel. 9. 10. 11. Use a wire brush to prepare the work area for painting. After the area has cooled, paint and preserve the affected area IAW TB 43-0144. Install the TLI transmitter (Figure 1, Item 2) to the mounting brackets (Figure 1, Item 8) and secure it with the bolts (Figure 1, Item 1), flat washers (Figure 1, Item 7), lockwashers (Figure 1, Item 6), and locknuts (Figure 1, Item 5).
0191-4
TM 55-1925-273-24&P-2 TRANSMITTER MOUNTING BRACKETS REPLACE - Continued 12. 13. 14.
0191
Ensure that all cables inside the tank are secured and that they will not interfere with the travel of the TLI transmitter float (Figure 1, Item 3) when the vessel pitches up and down or side to side. Ensure that all cable connections to components are secured. Remove all tools and debris from the interior of the tank. Exit the tank and install the manhole cover (WP 0098).
END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. Remove the lock outs and tag outs IAW FM 4-01.502. Operate the TLI system under usual conditions IAW TM 55-1925-273-10, ensuring proper operation of the system. Return the equipment to the desired readiness condition.
0191-5/6 blank
TM 55-1925-273-24&P-2 FIELD MAINTENANCE TLI TRANSMITTERS INSPECT
0192
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 3, WP 0344, Table 1, Item 27) Materials/Parts Rag, Wiping (Volume 3, WP 0343, Table 1, Item 132) Personnel Required Watercraft Engineer 88L (One must be trained in confined space entry) (2) Entry Supervisor/Attendant (1) References FM 4-01.502 Organizational Confined Space Entry SOP References (cont.) TM 55-1925-273-10 WP 0098 Volume 3, WP 0305 Volume 3, WP 0343 Volume 3, WP 0344 Equipment Condition Set to OFF the TLI SYSTEM. circuit breaker at 120 V emergency distribution panel No. 1. Lock out and tag out IAW FM 4-01.502. Manhole cover removed. (WP 0098) Tank prepared for confined space entry with Confined Space Entry Permit secured IAW Organizational Confined Space Entry SOP and FM 4-01.502.
0192-1
TM 55-1925-273-24&P-2
0192
INSPECT TLI TRANSMITTER
WARNING
Entry into an uninspected/unprepared confined space may result in serious injury or death to personnel. Only properly trained personnel may enter confined spaces, or act as entry supervisors and/or attendants for those working in confined spaces. Before entering into a confined space, the space must be cleared for entry and a Confined Space Entry Permit must be secured. All entry into confined spaces must be in accordance with FM 4-01.502. Failure to comply with this warning can result in serious injury or death to personnel. 1. 2. 3. Enter the tank and locate the Tank Level Indicator (TLI) transmitter (Figure 1, Item 4). Inspect the mounting brackets (Figure 1, Item 1) for adequate welds and proper preservation. Examine the attaching hardware (Figure 1, Item 2) for stripped screw threads, worn slots, and loss. Verify that there are no loose or missing bolts, flat washers, lockwashers, and locknuts on the mounting brackets. Replace or tighten hardware as necessary. Check the vertical alignment of the TLI transmitter (Figure 1, Item 4) in the mounting brackets IAW the applicable drawings. Ensure that the TLI transmitter (Figure 1, Item 4) is secured firmly in place. Examine the TLI transmitter (Figure 1, Item 4) for dents, cracks, or other physical damage. Use a dry, clean wiping rag to wipe any sludge and dirt off the stem of the transmitter (Figure 1, Item 4) that may interfere with the travel of the float (Figure 1, Item 5). Check that the cables (Figure 1, Item 3) are properly secured and that there are no nicks or wear in the skin of the cables from the TLI transmitters to the stuffing tube penetrator. Replace worn or damaged cables as necessary. Examine the cables (Figure 1, Item 3) for evidence of aging, burning, worn insulation, corrosion, or other signs of wear or damage. Replace worn or damaged cables as necessary. Ensure that the cable (Figure 1, Item 3) has some slack but does not interfere with the movement of the float (Figure 1, Item 5). Slide the float (Figure 1, Item 5) up and down the stem of the transmitter (Figure 1, Item 4). Ensure the float (Figure 1, Item 5) slides freely up and down the entire length of the stem. Remove all tools and debris from the interior of the tank. Exit the tank and install the manhole cover (WP 0098).
4. 5. 6. 7. 8.
9. 10. 11. 12. 13.
0192-2
TM 55-1925-273-24&P-2 INSPECT TLI TRANSMITTER - Continued

1 2 3 3 2 1
0192
4 5
5 2
4 1 2
2 5
M1314T73
TLI Indicator Transmitter.
Remove the lock outs and tag outs IAW FM 4-01.502. Perform the Operation Under Usual Conditions: TANK LEVEL INDICATOR SYSTEM SHUTDOWN procedure IAW TM 55-1925-273-10. Return the equipment to the desired readiness condition.
0192-3/4 blank
TM 55-1925-273-24&P-2 FIELD MAINTENANCE TLI TRANSMITTERS REPLACE
0193
INITIAL SETUP: Tools and Special Tools Apron, Utility (Volume 3, WP 0344, Table 1, Item 1) Faceshield, Industrial (Volume 3, WP 0344, Table 1, Item 5) Gloves, Chemical and Oil Protective (Volume 3, WP 0344, Table 1, Item 8) Gloves, Leather (Volume 3, WP 0344, Table 1, Item 9) Goggles, Industrial (Volume 3, WP 0344, Table 1, Item 10) Multimeter (Volume 3, WP 0344, Table 1, Item 15) Tool Kit, Electrical Repair (Volume 3, WP 0344, Table 1, Item 26) Tool Kit, Welder's (Volume 3, WP 0344, Table 1, Item 29) Materials/Parts Rag, Wiping (Volume 3, WP 0343, Table 1, Item 132) Tape, Insulation, Electrical; 3/4 in. (Volume 3, WP 0343, Table 1, Item 160) Twine, Fibrous; Linen (Volume 3, WP 0343, Table 1, Item 180) Personnel Required Watercraft Engineer 88L (One must be trained in confined space entry) (2) Confined Space Entry Supervisor/Attendant (1) References FM 4-01.502 References (cont.) Organizational Confined Space Entry SOP TM 55-1925-273-10 WP 0098 WP 0190 WP 0191 WP 0192 WP 0194 WP 0195 Volume 3, WP 0305 Volume 3, WP 0343 Volume 3, WP 0344 Equipment Condition Set to OFF the TLI SYSTEM. circuit breaker at 120 V emergency distribution panel No. 1. Lock out and tag out IAW FM 4-01.502. Manhole cover removed. (WP 0098) Tank prepared for confined space entry with Confined Space Entry permit secured IAW Organizational Confined Space Entry SOP and FM 4-01.502.
WARNING
0193-1
TM 55-1925-273-24&P-2
0193
TANK LEVEL INDICATOR (TLI) TRANSMITTER REMOVAL
NOTE
The TLI TRANSMITTER REPLACE procedure does not apply to the sewage collection tank TLI transmitter. For replacement of the sewage collection tank TLI transmitter, refer to the SEWAGE COLLECTION TANK TLI TRANSMITTER REPLACE procedure in this work package. 1. 2. 3. Locate the connection box (Figure 1) that connects the faulty TLI transmitter (Figure 2, Item 2) to the TLI system. Remove the screws (Figure 1, Item 1) that secure the connection box cover (Figure 1, Item 2). Remove the connection box cover (Figure 1, Item 2).
WARNING
Replace or repair components only after the affected circuit has been secured, locked out, and tagged out IAW FM 4-01.502. Performing replacement with the circuit energized may result in injury. 4. Use a multimeter to check for voltage at the connection box leads. If voltage is present, ensure that the proper circuit breaker is secured, locked out, and tagged out IAW FM 4-01.502. If no voltage is present, continue with the procedure. Determine which terminals connect the TLI transmitter cable assembly (Figure 2, Item 1) to the connection box (Figure 1) and which terminals connect the connection box to the TLI receivers. Label the correct location of all cable terminals in the connection box (Figure 1, Item 2).
5.
M1315T73
Figure 1.
Connection Box (Typical).
0193-2
TM 55-1925-273-24&P-2 TANK LEVEL INDICATOR (TLI) TRANSMITTER REMOVAL - Continued
0193
NOTE
Only the TLI transmitter cable assembly wires should be connected to terminals in the connection box. 6. Disconnect the TLI system cable wires that connect the connection box to the TLI receivers. Use electrical insulation tape to insulate the TLI system cable wires. Take care not to damage any fasteners that may have to be reused.
WARNING
Entry into an uninspected/unprepared confined space may result in serious injury or death to personnel. Only properly trained personnel may enter confined spaces, or act as entry supervisors and/or attendants for those working in confined spaces. Before entering into a confined space, the space must be cleared for entry and a Confined Space Entry Permit must be secured. All entry into confined spaces must be in accordance with FM 4-01.502. Failure to comply with this warning can result in serious injury or death to personnel. 7. 8. Enter the tank. Locate the cable assembly (Figure 2, Item 1) tank entry point, and follow the cable back to the transmitter (Figure 2, Item 2).
1 1
2 3
M1316T73
Figure 2. 9. 10. 11.
TLI Transmitter Configuration and Components.
Locate the cable assembly adapter (Figure 3, Item 1) and remove the setscrew (Figure 3, Item 2). Remove the cable assembly adapter (Figure 3, Item 1) from the TLI transmitter connector (Figure 3, Item 3). If the TLI transmitter (Figure 2, Item 2) is a dual mount, repeat Steps (9) and (10) until all cable assemblies are removed from the TLI transmitters.
0193-3
TM 55-1925-273-24&P-2 TANK LEVEL INDICATOR (TLI) TRANSMITTER REMOVAL - Continued

1
0193
M1317T73
Figure 3. TLI Transmitter (Typical).
WARNING
Removing components by means of wire brushing produces flying particles. These particles can cause serious injury to personnel. Wear protective faceshield, gloves, and long sleeves at all times during wire brushing operations. Failure to comply with this warning can result in serious injury to personnel. 12. Use a wire brush to scrape away any foreign matter from the mounting brackets (Figure 4, Item 6), the mounting bracket assemblies (Figure 4, Item 1), mounting bolts (Figure 4, Item 2), flat washers (Figure 4, Item 3), lockwashers (Figure 4, Item 4), and locknuts (Figure 4, Item 5). Discard lockwashers and locknuts.
CAUTION
Use care when removing TLI transmitters from their mounts. Excessive shock and vibration can damage its components.
0193-4
TM 55-1925-273-24&P-2 TANK LEVEL INDICATOR (TLI) TRANSMITTER REMOVAL - Continued 13. 14. 15.
0193
Remove the bolts (Figure 4, Item 2), flat washers (Figure 4, Item 3), lockwashers (Figure 4, Item 4), and locknuts (Figure 4, Item 5). Discard lockwashers and locknuts. Inspect the mounting bolts (Figure 4, Item 2) and flat washers (Figure 4, Item 3). Replace the bolts and/or flat washers if they are worn and damaged. Remove the faulty TLI transmitter module (Figure 4, Item 7) from the mounting bracket assemblies (Figure 4, Item 1).
2 3 1 4 5
6 5 4
3 2
M1318T73
TLI Transmitter Mounts (Typical).
0193-5
TM 55-1925-273-24&P-2 TANK LEVEL INDICATOR (TLI) TRANSMITTER INSTALLATION 1. 2. 3. Inspect the mounting brackets (Figure 4, Item 6) (WP 0190). Install the TLI transmitter (Figure 4, Item 7) in the mounting bracket assemblies (Figure 4, Item 1).
0193
Install the mounting bracket assemblies (Figure 4, Item 1) to the mounting brackets (Figure 4, Item 6) with the bolts (Figure 4, Item 2), flat washers (Figure 4, Item 3), lockwashers (Figure 4, Item 4), and locknuts (Figure 4, Item 5). Check the vertical alignment of the TLI transmitter (Figure 4, Item 7). Inspect the installation (WP 0190) , (WP 0191) , and (WP 0192). Install the TLI transmitter cable assemblies (Figure 2, Item 1) (WP 0195). Ensure that all cable assemblies (Figure 2, Item 1) are secured in place and will not interfere with the travel of the float (Figure 2, Item 3) when the vessel pitches up and down or side to side. Ensure that all cable connections to components are properly secured. Slide the float (Figure 2, Item 3) up and down the stem (Figure 2, Item 2) of the TLI transmitter (Figure 4, Item 7). Ensure that each float slides freely up and down the entire length of the stem with no interference. Connect the cable assembly wires to the terminals in the connection box (Figure 1) using the labels from Step (5) of TANK LEVEL INDICATOR (TLI) TRANSMITTER REMOVAL as a guide. Remove the labels. Inspect the TLI transmitter cable assemblies (WP 0194). Install the connection box cover (Figure 1, Item 2). Verify that all tools and debris are removed from the tank. Exit the tank and install the manhole cover (WP 0098). Remove the lock outs and tag outs IAW FM 4-01.502. Operate the TLI system under usual conditions IAW TM 55-1925-273-10. Return the equipment to the desired readiness condition.
4. 5. 6. 7. 8. 9.
10. 11. 12. 13. 14. 15. 16. 17.
END OF TASK
0193-6
TM 55-1925-273-24&P-2
0193
SEWAGE COLLECTION TANK TLI TRANSMITTER REMOVAL
WARNING
Sewage is a common mode of transmission for parasitic organisms that may have the capability of causing communicable diseases. Chemical protective gloves, goggles, and protective apron should be worn to help prevent contact with sewage. After coming in contact with sewage or contaminated equipment, be sure to clean yourself with a disinfectant soap. Avoid sewage contact with skin abrasions, punctures, cuts, and other open wounds. Wipe up and clean any spills and/or contaminated equipment using a disinfectant soap. Failure to comply with this warning can result in illness, serious injury, or death.
NOTE
The sewage collection tank must be as empty as possible to minimize the possibility of spillage and contamination. 1. 2. 3. Locate the connection box (Figure 1) that connects the faulty TLI transmitter (Figure 5,Item 6) to the TLI system. Remove the screws (Figure 1, Item 1) that secure the connection box cover (Figure 1, Item 2). Remove the connection box cover (Figure 1, Item 2).
WARNING
Replace or repair components only after the affected circuit has been secured, locked out, and tagged out IAW FM 4-01.502. Performing replacement with the circuit energized may result in injury. 4. Use a multimeter to check for voltage at the connection box leads. If voltage is present, ensure that the proper circuit breaker is secured, locked out, and tagged out IAW FM 4-01.502. If no voltage is present, continue with the procedure. Determine which terminals connect the TLI transmitter cable assembly (Figure 5, Item 6) to the connection box (Figure 1) and which terminals connect the connection box to the TLI receivers. Label the correct location of all cable terminals in the connection box.
5.
NOTE
Only the TLI transmitter cable assembly wires (Figure 5, Item 4) should be connected to the terminals in the connection box (Figure 1). 6. 7. 8. Disconnect the TLI system cable wires that connect the connection box (Figure 1) to the TLI receivers. Use electrical insulation tape to insulate the TLI system cable wires. At the tank top (Figure 5, Item 8), remove the junction box cover (Figure 5, Item 1). Label the correct location of all terminals (Figure 5, Item 9) in the junction box, and label the terminals on the replacement TLI transmitter (Figure 5, Item ).
0193-7
TM 55-1925-273-24&P-2 SEWAGE COLLECTION TANK TLI TRANSMITTER REMOVAL - Continued 9.
0193
Disconnect the terminals (Figure 5, Item 9) that connect the TLI transmitter to the junction box (Figure 5, Item 1). Prepare the wires for removal by bundling the TLI transmitter wires (Figure 5, Item 4) together and tying about a 24 in. (60 cm) length of fibrous twine to the end of the wire bundle.
CAUTION
Care must be taken when removing the flange mounted TLI transmitter (Figure 5, Item 6). Use a minimum of two crewmembers to remove the flange mounted TLI transmitter. Failure to comply can result in damage to the equipment and cabling. 10. Remove the bolts (Figure 5, Item 2) and lockwashers (Figure 5, Item 3). Remove the flange (Figure 5, Item 7) from the top of the tank (Figure 5, Item 8). Take care not to strike the TLI transmitter (Figure 5, Item 6) against any solid surfaces. Discard lockwashers.
NOTE
It may be necessary to rotate the TLI transmitter (Figure 5, Item 6) counterclockwise while holding the junction box steady in order to separate the junction box from the TLI transmitter. 11. Remove the TLI transmitter (Figure 5, Item 6) from the flange (Figure 5, Item 7) by holding the TLI transmitter shaft securely and rotating the retaining nut (Figure 5, Item 5) counterclockwise.
NOTE
Slowly separate the TLI transmitter from the flange and guide the wires (Figure 5, Item 4) as necessary to prevent damage. Allow the fibrous twine to pull through so that it can be used to guide the wires to the replacement TLI transmitter through the flange and into the junction box. 12. When the retaining nut (Figure 5, Item 5) is free from the threads, gently pull the TLI transmitter (Figure 5, Item 6) away from the flange (Figure 5, Item 7) until both units are separated.
0193-8
TM 55-1925-273-24&P-2 SEWAGE COLLECTION TANK TLI TRANSMITTER REMOVAL - Continued
0193
2 1 3
7 8
6 9
5
M1319T73
Figure 5. Junction Box and Flange Mounted Transmitter (Typical). END OF TASK SEWAGE COLLECTION TANK TLI TRANSMITTER INSTALLATION 1. 2. 3. Remove the fibrous twine from the TLI transmitter wires (Figure 5, Item 4). Tie the fibrous twine securely around the wires of the replacement TLI transmitter. Pull the fibrous twine from the dry side of the flange (Figure 5, Item 7), and guide the wires for the replacement TLI transmitter (Figure 5, Item 6) into place at the junction box terminals (Figure 5, Item 9). Push the threaded end of the TLI transmitter stem (Figure 5, Item 6) into position through the bottom of the flange (Figure 5, Item 7) and into contact with the retaining nut (Figure 5, Item 5).
0193-9
TM 55-1925-273-24&P-2 SEWAGE COLLECTION TANK TLI TRANSMITTER INSTALLATION - Continued
0193
CAUTION
Do not secure the TLI transmitter with the retaining nut until the junction box is properly installed on the stem or damage to the equipment will result. 4. 5. 6. Rotate the retaining nut (Figure 5, Item 5) clockwise over the threaded end of the TLI transmitter (Figure 5, Item 6) and tighten several turns. Position the junction box (Figure 5, Item 1) over the threaded end of the TLI transmitter (Figure 5, Item 6) while continuing to pull the wires (Figure 5, Item 4) into place with the fibrous twine. When the junction box (Figure 5, Item 1) is in place and the wires (Figure 5, Item 4) are completely through the flange (Figure 5, Item 7) and free of interference, secure the junction box (Figure 5, Item 1) to the TLI transmitter (Figure 5, Item 6) by holding the junction box in place and rotating the TLI transmitter clockwise. Rotate until hand tight plus 1/8 of a turn. Do not over tighten. Hold the TLI transmitter (Figure 5, Item 6) securely in place and tighten the retaining nut (Figure 5, Item 5). Install the TLI transmitter in the tank. Install the flange (Figure 5, Item 7) to the top of the tank (Figure 5, Item 8) with the bolts (Figure 5, Item 2) and lockwashers (Figure 5, Item 3). Take care not to strike the TLI transmitter (Figure 5, Item 6) against any solid surfaces, or to stress the cable connections at the junction box (Figure 5, Item 1). Remove the fibrous twine from the TLI transmitter wires (Figure 5, Item 4). Connect the TLI transmitter wires (Figure 5, Item 4) to the junction box terminals (Figure 5, Item 9) using the labels from Step (9) of SEWAGE COLLECTION TANK TLI TRANSMITTER REMOVAL as a guide. Remove the labels. Install the junction box cover (Figure 5, Item 1). Inspect the TLI transmitter cable assemblies (WP 0194). Install the connection box cover (Figure 1, Item 2).
7. 8.
9. 10.
11. 12. 13.
END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. Remove the lock outs and tag outs IAW FM 4-01.502. Operate the sewage collection tank TLI system under usual conditions IAW TM 55-1925-273-10. Return the equipment to the desired readiness condition.
0193-10
TM 55-1925-273-24&P-2 FIELD MAINTENANCE TLI CABLE ASSEMBLIES INSPECT
0194
INITIAL SETUP: Tools and Special Tools Multimeter (Volume 3, WP 0344, Table 1, Item 15) Tool Kit, Electrical Repair (Volume 3, WP 0344, Table 1, Item 26) Materials/Parts Rag, Wiping (Volume 3, WP 0343, Table 1, Item 132) Personnel Required Watercraft Engineer 88L (One must be trained in confined space entry) (2) Confined Space Entry Supervisor/Attendant (1) References FM 4-01.502 References (cont.) Organizational Confined Space Entry SOP TM 55-1925-273-10 WP 0098 Volume 3, WP 0305 Volume 3, WP 0343 Volume 3, WP 0344 Equipment Condition Set to OFF the TLI SYSTEM. circuit breaker at 120 V emergency distribution panel No. 1. Lock out and tag out IAW FM 4-01.502. Manhole cover removed. (WP 0098) Tank prepared for confined space entry with Confined Space Entry Permit secured IAW Organizational Confined Space Entry SOP and FM 4-01.502.
0194-1
TM 55-1925-273-24&P-2
0194
INSPECT DRY SIDE CABLE ASSEMBLY
WARNING
Replace or repair components only after the affected circuit has been secured, locked out, and tagged out IAW FM 4-01.502. Performing replacement with the circuit energized may result in injury. 1. Locate the connection box for the applicable Tank Level Indicator (TLI) transmitter cable (Figure 1, Item 4). Ensure that the connection box (Figure 2) is serviceable and undamaged.
NOTE
The sewage holding tank uses a 5 in. (13 cm) flange mount with a junction box to connect the TLI transmitter to the system. For this installation, the junction box and flange are dry side components. 2. 3. At the tank that contains the cable assembly being inspected, locate the cable penetration stuffing tube (Figure 1, Item 2) (or junction box). Inspect the cable (Figure 1, Item 4) from the cable penetration stuffing tube (Figure 1, Item 2) (or junction box) to the connection junction box. Examine the cable for evidence of aging, burning, worn insulation, corrosion, or other signs of wear or damage. At the tank top, inspect the cable penetrator retaining lug (Figure 1, Item 3) for damage and wear. Ensure that the penetrator lug (Figure 1, Item 3) is secured, and check that there is no evidence of tank leakage where the cable enters the tank. Inspect the exterior of the tank penetration stuffing tube (Figure 1, Item 2) (or flange) for cracks, deterioration, and wear. Check for evidence of tank leakage around the area where the stuffing tube (or flange) contacts the top of the tank (Figure 1, Item 1). Check for any unnecessary cable slack, and ensure that the cable is properly secured from the cable penetrator stuffing tube (or junction box) to the connection box.
4. 5. 6.
7.
0194-2
TM 55-1925-273-24&P-2 INSPECT DRY SIDE CABLE ASSEMBLY - Continued

2 1 3 2 3 1 5
0194
4 4 4
6 5 6
5 5 5 6 5
M1320T73
Figure 1. END OF TASK INSPECT WET SIDE CABLE
TLI Transmitter Configuration and Components.
WARNING
Entry into an uninspected/unprepared confined space may result in serious injury or death to personnel. Only properly trained personnel may enter confined spaces, or act as entry supervisors and/or attendants for those working in confined spaces. Before entering into a confined space, the space must be cleared for entry and a Confined Space Entry Permit must be secured. All entry into confined spaces must be in accordance with FM 4-01.502. Failure to comply with this warning can result in serious injury or death to personnel.
NOTE
There is no wet side cable assembly for the sewage holding tank junction box. Continue to the TEST TLI TRANSMITTER AND CABLE ASSEMBLY CONTINUITY procedure for junction box-installed TLI transmitters. 1. 2. Enter the tank and locate the TLI transmitter cable (Figure 1, Item 4) entry point. Use dry, clean wiping rags to wipe any sludge and dirt from the cable (Figure 1, Item 4). Clean the cable so that the full length can be inspected from the penetrator to the TLI transmitter and between TLI transmitters if the tank uses a dual TLI transmitter system. Examine the cable(s) (Figure 1, Item 4) for evidence of burning, worn insulation, corrosion, or other signs of wear or damage.
3.
0194-3
TM 55-1925-273-24&P-2 INSPECT WET SIDE CABLE - Continued 4. 5. 6. 7. Inspect the area of the cable penetration stuffing tube (Figure 1, Item 2) for damage and wear.
0194
Ensure that the cable (Figure 1, Item 4) is tight in the cable stuffing tube (Figure 1, Item 2) and that there is no evidence of leakage from outside the tank through the cable penetration tube (Figure 1, Item 2). Inspect the interior tank side of the cable penetration stuffing tube (Figure 1, Item 2) for cracks, deterioration, and wear. Check for evidence of contamination entering the tank from the area of the stuffing tube. Check that all cables (Figure 1, Item 4) inside the tank (Figure 1, Item 1) are secured in place and that they will not interfere with the travel of the TLI transmitter float(s) (Figure 1, Item 6) when the vessel pitches up and down or side to side. Ensure that all cable assembly connections to components are properly secured. Tighten any loose nuts and bolts (Figure 1, Item 5) as necessary.
8. 9.
END OF TASK TEST TLI TRANSMITTER AND CABLE ASSEMBLY CONTINUITY 1. 2. 3. Locate the connection box (Figure 2) that connects the TLI transmitter to the TLI system. Remove the screws (Figure 2, Item 1) securing the connection box cover (Figure 2, Item 2). Remove the connection box cover (Figure 2, Item 2), taking care not to damage any water protecting seals or gaskets.
1 2
M1321T73
Figure 2.
Connection Box.
0194-4
TM 55-1925-273-24&P-2 TEST TLI TRANSMITTER AND CABLE ASSEMBLY CONTINUITY - Continued
0194
WARNING
Replace or repair components only after the affected circuit has been secured, locked out, and tagged out IAW FM 4-01.502. Performing replacement with the circuit energized may result in injury. 4. Use a multimeter to check for voltage at the connection box leads. If voltage is present, ensure that the proper circuit breaker is secured, locked out, and tagged out IAW FM 4-01.502. If no voltage is present, continue with the procedure. Determine which terminals connect the TLI transmitter cable assembly to the connection box (Figure 2). Label the correct location of all cable terminals to be disconnected.
5.
NOTE
Only the TLI transmitter cable assembly wires should be connected to terminals in the connection box. 6. Disconnect and insulate the TLI system cable wires from the connection box terminals. Take care not to damage any fasteners or water protective seals that may have to be reused. Replace any parts that are damaged. Take continuity readings at the terminal points and verify that no connections are grounded. Determine the correct resistance reading by referring to the tag attached to the TLI transmitter tag (fastened to the TLI transmitter) and multiplying "WHOLE INCHES OF INDICATOR" (Figure 3, Item 1) by "OHMS OF RESISTANCE PER INCH OF INDIC. X 100" (Figure 3, Item 2). The correct calculated value should be between 1,000 and 2,500 ohms.
7. 8.
DESCRIPTION NO.
XM-XXXXX-XX-XXXX-X-X-XX-XX
PART NO. SERIAL NO. 1 2
M1322T73
Figure 3. 9.
TLI Transmitter Tag.
Measure TLI transmitter and cable assembly resistance at the connection box (Figure 2) by taking a resistance reading across the red and black wires. The resistance reading should be within 10% of the value calculated in Step (8). Measure resistance in ohms between the black wire and the white wire in the connection box (Figure 2). The measured resistance value should be 330 ohms 10% with all floats at the bottom rest position on the TLI transmitter.
10.
0194-5
TM 55-1925-273-24&P-2 TEST TLI TRANSMITTER AND CABLE ASSEMBLY CONTINUITY - Continued 11.
0194
Continue measuring resistance in ohms between the black and white wires and slowly raise the float(s) (Figure 1, Item 6) on the TLI transmitter(s) in the same order filling the tank would. The total measured resistance should increase from approximately 330 ohms (when the float[s] are completely lowered), to the calculated value from Step (8) plus 330 ohms (with the float[s] completely raised). All resistance values should be within 10% of calculated values. Remove all tools and debris from the interior of the tank. Exit the tank and install the manhole cover (WP 0098).
12. 13.
END OF TASK CONNECT AND TEST TLI TRANSMITTER 1. Connect the TLI transmitter cable assembly wires to the terminals in the connection box (Figure 2) using the labels from Step (5) of the TEST TLI TRANSMITTER AND CABLE ASSEMBLY CONTINUITY procedure as a guide. Install the connection box cover (Figure 2, Item 2). Remove the lock outs and tag outs IAW FM 4-01.502. Operate the TLI system under usual conditions IAW TM 55-1925-273-10, verifying proper operation of the system. Return the equipment to the desired readiness condition.
2. 3. 4. 5.
0194-6
TM 55-1925-273-24&P-2 FIELD MAINTENANCE TLI CABLE ASSEMBLIES REPLACE
0195
INITIAL SETUP: Tools and Special Tools Gloves, Chemical and Oil Protective (Volume 3, WP 0344, Table 1, Item 8) Goggles, Industrial (Volume 3, WP 0344, Table 1, Item 10) Multimeter (Volume 3, WP 0344, Table 1, Item 15) Tool Kit, Electrical Repair (Volume 3, WP 0344, Table 1, Item 26) Materials/Parts Compound, Silicone; Corrosion Inhibitor, 8 oz (Volume 3, WP 0343, Table 1, Item 46) Rag, Wiping (Volume 3, WP 0343, Table 1, Item 132) Twine, Fibrous; Linen (Volume 3, WP 0343, Table 1, Item 180) Personnel Required Watercraft Engineer 88L (One must be trained in confined space entry) (2) Confined Space Entry Supervisor/Attendant (1) References FM 4-01.502 References (cont.) Organizational Confined Space Entry SOP TM 55-1925-273-10 WP 0098 Volume 3, WP 0305 Volume 3, WP 0343 Volume 3, WP 0344 Equipment Condition Set to OFF the TLI SYSTEM. circuit breaker at 120 V emergency distribution panel No. 1. Lock out and tag out IAW FM 4-01.502. Manhole cover removed. (WP 0098) Tank prepared for confined space entry with Confined Space Entry Permit secured IAW Organizational Confined Space Entry SOP and FM 4-01.502.
0195-1
TM 55-1925-273-24&P-2
0195
REMOVAL 1. 2. 3. Locate the connection box (Figure 1) that connects the faulty Tank Level Indicator (TLI) transmitter to the TLI system. Remove the screws (Figure 1, Item 1) that secure the connection box cover (Figure 1, Item 2). Remove the connection box cover (Figure 1, Item 2).
1 2
M1323T73
Figure 1.
Connection Box (Typical).
WARNING
Replace or repair components only after the affected circuit has been secured, locked out, and tagged out IAW FM 4-01.502. Performing replacement with the circuit energized may result in injury. 4. Use a multimeter to check for voltage at the connection box leads. If voltage is present, ensure that the proper circuit breaker is secured, locked out, and tagged out IAW FM 4-01.502. If no voltage is present, continue with the procedure. Determine which terminals connect the TLI transmitter cable assembly (Figure 2, Item 3) to the connection box (Figure 1). Label the correct location of all cable terminals to be disconnected. Label the TLI transmitter cable assembly wiring. Disconnect the wires for the faulty TLI transmitter cable assembly (Figure 2, Item 3) from the connection box terminals. Remove the cable assembly from the connection box (Figure 1). At the tank that contains the faulty TLI transmitter, locate the tank penetration cable stuffing tube (Figure 2, Item 2) that is associated with the faulty TLI transmitter (Figure 2, Item 4). Locate and loosen the cable penetrator retaining lug (Figure 2, Item 1) on top of the cable stuffing tube (Figure 2, Item 2). Allow the lug to slide up the cable approximately 12 in. (30 cm). 0195-2
5.
6. 7. 8.
0195
WARNING
Entry into an uninspected/unprepared confined space may result in serious injury or death to personnel. Only properly trained personnel may enter confined spaces, or act as entry supervisors and/or attendants for those working in confined spaces. Before entering into a confined space, the space must be cleared for entry and a Confined Space Entry Permit must be secured. All entry into confined spaces must be in accordance with FM 4-01.502. Failure to comply with this warning can result in serious injury or death to personnel. 9. 10. Enter the tank. Locate the cable assembly (Figure 2, Item 3) tank entry point and follow the cable back to the transmitter (Figure 2, Item 4).
3 3 3
4 5 4 5 4
M1324T73
Figure 2. 11. 12. 13.
TLI Transmitter Configuration and Components (Typical).
Locate the cable assembly adapter (Figure 3, Item 1). Remove the setscrew (Figure 3, Item 5) that locks the cable assembly adapter to the TLI transmitter connector (Figure 3, Item 4). Carefully remove the cable assembly adapter (Figure 3, Item 1) from the TLI transmitter (Figure 3, Item 4). Cover the exposed connections of the TLI transmitter (Figure 3, Item 4) with a clean wiping rag. Secure the clean wiping rag to the transmitter with fibrous twine to prevent damage and/or contamination.
0195-3
0195
5 2
M1325T73
Figure 3. Cable Assembly Adapter and TLI Transmitter Connector (Typical). 14. Direct the crewmember outside the tank to slowly push the faulty TLI transmitter cable assembly (Figure 2, Item 3) into the stuffing tube (Figure 2, Item 2) while the crewmember in the tank slowly pulls on the fibrous twine. Adjust the position of the cable penetrator retaining lug nut (Figure 2, Item 1) as necessary to prevent interference during removal of the cable assembly. Guide the faulty TLI transmitter cable down through the stuffing tube (Figure 2, Item 2) until approximately 12 in. (30 cm) remains on the outside of the tank. Remove the cable penetrator retaining lug nut (Figure 2, Item 1) from the cable assembly (Figure 2, Item 3). Inspect the nut for damage and wear. Replace the nut if it is damaged and/or worn. Loop and tie a 4 ft (1.2 m) length of fibrous twine to the end of the cable assembly (Figure 2, Item 3) protruding outside the tank.
15. 16. 17.
NOTE
The purpose of the fibrous twine on the cable is to assist in guiding the replacement cable assembly from inside the tank through the stuffing tube to the outside of the tank. 18. Continue installing the TLI transmitter cable assembly (Figure 2, Item 3) down through the stuffing tube (Figure 2, Item 2) and into the tank.
0195-4
0195
NOTE
Take care not to pull the fibrous twine completely through the stuffing tube into the tank. Enough fibrous twine must be left outside the tank to adequately guide the replacement cable assembly through the stuffing tube. 19. 20. 21. When the cable assembly (Figure 2, Item 3) is completely inside the tank, remove the fibrous twine. Remove any items that secure the cable assembly in place in the tank. Remove the faulty cable assembly (Figure 2, Item 3) from the tank. Repeat Steps (12) through (14) on any remaining TLI transmitter cable assemblies (Figure 2, Item 3). Remove any items that secure them in place, and remove them from the tank.
END OF TASK INSTALLATION 1. 2. 3. From inside the tank, tie the fibrous twine hanging from the stuffing tube (Figure 2, Item 2) to the connection box end of the replacement TLI transmitter cable assembly (Figure 2, Item 3). Direct the crewmember outside the tank to slowly pull on the fibrous twine, while the crewmember inside the tank guides the cable assembly (Figure 2, Item 3) towards the stuffing tube (Figure 2, Item 2). Work together to pull and push the cable assembly (Figure 2, Item 3) through the stuffing tube (Figure 2, Item 2) until approximately 12 in. (30 cm) of cable from the replacement cable assembly remains outside the stuffing tube. Remove the fibrous twine from the end of the cable assembly (Figure 2, Item 3). Place the cable penetrator retaining lug nut (Figure 2, Item 1) over the cable assembly (Figure 2, Item 3). Ensure that the lug nut (Figure 2, Item 1) is properly positioned so that it can be installed in the stuffing tube (Figure 2, tem 2). Slowly and carefully push (from inside the tank) and pull (from outside the tank) the cable through the stuffing tube (Figure 2, Item 2) until all unnecessary slack from inside the cable assembly (Figure 2, Item 3) is removed from the tank and there is enough cable to reach the connection box (Figure 1). Ensure that the retaining lug nut (Figure 2, Item 1) remains in close proximity to the stuffing tube. Remove the clean wiping rag and fibrous twine covering the connections (Figure 3, Item 4) of the TLI transmitter.
4. 5.
6.
7.
WARNING
Do not allow silicone compound to come in contact with unprotected skin or eyes. Prolonged skin contact can cause illness or injury. Eye contact can cause serious injury. Always wear chemical protective gloves and goggles when handling silicone compound. Failure to follow these precautions can result in illness or serious injury.
CAUTION
Do not place silicone compound directly on the electrical connections. Damage to the equipment can occur. 8. Ensure that the O-ring (Figure 3, Item 2) is in place in the cable adapter (Figure 3, Item 1), then lubricate the O-ring with a small amount of silicone compound.
0195-5
TM 55-1925-273-24&P-2 INSTALLATION - Continued 9. 10. 11. 12. 13. 14. 15. 16. 17.
0195
Line up and press the adapter (Figure 3, Item 1) over the transmitter connector (Figure 3, Item 4) stem until it completely covers the black line unit on the TLI transmitter stem (Figure 3, Item 3). Holding the adapter in place, secure the adapter (Figure 3, Item 1) with the setscrew (Figure 3, Item 5) to the TLI transmitter connector stem (Figure 3, Item 3). If the TLI transmitter is a dual mount, repeat Steps (7) through (10) until all cable assemblies are installed. Ensure that all connecting cables (Figure 3, Item 4) are secured in place and will not interfere with the travel of the float (Figure 2, Item 5) when the vessel pitches up and down or side to side. Slide the float (Figure 2, Item 5) up and down the stem (Figure 3, Item 3) of the transmitter. Ensure that each float slides freely up and down the entire length of the stem with no interference. Position the cable penetrator retaining lug (Figure 2, Item 1) as necessary to align it with the top of the stuffing tube (Figure 2, Item 2). Install the cable penetrator retaining lug by rotating it clockwise. Cut to length, clean, and prepare the cable for installation in the connection box (Figure 1). Take continuity readings from the terminal points of the cable assembly to ground and verify that no connections are grounded. Determine the correct resistance reading by referring to the tag attached to the TLI transmitter (Figure 2, Item 4) and multiplying "WHOLE INCHES OF INDICATOR" (Figure 4, Item 1) by "OHMS OF RESISTANCE PER INCH OF INDIC. X 100" (Figure 4, Item 2). The correct calculated value should be between 1,000 and 2,500 ohms. Measure TLI transmitter (Figure 2, Item 4) and cable assembly (Figure 2, Item 3) resistance by taking a resistance reading across the red and black wires. The resistance reading should be within 10% of the value calculated in Step (17). Measure resistance between the black wire and the white wire in the connection box (Figure 1). The measured resistance value should be 330 ohms 10% with all floats at the bottom rest position on the TLI transmitter (Figure 2, Item 4).
18.
19.
DESCRIPTION NO.
XM-XXXXX-XX-XXXX-X-X-XX-XX
PART NO. SERIAL NO. 1 2
M1326T73
Figure 4. TLI Transmitter Tag. 20. Continue measuring resistance between the black and white wires and slowly raise the float (Figure 2, Item 5) on the TLI transmitter (Figure 2, Item 4) in the same order filling the tank would. The total measured resistance should increase from approximately 330 ohms (when the float[s] are completely lowered), to the calculated value from Step (18) plus 330 ohms (with the float[s] completely raised). All resistance values should be within 10% of calculated values. Remove all tools and debris from the interior of the tank.
21.
0195-6
TM 55-1925-273-24&P-2 INSTALLATION - Continued 22. 23. 24. Exit the tank and install the manhole cover (WP 0098).
0195
Connect the cable assembly wires to the terminals in the connection box (Figure 1) using the labels from Step (5) of REMOVAL as a guide. Remove the labels. Install the connection box cover (Figure 1, Item 2).
END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. Remove the lock outs and tag outs IAW FM 4-01.502. Operate the TLI system under usual conditions IAW TM 55-1925-273-10. Return the equipment to the desired readiness condition.
0195-7/8 blank
TM 55-1925-273-24&P-2 FIELD MAINTENANCE DAY TANK HIGH LEVEL ALARM, ALARM PANEL REPAIR
0196
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 3, WP 0344, Table 1, Item 27) Multimeter (Volume 3, WP 0344, Table 1, Item 15) Tool Kit, Electrical Repair (Volume 3, WP 0344, Table 1, Item 26) Materials/Parts N/A Personnel Required Watercraft Engineer 88L (2) References FM 4-01.502 References (cont.) TM 55-1925-273-10 Volume 3, WP 0307 Volume 3, WP 0344 Equipment Condition Set to OFF the FUEL OIL DAY TANKS (P&S) HIGH LEVEL ALARM circuit breaker at the machinery Direct Current (DC) distribution control panel. Lock out and tag out IAW FM 4-01.502.
0196-1
TM 55-1925-273-24&P-2
0196
DAY TANK HIGH LEVEL ALARM INDICATOR BULB REMOVAL 1. 2. 3. Set to OFF the FUEL OIL DAY TANK (P&S) HIGH LEVEL ALARM circuit breaker (Figure 1, Item 1) at the machinery DC control distribution panel. Lock out and tag out IAW FM 4-01.502. Remove the protective lens cover (Figure 2, Item 5). Remove the bulb (Figure 2, Item 6).
M1379T73
Figure 1. Machinery DC Control Distribution Panel.
0196-2
TM 55-1925-273-24&P-2 DAY TANK HIGH LEVEL ALARM INDICATOR BULB REMOVAL - Continued
0196
7 5 1 2 3 1 2 3 4 6
11 14 14 14 13
Figure 2. END OF TASK DAY TANK HIGH LEVEL ALARM INDICATOR BULB INSTALLATION 1. 2. 3. 4. 5. 6. 7. 8. 9. Install the bulb (Figure 2, Item 6) finger tight. Install the protective lens cover (Figure 2, Item 5) finger tight. Remove the lock outs and tag outs IAW FM 4-01.502. Set the circuit breaker to ON. Operate the day tank high level alarm under usual conditions IAW TM 55-1925-273-10.
10
12
M1327T73
Day Tank High Level Alarm Panel.
Cycle the TEST switch (Figure 2, Item 1) from OFF to ON and back to OFF to test the alarm circuit function. Press and release the HORN/STROBE SILENCE switch (Figure 2, Item 3) to silence the alarm. Verify that the replaced bulb (Figure 2, Item 6) illuminates correctly. Return the equipment to the desired readiness condition.
END OF TASK
0196-3
TM 55-1925-273-24&P-2
0196
DAY TANK HIGH LEVEL ALARM FUSE REMOVAL 1. 2. 3. Set to OFF the FUEL OIL DAY TANKS (P&S) HIGH LEVEL ALARM circuit breaker (Figure 1, Item 1) at the machinery DC control distribution panel. Lock out and tag out IAW FM 4-01.502. Remove the fuse holder (Figure 2, Item 14) from the panel. Remove the fuse from the fuse holder (Figure 2, Item 14).
END OF TASK DAY TANK HIGH LEVEL ALARM FUSE INSTALLATION 1. 2. 3. 4. 5. 6. 7. 8. Install the fuse in the fuse holder (Figure 2, Item 14). Install the fuse holder (Figure 2, Item 14) in the panel finger tight. Remove the lock outs and tag outs IAW FM 4-01.502. Set the circuit breaker to ON. Operate the day high level alarm under usual conditions IAW TM 55-1925-273-10. Cycle the TEST switch (Figure 2, Item 1) from OFF to ON and back to OFF to test the alarm circuit function. Press and release the HORN/STROBE SILENCE switch (Figure 2, Item 3) to silence the alarm. Return the equipment to the desired readiness condition.
END OF TASK DAY TANK HIGH LEVEL ALARM LAMP ASSEMBLY REMOVAL 1. 2. Perform the DAY TANK HIGH LEVEL ALARM INDICATOR BULB REMOVAL procedure in this work package. Loosen the captive screw (Figure 2, Item 4) and open the alarm panel.
WARNING
Replace or repair components only after the affected circuit has been secured, locked out, and tagged out IAW FM 4-01.502. Performing replacement with the circuit energized may result in injury. 3. Use a multimeter to check for voltage at the terminals (Figure 2, Item 11) on the back of the fuse holders (Figure 2, Item 14). If voltage is present, ensure that the proper circuit breaker is set to OFF, locked out, and tagged out IAW FM 4-01.502. If no voltage is present, continue with the procedure. Label and remove the wires (Figure 2, Item 8) from the terminals (Figure 2, Item 9) of the lamp assembly (Figure 2, Item 2). Remove the retaining nut (Figure 2, Item 7), and remove the lamp assembly (Figure 2, Item 2) from the alarm panel.
4. 5.
END OF TASK
0196-4
TM 55-1925-273-24&P-2 DAY TANK HIGH LEVEL ALARM LAMP ASSEMBLY INSTALLATION 1. 2. 3. 4. Install the lamp assembly (Figure 2, Item 2) in the alarm panel and secure it with the retaining nut (Figure 2, Item 7).
0196
Install the wires (Figure 2, Item 8) to the lamp assembly (Figure 2, Item 2) using the labels from Step (4) of DAY TANK HIGH LEVEL ALARM LAMP ASSEMBLY REMOVAL as a guide. Remove the labels. Close the alarm panel and tighten the captive screw (Figure 2, Item 4). Perform the DAY TANK HIGH LEVEL ALARM INDICATOR BULB INSTALLATION procedure in this work package.
END OF TASK DAY TANK HIGH LEVEL ALARM FUSE HOLDER REMOVAL 1. 2. Perform the DAY TANK HIGH LEVEL ALARM FUSE HOLDER REMOVAL procedure in this work package. Loosen the captive screw (Figure 2, Item 4) and open the panel.
WARNING
Replace or repair components only after the affected circuit has been secured, locked out, and tagged out IAW FM 4-01.502. Performing replacement with the circuit energized may result in injury. 3. Use a multimeter to check for voltage at the terminals (Figure 2, Item 11) on the back of the fuse holders (Figure 2, Item 12). If voltage is present, ensure that the correct circuit breaker is set to OFF, locked out, and tagged out IAW FM 4-01.502. If no voltage is present, continue with the procedure. Label and remove the wires (Figure 2, Item 10) from the terminals (Figure 2, Item 11) of the fuse holder assembly (Figure 2, Item 12). Remove the retaining nut (Figure 2, Item 13) and remove the fuse holder assembly (Figure 2, Item 12) from the alarm panel.
4. 5.
END OF TASK DAY TANK HIGH LEVEL ALARM FUSE HOLDER INSTALLATION 1. 2. 3. 4. Install the fuse holder assembly (Figure 2, Item 12) in the alarm panel and secure it with the retaining nut (Figure 2, Item 13). Install the wires (Figure 2, Item 10) to the fuse holder assembly (Figure 2, Item 12) using the labels from Step (4) of DAY TANK HIGH LEVEL ALARM FUSE HOLDER REMOVAL as a guide. Remove the labels. Close the alarm panel and secure it with the captive screw (Figure 2, Item 4). Perform the DAY TANK HIGH LEVEL ALARM FUSE HOLDER INSTALLATION procedure in this work package.
END OF TASK
0196-5
TM 55-1925-273-24&P-2
0196
TEST SWITCH REMOVAL 1. Loosen the captive screw (Figure 3, Item 3) and open the front panel.
WARNING
Replace or repair components only after the affected circuit has been secured, locked out, and tagged out IAW FM 4-01.502. Performing replacement with the circuit energized may result in injury. 2. Use a multimeter to check for voltage at the terminals (Figure 3, Item 10) of the fuse holders (Figure 3, Item 4). If voltage is present, ensure that the proper circuit breaker is set to OFF, locked out, and tagged out IAW FM 4-01.502. If no voltage is present, continue with the procedure. Label and remove the wires (Figure 3, Item 6) from the terminals (Figure 3, Item 7) of the switch assembly (Figure 3, Item 1). Remove the knurled retaining nut (Figure 3, Item 5) and remove the switch assembly (Figure 3, Item 1) from the alarm panel.
3. 4.
0196-6
TM 55-1925-273-24&P-2 TEST SWITCH REMOVAL - Continued
0196
2 1
3 5
1 6
11
2 9 4 4 8
10
M1328T73
Figure 3. Day Tank High Level Alarm Panel Components. END OF TASK
0196-7
TM 55-1925-273-24&P-2
0196
TEST SWITCH INSTALLATION 1. 2. 3. 4. Install the switch assembly (Figure 3, Item 1) and secure it with the knurled retaining nut (Figure 3, Item 5). Install the wires (Figure 3, Item 6) to the terminals (Figure 3, Item 7) of the switch assembly (Figure 3, Item 1) using the labels from Step (3) of TEST SWITCH REMOVAL as a guide. Remove the labels. Close the front panel and secure it with the captive screw (Figure 3, Item 3). Perform the FOLLOW-ON MAINTENANCE at the end of this work package.
END OF TASK RELAY REMOVAL 1. Loosen the captive screw (Figure 3, Item 3) and open the front panel.
WARNING
Replace or repair components only after the affected circuit has been secured, locked out, and tagged out IAW FM 4-01.502. Performing replacement with the circuit energized may result in injury. 2. Use a multimeter to check for voltage at the terminals (Figure 3, Item 10) of the fuse holders (Figure 3, Item 4). If voltage is present, ensure that the proper circuit breaker is set to OFF, locked out, and tagged out IAW FM 4-01.502. If no voltage is present, continue with the procedure. Remove the relay (Figure 4, Item 1) from the socket (Figure 4, Item 2).
3.
0196-8
TM 55-1925-273-24&P-2 RELAY REMOVAL - Continued

