NSW_RIB_ECP_159_Gear_Oil_Pressure_Gauge_(3).pdf

ECP 159

ECP159

Contract # USZA22-03-D-0003 Proprietary as per Limited Rights on page 1

USMI NSW RIB

ENGINEERING CHANGE PROPOSAL

Originator: Henry Relayson

United States Marine, Inc.

10011 Lorraine Rd Gulfport, MS 39503

Submittal Date: 9/9/08

Contract Number: USZA22-03-D-0003

Procuring Contracting Officer: Sandra Smith

ECP Number: ECP 159

Title: Marine Gear Gauge Change

Description of Change: Replace the marine gear temperature gauge with a marine gear oil pressure gauge.

Reason for Change: Marine gear oil pressure will indicate a problem earlier than marine gear oil temperature.

CAGE Code: 0NNZ7

Specifications Affected: 3.4.6. Propulsion System- Change paragraph seven to read “The Contractor shall install a marine gear oil pressure gauge.”

Drawings Affected: USMI production drawings:A3-Sh2(Detail 11C);E1-Sh2;E2-Sh4;L1-Sh1(Detail7A)

DDP/Interim Spare Item Change: Yes

Effect on Production Schedule: Yes

Proprietary as per Limited Rights on page 1

MODIFICATION JUSTIFICATION:

A major cause of failed marine gears is the loss of oil pressure, which in turn will cause the temperate to be elevated. By monitoring the pressure rather than the temperature, this will also help prevent running the gear when it is low on fluid. The monitoring of marine gear pressure will indicate a problem prior to a temperature change. This will allow the operator to discontinue use of the gear before major damage occurs.

MODIFICATION DESCRIPTION:

A detailed description of the production installation can be seen in Attachment 1. The retrofit installation can be seen in Attachment 2. The original marine gear oil temperature gauge USMI # (504-7002) will be removed and replaced with marine gear oil pressure gauge USMI # (504-7202). The marine gear oil temperature sender USMI# (233-7118) will be removed and replaced with a compatible oil pressure sender that is USMI # (504-7212).

The wiring will accommodate the new gauge and sender for production and a pigtail/adapter will be utilized for retrofits.

SCHEDULE:

This ECP can be implemented on production craft with a delivery date not less than 30 days after approval of the Delivery Order by all parties. Retrofit kits can be assembled starting 60 days after approval of the Delivery Order by all parties. These retrofit kits will be grouped 2 kits per shipment with 3 weeks between shipments.

The NSWRIB production schedule will remain14 weeks and 1day. (This includes approved ECP’s from 010 to 159)

WEIGHT AND MOMENT IMPACT:

Weight:

USMI # DESCRIPTION QTY UNIT

WEIGHT

TOTAL

WEIGHT

504-7212 Marine Gear Oil Pressure Sender(with elbow) 2 .30 .60 504-7202 Marine Gear Oil Pressure Gauge 2 .25 .50 504-7002 Marine Gear Oil Temperature Gauge 2 (.25) (.50) 233-7118 Marine Gear Oil Temperature Sender 2 (.25) (.25) Total Weight Change .05lbs .10 lbs

LCG:

Vessel Configuration

Weight (New)

LCG*

Delta

(inches)

VCG*

Delta

(inches) Light Load 14,634.42 0.0 -0.0 Full Load 18,834.42 0.0 -0.0 Total Weight Delta .10

* Positive value indicates a shift forward or upwards

LOGISTICS AND SPARING:

The following parts will be added to the MEL:

USMI# DESCRIPTION Qty UOM 504-7212 Marine Gear Oil Pressure Sender 2 EA

504-7202 Marine Gear Oil Pressure Gauge 2 EA

505-7992 3/8” NPT street elbow 2 EA

The following parts will be deleted from the MEL and DDP:

504-7002 Marine Gear Oil Temperature Gauge 2 EA

233-7118 Marine Gear Oil Temperature Sender 2 EA

Recommend the following parts be added to the DDP:

504-7212 Marine Gear Oil Pressure Sender 2 EA

505-7992 3/8” NPT street elbow 2 EA

The following list details the parts that make up this ECP:

USMI# DESCRIPTION QTY UOM

504-7212 Marine Gear Oil Pressure Sender 2 EA 505-7992 3/8” NPT street elbow 2 EA 311-3015 Marine Gear Oil Pressure Gauge Pigtail Assembly 2 EA 311-3016 Marine Gear Oil Pressure Sender Pigtail Assembly 2 EA

The following parts will be added to the PIO list:

311-3015 Marine Gear Oil Temperature Gauge Pigtail Assembly 1 EA

311-3016 Marine Gear Oil Temperature Sender Pigtail Assembly 1 EA

AUTHORIZED SIGNATURES:

9/9/08

Barry T. Dreyfus, Jr.

United States Marine Inc. President Date

Henry Relayson 9/9/08 United States Marine Inc. Project Manager Date

USSOCOM NSWRIB Engineer Date

USSOCOM NSWRIB Program Manager Date

USSOCOM NSWRIB Contracting Officer Date

PREPARATION COST:

Attachment 3

PRODUCTION OPTION PRICE:

Attachment 3

RETROFIT COST:

Attachment 3

Proprietary as per Limited Rights on page 1

Attachment 1

Production Installation

1) During production, the marine gear oil pressure gauge will be installed into the gauge panel and wired accordingly.

