ECP-128_TJ3020_1_HVAC_Upgrade.pdf

U S COAST GUARD

ASSET COMPUTERIZED MAINTENANCE SYSTEM

RB-M-45

TJ3020.1

REV’D 05/20/2013

ASSET NUMBER OPERATING ACTIVITY MAINTENANCE ACCOMPLISHED MAINTENANCE DUE

DATE ASSET HOURS DATE ASSET HOURS

MO DAY YEAR MO DAY YEAR

Serial #/Hours: ZULU DATE ZULU TIME Discrepancies Found: No__ Yes__

MO DAY YEAR

ITEM

DUE

CMS CODE ACTION DESCRIPTION CEINUM

TJ3021 MODIFY HVAC UPGRADE RM-B000-001

MANHOURS: MK ___.___ DC___.___ EM___.___ ET___.___ GM___.___ BM___.___ FN___.___ SN___.___ OTHER___.___

REMARKS: __________________________________________________________________

TECHNICIAN’S

SIGNATURE

TECHNICIAN’S

ID

* ASTERISK INDICATES QA

REQUIRED

QA

TIME COMPLIANCE TECHNICAL ORDER

TCTO TJ3020.1

ECN: 45RBM-B-00038

THIS TCTO IS APPLICABLE TO RB-M HULLS: 45602,45604,45605,45607,45608,45610,45612-45616,45619-45626,45628-45629 Hulls 45602,45604,45605,45607,45608,45610,&45612 will require retrofit of both units and the pump.

Hulls 45613-45616,45619-45626,45628,&45629 already have the correct pump but will required retrofit of both HVAC Units.

Hull 45602 will require completion of Auragen Soft-Start TJ3040.0 in order to meet the configuration baseline.

THIS TCTO TJ3020.1 SUPERSEDED TCTO TJ3020.0 DUE TO REVISING THE PART NUMBER FOR THE HVAC UNIT.

CHANGES WERE ALSO MADE TO THE GENERAL FORMATTING OF THE TCTO.

THIS TCTO DIRECTS AND AUTHORIZES THE RETROFIT OF THE HVAC UNITS.

ALL PARTS WILL BE PROCURED AS PART OF THE CONTRACT INITIATED DURING DEPOT. ALL VESSELS AT YOUR COMMAND MUST BE COMPLETED AT YOUR NEXT QUADRENNIAL DEPOT LEVEL AVAILABILITY. IF YOU ARE UNABLE TO

MEET THESE REQUIREMENTS CONTACT YOUR ASSET LINE MANAGER FOR DIRECTIONS.

Distribution Statement D: Distribution authorized to the DHS/CG/DoD and their contractors Administrative/Operational use, 04/19/11. Other requests shall be referred to the appropriate asset product line.

DESTRUCTION NOTICE: For classified documents, follow the procedures in DoD 5200.22-M, National Industrial Security Program Operating Manual, Section 5-705 or DoD 5200.1-R, Information Security Program Regulation, Chapter VI, Section 7. For unclassified, limited documents, destroy by any method that will prevent disclosure of contents or reconstruction of the document.

REVIEWED BY LOG YN DATA ENTRY

COMPLETED

SCHEDULED UNSCHEDULED

ENGINEERING CHANGE NOTICE

1. APPLICATION

a. This technical order is applicable to RB-M hulls 45602, 45604-45605, 45607-45608, 45610, 45612-45616, 45619-45626, 45628-45629.

b. Hulls 45602, 45604-45605, 45607-45608, 45610, & 45612 will require retrofit of both units and the pump.

c. Hulls 45613-45616, 45619-45626, 45628, & 45629 already have the correct pump installed but will required retrofit of both

HVAC Units.

d. Hull 45602 will require completion of Auragen Soft-Start TJ3040.0 in order to meet the configuration baseline.

2. PURPOSE

a. This technical order provides instructions for the retrofit of the HVAC units in the pilothouse and survivor compartment.

And on select hulls the HVAC raw water pump and strainer.

b. TCTO COORDINATOR

(1) Technical questions or comments associated with this TCTO should be referred to SBPL: CWO Jeff Paquette, email jeffrey.e.paquette@uscg.mil, (410) 762-6130.

3. WHEN TO BE ACCOMPLISHED

a. This TCTO shall be accomplished

(1) At the next quadrennial depot availability.

4. BY WHOM TO BE ACCOMPLISHED

a. The work required to accomplish this TCTO shall be performed by civilian contractors.

5. WHAT IS REQUIRED

a. SUPPLY INFORMATION AND REQUIREMENTS

(1) Kits/Parts/Materials Required

i. No kits or materials are supplied by the Coast Guard to assist in the completion of this TCTO.

b. Parts will be supplied under the scope of the contract to perform this installation.

c. The following parts required to comply with this TCTO are required to be provided by the contractor completing the work.

Questions regarding the HVAC retrofit parts should be referred to Jason Kempton (253) 867-2610 ext 3017 RBM-PRO.

