TM-55-1905-223-24-19

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TM 55-1905-223-24-19
TECHNICAL MANUAL
UNIT, INTERMEDIATE DIRECT
SUPPORT
AND INTERMEDIATE GENERAL
SUPPORT
MAINTENANCE INSTRUCTIONS
OIL-WATER SEPARATOR
FOR
LANDING CRAFT UTILITY (LCU)
NSN 1905-01-154-1191
DISTRIBUTION STATEMENT A: Approved for public release, distribution is unlimited.
HEADQUARTERS, DEPARTMENT OF THE ARMY
FEBRUARY 2008
TM 55-1905-223-24-19
WARNING SUMMARY
MODIFICATION HAZARD
Unauthorized modifications, alterations or installations of or to this equipment are prohibited and are in violation of
AR 750-10. Any such unauthorized modifications, alterations or installations could result in death or injury to
personnel or damage to the equipment.
MOVING MACHINERY HAZARDS
Be very careful when operating or working near moving machinery.
Running engines, rotating shafts and other moving machinery parts could cause personal injury or death. Before
maintenance is performed on motor driven equipment, the main circuit breaker should be de-energized and
labeled “OUT OF SERVICE.” Only authorized maintenance personnel should make repairs to this equipment.
ELECTRICAL HAZARDS
Respect all circuits. Precautions set forth in Naval Ship’s Technical Manual (NSTM), Chapters 300, 302, 310, and
320, shall be observed with respect to electrical equipment and circuits. Special precautionary measures are
essential to prevent applying power to the system/equipment at any time maintenance work is in progress.
Disconnect power and tag the circuit to warn of a potentially dangerous situation. Use a multimeter to ensure all
electrical circuits are de-energized before touching any part of the circuit. Before working on electrical system/
equipment, check with multimeter to ensure that system is not energized. Circuits not known to be dead must be
considered live and dangerous at all times. The voltages used to operate this equipment are high enough to
cause severe injury or death. When working near electricity, do not use metal rules, flashlights, metallic pencils, or
any other objects having exposed conducting material. Troubleshooting procedures frequently require that
checks be made while the power is on. Use extreme care to prevent contact with live circuit parts. Touching these
parts could result in electrical shock. Be sure to de-energize all equipment before connecting or dis-connecting
meters or test leads. When connecting a meter to terminals for measurement, use a range higher than the
expected voltage.
DO NOT REPAIR OR ADJUST ALONE
Under no circumstances should repair or adjustment of energized equipment be attempted alone. The immediate
presence of someone capable of rendering aid is required. Before making adjustments, be sure to protect against
grounding. If possible, adjustments should be made with one hand, with the other hand free and clear of
equipment. Even when power has been removed from equipment circuits, dangerous potentials may still exist
due to retention of charges by capacitors. Circuits must be grounded and all capacitors discharged prior to
attempting repairs.
TEST EQUIPMENT
Make certain test equipment is in good condition. If a test meter must be held, ground the case of the meter
before starting measurements. Do not touch live equipment or personnel working on live equipment while holding
a test meter. Some types of measuring devices should not be grounded; such devices should not be held when
taking measurements.
INTERLOCKS
Interlocks are provided for safety of personnel and equipment and should be used only for the purpose intended.
They should not be battle-shorted or otherwise modified except by authorized maintenance personnel. Do not
depend solely upon interlocks for protection. Whenever possible, disconnect power at power distribution source.
For Artificial Respiration, refer to FM 4-25.11.
a/(b blank)
TM 55-1905-223-24-19
LIST OF EFFECTIVE PAGES
NOTE:
This manual is a non superseding revision for the Oil-Water Separator System within TM 55-1905223-24-18-1 and TM 55-1905-223-24-18-2 dated 17 January 1989. Zero in the “Change No.”
column indicates an original page.
Date of issue is: 08 February 2008
TOTAL NUMBER OF PAGES IS 168 CONSISTING OF THE FOLLOWING:
Page
No.
*Change
No.
Cover.................................................................0
a/(b blank)..........................................................0
i and ii ................................................................0
1-1 through 1-12 ................................................0
1-13/(1-14 blank)...............................................0
2-1 through 2-110..............................................0
3-1 through 3-12.................................................0
4-1 and 4-2 .........................................................0
A-1/(A-2 blank) .................................................0
Page
No.
*Change
No.
B-1 through B-7/(B-8 blank) ............................. 0
C-1 and C-2 ........................................................0
D-1 and D-2 ..................................................... 0
Glossary 1 and Glossary 2 ............................... 0
Index 1 and Index 2 ........................................... 0
FP-1/(FP-2 blank)............................................. 0
FP-3/(FP-4 blank)............................................. 0
FP-5/(FP-6 blank)............................................. 0
FP-7/(FP-8 blank)............................................. 0
DA 2028 .......................................................... 0
Metric/PIN ....................................................... 0
A/(B blank)
TM 55-1905-223-24-19
TECHNICAL MANUAL
HEADQUARTERS
DEPARTMENT OF THE ARMY
WASHINGTON, D.C., 08 February 2008
UNIT, INTERMEDIATE DIRECT SUPPORT AND
INTERMEDIATE GENERAL SUPPORT
MAINTENANCE INSTRUCTIONS
OIL-WATER SEPARATOR
FOR
LANDING CRAFT UTILITY (LCU)
NSN 1905-01-154-1191
REPORTING ERRORS AND RECOMMENDING IMPROVEMENTS
You can help improve this publication. If you find any mistakes or if you know of a way to improve the procedures,
please let us know. Submit your DA Form 2028 (Recommended Changes to Equipment Technical Publications)
through the Internet, on the Army Electronic Product Support (AEPS) website. The Internet address is
https://aeps.ria.army.mil. The DA Form 2028 is located under the Public Applications section in the AEPS Public
Home Page. Fill out the form and click on SUBMIT. Using this form on the AEPS will enable us to respond
quicker to your comments and better manage the DA Form 2028 program. You may also mail, fax or e-mail your
letter or DA Form 2028 direct to: TACOM Life Cycle Management Command, ATTN: AMSTA-LC-LMPP/TECH
PUBS, 1 Rock Island Arsenal, Rock Island, IL 61299-7630. The e-mail address is [email protected]. The fax number is DSN 793-0726 or Commercial (309) 782-0726.
DISTRIBUTION STATEMENT A: Approved for public release; distribution is unlimited.
TABLE OF CONTENTS
PAGE
CHAPTER 1
Section I
Section II
Section III
CHAPTER 2
Section I
Section II
Section III
Section IV
Section V
Section VI
CHAPTER 3
Section I
Section II
Section III
Section IV
INTRODUCTION.............................................................................................................. 1-1
General Information ......................................................................................................... 1-1
Equipment Description and Data ..................................................................................... 1-1
Principles of Operation..................................................................................................... 1-10
UNIT MAINTENANCE INSTRUCTIONS.......................................................................... 2-1
Repair Parts, Special Tools; Test, Measurement, and
Diagnostic Equipment (TMDE); and Support Equipment................................................. 2-1
Service Upon Receipt ...................................................................................................... 2-1
Unit Preventive Maintenance Checks and Services (PMCS) .......................................... 2-7
Unit Maintenance Troubleshooting Procedures............................................................... 2-11
Unit Maintenance Procedures.......................................................................................... 2-29
Preparation for Storage or Shipment ............................................................................... 2-110
INTERMEDIATE DIRECT SUPPORT MAINTENANCE INSTRUCTIONS ...................... 3-1
Repair Parts, Special Tools; Test, Measurement
and Diagnostic Equipment (TMDE); and Support Equipment.......................................... 3-1
Service Upon Receipt ...................................................................................................... 3-1
Intermediate Direct Support Preventive Maintenance Checks and
Services (PMCS).............................................................................................................. 3-2
Intermediate Direct Support Troubleshooting .................................................................. 3-2
i
TM 55-1905-223-24-19
TABLE OF CONTENTS – Continued
PAGE
Section V
Section VI
CHAPTER 4
Section I
Section II
Section III
Section IV
Section V
Section VI
Intermediate Direct Support Maintenance Procedures .................................................... 3-4
Preparation for Storage or Shipment ............................................................................... 3-12
INTERMEDIATE GENERAL SUPPORT MAINTENANCE INSTRUCTIONS .................. 4-1
Repair Parts, Special Tools; Test, Measurement
and Diagnostic Equipment (TMDE); and Support Equipment.......................................... 4-1
Service Upon Receipt....................................................................................................... 4-1
Intermediate General Support Preventive Maintenance Checks and
Services (PMCS).............................................................................................................. 4-2
Intermediate General Support Troubleshooting............................................................... 4-2
Intermediate General Support Maintenance Procedures................................................. 4-2
Preparation for Storage or Shipment ............................................................................... 4-2
APPENDIX A
REFERENCES................................................................................................................. A-1
APPENDIX B
MAINTENANCE ALLOCATION CHART.......................................................................... B-1
APPENDIX C
EXPANDABLE/DURABLE SUPPLIES AND MATERIALS LIST...................................... C-1
APPENDIX D
TORQUE VALUES........................................................................................................... D-1
GLOSSARY
ABBREVIATIONS AND DEFINITIONS............................................................................ Glossary-1
ALPHABETICAL INDEX ................................................................................................................................. Index-1
FOLDOUT FIGURES
FO1. Electrical Schematic (SID) ..................................................................................... FP-1
FO2. Electrical Schematic (OEM) (Typical) .................................................................... FP-5
ii
TM 55-1905-223-24-19
CHAPTER 1
INTRODUCTION
Page
Section I.
General Information .............................................................................................................. 1-1
Section II.
Equipment Description and Data .......................................................................................... 1-1
Section III.
Principles of Operation.......................................................................................................... 1-10
SECTION I. GENERAL INFORMATION
1-1.
Scope. The scope of this manual is as follows:
a. Type of Manual. Unit, intermediate direct support, and intermediate general support maintenance
manual.
b. Model Number and Equipment Name. Oil-Water Separator (OWS) model OPB-10NP/SR02, Oil Content
Monitor (OCM) model ET-35N, Water Polisher, part number SN-FH-3P3S, and the Dirty Oil Pump, Model H-125
installed aboard the LCU 2000 Class Watercraft.
c. Purpose of Equipment. To provide separation of oil from oily waste water from the sludge tank, and
discharge water in compliance with U. S. Coast Guard regulations and International law.
1-2.
Maintenance Forms, Records, and Reports. Department of the Army forms and procedures used for
equipment maintenance are those prescribed by DA Pam 750-8, The Army Maintenance Management System
(TAMMS) Users Manual.
1-3.
Reporting Equipment Improvement Recommendations (EIR). If your Oil-Water Separator (OWS) needs
improvement, let us know. Send us an EIR. You, the user, are the only one who can tell us what you don't like
about your equipment. Let us know why you don't like the design or performance. If you have Internet access,
the easiest and fastest way to report problems or suggestions is to go to https://aeps.ria.army.mil/aepspublic.cfm
(scroll down and choose to submit an Equipment Improvement Recommendation (EIR), a Product Quality
Deficiency Report (PQDR) or a Warranty Claim Action (WCA). You may also submit your information using an SF
368 (Product Quality Deficiency Report). You can send your SF 368 via e-mail, regular mail, or facsimile using
the addresses/facsimile numbers specified in DA Pam 750-8, The Army Maintenance Management System
(TAMMS) Users Manual. We will send you a reply.
1-4.
Destruction of Army Materiel. Refer to TM 750-244-3 for instructions covering the destruction of Army
materiel to prevent enemy use.
1-5.
Preparation for Storage or Shipment. Administrative storage of equipment issued to and used by Army
activities will have preventive maintenance performed in accordance with the Preventive Maintenance Checks and
Services (PMCS) charts before storing. When removing the equipment from administrative storage, the PMCS
should be performed to assure operational readiness. Repacking of equipment for shipment or storage is covered
in Paragraphs 2-32 and 3-13.
SECTION II. EQUIPMENT DESCRIPTION AND DATA
1-6.
General Description. The Facet model OPB-10NP/SR02 Oil-Water Separator (OWS) is a single-stage
coalescer type unit designed for separating oil from oily waste water from the sludge tank and discharge water
overboard in compliance with Federal law. The unit is a vacuum type system to draw water into the coalescer
chamber. The system includes an Oil Content Monitor (OCM) to monitor overboard discharge and divert back to
the sludge tank when water quality fails to meet a preset level. A water polisher is also included to assist in
meeting federal requirements.
1-1
TM 55-1905-223-24-19
1-7.
Characteristics, Capabilities, and Features. A very broad view of the oil-water separator is as follows:
a. Characteristics.
(1)
Single-stage coalescer chambers with cleanable plates.
(2)
Oil content monitor to monitor purity of discharge water prior to overboard discharge.
(3)
Water polisher for use when OWS alone fails to meet federal regulations.
b. Capabilities and Features.
(1) Process 10 gallons per minute of oily waste water.
NOTE
Although the OCM has a limit of 70 PPM, DOD vessels are not authorized to
operate at this range. In accordance with DOD 4715.6-R1, Regulations On
Vessels Owned Or Operated By The Department Of Defense, the only
acceptable range of operation is 15 PPM.
(2) Two position switch to monitor 15 ppm or 70 ppm limits.
1-8.
Location and Description of Major Components. Figure 1-1 shows the engine room with locations of the
major components indicated. Refer to Figure 1-1 and the reference number key below for the descriptions of
these components.
a. Separator Tank (1). The separator tank houses the coalescer plates and is located in the engine room
starboard side aft of the EOS.
b. Oil-Water Separator (OWS) Pump (2). The OWS pump is located aft of the EOS, near centerline, under
the engine room ladder.
c. Water Polisher (3). The water polisher consists of a housing with 9 filters stacked 3 high and 3 wide and
located between the separator tank and the OWS pump.
d. Sight Glass (4). The flow sight glass is located on the forward inboard side of the separator tank.
e. Motorized Valve (5). The system operated electric valve is located above the sight glass.
f.
Dirty Oil Pump (6). The dirty oil pump is located forward port outboard side of the EOS.
g. Duplex Strainer (7). The duplex strainer is located forward port outboard side of the EOS and inboard of
the dirty oil pump.
h. Remote Indicator (Alarm) Assembly (8). The remote indicator (alarm) assembly allows for remote
operation and monitoring of the Oil Content Monitor (OCM) system, located inside the EOS on the starboard
bulkhead. Refer to Figure 1-2 for a detailed view and Table 1-1 for a list of the controls and indicators for the
remote alarm assembly.
i. Motorized Valve (9). The four system operated electric valves are located on the forward and aft
starboard side of the separator tank.
j. Oil/Water Sensor (10). The oil/water sensor consists of probes and is mounted on the oil tower on the
forward end of the separator tank.
k. Pressure Reducing Valve (11). Reduces seawater feed pressure to the OWS system and is located on
starboard side of the separator tank.
1-2
TM 55-1905-223-24-19
l. Oil/Air Sensor (12). The oil/air level sensor consists of probes and is mounted on the aft end of the
separator tank.
m. Pressure Switches (13). Two pressure-actuated diaphragm style pressure switches are mounted port
side of the separator tank and aft of the water polisher.
n. Compound Gauge (14). The pressure/vacuum gauge consists of electrical contacts for system control
and is located port/aft of the separator tank.
o. Control Panel (15). The OWS control panel consists of pushbuttons, switches, indicators and alarm,
located on the aft starboard bulkhead. Refer to Figure 1-3 for a detailed view and Table 1-2 for a list of the
controls and indicators for the control panel.
p. OCM Sampling/Sensor Assembly (16). The Sampling/Sensor Assembly is the direct interface with the
OWS system and is located on the starboard side bulkhead aft of the control panel. Refer to Figure 1-4 for a
detailed view and Table 1-3 for a list of the indicators for the sensor detection assembly.
q. OCM Remote Relay Assembly (17). The remote relay is mounted below the OCM diverter valve position
indicator on the starboard bulkhead. A junction box for system wiring connections is located directly under the
remote relay.
r.
Audible Alarm (18). The electric horn is mounted on the starboard bulkhead aft.
s. OCM Diverter Valve Position Indicator (19). The two lamp indicator is mounted aft of the OCM Sensor
Detection Assembly (SDA) on the starboard bulkhead.
t. OWS Circuit Breaker Panel (20). The circuit breaker panel is mounted on the aft bulkhead behind and
above the OWS separator tank.
u. Gauge Panel (21). The panel houses the purge water pressure gauge, OCM inlet gauge, OWS outlet
gauge, and strainer inlet and outlet gauges.
v. Diverter Valve (22). The diverter valve is located aft of the water polisher, below the gauge panel and
mounted in the piping system.
w. OCM Circuit Breaker Panel (23). The panel is located on the aft port bulkhead.
1-3
TM 55-1905-223-24-19
Figure 1-1. Location of Major Components.
1-4
TM 55-1905-223-24-19
Figure 1-2. OCM Remote Indicator (Alarm) Assembly Controls and Indicators.
NOTE
Although the OCM has a limit of 70 PPM, DOD vessels are not authorized to
operate at this range. In accordance with DOD 4715.6-R1, Regulations On
Vessels Owned Or Operated By The Department Of Defense, the only
acceptable range of operation is 15 PPM.
Table 1-1. OCM Remote Indicator (Alarm) Assembly Controls and Indicators.
No.
1
Control or Indicator
POWER ON
Function
OCM System is operating.
OCM is in alarm status.
3
OIL CONTENT EXCEEDS ALARM
LIMIT
PUSH TO SILENCE pushbutton switch
4
EFFLUENT OIL CONTENT
Numerical LCD display of oil content.
5
6
PUSH TO CHANGE ALARM LIMIT
(PPM) pushbutton switch
AT-SEA 70
Press to select the OCM Alarm Limit (15 or 70 PPM).
(Refer to note above.)
Alarm Limit of 70 PPM. (Refer to note above.)
7
IN-PORT 15
Alarm Limit of 15 PPM.
2
Press to engage and disengage the Alarm Buzzer.
1-5
TM 55-1905-223-24-19
Figure 1-3. OWS Control Panel Assembly Controls and Indicators.
1-6
TM 55-1905-223-24-19
Table 1-2. OWS Control Panel Assembly Controls and Indicators.
No.
1
Control or Indicator
POWER ON Indicator
2
SYSTEM HAND-OFF-AUTO
Switch
3
MANUAL START Pushbutton
Switch
MANUAL STOP Pushbutton
Switch
OIL VALVE OPEN Indicator
4
5
6
12
WATER INLET VALVE OPEN
Indicator
PURGE WATER INLET
OPEN Indicator
WATER OUTLET VALVE
OPEN Indicator
ALARM CONDITION TURN
SYSTEM OFF Indicator
STRAINER PLUGGED
Indicator
ALARM ACKNOWLEDGED
Pushbutton Switch
ELAPSE TIMER
13
OIL FLOODED Indicator
14
OIL FLOODED OVERRIDE
Pushbutton Switch
15
17
CHECK OWS SYSTEM
Indicator
PUMP CONTROL OFF-ON
Switch
HIGH VACUUM Indicator
18
OVERLOAD TRIP Indicator
19
HIGH PRESSURE Indicator
20
PUMP ON Indicator
7
8
9
10
11
16
Function
The white indicator light (LT-1) illuminates when 220 VAC 3-PH 60
Hz is applied to the OWS.
The switch (SS-1) selects the mode of operation of the OWS,
either manual or automatic. It has three positions HAND, OFF and
AUTO.
Pressing this switch (PB-2) with SYSTEM HAND-OFF-AUTO
Switch in HAND, starts the manual operation of the OWS.
Pressing this switch (PB-1) with SYSTEM HAND-OFF-AUTO
Switch in HAND, stops the manual operation of the OWS.
This amber indicator (LT-8) illuminates when oil outlet valve is
open.
This blue indicator (LT-7) illuminates when the water inlet valve is
open.
This blue indicator (LT-9) illuminates when the water valve is
open.
This blue indicator (LT-5) illuminates when the water outlet valve
is open.
This red indicator (LT-13) illuminates when a major fault has
occurred in the system and should be immediately secured.
This red indicator (LT-12) illuminates when Remote Differential
Pressure Strainer Switch is closed.
If the strainer plugged alarm sounds, pressing this switch (PB-4)
silences the alarm.
This elapse timer (ETI) operates when the motor is operating.
This red indicator (LT-10) illuminates when an excessive amount
of oil has collected in the OWS tank section or only air is present.
Pressing this switch (PB-3) allows the OWS system to continue to
operate, turns off OIL FLOODED and CHECK OWS SYSTEM
indicators and prevents the strainer plugged alarm from being
silenced.
This red indicator (LT-11) illuminates when any of the five alarm
conditions have occurred.
This switch (SS-2) controls the motor. It has two positions ON and
OFF.
This red indicator (LT-4) illuminates when high vacuum has
occurred in the system.
The red indicator (LT-6) illuminates when a motor speed overload
(motor over current) has occurred.
This red indicator (LT-3) illuminates when high pressure has
occurred in the system.
The red indicator (LT-2) illuminates when the pump is operating.
1-7
TM 55-1905-223-24-19
Figure 1-4. OCM Sampling/Sensor Assembly Controls and Indicators.
NOTE
Although the OCM has a limit of 70 PPM, DOD vessels are not authorized to
operate at this range. In accordance with DOD 4715.6-R1, Regulations On
Vessels Owned Or Operated By The Department Of Defense, the only
acceptable range of operation is 15 PPM.
Table 1-3. OCM Sampling/Sensor Assembly Controls and Indicators.
No.
1
1-8
Control or Indicator
70 PPM Indicator
Function
Alarm limit set to 70 PPM. (Refer to note above.)
2
15 PPM Indicator
Alarm limit set to 15 PPM.
3
RANGE PPM Indicator
Indicates system is operating.
4
WARNING 3 Indicator
5
WARNING 2 Indicator
OCM is in WARNING status 3. Dirt or foam in sample, or no flow;
maintenance required.
OCM is in WARNING status 2. Dirt or bubbles in sample.
6
WARNING 1 Indicator
OCM is in WARNING status 1. OCM Fuse (2 Amp) is blown.
7
POWER Indicator
OCM system power is available.
8
OIL CONTENT LCD Display
Numerical LCD display of oil content.
TM 55-1905-223-24-19
1-9.
Equipment Data. Characteristics and reference data are provided in Table 1-4. Also, see the equipment
data given in the operator’s manual, TM 55-1905-223-10.
Table 1-4. Equipment Data
Characteristics
Oil-Water Separator (OWS)
Manufacturer
Model Number
Tank Capacity
Processing Capacity
Pump
Pump Construction
Suction Lift
Effluent Discharge Head
Pump/Motor
Gauges:
Strainer In
Strainer Out
OWS Outlet Pressure
Purge Water Pressure
Compound Gauge
Oil Content Monitor (OCM)
Manufacturer
Model Number
Monitoring Capacity
Input Power
Gauges:
OCM Inlet Pressure
Normal Operating
Range
Reference Data
Facet International Inc.
OPB-10NP/SR02
138 Gallons
10 gpm
Jabsco #777-9003
Bronze housing, rubber impeller
10 feet of water
25 psi
Baldor #1706T
Instruments East, 30 PSI – 0 – 30 in Hq.
Instruments East, 30 PSI – 0 – 30 in Hq.
Weksler, 0 – 30 PSI
Weksler, 0 – 60 PSI
30 PSI – 0 – 30 in Hq.
< 5 PSI difference of Outlet
< 5 PSI difference of Inlet
5-15 PSI
10-12 PSI
< 15 PSI and < 16 in.HG
Advanced Marine Electronics
ET-35N
10 gpm
230 VAC
Weksler, 0 – 30 PSI
5-15 PSI
Water Polisher
Effluent Flow Rate
Filter Media
Number of filter canisters
Water polisher pressure gauge
Advanced Water Systems
10 gpm
PLFM
Nine (9)
Weksler, 0 – 30 PSI
< 12 PSI
Unit dimensions
OWS Tank:
Control Panel:
OCM:
Oil Content Monitor
Remote Indicator (Alarm)
Remote Relay Assembly
Water Polisher:
Unit weight (Approximately)
OWS:
Dry
Wet
OCM:
Oil Content Monitor
Remote Alarm Panel
Relay Assembly
Polisher:
Dry
37” x 31.375” x 68.4375”
31.35” x 24” x 8”
18.3” x 13.5” x 7.1”
9.5” x 7” x 4.4”
9.5” x 7” x 3.8”
49” x 39” x 16”
940 lbs.
2,400 lbs.
60.5 lbs.
6.9 lbs.
7.4 lbs.
694 lbs.
1-10. Safety, Care, and Handling. Safety precautions must be observed at all times while performing
maintenance. General WARNINGS and first-aid data appear in the front of this manual. Review all safety
information before starting any task. Carefully read through an entire maintenance procedure before performing
any maintenance function. Make sure the task can be done safely. All WARNINGS, CAUTIONS, and NOTES are
of great importance to your safety and the safety of the equipment.
1-9
TM 55-1905-223-24-19
SECTION III. PRINCIPLES OF OPERATION
1-11. Oil-Water Separator. The oil-water separator system utilizes four subsystems for operation and consists
of the dirty oil pump, oil-water separator, oil content monitor and water polisher. These subsystems are explained
as follows. See Figure 1-5 for the OWS system flow diagram.
a. Dirty Oil Pump. The dirty oil pump is a multi-use pump and when used for oil-water separation, is used to
pump oily waste water from bilges and other areas to the sludge tank. The dirty oil pump is also used to pump
bulk used oil from machinery to the dirty oil tank, and pump from the dirty oil tank to shore discharge facilities.
The START/STOP switches and pressure gauge are locally mounted near the pump for ease of operation with
remote stop buttons located on the 1st deck port and starboard.
b. Oil-Water Separator (OWS). The OWS subsystem consists of a control panel, separator tank, duplex
strainer, pump, oil/air and oil water sensors, compound gauge, sight glass, motorized valves, pressure
switches and gauge panel.
1-10
(1)
Control Panel. The OWS is controlled at the control panel and can be operated in two different
modes. HAND is used to operate for troubleshooting purposes and for maintenance functions, and
requires the manual START and STOP pushbuttons depressed for operation. AUTO is the normal
mode used for processing oily waste water from the sludge tank. The control panel houses system
indicators as shown in Figure 1-3 and an internal alarm when system failure occurs.
(2)
Separator Tank. The separator tank is where the physical separation occurs when the oil from the
water is attracted to the coalescing plates and floats to the top of the tank and into the oil tower.
The coalescing plates force the oil in the oily water to rapidly accumulate into large droplets. The
coalescing plates are arranged in two horizontal and one vertical stack inside the tank. Zinc anodes
are located in the tank to prevent galvanic action and protect the tank. The tank normally operates
in a vacuum condition while drawing oily water from the sludge tank. Oils with a specific gravity of
1.0 or greater cannot be separated by this system. Synthetic oils cannot be processed with this
system either. Significant amounts of detergents and emulsifying chemicals in the wastewater
influent will also affect the ability of the OWS to consistently produce a processed effluent
containing less than 15 ppm of oil.
(3)
Duplex Strainer. The duplex strainer removes non liquid objects from the oily waste water from the
sludge tank. The system does not require shutdown to clean a strainer basket.
(4)
OWS Pump. The OWS pump draws suction from the separator tank, and moves the water to
overboard discharge or back to the sludge tank. The rubber vane pump requires a flooded suction
to prevent pump damage from being run dry. A level sensor mounted in the sludge tank prevents
the OWS pump from operating in the AUTO mode when the sludge tank fluid level is low, protecting
the pump from running dry.
(5)
Oil/Water Sensor. The oil/water sensor consists of three electrodes which detect collected oil and
entrapped air in the oil tower. The OWS pump stops the motorized valves, which stops incoming
influent. The pump also opens the seawater feed to aid in purging the oil to the dirty oil tank.
(6)
Oil/Air Sensor. The oil/air sensor consists of two electrodes and shuts down the system if the
separator floods with oil or air. The sensor operates on the same principle described for the
oil/water sensor above. When immersed in oil or air, the electrodes deactivate safe-pak (LS2),
causing the relay to de-energize. The pump then stops. The effluent valve and oil discharge valve
close causing the audible alarm to sound and CHECK OWS SYSTEM and OIL FLOODED
indicators to illuminate.
(7)
Compound Gauge. The compound gauge is set to shutdown the OWS if either the pressure (15
psi) or vacuum (16 in. Hg) in the separator tank is reached.
(8)
Sight Glass. Located in the water discharge piping from the OWS pump to give the operator an
indication of system flow and quality.
TM 55-1905-223-24-19
(9)
Motorized Valves. These valves are controlled by the OWS control panel to open and close
depending on the signals from the oil/air and oil/water sensors. The four valves control the OWS
water supply and discharge, separator tank inlet, and oil discharge to the dirty oil tank. The valves
close on system shutdown.
(10) Pressure Switches. The pressure switches sense the pressure of the OWS system and shut down
the system when the pressure is either too high or too low.
(11) Gauge Panel. The gauge panel consists of four OWS system gauges and one OCM system gauge
for purge water pressure, OCM inlet pressure, OWS outlet pressure, strainer inlet and outlet
pressures.
c. Oil Content Monitor (OCM). The OCM controls the directional output of effluent from the OWS by
measuring the oil concentration in the processed water. The OCM sensor detection assembly (SDA) houses
the control section which sends a signal to the diverter valve to divert water overboard or back to the sludge
tank. Flush water of a minimum 5 psi is required to start the OCM and to clean out the detection assembly.
The flow through the OCM system is shown in Figure 1-6.
(1)
Sensor Detection Assembly (SDA). The SDA samples the processed discharge from the water
polisher or OWS (if water polisher is bypassed) and controls the operation of the OWS system. The
sample is measured to indicate oil content, and this signal is sent to the LCD display on the remote
alarm assembly and on the front panel display of the SDA. The Sensor Detection Assembly,
printed circuit board and elapsed timer must be replaced as a set every 2 years or 2,000 hours,
whichever occurs first.
NOTE
Although the OCM has a limit of 70 PPM, DOD vessels are not authorized to
operate at this range. In accordance with DOD 4715.6-R1, Regulations On
Vessels Owned Or Operated By The Department Of Defense, the only
acceptable range of operation is 15 PPM.
(2)
Remote Alarm Assembly. The remote alarm assembly displays the current oil content of the
processed water, provides a means to change ppm alarm settings from 15 to 70, and an
audio/visual alarm when the ppm set point is exceeded.
(3)
Remote Relay. The remote relay connects the SDA, remote alarm assembly, audible alarm and
OWS system at the control panel. A junction box provides a space for connections of the individual
assemblies.
d. Water Polisher. The water polisher contains three rows of filters stacked three high which further aids in
removal of oil from the processed water to attain parts per million setting or less.
1-11
TM 55-1905-223-24-19
Figure 1-5. OWS System Flow Diagram.
1-12
TM 55-1905-223-24-19
LEGEND:
OWS 17 DIVERTER VALVE
OWS 30 OCM SAMPLE VALVE
OWS 51 SAMPLE INLET VALVE
OWS 52 OCM INLET VALVE
OWS 53 OCM INLET PRESSURE VALVE
OWS 54 FLUSH INLET VALVE
INTERCONNECTION CABLES:
J1 P/N ST25009-1
J2 P/N ST25009-2
J3 P/N ST25009-3
J4 P/N ST25009-4
Figure 1-6. Oil Content Monitor (OCM) System Flow and Electrical Diagram.
1-13/(1-14 blank)
TM 55-1905-223-24-19
CHAPTER 2
UNIT MAINTENANCE INSTRUCTIONS
Section I
Page
Repair Parts, Special Tools; Test, Measurement, and
Diagnostic Equipment (TMDE); and Support Equipment .................................................. 2-1
Section II
Service Upon Receipt ........................................................................................................ 2-1
Section III
Unit Preventive Maintenance Checks and Services (PMCS) ............................................ 2-7
Section IV
Unit Maintenance Troubleshooting Procedures................................................................. 2-11
Section V
Unit Maintenance Procedures............................................................................................ 2-29
Section VI
Preparation for Storage or Shipment .................................................................................2-110
SECTION I. REPAIR PARTS; SPECIAL TOOLS; TEST, MEASUREMENT,
AND DIAGNOSTIC EQUIPMENT (TMDE); AND SUPPORT EQUIPMENT
2-1.
Common Tools and Equipment. For authorized common tools and equipment, refer to the Modified Table
of Organization and Equipment (MTOE), CTA 50-970, Expendable/Durable Items (Except: Medical Class V,
Repair Parts, and Heraldic Items), CTA 50-909, Field and Garrison Furnishings and Equipment or CTA 8-100,
Army Medical Department Expendable/Durable Items, as applicable to your unit.
2-2.
Special Tools, TMDE, and Support Equipment. Special tools; test, measurement, and diagnostic
equipment; and support equipment requirements are listed and illustrated in the Repair Parts and Special Tools
List (RPSTL), TM 55-1905-223-24P. These items are also listed in the Maintenance Allocation Chart (MAC),
Appendix B of this manual.
2-3.
Repair Parts. Repair parts are listed and illustrated in the Repair Parts and Special Tools List (RPSTL),
TM 55-1905-223-24P.
SECTION II. SERVICE UPON RECEIPT
2-4.
Checking Unpacked Equipment.
a. Inspect the equipment for damage incurred during shipment. If the equipment has been damaged, report
the damage in accordance with the instructions of DA PAM 750-8.
b. Check the equipment against the packing slip to see if the shipment is complete. Report all discrepancies
in accordance with the instructions of DA PAM 750-8.
c.
Check to see whether the equipment has been modified.
d. Remove and replace protective caps, plugs, inserts, wrappings, and tape when inspection/inventory is
completed. Inspect piping openings for damage. Wipe off dirt, grease, or protective films at time of installation.
e. Remove chocks from resilient mounted components.
2-5.
Deprocessing Unpacked Equipment. After receipt and inspection of unpacked equipment, make sure that
all packing materials, temporary braces, masking tape, etc., are removed from the material before installation.
2-6.