1
0196
M1329T73
Figure 4. END OF TASK RELAY INSTALLATION 1. 2. 3.
Relay Assembly.
Install the relay (Figure 4, Item 1) by lining up the pins and gently pushing it into the socket (Figure 4, Item 2) until it snaps into place. Close the front panel and secure it with the captive screw (Figure 3, Item 3). Perform the FOLLOW-ON MAINTENANCE at the end of this work package.
END OF TASK
0196-9
TM 55-1925-273-24&P-2
0196
HORN/STROBE SILENCE (PUSHBUTTON) SWITCH REMOVAL 1. Loosen the captive screw (Figure 3, Item 3) and open the front panel.
WARNING
Replace or repair components only after the affected circuit has been secured, locked out, and tagged out IAW FM 4-01.502. Performing replacement with the circuit energized may result in injury. 2. Use a multimeter to check for voltage at the terminals (Figure 3, Item 10) of the fuse holders (Figure 3, Item 4). If voltage is present, ensure that the proper circuit breaker is set to OFF, locked out, and tagged out IAW FM 4-01.502. If no voltage is present, continue with the procedure. Label and remove the wires (Figure 3, Item 8) from the terminals (Figure 3, Item 9) of the pushbutton switch assembly (Figure 3, Item 2). Remove the knurled retaining nut (Figure 3, Item 11) and remove the pushbutton switch assembly (Figure 3, Item 2) from the alarm panel.
3. 4.
END OF TASK HORN/STROBE SILENCE (PUSHBUTTON) SWITCH INSTALLATION 1. 2. Install the pushbutton switch assembly (Figure 3, Item 2) and secure it with the knurled retaining nut (Figure 3, Item 11). Install the wires (Figure 3, Item 8) to the terminals (Figure 3, Item 9) of the pushbutton switch assembly (Figure 3, Item 2) using the labels from Step (3) of HORN/STROBE SILENCE (PUSHBUTTON) SWITCH REMOVAL as a guide. Remove the labels. Close the front panel and secure it with the captive screw (Figure 3, Item 3). Perform the FOLLOW-ON MAINTENANCE at the end of this work package.
3. 4.
END OF TASK HORN/STROBE ASSEMBLY REMOVAL 1. Remove the two screws (Figure 5, Item 1) that secure the horn/strobe (Figure 5, Item 2) to the mounting plate (Figure 5, Item 4).
0196-10
TM 55-1925-273-24&P-2 HORN/STROBE ASSEMBLY REMOVAL - Continued
0196
WARNING
Replace or repair components only after the affected circuit has been secured, locked out, and tagged out IAW FM 4-01.502. Performing replacement with the circuit energized may result in injury. 2. Use a multimeter to check for voltage at the terminal board (Figure 5, Item 6). If voltage is present, ensure that the proper circuit breaker is set to OFF, locked out, and tagged out IAW FM 4-01.502. If no voltage is present, continue with the procedure. Label and disconnect the wires from the terminal board (Figure 5, Item 6). Remove the two screws (Figure 5, Item 3) that secure the mounting plate (Figure 5, Item 4) to the junction box (Figure 5, Item 5).
4 3 2 5
3. 4.
6 3 -IN -OUT TOP
SIGNAL LIGHT (IF SUPPLIED)
-IN -OUT -IN -OUT -IN -OUT

M1330T73
Horn/Strobe Assembly.
0196-11
TM 55-1925-273-24&P-2 HORN/STROBE ASSEMBLY INSTALLATION 1. 2. 3. 4.
0196
Install the mounting plate (Figure 5, Item 4) on the junction box (Figure 5, Item 5) and secure it with the two screws (Figure 5, Item 3). Connect the wires to the terminal board (Figure 5, Item 6) using the labels from Step (3) of HORN/STROBE ASSEMBLY REMOVAL as a guide. Discard labels. Install the horn/strobe (Figure 5, Item 2) on the mounting plate (Figure 5, Item 4) and secure it with the two screws (Figure 5, Item 1). Perform the FOLLOW-ON MAINTENANCE at the end of this work package.
END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. 4. 5. Remove the lock outs and tag outs IAW FM 4-01.502. Operate the day tank high level alarm under usual conditions IAW TM 55-1925-273-10. Cycle the TEST switch from OFF to ON and back to OFF to test the alarm circuit function. Press and release the HORN/STROBE SILENCE switch to silence the alarm. Return the equipment to the desired readiness condition.
0196-12
TM 55-1925-273-24&P-2 FIELD MAINTENANCE DAY TANK HIGH LEVEL ALARM LEVEL ALARM SENSOR REPLACE
0197
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 3, WP 0344, Table 1, Item 27) Multimeter (Volume 3, WP 0344, Table 1, Item 15) Tool Kit, Electrical Repair (Volume 3, WP 0344, Table 1, Item 26) Materials/Parts Tape, Antiseizing, 1/2 in. (Volume 3, WP 0343, Table 1, Item 158) Personnel Required Watercraft Engineer 88L (2) References FM 4-01.502 Volume 3, WP 0308 Volume 3, WP 0343 Volume 3, WP 0344 Equipment Condition Set to OFF the FUEL OIL DAY TANKS (P&S) HIGH LEVEL ALARM circuit breaker at the 24 V machinery Direct Current (DC) distribution control panel. Lock out and tag out IAW FM 4-01.502. Equipment Condition (cont.) Set to OFF the FUEL OIL XFER PUMP circuit breaker on the emergency switchboard. Lock out and tag out IAW FM 4-01.502. Set to OFF the FUEL OIL TRANSFER PUMP No. 2 circuit breaker (LT 803 Only), or the LVP FOR FUEL OIL TRANSFER PUMP No. 2 circuit breaker (All Other Vessels) at 440 V power panel No. 1. Lock out and tag out IAW FM 4-01.502. Day tank no more than half full.
0197-1
TM 55-1925-273-24&P-2
0197
DAY TANK HIGH LEVEL ALARM SENSOR REMOVAL 1. Remove the cover from the junction box (Figure 1, Item 2).
WARNING
Replace or repair components only after the affected circuit has been secured, locked out, and tagged out IAW FM 4-01.502. Performing replacement with the circuit energized may result in injury. 2. Use a multimeter to check for voltage at the terminal board (Figure 1, Item 3) inside the junction box (Figure 1, Item 2). If voltage is present, ensure that the proper circuit breaker is set to OFF, locked out, and tagged out IAW FM 4-01.502. If no voltage is present, continue with the procedure. Label and remove the output wires (Figure 1, Item 1) that connect the junction box (Figure 1, Item 2) to the alarm panel.
3.
0197-2
TM 55-1925-273-24&P-2 DAY TANK HIGH LEVEL ALARM SENSOR REMOVAL - Continued

1 2
0197
M1331T73
Figure 1.
Junction Box with Cover Removed.
0197-3
TM 55-1925-273-24&P-2 DAY TANK HIGH LEVEL ALARM SENSOR REMOVAL - Continued
0197
CAUTION
Care must be taken when removing the top mounted sensor to prevent damage to equipment and cabling. 4. 5. 6. Remove the alarm panel cable conduit (Figure 2, Item 2) from the junction box (Figure 2, Item 1). Loosen the 1-5/16 in. hex fitting (Figure 2, Item 7), and remove the sensor assembly (Figure 2, Item 6) from the top of the tank. Remove the junction box (Figure 2, Item 1) from the sensor assembly (Figure 2, Item 6).
4 6
M1332T73
Day Tank High Level Alarm Sensor Assembly.
0197-4
TM 55-1925-273-24&P-2
0197
DAY TANK HIGH LEVEL ALARM SENSOR INSTALLATION 1. 2. 3. 4. 5. Apply antiseizing tape to the male threads of the conduit (Figure 2, Item 2). Run the wires from the conduit (Figure 2, Item 2) into the junction box (Figure 2, Item 1). Install the junction box (Figure 2, Item 1) on the conduit (Figure 2, Item 2) hand tight plus 1/8 of a turn. Do not overtighten. Install the wires (Figure 1, Item 1) in the junction box (Figure 1, Item 2) using the labels from Step (3) of DAY TANK HIGH LEVEL ALARM SENSOR REMOVAL as a guide. Remove the labels. Install the junction box cover (Figure 2, Item 8) and secure it with the four screws (Figure 2, Item 3).
NOTE
Do not secure the sensor in the tank fitting until it has been tested. 6. Place the sensor stem (Figure 2, Item 4) into the tank fitting.
END OF TASK FOLLOW-ON MAINTENANCE 1. 2. Remove the lock outs and tag outs IAW FM 4-01.502 and set the circuit breaker to ON. Test the operation of the day tank high level alarm by lifting the sensor unit out of the tank fitting and sliding the float slowly up and down the sensor stem. Verify that the day tank high level alarm sounds when the float is placed at approximately the 95% full position. Apply antiseizing tape to the 1-5/16 in. hex fitting. Install the sensor assembly in the tank, and secure it with the 1-5/16 in. hex fitting. Tighten hand tight plus 1/8 of a turn. Do not overtighten. Return the equipment to the desired readiness condition.
3. 4. 5.
0197-5/6 blank
TM 55-1925-273-24&P-2 FIELD MAINTENANCE SEWAGE SYSTEM VALVES REPLACE
0198
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 3, WP 0344, Table 1, Item 27) Gloves, Chemical and Oil Protective (Volume 3, WP 0344, Table 1, Item 8) Goggles, Industrial (Volume 3, WP 0344, Table 1, Item 10) Suitable Drain Pan Materials/Parts Rag, Wiping (Volume 3, WP 0343, Table 1, Item 132) Personnel Required Watercraft Engineer 88L (1) References FM 4-01.502 TM 55-1925-273-10 Volume 3, WP 0309 References (cont.) Volume 3, WP 0343 Volume 3, WP 0344 Equipment Condition Set to OFF the MSD DISCHARGE PUMP AND BLOWER. circuit breaker (LT 803 Only), or the CONTROLLER FOR MSD DISCHARGE PUMP AND BLOWER circuit breaker (All Other Vessels) at 440 V power panel No. 4. Lock out and tag out IAW FM 4-01.502. Set to OFF the SEWAGE DISCHARGE PUMP No. 1. circuit breaker and the SEWAGE DISCHARGE PUMP No. 2. circuit breaker (LT 803 Only), or the LVP FOR STARBOARD SEWAGE DISCHARGE PUMP No. 1 circuit breaker and the LVP FOR PORT SEWAGE DISCHARGE PUMP No. 2 circuit breaker (All Other Vessels) at 440 V power panel No. 1. Lock out and tag out IAW FM 4-01.502. CLOSE all valves upstream and downstream of the affected valve. Lock out and tag out IAW FM 4-01.502. Ventilation fans operating under usual conditions IAW TM 55-1925-273-10.
0198-1
TM 55-1925-273-24&P-2
0198
SCUPPER GAG VALVE REMOVAL 1. 2. Partially OPEN the valve (Figure 1, Item 1) to equalize any internal pressure before removing any bolts. Place a suitable drain pan under the valve (Figure 1, Item 1).
WARNING
Toxic and flammable vapors are generated in the sewage system. Provide ventilation from outside source. Avoid open flames and prolonged breathing of fumes. Failure to comply with this warning can result in illness, serious injury, or death. Sewage is a common mode of transmission for parasitic organisms that may have the capability of causing communicable diseases. Chemical protective gloves, goggles, and protective apron should be worn to help prevent contact with sewage. After coming in contact with sewage or contaminated equipment, be sure to clean yourself with a disinfectant soap. Avoid sewage contact with skin abrasions, punctures, cuts, and other open wounds. Wipe up and clean any spills and/or contaminated equipment using a disinfectant soap. Failure to comply with this warning can result in illness, serious injury, or death. 3. 4. 5. 6. 7. Slowly loosen the bolts (Figure 1, Item 7) and nuts (Figure 1, Item 5) on the inlet side of the valve (Figure 1, Item 1). Allow pressure to vent and any liquid to drain into the suitable drain pan. Remove the bolts (Figure 1, Item 7) and nuts (Figure 1, Item 5) from the inlet side of the valve (Figure 1, Item 1). Remove the bolts (Figure 1, Item 3) and nuts (Figure 1, Item 2) from the outlet side of the valve (Figure 1, Item 1). Remove the valve (Figure 1, Item 1) from the vessel piping. Remove gaskets (Figure 1, Items 4 and 6).
0198-2
TM 55-1925-273-24&P-2 SCUPPER GAG VALVE REMOVAL - Continued
0198
2 3
6
Figure 1.
4
Flanged Scupper Gag Valve.
M1106T73
END OF TASK
0198-3
TM 55-1925-273-24&P-2
0198
SCUPPER GAG VALVE INSTALLATION
WARNING
Toxic and flammable vapors are generated in the sewage system. Provide ventilation from outside source. Avoid open flames and prolonged breathing of fumes. Failure to comply with this warning can result in illness, serious injury, or death. Sewage is a common mode of transmission for parasitic organisms that may have the capability of causing communicable diseases. Chemical protective gloves, goggles, and protective apron should be worn to help prevent contact with sewage. After coming in contact with sewage or contaminated equipment, be sure to clean yourself with a disinfectant soap. Avoid sewage contact with skin abrasions, punctures, cuts, and other open wounds. Wipe up and clean any spills and/or contaminated equipment using a disinfectant soap. Failure to comply with this warning can result in illness, serious injury, or death. 1. 2. Clean the flanges of the valve (Figure 1, Item 1) and the vessel piping using a wire brush, clean wiping rags, and water. Install the valve (Figure 1, Item 1) and two gaskets (Figure 1, Items 4 and 6) to the vessel piping. Secure it with the bolts (Figure 1, Items 3 and 7) and the nuts (Figure 1, Items 2 and 5).
END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. 4. 5. Remove the lock outs and tag outs IAW FM 4-01.502. Set the circuit breakers to ON. Operate the marine sanitation device under usual conditions IAW TM 55-1925-273-10. Check the valve and connections for leakage and proper operation. Return the equipment to the desired readiness condition.
0198-4
TM 55-1925-273-24&P-2 FIELD MAINTENANCE SEWAGE SYSTEM VALVES REPAIR
0199
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 3, WP 0344, Table 1, Item 27) Gloves, Chemical and Oil Protective (Volume 3, WP 0344, Table 1, Item 8) Goggles, Industrial (Volume 3, WP 0344, Table 1, Item 10) Suitable Drain Pan Materials/Parts Rag, Wiping (Volume 3, WP 0343, Table 1, Item 132) Personnel Required Watercraft Engineer 88L (1) References TM 55-1925-273-10 References (cont.) WP 0198 Volume 3, WP 0309 Volume 3, WP 0343 Volume 3, WP 0344 Equipment Condition Ventilation fans operating under usual conditions IAW TM 55-1925-273-10. Sewage system valve removed. (WP 0198)
0199-1
TM 55-1925-273-24&P-2
0199
TYPICAL BALL VALVE (FLANGED) REPAIR DISASSEMBLY
WARNING
Toxic and flammable vapors are generated in the sewage system. Provide ventilation from outside source. Avoid open flames and prolonged breathing of fumes. Failure to comply with this warning can result in illness, serious injury, or death. Sewage is a common mode of transmission for parasitic organisms that may have the capability of causing communicable diseases. Chemical protective gloves, goggles, and protective apron should be worn to help prevent contact with sewage. After coming in contact with sewage or contaminated equipment, be sure to clean yourself with a disinfectant soap. Avoid sewage contact with skin abrasions, punctures, cuts, and other open wounds. Wipe up and clean any spills and/or contaminated equipment using a disinfectant soap. Failure to comply with this warning can result in illness, serious injury, or death.
NOTE
Valve replacement procedures in this WP are for typical valves used in the sewage collection, holding, and transfer system. Actual removal and installation of the valves in this WP may differ slightly from the procedures as written. 1. 2. 3. 4. 5. 6. 7. 8. Remove the nut (Figure 1, Item 1) and the handle (Figure 1, Item 2) from the valve body (Figure 1, Item 12). Remove the gland nut (Figure 1, Item 3) from the valve body (Figure 1, Item 12). Remove the gland nut packing (Figure 1, Item 4) from the valve body (Figure 1, Item 12). Remove the valve stem (Figure 1, Item 5) from the valve body (Figure 1, Item 12). Remove the valve stem packing (Figure 1, Item 6) from the valve body (Figure 1, Item 12). Remove the retainer (Figure 1, Item 11) from the valve body (Figure 1, Item 12). Remove the gasket (Figure 1, Item 10) from the valve body (Figure 1, Item 12). Remove the valve seat (Figure 1, Item 9), the ball (Figure 1, Item 8), and the valve seat (Figure 1, Item 7) from the valve body (Figure 1, Item 12).
0199-2
TM 55-1925-273-24&P-2 TYPICAL BALL VALVE (FLANGED) REPAIR DISASSEMBLY - Continued
0199
7 8 9 10 11 12
M1107T73
Ball Valve.
0199-3
TM 55-1925-273-24&P-2
0199
TYPICAL BALL VALVE (FLANGED) REPAIR ASSEMBLY 1. 2. 3. 4. 5. 6. 7. 8. Inspect all valve components for wear and damage. Clean the parts of the valve using clean wiping rags and water. Install the valve seat (Figure 1, Item 7), the ball (Figure 1, Item 8), the valve seat (Figure 1, Item 9), and a gasket (Figure 1, Item 10) in valve body (Figure 1, Item 12). Secure them with the retainer (Figure 1, Item 11). Install valve stem packing (Figure 1, Item 6) in the valve body (Figure 1, Item 12). Install the valve stem (Figure 1, Item 5) in the valve body (Figure 1, Item 12). Install gland nut packing (Figure 1, Item 4) in the valve body (Figure 1, Item 12). Secure it with gland nut (Figure 1, Item 3). Install the handle (Figure 1, Item 2) and secure it with the nut (Figure 1, Item 1). Perform the applicable INSTALLATION procedure for the affected valve (WP 0198).
0199-4
TM 55-1925-273-24&P-2 FIELD MAINTENANCE SEWAGE DISCHARGE PUMP REPAIR
0200
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 3, WP 0344, Table 1, Item 27) Materials/Parts N/A Personnel Required Watercraft Engineer 88L (2) References FM 4-01.502 References (cont.) TM 55-1925-273-10 WP 0203 Volume 3, WP 0310 Volume 3, WP 0344 Equipment Condition Sewage discharge pump electric motor removed. (WP 0203)
0200-1
TM 55-1925-273-24&P-2
0200
COUPLING REMOVAL 1. 2. Loosen the setscrew (Figure 1, Item 3) from the coupling (Figure 1, Item 1). Remove the coupling (Figure 1, Item 1) from the pump shaft (Figure 1, Item 2).
2
M1380T73
Figure 1. END OF TASK COUPLING INSTALLATION 1. 2. 3. 4. 5.
Sewage Discharge Pump.
Install the coupling (Figure 1, Item 1) on the pump shaft (Figure 1, Item 2), and secure it with the setscrew (Figure 1, Item 3). Perform the ELECTRIC MOTOR INSTALLATION procedure (WP 0203). Operate the sewage discharge pump under usual conditions IAW TM 55-1925-273-10. Check the sewage discharge pump for proper operation and any signs of leakage. Return the equipment to the desired readiness condition.
0200-2
TM 55-1925-273-24&P-2 FIELD MAINTENANCE SEWAGE DISCHARGE PUMP, PUMP END REPLACE
0201
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 3, WP 0344, Table 1, Item 27) Apron, Utility (Volume 3, WP 0344, Table 1, Item 1) Gloves, Chemical and Oil Protective (Volume 3, WP 0344, Table 1, Item 8) Gloves, Leather (Volume 3, WP 0344, Table 1, Item 9) Goggles, Industrial (Volume 3, WP 0344, Table 1, Item 10) Helmet, Safety (Volume 3, WP 0344, Table 1, Item 11) Hoist, Chain, Hand Operated, 2 Ton (1,814 kg) (Volume 3, WP 0344, Table 1, Item 12) Sling, Endless (Volume 3, WP 0344, Table 1, Item 21) Suitable Drain Pan Materials/Parts N/A Personnel Required Watercraft Engineer 88L (2) References FM 4-01.502 TM 55-1925-273-10 WP 0203 Volume 3, WP 0310 Volume 3, WP 0344 Equipment Condition CLOSE all valves for affected pump. Lock out and tag out IAW FM 4-01.502.
0201-1
TM 55-1925-273-24&P-2
0201
WARNING
Never reuse locking hardware. Reuse of locking hardware such as lockwashers, locking nuts, cotter pins, and lock wire can result in undetected loosening of fastening hardware causing catastrophic component failure resulting in death, injury, or damage to equipment. Ensure that all locking hardware is discarded upon removal and replaced with new. REMOVAL 1. Place a suitable drain pan under the sewage discharge pump.
WARNING
Sewage lines may be under pressure. Loosen fittings on hoses and lines slowly. Allow fluid to run around threads of fitting, releasing pressure before disconnecting fitting. Releasing pressurized fluid suddenly may cause serious injury or death. 2. 3. 4. 5. Slowly OPEN the pressure gage fitting (Figure 1, Item 1) to relieve pressure from the sewage discharge pump (Figure 1, Item 8). After all pressure has been released, remove the bolts (Figure 1, Item 2) and the nuts (Figure 1, Item 4) securing the sewage discharge pump (Figure 1, Item 8) to the vessel's discharge piping. Remove the bolts (Figure 1, Item 5) and the nuts (Figure 1, Item 7) securing the sewage discharge pump's inlet (Figure 1, Item 8) to the vessel's inlet piping. Remove the gaskets (Figure 1, Items 3 and 6) from the sewage discharge pump (Figure 1, Item 8).
0201-2

1
0201
3 8
M1333T73
Figure 1. 6.
Remove the nuts (Figure 2, Item 4), the lockwashers (Figure 2, Item 3), the flat washers (Figure 2, Item 5), and the bolt (Figure 2, Item 1) securing the sewage discharge pump (Figure 2, Item 2) to the foundation. Discard lockwashers.
0201-3
0201
WARNING
All personnel in the vicinity of lifting operations should wear appropriate safety equipment including heavy gloves, hardhats, and safety shoes. Failure to comply with this warning can result in serious injury or death. 7. 8. Using the endless sling and chain hoist, carefully remove the sewage discharge pump (Figure 2, Item 2) from the foundation and move the sewage discharge pump to a workbench. Plug or tape over the exposed piping connections and the pressure differential connection on the vessel's piping to prevent contamination of the system.
1 2 DISCHARGE
INTAKE 5
5 3 4
M1334T73
0201-4
TM 55-1925-273-24&P-2 INSTALLATION 1. 2.
0201
Using the endless sling and chain hoist, carefully lower the sewage discharge pump (Figure 2 Item 2) onto the foundation and into place. Install the bolts (Figure 2, Item 1), flat washer (Figure 2, Item 5), lockwashers (Figure 2, Item 3), and nut (Figure 2, Item 4) securing the sewage discharge pump (Figure 2, Item 2) to the foundation. Do not tighten bolts at this time. Install the bolts (Figure 1, Item 5), a gasket (Figure 1, Item 6), and the nuts (Figure 1, Item 7) in the vessel's piping. Do not tighten bolts at this time. Install the bolts (Figure 1, Item 2), a gasket (Figure 1, Item 3), and the nuts (Figure 1, Item 4) securing the pump (Figure 1, Item 8) to the vessel's piping. Tighten the bolts (Figure 1, Items 2 and 5) securing the sewage discharge pump (Figure 1, Item 8) to the vessel's piping. Tighten the bolts (Figure 2, Item 4) securing the sewage discharge pump (Figure 2, Item 5) to the foundation.
3. 4. 5. 6.
END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. 4. Align pump IAW SEWAGE DISCHARGE PUMP ELECTRIC MOTOR REPLACE motor installation procedure (WP 0203). Remove the lock outs and tag outs IAW FM 4-01.502. Operate the sewage discharge oil pump under usual conditions IAW TM 55-1925-273-10, checking for leaks and proper operation. Return the sewage discharge oil pump to the desired readiness condition.
0201-5/6 blank
TM 55-1925-273-24&P-2 FIELD MAINTENANCE SEWAGE DISCHARGE PUMP, PUMP END REPAIR
0202
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 3, WP 0344, Table 1, Item 27) Faceshield, Industrial (Volume 3, WP 0344, Table 1, Item 5) Gloves, Chemical and Oil Protective (Volume 3, WP 0344, Table 1, Item 8) Gloves, Leather (Volume 3, WP 0344, Table 1, Item 9) Press, Arbor, Hand Operated (Volume 3, WP 0344, Table 1, Item 16) Suitable Drain Pan Tool Kit, Pump (Volume 3, WP 0344, Table 1, Item 28) Wrench, Torque, 0-250 lb-ft (0-339 Nm) (Volume 3, WP 0344, Table 1, Item 33) Materials/Parts Cleaning Compound, Solvent (Volume 3, WP 0343, Table 1, Item 37) Compound, Sealing; Silicone RTV (Volume 3, WP 0343, Table 1, Item 44) Layout Dye (Volume 3, WP 0343, Table 1, Item 93) Lubricating Oil, Engine; OE/HDO-40, 55 gal (Volume 3, WP 0343, Table 1, Item 104) Gasket, Casing Cover (Volume 3, WP 0310, Figure 62, Item 6) Qty: 1 Materials/Parts (cont.) Gasket, Impeller Gro (Volume 3, WP 0310, Figure 62, Item 5) Qty: 1 Seal, Oil, Outboard (Volume 3, WP 0311, Figure 62, Item 7) Qty: 1 Seal, Oil, Inboard (Volume 3, WP 0310, Figure 62, Item 4) Qty: 1 Personnel Required Watercraft Engineer 88L (2) References WP 0201 Volume 3, WP 0310 Volume 3, WP 0343 Volume 3, WP 0344 Equipment Condition Pump end removed. (WP 0201)
0202-1
TM 55-1925-273-24&P-2
0202
DISASSEMBLY
WARNING
Never reuse locking hardware. Reuse of locking hardware such as lockwashers, locking nuts, cotter pins, and lock wire can result in undetected loosening of fastening hardware causing catastrophic component failure resulting in death, injury, or damage to equipment. Ensure that all locking hardware is discarded upon removal and replaced with new. 1. 2. 3. 4. 5. Place a suitable drain pan under the pump's drain plug (Figure 1, Item 23). Remove the drain plug and drain all oil from the pump. Remove the vent plug (Figure 1, Item 14) from the bearing housing (Figure 1, Item 15). Remove the eight casing nuts (Figure 1, Item 17) securing the bearing housing adapter (Figure 1, Item 19) to the pump casing (Figure 1, Item 29). Separate the bearing housing adapter (Figure 1, Item 19) from the pump casing (Figure 1, Item 29) and remove the rear cover gasket (Figure 1, Item 28). Discard rear cover gasket. Install the impeller wrench onto the shaft (Figure 1, Item 8) and the key (Figure 1, Item 6).
0202-2

1 2 3 4 5 6 7
0202
13 8
12 14 11 15 16 10 9 17
18
19 20 24
23 25 22 26 27 28 29 21
33 32 31 30
M1335T73A
Figure 1.
Sewage Discharge Pump Assembly.
0202-3
0202
WARNING
The impeller could have sharp edges. Wear leather gloves to protect the hands when removing the impeller. Failure to comply with this warning can result in injury or death. Do not apply heat to the impeller to loosen it from the shaft. Liquid inside the impeller might cause an explosion. Failure to comply with this warning can result in illness, serious injury, or death.
NOTE
It may take several attempts using this method before the impeller is loosened. 6. Turn the impeller (Figure 1, Item 30) in the clockwise direction and move the impeller wrench in the 11 o'clock position. Quickly spin the impeller in the counterclockwise position causing the impeller wrench to impact the hard surface of the workbench. Refer to Figure 2.
M1336T73
Figure 2. 7. 8. 9. 10. 11. 12. 13.
Impeller.
Unscrew the impeller (Figure 1, Item 30) and remove it from the shaft (Figure 1, Item 8). Remove the impeller gasket (Figure 1, Item 27) from the shaft (Figure 1, Item 8). Discard impeller gasket. Remove the inboard deflector (Figure 1, Item 20) from the bearing housing adapter (Figure 1, Item 19). Remove the four nuts (Figure 1, Item 25) securing the gland (Figure 1, Item 33). Slide the gland away from the rear cover plate (Figure 1, Item 31). Install the brass shaft guide onto the shaft (Figure 1, Item 8). Remove the two capscrews (Figure 1, Item 18) securing the rear cover plate (Figure 1, Item 31) to the bearing housing adapter (Figure 1, Item 19). Slowly separate the rear cover plate (Figure 1, Item 31) from the bearing housing adapter (Figure 1, Item 19) and slide the rear cover plate off the shaft (Figure 1, Item 8).
0202-4
TM 55-1925-273-24&P-2 DISASSEMBLY - Continued 14. Remove the packing set (Figure 1, Item 26) from the rear cover plate (Figure 1, Item 31).
0202
NOTE
Do not discard lantern rings (Figure 1, Item 32). 15. 16. 17. 18. 19. 20. 21. 22. 23. Remove the two lantern rings (Figure 1, Item 32) from the rear cover plate (Figure 1, Item 31). Remove the brass shaft guide from the shaft (Figure 1, Item 8). Loosen the three bolts (Figure 1, Item 12) securing the bearing carrier (Figure 1, Item 1). Remove the bearing carrier. Remove the bearing carrier gaskets (Figure 1, Item 2) from the bearing carrier (Figure 1, Item 1). Remove the outboard oil seal (Figure 1, Item 13) from the bearing carrier (Figure 1, Item 1). Discard outboard oil seal. Remove the bearing snap ring (Figure 1, Item 4) using snap pliers. Remove and retain the shims (Figure 1, Item 3) from the bearing housing (Figure 1, Item 15). Remove the bearing locknut (Figure 1, Item 11) and the bearing lockwasher (Figure 1, Item 5). Discard bearing lockwasher. Remove the shaft (Figure 1, Item 8) from the bearing housing (Figure 1, Item 15).
CAUTION
Never apply pressure to the outer race of the bearings as this exerts excess load on the balls and causes damage to the bearing. 24. 25. 26. 27. 28. Remove the inboard bearing (Figure 1, Item 9), the outboard bearing (Figure 1, Item 10), and the slinger (Figure 1, Item 7) from the shaft (Figure 1, Item 8), using an arbor press. Remove the four capscrews (Figure 1, Item 22) securing the bearing housing (Figure 1, Item 15) to the bearing housing adapter (Figure 1, Item 19). Separate the bearing housing and the bearing housing adapter. Remove the O-ring (Figure 1, Item 16) from the bearing housing (Figure 1, Item 15). Remove the inboard oil seal (Figure 1, Item 21) from the inner race of the bearing housing adapter (Figure 1, Item 19). Discard inboard oil seal. Remove the Trico oil gage (Figure 1, Item 24) from the bearing housing (Figure 1, Item 15).
END OF TASK
0202-5
0202
WARNING
Cleaning solvent is flammable and its vapor is potentially explosive. Do not use cleaning solvent in the vicinity of spark, open flame, or excessive heat. Do not use cleaning solvent in unventilated spaces. Failure to comply can result in serious injury or death. Do not allow hydraulic fluid, engine oil, or cleaning solvents to come in contact with unprotected skin or eyes. Prolonged skin contact can cause illness or injury. Eye contact can cause serious injury. Always wear chemical protective gloves and goggles when handling hydraulic fluid, engine oil, and cleaning solvents. Failure to follow these precautions can result in illness, serious injury, or death. 1. 2. Using cleaning solvent, clean all the metal parts. Check for any binding, scoring, galling, or rough rotation on the inboard bearings (Figure 1, Item 9) and the outboard bearings (Figure 1, Item 10). Inspect all component parts for unusual wear or damage, and replace as required.
WARNING
Do not exceed 25 PSI (1.7 bar) nozzle pressure when using compressed air to dry parts. Wear goggles for eye protection. Do not direct air stream toward self or other personnel. Failure to comply with this warning can result in injury or death.
CAUTION
Do not permit the ball bearings to free spin in the bearing race as the bearing is being subjected to the compressed air. Bearing failure will result. 3. Direct a stream of compressed air at the bearings (Figure 1, Items 9 and 10) to blow out any debris.
END OF TASK ASSEMBLY 1. 2. 3. 4. Install a inboard oil seal (Figure 1, Item 21) into the inner race of the bearing housing adapter (Figure 1, Item 19). Install a O-ring (Figure 1, Item 16) into the bearing housing (Figure 1, Item 15). Connect the bearing housing (Figure 1, Item 15) and the bearing housing adapter (Figure 1, Item 19). Install the four capscrews (Figure 1, Item 22) securing the bearing housing to the bearing housing adapter. Put layout dye onto shaft (Figure 1, Item 8) then scribe a line in the layout dye for the location of inboard bearing (Figure 1, Item 9). Refer to Figure 3.
0202-6
0202
5.09 INCH
(129.3 MM)
Figure 3. 5. Bearing Positioning.
M1337T73
Install a slinger (Figure 1, Item 7) using an arbor press.
CAUTION
Never apply pressure to the outer race of the bearings as this exerts excess load on the balls and causes damage to the bearing. 6. Press the inboard bearing (Figure 1, Item 9) onto the shaft (Figure 1, Item 8) using an arbor press, aligning the edge of the inner race of the inboard bearing with the scribed line.
CAUTION
Never apply pressure to the outer race of the bearings as this exerts excess load on the balls and causes damage to the bearing. 7. 8. 9. Press the outboard bearing (Figure 1, Item 10) onto the shaft (Figure 1, Item 8) up to the shoulder of the shaft ring using an arbor press. Refer to Figure 3. Install a bearing lockwasher (Figure 1, Item 5) and the bearing locknut (Figure 1, Item 11) and engage the lockwasher's tangs into the locknut's slots. Apply a coat of lubricating oil on the shaft (Figure 1, Item 8) in the inboard bearing (Figure 1, Item 9), and the outboard bearings (Figure 1, Item 10), and the inside of the bearing housing (Figure 1, Item 15), and slide the shaft (Figure 1, Item 8) into the rear of the bearing housing. Install three set bolts (Figure 1, Item 12) into the bearing carrier (Figure 1, Item 1). Tighten the set bolts. Install the brass shaft guide onto the shaft (Figure 1, Item 8). Install the inboard deflector (Figure 1, Item 20). Install the impeller gasket (Figure 1, Item 27) onto the shaft (Figure 1, Item 8). Install the gland (Figure 1, Item 33) onto the shaft (Figure 1, Item 8). Slide the rear cover plate (Figure 1, Item 31) over the brass shaft guide and onto the shaft (Figure 1, Item 8) up to the bearing housing adapter (Figure 1, Item 19). Install the two capscrews (Figure 1, Item 18) securing the rear cover plate (Figure 1, Item 31) to the bearing housing adapter (Figure 1, Item 19). Tighten the two capscrews to the torque of 40 lb-ft (54 Nm).
10. 11. 12. 13. 14. 15. 16.
0202-7
0202
WARNING
The impeller could have sharp edges. Wear leather gloves to protect the hands when removing the impeller. Failure to comply with this warning can result in injury or death. 17. Screw the impeller (Figure 1, Item 30) onto the shaft (Figure 1, Item 8) until it is firmly against the shaft's shoulder.
CAUTION
Do not attempt to tighten the impeller on the shaft by hitting the impeller with a hammer or any other object or by inserting a pry bar between the impeller vanes. Serious damage to the impeller may result from such actions. 18. 19. Install the impeller wrench over the shaft (Figure 1, Item 8) and the key (Figure 1, Item 6). Grab the impeller (Figure 1, Item 30) in both hands with the impeller wrench handle to the left, spin the impeller forcefully in a clockwise direction to impact the impeller wrench handle on the work surface to the right.
M1338T73
Figure 4. Tightening the Impeller. 20. Determine the proper clearance using Table 1.
0202-8
TM 55-1925-273-24&P-2 ASSEMBLY - Continued Table 1. Temperature F (C) 200 (93) 200 to 250 (93 to 121) 251 to 300 (122 to 149) 301 to 350 (150 to 176) 351 to 400 (177 to 204) 401 to 450 (205 to 232) 450 (232) 21. 22. 23. Impeller Clearance Settings. Clearance to casing in. (mm) 0.018 0.003 (0.46 0.08) 0.021 (0.53) 0.024 (0.61) 0.027 (0.69) 0.030 (0.76) 0.033 (0.84) 0.036 (0.91)
0202
Measure the clearance between the impeller (Figure 1, Item 30) and the rear cover plate (Figure 1, Item 31) and record the distance. Subtract the desired clearance from the recorded measurement. Select shims (Figure 1, Item 3) to equal the sum of the subtracted measurement. Remove the three set bolts (Figure 1, Item 12) securing the bearing carrier (Figure 1, Item 1). Remove the bearing carrier.
NOTE
Install the thinnest shims first. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35. Install the shims (Figure 1, Item 3) between the bearing snap ring (Figure 1, Item 4) and the bearing housing (Figure 1, Item 15). Install the bearing snap ring. Install the outboard oil seal (Figure 1, Item 13) into the bearing carrier (Figure 1, Item 1). Install the three set bolts (Figure 1, Item 12) into the bearing carrier (Figure 1, Item 1). Tighten the set bolts. Recheck the clearance between the impeller (Figure 1, Item 30) and the rear cover plate (Figure 1, Item 31). Measure the thickness of the bearing snap ring (Figure 1, Item 4) and the shims (Figure 1, Item 3). The bearing carrier gaskets (Figure 1, Item 2) should equal 1-1/2 times the snap ring and the shim stack. Apply sealing compound between each bearing carrier gasket (Figure 1, Item 2). Place the bearing carrier gaskets (Figure 1, Item 2) stack inside the bearing carrier (Figure 1, Item 1). Install the bearing carrier (Figure 1, Item 1) onto the bearing housing (Figure 1, Item 15). Tighten the three set bolts (Figure 1, Item 12) 30 lb-ft (41 Nm). Install the two lantern rings (Figure 1, Item 32) into the rear cover plate (Figure 1, Item 31). Push the two lantern rings snug down into the rear cover plate using the gland (Figure 1, Item 33). Install the packing set (Figure 1, Item 26) into the rear cover plate (Figure 1, Item 31). Push the packing set snug down into the rear cover plate using the gland (Figure 1, Item 33). Install the gland (Figure 1, Item 33) into the rear cover plate (Figure 1, Item 31). Install the four nuts (Figure 1, Item 25) securing the gland (Figure 1, Item 33) Tighten the four nuts to 5 lb-ft (6.8 Nm).
0202-9
0202
Install the rear cover gasket (Figure 1, Item 28) onto the outer race of the rear cover plate (Figure 1, Item 31). Place the bearing housing adapter (Figure 1, Item 19) and the pump casing (Figure 1, Item 29) together.
NOTE
The casing nuts are non-lubricated. 38. 39. 40. 41. Install the eight casing nuts (Figure 1, Item 17) securing the bearing housing adapter (Figure 1, Item 19) to the pump casing (Figure 1, Item 29). Tighten the eight casing nuts to a torque of 15 lb-ft (20 Nm). Install the vent plug (Figure 1, Item 14) into the bearing housing (Figure 1, Item 15). Install the Trico oil gage (Figure 1, Item 24) into the bearing housing (Figure 1, Item 15). Install the drain plug (Figure 1, Item 23) into the bearing housing (Figure 1, Item 15). Tighten the drain plug.
CAUTION
Do not place the pump online before filling the bearing house adapter with oil. Damage to the pump will occur. 42. Fill the bearing housing adapter (Figure 1, Item 15) to the center of the oil sight glass with lubrication oil.
0202-10
TM 55-1925-273-24&P-2 FIELD MAINTENANCE SEWAGE DISCHARGE PUMP ELECTRIC MOTOR REPLACE
0203
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 3, WP 0344, Table 1, Item 27) Multimeter (Volume 3, WP 0344, Table 1, Item 15) Materials/Parts N/A Personnel Required Watercraft Engineer 88L (2) References FM 4-01.502 References (cont.) TM 55-1925-273-10 Volume 3, WP 0311 Volume 3, WP 0344 Equipment Condition Set to OFF the SEWAGE DISCHARGE PUMP NO. 1 circuit breaker or the SEWAGE DISCHARGE PUMP NO. 2 circuit breaker (LT 803 Only), or the LVP FOR STARBOARD SEWAGE DISCHARGE PUMP NO. 1 circuit breaker or the LVP FOR PORT SEWAGE DISCHARGE PUMP NO. 2 circuit breaker (All Other Vessels) at 440 V power panel NO. 1. Lock out and tag out IAW FM 4-01.502.
0203-1
TM 55-1925-273-24&P-2
0203
WARNING
Never reuse locking hardware. Reuse of locking hardware such as lockwashers, locking nuts, cotter pins, and lock wire can result in undetected loosening of fastening hardware causing catastrophic component failure resulting in death, injury, or damage to equipment. Ensure that all locking hardware is discarded upon removal and replaced with new. REMOVAL 1. Remove the screws (Figure 1, Item 4) and remove the cover (Figure 1, Item 1) from the electrical junction box (Figure 1, Item 3).
WARNING
Replace or repair components only after the affected circuit has been secured, locked out, and tagged out IAW FM 4-01.502. Performing replacement with the circuit energized may result in injury. 2. Use a multimeter to check for voltage at the wiring terminals in the junction box (Figure 1, Item 2). If voltage is present, ensure that the proper circuit breaker is set to OFF, locked out, and tagged out IAW FM 4-01.502. If no voltage is present, continue with the procedure. Label and remove the wiring (Figure 1, Item 3) from the electrical junction box (Figure 1, Item 2).
1
3.
2
M1108T73
Figure 1. 4.
Remove the two bolts (Figure 2, Item 5), four flat washers (Figure 2, Item 6), two lockwashers (Figure 2, Item 8), and two nuts (Figure 2, Item 9) from the coupling guard (Figure 2, Item 7). Discard lockwashers. Remove the coupling guard (Figure 2, Item 7).
5.
0203-2
TM 55-1925-273-24&P-2 REMOVAL - Continued 6. 7. 8. 9. 10. Loosen the motor coupling flange setscrew (Figure 2, Item 3). Slide the motor coupling flange (Figure 2, Item 4) towards the motor (Figure 2, Item 2). Remove the four bolts (Figure 2, Item 1), four lockwashers (Figure 2, Item 13), and four flat washers (Figure 2, Item 12) that secure the motor (Figure 2, Item 2). Discard lockwashers. Remove the motor (Figure 2, Item 2) from the foundation (Figure 2, Item 11). Remove the motor coupling flange (Figure 2, Item 4) from the motor shaft (Figure 2, Item 10).
0203
5
3
6
2 1 4
13 12
11 10
6 8 9
Figure 2. Electric Motor.
M2006T73
END OF TASK INSTALLATION 1. 2. Install the motor coupling flange (Figure 2, Item 4) on the motor shaft (Figure 2, Item 5) with the flat end towards the motor (Figure 2, Item 2). Install the motor (Figure 2, Item 2) on the foundation (Figure 2, Item 11) and secure it with the four bolts (Figure 2, Item 1), four lockwashers (Figure 2, Item 13), and four flat washers (Figure 2, Item 12). Do not tighten the bolts at this time.
0203-3
0203
Align the motor coupling flange (Figure 3, Item 1) and the pump coupling flange (Figure 3, Item 2), leaving approximately 0.016 in. (0.41 mm) space between the both flanges. To check the alignment between the motor coupling flange (Figure 3, Item 1) and the pump coupling flange (Figure 3, Item 2): a. b. c. d. The maximum angular offset shall be 1 degree, and maximum parallel offset shall be 0.015 in. (0.381 mm). Refer to Figure 3. Tighten the motor coupling flange setscrew (Figure 2, Item 3). Tighten the four bolts (Figure 2, Item 1). Perform Steps (a) through (c) until the alignment is correct.
STRAIGHT EDGE
MOTOR
0.015 IN. (0.381 MM) 2 MAXIMUM PARALLEL OFFSET
PUMP
M1112T73
Figure 3. Alignment of Pump Coupling Flange and Motor Coupling Flange. 5. 6. 7. Install the coupling guard (Figure 2, Item 7) and secure it with two bolts (Figure 2, Item 5), four flat washers (Figure 2, Item 6), two lockwashers (Figure 2, Item 8), and two nuts (Figure 2, Item 9). Install the wiring (Figure 1, Item 3) in the electrical junction box (Figure 1, Item 2) using the labels from Step (3) of REMOVAL as a guide. Remove the labels. Install the cover (Figure 1, Item 1) on the electrical junction box (Figure 1, Item 3), securing it with the screws (Figure 1, Item 4).
END OF TASK
0203-4
TM 55-1925-273-24&P-2
0203
FOLLOW-ON MAINTENANCE 1. 2. 3. 4. Remove the lock outs and tag outs IAW FM 4-01.502. Set the appropriate circuit breaker to ON. Operate the sewage discharge pump under usual conditions IAW TM 55-1925-273-10, checking for proper operation and unusual noises or vibration. Return the equipment to the desired readiness condition.
0203-5/6 blank
TM 55-1925-273-24&P-2 FIELD MAINTENANCE SEWAGE DISCHARGE PUMP ELECTRONIC MOTOR REPAIR
0204
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 3, WP 0344, Table 1, Item 27) Faceshield, Industrial (Volume 3, WP 0344, Table 1, Item 5) Gloves, Chemical and Oil Protective (Volume 3, WP 0344, Table 1, Item 8) Gloves, Leather (Volume 3, WP 0344, Table 1, Item 9) Lubricating Gun, Hand (Volume 3, WP 0344, Table 1, Item 14) Puller, Mechanical (Volume 3, WP 0344, Table 1, Item 17) Materials/Parts Cleaning Compound, Solvent (Volume 3, WP 0343, Table 1, Item 37) Compound, Sealing; Loctite 242 (Volume 3, WP 0343, Table 1, Item 43) Materials/Parts (cont.) Grease, Ball and Roller Bearing; 6.5 lb (Volume 3, WP 0343, Table 1, Item 75) Rag, Wiping (Volume 3, WP 0343, Table 1, Item 132) Personnel Required Watercraft Engineer 88L (1) References FM 4-01.502 WP 0203 Volume 3, WP 0311 Volume 3, WP 0343 Volume 3, WP 0344 Equipment Condition Electric motor removed. (WP 0203)
0204-1
TM 55-1925-273-24&P-2
0204
DISASSEMBLY 1. 2. 3. 4. 5. 6. 7. Remove the two grease drains (Figure 1, Item 19). Remove the grease fitting (Figure 1, Item 3). Remove the eye bolt (Figure 1, Item 7). Remove the two fan cover bolts (Figure 1, Item 6). Remove the fan cover guard (Figure 1, Item 1). Remove the fan clamp (Figure 1, Item 25) from the cooling fan (Figure 1, Item 2). Remove the cooling fan. Remove the four bolts (Figure 1, Item 5) from the front end bracket (Figure 1, Item 4). Separate the front end bracket from the frame (Figure 1, Item 8). Remove the two bolts (Figure 1, Item 23) from the front end bracket (Figure 1, Item 4). Separate the front end bracket (Figure 1, Item 4) from the frame (Figure 1, Item 8).
CAUTION
Use care to keep pressure around the bearing's outer race equal. Damage to the bearing can result. 8. 9. 10. 11. 12. 13. 14. Remove the wave washer (Figure 1, Item 24) from the front end bracket (Figure 1, Item 4). Remove the bearing (Figure 1, Item 22) using a bearing puller. Remove the front end inner cap (Figure 1, Item 21). Remove the back end grease fitting (Figure 1, Item 14) from the back end bracket (Figure 1, Item 12). Remove the key (Figure 1, Item 16) from the shaft (Figure 1, Item 17) keyway. Remove the slinger (Figure 1, Item 15) from the shaft (Figure 1, Item 17). Remove the four bolts (Figure 1, Item 20) securing the back end bracket (Figure 1, Item 12). Separate the back end bracket from the frame (Figure 1, Item 8). Remove the two bolts (Figure 1, Item 18) from the back end bracket (Figure 1, Item 12).
CAUTION
Use care to keep pressure around the bearing's outer race equal. Damage to the bearing can result. 15. 16. Remove the back end bearing (Figure 1, Item 13) using a bearing puller. Remove the back end inner cap (Figure 1, Item 11) from the shaft (Figure 1, Item 17).
NOTE
Do not remove the stator from the frame. 17. Remove the shaft (Figure 1, Item 17) and the rotor (Figure 1, Item 10) from the frame (Figure 1, Item 8).
0204-2