HVAC Unit Retrofit Parts Fabrication - Structural Parts List Reference

Drawing Number Manufacture Qty Unit Additional Description

180-660-B23 CUSTOM

FABRICATION 1 EA CUT PLATE, FORMED, 0.160 THK 5083H-116

180-660-B22 CUSTOM

FABRICATION 2 EA CUT PLATE, 0.160 THK 5083H-116

180-660-B20 CUSTOM

FABRICATION 1 EA CUT PLATE, FORMED, 0.190 THK 5083H-116

180-660-B15 CUSTOM

FABRICATION 1 EA CUT PLATE, 0.190 THK 5083H-116

180-514-F07 CUSTOM

FABRICATION 1 EA CUT PLATE, FORMED, 0.125 THK 5083H-116

180-514-F10 CUSTOM

FABRICATION 1 EA CUT PLATE, FORMED, 0.160 THK 5083H-116

180-511-D05 CUSTOM

FABRICATION 1 EA CUT PLATE, FORMED, 0.190 THK 5083H-116

180-511-D03 CUSTOM

FABRICATION 1 EA CUT PLATE, FORMED, 0.160 THK 5083H-116

180-511-D04 CUSTOM

FABRICATION 1 EA CUT PLATE, FORMED, 0.160 THK 5083H-116

612-001-0202 CUSTOM

FABRICATION 2 EA CUT PLATE, 0.160 THK 5083H-116

180-660-B19 CUSTOM

FABRICATION 1 EA CUT PLATE, FORMED, 0.190 THK 5083H-116

180-660-B21 CUSTOM

FABRICATION 1 EA CUT PLATE, FORMED, 0.125 THK 5083H-116

RETRO-180-514-F06 CUSTOM

FABRICATION 1 EA CUT PLATE, FORMED, 0.190 THK 5083H-116

180-514-F14 CUSTOM

FABRICATION 1 EA CUT PLATE, FORMED, 0.125 THK 5083H-116 5083H-

RETRO-180-514-F13 CUSTOM

FABRICATION 1 EA CUT EXTRUSION, SEE FABRICATION PREFAB

DETAIL 5086-H111

RETRO-180-514-F14 CUSTOM

FABRICATION 1 EA CUT EXTRUSION, SEE FABRICATION PREFAB

DETAIL 5086-H111

180-514-F08 CUSTOM

FABRICATION 1 EA CUT EXTRUSION, SEE FABRICATION PREFAB

DETAIL 5086-H111

180-514-F09 CUSTOM

FABRICATION 1 EA CUT EXTRUSION, SEE FABRICATION PREFAB

DETAIL 5086-H111

612-001-0305 CUSTOM

FABRICATION 1 EA EXTRUSION, PIPE, 5086-H111OR H112, SCH 40, 1.000,

ASTM B221

HVAC Unit Retrofit Parts Outfit Parts List

Part Part Number

Manufacture Qty Unit Additional Description

HANGER 205149 KMI 7 EA 1” CHANNEL RESEARCH TOOL & DIE WORKS

9C02A HANGER 1” LONG 6061 OR EQUIVALENT

HANGER 205150 KMI 1 EA 1” CHANNEL RESEARCH TOOL & DIE WORKS

9C02A HANGER 2” LONG 6061 OR EQUIVALENT

MATERIAL KMI 1 EA EXTRUSION, ANGLE, .187 X 2.00 X 2.00 ASTM -B-221,

5086 H-111 OR H112

MATERIAL KMI 1 EA EXTRUSION, FLATBAR, 5086-H111 OR H112, .1875 X

.7500, ASTM B221

MATERIAL KMI 1 EA EXTRUSION, FLATBAR, 5086-H111 OR H112, .1875 X

1.500, ASTM B221

MATERIAL KMI 1 EA EXTRUSION, FLATBAR, 5086-H111 OR H112, .1875 X

2.000, ASTM B221

MATERIAL KMI 1 EA EXTRUSION, FLATBAR, 5086-H111 OR H112, .3125 X

3.000, ASTM B221

ADHESIVE 211547 KMI AR EA ADHESIVE, INSULATION HANGER, 1 GAL, and MEI

ECO- HANGER GRIP 22-15, 800-1000 HANGERS/GAL

INSULATION

HANGER 211548 KMI 15 EA

INSULATION HANGER, ANNULAR RING STUD, 5356,

.181 ND x 1.000 LENGTH, PERFORATED BASE, ADHESIVE MOUNT, AGM INDUSTRIES ALT 177-

0875, 2.000 x 2.000 3003 ALUM BASE, NAVY

STANDARD

ANNULAR RING

DRIVE 212044 KMI 15 EA

ANNULAR RING DRIVE ON CAP, ALUMINUM,

.500” LONG X 0.906” DIA, AGM INDUSTRIES INC

ALNC-180 OR EQUAL

INSULATION KMI AR EA

INSULATION, TAPE, 3" WIDE, ALPHA ASSOCIATES

INC 59M-PS-3-WHITE, 100% FIBERGLASS SCRIM

AND POLYESTER FILM OR EQUAL

HVAC UNIT 221563 KMI 2 EA

HVAC UNIT, 27000 BTU, 230V/60HZ Marine Air

205410064 VCD27SZ/1 EH-HV-ES410A 8"ALM RHRST,

Coils coated with Heresite P-403L Baked Phenolic Coating, Drain Pipe fitted with 1” thick anti-slosh pad and ½” MPT fittings for drain hose connection, 8” mounting ring on blower outlet Cooling water connections made with ¾” slip on hose barbs. (HVAC UNIT INCLUDES SOFT START

OUTLINED IN TJ3040.0)

HVAC HEATER 212254 KMI 2 EA HVAC HEATER, 3000W, CRUISAIR HMDL3C-8-GR,

230V, 8.0 DUCT

TRIM 210276 KMI 1 EA TRIM, EDGE, RUBBER, BLACK, .250 OPENING x .500

DEPTH

CLAMP 208401 KMI 2 EA CLAMP, HOSE, WORM DRIVE, RANGE 5.625 TO

8.500, BREEZE 63128

DUCT 212545 KMI 1 EA DUCT, HVAC, 8.0 DIA x 8 FT LENGTH, THERMAFLEX

M-KC

DUCT 212542 KMI 1 EA DUCT, HVAC, 8.0 DIA x 2 FT LENGTH, THERMAFLEX

S-LP-10, NON-INSULATED

STRAP VELCRO 203222 KMI 1 EA

STRAP VELCRO, CUT TO 15.000 L x 1.000 W, MCMASTER #94905K118

CABLE TIE 206444 KMI 4 EA CABLE TIE, 29.7, 316, PANDUIT MLTFC8EH-LP316

CABLE TIE 206466 KMI 18 EA CABLE TIE, NYLON, BLACK

HOSE 113145 KMI 6 EA HOSE, PROTECTOR, EPHA HP4-B, 4" LONG, BLACK

SCREW 205220 KMI 2 EA SCREW, MACHINE FLAT SOCKET, 316, #10-24 x 1.000

SCREW 204290 KMI 8 EA SCREW, ALLEN SOCKET CAP, 316, #10-24 x .750

SCREW 117697 KMI 8 EA SCREW, HEX CAP, 316, .375-16 x 1.250

SCREW 117561 KMI 17 EA SCREW, HEX CAP, 316, .375-16 x 1.000

SCREW 212513 KMI 2 EA SCREW ALLEN SOCKET FLAT, 316, .375-16 X 1.50

SCREW 212475 KMI 2 EA SCREW ALLEN SOCKET FLAT, 316, .375-16 X 1.25

SCREW 118197 KMI 1 EA SCREW, HEX CAP, 316, .250-20 x 1.500

SCREW 118145 KMI 20 EA SCREW, HEX CAP, 316, .250-20 x 1.000

WASHER 117633 KMI 42 EA WASHER, FLAT, 316, .250

WASHER 117396 KMI 51 EA WASHER FLAT, 316, .375

WASHER 117560 KMI 18 EA WASHER FLAT, 316, #10

NUT 117632 KMI 21 EA NUT, NYLOCK, 316, .250-20

NUT 117397 KMI 25 EA NUT, NYLOCK, 316, .375-16

NUT 117559 KMI 10 EA NUT, NYLOCK, 316, #10-24

MACHINED 214109 KMI 1 EA MACHINED UHMW PART

MACHINED 207354 KMI 6 EA MACHINED PART, SHOULDER WASHER, UHMW,

.250ID X .375OD X .250L X .063

CABLE TIE 206444 KMI 2 EA CABLE TIE, 29.7, 316, PANDUIT MLTFC8EH-LP316,

1.0-8.0 BUNDLE DIA, POLYESTER COATED

CLAMP 208401 KMI 2 EA

CLAMP, HOSE, WORM DRIVE, 300 SERIES, GRIP

RANGE, 5.625 TO 8.500, BREEZE 63128, POWER

SEAL SERIES

ELBOW 207510 KMI 1 EA FITTING JIC FLARE ELBOW, 316, .750 MJ x .500 MB, PARKER 12-8 C5OX-SS, 90D, 12MJ-8MB

NUT 207448 KMI 2 EA FITTING BLKHD NUT, 316, PARKER 8-WLN-SS, .75-16

THREADS

PIPE 212291 KMI 1 EA FITTING PIPE, BARB, 316, .500 MNPT x .750 HB

PIPE 201954 KMI 1 EA FITTING PIPE, 316, .500 FNPT x .500 MB, PARKER 8-

1/2 F5OG-SS

CORDGRIP 212485 KMI 1 EA CORDGRIP, INSERT, MENCOM PG16-0X0, NO HOLES

CORDGRIP 209563 KMI 1 EA CORDGRIP, PLASTIC, .500 MNPT, .394-.551 GRIP

RANGE, MENCOM PCG-1/2-B, BLACK

NUT 209632 KMI 1 EA NUT, CORDGRIP, PLASTIC, .500, MENCOM 212PA/SW

SUB-ASSEMBLY 383-002 KMI 1 EA SUB-ASSEMBLY, SEE PREFAB DETAIL

SUB-ASSEMBLY 383-003 KMI 1 EA SUB-ASSEMBLY, SEE PREFAB DETAIL

SUB-ASSEMBLY 383-004 KMI 1 EA SUB-ASSEMBLY, SEE PREFAB DETAIL

SUB-ASSEMBLY 211-019 KMI 1 EA SUB-ASSEMBLY, SEE PREFAB DETAIL

SUB-ASSEMBLY 383-015 KMI 1 EA SUB-ASSEMBLY, SEE PREFAB DETAIL

SUB-ASSEMBLY 383-014 KMI 1 EA SUB-ASSEMBLY, SEE PREFAB DETAIL

SUB-ASSEMBLY 422-006 KMI 1 EA SUB-ASSEMBLY, SEE PREFAB DETAIL

SUB-ASSEMBLY 347-002 KMI 1 EA SUB-ASSEMBLY, SEE PREFAB DETAIL

SUB-ASSEMBLY 346-012 KMI 1 EA SUB-ASSEMBLY, SEE PREFAB DETAIL

SUB-ASSEMBLY 346-013 KMI 1 EA SUB-ASSEMBLY, SEE PREFAB DETAIL

SUB-ASSEMBLY 383-008 KMI 1 EA SUB-ASSEMBLY, SEE PREFAB DETAIL

SUB-ASSEMBLY 383-009 KMI 1 EA SUB-ASSEMBLY, SEE PREFAB DETAIL

SUB-ASSEMBLY 383-011 KMI 1 EA SUB-ASSEMBLY, SEE PREFAB DETAIL

HVAC Unit Retrofit Parts Outfitting – Hoses Parts List For hose lengths and labeling requirements refer to drawing 45RBM-505-001 Hose subassembly depicted in procedures