2) The gauge panel label has to be replaced with a new label that reads gear oil press instead of gear oil temp.

a) Remove all 7 nuts and washers.

b) Remove the existing label.

c) Install the new label.

d) Install all nuts and washers.

3) The marine gear oil temperature sender will be removed and replaced with a 0-400 psi pressure sender (USMI # 504-7212).

a) Remove the temperature sender from the marine gear to marine gear heat exchanger. (See Figure 1.)

i) Disconnect the wires.

ii) Remove the sender using a ⅞” deep socket and ratchet.

b) Install the new pressure sender.

i) Apply pipe sealant to the male side of the 90° elbow.

ii) Screw the 90° elbow into the port that the temperature sender previously occupied.

iii) Apply pipe sealant to the treads on the pressure sender.

iv) Screw the sender into the elbow. (See Figure 2.)

c) Connect the sender

Marine gear oil temperature sender

Figure 1

Electrical box on engine

Proprietary as per Limited Rights on page 1

i) Change the push on lug to a #10 ring terminal on both the yellow and black wires. Solder the ring terminals to the wires and cover with heat shrink.

ii) Connect the black ring terminal to either side on the sender.

iii) Connect the yellow ring terminal to the opposite terminal on the sender.

New marine gear pressure sender with elbow.

Figure 2

Proprietary as per Limited Rights on page 1

Attachment 2

Retrofit Installation

Materials List

USMI# DESCRIPTION QTY UOM

504-7202 Marine Gear Oil Pressure Gauge 2 EA 504-7212 Marine Gear Oil Pressure Sender 2 EA 505-7992 3/8” NPT street elbow 2 EA 000-0000 Marine Gear Oil Pressure Gauge Pigtails

Consisting of the following

2 EA

000-0000 Spade Terminal, 16-10 Crimp 6 EA 000-0000 Ring Terminal 16-10, Crimp 6 EA 304-7084 Wire 16 gauge (purple) 2 Ft 304-7046 Wire 16 gauge (black) 2 Ft 304-7050 Wire 16 gauge (brown/white) 2 Ft 000-0000 Marine Gear Oil Pressure Sender Pigtails

Consisting of the following

2 EA

000-0000 Ring Terminal 16-10, Crimp 4 EA 000-0000 Spade Terminal, 16-10 Crimp 4 EA 304-7097 Wire 16 gauge (yellow) 2 Ft 304-7046 Wire 16 gauge (black) 2 Ft 000-0000 Heat shrink 2 Ft

1) Remove the existing marine gear temperature gauge

a) Disconnect the wiring from the backside of the marine gear temp gauge. These wires and connectors will be reused.

i) Unplug the black connector from the gauge.

ii) Unscrew the blue and black wires from the gauge.

b) Remove the screws and bracket from the backside of the marine gear temperature gauge.

c) Pull the marine gear temperature gauge out of the gauge panel from the exterior of the console.

2) Remove the label on the back of the panel.

a) Remove all 7 nuts and washers.

b) Remove the existing label.

c) Install the new label.

d) Install all nuts and washers.

3) Install the marine gear pressure gauge.

a) Apply a small bead of silicon sealant to under side of the gauge bezel.

b) Insert the gauge clocked with the 300 psi up. (See Figure 3.) This will put the needle at the 12:00 position at cruise speed.

4) Connect the wiring to the back of the gauge. (See Figure 4.)

a) Connect the blue wire to the positive (+) terminal on the gauge for the light.

b) Connect the black wire to the negative (-) terminal on the gauge for the light.

5) Using the pigtail already attached to the marine gear oil pressure gauge, complete the remaining connections.

a) Connect the brown with white stripe wire to the existing brown with white strip wire utilizing the black connector. (See Figure 5.)

b) Connect the black wire to the existing black wire utilizing the black connector.

c) Connect the purple wire to the existing purple wire utilizing the black connector.

Position the gauge with 300 psi up

Figure 3

Figure 4

The blue and black wires for the gauge lights are connected as shown.

The black connector from the original gauge will be used for the connections to the new gauge.

Figure 5

Proprietary as per Limited Rights on page 1

6) Replace the marine gear oil temperature sender with a 0-400 psi pressure sender

(USMI # 504-7212).

a) Remove the temperature sender from the marine gear to marine gear heat exchanger. (See Figure 6.)

i) Disconnect the wires.

ii) Unscrew the sender using a ⅞” deep socket and ratchet.

b) Install the new marine gear oil pressure sender.

i) Apply pipe sealant to the male side of the 90° elbow.

ii) Screw the 90° elbow into the port the temperature sender previously occupied.

iii) Apply pipe sealant to the treads on the pressure sender.

iv) Screw the sender into the elbow. (See Figure 7.)

7) Connect the pressure sender pigtail to the engine electrical box.

a) Place a piece of the supplied heat shrink over the yellow wire on the pigtail.

i) Connect the male spade of the yellow wire into the existing female connector on the yellow wire.

ii) Cover the connection with the heat shrink and shrink into place.

b) Place a piece of the supplied heat shrink over the black wire on the pigtail.

i) Connect the male spade of the black wire into the existing female connector on the black wire.

ii) Cover the connection with the heat shrink and shrink into place.

Figure 6

Electrical box on engine

Marine gear oil temperature sender

New marine gear oil pressure sender with elbow and pigtail installed

Figure 7