7 1 2 3 4 5 6 8 9 10 11 12
0204
13 14 15 25 16
24 17
18 23 19 22 5 21 20 19
M1339T73
Figure 1. Sewage Discharge Pump Electric Motor. END OF TASK CLEAN AND INSPECT
WARNING
CAUTION
Do not allow the cleaning solvent to come in contact with the stator. Cleaning solvent may cause the stator to corrode. 1. 2. 3. Using cleaning solvent, clean the outside of the fan cover (Figure 1, Item 1), frame (Figure 1, Item 8), front end bracket (Figure 1, Item 4), back end bracket (Figure 1, Item 12), and bearings (Figure 1, Item 22). Check for any binding, scoring, or burrs on the bearings (Figure 1, Items 13 and 22) and all other removed parts. Inspect all components parts for unusual wear or damage and replace as required. Check the rotor (Figure 1, Item 10) and stator (Figure 1, Item 9) for obvious damage.
0204-3
TM 55-1925-273-24&P-2 CLEAN AND INSPECT - Continued
0204
WARNING
CAUTION
END OF TASK ASSEMBLY 1. 2. Install the shaft (Figure 1, Item 17), and the rotor (Figure 1, Item 10) in the frame (Figure 1, Item 8). Install the back end inner cap (Figure 1, Item 11) on the shaft (Figure 1, Item 17).
WARNING
Always wear gloves when handling hot bearings. Handling hot bearings with bare hands or skin may result in severe burns. Failure to comply with this warning can result in serious injury or death.
CAUTION
Never apply pressure to the outer race of the bearings as this exerts excess load on the balls and causes damage to the bearing. 3. 4. 5. 6. Heat the back end bearing (Figure 1, Item 13) to 250F (121C) in an oven to expand the inner race. Install the back end bearing onto the shaft (Figure 1, Item 17). Install the two bolts (Figure 1, Item 18) securing the back end inner cap (Figure 1, Item 11). Place the back end bracket (Figure 1, Item 12) on the frame (Figure 1, Item 8). Install the four bolts (Figure 1, Item 20) securing the back end bracket. Tighten the bolts. Install the front end inner cap (Figure 1, Item 21) on the shaft (Figure 1, Item 17).
0204-4
0204
WARNING
Always wear gloves when handling hot bearings. Handling hot bearings with bare hands or skin may result in severe burns. Failure to comply with this warning can result in serious injury or death. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. Heat the front end bearing (Figure 1, Item 22) to 250F (121C) in an oven to expand the inner race. Install the front end bearing onto the shaft (Figure 1, Item 17). Install two bolts (Figure 1, Item 23) securing the front inner cap (Figure 1, Item 21). Install the wave washer (Figure 1, Item 24) into the front end bracket (Figure 1, Item 4). Place the front end bracket (Figure 1, Item 4) on the frame (Figure 1, Item 8). Install the four bolts (Figure 1, Item 5) securing the front end bracket (Figure 1, Item 4) to the frame (Figure 1, Item 8). Install the slinger (Figure 1, Item 15) on the shaft (Figure 1, Item 17). Install the key (Figure 1, Item 16) in the shaft (Figure 1, Item 17) keyway. Install the cooling fan (Figure 1, Item 2) on the shaft (Figure 1, Item 17). Install the fan clamp (Figure 1, Item 25) securing the cooling fan. Install the fan cover guard (Figure 1, Item 1). Install the two fan cover bolts (Figure 1, Item 6). Tighten the fan cover bolts. Install the two grease drains (Figure 1, Item 19). Do not tighten the grease drains at this time. Install the grease fitting (Figure 1, Item 3) in the front end bracket (Figure 1, Item 4). Tighten the grease drain and grease fitting. Install the grease fitting (Figure 1, Item 14) in the back end bracket. Tighten the grease fitting. Install the eye bolt (Figure 1, Item 7) in the frame (Figure 1, Item 8). Tighten the eye bolt.
CAUTION
Do not apply grease through the front end or the back end grease fittings with the grease drains closed. 19. 20. Add 5-6 strokes of grease to the grease fittings (Figure 1, Items 3 and 14) using a hand lubricating gun. Wipe any excess grease from the grease fills using a wiping rag. Apply locktite thread sealant to the threads of the two grease drains (Figure 1, Item 19). Close and tighten the grease drains.
0204-5/6 blank
TM 55-1925-273-24&P-2 FIELD MAINTENANCE OILY BILGE SYSTEM PIPING STRAINER SERVICE
0205
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 3, WP 0344, Table 1, Item 27) Gloves, Chemical and Oil Protective (Volume 3, WP 0344, Table 1, Item 8) Goggles, Industrial (Volume 3, WP 0344, Table 1, Item 10) Suitable Drain Pan Materials/Parts O-ring (Volume 3, WP 0312, Figure 64, Item 2) Qty: 1 Personnel Required Watercraft Engineer 88L (1) References TM 55-1925-273-10 Volume 3, WP 0312 Volume 3, WP 0344 Equipment Condition N/A
0205-1
TM 55-1925-273-24&P-2
0205
SERVICE DUPLEX STRAINER 1. 2. 3. Position a suitable drain pan beneath the work area. Position the selector lever (Figure 1, Item 1) over the in-service strainer element. Loosen the T-handle (Figure 1, Item 5) and swing the bail (Figure 1, Item 6) clear of the cover (Figure 1, Item 2).
WARNING
Waste oil and other oily tank contents can cause personal injury if they come in contact with unprotected skin or eyes. Always wear chemical protective gloves and goggles when handling oil and other oily tank contents. Failure to follow these precautions can result in illness, serious injury, or death. 4. 5. 6. 7. 8. 9. 10. 11. 12. Remove the cover (Figure 1, Item 2) and O-ring (Figure 1, Item 3). Discard O-ring. Remove the strainer element (Figure 1, Item 4). Clean the strainer element (Figure 1, Item 4) with clean water. A wire brush may be used as necessary to remove hardened deposits. If the strainer element cannot be satisfactorily cleaned, replace it. Install the new or cleaned strainer element (Figure 1, Item 4) in the strainer body (Figure 1, Item 7). Install the cover (Figure 1, Item 2) using a gasket (Figure 1, Item 3). Swing the bail (Figure 1, Item 6) in place over the cover (Figure 1, Item 2) and tighten the T-handle (Figure 1, Item 5). Place the strainer element in service by positioning the selector lever (Figure 1, Item 1) over the strainer. Operate the oily bilge pump IAW TM 55-1925-273-10 and check the strainer for leaks. Return the oily bilge pump to the desired readiness condition IAW TM 55-1925-273-10.
0205-2
TM 55-1925-273-24&P-2 SERVICE DUPLEX STRAINER - Continued

2 3 1 4 5 6
0205
M1113T73
Duplex Strainer.
0205-3/4 blank
TM 55-1925-273-24&P-2 FIELD MAINTENANCE OILY BILGE SYSTEM VALVES REPLACE
0206
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 3, WP 0344, Table 1, Item 27) Gloves, Chemical and Oil Protective (Volume 3, WP 0344, Table 1, Item 8) Gloves, Leather (Volume 3, WP 0344, Table 1, Item 9) Goggles, Industrial (Volume 3, WP 0344, Table 1, Item 10) Suitable Drain Pan Materials/Parts Rag, Wiping (Volume 3, WP 0343, Table 1, Item 132) Tape, Antiseizing; 1/2 in. (Volume 3, WP 0343, Table 1, Item 158) Personnel Required Watercraft Engineer 88L (1) References FM 4-01.502 References (cont.) TM 55-1925-273-10 Volume 3, WP 0313 Volume 3, WP 0343 Volume 3, WP 0344 Equipment Condition CLOSE valve CA-56, COV-OILY BILGE PMP SUCT. Lock out and tag out IAW FM 4-01.502 . CLOSE valves upstream and downstream of the affected valve. Lock out and tag out IAW FM 4-01.502.
0206-1
TM 55-1925-273-24&P-2
0206
FLANGED ANGLE VALVE REMOVAL 1. 2. Partially open the valve (Figure 1, Item 1) to equalize any internal pressure before removing any bolts (Figure 1, Items 2 and 6). Place a suitable drain pan under the valve (Figure 1, Item 1).
WARNING
Waste oil and other oily tank contents can cause personal injury if they come in contact with unprotected skin or eyes. Always wear chemical protective gloves and goggles when handling oil and other oily tank contents. Failure to follow these precautions can result in illness, serious injury, or death. 3. 4. 5. 6. 7. Slowly loosen the bolts (Figure 1, Item 6) and nuts (Figure 1, Item 8) on the inlet side of the valve (Figure 1, Item 1), and allow the pressure to vent and any liquid to drain into the suitable drain pan. Remove the bolts (Figure 1, Item 6) and nuts (Figure 1, Item 8) from the inlet side of the valve (Figure 1, Item 1). Remove the bolts (Figure 1, Item 2) and nuts (Figure 1, Item 4) from the outlet side of the valve (Figure 1, Item 1). Remove the valve (Figure 1, Item 1) from the vessel's piping (Figure 1, Item 5). Remove gaskets (Figure 1, Items 3 and 7).
0206-2
TM 55-1925-273-24&P-2 FLANGED ANGLE VALVE REMOVAL - Continued
0206
1 5
5 7 8
M1114T73
Figure 1. END OF TASK FLANGED ANGLE VALVE INSTALLATION
Flanged Angle Valve.
WARNING
Removing components by means of wire brushing produces flying particles. These particles can cause serious injury to personnel. Wear protective faceshield, gloves, and long sleeves at all times during wire brushing operations. Failure to comply with this warning can result in serious injury to personnel. 1. 2. Clean the flanges of valve (Figure 1, Item 1) and vessel's piping (Figure 1, Item 5) using a wire brush, clean wiping rags, and water. Install the valve (Figure 1, Item 1) and two gaskets (Figure 1, Items 3 and 7) to the vessel's piping (Figure 1, Item 5), and secure it with the bolts (Figure 1, Items 2, and 6) and the nuts (Figure 1, Items 4 and 8).
0206-3
TM 55-1925-273-24&P-2 FLANGED ANGLE VALVE INSTALLATION - Continued 3. Perform the FOLLOW-ON-MAINTENANCE procedure at the end of this work package.
0206
END OF TASK FLANGED GLOBE VALVE REMOVAL 1. 2. Partially open the valve (Figure 2, Item 3) to equalize any internal pressure before removing any bolts (Figure 2, Items 6 and 7). Place a suitable drain pan under the valve (Figure 2, Item 3).
WARNING
Waste oil and other oily tank contents can cause personal injury if they come in contact with unprotected skin or eyes. Always wear chemical protective gloves and goggles when handling oil and other oily tank contents. Failure to follow these precautions can result in illness, serious injury, or death. 3. 4. 5. 6. 7. Slowly loosen the bolts (Figure 2, Item 7) and nuts (Figure 2, Item 8) on the inlet side of the valve (Figure 2, Item 3), and allow the pressure to vent and any liquid to drain into the drain pan. Remove the bolts (Figure 2, Item 7) and nuts (Figure 2, Item 8) from the inlet side of the valve (Figure 2, Item 3). Remove the bolts (Figure 2, Item 6) and nuts (Figure 2, Item 5) from the outlet side of the valve (Figure 2, Item 3). Remove the valve (Figure 2, Item 3) from the vessel's piping (Figure 2, Item 1). Remove gaskets (Figure 2, Items 2 and 4).
0206-4
TM 55-1925-273-24&P-2 FLANGED GLOBE VALVE REMOVAL - Continued
0206
6
M1115T73
Figure 2. END OF TASK FLANGED GLOBE VALVE INSTALLATION
WARNING
Removing components by means of wire brushing produces flying particles. These particles can cause serious injury to personnel. Wear protective faceshield, gloves, and long sleeves at all times during wire brushing operations. Failure to comply with this warning can result in serious injury to personnel. 1. 2. 3. Clean the flanges of valve (Figure 2, Item 3) and vessel's piping (Figure 2, Item 1) using a wire brush, clean wiping rags, and water. Install the valve (Figure 2, Item 3) and two gaskets (Figure 2, Items 2 and 4) to the vessel's piping (Figure 2, Item 1), and secure it with the bolts (Figure 2, Items 6 and 7) and nuts (Figure 2, Items 5 and 8). Perform the FOLLOW-ON-MAINTENANCE procedure at the end of this work package.
END OF TASK
0206-5
TM 55-1925-273-24&P-2 THREADED VALVE (TYPICAL) REMOVAL 1. 2. Partially open the valve (Figure 3, Item 1) to equalize any internal pressure before removing union (Figure 3, Item 3).
0206
Place a suitable drain pan under the union (Figure 3, Item 3) of the valve (Figure 3, Item 1) to be removed.
WARNING
Waste oil and other oily tank contents can cause personal injury if they come in contact with unprotected skin or eyes. Always wear chemical protective gloves and goggles when handling oil and other oily tank contents. Failure to follow these precautions can result in illness, serious injury, or death.
CAUTION
Failure to use two wrenches while loosening pipe fittings, couplings, and valves may cause damage to the valves, fittings, couplings, and piping. 3. 4. 5. Using the two wrench method, loosen the union (Figure 3, Item 3), and allow any pressure to vent and any fluid to drain. Using the two wrench method, remove the pipe (Figure 3, Item 2) from the valve (Figure 3, Item 1). Using the two wrench method, remove the valve (Figure 3, Item 1) from the vessel piping (Figure 3, Item 4).
M1116T73
Threaded Valve (Typical).
0206-6
TM 55-1925-273-24&P-2 THREADED VALVE (TYPICAL) INSTALLATION
0206
WARNING
Removing components by means of wire brushing produces flying particles. These particles can cause serious injury to personnel. Wear protective faceshield, gloves, and long sleeves at all times during wire brushing operations. Failure to comply with this warning can result in serious injury to personnel. 1. 2. Clean the threaded ends of the piping (Figure 3, Items 2 and 4) with a wire brush. Apply antiseizing tape to the threaded ends of the piping (Figure 3, Items 2 and 4).
CAUTION
Failure to use two wrenches while tightening pipe fittings, couplings, and valves may cause damage to the valves, fittings, couplings, and piping. 3. 4. 5. 6. Using the two wrench method, install the valve (Figure 3, Item 1) onto the vessel piping (Figure 3, Item 4). Using the two wrench method, install the pipe (Figure 3, Item 2) into the valve (Figure 3, Item 1). Using the two wrench method, install the union (Figure 3, Item 3) to the pipe (Figure 3, Item 2). Perform the FOLLOW-ON-MAINTENANCE procedure at the end of this work package.
END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. 4. 5. Remove the lock outs and tag outs IAW FM 4-01.502. Set the circuit breakers to ON. Operate the oily bilge system under usual conditions IAW TM 55-1925-273-10. Check the valve and connections for leakage and proper operation. Return the equipment to the desired readiness condition.
0206-7/8 blank
TM 55-1925-273-24&P-2 FIELD MAINTENANCE OILY BILGE SYSTEM, OILY PUMP REPLACE
0207
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 3, WP 0344, Table 1, Item 27) Suitable Drain Pan Materials/Parts N/A Personnel Required Watercraft Engineer 88L (2) References FM 4-01.502 References (cont.) TM 55-1925-273-10 Volume 3, WP 0314 Volume 3, WP 0343 Volume 3, WP 0344 Equipment Condition CLOSE valves OB-8 OILY BILGE PMP DISCH. TO OILY WST.STOR. TK., OB-9 OILY BILGE PMP. DISCH TO SHORE, OB-13 OILY WST.STOR. TK. TO OILY BILGE PMP. SUCT., OB-14 C.O.V.-OILY BILGE PMP. SUCT., and CA-56, COV-OILY BILGE PMP SUCT. Lock out and tag out IAW FM 4-01.502.
0207-1
TM 55-1925-273-24&P-2
0207
OILY BILGE PUMP REMOVAL
WARNING
Compressed air hoses and lines may be under pressure. Relieve pressure by operating the appropriate control valve, if possible. Loosen fittings on hoses and lines slowly. Allow the compressed air to run around threads of fitting, releasing pressure before disconnecting fitting. Releasing compressed air suddenly may cause severe personal injury or death.
CAUTION
Never attempt to disconnect union connections with only one wrench. Damage to the vessel's piping or to the pump's piping could occur. Always use the two wrench method. 1. 2. Slowly remove the air inlet line to release any air pressure. Place a suitable drain pan under the inlet union (Figure 1, Item 5).
WARNING
Oily waste hoses and lines may be under pressure. Relieve pressure by operating the appropriate control valve, if possible. Loosen fittings on hose lines slowly. Allow the oily waste to run around threads of fitting, releasing pressure before disconnecting fitting. Releasing pressurized oily waste suddenly may cause severe personal injury or death.
CAUTION
Never attempt to disconnect union connections with only one wrench. Damage to the vessel's piping or to the pump's piping could occur. Always use the two wrench method. 3. 4. 5. 6. 7. Using two wrenches, loosen the inlet union (Figure 1, Item 5) and allow the oily water to drain. Using two wrenches, loosen the outlet union (Figure 1, Item 1) and allow the oily water to drain. Remove the inlet union (Figure 1, Item 5) and the outlet union (Figure 1, Item 2) from the vessel's piping. Remove the four bolts (Figure 1, Item 3) and four nuts (Figure 1, Item 4) that secure the pump (Figure 1, Item 2) to the foundation. Remove the pump (Figure 1, Item 2).
0207-2
TM 55-1925-273-24&P-2 OILY BILGE PUMP REMOVAL - Continued
0207
5 4 4
M1117T73
Oily Bilge Pump.
0207-3
TM 55-1925-273-24&P-2
0207
OILY BILGE PUMP INSTALLATION 1. Install the pump (Figure 1, Item 2) to the foundation (Figure 1, Item 6), securing it with the four bolts (Figure 1, Item 3), and four nuts (Figure 1, Item 4). Do not tighten the bolts and nuts at this time.
CAUTION
Never attempt to connect union connections with only one wrench. Damage to the vessel's piping or to the pump's piping could occur. Always use the two wrench method. 2. 3. 4. 5. Using two wrenches, install the inlet union (Figure 1, Item 5). Using two wrenches, install the outlet union (Figure 1, Item 1). Tighten the four bolts (Figure 1, Item 3) and four nuts (Figure 1, Item 4) that secure the pump (Figure 1, Item 2) to the foundation (Figure 1, Item 6). Install the air line to the pump (Figure 1, Item 2).
END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. 4. Remove the lock outs and tag outs IAW FM 4-01.502. OPEN the valves. Operate the oily bilge pump under usual conditions IAW TM 55-1925-273-10, ensuring that the pump operates properly. Return the equipment to the desired readiness condition.
0207-4
TM 55-1925-273-24&P-2 FIELD MAINTENANCE OILY BILGE SYSTEM OILY BILGE PUMP REPAIR
0208
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 3, WP 0344, Table 1, Item 27) Gloves, Chemical and Oil Protective (Volume 3, WP 0344, Table 1, Item 8) Goggles, Industrial (Volume 3, WP 0344, Table 1, Item 10) Suitable Drain Pan Wrench, Torque, 0-250 lb-ft (0-339 Nm) (Volume 3, WP 0344, Table 1, Item 33) Wrench, Torque, 0-600 lb-in (0-68 Nm) (Volume 3, WP 0344, Table 1, Item 34) Materials/Parts Cleaning Compound, Solvent (Volume 3, WP 0343, Table 1, Item 37) Grease, Ball and Roller Bearing; 1.75 lb (Volume 3, WP 0343, Table 1, Item 74) Rag, Wiping (Volume 3, WP 0343, Table 1, Item 132) Tape, Antiseizing; 1/2 in. (Volume 3, WP 0343, Table 1, Item 159) O-ring (Volume 3, WP 0314, Figure 66, Item 3) Qty: 4 Materials/Parts (cont.) O-ring (Volume 3, WP 0314, Figure 66, Item 7) Qty: 7 Gasket (Volume 3, WP 0314, Figure 66, Item 12) Qty: 2 Personnel Required Watercraft Engineer 88L (2) References TM 55-1925-273-10 Volume 3, WP 0314 Volume 3, WP 0343 Volume 3, WP 0344 Equipment Condition Oily bilge pump removed. (WP 0207)
0208-1
TM 55-1925-273-24&P-2
0208
PUMP DISASSEMBLY
WARNING
Do not allow hydraulic fluid, engine oil, or cleaning solvents to come in contact with unprotected skin or eyes. Prolonged skin contact can cause illness or injury. Eye contact can cause serious injury. Always wear chemical protective gloves and goggles when handling hydraulic fluid, engine oil, and cleaning solvents. Failure to follow these precautions can result in illness, serious injury, or death. 1. 2. Drain the pump by turning it upside down and allowing any fluid to flow into a suitable drain pan. Mark a line (Figure 1) from each liquid chamber to its corresponding air chamber to assist in the proper alignment during assembly.
REFERENCE LINE
M1118T73
REFERENCE LINE
Figure 1. 3. 4. 5.
Alignment Marks.
Remove the four bolts (Figure 2, Item 2) and the four nuts (Figure 2, Item 27), and remove the two sets of discharge manifold clamp bands (Figure 2, Item 4). Remove the discharge manifold (Figure 2, Item 3) from the liquid chambers (Figure 2, Items 9 and 26). Remove the two discharge balls (Figure 2, Item 5), two valve seat O-rings (Figure 2, Item 6), and two valve seats (Figure 2, Item 7) from the discharge manifold (Figure 2, Item 3). Discard valve seat O-rings.
0208-2
TM 55-1925-273-24&P-2 PUMP DISASSEMBLY - Continued 6. 7. 8. 9. 10. 11. 12. 13. 14.
0208
Remove the four bolts (Figure 2, Item 16) and the four nuts (Figure 2, Item 20) and remove the two sets of intake manifold clamp bands (Figure 2, Item 18). Remove the intake manifold (Figure 2, Item 17) from the liquid chambers (Figure 2, Items 9 and 26). Remove the two intake balls (Figure 2, Item 10), two valve seat O-rings (Figure 2, Item 11), and two seats (Figure 2, Item 12) from the intake manifold (Figure 2, Item 17). Discard valve seat O-rings. Remove four nuts (Figure 2, Item 1) and four bolts (Figure 2, Item 13), and remove the two sets of liquid chamber clamps (Figure 2, Item 8). Remove the liquid chambers (Figure 2, Items 9 and 26) from the center block (Figure 2, Item 25). Remove the two outer pistons (Figure 2, Item 14) from the center block (Figure 2, Item 25). Remove the outer two diaphragms (Figure 2, Item 15), the two inner diaphragms (Figure 2, Item 19), and the inner pistons (Figure 2, Item 21) from the center block (Figure 2, Item 25). Remove the shaft stud (Figure 2, Item 22) and shaft (Figure 2, Item 23) from the center block (Figure 2, Item 25). Remove the seven GlydTM rings (Figure 2, Item 24) from the shaft (Figure 2, Item 23). Discard GlydTM rings.
0208-3
TM 55-1925-273-24&P-2 PUMP DISASSEMBLY - Continued
0208
1 8 1
27 4 2 27 26 5 6 7 1 13 9 14 15 19 21 22 13 10 11 12 23 22 20 21 19 18 14 10 11 12 25 24 8 1 4 2
16
18
15
16 17
Figure 2. END OF TASK Oily Bilge Pump.
M1119T73
0208-4
TM 55-1925-273-24&P-2
0208
CENTER BLOCK DISASSEMBLY 1. 2. 3. 4. 5. 6. Remove the bolt (Figure 3, Item 19) and the air valve screen (Figure 3, Item 18). Remove the snap rings (Figure 3, Item 1), and remove the air valve (Figure 3, Item 4). Remove the O-rings (Figure 3, Item 2) from the air valve (Figure 3, Item 4). Remove the guide caps (Figure 3, Item 3) from the air valve (Figure 3, Item 4). Remove the check body (Figure 3, Item 5), the check ball (Figure 3, Item 6), and remove the nipple (Figure 3, Item 7). Remove the four bolts (Figure 3, Item 17) and four nuts (Figure 3, Item 8) and remove the main valve body (Figure 3, Item 16), the air valve gasket (Figure 3, Item 15), the muffler (Figure 3, Item 9), and the muffler gasket (Figure 3, Item 10) from the center block (Figure 3, Item 14). Remove the three bolts (Figure 3, Item 20) and the three nuts (Figure 3, Item 12) and remove the two air chambers (Figure 3, Item 13) from the center block (Figure 3, Item 14). Remove the two gaskets (Figure 3, Item 11) from the center block (Figure 3, Item 14). Discard gaskets.
7. 8.
0208-5
TM 55-1925-273-24&P-2 CENTER BLOCK DISASSEMBLY - Continued
0208
2 3 4
3 2 1 5 6
13 20
19
11 9 10
18 11
14 15 16 17 13
Figure 3. END OF TASK Oily Bilge Pump.
12
M1120T73
0208-6
TM 55-1925-273-24&P-2 CLEAN AND INSPECT 1. 2. Remove the old antiseizing tape from the outer diaphragms (Figure 2, Item 15) and inner diaphragms (Figure 2, Item 19) and clean the sealing surfaces. Replace the antiseizing tape.
0208
Remove the old antiseizing tape from the air chambers (Figure 3, Item 13) and clean the sealing surfaces. Replace the antiseizing tape.
WARNING
Do not allow hydraulic fluid, engine oil, or cleaning solvents to come in contact with unprotected skin or eyes. Prolonged skin contact can cause illness or injury. Eye contact can cause serious injury. Always wear chemical protective gloves and goggles when handling hydraulic fluid, engine oil, and cleaning solvents. Failure to follow these precautions can result in illness, serious injury, or death. 3. 4. 5. 6. 7. Use cleaning solvent and clean wiping rags to clean all the removed parts. Check for any burrs on the sealing surfaces of all removed parts, and inspect all components for wear or damage. Check that the ports in the air valve (Figure 3, Item 4), the main valve assembly (Figure 3, Item 16), and the center block (Figure 3, Item 14) are free of debris and damage. Clean the air valve screen (Figure 3, Item 18). Inspect the main valve (Figure 3, Item 16) and center block (Figure 3, Item 14) for nicks and scoring. Inspect the air valve (Figure 3, Item 4) for excessive wear. A shiny aluminum color indicates that the air valve assembly is worn beyond working tolerances.
END OF TASK CENTER BLOCK ASSEMBLY 1. 2. 3. 4. 5. Install seven GlydTM rings (Figure 2, Item 24) on the shaft (Figure 2, Item 23). Install two block gaskets (Figure 3, Item 11) on each side of the center block (Figure 3, Item 14). Lubricate the shaft (Figure 2, Item 22) with grease and install it in the center block (Figure 3, Item 14). Install the two air chambers (Figure 3, Item 13) on the center block (Figure 3, Item 14), and secure them with the three bolts (Figure 3, Item 20) and three nuts (Figure 3, Item 12) tightened to 75 lb-in (8.5 Nm). Install the main valve body (Figure 3, Item 16), the air valve gasket (Figure 3, Item 15), the muffler (Figure 3, Item 9), and a muffler gasket (Figure 3, Item 10) on the center block (Figure 3, Item 14), and secure with the four bolts (Figure 3, Item 17) and four nuts (Figure 3, Item 8). Apply antiseizing tape to the male threads of the nipple (Figure 3, Item 7), and install it about half way into the center block (Figure 3, Item 14). Install the check ball (Figure 3, Item 6) in the check body (Figure 3, Item 5), and secure the check body to the exposed male threads of the nipple (Figure 3, Item 7) on the center block (Figure 3, Item 14). Install the two air valve caps (Figure 3, Item 3), and two O-rings (Figure 3, Item 2) on the air valve (Figure 3, Item 4). Install the air valve (Figure 3, Item 4) in the main valve body (Figure 3, Item 12) and secure it with two snap rings (Figure 3, Item 1).
6. 7. 8. 9.
0208-7
TM 55-1925-273-24&P-2 CENTER BLOCK ASSEMBLY - Continued 10.
0208
Install the air valve screen (Figure 3, Item 18) in the main valve body (Figure 3, Item 16), and secure it with the bolt (Figure 3, Item 19).
END OF TASK PUMP ASSEMBLY 1. Install the two inner pistons (Figure 2, Item 21), the two inner diaphragms (Figure 2, Item 19), and the two outer diaphragms (Figure 2, Item 15) on the shaft (Figure 2, Item 22), and secure them with the two outer pistons (Figure 2, Item 14) tighened to a torque of 33 lb-ft (45 Nm). Install the liquid chambers (Figure 2, Items 9 and 26) to the center block (Figure 2, Item 25) using the reference lines from Figure 1, and secure them with the liquid chamber clamps (Figure 2, Item 8), the four nuts (Figure 2, Item 1), and the four bolts (Figure 2, Item 13) tightened to a torque of 95 lb-in (10.7 Nm). Install the two seats (Figure 2, Item 12), two valve seat O-rings (Figure 2, Item 11), and the two intake balls (Figure 2, Item 10) in the intake manifold (Figure 2, Item 17). Install the liquid chambers (Figure 2, Items 9 and 26) and the center block (Figure 2, Item 25) on the intake manifold (Figure 2, Item 17), and secure them with the two sets of intake manifold clamp bands (Figure 2, Item 18), the four bolts (Figure 2, Item 16), and the four nuts (Figure 2, Item 20) tightened to a torque of 30 lb-in (3.4 Nm). Install the two valve seats (Figure 2, Item 7), two valve seat O-rings (Figure 2, Item 6), and the two discharge balls (Figure 2, Item 5) in the discharge manifold (Figure 2, Item 3). Install the discharge manifold (Figure 2, Item 3) on the liquid chambers (Figure 2, Items 9 and 26), and secure it with the two sets of discharge manifold clamp bands (Figure 2, Item 4), the four bolts (Figure 2, Item 2), and the four nuts (Figure 2, Item 27) tightened to a torque of 30 lb-in (3.4 Nm). Perform the OILY BILGE PUMP REPLACE INSTALLATION procedure (WP 0207).
2.
3. 4.
5. 6.
7.
0208-8
TM 55-1925-273-24&P-2 FIELD MAINTENANCE BALLAST SYSTEM PIPING/STRAINER SERVICE
0209
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 3, WP 0344, Table 1, Item 27) Gloves, Chemical and Oil Protective (Volume 3, WP 0344, Table 1, Item 8) Goggles, Industrial (Volume 3, WP 0344, Table 1, Item 10) Suitable Drain Pan Materials/Parts Packing, Preformed (Volume 3, WP 0315, Figure 67, Item 2) Qty: 1 Personnel Required Watercraft Engineer 88L (1) References TM 55-1925-273-10 Volume 3, WP 0315 Volume 3, WP 0344 Equipment Condition N/A
0209-1
TM 55-1925-273-24&P-2
0209
SERVICE DUPLEX STRAINER 1. 2. 3. Position a suitable drain pan beneath the work area. Position the selector lever (Figure 1, Item 1) over the in-service strainer element. Loosen the T-handle (Figure 1, Item 5) and swing the bail (Figure 1, Item 6) clear of the cover (Figure 1, Item 2).
WARNING
Used oil and other oily waste tank contents can cause personal injury if they come in contact with unprotected skin or eyes. Always wear chemical protective gloves and goggles when handling oil and other oily waste tank contents. Failure to follow these precautions can result in illness, serious injury, or death. 4. 5. 6. 7. 8. 9. 10. 11. 12. Remove the cover (Figure 1, Item 2) and preformed packing (Figure 1, Item 3). Discard preformed packing. Remove the strainer element (Figure 1, Item 4). Clean the strainer element (Figure 1, Item 4) with clean water. A wire brush may be used as necessary to remove hardened deposits. If the strainer element cannot be satisfactorily cleaned, replace it. Install the new or cleaned strainer element (Figure 1, Item 4) in the strainer body (Figure 1. Item 7). Install the cover (Figure 1, Item 2) using a preformed packing (Figure 1, Item 3). Swing the bail (Figure 1, Item 6) in place over the cover (Figure 1, Item 2) and tighten the T-handle (Figure 1, Item 5). Place the strainer element in service by positioning the selector lever (Figure 1, Item 1) over the strainer. Operate the oily bilge pump IAW TM 55-1925-273-10 and check the strainer for leaks. Return the oily bilge pump to the desired readiness condition IAW TM 55-1925-273-10.
0209-2
TM 55-1925-273-24&P-2 SERVICE DUPLEX STRAINER - Continued

2 3 1
0209
M1121T73
Duplex Strainer.
0209-3/4 blank
TM 55-1925-273-24&P-2 FIELD MAINTENANCE BALLAST SYSTEM VALVES REPLACE
0210
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 3, WP 0344, Table 1, Item 27) Gloves, Chemical and Oil Protective (Volume 3, WP 0344, Table 1, Item 8) Gloves, Leather (Volume 3, WP 0344, Table 1, Item 9) Goggles, Industrial (Volume 3, WP 0344, Table 1, Item 10) Suitable Drain Pan Materials/Parts Rag, Wiping (Volume 3, WP 0343, Table 1, Item 132) Tape, Antiseizing; 1/2 in. (Volume 3, WP 0343, Table 1, Item 158) Personnel Required Watercraft Engineer 88L (2) References FM 4-01.502 References (cont.) TM 55-1925-273-10 Volume 3, WP 0316 Volume 3, WP 0343 Volume 3, WP 0344 Equipment Condition Set to OFF the BILGE PUMP No. 1 circuit breaker on the emergency switchboard. Lock out and tag out IAW FM 4-01.502. Set to OFF the BILGE PUMP No. 2 circuit breaker on the main switchboard. Lock out and tag out IAW FM 4-01.502. CLOSE valves upstream and downstream of the affected valve. Lock out and tag out IAW FM 4-01.502.
0210-1
TM 55-1925-273-24&P-2
0210
THREADED VERTICAL CHECK VALVE REMOVAL 1. Place a suitable drain pan under the union (Figure 1, Item 3) of the valve (Figure 1, Item 4) to be removed.
CAUTION
Failure to use two wrenches while loosening pipe fittings, couplings, and valves may cause damage to the valves, fittings, couplings, and piping. Always use two wrenches. 2. 3. 4. Using the two wrench method, slowly loosen the union (Figure 1, Item 3) and allow any pressure to vent and any fluid to drain into the suitable drain pan. Using the two wrench method, remove the pipe (Figure 1, Item 2) from the valve (Figure 1, Item 4). Using the two wrench method, remove the valve (Figure 1, Item 4) from the vessel piping (Figure 1, Item 1).
4
Figure 1. END OF TASK THREADED VERTICAL CHECK VALVE INSTALLATION Threaded Vertical Check Valve (Typical).
M1122T73
WARNING
Removing components by means of wire brushing produces flying particles. These particles can cause serious injury to personnel. Wear protective faceshield, gloves, and long sleeves at all times during wire brushing operations. Failure to comply with this warning can result in serious injury to personnel. 1. 2. Clean the threaded ends of the piping (Figure 1, Items 1 and 2) with a wire brush. Apply antiseizing tape to the threaded ends of the piping (Figure 1, Items 1 and 2).
CAUTION
Failure to use two wrenches while tightening pipe fittings, couplings, and valves may cause damage to the valves, fittings, couplings, and piping. Always use two wrenches. 3. 4. Using the two wrench method, install the valve (Figure 1, Item 4) on the vessel piping (Figure 1, Item 1). Using the two wrench method, install the pipe (Figure 1, Item 2) in the valve (Figure 1, Item 4). 0210-2
TM 55-1925-273-24&P-2 THREADED VERTICAL CHECK VALVE INSTALLATION - Continued 5. 6. Using the two wrench method, install the union (Figure 1, Item 3) to the pipe (Figure 1, Item 2). Perform the FOLLOW-ON MAINTENANCE procedure at the end of this work package.
0210
END OF TASK FLANGED ANGLE/STOP CHECK VALVE REMOVAL 1. 2. 3. 4. 5. 6. 7. Partially OPEN the valve (Figure 2, Item 4) to equalize any internal pressure before removing any bolts (Figure 2, Items 1 and 7). Place a suitable drain pan under the valve (Figure 2, Item 4). Slowly loosen the bolts (Figure 2, Item 7) and nuts (Figure 2, Item 8) on the inlet side of the valve (Figure 2, Item 4), and allow the pressure to vent and any liquid to drain into the suitable drain pan. Remove the bolts (Figure 2, Item 7) and nuts (Figure 2, Item 8) from the inlet side of the valve (Figure 2, Item 4). Remove the bolts (Figure 2, Item 1) and nuts (Figure 2, Item 3) from the outlet side of the valve (Figure 2, Item 4). Remove the valve (Figure 2, Item 4) from the vessel piping (Figure 2, Item 6). Remove gaskets (Figure 2, Items 2 and 5).
5 6 8
M1123T73
Flanged Angle/Stop Check Valve.
0210-3
TM 55-1925-273-24&P-2 FLANGED ANGLE/STOP CHECK VALVE INSTALLATION
0210
WARNING
Removing components by means of wire brushing produces flying particles. These particles can cause serious injury to personnel. Wear protective faceshield, gloves, and long sleeves at all times during wire brushing operations. Failure to comply with this warning can result in serious injury to personnel. 1. 2. 3. Clean the flanges of valve (Figure 2, Item 4) and vessel piping (Figure 2, Item 6) using a wire brush, clean wiping rags, and water. Install the valve (Figure 2, Item 4) and two gaskets (Figure 2, Items 2 and 5) to the vessel's piping, and secure it with the bolts (Figure 2, Items 1 and 7) and the nuts (Figure 2, Items 3 and 8). Perform the FOLLOW-ON MAINTENANCE procedure at the end of this work package.
END OF TASK FLANGED GLOBE/GATE VALVE REMOVAL 1. 2. 3. 4. 5. 6. 7. Partially open the valve (Figure 3, Item 3) to equalize any internal pressure before removing any bolts (Figure 3, Items 1 and 5). Place a suitable drain pan under the valve (Figure 3, Item 3). Slowly loosen the bolts (Figure 3, Item 1) and nuts (Figure 3, Item 2) on the inlet side of the valve (Figure 3, Item 3), and allow the pressure to vent and any liquid to drain into the suitable drain pan. Remove the bolts (Figure 3, Item 1) and nuts (Figure 3, Item 2) from the inlet side of the valve (Figure 3, Item 3). Remove the bolts (Figure 3, Item 5) and nuts (Figure 3, Item 4) from the outlet side of the valve (Figure 3, Item 3). Remove the valve (Figure 3, Item 3) from the vessel piping (Figure 3, Item 6). Remove gaskets (Figure 3, Items 7 and 8).
0210-4
TM 55-1925-273-24&P-2 FLANGED GLOBE/GATE VALVE REMOVAL - Continued

1 2 3 4 5
0210
7
M1124T73
Flanged Globe/Gate Valve.
FLANGED GLOBE/GATE VALVE INSTALLATION
WARNING
Removing components by means of wire brushing produces flying particles. These particles can cause serious injury to personnel. Wear protective faceshield, gloves, and long sleeves at all times during wire brushing operations. Failure to comply with this warning can result in serious injury to personnel. 1. 2. Clean the flanges of valve (Figure 3, Item 3) and vessel piping (Figure 3, Item 6) using a wire brush, clean wiping rags, and water. Install the valve ( Figure 3, Item 3) and two gaskets (Figure 3, Items 7 and 8) to the vessel piping (Figure 3, Item 6), and secure it with the bolts (Figure 3, Items 1 and 5) and the nuts (Figure 3, Items 2 and 4). Perform the FOLLOW-ON MAINTENANCE procedure at the end of this work package.
3.
END OF TASK
0210-5
TM 55-1925-273-24&P-2
0210
FOLLOW-ON MAINTENANCE 1. 2. 3. 4. 5. Remove the lock outs and tags outs IAW FM 4-01.502. Set the circuit breakers to ON. Operate the oily bilge system under usual conditions IAW TM 55-1925-273-10. Check the valve and connections for leakage and proper operation. Return the equipment to the desired readiness condition.
0210-6
TM 55-1925-273-24&P-2 FIELD MAINTENANCE BALLAST SYSTEM VALVES REPAIR
0211
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 3, WP 0344, Table 1, Item 27) Materials/Parts Rag, Wiping (Volume 3, WP 0343, Table 1, Item 132) Retainer, Packing (Volume 3, WP 0316, Figure 68, Item 25) Qty: 1 Packing, Preformed (Volume 3, WP 0316, Figure 68, Item 21) Qty: 1 Packing, Preformed (Volume 3, WP 0316, Figure 68, Item 23) Qty: 2 Seat Valve (Volume 3, WP 0316, Figure 68, Item 22) Qty: 2 Indicator, Valve Opening (Stem Packing) (Volume 3, WP 0316, Figure 68, Item 32) Qty: 1 Disk, Valve (Volume 3, WP 0316, Figure 68, Item 31) Qty: 1 Seat, Valve (Volume 3, WP 0316, Figure 68, Item 30) Qty: 1 Materials/Parts (cont.) Gasket (Volume 3, WP 0316, Figure 68, Item 48) Qty: 1 Seat, Valve (Volume 3, WP 0316, Figure 68, Item 46) Qty: 1 Personnel Required Watercraft Engineer 88L (1) References WP 0210 Volume 3, WP 0316 Volume 3, WP 0343 Volume 3, WP 0344 Equipment Condition Ballast system valve removed. (WP 0210)
0211-1
TM 55-1925-273-24&P-2
0211
THREADED BALL VALVE REPAIR DISASSEMBLY 1. 2. 3. 4. 5. Remove the nut (Figure 1, Item 1), the lockwasher (Figure 1, Item 2), the flat washer (Figure 1, Item 3), and the handle (Figure 1, Item 4) from the valve body (Figure 1, Item 11). Remove the retainer (Figure 1, Item 5), the valve stem (Figure 1, Item 6), and the retainer packing (Figure 1, Item 15) from the valve body (Figure 1, Item 11). Discard retainer packing. Remove the packing (Figure 1, Item 7) from the valve body (Figure 1, Item 11). Discard packing. Remove the four bolts (Figure 1, Item 13) and flat washers (Figure 1, Item 12), and separate the end fittings (Figure 1, Item 8) from the valve body (Figure 1, Item 11). Remove the packing (Figure 1, Item 9), the valve seats (Figure 1, Item 10), and the ball (Figure 1, Item 14) from the valve body (Figure 1, Item 11). Discard packing and valve seats.
0211-2
TM 55-1925-273-24&P-2 THREADED BALL VALVE REPAIR DISASSEMBLY - Continued

1 2 3 4
0211
5 6
7 15
14
8 9 10 11
10 9 8 12 13
M1125T73
Threaded Ball Valve.
0211-3
TM 55-1925-273-24&P-2
0211
THREADED BALL VALVE REPAIR ASSEMBLY 1. 2. 3. Inspect all valve components for wear and damage. Clean the parts of the valve using clean wiping rags and water. Install packing (Figure 1, Item 9), valve seats (Figure 1, Item 10), and the ball (Figure 1, Item 14) in the valve body (Figure 1, Item 11), and secure them with the four bolts (Figure 1, Item 13), flat washers (Figure 1, Item 12), and the end fittings (Figure 1, Item 8). Install packing (Figure 1, Item 7) in the valve body (Figure 1, Item 11). Install the valve stem (Figure 1, Item 6) and retainer packing (Figure 1, Item 15) in the valve body (Figure 1, Item 11), and secure them with the retainer (Figure 1, Item 5). Install the handle (Figure 1, Item 4) on the valve body (Figure 1, Item 11) and secure it with the nut (Figure 1, Item 1), lockwasher (Figure 1, Item 2), and the flat washer (Figure 1, Item 3). Perform the applicable INSTALLATION procedure for the affected valve (WP 0210).
4. 5. 6. 7.
END OF TASK FLANGED STOP CHECK VALVE REPAIR DISASSEMBLY 1. 2. 3. 4. 5. Remove the nut (Figure 2, Item 9) and the handle (Figure 2, Item 8) from the valve body (Figure 2, Item 2). Remove the retainer nut (Figure 2, Item 10) and the packing gland (Figure 2, Item 7) from the valve body (Figure 2, Item 2). Remove the bolts (Figure 2, Item 5), the stem (Figure 2, Item 6), and the stem packing (Figure 2, Item 4) from the valve body (Figure 2, Item 2). Discard stem packing. Remove the bolts (Figure 2, Item 3), and remove the access cover (Figure 2, Item 11), and the packing gland (Figure 2, Item 12) from the valve body (Figure 2, Item 2). Remove the valve disk (Figure 2, Item 1) and the valve seat (Figure 2, Item 13) from the valve body (Figure 2, Item 2). Discard valve disk and valve seat.
0211-4
TM 55-1925-273-24&P-2 FLANGED STOP CHECK VALVE REPAIR DISASSEMBLY - Continued