Part Part Number Manufacture Qty Unit Additional Description

CLAMP 202788 KMI 36 EA CLAMP HOSE, 316, #012

CLAMP 202789 KMI 8 EA CLAMP HOSE, 316, #016

VALVE 204502 KMI 6 EA FITTING HOSE JIC FLARE, 316, .75 FJ x .75 HB, PARKER 30682- 12-12C

VALVE 205590 KMI 2 EA VALVE CHECK 0.750" SLIP, BOSWORTH 74-6

VALVE 204832 KMI 1 EA VALVE CHECK SWING, 1.000 HB, BOSWORTH 74-8

HOSE ASSY 206128 KMI 1 EA HOSE ASSY RBM HV-S12 0.75" BELLOWSFLEX 7910 "A" HOSE

HOSE ASSY 212396 KMI 1 EA HOSE ASSY RBM HV-S23 0.75" BELLOWSFLEX 7910 "A" HOSE

HOSE ASSY 206136 KMI 1 EA HOSE ASSY RBM HV-S18 1.0" BELLOWSFLEX 7910 "A" HOSE

HOSE ASSY 212395 KMI 1 EA HOSE ASSY RBM HV-S22 1.0" BELLOWSFLEX 7910 "A" HOSE

HOSE ASSY 212394 KMI 1 EA HOSE ASSY RBM HV-S21 0.75" BELLOWSFLEX 7910 "A" HOSE

HOSE ASSY 212392 KMI 1 EA HOSE ASSY RBM HV-P17 0.75" BELLOWSFLEX 7910 "A" HOSE

HOSE ASSY 212390 KMI 1 EA HOSE ASSY RBM HV-P18 0.75" BELLOWSFLEX 7910 "A" HOSE

HOSE ASSY 212391 KMI 1 EA HOSE ASSY RBM HV-P16 0.75" BELLOWSFLEX 7910 "A" HOSE

HOSE ASSY 212767 KMI 1 EA HOSE ASSY RBM HV-P18 0.75" BELLOWSFLEX 7910 "A" HOSE

HOSE ASSY 206133 KMI 1 EA HOSE ASSY RBM HV-P15 0.75" BELLOWSFLEX 7910 "A" HOSE

HOSE ASSY 212393 KMI 1 EA HOSE ASSY RBM HV-S20 0.75" BELLOWSFLEX 7910 "A" HOSE

HVAC Pump Retrofit Parts Fabrication – Structural (Not Required on All Hulls)

Drawing Number Manufacture Qty Unit Additional Description

180-256-D04 CUSTOM

FABRICATION 1 EA CUT PLATE, FORMED, 0.190 THK 5083-H116

180-256-D05 CUSTOM

FABRICATION 1 EA CUT PLATE, 0.190 THK 5083-H116

180-256-D01 CUSTOM

FABRICATION 1 EA CUT PLATE, FORMED, 0.250 THK 5083-H116

180-256-D06 CUSTOM

FABRICATION 1 EA EXTRUSION, FLATBAR, 5086-H111 OR H112, 1.0 X 1.0

HVAC Pump Retrofit Outfit Parts List - Outfitting (Not Required on All Hulls)