Preliminary Servicing and Adjustment. It is important that careful preparations and inspection be made
before the oil-water separator system is put in use.
a. Initial Setup, Oil-Water Separator (OWS). Before initial start of OWS, make the following inspection:
(1) Inspect OWS piping system to include all fittings and valves for serviceability (Figure 1-5).
2-1
TM 55-1905-223-24-19
(2)
Inspect OWS tank for leaks and tank cover is secure.
(3)
Inspect OWS pump for leaks (Figure 1-1).
(4)
Inspect OWS Control Panel for serviceability (Figure 1-3).
b. Oil Content Monitor (OCM).
c.
(1)
Inspect OCM panel for serviceability (Figure 1-4).
(2)
Inspect Remote Indicator (Alarm) Panel in EOS for serviceability (Figure 1-2).
Water Polisher.
(1)
Inspect polisher for leaks and covers are secure (Figure 1-1).
d. Dirty Oil Pump.
(1)
2-7.
Inspect pump for leaks (Figure 1-1).
Prestart Checks.
a. Verify that OWS has been previously shutdown properly and unit has been appropriately secured from
any prior maintenance activity.
b. Verify that circuit breakers for the OWS and OCM are turned on (FO-1, Sheet 2). Ensure that all
system valves are closed (Figures 1-5 and 1-6).
c.
Verify that sludge tank has sufficient level/volume to operate system (Figure 1-5).
d. Ensure that all associated gauge valves are opened.
NOTE
To conduct troubleshooting or training of the OWS system while inport, align
system to recirculate to sludge by pulling both pins on the diverter valve. Ensure
overboard discharge valves (OWS-18 and OWS-19) are shut and procede to
paragraph 2-8.4.
e. Ensure overboard discharge valves (OWS-18 and OWS-19) are opened.
2-8.
Normal Startup.
a. System Startup Procedure
(1)
(2)
Open the seawater supply valve (SW-45, Figure 1-5) from ASW system to the OWS. Ensure
seawater supply bypass valve (OWS 45) is shut.
(a)
Ensure that seawater regulator isolation valves (OWS-4 and OWS-44) are opened.
(b)
Verify that the purge water supply pressure available is 10-12 psig at the pressure gauge. If
not, adjust the pressure regulator valve (OWS-43) accordingly.
Align the valves for the OWS operation as follows: (Figure 1-5)
(a)
2-2
If operating from the sludge tank, open suction valve (OWS-3).
TM 55-1905-223-24-19
CAUTION
Avoid processing bilge water with high oil concentrations as this may result in
increased maintenance requirements for the OWS. Refer to steps 2-9.a and
2-9.c. If necessary use step 2-9.b.
NOTE
Under normal conditions, the dirty oil pump should be used to pump out bilge
pockets to protect OWS system from bulk oil and solids contamination.
(b)
If operating from the bilge, open the manifold suction COV (OWS-31), and the appropriate
bilge suction valve:
SPACE
Void below steering compartment
Engine room starboard bilge
Engine room port bilge
Remote hose suction
Tunnel bilge suction
Bow thruster suction
(3)
VALVE
(OWS-33)
(OWS-2)
(OWS-1)
(OWS-32)
(OWS-34)
(OWS-35)
VALVE LOCATION
Forward of Engine Operating Station
Forward of Engine Operating Station
Forward of Engine Operating Station
Forward of Engine Operating Station
Forward of Engine Operating Station
Forward of Engine Operating Station
(c)
If using the polisher, open the polisher inlet and outlet valves (OWS-48 and OWS-50), and
ensure polisher bypass valve (OWS-36) is closed.
(d)
If not using the polisher, open the polisher bypass valve (OWS-36) and ensure the polisher
inlet and outlet valves (OWS-48 and OWS-50), are closed.
Prime the OWS with water as follows: (Figure 1-5)
(a)
Open influent inlet valve (OWS-5) to prime suction piping.
(b)
Open the forward separator air bleed COV (OWS-56) at the oil discharge tower.
(c)
Open the aft separator oil bleed COV (OWS-55) near the backup oil sensor.
NOTE
When filling the OWS, water will always discharge out of the aft oil bleed COV
(OWS-55) before the forward air bleed COV (OWS-56) due to the difference of
design height.
(d)
Open the OWS manual fill valve (OWS-41) on the aft end of the OWS tank.
(e)
To prime the OWS pump, open OWS pump suction valve (OWS-46) and inlet prime valve
(OWS-60). Observe drain: when a steady stream is observed, close inlet prime valve
(OWS-60).
CAUTION
To prevent damage to the OWS, the following step must be followed in the
sequence given.
(f)
To ensure that the OWS tank is filled properly, fill OWS tank with water until water is observed
discharging from the aft oil bleed COV (OWS-55). Close the aft oil bleed COV (OWS-55),
continue filling unit until water is observed discharging from the forward air bleed COV (OWS56). Close the manual fill valve (OWS-41). Close the forward air bleed COV (OWS-56).
(g)
Open OWS discharge valve (OWS-6), OWS pump discharge valve (OWS 47) and OWS
discharge drain (OWS-57, if installed) to the dirty oil tank.
2-3
TM 55-1905-223-24-19
(4)
(5)
Flush the OCM as follows:
(a)
Select the IN-PORT (15 ppm) (7, Figure 1-2) OCM alarm set point for the OCM.
(b)
Ensure OCM selector switch is placed in the AUTO position.
(c)
Ensure that the OCM nozzle sampler valve (OWS-51, Figure 1-5) and OCM inlet cutout valve
(COV) (OWS-52) are opened.
(d)
Open the seawater flushing valve (OWS-54) to flush the OCM. Verify OCM inlet pressure
gauge indicates 5 to 15 psig.
(e)
Observe that water is discharging from OCM drain.
(f)
After 2 to 5 minutes of OCM flushing, close seawater flushing valve (OWS-54).
Start the OWS as follows:
NOTE
AUTO MODE – Use when sludge tank is above 50% of tank capacity. The
system will operate without operator assistance.
HAND MODE – Use when sludge tank is partially filled. The operator must
depress the start/stop pushbuttons to operate and secure the OWS. Constant
monitoring of the system is required.
(a)
Select mode of operation with system HAND-OFF-AUTO switch.
(b)
Set PUMP CONTROL switch to ON.
(c)
Depress the MANUAL START pushbutton (HAND mode only).
(d)
Observe the OWS control panel for indicator lights when started as follows:
-
OWS discharging overboard - POWER ON, WATER INLET VALVE OPEN, WATER
OUTLET VALVE OPEN and PUMP ON indicator lights illuminated.
-
OWS recirculating back to sludge tank - POWER ON, OIL VALVE OPEN and PURGE
WATER INLET OPEN indicator lights illuminated.
b. During Operation
(1)
Observe that the OWS discharge pressure gauge is indicating between 5 to 15 psig.
(2)
The following will be observed on the control panel when the OWS goes into the oil discharge mode
to the dirty oil tank:
(3)
2-4
(a)
POWER ON, OIL VALVE OPEN and PURGE WATER INLET OPEN indicator lights
illuminated.
(b)
Once the oil discharge mode is complete, the OWS resumes overboard/recirculation mode.
The OCM 3-way diverter valve (OWS-17) position indicator will be observed indicating the following
system modes.
(a)
Green light: OWS/polisher effluent is discharging overboard.
(b)
Red light: OWS/polisher effluent is recirculating back to the sludge tank.
TM 55-1905-223-24-19
c.
Shutdown Procedure (Normal or Emergency).
(1)
(2)
2-9.
Normal
(a)
If operating in HAND mode, depress the MANUAL STOP pushbutton. If operating in AUTO
mode, depress and hold the MANUAL STOP pushbutton until the OWS pump stops.
(b)
Place PUMP CONTROL and SYSTEM HAND-OFF-AUTO switches in the OFF position at the
OWS control panel.
(c)
Open the OCM seawater flushing valve (OWS-54) and flush OCM for 5 to 10 minutes. Close
seawater flushing valve (OWS-54) when complete.
(d)
Close the sludge tank suction valve (OWS-3).
(e)
To back flush oil tower:
1
Open the air bleed COV (OWS-56) on the oil discharge tower.
2
Open the manual fill valve (OWS-41). Flush OWS until clean water discharges from air
bleed COV (OWS-56). Close manual fill valve (OWS-41).
3
Close air bleed COV (OWS-56).
4
Ensure all OWS valves are closed.
Emergency
(a)
If operating in HAND mode, depress the MANUAL STOP pushbutton. If operating in AUTO
mode, depress and hold the MANUAL STOP pushbutton until the OWS pump stops.
(b)
Place PUMP CONTROL and SYSTEM HAND-OFF-AUTO switches in the OFF position at the
OWS control panel.
(c)
Close the sludge tank suction valve (OWS-3).
Dirty Oil Transfer Alignment
a. Dirty Oil Pump Bilge Suction Operations to Sludge Tank. (Figure 1-5)
NOTE
Under normal conditions the dirty oil pump should be used to pump out bilge
pockets to protect OWS system from bulk oil and solids contamination.
(1)
Turn on power at dirty oil pump motor controller. Ensure all OWS and LO valves are closed.
(2)
Select desired bilge suction valve:
SPACE
Void below steering compartment
Engine room starboard bilge
Engine room port bilge
Remote hose suction
Tunnel bilge suction
Bow thruster suction
VALVE
(OWS-33)
(OWS-2)
(OWS-1)
(OWS-32)
(OWS-34)
(OWS-35)
VALVE LOCATION
Forward of Engine Operating Station
Forward of Engine Operating Station
Forward of Engine Operating Station
Forward of Engine Operating Station
Forward of Engine Operating Station
Forward of Engine Operating Station
2-5
TM 55-1905-223-24-19
(3)
Open valves OWS-42, LO-47, LO-36, LO-37, LO-50, and OWS-59.
(4)
Depress dirty oil pump START pushbutton.
(5)
Visually verify that selected bilge area has been drained. If bilge does not drain, check dirty oil
pump strainer (LO-49) or appropriate bilge suction foot valve strainer for blockage. Ensure that only
one suction valve is open at a time.
(6)
When dirty oil pump loses suction (indicated on dirty oil pump pressure gauge), depress dirty oil
pump STOP pushbutton. Verify bilge water is below bilge suction at foot valve.
(7)
Ensure all OWS and LO valves are closed. Secure power at dirty oil pump motor controller.
b. Dirty Oil Pump Sludge Tank to Dirty Oil Tank.
NOTE
The bulk oil in the sludge tank should be pumped to the dirty oil tank if OWS is
continuously in the oil discharge mode after the water has been processed by the
OWS.
(1)
Turn on power at dirty oil pump motor controller. Ensure all LO valves are closed.
CAUTION
Compare soundings from dirty oil and sludge tanks to ensure transfer will not
overfill the dirty oil tank.
c.
(2)
Open valves LO-35, LO-47, LO-36, LO-37, LO-50, OWS-58 and OWS-57 (if installed).
(3)
Depress dirty oil pump START pushbutton and observe dirty oil pump discharge gauge for
discharge pressure.
(4)
Depress STOP pushbutton upon loss of pressure as indicated on dirty oil pump pressure gauge or if
desired tank levels are reached.
(5)
Close all opened valves and secure power at the dirty oil pump motor controller.
Dirty Oil Pump Bilge Suction Operations to Dirty Oil Tank (Figure 1-5)
CAUTION
In the event of a fuel oil spill, with subsequent AFFF application, the affected
bilge pocket should be pumped directly to the dirty oil tank. These agents restrict
the sensors ability to sense oil and can result in overboard oily waste discharge.
(1)
Turn on power at dirty oil pump motor controller. Ensure all LO valves are closed.
(2)
Select desired bilge suction valve:
SPACE
Void below steering compartment
Engine room starboard bilge
Engine room port bilge
Remote hose suction
Tunnel bilge suction
Bow thruster suction
2-6
VALVE
(OWS-33)
(OWS-2)
(OWS-1)
(OWS-32)
(OWS-34)
(OWS-35)
VALVE LOCATION
Forward of Engine Operating Station
Forward of Engine Operating Station
Forward of Engine Operating Station
Forward of Engine Operating Station
Forward of Engine Operating Station
Forward of Engine Operating Station
TM 55-1905-223-24-19
(3)
Open valves OWS-42, LO-47, LO-36, LO-37, LO-50, OWS-58 and OWS-57 (if installed).
(4)
Depress dirty oil pump START pushbutton.
(5)
Visually verify that selected bilge area has been drained. If bilge does not drain, check dirty oil
pump strainer (LO-49) or appropriate bilge suction foot valve strainer for blockage. Ensure that only
one suction valve is open at a time.
(6)
When dirty oil pump loses suction (indicated on dirty oil pump pressure gauge), depress dirty oil
pump STOP pushbutton. Verify bilge water is below bilge suction at foot valve.
(7)
Ensure all OWS and LO valves are closed. Secure power at dirty oil pump motor controller.
SECTION III. UNIT PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS)
2-10. Explanation of PMCS Table. PMCS is designed to keep the equipment in good working condition. This is
accomplished by performing certain tests, inspections, and services. Table 2-1 lists items to be serviced and the
procedures needed to accomplish the PMCS. The "Interval" column tells you when to perform a check or service.
If needed, PMCS may be performed more frequently than the indicated interval. The "Procedures" column tells
you how to perform the required checks and services. If your equipment does not perform as required, see Table
2-2, Troubleshooting. Report any malfunctions or failures on DA Form 2404/5988E. In the Item Number column
on DA Form 2404/5988E, record the appropriate Item Number from the PMCS Table.
The column labeled "Equipment is Not Ready/Available If:" of the PMCS, Table 2-1 is not intended to imply the
condition of the vessel. This column only indicates the condition of the equipment.
2-7
D – During
Item
No.
1
W – Weekly
M – Monthly
Interval
D
W
M
Q
S
A
A/R
Q – Quarterly
Items To Be
Inspected/Serviced
Gauge Panels
S – Semiannually
A – Annual
A/R-As Required
Procedures
Inspect for proper operation, see equipment
data Table 1-4.
Equipment is Not
Ready/Available If:
Instrument gauge
inoperative.
_________
WARNING
Always ensure affected circuits have been
secured, locked out and tagged out.
Performing maintenance with circuits
energized may result in death or injury to
personnel or equipment damage.
2
Oil Content Monitor
Ultrasonic Vibrator
Adjustment
Ultrasonic vibrator adjustment: Adjust core
of oscillation transformer on ultrasonic
generator PCB for maximum resonance
(maximum noise output) (Adjustment Task,
Paragraph 2-26).
Not possible to
determine the
coarse adjustment
range because only
weak or unsteady
noise is generated.
OCM Sensor Detection
Assembly (SDA)
Clean SDA by flushing (Paragraph 2-8).
Inspect for damage.
If warning lights 2
and 3 cannot be
cleared by flushing.
OCM Sensor Detection
Assembly (SDA), Printed
Circuit Board (PCB) and
Elapsed Time Indicator (ETI)
Remove and replace as a calibrated set
every 2,000 hours of operation or 2 years
after calibration date, whichever occurs first
(Paragraph 3-12).
ETI indicates more
than 2,000 hours or
more than 2 years
since calibration.
TM 55-1905-223-24-19
2-8
Table 2-1. Preventive Maintenance Checks and Services
Table 2-1. Preventive Maintenance Checks and Services
D – During
Item
No.
3
W – Weekly
M – Monthly
Interval
D
W
M
Q
S
A
A/R
Q – Quarterly
Items To Be
Inspected/Serviced
S – Semiannually
A – Annual
A/R-As Required
Procedures
Equipment is Not
Ready/Available If:
OWS Tank
Check zinc anode plug in OWS tank and
measure remaining zinc. Replace if less
than 3 inches in length (Paragraph 2-14).
If zinc is less than 3
inches in length.
OWS Tank
Clean coalescer plates when ppm alarm set
limit cannot be obtained by the OWS and
water polisher (Paragraph 2-14). Inspect
tank for damage and deterioration of tank
coating.
PPM set point is
exceeded IN PORT
or AT SEA.
Faulty level
indication.
Oil/Water and Oil/Air
Interface Sensors
Clean oil level sensor electrodes and
inspect for damage and corrosion. Service
and replace as needed (Paragraph 2-15).
5
Remote Relay Assembly
Check for loose electrical connections,
stuffing tubes and damage to door seals.
Repair as necessary (Paragraph 2-28).
6
Relief Valves
Test relief valve in accordance with relief
valve data (Paragraph 2-25).
Valve fails to
operate.
2-9
TM 55-1905-223-24-19
4
D – During
Item
No.
W – Weekly
M – Monthly
Interval
D
W
M
Q
S
A
A/R
Q – Quarterly
Items To Be
Inspected/Serviced
S – Semiannually
A – Annual
Procedures
A/R-As Required
Equipment is Not
Ready/Available If:
_________
WARNING
Always ensure affected circuits have been
secured, locked out and tagged out.
Performing maintenance with circuits
energized may result in death or injury to
personnel or equipment damage.
7
8
9
Motorized Valves
Clean motorized valves, inspect for
damage, and lubricate as required
(Paragraph 2-22).
Control Panel
Check for loose electrical connections,
stuffing tubes and damage to door seals.
Repair as necessary (Paragraph 2-20).
Check Valves
Clean check valves, inspect for damage,
repair or replace as necessary (Paragraph
2-31).
10
Sight Glass
Clean and inspect for damage.
11
Diverter Valve
Inspect and check knob for freedom of
movement (Paragraph 2-23).
Valve fails to
operate.
Valve stuck.
TM 55-1905-223-24-19
2-10
Table 2-1. Preventive Maintenance Checks and Services
TM 55-1905-223-24-19
SECTION IV. UNIT MAINTENANCE TROUBLESHOOTING PROCEDURES
2-11. Troubleshooting. Both a symptom index and a troubleshooting table are provided. The symptom index
will help you locate the information you need for troubleshooting.
SYMPTOM INDEX
Troubleshooting
Procedure
(Table 2-2)
OCM
Unstable oil content display; PPM values jump high then low.
Item 19
Audible Alarm inoperative when OCM is in Alarm mode on Remote Indicator (Alarm)
Assembly.
Item 24
OCM not operational during OWS operation.
Item 14
Indicators and displays inoperative while OCM is operating.
Item 22
PUSH TO CHANGE ALARM LIMIT (PPM) pushbutton switch (A2S1) (Figure 1-2) on
Remote Indicator (Alarm) Assembly does not change Alarm Limit of OCM.
Item 23
WARNING 1 (Red LED) illuminated.
Item 15
WARNING 2 (Red LED) illuminated.
Item 16
WARNING 3 (Red LED) illuminated.
Item 17
WARNING 2 and WARNING 3 (Red LEDs) illuminated.
Item 18
PUSH TO SILENCE switch (A2S2) does not function properly when OCM is in alarm
mode.
Item 25
OWS Control Panel
Depressing MANUAL STOP pushbutton does not stop system.
Item 11
POWER ON (OWS) indicator does not illuminate.
Item 1
Pump fails to start when MANUAL START pushbutton is depressed.
Item 13
Separator flooded shutdown.
Item 5
STRAINER PLUGGED illuminates when differential pressure (DP) is less than 5 in. Hg.
Item 8
STRAINER PLUGGED does not illuminate when differential pressure is greater than
5 in. Hg.
Item 9
System fails to start in AUTO mode.
Item 3
System fails to start in HAND mode when MANUAL START pushbutton is depressed.
Item 2
Check OWS System light illuminated with malfunction light.
Item 4
2-11
TM 55-1905-223-24-19
SYMPTOM INDEX
Troubleshooting
Procedure
(Table 2-2)
OWS System
System fails to secure when sludge tank is pumped dry.
Item 12
System fails to secure from oil discharge mode.
Item 10
No oil removal.
Item 6
Oil sheen in discharged effluent.
Item 20
OWS discharge is diverted inboard when OCM detects less
than alarm limit.
Item 21
Motorized operated valve will not open or close.
Item 7
Dirty Oil Pump output falls below 11 GPM.
Item 26
Table 2-2 lists the common fault conditions that may be found during operation or maintenance of the equipment.
Look for causes and do corrective actions in the order listed. This manual cannot list every symptom that may
show up, and it cannot list all the possible causes and corrective actions. If a symptom is not listed, or if it keeps
up after you have performed the corrective actions, notify your supervisor.
2-12
TM 55-1905-223-24-19
Table 2-2. Troubleshooting
Malfunction
Test or Inspection
Corrective Action
NOTE
During all troubleshooting, it is assumed vessel power source is operating
correctly, start up and shut down procedures correctly followed and all applicable
valves are open.
OIL- WATER SEPARATOR, MODEL OPB-10NP/SR02
1. POWER ON (OWS) indicator does not illuminate.
_________
WARNING
Under no circumstances should repair or adjustment of energized equipment be
attempted alone. The immediate presence of someone capable of rendering aid
is required. Before making adjustments, be sure to protect against grounding. If
possible, adjustments should be made with one hand, with the other hand free
and clear of equipment. Even when power has been removed from equipment
circuits, dangerous potentials may still exist due to retention of charges by
capacitors. Circuits must be grounded and all capacitors discharged prior to
attempting repairs.
STEP 1. Measure for 230 VAC across power in terminals (FO-1, Sheet 2 and FO-2).
If no voltage present, activate main disconnect switch.
STEP 2. Measure for voltage across lampholder terminals.
If voltage present, replace lamp (Paragraph 2-20).
STEP 3. Measure for voltage across lampholder terminals.
If no voltage present, correct wiring or replace lampholder (Paragraph 2-20).
2. System fails to start in HAND mode when MANUAL START pushbutton is depressed.
_________
WARNING
Under no circumstances should repair or adjustment of energized equipment be
attempted alone. The immediate presence of someone capable of rendering aid
is required. Before making adjustments, be sure to protect against grounding. If
possible, adjustments should be made with one hand, with the other hand free
and clear of equipment. Even when power has been removed from equipment
circuits, dangerous potentials may still exist due to retention of charges by
capacitors. Circuits must be grounded and all capacitors discharged prior to
attempting repairs.
STEP 1. Measure for voltage across switch.
If no voltage present, replace defective switch (Paragraph 2-20).
STEP 2. Measure for voltage across terminals with pushbutton depressed.
If no voltage present, replace pushbutton (Paragraph 2-20).
3. System fails to start in AUTO mode.
STEP 1. Check that liquid is above the high level sensor in sludge tank.
Wait for liquid level to rise.
2-13
TM 55-1905-223-24-19
Table 2-2. Troubleshooting - CONT
Malfunction
Test or Inspection
Corrective Action
OIL- WATER SEPARATOR, MODEL OPB-10NP/SR02 – CONT
3. System fails to start in AUTO mode. (cont).
_________
WARNING
Under no circumstances should repair or adjustment of energized equipment be
attempted alone. The immediate presence of someone capable of rendering aid
is required. Before making adjustments, be sure to protect against grounding. If
possible, adjustments should be made with one hand, with the other hand free
and clear of equipment. Even when power has been removed from equipment
circuits, dangerous potentials may still exist due to retention of charges by
capacitors. Circuits must be grounded and all capacitors discharged prior to
attempting repairs.
STEP 2. If sludge tank is full, inspect sludge level sensors and wires (Paragraph 2-15).
If sludge tank level sensors are stuck in the open position: service or repair (Paragraph 2-15).
If sludge tank level senor wires are charred or damaged replace (Paragraph 2-15).
STEP 3. If sludge tank is full, check operation of SAFE-PAK (LS3) (Paragraph 2-20).
Install jumper between TB1-20 and TB1-21 and TB-21 and TB-22 in OWS Control Panel.
If pump starts service or repair sludge tank level sensor (Paragraph 2-15).
STEP 4. SAFE-PAK (LS3) is defective. Measure for voltage across TB1-40 and TB1-N in OWS Control
Panel.
If no voltage is present replace SAFE-PAK (LS3) (Paragraph 2-20).
If voltage is present replace relay K-8 (Paragraph 2-20).
STEP 5. Relay R1 is defective. Measure for voltage across TB1-3 and TB1-N in OWS Control Panel.
If no voltage is present replace Relay R1 (Paragraph 2-20).
4. Check OWS System light illuminated with malfunction light.
STEP 1. Pump overload trip indicator is illuminated. Allow pump to cool, reset OL1 inside OWS Control
Panel (Figure 1-3).
If OL1 continues to trip, service or repair pump and motor (Paragraphs 2-16 and 2-17).
STEP 2. Oil flooded indicator is illuminated. Check oil discharge sample.
If oil flooded; drain OWS to dirty oil tank.
If contaminated or contains bubbles drain and service level sensors (Paragraph 2-15).
STEP 3. High pressure indicator is illuminated. Purge water and oil discharge valves remain open.
Shut purge water and oil discharge valves by deenergizing OWS. Ensure compound gauge is set at 15
psig (Paragraph 2-21).
Verify valve lineup (Paragraph 2-8).
Service or repair OWS pump or motor (Paragraphs 2-16 and 2-17).
Service or repair Motorized valves (Paragraph 2-22).
Service or repair Diverter valve (Paragraph2-23).
Service or repair Relief valve (Paragraph 2-25).
2-14
TM 55-1905-223-24-19
Table 2-2. Troubleshooting - CONT
Malfunction
Test or Inspection
Corrective Action
OIL- WATER SEPARATOR, MODEL OPB-10NP/SR02 – CONT
4. Check OWS System light illuminated with malfunction light. (cont).
STEP 4. High vacuum indicator is illuminated. OWS system operation will stop.
Shut purge water and oil discharge valves by deenergizing OWS. Ensure compound gauge is set
at 16in. Hg. (Paragraph 2-21).
Verify valve lineup (Paragraph 2-8).
Service or repair OWS pump or motor (Paragraphs 2-16 and 2-17).
Service or repair Motorized valves (Paragraph 2-22).
Test and replace Relief valves (Paragraph 2-25).
_________
WARNING
Always ensure affected circuits have been secured, locked out and tagged out.
Performing maintenance with circuits energized may result in death or injury to
personnel or equipment damage.
STEP 5. Strainer plugged indicator is illuminated. Indicates differential pressure greater than 5 psi.
Service (PMCS, TM 55-1905-223-10) or repair strainer (Paragraph 2-24).
Adjust or replace differential pressure switch (Paragraph 2-30).
5. Separator flooded shutdown.
STEP 1. Open valve OWS-55 (Figure 1-5). While depressing OVERRIDE pushbutton, depress MANUAL
START pushbutton.
If air comes from OWS-55, prime system by opening OWS-41.
If oil comes from OWS-55, restart system, remove oil.
6. No oil removal.
STEP 1. Remove Oil/Water sensor leads from terminals of interface.
If oil removal starts, service or repair sensor rod (Paragraph 2-15).
_________
WARNING
Under no circumstances should repair or adjustment of energized equipment be
attempted alone. The immediate presence of someone capable of rendering aid
is required. Before making adjustments, be sure to protect against grounding. If
possible, adjustments should be made with one hand, with the other hand free
and clear of equipment. Even when power has been removed from equipment
circuits, dangerous potentials may still exist due to retention of charges by
capacitors. Circuits must be grounded and all capacitors discharged prior to
attempting repairs.
STEP 2. Measure for voltage across SAFE-PAK (LS1) Load terminal and TB1-N (FO-2, Sheet 2).
If no voltage present, replace SAFE-PAK LS1 (Paragraph 2-20).
2-15
TM 55-1905-223-24-19
Table 2-2. Troubleshooting - CONT
Malfunction
Test or Inspection
Corrective Action
OIL- WATER SEPARATOR, MODEL OPB-10NP/SR02 – CONT
6. No oil removal. (cont).
_________
WARNING
Always ensure affected circuits have been secured, locked out and tagged out.
Performing maintenance with circuits energized may result in death or injury to
personnel or equipment damage.
STEP 3. Secure power and check contacts of relay R2 for continuity (FO-2, Sheet 2).
If continuity does not exist, replace relay R2 (Paragraph 2-20).
STEP 4. Defective oil discharge motorized operated valve. Check for voltage across terminals TB1-8 and
TB1-N (FO-2, Sheet 1).
If no voltage is present, replace motorized operated valve actuator (Paragraph 2-22).
If voltage is present go to Troubleshooting item 7: Motorized operated valve will not open or close.
7. Motorized operated valve will not open or close.
_________
WARNING
Under no circumstances should repair or adjustment of energized equipment be
attempted alone. The immediate presence of someone capable of rendering aid
is required. Before making adjustments, be sure to protect against grounding. If
possible, adjustments should be made with one hand, with the other hand free
and clear of equipment. Even when power has been removed from equipment
circuits, dangerous potentials may still exist due to retention of charges by
capacitors. Circuits must be grounded and all capacitors discharged prior to
attempting repairs.
STEP 1. Open or Close limit switch is out of adjustment. Verify position of valve mechanical indication.
If valve mechanical indication is open and OWS control panel does not indicate open, adjust open and
close limit switches (Paragraph 2-22).
_________
WARNING
Always ensure affected circuits have been secured, locked out and tagged out.
Performing maintenance with circuits energized may result in death or injury to
personnel or equipment damage.
STEP 2. Defective Open or Close limit switch. Manually activate open and close limit switch and check for
continuity (FO-2, Sheet 1).
If there is no continuity replace valve actuator (Paragraph 2-22).
STEP 3. Open valve actuator windings. Check for continuity of valve actuator windings (FO-2, Sheet 1).
If there is no continuity replace valve actuator (Paragraph 2-22).
STEP 4. Valve has seized. Remove valve actuator and check for valve freedom of movement (Paragraph
2-22).
If valve will not manually rotate or binding is noticed, replace valve (Paragraph 2-22).
2-16
TM 55-1905-223-24-19
Table 2-2. Troubleshooting - CONT
Malfunction
Test or Inspection
Corrective Action
OIL- WATER SEPARATOR, MODEL OPB-10NP/SR02 – CONT
8. STRAINER PLUGGED illuminates when differential pressure (DP) is less than 5 in. Hg.
STEP 1. Check valve lineup (Paragraph 2-8).
Open/Shut valves as required for desired system lineup.
_________
WARNING
Under no circumstances should repair or adjustment of energized equipment be
attempted alone. The immediate presence of someone capable of rendering aid
is required. Before making adjustments, be sure to protect against grounding. If
possible, adjustments should be made with one hand, with the other hand free
and clear of equipment. Even when power has been removed from equipment
circuits, dangerous potentials may still exist due to retention of charges by
capacitors. Circuits must be grounded and all capacitors discharged prior to
attempting repairs.
STEP 2. With system running, measure for voltage across DP switch terminals (FO-1, Sheet 1 and FO-2).
If voltage present, perform maintenance on differential pressure switch (Paragraph 2-30).
9. STRAINER PLUGGED does not illuminate when differential pressure is greater than 5 in Hg.
STEP 1. Check valve lineup (Paragraph 2-8).
Open/Shut valves as required for desired system lineup.
_________
WARNING
Under no circumstances should repair or adjustment of energized equipment be
attempted alone. The immediate presence of someone capable of rendering aid
is required. Before making adjustments, be sure to protect against grounding. If
possible, adjustments should be made with one hand, with the other hand free
and clear of equipment. Even when power has been removed from equipment
circuits, dangerous potentials may still exist due to retention of charges by
capacitors. Circuits must be grounded and all capacitors discharged prior to
attempting repairs.
STEP 2. With system running, measure for voltage across lamp holder terminals (FO-1, Sheet 1 and FO-2.)
If voltage present, replace lamp (Paragraph 2-20).
STEP 3. With system running, measure for voltage across DP switch terminals (FO-1, Sheet 1 and FO-2.)
If no voltage present, perform maintenance on differential pressure switch (Paragraph 2-30).
2-17
TM 55-1905-223-24-19
Table 2-2. Troubleshooting - CONT
Malfunction
Test or Inspection
Corrective Action
OIL- WATER SEPARATOR, MODEL OPB-10NP/SR02 – CONT
10. System fails to secure from oil discharge mode.
_________
WARNING
Always ensure affected circuits have been secured, locked out and tagged out.
Performing maintenance with circuits energized may result in death or injury to
personnel or equipment damage.
STEP 1. Verify that water is being discharged. Take a sample at valve OWS-23. Secure power and install
jumpers on terminals TB1-11, TB1-12 and TB1-13. Restart system.
If system secures from oil discharge mode, service or repair sensor rod (Paragraph 2-15).
If system continues to operate in oil discharge mode, replace SAFE-PAK (LS1) (Paragraph 2-20).
_________
WARNING
Under no circumstances should repair or adjustment of energized equipment be
attempted alone. The immediate presence of someone capable of rendering aid
is required. Before making adjustments, be sure to protect against grounding. If
possible, adjustments should be made with one hand, with the other hand free
and clear of equipment. Even when power has been removed from equipment
circuits, dangerous potentials may still exist due to retention of charges by
capacitors. Circuits must be grounded and all capacitors discharged prior to
attempting repairs.
STEP 2. Defective Relay R2. Check for voltage between LOAD of SAFE-PAK (LS1) and TB1-N.
If voltage is present, replace R2 (Paragraph 2-20).
STEP 3. Motor operated valves for Oil Discharge and Water Discharge are not functioning. Check for voltage
across terminals TB1-8 and TB1-N for Oil Discharge and TB1-7A and TB1-N for Water Discharge.
Troubleshoot Oil Discharge and Water Discharge using Troubleshooting item 7: Motorized operated valve
will not open or close.
11. Depressing MANUAL STOP pushbutton does not stop system.
_________
WARNING
Under no circumstances should repair or adjustment of energized equipment be
attempted alone. The immediate presence of someone capable of rendering aid
is required. Before making adjustments, be sure to protect against grounding. If
possible, adjustments should be made with one hand, with the other hand free
and clear of equipment. Even when power has been removed from equipment
circuits, dangerous potentials may still exist due to retention of charges by
capacitors. Circuits must be grounded and all capacitors discharged prior to
attempting repairs.
STEP 1. Measure for voltage across MANUAL STOP pushbutton terminals while depressing MANUAL STOP
pushbutton (FO-2, Sheet 1).
If no voltage present, replace MANUAL STOP pushbutton (Paragraph 2-20).