8 7 6 5 4 3 9
0211
2 1
10
5 3
11 12
13
M1126T73
Flanged Stop Check Valve.
FLANGED STOP CHECK VALVE REPAIR ASSEMBLY 1. 2. 3. 4. 5. 6. 7. 8. Inspect all valve components for wear and damage. Clean the parts of the valve (Figure 2, Item 9) using clean wiping rags and water. Install valve seat (Figure 2, Item 13) and a valve disk (Figure 2, Item 1) in the valve body (Figure 2, Item 2). Install packing gland (Figure 2, Item 12) on the access cover (Figure 2, Item 11) and secure the access cover to the valve body (Figure 2, Item 2) with the bolts (Figure 2, Item 3). Install the stem (Figure 2, Item 6) and stem packing (Figure 2, Item 4) on the valve body (Figure 2, Item 2) and secure it with the bolts (Figure 2, Item 5). Install packing gland (Figure 2, Item 7) in the retainer nut (Figure 2, Item 10) and install the retainer nut on the valve body (Figure 2, Item 2). Install the handle (Figure 2, Item 8) on the valve body (Figure 2, Item 2) and secure it with the nut (Figure 2, Item 9). Perform the applicable INSTALLATION procedure for the affected valve (WP 0210).
END OF TASK
0211-5
TM 55-1925-273-24&P-2 FLANGED CHECK VALVE REPAIR DISASSEMBLY 1. 2. 3. 4.
0211
Remove the nuts (Figure 3, Item 1) and bolts (Figure 3, Item 4), and remove the cover (Figure 3, Item 2) from the valve body (Figure 3, Item 6). Remove the gasket (Figure 3, Item 7) from the cover (Figure 3, Item 2). Discard gasket. Remove the valve hinge pin (Figure 3, Item 8) and valve seat (Figure 3, Item 5). Discard valve seat. Remove the plug (Figure 3, Item 3) from the valve body (Figure 3, Item 6).
8 3 4 4
5
M1127T73
Figure 3. Flanged Check Valve. END OF TASK FLANGED CHECK VALVE REPAIR ASSEMBLY 1. 2. 3. 4. 5. 6. Inspect all valve components for wear and damage. Clean the parts of the valve (Figure 3, Item 1) using clean wiping rags and water. Install valve seat (Figure 3, Item 5) and secure it inside the valve body (Figure 3, Item 6) with the valve hinge pin (Figure 3, Item 8). Install gasket (Figure 3, Item 7) on the cover (Figure 3, Item 2) and secure it to the valve body (Figure 3, Item 6) with the nuts (Figure 3, Item 1) and bolts (Figure 3, Item 4). Install the plug (Figure 3, Item 3) in the valve body (Figure 3, Item 6). Perform the applicable INSTALLATION procedure for the affected valve (WP 0210).
0211-6
TM 55-1925-273-24&P-2 FIELD MAINTENANCE BALLAST PUMP REPAIR
0212
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 3, WP 0344, Table 1, Item 27) Suitable Drain Pan Materials/Parts N/A Personnel Required Watercraft Engineer 88L (2) References FM 4-01.502 TM 55-1925-273-10 References (cont.) WP 0215 Volume 3, WP 0317 Volume 3, WP 0344 Equipment Condition Set to OFF the BILGE PUMP No. 1 circuit breaker at the emergency switchboard or the BILGE PUMP No. 2 circuit breaker at the main switchboard. Lock out and tag out IAW FM 4-01.502. Electric motor removed. (WP 0215) CLOSE all valves for the affected pump. Lock out and tag out IAW FM 4-01.502.
0212-1
TM 55-1925-273-24&P-2
0212
WARNING
Never reuse locking hardware. Reuse of locking hardware such as lockwashers, locking nuts, cotter pins, and lock wire can result in undetected loosening of fastening hardware causing catastrophic component failure resulting in death, injury, or damage to equipment. Ensure that all locking hardware is discarded upon removal and replaced with new. BALLAST PUMP HARDWARE REMOVAL 1. 2. 3. 4. Inspect for any damaged, corroded, or missing fasteners at the flanges and at the foundation. Remove the nuts (Figure 1, Item 7), lockwashers (Figure 1, Item 8), flat washers (Figure 1, Items 6 and 9), and bolts (Figure 1, Item 1). Discard lockwashers and any damaged or corroded fasteners. Remove the bolts (Figure 1, Item 3) and nuts (Figure 1, Item 2). Discard any damaged or corroded fasteners. Remove the bolts (Figure 1, Item 4) and nuts (Figure 1, Item 5). Discard any damaged or corroded fasteners.
1 3
2 9
5 8 6
M1340T73
Figure 1. Ballast Pump Hardware. END OF TASK
0212-2
TM 55-1925-273-24&P-2
0212
BALLAST PUMP HARDWARE INSTALLATION 1. 2. 3. Install the bolts (Figure 1, Item 1), flat washers (Figure 1, Items 6 and 9), lockwashers (Figure 1, Item 8), and nuts (Figure 1, Item 7). Install bolts (Figure 1, Items 3 and 4) and nuts (Figure 1, Items 2 and 5). Perform the FOLLOW-ON MAINTENANCE procedure at the end of this work package.
END OF TASK BALLAST PUMP COUPLING REMOVAL 1. 2. Remove the flange screw (Figure 2, Item 1) from the coupling (Figure 2, Item 3). Slide the coupling (Figure 2, Item 3) from the ballast pump shaft (Figure 2, Item 2) with the spider (Figure 2, Item 4).
4 3
M1341T73
Figure 2. END OF TASK BALLAST PUMP COUPLING INSPECTION 1. 2.
Ballast Pump.
Inspect the coupling (Figure 2, Item 3) for corrosion, deformation, and obvious damage. Replace the coupling if it is corroded, deformed, and/or damaged. Inspect the spider (Figure 2, Item 4) for damage, deformity, or deterioration. Replace the spider if it is corroded, deformed, and/or deteriorated.
END OF TASK
0212-3
TM 55-1925-273-24&P-2 BALLAST PUMP COUPLING INSTALLATION 1. 2. 3. 4. 5. 6. Install the coupling (Figure 2, Item 3) on the ballast pump shaft (Figure 2, Item 2). Install the coupling (Figure 2, Item 3) and secure it with the flange screw (Figure 2, Item 1). Install the spider (Figure 2, Item 4) in the coupling (Figure 2, Item 3). Install the electric motor (WP 0215).
0212
Operate the ballast pump under usual conditions IAW TM 55-1925-273-10, checking for leaks and proper operation. Continue to monitor the system occasionally while the system pressurizes fully. If leakage is detected, secure the system and stop the leakage.
END OF TASK STRAINER HARDWARE REMOVAL 1. 2. 3. 4. Inspect for any damaged, corroded, or missing fasteners at the flanges and at the foundation. Remove the nuts (Figure 3, Item 7), lockwashers (Figure 3, Item 8), flat washers (Figure 3, Items 6 and 9), and bolts (Figure 3, Item 1). Discard lockwashers and any damaged or corroded fasteners. Remove the nuts (Figure 3, Item 3) and bolts (Figure 3, Item 2). Discard any damaged or corroded fasteners. Remove the bolts (Figure 3, Item 4) and nuts (Figure 3, Item 5). Discard any damaged or corroded fasteners.
0212-4
TM 55-1925-273-24&P-2 STRAINER HARDWARE REMOVAL - Continued
0212
2 1
4 5
8
M1342T73
Figure 3. END OF TASK STRAINER HARDWARE INSTALLATION 1. 2. 3. 4.
Strainer Hardware.
Install the bolts (Figure 3, Item 1), and flat washers (Figure 3, Items 6 and 9), lockwashers (Figure 3, Item 8), and nuts (Figure 3, Item 7). Install the bolts (Figure 3, Item 2) and nuts (Figure 3, Item 3). Install the bolts (Figure 3, Item 4) and nuts (Figure 3, Item 5). Perform the FOLLOW-ON MAINTENANCE procedure at the end of this work package.
END OF TASK
0212-5
TM 55-1925-273-24&P-2
0212
FOLLOW-ON MAINTENANCE 1. 2. 3. 4. 5. Remove the lock outs and tag outs IAW FM 4-01.502. Set the applicable circuit breaker to ON. Operate the bilge/ballast pump under usual conditions IAW TM 55-1925-273-10. Check for leaks and proper operation of the bilge/ballast system. Return the equipment to the desired readiness condition.
0212-6
TM 55-1925-273-24&P-2 FIELD MAINTENANCE BALLAST PUMP, PUMP END REPLACE
0213
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 3, WP 0344, Table 1, Item 27) Gloves, Chemical and Oil Protective (Volume 3, WP 0344, Table 1, Item 8) Gloves, Leather (Volume 3, WP 0344, Table 1, Item 9) Goggles, Industrial (Volume 3, WP 0344, Table 1, Item 10) Helmet, Safety (Volume 3, WP 0344, Table 1, Item 11) Hoist, Chain, Hand Operated, 2 Ton (1,814 kg) (Volume 3, WP 0344, Table 1, Item 12) Sling, Endless (Volume 3, WP 0344, Table 1, Item 22) Suitable Drain Pan Materials/Parts Tape, Antiseizing; 1/2 in. (Volume 3, WP 0343, Table 1, Item 158) Personnel Required Watercraft Engineer 88L (2) References FM 4-01.502 References (cont.) TM 55-1925-273-10 WP 0215 Volume 3, WP 0317 Volume 3, WP 0343 Volume 3, WP 0344 Equipment Condition For ballast pump No. 1, CLOSE valves BB-26 B/B PMP NO. 1 BLST. SUCT, BB-29 B/B PMP NO. 1 BILGE SUCT, and BB-34 B/B PMP NO. 1 OVBD DISCH. Lock out and tag out IAW FM 4-01.502. For ballast pump No. 2, CLOSE valves BB-27 B/B PMP. NO. 2 BLST. SUCT, BB-30 B/B PMP. NO. 2 BILGE SUCT, and BB-32 B/B PMP NO. 2 OVBD DISCH. Lock out and tag out IAW FM 4-01.502.
0213-1
TM 55-1925-273-24&P-2
0213
WARNING
Never reuse locking hardware. Reuse of locking hardware such as lockwashers, locking nuts, cotter pins, and lock wire can result in undetected loosening of fastening hardware causing catastrophic component failure resulting in death, injury, or damage to equipment. Ensure that all locking hardware is discarded upon removal and replaced with new. REMOVAL 1. Place a suitable drain pan under the ballast pump (Figure 1, Item 8).
WARNING
Hydraulic hoses and lines may be under pressure. Relieve pressure by operating the appropriate control valve, if possible. Loosen fittings on hoses and lines slowly. Allow oil to run around threads of fitting, releasing pressure before disconnecting fitting. Releasing pressurized oil suddenly may cause serious injury or death. 2. 3. 4. Slowly open the pressure gage fitting (Figure 1, Item 1) to relieve pressure from the ballast pump (Figure 1, Item 8). After the pressure has been released, completely disconnect the pressure gage piping (Figure 1, Item 1) from the ballast pump's piping. Remove the four nuts (Figure 1, Item 10), four lockwashers (Figure 1, Item 11), four flat washers (Figure 1, Item 9), four bolts (Figure 1, Item 14), and four flat washers (Figure 1, Item 13) securing the ballast pump (Figure 1, Item 8) to its foundation (Figure 1, Item 12). Discard lockwashers. Remove the four nuts (Figure 1, Item 15) and four bolts (Figure 1, Item 16) securing the ballast pump (Figure 1, Item 8) to the discharge piping (Figure 1, Item 2). Remove the gasket (Figure 1, Item 3) from the discharge piping (Figure 1, Item 2). Remove the four nuts (Figure 1, Item 7) and four bolts (Figure 1, Item 6) securing the ballast pump (Figure 1, Item 8) to the suction piping (Figure 1, Item 5). Remove the gasket (Figure 1, Item 4) from the suction piping (Figure 1, Item 5).
5. 6. 7. 8.
WARNING
All personnel in the vicinity of lifting operations should wear appropriate safety equipment including heavy gloves, hardhats, and safety shoes. Failure to comply with this warning can result in serious injury or death. 9. Using the endless sling and chain hoist, remove the ballast pump (Figure 1, Item 8) from the foundation (Figure 1, Item 12).
0213-2
0213
2 16
15 14
3 4
5 13
9 8 12 11 10
Figure 1. END OF TASK Ballast Pump.
M1128T73
0213-3
TM 55-1925-273-24&P-2
0213
INSTALLATION
WARNING
All personnel in the vicinity of lifting operations should wear appropriate safety equipment including heavy gloves, hardhats, and safety shoes. Failure to comply with this warning can result in serious injury or death. 1. 2. Using the endless sling and chain hoist, install the ballast pump (Figure 1, Item 8) on its foundation (Figure 1, Item 12). Install the four bolts (Figure 1, Item 14), eight flat washers (Figure 1, Items 9 and 13), four lockwashers (Figure 1, Item 11), and four nuts (Figure 1, Item 10) securing the ballast pump (Figure 1, Item 8) to its foundation (Figure 1, Item 12). Do not tighten the bolts at this time. Install a gasket (Figure 1, Item 3) between the ballast pump (Figure 1, Item 8) and the discharge piping (Figure 1, Item 2) and install the four bolts (Figure 1, Item 16) and four nuts (Figure 1, Item 15). Do not tighten the bolts at this time. Install a gasket (Figure 1, Item 4) between the ballast pump (Figure 1, Item 8) and the suction piping (Figure 1, Item 5) and install the four bolts (Figure 1, Item 6) and four nuts (Figure 1, Item 7). Do not tighten the bolts at this time. Tighten the four bolts (Figure 1, Item 14). securing the ballast pump (Figure 1, Item 8) to its foundation (Figure 1, Item 12). Tighten the four bolts (Figure 1, Item 16) and the four nuts (Figure 1, Item 15). Tighten the four bolts (Figure 1, Item 6) and the four nuts (Figure 1, Item 7). Apply antiseizing tape on the male threads of the pressure gage piping (Figure 1, Item 1). Connect the pressure gage piping to the ballast pump's piping connection.
3.
4.
5. 6. 7. 8.
END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. 4. Align pump IAW BALLAST PUMP ELECTRIC MOTOR REPLACE motor installation procedure (WP 0215). Remove the lock outs and tag outs IAW FM 4-01.502. Operate the ballast pump under usual conditions IAW TM 55-1925-273-10, checking for leaks and proper operation. Return the ballast pump to the desired readiness condition.
0213-4
TM 55-1925-273-24&P-2 FIELD MAINTENANCE BALLAST PUMP, PUMP END REPAIR
0214
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 3, WP 0344, Table 1, Item 27) Faceshield, Industrial (Volume 3, WP 0344, Table 1, Item 5) Gloves, Chemical and Oil Protective (Volume 3, WP 0344, Table 1, Item 8) Gloves, Leather (Volume 3, WP 0344, Table 1, Item 9) Press, Arbor, Hand Operated (Volume 3, WP 0344, Table 1, Item 16) Wrench, Torque, 0-250 lb-ft (0-339 Nm) (Volume 3, WP 0344, Table 1, Item 33) Suitable Drain Pan Materials/Parts Cleaning Compound, Solvent (Volume 3, WP 0343, Table 1, Item 37) Compound, Sealing; Silicone RTV (Volume 3, WP 0343, Table 1, Item 44) Layout Dye (Volume 3, WP 0343, Table 1, Item 93) Lubricating Oil, Engine; OE/HDO-40, 55 gal (Volume 3, WP 0343, Table 1, Item 104) Gasket, Rear Cover (Volume 3, WP 0317, Figure 69, Item 9) Qty: 1 Gasket, Impeller (Volume 3, WP 0317, Figure 69, Item 6) Qty: 1 Packing, Preformed (Volume 3, WP 0317, Figure 69, Item 8) Qty: 1 Materials/Parts (cont.) Seal, Plain Oil, Outboard (Volume 3, WP 0317, Figure 69, Item 11) Qty: 1 Seal, Oil, Inboard (Volume 3, WP 0317, Figure 69, Item 5) Qty: 1 Personnel Required Watercraft Engineer 88L (2) References WP 0213 Volume 3, WP 0317 Volume 3, WP 0343 Volume 3, WP 0344 Equipment Condition Pump end removed. (WP 0213)
0214-1
TM 55-1925-273-24&P-2
0214
DISASSEMBLY
WARNING
Never reuse locking hardware. Reuse of locking hardware such as lockwashers, locking nuts, cotter pins, and lock wire can result in undetected loosening of fastening hardware causing catastrophic component failure resulting in death, injury, or damage to equipment. Ensure that all locking hardware is discarded upon removal and replaced with new. 1. 2. 3. 4. 5. Place a suitable drain pan under the pump's drain plug (Figure 1, Item 23). Remove the drain plug and drain all oil from the pump. Remove the vent plug (Figure 1, Item 14) from the bearing housing (Figure 1, Item 15). Remove the eight casing nuts (Figure 1, Item 17) securing the bearing housing adapter (Figure 1, Item 19) to the pump casing (Figure 1, Item 29). Separate the bearing housing adapter (Figure 1, Item 19) from the pump casing (Figure 1, Item 29) and remove the rear cover gasket (Figure 1, Item 28). Discard rear cover gasket. Install the impeller wrench onto the shaft (Figure 1, Item 8) and the key (Figure 1, Item 6).
0214-2
0214
13 8
12 14 11 15 16 10 9 17
18 19 20
24
23 25 22 26 27 28 29 21
33 32 31 30
M1343T73
Figure 1.
Ballast Pump.
0214-3
0214
WARNING
The impeller could have sharp edges. Wear leather gloves to protect the hands when removing the impeller. Failure to comply with this warning can result in injury or death. Do not apply heat to the impeller to loosen it from the shaft. Liquid inside the impeller might cause an explosion. Failure to comply with this warning can result in illness, serious injury, or death.
NOTE
It may take several attempts using this method before the impeller is loosened. 6. Turn the impeller (Figure 1, Item 30) in the clockwise direction and move the impeller wrench in the 11 o'clock position. Quickly spin the impeller in the counterclockwise position causing the impeller wrench to impact the hard surface of the workbench. Refer to Figure 2. Unscrew the impeller (Figure 1, Item 30) and remove it from the shaft (Figure 1, Item 8). Remove the impeller gasket (Figure 1, Item 27) from the shaft (Figure 1, Item 8). Discard impeller gasket. Remove the inboard deflector (Figure 1, Item 20) from the bearing housing adapter (Figure 1, Item 19). Remove the four nuts (Figure 1, Item 25) securing the gland (Figure 1, Item 33). Slide the gland away from the rear cover plate (Figure 1, Item 31). Install the brass shaft guide onto the shaft (Figure 1, Item 8).
7. 8. 9. 10. 11.
M1344T73
Figure 2. 12. 13.
Impeller.
Remove the two capscrews (Figure 1, Item 18) securing the rear cover plate (Figure 1, Item 31) to the bearing housing adapter (Figure 1, Item 19). Slowly separate the rear cover plate (Figure 1, Item 31) from the bearing housing adapter (Figure 1, Item 19) and slide the rear cover plate off the shaft (Figure 1, Item 8). 0214-4
TM 55-1925-273-24&P-2 DISASSEMBLY - Continued 14.
0214
Remove the packing set (Figure 1, Item 26) from the rear cover plate (Figure 1, Item 31). Discard packing set.
NOTE
Do not discard lantern rings. 15. 16. 17. 18. 19. 20. 21. 22. 23. Remove the two lantern rings (Figure 1, Item 32) from the rear cover plate (Figure 1, Item 31). Remove the brass shaft guide from the shaft (Figure 1, Item 8). Loosen the three bolts (Figure 1, Item 12) securing the bearing carrier (Figure 1, Item 1). Remove the bearing carrier. Remove the bearing carrier gaskets (Figure 1, Item 2) from the bearing carrier (Figure 1, Item 1). Remove the outboard oil seal (Figure 1, Item 13) from the bearing carrier (Figure 1, Item 1). Discard outboard oil seal. Remove the bearing snap ring (Figure 1, Item 4) using snap pliers. Remove and retain the shims (Figure 1, Item 3) from the bearing housing (Figure 1, Item 15). Remove the bearing locknut (Figure 1, Item 11) and the bearing lockwasher (Figure 1, Item 5). Remove the shaft (Figure 1, Item 8) from the bearing housing (Figure 1, Item 15).
CAUTION
Never apply pressure to the outer race of the bearings as this exerts excess load on the balls and causes damage to the bearing. 24. 25. 26. 27. 28. Remove the inboard bearing (Figure 1, Item 9), the outboard bearing (Figure 1, Item 10), and the slinger (Figure 1, Item 7) from the shaft (Figure 1, Item 8), using an arbor press. Remove the four capscrews (Figure 1, Item 22) securing the bearing housing (Figure 1, Item 15) to the bearing housing adapter (Figure 1, Item 19). Separate the bearing housing and the bearing housing adapter. Remove the O-ring (Figure 1, Item 16) from the bearing housing (Figure 1, Item 15). Remove the inboard oil seal (Figure 1, Item 21) from the inner race of the bearing housing adapter (Figure 1, Item 19). Discard inboard oil seal. Remove the Trico oil gage (Figure 1, Item 24) from the bearing housing (Figure 1, Item 15).
END OF TASK
0214-5
0214
WARNING
Cleaning solvent is flammable and its vapor is potentially explosive. Do not use cleaning solvent in the vicinity of spark, open flame, or excessive heat. Do not use cleaning solvent in unventilated spaces. Failure to comply can result in serious injury or death. Do not allow hydraulic fluid, engine oil, or cleaning solvents to come in contact with unprotected skin or eyes. Prolonged skin contact can cause illness or injury. Eye contact can cause serious injury. Always wear chemical protective gloves and goggles when handling hydraulic fluid, engine oil, and cleaning solvents. Failure to follow these precautions can result in illness, serious injury, or death. 1. 2. Using cleaning solvent, clean all the metal parts. Check for any binding, scoring, or galling, or rough rotation on the inboard bearings (Figure 1, Item 9) and the outboard bearings (Figure 1, Item 10). Inspect all component parts for unusual wear or damage, and replace as required.
WARNING
CAUTION
END OF TASK ASSEMBLY 1. 2. 3. 4. 5. Install a inboard oil seal (Figure 1, Item 21) into the inner race of the bearing housing adapter (Figure 1, Item 19). Install an O-ring (Figure 1, Item 16) into the bearing housing (Figure 1, Item 15). Connect the bearing housing (Figure 1, Item 15) and the bearing housing adapter (Figure 1, Item 19). Install the four capscrews (Figure 1, Item 22) securing the bearing housing to the bearing housing adapter. Put layout dye onto shaft (Figure 1, Item 8) then scribe a line in the layout dye for the location of inboard bearing (Figure 1, Item 9). Refer to Figure 3. Install a slinger (Figure 1, Item 7) using an arbor press.
0214-6
0214
CAUTION
Never apply pressure to the outer race of the bearings as this exerts excess load on the balls and causes damage to the bearing. 6. Press the inboard bearing (Figure 1, Item 9) onto the shaft (Figure 1, Item 8) using an arbor press, aligning the edge of the inner race of the inboard bearing with the scribed line.
CAUTION
Never apply pressure to the outer race of the bearings as this exerts excess load on the balls and causes damage to the bearing. 7. 8. 9. Press the outboard bearing (Figure 1, Item 10) onto the shaft (Figure 1, Item 8) up to the shoulder of the shaft using an arbor press. Refer to Figure 3. Install a bearing lockwasher (Figure 1, Item 5) and the bearing locknut (Figure 1, Item 11). Tighten the bearing locknut and engage the lockwasher's tangs into the locknut's slots. Apply a coat of lubricating oil on the shaft (Figure 1, Item 8), the inboard bearing (Figure 1, Item 9), the outboard bearings (Figure 1, Item 10), and the inside of the bearing housing (Figure 1, Item 15) and slide the shaft (Figure 1, Item 8) into the rear of the bearing housing. Install three set bolts (Figure 1, Item 12) into the bearing carrier (Figure 1, Item 1). Tighten the set bolts. Install the brass shaft guide onto the shaft (Figure 1, Item 8). Install the inboard deflector (Figure 1, Item 20). Install the impeller gasket (Figure 1, Item 27) onto the shaft (Figure 1, Item 8). Install the gland (Figure 1, Item 33) onto the shaft (Figure 1, Item 8). Slide the rear cover plate (Figure 1, Item 31) over the brass shaft guide and onto the shaft (Figure 1, Item 8) up to the bearing housing adapter (Figure 1, Item 19). Install the two capscrews (Figure 1, Item 18) securing the rear cover plate (Figure 1, Item 31) to the bearing housing adapter (Figure 1, Item 19). Tighten the two capscrews to the torque of 40 lb-ft (54 Nm).
10. 11. 12. 13. 14. 15. 16.
5.09" (1129.3 MM)
M1345T73
Figure 3.
Bearing Positioning.
WARNING
The impeller could have sharp edges. Wear leather gloves to protect the hands when removing the impeller. Failure to comply with this warning can result in injury or death. 17. Screw the impeller (Figure 1, Item 30) onto the shaft (Figure 1, Item 8) until it is firmly against the shaft's shoulder.
0214-7
0214
CAUTION
Do not attempt to tighten the impeller on the shaft by hitting the impeller with a hammer or any other object or by inserting a pry bar between the impeller vanes. Serious damage to the impeller may result from such actions. 18. 19. 20. 21. 22. 23. Install the impeller wrench over the shaft (Figure 1, Item 8) and the key (Figure 1, Item 6). Grab the impeller (Figure 1, Item 30) in both hands, with the impeller wrench handle to the left, spin the impeller forcefully in a clockwise direction to impact the impeller wrench handle on the work surface to the right. Determine the proper clearance using Table 1. Measure the clearance between the impeller (Figure 1, Item 30) and the rear cover plate (Figure 1, Item 31) and record the distance. Subtract the desired clearance from the recorded measurement. Select shims (Figure 1, Item 3) to equal the sum of the subtracted measurement. Remove the three set bolts (Figure 1, Item 12) securing the bearing carrier (Figure 1, Item 1). Remove the bearing carrier.
M1346T73
Figure 4. Tightening The Impeller.
0214-8
TM 55-1925-273-24&P-2 ASSEMBLY - Continued Table 1. Temperature - F (C) 200 (93) 200 to 250 (93 to 121) 251 to 300 (122 to 149) 301 to 350 (150 to 176) 351 to 400 (177 to 204) 401 to 450 (205 to 232) 450 (232) Impeller Clearance Settings. Clearance to Casing - in. (mm) 0.018 0.003 (0.46 0.08) 0.021 (0.53) 0.024 (0.61) 0.027 (0.69) 0.030 (0.76) 0.033 (0.84) 0.036 (0.91)
0214
NOTE
Install the thinnest shims first. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35. 36. 37. Install the shims (Figure 1, Item 3) between the bearing snap ring (Figure 1, Item 4) and the bearing housing (Figure 1, Item 15). Install the bearing snap ring. Install the outboard oil seal (Figure 1, Item 13) into the bearing carrier (Figure 1, Item 1). Install the three set bolts (Figure 1, Item 12) into the bearing carrier (Figure 1, Item 1). Tighten the set bolts. Recheck the clearance between the impeller (Figure 1, Item 30) and the rear cover plate (Figure 1, Item 31). Measure the thickness of the bearing snap ring (Figure 1, Item 4) and the shims (Figure 1, Item 3). The bearing carrier gaskets (Figure 1, Item 2) should equal 1-1/2 times the snap ring and the shim stack. Apply sealing compound between each bearing carrier gasket (Figure 1, Item 13). Place the bearing carrier gaskets (Figure 1, Item 2) stack inside the bearing carrier (Figure 1, Item 1). Install the bearing carrier (Figure 1, Item 1) onto the bearing housing (Figure 1, Item 15). Tighten the three set bolts (Figure 1, Item 12) 30 lb-ft (41 Nm). Install the two lantern rings (Figure 1, Item 32) into the rear cover plate (Figure 1, Item 31). Push the two lantern rings snug down into the rear cover plate using the gland (Figure 1, Item 33). Install the packing set (Figure 1, Item 26) into the rear cover plate (Figure 1, Item 31). Push the packing set snug down into the rear cover plate using the gland (Figure 1, Item 33). Install the gland (Figure 1, Item 33) into the rear cover plate (Figure 1, Item 31). Install the four nuts (Figure 1, Item 25) securing the gland (Figure 1, Item 33). Tighten the four nuts to 5 lb-ft (6.8 Nm). Install the rear cover gasket (Figure 1, Item 28) onto the outer race of the rear cover plate (Figure 1, Item 31). Place the bearing housing adapter (Figure 1, Item 19) and the pump casing (Figure 1, Item 29) together.
0214-9
0214
NOTE
The casing nuts are non-lubricated. 38. 39. 40. 41. Install the eight casing nuts (Figure 1, Item 17) securing the bearing housing adapter (Figure 1, Item 19) to the pump casing (Figure 1, Item 29). Tighten the eight casing nuts to a torque of 15 lb-ft (20 Nm). Install the vent plug (Figure 1, Item 14) into the bearing housing (Figure 1, Item 15). Install the Trico oil gage (Figure 1, Item 24) into the bearing housing (Figure 1, Item 15). Install the drain plug (Figure 1, Item 23) into the bearing housing. Tighten the drain plug.
CAUTION
Do not place the pump online before filling the bearing house adapter with oil. Damage to the pump will occur. 42. Fill the bearing housing adapter (Figure 1, Item 15) to the center of the oil sight glass with lubrication oil.
0214-10
TM 55-1925-273-24&P-2 FIELD MAINTENANCE BALLAST PUMP ELECTRIC MOTOR REPLACE
0215
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 3, WP 0344, Table 1, Item 27) Gloves, Leather (Volume 3, WP 0344, Table 1, Item 9) Helmet, Safety (Volume 3, WP 0344, Table 1, Item 11) Hoist, Chain, Hand Operated, 2 Ton (1,814 kg) (Volume 3, WP 0344, Table 1, Item 12) Multimeter (Volume 3, WP 0344, Table 1, Item 15) Sling, Endless (Volume 3, WP 0344, Table 1, Item 21) Materials/Parts N/A Personnel Required Watercraft Engineer 88L (2) References FM 4-01.502 References (cont.) TM 55-1925-273-10 Volume 3, WP 0318 Volume 3, WP 0344 Equipment Condition For ballast pump No. 1, set to OFF the BILGE PUMP circuit breaker on the emergency switchboard. Lock out and tag out IAW FM 4-01.502. For ballast pump No. 2, set to OFF the BILGE PUMP NO. 2 circuit breaker on the main switchboard. Lock out and tag out IAW FM 4-01.502.
0215-1
TM 55-1925-273-24&P-2
0215
WARNING
NOTE
Electrical junction boxes may vary in size, shape, and mounting position of the box on the motor frame. Electrical junction box covers may vary in number and placement of screws holding the cover in place. 1. 2. Remove the four screws (Figure 1, Item 1) from the electrical junction box cover (Figure 1, Item 2). Remove the junction box cover (Figure 1, Item 2).
WARNING
Replace or repair components only after the affected circuit has been secured, locked out, and tagged out IAW FM 4-01.502. Performing replacement with the circuit energized may result in injury. 3. Using a multimeter, check for available voltage at the wiring terminals. If voltage is present, ensure that the proper circuit breaker is secured, locked out, and tagged out IAW FM 4-01.502. If no voltage is present, continue with the procedure.
2 1
M1129T73
Figure 1.
0215-2
TM 55-1925-273-24&P-2 REMOVAL - Continued 4. 5. 6. 7. 8. 9. Label and disconnect the electrical wiring.
0215
Remove the two bolts (Figure 2, Item 5), the two lockwashers (Figure 2, Item 6), and the two flat washers (Figure 2, Item 7) from the coupling guard (Figure 2, Item 8). Discard lockwashers. Remove the coupling guard (Figure 2, Item 8). Loosen the motor coupling flange setscrew (Figure 2, Item 3). Slide the motor coupling flange (Figure 2, Item 4) towards the motor (Figure 2, Item 2). Remove the four bolts (Figure 2, Item 1), four lockwashers (Figure 2, Item 12), and four flat washers (Figure 2, Item 11). Discard lockwashers.
WARNING
All personnel in the vicinity of lifting operations should wear appropriate safety equipment including heavy gloves, hardhats, and safety shoes. Failure to comply with this warning can result in serious injury or death. Heavy loads can crush. Do not allow any body parts to come under the load or between the load and a stationary object. Failure to comply with this warning can result in serious injury or death. 10. 11. Using an endless sling and chain hoist, remove the motor (Figure 2, Item 2) from its foundation. Slide the motor coupling flange (Figure 2, Item 4) off the motor shaft.
5
3 2
6 7 8
1 4
12 11
10 9
M2007T73
Electric Motor.
0215-3
TM 55-1925-273-24&P-2 INSTALLATION 1.
0215
Slide the motor coupling flange (Figure 2, Item 4) onto the motor shaft (refer to Figure 2) with the flat end towards the motor housing (Figure 2, Item 2).
WARNING
All personnel in the vicinity of lifting operations should wear appropriate safety equipment including heavy gloves, hardhats, and safety shoes. Failure to comply with this warning can result in serious injury or death. Heavy loads can crush. Do not allow any body parts to come under the load or between the load and a stationary object. Failure to comply with this warning can result in serious injury or death. 2. 3. 4. 5. 6. Using an endless sling and chain hoist, position the motor (Figure 2, Item 2) on its foundation with the mounting holes aligned. Install four bolts (Figure 2, Item 1), four lockwashers (Figure 2, Item 12), and four flat washers (Figure 2, Item 11). Do not tighten at this time. Align the pump coupling flange (Figure 3, Item 1) and the motor coupling flange (Figure 3, Item 2) together leaving approximately 0.016 in. (0.41 mm) space between the ends of both flanges. Refer to Figure 3. Check the alignment between the pump coupling flange (Figure 3, Item 1) and the motor coupling flange (Figure 3, Item 2). The maximum angular offset shall be 1 degree and maximun parallel offset shall be 0.015 in. (0.381 mm). Refer to Figure 3.
STRAIGHT EDGE 1
OPTIMUM GAP BETWEEN FLANGES 0.016 IN. (0.41 MM)
1 MAXIMUM ANGULAR OFFSET
0.015 IN. (0.381MM) MAXIMUM PARALLEL OFFSET
2
M1132T73
Figure 3. Alignment of Pump Coupling Flange and Motor Coupling Flange. 7. 8. 9. Tighten the motor coupling flange setscrew (Figure 2, Item 3). Tighten the four bolts (Figure 2, Item 1). Install the coupling guard (Figure 2, Item 8) and secure it with two bolts (Figure 2, Item 5), two lockwashers (Figure 2, Item 6), and two flat washers (Figure 2, Item 7). Tighten the bolts.
0215-4
0215
Connect the electrical wiring using the labels from Step (4) of REMOVAL as a guide. Remove the labels. Install the electrical junction box cover (Figure 1, Item 2) and secure it with the four screws (Figure 1, Item 1).
END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. Remove the lock outs and tag outs IAW FM 4-01.502. Operate the ballast pump under usual conditions IAW TM 55-1925-273-10 and check for proper operation. Return the ballast pump to the desired readiness condition.
0215-5/6 blank
TM 55-1925-273-24&P-2 FIELD MAINTENANCE BALLAST PUMP ELECTRIC MOTOR REPAIR
0216
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 3, WP 0344, Table 1, Item 27) Gloves, Chemical and Oil Protective (Volume 3, WP 0344, Table 1, Item 8) Gloves, Leather (Volume 3, WP 0344, Table 1, Item 9) Goggles, Industrial (Volume 3, WP 0344, Table 1, Item 10) Lubricating Gun, Hand (Volume 3, WP 0344, Table 1, Item 14) Puller, Mechanical (Volume 3, WP 0344, Table 1, Item 17) Materials/Parts Cleaning Compound, Solvent (Volume 3, WP 0343, Table 1, Item 37) Compound, Sealing; Loctite 242 (Volume 3, WP 0343, Table 1, Item 43) Materials/Parts (cont.) Grease, Ball and Roller Bearing; 6.5 lb (Volume 3, WP 0343, Table 1, Item 75) Rag, Wiping (Volume 3, WP 0343, Table 1, Item 132) Personnel Required Watercraft Engineer 88L (1) References FM 4-01.502 WP 0215 Volume 3, WP 0318 Volume 3, WP 0343 Volume 3, WP 0344 Equipment Condition Electric motor removed. (WP 0215)
0216-1
TM 55-1925-273-24&P-2
0216
DISASSEMBLY 1. 2. 3. 4. 5. 6. 7. Remove the two grease drains (Figure 1, Item 19). Remove the grease fitting (Figure 1, Item 3). Remove the eye bolt (Figure 1, Item 7). Remove the two fan cover bolts (Figure 1, Item 6). Remove the fan cover guard (Figure 1, Item 1). Remove the fan clamp (Figure 1, Item 25) from the cooling fan (Figure 1, Item 2). Remove the cooling fan. Remove the four bolts (Figure 1, Item 5) from the front end bracket (Figure 1, Item 4). Remove the two bolts (Figure 1, Item 23) from the front end bracket (Figure 1, Item 4). Separate the front end bracket (Figure 1, Item 4) from the frame (Figure 1, Item 8).
CAUTION
Use care to keep pressure around the bearing's outer race equal. Damage to the bearing can result. 8. 9. 10. 11. 12. 13. 14. Remove the wave washer (Figure 1, Item 24) from the front end bracket (Figure 1, Item 4). Remove the bearing (Figure 1, Item 22) using a bearing puller. Remove the front end inner cap (Figure 1, Item 21). Remove the back end grease fitting (Figure 1, Item 14) from the back end bracket (Figure 1, Item 12). Remove the key (Figure 1, Item 16) from the shaft (Figure 1, Item 17) keyway. Remove the slinger (Figure 1, Item 15) from the shaft (Figure 1, Item 17). Remove the four bolts (Figure 1, Item 20) securing the back end bracket (Figure 1, Item 12). Separate the back end bracket from the frame (Figure 1, Item 8). Remove the two bolts (Figure 1, Item 18) from the back end bracket (Figure 1, Item 12).
CAUTION
Use care to keep pressure around the bearing's outer race equal. Damage to the bearing can result. 15. 16. Remove the back end bearing (Figure 1, Item 13) using a bearing puller. Remove the back end inner cap (Figure 1, Item 11) from the shaft (Figure 1, Item 17).
NOTE
Do not remove the stator from the frame. 17. Remove the rotor (Figure 1, Item 10) from the frame (Figure 1, Item 8) and stator (Figure 1, Item 9).
0216-2
0216
7 8 9 10 11 12 13
14 15 25 16
24 17
18 23 19 22 5 21 20
M1347T73
19
Figure 1. Ballast Pump Electric Motor (Typical). END OF TASK CLEANING AND INSPECTION
WARNING
CAUTION
Do not allow the cleaning solvent to come in contact with the stator (Figure 1, Item 9). Cleaning solvent may cause the stator to corrode. 1. 2. 3. Using cleaning solvent, clean the outside of the fan cover (Figure 1, Item 1), frame (Figure 1, Item 8), front end bracket (Figure 1, Item 4), back end bracket (Figure 1, Item 12), and bearings (Figure 1, Items 13 and 22). Check for any binding, scoring, or burrs on the bearings (Figure 1, Items 13 and 22) and all other removed parts. Inspect all component parts for unusual wear or damage, and replace as required. Check the rotor (Figure 1, Item 10) and stator (Figure 1, Item 9) for obvious damage.
0216-3
TM 55-1925-273-24&P-2 CLEANING AND INSPECTION - Continued
0216
CAUTION
END OF TASK ASSEMBLY 1. 2. Install the rotor (Figure 1, Item 10) in the frame (Figure 1, Item 8) and stator (Figure 1, Item 9). Install the back end inner cap (Figure 1, Item 11) on the shaft (Figure 1, Item 17).
WARNING
Always wear gloves when handling hot bearings. Handling hot bearings with bare hands or skin may result in severe burns. Failure to comply with this warning can result in serious injury or death.
CAUTION
Never apply pressure to the outer race of the bearings as this exerts excess load on the balls and causes damage to the bearing. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. Heat the back end bearing (Figure 1, Item 13) to 250F (121C) in an oven to expand the inner race. Install the back end bearing on the shaft (Figure 1, Item 17). Install the two bolts (Figure 1, Item 18) securing the back end inner cap (Figure 1, Item 11). Place the back end bracket (Figure 1, Item 12) on the frame (Figure 1, Item 8). Install the four bolts (Figure 1, Item 20) securing the back end bracket. Tighten the bolts. Install the front end inner cap (Figure 1, Item 21) on the shaft (Figure 1, Item 17). Heat the front end bearing (Figure 1, Item 22) to 250F (121C) in an oven to expand the inner race. Install the front end bearing on the shaft (Figure 1, Item 17). Install the two bolts (Figure 1, Item 23) securing the front inner cap (Figure 1, Item 21). Install the wave washer (Figure 1, Item 24) in the front end bracket (Figure 1, Item 4). Place the front end bracket (Figure 1, Item 4) on the frame (Figure 1, Item 8). Install the four bolts (Figure 1, Item 5) securing the front end bracket (Figure 1, Item 4) to the frame (Figure 1, Item 8). Install the slinger (Figure 1, Item 15) on the shaft (Figure 1, Item 17). Install the key (Figure 1, Item 16) in the shaft (Figure 1, Item 17) keyway. Install the cooling fan (Figure 1, Item 2) on the shaft (Figure 1, Item 17). Install the clamp (Figure 1, Item 6) securing the cooling fan. Install the fan cover guard (Figure 1, Item 1). Install the two fan cover bolts (Figure 1, Item 6). Tighten the fan cover bolts.
0216-4
TM 55-1925-273-24&P-2 ASSEMBLY - Continued 15. 16. 17. Install the grease fitting (Figure 1, Item 3) in the front end bracket (Figure 1, Item 4). Install the grease fitting (Figure 1, Item 14) in the back end bracket (Figure 1, Item 12). Install the eye bolt (Figure 1, Item 7) in the frame (Figure 1, Item 8).
0216
CAUTION
Do not apply grease through the front end or the back end grease fittings with the grease drains closed. 18. 19. Add 5 to 6 strokes of grease to grease fittings (Figure 1, Items 3 and 14) using a lubricating hand gun. Wipe any excess grease from the grease fills using a wipe rag. Apply the loctite thread sealant to the threads of the two grease drains (Figure 1, Item 19). Install and tighten the grease drains.
0216-5/6 blank
TM 55-1925-273-24&P-2 FIELD MAINTENANCE POTABLE WATER SYSTEM VALVES REPLACE
0217
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 3, WP 0344, Table 1, Item 27) Gloves, Chemical and Oil Protective (Volume 3, WP 0344, Table 1, Item 8) Gloves, Leather (Volume 3, WP 0344, Table 1, Item 9) Goggles, Industrial (Volume 3, WP 0344, Table 1, Item 10) Suitable Drain Pan Materials/Parts Rag, Wiping (Volume 3, WP 0343, Table 1, Item 132) Tape, Antiseizing; 1/2 in. (Volume 3, WP 0343, Table 1, Item 158) Personnel Required Watercraft Engineer 88L (2) References FM 4-01.502 TM 55-1925-273-10 Volume 3, WP 0319 References (cont.) Volume 3, WP 0343 Volume 3, WP 0344 Equipment Condition Set to OFF the HOT POTABLE WATER HEATER No. 1 and HOT POTABLE WATER HEATER No. 2 circuit breakers at the main switchboard. Lock out and tag out IAW FM 4-01.502. Set to OFF the POTABLE WATER PUMP No. 1 and POTABLE WATER PUMP No. 2 circuit breakers (LT 803 Only), or the LVP FOR POTABLE WATER PUMP No. 1 and the LVP FOR POTABLE WATER PUMP No. 2 circuit breakers (All Other Vessels) at 440 V power panel No. 5. Lock out and tag out IAW FM 4-01.502. Set to OFF the HOT POTABLE WATER RECIRCULATING PUMP circuit breaker (LT 803 Only), or the LVP FOR HOT POTABLE WATER RECIRCULATING PUMP circuit breaker (All Other Vessels) at 440 V power panel No. 4. Lock out and tag out IAW FM 4-01.502. CLOSE valves upstream and downstream of the affected valve. Lock out and tag out IAW FM 4-01.502.
0217-1
TM 55-1925-273-24&P-2
0217
THREADED HOSE CONNECTION VALVE REMOVAL 1. 2. Place a suitable drain pan under the valve (Figure 1, Item 1) to be removed. Slowly OPEN the valve (Figure 1, Item 1) and allow any pressure to vent and any fluid to drain into the suitable drain pan.
CAUTION
Failure to use two wrenches while loosening pipe fittings, couplings, and valves may cause damage to the valves, fittings, couplings, and piping. Always use two wrenches. 3. 4. Using the wrench method, loosen the valve (Figure 1, Item 1) from the vessel piping (Figure 1, Item 2), and allow any remaining fluid to drain. Using the two wrench method, remove the valve (Figure 1, Item 1) from the vessel piping (Figure 1, Item 2).
M1133T73
Threaded Hose Connection Valve.
0217-2
TM 55-1925-273-24&P-2 THREADED HOSE CONNECTION VALVE INSTALLATION
0217
WARNING
Removing components by means of wire brushing produces flying particles. These particles can cause serious injury to personnel. Wear protective faceshield, gloves, and long sleeves at all times during wire brushing operations. Failure to comply with this warning can result in serious injury to personnel. 1. 2. Clean the threaded ends of the piping (Figure 1, Item 2) with a wire brush. Apply antiseizing tape to the threaded ends of the piping (Figure 1, Item 2).
CAUTION
Failure to use two wrenches while tightening pipe fittings, couplings, and valves may cause damage to the valves, fittings, couplings, and piping. 3. 4. Using the two wrench method, install the valve (Figure 1, Item 1) on the vessel piping (Figure 1, Item 2). Perform the FOLLOW-ON-MAINTENANCE procedure at the end of this work package.
END OF TASK FLANGED GLOBE VALVE REMOVAL 1. 2. 3. 4. 5. 6. 7. Partially OPEN the valve (Figure 2, Item 3) to equalize any internal pressure before removing any bolts. Place a suitable drain pan under the valve (Figure 2, Item 3). Slowly loosen the bolts (Figure 2, Item 7) and nuts (Figure 2, Item 8) on the inlet side of the valve (Figure 2, Item 3), and allow any pressure to vent and any liquid to drain into the suitable drain pan. Remove the bolts (Figure 2, Item 7) and nuts (Figure 2, Item 8) from the inlet side of the valve (Figure 2, Item 3). Remove the bolts (Figure 2, Item 6) and nuts (Figure 2, Item 5) from the outlet side of the valve (Figure 2, Item 3). Remove the valve (Figure 2, Item 3) from the vessel piping (Figure 2, Item 1). Remove gaskets (Figure 2, Items 2 and 4).
0217-3
TM 55-1925-273-24&P-2 FLANGED GLOBE VALVE REMOVAL - Continued
0217
5
M1134T73
Figure 2. END OF TASK FLANGED GLOBE VALVE INSTALLATION
WARNING
Removing components by means of wire brushing produces flying particles. These particles can cause serious injury to personnel. Wear protective faceshield, gloves, and long sleeves at all times during wire brushing operations. Failure to comply with this warning can result in serious injury to personnel. 1. 2. Clean the flanges of the valve (Figure 2, Item 3) and vessel piping (Figure 2, Item 1) using a wire brush, clean wiping rags, and water. Install the valve (Figure 2, Item 3) and two gaskets (Figure 2, Items 2 and 4) to the vessel piping (Figure 2, Item 1), and secure it with the bolts (Figure 2, Items 6 and 7) and the nuts (Figure 2, Items 5 and 8). Perform the FOLLOW-ON-MAINTENANCE procedure at the end of this work package.
3.
END OF TASK
0217-4
TM 55-1925-273-24&P-2 THREADED VALVE (TYPICAL) REMOVAL 1. 2. Partially OPEN the valve (Figure 3, Item 2) to equalize any internal pressure.
0217
Place a suitable drain pan under the union (Figure 3, Item 4) of the valve (Figure 3, Item 2) to be removed.
CAUTION
Failure to use two wrenches while loosening pipe fittings, couplings, and valves may cause damage to the valves, fittings, couplings, and piping. Always use two wrenches. 3. 4. 5. Using the two wrench method, loosen the union (Figure 3, Item 4) and allow any pressure to vent and any fluid to drain into the suitable drain pan. Using the two wrench method, remove the pipe (Figure 3, Item 3) from the valve (Figure 3, Item 2). Using the two wrench method, remove the valve (Figure 3, Item 2) from the vessel piping (Figure 3, Item 1).
M1135T73
Threaded Valve (Typical).
THREADED VALVE (TYPICAL) INSTALLATION
WARNING
Removing components by means of wire brushing produces flying particles. These particles can cause serious injury to personnel. Wear protective faceshield, gloves, and long sleeves at all times during wire brushing operations. Failure to comply with this warning can result in serious injury to personnel. 1. 2. Clean the threaded ends of the piping (Figure 3, Items 1 and 3) with a wire brush. Apply antiseizing tape to the threaded end of the piping (Figure 3, Item 1 and 3).
CAUTION
Failure to use two wrenches while tightening pipe fittings, couplings, and valves may cause damage to the valves, fittings, couplings, and piping. Always use two wrenches. 3. 4. Using the two wrench method, install the valve (Figure 3, Item 2) on the vessel piping (Figure 3, Item 1). Using the two wrench method, install the pipe (Figure 3, Item 3) in the valve (Figure 3, Item 2).
0217-5
TM 55-1925-273-24&P-2 THREADED VALVE (TYPICAL) INSTALLATION - Continued 5. 6. Using the two wrench method, install the union (Figure 3, Item 4) to the pipe (Figure 3, Item 3). Perform the FOLLOW-ON-MAINTENANCE procedure at the end of this work package.
0217
END OF TASK FOLLOW-ON-MAINTENANCE 1. 2. 3. 4. 5. Remove the lock outs and tag outs IAW FM 4-01.502. Set the circuit breakers to ON. Operate the potable water system under usual conditions IAW TM 55-1925-273-10. Check the valve and connections for leakage and proper operation. Return the equipment to the desired readiness condition.
0217-6
TM 55-1925-273-24&P-2 FIELD MAINTENANCE POTABLE WATER PUMP REPAIR
0218
INITIAL SETUP: Tools and Special Tools Multimeter (Volume 3, WP 0344, Table 1, Item 15) Tool Kit, Electrical Repair (Volume 3, WP 0344, Table 1, Item 26) Suitable Drain Pan Materials/Parts N/A Personnel Required Watercraft Engineer 88L (2) References FM 4-01.502 References (cont.) TC 55-509-1 TM 55-1925-273-10 WP 0221 Volume 3, WP 0320 Volume 3, WP 0344 Equipment Condition Set to OFF the POTABLE WATER PUMP No. 1 or the POTABLE WATER PUMP No. 2 circuit breakers (LT 803 Only), or the LVP FOR POTABLE WATER PUMP No. 1 or the LVP FOR POTABLE WATER PUMP No. 2 circuit breakers (All Other Vessels) at 440 V power panel No. 5. Lock out and tag out IAW FM 4-01.502.
0218-1
TM 55-1925-273-24&P-2
0218
NOTE
Proper repair of the electrical wiring consists of replacement of the damaged wiring. When electrical casualty requires expedient repairs, repairs may be made by splicing. Splicing is authorized for repair of damaged cable, however the damaged cable must be replaced in its entirety at the most opportune time. Proper splicing methods should be performed IAW TC 55-509-1. ELECTRICAL WIRING REMOVAL
WARNING
NOTE
Electrical junction boxes may vary in size, shape, and mounting position of the box on the motor frame. Electrical junction box covers may vary in number and placement of screws holding the cover in place. 1. 2. 3. Remove the two screws (Figure 1, Item 5) from the potable water pump's electrical junction box cover (Figure 1, Item 4). Remove the junction box cover (Figure 1, Item 4) from the junction box (Figure 1, Item 2). Using a multimeter, check for voltage at the wiring terminals (Figure 1, Item 6). If voltage is present, ensure that the proper circuit breaker is set to OFF, locked out, and tagged out IAW FM 4-01.502. If no voltage is present, continue with the procedure. Label the wiring (Figure 1, Item 1) at the wiring terminals (Figure 1, Item 6) and make a sketch of the work area to permit proper assembly.
4.
0218-2
TM 55-1925-273-24&P-2 ELECTRICAL WIRING REMOVAL - Continued
0218
6 2
M1348T73
Figure 1. 5. 6. 7.
Electrical Junction Box (Typical).
At the potable water pump motor controller panel, label the wiring (Figure 2, Item 3) at the terminal (Figure 2, Item 4) and make a sketch of the work area to permit proper assembly. Remove the nut (Figure 2, Item 2) from the terminal (Figure 2, Item 4) and the stud (Figure 2, Item 1). Remove the terminal from the stud. Follow the wiring (Figure 2, Item 3) to the potable water pump's motor (Figure 1, Item 3), freeing it from the vessel's structure as required.
0218-3
TM 55-1925-273-24&P-2 ELECTRICAL WIRING REMOVAL - Continued