Number Manufacture Qty Unit Additional Description

PIPE 200725 KMI 2 EA FITTING PIPE, KING NIPPLE, 316, SCH 40, 1.250

CONNECTOR 208019 KMI 2 EA FITTING JIC FLARE, CONNECTOR, 316, 1.250 FJX x 1.250

FNPT, PARKER 20 G6X-SS

MACHINED

PART 212349 KMI 1 EA MACHINED PART, FLANGE, 316, 1.000, 150#, THREADED,

RAISED FACE PER ANSI B16.5, DRILLED TO 1.25 NPT

PIPE 119222 KMI 1 EA FITTING PIPE, NIPPLE CLOSE, 316, SCH 40, 1.250 MNPT x

CLOSE

VALVE 103474 KMI 1 EA VALVE, BALL, 316 BODY, 1.250 FNPT, FULL PORT,

MERIT V210FP-20

PIPE 200725 KMI 1 EA FITTING PIPE, KING NIPPLE, 316, SCH 40, 1.250

PIPE 101337 KMI 3 EA FITTING PIPE, KING NIPPLE, BRASS, SCH 40, 1.250

FITTING 210085 KMI 1 EA FITTING JIC FLARE, BLKHD UNION, 316, 1.250 MJ x 1.250

MJ, LOCKNUT, PARKER 20 WTX-WLN-SS

STRAINER 211373 KMI 1 EA

STRAINER, RAW WATER, SIMPLEX, RED BRASS BODY,

MONEL FILTER, 1.250 FNPT x 1.250 FNPT, FLOW RATE

28 GPM, GROCO ARG-1250

VALVE 210242 KMI 1 EA

VALVE, BALL, RED BRASS BODY, BRASS BALL, RPTFE

SEAT, 1.250 MNPT x 1.250 FNPT, 600 PSI WORKING

PRESSURE, APOLLO, 70-806-01-10, W/SS LEVER & NUT,

C84400 BODY

PUMP 209896 KMI 1 EA

PUMP, CENTRIFUGAL, RAW WATER, 12 GPM, 32 FT H20

WORKING PRESSURE, RED BRASS CASING, SMI-OPEN

RED BRASS IMPELLER, 3.000 IMPELLER DIA, 115/230

VAC, 60 Hz, SINGLE PHASE, 1/3 HP, 3550 RPM, TEFC, MAX 16 PSI, 1.250 FNPT x 1.000 FNPT, MARINE AIR 225500102 P120Z

PIPE 107947 KMI 1 EA FITTING PIPE, ELBOW, BRASS, 1.0 FNPT x 1.0 FNPT, 90

DEG

PIPE 210770 KMI 1 EA FITTING PIPE, BUSHING, RED BRASS, 1.000 MNPT x .750

FNPT

PIPE 105774 KMI 1 EA FITTING PIPE, KING NIPPLE, BRASS, SCH 40, .750

CONNECTOR 206349 KMI 1 EA CONNECTOR RECEPTACLE WEDGELOCK, PLASTIC,

DEUTSCH #W-3P, FOR DT 3 PIN RECEPTACLE, GREEN

CONNECTOR 206353 KMI 1 EA CONNECTOR RECEPTACLE, DEUTSCH DT04-3P-E008, 3

PIN, DT SERIES, WITH HEAT SHRINK BOOT

CONTACT 206228 KMI 3 EA

CONTACT, NICKEL PLATED, DEUTSCH #1060-12-0122,

STAMPED AND FORMED PIN, SIZE 12 FOR USE WITH

DTP RECEPTACLES 12-14 AWG

SUB-ASSEMBLY 208-026 KMI 1 EA SUB-ASSEMBLY, SEE OUTFITTING PREFAB DETAIL

SUB-ASSEMBLY 208-025 KMI 1 EA SUB-ASSEMBLY, SEE OUTFITTING PREFAB DETAIL

SUB-ASSEMBLY 209-009 KMI 1 EA SUB-ASSEMBLY, SEE OUTFITTING PREFAB DETAIL

SUB-ASSEMBLY 209-010 KMI 1 EA SUB-ASSEMBLY, SEE OUTFITTING PREFAB DETAIL

SUB-ASSEMBLY 208-027 KMI 1 EA SUB-ASSEMBLY, SEE OUTFITTING PREFAB DETAIL

SUB-ASSEMBLY 210-004 KMI 4 EA SUB-ASSEMBLY, SEE OUTFITTING PREFAB DETAIL

GASKET 111997 KMI 1 EA GASKET, BUNA N, 1.250 x .125 THICK, FOR 1.25" ANSI B

150# FLANGE

WASHER 203459 KMI 4 EA

WASHER, SHOULDER, NYLON, .500 ID x .625 OD x .625 LENGTH x .875 FLANGE OD x .0625 FLANGE THICKNESS

MCMASTER 6389K421 OR EQUAL

WASHER 210166 KMI 2 EA

WASHER, SHOULDER, UHMW, 1.563 ID x 1.750 OD x .078 LENGTH x 2.250 FLANGE OD x .125 FLANGE THICKNESS, .203 OA LENGTH, CUSTOM

WASHER 205569 KMI 5 EA

WASHER, SHOULDER, NYLON, .184 ID x .234 OD x .188 LENGTH x .312 FLANGE OD x .031 FLANGE THICKNESS, WASUSA 12SWS0441

WASHER 203459 KMI 4 EA

WASHER, SHOULDER, NYLON, .500 ID x .625 OD x .625 LENGTH x .875 FLANGE OD x .0625 FLANGE THICKNESS, MCMASTER 6389K421 OR EQUAL

WASHER 118239 KMI 5 EA WASHER FLAT, 316, #08

WASHER 117633 KMI 16 EA WASHER, FLAT, 316, .250

WASHER 118238 KMI 8 EA WASHER FLAT, 316, #06

WASHER 216448 KMI 8 EA WASHER FLAT, 316, M12, DIN 125 A4

NUT 118242 KMI 4 EA NUT, NYLOCK, 316, #6-32

NUT 117632 KMI 8 EA NUT, NYLOCK, 316, .250-20

NUT 118243 KMI 5 EA NUT, NYLOCK, 316, #8-32

NUT 117416 KMI 4 EA NUT, NYLOCK, 316, .500-13

SCREW 118196 KMI 2 EA SCREW, HEX CAP, 316, .250-20 x 1.250

SCREW 206579 KMI 4 EA SCREW, ALLEN SOCKET CAP, 316, #6-32 X .75

SCREW 118145 KMI 4 EA SCREW, HEX CAP, 316, .250-20 x 1.000 SCREW 204250 KMI 5 EA SCREW ALLEN SOCKET CAP, 316, #8-32 x .875 SCREW 117415 KMI 4 EA SCREW, HEX CAP, 316, .500-13 x 2.500

SLEEVE 210544 KMI 2 EA SLEEVE, BANDING, NEOPRENE, BLACK, .910 WIDTH,

PANDUIT PCSSH-B-CR

CABLE TIE 206444 KMI 3 EA CABLE TIE, 29.7, 316, PANDUIT MLTFC8EH-LP316, 1.0-8.0

BUNDLE DIA, POLYESTER COATED

HVAC Pump Retrofit Hose Parts (Not Required on All Hulls)

Number Manufacture Qty Unit Additional Description

HOSE ASSY 210766 KMI 1 EA HOSE ASSY RBM HV-S02 1.250" BELLOWSFLEX 7910 "A" HOSE

HOSE ASSY 210765 KMI 1 EA HOSE ASSY RBM HV-S01 1.250" BELLOWSFLEX 7910 "A" HOSE

HOSE ASSY 210767 KMI 1 EA HOSE ASSY RBM HV-S03 1.250" BELLOWSFLEX 7910 "A" HOSE

CLAMP 202788 KMI 2 EA CLAMP HOSE, 316, #012

CLAMP 202866 KMI 12 EA CLAMP, HOSE, 316, #020

(1) Action Required on Items in Stock

i. N/A

(2) Kits/Parts/Materials Required to Modify Items in Stock

i. N/A

(3) Disposition of Removed and Replaced Parts and Materials

i. Removal of old HVAC units is required to complete this TCTO.

ii. Removal of all hoses which with replacements depicted below is required to complete this TCTO.\

iii. Removal of old HVAC system foundations as detailed below is required to complete this TCTO.

iv. All edges of foundations cut will be ground smooth to eliminated sharp edges which may cut or damage personnel or equipment.

v. Retain all original wiring associated with the HVAC units. Wiring will be IAW drawings 45RBM-321-200, 45RBM-321-201, & 45RBM-514-001. Wiring is required to be supported by stainless steel straps. Rubber coating or chafing protection is required at all installed bands. Wiring may need to be extended or shortened to meet installation requirements.

vi. Cable & labels are required to be replaced if removed IAW 45RBM-321-200.

vii. All cable termination devices replaced on shortened or lengthened cables such as ring terminals but splices and ferrules will meet the requirements of ABYC E-11.

viii. All cable splicing will be in accordance with the following diagram.

ix. Dispose of all removed materials and equipment in accordance with local state and federal regulations.

x. After completion of depot level availability work the operation of the HVAC systems replaced will be verified by performing the HVAC test procedure in Section 7.a.(2).

xi. Drawings Required

(a) 45RBM-110-083 Rev(A) Hull Structure Module B - Deck

(b) 45RBM-180-256 Rev(A) Foundations - Cooling System

(c) 45RBM-180-511 Rev(B) Foundations – Compartment Heating

(d) 45RBM-180-514 Rev(A) Foundations – Air Conditioning Units

(e) 45RBM-180-660 Rev(B) Foundations – Seating

(f) 45RBM-256-101 Rev(B) Cooling System HVAC

(g) 45RBM-321-100 Rev(B) 60Hz Power Distribution System Schematic

(h) 45RBM-321-200 Rev(A) Wire Harness Arrangement

(i) 45RBM-321-201 Rev(A) Wire Way Arrangement

(j) 45RBM-406-001 Rev(A) Grounding and Bonding System Schematic

(k) 45RBM-511-002Rev( A) Compartment Heating Arrangement

(l) 45RBM-514-001 Rev(A) HVAC System Schematic

(m) 45RBM-514-003 Rev(B) Air Conditioning Units, Self Contained

(n) 45RBM-555-100 Rev(A) Fire Extinguishing System, Dry Chemical

(4) Estimated Size, Weight and Cost of Kits:

i. Size: N/A

ii. Weight: N/A

iii. Cost: N/A

• PERSONNEL INFORMATION AND REQUIREMENTS

WORK PHASE SKILLS LABOR-HOURS

Installation Depot 160 Inspection EPO 8 Total 168

d. SPECIAL TOOLS, FIXTURES AND SOFTWARE REQUIRED:

(1) N/A

6. HOW WORK IS ACCOMPLISHED

a. See attached instructions on page 12

7. SUPPLEMENTAL INFORMATION

a. OPERATIONAL CHECKOUT REQUIREMENTS

(1) RB-M-45 S00011.0 REV’D 01/05/2012 Electrical Isolation For Welding MPC

(2) Test Procedure-510-0001 HVAC System Operational Test.