If voltage present, replace relay R1 (Paragraph 2-20).
2-18
TM 55-1905-223-24-19
Table 2-2. Troubleshooting - CONT
Malfunction
Test or Inspection
Corrective Action
OIL- WATER SEPARATOR, MODEL OPB-10NP/SR02 – CONT
12. System fails to secure when sludge tank is pumped dry.
STEP 1. Secure system. Remove level sensor assemblies and visually check for dirt/sludge buildup.
Service or replace sludge tank level sensor(s) (Paragraph 2-15).
Replace SAFE-PAK (LS3-3) (Paragraph 2-15).
13. Pump fails to start when MANUAL START pushbutton is depressed.
STEP 1. Check control panel for illuminated indicator lamps to ensure power source is available to system.
Activate main disconnect switch.
_________
WARNING
Under no circumstances should repair or adjustment of energized equipment be
attempted alone. The immediate presence of someone capable of rendering aid
is required. Before making adjustments, be sure to protect against grounding. If
possible, adjustments should be made with one hand, with the other hand free
and clear of equipment. Even when power has been removed from equipment
circuits, dangerous potentials may still exist due to retention of charges by
capacitors. Circuits must be grounded and all capacitors discharged prior to
attempting repairs.
STEP 2. No power to pump motor.
Measure for 230 VAC across motor terminals (FO-1, Sheet 1 and FO-2.)
If no voltage present, see Troubleshooting item 4.
STEP 3. Depress MANUAL START pushbutton and check for voltage across terminals.
If voltage exists, replace MANUAL START pushbutton (Paragraph 2-20).
STEP 4. Place PUMP CONTROL switch to on and check for voltage across terminals.
If voltage exists, replace PUMP CONTROL switch (Paragraph 2-20).
STEP 5. Check for continuity of motor windings.
If motor windings are open, repair/replace motor (Paragraphs 2-16 or 2-17).
14. OCM not operational during OWS operation.
STEP 1. Move OCM selector switch to MANUAL for 3-5 seconds to provide power to the OCM and bypass
the OCM pressure switch.
If POWER ON (OCM) indicator illuminates, move switch to AUTO.
If POWER ON (OCM) indicator does not illuminate, check main disconnect switch.
STEP 2. Cable is loose or damaged. Verify connection, inspect for damage.
Tighten cable or remove and repair as required.
2-19
TM 55-1905-223-24-19
Table 2-2. Troubleshooting - CONT
Malfunction
Test or Inspection
Corrective Action
OIL- WATER SEPARATOR, MODEL OPB-10NP/SR02 – CONT
14. OCM not operational during OWS operation. (cont).
_________
WARNING
Under no circumstances should repair or adjustment of energized equipment be
attempted alone. The immediate presence of someone capable of rendering aid
is required. Before making adjustments, be sure to protect against grounding. If
possible, adjustments should be made with one hand, with the other hand free
and clear of equipment. Even when power has been removed from equipment
circuits, dangerous potentials may still exist due to retention of charges by
capacitors. Circuits must be grounded and all capacitors discharged prior to
attempting repairs.
STEP 3. No 115 VAC. Measure for 115 VAC across INPUT terminals on Power PCB Assembly (Figure 2-18,
Sheet 3).
If no voltage present, activate main disconnect switch.
STEP 4. Low sample pressure to the OCM. Verify 10 to 12 psi (minimum 5 psi at startup) at OCM inlet
pressure gauge and flow from OCM drain, check with flush water (OWS-54) as required.
Adjust inlet pressure for 10 to 12 psi. Clear blockages from OCM nozzle sampler to SDA inlet tubing.
Verify OCM valve line up (Paragraph 2-8).
_________
WARNING
Always ensure affected circuits have been secured, locked out and tagged out.
Performing maintenance with circuits energized may result in death or injury to
personnel or equipment damage.
STEP 5. Fuse on Power PCB Assembly is blown. WARNING 1 (Red LED) is lit. Check that fuse is in place
and intact.
Replace fuse as required (Paragraph 2-26).
_________
WARNING
Always ensure affected circuits have been secured, locked out and tagged out.
Performing maintenance with circuits energized may result in death or injury to
personnel or equipment damage.
STEP 6. OCM Operation Selector Switch Assembly is disconnected or defective. Verify that switch assembly
is plugged into the Power PCB (11, Figure 2-18, Sheet 1).
Plug switch assembly into Power PCB. Remove the switch assembly and check for continuity between
N.O., N.C. and C contacts on switch. Replace/repair switch assembly as required (Paragraph 2-26).
2-20
TM 55-1905-223-24-19
Table 2-2. Troubleshooting - CONT
Malfunction
Test or Inspection
Corrective Action
OIL- WATER SEPARATOR, MODEL OPB-10NP/SR02 – CONT
14. OCM not operational during OWS operation. (cont).
_________
WARNING
Under no circumstances should repair or adjustment of energized equipment be
attempted alone. The immediate presence of someone capable of rendering aid
is required. Before making adjustments, be sure to protect against grounding. If
possible, adjustments should be made with one hand, with the other hand free
and clear of equipment. Even when power has been removed from equipment
circuits, dangerous potentials may still exist due to retention of charges by
capacitors. Circuits must be grounded and all capacitors discharged prior to
attempting repairs.
STEP 7. Noise Filter Defective. 115 VAC measured across input but not measured at output terminals
(Figure 2-18, Sheet 3).
Replace Noise Filter POWER ON indicator (Paragraph 2-26).
_________
WARNING
Always ensure affected circuits have been secured, locked out and tagged out.
Performing maintenance with circuits energized may result in death or injury to
personnel or equipment damage.
STEP 8. Transformer is defective. 115 VAC measured across input but not at output wire leads
(INPUT terminals on Power PCB Assembly) (Figure 2-18, Sheet 3).
Repair wire leads or replace Transformer (Paragraph 2-26).
NOTE
If steps 1 through 8 do not correct the malfunction then the fault is in a PCB
board.
STEP 9. Processor or Power PCB is defective. Inspect for damaged, charred or burnt components.
Replace defective Power PCB (Paragraph 2-26) or Processor PCB with Calibration Kit (Paragraph 3-12).
_________
WARNING
Always ensure affected circuits have been secured, locked out and tagged out.
Performing maintenance with circuits energized may result in death or injury to
personnel or equipment damage.
15. WARNING 1 (Red LED) illuminated (Figure 1-4).
STEP 1. Fuse on Power PCB Assembly is blown.
Verify that fuse is in place, check for continuity through fuse.
Replace fuse as required (13, Figure 2-18, Sheet 1).
2-21
TM 55-1905-223-24-19
Table 2-2. Troubleshooting - CONT
Malfunction
Test or Inspection
Corrective Action
OIL- WATER SEPARATOR, MODEL OPB-10NP/SR02 – CONT
16. WARNING 2 (Red LED) illuminated (Figure 1-4).
STEP 1. High level of contaminants in the sample water.
Take sample from OCM drain, and check for solids, water color or bulk oil.
If water is darker than light tea, then the solids content is too high (Figure 1-4). Service or repair duplex
strainer (Paragraph 2-24).
Service the OWS (Paragraph 2-14).
STEP 2. High level of air bubbles in the sample water.
Check for air leaks in the OWS discharge or Nozzle Sampler piping.
Tighten all pipe joints and valve seals; remove sources of air leaks.
STEP 3. SDA glass cell defective.
Service or repair SDA glass cell (Paragraph 2-26).
17. WARNING 3 (Red LED) illuminated (Figure 1-4).
_________
WARNING
Always ensure affected circuits have been secured, locked out and tagged out.
Performing maintenance with circuits energized may result in death or injury to
personnel or equipment damage.
STEP 1. High level of detergent, dirt and/or bubbles in the sample water.
Take sample from OCM drain, and check for dirt, color and suds. Water darker than light tea means the
solids content is too high; suds indicate detergents or air bubbles.
Reduce the amount of solids. Service or repair duplex strainer (Paragraph 2-24).
Check for air leaks in the OWS discharge or Nozzle Sampler piping.
Tighten all pipe joints and valve seals; remove sources of air leaks.
Perform Operational Check and OCM Flush (Paragraph 2-8).
If WARNING 3 (Red LED) goes out, sample mixture is the problem. Service OWS tank (Paragraph 2-14).
_________
WARNING
Always ensure affected circuits have been secured, locked out and tagged out.
Performing maintenance with circuits energized may result in death or injury to
personnel or equipment damage.
STEP 2. Cable Assembly between Power Assembly and Sample/Detection Assembly is loose or defective.
Fasten Cable Assembly or repair as required (Paragraph 2-26).
2-22
TM 55-1905-223-24-19
Table 2-2. Troubleshooting - CONT
Malfunction
Test or Inspection
Corrective Action
OIL- WATER SEPARATOR, MODEL OPB-10NP/SR02 – CONT
17. WARNING 3 (Red LED) illuminated (Figure 1-4). (cont.).
_________
WARNING
Under no circumstances should repair or adjustment of energized equipment be
attempted alone. The immediate presence of someone capable of rendering aid
is required. Before making adjustments, be sure to protect against grounding. If
possible, adjustments should be made with one hand, with the other hand free
and clear of equipment. Even when power has been removed from equipment
circuits, dangerous potentials may still exist due to retention of charges by
capacitors. Circuits must be grounded and all capacitors discharged prior to
attempting repairs.
STEP 3. Ultrasonic Vibrator Assembly and Generator PCB out of adjustment or defective.
Check for good Ultrasonic Vibrator Signal (Paragraph 2-26). Adjust the vibrator signal as required. If
vibrator cannot be adjusted properly, use new Generator PCB to test.
Replace Generator PCB as required, or check wiring (Paragraph 2-26).
STEP 4. SDA assembly is dirty or defective. Service SDA (Paragraph 2-26).
If any components are damaged replace with calibration kit (Paragraph 3-12).
18. WARNING 2 and WARNING 3 (Red LEDs) illuminated (Figure 1-4).
STEP 1. OCM requires immediate service.
Perform all PMCS.
CAUTION
Do not use unapproved detergents when cleaning, may cause damage to
equipment.
STEP 2. High level of detergent, dirt and/or bubbles in the sample water.
Take sample from OCM drain, and check for dirt, color and suds. Water darker than light tea means the
solids content is too high; suds indicate detergents or air bubbles.
Reduce the amount of solids. Service or repair duplex strainer (Paragraph 2-24).
Check for air leaks in the OWS discharge or Nozzle Sampler piping.
Tighten all pipe joints and valve seals; remove air leaks.
Perform Operational Check and OCM Flush (Paragraph 2-8).
If WARNING 2 and WARNING 3 (Red LED) goes out, sample mixture is the problem. Service OWS tank
(Paragraph 2-14).
STEP 3. Extremely high level of oil in the sample (50% or more).
Take sample from OCM drain, and check for heavy oil content. Check OWS for gross malfunction, or
other source of oil in sample piping.
Service or repair OWS (Paragraph 2-14). Flush all OWS piping prior to discharge overboard, flush all
OCM sample piping (Paragraph 2-8).
Verify lower switch of the dirty oil tank level assembly was replaced with correct Float, Switch, Liquid
(Paragraph 2-15).
2-23
TM 55-1905-223-24-19
Table 2-2. Troubleshooting - CONT
Malfunction
Test or Inspection
Corrective Action
OIL- WATER SEPARATOR, MODEL OPB-10NP/SR02 – CONT
19. Unstable oil content display. PPM values jump high then low.
_________
WARNING
Under no circumstances should repair or adjustment of energized equipment be
attempted alone. The immediate presence of someone capable of rendering aid
is required. Before making adjustments, be sure to protect against grounding. If
possible, adjustments should be made with one hand, with the other hand free
and clear of equipment. Even when power has been removed from equipment
circuits, dangerous potentials may still exist due to retention of charges by
capacitors. Circuits must be grounded and all capacitors discharged prior to
attempting repairs.
STEP 1. Ultrasonic Vibrator Assembly and Generator PCB out of adjustment or defective.
Check for good Ultrasonic Vibrator Signal (Paragraph 2-26). Adjust the Vibrator signal as required. If
Vibrator cannot be adjusted properly, use new Generator PCB to test.
Replace Generator PCB (Paragraph 2-26) as required, or check wiring.
CAUTION
Do not use unapproved detergents when cleaning, may cause damage to
equipment.
STEP 2. High level of detergent, dirt and/or bubbles in the sample water.
Take sample from OCM drain, and check for dirt, water color and suds. Water darker than light tea
means the solids content is too high; suds indicate detergents or air bubbles.
Reduce the amount of solids. Service or repair duplex strainer (Paragraph 2-24).
Check for air leaks in the OWS discharge or Nozzle Sampler piping.
Tighten all pipe joints and valve seals; remove sources of air leaks.
Perform Operational Check and OCM Flush (Paragraph 2-8).
If PPM values return to normal, sample mixture is the problem. Service OWS tank (Paragraph 2-14).
STEP 3. OWS failure, allowing large slugs of oil to be discharged.
Take sample from OCM drain, and check for heavy oil content.
Check OWS for major failure, or other source of oil in sample piping.
Service or repair OWS (Paragraph 2-14). Flush all OWS piping prior to discharge overboard, flush all
OCM sample piping (Paragraph 2-8).
20. Oil sheen in discharged effluent.
NOTE
Although the OCM has a limit of 70 PPM, DOD vessels are not authorized to
operate at this range. In accordance with DOD 4715.6-R1, Regulations On
Vessels Owned Or Operated By The Department Of Defense, the only
acceptable range of operation is 15 PPM.
STEP 1. Alarm limit set to 70 PPM. Check RANGE/ALARM LIMIT indicators; above 15 PPM may result in a
sheen.
Set ALARM LIMIT (PPM) SELECTOR to 15 PPM.
2-24
TM 55-1905-223-24-19
Table 2-2. Troubleshooting - CONT
Malfunction
Test or Inspection
Corrective Action
OIL- WATER SEPARATOR, MODEL OPB-10NP/SR02 – CONT
20. Oil sheen in discharged effluent. (cont).
STEP 2. Verify diverter valve is NOT pinned in the overboard position.
Remove lock pin (45, Figure 2-15, Sheet 1) from diverter valve.
STEP 3. Diverter Valve defective. 115 VAC signal to valve circuit when OCM alarms (after 60 sec delay), but
valve does not divert flow to sludge tank.
Repair or replace Diverter Valve (Paragraph 2-23).
STEP 4. Cable Assembly J3 to Remote Relay Assembly from Sampling/Sensor Assembly connector loose or
defective. Verify cable connections, check continuity as required.
Repair, replace or tighten cable and connectors as required (Paragraph 2-26).
_________
WARNING
Under no circumstances should repair or adjustment of energized equipment be
attempted alone. The immediate presence of someone capable of rendering aid
is required. Before making adjustments, be sure to protect against grounding. If
possible, adjustments should be made with one hand, with the other hand free
and clear of equipment. Even when power has been removed from equipment
circuits, dangerous potentials may still exist due to retention of charges by
capacitors. Circuits must be grounded and all capacitors discharged prior to
attempting repairs.
STEP 5. Perform Verification/Confidence Test (Paragraph 2-26).
Identify the related symptom and perform corrective maintenance action to reduce oil sheen in discharged
effluent.
STEP 6. Remote Relay Assembly defective.
Replace Remote Relay Assembly (Paragraph 2-28).
21. OWS discharge is diverted inboard when OCM detects less than alarm limit.
STEP 1. Verify diverter valve is pinned to the solenoid.
Replace knob pin (8, Figure 2-15 Sheet 1) into the diverter valve.
_________
WARNING
Under no circumstances should repair or adjustment of energized equipment be
attempted alone. The immediate presence of someone capable of rendering aid
is required. Before making adjustments, be sure to protect against grounding. If
possible, adjustments should be made with one hand, with the other hand free
and clear of equipment. Even when power has been removed from equipment
circuits, dangerous potentials may still exist due to retention of charges by
capacitors. Circuits must be grounded and all capacitors discharged prior to
attempting repairs.
STEP 2. Diverter Valve malfunction: stuck in sludge tank position. Verify no 115 VAC signal to Diverter Valve
(there should not be any voltage present).
If 115 VAC signal is present, repair/replace Diverter Valve (Paragraph 2-23).
If 115 VAC signal is not present, perform Verification/Confidence Test (Paragraph 2-26).
2-25
TM 55-1905-223-24-19
Table 2-2. Troubleshooting - CONT
Malfunction
Test or Inspection
Corrective Action
OIL- WATER SEPARATOR, MODEL OPB-10NP/SR02 – CONT
21. OWS discharge is diverted inboard when OCM detects less than alarm limit. (cont).
_________
WARNING
Always ensure affected circuits have been secured, locked out and tagged out.
Performing maintenance with circuits energized may result in death or injury to
personnel or equipment damage.
STEP 3. Cable Assembly J3 to Remote Relay Assembly from Sampling/Sensor Assembly (Figure 1-6)
connector loose or defective. Verify cable connections, check continuity as required.
Repair, replace or tighten cable and connectors as required (Paragraph 2-26).
STEP 4. Remote Relay Assembly defective.
Replace Remote Relay Assembly (Paragraph 2-28).
_________
WARNING
Under no circumstances should repair or adjustment of energized equipment be
attempted alone. The immediate presence of someone capable of rendering aid
is required. Before making adjustments, be sure to protect against grounding. If
possible, adjustments should be made with one hand, with the other hand free
and clear of equipment. Even when power has been removed from equipment
circuits, dangerous potentials may still exist due to retention of charges by
capacitors. Circuits must be grounded and all capacitors discharged prior to
attempting repairs.
STEP 5. Power PCB Assembly defective. Verify alarm jumpers are in first "B" and second "A" position
(Figure 2-18, Sheet 2), verify no voltage across terminals 2 and 4, 2 and 6, and 2 and 7 when in
ALARM.
Replace Power PCB Assembly or correct wiring as required (Paragraph 2-26).
22. Indicators and displays inoperative while OCM is operating.
_________
WARNING
Always ensure affected circuits have been secured, locked out and tagged out.
Performing maintenance with circuits energized may result in death or injury to
personnel or equipment damage.
STEP 1. Cable Assembly J2 connectors to Remote Indicator (Alarm) Assembly from Sampling/Sensor
Assembly (Figure 1-6) connector loose or defective. Verify cable connections, check continuity as
required.
Repair, replace or tighten cable and connectors as required (Paragraph 2-26).
2-26
TM 55-1905-223-24-19
Table 2-2. Troubleshooting - CONT
Malfunction
Test or Inspection
Corrective Action
OIL- WATER SEPARATOR, MODEL OPB-10NP/SR02 – CONT
22. Indicators and displays inoperative while OCM is operating. (cont).
_________
WARNING
Under no circumstances should repair or adjustment of energized equipment be
attempted alone. The immediate presence of someone capable of rendering aid
is required. Before making adjustments, be sure to protect against grounding. If
possible, adjustments should be made with one hand, with the other hand free
and clear of equipment. Even when power has been removed from equipment
circuits, dangerous potentials may still exist due to retention of charges by
capacitors. Circuits must be grounded and all capacitors discharged prior to
attempting repairs.
STEP 2. Alarm PCB defective or incorrectly wired. Verify 115 VAC across terminals 2 and 3 on Alarm PCB,
verify wiring (Figure 2-18, Sheet 3, FO-1, Sheet 1 and FO-2, Sheet 1.)
If 115 VAC across terminals 2 and 3, replace Alarm PCB correct wires as required (Paragraph 2-27).
STEP 3. Cable Assembly defective. Verify 115 VAC across 2 and 4 on Power PCB, verify wiring (Figure 218, Sheet 3). Check continuity of Cable Assembly as required.
If 115 VAC across 2 and 4 on Power PCB but not on Alarm PCB, repair/replace cable assembly(s)
(Paragraph 2-26 and Paragraph 2-27).
STEP 4. Power PCB Assembly not properly connected or defective. Verify Power PCB wiring (Figure 2-18,
Sheet 3), 115 VAC across terminals 1 and 2, and 2 and 4.
If 115 VAC across 1 and 2 but not 2 and 4, replace Power PCB (Paragraph 2-26).
STEP 5. Processor PCB is defective. Inspect for damaged, charred or burnt components.
Replace defective Processor PCB with Calibration Kit (Paragraph 3-12).
_________
WARNING
Always ensure affected circuits have been secured, locked out and tagged out.
Performing maintenance with circuits energized may result in death or injury to
personnel or equipment damage.
23. PUSH TO CHANGE ALARM LIMIT (PPM) pushbutton switch (A2S1) (Figure 1-2) on Remote Indicator (Alarm)
Assembly does not change Alarm Limit of OCM.
STEP 1. Alarm Limit Selector Switch (A1S2) in the Sampling/Sensor Assembly not in the REMOTE position.
Put selector switch (A1S2) in REMOTE Position (Figure 2-18, Sheet 1).
STEP 2. Switch (A2S1) Defective. Check Switch (A2S1) and wiring for defects.
Repair/replace Cable Assembly or Alarm PCB as required (Paragraph 2-26).
STEP 3. Cable Assembly defective. Check Switch (A1S2) and wiring for defects.
Repair/replace Cable Assembly (Paragraph 2-26).
2-27
TM 55-1905-223-24-19
Table 2-2. Troubleshooting - CONT
Malfunction
Test or Inspection
Corrective Action
OIL- WATER SEPARATOR, MODEL OPB-10NP/SR02 – CONT
24. Audible Alarm inoperative when OCM is in Alarm mode on Remote Indicator (Alarm) Assembly.
_________
WARNING
Always ensure affected circuits have been secured, locked out and tagged out.
Performing maintenance with circuits energized may result in death or injury to
personnel or equipment damage.
STEP 1. Audible Alarm is silenced. Press the PUSH TO SILENCE pushbutton switch (A2S2) several times;
the ALARM SILENCED indicator will alternately illuminate.
Press the PUSH TO SILENCE pushbutton switch (A2S2) to reactivate.
_________
WARNING
Under no circumstances should repair or adjustment of energized equipment be
attempted alone. The immediate presence of someone capable of rendering aid
is required. Before making adjustments, be sure to protect against grounding. If
possible, adjustments should be made with one hand, with the other hand free
and clear of equipment. Even when power has been removed from equipment
circuits, dangerous potentials may still exist due to retention of charges by
capacitors. Circuits must be grounded and all capacitors discharged prior to
attempting repairs.
STEP 2. Alarm Buzzer is defective. Verify that the OIL CONTENT EXCEEDS ALARM LIMIT indicator (Red
LED) is illuminated, the ALARM SILENCED indicator is not lit, but switch A2S2 works. Check for
115 VAC to the Buzzer.
Replace Buzzer (Paragraph 2-27).
STEP 3. Cable Assembly defective. Verify 115 VAC across 2 and 3 on Power PCB (11, Figure 2-18,
Sheet 1), verify wiring is correct. Check continuity of Cable Assembly as required.
If 115 VAC across 2 and 3 on Power PCB but not across 1 and 2 on Alarm PCB, repair/replace cable
assembly(s) (Paragraph 2-26 and Paragraph 2-27).
STEP 4. Power PCB Assembly defective. Verify alarm jumpers are in first "B" and second "A" position
(Figure 2-18, Sheet 2). Verify wiring and check for 115 VAC across terminals 2 and 5 when in
alarm.
Replace Power PCB if 115 VAC across 2 and 5 (Paragraph 2-26) is not detected.
25. PUSH TO SILENCE switch (A2S2) does not function properly when OCM is in alarm mode.
STEP 1. Defective wiring or switch (part of item P/N ST5001).
Press the PUSH TO SILENCE switch (A2S2) several times; the ALARM SILENCED indicator will
alternately light.
Repair wiring, replace switch, or Alarm PCB as required (Paragraph 2-27).
26. Dirty Oil Pump output falls below 11 GPM.
STEP 1. Verify bilge water is below bilge suction foot valve (Paragraph 2-9).
If bilge water is above bilge suction at foot valve perform Dirty Oil Pump adjustment (Paragraph 2-18).
2-28
TM 55-1905-223-24-19
SECTION V. UNIT MAINTENANCE PROCEDURES
2-12. General. This section provides unit maintenance for the oil-water separator system, oil content monitor,
and water polisher. The tasks are for testing, alignment, inspection, service, adjustment, repair, removal and
replacement of subassembly components. These tasks are addressed in the following Paragraphs.
2-29
TM 55-1905-223-24-19
MAINTENANCE OF OIL-WATER SEPARATOR
2-13. The unit level replacement and repair tasks of the Oil-Water Separator are accomplished through
maintenance procedures in paragraphs 2-14 thru 2-31 of this chapter. Inspections, checks, services, and
adjustments are covered in PMCS, Table 2-1 and TM55-1905-223-10.
2-14.
OWS Tank. (Figure 2-1)
This task covers:
a. Inspect,
b. Service,
c. Repair.
INITIAL SETUP
Tools
Equipment Condition
Tool Kit, General Mechanic's,
5180-00-699-5273
Hoist, Chain, Hand-Operated, Hook Chain Fall 1/2 ton,
3950-00-235-4236
Torque Wrench (30 - 300 inch pounds),
5120-01-092-3278
Torque Wrench (30 - 300 foot pounds),
5120-01-125-5190
Lifting Sling,
3940-01-183-9412
TM 55-1905-223-10, Oil-Water Separator Secured,
Locked Out and Tagged (FM 55-502).
Materials/Parts
Cleaning Compound, Solvent, Item 1, Appendix C
Epoxy, Polyamide, Item 3, Appendix C
Rags, Wiping, Item 12, Appendix C
Warning Tags, Item 19, Appendix C
INSPECT
Inspection of the Oil-Water Separator Tank is accomplished through Preventive Maintenance Checks and
Services (PMCS, TM 55-1905-223-10) and (PMCS), Table 2-1 and maintenance procedures.
SERVICE
a. Perform Paragraph 3-11, Oil-Water Separator Tank removal steps a and b before cleaning coalescing
plates and removing zinc anodes.
________
WARNING
Always ensure affected circuits have been secured, locked out and tagged out.
Performing maintenance with circuits energized may result in death or injury to
personnel or equipment damage.
(1)
Loosen 20 swing bolts (2, Figure 2-1) and swing away from top cover (3).
CAUTION
Take care not to damage tank cover gasket (3).
(2)
2-30
Remove top cover (3) by lifting straight up and off using 1/2 ton chainfall and lifting sling.
TM 55-1905-223-24-19
(3)
Remove vertical plate assembly (6) and gasket (7).
(4)
Remove flow blocks (10) located between tank wall and horizontal plate (PORT) assembly (9).
NOTE
When removing horizontal plate assemblies (6, 7) identify position of installation
and remove by lifting on stainless steel plate clamp wrapping the plate
assemblies.
(5)
Remove horizontal plate (PORT) assembly (9) and horizontal plate (STBD) assembly (8).
(6)
Lay horizontal plate assemblies (8, 9) and vertical plate assemblies (6) on their side and spray with
freshwater. Ensure all sediment is removed from between the plates.
CAUTION
When cleaning tank, do not use sharp objects that may damage tank’s internal
coating.
(7)
Spray interior of tank to ensure all sediment is removed. If damage is discovered during tank
cleaning, conduct tank repairs prior to installation of plate assemblies.
(8)
Inspect top cover gasket (5) for damage. Replace if required.
(9)
Inspect vertical plate gasket (7) for damage. Replace if required.
(10) Inspect interior of tank and cover for damage to finish.
(11) Inspect zinc anodes (11). Replace if length is 3 inches or shorter.
(12) Install horizontal plate (PORT) assembly (9) and horizontal plate (STBD) assembly (8).
(13) Install flow blocks (10) between tank wall and horizontal plate (PORT) assembly (9).
(14) Install vertical plate gasket (7) and vertical plate assembly (6).
(15) Ensure top cover gasket (5) is installed correctly and not damaged.
(16) Install top cover (3) on tank. Torque all swing bolts (2) lightly once; then torque bolts in
accordance with torque table in Appendix D.
(17) Operate the OWS (Paragraphs 2-6 through 2-8) and check for proper operation.
REPAIR
a. Repair of the OWS tank consists of:
(1)
Replacing the zinc anodes (11).
(2)
Replacing the vertical plate gasket (7).
(3)
Touching up the polyamide epoxy coating in the tank.
2-31
TM 55-1905-223-24-19
LEGEND:
1. OIL/AIR INTERFACE SENSOR
2. TOP COVER SWING BOLTS
3. TOP COVER
4. OIL/WATER INTERFACE SENSOR
5. TOP COVER GASKET
6. VERTICAL PLATE ASSEMBLY
7. VERTICAL PLATE GASKET
8. HORIZONTAL PLATE (STBD)
9. HORIZONTAL PLATE (PORT)
10. FLOW BLOCK
11. ZINC ANODE
12. CAP SCREW
13. LOCKWASHER
14. SELF LOCKING NUT
Figure 2-1. Oil-Water Separator.
2-32
TM 55-1905-223-24-19
2-15.
Oil Level Sensors. (Figures 2-1, 2-2 and 2-3)
This task covers:
a. Service,
b. Removal,
c. Repair,
d. Replacement.
INITIAL SETUP
Tools
Equipment Condition
Tool Kit, General Mechanic's,
5180-00-699-5273
Tool Kit, Electrician’s,
5180-00-391-1087
Multimeter,
6625-01-265-6000
TM 55-1905-223-10, Oil-Water Separator Secured,
Locked Out and Tagged (FM 55-502).
Materials/Parts
Sensing Rod 8.94”, P/N 6059949P2
Sensing Rod 10”, P/N 6059949P3
Sensing Rod 15”, P/N 6059949P1
Lockwasher 5/8", P/N 6057182
Lockwasher, P/N 10926
Nut, Self locking, 1/2 x 13, P/N M45913/1-8CG5C
Float Assembly Kit, P/N 10654
Cleaning Solvent, Item 1, Appendix C
Rags, Wiping, Item 12, Appendix C
Warning Tags, Item 19, Appendix C
NOTE
Three oil level sensors are located in the oil-water separator system: two in the
OWS tank, and one inside the sludge tank. For purposes of maintenance, all
three are included here. The two oil interface sensors (Oil/Air and Oil/Water) are
identical. The oil/water sensor has two electrodes and the oil/air sensor uses
three electrodes.
SERVICE
Servicing involves cleaning rods and floats. Refer to removal section.
REMOVAL
_________
WARNING
Always ensure affected circuits have been secured, locked out and tagged out.
Performing maintenance with circuits energized may result in death or injury to
personnel or equipment damage.
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 or
injury to personnel or damage to equipment. In accordance with TB 43-0218,
ensure that all locking hardware is discarded upon removal and replaced with
new hardware.
2-33
TM 55-1905-223-24-19
1. OWS Level Sensors (Oil/Air and Oil/Water) (1 and 4, Figure 2-1):
a. Remove cover (2, Figure 2-2) by removing screws (1); label and disconnect wires from electrode
holder (6).
b. Remove and inspect cover gasket (3) for cracks and tears.
c.
Remove sensor flange self locking nuts (14, Figure 2-1) and hardware, discard self locking nuts and retain
other hardware for installation.
d. Raise sensor and flange gasket (8, Figure 2-2) upward until probe is clear of tank. Inspect gasket (8) for
cracks and tears.
e. Clean and inspect probe for chips, cracks or pitting. If chips, cracks or pitting are identified on the probe
then a new probe will be required before installation.
f.
Clean any dirt and sludge from center hole of mounting flange.
g. Clean flange gasket mating surfaces.
h. Install sensor using replacement procedure.
2. Sludge Tank Level Sensor (Figure 2-2 and Figure 2-3):
a. Label and disconnect wires inside the OWS junction box (Figure 2-3).
b. Remove stuffing tube (2) retaining nut and stuffing tube packing (1).
c.
Remove wires from OWS junction box stuffing tube (2).
d. Remove eight nuts (15) and washers (16) from flange (17). Retain nuts (15) and washers (16) for
replacement.
e. Raise level switch assembly flange (17) and gasket (13) upward until level switch assembly is clear of the
sludge tank. Inspect gasket (13) for cracks and tears.
f.
Remove fasteners connecting mounting bracket (19, Figure 2-2) to mounting plate (11, Figure 2-3).
Retain for installation. Remove level sensor to suitable work location.
g. Unscrew nut (12, Figure 2-2) from bottom of stuffing tube assembly (11).
h. Remove lockwasher (13), shield cap (14) and two magnets (15). Discard lockwasher (13).
i.
Remove float (16), bushing (17) and shield (18). Unscrew stuffing tube assembly (11) from mounting
bracket (19).
j.
Clean and inspect float (16), bushing (17) and shield (18). Replace if damage is identified.
k.
Test and install level sensor using replacement procedure.
REPAIR
1. OWS Level Sensors:
a. Replace defective rod(s) (9, 10 and 20, Figure 2-2) and electrode holders (6) when deterioration is
noticed.
b. Check flange gasket (8) and replace as required.
2-34
TM 55-1905-223-24-19
2. Repair of the Sludge Tank Level Sensor is by replacement of:
a. The sludge tank level sensor assembly.
b. The shield cap (18).
REPLACEMENT
1. OWS Level Sensors (Oil/Air and Oil/Water) (1 and 4, Figure 2-1):
a. Place flange gasket (8, Figure 2-2) on flange mating surface.
b. Insert sensor assembly into tank.
c.
Attach sensor to flange using flange bolts and hardware retained from removal and new self locking nut
(14, Figure 2-1).
d. Torque flange bolts (using a cross method tightening and torque wrench) to specification found in
Appendix D.
e. Connect wires to electrode holders (6, Figure 2-2) as labeled during removal.
f.
Install cover gasket (3) and cover (2) by installing screws (1) retained from removal.
g. Operate the OWS (Paragraphs 2-6 through 2-8) and check for proper operation.
2. Sludge Tank Level Sensor (Figures 2-2 and 2-3):
a. Screw stuffing tube assembly (11, Figure 2-2) into mounting bracket (19).