1 2 3
0218
M1349T73
Figure 2. Electrical Wiring To The Controller Terminal (Typical). 8. Remove the affected wire (Figure 1, Item 1) from the wiring terminals (Figure 1, Item 6).
END OF TASK ELECTRICAL WIRING INSTALLATION 1. 2. 3. Connect the wiring (Figure 2, Item 3) to the terminal (Figure 2, Item 4) using the labels and sketch from Step (5) of ELECTRICAL WIRING REMOVAL as a guide. Remove the labels. Install the nut (Figure 2, Item 2) on the stud (Figure 2, Item 1). Route the wiring (Figure 2, Item 3) to the water pump motor (Figure 1, Item 3) following the same path as the old wiring. Secure the wiring (Figure 2, Item 3) to the vessel's structure in the same manner as the old wiring assembly. Connect the wiring (Figure 1, Item 1) using the labels and sketch from Step (4) of ELECTRICAL WIRING REMOVAL as a guide. Remove the labels. Connect the wiring (Figure 1, Item 1) using the wiring terminals (Figure 1, Item 6) and remove the labels. Install the electrical junction box cover (Figure 1, Item 4) on the junction box (Figure 1, Item 2). Install the two screws (Figure 1, Item 5) in the junction box cover (Figure 1, Item 4). Perform the FOLLOW-ON MAINTENANCE procedure at the end of this work package.
4. 5. 6. 7. 8.
END OF TASK POTABLE WATER PUMP COUPLING REMOVAL 1. 2. 3. 4. Remove the electric motor (WP 0221). Remove the flange screw (Figure 3, Item 3) from the coupling (Figure 3, Item 1). Slide the coupling (Figure 3, Item 1) from the potable water pump shaft (Figure 3, Item 2). Perform the FOLLOW-ON MAINTENANCE procedure at the end of this work package.
0218-4
TM 55-1925-273-24&P-2 POTABLE WATER PUMP COUPLING REMOVAL - Continued
0218
3 2
M1350T73
Potable Water Pump.
POTABLE WATER PUMP COUPLING INSPECTION Inspect the potable water pump coupling (Figure 3, Item 1) for corrosion, deformation, and obvious damage. END OF TASK POTABLE WATER PUMP COUPLING INSTALLATION 1. 2. 3. Slide the coupling (Figure 3, Item 1) onto the potable water pump shaft (Figure 3, Item 2). Install the flange screw (Figure 3, Item 3) into the coupling (Figure 3, Item 1), and tighten. Install the electric motor (WP 0221).
END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. Remove the lock outs and tag outs IAW FM 4-01.502. Operate the potable water pump under usual conditions and check for proper operation IAW TM 55-1925-273-10. Return the equipment to the desired readiness condition.
0218-5/6 blank
TM 55-1925-273-24&P-2 FIELD MAINTENANCE POTABLE WATER PUMP, PUMP END REPLACE
0219
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 3, WP 0344, Table 1, Item 27) Materials/Parts N/A Personnel Required Watercraft Engineer 88L (1) References TM 55-1925-273-10 References (cont.) WP 0221 Volume 3, WP 0320 Volume 3, WP 0344 Equipment Condition Potable water pump and motor removed. (WP 0221)
0219-1
TM 55-1925-273-24&P-2
0219
WARNING
Never reuse locking hardware. Reuse of locking hardware such as lockwashers, locking nuts, cotter pins, and lock wire can result in undetected loosening of fastening hardware causing catastrophic component failure resulting in death, injury, or damage to equipment. Ensure that all locking hardware is discarded upon removal and replaced with new. DISASSEMBLY
NOTE
It may be necessary to rotate the motor shaft by hand to gain access to the capscrews. 1. 2. 3. Loosen, but do not remove, the two exposed capscrews (Figure 1, Item 4). Remove the four bolts (Figure 1, Item 2) and four lockwashers (Figure 1, Item 1) that secure the pump (Figure 1, Item 3) to the motor (Figure 1, Item 5). Discard lockwashers. Remove the pump (Figure 1, Item 3) from the motor (Figure 1, Item 5).
M1137T73
Figure 1. Potable Water Pump Assembly. END OF TASK
0219-2
TM 55-1925-273-24&P-2
0219
ASSEMBLY 1. 2. 3. 4. 5. Install the pump (Figure 1, Item 3) on the motor (Figure 1, Item 5) using four bolts (Figure 1, Item 2) and four lockwashers (Figure 1, Item 1). Tighten the two exposed capscrews (Figure 1, Item 4). Install the potable water pump and motor (WP 0221). Operate the potable water pump under usual conditions IAW TM 55-1925-273-10. Return the potable water pump to the desired readiness condition.
0219-3/4 blank
TM 55-1925-273-24&P-2 FIELD MAINTENANCE POTABLE WATER PUMP, PUMP END REPAIR
0220
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 3, WP 0344, Table 1, Item 27) Drill, Electric, Portable (Volume 3, WP 0344, Table 1, Item 4) Drill Set, Twist (Volume 3, WP 0344, Table 1, Item 2) Drill Set, Twist (Volume 3, WP 0344, Table 1, Item 3) Faceshield, Industrial (Volume 3, WP 0344, Table 1, Item 5) Gloves, Chemical and Oil Protective (Volume 3, WP 0344, Table 1, Item 8) Gloves, Leather (Volume 3, WP 0344, Table 1, Item 9) Goggles, Industrial (Volume 3, WP 0344, Table 1, Item 10) Press, Arbor, Hand Operated (Volume 3, WP 0344, Table 1, Item 16) Suitable Drain Pan Suitably Sized Lathe Threading Set, Screw (Volume 3, WP 0344, Table 1, Item 24) Materials/Parts Cleaning Compound, Solvent (Volume 3, WP 0343, Table 1, Item 37) Materials/Parts (cont.) Grease, Ball and Roller Bearing; 1.75 lb (Volume 3, WP 0343, Table 1, Item 74) Rag, Wiping (Volume 3, WP 0343, Table 1, Item 132) Gasket (Casing Gasket) (Volume 3, WP 0320, Figure 72, Item 6) Qty: 1 Ring, Wearing (Front Plate Wear Ring) (Volume 3, WP 0320, Figure 72, Item 3) Qty: 1 Personnel Required Watercraft Engineer 88L (1) References FM 4-01.502 TC 9-524 TM 55-1925-273-10 WP 0219 Volume 3, WP 0320 Volume 3, WP 0343 Volume 3, WP 0344 Equipment Condition Potable water pump removed. (WP 0219)
0220-1
TM 55-1925-273-24&P-2
0220
DISASSEMBLY
NOTE
Disassemble the potable water pump only as far as required to perform the maintenance work needed. 1. Drain the potable water pump. Flush with clean water if necessary.
WARNING
Cleaning solvent is flammable and its vapor is potentially explosive. Do not use cleaning solvent in the vicinity of spark, open flame, or excessive heat. Do not use cleaning solvent in unventilated spaces. Always wear chemical protective gloves and goggles when handling hydraulic fluid, engine oil, and cleaning solvents. Failure to comply with this warning can result in serious injury or death. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. Using a cleaning solvent, clean exterior surfaces of the unit. Inspect all component parts for unusual wear or damage, and replace as required. Remove the drain plug (Figure 1, Item 14) from the volute (Figure 1, Item 7). Remove the capscrews (Figure 1, Item 17) securing the backplate (Figure 1, Item 3) to the volute (Figure 1, Item 7). Separate the volute from the backplate. Remove the casing gasket (Figure 1, Item 15) from the volute (Figure 1, Item 7). Discard gasket. Remove the front plate wear ring (Figure 1, Item 6) from the volute (Figure 1, Item 7). Discard front plate wear ring. Remove the impeller screw (Figure 1, Item 10) and the impeller washer (Figure 1, Item 9). Remove the impeller (Figure 1, Item 5) from the shaft (Figure 1, Item 11). Remove the key (Figure 1, Item 8) from the impeller. Remove the capscrews (Figure 1, Item 18) securing the backplate (Figure 1, Item 3) to the bracket (Figure 1, Item 19). Separate the backplate from the bracket. Remove the backplate gasket (Figure 1, Item 16) from the backplate (Figure 1, Item 3). Remove the rear case wear ring (Figure 1, Item 4) from the backplate (Figure 1, Item 3). Remove the snap ring (Figure 1, Item 12) from the shaft (Figure 1, Item 11). Remove the mechanical seal (Figure 1, Item 1) from shaft (Figure 1, Item 11). Remove the sleeve (Figure 1, Item 13) from the shaft (Figure 1, Item 11).
NOTE
Do not remove the bracket or slinger from the motor. 15. Remove the stuffing box plug (Figure 1, Item 2) from the bracket (Figure 1, Item 19).
0220-2

1 2 3 4
0220
6 7 8 9 10
11 12
13
14
19
18
17
16
15
M1351T73
Figure 1. END OF TASK ASSEMBLY
Potable Water Pump Disassembly.
WARNING
Cleaning solvent is flammable and its vapor is potentially explosive. Do not use cleaning solvent in the vicinity of spark, open flame, or excessive heat. Do not use cleaning solvent in unventilated spaces. Always wear chemical protective gloves and goggles when handling hydraulic fluid, engine oil, and cleaning solvents. Failure to comply with this warning can result in serious injury or death. 1. 2. Using cleaning solvent, clean the disassembled parts of the unit before assembly. Install the stuffing box plug (Figure 1, Item 2) in the bracket (Figure 1, Item 19).
0220-3
TM 55-1925-273-24&P-2 ASSEMBLY - Continued 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. Install the shaft sleeve (Figure 1, Item 13) over the shaft (Figure 1, Item 11). Install the mechanical seal (Figure 1, Item 1) on the shaft (Figure 1, Item 11). Install the snap ring (Figure 1, Item 12) on the shaft (Figure 1, Item 11). Install the rear case wear ring (Figure 1, Item 4) on the backplate (Figure 1, Item 3). Install the backplate gasket (Figure 1, Item 16) on the bracket (Figure 1, Item 19). Install the capscrews (Figure 1, Item 18) into the backplate (Figure 1, Item 3). Tighten the capscrews.
0220
Install the key (Figure 1, Item 18) into the impeller (Figure 1, Item 5). Install the impeller (Figure 1, Item 5) on the shaft (Figure 1, Item 11). Install the impeller washer (Figure 1, Item 9) and the impeller screw (Figure 1, Item 10) to secure the impeller. Tighten the impeller screw. Install the front plate wear ring (Figure 1, Item 6) on the volute (Figure 1, Item 7). Install the casing gasket (Figure 1, Item 15) on the volute (Figure 1, Item 7). Lower the volute over the backplate (Figure 1, Item 3). Install the capscrews (Figure 1, Item 17) securing the volute (Figure 1, Item 7) to the bracket (Figure 1, Item 2). Tighten the capscrews. Install the drain plugs (Figure 1, Item 14) in the volute (Figure 1, Item 7). Tighten the drain plugs. Install the potable water pump (WP 0219). Remove the lock outs and tag outs IAW FM 4-01.502. Operate the potable water pump under usual conditions IAW TM 55-1925-273-10 and check for leakage and proper operation. Return the equipment to the desired readiness condition.
END OF TASK THREAD REPAIR Damaged female threads may be replaced by installing thread inserts. The procedure below describes this process.
NOTE
The size of the holes drilled and tapped will vary depending upon the size of the insert used. 1. 2. 3. Select the proper size thread insert. The proper size thread insert should have the same size female threads as the fastener that will thread into it. Measure the external thread size and pitch of the thread insert selected in Step (1) above. Select the tap that corresponds to the external thread size and pitch of the insert selected in Step (1) above. Also select the proper size drill bit (Figure 2, Item 1) for use with the tap.
0220-4
TM 55-1925-273-24&P-2 THREAD REPAIR - Continued
0220
WARNING
Drilling operations produce high velocity flying debris which can become lodged in skin or in the eyes. All personnel working in the area must wear protective eyewear, gloves, and long sleeves when performing grinding, needling, and chipping operations. Failure to comply with this warning can result in serious injury or death to personnel. 4. Drill out the damaged threads (Figure 2, Item 2) using the drill bit (Figure 2, Item 1) selected in Step (3) above. Chamfer the hole with a standard countersink (82 to 100 degrees).
2
Figure 2. 5.
M1352T73
Removing Old Threads.
Tap threads in the hole using the tap (Figure 3, Item 1) selected in Step (3) above.
1
M1353T73
Figure 3. 6.
Tapping New Threads.
Thread the insert (Figure 4, Item 2) into the threads until top of the insert is slightly below the surface.
0220-5

1
0220
M1354T73
Figure 4. 7.
Installing the Insert.
Drive down the keys (Figure 4, Item 1 and Figure 5, Item 3) using the insert's installation tool (Figure 5, Item 1) or a round, flat driver. The keys should be flush with the surface (Figure 5, Item 2).
1
M1355T73
Figure 5. 8.
Drive Down the Keys.
Thread a fastener of the desired thread size and pitch into the insert to ensure that the insert is installed properly.
END OF TASK MACHINING REPAIRS Due to replacement part availability, expediency of repair, and other factors, it may sometimes be necessary to repair existing pump components rather than replacing them. For example, a pump shaft may be worn in the seal area, but otherwise serviceable. If a new pump shaft is unavailable, or if the unit must be returned to service with minimal down time, it may be possible to build up and remachine the worn shaft area. The same holds true for volutes, housings, and impeller wear ring seats. Always confer with the work center supervisor before performing machining repairs to determine the proper course of action and to determine the feasibility of repair. No matter what form of machining repairs will be accomplished, ensure that the repairs conform to standard machine shop practices and procedures and all applicable regulations.
0220-6
TM 55-1925-273-24&P-2 MACHINING REPAIRS - Continued Machining 1. Chuck the impeller (Figure 6, Item 2) in a suitably sized lathe (Figure 6, Item 1).
0220
WARNING
Use extreme caution when working around rotating impeller and shaft. Do not wear loose clothing, jewelry, or anything else which might become entangled in the shaft or parts of the lathe that spin. Wear protective eyewear. Failure to comply with these precautions can cause serious injury or death.
CAUTION
Take care not to remove any material from the impeller itself during the machining operation. 2. 3. 4. 5. Machine away the wear ring (Figure 6, Item 3) until its thickness is approximately 0.030 in. (0.762 mm). With the impeller (Figure 6, Item 2) still chucked in the lathe (Figure 6, Item 1), use a cape chisel to gently cut one side of the impeller wear ring (Figure 6, Item 3), taking care not to gouge the impeller in the process. Remove the wear ring (Figure 6, Item 3) from the impeller (Figure 6, Item 2). Carefully inspect the seat area for the wear ring (Figure 6, Item 3). If the area is damaged, build up the damaged area and remachine using standard shop practices IAW TC 9-524. Use the wear ring to gage the outside diameter of the impeller (Figure 6, Item 2). The wear ring should be a light press fit (0.003 to 0.005 in. [0.0762 to 0.1270 mm] interference). Once the wear ring(s) (Figure 6, Item 3) is removed, remove the impeller (Figure 6, Item 2) from the lathe (Figure 6, Item 1). Install wear rings (Figure 6, Item 3) onto the impeller (Figure 6, Item 2) using an arbor press and refer to the ASSEMBLY procedure in this work package to install the impeller into the pump.
6. 7.
0220-7
TM 55-1925-273-24&P-2 MACHINING REPAIRS - Continued Machining - Continued

1 2 3
0220
M1356T73
Figure 6. Typical Impeller Machining. END OF TASK END OF WORK PACKAGE
0220-8
TM 55-1925-273-24&P-2 FIELD MAINTENANCE POTABLE WATER PUMP ELECTRIC MOTOR REPLACE
0221
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 3, WP 0344, Table 1, Item 27) Gloves, Leather (Volume 3, WP 0344, Table 1, Item 9) Goggles, Industrial (Volume 3, WP 0344, Table 1, Item 10) Multimeter (Volume 3, WP 0344, Table 1, Item 15) Tool Kit, Electrical Repair (Volume 3, WP 0344, Table 1, Item 26) Materials/Parts Tape, Antiseizing; 1/2 in. (Volume 3, WP 0343, Table 1, Item 158) Personnel Required Watercraft Engineer 88L (2) References FM 4-01.502 TM 55-1925-273-10 WP 0219 Volume 3, WP 0321 References (cont.) Volume 3, WP 0343 Volume 3, WP 0344 Equipment Condition For potable water pump No. 1, set to OFF the POTABLE WATER PUMP No. 1. circuit breaker (LT 803 Only), or the LVP FOR POTABLE WATER PUMP No. 1 circuit breaker (All Other Vessels) in 440 V power panel No 5. Lock out and tag out IAW FM 4-01.502. For potable water pump No. 2, set to OFF the POTABLE WATER PUMP No. 2. circuit breaker (LT 803 Only), or the LVP FOR POTABLE WATER PUMP No. 2 circuit breaker (All Other Vessels) in 440 V power panel No. 5. Lock out and tag out IAW FM 4.01-502. For potable water pump No. 1, CLOSE valves PW-16 C.O.V.-POT. WTR. PMP. No. 1 SUCT and PW-76 C.O.V.POT. WTR. PMP. No. 1 DISCH. Lock out and tag out IAW FM 4-01.502. For potable water pump No. 2, CLOSE valves PW-17 C.O.V-POT. WTR. PMP. No. 2 SUCT and PW-77 C.O.V. POT. WTR. PMP. No. 2 DISCH. Lock out and tag out IAW FM 4-01.502.
0221-1
TM 55-1925-273-24&P-2
0221
WARNING
Never reuse locking hardware. Reuse of locking hardware such as lockwashers, locking nuts, cotter pins, and lock wire can result in undetected loosening of fastening hardware causing catastrophic component failure resulting in death, injury, or damage to equipment. Ensure that all locking hardware is discarded upon removal and replaced with new. POTABLE WATER PUMP AND MOTOR ASSEMBLY REMOVAL 1. Remove the four screws (Figure 1, Item 3) and remove the junction box cover (Figure 1, Item 4) from the junction box (Figure 1, Item 1).
WARNING
Replace or repair components only after the affected circuit has been secured, locked out, and tagged out IAW FM 4-01.502. Performing replacement with the circuit energized may result in injury. 2. Use a multimeter to check for voltage at the wiring (Figure 1, Item 2). If voltage is present, ensure that the proper circuit breaker is secured, locked out, and tagged out IAW FM 4-01.502. If no voltage is present, continue with the procedure. Label, disconnect, and remove the wiring (Figure 1, Item 2) from the junction box (Figure 1, Item 1).
3.
M1138T73
Figure 1. Potable Water Pump Motor and Junction Box.
CAUTION
Never attempt to disconnect union connections with only one wrench. Damage to the vessel's standing piping could occur. Always use the two wrench method to disconnect piping unions.
0221-2
TM 55-1925-273-24&P-2 POTABLE WATER PUMP AND MOTOR ASSEMBLY REMOVAL - Continued 4. 5. 6. 7. 8.
0221
Disconnect the inlet union (Figure 2, Item 9) and outlet union (Figure 2, Item 10) from the potable water pump (Figure 2, Item 7) using the two wrench method. Remove the four bolts (Figure 2, Item 5), four nuts (Figure 2, Item 2), and four lockwashers (Figure 2, Item 3) that secure the motor (Figure 2, Item 4) to the mounting plate (Figure 2, Item 6). Discard lockwashers. Remove the entire potable water pump (Figure 2, Item 7) and attached motor (Figure 2, Item 4) to a suitable work area. Disconnect the inlet fitting (Figure 2, Item 8) and outlet fitting (Figure 2, Item 1) from the potable water pump (Figure 2, Item 7). Remove the potable water pump (Figure 2, Item 7) from the motor (Figure 2, Item 4) (WP 0219).
2 3 1
10
7
M1139T73
Potable Water Pump, Fittings, and Fasteners.
0221-3
TM 55-1925-273-24&P-2
0221
POTABLE WATER PUMP AND MOTOR ASSEMBLY INSTALLATION
WARNING
Removing components by means of wire brushing produces flying particles. These particles can cause serious injury to personnel. Wear protective faceshield, gloves, and long sleeves at all times during wire brushing operations. Failure to comply with this warning can result in serious injury to personnel. 1. 2. 3. 4. 5. Clean the male pipe threads of the inlet fitting (Figure 2, Item 8) and outlet fitting (Figure 2, Item 1) with a wire brush. Wrap the male pipe threads of the inlet fitting (Figure 2, Item 8) and outlet fitting (Figure 2, Item 1) with antiseizing tape. Install the inlet fitting (Figure 2, Item 8) and outlet fitting (Figure 2, Item 1) in the potable water pump (Figure 2, Item 7). Install the potable water pump (Figure 2, Item 7) on the motor (Figure 2, Item 4) (WP 0219). Position the potable water pump (Figure 2, Item 7) and attached motor (Figure 2, Item 4) on the mounting plate (Figure 2, Item 6).
CAUTION
Never attempt to connect union connections with only one wrench. Damage to the vessel's standing piping could occur. Always use two wrenches. 6. 7. Tighten the inlet union (Figure 2, Item 9) and outlet union (Figure 2, Item 10) on the pump (Figure 2, Item 7) using the two wrench method. Secure the potable water pump (Figure 2, Item 7) and attached motor (Figure 2, Item 4) to the mounting plate (Figure 2, Item 6) with the four bolts (Figure 2, Item 5), four nuts (Figure 2, Item 2), and four lockwashers (Figure 2, Item 3). Install and connect the wiring (Figure 1, Item 2) in the junction box (Figure 1, Item 1), using the labels from Step (3) of POTABLE WATER PUMP AND MOTOR ASSEMBLY REMOVAL as a guide. Remove the labels. Remove the lock outs and tag outs IAW FM 4-01.502. Operate the potable water pump under usual conditions IAW TM 55-1925-273-10. Check for leaks and proper operation. Return the potable water pump to the desired readiness condition.
8. 9. 10. 11. 12.
0221-4
TM 55-1925-273-24&P-2 FIELD MAINTENANCE HYDROPNEUMATIC TANK REPLACE
0222
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 3, WP 0344, Table 1, Item 27) Faceshield, Industrial (Volume 3, WP 0344, Table 1, Item 5) Gloves, Chemical and Oil Protective (Volume 3, WP 0344, Table 1, Item 8) Gloves, Leather (Volume 3, WP 0344, Table 1, Item 9) Goggles, Industrial (Volume 3, WP 0344, Table 1, Item 10) Suitable Drain Pan Materials/Parts Cleaning Compound, Solvent (Volume 3, WP 0343, Table 1, Item 37) Rag, Wiping (Volume 3, WP 0343, Table 1, Item 132) Tape, Antiseizing; 1/2 in. (Volume 3, WP 0343, Table 1, Item 158) Personnel Required Watercraft Engineer 88L (2) References FM 4-01.502 MIL-STD-769 S9086-VH-STM-010/CH-635 TM 55-1925-273-10 WP 0223 Volume 3, WP 0322 References (cont.) Volume 3, WP 0343 Volume 3, WP 0344 Equipment Condition Set to OFF the HOT POTABLE WTR HTR NO. 1 and HOT POTABLE WTR HTR NO. 2 circuit breakers at the main switchboard. Lock out and tag out IAW FM 4-01.502. Set to OFF the POTABLE WATER PUMP No. 1 and POTABLE WATER PUMP No. 2 circuit breakers (LT 803 Only), or the LVP FOR POTABLE WATER PUMP No. 1 and LVP FOR POTABLE WATER PUMP No. 2 circuit breakers (All Other Vessels) at 440 V power panel No. 5. Lock out and tag out IAW FM 4-01.502. Set to OFF the HOT POTABLE WATER RECIRCULATING PUMP. circuit breaker (LT 803 Only), or the LVP FOR HOT POTABLE WATER RECIRCULATING PUMP circuit breaker (All Other Vessels) at 440 V power panel No. 4. Lock out and tag out IAW FM 4-01.502. CLOSE valves PW-78, C.O.V. HYDR. PNEU TK. OUTLET.; PW-76, C.O.V. POT. WTR. PMP. No. 1 DISCH.; and PW-77, C.O.V. POT. WTR. PMP. No. 2 DISCH.. Lock out and tag out IAW FM 4-01.502. Both pressure switches removed. (WP 0223)
0222-1
TM 55-1925-273-24&P-2
0222
HYDROPNEUMATIC TANK REMOVAL
WARNING
Potable hoses and lines may be under pressure. Relieve pressure by operating the appropriate control valve, if possible. Loosen fittings on hoses and lines slowly. Allow the fluid to run around threads of the fitting or flange, releasing pressure before disconnecting fitting or flange. Releasing pressurized fluid suddenly may cause severe personal injury or death. 1. 2. 3. 4. 5. Remove the four bolts (Figure 1, Item 9) and the four nuts (Figure 1, Item 10) securing the vessel piping flange (Figure 1, Item 4) to the hydropneumatic tank flange (Figure 1, Item 5). Remove gasket (Figure 1, Item 6). Remove the air charge valve (Figure 1, Item 1) from the piping (Figure 1, Item 2). Remove the eight bolts (Figure 1, Item 8) and eight washers (Figure 1, Item 7) securing the hydropneumatic tank (Figure 1, Item 3) to its foundation. Plug or cap all open piping.
WARNING
Insulation is a skin and eye irritant. Wear goggles to protect eyes. Wearing loose-fitting, longsleeved, and long-legged clothing is recommended to prevent skin irritation. Wearing gloves is also recommended. Skin irritation cannot occur if there is no direct contact between insulation and skin. Failure to comply with this warning can result in serious injury or death. 6. 7. Remove all insulation from the hydropneumatic tank (Figure 1, Item 3). Discard insulation. Remove the hydropneumatic tank (Figure 1, Item 3).
END OF TASK HYDROPNEUMATIC TANK INSTALLATION
WARNING
Cleaning solvent is flammable and its vapor is potentially explosive. Do not use cleaning solvent in the vicinity of spark, open flame, or excessive heat. Do not use cleaning solvent in unventilated spaces. Failure to comply can result in serious injury or death. Removing components by means of wire brushing produces flying particles. These particles can cause serious injury to personnel. Wear protective faceshield, gloves, and long sleeves at all times during wire brushing operations. Failure to comply with this warning can result in serious injury to personnel. 1. 2. Using a wire brush and cleaning solvent, clean the vessel piping flange (Figure 1, Item 4). Install the hydropneumatic tank (Figure 1, Item 3) on its foundation.
0222-2
TM 55-1925-273-24&P-2 HYDROPNEUMATIC TANK INSTALLATION - Continued 3. 4. 5.
0222
Secure the hydropneumatic tank (Figure 1, Item 3) to its foundation with the eight bolts (Figure 1, Item 8) and the eight washers (Figure 1, Item 7). Install a gasket (Figure 1, Item 6) between the vessel flange (Figure 1, Item 4) and the hydropneumatic tank flange (Figure 1, Item 5). Secure the vessel flange (Figure 1, Item 4) and the hydropneumatic tank flange (Figure 1, Item 5) with the four bolts (Figure 1, Item 9) and the four nuts (Figure 1, Item 10).
WARNING
Removing components by means of wire brushing produces flying particles. These particles can cause serious injury to personnel. Wear protective faceshield, gloves, and long sleeves at all times during wire brushing operations. Failure to comply with this warning can result in serious injury to personnel. 6. 7. 8. 9. 10. 11. Clean the female pipe threads of the air charge valve (Figure 1, Item 1) and the male pipe threads of the piping (Figure 1, Item 2) using a wire brush. Apply antiseizing tape to the male threads of the piping (Figure 1, Item 2). Install the air charge valve (Figure 1, Item 1) on the pipe (Figure 1, Item 2). Install the pressure switches (WP 0223). Install the pressure gage and the sight glass. Refer to MIL-STD-769 and S9086-VH-STM-010/CH-635 for insulation replacement.
0222-3
TM 55-1925-273-24&P-2 HYDROPNEUMATIC TANK INSTALLATION - Continued
0222
2 3
9, 10 4, 5, 6 8
7
M1357T73
Figure 1. Hydropneumatic Tank. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. 4. Remove the lock outs and tag outs IAW FM 4-01.502. Pressurize the hydropneumatic tank (WP 0223). Observe the hydropneumatic tank and its connections, ensuring proper operation and checking for leakage. Return the equipment to the desired readiness condition.
0222-4
TM 55-1925-273-24&P-2 FIELD MAINTENANCE HYDROPNEUMATIC TANK PRESSURE SWITCH REPLACE
0223
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 3, WP 0344, Table 1, Item 27) Multimeter (Volume 3, WP 0344, Table 1, Item 15) Materials/Parts Rag, Wiping (Volume 3, WP 0343, Table 1, Item 132) Tape, Antiseizing; 1/2 in. (Volume 3, WP 0343, Table 1, Item 158) Personnel Required Watercraft Engineer 88L (2) References FM 4.01-502 TM 55-1925-273-10 Volume 3, WP 0323 References (cont.) Volume 3, WP 0343 Volume 3, WP 0344 Equipment Condition Set to OFF the POTABLE WATER PUMP No. 2. and POTABLE WATER PUMP No. 1. circuit breakers (LT 803 Only), or the LVP FOR POTABLE WATER PUMP No. 1 and the LVP FOR POTABLE WATER PUMP No. 2 circuit breakers (All Other Vessels) in 440 V power panel No. 5. Lock out and tag out IAW FM 4-01.502. Set to OFF the HOT POTABLE WATER RECIRCULATING PUMP. circuit breaker (LT 803 Only), or the LVP FOR HOT POTABLE WATER RECIRCULATING PUMP circuit breaker (All Other Vessels) in 440 V power panel No. 4. Lock out and tag out IAW FM 4-01.502. CLOSE valve PW-18, HYDRO. PNEU TK INLET and PW-78, C.O.V. HYDR. PNEU TK. OUTLET. Lock out and tag out IAW FM 4-01.502.
0223-1
TM 55-1925-273-24&P-2
0223
REMOVAL 1. 2. OPEN the hydropneumatic tank air charging connection valve (Figure 1, Item 6) to relieve the pressure in the hydropneumatic tank (Figure 1, Item 7). Remove the four screws (Figure 1, Item 1) from the pressure switch cover (Figure 1, Item 2).
WARNING
Replace or repair components only after the affected circuit has been secured, locked out, and tagged out IAW FM 4-01.502. Performing replacement with the circuit energized may result in injury. 3. Using a multimeter, check for voltage at the pressure switch terminals (Figure 1, Item 3). If voltage is present, check that the proper circuit breaker is locked out and tagged out FM 4-01.502. If no voltage is present, continue with the procedure. Label and disconnect the wiring (Figure 1, Item 4) from the pressure switch (Figure 1, Item 5). Remove the pressure switch (Figure 1, Item 5) from the hydropneumatic tank (Figure 1, Item 7).
4. 5.
END OF TASK INSTALLATION 1. 2. 3. 4. Place antiseizing tape on the male threads of the hydropneumatic tank (Figure 1, Item 7) pressure switch connection. Install the pressure switch (Figure 1, Item 5) on the hydropneumatic tank (Figure 1, Item 7). Connect the wiring (Figure 1, Item 4) to the pressure switch (Figure 1, Item 5) using the labels from Step (4) of REMOVAL as a guide. Remove the labels. Pressurize the hydropneumatic tank by performing the following actions: a. b. c. d. e. f. Verify that the hydropneumatic tank vent valve (Figure 1, Item 8) is CLOSED. Connect the end of the charging air hose to the air charging connection valve (Figure 1, Item 6) on the hydropneumatic tank. OPEN the air tool connection valve to supply compressed air to the pressure hose. OPEN the air charging connection valve (Figure 1, Item 6) and pressurize the hydropneumatic tank (Figure 1, Item 7). When the hydropneumatic pressure gage (Figure 1, Item 9) indicates approximately 60 PSI (4.14 bar), CLOSE the air charging connection valve (Figure 1, Item 6). CLOSE the air tool connection valve and disconnect the air hose from the hydropneumatic tank (Figure 1, Item 7).
0223-2
0223
5 3
1T 2L L2 1L T2 T1 L1
6
25 30 35 20 15 10 5 0 60 40 45 50 55
M1140T73
Figure 1. Hydropneumatic Tank Pressure Switch. END OF TASK
0223-3
2T
TM 55-1925-273-24&P-2
0223
FOLLOW-ON MAINTENANCE 1. 2. 3. Remove the lock outs and tag outs IAW FM 4-01.502. Operate the potable water system under usual conditions IAW TM 55-1925-273-10 and check that the potable water pumps cycle on and off in response to the system demands. Return the hydropneumatic tank to the desired readiness condition.
0223-4
TM 55-1925-273-24&P-2 FIELD MAINTENANCE PROPORTIONING BROMIDE FEEDER SYSTEM TEST
0224
INITIAL SETUP: Tools and Special Tools Water Sampling Test Kit, PH (Volume 3, WP 0344, Table 1, Item 31) Materials/Parts N/A Personnel Required Watercraft Engineer 88L (1) References TM 55-1925-273-10 References (cont.) WP 0225 WP 0226 Volume 3, WP 0324 Volume 3, WP 0344 Equipment Condition N/A
0224-1
TM 55-1925-273-24&P-2
0224
TEST
NOTE
Conduct this test routinely, and in conjunction with (WP 0225), after the bromide feed cartridge is replaced. 1. 2. 3. Press the air-bleeder button (Figure 1, Item 1) to bleed all air out of the canister. Operate the potable water system under usual conditions IAW TM 55-1925-273-10. OPEN the following valves: a. b. 4. PW-38, BROMINATOR OUTLET (Figure 1, Item 4) PW-37, BROMINATOR INLET (Figure 1, Item 3)
Verify that valve PW-36, BYPASS-BROMINATOR (Figure 1, Item 2) is CLOSED.
1 3
M1141T73
Figure 1.
Brominator.
0224-2
TM 55-1925-273-24&P-2 TEST - Continued 5. 6. 7. 8. 9.
0224
Check that the CARTRIDGE CHANGE indicator light (Figure 2, Item 2) is not illuminated, and that the cartridge change indicator meter (Figure 2, Item 1) is operating. Draw a sample of water from the test tap (Figure 2, Item 3). Insert a strip of test paper into the water sample. Remove the strip of test paper from the water sample and compare its color against the chart contained in the test kit. If the bromine level is below acceptable limits, as determined by the chief engineer, repair the brominator (WP 0226). If the bromine level is above acceptable limits, notify the chief engineer, who will determine the proper course for corrective action.
M1142T73
Figure 2. Brominator Cartridge Change Indicator. END OF TASK END OF WORK PACKAGE
0224-3/4 blank
TM 55-1925-273-24&P-2 FIELD MAINTENANCE PROPORTIONING BROMIDE FEEDER REPLACE
0225
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 3, WP 0344, Table 1, Item 27) Faceshield, Industrial (Volume 3, WP 0344, Table 1, Item 5) Gloves, Leather (Volume 3, WP 0344, Table 1, Item 9) Multimeter (Volume 3, WP 0344, Table 1, Item 15) Suitable Drain Pan Materials/Parts Rag, Wiping (Volume 3, WP 0343, Table 1, Item 132) Gasket (Volume 3, WP 0324, Figure 76, Item 14) Qty: 3 Personnel Required Watercraft Engineer 88L (2) References FM 4-01.502 References (cont.) TM 55-1925-273-10 WP 0224 Volume 3, WP 0324 Volume 3, WP 0343 Volume 3, WP 0344 Equipment Condition Set to OFF the BROMINATOR. circuit breaker in 120 V emergency distribution panel No. 1. Lock out and tag out IAW FM 4-01.502. OPEN valve PW-36, BYPASS-BROMINATOR. CLOSE valves PW-37, BROMINATOR INLET, and PW-38, BROMINATOR OUTLET. Lock out and tag out IAW FM 4-01.502.
0225-1
TM 55-1925-273-24&P-2
0225
WARNING
Never reuse locking hardware. Reuse of locking hardware such as lockwashers, locking nuts, cotter pins, and lock wire can result in undetected loosening of fastening hardware causing catastrophic component failure resulting in death, injury, or damage to equipment. Ensure that all locking hardware is discarded upon removal and replaced with new. BROMINE FEEDER CARTRIDGE REMOVAL 1. Place the suitable drain pan under the test tap (Figure 1, Item 13), and OPEN the test tap.
0225-2
TM 55-1925-273-24&P-2 BROMINE FEEDER CARTRIDGE REMOVAL - Continued
0225
2, 3 1 4
5, 6 24
22, 23
8 21
10
11 20 12 13 14, 15 16 17, 18
19
M1143T73
Figure 1. Cartridge Change Indicator/Brominator.
0225-3
TM 55-1925-273-24&P-2 BROMINE FEEDER CARTRIDGE REMOVAL - Continued 2. 3. 4. 5.
0225
Press the AIR-BLEEDER button (Figure 2, Item 1) on the feeder vessel (Figure 2, Item 13) and allow the water to drain. Loosen the T-nut (Figure 2, Item 3) and remove the lid retaining clamp (Figure 2, Item 15). Remove the lid (Figure 2, Item 2) and discard gasket (Figure 2, Item 14). Remove the bromine feeder cartridge (Figure 2, Item 4) and allow the water to drain from the cartridge.
CAUTION
Do not press the TIME TOTALIZER button to reset the number dials unless a cartridge is being installed, or damage could occur to the brominator. 6. Place the bromine feeder cartridge (Figure 2, Item 4) in a suitable container, mark the container "PARTIALLY EXHAUSTED CARTRIDGE," and record the date.
1 2 3 4 5
15 14 13 12
11 6
10 9
7 8
M1144T73
Figure 2. Brominator Feeder Assembly. 7. Using clean potable water, clean all the removed metal parts. Inspect all component parts for unusual wear or damage, and replace as required.
END OF TASK
0225-4
TM 55-1925-273-24&P-2
0225
BROMINE FEEDER CARTRIDGE INSTALLATION
CAUTION
Press the TIME TOTALIZER button to reset the time dial to zero only if a bromine feeder cartridge is being installed, or damage could occur to the brominator. 1. 2. 3. 4. Install the bromine feeder cartridge (Figure 2, Item 4) in feeder vessel (Figure 2, Item 13). Install gasket (Figure 2, Item 14) on the lid (Figure 2, Item 2) and install the lid. Install the lid retaining clamp (Figure 2, Item 15) and secure it with the T-nut (Figure 2, Item 3). Perform the FOLLOW-ON MAINTENANCE procedure at the end of this work package.
END OF TASK CARTRIDGE CHANGE INDICATOR/BROMINATOR ASSEMBLY REMOVAL 1. 2. 3. Place the suitable drain pan under the test tap (Figure 1, Item 13), and OPEN the test tap. Press the AIR-BLEEDER button (Figure 2, Item 1) on the feeder vessel (Figure 2, Item 13) and allow the water to drain. Remove the two screws (Figure 1, Item 22) and two washers (Figure 1, Item 23), and OPEN the cartridge change indicator cover (Figure 1, Item 21).
WARNING
Replace or repair components only after the affected circuit has been secured, locked out, and tagged out IAW FM 4-01.502. Performing replacement with the circuit energized may result in injury. 4. Using a multimeter, check for voltage at the wiring terminals. If voltage is present, ensure that the proper circuit breaker is set to OFF, locked out, and tagged out IAW FM 4.01-502. If no voltage is present, continue with the procedure. Label and disconnect the electrical wiring (Figure 1, Item 19). Loosen the screw on the strain relief (Figure 1, Item 12) and remove the wiring from the cartridge change indicator (Figure 1, Item 7). Loosen the two hose clamps (Figure 1, Items 8 and 11) and disconnect the hoses (Figure 1, Items 9 and 10). Drain the fluid from the hoses into the suitable drain pan. Remove the four bolts (Figure 1, Item 2), four flat washers (Figure 1, Item 3), four lockwashers (Figure 1, Item 5), and four nuts (Figure 1, Item 6) from the brominator inlet flange (Figure 1, Item 16). Discard lockwashers. Remove the four bolts (Figure 1, Item 17), four flat washers (Figure 1, Item 18), four lockwashers (Figure 1, Item 14), and four nuts (Figure 1, Item 15) from the brominator outlet flange (Figure 1, Item 20). Discard lockwashers. Remove the brominator assembly (Figure 1, Item 24) from the vessel's piping and discard gaskets (Figure 1, Items 4 and 16).
5. 6. 7. 8.
9.
10.
END OF TASK
0225-5
TM 55-1925-273-24&P-2 CARTRIDGE CHANGE INDICATOR/BROMINATOR ASSEMBLY INSTALLATION
0225
WARNING
Wire brushing operations can produce high velocity flying debris which can become lodged in the skin or in the eyes. Wire brushing in confined areas can result in debris flying from unexpected directions. All personnel working in the area must wear protective faceshield, gloves, and long sleeves when performing wire brushing operations. Failure to comply with this warning can result in serious injury or death to personnel. 1. 2. Use a wire brush and clean potable water to clean the inlet flange (Figure 1, Item 1) and the outlet flange (Figure 1, Item 20) flat surfaces. Install the brominator (Figure 1, Item 24) and gaskets (Figure 1, Items 4 and 16) and secure it with the eight bolts (Figure 1, Items 2 and 17), eight flat washers (Figure 1, Items 3 and 18), eight lockwashers (Figure 1, Items 5 and 14), and eight nuts (Figure 1, Items 6 and 15). Install the hoses (Figure 1, Items 9 and 10) on the brominator (Figure 1, Item 24), and secure in place with the hose clamps (Figure 1, Items 8 and 11). Install the wiring (Figure 1, Item 19) through the strain relief (Figure 1, Item 12) and into the cartridge change indicator (Figure 1, Item 7) using the labels from Step (5) of CARTRIDGE CHANGE INDICATOR/ BROMINATOR ASSEMBLY REMOVAL as a guide. Remove the labels. Tighten the screw on the strain relief (Figure 1, Item 12). Install the cartridge change indicator cover (Figure 1, Item 21) and secure it with the two screws (Figure 1, Item 22) and the two washers (Figure 1, Item 23). Perform the FOLLOW-ON MAINTENANCE procedure at the end of this work package.
3. 4.
5. 6. 7.
END OF TASK FEEDER ASSEMBLY REMOVAL 1. 2. 3. 4. 5. 6. Place the suitable drain pan under the test tap (Figure 1, Item 13) and OPEN the test tap. Press the AIR-BLEEDER button (Figure 2, Item 1) on the feeder assembly (Figure 2, Item 13) and allow the water to drain into the suitable drain pan. Loosen the clamps (Figure 2, Items 7 and 10) and disconnect the hoses (Figure 2, Items 8 and 9) from the bottom of the feeder assembly (Figure 1, Item 13) into the suitable drain pan. Perform the BROMINE FEEDER CARTRIDGE REPLACE REMOVAL procedure in this work package. Loosen the upper and lower wingnuts (Figure 2, Items 5 and 6) and open the upper and lower retaining clamps (Figure 2, Items 11 and 12). Remove the feeder assembly (Figure 2, Item 13) from the retaining clamps (Figure 2, Items 11 and 12).
END OF TASK FEEDER ASSEMBLY INSTALLATION 1. Position the feeder assembly (Figure 2, Item 13) between the retaining clamps (Figure 2, Items 11 and 12) and secure it by tightening the wingnuts (Figure 2, Items 5 and 6).
0225-6
TM 55-1925-273-24&P-2 FEEDER ASSEMBLY INSTALLATION - Continued 2. 3. 4.
0225
Connect the hoses (Figure 2, Items 8 and 9) to the feeder assembly (Figure 2, Item 13) and secure it with the clamps (Figure 2, Items 7 and 10). Perform the BROMINE FEEDER CARTRIDGE REPLACE INSTALLATION procedure in this work package. Perform the FOLLOW-ON MAINTENANCE procedure at the end of this work package.
END OF TASK DUAL FEED VALVE ASSEMBLY REMOVAL 1. 2. 3. 4. 5. Place the suitable drain pan under the test tap (Figure 1, Item 13) and OPEN the test tap. Press the AIR-BLEEDER button (Figure 2, Item 1) on the feeder top assembly (Figure 2, Item 13) and allow the water to drain into the suitable drain pan. Loosen the clamps (Figure 3, Items 2 and 6) that secure the hoses (Figure 3, Items 1 and 7) to the dual feed valve (Figure 3, Item 8). Remove the hoses (Figure 3, Items 1 and 7) from the dual feed valve (Figure 3, Item 8) and drain the fluid into the suitable drain pan. Remove the two screws (Figure 3, Item 3), the two locknuts (Figure 3, Item 4), and the two flat washers (Figure 3, Item 5), and remove the dual feed valve (Figure 3, Item 8). Discard locknuts.
3, 4, 5
8
Figure 3. END OF TASK DUAL FEED VALVE ASSEMBLY INSTALLATION 1. 2. 3. Dual Feed Valve Assembly.
M1145T73
Install the dual feed valve (Figure 3, Item 8) using the two screws (Figure 3, Item 3), two locknuts (Figure 3, Item 4), and the two flat washers (Figure 3, Item 5). Install the hoses (Figure 3, Items 1 and 7) on the dual feed valve (Figure 3, Item 8) and secure the hoses with the two clamps (Figure 3, Items 2 and 6). Perform the FOLLOW-ON MAINTENANCE procedure at the end of this work package.
END OF TASK
0225-7
TM 55-1925-273-24&P-2 FOLLOW-ON MAINTENANCE 1. 2. 3. 4. 5. 6. 7. CLOSE the test tap. Remove the lock outs and tag outs IAW FM 4-01.502. OPEN valves PW-37, BROMINATOR INLET, and PW-38, BROMINATOR OUTLET. CLOSE valve PW-36, BYPASS-BROMINATOR. Operate the potable water system under usual conditions IAW TM 55-1925-273-10. Test the brominator (WP 0224). Return the equipment to the desired readiness condition.
0225
0225-8
TM 55-1925-273-24&P-2 FIELD MAINTENANCE PROPORTIONING BROMIDE FEEDER SYSTEM REPAIR
0226
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 3, WP 0344, Table 1, Item 27) Multimeter (Volume 3, WP 0344, Table 1, Item 15) Soldering Iron, Electric (Volume 3, WP 0344, Table 1, Item 23) Materials/Parts O-ring (Volume 3, WP 0324, Figure 76, Item 9) Qty: 1 O-ring (Volume 3, WP 0324, Figure 76, Item 11) Qty: 2 Personnel Required Watercraft Engineer 88L (2) References TM 55-1925-273-10 References (cont.) WP 0225 Volume 3, WP 0324 Volume 3, WP 0343 Volume 3, WP 0344 Equipment Condition Affected proportioning bromide feeder component removed. (WP 0225)
0226-1
TM 55-1925-273-24&P-2
0226
WARNING
Never reuse locking hardware. Reuse of locking hardware such as lockwashers, locking nuts, cotter pins, and lock wire can result in undetected loosening of fastening hardware causing catastrophic component failure resulting in death, injury, or damage to equipment. Ensure that all locking hardware is discarded upon removal and replaced with new. LAMPS DISASSEMBLY 1. 2. 3. 4. 5. 6. Unscrew and remove the light indicator lens cap (Figure 1, Item 2) and lamp (Figure 1, Item 3) from the indicator light housing (Figure 1, Item 1). Remove the indicator light housing (Figure 1, Item 1) from the electrical box (Figure 1, Item 27). Remove the two screws (Figure 1, Item 22) and two washers (Figure 1, Item 21) securing the cover (Figure 1, Item 20) of the electrical box (Figure 1, Item 4). Open the cover. Remove the indicator light housing (Figure 1, Item 1) and wires (Figure 1, Item 28) using a soldering iron. Unscrew and remove the light indicator lens cap (Figure 1, Item 18) and lamp (Figure 1, Item 17) from the indicator light housing (Figure 1, Item 16). Remove the indicator light housing (Figure 1, Item 16) and wires (Figure 1, Item 19) using a soldering iron. Remove the indicator light housing from the time totalizer meter (Figure 1, Item 32).
0226-2
TM 55-1925-273-24&P-2 LAMPS DISASSEMBLY - Continued