(3) MPC J32006.0 Pilothouse HCAC Unit( Replace)

(4) MPC J32006.0 Survivor Compartment HVAC Unit (Replace)

b. WEIGHT AND BALANCE INFROMATION:

(1) PWR already updated by KMI/MMC during approval of ECP 128 under the scope of the RB-M contract.

c. TECHNICAL PUBLICATIONS AFFECTED

(1) All technical publications have been updated already by KMI/MMC during approval of ECP 128 under the scope of the RB-M contract.

d. TRAINING EQUIPMENT AFFECTED

8. RECORDS

a. ACTION REQUIRED ON MAINTENANCE RECORDS

(1) Upon completion of TCTO TJ3020.1, units shall forward the sign-off sheet to the Field Terminal Operator to document completion.

b. ACTION REQUIRED ON SUPPLY RECORDS

c. MODIFICATION IDENTIFICATION MARKING

*ALL WELDS ARE 5/32” DOUBLE CONTINUOUS UNLESS OTHERWISE NOTED*

SC Guard: Sub-Assembly 422-006

SC HVAC Base Foundation: Sub-Assembly 291-016

180-660-B27 Quantity = 1

Fabrication – Installation: Parts List

Drawing Number Manufacture Qty Unit Additional Description

180-660-B11 CUSTOM

FABRICATION 1 EA Cut Plate, 0.160 THK

180-660-B14 CUSTOM

FABRICATION 1 EA Cut Plate, 0.190 THK

RETRO-180-660-B24 CUSTOM

FABRICATION 1 EA Cut Plate, 0.190 THK

RETRO-180-660-B25 CUSTOM

FABRICATION 1 EA Cut Plate, 0.190 THK

180-660-B18 CUSTOM

FABRICATION 1 EA Cut Plate, 0.190 THK

180-660-B17 CUSTOM

FABRICATION 1 EA Cut Plate, 0.190 THK

RETRO-180-514-B03 CUSTOM

FABRICATION 1 EA Cut Extrusion, See Fabrication Prefab Detail

180-660-B27 CUSTOM

FABRICATION 1 EA Cut Extrusion, See Fabrication Prefab Detail

291-016 CUSTOM

FABRICATION 1 EA Sub-Assembly, See Fabrication Prefab Det

205149 CUSTOM

FABRICATION 4 EA 1” Channel Bracket, Purchased Part

205150 CUSTOM

FABRICATION 1 EA 2” Channel Bracket, Purchased Part

RETRO-180-514-B03 Quantity = 1

RETRO-180-660-B24 Quantity=1

RETRO-180-660-B25 Quantity 1

Step 1

Step 2

Step 3

Detail G

Step 4a

Step 4b

Detail AD

Detail A

Step 5a

Step 5b

Section K-K

Section J-J

Detail L

Step 6a

1. Weld pieces shown in red.

Step 6b

Detail W

Step 6c

1. Cut out the hole as shown. Note that this should line up with the existing indentation on Retro 180-660-B25

Step 7a

1. Weld pieces shown in red.

Step 7b

Section U-U

Section V-V

Detail R

Step 8

Section AE-AE

1. Weld where accessible

Section AC-AC

1. Weld where accessible

Outfitting – Prefab Parts List

Additional Description Part Part Number

Manufacture Qty Unit

HOSE ASSY 206128 KMI 1 EA HOSE ASSY RBM HV-S12 0.75" BELLOWSFLEX 7910 "A" HOSE

CLAMP 202788 KMI 6 EA CLAMP HOSE, 316, #012

VALVE 205590 KMI 1 EA VALVE CHECK 0.750" SLIP, BOSWORTH 74-6

HOSE ASSY 212396 KMI 1 EA HOSE ASSY RBM HV-S23 0.75" BELLOWSFLEX 7910 "A" HOSE

HOSE ASSY 206136 KMI 1 EA HOSE ASSY RBM HV-S18 1.0" BELLOWSFLEX 7910 "A" HOSE

CLAMP 202789 KMI 4 EA CLAMP HOSE, 316, #016

VALVE 204832 KMI 1 EA VALVE CHECK SWING, 1.000 HB, BOSWORTH 74-8

HOSE ASSY 212395 KMI 1 EA HOSE ASSY RBM HV-S22 1.0" BELLOWSFLEX 7910 "A" HOSE

FITTING 204502 KMI 1 EA FITTING HOSE JIC FLARE, 316, .75 FJ x .75 HB, PARKER 30682- 12-12C

HOSE ASSY 212394 KMI 1 EA HOSE ASSY RBM HV-S21 0.75" BELLOWSFLEX 7910 "A" HOSE

SC HVAC OVBD: Sub-Assembly 383-008

SC HVAC Condensate OVBD: Sub-Assembly 383-009

SC HVAC Cooling Water Supply: Sub-Assembly 383-011

Outfitting – Installation Parts List

Part Part Number

Manufacture Qty Unit Additional Description

SUB-

ASSEMBLY 383-008 KMI 1 EA SUB-ASSEMBLY, SEE OUTFITTING PREFAB DETAIL

SUB-

ASSEMBLY 383-009 KMI 1 EA SUB-ASSEMBLY, SEE OUTFITTING PREFAB DETAIL

SUB-

ASSEMBLY 383-011 KMI 1 EA SUB-ASSEMBLY, SEE OUTFITTING PREFAB DETAIL

HVAC UNIT 221563 KMI 1 EA HVAC UNIT, 27000 BTU, 230V/60HZ

PIPE 212291 KMI 1 EA FITTING PIPE, BARB, 316, .500 MNPT X .750 HB

PIPE 201954 KMI 1 EA FITTING PIPE, 316, .500 FNPT X .500 MB, PARKER 8-1/2 F5OG-

SS

NUT 207448 KMI 1 EA FITTING BLKHD NUT, 316, PARKER 8-WLN-SS, .75-16

THREADS

TRIM 210276 KMI 1 EA TRIM, EDGE, RUBBER, BLACK, .250 OPENING X .500 DEPTH

CLAMP 202788 KMI 10 EA CLAMP HOSE, 316, #012

CLAMP 202789 KMI 4 EA CLAMP HOSE, 316, #016

WASHER 207354 KMI 3 EA MACHINED PART, SHOULDER WASHER, UHMW, .250ID X

.375OD X .250L X .063

CUT PLATE 180-

660-B21 KMI 1 EA CUT PLATE, FORMED, 0.125 THK

HOSE ASSY 212393 KMI 1 EA HOSE ASSY RBM HV-S20 0.75" BELLOWSFLEX 7910 "A" HOSE

HVAC

HEATER 212254 KMI 1 EA HVAC HEATER, 3000W, CRUISAIR HMDL3C-8-GR, 230V, 8.0

DUCT

CLAMP 208401 KMI 2 EA CLAMP, HOSE, WORM DRIVE, RANGE 5.625 TO 8.500, BREEZE

63128

DUCT 212545 KMI 1 EA DUCT, HVAC, 8.0 DIA X 8 FT LENGTH, THERMAFLEX M-KC

STRAP 203222 KMI 1 EA STRAP VELCRO, CUT TO 15.000 L X 1.000 W, MCMASTER

#94905K118

SCREW 118145 KMI 7 EA SCREW, HEX CAP, 316, .250-20 X 1.000

WASHER 117633 KMI 14 EA WASHER, FLAT, 316, .250

NUT 117632 KMI 7 EA NUT, NYLOCK, 316, .250-20

NUT 117397 KMI 21 EA NUT, NYLOCK, 316, .375-16

SCREW 117561 KMI 13 EA SCREW, HEX CAP, 316, .375-16 X 1.000

WASHER 117396 KMI 39 EA WASHER FLAT, 316, .375

NUT 117559 KMI 6 EA NUT, NYLOCK, 316, #10-24

WASHER 117560 KMI 10 EA WASHER FLAT, 316, #10

SCREW 204290 KMI 4 EA SCREW, SOCKET CAP, 316, #10-24 X .750

CABLE TIE 206444 KMI 4 EA CABLE TIE, 29.7, 316, PANDUIT MLTFC8EH-LP316

HOSE 113145 KMI 6 EA HOSE, PROTECTOR, EPHA HP4-B, 4" LONG, BLACK

CABLE TIE 206466 KMI 18 EA CABLE TIE, NYLON, BLACK

SCREW 205220 KMI 2 EA SCREW, MACHINE FLAT SOCKET, 316, #10-24 X 1.000

CUT PLATE 180-

660-B19 KMI 1 EA CUT PLATE, FORMED, 0.190 THK

SCREW 117697 KMI 8 EA SCREW, HEX CAP, 316, .375-16 X 1.250

SUB-

ASSEMBLY 422-006 KMI 1 EA SUB-ASSEMBLY, SEE FABRICATION PREFAB DETAIL

1. The sheet metal screw on the left side cannot be reinstalled after rotation. Please leave out.

Step 2a

Step 2b

Step 3a

1. Slide HVAC unit aft side first into the foundation. Then rotate the forward side into position (tight fit). Secure with hold-downs as shown. Hold-downs are installed at each burn hole on the base plate.