NOTE
The Sludge Tank utilizes the same Switch Liquid Level, W/10’ Cable for both the
Upper and lower tank Level Switches. However, the lower Tank Level Switch
Requires replacement of the Float, Switch, Liquid Level Kit -with P/N 166053.
b. Install bushing (17) and float (upper or lower) (16) on lower portion of stuffing tube assembly (11).
CAUTION
Do not overtighten nut (12) or damage to shield (18) may occur.
c.
Install shield cap (14) with two magnets (15), new lockwasher (13) and nut (12) retained from removal
(Figure 2-2).
NOTE
The Sludge Tank utilizes the same Switch Liquid Level, W/10’ Cable for both the
Upper and lower tank Level Switches. However, the lower Tank Level Switch
Requires replacement of the Float, Switch, Liquid Level Kit -with P/N 166053.
d. Check operation of float (upper or lower) (16) and stuffing tube assembly (11) by connecting a
multimeter to the stuffing tube electrical leads (Figure 2-2).
e. Checking the float (upper switch) (16) proceed as follows:
(1)
With the float (upper switch) (16) resting on the shield cap (14), the multimeter should indicate open
circuit.
2-35
TM 55-1905-223-24-19
(2)
f.
Raise float (upper switch) (16) up off of the shield cap (14) to actuate stuffing tube assembly switch
and the multimeter should indicate closed circuit. Replace components as required if test is
unsatisfactory.
Checking the float (upper switch) (16) proceed as follows:
(1)
With the float (lower switch) (16) resting on the shield cap (14), the multimeter should indicate
closed circuit.
(2)
Raise float (lower switch) (16) up off of the shield cap (14) to actuate stuffing tube assembly switch
and the multimeter should indicate open circuit. Replace components as required if test is
unsatisfactory.
g. Attach float mounting bracket (19, Figure 2-2) to mounting plate (11, Figure 2-3) using mounting hardware
retained from removal.
h. Place flange gasket (13) on flange mating surface (Figure 2-3).
i.
Lower level switch assembly flange (17) into sludge tank on flange gasket (13, Figure 2-3).
j.
Install eight washers (16) and nuts (15) onto flange (17, Figure 2-3). Torque flange bolts (using a cross
method tightening and torque wrench) to specification found in Appendix D.
k.
Thread wires through OWS junction box stuffing tube packing (1), stuffing tube (2) and tighten stuffing
tube assembly (Figure 2-3).
l.
Connect wires from ship cable in OWS junction box as labeled during removal (Figure 2-3).
m. Operate the OWS (Paragraphs 2-6 through 2-8) and check for proper operation.
2-36
TM 55-1905-223-24-19
LEGEND:
1. SCREW
2. COVER
3. GASKET
4. JUNCTION BOX
5. GASKET
6. ELECTRODE HOLDER
7. FLANGE
8. FLANGE GASKET
9. SENSING ROD 15”
10. SENSING ROD 8.94”
11. STUFFING TUBE
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
NUT
LOCKWASHER
SHIELD CAP
MAGNET (2)
FLOAT
BUSHING
SHIELD CAP
MOUNTING BRACKET
SENSING ROD 10”
SCREW
Figure 2-2. Oil Level Sensors.
2-37
TM 55-1905-223-24-19
LEGEND:
1. STUFFING TUBE, PACKING
2. STUFFING TUBE (Y)
3. LATERAL (Y)
4. ADAPTER
5. STUFFING TUBE
6. LEVEL SWITCH
7. TUBE
8. FLOAT, LEVEL SWITCH
9. CAP
10. U-BOLT
11. PLATE
12. NUT, HEX HEAD
13. GASKET
14. STUD
15.
16.
17.
18.
19.
NUT
WASHER
FLANGE
ELBOW
ADAPTER
Figure 2-3. Sludge Tank Level Switch Arrangement.
2-38
TM 55-1905-223-24-19
2-16.
OWS Pump. (Figure 2-4 and 2-5)
This task covers:
a. Inspect,
b. Removal,
c. Repair,
d. Replacement.
INITIAL SETUP
Tools
Equipment Condition
Tool Kit, General Mechanic's,
5180-00-699-5273
Tool Set, Measuring, Machinist’s
5280-00-278-9919
Puller, Mechanical, Gear and Bearing,
5120-00-288-7710
TM 55-1905-223-10, Oil-Water Separator Secured,
Locked Out and Tagged (FM 55-502).
Materials/Parts
Oil-Water Separator Pump, P/N 777-9003
Pump Service Kit, P/N 90118-0003
Cleaning Solvent, Item 1, Appendix C
Gasket Material, Item 4, Appendix C
Grease, Item 5, Appendix C
Lubricating Sealant, Item 9, Appendix C
Rags, Wiping, Item 12, Appendix C
Warning Tags, Item 19, Appendix C
INSPECT
Inspection of the Oil-Water Separator Pump is accomplished through Preventive Maintenance Checks and
Services (PMCS, TM 55-1905-223-10).
REMOVAL
_________
WARNING
Always ensure affected circuits have been secured, locked out and tagged out.
Performing maintenance with circuits energized may result in death or injury to
personnel or equipment damage.
a. Remove coupling guard (2) to expose coupling (3) for disassembly (Figure 2-4).
b. If pump is to be replaced or moved to a different work location, remove the pump mounting hardware and
piping flange connections. Retain hardware for installation. Inspect gasket for cracks or tears and retain
hardware for installation. If pump is not required to be moved proceed to step d.
c.
Utilizing a bearing puller, remove pump coupling hub (6, Figure 2-5).
d. Remove end cover screws (14), end cover (13) and gasket (12).
e. Grasp hub of impeller (11) with water pump pliers and withdraw from body (10).
f.
Remove screw (9) and cam (17); clean sealant from cam (17) and body (10) bore.
g. Remove wearplate (16).
h. Remove bearing to body retaining ring (5).
i.
Press on impeller drive end of shaft (1) to remove shaft (1) and bearing (4) assembly.
2-39
TM 55-1905-223-24-19
j.
Remove ceramic seal seat and seat gasket from shaft. Press carbon seal seat out of body towards
impeller bore.
k.
Remove bearing shaft retaining ring (2).
l.
Support bearing inner race, press on drive end of shaft to remove shaft from bearing. Do not attempt to
remove bronze bushing which is pinned to shaft.
REPAIR
Inspect all parts from removal procedure for wear or damage and replace as necessary.
REPLACEMENT
a. If pump was moved from foundation for replacement proceed to step n, otherwise proceed to step b.
b. Press shaft (1) into bearing (4), using care to support inner race of bearing.
c.
Install bearing to shaft retaining ring (2) with flat side toward bearing.
d. Insert splined end of shaft (1) through bearing bore until bearing (4) contacts body (10).
e. Lubricate rubber grommet in ceramic seal seat with water and install on shaft, grommet toward bearing.
Install seal (carbon toward ceramic seat) in seal bore and press flush with bottom of impeller bore.
f.
Pressing on bearing outer race, install bearing into bore.
g. Install bearing to body retaining ring (5) in body (10) groove with flat side toward bearing.
h. Install wearplate (16) in body (10) bore, aligning slot in wearplate (16) with dowel pin in body (10).
i.
Apply a thin coat of sealant to cam screw (9) threads and top side of cam (17) and install in body (10)
with cam screw (9).
j.
Lubricate impeller bore and end surfaces of impeller (11) with light coat of water pump grease and start
impeller into bore with a rotary motion until splines engage, then push into bore.
k.
Install gasket (12) and end cover (13) and secure with end cover screws (14).
l.
Align keyways of coupling hub (6) and pump shaft (1) with shaft key (3) and press coupling hub onto shaft
ensuring key stays centered and flush.
m. Insert hub setscrew (7) and tighten. If pump was removed from foundation proceed to step n, otherwise
proceed to step q.
n. Install pump on mounting foundation, shim pump feet as required to ensure there is no distortion to pump
casing.
o. Attach piping flange connection using hardware retained from removal. If gasket damage was identified
on removal, install new gasket.
p. Fasten pump mounting hardware retained from removal.
q. Perform coupling alignment (Paragraph 2-17).
r.
2-40
Operate the OWS (Paragraphs 2-6 through 2-8) and check for proper operation.
TM 55-1905-223-24-19
LEGEND:
1. OWS PUMP MOTOR
2. COUPLING GUARD
3. COUPLING
4. OWS PUMP
Figure 2-4. OWS Pump And Motor Assembly.
2-41
TM 55-1905-223-24-19
LEGEND:
1. SHAFT
2. RETAINING RING (BEARING TO SHAFT)
3. KEY
4. BEARING
5. RETAINING RING (BEARING TO BODY)
6. COUPLING HUB
7. SETSCREW, HUB
8. COUPLING INSERT
9. SCREW (HUB)
10.
11.
12.
13.
14.
15.
16.
17.
BODY
IMPELLER
GASKET
END COVER
SCREW
SEAL
WEARPLATE
CAM
Figure 2-5. OWS Pump.
2-42
TM 55-1905-223-24-19
2-17.
OWS Pump Motor. (Figure 2-4, 2-6 and 2-7)
This task covers:
a. Align,
b. Removal,
c. Repair,
d. Replacement.
INITIAL SETUP
Tools
Equipment Condition
Tool Kit, General Mechanic's,
5180-00-699-5273
Dial Indicator,
5210-00-277-8840
Tool Set, Measuring, Machinist’s,
5280-00-278-9919
TM 55-1905-223-10, Oil-Water Separator Secured,
Locked Out and Tagged (FM 55-502).
Materials/Parts
Cleaning Solvent, Item 1, Appendix C
Grease, Item 5, Appendix C
Rags, Wiping, Item 12, Appendix C
Shim, Item 14, Appendix C
Straight Edge, Item 17, Appendix C
Warning Tags, Item 19, Appendix C
ALIGN
Perform coupling alignment as follows:
CAUTION
Align the motor to the pump or distortion to piping connections or pump casing
may occur.
NOTE
Maximum allowable parallel misalignment is 0.015 inch and maximum angular
misalignment is 0.018 inch.
a. With coupling hubs and star insert installed, ensure motor coupling hub is pushed flush with pump
coupling hub.
b. Align shafts so that a straight edge will rest squarely on both coupling hubs.
c.
Using a feeler gauge, insert the appropriate gauge between the insert and hub at 4 different points, 90
degrees apart to ensure angular alignment. Adjust position of the motor accordingly to achieve equal
clearances at all 4 points.
d. Attach the dial indicator as illustrated in Figure 2-6 on the pump end coupling hub ensuring anvil (stem) on
dial indicator is compressed halfway into indicator to check for parallel alignment.
e. Zero in the dial indicator.
f.
Rotate pump shaft to 180 degrees from top and check dial indicator reading at the bottom.
2-43
TM 55-1905-223-24-19
NOTE
Always make adjustments half of the reading as it will affect the dial reading at
the 0 degree position.
(1) Example: If reading is positive, motor is lower than pump, add shims between
all four motor foundation bolts in between the feet and base foundation to raise
the motor to a +0.010.
(2) Example: If reading is negative then motor is higher than the pump. Tighten
down motor foundation bolts to achieve a reading of -0.010.
g. Recheck dial reading at the 0 degree position after each adjustment.
REMOVAL
_________
WARNING
Always ensure affected circuits have been secured, locked out and tagged out.
Performing maintenance with circuits energized may result in death or injury to
personnel or equipment damage.
a. Remove coupling guard (2) to expose coupling (3) for disassembly (Figure 2-4).
b. Remove motor foundation bolts and slide motor (1) back to separate coupling halves (3). Retain
hardware for installation.
c.
Remove conduit box cover (13, Figure 2-7) removing screws (12).
d. Label and disconnect wires in conduit box to ensure proper motor rotation after installation. (Proper motor
rotation is counterclockwise facing shaft end.)
e. Remove coupling hub (17), machine key (16) and flexible coupling insert (18) from motor shaft with
bearing puller.
f.
If motor is to be replaced proceed to replacement procedure for installation of new motor; if bearing
replacement is to be completed proceed to repair procedure.
REPAIR (Figure 2-7)
Repair of the OWS pump motor is by replacement of the following items (Figure 2-7); Fan impeller (4), Rotor
assembly (8), Spring washer (9), Bearing (10), Bearing (11), Machine key (16) and Flexible coupling insert (18).
NOTE
If other maintenance is required to repair the motor, then motor replacement is
required.
To repair the OWS pump motor perform the following steps;
a. Perform removal procedure.
b. Remove three screws (2) securing fan housing (3). Remove fan housing.
2-44
TM 55-1905-223-24-19
c.
Remove mounting hardware and fan impeller(4). Retain hardware for installation.
d. Remove four bolts (6) and nuts (15).
e. Remove end bell (5 and 14).
f.
Remove spring washer (9) from motor shaft.
g. Remove bearings (10 and 11) from motor shaft.
h. Visually inspect all removed components for wear, damage and corrosion.
i.
Install bearings (10 and 11).
j.
Install spring washer (9) onto motor shaft.
k.
Install rotor assembly (8) into the stator assembly (7).
l.
Replace end bells (5 and 14) onto the stator assembly (7).
m. Insert the four t bolts (6); securing with the four hex nuts (15).
n. Install the fan impeller (4) with removed hardware.
o. Replace fan housing (3); securing with three screws (2).
p. Proceed to replacement procedure.
REPLACEMENT
a. Insert machine key (16) into slot on motor shaft.
b. Install coupling hub (17) onto shaft and align with machine key (16).
c.
Install flexible coupling insert (18) and coupling hub (19) onto coupling hub (17) and shaft.
d. Place motor on foundation aligning coupling hubs (17 and 19) of both motor and pump.
e. Align motor feet bolt holes over bolt holes in foundation and insert mounting bolts with nuts. Do not
tighten mounting hardware; allow sufficient play for insertion of shims for coupling alignment.
f.
Perform coupling alignment before proceeding to step g.
g. Install coupling guard (2, Figure 2-4).
h. Connect wires in conduit box as labeled on removal to ensure proper motor rotation. (Proper motor
rotation is counterclockwise facing shaft end.) If motor rotation is not counterclockwise reverse any two
incoming power leads.
i.
Install conduit box cover (13, Figure 2-7) with screws (12).
j.
Operate the OWS (Paragraphs 2-6 through 2-8) and check for proper operation.
2-45
TM 55-1905-223-24-19
Figure 2-6. Coupling Alignment.
2-46
TM 55-1905-223-24-19
LEGEND:
1. OWS PUMP MOTOR
2. SCREW
3. FAN HOUSING
4. FAN IMPELLER
5. END BELL
6. BOLT
7. STATOR ASSEMBLY
8. ROTOR ASSEMBLY
9. SPRING WASHER
10. BEARING
11. BEARING
12. SCREW
13. CONDUIT BOX COVER
14. END BELL
15.
16.
17.
18.
19.
NUT
MACHINE KEY
COUPLING HUB
FLEXIBLE COUPLING INSERT
COUPLING HUB
Figure 2-7. OWS Pump Motor.
2-47
TM 55-1905-223-24-19
2-18.
Dirty Oil Pump. (Figures 2-8 , 2-9 and 2-11)
This task covers:
a. Inspect,
b. Adjust,
c. Removal,
d. Repair,
e. Replacement.
INITIAL SETUP
Tools
Equipment Condition
Tool Kit, General Mechanic's,
5180-00-699-5273
TM 55-1905-223-10, Oil-Water Separator Secured,
Locked Out and Tagged (FM 55-502).
Materials/Parts
Dirty Oil Pump, P/N H-125 C.I.
Bearing, P/N 5847
Seal, Rotating, P/N 5579A
Plate, Wear, P/N 5405F
Shoe, P/N 5561PB
Cleaning Solvent, Item 1, Appendix C
Grease, Item 5, Appendix C
Oil, Item 10, Appendix C
Warning Tags, Item 19, Appendix C
INSPECT
Inspection of the Dirty Oil Pump is accomplished through Preventive Maintenance Checks and Services (PMCS,
TM 55-1905-223-10).
ADJUST
Adjustment involves removing one of the two front cover gaskets (24, Figure 2-9) from between the wear plate
(22) and front cover (25) when output capacity is below 11 gpm.
REMOVAL
_________
WARNING
Always ensure affected circuits have been secured, locked out and tagged out.
Performing maintenance with circuits energized may result in death or injury to
personnel or equipment damage.
a. Remove coupling guard (3) from base (5, Figure 2-8).
b. Close the nearest inlet and outlet valves.
c.
Drain pump by means of drain plug (27, Figure 2-9) in the front cover (25).
d. Disconnect the inlet and outlet piping connections.
e. Remove eight body nuts (4) from front cover (25).
f.
2-48
Remove front cover (25).
TM 55-1905-223-24-19
g. Remove three port plate screws (28) from the front cover (25).
NOTE
Mark location of sliding shoes (20) within pump unit. If the shoes are to be
reinstalled, ensure the orientation of the shoes are the same as when removed.
When installing new shoes, ensure the orientation of the original marked shoes
are the same.
h. Separate pump wear plate (22) from front cover (25). Mark the position of the shoes (20).
i.
Grasp shoe (20) and remove from rotor (18) by pulling straight out. Remove all three shoes (20).
j.
Mark coupling flanges (2, Figure 2-8) in a manner that they may be returned to their respective shafts
when reassembling. Remove the four pump mounting bolts and slide pump (4) away from motor (1).
k.
Loosen two set screws from coupling flange (20, Figure 2-11), and remove with machine key (22).
l.
Remove bearing cover screws (16, Figure 2-9) from drive end bearing cover (2) and outer end bearing
cover (15).
m. Remove end covers (2) and (15).
CAUTION
Do not rotate bearing locking collar more than one-quarter turn to prevent collar
from locking in opposite direction.
NOTE
A pin punch may be used to loosen tight collars.
n. Loosen set screws in bearing locking collars (part of 3) and remove collars by rotating in direction of pump
shaft rotation. (Proper motor rotation is counterclockwise facing shaft end.)
o. File down any burrs on the shaft left by set screws, using a finishing file.
p. Remove body nuts (4) from bearing housing (13).
CAUTION
Remove bearing housings (13) straight away from the pump body (32) to prevent
damage to working faces of the shaft seals (5).
q. Tighten forcing screws (14) intermittently.
r.
Remove one bearing housing (13) with bearing (3) still intact.
CAUTION
Replace the seals (5) if they are removed for a maintenance action.
NOTE
A little oil or grease on the shaft makes the stationary shaft seal (part of 5) slide
off more easily.
s.
Remove rotating seal (part of 5) from shaft.
t.
Remove rotor (18), from removed bearing housing (13) end.
2-49
TM 55-1905-223-24-19
u. Remove rotating seal (part of 5) from shaft.
v.
Remove opposite bearing housing (13) as described in step p.
w. Remove stationary seal (part of 5) from bearing housings.
x.
Remove bearing (3) from bearing housing (11).
y.
Remove blank flange nut (12) from the blank flange stud (9).
z.
Remove the blank flange (11) and blank flange gasket (10).
REPAIR
a. Repair to the dirty oil pump consists of replacing the following components as described in the
replacement procedures: drive end bearing cover (2) and outer end bearing cover (15), bearings (3),
shaft seals (5), bearing housing gaskets (7), blank flange gasket (10), rotor (18), shoes (20), pump wear
plate (22), port plate gasket (23), front cover gasket (24), drain plug (27) and port plate screw (28).
b. Any further repair to the dirty oil pump (1) requires the replacement of the dirty oil pump unit (1).
REPLACEMENT
CAUTION
When handling the seals, take extreme care not to damage or soil the mating
surfaces of the face ring and seat, or to get oil or other liquid on them. Avoid skin
contact on mating surfaces.
a. Before mounting rotating seal (part of 5) on rotor (18), lightly coat end of rotor with oil, which will allow
shaft seals to slide easily into the correct position when all parts are reassembled.
b. Mount seals (5) on rotor (18) in extended position and not compressed. Insert stationary seal (part of 5) in
recesses on bearing housings (13). A light oil coating on outside of seal seats (part of 5), taking care not
to soil seat, will facilitate installation in bearing housing recess.
c.
Mount bearing housing (13) on pump body, (opposite drive end), replacing all torn or damaged gaskets.
CAUTION
Maintain rotor in as much a horizontal position as possible to avoid stressing seal
face in bearing housing. Insert rotor end through seal face with constant
pressure.
d. Through open end of pump body, insert rotor through body into bearing housing already mounted on
pump.
e. Mount opposite bearing housing to body.
f.
Mount bearings (3) in bearing housings (13), using caution not to damage bearing races or pump body.
To facilitate bearing mounting, a small amount of grease should be used on race and bearing housing.
g. Outer end bearing locking collar (part of 3) should be flush with shoulder on rotor shaft. This locates the
shaft axially. Tighten locking collar in direction opposite shaft rotation. To make collar flush with rotor
shaft shoulder, tap rotor shaft with mallet hammer. Tighten set screw.
h. Mount other bearing locking collar.
i.
2-50
Replace both end covers (2) and (15).
TM 55-1905-223-24-19
NOTE
If the shoes (20) are to be reinstalled, ensure the orientation of the shoes are the
same as when removed. When installing new shoes, ensure the orientation of the
original marked shoes are the same.
j.
Install shoes (20) on rotor (18) by inserting shoes on cams.
CAUTION
Align gasket to front cover for proper seal.
k.
Install new port plate gasket (23) onto front cover (25).
l.
Insert screws (28) through front cover (25) and into the pump wear plate (22).
m. Tighten screws and examine gasket again for proper alignment.
NOTE
If gasket has gaps or tears after tightening screws, step (k) through step (m) must
be repeated to ensure a tight fit.
n. Replace front cover (25) on pump body (32) (dowel pins (19) will align position) making certain two
gaskets are installed and are in good condition, free of tears and dirt.
o. Install new blank flange gasket (10) onto the blank flange stud (9).
p. Replace the blank flange (11); securing with the blank flange nuts (12).
q. Replace shaft key (31)on to rotor (18) at install coupling hub (20, Figure 2-11); securing with
set screws (21). Reposition pump and secure mounting bolts. When the motor and pump are spaced
correctly, the distance as measured with calipers (2, Figure 2-10) is 2.375 inches.
r.
Realign flexible coupling (2, Figure 2-8) by performing alignment procedures (Paragraph 2-19).
_________
WARNING
Do not operate equipment unit with coupling guard (3, Figure 2-8) removed.
Serious personnel injury may result.
s.
Replace coupling guard (3) on base (5, Figure 2-8).
t.
Reconnect the inlet and outlet piping connections.
u. Open the nearest inlet and outlet valves.
CAUTION
Do not operate pump unit before initial filling (or after maintenance/disassembly)
to avoid damage to internal moving parts.
v.
Prime the dirty oil pump by removing filler plug (30, Figure 2-9) and fill pump completely with liquid.
w. Replace filler plug (30).
x.
Operate the OWS (Paragraphs 2-6 through 2-8) and check for proper operation.
2-51
TM 55-1905-223-24-19
LEGEND:
1. MOTOR
2. COUPLING
3. COUPLING GUARD
4. PUMP
5. MOUNTING BASE
Figure 2-8. Dirty Oil Pump And Motor Assembly.
2-52
TM 55-1905-223-24-19
LEGEND:
1. DIRTY OIL PUMP
2. BEARING COVER, DRIVE END
3. BEARING
4. BODY NUT
5. SHAFT SEAL
6. END STUD
7. BEARING HOUSING GASKET
8. CASE PLUG
9. BLANK FLANGE STUD
10. BLANK FLANGE GASKET
11. BLANK FLANGE
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
BLANK FLANGE NUT
BEARING HOUSING
FORCING SCREW
BEARING COVER, OUTER END
BEARING COVER SCREW
BEARING HOUSING DOWEL
ROTOR
FRONT COVER DOWEL
SHOE
FRONT STUD
PUMP WEAR PLATE
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
PORT PLATE GASKET
FRONT COVER GASKET
FRONT COVER
DRAIN PLUG WASHER
DRAIN PLUG
PORT PLATE SCREW
FILLER PLUG WASHER
FILLER PLUG
SHAFT KEY
PUMP BODY
Figure 2-9. Dirty Oil Pump.
2-53
TM 55-1905-223-24-19
2-19.
Dirty Oil Pump Motor. (Figures 2-8, 2-10 and 2-11)
This task covers:
a. Align,
b. Removal,
c. Repair,
d. Replacement.
INITIAL SETUP
Tools
Equipment Condition
Tool Kit, General Mechanic's,
5180-00-699-5273
Tool Set, Measuring, Machinist’s,
5280-00-278-9919
Puller, Mechanical, Gear and Bearing,
5120-00-288-7710
TM 55-1905-223-10, Oil-Water Separator Secured,
Locked Out and Tagged (FM 55-502).
Materials/Parts
Cleaning Solvent, Item 1, Appendix C
Grease, Item 5, Appendix C
Rags, Wiping, Item 12, Appendix C
Shim, Item 14, Appendix C
Straight Edge, Item 17, Appendix C
Warning Tags, Item 19, Appendix C
ALIGN
Perform coupling alignment as follows:
CAUTION
Align the motor to the pump or distortion to piping connections or pump casing
may occur.
NOTE
Maximum allowable parallel misalignment is 0.015 inch and maximum angular
misalignment is 0.070 inch.
a. With coupling hubs (18 and 20, Figure 2-11) and flexible coupling insert (19) installed, ensure motor
coupling hub is pushed flush with pump coupling hub.
b. Check parallel alignment by placing a straight edge (1, Figure 2-10) across the two hubs (18 and 20,
Figure 2-11).
c.
2-54
(1)
If there is a gap between a hub and the straight edge, use a feeler gauge and measure the gap. If
the gap is greater than 0.015 inches then realign the shafts by adjusting horizontally, adding or
removing shims.
(2)
Repeat, at a minimum of three different points, with out rotating the shaft until all gaps are less then
0.015 inches.
Check the angular alignment by placing a caliper (2, Figure 2-10) on the outside of both hubs and record
the measurement. Take and record at least three more measurements; determine the maximum and
minimum readings.
TM 55-1905-223-24-19
NOTE
When an adjustment is to be made during angular alignment checks, ensure
parallel alignment checks are repeated
d. Subtract the minimum reading from the maximum reading to determine the angular misalignment. If the
angular misalignment is greater the 0.070 inches realign the shafts and repeat parallel and angular
alignment steps.
REMOVAL
_________
WARNING
Always ensure affected circuits have been secured, locked out and tagged out.
Performing maintenance with circuits energized may result in death or injury to
personnel or equipment damage.
a. Remove coupling guard (3, Figure 2-8) to expose coupling (2) for disassembly.
b. Remove motor foundation bolts and slide motor (1) back to separate coupling halves (2). Retain
mounting hardware for installation.
c.
Remove conduit box cover (8, Figure 2-11) by removing conduit box screws (9).
d. Label and disconnect wires in conduit box to ensure proper motor rotation after installation. (Proper motor
rotation is counterclockwise facing shaft end.)
e. Remove setscrew (21) from coupling hub (18) and slide hub with machine key (14) from rotor (12).
f.
If motor is to be replaced proceed to replacement procedure for installation of new motor, if repair is to be
completed proceed to repair procedure.
REPAIR (Figure 2-11)
Repair of the dirty oil pump motor (1, Figure 2-11) consists of replacing the following components: Clamp (4), Fan
impeller (5), Annular ball bearings (11 or 13) and Flexible coupling insert (19).
NOTE
If other maintenance is required to repair the motor, then motor replacement is
required.
To repair the dirty oil pump motor (1), perform the following procedure:
a. Perform removal procedure.
b. Remove attaching screws (2) securing fan housing (3). Remove fan housing.
c.
Remove clamp (4) and fan impeller(5).
d. Remove bolts (16) securing end bells (7 and 15). Remove end bell (7) and shim (10).
e. Remove forsheda (17) and end bell (15).
f.
Remove annular ball bearings (11 and 13) from rotor assembly (12) using standard bearing puller.
g. Visually inspect for wear, damage and corrosion.
h. Install new annular ball bearings (11 and 13) onto rotor assembly (12).
i.
Install end bell (15) and forsheda (17).
2-55
TM 55-1905-223-24-19
j.
Install shim (10) and end bell (7).
k.
Install bolts (16) through end bell (15) to end bell (7).
l.
Install fan impeller (5) and clamp (4).
m. Install fan housing (3); secure using attaching screws (2).
n. Install coupling hub (18) with machine key (14) onto motor shaft; secure with setscrews (21).
o. Proceed to replacement procedure step b.
REPLACEMENT
a. Install coupling hub (18, Figure 2-11) with machine key (14) onto motor shaft; secure with setscrews (21).
b. Install flexible coupling insert (19) into coupling hub (18).
c.
Place motor on foundation aligning coupling hubs of both motor (18) and pump (20). When the motor and
pump are spaced correctly, the distance as measured with calipers (2, Figure 2-10) is 2.375 inches.
d. Align motor feet bolt holes over bolt holes in foundation and insert mounting bolts with nuts. Do not
tighten mounting hardware, allow sufficient play for insertion of shims for coupling alignment.
e. Perform coupling alignment before proceeding to step f.
f.
Install coupling guard (3, Figure 2-8).
g. Connect wires in conduit box as labeled on removal to ensure proper motor rotation. (Proper motor
rotation is counterclockwise facing shaft end.) If motor rotation is not counterclockwise reverse any two
incoming power leads.
h. Install conduit box cover (8, Figure 2-11); securing with conduit box screws (9).
i.
Operate the OWS (Paragraphs 2-6 through 2-8) and check for proper operation.
Figure 2-10. Dirty Oil Pump Coupling Alignment.
2-56
TM 55-1905-223-24-19
LEGEND:
1. AC MOTOR
2. SCREW
3. FAN HOUSING
4. CLAMP
5. FAN IMPELLER
6. STATOR ASSEMBLY
7. END BELL
8. CONDUIT BOX COVER
9. CONDUIT BOX SCREW
10. SHIM
11. ANNULAR BALL BEARING
12. ROTOR ASSEMBLY
13. ANNULAR BALL BEARING
14. MOTOR MACHINE KEY
15. END BELL
16. HEX BOLT
17.
18.
19.
20.
21.
22.
FORSHEDA
COUPLING HUB
FLEXIBLE COUPLING INSERT
COUPLING HUB
SETSCREW
PUMP MACHINE KEY
Figure 2-11. Dirty Oil Pump Motor.
2-57
TM 55-1905-223-24-19
2-20.
Control Panel. (Figure 2-12)
This task covers:
a. Inspect,
b. Repair.
INITIAL SETUP
Tools
Equipment Condition
Tool Kit, General Mechanic's,
5180-00-699-5273
Tool Kit, Electrician’s,
5180-00-391-1087
Iron, Soldering,
3439-00-204-3858
TM 55-1905-223-10, Oil-Water Separator Secured,
Locked Out and Tagged (FM 55-502).
Materials/Parts
Insulation Sleeving, Electrical, Item 7, Appendix C
Solder, Tin Alloy, Item 16, Appendix C
Warning Tags, Item 19, Appendix C
INSPECT
_________
WARNING
Always ensure affected circuits have been secured, locked out and tagged out.
Performing maintenance with circuits energized may result in death or injury to
personnel or equipment damage.
Inspect door locking devices for security, door gaskets for serviceability and terminal screws for tightness. Check
for signs of condensation inside panel, and discolored connectors from possible system malfunctions. Perform
Preventive Maintenance Checks and Services (PMCS, TM 55-1905-223-10).
REPAIR
Repair is through replacement of fuses (15 or 18, Figure 2-12), lamps (6A, 7A, 8A or 30A), relays (19, 23, 26 or
27), switches (28 or 29) and transformer (16) and pushbutton switches (3, 5 or 9).
_________
WARNING
Always ensure affected circuits have been secured, locked out and tagged out.
Performing maintenance with circuits energized may result in death or injury to
personnel or equipment damage.
1. Replacement of fuses (15 or 18):
a. Using fuse puller, pull fuse (15 or18) away from fuse block (14 or 17).
b. Install fuse (15 or 18) with a fuse puller by pushing fuse into fuse block (14 or 17).
2. Replacement of lamps (6A, 7A, 8A or 30A), relays (19, 23, 26 or 27), switches (3, 4, 9, 28 or 29) and
transformer (16) and pushbutton switches (3, 5 or 9):
a. When applicable; remove heat shrink sleeving from electrical terminals on unit and unsolder
interconnecting wires.
2-58
TM 55-1905-223-24-19
b. Disconnect interconnecting wires from electrical terminals on unit to be replaced. Label wires.
c.
Unfasten mounting hardware and remove unit. Retain hardware for installation.
d. Install replacement unit and tighten mounting hardware.
e. Connect interconnecting wires to electrical terminals on unit.
f.
When applicable install heat shrink sleeving as required and solder interconnecting wires to electrical
terminals on unit.
2-59
TM 55-1905-223-24-19
LEGEND
1.
2.
3.
4.
5.
6.
6A.
7.
7A.
8.
8A.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
30A.
Figure 2-12. OWS Control Panel.
2-60
CONTROL PANEL ENCLOSURE
N.O. CONTACT BLOCK
GREEN PUSH SWITCH
RED PUSH SWITCH
N.C. CONTACT SWITCH
AMBER PILOT LIGHT
INCANDESCENT LAMP
BLUE PILOT LIGHT
INCANDESCENT LAMP
RED PILOT LIGHT
INCANDESCENT LAMP
BLACK PUSH SWITCH
LCD DISPLAY ELAPSE TIMER
STARTER
UNIVERSAL ENCLOSURE
UNIVERSAL PANEL
2 POLE FUSE BLOCK
6A 250V FUSE
500 VA TRANSFORMER
1 POLE FUSE BLOCK
5A 250V FUSE
RELAY
SOCKET
RELAY
SOCKET
TIME DELAY RELAY
PLUG-IN SOCKET
TERMINAL STRIP
ELECTROMAGNETIC RELAY
SOLID STATE RELAY
SELECTOR SWITCH
SELECTOR SWITCH
WHITE PILOT LAMP
INCANDESCENT LAMP
TM 55-1905-223-24-19
2-21.
Gauge Panel (All System Gauges). (Figure 2-13)
This task covers:
a. Inspect,
b. Adjust,
c. Repair.