4
0226
5 6 7 1 2, 3 9 10 28 29 30 27 25 26 12 11 8
24 23 32 31 14
13
15 21 22 21 22 20 19 17, 18 16
M1146T73
Bypass Header Assembly.
0226-3
TM 55-1925-273-24&P-2
0226
LAMPS ASSEMBLY 1. 2. 3. 4. 5. 6. 7. 8. Connect the indicator light housing (Figure 1, Item 16) wires (Figure 1, Item 19) using a soldering iron. Install the indicator light housing into the time totalizer meter (Figure 1, Item 32). Install the lamp (Figure 1, Item 17) into the indicator light housing (Figure 1, Item 16). Thread the lens cap (Figure 1, Item 18) into the indicator light housing (Figure 1, Item 16) until it is finger tight. Connect the indicator light housing (Figure 1, Item 1) and wires (Figure 1, Item 28) using a soldering iron. Install the indicator light housing (Figure 1, Item 1) into the electrical box (Figure 1, Item 27). Install the lamp (Figure 1, Item 3) into the indicator light housing (Figure 1, Item 1). Thread the lens cap (Figure 1, Item 2) onto the indicator light housing (Figure 1, Item 1) until it is finger tight. Close the cover (Figure 1, Item 20) of the electrical box (Figure 1, Item 27) and install the two screws (Figure 1, Item 22) and two washers (Figure 1, Item 21) securing the cover of the electrical box.
END OF TASK TIME TOTALIZING METER DISASSEMBLY 1. Remove the two screws (Figure 1, Item 31), the two nuts (Figure 1, Item 25), and the two flat washers (Figure 1, Item 26) securing the time totalizer meter (Figure 1, Item 32) to the electrical box (Figure 1, Item 27). Remove the time totalizer meter (Figure 1, Item 32) from the electrical box (Figure 1, Item 27).
2.
END OF TASK TIME TOTALIZING METER ASSEMBLY 1. 2. Install the time totalizer meter (Figure 1, Item 32) in the electrical box (Figure 1, Item 27). Install two screws (Figure 1, Item 31), two nuts (Figure 1, Item 25), and two flat washers (Figure 1, Item 26) securing the time totalizer meter (Figure 1, Item 32) to the electrical box (Figure 1, Item 27). Tighten the two screws.
END OF TASK ELECTRICAL BOX DISASSEMBLY 1. 2. Remove the four screws (Figure 1, Item 23) and four lockwashers (Figure 1, Item 24) securing the electrical box (Figure 1, Item 27) to the inlet plumbing assembly (Figure 1, Item 4). Discard lockwasher. Remove the electrical box (Figure 1, Item 27) from the inlet plumbing assembly (Figure 1, Item 4).
END OF TASK ELECTRICAL BOX ASSEMBLY 1. 2. Place the electrical box (Figure 1, Item 27) onto the inlet plumbing assembly (Figure 1, Item 4). Install four screws (Figure 1, Item 23) and four lockwashers (Figure 1, Item 24) securing the electrical box (Figure 1, Item 27) to the inlet plumbing assembly (Figure 1, Item 4). Tighten the four screws.
END OF TASK
0226-4
TM 55-1925-273-24&P-2 FLOW SENSOR DISASSEMBLY 1. 2. 3. Loosen and remove the retaining nut (Figure 1, Item 5) securing the flow sensor (Figure 1, Item 6). Remove the flow sensor (Figure 1, Item 6) from the inlet plumbing assembly (Figure 1, Item 4). Remove the O-ring (Figure 1, Item 7) from the flow sensor (Figure 1, Item 6). Discard O-ring.
0226
END OF TASK FLOW SENSOR ASSEMBLY 1. 2. 3. Installl O-ring (Figure 1, Item 7) on the flow sensor (Figure 1, Item 6). Install the flow sensor (Figure 1, Item 6) in the inlet plumbing assembly (Figure 1, Item 4). Thread the retaining nut (Figure 1, Item 5) on the inlet plumbing assembly (Figure 1, Item 4) securing the flow sensor (Figure 1, Item 21).
END OF TASK ADAPTERS DISASSEMBLY 1. 2. Remove the adapter (Figure 1, Item 8) from the inlet plumbing assembly (Figure 1, Item 4). Remove the O-ring (Figure 1, Item 9) from the adapter (Figure 1, Item 8). Discard O-ring.
END OF TASK ADAPTERS ASSEMBLY 1. 2. Install O-ring (Figure 1, Item 9) on the adapter (Figure 1, Item 8). Install the adapter (Figure 1, Item 8) into the inlet plumbing assembly (Figure 1, Item 4).
END OF TASK OUTLET DISASSEMBLY 1. Remove the setscrew (Figure 1, Item 11) and the lockwasher (Figure 1, Item 10), and separate the inlet plumbing assembly (Figure 1, Item 4) from the outlet plumbing assembly (Figure 1, Item 15). Discard lockwasher. Remove the packing (Figure 1, Item 29), the fixed orifice (Figure 1, Item 30), and the packing (Figure 1, Item 12) from the outlet plumbing assembly (Figure 1, Item 15). Remove the adapter (Figure 1, Item 13) from the outlet plumbing assembly (Figure 1, Item 15). Remove the O-ring (Figure 1, Item 14) from the adapter (Figure 1, Item 13). Discard O-ring.
2. 3. 4.
END OF TASK
0226-5
TM 55-1925-273-24&P-2
0226
OUTLET ASSEMBLY 1. 2. 3. 4. Install O-ring (Figure 1, Item 14) on the adapter (Figure 1, Item 13). Install the adapter (Figure 1, Item 13) into the outlet plumbing assembly (Figure 1, Item 15). Install packing (Figure 1, Item 29), the fixed orifice (Figure 1, Item 30), and packing (Figure 1, Item 12) onto the outlet plumbing assembly (Figure 1, Item 15). Place together the inlet plumbing assembly (Figure 1, Item 4) and the outlet plumbing assembly (Figure 1, Item 15) and install the setscrew (Figure 1, Item 11) and a lockwasher (Figure 1, Item 10). Tighten the setscrew.
0226-6
TM 55-1925-273-24&P-2 FIELD MAINTENANCE HOT WATER HEATER ADJUST
0227
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 3, WP 0344, Table 1, Item 27) Materials/Parts N/A Personnel Required Watercraft Engineer 88L (1) References Volume 3, WP 0325 Volume 3, WP 0344 Equipment Condition N/A
0227-1
TM 55-1925-273-24&P-2
0227
ADJUSTMENT
WARNING
Take great care when working around energized electrical equipment. Contact between unprotected body parts and electrical conductors can cause serious injury or death. Do not wear jewelry or other conductive items while servicing energized electrical equipment. Failure to comply with these precautions can cause serious injury or death. 1. Open the access cover (Figure 1, Item 1).
1
M1147T73
Figure 1. 2. 3. 4. 5. 6.
Hot Water Heater.
Adjust the cutout thermostat control (Figure 2, Item 1) to the desired temperature. Adjust the cut-in thermostat controls (Figure 2, Item 2) to the desired temperature. Close the access cover (Figure 1, Item 1). Allow the water heater to operate for 60 to 90 min and observe the temperature reading. Repeat Steps (1) through (5) as necessary to obtain the desired temperature.
0227-2
TM 55-1925-273-24&P-2 ADJUSTMENT - Continued
0227
M1148T73
Figure 2. Water Heater Temperature Controls. END OF TASK END OF WORK PACKAGE
0227-3/4 blank
TM 55-1925-273-24&P-2 FIELD MAINTENANCE HOT WATER HEATER REPLACE
0228
INITIAL SETUP: Tools and Special Tools Faceshield, Industrial (Volume 3, WP 0344, Table 1, Item 5) Gloves, Leather (Volume 3, WP 0344, Table 1, Item 9) Goggles, Industrial (Volume 3, WP 0344, Table 1, Item 10) Multimeter (Volume 3, WP 0344, Table 1, Item 15) Suitable Drain Hose Suitable Drain Pan Tool Kit, Electrical Repair (Volume 3, WP 0344, Table 1, Item 26) Materials/Parts Tape, Antiseizing; 1/2 in. (Volume 3, WP 0343, Table 1, Item 158) Personnel Required Watercraft Engineer 88L (2) References FM 4-01.502 Volume 3, WP 0325 Volume 3, WP 0343 Volume 3, WP 0344 Equipment Condition Hot water heater prepared for replacement.
0228-1
TM 55-1925-273-24&P-2
0228
REMOVAL
NOTE
Unit replacement consists of readying the hot water heater for removal by securing, locking out, and tagging out IAW FM 4-01.502 the applicable valves and circuit breakers. After installation is complete, you must fill, test, and adjust the hot water heater. 1. At the main switchboard in Enclosed Operating Station (EOS), set to OFF, lock out, and tag out IAW FM 4-01.502 the circuit breaker for the applicable hot water heater being removed. Refer to Table 1 for the applicable hot water heater circuit breaker. Table 1. Water 1 2 Hot Water Heater Lock Out and Tag Out Guide. Inlet Valve PW-80, POT. WTR. TO H.W. HTR. PW-79, POT. WTR. TO H.W. HTR. Outlet Valve PW-82, H.W. HTR OUT PW-81, H.W. HTR OUT Recirculating Hot Water Valve PW-44, RECIRC TO H.W. HEATER PW-43, RECIRC TO H.W. HEATER
Main Switchboard Circuit Breaker HOT POTABLE WTR HTR No. 1 HOT POTABLE WTR HTR No. 2
2.
Set of OFF the HOT POTABLE WATER RECIRCULATION PUMP. circuit breaker (LT 803 Only), or the LVP FOR HOT POTABLE WATER RECIRCULATING PUMP (All Other Vessels) circuit breaker in 440 V power panel No. 4. Lock out and tag out IAW FM 4-01.502. CLOSE, lock out, and tag out IAW FM 4-01.502 the inlet, outlet, and recirculating hot water valves for the applicable hot water heater being removed. Refer to Table 1 for the applicable hot water heater hot water valves.
3.
WARNING
Never reuse locking hardware. Reuse of locking hardware such as lockwashers, locking nuts, cotter pins, and lock wire can result in undetected loosening of fastening hardware causing catastrophic component failure resulting in death, injury, or damage to equipment. Ensure that all locking hardware is discarded upon removal and replaced with new. 4. OPEN the access door (Figure 1, Item 14).
WARNING
Replace or repair components only after the affected circuit has been secured, locked out, and tagged out IAW FM 4-01.502. Performing replacement with the circuit energized may result in injury. 5. 6. 7. 8. Using a multimeter, check for voltage at the wiring leads. If voltage is present, ensure that the proper controller is secured, locked out and tagged out IAW FM 4-01.502. If no voltage is present, continue with the procedure. Label and disconnect the electrical wiring (Figure 1, Item 3). Attach a hose to the drain faucet (Figure 1, Item 9). Lift the manual relief lever on the relief valve (Figure 1, Item 1) to let air into the unit.
0228-2
TM 55-1925-273-24&P-2 REMOVAL - Continued 9. 10. OPEN the drain faucet (Figure 1, Item 9) and allow the water to drain into the suitable drain pan. Remove the vent drain (Figure 1, Item 16) from the relief valve (Figure 1, Item 1).
0228
CAUTION
Never attempt to disconnect or connect union connections with only one wrench. Damage to the vessel or the component piping could occur. Always use two wrenches. 11. 12. 13. 14. 15. 16. Remove the outlet union (Figure 1, Item 15) using the two wrench method. Remove the inlet union (Figure 1, Item 7) using the two wrench method. Remove the four retaining nuts (Figure 1, Item 4) and four lockwashers (Figure 1, Item 5) from the bulkhead brackets (Figure 1, Item 6). Discard lockwashers. Remove the retaining nuts (Figure 1, Item 13) and four lockwashers (Figure 1, Item 12) from the angle brackets (Figure 1, Item 11). Discard lockwashers. Remove the attached piping (Figure 1, Item 8) from the inlet union (Figure 1, Item 7). Retain the attached piping for the hot water heater. Remove the elbow (Figure 1, Item 10). Retain the elbow for the hot water heater.
WARNING
Heavy loads can crush. Do not allow any body parts to come under the load or between the load and a stationary object. Failure to comply with this warning can result in serious injury or death. 17. Using two crewmembers, remove the hot water heater (Figure 1, Item 2) from its foundation.
0228-3
0228
3 1 2
4 5 16
15 6 7
14 9 13
12 11 10
M1381T73
Figure 1. Typical Water Heater. END OF TASK
0228-4
0228
WARNING
Removing components by means of wire brushing produces flying particles. These particles can cause serious injury to personnel. Wear protective faceshield, gloves, and long sleeves at all times during wire brushing operations. Failure to comply with this warning can result in serious injury to personnel. 1. 2. Clean the male threads of the inlet pipe and the outlet pipe using a wire brush. Apply antiseizing tape to the male threads of the inlet pipe and the outlet pipe. Install the elbow (Figure 1, Item 10) and attached piping (Figure 1, Item 8) on the hot water heater (Figure 1, Item 2).
WARNING
Heavy loads can crush. Do not allow any body parts to come under the load or between the load and a stationary object. Failure to comply with this warning can result in serious injury or death. 3. Using two crewmembers, install the hot water heater (Figure 1, Item 2) on the angle brackets (Figure 1, Item 11). Secure the water heater to the angle brackets with the four retaining nuts (Figure 1, Item 13) and four lockwashers (Figure 1, Item 12). Secure the upper portion of the hot water heater (Figure 1, Item 2) to the bulkhead brackets (Figure 1, Item 6) with the four retaining nuts (Figure 1, Item 4) and four lockwashers (Figure 1, Item 5).
4.
CAUTION
Never attempt to disconnect or connect union connections with only one wrench. Damage to the vessel piping or to the component piping could occur. Always use two wrenches. 5. Connect the unions (Figure 1, Items 7 and 15) to the piping. Minor reorientation of the elbow (Figure 1, Item 10) may be necessary to properly align the unions. Tighten the unions (Figure 1, Items 7 and 15) using the two wrench method.
WARNING
Removing components by means of wire brushing produces flying particles. These particles can cause serious injury to personnel. Wear protective faceshield, gloves, and long sleeves at all times during wire brushing operations. Failure to comply with this warning can result in serious injury to personnel. 6. Clean the male threads of the vent drain (Figure 1, Item 16) using a wire brush. Apply antiseizing tape to the male threads of the vent drain.
0228-5
TM 55-1925-273-24&P-2 INSTALLATION - Continued 7. 8. 9. 10. Install the vent drain (Figure 1, Item 16) into the relief valve (Figure 1, Item 1).
0228
Connect the electrical wiring (Figure 1, Item 3) to the hot water heater (Figure 1, Item 2) using the labels from Step (3) of REMOVAL as a guide. Remove the labels. CLOSE the access door (Figure 1, Item 14). CLOSE the drain faucet (Figure 1, Item 9).
CAUTION
Do not turn the hot water circuit breaker ON until the hot water heater tank is full of water, or damage to heater elements could occur. 11. 12. 13. 14. 15. 16. 17. Remove the lock outs and tag outs IAW FM 4-01.502. Verify that the drain valve for the hot water heater is CLOSED. OPEN the vent valve (Figure 2, Item 1) on the applicable hot water heater to allow air to escape the hot water heater tank while filling. OPEN the inlet valve (Table 1) on the applicable hot water heater and observe the vent valve (Figure 2, Item 1). Allow the water heater tank to fill until a solid stream of water flows from the vent valve (Figure 2, Item 1). CLOSE the vent valve (Figure 2, Item 1). OPEN the applicable water heater outlet and recirculating hot water valves (Table 1). Listen for any air that may pass through the hot water recirculation pump. Purge any air in the hot water piping by cycling the hot water tank vent valves (Figure 2, Item 1). Air may also be purged by OPENING a hot water valve in the heads or the galley.
0228-6
0228
M1382T73
Figure 2. 18. 19.
Water Heater Vent Valve.
Set the applicable circuit breaker (Table 1) to ON. Set to ON the HOT POTABLE WATER RECIRCULATING PUMP circuit breaker (LT 803 Only), or the LVP FOR HOT POTABLE WATER RECIRCULATING PUMP (All Other Vessels) circuit breaker in 440 V power panel No. 4. Adjust the hot water heater cut-in and cutout temperature controls (WP 0227). Return the equipment to the desired readiness condition.
20. 21.
0228-7/8 blank
TM 55-1925-273-24&P-2 FIELD MAINTENANCE HOT WATER HEATER REPAIR
0229
INITIAL SETUP: Tools and Special Tools Multimeter (Volume 3, WP 0344, Table 1, Item 15) Tool Kit, Electrical Repair (Volume 3, WP 0344, Table 1, Item 26) Materials/Parts Tape, Antiseizing; 1/2 in. (Volume 3, WP 0343, Table 1, Item 158) Personnel Required Watercraft Engineer 88L (2) References FM 4-01.502 References (cont.) WP 0227 Volume 3, WP 0325 Volume 3, WP 0343 Volume 3, WP 0344 Equipment Condition N/A
0229-1
TM 55-1925-273-24&P-2
0229
REPLACE FUSES REMOVAL
WARNING
Replace or repair components only after the affected circuit has been secured, locked out, and tagged out IAW FM 4-01.502. Performing replacement with the circuit energized may result in injury. 1. Set to OFF the HOT POTABLE WATER RECIRCULATING PUMP circuit breaker. (LT 803 Only), or the LVP FOR HOT POTABLE WATER RECIRCULATION PUMP circuit breaker (All Other Vessels) in 440 V power panel No. 4. Lock out and tag out IAW FM 4-01.502. At the main switchboard in the Enclosed Operation Station (EOS), set to OFF, lock out, and tag out IAW FM 4-01.502 the circuit breaker for the applicable hot water heater. Refer to Table 1 for the applicable circuit breaker. Table 1. Water 1 2 Hot Water Heater Lock Out and Tag Out Guide. Inlet Circuit Breaker PW-80, POT. WTR. TO H.W. HTR. PW-79, POT. WTR. TO H.W. HTR. Outlet Valve PW-82, H.W. HTR OUT PW-81, H.W. HTR OUT Recirculating Hot Water Valve PW-44, RECIRC TO H.W. HEATER PW-43, RECIRC TO H.W. HEATER
2.
Main Switchboard Heater HOT POTABLE WTR HTR NO. 1 HOT POTABLE WTR HTR NO. 2
3. 4.
Open the access door (Figure 1, Item 7). Using a multimeter, check for voltage at the fuse (Figure 1, Item 5). If voltage is present, check that the proper circuit breaker (Table 1) is locked out and tagged out IAW FM 4-01.502. If no voltage is present, continue with the procedure. Using a fuse puller, remove the fuse (Figure 1, Item 5) from the fuse holder.
5.
END OF TASK REPLACE FUSES INSTALLATION 1. 2. 3. Using a fuse puller, install the fuse (Figure 1, Item 5) in the fuse holder. Close and secure the access door (Figure 1, Item 7). Perform the FOLLOW-ON MAINTENANCE procedure at the end of this work package.
0229-2
TM 55-1925-273-24&P-2 REPLACE FUSES INSTALLATION - Continued
0229
2 1 5
15 16 15 6
14 18
17
7 8
18 2 17 1 9
15 16 9 15 14 10 12
Figure 1. END OF TASK Water Heater and Components.
13
11
M1149T73
0229-3
TM 55-1925-273-24&P-2 REPLACE HEATING ELEMENT REMOVAL
0229
WARNING
Replace or repair components only after the affected circuit has been secured, locked out, and tagged out IAW FM 4-01.502. Performing replacement with the circuit energized may result in injury. 1. Set to OFF the HOT POTABLE WATER RECIRCULATING PUMP. circuit breaker (LT 803 Only), or the LVP FOR HOT POTABLE WATER RECIRCULATION PUMP circuit breaker (All Other Vessels) in 440 V power panel No. 4. Lock out and tag out IAW FM 4-01.502. At the main switchboard in the EOS, set to OFF, lock out, and tag out IAW FM 4-01.502 the circuit breaker for the applicable hot water heater. Refer to Table 1 for the applicable circuit breaker. CLOSE, lock out and tag out IAW FM 4-01.502 the inlet, outlet, and recirculation hot water valves for the applicable hot water heater. Refer to Table 1 for the applicable inlet, outlet, and recirculating hot water valves. Open the access door (Figure 1, Item 7). Using a multimeter, check for voltage at the fuse (Figure 1, Item 5). If voltage is present, check that the proper circuit breaker (Table 1) is locked out and tagged out IAW FM 4-01.502. If no voltage is present, continue with the procedure. Attach a hose to the drain value (Figure 1, Item 8). Lift the manual relief lever (Figure 1, Item 3) on the relief valve (Figure 1, Item 4) to let air into the tank. OPEN the drain valve (Figure 1, Item 8) and allow the water to drain from the tank. Label and disconnect the wiring form the heating element terminals (Figure 1, Item 12). Remove the four nuts (Figure 1, Item 13), the heating element (Figure 1, Item 11), and the gasket (Figure 1, Item 10) from the water heater.
2. 3. 4. 5.
6. 7. 8. 9. 10.
END OF TASK REPLACE HEATING ELEMENT INSTALLATION 1. 2. 3. 4. 5. 6. 7. 8. 9. Verify that the jumper configuration on the heating element matches the diagram in Figure 2. Position a gasket (Figure 1, Item 10) and the heating element (Figure 1, Item11) over the studs (Figure 1, Item 9). Install the heating element (Figure 1, Item 11), and secure it with the four nuts (Figure 1, Item 13). Connect the wiring to the heating element terminals (Figure 1, Item 12) using the labels from Step (9) of REPLACE HEATING ELEMENT REMOVAL as guide. Remove the labels. Close and secure the access door (Figure 1, Item 7). CLOSE the drain valve (Figure 1, Item 8) and remove the hose. Remove the lock outs and tag outs IAW FM 4-01.502 from the applicable inlet valve (Table 1) and OPEN the valve. Fill the tank with water with the manual relief lever (Figure 1, Item 3) on the relief valve (Figure 1, Item 4) lifted. When the water escapes from the relief valve (Figure 1, Item 4), CLOSE the relief valve.
0229-4
TM 55-1925-273-24&P-2 REPLACE HEATING ELEMENT INSTALLATION - Continued 10. Perform the FOLLOW-ON MAINTENANCE procedure at the end of this work package.
L1 L2 L3
0229
B1
A1
C1
A2
C2
B2
M1150T73
Figure 2. END OF TASK REPLACE THERMOSTAT REMOVAL
Heating Element Jumper Configuration.
WARNING
Replace or repair components only after the affected circuit has been secured, locked out, and tagged out IAW FM 4-01.502. Performing replacement with the circuit energized may result in injury. 1. Set to OFF the HOT POTABLE WATER RECIRCULATING PUMP. circuit breaker (LT 803 Only), or the LVP FOR HOT POTABLE WATER RECIRCULATION PUMP circuit breaker (All Other Vessels) in 440 V power panel No. 4. Lock out and tag out IAW FM 4-01.502. At the main switchboard in the EOS, set to OFF, lock out, and tag out IAW FM 4-01.502 the circuit breaker for the applicable hot water heater. Refer to Table 1 for the applicable circuit breaker. Open the access door (Figure 1, Item 7). Using a multimeter, check for voltage at the fuses (Figure 1, Item 5). If voltage is present, check that the proper circuit breaker (Table 1) is locked out and tagged out IAW FM 4-01.502. If no voltage is present, continue with the procedure. Remove the screw (Figure 1, Item 17) and remove the thermostat access cover (Figure 1, Item 18). Remove the screws (Figure 1, Item 1) and label and disconnect the wire terminals (Figure 1, Item 16). Remove the capillary tube (Figure 1, Item 14) from the thermo well.
2. 3. 4.
5. 6. 7.
0229-5
TM 55-1925-273-24&P-2 REPLACE THERMOSTAT REMOVAL - Continued 8. Remove the two mounting screws (Figure 1, Item 15) and remove the thermostat (Figure 1 , Item 2).
0229
END OF TASK REPLACE THERMOSTAT INSTALLATION 1. 2. 3. 4. 5. 6. 7. Install the thermostat (Figure 1, Item 2) and secure it with the two mounting screws (Figure 1, Item 15). Install the capillary tube (Figure 1, Item 14) into the thermo well. Connect the wire terminals (Figure 1, Item 16) using the labels from Step (6) of REPLACE THERMOSTAT REMOVAL as a guide. Remove the labels. Install the screws (Figure 1, Item 1) Install the thermostat access cover (Figure 1, Item 18), and secure it with the screw (Figure 1, Item 17). Close and secure the access door (Figure 1, Item 7). Perform the FOLLOW-ON MAINTENANCE procedure at the end of this work package.
END OF TASK REPLACE MAGNETIC CONTACTOR REMOVAL
WARNING
Replace or repair components only after the affected circuit has been secured, locked out, and tagged out IAW FM 4-01.502. Performing replacement with the circuit energized may result in injury. 1. Set to OFF the HOT POTABLE WATER RECIRCULATING PUMP. circuit breaker (LT 803 Only), or the LVP FOR HOT POTABLE WATER RECIRCULATION PUMP circuit breaker (All Other Vessels) in 440 V power panel No. 4. Lock out and tag out IAW FM 4-01.502. At the main switchboard in the EOS, set to OFF, lock out, and tag out IAW FM 4-01.502 the circuit breaker for the applicable hot water heater. Refer to Table 1 for the applicable circuit breaker. Open the access door (Figure 1, Item 7). Using a multimeter, check for voltage at the fuses (Figure 3, Item 2). If voltage is present, check that the proper circuit breaker (Table 1) is locked out and tagged out IAW FM 4-01.502. If no voltage is present, continue with the procedure. Using a fuse puller, remove the fuses (Figure 3, Item 2) from the fuse holder (Figure 3, Item 1). Label and disconnect the wiring (Figure 3, Item 4) from the fuse holder (Figure 3, Item 1). Remove the two screws (Figure 3, Item 3) that secure the fuse holder (Figure 3, Item 1) to the magnetic contactor (Figure 3, Item 7) and remove the fuse holder. Label and disconnect the control wiring (Figure 3, Item 5) from the magnetic contactor (Figure 3, Item 7). Remove the two mounting screws (Figure 3, Item 6) and remove the magnetic contactor (Figure 3, Item 7).
2. 3. 4.
5. 6. 7. 8. 9.
END OF TASK
0229-6
TM 55-1925-273-24&P-2 REPLACE MAGNETIC CONTACTOR INSTALLATION 1. 2. 3. 4. 5. 6. 7. Install the magnetic contactor (Figure 3, Item 7) and secure it with the two mounting screws (Figure 3, Item 6).
0229
Connect the control wiring (Figure 3, Item 5) to the magnetic contactor (Figure 3, Item 7) using the label from Step (8) of REPLACE MAGNETIC CONTACTOR REMOVAL as a guide. Remove the labels. Install the fuse holder (Figure 3, Item 1) and secure it to the magnetic contactor (Figure 3, Item 7) with the two screws (Figure 3, Item 3). Connect the wiring (Figure 3, Item 4) to the fuse holder (Figure 3, Item 1) using the labels from Step (6) of REPLACE MAGNETIC CONTACTOR REMOVAL as a guide. Remove the labels. Install the fuses (Figure 3, Item 2) in the fuse holder (Figure 3, Item 1) using a fuse puller. Close and secure the access door (Figure 1, Item 7). Perform the FOLLOW-ON MAINTENANCE procedure at the end of this work package.
1
7 6
2 5
4
M1151T73
Magnetic Contactor/Fuse Holder.
0229-7
TM 55-1925-273-24&P-2 REPLACE THERMOMETER REMOVAL
0229
WARNING
CAUTION
The elements for the hot water heaters are designed to be submerged in water when energized. Applying power to an empty hot water heater could cause damage. 1. Set to OFF the HOT POTABLE WATER RECIRCULATING PUMP. circuit breaker (LT 803 Only), or the LVP FOR HOT POTABLE WATER RECIRCULATION PUMP circuit breaker (All Other Vessels) in 440 V power panel No. 4. Lock out and tag out IAW FM 4-01.502. At the main switchboard in the EOS, set to OFF, lock out, and tag out IAW FM 4-01.502 the circuit breaker for the applicable hot water heater. Refer to Table 1 for the applicable circuit breaker. CLOSE, lock out and tag out IAW FM 4-01.502 the inlet, outlet, and recirculation hot water valves for the applicable hot water heater. Refer to Table 1 for the applicable inlet, outlet, and recirculating hot water valves. Attach a hose to the drain valve (Figure 1, Item 8). Lift the manual relief lever (Figure 1, Item 3) on the relief valve (Figure 1, Item 4) to let air into the tank. OPEN the drain valve (Figure 1, Item 8), and allow the water to drain from the tank. Drain the water from the tank to a level that is below the thermometer (Figure 1, Item 6). Unscrew the thermometer (Figure 1, Item 6) and remove it from the tank.
2. 3. 4. 5. 6. 7. 8.
END OF TASK REPLACE THERMOMETER INSTALLATION 1. 2. 3. 4. 5. 6. Apply antiseizing tape to the male threads of the thermometer (Figure 1, Item 6), and install the thermometer in the tank. CLOSE the drain valve (Figure 1, Item 8) and remove the hose. Remove the lock out and tag out IAW FM 4-01.502 from the applicable inlet valve (Table 1), and OPEN the valve. Fill the tank with water with the manual relief lever (Figure 1, Item 3) on the relief valve (Figure 1, Item 4) lifted. When water escapes from the relief valve (Figure 1, Item 4), CLOSE the relief valve. Perform the FOLLOW-ON MAINTENANCE procedure at the end of this work package.
END OF TASK FOLLOW-ON MAINTENANCE 1. Remove the lock outs and tag outs IAW FM 4-01.502.
0229-8
TM 55-1925-273-24&P-2 FOLLOW-ON MAINTENANCE - Continued 2.
0229
OPEN the applicable water heater outlet and recirculating hot water valves, listen for any air that may pass through the hot water recirculating pump. Purge any air in the hot water piping by cycling the hot water tank manual relief lever. Air may also be purged by OPENING a hot water valve in the water closets ro the galley. Set to ON the HOT POTABLE WATER RECIRCULATING PUMP. circuit breaker (LT 803 Only), or the LVP FOR HOT POTABLE WATER RECIRCULATION PUMP circuit breaker (All Other Vessels) in 440 V power panel No. 4. Set the applicable circuit breaker to ON. Adjust the hot water heater temperature. Adjust the hot water heater temperature. (WP 0227) Return the equipment to the desired readiness condition.
3.
4. 5. 6.
0229-9/10 blank
TM 55-1925-273-24&P-2 FIELD MAINTENANCE HOT POTABLE WATER RECIRCULATION PUMP REPLACE
0230
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 3, WP 0344, Table 1, Item 27) Multimeter (Volume 3, WP 0344, Table 1, Item 15) Suitable Drain Pan Materials/Parts Tape, Antiseizing; 1/2 in. (Volume 3, WP 0343, Table 1, Item 158) Personnel Required Watercraft Engineer 88L (2) References FM 4-01.502 TM 55-1925-273-10 References (cont.) Volume 3, WP 0326 Volume 3, WP 0343 Volume 3, WP 0344 Equipment Condition Set to OFF the HOT POTABLE WATER RECIRCULATING PUMP. circuit breaker (LT 803 Only), or the LVP FOR HOT POTABLE WATER RECIRCULATING PUMP circuit breaker (All Other Vessels) in 440 V power panel No. 4. Lock out and tag out IAW FM 4-01.502. CLOSE valves PW-42, HW RECIRC. PMP. SUCT., PW-43, RECIRC TO H.W. HEATER, and PW-44, RECIRC TO H.W. HEATER. Lock out and tag out IAW FM 4-01.502.
0230-1
TM 55-1925-273-24&P-2
0230
WARNING
Never reuse locking hardware. Reuse of locking hardware such as lockwashers, locking nuts, cotter pins, and lock wire can result in undetected loosening of fastening hardware causing catastrophic component failure resulting in death, injury, or damage to equipment. Ensure that all locking hardware is discarded upon removal and replaced with new. REMOVAL 1. 2. 3. Allow time for the water in the piping to cool. Remove the two screws (Figure 1, Item 4) securing the electrical junction box cover (Figure 1, Item 3). Remove the electrical junction box cover (Figure 1, Item 3).
WARNING
Replace or repair components only after the affected circuit has been secured, locked out, and tagged out IAW FM 4-01.502. Performing replacement with the circuit energized may result in injury. 4. Use a multimeter to check for voltage at the wiring terminals (Figure 1, Item 5) in the electrical junction box (Figure 1, Item 2). If voltage is present, ensure that the proper circuit breaker is set to OFF, locked out, and tagged out IAW FM 4-01.502. If no voltage is present, continue with the procedure. Label and disconnect the electrical wiring (Figure 1, Item 1) in the electrical junction box (Figure 1, Item 2).
5.
0230-2

1
0230
M1152T73
Figure 1. 6. 7.
Place a suitable drain pan under the hot potable water recirculation pump (Figure 2, Item 3). Loosen the pressure gage piping (Figure 2, Item 6) to relieve any pressure that may be in the hot potable water recirculation pump (Figure 2, Item 3) piping.
CAUTION
Never attempt to disconnect union connections with only one wrench. Damage to the vessel's piping or to the pump's piping could occur. Always use two wrenches. 8. 9. Disconnect the potable water piping at the hot potable water recirculation pump (Figure 2, Item 3) inlet and outlet unions (Figure 2, Items 5 and 7) using the two wrench method. Remove the four nuts (Figure 2, Item 9), four lockwashers (Figure 2, Item 10), eight flat washers (Figure 2, Item 2), and four bolts (Figure 2, Item 1) that secure the hot potable water recirculation pump (Figure 2, Item 3) to the foundation. Discard lockwashers.
0230-3
TM 55-1925-273-24&P-2 REMOVAL - Continued 10. 11. Remove the hot potable water recirculation pump (Figure 2, Item 3) from the foundation.
0230
Remove the inlet fitting (Figure 2, Item 8) and the outlet fitting (Figure 2, Item 4) from the hot potable water recirculation pump (Figure 2, Item 3).
1
10 9
8 7
M1153T73
Hot Potable Water Recirculation Pump.
0230-4
TM 55-1925-273-24&P-2
0230
INSTALLATION 1. 2. Apply antiseizing tape on the male threads of the inlet fitting (Figure 2, Item 8) and outlet fitting (Figure 2, Item 4) and install the fittings on the hot potable water recirculation pump (Figure 2, Item 3). Install the hot potable water recirculation pump (Figure 2, Item 3) on its foundation and secure it with the four nuts (Figure 2, Item 9), four lockwashers (Figure 2, Item 10), eight flat washers (Figure 2, Item 2), and four bolts (Figure 2, Item 1).
CAUTION
Never attempt to connect union connections with only one wrench. Damage to the vessel's piping or to the pump's piping could occur. Always use two wrenches. 3. 4. 5. 6. Connect and tighten the inlet and outlet unions (Figure 2, Items 5 and 7) to the potable water recirculation pump (Figure 2, Item 3) using the two wrench method. Install the pressure gage piping (Figure 2, Item 6) to the hot potable water recirculation pump (Figure 2, Item 3) and tighten the piping connection. Connect the electrical wiring (Figure 1, Item 1) in the electrical junction box (Figure 1, Item 2) using the labels from Step (5) of REMOVAL as a guide. Remove the labels. Install the junction box cover (Figure 1, Item 3) and secure it with the two screws (Figure 1, Item 4).
END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. Remove the lock outs and tag outs IAW FM 4-01.502. Operate the potable water system under usual conditions IAW TM 55-1925-273-10 checking for leaks and proper operation. Return the equipment to the desired readiness condition.
0230-5/6 blank
TM 55-1925-273-24&P-2 FIELD MAINTENANCE FIRE AND GENERAL SERVICE PUMP SERVICE
0231
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 3, WP 0344, Table 1, Item 27) Lubricating Gun, Hand (Volume 3, WP 0344, Table 1, Item 14) Wrench, Torque, 0-250 lb-ft (0-339 Nm) (Volume 3, WP 0344, Table 1, Item 33) Materials/Parts Compound, Sealing; Loctite 242 (Volume 3, WP 0343, Table 1, Item 43) Grease, Ball and Roller Bearing; 1.75 lb (Volume 3, WP 0343, Table 1, Item 74) Rag, Wiping (Volume 3, WP 0343, Table 1, Item 132) O-ring (Volume 3, WP 0327, Figure 79, Item 3) Qty: 1 Personnel Required Watercraft Engineer 88L (2) References FM 4-01.502 TM 55-1925-273-10 References (cont.) Volume 3, WP 0327 Volume 3, WP 0343 Volume 3, WP 0344 Equipment Condition For fire and general service pump No. 1, set to OFF the FIRE PUMP #1 circuit breaker on the emergency switchboard. Lock out and tag out IAW FM 4-01.502. CLOSE valves FM-6 FIRE/ G.S. PMP No. 1 SUCT, FM-16 FIRE/G.S. PMP No. 1 DISCH. TO FM, and FM-17 FIRE/G.S. PMP No. 1 DISCH. TO GS. Lock out and tag out IAW FM 4-01.502. For fire and general service pump No. 2, set to OFF the FIRE PUMP No. 2 circuit breaker on the main switchboard. Lock out and tag out IAW FM 4-01.502. CLOSE valves FM-7 FIRE/G.S. PMP No. 2 PMP SUCT, FM-14 FIRE/G.S. PMP No. 2 DISCH. TO FM, and FM-15 FIRE/G.S. PMP No. 2 DISCH. TO GS. Lock out and tag out IAW FM 4-01.502.
0231-1
TM 55-1925-273-24&P-2
0231
FIRE AND GENERAL SERVICE PUMP 1. 2. Align the on-service fire and general service pump to the general service system IAW TM 55-1925-273-10. Ensure that the engine-driven firefighting pump is standing by to pressurize the firefighting system IAW TM 55-1925-273-10.
NOTE
Adequate lubrication is assured if the amount of the grease is maintained at 0.25 oz (7.4 cc) to 0.5 oz (15 cc) of the capacity of the bearing and adjacent space surrounding it. 3. 4. 5. 6. 7. Remove the drain plug (Figure 1, Item 2) from the upper bearing cartridge (Figure 1, Item 1). Inject grease into the upper grease fitting (Figure 1, Item 3) using a lubricating gun until the old grease is seen coming from the drain opening. Wipe any excess grease from the grease fitting using a wiping rag. Remove the drain plug (Figure 1, Item 6) from the lower bearing cartridge (Figure 1, Item 4). Inject grease into the lower grease fitting (Figure 1, Item 5) using a lubricating gun until the old grease is seen coming from the drain opening. Wipe any excess grease from the grease fitting using a wiping rag. Leave out the upper and lower drain plugs (Figure 1, Items 2 and 6) and perform the FOLLOW-ON MAINTENANCE procedure at the end of this work package.
0231-2
TM 55-1925-273-24&P-2 FIRE AND GENERAL SERVICE PUMP - Continued
0231
3 VIEW A 4
VIEW B
M1154T73
Figure 1. END OF TASK SERVICE ELECTRIC MOTOR 1. 2. 3.
Fire and General Service Pump.
Align the on-service fire and general service pump to the general service system IAW TM 55-1925-273-10. Ensure that the engine-driven firefighting pump is standing by to pressurize the firefighting system IAW TM 55-1925-273-10. Remove the grease drains (Figure 2, Items 1 and 3).
CAUTION
Do not apply grease through the upper or the lower grease fittings with the upper or lower grease drains closed. 4. Add 0.4 oz (12 cc) of grease into the upper grease fitting (Figure 2, Item 2) using a lubricating gun. Wipe any excess grease from the grease fitting using a wiping rag.
0231-3
TM 55-1925-273-24&P-2 SERVICE ELECTRIC MOTOR - Continued 5. 6.
0231
Add 0.6 oz (18 cc) of grease into the lower grease fitting (Figure 2, Item 4) using a lubricating gun. Wipe any excess grease from the grease fitting using a wiping rag. Leave out the grease drains (Figure 2, Items 1 and 3) and perform the FOLLOW-ON MAINTENANCE procedure at the end of this work package.
0231-4
TM 55-1925-273-24&P-2 SERVICE ELECTRIC MOTOR - Continued
0231
M1155T73
Electric Motor.
0231-5
TM 55-1925-273-24&P-2 STRAINER SERVICE DISASSEMBLY
0231
WARNING
The strainer may be under pressure. Loosen the fasteners slowly and allow water to run around threads of the fitting to release any pressure before opening the strainer cover. Releasing pressurized water suddenly may cause severe personal injury or death. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Place the clean side of the duplex strainer online using the strainer selector handle (Figure 3, Item 1). Slowly loosen, but do not remove, the two bolts (Figure 3, Item 2) securing the cover (Figure 3, Item 5) to the strainer (Figure 3, Item 7) being serviced. Allow any pressure to vent and any fluid to drain. Loosen the T-handle (Figure 3, Item 3) and remove the locking bar (Figure 3, Item 4) and the cover (Figure 3, Item 5). Remove the O-ring (Figure 3, Item 6) from the cover (Figure 3, Item 5). Discard O-ring. Remove the basket (Figure 3, Item 8) from the strainer (Figure 3, Item 7). Discard contents of the basket. Using clean fresh water, clean all the removed parts. Remove any sediment from the basket (Figure 3, Item 8). Remove any debris from the interior of the strainer (Figure 3, Item 7) and wipe the inside of the strainer with a clean wiping rag. Inspect the basket (Figure 3, Item 8) and strainer (Figure 3, Item 7) for excessive rust or deterioration. Replace any worn parts.
1 2 3
4 5 6 7 8
M1156T73
Duplex Strainer.
0231-6
TM 55-1925-273-24&P-2 STRAINER SERVICE ASSEMBLY 1. 2. 3. 4. Install the basket (Figure 3, Item 8) into the strainer (Figure 3, Item 7). Install an O-ring (Figure 3, Item 6) on the cover (Figure 3, Item 2).
0231
Install the cover (Figure 3, Item 5) on the strainer (Figure 3, Item 7), securing it in place with the locking bar (Figure 3, Item 4). Tighten two bolts (Figure 3, Item 2) and the T-handle (Figure 3, Item 3).
END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. 4. Remove the lock outs and tag outs IAW FM 4-01.502. Align the piping for the serviced fire and general service pump to the general service system IAW TM 55-1925-273-10. Operate the serviced fire and general service pump IAW TM 55-1925-273-10 checking for leaks and proper operation. If the pump was serviced: a. b. c. 5. a. b. c. d. 6. Run the pump for 15 minutes to purge excess grease. Install the upper drain plug (Figure 1, Item 2) and remove any excess grease. Install the lower drain plug (Figure 1, Item 6) and remove any excess grease. Run the pump for 15 minutes to purge excess grease. Apply sealing compound Loctite 242 to the threads of the upper grease drain (Figure 2, Item 1). Install and tighten the grease drain to the torque of 20 lb-ft (27 Nm). Apply sealing compound Loctite 242 to the threads of the lower grease drain (Figure 2, Item 3). Install and tighten the grease drain to the torque of 20 lb-ft (27 Nm). Remove any excess grease from the drain's plugs.
If the electric motor was serviced:
Return the equipment to the desired readiness condition.
0231-7/8 blank
TM 55-1925-273-24&P-2 FIELD MAINTENANCE FIRE AND GENERAL SERVICE PUMP ALIGNMENT
0232
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 3, WP 0344, Table 1, Item 27) Materials/Parts N/A Personnel Required Watercraft Engineer 88L (2) References FM 4-01.502 References (cont.) TM 55-1925-273-10 Volume 3, WP 0327 Volume 3, WP 0344 Equipment Condition Set to OFF the FIRE PUMP #1 circuit breaker at the emergency switchboard or the FIRE PUMP NO. 2 circuit breaker at the main switchboard. Lock out and tag out IAW FM 4-01.502.
0232-1
TM 55-1925-273-24&P-2
0232
VERIFY ALIGNMENT
CAUTION
Keep the flexible coupling faces separated so that they do not make contact with each other when the motor shaft is forced to the limit of the bearing clearance toward the pump. Failure to comply with this caution can result in damage to the pump and motor. 1. Check the parallel alignment using a straight edge held against the edges of the coupling halves at any four places 90 degrees apart around the coupling. The straight edge should be parallel to the pump and the electric motor halves at all times. Check the angular alignment around the coupling by inserting a feeler gage at any four places 90 degrees apart around the coupling as shown in Figure 1.
STRAIGHT EDGE
2.
ANGULAR MISALIGNMENT
PARALLEL MISALIGNMENT
PERFECT ALIGNMENT
THICKNESS GAUGE
M1359T73
Figure 1. Coupling Alignment. 3. If the coupling is out of alignment, loosen the bolts securing the electric motor to the pump and check for foreign objects or dirt trapped between the electric motor and pump mounting surfaces. If no foreign objects or dirt are found, move the electric motor to achieve the desired alignment.
NOTE
Any adjustment to correct one direction of alignment may affect the other direction. Therefore it is necessary to recheck both the angular and the parallel alignment after each adjustment. 4. 5. 6. Check the parallel and angular alignment to ensure that the coupling has been correctly aligned. Remove the lock outs and tag outs IAW FM 4-01.502. Set the applicable circuit breaker to ON.
0232-2
TM 55-1925-273-24&P-2 VERIFY ALIGNMENT - Continued
0232
WARNING
Use extreme caution when working around rotating pump shaft. Do not allow hands or tools to come in contact with the shaft. Do not wear loose clothing, jewelry, or anything else which might become entangled in the shaft. Failure to comply with these precautions can cause serious injury or death. 7. 8. Operate the fire and general service pump IAW TM 55-1925-273-10, checking for any unusual noise or vibration. Return the equipment to the desired readiness condition.
0232-3/4 blank
TM 55-1925-273-24&P-2 FIELD MAINTENANCE FIRE AND GENERAL SERVICE PUMP REPAIR
0233
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 3, WP 0344, Table 1, Item 27) Faceshield, Industrial (Volume 3, WP 0344, Table 1, Item 5) Gloves, Chemical and Oil Protective (Volume 3, WP 0344, Table 1, Item 8) Gloves, Leather (Volume 3, WP 0344, Table 1, Item 9) Goggles, Industrial (Volume 3, WP 0344, Table 1, Item 10) Multimeter (Volume 3, WP 0344, Table 1, Item 15) Suitable Drain Pan Materials/Parts Rag, Wiping (Volume 3, WP 0343, Table 1, Item 132) Tape, Antiseizing; 1/2 in. (Volume 3, WP 0343, Table 1, Item 158) Personnel Required Watercraft Engineer 88L (2) References FM 4-01.502 References (cont.) TC 55-509-1 TM 55-1925-273-10 WP 0232 WP 0236 Volume 3, WP 0327 Volume 3, WP 0343 Volume 3, WP 0344 Equipment Condition Set to OFF the FIRE PUMP #1 circuit breaker at the emergency switchboard. Lock out and tag out IAW FM 4-01.502. Set to OFF the FIRE PUMP NO. 2 circuit breaker at the main switchboard. Lock out and tag out IAW FM 4-01.502. CLOSE valves FM-6, FIRE/G.S. PMP No. 1 SUCT; FM-7, FIRE/G.S. PMP No. 2 SUCT; FM-14, FIRE/G.S. PMP. No. 2 DISCH TO FM; FM-15, FIRE/G.S. PMP. No. 2 DISCH. TO GS; FM-16, FIRE/G.S. PMP No.1 DISCH TO FM; FM-17, FIRE/G.S. PMP No. 1 DISCH TO GS. Lock out and tag out IAW FM 4-01.502.
0233-1
TM 55-1925-273-24&P-2
0233
WIRING REPAIR Proper repair of 24 V wiring consists of replacement of the damaged wiring. When electrical casualty requires expedient repairs, repair may be made by splicing. Splicing is authorized for repair of damaged cables if the remainder of the cable is in good mechanical condition. The cable must be replaced in its entirety at the most opportune time. For proper splicing methods, refer to TC 55-509-1. WIRING (TYPICAL) DISASSEMBLY 1. Remove the two screws (Figure 1, Item 5), and remove the cover (Figure 1, Item 2) from the junction box (Figure 1, Item 4).
WARNING
Replace or repair components only after the affected circuit has been secured, locked out, and tagged out IAW FM 4-01.502. Performing replacement with the circuit energized may result in injury. 2. Use a multimeter to check for voltage at the wire terminals (Figure 1, Item 1). If voltage is present, ensure that the proper circuit breakers are set to OFF, locked out, and tagged out IAW FM 4-01.502. If no voltage is present, continue with the procedure.
0233-2
0233
3
M1360T73
Figure 1. 3. 4. 5. 6. 7. 8. 9.
Typical Junction Box.
Remove any covers or interference that restrict access to the wire being removed. Label all wiring to be removed, and make a sketch of the work area to permit proper assembly. Remove the nuts (Figure 2, Item 1) that secure the wire terminals (Figure 2, Item 3) in the motor controller, and remove the wire nuts from the wire terminals (Figure 1, Item 1) in the junction box (Figure 1, Item 4). Remove the wiring (Figure 1, Item 3) from the junction box (Figure 1, Item 4). Follow the wiring (Figure 1, Item 3) to the opposite end, freeing it from the vessel structure as required. Remove the wiring (Figure 2, Item 2) from the wire terminals (Figure 2, Item 3) at the opposite end. Perform Steps (1) through (8) for any other wire that may require removal.
0233-3
0233
M1361T73
Figure 2. END OF TASK WIRING (TYPICAL) ASSEMBLY 1. 2. 3. 4. 5. 6. 7.
Determine the wires to be connected by referring to the sketches and labels from Step (4) of WIRING (TYPICAL) DISASSEMBLY. Route the wires (Figure 1, Item 3) from the junction box (Figure 1, Item 4) along the same path as the old wires to the motor controller and secure wire terminals (Figure 2, Item 3) with the nuts (Figure 2, Item 1). Connect the wiring (Figure 1, Item 3) in the junction box (Figure 1, Item 4). Remove any remaining labels. Install any covering or interference removed during the WIRING (TYPICAL) DISASSEMBLY procedure. Install the cover (Figure 1, Item 2) on the junction box (Figure 1, Item 4), and secure it with the two screws (Figure 1, Item 5). Perform the FOLLOW-ON MAINTENANCE procedure at the end of this work package.
END OF TASK COUPLING REMOVAL 1. 2. 3. Remove the fire and general service pump electric motor (WP 0236). Loosen the setscrew (Figure 3, Item 4) from the coupling (Figure 3, Item 2). Remove the coupling (Figure 3, Item 2) and the coupling spider (Figure 3, Item 1) from the pump shaft (Figure 3, Item 3).
0233-4
TM 55-1925-273-24&P-2 COUPLING REMOVAL - Continued