Step 3b

1. Slide part 180-660-B21 down and secure with bolts to hold down outboard edge of HVAC tray.

Step 4a

1. Install hose assemblies as shown.

Step 4b

Step 4c

1. Install fittings as shown in the HVAC pan’s aft drain hole.

Step 4d

Note that hose 212393 must have the 212291 hose barb fitting installed prior to connecting it to the HVAC condensate fittings

Step 4e

Install banding as shown to secure hoses.

Step 5

Step 7

Step 8a

1. Install plate 180-660-B19 temporarily for match drilling then remove.

Step 8b

Step 8c

Step 8d

Step 8e

END OF SURVIVOR COMPARTMENT HVAC RETROFIT PROCEDURES

Pilot House HVAC Retrofit Instructions - Fabrication - Prefab

Part Part Number Manufacture Qty Unit Additional Description

CUT PLATE 180-514-F07 KMI 1 EA CUT PLATE, FORMED, 0.125 THK 5083H-116

CUT PLATE 180-514-F10 KMI 1 EA CUT PLATE, FORMED, 0.160 THK 5083H-116

CUT PLATE 180-511-D05 KMI 1 EA CUT PLATE, FORMED, 0.190 THK 5083H-116

CUT PLATE 180-511-D03 KMI 1 EA CUT PLATE, FORMED, 0.160 THK 5083H-116

CUT PLATE 180-511-D04 KMI 1 EA CUT PLATE, FORMED, 0.160 THK 5083H-116

CUT PLATE 612-001-0202 KMI 2 EA CUT PLATE, 0.160 THK 5083H-116

PIPE 612-001-0305 KMI 1 EA EXTRUSION, PIPE, 5086-H111OR H112, SCH 40, 1.000,

ASTM B221

TOOL 205149 KMI 3 EA 1” RESEARCH TOOL & DIE WORKS 9C02A HANGER

LONG 6061

MATERIAL KMI 1 EA EXTRUSION, FLATBAR, 5086-H111 OR H112, .1875 X

1.500, ASTM B221

MATERIAL KMI 1 EA EXTRUSION, FLATBAR, 5086-H111 OR H112, .1875 X

2.000, ASTM B221

MATERIAL KMI 1 EA EXTRUSION, FLATBAR, 5086-H111 OR H112, .3125 X

3.000, ASTM B221

*ALL WELDS ARE 5/32” DOUBLE CONTINUOUS UNLESS OTHERWISE NOTED*

PH Guard: Sub-Assembly 383-015

2. Weld pieces to the foundation where shown.

PH Guard Support: Sub-Assembly 383-014

1. Weld clip to the foundation where shown.

PH Duct Heater Foundation: Sub-Assembly 346-012

1. Weld the foundation where shown.

PH Relay Foundation: Sub-Assembly 346-013

PH Handrail: Sub-Assembly 347-002

1. Cut and Bend the pipe as shown.

2. Position the handrail doublers (612-001-0202) as shown and weld out 100%

180-514-F08 Quantity = 1

180-514-F09 Quantity = 1

RETRO-180-514-F13 Quantity = 1

RETRO-180-514-F14 Quantity = 1

Fabrication – Installation: Parts List

SUB-

ASSEMBLY 347-002 KMI 1 EA SUB-ASSEMBLY, SEE FABRICATION PREFAB DETAIL

SUB-

ASSEMBLY 346-012 KMI 1 EA SUB-ASSEMBLY, SEE FABRICATION PREFAB DETAIL

SUB-

ASSEMBLY 346-013 KMI 1 EA SUB-ASSEMBLY, SEE FABRICATION PREFAB DETAIL

CUT

EXTRUSION 180-514-F08 KMI 1 EA CUT EXTRUSION, SEE FABRICATION PREFAB DETAIL

CUT

EXTRUSION 180-514-F09 KMI 1 EA CUT EXTRUSION, SEE FABRICATION PREFAB DETAIL

CHANNEL

BRACKET 205149 KMI 3 EA 1” CHANNEL BRACKET, PURCHASED PART

CHANNEL

BRACKET 205151 KMI 1 EA 3” CHANNEL BRACKET, PURCHASED PART

ADHESIVE 211547 KMI AR EA ADHESIVE, INSULATION HANGER, 1 GAL, MEI ECO

HANGER GRIP 22-15, 800-1000 HANGERS/GAL

INSULATION

HANGER 211548 KMI 15 EA

INSULATION HANGER, ANNULAR RING STUD, 5356

.181 ND X 1.000 LENGTH, PERFORATED BASE

ADHESIVE MOUNT, AGM INDUSTRIES ALT 177-0875,

2.000 X 2.000 3003 ALUM BASE, NAVY STANDARD

RING DRIVE 212044 KMI 15 EA

ANNULAR RING DRIVE ON CAP, ALUMINUM, .500”

LONG X 0.906” DIA, AGM INDUSTRIES INC ALNC-

180 OR EQUAL

INSULATION

TAPE 212041 KMI AR EA

INSULATION, TAPE, 3" WIDE, ALPHA ASSOCIATES

INC 59M-PS-3-WHITE, 100% FIBERGLASS SCRIM

AND POLYESTER FILM OR EQUAL

Step 1a

1. Remove the 5 insulation panels in the AFT port vent box and port side AFT Pilot House.

2. Insulation pieces 4 and 5 are removed by cutting the pins, removing the insulation, and then removing the remaining part of the pin.

3. Insulation pieces 1, 2 and 3 are removed by cutting the center insulation flush along the vent box side insulation. The pins are then cut and removed same as pieces 4 and 5.