INITIAL SETUP
Tools
Equipment Condition
Tool Kit, General Mechanic's,
5180-00-699-5273
TM 55-1905-223-10, Oil-Water Separator Secured,
Locked Out and Tagged (FM 55-502).
Materials/Parts
Warning Tags, Item 19, Appendix C
INSPECT
Inspection of the gauge panel is accomplished through Preventive Maintenance Checks and Services (PMCS),
Table 2-1 and maintenance procedures.
ADJUST
The vacuum switch compound pressure gauge (6, Figure 2-13) shutdown setpoints are adjustable. If the OWS
shuts down at the wrong setting adjust as follows:
a. To adjust the pressure setting; rotate the outer adjustment on the gauge face to 15 psi.
b. To adjust the vacuum setting; rotate the inner adjustment on the gauge face to 16 in. Hg.
REPAIR
Repair is by replacement of gauges.
REMOVAL
_________
WARNING
Always ensure affected circuits have been secured, locked out and tagged out.
Performing maintenance with circuits energized may result in death or injury to
personnel or equipment damage.
Remove gauge from panel by performing the following steps.
a. Remove piping connection from system to gauge.
b. Remove mounting screws holding gauge to panel.
REPLACEMENT
a. Mount gauge into gauge panel using screws removed during removal.
b. Attach piping to gauge port connection. Check for leaks when system is placed back in service.
2-61
TM 55-1905-223-24-19
LEGEND:
1. PANEL, GAUGE
2. GAUGE, PRESSURE 0-60 PSI
3. GAUGE, PRESSURE 0-30 PSI
4. GAUGE, COMPOUND, 30” TO 30 PSI
5. GAUGE, ISOLATION VALVE
6. GAUGE, COMPOUND, 30” TO 30 PSI
VACUUM SWITCH
Figure 2-13. Gauge Panel (All System Gauges).
2-62
TM 55-1905-223-24-19
2-22.
Motorized Valves. (Figure 2-14)
This task covers:
a. Adjust,
b. Service,
c. Removal,
d. Repair,
e. Replacement.
INITIAL SETUP
Tools
Equipment Condition
Tool Kit, General Mechanic's,
5180-00-699-5273
TM 55-1905-223-10, Oil-Water Separator Secured,
Locked Out and Tagged (FM 55-502).
Materials/Parts
Valve, Ball, Actuated, 3/4” P/N 688888
Valve, Ball, Actuated, 1 1/2” P/N 6051688
Washer, Lock, 3/8”, Monel P/N 6052706
Washer, Lock, #10, Monel P/N 6052594
Cleaning Solvent, Item 1, Appendix C
Gasket, Material, Item 4, Appendix C
Rags, Wiping, Item 12, Appendix C
Warning Tags, Item 19, Appendix C
ADJUST
NOTE
The Oil Discharge (Master) and Purge Water (Slave) motorized valves and the
Influent (Master) and Pump Discharge (Slave) motorized valves are dependant
on each other for proper operation. Valve adjustment must be made for each
Master and Slave motorized valve as a set.
The cam adjustments can be made while the valve is installed in the system.
a. Remove the cover from the actuator assembly (1, Figure 2-14) by unscrewing.
b. To adjust valve open cam (Figure 2-14, exploded view), loosen set screw on cam 1 (valve open) (3).
c.
Rotate cam clockwise (A) for under-travel and counterclockwise (B) for over-travel. Tighten set screw
when adjustment is correct.
d. To adjust valve close cam, loosen set screw on cam 2 (valve closed) (2).
e. Rotate cam clockwise (A) for over-travel and counterclockwise (B) for under-travel.
f.
Tighten set screw when adjustment is correct.
g. Replace cover on the actuator assembly (1).
SERVICE
Service of the Motorized Valve is accomplished through Preventive Maintenance Checks and Services (PMCS),
Table 2-1 and maintenance procedures.
2-63
TM 55-1905-223-24-19
REMOVAL
_________
WARNING
Always ensure affected circuits have been secured, locked out and tagged out.
Performing maintenance with circuits energized may result in death or injury to
personnel or damage to equipment.
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 or
injury to personnel or damage to equipment. In accordance with TB 43-0218,
ensure that all locking hardware is discarded upon removal and replaced with
new hardware.
NOTE
Determine the position of the valve prior to removal, to ensure proper installation.
a. Remove cover from the actuator assembly (1, Figure 2-14) and place cover in safe location.
CAUTION
Care shall be taken not to damage cam mechanisms.
b. Label and disconnect electrical leads.
c.
Remove actuator assembly (1) by removing four screws (11) and four lock washers (10). Place actuator
assembly in a safe location if it is to be reused.
d. Remove nuts (6) and bolts (4) to remove the ball valve (5) from piping system. Place the valve in a vise or
other suitable retention tool in such a fashion so as to allow access to the valve and motor/valve
adaptor (10).
e. Match mark the actuator (1), motor/valve adapter (12) and ball valve (5). Remove capscrews (11) and
lock washers (10) to remove the actuator (1) from the mounting bracket (7). Discard lock washers.
f.
Remove motor/valve adapter (12). Retain for replacement.
g. Remove mounting bracket (7) from valve (5) by removing lock washers (8) and screws (9). Retain for
replacement. Discard lock washers.
REPAIR
Repair of the Motorized Valve is by replacement of actuator (1, Figure 2-14) or ball valve (4).
REPLACEMENT
_________
WARNING
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 or
injury to personnel or damage to equipment. In accordance with TB 43-0218,
ensure that all locking hardware is discarded upon removal and replaced with
new hardware.
a. Install mounting bracket (7, Figure 2-14) onto ball valve (5) using new lock washers (8) and
capscrews (9).
b. Install motor/valve adapter (12).
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TM 55-1905-223-24-19
c.
Install ball valve (4) in piping system using gasket material (cut to size) at both valve flange faces and
nuts (6) and bolts (4). Install flange bolts and torque to value specified in Appendix D.
d. Install actuator assembly (1) and secure to mounting bracket (7) using new lock washers (10) and
capscrews (11).
e. Thread electrical leads through conduit fitting and connect electrical leads as labeled during removal.
f.
Perform adjust procedure.
g. Operate the OWS (Paragraphs 2-6 through 2-8) and check for proper operation.
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TM 55-1905-223-24-19
LEGEND:
1. ACTUATOR ASSEMBLY
2. CAM 2 (VALVE CLOSED)
3. CAM 1 (VALVE OPEN)
4. BOLT
5. VALVE, BALL (3/4” and 1-1/2”)
6. NUT
7. MOUNTING BRACKET
8. LOCK WASHER
9. CAPSCREW
10. LOCK WASHER
11. CAPSCREW
12. MOTOR/VALVE ADAPTER
Figure 2-14. Motorized Valves.
2-66
TM 55-1905-223-24-19
2-23.
Diverter Valve. (Figure 2-15)
This task covers:
a. Inspect,
b. Removal,
c. Repair,
c. Replacement.
INITIAL SETUP
Tools
Equipment Condition
Tool Kit, General Mechanic's,
5180-00-699-5273
TM 55-1905-223-10, Oil-Water Separator Secured,
Locked Out and Tagged (FM 55-502).
Materials/Parts
Actuator, Solenoid, P/N AE3352170001
Spring, P/N 71104P0G1
Switch, P/N 50313POX9
Disc, Valve, P/N 04774AOP2
Cleaning Solvent, Item 1, Appendix C
Gasket, Material, Item 4, Appendix C
Rags, Wiping, Item 12, Appendix C
Warning Tags, Item 19, Appendix C
INSPECT
Inspection of the diverter valve is accomplished through Preventive Maintenance Checks and Services (PMCS),
Table 2-1 and Preventive Maintenance Checks and Services (PMCS, TM 55-1905-223-10).
REMOVAL
_________
WARNING
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 or
injury to personnel or damage to equipment. In accordance with TB 43-0218,
ensure that all locking hardware is discarded upon removal and replaced with
new hardware.
Always ensure affected circuits have been secured, locked out and tagged out.
Performing maintenance with circuits energized may result in death or injury to
personnel or equipment damage.
a. Remove cover from terminal box (17, Figure 2-15); inspect O-ring (18) for cracks and tears.
b. Label and disconnect terminal eyes (19) from terminal block (20).
c.
Loosen screws (26) and remove cover from limit switch (24).
d. Label and disconnect wires inside limit switch (24) and remove wires from switch body.
e. Remove nuts (55), bolts (58), washers and move diverter valve assembly away from piping flanges (57).
e. Discard gasket (56).
REPAIR
Repair of the diverter valve is by replacement of the actuator (2), valve disc (52), compression spring (43), switch
assembly (23), fluid valve stem (28), knob (7), resistor (46) and actuator arm switch (27).
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TM 55-1905-223-24-19
_________
WARNING
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 or
injury to personnel or damage to equipment. In accordance with TB 43-0218,
ensure that all locking hardware is discarded upon removal and replaced with
new hardware.
Always ensure affected circuits have been secured, locked out and tagged out.
Performing maintenance with circuits energized may result in death or injury to
personnel or equipment damage.
1. Solenoid actuator.
a. Remove cover from terminal box (17), inspect O-ring (18) for cracks and tears.
b. Label and disconnect terminal eyes (19) from terminal block (20).
c.
Remove screws (12) and lockwashers (13) from valve bracket (44).
d. Rotate solenoid (5) counterclockwise from pipe nipple (4). Gently pull solenoid wires through elbow (3)
and pipe nipple (4).
e. Install new solenoid (5), thread wires through elbow (3) and pipe nipple (4).
f.
Ensure plunger (11) is properly located inside solenoid (5).
g. Secure solenoid (5) to valve bracket (44) using screws (12) and new lockwashers (13).
h. Reconnect terminal eyes (19) as labeled during removal onto terminal block (20).
i.
Install cover onto terminal box (17), using new O-ring (18) if required.
j.
Operate the OWS (Paragraphs 2-6 through 2-8) and check for proper operation.
2. Switch assembly (23).
a. Loosen screws (26) and remove cover from limit switch (24).
b. Label and disconnect wires inside limit switch (24) and remove wires from switch body.
c.
Remove two mounting screws holding limit switch (24) to bracket (44).
d. Install limit switch (24) onto bracket (44) using mounting screws removed in step c.
e. Reconnect wires inside limit switch (24) as labeled in step b.
f.
Install cover onto limit switch (24) using screws (26).
g. Adjust indication arm (27) by loosening arm setscrew and adjusting arm until correct valve position is
indicated, then tighten setscrew.
h. Operate the OWS (Paragraphs 2-6 through 2-8) and check for proper operation.
3. Teflon valve disc (52).
a. Perform removal procedure.
2-68
TM 55-1905-223-24-19
b. Remove four bolts (47) and lockwashers (48) from valve body (49) and bonnet (61). Remove valve body
(49).
c.
Remove screw (50) and retaining disc (51), then remove valve disc (52).
d. Install new valve disc (52) and secure using screw (50) and retaining disc (51).
e. Install valve body (49) to bonnet (61) using four bolts (47) and new lockwashers (48).
f.
Perform replacement procedure.
g. Operate the OWS (Paragraphs 2-6 through 2-8) and check for proper operation.
4. Spring (43).
NOTE
The spring replacement requires the use of a pair of needle nose pliers and a flat
tip screwdriver. Ensure the spring is not extended or removal will be difficult.
a. Work screwdriver between eye bolt (22) and spring (43).
b. Grasp end of spring (43) with needle-nose pliers and remove from eye bolt (22).
c.
Place end of new spring (43) into eye bolt (22) and screwdriver in opposite end of spring (43).
d. Work flat tip of screwdriver into other eye bolt (22) and lever (42) end of spring onto eye bolt while
extending the spring.
f.
Operate the OWS (Paragraphs 2-6 through 2-8) and check for proper operation.
5. Resistor (46).
a. Remove cover from terminal box (17), inspect O-ring (18) for cracks and tears.
b. Label and disconnect terminal eyes (19) connected to resistor (46), from terminal block (20).
c.
Remove and replace resistor (46).
d. Reconnect terminal eyes (19) as labeled during removal onto terminal block (20).
e. Install cover onto terminal box (17), using new O-ring (18) if required.
f.
Operate the OWS (Paragraphs 2-6 through 2-8) and check for proper operation.
REPLACEMENT
a. Clean piping flange (57) mating surfaces.
b. Place diverter valve between piping flanges (57) and install a new gasket (56) at each flange face.
c.
Match bolt holes and insert bolts (58), washers and nuts (55) until hand tight. Torque to specification
found in Appendix D.
d. Reconnect wires (19) as labeled during removal onto terminal block (20).
e. Install cover onto terminal box (17), using new O-ring (18) if required.
f.
Operate the OWS (Paragraphs 2-6 through 2-8) and check for proper operation.
2-69
TM 55-1905-223-24-19
Figure 2-15. Diverter Valve (Sheet 1 of 2).
2-70
TM 55-1905-223-24-19
LEGEND:
1. VALVE SOLENOID
2. ACTUATOR
3. ELBOW
4. PIPE NIPPLE
5. SOLENOID
6. PIN NUT KNOB
7. KNOB
8. KNOB PIN
9. SCREW
10. LOCKWASHER
11. PLUNGER
12. SCREW
13. LOCKWASHER
14. NUT
15. CLAMP
16. SCREW
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
TERMINAL BOX
O-RING
TERMINAL EYE
TERMINAL BLOCK
FLEX NUT
EYE BOLT
SWITCH ASSEMBLY
SPDT SWITCH
LOCKWASHER
SCREW
SWITCH ARM
FLUID VALVE STEM
ROTARY SHAFT
HOUSING
O-RING
O-RING
33.
34.
35.
36.
37.
38.
39.
40.
41.
42.
43.
44.
45.
46.
47.
48.
SPRING
BUSHING
WASHER
RETAING RING
FINGER ASSEMBLY
SCREW
PIN
NUT
WASHER
LEVER
SPRING
BRACKET
LOCK PIN
RESISTOR
BOLT
LOCKWASHER
49.
50.
51.
52.
53.
54.
55.
56.
57.
58.
59.
60.
61.
VALVE BODY
SCREW
RETAINING DISC
VALVE DISC
PISTON TOP
PISTON BOTTOM
NUT
GASKET
FLANGE
BOLT
BOLT
LOCKWASHER
VALVE BONNET
Figure 2-15. Diverter Valve (Sheet 2 of 2).
2-71
TM 55-1905-223-24-19
2-24.
Duplex Strainer. (Figure 2-16)
This task covers:
a. Inspect,
b. Service,
c. Repair.
INITIAL SETUP
Tools
Equipment Condition
Tool Kit, General Mechanic's,
5180-00-699-5273
TM 55-1905-223-10, Oil-Water Separator Secured,
Locked Out and Tagged (FM 55-502).
Materials/Parts
Cleaning Solvent, Item 1, Appendix C
Rags, Wiping, Item 12, Appendix C
Warning Tags, Item 19, Appendix C
_________
WARNING
Always ensure affected circuits have been secured, locked out and tagged out.
Performing maintenance with circuits energized may result in death or injury to
personnel or equipment damage.
INSPECT
Inspection of the Duplex Strainer is accomplished through Preventive Maintenance Checks and Services (PMCS,
TM 55-1905-223-10).
SERVICE
Service of the Duplex Strainer is accomplished through Preventive Maintenance Checks and Services (PMCS
TM 55-1905-223-10).
REPAIR
Repair of the Duplex Strainer (Figure 2-16) is by replacement of:
NOTE
The Hayward Model 50 duplex strainer was installed with some installations of
the OWS. The Hayward Model 50 is obsolete and is replaced by the Eaton
Model 53BTX. Available replacement parts for the Hayward Model 50 is limited
to items (10 and 12), all others may only be obtained via local purchase.
a. O-ring (11 or 12).
b. Strainer (9 or 10).
2-72
TM 55-1905-223-24-19
NOTE
In the event that the cartridge O-rings, seats or seals need replacement, parts kit,
seal replacement P/N ST053K15BT, is available and includes cartridge
extraction tool and instructions.
c.
Parts Kit (53BTX) (Items 15 through 18).
To repair the Duplex strainer perform the following task:
a. Position handle (4) to opposite basket that maintenance is being conducted.
b. Remove applicable eye nut (5) from stud (13).
c.
Remove strainer cover (6).
d. Remove and replace O-rings (11 or 12), strainer (9 or 10), repair kit components (15 through 18) as
necessary.
e. Replace cover (6); securing with eye nuts (5).
f.
Position handle (4) over basket that was repaired.
g. Operate the OWS (Paragraphs 2-6 through 2-8) and check for proper operation.
2-73
TM 55-1905-223-24-19
LEGEND:
1. DUPLEX STRAINER
2. WASHER
3. CAPSCREW
4. VALVE HANDLE
5. EYE NUT
6. COVER
7. DUPLEX STRAINER BODY
8. PLUG
9. STRIANER (MODEL 53BTX)
10.
11.
12.
13.
14.
15.
16.
17.
18.
STRAINER (MODEL 50)
O-RING (MODEL 53BTX)
O-RING (MODEL 50)
STUD
CARTRIDGE
STEM O-RING
CARTRIDGE O-RING
SEAL
SEAT
Figure 2-16. Duplex Strainer.
2-74
19.
20.
21.
22.
23.
24.
25.
26.
17.
BALL
MIDDLE STEM
TOP STEM
CAPSCREW
VENT VALVE
PIN
STEM RETAINER
CAPSCREW
CAPSCREW
TM 55-1905-223-24-19
2-25.
Relief Valves. (Figure 2-17)
This task covers:
a. Inspect,
b. Test,
c. Removal,
d. Replacement.
INITIAL SETUP
Tools
Equipment Condition
Tool Kit, General Mechanic's,
5180-00-699-5273
TM 55-1905-223-10, Oil-Water Separator Secured,
Locked Out and Tagged (FM 55-502).
Materials/Parts
Cleaning Solvent, Item 1, Appendix C
Rags, Wiping, Item 12, Appendix C
Warning Tags, Item 19, Appendix C
_________
WARNING
Always ensure affected circuits have been secured, locked out and tagged out.
Performing maintenance with circuits energized may result in death or injury to
personnel or equipment damage.
INSPECT
Inspection consists of checking valve for leakage or damage.
TEST
The relief valve test should be performed while the system is in operation and discharging overboard.
NOTE
Ensure that valve opens at 28 psig and fully closes at 23 psig.
a. Create back pressure to system by slowly closing OWS pump discharge valve (OWS 47) until tank
pressure gauge on gauge panel reads 28 psig.
b. Verify flow through relief valve.
c.
Fully open OWS pump discharge valve (OWS 47).
d. Verify that there is no leakage from relief valve. If relief valve does not open or close fully; replace.
REMOVAL.
a. Remove the two union nuts (2, Figure 2-17) from piping.
b. Remove relief valve (1).
2-75
TM 55-1905-223-24-19
REPLACEMENT
a. Replace relief valve (1) in piping.
b. Tighten union nuts (2) onto the piping.
c.
Operate the OWS (Paragraphs 2-6 through 2-8) and check for proper operation.
LEGEND:
1. RELIEF VALVE
2. UNION NUT
Figure 2-17. Relief Valve.
2-76
TM 55-1905-223-24-19
2-26.
Oil Content Monitor Assembly. (Figures 1-5, 1-6, 2-18, 2-19 and 2-20)
This task covers:
a. Inspect,
b. Test,
c. Service,
d. Adjust,
e. Repair.
INITIAL SETUP
Tools
Equipment Condition
Tool Kit, General Mechanic's,
5180-00-699-5273
Tool Kit, Electrician’s,
5180-00-391-1087
Allen Wrenches, 5120-01-087-3616
Iron, Soldering
3439-00-204-3858
TM 55-1905-223-10, Oil-Water Separator Secured,
Locked Out and Tagged (FM 55-502).
TM 55-1905-223-10, Main Engine Secured,
Locked Out and Tagged (FM 55-502) while
conducting service and adjustment task.
Materials/Parts
Cleaning Solvent, Item 1, Appendix C
Cotton Swab, Item 2, Appendix C
Pipe Cleaner, Item 11, Appendix C
Rags, Wiping, Item 12, Appendix C
Silicon, RTV, Item 15, Appendix C
Warning Tags, Item 19, Appendix C
INSPECT
Inspection of the Oil Content Monitor is accomplished through Preventive Maintenance Checks and Services
(PMCS), Table 2-1 and Preventive Maintenance Checks and Services (PMCS, TM 55-1905-223-10).
TEST (Figure 2-18)
_________
WARNING
This procedure is performed on the system while in operation. Exercise extreme
care when working on/around live equipment.
NOTE
The Verification/Confidence test requires two personnel to effectively perform.
If at any point in this test procedure the required response called for in the
particular procedural step does not take place, discontinue the procedure until
further troubleshooting uncovers the fault.
Verification/Confidence. At initial installation or after any electrical repair or component replacement, perform the
Verification/Confidence Test step-by-step as follows:
a. Ensure the ASW Pump is on.
b. Ensure that the Sample Inlet Valve (OWS-51) and Flush Inlet Valve (OWS-54) are closed (Figure 1-6).
c.
Ensure that Operation Selector Switch (A1S1) (15, Figure 2-18, Sheet 1) in the Sampling/Sensor
Assembly enclosure is in the OFF position.
d. Turn main disconnect switch to the ON position to supply power to the OCM system (FO-1, Sheet 2).
2-77
TM 55-1905-223-24-19
e. Set the Operation Selector Switch (A1S1) (15, Figure 2-18, Sheet 1) in the Sampling/Sensor Assembly
enclosure to the AUTO position; set Alarm Limit (PPM) Selector Switch (A1S2) to 15 PPM position.
f.
Open the Flush Inlet Valve (OWS-54) and OCM Inlet Valve (OWS-52) and verify Pressure Regulating
Valve (OWS-43) for an inlet pressure of 10 to 12 psig (Figure 1-5).
g. Verify that the following occurs:
(1)
The Main Indicator Display POWER indicator illuminates green; 15 PPM range indicator
illuminates.
(2)
Water is discharged through the OCM drain.
(3)
The system solenoid valves begin cyclical control of the water.
(4)
The Remote Indicator (Alarm) Assembly display POWER indicator illuminates green, and that the
15 PPM indicator illuminates.
h. If any leaks are evident in the Sample and Detection Assembly, close the Flush Inlet Valve (OWS-54) and
position the Operation Selector Switch into the OFF position. Turn main disconnect switch to the OFF
position to disconnect power to the OCM before repairing the leaks as required.
i.
Gradually close the Flush Inlet Valve (OWS-54) until it is fully closed. Then, gradually open the Flush Inlet
Valve (OWS-54) until it is fully open. Verify that the following occurs:
(1)
Inlet pressure does not exceed 12 psig.
(2)
OCM energizes when inlet pressure exceeds 5 psig, and deenergizes when inlet pressure drops
below 5 psig. The Pressure Switch is preset at the factory to switch ON and OFF at
4.5 psig (+/- 0.5 psig).
_________
WARNING
Under no circumstances should repair or adjustment of energized equipment be
attempted alone. The immediate presence of someone capable of rendering aid
is required. Before making adjustments, be sure to protect against grounding. If
possible, adjustments should be made with one hand, with the other hand free
and clear of equipment. Even when power has been removed from equipment
circuits, dangerous potentials may still exist due to retention of charges by
capacitors. Circuits must be grounded and all capacitors discharged prior to
attempting repairs.
j.
Position Operation Selector Switch (A1S1) to the OFF position. Verify that the following occurs:
(1)
Main Indicator Display is inactive.
(2)
Remote Indicator Display is inactive.
(3)
No flow from the OCM sample drain.
NOTE
Operation Selector Switch (A1S1) has two label configurations which are (AUTO
OFF TEST) or (AUTO OFF MAN); the text in this technical manual uses the MAN
position.
k.
Position Operation Selector Switch (A1S1) to MAN position. Verify that the following occurs:
(1) Main Indicator Display POWER indicator illuminates; 15 PPM range indicator illuminates.
(2)
2-78
Remote Indicator Display POWER and 15 PPM indicators illuminate.
TM 55-1905-223-24-19
NOTE
Although the OCM has a limit of 70 PPM, DOD vessels are not authorized to
operate at this range. In accordance with DOD 4715.6-R1, Regulations On
Vessels Owned Or Operated By The Department Of Defense, the only
acceptable range of operation is 15 PPM. Steps l and m are for the
Verification/Confidence Test only.
l.
Position the Alarm Limit (PPM) Selector Switch (A1S2) to the 70 PPM position. Observe the following:
(1)
The Main Indicator Display 70 PPM range indicator illuminates.
(2)
The Remote Indicator Display 70 PPM AT-SEA indicator illuminates with Operation Selector Switch
(A1S1) in the AUTO position and the Flush Inlet Valve (OWS-54) open.
m. Position the Alarm Limit (PPM) Selector Switch (A1S2) to the REMOTE position. Press Push To Change
Alarm Limit (A2S1) pushbutton to alternately select 15 PPM IN-PORT and 70 PPM AT-SEA. Observe
that the Main Indicator Display ranges match.
n. Hold Processor Test/Check Switch (A1S3) on the Processor PCB within the Sampling/Sensor
Assembly (door) up into the check on position. Hold for 90 seconds. Verify that the following occur:
(1)
Within 20 seconds the Main Indicator Display will show red LED’s, and the green LED’s will
flash.
(2)
Within 20 seconds the red OIL CONTENT EXCEEDS ALARM LIMIT indicator on the Remote
Indicator Display will illuminate, and a high numerical PPM value will be displayed, and the audible
alarm will buzz.
(3)
Within 80 seconds the Diverter Valve will actuate and switch positions from overboard to sludge
tank.
o. Press PUSH TO SILENCE pushbutton (A2S2) on the Remote Indicator (Alarm). Buzzer should silence.
p. Release Processor PCB Test/Check Switch(A1S3) and verify that the following occur:
(1)
The Main Indicator Display stops flashing and shows a low-level reading (0 to 3 PPM).
(2)
The Remote Indicator Assembly alarm indicator goes out, and the PPM display shows a low-level
reading (0 to 3 PPM).
(3)
The Diverter Valve will change positions from sludge tank to overboard discharge.
q. Fully close Flush Inlet Valve (OWS-54).
r.
s.
Position the Operation Selector Switch (A1S1) to the AUTO position and proceed as follows:
(1)
Open Sample Inlet Valve (OWS-51).
(2)
Startup the OWS so that 5 to 15 psig pressure is present in the OWS Pump discharge piping.
(3)
Verify that the OCM activates and the POWER indicator illuminates.
(4)
Shutdown OWS to drop OCM inlet pressure to below 5 psig.
(5)
Verify that the OCM deactivates and the POWER indicator goes out.
Startup the OWS so that 5 to 25 psig pressure is present in the OWS pump discharge piping. Proceed as
follows:
2-79
TM 55-1905-223-24-19
(1)
t.
After 60 seconds, hold Processor PCB Test/Check Switch(A1S3) up in the Check on position. Hold
for 90 seconds. Verify that the following occurs:
(a)
Within 20 seconds, the Main Indicator Display will show red LED’s and the green LED’s will
flash.
(b)
Within 80 seconds the Diverter Valve will actuate and switch positions from overboard to
sludge tank.
(c)
While the Diverter Valve is in the sludge tank position, there is 5 to 25 psig pressure at the
Sample Inlet, and the OCM continues to operate.
Release Processor PCB Test/Check Switch(A1S3). The OCM will now sample and control the OWS
effluent discharge. Releasing switch A1S3 will not necessarily take the OCM out of ALARM.
(1)
If the OCM remains in ALARM for more than 30 seconds after the Processor PCB Test/Check
Switch(A1S3) is released; verify the OCM operation by introducing flushing water to the unit by
opening Flush Inlet Valve (OWS 54).
(2)
If the OCM display stops flashing and shows a low-level reading (0 to 3 PPM) with flushing water,
close Flush Inlet Valve (OWS 54).
(3)
Close If OCM Alarm engages, the OWS should be checked for proper operation.
u. Shutdown the OWS and verify that the OCM deenergizes when the OWS is shutdown.
v.
Perform UVA signal adjustment procedure. Position the Alarm Limit (PPM) Selector Switch (A1S2) to the
15 PPM position. The OCM is now ready to operate.
SERVICE
To perform the Sensor Detection Assembly (SDA) service, proceed as follows:
_________
WARNING
Always ensure affected circuits have been secured, locked out and tagged out.
Performing maintenance with circuits energized may result in death or injury to
personnel or equipment damage.
NOTE
If pitting, scratches or other blemishes are identified during any part of this
service, reassemble SDA and perform removal and replacement procedure
Paragraph 3-12.
Ensure OCM Inlet Valve (OWS-52) (Figure 1-6) is shut.
a. Loosen handnuts (1) securing sampling/sensor assembly enclosure door (2). Open door (2, Figure 2-19).
b. Locate SDA (9) on left-rear of enclosure (10).
c.
Disconnect SDA cable connector (4).
d. Remove mounting hardware (8) from SDA (9). Retain hardware for installation.
e. Lift SDA (9) up and away from the enclosure (10).
f.
2-80
Release tubing (5 and 7) from the quick-connect fittings (6 and 8) by compressing the quick connect fitting
collets and simultaneously pulling the tube in the opposite direction.
TM 55-1905-223-24-19
g. Inspect tubing (5 and 7) for damage. Clean tubing (5 and 7) using pipe cleaner and mild detergent or
alcohol or replace as necessary.
CAUTION
The Turbidimeter (9, Figure 2-20) (component of the SDA) and Processor PCB
(3, Figure 2-19) are factory calibrated as a matched set. If either component
requires replacement, the set must be replaced. Do not separate or mix these
components. Matched calibration is necessary for proper operation and cannot
be performed in the field.
h. Unfasten UVA mounting screws (1) and remove plastic anchor clips (2, Figure 2-20).
i.
Lift out UVA (21) and gasket (20) from vibrator housing (3).
j.
Clean and inspect UVA components.
k.
Unfasten vibrator housing (3) mounting screws (4) at top of SDA.
l.
Loosen nut on elbow fitting (19) on vibrator housing (3). Lift vibrator housing (3) off manifold block (9) of
the SDA.
m. Lift turbidimeter (8) out of manifold block (9) and remove O-rings (5 and 6) on top and bottom. Inspect Orings for cuts or tears, replace if required.
n. Remove glass cell (7) from turbidimeter (8).
o. Clean and inspect turbidimeter components.
p. Remove solenoid valves (16) from manifold block (9).
q. Remove O-rings (17) from manifold block (9).
r.
Remove machine screw (13) and manifold end plate (12) with O-rings (11).
CAUTION
Use of abrasive or sharp-edged tools to clean plastic parts may cause damage to
the unit.
s.
Inspect the ports and valve seat surfaces on the manifold block (9) (plastic block) and clean as necessary
using cotton swab, pipe cleaner and mild detergent.
CAUTION
Do not install upper and lower solenoid valves in wrong position. They are not
interchangeable.
t.
Place O-rings (11) onto manifold end plate (12); secure to manifold block (9) with machine screws (13).
u. Put O-rings (17) into position on manifold block (plastic block) (9).
v.
Secure the solenoid valves (16) onto the manifold block (plastic block) (9).
CAUTION
Exterior surfaces of the Glass Cell (8) and interior surfaces of the Turbidimeter
(9) must be clean and free of any moisture prior to assembly. Inspect, clean, and
dry as required prior to reassembly.
w. Insert glass cell (7) into turbidimeter (8) and install O-rings (5 and 6) in top and bottom.
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TM 55-1905-223-24-19
CAUTION
If assembly does not fit together snugly without force, check for misplaced or
pinched O-Rings (6 and 7).
x.
Carefully replace turbidimeter (8) into manifold block (9). Place vibrator housing (3) on top and fasten in
place using screws (4). Install screws in a cross method sequence; numerically 4A through 4D
(Figure 2-20). Use cross method pattern to tighten.
y.
Install elbow fitting (19) on vibrator housing (3).
CAUTION
Plastic anchor clips (2) have cutaway notches on one side to fit the UVA (21). Do
not install clips upside down or backwards.
z.
Install gasket (20) and UVA (21).
aa. Fasten UVA (21) and anchor clips (2) with mounting screws (1).
ab. Push inlet (5, Figure 2-19) and drain (7) tubing into the SDA quick-connect fittings (8) until they stop.
ac. Holding the SDA, insert tubes (5 and 7) into the enclosure quick connect fittings (6) mounted in the
sampling/sensor assembly.
ad. Hold SDA (10) in position and refasten mounting hardware (9).
ae. Connect cable connector (4) to OCM control panel (29, Figure 2-18, Sheet 3).
af. Open OCM Inlet Valve (OWS-52) (Figure 1-6) and check tubing for leaks. If tubes leak; correct as
required.
ag. Perform UVA adjustment procedure (Paragraph 2-26).
ah. Perform system Verification/Confidence Test (Paragraph 2-26).
ai. Close Sampling/Sensor Assembly enclosure door (2, Figure 2-19); tighten down handnuts (1).
ADJUST (Figure 2-18)
_________
WARNING
This procedure is performed on the system while in operation. Exercise extreme
care when working on/around energized equipment.
Under no circumstances should repair or adjustment of energized equipment be
attempted alone. The immediate presence of someone capable of rendering aid
is required. Before making adjustments, be sure to protect against grounding. If
possible, adjustments should be made with one hand, with the other hand free
and clear of equipment. Even when power has been removed from equipment
circuits, dangerous potentials may still exist due to retention of charges by
capacitors. Circuits must be grounded and all capacitors discharged prior to
attempting repairs.
NOTE
Do not attempt this procedure in an excessively noisy environment or if you have
a hearing impairment. In such instances, the use of an engine stethoscope may
make the audible determinations possible.
a. Ensure ASW Pump is on
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TM 55-1905-223-24-19
b. Make certain that the power remains connected while performing this adjustment (FO-1, Sheet 2).
Use shipboard safety procedures for working on energized electrical components.
c.