1
0233
2 4 3
M1362T73
Figure 3. END OF TASK COUPLING INSTALLATION 1. 2. 3. 4.
Fire and General Service Pump.
Install the coupling (Figure 3, Item 2) and coupling spider (Figure 3, Item 1) on the pump shaft (Figure 3, Item 3), and secure them with the setscrew (Figure 3, Item 4). Install the electric motor (WP 0236). Perform the FIRE AND GENERAL SERVICE PUMP ALIGNMENT procedure (WP 0232). Perform the FOLLOW-ON MAINTENANCE procedure at the end of this work package.
END OF TASK
0233-5
TM 55-1925-273-24&P-2 FLANGED GLOBE VALVE REMOVAL 1. 2. 3. 4. 5. 6. 7. Partially OPEN the valve (Figure 4, Item 3) to equalize the internal pressure before removing any bolts. Place a suitable drain pan under the valve (Figure 4, Item 3). Slowly loosen the bolts (Figure 4, Item 8) and nuts (Figure 4, Item 7) on the inlet side of the valve (Figure 4, Item 3), and allow any pressure to vent and any liquid to drain into the drain pan. Remove the bolts (Figure 4, Item 8) and nuts (Figure 4, Item 7) from the inlet side of the valve (Figure 4, Item 3). Remove the bolts (Figure 4, Item 5) and nuts (Figure 4, Item 6) from the outlet side of the valve (Figure 4, Item 3). Remove the valve (Figure 4, Item 3) from the vessel piping (Figure 4, Item 1). Remove gaskets (Figure 4, Items 2 and 4).
3
0233
M1363T73
0233-6
TM 55-1925-273-24&P-2
0233
FLANGED GLOBE VALVE INSTALLATION
WARNING
Removing components by means of wire brushing produces flying particles. These particles can cause serious injury to personnel. Wear protective faceshield, gloves, and long sleeves at all times during wire brushing operations. Failure to comply with this warning can result in serious injury to personnel. 1. 2. 3. Clean the flanges of valve (Figure 4, Item 3) and vessel piping (Figure 4, Item 1) using a wire brush, clean wiping rags, and water. Install the valve (Figure 4, Item 3) and two gaskets (Figure 4, Items 2 and 4) to the vessel piping, and secure it with the bolts (Figure 4, Items 5 and 8) and the nuts (Figure 4, Items 6 and 7). Perform the FOLLOW-ON MAINTENANCE procedure at the end of this work package.
END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. 4. 5. Remove the lock outs and tag outs IAW FM 4-01.502. Set the circuit breakers to ON. Operate the fire and general service system under usual conditions IAW TM 55-1925-273-10. Check for the proper operation of the system, and check connections for leakage. Return the equipment to the desired readiness condition.
0233-7/8 blank
TM 55-1925-273-24&P-2 FIELD MAINTENANCE FIRE AND GENERAL SERVICE PUMP, PUMP END REPLACE
0234
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 3, WP 0344, Table 1, Item 27) Faceshield, Industrial (Volume 3, WP 0344, Table 1, Item 5) Gloves, Leather (Volume 3, WP 0344, Table 1, Item 9) Goggles, Industrial (Volume 3, WP 0344, Table 1, Item 10) Helmet, Safety (Volume 3, WP 0344, Table 1, Item 11) Hoist, Chain, Hand Operated, 2 Ton (1,814 kg) (Volume 3, WP 0344, Table 1, Item 12) Sling, Endless (Volume 3, WP 0344, Table 1, Item 21) Suitable Drain Pan Materials/Parts Rag, Wiping (Volume 3, WP 0343, Table 1, Item 132) Personnel Required Watercraft Engineer 88L (2) References FM 4-01.502 References (cont.) TM 55-1925-273-10 WP 0236 Volume 3, WP 0328 Volume 3, WP 0343 Volume 3, WP 0344 Equipment Condition For fire and general service pump No. 1, set to OFF the FIRE PUMP #1 circuit breaker on the emergency switchboard. Lock out and tag out IAW FM 4-01.502. CLOSE valves FM-6 FIRE/ G.S. PMP No. 1 SUCT, FM-16 FIRE.G.S. PMP No. 1 DISCH TO FM, and FM-17 FIRE/G.S. PMP No. 1 DISCH TO GS. Lock out and tag out IAW FM 4-01.502. For fire and general service pump No. 2, set to OFF the FIRE PUMP No. 2 circuit breaker on the main switchboard. Lock out and tag out IAW FM 4-01.502. CLOSE valves FM-7 FIRE/G.S. PMP No. 2 SUCT, FM-14 FIRE/G.S. PMP No. 2 DISCH. TO FM, and FM-15 FIRE/G.S. PMP No. 2 DISCH. TO GS. Lock out and tag out IAW FM 4-01.502. Fire and general service pump electric motor removed. (WP 0236)
WARNING
NOTE
Notify the pilothouse that the fire and general service pump will be secured for maintenance. Align the fire main to be pressurized by the engine-driven firefighting pump IAW TM 55-1925-273-10.
0234-1
TM 55-1925-273-24&P-2
0234
PUMP REMOVAL 1. Place a suitable drain pan under the pump.
WARNING
The fire and service general pump may be under pressure. Loosen the plugs on the case slowly and allow water to run around threads of the fitting to release any pressure before removing the plug. Releasing pressurized water suddenly may cause severe personal injury or death. 2. 3. 4. 5. Slowly remove the drain plugs (Figure 1, Items 1, 9, and 13) and allow any pressure to vent and any water to drain into the suitable drain pan. Remove the eight nuts (Figure 1, Item 4) and eight bolts (Figure 1, Item 2) from the suction pipe connection. Remove the eight nuts (Figure 1, Item 5) and bolts (Figure 1, Item 7) from the discharge pipe connection. Remove gaskets (Figure 1, Items 3 and 6).
1 2
6 7
13 SIDE VIEW
12 11 10 FRONT VIEW
8 9
M1383T73
Figure 1. Fire and General Service Pump.
WARNING
All personnel in the vicinity of lifting operations should wear appropriate safety equipment including heavy gloves, hardhats, and safety shoes. Failure to comply with this warning can result in serious injury or death. Heavy loads can crush. Do not allow any body parts to come under the load or between the load and a stationary object. Failure to comply with this warning can result in serious injury or death. 6. Attach the chain hoist to the pump and remove the slack from the chain.
0234-2
TM 55-1925-273-24&P-2 PUMP REMOVAL - Continued 7. 8.
0234
Remove the eight nuts (Figure 1, Item 11) and eight lockwashers (Figure 1, Item 10) that secure the pump to the foundation. Discard lockwashers. Remove the pump from the foundation.
END OF TASK PUMP INSTALLATION
WARNING
Wire brushing operations can produce high velocity flying debris which can become lodged in the skin or in the eyes. Wire brushing in confined areas can result in debris flying from unexpected directions. All personnel working in the area must wear protective faceshield, gloves, and long sleeves when performing wire brushing operations. Failure to comply with this warning can result in serious injury or death to personnel. 1. Clean the suction flanges (Figure 1, Item 12) and the discharge flanges (Figure 1, Item 8) with a wire brush, clean water, and wiping rags.
WARNING
All personnel in the vicinity of lifting operations should wear appropriate safety equipment including heavy gloves, hardhats, and safety shoes. Failure to comply with this warning can result in serious injury or death. Heavy loads can crush. Do not allow any body parts to come under the load or between the load and a stationary object. Failure to comply with this warning can result in serious injury or death. 2. 3. 4. 5. 6. 7. Install the pump on the foundation using the chain hoist, and secure it with the eight nuts (Figure 1, Item 11) and eight lockwashers (Figure 1, Item 10). Remove the chain hoist. Install a gasket (Figure 1, Item 3) between the suction flanges (Figure 1, Item 12), and secure the suction flanges with the eight nuts (Figure 1, Item 4) and eight bolts (Figure 1, Item 2). Install a gasket (Figure 1, Item 6) between the discharge flanges (Figure 1, Item 8), and secure the discharge flanges with the eight nuts (Figure 1, Item 5) and eight bolts (Figure 1, Item 7). Install the drain plugs (Figure 1, Items 1, 9, and 13). Install the fire and general service pump electric motor (WP 0236).
END OF TASK
0234-3
TM 55-1925-273-24&P-2 FOLLOW-ON MAINTENANCE 1. 2. 3. 4. 5. Align pump IAW FIRE AND GENERAL SERVICE PUMP ALIGNMENT procedure (WP 0232). Remove the lock outs and tag outs IAW FM 4-01.502.
0234
Operate the fire and general service pump under usual conditions IAW TM 55-1925-273-10, checking for leaks and proper operation. Notify the pilothouse that the fire and general service pump is back online. Return the fire and general service pump to the desired readiness condition.
0234-4
TM 55-1925-273-24&P-2 FIELD MAINTENANCE FIRE AND GENERAL SERVICE PUMP, PUMP END REPAIR
0235
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 3, WP 0344, Table 1, Item 27) Drill, Electric, Portable (Volume 3, WP 0344, Table 1, Item 4) Drill Set, Twist (Volume 3, WP 0344, Table 1, Item 2) Drill Set, Twist (Volume 3, WP 0344, Table 1, Item 3) Faceshield, Industrial (Volume 3, WP 0344, Table 1, Item 5) Gloves, Chemical and Oil Protective (Volume 3, WP 0344, Table 1, Item 8) Gloves, Leather (Volume 3, WP 0344, Table 1, Item 9) Goggles, Industrial (Volume 3, WP 0344, Table 1, Item 10) Press, Arbor, Hand Operated (Volume 3, WP 0344, Table 1, Item 16) Puller, Mechanical (Volume 3, WP 0344, Table 1, Item 17) Suitable Drain Pan Suitably Sized Lathe Threading Set, Screw (Volume 3, WP 0344, Table 1, Item 24) Materials/Parts Compound, Sealing; Loctite 242 (Volume 3, WP 0343, Table 1, Item 43) Rag, Wiping (Volume 3, WP 0343, Table 1, Item 132) Gasket (Volume 3, WP 0328, Figure 80, Item 15) Qty: 1 Materials/Parts (cont.) Seal, Plain Encased (Volume 3, WP 0328, Figure 80, Item 3) Qty: 1 Seal, Oil (Volume 3, WP 0328, Figure 80, Item 5) Qty: 1 O-ring (Volume 3, WP 0328, Figure 80, Item 6) Qty: 2 Ring, Retaining (Volume 3, WP 0328, Figure 80, Item 13) Qty: 1 Seal, Oil (Volume 3, WP 0328, Figure 80, Item 11) Qty: 1 Personnel Required Watercraft Engineer 88L (2) References FM 4-01.502 TC 9-524 TM 55-1925-273-10 WP 0234 Volume 3, WP 0328 Volume 3, WP 0343 Volume 3, WP 0344 Equipment Condition Fire and general service pump removed. (WP 0234)
0235-1
TM 55-1925-273-24&P-2
0235
WARNING
Never reuse locking hardware. Reuse of locking hardware such as lockwashers, locking nuts, cotter pins, and lock wire can result in undetected loosening of fastening hardware causing catastrophic component failure resulting in death, injury, or damage to equipment. Ensure that all locking hardware is discarded upon removal and replaced with new. PUMP DISASSEMBLY 1. 2. 3. 4. 5. 6. 7. 8. Remove the bolts (Figure 1, Item 26) that secure the base (Figure 1, Item 27) to the pump body (Figure 1, Item 2). Remove the bolts (Figure 1, Item 3) that secure the alignment bracket (Figure 1, Item 1) to the pump body (Figure 1, Item 2). Remove the capscrews (Figure 1, Item 60), and remove the casing (Figure 1, Item 59) from the pump body (Figure 1, Item 2). Remove and discard gasket (Figure 1, Item 61). Remove the two capscrews (Figure 1, Item 20), and remove the outboard bearing caps (Figure 1, Item 19) and pin (Figure 1, Item 18). Remove the two capscrews (Figure 1, Item 43), and remove the inboard bearing cap (Figure 1, Item 42) and pin (Figure 1, Item 41). Remove the nut (Figure 1, Item 30), washer (Figure 1, Item 32), and gland clamp (Figure 1, Item 33). Remove the swing bolt (Figure 1, Item 34) from the outboard group. Remove the nut (Figure 1, Item 56), washer (Figure 1, Item 54), and gland clamp (Figure 1, Item 53), and remove the swing bolt (Figure 1, Item 51) from the inboard group.
CAUTION
Use care when moving the impeller and shaft assembly. The ceramic seats can be cracked from sliding down the shaft. To prevent the ceramic seats from being damaged, wrap the mechanical seals in a cloth to secure them. 9. 10. 11. 12. 13. 14. Remove the impeller (Figure 1, Item 11) and shaft (Figure 1, Item 7) from the pump body (Figure 1, Item 2). Remove the upper slinger (Figure 1, Item 37) from the end of the shaft (Figure 1, Item 7). Remove the capscrews (Figure 1, Item 36), and remove the inboard cartridge cap (Figure 1, Item 58) from the shaft (Figure 1, Item 7). Remove and discard gasket (Figure 1, Item 38). Remove and discard grease seal (Figure 1, Item 39). Using a mechanical gear and bearing puller, remove the inboard group bearing cartridge (Figure 1, Item 51), the grease seal (Figure 1, Item 55), and the bearing (Figure 1, Item 40) from the shaft (Figure 1, Item 7). Discard grease seal. Remove the slinger (Figure 1, Item 52) from the shaft (Figure 1, Item 7). Remove the upper gland (Figure 1, Item 44) from the shaft (Figure 1, Item 7). Remove O-ring (Figure 1, Item 50).
15. 16. 17.
CAUTION
Use care in removing the seal assembly to prevent marring or damaging the mating surfaces. 18. Remove the upper mechanical seal (Figure 1, Item 49) from the shaft (Figure 1, Item 7).
0235-2
TM 55-1925-273-24&P-2 PUMP DISASSEMBLY - Continued 19. 20. 21. 22. 23. 24.
0235
Mark the position of the upper sleeve (Figure 1, Item 46) on the shaft (Figure 1, Item 7) to ensure correct orientation of the upper seal collar (Figure 1, Item 48) during pump assembly. Loosen the setscrew (Figure 1, Item 47), and remove the upper seal collar (Figure 1, Item 48) and the upper sleeve (Figure 1, Item 46) from the shaft (Figure 1, Item 7). Remove and discard O-ring (Figure 1, Item 45). Remove the lower race (Figure 1, Item 24) from the shaft (Figure 1, Item 7). Remove the capscrew (Figure 1, Item 25), and remove the cartridge cap (Figure 1, Item 23) and the gasket (Figure 1, Item 22) from the shaft (Figure 1, Item 7). Remove the retainer clip (Figure 1, Item 28). Using a mechanical gear and bearing puller, remove the outboard group bearing cartridge (Figure 1, Item 29), the grease seal (Figure 1, Item 31), and the bearing (Figure 1, Item 21) from the shaft (Figure 1, Item 7). Discard retainer clip and grease seal. Remove the lower slinger (Figure 1, Item 17) from the shaft (Figure 1, Item 7). Remove the lower gland (Figure 1, Item 16) from the shaft (Figure 1, Item 7). Remove the O-ring (Figure 1, Item 15) from the lower gland (Figure 1, Item 16). Remove the lower mechanical seal (Figure 1, Item 14) from the shaft (Figure 1, Item 7). Mark the position of the lower sleeve (Figure 1, Item 12) on the shaft (Figure 1, Item 7) to ensure correct orientation of the lower seal collar (Figure 1, Item 13) during pump assembly. Loosen the setscrew (Figure 1, Item 35), and remove the lower seal collar (Figure 1, Item 13) and the lower sleeve (Figure 1, Item 12) from the shaft (Figure 1, Item 7). Remove and discard O-ring (Figure 1, Item 8). Remove the upper key (Figure 1, Item 10) from the shaft (Figure 1, Item 7). Remove the two pins (Figure 1, Item 4) and the outer races (Figure 1, Item 5) from the impeller (Figure 1, Item 11). Inspect the wear rings (Figure 1, Item 3) for damage and wear. If the outside diameter of the wear rings does not match the inside diameter of the outer races, the wear rings must be replaced. When replacing the wear rings, if the seating surface area on the impeller (Figure 1, Item 11) is damaged, build up the damaged area and machine using standard shop practices IAW TC 9-524. Verify that the outside diameter of the seating area corresponds to the inside diameter of the wear rings (Figure 1, Item 6). Remove lower key (Figure 1, Item 9) from the shaft (Figure 1, Item 7).
25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35.
36.
0235-3
TM 55-1925-273-24&P-2 PUMP DISASSEMBLY - Continued

5 4 36 6 1 11 58 57 56 55 54 53 4 6 52 51 3
DISCHARGE
0235
INBOARD GROUP 37
38 39 40 41 42 43 44
12 10 5 13 7 14 48 47 15 16 9 46 34 33 32 2 30 29 28 22 23 61 25 27 26 24
OUTBOARD GROUP
50 49
MECHANICAL SEAL
35
45 17 31 18 19 20 21 59 8
SUCTION
60
M1364T73
Figure 1. Fire and General Service Pump. END OF TASK
0235-4
TM 55-1925-273-24&P-2 PUMP ASSEMBLY
0235
WARNING
Wire brushing operations can produce high velocity flying debris which can become lodged in the skin or in the eyes. Wire brushing in confined areas can result in debris flying from unexpected directions. All personnel working in the area must wear protective faceshield, gloves, and long sleeves when performing wire brushing operations. Failure to comply with this warning can result in serious injury or death to personnel. 1. 2. 3. 4. 5. Clean the mating surfaces of the casing (Figure 1, Item 59) and the pump body (Figure 1, Item 2) with a wire brush, clean water, and wiping rags. Apply sealing compound on the inner diameter of the impeller wear rings (Figure 1, Item 6). Press fit the wear rings to the seating surfaces of the impeller (Figure 1, Item 11). Install the outer races (Figure 1, Item 5) on the wear ring (Figure 1, Item 6) seating surfaces of the impeller (Figure 1, Item 11). Secure the races with the two pins (Figure 1, Item 4). Apply sealing compound to the recess in the shaft (Figure 2, Item 1), and install the lower key (Figure 1, Item 9) on the shaft. Apply sealing compound to the recess in the shaft (Figure 2, Item 1), and install the upper key (Figure 2, Item 10) on the drive end of the shaft.
KEY IN SHAFT IS POSITIONED FIRMLY INTO SLEEVE KEYWAY 1 2
SHOULDER WHICH BALL BEARING WILL BE LOCKED AGAINST
DRIVE END 8.234 IN. (209.144 mm)
ROTATION
CURVE OF IMPELLER BLADE
M1365T73
Figure 2. 6. 7. 8.
Shaft Key for Rotation.
Install an O-ring (Figure 1, Item 8) on the lower part of the shaft (Figure 1, Item 7). Install the lower sleeve (Figure 1, Item 12) on the shaft (Figure 1, Item 7) using the marks from Step (29) of DISASSEMBLY as a guide to ensure correct orientation. Install the lower seal collar (Figure 1, Item 13) on the shaft (Figure 1, Item 7) using the marks from Step (29) of DISASSEMBLY as a guide to ensure correct orientation. Secure it with the setscrew (Figure 1, Item 35).
0235-5
TM 55-1925-273-24&P-2 PUMP ASSEMBLY - Continued 9. 10. 11. 12. 13. 14. 15. 16. 17. Install the lower mechanical seal (Figure 1, Item 14) on the shaft (Figure 1, Item 7).
0235
Install an O-ring (Figure 1, Item 15) on the lower gland (Figure 1, Item 16). Install the lower gland on the shaft (Figure 1, Item 7). Install the lower slinger (Figure 1, Item 17) on the shaft (Figure 1, Item 7). Install the bearing (Figure 1, Item 21), the outboard group bearing cartridge (Figure 1, Item 29), and grease seal (Figure 1, Item 31) on the shaft (Figure 1, Item 7). Secure them with a retainer clip (Figure 1, Item 28). Install the cartridge cap (Figure 1, Item 23) and a gasket (Figure 1, Item 22) on the shaft (Figure 1, Item 7). Secure them with the capscrew (Figure 1, Item 25). Install the lower race (Figure 1, Item 24) on the shaft (Figure 1, Item 7). Install an O-ring (Figure 1, Item 45) on the upper part of the shaft (Figure 1, Item 7). Install the upper sleeve (Figure 1, Item 46) on the shaft (Figure 1, Item 7) using the marks from Step (19) of DISASSEMBLY as a guide to ensure correct orientation. Install the upper seal collar (Figure 1, Item 48) on the shaft (Figure 1, Item 7) using the marks from Step (19) of DISASSEMBLY as a guide to ensure correct orientation. Secure it with the setscrew (Figure 1, Item 47).
CAUTION
Use care when installing the seal assembly to prevent marring or damaging the mating surfaces. 18. 19. 20. 21. 22. 23. 24. Install an O-ring (Figure 1, Item 50) on the upper mechanical seal (Figure 1, Item 49). Install the mechanical seal on the shaft (Figure 1, Item 7). Install the upper gland (Figure 1, Item 44) on the shaft (Figure 1, Item 7). Install the slinger (Figure 1, Item 52) on the shaft (Figure 1, Item 7). Install the bearing (Figure 1, Item 40), grease seal (Figure 1, Item 55), and the inboard group bearing cartridge (Figure 1, Item 57) on the shaft (Figure 1, Item 7). Install a grease seal (Figure 1, Item 39) and gasket (Figure 1, Item 38) on the shaft (Figure 1, Item 7). Install the inboard cartridge cap (Figure 1, Item 58) on the shaft (Figure 1, Item 7), and secure it with the capscrews (Figure 1, Item 36). Install the upper slinger (Figure 1, Item 37) on the shaft (Figure 1, Item 7).
CAUTION
Use care when moving the impeller and shaft assembly. The ceramic seats can be cracked from sliding down the shaft. To prevent the ceramic seats from being damaged, wrap the mechanical seals in a cloth to secure them. 25. 26. 27. 28. 29. Install the impeller (Figure 1, Item 11) and the shaft (Figure 1, Item 7) into the pump body (Figure 1, Item 2). Install the inboard group swing bolt (Figure 1, Item 51). Secure it with the nut (Figure 1, Item 56), washer (Figure 1, Item 54), and gland clamp (Figure 1, Item 53). Install the outboard group swing bolt (Figure 1, Item 34). Secure it with the nut (Figure 1, Item 30), washer (Figure 1, Item 32), and gland clamp (Figure 1, Item 33). Install the inboard bearing caps (Figure 1, Item 42). Secure them with the pin (Figure 1, Item 41) and the two capscrews (Figure 1, Item 43). Install the outboard bearing caps (Figure 1, Item 19). Secure them with the pin (Figure 1, Item 18) and the two capscrews (Figure 1, Item 20).
0235-6
TM 55-1925-273-24&P-2 PUMP ASSEMBLY - Continued 30. 31. 32. 33. 34. Install a gasket (Figure 1, Item 61) on the casing mating surface of the pump body (Figure 1, Item 2). Install the casing (Figure 1, Item 59) on the pump body (Figure 1, Item 2). Secure it with the capscrews (Figure 1, Item 60). Install the base (Figure 1, Item 27) on the pump body (Figure 1, Item 2). Secure it with the bolts (Figure 1, Item 26).
0235
Install the alignment bracket (Figure 1, Item 1) on the pump body (Figure 1, Item 2). Secure it with the bolts (Figure 1, Item 3). Install the fire and general service pump (WP 0234).
END OF TASK THREAD REPAIR Damaged female threads may be replaced by installing thread inserts. The procedure below describes this process.
NOTE
The size of the holes drilled and tapped will vary depending upon the size of the insert used. 1. 2. 3. Select the proper size thread insert. The proper size thread insert should have the same size female threads as the fastener that will thread into it. Measure the external thread size and pitch of the thread insert selected in Step (1) above. Select the tap that corresponds to the external thread size and pitch of the insert selected in Step (1) above. Also select the proper size drill bit (Figure 3, Item 1) for use with the tap.
WARNING
Drilling operations produce high velocity flying debris which can become lodged in skin or in the eyes. All personnel working in the area must wear protective eyewear, gloves, and long sleeves when performing grinding, needling, and chipping operations. Failure to comply with this warning can result in serious injury or death to personnel. 4. Drill out the damaged threads (Figure 3, Item 2) using the drill bit (Figure 3, Item 1) selected in Step (3) above. Chamfer the hole with a standard countersink (82 to 100 degrees).
0235-7
0235
2
M1366T73
Figure 3. Removing Old Threads. 5. Tap threads in the hole using the tap (Figure 4, Item 1) selected in Step (3) above.
1
M1367T73
Figure 4. 6.
Tapping New Threads.
Thread the insert (Figure 5, Item 2) into the threads until the top of the insert is slightly below the surface.
1
M1368T73
Figure 5.
Installing the Insert.
0235-8
TM 55-1925-273-24&P-2 THREAD REPAIR - Continued 7. Drive down the keys (Figure 5, Item 1 and Figure 6, Item 3) using the insert's installation tool (Figure 6, Item 1) or a round, flat driver. The keys should be flush with the surface (Figure 6, Item 2).
0235
M1369T73
Figure 6. 8.
Drive Down the Keys.
Thread a fastener of the desired thread size and pitch into the insert to ensure that the insert is installed properly.
END OF TASK MACHINING REPAIRS Due to replacement part availability, expediency of repair, and other factors, it may sometimes be necessary to repair existing pump components rather than replacing them. For example, a pump shaft may be worn in the seal area, but otherwise serviceable. If a pump shaft is unavailable, or if the unit must be returned to service with minimal down time, it may be possible to build up and re-machine the worn shaft area. The same holds true for volutes, housings, and impeller wear ring seats. Always confer with the work center supervisor before performing machining repairs to determine the proper course of action and to determine the feasibility of the repair. No matter what form of machining repairs will be accomplished, ensure that the repairs conform to standard machine shop practices and procedures and all applicable regulations.
0235-9
TM 55-1925-273-24&P-2 MACHINING REPAIRS - Continued MACHINING 1.
0235
Chuck the impeller (Figure 7, Item 2) and shaft (Figure 7, Item 4) in a suitably sized lathe (Figure 7, Item 1).
WARNING
Use extreme caution when working around rotating impeller and shaft. Do not wear loose clothing, jewelry, or anything else which might become entangled in the shaft or parts of the lathe that spin. Wear protective eyewear. Failure to comply with these precautions can cause serious injury or death.
CAUTION
Take care not to remove any material from the impeller itself during the machining operation. 2. 3. 4. 5. 6. Machine away the wear ring (Figure 7, Item 3) until its thickness is approximately 0.030 in. (0.762 mm). With the impeller (Figure 7, Item 2) still chucked in the lathe (Figure 7, Item 1), use a cape chisel to gently cut one side of the impeller wear ring (Figure 7, Item 3), taking care not to gouge the impeller in the process. Remove the wear ring (Figure 7, Item 3) from the impeller (Figure 7, Item 2). Repeat Steps (1) through (4) above for the wear ring (Figure 7, Item 3) on the opposite side of the impeller if necessary. Carefully inspect the seat area for the wear ring (Figure 7, Item 3). If the area is damaged, build up the damaged area and remachine using standard shop practices IAW TC 9-524. Use the wear ring to gage the outside diameter of the impeller (Figure 7, Item 2). The wear ring should be a light press fit (0.003 to 0.005 in. [0.0762 to 0.1270 mm] interference). Once the wear ring(s) (Figure 7, Item 3) is removed, remove the impeller (Figure 7, Item 2) and shaft (Figure 7, Item 4) assembly from the lathe. Install wear rings (Figure 7, Item 3) onto the impeller (Figure 7, Item 2) and install the impeller into the pump (WP 0237).
7. 8.
0235-10
TM 55-1925-273-24&P-2 MACHINING REPAIRS - Continued MACHINING - Continued

1 2 3 4
0235
M1370T73
Impeller Machining.
0235-11/12 blank
TM 55-1925-273-24&P-2 FIELD MAINTENANCE FIRE AND GENERAL SERVICE PUMP ELECTRIC MOTOR REPLACE
0236
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 3, WP 0344, Table 1, Item 27) Gloves, Leather (Volume 3, WP 0344, Table 1, Item 9) Helmet, Safety (Volume 3, WP 0344, Table 1, Item 11) Hoist, Chain, Hand Operated, 2 Ton (1,814 kg) (Volume 3, WP 0344, Table 1, Item 12) Multimeter (Volume 3, WP 0344, Table 1, Item 15) Sling, Endless (Volume 3, WP 0344, Table 1, Item 21) Materials/Parts N/A Personnel Required Watercraft Engineer 88L (2) References FM 4-01.502 TM 55-1925-273-10 References (cont.) WP 0232 Volume 3, WP 0329 Volume 3, WP 0344 Equipment Condition For fire and general service pump No. 1, set to OFF the FIRE PUMP #1 circuit breaker on the emergency switchboard. Lock out and tag out IAW FM 4-01.502. CLOSE valves FM-6 FIRE/ G.S. PMP No. 1 SUCT, FM-16 FIRE/G.S. PMP No. 1 DISCH TO FM, and FM-17 FIRE/G.S. PMP No. 1 DISCH TO GS. Lock out and tag out IAW FM 4-01.502. For fire and general service pump No. 2, set to OFF the FIRE PUMP No. 2 circuit breaker on the main switchboard. Lock out and tag out IAW FM 4-01.502. CLOSE valves FM-7 FIRE/G.S. PMP No. 2 SUCT, FM-14 FIRE/G.S. PMP. No. 2 DISCH. TO FM, and FM-15 FIRE/G.S. PMP. No. DISCH. TO GS. Lock out and tag out IAW FM 4-01.502.
ELECTRIC MOTOR REMOVAL
NOTE
Notify the pilothouse that the fire and general service pump will be secured for maintenance. Align the fire main to be pressurized by the engine-driven firefighting pump IAW TM 55-1925-273-10. Ensure that the engine-driven firefighting pump is operational and can be used to supply the fire main in case the remaining fire and general service pump fails.
0236-1
TM 55-1925-273-24&P-2 ELECTRIC MOTOR REMOVAL - Continued
0236
NOTE
Electrical junction boxes may vary in size, shape, and mounting position of the box on the motor frame. Electrical junction box covers may vary in number and placement of screws holding the cover in place. 1. Remove the two screws (Figure 1, Item 1), and remove the cover (Figure 1, Item 2) from the junction box (Figure 1, Item 4).
WARNING
Replace or repair components only after the affected circuit has been secured, locked out, and tagged out IAW FM 4-01.502. Performing replacement with the circuit energized may result in injury. 2. Use a multimeter to check for voltage at the wire terminals (Figure 1, Item 1). If voltage is present, ensure that the proper circuit breakers are set to OFF, locked out, and tagged out IAW FM 4-01.502. If no voltage is present, continue with the procedure. Label and remove the wiring (Figure 1, Item 3) from the junction box (Figure 1, Item 4). Attach the chain hoist to the eye pads (Figure 2, Item 1) on the motor (Figure 2, Item 5), and take a slight strain to remove the slack from the chain. Remove the four bolts (Figure 2, Item 2) and the four flat washers (Figure 2, Item 3) from the motor (Figure 2, Item 5).
3. 4. 5.
WARNING
All personnel in the vicinity of lifting operations should wear appropriate safety equipment including heavy gloves, hardhats, and safety shoes. Failure to comply with this warning can result in serious injury or death. Heavy loads can crush. Do not allow any body parts to come under the load or between the load and a stationary object. Failure to comply with this warning can result in serious injury or death. 6. Slowly lift the motor (Figure 2, Item 5) off the foundation (Figure 2, Item 4) using the chain hoist. Lower it to the deck.
0236-2
0236
3
M1371T73
Figure 1.
Typical Junction Box.
0236-3
0236
2 3 4
M1372T73
Figure 2. Fire and General Service Pump Motor. END OF TASK ELECTRIC MOTOR INSTALLATION
WARNING
All personnel in the vicinity of lifting operations should wear appropriate safety equipment including heavy gloves, hardhats, and safety shoes. Failure to comply with this warning can result in serious injury or death. Heavy loads can crush. Do not allow any body parts to come under the load or between the load and a stationary object. Failure to comply with this warning can result in serious injury or death. 1. 2. 3. 4. Attach the chain hoist to the eye pads (Figure 2, Item 1) on the motor (Figure 2, Item 5) and take a slight strain to remove the slack from the chain. Slowly lift the motor (Figure 2, Item 5) and position it on the foundation (Figure 2, Item 4). Verify that the mounting holes on the motor (Figure 2, Item 5) are aligned with the holes on the foundation (Figure 2, Item 4). Install the motor (Figure 2, Item 5) on the foundation, and secure it with the four bolts (Figure 2, Item 2) and the four flat washers (Figure 2, Item 3).
0236-4
TM 55-1925-273-24&P-2 ELECTRIC MOTOR INSTALLATION - Continued 5. Remove the chain hoist from the motor (Figure 2, Item 5).
0236
END OF TASK FOLLOW ON MAINTENANCE 1. 2. 3. 4. 5. 6. Perform the FIRE AND GENERAL SERVICE PUMP ALIGNMENT procedure (WP 0232). Remove the lock outs and tag outs IAW FM 4-01.502. Set the circuit breakers to ON. Operate the fire and general service pump under usual conditions IAW TM 55-1925-273-10, and ensure that the pump operates normally and without unusual noise or vibration. Notify the pilothouse that the fire and general service pump is back online. Return the equipment to the desired readiness condition.
0236-5/6 blank
TM 55-1925-273-24&P-2 FIELD MAINTENANCE FIRE AND GENERAL SERVICE PUMP ELECTRIC MOTOR REPAIR
0237
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 3, WP 0344, Table 1, Item 27) Faceshield, Industrial (Volume 3, WP 0344, Table 1, Item 5) Gloves, Chemical and Oil Protective (Volume 3, WP 0344, Table 1, Item 8) Goggles, Industrial (Volume 3, WP 0344, Table 1, Item 10) Hoist, Chain, Hand Operated, 2 ton (1,814 kg) (Volume 3, WP 0344, Table 1, Item 12) Lubricating Gun, Hand (Volume 3, WP 0344, Table 1, Item 14) Multimeter (Volume 3, WP 0344, Table 1, Item 15) Wrench, Torque, 0-250 lb-ft (0-339 Nm) (Volume 3, WP 0344, Table 1, Item 33) Materials/Parts Cleaning Compound, Solvent (Volume 3, WP 0343, Table 1, Item 37) Compound, Sealing; Loctite 242 (Volume 3, WP 0343, Table 1, Item 43) Materials/Parts (cont.) Grease, Ball and Roller Bearing; 1.75 lb (Volume 3, WP 0343, Table 1, Item 74) Rag, Wiping (Volume 3, WP 0343, Table 1, Item 132) Personnel Required Watercraft Engineer 88L (2) References TM 55-1925-273-10 WP 0236 WP 0245 Volume 3, WP 0329 Volume 3, WP 0343 Volume 3, WP 0344 Equipment Condition Electric motor removed. (WP 0236)
0237-1
TM 55-1925-273-24&P-2
0237
WARNING
Never reuse locking hardware. Reuse of locking hardware such as lockwashers, locking nuts, cotter pins, and lock wire can result in undetected loosening of fastening hardware causing catastrophic component failure resulting in death, injury, or damage to equipment. Ensure that all locking hardware is discarded upon removal and replaced with new. DISASSEMBLY 1. 2. 3. 4. 5. 6. 7. 8. 9. OPEN the grease drains (Figure 1, Items 19 and 30) and drain the grease from the unit. Remove the grease drains (Figure 1, Items 19 and 30). Remove the grease fitting (Figure 1, Item 15). Remove the eye pads (Figure 1, Item 3). Remove the canopy (Figure 1, Item 2) from the fan cover guard (Figure 1, Item 38). Remove the nuts (Figure 1, Item 37) and washers (Figure 1, Item 36) from the fan cover guard (Figure 1, Item 38). Remove the lock screw (Figure 1, Item 41) from the pump head shaft nut (Figure 1, Item 40). Remove the pump head shaft nut from the pump head shaft (Figure 1, Item 1). Discard lock screw. Remove the bolt and associated hardware (Figure 1, Item 6) from the bolted coupling (Figure 1, Item 5). Remove the bolted coupling (Figure 1, Item 5) and gib key (Figure 1, Item 4). Remove the locknut (Figure 1, Item 7) and lockwasher (Figure 1, Item 8) from the pump head shaft (Figure 1, Item 1). Discard locknut and lockwasher.
0237-2
0237
1 41 40
2 3 4 5
39 38 37 36 35 34 33 32 31 30 29 28 27 26
6 7 8 9 10 11 12 13 14
15
16
25
17
18 24 23 22 19
21 20
M1373T73
Figure 1. Fire and General Service Pump Electric Motor (Typical).
0237-3
TM 55-1925-273-24&P-2 DISASSEMBLY - Continued 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22.
0237
Remove the bolts and associated hardware (Figure 1, Item 39) securing the fan (Figure 1, Item 9) to the coupling adaptor (Figure 1, Item 11). Remove the coupling adaptor (Figure 1, Item 11) and the key (Figure 1, Item 10) from the pump head shaft (Figure 1, Item 1). Remove the ball retaining ring (Figure 1, Item 35) securing the ratchet ball (Figure 1, Item 34). Remove the ratchet ball. Remove the bolts (Figure 1, Item 32) securing the stationary ratchet (Figure 1, Item 31). Remove the stationary ratchet. Remove the bolts (Figure 1, Item 12) securing the bearing cap (Figure 1, Item 13) and remove the bearing cap. Remove the rotating ratchet (Figure 1, Item 33). Remove the bolts (Figure 1, Item 28) and washer (Figure 1, Item 27) securing the upper bracket (Figure 1, Item 26). Remove the upper bracket. Remove the bolts (Figure 1, Item 29) securing the bearing cap (Figure 1, Item 16) to the upper bracket (Figure 1, Item 26). Separate the bearing cap from the upper bracket. Separate the upthrust and guide bearing (Figure 1, Item 14) from the upper bracket (Figure 1, Item 26). Remove the grease fitting (Figure 1, Item 23). Remove the bolts (Figure 1, Item 24) from the lower bracket (Figure 1, Item 21). Separate the lower bracket from the stator and rotor housing (Figure 1, Item 25). Remove the bolts (Figure 1, Item 20) securing the bearing cap (Figure 1, Item 17) to the lower bracket (Figure 1, Item 21). Separate the bearing cap from the lower bracket. Remove the single bearing (Figure 1, Item 22) from the lower bracket (Figure 1, Item 21). Remove the tandem thrust bearings (Figure 1, Item 18) from the lower bracket (Figure 1, Item 21).
END OF TASK CLEAN AND INSPECT
WARNING
Cleaning solvent is flammable and its vapor is potentially explosive. Do not use cleaning solvent in the vicinity of spark, open flame, or excessive heat. Do not use cleaning solvent in unventilated spaces. Always wear chemical protective gloves and goggles when handling hydraulic fluid, engine oil, and cleaning solvents. Failure to comply with this warning can result in serious injury or death. 1. 2. Clean all of the removed parts with cleaning solvent and clean wiping rags. Check for any binding, scoring, or burrs on the bearings (Figure 1, Items 14, 18, and 22) and all other removed parts. Inspect all component parts for unusual wear or damage. Replace worn or damaged parts.
0237-4
TM 55-1925-273-24&P-2 CLEAN AND INSPECT - Continued
0237
CAUTION
Do not exceed 25 PSI (1.7 bar) nozzle pressure when using compressed air to dry parts. Wear goggles for eye protection. Do not direct air stream toward self or other personnel. Do not permit the ball bearings to free spin in the bearing race as the bearing is being subjected to the compressed air. Bearing failure will result. 3. Direct a stream of compressed air at the bearings (Figure 1, Items 14, 18, and 22) to remove any debris.
END OF TASK ASSEMBLY
NOTE
Refer to (WP 0245) for torque specifications of all torque callouts. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. Install the tandem thrust bearings (Figure 1, Item 18) into the lower bracket (Figure 1, Item 21). Install the single bearing (Figure 1, Item 22) into the lower bracket (Figure 1, Item 21). Install the bearing cap (Figure 1, Item 17) onto the lower bracket (Figure 1, Item 21). Install the bolts (Figure 1, Item 20) securing the bearing cap to the lower bracket. Install the lower bracket onto the stator and rotor housing (Figure 1, Item 25). Install the bolts (Figure 1, Item 24) into the lower bracket (Figure 1, Item 21). Install the grease fitting (Figure 1, Item 23) into the lower bracket (Figure 1, Item 21). Install the upthrust and guide bearing (Figure 1, Item 14) into the upper bracket (Figure 1, Item 26). Install the bearing cap (Figure 1, Item 16) onto the upper bracket (Figure 1, Item 26). Install the bolts (Figure 1, Item 29) securing the bearing cap to the upper bracket. Install the upper bracket (Figure 1, Item 26) onto the stator and housing rotor (Figure 1, Item 25). Install the bolts (Figure 1, Item 28) and washer (Figure 1, Item 27) securing the upper bracket. Install the rotating ratchet (Figure 1, Item 33). Install the bearing cap (Figure 1, Item 13). Install the bolts securing the bearing cap (Figure 1, Item 12). Install the stationary ratchet (Figure 1, Item 31) and install the bolts (Figure 1, Item 32) securing the stationary ratchet. Install the ratchet ball (Figure 1, Item 34). Install the ball retaining ring (Figure 1, Item 35) to secure the ratchet ball. Install the coupling adaptor (Figure 1, Item 11) and the key (Figure 1, Item 10) into the pump head shaft (Figure 1, Item 1). Install a lockwasher (Figure 1, Item 8) and a locknut (Figure 1, Item 7) onto the pump head shaft (Figure 1, Item 1). Install the fan (Figure 1, Item 9) onto the pump head shaft (Figure 1, Item 1). Install the bolts and associated hardware (Figure 1, Item 39) securing the fan to the coupling adaptor (Figure 1, Item 11). Install the bolted coupling (Figure 1, Item 5) and gib key (Figure 1, Item 4). Install the bolt and associated hardware (Figure 1, Item 6) into the bolted coupling (Figure 1, Item 5).
0237-5
0237
CAUTION
Failure to observe applicable torques may cause extensive damage to the electric motor. 18. Install the pump head shaft nut (Figure 1, Item 40) onto the pump head shaft (Figure 1, Item 1). Tighten the pump head shaft nut to the applicable torque (WP 0245) and align the pin hole with the lock screw (Figure 1, Item 41) hole in bolted coupling (Figure 1, Item 5). Install a locking screw (Figure 1, Item 41) into the pump head shaft nut (Figure 1, Item 40) and the bolted coupling (Figure 1, Item 5). Install nuts (Figure 1, Item 37) and washers (Figure 1, Item 36) securing the fan cover guard (Figure 1, Item 38). Install the canopy (Figure 1, Item 2) onto the fan cover guard (Figure 1, Item 38). Install the eye pads (Figure 1, Item 3). Install the grease fitting (Figure 1, Item 15). Install the upper grease drain (Figure 1, Item 30). Do not tighten the grease drain at this time. Install the lower grease drain (Figure 1, Item 19). Do not tighten the grease drain at this time.
19. 20. 21. 22. 23. 24. 25.
CAUTION
Do not apply grease into the upper or the lower grease fittings while the upper or the lower grease drains CLOSED. 26. 27. 28. 29. Add 0.4 oz (12 cc) of grease into the upper grease fill (Figure 1, Item 15) using a lubricating gun. Wipe any excess grease from the grease fills using a wiping rag. Add 0.6 oz (18 cc) of grease into the lower grease fill (Figure 1, Item 23) using a lubricating gun. Wipe any excess grease from the grease fills using a wiping rag. Apply Loctite thread sealant to the threads of the upper grease drains (Figure 1, Item 30). Torque the upper grease drains to 20 lb-ft (27 Nm). Apply Loctite thread sealant to the threads of the lower grease drain (Figure 1, Item 19). Torque the lower grease drain to 20 lb-ft (27 Nm).
0237-6
TM 55-1925-273-24&P-2 FIELD MAINTENANCE WORK SHOP EQUIPMENT PRESS, DRILL REPLACE
0238
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 3, WP 0344, Table 1, Item 27) Multimeter (Volume 3, WP 0344, Table 1, Item 15) Materials/Parts N/A Personnel Required Watercraft Engineer 88L (2) References FM 4-01.502 References (cont.) TM 55-1925-273-10 Volume 3, WP 0330 Volume 3, WP 0344 Equipment Condition Set to OFF the MACHINE SHOP EQUIPMENT JUNCTION BOX (LATHE/GRINDER/DRILL PRESS) circuit breaker in the load center distribution panel. Lock out and tag out IAW FM 4-01.502.
0238-1
TM 55-1925-273-24&P-2
0238
WARNING
Never reuse locking hardware. Reuse of locking hardware such as lockwashers, locking nuts, cotter pins, and lock wire can result in undetected loosening of fastening hardware causing catastrophic component failure resulting in death, injury, or damage to equipment. Ensure that all locking hardware is discarded upon removal and replaced with new. DRILL PRESS REMOVAL 1. Remove the two screws (Figure 1, Item 3) and the junction box cover (Figure 1, Item 4).
WARNING
Replace or repair components only after the affected circuit has been secured, locked out, and tagged out IAW FM 4-01.502. Performing replacement with the circuit energized may result in injury. 2. Use a multimeter to check for voltage at the terminals in the junction box (Figure 1, Item 4). If voltage is present, ensure that the proper circuit breaker is set to OFF, locked out, and tagged out IAW FM 4-01.502. If no voltage is present, continue with the procedure. Label and disconnect the drill press wiring (Figure 1, Item 2). Remove the four bolts (Figure 1, Item 5), four flat washers (Figure 1, Item 6), four lockwashers (Figure 1, Item 7), and four nuts (Figure 1, Item 8). Discard lockwashers. Remove the drill press (Figure 1, Item 1) from the workbench.
3. 4. 5.
0238-2
TM 55-1925-273-24&P-2 DRILL PRESS REMOVAL - Continued
0238
4 5 6
7 8
M1158T73
Figure 1. END OF TASK DRILL PRESS INSTALLATION 1. 2. 3.
Drill Press.
Place the drill press (Figure 1, Item 1) on the workbench, and secure it with the four bolts (Figure 1, Item 5), four flat washers (Figure 1, Item 6), four lockwashers (Figure 1, Item 7), and four nuts (Figure 1, Item 8). Connect the drill press wiring (Figure 1, Item 2) using the labels from Step (3) of DRILL PRESS REMOVAL as a guide. Remove the labels. Perform the FOLLOW-ON MAINTENANCE procedure at the end of this work package.
END OF TASK
0238-3
TM 55-1925-273-24&P-2
0238
SERVICE DISASSEMBLY 1. 2. 3. Open the pulley cover (Figure 2, Item 5) to gain access to the top V-belt (Figure 2, Item 3) and the bottom V-belt (Figure 2, Item 7). Move the center pulley shaft (Figure 2, Item 2), toward the spindle pulley (Figure 2, Item 6) and pull the bottom V-belt (Figure 2, Item 7) upward and remove it from the center pulley (Figure 2, Item 1) and the spindle pulley. Move the center pulley shaft (Figure 2, Item 2) toward the motor pulley (Figure 2, Item 4) and pull the top V-belt (Figure 2, Item 3) upward and remove it from the motor pulley and the center pulley (Figure 2, Item 1).
END OF TASK SERVICE ASSEMBLY
NOTE
Ensure that the V-belt is in alignment with the spindle, center, and motor pulley channels grooves. 1. 2. Move the center pulley shaft (Figure 2, Item 2) toward the spindle pulley (Figure 2, Item 6) and install the bottom V-belt (Figure 2, Item 7). Move the center pulley shaft (Figure 2, Item 2) toward the motor pulley (Figure 2, Item 4), and push the top V-belt (Figure 2, Item 3) down onto the center pulley (Figure 2, Item 1) and the spindle pulley (Figure 2, Item 6). Close the cover (Figure 2, Item 5). Perform the FOLLOW-ON MAINTENANCE procedure at the end of this work package.
3. 4.
0238-4
TM 55-1925-273-24&P-2 SERVICE ASSEMBLY - Continued
0238
1 2
7 4 6
M1159T73
Drill Press Components.
0238-5
TM 55-1925-273-24&P-2
0238
FOLLOW-ON MAINTENANCE 1. 2. 3. Remove the lock outs and tag outs IAW FM 4-01.502. Operate the workshop equipment under usual conditions IAW TM 55-1925-273-10 and check for proper operation of the drill press. Return the drill press to the desired readiness condition.
0238-6
TM 55-1925-273-24&P-2 FIELD MAINTENANCE WORK SHOP EQUIPMENT GRINDER, BENCH REPLACE
0239
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 3, WP 0344, Table 1, Item 27) Multimeter (Volume 3, WP 0344, Table 1, Item 15) Materials/Parts N/A Personnel Required Watercraft Engineer 88L (2) References FM 4-01.502 References (cont.) TM 55-1925-273-10 Volume 3, WP 0331 Volume 3, WP 0344 Equipment Condition Set to OFF the MACHINE SHOP EQUIPMENT JUNCTION BOX (LATHE/GRINDER/DRILL PRESS) circuit breaker in the load center distribution panel. Lock out and tag out IAW FM 4-01.502.
0239-1
TM 55-1925-273-24&P-2
0239
WARNING
Never reuse locking hardware. Reuse of locking hardware such as lockwashers, locking nuts, cotter pins, and lock wire can result in undetected loosening of fastening hardware causing catastrophic component failure resulting in death, injury, or damage to equipment. Ensure that all locking hardware is discarded upon removal and replaced with new. BENCH GRINDER REMOVAL
WARNING
Replace or repair components only after the affected circuit has been secured, locked out, and tagged out IAW FM 4-01.502. Performing replacement with the circuit energized may result in injury. 1. 2. Remove the four screws (Figure 1, Item 1) and the junction box cover (Figure 1, Item 3). Use a multimeter to check for voltage at the terminals in the junction box (Figure 1, Item 3). If voltage is present, ensure that the proper circuit breaker is set to OFF, locked out, and tagged out IAW FM 4-01.502. If no voltage is present, continue with the procedure. Label and disconnect the bench grinder wiring (Figure 1, Item 2). Remove the two nuts (Figure 2, Item 6), two lockwashers (Figure 2, Item 5), four flat washers (Figure 2, Item 2), and two bolts (Figure 2, Item 3). Discard lockwashers. Remove the bench grinder (Figure 2, Item 4) from the workbench.
1 1 2
3. 4. 5.
1
M1160T73
Figure 1.
Workshop Machinery Junction Box.
0239-2
TM 55-1925-273-24&P-2 BENCH GRINDER REMOVAL - Continued