Step 1b

1. Remove part as shown.

2. Remove the bolted fire extinguisher bracket and fill the 2 holes that remain with weld.

Step 3a – Overview

Detail K

Step 3b

1. Weld the items where shown in the following views.

Section H-H Detail G

Step 4

1. Reinstall the insulation pieces shown.

a. Reinstalling is done by gluing (211547) on special pins (211548) where the old welded pins were placed. The insulation is then placed over the pins and the caps (212044) are hammered onto each pin. The insulation is then re-taped (212041).

b. Note that the pin for insulation piece 4 will have to be relocated because the old pin lined up behind the new HVAC relay foundation

Outfitting – Prefab: Parts List

FITTING 204502 KMI 5 EA FITTING HOSE JIC FLARE, 316, .75 FJ x .75 HB, PARKER 30682-12-12C

CLAMP 202788 KMI 14 EA CLAMP HOSE, 316, #012

HOSE ASSY RBM HV-P17 0.75" BELLOWSFLEX 7910

"A" HOSE HOSE ASSY 212392 KMI 1 EA

HOSE ASSY RBM HV-P18 0.75" BELLOWSFLEX 7910

"A" HOSE HOSE ASSY 212390 KMI 1 EA

HOSE ASSY RBM HV-P16 0.75" BELLOWSFLEX 7910

"A" HOSE HOSE ASSY 212391 KMI 1 EA

VALVE 205590 KMI 1 EA VALVE CHECK 0.750" SLIP, UNION END DELRIN,

BOSWORTH 74-6

HOSE ASSY RBM HV-P18 0.75" BELLOWSFLEX 7910

"A" HOSE HOSE ASSY 212767 KMI 1 EA

HOSE ASSY RBM HV-P15 0.75" BELLOWSFLEX 7910

"A" HOSE HOSE ASSY 206133 KMI 1 EA

383-002

383-003

383-004

211-019

Outfitting – Installation: Parts List

Cut Plate RETRO-180- 514-F06

Custom Fabrication 1 EA Cut Plate, Formed, 0.190 THK

Cut Plate 180-514-F14 Custom Fabrication 1 EA Cut Plate, Formed, 0.125 THK

Cut Extrusion RETRO-180- 514-F13

Custom Fabrication 1 EA Cut Extrusion, See Fabrication Prefab Detail

Cut Extrusion RETRO-180- 514-F14

Custom Fabrication 1 EA

Cut Extrusion, See Fabrication Prefab Detail

Sub-Assembly 383-002 Custom Fabrication 1 EA Sub-Assembly, See Outfitting Prefab Detail

Sub-Assembly 383-003 Custom Fabrication 1 EA Sub-Assembly, See Outfitting Prefab Detail

Sub-Assembly 383-004 Custom Fabrication 1 EA Sub-Assembly, See Outfitting Prefab Detail

Sub-Assembly 211-019 Custom Fabrication 1 EA Sub-Assembly, See Outfitting Prefab Detail

Sub-Assembly 383-015 Custom Fabrication 1 EA Sub-Assembly, See Fabrication Prefab Detail

Sub-Assembly 383-014 Custom Fabrication 1 EA Sub-Assembly, See Fabrication Prefab Detail

HVAC UNIT 221563 KMI 1 EA HVAC UNIT, 27000 BTU, 230V/60HZ

ELBOW 207510 KMI 1 EA FITTING JIC FLARE ELBOW, 316, .750 MJ x .500 MB, PARKER 12-8 C5OX-SS, 90D, 12MJ-8MB

NUT 207448 KMI 1 EA FITTING BLKHD NUT, 316, PARKER 8-WLN-SS, 75-16

THREADS

SCREW 212513 KMI 2 EA SCREW SOCKET FLAT, 316, .375-16 X 1.50

SCREW 212475 KMI 2 EA SCREW SOCKET FLAT, 316, .375-16 X 1.25

WASHER 117396 KMI 12 EA WASHER FLAT, 316, .375

NUT 117397 KMI 4 EA NUT, NYLOCK, 316, .375-16

Machined 214109 KMI 1 EA Machined UHMW Part SCREW 118197 KMI 1 EA SCREW, HEX CAP, 316, .250-20 x 1.500 SCREW 118145 KMI 13 EA SCREW, HEX CAP, 316, .250-20 x 1.000

WASHER 117633 KMI 28 EA WASHER, FLAT, 316, .250

Machined Part 207354 KMI 3 EA Machined Part, Shoulder Washer, UHMW, 007, Configuration.250ID x .375OD x .250L x .063 THICK

NUT 117632 KMI 14 EA NUT, NYLOCK, 316, .250-20

CLAMP HOSE 202788 KMI 6 EA CLAMP HOSE, 316, #012

CABLE TIE 206444 KMI 2 EA CABLE TIE, 29.7, 316, PANDUIT MLTFC8EH- LP316, 1.0-

8.0 BUNDLE DIA, POLYESTER COATED

HVAC DUCT

HEATER 212254 KMI 1 EA HVAC DUCT HEATER, 3000W, CRUISAIR HMDL3C-8-

GR, CUSTOM, 230V, 8.000 DUCT

SCREW 204290 KMI 4 EA SCREW, SOCKET CAP, 316, #10-24 x .750

WASHER 117560 KMI 8 EA WASHER FLAT, 316, #10

NUT 117559 KMI 4 EA NUT, NYLOCK, 316, #10-24

CLAMP HOSE 208401

KMI

2 EA

CLAMP, HOSE, WORM DRIVE, 300 SERIES, GRIP

RANGE 5.625 TO 8.500, BREEZE 63128, POWER SEAL

SERIES,

DUCT 212542 KMI 1 EA DUCT, HVAC, 8.0 DIA x 2 FT LENGTH, THERMAFLEX, S-LP-10, NON-INSULATED

SCREW 117561 KMI 4 EA SCREW, HEX CAP, 316, .375-16 x 1.000

CORDGRIP 212485 KMI 1 EA CORDGRIP, INSERT, MENCOM PG16-0X0, NO HOLES

CORDGRIP 209563 KMI 1 EA CORDGRIP, PLASTIC, .500 MNPT, .394-.551 GRIP

RANGE, MENCOM PCG-1/2-B, BLACK

NUT 209632 KMI 1 EA NUT, CORDGRIP, PLASTIC, .500, MENCOM 212PA/SW

Step 1

1. Part 212485 is an insert gland that installs directly into the existing HF antenna cordgrip.

1. Modify part 207510 as shown.

1. Modify part RETRO-180-514-F06 as shown.

Step 5a

Step 5b

Step 6

1. Position the HVAC system and place the tray bolt down brackets as shown. Mark hole locations of each bolt down bracket.

2. Remove HVAC system and drill out holes. Note the single bolt on the outboard side goes through the UHMW shim and base plate.

Step 7a

1. Position the HVAC system and place the tray bolt down brackets as shown.

2. Mount the HVAC hold downs with the proper fasteners as shown. See Step 6b for stack information.

Step 7b

Step 8a

1. Install 383-002

Step 8b

1. Install 383-003 and 383-004

Step 8c

Step 9a

Step 9b

Step 9c

1. Install the existing fire extinguisher bracket at the location shown by match drilling.

Step 9d

Step 10a

Step 10b

Step 11

HVAC Pump Retrofit Instructions (Not Required on All Hulls)

Fabrication – Prefab: Parts List

Cut Plate 180-256-D04 KMI 1 EA Cut Plate, Formed, 0.190 THK Cut Plate 180-256-D05 KMI 1 EA Cut Plate, 0.190 THK Extrusion 180-256-D06 KMI 1 EA Extrusion, Flatbar, 5086-H111 or H112, 1.0 x 1.0