Loosen handnuts (1, Figure 2-19) securing Sampling/Sensor Assembly cover (2) and open.
d. Verify that Operation Selector Switch (A1S1) (15, Figure 2-18, Sheet 1) is in AUTO position.
e. Close Sample Inlet Valve (OWS-51).
f.
Open Flush Inlet Valve (OWS-54), so that water flows through the OCM and the pressure switch is
activated.
g. Verify that the OCM System is operating by observing red LED (A1DS8) (6, Figure 2-18, Sheet 1) on the
back of the Processor PCB.
h. Verify that water is flowing through the Sample and Detection Assembly. Flow can be seen through the
clear plastic tubing located on the front of this assembly.
i.
Listen for high-pitched tones from the UVA that repeat every 15 seconds (2-second tone, then 5-second
tone, repeat cycle). This tone must be fine-tuned for its loudest noise and steadiest pitch by adjusting the
Oscillator Transformer (Figure 2-18, Sheet 2) located on the Generator PCB.
j.
Locate the Oscillator Transformer on the Generator PCB. Turning the plastic oscillator core (screw) of
this transformer changes the signal to the vibrator. Adjustment of the oscillator core must be made in
strict accordance with step j through step q and the warnings and cautions below:
_________
WARNING
Under no circumstances should repair or adjustment of energized equipment be
attempted alone. The immediate presence of someone capable of rendering aid
is required. Before making adjustments, be sure to protect against grounding. If
possible, adjustments should be made with one hand, with the other hand free
and clear of equipment. Even when power has been removed from equipment
circuits, dangerous potentials may still exist due to retention of charges by
capacitors. Circuits must be grounded and all capacitors discharged prior to
attempting repairs.
CAUTION
The locknut on the adjustable plastic transformer core will damage the threads if
overtightened. After making the fine-tune adjustment, gently hand-tighten it.
When adjusting the oscillator core, use a wide blade (1/16-in. thick), insulatedhandle screwdriver that fits snugly into the core slot without damage.
k.
Rotate the oscillator core locknut counterclockwise one turn to allow free adjustment of the plastic core.
l.
Hold Processor PCB Test/Check Switch (A1S3) (9, Figure 2-18, Sheet1) on the Processor PCB in the
down position. This will cause a continuous oscillation signal that is more easily adjusted then the normal
intermittent signal.
(1)
Alternately turn the Oscillator Transformer core clockwise and counterclockwise to determine the
limits of the audible coarse adjustment range. When the Oscillator Core is tuned within the “coarse
adjustment range”, the UVA will produce an audible high-pitched noise. This noise will become
gradually louder as the core is adjusted towards the midpoint of this range and will be loudest and
have its most steady pitch when fine-tuned to the midpoint. The noise will decrease as the core is
adjusted away from the midpoint. (Figure 2-18, Sheet 2.)
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m. Using a marker pen, put temporary marks on the metal portion of the Oscillator Transformer, indicating
the limits of the coarse adjustment range. The core should then be turned to the center of this coarse
adjustment range, which is the fine-tune position. If it is not possible to determine the coarse adjustment
range because only weak or unsteady noise is generated, refer to Troubleshooting (Table 2-2) for
appropriate action.
n. Release Processor PCB Test/Check Switch(A1S3).
o. Tighten the oscillator core locknut by turning it clockwise while holding the core in the fine-tune position
with the screwdriver. Do not overtighten the locknut as it can damage the core threads.
p. Close enclosure door.
q. Tighten down handnuts.
REPAIR
CAUTION
The Turbidimeter Assembly(8, Figure 2-20) (component of the SDA) Elapsed
Time Indicator (14, Figure 2-18, Sheet 1) and Processor PCB (3, Figure 2-19) are
factory calibrated as a matched set. If either component requires replacement,
the set must be replaced. Do not separate or mix these components. Matched
calibration is necessary for proper operation and cannot be performed in the field.
1. Repair of the Oil Content Monitor is by replacement of the following components:
a. Cable assembly (25, Figure 2-18, Sheet 3).
b. Filter, Radio Frequency (26).
c.
Transformer, Noiseless (19, Figure 2-18, Sheet 1).
d. Power PCB Fuse (13).
e. Switches (9, 10 or 15).
f.
Circuit Cards (8, 11 or 20).
g. Glass Cell (7, Figure 2-20).
h. O-Rings (5, 6, 11 or 17).
i.
Gasket (20).
_________
WARNING
Always ensure affected circuits have been secured, locked out and tagged out.
Performing maintenance with circuits energized may result in death or injury to
personnel or equipment damage.
2. Loosen handnuts securing Sampling/Sensor Assembly door. Open door.
3. To repair Cable Assembly (24, Figure 2-18, Sheet 3):
a. Locate and tag cable connections for installation.
b. Gently pull cable plugs from cable plug sockets.
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TM 55-1905-223-24-19
c.
In the same manner as tagged for removal, gently push new cable into cable sockets.
d. Close enclosure door; tighten down handnuts.
e. Perform system Verification/Confidence Test procedure.
4. To repair the Filter, Radio Frequency (26, Figure 2-18, Sheet 3):
a. Label and disconnect the ground wires and input power wires from the Radio Frequency Filter.
b. Unfasten Filter, Radio Frequency mounting hardware using an allen wrench and pull out of enclosure.
Retain hardware for installation.
c.
Install new Filter, Radio Frequency with mounting hardware using an allen wrench.
d. Connect ground wires and input power wires to new Radio Frequency Filter.
e. Close enclosure door; tighten down handnuts.
f.
Perform system Verification/Confidence Test procedure.
5. To repair the Noiseless Transformer (19, Figure 2-18, Sheet 1):
a. Locate noiseless transformer cover plate (16) in center of enclosure.
b. Remove mounting hardware using an allen wrench. Retain hardware for installation.
c.
Remove noiseless transformer cover plate (16).
d. Label and remove noiseless transformer output wires from the Power PCB (input), terminals 1 and 2
(Figure 2-18, Sheet 3).
e. Disconnect noiseless transformer input wires and ground wire from the Filter, Radio Frequency
(26, Figure 2-18, Sheet 3). Label wires.
f.
Remove noiseless transformer (19) mounting hardware. Retain for installation. Remove noiseless
transformer (19).
g. Install noiseless transformer using mounting hardware retained from removal.
h. Connect noiseless transformer input and ground wires to the Filter, Radio Frequency (25).
i.
Connect noiseless transformer output wires to the Power PCB (input), terminals 1 and 2 on left.
j.
Fasten noiseless transformer cover plate mounting hardware, retained from removal, using an allen
wrench.
k.
Close enclosure door; tighten down handnuts.
l.
Perform system Verification/Confidence Test procedure.
6. To repair the Power PCB Fuse (13, Figure 2-18, Sheet 1):
a. Locate Power PCB (11) in lower rear of enclosure, and fuse (13) on the front left side of it, just above the
terminal barrier.
b. Remove faulty fuse (13).
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TM 55-1905-223-24-19
CAUTION
Fuse must be replaced with identical type and rating. Changing rating can cause
serious damage to the circuits it is meant to protect.
c.
Apply silicone adhesive (RTV) to each end of replacement fuse, and install into fuse holder.
d. Close enclosure door, tighten down handnuts.
e. Perform Verification/Confidence Test procedure.
7. To repair the Operation Selector Switch (A1S1) (15, Figure 2-18, Sheet 1) and Alarm Limit (PPM) Selector
Switch (A1S2) (10, Figure 2-18, Sheet 1):
a. Loosen handnuts securing door of Sampling/Sensor Assembly. Open door.
b. Locate switch plate subassembly and unfasten mounting hardware. Retain hardware for installation.
c.
Ease forward and unplug Operation Selector Switch (A1S1) (15) cable connector from the Power PCB.
d. The Operation Selector Switch (A1S1) (15) is part of a switch and cable assembly which should be
removed as a unit.
CAUTION
Make note of the original position of the Operation Selector switch (A1S1) before
removing from the Switch Plate. The replacement switch must be installed with
the same orientation.
e. Remove Operation Selector Switch (A1S1) (15) from switch plate using wrench.
f.
The Alarm Limit (PPM) Selector Switch (A1S2) (10) is part of Cable Assembly P/N ST25003 and must be
removed as an assembly. To remove this assembly, proceed as follows: (Figure 2-18)
(1)
Disconnect the ten-wire circular connector (part of Cable Assembly ST25003) (28, Figure 2-18,
Sheet 3) from the bottom of the enclosure.
(2)
Disconnect the color coded wires from Power PCB terminal strip that connects to the ten-wire
circular connector (black from [2], brown from [4], red from [5], orange from [9] and red from [8]).
(3)
Remove mounting hardware on transformer cover plate. Retain hardware for installation.
Remove cover plate for access to the Filter, Radio Frequency (26, Figure 2-18, Sheet 3).
(4)
Disconnect the wire (white) from the ground stud on the Filter, Radio Frequency (26, Figure 2-18,
sheet 3).
(5)
Remove switch from switch plate using wrench.
(6)
Carefully clip off any Ty-raps holding switch wires to the enclosure or to other wire bundles.
(7)
Remove Cable Assembly, which includes the switch, wires, and connector.
CAUTION
Install switch in original position. The reverse position will not correspond with
the legend on the switch plate.
(8)
2-86
Install new Alarm Limit (PPM) Selector Switch (A1S2) (10, Figure 2-18, Sheet 1) onto switch plate,
in the proper orientation, then tighten the switch nut.
TM 55-1905-223-24-19
(9)
Install circular connector onto bottom of enclosure, including EMI gasket.
CAUTION
During disassembly, do not damage EMI gasket under circular connector. Do not
omit it during reassembly.
(10)
Connect (white) wire to Filter, Radio Frequency (26, Figure 2-18, Sheet 3) ground stud.
(11)
Connect wires to the Power PCB terminal strip from the ten-wire circular connector (black from [2],
brown from [4], red from [5], orange from [9]) and switch (red from [8]).
(12)
Neatly bundle wires every 2 inches and fasten with small Ty-raps.
(13)
Install the transformer hold-down plate and fasten with mounting hardware.
g. Install switch plate subassembly and fasten with mounting hardware.
h. Close enclosure door, tighten down handnuts.
i.
Perform system Verification/Confidence Test procedure.
8. To repair the Processor PCB Test/Check Switch (9, Figure 2-18, Sheet 1):
a. Locate Processor PCB (8, Figure 2-18, Sheet 1) on open door.
b. Disconnect ribbon cable (25, Figure 2-18, Sheet 3) from Processor PCB.
c.
Remove mounting hardware for the Processor PCB. Retain hardware for installation.
d. Identify the location of the Processor PCB Test/Check switch on rear of PCB board.
e. Remove solder from connection with a soldering gun.
f.
Pull Processor PCB Test/Check Switch from PCB board.
g. Install new Processor PCB Test/Check Switch onto the PCB board ensuring the connections pass through
the board in the same manner as removed.
h. Solder the connections to the PCB board.
i.
Replace the Processor PCB board onto the door and secure with mounting hardware retained from
removal.
j.
Reconnect ribbon cable to Processor PCB
k.
Close enclosure door, tighten down handnuts.
l.
Perform system Verification/Confidence Test procedure.
9. To repair the Generator PCB (19, Figure 2-18, Sheet 1):
a. Locate Generator PCB (19) mounted in top rear of enclosure, and two power resistors mounted on the
right side wall of the enclosure (Figure 2-18).
b. Disconnect Ribbon Cable (23, Figure 2-18, Sheet 3) connector from Generator PCB.
c.
Remove mounting hardware for power resistors. Retain hardware for installation.
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TM 55-1905-223-24-19
CAUTION
The generator PCB is fastened to the enclosure with four socket head cap
screws. Do not remove any other hardware on generator PCB.
d. Remove mounting hardware for Generator PCB (19), and remove it. Retain hardware for installation. It is
not necessary to remove the heat sink from behind the Generator PCB (19). Leave heat sink in place.
CAUTION
Verify that power resistor wires connected to Generator PCB are clear from the
mounting points and the Heat Sink, so that they are not pinched or damaged
when installing the Generator PCB.
e. Install new Generator PCB (19) and fasten mounting hardware.
f.
Apply liberal amount of thermal grease to underside of power resistors and reinstall onto wall of
enclosure. Fasten mounting hardware.
g. Clean any excess grease from edges of the heat sink and power resistors.
h. Reconnect ribbon cable connector (23, Figure 2-18, Sheet 3) to Generator PCB.
i.
Perform UVA signal adjustment procedure.
j.
Close enclosure door, tighten down handnuts.
k.
Perform system Verification/Confidence Test procedure.
10. To repair the Power PCB (11, Figure 2-18, Sheet 1):
a. Locate Power PCB (11) in lower rear of enclosure, and switch plate subassembly which
partially covers the Power PCB.
b. Label and disconnect all wires connected to the terminal strip of the Power PCB (11). Tag wires.
c.
Remove mounting hardware for switch plate subassembly(12). Retain hardware for installation.
d. Gently pull switch plate subassembly forward and unplug operation selector switch A1S1 (15) connector
from power PCB (11).
e. Disconnect ribbon cable from connectors J1 and J4 on power PCB (11).
f.
Remove mounting hardware for Power PCB (11). Retain hardware for installation.
g. Gently pull Power PCB (11) forward, and unplug ribbon cable from connector J2 on underside of PCB.
h. Remove Power PCB (11). Remove ETI (14). Apply a small (pea size) drop of silicone adhesive (RTV) to
the underside of the ETI (14), and install onto the new Power PCB.
i.
Gently connect ribbon cable from SDA to Power PCB connector J2.
CAUTION
When installing ribbon cables, make certain that wires are kept free of the
fastened items and do not get pinched when assembled.
j.
Fasten Power PCB mounting hardware.
k.
Plug in ribbon cable from Processor PCB and Generator PCB into the proper connectors, J1 and J3.
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TM 55-1905-223-24-19
l.
Connect Alarm Limit (PPM) Selector Switch (A1S2) (10) wires to terminal strip of Power PCB (11).
m. Plug-in Operation Selector Switch (A1S1) (15) cable subassembly into J4.
n. Fasten mounting hardware for switch plate subassembly.
o. Close enclosure door, tighten down handnuts.
p. Perform system Verification/Confidence Test procedure.
11. To repair the Processor PCB (8, Figure 2-18, Sheet 1).
a. Locate Processor PCB (8) on open door.
b. Disconnect ribbon cable (24, Figure 2-18, Sheet 3).
c.
Remove mounting hardware for the Processor PCB. Retain hardware for installation.
d. Gently pull away from door far enough to locate the connecting wires to indicators mounted to door.
e. Tag and remove wires from the indicators mounted on the door.
f.
Replace the Processor PCB and reconnect removed indicator wires.
g. Place Processor PCB into position and secure with mounting hardware.
h. Connect the ribbon cable (24, Figure 2-18, Sheet 3) to the Processor PCB.
i.
Close enclosure door, tighten down handnuts.
j.
Perform system Verification/Confidence Test procedure.
12. To repair the Glass Cell (7, Figure 2-20), O-rings (5, 6, 11 or 17) and Gasket (20); perform service
procedures and replace.
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LEGEND:
1. POWER INDICATOR (A1DS1)
2. OIL CONTENT LCD DISPLAY (A1DS4)
3. 15 PPM INDICATOR (A1DS3)
4. 70 PPM INDICATOR (A1DS2)
(NOT USED)
5. RANGE PPM INDICATOR (A1DS10)
6. SAMPLE DETECTION ON INDICATOR (A1DS8)
7. OCM ALARM INDICATOR (A1DS9)
8. PROCESSOR PCB
9. PROCESSOR PCB TEST/CHECK SWITCH
10. ALARM LIMIT SELECTOR SWITCH (A1S2)
11. POWER PCB
12. SWITCH MOUNTING PLATE
13. POWER PCB FUSE
14. ELAPSED TIME INDICATOR (ETI)
15. OPERATION SELECTOR SWITCH (A1S1)
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
TRANSFORMER COVER PLATE
SENSOR DETECTION ASSEMBLY
SAMPLING/SENSOR ASSEMBLY
NOISELESS TRANSFORMER
GENERATOR PCB
WARNING 1 INDICATOR (A1DS5)
WARNING 2 INDICATOR (A1DS6)
WARNING 3 INDICATOR (A1DS7)
ELECTRICAL CABLE ASSEMBLY (SHEET 3)
ELECTRICAL CABLE ASSEMBLY (SHEET 3)
FILTER, RADIO FREQUENCY (SHEET 3)
POWER UNIT CABLE ASSEMBLY (SHEET 3)
REMOTE ALARM CABLE ASSEMBLY (SHEET 3)
REMOTE RELAY CABLE ASSEMBLY (SHEET 3)
SDA POWER CABLE ASSEMBLY (SHEET 3)
Figure 2-18. OCM Sampling/Sensor Assembly (Sheet 1 of 3).
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TM 55-1905-223-24-19
Figure 2-18. OCM Sampling/Sensor Assembly (Sheet 2 of 3).
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TM 55-1905-223-24-19
Figure 2-18. OCM Sampling/Sensor Assembly (Sheet 3 of 3).
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LEGEND:
1. HANDNUTS
2. ENCLOSURE DOOR
3. PROCESSOR PCB
4. SDA CABLE CONNECTOR
5. INLET TUBING
6. ENCLOSURE QUICK-CONNECT FITTINGS
7. DRAIN TUBING
8. SDA QUICK-CONNECT FITTINGS
9. MOUNTING HARDWARE
10. SENSOR DETECTION ASSEMBLY (SDA)
11. ENCLOSURE
Figure 2-19. Oil Content Monitor Sampling And Detection Assembly.
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LEGEND:
1. MACHINE SCREW
2. ANCHOR CLIP
3. VIBRATOR HOUSING
4. MACHINE SCREW
5. O-RING
6. O-RING
7. GLASS CELL
8. TURBIDIMETER ASSEMBLY
9. MANIFOLD BLOCK
10. CONNECTOR
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
O-RING
MANIFOLD END PLATE
MACHINE SCREW
PRESSURE SWITCH
MACHINE SCREW
SOLENOID VALVE
O-RING
MANIFOLD TUBING
ELBOW FITTING
GASKET
21.
22.
23.
24.
25.
26.
27.
28.
29.
UVA ASSEMBLY
O-RING
PLUNGER
SPRING
SCREW
SOLENOID VALVE BODY
SOLENOID VALVE COIL
COVER
LOCKING NUT
Figure 2-20. Sampling And Detection Assembly (Exploded View).
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TM 55-1905-223-24-19
2-27.
Remote Indicator (Alarm) Assembly. (Figure 2-21)
This task covers:
a. Inspect,
b. Repair.
INITIAL SETUP
Tools
Equipment Condition
Tool Kit, General Mechanic's,
5180-00-699-5273
TM 55-1905-223-10, Oil-Water Separator Secured,
Locked Out and Tagged (FM 55-502).
Materials/Parts
Circuit Card Assembly, P/N AME-220-95155-01
Warning Tags, Item 19, Appendix C
INSPECT
Inspection of the Remote Indicator (Alarm) Assembly is accomplished through Preventive Maintenance Checks
and Services (PMCS, TM 55-1905-223-10).
REMOVAL
_________
WARNING
Always ensure affected circuits have been secured, locked out and tagged out.
Performing maintenance with circuits energized may result in death or injury to
personnel or equipment damage.
a. Loosen door closure clamp screws (3, Figure 2-21, Sheet 1) of assembly and open door.
b. Remove retaining nuts (5 and 8).
c.
Remove rubber boots (3 and 5).
d. Disconnect cable assembly connector (13, Figure 2-21, Sheet 2).
e. Remove the six capscrews (16), lockwashers (15) and flat washers (14) from circuit card assembly (12).
NOTE
The two electrical leads between the Alarm Buzzer and the Alarm PCB are
permanent components of the circuit card assembly. Do not attempt to remove
them.
f.
Remove the circuit card assembly (12) from the Remote Indicator (Alarm) Assembly.
g. Disconnect and tag PUSH TO SILENCE switch (A2S2) (6, Figure 2-21, Sheet 1) wires from the circuit
card assembly (12, Figure 2-21, Sheet 2).
h. Disconnect and tag PUSH TO CHANGE ALARM LIMIT (PPM) switch (A2S1) (9, Figure 2-21, Sheet 1)
wires from the circuit card assembly (12, Figure 2-21, Sheet 2).
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REPAIR
Repair of the OCM Remote Indicator is by replacement of the following components:
a. Rubber Boots (4 and 7, Figure 2-21, Sheet 1).
b. PUSH TO SILENCE switch (A2S2) (6, Figure 2-21, Sheet 1).
c.
PUSH TO CHANGE ALARM LIMIT (PPM) switch (A2S1) (9, Figure 2-21, Sheet 1).
d. Circuit Card Assembly (12, Figure 2-21, Sheet 2).
_________
WARNING
Always ensure affected circuits have been secured, locked out and tagged out.
Performing maintenance with circuits energized may result in death or injury to
personnel or equipment damage.
REPLACEMENT
a. Connect the PUSH TO CHANGE ALARM LIMIT (PPM) switch (A2S1) (9, Figure 2-21, Sheet 1) wires to
the circuit card assembly (12, Figure 2-21, Sheet 2).
b. Connect the PUSH TO SILENCE switch (A2S2) (6, Figure 2-21, Sheet 1) wires to the circuit card
assembly (12, Figure 2-21, Sheet 2).
c.
Replace the circuit card assembly (12) in the Remote Indicator (Alarm) Assembly.
d. Replace the six flat washers (14), lockwashers (15) and capscrews (16) securing the circuit card
assembly (12) to the Remote Indicator (Alarm) Assembly.
e. Connect the cable assembly connector (13, Figure 2-21, Sheet 2) as illustrated.
f.
Replace rubber boots (3 and 5).
g. Replace retaining nuts (5 and 8, Figure 2-21, Sheet 1).
h. Close door and tighten door closure clamp screws (3).
i.
2-96
Operate the OWS (Paragraphs 2-6 through 2-8) and check for proper operation.
TM 55-1905-223-24-19
LEGEND:
1. FACE PLATE
2. SELF SEAL SCREW
3. DOOR CLOSURE CLAMP
4. ALARM SILENCE RUBBER BOOT
5. RETAINING NUT
6. PUSH TO SILENCE SWITCH
7. PPM SELECTOR RUBBER BOOT
8. RETAINING NUT
9. PUSH TO CHANGE ALARM LIMIT (PPM) SWITCH
10. EMI/RFI FACEPLATE SCREEN
11. FACE PLATE GASKET
12. CIRCUIT CARD ASSEMBLY
13. CABLE ASSEMBLY CONNECTOR
14. FLAT WASHER
15. LOCKWASHER
16. CAPSCREW
Figure 2-21. Remote Indicator (Alarm) Assembly (Sheet 1 of 2).
2-97
TM 55-1905-223-24-19
Figure 2-21. Remote Indicator (Alarm) Assembly (Sheet 2 of 2).
2-98
TM 55-1905-223-24-19
2-28.
Remote Relay Assembly. (Figure 2-22)
This task covers:
a. Inspect,
b. Adjust,
c. Repair.
INITIAL SETUP
Tools
Equipment Condition
Tool Kit, General Mechanic's,
5180-00-699-5273
TM 55-1905-223-10, Oil-Water Separator Secured,
Locked Out and Tagged (FM 55-502).
Materials/Parts
Relay, Solid State, Time Delay, P/N AME-10302
Relay, Solid State , P/N AME-10301
Resistor, 10K, 5W, P/N AME-10304
Warning Tags, Item 19, Appendix C
INSPECT
Inspection of the remote relay assembly is accomplished through Preventive Maintenance Checks and Services
(PMCS), Table 2-1 and maintenance procedures.
ADJUST
NOTE
DIP switches (7) are designed in 1, 2, 4, 8, 16, 32, 64, 128, 256, and 512 second
settings; in most cases 4, 8, 16, and 32 should be in the up (ON) position and all
others down (OFF). Time is determined by adding the value of the DIP switches
in the ON position.
Adjustment of the time delay relay (10, Figure 2-22) is by the position of the DIP switches (7) on the time delay
relay The optimum setting is 60 seconds, and a settling time between adjustments of 5 minutes is required to
insure the correct timing is attained.
REMOVAL
_________
WARNING
Always ensure affected circuits have been secured, locked out and tagged out.
Performing maintenance with circuits energized may result in death or injury to
personnel or equipment damage.
a. Loosen door closure clamp screws (1) of assembly and open cover.
NOTE
Removal of the components inside the remote relay assembly is limited to the
two relays (one primary and one spare), the time delay relay and two resistors.
b. Locate the components to be repaired or replaced.
c.
To remove the solid state relays (3):
(1)
Loosen the four terminal capscrews (4) to remove the resistor (5) and wires.
2-99
TM 55-1905-223-24-19
(2)
Unscrew the two relay capscrews (2) and remove the solid sate relay (3).
d.
To remove the time delay relay (10):
(1)
Disconnect wires from terminals 1 and 3.
(2)
Unscrew time delay relay capscrew (9) and remove time delay relay (10).
REPAIR
Repair of the remote relay assembly is by replacement of the following components:
a. Solid state relay (3).
b. Resistor (5).
c.
Time delay relay (10).
REPLACEMENT
_________
WARNING
Always ensure affected circuits have been secured, locked out and tagged out.
Performing maintenance with circuits energized may result in death or injury to
personnel or equipment damage.
a. To replace the time delay relay (10):
(1)
Replace time delay relay (10) and tighten the time delay relay capscrew (9).
(2)
Reconnect wires to terminals 1 and 3.
(3)
Check position of DIP switches (7).
b. To replace the solid state relays (3):
c.
(1)
Replace the solid state relay (3) and tighten the two relay capscrews (2).
(2)
Replace the resistor and wires and tighten the four terminal capscrews (4).
Close cover and tighten door closure clamp screws (1).
d. Operate the OWS (Paragraphs 2-6 through 2-8) and check for proper operation.
2-100
TM 55-1905-223-24-19
LEGEND:
1. DOOR CLOSURE CLAMP SCREWS
2. SOLID STATE RELAY CAPSCREWS
3. SOLID STATE RELAY
4. SOLID STATE RELAY TERMINAL CAPSCREWS
5. 10K, 5W FIXED RESISTOR
6. TIME DELAY RELAY (DETAIL VIEW)
7. DIP SWITCHES
8. CABLE CONNECTOR
9. TIME DELAY CAPSCREW
10. TIME DELAY RELAY
Figure 2-22. Remote Relay Assembly.
2-101
TM 55-1905-223-24-19
2-29.
Water Polisher. (Figure 2-23)
This task covers:
a. Inspect,
b. Service,
c. Repair.
INITIAL SETUP
Tools
Equipment Condition
Tool Kit, General Mechanic's,
5180-00-699-5273
TM 55-1905-223-10, Oil-Water Separator Secured,
Locked Out and Tagged (FM 55-502).
Materials/Parts
Kit, Gaket, P/N 55548
Kit, Float, P/N 55448
Kit, Valve Mechanism, P/N 69849
Filter Element, P/N SN-1213-09 (9 Ea Per Set)
Lubricating Grease, Item 8, Appendix C
Warning Tags, Item 19, Appendix C
_________
WARNING
Always ensure affected circuits have been secured, locked out and tagged out.
Performing maintenance with circuits energized may result in death or injury to
personnel or equipment damage.
INSPECT
Inspection of the water polisher is accomplished through Preventive Maintenance Checks and Services (PMCS,
TM 55-1905-223-10).
SERVICE
NOTE
Cartridges should be replaced when the inlet to outlet pressure difference rises to
+/- 5 psi OWS outlet pressure.
a. Remove hatch covers (2, Figure 2-23) and gaskets (18).
b. Remove PVC hold-down bracket (19) by lift and turning. Retain for installation.
c.
Remove spent cartridges (20) by lifting and rotating each cartridge.
d. Each cartridge butt seal and unit spindle must be lubricated prior to next step.
e. Replace cartridges (20) by lowering new cartridge into space - locate spindle, push down and turn until
cartridge drops 2" to seat.
f.
After all nine cartridges are set and seated, reinstall PVC hold-down bracket (19) by pushing down over
the top spindle.
g. Reset hatch covers (2) and gaskets (18) after lubricating top and bottom of gasket (1" perimeter).
h. Start inlet flow with discharge line open. Bleed off air after flow is established by loosening each hatch
cover slightly. The majority of air will bleed off through the automatic gas vent.
2-102
TM 55-1905-223-24-19
i.
Tighten hatches when fluid appears and return to service. (Float operated air valve (3) will vent remaining
air.)
REMOVAL
NOTE
The water polisher is a durable component which does not wear out through
normal use. Removal is required when the housing is uneconomical to repair.
a. Remove vent valve (2) from top of water polisher (Figure 2-23).
b. Disconnect piping to inlet and outlet of housing, and cap off pipes disconnected.
c.
Remove eight bed plate bolts and washers; attach a suitable lifting device to remove water polisher.
REPAIR
Repair to the water polisher consists of replacing the cover gaskets (18), pressure gauge (17), replacement of the
vent valve (4) or repairing the vent valve with gasket (5), float kit (6, 7 and 8) or valve mechanism kit (7, 8, 9, 12,
13, 14 and 15).
a. To replace the cover gasket (18):
(1)
Loosen tee handles (16) and remove hatch covers (2).
(2)
Removed old gasket.
(3)
Install new gasket (18) after lubricating top and bottom of gasket (1" perimeter).
(4)
Replace hatch covers (2) and tighten tee handles (16).
b. To replace the pressure gauge (17):
c.
(1)
Disconnect all piping from pressure gauge.
(2)
Disconnect mounting hardware and remove gauge. Retain hardware for installation.
(3)
Install new gauge and reconnect all mounting hardware.
(4)
Reconnect all associated piping to gauge.
To replace or repair the vent valve (4);
(1)
Remove vent valve by turning in a counter clockwise direction.
(2)
Remove the eight capscrews (10) and pull the valve cover (11) with the float assembly attached off
of the vent valve.
(3)
Inspect all float components to determine which repair kit is required.
(a)
Gasket (5) (Step 4), float kit (6, 7 and 8) (Step 5) or valve mechanism kit (7, 8, 9, 12, 13, 14
and 15) (Step 6).
(4)
Remove gasket (5) and replace with new. If this is only repair required proceed to step 7.
(5)
To replace only the float kit: remove the machine screw (8) and lock washer (7) to release the
float (6) from arm (15). Install new float kit to arm by securing float (6) with washer (7) and machine
screw (8). If this is the only repair required proceed to step 7.
2-103
TM 55-1905-223-24-19
(6)
(7)
To replace only the valve mechanism kit proceed as follows:
(a)
Remove machine screw (8) and washer (7) from float (6): retaining float for installation.
(b)
Pull the pin (13) from the seat bracket (9) releasing the seat bracket, arm (15), seat (14) and
seat gasket from the bottom of the valve cover (11) .
(c)
Place seat (14) onto the arm (15) and pass thought the seat bracket:
(d)
Set seat cover (12) on the arm passed through the seat bracket; align the holes on the seat
bracket (9) with the arm (15) and push pin (13) through the holes.
(e)
Replace retained float (6) onto arm (15) and secure with washer (7) and machine screw (8).
(f)
Check for ease of movement of float by raising and lowering several times.
Align gasket (5) onto the valve body (4). Place valve cover (11) with attached float assembly onto
the gasket and secure with eight capscrews (10).
d. Operate the OWS (Paragraphs 2-6 through 2-8) and check for proper operation.
REPLACEMENT
a. Install water polisher on bed plate and secure with eight bolts and washers.
b. Connect piping inlet and outlet, and direct vent valve discharge tube to the drain funnel.
c.
2-104
Operate the OWS (Paragraphs 2-6 through 2-8) and check for proper operation.
TM 55-1905-223-24-19
LEGEND:
1. WATER POLISHER
2. HATCH COVER
3. FLOAT OPERATED AIR VALVE
4. BODY VALVE
5. GASKET
6. FLOAT
7. LOCK WASHER
8. MACHINE SCREW
9. SEAT BRACKET
10. CAPSCREW
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
VALVE COVER
SEAT GASKET
PIN
SEAT
ARM
TEE HANDLE
DIAL INDICATING 1-30 PSI PRESSURE GAUGE
GASKET
PVC HOLD DOWN BRACKET
FLUID FILTER ELEMENT
Figure 2-23. Water Polisher.
2-105
TM 55-1905-223-24-19
2-30.
Differential Pressure Switch. (Figure 2-24)
This task covers:
a. Adjust,
b. Removal,
c. Replacement.
INITIAL SETUP
Tools
Equipment Condition
Tool Kit, General Mechanic's,
5180-00-699-5273
TM 55-1905-223-10, Oil-Water Separator Secured,
Locked Out and Tagged (FM 55-502).
Materials/Parts
Warning Tags, Item 19, Appendix C
ADJUST
_________
WARNING
Under no circumstances should repair or adjustment of energized equipment be
attempted alone. The immediate presence of someone capable of rendering aid
is required. Before making adjustments, be sure to protect against grounding. If
possible, adjustments should be made with one hand, with the other hand free
and clear of equipment. Even when power has been removed from equipment
circuits, dangerous potentials may still exist due to retention of charges by
capacitors. Circuits must be grounded and all capacitors discharged prior to
attempting repairs.
NOTE
The differential screw, which governs the point at which the contacts open,
may be turned clockwise to widen the differential slightly.
a. Turn differential screw (3, Figure 2-24) counterclockwise against stop for minimum differential.
b. Increase pressure to point where circuit is to close (5 psi).
c.
If contacts are open, turn range screw (2) slowly counterclockwise until contacts just close.
d. If contacts are already closed, turn range screw (2) clockwise until contacts open; then turn slowly
counterclockwise until contacts just close. This sets the closing point.
REMOVAL
_________
WARNING
Always ensure affected circuits have been secured, locked out and tagged out.
Performing maintenance with circuits energized may result in death or injury to
personnel or equipment damage.
a. Disconnect piping to differential pressure switch (1).
b. Remove cover by loosening cover screw (5). Label and disconnect wiring from differential pressure
switch internally and remove from housing.
c.