3 2 1 4
0239
10
2 5 6
M1161T73
Figure 2. END OF TASK BENCH GRINDER INSTALLATION 1. 2.
Bench Grinder.
Position the bench grinder (Figure 2, Item 4) over its mounting holes in the workbench. Install the two nuts (Figure 2, Item 6), two lockwashers (Figure 2, Item 5), four flat washers (Figure 2, Item 2), and two bolts (Figure 2, Item 3), and secure the bench grinder (Figure 2, Item 4) to the workbench. Connect the bench grinder wiring (Figure 1, Item 2) using the labels from Step (3) of BENCH GRINDER REMOVAL as a guide. Remove the labels. Install the junction box cover (Figure 1, Item 3) and secure it in place with the four screws (Figure 1, Item 1). Perform the FOLLOW-ON MAINTENANCE procedure at the end of this work package.
3. 4. 5.
END OF TASK SERVICE DISASSEMBLY 1. 2. 3. Remove the three screws (Figure 2, Item 9) securing the guard cover (Figure 2, Item 10) to the bench grinder (Figure 2, Item 4). Remove the left hand nut (Figure 2, Item 8) and the wheel flange (Figure 2, Item 7) securing the wheel (Figure 2, Item 1) to the bench grinder (Figure 2, Item 4). Remove the wheel (Figure 2, Item 1) from the bench grinder (Figure 2, Item 4).
END OF TASK
0239-3
TM 55-1925-273-24&P-2 SERVICE ASSEMBLY 1. 2. 3. 4. Install the wheel (Figure 2, Item 1) to the bench grinder (Figure 2, Item 4).
0239
Install the wheel flange (Figure 2, Item 7) onto the bench grinder (Figure 2, Item 4) and secure it with the left hand nut (Figure 2, Item 8). Install the guard cover (Figure 2, Item 10) onto the bench grinder (Figure 2, Item 4) and secure in place with the three screws (Figure 2, Item 9). Perform the FOLLOW-ON MAINTENANCE procedure at the end of this work package.
END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. Remove the lock outs and tag outs IAW FM 4-01.502. Operate the workshop equipment under usual conditions IAW TM 55-1925-273-10 and check for proper operation of the bench grinder. Return the bench grinder to the desired readiness condition.
0239-4
TM 55-1925-273-24&P-2 FIELD MAINTENANCE WORK SHOP EQUIPMENT MACHINE, ARC WELDER REPLACE
0240
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 3, WP 0344, Table 1, Item 27) Hoist, Chain, Hand Operated, 2 Ton (1,814 kg) (Volume 3, WP 0344, Table 1, Item 12) Multimeter (Volume 3, WP 0344, Table 1, Item 15) Sling, Endless (Volume 3, WP 0344, Table 1, Item 21) Materials/Parts N/A Personnel Required Watercraft Engineer 88L (2) References FM 4-01.502 References (cont.) TM 55-1925-273-10 Volume 3, WP 0332 Volume 3, WP 0344 Equipment Condition Set to OFF the WELDING MACHINE. circuit breaker (LT 803 Only), or the WELDING MACHINE, (WORKSHOP) circuit breaker (All Other Vessels) in 440 V power panel No. 5. Lock out and tag out IAW FM 4-01.502.
0240-1
TM 55-1925-273-24&P-2
0240
REMOVAL
WARNING
Take great care when working around energized electrical equipment. Contact between unprotected body parts and electrical conductors can cause serious injury or death. Do not wear jewelry or other conductive items while servicing energized electrical equipment. Failure to comply with these precautions can cause serious injury or death.
NOTE
Electrical junction boxes may vary in size, shape, and mounting position of the box on the motor frame. Electrical junction box covers may vary in number and placement of screws holding the cover in place. 1. 2. 3. Remove the screws (Figure 1, Item 3) from the electrical junction box cover (Figure 1, Item 5). Remove the electrical junction box cover (Figure 1, Item 5). Using a multimeter, check for voltage at the wiring terminals (Figure 1, Item 6). If voltage is present, ensure that the proper circuit breaker is secured, locked out, and tagged out IAW FM 4-01.502. If no voltage is present, continue with the procedure. Label and disconnect the electrical wiring (Figure 1, Item 4) at the wiring terminals (Figure 1, Item 6). Remove the bolts (Figure 1, Item 7) and flat washers (Figure 1, Item 8) securing the welder (Figure 1, Item 1) to the deck. Attach an endless sling through the welder (Figure 1, Item 1) lifting eye (Figure 1, Item 2) and use the hand operated chain hoist to lift the welder off the deck for removal.
4. 5. 6.
END OF TASK INSTALLATION 1. 2. 3. 4. 5. 6. 7. Slowly lower the welder (Figure 1, Item 1) to the deck and position the welder over the mounting holes in the deck. Install the flat washers (Figure 1, Item 8) and bolts (Figure 1, Item 7). Tighten the bolts. Connect the electrical wiring (Figure 1, Item 4) at the wiring terminals (Figure 1, Item 6) using the labels from Step (4) of REMOVAL as a guide. Remove the labels. Install the electrical junction box cover (Figure 1, Item 5) and secure it with the screws (Figure 1, Item 3). Remove the lock outs and tag outs IAW FM 4-01.502. Operate the workshop equipment under usual conditions IAW TM 55-1925-273-10 and check for proper operation of the welder. Return the welder to the desired readiness condition.
0240-2
0240
4 1 2 5 3
7 8
M1162T73
Welder.
0240-3/4 blank
TM 55-1925-273-24&P-2 FIELD MAINTENANCE WORK SHOP EQUIPMENT MACHINE, ARC WELDING REPAIR
0241
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 3, WP 0344, Table 1, Item 27) Faceshield, Industrial (Volume 3, WP 0344, Table 1, Item 5) Gloves, Leather (Volume 3, WP 0344, Table 1, Item 9) Goggles, Industrial (Volume 3, WP 0344, Table 1, Item 10) Multimeter (Volume 3, WP 0344, Table 1, Item 15) Tool Kit, Electrical Repair (Volume 3, WP 0344, Table 1, Item 26) Materials/Parts N/A Personnel Required Watercraft Engineer 88L (2) References FM 4-01.502 TM 55-1925-273-10 Volume 3, WP 0332 Volume 3, WP 0344 Equipment Condition Set to OFF the WELDING MACHINE. circuit breaker (LT 803 ONLY), or the WELDING MACHINE, (WORKSHOP) circuit breaker (All Other Vessels) at 440 V power panel No. 5. Lock out and tag out IAW FM 4-01.502.
0241-1
TM 55-1925-273-24&P-2
0241
SPARK GAP ADJUST AND INSPECT - DISASSEMBLY 1. Remove the 24 screws (Figure 1, Item 7) securing the cover (Figure 1, Item 10) to the arc welder, and remove the cover.
WARNING
Replace or repair components only after the affected circuit has been secured, locked out, and tagged out IAW FM 4-01.502. Performing replacement with the circuit energized may result in injury. 2. Use a multimeter to check for voltage at the fuse housing (Figure 1, Item 2) and inline fuse (Figure 1, Item 1). If voltage is present, ensure that the correct circuit breaker is set to OFF, locked out, and tagged out IAW FM 4-01.502. If no voltage is present, continue with the procedure. Press the spring-loaded door latch (Figure 1, Item 8) and OPEN the front access door (Figure 1, Item 9). Loosen the screw (Figure 1, Item 5) on each spark gap assembly. Insert a 0.008 in. (0.2032 mm) feeler gage between each spark gap contact point (Figure 1, Item 4). The feeler gage should be held firmly in place by the contact points. Push or pull the pressure point (Figure 1, Item 6) of the loosened contact point (Figure 1, Item 4) to correct the gap to 0.008 in. (0.2032 mm). Tighten the screw (Figure 1, Item 5). Remove the feeler gage.
3. 4. 5. 6. 7. 8.
END OF TASK SPARK GAP ADJUST AND INSPECT - ASSEMBLY
WARNING
Goggles should always be worn when working with compressed air. Failure to wear goggles when working with compressed air can result in serious injury or death. 1. Blow all loose dust and debris from the arc-welding machine using compressed air.
0241-2
TM 55-1925-273-24&P-2 SPARK GAP ADJUST AND INSPECT - ASSEMBLY - Continued
0241
WARNING
Wire brushing operations can produce high velocity flying debris which can become lodged in the skin or in the eyes. Wire brushing in confined areas can result in debris flying from unexpected directions. All personnel working in the area must wear protective faceshield, gloves, and long sleeves when performing wire brushing operations. Failure to comply with this warning can result in serious injury or death to personnel. 2. 3. 4. 5. 6. 7. 8. 9. Clean the weld terminals (Figure 1, Item 3) using a wire brush. If necessary, tighten the loose weld terminals. Visually inspect all cables and connections for damaged insulation, cuts, broken wires, and fraying. Install the cover (Figure 1, Item 10), and secure it with the 24 screws (Figure 1, Item 7). CLOSE the front access door (Figure 1, Item 9). Set the circuit breaker to ON. Operate the arc welder under normal conditions IAW TM 55-1925-273-10. Check for normal operation of the arc welder. Return the equipment to the desired readiness condition.
0241-3
TM 55-1925-273-24&P-2 SPARK GAP ADJUST AND INSPECT - ASSEMBLY - Continued

1 2
0241
10
7 0.008 INCH (0.0203 mm)
4 4
M1374T73
Arc Welder.
0241-4
TM 55-1925-273-24&P-2 FIELD MAINTENANCE PORTABLE ELECTRIC PUMP REPAIR
0242
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 3, WP 0344, Table 1, Item 27) Materials/Parts Compound, Sealing; Loctite 242 (Volume 3, WP 0343, Table 1, Item 43) Grease, Ball and Roller Bearing; 1.75 lb (Volume 3, WP 0343, Table 1, Item 74) Gasket (Volume 3, WP 0333, Figure 85, Item 15) Qty: 1 Personnel Required Watercraft Engineer 88L (1) References Volume 3, WP 0333 Volume 3, WP 0343 Volume 3, WP 0344 Equipment Condition Pump unplugged.
0242-1
TM 55-1925-273-24&P-2
0242
WARNING
Replace or repair components only after the affected circuit has been secured, locked out, and tagged out IAW FM 4-01.502. Performing replacement with the circuit energized may result in injury. JABSCO MODEL 11810-SERIES REPAIR DISASSEMBLY 1. 2. 3. 4. Remove the six screws (Figure 1, Item 1) from the end cover (Figure 1, Item 2). Remove the cover and the gasket (Figure 1, Item 3). Discard gasket. Remove the impeller (Figure 1, Item 4) from the pump's shaft. Loosen the cam screw (Figure 1, Item 8) and remove the cam (Figure 1, Item 5). Remove the wear plate (Figure 1, Item 6) and the shaft seal (Figure 1, Item 7).
M1157T73
Figure 1. Portable Pump (JABSCO Model 11810-Series). END OF TASK JABSCO MODEL 11810-SERIES REPAIR INSPECTION 1. 2. 3. Inspect the cover for damage or signs of wear. Replace a worn or damaged cover. Inspect the impeller for wear, bent/missing blades, or other obvious damage. Replace a worn or damaged cover. Inspect the wear plate for damage or signs of excessive wear. Replace a worn or damaged wear plate.
END OF TASK
0242-2
TM 55-1925-273-24&P-2
0242
JABSCO MODEL 11810-SERIES REPAIR ASSEMBLY
NOTE
The shaft seal's lip should face the back of the impeller. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Install a shaft seal (Figure 1, Item 7) in the seal's bore with the seal facing the back of the impeller (Figure 1, Item 4). Apply grease to the back of the shaft seal's lip. Install the wear plate (Figure 1, Item 6), aligning its slot with the dowel pin. Apply sealing compound Loctite 242 to the top of the cam (Figure 1, Item 5) and the cam screw threads (Figure 1, Item 8). Install the cam and cam screw. Lubricate the pump shaft's outer diameter with a light coat of grease. Align the impeller (Figure 1, Item 4) with the flat side on the shaft, and install the impeller. Install a gasket (Figure 1, Item 3) and cover (Figure 1, Item 2) on the pump. Install and tighten the six screws (Figure 1, Item 1). Connect a suction and discharge hose to the pump and submerge the end of the suction hose. Plug the portable pump into a 120 V AC outlet and check that the pump has good discharge flow. Return the portable pump to the desired readiness condition.
0242-3/4 blank
TM 55-1925-273-24&P-2 FIELD MAINTENANCE ARMAMENTS INSTALLATION AMMUNITION LOCKER REPAIR
0243
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 3, WP 0344, Table 1, Item 27) Faceshield, Industrial (Volume 3, WP 0344, Table 1, Item 5) Gloves, Leather (Volume 3, WP 0344, Table 1, Item 9) Materials/Parts Cement, Rubber (Volume 3, WP 0343, Table 1, Item 31) Compound, Silicone; Corrosion Inhibitor, 2 oz. (Volume 3, WP 0343, Table 1, Item 45) Isopropyl Alcohol, Technical (Volume 3, WP 0343, Table 1, Item 91) Rag, Wiping (Volume 3, WP 0343, Table 1, Item 132) Personnel Required Watercraft Engineer 88L (1) References Volume 3, WP 0335 Volume 3, WP 0343 Volume 3, WP 0344 Equipment Condition Ammunition locker empty with the high security lock removed.
0243-1
TM 55-1925-273-24&P-2
0243
THERMOMETER REMOVAL 1. 2. Remove the cover (Figure 1, Item 4) from the thermometer housing (Figure 1, Item 2). Remove the thermometer (Figure 1, Item 5) from the thermometer housing (Figure 1, Item 2).
1 2
1 6
M1375T73
Figure 1. Ammunition Locker Thermometer. END OF TASK THERMOMETER INSTALLATION 1. 2. 3. Adjust the jamnut (Figure 1, Item 3) on the thermometer (Figure 1, Item 5) as necessary to prevent the cover (Figure 1, Item 4) from damaging the thermostat when it is installed in the thermometer housing. Install the thermometer (Figure 1, Item 5) into the thermometer housing (Figure 1, Item 2). Install the cover (Figure 1, Item 4) on the thermometer housing (Figure 1, Item 2).
END OF TASK
0243-2
TM 55-1925-273-24&P-2 GASKET REMOVAL
0243
WARNING
Wire brushing operations can produce high velocity flying debris which can become lodged in the skin or in the eyes. Wire brushing in confined areas can result in debris flying from unexpected directions. All personnel working in the area must wear protective faceshield, gloves, and long sleeves when performing wire brushing operations. Failure to comply with this warning can result in serious injury or death to personnel. 1. 2. Loosen the dogs (Figure 1, Item 1) and open the lid (Figure 1, Item 6). Remove the gasket (Figure 2, Item 2) from the lid (Figure 2, Item 1).
1 2
M1376T73
Figure 2. END OF TASK GASKET INSTALLATION 1. 2. 3. 4. 5. 6. 7.
Ammunition Locker Gasket.
Fabricate a gasket (Figure 2, Item 2) using the old gasket as a template. Discard old gasket. Clean the gasket area of the lid (Figure 2, Item 1) with isopropyl alcohol and a clean wiping rag. Apply a light coat of rubber cement in the retainer gasket track of the lid (Figure 2, Item 1). Install the gasket (Figure 2, Item 2) and allow the rubber cement to cure for four hours. Apply a thin coat of silicone compound to the exposed area of the gasket (Figure 2, Item 2). Close the lid (Figure 1, Item 6) and secure it with the dogs (Figure 1, Item 1). Return the ammunition locker to the desired readiness condition.
0243-3/4 blank
TM 55-1925-273-24&P-2 FIELD MAINTENANCE ARMAMENT INSTALLATIONS GUN MOUNTS SERVICE
0244
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 3, WP 0344, Table 1, Item 27) Gloves, Chemical and Oil Protective (Volume 3, WP 0344, Table 1, Item 8) Goggles, Industrial (Volume 3, WP 0344, Table 1, Item 10) Materials/Parts Cleaner, Lubricant, Preservative (Volume 3, WP 0343, Table 1, Item 33) Cloth, Abrasive (Crocus Cloth) (Volume 3, WP 0343, Table 1, Item 39) Grease, Aircraft (Volume 3, WP 0343, Table 1, Item 71) Lubricating Oil, General Purpose; 16 oz (Volume 3, WP 0343, Table 1, Item 107) Rag, Wiping (Volume 3, WP 0343, Table 1, Item 132) Personnel Required Watercraft Operator 88K (2) References Volume 3, WP 0343 Volume 3, WP 0344 Equipment Condition Gun cover removed. Cradle locked at 0 degree elevation. Gun removed from cradle.
0244-1
TM 55-1925-273-24&P-2
0244
INSPECT CRADLE SLIDING BOLTS
NOTE
This task replenishes grease and oil on joints and pins ensuring free movement. 1. 2. Inspect the upper cradle's (Figure 1, Item 2) two upper bolts (Figure 1, Item 1) located in the cradle's sliding channels to ensure the proper tightness of the bolts. If the bolts (Figure 1, Item 1) are shoulder bolts, tighten each bolt until the self-locking nut is snug against the shoulder of the bolt. If the bolts are full-threaded bolts, tighten each bolt until the bolt can no longer be rotated by hand; then back off the self-locking nut 1/8 turn. The bolt should rotate if turned by hand, but should not rotate freely. Inspect the lower cradle's (Figure 1, Item 4) four lower bolts (Figure 1, Item 3) located in the cradle's sliding channels to ensure the proper tightness of the bolts. If the bolts (Figure 1, Item 3) are shoulder bolts, tighten each bolt until the self-locking nut is snug against the shoulder of the bolt. If the bolts are full-threaded bolts, tighten each bolt until the bolt can no longer be rotated by hand; then back off the self-locking nut 1/8 turn. The bolt should rotate if turned by hand, but should not rotate freely. If either of the two upper (Figure 1, Item 1) or the four lower bolts (Figure 1, Item 3) are corroded, rusted, or show obvious damage, replace bolts and self-locking nuts.
3. 4.
5.
M1163T73
Machine Gun Mount Upper Cradle.
0244-2
TM 55-1925-273-24&P-2 SERVICE
0244
WARNING
Do not allow hydraulic fluid, engine oil, or cleaning solvents to come in contact with unprotected skin or eyes. Prolonged skin contact can cause illness or injury. Eye contact can cause serious injury. Always wear chemical protective gloves and goggles when handling hydraulic fluid, engine oil, and cleaning solvents. Failure to follow these precautions can result in illness, serious injury, or death. 1. 2. 3. Clean any foreign matter from the lubrication points and exposed metal surfaces using a wiping rag before lubricating. Remove any surface rust using crocus cloth. Loosen the pintle clamp (Figure 2, Item 5) and remove the carriage (Figure 2, Item 2) and cradle (Figure 2, Item 1) from the stand (Figure 2, Item 6).
1
4 6
M1164T73
Figure 2.
Machine Gun Mount.
0244-3
TM 55-1925-273-24&P-2 SERVICE - Continued 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. Apply a heavy coat of aircraft grease to the carriage pintle (Figure 2, Item 3 and Figure 3, Item 1). Apply a heavy coat of aircraft grease to the stand socket (Figure 2, Item 4 and Figure 3, Item 10). Install the carriage (Figure 2, Item 2) and the cradle (Figure 2, Item 1) onto the stand (Figure 2, Item 6).
0244
Apply a light coat of aircraft grease to the threads of the pintle clamp (Figure 2, Item 5 and Figure 3, Item 9). Tighten the pintle clamp. Apply five drops of aircraft grease to the gun mount pins and bearings (Figure 3, Item 5) and the locking bearings (Figure 3, Item 3). Apply cleaner, lubricant, and preservative to the cradle lock bearing (Figure 3, Item 4). Apply a light coat of cleaner, lubricant, and preservative to the rear sight hinge area (Figure 3, Item 8). Apply a light coat of cleaner, lubricant, and preservative to the ammunition box securing lock (2 points) and hinge (Figure 3, Item 2). Apply a light coat of cleaner, lubricant, and preservative to the depression stop bolt (Figure 3, Item 6). Apply a light coat of cleaner, lubricant, and preservative to the safety and return spring (Figure 3, Item 7). Apply a light coat of grease to all exposed contact metal surfaces.
0244-4

1 2
0244
10 9
4 3 3
LEFT SIDE
RIGHT SIDE
M1165T73
Machine Gun Mount Lubrication Points.
0244-5/6 blank
TM 55-1925-273-24&P-2 FIELD MAINTENANCE TORQUE LIMITS
0245
TORQUE TABLES - HOW TO USE TORQUE TABLES
NOTE
The torque tables provided below should be used only in the absence of official manufacturer's recommendations. Bolt torquing should be accomplished within equipment manufacturer's recommendations. In the absence of manufacturer's instructions, follow the procedures below: 1. Measure the diameter of the screw you are installing and count the number of threads per inch or use a pitch grade. See Figure 1.
MEASURING THE DIAMETER OF THE SCREW
STANDARD
METRIC
COUNTING NUMBER OF THREADS PER INCH
S1001T73
Figure 1. 2. 3. 4.
Measuring Bolt Sizes.
Use the diameter and number of threads to find the bolt size in the table. To find the grade screw you are installing, match the markings on the head to the correct picture of Capscrew Head Markings shown in Figure 2. Look down the column under the grade until you find the torque limit for the diameter and threads per inch of the screw you are installing.
GRADE 2 GRADE 5 GRADE 6 OR 7 GRADE 8
S1002T73
Figure 2.
Bolt Grades.
0245-1
03/15/2011 Rel(1.8) root(torquewp) wpno(M00213)
TM 55-1925-273-24&P-2 Table 1. Bolt Size 18-18 Stainless Steel lb-in 2-56 2-64 3-48 3-56 4-40 4-48 5-40 5-44 6-32 6-40 8-32 8-36 10-24 10-32 1/4"-20 1/4"-28 3/16"-16 3/16"-24 3/8"-16 3/8"-24 7/16"-14 7/16"-20 1/2"-13 2.5 3.0 3.9 4.4 5.2 6.5 7.7 8.4 9.6 12.1 19.5 22.0 22.5 31.7 75.2 94.0 132 142 238 259 376 400 517 Brass lb-in 2.0 2.5 3.2 3.5 4.3 5.4 6.3 7.7 7.9 9.9 16.2 18.0 18.6 25.9 61.5 77.0 107 116 192 212 317 327 422 Silicon Bronze lb-in 2.3 2.8 3.6 4.1 4.8 6.1 7.1 8.7 8.9 11.2 18.4 20.4 21.2 29.3 68.8 87.0 123 131 219 240 349 371 480 Torque Table 1. Aluminum 2024 T4 lb-in 1.4 1.7 2.1 2.4 2.9 3.6 4.2 5.1 5.3 8.6 10.8 12.0 13.8 19.2 45.6 57.0 80 86 143 157 228 242 313 316 Stainless Steel lb-in 2.8 3.2 4.0 4.6 5.5 6.9 8.1 9.8 10.1 12.7 20.7 23.0 23.8 33.1 78.6 99.0 138 147 247 271 393 418 542 Monel lb-in 2.5 3.1 4.0 4.5 5.3 6.7 7.8 9.5 9.8 12.3 20.2 22.4 25.9 34.9 85.3 106 149 160 268 294 427 451 584 2.14 4.3 5.61 8.2 16.0 20.8 34.9 1.19 Nylon* lb-in 0.44
0245
0245-2
TM 55-1925-273-24&P-2 Table 1. Bolt Size 18-18 Stainless Steel lb-in 1/2"-20 9/16"-12 9/16"-18 5/8"-11 5/8"-16 3/4"-10 3/4"-16 7/8"-9 7/8"-14 1"-8 1"-14 541 632 752 1,110 1,244 1,530 1,490 2,328 2,378 3,440 3,110 lb-ft 1 1/8"-7 1 1/8"-12 1 1/4"-7 1 1/4"-12 1 1/2"-5 1 1/2"-12 431 390 523 4,810 588 703 Brass lb-in 443 558 6,515 907 1,018 1,249 1,220 1,905 1,895 2,815 2,545 lb-ft 413 390 523 490 588 703 Torque Table 1 - Continued. Silicon Bronze lb-in 502 632 697 1,030 1,154 1,416 1,382 2,140 2,130 3,185 2,685 lb-ft 383 361 485 447 822 851 Aluminum 2024 T4 lb-in 326 415 486 715 796 980 958 1,495 1,490 2,205 1,995 lb-ft 265 251 336 306 570 450 316 Stainless Steel lb-in 565 713 787 1,160 1,301 1,582 1,556 2,430 2,420 3,395 732 lb-ft 432 408 546 504 930 732 Monel lb-in 613 774 855 1,330 1,492 1,832 1,790 2,775 2,755 4,130 3,730 lb-ft 499 470 627 575 1,054 840 Nylon* lb-in
0245
NOTE
The torque values listed in Figure 3 are for permanent fastenings on steel structures. Torque Figures are in pounds-feet (lb-ft) unless otherwise noted.
0245-3
END OF WORK PACKAGE
END OF TASK Figure 3.
Screw, Stud, or Bolt Diameter Fastener Grade Designation Minimum Tensile Material
6 8 10 5/ 16 3/ 8 7/ 16 9/ 5/ 1 1/ 8
16
7/
1 3/8
Capscrew
SAE 2 ASTM A307
64,000 PSI
Low Carbon Steel Medium Carbon Steel or Low Alloy Heat Treated Medium Carbon Alloy Quenched Tempered 16-6
11
19
30
45
66
93
150
202
300
474
659
884
1057
Capscrew
SAE 5 ASTM A449 GR5
105,000 PSI
18
31
50
75
110
150
250
378
583
782
1097 1461 1748
Capscrew
ASTM A325
150,000 PSI
100
200
355
525
790
1060 1495 1960 2600
TM 55-1925-273-24&P-2
0245-4
Torque Table 2.
S1003T73
Capscrew
SAE J429 GR8 ASTM A364BD A490
150,000 PSI
13
28
46
75
115
165
225
370
591
893
1410 1964 2633 3150
Capscrew
316 Series
55
90
138
198
270
444
709
1071 1692 2360 6159 3780
Capscrew and Machine Screw Capscrew and Machine Screw Capscrew and Machine Screw Machine Screw
Stainless Steel
CU63 ZN37
9.6 20 lb- 23 lb- 75 lb- 132 20 lbin lb-in in in lb-in in
31
43
57
92
124
194
259
390
480
703
Stainless Steel
50,000 PSI 1010 Etc. Not Heat Treated 55,000 PSI
10 lb- 21 lb- 24 lb- 79 lb- 138 21 lbin in in lb-in in in
33
45
59
97
130
202
271
408
504
732
Yellow Brass
8 lb- 16 lb- 19 lb- 62 lb- 107 16 lbin lb-in in in in in
26
35
47
76
102
158
212
318
394
575
Steel
11 lb- 20 lb- 32 lb- 75 lb- 140 in lb-in in in in
0245
RECOMMENDED CHANGES TO PUBLICATIONS AND BLANK FORMS

For use of this form, see AR 25-30; the proponent agency is OAASA.
Use Part II (reverse) for Repair Parts and Special Tool Lists (RPSTL) and Supply Catalogs/Supply Manuals (SC/SM).
DATE Date you filled out this form.
TO (Forward to proponent of publication or form) (Include ZIP Code) U.S. Army TACOM Life Cycle Management Command ATTN: AMSTA-LCL-MPP/TECH PUBS
FROM (Activity and location) (Include ZIP Code)
Your mailing address
6501 E. 11 Mile Road, Warren, MI 48397-5000 PART I ALL PUBLICATIONS (EXCEPT RPSTL AND SC/SM) AND BLANK FORMS PUBLICATION/FORM NUMBER DATE TITLE
TM Number
ITEM PAGE PARAGRAPH LINE FIGURE TABLE NO.
Date of the TM
Title of the TM
RECOMMENDED CHANGES AND REASON (Exact wording of recommended change must be given)
0007-3 0018-2
Figure 2, Item 9 should show a lockwasher. Currently shows a flat washer. Cleaning and inspection, Step 6, reference to governor support pin (14) is wrong reference. Reference should be change to (12).
SAMPLE
TYPED NAME, GRADE OR TITLE
TELEPHONE EXCHANGE/AUTOVON, PLUS EXTENSION
SIGNATURE
Your Name
DA FORM 2028, FEB 74
Your Phone Number
Your Signature
APD V4.00
REPLACES DA FORM 2028, 1 DEC 68, WHICH WILL BE USED.
TO (Forward direct to addressee listed in publication) U.S. Army TACOM Life Cycle Management Command ATTN: AMSTA-LCL-MPP/TECH PUBS
DATE Date you filled out this form
Your Address
6501 E. 11 Mile Road, Warren, MI 48397-5000 PART II REPAIR PARTS AND SPECIAL TOOL LISTS AND SUPPLY CATALOGS/SUPPLY MANUALS PUBLICATION NUMBER DATE TITLE
TM Number
PAGE NO. COLM NO. LINE NO. NATIONAL STOCK NUMBER
Date of the TM
Title of the TM
RECOMMENDED ACTION
TOTAL NO. REFERENCE FIGURE ITEM OF MAJOR NO. NO. NO. ITEMS SUPPORTED
SAMPLE
PART III REMARKS (Any general remarks, or recommendations, or suggestions for improvement of publications and blank forms. Additional blank sheets may be used if more space is needed.)
Your Name
TELEPHONE EXCHANGE/AUTOVON, SIGNATURE PLUS EXTENSION
Your Phone Number
Your Signature
APD V4.00

For use of this form, see AR 25-30; the proponent agency is OAASA
DATE
6501 E. 11 Mile Road, Warren, MI 48397-5000 PART I ALL PUBLICATIONS (EXCEPT RPSTL AND SC/SM) AND BLANK FORMS TITLE PUBLICATION/FORM NUMBER DATE Field and Sustainment Maintenance Manual Including Repair TM 55-1925-273-24&P-2 31 January 2013 Parts and Special Tools List For Inland and Coastal Large Tug (LT) PAGE PARAGRAPH LINE FIGURE TABLE NO. RECOMMENDED CHANGES AND REASON
SIGNATURE
APD V4.00
DATE
6501 E. 11 Mile Road, Warren, MI 48397-5000 PART II REPAIR PARTS AND SPECIAL TOOL LISTS AND SUPPLY CATALOGS/SUPPLY MANUALS TITLE PUBLICATION/FORM NUMBER DATE Field and Sustainment Maintenance Manual Including TM 55-1925-273-24&P-2 31 January 2013 Repair Parts and Special Tools List For Inland and Coastal Large Tug (LT) PAGE NO. COLM NO. LINE NO. NATIONAL STOCK NUMBER REFERENCE FIGURE ITEM NO. NO. NO. TOTAL NO. OF MAJOR ITEMS SUPPORTED RECOMMENDED ACTION
PART III REMARKS (Any general remarks, or recommendations, or suggestions for improvement of publications and blank forms. Additional blank sheets may be used if more space is needed.)
APD V4.00

DATE
6501 E. 11 Mile Road, Warren, MI 48397-5000 PART I ALL PUBLICATIONS (EXCEPT RPSTL AND SC/SM) AND BLANK FORMS TITLE PUBLICATION/FORM NUMBER DATE Field and Sustainment Maintenance Manual Including Repair TM 55-1925-273-24&P-2 31 January 2013 Parts and Special Tools List For Inland and Coastal Large Tug (LT) ITEM PAGE PARAGRAPH LINE FIGURE TABLE NO. RECOMMENDED CHANGES AND REASON
SIGNATURE
APD V4.00
DATE
PART III REMARKS (Any general remark, or recommendations, or suggestions for improvement of publications and blank forms. Additional blank sheets may be used if more space is needed.)
APD V4.00

DATE
SIGNATURE
APD V4.00
DATE
PART III REMARKS (Any general remarks, recommendations, or suggestions for improvement of publications and blank forms. Additional blank sheets may be used if more space is needed.)
APD V4.00

DATE
SIGNATURE
APD V4.00
DATE
PART III REMARKS (Any general remarks, recommendations, or suggestions for improvement of publications and blank forms. Additional blank sheets may be used if more space is needed.)
APD V4.00
By order of the Secretary of the Army:

RAYMOND T. ODIERNO General, United States Army Chief of Staff
Official:
JOYCE E. MORROW
Administrative Assistant to the Secretary of the Army 1234514
DISTRIBUTION: To be distributed in accordance with the Initial Distribution Number (IDN) 255668 requirements for TM 55-1925-273-24&P-2.
THE METRIC SYSTEM AND EQUIVALENTS

LINEAR MEASURE 1 Centimeter=10 Millimeters=0.01 Meters=0.3937 Inches 1 Meter=100 Centimeters=1000 Millimeters=39.37 Inches 1 Kilometer=1000 Meters=0.621 Miles WEIGHTS 1 Gram=0.001 Kilograms=1000 Milligrams=0.035 Ounces 1 Kilogram=1000 Grams=2.2 Lb 1 Metric Ton=1000 Kilograms=1 Megagram=1.1 Short Tons LIQUID MEASURE 1 Milliliter=0.001 Liters=0.0338 Fluid Ounces 1 Liter=1000 Milliliters=33.82 Fluid Ounces SQUARE MEASURE 1 Sq Centimeter=100 Sq Millimeters=0.155 Sq Inches 1 Sq Meter=10,000 Sq Centimeters=10.76 Sq Feet 1 Sq Kilometer=1,000,000 Sq Meters=0.386 Sq Miles CUBIC MEASURE 1 Cu Centimeter=1000 Cu Millimeters=0.06 Cu Inches 1 Cu Meter=1,000,000 Cu Centimeters=35.31 Cu Feet TEMPERATURE 5/9 (F 32) = C 212Fahrenheit is equivalent to 100Celsius 90Fahrenheit is equivalent to 32.2Celsius 32Fahrenheit is equivalent to 0Celsius 9/5 (C + 32) = F
APPROXIMATE CONVERSION FACTORS

15
TO CHANGE Inches . . . . . . . . . . . Feet . . . . . . . . . . . . . Yards . . . . . . . . . . . . Miles . . . . . . . . . . . . Square Inches . . . . Square Feet . . . . . . . Square Yards . . . . . . Square Miles . . . . . . Acres . . . . . . . . . . . . Cubic Feet . . . . . . . . Cubic Yards . . . . . . . Fluid Ounces . . . . . . Pints. . . . . . . . . . . . . Quarts . . . . . . . . . . . Gallons. . . . . . . . . . . Ounces . . . . . . . . . . Pounds . . . . . . . . . . . Short Tons . . . . . . . . Pound-Feet . . . . . . . Pounds/Sq Inch . . . . Miles per Gallon . . . . Miles per Hour . . . . . TO CHANGE Centimeters . . . . . . . Meters . . . . . . . . . . . Meters . . . . . . . . . . . Kilometers . . . . . . . . Sq Centimeters . . . . Square Meters . . . . . Square Meters . . . . . Square Kilometers . . Sq Hectometers . . . . Cubic Meters . . . . . . Cubic Meters . . . . . . Milliliters . . . . . . . . . . Liters . . . . . . . . . . . . Liters . . . . . . . . . . . . Liters . . . . . . . . . . . . Grams . . . . . . . . . . . Kilograms . . . . . . . . . Metric Tons . . . . . . . Newton-Meters. . . . . Kilopascals. . . . . . . . Km per Liter . . . . . . . Km per Hour . . . . . .
TO
MULTIPLY BY 2.540 0.305 0.914 1.609 6.451 0.093 0.836 2.590 0.405 0.028 0.765 29.573 0.473 0.946 3.785 28.349 0.454 0.907 1.356 6.895 0.425 1.609
Inches . . . . . . . . . . . . . . . . . . . . . Feet . . . . . . . . . . . . . . . . . . . . . . . Yards . . . . . . . . . . . . . . . . . . . . . . Miles . . . . . . . . . . . . . . . . . . . . . . Square Inches . . . . . . . . . . . . . . . Square Feet. . . . . . . . . . . . . . . . . Square Yards . . . . . . . . . . . . . . . . Square Miles . . . . . . . . . . . . . . . . Acres . . . . . . . . . . . . . . . . . . . . . . Cubic Feet . . . . . . . . . . . . . . . . . . Cubic Yards . . . . . . . . . . . . . . . . . Fluid Ounces . . . . . . . . . . . . . . . . Pints . . . . . . . . . . . . . . . . . . . . . . Quarts . . . . . . . . . . . . . . . . . . . . . Gallons . . . . . . . . . . . . . . . . . . . . Ounces . . . . . . . . . . . . . . . . . . . . Pounds . . . . . . . . . . . . . . . . . . . . Short Tons . . . . . . . . . . . . . . . . . . Pound-Feet . . . . . . . . . . . . . . . . . Pounds per Sq Inch . . . . . . . . . . . Miles per Gallon . . . . . . . . . . . . . Miles per Hour . . . . . . . . . . . . . . .
0.394 3.280 1.094 0.621 0.155 10.764 1.196 0.386 2.471 35.315 1.308 0.034 2.113 1.057 0.264 0.035 2.205 1.102 0.738 0.145 2.354 0.621
TO
MULTIPLY BY
1 CM. 2
INCHES
Centimeters . . . . . . . . . . . . . . . . . Meters . . . . . . . . . . . . . . . . . . . . . Meters . . . . . . . . . . . . . . . . . . . . . Kilometers . . . . . . . . . . . . . . . . . . Square Centimeters . . . . . . . . . . Square Meters . . . . . . . . . . . . . . . Square Meters . . . . . . . . . . . . . . . Square Kilometers. . . . . . . . . . . . Square Hectometers . . . . . . . . . . Cubic Meters . . . . . . . . . . . . . . . . Cubic Meters . . . . . . . . . . . . . . . . Milliliters. . . . . . . . . . . . . . . . . . . . Liters . . . . . . . . . . . . . . . . . . . . . . Liters . . . . . . . . . . . . . . . . . . . . . . Liters . . . . . . . . . . . . . . . . . . . . . . Grams . . . . . . . . . . . . . . . . . . . . . Kilograms. . . . . . . . . . . . . . . . . . . Metric Tons . . . . . . . . . . . . . . . . . Newton-Meters . . . . . . . . . . . . . . Kilopascals . . . . . . . . . . . . . . . . . Kilometers per Liter . . . . . . . . . . . Kilometers per Hour . . . . . . . . . .
13
14
11
12
10
PIN: 082853-000

Inland and Coastal Large Tug (LT) NSN 1925-01-509-7013 (EIC XAG)

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Inland and Coastal Large Tug (LT) NSN 1925-01-509-7013 (EIC XAG)

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*TM 55-1925-273-24&P-2

HEADQUARTERS, DEPARTMENT OF THE ARMY 31 JANUARY 2013

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