*ALL WELDS ARE 5/32” CONTINUOUS*

HVAC Pump Cover: Sub Assembly 208-027

RETRO-180-256-D06

Outfitting – Prefab: Parts List

HOSE ASSY 210766 KMI 1 EA HOSE ASSY RBM HV-S02 1.250" BELLOWSFLEX 7910

"A" HOSE

CLAMP 202866 KMI 4 EA CLAMP, HOSE, 316, #020

PIPE 200725 KMI 2 EA FITTING PIPE, KING NIPPLE, 316, SCH 40, 1.250

CONNECTOR 208019 KMI 2 EA FITTING JIC FLARE, CONNECTOR, 316, 1.250 FJX x

1.250 FNPT PARKER 20 G6X-SS

HOSE ASSY 210767 KMI 1 EA HOSE ASSY RBM HV-S03 1.250" BELLOWSFLEX 7910

"A" HOSE

FLANGE 212349 KMI 1 EA

MACHINED PART, FLANGE, 316, 1.000, 150#,

THREADED, RAISED FACE PER ANSI B16.5, DRILLED

TO 1.25 NPT

PIPE 119222 KMI 1 EA FITTING PIPE, NIPPLE CLOSE, 316, SCH 40, 1.250 MNPT

CLOSE

VALVE 103474 KMI 1 EA VALVE, BALL, 316 BODY, 1.250 FNPT, FULL PORT,

MERIT V210FP-20

PIPE 200725 KMI 1 EA FITTING PIPE, KING NIPPLE, 316, SCH 40, 1.250

PIPE 101337 KMI 3 EA FITTING PIPE, KING NIPPLE, BRASS, SCH 40, 1.250

STRAINER 211373 KMI 1 EA

STRAINER, RAW WATER, SIMPLEX, RED BRASS

BODY MONEL FILTER, 1.250 FNPT x 1.250 FNPT, FLOW

RATE 28 GPM, GROCO ARG-1250

VALVE 210242 KMI 1 EA

VALVE, BALL, RED BRASS BODY, BRASS BALL,

RPTFE SEAT1.250 MNPT x 1.250 FNPT, 600 PSI

WORKING PRESSURE, APOLLO 70-806-01-10, W/SS

LEVER & NUT, C84400 BODY

PUMP 209896 KMI 1 EA

PUMP, CENTRIFUGAL, RAW WATER, 12 GPM, 32 FT

H20 WORKING PRESSURE, RED BRASS CASING, SMI-

OPEN RED BRASS IMPELLER, 3.000 IMPELLER DIA,

115/230 VAC, 60 Hz, SINGLE PHASE, 1/3 HP, 3550 RPM, TEFC, MAX 16 PSI, 1.250 FNPT x 1.000 FNPT, MARINE

AIR 225500102 P120Z

PIPE 107947 KMI 1 EA FITTING PIPE, ELBOW, BRASS, 1.0 FNPT x 1.0 FNPT, 90

DEG

PIPE 210770 KMI 1 EA FITTING PIPE, BUSHING, RED BRASS, 1.000 MNPT x

.750 FNPT

PIPE 105774 KMI 1 EA FITTING PIPE, KING NIPPLE, BRASS, SCH 40, .750

CONNECTOR 206349 KMI 1 EA CONNECTOR RECEPTACLE WEDGELOCK, PLASTIC,

DEUTSCH #W-3P, FOR DT 3 PIN RECEPTACLE, GREEN

CONNECTOR 206353 KMI 1 EA CONNECTOR RECEPTACLE, DEUTSCH DT04-3P-E008,

3 PIN, DT SERIES, WITH HEAT SHRINK BOOT

CONTACT 206228 KMI 3 EA

CONTACT, NICKEL PLATED, DEUTSCH #1060-12-0122,

STAMPED AND FORMED PIN, SIZE 12 FOR USE WITH

DTP RECEPTACLES 12-14 AWG

HVAC Strainer Outlet Hose: Sub Assembly 209-010

HVAC Pump Inlet Hose: Sub Assembly 210-004

Coolant Inlet Valve Assembly: Sub Assembly 208-025

1. Note part 212349 is a modified flange to adapt the 1” inlet side flange to the 1 ¼” pump side parts.

Coolant Strainer Assembly: Sub Assembly 209-009

HVAC Cooling Pump Assembly: Sub Assembly 208-026 Step 1a

1. Assemble HVAC pump deutsch plug receptacle as shown.

Step 1b

Outfitting – Installation: Parts List

Sub-Assembly 208-026 KMI 1 EA Sub-Assembly, See Outfitting Prefab Detail Sub-Assembly 208-025 KMI 1 EA Sub-Assembly, See Outfitting Prefab Detail Sub-Assembly 209-009 KMI 1 EA Sub-Assembly, See Outfitting Prefab Detail Sub-Assembly 209-010 KMI 1 EA Sub-Assembly, See Outfitting Prefab Detail Sub-Assembly 208-027 KMI 1 EA Sub-Assembly, See Fabrication Prefab Detail Sub-Assembly 210-004 KMI 4 EA Sub-Assembly, See Outfitting Prefab Detail

NUT 117416 KMI 4 EA NUT, NYLOCK, 316, .500-13

WASHER 216448 KMI 8 EA WASHER FLAT, 316, M12, DIN 125 A4

WASHER 203459 KMI 4 EA

WASHER, SHOULDER, NYLON, .500 ID x .625 OD x .625 LENGTH x .875 FLANGE OD x .0625 FLANGE

THICKNESS, MCMASTER 6389K421 OR EQUAL

GASKET 111997 KMI 1 EA GASKET, BUNA N, 1.250 x .125 THICK, FOR 1.25" ANSI

B150# FLANGE

WASHER 203459 KMI 4 EA

WASHER, SHOULDER, NYLON, .500 ID x .625 OD x .625 LENGTH x .875 FLANGE OD x .0625 FLANGE

THICKNESS, MCMASTER 6389K421 OR EQUAL

SCREW 117415 KMI 4 EA SCREW, HEX CAP, 316, .500-13 x 2.500

FITTING 210085 KMI 1 EA FITTING JIC FLARE, BLKHD UNION, 316, 1.250 MJ x

1.250 MJ, LOCKNUT, PARKER 20 WTX-WLN-SS

WASHER 210166 KMI 2 EA

WASHER, SHOULDER, UHMW, 1.563 ID x 1.750 OD x .078 LENGTH x 2.250 FLANGE OD x .125 FLANGE

THICKNESS, .203 OA LENGTH, CUSTOM

204250 KMI 5 EA SCREW SOCKET CAP, 316, #8-32 x .875

WASHER 205569 KMI 5 EA

WASHER, SHOULDER, NYLON, .184 ID x .234 OD x .188 LENGTH x .312 FLANGE OD x .031 FLANGE

THICKNESS, WASUSA 12SWS0441

WASHER 118239 KMI 5 EA WASHER FLAT, 316, #08

NUT 118243 KMI 5 EA NUT, NYLOCK, 316, #8-32

HOSE ASSY 210765 KMI 1 EA HOSE ASSY RBM HV-S01 1.250" BELLOWSFLEX 7910

"A" HOSE

CLAMP 202866 KMI 8 EA CLAMP, HOSE, 316, #020

SCREW 118145 KMI 4 EA SCREW, HEX CAP, 316, .250-20 x 1.000

WASHER 117633 KMI 16 EA WASHER, FLAT, 316, .250

NUT 117632 KMI 8 EA NUT, NYLOCK, 316, .250-20

SCREW 206579 KMI 4 EA SCREW, SOCKET CAP, 316, #6-32 X .75

WASHER 118238 KMI 8 EA WASHER FLAT, 316, #06

NUT 118242 KMI 4 EA NUT, NYLOCK, 316, #6-32

SCREW 118196 KMI 2 EA SCREW, HEX CAP, 316, .250-20 x 1.250

CLAMP 202788 KMI 2 EA CLAMP HOSE, 316, #012

SLEEVE 210544 KMI 2 EA SLEEVE, BANDING, NEOPRENE, BLACK, .910 WIDTH,

PANDUIT PCSSH-B-CR

CABLE TIE 206444 KMI 3 EA CABLE TIE, 29.7, 316, PANDUIT MLTFC8EH-LP316, 1.0-

8.0 BUNDLE DIA, POLYESTER COATED

Cut Plate 180-256-D01 KMI 1 EA Cut Plate, Formed, 0.250 THK

Extrusion RETRO-180- 256-D06 KMI 1 EA Extrusion, See Fabrication Prefab Detail

Detail B

1. Enlarge hole in AL03-901S as shown. Use template if provided.

1. Install sub assembly 208-025 as shown below.

Step 5

1. Modify part 180-256-D01 as shown. By placing part 180-256-D01 in it proper location and orientation (Level) (See Step 6d), mark holes, and match drill 5/16” holes.

2. Dimensions are for reference only. Ideal process is to match drill.

Step 6c

Step 6d

Step 7

1. Install 210-004 as shown

2. Attach existing pump outlet hose as shown