2-106
Remove mounting hardware from differential pressure switch housing. Retain hardware for installation.
TM 55-1905-223-24-19
REPLACEMENT
a. Install new differential pressure switch using mounting hardware retained from removal.
b. Connect wiring to differential pressure switch as labeled in removal.
c.
Connect and tighten piping to differential pressure switch.
d. Operate the OWS (Paragraphs 2-6 through 2-8) and check for proper operation.
LEGEND:
1. DIFFERENTIAL PRESSURE SWITCH
2. RANGE ADJUSTMENT SCREW
3. DIFFERENTIAL ADJUSTMENT
4. SETSCREW
5. COVER SCREW
Figure 2-24. Differential Pressure Switch.
2-107
TM 55-1905-223-24-19
2-31.
Check Valve. (Figure 2-25)
This task covers:
a. Inspect,
b. Removal,
c. Replacement.
INITIAL SETUP
Tools
Equipment Condition
Tool Kit, General Mechanic's,
5180-00-699-5273
TM 55-1905-223-10, Oil-Water Separator Secured,
Locked Out and Tagged (FM 55-502).
Materials/Parts
Tape, Teflon, Item 18, Appendix C
Warning Tags, Item 19, Appendix C
_________
WARNING
Always ensure affected circuits have been secured, locked out and tagged out.
Performing maintenance with circuits energized may result in death or injury to
personnel or equipment damage.
INSPECT
Inspection of the check valve is accomplished through Preventive Maintenance Checks and Services (PMCS),
Table 2-1 and maintenance procedures.
REMOVAL
a. Unfasten union nuts (1, Figure 2-25) and slide off of tail pieces (2).
b. Remove check valve body (5), preformed packing (3), and retainer ring (2) from inlet and outlet
passages.
c.
Clean and inspect parts, replace check valve if parts are damaged.
REPAIR
Repair of the check valve is by replacement.
REPLACEMENT
NOTE
Apply Teflon Tape to all threaded fittings.
a. Position new check valve (5), preformed packing (3) and retaining ring (4) with system piping tail piece (2)
and tighten union nut (1).
b. Operate the OWS (Paragraphs 2-6 through 2-8) and check for proper operation.
2-108
TM 55-1905-223-24-19
LEGEND:
1. UNION NUT
2. TAIL PIECE
3. PREFORMED PACKING
4. RETAINER RING
5. BODY
Figure 2-25. Check Valve.
2-109
TM 55-1905-223-24-19
SECTION VI. PREPARATION FOR STORAGE OR SHIPMENT
2-32. Administrative Storage. Administrative storage of equipment issued to and used by Army activities will
have preventive maintenance performed in accordance with the Preventive Maintenance Checks and Services
(PMCS) charts before storing. When removing the equipment from administrative storage, the PMCS should be
performed to assure operational readiness. Prepare components for shipment or limited storage in accordance
with the following instructions.
a. Pumps should be completely drained and dried.
b. Shaft extensions and other exposed machine surfaces should be coated with an easily removable rust
preventive.
c.
Place a corrosion inhibitor in the pump casing, such as Gulf-no-Rust Engine Oil, Grade 3, which conforms
to MIL-L-21260.
d. Cover components to protect them from weather and direct sunlight.
e. Either allow proper ventilation or tightly seal cover with a suitable amount of desiccant to ensure dryness.
f.
Storage locations for pumps that are near a source of vibration must be avoided.
g. Care should be taken to prevent extremes in temperature (below 32°F and above 110°F).
h. Shafts should be rotated 10-15 times, 2 or 3 times a month while in storage.
i.
2-110
If component(s) is/are to be in extended storage, repeat preparation procedures every 6 months.
TM 55-1905-223-24-19
CHAPTER 3
INTERMEDIATE DIRECT SUPPORT MAINTENANCE INSTRUCTIONS
Page
Section I
Repair Parts, Special Tools; Test, Measurement and
Diagnostic Equipment (TMDE);and Support Equipment ...................................................... 3-1
Section II
Service Upon Receipt ........................................................................................................... 3-1
Section III
Intermediate Direct Support Preventive Maintenance Checks and
and Services (PMCS)............................................................................................................ 3-2
Section IV
Intermediate Direct Support Troubleshooting ....................................................................... 3-2
Section V
Intermediate Direct Support Maintenance Procedures......................................................... 3-4
Section VI
Preparation for Storage or Shipment .................................................................................... 3-12
SECTION I. REPAIR PARTS; SPECIAL TOOLS; TEST,
MEASUREMENT, AND DIAGNOSTIC EQUIPMENT (TMDE); AND SUPPORT EQUIPMENT
3-1.
Common Tools and Equipment. For authorized common tools and equipment, refer to the Modified Table
of Organization and Equipment (MTOE), CTA 50-970, Expendable/Durable Items (Except: Medical Class V,
Repair Parts, and Heraldic Items), CTA 50-909, Field and Garrison Furnishings and Equipment or CTA 8-100,
Army Medical Department Expendable/Durable Items, as applicable to your unit.
3-2.
Special Tools, TMDE, and Support Equipment. Special tools; test, measurement, and diagnostic
equipment; and support equipment requirements are listed and illustrated in the Repair Parts and Special Tools
List (RPSTL), TM 55-1905-223-24P-1. These items are also listed in the Maintenance Allocation Chart (MAC),
Appendix B of this manual.
3-3.
Repair Parts. Repair parts are listed and illustrated in the Repair Parts and Special Tools List (RPSTL),
TM 55-1905-223-24P.
SECTION II. SERVICE UPON RECEIPT
Checking Unpacked Equipment.
3-4.
a. Inspect the equipment for damage incurred during shipment. If the equipment has been damaged, report
the damage in accordance with the instructions of DA PAM 750-8.
b. Check the equipment against the packing slip to see if the shipment is complete. Report all discrepancies
in accordance with the instructions of DA PAM 750-8.
c.
Check to see whether the equipment has been modified.
d. Remove and replace protective caps, plugs, inserts, wrappings, and tape when inspection/inventory is
completed. Inspect piping openings for damage. Wipe off dirt, grease, or protective films at time of
installation.
e. Remove chocks from resilient mounted components.
3-5.
Initial Setup Procedure. Includes operational checks and inspections that are not performed for a routine
startup. Direct support maintenance personnel will perform initial setup in accordance with the operator's manual
TM 55-1905-223-10.
3-6.
Normal Startup. Refer to operator's manual TM 55-1905-223-10.
3-7.
Shutdown Procedure (Usual or Unusual). Refer to operator's manual TM 55-1905-223-10.
3-1
TM 55-1905-223-24-19
SECTION III. INTERMEDIATE DIRECT SUPPORT PREVENTIVE MAINTENANCE
CHECKS AND SERVICES (PMCS)
3-8.
General. Refer to Chapter 2, Section III (Table 2-1).
SECTION IV. INTERMEDIATE DIRECT SUPPORT TROUBLESHOOTING
3-9.
Troubleshooting. Both a symptom index and a troubleshooting table are provided. The symptom index
will help you locate the information you need for troubleshooting.
SYMPTOM INDEX
Troubleshooting
Procedure
(Table 3-1)
OCM
High ppm in effluent and system continues to discharge
overboard.
Item 2
OCM not operational during OWS operation.
Item 3
WARNING 2 and WARNING 3 (Red LEDs) illuminated.
Item 4
OWS System
OWS tank does not reach operating vacuum pressure.
Item 1
Table 3-1 lists the common fault conditions that may be found during operation or maintenance of the equipment.
Look for causes and do corrective actions in the order listed. This manual cannot list every symptom that may
show up, and it cannot list all the possible causes and corrective actions. If a symptom is not listed, or if it persists
after you have performed the corrective actions, notify your supervisor.
3-2
TM 55-1905-223-24-19
Table 3-1. Direct Support Troubleshooting
Malfunction
Test or Inspection
Corrective Action
NOTE
During all troubleshooting, it is assumed vessel power source is operating
correctly, start up and shut down procedures correctly followed and all applicable
valves are open.
1. OWS tank does not reach operating vacuum pressure.
STEP 1. Check OWS piping connections for leaks.
Tighten leaking piping, or replace flange gaskets as required.
STEP 2. Check OWS tank cover for secure fasteners and seal around sealing area.
Replace OWS tank if distorted beyond repair (Paragraph 3-11).
2. High ppm in effluent and system continues to discharge overboard.
STEP 1. Check OCM SDA calibration date and last replacement.
Replace SDA, PCB and elapsed timer if calibration is expired (Paragraph 3-12).
3. OCM not operational during OWS operation.
_________
WARNING
Always ensure affected circuits have been secured, locked out and tagged out.
Performing maintenance with circuits energized may result in death or injury to
personnel or equipment damage.
STEP 1. Ribbon Cable Assembly between Power PCB and Processor PCB is disconnected or damaged.
Verify that cable is connected (Figure 3-2).
Visually check for damage and check continuity as required (Paragraph 3-12).
Fasten cable at both PCB connections and replace as required.
STEP 2. Cable Assembly between Power PCB and Sample/Detection Assembly disconnected, loose, or
defective.
Verify that cable is connected (Figure 3-2). Visually check for damage and check continuity as required
(Paragraph 3-12).
Fasten cable at both PCB connections and replace as required.
STEP 3. Pressure Switch on Sensor Detection Assembly is defective.
Switch OCM into MANUAL mode; verify POWER ON indicator illuminates in MANUAL. Switch OCM to
AUTO mode; verify POWER ON indicator illuminates. If OCM is in AUTO position and indicator does not
illuminate with 5 to 15 psi sample inlet pressure; Check continuity of switch contacts (N.O., N.C. and C).
Use flushing water (OWS-54) to test automatic on/off control.
Replace with Calibration Kit (Paragraph 3-12).
3-3
TM 55-1905-223-24-19
Table 3-1. Direct Support Troubleshooting
Malfunction
Test or Inspection
Corrective Action
3. OCM not operational during OWS operation. (cont).
_________
WARNING
Under no circumstances should repair or adjustment of energized equipment be
attempted alone. The immediate presence of someone capable of rendering aid
is required. Before making adjustments, be sure to protect against grounding. If
possible, adjustments should be made with one hand, with the other hand free
and clear of equipment. Even when power has been removed from equipment
circuits, dangerous potentials may still exist due to retention of charges by
capacitors. Circuits must be grounded and all capacitors discharged prior to
attempting repairs.
STEP 4. Power PCB Assembly defective.
Measure +5 VDC and -5 VDC between test points and GND on the Power PCB Assembly. It is defective
if the proper voltage is not measured.
Replace the Power PCB Assembly (Paragraph 3-12).
STEP 5. Processor PCB Assembly defective.
Check the system for proper operation with the new board before securing it tightly into place.
Replace with Calibration Kit (Paragraph 3-12).
4. WARNING 2 and WARNING 3 (Red LEDs) illuminated.
STEP 1. SDA, ETI and Processor PCB are defective. All other troubleshooting efforts have not corrected
symptom.
Replace components using Calibration Kit (Paragraph 3-12).
SECTION V. INTERMEDIATE DIRECT SUPPORT MAINTENANCE PROCEDURES
3-10. General. This section provides direct support maintenance for the oil-water separator tank and oil content
monitor assembly. To review the principles of operation for the oil-water separator subsystem, refer to Chapter 1,
Section III. Removal and replacement tasks for the oil-water separator tank and repair tasks for the oil content
monitor are in the following paragraphs.
3-4
TM 55-1905-223-24-19
3-11. Oil-Water Separator Tank. (Figure 3-1)
This task covers:
a. Removal,
b. Replacement.
INITIAL SETUP
Tools
Equipment Condition
Tool Kit, General Mechanic's,
5180-00-699-5273
Lifting Sling, 3940-01-183-9412
Hoist, Chain, Hand-Operated, Hook Chain Fall 1/2 Ton,
3950-00-235-4236
Torque Wrench (30-300 inch-lbs.), 5120-01-092-3278
Torque Wrench (30-300 ft-lbs), 5120-01-125-5190
TM 55-1905-223-10, Oil-Water Separator Shutdown
and Tagged “Out of Service – Do Not Operate”
(FM 55- 502).
Materials/Parts
Oil-Water Separator, P/N 689642
Cleaning Solvent, Item 1, Appendix C
Rags, Wiping, Item 12, Appendix C
Warning Tags, Item 19, Appendix C
REMOVAL
_________
WARNING
Always ensure affected circuits have been secured, locked out and tagged out.
Performing maintenance with circuits energized may result in death or injury to
personnel or equipment damage.
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. In accordance with TB 43-0218, ensure that all
locking hardware is discarded upon removal and replaced with new hardware.
a. Drain water from water pump by opening OWS-62 (10, Figure 3-1).
b. Drain OWS tank by opening valves OWS-14 (6), OWS-15 (7) and OWS-16 (8).
c.
Remove four nuts, lockwashers and bolts each from flanges and disconnect flanges at the OWS tank
influent inlet (9), effluent discharge (3), OWS drain valves (6, 7 and 8) and the oil discharge line (1).
d. Identify, tag and disconnect all attached electrical cables.
e. Disconnect piping from air bleed (12) and oil bleed (11).
f.
Remove eight bolts securing OWS tank skid base (5) to deck plate.
g. Attach lifting sling to four lifting points on skid base (5).
h. Remove oil-water separator.
3-5
TM 55-1905-223-24-19
_________
WARNING
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. In accordance with TB 43-0218, ensure that all
locking hardware is discarded upon removal and replaced with new hardware.
REPLACEMENT
a. Position oil-water separator properly and attach skid base (5) to deck plate with eight bolts. Refer to
Appendix D for proper torque of fasteners.
b. Remove lifting sling from four lifting points on skid base (5).
c.
Mate up flanges for OWS tank influent inlet (9), effluent discharge (3), OWS drain valves (6, 7 and 8) and
the oil discharge line (1) install with new flange gaskets. Install four bolts, new lockwashers and nuts
each from flanges and tighten to torque indicated in Appendix D of this manual for the particular fastener
used.
d. Connect piping to air bleed (12) and oil bleed (11).
e. Reconnect all electrical cables.
f.
3-6
Operate the OWS (Paragraphs 2-6 through 2-8) and check for proper operation.
TM 55-1905-223-24-19
Figure 3-1. Oil-Water Separator (Sheet 1 of 2).
3-7
TM 55-1905-223-24-19
LEGEND:
1. OIL DISCHARGE
2. PURGE WATER INLET
3. EFFLUENT DISCHARGE
4. ZINC ANODE
5. OWS TANK SKID BASE
6. OWS-14 TANK DRAIN
7. OWS-15 TANK DRAIN
8. OWS-16 TANK DRAIN
9. OWS TANK INFLUENT INLET
10. OWS-62 LOW POINT DRAIN
11. OIL BLEED
12. AIR BLEED
Figure 3-1. Oil-Water Separator (Sheet 2 of 2).
3-8
TM 55-1905-223-24-19
3-12. Oil Content Monitor Assembly. (Figure 3-2)
This task covers:
a. Service,
b. Repair.
INITIAL SETUP
Tools
Equipment Condition
Tool Kit, General Mechanic's,
5180-00-699-5273
Allen Wrenches, 5120-01-087-3616
Tool Kit, Electrician’s,
5180-00-391-1087
TM 55-1905-223-10, oil-water separator shutdown
and tagged “Out of Service – Do Not Operate”
(FM 55- 502).
Materials/Parts
Calibration Kit, P/N AME-1385
Cleaning Solvent, Item 1, Appendix C
Rags, Wiping, Item 12, Appendix C
Silicone, RTV, Item 15, Appendix C
Warning tags, Item 19, Appendix C
SERVICE
To service the oil content monitor assembly; remove and replace the SDA, PCB and ETI as a calibrated set every
2,000 hours of operation or 2 years after calibration date, whichever occurs first.
REMOVAL (Figure 3-2)
_________
WARNING
Always ensure affected circuits have been secured, locked out and tagged out.
Performing maintenance with circuits energized may result in death or injury to
personnel or equipment damage.
CAUTION
The Turbidimeter (component of the SDA) and Processor PCB are factory
calibrated as a matched set. If either component requires replacement, the set
must be replaced. Do not separate or mix these components. Matched
calibration is necessary for proper operation and cannot be performed in the field.
NOTE
Ensure OCM Inlet Valve (OWS-52) (Figure 1-6) is shut.
a. Loosen handnuts (1) securing Sampling/Sensor Assembly enclosure door (2). Open door (2).
b. Locate SDA (10) on left-rear of enclosure (11).
c.
Disconnect SDA cable connector (4).
d. Remove mounting hardware (9) from SDA (9). Retain hardware for installation.
e. Lift SDA (10) up and away from the enclosure (11).
3-9
TM 55-1905-223-24-19
f.
Release tubing (5 and 7) from the quick-connect fittings (6 and 8) by compressing the quick connect fitting
collets and simultaneously pulling the tube in the opposite direction.
g. Locate Processor PCB (3) on enclosure door (2).
h. Disconnect ribbon cable connector from bottom-left of door (2).
i.
Unfasten mounting hardware and remove Processor PCB (3). Retain hardware for installation.
j.
Locate ETI (12).
k.
Remove old ETI (12) (pull out).
CAUTION
The Turbidimeter (component of the SDA) and Processor PCB are factory
calibrated as a matched set. If either component requires replacement, the set
must be replaced. Do not separate or mix these components. Matched
calibration is necessary for proper operation and cannot be performed in the field.
REPAIR
Repair of the oil content monitor is by replacement of the Calibration Maintenance Kit (SDA, PCB
and ETI).
CAUTION
The Turbidimeter (component of the SDA) and Processor PCB are factory
calibrated as a matched set. If either component requires replacement, the set
must be replaced. Do not separate or mix these components. Matched
calibration is necessary for proper operation and cannot be performed in the field.
REPLACEMENT
a. Apply small quantity of silicone adhesive (RTV) to underside of new ETI (12), and install onto Power
Supply PCB.
b. Install new Processor PCB (3). Do not tighten mounting hardware.
c.
Check that LEDs on front of PCB (3) are in alignment with the Main Indicator Display by looking through
the front of the display. Use gentle pressure to bend LEDs into alignment as required.
d. Tighten mounting hardware.
e. Connect ribbon cable connector.
f.
Push inlet (5) and drain (7) tubing into the SDA quick-connect fittings (8) until they stop.
g. Holding the SDA, insert tubes (5 and 7) into the enclosure quick connect fittings (6) mounted in the
sampling/sensor assembly.
h. Hold SDA (9) in position and refasten mounting hardware (8).
i.
Connect SDA cable connector (4) to OCM control panel.
j.
Perform UVA adjustment (Paragraph 2-26).
k.
Perform system Verification/Confidence Test (Paragraph 2-26).
l.
Close Sampling/Sensor Assembly enclosure door (2); tighten down handnuts (1).
3-10
TM 55-1905-223-24-19
LEGEND:
1. HANDNUTS
2. ENCLOSURE DOOR
3. PROCESSOR PCB
4. SDA CABLE CONNECTOR
5. INLET TUBING
6. ENCLOSURE QUICK-CONNECT FITTINGS
7. DRAIN TUBING
8. SDA QUICK-CONNECT FITTINGS
9. MOUNTING HARDWARE
10. SENSOR DETECTION ASSEMBLY (SDA)
11. ENCLOSURE
12. ELAPSED TIME METER (ETI)
Figure 3-2. Oil Content Monitor, Maintenance Kit Electrical Equipment.
3-11
TM 55-1905-223-24-19
SECTION VI. PREPARATION FOR STORAGE OR SHIPMENT
3-13. Administrative Stowage. Administrative storage of equipment issued to and used by Army activities will
have preventive maintenance performed in accordance with the Preventive Maintenance Checks and Services
(PMCS) charts before storing. When removing the equipment from administrative storage, the PMCS should be
performed to assure operational readiness. Prepare components for shipment or limited storage in accordance
with the following instructions.
a. Pumps should be completely drained and dried.
b. Shaft extensions and other exposed machine surfaces should be coated with an easily removable rust
preventive.
c.
Place a corrosion inhibitor in the pump casing, such as Gulf No-Rust Engine Oil, Grade 3, which conforms
to MIL-L-21260.
d. Cover components to protect them from weather and direct sunlight.
e. Either allow proper ventilation or tightly seal cover with a suitable amount of desiccant to ensure dryness.
f.
Storage locations for pumps that are near a source of vibration must be avoided.
g. Care should be taken to prevent extremes in temperature (below 32°F and above 110°F).
h. Shafts should be rotated 10-15 times, 2 or 3 times a month while in storage.
i.
3-12
If components(s) is/are to be in extended storage, repeat preparation procedures every 6 months.
TM 55-1905-223-24-19
CHAPTER 4
INTERMEDIATE GENERAL SUPPORT MAINTENANCE INSTRUCTIONS
Section I
Page
Repair Parts, Special Tools; Test, Measurement and
Diagnostic Equipment (TMDE); and Support Equipment ................................................ 4-1
Section II
Service Upon Receipt ...................................................................................................... 4-1
Section III
Intermediate General Support Preventive Maintenance
Checks and Services (PMCS).......................................................................................... 4-2
Section IV
Intermediate General Support Troubleshooting............................................................... 4-2
Section V
Intermediate General Support Maintenance Procedures ................................................ 4-2
Section VI
Preparation for Storage or Shipment ............................................................................... 4-2
SECTION I. REPAIR PARTS; SPECIAL TOOLS; TEST,
MEASUREMENT, AUD DIAGNOSTIC EQUIPMENT (TMDE); AND SUPPORT EQUIPMENT
4-1.
Common Tools and Equipment. For authorized common tools and equipment, refer to the Modified Table
of Organization and Equipment (MTOE), CTA 50-970, Expendable/Durable Items (Except: Medical Class V,
Repair Parts, and Heraldic Items), CTA 50-909, Field and Garrison Furnishings and Equipment or CTA 8-100,
Army Medical Department Expendable/Durable Items, as applicable to your unit.
4-2.
Special Tools, TMDE, and Support Equipment. Special tools; test, measurement, and diagnostic
equipment; and support equipment requirements are listed and illustrated in the Repair Parts and Special Tools
List (RPSTL), TM 55-1905-223-24P. These items are also listed in the Maintenance Allocation Chart (MAC),
Appendix B of this manual.
4-3.
Repair Parts. Repair parts are listed and illustrated in the Repair Parts and Special Tools List (RPSTL),
TM 55-1905-223-24P.
SECTION II. SERVICE UPON RECEIPT
4-4.
Checking Unpacked Equipment.
a. Inspect the equipment for damage incurred during shipment. If the equipment has been damaged, report
the damage in accordance with the instructions of DA PAM 750-8.
b. Check the equipment against the packing slip to see if the shipment is complete. Report all discrepancies
in accordance with the instructions of DA PAM 750-8.
c.
Check to see whether the equipment has been modified.
d. Remove and replace protective caps, plugs, inserts, wrappings, and tape when inspection/inventory is
completed. Inspect piping openings for damage. Wipe off dirt, grease, or protective films at time of
installation.
e. Remove chocks from resilient mounted components.
4-5.
Initial Setup Procedure. Includes operational checks and inspections that are not performed for a routine
startup. Direct support maintenance personnel will perform initial setup, refer to Chapter 2 of this
technical manual and the operator's manual TM 55-1905-223-10.
4-6.
Normal Startup. Direct support maintenance personnel will perform normal startup, refer to Chapter 2 of
this technical manual and the operator's manual TM 55-1905-223-10.
4-1
TM 55-1905-223-24-19
4-7.
Shutdown Procedure (Usual or Unusual). Direct support maintenance personnel will perform shutdown
procedure, refer to Chapter 2 of this technical manual and the operator's manual TM 55-1905-223-10.
SECTION III. INTERMEDIATE GENERAL SUPPORT PREVENTIVE
MAINTENANCE CHECKS AND SERVICES (PMCS)
4-8.
PMCS. There is no PMCS at the general support level. Refer to Chapter 2, Section III.
SECTION IV. INTERMEDIATE GENERAL SUPPORT TROUBLESHOOTING
4-9.
Troubleshooting. There is no troubleshooting at the general support level. Refer to Chapter 3,
Section IV.
SECTION V. INTERMEDIATE GENERAL SUPPORT MAINTENANCE PROCEDURES
4-10.
General. There are no maintenance procedures at the general support level. Refer to Chapter 3,
Section V.
SECTION VI. PREPARATION FOR STORAGE OR SHIPMENT
4-11.
4-2
Storage. Refer to Chapter 2, Section VI.
TM 55-1905-223-24-19
APPENDIX A
REFERENCES
A-1. Scope. This paragraph lists the manuals, bulletins, specifications, and miscellaneous publications
referenced in this manual or required for maintenance activities.
A-2. Field Manuals.
FM 4-25.11
FM 31-70
FM 55-501
FM 55-502
First Aid
Basic Cold Weather Manual
Marine Crewman's Handbook
Army Watercraft Safety
A-3. Technical Manuals.
TM 55-1905-223-10
TM 55-1905-223-24-18-1/2
TM 55-1905-223-24P-1/2/3/4
TM 750-244-3
TM 43-0139
Operator's Manual for Landing Craft, Utility (LCU)
LCU 2000 Class Basic Craft Maintenance Manual
Repair Parts and Special Tools List for the LCU 2000
Class Watercraft
Destruction of Army Materiel to Prevent Enemy Use
Painting Instructions for Army Materiel
A-4. Technical Bulletins.
TB 43-0144
TB 55-1900-207-24
TB 740-97-4
TB-55-1900-204-24
Painting of Watercraft
Treatment of Cooling Water in Marine Diesel Engines
Preservation of Vessels for Storage
Welding on Watercraft
A-5. Military Specifications.
MIL-PRF-16173
MIL-PRF-21260
MIL-PRF-32033
Corrosion Preventive Compound, Solvent Cutback,
Cold-Application
Lubricating Oil, Internal Combustion Engine,
Preservative Break-In
Lubricating Oil, General Purpose, Preservative (WaterDisplacing, Low Temperature)
A-6. Miscellaneous Publications.
DOD 4715.6-R1
DA PAM 750-8
LO 55-1905-223-12
AR 750-10
Regulations On Vessels Owned Or Operated By The
Department Of Defense
The Army Maintenance Management System (TAMMS)
Users Manual
Lubrication Order for the LCU 2000 Class Watercraft
Army Modification Program
A-7. Forms.
CTA 8-100
CTA 90-970
DA Form 2028
DA Form 2404/5988E
DA Form 2408-16
DA Form 2410
SF Form 368
Army Medical Department Expendable/Durable Items
Army Expendable/Durable Items
Recommended Changes to Equipment Technical
Publications Blank Forms
Equipment Inspection and Maintenance Worksheet
Logsheet
Logsheet
Product Quality Deficiency Report
A-1/(A-2 blank)
TM 55-1905-223-24-19
APPENDIX B. MAINTENANCE ALLOCATION CHART (MAC)
SECTION I. INTRODUCTION
B-1.
THE ARMY MAINTENANCE SYSTEM MAC.
a. This introduction (Section I) provides a general explanation of all maintenance and repair functions
authorized at various maintenance levels under the standard Army Maintenance System concept.
b. The Maintenance Allocation Chart (MAC) in Section II designates overall authority and responsibility for
the performance of maintenance functions on the identified end item or component. The application of the
maintenance functions to the end item or component will be consistent with the capacities and capabilities
of the designated maintenance levels, which are shown in the MAC in column (4) as:
Unit - includes two subcolumns: C (operator/crew) and O (unit) maintenance.
Direct Support - includes an F subcolumn.
General Support - includes an H subcolumn.
Depot - includes a D subcolumn.
c. Section lll lists the tools and test equipment (both special tools and common tools sets) required for each
maintenance function as referenced from Section II.
d. Section IV contains supplemental instructions and explanatory notes for a particular maintenance function
as referenced from Section II.
B-2.
MAINTENANCE FUNCTIONS. Maintenance functions will be limited to and defined as follows:
a. Inspect. To determine the serviceability of an item comparing its physical, mechanical, and/or electrical
characteristics with established standards through examination (i.e., by sight, sound, or feel).
b. Test. To verify serviceability by measuring the mechanical, pneumatic, hydraulic, or electrical
characteristics of an item and comparing those characteristics with prescribed standards.
c. Service. Operations required periodically to keep an item in operating condition, i.e., to clean (includes
decontamination, when required), to replace filters, to preserve, to drain, to paint, or to replenish fuel,
lubricants, chemical fluids, or gases.
d. Adjust. To maintain or regulate, within prescribed limits, by bringing into proper or exact position, or by
setting the operating characteristics to specified parameters.
e. Align. To adjust specified variable elements of an item to bring about optimum or desired performance.
f. Calibrate. To determine and cause corrections to be made or to be adjusted on instruments or test,
measuring, and diagnostic equipment used in precision measurement. Consists of comparisons of two
instruments, one of which is a certified standard of known accuracy, to detect and adjust any discrepancy
in the accuracy of the instrument being compared.
g. Remove/install. To remove and install the same item when required to perform service or other
functions. Install may be the act of emplacing, seating, or fixing into position a spare, repair part, or
module (component or assembly) in a manner to allow the proper functioning of an equipment or system.
h. Replace. To remove an unserviceable item and install a serviceable counterpart in its place. Replace is
authorized by the MAC and is shown as the 3rd position code of the SMR code.
1
2
i. Repair. The application of maintenance services including fault location/troubleshooting ,
3
4
removal/installation, and disassembly/assembly procedures, and maintenance actions to identify
troubles and restore serviceability to an item by correcting specific damage, fault, malfunction, or failure in
a part, subassembly, module (component or assembly), and item, or system.
j. Overhaul. That maintenance effort (service/action), prescribed to restore an item to a completely
serviceable/operational condition as required by maintenance standards in appropriate technical
publications (i.e., DMWR). Overhaul is normally the highest degree of maintenance performed by the
Army. Overhaul does not normally return an item to like new condition.
1
Service - Inspect, test, service, adjust, align, calibrate, and/or replace.
Fault location/troubleshooting - The process of investigating and detecting the cause of equipment
malfunctioning; the act of isolating a fault within a system or unit under test (UUT).
3
Disassembly/assembly - The step-by-step breakdown (taking apart) of a spare/functional group coded item to the
level of its least component, that is assigned an SMR code for the level of maintenance under consideration (i.e.,
identification as maintenance significant).
4
Actions - Welding, grinding, riveting, straightening, facing, machining, and/or resurfacing.
2
B-1
TM 55-1905-223-24-19
k.
B-3.
Rebuild. Consists of those service/actions necessary for the restoration of unserviceable equipment to a
like new condition in accordance with original manufacturing standards. Rebuild is the highest degree of
material maintenance applied to Army equipment. The rebuild operation includes the act of returning to
zero those age measurements (hours, miles, etc.) considered in classifying Army equipment and
components.
EXPLANATION OF COLUMNS IN THE MAC, SECTION II
a. Column 1 - Group Number. Column 1 lists functional group code numbers, the purpose of which is to
identify maintenance significant components, assemblies, subassemblies, and modules with the next
higher assembly.
b. Column 2 - Component/Assembly. Column 2 contains the names of components, assemblies,
subassemblies, and modules for which maintenance is authorized.
c. Column 3 - Maintenance Function. Column 3 lists the functions to be performed on the item listed in
column 2. (For detailed explanation of these functions, see Paragraph B-2.)
d. Column 4 - Maintenance Category. Column 4 specifies, by the listing of a work time figure in the
appropriate subcolumn(s), the category of maintenance authorized to perform the function listed in
Column 3. This figure represents the active time required to perform that maintenance function at the
indicated category of maintenance. If the number or complexity of the tasks within the listed maintenance
function varies at different maintenance categories, appropriate work time figures will be shown for each
category. The work time figure represents the average time required to restore an item (assembly,
subassembly, component, module, end item, or system) to a serviceable condition under typical field
operating conditions. This time includes preparation time (including any necessary
disassembly/assembly time), troubleshooting/fault location time, and quality assurance/quality control
time in addition to the time required to perform the specific tasks identified for the maintenance functions
authorized in the maintenance allocation chart. The symbol designations for the various maintenance
categories are as follows:
C Operator or Crew
O Unit Maintenance
F Direct Support Maintenance (DS)
H General Support Maintenance (GS)
D Depot Maintenance
e. Column 5 - Tools and Equipment. Column 5 specifies, by number code, those common tool sets (not
individual tools); special tools; Test, Measurement, and Diagnostic Equipment (TMDE); and support
equipment required to perform the designated function, which shall be keyed to the tools listed in
Section III.
f. Column 6 - Remarks. This column shall, when applicable, contain a letter code, in alphabetic order, which
shall be keyed to the remarks contained in Section IV.
B-4.
EXPLANATION OF COLUMNS IN TOOL AND TEST EQUIPMENT REQUIREMENTS, SECTION Ill.
a. Column I - Reference Code. The tool and test equipment reference code correlates with a number code
used in the MAC, Section II, Column 5.
b. Column 2 - Maintenance Category. The lowest category of maintenance authorized to use the tool or test
equipment.
c. Column 3 - Nomenclature. Name or identification of the tool or test equipment.
d. Column 4 - National Stock Number. The National Stock Number (NSN) of the tool or test equipment.
e. Column 5 - Tool Number. The manufacturer's part number.
B-5.
EXPLANATION OF COLUMNS IN REMARKS, SECTION IV.
a. Column 1- Reference Code. The letter code recorded in Column 6, Section II.
b. Column 2 - Remarks. This column lists information pertinent to the maintenance function being performed
as indicated in the MAC, Section II.
B-2
TM 55-1905-223-24-19
MAINTENANCE ALLOCATION CHART
FOR
OIL-WATER SEPARATOR SYSTEM (cont)
(1)
GROUP
NUMBER
(2)
COMPONENT
ASSEMBLY
(3)
MAINTENANCE
FUNCTION
19
OIL-WATER
SEPARATOR
SYSTEM
INSPECT
(4) MAINTENANCE LEVEL
FIELD
SUSTAINMENT
UNIT
DS GS
DEPOT
C
O
F
H
D
0.1
1901
OWS TANK
INSPECT
0.1
SERVICE
(5)
TOOLS
AND
EQPT
1
0.5
1
8.0
1,3,4
REPLACE
190101
1902
190201
1903
190301
1904
1905
OIL LEVEL
SENSORS
OWS PUMP
OWS PUMP
MOTOR
DIRTY OIL PUMP
DIRTY OIL PUMP
MOTOR
CONTROL PANEL
GAUGE PANEL
(ALL SYSTEM
GAUGES)
8.0
1,3,4,5,9
REPAIR
16.0
1,3,4,5,9
SERVICE
0.5
1
REPLACE
0.5
1,10,11
REPAIR
0.5
1,10,11
INSPECT
0.1
1
REPLACE
1.5
1,2,6
REPAIR
0.5
1,2,6
ALIGN
1.0
1,7,2
REPLACE
1.5
1,6
REPAIR
3.0
1,6
ADJUST
1.0
1
REPLACE
2.0
1
REPAIR
4.0
1
ALIGN
1.0
1,7,2
REPLACE
1.5
1,6
REPAIR
3.0
1,6
INSPECT
INSPECT
0.1
0.2
(6)
REMARKS
A
1
0.1
REPAIR
2.0
INSPECT
0.1
ADJUST
0.2
REPLACE
1.0
1,11,12
1
B
B-3
TM 55-1905-223-24-19
MAINTENANCE ALLOCATION CHART
FOR
OIL-WATER SEPARATOR SYSTEM (cont)
(1)
GROUP
NUMBER
1906
1907
1908
1909
1910
1911
1912
B-4
(2)
COMPONENT
ASSEMBLY
MOTORIZED
VALVES
DIVERTER VALVE
DUPLEX
STRAINER
RELIEF VALVES
OIL CONTENT
MONITOR
ASSEMBLY
REMOTE
INDICATOR
(ALARM)
ASSEMBLY
REMOTE RELAY
ASSEMBLY
(3)
MAINTENANCE
FUNCTION
SERVICE
(4) MAINTENANCE LEVEL
FIELD
SUSTAINMENT
UNIT
DS
GS
DEPOT
C
O
F
H
D
0.5
(5)
TOOLS
AND
EQPT
ADJUST
0.5
1
REPLACE
1.5
1
REPAIR
2.0
1
INSPECT
0.1
0.1
REPLACE
2.0
1
REPAIR
4.0
1
INSPECT
0.1
SERVICE
0.3
1
REPAIR
3.0
INSPECT
0.3
0.3
1
REPLACE
0.5
1
0.5
1,11
0.3
TEST
1.0
SERVICE
1.5
ADJUST
1.0
REPAIR
2.0
INSPECT
C
1
TEST
INSPECT
(6)
REMARKS
1.0
B
1,8,11
11
1.0
1,8,11,12
D
0.3
REPAIR
1.0
INSPECT
0.1
ADJUST
0.5
REPAIR
0.5
1
1
B
TM 55-1905-223-24-19
MAINTENANCE ALLOCATION CHART
FOR
OIL-WATER SEPARATOR SYSTEM (cont)
(1)
GROUP
NUMBER
1913
1914
1915
(2)
COMPONENT
ASSEMBLY
WATER POLISHER
(3)
MAINTENANCE
FUNCTION
INSPECT
(4) MAINTENANCE LEVEL
FIELD
SUSTAINMENT
UNIT
DS
GS
DEPOT
C
O
F
H
D
0.1
(5)
TOOLS
AND
EQPT
(6)
REMARKS
SERVICE
2.0
1
REPAIR
2.0
1
DIFFERENTIAL
PRESSURE
SWITCH
ADJUST
0.5
1
REPLACE
1.0
1
B
CHECK VALVE
INSPECT
0.2
REPLACE
1.0
1
B
B-5
TM 55-1905-223-24-19
SECTION Ill. TOOLS AND TEST EQUIPMENT REQUIREMENTS
FOR
OIL-WATER SEPARATOR SYSTEM
TOOL OR
TEST
EQUIPMENT
REF
CODE
B-6
MAINTENANCE
CATEGORY
NOMENCLATURE
NATIONAL STOCK
NUMBER
PART NUMBER
1
O, F
Tool Kit, General Mechanic’s
5180-00-629-5273
(50980) SC-518090-CL-N05
2
F, H
Tool Set, Measuring, Machinist's
5280-00-278-9919
(50980) SC-528095-CL-A01-HR
3
O, F
Torque Wrench (30 - 300 inch
pounds)
5120-01-092-3278
(08194) 2002MR
4
O, F
Torque Wrench (30 - 300 foot
pounds)
5120-01-125-5190
(05047) B107.14M
5
O, F
Lifting Sling
3940-01-183-9412
(15434) 3375958
6
F
Puller, Mechanical, Gear and
Bearing
5120-00-288-7710
(81348) GGG-P781
7
F
Dial Indicator
5210-00-277-8840
(57163) 196A
8
F
Allen Wrenches
5120-01-087-3616
(55719)
AWM110DK
9
O, F
Hoist, Chain, Hand-Operated,
Hook Chain fall 1/2 Ton
SPNSN, 1/2 Ton
3950-00-235-4236
(81349) MILH904
10
O, F
Multimeter
6625-01-265-6000
(80058) AN/PSM45A
11
O, F
Tool Kit, Electrician’s
5180-00-391-1087
(80244) 5180-00391-1087
12
O, F
Iron, Soldering
3439-00-204-3858
(81349) W-S-570
TM 55-1905-223-24-19
SECTION IV. REMARKS
FOR
OIL-WATER SEPARATOR SYSTEM
REFERENCE
CODE
REMARKS
A
SEMI-ANNUAL:
CHECK ALIGNMENT OF PUMP AND MOTOR. SHIM UP IF NECESSARY IF
MISALIGNMENT OCCURS FREQUENTLY, INSPECT THE ENTIRE PIPING SYSTEM.
UNBOLT PIPING AT SUCTION AND DISCHARGE FLANGES TO SEE IF IT SPRINGS
AWAY THEREBY INDICATING STRAIN ON THE CASING. INSPECT ALL PIPING
SUPPORTS FOR SOUNDNESS AND EFFECTIVE SUPPORT OF LOAD.
ANNUALLY:
REMOVE THE ROTATING ELEMENT INSPECT THOROUGHLY FOR WEAR, AND
ORDER REPLACEMENT PARTS IF NECESSARY. CHECK WEARING CLEARANCES.
B
REPAIR IS BY REPLACEMENT.
C
SERVICE IS ACCOMPLISHED THROUGH PREVENTIVE MAINTENANCE CHECKS AND
SERVICES (PMCS), OF TM 55-1905-223-10 AND MAINTENANCE PROCEDURES.
D
THIS ITEM IS A CANDIDATE FOR DIRECT EXCHANGE WITH THE VENDOR.
B-7/(B-8 blank)
TM 55-1905-223-24-19
APPENDIX C
EXPENDABLE/DURABLE SUPPLIES AND MATERIALS LIST
SECTION I. INTRODUCTION
C-1.
Scope. This appendix lists expendable supplies and materials you will need to operate and maintain the
equipment. These items are authorized to you by CTA 50-970, Expendable/Durable Items (Except Medical, Class
V, Repair Parts, and Heraldic Items), or CTA 8-100 Army Medical Department Expendable/Durable Items.
C-2.
Explanation of Columns. The following provides an explanation of columns
found in the tabular listings.
a. Column (1) - Item Number. This number is assigned to the entry in the listing and is referenced in the
narrative instructions to identify the material (for example, "Use cleaning compound, item 5, App. C").
b. Column (2) - Level. This column identifies the lowest level of maintenance that requires the listed item.
C - Operator/Crew
O - Organizational Maintenance
F - Direct Support Maintenance
H - General Support Maintenance
c. Column (3) National Stock Number. This is the National stock number assigned to the item; use it to request
or requisition the item.
d. Column (4) - Description. Indicates the Federal item name and, if required, a description to identify the item.
The last line for each item indicates the Federal Supply Code for Manufacturers (FSCM) in parenthesis followed
by the part number.
e. Column (5) - Unit of Measure (U/M). Indicates the measure used in performing the actual maintenance
function. This measure is expressed by a two-character alphabetical abbreviation (for example, ea, in, pr). If the
unit of measure differs from the unit of issue, requisition the lowest unit of issue that will satisfy your requirements.
C-1
TM 55-1905-223-24-19
SECTION II. EXPENDABLE/DURABLE SUPPLIES AND MATERIALS LIST
(1)
ITEM
NUMBER
(2)
LEVEL
STOCK
1
F
6850-01-278-4421
Cleaning Compound, Solvent
(IBTR5) 997140
GL
2
F
6515-00-225-9648
Cotton Swab
(81348) GGA00616
BX
3
O
Epoxy, Polyamide (FlexKote #707)
GL
4
F
5330-00-641-1193
Gasket Material
(81348) HH-P-46
SH
5
O
9150-00-180-6382
Grease
(81349) MIL-PRF-24139
CN
6
O
4930-00-287-5419
Grease Gun
(58536) A-A-50477
EA
7
O
5970-00-109-3303
Insulation Sleeving, Electrical
(1001) 2674051
EA
8
F
9150-00-235-5555
Lubricating Grease
(81349) MIL-DTL-23549
LB
9
F
4940-01-123-4843
Lubricating Sealant
(59678) 13222E6227
GL
10
H
9150-00-111-3199
Oil
(81349) MIL-L-21260
CN
11
F
9920-00-292-9946
Pipe Cleaner
(19203) 840507
BX
12
F
7920-00-205-1711
Rags, Wiping
(81349) DDD-R-30
EA
13
F
1680-01-194-9799
Rubber Gloves
EA
14
H
Shim
EA
15
O
9160-01-515-2484
Silicone, RTV
(45152) 3119525
TU
16
O
3439-01-011-7281
Solder, Tin Alloy
(81346) ASTM B32
LB
17
O
4921-00-381-2733
Straight Edge
(10001) 692117
EA
18
O
8030-00-899-3534
Tape, Teflon
(81349) MIL-T-27730
RO
19
O
2835-00-015-0246
Warning Tag
(70210) S8145-55
EA
C-2
(3)
NATIONAL
NUMBER
(4)
DESCRIPTION
(5)
U/M
TM 55-1905-223-24-11
APPENDIX D
TORQUE VALUES
Scope. SAE capscrews are graded according to the strength of the capscrew. They are marked on the
D-1.
head so the correct strength and torque value are known. The tables in this appendix will list the capscrew
markings with correct torque values as well as values for pipe plugs and metric bolts.
CAUTION
When replacing capscrews, always use a capscrew of the same measurement
and strength as the capscrew being replaced. Using incorrect capscrews can
result in equipment damage. Bolts threaded into aluminum require much less
torque.
NOTE
Always use torque values listed in the tables when specific torque values are
unknown. The torque values listed in the tables are based on the use of
lubricated threads.
Table D-1. Capscrew Markings and Torque Values
Capacity Body
siz
e
Inches-Thread
1/4
5/16
3/8
7/16
1/2
9/16
5/8
3/4
7/8
1.0
-29
-28
-18
-24
-16
-24
-14
-20
-13
-20
-12
-18
-11
-18
-10
-16
-9
-14
-8
-14
SAE Grade # 5
Cast Iron or Steel
Ft-Lb
8
10
17
19
31
35
49
55
75
85
110
120
150
170
270
295
395
435
590
660
TORQUE
kgm
Nm
1.1064
10.8465
1.3830
13.5582
2.3511
23.0489
2.6277
25.7605
4.2873
42.0304
4.8405
47.4536
6.7767
66.4351
7.6065
74.5700
10.3725 101.6863
11.7555 115.2445
15.2130 149.1380
16.5960 162.6960
20.7450 203.3700
23.5110 230.4860
37.3410 366.0660
40.7985 399.9610
54.6285 535.5410
60.1605 589.7730
81.5970 799.9220
91.2780 849.8280
SAE Grade # 6 or # 7
Cast Iron or Steel
Ft-Lb
10
TORQUE
kgm
Nm
1.3630
13.5582
19
2.6277
25.7605
34
4.7022
46.0978
55
7.6065
74.5700
85
11.7555
115.2445
120
16.5960
162.6960
167
23.0961
226.4186
280
38.7240
379.6240
440
60.8520
596.5520
660
91.2780
894.8280
SAE Grade #8
Cast Iron or Steel
Ft-lb
12
14
24
27
44
49
70
78
105
120
155
170
210
240
375
420
605
675
910
990
TORQUE
kgm
Nm
1.6596
16.2698
1.9362
18.9815
3.3192
32.5396
3.7341
36.6071
6.0852
59.6560
6.7767
66.4351
9.6810
94.9073
10.7874
105.753
14.5215
142.3609
16.5860
162.6960
21.4365
210.1490
23.5110
230.4860
29.0430
284.7180
33.1920
325.3920
51.8625
508.4250
58.0860
568.4360
83.6715
820.2590
93.3525
915.1650
125.8530 1233.7780
136.9170 1342.2420
Capscrew Head
Markings
OR
OR
D-1
TM 55-1905-223-24-19
Table D-2. Pipe Plug Torque Values
Thread
Size
Actual
Thread O.D
in
1/16
1/8
1/4
3/8
1/2
3/4
1
1-1/4
1-1/2
Nm
8.1
10.4
13.7
17.3
21.6
26.7
33.5
42.2
48.3
(in)
(0.32)
(0.41)
(0.54)
(0.68)
(0.85)
(1.05)
(1.32)
(1.66)
(1.90)
In Cast Iron or
Steel Components
Torque
Nm
(ft-lbs)
15
(10)
20
(15)
25
(20)
35
(25)
55
(40)
75
(55)
95
(70)
115
(85)
135
(100)
In Aluminum Components
Torque
Nm
(ft-lbs)
5
(45 in-lbs)
15
(10)
20
(15)
25
(20)
35
(25)
45
(35)
60
(45)
75
(55)
85
(65)
Table D-3. Metric Bolt Torque Values
Cast Iron or Steel
Thread for general
purposes
(size x pitch (mm)
6 x 1.0
8 x 1.25
10 x 1.25
12 x 1.25
14 x 1.5
16 x 1.5
18 x 1.5
20 x 1.5
22 x 1.5
24 x 1.5
D-2
Head Mark 4
Torque
ft-lb.
2.2 to 2.9
5.8 to 8.7
12 to 17
21 to 32
35 to 52
51 to 77
74 to 110
110 to 140
150 to 190
190 to 240
(Nm)
(3.0 to 3.9)
(7.9 to 12)
(16 to 23)
(29 to 43)
(48 to 70)
(67 to 100)
(100 to 150)
(150 to 190)
(200 to 260)
(260 to 320)
Head Mark 7
Torque
ft-lb.
3.6 to 5.8
9.4 to 14
20 to 29
35 to 53
57 to 85
90 to 120
130 to 170
190 to 240
250 to 320
310 to 410
(Nm)
(4.9 to 7.8)
(13 to 19)
(27 to 39)
(47 to 72)
(77 to 110)
(130 to 160)
(180 to 230)
(160 to 320)
(340 to 430)
(420 to 550)
TM 55-1905-223-24-19
GLOSSARY
A
A/R
AME
AMP
ASSY
ASW
AUTO
BT
CN
COV
D
EA
EIR
ETI
EOS
DP
F
FM
FSCM
FT
FT-LBS
GL
GPM
HG
HZ
IN
IN-LBS
KGM
LBS
LCD
LED
LO
LT
M
MAC
MM
MTOE
Nm
NMP
NSN
OCM
OD
OWS
P/N
PB
PCB
PDQR
PG
PH
PMCS
PPM
PSI
PSIG
Q
RPSTL
S
SAE
ANNUAL
AS REQUIRED
ADVANCED MARINE TECHNOLOGY INC
AMPERE
ASSEMBLY
AUXILIARY SEAWATER
AUTOMATIC
BOTTLE
CAN
CUTOUT VALVE
DAILY
EACH
EQUIPMENT IMPROVEMENT RECOMMENDATIONS
ELAPSE TIMER
ENGINEERING OPERATING STATION
DIFFERENTIAL PRESSURE
FAHRENHEIT
FIELD MANUAL
FEDERAL SUPPLY CODE OF MANUFACTURERS
FOOT/FEET
FOOT POUNDS
GALLON
GALLONS PER MINUTE
MERCURY
HERTZ
INCH
INCH POUNDS
KILOGRAM
POUNDS
LIQUID CRYSTAL DISPLAY
LIGHT EMITTING DIODE
LUBE OIL
LIGHT
MONTHLY
MAINTENANCE ALLOCATION CHART
MILLIMETER
MODIFIED TABLE OF ORGANIZATION AND EQUIPMENT
NEWTON METER
NATIONAL MAINTENANCE POINT
NATIONAL STOCK NUMBER
OIL CONTENT MONITOR
OUTSIDE DIAMETER
OIL-WATER SEPARATOR
PART NUMBER
PUSH BUTTON
PRINTED CIRCUIT BOARD
PRODUCT QUALITY DEFICIENCY REPORT
PAGE
PHASE
PREVENTIVE MAINTENANCE CHECKS AND SERVICES
PARTS PER MILLION
POUNDS PER SQUARE INCH
POUND PER SQUARE INCH GAUGE
QUARTERLY
REPAIR PARTS AND SPECIAL TOOLS LIST
SEMI-ANNUAL
SOCIETY OF AUTOMOTIVE ENGINEERS
Glossary-1
TM 55-1905-223-24-19
SDA
SH
SS
STBD
SW
TAMMS
TM
TMDE
U/M
UVA
V
VAC
VDC
W
WCA
Glossary-2
SENSOR DETECTION ASSEMBLY
SHEET
SWITCH
STARBOARD
SEAWATER
THE ARMY MAINTENANCE MANAGEMENT SYSTEM
TECHNICAL MANUAL
TEST, MEASUREMENT AND DIAGNOSTIC EQUIPMENT
UNIT OF MEASURE
ULTRASONIC VIBRATOR ASSEMBLY/SUBASSEMBLY
VOLTS
VOLTS ALTERNATING CURRENT
VOLTS DIRECT CURRENT
WEEKLY
WARRANTY CLAIM ACTION
TM 55-1905-223-24-19
ALPHABETICAL INDEX
Subject, Paragraph
Subject, Paragraph
A
E
Administrative Storage; 2-32, 3-13
Equipment Data; 1-9
C
G
Characteristics, Capabilities and Features; 1-7
Common Tools and Equipment; 2-1, 3-1, 4-1
Control Panel
Inspect; 2-20
Removal; 2-20
Repair; 2-20
Replacement; 2-20
Service; 2-20
Checking Unpacked Equipment; 2-4, 3-4, 4-4
Check Valve
Inspect; 2-31
Removal; 2-31
Repair; 2-31
Replacement; 2-31
Gauge Panel (All System Gauges)
Adjust; 2-21
Inspect; 2-21
Removal; 2-21
Replacement; 2-21
General Description; 1-6
General Maintenance Procedures; 2-12
D
Destruction of Army Materiel; 1-4
Deprocessing Unpacked Equipment; 2-5
Differential Pressure Switch
Adjust; 2-30
Removal; 2-30
Repair; 2-30
Replacement; 2-30
Dirty Oil Pump
Removal; 2-18
Repair; 2-18
Replacement; 2-18
Service; 2-18
Dirty Oil Pump Motor
Align; 2-19
Inspect; 2-19
Removal; 2-19
Repair; 2-19
Replacement; 2-19
Dirty Oil Transfer Alignment; 2-9
Diverter Valve
Inspect; 2-23
Removal; 2-23
Repair; 2-23
Replacement; 2-23
Duplex Strainer
Inspect; 2-24
Removal; 2-24
Repair; 2-24
Replacement; 2-24
Service; 2-24
I
Initial Setup Procedures; 3-5, 4-5
L
Location and Description of Major
Components; 1-8
M
Maintenance Forms, Records and
Reports; 1-2
Maintenance Procedures
Intermediate Direct Support; 3-10
Intermediate General Support; 4-10
Unit; 2-13
Motorized Valves
Adjust; 2-22
Inspect; 2-22
Removal; 2-22
Replacement; 2-22
N
Normal Startup; 2-8, 3-6, 4-6
O
Oil Content Monitor Assembly
Adjust; 2-26
Inspect; 2-26
Removal; 3-12
Repair; 2-26
Replacement; 3-12
Service; 2-26, 3-12
Test; 2-26
Index-1
TM 55-1905-223-24-19
Subject; Paragraph
Subject; Paragraph
O
R
Oil Level Sensors
Removal; 2-15
Repair; 2-15
Replacement; 2-15
Service; 2-15
Oil-Water Separator Principles of Operation; 1-11
OWS Pump
Inspect; 2-16
Removal; 2-16
Repair; 2-16
Replacement; 2-16
OWS Pump Motor
Align; 2-17
Inspect; 2-17
Removal; 2-17
Repair; 2-17
Replacement; 2-17
OWS Tank
Inspect; 2-14
Removal; 3-11
Repair; 2-14
Replacement; 3-11
Service; 2-14
Repair Parts; 2-3, 3-3, 4-3
Reporting Equipment Improvement
Recommendations; 1-3
P
Preliminary Servicing and Adjustment; 2-6
Preparation for Storage or
Shipment; 1-5, 2-32, 3-13, 4-11
Prestart Checks; 2-7
Preventive Maintenance Checks and
Services (PMCS); 2-10, 3-8, 4-8
Explanation of; 2-10
R
Relief Valve
Adjust; 2-25
Inspect; 2-25
Removal; 2-25
Repair; 2-25
Replacement; 2-25
Test; 2-25
Remote Indicator (Alarm) Assembly
Removal; 2-27
Repair; 2-27
Replacement; 2-27
Remote Relay Assembly
Adjust; 2-28
Inspect; 2-28
Removal; 2-28
Replacement; 2-28
Index-2
S
Safety, Care and Handling; 1-10
Scope of Manual; 1-1
Special Tools, TMDE and Support
Equipment; 2-2, 3-2, 4-2
Shutdown Procedures; 2-8.c, 3-7, 4-7
T
Troubleshooting; 2-11, 3-9, 4-9
W
Water Polisher
Inspect; 2-29
Removal; 2-29
Repair; 2-29
Replacement; 2-29
Service; 2-29
These are the instructions for sending an electronic 2028.
The following format must be used if submitting an electronic 2028. The subject line must be exactly the
same and all fields must be included; however, only the following fields are mandatory: 1, 3, 4, 5, 6, 7, 8,
9, 10, 13, 15, 16, 17 and 27.
From: “Whomever” [email protected]
To: [email protected]
To: [email protected]
Subject:DA Form 2028
1. From: Joe Smith
2. Unit: home
3. Address: 4300 Park
4. City: Hometown
5. St: MO
6. Zip: 77777
7. Date Sent: 19-OCT-93
8. Pub no: 55-1915-200-10
9. Pub Title: TM
10. Publication Date: 11-APR-88
11. Change Number: 12
12. Submitter Rank: MSG
13. Submitter Fname: Joe
14. Submitter Mname: T
15. Submitter Lname: Smith
16. Submitter Phone: 123-123-1234
17. Problem: 1
18. Page: 1
19. Paragraph: 3
20. Line: 4
21. NSN: 5
22. Reference: 6
23. Figure: 7
24. Table: 8
25. Item: 9
26. Total: 123
27. Text:
This is the text for the problem below line 27.
RECOMMENDED CHANGES TO
PUBLICATIONS AND BLANK FORMS
DATE
Use Part II (reverse) for Repair Parts and Special Tool
Lists (RPSTL) and Supply Catalogs/Supply Manuals
(SC/SM).
For use of this form, see AR 25-30; the proponent agency is OAASA
TO (Forward to proponent of publication or form) (Include ZIP Code)
FROM (Activity and location) (Include ZIP Code)
AMSTA-LC-LMPP/TECH PUBS TACOM-RI
1 Rock Island Arsenal
Rock Island, IL 61299-7630
PART I – ALL PUBLICATIONS (EXCEPT RPSTL AND SC/SM) AND BLANK FORMS
PUBLICATION/FORM NUMBER
TM 55-1905-223-24-19
ITEM
PAGE
PARAGRAPH
DATE
08 Feb 08
LINE
FIGURE TABLE
NO.
TITLE
OIL-WATER SEPARATOR FOR LANDING CRAFT UTILITY
NSN 1905-01-154-1191
RECOMMENDED CHANGES AND REASON
* Reference to line numbers within the paragraph or subparagraph.
TYPED NAME, GRADE OR TITLE
DA FORM 2028, FEB 74
TELEPHONE EXCHANGE/AUTOVON, SIGNATURE
PLUS EXTENSION
REPLACES DA FORM 2028, 1 DEC 68, WHICH WILL BE USED.
USAPA V3.01
TO (Forward direct to addressee listed in publication)
FROM (Activity and location) (Include ZIP Code)
DATE
AMSTA-LC-LMPP/TECH PUBS TACOM-RI
1 Rock Island Arsenal
Rock Island, IL 61299-7630
PART II – REPAIR PARTS AND SPECIAL TOOL LISTS AND SUPPLY CATALOGS/SUPPLY MANUALS
PUBLICATION NUMBER
TM 55-1905-223-24-19
PAGE
NO.
COLM
LINE NO.
NO.
DATE
08 Feb 08
NATIONAL STOCK
NUMBER
REFERENCE
NO.
FIGURE ITEM
NO.
NO.
TITLE
OIL-WATER SEPARATOR FOR LANDING CRAFT UTILITY
NSN 1905-01-154-1191
TOTAL NO.
OF MAJOR
ITEMS
SUPPORTED
RECOMMENDED ACTION
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.)
TYPED NAME, GRADE OR TITLE
USAPA V3.01
TELEPHONE EXCHANGE/AUTOVON,
PLUS EXTENSION
SIGNATURE
RECOMMENDED CHANGES TO
PUBLICATIONS AND BLANK FORMS
DATE
Use Part II (reverse) for Repair Parts and Special Tool
Lists (RPSTL) and Supply Catalogs/Supply Manuals
(SC/SM).
For use of this form, see AR 25-30; the proponent agency is OAASA
TO (Forward to proponent of publication or form) (Include ZIP Code)
FROM (Activity and location) (Include ZIP Code)
AMSTA-LC-LMPP/TECH PUBS TACOM-RI
1 Rock Island Arsenal
Rock Island, IL 61299-7630
PART I – ALL PUBLICATIONS (EXCEPT RPSTL AND SC/SM) AND BLANK FORMS
PUBLICATION/FORM NUMBER
TM 55-1905-223-24-19
ITEM
PAGE
PARAGRAPH
DATE
08 Feb 08
LINE
FIGURE TABLE
NO.
TITLE
OIL-WATER SEPARATOR FOR LANDING CRAFT UTILITY
NSN 1905-01-154-1191
RECOMMENDED CHANGES AND REASON
* Reference to line numbers within the paragraph or subparagraph.
TYPED NAME, GRADE OR TITLE
DA FORM 2028, FEB 74
TELEPHONE EXCHANGE/AUTOVON, SIGNATURE
PLUS EXTENSION
REPLACES DA FORM 2028, 1 DEC 68, WHICH WILL BE USED.
USAPA V3.01
TO (Forward direct to addressee listed in publication)
FROM (Activity and location) (Include ZIP Code)
DATE
AMSTA-LC-LMPP/TECH PUBS TACOM-RI
1 Rock Island Arsenal
Rock Island, IL 61299-7630
PART II – REPAIR PARTS AND SPECIAL TOOL LISTS AND SUPPLY CATALOGS/SUPPLY MANUALS
PUBLICATION NUMBER
TM 55-1905-223-24-19
PAGE
NO.
COLM
LINE NO.
NO.
DATE
08 Feb 08
NATIONAL STOCK
NUMBER
REFERENCE
NO.
FIGURE ITEM
NO.
NO.
TITLE
OIL-WATER SEPARATOR FOR LANDING CRAFT
UTILITY NSN 1905-01-154-1191
TOTAL NO.
OF MAJOR
ITEMS
SUPPORTED
RECOMMENDED ACTION
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.)
TYPED NAME, GRADE OR TITLE
USAPA V3.01
TELEPHONE EXCHANGE/AUTOVON,
PLUS EXTENSION
SIGNATURE
RECOMMENDED CHANGES TO
PUBLICATIONS AND BLANK FORMS
DATE
Use Part II (reverse) for Repair Parts and Special Tool
Lists (RPSTL) and Supply Catalogs/Supply Manuals
(SC/SM).
For use of this form, see AR 25-30; the proponent agency is OAASA
TO (Forward to proponent of publication or form) (Include ZIP Code)
FROM (Activity and location) (Include ZIP Code)
AMSTA-LC-LMPP/TECH PUBS TACOM-RI
1 Rock Island Arsenal
Rock Island, IL 61299-7630
PART I – ALL PUBLICATIONS (EXCEPT RPSTL AND SC/SM) AND BLANK FORMS
PUBLICATION/FORM NUMBER
TM 55-1905-223-24-19
ITEM
PAGE
PARAGRAPH
DATE
08 Feb 08
LINE
FIGURE TABLE
NO.
TITLE
OIL-WATER SEPARATOR FOR LANDING CRAFT UTILITY
NSN 1905-01-154-1191
RECOMMENDED CHANGES AND REASON
* Reference to line numbers within the paragraph or subparagraph.
TYPED NAME, GRADE OR TITLE
DA FORM 2028, FEB 74
TELEPHONE EXCHANGE/AUTOVON, SIGNATURE
PLUS EXTENSION
REPLACES DA FORM 2028, 1 DEC 68, WHICH WILL BE USED.
USAPA V3.01
TO (Forward direct to addressee listed in publication)
FROM (Activity and location) (Include ZIP Code)
DATE
AMSTA-LC-LMPP/TECH PUBS TACOM-RI
1 Rock Island Arsenal
Rock Island, IL 61299-7630
PART II – REPAIR PARTS AND SPECIAL TOOL LISTS AND SUPPLY CATALOGS/SUPPLY MANUALS
PUBLICATION NUMBER
TM 55-1905-223-24-19
PAGE
NO.
COLM
LINE NO.
NO.
DATE
08 Feb 08
NATIONAL STOCK
NUMBER
REFERENCE
NO.
FIGURE ITEM
NO.
NO.
TITLE
OIL-WATER SEPARATOR FOR LANDING CRAFT
UTILITY NSN 1905-01-154-1191
TOTAL NO.
OF MAJOR
ITEMS
SUPPORTED
RECOMMENDED ACTION
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.)
TYPED NAME, GRADE OR TITLE
USAPA V3.01
TELEPHONE EXCHANGE/AUTOVON,
PLUS EXTENSION
SIGNATURE
By Order of the Secretary of the Army:
Official:
GEORGE W. CASEY, JR.
General, United States Army
JOYCE E. MORROW
Administrative Assistant to the
Secretary of the Army
0802505
DISTRIBUTION:
To be distributed in accordance with IDN 254813, requirements for TM 55-1905-223-24-19.
TM 55-1905-223-24-19
FO-1. Electrical Schematic (SID) (Sheet 1 of 2)
FP-1/(FP-2 blank)
TM 55-1905-223-24-19
FO-1. Electrical Schematic (SID) (Sheet 2 of 2)
FP-3/(FP-4 blank)
TM 55-1905-223-24-19
FO-2. Electrical Schematic (OEM) (Typical) (Sheet 1 of 2)
FP-5/(FP-6 blank)
TM 55-1905-223-24-19
FO-2. Electrical Schematic (OEM) (Typical) (Sheet 2 of 2)
FP-7/(FP-8 blank)
The Metric System and Equivalents
Linear Measure
Liquid Measure
1 centimeter = 10 millimeters = .39 inch
1 decimeter = 10 centimeters = 3.94 inches
1 meter = 10 decimeters = 39.37 inches
1 dekameter = 10 meters = 32.8 feet
1 hectometer = 10 dekameters = 328.08 feet
1 kilometer = 10 hectometers = 3,280.8 feet
1 centiliter = 10 milliliters = .34 fl. ounce
1 deciliter = 10 centiliters = 3.38 fl. ounces
1 liter = 10 deciliters = 33.81 fl. ounces
1 dekaliter = 10 liters = 2.64 gallons
1 hectoliter = 10 dekaliters = 26.42 gallons
1 kiloliter = 10 hectoliters = 264.18 gallons
Weights
Square Measure
1 centigram = 10 milligrams = .15 grain
1 decigram = 10 centigrams = 1.54 grains
1 gram = 10 decigram = .035 ounce
1 dekagram = 10 grams = .35 ounce
1 hectogram = 10 dekagrams = 3.52 ounces
1 kilogram = 10 hectograms = 2.2 pounds
1 quintal = 100 kilograms = 220.46 pounds
1 metric ton = 10 quintals = 1.1 short tons
1 sq. centimeter = 100 sq. millimeters = .155 sq. inch
1 sq. decimeter = 100 sq. centimeters = 15.5 sq. inches
1 sq. meter (centare) = 100 sq. decimeters = 10.76 sq. feet
1 sq. dekameter (are) = 100 sq. meters – 1,076.4 sq. feet
1 sq. hectometer (hectare) = 100 sq. dekameters = 2.47 acres
1 sq. kilometer = 100 sq. hectometers = .386 sq. mile
Cubic Measure
1 cu. centimeter = 1000 cu. millimeters = .06 cu. inch
1 cu. decimeter = 1000 cu. centimeters = 61.02 cu. inches
1 cu. meter = 1000 cu. decimeters = 35.31 cu. feet
Approximate Conversion Factors
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
pound-inches
To
Multiply by
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
newton meters
2.540
.305
.914
1.609
6.451
.983
.836
2.590
.405
.028
.765
29.573
.473
.946
3.785
28.349
.454
.907
1.356
.11296
To change
ounce-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
To
Multiply by
newton-meters
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
.007062
.394
3.280
1.094
.621
.155
10.764
1.196
.386
2.471
35.315
1.308
.034
2.113
1.057
.264
.035
2.205
1.102
Temperature (Exact)
°F
Fahrenheit
temperature
5/9 (after
subtracting 32)
Celsius
temperature
°C
PIN: 084599-000
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